|
SCENE |
VISUAL
|
AUDIO
|
| 1 |
"East Houston Plant" |
(Start
music.) |
|
2 |
"The Hardy #9 Dry End Formulation Process" |
(Music continues.) |
|
3 |
Logo of the Casterbridge Chemical Conglomerate. |
(Music fade.) |
| 4 |
LS
of main building in Hardy #9 Unit. |
This
is the Hardy #9 manufacturing unit. It's one of the
herbicide units at the Casterbridge East Houston Plant. |
| 5 |
Art
depicting war on weeds. |
It
can also be called an arsenal in the war against weeds. |
| 6 |
CU
of railroad tracks with weeds growing between ties. |
The
Hardy # 9 weed killers help clear vegetation from the
nation's railways. |
| 7 |
LS
of bayou. |
...and
stop weeds from choking the drainage systems needed
to fight flooding. |
| 8 |
LS
of tractor plowing field.. |
Hardy
#9 herbicides also boost agricultural production. |
| 9 |
MS
of DEO at panel board |
The
Dry End Operator, the DEO, puts together the final product. |
| 10 |
LS
of entire panel board. |
At
the panel board, the DEO controls formulation. The Operator
assures that each batch meets the standards Casterbridge
customers have come to expect. |
| 11 |
Art
listing formulation materials. |
The
DEO combines four types of materials known as the technical,
the premix, the rework, and the sifter rejects. |
| 12 |
LS
of drums of technical. |
The
technical is the actual weed killer. It makes up most
of the final product. |
| 13 |
CU
of bag of technical. |
The
technical can be dumped into the Dry End system from
either bags or drums. |
| 14 |
CU
of scoop inside open bag of premix. |
The
premix is a number of different ingredients blended
with the technical. They dilute the strength of the
technical and make the product perform better in its
practical use. |
| 15 |
CU
of drum of Wet & Wild.. |
Wet
& Wild, for example, is used as a wetting agent. |
| 16 |
CU
of rework and sifter rejects OUT-IN selector switch. |
Both
the rework and the sifter rejects are Dry End materials
that fail to meet product standards. Small amounts are
used in the formulation. |
| 17 |
MS
of drum of rework. |
The
rework is from the dust collection system and the vacuum
cleaning system--or any other material specified by
supervision |
| 18 |
CU
of DEO opening sifter rejects hopper. |
The
sifter rejects are the oversized pieces of product picked
up by the sifter. |
| 19 |
XCU
of formulation sheet. |
The
types and quantities of materials used are on the Formulation
Sheet. There is a Formulation Sheet for each product. |
| 20 |
MS
of DEO looking at log. |
Also
important to the DEO is the Log. Filled out at the end
of each shift, it is checked by the Operator coming
on duty. |
| 21 |
CU
of Log. |
The
Log includes the number of batches, the amounts of materials
left in the blenders and how many times the mill and
sifter were cleaned. |
| 22 |
CU
of Down Time Sheet. |
When
starting up, the DEO also checks the Down Time Sheet.
It records any problems experienced by DEO's on previous
shifts. |
| 23 |
CU
of dust collection equipment panel board lights. |
Some
pieces of equipment are normally left on between shifts.
These include the main dust collection system. |
| 24 |
MS
of Group C lights and master switch. |
It
is included in a group of equipment known as Group C.
Group C is first in an interlock which requires certain
equipment to be on in order for other equipment to operate. |
| 25 |
MS
of Group A lights and master switch. |
Group
C is followed by Group A. Most of Group A must be turned
back on by the Operator at the beginning of each shift. |
|
26 |
CU of sifter light on panel board. |
Group A includes the sifter and its related equipment |
| 27 |
CU
of Group B lights and panel board STOP push buttons. |
When
all of Group A are turned on, the DEO starts Group B.
Group B includes the mill and mill feed screws. |
| 28 |
LS
of fluid flo pump. |
With
the equipment turned on, the DEO Operator is ready to
begin formulation. Technical, premix, rework and sifter
rejects are fed to the fluid flo pump in its pit below
the first floor. |
| 29 |
LS
of product blender. |
The
fluid flo pump sends the materials up to the product
blender. The product blender is above the mill on the
third floor. |
| 30 |
LS
of mill. |
From
the blender, product drops down to the mill. |
| 31 |
LS
of sifter. |
After
it is ground in the mill, the product goes through the
sifter on the second floor... |
| 32 |
MS
of finished product bin. |
...
and into a finished product bin. |
| 33 |
LS
of group of hopper. |
The
four types of materials fed into the fluid flo pump
can be charged from hoppers. The hoppers are located
together on the second floor. |
| 34 |
LS
of tech hold bin. |
Sometimes
the technical is brought from the tech hold bin. Located
near the toppers, the tech hold bin stores large Quantities
of technical from the Hardy #9 Wet End. |
| 35 |
LS
of technical and premix blenders. |
Before
they enter the fluid flo pump, the technical and premix
are run through technical and premix blenders. These
blenders are above the fluid flo pump on the first floor. |
| 36 |
CU
of hand turning on fluid flo pump selector switch. |
At
the panel board, the DEO turns on the fluid flo pump.
