Document gQ2dMLqBBvnj3x6ED5ZXZKb3

INDUSTRIAL HYGIENE SURVEY OF VINYL FABRICS DIVISION BOUND BROOK. NEW JERSEY BY W. D. NEAL PLANT 312 INDUSTRIAL HYGIENIST JUNE 1974 SAFETY AND ENVIRONMENTAL PROTECTION DEPARTMENT UNION CARBIDE CORPORATION CHEMICALS AND PLASTICS DIVISION BOUND BROOK, NEW JERSEY ucc 067478 TABLE OF CONTENTS INTRODUCTION...................................................................Page 1 SUMMARY Vinyl Chloride.......................................................... Page 2 Solvent Vapor.........................................................Page 3 Dust................................................................................ Page 3 Ventilation................................................................. Page 3 Noise......................................................... Page 3 Lighting........................................................................Page 3 Radiation..............,.................................................. Page 3 RECOMMENDATIONS Vinyl Chloride........................ Page 4 Solvent Vapor............................................................ Page 4 Dust................................................................................ Page 4 Ventilation.......................................... .................. Page 5 Noise..............................................................................Page 5 Lighting....................................................................... Page 5 DISCUSSION OF TEST METHODS Vinyl Chloride..........................................................Page 5 Solvent Vapor............................................................Page 6 Dust................................................................................Page 6 Noise............................................................................. Page 6 Lighting.......................................................................Page 6 Radiation.................................................................... Page 6 Ventilation................................................................Page 6 DISCUSSION OF TEST RESULTS Vinyl Chloride......................................................... Page 7 Solvent Vapor........................................................... Page 9 Dust............................................................................... Page 11 Noise............................................................................. Page 11 Lighting...................................................................... Page 12 Radiation.................................................................... Page 13 APPENDIX.............................................................................Page 14 ACKNOWLEDGEMENTS........................................................... Page 20 UCC 067479 INTRODUCTION An Industrial Hygiene survey was conducted in the Vinyl Fabrics Division from late April through May to evaluate such health stresses as dusts, chemical vapors, noise, etc. against OSHA thres hold limit values and generally recognized good Industrial Hygiene practice. Particular attention was given to vinyl chloride as an air contaminant now under strict regulations as a carcinogen. The vinyl chloride portion of the survey was coordinated to enable compliance with the OSHA emergency standard which required three consecutive weeks of monitoring coninencing April 22. The survey also incorporated a sampling program request ed by Mr. R. N. Wheeler for vinyl chloride impact studies. Page 1 ucc 067460 SUMMARY Vinyl Chloride - Calendering Lines, Building 105. and Building 101. Bay 15 Ambient air on the first floor level contains no more than 1 ppm vinyl chloride, while ambient air on the blender mezzanine measures up to 7 ppm, the probable source of contamination being the blenders which, when charged with suspension type (QSAH and QSAH) resins, generate up to 4500 ppm vinyl chloride In their head spaces. Roof exhausts from the extruder and calender fume removal systems do not exceed 6 ppm. (See schematic. Appendix, Figure 1.) Personnel taking preblend samples from blenders occasionally encountered exposures of up to 175 ppm for periods of less than a minute due to the escape of volatiles when the blenders were opened. Abatement measures ere in progress, including addition of controls which permit purging of contsminated air from each blender prior to the operator opening the sampling port. This should eliminate the excursions and reduce the levels in the ambient air by minimiz ing the escape of vinyl chloride contaminated air into the work area. Vinyl Chloride - Foam Lines Vinyl chloride measured in the 1+0.5 ppm range during the bag-dumping of resin into mix tanks. The dispersion-type resins in use contain low residual monomer. Measurements at the oven exits by Mlran Indicated <1 ppm vinyl chloride in the oven smoke. Vinyl Chloride - Bulk Resin Unloading Vinyl chloride in the head space of van boxes in storage measured in the 2000 4500 ppm range. However, exposure to personnel during hook-up of the boxes for unloading into airveyors is limited to the 2+1 ppm range. OSHA Inspection for Vinyl Chloride A Region 2 OSHA Industrial Hygienist started a vinyl chloride Inspection June 20 and 21, but monitoring was interrupted when Line 1000 ran out due to shortage of resin. The Inspection is expected to be continued at a later date under normal production conditions. Notification of Employees In order to clarify the vinyl chloride situation as regards to Bound Brook employees, eight informational meetings were held on overtime for shift and day employees working in the Building 105 calendering and foam line areas; Building 101- Bay 10, Bay 15 and resin alrveyor operators, mechanics, union safety conmitteemen and union president. A 20 minute presentation included the back ground of events that led to the promulgation of the April 5, 1974 emergency temporary standard for vinyl chloride. Data determined from the survey was presented with precautionary procedures for avoiding potential exposure, followed by a question and answer period. Page 2 ucc 067481 Solvent Vapor - Ink Preparation and Printer Rooms. Building 105 Exposure of operators tending the printers averaged 40 to 507. of allowable dosage, while those preparing strike-offs and ink mixes averaged in the 53 to 707. range. The area of the test bench in the ink room averaged 67 to 92%, indicating the desirability of better ventilation or containment of solvents. Dusts - Building 105 Exposure of blender operators when resin is charged from tanks is 337. of the allowable TWA of 15 mg./cu. meter for nuisance (inert) dust. However, exposure exceeds the limit when blender operators hand-dump QYNA and other dusty powders into L-1000 blenders without ventilation. (Ventilation has since been provided, essentially eliminating the problem.) Operators in the foam mix room receive excessive exposure to resin dust while dumping bags of dispersion resin in the preparation of "skin" plastisols. The ventilation system for both mix dissolvers emits visable dust from the roof exhaust fan during bag dumping. Ventilation All systems were in operation except the Dynaclone which was operated intermittantly, the Trans-Vair system which was plugged, and the hood exhaust for the small weigh-ups on the blender floor. The first two systems have since been restored to continuous service. Noise There are no work stations where noise exceeds 90 dBA. Readings up to 96 dBA measured in close proximity to the FCM gear reducers and Line 1000 trim cutter indicate a need to post signs restricting exposure time or the installation of sound-proofing. Lighting Lighting is satisfactory except in certain warehouse areas, blender operating aisle, and shower rooms which are below ANSI standards. Radiation All eight sources tested satisfactorily. Page 3 UCC 067482 RECOMMENDATIONS Vinyl Chloride Abatement Immediate 1. Caution blender operators against inhalation of odiferous fumes (hydrocarbon solvents, etc.) which may also carry vinyl chloride. To avoid inhalation of such fumes, make certain operators use long-handled scoops and stand away from sample port for at least one minute after opening port before sampling. (This has been done.) Interim 2. Adjust vent valves on blenders to continuously purge air and vapors from blenders during blending and discharge, thereby avoiding build-up of vinyl chloride in the air space of the blenders. 3. Provide controls for applying full exhaust on blenders during sampling and entry for cleaning or repairs, thereby preventing escape of contaminated air and protecting personnel working in blenders. Longer-Term 4. Reduce residual monomer content of feedstock resins. 5. Provide a back-up ventilation system to permit continuity of operations in the event of outage of the existing system. Blenders should not be operated without adequate ventilation unless operators are supplied with air-supplied or self-contained breathing apparatus. 6. Install a local exhaust system on the Bay 15 blenders in Building 101, none existing at present. Solvent Vapors Abatement 1. Replace open containers (palls, dixie cups, etc.) for solvents with closed UL-approved containers. 2. Maintain closer surveillance of existing local exhaust systems, particularly at No. 1 printer, to insure their optimum operation to prevent the escape of solvent vapors into the work area. Hot air blasts should not be allowed to exceed exhaust capacity. Dust Abatement Recommendations 3, 5 and 6 under Vinyl Chloride Abatement will significantly reduce exposure in the blender area. In addition, the following are proposed: 1. Improve maintenance of feeders over Line 1000 banburys to prevent material leakage. 2. Eliminate blow-back from Lines 2000 and 3000 trim cyclones. 3. Install a ventilated booth for weighups on the blender floor, similar to that provided for color dispersions. Page 4 UCC 067483 Dust Abatement (Continued) 4. Install a more effective dust collecting system for the north mixer station in the foam mixing room. 5. Institute special precautions with the use of powdered lead or other toxic compounds, including mandatory wearing of approved respirators. Ventilation See Reconmendations 2, 3, 5 and 6 under Vinyl Chloride Abatement and Recomnendations 3 and 4 under Dust Abatement. Local ventilation on the blenders appears to be the key to avoiding contamination of the working environment with vinyl chloride released in the blenders. This will become even more critical if and when the present emergency standard is lowered in the direction of "zero tolerance." Noise Abatement Line 2000 FCM gear reducer should be posted to limit exposure without ear protection to three hours, and the area north of Line 3000 FCM posted for a six hour limit. The in-line trim cutter should be further sound-proofed for a 5 dBA attenuation. Lighting Provide additional lighting in the blender area, blender panel boards, ware house areas, shower room and lunch room as outlined under Discussion. DISCUSSION Test Methods Vinyl Chloride: Temporary TLV-50 ppm (ceiling limit, no TWA). Vinyl Chloride is collected according to CAP Method 38C-9C1-R2, drawing a measured amount of air through a glass tube packed with activated charcoal. Any organic vapors are adsorbed on the charcoal, and later desorbed in the laboratory with carbondisulfide. The extract is then analyzed by gas chromatography. The procedure is designed for four hours of continuous monitoring at a flow rate of 28 ml. per minute. Since such long-term sampling does not detect excursions of short duration, certain tasks with higher potential of exposure