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VCM HEALTH TRAINING PROGRAM ABERDEEN FEBRUARY, 1977 1. Title (Typed slide) 2. Type Slide 3. Type Slide 4. Type Slide 5. Tank Farm/ Super Type 6. Frostbite Limb 7. Gas leak cartoon -1- -f Today we want to talk to you again about ways to further reduce your exposure to vinyl chloride monomer (VCM), the raw material we use here in the manufacture of poly vinyl chloride (PVC) plastic resin. Vinyl chloride monomer became regulated under the Occupational Safety and Health Act in April, 1975. These regulations apply to the manufacture, reaction, trans portation, storage, handling, or use of VCM or PVC. Because of the technological advances over the last year, these regulations do not apply to the handling or use of products made from PVC, such as Compound, Dry Blend etc. VCM, stored in these tanks, is a colorless, sweet smelling gas at normal temperatures and a liquid under pressure. It is handled as both in our plant. You should avoid situations where VCM could be smelled or touched. Liquid VCM could cause your skin to become severely frostbitten. You are likely to come in contact with VCM only through leaks or spills. VAB.0001078218 8. Type slide or Reynolds 9. Type Slide 10. New Slide (Fire) 11. New Slide (Nurse) 12. Type slide 13. New slide 14. Type slide -r -2- VCM has been labeled as a hazardous material. Breathing in high concentrations can cause dizziness or create a narcotic effect. VCM has a flash point of minus -108 degrees Farenheit and has explosive limits that make it three times as flammable as gasoline. VCM releases highly toxic and irritating fumes of hydrogen chloride gas when it burns. In halation of sufficient quantities can cause severe lung damage or death. Conoco, through the Medical Division, is continually monitoring the health of its employees by regularly testing blood samples. These samples are drawn twice per year. Disclosures over the past years have in dicated that exposure to EXCESSIVE con centrations of VCM over LONG periods of time could cause cancer of the liver, In the history of the manufacture of VCM and PVC, there have been 48 deaths recorded world wide from angiosarcoma, the rare liver cancer linked to VCM. The data to substantiate the link between liver cancer and VCM was released to the public in January, 1974 when B.F. Goodrich reported that the death of two employees may have been oc- VAB.0001078219 cupationally related to VCM. 15. Type slide 16. New slide 17. Type slide 18, Type slide 19. Type slide 20. Type slide 21. New typed slide i -3- 4 It is believed that the victims had been exposed to large concentrations of VCM over a number of years. Twenty*;Oner of the deaths were reported in the United States where there are an estimated 6,500 people in PVC/VCM manufacturing and about 97,000 in plastics and resin fabrication. To date, there have been no cases of angiosarcoma in any of Conoco's plants. Several years before the discovery of angiosarcoma, a finger bone disease, acroostosteolysis, known to us as AOL, was discovered and linked to the manual cleaning of PVC reactors. AOL is characterized by any combination of: -- a sensation or feeling that hands are cold, very small areas of damage to finger bones that are detected by X-ray examination, -- and a thickening and drying of the skin of the hands and forearms, The condition is reversable by removing the employee from exposure to liquid VCM, Conoco Chemicals is very concerned about the safety of its employees and therefore has done everything possible to reduce employee exposure to VCM, VAB.0001078220 22. Type slide 23. Type slide Sign 25. Split shot 26. Sign In Area 27. Type slide 28. New slide 29. New slide r--r -4-f With your help, we have achieved the maximum permissible exposure limit of one part per million averaged over an eight hour period plantwide, Certain parts of our plants will, however, continue to be designated as regulated areas because VCM concentrations occasionally exceed the maximum permissable exposure limit. Signs which say REGULATED AREA - CANCER SUSPECT AGENT AREA - AUTHORIZED PERSONNEL ONLY - are posted at each entrance . . . F There are two remaining regulated areas in our plant. They are Large Reactors and certain parts of the VCM Tankfarm . Before entering a regulated area, EVERYONE must sign the regulated area log for that area. Regulated areas are restricted to authorized personnel who have work assignments in those areas. All other personnel must stay out. The VCM health regulation also requires that appropriate respiratory protection be made available in plants manufacturing PVC or VCM. NIOSH has approved an organic vapor cannister type gas mask for use in environments of up to 25 ppm of VCM, however a 10 ppm maximum is used in our plant for this canniste^^^i^ir^^]. -5- A i Cannisters must be replaced after a total of four hours use or at the end of your shift, whichever comes first. 