Document KJYJOKVEKkpb8xpBkoYnzjM70

V SUMMARY OF TEXAS CITY RESPIRATORY PROTECTION 05-09-58: Memo, Gilmore to Magliolo - documents presence of air masks in ft/ft plant. 10-13~53: Memo, Ozarchuk to file, recommending test of air purifiers on existing plant air supply for airline hoods t masks. 08-02-65: Memo, Dillon to Ozarchuk - list of all Air Paks/Masks in plant: All Service, Scott Air-Pak, Chemox, MSA Air Mask, Oxygen Mask. 05-7-67: (Per Decker) had MSA Respirators, Airline respirators, CN Escape mask. 07-29-68: Memo, Ozarchuk to Gilmore - Had Airline Resp., HCN Sample Masks, Safety Showers, Eye Baths, Dust ( Chem. Cartridge Respirators. 12-7-73: Memo, Dillon to Ozarchuk - list of all masks in plant: Scott, MSA Air Pak, All Service, HCN Cannister, Vapor Suit. 02-28-78: Memo, Williams - Recommending use of 3M #8712 organic vapor disposable respirator. 05-25-73: Orum to Schwab - Comfo II Resp., Half face fresh air mask, Comfo II dust resp.. Full face fresh air, Escape mask, Anfed hoods. 12-21-78: P-Bulletin - P-0130 issued - Resp. Protection 01-7-79 = Plantwide Training (documented in our files) for above P-Bulletin. 03-7-85: Quit ordering disposable organic vapor respirators (3M 8712). 01-7-86: Started using High Efficiency Dust Filters - Asbestos. MAP 001415 LAM023291 RESPIRATOR PROGRAM REFERENCES Breathing i r (2) Gas Masks Respirators NIOSH Warn ng - Scott Air Paks Quanta live Fit Testing Respirator Test Faci1ity MAP 001416 LAM023292 GENERAL INFORMATION PLANT LOCATION The plant Is located at the southeast corner of Texas City. Total plant area is 358 acres of which 243 are in use for manufacturing. This total acreage includes 80 acres northeast of Texas City in the Amburn Tract, 18 acres south of the plant at Swan Lake, and 18 acres of peripheral property adjacent to the plant. The Amburn Tract property is the site of our fire training area and a lagoon used to decant river mud from the plant water treating clarifier. The Swan Lake property is used for non-hazardous waste disposal. ORGANIZATION Manufacturing operations at Texas City are administered by the Fibers and Intermediates Company, which operates the acrylonitrile and acetone cyanohydrin units, site utilities, and environmental control operations. The Polymer Products Company is a guest operator of six manufacturing units - ethylbenzene, styrene, oxo alcohol, phthalic anhydride, phthalate esters, and tertiary butylamine. The Industrial Chemicals Company is a guest operator of the acetic acid and methanol manufacturing units. The Agriculture and Nutritional Products Company is a guest operator of the lactonitrile, lactic acid, and iminodiacetic acid manufacturing units (IDA Is currently mothballed). Other Manufacturing functions at Texas City include MISD, Accounting, Personnel, Plant Engineering and Distribution. The Personnel department includes the medical dispensary, industrial hygiene laboratory, plant security, and cafeteria. Plant Engineering includes instrument, electrical and mechanical maintenance, project construction groups with a large central shop facility, purchasing, stores, an engineering design group for plant projects and a material/mechanical technology group. The Distribution department Includes material handling, production planning and scheduling, and the quality assurance laboratory. The Technical Center at Texas City includes a process engineering group which sup ports capital project development, research and development laboratories and a CEO project support group. The Texas City plant has historically used contractors to supplement Monsanto craftsmen and to execute capital project work. For the last few years, the number of contractor supplement to maintenance has gone down significantly. Monsanto Maintenance now works in our Plant Capital Projects group which in the past has been total contract manpower. We have provided an average of 40 Monsanto craftsmen per day to Capital Project work. Overall the contractor headcount has been down during 1983 and 1984 except for turnarounds that have occurred. MAP 001417 LAM023293 Page 2. EMPLOYMENT The plant employs 1364 people in the following classifications: Wage 855 Salaried: Manufacturing, Exempt Non-exempt 263 101 Process Technology, Exempt Non-exempt 81 47 Corporate Engineering, Exempt Non-exempt 12 2 MPP Distribution, Exempt 3 Total 1364 Plant operating and craft wage personnel are represented by the Texas City, Texas, Metal Trades Council, an association of thirteen craft and operating unions. Cafeteria workers are represented by Local 347, International Union of Operating Engineers, AFL-CIO. Security guards are represented by the Associated Guards of the United States. MAJOR PRODUCTS The major finished products of the plant are as follows: Acrylonitrile used for fibers, nylon and structural plastics. Acetic Acid used in making cellulose acetate and vinyl acetate monomer, and for fiber and agricultural production. Acetone Cyanohydrin used for manufacturing polymethyl methacrylate plastic. Iminodiacetic Acid used as a raw material for Roundup. Synthetic Lactic Acid used in the food industry as a preservative. Methanol used in the production of anti-freeze, formaldehyde and acetic acid. Oxo Alcohol used In manufacture of phthalate esters. Phthalic Anhydride used in plasticizers, polyesters, alkyd resins, dyes and pharmaceuticals. MAP 001418 LAM023294 Page 3. Phthalate Esters used in food-grade plastics, floor tile, film, fabrics and adhesives. Styrene Monomer used for plastics, synthetic rubber, and surface coating material s. Tertiary Butylamine (TBA) used as intermediate for the rubber and tire 1ndustry. TEXAS CITY PLANT HISTORY 1941 ... Thirty-acre tract purchased under auspices of Defense Plant Corporation. 