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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
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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
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DTH 000100336
CHART I
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ABERDEEN CHEMICAL PLANT INJURY PERFORMANCE
T o ta l Employees
No. o f In ju rie s X 1
Frequency =
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DTH 000100337
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 000100338
CHART III
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ABERDEEN CHEMICAL PLANT PERSONNEL DOSIMETRY TRENDS
100
TOTAL PARTICULATES!-
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DTH 000100339
CHART IV
LEAD EXPOSURE CONTROL TRENDS
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 000100341
DTH 000100342
1980 Budget Actual
1981 Budget Actual
1982 Budget
WAREHOUSE INVENTORIES
0739 Account
0744 Account
$1,330 MM 1.300
$1,759 MM 1.369
1.491 1.495
1.390 1.177
1.510
1.210
Total
$3,059 MM 2.669
2.881 2.672
2.720
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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 000100348
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1981 BUDGET VS 1981 PERFORMANCE ABERDEEN CHEMICAL PLANT
INCREMENTAL MMM BTU/LB. %
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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
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ENERGY CONSERVATION FORECAST - 1982
ABERDEEN CHEMICAL PLANT
INCREMENTAL
MMM BTU/Yr.
____ %
1981 Energy Reduction vs 1972 (CMA Adjusted Basis)
-
1982 Changes vs 1981 Performance
Product Mix Effects Increased Production Impact V-ll Centrate Heat Recovery (4 months)
33.1 27.0 13.4
2.2 1.8 0.9
V-10 Centrate Heat Recovery (10 months)
Boiler Blowdown Recovery
(10 months)
12.5 6.7
0.8 0.4
Cooling Tower Fan Control (11 months)
1.8 0.1
Dryer Insulation (6 months)
1.4 0.1
Undefined Energy Savings
4.5 0.3
Net Change 1981 to 1982
100.4
6.6
1982 Budget CMA Adjusted Reduction
% ADJ. CMA 35.5
42.1
DTH 000100353
DTH 000100354
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
DTH 000100355
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EXPANSION START-UP KEY ITEMS
MAJOR EQUIPMENT Fluid Bed Dryer D-7A5 EXPANSION REACTOR D-700 Expansion Reactor
START-UP DATE October 28, 1981 December 17, 1981 March 12, 1982
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ABERDEEN FVC EXPANSION PROJECT
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BUDGET ALLOCATION
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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
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$12,000,000
3,2t|8,000 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 000100360
ABERDEEN PVC EXPANSION
NEW OPERATOR TRAINING
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DTH 000100362
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 000100363
DTH 000100364
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 III. OPERATING PERMITS RECEIVED - NPDES - RCRA IV. OTHER - State of Mississippi has NESHAPS authority for the vinyl
chloride standard.
DTH 000100365
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. $M
650 325 113 400 100
16 25 24
560 50 80
727
DTH 000100366
dth 000100368
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 000100369
CHART I
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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 000100371
CHART III
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ABERDEEN CHEMICAL PLANT PERSONNEL DOSIMETRY TRENDS
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PEL = Permissible Exposure Limit
DTH 000100372
CHART IV
LEAD EXPOSURE CONTROL TRENDS
1978
1979
1980
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 000100374
DTH 000100375
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 000100376
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 000100377
1980 Budget Actual
1981 Budget Actual
1982 Budget
WAREHOUSE INVENTORIES
0739 Account
0744 Account
$1,330 MM 1.300
$1,759 MM 1.369
1.491 1.495
1.390 1.177
1.510
1.210
Total
$3,059 MM 2.669
2.881 2.672
2.720
000100378
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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
DTH 000100384
DTH 000100385
EXPANSION START-UP KEY ITEM
Fluid Bed Dryer D-745 EXPANSION REACTOR D-700 Expansion Reactor
START-UP DATE
October 28, 1981 December 17, 1981 March 12, 1982
DTH 000100386
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DTH 000100388
ABERDEEN PVC EXPANSION PROJECT
AFE 9719 & 9759
Mm
PEDICTED TOTAL
(OVER) UNDER
EQUIPMENT BULK MATERIALS OUTSIDE ENGINEERING FIELD CONTRACTS CONT.-EXTRA FIELD WORK CONT.-FIELD CHANGE ORDERS CONXO 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 000100389
ABERDEEN PVC EXPANSION
NEW OPERATOR TRAINING
ABERDEEN PVC EXPANSION
EW OPERATOR TRA IN IN G
DTH 000100391
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 000100392
000100393
dth
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 III. OPERATING PERMITS RECEIVED - NPDES - RCRA IV. OTHER - State of Mississippi has NESHAPS authority for the vinyl chloride standard.
DTH 000100394
CURRENT ENVIRONMENTAL PROJECTS
PROJECT
AFE DATE
VCM CONTAINMENT
EXPECTED START-UP
SPARE INCINERATOR
EMERGENCY AMS KILL SYSTEM FIXED POINT MONITOR DATA COMPUTER
& WARNING LIGHTS
EMERGENCY COOLING FOR REACTORS REACTOR HIGH LEVEL ALARMS RVCM RECEIVER HIGH LEVEL ALARMS
1/80 11/80
9/80 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. $M
650 325 113 400 100
16 25 24
560 50 80
727
DTH 00100395