Document QkXpaDMM5OwQeDqnBLQmpJpbR

"THE WORD ON AROCLOR" Issue No. 2 2nd Qtr., 1968 FOREWORD This is issue #2 in the "stupendous" publication series. The comments and suggestions received on the first issue were extremely favorable and help ful. We appreciate your comments and hope that each of you will continue to make your views known to us. As there is much news to communicate since our last issue, "let's have at it!" 1968 2ND QTR. REVIEW The first quarter of '68 was outstanding, but the second quarter performance was equally as strong. Here are some of the results achieved. SAFETY 2nd Qtr. Year to Date Number of Disabling Injuries Number of Serious Injuries Number of Minor Injuries Minor Injury Frequency (Inj/: Number of Injury Free Months =0 0 =0 0 = )= = 79 1-75 1.20 (Target 1.0 0 -1 Max.) The safety ride was as smooth as a Tennessee Walking Horse until a two week period in June arrived. During that period the steed must have gotten a burr under his saddle because 5 minor injuries were incurred. All members of the department yelled WhoalT with the result being an abrupt halt in the disturbing injury performance. As is also the case for the entire plant, we are having an excellent year in safety, and if we can keep unsafe acts under control we can end up with the best record ever attained. If we're to break this record each of us must - "Develop a keen Safety Awareness". Just a few items which should cross your mind each time you perform a task include the following? 1) Do I understand what's to be done? 2) Do I know how to do the job safely? 13) Do I have the proper tools and safety equipment to do the job? 4) What are the hazards on this job? HOUSE5K)EEIPfINGI know the answers to questions 1 2tnhdruQt4r. will I maYkeeaursetooDf ate the answers in doing the job? Dept, place rating = 6 1 Number of months rated first place = Total points received = 0 8ll (900 3 1688 (1800 possible) possible) DsW 308420 Y STLCOPCB4070093 2 It's obvious from the place and point ratings received during the second quarter that our housekeeping level has slipped. There are some reasons for this drop to be sure, but we can do much better than that evidenced by second quarter results. Are we going to give-up our "Gold Broom" award without a struggle? The third quarter promises to be our most trying housekeeping period due to the construction activity preceding our expansion start-up. It will take the cooperation and effort of each of us to achieve our first place target. And incidentally. Corporate Inspection Time (October) is really just around the corner. We received "honorable mention" in last year's inspection, but how will we fare in '68? To repeat a phrase from our last issue - "Are you up to the challenge ahead?" PRODUCTION - 2nd Qtr. Total Aroclor Production = Up 5*1# over 2nd Qtr. of '67 Total Pyranol Production = Down 33.6# over 2nd Qtr. of '67 Total Pydraul Production = Up 93.4# over 2nd Qtr. of '67 Total Production = Down 0.7# over 2nd Qtr. of '67 Record Broken Monthly Records New Record Date Old Record Date Total Aroclor Production May, 1968 November, 1967 Total Dept. 246 Production May, 1968 November, 1967 Pydraul 280 Production 5.9# June, 1968 December, 1967 Through the first half of 1968 we have produced 4.1# more than thru the record first half of 1967. In fact, output during the second quarter of '68 was the second highest ever achieved for a quarterly period. The down ward trend in Pyranol production this past quarter and this year is due to raw material shortages. In spite of the outstanding performance, however, our inventory levels continue to lag at the low levels set during the first quarter of this year. The objectives of our new plant are to provide quality and capacity tomeet sales requirements in the years ahead. At the outset it appeared we'd have the plant on line well ahead of the market place requirements; however, we find ourselves "sold-out" in 1968. The'68 production results tc date have kept pace with sales, but with no sales relief in sight and with the start up of the new manufacturing facilities some 3 months away we must continue to perform at the high level demonstrated so far this year. As noted above 3 new production records were established during the second quarter. This brings our total this year to 5. Our "hats-off" to each of you for the part you played in making these records possible. SIGNIFICANT EVENTS Still Feed Preheater - The spiral heat exchanger installed in the feed line from #1 blow tank to the stills was successfully started-up on April l6. The new unit achieved its objective of eliminating "HFR" from the chlorinator log sheets. The trial period was culminated on May 31 with the end-of-trial Article 10 discussion at which both the Premium and Second Operator classifications were granted a 4^/hr. wage adjust ment. Our thanks to the men who helped make this start-up a success. DSW 308421 STLCOPCB4070094 -3- TCB - We received l6o drums of TCB from Progil in France to help relieve the TCB shortage situation. This material will be used intermittently throughout the rest of '68. Pydraul 280 - This product was produced for the first time this year, and a new production record was