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* yn S. S. DUNN INTEROFFICE CORRESPONDENCE 23,b 3Are July 31, 1979 E. R. Averill cc' W, M. Blackwell H. E. Coussou R. J. Land C. V. Phillips J. K. Stewart, M.D. W. E. Sweeney L. A, Unger INDUSTRIAL HYGIENE BASELINE EXPOSURE STUDY MOBIL CHEMICAL COMPANY CHEMICAL COATINGS DIVISION SPECIALTY DIVISION BEAUMONT. TEXAS INDUSTRIAL HYGIENE SURVEY HRH-16-7/79 Attached is the Industrial Hygiene Report covering the industrial hygiene base line exposure study which was completed during the 2nd Quarter, 1979 with the assistance of H. E. Coussou, BCSP Safety Supervisor. The purpose of the study was to determine representative employee exposure to various potentially hazardous chemical and physical environmental factors associated with BCSP operations. A total of fifty-two (52) exposure measurements for gases, vapors, and particu lates were conducted at the Acrylic, Catalyst, SHF, and 1259 units. This involved Che collection of a series of area, source, and employee breathingzone air samples. In addition, several wipe samples for nickel nitrate content were collected in the Catalyst area to determine the possibility of nickel contamination outside of the solution preparation area. Overall, the findings of the study are favorable. None of the measurements exceeded the respective OSHA permissable exposure limits (PEL's). The attached report contains the results of the monitoring as well as recommendations regard ing improvements. The data developed from the exposure measurements is necessary to establish compliance with existing permissable exposure limits and should be retained in the BCSP OSHA file. This information will further be helpful in setting priorities for additional exposure monitoring and determining the impact of new regulations as they are developed. Thanks again for your cooperation and assistance. If you have any questions, I can be contacted in Houston on Extension If5756. m. BAL:jrt Attachment B. A. Larson Industrial Hygienist 06216 447986 INTRODUCTION An industrial hygiene survey was performed at the Beaumont Chemical Specialties Plant during the second quarter ot *379 to determine employee baseline exposure to various chemical materials and physical agents regulated by OSHA which result from piant operations. The study was conducted by B. A. Larson, Industrial Hygien ist, Mobil Chemical Company, and H. E. Coussou, 3CSP Safety Supervisor. The chemicals and environmental factors of concern in the study are listed by operating area/location as follows: Acrvlics Unit Catalvst Unit SHF Unit 1259 Unit Flare -Methyl Acrylate -Nickel -Boron Triflouride -Hydrogen Sulfide -Hydrogen Sulfide -Methyl Methacry -Silica late -n-Propyl Alcohol -^Isopropyl Alcohol -Nitrous Oxides --Noise -Methyl Alcohol -Sulphur Dioxide In addition, carbon monoxide is present at the offsite catalyst warehouse and the drum storage area when there is heavy forklift activity. A total of forty-five (45) exposure measurements were conducted to determine airborne concentrations of regulated materials. Of these, eight (8) were area samples placed to determine ambient concentrations of vapors released in the Acrylic and 1259 Units. Sixteen source samples for SO*, H,S, and NO were collected at the Flare Area and another two (2) for Methyl Acrylafe and Methyl Methacrylate were collected at the vent of Tank 503 in the Acrylics Area. Nineteen (19) employee breathing-zone samples were collected at the above areas to determine time-weighted average exposure levels. A summary of survey findings and recommendations by location is detailed below. II. SUMMARY A. Acrylics Unit Five air samples were collected in the Acrylics Unit to determine airborne concentrations of Methyl Acrylate and Methyl Methacrylate under normal conditions of operation. The OSHA Permi3sable Exposure Limits (PELS) for these materials are 10 PPM and 100 PPM,respectively. Measurements, consisting of breathing-zone air samples collected over a full-shift of operation, were completed to determine repre sentative time-weighted average personnel exposure by job description. Two samples were collected to determine the acrylics operator's exposure. An employee air sample was also collected during tank truck unloading. An area sample was collected three feet above ground level at the pump adjacent to tank #201 to determine ambient concentrations of MA and MMA in the general plant environment. In addition, a source sample was collected at the vent of tank #503. 