ENVIRONIM1AL PROTECTION AGENCY 'Q AIR QUALITY MONITORING BRANCH ------- JUNE. 1978 QOAHiy SURVEY - CERTAIN-TCD PRODUCTS 'CDRPOPATIffl , PA EWIRQNTCTTAL PROTECTION AGENCY - REGION III » . SURVEIlMCE & ANALYSIS AIR QUALITY MONITORING BRANCH at: ROBERT IWER THEODORE ERDMAN DAVID O'BRIEN ------- JUNE, 1978 AIR QUALITY SURVEY - CERTAIN-TEED PRODUCTS CORPORATION MOUNTAINTOP, PA ROBERT KRAMER THEODORE ERDMAN DAVID O'BRIEN ------- Certain-Teed Products Corporation Mountaintop, PA Table of Contents Abstract 1. Summary 2. Plant Operating Conditions During Testing Periods 2.1 Glass Furnaces 2.2 Forming Lines 2.3 Curing Ovens 3. Site Selection and Location 4. Meteorological Data 5. Sampling Procedures 5.1 Phenol 5.2 Formaldehyde 5.3 Fiberglass 6. Analytical Procedures 6.1 Phenol 6.2 Formaldehyde 6.3 Fiberglass 7. Field Quality Control Procedures 8. Chain of Custody Shipping Procedures 9. Test Results 10. Conclusions Figures Figure 1 Figure 2 Plant Process Flow Diagram Sampling Sites Locations - May 1 Figure 3 Sampling Sites Locations - May 2 Figure 4 Sampling Sites Locations - May 4 Tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Plant Production Data Site Identifications Meteorological Data - May 1 Meteorological Data - May 3 Meteorological Data - May 4 Test Results -1- ------- Appendices A Plant Production Data B Meteorological Data C Test Procedures D Operation of Sampling Train - Data Summary E Description - Hastings Mass Flow Meter F Rotometer Calibration Data G Test Results H Health Effects Data I Participants in Survey -2- ------- ABSTRACT At the request of Stephen Jellinek, Assistant Administrator, Toxic Substances, and in response to citizens inquiries as to the air quality in tneir neighborhood, an ambient air survey was conducted by the Environmental Protection Agency, Region III, Philadelphia, PA. The EPA tests were conducted May 1st, 2nd and 4th, 1978. This survey was intended to to measure ambient air concentrations of phenols, formaldehyde and fiberglass particles in the area of the Certain-Teed Products Corpor- ation, Mountaintop, PA. The test results for formaldehyde concentrations indicated that the downwind concentrations ranged from non-detected to 251 parts per bil- lion (ppb). The time weighted average concentration was 75.2 ppb. The upwind concentrations ranged from non-detected to 80 ppb. The upwind time weighted average concentration was 21.9 ppb. The minimum detectable limit was approximately 5 ppb for formaldehyde. The test results for phenol concentrations indicated that the downwind concentrations ranged from non-detected to 21 ppb. The time weighted average concentration was 5.4 ppb. The upwind concentrations ranged from less than 1 ppb to 69 ppb. The time weighted average concentration was 13.6 ppb. The minimum detectable concentration was approximately 1 ppb for phenol. The EPA test results indicate that the formaldehyde emissions from the plant may cause eye, nose and throat irritation. Headaches may also be caused by exposure to formaldehyde at the measured concentrations. -3- ------- 1. SUMMARY At the request of Stephen Jellinek, Assistant Administrator, Office of Toxic Substances, and in response to citizens inquiries as to the air quality in their neighborhood, the Air Quality Monitoring Branch of the Surveillance and Analysis Division, Region III, conducted, with the support of its Wheeling Field Office, an ambient air study around Certain- Teed Products Corporation, Mountaintop, PA. The purpose of the study was to determine whether pollutants were present in the ambient air in sufficient quantities to present an imminent and substantial endangerment to public health. The pollutants sampled for included phenols, formalde- hyde and fiberglass particles. These samples were obtained May 1st, 2nd and 4th, 1978. The sampling and analytical procedures for formaldehyde and phenol were conducted in accordance with the methods documented in "Air Sampling and Analysis", Intersociety Committee, American Public Health Association, 1972, Method #15C 112 for formaldehyde and Method #ISC 116 for phenol. The sample collection and analytical procedures for