Document gbEXpEgLddr5rQRxVDmdGJQ0N

TO: H. R. Jepsen, Jr. Monthly Report SUBJECT: October, 1977 FROM: C. S. Cunaning LOCATED AT: Leominster, Ma. DATE: November 8, 1977 - 4-- * Z, c*. c- HIGHLIGHTS: 1. On October 17, 1977, c. Cunaning tendered his resignation effective November 15, 1977. 2. Contracts were approved to replace portions and make major repairs to the Polyco alarm and sprinkler systems. Work will commence in November. 3. Acceptance tests were performed on the new diesel fire pumps by the con tractor, insurance carrier, and safety departments. The Leominster Fire Department was invited to attend as observers. 4. Operation of the new fire pumps resulted in an overpressure and failure of an underground water main on October 21, 1977. The break was isolated with no fire protection impairment and repairs were completed on October 25, 1977. 5. Industrial Risk Insurers conducted a periodic inspection of the site October 17-21, 1977. A number of formal recommendations were deleted from their list as a result of the extensive work performed in the last few months. 6. Lost Time Injury - October 1, 1977. Sherman Streeter was knocked to the ground by a contractor's supervisor after a steam line ruptured in the new pump house. Sherman sustained a fractured hip and will be out of work for several months. VINYL CHLORIDE CONTROL: 1. Monitoring Summaries (Personnel) A. Monthly Monitoring Tests 1. Personnel on Regulated Roster 2. Personnel Tested 3. Personnel Tests 4. Invalid Tests 5. Repeat Tests 6. Area Tests 7. Total Tests 188 182 189 13 23 5 230 B. Monthly Average by General Job Categories 1. PVC Operators 2. PVC Helpers 3. Dryer Bldg. 4. PVC Supv. &Eng. 5. Polyco 6. Shipping 7. Maintenance 8. Development 9. Oper. & Admin. 10. Total Site 1.5 2.2 1.2 1.2 0.9 0.3 1.1 1.8 0.2 1.2 2. Area Monitoring A. VCM Monitoring 1. High Level Alarms a) PVC Reactor Rooms b) PVC Dryer Bldgs. c) other pvc Points d) Polyco Reactor Rooms e) Other Polyco Points 90 1 13 9 52 BOR 013657 H. R. Jepsen, Jr. Monthly Report - October, 1977 From: C. S. Cumming Page - 2 A. VCM Monitoring (con't) 2. Low Level Alarms a) PVC Reactor Rooms b) PVC Dryer Bldgs. c) Other PVC Points d) Polyco Reactor Rooms e) Other Polyco Points 356 15 49 18 59 B. MAC Room Status 1. Bendix Monitoring System a) System #1, Monitoring 16 points recorded alarms as listed below: High Level Alarms Low Level Alarms 28, duration of alarms in minutes 4,966 537, duration of alarms in minutes 18,205 Percentage of time system 1 points in alarm - 3.24% b) System #2, Monitoring 15 points recorded alarms as listed below: High Level Alarms low Level Alarms 188, duration of alarms in minutes 8,391 773, duration of alarms in minutes 22,590 Percentage of time system 2 points in alarm - 4.63% c) System #3, Monitoring 9 points recorded alarms as listed below: High Level Alarms Low Level Alarms 61, duration of alarms in minutes 11,757 77, duration of alarms in minutes 1,944 Percentage of time system 3 points in alarm - 3.41% Total number of alarms for the month of October - 1,664 Total alarm duration in minutes - 67,853 Percentage of time all points in alarm - 3.80% 2. Bendix Monitoring Equipment Downtime 1. Systems 1 & 2 experienced no downtime. System 3 was down for 240 hours (32.2% of available time) due to failure of a heater element. 3. HnU Unit Status All three units are operational at this time. 4. Monitoring Equipment Expenses A. Bendix Corp. $565.00 B. HnU, Inc. 39.60 C. A.J. Sipin &Co. 310.00 D. Total Expenses $914.60 5. Summary Leaking manholes continue to be the primary source of excursions. It appears that operators are not being sufficiently supervised since many leaks are the result of failure to follow procedures. Other excursion sources are leaking flanges and valve packing. We have a continuing problem with Procedures Supervisors failing to investigate excursions. A critical failure of our present daily and weekly reporting