Document Z4Xz9nMo8GqZ5dRN2oZj0o62Y

/> f* a <i MONSANTO COMPANY __________ Texas Cityj Texas *v Date : January 23, 1967 To : Ray Rosenberg ccl T. E. Alien H. W. Cutcher C. H. Duhon W. C. Fuller J. A. Gla s s W. R. Nisbet J. L. Schlechte T. E. Shirley VCM Supervision (3) Subject: Quarterly Manufacturing Report Fourth-Quarter, 1966 SUMMARY Production rates for the fourth quarter, in percent of plant rated capacity, were: VCM 112$ Depa rtment 23 EDC 111$ Department 26 EDC 78$ Rates were limited mainly by: l) 92 hours CbH2 reaction shutdown to upgrade the C2H2 compression system, 2) C2H2 availability, 3) Cl2 shortage, and 4) C2H4 shortage. Quality control presented some problems. 4.24 MM lbs. of off-spec VCM was made. All off-spec VCM was rerun or shipped to Carbide. The quarterly unit manufacturing cost was 5.447 lbs. VCM. This was above standard (5-307 $/lb.) because of: 1) high variance in Department 23 due to chlorine pure ($124,000 above Standard), 2) above Standard catalyst usage in Department 26 ($14,500 above Standard), and 3) low VCM volume in October and November caused by raw material shortages (C2H2, Cl2, and C2H2|). CBY 1112503 RSV0032931 OPERATING DETAILS A. Summary Table Production VCM- MM Lbs. Cracking Reaction Total ) -2- Oct. Nov. Dec. 4th Qtr. Std. Y-T-D 8.56 3.48 12.04 8.93 2.74 11.67 10.70 4.30 15. 00 28.1 10.5 38.6 27.6 6.9 34.5 111.5 34.5 146.0 EDC - MM Lbs. Department 23 Department 26 Total Acid, M Gals. Scheduled - Acid 12.71 1.53 14.24 0 46 13.09 1.67 14.76 114 85 On-Stream Time Craeking Reaction Department 23 Department 26 Department 21 Yields Depa rtment_22_ EDC to VCM C2H2 to VCM 100. 0 91.0 100.0 94.7 17.5 98.9 76.3 95.4 90.3 31.1 Oct. 95.05 96.36 Nov. 96.15 97.47 Department_23 C 2Hh EDC Cl2 to EDC 99.10 94.07 97.14 98.08 Deartment_26_. C2H4 to EDC HC1 to EDC 71.96 75.80 65.49 67.88 15.91 1.66 17.57 63 0 41.71 4.86 46.57 177 131 37.5 7.5 166.0 21.7 45.0 187.7 _ 1,483 - 1,372 99.2 86.6 93.0 91.4 22.7 99-3 84.3 96.1 92.1 23.8 99.6 93.7 94.0 88.3 52.5 Dec. 97.0 98.34 Standard 95-5 97-0 99.91 95.97 95.0 95-0 77-42 77.28 88.4 91.0 CBY 1112504 RSV0032932 ^ OPERATING!- DETAILS (continued) ') -3- B. Operations and Maintenance October, 1966 The following is a list of conditions which reduced VCM pro duction during the month: 1. Lack of chlorine eausedl,046 M lbs. lost production. 2. 22D7 reboiler fouling and switching caused 66l M lbs. lost production. 3. Lack of refrigeration due to repairs on 2206 motor (150 ton Carrier refrigeration) caused 287 M lbs. lost production. 4. Lack of acetylene caused 222 M lbs. lost production. 5. Mechanical problems with the 22C1 and 22C7 acetylene compression system caused 278 M lbs. lost production. Major maintenance in Department 22 consisted of: 1. Catalyst changeout of 22R1-6. 2. The motor of the 150T refrigeration unit was rewound. 3. Motors of acetylene compressors 22C1 and 22C7 had bearing replacement. 4. The motor of acetylene compressor 22C7 was rewound. 5. The 22C7 motop shaft was replace. 6. The VCM fractionator reboiler was switched once. In Department 23, one EDC cooler bundle (23E2-1) was changedout because of corrosion. In Department 26, the "Monitor" glass seal was replaced during a minor shutdown of the reactor, 26RI. On startup, the new seal leaked into the electrical conduit, damaging the control units of both the Monsanto designed "Monitor" and the Fenwal system. Revisions to the EDC measuring system have not improved accuracy. Plugging of the sample line to the cracking gravitometer (22H1-5) has improved,but control of the chlorine is poor. November, 1966 The following is a list of conditions which reduced VCM production during the month: 1. Lack of C2H2 due to West Plant shutdown caused 1,395 M lbs. lost production. 