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SAFETY & HOUSEKEEPING PLANT INSPECTION 1980 MONSANTO CHEMICAL INTERMEDIATES COMPANY TEXAS CITY SC 17635 STG 108A055 COMPANY CONFIDENTIAL LAM025889 TO: THE 1980 PLANT INSPECTION COWITTEE Welcome to the Texas City plant. We look forward to sharing with you our experiences, philosophies, and approach to safety. These inspections provide for us an opportunity to obtain an unbiased assessment of our effectiveness in managing safety. Our emphasis in Texas City is not on statistics, but on incidents. We have continued to focus on ALL incidents to try to determine root cause and take corrective action. We strongly believe that if we are respon sive in taking corrective action to prevent recurrence of these, the statistics will take care of themselves. We also encourage safety sugges tions through our unit and craft safety suggestion log books. We are comnitted to responding to and providing feedback on each of these. We are finding that more and more of these suggestions are being taken care of at the unit level as they should be. You will hear more about our safety programs during our presentations; however, there are a few points I would like to make. Based on a detailed analysis of our safety organization, training, and emphasis, we feel that the key elements are in place. Our current thrust is on emphasizing basic safety principles and attitudes with the objective of improving the cuality and followup on safety programs plantwide. We are consciously avoiding any type of hoopla program. Instead, our emphasis is on making safety awareness an integral part of the way we conduct our business. As a special emphasis of this inspection, we would very much appreciate it if, during your tour of our facilities, you talk to as many of our wage and first-line supervision as possible. This is "where it all happens" and we would like your help in assessing how this group perceives our safety pro cedures, programs and most importantly, our commitment. During the feed back session, we encourage you to be candid with us and "tell it like it is" in this as well as all other areas. We hope your visit with us will be helpful, informative, and enjoyable. We are proud of our people and our facilities and are anxious to intro duce them to you. Sincerely, Sept. 1980 G. L. Tromblee Plant Manager SC 17636 STG 1084056 LAM025890 1980 INSPECTION TEAM GEORGE F. KNOLLMEYER, Chairman Plant Manager J. F. Queeny Plant, St Louis EDUCATIONAL BACKGROUND; BS-ChE University of Missouri 1951 WILLARD (Will) F. DUNN Manufacturing Supervisor Pensacola, Florida EDUCATIONAL BACKGROUND: BS-ChE Georgia Institute of Technology 1953 GLEN E. MERTZ Engineering Specialist W. G. Krummrich Plant, St. Louis EDUCATIONAL BACKGROUND: BS-ChE University of Missouri MS-ChE University of Missouri 1973 1976 SC 17637 ST6 1084057 I.AM025891 PATRICK (Pat) M. PAYNE Personnel Supervisor Columbia, Tennessee EDUCATIONAL BACKGROUND MS-Labor & Industrial Relations Michigan State 1974 CARL L. SCHENCK Supt. of Accounting & Control Soda Springs, Idaho EDUCATIONAL BACKGROUND. MBA Washington University 1973 /fr*f TERRY WOLLIN General Manufacturing Supervisor Soda Springs, Idaho EDUCATIONAL BACKGROUND: BS-ChE Illinois Institute of Technology 1970 SC 17638 STG 1084058 LAM025892 PLANT MANAGER'S SAFETY BOARD \ W.G. JUHL PT Director V. G. T. RYAN Supt. Mfg. G. A. DANNER Supt. Plant Serv. N G. W. BOSTICK MISD Manager J.G. TRAFTON Supt. Mfg. D.W. METTEN Supt. Acctg. B. C. LANCASTER CED Site Supt N SC 17639 G.W. DAUES Supt. Mfg. 4 D. E. KALDENBERG Supt. Personnel C. F. NAVARRETE Supt. Mfg. om o G. E. SMALL Mgr. Proc. Engr. CED Kc* V) c. m. McCullough Plant Engineer LAM025893 SAFETY and HOUSEKEEPING ACTION COMMITTEE (SHAC) C.M. CRUSE Chairman Mfg. Supt. C. N. McCLANAHAN Maint. Zone Supt. W. R. STOCKWELL Engr. Specialist Plant Serv. SC 17640 ). M. WILLOCK Proc. Tech. Group Supv. STG 1084060 LAM025894 SC 17641 STS 1084061 LAM025895 Monsanto Texas City People Making Safety Happen SC 17642 ST6 1084062 LAM025896 GENERAL INFORMATION PLANT LOCATION The plant is located at the southeast corner of Texas City. Total plant area is 358 acres of which 243 are in use for manufacturing. This total acreage includes 80 acres northeast of Texas City in the Amburn Tract, 18 acres south of the plant at Swan Lake, and 18 acres of peripheral property adjacent to the plant. The Amburn Tract property is the site of our fire training area and a lagoon used to decant river mud from the plant water treating clarifier. The Swan Lake property is used for nonhazardous waste disposal. ORGANIZATION Manufacturing Operations at Texas City are administered by the Chemical Intermediates Company, which operates seven manufacturing units plus site utilities and environmental control operations. The Industrial Chemicals Company is guest operator of six manufacturing units. Other Manufacturing functions at Texas City include MISD, Accounting, Personnel, Plant