Document 3Ner5r8g907oad4GXpm4mq9O0

--(=--'3* 7 = E-- 3\irvev or c ccyj'Airf ,ueer.; Flar.t ..ass; -- *-- .c* : ,* 4*-- tom - T Sits.* ^ ^ ~~r 7 REPORT ~*viJrVt * " - >_ .j. q.^*' ^ ,v ' kafarsr-T L;^-VJ7--'^---^ *5 ^ *%* ' ` antes M. WATER PCB-SD0000062588 T 5s,~ 3'itv0v : or - ~ -- t >*--* r\ r\ i v-vr . . w/v-< - ^ ^ ^. .*'iLi * A ^ueeny r _sr.: sscuri ML u u J J*t / / l ly?S**4-' "'r*- "**"* *\ / , - *- _2f+T`v V. . The Travelers Companies gYn rvi s fapjFf^ff0s&':s^ *i j i : = OOTO94-g; **:IT{jATI!? U WATER PCB-SD0000062589 J -xrcsures c -/ Tit . \;q>;5/.].'7C Mi. *t / i - WATER PCB-SD0000062590 u . .ons lean visn lo: #e such as a fire cr s e b-" w* n c; -raveiers ;ir.ee: .reci: ed eer.y Plan s , . .15 s ouri ro s s r i ar. i vs. s c r. c 5 e a ss ccter.cials f ion. oc = ' "*r. as e snar.dno ac :c"ensaii: > *,-r* a -9 e ^eie e ixe e;:e s exerciser cy i::e rrevemcn e::rrrs. ' - a c-*v.roV -"PQT- z"'C ?er: sen, s -- ers ec ? <- - > a cor., . rave.ers _r.nr.eer . 1 S 5 0 o q "ress erreser.ialive, accg on c ear s s exrerier.ee res ai lie co e r. z i r. oe r MAT s- * MCySA-yTO AuL t '"r" i A 71 - Wl u L U i H / / H WATER PCB-SD0000062591 .r - u * . .unie, u r o.ueer.y r,*art Manager, veleaned the survey tea. Louis. After this preliminary meet: .g, the s'urvey tear: set wi t:`. j~er.era_ oupeo internments iter-/ rMM4wd*a>f Wer - . . w* m. u rv Elmer il&lcne, and Ed - a -ig Ter* ar. overview c the St. Louis tlar.* uurcr.g the survey ar.d the plant tour, additional tecr.r.ical support vas provide-: Ler. otc:._oriar, .ti-ities Suoertr.ter.uer.t ,m r.egers, ! lair ter are e -er.era-- ozocrirtereenz Esute"*"' '"tar*u;=j^"t Harvey organ, Safety director .> a. ai"o. ,,or.r. -o-oucen, uupv. ._air.ter.ar.ee _ti_ities ana rctating ncpuipment . E. Truschert, Mechanical Lepartmer.t Operations Superintendent inn tr.e survey, tr.e specsa_ist: :ir.c the production operation, : c c " sr * *---------> -- - o the o.art j.aycut virc-unr rc&away &e cessioi-.it y) , t r s Llities, and employee reccrzo .siuerec. tr.e rcacnirery are ecuipser.t su: available utilities, water supp" `, arc : * otiers >*** er the ^ aru r~es su~e va>*' atie**s , ,,..e s * .re systems , standby er seccrdar ,ss. .t, :cuc-etier. of the survey, tr.e tear. :: engineers r.et witr Mb ..arvey ..organ ^ - - a' > - ->-' r~ '''''"ear 'was advised tr.at fzree" a r* /-vt---- c :':r the T. 1 . Hueeny riant would be issued frsr. The Travelers vp'.-p:;--- . .. Aj . 115 f'oL >_ J 3 *r 7 7 ! WATER PCB-SD0000062592 rrcte b : ere: a. <=: aco c. cr,e > ear survey - a -- ' c ct .er.le e 'r *rss" c^* e ccr.e - -*. - a. - * - j A 713 S h WATER_PCB-SD0000062593 J ...e l. . . vueer.y p^ant rcar.uf accures pr.arr.aceutica_s, additives, ar.d intermediate ' J -"to car.t' iti'es :' 3r.icr.ent trailer ir. ;; salver, trusts ar.d pa__eticeu tar va..:> car lets ar.d by truck/ 'lit.; Pie excerticr. cf et'r.ylene ,ior. is reacted viol. vinyl crlcriue to produce a vater based latex material tuis is rur. at tne elevated pressure of 1,7C1 psig), all reactions are carried a t..ic.c s..alien unit designed for psig. .'icst processes consist cf seal :aced cater, f.-ce coeraticr.s crocuced ir. ;1C gallon vessels, lovever, .ssc : largo scale processes. p * ac ' anu rrcouccs i ir.c. cue CwCer/a- 3ns cf tne survey :sa:.n are in cue Aypeuuix. *nese previne cue basis fer "v cf c..e r ecorucenuacicns. JIM/ WATER PCB-SD0000062594 Jcrrcstcn Control tabulates t..e res;j`.a'.:e of serial to corrcs estaolis:. t:.e vear rates cf ir.terr.al tar_-: ccatir.^o ar.d plastic 1 n.ers. -r. ccn- jtr.cti at. vit.u operator.* super.'! si or., trio uepartrer.t develops e: ipr.er.t ir.spec- "'*'*'**. rccuirercents &r. u s 01 s i n s c e c t * o r. ^rscusr.c" s 5 * 1 h g*.* * * 0 tr.eir disposal a large amount cf instruments (ir.c--.aing a stereo microscope) tc test the ecuarnert ana to analyte failures. A cemrreuensive ir.vestigaoicrt ar.d reviev :rpecercy, veucers are ser fp * * * - - ) ve__ir, :s set y t n e . u ir.g School i; ul s C-- : e uucres are aevcl V.. c * a * ^ .accratcries are used for velumer.t .sues *.