Presentations May 23 – 25, 2005 Portland, Maine

For related information visit: http://www.newmoa.org/prevention/mercury/conferences

Mercury Use in Switches, Relays & Measuring Devices

Terri Goldberg, NEWMOA/IMERC

Overview• Source of Information• Mercury Use in Switches &

Applications • Mercury Use in Relays &

Applications• Mercury Use in Measuring

Devices• Where to go for more

information

Data Source

• State Notification Requirements

• Clearinghouse -- IMERC• Mandatory Reporting to Sell in

States with Notification • Online Database• Non-compliance• Data Summarized in Series of

Fact Sheets – IMERC webpage• Amount per component & total

in all units sold in US in 2001

What Are Mercury Switches?• Switches are products or devices

that open or close an electrical circuit, or a liquid or gas valve.

• Mercury Float Switch: actuated by rising or falling liquid levels

• Mercury Tilt Switch: actuated by a change in the switch position

• Mercury Pressure Switch: actuated by a change in pressure

• Mercury Temperature Switch: actuated by a change in temperature

• Mercury Flame Sensors

Amount of Mercury in Switches

• Tilt Switches: can range from about 0.05 grams to almost 5 grams

• Float Switches: can range from more than 0.1 to more than 65 grams (float switch units with up to six individual switches)

• Miscellaneous Switches: 0.005 to 5 grams

• Flame Sensors: more than 1 gram

Uses of Switches

• Tilt Switches: cars; recreational vehicles; electric, gas & water meters; space heaters, manufacturing/miscellaneous

• Float switches: pumps & pump systems

• Other Switches: motor vehicles • Pressure controls: fire control

units, manufacturing/ miscellaneous

Total Mercury Use in Switches – US Sales, CY 2001, Pounds• Tilt Switches: 14,302 • Flame Sensors/Switches: 3,853• Pressure Controls: 2,099• Float Switches: 13,282• Other Switches: 13,772

Total Mercury in Switches: 47,308 (over 23.6 tons)

Mercury Use in Thermostats: 25,945 (about 13 tons)

Note: UNDERREPORTING

What are Mercury Relays?

• Relays products or devices that open or close electrical contacts to effect the operation of other devices in the same or another electrical circuit; often used to turn on & off large current loads by supplying relatively small currents to a control circuit

• Mercury Displacement Relays• Mercury Wetted Reed Relays• Mercury Contact Relays

Amount of Mercury in Relays

• Various Relays (individually): 0.005 to more than 1 gram

• Units with 1 to 6 Poles/Relays: 0.01 – > 1 grams

• Relay Controls (can have 8-32 relays): 0.12 - 0.32 grams

Uses of Mercury Relays

• Telecommunications Circuit Boards

• Rotating Electrical Connectors• Chemical Analyzer• Manufacturing/Miscellaneous• Cooking Equipment

Total Mercury Use in Relays – US Sales, CY 2001, Pounds

• All Relays & Relay Controls: 62,208 (about 31 tons)

• UNDERREPORTING

Total Combined Mercury Use— CY 2001, US Sales

• Total Mercury Use in Switches & Relays: ~54.5 tons

• Total Mercury Use in Switches, Relays, & Thermostats: ~67.5 tons

State Bans on Sales of Mercury Switches, Relays, & Thermostats

• Phase Outs/Bans on Sale of Mercury Switches & Relays: CT, ME, IL, RI, VT

• Specific Phase Outs/Bans on Sale of Mercury Auto Switches: CA, ME, WA, OR

• Phase Outs/Bans on Sale of Mercury Thermostats: CA, CT, ME, RI, VT

• Restrictions on Sales of Thermostats: OR, WA

Examples Reported Phase-Outs of Mercury Use in Switches & Relays

• Switch used in hydraulic level device in RVs -- Coachmen

• Car Anti-lock braking system – Daimler Chrysler

• Car Light Switches— Ford & GM• Trailer Braking Systems –

Hopkins• Hood & Luggage Door Switches

– International Truck & Engine• Fire Control Units – Joslyn Clark

Controls• Vaccum Pump Pressure Switch –

PACCAR, Inc.

