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ESCAMBIA PLANT INTEROFFICE MEMORANDUM
To; W. J. Stueben
From: K. J. Femrite Re: Industrial Hygiene Monitoring
Date:
16 November 1978
Copies:
J. G. Tolar _ <^~R. L. Duggan^
S. J. Hardee
VCM in PVC Plant
Personnel monitoring for VCM consisted of an eight hour TWA and a fifteen minute ceiling exposure sample per man assigned to PVC operations. Laboratory and maintenance personnel were monitored by a single eight hour TWA sample.
Ninety-two percent of the eight hour TWA samples analyzed this month were below the OSHA standard of 1.0 ppm for VCM exposure. Eighty-six percent were below the OSHA action level of 0.5 ppm. Exhibit I details VCM exposure and its frequency of occurrence during October.
A statistical survey of the VCM personnel monitoring determinations from January, 1978, through October, 1978, was undertaken. The average
VCM exposure and its standard deviation at the 95 percent confidence level was determined for each job in PVC operations. The results reveal that the outside/recovery operator is routinely exposed to VCM levels over the 1.0 ppm level each eight hour shift. The sune operator wears a fresh air mask 10-35% of the time during his work shift which significantly reduces the amount of VCM that he inhales. The results also reveal that the shift supervisor and the senior operator are occasionally exposed to VCM levels over the 1.0 ppm limit. Their exposures are probably due to them working in problem and or upset conditions, Exhibit II details VCM exposure levels versus job in the PVC plant.
DMF in Chemical Cleaning
Two determinations for DMF exposure show levels below 2 ppm for the DMF recovery operator. The eight hour TWA for DMF is 10 ppm.
Results from a statistical survey of DMF monitoring determinations reveal the operator is exposed to DMF levels from non detectable to 10.5 ppm over an eight hour shift. The average and standard deviation of the exposure data at the 95 percent confidence level is 2.8 ppm 6.6 ppm. The DMF exposure determinations are wide ranging with only 20% of the determinations above the OSHA action level of 5.0 ppm. Exhibit II details DMF exposure for the operator.
AP00032973
W. J. Stuebcn 16 November 1978 Page Two
Ammonia in the AN Plant
Personnel monitoring results for ammonia revealed levels below the
OSHA action level of 12.5 ppm. The eight hour TWA for ammonia is 25 ppm.
Samples were taken twice a week for six hours during the work shift. Exhibit-HI
details ammonia exposure in the AN plant.
*
A survey of the prill tower operators exposure to ammonia was undertaken. Grab samples were taken in his work area where he was poten tially exposed to ammonia fumes. Samples were taken using length of stain detection tubes.
The results show that the operator is exposed to 5 ppm or less ammonia in the permalene solution room. The operator is in the permalene room approximately 30 minutes to one hour each eight hour period. The operator is exposed to 30 to 70 ppm ammonia every time he enters the top of the prill tower. He spends approximately 30 minutes at the top of the prill tower 3 or 4 times an eight hour period.
NO in the An Plant
Four area monitoring samples for NO and NO in the wet bay area of
the AN plant showed levels below 0.1 ppm for NO and
The eight hour
TWA limit for NO is 25 ppm while that for N02 is 5 ppm. Samples were
taken 50 feet downwind of the nitric acid storage tank at ground level and on
the second floor.
CO in MeOH Synthesis
The average of two eight hour TWA personnel monitoring samples for carbon monoxide for the methanol synthesis operator was 6.2 ppm. The eight hour TWA limit for CO exposure is 50 ppm.
Allyl Compounds in ICR&D Laboratory
Personnel exposure to allylchloride in the ICR&D laboratory continues to be a problem. The average of four determinations for allylchloride this month was 1.5 ppm. The eight hour TWA exposure limit for allylchloride is 1.0 ppm. All but one of the samples analyzed this month for allylchloride was above the OSHA action level of 0.5 ppm for allylchloride exposure.
Personnel exposure to allyl amines continues to be minimal this month as the ICR&D laboratory has not started separatory distillations. Exhibit IV details allyl compound exposure in the ICRfctD laboratory.
AP00032974
W. J. Stucben 16 November 1978 Page Three
Amines Industrial Hygiene Method Development
Development of gas chromatograph columns for analytical separations of butyl, propyl, allyl, and ethyl-butyl amines has been completed. Work that still remains to be accomplished is establishing desorption efficiencies, minor instrument fine tuning, and initial sampling for the amines. The ClC columns and what each column separates is listed below for all amine products.
