Document oMeLJJpgk26Qob1oDnX6895yX

OCC 11496 Af??ER--COFFICE CORRESPONDENCE p-tl8`2 B___________________ _ -TC Mr. Harold Birr - Delaware City SUBJECT Industrial Hygiene Survey FROM May_3J_1972 Mr. W. E, Driscoll - S. E. E. Attached is the report of the survey made in your Compounding Department, The report for the Paste and Suspension Bagging areas will be forthcoming just as soon as I receive the results from the lab. WED:mk Attachment uJcX) ____ _ W. E. Driscoll__ [ S! I >t! i OCC 11497 i i "Utn cmct COKRESf'DHtENCE ^ EG Mr. Harold Birr - Delaware City SUSJFC1 iFROM Industrial Hygiene Survey - Delaware City r 1*4 i'y l' I MT'AITLL May 3, 1972 Mr. W, E. Driscoll - S. E. E. Introduction At your request, an Industrial Hygiene survey was conducted on March 27, 28, 29, 1972, in the Compounding Department and the Paste and Suspension Bagging areas of the PVC plant. A series of samples were taken to determine the concentration of airborne dust as it relates to the health and safety of the employees. According to the Occupational Safety and Health Act of 1970, Sub part G section 1910.93 (c) Table G-3: An employee's exposure to any material listed in table G-3 in any 8-hour work shift of a 40-hour work week, shall not exceed the 8-hour time weighted average limit given for that material in the table. Fifteen (15) milligrams of dust per cubic meter of air is the time weighted average for an inert nuisance dust. Ledge dust samples were also taken throughout the compounding department to be analyzed for explosibility. Summary of Results Compounding Department Blending Floor Four of the six (6) samples taken showed dust concentrations above the time weighted average for an inert nuisance dust. This area merits attention because of the high concentrations of dust and the possibility that contaminants other than inert nuisance particles are present, especi ally lead as noted in the Aetna Report of April 5, 1971. Weigh Feeders The weigh feeders (2) are located directly below the blenders on the 2% floor. This area sample was high at 73.6 mg/m^. FCM Operation 3 The 2nd floor at the FCM operator's station had readings of .6 mg/m at the control panel and 7.1 mg/nr* while the operator was sweeping dust off the machine. First Floor The first floor was relatively dust free, the sample at the operator's desk showed 0 mg/m^. i t OCC 11498 -2- Conc1usiops and Recommendations 1. The raw material handling operation on the blending floor should be evaluated to determine a more efficient means of adding the raw mater ials to the blenders. In the meantime, due to the high exposure during this operation, respirators should be made mandatory. 2. All cleanup operations should be done with a vacuum system as opposed to sweeping or blowing with air. 3. Minor repairs should be made on the weigh feeders to eliminate leaks. Proper gasketing and maintenance would help in this area. 4. Once repairs are made and some reasonable substitute or modified process for handling raw materials is adopted, the entire department should be vacuumed, beams and pipes included. This recommendation will be more urgent depending on the results of the dust explosibility testing which is presently underway. The results of this testing will be handled in a separate report. Discussion The blending floor housed the most serious problem in that the exposure is not limited to inert nuisance dusts. The chemical and toxicological properties of each material used in this area should be checked to determine what the em ployee may be exposed to. The highest readings occurred during and following the loading and unloading of the large hopper of raw materials. During this operation bags of raw materials are slit and dumped into the hopper causing much visible dust in the area. Once the hopper is full, it is hoisted up and over to the blenders. The unloading also causes visible dust in the area of the operators breathing zone. Other noticeable leakage occurred from the tops of the blenders. The ports where materials are added should be covered more securely. Also there was a leak on the #2 blender at the drive shaft where it exits from the blender on the control panel side. On the second level at the FCM operation, the exposure was low (.6 mg/m^) except during the cleaning of the machine. While cleaning, the operator swept the accumulated dust from the machine. This resulted in the higher (7.1 mg/m^) reading. Cleanup