Document wZGg0jk9kgXYNr4xzd5DoYEJ

SOUP AROCLOR EXPANSION ANNISTON PUNT S&L22S& 4 DIRECTOR'S REVIEW MEETING GENERAL OFFICES ' NOVEMBER 25, 1969 DISTRIBUTION: M. W. Farrar - G.O. R, A. Haydel - Annlaton D.B. Hoamer G.O.' R. E. Howard - G.O. R. M. Kounta - G.O. A. Kuhn - G.O. J. A. Morgan - G.O. W. B. Fapagaorga - Annlaton H. E. Schalk - G.O. J. E. Sprlnggata - G.O. J. E, Smith - G.O. R. J. Stratmeyer G.O. H. L. WUllama - Annlaton R. S. Yataa - G.O. 4 0355989 TOWOLDMONOQ48372 0355989.01 TOWOLDMONOQ48373 AA DIRECTOR'S REVIEW MEETING SOLID AROCLOR EXPANSION - ANNISTON CEA-2080 9:00 A.H. -- November 25, 1969 -- Room 303 -- "C" Building -- G.O. I. Introduction..................................................................................J. E. Smlth/H. L. Hllllem* II. Objectives ............................................................... ...................................... .. ..W. E. Vo III. Summary of Process and Equipment............................................ .....R. A. Yates IV. Current Status j A. Construction........................................................................................... j..R. S.Yates B. Manning.................................................................................... H. L. Williama/W. E. Voss C. Training Program............................................................................. W. E. Voss D. Overall Timing....................................................................R. S. Yates/W. E. Voss V. Start-Up Plan......................................................................................................... W. E. Voss VI. Project Risk Review of PFA..................................................................R. S. Yates/W. E. Voss 0355990 TOWOLDMONOQ48374 0355990.01 TOWOLDMONOQ48375 SOUP AROCLOR EXPANSION - ANNISTON sba-mq START-UP OBJECTIVES 1. Demonstrate the safe operation of the expanded Solid Aroclor facility to produce 20.0 M lbs/year of "In specification" Aroclor 5460. \ $ iftjj ij -1 2. Effectively define any problems which occur In meeting objective Number 1, and resolve with the proper group (Mfg., CEP, Malnt., etc.). ' ", 3. Demonstrate the ability of the expanded facility to meet standard manufacturing cost. A. Start-up cost do not exceed budget. ' ii 5. Determine the ability of the expanded facility to produce Aroclor 1 5460 that can be PDA approved (0.4% PCB). , .. a 0355991 .1 I TOWOLDMONOQ48376 0355991.01 TOWOLDMONOQ48377 SOLID AROCLOR EXPANSION AW11ISIOH - CEA 2080 PROJECT SCHEDULE 1. Completion of Utility and Thermlnol Circulating Systems. 1/2/7.0 2. Start-Up of Thermlnol Circulating Systems. 1/5/70 3. Complete Construction on Process Equipment. 1/15/70 4. Check Out Process Equipment and Calibrate Instruments. 1/15/70 - 1/30/70 5. Start-Up New Facility for Production of Aroclor 5460. 2/2/70 6. Complete Demonstration of Design Yields and Bracket III Capacity (See attached 1970 Sales Requirements). 2/28/70 7. Complete Demonstration of Dealgn Capacity (20 M lbs./yr. rate). 3/15/70 PROJECT DEMONSTRATION Process simulation or check-out of this equipment Is limited to sctual production of Aroclor 5460. Project demonstration will consist of Introducing Santowax R Into the weigh tank with a thorough check of equipment operation and Instrument accuracy. From the weigh tank, one chlorlnator will be charged, chlorination accomplished and all features of the equipment checked out before the second chlorlnator la put Into service. The 5060 batch produced In .the first chlorlnator will be tranaferred to and held In the blow tank while the aecond chlorlnator la being cycled through a batch. During thla holding period, the blow tank equipment testing can be started. f i r u *I-- 1 tl S'* 0365W2 TOWOLDMONOQ48378 Project Demonstration (Contd.) 