Document dnaaV93ELDXqQ0ke92RYzL6NQ

ABERDEEN CHEMICAL PLANT 1981 ANNUAL REVIEW * MARCH 17, 1981 DTH 000100396 DTH 000100397 -5AFtY lA&l $ HNHH X. 3T^ ^ ^r* <"*^<C.s fcJA<k-T 3^ C W\ \c*-\ >fps .'& Trervfe (0,,-T-m) L e<*$- &xposiA rt Co-i'trS 1 Tre^ Cc^Jaar t i_l_V ^ Moi6C CoaT^I lr0^resJ ExprM\o^ &CjU< 7" T TA (I \Jvtko*.''' <xLoif ProJbu.c.i'-vj TU.i *P*~-T. Fou' Pk*e. ptr-e.W*Te* Xu prox/e** e *a t- Psojc&t. $AP6rr ; 1 e>82, '?t>VJg 11AjU^ Glacis A. U> s t ~Ti >m_ 3, Cs** C. Pirs.T A-*iJ lOTAc- O 4 3x ^ Ce Prog rn\_-- <e^ le^e^TS fttW P/^6> *i a. Vert _____B jCFer^ >c^v-( ^kpo5*ve. Proj* *>eT Prpjr-oi C. Mejicol 7) It/ISIOA Noise S Apr.l __,l). P*^w. fre^ii(oci| O'f VtM c I ise f?eK/i* , 3`v'A`KT Proc^HiArC.. ............ T5L. Co(ApVere pk ie II1 f-<r-e. Prt>Tfc.-no>\ a PLse_32". .. V- CoMpleTe liiSTcvdA-rtoiN o-f 'Hv- (?e.e.-ro^ CosI'aj <*ve^ -ICil| Pr(yee.TS '"tfoe.V'*^ ( Are* s, V1 ' C*pi ere. _jata|(t<0'\ A<j rr*'*'' a SijsreiMj an "^-fOti ^ O'CcOo^fi^tTlVl #- CoAkpleTrS Er^i .-<>^ o-f Lig i>T r A-A^ IT* T-'O 5yyte^s OA T>-300 4^-400 te^-ro^. (jk&Y- Z5 s^O ^ : DTH 000100398 PUNT ChE/aic^'- OtfSiMerRV TW-EWOl VCM -1,---- -i-- - ! " ------j,,------; --1-- j| !j ri | ! i 1 j s -- 4i _J1__1L_J1_____ , \---- ! 1 !J_____L 1 L!i j_____ f~ i Ii ' 1... -- 1 | | 1 __1 i 11 1i LEAD Jan. Feb. Mar. Apr. May June ; July Aug. Sept. Oct. Nov. Dec. Jan. | Feb. 1 Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dei. | i9 C>Q__ 19 *1 19 B 2. DTH 000100399 SAFETY 1980 REVIEW I. Injury Trends (See Chart I) II. Monthly Safety Meetings on specific topics selected by Safety Director. Films used to support topics whenever possible. III. Attitude Emphasis - Meetings conducted in October with Supervisory Personnel on a departmental basis focused on efforts needed to improve injury/accident prevention. November Plant Safety Meetings conducted by Safety Director with Management representation focused on injury/accident prevention and open discussion of safety problems. IV. Phase I Fire Protection Improvement Project completed. V. Initiated use of 3M "Airnat" respirator in Compound Department to reduce employee exposure to lead (See Chart II). VI. CED Noise Survey DTH 000100402 SAFETY 1981 PLANS I. Injury Goals A. No Lost Time Injuries. B. Reduce Medical Cases 507,, to 8. II. Continue Attitude Emphasis. Hazard Control Methods directed at sound job planning, teamwork, communication, training and effective followups. III. Work Environment * A. Review job tasks with high lead exposures, specify work practices, and provide engineering requirement specifica tions as necessary to reduce exposure. B. Monitor on a routine basis for VCM, Lead, Antimony and Total Dust. C. Conduct monitoring for toxic raw materials, intermediates, and finished products. D. Revise monitoring data card to fit current needs - Complete. ^ ' E. Monitor performance of ventilation systems. F. Conduct Noise Survey and make recommendations for noise reduction as necessary. G. Improve Catalyst handling in plasticizer operation. IV.Build and startup plant expansion without serious loss producing incident. V. Revise and issue Plant Emergency Plan to include required items from new OSHA Fire Protection Standard - Complete. VI.Conduct First Aid refresher course for off-shift first aid personnel - Complete. VII. Supply Monthly Safety Meeting topics which focus on most important safety topics. VIII. Complete field work on Phase II Fire Protection Improvement Project. IX. Engineering on Phase III Fire Protection Improvement Project and Project operationg by year end. X. Install Lightnin Agitators on D-500 and D-600 reactors. DTH 000100403 ABERDEEN CHEMICAL PLANT I INJURY PERFORMANCE 8 6 4 2 0 40 30 20 10 0 FREQUENCY DTH 000100404 CHART II %< PEL r ( c 19^0 ABERDEEN CHEMICAL PLANT CHEMICAL