Document dQqMDr5n2bmraBp4G8Gr5N9vq

Interoffice Communication To R. D. Gamblin - Houston From J. A. DeBernardi Date January 11, 1982 subject VCM Plant Objectives - 1982 conoco Attached you will find the subject objectives per your request of November 16, 1981. Attachment CCR 000067455 NAME J. A. DeBernardi PART A QUANTITATIVE GOALS SAFETY & HEALTH Results 1981 Objective 1982 1. Have no lost-time injuries in 1982. 0 0 2. Limit medical cases to three in 1982 assuming one plant turnaround during the year. 5 3 3. Limit total injuries during the plant turnaround period to five assuming one plant turnaround in 1982. During normal operation limit total injuries to 8. Normal Operations: Permanent Temp./Casual Turnaround: Permanent Temp./Casual 4. Correct deficiencies noted in plant hygiene audit conducted in Dec., 1981. 5. Complete hazardous bleeder valve iden tification and blinding/plugging program. 8 1 1 6 16 - - 7 1 1 4 13 June, 1982 May, 1982 6. Provide training and instructor certi fication in CPR/First Aid for one lab oratory analyst. - December, 1982 ENERGY 1. Operate at an energy usage rate during 1982 based on 580MM lbs. of VCM production and one plant turnaround not to exceed 4,162 BTU/lb. of VCM production. Basis: Enerqy consumption based on the adjusted CMA calculation basis. 4965 BTU/lb. of VCM production (3.09% reductior from 1972 base). 4,162 BTU/lb, of VCM production (18.5% reduction from 1972 base). 1st Quarter Results CCR 0 0 0 0 6 7 4 5 6 CCR 000067457 NAME PART A QUANTITATIVE GOALS ENERGY (CONTINUED) 2. Implement a steam trap inspection and maintenance program. Results 1981 ` Objective 1982 June, 1982 3. Develop and implement an energy con - August, 1982 servation design check list for process designs. 4. Develop two economically attractive projects One in 1982 Cap to reduce energy consumption for the 1983 ital Budget. Capital Budget. August, 1982 5. Define energy savings projects with poten 704MMM BTU/yr. tial energy savings totaling 200MMM BTU/yr. define. Definition to include preliminary process design and cost estimate, and economic calculation. December, 1982 PRODUCTION AND COSTS 1. Produce 580MM lbs. of VCM as budgeted pro 465.6MM lbs. VCM vide there are no external restrictions related to this rate (market conditions, raw material supply, natural gas supply,etc. ) EDC ($549.9M) 2. Meet budgeted variable cost efficiency. VCM ($350.9M) (Price variances are excluded). Incin($554.7M) ($1,455.5M) 3. Meet budgeted maintenance costs (one turn around in 1982) 580MM/1bs. of VCM As budgeted As budgeted 4. Complete the 1982 plant turnaround on schedule and within budget. T/A time-21 days T/A time- 20 days T/A cost-$l.19MM T/A cost-$1.09MM 5. Execute a 5-year contract for sale of plant heavy-ends by-product to PPG. - March, 1982 6. Develop one economically attractive cost savings project to be included in 1983 Capital Budget. One project in 1982 Capital Budget. August, 1982 Results i CCR 000067458 NAME PART A QUANTITATIVE GOALS PRODUCTION & COSTS (CONTINUED) Results 1981 Objective 1982 7. Reduce 0739 warehouse account value by 10.3% of the end 1981 value excluding additions necessary for oxy revamp spare parts. - 10.3% reduction 8. Reduce 0744 account value by 8.6% of the projected ending 1982 value given in Oct., 1981 subject letter assuming the o*y revamp project will be on line in second quarter 1983. 8.6% reduction 9. Produce muriatic acid to satisfy Reagent Chemicals demand for 27% material. 2.5MM lbs., 27% muriatic acid(dry basis) PERSONNEL 1. Maintain a non-union field and office work Non-represented Maintain non-union force at the VCM Plant. status maintained. workforce. 2. Maintain a minority hiring rate that assures 22.8% minority minority representation in the field work representation. force that is equal to or greater than availability statistics (1982 available statistics. %) 3. Maintain a female hiring rate of 25% into field workforce. No permanent fe males hired. Female hiring rate of 25%. 4. Recruit two Process Engineers into the plant Five Process Recruit two Process organization in 1982. Engineers recruit Engineers. ed. 5. Recruit one Mechanical Engineer into the Recruit one Mechanical plant organization in 1982. Engineer. 6. Recruit one Safety Engineer into the plant organization in 1982. - Recruit one Safety Eng. 7. Provide supervisory training in non-union status maintenance to one supervisor. One supervisor to training One supervisor to training course. Results 1 NAME PART A QUANTITATIVE GOALS ENVIRONMENTAL CONTROL Results 1981 Objective 1982 1. Operate the plant's secondary system within effluent concentration parameters (ex cluding system by-passes caused by heavy rains.) Five violation notices filed. pH - 5 TSS - 0 COD - 0 bod5 - 0 No non-compliance reports. 2. Correct deficiencies noted in plant environ mental audit conducted in December, 1981. - May, 1982 3. Correct EPA noted variances in plant NPDES - September, 1982 effluent testing procedures. 4. Develop a slide/tape training presentation - November, 1982 for plant employees related to plant environmental permits, procedures, etc. 5. Operate plant EPA-VCM emission control equipment with compliance factors as follows: a) Incineration System Oxy Vent Shiploading Carbon Beds Steam Stripper System Vent Blower System 99.82% 99.26% 100% 99.95% 100% 99.85% 99.50% 100% 100% 100% b) No plant shutdowns are caused by incinerator system failures. o r> 7Q O oO oo> No plant shutdowns No plant shutdowns o Results NAME PART B STRETCH GOALS Results 1981 SAFETY & HEALTH 1. Limit total injuries in 1982 assuming one plant turnaround to eleven. 16 total injuries. 2. Prepare a slide/tape safety orientation program specifically for contract personnel training. ENERGY 1. Define energy savings projects with poten tial energy savings totaling 400MMM BTU/yr. Definition to include preliminary process design and cost estimate, and economic calculation. 704MMM BTU/yr. defined. PRODUCTION & COSTS 1. Reduce 0744 account value by 20% of the projected ending 1982 value given in Oct., 1981 subject letter, assuming the oxy re vamp project will be on-line in second quarter 1983. Objective 1982 11 total injuries. Oct., 1982 Dec., 1982 20% reduction o o o o o o O' -4 oO' Results PART C NON - QUANTITATIVE GOALS 1. Complete the microfilming and storage of plant records re lated to OSHA, Federal and State environmental data. 2. Finalize the reporting policy for Superfund reporting in regard to routine/non-routine occurrences and NESHAP incidents, with input from Houston Legal and Environmental Departments. 3. Complete the scope definition and gain approval for funding for the coking/decoking research project at Purdue University. 4. Complete the required definition work by the plant and/or R&D related to the furnace transfer line exchanger project. 5. Work with DuPont personnel on possible synergisms between the VCM Plant and DuPont operations (i.e. boiling liquid reactor, light-ends usage, etc.) 6. Provide required plant personnel to work on the modernization project, project team. NAME Results o o7> o o o o O' O'