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|<U4 (SpM) INTER- OFFICE MEMO TENNECQ CHEMICALS, INC. \ To G.I. Rozand At Piscataway date April 9, 1974 Prom W.C. Champion Subject VCM Monitoring Program March, 1974 At Burlington Copy to Dr. T. Aalto H.B. Carr J. Fath P.A. Ketterer J.F. Kilcullen J.W, Poarch P.M. Reed D . Rhoads F.X. Ritter Dr. M. Rosen P.R. Scarito A. C. Siegel D. I. Smalley J.T, Sweeney C.G. Thompson file Resin Plants - Operating Area Monitoring (High Personnel Exposure) Air monitoring via Century OVA continued at both plants. The results shown in Tables I (Flemington) and II (Burlington) summarize the findings for each plant and compare the March readings with those reported last month. In the two plants, only five areas had average concentrations in excess of 50 ppm. These were: 1. Flemington tank farm area (500 ppm) - an outdoor area of generally low personnel exposure time. 2. Burlington homopolymer compressor area (76 ppm) - this problem has been corrected by improved ventilation. 3. Dispersion ''A" Plant latex blend tank area (240 ppm) - improved ventil ation is being engineered. 4. Dispersion ''A" Plant penthouse (94 ppm) - a single day's high readings due to a tower Tiatch leak led to this high average. 5. Dispersion "B" Plant latex blend tank area (60 ppm) - improved ventil ation is being engineered. In Flemington, only one other area exceeded a 25 ppm average - the monomer unloading compressor shack (28 ppm). All but seven Flemington monitoring points showed the same or lower averages in March, compared with February's figures. In the reactor building, higher than desired concentrations around the recovery compressors (21 ppm average) caused high concentrations immed iately above at the foreman's desk on the reactor floor (22 ppm), and also in the stripper bottom (10 ppm), stairwell (20 ppm), lavatory (17 ppm) and charge meter (14 ppm) areas. Ventilation changes are being engineered which should reduce exposures in these five areas. The remaining two points which increased reflect high readings at the bagger station during Gaylord filling COLORITE 012773 Page 2 (17 ppm average), a very infrequent operation, and sampling of bulk trucks \ (13 PPm). The Burlington resin plants showed significant reductions in VCM exposure, -with only two monitoring points showing an increased average in March. Both of these were due to single incidents of monomer leaks discovered during monitoring, which had significant effects on the averages. In ad dition to the >50 ppm areas mentioned above, Burlington had three areas of greater than 25 ppm average exposure: copolymer recovery area (30 ppm), dispersion "A" Plant wet cake bin (28 ppm) and tower cleaning (38 ppm). Although all Burlington plant areas had generally reduced exposures, the plastisol plants showed the greatest improvements, with average exposures in both plants reduced by 75%. This reflects improvements in plant ventilation and stripping techniques. Further efforts to preclude excursions over 50 ppm VCM and reduce average exposure by increased ventilation are underway. A number of job functions which showed high readings in February were not monitored in March, since the use of air-supplied breathing apparatus is now required for these jobs. These jobs are indicated on the attached ta bles. Time-Weighted Average (TWA) Exposure Values Although the significance of time-weighted exposure averages is questionable in light of the recent OSHA emergency standard, we have recalculated the TWA's for our plant operating personnel as an indicator of improvement in work practices and as a guide in identifying remaining problem areas. Job time analyses were reviewed and revised by Production management, and TWA exposure values calculated. Tables III and IV compare the March results with those reported last month for Flemington and Burlington, respectively. As previously mentioned, a number of high exposure job functions now require supplied breathing air, and this has resulted in greatly reduced TWA's for the affected personnel. No