Column A
Column B
Monomormalbutylamine (MNBA) Dinormalbutylamine (DNBA) Mononormalpropylamine (MNPA) Dinormalpropylamine (DNPA) MonoalLylamine (MAA) Diallylamine (DAA)
Monomethylamine (MMA)
Efimethylamine (DMA)
Trimethylamine (TMA)
Monoethylamine (MEA)
Diethylamine (DEA)
Triethylamine (TEA)
^
Ethyi-normalbutylamine (EBA)
Column C
Isobutyronitrile (J.BN) Dimethylforxnamide (DMF)
Column A - 1 5 ft X 2 mm glass packed with 10% CW 1500 + 3% KOH on Chromosorb W(HP).
Column B - 10 ft X 2 mm glass packed with 4% CW 20M + 0.8% KOH on Carbopack B.
Column C - 6 ft X 1/8 in stainless steel packed with 0.2% CW 1500 on Carbopack C.
Methyl Chloroform in Maintenance
Results for methylchloroform exposure in the compressor house and Area B maintenance shop show levels below 30 ppm. The eight hour TWA for methylchloroform is 350 ppm. Samples were taken using theGasbadge, collec tion system. The samples were analyzed by Gasbadge for methylchloroform content. Exhibit V details methylchloroform exposure in these areas.
1) Two synthesis routes are possible for EBA. analysis. 1. DEA + MNBA - EBA + TEA
Columns A&B are required for the
2. MEA + DNBA - EBA + DEA
AP00032975
KXlUlilT I PERSONNEL MONITORING FUJI VCM
OSHA Standard:
1 ppm 8-honr TWA 5 ppm 15-minute Ceiling Exposure
Fifteen Minute Ceiling Exposure
Concentration Range / ppm - VCM
5 1. 01 - 5 0. 51 - 1 0. 0.- 0. 50
Frequency ^Percent}
0 .0
6 94
Total
100
Eight Hour TWA
Concentration Range PPM - VCM
5 1. 01 - 5 0. 51 - 1 0. 0 - 0. 50
Total
Frequency (Percent)
0 8. 6 86
100
Number of Samples Analyzed
0 0 2 *n
32
Number of Samples Analyzed
0 4 3 42
49
AP00032976
PVC/C11EM CLEANING
Job
VCM1
% of Time*
DMF2
PPM Air Mask Used PPM
AMS PPM
TCE PPM
DUST nifi/m3
Supervisor
.41.6
Senior Operator
.3* .9
Solution Operator
,Z .7
Control Rm. Operator .1* .3
Artisan Operator
.2 .3
Dryer Operator
.2 .4
Outside Operator
1.12.4
Maintenance Operator NED3
(lagging Operator
NED3
Loading Operator
NED3
0-10 0-10 10-35 0-10 0-10 0-10 10-35 NED* NED3
NED3
-
2.8*6.6
-
-
No Method
tt
H
tt
1!
ti
No Method
m
^" n n ii n n
ii
NED* NED
1) Avg. & std. dev. at 95% confidence level of 29 deter ninations from 1 /78 thru 10/78. 2) Avg. 4t std. dev. at 95% confidence level of 14 determinations from 1/78 thru 10/78. 3) Not enough data for statistical use.
AP00032977
EXHIBIT III AMMONIA IN THE AMMONIUM NITRATE PLANT
OSHA Limit: 25 ppm
Date
10/13 10/13 10/13 '10/13 10/16 10/16 10/16 10/16
Job
No. of Hours No. of Samples Average Ammonia
Sampled
Taken
Exposure, ppm
Wet Bay Operator (1) Wet Bay Operator (2) Wet Bay Operator (3) Dry Bay Operator Extra Operator Tower Operator Instrument Technician Shift Supervisor
6 6 2 6 6 6 6 6
3 3.9 3 ' 2.0 1 2.6 3 4.3
3 2.4 3 9.1 3 4.9 3 2.2
AP00032978
EXHIBIT IV
ALLYL COMPOUNDS IN ICR&D LABORATORY
OSHA Limit! Allyl Chloride-1 ppm Allyl Amines -None
Date
No. of Hours Sampled
10/2 ' 10/4
10/5 10/16 10/17 10/20 10/21
.