1942 ... Construction started on Styrene monomer unit and supporting Ethylene units. 1946 ... Plant purchased by Monsanto from United States Government. 1947 ... Ship explosions In harbor completely destroyed plant; reconstruction of Styrene and Ethylene units started immediately. 1951 ... Construction begun on Acrylonitrile, Hydrogen Cyanide, and Vinyl Chloride monomer units plus supporting Oxygen and Acetylene units; major expansion in Styrene. 1952 ... Started up Oxygen, Acetylene, Hydrogen Cyanide, Acryloni tri le and Yinyl Chloride monomer units. 1954 ... Construction begun on Methanol and low density Polyethylene units plus high-purity Ethylene units. 1955 ... Started up TBA unit and low density Polyethylene. 1956 ... Construction begun on new Ethylene units. 1957 ... Started up new Ethylene unit. 1959 ... Tract of 68 acres adjacent to plant acquired and filled by dredging for future plant expansion. 1962 ... Construction begun on high density Polyethylene unit. 1963 ... Started up Lactic Acid unit. 1969 ... 22 acres adjacent to south side of plant acquired for new deep water docking facility and product storage area. Construction started on new Methanol and Acetic Acid units. Construction begun on Phthalic Anhydride and Esters units. MAP 001419 LAM023295 Page 4. 1970 ... Started up new Methanol, Acetic Acid and Esters units. Acetylene, Acrylonitrile, Vinyl Acetate and old Methanol units shut down and dismantled. Construction begun on Oxo Alcohol and new Styrene units. 1971 ... Started up EVCL unit. Started up Phthallc Anhydride and Oxo Alcohol units. 1972 ... Part of low density Polyethylene shut down. Started up new Styrene unit. Started up new primary waste water treatment. 1973 ... Signed contract for secondary waste water treatment at Gulf Coast Waste Disposal Authority (GCWDA) regional treatment facility. 1974 ... Started up new Ethylbenzene unit. Construction begun on new Acrylonitrile unit. EVCL unit shut down. 1975 ... Construction started on Acetone Cyanohydrin unit. Low density Polyethylene unit shut down and dismantling started. Started up GCWDA secondary treatment facility. 1976 ... Acetone Cyanohydrin started up. Low density Polyethylene dismantling complete. 1977 ... Started up new Acrylonitrile unit. Hydrogen Cyanide unit shut down. 1978 ... Chrome-Zinc removal project completed. Storm water diversion project completed. 1979 ... Major energy conservation project completed. Boiler fuel conversion project completed. MAP 001420 LAM023296 V Page 5. 1980 ... Acrylonitrile Exposure Reduction project completed. Ethylene plant shut down, dismantling. Started up GCWDA regional disposal facility for hazardous solid waste. 1981 ... Evaluation of coal utilization. Benzene Exposure Reduction project completed. Benzene pipeline from Shell and Exxon put on line. 8.7 acres south of plant leased. COj line from Air Products to Methanol completed. 1982 ... AN conversion to Nitto catalyst. Demonstration of Phthallc Anhydride energy conservation project. Startup and shutdown of IDA II. High density Polyethylene shutdown. 1983 ... Install packing in EB/SM splitter column. Texas City site study. 1984 MAJOR PROJECTS Cogeneration evaluation. Acetic Acid debottlenecking. Methanol reformer rehabilitation. Complete cooling tower consolidation. MAP 001421 LAM023297 MCN3ANTC COMPANY Texas City, Texas September 7, 1973 TO: Tony Ozarchuk Subject: Gas Mask Number, Location, and Type' * NUMBER TYPE LOCATION Dept. 10 AS-1 AS-2 AS-3 SC-1 All Service All Service All Service Scott Air- Pak South side of control house, outside. North side of control house, outside. Middle of compressor house, west wall. In control house by north door. SC- 2 SC- 3 Scott Air- Pak Scott Air- Pak Dept. 13 East outside wall of storage bldg. East outside wall of old Dept. 2-3 control house. Dept. 13,14,15,16 SC- 4 SC- 5 AS-4 Scott Air- Pak Scott Air- Pak All Service Inside south east door of control house. Inside south east door of control house. South outside wall of control house. Salt Water Pump House AS- I ASSC- All Service All Service Scott Air- Pak North outside of pump house. North outside of pump house. Inside pump house, south wall. AS-7 AS-64 SC- 7 All Service All Service Scott Air- Pak Docks 1,3', 5 Dock 1 on wall of shack. Dock 3 on wall of shack. Dock 5 east end on handrail. Pilot Plant SC- 10 as-8 AS-9 AS-65 AS-10 M.S .A.Air-pak All Service All Service All Service All Service East outside wall of Butler Bldg. First floor, middle of bldg, foot of stairs. Second floor middle of blclg. on handrail. Second floor, middle