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J. T. Payne, (SS-18), Texas City, Texas
OaTC August 1, 1984
, G. L. Tromblee
SUUfCT
SHAC MINUTES - 8/1/84
PLAINTIFF'S EXHIBIT MON-1886
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SHAC Members:
E. P. Bailey S. W. Moncla J. D. Richards J. A. Stal, Jr. R. T. Hammann
22 513D
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These are the minutes of the August 1, 1984, SHAC committee meeting.
Future SHAC Meetings
SHAC meetings have been scheduled for the VIP Conference Room at 1:00
p.m. for the following dates:
August 3, 15, 22, 29
September 5, 12, 19, 26
October 3, 10, 17, 24
Project Assignments
Project
Rep.
Status
Parking Area Designations
J. D. Richards
Emergency Center Communication R. T. Hammann
Assembly Point Signs
J. D. Richards
Methanol Incident
J. Stal
Emergency Drill
S. Moncla
Contractor Safety Film (5 min.)
J. D. Richards
Areas have been designated in all units. A sticker for car dash boards has been developed.
Phone number finalized 3816.
A sign has been developed and is to be made.
Recommendations will be reviewed at the Aug. 1st meeting of SHAC for a report to PMSB 8/84.
Possibly re-sched uled for end of Sept, and will
be conducted with Danforth Hospital. In progress
SC 000829
LAM002027
SHAC MINUTES - 6/20/84
PAGE 2
Annual Safety & Housekeeping Inspection
The SHAC committee is not in favor of a change in the date of the annual inspection, but would not object to a change in the date. A number of activities and contacts will have to be changed if the dates are changed.
The inspection tour schedule was reviewed and is attached.
The annual inspection action plan was updated and revised and is attached.
Quarterly Inspection
The SHAC quarterly inspection will be held August 6th thru 17th. The unit safety analysis are attached. It was decided to wait until after the AN-5 Shutdown to perform the quarterly inspection ir> AN-5.
Contractor Safety Program
Contractor have raised questions on respirator fit testing. These questions will be investigated separately.
( The contractor safety orientation film is being planned.
STOP Observation
The June STOP observations will be published in the plant news within the next two weeks.
Hourly Safety Committee
Don Jordan was elected chairman of the hourly safety committee.
General Safety
A new toxicity manual has been developed by Safety and will be distributed shortly.
JTP:sr Attachments
LAM002028 SC 000830
1984 TEXAS CITY SAFETY AND HOUSEKEEPING INSPECTION GUIDELINES
THEME SAFETY THROUGH EMPLOYEE INVOLVEMENT
EMPHASIS AREA
' Involvement of People in Safety ` Safety Results and Trends * STOP Program ' Adherence to Safe Procedures and Practices ' Acceptance of Personal Responsibility for Safety ' Attitude and Awareness of Safety at all Levels ' Evidence of Management's (all levels) Commitment to Operate Safely ' Health and Industrial Hygiene Programs ' Programs for Good Housekeeping and Preservation of Assets ' Use of Promotional Activities * Follow-up on Last Yearns Inspection Recommendations
INSPECTION DATE The plant will be inspected September 19, 20, 21, 1984.
INSPECTION TEAM
General Superintendent Superintendent Engineer Foreman Hourly (One of the above should be from Process Technology)
RATINGS
The inspection committee will not give the plant an overall rating??
Individual areas will be given ratings, and plaques will be awarded to the best area in each of four categories: units, crafts, labs and offices and services.
Evaluations will be made based on safety performance, policies and practices, housekeeping conditions and involvement of people that ensures an effective, sustained safety attitude for outstanding safety performance.
Outstanding
- Stands out from all areas (comparison based on theme criterion). No safety practice deficiencies. Housekeeping performance equal to achievement potential.
sc 000831
LAIVI0302g
1984 TEXAS CITY SAFETY AND HOUSEKEEPING INSPECTION GUIDELINES
PAGE 2
Excel lent
Very favorable compared to acceptable standard (based on theme criterion). Very few safety practice deficiencies. Housekeeping performance nearly equal to achievement potential.
