Document Xz8NdZ6bYroVBR7OkdpqYeLEy

Ofi !&J//A L MONSANTO COMPANY ORGANIC CHEMICALS DIVISION STANDARD MANUFACTURING PROCESS FOR PYDFAUL A-200 DEPT. 259 PYDRAUL 280 DEPT. 259 Supersedes: Standard Manufacturing Process for Pydraul A-200 in Department B-2G6, dated October, 1966. Prepared by: R. M. McCutehar: K hi MVP\., 1,/ = - I [ Approved by: Issued: Deceinb'.':'. Copyof 'M'HM CJLu wane General,-Manufacturing Superintenden A<- tz-jn f?o He starch b 7? cWkX-__________ t v/V? o Ms nufaot uring~Ma nagcQi - This process in the pm ; Honoetuo Company and the recipient is responsible for its nr "c. It contains confidential Information of Monsanto Company v:h.3ch . : rot be reproduced, revealed to un authorised persons cr sen: ov.v:.-.'.o the company without proper authori zation. Either reia'n i.r sc-cure file or return to the Standard Document Department. MQNS 046571 DISTRIBUTION SHEET 1. Technical Infonnation Center 2. Technical Information Center 3. Record Center 4. Manufacturing Manager 5. Manufacturing Superintendent - w.a.K. 6. W.G.K. Department Supervisor 7. W.O.K. Technical Service Department 8. W.G.K. Process Research 9. W.G.K. Library 10. D. Danna - 0.0. 11. D. Danna - G.O. 12. D. Danna - 0.0. 13. Extra lit. Extra 15. Extra AMENDING RECORD SHEET MONS 046573 SECTION I SECTION II SECTION III SECTION IV APPENDIX A APPENDIX B APPENDIX C APPENDIX D APPENDIX E APPENDIX F APPENDIX 0 APPENDIX H APPENDIX I APPENDIX J APPENDIX K APPENDIX L APPENDIX M APPENDIX N TABLE OF CONTENTS Index Synopsis of Process Process Plow Sheet Process In Detail Comments on Process Equipment List Finished floods and Raw Material Specifications Physical Constants Utilities Personnel Packaging and Shipping Material Balance Product Losses Process Control Safety and Toxicity Background Information Time Cycle and Capacity Quality Considerations Miscellaneous Page 1 2 3 6 8 9 10 14 15 17 18 19 20 21 25 26 27 29 MONS 046574 MAJOR CHANGES from process dated October, 1966, follow: The only changes of consequence Incorporated In this Standard Manufacturing Process from data In superseded SMP's are: 1. Santolube 70A Is used Instead of Santolube 70. 2. Trlcresyl phosphate produced at the W. G. Krummrlch Plant Is used In Pydraul 280, rather than TCP produced at the J. F. Queeny Plant. 3. "Bolldown" production Is used In Pydraul production. This material may be less stable (from an electrical use standpoint) than normal finished goods and may be over 20 APHA in color. This may or may not have been normal practice at the time of the previous SMP. *(. Annual capacity Is 7-OM lbs. instead of 5.0M lbs. R. M. McCutchan MOMS 0<i6575 1 DEPARTMENT 259-Standard Manufacturing Process pyaraui a-200 ana pyaraai 280----------------------------- section 1 Synopsis of Process Pydraul Is a trade name used to designate a series of hydraulic fluids. Pydraul A-200 was the first one produced at the W. 0. Krummrich Plant. Later (April, 196*4) Pydraul 280 was produced. Both are fire resistant, the 280 being used almost exclusively In mining applications. Pydraul A-200 has a slightly higher specific gravity, but the 280 Is more viscous. Both Pydrauls are blends of Aroclor, phosphates (280 only), small amounts of petroleum additives, dye, and a defoaming agent. The blend components are as follows: Raw Material j fwt.) except as Indicated A-200 280 Aroclor 12*42 33(vol Aroclor 12*48 67(vol Aroclor 1260 -- Trlcresyl phosphate - Santolube 70A 0.5 Lubrlzol 1360 0.5 DC Fluid 200, 350CS 0.005 DuPont Oil Blue A Dye 0.0005 Azo Oil Black 0.0002 0.002 0.0007 Pydraul A-200 and 280 are sold In 55 gal. drums and 5 gal. cans. Pydraul A-200 Is also Bold In bulk quantities. HONS 04657b 2. DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and Pydraul 2tip SECTION II Flow Sheets TS-D-A695 and TS-D-9472 are flow diagrams of Dept. 2t6 (Aroelor) and Dept. 259 (Pyranols and Pydrauls). The only equipment used In Pydraul production Is #1 Mix Tank and pump. Items 159 and 155 on 18-09*1695. ( MOMS 046577 HONS 0 4 6 5 7 8 HONS 0 4 6 5 7 9 3- DEPARTMENT 259 - Standard Manufacturing Process Pvdraul A-200 and Pvdraul 280~ SECTION III Process In Detail A. Batch Data The raw materials necessary to produce typical batch sizes are: Raw Material A-200 12,000 Gal. Aroclor 1242 4000 gal. Aroclor 1248 Aroclor 1260 800--0 gal. Tricresyl phosphate -- Santolube 70A 700 lbs. Lubrizol 1360 700 lbs. DC Fluids 200,350CS 7-5 lbs. DuPont Oil Blue A Dye 326 gms. Azo Oil Black 120 gms. A-200 8,000 Gal. 2670 gal. 533--0 gal. -- 500 lbs. 500 lbs. 5.0 lbs. 264 gms. 80 gms. 280 140,OOC1 Lbs _ 87,000 lbs. 22,500 lbs. 30,000 lbs. --560 lbs. 3-0 lbs. --1.0 lbs. B. Blending Of Major Components Primary chemical reactions are absent in the production of the Pydrauls. The only process step is blending, which is done at 80-100c. A-200 Aroclor 1242 and 1248 are pumped from storage in Dept. 246 to #1 Mix Tank. The mixture is agitated for four hours, and a 16 oz. sample taken for analysis of specific gravity. The desired specific gravity of the Aroclor mixture is 1.429 1.431 @ 25C. Small additions of either Aroclor 1242 or Aroclor 1248 are added as necessary to achieve this gravity. When the small components are added later, the specific gravity usually decreases by 0.003-0.005. 280 Tricresyl phosphate (TCP) is received by trailer and pumped to #1 Mix Tank. The necessary weights of the Aroclor 1248 and Aroclor 1260 are calculated based on the trailer weight of TCP. The Aroclors are transferred to #1 Mix Tank, agitated for four hours, and a 16 oz. sample taken for analysis of specific gravity and viscosity. MONS 046580 H. DEPARTMENT 25Q - Standard Manufacturing Process Pydraul A-200 and Pydraul g80 SECTION III (cont'd.) ProceBB In Detail (cont'd.) B. Blending of Major Components (cont'd.) 280 If the specific gravity or the viscosity of the batch Is off specification, one or more the the following factors may have caused the deviation. a. An error In charges made to the vessel. b. Specific gravity and viscosity specifications for the raw materials, are broad and the properties of the batch will be affected accordingly. c. Insufficient mixing. The properties of the batch are brought into specification by following this guide: d. If both viscosity and specific gravity are out of specification, adjust charges to correct viscosity first. In so doing, the specific gravity will be corrected normally at the same time. If only the specific gravity Is off specification proceed to e. below. 1. If the 1Q0F viscosity Is high - "out of specifi cation" - add TCP. The addition of 1.0 lbs. TCP/100 lbs. batch will lower the 100F viscosity of the batch about 1.5 centiStokes. 2. If the 100F viscosity Is low, - "out of specifi cs t Ion ',~~^~SLd3~Kroclorl2SQ'. The addition of 1.0 lb. Aroclor 1260 per 100 lb. batch will Increase the 100F viscosity about 1.7 cs. e. After making the necessary adjustment for viscosity, if the specific gravity is still out of specification, proceed as follows: 1. If the SP. Or. 25/25C is high, add a mixture or 68 wt. % TCP and 32 wt. ^ Aroclor 1260. Add 1 lb. of this mlxture/100 lbs. batch for each 0.0012 units high. 2. If the Sp. Or, 25/25C Is low. Add a mixture of 91 wt. % Aroclor 1248 and 9% Aroclor 1260. Add 10.0 lbs. of mixture per each 100 lbs. batch per 0.0067 units low. HONS 046581 5. DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and Pydraul 280 SECTION III (cont'd.) Process In Detail (cont'd.) C. Blending of Minor Components Only after proper specific gravity and visoosity are obtained are the minor components added. This should be done when the batch temperature has fallen below 70C. At higher temperatures Lubrizol 1360 begins to decompose. Lubrlzol 1360 Imparts good anti-wear properties to Pydraul A-200. Since TCP provides ample anti-wear protection, Lubrlzol 1360 is not a components in Pydraul 280. Santolube 70A is a rust inhibitor. Dow Corning Fluid inhibits foaming caused by Santolube 70A. The dye does not change any property other than color. D. Sampling and Packaging After all components have been added the batch is agitated for six hours. Three 16 oz. samples are taken for final analysis. If the batch meets all specifications (See Appendix B), the finished Pydraul is drummed or loaded in trailers (A-200 only). Drum net weights are: 55 gal. 5 gal. Pydraul A-200 Pydraul 280 6*45 lbs. 625 lbs. 59 lbs. 60 lbs. The Pydraul must be allowed to cool to *40C or less to fill drums to the proper weight. When Pydraul A-200 is loaded in a tank trailer, two 16 oz. samples from each compartment are taken for analysis. 0A6582 b. DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and Pydraul 280 ' SECTION IV Comments on Process A. Blending Any ln-speciflcatlon Aroclor can be used for Pydraul production. Experience indicates that good correlation of specific gravity and visooslty of the finished goods is more easily obtained when the specific gravity and viscosity, of the Aroclors are near the middle of the specification ranges. When producing Pydraul 280, the targeted specific gravity is toward the lower end of the specification range. It is much easier to add additional Aroclor than it Is to add more TCP. B. Yields All Aroclor yleldB are assumed to be standard, 99% of theory. Exact proportions vary from batch to batch depending upon the exact specific gravity of the Aroclors involved. The only raw material on which an actual yield is calculated is TCP. Standard is 99% of theory, but this has seldom been achieved. In spite of close process control, YTD (1970) yield is 97-3^The primary reason Is that small Aroclor adjustments are not made after specification Is obtained. This is because If too much Aroclor is added and more TCP is necessary, then drums of TCP must be ordered. The department has no TCP storage. C. Qua 11ty Care is taken to avoid a Pydraul 280 batch with specific gravity higher than specification for the reasons mentioned above. All other analyses for Pydraul A-200 and 280 are relatively easy to obtain. Nearly all "bolldown" production from the Aroclor operation is used to make Pydrauls. Aroclors with colors up to about 150APHA are suitable for Pydrauls. Pydrauls of the 312 series, produced at JFQ can tolerate Aroclor color up to about 300-350 APHA. MQNS 7. DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and Pydraul 280 SECTION IV (oont'd.) D.__ Capacity The Pydraul capacity of Dept. 259 Is about 7.OM lbs. per year. This Is equivalent to one 12,000 gal. batch per week. The only bottleneck Is storage. The #1 Mix Tank has the dual purpose of a blending tank and a storage tank. Bulk orders often are placed with very little lead time. Therefore, bulk amounts are sometimes held In #1 Mix Tank in anticipation of an order. At other times drumming from #1 Mix Tank Is delayed due to a greater need for other drummed products. Pydraul A-200 and Pydraul 280 occupy the same equipment. HONS 046584 8. DEPARTMENT 259 - Standard Manufacturing Process Pvdraul A-200 and Pvdraul 280 APPENDIX A EQUIPMENT LIST ITEM NO. EQUIPMENT NAME EQUIPMENT NO.________ DESCRIPTION 159 #1 Mix Tank, 21-0321 Tank (Nooter), Dwg. 0-6^55, 1^' O.D. Speed Reducer 37-5176 x 10' high, 3/8" shell, steel and Motor 66-2168 construction. Capacity Is 15,000 gals. Agitator motor Is 7-5 HP, 1750 RPM. 155 #1 Mix Tank 19-3172 Pump and 66-2651 Motor Durco pump model WH2 alloy construc tion, 2" x 1 1/2" with 8" Impeller. Capacity of 160 gpm at 55' head. HONS 046585 9. DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and Pydraul 280 APPENDIX B SPECIFICATIONS The following Is a list of the raw materials used In the manufacture of Pydrauls at the W. 0. Krummrlch Plant. Specification sheets that a available are Included. Material Code Raw Material 81101 81102 81105 80071 81797 39050 31100 20640 20317 Aroclor 1242 Aroclor 1248 Aroclor 1260 Trlcresyl Phosphate Santolube 70A Lubrlzol 1360 DC Fluid 200.350CS duPont Oil Blue A Dye Azo Oil Black The following Is a list of the finished Pydrauls produced In Department 259. Specification sheets are Included. Product Code Product 81096 81119 Pydraul A-200 Pydraul 280 MONS 046586 Monsanto W.G, Krummrich Anniston FINISHED PRODUCT SPECIFICATION > PRODUCTION P. K. Heisler ALSO W. E. Ault MMUCT Aroclor 1242 |Mv. Ar Non-Electrical Grade |WGK 246 2 WGK & Ann. OATS I'/lffVtVl' 9/25/67 APPROVAL* aiumum 81101-82612 ALBS CODS Sales 1040-240-04/11/16-03/09 '-- "m" '1 M-. E-. Gibbs DUALITY CONTROL fCM*l ChmmlnO W. J. Gresham IMOCA MOL NT. lUMMIMI MICC OP 7/15/64 CMARACTBRISTIC Mixture ample pon analysis 3 x 16 oz. W.M. Bottles UNIT* UNRESTRICTED INFORMATION (R) (R) (R) (R) (R) Condition Color, A PI IA Sp. Gr\ (25/15. 5C. ) Acidity (mg. KOH/g.) Moisture (H*0) (ppm) Clear 100 max. 1.381 - 1. 392 0. 010, max. 50, max. >a*us6 ov'' 11 r " ' T " 1 --"l,_lu- L,. E. Hornback MTNM WGK 10084 10084 10114 10087 10620 Anniston G-l 046 052 050 047 Distillation Range (ASTM D-20 Corrected) 10% Distilled by wt. 90% M "" Viscosity @100F. (SUS) Flash Point (F) Fire Point 3259C. , min. 3609C. , max. 82 - 92 338 - 392 None 10117 14-31-54 10086 10123 10123 049 14-28 -54 14-28-54 (Hi /touttn* Anmlytii, Alt mtkart Annlytnd ky rfMH Only HONS 046587 Monsanto OAOANIC CHEMICkLl OIVIMON W . G. Krummrich & Anniston FINISHED PRODUCT SPECIFICATION production P. E. lleisler ALII W. E. Ault ItNCRAL DESCRIPTION PRODUCT BOOT. ||vW' ....................... ull 1 BWGK b Ann. IftMl IMIMivI 81102 82641 IAIII CODC Sales | 9/25/67 1040-260-04/11/16-03/09 MIIAHCH M E. Gibbs QUALITY CONTROL (ChiO* ChmmltQ W. J. Gresham CHi MIC AL FORMULA . Mixture An " MOL IT. luMMiDti spec*. or 7/15/64 CHARACTERISTIC lARFLl FOR ANAiraM 3 x 16 oz. W.M. Bottles LIMIT* IMVIt BY L. E. Hornback MITMOD UNRESTRICTED INFORMATION WGK A nni ston (R) Appea ranee Colorless to light, yellow-green liquid 10084 G-l <R) Condit ion Clear (R) Color, APHA 100 max. (R> Sp. Gr. @65/15. 5'C. 1.405 - 1.415 (R) Acidity (mg, KOIl/g,) 0. 010, max. (R) Moisture (H20) (ppm) 50, max. (R) Viscosity @130F. (SUS) o CO i r- Flash Point (F) 370, min. 10084 10084 101 14 10087 10620 10086 10123 G-l 046 052 050 047 049 14-28-54 L (ft) Routine Analysis, All others Analysed by refusal Only HONS 046588 Monsanto OR O AN IC CMtCMIC ALl OIVISIOM W. G. Krummrich & Anniston FINISHED PRODUCT SPECIFICATION HIIOOWCTI P. P. Heislcr SALKS W. E. Ault 4 C NCR Ak GKSCRIPTlON PRODUCT Aroclor 1260 Non-Electric Grade r k ANT PIIOOOCT use [OrtPT, Ai WGK 24 6 ? WGK & Ann. 5TTk ifpFocTTvl: ' 81105 - 82614 tffiLuu a Sales 9/25/67 APPROV AkS ncciiAncH 1040-290-04/11/16-03/09 M. K-. Gibbs quality control (Chief CKtalr.O W. J. Gresham CKSfc'^AL FlMJUULA Mixture MOk WT. supcnsuoits specs. of 7/15/6*1 CHAP ACT ERISTIC SAMPLE PGR ANALYSIS 3 x 16 oz. W.M, Bottles LIMITS U NR F.ST1U CITED INFORMATION (10 Condition 00 Color, APIJA 00 Sp. Gr. @90/15. 5'C. 00 Acidity (mg. KOll/g. ) 00 Moisture (HzO) (ppm. ) (10 Viscosity @210"F. (SU S) CJ ea r 150, max. 1.555 - 1.566 0. OH, max. 50, max. 72 - 78 idliUCO ST L. E. Hornbnck ur.Tii.va WGK 10084 10084 10114 10087 10620 10086 Anniston G-l 046 052 060 047 049 Flash Point Fire Point None None 10123 10123 14-28-54 14-28-SI t. fit I . ill .i 1___ J ., n.i,, HONS 046589 Monsento OnOANIC CHf.MIC Al.i DIVlBION RAW MATERIAL SPECIFICATION MATERIAL COOK 80071 PLANT WOK DATE EFFECTIVE. 1/31/G9 APPROVALS MATERIAL Tricresyl riiosphate A Greet UB1NC DEPT*. 259 UPTLIKR J F. Queeny J, W. Molloy VS5ir5t-- J. Leyerle EKNtiWAL PCtC WIRT ION . (cn3c6iu)3 po< laker_______ ou' ,LIT Y CONTROL (Chlcl Chtinltt) R. Blowers CHEMICAL FORMULA mol. wt. 568.18 *ui*rtRVcotT* n'eci or < 13/27/G8 CHAHACTinilTIC TEST On Each Lot umplk for analt us 1 x 16 oz. NH Bottle LIMITS Internal Use ' j msvld oy" * |ilg(;erson/Rt.lte.ri HET MOD JFQ Methods WGK Method: Acidity 0.20 meq./lOO grams max. (=0.01$ as H3FO.1 ) 'I - A 12,236 (R) Appearance Clear, practically color 16 - B less to light yellow liquid 12,233 a 1 CO f^N Color APHA 75 max. 10,00V Moisture (By KF in methanol) 0.15$, max. 78 - B 12,238 Odor No foreign odor .81* - A 10,060 (R) Specific Gravity at 25/25C. 1.157 to 1.173 116 - B Stahl lity to' KMnO< (R) Refragtive Index * 65$ transmission min. i.sg'io - 1.5560 118 - D 11,78': . `identification only. Tentative limits based on very little data, Shipments are not to be rejected because of failure to comply with these limits. MONS 046590 Monsanto O'lOANIC CHEMICAL* DIVISION RAW MATERIAL SPECIFICATION PRODUCTION J. W. Molloy PROCUf<r.MKNT J. Leyerle DESCRIPTION MATERIAL CODE MATERIAL 82130 .5 /'/']/ S antolube /O-A PLANT ' USING DEPT*. WGK DATE EFFECTIVE 2S4 tUPPLILH 1/23/70 Nltro APPROVALS n L FitARC H J. F. Palmer, Jr. QUALITY CONTHOL (CM*/ Chmllt) R. Bloviers CHEMICAL FORMULA SUPERSEDES IPECI OF , - . ^_tt224S2-_. CHAN ACT T.HUT 1C TEST*' I SAMPLE FOR AM ALTAI* . 1l2 1LS5- LIMIT* UNRESTRICTED [ISSUED BY -Mis*____ lsy&^ HjjjKg'.'OQD Ltjij METMOO RESTRICED On-eaoh lot Appearance and. . Condition Clear, oily liquid 6-C-01 Color, ASTM Dll. Neutralization Number 5. 5 max. 56 J 5 ASTM D-1500 6-A-26 . S.olublllty, 5% by Volume In B & A Petroleum Ether (30 -60C). Clear 6-V-22 Erpulslon ^0,110,0(30 min. ) Upon Request . ;: 6-S-28 Santolene C Presence . Specific Gravity at ?5C . . Typical .0.92 + 0.5 ' Positive Phosphorus . Test 6-S-59 . 6-D-07 Viscosity, SUS pt 210P. * Typical 180 + 110 6-X-02 MONS 046591 r.iOnse>nlo OKOANIC CHEMICALS DIVISION RAW MATERIAL SPECIFICATION PRODUC t ion P. E. Helsler PROCUREMENT JU.. Ley crle . BNSRAL DESCRIPTION ' MATERIAL CODE MATERIAL 39050 PLANT Lubrizol 1360 UtlNO OCPTS. WGK date til' rucTive , 259 - UPPLICN 12/6/67 Lubrizol APPROVALS RC6CARCH . L. R. Stark QUALITY CONTROL (Chlml Cl.j1*0 W. J. Gresham CHEMICAL FORMULA SI/PCRSXOftS SPECS DC 11/20/64 characteristic SAMPLE FOR ANALYSIS en2swxwvi1K6iLiiocuz^.niiWsm,Muw, itvBsAojtMtule.if LIUITO L. E. Hornbag;k<j mAfc*rvr; UNRESTRICTED INFORMATION Specific Gravity @15.5/15.5C Phosphorus Sulfur ' Zinc Viscosity @210F (98.9c; Pounds/gallon @15.5C about 1,125 7.8$, min. 16,0$, min. 8.2*, min, about 60 SSU about 9.55 Analyses to be obtained from Supplier on request. Shippers analysis covering the above requirements will be mailed to the W. G. Krummrich Plant Laboratory - Chief Chemist the same day 'shipment is made. HONS 046592 _ teento LL RAW MATERIAL SPECIFICATION FnonuCTlOH T. W. Dalton 1'ROC URL Mr. NT K. F. Ncunuc.bcl QgNCRAl. DESCRIPTION MATERIAL CODE MATERIAL 31100 Dow Corning 200 Fluid SLANT USING OCPTi. WGK 259 DATE EFFECTIVE SUPPLIER . 4/17/68 l)ow Corning Corp. APPROVALS RESEARCH J. W. llakcr . C. A, Pratte OUALITV CONTROL (CM*./ ChvmUl) W, J. Gresham C MEM1C AL FQUMUL * *yi-.Neofc ii'ici or " 3/18/65 CHtnACI ERISTIC son ample analysis 1 X 8 07.. W, M, Bottle LIMITS UNKFSTR1CTKD INFORMATION Appearance Syrupy Liquid Viscosity @25rC. 330 - 370 cs. Color - Modified ASTM D-848-45T 1,5, max. Flash Point 6 00 0 F. , min . Neutralisation Number 0. 05, max. Stability (Viscosity Change aflor 16 hrs. @200*0.) 10, max, _L. K. IJoiT.bi._ck_ MCTMOO T-2131 1-2132 T-2M2 T-2138 80-B ( J1 < 118-31100 (JFQ) This material is shipped upon invoice certification of compliance with specifications. .: (H) Kautlna An an.. MGNS 046593 " 'Monsanto.... OROAHIC CHCMICALt OIVUION FINISHED PRODUCT SPECIFICATION ' PRODUCTION i). Mollov ALC* W. E. Ault . CMCNAl DC *CR IHT ION FYDKAUL A-200 WGK "sTooucr dou?" 81096 fT>Tirc>Ydnvir vrrtToi?u 4595-200-11-03 APPROVAL* AlltHAMeH J. W. Dakar OUALITY CONTROL (Chit! ChemtH) R. Blowers - CHBMICAL FORMULA OCV' Vj'J Salec molut. __ BU^KNSK^plTipacS. OP _______ 'HAH ACT CmtTIC MIXTURE AL^U.I FOR AMALVltt 2 x 16 oz, V/.M, Bottles LIMIT* l**UttO UY Higgerson/Stit;os MB T MOO UNRESTRICTED INFORMATION (R> Appearance Cloudy, Blue Liquid 12, 809 (R) Flash Point (R) Moisture, K.F, (R) Neutralization Number (R) Sp. Cr, @ 25/25 *C, (R> Viscosity, @ 50 *F, @ 100*F. @ 210*F, RESTRICTED INFORMATION 1R) Foam Teat 350"F., min. 0.05%, max. 0, 80 - 1,10 mg, KOH/g, 1.415 - 1.430 900 ci,, max. 30, 0 - 33,0 cs. 2.80 - 3. 00 cs. - 150 ml., max. * 12, 803 12,810 12,794 12,804 12,837 12, 805 *Disposition of lots failing this limit will require approval of the Sales Department. HONS 046594 Monsanto OAOAN1C CHlMICALI DIVISION FINISHED PRODUCT SPECIFICATION PRODUCTION P. K Heisler ALB* w. fi. Ault 1 FCXnT**- coos w*i 6i+I WlPG7KKfivI--------- iiLia81to11ll9 Sales ] io/i:.'o7 4S96-280-11- 0}___________________ APPROVAL* NCIIAAtH J. W. Baker QUALITY CONTROL (CM*/ CAmI0 W. J, Gresham CHEMICAL FORMULA MOL WT. lUPIRIIDCI IRKC*. OF .............. I*AMDLBrOR ANALVBI* |lfc*UCOOV 12/28/64 .|2 X 16 OZ, W.M, Bottle 1 L. E, Hornback LIMIT* UNRESTRICTED INFORMATION (R) Appearance (R) Acidity (Neut. #) (R) Moisture (R) Pour Point (R) Flash Point ; (R) Viscosity 100F 210F (R) Sp. Gr. @!25/250C '* Cloudy Blue Liquid 0.2 - 0.5 mgKOH/g 0.15$, max. +20F, max. 350F, min. 56 - 62cs 5.90 - 4.10 cs 1.385 - 1.405 MIT MOD 12809 12794 12810 10115 12803 12837 12804 MGNS 046595 DEPARTMENT 259 - Standard Manufacturing Process P.vdraul A-200 and 280 APPENDIX C PHYSICAL CONSTANTS 10. This section contains physical constants data and physical and functional properties of Pydraul A-200. NUNS 046596 Din PHYSICAL CONSTANTS DATA HMmUer ................. .. AROCLOR 1260 ' " STRUCTURAL FORMULA COMPILED UT _ AJW^E.IIenhur*T__ Fonsnlo Molecular Wdshi fc. NAMS ,_ $ llUPnlrl II B ita " fri 11m Print rt mm fiif Hoi Polr.l ft ir,m q''tdllilrjj'olnt k'n 91 11m Point it!iclllc Gnvltv n . 25/25 /"C. Sp1tlllc Owltv * nn/15 Rur liduaTsT# 25 SC ' - Co .'llekr.l ol Entr.ision on-100C fltlirrllvs IrJix 7Bur i Inlit R:d trcltim 0wa.Tr.c1j Ultra Violet Sjsctiira m-lvoce) m wsltue 210IJ.V. YllodtY tin ran Tn'lon $91 4IIIIV In Wrttr toll r>lllh> In . Sol Allltv In ......... ...... ...... Oat 4/25/57 Cl 6.25 'irMl 7R*'"Ik 9R lOUBfilLLIUlS________ . 381 (A vk. 1 ' -I-UXElUnaft 3ft5-420wC. 195-24Rur. s.tlsJiyxcaii)L ___ Jioo.50xna^uU^QIL-Xli(J.'l!: II II Non-Crvstallizln II 1.620 1.555-1. 566 13.50 0 0. 000B7 ce/ce/"C. 1.6455-1.6465 J'itci(icEiUan_!l/J``ili5L _ MB OP-115 Ir.atinn g/lA/SS.__ 72-78 SUS MR OP-115 Trsoliihlp f . ____________ __ ________ 1 Flt;!> Petrt fii c. c. OliFfctl,C. & 9 <lf f>' ? Hh| ol Firr.r'lcn . - o. c. 1 ttirad Sl'PIlily (crl./>3/nln.) L'lmt l|r-i or Fr.lrn Litent Hr>t o! Vfi). . _ cal/ppi . __ Scaclllc Hart @ 25C. Critical Tr~ssrr.tu.-e , Critic-J Pi:r.'fe________ ansodrtlM Ccr-Pnt . Speclftc Heat 5 300C. Kv.. 46 0.228 0. 303 _______ Pour Point Sm Dielectric Constant. 100&C. M 8 CO cv. u i o 25r34uC. 3.6-3.8 tl Calculated1 MR OP-115 It II " ONS 046597 ----------- Toikily (Gii* Rtferrnee) Contact Medical Dent. * MB OP-115 a.... PHYSICAL CONSTANTS DATA 'tVpnrxHci--------------- STRUCTURAL FORMULA AROCLOR 1248 A.M. Ellenburg NAME fe mala Wo ecultr Weieht ta>Miance ft lint Point# 760mm Range Boflin! Point at 3 no " .. Si lint Point X mm ft. lint Point X mm P'Sstollizlnt Point Eel MitIon Point &icllicGravity Sic cific Gravity* Po lids pm Gal. n 25/25 C] 65/15. 5UC. 25 C Coelflclcnl of Expansion 5>R-fi5C. Roluctlvo Index t 25uCn i Ini 1 Rod SPOCtrum (Relttmct) Ull 1 Violet Speetrum Olderence) Ylcosily* 130F, XUcosltv* Sail *eTfP*lon Dynes/cm @20UC. Mjbllitv Sol Ltillltv In V/Xct In 3A Alcohol 25C. Sol jbllitv In i"vrldtne _ (3 29UC. _ 4-25*57 Cl 2 H6 Cl4 292 (Avg.) Yellow Tinted Mob. Oil 345-385C. 165-210V SOURCE Is DATF Monsanto Bull. OP-115n M It Non-crystalltz lng II 1.445 1.405-1.415 12.04 ,,________ 0. 00070 cc/cc/uC. 1.6285-1. 6305 II Specifications 9/9/54 M.B.OP-115 Specification 9/9/54 * 73-80 SUS 44.2 Insoluble 15 g. /100 cc 111.4'b. /100 cc M.B. OP-115 J. Coll. Scl. 7 . 166, (195 .JVL^..OP_-n 5~ It FIssli Print C. 0. c. Fir Pdf.l C r n r. He: 1 of PfbiUftlm Her ol Funllcn 16swart Sl/blllty fccl.Aa/miiO titMt Rant ol Fuslcn titwil Ro.'l ol Van. cal/gm. Senelite Hast a 2Ruri cut leal Timitlm cm Ic.'il Pn?rw.-t BitsoelrtlM Crertfrt Ss eelNe Heat (Si SOO^C.- T96C None 54 0.277 0.356 Pour Point Thermal Conductivity, cal/ M ImS TS cm/^C/sec. Dielectric Constant. 100c. . e0 feO cv. U 1 o 0C. or lower 23.6 @ 28c 4. 5-4. 7 It If -- Calculated.................... ...... M.B. OP-115 _ . u II To be Dubllshed _M.B.-QErU5-- . 0NS 046598 -- Toxicity (Civ Reference) r1 - - J*'" *../</ ns%t A* Contact Medical Dept. M.B. OP-115 out*id* of Monsanto Chtmiedl Company. Vt* additional thftts if necessary. 3.... PHYSICAL CONSTANTS DATA `TOiffSer ~ -- ~~ AROCLOR 1242 - -- : STRUCTURAL FORMULA rPMFRED'lY " GbO NAME Formula Molecular Welcht tarcarance Bollint Point at 760 mol Ranne Boltins Point at 3 mm Boflinv Point A arm '' Boiling Point 4 mm CrysIsIJizlnp Point Mfilttof Point Solution Point Snocinc Gravity 25/25'C. Specific Gravity 25/15.5C. Pounds par Gal. t> 25 C Coefficient oi Expansion 25*65 C. Rolraotlvo Index 25 'C. n J Inlia Rod Sncclium (nrlactiee) Ultra Violet Spectrum (Reference) Viscosity o 210F. Viscosity* 100"F. Surfree Tension Dyne n/cm @ 20*C. Sofubflitv in Wrier {o|r>l||ty in 3A Alcohol ( 29 C. Solubility In Pyridine @30'C. Cl2 h7 ci , 257 (ave.) Colorless Mobile Oil 325 - 360'C. 155-1 95 "C. Non-crystallizing 1.380 1.381 - 1.392 11.50 0.00068 cc/cc/'C. 1.6245 - 1.6265 34-35 BUS 82-92 SUS 45. 3 Inedible 23.3 sr./lOO cc 132.5 E./100 cc SOURCE 6 OATE Mi-nnartft Bui1, DP-1 m ;/ n n It It Speciflcat on 2-14-55 OP-L15 II M. B, OP-I 15 M T, Cell. Sc;. -7-, t66,<lQ52 M B. OP-115 ' ' ' II II Flash Poll,! ^XtHahodi c. o. c. Fin PointC c.o.c. Heat ol Cm^tlon Heat ot FoinrLticn Thermal StrbiUtY (czt.Aft/miiO Lftenl Hast ol Fusion Lf.tcnt Hnat ol Vro. cal / pm. Soeelllc Heel @ 25 'C. Ctllictl Temoetalute Critical Pressure Dissociation Ccnstfnl Specific Heat @ 300 "C. 180 'C. None 61 0.293 0. 380 Pour Point Thermal Conductivity, cal/ w cm/ w eec. l Dielectric Constant, 100C.. e 60 cv. O S -14C. or lower 24.0 (5) 28 . 4.7 - 4.9 II II M. B, OP-115 - II II pJ.