Document KJ039NL7gw3LgE5LmE6L4N4k2

A a*d Chmoct& KSCAHtIA PLANT INTEROFFICE MEMORANDUM To: R. E. Jones From: W . J . Stueben Dot.: Copl: 13 July 1976 Monthly Report - Safety Dept. - June 1976 A new plant ambulance was placed in service on 10 June 1976. The Dodge Maxivan we now have, replaced a 1969 Plymouth Belvedere station wagon and has the room to handle almost any emergency we could have in the plant. Plans for the new dispensary building were approved in June 1976. The building will house the guards, nurse and the safety offices. It will place the dispensary at the edge of the plant property instead of in the middle of the plant. Officer Lee Tubbs of the Florida Marine Patrol was made available for safety meetings. Officer Tubbs has his own television show and is well known throughout the community. He spoke to approximately 80 people. A Safety Orientation Meeting was given to the group of engineers who will be part of our startup support at St. Gabriel. The session was given by the Safety Engineer at the request of J, McMakin. Inputs were also made In the following areas: Nitric Acid Plant failure, Hell's Corner revision, mercury sampling in the shops, loading procedures, oxygen deficiency instrumentation, first aid training, PVC expansion, fire crew training, St. Gabriel plant safety programs, plant insurance requirements.OSHA inspection followup and Safety Supervisor training. William J. Stueben Safety Engineer AP00041845 MONTHLY REPORT July, 1976 CHEMICALS GROUP ESCAMBIA PLANT wsmsm L AP00041846 MONTHLY REPORT July, 1976 CHEMICALS GROUP ESCAMBIA PLANT received |W6 ?6 ',a7b W. R. SCHOFIELD AP00041847 /\ &$b7%0c&tctl<Wdemtca& eseAMItA SCANT me. INTKROFPICI MKMORANDUM To: Mr. A. K. McMillan From: r. e. Jones Re: Monthly Report - July, 1976 Dot*: Copies1. 9 August 1976 Pace operations for July were generally good except for Amines. Hot weather coupled-with severe electric storms early in the month contributed to plant problems. Four separate power failures caused by heavy ILghtnLng in the area caused outages in No. 1 Nitric Acid, "B" Area and both Amines plants. Ammonia production was 7, 366 tons or 94% of standard with an overall gas efficiency of 43.2 MM BTU/ton (Budget 45.4). Operating emphasis has been to improve plant reliability and efficiencies rather than throughput. Restrictions were placed on reformer firing to improve onstream time and to reduce waste heat boiler silica fouling. This program has been successful thus far in generating large positive variances offsetting negative volume effects. July values will continue to reflect the effects of this program. Use of once-through well water for primary loop cooling will be evaluated since the effluent treatment system is operating very well during the hot summer months and is capable of handling the added volume. Waste heat boiler fouling by silica is still under control with the plant actually having a net steam export. Nitric Acid production continued better than budget at 17,2 15 tons versus a standard of 14, 706 tons. A total of 39 hours of downtime was incurred by the No. 1 acid plant due to the four power outages. A vital controller which activates the trip-out interlock switch was found to be operating on the plant HO volt system. The loop has been rewired to the emergency power system and should prevent further trips due to power "dips". Some control problems still exist with using the Masar refrigeration compressor discharge for ammonia feed for the gauze. Additional instrumentation equipment has been located and will be installed during the next scheduled outage. Ammonium nitrate area production continues well in excess of budget due to the extended fertilizer season. Monthly production figures are presented below: AP00041848 T Mr. A. K. McMillan -2- 9 August 1976 July Actual Budget Year to Date Actual Budget 83% A. N. Prills Urea Urea Solution Bay-Sol 19, 601 14,693 1,896 4, 980 47 11,333 8,759 966 2, 643 506 153,021 135,781 17,540 49,666 2,916 174, 763 139,030 15,969 41, 248 12,330 As can be seen, due to the late season sales, year-to-date budget production levels are close to being achieved in the prill area. Continued good ammonia plant availability is also allowing urea and urea solutions to exceed budget levels. It is expected that production volumes will continue at above budget rates in these areas. PVC production continued above budget at 6,891 M lbs. (101.7% of budget). An additional 73M lbs. was lost due to startup after the scheduled June outage for project tie-in work. Off-grade production continues low at 0.36% of total production. VC1 efficiency continues good at 95.9% as compared to budget of 95. 