of bldg., on handrail. Third floor top of stairs on handrail. Control Lab AS-11 SC- 11 AS-12 AS-13 All Service Scott Air- Pak All Service All Service First floor east end. First floor east end. First floor west end. Second floor east wall. MAP 001422 LAM023298 NUMBER AS-14 AS-15 AS-16 AS-17 SC- 12 AS-29 AS-30 AS-31 AS-25 AS-26 AS-32 AS-33 AS-34 AS-35 SC- 13 AS-16 SC-14 AS-17 AS-18 AS-19 AS-20 AS-21 AS-22 AS-23 AS-24 AS-59 AS-60 AS-61 SC-15 AS-62 AS-63 SC-16 SC-17 AS-36 TYPE LOCATION i Control Lab Cont. All ServiceAll Service Second floor west wall. Inside east door Research 2. All Service All Service M.S.A.Air-pak All Service All Service All Service All Service All Service Research 2 ' First floor west end of west wing. First floor east end of west wing. First floor east end or west wing. First floor'east end of east wing. Second floor west end of west wing. Second floor east end of east wing. R.P.U. inside on wall by cells. High Pressure Cells control room west wall. All Service All Service All Service ATI Service Scott Air- Pak Research 1 First floor east end of hall. Second floor east end of hall. Second floor west end of hall. Third floor west end of bldg. First floor west end of bldg. Dept. 24 All Service Scott Air- Pak All Service All Service Inside control house near door. Inside control house on south wall. North of 24H1. On 24H1 stack. Power 2 All Service All Service All Service All Service All Service All Service All Service All Service All Service Scott Air- Pak North outside wall of chlorinating room. South of boiler house outside. Middle inside of boiler house. Middle inside of boiler house. Middle inside of boiler house. Middle inside of boiler house. AN Loading Rack East end of loading rack ground level. West end of loading rack ground level. West side of carloaders shack. West side of carloaders shack. Esters Loading Rack All Service All Service Scott Air- Pak Scott Air- Pak Middle of loading rack ground level, Middle of loading rack ground level, South end of loading rack ground level, South end of loading rack ground level. Dept. 19,25,27 Control House All Service North end near door. MAP 001423 LAM023299 NUMBER AS-37 SC-18 SC-19 AS-41 AS-42 SC-20 AS-38 AS-39 AS-40 AS-50 AS-44 AS-49 AS-45 AS-46 AS-47 AS-48 AS-52 AS-53 AS-54 AS-43 AS-51 AS-58 AS-55 AS-57 AS-56 SC-18 TYPE All Service Scott Air- Pak Scott Air- Pak HCN Canister All Service All Service Scott Air- Pak HCN Canister Vapor Suit Vapor Suit All Service All Service All Service HCN Canister All Service All Service All Service All Service All Service All Service All Service All Service All Service All Service All Service All Service All Service All Service All Service All Service Scott Air- Pak LOCATION Dept. 19,25,27 Control House Ccr. North end near door. North end near door. North end near door. North end near door, (approx. 6 at this location) South end near door. South end near door. South end near door. South end near door, (approx. 6 at this location) In safety e<?uip. cabinet. In safety equip, cabinet. In safety equip, cabinet. In safety equip, cabinet. In safety equip, cabinet. In safety equip, cabinet. (approx. 14 at this locatl Dept. 19 Compressor House West wall near door. Dept. 19 South end of structure ground level.. North end of structure ground level. Second deck east side. Third deck east side. Fourth deck east side. South end, second deck of reaction structure. Dept. 25 East side of structure ground level. Second deck top of stairs west handrail. Third deck top of ladder east handrail. Dept. 27 North end of structure ground level. Second deck on handrail. Dept. 19 Storage Area South of 19T10s. West side of 19T10s on firewall. Top of Ammonia tanks. West of Ammonia tanks on 25T12-2 firewall. Main Gate Insine guard office, south wall. MAP 001424 LAM023300 Total number of masks and safety equipment In my area is as follows. Also the emergency equipment In First Aid and the Ambulance Is checked along with gas masks. Totals 65 All Service Gas Masks 18 Scott Alr-Paks 26 HCN Canister Masks 2 MSA Alr-Paks 2 Vapor Suits 1 02 Pneophore G. Dillon MAP 001425 LAM023301 I Monsanto TO 'k_i f V George Orum, Texas City, Texas May 25, 1978 Face Mask Requirements Bv Craft Leonard Schwab >. 'c Craft Foremen N. J. Broussard Paul Siems C. M, McCullough /' N : Craftsmen are subject at any time to be required to wear the respiratory equipment as listed below. All must be able to wear the equipment specified for each craft and have the face mask seal appropriatly without impingement by facial hair. PIPEFITTERS PAINTERS Full face fresh air mask. Half face fresh air mask. Airfed hoods (beards no problem) Comfo II respirator boilermakers OPERATING ENGINEERS Full face fresh air mask Half face fresh air mask C--. c V. if.. ./ MACHINIST Full face fresh air mask Half face fresh air mask. O* --E i fS A INSULATORS Comfo II dust respirator Escape mask TRUCK DRIVERS None 7 J 7 LABORERS Full face fresh air mask Half face fresh air mask Confo II dust respirator Full face fresh air mask Half face fresh air mask Comio II dusy respirator CARPENTERS Fu 11 face, fresh air mask Half face fresh air mask 0 rms George Orum MAP 001426 LAM023302 Texas City, Texas1'' **i- -v-*v \ 'jy-' .' Joe Hagliolo - Texas City, Texas Tony Csarchulc v *' May 9. 