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Monsanto
FOv -NAME 4 lOCAHON}
C. L. Wilson Noel L. Rickard - Texas City, Texas
50D
DATE SUBJECT BCEEBENCE
August 26, 1976
SAFETY TOPICS FOR SAFETY gOWTACT '76
L. I. Baker r! Rosen^g"
G. T. Ryan L. N. Vickery
PLAINTIFF'S EXHIBIT
TO Arnold Glass
Following are the four safety topics for the Safety Contact *j6 Program from Department 50:
1. Lockout Procedure 2. Decontamination Procedure 3. Sampling Procedure 4. Iodine Handling Procedure
es SC 14572 LAM015164
SAFETY TOPICS - CONTACT SAFETY '76
DEPARTMENTS 19-25-27-29 Emergency lighting Safety goggle regulations Emergency Procedure Plan Personal protective equipment Sampling toxic streams Handling of samples of hazardous materials
14573
LAM015165
DEPARTMENT 33 SAFETY TOPIC '76
1. Lockout P41. 2. Prepare 33V2 for entry. 3. Put on the Scott Air Pak.
/jp 8/30/76
A. R. Kivich G. G. Chestnut
14574
LAM015166
DEPARTMENT 56
1. 56V1 preparing for maintenance. 2. PA system preparing for maintenance.
DEPARTMENT 48
1. R101 O.H. line preparing for maintenance. 2. C701 preparing for maintenance. 3. Hydrogenators catalyst change out.
/j.p 8/30/76
N. G. Trainer T. J. Kennedy
SC 14575
LAM015167
DEPARTMENT 53 SAFETY TOPICS FOR CONTACT *76 PROGRAM
1. Hazards associated with and proper precautions to take when preparing the 53E6 switch condenser drain lines for maintenance to disconnect, connect, or break into to avoid hazard to fitters (PA burns).
2. Hazards associated with and proper precautions to take in closing off the column vacuum jets to keep column vacuum from pulling in air or vapors from outside columns (explosive or contamination hazard).
3. Hazards associated with and proper procedure required to return a 53E7 switch condenser to service following a repair job - specifically how to avoid getting any water into the hot oil system which could result in a severe overpressure of equipment (overpressure and equipment rupture hazard).
/jP 8/30/76
G. A. Hart Ken Harris
14576
LAM015168
SAFETY TOPIC LIST
ANALYZER
1. Handling and changing cylinders. 2. Flushing sample lines. 3. Changing sample valves. 4. Sample oven jobs have burn hazard.
ELECTRONIC SHOP
1. High voltage troubleshooting. 2. Changing CRT's or picture tubes. 3. Watch for electrolytic capacitor explosions. 4. Beware of temporary exposed wiring during tests or troubleshooting. 5. Isolation transformer is necessary on equipment that has no internal
isolation. 6. Discharge capacitors when equipment has no power on. 7. Dynatrol replacement. 8. Proper use of soldering equipment.
CONVENTIONAL FIELD
1. Checking seal meter. 2. Checking displacers on level transmitters. 3. Blowing down steam meters. 4. Chlorinator troubleshooting and repair. 5. HCN pH sampling. 6. Thermocouple removal (hot).
CONVENTIONAL SHOP
1. Handling heavy equipment (valves, etc.) 2. Opening enclosed instruments that may contain hazardous materials. 3. Lathe operation. 4. Use of welding and cutting equipment. 5. Use of drill press and grinders. 6. Use of hydraulic press. 7. Shop hand tools.
8/25/76
C. E. Coulston Hourly Safety Comm. Rep. Instrument Dept.
SC 14577
LAM015169
INSULATION DEPARTMENT LIST OF SAFETY TOPICS
1. Burn protection (hazard area). 2. Handling of asbestos material. 3. Working in cover goggle area. 4. Stripping of caustic lines, electric traced lines, hot
lines, rusty and corroded lines. 5. Working in high places.