fiberglass are • contained in the "NIOSH Criteria for a Recommended Standard, Occupational Exposure to Fibrous Glass", U.S. Department of Health, Education and Welfare (publication #77-152). The sampling network consisted of two sampling sites, one upwind and one downwind from the plant. The upwind sampling site included a meteorological station which monitored wind speed and direction during the sampling periods. Every reasonable attempt was made to locate the downwind sampling sites in an area where the emissions could be seen touching the ground. The purpose of this was to obtain the maximum possible concen- trations during the sampling periods. The weather conditions for the samples obtained May 1st and 2nd were condusive for this particular sampling network, however, the weather conditions during May 4th allowed the plum to touch the ground only on an intermittent basis. The sampling periods chosen over the three day period included operating hours from each of the three operating shifts at the plant. A plant inspection was conducted to assure that the process equipment was not altered in order to lower the plant emission rates. Production data obtained during the inspection indicated that both production lines were operating normally during the three days of the survey. -4- ------- The test results for formaldehyde concentrations indicated that the downwind concentraitons ranged from non-detected to 251 ppb. The time weighted average concentration was 75.2 ppb. The upwind concentrations ranged from non-detected to 80 ppb. The upwind time weighted average concentration was 21.9 ppb. The minimum detectable limit was approxi- mately 5 ppb for formaldehyde. The test results for phenol concentrations indicated that the downwind concentrations ranged from non-detected to 21 ppb. The time weighted average concentration was 5.4 ppb. The upwind concentrations ranged from less than 1 ppb to 69 ppb. The time weighted average concentration was 13.6 ppb. The minimum detectable concentration was approximately 1 ppb for phenol. The test results for fiberglass particles indicated that the only fibers found were naturally occurring fibers, not fiberglass. The test results indicate that the formaldehyde emissions from the planf may cause eye, nose and throat irritation. Headaches may also be caused by exposure to formaldehyde at the measured concentrations. -5- ------- PLANT PkOCEbb I LOW L-IA'-.kAM FIGURE I DRY ESP • GLASS ; I LINE M-2 . FURNACE r-ji PRODJCT FLO'.^ f /^^HIGH I JSTACK 7l _/ SCRUBBER UNITS FORMING .CHAMBER CURING OVEN FOfMING CHAMBER -I CURING OVEN > tr ..v__ ! WET A INCINERATOR I UNI" EXISTING AIR POLLUTION CONTROL SYSTEM (MAY 4, 1978) ' AIR POLLUTION SYSTEM-UNDER CONSTRUCTION ------- 3. SITE SELECTION AND LOCATION The major objective in selecting the following sites was to simultan- eously obtain upwind and downwind samples. In the case of the downwind sites, the sampling trains were moved to the point where the emissions from the plant could be seen touching the ground. The weather conditions on May 1st and 2nd were such that the emissions from the plant could easily be seen as they touched the ground. These weather conditions remained fairly constant, and therefore, the plume touch down area from the plant also remained in the same general area. In addition, this "down wash" from the plant was not interrupted by periods of light wind speeds. The light wind speeds and variable wind directions which occurred during the samples obtained May 4th, caused the plant emissions to touch ground level only on an intermittent basis. -12- ------- .Table #2 Site Identifications May 1. 1978 Times at Location 4:49 pm-8:56 pm Site Code and Identification 1) 2) 3) 4) Distance and direction from high stack - 90 ft, SE Downwind site Closest residential home - Wester residence; 79 Church Rd. (60 ft SW of Site A) 8:56 pm-12:00 midnight 5:15 pm-12:00 midnight 1) 2) 3) 4) 1) 2) 3) 4) Distance and direction from high stack - 800 ft. SW of high stack Downwind site Closest residential home - Wester residence; 79 Church Rd. (200 ft SW of site C) B Distance and direction from the stack - 3000 ft NW of high stack Upwind site Located at Dana Perfume Corp. -13- ------- Table #2 Site Identifications May 2. 