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conoco Interoffice Communication To : Robert L. Lembke From : Allan H. Sather Date : July 13, 1978 Subject : ANNUAL MEDICAL / INDUSTRIAL HYGIENE INSPECTION ABERDEEN CHEMICAL PLANT RECEIVES mt i w m MEDKALON. Dr. Oran D. Steffey completed his annual Medical/Industrial Hygiene Inspection of the Aberdeen Plant on June 14, 1978. As was noted in his memo to you. Dr. Steffey inspected virtually all of the plant. During that inspection, he made note of items which he felt were substandard. The following is a response to the specific items noted. Dryer Building - Number 6 dryer star valve drive guard was replaced shortly after it was noted missing. Old Dryer Building V-10 Area - The support and drive mechanisms on all seven (7) plant dryers have been noted in the 1978 Plant Safety Audit as being substandard. Current plans call for a general upgrading of guards to be accomplished by January, 1979. Supply Storeroom - A continuing effort is being made by Administrative Services Department personnel to safely and efficiently organize this area such that material storage in aisleways may be eliminated. Some of the materials currently being stored in the west end of this area will be relocated to the V-10 AFE Storage Area following some security improvements. p Plasticizer Building - The hood noted in the report as being out of service is no longer needed. Development Laboratory - The air register and related duct work will be cleaned by July 14, 1978. We sincerely appreciate the recognition given by Dr. Steffey concerning the improvements made in the plant since his February, 1977 inspection. Personnel in all areas of plant operations have worked hard to accomplish them. It is indeed pleasing to us to see that the efforts have been recognized. We look* forward to Dr. Steffey's 1979 inspection. A. H. Sather Safety Director cjt c: GGD, REL t VAB.0001050276 Robert t. Lenbke, M.D. Oran B. Stefftjr June 20, 1978 ANNUAL MEDICAL/INDUSTRIAL HYGIENE INfFECTlON - ABERDEEN CHEMICAL PLANT A % During June 12-14, 1978, a trip was udt to tha Aberdeen Chemical Plant for tha purpose of physically ehacklng tha various operations from tha standpoint of 08HA standards which cover General Environmental Control Sanitation, and ganaral use of toxic and hasardoue uatarlale. Tha following areas wars covered fron a ganaral Industrial standpoint: Main Offices Adulnlstratlve Services West Warehouse Color Weigh Boon Manual Bagging Automatic Bagging Line III Dry Blend Control Boon Line I Laboratories Plasticiser Building Main Change Boon Central Break Boon Shops Storeroon Dryer Building Steen Generation Plant Conpressor Building Building Silos Dnnmed Material Storage Empty Drun Storage Lubersol Storage Reactor Areas Central Control Boon VCM Unloading Phthallc Anhydride The following comments are made relative to specific areas of the Aberdeen Plant: Dryer Building - The overhead sprocket and chain on the third shaker fron the north needs the guard replaced. Old Dryer Building V-10 Area - Pence guards should be Installed in front of roller-bearing aurfisces located on the east side os the east dryer drum and on the west of the west dryer drun. - In general, materials need to be stored note orderly. Aisles are stacked with various Items and materials. The materials in the west end of the storeroon need to be stored in an orderly manner. Plasticiser Building - The hood In the sample room Is not working. It is recossMtnded that a check be made for the use of this hood and If one exists, that the equipment be placed in operable condition. VAB.0001050277 UP " I M 1..........MPf Robert l* Uribk*! M.D. Pat* Two Jana 20, 1078 * The air register gratings need to be cleaned area. The Aberdeen Chemical Plant vas found In very good shape. The following is a partial list of improvements which have been made or which are la the process of being finished: I. A new centralised control room has been coastnaeted. 2* A new dry blend control room with restroom facilities is being finished. 3. A new dry bleed system has been installed on Line HI. 4. A new building ventilation-cleaning system hss been installed. 5. Pour new reactors haw# been located in the area of tbs old V-12 reactor building. 6. Crest improvements have bean mads In the VCM unloading area. This includes a new unloading rack system. 7. A now PTC manual bagger system is being installed. 8. Progressive improvements are being made in the color weigh room. This Includes the room end vent system being tied into the new building ventilation-cleaning system. 