Document V3jVR8X2Oy23Q3bKQve5e0XL8

1984 TEXAS CITY SAFETY AND HOUSEKEEPING INSPECTION GUIDELINES -7/n /e4- THEME SAFETY THROUGH EMPLOYEE INVOLVEMENT PLAINTIFF'S EXHIBIT EMPHASIS AREA * Involvement of People in Safety ' Safety Results and Trends ' STOP Program ' Adherence to Safe Procedures and Practices * Acceptance of Personal Responsibility for Safety * Attitude and Awareness of Safety at all Levels ` Evidence of Management's (all levels) Commitment to Operate Safely ' Health and Industrial Hygiene Programs ' Programs for Good Housekeeping and Preservation of Assets ' Use of Promotional Activities * Follow-up on Last Year's Inspection Recommendations INSPECTION DATE The plant will be inspected September 19, 20, 21, 1984. INSPECTION TEAM General Superintendent Superintendent Engineer Foreman Hourly (One of the above should be from Process Technology) RATINGS The inspection committee will not give the plant an overall rating?? Individual areas will be given ratings, and plaques will be awarded to the best area in each of four categories: units, crafts, labs and offices and services. Evaluations will be made based on safety performance, policies and practices, housekeeping conditions and involvement of people that ensures an effective, sustained safety attitude for outstanding safety performance. Outstanding - Stands out from all areas (comparison based on theme criterion). No safety practice deficiencies. Housekeeping performance equal to achievement potential. SC 000470 LAMOOI668 1984 TEXAS C-IT--Y---S--A--F-E--T-Y----A--N-D----H-O--U--S--E-K--E--E-P--I-N-G-----IN--S--P--E-C--T--IO--N----G--U--I-D--E--L-I-N--E--S-----------------------P--A-G--E---2- f Excellent - Very favorable compared to acceptable standard (based on theme criterion). Very few safety practice deficiencies. Housekeeping performance nearly equal to achievement potential. Good - Favorable compared to acceptable standard (based on theme criterion). Few safety practice deficiencies. Housekeeping performance at acceptable level. Unsatisfactory - Inferior compared to acceptable standard (based on theme criterion Unacceptable level of safety deficiencies. Unacceptable housekeeping level. Areas rated will be all units (including outside battery limits), main shops, instrument shop, electrical shop, stores, control lab, Research 1, 2 and 3. INSPECTION RESULTS The general results of the plant inspection, including the outside areas, will be communicated Monday, September 24, 1984. The results will be communicated with the expanded staff, SHAC, Technical Center Safety Committee, Office Safety Committee and Hourly Safety Committee present. Group size has to be limited due to seating available in the Research II Conference Room. SC 000471 LAM001669 INSPECTION TOUR SCHEDULE FIRST DAY: WEDNESDAY, SEPTEMBER 19 t Arrive Texas City (Personnel Building Training Room) 8:00 a.m. 9:00 a.m. PRESENTATIONS 8:15a.m. 1. Overall Texas City Safety Program Minutes R. T. Hammann (Bob) Loss Prevention & Safety Supt. 10 2. Plant Manager'sSafety Board (PMSB) and Safety Advisory Committee (SAC) 10 3. Safety and Housekeeping Action Committee (SHAC) E. P. Bailey (Paul) 10 4. Plant Manager's Comments G. L. Tromblee (Gene) 5 5. InspectionKickoff 5 6. Discussion Distribution of Safety Equipment 10 BEGIN INSPECTION 9:30 a.m. SC 000472 LAM001670 1984 INSPECTION TOUR SCHEDULE FIRST DAY: WEDNESDAY, SEPTEMBER 19 Walk To Power 2. WATER TREATING - PLANT AIR - POWER 2 0900-0940 Treatment of raw Brazos