1978 Times at Location Site Code and Identification 9:30am-10:50am 1) A 2) Same location as May 1st, Site A 3) Downwide site 10:50am-2:05pm 1) D 2) Distance and direction from high stack - 1100 ft. SE of high stack 3) Downwind site 4) Closest residential home - Wester residence; 79 Church Rd. (150 ft. NW of site D) 2:10pm-5:00pm 1) E 2) Distance and direction from high stack - 1300 ft. SE of high stack 3) Downwind site 4) Closest residential home - Wester residence; 79 Church Rd. (350 ft. NW of site E) 5:00pm-6:00pm 1) F 2) Distance and direction from high stack - 1350 ft. SSE of high stack 3) Downwind site 4) Closest residential home - Wester residence; 79 Church Rd. (400 ft. NNW of site F) -14- ------- Table #2, May 2, 1978 - Continued 9:25am-6:00pm 1) B 2) Same location at May 1st, site B 3) Upwind site -15- ------- Table §2 Site Identifications May 4. 1978 Times at Location Site Code and Identification 11:45 pm (May 3rd)-5:00 am 1) G 2) Distance and direction from high stack - 1200 ft SW of high stack along Church Rd. 3) Downwind site 4) Approximately 1000 ft. SE of Wester residence; 79 Church Rd. 12:15 am-5:00 am 1) H 2) Distance and direction from high stack - 2500 ft. NNE of high stack 3) Upwind site 4) Adjacent to Foster-Wheeler metal fabrication plant -16- ------- 4. METEOROLOGICAL DATA The Climatronics Corp., Model WM-III-540, wind speed and direction system was used to obtain the meteorological data and was always located at the upwind sites. The data obtained May 2nd and 4th indicated that the sampling sites were within ± 20° of the average wind direction at the downwind sites. The meteorological data obtained May 1st indicated considerable vari- ation between the average wind direction and the downwind site locations. Since all participants in the survey felt certain that the site was located in the proper downwind position due to the odors and the "high stack" water droplet downwash that were observed, it is believed that the discrepency was due to misalignment of the weather vane. The following data is supplied for each of the three sampling periods, which are: 5/1/78, from 6:00 pm to midnight 5/2/7By from 10:00 am to 6:00 pm; and 5/4/78, from midnight to 5:00 am 1) Maps showing site locations and average wind direction (WD) (arrow) 2) Summary showing duration of different WD 3) Average wind speeds WS and WD for each hour during the sampling period and also the overall WS and WD average 4) List of WS and WD (5 minute intervals) during the sampling period (Appendix B) 5) A copy of the strip chart for the WS and WD for the sampling period (Appendix B) -17- ------- Table #3 Meteorological Data May 1, 1978 N=0°/360° S=180° Sample Time: E=90° W=270° 6:10 pm - midnight Sample Site B Average WD = 338°/340<> from all 5 minute readings WDo Each x = 5 minute time interval Length of time in minutes 310 xx 10 315 320 xx 10 325 330 xxxxxxxxx 45 335 xxxxxx 30 340 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxx 155 345 xxxxxx 30 350 xxxx 20 355 xx 10 360 xxx 15 Hourly Averages Time of WS WD Samples MPH Degrees 6:30-7:00 pm 11 344 7:00-8:00 pm 12 346 8:00-9:00 pm 11 336 9:00-10:00 pm 10 336 10:00-11:00 pm 9 334 11:00-12:00 pm 11 341 -18- ------- MlbS LOCATIONS FIGURE 2 Mav 1. 1978 Sites: A. R & C Average Wind = 340° ' t'ark, Ar«\i o* diii Top, P: ------- Table #4 Meteorological Data May 2. 1978 N=0°/360° 5=180° Sample Time: E=90° W=270° 10:00 am - 6:00 pm Sample Site B Average WD = 322° from all 5 minute readings WD° Each x = 5 minute time interval Length of time in minutes 270 xxx 15 275 280 xx 10 285 290 295 300 xx 10 310 xxxxxxxxxxx 55 315 xx 10 320 xxxxxxxxxxxxxxx 80 325 320 xxxxxxxxxxxxxxxxxxxxxxxxxx 130 335 xx 10 340 xxxxxxxxxxxxxxxxx 85 345 xxx 15 350 xxxxxxxxx 45 355 360 xxxx 20 Hourly Averages Time of WS WD Samples MPH Degrees 10:00-11:00 am 10 330 ll:00-noon 11 338 noon-1:00 pm 10 323 1:00-2:00 pm 10 328 2:00-3:00 pm 12 317 3:00-4:00 pm 12 330 4:00-5:00 pm 11 ' 326 5:00-6:00 pm 8 329 Overall average: 11 328 -20- ------- SAMPLING SITES LOCATIONS FIGURE 3 May 