Document B8j8VpzwjJM6LwgGxemk5vkow

CRITIQUE OF 1984 ANNUAL SAFETY AND HOUSEKEEPING INSPECTION A. DATE OF INSPECTION 1. Get the date of the inspection established as early as possible. 2. It will be of help if the plant manager, the plant engineer, and the safety superintendent are in the plant the two weeks prior to the inspection--as well as for the inspection. 3. The schedule should avoid major shutdowns or startups. 4. The 1984 committee recommends late September or October for pleasant weather conditions. 5. Try to avoid other major activities such as the United Fund. 6. Establish a preparation action plan with responsibilities and due dates (EXHIBIT I) several months ahead of the inspection. 7. A large effort will be required to get housekeeping up to standard without a last minute blitz. B. PRE-INSPECTIONS 1. The quarterly safety and housekeeping inspections were scheduled 4-5 weeks prior to the annual inspection. a) All of the inspections were completed in one week. b) This effort should start at least two months prior the the Annual Inspection to allow time to correct deficiencies. c) The request for ladder inspections should be issued at least two weeks before this inspection. The 1984 SHAC committee believe this inspection should be completed in one week. Ladders tend to travel from unit to unit, and unless the Inspections are scheduled together some will be missed. It's a good Idea for the units to check the ladders again the week before the annual Inspection. d) Prior to the annual inspection, Polaroid pictures should be taken during the quarterly inspection and should be given to the appropriate general superintendent to hi-lite deficiencies. Prior to the annual inspection, each general superintendent should be inspecting his own areas in the quarterly inspection. e) Extra emphasis should be given to warehouses, and the use of safety equipment during this inspection. All areas should anticipate being asked to demonstrate the safety equipment in their areas. SC 000193 LAM001390 B. PRE-INSPECTIONS - ccnt'd. 2. A member of the SHAC comnittee and a safety Inspector made a drive-around inspection of the plant approximately three weeks before the annual inspection and two days before an expanded staff meeting. Slides were made, developed in Houston on a one-day basis (Ecktachrcme), and show at the expanded staff meeting. The staff was told most of the details of the inspection and presented with checklists to be used. 3. Next, the general superintendents and plant manager made a drive-around Inspection with SHAC representatives. Providing them with the tape recorders for their comnents will cut down the time required for these inspections. 4. A good idea is to encourage all groups in the plant to have daily safety meetings the two weeks prior to the inspection. Maintenance and some units did and the results were evident. See EXHIBIT II for topics which were covered. 5. Development of the inspection booklet should begin very early. PT/technical organization charts should be added to the booklet. C. PERSONNEL INVOLVEMENT 1. It is important that as many plant personnel as feasible be used In preparing for the annual inspection. a) Be sure contact supervisors and Hourly Safety Comnittee members are used on the guest inspection teams. b) Units being Inspected should use members of their unit/craft safety teams to host the guest inspectors. D. INSPECTION PUBLICITY 1. Publicity should start early - at least two months prior to the inspection. In 1984, the Office Safety Comnittee was asked to organize the publicity, but they got off to such a late start that publicity was minimal. 2. A "countdown" board the the main gate and west gate should be considered. 3. Articles on the inspection should be included each week in the Plant Newsletter. Articles could hi-lite the emphasis areas of the inspection (EXHIBIT III). The Issue prior to the Inspection should include pictures and biographical data for each of the Inspectors (EXHIBIT IV). 4. Messages about the inspection should be included on Touch 85 and on the hourly paychecks. E. TEAM MAKEUP In 1984, all of the inspectors were from the Chocolate Bayou Plant. They represented a cross section of positions from a general superintendent to an operator. This wide range of experience was an excellent Idea and should be continued. lAW\001391 -2- SC 000194 ANNUAL INSPECTION 1. The night before the inspection, the plant manager, SHAC, and the chairman of SAC, HSC, OSC, and TCSC met the inspection team for dinner. The plant manager presented some plant history, and the chairman of each safety conmittee reviewed the purpose of their committee (EXHIBIT V). This dinner was a great success. It not only gave the inspectors a good background prior to the inspection, but it also helped establish a relationship between the Inspectors and the SHAC members who hosted them during the inspection. 2. All units should have a 5-minute presentation to cover their safety performance, what they make, hazards involved, number of people, and to introduce the guides. These presentations should be made in as large a room as possible. 3. A couple of days prior to the Inspection, those units where breaks will be taken, should be reminded to have drinks and snacks available. 4. Lunch was held in the cafeteria conference room. The inspectors went through the food lines, but Texas City Plant paid for the lunches. During the 1984 lunches, an attempt was made to give the inspectors a chance to meet the higher levels of supervision in the plant. This was less than successful. In the future, the lunch should just be the inspectors and their hosts and should be considered as a break. 