9. The phthelle anhydride unloading has been completely re-englneered to unload from tank cars* 10. Crest improvements are being made in the provision of offices end training rooms for the Safety Division. II. A new fire training eras has been completed end la in nee. 12. A new VCM incinerator is being completed. 13. The laboratories have been increased in else. 14. The shops and storeroom supply have been Increased In else. Management end plant personnel ere to be commended for the progress which is being made to provide e safe end healthful workplace. A Oran D. Steffey Industrial Hygienist rle VAB.0001050278 Robert L* Mkii M.D. Oran D. Staffay June 20, 1978 MXDICAL/INDUSTRIAL HYGIENE INSPECTION - ABERDEEN TRANSPORTATION WAREHOUSES AND TRUCK MAINTENANCE FACILITIES On Jana 14, 1978, part of ay tlaa vai apant at tha Abardaan Transportation Warehouses and Truck Maintanaaca facilities. Tha purpose of tha visit was to physically shack tha various operations from tha standpoint of OSBA standards which cover General Environasntal Control-Sanitation, and general use or presence of tonic and hasardous naterlals In tha work area, Tha following consents are made relative to tha Transportation Department activities at tha Abardaan area: All areas ware found clean and in vary good condition* A new oil change grease pit has base constructed along with water and oil handling facilities. Plastic roof skylighting and additional lighting as bean provided In tha repair area along with painting tha walls a white color to improve reflected light* A change-stiowar room along with lounge has been provided* Management and the personnel at these facilities are to be commended for their continued interest and efforts to provide clean, safe, and healthful working areas* Oran D. Steffey Industrial Hygienist rla VAB.0001050279 Robert L. Lembke, M.D. To Jim Landers A Date 4/14/77 For your Information. ORIGINAL SIGNED BY ROBERT L. LEMBKE. M. D. iDiCAi! uuoroi Robert L. Lembke, M.D. Medical Director cc with att: Lowell C. Reed bcc with att: CLW HHJ WWM ODS*'' nwnuMiiiwp VAB.0001050280 conoco Interoffice Communication To : Dr. R. L. Lembke From I G* G* Draper Date : April 6, 1977 Subject : INDUSTRIAL HYGIENE INSPECTION - FEBRUARY 7-10, 1977 RECEIVED Am 12 an MEDICAL DlV. The attached memo from A. H. Sather outlines the Aberdeen Plant's action program developed as a result of Dr. Steffey's inspection of our facilities on February 7-10, 1977. G. G. Draper ct Attachment c: REL VAB.0001050281 Interoffice Communication * To : C. G. Draper From : A. II. Sather D.ite : April 5, 1977 Subject : INDUSTRIAL HYGIENE INSPECTION - FEBRUARY 7-10, 1977 RECEIVED APR 12 m The following comments arc in response to those made by Dr. Oran D. Steffcy in his Aberdeen Plant Industrial Hygiene Inspection Report dated 2/18/77. DRY BLEND CONTROL A Central Vacuum Cleaning System will be installed under AFE. 9176 through out the Compound Department Area. Our Mechanical Engineering Group has targeted completion for 7/77. This will place a Central Vacuum System outlet inside the Dry Blend Control Room. PLASTICIZER BUILDING Jerald V. llptain lias done some preliminary job task sampling in this area. Samples taken to date Indicate that our sampling equipment is inadequate for current needs. A high-volume sample pump (88 liters per minute) has been identified for purchase under the 1977 Safety Equipment AFE. The high-volume drawn by this sampler will allow us to gather definitive exposure samples within the required limits of accuracy for short-term exposures (less than 5 minutes). COMPRESSOR BUILDING The stored materials noted in this area will be moved to a relocated storage building north of the Powerhouse Building by 4/IS/77. This will eliminate the congestion around equipment in the west end of this building SI I0PS t? The maintenance area improvements noted during Dr. Steffey's inspection have begun. The stores area relocation is now complete. The layout for the Instrument Shop has been finalized and contract let for construction. Current estimates for the completion of this project is the second quarter in 1977. p COLOR WEIGH ROOM The color weighman has been instructed to use the foot operated pad for controlling the ventilation system while weighing up material, (ihcmi.cn 1 exposure monitoring will be conducted to determine if an exposure problem exists. VAB.0001050282 (I. G. Draper Industrial Hygiene April 5, 1977 Page 2 Inspection A OUTSIDE DRUMMED CHEMICALS STORAGE Material stored in the noted damaged corrosive chemical storage drums will be transferred to new drums by 