Good
Favorable compared to acceptable standard (based on theme criterion). Few safety practice deficiencies. Housekeeping performance at acceptable level.
Unsatisfactory
Inferior compared to acceptable standard (based on theme criterion). Unacceptable level of safety deficiencies. Unacceptable housekeeping level.
Areas rated will be all units (including outside battery limits), main shops, instrument shop, electrical shop, stores, control lab. Research 1, 2 and 3.
INSPECTION RESULTS
The general results of the plant inspection, including the outside areas, will be communicated Monday, September 24, 1984. The results will be communicated with the expanded staff, SHAC, Technical Center Safety Committee, Office Safety Committee and Hourly Safety Committee, Unit-Craft Safety representatives, and Unit-Craft Safety promotion team present. Group size has to be limited due to seating available in the cafeteria.
SC 000832
t*fl\002<>30
INSPECTION TOUR SCHEDULE
r
TUESDAY NIGHT, SEPTEMBER 18
PRESENTATIONS
1. Overall Texas City Safety Program
Minutes
R. T. Hammann (Bob) Loss Prevention & Safety Supt.
10
2. Plant Manager's Safety Board (PMSB) and Safety Advisory Committee (SAC)
10
3. Safety and Housekeeping Action Committee (SHAC)
E. P. Bailey (Paul)
10
4. Plant Manager's Comments
G. L. Tromblee (Gene)
5
5. Inspection Kickoff 6. Discussion
5
10
SC 000833
LAM002031
1984 INSPECTION TOUR SCHEDULE
FIRST DAY: WEDNESDAY, SEPTEMBER 19
Arrive Texas City (Personnel Building Training Room) Distribution of Safety Equipment. Coffee & Rolls.
Begin Inspection.
0800 0815
Walk To Power 2.
WATER TREATING - PLANT AIR - POWER 2
0820-0900
Treatment of raw Brazos River water for plant use and generation facilities for breathing, instrument, and general plant air. Facilities for steam generation and boiler feed water treatment.
HOSTS
INSPECTORS
SHAC MEMBER
Meet in Control Room
Pick up cars parked by cylinder racks beside Stores. Drive to Acetic Acid Control House.
DEPT. 50 ACETIC ACID
Acetic Acid is produced from carbonylation of methanol. This area includes catalyst preparation and product distillation facilities.
HOSTS
INSPECTORS
SHAC MEMBER
0900-0930
Park beside Control House. Meet in Control Room.
Drive to Phthalic Anhydride Control House.
SC 000834
-2-
LAM002032
1984 Inspection Tour Schedule, Wednesday, September 19 (Continued)
DEPT. 53 PHTHALIC ANHYDRIDE
0930-0945
Manufacturing process which uses BASF technology to convert air and orthoxylene to phthalic anhydride.
HOSTS
INSPECTORS
SHAC MEMBER
Park beside Control House. Meet in Control Room.
Drive to Dept. 48-56.
COFFEE - 0X0-ALC0H0L - PHTHALATE ESTERS
DEPT. 48/56 0X0 ALCOHOL-PHTHALATE ESTERS
Oxo alcohol area uses CO + H2 blend gas and olefins as raw materials. Phthalic anhydride and oxo alcohol used to manufacture phthalate esters.
HOSTS
INSPECTORS
SHAC MEMBER
Walk to Dept. 33.
DEPT. 33 LACTIC ACID, DRUMMING FACILITIES & CT-8
Manufacturing for pharmaceutical grade lactic acid from lactronitrile.
HOSTS
INSPECTORS
SHAC MEMBER
0945-1000 1000-1030
Park at Formaldehyde Storage Area (77T101). Meet in Control House.
1030-1100
Meet in Control House.
Pick up cars at 77T101, drive to Zone I office.
