Document vVN9g27G122O7M7Z78NeGEvLm

TO FROM SUBJECT FfiD powtor ofl*r. a bidg. no. Phillip Donatacclo ouEYomtEneft HELD POINT OR DffT. & BLDG. NO. 0A7TH61FTS? Plana FrieszMarch 9, 1992 ' ~-- 1991 INDUSTRIAL HYGIENE SUMMARY - HENRY PLANT During 1991, Henry Plant personnel were monitored for exposure to noise, vinyl chloride, toluene, heavy metals, nuisance dust (total PVC and total unspecified), aniline, methylene chloride, acetone, chlorine, carbon disulfide, and chromic acid. A. Noise (OSHA Permissible Exposure Limit 100% dose/90 decibels) (OSKA Action Level for Hearing Conservation Program 50% dose/85 decibels) (BFG Permissible Exposure Limit 50% dose/85 decibels) DuPont Mark X noise dosimeters were used to monitor 142 representative employees in different job classifications for noise exposure. The noise dosimeter is worn by the employee to measure his total exposure to noise over the work shift. All continuous, intermittent and impulsive sound levels are integrated during the monitoring period to provide the accumulative noise exposure in percent dose. NOISE EXPOSURE BY AREA AREA JOB CLASS NO. OP EXPOSURE MAXIMUM NO. OP MONITORINGS AVERAGE EXPOSURE MONITORINGS >50% DOSE f% DOSE) f% DOSE) Comp. Bldg. (741) PC Bldg. (712) Foreman PC Bagger OBTS (Front End) Op. OBTS (Back End) Op. Geltrol Op. X-70 Op. Stalite/Van Lube Op. MBTS Op. PC Malnt. Coordinator PC Technical PC Foreman 1 5 3 3 1 2 5 4 1 1 1 1 87.13 87.13 3 48.22 61.32 1 45.27 71.52 0 31.90 33.21 0 29.86 29.86 0 28.34 34.87 0 25.32 39.84 0 23.69 37.07 0 18.56 18.56 0 6.83 6.83 0 5.30 5.30 A/E Bldg. (725) Curite 18 Op. BETS Op. Foreman 2 0 47.10 47.11 2 1 27.12 50.73 3 0 16.53 24.86 SR3-495G-E M A ? Br'nti<%g Co. Henry. IN NGC 14746 80ISB EXPOSURE BY ARIA AREA IBT-Crude Bldg. (711) JOB CLASS MBT-C Op. NO. OF EXPOSURE; MAXIMUM MO. OF MONITORINGS AVERAGE EXPOSURE MONITORINGS >50% DOSE \\ PQffiS) 1 0 20.64 20.64 ifflee/Maint.Shop/ PVC Maintenance Warehouse (713) PC Maintenance Warehouse Bldg. (735) Warehouseman 1 7 '7 1 116.13 116.13 0 28.09 42.04 0 14.76 25.13 "Indicates areas that are currently posted as "High Noise" and hearing protection is required. The polymer chemicals department baggers are required to wear hearing protection while bagging. The 3114 back end operators also wear hearing protection while packaging. Noise reduction projects that were completed for the polymer chemicals areas during 1991 are as followsi 1. Building 712 Baggers* Piped discharge air rom air baggers to outside the building. 2. Building 725 Third Floor Area - There were two projects completed in thiB area to reduce the noise level. The first was insulating the filter air receiver. This eliminated the shrill of the air passing through the receiver. The second project completed was to enclose the filter hydraulic skid in a sound curtain. This skid unit had several loud pieces of equipment as a part of it. B. NUISANCE DUST (Total Dust Exposure Limit - IB mg/m5) Operators in the Compounding Building, Dryer Building, Resin Reclaim, PC Building (712), and at Wastewater Treataent were monitored for the total dust (unspecified or PVC). There were no exposures exceeding the permissible limit. TYPE PVC Total PVC Total PVC Total JOB CLASS Dryer Op. (732) PVC Bagger (732) Resin Reclaim Op. (732) AVERAGE PERSONHELMAXIHUH NO. OF EXPOSURE EXPOSURE MONITORINGS (mg/ml) Img/mi) _ 4 1.92 5.50 4 1.18 2.34 1 0.59 0.59 Unspecified Total Unspecified Total Unspecified Total Unspecified Total Unspecified Total Compound Packager (741) PC Bagger (712) Compound Henschel Op. (741) Compound Mill Op. Waste Treatment Op. (adding filter aid to press) 1 1 2 1 1 1.03 0.96 0.37 0.21 0.07 1.03 0.96 0.53 0.21 0.07 NGC 14747 C. TOLUENE (Permissible Exposure Limit 100 ppm) During 1991, personnel monitoring for Toluene exposure was done in the Polymer Chemicals Building 712 and the Crude Building (711). The monitoring results continue to show that there is little toluene exposure. Spot check monitoring will be done quarterly for a representative operator from the X-70/Geltrol and MBT-Crude