Engineering and Plant Services. The Personnel depart ment includes a medical dispensary and industrial hygiene laboratory. Plant Engineering includes instrument, electrical, and mechanical mainte nance and project construction groups with a large central shop facility, as well as plant security and off-shift supervisory personnel. Plant Services includes purchasing, stores, production planning and scheduling, and material handling functions, an engineering design group for plant projects, and a materials/mechanical technology group responsible for fabrication and rotating equipment specification as well as inspection of existing equipment. The plant also operates a Control Laboratory for process and product analyses. Process Technology at Texas City includes a major laboratory and engineer ing center which supports product line operations and capital projects and provides process and analytical technology development as well as business planning guidance. Styrene and acetic acid licensing are also administered through the Process Technology department. Corporate Engineering at Texas City Includes a process engineering group which supports Chemical Intermediates capital project development and a construction group which executes CED projects at the plant. Other staff functions at Texas City include Marketing and Patent offices. sc ^643 STG 1084063 LAM025897 EMPLOYMENT The plant employs 1736 people, in the following classifications: Wage Salaried: Manufacturing,.Exempt Non-exempt Process Technology, Exempt Non-exempt Corporate Engineering, Exempt Non-exempt Marketing/Patent, Exempt Non-exempt 1029 356 139 118 68 13 2 5 6 Total 1736 Plant operating and craft wage personnel are represented by the Texas City, Texas, Metal Trades Council, an association of thirteen craft and operating unions. Cafeteria workers are represented by Local 347, Inter national Union of Operating Engineers, AFL-CIO. Security guards are re presented by the Associated Guards of the United States. MAJOR PRODUCTS The major finished products of the plant are as follows: CHEMICAL INTERMEDIATES COMPANY Styrene Monomer used for plastics, synthetic rubber, and surface coating materials. High Density Polyethylene used in the plastics industry as film, wire coating and molding material. This unit is ex pected to operate until 1983 under contract to Cities Service. Methanol used in the production of anti-freeze, formal dehyde and acetic acid. Acetic Acid used in making cellulose acetate and vinyl acetate monomer, and for fiber and agricultural production. Acetone Cyanohydrin used for manufacturing polymethyl methacrylate plastic. Acrylonitrile used for fibers, nylon and structural pieties. SC 17644 $TG 1084064 LAM025898 INDUSTRIAL CHEMICALS COMPANY Synthetic Lactic Acid used in the food industry as a preservative. Phthalic Anhydride used in plasticizers, polyesters, alkyd resins, dyes and pharmaceuticals. Phthalate Esters used in food-grade plastics, floor tile, film, fabrics, and adhesives. Oxo-Alcohol used in manufacture of phthalate esters. Tertiary Butylamine (TBA) used as intermediate for the rubber and tire industry. TEXAS CITY PLANT HISTORY 1941 ... Thirty-acre tract purchased under auspices of Defense Plant Corporation. 1942 ... Construction started on Styrene monomer unit and supporting Ethylene units. 1946 ... Plant purchased by Monsanto from United States Government. 1947 ... Ship explosions in harbor completely destroyed plant; recon struction of Styrene and Ethylene units started immediately. 1951 ... Construction begun on Acrylonitrile, Hydrogen Cyanide, and Vinyl Chloride monomer units plus supporting Oxygen and Acetylene units. 1952 ... Started up Oxygen, Acetylene, Hydrogen Cyanide, Acrylonitrile and Vinyl Chloride monomer unit. 1954 ... Construction begun on Methanol and low density Polyethylene units plus high-purity Ethylene units. 1956 ... Construction begun on new Ethylene units. 1957 ... Started up new Ethylene unit. 1959 ... Tract of 68 acres adjacent to plant acquired and filled by dredging for future plant expansion. 1962 ... Construction begun on high density Polyethylene unit. 1963 ... Started up Lactic Acid unit. SC 17645 sT6 1084065 LAM025899 1969 ... 22 acres adjacent to solith side of plant acquired for new deep-water docking facility and product storage area. Construction started on new Methanol and Acetic Acid units. Construction begun on Phthalic Anhydride and Esters units. 1970 ... Started up new Methanol, Acetic Acid, and Esters units. Acetylene, Acrylonitrile, Vinyl Acetate and old Methanol units shut down and dismantled. Construction begun on Oxo-alcohol and new Styrene units. 1971 ... Started up EVCL unit. Started up Phthalic Anhydride and Oxo-alcohol units. 1972 ... Part of low density Polyethylene shut down. Started up new Styrene unit. Started up new primary waste water treatment unit. 1973 ... Signed contract for secondary waste water treatment at Gulf Coast Waste Disposal Authority (GCWDA) regional treat ment facility. 