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Table A l. l
Person Tears by Age Group and Calendar Tear fo r P lant f l
I
(W
o
"iIO KK.|
O A
NK mcr* w\
9> +
I
<o+ f WIft CD
ft
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P<S0hN0* 1 K0sfD*4>
<#0<e x
0 *
e * f*
<0 00
9*0 <*
0
0
511971 0409
Table A1.2
Person Tears by Age Group and Calendar Tear f o r P la n t #2
3 9* OL. I
A-2 511971 0410
l V
Table a l.3 Person Tears by Age Group and Calendar Tear f o r P la n t 14
A3 511971 0411
Table A l.4 Parian Year* by Age Group and Calendar Year fo r P la n t IS
1 p-
1o 1 A-
oo
o
I I
I
< P- < I P* 0 < * P-
4.
1
a Pr a-
!2
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A
AA
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A A O
ma A r
^m
4 A*
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e IA Al
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o 4 44
am 44
p*ia <
no *
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id A p
a A 44
4 At Ad N
r>
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N
44
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k
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CA
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k A
Jt CA
k A
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k A
Jt CA
k A
Jt
CA
kkkkk kk
k A _ Jt CA
k
k A
Jt CA
k
k A
Jt CA
k
k A
Jt CA
k
k A
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k
k A P*
Jt Ca
k
A kk A A .
Jt Jt CA CA
kk
a ?
aNf oAt aAi ei
II AO A
n
A-4 511971 0412
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Table A1.5
Person Tears by Age Group and Calendar Tear fo r P la n t #6
m
* jt
c
at L.
Jt Cm m9 4.
m
Jt
cm
* L,
4. m
Jt
c
at .
c m
Jt e at 4.
c at
t.
Jt c* at c
& 9
Jt C at &
Jt
C9
ma L
C.
Jt C <i at
a. 9
Jt C at 4.
&
jt c at 4.
4.
jt
Cm
9 it 4.
4.
c
Jt
c 4.
9
Jt C at 4.
4.
Jt
C9
a at 4.
a 9
4. O ON
V
1 o
M 1 9\
m o
m e
l r>
o1
9 1 rv
m Wl 1l o w\
<o o
t 9%
* o
a* 1 an
o1
9
9
A-5 511971 0413
Table A l.6 ' Person Tears by Age Group and Calendar Tear f o r P la n t #7
: /
!' i
IN I
^O wts
m e H
4O m M* Nm MoIA
m O'
O*
* to
0 tO
* M
m O
-o
memm
m <0
04 Mo|
iaa mm<o
w\ M
e
TOTAL
Parson Tears At Risk
1247.7
480
3998.4
948
4703.5 974
4482.7
974
4934.0 1048
2959.1 22524.5
1007
1144
'I
> II
r
V
Peraon Tears by Age Group and Calendar Tear f o r P la n t 18
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>o O O* ^.
I
O
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*- I Io IN I
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I in
II
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OO N O
O' N
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0 KN
0
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O
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N
mo
N m <r
N
mn M <
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em NN
e O' KN
N 0o
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NO 0
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O H
IN
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IN HH ON NN OH NH H N N
I0 I IN
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o u oo
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C0 H N 0C 4.
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Jf
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o>
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4 40
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Jf C0 9 * 00
9 * 00
a? o O0I0'
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A-7 511971 0415
1
Person Tears bp Age Group and Calendar Tear fo r P la n t 110'
0000 0 0 0
0*0
0*0
0*0
0*0
0*0
0*0
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JC cO * OK L * O' K
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ok
k o oK
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4C c * OK 4. % o<
o L. o >-
JC Co o * o ct 4. o * oo
JC co O 4 OK * OK
al O*v Ni iIV vow
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wI oI tw oI
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l
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A-8
5^971 0416
V '*V rrrr.T-.' U>/
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/
Person Years by Age Group and Calendar Year fo r P la n t #12
4 e o OK
0
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4
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CD
N
0 0*
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A
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94
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0
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94
00
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0
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40
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4
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0
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0
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0
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94
0
0 4
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a A
0
04
0
m 4
0 CD
94
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40 4
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CD 0
0
00 0
eg 0 0
00
oo
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1o
0
IO 94
m rg
44
A A CD A 94 4
00
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00
0
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eg
94 94 94 0
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eg eg 0 0 0 O 0 0 0 0 0 0
00
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A-9 511971 0417
Table A1.10
Parson Teara by Age Croup and Calendar Tear f o r P la n t 113
o *> e f\ ^ r* k
o
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cd
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o cma iMn m c h m
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0H
m m.