5. The 1984 SHAC members critiqued the Inspection schedule after the inspection. The modified scheduled (EXHIBIT V) is recommended for the 1985 inspection. 6. Car reservations should be made early, and keys should be obtained the day before the inspection. Cars should be inspected, cleaned, and filled with gas. 7. Office personnel should be encouraged to be in their office when the Inspectors are scheduled to be in their area. 8. Tour Guides - Guides, who host the Inspection teams at each unit, should be prepared and have a message. Involved discussions about the process should be discouraged. Use hourly personnel where possible. Guides should have a pre-planned route, but should be flexible to the inspector's desires. Every person in the units should have a name tag, listing occupation, the day the unit is Inspected. It should be emphasized to the units to minimize the number of changes in guides after the names have been given to SHAC. 9. Hosts - Each Inspector was hosted by a SHAC member. Hosts were rotated at noon each day. The plant manager "free-lanced", but was with the Inspection teams throughout the inspection. General superintendents met the teams at each area of responsibility. -3- LAM001392 SC 000195 F. ANNUAL INSPECTION - cont'd. 10. Information packets - Each inspector was presented an information packet containing the following items: a) Monsanto vinyl attache case with name embossed. b) Brcwn vinyl Monsanto clipboard. c) Monsanto pen and penci1 set. d) Monsanto Guide to Accident Prevention booklet. e) Contractor Guide to Accident Prevention. f) Emergency Procedure and Fire/Spill Alarm card. g) Battery limits piping color code chart. h) Miscellaneous literature of Texas City Plant. i) Small pocket notebook. 11. Personal Needs - Each inspector was supplied with a hard hat, safety glasses, ear plugs, and cover goggles. Rain gear Csuits and boots) were obtained in case of rain. Names were pre-printed on the hard hats. Name tags and temporary badges were also provided. 12. The 1984 inspection team made a sumnary report to 400 members of the plant In the cafeteria. The report took approximately one-half hour and was well received by all who attended. E. P. Bailey, Chairman R. T. Hartmann S. W. Mono la J. T. Payne J. D. Richards J. A. Stal -4- LAM001393 SC 000196 EXHIBIT I DATE 7/1 7/23 8/1 8/1 8/15 8/6-17 8/15 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 Comnittee responsibility for publicity. RTH Complete. Send copy of previous inspection, recommendations to Superintendents. By 8/31 all Items complete - written response. JAS Complete. Send out notice that all ladders are to be inspected and new tags attached by 9/1. Inspectors named. RTH RAF Complete. Complete 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 Complete. 3rd Quarter Safety S Housekeeping Insp. SWM Complete. 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 Complete. 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 JAS by cafeteria including designated eaters). Four cars reserved - drivers S movers JTP selected. Complete Complete On Order. Complete. Complete. SC 000197 LAM001394 9/4 9/5 9/5 9/10 9/10 9/13-14 9/18 9/19-21 9/24 10/3 Mail information to inspectors. JAS SHAC drive around inspection -- made si ides. Use 3rd Quarter comments. Communicate inspection schedule. JTP Include pictures and history of inspectors In plant newsletter. JAS Expanded Staff -- review slides, inspection details and check list. JTP Obtain equipment for inspectors -- hard hats (with names), safety glasses, ear plugs, cover goggles, rain gear (suits and boots), name tags, and temporary badges. RTH Drive around Inspection -- each General EPS Superintendent accompanied by one SHAC members. Short wrap-up staff meeting after Inspection. Evening meal with inspectors and presentations. EPB Inspection ALL Feedback Critique JAS SHAC Complete Complete Complete Complete Complete JAS:sr 6-12-84 SC 000198 -2- LAM001395 EXBIHIT II EMERGENCIES 1. What is your area fire/spill code? Where can you find out if you're not sure? The area fire code is listed on the plant phones. 2. How do you report a fire/spill? Dial 112 + the area code, stay on phone till the guard answers; tell guard location and nature of problem. 3. How would you get an ambulance or medical assistance to an area? Dial 2222 on the plant phone -- the guard will answer -- tell him the location and nature of the problem; he will contact the medical department for re sponse. 4. Where and who do you report to when the fire/spill alarm sounds? "STOP ALL WORK AND SPARK PRODUCING EQUIPMENT" -- Go to the nearest designated instruction point and report to the warden. All people report to an Instruction point when the fire/spill alarm sounds. REMEMBER -- Spectators are not permitted to attend any emergency. 5. What do you do when you are driving a motorized vehicle, and the fire/spill alarm sounds? Move the vehicle to side of road, turn-off ignition, leave keys in Ignition, and report to nearest instruction point. 6. Why should you know the wind direction, and how can you find out? Observe steam vents, flags, wind socks, etc. for wind direction. You should know this for a plan of escape, if necessary for vapor movement. Once at your instruction point, wind direction and velocity will be passed on to you by your warden. 7. What is the alarm for a major emergency? 