Document bkB4gNr9QGxj2R4NKBo3x8ok

*CC f SOtTO Monsanto rtOM (NAM| l LOCATION) SuftjfCT J. T. Payne, (SS-18), Texas City, Texas July 13, 1984 SHAC MINUTES - 7/11/84 ce G. L. T rccrib 1 ee M. A. Riddle 0-10 0-22 tfHUNCf TO : SHAC Members: p. Bailey w. Monel a D. Richards A. Stal, Jr. T. Hartmann 2Z 513D 1Z OA-11 0-22 These are the minutes of the July 11, 1984, SHAC ccrrmittee meeting. Future SHAC Meetings July 18 July 25 12:30 p.m. 12:30 p.m. Cafeteria Conference Rocm Cafeteria Conference Room Shutdown Safety Maintaining safety performance during shutdowns has been a problem In ( the past. A detailed safety plan has been developed to guide people to a safe shutdowns. A 12-minute AN safety film has been developed by Joe Swain. A 5-minute safety orientation at the start of every shift will be implemented. Safety reminders may be used in the areas and structures. Supervisors may be required to turn in 1 STOP card a day during the shutdown. Annual Inspection Techniques were Investigated to permit feedback to as many hourly persons as possible. The inspection results will be presented in the cafeteria. A second draft of the annual Inspection guidelines and inspection tour schedule (attached) was reviewed for approval. Feedback is requested by the next meettng. Contractor Safety Program The contractor safety program has been reviewed with purchasing. An action plan has been developed with purchasing for implementation. The contractor safety program is being put into the p-bulletin form. Questions have been raised on Implementation of the respirator fit certification of the contractor safety program. It Is anticipated that the program will be reviewed with contractor beginning the week of July 23rd. A 5-minute safety film will be developed by Joe Swain. SC 000885 LAM002083 r SHAC MINUTES - 6/20/84 Project Assignments PAGE 2 Project Rep. Status Parking Area Designations Emergency Center Phones Assembly Point Signs Methanol Incident Emergency Drill ( Nov 1) Contractor Safety Film (5 min.) J. D. Richards R. T. Hamnann J. D. Richards J. Stal S. Monc1 a J. D. Richards Areas are being designated. Changing phone nos. Waiting on phone nos. In progress General Permit Procedure The biggest problem with the general permit is maintenance reluctance to sign the permits. A review of the general permit problems and success will be made before August 1. Escape Mask There are 410 escape masks ($123k) existing In the plant. Training on half of these Is performed annually and half of the owners do not train ( on use of the masks. AN has 192 of the escape masks. SHAC recommends that the following be done: 1. SAC should develop a statement of what the escaped masks are going to be used for. 2. Each of the owners of escape masks should evaluate their need for escape masks relative to the SAC position statement. 3. Each owner of the masks should develop a training program on the masks. 4. Each owner should keep records on the training and record inspection of the masks. 3rd Quarter SHAC Safety - Housekeeping Awards The 3rd Quarter SHAC Safety - Housekeeping awards will be give out on July 12. SHAC will meet at the carport at 8:25. ( v dTP:sr Attachment J. T. Payne SC 000886 LAM002084 ANNUAL INSPECTION PREPARATION ACTION PLAN DATE 7-1 7-23 8-1 8-6,7,8,9,10 8-15 8-30 8-31 9-4 9-5 RESP. STATUS Inspection route and timing defined - dry runccmpleted to determine parking places, cars needed, guide meeting place. JTP 6 JDR Complete and attached. Assign Office Safety Committee responsibility for publicity. RTH Complete. Send copy of previous inspection, reconmendations to Superintendents. JAS Believed complete. Send out notice that all ladders are to be Inspected and new tags attached by 8/3. RTH Encourage Plant Manager, Plant Engineer, and Safety Superintendent to be in the plant the 2 weeks prior to the Inspection. EPB Obtain pictures and information on the Inspectors. JAS 3rd Quarter Safety Housekeeping