River water for plant use and generation facilities for breathing, instrument, and general plant air. Facilities for steam generation and boiler feed water treatment. HOSTS INSPECTORS SHAC MEMBER Meet in Control Room Pick up cars parked by cylinder racks beside Stores. Drive to Acetic Acid Control House. DEPT. 50 ACETIC ACID, CT-5 Acetic Acid is produced from carbonylation of methanol. This area includes catalyst preparation and product distillation facilities. HOSTS INSPECTORS SHAC MEMBER 0940-1010 Park beside Control House. Meet in Control Room. Drive to Phthalic Anhydride Control House. COFFEE - PHTHALIC ANHYDRIDE (Arrangements by Department) HOSTS INSPECTORS SHAC MEMBER SC 000473 1010-1025 Park beside Control House. Meet in Control Room. LAIVI001671 1984 INSPECTION TOUR SCHEDULE, WEDNESDAY, SEPTEMBER 19 DEPT. 53 PHTHALIC ANHYDRIDE Manufacturing process which uses BASF technology to convert air and orthoxylene to phthalie anhydride. HOSTS INSPECTORS SHAC MEMBER PAGE 2 1025-1055 f Drive to Dept. 48-56. DEPT. 48/56 0X0 ALCOHOL-PHTHALATE 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 Pick up cars at 77T101, drive to car port. LUNCH - Trays in Cafeteria Conference Room. SC 000474 Park at Formaldehyde Storage Area (77T101). Meet in Control House. 1135-1205 Meet in Control House. LAJV1001672 1984 INSPECTION TOUR SCHEDULE, WEDNESDAY, SEPTEMBER 19 Walk to Zone I Office. ZONE I OFFICE Offices and conference room used by maintenance personnel for styrene process. HOSTS INSPECTORS SHAC MEMBER PAGE 3 f 1300-1310 Walk to Operating Engineers Offices. OPERATING ENGINEER OFFICES Offices for operating engineers personnel. HOSTS INSPECTORS SHAC MEMBER Walk to Fire Station. FIRE STATION Two buildings which house the Texas City plant's fire fighting facilities. HOSTS INSPECTORS SHAC MEMBER 1320-1335 Walk to Electric Shop. ELECTRIC SHOP Consists of central shop facilities and offices for power distribution, electrical maintenance, and maintenance engineering personnel. HOSTS INSPECTORS SHAC MEMBER SC 1335-1350 LAM001673 000475 1984 INSPECTION TOUR SCHEDULE, WEDNESDAY, SEPTEMBER 19 Walk to AN loading rack. AN LOADING RACK, ESTERS LOADING RACK Rail car handling facilities for acetic acid, methanol, TBA, sulfuric acid, IBY, ACH, and esters. HOSTS INSPECTORS SHAC MEMBER Pick up cars at truck loading spot west of 51T17-2. Drive through North Storage. PA LOADING RACK Rail car handling facilities for phthalic anhydride. HOSTS INSPECTORS SHAC MEMBER PAGE 4 1350-1410 1410-1420 Park north of reformer. Drive to Dept. 513 Control House. PRIMARY TREATMENT, AMMONIA TANK Facilities for primary treatment of all plant aqueous waste streams. Ammonia storage tank provides raw material for AN manufacturing facilities at Texas City and Chocolate Bayou. HOSTS INSPECTORS SHAC MEMBER 1425-1450 Meet at 513 Control Room. SC 000476 LAMOOI674 1984 INSPECTION TOUR SCHEDULE, WEDNESDAY, SEPTEMBER 19 BARGE & SHIP DOCKS 5, 4, 3, 2, 1 Barge and ship loading/unloading facilities for raw materials, products, used at and produced by Texas City plant. HOSTS INSPECTORS SHAC MEMBER PAGE 5 1450-1530 Meet at Dock 5. Drive through sandblasting, NSI Warehouse, Maintenance Laydown, Salvage Areas 1530-1600 SC 000477 LAM001675 1984 INSPECTION TOUR SCHEDULE SECOND DAY: THURSDAY, SEPTEMBER 20 CAFETERIA CONFERENCE ROOM - Coffee & Rolls Drive through South 22. HOSTS INSPECTORS SHAC MEMBER 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 0815-0825 Park cars beside old Pilot Plant. 