*e-cs, - o c c o>* Q 0 COr .ursine overcceeus .tlicate secies c: tu ____*0. esc n c - - .1a1r.ta1r.eu; ucvever, : ; miksaa:: . r / . v IM.vji Li i w' . * W .1 sic for neve-cping a ,;:c. 1. F. 1/ueeny plant, ve g: eloped; however, they arc Put- c j 1 *t 7 / WATER PCB-SD0000062595 ...s <. , r . Hueeny p--ant employs approximately l,oQ0 people vcrxi.og tiu-ee shifts Pre-employment and peri {including x-rays ar.d audiometric tests) are given to all employees -eu r.os- oioal anc physical tr.erapy facilities; is available for emergency ana follov-v treatment. Cr.e doctor is or. duty during the day shift; another doctor is em ployed or. a part time basis for the ether shifts. A nurse is or. duty or. each shift. A radiologist is also or. t..e staff. s.tt.ovess must veer cersona- orotective e C U1ZZZQT. t \ Sal 6 V/ g-.2.55cSt :t*pv arc 0V9< sleeves rolled ievr;. 1' i vorr. v:;en nanc-ing ^_ass a chemicals. To protect, e :yees v..c are exposed to toxic chemicals, urine ar bleed sar.oles are rerula taxer, from t.'.ese oecole. - -- S O * r ;vers_. ent-ovee sa;^" -> a v Q * O - safetv meetings are neid ar.d records are mamcame: .ne ot WATER PCB-SD0000062596 ot ea - ..e J. . Queeny p_a::t is provide: 5 tear. four po'ur.u per uour oilers, cr.e 210,^33 count per r.cur boiler, ar.u t;_ree snail vaste heat units r. t.ne reactors at t.ne n&Ieic aciu plant capable of producing u^,33G pounds ;er Ti.e gas-fired boilers are equipped vi full F.l.A. fla.ne failure C eate ,r.icr. surt-ies e^eetr ;. * at oyo- SUwS s are c 7..e rla e C 5 *" * ~ y Q >" ;UCS*a* Z-zr.z are .;ca,*e - *o e a e er.ae ?ratcr2 r ever e sutt-ie c " a c ** **>*' r* a cr.e e !I.-ctC 8k< ess UJ r.e c: t. e s e *.. . ,, 3 d. 1 ee S.C. S3 ites at ea ca arc ecessarv :cr * -- --* a ' . f;--y MATERIAL: MONSANTO cov^HAGE LITIGATION Huu LJ-** ' cu WATER PCB-SD0000062597 loc a irive as e c * ' -* o er.tral riant a 2 .e cQ je instated at a separate from uui_: is sutt-te e c are eustr.z e vater. s. tvers - - '-- w j m 5 Ai; to iUHAlICE COVERAGE t* *- u * ^ c WATER_PCB-SD0000062598 ~es or. c: es The u . . ,uee area cr. a xiioate the Lissiscippi River & ar 2 s a cpe > is a:eo or. a acres c on t..e sc siue o e entire r_a; s fenced ar.d is catrc esz .stria. ext to se e neve unary c: gs a s are a ixtencr e construction vit.. exterior e are s ar. a_a o _ 07' z ~a ^c f g * y _ e^ s. * va 0 v -- c. ca -* " " ~ e; o ;c.-;s a vs * g * - Ck *-- o - .VI': 1 I---- L. . Fuu -JJtici WATER PCB-SD0000062599 WATER PCB-SD0000062600 fc_ press -are is not restored to at least 115 psi, the electric pump will start secor.os after tne steam turbine. If the pressure requirement i's not satisfied, the number 1 diesel pump will come on in 25 seconds followed 25 seconds later cy the number 1 diesel pur.?, if necessary. Alarms are monitored at the fire house. Both diesel drivers are completely supervised for such things as failure to start, power, abnormally high cooling water, and low oil pressure. The electrical fire pump is supervised for power supply; tne steam driven pump is sutervised for low steam pressure. .All four pumps are regularly checked to make sure they are running orcrerlv. --,, cm___.._._-m_________ Protection: All manufacturing buildings are protected b dry pips automatic sprinkler systems vim an occasional deluge system and or.e or two vet pipe systems. 7r.e regular maintenance crew takes care of the sprin kler systems. All systems are provided with water flow supervision, including <a v* r.tral Station sutervisicr. and remote supervision to the plant fire station an; .ant guard nouse. :se buildings are crctected bv irv rice sprinkler svstems. Stock is the entire plant approximate.;- .m feet apart. A r.umcer of strategioa--y located monitor r.cocles are distributed throughout the trcoertv, .ster to ------------- t>~~ --o- umrlcyees are instructed to report fires by dialing 222. This sounds an a_a: at the guard office, the Safety lirectcr's office, and the plant fire static: The guars, scur.as the plant fire alarm system and telephones the public fire department. MATl.