10 aecond blast of plant siren, and air horn followed by rapid succession of blasts on air horn. 9/11/84 VPO :sr LAM001396 1 SC 000199 8. What is the alarm for evacuation? Continuous blast of plant siren, and air horn. 9. Do you know where the fire extinguishers are in your work areas, and do you know how to use them? After you've located the fire extinguishers, learn to use it. Ask your super visor for assistance, so you will know how to use it. 10. How often are fire extinguishers' capacity checked? Each area should read the gauge weekly on their fire extinguishers, and our Loss Prevention group checks them each 6 months. 11. How do you get a fire extinguisher recharged or repaired? Call the Fire Department, and report the problem; they will send someone to correct it. 12. How is a fireman's bicycle designated, and what is the rule for using It? All firemen's bicycles are painted red, and they are to be ridden by firemen only. 9/11/84 VPO :sr -2- LAM001397 sc 000200 INSPECTIONS 1. How often do we inspect building elevators? Each month by Houston Elevator Company. All elevators are required to have an annual inspection. 2. How often do we inspect hoses? What color tape should the current Inspected hose have on them? Utility hoses are inspected every 6 months. The current color code (tape) should be white. Steam hoses are hydrostatically tested each year and are visually inspected each 6 months. Transfer hoses, as on the docks, are hydrostatically tested each 12 months and are stamped on a plate on the hose. 3. How often do we inspect hoists (chain falls), and what color dot designate the current inspected hoists? Inspected with a test load yearly, and current inspected hoist should have a white dot on them. 4. How often do we inspect fire extinguishers? They should be checked weekly by owning department, and checked by Fire Department every 6 months which is recorded on a tag hanging on the extinguisher. 5. How often do we check eye baths and emergency showers? Operating units check theirs daily. Others should be checked daily also. The required period is weekly. 6. How often do we inspect manlifts? They are inspected monthly by Safety Department, but should be Inspected daily by users. 7. How often do we inspect grinding wheels? Wheels are dressed and inspected weekly by machinists, but should be check daily by users. 8. What is the normal inspection time on relief valves? Normal inspection time is yearly. Some valves are scheduled on a 24 month cycle as determined by area needs. 9/12/84 AM B; VPO: sr LAM001398 1 SC 000201 9. How often are ladders inspected? Ladders should be visually inspected by the user each time the ladder is used. Annually all ladders must be inspected and have a Ladder Safety Inspection tag permanently attached to the ladder. A permanent recored of the annual ladder inspection will be kept in each area by the owners. 10. How often are breathing air hoses inspected? Every 6 months, and color coded for the period inspected. Present color is white. 11. How often are deluged sprinkler systems checked? They are checked and recorded weekly. A drain test Is performed monthly. 12. How often are area emergency lights checked? They are checked weekly. 13. What pressure are steam hoses hydrostatically tested? Once a year, normally in January, steam hoses are to be hydrostatically tested at 115 psig. 14. Is record keeping for utility hose inspections required? NO -- ONLY color coding of the hose itself. Current color is WHITE ("2nd Half - Even Year") 15. How often must boilers be inspected? Every boiler must be inspected by an authorized inspector, stamped with a state registration number, and a Certificate of Operation issued and displayed under glass, on or near the boiler before the boiler Is placed in service. Thereafter, boilers must be inspected internally at intervals not to exceed 12 months; unless, an extension has been requested and granted by the inspection agency. Mqjor repairs and all repairs to pressure parts by welding are subject to Inspection and approval by the authorized inspection agency. SC 9/12/84 AM B; VPO :sr 000202 -2- LAM001399 WORK PROCEDURES S PRECAUTIONS 1. When assigned a job to be done in a Production unit, what should be done before entering the unit, and why? Check with Chief Operator to be sure to be sure it is safe to work In the unit, and also to let him know you are in the unit In the event of an emergency. Inform him when you leave the area also. 2. What procedure must be used before working on any rotating equipment? Describe this procedure. The Lock-Out Procedure must be used. Inform Chief Operator of what equipment Is to be worked. His people should go the the equipment and turn-off switch. Both you and operator go to the breaker room and install production lock and your lock on breaker that has been turned off for this equipment. Both you and operator go back to the piece of equipment and try switch to make sure the correct main breaker was turned off. Be sure to remove your lock when the job is complete. 3. When entering a unit to perform work, what are some things that you should be aware of? You should be find out what the fire and spill code is for that area. You should find out what type of personal protective equipment is to be used, such as, cover goggles, ear plugs, etc. You should find out where the emergency instruction point is, and who the wardens are. You should be aware of the chemical hazards In the area. You should locate safety shower or eye baths near your assigned work. You should be aware of the wind direction and an escape route in the event of an emergency. You should locate the nearest fire extinguisher in the event you need it. Think of others. 