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SAFETY & HOUSEKEEPING PLANT INSPECTION 1981 ( PLAINTIFF'S EXHIBIT MONSANTO CHEMICAL INTERMEDIATES COMPANY TEXAS CITY sc ,7sa? STG 1083988 COMPANY CONFIDENTIAL LAM025942 TO: THE 1981 PLANT INSPECTION COMMITTEE Welcome to the Texas City plant. We look forward to sharing with you our experiences, philosophies, and approach to safety. These inspec tions provide 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 be1'eve 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 sug gestions through our unit and craft safety suggestion log books. We are committed 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 quality and followup on safety programs plantwide. We are concerned by an increase in both the number and seriousness of our incidents in 1981 and are trying to find the right combination that will turn this around. 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 procedures, programs and, most importantly, our commitment. Also, please test the level of knowledge and understanding of our safety related procedures. During the feedback 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 look forward to intro ducing them to you. Sincerely, G. L. Tromblee Plant Manager SC 17688 STG 1083989 LAM025943 1981 INSPECTION TEAM NEEDHAM COPPEDGE, Chairman Plant Manager Columbia, Tennessee Plant ). R. "JIM" LOVE Project Engineering Superintendent J. F. Queeny Plant, St. Louis Q MICHAEL E. WHELAN Plantwide E & I Supervisor W. G. Krummrich Plant, St. Louis JOHN R. ZELLE Manufacturing Supervisor W. G. Krummrich Plant, St. Louis SC 17689 ST6 1083990 LAM025944 PLANT MANAGER'S SAFETY BOARD W.G.Juhl PT Director G.T. Ryan supt. Mfg. G. A. Danner Supt. Plant Serv. S. G. Pappas Energy Coordinator J. G. Trafton Supt. Mfg. B. C. Lancaster CED Site Supt. D. W. Metten Supt. Acctg. G.W.Daues Supt. Mfg. O. E. Kaldenberg Supt. Personnel C. F. Navarrete Supt. Mfg. G. E. Small Mgr. Proc. Engr. CED C. M. McCullough Plant Engineer SC 17690 LAM025945 1083991 SAFETY & HOUSEKEEPING ACTION COMMITTEE (SHAC) K. E. Bretz Mfg: Supv. ). L. Carothers Engr. Spec. J. A. Glass Supt., LP&S j.). McClellan Chairman Mfg. Supt. J. M. Gatewood Maint. Supt. K. D. Oden Group Supv. SC 17691 John Stone Safety Engr.--CED STG 1083992 LAM025946 SAFETY ADVISORY ACTION COMMITTEE (SAC) G.W?Daues Chairman Supt. Mfg. D. E. Kaldenberg Supt. Personnel C. F. Navarrete Supt. Mfg. S. G. Pappas Energy Coordinator SC 17692 ST6 1083995 LAM025947 PROCESS TECHNOLOGY SAFETY COMMITTEE P. D. Johnson Linda Lewis David Truitt Chairman Wen-Chin Liao R. L. Long W. H. Temple SC 17693 STG 108399% LAM025948 HOURLY SAFETY COMMITTEE W. E. Bean Chairman ]uly-Dec. Insulator ). M. Burkhalter Pipefitter Jessie Butler Chairman Jan.-May Prod. Foreman L. E. Derrick III Pumper-Gauger E. L. Doty Operator Austin Gates Chairman May & June Laborer Vivian Hargrove Operator C.O. Jackson Operator J. H. Martin Operator A. E. Mofley Operator Ruby Mosley Janitor C. R. Richardson Operator M. A. Riddle Safety Engineer SC 17694 R. L. Sartain Boilermaker STG 1083995 U/VI025949 OFFICE SAFETY COMMITTEE Vtr~- Dorothy Bibby PT-AN Ernestine Chuoke ESTERS-MICC Marilyn Decker PT-MEOH/HOAC Quirino Escamilla PT-STYRENE R.T. Hammann Safety Fay Hogg Material Handling Sue Lessa Chairman July-Dee Maintenance L. K. Salles MISD P. H.Siems Maintenance A. R. Sorensen PT-AN Loretta Thomas Engineering T. W. Triplett Accounting Peggy Wansbrough Chairman Jan-July Prod. Control Betty White ESTERS-MICC J.E. Williamson Plant Security Kathryn Woodard Stores SC 17695 *Te l083"6 LAM025950 ACCOUNTING SAFETY COMMITTEE H. C. Hughes Chairman SC 17696 ST6 1083997 LAM025951 sc 17697 ST6 1083998 UM025952 i Monsanto l Texas City I I A SAFER PLACE TO I WORK BECAUSE OF ME I l l l l j i LAM025953 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 MISO, 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 oprations 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 17699 STG 1084000 LAM025954 EMPLOYMENT