4-29-77. The Administrative Services Raw Material Group will check this area on a monthly basis to insure that any damaged containers are taken out of service immediately. New signs will be ordered and pressed into service as soon as they are received. POWERHOUSE BUILDING The new control room is progressing at a sat is Factory rate. Dr. Steffey's recommendations for the maximum segregation of foodstuffs and water analysis chemicals have been adhered to in the design specification. PHTHAL1C A1INYDRIDE STORAGE APEs 9565 and 9027 covering the much needed improvements in the Phthalic Anhydride Unloading System arc currently under construction with an estimated completion date of 5/16/77. To date, 2 design and safety reviews have been held. The first review occurred following the design phase of the project and the second occurred after the unloading equip ment was placed and the piping phase was nearly complete. A final pre startup safety review is scheduled prior to unit startup. We enjoyed having Dr. Steffey visit our plant. Ilis comments were viewed as constructive and are appreciated. We look forwarded to his next visit. A. 11 Sa t her Director ct c: Department Meads VAB.0001050283 CONFIDENTIAL Interoffice Communication To From Daw R. F. Hoffine, Aberdeen, Mississippi Robert L Lembke, M. D., Ponca City, Ok 1 *kruny February 28, 1977 Subject Medical-Industrial Hygiene Inspection - Aberdeen Transportation Warehouses and Truck Maintenance Facilities As you know, on February 8, 1977, Dr. Oran Steffey. Industrial Hygienist, Medical Division, made an inspection of your Transportation warehouses and truck maintenance facilities. Attached for your information is a copy of Dr. Steffey's report to me. The report is self-explanatory. You are to be commended for the continuing improvement of your facilities from a medical-industrial hygiene standpoint. S15KCD BTf ROBttiT L LEWiBKE, M. D. MEDICAL DIRECTOI Robert L. Lembke, M. D. Medical Director ems Carbon copy to: Bob Cleaver, Houston Blind copies to: B. R. Brown Lowell C. Reed C. L. Whetstone, M. D. W. W. Massad, M. D. TJ U Trvnoo J) # A r VAB.0001050284 Interoffice Communication To From Date Subject Robert L. Lernbke, M.D. Oran D. Steffey February 18, 1977 MEDICAL/INDUSTRIAL HYGIENE INSPECTION - ABERDEEN TRANSPORTATION WAREHOUSES AND TRUCK MAINTENANCE FACILITIES On February 8, 1977, part of my tine was spent at the Aberdeen Trans portation Warehouses and Truck Maintenance facilities. The purpose of the visit to these areas was to physically check the various operations from the standpoint of OSHA standards which cover General Environmental Control - Sanitation, and general use of toxic and hazardous materials. The following comments are made relative to specific areas of the Transportation Department activities In the Aberdeen area: East Warehouse Plant Area - This area was found to be clean and in good shape. Prairie Warehouse - Facilities were clean and in good shape both inside and outside. The truck maintenance has been moved from the location near the west highway entering Aberdeen to the Prairie Warehouse facilities. This affords much more room and a very good storage area for parts and equipment. We were asked to make recommendations concerning belt-fly wheel guarding of two air compressors. One Is now located within the parts and equipment area and sits In such a position that guarding Is not felt to be necessary. The other compressor Is located in the work area of the maintenance shop near one of the doors and this one should have a guard or fence sufficient to prevent exposure to moving belts or fly wheels. A question of sufficient lighting was posed. Discussion suggested that light colored plastic panel sky lighting be provided in the roof in this particular area. Painting the celling, rafters, and walls white would most certainly Increase the lighting quality of the area. It should be realized that If plastic sky lighting Is Installed with the thought of It being less expensive and it Is found to not afford sufficient lighting, other means will have to be used to solve this Important problem. Whatever Is done. It Is recommended that lighting quality readings be made to be sure that sufficient lighting is provided In the various areas commensurate to the jobs which are being performed. Every person concerned with the transportation operations in this area Is to be commended for his efforts, attitudes, accomplishments. It Is a great pleasure to meet with these people at this facility. * Industrial Hygienist rla VAB.0001050285 CONFIDENTIAL conoco Interoffice Communication