06211 447987 IX . SUMMARY (Continued) Sample collection was performed by the charcoal tube method as specified by XIOSH. Sample analysis was conducted by an analytical laboratory accredited by the AIHA. Monitoring results are listed in Table 1. 1. rladings -Personnel exposures to MA/MMA under normal operating conditions are well beiow the limits prescribed by OSHA (As detailed in Table 1). -Background levels of MA/MMA do not exceed 1 PPM. The major sources of emissions are various pump seals, sampling points, and the />503'vent. -As expected, relatively high concentrations of MA/MMA were measured at the f/503 vent. Due to the remote location and dilution factors, however, there Is minimal potential of employee exposure. 1. Recommendations -Additional MA/MMA exposure monitoring should be conducted quarterly by the plant industrial hygiene monitor to better define employee/area exposure levels. The data developed from a regular monitoring program is also necessary to establish ongoing compliance with OSHA health regulations, determine exposure variations due to operational changes, and is helpful in identifying and minimi zing conditions and work practices which contribute to exposure. Measurements to determine short-term exposure to ammonia during drum transfer should also be completed. 3. Catalyst Unit Three breathing-zone air samples were collected in the Catalyst Unit to deter mine airborne concentrations of nickel and crystalline silica. These materials are components of two of the basic raw materials (nickel nitrate, silico aiuminuml and are regulated by OSHA in their PEL listing (0.10 mg/M -Nickel; 10 mg/M - Crystalline Silica). Catalyst operator exposure evaluations %Si02 + 2 were completed for manufacturing cycles involving calciner-drum filling operations, muller mixing, and routine shift duties. A series of wipe samples was collected on the second floor of the Catalyst area to determine the extent, if any, of nickel nitrate contamination in areas adjacent to the nickel solution preparation mixer. Nickel is a respiratory irritant when inhaled and may cause dermatitis and skin sensitization following repeated contact at significant concentrations. Several bulk samples of catalyst were also collected to measure the content of crystalline silica. Air samples for nickel and silica were collected with portable vacuum pump3 and filter media according to standard sampling methods recommended by NIOSH. Wipe samples for nickel were obtained using cellulose filters according to the procedure outlined by OSHA in their Industrial Hygiene Field Operations Manual. All sample analysis was performed by an accredited industrial hygiene laboratory. A summary of the air sampling results and nickel and silica concentrations are listed in Tables 2 and 3. 0(5 y i ~ 447988 II. SUMMARY (Continued) 3. Catalyse Unit Sound level data adapted from report E.H. 69-76 is shown in Table 4 for areas where noise levels exceed 90 d3(A). These include the catalyst blower,walkway and compressor area. Ordinarily, employees would not be required to work in these areas for extended periods, therefore, daily noise exposure would be expected to meet OSHA requirements. 1. Cindings -Operator exposure to airborne nickel is minimal. Our data indicates that full-shift exposure is a degree of magnitude below the present OSHA permissable exposure limit. -Silica exposure is below the OSHA PEL during normal shift work. Exposure approaches the PEL, however, when the operator is assigned to the calciner area for an extended period. For example, we found that the operators exposure is 90% of the PEL when operating the calciner for seven hours, yet only 20% when operated for two hours. -Surface nickel concentrations on the second floor outside of the nickel preparation mixer area are low. The levels measured on the second floor hand rail are 10,000 times less than the amount found at the mixer opening. * -Employee noise exposure may exceed OSHA limits at the calciner. Additional noise measurements should be completed. 