were monitored at rates up to 115 ml. per minute for short periods in order to obtain a sample of sufficient quantity to measure. This method has greater accuracy than that used by OSHA which uses commercial charcoal tubes having only 207. of the capacity of the especially prepared UCC/C&P tubes. Samples taken during this survey were analyzed by the C&P Environmental Health Lab at the South Charleston Technical Center. The Miran I portable infrared gas analyzer which proved useful for continuous area air monitoring at the South Charleston plant was borrowed during the week Page 5 ucc 067484 Test Methods Vinyl Chloride (Continued) of June 17 from the C&P Environmental Health Lab for vinyl chloride monitoring. It proved helpful in confirming that some areas not completely monitored by the charcoal tube method were low in vinyl chloride, but interference at the 10.7 micran wavelength was encountered when monitoring process equipment such as the blenders, mixers and extruders. The interference was traced to non-descript hydrocarbon solvents introduced into the preblend with the stabilizer, causing the Miron I to read higher-than-actual vinyl chloride concentrations. These "mineral spirits" rule out the use of total hydrocarbon analyzers such as the Century Organic Vapor Analyzer. TCA instruments can provide on-the-spot assurance, however, of safe vinyl chloride levels if their total readings, after correcting for vinyl chloride, read under the allowable 50 ppm limit. Instrument noise encountered with the Miran I renders it*unreliable for vinyl chloride measurements under 1 ppm. Solvent Vapors: TLV - See Table, Page 9. Organic solvent vapors are collected according to C&P Method 38C-8A2-Ra, similar to the method for vinyl chloride but using smaller carbon tubes. Complete analysis of all hydrocarbons collected is made by gas chromatography and the data used to calculate micro-grams per cubic meter of air and ultimately, the dosage. Since there are no restrictive ceiling limits on the solvents in use, exposure is best measured by personnel sampling over longer time periods. However, for purposes of control by locating the main sources of contamination, the Century Organic Vapor Analyzer is used to provide on-the-sport direct readings of total hydrocarbons based on 1007. response to methane in air. Dust: TLV - 15mg/M^ for Total Inert Dust. C&P Method 38C-10X2-R2.4 is used for measuring total airborne dust by gravimetric analysis. A measured stream of the sample air is drawn through a preweighted FVC membrane filter by means of a battery-operated personal monitoring pump (MSA Model G) carried by the operator. After vacuum drying, the filter is reweighed to yield a measure of the dust concentration. Noise: TLV - 8 hours at 90 dBA, with a 507. reduction in time allowed for every increase of 5 dBA. A Model 2209 Bruel and Kjaer impluse precision sound level meter was used to measure sound pressure levels from noticeable noise sources. Lighting: ANSI Specification All.1-1965 (R 1970) in lieu of OSHA specifications. For Chemical and Rubber Manufacturing Toilets and Washrooms Panel Boards 30 ft-candles 30 " 50 " Light intensities were measured with a Weston "Photronic" meter. Radiation: Code of Federal Regulations, Title 10, Part 20. Maximum allowable leakage - 0.005 microcuries. Wipe tests are conducted by Industrial Nucleonics Corporation on a contract basis. Ventilation: As required to limit air contaminants to concentrations listed under Subpart G, Section 1910.93. Air velocities were measured with an Alnor Jr. Velometer. Page 6 UCC 067485 Tost Results Vinyl Chloride - See Appendix, Table 1 The scheduling of the Vinyl Fabrics Division survey to coincide with the mandatory monitoring specified in the OSHA emergency standard afforded an excellent opportu nity to thoroughly examine the effects of the new regulation on Bound Brook opera tions with a minimum of delay and effort. These effects were not fully anticipated at the outset, the general concensus being that the new regulation was mainly directed at the VC chemical and PVC polymerizing plants rather than the downstream fabrication plants. However, detection of up to 9700 ppm VC in the air space of a van box loaded with QSAN resin clearly demonstrated the presence of VC at Bound Brook and the need to control any further release of VC in downstream operations. The high level of VC would be expected since a typical load of 40,000 pounds of PVC resin with a residual monomer content of 0.2% contains 80 pounds of VC- If only 17. of this diffuses into the air space above the resin, assuming the air volume to be 207. of the volume of the box, or (0.2)(1900)< m 380 cu. ft., the 0.8 pounds of VC entering the air could amount to /p.8 IbA (359 cu. ft \62.5 mtj \ lb-mol conditions. 380 cu. ft Some dilution of these high concentrations can be expected as the box is emptied, but proper precautionary procedures for safe entry should be followed by personnel prior to entering for cleaning or repair. However, there is presently no such occasion for entry at Bound Brook. If the portion of OSHA's May 10 proposed "zero" tolerance standard specifying labelling becomes law which is expected, van boxes of PVC resin will probably be treated as containers of VC, requiring the posting of consplcious warning signs. Refilling empty containers may also require the restriction of VC emission from the atmosphere if EPA imposes tight regulations. In contrast, personnel who connect the van box outlets to the airveyors experience exposure of only up to 2 ppm. Evidently the hook-up procedure of inserting the rubber spout into the airveyor inlet confines the resin within essentially a closed system, while the operator breathes fresh air from outdoors. Although there are usually visable accumulations of resin dust in the airveyor shed (Bldg. 102) any residual VC evolving therefrom is evidently highly diluted by the high volume of naturally-circulated ambient air. The next evolution of appreciable quantities of VC measuring up to 4450 ppm occurs in the ribbon blenders, probably accelerated by the heating and agitation. An existing ventilation system connecting all eleven blenders to a dust collector and exhaust fan was designed to abate dusting during the gravity feed of resin to the blenders and the charging of liquids. However, during the survey, this "Trans Vair" system was inoperative due to pluggage. As a result, sufficient VC evidently contaminated the air during charging operations to raise the level in the ambient air on the blender floor to 7 ppm. During the week of May 13 the ventilation system was cleaned out and reactivated, but No. 3 blender on Line 3000 and Nos. 1 and 3 on Line 2000 received little or no vacuum from the system due to misalignment of connections causing the flexible connecting sleeves to constrict and pinch off air flow. These misalignments have since been corrected so that all eleven blenders are properly connected to the vent system. The importance of ventilation on the blenders as a prime means of abating exposure of operators to VC was demonstrated by measurements taken while the blenders were Page 7 ucc 067486 Test Results - Vinyl Chloride (Continued) being manually charged without benefit of ventilation. Escape of VC bearing fumes into the breathing zone of the operator was evidenced by values of up to 46 ppm VC for on-the-raan samples during bag-dumping. Subsequent tests taken with the local exhaust system operating were substantially reduced, one measurement being under 1 ppm. Although the vent system automatically vents each blender during the charging cycle, thereby protecting the operator by draining air Inward through the charging hatch rather than releasing fumes into the room, there is no such protection to operators when they reach into the blenders to scoop samples of preblend for color-checking. This is done after about 45 minutes of blending after the air confined within the head space has picked up VC from the heated and tumbled resin. The high levels of VC in the airspace of closed blenders, and lack of negative pressure in the blenders, caused high excursions of up to 175 ppm measured while operators sampled unventilated blenders. Although the time required to scoop a sample of preblend is less than a minute, the fact that the operator's face is so close to the hatch opening accounts for the excursions measured. The total exposure from the excursions is probably less than three minutes per eight hour shift, considering that each sampling of preblend takes less than 20 seconds, and no more than eight blenders are sampled by any one operator. While considering the high excursion levels measured for short time periods, it is Important to note the significance of selecting the time span for testing. Present OSHA monitoring procedures call for a ten-minute sampling period at a rate of 100 ml/min. Under such conditions, a short-lived excursion of less than a minute would not be detected, and the integration with time which occurs during such sampling could result in an average level well within the present limit of 50 ppm. This is apparent if we assume a likely profile of VC levels and calculate the time-weighted average according to the following plot, assuming an initial level of 180 ppm for the first 20 seconds the blender hatch is opened, and an average of 90 ppm while the level decays after the hatch is closed for the next 40 seconds, and an ambient level of 6 ppm in the blender area. The ten-minute time-weighted average (TWA) would be given by: ( J20 sec.\ (40 sec A 60 / (180 ppm) 4- \ 60 90 ppm 4- (9 min.) (6 ppm) * 60+60+54 = 17.4 ppm 10 10 There is, however, the possibility that OSHA might revert to the NI0SH "grab" sample method of monitoring, in which case an air sample could be collected in less than one minute during the time of the excursion, and thereby indicate a violation of the 50 ppm ceiling limit. It is for this reason, in addition to detecting excursions in order to design abatement measures, that the short term samples were taken. As a preliminary safeguard, the blender operators have been provided with longhandled scoops which permit the withdrawal of material from blenders at a safer distance from the hatch opening. In addition, the operating department is planning to provide manual controls for the vent valves which will permit the operator to place a blender under the reduced pressure of the exhaust systen prior to opening the blender hatch for sampling. This should afford complete Page 8 UCC 067487 Test Results - Vinyl Chloride (Continued) protection to the operator and serve to lower the VC present in the ambient air of the building. Exposure of personnel downstream from the blenders appears minimal, evidently no higher than 1.4 ppm. This would be expected from the high volatility of VC and the extensive high temperature and mechanical working received in the mixers, extruders and calenders, which tends to strip out volatiles, exhausting them thr ugh the roof vents. Tests conducted in the foam operation indicated negligible exposure to VC under 1 ppm. This is probably due to the use of dispersion-type resins low in residual monomer as compared with suspension resins. Tests of the Bay 15 in Building 101 operation indicated no levels above 1 ppm on the first floor including the banbury operator, and only an excursion to 5 ppm at the blender while the operator added colorants through a small hatch. However, exposure may be greater during bag-dumping since no ventilation is provided. Solvent Vapors - See Appendix, Table 2 Operators in the printer and ink preparation areas have