11 8
11.5 8.3
11 10
6
Allyl Chloride PPM
3.7
-
0.8 1.3
-
0.04
-
Mono Allyl Amine PPM
0.06
-
<.02
-
<.04
oH a
V
Di Allyl Amine PPM
< .02 -
-
-
< .03
AP000I2979
EXHIBIT V
METHYL CHLOROFORM IN MAINTENANCE
TLU: 350 ppm
Date
Job
Sampled.
Methylchlorofo PPM
S/16 S/26 8/16 8/16 8/16 8/20 8/20 8/20 8/20 8/20 9/7 9/7 9/8 9/8
Compressor house mechanic
n ii it
ii ti ti ii ii ii
nit ii
ii ti ii
it ii
n it
Area B Mechanic
ti n
ii
it it
tt
n ti
ti
it ii
7.0 7.0 7.0 7.0 7.0 5.7 6.0 6.0 6.0 6.0 TL5 7.5 6.5 6.0
,
> ' 9.4 8.3
29.0 8.8 8.2 1.8 15.3 1.0 1.1 0.7 6.5 0.8 0.2 0.3
AP00032980
To
Industrial Hygiene Report February 1994
B. G. Roberson M- Ward
hT~J. smith
\
From: R. L. Heath
Monitoring was per-formed in B-Area during the month 0+ February. The results are on the -following pages.
There were no alerts issued in February.
The St. Gabriel plant borrowed our noise monitors during the month.
W. A. Lowery requested a noise survey on the train engine to compere the noise levels with and without the windows and doors open. That monitoring was completed.
To improve the dust monitoring, preweighed matched -filters are being used.
Reba Heath
AP00032981
Hygiene Monitoring
During the month of February, hygiene monitoring was conducted for Noise < 1 sample), Ammonia (6), Chloroform Formaldehyde (5), and Respirable Dust (8).
(3),
Chemical-Area
Completed Hygiene Monitoring
<Action Level
>Action Level
Permissible Exposure Limit
Noi se -B Area Maint
l
Ammonia
-Wet BayVDry Bay 3
--Solutions
3
Formaldehyde
-Wet Bay\Dry Bay 3
-Solutions
4
AP00032982
Year to Date Industrial Hygiene Monitoring Results
Chemical--Area
Action Level
Action Level
Permissible Exposure Limit
Ammonia -AN Wet Bav -AN Solutions -NH3 Loading -NH3 Operator
Asbestos -30 min -Duration -Area samples
3 3> l
Benzene -#2 Amines Oper.
Carbon Monoxide -Compressor House
2
Chloroform -AN Dry Bay
Di ethanol Mi ns --NH3/MeOH Oper.
Dimethylamine -Drum Filler -Bung Tightner -Unhooking Car
Di methyl f orntMl de -Amines Loader -Drum Filler --Bung Tightner
Fibers --Fiberglass -Ceramic -fiber
Farmaoiide -Pilot Plant Oper.
Formaldehyde --AN Solution Oper. -AN Dry Bay Oper.
3 ^
Hydrogen Cyanide -Pilot Plant Oper.
AP00032983
year To Date Industrial Hygiene Monitoring Results
Continued
/ami cal -Area
Action Level
>Action Level
Permissible Exposure
Limit
thanol [ -Truck Loader j -Tankcar Loader
-Loading Qper. I
jthyl amines [ -#1 Amines Oper. j -Drum Filler
-Bung Tightner
trogen Dioxide --Nitric Acid Loader
iise -NH3/MeOH
-Process
-Maint -E*E j -Compressor House -Pilot Plant
-HN03 j -Process I -Maint
-I&E
--AN
-Process --Maint
-IlcE
-Amines -Process -Maint
-I&E -Train Crew
-Engine Qper --Switchman -Main Shop -Warehouse Receiving -Engineeri ng
-Pilot Plant Office -Hydrogen
-Process -Maint
-l&E
1 3 I
2
AP00032984
Alert #
Industrial Hygiene Alerts For FY94
Date
E:<p 1 anati on
AP00032985
Monitoring Activity
December Benzene
November Lead CO Noise
Complete
wOinDl ete Ccmolete No samples
taken-pumps out tor
calibration
December Noise survey-B Area Noise Main Shop
Complete Two samples taken
January
Noise HN03 area
3 in Maint. and 1 in process.
TEA Drumming
4 samples taken
DMA Drumming
2 samples taken
DMF Drumming
no samples
DMF Loading
no samples
Ventilation B Area
incomplete
Formamide Pilot Plant incomplete
HCN Pilot Plant
incomplete
Noise Pilot Plant
incomplete
AP00032986