Document o9DR2jqQa5MYx6K6a0QRDeqME

Building B-101 Dow U.S.A. The Dow Chemical Company 2301 N. Brazosport Blvd. Freeport, Texas 77541-3257 R6<e.v) OCCUPATIONAL HEALTH SUMMARY REPORT LOCATION: PERIOD COVERED: UNIT I (VINYL CHLORIDE PRODUCTION) March 2 - April 30, 1993 MEDICAL: 6- C. K. Browdy, M.D. Occupational Health Associate Date INDUSTRIAL HYGIENE A ___________ 6-7-^ M. A. Blue Industrial Hygienist Date .APPROVED: REVIEWED: S. L. Smolik Unit Manager cc: L. J. Burmeier J. H. Saunders, M.D. J. H, Lippman Summary File Date R&S151030 OCCUPATIONAL HEALTH SUMMARY REPORT This is a voluntary participation program. The group population is eighty-seven. Twenty individuals have current information and were not examined at this time. One individual is off on personal medical leave. Sixty-three individuals were examined between March 2,1993, and April 30, 1993, for a 95% participation rate. The Chemical and Physical Agent Inventory (CPAI) for Unit I, the vinyl chloride monomer production plant, shows that the chemical and physical agents of greatest concern are vinyl chloride, ethylene dichloride, hydrogen chloride, carbon tetrachloride, sodium hydroxide, and noise. Based on a review of current Industrial Hygiene monitoring data described below, the Process and Unit Technician job classifications are followed on the Vinyl Chloride Medical Surveillance Requirement (MSR). This MSR conforms with the OSHA Vinyl Chloride Standard. The 1989 Industrial Hygiene monitoring data is summarized in I. H. Report No. OC-3138-89C. Eight-hour time-weighted average (TWA) and short-term monitoring for vinyl chloride, ethylene dichloride, ethyl chloride, 1,1,1-trichloroethane, 1,1,2-trichloroethane, and carbon tetrachloride was conducted. All eight-hour TWA potential exposures to vinyl chloride were below the action level of 0.5 ppm except for the Loading Technician which was 0.94 ppm. The OSHA Permissible Exposure Limit is 1.0 ppm. Short-term monitoring for the Loading Technician showed potential exposures ranging from 0.17 to 11 ppm. The higher concentrations occurred during tank car sampling. In addition, the Process Technicians in the vinyl distillation area exceeded the Short-Term Exposure Limit (STEL) for vinyl chloride. Process Technicians in the direct chlorination and repair areas exceeded the STEL for ethylene dichloride. New sampling systems have been implemented in the loading and direct chlorination areas to reduce exposures. Employees wear full face airline respirators whenever there is a significant potential for exposure. Exposures to the other five chemicals listed above were less than 5% of their respective Industrial Hygiene Guides. 1 CONFIDENTIAL R&Si5i03i ' *, * , * , ! v.UNITI Page 2 The 1990-1991 Industrial Hygiene monitoring data for furnace maintenance is summarized in I. H. Report No. OC-3702. Monitoring was done for hydrogen chloride, vinyl chloride, ethylene dichloride, and dust. Average personnel exposures were significantly less than the acceptable guidelines for each chemical except ethylene dichloride. Average exposures to ethylene dichloride at 7.4 ppm during top 90 removal and 5.7 ppm during the let down valve removal exceeded the Short-term Exposure limit of 2 ppm. Area samples taken one foot from the let down valve and the top 90 on July 26, 1991, at >20 ppm exceeded the acceptable guideline of 5 ppm ceiling for hydrogen chloride. Full-face airline respirators were worn during the top 90 removals. The 1990-1991 Industrial Hygiene monitoring data for tank car off loading activities is summarized in I. H. Report No. OC-3652. In 1990 average eight-hour time-weighted average exposures for the Loading Technicians were 1.7 ppm which exceeded the OSHA Permissible Exposure Limit for vinyl chloride of 1 ppm. In 1991 due to adjustments made to the laboratory hood and purge times, average exposures were reduced to 0.69 ppm, which exceeds the OSHA Action Level. Short-term personnel monitoring during tank car hook-up, sampling/analysis, and disconnect indicated exposures exceeded the OSHA STEL during hook-up and sampling/analysis. Full-face airpurifying respirators with canisters approved for vinyl chloride use were used during tank car hook-up, sampling, and analysis. Adjustments to the laboratory hood resulted in a significant reduction in potential exposures during the analysis of samples, therefore, respirators are no longer required during analysis. The 1992 Industrial Hygiene monitoring data for tank car off-loading activities is summarized in I. H. Report 003951. Results of eighthour time-weighted average personnel monitoring with an average of 0.62 ppm continue to exceed the OSHA Action Level of 0.5 ppm. Short-term monitoring was conducted during tank car hook-up, sampling, sample analysis and disconnect. All results were nondetectable with the exception of one sample during sample analysis. Results of area monitoring in the tank car off-loading laboratory were both non-detec table, a significant decrease form average results in 1991 of 0.84 ppm. CO NFIDENTIAL R&s 151032 UNIT I Page 3 The 1991 Noise Survey is summarized in I. H. Report No. OC-370090N. Average personal noise exposures were less than 50% (85 dBA) of the OSHA Permissible Exposure Limit of 90 dBA for all monitored job classifications. These job classifications are not in the Texas Operations Hearing Conservation Program. Eight individuals have limitation of respirator usage based on initial screening of the medical examination data. Please see Attachment A for medical limitation of respirator usage. If these medical restrictions interfere with an individual's job requirements, further evaluation at the Occupational Health Department should be arranged to fully assess the need for medical limitation of respirator usage. The liver is considered the main target organ for vinyl chloride. Fourteen individuals of the sixty-three tested have minimal elevation of one or two of the five liver enzyme tests done. Four * individuals have mild to moderate elevations of two or more of the five liver enzyme tests done. Two of these four individuals returned to normal on recheck testing and the other two were significantly decreased on recheck testing. Five individuals have reported to the Occupational Medicine Department since Januaiy, 1993. One individual had a hydrochloric acid inhalation, two individuals had possible skin exposures to ethylene dichloride, one individual had a laceration which required sutures, and one individual (contractor) sustained second degree bums to the face from hydrochloric acid. Individuals with life-style factors that are amenable to medical or dietary intervention include the following: fifteen smokers, fortyfour individuals who are overweight, sixteen individuals with uncontrolled hypertension, and twenty-five individuals with elevated cholesterol levels. Please see Attachment B for a graphic representation of this data. Please contact the Up-With-Life Program (238-4334) for assistance in modification of these life-style risk factors. Attachments CONFIDENTIAL R&si 51033 ATTACHMENT A June 4, 1993 MEDICAL LIMITATION OF RESPIRATOR USAGE The following eight individuals may wear respirators for escape only: The following seventy-nine individuals have no medical limitation of respirator usage: ID C/D cn o CO ATTACHMENT A Page 2 CONFIDENTIAL REDA CTED 3Sc?Dn cn o co CD -^S^ATTACHMENT A * ***^: . * * r'V 's. ' i1'. v. * * - 1 * j .*; - Wi * *-* ' "flfi Page 3 R&s151036 REDACTED CO NFIDENTIAL *, ,, - - " ATTACHMENT B June 4, 1993 RISK FACTORS Data from "UNIT I DATA 6/93' CHOLESTEROL HYPERTENSION OVERWEIGHT SMOKERS m % TX OPRS % UNIT I % UNIT I CONFIDENTIAL R&s151037