Document e5RY0LX8nmD9bDg7R9yX5bkZM
Enterofficc A\ciiiorniulum
TO (Name and Location)
M. R. Stenzel - Dallas
FROM (Name and Location)
C. W. Whaley - BCP
PLAINTIFFS EXHIBIT
CEL-123
[l
[S/74)
OATE
March 12, 1984
REFERENCE NO.
CWW-450-84
cc: J. N. Gann A. B. Savage B. A. Melaas - Dallas G. A. Vos - Dallas
SUBJECT: Evaluation of Bay City Plant Industrial Hygiene Monitoring Needs for 1984
You pointed out in the Bay City Plant industrial hygiene audit that the method in which we derived the number of samples to be collected in 1983 was inappropriate. As you know our plan was based on available manpower. You also stated that until company/corporate sampling strategy guide lines are established. Bay City Plant should continue to use my approach established several years ago for determining monitoring needs.
Attached is my evaluation of 1984 industrial hygiene monitoring needs for the Bay City Plant along with supporting information. If we pursue this program, validation of analytical methods for acetic acid and n-butanol will be necessary. In my view this data is needed to establish "baseline" exposure information for the key products and raw materials at the Bay City Plant. I would appreciate your comments regarding the proposed sampl ing needs.
As you know, B. A. Melaas is currently trying to clarify the Company's strategy for determining the number of samples to be taken. It is our understanding that he plans to have this issue resolved by April 1, 1984.
CWW/bl
005852
Evaluation of Bay City Plant Industrial Hygiene Monitoring Needs For 1984
005853
Carbon Monoxide Samples
Job Classification
Exposure Zone 1 5-20
Warehouse/Stockroom A-Operator B-Operator Analyzer Mechanic A/B Maintenance (Any Craft)
3 3 3
3
CO GO Cx> GO
32
005854
Acetaldehyde Samples
Job Classification
A Operator B Operator Analyzer Mechanic A/B Maintenance (All Crafts) A Analyst - Shift B Analyst - Shift A Analyst - Day A/B Personnel Clerk/Technical
Exposure Zone
36 2 6 23 25
573*
4/3* :
4. 7
5/2* 5/2* 5/2*
5/10*
5
29 4
*8 Hour TWA/STEL
NOTE: Obtain additional samples on operations and maintenance personnel during turnaround (<v7 samples).
005855
Vinyl Acetate Samples
Exposure Zone
Job Classification
A Operator B Operator Analyzer Mechanic A/B Maintenance {All Crafts) A Analyst - Shift B Analyst - Shift A Analyst - Oay A/B Personnel Clerk/Technical
3 6 23 25 29 36
3/5*
3/7*
3/3*
0/3* 3/3* V 4*
5 2
*8 Hour TWA/STEL
NOTE: Obtain additional samples on operations and maintenance personnel during turnaround (-v7 samples).
005856
Job Classification
A Operator B Operator Analyzer Mechanic A/B Maintenance (All Crafts) A Analyst - Shift B Analyst - Shift A Analyst - Day A/B Personnel Clerk/Technical
Acetic Acid Samples
Exposure Zone
3 6 23
7/7*
7/7*
5 7
5/3* 5/3* 5/3*
25 5
29 36 7/7*
4
*8 Hr TWA/STEL
NOTE: Obtain additional samples on operations and maintenance personnel during turnaround (yj samples).
005857
n-Butanol Samples
Exposure Zone
Job Classification
5 6 23 25 29
A Operator B Operator Analyzer Mechanic
Maintenance (All Crafts) A Analyst - Shift B Analyst - Shift A Analyst - Day A/B Personnel Clerk/Technical
7/7* 7/7*
7/7*
5
7
5/3*
5/3*
5/3*
5
5
*8 Hr TWA/STEL
NOTE: Obtain additional samples on operations and maintenance personnel during turnaround (<\7 samples).
005858
n-Propanol Samples
Job Cl assification
A Operator B Operator Analyzer Mechanic Maintenance (All Crafts) A Analyst - Shift B Analyst - Shift A Analyst - Day A/B Personnel Clerk/Technical
Exposure Zone
5 6 23 25 29
5/3*
7/7*
0/3*
4
4
5/3*
5/3*
5/3*
5
4
*8 Hr TWA/STEL NOTE: Obtain additional samples on operations and maintenance personnel during turnaround ' [*7 samp!es).
005859
Exposure Zone
002
003 005 005 005 007 008 009 020 020 020 023 023 032 033 036 036
Noise Samples
Job Classification .