1974 ... Started up new Ethylbenzene unit. Construction begun on new Acrylonitrile unit. EVCL unit shut down. 1975 ... Construction started on Acetone Cyanohydrin unit. Low density Polyethylene unit shut down and dismantling started. Started up GCWDA secondary treatment facility. 1976 ... Acetone Cyanohydrin unit started up. Low density Polyethylene dismantling complete. 1977 ... Started up new Acrylonitrile unit. Hydrogen Cyanide unit shut down. SC 17646 STG 1084066 LAM025900 1978 ... Chrome-Zinc removal project completed. Storm water diversion project completed. 1979 ... Major energy conservation project completed. Boiler fuel conversion project completed. 1980 ... Acrylonitrile Exposure Reduction project completed. Ethylene plant shut down, dismantling. Started up GCWDA regional disposal facility for hazardous solid waste. 1981 MAJOR PROJECTS Plasticizers expansion. Phthalic Anhydride energy conservation and debottlenecking. IDA II. ST6 1084067 LAM025901 **#******** St*>T MFG ho^e/env aom * QllAL ASSURANCE * GW OAmES J director mfg $ MIC F J HOLZAPFEL * ******** I I Ztl * SUPT MFG INDUSTRIAL chemicals J G TRAFTON ***** MGR INFORMATION * SYSTEMS * P E PARISOT l I MISD MGR * * 6 W BOSTICK *** ***** I f ********* L * MFP SUPT * MFG SUPT * HO^E * OXO ALCOHOL * polymerization I ft* J TOWNSEND * ESTERS/PA H M LACY * a**************** * data * proc suPw * n e marabella i r * MPF SUPT L ** MFDINpIESHING TSD/MFG SUPT IDA/LA project leaoer * * P J BURKETT a m conrad c o holmes ********** L Fs ******'* SP eng RPFCIAI 1ST TECHNICAL SERVICE SUPT * * BUSINESS SYS U V MARSHALL D R WISE * SPECIALIST v* * * * K E RICKE * * E * SR SPEC * * ENV ADM * G. LUNSFORD *****#* * * *Ffc SUPT * IDA * T KIRK g ********#* CHIEF CHEMIST V " FraNCHETTI SC 17647 STG 1084068 nsanto chemical TERHEOIATES COMPANY NUFACTURIN6 DEPARTMENT XPATSFMCprIOTY YY. EXYAQSAft LA A/1025902 W.G. JUHL PROCESS TECHNOLOGY OIRECTOR X .H . STANTON DISTINGUISHED PELLOW LAM025903 P rocess Technology D epartm ent Texas C ity I1 SC 17649 ST6 1084070 LAM025904 SC 17650 STC 1084071 LAM025905 Accelerated Vessel Inspection Program ACCELERATED VESSEL INSPECTION PROGRAM (AVIP) Monsanto Texas City began a comprehensive program of vessel inspection after failures of atmospheric storage tanks in 1978 and 1979, one causing five fatalities. Over 1300 major vessels in the plant have been scheduled for regular inspection each 1-5 years depending on the nature of the service and the extent of previous inspection data. Metal vessels are inspected visually, with thickness readings and condition of plates and welds recorded. FRP tanks are inspected visually and with acoustic emis sion techniques. 1980 was the second full year of the AVIP program, with a high level of inspection effort. Over 93% of scheduled inspections are presently complete, and more will be accomplished in shutdowns scheduled through October. The inspection schedule is regularly reviewed by the Safety and Housekeeping Action Corrmittee and reported each month at meetings of the Plant Manager's Safety Board. As a result of the program, extensive repairs and replacements of FRP vessels have been completed. Of 25 FRP vessels inspected, 9 were replaced, 9 required major or minor repairs, and 7 passed inspection. Among metal vessels surveyed, a 30,000 gallon rubber-lined acid tank in the Power Department was condemned and replaced after visual internal inspection. The tank had been in service since 1956 without previous history of internal inspection. A 15,000 gallon sulfuric acid tank in the acrylonitrile unit was found to have 20% of welds defective. This tank had been in service since 1977. Many other vessels have also been found to require major or minor repairs, and confidence in the condition of all vessels has been significantly increased as a result of the in spection, the documentation of vessel condition, and the follow-through to correct any deficiencies noted. To improve and facilitate the inspection program, more than $75,000 has been spent for new inspection equipment, including acoustic emission test equipment. Test procedures have been refined and published, and the pro gram is now being extended to cover critical heat exchangers. This comprehensive program of equipment inspection complements existing programs for relief valve and turbine overspeed testing to assure that plant capital assets are maintained in safe operating condition. It also assures that a sound engineering definition of equipment condition and performance history is available to guide present and future maintenance programs. Through this effort, a major contribution is made in assuring the safety of personnel and reliability of plant operations. SC 17652 STG 1084073 LAM025907 Monsanto, Texas City Safety Organization POLICY FORMULATIONS & DECISIONS SC 17653 LAM025908 STG 1084074 PLANT MANAGER 33 GROUPS 150 MEMBERS supv/hourly opn's/maint 8 MEMBERS PLANTWIDE HOURLY INPUT 