established during the run. To elimi nate the troublesome drum handling of one of the raw materials, it was successfully received by trailer for the first time. High Chlorinator Temperature - The chlorination temperature was in creased on April 8 to protect the Aroclor quality from the higher bromine levels in the chlorine supply. Fume problems at the sampling points resulted, and a new project to collect these fumes and those at the drumming station has been designed. The equipment for this project is now on order. New Chlorination Catalyst - Trial runs utilizing a new chlorination catalyst were made in May and June. The purpose of the catalyst is to improve product quality. Results to date indicate only marginal improvement. Further testing is scheduled for the third quarter. Nitrogen Blanketing - Start-up of the nitrogen blanketing system on #9, 10 & 11 storage tanks was attempted in June, but was unsuccessful due to leaks. The purpose of the blanketing is to preserve product quality in storage. The system will be tested again during July. Off-Gas Condenser - The condenser in the off-gas scrubbing system failed and allowed water to enter the HC1 transmission line and mist eliminator. Extensive corrosion damage resulted, but with the excep tion of the condenser itself has been repaired. The condenser is "unrepairable" and we are attempting to operate without it until the new scrubbing system starts-up in October. Aroclor 1232 - A special run of this product was made during June. The close process control necessary for this product and practiced by each of you during the run was evident in the results achieved. r " New Office - The new foreman's office on the second level was activated in June "sans air conditioner". The model of the expansion is located in this office and we invite your review, comments, and discussion on the new layout. Phase I Article 10 Discussion - The Article 10 Discussion on Phase I of the Aroclor Expansion (Tank Farm) was held on June 13- The responsi bility for the majority of the equipment installed during this phase was added to the Second Operator classification. A 5-2^/hr. wage increase was granted to the classification as a result of this change. An ex tended trial period (approximately 45 days) was agreed upon at the meeting. New Biphenyl Storage Tank - The new 100,000 gallon biphenyl storage tank was successfully brought on line in June. The department repair man is currently assigned responsibility for operation of this vessel. DSW 308422 STLCOPCB4070095 -4 - 1968 - THINGS TO COME As predicted previously the rate of installation of our expanded facilities has increased drastically. All of Phase I will be completed early in August and Phase II completion is scheduled for mid-October. A brief time table of significant events is as follows: Date Arrival of "Coon-Dog" McCoy as Dept. Repairman Start-up existing nitrogen blanketing system on #9, 10 and 11 storage tanks Upgrade Supervisor's Office (Priority Job) Start-up Phase I - Anyone's Guess July (late) July (late) July & August (intermittent) Third trial run using new chlorination catalyst - July (late) End of trial discussion on Phase I - August (mid month) Article 10 discussion on Phase II Upgrade Control Room (air conditioner at last) Start-up Phase II - August (late) Sept, (maybe) October (mid month) PERSONNEL Not included on the list, but important to each of you is the assignment of Jim Cagle from the plant start-up group as relief foreman behind Virgil Brawley. This change will allow Virgil to concentrate full time on the ex pansion start-up. Jim will arrive in the Dept, on July 22 to begin train ing, will return to Dept. 237 about Aug. 1 for a 3-week start-up run there, and then back to 246 full time. In the meantime Bill Crabtree has agreed to move-up behind Virgil until Jim can take over the department. Your con tinued assistance and cooperation with these men in their new assignments is certainly appreciated. Editor's Note: Word has it that an illustrious member of Dept. 246 will attempt to make a production run of "chili" during July. Save your confederate money! SUMMARY To date in '68 our accomplishments have been ones of which each of you can be proud. A final "tip of the cap" to each of you for your help in making these achievements possible. Many changes and challenges have already been made and met successfully, but this is only the beginning. Aside from the rigors of construction and start-up preparation of the equipment probably the biggest challenge ahead rests with the present and future 246 personnel. As we have informally discussed with you previously, new jobs will result and changes in existing jobs will be made with the advent of the expansion. We face the pains of re organization and training in the coming months. To successfully "pull this one off" we need the interest and ideas of all department personnel. A rousing success both now (Phase I) and in the Fall (Phase II) will benefit each of us by securing our position in this excellent product line. As has already been proven in the past we know we can count' on each of you to do his part in the coming months. .* r Virgil ghw DSW 308423 Harry STLCOPCB4070096