0825-0835 SUPER SHACK, AN INCINERATOR, DRIVE THROUGH STYRENE RACKS, ACY RACK AND EAST STORAGE HOSTS INSPECTORS SHAC MEMBER 0835-0855 SC 000478 LAM001675 1984 INSPECTION TOUR SCHEDULE, THURSDAY, SEPTEMBER 20 DEPT. 13 AKLYLATION, CT-1 Ethylbenzene is produced by the reaction of benzene with ethylene in the present of an aluminum chloride-organic catalyst complex. HOSTS INSPECTORS SHAC MEMBER DEPT. 15 DEHYDROGENATION Synthesis area for dehydrogenation of ethylbenzene to crude styrene. HOSTS INSPECTORS SHAC MEMBER COFFEE - SYTRENE-EB (arrangements by department) DEPTS. 14 & 16 STYRENE - EB DISTILLATION Dept. 14 - Ethylbenzene purification facilities. Dept. 16 - Styrene purification facilities. HOSTS EB INSPECTORS SHAC MEMBER SM PAGE 2 0855-0925 Park south of 14-16 Control House by Smoke Shack. Meet in Control Room. 0925-0950 Meet in Control Room. 0950-1005 1005-1035 Meet in Control Room. Drive to Salt Water Pump House and Zone 1 Warehouse. 000479 LAM001677 1984 INSPECTION TOUR SCHEDULE, THURSDAY, SEPTEMBER 20 SALTWATER PUMP HOUSE AND ZONE 1 WAREHOUSE HOSTS Zone 1 Warehouse INSPECTORS SHAC MEMBER PAGE 3 1035-1050 Split Team. Pump House LUNCH - Trays in Cafeteria Conference Room Walk to Stores. STORES Stores includes the shipping and receiving docks, storage bins of inventory items, and offices. HOSTS INSPECTORS SHAC MEMBER 1100-1130 1130-1200 Pick up cars in car port. Drive to Warehouses. WAREHOUSE A-B-C-F-G Warehouse A contains class A materials such as spare parts, paper goods, packing materials. Serves receiving function. Warehouse B contain flammable liquids, acid, paint. Warehouse C contains class A materials, such as, insulation, packing. SC 000480 1200-1230 LAMOOI678 1984 INSPECTION TOUR SCHEDULE, THURSDAY, SEPTEMBER 20 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 ZONE 2 OFFICE Offices for west plant maintenance personnel. HOSTS INSPECTORS SHAC MEMBER PAGE 4 Split team. Park across from Zone 2. 1230-1245 Drive to car port. RESEARCH NO. 1 This building houses analytical, catalyst characterization, radioisotope, and MIC Tech Services labs and bench scale reactor systems. HOSTS INSPECTORS SHAC MEMBER 1245-1255 1300-1340 Meet 1st floor west side. SC 000481 LAM001679 1984 INSPECTION TOUR SCHEDULE, THURSDAY, SEPTEMBER 20 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 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 PT WAREHOUSE & SOLVENT STORAGE HOSTS INSPECTORS SHAC MEMBER PAGE 5 1340-1440 Meet at Visitor's lobby Northwest corner - 1st floor. 1440-1455 Meet at North entrance below stairway outside. 1455-1505 Walk to Main Office Building. COFFEE - CAFETERIA (arrangements by Cafeteria) 1505-1515 SC 00482 LAM001680 1984 INSPECTION TOUR SCHEDULE, THURSDAY, SEPTEMBER 20 CAFETERIA Main plant cafeteria. HOSTS INSPECTORS SHAC MEMBER PAGE 6 1515-1525 Meet at cash register. DISPENSARY Provides facilities for emergency first aid and for monitoring employee health. HOSTS INSPECTORS SHAC MEMBER MAIN OFFICE - 2nd, 3rd and 4th floors Main Office building for manufacturing, distribution, environmental, safety, personnel and marketing personnel. HOSTS INSPECTORS SHAC MEMBER 1525-1535 1535-1555 Split teams. Meet in foyer. 