job classifications in either plant show expos ures of greater than 50 ppm TWA. In Flemington, only one job - that of shift- foreman - is over 25 ppm. At Burlington, three classifications are over 25 ppm - plastisol "A" Plant tower operator/dumper, plastisol laborer/tower cleaner (water) and plastisol tower cleaner (manual). As the area monitoring data show, however, many excursions of greater than 50 ppm exposure continue to be encountered. The frequency of these excursions, and their consequent effect on TWA's, will only be determined when permanent monitoring becomes available. * Personnel Monitoring Three types of personal monitoring pumps have been obtained and are under evaluation. The Bendix pump, widely used for dust analysis, has a through put rate (designed for nominal 2 liters/minute) which is too fast for use with a carbon absorption cartridge. The MSA pump, the standard pump used for monitoring organic solvent vapors and TCE, has a designed nominal throughput rate of 1 liter/minute. This flow rate gives significant ''break through" (loss) of VCM in the standard carbon absorption tube in ten minutes of operation. Although it is possible to operate this pump at lower rates. COLORITE 012774 Page 3 we have found it difficult to do this with acceptable reproducibility. A third pump of new design is the "Sipin" pump, manufactured by SKC, Incor porated. This pump is lighter in weight and quieter in operation than ihe others, and offers a rate range of 20 to 80 milliliters/minute. At arbi trarily selected rates of 25 and 50 milliliters/minute, we have found good results (no break-through) with these pumps, using the standard cartridge, for sampling times from ten to forty minutes. Mr. Ketterer is refining the analytical method and establishing test accuracy, but it appears that this pump will meet the requirements of the OSHA emergency standard. At the present time, we have two of these pumps, with an additional four pumps expected before April 20. An additional twenty-four pumps have been ordered to allow complete coverage of our resin and compound plants, and to support Nixon, Newton and customer processing operations. These pumps are expected in early May. Residual Monomer in Resin The original estimates of residual VCM concentration in homopolymer resins, as reported last month, were found to' be somewhat optimistic. Homopolymer "as shipped" averages between about 350 ppm and 1300 ppm in VCM content, de pendent upon resin f-. Copolymers "as shipped" averaged from 110 ppm to 150 ppm in residual VCM, while plastisol resins averaged from 8 to 35 ppm. The residual monomer content of blending resin has been significantly reduced through process changes. Although we do not know what levels of residual monomer will ultimately be tolerated in the resins we produce, considerable effort has been made in both plants to reduce these levels in all products. Improved stripping tech niques continue to be developed in both plants, with extended time under vacuum and higher stripping temperatures the major variables. At riemington, stripper jacket heating is being explored. Varied drying techniques (higher temperatures, longer residence time) are being tried at both plants. Finally, the effect of air purging of resin bins is being investigated at both plants and on a bench scale in Piscataway R&D. The impact of these efforts on plant productivity has not yet been fully assessed. Based upon preliminary data, productivity of BR-501, when run in the entire Homopolymer Plant, will be reduced by 1 - 1^ batches/day because of extended stripping cycles. If BR-501 is run in two reactors in either the Homopolymer or Copolymer Plants, thus tying up one stripper, the pro ductivity of 10R or 315 would suffer.' Table V gives the residual VCM data for the Flemington Plant. The VCM con tent of PVC 200-2 is higher than desirable, but this may be resolved by heating of the stripper jacket. The residual VCM in PVC 225 averages 600 ppm, mainly because of the poorer efficiency of "A" dryer compared with "B" dryer. This