Document QgyDv1y4yr7j96pwOOdKDDxQ4

MONSANTO COMPANY ORGANIC CHEMICALS DIVISION ANNISTON, ALABAMA STANDARD MANUFACTURING PROCESS FOR AROCLOR Departments 826.08 826.17 Supersedes: Standard Manufacturing Procesa For Aroclor Issued: 10/22/57 Prepared by: M. J. Williams Prod. Foreman Supervisor: V. R. Haupt Production Supt.: R. C. Moody Issued: September, 1966 COPT NO. IL CONFIDENTIAL INFORMATION This process Is the property of Monsanto Company and the recipient Is responsible for Its safekeeping. It contains confidential Information of Monsanto Company which amat not be reproduced, revealed to unauthorized persons, or sent outside the Company without proper authorisation. Either retain In a secure file or return to the Standards Department. NEV 24943 738198 STANDARD MANUFACTURING PROCESS FOR I AROCLOR m m x j. SAFETY & TOXICITY DATA AND ACCIDENT REPORTS N Safety of operations In the Aroclor Plant depends on the Individual operator. Materials being handled and operations must be observed olosely to guard against the following: Cause and Action to Prevent 1. Chlorine Gas Chlorine gas is a very toxic corrosive gas. Leaks or high pressure can occur to liberate It. Action to Prevent a. Report Chlorine gas exposure Immediately for treatment with Antidote. Milk may be used In mild cases to relieve throat Irritation. Oxygen from the resuscitator In the Dispensary is available. b. Keep gas mask In good condition. Keep a good canister in the mask. Use these type masks only in chlorine concentrations to 2-3% chlorine in air. c. Use a Scott Air Pak in concentrations of chlorine gas above 3% in air. Three units are available in the AroclorBlphenyl .Department. d. If caught in chlorine gas without a mask hold your breath and go cross wind until you are out of range of the gas. Place a handkerchief over your nose in small quantities of chlorine. e. Report all chlorine leaks for repair immediately. Make temporary repairs with tape if possible. f. In case of a major chlorine leak the source of chlorine gas must be stopped. Notify the Chlorine Plant Immediately If the pressure on the chlorine manifold exceeds 30 pslg. Cut off liquid chlorine from the car. ( NEV 024944 738199 APPENDIX J 2. V Cause and Action to Prevent 2. ThenI Burn Contact with hot uninsulated product lines ar the chlorlnatore and still areas. Contact with uninsulated steam lines and open steam. Contact with hot Aroclors from broken lines or leaks. Contact with open flames at stills or from heating lines In the department. Action to Prevent a. Know that contact with equipment and product will cause a thermal b u m due to the high temperatures. Make changes In operations with this hazard in mind. b. Know the first aid treatment for bums. Cold Water Treatment attached. c. Wear gloves and long sleeve shirts with the sleeves rolled down when operating. Gloves and clothing can make the difference between first and second degree bums. d. Report uninsulated lines for repair of insulation. e. Use only steam lines with hose and hose clamps In good condition. f. The following operations are hazardous and should be done with care: (1) Catching samples at the Aroclor chlorlnator circulating pumps. (2) Sampling the Solid Aroclor still receiver. (3) Drawing bottoms on the Aroclor atills. 738200 NEV 0249^5 Cause end Action to Prevent An explosion could occur in the chlorinators by slugging liquid chlorine to the distributor. Slugs of liquid chlorine could react fast enough to cause excessive pressure in the vessel. A rupture of the chlorlnator could occur. Action to Prevent a. Observe operation of the chlorine vaporiser and do not let liquid chlorine get into the rotameters. Pipe lines will be frosted. b. In case chlorine feed lines are frosted, close liquid chlorine feed valve to the vaporiser. Check steam addition to the vaporiser. Do not start up until source of trouble has been located. C. Observe temperature of the chlorlnator periodically and be sure it is not too hot (180C. maximum). Slipping on cement floors, stairs, Aroclor on floor, Ice conditions; tripping over objects (hose, pipe, valve handles, etc.); or losing footing on ladders, etc., can cause falls. Action to Prevent a. The majority of minor, serious, and near*mlsa injuries in the Aroclor Dept are the result of falls. Prevention is always within the ability of the operator by use of expert operating practices. NEV 0249^6 738201 APPENDIX J 4. V C a m e nd Action to Prevent 4 Falls (Contd.) b. The following Items should be done; (1) Return hose to rack after using. (2) Keep operating areas clean of all foreign objects. (3) Return ladders to racks when not In use. (4) Keep gloves on end hands out of pockets especially going up stairs. (5) Place guards around any area that presents a haeard that should be guarded. c. Poor lighting due to burned out bulbs khould be corrected at once. Poor lighting due to Inadequate facilities should be reported. d, Spills nust be cleaned up Immediately following their occurrence. Report any spill that cannot be cleaned up within the shift to the Chief Operator. 