The plant employs 1697 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 Total 969 372 136 126 61 21 2 5 5 1697 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 representef by Local 347, International Union of Operating Engineers, AFL-CIO. Security guards are represented 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 Pol ethylene used in the plastics industry as film, wire coating and molding material. This unit is expected to operate until 1983 under contract to Cities Service. Methanol used in the production of anti-freeze, formalde hyde 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 plastics. SC 17700 STG 1084001 LAM025955 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 Butyl amine (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 units. 1954 ... Construction begun on Methanol and low density Polyethylene units plus high-purity Ethylene units. 1955 ... Started up TBA unit. 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 17701 ST6 1084002 LAM025956 1969 ... 22 acres adjacent to south 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. 1973 ... Signed contract for secondary waste water treatment at Gulf Coast Waste Disposal Authority (GCWDA) regional treatment 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 started up. Low density Polyethylene dismantling complete. 1977 ... Started up new Acrylonitrile unit. Hydrogen Cyanide unit shut down. 1978 ... Chrome-Zinc removal project completed. Storm water diversion project completed. SC 17702 STG 108*003 LAM025957 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 ... Evaluation of coal utilization. Benzene Exposure Reduction project completed. Benzene pipeline from Shell and Exxon put on line. 8.7 acres south of plant leased. C02 line from Air Products to Methanol completed. 1982 MAJOR PROJECTS AN conversion to Nitto catalyst. Demonstration of phthalic anhydride energy conservation and debottlenecking projects. Install packing in EB/SM splitter column. Start-up of IDA II. SC 17703 STC 108*004 LAM025958 W .f.. JL'HI PROCESS TFCHNOLOflr * OIWECTOH W .H . STANTON DISTING UISHED * FELLOW * 2 &D C a: WJ *fftt * a < cru. e 2 C-"T~2o? 2* S a>oUaL 2c X Uab2J nI>T- foftt_ ff*tt SC 17704 e ft ---aor>t*rc/i*ywr?z i*/>caa<oji:5.f-. *t* x ^a ft Q7* *fftt ft r ft c ir c iJ STG 1084005 i /u\nn9RQR9 V *r f*t -MNp<,iA'.0f- ( ijSI * - --------------------- -- I |___ * * r,. l vrn * . s * uSiI' ACT T Process Technology Department Texas C ity A u g u s t, 1981 ^nj ,s. .v\ piRQp ftmr-m STG 1084006 LAM025960 SC 17705 MONSANTO CHEMICAL INTERMEDIATES COMPANY MANUFACTURING DEPARTMENT TEXAS CITY TE*AS JULr 15 19A1 i 4*! SC 17706 ST6 1084007 LAM025961 6cock Plow SAFETY IN FO R M A TIO N SC 17707 STG 1084008 LAM025962 afety graining and Accident Reduction Techniques Correction I I Commitment Motivation STG 1084009 i Prevention ! I l Training 1 Identification Communication SC 17708 LAM025963 J^onsanto for Safety and JJealth April 1981 SC 17709 LAM025964 OMMUNI CAT I ON c u PGRADES LANT FACE-TO-FACE COMMUNICATION: AFETY s WARENESS A F EOR MPLOYEES IN ONE-ON-ONE SAFETY MEETINGS BETWEEN ALL EMPLOYEES AND THEIR IMMEDIATE SUPERVISOR EMPLOYEES WILL RECEIVE: MONSANTO SAFETY POLICY CERTIFICATE COFFEE CUP OPPORTUNITY TO DISCUSS SAFETY IN PRIVATE WITH THEIR SUPERVISOR OVERALL THEME: COMMUNICATION OF INDIVIDUAL, SUPERVISOR AND TEAM RESPONSIBILITY FOR SAFETY sc 17710 $TG 1084011 LAM025965 Monsanto, Texas City Safety Organization POLICY FORMULATIONS & DECISIONS SC 17711 STG 1084012 LAM025966 PLANT MANAGER 33 GROUPS 150 MEMBERS supv/hourly opn's/maint 8 MEMBERS PLANTWIDE hourly INPUT 4 hEMJERS LABS AND BENCH UNITS 9 MEMBERS OFFICE WORKERS SC 17712 STC 1084013 LAM025967 TEXAS CITY SAFETY PHILOSOPHY WHERE SAFETY STARTS <^A/{onano <zSafzt\j ^PoUcjj .Safety is a primary responsibility of cstry employs at the Qtexos City Plant Che company recognises its obligation to proaibe e&rry rmploye a safe aub hraltMul place in fuhicb to bark. Co this enb, curry reasonable effort toil! be