-.IAL; MONSANTO . ^ '.."A ji j.IT. 2A. 13N K t >- WATER PCB-SD0000062601 J nnp_cyees are tra. r.ed to follow a ere- ar.r.ed evacuati posted ir. all the departments and V....' - r.gs indicating evacuation center for each depart: ;ent. progra: e loca' Signs are cf the ding cf the plant fire alarm, the general super intendent cf each a: reports to the emergency control center. This is primarily a com- center supplied with radios to be operated by the General Superin.'laintenar.ee, the General Superintendent of PC and D, and the Safety director ho has a radio which keeps him in contact with the safety engineers ar.c tr.e : i s vehicles). Ir. the emergency control room, there is an override, for tr.e ublic address system. 7r.e city battalion chief i s in charge cf cteratior.s at the fire scene. He is assisted by the plant p erscmel. :r.s nave oee: made for relocating the disaster control headquarters mt grfunds . J. F. Queer// plant management feels that they would be flexible enough to move off the premises if conditions warranted because cf the portable equipment they use. 7r.e primary responsibility cf the -5 employees on the plant rescue squa is life safety. 7tey receive orders from the plant fire chief and are at ! s disposal in case cf an emergency, luring the explosion in Building II, he rescue squad removed all 27 victi s in three minutes. c cublic streets a s has allowed tne J e ar ee ee.uy QC w w ft -12- I Al; V. IKcA'-TC AGE LiriGl'IIlK e sa.es across HLL .ijt / ;3 WATER PCB-SD0000062602 u these public streets are monitored cy remote control to ailov fire department arc r.ctor vehicle access to the plant. All employees ar.c visitors are issued cadres which (when they are inserted into a reading device at the gate; will activate a computer which, in turn, will eitaer open or refuse to open the gate. From the central guard office, all gates are monitored by closed circuit television cameras. All gates can be opened by har.c in the event of a power failure. In case of an emergency, guards automatically oner, all rates. - * - >j r* i ^ ^ PU Ci / 0 C WATER PCB-SD0000062603 o Common Hazards imposes r: libs Ir. several cf tne manufacturing buildings, wiring vas poorly maintained. There were numerous violations cf code requirements in Class I, Division 1 and Divi sion 2 locations. In some locations, unapproved man fans had beer, installed in violation of the code. designated areas only, "Do Smoking" rules are strictlj er.fcrcec. rersor.ne_ er.term; r.'-if's.za'jjt"L?"iz s,>*e "***a c a' ~ ^ ' a&V6 :izaretaes ana .ignters outsiae tr.e area. housekeeping is good with only a few areas, such as Building were ooor. where ccniiti: In adequate permit program is in effect for welding and entering tanks. ,nemica_ ar.c - p.rr a ~ n : r.~ humercus J_ass - cr.emuca_s are usee tareugneut th.e p_ant in tae nar.uf acturtr.g processes. Phosphoric oxychloride decomposes when it comes ir. contact with water. ler.tcyl peroxide, a powerful oxidising agent, was stored in excessive amounts ar.d vas being handled improperly in the manufacturing area. Two hunuren pfunds cf benzoyl peroxide were stored with possible contaminants. humercus sartor, dioxide and nitrogen blankets were found cr. vessels, converters, reactors, ar.d mills throughout the manufacturing area. In Building DD, r.itrol is kept cr. buggies under specially designed automatic srrinklers 'until the stability cf the baton can he verified. ` r'TIC MhTBBlAl. V. CL'S.hi 7 0 w O C -t ' c f WATER PCB-SD0000062604 cperly emeu; r.ovever, -.here are numerous car--: cars ana car--: trailers used to carry flammable liquids cnrcugr.cuc t'.:e property. Flammable liquid process supply piping (both over head and above ground) passes throughout the manufacturing area. These overr.ead lines are not identified and, in many cases, are subject to accidental 1 thylene oxide 'unloading facilities are provided with vater spray for terepera- -- -> o - or :r. veu--u ae--p guarc. against tr.e cession--icy of an -- - -- ~ "* s * ' -- q - - 0t. * r c " * ar "IT/' ' av" ` - ' OS" * ^ " ? v 0 0 adjacent to the etr.yler.e oxide faciliryand the perimeter fence. A failure ci 3..e es. -3; C* OOCA -&T.2. rrocessi: 5v o :s3ea '-A. S'* - -.ms is &r. ^ >*9H3S33Y6 3 3 r. S * T'-l C " 1 c r. Preser.'