2 When both chlorlnators have produced a batch of 5060and the blow tank haa been checked out with the double batch the materialwill be tranaferred to the atlll for refining to 5460. Throughout thla teatlng period all equipment and lnatrumentatlon will be obaerved utilising round-the-clock technical eupervlalon aa will routine operator attention. All equipment must perform well In each step of the process before the next step la attempted. It la estimated that four (6) chlorlnator batches and two (2) atlll batches will be processed In the system before all corrections and modifications are made. ' At such time as all supervision and CED personnel agree that the equipment Is In operating condition, the facility will be operated, at Bracket 3 capacity. Special Note must be given to the fact that forecasted sales requirements and Inventory capability do not permit operation at design capacity (20.0 H lbs/yr.) for a full month In early 1970. Therefore, achievement of design capacity will be a judgment factor utilising all personnel Involved In the start-up and short period production rates. f. Li |` . X i V It * , < ! ` 0355993 .4 * TOWOLDMONOQ48379 SOUP AROCLOR EXPANSION ANNISTON - CEA 2080 1970 February March April May FORECASTED SALES REQUIREMENTS 5460 1,095,000 1,159,000 1,132,000 1,245,000 Mcltt.t_____________________ 2080 Daalgn 23 Caoacltv 2,467,000 1,235,000 1,666,700 2,467,000 1,235,000 1,666,700 2,467,000 1,235,000 1,666,700 2,467,000 1,235,000 1,666,700 TOTAL 1970- 12,200,000 14,820,000 20,000,000 TOWOLDMONOQ48380 <\ RISK ANALYSIS I I 4 0355994*01 ti 1 I TOWOLDMONOQ48381 ? POTKHTIAL PROBLEM ANALYSIS BMWIW - JfflWWH CEA-2080 SPECIFIC POTENTIAL PROBLEMS I. RAW MATERIALS 1. Santowax R a. High percent Quatraphenyla b. High percent Biphenyl c. High percent water d. Availability 2. Chlorine a. Quality b. Availability 3. FeCU a. Quality - percent water b. Availability 4. Lime a. Quality - percent water b. Availability u. fflWRmmw tm 1. Welsh Tank a. Incorrect weight b. . Inadequate Catalyat c. Poor or no agitation d. Water leak Into tank PROBLEM 70 10 50 10 10 6 50 10 10 2 10 10 50 3 10 10 10 6 10 10 10 5 40 6 10 4 10 6 1 i i | f , , 700 500 ; 60 500 ?! 20 100 S 150 7 100 60 100 50 240 40 60 4. fHi.! \ i. 0355995 TOWOLDMONOQ48382 Potential Problem Analysis Solid Arodor Expansion - CEA-2080 2 _____hotto. ?9TBBTiAf) mwmmsi&i_______________________________________ sums______ m II. CHLORINATION AREA (Contd.l 1. Welsh Tank (Contd.) Fire . Sampling hazard 8* Pump failure h. Line pluggage 10 10 100 10 10 100 10 10 100 20 5 100 ChlortMtws a* Liquid chlorine Into chlorlnator b. Fire c. Circulating pump failure d. Demister pluggage or failure a* Overcharge f. Poor or no temperature control 8- Poor or no chlorine flow control h. Out of spec chlorination level 1. Plugged lines J. Chlorine flow failure k. Soft point determination i. Thermlnol leaks Into batch ms Overpressurize 10 7 70 10 10 100 30 10 300 50 6 300 60 4 240 60 6 240 50 4 200 40 8 320 30 7 210 10 7 70 10 7 70 30 10 300 10 8 80 0355996 TOWOLDMONOQ48383 Potential Problem Analysis Solid Aroclor Expansion - CKA-2080 3 SPECIFIC