1958 Air Masks Daring a Spill rt- ? A'Hpte^jr You requested that Z consider the Item brought up in the Trocesa Hasard Caxaittee's report ecnoernlng the use of air casks during a spill emergency* Wa do not see the need of the lnoluslon In the Procedure Bulletin So. 31 of a rule concerning the disposition of. air casks during a spill, Our reasons ore as follows* f'&o-^...va..**-*-u** Any spill In tbs'Styrene, Ethylene or Polyethylene plants would not affoot those using air casks .--.vibe air Masks are used in Departments 31# 18 and VCM.) She spill which would T&r affect the air system would have to cone from tho north or-&&&$ norttweet and in'sufficient quantities to rise over or go around the l&vst ooollag tovcr north of Doportoont 17 QDd reach the air intake* We believe that a eplll of this magnitude would be a major emergency of which everyone In the eurrounding areas would be fully aware of and eould be eaelly instructed to discontinue the use of the air Masks#- m For these reasons we do not feel Justified in making a firm proocdure requiring that persons using air masks Issaediately :--^3gS^5S& discontinue such use during any and all spills# v~;?-:>^v ui'.: ' r- v . - V ,v. `mv: - * 'Y.V. *<, .!&?$ tv'SSSBfea ^ MAP 001427 LAM023303 \ 14. v f<J.' p- -v V- X' Map 001428 LAM023304 C PRODUCTION COSTS with CLEAN COMPRESSED AIR ^ m O Remove? alii OlWATER*, ORGANIC VAPORS. 'Tjrp. B ' GRIT and. SCAL r .'ss? i s 'Tsrrrir* t/t.rr't C.'r'^rrts.'** -it* m Manufacturer Cuts R|tctf f0% A pinpoint flw in the lcquct lining of food or bevertg* can maker it unlawful to use. Re* feat were running as high u 10% with chit can manufacturer'! former air cleaning lyttem used in lacquer *pr*r operation. Bullard Type B Puri* her* cut reject* to lest than 1%; iflstailatioa co*t 21% of former cyttem. Air cleansed by Bullard Compressed-Air Purifiers protects your tools and the men who use them. The savings effected in this way frequently pay for purifiers in a short time -- then over and over again. PROTECTION for fine air-tools Moisture, dusts, grit and rusr particles that are so harmful to dose-tolerance moving parts in compressed-air tools, are eliminated. The efficient filtering process of Bullard Com pressed Air Purifiers removes completely these harmful in gredients . . . protects parts against rust and scoring. Thus, with dean air, cools function smoothly and their life is greatly prolonged. Rotor Makar SHavat Casts Air operated machine tool* used by an electric racor and dipper manufacturer have several years added to their lives. Effective, total elim ination of moisture, corrosion and 6ne scale scratching of delicate tool parts is accomplished at a filter tnj of 2c a day. Tools need less main tenance, do better work. Etchings Worth Coming Up to Saa Compressed *tr blows "dragon s blood" from topper halftones tn a Urge photo engraving plant. Moisture in the air was "pasting" the powder to the copper anJ blemithing the work. Bullard Comp.resscd Air Purcftrrj now help skilled craftsmen turn out masterpieces every INDISPENSABLE for lacquering and fine spraying The moisture-free air these processes require is assured by the positive filtering anion of Bullard Compressed-Air Purifiers. This air makes possible the highest quality of fine lacquering, spraying and enameling; effectively cleans plastic molds and makes metal spray stick. It keeps lines dear for top production COMFORT and SAFETY --for air-supplied mask wtaren. Give pure air to workers wearing air-supplied hoods, helmets or masks. Unpurified com pressed-air breathed by workers may cause lung injury or illhealth. Bullard Compressed-Air Purifiers remove dust, mois ture and oil fumes from compressed air. making it completely safe for breathing. Workers are fed only the purest air possible. MAP 001429 LAM023305 ... . UatpHol SJSgbKS** P^I-.avlyinf: ^r?SiLrUssoliopt T' *"***.!,, room* fo* if* Aif pun6cr ppuitalioty d``"u$y <h * * ,./.h-<. com- ss-as5srs-""" '""" both hum --"STS-t work- hw* * '^uwiV-c-* -;v CIU dty- Al b*u*`1 |i^ _^hH*h /'* Tak 0P *r# , th- (0ol--1hi* PJcli U.J..WTr^-'TJKS?- 5Sggffatf*W "* ~nft *h*` `u?!Lv.p.c.-y '"*1h The am* P"" . houla hsy* V7_or*sicif in- LOW * COST maint E N A N C i 's\ t Efficient filtering of dust, moisture and organic vapors from compressed air, both mechanically and chemically, is shown by this cut away view of a Bullard Compressed-Air Purifier. Filter ing compounds are entirely separate from water condensation chamber, eliminating fre quent renewal of these compounds. 