. ccr.p\ :sure 3333 t, an loll pre :a accui: ch.. w* a. .santo-o'-neu science:ic computer . 3 .-- 3 C :r::sr rccz. scr.s,i3icr.s ir. 3i.is ^rss. ir.c--uss sevsr 3&3-.2S r\33 23 3.32 -.^001*5 r rr.2.3 3 i .re detection cr protection system, no cut-off from other office: :.oly eye-level glass partitions are provided), th O -- * r. o *e extinguishers, an excessive amount of combustsoles in tn: - - e 2.332 3 "^2 ] 1 ~ w ^ 3 3 7". 1*2331*333333 S* y i -rsf ijj MONSANTO '"hV^a'-GI LITIGATION Wu. l/JJI (CC WATER PCB-SD0000062605 ...e new .oaueic annyanae process w:,, oe centre__ed from this rocr by corrouter. As ~ore processes are pus on conputer control, proper protection of this root: vi11 become more critical. Natural Forces . 7r.e J,T, Queeny plant is located in an area subject to tornadoes, severe thunder stores, and hail stores. Inis slant is in a lone II eartneua/.e area and vculu orebahlv sustain eoderate 7ne danger of flooding is reeote. 7..e flood stage or. the ilicsissippi is 30 feet at t.tis location, 7he plant grade is <-2 feet. 7;.e flood record in this area indicates that the lo?3 flood eay have reached -2 feet; hovever, each r.ajor flood following ti-at has never gone over 3o,?I feet. The levees which have beer continues sout.uward oast tnis location nave alleviated nuch of t..e dancer of area which wo ;c:ect riots. .0 reduce toe dangers a_is malicious nis :ne p_ar.t nas :eve_opeo a tignt security oyster:. -.oe nac_ er.er.t has tans eve: orecaution :o secure the slant orcoertv frer. unautr.oriced he a 2. >ssel~ are a-ez'-ats v cf exrlezicr. 7a NiOhSAhlh T-'-niT'OU a. Kt-w / ci WATER PCB-SD0000062606 J 6CV_ ar. explosion include hs.nz.li~z .tunereus flammable liquids and solvents and t!.e flann.aole liquia piping tr.at is exposed :o damage. * ler.era. _dacidicy Execsures The enters plant is fenced and patroilea by security guards. Visiters to tne plant are provided wit;, an escort and protective equipment. All comer, carriers ^ ^ - - - a ~ * <= r * -- ^ ~ . > a Qj * m - c g, ^ 0 ^2 s s , 2* s "re vi ded v i * r. protective equipment, are told about the "lio Smoking" rule, and are instructed to crive at the proper speeus. The vessels arc transfer lines or. tne Slay Terminal bridge carry butanol, toluene, benser.e, steam, and sulpr.uric acta. 'Tne area belov these lines is open to the public ana a rupture Severn a minor one on the sulphuric line) could create prob lems . Autcr.c;c_e Ircmcsures ^ ^ vc ? *. soever O'* c t - * vi z.''e -- z,qt.Sirzrr.2r.t ..0zzs _sceu 3 s ci *j Lffioult to uetermme tne effectiveness of Q/^q " - "n * - o' e.xrooure to loss from, aircraft. Since r.unercrus verities use ere 'a--------- < ~ a . ' = r ualiveries, tne possibility c m -- m r* o X1SE3 . h'ATTn.'Al: klKSifTT `1 " "<}?-, ' 14 TM ' r' O' WATER PCB-SD0000062607 o sure The dd",' located exposure Idi.ng is exposed -ode tely by the 3er.Ja.-ir. d.ocre Pai feet I.'crth of the pia; ; however, there is r.c ether s Company if icar.t T5 Oi-Utl to :ontrci has spent over three 9 and r.as projected exper- iior. dollars during the period from es over ter. million for the period al atmosphere. Approx: 275 have a lev pote: the vents are equip; .'.or. sar as an c-ocr cor. cc__ectors, a or cor. p2*"C2r/. as em .nave r.o po oh ooter.tial. er.ts to the r. potential, cximately 515 of ar.e_ arm perscr.r.e_ vr.o re ave ir.stalleo many scrubbers, have the d. P. Queer.y plant -ater s samples e '.'