dryer difference has been noted on almost a daily basis, and probably reflects the lower temperatures encountered in the fluid bed "A" line. It is hoped that this will be resolved by increased temperatures and efficient use of antistats. PVC 250 and PVC 250-3 appear lower in residual VCM than PVC 225, but there is insufficient data to draw firm conclusions. At Burlington (Table VI), residual VCM content is generally similar to that in Flemington for the same product types. The steam-stripped resins (PVC COLORITE 012775 Page 4 175, 10R) show lower residual monomer concentrations than would be expected from their molecular weights. Extensive efforts to reduce the VCM content \ in 10R for Nixon to below its current level of 500 ppm "as shipped" are underway. A lot employing high temperature steam stripping and containing about 125 ppm of VCM has been prepared for evaluation at Nixon, where the effect of this stripping technique on heat stability will be determined. A steam-stripped lot of PVC 200-2, also prepared for evaluation at Nixon as part of an effort to eliminate trichlorethylene as a chain transfer agent, had much lower VCM content (217 ppm) than similar product produced without steam stripping (900 - 3000 ppm). The data for PVC 225 and 250-3, produced in limited quantity at Burlington, show these resins to be generally similar to Flemington production. Blending resin, which was identified as a particular problem area lastmonth, has been significantly improved. Longer stripping times and increased dryer temperatures led to a drop in the average VCM content from over 2800 ppm in the first half of March to about 600 ppm in the second half. The data for residual monomer in copolymer and plastisol resins may be found in Tables VII and VIII, respectively. These product types do not appear to represent a problem area. In addition to analysis of product, as produced and shipped, studies were made to determine the effects of aging and bin air purging on residual VCM content. The data for various product types aged in a fiber container in the laboratory are presented in Table IX. These data show that, for most products, residual VCM is reduced by 50% or more after five days of aging. In the resin plants, bins containing various resin types were set aside and purged with approximately 10 cfm of ambient air for up to eighteen days. Tables X through XII show the results of bin purging and static storage (in bags) of PVC 200-2, PVC 225 and PVC 250. For the PVC 200-2, the monomer content was halved within one day in both bin and bags. After nine days, the monomer content was about 220 ppm in the bin and about 360 ppm in the bags. For the PVC 225, starting at a lower average residual VCM concentra tion, the 50% reduction was not reached until the fifth day in the bin. In bags, the 50% reduction level occurred in the second day. By the ninth day, the monomer concentration was about 30 ppm in the bin, 165 ppm in the bags. The 250 gave a faster reduction, with monomer content reduced by half in the first day in both bin and bags. After four days' aging, the monomer content of the resin in the bin was -<100 ppm. At Burlington, a bin containing 10R was air purged for eighteen days. As shown in Table XIII, this process had no measurable effect. An R&D program has been initiated to further study the effects of purging on resin. Preliminary results indicate the positive effect of higher air through-put rates and elevated temperatures. As a reference point, competitive resins purchased for use in'our Compound Plant and at Nixon were analyzed for residual VCM. A comparison with sim ilar Tenneco products showed: Competitive Resin (no. of samples) Average VCM, ppm Tenneco Type Average VCM, ppm Firestone 9300(5) 635 Hooker 282 Airco (1) (l) I 2600 519 Stauffer 608 (2) 579 225 200-2 315 10R 607 1281 no 505 COLORITE 012776 Page 5 Burl 'j'gton Compound Plant Continued OVA area monitoring during March showed low operator exposures, as can be seen from Table XIV. Analysis of air samples taken in the blender area show a high 