Tp Gary Draper, Aberdeen, Mississippi From Robert L. Lembke, M. D., Ponca City, Oklahoma Oat * Subject February 28, 1977 t Medical-Indus trial Hygiene Inspection - Aberdeen Chemical Plant As you know, during February 7 to 10, 1977, Dr. Steffey made an Industrial hygiene inspection of your chemical plant* Attached for your information is a copy of Dr. Steffeyfs report to me. The report is self-explanatory. You are to be greatly commended for your efforts and progress in improving your plant from a medical-industrial hygiene standpoint. As always, we appreciate the courtesies shown our staff during their visit to your plant. We appreciate your cooperation very much, and we also hope that you and your staff might find us as cooperative. OftICIHM BY MBKU IW ft J., i feiviyfW MMOQit . Robert L. Lembke, M. D. Medical Director ems Carbon copies to: Allen Sather, Aberdeen Robert W. Gerwig, Houston Leon Vernon, Houston R. E* Lehmkuhl, Houston Dave Kuhn, Houston Blind copies to: B. R. Brown Lowell C. Reed C. L. Whetstone, M W. W. Massad, M. D H. H. Jones, M. D. -O. D. Steffev A VAB.0001050286 Interoffice Communication To From Date Subject Robert L. Lembke, M.D. Oran D. Steffey February 18, 1977 ANNUAL MEDICAL/INDUSTRIAL HYGIENE INSPECTION ABERDEEN CHEMICAL PLANT During February 7-10, 1977 a trip was made to the Aberdeen Chemical Plant for the purpose of physically checking the various operations from the standpoint of OSHA standards which cover General Environmental Control - Sanitation9 and general use of toxic and hazardous materials. The following comments are made relative to specific areas of the Aberdeen Plant: Administrative Services Area - This area was found to be In good condition. Storage Overhead the Transportation Offices - The wood railings around the periphery of the open storage area have been replaced with rigid all metal railings and the area has been cleaned. The closed storage area has been cleaned and the air conditlonlng/utlllty room has been renovated and cleaned. Main Offices - These offices were found to be in good condition. The storage room In the engineering offices has received housekeeping attention and Is clean and orderly. Line I - This area was found in good condition. Line III - This entire area was shut down at the time of this Inspection but was found to be clean. * Dry Blend Control - This room was found In good shape. It is recommended that an Industrial vac be used to control and clean dust off equipment* walls and floors in this room. Laboratory - Discrepancies which we have reported in the past have been corrected within feasible limits. The plans are to expand these facilities which should allow for proper dealing with recognized problems. Main Lunch Room - This area was found to be clean and In good condition. The celling had been lowered and lighting Installed therein as per our recommendations. The food and soft drink vending machines were clean and sanitary. Plasticiser Building - This building was found to be clean and In good condition. It Is recommended that operations In this building be monitored for substances In work room air to define what may be present during operations and then extend the efforts to personnel monitoring for specific substances. VAB.0001050287 A Robert L. Lembke, M.D. February 18, 1977 Page Two Compressor Building -- This building was found to be in good shape for the most part* It Is recommended that materials which appear to be temporarily stored In the west end of the building be moved to another more acceptable storage location* The present condition presents somewhat of a congested area around equipment* Dryer Building - This area was clean and In good condition* Shops - Plans are to upgrade the area for the ventilation of welding fumes and a general renovation of the area is being recommended Supply Storeroom - A new storeroom has been constructed and moving into this area was in progress* This will allow more room for the purpose of supply storage and the old area, utilised by the supply storeroom, will be used by the electrical shop* Color Weigh Room - The foot operated pad for controlling the motor-fan ventilation system to the dust removal hood was not being used. This foot operated pad should be left on the floor in front of the hood and weigh scales and under all circumstances of weighing materials it should be used to activate ventilation. It is recommended that work room air dust sampling and personnel dust monitoring be done In this area* Outside Drummed Chemicals Storage - The Drummed Chemicals Storage located In the fenced area southeast