POTENTIAL PROBLEMSPROBLEM ii. wmimw tm (contd.) SERIOUS TOTAL 3. Blow Tank 1, Overcharge b. Thermlnol leaks c Temperature control d. Insufficient air e. Ejector plugged f. Pump failure 8* Insufficient HC1 removal h. Overpressurize 1. Water In product J. Off-Spec. Material k. 5060 production capability i. Rework off-spec, material 20 10 10 10 20 20 20 20 70 10 100 50 |j 1 7 140 8 80 5 50 6 60 7 140 4 80 5 150 7 140 2 140 3 30 5 500 6 300 Off-Gas Svatem a. Contaminate blow tank b. Temperature control-condenser c. Water d. Overpressurize e Plug Condenser f. Plug return line g. Pump failure h. Off-gaa line capacity 1. Off-gas line pluggage J. Thermlnol leaks 20 7 140 30 6 180 10 6 60 30 5 150 30 6 180 30 5 150 20 4 80 20 8 160 40 6 320 20 8 160 035599? TOWOLDMONOQ48384 Potential Problem Analyst* Solid Aroclor Expansion - CEA-2080 4 ------ BEBCffK MBIMi PfiPBLE^S_______ _PROBLEM III. STILL AREA 1. Still a. Insufficient vacuum b. Overcharge c. Cyclone Operation poor d. Lime addition equipment failure e. Incorrect lime charge f. Poor lime mixing g. No. yield Improvement h. Montar draw-off 1. Pump failure j. Condenser design k. Condenser pluggage 1. Thermlnol leak m. Condenser temp, control n. Pump replacement Still Heater a. Coll rupture b. Gas explosion c. Coll pluggage d. Temperature control e. Coll flow Instrument f. Coll replacement g. Heater capacity h. Sucking coll SERIOUS TOTAL 50 60 20 40 30 70 80 60 40 20 20 20 20 40 20 40 20 10 90 50 30 60 9 4 4 3 6 2 8 6 9 8 S 8 5 4 S 9 8 8 3 3 6 7 M 450 i; v. 240 80 % 120 180 ;| 140 640 h 360 360 160 160 160 100 160 160 360 160 80 270 150 180 420 0355998 TOWOLDMONOQ48385 Potential Problem Analyst* Solid Atoelor Expansion CEA-2080 1 ......... ' " srnms ECTffllAkJygBlftMSproblem ........ . serious III. STILL AREA (Contd.) 3. Still Receiver a. Level control b. Vacuum problems Ce Pump failure d. Plugged lines 6e Temperature control f. Off-spec. Material g. Water 4. Still Jet Pluggage b. Capacity Ce Corrosion d. Catch tank temp, control * Leak In Barometric leg f. Drain knockout tank S* Level Indication (lack of) h. Jet breakage 1. Steam quality 5 ................................... i ------------ '.i- total ' : 30 6 180 10 6 60 20 4 80 20 4 80 20 4 80 30 6 180 10 7 70 50 5 250 30 8 240 30 8 240 20 5 100 30 5 150 20 5 100 20 5 100 20 5 100 20 5 100 MAIN THBRMINOL SYSTEM a. Pump failures b. Distribution Ce Temperature control d. Heater capacity Thermlnol leaks 40 9 360 30 8 240 30 4 120 20 8 160 20 8 160 0355009 TOWOLDMONOQ48386 Potential Problem Analysis Solid Aroelor Expansion - CEA-2080 ____________ SPECIFIC POTENTIAL PROBLEMS_____ ___ V. a. Inability to achieve Plant Standards VI. MANPOWER a. Labor hog VII. SAFETY a. Thermal burns b. Use of torches c. Montar draw-out ' VIII. HC1 AREA a. Absorber capacity b. Drowning Jet capacity c. Waste treatment capacity IX. mums a. Steam b. Water c. Air d. Electricity ' f 6i PROBiffii__ SSUS&S___ IM 30 8 240 30 9 270 30 9 270 1 20 9 180 30 9 270-1 80 5 400 10 8 80 50 8 400 10 8 80 10 8 80 50 8 400 10 8 80 0356000 TOWOLDMONOQ48387 POTENTIAL PROBIEMS LIKELY CAUSES I. RAH MATERIALS PREVENTION lake Preventive Action or Accent Risk PROTECTION Set Contingent Action or Accent Risk PROVIDE FOR INFORMATION 1. Santowax R a. Quatraphenyl in SW R 1) Process control at S/R column 2) Pump wrong S/R to Aroclor 1) TSD Study-Process Knowledge 2) Operator training 1) Adjust 5060 softening point 2) Biphenyl Dept, blend S/R b. Biphenyl in S/R 