Document ymNDpvEqXJm3n1bkJZ6GdO47D

~o Monsanto MONSANTO POLYMERS & PETROCHEMICALS CO. 730 Worcester Street Indian Orchard, Massachusetts 01051 Phone: (413) 788-6911 September 10, 197 5 Mr. Rudolph Bayerle, Director Occupational Safety Health Administration Room 501 436 Dwight Street Springfield, Massachusetts 01103 SUBJECT: Regulated Areas Regulation 1910.93q VCM Dear Mr. Bayerle: In accordance with paragraph n of 0SHA regulation 1910.93q, Vinyl Chloride, please be informed that Monsanto Company has ceased vinyl chloride operations at its Springfield Plant, 730 Worcester Street, Indian Orchard, Massachusetts. The two regulated areas established in accordance with paragraph e, OSHA regulation 1910.93q, and reported to you in my letter of April 22, 1975 were cleared of VCM and PVC as follows: manufacturing area (regulated area No. 1) effective August 8, 1975; and warehouse area (regulated area No. 2) effective August 28, 1975. Therefore, these areas have been deregulated as regards OSHA regulation 1910.93q. ! /pjc G. M. Ellsworth Plant Manager Monsanto Company D. V. Bierwert R. L. Bourget R. W. Bueker G. W. Fletcher (2 D. L. Gendron P. S. Park G. L. Smith a unit of Monsamo Company WSV0024407 IN 10 REV7 11-64 AHE Monsanto D.L. Gendron DATE August 15, 1975 subject Rail Cars Containing RVCM VCM REFERENCE TO R.W. Bueker c&- R.L. G.W. R.B. D.H. J.A. Bourget Fletcher Gibb Howe Tierney Following is a status list of VCM tank cars remaining in the plant. Car No. Contains Amount CEst. Amt.) 33008 33021 33028 33023 RVCM RVCM RVCM VCM .220 MM lbs. .220 MM lbs. ?~heel from #2 tank (.140 MM lbs.) Please arrange to store these cars elsewhere than in Tank Farm K-l, as the 84 Bldg./Tank Farm regulated area will be de regulated effective 8/12/75. Also, until disposition of this material can be arranged, please have the RVCM cars sampled and tested for phenol and peroxide content once a week. Significant changes in phenol content or the appearance of any peroxides should be reported to me immediately. 7 D. L. Gendron /hs pcvnm^ns IK |P RfV 1) fc4 AHP Monsanto \y / D.L. Gendron _ CC; date August 15, 197 5 subject End of, VCM Storage in 84 Bldg/Tahk Farm Regulated Area REFERENCE TO File Bourget Bueker - f Bulk storage of VCM and PVC was ended in the 84 Bldg/Tank Farm regulated area on August 12, 1975. As of that date, entry logs for personnel entry into that regulated area are no longer being maintained. D.L. Gendron /hs RKV007.4409 Monsanto V Springfield, Massachusetts July 24, 1975 subject TANK FARM K-l - VCM SHUTDOWN CC: D.V. Bierwert R.W. Bueker E.E. Scully C.A. Taylor REFERENCE TO D.L. Gendron R.F. Sackett SUMMARY 84 building will empty #1 and #6 tanks of all VCM they need to complete kettle charges. All RVCM'to be pumped by 84 to 2' RVCM tank. #1 and #6 tanks is to be pumped to tank car by TSM. RVCM from #2 tank will be pumped to tank car by TM. #1, #6, and 2 tank will be removed _from VCM service by TSM with Mainten ance pipers. All tanks and lines water flushed and drained, steamed,' blanked, pressure relief valves removed and compressors and pumps locked out. DETAIL 1. When 84 building has finished draining all liquid VCM needed, close all valves to and from 84 building from #1 and #6 VCM tanks. Lock out 84 building charge pump. Responsibility: 84 Building 2. Pump all liquid VCM from #1 and #6 tanks to tank car. Disconnect tank car. Responsibility: TSM 3. Fill 1 tank with water to 100%, vapors to w6 tank through overflow line. Close valves. Open vapor line vent to air to prevent water pressure buildup. Remove pressure relief valves. Drain tank. Check for VCM vapors. Steam tank until no VCM vapors detected. Responsibility: Maintenance and TSM 4. Fill #6 tank with water to 90%, vapors to #2 tank through overflow line. Compress vapors from #6 to #2 Olbs. pressure. Check for liquid vaporization. Continue filling slowly to 100% vapors to #2 through vapor line,. Close all valves. Open vapor line. Vent to air to prevent pressure buildup. Remove pressure relief valves. Drain tank. Check for VCM vapors. Steam tank until no VCM vapors detected. Responsibility: Maintenance and TSM nm AA1 2 5. Be sure 84 building has pumped allRVCM to #2 tank. Pump all RVCM liquid from #2 tank to tank car. Compress vapors from 2 VCM tank to tank car to Olbs. Close valves and check for vaporization. Repeat vapor compression if necessary. Responsibility: TSM 6. Fill #2 tank with water to 90%. Compress vapors to tank car. Continue filling with water to 100% venting to stack. Close valves, vent tank, remove pressure relief valves. Drain tank. Check for VCM vapors. Steam tank until no VCM vapors detected. Responsibility: Maintenance and TSM 7. Check gauge in tank car. Take four sample bombs. Disconnect tank car. Responsibility: TSM n 8. Flush all dock lines and pumphouse lines and manifolds - vent to stack at KO tank. Flush KO tank. Steam until no VCM vapors detected. Blank all open lines. Vent two compressors to stack - lock out. Responsibility: TSM /mp T?cvnrm4i i Monsanto C. D. Riggs >ate December 13, 19 74 SUBJECT tEFERENCE 'O R, L. Bourget ---RT W. Bueker P. Dugan D. L. Gendron GC-' M. A. Kulig M. A. Petronino D. E. Philpott Per the OSHA VCM health standard, the establishment of "regulated area" is required where PVC or VCM is "manufactured, reacted, repackaged, stored, handled, or used/' Attached are the instructions which will be posted at the sign-in entrance point of the "regu lated area" which includes 84 Bldg, and K-l tank farm. Note that the 84 blowdown room, 82 pumphouse, and RVCM compressor room are not listed as "required" respiratory areas. One or more of these areas may be changed to "required" respiratory areas if VCM concentration data warrants by December 31, Please return comments by 12/20. Rsvno?44iq NOTICE All persons entering this area: The PVC 84 Bldg, and K-l tank farm area as shown on the diagram below is a "Regulated Area" as described in the OSHA Standard for Exposure to Vinyl Chloride. This area is a cancer suspect agent area and only authorized personnel may enter. All persons who enter must read the adjacent list of requirements and comply accordingly. DCvnn-MAn REQUIREMENTS FOR VCM "REGULATED AREA" 1) Authorized personnel only may enter this area--you are author ized if you have Monsanto related business in the area. Passersby are not permitted to enter. 