Document rBE51eEweDZkGDp3JRBR4ajaG

"THE WORD ON AROCLOR" Issue No.l 1st Qtr. 1968 FOREWORD This is the first in a series of "stupendous" publications which will be issued each quarter. The purpose of this newsletter and future issues is to inform each member of the Dept. 246 organization of the accomplishments made and the significance and timing of the many changes which will occur in the coming months. We invite your comments and questions on anything discussed in these publications and/or on anything else which concerns Dept. 246. 1967 REVIEW Before summarizing the 1968 first quarter results and future plans it's worthwhile to take a brief look back on "where we've been". SAFETY Number of Disabling Injuries 0 Number of Serious Injuries 0 Number of Minor Injuries 11 Minor Injury Frequency 0.72 injuries/man/year (Target 1.0 maximum) Number of Injury Free Months =7 As the statistics bear out, safety performance in the area during 1967 was outstanding. The achievements in safety are ones in which each of you can take a great deal of pride. HOUSEKEEPING: Dept, place rating for the year = 1st place("Gold Broom Award") Number of months rated 1st place = 7 Total points received for the year = 3379(3600 possible) It's obvious that housekeeping also was outstanding during 1967. From a very slow start in January and February momentum picked up and a first place rating was achieved in March. After March continued enthusiasm and pride in the department resulted in receipt of "The Gold Broom Award" for placing first in our respective group for the year. As difficult as the Aroclor department is to keep clean, particularly in light of all the construction which went on during '67* this award is especially significant. PRODUCTION:(1) Annual: Total Aroclor Production = 29,773,6ll#e Total Py^ancrl Production = 9,257,191# Total Pydraul' Production = 2,656,087# Total Aroclor 1254 - 10$ Xylene Mix Production 139,700# . Total Production = 41,525,589# = DSW 308424 STLCOPCB4070097 2 (2) Annual Records: New Record Old Record(Date) Total Aroclor Production 29,773*611# 2b,496,387#(1965) Total Dept. 246 Production 41,826,58# 4l,8l5,632#(1965) (3) Monthly Records: New Record(Date) Old Record(Date) ` Total Aroclor Production 2,887,372#(11/67)2,79,453#(10/67) Total Aroclor Production 2,887,372#(ll/67)2,746,782#(4/67) (30 day month) Total Pydraul Production 529,047#(12/67) 488,001#(12/65) Pydraul 280 Production 113,287#(12/67) 104,375#(1/65) Total Dept. 246 Production 4,l82,101#(ll/67)4,l65,636#(3/65) If you counted a total of nine(9) new production records, you hit the grand total right on the button. There too, the record speaks loudly and clearly on the accomplishments of Dept. 246 during 1967. The Aroclor operation is a prime example of how Safety, Housekeeping and Production "Go Hand in Hand". 1968 1st QUARTER REVIEW Enough said about 1967 let's move on to achievements made during the first quarter of this year. SAFETY: , Number of Disabling Injuries = 0 Number of Serious Injuries = 0 Number of Minor Injuries =2 Minor Injury Frequency = 0.53 injuries/man/year(Target 1.0 max.) Number of Injury Free =1 Months Who was it who said, "it couldn't be done?" In spite of the excellent performance during '67, our safety record continues to improve. It is apparent that each of you have accepted responsibility for not only your own personal safety, but also for the safety of your fellow worker. This type attitude is the only way we can achieve our main objective - "to continue to improve the safety of Dept. 246 operations". HOUSEKEEPING: Dept, place rating for the year = 1st place , Number of months rated 1st place = 3 Total points received to date =< 877(900 possible) As was the case with safety, our housekeeping in the area remains at a very high level. Sometimes, with all the construction actively underway, we're not sure how we're able to do it; but one thing for certain is that without the individual effort-of everyone in the department the outstanding results to date could not have been attained. The rating received for the first quarter was difficult to achieve, and with construction activity picking-up the situation is expected to get worse. Are you up to the challenge ahead? f -jo* STLCOPCB4070098 PRODUCTION(1) 1st Qtr. -3- Total Aroclor Production = 7,372,836# Total Pyranol Production = 1,444,515# Total Pydraul Production = 1,508,568# Total Aroclor 1254-10$ Xylene Mix Production = 23,400# Total Production = 10,349*319# (2) Monthly Records New Record(Date) Old Record(Date) Pydraul A-200 Production 563*845# 1/68 485,001# 12/68 Total Pydraul Production 