1) Process control 1) Operator training- at Biphenyl stil understanding of need 1) Sell as 5060 2) Analyze Biphenyl still feed and Santo. C and control <0.31 Biphenyl in S/C 2) S/R analysis to proceed Santowax R charge 1) Analyze prior to use at S/R 2) Plot trends 1) FDA Specs ' 2) Plot trends d. Availability 1) Insufficient S/R 1) Increase S/R capacity capacity 1) Debottleneck S/R capability 1) Increased capacity required in 3rd Qtr. 1971 II. CHLORINATION AREA 1. Heidi Tank b. Inadequate Catalyst 2. Chlorinators c. Pump Failure 1) Operator error 1) Accept risk 2) Catalyst quality 2) Accept risk 3) Poor mixing 3) Accept risk 1) Operator training 2) Visual inspection 3) Agitator shutdown slsrm Study Catalyst' Quality and effects on process 1) Overloaded motor 1) Non-overloaded motor 2) Grounded motor 2) Accept risk 3) Seal failure 3) Accept risk 4) Errosioo/Corrosic l 4) 316 SS pump 1) Alarm-Shut chlorine valve 2) Alarm-Shut chlorine valve 3) Jacketed pump face-Opr. and mechanic training 4) Std. chlorinetor pump Observe pumps and seals for wear at regular intervals to o ** TOWOLDMONOQ48388 POTENTIAL PROBLEMS LIKELY CAUSES PREVENTION Take Preventive Action or _______ Accept Risk____________ PROTECTION Set Contingent Action or Accept Risk_______ PROVIDE FOR INFORMATION II. CHL0R1. AREA 2. di1nHnfril d. Demister plug- 1) Overcharged gage or failure chlorinator 2) Burpped chlori nator 3) Lack of heat 4) Water in system 1) Weigh charge-blow tank level 1) Accept risk 2) Operator training-Proper 2) Accept risk chlorine addition, chlo rine flow, control failur^ 3) Accept risk 3) Tracing on demister 4) Do not charge wet batch 4) Accept risk Study need for chlorinator level indicator 5) Plugged drain lin^ 5) Removed cup in new design 5) Accept risk 6) Drain line fell off 7) Corrosion 6) Accept risk 7) 316 SS wire 6) Visual inspection 7) Accept ride e. Overcharge 1) Heigh tank oper. 1) Monthly check scales Interlock prevent pump ing in S/R while pimping out S/R to chlorinator 1) Heigh tank overcharge alarms Study need for chlorinator level indicator 2) Incomplete pump 2) Accept risk out of chlor. 2) Blow tank level in dication f. Poor Cblorinator 1) Circ. pump con 1) Accept risk Temp. Control dition or failure |2) Product cooler or 2) Jacketed w/Thermlnol lines plugged 1) Pump shutdown stops Cl, flow and alarms 2) Hi temp, stops CI2 flow| and alarms 3) Therminol cool 3) Accept risk ing system fails Therminol low flow alarms 4) Temp. Control loop failure 5) Main Therminol distrib. system hot for circ. lines 4) Accept ride 5) Accept ride Hi-Lo Therminol temp. alarms Redundant temp, in dication Therm, low flow alarm 0356002 * TOWOLDMONOQ48389 POTENTIAL PROBLEMS LIKELY CAUSES PREVENTION Take Preventive Action or Accent Risk PROTECTION Set Contingent Action or Accent Risk PROVIDE FOR INFORMATION II. CHLORI. AEEA 2. Cll1r<ul-lir g. Poor CI2 Flow Control 1) S/R or 5060 back in 1) Accept risk line 2) CI2 tar In line to 2) Accept risk vaporizer 1) Steam trace and thermon fron aanual valve to chlorinator . CO2 blow upstream fron Orifice 2) Work with vendor 3) Flow control loop failure 3) Accept risk 3) Accept risk 4) Failed distributors 4) Monel distributors 4) Periodic inspection 5) Pressure Control loop failure 5) Accept risk 5) Accept risk h. Chlorination Level 1) Undercharge of chlorinator 1) Continuous Sp.Gr. Monitoring 1) Operator training and monitoring of operation 2) Circulation poor 2) Continuous