64D**5Otf0>*tr4r1 * t 4^ Under avenge condition*, one filter refill lull for 12 monthi. (Under ideal compressor condi tions users have reported no replacements in severs! years). Recharging is an easy job. An ordinary- socket wrench removes ana replaces heidboits. Refill is a self-contained cartridge, . ready to opente instantly. Pressure tank is heavy gauge galvanised welded steal, fully tmted fir in excess of mead capacity. TYPE Cubic feet per min. of free air Max. working pressure in lbs. per *q. in. Pipe sizes (inlet and outlet) Outside dia. of shell Over-all height Net weight A" 10-JS 100 1" 5" 20" 26 lbs. "B" 35-100 125 1 Vi" 8" 48" 94 lbs. "C" 100-150 125 2" 12" W'f 177 ICS SIX OUTLET PURIFIER 1ighr enough to be cUsied t* portable, yet with the nr capacity of ttationary models, the 6-ouciet air purifier is a Type A purifier with manifold, pressure regulator and relief valve added. Mandard % inch tap threads permit ready attach* ncm of any air line fitting to operate all makes of 'pray guns or air tools, plus any type of protective urline hood or helmet for operator protection. From ne to six hoses may be attached. Working pressure > pre-set and controlled by a pop-off valve installed ihead of the manifold receiver. Me. 41 P4 Typa A Purifier A Refill Type B Purifier B Refill Type C Purifier C Refill Six Outlet Purifier A Refill Catalog Ne. 41A Catalog No. 41 A.F Catalog Na. 41B Catalog Ne. 41 -B-F Catalog No. 41C Catalog No. 41-C-F Catalog No. 41 >P6 Catalog No. 41-A-F 75*00 3.50 216. CO 51 *CQ- 317*CC 92.00 13^*00 8.50 a --'-is "* * * . r _ Guardian Safety Equipment Company " :*! P.O.Box 13364 .. * . " , ,v7'*.r:`- Houston 19, Texas ' j f 'i Phene: UNderwood 9*2461 -LjSfPv3 MAP 001430 LAM023306 f ( *i J'-L )J A" (/"-v?V-Us C-iOu`-<l,i JL'-O VrAxJfA. av-3. v<l&ilV-X> IH5 o io AAaX 5.. *\ n .>< jugg2Va/... , C^X^-clO, 0Jw<. fc-j; aerA-uC-\ Ase^x SuXv^lSL G-^X AluAA_ 3. AyX CLG'n^Jl^OA G-CuXA cC\ >.A'AAb'-v^ AtefciV,. 0i& ixjA ir.X^A1 -* 3 "\ \- N\0V-X AyA'. A< XOy y. j-^\ ASGiX AXC^A- Cu-X ^ r .\ * a. t^v-. ^ *N . ___V - L -- -. V a- r>^. X}-. ,'\.i>> Ag-g', . v^ojO?, a lx crcxt /"\ ;..o--v -\ *\ TA_.._x xA-AA_ .. . Au^i c). .joP-CC ic7~ v>v Iakl^ca xr-VL'-Gc x_....... -xjc4c,.Uv3 _ \. Ap j--xN;. Ay..AAA cx, -\ c_v7 -'AX. JiAXv j. A---'-. xxjy .O- AaK: 5v''; 1. vV.*-1 ,. - Xi cs cx X i" .-> U'/.'OY.i11 (Gx. G^X (o 1- ViX>..i . 0-r A fcX ley A '.L.'.'iV. ixalcXA V.UA \XU>U.:x ^ ' rs, % o , !\ ' .' a'A- CX>-*. AAX\ axT-A .JjlXx 0 :\Ax 3- nx '-.-aop (lArxxA xe-ev.x x.xx.rAL xX-xC.u-tAa. 0\ ^cajA.clA 0 MAP 001431 LAM023307 4. :jl. :x :lA;-a- lga./ o. :r.^ ie`. .x -c-\ *vo - \ -A A ' i ;; * a A. IlAAIA. ;a ru.7.. \IL Uou/Ji. r. r- a Vp A - _;a a- c-4 A'1' '* ,1 A'-U. .AG'.'--' C-U_..A>/',. fJ \ t A, -'A 1eu.'~L \ _` f\ *> JH ul~A\ >k YY.0-'JAt A_ N W' \ > * , l '' -^ ------ - A* a-- ..._A'\ 1. -A'-'-O .L. Au 5 ' VsA,'. JO A __ O _^aO.''-_JU;-'o5a ;v- ao.l 'cr:,, ___*Li^v. )i-aichjxsSL A i)iioiA cTM V r 7\ ; *. , -if. ,, ~A -^-r __ 5. AL> . J\\(L )\.SJX.C.<i 0-^ UctCaA O VAA\ ___ jo. Q/iv ..^aiocAjOuS. $ A *' ALO. ^UHxlSL .......T C:cVf--:\. 0-r. 2\t;~- jo .11, A' J-t O'a VV J .u ' ''^A' aA_Va>7 L:VsO_.\_. 'AA, tAT >. A - A-.vf-o-A _n A-Av JJA\>a, m . Vr^% .v- v ..a- ~ ^Vi l -\A'._ ^ . -"A- ~y .,oV .`"JlA\ CrC^(L --Ai--,A CL \'^:V a.. >' ^j-- a\ / .. ,'(<V'/>- ,-V A . , .Y.' <,, ' .A A A . s -\VA\C\ U~ C-CAJ-:. \ JA.'A' & \ r\ r Li A,V.jA^ MAP 001432 LAM023308 i rv 1 ^_ i--o'CL- r:an-! ^ \ ^ A-- ^\\ >-0. >. '. \ -9\-- 0-v^ --vL-N'.'-- _. . ... w*. > \T' . .Wr^A\,'A>:-^.\ A^Vr'. A-, A~. "tZL';.,l_, j^>.A -L^ XJJA'-c.^ 9 Sx-. -w 9 )x XoJ . '. ^X. 1 '. 1 >S _ ' X ; ;; . m . j;;X- >, *\\ *` V. >1`\ JJU-C-' `.9~ 7 \ v7\ +**' i ^ ^ "9 * ` r-` i ^ ^ y w **-s V JLXX. ' i . "'S _w ' ; i; J J :5. Avl^<r'_' L.'-C* *.X /v ^ -N..JjjL-fc\ iLx9V - ,o i. ia-At i .^. 9 9.1V. \ .j Aw^:>i^\AL-A^ "** S- -A_ ^ \ /" A -t<-v OfA- X: A'>-i a JAv.ca. .a-*. . -v . v' ..A'c.1,' -Lv.Civ xXj^.x -U AL^-Y.^ U^X .'XV.'./H Li-Ov 9vj>xx^. -- r- '- > '9 S-^y.f'.. t'.-if \ \. ,.. ~ a A. . . . i-~. J-'-'O O . ..l/v'". v- % , 4- '^ -i_ ^eo\. ..-AN-A a -~V A- JO-XA vAX-V X-V`1' V "vvt-- ,,~v.'v X'->x{5 'a AA Av u>jv'.\ .v:aW aA-'v.;/^ Lxxjc'-^ V ) ./<^ ;-v.', V ,\ V-^X av*^* .*^VwV\J- ,^** . :r. 1L , 0j_^~ 1'; >> ^ ~~ O MAP 001433 LAM023309 'V..1 V 'V- -o: /\A V1 fs VSUL* ^UJ/r :-y \ M VAOi \ j.l>" - r\ , > , . :r. .C. Vi-; _\ 1' r ' -v. .1 iTX'/;. r \. i' aa a a-c: C--S o'_' r*;' Qrr\ '. .D . ' n.. " .A. <S> oOTJAi^X. _.jOAV __ ,.\. 5. v CU <1 Vii>J-A'L V *v c.-s * T* p \' XoA'-^-T-f ^JbS\- "s` v^ * -- \ .lc-' '-T ' - *\ . \ v-Lo\ . *. - r * ;* w.T .a'A-3 s^. VjXJfJL *\ ..;j .'j*-'* 'Lv'-CY.A1 ^.'.-r; .u'-.A .) ; ,-\ * ` tA' :-v - < - .y.-!- JV N I * .vO. K. \ MAP 001434 LAM023310 Monsinio ' =" Tony Ozarchuk - Texas City, Texas July 29, 1968 Inspection Sheets -- Inspection of Safet-y Equipment TO C. L. Gilmore V ( Opk-rv. >icy_ v'wL'^ Canister and Bottled Air Type Gas Masks These masks are thoroughly Inspected semiannually and maintained in all units of the plant in cases sealed with lead wire seals. An inspection card is mounted in the sealed case which shows the date of inspection and the signature of the inspector making the inspection. In the event a seal is broken inadvertently or intentionally, the gas mask is taken to the Safety Supply room for a thorough check and inspection before being replaced in the unit. After a gas mask is used, it is thoroughly washed and sterilized, any worn parts are replaced and thoroughly checked before being placed in the unit. In all cases whenever a seal is broken on a gas mask case, the mask is thoroughly checked and the information as to date of inspection and by whom is placed