4 MEMJERS LABS AND BENCH UNITS 9 MEMBERS OFFICE WORKERS Sc 17654 STS 1084075 LAM025909 TEXAS CITY SAFETY PHILOSOPHY WHERE SAFETY STARTS CORPORATE SAFETY POLICY - It is the safety policy of the Monsanto Company that every employee is entitled to a safe and healthful place in which to work. To this end, every reasonable effort will be made in the interest of accident prevention, fire protection, and health preservation. This policy covers all employees at the Texas City plant. All of the plant organizations -- line, staff and formal safety-oriented organizations -- are designed to fulfill the spirit and the letter of this policy. ROLE OF MANAGEMENT AND THE INDIVIDUAL - Management is fully responsible for initiating and administering an effective safety program. Each employee must fully accept the re sponsibility for his safety and that of his co-workers by conscientiously observing safe work practices and cultivating safe working habits in himself and his fellow workers. Thus the management and the individual workers are mutually involved in a continuing effort to eliminate acts and conditions which could lead to accidents, fires, or to be injurious to the health of anyone. The Plant Manager, although responsible for the entire safety program, assigns responsibilities for the administra tion of program details. SAFETY TRAINING. A KEY ELEMENT IN ALL JOB TRAINING- Safety training is an integral part of job training, and as such, is the responsibility of the supervisory staff. Job training is incomplete unless it considers and properly addresses the hazards of the job. Un less a way has been developed to do a job and do it safely, the plans for the job and the training of the employees to perform the job is in complete. In addition to the on-the-job safety training, plantwide safety training programs are conducted. They are the responsibility of the Safety and Housekeeping Action Committee (SHAC); however, joint accountability for the effective plant training program is shared by the Loss Prevention and Safety Department. SAFETY PERFORMANCE INJURY STATISTICS - Injury and illness rates in specific categories are developed on a plantwide basis and are broken down by department, crafts or operating areas to provide indicators of safety performance in large and small work groups throughout the plant. These SC 17655 ST6 1084076 LAM025910 safety statistics are developed and plotted on a weekly, monthly and annual basis to show the responsible supervisors where their area performance stands in relation to their own history and to plantwide performance goals. Plant safety goals are established by general management for the plant as a whole. SAFETY PERFORMANCE REVIEW AND CONTROL - Injury and illness records are reviewed weekly, monthly, quarterly and annually in every review of overall plant performance at every level. Significant deviations require explanation as to cause and appropriate corrective or preventive actions. The greater the de viation from expected performance, the higher in the organization the deviation will be reviewed. SUMMARY At Texas City, safety is an integral part of our everyday work. Job training is not complete until the person performing the work knows how to do the job safely. Work planning is not complete until the safety considerations are satisfied. Work execution requires prior review of the possible hazards and necessary actions required to meet them safely. Safety performance is a primary consideration in the evaluation by supervisors of employee job performance. Safety performance is reviewed at regular intervals along with all other aspects of the job or work in progress. All employees are involved in safety considerations in the work place. Safety performance is reviewed by management at every level and is a key element in judging managerial performance and control. Safety is not a thing apart. It is an integral part of our way of doing business. SC 17656 STG 1084077 LAM025911 TOTAL INJURY RATES/(CASES) Racordablt, Lost Workday, and Days Away 4-YEAR COMPARISON 3.5 3.0 2.5 2.0 1.5 STS 1084078 1.0 980 0.5 1976 1977 RECORDABLE 1978 1979 1980 LOST WORKDAY EfSjN DAYS AWAY 1IIIIII1IIIIII1IIIIII U/W025972 SC 17657 SC 17658 ST6 1084079 LAM025913 MCI 1979 INSPECTION REPORT RECOMMENDATIONS and RESPONSES 1. Consistency. The plant has many outstanding safety procedures; however, we found a number of variations being followed. We recommend a review of safety procedures and practices with an eye towards greater con sistency throughout the plant. RESPONSE: Concerns about consistency in plant safety procedures and practices have been studied by SAC. Much of the variety arises from actual differences in nature and extent of hazards involved. One frequently mentioned area of concern has been the use of work permits. SAC has reviewed the use of work permits with responsible plant per sonnel, and reconmended that the use of work permits be left as an option for individual manufacturing units. The decision to use them or not should be made jointly by Manufacturing and Maintenance. The Loss Prevention and Safety Department will publish a description of the work permit system along with advantages and disadvantages during the 4th quarter of this year so that the units can review the matter and make a decision. 