Document 50ENG4ZdJgdgDq2Qaa2Z5jGkz

r.Vi'u5 ' .-13 lilt' :it A vc k ::i?,ic-iu?.i!is . . PROCESS Operating since 1907 Direct ohlorlnatlon of ethylene Oxychlorination,of ethylene. VC Production - 335 nillion IBs per jeer , :;x b Stauffer licensed process: [fcrect chlorination of ethylene. Oxychlorination of ethylene VC Production * J9Q pillion lbs per yeas Operating since Oct., 1973 .' :;t C-. B.F. Goodrich process: Direct chlorinati'> of ethylene.* Oxychlorination of ethylene ' VC Production - 290 million pounds per year. * ** Operating since 1963 *9 *- MAY 13*1974 GENERAL PLANT LATOUT. R. N. WHEELER, JR. EMPLOTEES Sr.'CLVED Outdoor facility. *. ^Control room located in separate, remote building Outdoor facility. * * j - . V. ' Control reran located in separate,' remote building* under positive pressure. i* i.` Outdoor., facility Control room located inseparate, remote building wider positive pressure.. -1' 2 control room ope'-fi'-orJ per shift sti control room most ti shift. 3 employees Involved with uork outsic control room; tankjcur loading, inspet minor repairs etc^4fallinlntetenrance crev <fc not routinely stayy'Pf-nt VVCC,,ai rea hut is | present for other jftjrenym"inor problems 1 shift*foreman-- ^.;trol 1 VC operator - furjfices; distill, pn 1 EDC operator ef fluents. Rcfjttot, washers, d*1- 1 Oxychloride operr^r - Chlcr- reaetc' utilities. EDC reccV'ry system. -. 2 Tank car loaders^*. 6-8. hrs./shift. I Maintenance crew-sr"* as Plant A. 1 shift foremand^-.trol r=o= 1 VC operator forceaa - control room 3 VC operators J outside; samples, Im tlon, minor repairs 1 maint. foreman - J.'ntrol room B mechanics (day sh^:t;* 2 on night) -- side. *. :;rD Direct 'chlorination `of ethylene '. * * VC Production - dot divulget^operating since 1957 Outdoor-facility. Control room located in separate, remote' building "c under positive pressure. Analytical.lab in adjacent room separated by conmon door and vail. " . .r! Chlorination of acetylene Mercuric chloride, catalyst impregnated in petroleum coke. Outdoor facility. ' * . - -- Control room located in seperate, remote building unadeexr positive pressure. , . VC Production---330000 million lbs pep year - - -i- * nt*'.: ^ 7^77^1'-"pA.'. I*.. * ... ;9-9 KWEgK-fH;-'v .' ' V,rV I - 1V'; 't -l- Ji,> ' 1 VLi1 "r * f i ,'.4ic V.'- L.shift super con vrpl room 2 operating' specialTts - inside ard a 1 senior operatingT:ccknlcian - tcV.ej andEDC product sanjf.c; inspections. 1 operating techr.icjfih outside; resp slble for transfersKTroar tank to tank; spectionsv if 2 tank car loadcrs-|j 4 hours/dav 1 1-th. tnehnl { nit ~ f r- ,!>-- 1 Foreman - control!f:oom 6 hrs; tours ,2 hrs. 1 senior operator -I; :ontrol room 8 hr* 1 technician - coat >1 room 4 hrs; VC . simples;- inspectin' * other outside vj ucc 049350 ' 71 Tit: All? A 'VO K*J:iffACTUitIIIfl AIR HOHITORIHC ACTIVITIES Vone at present. A previous survey of several out door areas showed "very low levels" Dry test meter - 3ft.V*^* .V I Cas chromatography. . Recently purchased an infrared portable analyzer: Attempting to develop personal sampling techniques. .* * . tr i PRODUCT SAKP1.1HG METHODS ' l 'f' PRODUCT SAMPLE AKAl/ilCAL PROCEDURES jit b Personal samples collected in plastic hags for TWA ; "Quick connect and disconnect" sampling bomba - 2.S ml/min rate. 2 liters. Performed once each .shift takes X. . Analysis by flame Ionization CC. about 1 minute. ; r| j. Future plans for-continuous monitoring device (Wilks .*** \v 4 T.. 7 -i v* i *, ' J.. * : M* ' 3- * - 3. . ,, * .. cjit JIT 0 JIT E Detector tubes used- to sample VC column before employee entry* Century OVA ordered. ./ ; - Flame ionization detector presently taking area' samples. Two-valve sampling bomb - 2 liters. * Performed by same operator 2.-4 '] times per shift.