on the record card before the case is resealed. Airline Resoirators These masks are used primarily in Departments 18, VCM, and 31. A supply of this type mask is maintained in special cabinets in these units and as these respirators are used, they are placed in a used mask container in the unit. These respirators are picked up by the Safety inspector, taken to Safety Supply; and are washed, sterilized, and inspected for worn or damaged parts. The final inspection on this type mask is made by the Safety inspector prior to being placed in sealed plastic bags and delivered back to the unit's gas mask cabinet. HCN Sample Masks These masks are used in Departments 19 & 20 and the same procedures are followed as with the airline respirators. Safety Showers and Eye Baths Visual inspection of safety showers and eye baths are made by the Safety inspectors on trips to their inspection units to make atmospheric tests and in conjunction with their safety sampling program and other area visits. MAP 001435 1 v<. / LAM023317 C. L. Gilmore V July 29, 1 Dust and Chemical Cartridge Respirators These type respirators are issued to individual employees for specific Jobs from the Safety Supply room. Upon completion of the job, respirators are returned to the Safety Supply room where they are disassembled and new filters installed. These respirators are then placed in plastic containers and are ready for reissue. Atmospheric Testing Equipment The Davis Explosimeters are checked each morning in a flammable vapor to be sure that the instrument is working. Once c*_ch week the instruments are checked with a special kit in a two per cent methane-air mixture for accuracy. The instruments used to check for oxygen-deficient areas are checked weekly on the nitrogen stream in Department 17. TO/wa MAP 001436 LAM023312 G. Ostermnn July 16, 1968 y W/ Texas City, Texas A. J. Bolton L L l)r>ilC C. L. Gilmore The Flant Manager's Safety Board is reviewing the procedures for Safety Inspection. Ac part of this review, I would like to have copies of any inspection sheets that you currently U6e to control the inspection of safety equipment. _?l Z need these sheets by August 1. ItX Cij'UJ-: t'-ss. uJ- CO:lrt /VA"\ t G. Ostcrrr.an MAP 001437 LAIVI023313 COST STUDY ORGANIC VAPOR RESPIRATORS Increased usage of organic vapor respirators has created growing demands on supplies and labor along with increasing cost. Newly developed equipment has become available which will fulfill our needs with a minimum amount of labor, supplies and drive down cost. Our present Comfo II organic vapor respirators are used for one 8-hour shift and then exchanged. These used respirators are collected and prepared for re-use. This preparation involves complete disassembly; washing with cleaning agents; drying; replacing cartridges; inspecting by a safety inspector, re-assembling, sterilizing and sealing in a plastic bag. This tedious process is necessary to insure that the respirator is safe and efficient for use. A newly developed "one-way" or disposable respirator is now available. The unit is the 3M #8712 organic vapor respirator. The respirator would provide the same protection as the Comfo II. The results of a study of our in-plant usage has provided evidence that by using the new disposable masks we would benefit in an annual savings of $2800. The attached chart outlines costs comparisons. DGW/sh February 28, 1978 David G. Williams MAP 001438 LAM023314 APPENDIX I COST STUDY CHART The 3 M organic vapor respirator #8712 ea. $4.58 Comfo II ea w/out cartridge $8.85 (2) Comfo II cartridges (two required) 3.40 Comfo II unit complete . $12.25 ACTUAL COST COMFO II (Cost at present annual consumption rate) Comfo II units used per year 4,212 Total cartridge cost $14,321 Unrecovered (lost)masks 3,950 Total cost per year $18,271 or $4.34each Additional costs Cost per Comfo II unit Labor to clean, sterilize, etc. Supplies (detergent,alcohol, plastic bags, etc.) estimated Actual cost of Comfo II $4.34 .89 .02 $5.25 $5.25 Savings per unit using 3M #8712 Annual Savings using 3M 8712 .67 $2,822.00 Since an annual savings would be realized by using the 3M 8712 organic vapor respirator, it is strongly recommended that we provide them for usage at our plant. MAP 001439 LAM023315 'lonsiinto Tony Ozarchuk - i>-j * Texas City, Texas \ March 6, 1978 N/ Respiratory Equipment Louis Decker J. A. Glass/J. E. Clark TO Gerald Osterman - Port Plastics Dear Gerry: This is in reply to your recent telephone request to Louis Decker for information on respiratory equipment, and our procedures on this equipment. I am enclosing several xerox copies of manufacturers1 information and a copy of our Procedure Bulletin, P-0130, "Respiratory Life Support Systems." The small portable plastic packaging machine, Sealmaster Model A20-A, which we use after cleaning and inspecting our masks, is available from Packaging Aids Corporation, 370 Brannan Street, San Francisco, California 94107. telephone 1*15*362-9202. If you need any additional information, please let us know. Best "personal regards. -d-7 TO/sh Enclosures MAP 001440 LAM023316 Vv GENERAL INFORMATION PLANT LOCATION The