2, 1978 Sites: A. B. D, E & F Average Wind = 322° art ------- N=360° E=90° WD° 10 20 25 30 40 45 50 55 60 70 80 90 110 120 125 130 140 275 310 330 340 350 360 Table #5 Meteorological Data May 4, 1978 S=180° Sample Time: W*270° midnight - 5:00 am Sample site H Each x = 5 minute time Interval Length XXX XX X xxxxxxxx xxxxxxxxxx X XX XX XXX X X X XX X X X X X X X XX xxxx xxxx of time in minutes 15 10 5 40 50 5 10 10 15 5 5 5 10 5 5 5 5 5 5 5 10 20 20 Time of Samples midnight-1:00 pm 1:00-2:00 pm 2:00-3:00 pm 3:00-4:00 pm 4:00-5:00 pm Hourly Averages US MPH 3 2.5 2 2 2 WD Degrees 50 71 11 15 38 Overall average: 37 -22- ------- SAMPLING SITES LOCATIONS FIGURE 4 May 4, 1978 Sites: G & H Average Wind = 35° .' • 1 Indus i ' T Park, Area of Mountain Top, Pa. ------- 5. SAMPLING PROCEDURES The sampling and analytical procedures used for formaldehyde and phenol were in accordance with the methods documented in "Methods for Air Sampling and Analysis, Intersociety Committee American Public Health Association, 1972". The specific methods are method #1SC 112 for formal- dehyde and method #1SC 116 for phenol (see Appendix C). The laboratory analyses for these samples were conducted by the Wheeling, West Virginia Field Office of the Environmental Protection Agency, Region III. The sampling and analytical procedures for fibrous glass are described in "Criteria for a Recommended Standard - Occuaptional Exposure to Fibrous Glass", U.S. HEW NIOSH DEW (NIOSH), publication #77-152. The analyses of these samples were conducted by McCrone Associates, Chicago, Illinois. 5.1 Phenol Sample Collection Procedure The sampling train for phenol consisted of one fritted midget impinger connected to a battery operated personnel sampler pump by 2 feet of 1/4 inch ID latex tubing. The absorbing solution was 15 milliliters of O.ln NaOH. The sample trains were leak checked before sampling by pulling a 2 inch Hg vacuum and observing a vacuum gauge attached to the impinger intake. No leak existed if the vacuum remained constant. Samples were collected for about 2 hours at a flow rate between 550 and 1200 ml/min (see Appendix D - Data Summary of Sampling Pumps). The flow rates were determined by using a calibrated rotometer which was an integral part of the sampler. At the termination of each sampling period, the 15 ml of exposed absorbing solution was transferred to a O.ln NaOH prerinsed 100 ml plastic sample bottle. The impinger was rinsed twice with O.ln NaOH twice and the rinses were transferred to the sample bottle. Approximately 5 ml of 10% cupric sulfate was added to the sample bottle to preserve the sample. -24- ------- 5.2 Formaldehyde Sample Collection Procedure The sampling train consisted of two fritted midget impingers con- nected in series with teflon tubing. The impingers were connected to a battery operated personnel sampling pump by 2 feet of 1/4 inch ID latex tubing. 15 mis of MBTH (see Appendix C) absorbing reagent was placed in each impinger. The sample trains were leak checked before sampling by pulling a 2 inch Hg vacuum and observing a vacuum gauge attached to the impinger intake. If the vacuum gauge reading remained constant, there were no leaks in the sampling train. The samples were collected simultaneous for about 2 hours at a constant flow rate between 250 and 6540 ml/min (see Appendix D - Data Summary for Operating of Sampling Pumps). The flow rates were determined by using a calibrated rotometer which is an integral part of the pump. At the termination of each sampling period, the exposed impinger solutions were transferred to a 100 ml plastic sample bottle which was prerinsed with MBTH. The impingers were rinsed twice with MBTH and the rinses were transferred to the sample bottle. 