Document 6B4kJNG9xXd0mdxJMEEXDd06d

PLANT MANAGER'S SAFETY BOARD MINUTES OF MEETING MARCH 17. 1982 Present were: G.W. Bostick for G.A. Danner G.tf. Daues R.T. Hammann for J.A. Glass H.O. Reid for D.E. Kaldenberg. B. Nappier for B.C. Lancaster D. D. Kos C.M. McCullough E.W. Bell for D.H. Metten R.A. Hernandez for C.F. Navarrete M.L. Owens S.G. Pappas G.T. Ryan S.S. Moncla for J.G. Trafton G.L. Tromblee I. REVIEW OF STATISTICS--R. T. Hannnann A. Texas City Plant Safety Performance Summary - February 1982 (A) WITHOUT LOST WORKDAYS (medical treatment only) (B) LOST WORKDAYS B} RESTRICTED ACTIVITY B2 DAYS AWAY FROM WORK (C) FATALITIES TOTAL RECORDABLE CASES 1981 1982 1982 Feb. YTD Feb. YTD TARGETS 2 5 0 3 11 0 20 1 2 0 00 0 0 20 1 0 00 0 2 70 4 13 INJURY RATES PER 200,000 MANHOURS 1981 MTD YTD TOTAL INJURY - TIR 12.14 12.39 TOTAL RECORDABLE - TRR 1.52 2.55 TOTAL LOST WORKDAY - TLWR 0.00 0. 73 DAYS-AWAY-FROM-WORK - DAWR 0.00 0.73 1982 1982 MTD YTD TARGETS 5.34 0.00 0.00 0.00 9.02 1.44 0.36 0.36 -- 0.75 0.12 -- YTD 1982 MCIC TARGET YTD 1.45 1.65 ----- 0.37 ----- 0.37 B. Comments on Statistics--R.T. Hammanna During the month of February there were seven injuries reported, none of which were recordable. Areas showing rising trend line or no improvement in their trend line are: Boilermakers, Operators, *ENB Goal will be used when received from GLT SC 003267 LAM004281 PMSB Meeting Minutes - March 17, 1982 Page 2 Departments 13/14/15/16, Departments 44/45/46, Departments 48/56, Department 51, and Analysts. Some areas that have an exceptionally good safety record are: Electricians, Insulators, Department 50, and Department 513. C. Contractor Safety--C.M. McCullough Two Recordable Injuries (one of which was a days-away case) occurred in February. We are at approximately the same pace as last year. Heavy workload is coming up.In the near future requiring Increased diligence on the part of all personnel. Contractor statistics are attached to these minutes. D. CEP Project Safety--Bill Nappier for B. C. Lancaster One Recordable Injury was reported in February, and there are no Recordable Injuries to date in March. Some assistance will be pro vided during the next three months in the area of incident investiga tions. A person has been assigned to the plant CED group to review incident and accident investigations, and hopefully give some Insight into what is happening. Forces will be reduced during the next three months due to the decrease in major workload on IDA II. CED Safety Statistics are attached. Gene reported he has learned that Brown and Root has not had a lost time injury since starting work at Amoco (over 1M manhours worked); requested that CED check into their program. II. REPORT OF THE SAFETY ADVISORY COMMITTEE (SAC)--S. G. Pappas A. Pipeline Emergency Responsibilities A memo with the attached proposal will be issued by SAC this week. The problem that exists in this area is that no single group has been responsible for the pipelines and only MMTS has assumed some respon sibility--in that they inspect the lines. Equipment and personnel have not been available to handle any emergencies. Recommendation is that we use a team approach under the direction of the Distribution Department. Gene requested that we utilize as much of the existing emergency response team as possible. George Bostick, who is our Merit Coordinator, will be responsible for handling this much the same as tank truck--tank car emergencies are handled. An additional point that was brought out is that ownership of the lines needs to be clarified. Will Distribution have responsibility for lines from the battery limits or from the plant boundary? SAC SC 003268 LAM004282 PMSB Meeting Minutes - March 17, 1982 Page 3 will reconsider this item, if it is not spelled out in the memo to PMSB for review. Tom Ryan commented that we do not have written plans in the plant for curtailment of nitrogen or water to the plant. The utilities group will work on developing these plans. B. Union Carbide Pipeline Identification System A Union committee member recommended we consider the Carbide system to alert personnel of the safety equipment required to work on speci fic vessels or lines by means of stickers or placards throughout the plant. LP&S has investigated. The system is used by Carbide pri marily for information of emergency crews. It identifies minimal requirements, and may generate more confusion than help make the plant safer. It is recommended that safety equipment continue to be specified as it is now, based on assessment of the job by supervision Involved. This information will be conveyed back to the