2) All persons who enter for the first time on a given day must enter at this point and sign in name and date on the log sheet. Once you have signed in for the day you may come and go from the "Regulated Area" at locations other than this sign-in point and you do not have to sign in. It is not necessary to sign out upon leaving the "Regulated Area". The following persons are exempt from the above sign-in regula tion: Monsanto Dept. 80 PVC wage employees Monsanto PVC Department Supervision Monsanto South Plot Area Mechanics and Oiler 3) Some areas within this regulated area are "hazardous" because they contain vinyl chloride vapor. These areas are posted with signs reading: Cancer-Suspect Agent In This Area Protective Equipment Required Authorized Personnel Only These "hazardous" areas are shown on adjacent Figs. 1 and 2. Some of these "hazardous" areas require that air respirator pro tective equipment be worn and the areas are so posted. Respira tory protection is voluntary in the remainder of the "hazardous" areas. Consult PVC supervision to procure necessary air respira tor equipment and instruction. 4) Do not break open any VCM or PVC containing equipment without first consulting PVC supervision for instructions. This type of work may require respiratory equipment. 5) Consult PVC supervision before moving any of the rope barriers surrounding this "regulated area". nCUAA'I/l/l 1 A S'l m o o AS 41 ARtA /t\/cA / xb CamPUKidR./ ' "ROilVA / ^ \/_ / // `PAINT FIS 1 grookId f loo?-, w me .,__ . *, . fyo*)' / PCfwp House, ;'...Z__ __ ^ Z// Ufc\ATW>U5 ^CL^^ATOfl E^UUr'friW veu^Tmx \\K\hXxm^- nR.Fp\ - ^r> p ir ^\Qft. i prAt^X im uuA sa FIG. Z Second floor m miAWMOs fiREfl- ^^.riFUVTAp. EqUiPviftsopft \l6UJNrTA?P-( Hjvvfwwur ftR.cn - R<; p l ftfl Top. & iJ 1P TT E Pit' DATE PVC REGULATED AREA SIGN-IN LOG NAME - ( \ pcvnroAAl 7 Vt jI 1/ ^2 ZT<r /& /%^J>Jw /"/S ^ ^ 3 <j ^.o | ^ rTr^t^J ^t, ,sd>6*HU*&/ <2^ &&t- c. s*7 &x ^V~^7' &bh*-r * '>rU-s*--v # s?r*z*y //'/>'i-'iX` *2-/3 " 2 >o 'y?'' -^'J y'VC/^ S^"C. C/tASi"~Siq~t -t~/AlS / li^wut__ b^&$nrx! /F* Sic P/ - -Bib^o .Xb*<X-, X-enX. J/^. '"TTK^ ^ S/r^' ^'>'i^.--_ ^h<r+3 jb ^ 1 3 >? C..... . j^M^T / &*%,,. /&//} (/ "^^S-45-- <3-+**~4 - ^-J^-,^.imt,.mw|,|Mr /<5 O /^7t # DCUAm/l/11? Lonsu^to * C. D. Riggs oate January 8, 1975 subject RVCM Storage, Loading, & Shipping reference Memo 12/19/74 TO -"Rt W. Buelcer J. A, Tierney CCi R L. Bourget D. L. Gendron D. E. Philpott This is to summarize action to date and to submit plans for the handling of RVCM per our discussion on 1/8/75. Since the meeting with Bueker, Philpott, Tierney, and Riggs on 12/17/74 the following action has taken place: (Reference memo 12/19/74) ^Approximately 10,000 gal. of RVCM has been pumped to #2 RVCM tank in K-l tank farm. This is a lower fillage rate than anticipated. A revised estimate is that a quantity of 165,000 pounds will be accumulated and ready to ship week of 1/27/75. * Samples have been taken from #2 tank and results are as follows: 12/20/74 ~ 1/3/75 1/3/75 1/3/75 - 28 ppm phenol in RVCM 26 ppm phenol in RVCM 0% peroxide in RVCM one sample taken and stored for evidence of polymer formation. of cloudiness as of 1/7/75. visual No evidence * A temporary procedure has been written and used to transfer RVCM to #2 tank. * 84 Bldg, phenol injection system was checked, and cleaned to insure operability. * Reviewed need for check valve in line to tank #2 (Riggs, P. Tardif, D. Philpott) and considered fact that RVCM transfer pump pressure could in fact lift #2 tank relief valves.'* Exist ing system is considered adequate. * Reviewed details of RVCM with Borden Co. 1/7/74 (Riggs/Joe Dagenfelder-Plant Manager). Borden has evidence that 10-20 ppm phenol concentration is adequate for shipment. They want RVCM with a 10-20 ppm phenol concentration but will use up to 24 ppm. A. P. Torrenzano recommended 40-50 ppm to start system out. Borden confirmed they do not use hT2 tor rail car unloading. Recommendations for future plans-- * It is recommended that the first rail car be shipped to Borden with 20-25 ppm phenol with the following sample plan: RQvnrnzLii q ----- Until rail car is loaded, sample tank #2 every 2 weeks and confirm phenol 20-25 ppm peroxide 0% ----- Sample #2 tank just prior to loading and test for phenol and peroxide and check visual sample taken 1/3-/7 5 for polymer formation, ------Sample rail car after loading and test for phenol and peroxide. ----- Sample rail car, obtain results after weighed in West Springfield and before leaving for Leominster. ----- If rail car does not get to Borden, Leominster within 5 days of leaving West Springfield (normal trip 4 days) then sample car in route and test for phenol and peroxide. Borden plans to sample car upon receipt in Leominster. Phenol concentration can be increased in #2 tank by increasing phenol system charge and phenol could be blown into a rail car if required. Responsibility - PVC Mfg./T&M * Additional testing after the 1st rail car should include peroxide and phenol every 2 weeks and 1 stored visua) sample (stored for 40 days). Responsibility - PVC Mfg. * After accumulation of monomer data if results show sustained phenol levels and no peroxide and polymer then ship subsequent rail cars at 15-25 ppm, testing each car after loading for phenol and peroxide. Responsibility - PVC Mfg. * Repair seal and refill oil reservoir in tank farm pump to be used for loading. Responsibility - PVC Mfg. * Confirm that 30,000 lb. VCM cars can with a 22,000 1tT. load to Leominster. cyM Responsibility - T & M Supv. * A rough draft of the procedure for tank car loading operation has be been prepared by J. Tierney. Procedure should be completed and ap proved. It was originally suggested that remaining vapor in the VCM car to be loaded with RVCM should not be pumped out because of the chance of introducing 03. However, upon review, pressure in the empty car is not reduced to below 5 psig and the compressor system will not see RVCM. Therefore, the VCM cars will be pumped of vapors psvnn944?n 3 as is the current procedure. The plan calls for loading empty VCM cars, shipping RVCM to Leominster and then returning empty RVCM cars to Dow for -virgin VCM service. * Operation of tank farm pump and seal should be reviewed and in cluded in tank farm pumping procedure. Responsibility - PVC & T&M * Start stop switch and alrm for tank farm pump will be disconnected on 88 Bldg, kettle floor. Responsibility - PVC * The need for a logging of #2 tank tillage was discussed. The 84 Bldg, lead operator log will be revised to include a record of 8 4 RVCM tank pumping and #2 tank fillage. ^ j Responsibility -- PVC/J`W C. D. 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(y-f&^^L. <,v.&y 000/*^ t/ A AA~~Z*fr ?h- A3 to*. ^>o^1 /? ... ^._*.. ^_j. _j___^_t?^_e- 2TW ^^ '5^* 7^ **v^Jc~~ J$ , ^'~&^p J7 C^\^rp ^*3>r'^'fc-.,_ a^c-sfj c&f&v-e^ v . . ' ..Q^ r/*r' *y^ c -^.. ^c/u3$.......... //_.__ 1&J^~L *T . ^^S~- 1 -. - <~f-& yW/^^ / jZ* i i^- 4'-'/ 7^*^ ^ ^ _/^ 2 1 V^C* lA^~- I '/>T -^ j/ #/f /'sf^i' \^A^aAi &AiA' A?"'&*-?% /^V ___ ^ (//? (f .,. ^ .A^n^s -dX~>.