2. Safety Tape. Yellow safety tape is used for a number of non-safety purposes. We recommend its use be restricted to safety related purposes and that an identification tag be required to identify the reason for the tape's use and the individual responsible. RESPONSE: SAC has reviewed existing policies for the use of safety tape and recommended that the present policy be retained -- red tape used by the Fire Department for fires and spills, and yellow tape used to identify general hazards. A plantwide bulletin board notice has been posted to remind people on the proper use of safety tape. The use of more kinds of tape and/or signs to identify why the tape was put up was considered and rejected because of the additional complexity involved. 3. Car Seals. These were evident throughout the plant. While everyone knew they represented the equivalent of a lockout device, few people knew who had the authority to remove them. We recommend a formal plant wide procedure be established identifying who has the authority to install or remove car seals. RESPONSE: SAC is responsible for making recommendations on the proper use of car seals as a lockout device. This item has been included in the inspection checklist for the quarterly Guest Housekeep ing Inspections. The practice is also under study by the Hourly Safety Committee and their recommendation is expected in October. SC 17659 STG 1084080 LAM025914 -2- 4. Breathing Air Supplies. Conversion to a central breathing air supply raises additional questions about system reliability. Some areas of the plant are alarmed if local conditions jeopardize the breathing air supply. Others are not so alarmed. We suggest a careful study be made of the reliability and safety of the central breathing air system, including alarms. RESPONSE: The Utilities Department is responsible to assure the re liability and safety of the central breathing air system, including alarms. An Advisory Investigating Team has been formed to provide input about user's needs for improving the system. A report on breathing air filters installed in operating units has been issued by Plant Engineering. An analyzer which continuously monitors the breathing air system for organic contamination has been installed. An engineer in the Utilities Department has been assigned to complete a study with recommendations for further improvements in the breathing air system. 5. Eye Wash Stations/Safety Showers. Use of alarms and green identifica tion lights on safety showers was inconsistent. We recommend all safety showers be reviewed for the consistent use of lights and alarms. We further recommend consideration be given to the installation of hosetype eyewash stations rather than the currently fixed type so that a second person can irrigate the eyes of an injured individual. RESPONSE: SAC is currently studying this question. A plant survey has been completed to provide data on the number and type of shower/eyebath installations and alarms provided. OSHA has recently issued for review a proposed standard for eyebath and safety showers. Until the OSHA position is clarified, SAC recommends against upgrading existing systems that do not now have alarms or lights. SAC does recommend that in new construction, all eyebaths and safety showers have alarms and lights, and further that the situation be reviewed again in six months taking into account the status of the OSHA standard at that time. 6. Phthalic Anhydride Tank Vent. Fumes from a phthalic anhydride storage tank were quite strong, thus creating an industrial hygiene concern. We recommend the project to control vent vapors from phthalic anhydride tanks be expedited. RESPONSE: A trial installation of a vent condenser employing new technology Is being installed on one Phthalic Anhydride storage tank. The system is scheduled for an October, 1980 startup. If it proves successful, other tank vents will be similarly equipped. SC 17660 ST6 1084081 LAM025915 -3- 7. Use of Yellow Safety Markings. We recommend each location where safety yellow is used be clearly marked to identify the specific safety con cern. We further recommend consideration be given to extending the use of safety yellow to identify extra-hazardous intra-department piping. RESPONSE: SAC currently has this item under study. They are reviewing the existing plant procedure on Super-hazardous Materials as it applies both to piping within and between operating units. A recommendation is expected in the 4th quarter of this year. 8. Shift Fire Protection and Emergency First Aid. We found the plant to be excellently staffed with trained fire protection and first aid