chronically expressed concern over the levels of solvents in the air, largely due to the low odor threshold values of the solvents used which tends to emphasize their presence even at safe low levels. Fears were exacerbated by the cases of peripheral neuropathy reported out of the Columbus Coated Products episode involving MBK and M1BK. Previous monitoring in the printer and ink room areas was done by the Century Organic Vapor Analyzer, a useful direct-reading instrument for hydro carbons. This is very effective for locating sources of emissions and measuring total hydrocarbons. Its limitation is lack of identification capability; one must know by other means what particular hydrocarbon is present in order to determine actual PPM. Moreover, the Centruy OVA is not adaptable as a dosimeter for personnel monitoring. Therefore for the first time at Bound Brook, charcoal tubes worn by operators were used to accurately measure exposure of operators working in the solvent areas. The measurements reported herein were taken in February In anticipation of an inspection by a New Jersey Department of Labor Industrial Hygienist as the result of an employee complaint. The charcoal tube method was selected as the most effective means of monitoring and considered superior or at least equal to any method expected to be used by the State Hygienist. A State inspection was actually made a month later, the Industrial Hygienist using a J&W Model SS-P combustible gas detector rather than charcoal tubes. The reason given for not using charcoal tubes was the lack of analytical personnel. Readings on the J&W PPM scale were considered satisfactory by the State Hygienist, hence there was no need to submit our charcoal tube findings. We would, however, expect OSHA to use the charcoal method instead of the J&W "sniffer" which has insufficient sensitivity in the 0 to 200 ppm range. The principal solvents in use during the monitoring, plus MBK used at Borden's Columbus Coated Products, are listed below with pertinent data: Methyl ethyl ketone (MEK) or 2-Butanone *Methyl butyl ketone (MBK) or 2-Hexanone Methyl Isobutyl ketone (MIBK) or Hexone Tetrahydrofuran (THF) 2-Nitropropane (2-NP) *Not used at Bound Brook. Page 9 TLV PPM me/M^ 200 590 100 410 100 410 200 590 25 90 VP @ 20C MM 70 2.6 15 138 13 BP @ 760MM C 80 127 116 65 120 ucc 087488 Test Results - Solvent Vapors (Continued) MEK and THF, being the more volatile of these solvents, readily generate odiferous vapors locally and are therefore subject to complaint if operators get too close to containers. Fortunately, these have the highest TLVs. M1BK, having low odor threshold level. Is quite noticeable. Moreover, Its nomenclature is often confused with the MBK associated with the Bordon problem. The low volatility of the more toxic 2-NP renders it a minor factor in the working environment. An appreciation for how these solvents contribute to the overall dosage can be seen by reference to the Appendix, Table 2, which lists the amounts of the various solvents collected from the air on charcoal. Although MEK and MIBK are generally used on a 50-50 weight basis is the No. 1 Printer, the amounts evaporated into the air are roughly in proportion to their vapor pressures, resulting in consider ably lower concentrations of the more toxic MIBK than the leBS toxic MEK.^ The chief operator's intake analyzed in the ratio of 151 MEK to 29 MIBK (mg/M ) while the relief operator performing similar tasks analyzed 185 MEK to 37 MZBK. Actual exposure is calculated from the chromatagraphic analysis of the sample, taking into consideration the amount of each compenent and its ratio to the TLV for the maximum dosage allowed for eight hours. Using the general formula for calculating dosage: Cl T1 C2 T2 + "** Tn 1 For Maximum Permitted dosage for n number of components. C Actual Measured Concentration (mg/M ) T TLV Concentration (mg/M**) The dosage Imparted by each of the four components is calculated In the last columns of Table 2. It is worthy of note that these solvents have no ceiling limits, therefore there is no need to test for excursions and long sampling times are quite proper for determining exposure. Nevertheless, it is important to periodically monitor the printers with the direct-reading Century to maintain control of solvent vapors in the working environment. Certain zones within the printers yield measurements in the 100-300 ppm range as follows: tus Me Mu. IPrinter, between tnfc Hist June 2 etui 1 Inside Mu. 1PrlnUei , between Ink BtaMutm 1 and Unwinder Inside No. 3Printer, between Ink Stations 1 and 2 Inside No. 3Printer, between Ink Stations 3 and 4 Outside No. 3 Printer, between No. 1 and 2 Ink Pots Although the chief and relief operators frequent these zones in which the air may contain contaminants above the TLV, time studies indicate they spend less than half their time in such areas. This is confirmed by the charcoal monitoring results of 0.40 to 0.50 (40 to 50%) of allowable dosage. The other members of the printer crews were not tested since their tasks do not Involve handling solvents, their time being spent in the wind-up and packing areas away from the solvent fumes. The strike-off day shift operator appeared to have the greatest exposure of 70%, probably due to a particularly active day of color matching and frequent cleaning with solvents. The ink coordinator, in preparing mixes in the ink room where area sampling indicated 67 to 92% dosage, analyzed only 53% allowable exposure. The area samples are representative of extreme conditions in the ink room, having been taken in a poorly-ventilated comer near the Cowles mixers. Page 10 uco 067489 Dust - See Appendix, Table 3 Dust monitoring was conducted in the two areas of greater concern to personnel: the blender mezzanine and the foam line mix room. DuBting appeared highest during the charging of resin and fillers into the blenders, there being no ventilation on the blenders during monitoring. Dusting was particularly severe in the area of the Line 1000 blenders which were being charged largely by handduraping QYNA resin. Even with the highly visable releases of^dust, all long term samplings analyzed in an acceptable range of 2 to 7 mg/M . With no ceiling limit on dust exposure, there are no violations from the excursions which occur during charging. However, such excursions, one of which was measured at 170 mg/hr during the hand-dumping of QYNA, create a housekeeping problem and concern on the part of employees. This source of dusting is effectively eliminated when the blender is connected to a vacuum source such as the Trans-Vair blender exhaust system. When this system is operating effectively, the capture velocity at the open blender hatch exceeds 100 fpm, thereby conforming to the control velocity specified in the State of New Jersey Department of Labor Chapter 122, Exhaust Systems (proposed). Other sources of dust observed during the survey were leaks from the Line 1000 overhead feed system. There were dust emissions from the skip hoist dumping location where a side plate had been removed and there was no exhaust due to the Dynaclone dust collector system being down. Considerable leakage occurred from the screw conveyor feeding the banburys. Other principal sources were the hoppers of Lines 2000 and 3000 FCMs where blow-back of preblend occurred due to a high flow of air from the trim recycle cyclones. Dusting in the foam mix room was highly visable during bag-dumping of resin at the mixing stations. However, on-the-man samplings taken during bag-dumping gave values within limits. Dusting at the foam mixer (south station) measured lower at 5 mg/M3 than that at the skin mixer (north station) which measured 18 mg/M3 during 15 minutes of bag-dumping. However, this averages to a much lower level when time away from the dust emission is added. Nevertheless, improvement is recommended for this station where ventilation system for the mixers produces visable emissions from the roof exhaust fan, evidently due to resin by-passing the filters in the entrance chambers. This will require correction for compliance with EFA requirements. During monitoring in the blender charging area, several operators expressed concern over the use of Cab-O-Sil, a particularly light and dusty powder. Vendor's data indicates this to be amorphous, containing no toxic crystalline silica. The problem from breathing the dust is its high affinity for moisture, causing drying the of throat if inhaled. Another concern pertained to the weigh-up and handling of toxic powders. None were seen in use during monitoring, but a pallet load of "Dyphos", dibasic lead phthalate, was noticed on the blender floor. It was explained that this was used for a short run of a customer's formula, and may not be run again. If necessary to use such material, approved (Dustfoe) respirators should be required during handling, full ventilation should be available at the charge point, and the formula should be adjusted to permit the use of full weight bags rather than requiring weigh-ups. Noise No noise levels above 90 dBA were measured in any operating areas. High levels were measured in the immediate vicinity of the FCM drives and the Line 1000 on line trim blower enclosure. Sound pressure levels are as follows: Page 11 ucc 06 7490 Noise (Continued) Item Location Allowable dBA Time, Hrs. Line 1000 1 Within two feet of trim blower enclosure in aisle between L-1000 and L-2000 calenders 2 Two feet west of lower calender roll 3 Foot of stairway to calender 4 Aisle between cooling rolls and take-off 86-95 88 87 87 4 8 8 8 Line 2000 5 Directly below inlet to trim cutter housing 6 Within one foot of FCM gear drive 85 8 97 3 Line 3000 7 Between FCM and panel, north of drive 91 6 8 Hydrotherm blowers, within one foot Motor-Generator Room 88 92-99 8 2* * Already Posted Items 1, 6 and 7 require posting of signs reading "CAUTION- - EAR PROTECTION MUST BE WORN WHEN WORKING IN THIS AREA FOR MORE THAN _____ HOURS PER DAY." Since Item 1 is on the "fringe" of the take-off area, it is recommended that damping material be added to the enclosure and conveying lines in order to reduce noise levels below 90 dBA. Ventilation openings may have to be closed or baffled to achieve sufficient noise reduction. Lighting Lighting in most operating areas is above standard with the exception of the blender floor where Intensity along the main aisle between the panel boards and blender charge hatches measures as low as 3 ft-cdl. Lowering the upper fluorescent fixtures or installing local lighting would Improve illumination in this busy area. The panels are in need of local lighting to facilitate reading controls and indicators. Local lighting is recommended for the log table to increase illunination from 3 ft-cdl. to 50 to improve readlbllity of work sheets. Warehouse areas are minimal, largely due to lights no longer centering on aisles. The east warehouse foam roll storage racks are in need of better illunination measuring 1 ft-cdl. along the C and E racks. Lights obscured by these racks should be centered over the aisles between D and E racks and C and CC racks. A minimum of 5 ft-cdl. should be available, with 10 being desirable. A similar situation applies to the storage area for the embossing rolls. Illumination in the main men's room area ranges between two extremes: 125-150 ft-cdl. in the lavatory-toilet room versus ANSI standard of 30 ft-cdl. and 3 ftcdl. in the shower room. Better lighting is therefore reconsnended to bring the level up to 30 ft-cdl. in the shower room and drying area. The locker room is satisfactory. Lighting in the lunch room measured in