of the East Warehouse has a number of leaky caustic drums* These are located along the west fence of this area and are delineated by a chain to which a "Danger -- Hazardous Material" sign had at one time been attached* The sign had been removed and was laying atop one of the leaking drums and was In a state of corrosion. Materials In these drums should be removed to new drums, the contents should be labeled, and the "Caution" sign should be replaced* It is recommended that this entire storage area be periodically checked for damaged or leaky containers and appropriate actions be taken for safe containment and proper labeling* Powerhouse Building -- It is recommended that when the proposed control room is built the water-test bench and associated chemicals be placed In a part of the room sufficiently removed from the area in which food or coffee might be consumed or where personnel might be required to be most of the time during recording of operational conditions. In addition to the comments made on the above areas, the following observations are made: Management personnel at the Plant appear to be quite aware of the industrial hygiene and safety problems associated with the Phthallc Anhydride Storage* Much effort is being made to complete a system which will allow for the transfer of phthallc anhydride from rail cars to the storage tanks. VAB.0001050288 Robert L. Lembke, M.D. February 18, 1977 Page Three It Is agals reco--ended that during the tine vhes this system Is being coupleted, proper safety and maintenance checks be made on the existing equipment used in the handling of phthallc anhydride transfer and atorase. The Aberdeen Chemical Exposure Abatement Program was discussed with Mr. Gerald Uptain. This program Is thoroughly supported by me and I would urge full Implementation of the plan. VCM Personnel Dosimetry Plan changes were also presented by Mr. Uptaln for my consideration and comments. These appear to allow for discontinuance of much personnel monitoring while allowing the efforts of the program to exceed the VCM standard's requirements In this area. If this indeed proves to be the case, I would approve that this plan be instituted. Many improvements have been made and are being made at the Aberdeen Plant. Management and safety are quite aware of the problems which must be solved. These people are to be commended for their efforts and their attitudes. Any industrial hygiene recommendations and statements relative to discre pancies as written into any Medical/Industrial Hygiene report are meant to constructively indicate interest for further Improvements which should be carried out for both the safety and health of our workers. In no way is this meant to reflect against the fine work accomplished and that which is in progress. Oran D. 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Draper Date November 29, 1976 Subject DR. 0. D. STEFFEY'S OCT. 3, 1976 INDUSTRIAL HYGIENE INSPECTION OF THE ABERDEEN PLANT 4 rOK ** jHEDtCM- DW. The attached memo from Mr. A. H. Sather to G. G. Draper outlines the Aberdeen Plant's action program developed as a result of Dr. Steffey's inspection of our facilities on October 3, 1976. You will note that we have covered in considerable detail the work that has beeen completed and is ongoing in our Phthalic Anhydride Storage Area. This is in response to Dr. Steffey's statement that the same general con ditions existed in this area as had been noted in his April, 1976 inspection. As outlined in Mr. Sather's memo, work in the phthalic unloading area has been progressing at a rate consistent with sound engineering principles and although there are items yet to be completed, there has also been significant progress. We plan to complete the three phthalic anhydride unloading projects currently in progress in the first quarter of 1977. This will leave one additional project which is provided for in the 1977 Capital Budget. This project will be designed to contain phthalic anhydride vapors within the plasticizer building and outside storage tanks and is scheduled to be completed in the last quarter of 1977. * We appreciate Dr. Steffey's comments as outlined in his report. However, the majority of the items in his inspection related to general safety and house keeping items, many of which had previously been identified and action initiated as a result of our Safety Department's area audits and our Employee Safety Action Request Program. We would appreciate it if in future inspections, H Dr. Steffey would direct his emphasis to Industrial Hygiene problems such as chemical