A Operator A Operator Shift Supervisor A Operator B Operator A Operator B Operator A Operator Shift Supervisor A Operator B Operator A Operator Shift Supervisor A Operator Shift Supervisor Shift Supervisor B Operator Boilermaker Electrician Instrument Person Pipefitter Machnist Rigger Welder Analyzer Mechanic A/Brothers Personnel
o i w u w w w w u w u w u w u u w w w w w w w w t o w CO
Number of Samples
005860
Contaminant
Triphenyl phosphine
Benzene
Carbon Tetrachloride Chloroform Hydrazine
Lime Hydrogen Sulfide Nickel Carbonyl Iron Carbonyl Welding Fume Asbestos
' Miseel1aneous'Samples
Exposure Zone
5 20 6 20 23 6 6
7 7 7 20 ' 32 32 3
Job Classification
A/B Operator A/B Operator A/B Analyst A/B Operator A Operator A/B Analyst A/B Analyst A Operator Area A Operator A/B Operator Area Area Wei der A/B Personnel
Number Of Samples
5 5 5 5/5* 5/5* 3 3 0/3* 3 5 3 As Needed As Needed 10 10
*8 Hr TWA/STEL
005861
EXPOSURE RATINGS 1 - Major potential contact - characterized by manual and maintenance
operations such as emergency repairs, clean up spills, packaging volatile or dusty materials without exhaust ventilation, changing catalyst, cleaning vessels. 2 - Moderate potential contact - characterized by manual operations such as bagging chemicals, catching samples, materials handling. 3 - Minor contact - characterized by semi-closed systems with low level exposure likely. 4 - No contact - characterized by closed chemical system which prevents occupational exposure.
005862
Industrial Hygiene Monitoring Guidelines
Monitoring to insure acceptable exposure to regulated or suspect carcinogens (Benzene, Asbestos, Hydrazine, Nickel, Carbon Tetra chloride, Chloroform). .
Monitoring indicated by Ames or other toxicological testing.
Monitoring to determine compliance position with new OSHA regulations.
Monitoring to establish baseline conditions and "average" employee exposure to key plant products and raw materials for the Health Monitoring Pro gram.
Monitoring to determine compliance position with new NIOSH recommendations.
Monitoring chemicals (not previously included) thoroughout the plant with exposure rating of 2 (moderate potential for exposure).
Monitoring chemicals (not previously included) with exposure ratings of 3 (minor contact).
Priority Rating 1
2 2 2
3 3 4
005863
Exposure and Monitoring Priority Ratings For Bay City Plant Contaminants
Exposure Zone 1
Carbon Monoxide Welding Fume Noise 1,1 J.Trichloroethane
Exposure Zone 2
Acetaldehyde Noise Chioracetaldehyde
Exposure Zone 3
Noise PBQ Vinyl Acetate Hydroquinone Acetic Acid Chioroacetaldehyde
Exposure Zone 4
Noise
Exposure Zone 5
Noise n-Propanol Carbon Monoxide n-Butanol TPP Butyraldehyde Propionaldehyde Nickel (Raney Catalyst) Iso Butanol Iso Butyraldehyde
Exposure Zone 6/10/28/29/30
n-Butanol n-Propanol Acetic Acid Acetaldehyde Vinyl Acetate Benzene Carbon Tetrachloride Chioroform Iso-Butanol
Exposure Rating
:2 2
2
2
4 (3)
2 2 2 2 4 (3)
2 3 (4)
2 2 (3)
2 2 2 2 2
2 2 2 2 2 2 2 2 ?
r-- CM CO CM CM OJ CM CO CM CO CM CM CM CM CM CM CM CM CM CM l-- CMCM CM N CM CM CM r * I-- t-- CM
Priority Rating
2
Exposure Zone 6/10/28/29/30
Iso Butyraldehyde Butyraldehyde Propionaldehyde Heptanal Noise Nonanal Heptanoic Acid Nonanoic Acid
Exposure Zone 7
Calcium Oxide (Lime) Hydrazine Noise
Exposure Zone 8
Noise Ferrous Sulfate
Exposure Zone 9
Noi se Carbon Monoxide
Exposure Zone 11
Noise
Exposure Zone 20
Noise Carbon Monoxide Benzene Oxalic Acid Hydrogen Sulfide TPP Manganese Acetate Copper Acetate Heptanal Nonanal Heptanoic Acid Nonanoic Acid
Exposure Zone 22
Noise
Exposure Zone 23
Vinyl Acetate Noise Acetaldehyde Benzene
Page 2
Exposure Ratinq
2 2 2 .2
2 :2
2
Priority Rating
2 2 2 2 2 2 2 2
23 31
2
2 23
3 (4)
2 2
2..