Insp. SWM Guides named for each area of plant. SHAC member will host each Inspector rotate at noon each day. Plant Manager Safety Superintendent will freelance. General Superintendents will meet team at each area of responsibility. JTP JDR SHAC drive around inspection -- made s11des. SWM All reconmendations from last annual Inspection completed. Route and guide list published and issued. Information for inspectors (booklet, etc.) completed. Name tags (name and position) completed for inspectors, guides, etc. Lunch arrangements completed (catered by cafeteria). JTP JDR JAS RTH EPB Mail information to inspectors. Include pictures and history of inspectors in plant newsletter. Expanded Staff -- review slides, inspection details and check list. JAS LAM002085 JAS SC 000887 9-10 9-12 9-14 9-18 9-19,20,21 10-1 SHAC/Plant Manager drive around Inspection - take slides. Plant Manager mail letter to all employees heme. Obtain equipment for inspectors -- hard hats (with names), safety glasses, ear plugs, cover goggles, rain gear (suits and boots), name tags, and temporary badges. SWM EPB RTH Expanded Staff meeting -- review slides. SWM Drive around Inspection -- each General Superintendent accompanied by two SHAC members. Short wrap-up staff meeting after inspection. SWM Evening meal with inspectors and presentations. Tromblee, Forsthoffer, Hammann and Chairman of SAC, SHAC, TCSC, OSC, HSC. EPB Inspection SHAC Feedback JAS.'sr 6-12-84 -2- sc 00888 LAM002086 1984 TEXAS CITY SAFETY AND HOUSEKEEPING INSPECTION GUIDELINES THEME SAFETY THROUGH EMPLOYEE INVOLVEMENT EMPHASIS AREA ' Involvement of People in Safety ' Safety Results and Trends ' STOP Program ` Adherence to Safe Procedures and Practices ` Acceptance of Personal Responsibility for Safety ' Attitude and Awareness of Safety at all Levels ' Evidence of Management's (all levels) Commitment to Operate Safely ' Health and Industrial Hygiene Programs ' Programs for Good Housekeeping and Preservation of Assets ' Use of Promotional Activities ' Follow-up on Last Year's Inspection Recommendations INSPECTION DATE The plant will be inspected September 19, 20, 21, 1984. INSPECTION TEAM General Superintendent Superintendent Engineer Foreman Hourly (One of the above should be from Process Technology) RATINGS The inspection committee will not give the plant an overall rating?? Individual areas will be given ratings, and plaques will be awarded to the best area in each of four categories: units, crafts, labs and offices and services. Evaluations will be made based on safety performance, policies and practices, housekeeping conditions and involvement of people that ensures an effective, sustained safety attitude for outstanding safety performance. Outstanding - Stands out from all areas (comparison based on theme criterion). No safety practice deficiencies. Housekeeping performance equal to achievement potential. SC 000889 LAM002087 1984 TEXAS CITY SAFETY AND HOUSEKEEPING INSPECTION GUIDELINES PAGE 2 Excellent - Very favorable compared to acceptable standard (based on theme criterion). Very few safety practice deficiencies. Housekeeping performance nearly equal to achievement potential. C Good - Favorable compared to acceptable standard (based on theme criterion). Few safety practice deficiencies. Housekeeping performance at acceptable level. Unsatisfactory - Inferior compared to acceptable standard (based on theme criterion) Unacceptable level of safety deficiencies. Unacceptable housekeeping level. Areas rated will be all units (including outside battery limits), main shops, instrument shop, electrical shop, stores, control lab, Research 1, 2 and 3. INSPECTION RESULTS The general results of the plant inspection, including the outside areas, will be communicated Monday, September 24, 1984. The results will be communicated with the expanded staff, SHAC, Technical Center Safety Committee, Office Safety Committee and Hourly Safety Committee, Unit-Craft Safety representatives, and Unit-Craft Safety promotion team present. Group size has to be limited due to seating available in the cafeteria. 