-B._Qg-.U5. MONS 046599 Tex cilV fCivt Reference) Contact Medical Den<;_ __M*J3_.D.P. -1JL5 urTK. *t... jn,. ikntdti not be released outtide of Monsanto Chemical Company. Use additional sheets if necessary. DEPARTMENT 259 - Standard Manufacturing ProceBS PYDRAUL A-200 and 280 APPENDIX C PHYSICAL CONSTANTS - W. 0. KRUMMRICH PLANT 11. Appearance: VlBCoslty: at 210F at 100F at 40p Density: at 100F at 60F. *PYDRAUL A-200-PHYSICAL & FUNCTIONAL PROrERTI Slightly cloudy, light yellow, oily liquid. Centistokes Saybolt Universal Seconds 2.86 30.14 1920. 35.8 142. 8500. 1.4l6l gra./ral. 1.4305 gm./ml. Flash Point (COC): Fire Point (COC): 380F. 680oF.U) Hot Manifold (MIL-F-7100), 1300F.- Does not flash or burn on tube or after leaving tube. Low Pressure Spray Flammability (AMS 3150-B) - Flame brightened, but did not increase. High Pressure Spray Flammability (AMS 3150-B)- Will not ignite. Molten Metal Ignition (molten aluminum alloy at 1150 to 1250F) spontaneously ignite. Flashes by spark. Doe: Pour Point: + 15 p- Neutralization No. ------mg m/ern': 'to pH 11: 0.83'2' Steam Turbine Oil ,, Rust (ASM R-665) 10.0 at 48 hoursO) M0NS 046600 Foam (ASTM D-892) at 75F at 200F. at 75F Shell Four-Ball Wear: 167F, 630 RPM, 1 hr. Foam Vol. ml. Collapse Time Seconds 30 60 8 60 35 60 Steel-on-steel 4 Kg. - 0.21 mm. 10 Kg. - 0.29 40 Kg. - 0.43  :;r PC.' - Standard Manufacturing Process rvbSMiT, A-POO and 280 Ali'UND.IX C it-. l CA i. CONSTANTS (Cont'd.) - W. 0. KRUMMRICH PLANT ."hell Four-Ball Wear .1.6/oj,630 ftpM, 1 Hr. Steel-on bronze 4Kg. - 1.20 10 Kg. - 1.40 40 Kg. - 1.70 /Union R.P. Passing load - 48 lb. Passing torque - 4l lb. 24,000 psl. Abnen Wear (wt. lone mg.)* Timkon Load (1i r, s i "r'lgji 1.3 mg. 50 lb.. 16,340 psl film strength mi Turbine Oil Oxidation (ASTM D-943): (1008 hours exposure) Vi density 100V. Initial FI nal PIOhF. Initial F:l nal Aridity Initial, TAN Final, TAN Fluid Ap)!rirance Stool Appearance Copper App. Four-Pal 1 Wear: 30.12 cs. 30.03 cs. 2.87 cs. 2.86 c s. 0.82 0.21 Greenish brown with greenish white deposit in tube bottom. Soft black deposit on surface. Black rough (etched) surface. Initial 10 Kg.-0.29 mm.. Final 10 Kg.-0.4l mm. l d.-, t i on -Corrosion: (Fed. Sped. 791 Method 530.8 250F). Wo1.nl Attach (wt. change mg/cm. ) 168 hrs. at Copper Alum!num Magnesium Steel Cadmium Plate - 0.05 no etoh. -+0.01 clear - 0 very slight -+0.01 clear - 0.01 clear ; nooraity 100)?. Initial Final P 1.01?. Initial FI nal iidity, TAN Thitial Final 30.1 cs. 31.8 cs. 2.86 2.93 0.82 0.68 MONS 0A6601 Itv.-ipoiMU on Loss, 0.6 DEPARTMENT 259 - Standard Manufacturing Process 13. PYDRAUXi A-200 and 280 APPENDIX C PHYSICAL CONSTANTS (Cont'd.) - W. 0. KRUMMRICH PLANT Oxidation-Corrosion: (Fed. Spec. 791 Method 530.8, 168 hrs. at 250F.) (Cont'd.) Fluid Appearance: Clear, light amber, no deposits. (1) fluid boiled over onto heater. (2) apparent high acidity due to nature of additives present. (3) rust rating: REL M-400, 10.0 - no rusting. MONS 046602 DEPARTMENT 2fiQ - Standard Manufacturing Process P.vdraul A-gOO and 280 APPENDIX D UTILITIES The utilities used In Pydraul production are electricity and 80 psl steam. Both are treated as variable costs on the cost report. The usage of each Is shown below. 1. ELECTRICITY - 1970 YTD (9 mos.) average monthly usage Is 2000 KWH. ItemB using electricity are: Item No. EaulDment Rating Voltage 155 #1 Mix Tank __ HP 440 Pump 159 #1 Mix Tank 7.5 HP 440 Agitator -- Miscellaneous 110 2. fin PRT_KTEAM - 1970 YTD (9 mos.) average monthly usage is 325M BTU's. Steam is used In the #1 Mix Tank heating coll, pipe tracing, and for miscellaneous cleaning. HONS 046603 15. DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and 280 APPENDIX E PERSONNEL Departments 246 and 259 are operated with one work force. For this reason the description of operating classifications and assignments given below are for both Dept. 246 and 259. OPERATING CLASSIFICATIONS JOB Premium Operator Still Operator Second Operator Standard Operator #1 Swlngman #2 Swlngman Repairman Porter NUMBER OF MEN (21 shifts/week) 4 4 4 2 1 1 1 _____1/2 17 1/2 men There is one premium operator, one still operator, and one Becond operator every shift. The Standard Operators work the day and middle shifts 5 days/week. #1 Swlngman works as the hourly foremen on Saturday and Sunday, as Premium Operator on Monday, and Repairman on Thursday and Friday. #2 Swlngman works 3 shifts as a Standard Operator, one shift as a Still Operator, and one shift as a Second Operator. The repairman works Saturday-Wednesday on the day shift. The porter works 1/2 time In 246/259 and 1/2 time In 243/244/248. A typical work schedule Is Included In this Appendix. OPERATING ASSIGNMENTS Only the major equipment and operating responsibilities are Indicated in this listing. All are responsible for safety and housekeeping. PREMIUM OPERATOR! Operates 4 continuous chlorlnators and 5 batch chlorinators. The premium operator has been required to run only 4 of the 5 batch chlorlnators if the continuous chlorinators are running. STILL OPERATOR: Is responsible for 4 take-over stills, runs only 3 or less at a time. SECOND OPERATOR: Operates two blend tanks, two finished product tanks, 9 storage tanks, three mix tanks, makes all Pyranol and Pydraul mixes, loads trailers and tank cars, and belongs to the Fire Brigade. MONS 046604 DEPARTMENT gS9 - Standard Manufacturing Process Pvdraul A-200 and g6o 16. APPENDIX E (cont'd.) STANDARD OPERATOR: Fills, stencils and labels 5-pint bottles, and 5, 30, and 55 gallon drums. REPAIRMAN: Unloads cars and trailers of biphenyl, TCB, TTCB, and finished product. Does minor repair work In department. HOURLY FOREMAN: Is department foreman on weekends, responsible for maintenance arrangements, night sheets, and line-up of work. PORTER: Cleans offices, control room, repair room, rest room, and smoking shelter. HONS 04660^ SOB *1 SumtMAY RenuemAi/ PHen. 2"-' OPBR. Sra opbr. n StM opbr ^2 Stows filhl DEPi 24<o SCHBDUC.es , .11 4 fruirj*(tmu V r3 s rt T WT f S 11 22i2//2 S Z1 nt 22 v 2 t t r ( s Z1 5 1 2 * 2 r 2 WT 2i F / 5 1 2 smtwt;i 21 2 2 2 t 12i snrwrps 31 2 2 2 l 1 2I S M T rf s 11 2222112 Piteniuiv) OPsttATcK D LM 53 51 SHS`)N5 `6(46 4U 3 3 3 3 55 s s s L L L L 3 33 3 3 l 4444 4 66(3333 3 / imtH* 5555 Si 6 31 4 4 4 4 14 SS5SSL& (((3333 6 6 6 3 3 3 3" 6663533 JH4444 3144444 Still OfsRATiR 0 ML IH76(613/313 14 14 W /V itif is n it 1313 15/i IL a HIft ft 14 H IH IS IS i1s31n31it31f3t 1f3t isis It IL J4l4 is n a it it ft/6 1313131313 IS14 14 14 Is Wiff Hiff /i'3/3/3/3 urnH IH H /S'/S' ft ft ft M W (4 I4 (5 IILSIILS1I3S1I3II1L3IL13 is IL 13 ISIS 1517 IL 11)313 14 14 IH 14 IL IL IL (1431IS31I3S Sect>nt> OPBRvnR, 0 ML 1112122A 210219119 1* mm 7 7 7 H1 1 f9o 1 4 A to to to n 71 7 7 ff U1 l 10 n 7 7 7 7 1If1f1fA(!( ?10 19 if A10 1A0 run 1A1 Ai >i0n!0 'i0 !10 41 ioi 7 A 7 to 7 to 7 it 7 ir rrrfi to 7 1 io m 7 f ? fr 1114 77 ri AJ/O SOtPamBoRaffrroo* 1*19 APRIL Mf< y JUNE iTl/LY PUCViT SerremBSR Octo SEP HoYsn gas n0 nyin*5jf h // u n /* // STTf S S M S(23-/ 6 /oil izaiYiSK (7 /= 11 2113 2Y2S2L 21 112 2343(11 9 rtj 13 lYlSUmf A 25 2 It1117 321130 31! r2 t2i (U2 /I2I /* n r*r r s 7 n / 11 20 27 2223 3* 1 1 3 A /lit (3 1*//^ U2Utf 2T2& ivr(7 n %ii iiti uii aii uii n yurwTFs HfJWlf/t/7 /f MiriL ziis a u S L 7 t A 10 II Ik 17 It 13 loll 21 221221 J I X3 r A 10 II 1X13 lY n% tin u an ii ii ii ii ii snr lAleu wZ11r31Af1Ss- 17 S 1M1ITIXI 1I2t W 1II2 r uniinso 1111 F 17 s n%i2U\inn ii it ii ii ii SM rWTPs 1 2 3456734 31 113456 i r a i9 m3ii lV/rft/7Jr/9^tf 12 13 lY ISIk 11 It n it znxnvnfit n XI21 ?. 3/ 13IYISXL111173 li 1 12 3 4 s' L 7 s A m il 11 4i- (i n II 1113 IH />' ft 17 If ti 19 Zl UU *V ISILI7/flAUll iizuzYisnuir^5?____________ preen bsr 6 7 S' 4 10 /Ml rx/&n ///i Mil IXIM-YlSU- IT 2P21 79 SI / 2345 1221 TAV FeBROAtty i9n /j uiujv/:. Xtl?Af *13* 11 1 X 3ASi 7 3 * r t r i/ Z. 7 /// a /j /V/r/* T A /o a m3 14 rf/i 12 It 19 le V U1319ZSH13 mm?c h APRIL 2.1 / 25 i 21.23 .r ? " 4 / II ii /? W Af/i ;j It It li 2J 22ZS;V2g2inMlS Soil trr. n 2J1 > i? lit12V iru itj/u i 1 ?- 3 w rt 7 s: i i* 17. DEPARTMENT 259 - Standard Manufacturing Process Pvdraul A-200 and 280 APPENDIX F PACKAGING AND SHIPPINO About 50$ of the Pydraul A-200 produced Is sold In trailers and 50$ In drums. All of the Pydraul 200 Is Bold In drums. The two Pydrauls account for about 1/3 of the total drumming done In the Aroclor department. Finished lots of Pydraul are sampled In the mix tank and again In the trailer when sold bulk. Samples are normally not taken from drums. Drumming Is done at about 40C Into 5 and 55 gal. drums. The drums are steel, 18 gauge, no lining, and are painted white. CONTAINERS AND WEIGHTS Product 30 Gal. 55 Gal.. Trailers Cars Pydraul A-200 59# -- 645# Yes No. Pydraul 280 60# -- 625# No No The drummed product is sold to the WGK warehouse and from there sold to customers. Mlnlmums and maxlmums for number of drums in the warehouse Is set by Production and Production Planning personnel. They are reviewed at least once a year. Warehouse stock reports are reviewed by production at least weekly to determine needs. On the following page Is a listing of all Dept. 246/259 drummed products. HONS 046607 Aroclor Dept. 246 - Drum Stocks Product '252 x 600 JS,, Grade 241 Minimum Maximum On Hand J.2H2 x 600 NE ____ 240 12,42 A 15, S_____ ____ 241___ 14 A...5.5..HJ5_____ 25o 1248 x 600 E_____ ____ 21___ 1248 A 6QQ N____ ____ 2Q___ 1248 x 55 E_______ 261 1248 x 55 NE_____ 260 1254 x 600 E 281 1254 x 600 NE 280 1254 x 60 E ____ m___ 1254 x 60 NE_____ 280 1260 x 600 E 1260 x 600 NE 1260 x 60 E 1260 x 60 NE 291 290 291 290 1262 x 600 NE 1262 x 60 NE 500 500 1254 + 10* Xvlem 256 Thermlnol FR I x 600 I x 55 11 x 600 11 x 55 III x 600 HI x 6Q________ 245 245 . 265 265 25 285 Pyranol tc Pydraul 1200 PPO x b74 1666 PPO x 300 1560'PPO' x.65 500 200 500 70-36 PPO X 674 " " PPO x 300 " PPO x So 510 510 510 Eate_ Needed Date Filled A13B38 x 675 A13B3B"x-3EO A13B3B'x 6y 'A13B3B x 60 1245 PPO x 600 1242 PPO' x '32U 1242 PPO x 56 300 300 300 215 015 yaraul A200 x 6115 Pydraul A200 x Pydraul 286 x o5; Pydraul 20U x 00 200 500 280 250 MQNS 046608 11 -- 18. DEPARTMENT 259 - Standard Manufacturing Process Pvdraul A-200 and 280 APPENDIX 0 MATERIAL BALANCE A detailed material balance on Dept. 259 was not made because losses In the process are negligible In terms of yield. Minor losses are discussed In Appendix H. Trlcresyl phosphate yields are normally less than standard (99.0#). This Is due to the fact that blends are made and adjusted to a specific gravity range rather than by percent composition. MONS 046609 DEPARTMENT 259 - Standard Manufacturing Process Pvdraul A-200 and 280 19. APPENDIX H PRODUCT LOSSES Very small losses occur at #1 Mix Tank pump as leakage. Drip pans are routinely checked and emptied Into scrap Aroclor drums as needed. Sample bottles are flushed with the Pydraul that is being sampled. The flush material is put into scrap Aroclor drums. Essentially no product goes to either a sewer or the atmosphere. MONS 046610 DEPARTMENT 259 - Standard Manufacturing Process frydraul A-200 and 2B0~ APPENDIX I PROCESS CONTROL 20 Three forms are Included In this section: 1. A table of process control variables. 2. A Pydraul batch sheet. 3- A dally transfer sheet (for all transfers made by Second Operator). KEY VARIABLES The only process type key variable Is the s.g. of the Aroclor blend when making a Pydraul A-200 mix. This should be adjusted to 1.429-1.^31 @ 25C before proceeding with the additives. The finished goods must of course be In specification. MONS 046611 Kind of Mix Material Added BP AP Date DEPT. 250 (#x Mix Tank) ' - Lot Ho. _'__________ Time AM PM Operator Date Comments Sampled by Analysis Received: Sp. Gr. Date Date Time Time Viscosity AM PM Adjustments &. Resamples Material Added BP AP Date ---- . Time Operator Date Time Analysis Received Operator Date Time Sp.Gr. Viscosity HONS 0 4 6 6 1 2 Material Lubrizol 13b0 Bantolube 70 D. C. 200 Fluid Blue A Dye Azo Oil Black Dye Lbs. TT55----- Final Sample Taken by Final Sample OK'd by Lab at PM Operator at XM AM PM Drfr S&lMt OP`*ATt>pC DAiLy rknHSFtH StierT t)ATS PfobUtT Lor Flort fiJtn&ek nuk 6.P. fiP. ofimtod TO TAtfK 0.P. A.P. Opefinro*. CoWne*/TS X c (n * O' HO-' 21. DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and 2H0~ APPENDIX J SAFETY AND TOXICITY DATA The following data Is pertinent for Departments 246 and 259: I. LOCATION OF SAFETY EQUIPMENT A. Fire extinguishers 1. Carbon dioxide - 1st floor, NE of lean-to 2. Dry chemical - 1st floor, SE of lean-to 3. Dry chemical - 2nd floor, west wall 4. Dry chemical - 2nd floor, west wall B. Gas masks 1. 1st floor, on sprinkler house 2. 1st floor, outside west wall of repair room 3. 2nd floor, on west wall 4. Control room, east wall 5. 4th floor, on handrail by #1 chlorlnator C. Scott air pak 1. Outside west wall of lean-to D. Emergency clothing 1. Box on 2nd floor, west wall E. Safety showers with eye wash 1. Batch department, 1st floor 2. V " 2nd floor 3. " " 3rd floor 4. Continuous department, 1st floor 5. " " 2nd floor 6. " " 3rd floor 7. West side of tank farm (alarai In control room) 8. Control room (eye batch only) MONS 046614 r DEPARTMENT 59 - Standard Manufacturing Process P.vdraul A-200 and 200 22. APPENDIX J (cont'd.) SAFETY AND TOXICITY DATA II. SAFETY PRECAUTIONS AND DATA A. Personal safety equipment 1. Hard hat 2. Safety glasses 3- Goggles )). Rubber or canvas gloves 5. Rubber overshoes B. Fire Pydraul A-200, 280 and their components are not fire hazards. Automatic fire extinguishers and sprinklers have been Installed in building CR to combat fires. C. Toxicity (see next section) D. Miscellaneous There are many accidents that can occur which may be classified as health and safety hazards. These accidents can result from steam leaks, product leaks, and other minor hazards normally present to some degree in a chemical plant. E. Safety Record (Depts. 21)6/259) 1. Lost time accidents - Last occurred on January 28, 19)18. 2. Serious Injuries -- The last two serious Injuries were: (a) 8/5/70 - See attached Informal Investigation report. (b) 12/2/68 - Refer to formal investigation report L-17-20-68. 3. Minor Injuries - For the years 1969 and 1970, the frequency of minor injuries Is about one per month, or about - 0.75 per man per year. I MCNS 046615 DEPARTMENT 239 - Standard Manufacturing Process Pvdraul A-200 and 280 APPENDIX J (oont'd.) SAFETY AND TOXICITY DATA 23. III. TOXICITY A. Lubrlzol 1360 This additive should not be heated above 120C as HgS can be liberated. H2S (hydrogen sulfide) is a poisonous gas. B. Aroclors * 1. Recommended maximal atmospheric concentrations (MAC for 8 hrs.): a) Aroclor 1242 - 1.0 mg per cubic meter of air b) Aroclor 1254 - 0.5 mg " " "" " 2. Hazards and control a) Inhalation: Absorption is chiefly by Inhala tion. Concentrations In the workroom atmosphere should be maintained below the recommended levels. Where the chlorinated diphenyls are used at room temperatures, the hazard of Inhalation Is considered slight or absent. When these materials are subjected to elevated temperatures, the process either should be completely enclosed or other adequate mechanical exhaust ventilation must be provided to reduce concentrations to safe levels. b) Skin contact: Operations and handling procedures should be such as to avoid the possibility of prolonged or repeated skin contact. Contaminated clothing must be laundered before reuse. c) Eye contact: Eye protection should be used where there Is a possibility of liquid splashes. 3. Emergency Treatment: Skin surfaces exposed to chlorodlphenyls should be thoroughly washed with soap and water at once. If clothing has been contaminated it Bhould be removed promptly. If exposure to a high vapor concentration occurs, as in the case of spills at elevated temperatures, the patient should be moved from exposure and kept at rest until Been by a physician. Oxygen should be administered If breathing is difficult. MQNS 046616 21). DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and 280 APPENDIX J (cont'd.) SAFETY AND TOXICITY DATA (cont'd.) III. TOXICITY (cont'd.) 3. EyeB contaminated with chlorodlphenyl should be Irrigated with water for at least 15 minutes and the patient should be seen by a physician. 1). Special procedures: Persons who are regularly or repeatedly exposed to chlorodlphenyls should be examined periodically to detect early evidence of skin Irritation and/or liver damage. Persons with known liver disease should not be exposed to repeated contact with the chlorodlphenyls. The Information In this section is from the Hygienic Guide Series published by the American Industrial Hygiene Association. The particular pamphlet Is "Chlorodlphenyls", Jan.-Feb. 1965. MONS 046611 MONSANTO COMPANY Sauget, Illinois August 1^, 1970 cc: 0. L. Bratsch D. J. O'Toole R. M. McCutchani-r TO: Mr. Bill Corlew SERIOUS INJUKY ACCIDENT INFORMAL INVESTIGATION DATE OF INCIDENT: August 5, 1970 LOCATION: Unloading Dock #5, Track 10A TYPE OF ACCIDENT: Struck by Thermocouple CAUSE OP ACCIDENT: Faulty Procedure NATURE OF INJURY: Laceration above left eyebrow PERSON INVOLVED: Carl McCoy, Repairman INVESTIGATING COMMITTEE: Walt Parker Roy Hall Woody Ban V. Brawley, Chairman /gja HONS 046618 Bill Corlew Serious Injury Accident Information Investigation WOK DESCRIPTION The repairman was heating a tank car (NATX 21258) of Biphenyl for unloading. The 2 Inch standpipe was full of solid Biphenyl (x'pt Is 68.8C). Normal practice Is to lower a "hair-pin" - steam pipe Into the standpipe to melt the Biphenyl, this practice was followed. The hair-pin was then removed and an 8 foot s.s. thermocouple was inserted In the standpipe. The thermocouple senses the Biphenyl temperature and a TIC controls an automatic valve In the steam line to the heating coils on the car. Two hours later the standpipe was still full of Biphenyl but It had solidified around the top of the thermocouple. An 18 Inch halr-pln steam pipe was used to melt the frozen Biphenyl around the top of the thermocouple. When the halr-pln had melted 15 Inches down, the thermocouple suddenly raised upward with great force striking the repairman above the left eyebrow.. The Investigating committee concluded that both ends of the standpipe was plugged with solid Biphenyl and the Biphenyl between the plugs expanded from the heat applied to the car. The top plug raised upward when the pressure beneath It was great enough to break the bond that was holding It to the standpipe. At this time the plug was being melted by the 18 inch steam pipe. The moisture content on this car was 510 p.p.m., normal Is 50 p.p.m. This could have been a contributing factor In the Incident by vaporizing In the standpipe and exerting additional force on the top plug. HONS 046619 Bill Corlew Serious Injury Accident Information Investigation Page 3 8/14/70 WGK SPECIFIC RECOMMENDATIONS 1. Use the air Inlet line for the thermocouple. 2. If the air Inlet line cannot be used for the thermocouple, ' th6 standpipe will be used but only after air Is blown ' thru It to be certain It Is open. 1~ ' - 3. If neither of the above can be used, the large dome opening will be used. OENERAL NOTES Our Biphenyl dept. In AnnlBton, Ala., was called to discuss this Incident. They never had an experience of this nature, but did comment that solid Biphenyl seems to expand as It Is thawed. We wanted to discuss the unloading of Biphenyl cars by pump or air pressure but they do not unload cars. Mr. Iamar Falkner, Dept. Supervisor, appreciated the fact that we called to advise them of the Incident. /gjs Investigating Committee Walt Parker Roy Hall Woody Ban HONS 046620 MGNS 046621 DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and 2&0 APPENDIX K BACKQHQUND INFORMATION 2`j. Monsanto has been actively Interested In functional fluids since 19^8. TVo lines of produots, Skydrol fire resistant aircraft hydraulic fluids and Pydraul fire resistant industrial hydraulic Fluid, have been introduced and several individual fluids have reached commercial status. Formulation work was done by Monsanto on an Aroclor base fluid:; in an effort to develop a satisfactory fluid of lower price than the Pydrauls available on the market. Viscosity index improved versions were abandoned due to unfavorable costs and performance characteristics. This project resulted In a non-viscosity Index improved, fire resistant, Aroclor base Industrial type hydraulic fluid designated OS-95. In May 1958, six batches of OS-95 (later to be named Pydraul A-200; were prepared for the first time In the research pilot plant. Pydraul 680 was first product in April, 1964. Its primary use is in mining applications in Europe. HONS 046622 DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and 280 26. APPENDIX L TIME CYCLE AND CAPACITY The cost standard capacity (1970 and 1971) of Dept. 259 for Pydraul production Is 585*000 lbs./mo. or_approximately 7K lbs./year. The production for 1970 will be about 3.5M lbs. of Pydraul A-200 and l.CW lbB. of Pydraul 280. Storage facilities are the limiting factor In Pydraul production. There is no finished goods storage tank. Trailers are loaded and drums filled directly from the #1 Mix Tank. The following table shows an approximate time cycle for a 12,000 gallon batch of Pydraul A-200 or 280. TIME CYCLE Charge major components (Aroclors and TCP) Blend major components Sample for control and analysis Charge additives Blend total batch Sample and final analysis TOTAL 4 hours 3 hours 2 hours 1 hour 3 hours hours hours (If one adjustment for specific gravity or viscosity Is needed, add 6 hours) From this point on, the batch cycle is dependent upon how the batch Is packaged. If it is all bulk shipments, 3 or 4 trailers could be loaded in one shift If they were properly scheduled. Actual pumping time Is about 1 hour for a WOO gallon trailer. Drums (55-gallon) can be filled at a rate of 40-44 per man per shift. This means that about - '5_6 man-shifts of drumming are needed if the entire tank Is to be drummed. Usually two man shifts of drumming per day are done. Drumming can be delayed even more If an urgent need arises for a different drummed product. The production of another Pydraul batch must be delayed at times because there Is no storage tank, only a mix tank. For instance: WOO gallons of Pydraul A-200 are in the mix tank with plans for drumming it that day. An order Is received for a trailer of A-200 for the next day. There 1b not enough time to drum the A-200 and make another batch, so the mix tank must sit idle for a day until the trailer Is loaded. MGNS 046623 Dept. 259 ~ Standard Manufacturing Process 27. PYDRAUL A-200 - 280 APPENDIX H QUALITY CONSIDERATIONS Pydraul A-200 is an Aroolor base, fire resistant, industrial type hydraulic fluid which was formulated to meet viscosity and lubricating requirements, and anti-rust characteristics specified by the sales department. The physical and functional properties of Pydraul A-200 are discussed in the following sections. 1. VISCOSITY The required viscosity range of Pydraul A-200 is 200 to 300 absolute SUS. The results of formulation work as given in table 1 indicate that a mixture of one part . Aroolor 1242 to two parts Df Aroclob 1248 by weight exhibits the lower limit viscosity of 200 SUS absolute at 100P. 2. LUBRICATING PROPERTIES Results of four-ball wear tests on the Aroolor base stocks as given in table 2 indicates the necessity of an anti wear additive. Lubrizol 1360 impartB good anti-wear properties to Aroolor based fluids. 3. RUST INHIBITION Previous work with rust inhibitors for Pydrauls has Indicated that Santolube 70 is relatively effective as an inhibitor as measured by the ASTM D-665 rust test. 4. MISCELLANEOUS A. APPEARANCE Pydraul A-200 Ib a blue liquid with a hazy appearance. The haze Ib due to very small quantities of antifoamant, DCF-200. B. FOAM The use of Santolube 70 in the Pydraul blend causes undesirable foaming. A concentration of 50 ppm Dow Corning Fluid 200 inhibits foaming. C. NEUTRALIZATION NUMBER Unused Pydraul A-200 has a total acid number of about 0.8. This apparent high acid number is due to the nature of the Lubrizol 1360 and Santolube 70 present. HONS 046624 DEPARTMENT 259 - Standard Manufacturing Process Pydraul A-200 and 280 28. APPENDIX M QUALITY CONSIDERATIONS 4. MISCELLANEOUS D. Process Changes It Is important that any contemplated process changes be carefully evaluated before the actual change is made, since the quality of Pydraul A-200 can only be determined by full scale performance tests. Tests such as those given in table 3 are necessary to evaluate the product. E. Boll Down Material At the end of a distillation run, the still charge is partially boiled down and then transferred to #2 Still where it is further boiled down. The production from #2 Still (by current practice) is always used for Pydraul A-200 production. MONS 046625 TABLE 1 HIGH AROCLOR FLUID FORMULATION Formulation (% wt.) Kinematic viscosity CentlstoKes 100?. 210f. Saybolt Seconds Kin; "aBsT 100 F- 1006f. 1 53% Aroclor 1248, 4536 Aroclor 1242 2 18^ Aroclor 1254, 82^ Aroclor 1242 27.6 24.7 -- -- 130 l8j 117 166 3 78^ Aroclor 1248, 22% Aroclor 1232 22.6 -- 108 150 4 61% Aroclor 1248, 59% Aroclor 1242 29.0 -- -- 193 3 20% Aroclor 1254, &C% Aroclor 1242 6 8I56 Aroclor 1248, 1936 Aroclor 1232 25.7 24.30 -- -- 7 6536 Aroclor 1248, 55% Aroclor 1242 8 27% Aroclor 1254, 7358 Aroclor 1242 30.17 29.6 -- -- 142 200 9 8856 Aroclor 1248, 12% Aroclor 1232 31-3 -- 10 6656 Aroclor 1248, 33?6 Aroclor 1242, 0.36 santolube 393, 0.5% santolube 70, 100 ppm. DCF-200 30.22 2.87 142 200 =t 0 0 HONS 0 4 6 6 2 7 TABLE 2 Aroclor 1242 Lot * pydraul p-9 Aroclor 1248 Lot Sant. 393 * PYDRAUL A-200 ADDITIVE STUDY Sant, 70 * Other Additive * 4-sall Wear (i) 0.63 Cellulube 220 0.56 T-410 100 00 0 0 0.81 -- 0 T-512 100 0 0 0 0.83 T-410 33 T-512 66 0.5 T-410 33 T-512 65.95 1.0 0 0.05 0 0 -- -- T-410 T-412 3315 T-512 3315 T-523 66.3 0.5 66.3 0.5 0.05 0.05 0 0 0.55 0.53 T-410 T-412 T-412 33 T-512 33 T-523 33.1 T-523 66 0.5 66 0.5 66.1 0.5 0.5 0.5 0.05 0 0 0.25^) 0.46 0.45 -- T-412 T-412 33.1 T-523 33-0 T-523 66.25 0.5 66.15 0.5 0.05 0.05 0.20^) ___ -- -- 33.0 -- 66 0.1 0 0 0.53 (1) 1 hr., 40 kg., 630 rpm, isteel--on-stee: (2) squealing during most of run. (3) NO. 5 process oil (santolube 70 inert). (4) Dloctylmaleate. Almen EP Load Torque Pounds psi 50 43 27 35 ---- 50 44(2) 40 (2) 38(2) 34(2) 38 39 34 46 38 48 50 38(2> __ 4l 40 40 __ -- --- ' -- TABLE 3 EVALUATION OF USED PYDRAUL A-200 Chevrolet - Bay City Division - 260 Hr3 . (14 hrs. at 19QF-) Viscosity 100p., cs. 210F., cs. 4-Ball wear (630 rpm, 1 Hr., 1675F.) pydrau! A-200 New >0.63 2.89 pyuraul A-200 Cncv.