.e -.e c_an: oertv tr.e cl ant e a ally cor.tro__e ar a .CVS e !liss s sever. '.arge s a * _q ~~ fa \* ^ a_ ana tota_ ar sever crosses e s in so: f tr.e chemical tanks C2 er. r--r wxn1 ^.irrt.;iAt 1*'.. *c --\ T mvrpinv LIT!jATICK f'v.u . j;i / ? i WATER PCB-SD0000062608 &- recently, Monsanto nas ir.soa__eo a _arge neutralization oasm on the pj.ar.t. They bleed off 1,100 gallons per minute of water waste from the, city sever through the neutralization basin to the ISD Bissel Plant which has primary treatment only. A lime neutralization system is used to control ph. .'lest of the in-process drains from J. P. lueer.y plant buildings go to this neutraliza tion basin. It is possible for flammables, corrosives, and toxic materials to reach the basin. If there was a large spill of such materials, Monsanto would be required to notify the Mil. Liquid wastes are monitored and records are maintained. Before wastes are dischargee into the Mississippi Liver, they receive primary treat-m-ee.-- tne-h Louis :il. By 1575-Td, the City of St. Louis hopes to install a secondary system. landfill areas locates across tne Mississippi Liver are usee joirt_y vit.n tne Irummrich Plant for tne disccsal of corrosive and toxic liquids and solid wastes, inis cannot continue nuc.n longer because the State cf Illinois is ocmev..at concerned about this cis~csal method. Test wells at tne lsnc.fi -- -- . - - . p * a > V ^ P * i - o - - 1C. V. ..... . , V "TIT MA7ISIAL: MCMAi'TO COVERAGE LITIGATION j c -t i L WATER_PCB-SD0000062609 .r.e survey tear: agrees t::at a severe exposure to less exists because oi tie -oxioi sf tr.e p-ar.c .uir.gs. Several operating units could be destroyer an e xr _ o si or. or This is especially true in the older areas cf the - -- "5s -- ' i - i r., ar.u S are ceir.g razee. oner, this rrc- grar is completed, the exposure to loss of multiple units vill decrease. rrir.ciole liabilitv exposure is associated with larse stills cf toxic or c.nemica_s vithir. tr.e t.sr.t or curing tne trar.stcrtatior. cf matena_s sac etv its VI** f`j^rtde'ed"*'0 AA <-* C " A -CSS A . r , r^ueeny p^art nas a cssitive loss prevention regram and a root a* e toward safety, Hoveve , ve feel there is a nee for additional c orcertrate effort ir. v:ur safety a tivities to reduce loss tentials as - . . -- r-. Q ase: c c: tne .css, <,ueer.y comrade a. a a et the hazardous Coera 8S, We oter. a es y e l.a ay ^ o A e Q e : cr .ent arc. as -r- ViTIHIAl: M0V3ANT0 --U Uyrp.iGE LITISA-*-'1' Fl u wjjin; WATER PCB-SD0000062610 - ---. j a tar--: _ace,, e cents LtS tr.e x. ana sr: .a re esta: s a; jhed, _aoe_s sr.ou_; e re- cf the r-aterials. .-rcce: -tr.es t c ate the catena- m transfer. __tanxs containing toxic, corrosive, ana "lannaole rcaterial should he diked to orever.t accidental release to cuolic severs or cuc-ic vaters. .r.e practice c: aisposir. n -icuia vastes to a _ar.u: i__ site sr.ou_u ce evaluated. We question ".*0 aUVl2d u 1 -- 1 - V 01 *.11.5 1VT0 Cl 0_lSpCSa_k. because cf tr.e possicili i */ of ic r.i anil -113 em e r i r. r> s ur f a c e air s ub * face vaters. c .S lie s a* a. r ^ v> ^ nanieiaice scar --2- - O' s oe & e. eraie C a ao ar ed. e o a ' ya e e ir. lie elieve ic lie er.e c re-ieves c: lie :r3.ze :l ce s should ce revieve e observes *_ ercxide soiree. *5 for use ari--ar raiens- vas sure a es sjo oner dual dir.z ad "ace rner mar.;: -- s * o'-' o' c . creiera: fiTLr.i/u.. h-' AVERAGE LITI GATIOH WATER PCB-SD0000062611 needed for the operation should be stored in a manufacturing area at any one tine, larger quantities of ber.acyi peroxide should be stored in the specially designed building of nonconbustible construction. --"les should r.ot be permittee. tc :arx unuer Harm cue ana :crrosive chemical pipelines between the terminal and the Monsanto plant, This area should be fenced or appropriately posted to eliminate public parking. lie supe: operations wr.ere tr.e worn was r.ot properly evaluated and super'.'