- / $_ . (bt^Zr-rf-. *A. V Ai ^fL/i {^Z--S-- A- r * V -rf *. CaA .'rr^yy^^.. HSVnfP.4424 Monsanto C. IK Riggs 3ate December 19, 19 74 subject RVCM Storage, Loading Shipping reference D. E. Philpott J. R. Tierney R. L. Bourget D. L. Gendron A. P. Torrenzano This is to summarize our discussions of 12/17/74 and report new informaation relative to RVCM storage, loading and shipment to Borden Co. As discussed, the following action will be taken prior to RVCM loading: -----Review need for check valve in line from 84 tank to #2 tank in K-l tank farm. -----Confirm that 84 RVCM pump : i*n*1go #2" tank. c v*\*Lt*x%.it* % *(&>/ 7//*<.*J.*i_ 7<<j*/- s^ //. tlr -H"WVrriitte procedure for transfer of RVCM to #2 tank (prevent ove-* ----- ^ -----Insure that 84 Bldg, phenol system is operational and test RVCM "in #2 tank to insure minimum 50 ppm phenol inhibitor. 2.VV V -----Confirm details from Borden, i.e.-will they take RVCM, where will it go, do they introduce N when unloading. //* */v -----Put positive lock on valve to 84 pump in tank farm to preclude charging RVCM to 84 Bldg. AJo J P -----Develop procedure for tank car loading (if possible, obtain reference procedure from Dow, may necessitate testing car for O2 content). C. Riggs C. Riggs/ J. Tierney R. Bueker/ J. Tierney --Have MT rail car available for loading when re quired . R. Bueker/ J. Tierney I have confirmed from discussions with R. Bourget that Borden will indeed be buying RVCM and that RVCM cars will be shipped to Borden Co., Leominster, Mass. We believe, but will"Xohfifm,`\t`hj^^Eorden does not introduce in unloading procedure^. At least the firstK^hipment will be tested for phenol inhibitor to injure 50 ppm pheno } Per R. Bourget, rail cars loaded with RVCM and empt'i"M"tfy"''B'erden could be sent back to Dow for VCM loading;and providing there was no pcvnnoAzios 2 significant heel after unloading, these would be adequate for 8*{ Bldg. VCM. Using an emptied VCM (instead of RVCM) car in this way to load RVCM may -have a safety advantage in that the -same car (s) would not be used exclusively for RVCM, a situation which would improve conditions for peroxide formation and O2 buildup. Timing for'the loading operations estimated as follows: #2 tank effective capacity (901) 31,000 gal. 84 Bldg. RVCM generation 1,070 gal./day Tank car capacity 165,000# = 22,000 gal. (max. wt. limited by railroad requirements Spfld. to Leominster) #2 tank fillage on 12/18/^18% Void space left = 6,200 gal. 3 24,000 Time at which 1st car must be loaded: no later than 22 days, i.e.Jan. 10, 1975 Maximum frequency of loadings =,with 22,000 gal. car 20 days. In addition to the above actions, I will review technical aspects of the plan with A. P. Torrenzano to confirm safety, Borden's RVCM pro cessing plans, etc. Additional work may be required, i.e. filtering, routine impurity testing, etc. /m UlA/vLo/os S-3-59 MATERIALS HANDLING PROCEDURE FOR LOADING VINYL CHLORIDE INDEX I. Special Safety Instructions II. General III. Detailed Loading Instructions Copies of this procedure were distributed to: .1r, W. T. Anders on C. Berg R. H. DuV on V. E. Logan oW W. E. Seelbach VCM Rack Extra (5) RSV0024427 LOAD; nod MC o;-SR Page 2 I . S p s c i s 1 Safety In A, Do not inhale excessive amounts of vapor, VCM is an anesthetic and, because it excludes oxygen, is also an asphyxiant. In addition, it accumulates in the body. It is not easily thrown off. B. Do not unnecessarily let large amounts of VCM to atmos phere. It is highly flammable. C. If any welding or cutting is being done in the area, have the work stopped until through depressuring cars. This will be corrected by addition of a line to the flare at a later date. II. Genera'l Vinyl chloride monomer (VCM) is loaded info pressure-type tank cars from storage tanks 22T9-1 and 2. The loading rack has 12 loading spots located on two tracks. The cars are loaded through lines from 22P25-1 and 2 pumps, which take suction from the storage tanks. Vapor from the vapor lines of the tank car returns to the storage tanks. III. Detailed Loading Instructions 1. Attach ground cable to tank car. 2. Remove all pipe plugs from valves. 3. Connect gas hose to the car. 4. Pressure-up cars to storage tank pressure. 5. Plug dome holes and fill dome with water. ` 6. Check for all leaks and put information on card to be tied to cars. 7. After all leaks have been repaired, connect liquid hose to tank car valves. 8. Line up valves from storage tank through pumps to tank car. 9. Open liquid and gas valves on car. 10. Start pumps. / RSvnn?44?K  ro r0o OJ CM LOADInG VIKYD CHLORIDE MONOMER III. Detailed Loading Instructions (Cont.'d.) 11. Set gauge rods on 18" outage and open valves. 12. When V'CM starts blowing at 18", raise gauge rod to 10". 13. When VCM blows at 10", shut off gas and liquid valves on car. 14. After the last car is filled, shut off pumps and block In lines. 15. Take temperature and pressure of the car and record on ^loading report. ' 1-6 Two liquid samples are taken. One in bomb and one in thermos bottle. 17. Install plugs in all valves and apply -seals. , 18. Close dome and seal. "19- Apply dangerous placards. Remove ground cable. Complete loading report and check list. Take samples to lab. Special for Phenol-Added Cars 1. After leaks have keen repaired and rechecked, depressure car. 2. Pour required phenol in the liquid line. 3. Connect car and proceed as above. I RSVnn?44?.9 , J. S. Darden - G4NL October 22, 1974 Magnetic Gage Installation for VCM Tank. Cars EFCiDVB F. S. Bonham A. J. Frankel - G4NG G Wessels E. f. Celette - E3SG . .r . N-:- . '' ' ;- - The estimated cost to install a magnetic level gage in one of our VCM tank cars - MCPX 33000 series - is as follows; Cleaning car {vent, steam-and dry) ` $210 :V:i f , Cost of magnetic level gage (3 month..delivery) 'V.vv.!. ffp.C Installation cost ' Nitrogen purge to 200 ppm 1; (Dow at Freeport has done this ' work in the past) y'y`-:AT_ - .. 'Jsj,"y Total Estimated Cost $335 $220 ^ $100 $865 per car The time schedule to complete this work would be as follows: ,. Estimated delivery of 20-30 magnetic gages 3 months Estimated time required per car at shop for installation Estimated total time 2-4 weeks* 3%-4 months (after authorization * This installation time would be based on giving the shop a minimum of 3 months advance notice and maintaining approximately 5 cars at the shop as a backlog* Once work begins, the repair shop should complete a minimum of one car per week. Joe Darden jb Tjownm/Miri Monsanto FOM N*ME ft LOC*T(ON. E. F. Celette - E3SG October 10, 1974 SUBJECT i VCM TANK CARS ftEFERENCt TO "i ` , ' 1 \ H,-:i v ,1 Messrs. - ; `" -': < /), V. Bierwert - 1870 F, S, Bonham - G4NLi J. S. Darden - G4NL A. J. Frankel - G4NE G. M. Simmons- - E3NF R. G. Wessels - G4NK (p d) 1H0 This is to summarize the VCM car situation concerning needs, and the magnetic gauging requirement by Dow following conversations I had with Borden and Ethyl. I haye also taken the liberty of proposing the steps we should take to respond. Please let me know if anyone has some better ideas. Borden: Dennis Zahn, Manager Distribution Services 614/225-4636 Ethyl: Bill Brydon, Marketing Manager for Chlorine Related Products, industrial Products Division 504/387-0131. 