Sp.Gr. Monitoring 3) Cl2 Flow high 3) Continuous Sp.Gr. Monitoring 4) Stepper-Timer 4) Operator checks i. Plugged Lines 1) Hot theminol system 1) See IV. a. and b. failure 2) Over chlorination 2) See II. 2. h. 3) Pump failure 3) See II. 2. c. 1. Theminol leaks into Product 4) Downtime 4) Proper line drainage and heating provided 1) Jacketed piping 1) No Jacket over welds 2) Natl, of constructio i2) Stainless steel 3) Hater in Santowaz 3) Accept risk 4) Accept risk 1) Accept risk 2) Accept risk 3) Process control in S/R Dept. Preventive Maint. 0356003 (A ..... ------ TOWOLDMONOQ48390 POTENTIAL PROBLEMS LIKELY CAUSES PREVENTION Take Preventive. Action or Accent Risk PROTECTION Set Contingent Action or Accent Risk II. CHLORI. AREA 3. Blow Tank k. 5060 Production 1) Off Spec. 5060 capability in blow tank United 1) Accept risk 1. Rework of offSpec. Material 1) Poor process control 1) Operator training-improved process control 1) Quality control in S/R Dept. Provide line to #2 blow tank 1) Provide ability to return to blow tank for rework 6. Off-Gas Svsten i. Off-Gas Line Pluggage 1) Overcharged chlori. 1) See II. 2. e. 2) Demister Plug 2) See II. 2. d. 3) Line size 3) Accept risk 3) Install larger line III. STILL AREA 1. Still a. Insufficient Vacuua b. Overcharge 1) Pump packing leaks 2) 3-May valve 1) Proven packing material and method 2) Accept risk 1) Spare pump 2) Operator training 3) Condenser Design 3) Proven design 3) Accept risk 4) Jet design 4) Accept risk 4) Accept risk 5) Knock-Out Pot 6) Condenser Tenp. Control 7) Receiver Overcharge 8) Cyclone design 5) Tangential Entry Plate Coils 5) Accept risk Heating & Cooling 6) Accept risk 6) Accept risk 7) Level indication 8) Accept risk 7) Operator inspect when in doubt 8) Accept risk 1) Level switch failure 1) Accept risk 1) Operator stick assure PROVIDE FOR INFORMATION V009510 ^ *' / -w?;L_A-- ... TOWOLDMONOQ48391 POIEHTIAL FROBIEMS III. STILL AREA LIKELY CAUSES FREVEHTIOH Take Preventive Action or Accent Risk 1. Still g. Ho Yield Improve 1) Santovax quality ment 2) Receiver too small 1) Biphenyl & TSD efforts 2) Accept risk 3) Still pump NPSH 3) Sump on still pot 4) Beater hold up 4) Sump on still pot h. Montar Draw-Off Problems 1) Still bottom nozzle 1) Adequate size design 2) Long draw off line 3) Large Ho. of drums to handle 2) Therminol jacketed lines sloped 3) Improved yield 1. Pump Failure 1) Long shaft 1) Accept risk 2) Lime pluggage 2) Accept risk 2. Still Heater b. Gas Explosion e. Coll Flow In strument h. Sucking Coll 1) Failure of safe guard system 2) Operating error 3) Gas leak 1) Pluggage 1) Accept risk 2) Operator training 3) Accept risk 1) Accept ride 1) Plugged vent valve 1) Therminol heated vent nozzle and valve PROTECTION Set Contingent Action or Accent Risk PROVIDE FOR mFORKATION 1) Accept risk rework 2) Pump out receiver during batch 3) Accept risk 4) Accept risk 1) Accept risk 2) Accept risk 3) Provide increased roller conveyor capacity 1) Spare pump 2) Lower yield and don't distill as far down Justify Sandvik Belt 1) Accept risk with proper maintenance 2) Gas test before Ignition 3) Gas test before ignition 1) Coil outlet temperature Hi shutdown 1) Operator Rod Out 035600$ - .. : .... -'vJ-A. _ ___ TOWOLDMONOQ48392 POTENTIAL PROBLEMS LIKELY CAUSES PREVENTION Take Preventive Action or Accent Ride PROTECTION Set Contingent Action or Accent Risk PROVIDE FOR INFORMATION lit. STILL AREA A. Still Jet a. Pluggage 1) Knockout Tank 1) See III. l.a. b. Capacity c. Corrosion 2) System Air Leaks 2) Accept Risk 3) Product Temperature 3) Accept Risk too high 1) Jet Design 1) Accept Risk 1) HC1 in system 1) Accept Risk 2) Overheated bottoms liberate HC1 2) Accept Risk 2) Test for leaks and repair . 