3 (4)
2 (3) 2
3 (4) 2 (3)
2 2 2 2 2
2
2 2
1 3 2 2 3 3 2 2 2 2
-2
22
2
2 2
21
nncocc
Exposure Zone 23
n-Butanol n-Propanol Acetic Acid Isobutyraldehyde Isobutanol Hepanoic Acid Nonanoic Acid
Exposure Zone 24
Noi se
Exposure Zone 25
n-Butanol n-Propanol Acetic Acid Acetaldehyde Vinyl Acetate Iso Butanol Iso Butyraldehyde Heptanoic Acid Nonanoic Acid Noise
Exposure Zone 32
Noise Carbon Monoxide Nickel (Catalyst) Nickel Carbonyl Iron Carbonyl
Exposure Zone 33
Noise Carbon Monoxide
Exposure Zone 34
Methyl Ethyl Ketone Silica (crystalline) Noi se
Exposure Zone 35
Acetic Acid Benzene
Exposure Zone 36
Noise Vinyl Acetate Acetaldehyde
CM
CM CM CM CM CM CM CM CM CM CM
--CM C J CM CM CM CM CM
Exposure Rating
2 2 2 2 2 2 2
Page 3
Priority Rating
CM CM t CM CM
CM CM
2 2 2 2 2 2 2 2 2
3 (4) 2
3 (4) 3 (4)
3 (4)
i1 Ifj
2 2
2 2
005866
CO CO CM
CM r--
CM CM CM
General
Asbestos Welding Fume
- Total Particulates - Nickel - Copper - Iron Oxide - Total Chrome - Chrome VI
Exposure Rating
1 (3) 2
Page 4
Priority Rating
1 1
005867
crofficc i\kiiionm(liu
Name and Location)
*As Listed
(Name and location)
* 7L B. Savage
GEN 55 (RCV.6/74)
DATE
January 21, 1983
REFERENCE NO.
ABS-11-83
L. Tejml A. Dunn N. Gann R. Pennington E. Allen G. Cornman J. Cribb
cc: B. L. Fritz L. T. Pless B. A. Logue J. C. Nash G. E. Organ C. W. Whaley C. C. Stone C. D. Barrett - Dallas M. L. Stenzel - Dallas
SUBJECT: Industrial Hygiene Monitoring 1983
Bay City Plant management is committed to providing a safe and healthy work place for its employees. All feasible means will be utilized to prevent significant employee exposure to industrial chemi cals and prevent increased employee hearing impairment.
To implement this commitment, it is necessary to monitor the plant employees' exposure to various potentially hazardous chemical and physical agents. This is accomplished by obtaining a series of samples on a representative group of employees who are potentially exposed to these agents.
C. W. Whaley defined a monitoring program for 1983 in his letter CWW-358-82. I have attached a copy of that program as revised.
Each supervisor should help his employees realize this sampling is being done to protect the employee and that his participation is a required job function.
We will provide a sample schedule to each supervisor/group leader at least a week prior to sampling. The unit supervisor/group leader should have the designated employee prepared for monitoring at the scheduled time. The sampling devices are such that they should not interfere with the employee's assigned work.
The unit supervisor/group leader's role is vital in the success of the program. With your cooperation and support this program should run smoothly.
Noise and vinyl acetate monitoring will start in February. I will be issuing a schedule next week.
ABS/las Attach.
A. B. Savage
005868
ABS-lT-83
TABLE I 1983 Industrial Hygiene Monitoring Schedule
Page 2
Contaminant
NoIIise II II II tl II II II II II II II II II II II II II II 11 II II II II
Zone
Job Classification
002 003 005 005 . 005 007 008 009 020 020 020 023 023 032 033 036 036
--
--
--
--
--
--
--
--
A Operator A Operator Shift Supervisor A Operator B Operator A Operator B Operator A Operator Shift Supervisor A Operator B Operator A Operator Shift Supervisor A Operator Shift Supervisor Shift Supervisor 8 Operator Boilermaker Electrician Instrument Person Pipefitter Machinist Rigger Welder Analyzer Mechanic
Total
Number of Samples
5 5 5 5 5 _5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
125
Vinyl Acetate II II II II II II II U II II II II It II II II II II
II II
003 006 006 006 010 010 023 029 036 033 & 036
036
A Operator
A Analyst - Shift B Analyst - Shift A Analyst - Day A Analyst - Shift A Analyst - Day A Operator Clerk (Technical) B Operator Maintenance Personnel (Machinist, Boilermaker,
Pipefitter, etc.) Analyzer Mechanic
Total
* Take about 6 8-hour TWA samples during shutdown of unit. ** Take about 5 STEL samples during PBQ mixing.
4* 4 3 3 4 4 5 5 10** 7
5
64
005869
ABS-11-83
TABLE I (Cont'd)
Page 3
Contaminant
Proptl anol (I
It
II
ll
II II II H
II
Zone
005
006
006 010 010 023 029 005 005
Job Classification
A Operator B Operator A Analyst - Shift B Analyst - Shift A Analyst - Day A Analyst - Shift A Analyst - Day A Operator Clerk (Technical) Maintenance Personnel Analyzer Mechanic
Number of Samples
12* 12* 4
4 7. 4 4 10 7
15**
7
Total
86
* Take about 6 8-hour TWA samples during shutdown of unit. **Take about 6 8-hour TWA samples during unit turnaround.
Other contaminants (i.e., carbon monoxide, welding fume, triphenylphosphine, nickel carbonyl, lime, hydrazene, parabenzoquinone, asbestos, etc.) will be monitored as time permits or upon request.
Total
41
0<ri- OoA&Ajb A"
005870