-Bay City Div., 26o Hr. 31.8 3.05 Steel-on-steel 4 kg. 10 kg. 4o kg. Steel-on-Bronze 4 kg. 10 kg. 40 kg. Neutralization Number .21 29 .43 1.20 1.40 1.70 0.82 tan .20 .26 .59 95 1.48 1.69 0.82 tan RUBt Test (REL, F-101, 10.0-perfect) Appearance 10.0 yellow, Blight cloudy 10.0 Reddish-brownnearly opaque MONS 046628 DEPARTMENT 59 - Standard Manufacturing Process P.vdraul A-200 and ggp 29. APPENDIX N MISCELLANEOUS This section contains the following information: 1. Additional Raw Material Information 2. References 3. Production Cost Standard (1971) Operation Report (1970 YTD) 5. Status Report on Safety Audit (11/2/70) 6. Department 246 Safety Audit (May, 1969) 7. 1970 W.G.K. Aroclor Group Objectives (1/28/70) 8. Manufacturing Improvement Plan for Aroclor (March, 1970) MONS 046629 l Dept., g5q - Standard Manufacturing- Process PYDRAUL A-2QO & 280 APPENDIX N RAW MATERIAL 1. AROCLOR 1242 Aroclor 1242 Is received from Department 246 by pipeline. Aroclor 1242 batches are composited In a storage tank and a lot analysis is run on the composite sample. The Aroclor 1242 must pass all non-electtical specifications before It Is transferred to Department. 259 2. AROCLOR 1248 Aroclor 1248 Is received from Department 246 by pipeline. Aroclor 1248 Is composited and sampled In the same manner as Aroclor 1242. 3. LUBRIZOL 1360 Lubrlzol 1360 Is received In 55 gallon drums. 4. SANTOLUBE 70 A Santolube 70Ais received from the Nltro plant in 55 gallon drums. 5. BLUE A DYE Blue a dye is purchased from the DuPont Company. The material Is received in 25 lb. boxes. 6. AZO BLACK DYE Azo black dye is from the Allied Chemical Company. The material is received in 25 pound boxes. 7. DOW CORNING FLUID 200 Dow Corning Fluid 200 is purchased from the Dow Corning Corporation. The material is received In 5 gallon cans. 8. TRTCRRSYL PHOSPHATE TCP Is received by trailer from Dept. 243/244/248 at W.Q.K. Until mld-1970, it was received from J.F.Q. ( MONS 046630 Dept. 259 - Standard Manufacturing Process PYDRAUL A-200 and 280 APPENDIX N REFERENCES 1. St. Louis Research Report No. 2472, Job No. 2-02-760.01 3505 (II), February 16, I960. Title: Functional Fluids Application Research Summary: This Report includes application studies of Aroclor base fluids. Discussion includes formula tion, physical and functional properties of Pydraul A-200. 2. St. Louis Research Report No. 2842, Job No. 2-02-750.01-3550, November 7, 1961. Title: Application Research - Fire Resistant Fluids Summary: Report includes investigation of problem areas arising in Pydraul fluids. Reference Job numbers are 3505, 3766 and 4009. 3. St. Louis Research Report No. 1562, Job No. 2-02-750.01-2815, July 6, 1956. Title: Function Fluids - Application Research for 1954-55. Summary: Report includes formulation studies, property determinations, and sample preparations of Pydraul s. ( mons PRODUCTION COST STANDARD PLANT _______ | /VCfiA \il-_OAY TH DIV. LOC DIV. LOC CCTR PRODUCT PROOOCT______ 2_ [effective / 4* 5 4-7 an 17-19 14-17 1S-20 2I-2S PRODUC now COOT _ / o <] ___ [capacity g' 1 eoOp *??j\ A.r'j Ysufhl BULK INV. STD. COST ' 3y.C>_ [COST UNIT ' DUPLICATE COLS.-4.25 pf INTO ALLCARDS 1-3 _ 4-75 PRODUCT coc 27-33 34-37 CR7 3xp ..c] 4 (XsTu-'Y LoOl 'MCR7 ,IsS..prl `ZHofg CR7 0. 'L..IMPn.___Uk>- XUli\0iO2mi\ CR7 -/UsLLt'L-uyi. IJjddJJlteipiPA qnj CK7 L. . \sonSjxaJ CR7| CR7 CR7 .SSA*L-VJ/\.____ \sris\~`fjJ2A CR7 om. CR7 IM? CR7 CR7 CR7 CR7 CR7 C+?sifii? OlBal iU'A.- CR7 R/M Wheg. A HonJHng CR7 0<ei Teiel Moi'le. CR7 By>Pf4ucU CR71 STD. YIELD STANDARD QTY. PER UNIT 54-57 r*58*60 /&v--a __ AT? /!r;y __~KJI_---_-_--/!- "jvT CR7 CR7| CR7 CR7 CR7 CR7 Net Tetel Moierlele DO NOT KEY PUNCH DATA BELOW THIS LINE MAT'L. USACE DATA COOE Vllof ' i ) 0 V' MATERIAL isy BRACKETS 12 Oy*Hnfl_Pyl4: DAY 1 SHIP TS 3o 20 3 2f CLASSIFICATION 6j Ceit/Shut Down i|2 e Ceit/$lwi-U Cett/Chenaeover Phg Changeov THEO. US AO E 33.0 0 34 56 j AMOUNT THEO. TO STOLON *'-Vd / 7 9 TYPE PKO. c!J7ib STD LBS THEO LBS 1 T Hf O'S 1 O 3 t 3. 0 3 /aS' /. S: / V.7T-r' NET LB./PKC. Grot* Lb./Pkg. Net Lb./Pellet C.o.i Lb.^Pol 'F/J,' h'l3 5V/2J1 ' i'7 -- 'W>r -- ---....... Phg. Role Lb /Me. _____________ CONTAINERS:______ USACE/UNIT PRICE PER CONT. CONT. COST/ UNIT: / PKO UNIT STD J.yUrr IZr-AM.: esr/ Ui ------- mz HONS 046633 OTHER INFORMATION SIGNATURE '2k.oLL iitipLi ___ DOWNTIME SUMMARY Repoi> Other___ Inventory Loo P.9. Jjjl > j'O ' _ PRODUCTION COST STANDARD = _____ PUNT W, & / PRODUCT: t Otyl/hpiti-_____, . . ______! PRODUCT COPeT LOC c.cin / f) CAPACITY: _ COST UNIT: B-M I2-I3j 14-17 000 5\ 0?.^ Ary;31 ClUL_ 18-70 21-25 1-3 IlIEl NV. ST(X_ CR5 (i. 2?4 ____ 4-25________ DUPL. COLS. 4-25 INTO ALL CARDS DUPLICATE COLS. 4 25 INTO ALL CARDS BRACKET 1 INV STD. UNIT COST BRACKET 2 __ 4-35___________ _ PRODUCTION BAT. OTV. PRODUCT COST 1SV/T ^/7 fA ~ 38-401 EQUK'MC. Drpl. No. ` A: (fjoa -J/Ojl 'WVWco BRACKET 3 o' Ife'l out HONS 046634 1 ACTUAL SCHED. ACT.YTD DEPT. 246 1ST OPERATION REPORT Aroclurs 811.00 PRODUCTION - TOTAL AROCLORS(42.7M# In 1969) .7AH . FEB. MAR. APR. J MAY JUNE JULY AUG. SEPT. OCT. NOV. DEC. 3118613 2841584 3969985 3969407! 397325* 4054901, 5055954 4267264 3793791 408*713 *633687 5928859 3118613 2841584 3118613I 5960197 3969985,139368949o9H53937132^51* line*on* 4960000 4267264 9930182 219277*7 26983701 31290965 3793791 35044756 *08*713 *800000 39129*69 43763156 *959846 9692015 1232 1242 1248 1254 1260 1262 00 0 33507 -0- 2133478 1659600 2720901J2*6335i 25*0720 329056 548981 388068 74281i 25*780 -0- 0 229313612360725 587958j aiosi6 399369 573264 51941a 510227 *21138 825087 1*32762 256710 0 59739 34l6oa 219511 746609 3*7923 291051 0 0 10 -0- ____ -Qt -02227526 569605 1163566 306577 -0- -0- 243105* 225583 722600 *1581* -0- -0- -0- 265833* 3659746 325*88 285346 883225 217666 -0- 446041 2*255* -0- 42350 4692201 PPfiPOfi 521978, 4*4122 -0- . _ __ MONTH YTD PER CENT YIEIjD ON BIPHENYL:____ Std; 98.0{t 1969 : 99 23* 100.99 101.82 98.6c lC0.6q 98.78 1WL26 101.60 101.31 1QO-99 101.39 100.26 10.0.38 100.03 100.or 100.35 100.48 99.19 102.13 100.3* 100.52 100.93 100.57 99.30 100.41 TCC RESISTIVITY POWER FACTOR NO. OF LOTS ,F. QUAT.TTY AOVFER1A2.f42 EG T,OTR:___QL969 Ayg s: 0.15 DDm: 3000 x 10^ ohm-cm: 2.1^1 0.11 ___ yi 0.14 0.15 0.20 0.16 0.16 0.12 0.15 0.2^ 0.28 0.24 5900 12270 976d 10970 14780 9480 14,660 76*0 12,900 14,900 14,*00 1-65 1.61 0.98 0.57 0.7* 0.97 1-36 0.91 1.37 1.12 1.10 O.89 4 68 5 8 _____ a 64 68 11 ___ i3___ MINOR_____________ SKRTOTIS SAFETY(12 minor Injuries In 1969) i _______ Q 00 2 ----------- 3 1 -0- 0 0 ___ 2____ ----------0- 12 c 0 --i-------- 00 00 10 0 ___ 0 number - -iMPLAINTS 19 In 1969)_______________________________________ _________ _________ _________ I ol ll a l li c I oI o 1 0 j oI o J o Io _____ ] HONS 046636 . 2. PKRSOITWELf1969 JAN. FEB. OVERTIME 8.2 11.4 O.T..YTD EXTRA HRS. 8.2 9.7 9.7 6.9 E.H. ,YTD 9.7 8.4 ABSENTEE HRS. 2.5 2.5 ABSENTEE HRS.YTD 2.5 ____ hi O.T. 10.8*. E H. 5,6*.. ABS.HRS. 5.4<1 MAR. APR. MAY JUNE JULY AUG. 5.6 e.i 12,0 21.4 22-0 14.9 8.5 11-5 9-5 1.7 8.2 5-4 8.4 5.5 9-Q 10-9 12.7 15.0 7.7 7.1 ___Q-9 5.4 8.3 ft 1 ___ft-3 - 7.6 2.6 _____ ___2~n___ 6.5 2.2 2.6 2.6 ------- fcrV- ---- 2-3---- 2.9 WHSE. nEPT. TOTAL INVENTORY (1969 Averagjwe:* Whse. 1240M#, Dept. 1320M#) 1091 1162 1056 1017 SQO ____ 459 465 _ 1285 1098 926 1238 n.05 789 1264 2376 2260 1982 2255 1621___ 1248 1727 280 1258 1518 SEPT. 16.6 15.4 6.5 7-5 13.6 4.0 OCT. 17.6 14.0 12.4 8.1 9.8 ,4'T 493 1411 1909 454 1071 1525 NOV. 8.2 13.6 7-6 8.1 k.o 4.6 DEC. 9.0 12.1 0.5 6.7 1.2 4.3 645 1176 1821 955 1560 2315 I I) oX 2 Co o OLOi'' "Vj ACTUAL ACT. YTD ; DEPT. 259 1970 jPERATION REPORT Pyranols 810.90 rawuuvx JAH. FEB. MAR. APR. MAY i JUKE 975824 874607 902782 15495*2 112505d 1332715 075824 874607 902782 1549342 11250581 1332T15 975824 1850431 2753213 4302555 5427(11 ^ 6T60328 --------------1-------------- 1-------------- :-------------- 1-------------- JULY AUG. SEPT. OCT. 1 NOV. i DEC. U.74529 1162698 1015412 2086825 | 1165616) 1813463, U74529 116260ft 1 101slid 2086825 ! U65616! 1813463 7934857 '9097555 ! lau^Tl 12199792) 13365*061 15178871 PYRAW0L3 BY KIND 1260..fPO !... 70/30! V!i: 331250 170464 1242 PPO 253365 A13B3B_____________ : 220745 FR-0 116992 198100 450520 457472 201000 251000 106095 -(3790). 191641 641781 448100 127820 494516 184436 l68l97i 517414 28771^ IlflAHc 17463d URpiftn 253877 617571 49T351 101125 244595 144755 . 166875 104015 340554 48837?! 929867 11100a 420860 61510I 3T1919 50510 129408 562562 365600 108046 -o- -0554AR6 947240 111672 -0- TCB TCB TTCB TTCB MO. YTD Mo. YTD ! YIELDS - (TCB 1969 Act. 98.3*. 1970 Std. 98.0*; TTCB 1969 Act. 94-3* 1970 Std. 98.0*) 96.48 96.48 99.41 99.41 100.62 98.50 96.38 9ST.18 99.03 98.69 - 99.16 100.74 99.4? 105.67 100.16 101.01 99.76 98.93 99-311 99-71 99-75 ini. 1I1 101.31 99-79 99-75 98.26 100-95 QQ.SQ 99-73 102.34 1 ioi.il 97.47 99*44 99.63 99-60 94^15 103.99 100.72 IOI.36 | 98.51 100.88 99-51 99-59 95-78 _!03iP9_ 101.04 101-32 INVENTORY WKSE. 467 dept. TOTAL_______________ 316 783 (1969 Average: 228 185 j 212 288! 440 473 i Whse. 358 392 750 54PM#, Dept. 300M#) 14R 362 496 300 253 241 643 _____6H. ___ 717 ____363-- 152 ____515--, 323 | 336 j 659 j 664 I 493 | 1157 | 784 389 1173 778 294 1072 X c z ts> oua> DEPT. 259 1970 Oi-jtATIOH REPORT Pydrauls A-200(8l0.96) KHU1IUL.T Lua r-fl.* fcW \ 11 7. JAR. FEB. MAR. APR. ! MAY JURE JULY miAT. 92302 140200 270741 *132000 134225 240760 mi. 92302 140200 270741 432000 TlhOOC 286485 240760 ZT...YTP__________ 92302 _2325fl 50324; 935243 1069468 1355953 1596713 AUG. 281270 281270 1877983 SEPT. 408380 408380 2286363 1 n 1 OCT. | NOV. 255500 416923 255500 1 416923 12958786 DEC. 294140 294140 3252926 ISE. 2PT. 1TAL INVENTORY A-2QO(1969 Average: Whse. 27QM#, Dept. 8PM#) 415 75 490 179 195 Rq 0 268 195 445 212 .71 6* 516 _____ 2ir 176 217 IS? 200 184 136 ______22- 135 -0- 312 312 181 _____32L _____ 1&_J 318 123 441 479 4 483 - 1TUAL 1HED. . 1T.YTD .. DRAUL 625 Pydraul 280(811.19) PRODJCTION-280 (0.96fi# in 1969) _________ 0 132500 0 132500 00 00 9687^ 265000 131A-73 1 265000 131875 0 132500 132500 132500 229373 494375 626250 ;. 118750 118750 745000 0 0 745000 113125 113125 858125 125000 125060 983125 a 0 983125 127424 YTRT.r)fTnp 1969 Act. 91.1970 Std. 99.0j6) ______________________________ _________ _________ _________________ IP Mo. N/A 97.26| 1 N/A J N/A 93.61 98.79 101.80 92.52 0 98.09 108.31 1 98.62 IP YTD__________ N/A 97.26 97.2697.26 95.68 97.32 98.23 97.27 97.27 97.38 98.65 1 98.65 HSE. EPT. OTAL IHVENTORYf1969 Average: Whse. 100M#. Dept. -0-) 85 90 00 85 ______ 2Q 46 0 46 46 1 00 46 ___1 22 ______ j 44 72 ______58_I_ 58 0 _______lL 1 ___ 1?___ ______591 ___ 52_ 173 -0- 173 35 -0- 35 46 30 76 HONS 046639 comments JANUARY Operations normal. "Extra hours" high due to training for vacation relief and replacement of man laid off. . FEBRUARY The resistivity of the 1242 EG lots would appear to be significantly higher, but this must be qualified. .First, quality averages are meaningful only over periods longer than one month because the range is wide. Second, the laboratory air scrubber was Installed and may(or may not) account for two unusually high resistivity analyses. The TCB and TTCB yields are actual for 1970 and do not reflect credit received in 1970 for mischarges in 1968-69. Pyranol stocks are low partly by decision,partly because of -TCB shortage. ' MARCH " Operations normal. Volume increased. APRIL Operations normal. Total group production was second highest on record. Total Pyranol production was at highest level in past six years, reflecting shift of Aroclor 1260 and 1260 blends from Anniston. Better Aroclor electrical properties reflect Improved analytical techniques - no reason to believe the quality has shifted. MAY The production rate continued at a high level. A bulk shipment of Aroclor 1254/10# Xylene was made In a trailer in Dept. 268. The demand for Aroclor 1260 was unusually high causing some late shipments of 1260 blends. Be ginning on about 5/12 and lasting for approximately one week, sulfuric acid and carbon tetrachloride waE entrained In the chlorine received. All Aroclor 1242 produced during this time was In specification (EG) but unstables were higher than normal. Aroclor 1254 made at this time was also high In unstables but In spec. The 1254 was used as non-electrical. JUNE Sulfuric acid In chlorine continued to be a problem In the first half of June. High TCC's were noted in one lot of Aroclor 1242EG; lot KM-477 had O.36 ppm vs. a "normal" of 0.1-0.-2 ppm. Yields on Biff, TCB, and TTCB are all above standard for the month and YTD. TCP yield 1b below std., 97-32# actual vs. 99-0# standard, but Is much Improved over last year's actual of 91.7#- Total inventories, bulk and drummed, continue a downward trend. Overtime Is high covering vacations and an open Still Operator's Job. JULY Total Aroclor production was highest ever, reflecting the sudden demand for plasticizers grades. Yields on B10, TCB, TTCB and TCP were all above standard. Drained 33 l/2 gallons of sulfuric acid from the Clg brink tanks during the month. Total Inventories were raised considerably because of the Increase In c'les. Overtime was high due to vacations and training of operators and new employees to enable the dept, to Increase production of heavy Aroclors. MONS 046640 AUGUST SEPT. -2- :: The demand for plasticizer Aroclor faded by mid-month. The four shift helpers hired to meet the high demand during July/Augu8t vere released on 8/24. The demand ; for.drummed products vas lover as -inventories of NE } Aroclors vere allowed to drop to near zero. The ~ necessity for overtime decreased but vas still higher than normal. A serious injury (first for the year) . vas sustained by Carl McCoy. Production level returned to "normal" after high surge demands in July and August, "normal" level will be increasing as customers are transferred from Anniston to WGK. Shipped to Sprague Electric in September and will ship to Westinghouse, Bloomington, in October. Since the Bi 0 yield YTD continues to be over 100$, a few comments are in order. Since Aroclor 1242 is a mixture of isomerB of varying molecular weights, degree of chlorination is measured by sp. gr., 1.301-1.392 @ . 25 C, which corresponds to 41.5-42.5$ chlorine by weight. Theory chlorine is 42.0$. The percent difference in the amount of chlorine used between 42.0$ and 42.5$ by weight in the finished goods is about 1.2$. Therefore, it is theoretically possible to have over 100$ yields on B10 if the Aroclors are consistently chlorinated to near their upper limits and there are no significant losses. Bi 0 tank car weights are not checked and may also contribute to the high yields. The biphenyl yield shown in this report reflects actual operations. The cost report data will appear slightly different because some reworked Aroclor was transferred to 811.00. Resistivity of Aroclor 1242 EG has been better than last year. This is probably more a factor of sampling and analysis than product quality. The complaint procedure as practiced has changed. Last year complaints were formal. This year, complaints are relayed personally and acted upon quickly. Formal complaints are Beldom written up. Absenteeism is high because W. Walker and C. McCoy have been absent about the entire month. Extra hours are high to cover -the absenteeism, vacations, and for training a man to replace R. Antoff who is being laid off - more in October. Overtime is high to cover absenteeism and for extra drumming. TCB and TTCB yields are actual on this report. The cost ireport data will be different because it includes credit __received from Hooker early JLn the year and because one lot :of reworked Aroclor was transferred to Pyxanols. MONS 046641 pCTOBER -3- Fyranol production set a record of 2.06m lbs* _Order level was high and inventories were increased by 0*5M lbs. to a more "normal" level. Whse. stock had been quite low. Aroclor 12421X3 customers new to WGK serviced in October were Westlnghouse (Bloomington), CornellrDubllier, and Electronic Components* The only former Anniston customer not yet served is Aerovax. Aroclor 1260EG production i6 still out of specification on A.C* Cl" and sometimes on Monsanto Stability* Details on this problem are reported in a separate report. One indi cation of poorer Aroclor 1242EG quality appeared in October. The TCC's have increased significantly, from an average of O.15ppm to 0.23 ppm, with two lots being over 0.30 ppm* A relationship between these two problems has not been established. ' The primary reason for high overtime hours has been the high demand for drummed products; also some vacation time was covered with overtime. November O.T. should be less than 10.0. A utility shift helper has been obtained for drumming. A third standard operator Job wili be posted if drum demand continues. Extra hours were high because three men were laid off (D. Hindman, P. Lutman, and D. Athy) and their replacements trained. This will continue into November. Absentee hours decreased from September because W. Walker returned in mid-month,, but C. McCoy was again absent for the entire month. NOVEMBER The third lot of Aroclor "scrap" was reworked. The material was Inerteen PPO. Total Aroclor production in November was second only to Juiy, 1970. Aroclor 1242 production was nearly 1.0M lbs. higher than the previous high made in March, 1970. The thermal chemical chlorides analysis of Aroclor 1242 continued to climb, a two-month trend. The range on 11 electrical grade lots was 0.21-0.38 ppm; the average was 0.28 ppm. This trend is not reflected in any other analysis. The Aroclor 1260 quality problem is still not resolved. There is some evidence that at least part of the problem is analytical. A sample of 1260 that was analyzed as out of specification by the WGK laboratory (Monsanto stability and after corrosion chlorides) was in specification on both properties as analyzed by the Anniston laboratory. Labor figures of overtime, extra hours, and absenteeism returned to more normal levels after high levels for several months. ------ ANTICIPATED IN DECEMBER 1. Record production of Aroclor 1242 and total Aroclors. 2. Higher inventories due to loading extra thnk cars before the receipt of orders. 3. High overtime, especially in still operator category. 4. First time production of Pydraul 625 and a short run of seldom made Aroclorl232. MGNS 048642 DECEMBER -4- Aroclor production vas at an all-time high breaking the previous record_(July, 1970) by 1756. Aroclor 1242 pro duction vas 4.7M lbs. and downtime vas only about 0-5#. Using the standard OST of 91# Aroclor 1242 capacity is about 52M lbs./year. This is approximately the same capacity demonstrated several months ago in a two-day run. Aroclor 1242 thermal chemical chlorides improved over last month but they are still higher than the 1969/fimt half of 1970 "normal". Two lots of Aroclor 1260 were produced and both were in specification on all properties - first time in three months. Operating conditions were not changed for either the 1242 or 1260. Minor injuries during 1970 were 12 in number - identical to 1969. Dnmi stocks of the fastest moving products were Increased to targeted levels - finally caught up from the surge demand experienced in July and August. The removal of slow-moving items is to be completed by 4/l/71. PyrRnol production vas the second highest on record, including nearly 1.0M lbs. of Inerteen 54201 CM. Mo Inerteen PPO was produced and no more will be produced until open orders are in hand. About 10,000 gallons of Pydraul 625 were produced. This vas the first time produced at W.G.K., and possibly only time. Pydraul 625 is an obsolete product. Total Aroclor Group production broke the old record (July, 1970) by 23#. HONS 046643 Monsanto VROM (NftMt ft Li Tt URilCI HfCMNCt TO : #' R. M. McCulchan. W. Q. Krummrlch November 2, 1970 Status of Dept. 246/259 Safety Audit Recommendations of May, 1969 V. Brawley T. Carrico D. O'Toole D. Scbll.llnger B. Corlew This memo Is a second status report on the 36 recom mendations made in the Dept. 246/259 Safely Audit Issued In May, 1969. The first status report of 3/5/70 Is attached. The box score is: Date Recommenda tion Completed No Work Justified Job Open May, 1969 3/5/70 9 - 36 3 24 11/1/70 19 11 6 Completions (or decisions to do no wort) on tin: remaining six recommendations will be made by 4/1/71. Details on the current status follow. "Open" roc...... are marked with an asterisk. Recommendations 1. (a) The west biphenyl storage tank (Tf.-.n 102) should be controlled at 100C or below, no (b) the tank equipped to handle a flammable liquid. Status - A Taylor Fulscope tempera o . .nlrol Vr control at 95 C. Completed on 3/23/70. 2. (a) The batch biphenyl head tank (if.-n 103) should be kept at or below 100C., or (b) the tank equipped to handle a flammable liquid. Status - Lowering the temperature 0 l.fo h! phenyl tank (#1, above) causes the normal temp. . f u m In the biphenyl head tank to be about 100C. No fn.fl... : work will be done. *3- A means should be found to control, ti.r f.. i.ipeia 1.11 re In the biphenyl/catalyst mix tank (Xt.an 403) at 100C or less. Status - Work done on #1 (above) did not. help much In controlling the temperature in the 1. i pbw.y 1/i-n laly st mix tank. Further work yet to be done. MQNS 0466A4 B. W. Corlew Status of Dept. 246/259 Safety audit Recommendations of May. 1969 Page 2 W.Q.K. 11/2/70 Recommendations (cont'd.) 4. A high pressure alarm set for 45 psl should be Installed on the chlorine vaporizer (item 116). Status - No work Justified. 5. A high pressure alarm set for 50 psl should be Installed on the nitrogen header. Status - No work Justified. 6. The xylene storage area should be laid off and a sign "Xylene-Flammable" erected. Status - Completed. 7. A means should be found to Insure that Lubrlzol 1360 Is not heated above 100C. Status - A drum of Aroclor 1248 was put on the plate coil heater for 4 days. At the end of the time, the temperature was 65C. No further work will be done. *8. (a) Put flooring on the level of the discharge piping from the batch chlorlnators, or (b) direct the discharge lines away from the working area and a blown seal warning device be Installed. Status - The rupture disc lines will be extended down to floor level after #9 (below) is resolved. *9. Investigate the adequacy of the size of the rupture discs (8") and discharge line (3") on the batch chlorlnators. Status - TSD Investigating what Is considered safe practice. 10. All temperature alarm and automatic cut-offs on all chlorlnators should be checked at 6 month Intervals. Status - All safety devices have been put on a check list and are tested routinely by department or by Instrument shop. MONS 046645 B. W. Corlew Status of Dept. 246/259 Safety Audit Recommendations of May. 1969_____________________ Page 3 W.G.K. 11/2/70 Recommendations (cont'd.) 11. (a) A procedure should he adopted to prevent dropping the wrong chlorlnator batch to #2 blow tank, or (b) #2 blow tank should be properly equipped to handle a flammable liquid. Status - #2 blow tank Is now closed to the atmosphere as a result of the blow tank demister project. It Is vented only to the drowning Jet. No other work will be done. 12. A level recorder should be Installed on #2 blow tank.. Status - #2 blow tank now has a percentage gauge located in the control room and in the field. 13. (a) The gas fired still furnaces should be Insulated and properly guarded, or (b) a warning sign be placed on the furnaces. Status - Since there Is very little work activity near the furnaces, Insulation or additional guarding Is not necessary. 14. Expedite completion of TSD Project 6928 - "Install Level Recorder on #2 Still". Status - Completed. 15. Complete all actions recommended In formal Investigation L-17-20-68. Status - Completed. 16. Expedite completion of TSD Project 6939 - "Install Level Measurement on Product Tanks". Status - Completed. 17. Develop project to nitrogen blanket #1 and #2 Blend and Finished Product Tanks. Status - These two tanks are not used often. Fumes are very minimal. No work Is Justified. M0N5 046646 B. W. Corlew Status of Dept. 846/259 Safety Audit Recommendations of May. 1969 Page 4 W.O.K. 11/2/70 Recommendations (cont'd.) 16. Expedite completion of TSD Project 5377 - "Upgrade Lighting System In Dept. 246". Status - Completed. *19. Determine flash point of Inerteen PPO, 54201 CM, and 54201 KA after the Glycidyl Phenyl Ether has been added. If the storage temperatures are within 15C. of the flash point, either (a) Equip tank to handle flammable liquid, or (b) lower the storage temperature. Status - Work yet to be done. 20. Install relief system on 18" filter used when loading or drumming pyranols. Status - No work 1b Justified. 21. Upgrade grounding system for Xylene drums. Status - Completed. 22. Concerning the Aroclor 1254 - 10# Xylene mix. (a) Determine flash point of mix. ib) Lower storage temperature as much as possible. (c) Evaluate need for vent and flame arrestor on #1 blend tank. (d) Ground In #1 blend tank. (e) Ground the Xylene mix drumming facilities and further alter to adhere to Monsanto safety specifications of handling flammable liquids. Status - All work was completed In anticipation of producing an Aroclor 1260/10# Toluene mix.* *23. Introduce a sufficient quantity of steam Into the scrubber stack to snuff out any fire which could conceivably occur at the outlet. Status - Work yet to be done; evaluation. 