5%. Personnel monitoring improved for July with 92% of 8-hour TWA's below 1 ppm and 96% of 15-minute TWA's less than 5 ppm. Methanol production for July was much improved with 3,406 M gallons produced (130% of budget) in spite of 4 power outages and 3 unscheduled reformer outages for tube repairs. More conservative reformer operating restrictions have been effected to improve plant reliabilities. Augmenting the favorable volume effect, efficiencies and spending variances were also favorable. August should continue to exhibit these generally improved trends in methanol operation. Amines production was very erratic during July as a result of the almost continuous power outages during the first of the month coupled with the very hot weather experienced late in the month. Methylanrin.es production continues below budget levels both in volume and efficiencies. Power outages during the month caused production interruption totalling four days with subsequent losses in yields and volumes. A total of 1. 1 MM lbs. of MMA was recycled across the catalyst in July as a result of full inventories. At month end additional storage was made available and Carbide specification material-production was resumed. By August 8 all available storage will be full and 1. 5 MM lbs. of Carbide specification MMA will be in inventory. Recycle of MMA will then be required. Additional TMA storage is also being prepared and full inventories of this material is expected by midAugust at which time the plant will be changed over to ethyls production. AP00041849 7 Mr. A. K. McMillan -3- 9 August 1976 In addition to the plant outages resulting from the early month power failures, other operating difficulties were encountered which contributed to the plant's overall poor performance. By-product methanol produced during DMF production was charged to the plant for a period of 10 days during which time "oils" from the process layered out in the TMA separation column causing periodic upsets and production of off-specification TMA. This material which had to be recycled amounted to about 800,000 lbs. Because of plant instabilities at this time an additional 2.00,000 lbs. of DMA production was lost. The DMF methanol has been since eliminated as methylamines feed and has been diverted into the methanol plant distillation for recovery. Other problems associated with hot weather include high vent rates from the high pressure scrubber and higher vapor losses from storage. New high pressure water pumps to reduce the process vent losses have been ordered and will be installed in September of this year prior to the next scheduled methyls run. The No. 2 Amines plant produced ethyls all month with many of the same problems experienced by the No. 1 plant resulting from the power outages experienced early in the month. Not enough columns are available in the No. 2 plant to produce DEA continuously, therefore 95% DEA material is accumulated for purification in the 72" batch still. Since the still was in DMF production for 75% of the month, very little DEA was produced. This material amounting to 600M ibs. will be recovered in August with a resulting improvement in both volume and yield effects. Rates in the No. 2 plant have been lower than budget due to reaction heat restrictions. At month end budget rates were being achieved. However, plans are for conversion to MIPA in mid-August and budget levels of this product are readily attainable in the No. 2 plant. The effluent treatment system continues to perform excellently with Total-N discharges averaging below 500 lbs. for the third straight month. No amines wastes are Included in these values. Preliminary construction work was begun on the final NPDES effluent project after Executive Board approval in mid-July. Work is proceeding to permit attainment of final levels by January 1, 1977. August performance for the plant should continue to show effects of the improved operations in ammonia and methanol. A reduction in sales demands in ammonium nitrate should reduce production volumes to normal levels. A 10-day outage has been scheduled in prilling to install the stainless steel lines in the reclaim area. AP00041850 Mr. A. K. McMillan 4- 9 August 1976 PVC is expected to continue at budgeted rates and efficiencies. Amines will have two outages for product changeover due to delays in St. Gabriel startup. Improvements in product rates and yields have already been made and are expected to continue through August. REJ:fls Attachments (5) ' E. Jones AP00041851 AP0004I852 Ip II * s*i ^ sss!