!sed. A pipe section being removed from the II Building swung around and cane in contact with pipelines and reactors. *e observed one crane operation where the boon car.e in contact with an overhead electrical cable. A. coal, dump truck was -unloading materials at tr.e power house with the box in contact with overhead chemical lines. It was difficult, at times, tc find the suoerviscrs in the coeratinn area. .os computer room s;.ou_u ce cu ff from the act coning c:dices r.cr.ccmbustible enclosure. products c.f .. svstem and an automatic fire extinguishing system should be install A separate heating and air conditioning system should be prcviceu the commuter room tc isolate it from the office building system. All unnecessary combustibles suer, as furniture, card storage, etc. - - a r*-ea.moves :.~e computer room. 7.7 M^.TFPIAI i t- s. f -;.du LITIGATION ^ ^ C C j 3 *1 ^ : WATER_PCB-SD0000062612  X* UJ1 t 7 O Tw' :AT WATER PCB-SD0000062613 J i >1 V..1- o P vt- '.JJt/'li WATER PCB-SD0000062614 'J ?:;cl - juiid. anc _..r essaues f: e ,'!cr.sa ,-c- a`. -- C r~ ' 3 S a--. 1S C L. e s usee :r. t..e c a va~a c/ree i"s c \* a ase cxiuaticr. of a va er ar. a ^ 'ar.sf erred .e:: :crs are sar ex c W - .. -* W :ess <3 __a.. a S '"SEC xi as, r> a sc: aa_es: arx.yeacsea ser.sere, c. ec as as he a* a cr:,e ase Q a .. S " .. --Y S a e ~iscs s.*.e s-aer reass: e as O n c^r.sracsc,rt* I~ ''ATIJ.IAL Ci ~-I 'TVERAGE LITIGATION :a ce 2> - * s ^ 0 S S Mu WATER_PCB-SD0000062615 relieve through a -a rupture case cr tr.rougr. tr.e ccnaenser. The reaction rate is controlled 'ey the addition cf hydrochloric acid. The reactor car. be dumped or flooded wit:: water. The resulting mass is centrifuged, flash dried, sifted, graded, ar.d air conveyed to bulk loading cr bag packaging. Food grade funaric acid is 'used as preservative cr the product is sold to resin nanuf acturers. Production is 2.3 million Ics./yr. Phthalate Bsters - Building C-- - Processes involve such materials as phthalic ar.r.yanue, butar.cl, ethar.cl, and sulfuric acid ir. batch reactors to produce * " -- * r - ..* vr- ^^-r*o a -r;r*** Li.i.c* hur.^ _ l r ^ ^ ~v ^ shipment in tanh true/., tanr. car, and drum quantities, 31soner.cl - A (BPAi - Building TC - Phenol, acetone, toluene, ar.d nercaptar.s react in a semi-continuous process without i.tpcsed press'ore to produce BPA. .-Iter purification it is dried ar.d bagged as a flaked product. ..CTZ: Bone open 'wiring indicated that electrical equipment r'* gr o ~ ~ "os ccc-'"atinr r ztcrv, t.'.is cter ate cr. na'* ~s closet devn by tne eni c: 1J"1, Toluene Sulfonic Acid' - (TEA) - Building lb - V&pcrioed tcluer.e is sulfonates, vit;. sulfuric aciu in a batch reactcr operating at 11 psi. .Ill; A cher.ci residue trailer used to transport vaste tr.encl acrcss the liver tc a landfill site at p.iai ' OT VTIGATIO^ A C 12 2 7 7 v v WATER PCB-SD0000062616 rr.ssrr.ate asters noil ding - Phosphorus oxychloride, pher.ci, or ^-etnyl r.ey.ar.c_ are re; ir. 'rater, reactors under slight negative crescure to tree phosphate esters. 7r.e heat of reaction is removed from the reactor by usir.; kerosene as a heat transfer medico:. Phosphorus oxychloride decomposes vr.en contact with water. Trichloroethylene may be substituted for kerosene as a coolant, licyuid phosphate esters are washed, dehydrated, and filtered. A phenol stripping 'unit is associated with this process. _.-_r_._tr_._a___a_t_e ast.e. rs - c; -~-'5 * - -opnenyu pro *liwS W J k Km &J involving reactions of material such as pr.thalic anhydride, toluene sulfcr.yl chloride, caustic ar.d sulfuric acia. ..nos os c.ne c: tr.e c_cest ouo_cings ir. tae p^ar.t ar.d reflects poor housekeeping. ua. ar.ny a e s a c _a c ..nos ;ve mace atch reaction Pfaudler react s, crovoce for glass line uutsooe atmostr.e: ' 'a * c zr.e ers aco ~ JJ - Aaleic ar.d furcaric acics are reacts a hlcric acid as a catalyst* *. 711 MA"-~ r 70 coverage litigat ION WATER PCB-SD0000062617 u Para-chlcrcaniline (?CA) is also an internediate produced in this building, is the most toxic material -used in the plant and produces cyanosis. VOTE: The II Building vai involved in an explosion on September 3, 1973 which resulted in one fatality. In 26 days, 27 people were treated at a hospital, (12 were hospitalized for sometime) and one man is still out but will return to work soon on limited duty. The re maining people are back to full duty. The explosion was the result of an alcohol spill in which approximately 300 gallons of material was released. "The entire north end of the building was blown out and seme of tr.e equip ment and much of the piping was damaged, liability damage was limited. The only information we could Owtair. is or* at -.css va.s -- sss "r.en vtij.