exposures. This is an area where we could certainly use the expertise of an Industrial Hygienist and based on proposed governmental regulations will become increasingly critical to our operation. Again, we appreciate Dr. Steffey's comments and look forward to his next visit. G. G. Draper jf Attachment c: RWS, AHS, REL VAB.0001050298 \ | G. G. Draper November 19, 1976 Semi-Annual .Industrial Hygiene Inspection Page 2 I A DRYER BUILDING* 1 2 3 4 H in Roof Area - Work on several of the items mentioned in this section of the report had already begun when Dr. Steffey made his inspection tour. Those items are as follows: p 1. The piping crossover handrails on the south roof walkway have been revised. * * r 2. Material was on order for the dryer exhauster belt and coupling guards. This project has since been completed. 3. The dryer building roof lighting item was the subject of an ESAR (Employee Safety Action Request) submitted on 7/27/76 by C. Hawkins and will be estimated by 12/8/76. L" 4. A work order requesting fiberglass roof walkways was being estimated at the time of Dr. Steffey's visit. Material to be ordered by 11/31/76. Temporary repairs will be made until material is received. Walkway sections will be replaced on an "as needed'1 basis after materials arrive until all walkways have been replaced. * Other roof area problems currently being corrected: 1. The roof edge safety railing will be repaired by 1/31/77. 2. All exhauster area walkway gratings will be secured no later than 1/1/77. * 3. Roof sections that are in need of repair will be estimated by 12/15/76. Until the time that repairs can be made, the affected areas will be roped off and "DO NOT WALK ON ROOF" signs' installed. Inside Areas - First floor motor-to-pump coupling guards have been checked and will be repaired or replaced by 12/15/76. Centrifuge deck grating has been repaired or resecured. The need for fresh air stations is being checked on a plant-wide basis. Where there is a continued need, new couplings will be provided as needed and protective caps provided on all couplings. m i Old Vinyl Maintenance Shop - Some large reactor project material is currently being stored in this building. This material will be moved into the old V-10 reactor building when the contractors have completed the work (estimated completion date 1/1/77). The machine oils stored on the east pad of the building will remain in that location. A sheet metal barrier wall will be installed on the south end of the machine oil storage area by 1/15/76. Fabrication welding will be discontinued on the southwest pad of the build ing until the barrier wall is installed. VAB.0001050299 G. G. Draper November 19, 1976 Semi-Annual Industrial Hygiene Inspection Page 3 Shops - The main shop will be rearranged as soon as the storeroom is moved to its new location. A new electrical system will be installed per Conoco and OSHA standards. Welding fume hoods are going to be installed as a part of the approved shop equipment AFE and welding screens will be used whenever welding is in progress. Shop revision scheduled for first quarter of 1977. 'm # i Maintenance shop personnel have been told that if they cannot keep their coffee urn and cabinet clean and sanitary, they will no longer be able to make coffee in the shop. The cleaning,solvent currently in use is non-flammable and is generally recognized as safe in this application. Solvent vat to be relocated in maintenance shop revision. Fume hood to be included in project scope. h t Fire Pump House - All oil drums and dead grass have been removed from this area. The guard rails will be installed by 12/30/76. t Old Scrap Unit - All power to this unit has been disconnected. Contract with used equipment purchaser specifies that the equipment be removed from area as it stands. i i * t Dry Blend Roof and Silo Equipment - Drive belt guards on dry blend roof and inside silo 475 will be enclosed by 12/31/76. Water drainage between silos 476 and 490 has been estimated and is currently waiting on approval. VCM Sample Bombs - Valve nipples on sample bombs are to be sealed with caps before samples are brought into the laboratory area. The caps have been ordered and received. We are currently waiting for chains to permanently attach caps to bottles. This project to be complete by 12/10/76. Plant Drinking Fountains - Fountains will be cleaned by prescribed method by building attendants in those areas assigned to building attendants. All other fountains to be cleaned by operating personnel. Cleaning frequency, t once per week. Old Dry Chem Storage Building - This