Document xjG41z3YmMRnzE0wOBDGea6g0
February 20, / 1980 SAL 000109040
AGENDA
9:30 a.m..........
10:30 a.m..........
Toxic Exposure & Industrial Hygiene
10:40 a.m..........
Production - Vinyl......................... ..
Production - Other...........................
Cost Control........................................
Energy Management............................
Efficiency Improvement................. ....Charles Miller Program
Productivity........................................
Absenteeism Overtime
.......... ....Jim Carter
Restrictive Work Practices
Special Items...................................... ....Randell Jackson Dick Frohreich Charles Miller
12:30 p.m..........
1:30 p.m.......... .......... Executive Presentation................
2:30 p.m..........
SAL 000.109041
12 MONTHS MOVING AVERAGE
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VCM DOSIMETRY TREND, BELOW I PPM -ABERDEEN-
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SAL 000109044
1979 PLANT SAFETY ACCOMPLISHMENTS
RIGGING TRAINING PROGRAM
- Films - April - Crane Inspection and Certification Bureau
MONTHLY SAFETY MEETINGS
EMPLOYEE SAFETY ACTION REQUEST (ESAR)
PLANT SAFETY AUDIT BY SAFETY DEPARTMENT
- Physical Hazards - Lighting - Noise
SAFETY PROCEDURES FOR CLEARING PLUGGED LINES
OSHA SAFETY INSPECTION
SUPERVISOR'S SAFETY WORKSHOP - SAFETY AWARENESS
- Accident and Injury Control Procedure - Film Review
EMPLOYEE SAFETY RESPONSIBILITIES PROGRAM
NEW COMPOUND LINE
- Pre-Startup Safety Reviews - Operating Manual/Training
JOB SAFETY ANALYSIS (32)
CHEMICAL EXPOSURE
LEAD
- Initial Sampling arid Analysis - Changes and Follow-Up Monitoring - Color Weigh Room
VCM
- Routine Monitoring Program - OSHA Industrial Hygiene Inspection
1980 PLANT SAFETY PLANS PEOPLE EMPHASIS
"WIN WITH SAFETY" CAMPAIGN - Sports Themes with Focus Topics - Monthly Safety Meeting Emphasis with Film Support - Posters
TRAINING - Job Safety Analysis - Standard Operating Procedures - Home Study Course - Department Heads - Employee Safety Responsibilities Program - Hourly Involvement - Fire Watch Training
SAFETY COMMITTEE PLANT SAFETY AUDIT BY DEPARTMENTAL AND SAFETY PERSONNEL
- Physical Hazards - Noise - Lighting STUDY OF BAGGING OPERATION ONGOING PROGRAMS CHEMICAL EXPOSURE - Statement of 1980 Program - Update Files - Review Regulations - Recheck Exposures - Review VCM and Lead Data to Redefine Monitoring Requirements
SAL 000109046
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SAL 000109047
PRODUCTION A POUNDS)
VINYL PRODUCTION SUMMARY 1971 - 1979
SAL 000109048
COMPOUND DEPARTMENT
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SAL 000109049
PVC COMPOUND OPERATIONS PRODUCTION SUMMARY
Department Compound Dry Blend Plasticizer
1977 Actual (MM Lbs.)
30.1
42.1
8.9
1978 Actual (MM Lbs.)
40.7
59.8
10.4
1979 Actual (MM Lbs.)
44.3
50.1
11.5
1980 Budget (MM Lbs.)
60.0
32.6
25.0
SAL 000109050
1980 OPERATING DEPARTMENT OBJECTIVES
Department Compound Dry Blend Plasticizer
Production
Budget
Forecas t
(MM Lbs.)
(MM Lbs.)
60.0
58.6
32.6
27.8
25.0
15.1
Effi ciency
Budget
Forecast
(Lbs./Lb. ) (Lbs./Lb.)
1.01299
1.01299
1.00318
1.00318
1.09087
1.09087
A. PRODUCTION OBJECTIVES RATIONALE
The 1980 production objectives are based on projected product mix as supplied by the Business Area for the 1980 Fixed and Variable Cost Budget. Compound production will be obtained by 7 day/week operation of two compound lines, and Dry Blend production will be achieved by a 5 day/week, 2 shift/day operation.
B. EFFICIENCY OBJECTIVES RATIONALE
The efficiency objective is based on the budgeted product mix.