Which Measuring Devices Contain Mercury?

• Barometers• Hydrometers• Manometers• Psychrometers &

Hygrometers• Sphygmomanometers• Strain Gauges• Thermometers

Amount of Mercury in Measuring Devices

• Barometer: 395-622 grams• Thermohydrometer: > 1 gram• Manometer: 28-74 grams• Psychrometer: 5.2-6 grams• Sphygmomanometer: 104.2-

124.5 grams• Strain Gauge: > 1 gram• Thermometers (including fever,

laboratory, medical, industrial, & cooking): >0 - 0.005 - >1 gram

More on Thermometers

• Fever thermometers: ~0.5 grams

• Laboratory thermometers: ~ 3 grams

• Industrial thermometers: much more than 1 gram (maximum amount reported as 117 grams)

Total Mercury Use in Measuring Devices – US Sales; CY 2001; Pounds

• Barometers: 353• Hydrometer/Thermometer: 8• Manometers: 1,936• Psychrometers: 3• Sphygmomanometers: 4,002• Strain gauge: 1.5• Thermometers: 3,221

Replacement mercury: 118Total for all Measuring Devices:

9,642.5 (about 4.8 tons)Note: UNDERREPORTING

Measuring Devices Phase-Outs

• Thermometers: Princo• Thermometers: Taylor Precision

Products

State Bans on Sales of Mercury Measuring Devices -- Examples

• Manometers: CT, ME, MN, VT, WA

• Thermometers: CA, CT, IN, IL, ME, MD, MA, MI, MN, NH, NY, OR, RI, WA, VT

• Instruments & Measuring Devices: CT, ME, RI, VT

More Information

• Draft “Mercury Use in Switches & Relays” (not yet published online)

• “Mercury Use in Measuring Devices” — www.newmoa.org/prevention/mercury/ imerc/FactSheets/measuring_devices.doc

• Mercury-added Products Database – www.newmoa.org/prevention/mercury/imerc/

notification/

Contact: Terri Goldberg, (617) 367-8558 x302

PresentationsMay 23 – 25, 2005Portland, Maine

Reducing Mercury Switches and Relays

in Illinois

Why focus on switches and relays?

• Wanted comprehensive mercury legislation initially

• Fever thermometer and novelty item ban signed into law in 2003

• Switches and relays large source of mercury in manufacturing

Initial Proposal• All switches and relays except

those:– Required under Federal law or

contract– Used to replace switches and

relays that are components in larger products in use prior to July 1, 2007 and

• Larger product is used in manufacturing or

• Switch or relay is integrated into larger product

Opposition• Thermostat manufacturer

– TRC program– Voluntarily phasing out

• Electric utility company– Nuclear plants and emergency

situations– Federal law provision

• Medical diagnostic equipment manufacturer– Component of larger product

provision

Final Legislation

• Ban, as of July 1, 2007, on sale, offer of sale, distribution and offer of distribution

• Applies to: – Individual mercury switches and

relays– Mercury switches and relays that

are product components

Final Legislation• Exemptions for

• Climate control thermostats• Electrical generating facilities• Medical diagnostic equipment

• Manufacturers may request exemptions for other uses

• Report to Governor and Legislature on climate control thermostats

Exemptions

• Submit request to IEPA by July 1, 2006

• IL EPA to develop rules and prescribe forms for exemption requests

• Manufacturer must demonstrate:– End of life collection, transportation

and processing system for switches, relays, instruments or pieces of equipment that is widely available and convenient exists

Exemptions

AND

• The specific use or uses of the switch, relay, instrument, or piece of equipment provides a net benefit to the environment, public health, or public safety when compared to available non-mercury alternatives.