24. Expedite completion of TSD Project 7004 - "Alter Truck Loading Dock\ . Status - Completed. MONS 046647 B. W. Corlew Status of Dept. 246/259 Safety Audit Recommendations of May, 1969 Page 5 W.G.K. 11/2/70 25. Write more specific procedures for shutdown during the preparation of a Xylene blend. Status - No work will be done because Xylene blends have been discontinued. 26. Evaluate need for an emergency exit on the north side of the department. Status - The possibility of a person being trapped on the north side of the second or third levels Is extremely remote. No work Is Justified. 27. Provide for emergency lighting for Dept. 246. Status - Purchase of emergency lighting Is not Justified. *28. Maintain a spare flame arrestor for Item 403 {catalyst mix tank). Status - Will resolve when recommendation #3 is completed. 29. Relocate chlorine discharge line from chlorine vaporizer rupture disc. Status - Completed. 30. Locate a 500# dry chemical fire extinguisher near Item 401 (100,000 gal. biphenyl storage tank). Status - No work Justified. 31. Items 401 and 102 should be Identified "BIPHENYLFLAMMABLE ). Status-Completed. 32. Extend fume removal system to continuous chlorlnator area. StatuB - Completed. 33. Improve lime delivery method to #3 and #4 stills. Status - A ramp has been installed on second level so a dolly can be used for delivering lime. A' forklift pad will be installed later (is a part of Incineration project estimate). HONS 046648 B. W. Corlew Status of Dept. 246/259 Safety Audit Recommendations of Hay. 1969 Page 6 W.G.K. 11/2/70 34. Evaluate need for monitor nozzle near Item 401. Status - No work Justified. 35- Evaluate need for controlled drainage from area around Item 401. Status - No work Justified. 36. Install Improved venting system on Item 102 (west Biphenyl tank). Status - Completed. Wl 'C.tL /gjs R. M. McCutchan HONS 046649 4 '/Vj ' I MONSANTO COMPANY ORGANIC DIVISION W. G. KRUMMRICH PLANT PROCESS SAFETY AUDIT DEPARTMENT 246 AROCLORS, PYRANOLS, PYDRAULS Supervisor R. M. McCutchan Supt. _________ J. W. Molloy Written by: II. F. Ray R. M. McCutchan May - 1969 mons 046050 i. Depts 246 and 259 SAFETY AUDIT RECOMMENDATIONS The following list of recommendations are included in the Safety Audit. An approximate priority has been set by department supervision for action on these recommendations. Targeted dates for completion of evaluation and/or action on the priorities are: Priority Date 1 8/1/69 2 2/1/70 3 11/1/70 Recommendation Priority 1. (a) The west biphenyl storage tank (Item 102) should be controlled at 100C. or below, or (b) the tank equipped to handle a flammable liquid. 2 2. (a) The batch biphenyl head tank (Item 103) should be kept at or below 100C., or (b) the tank equipped to handle a flammable liquid. 2 3. A means should be found to control the temperature in the biphenyl/catalyst mix tank (Item *103) at 100C. or less. 1 1). A high pressure alarm set for *15 psi should be installed on the chlorine vaporizer (Item 116). 3 5. A high pressure alarm set for 50 psi should be installed on the nitrogen header. 3 6. The xylene storage area should be laid off and a sign "Xylene-Flammable" erected. 1 7. A means should be found to insure that Lubrizol 1360 is not heated above 100C. 2 8. (a) Put flooring on the level of the discharge piping from the batch chlorinators, or (b) direct the discharge lines away from the working area and a blown seal warning device be installed. 3 9. Investigate the adequacy of the size of the rupture discs (8") and discharge line (3") on the batch chlorinators. 3 10. All temperature alarms and automatic cut-offs on all chlorinators should be checked at 6 month intervals. 1 11. (a) A procedure should be adopted to prevent dropping the wrong chlorinator batch to //2 blow tank, of--(b) blow tea*, or (b) //2 blow tank should be properly equipped to handle a flammable liquid. 3 M0NS 046651 Dopts. 246 and 259 , Recommendation Priori 1?. A level recorder should be installed on #2 blow tank. 3 13. (a) The gas fired still furnaces should be insulated and properly guarded, or (b) a warning sign be placed on the furnaces. . *3 ll). Expedite completion of TSD Project 6928 - "Install Level Recorder on #2 Still. 1 15. Complete all actions recommended in formal investigation L-17-20-68. 1 16. Expedite completion of TSD Project 6939 - "Install Level Measurement on Product Tanks". 1 17. Develop project to nitrogen blanket #1 and #2 Blend and Finished Product Tanks. 2 18. Expedite completion of TSD Project 5377 - "Upgrade Lighting System in Dept. 246". 1 19. Determine flash point of Inerteen PPO, 54201 CM, and 54201 KA after the Glycidyl Phenyl Ether has been added. If the storage temperatures are within 15C. of the flash point. either (a) Equip tank to handle flammable liquid, or (b) lower the storage temperature. 2 20. Install relief system on 18" filter used when loading or drumming Pyranols. . 3 21. Upgrade grounding system for Xylene drums. 1 22. Concerning the Aroclor 1254 - 10$ Xylene mix: . 1 ?a) Determine flash point of mix. IU'F- (SDV (b) Lower storage temperature as much as possible. (c) Evaluate need for vent and flame arrestor on $1 Blend Tank. fdl Ground #1 Blend Tank. (e) Ground the Xylene mix drumming facilities and further alter to adhere to Monsanto safety specifications for handling flammable liquids. 23. Introduce a sufficient'quantity of steam into the scrubber stack to snuff out any fire which could conceivably occur at the outlet. 2 24 . Expedite comoletion of TSD Project 7004 - "Alter Truck Loading Dock1'. 1 25. Write more specific procedures for shutdown during the preparation of a Xylene blend. 1 26. Evaluate need for an emergency exit on the north side of the department. 27. provide for emergency lighting for Dept. 246. MQNS 046652 3 3 Dcpts. 246 and 259 ill. Recommendation Priority 28. Maintain a spare flame arrestor for Item 403 (catalyst mix tank). 2 29. Relocate chlorine discharge line from chlorine vaporizer rupture disc. 1 30. locate a 500# dry chemical fire extinguisher near Item 1)01 (100,000 gal. biphenyl storage tank). 3 31. Items ll01 and 102 should be identified "BIPHENYL-FLAMMABLE). 1 32. Extend fume removal system to continuous chlorlnator area. 2 33. Improve lime delivery method to #3 and #4 Stills. 1 34. Evaluate need for monitor nozzle near Item 401. 2 35. Evaluate need for controlled drainage from area around Item 401. 2 36. Install improved venting system on Item 102 (west biphenyl tank). 2 HONS 046653 FHOCESS SAFETY AUDIT . Dept. 2^6 Aroclors, Pyrsnols, Pydrnuls, Inerteens Raw Materials ' The following toxic rating code will be used in describing the toxicity of these materials: 0 - none 1 - slight ' 2 - moderate . 3 - high U - Unknown A_.__ Biphenyl (Code 82601) 1. Synonyms: Diphenyl - 2. Description: White flakes or solid off white mass; """somewhat pleasant odor. 3. Constants: Mol. Wt. 15^-2; M.P. 69C.; B.P. 255 C.; Density .9910 7`jAC . i(.* Fla8h_Point: 235 F. (C.C.) 5.* "Auto Ignition Temperature: 100^1 F. 6. Toxfc"'j]"azard Hating: " "Acute local: 0 Acute Systemic: Ingestion 3 Inhalation 3, Chronic Local: U . * See Appendix I for definition of these terms 7. .'6. 9. 10. . Fire Hazard: Definitely when exposed to heat or flame; can react with oxidizing materials. Fi refighting; COg or dry chemical Voriaula: C'gli^CgHc, Biphenyl vapors are irritating to the upper respiratory tract. Workers should not be exposed to vapor levels throughout their shift in excess of the threshold limit value of 1 milligram per cubic meter of air (or"about 0.2 ppm). The compound, or organic solutions of the compound can absorb through the Intact skin; therefore, repeated skin contact should be avoided. - Biphenyl is received in 10,000 or 20,000 gallon tank cars on Track 10A from Anniston and in U,000 gallon trailers from Associated Sales. The crystallized biphenyl is melted with 80 lb. steam using the colls in the cars and additional hairpin coils if necessary. There are temperature indicating on-off controllers on tank car unloading spots 5 and 6 to keep the biphenyl from heating above the flash point. Temperature in the car is measured using a portable thermocouple and is controlled at 100C. +_ 2. MONS 046654 A. Biphenyl (continued) During the plant air (30 psjg max.) unloading of the molten biphenyl there is no steam on the tank car coils so the material cannot be overheated. The transfer of the biphenyl to storage begins after the operator has visually Inspected the car and has determined all the biphenyl has melted. The tank trucks received from Associated Sales are unloaded at the Spot #4 tank car loading/unloading dock. The material in the tank truck is always in the liquid state and below the flash point so that no heating is applied in the department. Tank car unloading spots 5 and 6 are equipped with self-supporting counterbalanced unloading arms and plant standard Hemco adjustable access ramps. Both docks are adequately grounded. The molten biphenyl is then transferred to either the 100,000 gallon (Item 4oi) or 25,000 gallon (Item 102) storage tanks. The biphenyl is stored iri Item 401 at 100C. The tank is equipped with a steam jacketed flame arrestor on the vent and a proteclosea.1 .manway cover to protect the tank against overpressurixation. The tank temperature is controlled by a field mounted temperature indicating controller (capillary system) which allows Bo# steam to enter two flntube heaters inside the tank. The tank tempera ture is also recorded from a separate thermocouple on point /'] of the 24 point, panel mounted temperature recorder (TK48). A high temperature alarm sounds of point #3 reaches l_l_3t'C_L Steam pressure on the manway, flame akrestor, and pipe! ine'tracers is reduced to 18# to avoid heating the product above the flash point. The tank level- is indicated both at the tank and on the panel board on a 0-100$ dial gauge. This tank is grounded in three places. The biphenyl is stored in Item 102 at 100 - 120C. ,The tank temperature is recorded on point #11 of panel mounted 12 point recorder 29 - 6638. There is no temperature alarm system for this tank. The temperature controller is a self contained field mounted capillary system utilizing 80# steam. The tank is vented to the atmosphere and there is no dip-pipe in the charging line to the tank. It is recommended that either 1.___T8c_^torape temperature be co~nt~rorr?d~ aiT~i(lK7''C . ^r[nJiTow_or JT. TKe_tank_be cqufpped~~tb Handle e. flammaSle".liquid'. "(See Appendix 1 for'prope flammable liquid handling conditions.) Items 1)01 and 102 should be identified "Bipfienyl-Flammable". Fumes from the vent on TteiiTTO'?'"are s3gnTficeufTt-3uring a transfer of biphenyl to the tank It is recommended that an improved venting method be installed on Item 10'2T ~ The biphenyl is transferred by a submerged pump from Item 102 to either the batch chlorinator head tank (Item 103), to the catalyst mix tank (Item 403), or to #6 chlorinator (Item 406). Item 103 is a 700 gallon measuring tank located in the batch chlorinator area on the fifth level (top). There is a 1-1/2 inch traced and insulated overflow/vent line back to Item 102 to main tain a constant charge size (500 gal.) to the batch chlorinators. MQNS 046655 - 3A. Biphenyl (continued) .. ' The biphenyl is kept molten with 80,f steam reduced to hoff. A 6o,f relief valve protects the Jacket. 40# steam (lt2C.) keeps the head tank temperature above the flash point of biphenyl. There is no temperature recorder, controller or alarm on this system. This tank is considered a closed vessel. It is recommended that either 1, The tank temperature be kept_ at or bcTow TOCr'C .* o*r_2. The STpheny 1 head tank fee 'properly' equipped to-handle-a Tlammab Ie~lTqu~fcr. . ' Item 403 is a 1272 gallon feed tank located on the third level (top) in the continuous chlorinator area. There is a traced and insulated 3 inch overflow line which ties into the li inch over flow line from the batch head tank on the second level of this batch chlorinator structure. The tank is vented to the atmosphere and is equipped with a steam jacketed flame .arrestor. Steam pressure on the flame arrestor is controlled at 18#. The tank temperature is maintained by controlling the flow of 80;? steam to an internal pipe coil utilizing a field mounted temperature indi cating controller (capillary system). Although the tank temperatu is set for 100C. the contents are normally in the range 120-130^C due to tracer heat-up in the circulating system. Level in' the" tank is indicated at the tank and recorded on the control panel. KeCle catalyst is introduced into the tank manually on a oncc/day frequency. The tank is open to the atmosphere when charging catalyst. It is recommended that means be'found to allow the tank temperatur to be _c on troll edat 100 C ^ or "less . It is also recommended that' a spare ~fTame ~arrestor he malntalnedT ltcm-jr<3b is a' 1729 gaflori" chlorinator located immediately east of Item 4 03. The biphenyl is fed continuously to this tank through a flow control system. The biphenyl is introduced into the chlori' nated reaction mass via a dip pipe. Normal operating temperatures of this closed vessel is 150C. . Chlorine (Code 81059) .. 1. Description; Greenish yellow gas 2. Formula; CT? 3.- 'Co'nsTSnTs: Mol. Wt. 70.914; M-P. = 101C.; Density 1.47 @ 0C. 4. Toxic Hazard Rating: '"Scute local': Irritant 3; Inhalation 3 Acute systemic: 0 Chronic local: U . Chronic systemic: U M.A.C. - 1 PPM in air per 8 hour day B.P. - 5. Toxicology! Chlorine is extremely irritating to the mucous membranes of the eyes and respiratory tract. It combines wit) moisture to liberate nascent oxygen and from hydrochloric acb MUMS 046656 -4 - B. Chlorine (continued) ' 5. Toxicology: (cont'd) . BotfPoi these substances, if present in quantity, cause in flammation of the tissues with which they come in contact. If the lung tissues are attacked, Pulmonary edema may rebult. A concentration of 3-5 ppm produces a detectable odor; 13 PPM causes immediate irritation of the throat. Concentrations of 50 PPM are dangerous for even short exposures. 1000 PPM may be fatal dven when the exposure is brief. Because of its intensely irritating properties, severe industrial exposure seldom occurs, as the workman is forced to leave the area before he can be seriously affected. In coses where this is impossible, the initial irritation of the eyes and mucous membranes of the nose and throat is followed by cough; a feeling of suffocation and later pain and a feeling of constriction in the chest. If exposure has been severe, pulmonary edema may follow with rSles being heard over the chest. 6. Fire Hazard: Moderate - can react to cause fire or explosion upon'contact with turpentine, ether, ammonia Gas, illuininatin, gas, hydrocarbons, hydrogen and powdered metals. 7. Explosion Hazard; Present by reaction with reducing agents. 8. Disaster Control: Dangerous; emits highly toxic fumes; will react" with water to form toxic and corrosive fumes of I1C1; Is heavier than air - gas will hug the ground. People without adequate protection should go across wind until out of the affected area. Chlorine is transferred by a 6" pipe line from the Chlorine ." Department. As it enters the department it passes through two Brink Demisters (Items 115, 590) In parallel which remove any entrained liquids. From there it passes through a chlorl . vaporizer (Item ll6) which adds enough heat to prevent any liquid chlorine from entering the system. . The vaporizer uses regulated 80# steam to heat up the incoinin . chlorine. If the Clp pressure reaches 40 lbs., the steam is automatically shut off thus preventing further pressure buildup. If due to a plug in the chlorine line past the vaporizer, the chlorine pressure builds up to 50// a relief valve and a rupture disc will relieve the pressure. This situation is highly unlikely as the chlorine supply pressure is controlled at qo // in the chlorine department. However, since a failure in the steam controller or the chlorine department controls could cause a pressure of 50/* to be exceeded and a subsequent discharge of chlorine gas to the atmosphere, it__ls recommended that a high pressure alarm for 45 psl be_lnstall_ef on the vaporizer. Also, the chlorine discharge line from Fhe 7u~nTuf'e~dT?c~should be relocated for Improved- operato'r s~afety~. MOMS 046651 5- - C_.___Nitrogen (Cock; 43099) ' 1. Description: Colorless gas ' 2. FormuIaT Ng 3. ConsTants: Mol. Wt. 28.02; M.P. - 210C; B.P. - 195.8C.; Density 1.2506 gr/liter at 0C. ' 1). Toxicity: None. In high concentrations it is an asphyxiant. Nitrogen is used for blanketing Aroclor in the blencl tanks, surge tanks, finished product tanks, and storage'tanks and on the //l blend tank system before making a 1254 and 10% Xylene mix. It is handled properly. Nitrogen lines are identified with orange signs with black letters. No Corby connections are present. The nitrogen is stored in a liquid storage tank owned, operated, . and maintained by Air Products. The tank is protected from over- pressurip.ation by a relief valve set for 125?/ and a rupture disc set for Header pressure is controlled at 38?/. There is an alarm for low supply pressure (10//) but none for high pressure. It _is_ recommended that a high pressure alarm set for 50t/ be in- SCalled- for~~Xhe~ nitrogen header to avoid damaging' the nitrogen 'pressure control valves. D. Xylcne (Code 64 005) 20% Ortho 36% Meta 15% Para 20% Kthyl benzene . Purchased from Shell Petroleum Co. 1. Description: Colorless liquid. . 2. Formula-: " "CgHJi (Clle)p 3. Flash pt. 05 F. to 100 F. depending on composition of ' isomers. 4. Density: .864 @ 20/4 C. 5. Vxplosive Range: 1.1 to 7.0% in air. 6. froxic Hazard' Hating: ' Acute Cecal: irritant 1 . Acute Systemic: Inhalation 1 ' Chronic local: Irritant 1 , Chronic Systemic: Inhalation 1 Skin Absorption 1 7. M.A.C. : 200 PPM in air. o. Eire Hazard: Dangerous when exposed to heat or flame; can react with'oxidizing materials. 9. Fire fighting: Foam, COg, or dry chemical. 10. Explosion Hazard: Moderate in vapor form. . Xylene is used only to make an Aroclor 1254 and 10% Xylene ml It is received in 50 gallon steel drums and stored on pallets on the cast side of the department. Xylene is extremely flammable and should be handled arid labeled as such. 1l h recommended that the Xylene storage area be laid off and a sign ""Xylcne - FIamnia'5.ITe1' erected. MOWS 046658 6. - - ft.__ Trichlorobcnzene (Code 60200) . ' 1. 2. 3. It. 5.. 6. Description: Colorless liquid as received in Aroclor Department It" is a'mixTure of 1,2,3 and 1,2,A TCB and possibly other isomers. Forrnulp.: CfiHqClq * Constants^ Mol. Wt. 181.5; M.P. approx. 10C., B.P. 213C. Flash Pi. about 230 P. (C.C.) Toxic iiazard Rating: Acute local: U Acute Systemic: Ingestion 2; Inhalation 2 Chronic local; causes loss of hair of experimental animals. Chronic Systemic: Ingestion 2; Inhalation 2 Pire Hazard: Moderate when exposed to heat or flame. When heated' to "cTecomposition (300C. + ) it emits highly toxic fumes of chlorides. Can react with oxidizing materials. 7. Fire fighting^ Water, foam, C02 or dry chemical. TCH is used as ii blending agent in the production of Pyranols. It is handled and stored safely in underground storage tanks #5 or #6. 8. Handling: TCB is normally received in cither 8000 gallon Lank cars or "Tn 55 gallon drums. Unloading is handled by a positive displacement pump in cither case. TCB may also be received by tank truck (*1000 gal.). Unloading is then handled either by gravity or centrifugal pump. F. Tri Cresyl Phosphate (Code 80l80) 1. Synonyms: 0-Tolyl phosphate 2. Rescription: Colorless liquid 3. Formula: (CI^CgHiiU ----- M. ConstantsMol. Wt. 368.36; M.P. -25 to -30C. B.P. *I10C. 5. yia8h~i-,olnt: A6o F. (C.C.) . 6, Toxic^Hazard Rating: '' Acute EocaT: U , . Acute Systemic: Ingestion 3; Inhalation 2; Skin Absorption 2. Chronic Local: U Chronic Systemic: Ingestion 2, Inhalation 2; ' . Skin Absorption 2. 7. Fire Hazard: Slight when exposed to heat or flame. When beatecTto decomposition it emits highly toxic fumes of oxides ' of phosphorus; can react with oxidizing agents. 8. Fire Fighting: Water, foam, COp or dry chemical. It is us.cd In the production of Pydraul 280. 9. Handling: TCP is received in either *1000 gallon tank trucks or in 55 gallon drums. Unloading is handled by a centrifugal pump for the trailers and a positive displacement pump for the drums. Trailers are unloaded directly into #1 mix tank. M0NS 046659 -7- Gljrcidyl Phenyl Ether (PPO) (Code 36100) _ 1. T)eBC_ri^tion^ Liquid . 2. Formula: CHo CHOCHo 53. const'knTs: M.P. 3-5 C.; B.P. 2>I5C. . WysVn'oint: 175 F. (O.C.) 5. VoxIcjTazard Reting; ' Acute local': "U Acute Systemic: Ingestion 3; Inhalation 3. ' Chronic local: U Chronic Systemic: U 6. Fire Hazard: Moderate; when exposed to heat or flame. Can react with" oxidizing materials; The vapors of glycidyl phenyl ether normally will not present a hazard at room temperature. Inhalation of vapors above 6oC. should be avoided. Material should be kept from eyes or skin. 7. Fire Fighting: Water, foam, C02 or dry chemical. When heated to decomposition it emits toxic fumes. 8. Handling^ Avoid contact with eyes or skin. Wash off with wale Tf'any is spilled on the skin. G.lycidal Phenyl Ether is used as a chlorine scavenger in producing Pyranols; Inerteen PPO, D^POIKA, and 5^1201 CM. It is stored safely in drums. The material is added to the blend through the suction pipeline of the #2 and #3 mix tank cir- culnting pumps. Lime (Code 38800) (Calcium Oxide) 1. Description: Fine white or slightly gray powder, Rhomeric Trigonal* crystals. 2. Formula: CaO 3. Toxic Hazard Rating: Acute local: Irritant 3; Ingestion 1; Inhalation 3 Acute Systemic: Ingestion 2; Inhalation 3; Skin Absorption 0 . Chronic local: Irritant 3 Inhalation 2 Chronic Systemic: Ingestion 2, Inhalation 3; Skin Absorption 0. h. Toxicol ogy_:_ Has "a"caustic reaction and therefore is irritating to the skin. As a dust it can cause dermatitis and irritalia of the eyes and mucous membranes. It is a genera] nuisanc type of dust. 5. Fire Hazard; None MQNS 046660 6. Explosion* Hazard: Virtually none 7. Stand'! ing: Dust respirator, adequate protective clothing, in- . eluding rubber coated gloves, optional rubber full cover apron, and full cover plastic goggles should be used when handling Hi (dust). Adequate ventilation and dust removal equipment r.houli be used in the handling area. Lime is added to the stills to neutralize any liberated l'.Cl p-m prevent sublimation of the FeCl-^ catalyst. It is handled in bOtf bags. ' -8- Attopulgus Earth (Code 19;I00) ' Attapulgus earth is an inert material and is handled in bags, drums or buckets. There should be no toxicity involved in handling tills material, but as a matter of personal cleanliness, it shoulrj be washed from the skin or brushed from the clothing after handling, it It should not be blown from the clothing or skin with on air hose as this is an unsafe practice. J. Trl-Tetra Chlorobenzene Mix (Code 58500) Received in tank cars, trailers or drums. This is a mixture of trichlorobenzene and tetra chlorobenzene. It is similar in properties to TCB and should be handled in the same way. It is 6tored in #5 or //6 underground storage tanks. K._Unox_Epoxide (Code 61320) Handled in drums and used in production of'Pyranol A13B3U. Purchased from Union Carbide; This material is dicyclo diepoxy carboxylate. Prolonged and repeated contact of liquid or breathing of vapors or mists may cause delayed and serious injury. Operators should avoid contact of this material with skin or clothing and should avoid inhalation of vapors or mists. In case of contact the skin should be washed thoroughly with plenty of soap and water and contaminated clothing and shoes should be removed. h.__ Dow CornIng Fluid (Code 31100) A defoamer used in Pydraul blends. It ha.s a flash point in the order of 600 F. and should present no particular hazard iri handling. In the interest of personal cleanliness it should be washed off if it comes in contact with the skin or clothing. M. Santolube 70A (Code 82130) ' Used in Pydraul A-200. Purchased from our Nitro Plant. This material chemically is the product of Oleic Acid and Tricthylcnc tetramine reacted in Benzene with Tetra-prophenyl succinic onhydrid and #5 oil. Its exact structure is unknown. Handled in drums - should present no hazard as long as it is not over heated to de composition. Should not breathe fumes. Should be washed off if it . comes in contact with the skin. H. Blue A Dye (Code Pod'lOp'and AZO Oil Black Dye (Code 20317) Used only in small quantities in Pydraul A-200 and Pydraul 260. Should present no particular safety hazard. Should be washed off if in contact with the skin. 0. Porocel (Code 1Rp69) Poroccj is an activated bauxite ore in 20/60 mesh form used for packing in the absorbers. It is received in 50// bags and manually dumped into the columns. Since it is aninert material there shouh be no toxicity involved in handling, but as a matter of personal cleanliness, it should bo washed from the skin or brushed from the clothing after handling it. HONS 04666l " -9P. I-ubrlzol 3360 (Code 39050) 1. Chemical Dame: Zinc dialkyl dlthiophosphates (an oil diluted blend). ' 2. Description: Amber oily liquid 3. formula; (110)2 F-S-S 2 Zn "K" is a blend of 50? iso-butyl and 50% primary amyl.. A. Flash Point: 380F. (C.O.C.) 5. Decomposition Temperature: 130C. (truce amounts of 1I?S) ' ' 220C. (rapid) 1 6. Toxicityj Moderately toxic and is an eye and shin irritant. Direc 'pKysical'contact should be avoided. At high temperatures (see above) decomposition releases hydrogen sulfide (H2S) a very poisonous gas. In the presence of water hydrolystation occurs, again generating H2S. 7. Handling^ From a safety standpoint Lubrizol 1360 should not be Heated above 120C. to avoid generation of HpS. To maintain maximum quality, a temperature of should not be exceeded. A drum warmer is used to heat the 1360 prior to pumping into a blend. The warmer uses 80# steam (l62C."). It Js_ recommended that a_means be found to insure that the 1360~~fs~no{"Heated"above T6o5c. ......... fy. Ferric Chloride (Code 33500) ' 1. Description^ Granular solid 2. Formula': FeClg (Anhydrous) 3. Constants: Mol. Wgt. - 166.22, Melting Pt.