1. We want to continue the Ethyl exchange through the end of the Ethyl contract with Great American (April 30, 1975) for two reasons: a) Maximum volumes for Monsanto Annual Volume Tariff b) Defers having to use Monsanto cars for the Monsanto half of the GA contract until after said cars are freed up by cessation of PVC homopolymer production at Springfield February 1, 1975. 2. Ethyl is willing to continue the exchange through April 30, 1975. 3. To make it possible for the Ethyl exchange to continue through April 30, 1975, Dow will have to agree to load the cars Ethyl is sending to Dow Freeport for loading the Monsanto payback end of the exchange. -9 rtf RSV0024431 D, V. Bierwert et al VCM TANK CARS -2- October 10/. 1974 4. The cars being used in the Monsanto payback leg to Ethyl are Borden cars, since the payback is going to Borden. 5. The Borden cars presently in use do not have magnetic gauging devices, but in February, 1975 Borden is scheduled to receive 40 new VCM cars from Union Tank which will have magnetic gauging devices on them. Borden has agreed that they will put these cars into the Dow pickup starting in February (assuming their car delivery stays on schedule). 6. Alan Frankel: Please inform Dow of item 5 and try to get confirmation that it will be satisfactory to Dow to continue to ' load the payback material in Borden cars without magnetic gauging devices until the new Borden cars come on the scene; now expected to be in February, 1975. 7. If this is successful, George Simmons should go back to Ethyl to formalize extension of the Monsanto/Ethyl exchange through April 30,. 1975. 8. JJoe Darden should obtain very soon the best schedule possible for installation of magnetic gauging devices on 20 Monsanto cars. He should transmit this to Alan Frankel. 9. Alan Frankel should inform Dow of this schedule, try to get / confirmation from Dow that this is satisfactory. He should also try to get Dow agreement that the 14 cars which we will have in supply of the Monsanto/Great American volumes between April 30, 1975 when the new Borden cars are withdrawn because of termination of the Ethyl exchange and the termination of our Great American contract December 31, 1975 can continue to be loaded at Dow without magnetic gauging devices. 10. If Dow refuses to let the 14 Monsanto cars in Great American service be used between April 30 and December 31 without magnetic gauging devices, Borden has said they might consider swapping cars with Monsanto for that period so we could use the new Borden cars for our move to Great American through the end of 1975. D. V. Bierwert et al VCM TANK CARS -3- - October 10, 1974 11, A bit of intelligence I got from Borden: a) They talked with Bill Duncan, the Dow contact man . specified for information on the gauging devices, Duncan was a little vague on timing required, but Borden was given to understand that Dow would not be adverse to a.time schedule for completion by end 1975. b) Dow is using lathcoat for installation of gauges on their cars. 12. Intelligence from Ethyl: At present Ethyl is not planning to put magnetic gauging devices on their own cars, and instead is working on an alternative way of meeting OSHA standards by modification of loading equipment and procedures. Ethyl was not willing to tell us exactly how since internal security clearance to do so had not been obtained (or requested). However, Ethyl did say it was a containment and recycle system with a flare for contaminated material. We are free to tell Dow about this, and if Dow is interested they should contact Bill Brydon at Ethyl directly. ?- Monsanto E. F. Celette - E3SG October 16, 1974 VCM REGULATIONS DISTRIED TICK INVOLVEMENT 'V G. M. Ellsworth - 1870 G, L. Smith - E3SH TO V. Bierwert - 1870 F, S, Bonham - G4NL R, L. Bourget - 1870 R. K. Dunlop - G4NA W, L,, Friehs - G4NK W. R. Srhaeffir - C3SH G, R, S;idc - G4EC T. C. Stewart - G4NA R. Gi Wcssels - C4NK This`is to summarize discussions at a meeting October 11 with Corporate Distribution and by phone with Bob Bourget. The new OSHA regulations on VCM were reviewed, and a plan of action proposed for those items of the regulation involving distri bution activities. Routine Operations PVC 1. Package warning labels: Basically Borden's responsi bility to specify and provide bags, Bourget to contact Borden for instructions. Twining available to assist as appropriate. 2. Bulk truck warning signs: same as for package warning labels. Plant Traffic responsible for implementation. VCM 1. Loading at Dow Freeport: Dow's responsibility. 2. Modification of tank cars to meet Dow's responsibility during loading. Rail Section of Corporate Distribution is coordinating. 3. Tank car warning signs: a) Determine whether DOT will specify. CDD responsibility. h) Determine how rest of industry will implement 1. Bonham t. ` vi r v v-c / MC.A "Frans portal ion Commit: : ..At u:i,. in Wshinginn 10/19-22, Rsv/vm/m f D V. Bierwert el ai VCM REGULATIONS DISTRIBUTION INVOLVEMENT October 16, 1974 T. Su-w.u'i I'l'vii'v, lie is as s i >c in' cd. itii g roups with which 3. Celettc- to review with VCM sub-committee. of SPI Distribution Committee at New Orleans meeting October 22-24. c. Gear up to implement, prior to December 1 (be ready to not implement if a stay is obtained) Tank car unloading: Will be- handled as part of the Springfield plant's program to conform to regulations. Boureel/Bierwert responsibility includes equipment, training, monitoring, emergenc y procedures, etc Out -of - Plant Emergencies 1. informing RR of nature of material. I y Stewart to request legal opinion from P. S, Park, .2 Revise CHEMTREC data sheet, ODD responsibility to work out with MCA CHEMTREC Committee (R, Sido checking) 3. Since VCM incidents will take on a different character with the heavy focus on VCM, we should review and formaline the procedure for Monsanto reaction to and help in - transportation incidents, Celette will investigate. RSV0024435 --:aTffM TO Mr. Ti Dintin, Plant Engr. Mohsant Company Plastics Div* JK.2 Mens ant Ave.___________ ^^>ringield, Mass* 01051 l;ea; v""ab^:s#sS'>5'^'6- ; MCCCATCC --..... - ---------------------------------------------------------------------------------- ------------------------------------------------------------------ ---------------- Dear Mr. Dimtin: ' J " ' 'tt, <?* ' , ' ' ' ^-W-. (.Vfvir ' Attached is a quotation sheet covering a 9 X 9 Penn. compressor"that is still m operation and m good. running condition. It can be seen m operation and he pulled out or service at nee. Location is in the Conn. Area. ::: -V__; ~ i ,r?