2nd Floor 3rd Floor 4th Floor QUALITY ASSURANCE LAB Laboratory facilities needed to conduct analyses required for production and shipment of petrochemicals from Texas City plant and for environmental control. HOSTS INSPECTORS SHAC MEMBER 1555-1630 LAM001681 SC 000483 1984 INSPECTION TOUR SCHEDULE, FRIDAY, SEPTEMBER 21 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 PAGE 2 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. Ammonia and propylene are used as raw materials. Includes slip stream reactor. (Start in South end, end near MeOH.) HOSTS INSPECTORS SHAC MEMBER Drive car to methanol COFFEE - METHANOL (arrangements by dept.) SC 000484 0920-1025 Meet in Control House Park East of Control House off South St. 1025-1040 LAM001682 1984 INSPECTION TOUR SCHEDULE, FRIDAY, SEPTEMBER 21 DEPTS. 44-45-46 METHANOL, CT-3&4 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 PAGE 3 1040-1110 Meet in Control House DEPTS. 19-23-25-27-29 HCN-ACN-TBA-LN-ACY, CT-2 Manufacturing facilities for acetonitrile purification, tertiary butylamine, lactonitrile and acetone cyanohydrin. HCN Storage. HOSTS INSPECTORS SHAC MEMBER 1110-1205 Meet in Control House Drive car to Cafeteria LUNCH - Trays in Cafeteria Conference Room 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 1305-1330 Meet at Shift Office SC 000485 LAW1001683 1984 INSPECTION TOUR SCHEDULE, FRIDAY, SEPTEMBER 21 SOUTH MAINTENANCE BUILDINGS, INSTRUMENT SHOP & GARAGE Building include carpenter-insulator shop, instrument department shop, field maintenance offices, and garage facilities. HOSTS Maintenance INSPECTORS SHAC MEMBER Instrument RECAP PAGE 4 1330-1415 1415-1630 4 SC 000486 LAW1001684 EDC 7/1 7/23 8/1 8/6-10 8/15 8/30 8/31 9/4 9/5 9/10 ANNUM INSPECTION PREPARATION Resp. Inspection route and timing defined - dry run completed to parking places, cars needed, guide meeting place. JTP/JDR Assign Office Safety Committee responsibility for publicity. RTH Send copy of previous inspection recommendations to Superintendents. By 8/31 all items complete - written response. JAS Send out notice that all ladders are to be inspected and new tags attached by 8/3. RTH Encourage Plant Manager, Plant Engineer, and Safety Superintendent to be in the plant the two weeks prior to the inspection. By 8/15 obtain pictures and information on the inspectors, sizes, etc. EPB JAS Third Quarter Safety & Housekeeping Inspection. SWM Guides named for each area of plant. SHAC member will host each inspector - rotate at noon each day. Plant Manager and Safety Superintendent will freelance. General Superintendents will meet team at each area of responsibility. JTP/JDR SHAC drive around inspection - make slides. Use 3rd Quarter comments. SWM/JDR All recommendations from last annual inspection completed. JAS Route and guide list published and issued. JTP/JDR Information for inspectors (booklet, etc.) completed. JAS Name tags (name and puyitiun-) completed for inspectors, guides, etc. RTH Lunch arrangements completed (catered by cafeteria, sitdown) EPB Mail information to inspectors. JAS Include pictures and history of inspectors in plant newsletter. JAS/RTH Expanded staff - review slides, inspection details, and check list. SWM SHAC/Plant Manager drive around inspection - take slides. SWM Plant Manager mail letter to all employees home. EPB 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 SC 000487 EDC 9/12 9/14 9/18 9/19-21 10/1 2- - Expanded staff meeting - review slides. Drive around inspection - each General Superintendent accompanied by two SHAC members. Short wrap up staff meeting after inspection. Evening meal with inspectors and presentations. Tromblee, Forsthoffer, Hammann, and Chairman of SAC, SHAC, TCSC, OSC, HSC. Inspection Feedback Resp. 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