Document 6beGgmDyOGyN4Xo0V7LYpMaNo

1 INTER-OFFICE MEMO TENNECO CHEMICALS, INC. / % To J From Mlringoff T * Sweeney \/ Subject Flemington Monthly Report February, 1981 At Piscataway At Flemington r, - Date March 2, 1981 Copy to U P Benn R. A. Donovan W. R. Fogelsangei. D. M. Hershkowitz M. R. Haymon R. R. Neugold C. K. Newman R. B. Robertson G. I. Rozand W, Rupp R. A. Sloff Dr. W. Sorensen M. E. V7agshul X. Production Production in February (28 day month) was good at 7.570 M lbs., representing 101.3% of the'budgeted average daily production rate. II. Quality A. "RFT" "RFT" for February was standard" at-88.6%. B. Grade III Summary '''"Grade III production in February was low at 1.6% (0.123 M Lbs.) The Grade III production resulted mainly from drying system clean outs following bag changes in both the "A" and "B" primary resin collectors. . * C. Customer Relations 1. During the month the plant experienced no customer rejec tions standard product. 2. Kentile returned one truckload of tailings as being "too coarse." D. Quality Improvements 1. The slurry electromagnets are continuing to function well. Plans continue forward towards the permanent purchase and installation of these magnets, and the evaluation of an electromagnet in the dry resin stream. 2. In a further effort to reduce metal contamination the reactor cleanout procedure was revised to provide high pressure gunout and rinse of each reactor after major cleaning. This high pres sure gunout and rinse will remove any loosened metal or glass re sulting from the cleaning prior to returning the reactor to servic TEN-F|_eM 200S9 TEN 4663 t / (2) 3. The use of extended stripping conditions continues to result in reduced total product volatiles. In an effort to reduce the water content of the resin a two-pronged concurrent approach is being employed| a. Plant trials at Flemington involving simulation of certain aspects of the Burlington manufacturing procedure. b. . Re-engineering of the secondary resin collectors to provide fluid bed drying capability. 4. CBS has requested Type 318 resin for their March 1981 orders. III. Yield Yield was very slightly below standard at 97.1% vs. 97.2%. The plant experienced a small yield loss (.0.1 - 0.2%) resulting from operating the recovery systems at a lower than normal pressure for a short period while repairs were performed on the compressor systems. IV. V. Overtime *> * O Overtime in February was at 22.,7%. The plant incurred abnormal levels of over time due to an extremely large export bagging order^ RCRA compliance projects and expansion project construction watch. +Z ` .'Z. C. --' General Operations ^* A. Reactor Building VCM Level Reactor. Building VCM level for February was low at 0.3 ppi<. B. Safety V 1. OSHA Days Away from Work Cases = 0 2. OSHA Restricted Duty Cases -1 The plant has now worked 467 consecutive days without a lost time injury. Safety Training, 26 supervised and Emergency Response team members received Multi Media First Aid Training during the month of February. C. RCRA During the month an extensive program was undertaken and completed to assure plant compliance with all aspects of the RCRA program. C. Expansion 1. Construction on the overhead silo installation continued throughout the month. On February 27 the two silos were erected. Completion date of this project is estimated at April 1. As a continuing interim measure, resin is being loaded into trucks at Flemington and transferred into hoppe cars at Ringoes, New Jersey. TEN 4664 /- (3) 2. Engineering is continuing to investigate the cause of intermittent fail ures in the Water Addback metering system. Current evidence points to. faulty operating secondary meters. This problem is under current discussion with the manufacturer. D. Fetterolf Dump Valves The new type Fetterolf dump valve continued to function extremely well. The plant has submitted an order to purchase this new type Fetterolf dump valve for the other nine reactors. E. Personnel 1. Mr. W. Schomp and Mr. D. Hutchins manned the Ringoes railcar loading opera tor in February. 2. Mr. J. Trimmer was hired at the Storekeeper. 3. Mr. W. Van Ness, Boiler Operator, passed away late in December. Mr. J. Wyckoff, Utility Operator, hgs taken the Boiler Operator position and the plant is currently processing applications to fill the vacancy. 4. Mr. W. Fogelsanger, Plant Engineer, together with Mrs. Shirley Robbins, PersonnelSupervisor, made a SEED presentation to. the Hunterdon County PTA. 5. Mr. Robert Robertson, Safety and Training Supervisor was appointed Deputy Coordinator, Department of Emergency Perparedness, Hunterdon County by the Board of chosen Freeholders. -. VI. The Flemington Plant received the first annual plant productivity award at the annual management meeting in Princeton. . Summary - Attached f VII. Capital Spending Status Report - Attached. VIII. Manufacturing Cost Projection - Attached. TEN 4665