personnel and equipment during day shifts on weekdays. However, we recommend a review of these areas during off-shifts. Specifically: A. Is the volunteer fire protection group's response time adequate, especially under adverse weather conditions such as street flooding? B. Should additional monitor nozzles be considered for fire protection? C. Does the plant need to expedite the training of additional emer gency first aid personnel (EMT) for off-shift coverage? RESPONSE: A. Volunteer fire crew response has been improved by the inclusion of volunteers from among shift workers in the plant. Eight new volunteers have been added to date, and more are being recruited. B. We have continued to add monitor nozzles to increase our fire protection coverage throughout the plant. Two additional monitor nozzle systems have been added since the 1979 Annual Inspection. There are several more under consideration for new projects. C. The training of additional Emergency Care Attendants has been emphasized this past year. We now have 135 Monsanto Industrial Emergency care attendants (MIECA's) and 6 Emergency Medical Technicians (EMT's). Plans have been approved to increase -the number of MIECA's to serve some areas that do not have coverage at this time. Participation in this program is being encouraged by special identity jackets and tuition refund. SC 17661 ST6 l084082 LAM025916 -4- 9. Identification of Hazardous Chemical Handling Areas. Most departments identify the hazardous chemicals handled within their area by the use of charts within their control rooms. However, we recommend more emphasis be placed on identifying the specific locations within each department where extra hazardous chemicals are handled, especially if they cannot be readily identified, such as carbon monoxide. RESPONSE: SAC have reviewed this recommendation and feel that the existing policy, which requires that anyone working in an area be aware of potential hazards in that area and knowledgeable in emergency response, is adequate. It is the responsibility of super vision in each area to assure that the existing policy is effectively implemented. SAC suggests that the Unit-Craft safety promotion teams in each area review their procedures, labeling, etc., for effectiveness and make any necessary corrections. 10. Face Shields. Use of personal safety equipment was evident throughout the plant. However, we recommend further expansion of the use of such equipment to include mandatory use of face shields in addition to goggles during sampling or decontamination procedures involving hazardous chemicals. RESPONSE: SAC has reviewed the use of face shields with plant mainte nance groups. They have concluded that the use of face shields would increase the level of personnel protection provided for some jobs within the plant. SAC has recommended that an audit of jobs done in each unit be conducted by operating and maintenance foremen with the assistance of plant safety inspectors to assure that adequate face protection is provided. The results of these audits will be reported to responsible supervision for incorporation into job procedures during the 4th quarter of this year. SC 17662 STG 1084083 LAM025917 TOUR GUIDE w SC 17663 STS 1084084 LAM025918 s. r*- 0) o c a U u CO to u po-- i o 4-* (/) u. c p-> o T" CJ (A CO to CD i uc U 0) u o> c (Si CO I CJ U. I >s> -o atO. <o L. 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Overall Texas City Safety Program J. A. Glass (Arnold) Loss Prevention & Safety Supt. 15 3. Plant Manager's Safety Board (PMSB) and Safety Advisory Committee (SAC) G. W. Daues (Greg) Supt. of Mfg., Polyethylene 15 4. Safety and Housekeeping Action Committee (SHAC) C. M. Cruse (Max) Mfg. Supt., Ethylene and Ethylbenzene 15 5. Hourly Safety Committee (HSC) 0. E. Lonsford (Joe) Boilermaker, Plant Engineering 5 6. Process Technology Safety Committee L. L. Lewis (Linda) Sr. Chemist, Process Technology 5 7. Office Safety Committee P. A. Wansbrough (Peggy) Clerk, Distribution Scheduling 5 8. Plant Manager's Comments G. L. Tromblee 5 9. Inspection Kickoff J. M. Willock (Mike) Group Supv., Process Technology 5 10. Discussion 10 Distribution of Safety Equipment 11. Coffee Break 15 BEGIN INSPECTION SC 17668 10:00 a.m. STG 1084089 LAM025923 TUESDAY, SEPTEMBER 23 DEPTS. 