8pills are to be reported In the log book. 5. Fires Fires can occur by: Biphenyl Santowax R or Santowax C Ignition. Chlorine problems In the vaporleer allow ing reaction with steam to release hydrogen. Furnace burner backfire. Wood, rags, or paper on hot lines. Sparks from welding apparatus of open flames. NEV 024947 738202 APPENDIX J 5 5. Fire (Contd.) Cause nd Action to Prevent Action to Prevent a. Area must be clear of trash or flammable material. Dae trash kips and cans. b. Smoke only In areas so designated. c. Use spark producing equipment only with a fire permit and proper in spection. d. Use care In lighting gas torch or the still furnaces. e. Fire fighting equipment Includes: (1) Two wheeled dry powder units. (2) Bose house with 200 ft. of hose. (3) Two dry powder hand extinguishers, One CO2 hand extinguisher. (A) Two 3/4" water hoses. (5) Bose connection north of Santovax. (6) Scott Air Paks. (7) Fire truck in fire house. f. Observe visitors in the plant and be sure they observe safety rules. 738203 APPENDIX J 6 Cause and Action to Prevent 6. The following Is * list of chemicals handled In the Aroclor Plant operations and the precautions to be taken during their handling: a. Chlorine Gas This Is a corrosive gas which Is toxic. Leaks or back pressure can occur and liberate chlorine gas In the area. Operators should have their cartridge type respirators handy at all times while in the area. Use of gas masks Is explained in Section 1. Chlorine Gas. If you are caught without a gas mask, and large amounts of chlorine gas are liberated, hold your breath and go cross wind until you are out or range of the gas. Once out of the area, obtain an emergency gas mask and return to the area and correct the trouble. A victim of chlorine gas fumes oust be removed as quickly as possible from the gaseous area. Place patient on his back with head and back elevated. Milk may be used In mild cases as a relief from throat Irritation. If the patient has stopped breathing, start artificial respiration Immediately. b. Biphenyl - Biphenyl is a flammable material which will burn. Burning should not be done in the presence of Biphenyl or Biphenyl vapors. The melting point is 68.7C., and the auto ignition temperature Is 258C, Inhalation of Biphenyl fumes is not recommended, since it can cause a drugged effect on the person. c. Santowax R Saptowax R is a flammable material which will burn. It is relatively non-toxic to human beings. However, the vapors of Santowax R are irritating to the mucous membranes and bronlchial tract. Pro longed breathing of the vapors should be avoided. The melting point is 140C. NEV 024949 738204 APPENDIX J 7 I Cause and Action to Prevent 6. (Continued) d. Santovax C Same as Santovax R, since It is the crude material prior to distillation. e. Ferric Chloride Ferric Chloride is a black-brown solid. It causes only slightly Irritating effects on the skin or mucous membranes. When heated It vill decompose and release toxic fumes of Chlorine. It will react with water to produce toxic and corrosive HC1 fumes. f. Attapulgus Earth This material Is a dried earth. Ho danger In handling. Wash off with water to clean. f. Hydrated Line No particular hatard in handling this material. The dust is irritating to the eyes and skin) and should be washed off with water. h. Crude Aroclora Crude Aroclors are hot since all are handled in steam traced or jacketed lines. They can easily cause thermal bums in contact with the skin. Prior to air bloving the material has HCl fumes entrained in it which are Irritating to the skin or mucous membranes. 1. Hydrogen Chlorine Gas This is a corrosive gas which is toxic. It is irritating to the mucous membranes to the eyes and to the respiratory tract. It will react with water to form Hydro chloric Add. J. Still Bottom or Residue Fumes from still bottoms are toxic. They are extremely irritating to the mucous membranes to the eyes and respiratory tract. NEV 02*950 738205