Document a1Gx9N6n3zkENg8OMQm0pb20B

1982 ANNUAL REVIEW ABERDEEN CHEMICAL PLANT MARCH 23, 1982 AGENDA TOPIC I. SAFETY II. COST CONTROL AND CASH CONSERVATION III. ENERGY CONSERVATION IV. PVC EXPANSION V. DEVELOPMENTAL PRODUCTS VI. ENVIRONMENTAL PRESENTED BY A. H. SATHER S. J. VINCENT C. R. MILLER P. E. MARKEY P. J. KOBER V. E. MESSICK DTH 000050673 DTH 000050674 SAFETY 1981 HIGHLIGHTS I. INJURY TRENDS (CHART I) II. KEY ELEMENTS (CHART II) III. CHEMICAL EXPOSURE TRENDS (CHART III) IV. LEAD EXPOSURE CONTROL TRENDS (CHART IV) V. EXPANSION AND PLANT MODIFICATION SAFETY DTH 000050675 CHART I ABERDEEN CHEMICAL PLANT INJURY PERFORMANCE x u ta x iJ iu p x u j - 1. C L J U C 1 1 L ) -- oj u DTH 000050676 CHART II SAFETY PROGRAM KEY ELEMENTS I. JOB PLANNING II.TEAMWORK III. COMMUNICATIONS IV.TRAINING V. FOLLOW-UP Plant Goal - Everyone goes home unhurt. DTH 000050677 CHART III %< PEL ABERDEEN CHEMICAL PLANT PERSONNEL DOSIMETRY TRENDS :i T i ooo :1; j 1 | 1 1 1- ~ >r - < s> -- t r. 31___ _______________ i-------------------------- PEL = Permissible Exposure Limit : 82 | i --------------------------------------------------------1 DTH 000050678 IV 90 80 70 60 50 40 30 20 10 LEAD EXPOSURE CONTROL TRENDS 1979 1980 DTH 000050679 1981 SAFETY 1982 PLANS I. INJURY GOALS A. Lost Time B. Medical C. First Aid Total 0 4 32 36 II. VCM OVEREXPOSURE PROGRAM III. NOISE CONTROL PROGRAM IV. FIRE PROTECTION IMPROVEMENT PROJECT V.CONTRACTOR SAFETY PROGRAM DTH 000050680 DTH 000050681 COST CONTROL AND CASH CONSERVATION I. 1981 ABERDEEN COST PERFORMANCE A. Variable Cost Variance Due to Efficiency Due To Price $ 455 M $12,859 M B. Fixed Cost Variance $ 2,266 M II. 1981 PROFITABILITY IMPROVEMENT ITEMS Target $1,129 M Actual $2,463 M A. PVC Variable Cost B. Upgrade H-Grade Resin C. Reduce Sifter Overflow Production D. Use of 5425 Resin in 18031 Compound E. Compound Stream Factor F. Utility Costs G. Plant Fixed Costs III. 1982 CASH CONSERVATION IMPROVEMENT (First Six Months) A. Payroll and Benefits $ 80 M B. Maintenance and Contract Costs 135 M C. Antioxidants for PVC 40 M D. Reduction of H-Grade Resin Production 80 M E. Capital Project Delays DTH 000050682 COST CONTROL AND CASH CONSERVATION (Continued) IV. INVENTORY CONTROL - WAREHOUSE AND RAW MATERIALS A. 0739 Inventory 1. Warehouse Stock Levels 2. Price Competition 3. Cost Analysis B. 0744 Inventory V. PRODUCTIVITY IMPROVEMENTS A. Resin B. Compound C. Maintenance D. Labor Agreement E. Energy DTH 000050883 1980 Budget Actual 1981 Budget Actual 1982 Budget WAREHOUSE INVENTORIES 0739 Account 0744 Account $1,330 MM 1.300 $1,759 MM 1.369 Total $3,059 MM 2.669 1.491 1.495 1.390 1.177 2.881 2.672 1.510 1.210 2.720 DTH 000050684 DESCRIPTION ^ S r & - AS 0F IN IT IA L _____ CHANGE _____ VERIFY J ' l tCONOCO # Z . " Z f 3 ^ rS & / / ~ f``/ t o __________________________________________________________ UNIT OF ISSUE - WHERE USED _C- y '=C~'? 