Document evON8ELw5q2rX3YQNqrdnQQRp

PLANT MANAGER'S SAFETY BOARD MINUTES OF MEETING JANUARY 1983 Present were: G.A. Danner G.W. Daues R.M. Fritz D.E. Kaldenberg B.C. Lancaster D.D. Kos C.N. McClanahan D.W. Metten S.G. Pappas G.T. Ryan J.G. Trafton G.L. Tromblee J.A. Glass R.T. Hammann I. REVIEW OF STATISTICS--J.A. Glass A. Texas City Plant Safety Performance Summary - December PLAINTIFF'S EXHIBIT (A) INJURIES WITHOUT LOST WORKDAYS (medical treatment only) (B) LOST WORKDAYS CASES **Bt RESTRICTED ACTIVITY **B2 DAYS AWAY FROM WORK CASES (C) FATALITIES *TOTAL RECORDABLE CASES DEC YTD 0 18 17 00 17 00 1 25 DEC YTD 0 13 05 00 05 00 0 18 11 2 -- -- -- 13 28% INJURY RATES PER 200,000 MANHOURS 1981 DEC YTD 1982 DEC YTD 1982 TARGETS 1982 MCIC TARGET YTD TOTAL INJURY-TIR TOTAL RECORDABLE-TRR TOTAL LOST WORKDAY-TLWR DAYS-AWAY-FROM-WORK-DAWR 3.45 0.69 0.69 0.69 13.66 1.47 0.41 0.41 7.33 0.00 0.00 0.00 10.07 1.08 0.30 0.30 ___ 0.75 0.12 ----- ----- 1.45 1.18 ----- 0.36 0.24 sc 002491 LAM03698 PMSB Meeting Minutes--January 19, 1983 Page 2 B. Comments on Statistics--J. A. Glass Year end 1982 safety performance showed the following: 30 year record low mlmber of total injuries (168 vs. 233 in 1981) * 28Z reduction in total recordable cases (18 vs. 25 in 1981) 82 recordable rate (108) was lower than MCI target (1.45) and overall average (1.18). Days-away-from-work cases were lower than last year (5 vs. 7 in 1981) the DAW rate (0.30) was slightly higher than the MCI overall average (0.24) HONOR ROLL COMMENT Dept. 33 No injuries all year. Dept. 48/56 Beat best previous year, two injuries in entire year. No injury since last September. Dept. 53 Beat best previous year, two injuries in entire year. No injury since last August. Power 2 Beat best previous year. No injuries first six months. Current trend equals best previous year. Dept. 513 Beat best previous year, two injuries in August. None before in 1981, none since. POSITIVE COMMENT Overall, the following groups showed improvement over their best previous record performance: Instrument (no recordable injury but rising Stores (had one recordable injury) Shops (had one recordable injury) Machinists (had three recordable injuries) trendline) The following groups were within normal limits and improving during the last quarter of 1982: Painters Insulators Electricians SC 002492 LAM003699 PMSB Meeting Minutes--January 19, 1983 Page 3 ALSO IMPROVING The following groups had rising trendlines and showed improvement during last quarter: Analysts HCN Complex CAUTION GROUP The following groups have rising trendlines within normal limits: Laborers Pipefitters Carpenters Boilermakers Pumper Gaugers Department 51 The following groups have rising trendlines and are above normal limits: Department 50 Department 44/45/46 Department 13/14/15/16 C. Contractor Safety--C. M. McClanahan Total plant contractor safety showed a continued reduction in all categories. The full year being significantly lower than last year. However, Capital Project injuries were slightly higher in all areas except Total Days Away Rate. Details for this group are attached. D. CED Project Safety--B. C. Lancaster This group showed a remarkable reduction in Total Injury, Total Recordable and Lost Work Day cases and continued a decline in injury rates that began in 1979. This impressive record was made while undertaking fifteen projects with greater than $100M in capital addi tions using 1300 new hires. We are quite