30. New slide Full face/ half/Scott Air Pak You will continue to be required to use respirators connected to our fresh air supply or a Scott Air Pak when: 31. Old 33 slide ! Opening and entering reactors, recovery knock-out tank, blow down tank, receiver or any vessel which has contained VCM. . . 32. Type slide (old 45) Take down and clean out of recovery lines. . . 33. Old 40 slide Changing VCM filters after recovery . . . 34, Old 41 slide Sampling the large reactors . . . 35. Old 43 slide Connecting or disconnecting VC railcars or working in the VCM compressor shed . . . 36. Type slide (old 49) Any job in an area where the concentration of VCM is greater than 10 ppm requires fresh air protection. 37. Type slide (old 50) Remember: Between 1 ppm and 10 ppm, use an approved cannister gas mask. Between 10 ppm and 1,000 ppm use an air-line respirator. Above 1,000 ppm or in unknown concentrations, use a Scott Air Pak. 38. New Shot The company has no objections to beards. VAB.0001078222 39. New shot 40. New shot 41. Type slide (old 54) 42. Old 60 slide 43. New Shot 44. Old SLide 57 -6- A However, you should know for your safety if a beard interferes with your achieving a tight seal on the face mask of your respirator, the beard should be trimmed or removed. Employees with beards will be requested to demonstrate by test to their Supervisor that they can maintain a godd face seal.' Minor mechanical failure such as leaky valves and seals could result in VCM concentrations in excess of the permissible limits, which are: 15 minutes at 5 ppm and an 8 hr. average of 1 ppm or less. Some indicators of VCM leaks are small ice formations, condensed water or frost on pipes, and hissing sounds from processing equipment which contains VCM like valves, flanges, packing and the like. Our continuous monitoring system graphically records the concentrations of VCM throughout the plant on the G,C. panels located in Large Reactor Control Room, Dryer Control Room and Q. C, Lab. The Lead Operator or Lead Technician will notify you of concentrations above the permissible limits of 1 ppm in your area either by twoway radio or the paging system. VAB.0001078223 45. New shot (Repeat respirator) 46. Type slide (old 59) 47, New Shot 48. New shot 49. Old #62 50. Old #63 51. Old 64 Type 52. New shot 53. Old #66 -7- A If the job you are doing requires you to remain in the area where VCM concentrations are above the permissible limits, you must wear the appropriate respiratory protection. If you are not required to stay, you must remain away from the area until you have been notified that the VCM concentration is below the permissible limits. When necessary, you will be issued protective coveralls and gloves. They must be worn along with your respiratory protection when: cleaning reactors, . . Unloading VCM tank cars ... Cleaning out sweco screens , . , or while performing any job where your skin might come in contact with liquid VCM. Disposable protective clothing should be n discarded after each use. The necessary VCM protective equipment will be issued to everyone, including non-employees. Non-employees will be required to use the protective equipment just as you do and to follow the same safety procedures regarding VCM. VAB.0001078224 54. old #67 55. New shot 56. New shot 57. New shot 58. Reshoot 59. Old 71 60. New Shot (Sensors) 61. Old 73 -8- The OSHA VCM Standard requires us to sample the air in our work areas for VCM by Personnel Dosimetry and by fixed multi point monitors. We use this information to help us minimize your personal exposure and to monitor our progress in the reduction of VCM concentration in the plant. Our dosimetry equipment consists of a pump and a gas bag . . or . . . Pump and charcoal tube . The dosimetry samples are analyzed for VCM content in our lab. These results are tabulated, recorded and made available at your request by asking your Supervisor or Department Head. Our four (4) Honeywell fixed point automated gas chromatograph monitoring systems sample air in all areas of our plant 24 hrs. per day, year around. Sensors like these will collect air samples at more than forty (40) points throughout our plants., The gas chromatograph analyzes these samples and sets off an alarm when a concentration of VCM is higher