'lS7~__________________________________ _________________ __________________________________ ___________________________ OPERATING IMPACT I F NOT STOCKED ___________________________________________________________ o rH LO V 2o m X ou:" h* So Uu UlaiS) 1r~-0^) g x3 s* o H in ID 5 uj 5 SS HZr*; UJ yj Xm l_t/> ^ UJ X5 V v DTH 000050687 CONSERVATION 00005068^ dth ENERGY CONSERVATION PROGRAM I. ENERGY PERFORMANCE HISTORY A. Ten Year Performance on CMA Basis B. 1981 Performance II. MAJOR 1982 PROGRAMS A. Reduced Operation Program 1. 1980-81 Monthly Performance 2. Energy Consumption Analysis 3. Short Term Program 4. Long Term Plan 5. Shutdown Planning B. Boiler Operation Program 1. O2 Operating Ranges 2. Refractory Inspections/Infrared Survey 3. Boiler Feedwater Quality 4. Economizer Operations Guidelines 5. MED Consultation 6. Training C. Steam Trap Program 1. Utility Area 2. Comprehensive Steam Trap Inspection D. Insulation Program 1. Freeze Protection Plan 2. Energy Related Insulation Surveys E. Plant Air Conservation Program 1. Existing Air System 2. 1982 Conservation Program F. Capital Projects 1. V-10 Centrate Heat Recovery 2. V-ll Centrate Heat Recovery 3. Cooling Tower Fan Control III. ENERGY AWARENESS A. Energy Consumption Monitoring 1. Current Reporting 2. Proposed Project B. Daily Accountability C. Employee Awareness 1. Inclusion of Energy Related Topics in Operations Manuals 2. Active Involvement of All Employees IV. 1982 ENERGY CONSERVATION FORECAST DTH 000050689 1981 BUDGET VS 1981 PERFORMANCE ABERDEEN CHEMICAL PLANT INCREMENTAL MMM BTU/LB. % % ADJ. CMA 1981 Budgeted Energy Reduction 40.9 1981 Changes vs 1981 Budget Product Mix Effect Decreased Production Impact Boiler Blowdown Heat Losses Undefined Energy Consumption Net Change 1981 Budget vs 1981 Actual (45.6) (25.0) ( 6.3) ( 4.5) (81.4) -3.0 -1.7 -0.4 -0.3 35.5 DTH 000050691 10 X 10 T O T H E C E N T IM E T E R 10 X 2'i CM . K F U F F F l. 8e ESSER CO M*nc IN USA ENERGY CONSERVATION FORECAST - 1982 ABERDEEN CHEMICAL PLANT 1981 Energy Reduction vs 1972 (CMA Adjusted Basis) INCREMENTAL MMM BTU/Yr. ____ % 1982 Changes vs 1981 Performance Product Mix Effects Increased Production Impact V-ll Centrate Heat Recovery (4 months) V-10 Centrate Heat Recovery (10 months) Boiler Blowdown Recovery (10 months) 33.1 27.0 13.4 12.5 6.7 2.2 1.8 0.9 0.8 0.4 Cooling Tower Fan Control (11 months) 1.8 0.1 Dryer Insulation (6 months) Undefined Energy Savings 1.4 0.1 4.5 0.3 Net Change 1981 to 1982 100.A 6.6 1982 Budget CMA Adjusted Reduction % ADJ. CMA 35.5 42.1 DTH 000050094 DTH 000050695 ABERDEEN PVC EXPANSION PROJECT A. PROJECT HISTORY AND DEVELOPMENT B. TECHNOLOGY ADVANCEMENTS 1. XXL Reactors 2. Fluid Bed Dryer C. PROJECT COST D. FUTURE WORK 1. Optimization and Rate Improvement 2. Operator Staffing and Training Program r DTH 000050696 Zac << CN LO CN CN CO 1 r alii 8m \\ \\ \\ au 