2. Lack of HCi users caused by: 1) not making acid for out side sales, 2) 26 downtime due to lack of 02 and shutdown repairs, 3) C2H2 reaction downtime because of lack of C2H2. These caused lost production of 602 M lbs. CB* 1112505 RSV0032933 OPERATING DETAILS -4- B. Operations and Maintenance (continued) November, 1966 - 3. Shutdown of 5 hours to repair a leak on 22D5 VCM absorber gauge glass nozzle caused lost production of 260 M lbs. 4. 1 1/2 hour power failure caused 236 M lbs. lost production. 5. Switching of 22D9 reboiler caused 206 M lbs. lost production. The following is a list of major maintenance work done in VCM during the month: 1. Switching 22D9 reboiler. 2. Switching 22E1 (cracker feed vaporizer) bundles twice. 3. Recharging 22R3 hydration reactor. 4. Repairs to 26s8, waste catalyst separator. Department 23 operations and maintenance were normal. Department 26 operation was erratic due to 02 supply problems while Department 17 was down. EDO accountability in Department 26 is still low. Work is continuing to correct this. The "test" gravitometer on 22H1-5 appears to be operating satis factorily so far as the analyzer is concerned. Minor Cl2 control problems still exist. December, 1966 The following is a list of conditions which reduced VCM production during the month: 1. Up grading of the C2H2 compression system caused reaction to be down 92 hours with a lost production of 644 M lbs. 2. Power failure on December 15 caused 116 M lbs. lost production. 3. Repairs to the 22C2, VCM blower, caused 59 M lbs. lost production. The following is a list of major maintenance work done in Depart ment 22 during the month: 1. The bearings were replaced on 22C2, compressor and motor. 2. New wire was pulled to the No. 2 load center to replace the one which grounded out. 3. Switching 22E1 (cracker feed vaporizer) bundle three times. 4. Switching 22E30 (22D10 reboiler) one time. 5. Recharging of 22R4 (l & 2) butadiene absorbers. 6. Upgrading of the C2H2 compressor system. CBY 1112506 RSV0032934 OPERATING DETAILS B. Operations and Maintenance (continued) -5- December-, 1966 7. Recharging of 22A2 (1 & 2) VCM dryers. 8. Recharging of 22R1-5 VCM reactor. The "test" gravitometer on 22H1-5 has proven acceptable. The other four gravitometers are being revised similar to the one on 22H1-5. The VCM purification system operated at 235 MM lbs./year rate equivalent to 117.5$ of original design. This was the first time this system has operated above 185 MM lbs./year rate. Major maintenance in Department 23 consisted of the following: 1. Replacement of 23E2-2 and 23E2-4 (EDC cooler) tube bundles due to corrosion. 2. Inspection and cleaning of 23T1-2 Cl2 storage tank. Department 23 operations were normal all month except for the chlorine tank maintenance and minor interruptions in the chlorine supply from the barges. Major maintenance in Department: 26 consisted of the following: 1. Replacement of the 26S8, waste catalyst separator. Keystone valves. 2. Cleaning of the 26E5, EDC-caustic, cooler. 3. Relocation of 26T2, product EDC, LCV to improve product EDC metering. 4. Replacement of about 15 feet of piping from 26K1, caustic scrubber, overhead to 26CI off-gas compressor. Department 26 operations were normal. Differential pressure across the reactor has increased during the month. This limits capacity at about a 30 MM lbs./year rate. EDC accountability is still low. The P. T. & E. group is continuing to work on this problem. C. Personnel and Safety Octobe r, 1966 CBY 1112507 Safety meetings were held with all operators on "Review of the September Chlorine Spill." There was one operator minor injury caused by chlorine inhalation. Mr. I. Berlin, unit clerk, resigned from the Company to take other employment. RSV0032935 OPERATINC- DETAILS 1 -6- C. Personnel and Safety - continued November, 1966 Safety meetings