-'-'j-wo* '."r.ile roa/.ing obis survey, ve observed riggers using a crane to remove piping from an upper floor cf this builii.no in a poorly.' supervised procedure. Tr.e piping was swung cut cf the building and struck a reactcr. One mar. was working directly under the load. Ve also observed a relief valve from a nitrogen and oxygen suotlv line to a reactcr which vented directly into the building. This building was still 'under construction because cf the explosion; however, it was bac.-: in ccerati c.n. u. - r-:_:_i. u'tsahto CCVIHAGZ LI7I0ATICK P i_ u -Uuico WATER PCB-SD0000062618 3 "v'*"*.' - Salicylic Acid - 3uildir.g A and BBS - Phenol is dissolved in 5C;i caustic soda. The sodium phenate forced is pumped to a converter (ball mi 11),. dried under vacuus, and a carbon dioxide blanket. The dry sodium phenate is slurried with vater ar.d acidified with carbon dioxide to fore salicylic acid. Excess phenol is stripped with steam. Salicylic acid is precipitated, centrifuged, drum dried, and packaged in 55 gallon druxs or transferred to aspirin mar.ufacfaring. iscinn sauic\u: c acid ar.d acetic anhydride are batch reacted, Aspirin ,acetv_,sa_icylic aci s crystalioed from the acetic acid by-product, Tr.e asoirir. is cooled at of3 er.trifuged, flash dried to remove acetic acid odor, and transferred to a tower for gravity handling. Some aspirin is nixed with starch in a roll ccr.pacter to obtain proper sticking characteristics. Aspirin that will not be made into.tablets by pharmaceutical houses will not contain starch. Both products are subjected to close quality control which includes magnetic separators, sampling of blenders, and final drum samples wh: are retained for years. .ney nave no a&verse rL s wcry ouildir.g - Salicylic acia is reacted with sulfuric aciu using Balicvlate - B'uildir.g r - Aeor.ancl ana salicylic acia are heatea ir. t: presence of sulfuric acid. A-ccr.ol is removed cy custi--atior - ^ g ~ * e 11 r. ft Para-oner.etiair. c_us acetic amhyanae in tr.e preset: o: etr.y. alcohol produces pher.acetir. which must be stripped from acetic acia. .r.e duct is decolorized with charcoal, dissolved in ethyl alcohol, cooled, rysca_ liced, centrifuged, flasr. dried, sifted, ar.d packaged. There is a dus: :a eon v_ alcohol extlosior. zcter.tiaJ --*--- ----- fc ' *" W l T* - - i * UC.'.'SAITC c:.v:?.age .IT1GAT1CH icU WATER PCB-SD0000062619 Zthaccl - Building K - Anisidine, ortho-phenetidin, and sodium nitrite are reacted in the presence of 50',> copper sulfate to produce ethaccl, a liquid intermediate used in the nanufact'ure of ethovan. Zthovar ethovan (ethyl vanillin). Oleum, nitrobenzene, plus sulfuric acid are usee in the production of nitrobenzene sulfonate. The final product -undergoes distillation and benzene extraction. .* *1*1.1 1 ddr.gs K and H - T.mhis is a fusion reaction uetveen pner.c. .e in a small batch pro cess ich requires quenching, prend packaging. Cperati or.s ; :atec at T to o wCr w r< s away .ouue: fnloride - Bulldine HHK - Toluene reacts vith chlorcsulfonic acid to produce para-ortho and netaisomers of toluene sulfcnyl chloride. _.-.ese are separated by distillation. .r.e crthc-isomer is reacted vith a: oc vie._ ortno-tcuuer.e su_iamze. ;cze c: t.nese interrr.eouaoes ar -o c * O. -- .er.oeo ar billed before oac/.acir.: -.2 oacriaptes .oiuene sul famines are refined usir.s methanol in a recrystallizj -c --si' ~~' oroduct is cer.oniuzec ar.u cried. ;1 is reccverez. material: wg;;?aM0 COVERAGE LITTG.