-3-
SC 000835 LAM002033
1984 Inspection Tour Schedule, Wednesday, September 19 (Continued)
Walk to Zone I Office.
ZONE I OFFICE
Offices and conference room used by maintenance personnel for styrene process.
HOSTS
INSPECTORS
SHAC MEMBER
1100-1110
Walk to Operating Engineers Offices.
OPERATING ENGINEER OFFICES Offices for operating engineers personnel.
HOSTS
INSPECTORS
SHAC MEMBER
Walk to Fire Station.
FIRE STATION
Two buildings which house the Texas City plant's fire fighting facilities.
HOSTS
INSPECTORS
SHAC MEMBER
Walk to Electric Shop.
1110-1120 1120-1130
-4-
SC 000836 LAM002034
1984 Inspection Tour Schedule, Wednesday, September 19 (Continued)
ELECTRIC SHOP
Consists of central shop facilities and offices for power distribution, electrical maintenance, and maintenance engineering personnel.
HOSTS
INSPECTORS
SHAC MEMBER
1130-1145
LUNCH - Cafeteria Conference Room Walk to AN loading rack. AN LOADING RACK, ESTERS LOADING RACK, TANK TRUCK RACK, SCALE HOUSE
Rail car handling facilities for acetic acid, methanol, TBA, sulfuric acid, IBY, ACH, and esters.
HOSTS
INSPECTORS
SHAC MEMBER
1145-1230 1235-1300
Pick up cars at truck loading spot west of 51T17-2. Drive through North Storage.
PA LOADING RACK
Rail car handling facilities for phthalie anhydride.
HOSTS
INSPECTORS
SHAC MEMBER
Drive to Dept. 513 Control House.
SC 000837
-5-
1300-1310 Park north of reformer.
LAM002035
1984 Inspection Tour Schedule, Wednesday, September 19 (Continued)
PRIMARY TREATMENT, AMMONIA TANK
1310-1335
Facilities for primary treatment of all plant aqueous waste streams. Ammonia storage tank provides raw material for AN manufacturing facilities at Texas City and Chocolate Bayou.
HOSTS
INSPECTORS
SHAC MEMBER
Meet at 513 Control Room.
BARGE & SHIP DOCKS 5, 4, 3, 2, 1
Barge and ship loading/unloading facilities for raw materials, products, used at and produced by Texas City plant.
HOSTS
INSPECTORS
SHAC MEMBER
1335-1445 Meet at Dock 5.
Drive to cafeteria conference room.
COFFEE - CAFETERIA CONFERENCE ROOM
Drive through sandblasting, NSI Warehouse, Maintenance Laydown, Salvage Areas
HOSTS
INSPECTORS
SHAC MEMBER
1445-1500 1530-1600
Drive through South 22.
HOSTS
INSPECTORS
RECAP
SHAC MEMBER
1530-1600
LAM002036
-6-
SC
000838
1600-1630
1984 INSPECTION TOUR SCHEDULE
SECOND DAY: THURSDAY, SEPTEMBER 20
CAFETERIA CONFERENCE ROOM - Coffee & Rolls Drive to Material Handling
MATERIAL HANDLING OFFICE BUILDING
Offices for supervision of distribution operations, materials handling foreman and clerk; mail room, printing & office services; QA Lab offices.
HOSTS
INSPECTORS
SHAC MEMBER
0800-0815
Park cars beside old Pilot Plant.
0815-0825
SUPER SHACK, AN INCINERATOR, DRIVE THROUGH STYRENE RACKS, ACY RACK AND EAST STORAGE
HOSTS
INSPECTORS
SHAC MEMBER
DEPT. 13 AKLYLATION, CT-1
Ethylbenzene is produced by the reaction of benzene with ethylene in the present of an aluminum chloride-organic catalyst complex.
HOSTS
INSPECTORS
SHAC MEMBER
SC 000839
-7-
0825-0845
0845-0915
Park south of 14-16 , Control House by Smoke Shack. Meet in Control Room.
