Document rp4yGzEpB91J4YQY8QNRkoMa7

72/Wr Cr-aAL$ SAFETY & ENVIRONMENTAL 1. Reduce the number of lQppm C12 detections from 88 in 1990 to 75 in 199.L Process: Cooke/Supervisors * Continue thorough "root cause" analysis and documentation of each spill. * Assign follow-up action points to an engineer. * Report status of corrective action quarterly in Plant Safety Report 2. Maintain the number of Chlorine Plant RMT Cases at 1 in 1991 Process: Serpas/Supervisors * Improve Chlorine Plant Safety Committee activity * Improve tracking of followup on all UCR's and Incidents * Develop UCR database for improved analysis/reporting of data 3. Maintain the number of NPDES violations at 0 in 1991. Process: Cooke/Supervisors 4. Reduce the number of Contractor OSHA Recordables from 2 in 1990 to 0 in 1991. Process: Serpas * Conduct daily contractor "tailgate" safety meetings. * Conduct weekly project/maintenance safety planning meetings. * Staff member to attend weekly contractor safety meeting. * Hard money contractor program 5. Implement a program to improve the reliability of containment of liquid chlorine. Process: Landers * Complete EBV testing, Pressure Vessel Program inspections, repair/upgrade necessary piping and insulation for T-54 * Develop similar program for T-56 * Identify and develop PM program for critical liquid chlorine piping. * Develop criteria for a reliable one chlorine storage sphere operation 6. Increase environmental awareness in thcJ>lant Process: Cooke * Conduct one communication/training meeting per quarter. 7. Continue a Housekeeping Improvement Program Process: Yonts * Improve Housekeeping Index 10% over last year as measured by quarterly audits * Provide 100% follow-up on audit action points with quarterly report to Pit. Supt/Staff * Improve plant janitorial service Get rid of the off-site "boneyard" 3/1/91 J.J.M. pg. 2 91PltGoals.90Sum DO A 023775 CONFIDENTIAL 8. Develop and implement a program of identification and elimination of Leak Repair Devices Process: Yonts/LeBlanc * Provide 100% compliance to S&LP Standard S-317 * Develop and implement a program to identify and record all leak repair devices * Reduce the number of leak repair devices by 20% 9. Know what our plant emissions are. Develop on line Waste Production Report Process: Guillory * Develop a computer program to calculate plant waste from process data * Issue a monthly report showing waste sources, destinations, and the balance of waste discharged versus waste generated * Concentrate on STP, HCL, NaOH, and Freon in 1991 10. Develop 5 and 10 year ''Environmental Improvement Plan" Process: Jefferies * Develop a priority list of plant improvement projects to meet the following criteria: 1) No regulatory non-compliances 2) Minimize the volume of waste requiring secondary treatment 3) Continuously monitor the quantity of waste generated * Provide a brief project scope, alternatives, schedule and preliminary cost estimate QUALITY PERFORMANCE 1. Finalize internal customer product specifications for chlorine, cell effluent and H2. Process: Cooke * Visit each of 6 chlorine, 3 caustic and 2 hydrogen customers Develop and communicate a customer product specification for each 2. Finalize raw material specifications for brine. HC1. H2SQ4. CC14. CQ2 and Na2S203, Process: Cooke Develop specification parameters Obtain signed agreements with each vendor * Provide method to verify compliance 3. Improve customer complaint program Process: Landers Provide permanent record keeping system for all customer complaints * Provide preliminary response to all customer complaints within 4 working days * Provide quarterly report to Pit Supt/Staff which includes events, response, cause and corrective action DO A 023776 CONFIDENTIAL 3/1/91 