-'.Till ^uC WATER PCB-SD0000062620 0 Ber.zoic Acid - Structure 2799 - This is a liquid phase oxidation of toluene using air at 200 psi. The benzoic acid is distilled, crystallised, and pimzpec in a molten state to ether plant processes. Me were advised that this unit will be sr.ut down in one year. It is too snail to compete. Sodium 3er.soate - Building AA - Molten ber.zcic acid and-caustic are reacted in a batch process at atmospheric pressures and beicv 100C. The product is con centrated and crystallised in a drum dryer. There appeared to be a dust problem in packaging. The sprinkler system was heavily coated with product. IS? benzoic acid is processed in Building B in a subliming process. The benzoic acid (heated with 100 psi steam) is allowed to sublime ir. two (30* x "O') tents. Employees transfer the benzoic acid from the tents by hand, using shovels. They are equipped with air supplied respirators. _asso Building PA - .r.is is a curse stem reaction ir. which dietr.yla-T.ine vion caraf ormalcer.voe sc.c. cr._croacetY_ cm-- cnce i, wACJ us erg monocr._orccer.zene , MOB, as a solvent carrier to produce or. intermediate --* - e- vgo e; " - - S'-- , - scruoceu. One internemace is neutra_izs :ca, strippec q. excess mstr.anc_, wesue d with ammonium er.uor; produce : active prod (me t h c xy me t hy 1) acetar.iO :e, and mor.ee r.lcrober.zer.e. Tr.e reactic is similar to tr.e process e ar r i e d c r. at the Muse atir.e plant at Muscatine, :va. The product is used as a hercicid` ':r weed c or.trol on soybean and com :rcos. .zrezer. ^:e: are suitable . :* aiscs, ar.i a . - " J\L ; ^ ^ )pI:;oe ccvef.age litigation WLu LJJlCbl WATER_PCB-SD0000062621 u :ui. This product is used as a rubber additive. It involves reactions between anilir.e, formaldehyde, and nitrcprcpane at atmospheric pressure. The product is dried under a vacuum, oil is added, and the final product centrifuged and dried, The product is thermally 'unstable in various stages of production (including the final product) since it contains its own oxygen. Its stability is checked c arefully by laboratory analysis since it can decompose at normal temperatures, It is held in buggies equipped with sprinklers and alarms during this phase. As a final product, it is blended with clay. The product nas a- fire history, tr. us fleecing with water is essential. Bif- - Building ID - This is an intermediate product used in the production cf L-DCPA (a material used to treat Parkinson disease). It involves reactions between ?YQ and sodium hydroxide with further reduction by hydrogen and a metal catalyst. A trailer is 'used for transporting the water soluble product to Building k for crystallisation. .DOTE: Electrical equipment and fixtures in this building were r.ct all suitable fer hazardous operations: the hyc.rcger. meter was located above tr.e reactor, some lamps above the equipment were not properly supported, ' and '=ar. fans with extension cords were in use. The process has seme fire experience. ill. . L. ~ - - . " - HiS'JRAl'CE COVIP.ABE * l * j r. MC Li wlbnouc WATER PCB-SD0000062622 Interim Production Facility - Building V,' - This building is used for trial pro duction to prove stability. It involves semi-permanent laboratory production. We observed an eitulsification reaction involving vinyl chloride (at 100 psi) and ethylene (at 1,750 psi) with a catalyst in a high pressure agitated reactor. Tne ethylene vas being supplied from cylinders on a tank truck and the vinyl chloride from a tank car. IICTZ: In another area of this building, ve observed a methanol leak from a reactor to a sever. HLL l . m )!A7Z?.I A1: u O'-'>n.-uAGE LIIIOATIOl? C3 2s 6 uo WATER PCB-SD0000062623 TRANSCRIPT OF PROCEEDINGS - IN THE SUPERIOR COURT OF THE STATE OF DELAWARE IN AND FOR NEW CASTLE COUNTY MONSANTO COMPANY, Plaintiff, v. AETNA CASUALTY & SURETY COMPANY, ~ al. , Defendants. Civil Action Number 88C-JA-118-1-CV NON-ARBITRATION CASE KELLY DEPOSITION EXHIBITS PROTECTED MATERIAL: MONSANTO INSURANCE COVERAGE LITIGATION Washington, D. C. Thursday, February 4, 1993 ACE - FEDERAL REPORTERS, INC. Stenorype Reporters 1120 G Street, NW Washington, D.C. 20005 (202) 347-3700 NATIONWIDE COVERAGE 800-336-6646 WATER PCB-SD0000062624