- sublimes, "solubility in I)20 = very soluble with heat rise. A. Toxic Ij-r/nrcl Hating . Acute Local: "irritant 1; Ingestion 1 Acute Systemic: 11 Chronic local: Irritant 1 . Chronic Systemic: U 5. Fire Hazard: There is no fire hazard under normal conditions, . 6ut"ft~will emit toxic fumes at high temperatures. 6 Handling: Protect the skin with approved protective clothing, avoid the breathing of FeClv dust, wear approved respirator with adequate cartridge, ana protect the eyes with approved goggles. There are no storage regulations; however, it Bhould be stored in a dry place as heat is released upon solution in water and wet ferric chloride will not catalyze the chlorination reaction. R. General Comments 1. All raw materials "used are stable under the present operating conditions and would remain stable under conditions caused by imaginable equipment failure. 2. Biphenyl, Xylene and glycidal phenyl, ether must be handled ns flammable liquids under present operating conditions. 3. Hone of the operating areas is enclosed in such a way as to permit exposure to toxic materials. A. The operators are knowledgeable and trained to carry out tinavailable emergency procedure in the event, of a spill. HONS 046662 - 9a - R. General Comments (continued) 5. Adequate fire control is available in storage areas with the exception of biphenyl. It is recommended' that: a. A 500# dry chemical fire extinguisher be located ' near item 1401. b. Evaluate the need for a monitor nozzle near Item 1401. c. Evaluate the need for controlled drainage from area around Item 1401. HONS 046663 10 ljuocKSS A_._ Chlorination Aroclor is produced by the batchwlse and continuous chlorination of biphenyl, or other Arocloro with snift gas chlorine (delivery pressure ?5 to 30 psig) at a pressure of 2 - k psig. Normal operating tempera tures are between 120 and 195"C. Hydrogen chloride gas is liberated during the reaction and is piped to the muriatic acid and chlorosulfonic acid departments. Ferric chloride is a catalyst for the reaction. - The chlorination reaction is exothermic (510 BTU/U). of chlorine) and is stable. Biphenyl can be chlorinated as fast as the exothermic . heat can be removed from the batch and still maintain a batc_h tempera ture of 150c. Continuous chlorinator temperatures vary from 150'C. in //6, l6`5C. in #7, l80C. in jj to 195C. in #9- In order to remove this heat, the reaction mass is continuously circulated at an average flow rate of 200 - 250 gpm from the bottom of the chlorinator up through nil air-cooled heat exchanger (capacity 1,200,000 BTU/hr.) and back into the top of the chlorinator. Maximum batcli chlorinator chlorine flow rate is 1500 lbs./hr. (pipe size and supply pressure' limiting). At 510 BTU/lb. this rate of chlorine flow produces 765,000 BTU/hr. which can be safely removed by the heat exchanger. The maximum for the continuous chlorinators is 1700#/hr. which is equivalent to 865000 BTU/hr. Chlorination temperatures are measured at the following points: 1. In the center of the batch chlorinators. 2. At the overflow of the continuous chlorinators. 3. Just below the chlorine sparger in all chlorinators. . At the discharge of the batch chlorinator circulating pumps. 5. At the discharge of all of the air-cooled heat exchangers. Point 1 is recorded on the 12-point recorder (6638). Point 2 is alarmed at 200C. Point 3 alarms and shuts off the chlorine flow at 225C. in the butch chlorinators, and alarms at 200"C. and shuts off chlorine flow at 205C. in the continuous chlorinators. Point it is recorded on the 12 point recorder (6638). Point 5 is alarmed for low temperature (120C.). Each batch chlorinator is protected by a 8" - 20 lb. carbon rupture disc with a 3" discharge ebove the top operating level. Should a chlorinator rupture disc break any discharged liquids would be blown down through the grating onto anyone below. It is recommended that ei theru. . ,1. Flooriiig_be put on the level of the discharge pining from the chloriiiators * or " "" 2. Th'ir'dTacharse lines be directed away from the working area and a ~KT6v.:n~scal"'warning ~3evice~(ore'ssure}- be"'InstaTled 3. The >.i'zfng ~oT the" rupture disc e'rif'd'lB'chargcIlne be investl- gnled . Ijbi) css_ The ~8'T' disc' ba-oke" up ~in~to small piccos it might be'possible to c.log~the ^discharge line with large" pieces"1* carbon. ' HONS 046664 A. Chlorination (continued) In addition to the rupture system, the batch chlorinators can be manually vented. All of the manual vents are tied into a central header system which is vented to #1 blow tank. This vent system is adequate. Since several Sp. Gr. samples are required for control of the batch chlorination a fume collection system has been installed for all five sampling points as well as for the finished product drumming station. It is recommended that the fume removal system be extended to the conffinuous chlorlnator area. Each continuous chlorlnator is protected by a 3" - 47 psig carbon rupture disc.with a 3" discharge to the ground level. This system is adequate. In addition to the rupture system, the continuous chlorinators can be manually vented. All of the manual vents (3") are tied into a central header system which is vented to the continuous blovi tank. This 6ystem is adequate. . The chlorination system is well controlled. However, it i_s recommended the.t all temperature alarms and automatic cut-offs be checked.at 6 month Intervals. *' Contamination of reactants with water and sulfuric acid will slow down if not completely stop the reaction. The same hazard exists here as it docs when the chlorinators are short charged or not charged at all and chlorine flow continues. Because there is no means to detect chlorine in the off-gas (HC1), it is possible to chlorinate in the Brink demister or HC1 transfer piping. When the heat from this exothermic reaction raises the temperature to 250"C., the chlorine will ignite the iron pipe. To detect the presence of chlorine in the off-gas header high temperature alarms set pt.) are provided for each batch chlorlnator & high temperature shut downs set for 175C. are also provided. A high temperature alarm set for 200C. is installed in the continuous chlorinator off-gas header. After use, samples from the continuous chlorinator system arc fed by gravity into a sample surge which is continuously vented to the blow tank. This tank is also protected by a combination pressure/vacuum relief device (See App. XV). The tank is manually heated with Bo/' steam applied to an internal coil. Temperature and level are indicat in the field. * The HC1 gas generated in the chlorinators passes through a shell and tube, water cooled heat exchanger and a brink demister Tor removal of entrained Aroclor prior to transfer to Dept. 218 and 217. The entrained material is collected in the off-gas storage tank. This tank is heated automatically by addition of 80;/ steam to external panel coils. Tank level, pressure, and temperature are indicated in the field. The tank is protected with a 3" - 27}/ carbon rupture disc Tile relief line discharges to the ground level. The tank may also be manually vented to the blow tank through a 3" line. MONS 046665 12 General Comments on Chlorination 1. Safe handling limits have been established and are observed. 2. There is no provision for disposing of reactants in an emergency. 3. All Instruments fail safe. B. Aeration The Crude Aroclor is transferred from the batch chlorlnalors to #2 blow tank. This is a 2000 gal. steel tank with coils, an air sparger, and an 18" vent line. Here the Aroclor is air blown for 2 hours to remove any HC1 remaining in the crude. There are no controls on this tank. 200 lb. steam is used on the . coils for the batch-made Aroclors 1248, 1254 and 1260. There is no danger of operating within the Aroclor flash points as long as this procedure is followed. It is possible, however, that the operator could drop the wrong batch from the chlorinator (i.e. one just charged). This would mean that essentially biphenyl was being heated with 200# steam (380 F = 200C.). Since bipher flash point is 235F., it is recommended that cither: 1. ' A proc_edure_be adopted to prevent dropping the wrong chlori- hator. " ....................* " " ' 2. #2 Blow tank be properly equipped to handle a _flanimabl Tiqui'cT ~ ........... ............... * .......... - - - -............. Since there is no level recorder or controller on the tank, it is possible to overflow the tank and its hot contents on those below. It Is recommended that: 1. A level recorder be put on #2 blow tank. After air blowing, the contents of #2 blow tank are transferred to #1 blow tank where It is continuously fed to the distillation system. There is a level indicator but no steam pressure regu lator on //I blow tank. The contents of #1 blow tank can be fed through a Bpiral heat exchanger for heating prior to transfer to the stills. 200,# is the heating medium. The preheater is pro tected on the product side by a 100,# rupture disc which discharge into #1 blow tank. See App. IV. Both the #1 and #2 blow tank vents (18") are tied into the drowning jet as well as to the atmosphere. The crude Aroclor (1142) is transferred from the continuous chlorinators to the intermediate storage tank. This is a. 15,000 gallon steel tank with external plate coils. Here the Aroclor is stored at 190C. prior to being further processed. This tank is continuously vented (3") to the I1C1 drowning Jet. There is also a 3" combination pressure/vacuum relief valve to protect the tank should the vent plug. Tank level is indicated both at the tank and on the control panel. A high level alarm sounds at 90# tank level. This system is adequate. HONS 046666 - 13 - The crude Aroclor is aerated continuously ns it is being red to //3 still. The continuous blow tank is 1000 gallon steel vessel which is vented to the drowning jet. 5# air is provided by a positive displacement air blower through five 2" dip pipes. The venting system for the tank consists of two V lines tied into a 3 2" line to the drowning jet. Tank level is indicated and con trolled in the field; however, high (90;$) and low (10;.!) .level alarms sound at the panel in the control room. The city water booster pump which supplies water for the 11C1 drowning jet is alarmed at the control panel on shutdown to ovoid 11C1 fume emissions. Distil 1 ation The straight take-over vacuum distillation in carried out in four still systems: #1 still (1100 gal. steel), #2 still (2200 gal. steel), #3 & f/4 stills (2046 gal. steel)^ Normally f'/l, f/2 and //4 stills are fed continuously from //I blow tank and #3 still fed continuously from the continuous blow tank. However, due to piping flexibility any still can be fed from any desired blow tank. In any event the feed rate is controlled automatically to maintain a set level in the still pots. The contents of d'l (V f/P still are circulated continuously through gas fired furnaces (one for each sti.il). These furnaces are uninsulated and arc in a position where personnel contact is possible. It Is recommended that either 1. The still furnaces be insulated and' properly guarded or 2. A warnfng sign b~plac~ed oh the furnaces. Periodically the stills are charged with lime to neutralize residual HC1. Currently the lime is manually carried to //3 and //4 Stills on the second level (14'). It 1 ^ recomme^ncled that an Improved iime delivery method be used, ' The contents of //3 and #4 stills are circulated continuously through therminol fired shell and tube heat exchangers (one for each still). The entire heating system is adequately insulated for personnel protection. . The therminol is heated in n gas fired furnace which, is equipped with controls and interlocks specified by the CEO Safety emd Property Protection Section (See App IV). Vacuum (30 - 50 mm Hg absolute) is mounted by six --2 stage non condensing steel Worthington ejectors. One jet is required for each still that is operating so there are two installed spaces. Steam pressure is reduced to l6o#, but the jets will take in execs of the maximum 200/' available. ' Each still pot & still receiver is equipped with a rupture disc and discharge line (Sec Appendix IV). In each case both the rupture disc and discharge line is properly sized and located. Each still is equipped with sufficient temperature measurement to insure safe operation. Overheating of the still contents causes formation of a tur-like substance, but presents no safety hazard. The level in the f/3 & J?4 still pots is indicated both in the field and on the control panel. Normal control point is 50;$ full. One alarm sounds on low (10;$ and high (90;$ ) level conditions. HONS 046667 - 14 - Dlsl.illntlon (continued) . The level in //\ still is recorded on the control panel. At present there is no level indication, other than feed valve position, for // still. However, TSD Project 6928 - "Install level recorder on #2 Still" is scheduled for completion in'early 1969. It is recommended that completion of this project be ex^edited. . . The levels in #1 & #2 (1000 pal. each, monel) receivers are recorded on the control panel. These tanks are emptied batchwise using a positive displacement pump. The levels in j/3 & #1 receivers (8?9 gal- each) are indicated in the field. An alarm sounds on high (90#) and low (10#) level conditions. Normal set point of 90# is controlled by continuous pump-out using a centrifugal pump & level control system. Temperature in all four receivers is controlled by manuo.1 addition of BO// steam to internal coils. Steam heating is rarely needed except Tor Aroelor 12f>0 production. A serious injury was incurred by a pipefitter in December, 1968 when removing the cap from the lime addition nozzle on /pI still pot. The accident resulted from pressure build-up on the still duo to inadequate venting. It is recommended that all the actions resulting from the_ formal InveBtl'gatTon ('L~l7-S6-'68') outfits fiicY dent foe completed as soon as possible on all four _stJl_t systems. The specific recommendations made in L-17-20-68 arc: 1) Forward flow valves from the stills to the receivers should remain open at all times except when taking a still sample. A sign should be placed at the valve stating this. 2) The Jets should be on while charging crude Aroelor and lime. 3) Change the one inch vent line on the still to a two inch line. Replace the vacuum indicator with a pressure/vacuum indicator. Keep vent valve open while removing the still cap. 4) Operating Instructions for the still charging procedure should be revised to specifically include the above recommends tlons. Operators should be retrained according to the revised instructions. 5) The design of the lime charging port should be evaluated for safe and easy operation. 6) Evaluate the adequacy of the grounding of the still. HONS 046663 1). i'oroccl Treating The distilled Aroclor is transferred from the four still receivers to the absorption system. The major items of equipment in' the four treating system include the following: i/1 & i/?- blend tanks (2000 gal. each, zinc & tin lined); i/3 & //k surge tanks (10h5 gad. each, aluminum); i/1, i/2, i/3 & i/k absorbers (3' diarn. x IV high, 316 SS) //I & //2 finished product tanks (2000 gal. each, zinc & tin lined); #3 & #4 finished product tanks (10k5 gal. each, aluminum); i/1, $2 & #3 polishing filters (316 SS). Levels in i/1 & if?, blend tanks are indicated in the field. Since transfers are made into these vessels on a batch basis, this presents no problem. Temperature is controlled by addition of city water (manual) or 80# steam (automatic) to Internal coils. The tank temperature is indicated in the field and recorded ori the control panel. This system presents no hazard. Doth these tanks arc presently vented to the atmosphere. Levels in #3 & i/h surge tanks are Indicated in the field and on the control panel. Hi (90$) and low (10$) level conditions are alarmed ut the control panel. A level of 50$ is normally main tained by balancing the absorber feed rate out of the surge tank against the still receiver input to the tank. Temperature is auto matically controlled by addition of city water or 80;" steam to internal coils. The tank temperature is indicated in the field and the temperature of absorber feed stream out of the tank is recorded on the control panel. . ( MONS 046669 - 15 - D. Porocel Treating (continued) . Both surge tanks are normally closed and nitrogen blanketed. Tank pressure is controlled between 4*1" W.C. and 47" W.C. by self contained pressure control valves. In the event the pressure control system fails, the tank is protected by a 2" combination varec pressure/vacuura relief device set for 6 oz. pressure and 1/2 O'/., vacuum (See App. IV). Both these pressure control systems are adequately sized. The four absorbers are packed with 5*100# of Porocel (See Section 1) The distilled Aroclor is fed by a centrifugal pump through a flow ' controller down through the porocel bed. The absorber is pruLcctoi from overpressurization by a 2" - 10*1# rupture disc. The relief line discharges at ground level. Temperature in the absorber is automatically controlled by addition of 80# steam to tracers on the outer wall of the vessel. Absorber temperature is indicated in the field. Aroclor leaving the absorbers passes through the polishing filters for removal of any poroccl particles going forward from the ab sorber. Pressure on these filters is indicated in the field, however, there is no pressure relief system. Since (1) the filter: are designed to hold 100#, (2) the filters are only sparingly traced v:ith 80# steam, and (3) maximum pump pressure on the filter: is 80# (normal 15#), it is felt that no pressure relief system Jr. required. After passing through the polishing filters the finished Aroclor enters the finished product tanks. Material is normally stored in these tanks at 100C. by manual addition of 8o# steam to internal, coils. Temperature of #1 & #2 finished product tanks is recorded on the control panel; that of #3 & #*l finished product tanks is indicated in the field. ..Tjevel in #1 & #2 finished product tanks is measured by sticking the tank as these tanks are vented to the atmosphere; Approved T3 Project 6939 - "Install Level Measurement on product Tanks" propos continuous field indication of these tank levels. Due to the bate . wise operation of these tanks, field indication is sufficient. In the interest of_ improved operations, potential product quality ~fmp"rovcmcTIt, 'and" reduced' operator coni act with_ A'focTo_r_r'um('s,__iit _ Tb recommended "that 'completion o~f~ this project `b'e'cxpodfted * ' ' Level in #3 & #*) finished product tanks is indicated in the field and on the control panel. An alarm will sound when a high (90;o) level occurs. Normally, these two tanks are closed and Nitrogen blanketed. The pressure control and relief systems for these tanks is identical to those explained previously for #3 & #*< surge tanks. In the interest of improved operations, potential product Quality 'fmpro'veme"n_t,_ancr reduced- operator contact 'with Aroclor fumes, it "fs recommended tnat" a project be developed to nitrogen Ljacket. ?! _] E~#?'t'lThcrah~d'~]rinTsIiea product tanks similar to'tfie systems nfufj oWocC"on"#3 & #' 'surg'd and fini r.he~ci~pro'duc't tanks HONS 046670 - 16 General Comments on the Process _ 1. Accidental contamination of reactants will not form undesirable side products. 2. Trocess piping and controls are installed so as to prevent improper mixing of chemicals. 3. Sewering of materials would result in no hazards. If biphenyl, xylene, or glycidyl phenyl ether is sewered precautions must be taken to prevent ignition of the flammable liquids. <1. Department guarding conforms to the Illinois Health and Safety Code. 5. Ventilation is adequate to avoid exposure to toxic materials during all routine operations. ' .6 Lighting in_ the ^batch i^hlorinato_r _area is _below standard. It is recommended That completion of approved TSI) P-rojcc't - ""Upgrade Lightlng~'System IrTTlcpt~ ~SIn5w~bc expedited. ' III.___F i rilshe d_ Goods A. Blending and Finished Product Handling Aroelors are produced in a variety of grades and blends for use in capacitors, transformers, heat transfer fluids and plasti cizers. Sec Appendix II for a complete list of the Aroelors produced and their blends. ' After the Aroclor has been porocel treated in the absorbers and transferred to the finished product tanks, it is transferred to an appropriate storage tank. Aroclor vapors are toxic in high concentrations as well as irritating to the upper respiratory tract. Workers should not be exposed to vapor levels throughout their work shift in excess of the threshold limit value (TLV) of 1 mg/M3 of air (or about 0.1 ppm). The material can absorb through ' the Intact skin and on repeated contact can remove the natural oils from the skin and cause irritation and/or dermatitis. Skin or eye contact should be avoided. 1. Aroclor for Sales Aroclor that is to be sold without an additive is normally stored as follows: a. Aroclor 12^2 - tanks //9 and 11 (20,000 gal. each), #1h a nd #15 (22, 000 gal. each). b. Aroclor 12k8 - Storage tanks #7 & #10 (20,000 gal. each). c. Aroclor 125;t - Storage tanks #12 & #13 (22,000 gal . each). d. Aroclor 1260 - Storage tank #16 (22,000 gal.). MONS 046671 - 17 - A_.___B1 priding and Finished Product Handling (continued) All storage tanks are equipped with the proper breather or con servation vents. Storage temperatures (100C.) are not such that grounding or flame arrestors be required. g. Pyranols * l'yranols are used mostly in transformer applications and are made by blending Aroclors with chlorinated benzenes and other additives. These materials are mixed in //2 mix tank (1^1,500 gal .) and //3 mix tank (17,000 gal.) and then transferred to finished product containers. This system is adequately protected. Three pyranols - Irierteen PPO, 5^201 CM, and 5^4201 KA - use O.POji' Glycidyl Phenyl Ether as an additive. This material has a flash point of 171 ]'. (0oC.). It is added to the Aroclor - Trichlorobcnzerie mix through tiie auction side of the circulating pump after laboratory analysis is com pleted. Storage temperature of the contents in ,f2 iiiix tank is between 90 and 100C. This is above the flash point of the Glycidyl Pheny.l Ether but may not be above flash point of the mix. It is recommended that a cample of Incrteen PPO, 5*1201 CM and 5^4201 KA be takcrT'afCer'thc~>:thcr Has been' added lin'd a Tl~as~h "point determined. If storage tempo ratur'er. "arc VftHin r'3c~'6f "tFie~fIa'sl) point eTtKer: ' ' ........................ 1. The tank must be properly equipped to handle a flammable ' liquid" or " * -- "" .................... .... 2.___yfie oCorago_tempejaature must be lowered. These materials are circulated through`an 18" filter before transferring to the finished product containers. This filter is not protected with a rupture disc or relief system. It is recommended that an appropriate relief system be installed on the `filter. " ~ Pydrauls are used mostly as heat transfer mediums. They are made by blending various Aroclor grades with additives. They are mired in #1 blend tank and stored under proper conditions. 1|, Aroclor 125^ and 10$ Xylene Mix Xylene has a flash point of 85 - 100F. which classified it very definitely as a flammable liquid. This mix is made in #1 blend tank. The xylene is stored in drums and unloaded by use of a dip pipe put into the drums. The drums are grounded but not adequately. It__is recommended that this grounding system be checked and a proper o'nc'Instai led'. ~ " During preparation of a xylene mix smoking is permitted only in the control room and Foreman's office and signs are put up in the depart ment to that effect. Electrical cigarette lighters are removed from their receptacles. #1 still is allowed to run as usual by pnrMlnslor of the fire insurance inspector but $2 still furnace is shut off and kept off until the batch is complete, any spills cleaned up, the t.-mv closed off arid a gas test of the area made. These provisions are a must. HUNS 046672 - 18 - III.__Finished Goods (continued) ' It Is recommended that: 1. The flash point of the Aroclor 3 5*1 and Xylene mix Joe determined. IT, storage Temperature be kept as .toy; as possible. ~ -- - - tj~ Evaluate nce~(T~for vent and flame arrestor orTjyi' Blend_Tanlj._ 5.__frfie arilt"be~6roundea. "" '" Jj7__ Ground the Xylene drumming facilities and further alter to adhere . to Monsanto safety specifications for handling flammable" YfquTds " ' ----------------------------------- 5_.