/a This might he the fastest way te solve your y X 6 Pehn, compressr pn blem SIGNED r>GX-uj..y t - -----. ............................. t....... .......... -- ~ ....... "....... :.................. l:W ^Pn.~h<a % ___________________________________________________________________________ (______________ * i _ JrtQftOMOMlU-H13f1t PTEHAJSK* PHODUCT SIGNED THIS COPY FOR PERSON ADDRESSED DATE ' rr' . 0 4STH STREET AND DELL. AVENUE * NORTH BERGEN, NEW JERSEY 07047 (A COMPRESSOR MANUFACTURER SINCE .1902) Naw York Telephone 212 - 244-7665 New Jersey- Telephone , 201 - 865*4848 W % [/?*>* v -"V, -- CLASS 3-AT C . -Sx 'frjgA?*; < f*TM** _". > ''. ` . i-' _ . - / j .. -~-ci .j iI**"i.^L--M-`..r*r'4-n'-- - - wmrn sekpics - * - - - - - - - - ^ ................. . . _ ...V b r i-c a: t e r> 1 40 H? Hotor Required : : '- vr- 9 x 9 Pennsylvania 3-ATG roller bearing, straight line, single stage/water cooled double acting Air Compressor, equipped with: l. Oilless cylinder construction /../'v1;-:' ':,C"Free air unloading ; Air inlet filter ''^.'^yMulti^V-belt drive including compressor and . -" S'v';-~ :-7'- motor sheave & necessary belts .' 40 HP motor, 3/60/220 or 440-volt with top motor, mount . Pipeline aftercobler equipped with moisture separator x '-'v4-v-V ` Price: F.O.B* shipping pointTerms-; 25% deposit with order. eefitbliSspeb^on Quotation Sheet 3 V 210 SP0R ' To Our Compressor Friends : We rebuild flli make compressors and are in no way connected with the original manufacturer, except where our own originals are rebuilt. The plant as shown is our own of which we are duly proud. We invite our customers to see our plant and see how well equipped we are tq build and rebuild compressors. With over sixty years of compressor building and, rebuilding our name and the integrity back of it is our, guarantee, AMERICAN AIR COMPRESSOR CORP- THE PLANT BEHIND THE PRODUCT m ^OCNr >GO Pi uauc vnilP COMPRESSOR RE-BUILT BY COM PRESSOR M EN ALL QUOTATiONS SUBJECT TO PRIOR SALE IN 10 REV, 11-64 AH6 Monsanto %) Springfield, Massachusetts date June 11, 19 7 4 subject VINYL CHLORIDE MONOMER UNLOADING REFERENCE TO A1 Shadensack cc. R.L. Bourget C.D. Riggs Attached is a diagrammatic sketch of the vinyl monomer unloading at the Springfield plant which I described to you yesterday. As you know, the unloading takes place in two stages - the liquid transfer and the removal of the residual vapor. I have also included the specifications of the two unloading compressors and a drawing of "knock out" tank used in the system. If you have any questions I will be happy to answer. R.W. Bueker Supt. Transportation Materials : mp JulA * : Tc T'c 3S^vS> DOW CHEMICAL U.S.A. May 15, 1974 1/ 800 PIERRE LACLEDE CENTER 7733 FORSYTH BOULEVARD ST. LOUIS, MISSOURI 631 OS Mr. A. J. Frankel .Manager, Haw Materials Purchases Monsanto Company 800 N. Lindbergh Boulevard St. Louis, Missouri 63166 Dear Alan: UNLOADING VINYL 'CHLORIDE MONOMER TANK CARS For many years Vinyl Chloride Monomer tank cars have been unloaded by utilising either an inert gas or Vinyl Chloride gas as a pressurising medium to empty the car. We now find it necessary to request that our customers use only Vinyl Chloride gas for this purpose. This action is necessary to prevent contamination of the "heel" which often makes purging a necessity before again loading the car at our facility. We are all facing more stringent regulations governing the air quality, water quality and worker environment. This change will be of great benefit in helping meet our mutual obligations and in addition will have a beneficial effect on Vinyl Chloride Monomer quality. We appreciate your cooperation and ask that this change be made by July 15, 1974. If we can help you In any way, let us know. Sloya ff./Knaup Office Sales Supervisor si AN OPERATING UNIT OF THE DOW CHEMICAL COMPANY PSV00?44?9 |N 10 ffEV M-M A MB Monsanto date: SUBJECT REFERENCE TO Springfield, Massachusetts April 29, 1974 )V cc.- Mr.G.M.Ellsworth Mr.F.J,D'Amario Shift Supers This is for your information. At the recent Vinyl Chloride Safety Association meeting, the derailment of a Tenneco VCM railroad car was discussed. Later, when talking with the Tenneco safety manager, he told me that they used the services of Arthur L. Proefrock, Hulcher Road, P.O. Box 191, Virdin, Illinois, telephone: 217-965-3361. He is a specialist in railroad accidents involving hazardous cargoes, and operates on a nation-wide basis. - G . W . F l'e t cher A Af\ Monsanto FROM JNAME & LOCATION J. S. Darden - G4NL March 5, 1974 PURGING VINYL CHLORIDE CARS TO 1870 MR. R. W. BUEKER A cc MESSRS: H. T. HALE F. S. BONHAM 1870 - J. H. KNAPP This memo will confirm our conversation of March 5, 1974. Tank cars in VCM service that were shopped recently for repairs were released from the shop without a "nitrogen pad." Several of these cars have been loaded at Dow in Freeport, Texas and are enroute to the Springfield plant. These car numbers are: MCPX 33006 MCPX 33033 MCPX 33030 MCPX 39000 Before these cars were loaded at Dow they were purged with nitrogen to 4,000 PPM of oxygen. There are an additional seven cars which have left repair shops without a "nitrogen pad." When these cars arrive at Dow they will be purged with nitrogen to reduce the oxygen content to 4,000 PPM. Dow will charge approximately $50 per car for this purging. All of these cars have been steam cleaned at the repair shop and dried with rags. I would expect that these cars will have a small amount of rust. The rust in these cars will not create any significant problems. As most tank car repair shops are not equipped for purging, we will continue to handle shopped tank cars in this manner. Dow will perform the purging operation prior to loading. /mw Dovnm^/t/i T TO Messrs. W. Bueker A. G. Eisold J. H. Knapp C. F. Smith The projection of 2-26-74 indicated that immediate steps be taken to supplement our supply from the known BFG inventory that was offered to us. On 2-27-74 I contacted Jim Wolff and made following arrangements: 1. 5 cars will be diverted and reconsigned to Monsanto Indian Orchard. 2. Monsanto will pay the freight collect and diversion-reconsignment charges. 3. Monsanto will pay $0.06/pound for the VCM. 4. The tank cars are to be emptied as soon as possible and returned to BFG at Calvert City, Kentucky. 5. We requested 111. Central - Chicago - Penn Central routing, 6. Car identification, location intransit and routing will be phoned to Springfield Friday 3/1/74. 7. Monsanto will ship 5 cars of VCM from Dow at the rate of one per week starting week of April 21 to BFG Calvert City plant. 8. Monsanto will bill BFG at the $0.06/pound price. 