43 ppm VCM during preparation of a blend utiliz ing high monomer content Hooker resin (2500+ ppm VCM). All other airsamples analyzed in this area, as well as in other parts of the Compound Plant, showed 5 ppm or less. Flexible pellet samples analyzed just after production showed 0-4 ppm of VCM. A single sample of record compound contained 105 ppm. Foam and Plastics Division Air monitoring and product and air analysis surveys were made at both the Nixon and Newton Plants of the Foam and Plastics Division. The results generally paralled those found in our Compound Plant: operator breathing zone exposure was low (^16 ppm VCM), while flexible (Newton) product con tained no detectable VCM and rigid (Nixon) product contained 140-200 ppm VCM, Detailed reports on these visits are appended. Environmental Considerations In an effort to ascertain the quantity of VCM which may be leaving our plant site in the air, samples of air were taken for analysis at the plant perim eter at both sites. A second consideration for this work was to identify points of low VCM concentration where an intake for breathing air could be placed. As shown in Figures I - IV, as high as 3 ppm at Fleraington and 3.7 ppm at Burlington were detected at the perimeter fence. Water samples from our final effluent at both plants were also analyzed. The maximum detected concentration of VCM in these samples was 1 ppm. Attachments, WCC/jst COLORITE 012777 TABLE I FLEMINGTON RESIN PLANT VCM MONITORING SUMMARY February & March, 1974v ! Monitoring Point Reactor Building - Ground Floor 1. Slurry Basket Area 2. Slurry Basket During Cleaning *3. Slurry Sample from Stripper 4. Methocel Make-Up Area 5. Center Aisle *6. Recovery Comp. Room - Between Comp Reactor Building - Second Floor 7. Center Aisle 8. Open Reactor Area *9. Charge Meter Area 10. Stripper Platform *11. Foreman's Desk 12. Operator's Desk 13. Panel Board *14. Stairwell Anteroom *15. Lavatory Hamer Blind Area x7. Reactor Opening Recovery Tanks 18. Recovery Tank Area 19. Recovery Tank Draining Operation 20. Walkway Near Bunker 21. Catalyst Weigh House 22. Settling Ponds Boiler House 23. North End 24. South End Underground VCM Storage Tanks 25. Tank Farm Area 26. Checking Tank Level 27. Checking Blend Tank LEL and 0 28. Compressor Shack 29. Walkway Between Tank Farm & Blend Tank VCM Rail Car Unloading 30. Platform Area 31. VCM Rail Car Hook-Up 32. VCM Rail Car Disconnect '. VCM Rail Car Sampling (^February 2-25 and March 4-29 *Monitoring Points Showing an Increased Avea OVA Reading ^ PPm February March Maximum Average Maximum Average 20 10 -- --7 11 7 10 7 30 8 20 6 Air Required 40 10 10 6 10 6 100 21 15 8 100 34 15 10 20 9 30 10 30 11 25 10 30 10 30 10 ---- -- 12 6 70 9 50 14 25 7 80 22 20 9 40 9 60 20 50 17 10 6 Air Required - 10,000 8 7 7 -- 2,172 5 5 5 10 5 Air Required 64 54 64 7 .5 *^ 10,000 200 150 -- 6 6 4,675 90 79 -- 64 64 10,000 500 Air Required Air Required 200 28 12 5 ---- ---- -" 10 5 Air Required Air Required Air Required in March COLORITE 012778 FL^MINGTON MONITORING SUMMARY - Pago 2 y Monitoring Point Dryer Area/Warehouse 34. Slurry Transfer Hook-Up 35. Dryer Monitoring Desk 36. Dryer Panel Board 37. Wet Cake Sampling 38. Maintenance Office 39. Maintenance Shop *40. Foreman's Office 41. Bagging Room *42. Bagging Machine - Operator's Station 43. Warehouse 44. Warehouse Office Bulk Loading Areas 45. Tower Area 46, Transfer Line Hook-Up 47. Bulk Truck Hook-Up *48. Bulk Truck Sampling 49. Bulk Rail Car Hook-Up 50. Bulk Rail Car Sampling Quality Control Laboratory 51. Laboratory 1 52. Laboratory 2 . Laboratory 2 Desk a4. Office 55. Lunch Room 56. Black Top Area Adjacent to Warehouse 57. Up-Wind Plant Location 58. Down-Wind Plant Location Pilot Plant 59. Reactor Area - First Floor 60. Reactor Area - Second Floor 61. Reactor Dumping 62. Reactor Cleaning 63. Finishing Area OVA Reading, ppm February March Maximum Average Maximum Average 12 9 97 -- -- -- 30 13 86 -- 30 15 76 76 18 8 12 6 15 6 17 8 10 6 12 8 10 7 12 7 100 17 10 6 96 -_ 15 8 -8 -6 -- --- 15 6 75 -- 30 13 -- 15 9 20 13 22 13 25 13 10 8 -- -- -- 10 40 40 40 10 6. 