44-45-Ji6 METHANOL Raul Hernandez Tommy Nelson/Don Carter Earl Johnson Lee Vickery/Leon Latimer Pinky Cole/Jimmy Desormeaux Doug Ziesse 10:00 a.m (Knollmeyer, Cruse) (Dunn, Glass) (Mertz, Willock) (Payne, Conrad) (Schenck, Fiesinger) (Wollin, Stockwell) COFFEE BREAK (Acetic Acid) DEPT. 50 ACETIC ACID Raul Hernandez Byron Johnson Frank Weis/Bobby More Dennis Dorsey/Yankee Wilson Olan Johnson Charlie Elfstrom DEPT. 51 - ACRYLONITRILE Jessie Butler Bill Howe Mark Devore Hap Ferguson James Freeman Robert Bolen 10:30 a. m. 10:45 a . m. (Knollmeyer, Cruse) (Dunn, Glass) (Mertz, Willock) (Payne, Conrad) (Schenck, Fiesinger) (Wollin, Stockwell) 11:15 a. m. (Knollmeyer, Cruse) (Dunn, Glass) (Mertz, Willock) (Payne, Conrad) (Schenck, Fiesinger) (Wollin, Stockwell) CARS to MAIN OFFICE 12:15 p. m. SC 17669 ST6 1084090 LAM025924 Tuesday, September 23 cont'd CAFETERIA CONFERENCE ROOM (Tray Lunch) CARS to ZONE 1 OFFICE 12:30 p.m 1:00 p.m. ZONE 1 OFFICE Sam West Rodie Santarelli Jimmy Gibbs Bill Burkett Ivy Partain Alvin Soderberg 1:05 p.m. (Knollmeyer, Stockwell) (Dunn, Cruse) (Mertz, Glass) (Payne, Willock) (Schenck, Conrad) (Wollin, Fiesinger) DEPT. 15 - DEHYDROGENATION Hugo Darden A1 Mofley Rob Fransham Jim Ryan Earl Moore John Couch 1:20 p.m. (Knollmeyer, Stockwell) (Dunn, Cruse) (Mertz, Glass) (Payne, Willock) (Schenck, Conrad) (Wollin, Fiesinger) DEPTS. 14-16 STYRENE - EB DISTILLATION 1:40 p.m. A1 Mofley Rob Fransham Evelyn Tolden Jim Gore Rudy Willis Jerry Mitchiner (Knollmeyer, Stockwell) (Dunn, Cruse) (Mertz, Glass) (Payne, Willock) (Schenck, Conrad) (Wollin, Fiesinger) SC 17670 STG 1084091 LAM025925 Tuesday, September 23 cont'd DEPT. 13 ALKYLATION Carroll Smith Rudy Willis Evelyn Tolden Bill Platt Larry Wheaton Houston Mil stead CONTROL LABORATORY Victoria Franchetti Jerome Caffey Winnifred Evans Art Buitron 2:10 p.m. (Knollmeyer, Stockwell) (Dunn, Cruse) (Mertz, Glass) (Payne, Willock) (Schenck, Conrad) (Wollin, Fiesinger) 2:40 p.m. (Knollmeyer, Stockwell) (Dunn, Cruse) (Mertz, Glass) (Payne, Willock) (Schenck, Conrad) (Wollin, Fiesinger COFFEE BREAK (Material Handling Office) 2:50 p.m. MATERIAL HANDLING OFFICE BUILDING 3:10 p.m. Conrad Ber.g Frank Bales Dante Paganucci Rusty Wilson Charlie Loney Leo Garcia (Knollmeyer, Stockwell) (Dunn, Cruse) (Mertz, Glass) (Payne, Willock) (Schenck, Conrad). (Wollin, Fiesinger) SC 17671 ST6 1084092 LAM025926 Tuesday, September 23 cont'd BARGE & SHIP DOCKS (1,2,3,4,5) (Pick up Cars) Conrad Berg Frank Bales Dante Paganucci Rusty Wilson Charlie Loney Leo Garcia 3:20 p.m. (Knollmeyer, Stockwell) (Dunn, Cruse) (Mertz, Glass) (Payne, Willock) (Schenck, Conrad) (Wollin, Fiesinger) PRIMARY TREATMENT, AMMONIA TANK, NORTH 68 4:00 p.m. Vernon Fields Bill Wooley Jack Hutchinson Bruce Fortenberry Raeann Reid Ed Hendricks (Knollmeyer, Stockwell) (Dunn, Cruse) (Mertz, Glass) (Payne, Willock) (Schenck, Conrad) (Wollin, Fiesinger) END of FIRST DAY of INSPECTION SC 17672 STS 1084093 LAM025927 SC 17673 STG 1084094 LAM025928 WEDNESDAY. SEPTEMBER 24 STORES Tom Crump Terry Grubbs Vernon Bruggman Helen Guinn Sonny Hobbs L. C. Gilmore 8:10 a.m. (Knollmeyer, Fiesinger) (Dunn, Stockwell) (Mertz, Cruse) (Payne, Glass) (Schenck, Wiliock) (Wollin, Conrad) SHOPS BUILDING Leonard Schwab George Clark Jack Fasetta Howard Scoggins Wes Noel Tommy Glover 8:35 a.m. (Knollmeyer, Fiesinger) (Dunn, Stockwell) (Mertz, Cruse) (Payne, Glass) (Schenck, Wiliock) (Wollin, Conrad) COFFEE BREAK (Shops Building, 2nd Floor) 9:15 a.m. SOUTH MAINTENANCE BUILDINGS & GARAGE 9:30 a.m. Jack Goodson Doyle Beard R. C. Williams Curtis McGowen Vernon Mapes Leonard Schwab (Knollmeyer, Fiesinger) (Dunn, Stockwell) (Mertz, Cruse) (Payne, Glass) (Schenck, Wiliock) (Wollin, Conrad) SC I?674 STS 1084095 LAM025929 Wednesday, September 24 cont'd WATER TREATING - PLANT AIR Larry Young Jim Uptmore Donis Shotwell Dan Moore Bill Bazemore George Drum 9:45 a.m. (Knollmeyer, Fiesinger) (Dunn, Stockwell) (Mertz, Cruse) (Payne, Glass) (Schenck, Willock) (Wollin, Conrad) POWER 2 Larry Young Jim Uptmore Donis Shotwell Dan Moore Bill Bazemore George Orum 10:00 a.m. (Knollmeyer, Fiesinger) (Dunn, Stockwell) (Mertz, Cruse) (Payne, Glass) (Schenck, Willock) (Wollin, Conrad) INSTRUMENT SHOP Sam Scarcella 10:25 a.m. (Knollmeyer, Fiesinger) (Dunn, Stockwell) (Mertz, Cruse) (Payne, Glass) (Schenck, Willock) (Wollin, Conrad) CAFETERIA CONFERENCE ROOM (Tray Lunch) 11:05 a.m. SC ST6 108^096 LAM025930 Wednesday, September 24 cont'd DEPTS. 19-25-27-29 (HCN-TBA-LN-ACY) 11:50 a.m. Jasper Jennings Bill Taylor Mike Sweeney (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) AN LOADING RACK Vic Osburn Glen Vogtman Frank Bales Rusty Wilson Charlie Loney Jim Uptmore 12:30 p.m. (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) WAREHOUSE A-B-C Tom Crump Terry Grubbs Vernon Bruggman Kathryn Woodard Norman Frazier Lawrence Hogan 12:40 p.m. (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) ZONE 2 OFFICE Rufus Baca Bill Riddick Alvin Berry Andy Kuehl Sue Lessa Donna Wade 12:55 p.m. (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) $TG 1084097 LAM025931 Wednesday, September 24 cont'd CED OFFICES & SHOPS Bill Nappier Bruce Rule Ralph Tidwell Howard Bahr 1:10 p.m (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) CAPITAL PROJECTS AREA Ben Arnold Calvin Wills Sam Sadler Woody Silvertooth Carlos Mata Mickey Nye 1 :30 p.m. (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) DEPT. 33 - LACTIC ACID Frank Bates Lester Congor Joe Johnson Don Thomas Alan Tovrea Fred Menotti 1:45 p.m. (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) DEPT. 48-56, 0X0-ALC0H0L- PHTHALATE ESTERS 2:05 p.m Tom