Exemptions

• Granted for 5 years• With or without conditions• Renewals – must demonstrate

original reasons for exemption still exist

• IL EPA must consult with other states prior to granting exemptions– Joined IMERC in December 2004

Universal Waste• Legislation designated mercury

switches and relays as Universal Waste

• Required IL Pollution Control Board to adopt rules

• Rules went into effect 4/13/05

Becky LockartOffice of Pollution PreventionIllinois Environmental Protection AgencyP.O. Box 19276Springfield, IL 62794-9276

217-524-9642Becky.Lockart@epa.state.il.us

PresentationsMay 23 – 25, 2005Portland, Maine

Mercury P2 ProgramReducing Mercury Containing Equipment

Mercury P2 Program

• Presenter: Patrick S ZomboSenior Environmental Plannerc/o Consumers Energy Co.

1945 W Parnall RdJackson, MI 49201

phone 517 788 0647fax 517 788 1064

email pszombo@cmsenergy.com

• Go for the BIG FISH….. You’ll spend the same amount of time

baiting the hook……

“Good Stuff”

Mercury P2 Presentation

Electric Service AreaGas Service AreaCombination Electric & Gas Service Area

Eletric and Gas Service Area

WhitingPlant

KarnPlant

Marrow

Allegan

Croton

Rogers

Webber

Hardy

Thetford

CampbellPlant

CobbPlant

PalisadesNuclear

Plant

MidlandCoogenerationVenture Site

LudingtonPumpedStorage

Tippy Hodenpyl

Gaylord

Mio

Alcona CookeFooteLoud

5 Channels

WeadockPlant

Customer Service CentersSteam PlantNuclear PlantHydro PlantPeaking PlantCogeneration Plant

Harrisville

Tawas

Rose City

Standish

Gladwin

Prudenville

Bay City

Manistee

Benzonia

TraverseCity

Big RapidsClare

Cadillac

Gaylord

Cheboygan

BoyneCity

Lapeer

Livonia

PontiacMacomb

Howell

Lansing

Owosso Flint

Midland

Saginaw

Jackson

Adrian

SouthMonroe

Jonesville

Battle Creek

Bronson

Hastings

Kalamazoo

EastKent

Allegan

Zeeland WestKent

NorthKent

Greenville

Alma

Ludington

Freemont

Muskegon

Bad Axe

Charlotte

Why Initiate MCE reduction program?

• Environmental Concerns:– Public awareness: Fish Advisories – Binational Toxics Strategy Workgroup– Michigan P2 Task Force Recommendations– Difficulty of dealing with Mercury emissions

• Waste Management Concerns:– Hg both Listed and Characteristic RCRA waste– Land Ban Restricted– Required EPA specified treatment technology or– Treatment to UTS– Expensive waste stream

Implement Voluntary Program

• Obtain Upper Management Support• Incorporate existing related Programs

– Mercury Regulator program– Corporate P2 Program– Strong Recycling Program

• Establish Mercury P2 Team– Program Champion– Environmental Coordinators

• Include Key Departments– Facilities Legal Purchasing– Maintenance Environmental

• Get more help!

Work The Plan

• Set Goals/Milestones

• Keep Team Informed

• Share Results

• Example: Identify potential MCE– Complete an Inventory– Identify types and quantities of MCE– Identify Location(s)– Identify Responsible Units

• Identify Alternative Equipment

Consumers Energy 1996 Inventory

Numbers Represent Total Pounds

t

(Estimated Total is 2464 Pounds)

Customer Gas Regulators 406

Ring Balances 88Bottled/Stock Mercury 455.6

Misc. Equipment 141.7

Gas Extraction Apparatus 18.5Chart Recorders 4

Various Meters 537

Lab Use 11.1Switches/Relays/Timers/Gauges 408.5

Manometers/Barometer 368.9

Thermostats/Thermometer 24.7

Electric Business Unit

Manometers 348

Thermometers 3.5

Misc. Equipment 89.2

Flowmeters 201

Timers 318.8Repair Equipment 30.1

Relays 48.3

Drum Level Meters 24

Gauges 0.59Switches 35.3

Thermostats 16.31

Ring Balances 88

Bottled Mercury (In Stock)