the 3-5 ft-cdl. range. An improvement to 10 ft-cdl. is reconmended. Page 12 UCC 067491 Radiation - See Appendix, Table 4 Results of the last semi-annual inspection of March 19, 1974 by Industrial Nucleonics Corporation are reported. Page 13 UCC 087492 APPe NDIX F I & 1Vinyl Chloridf Measure me ntj B LDfir ior jE Mrrz&tttf'l S'tan'uacy; PROPosa^ " .T# ppaa ^ ax. ^ "N<~` - ?ero :KiO^^dcJ V 04 E ArDt e Vt.HT 5 YS TE hA QYMA ;n-ah- 7.000 4500 94oo- 3700 C.J _ Resin LNl CAJE^ 2,0 Page 14 ; ucc 08749 \ APfKMDIX, TABU 1 LOCATION OR JOB POSITION RBSVLTS OP C1ARCOAI TUBS SAMFLIHQ AMD AMALTS13 FOR T1HTL CHLORIDB SAMPLZNO Ties Rata eln. al/ain Sanple voluae Liters Vinyl Chloride Has PPM ARIA SAMPUS: Air space in van Box loaded with OSAR, Blend 1(03 Air space in van Box loaf*4 with 09AN, BlenA B9B8 Air space in van Box loaded with OSAR, Blend 5027 L-l 1lender 1--el lately after charging QTJU L-2 Blender after Blending of 90AM, plaatielxera, eto. Ir2 Blender after eharglng OSAR, Before plaatlelaera, eto. L-2 Blender after eharglng QSAM, Before plaatlelaera, te. L-3 Blender panel Board area Bldg. 101, Bay 15 blender area Bldg. 101, Bay 15, Banbury discharge Dynaolone exhaust (vent fro* L-l BanBurya) L-2 Preblend feed to PCM L-2 PCM discharge L-3 PCM dlaeharge L-2 Bxhauat free Royle extruder hopper L 1 Bxhauat froa Royle extruder hopper L-2 Discharge froa Royle extruder die Rear of L-3 Calender rolls L-2 Calender stack exhaust L-2 Calender eabosalng rolls 66 30.5 52 31 30 32 3* 30 77 31 31 33 20 31 138 31 20 87 3h 77 127 31 10B 30 120 33 12 110 210 33 11 110 125 33 10 100 60 28 85 30 2.02 1.61 O.36 1.02 2.38 1.12 0.62 *.27 1.7* 2.62 3.9* 3.12 3.96 1.32 6.91 1.21 *.13 1.00 1.68 2.55 8*00 9700 71* 292 90 2T000 35 *BB8 7180 251* 3191 2017 78 7-2 5-7 1.3 0.75 18 0.1 1.8 7-5 0.9 6.0 0.6 9.0 106 2.7 6.0 l.l 0.35 9.0 O.85 1.9 2B 0.71 5.6 13-5 2.1 PRRSOBRXL SAMPXSS: Resin Alrveyor Operator connecting ran box Mo. 657 of OSAR Resin Alrveyor Operator connecting ran Box Ho. 807 of OSAN B 30 2.1 85 0.12 0.18 0.6 1.96 <1.8 . 3.9 ucc 067494 Page 15 APPENDIX, TABLE 1 (eont.) LOCATION OR JOB POSITIOH SAMPLING Tine Rate min. atl/mln L-3 Blender Operator L-2 Blender Operator L-l Blender Operator L-2 Blender Operator, charging blender L-3 Blender Operator, charging blender L-3 Blender Operator L 3 Blender Operator, charging blender L-2 Blender Operator, charging blender L-l Blender Operator, charging blender L-3 Blender Operator, charging blender, (blander vented) L-2 Blender Operator, charging blender, (blender vented) Bay 13 Blender Operator, charging blender Bey 15 Banbury Operator Bay 15 Calender Operator L-2 Calender Operator L-3 Calender Operator L-2 Calender Operator L-l Calender Operator L 1 Blender Operator, sampling blander L-l Blender Operator, sanpllng blender L-2 Blender Operator, sampling blender L-2 Blender Operator, sampling blender L-3 Blender Operator, sampling blender L-3 Blender Operator, sanpllng blender Blender Operator, roll-milling sample of preblend Blender Operator, roll-milling sample of preblend Foam Line, Skin Mixer Foam Line. Poam Mixer Bag lo. Bldg. 101, preblend Operator, charging tote bln Bay 10, Bldg, 101, Preblend Operator, charging Bay 7 blender Bay 10, Bldg. 101, Mill Operator 152 1S3 173 3.5 3.3 96 11.5 2.8 9-7 3.5 4.0 2.0 35 36 152 155 148 3% *5 1.0 1.0 0.5 1.0 1.0 5.0 4.0 19 15.9 19 8 30 31 30 30 31 31 30 30 32 90 105 115 85 105 71 32 30 30 81 82 105 105 95 105 105 105 108 30 JO 90 105 65 Sample Volume Liters 5.46 5.50 5.19 0.108 0.103 2.88 0.3*5 0.09 O.87 0.368 0.460 0.170 3.68 2.70 *96 4.65 4.44 2.76 0.37 0.105 0.105 0.0*75 0.105 0.105 0.525 0.432 0.56 0.48 1.71 0.8* 2.55 Vinyl Chloride Pons PPM ro 90 37-5 2.5 1.0 19.3 *.5 5.1 101.7 < 0.3 11-9 2.3 < 1.8 < 1.8 13.5 8.1 2.7 *.l 165 1.7 4.1 3.* 29.* 34.5 C 0.8 4o.8 < 1.5 0.6 4 0.6 4 0.6 0.6 6.5 6.4 2.8 91 3.8 2.7 5.1 22.2 45.8 < 0.9 10.1 5-2 < 0.2 <0.3 1.1 o.T 0.2 0.6 175 6.3 15.3 28.1 110 129 < 0.6 < 0.7 < 1.1 0.5 40.14 Co.28 0.1 t \ APPKKDIX, TUU 2 RBSUn OP C1ARCOAL T8BZ SAMPLIRO ADD AHALTS13 FOR SOLVBTT VAPORS TLV o. 1 Printer Chief Operator - D. K. Relief Operator - J. 0. >o. 3 Printer Chief Operator - 1. A. Relief Operator - I. J. Striice-Off Ooerator - P. T. Znlc Coordinator - 1. V. Ink Room (Area) Ink Room (Area) spl Tine In. Rate al/aln 142 104 108 88 113 115 116 120 104 95 117 120 94 80 144 115 Saaple Volm Liters HBX Dg/Vp 590 H I BX a/m5 410 THP *^M5 590 2 - VP mg/m> 90 Calculation of Doaagea HEX MIBI nr 2-MP total 14.8 9-6 2230 151 1770 185 13.0 13-9 9-9 14.0 7.5 16.6 2150 166 2240 l6l 1190 120 2430 174 1600 214 7406 447 425 29 1060 72 70 5 350 37 270 28 40 4 40 3 130 10 <40 O 40 3 870 63 70 5 1290 130 780 79 <40 <4 130 9 1440 103 60 4 175 23 930 124 <40 <5 230 14 1134 68 <40 <2 15i+ 22+ 12 +-5-0-50 590 410 590 90 185 ^ 37 , 28 f 4 _ 0.49 590 410 590 90 166 +__ 2 + _1 + _2 590 410 590 90 l6l + _3 + _62 + _i590 410 590 90 120 + 120 + _J2 + 4. 590 410 590 90 ni+9 + i2i + _i590 TO 590 90 2!i + _22 + i + _5590 410 590 90 447 _14 + _68 + _2 . 590 * 410 590 90 .40 .50 -70 .53 -67 .92 0674 96 Page 17 APPENDIX, TABLE 3 RESULTS OP ORAVMBTRIC ANALYSIS POR RESIN DOST CALENDER LINES: L-l SI nder operator, nUe small weigh-ups, no blender charging L-2 Blender operator, 2 blender charges, minima bag-dumping L-3 Blender operator, 2 blender oharges, noderate bag-dunplng Log table, blender ness., (Area sample) L-l Blender operator, Dumped *5 bags QTKA into blender L-l Blender operator, duoped 7 bags of fillers, i bag Cab-O-Sil. 2 weigh bags L-l Blender operator, prepared 5 weigh bags of Cast, *11AB, and charged 1 blender Above samplings were nade without ventilation on blenders. SAMPLING Tine Rate nln. nl/min 103 1650 128 1690 103 1600 150 1600 10 1675 12 1750 75 1750 Air Vol. Liters 170 216 165 2*0 16.75 21 131 POAN LINE: "S*in"nixeri nade 2 nixes, dumping 11 bags of Narvlnol resin and 5 bags of Pllovlc into each "Foam" mixer: dunned 22 bags of GTJVI:A 1*.9 22.0 1725 HOP 25.7 27 -i......... Sample Weight MB*. 980 810 920 560 28* 125 870 *70 190 m*/H5 f .8 3.8 5.6 2.3 170 6c 6.6 18.3 5.1 ucc 067497 Page 18 * API /IX, %BLE 4 FIELD WIPE TEST REPORT (Long rm) tf'U/C /O la Customer. fO (l & A. lb Address _ 3/Ci. *-/<' A-/ O - Due Date 1 c Id le cJ> 3 4 5 6& Source No. Frame No Gauge No, Labels W. T. Shutte r Indica. Test Bv 6b Date 7 Remarks | Lab| Tc^: A'-JS-il oi'a_4/M cli/Sj?// O/C S'361 -t oo3:H-n/ &c 3*)417f CA. S-3i 7-r >4/?9 co v2 *S/)J oK S-Jip-T o`h sStlfO co4t *4*13 C*L o4i>4//z4 o~fc *4/?) 1 cc CC?tr3()4j\ CM- S-U4-T j -l/cJWu Cc? CS-Jiol (>4?3l /CcO CAi 3?A9 4/y>s7s . ]f>> i".-ftoL,/ ^ /S" Sc/ss/" /*AsvsL. t/jr,;-/. cl. cvc ZiAst/A , /r.4<T aAssA. A/Zs~ 1 J i', ?&'?$ aCs/A 77AC ///4 cM ..!//' f f A CC Sh/?/ CMC fiki'-fZ 3//if?</ Cl/ /* I~ ^6t*s /* /A t' Cs j| O cA /t--S !''^ :yy'-'t // i 447 CAC/L A///7 c f/s. C A. jfc /toft? /1> f /c, s~ A/its /i A :?/C t/MSI 3/r*h<f D< Z>7 /, y / * as j*. cs C- */c J/tcM- sfnhi $/fj f /*s IT ...4i hZdtt. sfrtfrf tfs O'y /tS /~C 7'St/A // tf/'f *A'f c/C _ "A. ' t /'*' *1 . * V / /, ff *- tsK iu^A, /I fakd/:L MfnfiY s/rth( /IsJ /f y //,, !'</ /'**<:' / I' a /(. y M scsco l * 4/1"f f MOLf-L. 4t/><f /3T$ SI^sff/L j ki/Z f- /?;// /3~7 A/sSsfJAyJ/S * Jt- . CAAsJ- fizz7 /SI AsyAA^Afii 7//1 tff WZ-. ?/&/?</ 2 o< // 7 SzsffcC ,-?zAsZ J, y/rt M# faiM ,?, ^ /ST'sC^SA /y/ZZ \ i /(Z7 aSom/Z fr/rjrz///y;A ........... .... '/ ^y jCv/ 'sC/. /?. &>. VrV - i rZ\ S&. / t/ At /cAj A, 7s?S A Ass /si _{ l 1-------- 1 S?,. s ,7. 47 sZ40 7 Is SjJsi/ As 1 * <>fs\ si /Liz ,'lA.,A S,SS7%^"'.S,-------------- 1---------1 A77/* 'st fV A M-- (r>7f"i A 'i y. ;".i,y A* /3/C < r" '> - A - Ssss/y zfc A?* C4 -Ts^Ss/S, /lAss^rl/A---------! 11! J1 t v / - A? f . / r / >7*/u ' is/s/3 AAt cc A2i/J> , 4/A^/ss' *3a,"cSsJl. ---------Ii v-J. AsS.\- ' V ' /**r< r^- JT > . t-.-. c A f ' 7 s?C_ y**.!, Z/' . S S S'l Sy----- .'------ ---- ! 1 'BF-, (4-10-73) / Pa 9 Installation Supervisor: ucc 087498 X1 1 ACKNOWLEDGEMENTS The execution of this eurvey was particularly facilitated through the uniinited cooperation of the following individuals: Operations; J. Kerman, H. Koenig, S. Molnar, M. Shvidrik, W. Westcott, F. Wick and T. Zambo, Production Supervisors Analytical Service; J. Cavender, G. Hurley and J. Neff, Chemicals and Plastics Environmental Health Lab, South Charleston; Safety and Environmental Protection; R. E. Rosfjord Page 20 UCC 067499 DISTRIBUTION Mr. J. D. Baker - BB Mr. R. A. DeCoudres - BB Mr. L. F. Doyle - BB Mr. J. L. Goodson/Shlft Superintendents Mr. P, Granger- BB Mr. N. H. Ketcham - SCTC Mr. F. J. McCarthy - Chicago Dr. c. S. McKinley - BB Mr. R. E. Peele/R. E. Graebert - SCTC Mr. E. B. Sharp/F. L. Wlegleb - BB Dr. A. B. Steele - NY-28 Mr. R. N. Wheeler - SC Mr. D. L. Wiley - NY-21 received r. N. WHEELER, ucc $67500 DEPARTMENT OF HEALTH, EDUCATION, AND WELFARE CHOLIC, lif All H SCR Vice 0-NTi:n FOR . iSCASt lONTRCH ' I \ I ,1 I . 'I Ai\ .11 , J RECEIVED MAY 09 1974 R. N, WHEELER, JR, April 23, 1974 \) (2MltJ Z) U \ KC- R. W. Holland, M.D, Union Carbide Corporation 437 McCorkle Avenue, S.W, South Charleston, West Virginia 25303 Dear Dr. Holland: Enclosed Is a copy of our proposal for medical screening at the Union Carbide plant In South Charleston. As we discussed over the phone, this protocol is in the preliminary drafting stage and subject t further revision. When completed, the finished version will be forwarded to you, along with the appendices. Respectfully, "i /^ ' ' Enclosure ASG/mc A. Scott Grivas, Jr., M.D. ' ^ Cancer Section Cancer and Birth Defects Division Bureau of Epidemiology _____ ucc 067501 \ DRAFT (2) PROTOCOL EVALUATION OF MEDICAL SCREENING FOR THE detection of liver disease among vr.n'L chloride workers Background and Objectives The recent recognition of angiosarcoma of the liver among workers * engaged in the polymerization of vinyl chloride, together with preliminary results of animal toxicologic studies.strongly implicate vinyl chloride monomer as a serious carcinogenic hazard for occupationally-exposed indi viduals. Preliminary evidence also suggests that VCM may induce toxic liver alterations, portal fibrosis in particular, long before the develop ment of frank liver malignancy. It is the purpose of this study 1) to determine those diagnostic laboratory procedures best suited, both in specificity and sensitivity, for the detection of liver disease among workers at vinyl chloride polymerization, plants; 2) to identify as completely as possible specific workers with liver abnormalities so that they may be removed from vinyl chloride exposure and referred for appropriate medical evaluation and therapy; and 3) to identify other medical illnesses which might conceivably be related to vinyl chloride exposure. | Investigators 1. A. Scott GVlvas, Jr., M.D., EIS Officer, Cancer : StlutiOU, Cue. 2. Joseph Mallov, M.U., physician with NIOSH. t- 3. WBMk Holland, ILL., i'lanl Medical Director, Union Carbide Corpora- tJon, Soutli Liiuicnlou, Virginia. * ucc 067SO 4. Coleman Carter, N.D., EIS Officer, Cancer CDC. Section, 5. Henry Talk, M.D., EIS Officer, Cancer Section, CDC. 6. Clark W. Heath, Jr., Director, Cancer and Birth Defects Division, CDC. Study Design * The study will be performed jointly by the CDC/NIOSH and the Union Carbide Corporation at the Union Carbide plant located at South Charleston, West Virginia. Three groups of plant workers will be selected for intensive medical screening. They are (1) plant personnel currently engaged in the polymerization of vinyl chloride, (2) administrative personnel, such as salaried persons, clerks, secretaries, etc., and (3) plant Jv in non-vinyl chloride-related jobs, such as the production of rubber/other synthetic plastics, etc!] Participation in this study will be by volunteer consent. It is hoped that virtually all persons directly engaged in vinyl chloride polymerization work be enrolled in the study. Union officials at the plant will be informed in detail of the purposes of the study and___________ their cooperation will be sought to encourage all union members to participate. * A special consent form will be signed by each participant (Appendix A). r The size of the study group is estimated at approximately 320 persons. This could Include 160 current vinyl chloride workers together with an equal number of controls, matched for of eurlvj*iient auu selected by systematic sampling from administrative staff and non-PVC plant personnel. Medical screening, as detailed bole'*, will be cor-'uctcd :'n collaboration with Union Carbide medical paraonncl, utilizing the nodical facilities at UCC 067503 3 the plane and In the South Charleston, West Virginia, area. CDC/NXOSH will provide a team of physicians to assist with the screening procedure. It is estimated that all 320 workers can be medically evaluated within 1-2 weeks. Forty-five minutes to 1 hour will be appropriated for the screening of each individual worker. Screening is tentatively scheduled to begin Monday, July 1, 1974. Whenever possible, arrangements will be made for local laboratories to perform the analysis of the more commonplace medical tests. The facilities of specialized research laboratories, however, will be utilized for special tests (e.g., proline hydroxylase, alpha fetoprotein, sarcoma specific antigens, etc.).