* 5 *H Sa|H ^sf!1I 1 m $ 3 E` CftS ' i l 51*1 ftj[2 E |i I * I i i i i &'h1 r S ' '8 ' 8 n .......... III! J o b fl 3a bx is S !!' "Hwb ftSft ' t l **fS fi H 0 I S' aaa i' I ftlr 1 i 3 *5" | 111 H %S l a* * ,.. atLsfsg SSft 1 is I Ss' t S' 1 6 sijj SS sis a 32ft '3 | a a*1j' v'Z* iKl lX2| SH S ft * X* 1 3$ ? 1 1 4? 1 5 i ii 9' 1 3 ;5 3 s' 5 Ir1 I 'i'i 3 s'S'si S3f 5 ? SI *sn? S' ^psi dsr i 3""i d: a 3 | SH '* i m 3 1* 31 sfe ... ' 1 "H<H ' t- 3 a I"'!4 .... I^4 fHH ' ' ' P i' ws 1 n 51 i * a~s i 23 j is 1 H 111 11 sa & ' 111 M} m>4 . 5 Sflfl 1 m * .* gj H .... H Hill N * tiiir '"' ' ft 3- 3 , w g s ' s 3 1 3 1 a ft !1 INI IP | p- *p R 1 4 14* y 1 *V .\ . <jj . . 44 ft*S ft h is 1 1 1 *3ss ft a~' 5 Sl* ' ' 9 5"S "S** s *M" 3 s! el *5 f 1 1 H*38ft P . S 1*11 5 > 5 6 ft rl g isHB *i H * 1 1 1 -aflgu 5 m*tt' s g HMI l * l"l * I is sc a* laws s ?af 5 i 1 1 lld> 1 1 5 rf <s S 'ft ' P* I 1 *. 1 p sa ^a j ii i i1! ft ? t 1 I *1 Si hi 1 2 - pil llhl t mu 11 s 4i 'III! l jj iitl 1 iii* 1 iill i i AP00041853 4 i M$ { ) Unfavorable Variance from Standard PRODUCT COST VARIANCE STATEMENT FORWARD REPORT July, 1976 8/19/76 Facility Pace Period Year End FY1976- Production (000) Actual A. Production Related Variances ' I. Raw Material Conversion II. Volume c) Offgrade EH. Soendine (Use) (at std. S/nnit) # d) Utilities IV. Spendinfl_JRate^ Total Spending (Rate) Ammonia Nitric Acid 63% AN 94,300 176,474 88,807 166,988 197,908 179,179 Prills Urea/Sol. Methanol Amines 153, 312 147,450 18, 005 21.130 27, 400 30,825 112, 338 88, 1 PVC 76,116 76.450 Total 7 13 1B6 62 2 44 374 (35) 653 (56) Jim jrm--r _ - - _ - 82 03 T5---------------------9---------- l*V) (15) 42 109 171 39 190 4 5 15 19 35 78 _ _ - 57 (24) (35) 119 190 307 - (707) ^ 1 ? (651) _ (89) *84) 1295) _ 94 -- ____&L_ - - (796) 112 (862) 2 18 --LI 2)_____ 49 1 28 1 86 _X5B \_____ , (51____ 85 3 29 TTOTT (73) 1194) V (227) Zti (106) 223 233 -(15L _ -284 185 43 7200) 286_______ 136_______ --949..,. (25) 4* --29----------- 113 - 9 3d - 112 51 21 11 2 3 73 35 8 - 59 --26______ - 5 19 72 10 114 Z5 34 136 18 7R (54) _ 236 69 "f?8..... (IQ)______ 486 TOTAL PRODUCTION RELATED VARIANCES 50 254 323 395 50 (90 42 203 l. 226 AP00041854 M$ ( ) Unfavorable Variance From Standard PRODUCT COST VARIANCE STATEMENT FORWARD REPORT July, 1976 8/19/76 Pace Page 2 Year End FY1976 B. V. Purchase Price Variances - a) Raw Material b) Purchased Utilities c) Feedstock Mix d) Other (maint. mat'l, op. sup.tetc.) Total Purchase Price C.V1. Business Variances a) Volume b) Systems Variance c) Other Total Business Variances Ammonia Nitric Acid 83% AN (101) (89) _ 1 3 Tim-- --T---------- 4 - 4 (147) -_ - l\A7\ (68) - [681 Prills Urea/Sol. Methanol Amines 11 (168) (34) 5 - (211) (1) - - - (243) l6 - 12 (266) (23) - (23) 12 445 --- 12 445 (106) T391 (234) (379) PVC Total 198 6 - (1) 203 (93) (283) (243) 1 (608) (237) T7E (5) (66) (124) 137 (239) (226) TOTAL PRODUCT COST VARIANCES FROM STANDARD VK. Budeeted Variances from Standard a) Raw Material Cost b) Purchased Utilities Cost c) Volume d) Spending e) System Total Budgeted Variances TOTAL VARIANCES FROM BUDGET a) Production Related b) Purchased Price Variances c) Business Variance (140) 22 m - _ - 22 (162) 50 (212) - 111 m - 111 254 4 (147) 259 388 62 (25) (603) 340 392 _ __ _ - _ - - -- 259 388 62 323 395 50 4 16 68 --,.12UP--.( ).......... _______ (25) [91) 7371] 445 (1) - m (602) 43 (266) (379) - I 171 172 22 _ _ _ 1?1 193 168 199 202 203 _L ?26 (630 (237)_____ -(327 AP00041855 PRODUCTION SUMMARY Agricultural Chemicals (tons) Ammonia Nitric Acid 83% AN Bay-Sol Prills Urea U-3Z Industrial Chemicals Amines (M lbs -) Methanol (M gals.) Plastics PVC (M lbs.) July Actual Budget Year to Date Actual Budget August Estim. Budget Plant Inven. 7,366 17,215 19,601 47 14,693 1,896 4,980 8,382 73,607 80, 608 7, 600 8, 382 3, 031 10,470 136,516 155,070 15,900 9,450 325 11,333 153,021 174,763 17,700 10,090 1,729 506 2.916 12,330 90 920 0 8,759 135,781 139,030 6,000 5,451 1,730 966 17,540 15,969 1,850 1, 136 31 2,643 45,841 41,248 4,300 2, 643 2,245 6,840 3,406, 11,846 2,630 73, 165 93,621 24,025 21,290 7,560 11,680 14,716 3,400 2, 630 2,099 6,891 6,777 62,820 62,439 6,850 6,777 2,747 AP00041856