mob* in tlje interest at acribent preumtion, fire protection anb health peesemation. <AH employees are obligateb to perform their assigneb buties safely by follotoing establishrb safe barking praccbmes, using proper safety equipment, aub by reporting anb correcting unsafe acts or conbitians. s* 2^__ ^ TEXAS CITY SAFETY POLICY 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 respon sible for initiating and admi nistering an effective safety program. Each employee must fully accept the responsibility 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 manage ment 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 respon sibilities for the administration of program details. SC 17713 STG 100*01* LAM025968 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. Unless 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 Incomplete. 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 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 deviation 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 perfor mance 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 17714 jTG 108*015 LA/VI025969 INJURY RATES/CCASES) RECORDABLE, LOST WORKDAY, AND DAYS AWAY 5 - YEAR COMPARISON AUGUST 1981 3.5 ---------------------------- ---------------------------- ---------------------------- --------- 3.0 INJURY RATE INJURIES PER 2 0 0 ,0 0 0 M A N - HOURS- STG 1084016 1977 RECORDABLE RATE 1978 1979 LOST WORKDAY RATE SC 17715 1980 DAYS AWAY RATE 1981 LAIVI025970 m 1880 INSPECTIO N STATUS SC 17716 ft STC 1084017 LAM025971 1980 MCI SAFETY AND HOUSEKEEPING INSPECTION TEXAS CITY PLANT SEPTEMBER 23 THRU 25, 1980 RECOMMENDED FOR FURTHER CONSIDERATION 1. Two departments, 35P, 954, had 30-40% of their relief valve tests overdue. STATUS: Dept. 35P--All relief valves which were on the delinquent list of 1/81 were checked during the major shutdown in 2/81. This department is currently in good shape in relief valve testing. Dept. 954--Relief valve program was updated and all valve inspections are up-to-date. A problem exists with the reporting system' that is currently used for this department. Many relief valves are spares and are not checked until prior to being put in service. These show up as delinquent on the status report. Work is under way to correct this situation. 2. Although the "breaking into" procedure is being followed, we do have a concern relative to the optional use of a special work permit in the plant. For example, the HCN, phthalic anhydride, AN and PE polymerization units required special work permits and other departments did not. This can lead to confusion among the mechanics relative to whether a per mit is required for work in a given department. STATUS: PMSB decision on 7/23/80 that work permits be used on a unit or job option basis. This was recon sidered by SAC and discussed with operating and maintenance supervisors. On 11/11/80, SAC recon firmed that the 7/23/80 PMSB decision should not be changed. 3. The fire protection systems for Docks 3,4 and 5 did not include "monitor coverage" or a readily available fire water supply. We understand that an evaluation is under way to improve the protection. STATUS: Meetings were held with Safety and the final report with recommendations will be issued by R.T. Hammann by October 1, 1981. 4. In our discussion with contractors, they had an apparent healthy attitude relative to their safety responsibility but had trouble recalling what action they should take if they heard a fire alarm or an evacuation signal. SC 17717 STG 1084018 LAM025972 1980 MCI Safety and Housekeeping Inspection Texas City Plant--September 23 thru 25, 1980 Page 2 STATUS: Extra effort in communications has been under way. Heavy emphasis on this is included in safety training. Contractors were issued plant fire code stickers which attach to safety hats. A video tape is being prepared by Capital Projects for use with contract personnel in learning plant safety practices. 