4. What work requires a Fire, Entry, or Special Permit? Work performed In the plant which might provide a source of Ignition, require the entry into a closed vessel, or be of an especially hazardous nature. A closed vessel is defined as any piece of equipment which must be entered through a manhole, or constricted opening; this could be a ditch or excavated area. 9/14/84 VPCKsr -l- LAM001400 SC 000203 5. What is the rule for people who wear'contact lenses, that enter laboratories, or manufacturing areas? Contact lenses are not be worn in manufacturing areas, or laboratories; unless cover goggles are worn. 6. Is a work permit required for hydroblasting? Only trained people shall be permitted to operate hydroblasting equipment. A work permit is required. 7. Who is required to wear a life jacket on barges? Any employee who goes onto the barge for any reason. 8. Where may work be performed that might provide a source of ignition and not require a fire permit? In main Shops Building, unless work is to be done on a closed or contaminated vessel. Also, in certain designated "open areas" in the plant that have an open area permit. 9. When does the Texas City terminal railroad switch engine in the Plant normally? On Monday through Friday at 1700 till about 2000, depending on the number of cars being switched In and out. On Saturday, a switch normally does not occur. The switch on Sunday Is normally In the early afternoon. When the engine Is in the plant, the yellow lights along the track should be flashing. 10. How far from the railroad track can equipment be placed? No less than 6 feet from the rail. This clearance must be maintained at all times. 11. Who checks condition of electrical hand tools and extension cords; how do you know they have been checked? All electrical hand tools and extension cords must be checked and tagged as to their safe condition by the Electric Shop, before they are issued from the Tool Room. 12. Yellow colored pipe designates what type of material? Superhazardous products, such as, HCN, ACY, LN, liquid chlorine, or any line which normally contains or may contain greater than 0.5% free HCN. 9/14/84 VPO :sr sc 000204 2- - LAM001401 PLANT INSPECTION S SAFETY PROMOTION TEAMS 1. When is the plant inspection set for? Wednesday, September 19, 1984 Thursday, September 20, 1984 Friday, September 21, 1984 2. What is the 1984 THEME for the Inspection? "Safety Through Employee Involvement" 3. Who are the Inspectors, and where are they from? All of the inspectors are from the Chocolate Bayou Plant. They are: Bob Jones Rick Atchinson Jim Graham Neil Ingram Dave Scarr Pete Colburn - Chairman 4. When will the inspection results be given and where? Monday, September 24, 1984, at 1400 p.m. In the Cafeteria. Everyone available is invited. 5. What does STOP stand for? Safety Training Observation Program 6. What does PMSB stand for, and who Is on PMSB? Plant Manager's Safety Board. Members are: Gene Tromblee Ray Forsthoffer Jack T rafton R. L. Hammond Paul Bailey George Bostick Bob Hammann George Pappas Tom Ryan Gene Wofford Doug Metten Bill Lancaster George Small John Hagood - Chairman 9/14/84 VPO :sr -1_ LAM001402 SC 000205 7. What is the function of PMSB? The PMSB will act to establish and approve safety policies at the Texas City location. They will establish goals and objectives to fulfill the Monsanto Safety Policy. 8. How often does the PMSB meet? Monthly. 9. What does SHAC stand for and who is on SHAC for 1984? Safety and Housekeeping Action Committee for 1984. Members are: Paul Bailey Jack Richards Joe Stal Thurman Payne Steve Moncla Bob Hammann - Chairman 10. What is the function of SHAC? This committee is responsible for: a. Management and execution of overall Plant safety and housekeeping programs. b. Decision and follow through on the appropriate actions necessary to resolve specific problems. c. Investigation and response to suggestions from the Hourly Safety Committee. d. Execution of assignments as designated by PMSB/SAC. e. Implementation of the contractor safety rules as pertains to CED and non-plant employees working on the site. 11. How often does SHAC meet? Weekly. 12. What does SAC stand for, and who are the members of SAC? Safety Advisory Committee. The members are: Tom Ryan George Bostick R. L. Hammond Bob Hammann - Chairman - Exofficio member 9/14/84 VPO:sr SC 000206 2- - LAM001403 13. What is the function of SAC? Formulating and recommending plant safety policies to the Plant Manager and PMSB. The committee has the responsibility and authority to investigate Individual safety matters, to consult with others for advice or assistance and to decide those changes in policy which will be presented to the Plant Manager and PMSB for approval. 14. How often does SAC meet? Monthly. 15. Who is on the Process Technology (PT) Safety Committee this year? Kay Finney Bill Haynes James McGinty Glen Olson Y. C. Liu David Hanson - Chairman 16. What is the function of the PT Safety Committee? Due to the unique problems of the PT Department as pertains to safety and housekeeping considerations, a special committee of members from this organization will be maintained to formulate internal policies and to provide input to the PMSB and SHAC. 17. How often does the PT Safety Committee meet? Monthly. 