LAM002037
1984 Inspection Tour Schedule, Thursday, September 20 (Continued)
DEPT. 15 DEHYDROGENATION
0915-0940
Synthesis area for dehydrogenation of ethylbenzene to crude styrene.
HOSTS
INSPECTORS
SHAC MEMBER
Meet in Control Room.
COFFEE - SYTRENE-EB (arrangements by department)
DEPTS. 14 & 16 STYRENE - EB DISTILLATION
Dept. 14 - Ethylbenzene purification facilities. Dept. 16 - Styrene purification facilities.
HOSTS EB
INSPECTORS
SHAC MEMBER
SM
Drive to Salt Water Pump House and Zone 1 Warehouse.
SALTWATER PUMP HOUSE AND ZONE 1 WAREHOUSE
HOSTS Zone 1 Warehouse
INSPECTORS
SHAC MEMBER
0940-0955 0955-1025 Meet in Control Room.
1025-1040 Split Team.
Pump House
-8 -
LAM002038 SC 000840
1984 Inspection Tour Schedule, Thursday, September 20 (Continued)
Drive to car Stores.
Walk to Stores.
STORES
Stores includes the shipping and receiving docks, storage bins of inventory items, and offices.
HOSTS
INSPECTORS
SHAC MEMBER
1040-1110
Pick up cars in car port. Drive to Warehouses.
WAREHOUSE A-B-C-F-G
Warehouse A contains class A materials such as spare parts, paper goods, packing materials. Serves receiving function.
Warehouse B contain flammable liquids, acid, paint.
Warehouse C contains class A materials, such as, insulation, packing.
Warehouse E contain materials needed for maintenance work orders.
Warehouse F contains long storage items, such as, mechanical equipment.
Warehouse G contains dry raw materials, such as, iodine, Fullers Earth, etc.
HOSTS
INSPECTORS
SHAC MEMBER
SC 000841
-9-
1110-1140
Split team. Park across from Zone 2.
LAM002039
1984 Inspection Tour Schedule, Thursday, September 20 (Continued)
Drive to Cafeteria LUNCH - Cafeteria Conference Room Drive to Zone 2 office ZONE 2 OFFICE
Offices for west plant maintenance personnel.
HOSTS
INSPECTORS
SHAC MEMBER
1145-1230 1230-1245
Drive to car port. RESEARCH NO. 1
This building houses analytical, catalyst characterization, radioisotope, and MIC Tech Services labs and bench scale reactor systems.
HOSTS
INSPECTORS
SHAC MEMBER
RESEARCH NO. 2
This building houses Technology Dept, and Industrial Hygiene labs, AN Catalyst Preparation facilities, and AN and Styrene bench scale reactor systems. The instrument development and control department is located upstairs.
HOSTS
INSPECTORS
SHAC MEMBER
1245-1255 1300-1340
Meet 1st floor west side.
1340-1440
Meet at Visitor's lobby Northwest corner - 1st floor.
SC 000842
- 10 -
LAM002040
1984 Inspection Tour Schedule, Thursday, September 20 (Continued)
RESEARCH NO. 3
This building houses MMTS offices, QA Lab chemists offices, crafts and maintenance offices and MMTS labs and shops as well as lab supply overstock.
1440-1455
HOSTS
INSPECTORS
SHAC MEMBER
Meet at North entrance below stairway outside.
PT WAREHOUSE & SOLVENT STORAGE
HOSTS
INSPECTORS
SHAC MEMBER
1455-1505
Walk to Main Office Building.
COFFEE - CAFETERIA (arrangements by Cafeteria)
CAFETERIA
Main plant cafeteria.
HOSTS
INSPECTORS
SHAC MEMBER
1505-1515 1515-1525
Meet at cash register.
LAM002041 SC 000843
1984 Inspection Tour Schedule, Thursday, September 20 (Continued)
DISPENSARY
Provides facilities for emergency first aid and for monitoring employee health.