563*845# 1/68 529*047# 12/67 Would you believe that despite producing 932,464# more during the first quarter of 1968 than for the same period in 1967 that our product inventories are at an all time low? Well, it's a fact! Our anticipated 1968 sales requirements have nearly reached our rated capacity so the heat is really on to maximize Dept. 246 production. Although the "heat" is sometimes uncomfortable, a hot product line is a far better choice to work with than product lines which are cold, sluggish or dying altogether. The versatility of our products plus our delivery and quality reliability have continued to accelerate our sales growth to the point where we are truly experiencing "growing pains". By the way, there is no relief in sight. SIGNIFICANT EVENTS: New Chlorine Line - The new 6" chlorine line was tied in on February 23 and the supply of chlorine now meets our requirements. Without a doubt each of you have noted the change in the chlorine pressure, chlorinator on-stream time and batch chlorination time. We expect to maintain operation at this high rate indefinitely. Still Feed Preheater - A spiral heat exchanger was installed in the feed line from #1 blow tank to the stills. The objective of this unit is basically to eliminate "HFR" from the chlorinator log sheets. We completed the initial Article 10 Discussion on this new installation on March 29. A mid-April start-up and subsequent 30 day trial operation period is expected. TCB - We evaluated 2000 gallons of TCB from a new supplier, Dover Chemical in Ohio, in an effort to ease the TCB shortage problem. Our Inerteen PP0 produced with this new TCB was acceptable to the customer. New Blend - Westinghouse has now switched to a new Pyranol called 54201 CM or-"1242 PP0". We expect to produce an increasing amount of . this blend and less 54201 KA(1254 PP0) in the future. The one lot of this new product we made in February met all specifications. Pydraul A-200 - Shipments overseas were very heavy due to, law enforcement step-up requiring fire resistant hydraulic' fluids to be used in the German coal mine equipment. , T * STLCOPCB4070099 -h- Overchlorination - A batch of Aroclor. became overchlorinated in #1 chlorinator on.^2/15, and resulted in the unit being out of service for 3 weeks. We modified our operating procedures to try to avoid a recurrence of this situation. High Chlorides - High chloride trouble in the finished product plagued us during March. We found that reducing the 36" press filtering temperature enabled us to control this problem. 1968 - THINGS TO COME It's probably evident to each of you that the rate of installation of our expanded facilities has increased. At present almost everything seems to be going for us. Expected completion dates of significant portions of the expansion along with other related process changes are as follows: Raise chlorination temperature Start-up still preheater Start-up existing nitrogen blanketing system on #9, 10 and 11 storage tanks Increase chlorine feed rates End of trial discussion on still preheater Article 10 discussion on Phase I of the Expansion-Tank Farm Start-Up Phase I Trial run using new chlorination catalyst Article 10 discussion on Phase II of the Expansion-New Production Facilities Start-Up Phase II of the Expansion April(early) April(mid-month) April(late) April(late) May(mid-month) May(mid-month) May (Biphenyl system) June(Aroclor system) June September October SUMMARY To say that 1967 was a very good year is nearly an understatement. Out standing is probably more fitting. But even *67 performance is being overshadowed by '68. Our congratulations and appreciation to each of you for the part you played in making these fine accomplishments possible. As we've stated many times before this type performance is one of the reasons why the Aroclor Expansion is underway at WGK. We face many challenges and changes during 1968. Each of which are ' dependent on the one which preceded it. What we hope to accomplish during '68 centers on the following items: - (1) Meet '68 sales requirements. (2) Start-up new manufacturing facilities to enable us to meet future sales requirements. (3) Improve Aroclor quality through improved technology in both the new plant and the existing plant. All of us will benefit from attainment of these '68 goals through increased job security. *. DSW 308427 STLCOPCB4070100 -5Only through your continued interest and support in Dept. 246 operations can we achieve these objectives. We know we can count on each of you to do his part in the months ahead. Vi i mh DSW 308428 STLCOPCB4070101