system is the consistent absence of reasons for alarms. This seems to indicate ither that the Supervisors are not investigating any but the most serious alarms or that they are not taking the time to record the data. BOR 013658 tt. R. Jeps n, Jr. Monthly Report - October, 1977 From: C. S. Cumming Page - 3 5. Sunmary (con't) Enforcement of respiratory protection regulations has become virtually nonexistent. Supervisors at all levels below Superint ndent have been observed in alarm areas with no respiratory protec tion in use. On several occasions it was pointed out to the Supervisor that protection was required but no cooperation was forthcoming. If supervision continues to set an example like this, we cannot hope to enforce safety regulations of any type on the site. EPA CONSTRUCTION 1. Procedures A. Procedures were written and established, as listed, that will be in effect during the entire construction project: 1. Hot Work Permits 2. Coordination of EPA construction and Borden Operational Require ments 3. Monitoring of EPA construction personnel for Exposure to Vinyl Chloride 4. Evacuation of EPA construction personnel during alarm conditions 5. After hours work by construction personnel B. In addition, other policies were established in letter form concerning the following: 1. Personnel control 2. Regulated area sign in logs 3. Reporting of lost construction time during alarm conditions 4. Weekly C&R manpower report 5. Entrance to regulated areas 6. Smoking areas 7. Fire Watch responsibility 8. Parking areas 9. Adherence to Borden safety procedures Signs were made and posted at the pipe fabrication facility indicating Hot Work and smoking will cease during alarm conditions. Signs were also posted at entrances to areas off limits to construction personnel. 2. Events A. Due to extensive burning and welding at the new recovery building area, the column recovery system was shut down and evacuated for approximately 3 weeks. A fire guard (D. Picard) was in the area during all burning and welding. B. An incident occurred on 9/27/77 when construction personnel closed a valve which supplies water to the Bldg. 1-W deluge system. Borden personnel were unaware that the valve had been closed and consequently the deluge system was without supply water overnight. The incident is discussed in detail in C. Cumming's letter dated 9/30/77, subject: Fire Protection Equipment. The incident was discussed with construction supervisors informing them of the seriousness of what occurred and that compliance with the Coordination Procedure would eliminate a recurrence. C. While excavating for the gasholder foundation at Polyco, an 8" fire water line was discovered that did not appear on our blueprints. With the aid of DuPont drawings, the line was found to be capped on DuPont property west of the Polyco tank farm. The line was then isolated and capped south of hydrant house #11 near th Polyco railroad siding. This eliminated the interference at the gasholder foundation area. BOR 013659 H. R. Jepsen, Jr. Monthly Report - October, 1977 From: C. S. Gumming Page - 4 2. Events (con't) 0. No major construction delays occurred that were related to Borden operations. Construction personnel evacuated the site twice during the month for approximately 15 minutes on each occasion. Both were the result of activation of PVC fire alarms neither of which was fire con nected . FUTURE ACTIVITIES I. Take over of Safety Department functions by various operations groups. 2. Commencement of work on Polyco alarm and sprinkler systems (upon award of contracts - November, 1977). CSC/kxs cc: Book (15) D. Moreira (10) Slocumb C. Snyder BOR 013660 I c c1: --C4 0duo2. a rHTMCCOfli u cdH 0-p2 oB n *pfP--H* 02 ffl J034) 0P2 ^acP a V- > < *-upopv <D e->op OIj wc ,pci od3 OM c0p~* to rH *dop p*H->* dP o ox: aiaa* r_" C --* >i 3o3 CO 1-- C --tjI toSOu-i C0 &* TdC3 ip 0cPoci r-H paCaHO s iEoHd-P* eo E-* -0P3 oJ PVC PCLYC3 7 5 ! 