___By-product HC1 ` a. Synonyms: Muriatic acid, Chlorohydric Acid, Hydrogen Chloride. b. liescripITIoii: Colorless gas C. Formula^ lid d . Toxic Hazard Rating ~' Acute To'caT: Irritant 3; Ingestion 3. Inhalation 3 Acute Systemic: U . Chronic local: Irritant 2 Chronic Systemic: U e. M.A.C.: 5 ppm in air for 8 hr. day f. Toxicology: Hydrogen chloride is an irritant to the mucous membranes of the eyes and respiratory tract. Concentration of 35 ppm causes irritation of the throat after short exposure. Concentrations of 50 to 100 ppm are tolerable for 1 hour. More serious exposures result in pulmonary edema and often laryngeal spasm. Concentrations of 1000 to 2000 ppm are dangerous even for brief exposures. Mists of HC1 are considered less harmful than the anhydrous form since the droplets have no dehydrating effect. . This by-product containing a small amount of hydrogen is collected in a common header and flows to the central 11C1 ab sorption unit for the production of Muriatic Acid in Dept. 2]8 of Chlorosulfonic Acid in Dept. 217. If Dept. 210 e.r 2.17 is unable to use all the off-gas, it may be sewered in the Aroclor department after drowning it with water in a drowning jet. The removal of HC1 from the off-gas concentrates the original quant it; of hydrogen and air to a point within the explosivelimits. Therefore, it is recommended that a sufficient quantity of steam be IritroSucedTnto~he"scrubbor stock "to" snuff out any fire which c^oul'crc'onc'eTvaB'iy occur'aX the outlet. " " " " _ loading Facilities * All loading facilities are adequate with the exception or the tank truck loading dock. It is recommended that an adjustable loading ramo be installed to compensate for varying trailcr sires Approved TSlf Vrojcct 7CM "Alter Truck ~)oe~(iTng~~DocTflr encompas'ses "this recommendation. " MQNS 046673 - 19 - TV .__Safety Kqui pment Stretcher Case on Pole 50 Ft. S.E. of Dept. 25*1. A. 1st Moor pi re jfxtTnfjui shers DryTheml'cST- North of Sprinkler House 2. Carbon Dioxide snow - West wall at lean-to door. Shower Location 1. Southeast Corner by Water Tank 8. New Area 3. Tank Karin (Alarm on Control Panel) 1. Eye Dath SE corner by water tank 2. Eye Hath New Area 3. Eye Bath Tank Farm Gao MjiRk 1 . "North wall of sprinkler house . 2. Outside on west side of repair room. Scott Air Pak - Outside on west wall of lean-to. B. Pnd Floor ~"Klre"Extln{>\i is hers T. Dry Chemical - West wall at head of stairs. 2. Dry Chemical - West wall at head of stairs. Shower location 1. Southeast 'Corner in old area. 2. New Area 1. Eye Bath 2. Eye Bath New Area , Eye Bath - Control Room ' Gas Masks T: Control Room 2. S.W. Corner Head of Stairs Emergency Clothing - West Wall C.__ Mezzanine Floor at //I & //P Still Furnaces " 'Safct'y Shower Eye Bath D. 3rd Floor . * 1". Safety Shower Old Area 2. Safety Shower New Area 1. Eye Bath Old Area 2. Eye Bath New Area MGNS 046674 20 General Comments on Safety Equipment and Operations. 1. Sufficient instructions are available to cover shutdown during an emergency situation (steam failure, power failure, water failure, plant disaster). Date of last review - April'19u6. It^ is recommend_ed_ tlnat more specific procedures be writ cover t;Kutflown jur~ing~The p're'paratTon of a xylene Tlen<). * "' 2. It is possible to trap personnel on the north side if the south and middle part of the department is contan.5 noted. It is recommended that the installation of an emergency exit on the- nortK s'fHe^oT the department lie consTdcred 3. There are no emergency lighting facilities. It. is recommended that equipment for emergency lighting be proviefed. - " MONS 046675 APPENDIX IDefinitions A) Plash Point The lowest temperature at which a flammable liquid will give orr n flammable vapor which will burn momentarily. Fire protection standards recognize the "closed up (c.c.)" flash point. This Id determined by testing the material in a closed cup. This test reveals the lowest temperature at which sufficient vapors escape at the surface of the material to flash when an ignition source is applied. This flash point temperature is the lowest tempera ture at which a stable explosive mixture of the material vapor and air can exist, and is the lower explosive limit expressed as temperature. Many manufacturers, trade publications and the Interstate Commerce Commission recognize the "open cup (o.c.)" flash point. This is determined by testing the material in an open cup. Because some vapor escapes during the test and because the vapor above the liquid is usually cooler than when the closed cup test is made, the "open cup" test is as much as fifty or more degrees higher than the closed cup figure. For this reason most of the flash points listed in this audit arc by the "closed cup" method. We consider a liquid as flammable when the flash point is 1^0F. or lower by the tag closed cup method (American Standards for testing materials or A.S.T.M. D56-56). Materials having flash points above ]JlO F. should be: treated as flammable liquids if they are stored, handled or processed within a temperature range starting at 15F. below their flash point and extending to above the auto ignition temperature. B) _Ignition Temperature (Fire Point) The minimum temperature at which ignition will occur by application of flame or spark and burning will continue without further heating or application of flame. . C) _ Auto Ignition Temperature The minimum temperature at which the substance will ignite spontan eously upon heating. The degree of danger is determined largely by the flash point of the liquid, the concentration of vapors in the air (whether the'vapor-air mixture is in the explosive range or not) and the possibility of a source of ignition at or above a temperature sufficient to cause the mixture to burst into flame. D) Rcferences 1) Factory Insurance Association: Safeguarding flammable liquids (1953) . HONS 22 D) References (continued) 2) National Safety Council: Accident Prevention Manual for Industrial operations. (1955)-. , 3) National Fire Protection Association: Standards of the National Board of Fire Underwriters for Storage, Handling and use of Flammable liquids. (Bulletin #30, 1998). i|) Commission of Illinois Publication: Rules and Regulations relating to labeling in the use. Handling and Storage of Substances Harmful to the Health and Safety of Employees. (June 1951)- . 9) Section VIII of the W.G.K. Design and Construction Manual Safety Guidelines by T. H. Becker, 1998 and 1999, Kt Flammable Liquid Handling Precautions '. 1) Flame arrestor on tank vents. 2) Proper tank grounding per Std. E.2. 3) Dip pipe In loading line per D.3.2 Std. 31. >1) Flammable tanks indicated by signs "Flammable". 5) Inerting of the Tank. , MONS 046677 APpiXPXX XI Finished Products Product Aroc_ors 1132-1232 (Code 811.15 Composition ' Chlorinated 3iphenyl 32# Chlorine '. - 23 - Flash Point i Boiling Point (Too =3) 1142-1242 j011.01 Chlorinated > 3oOu?. Biphenyl j chlorine ! c.c. i il4o-124d j Oil. 02 j Chlorinated j 302"?. 1 i 3iDhenyl - 48# j c.c. ! ! Chlorine I 1134-1234 [011.03 Chlorinated : None J- Biphenyl - 5^# i i Chlorine i H'60-1260 jail. 00 Chlorinated j None 'j TI32-T252 j 8lT.'07-- 1 i Inerteen P?0 j (1200 ?P0J |810.92 1 ( ! j; Biphenyl - 60# Chlorine Chlorinated Biphenyl - 62# Chlorine 60# Aroclor 1260 plus 40# Trichlorobenzene plus 0.20# Glycidyi ohenyl Ether (PPO) j | ( None j 1. i Flash j ?t. of ! TCB is j i I 34201 KA 010.9a | 70# Aroclor 12p4, ; " (123^ PPO) j 30# Trichloro- j. j Senzene and .20# j j Glycidyi phenyl i s ether. ; 54201 CM (1242 PPO) -- - I 011.10 j 11 100# Aroclor 1242 and 0.20# Glycidyi phenyl ether. i i j ; ! | j ! ; j i | ! ! 325WC i j 1 3*+5 i ! 35"C. | i 3S5"C. | i ! 390VC. i ! | --) j 1 1 t i j 1. N.I.Sax - Dangerous Properties of Industrial Products. 2. T.H.Becker - V.'.G.X. plant Flammable Hazardous Materials. Slight fire hazard when exposed to heat or flame. Can become dangerous when heated to decomposition. Aroclors can emit highly toxic fumes. No problem ooerating temperatures. " " a, I 5 "J , "* x .* Slight fire hazard when exposed to heat or flame. Vapors of Glydicdyl phenyl ether should not be inhaled above 60C. No problem at operating temperatures. ' Same as above ' - 24 Finished Products M9990 SNOH !' . Product : 12b1- - ; 100 Xylene ;! Code Conocsition STITTS"' 90% Aroclor 1254 and 100 Xylene ' Pyranol A133 33 810.97 450 Aroclor 1260 plus 550 tri-tetra chlorobenzene and 0.1250 Unox Eooxide. ! Flash Soiling =>oint j Point `(760 mm) i ?Iasn # !-- j Pt fZ* ] 1 ! of Xylene j is 85 to j 100 F. j ! j rj ; ! REXAF.XS Fire and Explosion Hazara wr.an exposed to heat or flame due to presence of . Xylene. Fire and explosion hazard when exposed to heat or flame. Should avoid pro longed breathing of fumes. No problem at operating temperatures. Pydraul A-200 Pydraul 200 Santicizer 794 Mor. tars 810.96 "Bl'l.TS- 811.04 555755 33-1/30 Aroclor 1242, 66-2/30 j Flash j >\j~ Aroclor 1248 : plus minor amounts] i j of Santolube 70. i Lubrizol 136o,DCF,; A20-011 Black dye i and blue A dye. ! Aroclor 1260, j Flash Aroclor 1248 plus j Pt. of 21.80 Trieresyl j Aroclor phosphate and j 1248 minor amounts of i is 1 i \51 __ f" 1t 1 Santolube 70 j 3S2F. * (.400) DCF and j ] j j--3iue A dye. j 5C0 Aroclor 1248 Flash Pt. and 500 Aroclor : .of Aroclor; 1260. >; 1248 is 332"F. 5 'Still bottoms from Aroclor Process. 1 j j i" Slight fire hazard when exposed to heat or flame. Can become dangerous when heated to decomposition as it will then emit highly toxic fumes. No problems at temperature handled in the dept. Same as above. . , Same as above. ' No problem at operating temperatures. These materials are extremely hot and must be handled carefully. Fumes must not be inhaled. Present drum area is enclosed and should be adequate. Fume irespirator should be worn. 1 APPSSPIX III Dept. 2^6 - Group Squipnent (Batch Plant) MUNS 0 4 6 6 8 0 i* : J 1 * Capacity Jacket i Service 1 Size 1 Gallons > Relief 21-2210 ! Biphenyl S 10'6" xi 25,000 l Coils i (102) j Feed Tank ^ 40'6" < i 21-0767 ! Biphenyl 1 4-6" x > 700 i No Jacket ] ! Yes ! (103) [ J 1 4' \i i \* 5f i 21-3261 | Chlorinator 3' x l6'( 850 s Jacket i (105) | #1 i il ,,s J $ over lower) i half of ; i v! /i 1 i ! i \ tank. 90# ; ( set on re-? i lief valve! J! 21-32^5 I Chlorinator 3 x 161,! 850 s (106) 1 #2 1 *1 21-3251 J i J Chlorinator 3' x l6'\ 850 i< " 1 1 (107) j #3 ]. i | 21-1283 1 Chlorinato5 3' x l6'i 850 (108) j #4 | l 21-11*32 j Chlorinator 3' x i6'l 850 (109) | #5 j I -t 38-5^87 | Chlorine f 8'-5/8" x (116) 5 Vaporizer j 11' s (In par- i allei with new Vaooi:. .| I J J y. Iten #590) 1 i It 1! 2 " ii .5 5S5i ? j! j When \ internal \ pressure -j 50# steam :i t* i auto. off. shutj } 21-2086 j Blow Tank jj 7' X 7* t 2,000 (126) j #2 j 1 Coils - no.) Jacket 1 i j 1 s ___ Breather i Plane 1 Relief or 5 Vert * Arrestor ^ Ruoture Disc' C-rour.ced 2" 3 ?! It" Vented to 3 ji BiDhenyl Stg. Tk. 1 i No ij None | b : 1 ' ; No i t. :4 ' t l 2" Valved- | No f Rupture s No line headed j Disc @ with the chlor. to 1 #1 blow { 1 20# - 3" line OK i 1 tank. t* 1 s No r 11 l1 *. *,1 No i 1 f It . tK, No l ;T[ fj No i t i 11 f! ` ' ' i No , ' A V,1 No jj Jn 3i . ' * 3 11 j. NO h i No '< Ko si 5 No I No 1\ ;4 | K No f V . n i! | l 2 18" vent r i| line to handle ai blowing. 5 No 1 No h V t i No ,1 Nu.T.'ser f~z r Nur.oer) 20-C043 (130) Serv- ce --* 27-C045 (131) Furnace #1 20-0062 (133) Still #2 Size 1 i Capacity lla-i. Jacket Relief 6' x 5'6" 1100 No Jacket 3/16" X 3'9" x 4'lOi" 600,000 3TU 6' x 2200 Gal. 11'10" - n M Dept. 246 'j Breather Vent i Flaae Arrestor So Vacuum No 6" Vent Stack to roof No No No 1 Relief or Ruoture Disc 30# Ruoture Disc &`4" Line j i Grour. I No ; No No 30# Rupture Disc L 4" Line No T 9 9 9 * 0 SNOW .-.3-0770 >136) 38-1378 (137:) 21-0771 (138) 21-1377 (139) 21-0779 (142) Condenser #1 Condenser #2 Receiver #1 Receiver #2- Blend Tnk. #1 12" D x 5' 12" D x 5" 5'6" x 5'6" 5'6"x 5 *6" 7' x 7' No No No No No No 1000 N 3 Jacket No No 1000 It * 2000 K 3 Jacket tt It - 2" line around Bldg, dischg- 2 ft. from t ground. ' No No No No It No No No No tt No . 21-1399 (143) Blend Tnk. 7' x 7' #2 2000 II . 2" thru leanto tees into #1 vent. No No . No' 15-0238 (145) Sparkler Filter 21-0780 ^fc) 2i-l4or / i<\ Fin Prod. j Yank #1 < i Fin.?rcd. ! r->. v ..Vo 38" 7' x 7' j \7< x 7' -- Yes No No No . 2C00 1 ! ! II! i 2C00 j *i i 2" (manifold 2" conserva- t*nr\ VfT.t d: schg. ! ; j ! above control room) No 21-1310 (152) 21-3526 (154) 21-2404 (156) i j . Service \ Size 11 Capacity^ iGallons I Stg. Tank #3 TC3 #3 Mix Tk. Pyranol Stg. Tank ] #? 1248 ; 10 ' x 261 5 ] $ !12'6" x i ? 22 ' i *; >13' X 20'S *1 15,000 < : 20,000; i * 20,000 \ :] - 27 - Dent. 246 Jacket Relief * Breather ^ Ver.t i l No \ 2 oz. \ No ] 3" Traced \ & Insulated i i4 No Vent 7lar.e Arrestor * No 5 "\ .. i Relief or ; Ruoture Disc 1 Grounded No NO 21-0750 ; Blow Tank ? T' x 7' . } 2000 (167) #1 No 18" Vent 21-0321 i #1 Mix (159) j Pydraul 14' x 10's 12500 | No 2" Vent No 21-2621 | #2 Mix (164 } j *10'6" x 2-3' 14580 | No 3" raced 5s 21-1396 i #2) Catch 4'6" x 5'S". -- (186)(185) 'S 21-0756 j #1) Pots J4'6" x 5'p" --__ 38-5328 & Air Cooled |l.2 M 38-5564 1 Heat 5' BTU 67 > Exchanger (162) j #6 TC3/TTCB5 9,500 iri S j ] l i) iis (117) i #9 1242 $ 20,000 51j 21-4085 j #10 1248 (118) 20,000 j No No No No No 21-4086 : #11 1242 (119) : . s j20,000 No ii No l i i5 " J| . i$ $1 sl f li" - 3 ft- | j From Ground J j Level 5 0 3" Conserv. \ ) Vent + j oz . s C 1Jfic " s 43 (r{.j 3" Conserv. 5 * Vent + -J- oz.? 1 i- iSt !* u No No No No it 1 !' \ , - 1 | 2 ? | s s a* $ iai NO NO No NO 11 I \ l No ji g No i f | No | c< .1 B No MONS 0 4 6 6 8 2 1 Sept. 245 (1800 Expansion)' er) 1 Service 21-5229 j Biohenyi (401) j Stg.Tank Site I Capacity) j Gallons j ] 25' x 30'- 110,000 i ? .i i I iS Jacket . Belief Coil 40# Set Breather l Blare Vent i Arrestor \Yes. 6" j6:' Steam j Steam Jack-'Jacketed I eted. Event with l iflame ; (arrestors. belief or Runtvre Disci Grounded "Protectoseal; 2 Grounds Relief Cover j north & on manway. I south sides.. HONS 0 4 6 6 8 3 21-5230 (403) 3iohenyl Mix Tank 21-5232 i #6 Chlor(406) i inator s*28-588d ! #6 Chlor. y (408) j Cooler 21-5233 j #7 Chlor. (410) j Cooler i 38-5889 1 #7 Chlor. (412) | Cooler 21-5234 j #8 Chlor. (414) j 5'6" x 6 09" 1,272 f Coil 1 3 U' X 20' I 1,750 3 Shell i Traced s So Jacket -J -- i Ko Yes. 4" Steam Jacketed SYes. Jacke:tfd (50# set on !F.A.Jacket f No No ,j No. (VentedS to off gas s system) ij No 3" Rupture <= No Disc - 47 lhs? - No No No \ No U' x 20 J 4' x 20' 1,750 l Shell _ \ Traced (So Jacket 3 -- | No ' No (Vented ! to off gas ' system) ' J ?. No 1,750 i | Shell j; Traced 5 No Jacket No (Vented ( to off gas j system) i No No, NO 3" Rupture ? No Disc - 47 lhsE t NO i NO P \ 3" Rupture No ) Disc - 47 lbs;' 38-5890 (416) 21-5235 (413) #8 Chlor. Cooler I No No #9 Chlor. J4' x 20'. | 1,750 j Shell ( No (Vented 5 Traced { To off gas S No Jacket system) No No No f NO j! 3" Rupture ( No Disc - 47 Lbs;' 38-5891 ; #9 Chlor. (420) j Cooler 3 No No No NO No - 29 'Turner 5 (Iter. ! 21-5236 j (-22) j 21-5237 i (ft2ft) j 38-5892 ! (^27) j 21-5238 1 (ft29) ! i 21-5269 ! (^35) i 1 21-5239 ! (502) j 38-5393 1 (50ft) j 33-5895 i (506) j 21-52ftl? (508) \ 2 1 !. i ,,, \ Service \ Size i >Caoacit y; jacket ! Gallons i Relief Blow Tank Int erzed. j ft' x 10' j 1,000 i j 1 i r j ! 11' X. 22* 15,000 No Coils Stg.Tk. } . j j t t ii Off Gas 5 20" x i -- it Condenser Off Gas 5 ! 7'6" x . i 8l9"3,080 t 5s Stg.Tank i , /ii No No Sample s l 3'6" x 4*3" 325 t 'i No Surge Tank' j i St 1 #3 stm i 78" x 93? Pot jj $l __ I #3 Still | Keat Exch.s; I 2,0ft6 ? 6 ! __ a1; r? f No No #3 stiii 5 j Vaoor Cond. '\ #3 i S'xS'S" ! Receiver J '? Tank j[ 2_ 829 5 No f. Coil f 21-52ft0} (511) ? 33-58961 - (513) i #ft Still jj 78" X 93" 2,046 ?ot i 5* v #ft Still ^ "-- Condenser j , ) 5 J, > No NO Dept. 246 (laOO Expansion) . 3reatfter Flar.e 5 Arrestor Vented to . So Drowning Je ? i p 3" Vac-Press> No 6 oz. closes 4 oz. opens; No No 'i f Relief or ; Runture Disc 1 Grounded No | NO it No (Vented to: One - on Blow Tk. );i East Side S No ^ No 15 No. NO 1 3" Rupture ; No Disc 3ft# Burst. 2" Vac-Press 6 oz. press* No ! 4 oz. Vac. No No 3__ J i No II t j, 3" Rupture 1 Disc - 20# Burst. t No No !i No 5 No i No l No f i No sNo sK No. | 3 j Ifo '1 jf No I Relief Valve No { 125# Press, ij ' $ { | 3" Rupture I No ) Disc. 10ft# "< } Burs t. `k5 " 3" Ructure i No I Disc 20# 5. ( Burst. ,* !i 5 ij ReliefValve) No^ h 125#Press. 5 HONS 0 4 6 6 6 4 - 30 - Dept. 246 (l800 Expansion) MONS 0 4 6 6 8 5 cuip. j Nurr.cer 1 (iter. i Nuroer^ ' 21-5242 ! (515) ; Service #4 Still Rec. Tank 1 !! j 1 Size j* Caoacity;. :Gallons ! i 5' x 5'3 829 \ { {l Jacket Relief Coil 21-5257 ; #3 Catch (523) 1 Pot S ;3,6"x4'3" 1 1 P 325 ? No 21-5253 i (524) ; 33-5894 ! (526) ] #4 Catch i 3'6"x4'3 Pot 1! 5 #4 Still } _ Heat Exch* l j ! ITN mC\J f __ ? .! No No 21-5259 j (530) | *> 'S #3 Surge Tank >, \4 5'x6'9" * 13 1,045 5 * $ 1^ l Coil 21-5243 ; #1 (532) ] Absorber i ! 36"x15' \ | j (Packed! Shell $'5900 1'osfl Packed j of Porocel) 21-5261S (534) 3 J l 21-5260 i #P3roFduincitshTekd. ? 5'x6'9" i 1,045 ii 'i ic i \ J #4 j 5'x6'9" I 1,045 | (537) } Surge Tk. jj Coil Coil 2i -5244 ? (539) | .j t #2 Absorber 36"x15' s j; 5 i ll 5 (Packed' * ;with 5900 Jlbs. Of r jl P orocel)' ;* t 3 Shell Traced 1| \ Breather \ Flame ' 5 Vent < Arrestor i j No s \ i No i i '{ No ? iKo ; * >; * INo ii ; No '?4 A | NO (No > '3 J i 2" press- \) No ' Vac relief *- i 6 oz. - 4. ; 1/2 oz. Np j Blanket. i s No ii |N | ` . ' 5 | | | Relief or f Ruature Disc: C-rcur.ded 3" Rupture Disc, lot# Burst. 5 No K ? No No No No No No No No sK 5 2" Rupture f disc, 140lbs.. byrst. j No i 2" press-- 1 No ; vac. relief l6 oz. - 1/2 ibz. jN2 Blanket * i 2" Press-Vaci. No 5 Relief 6 oz r. i 1/2.oz. N? 5 Blanket. 1 j No - P <i . i' No y }. fc j NO . ; No $t S' .H I No No 8. f 2" Rupture disc. 140# ii burst. . * ii s. No 31 - Deot. 2^6 (l80Q Expansion! Number; I Ser-rfc j Capacity; Size ;Gallons i 21-5245 #3 Absorber {36" x 151 5 (Packed; (540) ' (with 590<? libs. of ) iporocel) : Jacket Relief Shell Trac ed Breather Vent No Flar.e Arrestor Relief or Runture Oise ? C-rcunded No S 2" Ruoture No f disc. 14c# f burst. HONS 0 4 6 6 8 6 21-5247! #ii. Finished 5'x6'9" (542) ! Product Tkj 1,045 i coil ]1 21-5246] #4 Absorbed 36"xl5 ^/^>545) i !(Packed \ Shell 'kith 5900# Traced ijof Porocel) .f 21-5248' #14 Fir.ishe<il2'6"x24' j 22,000 i (558) j Product Stgj jf ; Tank { 3S Coll J! Iy js s 21-5245; #15 Finished 12'6''x24'- 22,000 jj (559) i Product Stg,j Ij * Tank. j '< { j 2" Press-Vac. j Relief. S i 6 oz. - . i i 1/2 oz. N2| { Blanket 3 NO j 3" pressl Vac. 6 oz. 1/2 oz. N2 5 Blanket . No No NO 21-5250? #12 Finished 12'6"x24') 22,000 ij (560) | ProductStg.] | 'i 3 Tank f I f; ! 1 21-525l| #16 Finished; 12'6"x24`-; 22,000 3 (561) i Product Stgj j| *S Tank fJ $- ** 21-5252] #13 Finished 12'6"x24| .22,000J (562) 3 Product Stg4 j i Tank 3 ( * > i 38-5897; Therainol 6'4"x36,6'5 (585) Heater | ? s !* -- *, i (j 5 ? i No jt No 'i No No 3 2" Rupture s disc - 140# | burst. I NOI { 5 |,, 3. NO No No 2 - North & South Side. 'V No - 32 - iCTUiO j Nurr.ter i f --J. Nurfoer) i i k Service : Size i |1 !? > Caoacity) i Gallons * 21-5253 (556) Thenr-ir.ol j 6o"x72" 1 Surge Tank i i ! 950 15-0733 j Mist ' 20"x6'3V (590) j SliainatoJ (Installed eor Clg J in parallel with existing unit Itein #115) j -- Jacket Kelief Coil So i 2 4 3reather V Vent Yes No ij ?5 : Flane * ` Arrestor 3 j belief or ? Suoture Disc? Greundea No No No No * No No MONS 0 4 6 6 8 7 i - 33 APPENDIX IV Dept. 246 - Safety Devices Relief Valve, Rupture Disc, and Interlocks 4 Continuous Chlorinators ' 3" Hupture Disc, ll7 lbs. Bursting Pressure. 51-13594 Chlorinators 6-9 Rupture Disc discharge at ground level directly south of Blow Tank. ! Chlorinators 6-9 has a chlorine valve Interlocked to both pump and high temperature at Sparger (205C.) - FeCla Mix Tank Item'll 03 Jacketed Flame Arrestor. This contains a Relief 1/2" valve to (Steam) Jacket. Discharges at 50 psig. 7-83332 Intermediate Storage (Item 424) 3" Combination vacuum-pressure vent pressure of 60Z closes. Vacuum of 40gopen. 5-16922 ^-Continuous Chlorinator Fans These are interlocked to temperature. Items 4o8, 412, 4l6, 420 Will not start unless 120C. in chlorinator. Off Gas Stg. Tk. (Item 429) Sample Surge Tk. (Item 435) B10 Stg. Tk. (Item 401) 3" Rupture disc 27# bursting pressure 51-13595. 2" Combination pressure vacuum relief valve 6 oz. pressure, 4 oz. vacuum 5-16841. 1" pressure relief valve. Set at 4o// located in 80# steam line to tracers. 24" "Protectoseal" relief cover on manway. 6" Jacketed flame arrestor. Steam to jacket reduced to 18 PSIG. MONS 046608 ~ - 34 - ' Dept. 246 - Safety Devices Relief valve. Rupture Disc and Interlocks #3 & r!,!l Still Pots items 502 & 511 #3 & 4 Condensers items 50f> & 513 #3 & 4 Receivers items 508 & 515 #3 & 4 Surge Tanks items 530 & 537 #3 & 4 Finished Product Tanks Items 53I4 & 5^2 ' ' #12/'13, 14, 15 & 16 Finished product Storage Tanks Items 560, 562, 558, 558 & 561 #1. 2, 3 & 4 Absorbers Items 532, 539, 540 & 545 Therminol Furnace Heater Item 585 Therminol surge tank Item 586 MONS 046689 3" Rupture Disc. 20 lbs. Bursting Pressure 51-13593 Still #3 discharges So. of Still Ground Level. Still #4 discharges No. of Still Ground Level. 1/2" Relief Valve 125# Relief Pressure 7-83333 (1) 3" Rupture Disc 104# Bursting Pressure 51-13591 (2) An electrically operated Solenoid valve is interlocked in this system. Pump failure will activate the solenoid to close the auto, valve in the forward flow line. . The solenoid is also activated when the receiver reaches a low level. Low level is 20$. Both receivers discharge at the same respective locations as #3 & #4 Stills. 2" Combination Relief Device 6 oz. pressure - 1/2 oz. vacuum 2" Combination Relief device. 6 oz. pressure - 1/2 oz. vacuum 3" Combination Relief Device 6 oz. pressure - 1/2 oz. vacuum 2" Rupture Disc .` 104# Bursting Pressure 51-13592 All absorbers discharge at g'rouncf level directly below absorbers. (1) Pump failure, low therminol flow, (20(? GPM) . . (2) Less than 10# gas pressure, k more than 3<Vr gas pressure. Both shut down the system. (3) The furnace has a purple peeper to watch the pilot flams. (4) A timer is used to keep furnace at the low fire sotting for 10 nir.ute before the high fire setting can b activated. (auto valve 1/3 open). (5) A purge system is in this furnace. The pilot can not be ignited until r. nxvar. 1,,-r.n comi.l 0 to,'1. . 7/1/68 Item i. 2. 3. 4. 5. 6. 7. 8. - 35 DEPT. 246 - SAFETY DEVICES RELIEF VALVES, RUPTURE DISCS, AMD INTERLOCKS Equipment Location _De scri.ption 5 chlorinators Items .105 thru 109 '' Rupture disc, carbon, 8 Inch,* 20 PSIG bursting pressure 70F. Storeroom code 51-13466. #1, 2, 3 and 4 chlorlnator rupture disc discharges are 3" and discharge on top level. ' t #5 chlorlnator rupture disc discharge in 3" and discharges on 1st level, 14" above floor. 5 chlorlnator jackets Items 105 thru 109 80// steam, no regulator. Pressure relief valve set for 90tf. Storeroom code 04-31632. 7/1 still item 130 Rupture disc with vacuum support 8 inch, monel, bursting pressure 31 PSIG @ 72F. Storeroom code l-134c Rupture disc discharge is 6", and is directed West above roof of lean-to, 4th level. #2 still Item 133 . Rupture disc with vacuum support, 8", monel, bursting pressure 31 PS1C @ 72F. Storeroom code 5.1.-1348?.. Rupture disc discharge Is 4" and is directed east above roof <?f control room, 3rd level. , Chlorine Vaporizer Item ll6 Consolidated bronze safety valve type 1471 (1" NPT sco/d.) Ea3t end. top of vaporizer, pressure relief or Cl2 side Set for 50 PSI. Chlorine Vaporizer Item 116 Rupture disc burst @ 50 PSI 100f Model 1A. Storeroom Code 5-1 ~ 13if 1 6 Chlorine Vaporizer Item ll6 East end, bottom of vaporizer, mercoid T pressure switch set at PSI, (.. ' * turn off steam Is behind S.E. panel: board in control room. 1 Sparkler press 36" Item 145 Jacket tested for 100 PSI. 80" stc: regulated to 20ft. Storeroom code pressure relief valve - 0.4-3163 2. HONS 046690 Item 9 10. 11. 12. 13. - 36 - Equipment Location Biphenyl Head Tank Jacket Item 103 Biphenyl storage Item 102 Preheater for stills 5 Chlorlnators Item 105 thru 109 5 Chlorlnators Item 105 thru 109. Description Jacket tested for 105// hydrostatic pressure. Using 80ft steam regu lated to 40//. Storeroom code for pressure relief valve 04-31632 High temperature alarm read from 12 point recorder 29-6638. Designed for 220 PSI, tested for 330 PSI. 2" carbon rupture disc, set for 100 PSI @ 350F. (Not a Special Order.) Spared in Dept. Stocked locally. There are 2 alarms and 2 Interlocks on each chlorTnator: (1) A high temperature thermo couple is in the HC1 line on top of each chlorinator. Alarm Is set at l60C. Chlorine cut-off point is 175C. (2) A high temperature interlock (chlorine shutdown) and alarm are activated at 225C. The temperature is sensed at the bottom of the chlorinator near the chlorine sparger, and is indicated on individual panel board indicators. MGNS 0*6691 . - 37 - .. . MOT. _2|t6_ SAFETY DEVICE INSPECTION METHOD Jc FREQUENCY RELIEF VALVES, RUPTURE DISCS, AND INTERLOCKS Item I. 2. 3. t\. 56. 7. B. 910. li. 12. 13. Description f?l thru #5 Chlori.nator rupture discs Frequency* 12 months //l thru #5 chlorinator Jacket relief valves //l still rupture disc #2 still rupture disc Chlorine vaporizer rupture disc Chlorine vaporizer relief valve Chlorine vaporizer Mercoid pressure switch . 36" press jacket relief valve Biphenyl head tank jacket relief valve Biphenyl storage tank high temperature alarm Preheater rupture disc //l thru #5 chlorinator high temperature off gas alarm 7/1 thru w 5 chlorinator high temperature off gas shutdown 12 months 12 months 12 months 12 months 12 months 12 months 12 months 12 months 6 months 12.months 6 months 6 months Me thod Inspect discharge line thru cross Replace Replace Replace Replace if necessary Replace Manual check Replace Manual chock manual check Replace if necessary Manual check Manual check In addition to visual inspection-during monthly ha:i:ard inspection. HONS 04669i - 38 - APPENDIX V Dept. 246 - Grounding; List Location of Grounds on New Expansion. On Steel Structure: (All on ground level) Nitrogen Storage: Located at South Side @ 1st, 3rd, 5th Vertical Support. North Side @ 2nd, 4th, 6th Vertical Support. I One ground located East side on the North Support. Biphenyl Storage (Vertical): Two grounds one on North side - Other on South side. Tank Farm: #9 Tank: #10 Tank: #11 Tank: #12 Tank: Tank: Tank: #15 Tank: #16 Tank: None None None (Grounded ( ( thrnu Bolts it in Concrete) ) Two Grounds Located at North Side & South Side Tv/o Grounds Located at North Side & South Side Two Grounds Located at North Side & South Side Two Grounds Located at North Side & South Side Two Grounds Located at North Side & South Side Intermediate Storage : One Ground Located at West Side New Office & MCC: Two Grounds, Located 1 Foot Under Ground Level, at Foundation. Loading Dock #5: One.Ground Located Northwest Support. Loading Dock #6: One Ground Located Northeast Support. HONS 046693 Sauget, Illinois January 28, 1970 Me ssr.P . G. L. Bratsch R. M. Blowers T. W . T)a.11 on D. W. Jachr.cn W . A. Kuhn - 0 J. J. I.uecken C. B. Williams 1970 AR0C1 .OR GROUP OBJECTIVES I. SAFETY A. OEj'ectives 1. No BerlouB injuries for Dept. 246 and maintenance personnel in 246 area. 2. No disabling injuries for Dept. 246 and maintenance personnel in 246 area. 3. 