were held with all operators on the use of the Scott Air-Pak. There were three minor injuries: l) an operator inhaled Cl2 from a leak when returning the cig injection system to service, 2) a pipefitter received minor skin irritation when clamping a HC1 leak, and 3) a boilermaker chipped a tooth when his wrench slipped and hit him. Mr. H. W. Cutcher was sent to the Japan MMK Plant for three weeks to assist them in cleaning out their EDC purification column which had plugged. December, 1966 The safety meeting for the month was a movie, "Pacts About Backs." There were three (3) injuries: l) an operator received a skin irritation from HC1 fumes when preparing equipment for maintenance, 2) an engineering aid inhaled EDC fumes while inspecting the 26RI reactor, and 3) an instrument repairman pricked his hand on some insulation wire. D. Costs Total Mfg. Cost - $______ Total Mfg. Unit Cost - $ Actual* Standard Actual* Standard October November December 4th Qtr. Total Total for Year 704,671 639.021 764,853 8,255,148 638,781 619,485 796.008 2,054,274 7,843,581 5.854 5. 474 5.099 5.652 5.307 5.307 5.307 -573-C7 The main contributors to the above standard costs were: 1. High variance from Department 23 due to Cla price ($124,000 above Standard). 2. Above Standard catalyst usage in Department 26 ($14,500 above Standard). 3. Low VOM volume in October and November caused by raw ma terial shortages (CaH2, Cl2 a^i C2H^). * Corrected for variances from Department 22 and 23. cbY UIZ508 RSV0032936 OPERATING DETAILS E. Quality October, 1966 Quality control presented some problems. Minor intrument upsets caused 260 M pounds to be off-spec in dilatometer. 780 M pounds of VCM off-spec in allene and methyl acetylene was made during the time the acetylene purification system was down for electric motor repairs. 1*5 MM lbs. of VCM showed 0*5 ppm HC1 after transferring to the on-spec sphere. 442 M lbs. was rerun; remain der was shipped. Total gross production from 22D14: 1.3,640 M lbs. Total slopped (off-spec): 380 M lbs., 2.656 of gross (Off-spec in allene and methyl acetylene) Recycle due to 22T9 vent and 22T32 inventory changes: 5.4956 of gross. 749 M lbs., Total on-spec production: 12.511 M lbs. Four tank cars (270,OOC ' lbs.) were shipped to Carbide; one low on dilatometer, and the others high on allene and methyl acetylene. November, 1966 Except for HC1, quality was generally good. 400 M lbs. of VCM was off-spec in HC1 and was transferred to 22T9-1 (off-spec sphere) for rerun. No VCM off-spec in MeC2H2 and/or allene was made while the C2H2 purification system was down for recharge of the 22R3 hydration reactor. Total gross production from 22Dl4: 13,241 M lbs. Total slopped (off-spec): (HC1) 5^1 M lbs, 4.156 of gross Recycle due to 22T9 vent and 22T32 Inventory changes: 1,123 M lbs., 8.4856 of gross. Total on-spec production: 11,577 M lbs. December, 1966 1.6 MMlbs. of VCM became off-spec in HC1 after transferring to the spec storage sphere. This occurred probably because of cross con tamination in the VCM vent system. This material has been rerun. CB* 1112509 RSV0032937 OPERATINGr DETAILS -8- E. Quality - continued December, 1966 400 M lbs. VCM was made which was low in dilatometer. This was caused by the start-up in reaction and by column flooding. 200 M lbs. of VCM was made which was off-spec in EtCl. This was caused by column flooding. This 600 M lbs. of VCM was made in one day. All off-spec VCM was rerun during the month. Total gross production from 22D14: 19,500 M lbs. Total slopped (off-spec): 865 M lbs., 4.58$ of gross (400 M lbs. low in dilatometer, 200 M lbs. high on EtCl, and 185 M lbs. high in HCl). Recycle due to 22T9 vent and 22T32 inventory changes: 600 M lbs., 3.17$ of gross. Total on-spec production: 17,435 M lbs. K. P. Webb CBY 1112510 RSV0032938