J.J.M. Pg- 3 91PltGoals.90Sum 4. Apply for General Manager's Quality Award bv 1 Aug- Process: Serpas * Complete draft in March * Submit application in April * Prepare for audit in June * Schedule audit in July 5. Redefine and implement a Plant Improvement Suggestion Program Process: Guillory * Review the new suggestion program with staff and shifts during 1Q91 * Furnish suggestion feedback by distributing a quarterly report showing the status of all incomplete suggestions * Forward at least 10 suggestions to the Operation Upswing Committee 6. Hydrogen Collection & Distribution Reliability Process: Haney * Use statistical tools to track quality and calculate process capabilities for each spec component * %.Reduce the number of unit trips caused by sudden load changes by 20 * Investigate all unit (Chlorine and CA-II) service interruptions and quality excursions. Assign follow-up action to appropriate personnel. * Continue communications with APCI: - Publish a monthly report which includes H2 availability and monthly highlights. - Continue monthly planning meetings with APCI personnel. 7. Track kev controllable process variables in SPC format. Process: Hull * Work with Paul Yonts, Dickie LeBlanc, Jim Haney and Steve Landers * * Reduce the use of key supplies (Freon, HC1, Na2S203, CC14, H2S04) while maintaining or improving product quality and process reliability PEOPLE DEVELOPMENT 1. Continue the development of a comprehensive plant training program OPT). Process: Serpas * Progress during 1991 should be consistent with the plan to complete the program by 3Q91 working within overtime restrictions. 2. Develop a Management of Process Change program. Process: Meyer Complete 1st pass on plant P&ID's conversion to electronic format * Utilize and document all 6 phases of project discipline on all physical and procedural changes. * Develop a program of documenting plant process changes, either physical or procedural, before these changes occur. DO A 023777 CONFIDENTIAL 3/1/91 J.J.M. pg. 4 91PltGoals.90Sum 3. Complete Chlorine Plant Performance Review Cycle, (attached) Process: C12 Plant Supervisors/Muller 4. Develop a 5-vear Quality Performance Plan Process: Serpas * Items to be included are: further education of plant personnel of customers' needs; SPC/SQC development; personal growth plans; long term use of IPT by everyone * Schedule: Identify areas for improvement by August; Develop outline in October 5. Provide training opportunities for all Chlorine Plant d Process: Muller * Document personal development training history for each person - 1Q91 * Discuss personal development needs/desires in coaching session - 2Q91 * Develop and communicate training opportunities list for each person - 4Q91 6. Optional team building exercisers). Process: Muller COST MANAGEMENT 1. Achieve 1990 Chlorine Plant Strategic Projects benchmarks. Sponsors as indicated on attached list 2. Manage expense and capital spending within specified budgets. Process: Meyer and All * The 1991 plant budget is: WORK ORDER TYPES 11 12 13 TOTAL! 21 1991 BUDGET (M$) 4350 3100 200 7650 1 2600 * Track controllable costs, history and commitments, on a monthly basis. Project final costs verses budgeted amounts for controllable spending. * Promote use of "Project Report" sheets as a tool to communicate plant needs and approvals. 