^ Contractural arrangements for the performance of these tests will be made during Mary 1974. The costs of such tests will be assumed by CDC/NIOSH. Medical Screening Screening will consist of 1) medical history, b) physical examination, and 3) laboratory testing* Special forms will be used for recording findings f medical history and physical examination (Appendices B and C). The following laboratory tests will be performed on each study ftarticipant: 1, Hematology a. CBC with a differential b. Platelet count c. Reticulocyte count 2. Urinalysis a. Routine urinalysis b. Urine bilirubin and urobilinogen ucc 06750-4 4 3. Serology a. Direct and Indirect reacting bilirubin b. Alkaline phosphatase, gamma-glutamyl transpeptidase, LDH c. SCOT, SGFT d. ICG-indocyanine green (measurement of disappearance rate of ICG using dichromatic ear densitometry at a dosage of 5 mg/kg of ICG) e. Proline hydroxylase f. Hepatitis B antigen g. Carcino-erabryonic antigen,:alpha fetoprotein, F-antigen, and sarcoma-specific antigens. , h. B-12 binding protein i. Serum protein electrophoresis 4. Spirometry a* Vital capacity b. Forced expiratory volumes 5. Radiologic procedures a. Chest x-ray b. Hand x-rays (><*& 4^^ d. Liver spleen scan. Comments Any worker identified by such a screen procedure as having possible * e liver impairment will be removed from vinyl chloride exposure and r-j Tarred ** * to his personal physician Tor further diagnostic evaluation and therapy. ucc 067505 5. If a liver biopsy is then felt indicated, an attempt will be made to obtain biopsy slides and tissue blocks for review by Drs. Thomas and Popper at NIH. In this manner, we hope to uncover any additional cases of angiosarcoma of the liver and also identify any premalignant hepatotoxicity, possibly associated with exposure to vinyl chloride. Workers found to have abnormalities of other organ systems, unrelated 0 to hepatobiliary disease, will also be referred to their private physicians for appropriate evaluation and therapy, A special letter (Appendix D) will then be sent to these physicians requesting, for each worker thus referred, specific followup information, such as final diagnoses, therapy, and prognosis. In this manner Information regarding overall morbidity among workers at polymerization plants may be obtained. , As a result of this study and of related work elsewhere, it is hoped that decisions can be made regarding the sensitivity and specificity of the various screening procedures aimed at detecting liver disease among asymptomatic workers at vinyl chloride polymerization plants. Comparison of test results between vinyl chloride workers and non~vlnyl chloride controls (administrative staff and plant personnel employed in non-PVC related jobs) will help validate judgments concerning the usefulness of these various tests* Hopefully on the besis of test results obtained from this study, more precise recommendations can be developed concerning medical screening procedures which should be employed to protect the health of persons potentially^exposed to vinyl chloride in industrial settings. 7 ucc 067506 IJCC 067507 RECEIVED DEPARTMENT OF HEALTH, EDUCATION, AND WELFARE PmiUC HCALTM SERVICE cr.NTEn for oiscASt control M \ | ,|i , *t ,|/\ ltj , ,, j MAY 09 1974 R. N. WHEELPR. JR. April 23, 1974 0 rv r.c. R. W, Holland. M.D. Union Carbide Corporation 437 McCorkle Avenue, S.W. South Charleston, West Virginia 25303 KX/2z Dear Dr. Holland: Enclosed Is a copy of our proposal for medical screening at the Union Carbide plant In South Charleston. As we discussed over the phone, this protocol Is In the preliminary drafting stage and subject to further revision. When completed, the finished version will be / forwarded to you, along with the appendices. Respectfully, Enclosure ASG/mc A. Scott Grivas, Jr., M.D. ' ^ Cancer Section Cancer and Birth Defects Division Bureau of Epidemiology ucc 067508 DRAFT (2) PROTOCOL EVALUATION OF MEDICAL SCREENING FOR THE DETECTION OF LIVER DISEASE AMONG VIHYL CHLORIDE WORKERS Background and Objectives The recent recognition of angiosarcoma of the liver among workers * engaged in the polymerization of vinyl chloride, together with preliminary results of animal toxicologic studies,strongly implicate vinyl chloride monomer as a serious carcinogenic hazard for occupationally-exposed indi viduals. Preliminary evidence also suggests that VCM may induce toxic liver alterations, portal fibrosis in particular, long before the develop ment of frank liver malignancy. It is the purpose of this study 1) to determine those diagnostic laboratory procedures best suited, both in specificity and sensitivity, for the detection of liver disease among workers at vinyl chloride polymerization, plants; 2) to identify as completely as possible specific w rkers with liver abnormalities so that they may be removed from vinyl chloride exposure and referred for appropriate medical evaluation and therapy; and 3) to identify other medical illnesses which might conceivably be related to vinyl chloride exposure. ( Investigators 1. A. Scott GVlvas, Jr., M.D., EIS Officer, Cancer J Sci.Lj.ou, CuC. 2. Joseph Mallov, M.U., physician with NIOSH. K 3. VBI Holland, II.D., .riant Medical Director, Union Carbide Corpora tion, Soutli Cii-irlcslon, List Virginia. ucc Q67509 2 4. Coleman Carter, M.D,, EIS Officer, Cancer CDC. Section, 5. Henry Talk, M.D., EIS Officer, Cancer Section, CDC. 6. Clark W. Heath, Jr., Director, Cancer and Birth Defecta Division, CDC. Study Design * The study will be performed jointly by the CDC/NIOSH and the Union Carbide Corporation at the Union Carbide plant located at South Charleston, West Virginia. Three groups of plant workers will be selected for intensive medical screening. They are (1) plant personnel currently engaged in the polymerization of vinyl chloride, (2) administrative personnel, such as salaried persons, clerks, secretaries, etc., and (3) plant pej30flBeJ^^v4u75'c"V 0 in non-vinyl chloride-related jobs, such as the production of rubber, other synthetic plastics, etc?} Participation in this study will be by volunteer consent. It is hoped that virtually all persons directly engaged in vinyl chloride polymerization work be enrolled in the study.. Union officials at the plant will be informed in detail of the purposes of the study and------------- their cooperation will be sought to encourage all union members to participate. * A special consent form will be signed by each participant (Appendix A). f The size of the study group is estimated at approximately 320 persons. This could include 160 current vinyl chloride workers together with an equal number of controls, matched for *'*'=> erd ''""rticn of ei..,. lament auti selected by systematic sampling from administrative staff and non-PVC plant personnel. Medical screening, as derailed bole**, will beconducted :'n collaboration with Union Carbide medical personnel, utilizing the nodical facilities at ucc 067510 3 the plant and in the South Charleston, West Virginia, area, CDC/N10SH will provide a team of physicians to assist with the screening procedure. It is estimated that all 320 workers can be medically evaluated within 1-2 weeks. Forty-five minutes to 1 hour will be appropriated for the screening of each individual worker. Screening is tentatively scheduled to begin Monday, July 1, 1974. Whenever possible, arrangements will be made for local laboratories to perform the analysis of the more commonplace medical tests. The facilities of specialized research laboratories, however, will be utilized for special tests (e.g., proline hydroxylase, alpha fetoprotein, sarcoma specific antigens, etc.)^ Contractural arrangements for the performance of these tests will be made during Mary 1974. The costs of such tests will be assumed by CDC/NIOSH. Medical Screening Screening will consist of 1) medical history, b) physical-examination, and 3) laboratory testing. Special forms will be used for recording findings f medical history and physical examination (Appendices B and C). The following laboratory tests will be performed on each study participant! 1. Hematology a. CBC with a differential b. Platelet count i c. Reticulocyte count 2. Urinalysis a. Routine urinalysis b. Urine bilirubin and urobilinogen ucc 087511 4 3. Serology a. Direct and indirect reacting bilirubin b. Alkaline phosphatase, gamma-glutamyl transpeptidase, LDH c. SCOT, SGP'f d. ICG-indocyanine green (measurement of disappearance rate of ICG using dichromatic ear densitometry at a dosage of S mg/kg of ICG) e. Proline hydroxylase f. Hepatitis B antigen g. Carcino-embryonic antigen,:alpha fetoprotein, F-antigen, and sarcoma-specific antigens. , h.' B-12 binding protein i. Serum protein electrophoresis 4. Soirometrv a. Vital capacity b. Forced expiratory volumes 5. Radiologic procedures a. Chest x-ray b. Hand x-rays * d. Liver spleen scan. Comments Any worker identified by such a screen procedure as having possible liver impairment will be removed from vinyl chloride exposur" and rofc-rred to his personal physician (nr further diagnostic evaluation and therapy. ucc 067512 5. If a livur biopsy is then fell: indicated, an attempt will be made to obtain biopsy slides and tissue blocks for review by Drs. Thomas and Popper at NIH. In this manner, we hope to uncover any additional cases of angiosarcoma of the liver and also identify any premalignant hepatotoxicity, possibly associated with exposure to vinyl chloride. Workers found to have abnormalities of other organ systems, unrelated i to hepatobiliary disense, will also be referred to their private physicians for appropriate evaluation and therapy. A special letter (Appendix D) will then be sent to these physicians requesting, for each worker thus referred, specific follow-up information, such as final diagnoses, therapy, and prognosis. In this manner information regarding overall morbidity among workers at polymerization plants may be obtained. , As a result of this study and of related work elsewhere, it is hoped that decisions can be made regarding the sensitivity and specificity