3) Monitor condenser temp, control system 1) Accept Risk 1) Prevent water in system 2) Instrument maintenance operator training IV. MAIN THERMINOL SYSTEM a. Pump Failure 1) Low level in system 1) Horizontal pump eliminate leaks level indication 1) Accept risk b. Distribution 2) Seal failures 1) Piping Sizing 2) Seal guard system 1) Improved design better temperature indication 2) Accept risk 1) Piping modifications V. HOUSEKEEPING a. Inability to Maintain Plant Standards 1) Therminol leaks 2) Product leaks 1) Improved design using 316 SS 2) Equipment arrangement 1) Proper emphasis on housekeeping 3) Operating errors 3) Operator training 0356006 4) System pluggage 4) Improved therminol distrib. jacketed lines, better system drainage 5) ^tUig stations properly 6) Sample funnels returned to weigh task. 1 ---------- TOWOLDMONOQ48393 POTENTIAL PROBLEMS VI. MANPOWER HOG LIKELY CAUSES 1) Manual Operating functions 2) Housekeeping probleas PREVENTION Take Preventive Action or Accent Risk 1) Instrumentation on levels. flows, temperatures, gravities, control room layout improvements. PROTECTION Set Contingent Action or Accent Risk 1) Proper instrument maintenance 2) Improved equipment design and layout. Provide propel housekeeping equipment 2) Increased emphasis on housekeeping PROVIDE FOR INFORMATION Continuing Manpower study to reduce oper ating load by modifications or new design 3) Plugged lines 3). Jacketed piping, improved therminol distribution, insulation and tracing 3) Accept risk VII. SAFETY a. Thermal Burns 1) Uninsulated piping ' 1) Adequate Insulation on and vessels hazardous areas 2) Sucking coil 2) Heating on vent valve 3) Leaks 3) Accept risk 4) Lighting gas heatei 4) Operator training c. Montar Draw-Out 1) Fuses 1) Fume Collection System 2) Sticking rollers 2) Proper maintenance and housekeeping 1) Safety awareness by all concerned 2) Personal Protective equipment 3) Proper maintenance 4) Follow procedures 1) Personnel protection equipment Safety Audit after three months operation 3) Overfilling drums 3) Accept risk 3) Operator training 4) Insufficient rolle 4) Provide for navimum conveyor number of drums 0356007 TOWOLDMONOQ48394 POTENTIAL F&OBLD6 LIKELY CAUSES VIZI. HC1 AREA a. Absorber Capacit 1) Increased BC1 load c. Haste Treatment 1) Increased load PREVENTION Take Preventive Action or Accent Risk 1) larger drowning jet Automatic drowning operation 1) Accept risk PROTECTION Set Contingent Action or Accent Risk PROVIDE FOR INFORMATION 1) Further CED effort in Muriatic Acid area 1) Provide additional neutralization facilities TSD Study and Definition in HC1 Area IX. UTILITIES c. Air 1) Insufficient air for new instru ments 2) Dryer capacity 1) All available instrument air compressors and dryers in good operating con dition 1) Purchase additional air capacity Study improved central air system 0356008 = " .V.- , V SUP .Si ' -J5 *- TOWOLDMONOQ48395 STAIT-OP 0356008*01 TOWOLDMONOQ48396 SOLIP AROCLOREXPANSION ANNISTON - CEA 2080 The start-up expenses for the Solid Aroclor Expansion are estlnated at $93,310. The detailed'budgets for the Preparation and Operation Phaaea are Included In this section. This budget has only recently been prepared and Is not approved. SUMMARY Preparation------------------------ Per cent of Approved Capital-------------- ----- 8.5 Actual and Estlnated Expenditure In 1969 - Preparation--....................................