0f 0 0 4 1L--1 : 2 *1 f 2 1 22 1 11 1 0 0 o i 1 0 0 } i: 0 0 2 ! 4 0 .**A-Lil * JC*irUl Cllj s:-:ippi:;j It'CL'-GPZR SALARY TOTAL i 10 p- i- 2 j1 3 1 0 i .. 0 0 1 8 1 iX -* --t----------- -2|--1 0 ------- -t 10 ........ 0L 0 1 0 0 5!1 i 1 0i 0 0 0 1 1 0 0 0 4 1 !0 j1 : 12 0 7 o! f JL 0 "H---------- -J 21 1 : I 0i * o> V 4i 3i i--. o: 3! 0: 2 0 4 1 43 0 4 c? Uo 4-> 0 oJoJ o 0) p> CO 0 Z-* u 1 -P C to 3o S PJ -P to O t--1 CO > d a CO p p 0 ZZ C aS S PVC 21 7 i ! 3 1 123,480 P0LYC0 4 0 1 0 i 44,284 MAINT ' 7 1 6 60,233 SHIPPING i:o::-dper 41 3. 1 1 32 1 1 ; 26 23,995 111,606 SALARY TOTAL 0! i 39 0: o 4 : 67 224,533 590,254 0) a P -p 0 d d -P os d cc <V -P aj PS a O >> c P p -P o H H pd o4 c4 0) 0 5> > u M <l> a> Cz-t CO CO C-- t- 'O t-- C^ t-- Cn 0^\ ON ON pH rH pH pH cc c-* P> -P CO CO rc\ c-- h--. P> CO "p1 dd i-J PJ oo oo cd p< p 10 CO CO CO ^-1 GJ d 0) o d~t 7 E, *T 0 T! ' --i 8.1 25.7 24 322 37 :118,694 0.0 0.0 0 0 135 132,244 16.6 63.1 99 695 21 34,907 41.7 8.9 0.0 1334 6.4 233 0 I 103 4 2,101 3 15,543 0.0 0.0 0 0 , 6.77 13.9 113 171 -- 3 42,007 BOR 013661 man Ad Kirs rirTTuKSS hkpodt KMPLOYKK INJURIES y\Nl) IIJ.NKSSES RECORD TYPE STATISTIC CONTROL (DIVISION USE ONLY) ORIGINAL REVISION DIVISION CODE ESIS LOCATION CODE DIVISION_________ ' 12 A THIS MONTH THIS YEAR TO DA TE B LAST YEAR TO DATE PLANT or BRANCH _The rmop la s tics-^Leominster MON 7>/________ OctoberYEAR 2-222___________ 7 9 10 11 Man hours 13 - 20 21 56,010 56,010 29,120 est F1 RS T A1D CASTS _ _- 25 25 N/A TOTAL HECORDA8LE INCH DENTS 23 24 24 2 2 TOTAL RECOROABlE INCIDENT RATE 7.14 . 7.14 68.70 i^ O RECORDABLE INCIDENTS TOTAL LOST workdays NUMBER OF LOST WORKDAY CASES 27 29 30 - 32 57 1 57 1 00 LOST WORKDAY CASE RATE 1.8 1.8 0.0 INCLUDE ONI V LOST WORKDAYS AND l OST WORKDAY CASES UNDF R COLUMN 9A OF THE LOG, L-10O CURRENT YEAH GOAL ----------------------------- DATE EMPLOYEE NAME OCCUPATION DEPARTMENT BRIEF DESCRIPTION OF ACCIDENT CAUSE OF ACCIDENT LOST WCOARSKED{A/)Y FATALITY (*) 10/5 S. Streeter Safety Hlp'i Safety Employee Knocked Down Unsafe Act by Contractor X 10/11 R. Primeau Util. Hlp'r PVC Chemical in Eye Unsafe Act by Other Emp. -- -- --- - ------------- ------------------ ----------- ------ -- ----- --- -........-- -- -- -------- -- ------------- - ---------- - ........... ----- -- COMMENTS ON ANY SAFETY TRAINING JOB ANALYSES & COMMITTEE ACTIVITIES T*ie increase in first aid cases is primarily a result of an improved reporting system rather than a rash of injuries. MAIL TO DIVISION SAFETY OFFICE NO LA TER THAN THE 2nd WORKING DAY OF THE MONTH COVERING THE PRIOR MONTH RESUL TS, BOR 013662 uau. MANAGE Ft November 7, 1977 DATE TOTAL HI LOHUAliU 1NCI D1 NT H A11 NO Or RECORDABLE- INCIDENTS X 200.000 manhounsworkln LOS T WORKDAY CASE HA TL 'NO. or lost WORKDAY CASES X 200.000 MANHOURS WORKED t Dl VISI ON RECORD TYPE Chemical MANAGER'S PROGRESS REPORT VEHICLE ACCIDENTS OHIG \ A REVISION STATiST'C CONTROL (DIVISION USE ONLY) DIVISION CODE ests location code r l> PLANT or Thermoplastics BRANCH Leominster MONTH____October 7 YEAR 1977 9 10 TATE employee NAME "T OCCUPATION description of accident PREVEN7A9LE (P) DOT \0V reportable PREVENTA3LE (NP) __ ________ + T I MAIL TO DIVISION SAFETY OFFICE NO LATER THAN THE 2nd WORKING DAY OF THE MONTH COVERING THE PRIOR MONTH RESULTS DRIVER TRAINING numbe r of smith SYSTEM INSTRUCTORS NUMBE R OF SMITH SYSTE M DRIVE RS NUMBE R OF DOC INSTRUCTORS ,'VBE R OF DOC DRtVERS THIS MONTH I YEAR-TO-DATE j 0 | l---------- ----------- _---------- ------------ ---- I__________ ... --------------- ------ - ....... 1.- 0 -___-___ . |0 ____ .,_1_,,_____________________________________ 0 COMMENTS ON DEFENSIVE DRIVER TRAINING (e.g., __ ___________ __________________________________________________________________ DDC, SMI TH SYS TEM, etc.) VEHICLE MILES PREVENTABLE VEHICLE FREQUENCY RATE = NO. OF PREVENTABLE ACCIDENTS X 1,000,000 VEHICLE MILES JJQR 013663