Union Committee at the next meeting. C. Review of Procedure Bulletin P-0119, "Open Area Permits" Further work needs to be done to ensure complete understanding of this procedure. This will involve: 1) a SHAC alert reviewing the procedure, 2) review at the next safety meeting for each unit or craft, 3) review by LP&S as to rational behind length of time of these permits. In addition, need to establish some control mechanism for review of permits in existence. D. MCI Housekeeping Inspection Recommendations-Clarify "First Flange Rule" There are different interpretations of the "First Flange Rule" in various areas of the plant for good reasons. The only pla'ntwide interpretation that SAC can recommend is that the "First Flange Rule" should be "the approach that is safe for the job in question". They recommend: 1. Through the line--review specific approach to breaking into lines and equipment in each operating area and ensure that the approach is safe for each application. 2. Those areas that recognize a "First Flange Rule" procedure should continue to do so. 3. LP&S will review the CMA approach toward safe handling of jobs through uniform performance standards to determine if application of this system will enhance safety of the breaking into process equipment procedures. SAC will monitor the progress of this review. 003269 LAJW004283 PMSB Meeting Minutes - March 17, 1982 Page 4 It was felt by PMSB that this was not enough. The problem with the "First Flange Rule" was mainly one of confusion. This is due to the name itself which was really used in the past to determine which craft had jurisdiction on equipment. SAC needs to re-look at this problem, and redefine the "First Flange Rule". If needed, Manufacturing/Maintenance superintendents should be brought together to agree on the philosophy of the "First Flange Rule". This information would then be conveyed to the plant to eli minate the current confusion that exists. III. REPORT OF THE PLANT SAFETY AND HOPSEKEEPING ACTION COMMITTEE . (SHAC)--D.D. KOS A. 1982 SHAC Goals/Objectives The 1982 SHAC JRA was developed and issued to PMSB. This will be used to keep activities in focus through the year, and to evaluate overall committee performance at year end. The SHAC Minutes of March 3, include a detailed action plan with responsible persons and required timing as necessary to meet the JRA goals. B. Pnit/Craft Team Effectiveness Survey An audit of the effectiveness of the Unit/Craft Safety Promotion Teams was kicked off on March 8. Members of SHAC will visit the Contact Supervisor and Unit Representative to discuss how the team is performing. Visits will be completed by March 19, after which an evaluation of the overall performance of this group will be completed. C. "Count" Safety Program--Shot In The Arm The first quarter 1981 brainstorming safety suggestions have been reviewed in detail. This information will input development of the late second quarter "Count" safety promotion program. The action plan is targeting PMSB review and approval at the April meeting. D. Hourly Safety Committee February Meeting All personnel were present plus an additional one as the retiring Power 2 representative and his replacement both were there. Mike McCullough was the guest speaker. He discussed the status of the Count Down Safety Program, January and February Monsanto and Contractor injuries, and the investigation report on the January pipefitter days-away-from-work injury. The report on this accident was very well received by the HSC members. Discussion followed on improving the dissemination of information from these investigations. Based on this discussion the following action is being taken: 003270 LAM004284 PMSB Meeting Minutes - March 17, 1982 Page 5 The SHAC bulletin which summarizes these investigations will be reinstituted in order to improve the timeliness of this report. The investigating committee on the muriatic acid incident will be asked to provide a summary of the Incident within three working days Including causes and any reccnmaendations developed at that time. This preliminary report will be reviewed by SHAC (D. D. Kos), Personnel (H. 0. Reid), and Gene Tromblee prior to being Issued. SAC needs to review the investigation procedure to see if this preli minary report should be instituted as a permanent part of the proce dure. E. First Quarter Safety/Housekeeping Inspections The quarterly inspections are in the process of being scheduled for the week of March 29, and April 5. PMSB inspectors will be contacted this week to nail down an acceptable schedule time. In addition, Dennis Kos will schedule a time