-........... $20,230 Estimated Expenditure In 1970 Preparation and Operation ------------------------------ $73,080 j | fi >, i 1i ", 0356009 TOWOLDMONOQ48397 Manufacturing Wages Manufacturing O.H. Salaries Salary O.H. Supplies Clothing & laundry Travel Stationery-Printing Mechanical Expense Meetings & Conferences TOTALS SOI.TP A<1C11 KTPAMSIOH ANNISTON - CEA 2080 JOB BO. 916.56 PREPARATION PHASE_________________ START-UP BUDGET 1st Qtr. 2nd Qtr. 3rd Qtr. Oct. Nov. 1969 1969 1969 1969 1969 Dec. 1969 ---- -- -- - -- --- " -- -- 867 895 1,690 20 2,000 7,500 155 158 308 4 360 1,350 -- 70 - 100 2,000 --- "- - 164 150 189 - 750 500 -- - - - 200 500 1,186 1,203 2,257 300 24 3,410 12,150 Jan. 1970 4,000 700 7,500 1,350 2,000 150 200 200 5,000 450 21,550 TOTAL 4,000 700 20,472 3,685 4,170 150 1,953 900 5,000 750 41,780 0356010 TOWOLDMONOQ48398 PREPARATION PHASE START-UP BUDGET ' iaam, pbmp ' MANUFACTURING WACES Training for 12 men AO overtime houra $4,000 . Operating peraonnel for the expanded plant will be thoae now operating In tha Aroclor Department. Theae operatora are familiar-with the proceaa and the general type of equipment being Installed on CRA 2080. Due to their continuing operating dutlea up to the time of atart-up of CEA 2080, all training muat be performed on overtime. SALARIES $20,472 Through October 1969, only the required portion of the manufacturing representative's salary has been charged to the Preparation Phaaa. Late In November one technical man will be picked up to begin detailed preparation of the start-up manual. In December and January tha budgat provides for full time utilization and training of four (4) shift supervisors, the start-up aupervlsor, and the manufacturing repre sentative. gVPfUfig Houaekeeplng Equipment Safety Equipment Safety Slgna Utility Lockera and Cablneta Training Supplies Other Miscellaneous purchases $4,170 TRAVEL $1,953 Trips for the Manufacturing Representative to visit CED. Attendance of concerned peraonnel at the Director'a Review Meeting requires the large budgeted amount In November. MECHANICAL EXPENSE Inetrument Check-Out and Calibration IPO's $5,000 I : L ' `i ' .< f> ! fl 0356011 TOWOLDMONOQ48399 Raw Materials Steam Salaries Salary O.H. Factory Supplies laboratory Production Research Mechanical Expense Performance Volume TOTALS sm.Ti> aannflR EXPAHSIOH AHHISTOH - CEA 2080 OPERATIOH PHASE - START-PP BPDCEX COST ABOVE 1970 SOUP AROCLOK COST STAKDARD February 1970 5,100 1,000 6,000 March 1970 - 2,500 Total -- 5,100 1,000 8,500 1,080 450 1,530 1,000 500 1,500 1,200 600 1,800 1,000 15,000 10,000 1,000 25,000 6.100 6.100 37,480 14,050 51,530 2109M 0 TOWOLDMON0048400 OPERATION PHASE - 3TART-PP BUDGET EXPENSE DETAILS BASISs Begin producing Aroclor 5460 Schedule Production-Bracket 3 New facility will produce - Feb. 9OX Bkt. 3 Mar. 100% Bkt. 3 Yield on Raw Materials - Feb. 73% Mar. 80% 2/2/70 1,235,000 1,115,000 1,235,000 YTO VAMOSE. Peb. 1970s 1,115,000 ($6.09 - $5.64) 100 $5,018 PERFORMANCE VOLUME Feb. 1970s (1,235,000 - 1.115.000) $5.09 100 MKHAMKAt HMfflgB Feb. 1970s Appropriation Request Approval for Start-Vp Modifications Mar. 1970s Additional Correction Expense $6,108 $15,000 $10,000 4 I 4 II .1; $ I I 1 'l 'ij s| 0356013 TOWOLDMONOQ48401