5. Some of our conversations, particularly in the Maintenance Department, indicated that personnel may not be getting full value out of your safety meetings. Most of the mechanics that we talked to were confused about the content of the last meeting. STATUS: In order to provide for more informal craft safety meetings that promote better participation and interest, we have changed our system to alternate each month between the regular total craft safety meeting and the decentralized zone/area meetings. 6. We endorse the program under way for respiratory protection and the individual respirator quantitative fit program that will be implemented shortly. STATUS: Extensive quantitative respirator fit testing was completed early this year. Measurements were made on a total of 719 people within the last year. 7. We do have a concern about the reliability of the breathing air system and what appears to be the lack of an automated alarming device to alert personnel of the problem. Otherwise, this system is an excellent one. STATUS: The breathing air system is presently monitored utilizing a continuous analyzer. All units are notified directly from personnel in the Utility Department if an alarm sounds indicating con tamination in the breathing air system. Work is now under way on a project that will result in a completely new and isolated system for the breathing air system. This project is expected to be completed in October. The new system will be one of the best in the industry. 8. The Monsanto Industrial Emergency Care Attendants are an important well-trained group. Better identification of the personnel in the group and publication of their availability on shifts could provide more prompt response and care until the ambulance arrives. SC 17718 STG 108*019 LAM025973 1980 MCI Safety and Housekeeping Inspection Texas City Plant--September 23 thru 25, 1980 Page 3 STATUS: Signs have been installed at appropriate locations throughout the plant. These signs not only designate that Emergency Care Attendants are in the area but also list the names of those attendants. STATUS OF FOLLOW-UP ON RECOMMENDATIONS OF THE 1980 INSPECTION TEAM 1. Where oxygen cylinders are stored with acetylene or other flammable gas cylinders, install approved barriers to isolate the oxygen. STATUS: These cylinders are stored in the same dock at Stores but not together. A safety rule we follow for oxygen cylinders and other oxidizers is as follows: Oxygen cylinders in storage shall be separated from fuel gas cylinders or combustible materials a minimum distance of 20 feet or by a non-combustible barrier of at least 5 feet high having a fire resistance rating of at least one-half hour. Since there isn't enough room at the present cylinder dock to build a barrier and the oxygen cylinders are stored 20 feet away from the flammable gas cylinders, no action has been taken. This conforms to 0SHA Standards. 2. Audit the storage of flammables in the control labora tory to insure the use of proper containers and storage areas. STATUS: Flammable storage cabinet was installed. Retained samples, some of which are flammable, are stored in refrigerator and wooden shelves at ambient temperature. A new refrigerator has been installed for storage of these retained samples. 3. Consider instituting a procedure that requires the installation of a fire extinguisher on all mobile equip ment . SC 17719 ST6 1084020 LAM025974 1980 MCI Safety and Housekeeping Inspection Texas City Plant--September 23 thru 25, 1980 Page 4 STATUS: This is standard procedure and mobile equipment is now equipped with extinguishers. 4. Fully communicate the hose inspection and testing proce dure to ensure compliance. STATUS: Action Plan--SHAC prepared a bulletin board announcement. Objective: Plantwide compliance to be confirmed by First Quarter 1981 Guest Housekeeping Inspections. This was done. Publicity being repeated in third quarter 1981. 