proud of this fine record that CED has accomplished at this site. Details are attached. II. REPORT OF THE SAFETY ADVISORY COMMITTEE (SAC)--G. W. Daues Greg Daues called for reports on the recommendation of the 1982 Safety and Property Protection Survey item 82-2 Emergency Shutdown/Standby Procedures. Each General Superintendent was instructed to report in writing their comment prior to the February PMSB meeting. J. A. Glass reported on the status of the recommendation for a survey of low pressure steam "boots". A meeting was held with Paul Bailey who sc 002493 LAM003700 PMSB Meeting Minutes--January 19, 1983 Page 4 outlined that their department's position was that corrosion occurs on low pressure steam lines due to water leaking under insulation. It is vitally important to maintain a good water barrier coating over the insulation. A plantwide inspection of all of the low pressure boots would be economically unfeasible. Paul agreed to develop an inspection test program for checking a-'Treasonable number of these low pressure steam boots to determine the nature and extent of the plantwide problem of corrosion at these locations. The program will be circulated for review prior to the next Plant Manager's Safety Board meeting. III. REPORT OF THE PLANT SAFETY AND HOUSEKEEPING ACTION COMMITTEE (SHAC)-- D. D. Ros A. Hourly Safety Committee 1. Six of eight in attendance (one retired, one vacation). 2. Reviewed last PMSB meeting highlights, methanol plant flare incident, chemical burn incident in control lab, IDA waste spill, and new 1983 safety calendars (to be posted on bulletin boards). 3. Physical Fitness Promotion Article given to Donna Dickson for Plant News. 4. Plant concerns: a. First Flange Rule - no policy or consistency. b. AN-5 pump seal leak. c. HCN piping at WOB has open flanges versus Departments 19 and 77 policy of blind flange use (special training program scheduled). B. Eyebath/Safety Shower The proposed standard was submitted to PMSB for comments. Very few were received. Comments were incorporated. With SAC and PMSB approval, a SHAC Alert will be issued, introducing the new standard, and requesting retrofitting action plans on double eyebaths and freeze protection by end of 1984. The standard will issue to PMSB for final approval January 31, 1983. When approved, SHAC Action request will be issued. C. 1982/1983 SHAC Transition Transition meeting held January 13, 1983. Official transfer is planned January 31. SC 002494 LAM003701 PMSB Meeting Minutes--January 19, 1983 Page 5 D. Quarterly Inspections All completed January 3 through 14, 1983. Inspectors were tough and thorough. E. 1982 In-House Annual Safety/Housekeeping Inspection Critique Memo covering critique of 1982 annual inspection was issued. F. 1982 SHAC--Still Working List 1. Complete revision of two P-Bulletins. 2. Bottle disposal policy memo to SAC. 3. Develop "Competition Quarterly Inspection" publicity for 1983 SHAC. 4. Hose storage policy memo to SAC. 5. Issue safety shower/eyebath retrofit request. 6. Out of battery tank valve blinding policy incorporated into P-Bulletin. 