in dusty areas should be done with a vacuum system not sweeping or blowing with air. At the weigh feeders there was much visible dust resulting from leaks which could be easily corrected. Very seldom does anyone spend time in this area, however, if these were corrected it would remove much of the dust which makes housekeeping a problem. OCC 11499 -3- Procedure Samples were taken with a Gelman midget impinger, and MSA portable vacuum pump (Monitaire). The air sample was drawn at 0.1 cubic feet per minute through distilled water. The trapped dust was filtered and weighed using type HA Millipore filter (0.45 micron pore size). Both the filter paper and collected samples were dried to a constant weight at 105 C. Sample Calculation Sample #1 Length of Sample (27 Minutes) Result of Analysis (6 Mg.) (27 Minutes) Minutes M3 357TTK .077 M3 6Jfe__ _ .077 M3 WEDnnk Attachments cc: _ Mr. J. Zimmerman - IP 349 or r*e fr&zy fAe A / W, E. Driscoll OCC 11500 OCC 11501 Sample # 1. Result (Mr/mS 7.8 2. 23.0 3. 79.4 4, 111.8 6. 8.5 7. 15.5 9. 73.6 5. .6 10, 7.1 8. 0 COMPOUNDING D E P A R TMENI Time Started 11:03 a.m. Total Time 27 Min. Dust Content of Sample Mg ,6 ________________ Description At control panel on blending (3rd, floor) 11:06 a.m. 23 Min. 1,5 On platform between mixers - mixers operating 11:40 a.m. 4 Min, .9 On platform between mixers while un loading bucket 11:45 a.m. 6 Min. 1.9 Operators breathing zone while filling bucket 2 :43 p.m. 54 Min. 1.3 Blending floor at control panel (same as #1.) 3:38 p.m. 75 Min. 3.3 On platform between mixers and also at control panel 4 :30 p,m. 24 Min. 5,0 On 2% level between weigh feeders 2:38 p.m. 62 Min. ,1 2nd floor at FCM Control Panel 5:06 p.m. 20 Min. .4 2nd floor at FCM control panel - operator was cleaning machine (sweeping dust off on to the floor) 3:00 p.m. 180 Min. 0,0 At operator's desk - 1st floor RAW MffiEfctAL POPPED SAMPLE *4 DfcUM 4 PLALLET bzA&e OCC 11502 y>' v:: t-" s s' <r'\ \ \,b ,7 Control. PAMCl. motto ScAi BLEN0IW6- FUX3H. CCWP0OMO/W& DEPT. Pvc Pu^ur, DemwAP.6 Ap REPORT OF TECHNICAL SERVICES STUDY PREPARE R; DIAMOND SHAMROCK COMPAQ DELAWARE CITY, DELAVJARE subject -- INDUSTRIAL HYGIENE SURVEY PREPARED BY- E. B. ENGEL INDUSTRIAL HYGIENIST SURVEY DATE- 19?1 P.S. PERSONAL SERVICE from the office of- ALEXANDER & ALEXANDER, INC. This study has been made to assist the named insured in a loss control program. It is confidential and is not to be used for any other purpose. It does not purport to include every loss potential, code violation or exception to good practice but relates only to those hazards specifically examined and described herein. An Engineering Service of: IC-2460-B) 6-69 LIFE & CASUALTY occ 11503 Hartford, Connecticut CAT. IS8204 PRINTED IN U.5.A. DIAMOND SHAMROCK COMPANY DELAWARE CITY, DELAWARE April 5, 1971 PURPOSE: At the request of Charles Burkins, Assistant Employee Relations Manager, an industrial hygiene survey was conducted to evaluate employee exposures to lead compounds being used in the FVC Compounding Department. In addition to lead measurements, we also measured levels of cadmium and tested the explosibility of dust which had settled out on building ledges, CONTACTS: Mr. C. Burkins, Assistant Ehrployee Relations Manager, and R. Zorich, Process Engineer, were contacted at this visit. We were ac companied on this survey by R. Willing, .Etna Engineering Representative from our Wilmington, Delaware, Office, who regularly services this loca tion. CONCLUSIONS: Concentrations of lead greatly in excess of the threshold limit value were measured in the breathing zone of an employee loading bags of dibasic lead stearate into the hopper prior to loading the blenders. Air samples for lead in other areas and all samples for cadmium were below the threshold limit values for these metals. The sample of ledge dust was found to be explosive in cur laboratory. RECOMMENDATIONS: A, Dust-control equipment should be installed on the loading hopper to control dust emission when bags of lead compounds are being loaded. B. A housekeeping program should be adopted to frequently and regularly clean the building and equipment to prevent build-up of dust. / OCC 11504 / C\ -2- PROCEDURES: Air samples for lead and cadmium compounds were collected by drawing air at the rate of 20 liters per minute through membrane filters. The filters were returned to our Hartford Laboratory where the amounts of