5. Consider expanding the training for hourly personnel (particularly mechanics) to imprne their knowledge of the hazards and handling precautions for the toxic materials that they work with. STATUS: Plantwide craft safety training has been con ducted on AN burn hazards and NSI hazards. In addition, the new MICS system has process hazards information as a part of work data on the CRT. This is available for all craftsmen. 6. Reemphasize the lockout procedure to insure full compliance. STATUS: Action Plan--All departments reviewed lockout procedure for compliance. In addition, we identified some conditions that require special attention (i.e., when maintenance removes lock before work is completed--shift change). /br SC 17720 STG 1084021 LAM025975 T O U R G UIDE SC 17721 STG 1084022 LAM025976 TOUR GUIDES Chairman N.Coppedge J.Love First Day: TUESDAY A.M. - October 13 Methanol; Acetic Acid; Acrylonitrile McClellan Stone TUESDAY P.M. - October 13 Gatewood Zone 1 Office; EthylbenzeneStyrene; Control Lab; Material Handling Office; Docks; Primary Treatment - North 68 Storage; Electric Shop; Stores McClellan M.Whalen Oden Carothers J.Zelle Bretz Oden Second Day: WEDNESDAY A.M. - October 14 Shops; Garage; Water Treating; Power 2; Hydrogen Cyanide Complex WEDNESDAY P.M. - October 14 AN Loading Rack; Warehouses; Zone 2 Office; CED Office & Shops; Capital Projects Area Lactic Acid; Oxo-AlcoholEsters; Phthalic Anhydride; Polyethylene facilities; West Gate; South 22 Storage Carothers Bretz Gatewood Oden McClellan Stone Stone McClellan Third Day: THURSDAY A.M. - October 15 Personnel Building; LockersSafety Supply; Main Gate; Cafeteria; Dispensary; Fire Station; Office Annex; Main Office; Research Buildings McClellan Carothers Bretz SC 17722 Gatewood STG 1084023 LAM025977 SC 17723 ST6 1084024 LAM025978 SITE MAP SC 17724 STG 1084025 LAM025979 SC 17725 1064026 LAM025980 INSPECTION TOUR SCHEDULE FIRST DAY: TUESDAY. OCTOBER 13 Arrive Texas City (Personnel Building Training Room) Coffee and Rolls Inspectors Meet Staff 8:00 a.m. PRESENTATIONS 1. Overall Texas City Safety Program J. A. Glass (Arnold) Loss Prevention & Safety Supt. 2. Plant Manager's Safety Board (PMSB) and Safety Advisory Committee (SAC) G. W. Daues (Greg) Supt. of Mfg., Polyethylene 3. Safety and Housekeeping Action Committee (SHAC) J. J. McClellan (Joe) Mfg. Supt., HCN Complex 4. Plant Manager's Comments G. L. Tromblee (Gene) Plant Manager 5. Inspection Kickoff K. D. Oden (Ken) Group Supv., Process Technology 6. Discussion Distribution of Safety Equipment Coffee Break 8:25 a.in. Minutes 10 10 10 5 5 10 15 BEGIN INSPECTION SC 17726 9:30 a.m. STG 1084027 LAM025981 Tuesday, October 13, cont'd Page 2 DEPTS. 44-45-56 METHANOL 9:30 a.m. Methanol, CO, and H? are produced by steam reforming of natural gas and COg. CO and are^used in the production of oxy-alcohol and acetic acid. Val Bolton Irvin Cole Don Carter Craig Johnson (Coppedge, McClellan) (Love, Stone) (Whalen, Oden) (Zelle, Bretz) COFFEE BREAK (Acetic Acid) 10:00 a.m. DEPT. 50 ACETIC ACID 10:15 a.m. Acetic acid is produced from carbonylation of methanol. This area includes catalyst preparation and product distillation facilities. Byron Johnson Frank Weis Bobby Moore Yankee Wilson . (Coppedge, McClellan) (Love, Stone) (Whalen, Oden) (Zelle, Bretz) SC 17727 STG 1084028 LAM025982 Tuesday, October 13, cont'd Page 3 DEPT. 51 ACRYLONITRILE 10:45 a.m. Two reactor trains and a single purification train are used to produce acrylo nitrile and hydrogen cyanide as a by-product. Ammonia and propylene are used as raw materials. M. T. Devore Don Rosson Loyd Archer Hap Ferguson (Coppedge, McClellan) (Love, Stone) (Whalen, Oden) (Zelle, Bretz) CARS to MAIN OFFICE 11:45 3 fn CAFETERIA CONFERENCE ROOM (Tray Lunch) 12:00 p.m. CARS to ZONE I OFFICE 12:30 p rn ZONE I OFFICE 12:35 p ni Offices and conference room used by maintenance personnel for styrene process. Sam West Rodie Santarelli Jimmy Gibbs J. W. Paschal (Coppedge, Gatewood) (Love, McClellan) (Whalen, Carothers) (Zelle, Oden) SC 17728 STS 1084029 I AIVin7RQft3 Tuesday, October 13, cont'd Page 4 DEPT. 15 DEHYDROGENATION 12:45 p.m. Synthesis area for dehydrogenation of ethylbenzene to crude styrene. Allen Lamb Hugo Darden Earl Moore George Bryan (Coppedge, Gatewood) (Love, McClellan) (Whalen, Carothers) (Zelle, Oden) DEPTS. 