6 7 6 13 12 10 6 4 5 4 8 10 - ' 11 6 6 8 6 10 5 75 11 5 -- -- 54 Monitoring Points Showing an Increased Average in March ! jtf.c, Champion April 9, 1974 COLORITE 012779 TABLE IX BURLINGTON RESIN PLANTS VCM MONITORING SUMMARY February & March, 1974U) OVA Reading, ppm Monitoring Point Copolymer Plant, Ground Floor ~T. Copolymer Drag-Out, Outside 2. Copolymer Slurry Pumphouse 3. Blacktop, Outside Near BMW Tank 4. South-East Stairwell *5. Recovery Area, Outside 6. Braining Recovery Receivers 7. Braining Master Mix Tanks 8. Braining Recovery Pumps 9. Recovery Compressor Area 10. Center Aisle 11. Reactors, Clean-Out Valve Open 12. Solution Make-Up Tank Area 13. Dry Chemical Weighing Area 14. Weigh Scale Area February Maximum Average IS 10 75 64 24 11 30 16 --- -40 14 70 18 50 29 20 10 ---- --- March Maximum Average 15 5 74 44 18 5 300 30 Air Required Air Required Air Required 35 7 12 4 54 54 54 54 Copolymer Plant, Second Floor T57 Lavatory 16. Panel Board/Desk Area 17. Center Aisle 18. Weigh Scale Area 19. Reactors, Opening 6" Access Hole 20. Reactors, Opening Manway 21. Reactors, Manual Cleaning 22. Chemical Hoist, Outside 23. Blend Tanks, Catwalk 24. Blend Tanks, Sampling for O2 25. Walkway to Homopolymer 20 12 30 12 25 12 22 13 _-- -- -15 7 15 11 -- --- 32 7 22 7 85 85 20 14 Air Required Air Required 94 40 7 Air Required 50 15 Homopolymer Plant, Second Floor 26. Panel Board/Besk Area 27. Center Aisle 28. Opening Reactor Lenape Cover 29. Reactor Washout 30. Manual Reactor Cleaning 31. Sampling Blend Tanks for 02 55 50 200 - - - 30 21 81 - - - 50 15 27 11 100 31 Air Required Air Required Air Required Homopolymer Plant, Ground Floor 32.Slurry Pumphouse 33. Recovery Area, Outside 34. Recovery Compressor Area 35. Weigh Scale Area 36. Center Aisle 37. Reactors, Clean-Out Valve Open 38. North-West Stairwell (l) February 2--25 and March 4 -- 29 15 10 50 25 700 130 70 32 100 23 25 18 17 10 . 20 30 500 50 15 80 '18 8 11 76 18 8 17 6 *Monitoring Points Showing an Increased Average in March COLORITE 012780 BURLINGTON MONITORING SUMMARY Page 2 OVA Reading, ppm \ .ionitoring Point February Maximum Average March Max imuin Average Dispersion Plant "A", Ground Ploor 39. "A" Plant Drag-Out, Outside 40. North-East Stairwell 41. In-Line Mixer Area 42. Moyno Pump Area 43. Dryer Panel Board Area 44. Under Tower, Opening Hamer Blind 45. Under Tower, Water Cleaning 46. Under Tower, Manual Cleaning 18 25 100 150 120 60 - - 7 9 48 54 50 36 - - 73 13 5 65 17 45 16 55 20 100 21 100 21 100 21 Dispersion Plant "A", Second Floor 47. North-East Stairwell 48. Stripper #1 Area 49. West Cake Bin Area 50. Latex Blend Tank Area 51. Homo System Area 20 150 500 4000 110 10 55 160 923 60 23 50 90 1800 50 7 17 28 240 18 Dispersion Plant "A", Third Floor i52. Panel Board/Desk Area 53. Catwalk, Filter #1 54. Back of Filter #1 55. Back of Filter #2 56. Catwalk, Filters #2 and #3 i7. Back of Filter #3 58. Batch Mix Tank, Back 59. Batch Mix Tank, Weigh Scale 60. Catalyst Charge Pot 61. Cake Breakers 62. Elevator 300 2000 - - - 500 - 4000 15 116 ' 226 - 194 -- -- 390 7 64 100 100 100 100 100 65 65 65 35 22 18 22 22 22 22 22 22 22 22 19 5 Dispersion Plant "A", Penthouse *63, Center Aisle 64. Opening Tower Manway 65. Water Cleaning Tower 66. Manual Cleaning Tower 67. North-East Stairwell 100 - 25 16 -- 10 2000 94 Air Requ ired 100 38 100 38 60 9 Dispersion Plant "B", Penthouse <>8. Center Aisle 69. Opening Tower Manway 70. Water Cleaning Tower 71. North-West Stairwell 100 - 100 16 -- 29 30 8 Air Required 15 9 12 5 Dispersion Plant "B", Third Floor 72. North-West Stairwell 73. Back of Filter #6 74. Back of Filter #5 75. Catwalk, Filters #5 and #4 76. Back of Filter #4 77. Catwalk, Filter #6 78. Cake Breaker Area 79. Batch Mix Tank, Back 90 600 - -- - -- 750 200 17 80 - - - -- 149 70 * 13 25 25 25 25 25 17 25 6 11 11 11 11 11 10 11 *Monitoring Points Showing an Increased Average in March COLORITE 012781 BURLINGTON MONITORING SUMMARY Page 3 .ionitoring Point Dispersion Plant "B", Third Floor (cont'd) 