18. Who is on the Office Safety Committee this year? Leo Garza Penny Johnson Tom Biegel Laura Inskeep Sue Mears Elaine Salles Greg Stadter Martha Thompson Mike Ward Mark Riddle - Chairman 19. What is the function of the Office Safety Committee? Provide safety programming of all types. Including safety meetings for office personnel wherever their offices may be located. 20. How often does the Office Safety Committee meet? Monthly. 9/14/84 VPO :sr SC 000207 -3- LAM001404 21. Who is on the Hourly Safety Committee (HSC)? Oscar Jordan Larry Bonds James Platt Ben Peek Robert Kozlek Daniel Nelson Charles Davis Madeline Hare 22. What is the function of the HSC? Chairman Provides participation in the plant safety program by hourly employees wherein the exchange of ideas and suggestions can lead to an improvement in the plant overall safety performance. 23. How often does the HSC meet? Monthly. 24. Who is the unit/craft safety representatives for your unit or craft? Discuss your contact supervisor, hourly representative. Instrument representative, HSC, unit maintenance foreman, and unit maintenance craft representative as it pertains to your area or craft. 25. What is the function of the unit safety promotion teams? Provide an effective tool to deal with safety needs and problems unique to individual operating units or groups. 9/14/84 VPO :sr SC 000208 -4- LAM001405 GUIDE TO ACCIDENT PREVENTION 1. Your job has 4 basic requirements. What are they? 1. Knowledge - THE SAFE WAY - know the safe way to perform your work. 2. Thought - THINK BEFORE YOU ACT. 3. Awareness - TAKE NOTHING FOR GRANTED. 4. Application - WHEN IN DOUBT - CONSULT YOUR SUPERVISOR OR CHIEF OPERATOR. 2. What is our safety slogan? SAFETY IS AN INDIVIDUAL RESPONSIBILITY. 3. What does RED barricade tape mean around an area? This color tape used to restrict entry into an area by unauthorized personnel because of chemical spill or fire. 4. What is the normal personal protective equipment required In the plant? Hard hat, safety glasses, cover goggles, long pants, and closed toed, non-porous shoes. 5. What safety device is required to prevent two crow's feet from coming apart? A lanyard pin. 6. What are the 3 classes of fire extinguishers, and what are they used on? 1 OF FIRE TYPE OF FIRE EXTINGUISHER TO USE A WOOD, PAPER WATER B OIL DRY CHEMICAL OR C02 C ELECTRICAL DRY CHEMICAL OR C02 7. What type of vessels or line CAN NOT be hot tapped? Lines or vessels containing acetylene, ammonia, chlorine, or oxygen including compressed air shall NOT be hot tapped. 9/17/84 VPOrsr SC 000209 -1- LAM001406 8. Do you add water to acids or acids to water? Always add acid to water slowly and stir to dissipate heat. 9. Name some of the respiratory protection available in the plant. 1. Canister type gas masks. 2. Air line or supplied air equipment. 3. Chemical cartridge-type respirators. 4. Dust (filter-type) respirators. 5. Self-contained air mask (Scott MSA) 6. Pocket type respirator. 7. Escape mask. 10. What'requirement is necessary on platforms or scaffold more than 10 feet above the ground or floor? Handrails and toeboards are required on all open sides and ends of the scaffold or platform. 9/17/84 VPOisr SC 000210 -2- LAM001407 SAFETY PRACTICES 1. EMERGENCY PROCEDURE PLAN (EPP) When there Is little or no advance warning of the emergency, the EPP will be activated by a ten-second blast of the plant siren followed by a rapid succession of blasts on the code horn lasting for approximately one and one-half minutes. At this signal, emergency organization personnel will report to duty stations. Non-assigned personnel should report to their Instruction points. 2. LADDER INSPECTIONS Each area which owns ladders must have written record of annual inspections. Ladders must have annual inspection tag on ladder. The ladder must be numbered to Identify the ladder and show ownership. It must have sticker which states "Inspect Ladder Before Using". All ladders to be Inspected visually by the user before using it. 3. SAFETY EQUIPMENT INSPECTIONS A. Weekly 1. C02 extinguishers and dry chemical extinguishers - 2. Eyebath and safety showers (Including flushing, alarm testing, and condition of light and signs) B. Monthly 1. Breathing air pipelines 2. Respiratory equipment C. Semi-Annually 1. Utility hoses 2. Breathing air hoses 3. All fire extinguishers D. Annually 1. Ladders 2. Steam hoses - hydrostatic 3. Marine and chemical hoses 9/18/84 VPO :sr SC 000211 1- - LAR/1007408 4. LOCKOUT PROCEDURE A. Used on mechanical equipment to prevent movement which could cause injury to personnel or damage to equipment (padlocks). B. Used on piping systems to prevent contamination or pressure release while a system is Isolated (padlocks and carseals). C. Electrical circuits to prevent energizing a system which could cause personnel Injury or equipment damage (padlocks). D. Electrical/Instrument Devices may require valves blocked In as well as electrical circuits locked out (padlocks and carseals). 5. Chain hoists are Inspected yearly with a test load. The ones tested this year have a WHITE dot on the body. The user should visually check a hoist each time it is used. 6. Utility hoses are inspected each 6 months. The present color for 2ND HALF EVEN YEAR Is WHITE. 7. Relief valves are normally pulled and tested once a year unless specified. They are tagged with the test date and test pressure on the valve. A IBM print-out is sent to all owners with records of relief valves and test dates. 