5.3 Fiberglass Sample Collection Procedure The sampling train consisted of a 37mm 0.8 micron milipore filter held in the bottom half of a plastic filter holder cassette. The backing of the cassette was retained in the holder to support the filter. The filter holder was connected to a battery powered per- sonnel sampler pump with 2 feet of 1/4 inch ID latex tubing. Samples were collected for about 2 hours at a flow rate held con- stant between 2200 and 2900 ml/min (see Appendix D - Data Summary for Operation of Sampling Pumps). The flow rates were determined by using a calibrated rotometer which is a integral part of the sampling pump. At the termination of each sampling period, the filter holder cassette was sealed. -25- ------- 6. ANALYTICAL PROCEDURE 6.1 Phenol Analyses The phenolic compounds are trapped by the acid/base reactions of the acid hydrogen of the phenol group with the NaOH in the impinger solution, thus forming a sodium salt. The entire sample was used for one analysis. The 40 to 50 ml of solution in each sample bottle was diluted to 500 ml. The solution was acidified with phosphoric acid. 90% of the sample volume was distilled into a receiver. The distillate was adjusted to PH 10.0 + 0.2 using an ammonium chloride hydroxide buffer. 4 amino-antipyrine was added to the distillate which rapidly formed a coupling product with all phenolic compounds present. The coupling product was extracted into a small volume of chloroform which was made up to mark and read at 460 mm in a Spec 20 spectrophometer. The Wheeling Field Office operates a routine quality control pro- gram for the phenol analysis which includes external audits (WFO QA Procedures Manual). 6.2 Formaldehyde Analysis The formaldehyde initially collected in the sampling solution of MBTH reacts to form an azine. At the laboratory, the contents of the sample bottles (40 to 60 ml) were made up to 100 ml with MBTH absorbing solution. A 10 ml aliquot of the 100 ml samples were transferred to a receiver. 2 mis of ferric chloride-sulfanic acid solution was added to the 10 ml aliquot which oxidizes the excess MBTH in the solution forming a reactive cation. The cation reacted with the formaldehyde-MBTH azine forming a very stable blue catonic dye in acid media which was read in a Spec 20 spectrophometer at 628 nm. 7 spiked samples were prepared using exposed absorbing solutions collected at Mountaintop, PA. These experiments indicated that excellent recovery can be expected from the analytical procedures used with the Mountaintop samples. ' 3 of these samples were used in a standard addition experiment. The experiment indicated that there were no interferences present during analysis of field samples. -26- ------- 6.3 Fibrous Glass Analysis The filter was examined under a visible microscope with the filter in a medium of identical optical density. Under this condition the filter is transparent. Fibrous glass is easily distinguishable from other fibers because, characteristically, fibrous glass particles are large and more uniform in shape than naturally occurring fibers. Fiber counting was performed by traversing the field of the sample identifying and counting fibrous glass particles as they appear. The number of traverses is determined by the frequency that fibrous glass particles are encountered. -27- ------- 7. FIELD QUALITY CONTROL PROCEDURES A significant error can be introduced if the rotometers are not cal- ibrated properly, therefore, the rotometers on the pumps were calibrated using a Hastings Mass Flow Meter (see Appendix E). The Hastings Mass Flow Meter was, in turn, calibrated using a bubbler meter which is traceable to a primary standard. An increase of 5% in sample volume was made to adjust for differences in field conditions to standard conditions (25°C, 760 mm barometric pressure), This correction is based on an average temperature of 10°C during sampling. No correction was made for differences in barometric pressure because the Hastings Mass Flow Meter used to calibrate the rotometers is not sensitive to variations in atmosphereic pressures. The variation of flow that could be attributed to differences in atmospheric pressure during sampling was less than 1%. No correction was made for moisture content of the air because, under worst conditions, the error is less than 1%. Calibration data can be found in Appendix F. -28- ------- 8. CHAIN OF CUSTODY PROCEDURES - SHIPPING Chain of Custocty Procedures were followed during the sampling program. The arrival and departure of Individuals at the sampling sites