9. Tank car shipments will be collect to BFG, 10. Monsanto purchase order T-66364 was assigned to the purchase from BFG. 11. The cars we receive are expected to contain about 180M pounds each and may be Dow material from Plaquemine. This is essentially a pound for pound swap of material. Every effort will be made to balance out. -cont'd,- nnT TAAI"! ^ A A I"s Supplemental VCM Contacts Marketing - Jim Wolff Traffic - Mike Winter B. F. Goodrich Chemical Co. 6100 Oak Tree Road Independence, Ohio 44131 Page 2. February 28, 1974 DVB/jhb Rsvnn?4443 <<i0 r;V 11-64 AH6 , Monsanto > J. J. Uihlein--Springfield DATE October 2, 1973 SUBJECT REFERENCE Removal of #3, 4 5 Tanks from VCM Service TO D. L. Gendron C. D. Riggs R. F. Sackett P. A. Tardif J. A. Tierney CC: R. L * Bourget w. Bueker K. w. Howes M. A. Kulig . W. A. Sitnik CED has requested that we remove #3, 4 5 tanks from VCM service by the end of October so that they may begin dis mantling. Since this requires the cooperation of all of you, I have tried to identify the steps required and assigned target dates in order to meet the October 31st deadline (attached). Item #1 has already been discussed and hopefully activity is scheduled for this week. Since each step requires that the preceding step be completed, it is essential that we all know of any delays. Please review what is required and let me know of any problems. /pld attachment T?SV(W94444 / Objectives 1. By 10/31, remove tanks 3, 4 5 from VCM service. 2. Avoid any disruptions to PVC operations due to above. Action Plan 1. Manifold #2 tank into #1 #6 tank overflow. / Responsibility: Russ Sackett Timing: 10/8/73 2. Notify 88 '84 Building personnel that tanks 3, 4 5 are being removed from service. Review new method of operation (per AVL memo of 8/27/73 to DLG) with all 'concerned. Responsibility: Cary Riggs/Dave Gendron Timing: 10/12/73 3. Remove 3, 4 5 from service and fill with water. Responsibility: Joe Tierney Timing: 10/19/73 4. Isolate tanks 3, 4 5 l^y breaking inlet and outlet piping at tanks and at connections to VCM headers. Blank VCM headers as close as possible to VCM iso lation valves. Responsibility: Paul Tardif Timing: 10/31/73 J. J. Uihlein 10/2/73 pc-wnm/M/K A. V. Laakso August 27, 1973 VCM Storage Tanks D. L. Gendron C. D. Riggs R. L. Bourget --3. J. Uihlein When the L600 project takes over three of the VCM tanks in Tank Farm for AN service, we will be left with tanks 1, 2, and 6 for VCM usage. The attached schematic shows the proposed usage procedure when the switch is made. On some weekends, both pumps will have to draw from VCM tank No. 1. This should be no problem based on the tests I ran in early August using one tank to feed both pumps. This practice will represent no change for the 84 Bldg, lead operator. However, it will be something new for the 88 Bldg. CKO. At the time of implementa tion you should both plan to orient your LO's and CKO's about the change. Cary, you will need to spend more time training your CKO's as required. Attachment A. V. Laakso vcm Supply COf&cdy */ . 030 'g'/.soo 30, OOQ zo. ooo &f, ooo Sf, OOO *kJL| ust. ,, 10 Ml. OOO -r-7. " W,7oO goJ. ptT do+j 84 * is.soo -f 7.4> * i4,4oogeJ. per ^olj ^^Ui^>i'or\e> ) | it- rs *\/*U cowi Mor\ oJlr ^louo loe.'Vu^t^ Op&ro4~h^C| PracTic^ 8>A- cVvojjj Provn **? 8>> cXfcxuo fV *Z_ . I^or ^aJLii^ a. 4 b Ur . SappU^ . lop off to't'U "hvlAob c>v-> fV \ v\'"W, t Opfcn iajIo^o \ja$\) t 4*d ^ \ j uo^r Tr,-*~1/. flnt'-S' ^ O or 1 i?<;vnrnAAd7 IN 10 Rl,. it M AMB F date SUBJECT reference TO J. J. Uihlein--Springfield November 26, 1973 Removal of #3, 4, S 5 Tanks "from VCM Service D. L. Gendron C. D. Riggs R. F. Sackett P. A. Tardif J. A. Tierney cc.- R. L. Bourget R. W. Bueker R. E. Cummings K. W. Howes M. A. Kulig The above tanks have been removed from VCM service and #2 tank has been tied into the #1 - #6 tank overflow header. From here on, you will be operating according to the plan outlined by A1 Laakso on 8/27. Many thanks to each of you who helped make this change over go so1' smoothly. /pld Attachment TJQVnfVMAAS A. V. Laakso August 27, 1973 VCM Storage Tanks D. L. Gendron C. D. Riggs R. L. Bourget d. J. Uihlein When the L60D project takes over three of the VCM tanks in Tank Farm for AM service, we will be left with tanks 1, 2, and 6 for VCM usage. The attached schematic shows the proposed usage procedure when the switch is made. On some weekends, both pumps will have to draw from VCM tank No. 1. This should be no problem based on the tests I ran in early August using one tank to feed both pumps. This practice will represent no change for the 84 Bldg, lead operator. However, it will be something new for the 88 Bldg, CKO. At the time of implementa tion you should both plan to orient your LO's and CKO's about the change. Cary, you will need to spend more time training your CKX)'s as required. /m Attachment A. V. Laakso ncvono/M/io v c /-j % Supply. Cof&cJy . &'0$0 3^300 30, OOO & ZO.OOQ Sf, OOO ?7.000 SbJU^ use. a& 64 10* II. OOO -T- 7.4> 3 x I3.SOO -ir 7. *<6 W,7OO goJ. pf - 1^, H oo QaJ. per ^tcuj ,"^Ul^\0'AS ) Ti Z. ir\ COW \^or\ *</f*u i -% 4 OpzCoJc iviCj Pcac^\Cf. o^Lr flouo be'VuJfc^ ti7'i ujseb. *-* 0A cX^Oujj) -ffo-m ^<o ^ > cX-Ccujo fVcwv^ ^"2. . hiof/najUU^ 3_ HbUf . -- Top off loo-**^ 'Hvulc'b 0V\ f-V i . - Operi uc^oe. "To ^ \ (uc> or Ci^-o') Wjht-n Lpur QnfMi fV\ . PQvnn-Md^n DOW CHEMICAL U.S.A. October 3, 1973 1330 BOYLSTON STREET CHESTNUT HILL. MASSACHUSETTS 02167 Monsanto Company Springfield Plant Mr. Charles F- Smith 730 Worcester Road Indian Orchard, Mass- 01051 Dear Charlie: We have heard from the loading supervisor at our Oyster Creek division concerning the two leaking VCM tank cars, MCPX-33018 and MCFX-33010. Neither car appeared to be leaking when they left the plant and presumably it started during the trip due to content pressure. On future Monsanto shipments, our loading crews will leak test all fittings and check liquid level gauges before releasing the tank cars. We sincerely are sorry for the inconvenience we have caused and will do all we can in the future to prevent a recurrence. RSV0024451 CC: D. v. Bierv.'er : w. Bueker P. V. Kol:oszyna f /'V' * MONSANTO POLYMERS S. PETROCHEMICALS CO. 730 Worcssur Streel Indian Orchard, Massachusetts 01051 Phone: (413) 788-6911 "September 21, 1973 Hr. William Auvenshine Dow Chemical Company Oyster Creek Division 0. Box BB - _ . . . . Freeport, Texas 77541 >. . Reference: . VCH Tank Car .Shipments. _ Dear Hr. Auvenshine: Monsanto tan); car MCPX 3 3018 was shipped from Dow Chemical C*-\ T-, J-T**! \ 5 *V"V* ~2^-"^'i WV- *I- V exas August 17 , 197 3 loaded with VCH. This car was consignee :o Monsanto Company, Indian Orchar d, Has sachuseits. On August 24th the car a -ived at the Penn Central Railroad Y t; ^ t; r~> 2. Ti ^ 7 2. ** _L C Hass, and VCH was round- to n<= Monsanto