of the various screening procedures aimed at detecting liver disease among asymptomatic workers at vinyl chloride polymerization plants. Comparison of test results between vinyl chloride workers and non-vinyl chloride controls (administrative staff and plant personnel employed in non-PVC related jobs) will help validate judgments concerning the usefulness of these various tests. Hopefully on the basis of test results obtained from this study, more precise recommendations can be developed concerning medical screening procedures which should be employed to protect the health of persons potentially^exposed to vinyl chloride in industrial settings. f ucc C/-H, Qplcle-r^to lo^vj I [_DO NOT COPY OR OUOTE -1- DRAFT VI Brain Cancer in Petrochemical Workers A Case Series Report Nineteen primary brain cancer deaths have been found among workers at one United States petrochemical plant. We believe this is the largest single series of presumably occupationally-related brain cancers reported in the medical literature. In November, 1978, the Occupational Safety and Health Administration (OSHA), the Federal occupational health enforcement agency of the U.S. Department of Labor, received an employee complaint that work-related chemical exposures might have caused brain tumors in fellow workers as well as his own recently diagnosed brain cancer. OSHA's Office in Houston, Texas began an investigation of brain cancer mortality at the employee's worksite* a moderate-sized petrochemical production facility in Texas City, located in Galveston County south of Houston. Workers, family members and surviving relatives, union officials, local physicians and hospital staff, Texas state health officials and company personnel were interviewed. Four primary brain tumor deaths were discovered among former employees in this way. It is ironic that the worker who filed the original complaint with OSKt was found to have a metastatic carcinoma to the brain, and is not counted amonq the cases. The plant physician subsequently reviewed death infor-stion maintained by the medical department, primarily covering workers who died while employed and who by virtue of 15 years of company service were eligible for death benefits. Ten deaths from primary brain cancer were identified. These ten ucc 067515 DO NOT COPY OR OUOTE -2- DRAFT VI included the four previously found. OSHA then requested technical as sistance from the National Institute for Occupational Safety and Health (NIOSH), Its companion research agency in the U.S. Department of Health, Education, and Welfare. In February, 1979 OSHA, NIOSH, and the company established a collaborative study plan to Investigate the apparent excess of brain cancers. An his torical prospective cohort mortality study was begun to determine the Standardized Mortality Ratio (SMR) for brain cancer, and whether there exists any other unusual mortality pattern. Also included within the cohort study is a case-control study of all primary brain cancer cases to estab- lish whether a particular job or chemical exposure at the plant Is asso-~' ciated with an excess risk of brain cancer. A reference neuropathology laboratory has agreed to examine autopsy and surgical pathology specimens to provide histologic confirmation of the cause of death. Each of these studies is well underway, and results are expected within a few months. An experimental case-finding technique was added to the study design to provide an early estimate of the extent of the problem. A computerassisted search was conducted of Texas Bureau of Vital Statistics data maintained by the M.D. Anderson Tumor Institute Department of Epidemio logy. Since company records showed that 99% of plant employees reside in Galveston, Harris and Brazoria counties, a list of all primary brain cancer deaths among males more than twenty years of age from 1950 through 1977 was obtained for these three counties. This list of 732 primary brain ucc 067516 | 00 NOT COPY OR QUOTE -3- DRAFT VI cancer deaths was matched against company personnel files. Four additional confirmed cases resulted. Further investigation of company records re vealed two more cases. Three other employees became ill during the pre liminary period of the study. All cases were deceased as of March, 1980. The current total of 19 cases is the subject of this case series report. Work history data for the 19 cases are provided in Table 1. The average age at death for the cases was 52; the youngest died at age 30, and there were four deaths after age 60. Over half the deaths occurred between ages 50 and 59. The age distribution observed in this series does not differ significantly from that reported in other series. Total length of employment at the plant ranged from 1 month to slightly more than 35 years, with a median value of 20 years. Two cases had short exposure periods of 38 and 29 days respectively. Median length of employ ment excluding these two cases was 22 years. The interval from first employment to death, which provides an estimate of latency, varied from as few as 3 1/2 years to nearly 36 years, with a median of 24 years. The median values for exposure and latency period in this series are typical of those found for other tumor types In occupational cancer investigations and are consistent with a hypothesis of occuoational etiology resulting from chemical exposures. No particular trend or clustering by hire date among the cases has been Identified as compared to the general plant population. One case was 00 NOT COPY OR QUOTE -4- DRAFT VI hired in late 1940 as part of a small plant start-up crew. Three wore were hired in 1941 during the first year of plant operation, and the others at fairly regular intervals until the last group of four started work during 1953. The first death occurred in 1956, followed by five others during the 1960's. Twelve of the deaths occurred after 1970, three of them during the past year. No established pattern is evident from the observed years of death, but there is no evidence that the rate of appearance of cases is declining. The plant has a current workforce of slightly more than 2,200, including nearly 1,500 hourly and production employees. The average age is 44, and approximately 1,050 current employees have 25 or more years of company service. Since the plant began operation in 1941, there have been a total of 8,850 employees. These Include 6,802 white males, 884 black males, 1,083 white females, and 81 black females through December, 1979. The distribution by county of residence for current workers is provided in Table 2. The plant also engages a temporary independent contractor work force of 100-250 daily, mostly for construction jobs. Unfortunately, no employment records are available for this group. Dcmoqraohic and cause of death data from the death certificates are pro vided in Table 3. All cases occurred among male employees, 18 whites and 1 black. The mortality rate for primary brain cancer in Texas among black males is about one-half that for white males.^ However, very little can be said regarding the racial distribution of cases, since it appears EM -MllViT "'?u .it Tgmiu. . ui p ucc 067518 00 NOT COPY OR QUOTE -5- DRAFT VI that increased numbers of black employees have been employed at the plant only in recent years. All but one of the cases were native-born Americans; the lone exception was Norwegianv The great majority of the cases were born In Texas, two were from Louisiana, and one each was from Massachusetts, New Mexico, and Oklahoma. None of the U.S. states of origin have a particularly high risk for brain cancer, compared to the U.S. national average. There Is pre sently no information available about the age of the cases when they moved to Texas, or where else they may have lived. Sixteen of the cases were Galveston County residents at the time of death; the other three were from Harris County. The possibility of an environ mental etiology related to Galveston County was considered. County-wide data from the National Cancer Institute on the brain cancer mortality rates for Harris, Galveston, and Brazoria Counties from 1950-1969 are In the mid-range for Texas and U.S. national values as shown in Table 4. A survey made by the Texas State Department of Health for 1977 showed that the Galveston County brain cancer crude mortality rate was 3.6/100,000. There is no evidence from these data that local environmental factors outside the plant are responsible for the apparent excess of brain cancer. To obtain an initial estimate of the brain cancer risk, brain cancer deaths among adult white males in Galveston County were analyzed using the list described previously. A total of 54 primary brain cancer deaths occurred In the county from 1962 through 1977. To establish a rough ucc 067519 -6- DRAFT VI comparison, information from the Health Services Administration on county population characteristics was used.*5* In 1970 Galveston County was 68X white, and 62X of the population were between the ages of 14 and 64. A 1970 county population estimate was 170,000 of whom 49X were males.^ Thus, the white male population of employment age at risk during 1962-1977 was somewhat less than 38,000; the plant white male population was about 1,800 or about 5X of the county total. Yet during this period, 11 of 54 brain tumor deaths among county residents occurred in plant employees, nearly 20X of the total. This suggests an approximate plant-wide risk of ^ about four-fold. The underlying causes of death as recorded on the death certificates are listed in Table 2. Nine cases of glioblastoma multiforme were recorded directly on the certificate. Further investigation of hospital and physi cians' records provided evidence that there were six additional cases of glioblastoma multiforme among the total of 19. According to these records one case also was reported to be a metastatic lesion to the cerebellum. Preliminary medical evidence thus suggests that 81X (15/19) of the tumors were glioblastomas. Because this type of tumor usually accounts for 40-55X of deaths in reported brain cancer series, this would indicate an excess of qlioblastoma multiforine among these cases.