than the permissible limit of 1 ppm. VAB.0001078225 62. Old 74 63. Old 75 64. Old 78 65. New Shot S H Manual 66. Old 83 67. Old 84 68. Old 85 -9* w A person on each shift is designated to notify employees of high VCM levels in their areas. All people in the high level area who are not equipped with appropriate respiratory pro tection must leave the area immediately after notification. You will continue to be trained in the emergency procedures to be followed in the event of an unforeseeable major VCM gas release or fire. These procedures are fully detailed in the PVC Plant Safety and Health Manual for our plant. We will continue our medical surveillance of all employees which includes liver profile, blodd work and urinalysis studies. These provide the best diagnostic test available to detect the symptoms of angiosarcoma. You will also be given, at the Company^ expense, a periodic complete physical examination including chest X- ray and pulmonary funtion . . . . . . Along with your compelte medical and work background histories. VAB.0001078226 69. Old 87 70. Old 88 71, New shot (Close-up record log) 72. Old 90 73. Old 91 74. Repeat #8 slide 75. Repeat #9 -10- We legibly and appropriately label containers of PVC, VCM, PVC waste from reactors and waste contaminated with VCM, Also, we are required to keep and maintain records of our personnel dosimetry, Honeywell readings, medical histories, and authorized personnel rosters. Also, your Doctor will be furnished any and all medical records you request in writing. We maintain records regarding regulated areas. number of employees working in those areas, and all exposures in excess of 1 ppm as determined by personnel dosimeters. Copies of the current OSHA VCM Standard can be obtained by asking your Supervisor, De partment Head or any member of the Safety Department. Okay, letfs briefly review some of the major points we have just covered. Remember, VCM has been labeled as a hazardous material, When breathed in high concentrations, it could cause dizziness on create a narcotic effect, VCM has a flash point of minus -108 degrees Farenheit and has explosive limits which make it three times as flammable as gasoline. VAB.0001078227 76. Repeat #6 77. Repeat #12 78. Repeat #28 79. Old 97 80. Repeat #35 81. Repeat #61 82. Repeat S H Shot #65 83. Repeat #68 -li ft i Contact with liquid VCM could cause your skin to become severely frostbitten. Exposure to EXCESSIVE amount of VCM over LONG periods of time could cause liver cancer. In each case, the appropriate respiratory protection will be provided for your use in VCM environments in excess of the per missible limits. You will continue to be required to use an air supplied respirator when doing jobs where the potential for VCM exposure is greater than 10 ppm. You will also be required to wear protective clothing when performing any job in which your skin could come in contact with liquid VCM, To minimize your exposures to VCM and to check our progress in reducing VCM concentrations in the air, we are continuously sampling and s. monitoring the quality of plant air. h Know your emergency procedures as outlined in the Safety and Health Manual. 4- and finally, our medical surveillance program is for your protection. VAB.0001078228 84. Riant Aerial 85. Old #103 -12- 4 Through your efforts, we are complying with the ameiided 0SHA VCM regulations that went into effect in 1976, We ask that you con tinue to give your cooperation in helping us comply with any further regulations. Now, we*ll have a question and answer period. VAB.0001078229 THIS IS CONOCO CHEMICALS ABERDEEN OCTOBER, 1976 -1- 4 1. Title Slide Hello ladies and gentlemen. Today I want to show you the world of Conoco Chemicals... 2. Two men in lab The part of Continental Oil Company that has built a healthy, expanding business in convert ing crude oil and natural gas into chemicals. 3. Pouring detergent plastic resin over globe We*11 be telling you how Conoco Chemicals supplies the world's detergent and plastics industries and what results from the work you do. 4. Montage of products with model Let's start with results: products our customers make from our products. 5. Palmolive dishwashing liquid Washing dishes . . . 6. Putting detergent in machine or clothes is a daily chore in our homes. Well, Conoco is the world's leading producer of raw materials for the detergents that we use. 7. Lab Shot We were the first to announce a scientific breakthrough in developing chemicals from petroleum for biodegradable -- or "soft" detergents . . . (more) VAB.0001078230 THIS IS CONOCO CHEMICALS ABERDEEN OCTOBER, 1976 4 19. Pretty girl watering lawn garden hose , . , 20. Plastic pipe and plastic pipe. 21. Montage of products Floor tiles, records and toys are also made from our PVC, 22. Lab technician Our chemicals go into lots of other industrial and consumer products from, . . 