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mn m
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mo m
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m N ^ *+
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e
t DC
r
4
m
c^
Jf m
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4
4
m
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4
m
jr
cm *
mo
4
4
m
jr
cm O -4 s 4
4
m JC
cM O c o 4
4
m JC
cM
9- 1 CC 4
4
JC cM M K
m
JC
cM O c use 4
44 4
JC cm 9 *< DC
m JC
C9 e - MO 4
m JC
C9 O MO 4
JC
CM 0
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4
jc CM O 40 MO
m
jc c
4 MO 4
M 4
m JC JC M CM *4 9 m o MO
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9
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&
A-10
511971 0418
Person Tears by Age Croup and Calendar Tear fo r P la n t 114
in* ^ m
i
4N
Of)
P* f>
\ O
n <
O' ^ M t
*IA O O i
94 A* <
' Person Tears bp Age Group and Calendar Tear f o r P la n t 115
I
* |
k V
o m o <a m
<<o <i
m
h
fI
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r
> 94 ^
O
a *6
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m o -c
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m
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o
m f44 N
9 V> O' 94
9* 94 (A
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f> K 94 m
A- O'
4 o
4 94 94 IA
94 94 .
m in
04
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1
o *
oo
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4A
IA N f) m
mn 9O' N
N rt O 94 n
o 14 94 #> 9|
NW m f) 94
94 n m 94 #n
Ol a* o N
n N 94 94
NO N
94
<M O 94 O' 94
rf\ o
^ 94
oo o
r 94
N
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n 1 % 0\
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i
94
<4 9*
94 0 94 N
4 94 94 *4
94 O' +4
4 94 9- 94 14
m * 94
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94
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n ^
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or CM k O *
k
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k 9
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k 9
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a. k
C
Jf c
k
kk O9
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l 4#
M k 9
C
k 41 9*
tm 9
M
C
k
k 9
Jf C k
. k
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c
k
kk 9
*-
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k
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tkf
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IT.
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t I
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9> 0 ^ 0
A-12
511971 0420
Appendix II-A Methods Used In Obtaining Exposure Data n
Estimation of employee exposures in Plants Nos. 1, 2, 3, 8, 9, 13, and 14 mere based on air and biological sampling and extrapo lation. It was the judgment of the industrial hygienist that smelting plants could be meaningfully delineated into three environmentally different periods designated as early, prehooding, and contemporary operation. This was based on both objective and subjective evaluations by the hygienist who has made such evaluations from the late 1940's to the present.
Estimations of exposures that occurred prior to this time were made possible by extrapolation of more recent objective findings, in accord with detailed plant histories that were kept for all of the plants. The plant historians faithfully recorded all pertinent (and many Irrelevant) events that took place in their plants from their beginnings. Comments on environmental conditions and technological and engineering changes recorded in the finest detail were Important elements of these histories, because of this, it is believed that even the earliest estimates are valid to within at least an order of magnitude.
A-13
511971 0421
V
The designated year In which a plant went from one environmental period to another (i.e., from early to prehooding or to contemporary operation) was based on the years during which engineering changes took place that would significantly Improve
.9
the working environment. Such changes did not take place at the same time in all smelters. Thi6 explains why the cut-off dates differ from plant to plant. Depending upon the age of the plant and the environmental improvements that took place, a plant could have gone through one, two, or three environ mentally different periods. The rationale for the exposure values assigned to smelting plant employees working during
.t
each of the environmentally different periods is given below.
CONTEMPORARY
This period includes the time following Installation of pot hoods to the cut-off year of the mortality study. Except for the effects of wear and tear on equipment, minor variations in work practice and environmentally insignificant engineering or technology changes, exposures throughout this period could be expected to be relatively constant.