{1237,8) The difficulty of precise neuropathological diagnosis for brain cancer is recognized, and the pathology review is expected to better define this observation. Th plant is a diversified petrochemical manufacturing facility with a la te number of major product lines. Including ethylene, butadiene, naphtha. ucc 067520 DO NOT COPY OK QUOTE -7- DRAFT VI ethylene dichloride, diethyl sulfate, glycols, aldehydes, acetates, alcohols, amines, organic acids, and plastics and resins (polyethylene, vinyl chloride* vinyl acetate copolymers, phenol`formaldehyde resin). Review of the plant's chemical inventory reveals the presence of at least 11 recognized or suspect carcinogens in significant quantities as raw materials, reaction by-products, or manufactured compounds. These are shown In Table 5. Careful preliminary examination of the work histories of affected employees does not yet establish any common job title, department code, or chemical exposure. Eight of the men were chemical operators in production departments but they were spread throughout the plant, and worked on different chemical processes. Six others were maintenance workers who may have had the. opportunity for plant* wide exposures over the years. Two worked in the chemical shipping depart ment as weighmasters with likely multiple exposures. Five worked in various construction trades. Work histories on the cases are limited to employment by the company with two exceptions. Case 1 was a salaried employee at a nearby petrochemical plant from 1948-1964, and Case 6 worked as a pipefitter from 1952-1974 in the same plant. No information about other potential chemical exposures is presently available. The detailed examination of work histories in the case-control study offers the best opportunity to establish a connection between a particular chemiCcYl exposure or type of work and an excess risk of brain cancer. A detailed literature search for compounds inducing brain cancer has identi fied 26 different chemicals from experimental animal studies as shown In Table 6. Review of available epidemiological studies provided in Table 7 ucc 067521 -8- DRAFT VI offers several intriguing clues, but little solid documentation for occupa tionally-related brain tumors, except in the case of vinyl chloride. Recent mortality studies of oil refinery workers in Canada ^^and petrochemical workers in Texas (^suggest the possibility of an excess brain cancer risk among these groups, although as yet no specific causative agent has been identified. \ A comparison of experimental studies, epidemiological data, and the plant chemical inventory shows that vinyl chloride, acrylonitrile, and diethyl sulfate are possible suspect agents for inducing brain cancer In these workers. On the basis of prior knowledge from human and animal studies, and its presence in the work environment under poorly controlled circumstances in the past, vinyl chloride must be the first compound considered. However, to date, examination of the work histories of the 19 cases does not support a significant positive association with vinyl chloride exposure, and other agents must be carefully evaluated. The information available indicates that this number of brain tumors is excessive in a population of this size, and that the tumors are likely to be occupationally-related. There Is no good evidence to Implicate non plant, general environmental factors. A very careful and tKorough Investi gation of this situation must be made, since a previously unsuspected chemical exposure may be responsible for this striking appearance of brain cancers in a single petrochemical plant. ucc 067522 REFERENCES Draft VI 1. Fan KJ, Kovl J, Earle KM. The ethnic distribution of primary central nervous system tumors: AFIP, 1958 to 1970. J Neuropathol Exp Neurol. 1977; 36: 41-49. 2. Schoenberg BS, Christine BW( Whlsnant JP. The descriptive epidemiology of primary Intracranial neoplasms: the Connecticut experience. Am J Epidemiol. 1976; 104: 499-510. 3. Choi NW, Schuman LM, Gullen WH. Epidemiology of primary central nervous system neoplasms. Am J Epidemiol. 1970; 91: 238-259. 4. Mason TJ, McKay FW. U.S. cancer mortality by county, 1950-1969. Bethesda, Md.: National Cancer Institute, 1974. (DHEW publication no. [NIH] 74-615). 5. The Texas Department of Health and the University of Texas System Cancer Center M.D. Anderson Hospital and Tumor Institute. Impact of cancer on Texas, 1978: 99. 6. U.S. Bureau of the Census. County and city data book, 1972 (A statistical abstract supplement). Washington, D.C.: U.S. Government Printing Office, 1973: 450. 7. Zimmerman HM. Brain tumors: their incidence and classification in man and their experimental production. Ann NY Acad Sci. 1969; 159: 337-359. 8. Percy AK, Elveback LR, Okazaki H, Kurland LT. Neoplasms of the central nervous system. Neurology. 1972; 22: 40-48. 9. Tabershaw IR, Gaffey WR. Mortality study of workers in the manufacture of vinyl chloride and Its polymers. JOM. 1974; 16: $09-518. 10. Waxweiler RJ, Stringer W, Wagoner OK, Jones 0. Neoplastic risk among workers exposed to vinyl chloride. Ann NY Acad Sci. 1976; 271: 40-48. 11. Theriault G, Goulet L. A mortality study of oil refinery workers. . JOM. 1979; 21: 367-370. 12. Thomas TL, DeCoufle P, Moure-Eraso R. Mortality among workers employed in petroleum refinino and petrochemical plants. JOM. 1980; 22: 97-103. 13. Vasquez L. Gliomas In a rat fed with 2-acetyl-aminofluorene. Nature. 1945; 156: 296-297. 14. Maiton1 C, Cllibertl A, DiMaio V: Carcinogenicity bioassays on rats of acrylonitrile administered by inhalation and by ingestion. Med Lav. 1977; 68: 401-411. ucc 067523 DRAFT VI 15. Druckrey H. Specific carcinogenic and teratogenic effects of 'indirect' alkylating methyl and ethyl compounds, and their dependency on stages of ontogenic developments. Xenobiotica. 1973; 3; 271-303. 16. Zulch KJ, Mennel HD. Recent results In new models of transplacental carcinogenesis in rats. In: Tomatis l, Mohr U, Davis W, eds. Trans placental carcinogenesis. Lyon: IARC, 1973: 29-44. 17. Takizawa S, Nishihara H. Induction of tumors in the brain, kidney, and other extra-mammary gland organs by a continuous oral administra tion of N-tnitrosobutylurea in Wistar/Furth rats. Gann. 1971; 62: 495-503. 18. Hirono I, Laqueur GL, Spatz M: Tumor induction in Fischer and Osborne-Mendel rats by a single administration of cycasin. JNCI. 1978; 40; 1003-1010. 19. Druckrey H, Kruse H, Preussmann R, Ivankovic S, Landschutz C. Cancerogene alkylierende substanzen III. alkyl-halogenlde,-sulfate,sulfonate und ringgespannte heterocyclen. Z Krebsforsch. 1970; 74: 241. 21. Schoental R. Carcinogenic action qf elaiomycin in rats. Nature. 1969; 221: 765-766. 22. Swann PF, Magee PN. Induction of rat kidney tumours by ethyl methanesulphonate and nervous tissue tumours by methyl methane-sulphonate and ethyl methanesulphonate. Nature. 1969; 223: 947-949. 23. Ivankovic S. Experimental prenatal carcinogenesis. In: Tomatis L, Mohr U, Davis W, eds. Transplacental carcinogenesis, Lyon: IARC, 1973: 92-99. 24. Magee PN. Mechanisms of transplacental carcinogenesis by nitroso compounds. In: Tomatis L, Mohr U, Davis W, eds. Transplacental carcinogenesis. Lyon; IARC, 1973: 143-148. 25. Alexandrov VA. [Transplacental blastomogenic action of N-nitroso methylurea on rat offspring']. Vopr Onkol. 1969; 15: 55-61. 26. Napalkov NP. Some general considerations on the problem of transpla cental carcinogenesis. In: Tomatis L, Mohr U, Davis, W, eds. Trans placental carcinogenesis. Lyon: IARC, 1973: 1-13. 27. Ulland B, Finkelstein M, Weisburger EK. Rice JM, Weisburger JH. Carcinogenicity of Industrial chemicals propylene imine and propane sultone. Nature. 1971; 230: 460-461. ucc 067524 DRAFT VI 28. Schoental R, Cavanagh JB. Brain and spinal cord tumors in rats treated with pyrrolizidine alkaloids. JNCI. 1972; 49: 655-671. 29. Maltoni C. Predictive value of carcinogenesis bioassays. Ann NY Acad Sci. 1976; 271: 431-443. 30. Milham $. Cancer mortality patterns associated with exposure to metals. Ann NY Acad Sci. 1976; 271: 243-249. 31. Cleimesen J. Are anticonvulsants oncogenic? Lancet. 1974; 1: 705-707. 32. Clemmesen J, Hjalqr1m-Jensen S. On the absence of carcinogenicity to man of phenobarbltal. Acta Pathol Microbiol Scand (Suppl). 1977; 261: 38-50. 33. Gold E, Gordis L, Tonascla J, Szklo M. Increased risk of brain tumors in children exposed to barbiturates. JNCI. 1978; 61: 1031-1034. 34. Brooks WH. Geographic clustering of brain tumors in Kentucky. Cancer. 1972; 30: 923-926. 35. Creaaan ET, Fraumeni JF. Deaths from brain tumors in eastern Kentucky 1950-69. JNCI. 1973; 51: 1717-1718. 36. Trouillas P, Menaud G, DeThe G, Aimard G, Dev1c M. Etude epidemiologique des tumeurs primitives du nevraxe dans la region Rhone-Alpes. Rev Neurol. 1975; 131: 691-708. 37. Cantor KP, Hoover R, Mason TJ, McCabe, LJ. Associations of cancer mortality with halomethanes in drinking water. JNCI. 1978; 61: 979-985. 38. Cooper VIC. Cancer mortality patterns in the lead Industry. Ann NY Acad Sci. 1976; 271: 250-259. 39. DeCoufle P. Further analysis of cancer mortality patterns among workers exposed to cutting oil mists. JNCI. 1976; 61: 1025-1030. 40 Mancuso TF, Ciocco A and El-Attar AA. An Epidemiological approach to the rubber industry. JOM. 1968; 10: 213-232. 41. McMichael AJ, Spirtas R, Kupper tl. An epidemioloqic study of mortality within a cohort of rubher workers, 1964-72. 10M. 1974; 16: 450-464. 42. Monson RR, Fine, LJ. Cancer mortality and morbidity among rubber workers. JNCI. 1978; 61: 1047-1053. 43. Schuman LM, Choi NW, Gullen WH. Relationship of central nervous system neoplasms to toxoplasma gondii infection. Am J Public Health. 1967; 57: 848-856. ucc 06752$ DRAFT VI 44. Monson RR, Peters JM. Proportional mortality among vinyl chloride workers. Lancet. 1974; 2: 397-398. 45. Byren D, Engholm G, Englund A, Uesterholm P. Mortality and cancer morbidity in a group of Swedish VCM and PVC production workers. Environ Health Perspect. 1976; 17: 167-170. uec 067526 Table 1. WORK HISTORY DATA FOR 19 PRIMARY BRAIN CANCER CASES IN A TEXAS PETROCHEMICAL PLANT Date of Case Hire Date of Death Length of Age at Employment Death (years-months) Job Title Department -1 -2 '2 ,5 <6 7 -8 -9 10 -11 -12 -13 14 -15 16 -17 -18 -19 12/16/40 05/18/41 07/29/41 11/30/41 07/09/44 09/18/44 09/18/46 09/26/46 01/12/48 09/21/48 03/02/49 01/25/50 10/19/50 10/23/50 09/19/51 04/27/53 OV17/53 OC/21/53 10/30/53 05/15/64 02/19/66 05/18/76 12/13/65 10/28/79 05/21/74 03/07/79 03/22/73 01/26/71 07/02/75 06/05/71 01/13/68 05/14/74 02/18/80 01/08/74 10/03/56 04/05/62 05/05/71 12/21/78 51 56 66 55 59 55 55 63 53 49 61 66 59 57 52 33 30 44 49 3-6 24-8 31-8 20-4 35-0 0-1 32-3 26-6 1-2 2-1 22-3 16-7 17-1 28-10 22-3 0-1 : 8-7 17-3 24-8 Operator Operator Foreman Operator Bol lermaker Operator Laborer/Oiler Operator Painter Pipefitter Operator Equip. Operator Operator Operator Machinist Machinist Weighmaster Operator Weighmaster Production Production Maintenance Production Structural Shop Production Maintenance Production Maintenance Maintenance Production Maintenance Energy Systems Production Machine Shop Maintenance Shipping Production Shipping ucc 067527 \ \ Table 2. CURRENT PLANT WORKFORCE BY COUNTY OF RESIDENCE County of Residence Galveston Harris Brazoria Other Total Type of Employee Hourly Salaried 1,389 44 41 7 1,481 609 110 15 4 738 Source: Data provided by company Total 1,998 154 56 11 2,219 Percent 90.0 6.9 2.5 0.5 100.0 ucc 067528 ucc Table 3. DEATH CERTIFICATE DATA FOR 19 PRIMARY BRAIN CANCER CASES IN A TEXAS PETROCHEMICAL PLANT Race/ Cause of Death Case Sex Residence Place of Birth Death Certificate Medical Records 1 tn Galveston Texas Carcinoma of Brain Glioblastoma (MR)* 2 v Galveston Missouri Malignant Brain Tumor Meningioma (A) 3 w. Harris Texas Brain Tumor Glioblastoma (A) 4 w Galveston Texas Brain Tumor-Meningioma Meningioma (MR) 5 Galveston Louisiana Glioblastoma Glioblastoma (SP) 6 m Galveston Texas Brain Tumor-Glial IV No Records Available 7 BM Galveston Texas Glioblastoma Glioblastoma (MR) 8 W4 Galveston Texas Glioblastoma Glioblastoma (SP) 9 tfl Galveston Hassachusetts Cerebellar Timor Metastatic Cerebellar Tumor (SP) 10 Harris Texas Astrocytoma Astrocytoma-Grade I (SP) 11 ! Galveston Texas Malignant Glioma Glioblastoma (MR) 12 Ut Galveston New Mexico Glioblastoma Glioblastoma (A) 13 ill Galveston Norway Glioblastoma Glioblastoma (SP) 14+ w Galveston Texas Glioma-Grade III Astrocytoma-Grade IV (MR) 15 m Galveston Texas Glioblastoma Glioblastoma (A) 16 w Harris Texas Glioblastoma No Records Available 17 hM Galveston Louisiana 18 IH Galveston Texas 19 WM Galveston Texas Brain Tumor Malignant Glioma Brain Tumor Glioblastoma (A) Glioblastoma (SP) Glioblastoma (A) Data from company records, death certificate not available Source: HR-Medical Records; A-Autopsy; SP-Surgical Pathology \ Table 4. BRAIN AND OTHER CHS CANCER MORTALITY, 1950-1969: AVERAGE ANNUAL AGE ADJUSTED RATES PER 100,000 Location White Male White Female Black Male Black Female United States 4.4 2.9 2.3 1.5 Texas 4.3 2.9 1.9 1.5 Galveston County 4.5 2.9 2.5 2.1 Harris County 4.5 3.6 2.0 1.9 