3. Develop 5-vear Plant Improvement Project Plan Process: Guillory Develop a 5-year vision of the plant in coordination with the Chlor-Alkali Tech Team * Develop a schedule of plant improvement projects to achieve the vision 3/1/91 J.J.M. DO A 023778 CONFTDFNTTAL Pg- 5 91PltGoals.90Sum 4. Operate the plant at 96.5% chlorine availability defined as follows: shortages = internal customer service interruptions + T/C missed shipments demand = production + shortages Availability = actual production/demand Process: Serpas * Calculate monthly availability by the 15th of the following month * Define/catagorize causes of shortfalls monthly 5. Solve the cell foaming problem Process: Serpas * Work with R&D to identify foaming agent * Determine contributing factors * Evaluate/provide corrective action items 3/1/91 J.J.M. DO A 023779 CONFIDENTIAL pg. 6 91PltGoals.90Sum CHLORINE PLANT PERFORMANCE REVIEW CYCLE - 1991 JANUARY 1990 Performance Ratings communicated 1990 Plant Goals Assessment completed 1990 JPR's conducted FEBRUARY 1991 Plant Goals developed 1990 JPR's completed 1991 Individual Goals development begins Contingent Performance Award determination completed MARCH 1991 Individual Goals developed CPA's distributed Merit Program Planning completed APRIL - NOVEMBER Individual and Plant goals are reviewed and updated formally at mid-year. Communication/coaching is ongoing. DECEMBER Performance Ratings completed 3/1/91 J.J.M. DO A 023780 confidential pg- 7 91PltGoals.90Sum CHLORINE PLANT PROJECT GOALS -1991 | DESCRIPTION Clean Main Brine Head Tank Relocate T-103B SO# Sniff Chlorine Air Ecology Salt System Renovation Plant Painting Program Upgrade H2S04 Piping to Alloy-20 Update P&ID's Upgrade FRP H2S04 Walls Repair P-20 Foundations APCI Metering Improvements Chlorine Instrumentation Upgrade Rectifier 1 Replacement Rebuild Circuit # 5 T-102B Replacement Replace MC-500/600 - 1500Hp Venturi Scrubber Upgrade Repl Aux Brine to Cir #5 Bellows Valve Program Replace C-91 PSVs D-100B C12-H20 Evactor PC Additions - 2 Upgrade EC-600 to DR Piping Replace C-100B lube oil pumps/pipe Wet Chlorine Vacuum Relief System Condensate Collection & Distr Insulation Improvement 02 Liquid Containment Improvements T-54 Inspection New Plant Radio System Wet Chlorine Compr Reliability Waste Alkalinity Recovery Cell Effluent Hypochlorite Removal Hydrogen Collection 02 Analyser Degass H2 in Cell Effluent Chlorinated Organics Storage Oil/Freon Seperator Floe System Upgrade Hard Freon Replacement Rebuild East/West Trench Chlorine Air Monitors Redundant Sludge Acidification N2 Auto Purge Chlorine Cells Replace Cell Area Utility Piping Replace C-40 Lube oil Pumps & Htrs Instal Air Flowmeters to Brine Filters T-13 Control Upgrade Aux Cells from Western Div T.L. Line Replacement Start-up Blower Vacuum Relief 3/1/91 Proj No Ph EoY 282936 6 6 277000 6 6 76991 5 6 78754 5 6 296489 5 6 278115 5 6 217101 5 6 292085 5 6 278937 5 6 289993 5 6 77930 4 5 62100 4 5 22500 4 6 232893 4 6 277554 4 6 209604 4 6 277744 4 6 289500 4 6 289496 4 6 291010 4 6 79124 4 6 292997 4 6 290995 4 6 78938 2 6 78937 2 6 294689 2 6 26 26 291823 2 6 77540 1 2 78943 1 2 78936 1 6 78941 1 6 78894 1 2 78940 1 3 16 16 79085 0 1 78755 0 1 77539 0 1 78950 0 1 02 06 06 06 06 01 02 02 MfgRep Hull Haney Meyer Yonts Bertrand Haney Meyer, etal Haney Haney Haney Jeff/Hull Hull LeBlanc Haney Hull Haney Jefferies Landers Landers Haney Williams Landers Haney Haney Guillory Landers Landers Landers Yonts Guillory Guillory Haney Haney Haney Landers Guillory Yonts Guillory Meyer Cooke Cooke Haney Yonts Yonts Yonts Yonts Hull Hull Haney AuthDate Jan-91 Nov-90 Nov-89 Sep-90 Oct-90 Nov-90 Jan-90 Jan-91 Jan-91 Jan-90 Jan-89 Oct-90 Jun-90 Oct-90 Mar-90 Dec-90 Jan-91 Mar-91 Feb-91 Feb-91 Jan-91 Jan-91 Jan-91 Jan-91 Jan-91 Jan-92 Plan Type| 50 21 10 21 10,400 24 780 24 310 12 50 21 50 21 25 21 25 21 15 21 9,700 24 2,000 12 600 21 400 12 200 12 100 12 90 21 40 21 25 21 20 12 17 24 10 12 10 12 315 24 180 24 100 12 100 21 50 13 25 21 9,500 24 1,100 24 350 24 300 24 300 24 200 24 80 24 75 24 15,000 24 5,500 24 1,100 24 525 24 300 24 170 12 50 12 40 24 20 21 24 12 24 DO A 023781 CONFIDENTIAL 91ProjGoals.90Sum