HOSTS
INSPECTORS
SHAC MEMBER
1525-1535
MAIN OFFICE - 2nd, 3rd and 4th floors
Main Office building for manufacturing, distribution, environmental, safety, personnel and marketing personnel.
HOSTS
INSPECTORS
SHAC MEMBER
QUALITY ASSURANCE LAB
Laboratory facilities needed to conduct analyses required for production and shipment of petrochemicals from Texas City plant and for environmental control.
HOSTS
INSPECTORS
SHAC MEMBER
RECAP
1535-1555
Split teams. Meet in foyer. 2nd Floor 3rd Floor 4th Floor
1555-1630
1630-1635
- 12 -
SC 000844 LAM002042
1984 INSPECTION TOUR SCHEDULE
THIRD DAY: FRIDAY, SEPTEMBER 21
CAFETERIA CONFERENCE ROOM - Coffee & Rolls
OFFICE ANNEX
First floor of this building contains office for Technology Dept., Engineering Services and Guest Tech Service Group, Central Files, technical library and computer room.
HOSTS
INSPECTORS
SHAC MEMBER
0800-0815 0815-0840
Split Teams. Meet in Main Lobby.
Second floor contains office facilities for Accounting, MIS Department with computer facilities, Plant Engineering Technical Support.
HOSTS
INSPECTORS
SHAC MEMBER
Meet in Front Entrance 1st floor.
PERSONNEL TRAINING, PURCHASING BUILDING
Building contains plant purchasing offices, training facilities, video tape lab.
HOSTS
INSPECTORS
SHAC MEMBER
0840-0855
Meet in Personnel Building Training Room.
- 13 -
sc 000845
LAM002043
1984 Inspection Tour Schedule, Friday, September 21 (Continued)
LOCKER BUILDING NO. 1 & SAFETY SUPPLY
Building houses separate lockers, showers, and changing rooms as well as the safety supply store.
HOSTS
INSPECTORS
SHAC MEMBER
0855-0910
GUARD HOUSE
Major plant entry gate with offices for supervisors and security group.
HOSTS
INSPECTORS
SHAC MEMBER
0910-0920
Drive to Dept. 51.
DEPT. 51 ACRYLONITRILE, CT-9
Two reactor trains and a single purification train ar used to produce acrylonitrile, acetonitrile and hydrogen cyanide as a by-product. Ammonia and propylene are used as raw materials. Includes slip stream reactor. (Start in South end, end near MeOH.)
HOSTS
INSPECTORS
SHAC MEMBER
0920-1025
Meet in Control House Park East of Control House off South St.
Drive car to methanol COFFEE - METHANOL (arrangements by dept.)
- 14 -
1025-1040
SC 000846 LAM002044
1964 Inspection Tour Schedule, Friday, September 21 (Continued)
DEPTS. 44-45-46 METHANOL, CT-3&4
1040-1110
Methanol, CO, and H2 are produced by steam reforming of natural gas and C02. CO and H2 are used in the production of oxo-alcohol and acetic acid.
HOSTS
INSPECTORS
SHAC MEMBER
Meet in Control House
DEPTS. 19-23-25-27-29 HCN-ACN-TBA-LN-ACY, CT-2
Manufacturing facilities for acetonitrile purification, tertiary butylamine, lactonitrile and acetone cyanohydrin. HCN Storage.
HOSTS
INSPECTORS
SHAC MEMBER
1110-1205 Meet in Control House
Drive car to Cafeteria
LUNCH - Trays in Cafeteria Conference Room
SHOP BUILDING
Central shops consists of facilities for pipe fabrication and plate and exchanger, machine and paint shops. Building also includes training rooms and various maintenance offices.
HOSTS
INSPECTORS
SHAC MEMBER
1205-1305 1305-1330
Meet at Shift Office
- 15 -
sc 000847
LAM002045
1984 Inspection Tour Schedule, Friday, September 21 (Continued)
SOUTH MAINTENANCE BUILDINGS, INSTRUMENT SHOP & GARAGE
Building include carpenter-insulator shop, instrument department shop, field maintenance offices, and garage facilities.