23. Saturn Rocket take-off rocket fuel. , . 24. Vials of pills to pharmaceuticals. , , 25. Girl putting on Jergens hand lotion and cosmetics and beauty lotions. 26. 1870 Train enroute It all began back in the early 1870's when the railroads were rolling back the Western Frontier, 27. Coal oil lamp They carried with them coal oil lamps among new conveniences for the pioneer settlers. 28. Issac Blake portrait Issac E. Blake of Ogden, Utah saw a market for coal oil lamps. He and three western business pioneers. . . 29. Butte, Montana facilities incorporated the Continental Oil and Trans portation company in November 1875, 30. Horse-drawn Wagon It started life with the sole purpose of distributing the petroleum products of other companies. (more) r VAB.0001078231 THIS IS CONOCO CHEMICALS ABERDEEN - OCTOBER, 1976 -5- 38. Early Marland service station 39. Red triangle mark 40. Capsule mark 41. World map from annual report 42. 7 Billion type line 43. 7 Billion and 16th Build 44. 7 Billion and 22nd-16th Build 45. All figures Build 46. Corporate building 47. Ponca City aerial In 1929 Marland and Continental merged under the name Continental Oil Company. . and adopted the red traingle trademark. Headquarters moved to Ponca City. Today Continental does not just find, produce, refine and market petroleum products. It is a diversified enery and resources company with more than 40,000 employees in some 35 countries. In 1974 Conoco had annual sales in excess of 7 billion dollars. It is the 16th largest United States company in sales. , , And 22nd in assets. . . It is ranked among the top 50 companies in the world. Corporate headquarters is in Stamford, Conn. Ponca City, where the largest of ConocoTs seven refineries is located, is now the service center of the corporation. (more) VAB.0001078232 THIS IS CONOCO CHEMICALS ABERDEEN - OCTOBER, 1976 4 55. Vernon portrait Leon Vernon is vice president-operations, respon sible for Chemicals' manufacturing, marketing, supplies and distribution, and bio-medical and environmental affairs. 56. Conoco Towers Headquarters is in Conoco Towers at Greenway Plaza in Houston. 57. 58. Baltimore Aerial Our marketing, accounting and other support groups are located here. We operate plants throughout the United States in Baltimore, Maryland... (3 second pause) 59. Hammond 60. Lake Charles Aerial 61. Pitt-Consol Facade 62. Oklahoma City aerial 63. Aberdeen Aerial 64. Old Aberdeen Site Hammond, Indiana. . . (5 second pause) Lake Charles, Louisiana. . . (5 second pause) Newark, New Jersey. . .(5 sec.) Oklahoma City, Oklahoma (3 sec.) and Aberdeen , Miss. (5 sec.) Lets talk for a few minutes about our Aberdeen plant. This plant was built by Thompson-Apex Company and originally called Monroe Manufacturing. It came on stream in 1963 as a 50 million pounds per year operation. Continental acquired it in 1964 along with other facilities since sold. (more) VAB.0001078233 THIS IS CONOCO CHEMICALS ABERDEEN - OCTOBER, 1976 -8- 4 65. Conoco Plastics Slide 66. Chloride R/C*s 67. Storage Bullets 68. Sphere * 69. Piping to Lg. Rx, 70. Large Reactor Continued expansion of the plant increased its capacity to a peak of nearly 350 million pounds per year in 1973. Compliance with OSHA and EPA regulations however, resulted in the shutdown of all the small reactor build ings reducing capacity to approximately 150 million pounds per year in 1975. The new capacity replacement project scheduled to come on stream in early 1978 will bring capacity back up to the 1973 level of 350 million pounds per year. Vinyl Chloride monomer is a water clear liquid shipped to our plant in tank railcars from Conoco*s Lake Charles VCM Plant, The VCM is stored in 3 separate storage tanks. The two storage bullets hold 450,000 pounds each. In 1975, a 640,000 gallon sphere was con structed which holds 4,5 million pounds. From the storage tanks, the VCM is piped to the large reactor area,, Conoco*s Large Reactor Technology was the first of its kind in the world. In these reactors. Vinyl Chloride is converted from its liquid- monomer state into millions of very small solid white particles in a water slurry. (more) VAB.0001078234 THIS IS CONOCO CHEMCIALS ABERDEEN - OCTOBER, 1976 71. Dryers 72. Welex 73. P-1 Building 74. Line 3 Mill 75. Bags -9- A The water is removed from the slurry in Rotary gas fired