000109031 SAL-
COMPOUND LINE V STATUS
Compound Line V is currently operating 12 hours per day, 5 days per week with Line I operating the remainder of the 5 day per week schedule. This allows Line I to replenish the packaged compound inventory while at the same time allowing work to proceed on Line V operating problems. The following is a summary of major problems which have hindered Line V production:
I.Intensive Mixing Equipment
A. Mixing Cycle Alterations B. Raw Material Piping and Valve Revisions C. Bearing Lubrication Revisions
II. Orbitran Process Controller
A. Rewiring Electrical Interface Between Field and Panel B. Modifications to Load Cell Installation C. Reprogramming of Microprocessor for Automatic Sequencing D. Modifications to Control Panel for Heat Removal E. Rewiring of Foxboro Spec 200 Instruments
III. Wemer-Pfleiderer Equipment
A. Pellet Transfer System Plugging B. Screw Configuration Changes (18 Configurations Tested to Date) C. Compound Quality
1. Melt Flow 2. Hard Particles 3. Gels 4. Color (White Compounds Only)
Of the eleven problem areas listed above, all but three have been solved: pellet transfer system plugging, screw configuration changes and quality control of hard particles. Work is continuing on these areas with the assistance of Werner-Pf'leiderer and PAL personnel.
To date three Line V produced compounds have been evaluated by customers. Two of these evaluations were successful while the third test resulted in a rough surface on fence wire which is due to hard particles. The major emphasis is now being concen trated on solving the hard particle problem. Once this is accomp lished, the remainder of the sample compounds can be produced and shipped to customers for evaluation.
SAL 000109052
COST CONTROL
MAJOR COST ITEMS COMPARISON
TT7S Budget
M$ vm Actual
IM Budget
1. VCM Raw Material
49,280
56,414
69,478
2. Operating Payroll
2,039
2,060
2,174
3. Salaried Payroll
1,549
1,584
1,800
4. Electricity
1,611
1,593
2,025
5. Natural Gas
1,385
1,552
1,861
6. Dry Blend Stabilizers
1,370
1,598
1,336
7. PVC Initiators
1,244
1,120
1,475
8. Capital Expenditures
3,035
2,719 a-11,102
9. Downtime of PVC Operation
Approximately 90 Per Day
CAPITAL APE'S
Date
Title
Invest
First Year Savings
5/79 Charge Water Heating Improvements $ 35 M
$ 21.6 M
6/79 Boiler Burner Replacement
170 M
17.1 M
1/80 Centrifugal Air Compressor
340 M
185.4 M
7/80 Methocel Charge Revisions
66 M
24.0 M
10/80 Boiler Economizers
120 M
49.7 M
11/80 Methocel Analyzers
35 M
60.1 M
3/81 Centrate Rinse Water System
300 M
137.4 M
11/81 Compound Die Face Pelletizer
1200 M
428.3 M
SAL 000109056
C. IMPROVED COST CONTROLS BY DEPARTMENTS 1. Administrative Services a. Purchasing Competition b. Pallets and Scrap Metals c. Storeroom Procedures and Controls d. Stock Reduction and Obsolete Items 2. General Plant a. Reduce Accidents to People and Equipment b. Reduce Process Spills and Leaks c. Energy Savings 3. Mechanical (With Utilities) a. Continue Bulk Chemical Purchases b. Increase Cooling Tower Cycles c. Scheduling and Call-In Justification (Overtime Control) d. Reduce Emergency Work Orders e. Repetitive Failures Solved f. Improved Productivity 4. Dry Blend and Compound a. Minimize Use of Materials b. Quality Controls 5. Vinyl Reactors and Dryers a. Stream Factor Improvements b. Vinyl Efficiency (PVC and VCM Loss Controls) c. Minimize Use of Materials
S$L
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-ENERGY. PERFORMANCE CMA REPORTING METHOD
ABERDEEN PVC PLANT
ITEMS AFFECTING ENERGY PERFORMANCE ABERDEEN PVC PLANT
1980 Budget - 27.8% reduction in energy usage compared to the 1972 Base Year by the CMA Reporting Method.
RECENT IMPROVEMENTS
Energy Savings MMM BTU/Yr.