8. All contractors working in the Plant are presented a safety orientation program conducted by pla'nt personnel. They all have monthly safety meetings along with weekly area meetings. All contractors abide by Monsanto's safety policies as described in our P-Bulletin manual. Their health practices such as, personnel exposure reductions, noise hygiene, asbestos hygiene, etc. follow Monsanto's guidelines. 9. STOP is a method of safety training to learn to observe conditions and situations to eliminate safety hazards and personnel injury. STOP cards are utilized not only to Identify the condition, but to report the corrective action taken to eliminate the unsafe act or condition. 10. INJURY/INCIDENT INVESTIGATION The general superintendent of the department In which the injury or incident occurs is responsible for the Investigation of the injury/incident review, approval, and distribution of the reports, and for corrective actions defined in the report. The timing allowed for these investigations and reports is no longer that 5 working days. Investigations are to start immediately on Injuries or Incidents. This applies to contractors as well as Monsanto personnel. Follow-up on corrective actions is ongoing with written updates required. 9/18/84 VPO :sr LAM001409 SC 000212 11. PLANT SAFETY This year we've had only two recordable injuries. There have been no loss work day cases. Find out safety statistics from your area or craft foreman. This is one of the best safety records this plant has had. 12. What are some of the off-the-job safety promotions the plant has? A. Safety magazine sent to homes. B. Health fair at Nessler Center. C. RAPE program by Office Safety Committee. D. Defensive driving course. E. Red Cross sponsored CPR courses. 9/18/84 VPO :sr SC 000213 -3- LAM001410 EXHIBIT III 1984 TEXAS CITY SAFETY AND HOUSEKEEPING INSPECTION GUIDELINES THEME SAFETY THROUGH EMPLOYEE INVOLVEMENT MAJOR OBJECTIVES Help the Plant. ' Emphasis Involvement at all levels while specifically keying Into wage and first line supervision. ' Provide ample opportunity to share experiences. ' Audit bottom line effectiveness of plant programs. ' Be cost effective. EMPHASIS AREA * Safety/Loss Prevention Programs/Practices --Procedures ::Are safety procedures up-to-date and accessible to everyone --Job Safety Analysis/STOP Program Effectiveness --Personal Protective Equipment --Industrial Hygiene Practices "Hearing Conservation Program --Incident Investigations "Timeliness and Follow-up --Emergency/Disaster Planning "Employee understanding --Participative Management Approaches "Acceptance and effectiveness of unit/craft safety team "Effectiveness of safety log book --Condition of Safety Equipment "Ladders, hoses, hoists, relief valves ' Safety Training * Employee Perception of Safety Commitments * Off-The-Job Safety "What can plant do to help ` Contractor Safety 6 Health ' Housekeeping INSPECTION DATE The plant will be inspected September 19, 20, 21, 1984. LAM001411 SC 000214 INSPECTION TEAM Team Organization --Exchange Inspection Teams --Inspection Team - Texas City General Superintendent-Chairman- Bob Jones Superintendent - Neal Ingram Safety Superintendent - John Usrey Engineer - Jim Graham Foreman - Dave Scarr Hourly - Rich Atchison --One Team Member From Safety Department --Inspection Will Last Three Days Plus Feedback --Training Will Be Responsibility of Team Chairman RATINGS No competition between plants. Outstanding departments will be highlighted for recognition. INSPECTION RESULTS The general results of the plant Inspection, including the outside areas, will be ccnmun I cated at 2 P.M., Monday, September 24, 1984. The results will be communicated to all personel not needed to run the plant in the cafeteria. SC 000215 -2- LAM001412 EXHIBIT IV Plant Inspection Set For September 19, 20, 21 This year's Safety and Housekeeping Inspection will be September 19, 20 and 21. The 1984 theme, "Safety through Employee _ Involvement", means the inspectors will be looking for employee participation in safety pro grams and practices. Some examples of possible topics for discussion include: Permits and Procedures Job Safety Analysis and STOP effectiveness Incident Investigation Practices . 'Safety Training In addition, as always, the team will be checking on housekeeping and the condition of safety equipment. The inspection results will be given Monday, Sept ember 24 at 2 p.m. in the cafeteria. Everyone available is invited to attend. Inspectors for this year are all from the Chocolate Bayou plant: Rick Atchison, Jim Graham, Neil Ingram, Bob Jones, Dave Scarr, and Red Usrey. Following is a picture and brief background on each. santo-Chocolate Bayou in 1976. Rick resides in League City with his wife, Patricia, and their two children. JIM GRAHAM James P. "Jim" Graham is Group Supervisor, Instrument Development and Control in the Technology group at Chocolate Bayou. He earned a B.S. degree in chemical engineering from New Mexico State in 1969 and joined Monsanto-Texas City as a process engineer in the Tech nology group that same year. Jim assumed his current position in 1983. He and his wife, Susan, and their son live in LaMarque. RICK ATCHISON Richard L. "Rick" Atchison is a processor in the sorbic manufacturing area at Chocolate Bayou. He joined Mon- i NEIL INGRAM i LAM001413 SC 000216 Neil M. Ingram is Superintendent of Plant Engineering at Monsanto-Chocolate Bayou. He earned a B.S. degree electrical engineering from Louisiana Tech in 1977 and ,^med Monsanto-Chocolate Bayou that same year as a maintenance engineer. Neil and his wife, Kay, reside