000890 SC C UAM002088 *1 INSPECTION TOUR SCHEDULE FIRST DAY: WEDNESDAY, SEPTEMBER 19 Arrive Texas City (Personnel Building Training Room) 8:00 a.m. PRESENTATIONS 8:15a.m. 1. Overall Texas City Safety Program Minutes R. T. Hammann (Bob) Loss Prevention & Safety Supt. 10 2. Plant Manager's Safety Board (PMSB) and Safety Advisory Committee (SAC) 10 3. Safety and Housekeeping Action (' Committee (SHAC) E. P. Bailey (Paul) 10 4. Plant Manager's Comments G. L. Tromblee (Gene) 5 5. Inspection Kickoff 5 6. Discussion Distribution of Safety Equipment 10 BEGIN INSPECTION 1 -1- 9:00 a.m. LAM002089 SC 000891 1984 INSPECTION TOUR SCHEDULE FIRST DAY: WEDNESDAY, SEPTEMBER 19 C Walk To Power 2. WATER TREATING - PLANT AIR - POWER 2 0900-0940 Treatment of raw Brazos River water for plant use and generation facilities for breathing, instrument, and general plant air. Facilities for steam generation and boiler feed water treatment. HOSTS INSPECTORS SHAC MEMBER Meet in Control Room Pick up cars parked by cylinder racks beside Stores. Drive to Acetic Acid Control House. DEPT. 50 ACETIC ACID Acetic Acid is produced from carbonylation of methanol. This area includes catalyst preparation and product distillation facilities. HOSTS INSPECTORS SHAC MEMBER 0940-1010 Park beside Control House. Meet in Control Room. Drive to Phthalic Anhydride Control House. COFFEE - PHTHALIC ANHYDRIDE (Arrangements by Department) -2- 1010-1025 C SC 000892 U/VI002090 1984 Inspection Tour Schedule, Wednesday, September 19 (Continued) DEPT. 53 PHTHALIC ANHYDRIDE 1025-1055 Manufacturing process which uses BASF technology to convert air and orthoxylene to phthalie anhydride. HOSTS INSPECTORS SHAC MEMBER Park beside Control House. Meet in Control Room. Drive to Dept. 48-56. DEPT. 48/56 0X0 ALCOHOL-PHTHALATE ESTERS Oxo alcohol area uses CO + H2 blend gas and olefins as raw materials. Phthalic anhydride and oxo alcohol used to manufacture phthalate esters. HOSTS INSPECTORS SHAC MEMBER Walk to Dept. 33. DEPT. 33 LACTIC ACID, DRUMMING FACILITIES & CT-8 Manufacturing for pharmaceutical grade lactic acid from lactronitrile. HOSTS INSPECTORS SHAC MEMBER Park at Formaldehyde Storage Area (77T101). Meet in Control House. 1135-1205 Meet in Control House. Pick up cars at 77T101, drive to car port. LUNCH - Trays in Cafeteria Conference Room. SC 000893 -3 - LAM002091 1984 Inspection Tour Schedule, Wednesday, September 19 (Continued) Walk to Zone I Office. ZONE I OFFICE Offices and conference room used by maintenance personnel for styrene process. HOSTS INSPECTORS SHAC MEMBER 1300-1310 Walk to Operating Engineers Offices. OPERATING ENGINEER OFFICES Offices for operating engineers personnel. HOSTS INSPECTORS SHAC MEMBER Walk to Fire Station. FIRE STATION Two buildings which house the Texas City plant's fire fighting facilities. HOSTS INSPECTORS SHAC MEMBER Walk to Electric Shop. 1320-1335 00089* SC -4- LAM002092 1984 Inspection Tour Schedule, Wednesday, September 19 (Continued) ELECTRIC SHOP Consists of central shop facilities and offices for power distribution, electrical maintenance, and maintenance engineering personnel.Walk to AN loading rack. HOSTS INSPECTORS SHAC MEMBER 1335-1350 AN LOADING RACK, ESTERS LOADING RACK Rail car handling facilities for acetic acid, methanol, TBA, sulfuric acid, IBY, ACH, and esters. HOSTS INSPECTORS SHAC MEMBER 1350-1410 Pick up cars at truck loading spot west of 51T17-2. Drive through North Storage. PA LOADING RACK Rail car handling facilities for phthalic anhydride. HOSTS INSPECTORS SHAC MEMBER Drive to Dept. 513 Control House. SC 000895 -5- 1410-1420 Park north of reformer. LAM002093 1984 Inspection Tour Schedule, Wednesday, September 19 (Continued) PRIMARY TREATMENT, AMMONIA TANK 1425-1450 Facilities for primary treatment of all plant aqueous