1 E3 ABERDEEN PVC EXPANSION TIME TABLE OVERVIEW tt z t3t tt oo $ h- u o<3 tt z z Kft-- uUl I/I t2t z 2 <Ul Z a.Ul o Ul o o o tt < o u 3 tt < zU VJ Ul z tt o> tt zUl oo O Ul <U < o CL < 3 tt tt ttQ -- >< 3/* o tt i/I Z < 2 CL o0 00 Q < tt u< SJ tt < zz zu i/I tt tt < Ul 2tt I/I < z< Ul tt u<o zu< O < tt I tt Ui I/I u 0 O Ul Ui tt tt CL s AFE o3 > G o UJ s u ua < LU UJ oc oz 3 l < IN H- oc 2 <h- CL o t- 03 CD Oion ooo EMSJQN. ST/W-UP riftjQR equipment KEY ITEMS Fluid Bed Dryer D-745 EXPANSION REACTOR D-700 Expansion Reactor START-UP DATE October 28, 1981 December 17, 1981 March 12, 1982 DTH 000050698 ff eo CU"N> CN fO DTH 000050699 US o < rDC ABERDEEN CHEMICAL PLANT DRYERS OVERSIZE*-! `-PRODUCT T DTH 000050700 ABERDEEN PVC EXPANSION PROJECT AFE 9719 & 9759 aiEMIon W0 SSL EQUIPMENT BULK MATERIALS OUTSIDE ENGINEERING FIELD CONTRACTS CONT.-EXTRA FIELD WORK CONT,-FIELD CHANGE ORDERS CONOCO FIELD COST UNALLOCATED CONTINGENCY PERFORMANCE BOND ALL RISK INSURANCE SALES TAX CHANGE ORDERS #1 - 12 TOTAL 3,385,000 1,650,000 1,367,900 4,048,900 161,000 150,000 170,000 691,900 103,000 24,300 248,000 0 $12,000,000 3,248,000 1,787,000 1,058,000 3,293,900 409,100 88,300 215,000 121,600 15,800 10,500 58,000 ( 1.236.800) $11,542,000 137,000 ( 137,000) 309,900 755,000 ( 248,100) 61,700 ( 45,000) 570,300 87,200 13,800 190,000 (1.236.800) $458,000 DTH 000050701 ABERDEEN PVC EXPANSION NEW OPERATOR TRAINING DTH 000050703 DEVELOPMENTAL PRODUCTS I. 5265 RESIN A. Fittings Market B. CTA C. Plant Production II. 90172 DRY BLEND A. Fittings Dry Blend B. Field Trials C. Plant Scale Test Run III. RP-100 PROGRAM A. Compounded Pellet Replacement B. Twin Screw Formulation C. Single Screw Formulation D. Plant Production DTH 000050704 DTH 000050705 1981/82 KEY ENVIRONMENTAL FACTORS I. PROJECTS COMPLETED - Reactor Double Rupture Disc Replacement - Improved Rupture Disc Holders - Batch Water Strippers - Diking and Curbing II. COMPLIANCE TESTS CONDUCTED - Batch Water Strippers - Fluid Bed Dryer - New Module Expansion Reactor m. OPERATING PERMITS RECEIVED - NPDES - RCRA IV. OTHER - State of Mississippi has NESHAPS authority for the vinyl chloride standard. DTH 000050706 CURRENT ENVIRONMENTAL PROJECTS PROJECT AFE DATE VCM CONTAINMENT EXPECTED START-UP SPARE INCINERATOR 1/80 EMERGENCY AMS KILL SYSTEM FIXED POINT MONITOR DATA COMPUTER & WARNING LIGHTS 11/80 9/80 EMERGENCY COOLING FOR REACTORS REACTOR HIGH LEVEL ALARMS RVCM RECEIVER HIGH LEVEL ALARMS 5/81 11/80 4/81 4/82 6/82 4/82 5/82 1/83 11/82 STEAM STRIPPING INSTRUMENTATION BLEND TANK EXHAUSTERS 4/81 12/81 11/82 9/82 WATER-NPDES PERMITTING WASTE WATER TREATMENT REVISIONS 6/81 PLASTICIZER SPILL CONTAINMENT 4/81 PLASTICIZER' IRRITANT CONTROL 12/80 9/82 10/82 6/82 SOLID WASTE RESIN RECLAIM SYSTEM 12/80 1983 CAPITAL BUDGET VCM RELIEF VALVE CONTAINMENT 6/82 CAPITAL COST. SM 650 325 113 400 100 16 25 24 560 50 80 727 DTH 000050707