- Takes about 1 minute for each sample., Bomb purged with VC at point of operation. *. . ' r . .. i -. . VampI s /Sarnn lietlvod/. are taken in lab every 6 months. If levels axe-below 50 ppm. nothing doncj -ill- sample every 3 mas. in future. 1967 survey shovt 1 control boom & lab. exposurcs-9-60 pi>m. 1970 survey showed exposures-1-20 ppm. (Installed SAME AS PUNT C EXCEPT 1 LITER BOMBS hoods*In lab-for sample analysis) 1973-Bicn has iu'mt'crs. _ . '. Cion lias data on'past monitoring. Presently at-, tcnpllng to obtain area levels fur Indications as to nr r* mil .lovol r 'for fiimre rumllnc. '.-e previous monitoring. Present activities include, area samples (grab; CC analysits^of control room ( 2 ppm), tank car loading area (found up to 1000 Same as plant C. Alr.o, pit test is performed once each shift on crude VC using Brora Thymol blue-in dicator In a 25 ail flask'and tapping VC -- ppm hut not at employees work station) and spot process line. This Is dona once each shift and'.*' cheeping around pump seals. 25ppm was found -at load' takes about one minute. This 'operation gives ': * ing area work station while 7.tank cars vera being Smnl<>|l ("nnrranllv 7-3 nw"Y * exposure but levels unknown* i `I Analysis performed "vArjer lab hoods*- a. not kept under hoodr'Jat all times. -Lzb! separate room from cVr.trol room but hz; common wall and door rind same pressurej Ko food permitted ij'lah. . IV-S Same as plant D excc,Va separate tens general lab is used inclusively for VC analysis with co=oa"'!oor between thatt areas and common doo|> between general 1 and control room* ||. . ; -'V VO.O vW'':V ' 04935 at A , A* ?; \ 1 " '- --,' . '-!' .' * * '!. A1*' :./,j;V"*-.'''- ; *'1 wi >..,%... . , ../... , ., . ' -, .,' ,, : x ,, , ;............................................................................. j vc ii-y.ijn'rtiv.vr, * .. LASELI'S AKD POSTING * None observed which would be designed inform employees ''<' : u.*.*''.''^^^.^.'.- '. * S.***/.*.?-J*,`'Htfv^*<'! <!<.' * * * ... *' i''i/.',w.,,:*/, V.' .... J_ ^ . SANITATION jj ; :. .'*'*Vrv/V'i-.V'.-'' -' - * ~ ' -- T_. I t-. . .] in ^ | .-. * ..*. | ' *t PROTECTIVE IHINC '-> ' > ' -"'-.V _ : Shower facilities, lavatories, and locker available but use not required. Any equipment issued such as gloves, goggles, harjl hat or respirator is maintained, cleaned, etc. by' the employee. ' ' No restrictions on food storage or consumption. .1" : Gloves are issued vit ura is not mir.lt No other clothing issued. -Lover., Us available for yess-J cleaning but use required. I *.? b V SAME AS_ PLANT X . *: r . '1 i \ty i *4 V SAME AS PUNT A .t ::x o SAME AS PLANT a f - -. * l r . ?;.fh*e . SAME AS PLANT ' X-"'*]' '* ' 'V^ * y. . -Jt ISAME *AS SLANT' A / HvK '>!* '4 : ' ;*! '*.'* ..- . . * v'-* ' j` ; .* '*!; ; :* ^ i . ` v '\'.i~yy. ' * ^ * % V4 -]'* ' . ` ". 'rv' :;.4~ .. :.i ilia J.1 i . * . * ,u'-l i'" * ,:*i; ' . *./. SAME AS- PLANT A i- l; if v' Xf i 'SAME. AS *!?LA1{T Ji i . . . Ut *f a *r .x jf*,-v- 33 i i - - a Some as .plant A except food and eating' ; - is prohibited in* VC,-. t ?, * area, " '. V 1 ' -.VV-rir-X t " - ' '1 > v- a--.t,. SAME AS /PLANT A * . ;t e . - `SAME Jt ** AS PLANT I' . * . ^.1 : -. 'i *', > V..*.. iM.t .ucr . <* _ tj>. .fc .*+. * j ' `SAME. AS PLANT . . , * i . >.: . . i----*. ryJl'X `u: J. , ' . . y~ .' SAME AS ff'LAirt A .. .-V-. i - , V. A'.t-i-. XiS.. ; ... B-a'Jr. V - 11 - - 049352 VjC" --'*','&** '- Z&zD IVlTCi . '.o jj/jiuF.vJi . _ protective . eIuifieht Cr'c-'ta.j fHyfr.jfri>:*e'A".I-:e*.,v1.vf.j. ..' *. .'; v.'*-ivr-`j-,ru-*-* ;.Va . v**. .."*.*, .. -\ . ; ?;- j* i ^ ewiatce miKXKQ : # " 9 1: MEDICAL XfECCRAMS "TT MX A . .air b i' t / *, * Hard hats and goggles issued and use required but * Foreman attend safety meeting once a stonth and pass not enforced. Emergent;- chem.