was contacted by the railroad and personnel from the plant bro ke the dome cover seal to determine the cause of the leak, 1/4 inch tesi valve pipe was found to be cracked. Thi : pipe was tnen broken on at x.ne crack and a wooden pet wa i inserted into the remaining section oj. tne 1/4 inch pipe to prevent further, leakage. The . car. was then switched to the plant for emergency unloading. It was estimated that approximately 400 gallons of VCH had been spilled while car was in transit. ` It appears that the crack in the-1/4 inch valve pipe occurred during the loading operation at Dow Freeport, Texas. This car has been shopped for the necessary repairs. The purpose of this letter is to once again stress the importance of careful inspection of each empty VCH car prior to loading with product. Corrective action must be taken to prevent reoccurrence of incidents similar to this one. As we all know, ship: ants anc handling of hazardous conmoditzes are under close scru ir.v these davs bv the regulatory agencies involved and any neg igence or carelessness by parties involved -cent'd.2 unit c! Mcr sar-'.c CsTpeny i?<ivnn'M4<;7 Mr. William Auvenshine Dow Chemical Company Page 2. September 21, 1973 / can result in penalties and adverse publicity. Your efforts to tighten up on VCM car inspection procedures will be appreciated. Very truly yours, / J. H. Knapp L-"/Traffic Manager JHK/jhb ASSOCIATION OF 'ATIONS AND MAINTENANCE DEPARTMENT BUREAU OF EXPLOSIVES RICAN RAILROADS BUILDING WASHINGTON, D.C. 20036 202/293-4048 R. R. MANION Vice-President R, M. GRAZIANO Director end Chief inspector T, J, Bauer, inspector 29 Golfview Dr, Apt. A-3 Newark, Delaware 19711 302/731-9613 Mr. J. H. Knapp, Traffic Manager Monsanto Conpany Indian Orchard, Massachusetts. 025-T-l- PC September 7> 1973 Dear Mr. Knapp: This refers to MCPX 33018 tank car loaded with vinyl chloride observed leaking while being held in Penn Central yard, W. Springfield, Mass. August 24, 1973. It is ray understanding a representative frora your plant answered the call for assistance, and it was reported " sampling valve broken off at base, and unable to replace1'. At your convenience, will you kindly advise whether valve was broken off in an attempt to make repairs at the seene by your representative^or was. it^kund in that condition upon his Inspection? A detail description of coURtions found would be appreciated. Very truly yours cc: 0.A.Garland,Jr., Ass 11.Director-Field Gper&tions-B.i.. Ti O't rAA'1 A AC A Qdouston Train Derailment and the Subsequent Hearing TERRY C. HAYES NFPA Fire Service Specialist Mr. Hayes's article consists of a report of a de railment and fire and summary of the testimony at the hearing. The January 1972 issue of Fire Command! contains a similar report of the ac cident and, in addition, a detailed discussion of its lessons for fire departments. On October 19,1971, officers and men of the Houston, Texas, Fire Department were stunned and injured by a violent blast from a fire-involved railroad car contain ing vinyl chloride. The fire companies had responded to a train wreck and were attempting to direct cooling streams on the critical part of the fire. When the explo sion occurred four chief officers in command at the ^ne and 21 company officers and fire fighters were ^Socked out of action. One training officer was killed, 14 fire fighters and five news men were injured, and a Fire Department pumper was destroyed. Like previous fire tragedies, this incident brought a number of lessons to the fire service, the most important of which is this: When hazardous chemicals are in volved or exposed to fire, treat them with maximum re spect.! In this incident many other persons might have died except for miraculous quirks of good fortune. At approximately 1:40 pm Missouri Pacific Freight Train 94 entered the city limits of Houston, Texas, mov ing 82 cars of freight from tire coastal region, the heart of the area's petrochemical complex. At 1:46 pm the Houston Fire Department alarm office was Hooded with telephone calls reporting a fire and ex plosion in the vicinity of Almeda Genoa Road and Mykawa Road at the railroad tracks. At 1 ;47 pm the first Fire Department units dispatched acknowledged that they were responding. They ar rived at the scene and at 1:51 pm reported a train derail ment and several railroad cars on fire. The first-arriving chief officer asked for two additional pump companies. Fire fighters prepared to direct hose streams on the exposed tank cars to keep them cool and, it was hoped, ^^WAllthe photos in this article are used by courtesy of the Hous ton Fire Department. Operations just before violent rupture of vinyl chloride tank. The resulting fireball caused burns and other injuries to ap proximately S fire fighters and newsmen. One fire fighter suf fered fatal injuries. prevent further pressure buildup and fire involvement. Getting water on the tanks was not easy; the nearest fire hydrant was over six-tenths of a mile away. To complete the relay the district chief called for a secondalarm response. The area was sparsely settled, with about 13 in habited dwellings and small businesses located over half a square mile. Those persons were evacuated by police, but the black smoke that could be seen for miles brought spectators flocking to the scene, adding to the problems of the emergency forces. An aerial ladder was raised and a ladder pipe, which was fed by two 2!s-inch hose lines, was placed in serv ice to cool the exposed tanks. The pipe was set up to be operated manually or remotely from the aerial. Meanwhile, an attempt was being made to bring water in from the next hydrant, over a mile away. FIRE JOURNAL - MARCH 1972 13  t- ! r / ; ' -'"s# ';"4WW w'j_-- r , ' --i V,i i & ' -a <W'S irrr . <T ; 5 '<'n> ; j: i * Ef:V'. '.