80. Batch Mix Tank, Weigh Scale 81. Catalyst Charge Pot 82. Panel Board/Desk Area 83. Latex Blend Tank - Tween 20 Funnel 84. South-Center Stairwell Dispersion Plant "B", Second Floor 85, Latex Blend Tank #6 86. Stripper Area 87. Wet Cake Bin Area 88. Homo System Area 89. Lavatory Dispersion Plant "B", Ground Floor 90. North-West Stairwell 91. ''B" Plant Drag-Out, Outside 92. Dryer Panel Board Area 93. In-Line Mixer Area 94. Moyno Pump Area 95. Vacuum Pump Area 96. Under Tower, Opening Hamer Blind 97. Under Tower, Water Cleaning 8. Under Tower, Manual Cleaning Tank Farm 99. Unloading Station, Outside 100. Tank Car, Sampling 101. Tank Car, Connecting Lines 102. Storage Tank Level Check 103. Compressor House #1 104. Compressor House #2 105. Refrigeration Building Classification Building 106. Atomizer Room 107. Plastisol Bagger 108. Syntrons 109. Merchan Feeder Area Suspension Dryer Building 110. Dryer Panel Board 111. Operator's Desk 112. Dryer Area 113. Copolymer Bagging Station 114. 10MM and 40MM Bagging Station 115. Cleaning Copolymer Dryer 116. Cleaning 40MM Dryer .7. Cleaning 10MM Dryer 118, Centrifuge Deck 119. 40MM and 10MM Line Magnets OVA Reading, ppm February March Maximum Average Maximum Average -- ---60 17 25 11 25 11 14 9 - 17 7 350 174 150 42 120 43 100 36 50 14 400 60 24 11 18 11 30 12 84 20 15 35 150 150 40 100 - - 10 8 22 43 ' 47 23 29 - - 84 64 20 8 25 11 20 10 20 10 18 8 18 8 -- - 500 - - 180 50 - - 213 - 71 16 - 32 Air Required Air Required Air Required 15 3 12 4 83 15 6 30 19 30 16 200 50 73 95 75 65 50 24 --- 60 22 18 16 ------ 40 20 20 20 7 8 - 10 7 10 -- - 12 25, 5 5 6 5 6 -- -- - 5 8* COLORITE 012782 BURLINGTON MONITORING SUMMARY Page 4 \ -nitoring Points 120. 10MM Sifter 121. 40MM Sifter 122. 123. 124. 10MM and 40MM Line Palletizing Copolymer Palletizing Dispersion Palletizing 125. Lunch Room-East End 126. Lunch Room-West End 127. 128. 129. Maintenance Shop-North End Maintenance Shop-South End Maintenance Shop-Welding Well Production and Maintenance Offices 130. Maintenance General Foreman's Office 131. Maintenance Foreman's Office 132. Engineer's Office 133. Safety Supervisor's Office 134. Production Foreman's Office Warehouse !)35. West Aisle 6. West-Center Aisle 37. Checker's Desk Area 138.' Shipping Office 139. Receiving Office 140. East-Center Aisle 141. East Aisle 142. Bass Office Copolymer Bulk Station Ii37 Sifter Desk 144. Second Desk 145. Tailing Hopper, Outside Loading Area 146. Homopolymer Transfer House 147. Bulk Truck 148. Hopper Car 149. Initiator Freezer 150. Initiator Weigh House Effluent Plant isir Ground Floor-South 152. Ground Floor-North 153. Laboratory 154. Second Floor-North > Second Floor-South x>6. Catwalk, Outside 157. Boiler House-North 158. Boiler House-South i OVA Reading , ppm Februaiy March Maximum . - 20 27 50 22 - 20 - 18 Average _ - 20 16 24 12 - 10 - 9 Maximum Average 20 7 18 7 15 6 15 7 96 94 64 74 95 17 6 22 - 30 30 12 - 14 15 94 10 4 10 4 10 4 11 4 50 150 35 25 30 150 20 -- 15 50 14 13 10 54 9 -- 15 6 50 12 74 85 64 18 9 13 6 53 54 53 43 83 10 3 83 ---- ------ mm 63 22 22 93 43 44 __ ---- 55 ---- -- 43 --- 43 43 33 43 43 15 4 33 3* 2 COLORITE 012783 BURLINGTON MONITORING SUMMARY Page 5 nitoring Point ARDO Building 159. Operator's Desk Area 160. Panel Board 161. Latex Blend Tank Quality Control Laboratory 162. Hood Area 163. Desk Area 164. Constant Temperature Room 165. Analytical Laboratory 166. Vent Area 167. Reception Area 168, Office Hallway 169. Outside Plant-Upwind 170. Outside Plant-Downwind OVA Reading, ppm February Mareh Maximum Average Maximum Average 15 6 --- 43 52 63 85 28 75 28 -90 27 35 13 - --- 35 14 26 15 18 9 22 14 -- 75 75 32 32 W. C. Champion April 9, 1974 COLORXTE 012784 TABLE III FLEMINGTON PLANT OPERATING PERSONNEL TIME-WEIGHTED VCM EXPOSURES February & March, 1974 Employee Classification 1. Polymerization Foreman 2. Shift Foreman 3. Reactor Operator/Charger 4. Reactor Operator/Dumper 5. Reactor Operator/Relief 6. Utility Operator (2) 7. Dryer Operator 8. Warehouseman (2) 9. Bagger (3 ) 10. Boiler Operator 11. Lead