DOSIMETRY TRENDS Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. i Mar. j ! Apr. May June July Aug. Sept. Oct. Nov. Dec. iq 82 DTH 000100405 DTH 000100406 ABERDEEN PVC RESIN EXPANSION I. INTRODUCTION II. PROJECT DESIGN A. Large Reactors B. Fluid Bed Dryer 111 PROJECT SCHEDULE A. Fluid Bed Dryer and Silos B. Slurry Blend Tanks C. Reactors, Etc. D. Targeted Completion E. Cost Report IV. CONSTRUCTION COORDINATION A. Safety Training B. Contractor Work Permits C. Continuous Monitoring D. Frequent Communications E. Process Tie-Ins V. STAFFING A. Manpower Requirements B. Timing C. Training DTH 000100407 ABERDEEN PVC RESIN EXPANSION VI. STARTUP A. Equipment an-^ Instrument Check-Out B. Startup Assistance C. Spare Parts VII. RELATED PLANT PROJECTS A. Waste Water Stripper B. Waste Water Treatment Revisions C. VCM Storage Track D. Chem Wash System E. Multigrade Resin Facilities DTH 000100408 ABERDEEN PVC R ESIN EXPANSION SCHEDULE DTH 000100409 RELATED PLANT PROJECTS WASTE WATER STRIPPER WASTE WATER TREATMENT REVISIONS VCM STORAGE TRACK CHEM WASH SYSTEM MULTIGRADE RESIN FACILITIES DTH 000100410 DTH 000100411 PLANT OPERATIONS & COST REDUCTION I. GENERAL OPERATIONS A. 1980 Performance B. 1981 Objectives II. VARIABLE COST REDUCTION PROGRAMS A. VCM Efficiency 1. History, Three Year Plan 2. VCM Loss Reduction 3. Reactor Foaming Control 4. Improved Particle Size Control 5. Resin Loss Reduction 6. Accounting Controls B. New Additive Development 1. Initiators 2. Chain Transfer Agent 3. Suspending Agents 4. Calcium Stearate 5. Anti-Oxidants SIX MONTH INTERIM COST CONTROL PROGRAM A. Sifter Overflow Reclaim & "H" Grade Bag Inventory Reduction B. On-Going Pallet and Scrap Metal Recycle C. Optimize VCM Railcar Weighing ; D. Optimize In-Plant Railcar Switching IV. COST SAVING CAPITAL PROJECTS A. Sifter Overflow Reclaim System B. Automatic Resin Bagger C. Vacuum System for Dryer Buildings DTH 000100412 >> c_> z wH CJ H Pm W H Z C J su Pm > hJ ow O<l-M HU SW W oW Pm w <-3 wQ Pwi OH PQ < Pi O Hco M X H----------i------------- 1----*_----------1--------------4------1-------- --1----------1-------------H----------1---------- CN i--H i-H --1 o CTi r--4 O 00 vO m CO CM ooOoooo H i--4 i--4 r--l r--4 r-l r--4 r--4 r--l 1-1 r--4 1 .... " r--4 o r--4 Nisaa DA9 '91/WOA `91 `A0KaiDI99a NOA DTH 000100413 1980 ABERDEEN COST PERFORMANCE VARIABLE COST VARIANCE DUE TO EFFICIENCY DUE TO PRICE FIXED COST VARIANCE TOTAL r-H N*\ oo $ mM $. 677 M $1,658 M DTH 000100414 ABERDEEN PRODUCTION OO CD LU COQ CO CQ COcQc D_ oo cn to in 04 nq O' la -=r i--i NQ Ll_ LU CD CD ca CQ o __ I CO *=C CQ cu s; *=c s: &? B-e CNI CD 1--1 o OO r>* oo cr lo LTV m cn m CD cr LA o cr 04 r-H CM . 1-- CO LU CQ CD __ 1 Q CQ SI LO CD LA CD CM LA hA LO OI NO CQ 04 1-- CD 1---- 4 Z LU CD LU =3 ___ 1 >---- 4 s: _J o CQ t---- H-- >- CI CO O' TS" >- <c < i--* CD O' ___ 1 Q. > CD ca CU LU CD DTH 000100415 NEW /fbDITIVE DEVELOPMENT INITIATORS - DUAL INITIATORS - HIGHER PRODUCTIVITY INITIATORS - LUCIDOL L-46 - WITCO 5A5 M CHAIN TRANSFER AGENT - BENEFITS OF LOWER OPERATING PRESSURES - PROVIDES POTENTIAL TO PRODUCE 0.68 VISCOSITY RESIN SUSPENDING AGENTS - ALTERNATE SOURCE DEVELOPMENT (HENKEL?) - POTENTIAL FOR IMPROVED PARTICLE SIZE DISTRIBUTION CALCIUM STEARATE - ALTERNATE SOURCE DEVELOPMENT ANTI-OXIDANTS - CONTINUING SEARCH FOR NEW ANTI-OXIDANTS FOR IMPROVED HEAT STABILITY DTH 000100416 PROFIT IMPROVEMENT I. ENERGY A. Steam * 1. Boiler Operation a. Low Production Periods b. Natural Gas c. Corrective Feedback 2. Optimize Steam Use a. Steam Stripping b. PVC Conversion c. Rinse Water d. Steam Injection 3. Steam Traps 4. Leak Survey and Repairs B. Air 1. Shutdown Air Compressors as Feasible 2. Evaluate How to Extend the Life of Reciprocating Compressors 3. Evaluate Large Air Users For Possible Replacement