plant Is located at the southeast corner of Texas City. Total plant area Is 358 acres of which 243 are in use for manufacturing. This total acreage Includes 80 acres northeast of Texas City in the Amburn Tract, 18 acres south of the plant at Swan Lake, and 18 acres of peripheral property adjacent to the plant. The Amburn Tract property is the site of our fire training area and a lagoon used to decant river mud from the plant water treating clarifier. The Swan Lake property is used for non-hazardous waste disposal. ORGANIZATION Manufacturing operations at Texas City are administered by the Fibers and Intermediates Company, which operates the acrylonitrile and acetone cyanohydrin units, site utilities, and environmental control operations. The Polymer Products Company is a guest operator of six manufacturing units - ethylbenzene, styrene, oxo alcohol, phthalic anhydride, phthalate esters, and tertiary butylamine. The Industrial Chemicals Company is a guest operator of the acetic acid and methanol manufacturing units. The Agriculture and Nutritional Products Company is a guest operator of the lactonitrile, lactic acid, and iminodiacetic acid manufacturing units (IDA is currently mothballed). Other Manufacturing functions at Texas City include MISD, Accounting, Personnel, Plant Engineering and Distribution. The Personnel department includes the medical dispensary, industrial hygiene laboratory, plant security, and cafeteria. Plant Engineering includes instrument, electrical and mechanical maintenance, project construction groups with a large central shop facility, purchasing, stores, an engineering design group for plant projects and a material/mechanical technology group. The Distribution department Includes material handling, production planning and scheduling, and the quality assurance laboratory. The Technical Center at Texas City includes a process engineering group which sup ports capital project development, research and development laboratories and a CED project support group. The Texas City plant has historically used contractors to supplement Monsanto craftsmen and to execute capital project work. For the last few years, the number of contractor supplement to maintenance has gone down significantly. Monsanto Maintenance now works in our Plant Capital Projects group which in the past has been total contract manpower. We have provided an average of 40 Monsanto craftsmen per day to Capital Project work. Overall the contractor headcount has been down during 1983 and 1984 except for turnarounds that have occurred. map ooi44i LAM023317 V Page 2. EMPLOYMENT The plant employs.1364 people in the following classifications: Wage 855 Salaried: Manufacturing, Exempt Non-exempt 263 101 Process Technology, Exempt Non-exempt 81 47 Corporate Engineering, Exempt Non-exempt 12 2 MPP Distribution, Exempt 3 Total 1364 Plant operating and craft wage personnel are represented by the Texas City, Texas, Metal Trades Council, an association of thirteen craft and operating unions. Cafeteria workers are represented by Local 347, International Union of Operating Engineers, AFL-CIO. Security guards are represented by the Associated Guards of the United States. MAJOR PRODUCTS The major finished products of the plant are as follows: Acrylonitrile used for fibers, nylon and structural plastics. Acetic Acid used in making cellulose acetate and vinyl acetate moncmer, and for fiber and agricultural production. Acetone Cyanohydrin used for manufacturing polymethyl methacrylate plastic. Iminodiacetic Acid used as a raw material for Roundup. Synthetic Lactic Acid used in the food industry as a preservative. Methanol used in the production of anti-freeze, formaldehyde and acetic acid. Oxo Alcohol used in manufacture of phthalate esters. Phthalic Anhydride used in plasticizers, polyesters, alkyd resins, dyes and pharmaceuticals. MAP 001442 LAM023318 V V Page 3. Phthalate Esters used in food-grade plastics, floor tile, film, fabrics and adhesives. Styrene Monomer used for plastics, synthetic rubber, and surface coating materials. Tertiary Butylamine (TBA) used as Intermediate for the rubber and tire 1ndustry. TEXAS CITY PLANT HISTORY 1941 ... Thirty-acre tract purchased under auspices of Defense Plant Corporation. 1942 ... Construction started on Styrene monomer unit and supporting Ethylene units. 1946 ... Plant purchased by Monsanto from United States Government. 1947 ... Ship explosions in harbor completely destroyed plant; reconstruction _ of Styrene and Ethylene units started immediately. 1951 ... Construction begun on Acrylonitrile, Hydrogen Cyanide, and Vinyl Chloride monomer units plus supporting Oxygen and Acetylene units; major expansion in Styrene. 1952 ... Started up Oxygen, Acetylene, Hydrogen Cyanide, Acrylonitrile and Vinyl Chloride monomer units. 1954 ... Construction begun on Methanol and low density Polyethylene units plus high-purity Ethylene units. 1955 ... Started up TBA unit and low density Polyethylene. 1956 ... Construction begun on new Ethylene units. 1957 ... Started up new Ethylene unit. 1959 ... Tract of 68 acres adjacent to plant acquired and filled by dredging for future plant expansion. 