Brazoria County 3.1 3.9 1.2* 1.5 *Based on one case The ranqe of U.S. rates for males for counties with >10 deaths from 1950-1969 were 3.1-5.4 (white) and 1.3-3.9 (black). The range of Texas rates for white males for counties with >deaths from 1950-1969 was 2.3-10.8. Source: U.S. Cancer Mortality by County, 1950-1969, National Cancer Institute, DHEW Pub. No. (NIH) 74-615, Bethesda, Maryland, 1974 ucc 067530 Table 5. RECOGNIZED AND SUSPECT CARCINOGENS IN A TEXAS PETROCHEMICAL PLANT Acrylonitrile Benzene Diethyl sulfate Dloxane Ethylene dichlorlde Hydrazine Isopropyl Oils Trlchloroethane Trichloroethylene Vinyl chloride Vinylidene chloride ucc 087531 Table 6. EXPERIMENTAL BRAIN CARCINOGENS 2- Acetylaminofluorene (13) Acrylonitrile (14) l-Aryl-3,3-Dialkyltriazenes (15) Azoethane* (16) Azoxyethane* (16) Azoxymethane (15) Butylnitrosourea (17) Cycasin (18) 1,2-Diethylhydrazine (15) Diethylnitrosamine* (15) Diethyl Sulfate* (19) Dimethylbenzanthracene* (20) Dimethyl Sulfate* (19) Elaiomycin (21) Ethyl methanesulphonate (22) Ethylnitrosobiuret* (16) Ethylnitrosourea* (23) 1-Methyl-2-Benzyl-Hydr azine* (15) Methyl methanesulphonate (24) Methylnitrosourea* (25) Methylnitrosourethane (intraplacental) (26) Procarbazine* (23) Propane Sultone (27) Propylene Imine (27) Pyrrolizidine Alkaloids (28) Vinyl Chloride (29) Transplacental carcinogenesis ucc 067532 Table 7. EPIDEMIOLOGICAL STUDIES; CLUES TO HUMAN BRAIN CANCER ETIOLOGY Aluminum Workers (30) Anti-Convulsant Use (31,32,33) Farm/Rural Residents (3) Geographic Clustering Kentucky (34,35), Rhone Valley (36) Halomethanes in Drinking Water (37) Lead Smelter Workers (38) Machinists (39) Oil Refinery Workers (11) Petrochemical Workers (12) Rubber Workers (40,41,42) Toxoplasmosis (43) Vinyl Chloride Workers (9,10,44,45) ucc 067533 Brain Cancer Cluster Investigation in a Texas City, Texas Chemical Plant Sanford S. Leffingwell, MD, MPH Richard Waxweiler, PhD David Glenn, MD John Carvajal, -- Victor Alexander, MD, MSPH October, 1980 ucc 061534 Introduction: In February of 1979, The National Institute for Occupational Safety and Health (NIOSH) of the Department of Health and Human Services, the Occupational Safety and Health Administration (OSHA), of the Department of Labor, and the Union Carbide Corporation began an investigation of a cluster of brain tumors'at the company's Texas City,tTexas plant. The initial events and the characteristics of the cases have been described by Dr. Victor Alexander. We here describe the conduct and present status of a case-control study of occupational histories of employees of that plant who developed primary brain tumor s. Methods and Materials: The method of case identification has been described by Dr. Alexander; the company was able to identify 12 cases, matching company records with lists of all adult males who were residents of surrounding counties and who died of malignant brain tumors yielded four more cases, three additional cases became ill and died during the course of the study, and three cases have been found so far in the course of determining the vital status of all workers ever employed in the plant. Medical records and tissue specimens were obtained, where possible, and a best diagnosis was chosen from the available evidence. ucc 061535 (9/29/80) page 2 Following the advice of Schoenberg al., we included all deaths due I to primary intracranial neoplasms except those of the pituitary. This excluded one case with a metastatic lesion and one with a congenital anomaly but with no tumor found at autopsy. Two of the most recently discovered cases have not been included, pending confirmation of the diagnosis. Analyses of the residual 18 cases will be done both for the g^oup as a whole and for the 15 proven gliomas. ' For each employee, the company completed coding sheets containing identifying personal data, date of each new job title or department code, job code, department accounting code, and date of each layoff or date of termination. Vital status was coded, when known. Every 50^ record was copied and sent to NIOSH for independent verification of coding. A random sample of the original records will be drawn by NIOSH and used for verification of completeness of cohort identification. Six controls were drawn for each case from the pool of all people ever employed at the plant. Cases were matched to potential controls by race and sex; date of birth was matched to within three years; date of first hire .for the control was before that of the case, but not more than three years before; the date the control was last employed was later than the case's last date of employment. The control could be living but, if dead, must not have died of a malignancy. Pools of controls meeting the criteria outlined above were formed and the actual controls used were drawn by random number from the pool. ucc 067538 19/29/30) page 3 The company provided translations for the job and department codes and ; provided a list of chemicals encountered in each njajor department - group. The departmental coding schemes used for accounting purposes within the plant have changed over the years, so a common list tracing the history of each department was prepared and all codes were transformed to conform to a single coding scheme. Although catalysts have%changed often, there appears to be no problem in characterizing I1 the feedstocks, intermediate products, and output of each department ) through the years the plant has been in operation. t ^ Each job, department, major department group, or chemical exposure represented by at least three cases was tested for possible 2 significance by X or Fisher's Exact Test. Since this approach is a multiple sampling technique which should lead to about one significant" association for every twenty jobs, departments, or exposures considered, it is used here as an hypothesis generating mechanism, not as a means of properly testing the hypotheses. For example, since at least one case was exposed to each of nearly 200 chemicals, chance alone should lead to identification of about 10 chemicals whose proportion is significantly different between cases and controls. About half of the ten would be positive and half would be negative associations. ucc 067537 < (9/29/30) Results: page 4 Only one job code, "Operator" was represented by more than three cases. Table I shows the distribution of operators among the cases and controls. There is no significant difference in proportions. When 4analyzed by department accounting code* only the maintenance department, with eight cases, was represented by more than three cases. Table II shows the distribution of maintenance department workers among the cases and controls. Grouping the accounting codes into major departments did not yield any new concentrations of three or more cases. There were no significant differences in proportions. When cases and controls were analyzed by chemical exposures, a new problem was encountered: difficult to characterize accurately, due to their mobility throughout the plant. Accordingly, as a first step, we have examined the data in three ways: in the first, maintenancemen are excluded from analysis; in the second, they are considered to have been exposed to everything in the plant; in the third, they are considered to have been exposed to nothing in the plant. The data are presented in Tables III, IV, and V; only those chemicals to which more than three cases were exposed and which showed a relative risk greater than 1.0 are tabulated. ucc 067538 (9/29/BO) Discussion; page 5 So far in the course of this investigation, no convincing association has been found between any historical exposure and the development of brain tumors at this plant. The incomplete characterization of the maintenance employees' exposures is a significant weakness in the analysis done so far, but fortunately can be corrected, at least in \ part, by further review of existing records. Some of the maintenance department employees had reasonably well defined exposures; for example, one case was an instrument repairman whose work rarely took him out of the instrument shop. He plan to define exposures of cases and controls who worked for the maintenance department as completely as possible and study the full data set. At that time, there should also be enough information at hand to study the exposures by latency. It is possible that the tumors seen are the result of a more general effect or exposure. We plan to examine the geographic location within the plant of cases and controls, to see if any pattern emerges, and will atempt to determine the residence at time of first hire, to see if there appears to be any unusual clustering outside the plant. Finally, we must ask whether we are really seeing an effect which requires explanation. The excess of observed over expected reported 2 earlier , combined with an apparent excess when compared to local 3 rates , could be the result of chance. The reported correlations 19/29/80) page 6 with duration of employment and latency since first employment argue against this hypothesis but do not refute it. Inquiry into exposures present in other populations with apparent excesses of brain tumors may provide needed additional clues. ucc 067540 (9/29/80) page 7 Table 1: Distribution of Operators Among Cases and Controls 1A. All Cases Operators Non-operators Total Cases 9 9 18 1 Controls 1 1 49 1 1 59 i J 108 1 O4dAds ratio * 1.2; X^ * 0.045; *p greater than 0.75 IB. Proven Gliomas Operators Cases 7 Controls 40 Non-operators 8 50 Total 15 90 Total 58 68 126 Total 47 58 105 Odds ratio M 1.1; X^ D.024; p greater than 0.75 ucc 067541 f (9/29/30) page B Table II: Distribution of Maintenance Workers Among Cases and Controls IIA. All Cases Maintenance workers Cases 7 Controls 46 Total 53 Non-maintenance workers 11 62 73 Total 18 108 126 Odds ratio * 0.86; 0.087; p greater than 0.75 IIB. Proven Gliomas Maintenance workers Non-maintenance workers Total Cases 7 8 15 Controls 37 53 90 Odds ratio " 1.3; X^ - 0.163; p greater than 0.75 Total 44 61 105 ucc 067542 (9/25/80) page 9 Table Hit Distribution Among Cases and Controls of Workers Exposed to Selected Chemipals (Maintenancemen Excluded) I1IA. All Cases Exposed 1. Diethyl ether 2. Ethanol 3. Sodium phosphate salts 4. Lubricating oil 5. Nonoethanolamine 6. Ethylene glycol 7. Naphtha 8. Potassium hydroxide Cases 3 3 3 6 4 3 3 2 Cont. 2 2 2 15 10 8 8 5 Total 5 5 5 21 14 11 11 7 odds 7.87 3.20 1.73 1.41 1.44 P* 0.07 0.30 0.42 0.80 0.81 Unexposed 1. Diethyl ether 4 21 25 2. Ethanol 4 21 25 3. Sodium phosphate salts 4 21 25 4. Lubricating oil 189 5. Monoethanolamine 3 13 16 6. Ethylene glycol 7. Naphtha 4 15 19 4 15 19 8. Potassium hydroxide 5 18 23 Total * Fisher's exact test 7 23 30 UCC 067543 \ (9/2&/80) page 10 Table III (Con't): Distribution Among Cases and Controls of Workers Exposed to Selected Chemicals (Maintenancemen Excluded) 1UB. Proven Gliomas Exposed 1. Diethyl ether 2. Ethanol 3. Sodium phosphate salts 4. Lubricating oil 5. Monoethanolamine 6. Ethylene glycol , 7. Naphtha 8. Potassium hydroxide Cases 2 2 2 4 3 2 2 2 Cont. 1 1 1 9 6 5 5 2 Unexposed 1. Diethyl ether 2. Ethanol 3. Sodium phosphate salts 4. Lubricating oil 5. Monoethanolamine 6. Ethylene glycol 7. Naphtha 8. Potassium hydroxide 2 2 2 0 1 2 2 2 13 13 13 5 8 9 9 12 Total 3 3 3 ---O---d--d5s jI pr* 1 13.0 ( 0.11 1 13 inf. | 0.23 9 4.00 | 0.29 7 1.80 | 0.86 71 4 6.00 | 0.98 1 ! 15 15 15 5 9 11 11 14 Total * Fisher's exact test 4 14 18 UCC 067544  I (9/29/80) page 11 Table IV: Distribution Among Cases and Controls of Workers Exposed to Selected Chemicals (Maintenancemen Counted as Exposed) 4 4 1 ucc 067545