building currently houses: 50 pound bags of Methocel, 100 pound fiber drums of Hydroquinone, drummed DOP and isoprene, along with several items of misc. equipment. Each of these items is used in the large reactor area in small quantities. The building is scheduled to be dismantled as a part of the capacity replacement project in the very near future. Large reactor area personnel enter this building once or twice per shift for ten-to-fifteen minute intervals to get needed raw materials. The isoprene will be moved from this area to V-ll. Due to the short future of this building, no additional ventilation will be installed. Since the only liquid material to be stored in this area will be moved, the Safety Department has approved the removal of the existing safety shower. VAB.0001050300 i G. G. Draper November 19, 1976 Semi-Annual -Industrial Hygiene Inspection Page 4 Phthalic Anhydride Storage - Contrary to Dr. Steffey's report, conditions in this area have indeed improved since his last visit in April. The following items have been completed since April, 1976. 1. The second phthalic*anhydride storage tank has been put into service. This additional storage capacity has allowed us to place railcar size orders in preference to tank truck size orders. The data shown below illustrates that point. Jan.-March, 1976 April-Oct., 1976 Number of PA Railcars Number Jof PA Trucks % of Railcars by Weight i i * Only two bulk trucks 4 used since 5 7 64% July 1, 1976. 21 11* 83% A. The increased number of railcars has resulted in fewer connect/ disconnect operations to unload the same amount of material. B. Railcar unloading hoses are connected to the car by threaded fitting or 4 bolt flange as opposed to the "Karri-Lock" type fitting used to connect unloading hoses to tank trailers. 2. Phthalic anhydride is now unloaded during daylight hours only. 3. The following personal protective equipment is now required when plant personnel are unloading phthalic anhydride; face shield, long sleeve jacket or coveralls and gloves. H 4. In the past, we have discovered manhead gasket leaks during heat-up and have changed the gasket ourselves. Our purchasing department has notified our suppliers that cars found in this condition will be returned. * h In addition to the above, progress on the following AFE projects is continuing at a steady pace: 1. AFE 9204 - Phthalic Anhydride Unloading Revisions - p A. A new rail spur for phthalic anhydride cars is complete. **B. m C, New unloading rack and ramp to provide ease of acccss/egress to car dome is now complete except for ramp cylinder air supply. This project is to be completed by 1/31/77. Remote pressurization station to be completed by 1/31/77. D. Revised unloading piping to be complete by 1/31/77*. VAB.0001050301 6. G. Draper November 19, 1976 Semi-Annual Industrial Hygiene Inspection Page 5 A (This AFE was initiated in response to the recommendations made by the injury investigation team report of the yard operator injury of July 28, 1974, mentioned in Dr, Steffey's report. Let me emphasize the fact that this injury could not have occurred in 1976. This injury was the direct result of a trapped "hot gas pocket" in the unloading line. All phthalic anhydride cars that enter our plant are equipped with a "steam-jacketed" unloading line specifically designed to eliminate trapped gas pockets. If a car is not so equipped, we will not accept it for unloading). 2. AFE 9375 - Phthalic Anhydride (QMS) - **A. Completion of inert gas piping system for inert blanketing of railcars, storage tanks, and tank trailers with C02 bottle backup system targeted for 1/31/77. **B. Revised phthalic anhydride tank top gauging platform is complete. I C. Rre-unloading pressure test connections have been installed in the unloading lines to eliminate leaks before the system is "heated-up". f 3. AFE 9365 - Safe Handling of Phthalic Anhydride - **A. i i A new truck unloading station will beinstalled to the east of the new rail spur. **B. Additional safety shower. **C. p ** Improved lighting. p All items part of a mechanical bid package to be issued 12/8/76 and completed by 1/31/76. Steam tracing, insulation, painting, and electrical to be complete by 2/28/77 for system start-up. 4. 1977 Capital Budget Item - Phthalic Anhydride Emission Control Project - r .