1962 ... Construction begun on high density Polyethylene unit. 1963 ... Started up Lactic Acid unit. 1969 ... 22 acres adjacent to south side of plant acquired for new deep water docking facility and product storage area. Construction started on new Methanol and Acetic Acid units. Construction begun on Phthalic Anhydride and Esters units. MAP 001443 LAM023319 Page 4. 1970 ... Started up new Methanol, Acetic Acid and Esters units. Acetylene, Acrylonitrile, Vinyl Acetate and old Methanol units shut down and dismantled. Construction begun on Oxo Alcohol and new Styrene units. 1971 ... Started up EYCl unit. Started up Phthalic Anhydride and Oxo Alcohol units. 1972 ... Part of low density Polyethylene shut down. Started up new Styrene unit. Started up new primary waste water treatment. 1973 ... Signed contract for secondaty waste water treatment at Gulf Coast Waste Disposal Authority (GCWDA) regional treatment facility. 1974 ... Started up new Ethylbenzene unit. Construction begun on new Acrylonitrile unit. EVCL unit shut down. 1975 ... Construction started on Acetone Cyanohydrin unit. Low density Polyethylene unit shut down and dismantling started. Started up GCWDA secondary treatment facility. 1976 ... Acetone Cyanohydrin started up. Low density Polyethylene dismantling complete. 1977 ... Started up new Acrylonitrile unit. Hydrogen Cyanide unit shut down. 1978 ... Chrome-Zinc removal project completed. Storm water diversion project completed. 1979 ... Major energy conservation project completed. Boiler fuel conversion project completed. MAP 001444 LAM023320 V Page 5. 1980 ... Acrylonitrile Exposure Reduction project completed. Ethyl-ene plant shut down, dismantling. Started up GCWDA regional disposal facility for hazardous solid waste. 1981 ... Evaluation of coal utilization. Benzene Exposure Reduction project completed. Benzene pipeline from Shell and Exxon put on line. 8.7 acres south of plant leased. CO2 line from Air Products to Methanol completed. 1982 ... AN conversion to Nitto catalyst. Demonstration of Phthalic Anhydride energy conservation project. Startup and shutdown of IDA II. High density Polyethylene shutdown. 1983 ... Install packing in EB/SM splitter column. Texas City site study. 1984 MAJOR PROJECTS Cogeneration evaluation. Acetic Acid debottlenecking. Methanol reformer rehabilitation. Complete cooling tower consolidation. MAP 001445 LAM023321 -li 1<V3T10 V op . _^5>*T2,&r<HvrK . A-H2 .'Sr^.srfcs.vi-I ^U-lSCe _Qi2j^iLtirAr.c,____ A^n 4-4hs*Q6/3_________________________ uj 3-3___M-SivuSO-- Ljvrrt t3~)> -- 3figofrQ 'P^^T Lufc^,-r- a f= 'Pi-aT Tl^a^- JSto* ujxs____ a ss^wrcw*__ U*o f^--^oo ^ _Pv/v***i_At ft. CZo^PrtAfcSorV* . *SriV3&^ S3CT3B*t>*Q TO S^VP 'PitovlT *riAi*> v>4.e.uJD^P *. T^a<.3 \t7.x ^^45____________I________________ ___ _______"Pl-m4-T~_____________________________________ ../ S-VffeD__l?W?r__ &Z3A___________________ _*__ AeWivtairfiA___ rcA*4W *5 -'2.'?- -s -ns oa^ it. ______________ |L SAgJS- ir4 l^fe fia____ SsfTS4iIlA.<_______qca^ac *?TXrR43 11 >4aT___ V^^iZ&rc*o_ A^4AC.M 2_CfuS vvK>TX<-t-C^ OIH "SHVrgj^ [HrVTXCLC>0____L _La**____ L3r^L_4jz^fe^c___ AejPacu^o______ ^_|jas 1 ______________ ____ T2, Sm _l_fc4\9fcl ^VPPt2^c^^ -tUAS 13 A iua^ 3-nnxrco L>P ,2-|2."71 S l A 'PiLQWflr-n Pent. ^ VS4<1 . 5SPC/t^rmJ 3M<i TBJ-'l -P^VT U,ftCT* CSS f-1* V 'EM ID a._M. cf_G. V * Xf/A^/, Lmim^ MAP 001446 LAIVI023322 ,, Monsanto .oc.-~i j. e. Fox, LP&S, Texas City ftalf April 28, 1978 K/lJ i UftrfO Industrial Hygiene Bulletin " Breathinq Air Quality Criteria"- Number 78-5 Your memo of 3/3/78 TO J. F. Carlisle OA-4 cc: R. Buy OA-4 J. B. Cook 0-13 G. A. Danner 0-8 W. C. Fuller 0-11 W. R. Furley OA-4 J. A. Glass 0-22 F. E. Grissom 0A-5 G. Lunsford 0-21 M. McCullough 0-12 W. L. Riddick 1Z G. L. Stacy 0-11 SHAC Central Files As per your request, I have compared the subject DMEH bulletin on "Breathing Air Quality" with the present West plant system to see if we meet the criteria. Although I am not totally familiar with the West plant system, X have noted a number of differences between what we have and what the DMEH bulletin recommends for compliance with the regulatory agencies involved with breathing air quality. 1. The bulletin stresses that all breathing air should be isolated from other air systems. There should be no potential for cross connections. As you know, our system is a dual system which separates breathing air from plant air just downstream of the compressor. 2. Our breathing air system is equipped with a high temperature alarm, but it does not, as recommended, have a automatic shutdown feature. 3. The relative humidity of our breathing air is much less than the recommended minimum of 12%. 4. Presently our system is not monitored for potential toxic materials. A monitored system to meet this requirement has been in the development stages for more than a year. Process Technology indicated that the system should be installed within one month. In talking with Jim Cook, I understand that an engineering study is also in progress by Charlie Hill to determine what is needed to upgrade our present system. nS ^/^ohn E. Fox gr MAP 001447 LAM023323