Boiler Burner Replacement
12.2
Increased Conversion on 5385 Resin
15.5
Steam Stripping Conditions New Module
24.8
Steam Leak Repair Program
31.0
Charge Water Heating Improvement
6.6
Specialty Compound Line
6.0
New Centrifugal Air Compressor
2.0
CONTEMPLATED TO IMPROVE QUALITY
Larger Agitator Blades in CRP Reactors
-12.7
1980 BUDGET PROJECTS
Boiler Economizers
16.9
Centrate Rinse Water
40.0
Die Face Pelletizer
18.8
Effect On Energy Reduction
7 0.6 0.8 1.3
1.6 0.3 0.3 0.1
-0.7
0.9 2.0 1.0
SAL OOoi 09o
1972 1973 1974 1975 1976 1977 1978 1979
TOTAL ENERGY CONSUMPTION AND COSTS ABERDEEN PVC PLANT
MMM BTU'S CONSUMED
1175 1419 1316
637 775 783 1138 1316 1410
TOTAL ENERGY C0ST-$M 762 947 1053 749 1047 1300 2202 3188 4137
AVERAGE COST $/MM BTU 0.65 0.67 0.80 1.18 1.35 1.66 1.93 2.42 2.93
(1) 1980 Reforecast 12/26/79
NATURAL GAS POLICY ACT OF 1978
Alternate Fuel for Incremental Pricing
No. 6 Fuel Oil No. 2 Fuel Oil
Increased Cost $M/Year
160 1,700
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SAL 000109060
VINYL DEPARTMENT
VCM EFFICIENCY
The 1980 VCM efficiency objective is 1.01960 pounds VCM per pound of PVC. The following is a list of current efforts and plans to meet the VCM efficiency objective. I. VCM LOSSES
1. Monitoring of all process valves and piping in VCM service for possible leakage.
2. Reduction in quantity of VCM vented to the incinerator through optimization of the vent refrigeration system and concerted effort from operations to reduce losses.
3. Slurry stripping averages continue to improve. 4. Process and instrumentation revisions will have a
positive effect on reactor and recovery system seal failures. 5. Revisions to operating procedures and instrumentation will result in prevention of relief valve discharges. II. REACTOR FOAMING LOSSES
1. Control of batch size has reduced periodic batch foaming.
2. Utilization of new antifoam agent has allowed increased batch size without excessive foaming.
III. COARSE BATCHES 1. Improvement in colloid make-up procedure has resulted in reduced number of coarse batches.
IV. SLURRY LOSSES 1. The strict adherence to the spill prevention program has shown no evidence of blend tank overflows. 2. Process and mechanical improvement at: known slurry loss sources.
SAL 000109061
V. PVC LOSSES 1. Dryer dust collectors were revised in 1979. This has led to marked improvement in resin losses from collectors. 2. Resin spill prevention program has led to reduction of loading losses as well as normal transfer losses. 3. Recovery of railcar heels is now possible with portable vacuum system. 4. Process and mechanical improvement at known resin loss sources.
VI. ACCOUNTING 1. Several cross-checks have been established to minimize accounting/inventory errors. 2. Truck and rail scales undergo checking on frequent basis.
SAL 000109062
V IN Y L CHLORIDc. EFFICIENCY
(OAd g-i/'S'i) aovsn hda
000109063
PRODUCTIVITY
I. PRODUCTIVITY MM LB./MAN YEAR A. Total Plant B. PVC Resin
11 COORDINATION AND PLANNING A. Shutdowns and Turnarounds B. Take Advantage of Weather 1. Winter a. Initiator Loadings b. Test Runs in Reactor Area c. Reactor Modifications d. 5465 Production e. Chemical Cleaning for Summer 2. Summer a. Test Runs in Dryer Area b. Dryer Modifications c. Minimize 5465 Production C. Contingency Planning D. Utilize Manpower Flexibility E. Priorities
III. MAINTENANCE A. Work Sampling B. Reduced Emergency Work C. Improved Equipment Reliability D. Reducing Repetitive Equipment Failures E. Interaction Management
000109064 S Al--
IV. STREAM FACTOR IMPROVEMENT V. ENGINEERING A. Debottlenecking and Automation B. Project $/Man Year
VI. laboratory A. Improved Equipment B. Samples/Man
VII. WORK WITH RESEARCH & ENGINEERING VIII. MOTIVATION
A. Feedback B. Interaction Management C. Training D. Competition and Involvement
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ABSENTEEISM - OVERTIME - RESTRICTIVE WORK PRACTICES
Absenteeism
Total absenteeism for 1979 was 3.7% of straight time hours worked.