T
Potroom Exposures Pot Tender. All values for this classification are based on actual measurement with the exception of some sulfur dioxide values. In these Instances, the exposures found
A-14
511977 0422
in the other plants (all quite consistent) were assigned where values were missing.
t
Anode. The same comments relating to pot tender' apply here.
Crane Operator. Some values were derived from actual measurement; others were extrapolated values determined either from other plant data or from urinary fluoride measurements.
Other Job Classes. All of these are extrapolations based on urinary fluoride data and estimations of the relative exposures of these employees with respect to those whose exposures have been measured.
Carbon Plant Exposures All Job Classes. Exposure values are based on actual measurements.
'{PREHOODING
At the beginning of this period, the plant histories showed that a considerable number of changes took place in the plants that would have a considerable Impact on environmental conditions
A-15
511971 0423
(e.g., new equipment, improved technology, installation of exhaust systems, etc.)* This period was terminated when hoods mere installed on the pots.
Potroom Exposures Pot Tender. Anode and Crane Operators. During this period, a considerable amount of area sampling was done for fluoride evaluations. Knowledge of the time spent in various areas of the potroom made it possible to estimate some employee exposures. Urinary fluoride data made it possible to rank order fluoride exposures to all job classes. The estimated values were consistent with exposures measured by an Industrial hygiene survey performed in one smelter in 1946 by a state Department of Health.
Total particulates were estimated from the fluoride results. Sulfur dioxide exposures were estimated to be higher than those that would be found in hooded potrooms. The health department survey confirmed thi6 and established the level of these exposures.
^ Since the principal source of coal tar pitch volatiles, even during the preboodlng period, was the carbon plant, it is reasoned that the CTPV exposures should not be significantly different than those measured in the contemporary period.
A-16
511977 0424
Other Job Classes. Exposures to other Job classes are based on extrapolation from the values determined for pot tender, anode and crane operator, together with more recent air sampling and urinary fluoride data that provide a rank ordering of exposures according to Job class.
Carbon Plant Exposures All Job Classes. All exposure values are based on professional Judgment. Subjective evaluations recorded in plant histories Indicate that dust concentrations Increase as one goes backward in time. Results of dust measurements made during this period by the particle count method confirmed this.
There environmental improvements were made, they almost
always were concerned with dust control. Little attention
was paid to the volatiles emitted from the pitch. From
thi6 one would assume that, although one'might expect
somewhat higher coal tar pitch exposures as one goes back
in time (because Of generally poorer environmental
controls), there would be a definite limit to the maximum
^ exposures to CTPV. One would have to remove few controls
before there were no controls, mixing was a batch process
with a limited capacity of the mixing vessels, and the
maximum temperature of the mix was essentially constant
through time. On the other hand, since the sources of
dust were infinite, there appeared to be no limit to the
amount of dust that could be generated. A-17
511971 0425
Pneumatic tools were common throughout this period so that one would expect benzene soluble values to be higher than those for PPOM (i.e., because of oil in the compressed air).
During this period, there undoubtedly were significant exposures to pitch dust. which obviously would increase benzene soluble, PPOM, and B(a)P values. We have no way of estimating the magnitude of these exposures. On the other hand, by virtue of the manner of their generation, these dusts should contain much less respirable material than that which would be found in the particulates originating from heated pitch.
EARLY OPERATION
Potroom Exposures Very little quantitative data is available for this period. Exposure estimates are based on professional judgment and the plant histories. Fluoride exposures are anticipated to be about the same as those estimated to exist in a plant of very early technology (and in which area measurements were made) where pots tgiere small and ventilation was generally poorer. No significant
i
exposures to CTPV are expected since there were no sources of pitch In the potroom.
A-18
511971 0426
Carbon Plant Exposures These values also are derived from professional judgment and plant histories. One would have expected that benzene soluble and CTPV would generally coincide since there was more hand labor (i.e., fewer, pneumatic assists) and the only source of benzene soluble material would be the pitch.