2. Recommendations -A high-efficiency vacuum cleaner should be provided to minimize dusting during catalyst cleanup. -Additional air sampling should be performed to better define operator exposure to Silica during calciner operations. The use of respiratory protection should continue to be required. Local exhaust ventilation should be considered if our additional monitoring indicates an exposure problem. -Operator exposure to noise should be established by performing a noise 4 dosimetry study. Hearing protection should be required for mechanical work involving the blower or compressors and during calciner operations. C. SHF Unit The SHF process located in Building 2 is normally a closed system and very little opportunity exists for employee exposures during normal operations. OSHA regulated materials processed In this area include n-Propyl alcohol, n-Butyl alcohol and boron triflauride (BF,). The permissable exposure limits for these are 200 PPM, 100 PPM and 1 PPM, respectively. r BF is a visible white fume which is highly irritating to the eyes and respiratory passages. On contact with moisture or humid air, it rapidly decomposes to form flouroboric and boric acid (nonregulated). Because of the instability of BF. in air, there is no valid method for measuring employee exposure. (It is ironic that ^OSHA has adopted a level which cannot be enforced.) 06219 447989 II. SUMMARY (Continued) C. SHF Unit (Continued) L. Findings -An employee breaching-zone sample for n-Propyl alcohol was collected over a full shift to determine the time-weighted exposure level of J. Brawn, SHF operator. The analysis of the sample indicates a TWA exposure of less than 0.05 PPM. -Exposure to BF^ in the SHF process area is judged to be practically nil. No leaks,: emissions, or odors were observed. Normal preventative maintenance should be adequate to control leaks/exposure. 2. Recommendations -Further industrial hygiene testing should be performed to establish n-3utyl alcohol exposure levels. D. 1259 Unit Three air samples were collected at Building 2 in the 1259 area to determine airborne concentrations of Methanol and Isopropanol (PEL's 200 PPM, 400 PPM), a3 well as, n-Propyl alcohol which is present from the SHF process. A breathingzone sample was collected to evaluate the time-weighted average exposure of the 1259 operator. Two area samples were also collected to determine ambient vapor concentrations on the first and second floors near process equipment (V-135, V-140). Samples were collected according to the NIOSH charcoal tube procedure. Sample analysis was performed by an accredited laboratory. Monitoring results are summarized in Table 5. Hydrogen sulfide measurements were taken at several locations in the 1259 area where chere is a potential for leaks. These include the knockout pot and the manway of the BOU solids tank. 1. Findings -Operator exposure to Isopropanol was found to be less than 1 PPM as . a time-weighted average. Methanol and n-Propanol concentrations were below the sensitivity of the analytical method. -Ambient concentrations of Isopropanol ranged from 0.17 PPM to 0.76 PPM. -Hydrogen sulfide concentrations at the knockout pot and BOH solids tank did not exceed 3.0 PPM. E. Flare A series of direct-reading measurements were taken at various locations in the vacinity of the BCSP flare to evaluate ambient concentrations of hydrogen sulfide, sulphur dioxide, and nitrous oxides. The purpose of these measurements 06220 447990 II. SUMMARY (Continued) E. Flare (Continued) wan ,,to determine maximum concentrations resulting from flare emissions during 1259 adduct addition. Sixteen air samples for these materials were collected at four areas west of che flare (downwind). At three locations, measurements were taken at ground level. The fourth sampling point located at the landing of che 0/A propylene tank is approximately 20 feet above grade. Air samples for sulphur dioxide and nitrous oxides were collected using Orager length^of-stain tubes having minimum sensitivities of 0.1 PPM and 0.5 PPM, respectively. Hydrogen sulfide measurements were taken with a BioMarine direct-reading survey instrument having a sensitivity of 1.0 PPM. Each of the four sample locations are illustrated in Figure 1. 