Boiler Man 12. Guard 13. Laboratory Technician/Day 14. Laboratory Technician/4-12 5. Laboratory Technician/Shift February 75* 159* 15 13 24 30 11 8 16 6 6 9 9 10 10 March 13 38 10 8 9 5 6 6 10 4 4 8 9 8 17 *Over 50 ppm TWA Data for Periods: February -- 2/7/74 -- 2/27/74 March - 3/4/74 - 3/29/74 W.C. Champion 3/30/74 COLOR!TE 012785 tabu: iv BURLINGTON RESIN PLANTS/ OPERATING PERSONNEL TIME-WEIGHTED VCM EXPOSURES February & March, 1974 Employee Classification Suspension Area 1. Area Foreman 2, Homopolymer Reactor Operator/Charger '3. Homopolymer Reactor Operator/Dumper 4. Copolymer Reactor Operator/Charger 5. Copolymer Reactor Operator/Dumper 6. Dryer Operator 7 Bagger/Cleaner 8. Labor Pool/Bagger Plastisol Area 9. Area Foreman 10. Shift Foreman 11. "A" Plant Tower Operator/Charger 12. T,A" Plant Tower Operator/ Dumper 13. "B" Plant Tower Operator/Charger 14. "B" Plant Tower Operator/Dumper 15. Laborer/Cleaner (Jet) 16. Laborer/Cleaner (Manual) i.7. Bagger 18. Atomizer Dryer Operator 19. Additive Dryer Operator Laboratory 20. Quality Control Laboratory Supervisor 21. Analytical Chemist 22. Colorist 23. Quality Control Technic ian/Day 24. Quality Control Technician/Shift Warehouse and Miscellaneous 25. Warehouse Supervisor 26. Warehouse Clerk 27. Warehouse Receiving Clerk 28. Warehouseman - Outside 29. Warehouseman - Inside 30. Effluent Operator 31. Boiler Operator 32. Lead Operator/Boiler-Effluent 33. Utility Man - Outside 34. Utility Man - Inside 35. Yard and Service Man - Outside 36. .Yard and Service Man - Inside *0ver 50 ppm TWA Data for Periods: February - 2/11/74 - 2/25/74 March - 3/4/74 - 3/29/74 TWA, ppm February March 27 56* 44 13 17 22 44 18 10 13 15 6 6 6 7 6 69* 39 103* 114* 45 69* 25 21 18 17 7 11 6 19 27 9 12 41 37 5 5 3 13 8 25 14 26 14 26 11 24 12 16 4 10 4 11 4 15 3 17 4 73 43 10 3 11 3 26 6 33 94 W.C. Champion 3/30/74 COLORXTE 012786 Type PVC 200-2 PVC 225 PVC 250 PVC 250-3 TAB! 1 FLEMINGTON HOMOPOLYMER - RESIDUAL VCM March 5, 1974 - April 4, 1974 No. of Samples DRYER "A" Average VCM, ppm Range VCM, ppm 2 2325 1540,3110 14 694 126-1108 2 412 369,454 1 457 - No. of Samples DRYER "B" Average Range VCM, ppm VCM, ppm 5 1213 901-1390 6 405 63-721 3 259 196-340 1 688 - BULK SHIPMENTS No. of Samples Average VCM, ppm Range VCM, ppm 8 1281 315-2740 38 607 220-1010 12 427 130-613 1 398 - COLORITE 012787 A W. C. Champion April 95 1974 TABLE VI BURLINGTON HOMOPOLYMER - RESIDUAL VCM February 26, 1974 - April 4, 1974 DRYER SAMPLES No. of Samples Average VCM, ppm Range VCM, ppm BULK SHIPMENTS No. of Samples Average VCM, ppm Range VCM, ppm PVC 150* PVC 175* 1 290 -- - -- - 3 503 440-569 PVC 10R* 8 538 310-790 23 505 121-741 PVC 200-2* 9 217 160-305 -- - PVC 200/12R -'0 225 1 1685 - 4 681 270-1210 -- - 7 343 64-920 PVC 250-12S PVC 250-3 1 525 - 3 538 430-650 -- - 5 542 386-615 BR-501 2/16 - 3/15 28 1638 195-5550 13 2828 550-5550 - 3/16 - 3/31 15 606 195-1535 - % *Steam stripped. The 200-2 was an experimental trial of this technique * - -- W.C. jChampion April 9, 1974 COLORITE 012788 Type 315 389 390 TABLE VII BURLINGTON COPOLYMER. - RESIDUAL VCM March 4, 1974 - April 4, 1974 DRYER SAMPLES No- of Samples Average VCM, ppm Range VCM, ppm 15 173 95-410 2 183 140,225 4 414 140-705 BULK SHIPMENTS No. of Samples Average VCM, ppm Range VCM, ppm 21 no 57-585 1 115 - 10 152 73-340 W,C. Champion April 9, 1974 COLORXTE 012789 TABLE VIII PLASTISOL RESIN - RESIDUAL VCM March 4, 1974 - April 4, 1974 Jm. 1730 1738 1755 0565 No. of Samples 5 4 1 3 Average VCM, ppm 21 35 23 8 Range VCM, ppm 4-46 12-100 4-15 W.C. Champion April 9, 1974 COLORITE 012790 TABLE IX VCM LOSS WITH TIME Type Lot Number 225/16R TT 200-2 tt tt 224118 224119 184059 184063 184065 Dryer A B B A B Flemington Plant Initial 1 Day 2 Days 3 Days 5 Days 6 Days 9 Days 10 Days 1108 323 1390 3110 1343 463 154 911 2305 967 358 150 690 1428 826 - 516 1105 653 67 71 -- - 331 898 590 - 26 17 574 378 287 - Tye Lot Number 10R 2. -12 225/16R tr 250-3 tt 494003 ft 394006 234026 234028 334027 334029 Type 315 ft ft ft 390 ft 389 Lot Number 614009 614010 tl 614011 