lead and cadmium were determined by digesting the filters with concentrated nitric acid, placing the metal salts in solution and analyzing by atomic absorption spectrophotometry. The explosibility of the ledge dust was determined by producing a cloud of this dust in a chamber through which an electric arc was passing. RESULTS: The results of our air sampling are listed in the Appendix. The sample of ledge dust was found to explode in our laboratory test chamber. DISCUSSION: In evaluating the results of air samples, we use as guides Threshold Limit Values, which have been adopted by the American Conference of Governmental Industrial Hygienists. The threshold limit values, refer to airborne concentrations of substances and represent conditions under which it is believed that nearly *fi 1 workers may be repeatedly exposed, day after day, without adverse effect. Because of wide variation and individual susceptability, exposure of an occasional individual at or even below the threshold limit value may not prevent discomfort, aggrava tion of a preexisting condition, or occupational illness. Threshold limit values should be used as guides in the control of health hazards and should not be regarded as fine lines between safe and dangerous conditions. The two lead compounds being used at the time of our survey were dibasic lead stearate end dibasic lead phthalate. Threshold limit values have not been established for these two compounds. As a general rule, lead exposures are evaluated on the basis of the lead itself under the as sumption that most lead compounds will be broken down in the body and their toxic action will be related to the lead content itself. The threshold limit value for lead is 0,2 milligrams per cubic meter of air. Our Appendix lists the results of our air sampling for lead. While lead was measured in several areas, only one area was above the threshold limit Yalue. This sample was taken in the breathing zone of an employee while he was emptying bags of dibasic lead phthalate into the hopper that loads the blenders. This operation was extremely dusty and our results were more than nine times the threshold limit value. Either local exhaust ventilation should be installed to control the dust generated by this procedure or another means should he developed of loading the blenders which will not produce dust clouds. The threshold limit value for soluble salts of cadmium is 0.2 milligrams per cubic meter, expressed as cadmium. While we were able to detect cad mium in certain operations, our results were well below this threshold limit value. OCC 11505 -3Although this particular plant has been in operation less than a year, there is a considerable build-up of dust on building structures, es pecially the top levels. Our laboratory tests show that this dust pre sents a serious explosion hazard. A housekeeping program is urgently needed, which will regularly clean all of the building surfaces to pre vent the accumulation of this explosive dust. Dust was noticed escaping from equipment on the top deck by materials being transported from storage bins to the mixers, in the areas of blenders, hand-loading of the hopper, area of the weigh scales, and around the mill. Reworking these pieces of equipment to reduce the amount of dust given off would greatly assist the housekeeping program. Since this dust will explode, it is imperative that there be no open flames, direct heat, or sparks, or other sources of ignition in areas where the dust becomes airborne. Cleaning should be done using a vacuum cleaner rather than a broom or other means which would stir up the dust. Edward B. Engel 35 Industrial Hygienist OCC 11506 Location 1. Top deck in aisle, just below exhaust fan. 2. Between blenders. 3. Weigh feeder deck. h. Mill control station. Mezzanine over roll mill. 6. Roll mill operator. 7, Beside conveyor line for bagger. P. OBZ loading hopper with dibasic lead phthalate. APPENDIX A DIAMOND SHAMROCK CO. DELAWARE CITY, DELAWARE April 5, 1971 Results of Dust Samples Cadmium Concentration 0.0017 mg/m3 O.Olli negative negative negative trace negative not taken Lead Concentration 0.098 mg/m^ v O.ORh 0.006 O.OOl* trace not taken 1.8? mg/n^ - milligrams per cubic meter of air OBZ _ Operator's breathing zone Concentrations are expressed as mg of metal either lead or cadmium Threshold Limit Values: Lead 0.2 mg/m^ Cadmium (soluble salts as Cd) 0.2 mg/m^ / OCC 11507