Kennedy Bill Recknor J. T. Shipley Norbert Novak Charlie Balez Ron Istre (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) SC 17677 STS 1064098 LAM025932 Wednesday, September 24 cont'd DEPT. 53 - PHTHALIC ANHYDRIDE George Hart Bill Crowder John Ringer Kelley Stinson Billy Thompson Charlie Freeburgh 2:40 p.m (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) COFFEE BREAK (Polyethylene Safety Lab) 3:00 p.m. POLYETHYLENE CONTROL LAB Bemie Jacobs Richard Bledsoe Tommy Stewart Mary Ann Moore Don Jordan Ed Carr 3 :25 p.m. (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass (Wollin, Willock) DEPT. 35F - POLYTHYLENE Ray Burkett Charles Griffith Ken Gore Tom Gongora Trinidad Salazar Horace Bullock 3:35 p.m (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) DEPT. 35P - POLYETHYLENE 3:55 p.m. Riley Townsend John Townsend Tom Kessler Tom Herring Wendy Youngdoff Jim Horan (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) SC 17678 STG 1084099 LAM025933 Wednesday, September 24 cont'd HIGH DENSITY POLYETHYLENE PACKOUT & WAREHOUSING/BULK LOADING 4:20 p.m. Ralph Anderson Hy Treaccar Tom Hartnett Ben Mundy Harlan Bessier Betty Dunquez (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) WEST GATE Fred Herzog Bob Steinkuehler 4:35 p.m. (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) LOCKER BUILDING Tony Ozarchuk Weldon Nonnenmacher Louis Decker Gordon Dillon Eddie Gay Booker T. Watson 4:45 p.m. (Knollmeyer, Conrad) (Dunn, Fiesinger) (Mertz, Stockwell) (Payne, Cruse) (Schenck, Glass) (Wollin, Willock) SOUTH 22 (in Cars) 4:55 p.m. END of SECOND DAY of INSPECTION sc 17679 STG 1084100 LAM025934 17680 STS 1084101 LAM025935 THURSDAY, SEPTEMBER 25 PERSONNEL BUILDING Donna Dickson Glenda Meisetschlaeger Amelia Padilla Gloria Cash Martha Fletcher Frances Bond 8:15 a.m. (Knollmeyer, Hillock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass) LOCKER BUILDING NO. 1 & SAFETY SUPPLY Ken Milner Gordon Dillon Louis Decker Weldon Nonnenmacher Tony Ozarchuk 8:25 a.m. (Knollmeyer, Hillock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass) RECEPTION OFFICE & GUARD HOUSE 8:40 a.m. Glendora Hill Joe Walters Fred Herzog (Knollmeyer, Willock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass) CAFETERIA Adele McCoy Laverne Chandler Ursula Rodriguez Selma Beal 8:50 a.m. (Knollmeyer, Hillock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass) SC 17681 STG 1084102 LAM025936 Thursday, September 25 cont'd DISPENSARY Judy Made Dora Sandejas Patty Burke Tony Ozarchuk FIRE STATION Jim White Ham Hamilton OFFICE ANNEX (1st f1oor) Maxie Dillon Keith Okamoto June Edwards Else Jackson OFFICE ANNEX (2nd floor) Frieda Jones Juanita Samsom Les Salles Carol Holmes 9:05 a.m. (Knollmeyer, Willock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass) 9:15 a .m. (Knollmeyer, Willock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass) 9:30 a.m. (Knollmeyer, Willock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass) 9:40 a.m (Knollmeyer, Willock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass) SC 17682 STS 1084103 LAM025937 Thursday, September 25 cont'd MAIN OFFICE (2nd & 3rd floors) 10:00 a.m. Chris Rodriguez Inna Williams Dora Hundley Mary Williams Evelyn Harrison Gerry Kelley (Knollmeyer, Wi1lock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass) COFFEE BREAK (Cafeteria Conference Room) 10:20 a.m. RESEARCH NO. 1 Linda Lewis Bill Temple Lynell Cale John Thorman Lee Owens Rose Mary Fritz 10:35 a.m. (Knollmeyer, Willock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass)- RESEARCH NO. 2 Linda Lewis Bill Temple Lynell Cale John Thorman Lee Owens Rose Mary Fritz 11:00 a.m. (Knollmeyer, Willock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass) SC 17683 ST6 1084104 LAM025938 Thursday, September 25 cont'd RESEARCH NO. 3 Linda Lewis Bill Temple Lynell Cale John Thorman Lee Owens Rose Mary Fritz 11 :50 a.m. (Knollmeyer, Hillock) (Dunn, Conrad) (Mertz, Fiesinger) (Payne, Stockwell) (Schenck, Cruse) (Wollin, Glass CAFETERIA CONFERENCE ROOM (Seated Lunch) 12:30 p. m. CAFETERIA CONFERENCE ROOM Committee Caucus 1:15 p.m. RESEARCH 2 CONFERENCE ROOM Committee Report to Expanded Staff 3:00 p. m. END of INSPECTION SC 84 STG 1084105 LAM025939 1 NOTES *vf ^Vw/^ <* ^ X^WWJ. Aj^ ,i^~ <* .-4 * 'f'-ff. f ^^({/t ^ *SU**u> _ V -- A+<-Jt^UZ ' _ 3 j+*-iL*Jz - / x*6-o - / X/4 _ <?X - /^L ^Zf^/Y . I ^ J J^Ly ~ T---^ --z^r . ^ y^--y u4 -- ^u^JfiZ 7^-4-^ /dl_ o&H --*"*?' x--' ,^-t cLy+Z- C 0> - " 5*^Jy f-^a-M - -- >< J^***c /*.-+' Jl/s* /s. -S' --- j -- ^v ^ <- -- jc7Z.f* ,Jf~.- -~~* ^^.^.a-Ci^ 4~~L*S - - ^i' SC 17685 )(2~cjLs *l *l r' adun .< - - J_, f' /&Lt-Zii-. +* '/* ^ f*. t^y Mt 2- -?~~~h' -Hr ~L^e4 t yyt*+~ ^ 1 ^* i- $t( 108*10* LAWI025940 \.. NOTES * yis^y /, /?o mX i, rff <- _?, j3sujzX~y ~ <?. /i , / 4.. ^-< ^^JU. /<3^vt - >>^>.-^/xzsiZr^ ^V( 7. 2i, ft' fi'~'/m-* -*/'*''^' ' *** -'* ^-. -g_/ c^*c~S d$^z~> -j st4X.+ J&Ji*}- yyr. ii *-, *-#u/x2> SC 17686 *T6 1064108 LAM025941