754009 754011 694003 ""SI 501 tf ft Lot Number 454011 454012 TT Burlington Plant Homopolymer Initial 1 Day 471 430 526 960 1210 650 430 348 -- 96 386 539 390 375 2 Days 306 280 73 171 161 80 246 5 Days 239 244 39 59 80 20 - Copolymer Initial 141 400 150 243 570 240 138 , 1 Day 104 372 130 141 410 95 2 Days 71 320 128 380 173 96 Blending Resin Initial 3592 550 547 1 Day 1981 - 385 2 Days 1621 345 286 6 Days -- " 95 5 Days 57 212 99 105 330 129 76 5 Days 794 99 136 COLOR!TE 012791 im. 1730 ri Lot Number 804008 804009 0565 854014 1755 834019 Dispersion Resin Initial 1 Day 4 <1 46 5 42 23 6 2 Days <1 <1 <1 1 5 Days <1 <1 1 2 " W.C. Champion April 9, 1974 COLORITE 012792 TABLE X FLEMINGTQN BIN AIR PURGING STUDY PVC 200-2, Lot; 184066 March 28 Dryer Samples 3 hours 6 hours 9 hours Residual VCM, ppm 1753 1300 1487 Date March 29 March 30 March 31 April 1 April 2 April 3 April 4 April 5 April 6 Truck Samples Residual VCM, ppm 2nd Blow 5 th " 708 821 Pallet 1 2 Pallet Samples Residual VCM, ppm 833 682 2nd Blow 5th " 526 605 Pallet 1 "2 614 633 2nd Blow 5th " 482 576 Pallet 1 >< 2 606 614 2nd Blow 5th " 330 400 Pallet 1 "2 519 601 2nd Blow 5th " 372 344 Pallet 1 "2 530 559 2nd Blow 5th u 2nd Blow 5th " 2nd Blow Sth " 277 96 % 221 170 205 91 Pallet 1 "2 410 403 Pallet 1 * 2 Pallet 1 "2 # 411 417 331 295 2nd Blow 5th " 185 252 Pallet 1 "2 363 360 W. C. Champion April 9, 1974 COLORITE 012793 ' -V A TABLE XI FLEMINGTON BIN AIK PURGING STUDY rvc 225, Lot 224152 March 27 sJ Dryer Samples 3 hours 6 hours 9 hours Residual VCM, ppm 357 378 926 Date March 27 Truck March 28 Truck March 29 March 30 March 31 April 1 April 2 April 3 April 4 Truck Samples Residual VCM, ppm 2nd Blow 5th " 364 427 Pallet Samples Residual VCM, ppm Pallet 1 "2 374 350 2nd Blow 5th " 237 287 Pallet 1 "2 211 217 2nd Blow 5th " 285 373 Pallet 1 "2 201 242 2nd Blow 5th " 269 331 Pallet 1 "2 222 282 2nd Blow 5th " 131 237 Pallet 1 "2 142 209 2nd Blow 5th " 195 170 Pallet 1 "2 240 120 2nd Blow 5th " 104 223 Pallet 1 "2 187 175 2nd Blow 5th " 50 103 Pallet 1 "2 129 113 2nd Blow 40 Pallet 1 162 5th " 25 "2 170 | W.Ci Champion April 9, 1974 COLORITE 012794 ( i\ i<i i l i lz$ i j | { * *i 1 t i TABLE XII * \ FLEMI.NGTON BIN AIR PURGING STUDY PVC 250, Lot 264098 March 27 Dryer Samples 3 hours 6 hours 9 hours Residual VCM, ppm 467 454 445 Date March 28 March 29 March 30 March 31 April 1 April 2 April 3 April 4 April 5 Truck Samples Residual VCM, ppm 2nd Blow 5th 341 280 Pallet Samples Residual VCM, ppm Pallet 1 ' 2 351 359 2nd Blow 5th " 188 382 Pallet 1 "2 279 344 2nd Blow 5th " 200 210 Pallet 1 "2 286 340 2nd Blow 5th " 105 81 Pallet 1 "2 210 284 2nd Blow 44 Pallet 1 130 5th " 70 ' 2 200 2nd Blow 5th 74 109 Pallet 1 "2 236 274 2nd Blow 59 Pallet 1 149 5th " 68 2 159 2nd Blow 5 th 55 17 Pallet 1 "2 # 139 163 2nd Blow 5th 46 108 Pallet 1 * 2 113 53 W.C. Champion April 9, 1974 COLORITE 0X2795 TABLE XIII BURLINGTON BIN AIR'PURGING STUDY PVC 10R, Lot 494003 March 16, 1974 Dryer Sample - 550 ppm VCM ^ lo eCv-v Date March 19 March 21 March 21 March 22 April- 1 April 2 April 2 April 3 VCM, ppm 340 584 899 490 340 495 307 659 * Vt l i } f \f f | i \ W.C. Champion April 9, 1974 COLORITE 012796 ' TABLE XIV BURLINGTON COMPOUND PLANT AIR MONITORING SURVEY Monitoring Point Mixer Floor - Operator Room Hoist Lead Room Mixer #1 (closed) Mixer #2 (closed) Mixer #3 (closed) Panel Board CM Belt Feeder Ground Floor - Between Panel and CM Incline from CM to Mill Cooling Trough - East End Cooling Trough - West End Dicer Room Shaker Packing Area Foreman's Office Lunch Room Locker Room Maintenance Shop - West End East End/Welding Area Color Room Laboratory Laboratory - CT Room Warehouse - NW Aisle Warehouse - SW Aisle Warehouse - Office Outside Building (North) Average OVA Reading, ppm (, February ^ } March1 ' 46 95 10 6 13 7 11 8 96 10 6 35 6 17 5 60 12 54 .4 4 10 5 65 75 44 34 34 63 (solvent) 50 (solvent) 6 5 34 45 58 34 34 34 33 ^^February 26 and 27 (2 Wch 21 - 28, April 1, 2, 5 W.C. Champion April*9, 1974 COLORITE 012797 COLORITE 012798 COLORITE 012799 COLORITE 012800