< This system is designed to contain phthalic anhydride vapors within the plasticizer building charge vessels, outside storage tanks and unloading vessels (cars and trucks). During Dr. Steffey's visit on October 3, 1976, a PA railcar was observed with a heavy deposit of crystallized PA on the unloading nipple. This is what undoubtedly led Dr. Steffey to report that there had been little progress made in this area since his April, 1976 visit. The leak had been detected when pressure was applied to the car to initiate the unloading process. When the leak was detected, the operator shutoff the inert gas used for pressuring up the car and proceeded to close the unloading valve. However, this car was not equipped with a shutoff valve on the unloading nozzle which resulted in the fitting leaking until the car dcprcssurcd. VAB.0001050302 G, G. Draper November 19, 1976 Semi-Annual industrial Hygiene Inspection Page 6 4 i A To prevent a reoccurrance of this type, the following procedures have been implemented: A. Specifying, in a written PA unloading procedure that we will not accept any phthalic anhydride cars that are received without properly installed unloading equipment. (A Koppei'S Chemical bulk railcar has been received without an unloading line. Our Purchasing Department has specified to Koppers that this car will not be unloaded until a valve is installed on the unloading line, or the car is replaced by one that is equipped properly). B. New pressure testing connections installed on 11/11/76 will be utilized for testing the integrity of the system prior to starting the unloading process. They can also be utilized for blowing transfer line clear follow ing unloading nozzle shutoff if a leak develops. Current personnel dosimetry data from the phthalic anhydride handling areas indicate that all jobs and process vents which provide possible overexposures will either be phased out or eliminated by the projects currently in progress and the 1977 capital project. A1 Sather r mm VI A VAB.0001050303 ABERDEEN PERSONNEL EXPOSURES TO VCM - NOT WEARING RESPIRATORS - 1975-1976 Brewer, Jimmy 4/75 * 6.1 Yard operator, helping unload a VCM rail car. Gates, Elmer 7/75 - 15.6 Warehouse worker, was moving fresh bagged resin from the vinyl bagging area Into East Warehouse. Harlow, Willis 11/75 5.98 Maintenance mechanic, working on D-600 gearbox. Hawkins, Charles 4/76 2.34 Large reactor operator, changing VCM filters. 6/76 1338 Large reactor operator, cause not known for sure. Suspected exposed while changing of slurry transfer lines on blend tanks. Johnson, Don 1776 6.1 Large reactor operator, cause not given. Vinyl dryer utility, while worklgg In V-ll Dryer Building. Patterson, Randy 7/75 * 18.5 Warehouse worker, was moving fresh bagged resin and worked on shrink wrap operations. lay. Cacti 4/7$ * 2.9 5/76 ** 1.66 Transportation warehouse worker, while transferring fresh resin from the staging area to the East Warehouse. Same reason. Stanton, Tommy 7/75 * 20.6 Laboratory technician, beaker of liquid VCM was being boiled off for peroxide test In a malfunctioning lab hood. Transportation warehouse worker, moving fresh resin from staging aaea to East Warehouse. 4/36 1.67 Transportation warehouse worker, moving fresh resin from staging area to East Warehouse. York, Charles 4/75 * 13.6 Development lab technician, VCM sample bomb valve leaked In laboratory. Young, Cohn 7/75 18.1 Warehouse worker, working on shrink wrap operations. VAB.0001050305 *1 VAB.0001050306 * I O s tro v s k i, Gevdon______ I 1 13.91 3 .0 I 114.2 'V * rt VAB.0001050307 i v r*Fh- . Jinld Uptain - AbtrdMB ChMietl Plant Oran D. Staffay - Ponca City* Oklahoua Hirraibtr 24, 1974 CONOCO CUTTING OIL AMD 30LU1LS OIL 4a par your inquiry va ara sanding your offlea Infers*tion far tba lngradlanta ef Ceaoeo Spaatrun 011*220 and Ceneae Soluble Oil 7931* Cannae Spaatrun Cutting 011*220 Inaradlant .!+ 5513 Croaa Cut SulfurlsadOil 5514 Creaa Cut SulfarlsadOil 4M323 * Gear Oil Additive, di-alkyl phosphate 4X325 * Chlerewex ,/ 4M550 * Synthatle Sulfurlsad Spurn Oil AX220 - FaraflewXax-Maphthalene Ccabinetion with traaas ef chlorine (four depressant and dewaxing aid) Raw Sulfur X by Tol-- 49*10 44.25 0.50 3*00 2.80 0*10 0*25 Ceneae Soluble Oil 7931 Ingredient X by Tola*. 5510 Maphthaala 100 Purchased Blending Oil 5717 170 Pale Neutral Oil 4X194 Detergent * Dispersant 4X193 Datargant - Dispersant 4X194 Datargant * Dispersant 4X195 Datargant - Dispersant 4X344 Maphthaala Mid 4X547 Triethanolantes Potaseiua Hydroxide 31.13 32. ao 8.45 0.90 3.23 0.63 0.67 0.48 1.23 Me would invite your inquiry into any ether cutting fluids you nay have far use in your plant* Any followup infemstloe having to do with the health prohlens Which nay be related to setting ells will ha sent to your office. Oran D. Steffay Xnduatrial Hygienist rla 4 r HIfW *r *VW VAB.0001050308 itmW *4*.