14-16 STYRENE - EB DISTILLATION Dept. 14 - Ethylbenzene purification facilities Dept. 16 - Styrene purification facilities Louis Rooks Larry Young Allen Lamb Jim Gore (Cappedge, Gatewood) (Love, McClellan) (Whalen, Carothers) (Zelle, Oden) 1:05 p.m. SC 17729 STG 1084030 LAM025984 Tuesday, October 13, cont'd Page 5 DEPT. 13 ALKYLATION 1:35 pm Ethylbenzene is produced by the reaction of benzene with ethylene in the presence of an aluminum chloride-organic catalyst complex. Morgan Holder Roger Lubojasky Carroll Smith Rudy Willis (Coppedge, Gatewood) (Love, McClellan) (Whalen, Carotners) (Zelle, Oden) CONTROL LABORATORY 1*55 p.m. Laboratory facilities needed to conduct required analyses for production and shipment of petrochemicals from Texas City plant. John Kilfoy Myrna White Fay Johnson Wilma Elgamal (Coppedge, Gatewood) (Love, McClellan) (Whalen, Carothers) (Zelle, Oden) COFFEE BREAK (Material Handling Office) SC 17730 2:15 p.m. STG 1064031 LAM025985 Tuesday, October 13, cont'd Page 6 MATERIAL HANDLING OFFICE BUILDING 2:35 p.m. Offices for supervision of distribution operation, materials handling foreman and clerk. Grace Warren Joe Cantrell Glen Vogtman Frank Bales (Coppedge, Gatewood) (Love, McClellan) (Whalen, Carothers) (Zelle, Oden) BARGE & SHIP DOCKS (1,2,3,4,5) 2:45 p.m. Barge and ship loading/unloading facilities for raw materials, products, used at and produced by Texas City plant. (Pick up Cars) Tom Hartnett Mike Westmoreland Daye Glass Dante Paganucci (Coppedge, Gatewood) (Love, McClellan) (Whalen, Carothers) (Zelle,Oden) PRIMARY TREATMENT, AMMONIA TANK, NORTH 68 3:25 p.m. 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. Gene Sprock Dan Moore Bill Wooley Jack Hutchison (Coppedge, Gatewood) (Love, McClellan) (Whalen, Carothers) (Zelle, Oden) SC 17731 STG 1084032 LAM025986 Tuesday, October 13, cont'd Page 7 ELECTRIC SHOP 3:50 p.m. Consists of central shop facilities and offices for power distribution, electrical maintenance and maintenance engineering personnel. Mat Mathison (Coppedge, Gatewood) (Love, McClellan) (Whalen, Carothers) (Zelle, Oden) STORES 4:00 p.m. Stores include the shipping and receiving docks, storage bins of inventory items, and offices. Tom Crump Terry Grubbs John Catching Kathryn Woodard (Coppedge, Gatewood) (Love, McClellan) (Whalen, Carothers) (Zelle, Oden) END of FIRST DAY of INSPECTION SC 17732 STG 1084033 LAM025987 SC 17733 STG 1084034 LAM025988 SECOND DAY: WEDNESDAY, OCTOBER 14 Page 1 SHOPS BUILDING 8:10 a.m. Central Shops consists of facilities for pipe fabrication and plate and exchanger, machine, and paint shops. . Building also includes training rooms and various maintenance office. Howard Jackson Bill Recknor Joe Haskovec Andy Devris (Coppedge, Carothers) (Love, Gatewood) (Whalen, McClellan) (Zelle, Stone) HOURLY SAFETY COMMITTEE PRESENTATION COFFEE BREAK (Shops Building, 2nd Floor) 9:10 a.m. SOUTH MAINTENANCE BUILDINGS, INSTRUMENT SHOP 4 GARAGE 9:25 a.m. Building includes carpenter-insulator shop, instrument department shop, field maintenance offices, and garage facilities. Art Rich Jack Goodson Raymond Guidry Sherman Jones (Coppedge, Carothers) (Love, Gatewood) (Whalen, McClellan) (Zelle, Stone) Sam Scarcella - Instrument Shop SC 17734 STG 1084035 LAM025989 Wednesday, October 14, Cont'd Page 2 WATER TREATING - PLANT AIR 10:05 a.m. Treatment of raw Brazos River water for plant use and generation facilities for breathing, instrument, and general plant air. Dan Bowers Jim Uptmor Harry Mercantel George Orum (Coppedge, Carothers) (Love, Gatewood) (Whalen, McClellan) (Zelle, Stone) POWER 2 10:20 a.m. Facilities for steam generation and boiler feed water treatment. Nick Monroe Donis Shotwell George Orum Harry Mercantel (Coppedge, Carothers) (Love, Gatewood) (Whalen, McClellan) (Zelle, Stone) SC 17735 STG 1084036 LAM025990 Wednesday, October 14, Cont'd Page 3 DEPTS. 