For Plant 5, estimates of prior exposure were developed by utiliz ing:
(1) Industrial engineering studies which documented work practices and labor-saving devices# from start-up to present. As the plant was modernized, the worker efforts decreased.
(2) Control of emissions - that is# the capture of fumes im proved# as documented by daily emperical measurements of a "smoke index" by plant personnel.
(3) Worker opinion - that is# workers and supervisors who were employed during start-up provided opinions regarding condi-* tions of smoke and difficulty of work.
For Plant 12, the industrial hygiene program began in 1972# t:nd results are based upon averages during this period. In 1975# re cycled scrubber ore was Introduced and exposures increased signifi
T
cantly. Data presented in previous years are simply estimates by the Industrial hygienist who integrated historical engineering changes# feedback from plant personnel# and his best judgment.
A-19
511971 0427
,In Plants 4 6, 7, 10, and 15, exposure measurements for the period
between 1973 and 1977 reflect results of routine Industrial hygiene 1.
studies. Since 1978, however, sampling studies in these plants have followed the recommended strategy of Leidel, Busch, and Lynch in their *Occupational Exposure Sampling Strategy Manual." Utilizing this approach, a large enough sample size was collected for each job category to yield a ninety percent (90Z) probability that at least one individual in each group had an exposure level in the highest ten percent (10Z).
Zn order to arrive at estimates of prior exposure levels, two
, ,factors were considered for all jobs,' in Plants 4 6 7, 10, and 15:
(1) The time an employee was exposed at the worksite in an 8-hour shift. Prior to 1960, estimates of actual time worked were provided on a plant by plant basis. After 1960, industrial en gineering time studies were used to determine actual time worked.
(2) The effect of engineering controls, i.e., enclosing potsduring the period 1941 to 1977.
Plants 4 and 15 have been divided into their respective north and south plants. While such a breakdown would not be included in the employee personnel records, all employees working at Plant 4 prior `to 1959, and Plant 15 prior to 1968, would have been considered south plant employees.
A-20
B,197'o428
V
Zn arriving at a multiplier to ascertain the effect of pot en closure for Plant 4 (north and south plants) Coal Tar Pitch Volatiles (Benzene solubles) data were used from special studies undertaken in early 1973. At that time the north and south plants of Plant 4 were partially enclosed. These data, collected in 1973 for the north and south plants, were then compared to data collected in 1976 and 1978, after the pots had been fully enclosed. The ratio
I
of exposure levels (fully enclosed divided by partially enclosed) produced an enclosure factor which reflects the effects of fully enclosing a pot. As can be seen from Table 2, Plant 4 (south plant) was partially enclosed from 1957 to 1973. Consequently, a 3.7 en closure factor was obtained and used for this entire period. Al though there are no data to calculate an enclosure factor for the open pot (1941 - 1957), plant history records indicate a substantial reduction in visual pot emissions, with the partial enclosure of the pot. As a result, an enclosure factor of 4.5 (estimated) was de cided upon for the open pot. See Appendix B, for example of en- . closure factor calculations.
Utilizing the estimate of actual time worked in an 8-hour day and the enclosure factor, appropriate multipliers were developed for Plants 4, 6, 7, 10, and 15 (See Table 2). For example: Plant 4, south plant: 1957 to 1961 (partial enclosure) - The estimated work time is 6 hours, and an enclosure factor of 3.7 was developed for that time period. Given that 4.5 hours is the actual time worked
A-21
511971 0429
today, the multiplier is calculated by the product of the enclosure factor (3.7) and the estimated time worked (6 hours), divided by the actual time worked today (4.5). See Appendix C, for exposure estimate calculations. It should be noted that, for Plants , 7, and 10, an enclosure factor was not utilize^* since the control technology used at those plants has remained the same since start* up. Therefore, in Plants , 7, and 10, the final multiplier only reflects the longer hours worked during the earlier time period.
In addition, a special sampling study was carried out at Plants 6 (Soderberg) and 7 (prebake), to determine the relative exposures for maintenance and casting workers.^ Those data were utilized to estimate the exposure of similar employees at all other facilities covered by the study.
T
A-22
511971 0430