/j.P 8/30/76
S. Jones
SC 14578
LAM015170
BOILERMAKERS
1. 10E65 maintenance. 2. 53E6 switch condenser maintenance - bundle replacement. 3. Methanol reformer - header repair & pigtail crimping. 4. 35V1-1, 2, 3 - cleaning polymer out of reactor. 5. 13E3's - unheading, rodding, and cleaning. 6. Installing boom and lift cranes, taking out boom.
/jP 8/30/76
Anderson/Leach
14579
LAM015171
CARPENTERS
1. Building scaffolds around expansion joints and piping on 15Rl's.
2. Scaffolding beside CT-8. 3. Work on scaffolds near vent hoods.
/jP 8/30/76
Grimes /McGowan
SC 14580
LAM015172
ELECTRICAL SHOP SAFETY TOPICS FOR DISCUSSION
1. Relamping. 2. Changing belts on motors. 3. Changing out 480 volt breakers. 4. Battery maintenance. 5. Load switching (power distribution). 6. Motor repairing. 7. Disconnecting and handling motors.
/jp 8/30/76
J. S. McCurley J. D. Kemmerling
SC 14581
LAM015173
PAINT DEPARTMENT
1. Sandblasting. 2. Spray painting. 3. Stageing.
/ j.P 8/30/76
T. H. Glover J. F. Thompson
Sc 14582
LAM015174
PIPEFITTERS
1. Install slip blinds (for what purpose). 2. Remove piping (for what purpose). 3. Clean screens. 4. Fabricate piping. 5. Cut out slip blinds. 6. Hook up barges & ships (disconnect same). 7. Hook up HCl trucks (disconnect same). 8. Hook up sulphuric acid cars (disconnect same). 9. Weld up steam leaks. 10. Revise existing piping. 11. Remove relief valves and install. 12. Remove instruments and install. 13. Water blast contaminated pipe. 14. Rattle plugged pipe. 15. Using heavy equipment to install or remove pipe, valves, etc. 16. Making pipe hanger in the field. 17. Breakout out plugged piping. 18. Repairing underground piping. 19. Remove, repair, and replace seal piping on mixers, compressor
pumps, etc. 20. Replace filters. 21. Hot tap connections. 22. Install rupture disk. 23. Breaking out hazardous piping such as HCN.
/jp 8/30/76
sc 14583
LAM015175
MACHINISTS
Page 1 of 2
1. 16P54-3 - cooling water pump. 2. 15Pl5's & 16's condensate pumps. 3. 13P5's. 4. 10P31 waste oil pumps. 5. Routine running repairs on Clark engines (Dept. 10). 6. 977 DM 14-2 clarifier. 7. CT2 - cooling tower (gear box) (fan). 8. 50P102 DT (product pump). 9. 35N8-1 & 2 seals. 10. 35G1 & 2 & 3 die plates. 11. 35G1, 2, & 3 blobs. 12. 35G1-3 blade changes. 13. 35NN7-1 & 2 seals. 14. Tank car valves (Research Dept.). 15. Diesel repair on barges (Research Dept.). 16. 513 P202's slush pump (Research Dept.). 17. 513 P207's acid pumps (Research Dept.). 18. Dept. 17 fire pumps - alignment. 19. CR-1 - Manitowac - pull main drive wheel & axles (garage). 20. CR-1 - Manitowac - pull draw works (garage) (drum shaft
assembly). 21. CR-6 Pettibone - pull boom and or wheels (garage). 22. 56R1-1, 2, 3, 4 - change agitator shaft. 23. 53V1-1, 2, 3, 4, 5 - Dingier valves - replace gear box. 24. 48P406-1 & 2 - Sundine pump & gear box - repair & replace. 25. 48C701 - compressor - valve change.