HOSTS Maintenance
INSPECTORS
SHAC MEMBER
Instrument
1330-1415
RECAP
1415-1630
SC 000848 LAM002046
DATE 7/1
7/23 8/1 8/1 8/15 8/6-17 8/15
8/30 8/31
ANNUAL INSPECTION PREPARATION ACTION PLAN
RESP.
STATUS
Inspection route and timing defined - dry run completed to parking places, cars needed, guide meeting place.
JTP/JDR
Complete.
Assign Office Safety Committee responsibility for publicity.
RTH Complete.
Send copy of previous inspection,
JAS Complete.
recommendations to Superintendents.
By 8/31 all items complete - written
response.
Send out notice that all ladders are to be inspected and new tags attached by 9/1.
Inspectors named.
RTH RAF
Complete.
To be completed 8/3.
Encourage Plant Manager, Plant Engineer, and Safety Superintendent to be in the plant the 2 weeks prior to the inspection.
EPB
Complete.
Obtain pictures and information on the inspectors, sizes, etc.
JAS
3rd Quarter Safety & Housekeeping Insp.
SWM
Guides named for each area of plant. SHAC member will host each inspector rotate at noon each day. Plant Manager will freelance. General Superintendents will meet team
at each area of responsibility.
JTP/JDR
SHAC drive around inspection -made slides. Use 3rd Quarter comments. Communicate inspection schedule.
SWM
All recommendations from last annual
JTP/JDR
inspection completed.
Route and guide list published
and issued.
Information for inspectors
JAS
(booklet, etc.) completed.
Name tags (name and position)
RTH
completed for inspectors, guides, etc.
Lunch arrangements completed (catered
EPB
by cafeteria including designated eaters).
Three cars reserved - drivers & movers
SWM
selected.
SC
000849
LAM002047
9/4 9/5 9/5 9/10
9/12 9/14
9/18
9/19-21 10/1 10/3
Mail information to inspectors.
JAS
Include pictures and history of inspectors in plant newsletter.
JAS
Expanded Staff -- review slides, inspection details and check list.
SWM
SHAC/Plant Manager drive around inspection - take slides. Plant Manager mail letter to all employees home. Obtain equipment for inspectors
-- hard hats (with names), safety glasses, ear plugs, cover goggles, rain gear (suits and boots), name tags, and temporary badges.
SWM EPB RTH
Expanded Staff meeting -- review slides. SWM
Drive around inspection -- each General Superintendent accompanied by two SHAC members.Short wrap-up staff meeting after inspection.
SWM
Evening meal with inspectors and presentations. Tromblee, Forsthoffer, Hammann and Chairman of SAC, SHAC, TCSC, OSC, HSC.
EPB
Inspection
ALL
Feedback
ALL
Critique
SHAC
JAS:sr 6-12-84 <v
SC 000850
-2-
LAM002048
DEPT.
44/45/46 513 Power 2 33 48/56 15/16 50 13/14 51 Mat. Handl. 53 HCN Complex
UNIT SAFETY ANALYSIS 3RD QTR. 1984
RI_ TIR INCIDENT INSPECTION
00 00 00 00 0 6>.5
0 7'.2
00
0 12!. 1
0 14 .8
0 17'.0 0 191.7 0 21 .7
NO NO NO NO NO NO YES NO YES NO NO NO
I I I I I I II II II II II II
8/2/84 sr
000851
LAM002049
SHOP SAFETY ANALYSIS 3RD QTR. 1984
CRAFT
INSTRUMENT PAINTERS INSULATORS PIPEFITTERS CARPENTER BOILERMAKERS MACHINISTS ELECTRICIANS
11 TIR
00 00 00 0 33.3 0 48.8 0 23.4 0 7.5 00
ALL ELIGIBLE FOR AWARD
8/2/84 sr
SC 000852 LAM002050