0.75 minor injuries per man per year for Dept. 246 personnel. 4. Three minor injuries per year for all maintenance personnel while in Dept. 246. E. Actions _ 1. Evaluate need for sight glasses where they exist in preparation for plant wide change to Pres-Sure glasses. 2. Supply department data to comply with WGK Procedure L-40. 3. Use safety device and interloch system inspection frequency developed for department. 4. Install addition to fume removal system. 5. Issue quarterly status for Safety Audit. . 6. Evaluate gas mask location/ relocation to control room. 7. Install ramp for lime delivery to 2nd level. 8. Install concrete pad for fork lift lime delivery. 9. Make safety evaluation of drum leanto. 10. Review grounding of Equipment a. List equipment to be grounded b. Implement grounding 11. Establish equipment preventive maintenance procedure(SIAM). 12. Extend elevator to 29 foot level. 13. Widen walkway around fume scrubber. 14. Complete repairs on ONA explosion damage. 15- Install ela'-m in drumming station. EDC ne.-.pmcibJ 1 J t 47T T>S'D/P rocT 4/1 IYocaw.'OIow Con- Production tin uinG 7/1 TSD 4/15 Produe tion 4/1 Safety/ Production 2/1 Maintenance 7/1 ;;< oh. Design 1/1 Mech.Design 4/1 Maint. /'Prod 2/1 Maint./Prod 4/1 Ms jn-r.. 1/1 Maint. 5/1 Maint. 5/1 Me. in t. Maint.. 6/1 F"<T HONS 046694 2 II. QUALITY A. Objectives . 1. Maintain 196? Aroclor Quality Level 1969 a 1242 1254 a. Resistivity(10* OHM-CM) " " 3021 19785 b. Power Factor(% at 60 CY) /"> 2.09 0.6l c. TCC(PFM) *!'' 0.15 0.52 2. Customer Complaints: <0-3/100 shipments (1969 Actual: 0.51/100 shipments) 3. Improve reproduceability of electrical analysis. B. Actions KDC Rcsponsihi1i 1. Resolve status of new electrical T/l Laboratory analysis(dependent on lab air scrubber). 2. Determine reasons for and correct * TED discrepancies between lab analysis and in-line Instrument indications of electrical properties. 3. Define effects of storage retention. 4. Define quality degradation during * TSD TSD loading; need for loading through Porocel. 5. Evaluate need for Isolated area for Aroclor analytical work. 6. Improve maintenance of Aroclor quality * Laboratory Production in sampling bottles. (Dependent on Action No.l also). a. Sulfur treated bottles b. Bottles at constant temperature 7. Install facilities to blow the mix 5/1 pj uCiuC Lion tanks with nitrogen. 8. Operating procedures changed to Con- Products on unload Pyranol cars with nitrogen. tin uing 9. Install weather protection at loading docks. 1/1 Mcch. Design 10. Alter piping to locate polishing filters ahead of absorbers in #3 and 6/1 Production #4 still systems. 11. Relocate gear meters to point in 6/3 Production process where maintenance costs will be decreased. 12. Complete tank car inspection procedure. Con- Prod. ui np 13. Monitor quality of product and 3/1 TSD/Prod. chlorine during change to Ag Grade KC1. 14. Provide sales sample with necessary 4/1 Prod. information for proper handling of Aroclor products. Dependent on accomplishment of Objective 3- MONS 046695 -3- III. CAPACITY 5. Objectives _ 1. Meet 1270 sales forecast of 42M pounds Aroclors and 12M pounds Aroclor blends. B. Actions _ 1. Make Brodlmatic meters operable. 2. Publish MIP and issue status periodically. 3. Demonstrate maximum capacity. 4. Insulate #7 storage tank. 5. Evaluate need for improved mixing facilities. ' 6. Evaluate need for Increased loading rate of Pyranols. 7. Demonstrate use of filter in xylene mix drumming line. EDO Rccponsibillt 771 FrocT. 2/1 TSD Qrt. Prod. 85 TSD Prod./TSD 4/1 Production 2/1 Production IV. COST A. Objectives 1. Ho negative variance from 1970 cost standard. 2. Mechanical expense not to exceed 1970 budget. . 3. Overtime for Dept. 2ft6 personnel - 8#. 4. Absenteeism for Dept. 246 - 3 % 5. Mechanical overtime 4# 1. Complete and implement preventive maintenance list. 2. Install new pumps on #2 and #3 mix tanks. 3. Annual physical inspection of ware house stock to reduce repackaging costs. 4. Set drum inventory levels agreed on by Production, Marketing and Production Planning. 5. Eliminate overtime on porter Job. 6. Complete upgrading of control room. 7. Evaluate dismantling air dryers. 8. Dismantle spiral heat exchanger. 9. Check asset run versus physical check of department. 10. Obtain credit for TCB and TTCB rav? material mischarges in 1969. 11. Determine maximum water content in steel-HC1 systems to avoid corrosion in off-gas system. 12. List and evaluate needs on high repair cost items. EDC 3/1 6/1 6/1 3/1 # 9/1 4/1 4/1 3/1 9/1 2/1 Hesponr'tillt Maine./prod. Maint. Production Productl ori Production Maintenance Production Production Producti ori Purchasing TSD Maintenance HONS 046696 V. YIELDS A. Objectives Biphenyl TCB TTCB TCP Qoal 70 Std. 38~-------9 98 99 69 Act 99-24 98.34 94.30 91.66 70 Act. B. Actions 1. Continue close surveillance of blending procedures and raw material shipments. EDO Responsthl 111 Obn- Prod. tin uing VI. PROCESS CONTROL A. Objectives 1. Improve operational control of the process. B. Actions 1. Identify key process variables and initiate control charts. 2. Prepare new operating Instructions. 3. Prepare Standard Manufacturing Process. 4. Complete Data Bank. 5. Establish and implement key variable audit. 6. Make pertinent process control data available to operators. EDC Re spoil stbilit m Production'" 7/1 Production 12/1 Production 11/1 Prod./TSD 6/1 Prod./TSD 1/1 Production VII. POLLUTION 1T. Objectives 1. Reduce Aroclor losses to sewer from 130 pounds per day to 10 pounds per day from department. 2. Evaluate need to reduce HC1 air pollution. 1. Quantify process material going to toxic dump. 2. Determine adequacy of drowning Jet. 3. Catch all wasteB from drip pans and sample lines. 4. Modify piping on continuous blow tank to prevent accidental Aroclor lossec to sewer. 5. Modify absorber relief lines to prevent Aroclor from reaching the Eewer. 6. Design and install a sewer basin to trap accidental Aroclor losses. 7. Establish two week PM on blow tank level control(discontlnue with Item 4 completion). EDC Res^onsibilii t/t Prod"Ctlon 6/1 TCD 3/1 Prod no* ion 5/1 Mech. Design 6/1 TSD 7/1 Mcch.Design/ TSD 1/15 Maintenance HONS 04669 7 -5- VII. POLLUTION(Cont'd.) H.Lftcftions EDC ResponsibiUt 8. Uesign and install a system to l/l/^TSD c remove Aroclor entrained in HC1 routinely sewered through drowning Jet. 9. Continue to monitor sewers to find Con- Production sizes and locations of Aroclor losses tin Control in plant. uing Group Members: V. F. Brawley T. H. Carrico Bob Eden R. M. Humphries W. A. Krull J. R. Kucter R. M. McCutchan ( ( MONS 046698 COMPANY CONFIDENTIAL MANUFACTURING IMPROVEMENT PLAN for AROCLOR DEPT. 246 Approved: tT. W. Dalton, Gen, 'Supt. Manufacturing DeuBTHTr, Maintenance ipt., Date Approved: Jan. 29, 1970 Date Issued : March, 1970 Prepared by: W. A. Krull R. M. McCutchan R. M. Humphries R. M. Fabian T. E. Greenman Technical Services a2= MQNS 046699 AROCLOR MANUFACTURING IMPROVEMENT PLAN DISTRIBUTION W. G. Krummrlch Riant Q. L. Bratsch T. W. Dalton C. N. Deubner D. W. Jackson W. L. Watson/D. T. Mayer T. E. Greenman M. J. Beaudlne L. W. Sprandel R, M. Humphries . gf*, R. M. McCutchan^n' Brawley/ T. Carrico R. M. Blowers B. R. Williams/C. F. Buckley Anniston J. C. Landwehr General Offices *H. S. Bergen W. A. Kuhn D. Danna (4) R. E. Howard/J. 0. Bright/ R. M. Kountz D. B. Hosmer/F. J. Holzapfel W. E. Chandler W. R. Richard D. A. Olson P. G. Benignus South Second Street T. M. Patrick R. H. Munch * Summary Only MOMS 046100 TABLE OF CONTENTS SECTION Summary P.I.P. Status Action Plan Details Process Synopsis Optimum Process Capacity Quality Yields Pollution Control Process Control Assets Personnel Mechanical Expense Conversion Costs Appendix PAGE I 3 3 6 6 6 7 9 12 12 15 15 16 16 18 22 NO. I II III IV V VI VII VIII IX X XI XII TABLES Title PAGE Sales Forecast W.G.K. Production Blend Production Capacity Comparison Raw Material Usage Waste Materials Mechanical Expense Repair Costs Raw Material Comparison Direct Cost Comparison Indirect & Total Comparison Aroclor Costs 7 7 8 8 12 14 16 16 18 19 20 20 APPENDICES A Present Flow Sheet 23 B Possible Continuous Flow Sheet 24 C Electrical Grade Analysis 25. D Quality Comparison 27 E Department Personnel 28 F Work Plan a Process Control Status 29, 32 Report MONS 0A6701 Aroclor M.I.P 1 March, 1970 SUMMARY:. A. Objectives W. G. Krummrich Plant will help maintain the Aroclor franchise position by making Aroclor of a quality to match any in the world at or lower than the current cost. The Aroclor depart ment also has the necessary capacity to meet the market demand as forecasted. The present position and needed modifications are outlined below. B. Capacity s Sales for WGK Aroclors are forecasted to increase from 42.9H pounds In 1970 to 59.2R pounds In 1974. The Aroclor expansion was designed for 70. OR pounds/year capacity. However, a decision was made not to install all of the storage tanks since they are not required at present rates. Storage capacity and operator work loads restrict present capacity to an estimated 55.OM pounds/ year. Present capacity is adequate until 1973. Drumming, blending, storage, and off-gas drowning Jet capacities will be investigated to insure adequate surge capacity to meet fore casted sales. C. Quality During 1969 Manufacturing at WGK demonstrated the capability of producing electrical grade Aroclors which are equivalent to Anniston's from a customers point of view. The present quality is Btated to be more than adequate by the Business Group and no effort will be made to improve it at this time. Efforts will be directed at maintaining this position. The following table shows the present quality situation for Aroclor 1242. Present Aroclor 1242 Specification TCC (PPm) Resistivity (10^ ohm-cm) 0.15 O.65 max., 3000 500 min. Power Factor (# at 60 cy.) 2.1 Hone D. Yields The present biphenyl yield in Aroclor production is 99+#, total potential compared to theory is only $10,000. Ho TSD effort is planned in this area. In 1970 Manufacturing's goal is to improve raw material yields on $ , .*Pydraul and Pyranol blends from 94# to 98#. Estimated Bavings are 5 000 q *0NS Aroclor M.I.P. 2 3/70 SUMMARY; E. Pollution Control Water pollution control 1b the major problem area for this product group and correspondingly the bulk of the TSD effort for 1970 will be in this area. Losses are presently being Investigated by the Pollution Control Section. The total effort and costs are presently In the process of being defined with a plant goal of 10 pounds per day set by 1/1/71. F. Process Control Effort is underway to develop the Aroclor data bank. The Operating Instructions and Standard Manufacturing Process documents will be revised by Production. The Department Safety Audit is current. Control charts have been developed and are being maintained by Production. 0. Conversion Costs The manufacturing costs in 1969 for producing Aroclors at WOK and Anniston were essentially the same ($7.421/cwt 9 WGK vs. $7.435/cwt 9 Anniston). Increasing costs due to wages, salaries and materials at WGK are expected to be offset by increased production volume this year and in 1971. Following is a manu facturing cost projection: 1968 1969 1970 1971 Total Bulk Aroclor Manufacturing Costs $/cwt 6.785 7.421 7.236 7.280 Present TSD effort in the chlorine department is projected to reduce chlorine costs from $53.34/ton to $41/ton by mld-1971. When this occurs, it will reduce Aroclor costs by an additional $0.65/cwt to $6.62/cwt. Thi6 is equivalent to $300,000/year savings at a 46.0M lbs/yr rate. H. Mechanical Expense The true repair portion of the mechanical expense is expected to increase in 1970 as the result of the expansion capital installed in late 1968 and due to increased labor and materials costs. High repair cost items will be reviewed to determine possible cost reductions. HONS 046703 Aroclor M.I.P -3 3/70 SUMMARY: I. Manpower The projected manpower expenditure for TSD process engineering Is 150 mandays for 1970. If TSD becomes Involved with re claiming Aroclors this estimate would Increase substantially. P.I.P. STATUS The following items were part of the PIP dated 2/21/68 or the P.I.P. six month status dated 11/22/68. This table gives the present status of these items as of January 1 19 7 0. Any items that were com plete at the time of writing the six month status are not included in this list. JOB STATUS 1. Coordinate Quality Tests Quality adequate as stated by W. A. Kuhn in memo dated 8/25/69. Some items noted in M.I.P. 2. Fume Removal System Installation complete. Extension of system in M.I.P. Action Plan 3. Improve Blend Operation Project complete 4. Instrumentation Changes Complete 5. New Drumming Facility Carried over to MIP 6. Horizontal pump and boildown facility #1 still Project dropped. 7. Investigate Possible Blend Specification Changes In progress by Production supervision. Other items mentioned in the PIP which may require woik are biphenyl drying, bromine in chlorine, additional blend storage, and blend specifications. The blend items have been carried over to the M.I.P. The raw material items were not carried over since quality is adequate and Anniston is trying to eliminate the water contamination of biphenyl. However, the raw material quality will be monitored. ACTION PLAN On the following pages is the plan for completing projects to improve the manufacture of Aroclors at WGK, The need for the projects Is described in the Details Section of this document. MONS 046704 Aroclor M.I.P -k - 3/70 GOALS AMD WORK PLAN ITEM RESPONSIBILITY EDO* I. COST: MEET THE 1970 COST STANDARDS FOR ALL PRODUCTS A. Reduce Drumming Costs 1. Evaluate Improved Drumming Facility TSD (Process) 6/1/70 B. Increase Yields 1. Improve blend raw material yields Production 1/1/70 2. Chlorine Usage Study C. Reduce Maintenance Costs TSD (Process) 1/1/71 1. Determine Off-Gas Corrosion Level TSD (Process) 9/1/70 2. Preventive Maintenance List Production/ Maintenance 3/1/70 II. QUALITY: ALL SHIPMENTS RECEIVED BY CUSTOMERS IN SPECIFICATIONS A. Roofs on Loading Docks TSD (Mech. Design) 6/1/70 B. Resolve Electrical Property TSD/Prod./Maint. wn Measurement (Contingent on Lab Air Scrubber)\ C. Pre-Loading Quality Treatment TSD (Process) * D. Ag Grade KC1 Test (Bromine) TSD (Process) 3/1/70 III. CAPACITY: HAVE PRODUCTION CAPABILITY TO MEET SALES NEEDS A. Replace Mix Tank Pumps Maintenance 6/1/70 B. Drowning Jet Evaluation TSD (Process) 6/1/70 C. Improve Mix Tank Mixing Production/TSD 8/1/70 D. Establish Minimum Drum Inventory Level Approved by Prod,, Produc tion Planning & Marketing Production 3/1/70 * Dependent on ability to reproduce electrical property measurements or II B. MONS 046705 Aroclor M.X.P. -5 - 3/70 GOALS AND WORK PLAN (Continued) ITEM RESPONSIBILITY IV. SAFETY: NO DISABLING OR SERIOUS INJURIES TO PERSONNEL IN THE DEPARTMENT A. Fume Removal System Extension TSD (Process) B. Lime Delivery Facility TSD (Mech. Design) C. Safety Audit Items Production EDC 7/1/70 Hold 11/1/70 POLLUTION; PREVENT AROCLOR FROM LEAVING THE DEPARTMENT IN THE SEWERS A. Control Rupture Disc Discharge B. Install Sewer Basins C. Sewer Pollution Check TSD (Process) TSD (Mech. Design) TSD (Pollution Con trol) 6/1/70 7/1/70 Continu D. Reduce Blow Tank Aroclor Losses TSD(Process) 10/1/70 E. Check Aroclor in Off-Gas TSD (Process) 4/1/70 F. Catch Wastes from Drip Pans and Sample Lines Production 3/1/70 G. Piping Modifications on Blow Tank TSD (Mech. Design) 5/1/70 PROCESS CONTROL: MAINTAIN CONTROL OF PROCESS k PREVENT UPSETS A. Complete Process Variable Chart and Key Variable List Production 4/1/70 B. Revise Operating Instructions Production 7/1/70 C. Revise Standard Manufacturing Process Production 12/1/70 PUNT IMPROVEMENT: MAINTAIN HIGH LEVEL OF HOUSEKEEPING AND IMPROVE OPERATIONS A. Upgrade Control Room TSD (Mech. Design) 4/1/70 B. Dismantle Obsolete Equipment C. Road k Sewer Improvements Maintenance TSD (Mech. Design) 3/1/70 Hold D. Pave Tank Farm TSD (Mech. Design) Hold E. Replace Lean-To TSD (Mech. Design Hold MQNS 046706 Aroclor M.I.P -6 - 3/70 DETAILS: A. ProceBa Synopsis 1. Present Situation Department 246 produces Aroclors with 32, 42, 48, 54, 60 and 62 percent chlorine. The name for each Aroclor utilizes a four digit suffix number in which the last two digits indi cate the approximate weight percent chlorine. For example, Aroclor 1242 contains approximately 42# chlorine. Aroclor 1242 is produced continuously and the others batchwise, but the main process steps are the same. A flow sheet depicting the process is attached as Appendix A. The chlorination is done by contacting biphenyl with chlorine gas to cause a substitution of chlorine atoms for hydrogen on the biphenyl molecule. The reaction is catalyzed with ferric chloride. Aroclor and hydrogen chloride are produced. The hydrogen chloride is piped to the chlorosulfonlc and/or muriatic acid departments. The Aroclor produced is sent to an inter mediate storage tank. From the storage tank the crude Aroclor is blown with compressed air to remove any remaining HC1 and then straight take over distilled with lime. The distilled Aroclor is put through a porocel packed absorber and held in nitrogen blanketed storage. The Aroclor is either shipped as 1b or blended with other Aroclors, trichlorobenzene (TCB) or tri-tetrachlorobenzene (TTCB). The blends are made by pumping the materials to a tank where they are mixed to produce the correct properties. Products are shipped in tank cars, tank trailers and drums. 2. Optimum Process The optimum process for Aroclor production should be the con tinuous production of all the Aroclors. This could be done by UBlng seven chlorinators in series as Bhown on the flow sheet attached as Appendix B. The number of stills needed would depend on how many products it was necessary to produce at any one time. Appendix B shows the proposed optimum process with three still lines. This system utilizes existing equipment primarily, with some additions necessary. The optimum process will actually depend on the amount of produc tion as well as the relative amounts of each. The forecasted rate does not warrant continuous chlorination to higher levels. gONS Aroclor M.I.P. 7 3/70 DETAILS: B. Products - By-Products 1. Capacity The following table shows the February 15, 1970 BaleB fore cast for Monsanto U. S. Liquid Aroclors. TABLE I SALES FORECAST (M POUNDS) Product 1221 1232 1242 1248 1254 1260 1262 TOTAL 1970 0.5 1.3 54.4 7.1 13.7 4.3 1.1 82.4 1971 0.2 0.8 14.5 4.6 1.2 89.8 1272 0.2 0.9 64.7 9.6 15.2 5.0 1.2 96.8 mi 0.2 a.i 69.8 10.2 16.2 5.4 1.3 104.2 Table II uses the February 15, 1970 sales forecast to show the part of the total U.S. Liquid Aroclor forecasted for production at W.G.K. The table also shows the 1969 production. Table III (on the following page) shows the forecasted blend production at W.G.K. TABLE II Product 1221 1232 1242 1248 1254 1260 1262 TOTAL W.G.K. PRODUCTION (H POUNDS) 1969 1970 1971 0 0.1 22.7 7.0 8.6 4.2 0.1 0 0.3 24.2 6.7 7.7 2.9 0.1 0 0.4 27.0 7.5 8.4 3.0 0.1 42.7 41.9 46.4 1272 0 0.5 29.8 ft ^ 8.9 3.3 0.1 50.9 1222 0 0.7 32.7 8.8 9-6 3.5 0.1 55.4 MONS 046708 Aroclor M.I.P. -8- 3/70 TABLE III *BLEHD PRODUCTION (ffi POUNDS) Product 1260 PPO 1254 PPO 1242 PPO A13B3B TOTAL PYRANOL 1969 2.8 4.9 3.5 1.7 12.9 1970 0.7 4.2 0.7 1.2 6.8 i2Zi 0.7 4.7 0.8 1.2 7.4 1972 0.7 5.0 0.9 1.3 7.9 Pydraul A-200 Pydraul 280 1254-10# Xylene 4.0 1.0 0.2 4.2 0.8 0.15 4.8 0.9 0.15 5.0 1.0 0.15 * The Aroclor in these blends is already included in Table II. 1213 0.8 5.5 1:0 1.4 8.7 5.2 1.1 0.15 Table IV shows the known capacity of each step of the process in relation to the required capacity. The required capacity is taken from the 1973 forecast in Table II. The demonstrated capacity figures came from production records and capacity checks. TABLE IV CAPACITY COMPARISON fB #/YEAR) Process Step Demonstrated 1969 Production 1970 Forecast 1973 Forecast Chlorination (1142) Chlorination (other Aroclors) Distillation (1242) Distillation (1248 k 1254) Distillation (1260, 1262, 1232) Absorption (1242) Absorption (1248) Absorption (1254) Absorption (l260) Blending (Pydrauls) Blending (Pyranols) Drumming (All) 37.5* 25-9** 31.9* 21.9** 8.5** 51.7* 35-9* 34.4* 60.7* 6.3** 14.5** 17.2*** 22.7 20.0 22.7 , 15.6 4.4 22.7 7.0 8.6 4.2 5.0 12.9 13.3 24.2 17.7 24.2 14.4 3.3 24.2 6.7 7.7 2.9 5.0 6.8 12.0 32.7 22.7 32.7 18.4 4.3 32.7 8.8 9.6 3.5 6.3 8.7 15.4 * Capacity Check ** Extrapolated Monthly Production Record *** Extrapolated Monthly Production Record with 13 shifts/week plus overtime. Aroclor M.I.P. -9- 3/70 DETAILS B. Products - By-Products 1. Capacity (Continued) In every case In Table IV, the demonstrated capacity exceeds the forecasted 1973 production requirements. The chlorination and distillation figures represent something less than maximum capacity, so these operations appear adequate through 1973. The absorbers and blending also appear adequate. The drumming and blend storage capacities Mere marginal in 1969. However, with the significant decrease forecasted for Pyranol blends (12.9 H pounds in 1969 vs. 6.8 H pounds in 1970) capacity in this area is adequate. The Pydraul and Pyranol blends will be watched for sales forecast changes and actions planned accordingly. It is anticipated that Aroclor storage would restrict capacity to about 55 pounds per year. This is above the 1973 forecast but the restriction may require investigation. When the recent expansion was installed, CED forecasted a need for three more 22,000 gallon storage tanks in 1970, but due to the reduced forecast, the additions can probably be postponed. To operate the department at full rate, personnel additions may be necessary. It is anticipated by Production that the chlorlnators and stills would need additional operators. Production will attempt operation at high rates at 6 month intervals to insure system capability. The off-gas drowning Jet in the department could restrict capacity due to Jet size if it becomes necessary to operate when muriatic acid and chlorosulfonlc acid are shut down. An evaluation of the scrubber will be made to determine the operating limit of the present system and the cost to add capacity. 2. Quality As specified by W. A. Kuhn in a memo dated August 25, 1969 the finished goods quality of the Aroclor presently produced is satisfactory. Only minor projects to maintain the quality will be done. A project to put roofs on the tank car loading docks will be done which will insure against contamination while loading. HONS 046710 Aroclor M.I.P 10 3/70 DETAILS: 2. Quality (Continued) The following table relates the present storage tank quality of Aroclor 1242 to the present specifications. It also shows the present control levels at which production becomes concerned that the quality level is deteriorating and correc tive action Is taken. AROCLOR 1242 QUALITY TCC (ppm) Resistivity (109 OHM-CM) Power Factor (% at 60 cy.) Specification 0.65 max. 500 min. None Storage Tank Quality 0.15 3.000 2.1 Control Level 0.20 1.500 3.5 The major quality concern at the plant is the analytical method used for electrical properties. The problem exists in the reproduceabillty of results with both the present method and the new tentative method. The tentative method tends to show better properties but is inconsistent. The present method requires meticulous lab procedures or shows poor results. To compound the problem, the manner of taking and handling the sample can ruin the results. This whole problem needs to be resolved. The lab is installing a new air scrubbing system which may help the new tentative method. The short term procedure is to have Organic Research run samples periodically to check the plant lab results. Lcnger term, the new system will be checked when the air scrubber is installed. If it looks like the problem is solved, we will use this procedure. If not, an evaluation of an isolated Aroclor analytical facility will be made. Improved sampling procedures will also be tried. Other measures that may improve the quality of Aroclor will be held in reserve until a better quality is needed to meet market demands. A list of these follows: Measure Effect 1. Separate chlorine revaporization Better quality raw material 2. High temperature aging May have slight stability benefit 3. Alternate absorber packings Better electrical or stability qualities M0NS 046711 Aroclor M.I.P 11 3/70 DETAILS: 2. Quality (Continued) Aroclor quality Is generally consistent, but one upset has occurred. Colored product suddenly appeared In early June, 1969 and stayed until July. Procedures used to eliminate the problem included: Cleaning the intermediate storage tank, still, receiver and the line between the still and receiver; changing the porocel absorber; and making sure the still vacuum is vented at the receiver and not at the Btill. Since July 20, 1969 there has not been a color higher than 15 APHA. Of the items attempted to remove the color, it seems the venting of the still is the most likely suspect. Venting at the still could cause off color material to be drawn forward from the still bottoms. For a few consecutive lots in September, 1969 Monsanto stability was high. After many attempts and failures at both Anniston and W.O.K., the lab re-runs came out within specifications. Part of the lab equipment evidently became contaminated. The quality of the Aroclor hod not changed. The quality of raw materials will be monitored with control charts. In May, 1969 the water content in biphenyl increased to 100 ppm. This could cause excessive corrosion in the off gas system. Since October, 1969 the water content has returned to a normal level of about 50 ppm. An evaluation will be made of a filtering and absorbing step Just prior to loading tank cars and tank trailers. It is occasionally necessary to resample and sometimes unload a car or trailer beosuse the electrical properties have deteriorated. Nine complaints were received from customers in 1969 of which seven pertained to shipping container complaints and only two on material quality. Appendix C contains a table showing some of the properties of W.O.K. Aroclor. The figures represent August, 1969 YTD produc tion. The other table in Appendix D shows a comparison between Monsanto, Bayer, Soviet Askarel, Prodelac and Kanegafuchi products of similar chemical makeup. From the table, it can be seen that the products have similar quality except for the generally inferior quality of the Soviet Askarel. This table was made UBlng WGK, PR & D Report Ho. 2, Job No. 4 023, dated 4/28/69; Anniston Research and Development Report No. 3, Job No. 370-502, dated 7/19/68; and a memo from C. R. Coleman, Ruabon to J. N. Haggart, Brussels, dated 5/28/69. HONS 046712 Aroclor M.I.P. 12 - 3/70 DETAILS: B. Products - By-Products (Continued) 3. Yields The cost sheets and operations reports for 1969 for Dept. 2<i6 were used to derive this table. TABLE V RAW MATERIAL USAGE Raw Material Theory (Total Pounds) Actual (Actual-Theory) Difference $/yr Potential Biphenyl 23,159,050 23,338,758 179.708 10,000 Chlorine TCB TTCB 39*998,41? 