7. Shower alarm bypassing policy and control of crowfoot on process policy addition into P-Bulletins. IV. GENERAL PERMIT PROCEDURE--R. T. Hammann After a thorough discussion by members of the Board, the Plant Manager directed that the proposed revisions be made and that following the revisions, R. T. Hammann would review the changes with Trafton, Ryan, and McClanahan prior to issue. Since this is the first time the General Permit Procedure has been put in place, it is expected that it will be tried for six months and tested in the field expecting feedback for future revisions. Appropriate training sessions must be held prior to its general use throughout the plant. V. REVIEW OF INCIDENTS The Plant Manager has indicated that incident report recommendationed actions must show person responsible and completion date. Use of func tional responsibility is unacceptable. Monsanto Incidents Date Incident No. Description 12/10/82 82-35 (issued) Spill--Dept. 77; waste surge tank overflowed into pit; high HCN levels; NO EXPOSURE. (Peebles) LAM003702 SC 002495 PMSB Meeting Minutes--January 19, 1983 Page 6 12/07/82 82-36 (issued) First Aid Case--Dept. 44; pipefitter; explosion at flare header; punctured ear drum. (Cruse) 12/14/82 82-37 (issued) First Aid Case--Q.A. Lab East; Janitor; poured sulfuric acid in caustic waste drum; minor burn to neck. (Rolingson) 12/23/82 82-38 (not issued) Operator dropped quart bottle of HCN in Quality Assurance Control Lab. VI. STATUS OF S-T-O-P PROGRAM--G. W. Daues The rate of turned in STOP cards has slacked off. Supervisors should be encouraged to continue to make the observations and report them. The STOP Program for Chiefs and Leadmen is well along and proceeding according to schedule. Actual chiefs and leadmen training will begin in February. VII. PLANT MANAGER'S COMMENTS The Plant Manager commented on the importance of the continuation of the STOP Observations and turning in the cards. Although he did not mandate STOP Observation card quotas for the plant as a whole, be expects to have them be a part of the goals for the General Superintendents. The main emphasis is on making the observations and corrections on a daily basis. Attachments JAG/es J. Arnold Glass sc 2496 LAM003703 TOTAL PLANT CONTRACTOR SAFETY TOTAL INJURY CASES RECORDABLE CASES LOST WORK DAY CASES DAYS AWAY CASES 1982 YTD ^ 54 13 3 TOTAL MANHOURS WORKED (MHW) FREQUENCY RATES/200,000 MHW TOTAL INJURY RATE TOTAL RECORDABLE INJURY RATE TOTAL LOST WORKDAY RATE TOTAL DAYS AWAY RATE 512,497.5 21.1 5.1 1.2 Dec. '82 1931 Totals 1 70 0 12 05 24 ,9 79.5 521,991 o o 8.0 26.8 4.5 0.0 1.9 SC 002497 LAM003704 CAPITAL PROJECTS CONTRACTORS * TOTAL INJURY CASES RECORDABLE CASES LOST WORK DAY CASES DAYS AWAY CASES 1982 YTD 33 6 2 Dec. '82 0 0 0 TOTAL MANHOURS WORKED (MHW) FREQUENCY RATES/200.000 MHW 213,661.5 9 ,641 TOTAL INJURY RATE 30.9 TOTAL RECORDABLE INJURY RATE _________5_6_________ TOTAL LOST WORKDAY RATE TOTAL DAYS AWAY RATE 1.9 0.0 0.0 0.0 1981 Totals 22 4 2 161,709 27.2 4.9 2.4 sc 002498 LAM003705 CED CONSTRUCTION TEXAS CITY PLANT ACCIDENT STATISTICS NUMBER OF CASES Last Workdays (Days Away) Fatalities Total Injury Total Recordable FREQUENCY RATES Total Injury Total Recordable Total Lost Workdays MANHOURS WORKED 12/82 0 0 1 0 YTD . 12/31/82 7 0 59 12 11.7 0 0 16,988 28.8 5.8 3.4 408,919 SC 002499 LAM003706 CED CONSTRUCTION TEXAS CITY PLANT ACCIDENT STATISTICS 1979 1980 1981 1982 NUMBER OF CASES Total Injury 98 Total Recordable 34 Total Lost Workdays 20 FREQUENCY RATES Total Injury Total Recordable Total Lost Workdays 140.0 48.6 28.6 MANHOURS WORKED 140,000 113 19 14 88.4 14.9 11.0 255,000 146 22 17 59 12 7 43.7 6.5 5.1 667,388 28.8 5.8 3.4 408,919 sc 002500 LAM003707 ACCIDENT STATISTICS CED TEXAS CITY INJURY RATE ----------RECORDABLE RATE LOST WORKDAY RATE LAJVI003708 SC 002501