19-25-27-29 (HCN-TBA-LN-ACY) 10:30 a.m. Manufacturing facilities for tertiary butylamine, lactic acid, and acetone cyanohydrin. Jasper Jennings Bill Taylor Mike Sweeny Janet Townsend (Coppedge, Carothers) (Love, Gatewood) (Whalen, McClellan) (Zelle, Stone) CAFETERIA CONFERENCE ROOM (Tray Lunch) 11:15 a.m. AN LOADING RACK 11:45 a.m. Rail car handling facilities for acetic: acid, methanol, TBA, sulfuric acia. IBY, and ACH. Conrad Berg Jerry Hudspeth Rusty Wilson Charlie Loney (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) SC 17736 STG 1084037 LAM025991 Wednesday, October 14, Cont'd Page 4 WAREHOUSE A-B-C 12:05 p.m. Three warehouses containing spare parts, valves, hoses, electrical cable, flamable liquids, paints, insulation supplies, sample bottles, etc. Tom Crump Terry Grubbs John Catching Kathryn Woodard (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) ZONE 2 OFFICE Offices for west plant maintenance personnel. Jack Richards Charles McClanahan Alvin Berry Andy Kuehl (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) 12:20 p.m. sc 17737 STC 1084038 LAM025992 Wednesday, October 14, Cont'd Page 5 CED OFFICES & SHOPS 12:35 p.m. Offices, warehouses, and shops for Central Engineering Department. Bill Nappier George Lavayen Jeff Peterson (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) CAPITAL PROJECTS AREA 12:55 p.m. Area includes offices, a shop and fabrication area, and tool room. Ben Arnold Calvin Wills Gino Inman David Spence (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) SC 17738 LAM025993 STc 1084039 Wednesday, October 14, Cont'd Page 6 DEPT. 33 LACTIC ACID 1:15 p.m. Manufacturing facilities for pharmaceutical grade lactic acid from lactonitrile. George Williamson Rodger Roulette George Chesnut Lester Congor (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) DEPT. 48-56 0X0-ALC0H0L - PHTHALATE ESTERS 1:35 p.m. Oxo-alcohol area uses CO + H~ blend gas and olefins as raw materials. Phthalic anhydride and oxo-afcohol are used to manufacture phthalate ester. Jose Gaviria J. T. Shipley Norbert Novak Vernon Fields (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) SC 17739 STG 1084040 LAM025994 Wednesday, October 14, Cont'd Page 7 DEPT. 53 PHTHALIC ANHYDRIDE 2:10 p.m. Manufacturing process which uses BASF technology to convert air and ortho xylene to phthalic anhydride. Steve Monel a Jeff Soley 01af Omenson Carl Richardson (Coppedge, Bretz) (Love,' Oden) (Whalen, Stone) (Zelle, McClellan) COFFEE BREAK (Polyethylene Conf Rm) 2:30 p.m. POLYETHYLENE CONTROL LAB 2,55 p.m. Laboratory facilities for providing analytical data for the production of HDPE. Roland Williams Tommy Stewart Mary Ann Moore Joe Alessi (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) sc 17740 STC 1084041 LAM025995 Wednesday, October 14, Cont'd Page 3 DEPT 35F POLYETHYLENE 3:05 p.m. Manufacturing area that converts HDPE powder from the polymerization unit into finished product pellets. Ray Burkett Gerald Berry Ken Gore Judge Hadley (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) DEPT. 35P POLYETHYLENE 3:25 p.m. Manufacturing process which converts ethylene to solid high density poly ethylene via a Ziegler catalyst polymerization. Riley Townsend John Townsend Wendell Youngdoff Leroy Vornkahl (Coppedge, Bretz) (Love, Oden) (Zelle, McClellan) (Whalen, Stone) Sc 17741 STS 1084042 LAM025996 Wednesday, October 14, Cont'd Page 9 HIGH DENSITY POLYETHYLENE PACKOUT & WAREHOUSING/BULK LOADING 3:50 p.m. Packaging, storage, and loading facilities for high density polyethylene product. Ralph Anderson Hy Treaccar Tom Hartnett Ben Munday (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) WEST GATE 4:05 p.m. Major plant entry gate with facilities for producing employee identification cards. Fred Herzog Martha Ray (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) SC 17742 STG 1084043 LAM025997 Wednesday, October 14, Cont'd