-cart. respirator:) . info, on to his crow (informally). ' ' Issued 'to eacb employee 'who is then responsible"1 for No formal plant safety program for employees. Each its maintenance. Ho routine operations are requir foreman morc'or less is responsible for his own ct.ew ed to be performed with respirators 4 and establishes any rules, as he sees fit-on the Job. Gas masks available in control room & several^sta tions in plant, including loading area, their ,c'ondi training appears to be the rule for the VC workers. tion is suspe'et. - . *[. V. + Tt * Five week training program given to VC operators. Sane as Plant A except no self-rescue \ * After this each foreman is responsible for further . respirators provided. BOth demand and \N\ training his crew might rocleva; pressure-demand resporators aru kept " j - . ... -- -i * in control room end other stations. /.. ` ] * ' .. . * .. .. ' * Preplaceaenh requl.^d (general) Periodic (3-5 yrs.^ offered. SMA-12 for each VCporker now offered: Future program n.^: defined .. ;* i Preplaceaent required .(general) Special periodic fc>: VC workers offere (not sure lx manda.'^ry^-Fhysician can suggest further te.ls for any erployee (see discussion in Searing transcript) M . i; AN? C AMT D Same' as plant A except respirator is for VC column entry. Check respirator.! quarterly. '* Por extremely high exposures a full rubber suit is available. ' * ,t * Informal - Foreman responsible for crew training. No formal training in respirator use - ..most of these people already,'know how to use respirators." No formal safety meetings for employees to pass on info, of now hazard data etc,.' Foreman are expected to hold crew meetings each month. -------------- Same as plant A except u.e of n chemical cartridge respirator is required t r VC product sampling and brcaking'lnto VC cquipmt t. Also, SCU.A is avail able for emergency use at the point of entry into VC vessels and the cnplcce entering the vessel is harnessed if.any possibility of him passing out. Chemical cartridges will be replaced once a month. Ihe 2'SCBA's and the 2 full face piece gas-masks checked weekly and canul::ters replaced as-rccoomenb Special meetings held for employees when new data . on. hazards surfaces. Regular (frequency?) safety " meetings also bald. . ;;l:, . j . *. . 1i t< . .* e^ *. . .< . 1 * ' . j Pccplaccment requii'.id (general).Mandat SMA-12 for all yc workers every 6 =05. Optional general periodic availabl ea year. 3 . ; Kurseon duty during'day* shift; physic! visits plant once 1 day. Liver. function and ^'!A*11- required* for VC workers plong wi-h general ccnprehe Recheck all'abnomtlrties. ' Future prog being considered "(s^-letter 3-12-7A-E *r** -JIT . * * * , * l* | ' Same as plant A -.llas-ono self contained suit availab%le. *, . . t . . * * *v 1 * ** : *,* ' . . * . . * * . Informal - on the Job training mostly with - Preplaceaent required (general) ar.nuel foreman responsible for additional crew training. offered. ;j , -1%V ' . 1 . l* * * * * r. ? ,1 ^ .; ' .* i . ' ** l . - * Plan for future spe lcl mandatory exa= for-VC workers. Program not yet.set. - 1 Kurs^ on duty durin} day shift cnly. - o c: V/, co O cn co # 5VtD IVITTl AST & VC HAtiKFACTtiittro ' __ ENGINEER1KC CONTROLS : : .*;-34 K8,*. - / 4'-^ ^ V . * work iTAcrices VC leaks.detected l*y r. 1,-Jit and tmcll. ' Ho routine inspection prugrnw for leaks, : Minor leaks repaired when convenient. Ho enforcement of good work practice procedures. Tank car louder calls into control room every 2 h/a. Vessels purged with boll!up, wntcr and soap, checked for 02 and explosive atm..prior to* qntry. HOUSEKflpK Work areas gehcralli orderly out s-rc* equipment badly corjoded. T--ediare i on leaks and spllls^not -evident. Since guard rails in 'processing areas loading deck missini-appeared under r* ;JfT B Air conditioned control room under positive pres sure. . Howevet, incoming sir did not appear treated for VC removal. .: MSA. combustible gas alarm in control`room. Regular maintenance only on .day shift. * Complete plant inspection viral.illy every 6 mos. - - X-Ray