waste streams. Ammonia storage tank provides raw material for AN manufacturing facilities at Texas City and Chocolate Bayou. HOSTS INSPECTORS SHAC MEMBER Meet at 513 Control Room. BARGE & SHIP DOCKS 5, 4, 3, 2, 1 Barge and ship loading/unloading facilities for raw materials, products, used at and produced by Texas City plant. HOSTS INSPECTORS SHAC MEMBER 1450-1530 Meet at Dock 5. Drive through sandblasting, NSI Warehouse, Maintenance Laydown, Salvage Areas 1530-1600 -6 - 000*9 SC *1 LAM002094 1984 INSPECTION TOUR SCHEDULE SECOND DAY: THURSDAY, SEPTEMBER 20 CAFETERIA CONFERENCE ROOM - Coffee & Rolls Drive through South 22. HOSTS INSPECTORS SHAC MEMBER MATERIAL HANDLING OFFICE BUILDING Offices for supervision of distribution operations, materials handling foreman and clerk; mail room, printing & office services; QA Lab offices. HOSTS INSPECTORS SHAC MEMBER 0800-0815 0815-0825 Park cars beside old Pilot Plant. 0825-0835 SUPER SHACK, AN INCINERATOR, DRIVE THROUGH STYRENE RACKS, ACY RACK AND EAST STORAGE HOSTS INSPECTORS SHAC MEMBER 0835-0855 SC 000897 -7- LAM002095 1984 Inspection Tour Schedule, Thursday, September 20 (Continued) DEPT. 13 AKLYLATION, CT-1 Ethylbenzene is produced by the reaction of benzene with ethylene in the present of an aluminum chloride-organic catalyst complex. r0855-0925 HOSTS INSPECTORS SHAC MEMBER Park south of 14-16 Control House by Smoke Shack. Meet in Control Room. DEPT. 15 DEHYDROGENATION Synthesis area for dehydrogenation of ethylbenzene to crude styrene. HOSTS INSPECTORS SHAC MEMBER 0925-0950 Meet in Control Room. COFFEE - SYTRENE-EB (arrangements by department) 0950-1005 DEPTS. 14 & 16 STYRENE - EB DISTILLATION Dept. 14 - Ethylbenzene purification facilities. Dept. 16 - Styrene purification facilities. HOSTS EB INSPECTORS SHAC MEMBER 1005-1035 Meet in Control Room. SM Drive to Salt Water Pump House and Zone 1 Warehouse. -8 - 000898 SC C > LAM002096 1984 Inspection Tour Schedule, Thursday, September 20 (Continued) SALTWATER PUMP HOUSE AND ZONE 1 WAREHOUSE 1035-1050 HOSTS Zone 1 Warehouse INSPECTORS SHAC MEMBER Split Team. Pump House LUNCH - Trays in Cafeteria Conference Room Walk to Stores. STORES Stores includes the shipping and receiving docks, storage bins of inventory items, and offices. HOSTS INSPECTORS SHAC MEMBER 1100-1130 1130-1200 Pick up cars in car port. Drive to Warehouses. WAREHOUSE A-B-C-F-G Warehouse A contains class A materials such as spare parts, paper goods, packing materials. Serves receiving function. Warehouse B contain flammable liquids, acid, paint. SC -9- 1200-1230 000899 LAM002097 1984 Inspection Tour Schedule, Thursday, September 20 (Continued) Warehouse C contains class A materials, such as, insulation, packing. Warehouse E contain materials needed for maintenance work orders. Warehouse F contains long storage items, such as, mechanical equipment. Warehouse G contains dry raw materials, such as, iodine, Fullers Earth, etc. HOSTS INSPECTORS SHAC MEMBER Split team. Park across from Zone 2. ZONE 2 OFFICE Offices for west plant maintenance personnel. HOSTS INSPECTORS SHAC MEMBER 1230-1245 Drive to car port. RESEARCH NO. 1 This building houses analytical, catalyst characterization, radioisotope, and MIC Tech Services labs and bench scale reactor systems. HOSTS INSPECTORS SHAC MEMBER 1245-1255 - 1300-1340 Meet 1st floor west side. - 10 - SC 000900 n LAM002098 1984 Inspection Tour Schedule, Thursday, September 20 (Continued) RESEARCH NO. 2 1340-1440 This building houses Technology Dept, and Industrial Hygiene labs, AN Catalyst Preparation facilities and AN and Styrene bench scale reactor systems. The instrument development and control department is located upstairs. HOSTS INSPECTORS SHAC MEMBER Meet at Visitor's lobby Northwest corner - 1st floor. RESEARCH NO. 3 This building houses MMTS offices, QA Lab chemists offices, crafts and maintenance offices and MMTS labs and shops as well as lab supply overstock. HOSTS INSPECTORS SHAC MEMBER 1440-1455 Meet at North entrance below stairway outside. PT WAREHOUSE & SOLVENT STORAGE HOSTS INSPECTORS SHAC MEMBER 1455-1505 Walk to Main Office Building. COFFEE - CAFETERIA (arrangements by Cafeteria) 1505-1515 SC 000901 - 11 - LAM002099 1984 Inspection Tour Schedule, Thursday, September 20 (Continued) CAFETERIA Main plant cafeteria. 