Page 10 LOCKER BUILDING 4:15 p.m. Building contains lockers, showers, and dressing rooms for employees. Weldon Nonnenmacher Louis Decker Gordon Dillon Steve Lawless (Coppedge, Bretz) (Love, Oden) (Whalen, Stone) (Zelle, McClellan) SOUTH 22 (in Cars) END of SECOND DAY of INSPECTION 4:25 p.m. SC 17743 ST6 1084044 I & M09KQQQ INSPECTION Sc 17744 STG 1084045 LAM025999 PERSONNEL BUILDING THIRD DAY: THURSDAY. OCTOBER 15 Group A Inspectors: Coppedge, Love Page 1 8:00 a.m. Building contains personnel offices, training facilities and a video tape lab. Nancy Wilbanks 61enda Meisetschlaeger (Coppedge, McClellan) (Love, Carothers) LOCKER BUILDING NO. 1 & SAFETY SUPPLY 8:20 a.m. Building houses separate lockers, showers, and changing rooms as well as the safety supply store. Ken Milner Gordon Dillon (Coppedge, McClellan) (Love, Carothers) SC 17745 LAM026000 STG 1084046 Thursday, October 15, Cont'd Page 2 RECEPTION OFFICE & GUARD HOUSE 8:40 a.m. Major plant entry gate with offices for locksmith, supervisors, and plant receptionist. Glendora Hill Fred Herzog (Coppedge, McClellan) (Love, Carothers) FIRE STATION 9:00 a.m. Two buildings which house the Texas City plant's fire fighting facilities. Jim White Ham Hamilton (Coppedge, McClellan) (Love, Carothers) SC 17746 STG 1084047 LAM026001 Thursday, October 15, Cont'd Page 3 PROCESS TECHNOLOGY SAFETY COMMITTEE PRESENTATION OFFICE SAFETY COMMITTEE PRESENTATION COFFEE BREAK (Cafeteria Conference Room) 9:30 a.m. DISPENSARY 10:00 a.m. Provides facilities for emergency first aid and for monitoring employee health. Betty Culbreth, RN Tony Ozarchuk (Coppedge, McClellan) (Love, Carothers) CAFETERIA Main plant cafeteria. Adele McCoy Laverne Chandler 10:10 a.m. (Coppedge, McClellan) (Love, Carothers) SC 17747 LAM026002 STS 1084048 Thursday, October 15, Cont'd Page 4 MAIN OFFICE (2nd and 3rd floors) 10:20 a.m. Main office building for manufacturing, distribution, environmental, safety, and marketing personnel. 2nd Floor: 3rd Floor: Betty White Evelyn Harrison Honda Garza Bea Soto (Coppedge, McClellan) (Love, Carothers) (Coppedge, McClellan) (Love, Carothers) RESEARCH NO. 1 10:45 a.m. This building houses analytical labs and bench scale reactor systems. Dave Truitt Ernie Dupuis (Coppedge, McClellan) (Love, Carothers) SC 17748 LAM026003 STS 1084049 Thursday, October 15, Cont'd Page 5 OFFICE ANNEX (1st floor) Group B Inspectors: Whalen, Zelle 8:00 a.m. First floor of this building contains, offices, technical library,and computer room. Jim Sheehan Mary Caban (Whalen, Bretz) (Zelle, Gatewood) OFFICE ANNEX (2nd floor) 8:30 a.m. This floor contains office facilities for accounting, mechanical & materials technology, MIS department with computer facilities. Stella Martinez Lois Standley (Whalen, Bretz) (Zelle, Gatewood) SC 17749 LAM026004 ST6 1084050 Thursday, October 15, Cont'd Page 6 FIRE STATION 9:00 a.m. Two buildings which house the Texas City plant's fire fighting facilities. Jim White Ham Hamilton (Whalen, Bretz) (Zelle, Gatewood) PROCESS TECHNOLOGY SAFETY COMMITTEE PRESENTATION OFFICE SAFETY COMMITTEE PRESENTATION COFFEE BREAK (Cafeteria Conference Room) 9:30 a.m. RESEARCH NO. 2 10:00 a.m. The AN, styrene, and ARMS bench scale reactor systems are operated in this building. The analytical Instrument development department is located upstairs. John Thorman Lee Owens (Whalen, Bretz) (Zelle, Gatewood) SC 17750 LAM026005 I STG 1084051 Thursday, October 15, Cont'd Page 7 RESEARCH NO. 3 10:30 a.m. This building houses the offices for the ARMS personnel with crafts and main tenance offices and shops located on the first floor. John Thorman Lee Owens (Whalen, Bretz) (Zelle, Gatewood) Group A & B Inspectors CAFETERIA CONFERENCE ROOM (Committee Caucus) 11:15 p.m. CAFETERIA CONFERENCE ROOM (Seated Lunch) 12:15 p.m. RESEARCH 2 CONFERENCE: ROOM Committee Report to Expanded Staff 1:00 p.m. END Of INSPECTION 2:00 p.m. SC 17751 STG 1084052 LAM026006 NOTES SC 17752 LA A/1026007 ST6 1084053 SC 17753 STG 1084054 LAM026008