The most significant reason for the high rate of absenteeism was the dramatic increase in the nuaber of long-term disability cases, as com pared with the previous year. In 1979, twelve employees were disabled for at least one month and, of these, four were disabled for six months or longer. Of the 10,944 absence hours lost in 1979, 9,232 were for long term disability. Less than one-half of one percent of plant absente eism was attributable to reasons other than medically verified disability.
Given the work orientation of our employees and a strong absenteeism policy, but barring a high level of long term disabilities, we should be able to improve our performance in 1980.
Overtime
Total overtime for 1979 was 10.8% of straight time hours worked. This compares with a plant goal of 10.7%.
High overtime levels in the Vinyl Department were attributable to the use of General Helpers as resin baggers, rather than for the purpose of vacation and absence relief, as originally intended.
In the Maintenance Department, "round-the-clock" coverage was provided in many instances to minimize equipment downtime and to improve availability of maintenance services. An example is the three-week, 24 hours/day coverage provided for the agitator test run. While all known outages allowed for most work to be performed on straight-time, major emergency work often resulted in premiun hours and pay, because of short notice.
Our plant goal for 1980 is 9.7%. To meet this goal, operators in the Vinyl and Compound Departments are being trained to more effectively trouble-shoot equipment problems and thereby reduce unnecessary call-ins. Additional training will be given maintenance employees to minimize repetitive repairs and the filling of Utility Department vacancies on straight time is being considered.
Ihe operating departments will utilize absence relief personnel when avail able, and, when possible, vacancies will not be filled.
Restrictive Work Practices
Although our bargaining agreement does not greatly restrict management's efforts to operate the plant, there are several provisions that hamper efficiency or have the potential to do so.
SAL 000109070
ABSENTEEISM - OVERTIME - RESTRICTIVE WORK PRACTICES (Continued) Holdover overtinE in tine Maintenance Department, for example, cannot be required of the employees who perform the same job cn straight time. Job continuity suffers as the result. Some recent changes in overtime procedures may alleviate this problem, however. In operations, transfers within departments, are governed by seniority. Problems occur when a work assignment is given an employee who interprets it as a transfer. In a department like Compound, where moves between lines and pieces of equipment, within the same classifications, are necessary and frequent, a strict interpretation and application of the seniority provision would be burdensome and inefficient. So far, we have managed to side-step the issue, but it will soon be tested in a grievance scheduled for arbitration.
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SAL 000109073
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SPECIAL ITEMS PVC RESIN EXPANSION PROJECT
STATUS REPORT
AFE amount $12,000,000.
Litwin Engineers and Constructors selected as the engineering contractor.
A project accountant has been assigned.
Revisions to process designs complete.
All major equipment has been ordered with latest deliveryscheduled by 1/1/81.
Field work expected to commence in 7/80.
Project completion expected by 7/81.
j
Permitting:
- NESHAPS Permit granted - Construction Permit granted - Effluent Limitations for NPDES Permit established
000109076 SAL
SPECIAL ITEMS EPA COMPLIANCE ABERDEEN PVC PLANT
RELIEF VALVE DISCHARGES
1979 1980<12)
NUMBER 3 2 1
SLURRY STRIPPING
Period
9/1/78 to
3/1/79
Number of Days Over 400 ppm.
37
Average, ppm VCM
. 322
3/1/79 to
9/1/79
2
199
# VCM 3,397
32,600 24
9/1/79 to
Date 13
243
(1) August thru remainder of year (2) To date
SAL 000109077
SPECIAL ITEMS TEST PROGRAMS - 1980
TYPE 1. Agitation 2. Steam Sparging Nozzles
3. Chain Transfer Agent for 5305 4. Addition of Iso-Octane to
Polymerization Formula 5. Use of L-10 Instead of L-223
Initiators for 5385 Type Resin 6. Drying Pond Resin 7. Use of Centrate Water as
Reactor Rinse Water
8. Suspending Agent Changes 9. Old Reactor Agitation Revision
OBJECTIVE
Improve Quality
Reduce Vibration
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Produce at Lower Pressure
Reduce Residual VCM in Slurry-
Cost Saving
M'1 Environmental " ^ JIm\
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Energy Cost Saving & Reduce Flow Thru Secondary Waste Treatment System
Improve Quality
Increase Production and Reduce Maintenance and Labor Costs
SAL 000109078