SC 14584
LAM015176
Page 2 of 2
MACHINISTS (cont'd) 26. 44P103-1, 2, 3 - pumps & turbine - remove & replace pumps
P.M. or turbines. 27. 972 CT3 B 1 thru 10 - P.M. on cooling tower fans. 28. Tool room - removing tarps. 29. Bench (general) pump repairs.
/ip 8/30/76
Zeller Puckett
sc 14585
LAM015177
OPERATING ENGINEERS
1. Traveling cranes thru plant. 2. Getting off & on cranes. 3. Laying Dept. 10 Petro Chem heater stacks down. 4. Remove & install 10E65's.
/j.P 8/30/76
Black McRae
sc 14586
LAM015178
SAFETY TOPICS - CONTACT SAFETY '76 LABOR DEPARTMENT Lifting hazards Slipping handling Handling NSI material Personal protective equipment
sc 14587
LAM015179
SAFETY TOPICS - SAFETY CONTACT '76 TRUCK DEPARTMENT Safe handling of laboratory materials Safety in getting on or off the truck Handling of drums of scrap Transferring tool boxes
sc 14588
LAMOI5180
SAFETY TOPICS - SAFETY CONTACT '76 NIGHT JANITORS Dumping of containers Lifting Ladder safety Changing lights Slipping hazards
SC 14589
LAM015181
PURCHASING/STORES SAFETY TOPICS
Sc
1459 0
What do you do when the fire (or spill) alarm is sounded. Is it fire r spill? What type communication? Do you run outside or stay inside? Do you use the telephone? During spill, is building pressured up?
Do you know the location and how to work the fire extinguishers in your office area?
Do you know all plant exits? If not, where would you find out if floor warden was not available?
Inspecting material packaged in cardboard cartons w/staple closures, wooden crates, steel bands.
Unloading palletized material at Receiving Dept.
Shipping of chemical product samples.
Handling of NSI at NSI Warehouse.
Receiving procedure for compressed cylinders. (Ask about compressed air.)
Loading and unloading of four wheeled freight hand trucks (routine).
Use of elevators and dumbwaiters.
Handling of blasting caps.
Personal safety equipment requirements in Stores Dept.
Driving fork lift trucks on ramps.
Removing heavy materials from bin by hand.
Coating parts with hot seal peel. Unloading raw material trailer trucks.
LAM015182
Handling cylinders (compressed gas).
8/27/76
PE LAB
sc
14591
1. Preparation of test slabs for determining polymer properties. 2. Use of viscosity testing equipment (MCER - viscosity). 3. Sample preparation for liquid slurries.
/jp 8/30/76
LAM015183
14592 sc
SAFETY TOPICS - SAFETY CONTACT '76 CONTROL LABORATORY Safe handling of unlabeled materials Dumping waste materials Safe handling of glassware Safe handling of samples in bottles
LAM015184
August 25,1976
SAFETY CONTACT '76 PROGRAM
TO HOURLY SAFETY COMMITTEE MEMBER BOBBY SANDERS
I,as Supervisory contact for Material Handling.have been asked to make a list of safety topics. They are the following
1. Trackmobil safety--for polyethylene section. 2. Safety in loading and unloading ship and barges. 3. Tankcar loading and unloading safety. 4. Tanktruck loading and unloading safety. 5. Drum loading safety.
SC 14593
Joe A. Cantrell
LAM015185
SAFETY TOPICS - SAFETY CONTACT '76 GUARDS Safe handling of traffic at gates Foot patrol tripping hazards Defensive driving Construction area hazards
Sc l*S94
LAM015186
CAFETERIA
1. The safety hazards of cooking. 2. The safety hazards of waitress work. 3. The safety hazards of dish washers.
/jp 8/30/76
C. Merryman L. Chandler
sc 14595
LAM015187
MECHANICAL TECHNOLOGY (Topics I Gave to Gupton)
1. Use of office equipment, electrical precautions. 2. What to do in case of fire. 3. Laboratory safety - personal protection while working
with metal. 4. Field safety - conditions and procedures for inspecting
equipment.