with Gene Tromblee to make a tour of the plant with special emphasis on periphery areas. IV. LOSS REPORTING--R.T. HAMMANN/J.A. GLASS No outstanding reports. V. STATUS OF BREATHING AIR SYSTEM PROJECT--G.T. RYAN Problems have been encountered with moisture control due to inadequate knock out pots. Some damage was done to one of the compressors. New knock out pots will be installed, and additional work will be done on the system prior to putting it back in service by April 1. There is a defi nite need to have this system back in service by that time as a major shutdown will start in AN-5. VI. REVIEW OF INCIDENTS The following Monsanto incident was reviewed: Date Incident No. Description 2/17/82 82-06 (Issued 2/17/82) No Injury--Investigation of AN spill on 1/30/82, from vent line of Material Handling; slop tank T-76 North of Dock #2. (L. Thomas) sc 003271 A2.8S PMSB Meeting Minutes - March 1 7, 1982 Page 6 Contractor Incidents No reports have been issued; although some discussion took place on: 2/18/82 C-82-03 Recordable Injury/Days-Away-From- Work--Crescent Electric--IDA lab; cutting diffuser lenses with pocket knife; laceration to right index finger & severed two tendons. (R. Supak) 3/10/82 C-82-04 No Injury--Sline painter--Zone 1 at CT-1; struck HCL line with manlift causing rupture and sprayed with acid. (R. Supak) 3/10/82 C-82-05 Recordable Injury--Contract Guard-- Gate #34; was getting drink from water cooler, stumbled and fell against building, struck hand against glass window breaking window and cutting hand; laceration to left hand. VII. PORTABLE BUILDINGS IN PLANT--D.D. KOS/C.M. McCULLOUGH A survey has already been conducted by maintenance on the number, loca tion, and ownership of portable buildings in the plant. An Action Alert will be issued by SHAC requesting all owners to either develop an action plan for getting rid of the buildings that they have, or justify their exlstance. VIII. PLANT MANAGER'S COMMENTS Up until March 16, the plant had been running really well since late January. However, on March 16, we had a Recordable Injury--a pumper gauger was sprayed with muriatic acid due to a dome cover failure under pressure; a trip-out of the reactors in AN-5 which caused a steam cur tailment in the plant; cold box trip-out in Methanol; and CO compressor overspeed failure in Methanol. These items show that we need to increase our emphasis and get the momentum back on safety awareness. Priority is high for our next "shot in the arm" program to raise plant sensitivity. Attachments RTH: es R. T. Hammann SC 003272 LAM004286 TOTAL PLANT CONTRACTOR SAFETY TOTAL INJURY CASES RECORDABLE CASES LOST WORK DAY CASES DAYS AWAY CASES 1982 YTD 9 2 1 Feb.'82 3 1 1981 Totals 70 12 15 TOTAL MANHOURS WORKED (MHW) FREQUENCY RATES/200.000 MHW TOTAL INJURY RATE TOTAL RECORDABLE INJURY RATE TOTAL LOST WORKDAY RATE TOTAL DAYS AWAY RATE 83,384 21.6 4.8 2.4 37,920 521,991 15.8 5.3 5.3 26.8 4.5 1.9 Note: January's statistics are adjusted to reflect total Contractor manhours worked (straight time plus overtime). Previously, contractor manhour statistics were taken from monthly contractor exception report compiled and published by the Maintenance Planning Department. These manhours were straight time manhours only. Manhours are now obtained directly from time sheets. Contractors home office and Contractor Superintendents in the Plant. SC 003273 LAM004287 1982 SAFETY - TOTAL CONTRACTORS Total Injuries Curomulative In ju r ie s Cummulative TIR Cummulative Recordable In ju rie s Cum m ulative RIR RecordabTe Injuries Recordable Inju-ry Rate CSC. FEB. VM, may jcn. ^L. A'Jfi. SEP. OCT. SC 003274 LAM004288 CAPITAL PROJECTS CONTRACTORS TOTAL INJURY CASES RECORDABLE CASES LOST WORK DAY CASES DAYS AWAY CASES 1982 YTD 7 2 1 TOTAL MANHOURS WORKED (MHW) FREQUENCY RATES/200.000 MHW 40,602 TOTAL INJURY RATE TOTAL RECORDABLE INJURY RATE TOTAL LOST WORKDAY RATE TOTAL DAYS AWAY RATE 34.5 9.9 4.9 Feb. '82 3 1 1981 Totals 22 4 1 17,323 2 161,709 34.6 11.5 11.5 27.2 4.9 2.4 SC 003275 LAM004289 1982 Safety - Captial Frojects Total Injuries --------------Total Injury Rate Cummulatlve TIR C?.. .*Vi. Recordable Injuries --------------Recordable Injury Rate FE3. * VA3. * AP3. JU>. AVG. fSP. OCT. Cum m ulative RIR sc 003276 LAM004290 CED CONSTRUCTION TEXAS CITY PLANT ACCIDENT STATISTICS NUMBER OF CASES Without Lost Workdays (Medical Treatment Only) Lost Workdays (Days Away) Fatalities Total Injury Total Recordable FREQUENCY RATES Total Injury Total Recordable Total Lost Workdays 2/82 10 0 0 10 1 39,6 4.0 0 MANHOURS WORKED 50,543 sc 003277 YTD 2/28/82 18 1 0 19 3 36.8 6.1 2.0 97,823 LAN'004291