356

Numbers Represent Total Pounds in Each Type of Equipment

(Estimated Total is 1559 Pounds)

Gas Business Unit

*

Numbers Represent Total Poundsin Each Type of Equipment Used

(Estimated Total is 808 Pounds)

Customer Gas Regulators 406

Thermostats/Thermometers 1.3

Spare Meters 64

Switches 5.18

Flowmeters 248

Manometers 11.8

Misc. Equipment 23.6

Mercury Stock 43.64

4Chart Recorders

OSD Business Unit

Interference RemovalChemicals 2

Switches 0.312 Thermometers 1.46

Hg Sealed Pistons 0.0656Mercury Stock

Gas Extraction Apparatus 18.5

Barometers 8.5

Thermostats 1.74

Mercury Fix Point 6.5

Thermocouple Juncs. 0.02

Stokes Gauges 2

Numbers Represent Total Poundsin Each Type of Equipment Used

(Estimated Total is 97 lbs)

0

200

400

600

800

1000

1200

1400

1600

Electric Gas OSD

SBU Comparisons

k

Total Strategic Business Units of Consumers Energy Company (Estimated Total is 2464 Pounds)

1559

808

97

Mercury Quantities (lbs)

0

200

400

600

800

1000

1200

Electric Gas OSD

Comparison: In Service/Stock 1996

Strategic Business Units of Consumers Energy Company (Estimated Total is 2464 pounds)

Mercury Quantities (lbs)

396.1

1162.9

99.4

708.9

58.0

39.0

(1559) (808) (97)

equipment in service

equipment in stock

Key Activities

• Recycle excess stock Hg

• Consolidate @ Key Locations:– Required Stock Hg– Required MCE

• Replace – Regulators– Flame Sensor Switches– Thermostats– Lab I&C equipment– Switches/relays etc from Meters

Key Activities

• Education Initiatives/Training– Meter Readers– Gas Service Workers– Lab Technicians– Purchasing Staff– Coordinators

• Purchasing Criteria– Equipment that is mercury Free– Lamps– Batteries

0

500

1000

1500

2000

Electric Gas OSD

2005

1996

SBU COMPARISONS OF MERCURY QUANTITIESAS OF JANUARY 2005

Total Strategic Business Units of Consumers Energy Company1996 Inventory - 2464 lbs

2005 Inventory - 853 lbs (65% Reduction)

MercuryQuantities (lbs)

1559

808

97 695

138 20

Mercury P2 Program Progress

• Consumers Energy’s 7th progress report completed April, 2005.

• 98+% reduction in Elemental Stock Mercury in use in facilities since 1996 (baseline year).

• 65% reduction in Mercury and Mercury Equipment since 1996.

• Company stocks exclusively low Mercury (green) batteries and lamps.

• Over 340,742 pounds of Batteries recycled through 2004.

• Over 298,885 pounds of Lamps recycled through 2004.

MP2 Progress (continued)

• Meter Move out Program 38% complete• Removal program for gas regulators

strengthened. • Discontinuation of use and removal of

Mercury flame sensor switches and Mercury thermostats from repair stock.

• Removal of Mercury oven temperature gauges from repair stock.

• Systematic removal and replacement of Mercury relays, timers and switches during routine in‑house meter servicing.

MP2 Progress (continued)

• Heightened employee awareness of Mercury through training and updates.

• Over 80,000 students have seen “In Concert with the Environment” a Company sponsored energy awareness program.

• Consumers Energy program Inventory used as model by USEPA Region V.

• Consumers Energy program presented at regional seminars throughout the Midwest.

Mercury P2 ProgramReducing Mercury Containing Equipment

Thank You

Mercury P2 Program

• Presenter: Patrick S ZomboSenior Environmental Plannerc/o Consumers Energy Co.

1945 W Parnall RdJackson, MI 49201

phone 517 788 0647fax 517 788 1064

email pszombo@cmsenergy.com