inspection if felt needed. * - Leak repair and vessel entry-procedures appeared to exist but did*not appear to he strictly enforced. Emergency procedures in written form exist. Housekeeping good. . Hew facility. . Equi.;xent condition and work areas.ia jr'.od shape. i *' ANT.C III 0 :it s oc -fi o CCDJ Xo Air conditioned control room under positive pres sure. Incoming air did not appear treated for VC removal. ' ... . `* . "r . Cat detectors located throughout plant. Air conditioned control room under positive - pressure. **".! ..... - . . . Detected lcakcs are reported to foreman for instruc tion on how and uhcu to repair, V,'. Employees carry emergency chemical cart, half face piece respirators. . Written procedures for all VC activities (i.c. load ing,' vessel entry,' emergentles)given to all employees strict adherence or complete knowledge t> these proccdurcs by employees is doubtful. Completion of checklist iu rr-juiruu p.ivi lo vegsei entry, (i.c. soap 'it wntcr wash, purge with air, 2 Check. oxTtl. check etc.)._____________ __________________ Employees carry emergency respirators at all times. Clicm. cart, resp., monugn-glcs required for VC sampl ing and eqpt. tenrdown. SCl'A, harness .available for vessel entry. t>2 checked and explosive ntm. Written operating and emergency procedures available. Visual inspection of VC facility monthly. Ppcrnt.lon shutdou and leak repair a;vonivd to uu lopeiiuuul dtri-.iiugultdilc of leak and nperallenal convenience. Similar to Pljint A . J > n , ;. : ,.*!* i;* -:i -1 *-r i .1 ! Similar to Fljmt k - except process equipment in bet shape* v Stand upwind of any VC leak (came for A.,B,C,6.D) Supplied air respirators used for n.ll.vessel entry. .Written operating and emergency proce.uuraa booklet nvnilahle to mini oven*, who want them. Poor housekeeping* ff.eaks evident. of .this plants equl^ent was badly c,cz vlth meseroja leaks^in.process ` l,i' " >l*x V - ,- ** > :s - f* 049355 - n*:*f *** - *\ _.* l"V IvjjiatmyAcmiBG'j :k>2________ * `."7-V* '*v f'. ^xViH%~y} '*^1' *; -h~-*; -ANl A * *-.: w; .'>** ./: :' .* ' .i ;v l W * *****>.?++! Tank car loading operation - .-; .* VC product sampling operation j*' ` R-ejp--a---ir -o--f---leaksp, Vi C equipment tear down* and maintenance i j * i VC vessel entry :3m iil tis m^ 1.. Employee trailing.* . !vt* 2. Enforcement j good voodt pracd . (l.e, use';(of gloves^ gojggle^:,' 3. Preventative aaisteumce kJJlT B 'Ethyl Chloride "; \ '' Chloro fora- - Trichlorethyleqe . '1,1,2 Trlchlorethane other chlorinated hydrocarbooe. HCL - . ?**+ t>'ix*:<s . .-, ,,-;l, . ^ ^e- Tank .car loading, operation' s VC product sampling operation * \ Repair o leaks, VC equipment tear down ' and maintenance . - }- VC vessel entry; - : i' *' 5. Enforcement oi* wfi tten murk, pcocl' 6. Medical and' m:-ittorlng artivitie^ 7. Sanitation anci ckre of pmt. elo: P ^ ' i?.i i- 1 end eqnhrent. "* * Tank car loading operation , p; tv Aiv% I., :.: ` ^yc product sampling opcratloa^;^;^ ----- Repair of leaks, VC equipment tear doim^.: 1 - " *. > ' and maintenance *' f *'* r f I*v VC vessel entry;7 * vf". v tr"* *i '> ,'> 5 *-*****- ' 9'. Ceneral.'lack cj^knovtcd^e of rmi * 'workers''actual eosnru K*7 I'* .*____ 10.;Most'safety nies are deslcand t *>>V^*' * -- ' .; -_"j>reveae .fir |s end ptemstpn. Tank car loading operation !. . C, . VC product sampling operation;1 ?*'''< *;) V6 product sample analysis operation ' r (* *i"*" end labarea . t'1 Control room adjacent to lnb,.^^.:.-.].. .... ,7.^ Repairs; equipment teardown; .vessel'entry. ~rllyi rneral lack o j "concern mt f itdu * ............. ,'s,* . .-t health relati'ji to VC-dcm * *' * - '' . Butadiene* 2-6ppm,S'. : ;J * V. .ffe'' *,ethTl acetylene"' - ^ i&'r >* I'i.:Vl*: * propadiene .. _ methyl. chlorld 'v 1' i >/;*,, *' 7 ' -V.' -t- - i . . r* Same ap Plant D * *:s'. * . j. ; .T" , * ..t. .* i2 -it . f tm >* "> > SX .* v3;/ ;;*=