/jP 8/30/76
`S'C
LAM015188
sc 14597
Page 1 of 3
SAFETY TOPICS FOR "SAFETY CONTACT" EXPERTS - AN-5
TOPIC 1. Fire Permit Procedure
2. Protective Devices, Large Rotating Machinery Safety (i.e., vibration, thrust, low oil, overspeed, etc.)
3. Construction Area Safety
4. HCN handling (Applies to both AN-5 and Dept. 19)
5. Hazards of Handling LPG's (propylene)
POSSIBLE APPLICATION
a. New piping in existing racks; role of CED, future owner and adjacent area supervision and operators.
b. New construction in existing plant (i.e.. North Storage Area) Permit vs. "Open Area."
a. AN-5 main air compressors
b. Methanol compressors.
c. Styrene axial compressors (Vanderford good candidate here).
a. Things to be alert to when touring and const, area, hazards.
b. "Safest" time to visit area.
a. HCN sampling in AN-5.
b. "First flange rule" in AN-5.
c. "Buddy system" in AN-5.
d. Operator back-up for Maint., P.T., etc.
e. Precautions when incinerating liquid HCN.
f. Decontamination of HCN handling eqpt. (heads col., condenser, etc.) and piping.
g- Reporting to Chief Operator prior to entering AN-5 Mfg. area.
a. Handling RV discharges (thermal RV's to vent headers, flare, etc.)
b. Bleeding down LPG piping (valve freeze-ups, double block and bleed design in AN-5, bleeders hand piped to vent headers, etc.).
LAM015189
Page 2 of 3
AN-5 (cont'd)
TOPIC
POSSIBLE APPLICATION
6. LPG Pipeline Safety (propylene)
a. Above applications apply.
b. Special controls (i.e. high down stream pressure overrides, low upstream pressure).
c. Remote shutoffs at fence line.
d. Clearing a pipeline of liquid (i.e. line pigging facilities).
e. Clearing a pipeline of moisture and air prior to introduction of LPG's.
f. Optional - piping classes for
LPG's, relationship between piping class and RV settings; why are we using 600 lb. class
pipe?
7. Hazards of Handling Steam (AN-5, Power 2 MeOH, SM, PA, etc.)
a. Safe method of warming up headers, vessels, turbines, etc. (avoidance of water - hammer, etc.)
b. Detecting/handling leaks in HP steam service.
c. Avoiding contact with hot equip ment; personnel protection, etc.
8. Safe Operation of Boilers
a. Flame scanner system.
and Furnaces (Power 2, MeOH,
AN-5, SM, PA, etc.)
b. Boiler interlock system; why
necessary?
c. Necessity of purging firebox prior to ignition.
d. Monitoring/control of excess air;
hazards of "combustibles,Uo r o v* J o P 1
rtmki i f* ^ 4 K 1 OC ^
Sc e. Hazard of flashbacks.
LAM015190
} Page 3 of 3
AN-5 (cont'd) TOPIC 9. Importance of Comraunica-
tions in Large Units (AN-5)
10. Safe Use and Care of Operator's "Tools" and Protective Equipment
POSSIBLE APPLICATION
a. Safety advantages of maintaining radio contact with Control Room.
b. Use of radios and other comm./ alarm devices during spills.
c. Handling and controlling hazards via telephone "hot lines" (i.e., HCN to Dept. 19; ammonia spills, etc. )
a. Valve wrenches; how to use properly (how does small man operate those big valves).
b. Proper use of pipe wrenches, channel locks, why these aren't good substitutes for valve wrenches.
c. Operator radio as a tool.
d. Use and importance of plastic gloves, cover goggles, rubber boots & slicker suits, longsleeved shirts.
/jP 8/30/76
Sc l4599
L. Schlechte J. H. Swain B. V. Kukkuk
LAM015191