in Alvin. BOB JONES Robert N. "Bob" Jones is Superintendent of Manufac turing at Monsanto-Chocolate Bayou with responsibility for the IDA/NTA, SAB, DPO/Formalin product lines. earned a B.S. and M.S. in chemical engineering from the University of Arkansas in 1965 and 1966, respectively. Prior to assuming his current responsibilities this year. Bob worked at El Dorado, Arkansas; Anniston, Alabama; Muscatine, Iowa; Deep River, Connecticut and General Offices and Queeny plant in St. Louis. Bob resides in Alvin with his wife, Barbara, and their three children. DAVE SCARR w,,vid A. "Dave" Scarr is a shift foreman in the acrylonitrile manufacturing area at Chocolate Bayou. He joined Monsanto Chocolate Bayou as a processor in 1979 and assumed his cur rent position in 1982. Dave resides in Alvin with his wife, Barbara, and their son. SC 000217 John C. "Red" Usrey is Safety and Loss Prevention Super intendent at Chocolate Bayou. He began his career at Chemstrand in Pensacola, Florida in February, 1954 as a chemical operator trainee. He transferred to Chocolate Bayou as a production foreman in hydrocarbons in February, 1962 and assumed his current position in June, 1980. Red and his wife, Nell, reside in Alvin. TEST YOUR SAFETY KNOWLEDGE In preparation for the September 19-21 Safety and Housekeeping Inspection, test your safety knowledge on the puzzle below. The answers are on Page 4. ACROSS 1) Abbr. for Plar.t Manager's Safety Board 4) safety rules and regulations 5) Think you act 6) 1984 Safety and Housekeeping Inspection Theme- Involvement (with 17 across and 7 down) 8) Complacencyto accidents 9) I am responsible foractions 11) See 10 down 12) Do you know your fire and spill ------------------ 13) Practice driving 14) Safety is---------------to cost, quality, production and morale 17) See 6 across 18) permit before starting work DOWN 2) Plant Safety Slogan - is an Individual Responsibility 3) Take immediate action when you observe an unsafe act 7) See 6 across 10) Be safe both at -------------- and at------------------ (with 11 across) 15) Most injuries are caused by unsafe -- 16) Always wearprotective equipment LAM001414 EXHIBIT V INSPECTION TOUR SCHEDULE TUESDAY NIGHT, SEPTEMBER 18 PRESENTATIONS 1. Introduction - Welcome - Plant History and Operating Status 2. Overall Texas City Safety Program G. L. Tromblee (Gene) Plant Manager Minutes 15 R. T. Hamnann (Bob) Loss Prevention S Safety Supt. 15 3. Plant Manager's Safety Board (PMSB) and Safety Advisory Comnittee (SAC) G. W. Bostick (George) Services Superintendent 15 4. Safety and Housekeeping Action Comnittee (SHAC) E. P. Bailey (Paul) Maint. Supt., West Plant 15 5. Hourly Safety Comnittee (HSC) 6. Technical Center Safety Comnittee (TCSC) 7. Office Safety Comnittee (OSC) 8. Inspection Kickoff 0. D. Jordan (Don) Carpenter, Plant Engineering 5 K. Finney (Kaz) Sr. Chemist, Technical Services 5 L. Garza (Leo) Technician, Process Technology J. A. Stal (Joe) Group Supv., Process Technology 5 5 LAM001415 SC 000218 EXHIBIT VI 1985 RECOMMENDED INSPECTION TOUR SCHEDULE FIRST DAY Arrive Texas City (Cafeteria Conference Room) Distribution of Safety Equipment. Coffee S Rolls. Begin Inspection. 0800 0815 Walk To Power 2. WATER TREATING - PL4NT AIR - POWER 2 Treatment of raw Brazos River water for plant use and generation facilities for breathing, Instrunent, and general plant air. Facilities for steam generation and boiler feed water treatment. 0820-0900 HOSTS INSPECTORS SHAC MEMBER Meet in Control Rocm. 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 fac i 1 i t i es. 0905-0945 HOSTS INSPECTORS SHAC MEMBER Park beside Control House. Meet in Control Rocm. Drive to Phthalic Anhydride Control House. 1 LAM007416 SC 000219 DEPT. 53 PHTHALIC ANHYDRIDE Manufacturing process which uses BASF technology to convert air and orthoxylene to phthalic anhydride. HOSTS INSPECTORS SHAC MEMBER Drive to Dept. 48-56. COFFEE - OXO-ALCOHOL - PHTHALATE ESTERS DEPT. 48/56 0X0 ALC0H0L-PHTHAL4TE 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 0950-1030 Park beside Control House. Meet in Control Room. 1035-1050 1050-1120 Park at Formaldehyde Storage Area (77T101). Walter Meet in Control House. 1120-1150 Meet In Control House. Pick up cars at 56T16, drive to car port. LUNCH - Cafeteria Conference Room 000220 SC 2- - 1155-1255 LAM001417 Walk to Zone I Office. ZONE I OFFICE - OPERATING ENGINEER'S OFFICE Offices and conference room used by maintenance personnel for styrene process. Offices for operating engineers personnel. HOSTS INSPECTORS SHAC MEMBER 1300-1310 Split Team. HOSTS INSPECTORS SHAC MEMBER Walk to Fire Station. FIRE STATION Two buildings which house the Texas City plant's fire fIghting faci1itIes. HOSTS INSPECTORS SHAC MEMBER Walk to Electric Shop. 1315-1325 - 3 SC 000221 LAM001418 ELECTRIC SHOP Consists of central shop facilities and offices for power distribution, electrical maintenance, and maintenance enginee ring pe rsonne1. HOSTS INSPECTORS SHAC MEMBER 1325-1340 Walk to AN loading rack. AN LOADING RACK, ESTERS LOADING RACK, TANK TRUCK RACK, SCALE HOUSE Rail car handling "faci1 11ies for acetic acid, methanol, TBA, sulfuric acid, IBY, ACH, and esters. HOSTS INSPECTORS SHAC MEMBER 1340-1410 P.ick up cars at truck loading spot west of 51T17-2. Drive to Dept. 513 Control House. COFFEE - PRIMARY TREATMENT (arrangements by department) PRIMARY TREATMENT, AMMONIA TANK Facilities for primary treatment of all plant aqueous waste streams. Arrmonia storage tank provides raw material for AN manufacturing facilities at Texas City and Chocolate Bayou. HOSTS INSPECTORS SHAC MEMBER 1415-1430 1430-1500 Meet at 513 Control Room. SC 000222 -4- LAM001419 Drive through sandblasting, NS I Warehouse, Maintenance Laydown, Salvage Areas HOSTS INSPECTORS SHAC MEMBER BARGE SHIP DOCKS 5, 4, 3, 2, 1 Barge and ship ioading/unloading facilities for raw materials, products, used at and produced by Texas City plant. HOSTS INSPECTORS SHAC MEMBER Drive through South 22. HOSTS INSPECTORS SHAC MEMBER Drive to carport RECAP - Cafeteria Conference Rocm 1500-1510 1510-1550 1550-1605 1605--? "5- LAM001420 SC 000223 1985 RECOMMENDED INSPECTION TOUR SCHEDULE SECOND DAY CAFETERIA CONFERENCE ROOM - Coffee 6 Rolls Walk 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 Pi lot Plant. 