1515-1525 HOSTS INSPECTORS SHAC MEMBER Meet at cash register. DISPENSARY Provides facilities for emergency first aid and for monitoring employee health. HOSTS INSPECTORS SHAC MEMBER 1525-1535 MAIN OFFICE - 2nd, 3rd and 4th floors Main Office building for manufacturing, distribution, environmental, safety, personnel and marketing personnel. HOSTS INSPECTORS SHAC MEMBER QUALITY ASSURANCE LAB Laboratory facilities needed to conduct analyses required for production and shipment of petrochemicals from Texas City plant and for environmental control. HOSTS INSPECTORS SHAC MEMBER - 12 - 1535-1555 Split teams. Meet in foyer. 2nd Floor 3rd Floor 4th Floor 1555-1630 sc 000902 LAM002100 1984 INSPECTION TOUR SCHEDULE THIRD DAY: FRIDAY, SEPTEMBER 21 CAFETERIA CONFERENCE ROOM - Coffee & Rolls OFFICE ANNEX First floor of this building contains office for Technology Dept., Engineering Services and Guest Tech Service Group, Central Files, technical library and computer room. HOSTS - INSPECTORS SHAC MEMBER Second floor contains office facilities for Accounting, MIS Department with computer facilities, Plant Engineering Technical Support. HOSTS INSPECTORS SHAC MEMBER PERSONNEL TRAINING, PURCHASING BUILDING Building contains plant purchasing offices, training facilities, video tape lab. HOSTS INSPECTORS SHAC MEMBER 0800-0815 0815-0840 Split Teams. Meet in Main Lobby. Meet in Front Entrance 1st floor. 0840-0855 Meet in Personnel Building Training Room. SC 000903 - 13 - LAM002101 1984 Inspection Tour Schedule, Friday, September 21 (Continued) LOCKER BUILDING NO. 1 & SAFETY SUPPLY Building houses separate lockers, showers, and changing rooms as well as the safety supply store. HOSTS INSPECTORS SHAC MEMBER r0855-0910 GUARD HOUSE Major plant entry gate with offices for supervisors and security group. HOSTS INSPECTORS SHAC MEMBER 0910-0920 Drive to Dept. 51. DEPT. 51 ACRYLONITRILE, CT-9 Two reactor trains and a single purification train ar used to produce acrylonitrile, acetonitrile and hydrogen cyanide as a by-product. Ammonia and propylene are used as raw materials. Includes slip stream reactor. (Start in South end, end near MeOH.) HOSTS INSPECTORS SHAC MEMBER 0920-1025 Meet in Control House Park East of Control House off South St. Drive car to methanol COFFEE - METHANOL (arrangements by dept.) 000904 SC - 14 - 1025-1040 t 1 LAM002102 1984 Inspection Tour Schedule, Friday, September 21 (Continued) DEPTS. 44-45-46 METHANOL, CT-3&4 1040-1110 Methanol , CO, and H2 are produced by steam reforming of natural gas and C02. CO and H2 are used in the production of oxo-alcohol and acetic acid. HOSTS INSPECTORS SHAC MEMBER Meet in Control House DEPTS. 19-23-25-27-29 HCN-ACN-TBA-LN-ACY, CT-2 Manufacturing facilities for acetonitrile purification, tertiary butyl amine, lactonitrile and acetone cyanohydrin. HCN Storage. HOSTS INSPECTORS SHAC MEMBER 1110-1205 Meet in Control House Drive car to Cafeteria LUNCH - Trays in Cafeteria Conference Room SHOP BUILDING Central shops consists of facilities for pipe fabrication and plate and exchanger, machine and paint shops. Building also includes training rooms and various maintenance offices. HOSTS INSPECTORS SHAC MEMBER 1305-1330 Meet at Shift Office SC 0090s - 15 - LAM002103 1984 Inspection Tour Schedule, Friday, September 21 (Continued) SOUTH MAINTENANCE BUILDINGS, INSTRUMENT SHOP & GARAGE Building include carpenter-insulator shop, instrument department shop, field maintenance offices, and garage facilities. HOSTS Maintenance INSPECTORS SHAC MEMBER Instrument 1330-1415 RECAP 1415-1630 SC 000906 - 16 - LAM002104