Electrical 1. Replace Oversize Motors 2. Utilize Energy Efficient Motors 3. Ensure High Power Factor D. Proj ects 1. Boiler Economizers 2. Centrate Heat Recovery 3. Dryer Insulation 4. Cooling Tower Fan Controls 5. Dual Speed Agitator Motors dth 000100417 PROFIT IMPROVEMENT II. PLANT STREAM FACTOR IMPROVEMENTS A. Equipment Operations 1. Curtail Equipment Operation as Possible 2. Improve Equipment Reliability B. Control Overtime in All Areas 1. Operations 2. Maintenance 3. Laboratory C. Improve Productivity 1. Work Sampling 2. Supervisory Involvement 3. Training in All Areas 4. Improved Scheduling D. Critical Spares 1. Storeroom Parts Review III. WAREHOUSE, RAW MATERIALS, SERVICES A. Review of Inventory Levels B. Competitive Pricing 1. High Volume Storeroom Items 2. Discounts 3. Capital Materials C. Monthly Variance 1. Defer Projects 2. Evaluate Unbudgeted Items 3. Control Operating Supplies DTH 000100418 PROFIT IMPROVEMENT III. WAREHOUSE, RAW MATERIALS, SERVICES - (continued) 1. Bell System Teleprinters 2. Warehouse Stock to Replacement Value DTH 000100419 DTH 000100420 CURRENT ENVIRONMENTAL PROJECTS PROJECT VCM CONTAINMENT AFE DATE EXPECTED COMPLETION CAPITAL COST, $M WATER STRIPPING ^ SPARE INCINERATOR ^ REACTOR PRESSURE RELIEF MODIFICATIONS v EMERGENCY AMS KILL SYSTEM - FIXED POINT MONITOR DATA COMPUTER ^ & WARNING LIGHTS BREATHING AIR MODIFICATIONS EMERGENCY COOLING FOR REACTORS REACTOR HIGH LEVEL ALARMS - RVCM RECEIVER HIGH LEVEL ALARMS - IMPROVED RUPTURE DISK HOLDERS ^ ' STEAM STRIPPING INSTRUMENTATION A/80 1/80 11/80 11/80 A/80 9/80 5/81* 10/81* A/81* A/81* A/81* WATER-NPDES PERMITTING WASTE WATER TREATMENT REVISIONS PLASTICIZER SPILL CONTAINMENT PLASTICIZER IRRITANT CONTROL 6/81* A/81* 12/80 RCRA-HAZARDOUS WASTE RESIN RECLAIM SYSTEM CAPABILITY TO RECEIVE OKC POND RESIN GROUNDWATER MONITORING 12/80 6/81* 3/81* 6/81 8/81 10/81 9/81 , 9/81 5/81 8/82 3/82 9/81 12/81 12/81 3/83 6/82 9/81 1/82 1/82 11/81 810 650 560 325 113 21 AOO 26 16 27 25 560 50 80 727 105 30 * 1981 BUDGET DTH 000100421 DTH 000100422 KEY 1980 ACCOMPLISHMENTS 1. Positive Overall Plant Efficiency Variance of $144 M. 2. Positive Overall Plant Fixed Cost Variance of $837 M. 3. Record High Vinyl Efficiency of 98.1%. 4. Maintenance Productivity Increased 8.7% to 6170. 5. Maintenance Overtime 5.1%. 6. Major problem with Capacity Replacement Reactor Vibration was solved. 7. Completed 1 year without a lost time injury. 8. Although medical cases increased, safety improvements were started in 1980 leading to a record 197 days without an injury requiring medical attention in 1981. 9. Reduced Quality Complaints 25% in a reduced sales year when customers are most sensitive to quality. 10. Conducted additional agitation studies and modified PVC Reactor Agitators and Methocel Addition for major improvement in particle size. % 11'. Conducted several test runs of alternate initiators, calcium stearates, suspending agents and chain transfer agents. 12. Developed and Commercialized method to lower 5305 operating pressure 20 PSIG thereby decreasing potential for relief valve discharges. 13. New 2 Year Contract with U. S. Steelworkers of America Union. 14. Testing and Commercialization of Low Cost Single Screw Dry Blend. 15. Produced Developmental Quantities of RP-100 Profile Dry Blend. 16. Decreased Reactor Gearbox Failures from 19 to 6 and Reactor Seal Failures from 36 to 20. 17. Reduced manhours spent on "E" Work Orders from 29 to 14.9% of total maintenance hours. 18. Scheduled reactor and dryer areas for maximum utilization of inventory control time to do major maintenance, conduct test runs and minimize overtime. 19. Improved standards for new hourly employee selection and increased probationary period to 120 days. 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