0820-0830 SUPER SHACK, AN INCINERATOR, STYRENE RACKS, AND ACY RACK HOSTS INSPECTORS SHAC MEMBER 0830-0850 DEPT. 13 AKLYLATION, CT-1 Ethylbenzene is produced by the reaction of benzene with ethylene in the present of an aluninun chloride-organic catalyst complex. HOSTS INSPECTORS SHAC MEMBER SC 000224 6- - 0855-0920 Meet In Control Room. LAM001421 DEPT. 15 DEHYDROGENATION Synthesis area for dehydrogenation of ethylbenzene to crude styrene. HOSTS INSPECTORS SHAC MEMBER 0920-0945 Meet at CT-1 COFFEE - STYRENE/E8 (arrangements by department) DEPTS. 14 S 16 STYRENE - EB DISTILLATION Dept. 14 - Ethylbenzene purification facilities. Dept. 16 - Styrene purification facilities. HOSTS EB INSPECTORS SHAC MEMBER SM 0945-1000 1000-1020 Meet in Control Room. Drive to Salt Water Pump House and Zone 1 Warehouse. SALTWATER PUMP HOUSE AND ZONE 1 WAREHOUSE HOSTS INSPECTORS Zone 1 Warehouse SHAC MEMBER 1025-1035 Split Team. Pimp House -7- LAM001422 SC 000225 Drive to car port. 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-E-F-G Warehouse A contains class A materials such as spare parts, paper goods, packing materials. Serves receiving function. Warehouse B contain flamnable 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 1115-1135 Split team. Park across from Zone 2. SC 000226 LAM001423 Drive to Zone 2 office ZONE 2 OFFICE Offices for west plant maintenance personnel. HOSTS INSPECTORS SHAC MEMBER 1135-1145 CED OFFICE AND WAREHOUSE Offices for CED constuction personnel and CED project storage. HOSTS INSPECTORS SHAC MEMBER 1145-1155 Split team. Drive to Cafeteria LUNCH - Cafeteria Conference Room Walk to Research 1 RESEARCH NO. 1 This building houses analytical,, catalyst characterization, radioisotope, and MIC Tech Services labs and bench scale reactor systems. HOSTS INSPECTORS SHAC MEMBER 1200-1300 1305-1345 Meet 1st floor west side. 9- - LAM001424 SC 000227 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 1345-1425 Meet at Visitor's lobby Northwest corner - 1st floor. 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. HOSTS INSPECTORS SHAC MEMBER 1425-1445 Meet at North entrance belew stairway outside. PT WAREHOUSE S SOLVENT STORAGE HOSTS INSPECTORS SHAC MEMBER 1445-1500 Meet at PT Warehouse Walk to Main Office Building. SC 000228 - 10 - LAM001425 COFFEE - CAFETERIA (arrangements by Cafeteria) CAFETERIA Main plant cafeteria. HOSTS INSPECTORS SHAC MEMBER 1505-1520 1520-1530 Meet at cash register. DISPENSARY Provides facilities for emergency first aid and for monitoring employee health. HOSTS INSPECTORS SHAC MEMBER 1530-1540 MAIN OFFICE - 2nd and 3rd floors Main Office building for manufacturing, distribution, environmental, safety, personnel and marketing personnel. HOSTS INSPECTORS SHAC MEMBER 1540-1600 Split teams. Meet in foyer. 2nd Floor 3rd Floor LAM001426 ll SC 000229 QUALITY ASSURANCE LAB Laboratory factl111es needed to conduct analyses required for production and shipment of petrochemicals from Texas City plant and for environmental control. HOSTS INSPECTORS SHAC MEMBER RECAP - Cafeteria Conference Room 1605-1625 1630-? SC 000230 12 LAM001427 1985 RECOMMENDED INSPECTION TOUR SCHEDULE THIRD DAY CAFETERIA CONFERENCE ROOM - Coffee S 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 2nd floor Cat Xerox). PERSONNEL TRAINING, PURCHASING BUILDING Building contains plant purchasing offices, training facilities, video tape lab. HOSTS INSPECTORS SHAC MEMBER - 13 - 0840-0855 Meet In Personnel Building Training Room. sc 000231 LAM001428 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 GUARD HOUSE Major plant entry gate with offices for supervisors and security group. HOSTS INSPECTORS SHAC MEMBER 0855-0910 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. Aimonia 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. 000232 - 14 - LAM001429 Drive car to methanol CAN hosts drive cars to Methanol) COFFEE - METHANOL (arrangements by dept.) DEPTS. 44-45-46 METHANOL, CT-3S4 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 1025-1040 1040-1110 Meet i n Control House DEPTS. 19-23-25-27-29 HCN-ACN-TBA-LN-ACY, CT-2 Manufacturing facilities for acetonitrile purification, tertiary butyl amine, 1 actonitrlie and acetone cyanohydrin. HCN Storage. HOSTS INSPECTORS SHAC MEMBER 1115-1145 Meet t n Control House Drive to Cafeteria LUNCH - Trays In Cafeteria Conference Room 1150-1250 000233 - 15 - LAM001430 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 1250-1320 Meet at Shift Office SOUTH MAINTENANCE BUILDINGS, INSTRUMENT SHOP S GARAGE Building Include carpenter-insulator shop, instrument department shop, field maintenance offices, and garage facilities. HOSTS Maintenance INSPECTORS SHAC MEMBER 1320-1405 Instrument RECAP - Cafeteria Conference Room 1410-? - 16 - LAM001431 SC 000234