-A ^ ' -r^ ,-K^`vr A. 7 j -s TVfe1-.JV,*;","`-'-".!'A.rfi ^ ^ , *4 * ' '-/" -** $: L *sw' Junction of Mykawa Road (parallel to tracks) and Almeda Genoa Road. Although this was a sparsely populated area, the dense smoke attracted spectators from miles away. At 2:08 pm the chief officer at the scene requested three additional pumpers, and at 2:20 an additional pumper was dispatched, making a total of 15 pumpers and men, plus support units to combat the fire, which was becoming more intense by the minute. At 2:28 (approximately one minute before the explo sion) Fire Chief C, W. Cook, en route to the scene, radioed the officer in charge and asked if he knew the contents of the involved tank cars. The response was: View of Mykawa Road before blast. The white tank near speed limit sign received a massive puncture during the derailment and lost most of its contents of 48,000 gallons of vinyl chloride. This tank was moved 200 feet end over end when another vinyl chloride tank car ruptured violently, 43 minutes after the Fire Department received its alarm. The latter tank is obscured by smoke. "We've had two reports, one of ethyl chloride, the ot},,, methyl chloride. We do not know for sure. Th( t, also caustic soda involved." At 2:29 pm, 43 minutes after the first report to ;., alarm headquarters and 38 minutes after the am., of the first-in fire companies, one of the tank cars - ]..,M identified as a 48,000-gallon tank car of vinyl chloral, ruptured violently, creating a huge fireball. The i_. rounding area was showered with parts of tank (un rocks, crossties, and flying debris caught up with }* massive release of energy. Accelerated fire buildup seconds before the rupu-, gave most of the fire fighters just enough time to ter. and run. As a result, most of their burns were receii,,; on backsides and hands. However, Andy Nelson, v. had helped set up the ladder pipe, had climbed b.,, { to the nozzle before the rupture and was caught on mof the ladder to suffer tire full force of the fireball blast. Half on his own power and half falling, he it down the ladder and was helped to an ambulance U fellow fire fighters. His bunker coat was in shreds. hip boots showed signs of melted rubber, his htd>; was badly charred, and he was in critical condition;he was alive. T. J. Hathaway, recently assigned to d* Fire Department Training Division, was killed. All available ambulances were rushed to the scorn The fire chief arrived to find his assistant, a deputy s.r.J two district chiefs, three captains, four chauffeurs, npipe-and-ladder men, the chief mechanic, the chief ti special services, one investigator, and one fire inspect;* View of Mykawa Road before blast. The crew at left W monitor nozzle in position and is waiting for water. The t-v frost line faintly visible on the tank indicates that the tonl lost most of its contents in the derailment. ~*%i -V`- i * * ` 'S' . ^ '' ' . - > -t. ' % j f i?svnn?44^ The lank car that ruptured violently came to rest approximately 400 feet away. The tatik shown in the two photos at the bottom of the opposite page after it had been moved 200 feet. out of action and on their way to the hospital. There was still a major fire to be fought, and Chief Cook regrouped his men and sent for additional help and equipment. At 6:57 pm the fire was out. A survey of the scene revealed one fire fighter dead, an^fe taken to hospitals, along with five injured newsm<S^4 injured but remaining at the scene; one Fire Department pumper, a two-ton truck, and a station wagon destroyed; 16 rail cars either destroyed or heavily damaged, with their cargoes of butadiene, vinyl chloride, acetone, fuel oil, styrene, and caustic soda. The property damage has been estimated at more than $375,000, excluding the damage to the track and road bed. The National Transportation Safety Board con ducted an investigation and hearing to try to deter mine the cause of the derailment and the reason for the loss of life and injuries. The hearing lasted four days, with 25 witnesses called before the Board of In quiry. Seven of the witnesses were employees of the Santa Fe Railroad, eight were from the Missouri Pacific, four were from the Houston Fire Department, three were eyewitnesses, one was from the Railway Products Institute of the Association of American Railroads, one was from Union Carbide Corporation, and one was from the NFPA. There were eight parties to the hearing, so desig nated by the NTSB as persons, agencies, companies, and associations deemed necessary in the public in tent whose special knowledge or participation in the instigation would contribute to the emergence of per tinent evidence in the case. The parties were: the Mis souri Pacific Railroad Company, the Atchison Topeka and Santa Fe Railway Company, the City of Houston, the Congress of Railway Unions, the Brotherhood of Locomotive Engineers, the International Association of Fire Fighters, the Federal Railroad Administration, and the Dow Chemical Company. The Chainnan of the Board of Inquiry was the Hon orable Isabel A. Burgess. After being placed under oath, each witness was questioned by a member of the Technical Panel of the NTSB, then by a member of the Railroad Commission of Texas, Then representatives of the eight parties to the hearing were permitted to question the witness. There were two theories advanced by witnesses as to the cause of the derailment -- either track failure or impact action of the train creating heavy pushing forces that resulted in derailment. At the time of this writing the NSTB, which has the task of determining the cause of the derailment, had not made public its report. Since space will not permit a detailed account of the testimony given during the four days, the following is an attempt to condense the more pertinent facts into a meaningful account of the proceedings. There were 16 railroad cars in the main derailment area, among them six tank cars of vinyl chloride, three of fuel oil, and one each of acetone, butadiene, and formaldehyde. One tank car containing 48,000 gallons of vinyl chloride received a massive puncture during the derailment, causing it to loose most of its contents. The spilled vinyl chloride caught fire imme diately. Another car containing vinyl chloride received (Continued on page 17) T?cvnrm447 13. L. Gendron April 1 * 1973 Pushing into #1 and #6 Tasks d. A. Tierney A. Y. laakso ,J?. W. Bueker /) As a result of a recommendation made during the Investigation f NearfMiss #13-71 , (liquid VCM in the burning stack), an over flow line was Installed connecting #1 and #6 YCM tanks. Since that time, whenever YC$ vapors fro either of these tanks are used in pumping out a VCM car, the pressure is lowered in both tanks simultaneously. This lower pressure often causes the M Bldg. V-CM-.charge pump t cavitate, and oar ability to charge ?CK is lost, with;potentially serious quality and safety conse quences. Lowering pressure in the other four tanks supplying SB and 92 Bldgs, does not have this critical feature, since the kettles are not charged directi)' fro the tank far pump as is the case to 484 Bldg. Consequently, It seems that this situation can fee resolved simply by not using #1 or #6 tanks as sources of VCM vapor, Please take the necessary steps to insure that this is accomplished. Thank you. D. L. Gendron /ra Monsanto DATE Springfield, Massachusetts July 29, 1974 SUBJECT REFERENCE TO J.A. Tierney '-72 - / 3- cc. G.W. Fletcher D.H. Howe Recent tests of VCM concentration levels taken at the VCM pump house, building 82, indicate that concentrations of VCM are below 50PPM which the exhaust fans are running and the floor ex haust is operating. Therefore, it will not be necessary to wear the Scott Air Pac in the pump house while the above conditions exist. R.W. Bueker