processes, and annually for a representative operator from each other job classification that may be subject to toluene exposure. TOLUENE EXPOSURE AREA NO. OF AVERAGE MAXIMUM MONITORINGS PERSONNEL EXPOSURE (ppm) EXPOSURE (ppm) Crude Bldg. Operator (711) Geltrol Operator (712) OBTS (Front End) (712) PC Foreman (712) 3 4 1 1 1.27 1.00 1.00 1.00 1.80 1.00 1.00 1.00 D. HEAVY METALS Two weld shop employees and a compounding Henschel operator were monitored for exposure to heavy metals. A personnel monitoring pump (2 1pm flow rate) with an 0.8 micron, mixed- cellulose ester filter in a 3-piece cassette was used. Samples were sent to an outside laboratory for analysis. There were no exposures exceeding permissible exposure limits. The permissible exposure limit is shown in parenthesis next to the metal name. HEAVY METAL AVERAGE EXPOSURE tmq/ml) WELD SHOP COMPOUNDING Antimony (0.5 mg/m3) Cadmium, as fume (0.1 mg/m3) Chromium VI (0.05 mg/m1) Lead (0.05 mg/m1) Nickel (1 mg/m3) Iron Oxide fume (10 mg/m3) 0.0001 0.0032 0.0007 0.001 0.036 0.0002 0.0004 E. ACETONE (OSHA Permissible Exposure Limit * 750 ppm 8 hour 1000 ppm Short-term Two laboratory operators were spot-checked for a full-shift and a short-term acetone exposure. The full-shift monitoring was done with a 3m gas badge and the result was 18 ppm. A short term monitoring was done with a sampling pump and charcoal tube while the operator was cleaning glassware with acetone at the sink. This sample result was 95 ppm. The lab operators will continue to be spot checked periodically for acetone exposure in order to verify that no exposure problem exists. NGC 14748 F. ANILINE (OSHA Permissible Exposure Limit - 2 ppm) Three operators in the HBT-C building were monitored for aniline exposure using a monitoring pump and silica gel tubes. All exposure results were less than 3.08 ppm. This agrees with past years samples and indicates that there is no aniline exposure problem in the crude building. 6. HETHYLENE CHLORIDE (Current OSHA 8-hour TWA - 500 ppmt Proposed OSHA 8-hour TWA - 25s Proposed OSHA Action Level 12.5 ppmi Proposed OSHA Short-term Limit 125 ppm) Three A/E building operators were monitored for full-shift exposure to methylene chloride. The average exposure result was 3.46 ppm and the maximum was 4.49 ppm. A short-tern sample was also taken while the operator was collecting a column bottom sample. The STEL result was 1.98 ppm. Additional samples will be taken until a representative operator from each shift has been monitored for TWA and STEL exposure. H. CARBON DISULFIDE (8-Hour TWA Exposure Limit - 4 ppmt Short-Term Exposure Limit 12 ppm) The Polymer chemicals tank farm operator was monitored twice for full-shift exposure to carbon disulfide. The average exposure was 0.16 ppm and the maximum 0.20 ppm. A short-term (15 minute) sample using a charcoal tube and a monitoring pump was also done while the operator worked on the CS2 pump. The analysis result for this sample was 22.5 ppm which exceeds the STEL. Because of this exceedance, all tank farm jobs involving CS2 will be evaluated and respirator usage required for any tasks that are suspect of causing exposure. Respirator use during work on the CS2 pump has been written into the PC tank farm procedure. I. CHLORINE (Short-Term Exposure Limit 1 ppm) The Polymer Chemicals tank farm operator was monitored for chlorine exposure over a one-hour period which included the unhooking of a chlorine railcar. A passive diffusion tube for chlorine was used as the monitoring device. There was no color change at all in the tube following the monitoring which indicated negligible exposure. Additional monitoring will be done to verify this result. J. CHROMIC ACID (Permissible Exposure Limit - 0.1 mg/*1 ceiling) The raw materials laboratory operator was monitored on a day when he was using chromerge (chromic acid solution) to clean glassware. The monitoring result was 0.0084 rag/m' as chromic acid. The wastewater treatment laboratory operators also use chromerge and will be monitored. NGC 14749 K. VINYL CHLORIDE (Permissible Exposure Limit " 1 ppm) All operators in the Poly and Dryer building as well as the PVC Tank Farm are monitored for vinyl chloride exposure at least once per year. The schedule of monitoring then follows the OSHA VCL standard which requires monthly monitoring for any exposure greater than 1.0 ppm until two consecutive monitorings are less than 0.5 ppm. The employee need not be monitored again during the year if his annual monitoring result or the two consecutive monitorings are below 0.5 ppm. All VCL monitoring samples were collected on Reiszner gas badges and analyzed by an AIHA accredited laboratory. VINYL CHLORIDE MONITORING (POLY AND DRYER BUILDING) Year 1987 1988 1989 1990 1991 No. of People Monitored 248 314 403 277 261 Averace (odd) 1.06 1. 15 1.36^ 0.72 0.70 % Greater Than 1 ppm 21 27 35 12 13 \ Less Than 0.5 non 58 48 40 64 65.5 VINYL CHLORIDE EXPOSURE BY JOB CLASSIFICATION j JOB CLASS NO. OF MONITORINGS oly Cleaner (enters polys) [RC Poly Cleaner/Helper ecovery Operator aste/LoSope charge VC Foreman earl Charge & E Operator alve Cleaner iryer Operator )ryer Bldg. Foreman >VC Bagger 'ank Farm Operator >ilo Operator ?VC Engineer/Technician 'atalyst Makeup 14 18 17 37 19 .42 5 3 32 8 37 4 8 4 2 NO. ABOVE 1 PPM 10 3 1 14 4 2 1 0 1 0 0 0 0 0 0 AVERAGE EXPOSURE (PP*> 2.46 1.39 1.27 1.07 0. 57 0.47 0.45 0.41 0.36 0.33 0.28 0.28 0.25 0.25 0.25 MAXIMUM EXPOSURE (ppm) 15.00 14.00 18.00 8.00 2.20 2.60 1.20 0.59 1.40 0.84 0.53 0.37 0.27 0.25 0.25 NGC 14750 RESPIRATOR COMPLIANCE (POLY BUILDING) Year 1987 1988 1989 1990 1991 No. of Exposures Greater than 1 ddd 53 72 140 34 35 No. of Exposures Greater than 1 W/0 Respirator 15 24 40 9 12 Respirator Compliance 72% 67% 71% 74% 66V^ The job class breakdown is as follows for Poly Building employees exposed to greater than 1 ppm VCL without the use of a respirator. JOB CLASS HO. OF EXPOSURES Paste/LoSope Charge Operator Recovery Operator HRC Poly Cleaner/Helper 10 1 1 Since there have been a number of vinyl chloride exposures to the paste/LoSope charge operator that were greater than 1 ppm without respirator protection, this job Is being closely evaluated. One task of the job that has come to light as a source of VCL exposure is opening the poly manhead after the charge has been recovered without valving in the exhaust to the poly. OVA checks of this task have shown zero ppm with the exhaust valve open and as high as 5000 ppm at the manhead with the exhaust closed. The PVC area management has re-emphasized with all operators the necessity of valving in the exhaust before opening the poly manhead to sample the charge. Another possible source of vinyl chloride is drilling material out of the condensers which is then dropped Inside the building. Several high personnel exposures have occurred on the same day as the drilling task. The condenser drilling procedure will be changed to require drilled material to be dropped to the poly and for the poly exhaust to be on while the drilling is taking place. Other tasks of the paste/LoSope charge operator will be checked with an OVA and/or personal monitoring device. These tasks include changing vinyl filters, sampling seed polys, sampling foam traps, and dropping polys. L. MEDICAL SURVEILLANCE SUMMARY Total number of Examinations - 298 Number of Examinations which showedi NGC a. Hearing loss - 24 b. Report by Department Whse. - 3 Uti. - 1 Maint. - 5 PVC - 3 P.C. - 9 Comp. - 3 Follow-up Activities; 1. Send letter to each employee stating they have a S.F.S. 2. Retest each employee within 21 days. 3. Reinstruct each employee In the proper use of hearing protection. 4. Reevaluate their working area. Please call me at 9407 if you have any questions on this information. DF/bs/9208 ccs D.M. Kidd V.D. Marquis D.L. D.E. R.D. W.J. J.D. K.W. M.E. Piccinelli Giffin Webber Grudzinski Krumholz Prather Guyer Diana Friesz J.B. Hattingly T.L. Castor J. L. Schwarz K. E. Musselman D. Gleghorn - Cleveland R.J. Grahek - Cleveland K.J. Hillings - Brecksville S&E Operators (2) PVC Foreman (4) PC Foreman (4) File NGC 14752