1. Findings -Ho significant levels of H,S, S07, or NOx were detected in any of che air samples. All measurements indicated concentrations below che limits of sensitivity for each of che measurement techniques. F. Drum Storage Area & Offsite Catalyst Warehouse Carbon monoxide measurements were performed at the drum storage area and the offsite catalyst warehouse to determine levels resulting from forklift traffic. The OSHA permissable exposure limit is 50 PPM. All windows and door3 were open during the test. In the drum loading area, a short-term breathing-zone sample was collected during drum stacking. At the offsite catalyst warehouse, both a breathing-zone and area sample were completed. 1. Findings -Breathing-zone concentrations of CO were 15 PPM at che drum loading area and 35 PPM at the catalyst warehouse. -CO concentrations at the exhaust of the forklifts ranged' from 600 to 1,000 PPM. 2. Recommendations -Additional CO measurements should be conducted during che winter months when natural ventilation is reduced. 06221 447991 Figure 1 - A ir Sampling Locatlona-BCSP F lare BCSP P erim eter TABLE 1 447992 oo3 3 oo3 3 O p* -i 3 oo O Q o o W> oo a un * rS* 0U1J H Xw MS}-* g -* ^ Ua*t <m3 -2 5 > Ui 3 ^ JZ Z fz-> 'SS3 2o s- 5aHi <-- afs Za za </i U CJ <Z3J u3i M>oa<-4 < * w V t0a '' e s u -aa. Ao> ii at F* C a. ac <XuU 0f<1 F4 <X XUu< <Ao MV OO. 3Ofi* I A* (A a N Cal -1 3H Mi S oe u3 oM 447993 TABLE 3 447994 C/3 ^ U-4i 0P-** C/3 CO JH 35 cu ui <n 2 Ui </j CSTO aaO n r-. WgO3* u0 o G ad a v^O4 oo o o C<O3c9J' *H**. 0a0 oc jj oao uuucVO0 <-* om <CoO3M> o MN M -4 o o o f** NoH/Mo3 H2OU8 u< *3 H -1 C>/*3 CJ H 1-4 < Z CJ 4 H r4 *4 <9 r4 G M 01 0) GU 11 o G Ji .* 4 .* 44 u CJ <J cj >4 O *4 3 z z z z4 4 44 4 44 C/3 C/3 M 00 O C Ps 4 >* 0) W 1G U 1) a r4 3C o0 oo <4 p4 U f-4 O 4 4 GG 4 CJ CM 0a a 01 o u w U Q J* i-4 0 G IG u 4 CJ <*4 0 a 44 G (4 U Ga G G <9 0 *0 ZO o 01 CM f4a G 0 44 o o 01 *4 CJ <M h4 O i O <4 IM G O J* cu a OW'O <M -a M CU QG O0 0 0 'o HM 4 <M CM G H , zo 01 H ZQ N ZQ r4 zO r4 aa G a G Oi <4 paG *4 C/3 3 4 3 0 CM zo 't A CU-"J SOUND LEVEL MEASUREMENTS 447995 99 <0uu J0 CO u 0) 9} 0<2u oaso 0o1 w* U r(u9s0 o3a a ^<-4 oM CON OI >9% 9 U3O4 W9 u*V9*4 OC <4J Cu<O99UO0 uoaa. U < zO 09 1U <m n 300 2 'po*O0l*\ as ua CoMau CMM3  *T N oN 3 0 QOO SO vf N N < 2 w x ou 3* 0,0 VV , VN/ /*> m *"! O , N/V 3 Z < 3. z( Wz < 2 V) 3 Ui z >- a<. H.j 3< XM &O 3 14 -1 *2 A 3 < 233 p < :4 S H x *o zo s< --H (843 m>f in n m 55: oc?a o -co* ou em ao. Qo .JUZAto a# I -XZ -a3.-o4 ea 0 C CL Z 3U VC*4 `jA z33 3 S3 33 < C Q a ao9 ac a u uo <j w 41 a 0. o j o n to Oa ^4 tto to 0Oa0 Cto c C'4 Oto < wn l > <3 X 3 01 v<rok* 447996 Cr*'i- C'4 O ' J-273 5 T M. S. RIGGS INTEROFFICE CORRESPONDENCE date April 16, 1979 cc E. R. Averill P. R. Chaney L. Levin W. D. Mitterlehner W. E. Sweeney ASBESTOS CONCENTRATIONS RESULTING FROM 0/A INSULATION DEMOLITION HRH-9-4/79 MOBIL CHEMICAL COMPANY PETROCHEMICALS DIVISION February 10, 11, 12, 1979 INTRODUCTION Six general area air samples were collected on February 10, 11, 12, 1979 during contract insulation removal at the O/A boiler preheater to determine the presence of asbestos fiber. All Rosendahl contract personnel working in this area were supplied with approved respirators and protective clothing. SUMMARY Asbestos concentrations are listed below by sample number, location, and date. The OSHA pcrmissable exposure limit (PEL) for employee exposure is 2 fibers/cc. Samde No. Date O/A-l 2/10/79- O/A-2 2/10/79 0/A-3 2/10/79 O/A-4 2/10/79 O/A-5 2/11/79 0/.A-6 2/12/79 Locaeion/Ooeration S. Side of Boiler 20 Ft. Downwind Near Bailer - Little Work In Progress . Near Boiler - Insulation Cleanup Near Boiler - Insulation Cleanup Near Boiler - Insulation Cleanup S. Side of Preheater After Cleanup Total Fiber 48,900 Fibers/cc 0.81 3,700 0.06 25,600 0.42 9,800 0.16 96,500 3,700 1.6 0.06 06228 447997 M. S. HIGGS INTEROFFICE CORRESPONDENCE 2' 4/16/79 Asbestos concentrations did not exceed 2.0 fibers/cc in any sample, however, this data may not be representative of personnel exposure at the breathing-zone. RECOMMENDATION In cooperation with Rosendahl, an additional series of employee breathing-zone samples should be collected at the time of the next scheduled removal operation. The results of this monitoring should be provided to Rosendahl as documentation of compliance with the exposure limit and initial monitoring required in the OSHA standard. BAL:jrt B. A. Larson Industrial Hygienist 06229 447998