were noted in the site logs. The preparation of the sample train and the initiation of sampling were witnessed and noted in the site logs. The termination of sampling and removal of the samples were witnessed, noted in the site log and on the chain of custody cards attached to each sample. The samples were sealed with an inspector's seal. The samples were turned over to the EPA personnel responsible for ship- ping the samples. This transfer was noted on each chain of custody card. The EPA personnel responsible for shipping the samples identified the destination of each sample on the chain of custody card. He also prepared the samples for shipment, and sealed the shipping containers with two inspector's seals. Three sets of phenol and formaldehyde samples were shipped in ice to EPA, Region III, Wheeling Field Office. The samples were transported by Allegheny Air Cargo from Wilkes-Barre/Scranton International Airport at the following times: 12 noon, May 2nd; 6.00 am, May 3rd; and 6:00 am, May 4th. The Wheeling Field Office recorded receipt of the sealed shipping con- tainers (metal coolers) and secured the samples until analysis. The time between termination of sampling and beginning of analysis for the phenol and formaldehyde samples was 37 hours for the first set, 17 hours for the second set and 7 hours for the third set. The fibrous glass samples were shipped in a sealed container to McCrone Associates. The acknowledgement receipt was returned signed. -29- ------- The assumption is made that the collection and recovery efficiencies of both methods were 100%. The documentation on the methods support this assumption. The flow rates, and sampling train designs were consistent with those prescribed in the methods. The sensitivity of the fibrous glass method was taken directly from the method, Appendix C. The sensitivity is 0.2 fibers per ml - 20,000 fibers per M3. -30- ------- 9. TEST RESULTS The table below gives the concentration found in each sample, the time weighted average concentration of each sample day, and the time weighted average for the entire study. Table #6 - Test Results Formaldehyde (ppb) Sample Date: Run Number Upwind Downwi nd Sample Date: Run Number Upwind Downwi nd Sample Date: Run Number Upwind Downwi nd May 1st 1 2 3 avg. 0082 19 25 0 26 Phenol (ppb) May 1st 1 2 3 avg 2 69 2 25 1 1 21 7 Fibrous Glass May 1st 1 2 3 - ND ND ND - ND May 2nd 1 2 3 - 45 80 151 173 251 May 2nd 1 2 3 29 2 14 2 1 2 May 2nd 1 2 3 ND ND ND ND ND ND May 4th 4 avg - 63 49 151 4 avg 2 13 1 2 4 ND ND 1 2 avg 29 6 18 41 0 7 May 4th J 2 avg 1 1 1 708 May 4th 1 ND (ND = ND survey avg 23 _ 75 -* survey avq 14 4- 5 Non-Detect The List of Samples and Test Results contained in Appendix G were used in generating the table shown above. The sensitivity of the phenol and formaldehyde analyses were dependent upon analytical sensitivity and the air volume samples. The minimum detectablilites were: 1. Phenol - 1 ppb 2. Formaldehyde - 5 ppb -31- ------- 10. CONCLUSIONS When the EPA test results for phenols are compared to the health effects data (see Appendix H), it can be seen that no adverse effects at the measured concentrations can be associated with phenols. When the measured concentrations of formaldehyde are compared to the health data (see Appendix H), it is apparent that the formaldehyde emissions from the plant can cause eye, nose and throat irriration in sensitive populations. Headaches may also be caused by exposure to formaldehyde at the measured concentrations. The installation of the new control equipment, which is expected by December, 1978, should reduce ambient levels of phenol and formaldehyde by at least 85%. This will bring ambient phenol concentrations well below any human response factor, however, even with this expected effeciencies, ambient concentrations of formaldehyde may still cause eye irritation and odor responses. The eye irritation threshold (19 ppb) and odor threshold (50 ppb) of formaldehyde are very low values. It should be noted that in addition to the control of the phenol and formaldehyde concentrations, total particulates should be reduced by 95%. -32- ------- |