dryers such as these. Hot air is blown through the dryers and evaporates the water. The remaining small white particles are the end product called PVC Resin. This can be sold as is or transferred to other operations within the plant as a raw material. Dry Blend is a product that uses Resin as a base raw material. The Welex mixers com bine resin along with other raw materials to produce a product that is used in the pro duction of rigid pipe. Alcohol from Conoco1s Lake Charles Plant is re acted with other raw materials to make a clear oil known as plasticizer and is used in the compounding operation. It is this raw material that makes compound flexible. Various mixtures of PVC resin, plasticizer, color pigments and fillers are combined in the pre sence of heat and pressure on these mills to form Compound. Our customers receive Compound in a pellet form from which a finished product is manufactured by reheating. All finished products leave our plant in one of the following: 50 pound bags. . . (more) VAB.0001078235 THIS IS CONOCO CHEMICALS ABERDEEN - OCTOBER, 1976 76. Gaylord 77. Bulk Trailer 78. Bulk R/C 79. Transportation 80. Organizational Chart + 81. Lab Shot 82. Admin. Services Shot 83. Safety Shot -10- * 750 pound Gaylord boxes. . . Bulk Hopper Trailers. , . Bulk Hopper Railcars. . . Plasticizer is either shipped in 55 gallon drums or tank trailers. The Conoco Transportation Department ids responsible for all shipments leaving the Aberdeen Plant. Let us now take a look at the operations support groups here at Aberdeen . , . The Aberdeen Plant Laboratory monitors the quality of all our products. In addition, our chemists work hard to develop new products to meet our customers specifications. Administrative Services inludes all pur chasing, accounting, receiving and secretarial functions. This group makes the paperwork flow smoothly. The Safety Departments responsibilities are to maintain the health and safety of our employees and to protect plant equip ment as well as improve employee skills. (more) VAB.0001078236 THIS IS CONOCO CHEMICALS ABERDEEN - OCTOBER, 1976 -11- A 84. Engineering Shot 85. Aberdeen Aerial 86. Aeriator Pond 87. Road Shot 88. Office Building 89. Large Reactor Our design engineering group is divided into 2 functional groups: Process and Mechanical. Process Engineers specify process equipment and Mechanical Engineers handle all support engineering and field installation. A major concern of Conoco Chemicals is the assurance that its employees have a pleasant working environment. Several major projects have been completed to accomplish this. One of these is a series of Polution Control Ponds that meet the State Water Commission Standards. Another project, completed in 1976, was the resurfacing of all plant roads. Also, a new office area was completed in September, 1975, which provided a central location for all Engineering, Operation Department Heads, Administration and Industrial Relations. There are several planned projects to be completed in the near future. One of these is 4 new large reactors which will more than double the size of the existing reactor department. As stated previously, these should be in operation by early 1978 and will return the plant to its 1973 capacity. VAB.0001078237 (more) THIS IS CONOCO CHEMICALS ABERDEEN - OCTOBER, 1976 * 90. Line 3 shot A new compound unit is an important part of the Capital Budget for 1977. This unit will re place the out dated Banbury Line presently in use 91. P-1 Shot The plasticizer unit will be expanded in order to supply the new compounding operations. This, too, is an important part of the 1977 Capital Budget. 92. Aberdeen Aerial With the current projects underway and the planned future projects, you can see the bright future in store for the Aberdeen Plant, 93. Merger Book Cover 94. Baltimore Plant overview The Baltimore plant, built as a refinery in 1915, has been a part of Continental Oil since the merger with Marland. n In 1947 Conoco built its first petrochemical plant there to produce basic raw materials for household detergents arid industrial cleaning compounds. 95. New Nalkylene Unit Facilities were expanded in 1965 to produce our prime soft detergent intermediate, NALKYLENE detergent alkylate. 96. 2 Men sampling product 97. 