2,603,092 991.327 42,668,421 2,647,033 1,051,778 2,670,008 43,941 59,951 73,000 5,000 7.000 The yield on Biphenyl is 99-3# and would be difficult to improve. The chlorine yield is not an accurate figure since a pro-rating ?rocedure is used to determine usage. An attempt will be made o determine actual chlorine losses. The low TCP, TCB and TTCB yields will be investigated by Production. The amount of these materials actually received may not be the same as the amount Purchasing specifies. If this is not the problem further Investigation may be necessary. . Pollution Control The escape of Aroclors to the environment poses a serious business threat to this product group. There is concern not only in the production of these products, but also customer handling of these products and the disposal of spent material. To cope with this problem we must reduce plant losses, educate users and resolve customer spent material disposal. The WGK plant objectives for 1970 are to reduce Aroclor losses to the sewer to 30 pounds/day by 10/1/70 and to 10 pounds/day by 1/1/71. M0NS 046713 Aroclor M.I.P. - 13 3/70 DETAILS: 4. Pollution Control (Continued) Present losses are estimated to be 230 pounds/day by the TSD Pollution Control Group. Of this total 130 pounds/day are estimated lost by Department 246 and the remainder from other departments in the plant. These goals require the following actions: a. Production housekeeping to reduce leaks and spills reaching the sewer. Actions have been taken to do this and more will be added as data shows the need. b. A project to prevent the blow tank from overflowing due to instrument failure as it has in the past. Piping the blow line through the intermediate storage tank will pre vent this loss. Mechanical Design has the project package out with completion expected in March, 1970. This is Estimate Number 1493 for $5,400 expense. c. A project to prevent the losses from the relief lines of the absorbers from reaching the sewer. This is necessary because the rupture discs have allowed material to reach the sewer in the past and although production has made operation changes, we cannot be sure losses will not occur again. This project has Estimate No. 1512 for $6,000, of which $1,500 is expense and $4,500 capital. Installation is expected by 7/1/70. d. A system to remove Aroclor carryover in the blow tank line is necessary since we know at least 25 pounds per day is lost here. This goes to the sewer through the drowning jet. Controls will be installed to reduce the air flow and an estimate will be made of costs to reduce the amount carried over in the remaining air. e. A basin intercepting the sewer to collect the non-routine losses is beLng considered. This would allow the Aroclor to settle out of the sewer water leaving the department. The total estimated expenditures for all these projects is about $50,000, half expense and half capital. MOWS 046714 Aroclor M.I.P. DETAILS: 14 5/70 4. Pollution Control (Continued) Other pollutants are not thought to be of a serious nature. Atmospheric pollution is held down using a scrubber which will be evaluated for capacity. Some HC1 loss is evident when a large amount of off-gas is sewered in the department. Using yield data, the amount of waste materials was esti mated by R. McCutchan based on 40 R pounds per year production. These figures account for all yield losses and are maximum amounts. This estimation is shown in Table VI. TABLE VI WASTE MATERIALS Material Atmospheric Pollutants #/Year HC1 Chlorine Aroclor + Biphenyl Pydraul TCB & TTCB Pyranol 8,000 Not Measurable Very Small Slight 1,800 3,600 Sewer Pollutants (Potential) HC1 Aroclor TCB & TTCB Chlorine Pydraul & Pyranol 200,000 50.000 10.000 0 10,000 Toxic Dump Montar Aroclor Pyranol Pydraul 160,000 40,000 0 0 MOMS Aroclor M.I.F. - 15 5/70 DETAILS 5. Process Control The present level of operator training is adequate and the present training policy for new operators will be continued. The length of operator training varies from 3 to 6 weeks depending on the Job. The May, 1969 safety audit contains a number of control items which will be completed according to the priority set in the audit. A quarterly review and report on these items will be made. In addition to these items the blending procedure may need modification depending on the outcome of the blend specifi cation study. Control charts are being initiated for the finished product and raw material analysis variables. These charts should give an indication as to the level of control existing in the department and the areas in need of improvement. The Standard Manufacturing Process documents are being re vised by Production. The documents will be completed for all products and processes. Attached as Appendix F is a list of process control measures to be taken along with expected dates of completion. C. Assets Since the facility is presently adequate to meet the forecasted manufacturing requirements, no major additions or changes are anticipated. The project to replace the lean-to used for drumming is presently on hold with no date of completion fore casted. Minor changes in the assets of the department are outlined in the Action Plan and explained in various parts of the Details Section of this document. The capitalization of the facility as of January 31, 1970 was: Asset Value *2,037,107 Accrued Depreciation Book Value 769,495 1,267,612 HONS 04671b Aroclor M.I.P. - 16 - 3/70 DETAILS: D. Personnel No change In the present number of personnel is anticipated. The present number of operators is sufficient to handle the forecasted manufacturing requirements up to 55 M pounda/year. If the rate is increased to a level near 100^, additional operators may be needed. A study of the needs of the department will be made when it appears the need is arising. A listing of operators and their duties is attached as Appendix "D". The total number of operators in the department is 17-1/2, E. Mechanical Expense The 1968 and 1969 mechanical expense and the 1970 budget for Dept. 246 is tabulated below: TABLE VII Areas and Shops Plant-wide 91< 92 & 93 expense % Absorbed O.H. 1268 32,808 37,367 86,156 1,768 1969 54,600 39,700 41,200 - 4,600 1970 (Budgi 49,700 50,500 66,900 -- 158,099 131,000 167,100 The primary repair cost occurred in the following categories: TABLE VIII i268 19 pumps 15.153 21 Tanks 3,689 87 Dept. Repairmen 4,018 97 Piping 5,339 29 Instrument 7,820 35 Ejector 2,345 80 Painting 2,769 82 Insulation 6,158 96 Electrical 5,537 98 Structural Steel 10,189 122 Change 1969-1968 1970 (Budget) 25,400 5,013 11,600 5,300 16,300 700 200 12,190 2,800 500 10,247 1,324 7,582 0 ?9(-) 8,480 1,645 f-J 2,569(-) 6,032 2,737(-) 9,689(-) 19,700 3,400 9,800 6,900 12,800 2,500 5,900 15,200 9,300 500 HONS 046717 Aroclor M.I.P 17 - 3/70 DETAILS: E. Mechanical Expense (Continued) Of particular Interest are: Pumps: Pumps accounted for 26.9# of the total true repair expense. A Malnt. Engineering assignment has been Initiated to solve the therainol pump cost problem. This pump and other pump seal problems have been identified as the major problems. Dept, Repairman: This item accounted for 12.3# of the true --' repair costs. These costs will be reduced In 1970. High costs are attributed to leaks from new piping Installed by outside contractors. Material costs will be investigated to Improve any repetitious repairs being made by the repairman. Instruments & Ejectors: These items accounted for 18# of the true repair expense. Costs will be approximately the same in 1970. Inflationary increases will be compensated for by Improved P.M. of equipment. Insulation: Insulation costs accounted for 12.9# of the true repair costs. Normal repairs and programmed upgrading planned for 1970 indicate an expenditure of approxi mately the same magnitude. Maintenance Engineering: 1) Replacement of the obsolete Taber pumps on the #2 and #3 mix tankB is planned for 1970. 2) Alarm system tie-in for.the spare #2 still pump will be completed in 1970. 3) Implement Safety and Inspection Procedure for unfired pressure vessels in 1970. Programmed Plant Improvements: 1) Provide drainage North of department along tracks $ 30,000 Cap. 2) Replace lean-to to Building CR $100,000 These projects are on hold status at the present time. M0NS 046710 Aroclor M.I.P. - 18 - 5/70 DETAILS: E. Mechanical Expense (Continued) Corrosion In the off-gas system has occurred In the past in the header and the condensate tank vapor space. It would be useful to determine what moisture level can be tolerated, but it is not known if this level can be determined. If there is a good prob ability of success, the determination will be attempted on a low priority basis. Estimated damages of $25,000 resulted from the explosion in Department 222. The repairs are presently in progress. F. Conversion Costs Table IX below shows a comparison between Krummrich and Anniston Liquid Aroclor raw material costs. The figures were obtained from the cost reports for the year 1969. Following is the comparison: TABLE IX RAW MATERIAL COMPARISON (ji/POUND) Item W.O.K. Anniston Difference W.O.K. - Anniston Chlorine Biphenyl Drums HC1 Nitrogen Lime 5 Oal. Cans Clay and Porocel Ferric Chloride 2.674 2.952 0.199 0.5750.013 0.001 0.004 0.005 0.006 2.43? 2.824 0.306 0.198- 0.023 0.007 0.004 0.003 0.002 0.241 0.128 0.1070.3770.0100.006- -- 0.002 0.004 Net Material Cost Material Handling 5.279 0.021 5.404 0.013 0.1250.008 TOTAL RAW MATERIAL COST 5.300 5.417 0.117- HONS 046719 Aroclor M.I.P. - 19 - 3/70 DETAILS: F. Conversion Costs (Continued) Although the total raw material costs are almost the same, there are some outstanding differences between the two plants. The muriatic acid credit at Krummrleh is much higher and off sets the higher cost of chlorine and biphenyl. This compari son does not mean a great deal since the usage of raw material would depend on the type of Aroclor being produced. Chlorine and biphenyl are more costly at Krummrleh. Table X shows the direct conversion costs. TABLE X DIRECT COST COMPARISON (ji/POUND) Item Steam Electricity Comp. Air Water Oas Wages Salaries Payroll Overhead Supplies Packing Labor Packing Overhead Laboratory Clothing & Laundry Technical Services Experimental Rental Equipment Prod. Process Res. Prod. Dept. Contr. Tank Car Storage Mech. Expense Start-up Expense Waste Disposal Research W.O.K. 0.216 0.029 0.030 0.024 0.004 0.372 0.070 0.074 0.050 0.044 0.023 0.074 0.011 0.037 -- 0.002 0.047 -- 0.005 0.305 -- -- Anniston 0.137 0.023 -- 0.020 0.021 0.261 0.041 0.056 0.058 0.050 0.018 0.051 0.005 0.070 0.116- -0.008 0.026 0.015 0.561 0.018 0.074 0.001 Difference W.O.K. - Anniston 0.079 0.006 0.030 0.004 0.0170.111 0.029 0.018 0.0080.006- 0.005 0.023 0.006 0.0330.116 0.002 0.039 0.0260.0100.2560.0180.0740.001- TOTAL DIRECT CONVERSION 1.417 1.398 0.019 HONS 046720 Aroclor M.I.P - 20 3/70 DETAILS: F. Conversion Costs (Continued) Although the preceding table shows the total direct conversion costs about the same, four differences are evident. W.G.K. steam costs more per M BTU than Anniston, explaining the steam difference. Steam usage is about the same. Anniston has a credit listed under experimental amounting to about 12^/cwt. Mechanical Expense and waste disposal are items where Anniston is significantly higher than W.G.K. Table XI shows the indrect costs and a total. TABLE XI 1969 INDIRECT 8c TOTAL COMPARISOH U/POUflD) Item W.G.K, Anniston Difference Total Raw Material Total Directs Depreciation F.I.E. 5.300 1.417 0.403 0.301 5.417 1.398 0.297 0.323 0.117 0.019 0.106 0.022- TOTAL PRODUCT COST 7.421 7.435 0.014- The total product cost was roughly the same for the two plants. Anniston's higher raw material costs, due primarily to a smaller HC1 credit, are offset by the WGK depreciation being higher than Anniston. Table XII breaks down the Krummrich costs for 1968 and 1969; 1970 cost standards for a rate of 3*520,000 pounds per month (3*347,000 forecasted); and a rough prediction of 1971 costs. The 1968 and 1969 figures are corrected to reflect an approxi mate bulk cost which would correspond to the cost standard figure. The 1970 and 1971 figures represent a bulk cost taking into account the forecasted amount of each Aroclor. TABLE XII AROCLOR COSTS N/POUMD) Item Total Raw Material Total Directs Total Indlrects 1968 4.770 1.545 0.470 iaa 5.300 1.417 0.704 1970 Std. 5.169 1.386 0.681 1971 5.200 1.430 0.650 Total Aroclor 6.785 7.421 7.236 7.280 HONS 46721 Aroclor M,I.P. 21 3/70 DETAILS: F. Conversion Costs (Continued) The costs forecasted for 1971 assume that the raw material price will not change significantly. Items showing an anti cipated increase are labor, salaries, payroll overhead, and mechanical expense. These Items were increased by about 10$S, The increases were offset by an anticipated increase in production causing the total costs to hold roughly the same. Present WGK plant Chlorine costs are $53.34/ton ($.02667/lb). This cost is targeted to be reduced to $4l.00/ton ($.020/lb) by 7/1/71. This would decrease liquid Aroclor manufacturing costs by approximately $0.65/cwt to $6.63/cwt in mid 1971. This is equivalent to $300,000/yr at a 46.OR lb/year rate. The following lists show the relative dollar amounts of each category and are taken from the December, 1969 YTD cost sheet. COSTS Items Amount Raw Materials Direct Costs Viages Mechanical Expense Steam Laboratory Payroll Overhead Salaries Prod. Process Res. Supplies Packing Labor Technical Services Compressed Air Electricity Packing Overhead Water Purchased Cl It Laundry Safety Tank Car Storage Gas Clothing Laundry Rentals Equipment Experimental Plant Trucks Indirect Costs Depreciation PIE $2,266,443 606,474 159,072 130,441 92,552 31,734 31,802 29,857 20,017 21,213 18,807 15,675 12,877 12,222 10,022 10,218 3,082 2,245 1,877 1,615 906 200 40 301.08q 172,113 128,976 71.4 19.1 5.0 4.1 2.9 1.0 1.0 0.9 0.6 0.7 0.6 0.5 0.4 0.4 0.3 0.3 0.1 0.1 0.1 0.1 -- ... ... 9.5 5.4 4.1 100.0 100.0 26.3 21.5 15.3 5.2 5.2 4.9 3.3 3.5 3.1 2.6 2.1 2.0 1.7 1.7 0.5 0.4 0.3 0.3 0.1 0.0 0.0 100.0 5-T. 2 42.8 TOTAL $3,174,006 100.0 * This shows the breakdown of each major division. HONS q<,6722 Pin AROCLOR COST!! AND PRODUCTION COMPARISON GRAPH 8 7 6 Dollars per cwt Liquid . >clor r, J 4 Productio H i) U on poundr. per year i HONS 046723 Aroclor M.I.P. - 22 3/70 V. APPENDIX The following pages are the items mentioned in the report as additional information relating to the process, quality and personnel. MONS 04672* - 23 APPENDIX A MOMS 046 7^5 APPENDIX B POSSIBLE COl. ilNTJOUS ARRAKGEKEin. Bottoms 7" * rBottoms *3 itiiii Bottoms #4 |-----------Stilll MONS 0 4 6 7 2 6 - 25 - APPENDIX C 1969 ELECTRICAL GRADE AROCLOR ANALYSIS 1242 Lots KL-403 -4 -9 - 12 - 15 - 22 - 25 - 27 - 29 - 31 - 34 - 37 - 39 - 43 - 44 - 46 - 47 - 49 - 51 - 52 - 54 - 55 - 57 - 63 - 65 - 68 - 71 - 76 - 78 - 80 - 81 - 84 - 86 - 88 - 89 - 91 - 93 - 96 - 98 - 99 4003 4 006 4007 4016 4018 4019 TCC (ppm) 0.13 0.16 0.11 0.12 0.12 0.15 0.12 0.13 0.11 0,16 0.18 0.18 0.19 0.11 0.12 0.14 0.16 0.14 0.11 0.18 0.14 0.12 0.18 0.08 0.10 0.17 0.07 0.16 0.15 0.12 0.13 0.25 0.09 o.i4 0.15 0.10 0.17 0.17 0.23 0.13 0.13 0.17 0.24 0.10 0.14 0.19 Resistivity XIO 2600 1850 89OO 2680 2400 1475 10400 2640 64 04 1675 1065 3250 2150 1360 1300 2650 1750 4000 2000 1000 945 1020 2400 2640 1850 7450 2800 8160 1760 2480 2400 5925 2320 1480 3840 3650 104 0 5443 2240 632 2000 1105 1841 1200 8000 6300 % Power Factor 1.26 2.16 0.77 1.62 1.66 3.83 0.60 1.98 O.99 2.31 3.16 1.31 1.27 2.94 1.40 1.99 2.83 1.19 1.77 2.94 2.29 2.50 2.01 1.80 1.80 0.8l 1.34 0.99 2,82 1.86 1.74 1.17 2.58 2.58 1.98 1.39 3.42 4.80 2.76 4.17 1.68 2.65 1.89 1.51 1.48 1.17 Specification 0.65 Max 500 Min. None MONS 046727 - 26 APPENDIX C 1969 ELECTRICAL GRADE AROCLOR ANALYSIS 1 (Continued) 1242 Lots TCC (ppm) Resistivity X10'9 4021 4025 4030 4038 4o4l 4048 0.15 0.16 0.14 0.14 0.25 0.11 2960 1200 3760 3520 1680 1520 Power Factor 1.^9 4.62 1.2Q 2.28 3.00 2.70 1242 Average Specification 12^4 Lots KL-603 -4 -7 -9 - 13 - 15 - 17 - 24 - 26 - 30 - 53 - 43 - 45 1254 Average Specifications 0.15 O.65 Max. 0.57 0.77 0.80 0.49 0.57 0.46 0.41 0.55 0.36 0.44 0.30 0.55 0.55 0.52 None Set 3021 500 Min. 8000 9445 16,250 17.600 30,400 7200 10,900 30,400 20,800 40,000 32,018 14,408 16,810 19,556 500 Min. 2.09 None 0.43 0.44 O.36 0.35 2.46 0.46 O.76 O.29 0.32 0.56 0.36 0.69 0.47 0.60 None Set 1260 Lots KL-1003 -5 -6 -11 -12 -17 -18 1260 Average Specification 1 Not Analyzed 1 | 53,631 24,800 64,037 160,000 9,846 26,415 60,038 56,966 500 Min. 0.19 0.30 0.27 0.45 0.60 0.32 0.20 0.33 None Set MONS 046728 - 27 - APPENDIX D QUALITY COMPARISON FOP ELECTRICAL GRADE AROCLOH J.g'lg Property Monsanto Specifi- cation .1. W.G.K. Annie ton Kancga- Askarel flayer^ fuchi Prodelac Color (APHA) 40 Max. Pree Chloride (ppm) 0.05 Max Acid No. (Mg KOH/g) 0.010" Monsanto [Stability 0.4 Max (ppm) Hydrolysis Chlorides 0.5 Max (ppm) Thermal Chemi cal Chlorides 0.65 Max (ppm) Wcstlnghouse inability (ppm) ND at 25C 1.6240 1.6260 Sp. Gr. at 1.381 - 23 C. Viscosity at 1.392 100C (SOS) 82 - 92 Pour Plant (*C) Power Pactor -14 Min. (100C) 1000 cycles 60 cycles D3 electric Constant 4.70 - (100C) 4.90 1000 cycles 60 cycles Resistivity at 100'C n 500 (0IIM-CMX10 3 ) Distillation Range (C) 10* 325 Min 90# 360 Max Water (ppm) 35 Max 10 0.02 ' 0.001 0.12 0.06 0.14 0.30 1.6251 1.384 85.6 -17 0.15 1.95 4.83 4.86 3500 331 353 18 15 0.01 0.001 0.10 0.12 0.18 0.32 1.6247 1.386 87.2 -18 0.12 1.00 4.82 4.83 3600 327 352 27 40 0.009 0.002 0.37 0.67 1-95 1.6228 1.380 79.0 -15 0.50 4.50 4.72 1200 323 351 28 10 10 0.009 0.018 0.001 0.001 0.03 0.03 0.07 0.11 0.14 0.16 1.6240 1.6251 1.381 1.391 0.25 2.01 4.81 0.36 3.81 4.88 800 500 327 349 62 328 350 94 10 0.018 0.001 0.06 0.11 0.16 1.6246 1.387 0.26 2.40 4.89 700 329 346 51 1) Prom WGK, PR&D Report No. 2, Job No. 91370:4022, dated 4/20/69. 2 Prom Anniston Report No. 2, Job No. 370-503 dated 7/3/68. 3) Prom samples received at Anniston In 1968 and reported in Research & Development Report No. 3, Job No. 370-502, dated 7/19/68. HONS 046729 APPENDIX E DEPARTMENT 2k6 PERSONNEL |~Supervisor | | Foremen (2)| Pr^jj^um Still (*) Second Oper. (4) Swingman #2 Tl) 7' Days/Wk 3 Shifts/ Day 7 Days/Wk T Days/Wk 3 Shifts/ 3 Shifts/ Day Day 21st Shift-Still Duties Duties Duties 21st Batch 2 Stills Shift-Second 5 Chlori- 3 Mix Tanks nators S&S New Tank Farm Standard Catalyst 2 Stills 1 Day 1 Mix Tank Load all Standard 2 Blow Cars and Biphenyl Tanks Trailers 1 Head Tank Pump b Absorbers Finished 1 Off Gas and Product Condenser Complete Tanks to Charge of Storage 1 Off Gas Therminol Storage Heating Tank &MIst System Eliminator Contin Sample uous 1 Surge Tank Blow Tank k Continuous Chlcrinators Standard (2) 5 Days/Wk 2 Shifts/ Day Duties All Drumming of material in Dept. Repair U) 5 Days 1 Shift Biphenyl Handling and All Repair Work P(1o/r2te) r Monday 3 Days/Wk 21st Shift- 1/2 Shift/ Premium Day Thurs & Fri 2 Days Repairman Sat. & Sun. 2 Days Relief Foreman Clean Con- trol room. Rest Room, 2 Offices and Smoking Shelter MONS 046730 A??E DC F. WORK FI ' NO. ITEM EST. COST EST. MAN-DAYS RESPONSIBILITY SDC COMMENTS 1 Reduce Drumming Costs A. Insulate #7 Storage Tank $2500 0 TSD (Process) 1/1/70 CANCELLED B. Evaluate Improved Drumming 2. Increase Yields 05 TSD (Process) 6/1/70 Report Drafted A. Improve Blend Raw Material Yields 00 Production 1/1/70 Action Taken B. Chlorine Usage Study 0 10 TSD (Process) 1/1/71 In Progress 5. Reduce Maintenance Costs A. Determine Off-Gas Corrosion 0 10 TSD (Process) 9/1/70 MMST Advice Needed B. Preventive Maintenance Lists 4. Maintain Quality 0 10 Prod/Maint. 3/1/70 In Progress w 1 A. Roofs on Loading Docks B. Resolve Electrical Property Measurement 8000 0 C. Preloading Quality Treatment T.B.D. 15 0 20 TSD (Mech. Design' 6/1/70 TSD/Maint TSD (Process) l-'lAl * Waiting for Lab Scrubber Waiting for 4B MONS 0 4 6 7 3 1 D. Ag Grade KC1 Test C < Maintain Adequate Capacity A. Replace Mix Tank Pomps B. Drowning Jet Evaluation 0 10 $5000 0 5 TSD (Process) 3/1/70 Check effect on Aroclor Maint. TSD (Process) 6/1/70 6/1/70 Obsolete. Check CaDacity Improve Mix Tank Mixing 0 Production/ 7SD (Frocess) 8/l/7C * Dependent on ability to reproduce elect;rical property measurements - 4B. Minor Modi fication WORK PIAN * (Continued) APPENDIX F. NO. ITEM EST. EST. COST MAN-DAYS RESPONSIBILITY EDC COMMENTS 5. Maintain Adequate Capacity (Cont'd) D. Establish Minimum Drum Inventory 0 5 Production 3/1/70 6. Provide Safe Working Atmosphere A. Fume Removal System Addition $8000 B. Lime Delivery Facility 1000 10 5 TSD (Process) TSD (Mech. Design) 7/1/70 Hold Extension of System waiting for fork lift app. c. Safety Audit Items T.B.D.. 15 Production 11/1/70 Ref. Safety Audit 7. Keep Aroclor from Sewers A. Control Rupture Disc Discharge 5000 15 (TSD-Process) 6/1/70 Recycle to Surge Tank B. Install Sewer Basins $11,000 15 TSD (Mech. Design)7/1/70 Trap Aroclor c. Sewer Pollution Check 0 TSD (Pollution Cont. Sampling to Control) continue HONS 0 4 6 7 3 2 D. Reduce Blow Tank Losses 0 10 TSD (Process) 10/1/70 Aroclor to sewer E, Determine Amount of Aroclor in Off-Gas F. Catch Wastes from Drip Pans 4 Sample Lines 05 00 TSD (Process) Production 4/1/70 3/1/70 At Depts. 217 & 218 G. Piping Modifications on Blow Tank 5400 20 TSD (Mech. Design 5/1/70 0 SNOW APPENDIX F. WORK PLAN - (Continued) NO. ITEM EST. EST. COST MAN-DAYS 8 Maintain Control of Process A. Complete Process Variables Chart & Key Variable List 0 10 B. Revise Operating Instructions 0 10 C. Revise Std. Mfg. Process 0 10 9 Maintain High Level of House keeping and Improve Operations A. Upgrade Control Room $14,000 0 B. Dismantle Obsolete Equipment 2,700 0 C. Road & Sewer Improvements 30,000 20 D. Pave Tank Farm T.B.D,, 10 E. Replace Lean-to $200,000 30 RESPONSIBILITY EDC COMMENTS Production Production Production 4/1/70 In progress 7/1/70 In progress 12/1/70 In progress TSD(Mech.Design) 4/1/70 In progress Maintenance 3/1/70 In progress TSD(Mech.Design) On Hold No work being done tl M If On Hold No work being done ft II tl On Hold No work being done *rtL9*rO SNOW APPENDIX G. PROCESS CONTROL STATUS REPORT AND OBJECTIVES PROCESS Aroclor Pyranols Pydrauls I. Data Bank a. Standard Manu facturing Process 3/1/70 3/1/70 3/1/70 b. Safety Audit 3/1/70 3/1/70 3/1/70 c. Tentative Process 3/1/70 3/1/70 3/1/70 d. Chemical/Physical Properties 3/1/70 3/1/70 3/1/70 e. Monthly Operation Reports 3/1/70 3/1/70 3/1/70 f. Monthly Key Variable Reports 5/1/70 5/1/70 5/1/70 g. Process Control Audits 8/1/70 8/1/70 8/1/70 h. Con|>laint File 3/1/70 3/1/70 3/1/70 i. Customer Service File 3/1/70 3/1/70 3/1/70 j. Log Sheets 3/1/70 3/1/70 3/1/70 k. Operating Instruc tions 3/1/70 3/1/70 3/1/70 1. Data Bank Index 3/1/70 3/1/70 3/1/70 m. IFO's 3/1/70 3/1/70 3/1/70 II. Variables Analysis a. Variable Analysis 2/20/70 3/1/70 3/15/70 b. Key Variables /* Vaar Vari able Pppnrt 4/1/70 /Tn 4/1/70 5 /I /7(1 4/1/70 c, /I /7D 125^/1056 Xylene Mix 12/1/70 3/1/70 3/1/70 3/1/70 3/1/70 5/1/70 8/1/70 3/1/70 3/1/70 3/1/70 3/1/70 3/1/70 3/1/70 3/15/70 4/1/70 c, /I /7n APPENDIX G (Continued) PROCESS CONTROL STATUS REPORT AND OBJECTIVES (Continued) III. Standard Manufacturing Process Revision Aroclor Pyranols Pydrauls 125V10# Xylene Mix a. Variable Analysis b. Key Variables Current-Batch 10/66 Cont. 9/68 Rev. 9/1/70 ft Current-10/66 Rev. 11/1/70 it Current-10/66 Rev.-12/1/70 ft Current-None Rev.-12/1/70 ft c. Documentation and Reporting ft ft tr ft IV. Key Variable Control Ins trumentation a. IPO b. IPMO c. PM Program d. Control Setting Documentation Complete Complete 6/1/70 6/1/70 Complete Complete 6/1/70 6/1/70 Complete Complete 6/1/70 6/1/70 Complete Complete 6/1/70 6/1/70 V. Operating Instructions MQNS 0 4 6 7 3 5 a. Revision Current-10/66 Current 10/66 Rev. 6/1/70 Rev. 7/1/70 b. Operator Training 9/1/70 9/1/70 VI. Management System Same as a. Reporting System II c. 5/1/70 5/1/70 b. Process Control Committee 7/1/70 7/1/70 c. Process Audit 8/1/70 8/1/70 Current-10/66 Rev. 7/1/70 9/1/70 5/1/70 7/1/70 8/1/70 Current-10/66 Rev. 7/1/70 9/1/70 5/1/70 7/1/70 8/1/70