2 Men loading railroad tankcar The plant now produces, roughly 450 million pounds a year of some individual chemicals. . . which are used in a variety of applications from clothes-washing to the pickling of steel. (more) VAB.0001078238 THIS IS CONOCO CHEMICALS ABERDEEN - OCTOBER, 1976 98. View of Alcohol plant 99. Man in control room 100. LCCP Normal Paraffin Unit 101. VCM plant overview 102. Ethylene plant view across pond 103. Ethylene Terminal 104. Ethylene towers -13- 4 Conoco attracted worldwide attention in 1962 when it brought on stream a $10 million ALFOL R Alcohol Plant In Lake Charles. The plant's capacity has been expanded twice until today it produces 200 million pounds of raw materials a year for the detergent, plas ticizer and specialty chemical markets. Another plant unit produces feedstocks for Baltimore's NALKYLENE R alkylate process. A 600 million pounds per year vinyl chloride monomer (VCM) plant, then the world's largest.,. and a 500 million pound ethylene plant, came on stream at Lake Charles in 1968. Our new ethylene tanker terminal came on stream in 1974 at the Lake Charles complex's marine dock. It will be used for imported ethylene to supplement the production of our ethylene plant. Ethylene is a basic building block of the chemical industry. More than half of our annual production is used as feedstock by the VCM plant and a large part of the remainder by the alcohol plant. (more] VAB.0001078239 THIS IS CONOCO CHEMICALS ABERDEEN - OCTOBER, 1976 105. VCM plant control panel -14- 4 Under a licensing agreement with Stauffer Chemicals, the Lake Charles VCM plant produces this gaseous chemical intermediate used in the manufacture of PVC plastic resin. 106. OKC Large Reactors 107. Control Panel Operators The Oklahoma City plant came on stream in 1971. It uses exclusively the large reactor technology developed by Conoco at Aberdeen. L This new technology for more economical manufacture of PVC resin is being offered for licensing all over the world. 108. Plant construction The plant was originally designed to pro duce 70 million pounds. But continued expansion of the plant raised its capacity to over 180 million pounds in 1974. 109. Plant establishing view Our Hammond plant produces a variety of sulfonates which are utilized as surfactants in biodegradable detergents. 110. Detergent formulacartoon You won't find the word surfactant in a dictionary. It's a chemical term for "surface active agent," A detergent molecule in a cleaning product formulation is a surfacant. 111. Molecule cartoon It lowers surface tension of the water and improves water's ability to penetrate and loosen dirt, (more) VAB.0001078240 THIS IS CONOCO CHEMICALS ABERDEEN - OCTOBER, 1976 112. Men loading tank 113. Foreman Ted Blue 114. Drumming operation 115. 2 Men at Control board 116. Loader picking up drums 117. Sampling 118. Superintendent/man in front of unit -15- * Baltimore and Lake Charles provide the feed stocks for Hammond's operation. The plant came on stream in 1969. It combined the operations of a Chicago plant, acquired from Stepan in 1952, and a batch sulfonation plant built in Hammond by Conoco in 1958. Our Newark plant, known as the Pitt-Consol Chemical Company, uses phenol and methanol feedstocks to manufacture a variety of cresylic acids. The plant has a a year. capacity of 50 million pounds The cresylics are used as base raw materials by the plastics, rubber, oil additive and pharmaceutical industries. Since Pitt-Consol was formed in 1955, the plant has undergone extensive revision and expansion of its production facilities. Included was the construction of a unit to synthetically produce the cresylics. This technology was available in 1966 and the plant was built in time to take advantage of the decline of cresylics from natural sources. (more) VAB.0001078241 THIS IS CONOCO CHEMICALS ABERDEEN - OCTOBER, 1976 -16- <f 119. Salesman/car 120. Engineering group 121. Location map 122. Condea 123. Nissan Conoco 124. Petresa 125. Vinatex-Havant 126. Brussels scene 127. Office Scene 128. Engineer 129. Mechanic Supporting our efforts are Conoco Chemicalfst domestic force of 18 sales managers and sales representatives, who sell our products coast-tocoast, , , . and the chemical section of Conoco1s Research and Engineering Department in Ponca City, Here talented engineers and scientists help perfect our products and processes, and ways to improve the environment. Conoco Chemicals also makes and markets chemicals, including PVC resin, in more than 30 countries. We have eight affiliate companies with plants in: West Germany , , .(3 second pause) Japan ... (3 second pause) Spain . , , (3 second pause) and England. (3 second pause) Conoco Europe SA is our European marketing and sales office located in Brussels, It takes a lot of different people , , ,3 sec.) . , , doing a lot of different jobs, , ,(3 sec.) , , . to give Conoco success, , ,3 sec,) (more) VAB.0001078242