The pump is fed by four rotary discharge valves. The
valves transfer the materials from... |
| 37 |
CU
of technical blender OUT-IN selector switch. |
...
the technical blender ... |
| 38 |
CU
of premix blender OUT-IN selector switch. |
...
the premix blender... |
| 39 |
CU
of rework hopper OUT-IN selector switch. |
...
the rework hopper ... |
| 40 |
CU
of sifter rejects hopper OUT-IN selector switch. |
...
and the sifter rejects hopper. |
| 41 |
Art
of fluid flow pump stages. |
The
fluid flo pump has a four-stage cycle: FILL, ACTIVATE,
DISCHARGE and PURGE. |
| 42 |
CU
of FILL light. |
During
the FILL stage, the rotary discharge valves open in
sequence. |
| 43 |
Art
of rotary discharge valves feeding fluid flo pump. |
The
four types of materials are released to the fluid flo
pump. |
| 44 |
CU
of present weight indicators. |
Panel
board presets control the weights reached as the materials
are added |
| 45 |
CU
of ACTIVATE light. |
The
fluid flo pump then enters the ACTIVATE stage. |
| 46 |
Art
fluid flo pump at 32 psig. |
During
the ACTIVATE stage, the pump pressure rises to around
32 pounds per square inch. |
| 47 |
CU
of DISCHARGE light. |
Next,
a RED light comes on, and the fluid flo pump enters
the DISCHARGE stage |
| 48 |
Art
of fluid flo pump transferring materials to product
blender. |
A
bladder valve releases the materials, and the pressure
forces the materials up to the product blender. |
| 49 |
CU
of PURGE light. |
When
the pressure drops to around 20 pounds, the bladder
valve closes, and the PURGE stage follows. |
| 50 |
Art
of PURGE stage. |
During
the PURGE stage, a special PURGE line releases the remaining
pressure and materials up to the product blender. |
| 51 |
CU
of fluid flo pump tank pressure gauge pointing to "0." |
When
the pressure returns to ZERO, the fluid flo pump is
ready to accept another batch. |
| 52 |
CU
of product blender low weight pre-set. |
The
product blender needs a certain minimum amount of material
for optimum blending. This is regulated by a low weight
preset on the panel board. until the low weight is first
reached, the fluid flo pump will not receive any rework
or sifter rejects during the FILL stage |
| 53 |
MS
of product blender scale. |
The
Operator watches the product blender scale. |
| 54 |
CU
of product blender scale pointing to low weight figure. |
The
fluid flo pump will not send any additional batches
while the product blender is above the low weight. |
| 55 |
CU
of hand turning on product blender rotary discharge
valve. |
As
soon as the product blender goes above the low weight,
the DEO turns on the product blender rotary discharge
valve |
| 56 |
LS
of chute to mill. |
This
valve releases product down a chute to the mill |
| 57 |
CU
of product blender scale pointing to figure below the
low weight . |
When
enough product has been released, the weight in the
blender goes back below the low weight. |
| 58 |
Art
of fluid flo pump transferring to product blender. |
In
order to maintain the low weight minimum, the fluid
flo pump then sends up an additional batch. it Will
continue to send more materials whenever the product
blender goes below the low weight. |
| 59 |
CU
of product blender rotary discharge valve speed gauge. |
How
often more materials are needed is determined by the
speed of the product blender rotary discharge valve.
At the panel board, the speed is set f or each product. |
| 60 |
MS
of mill feed screws. |
As
the valve releases the materials down a chute, three
feed screws inject the product into the mill. |
| 61 |
Art
of mill. |
Inside
the mill, the mill rotor grinds the materials. |
| 62 |
MS
of air slide. |
The
ground product falls through a mill screen to the air
slide. |
| 63 |
CU
of sifter. |
The
air slide takes the materials down to the sifter. A
screen inside the sifter holds back large pieces of
product |
| 64 |
MS
of sifter rejects conveyer. |
The
sifter rejects conveyor takes the oversized material
to the sifter rejects hopper. |
| 65 |
Art
of sifter and good product bins. |
Meanwhile,
the good finished product passes through the sifter
into one of the two finished product bins. |
| 66 |
MS
of premix blender scale. |
During
formulation, the DEO must make sure that technical and
premix are dumped when needed. |
| 67 |
MS
of drum of premix. |
The
weighing of the various premix ingredients is critical.
This is handled by the DEO personally. |
| 68 |
MS
of Utility Helpers dumping technical form bags. |
Utility
Helpers may assist the DEO by dumping technical. |
| 69 |
CU
of DEO opening drum. |
Work
gloves must be worn when working with drums. |
| 70 |
CU
of DEO wearing goggles and respirator mask. |
Although
not specifically required, goggles and a respirator
mask are recommended during all dumping |
| 71 |
DEO
on first floor wearing soft hat and safety glasses. |
Other
safety equipment is required throughout the Dry End,
depending on the job being done. A soft cap and safety
glasses are the minimum for the first floor. |
| 72 |
MS
of entrance to fluid flo pit. |
However,
a hard hat and goggles must be worn when entering the
fluid flo pump pit. |
| 73 |
MS
of DEO in stairwell, wearing hard hat and safety glasses. |
A
hard hat and safety glasses are the minimum above the
first floor. |
| 74 |
MS
of DEO cleaning mill, wearing hard hat, work gloves,
goggles, and respirator mask. |
Goggles
and work gloves are necessary when cleaning the mill
or the sifter. A respirator mask is recommended. |
| 75 |
MS
of eyewash fountain. |
All
Casterbridge personnel must be alert to possible chemical
exposure. Emergency eyewash fountains are throughout
the unit. |
| 76 |
Art
depicting DEO solving problems. |
Being
safe is just a part of being a DEO. The job demands
careful attention to the formulation process and solving
problems as they arise. |
|
77 |
LS of premix on scale. |
It involves accurately charging the materials ... |
| 78 |
MS
of fluid flo pump. |
operating
the fluid flo pump |
|
79 |
CU of product blender low weight. |
blending the materials ... |
| 80 |
MS
of mill. |
grinding
the product to specifications . . . |
| 81 |
MS
of sifter. |
...
and sifting the formulation for the final product. |
| 82 |
LS
of pack out line in operation. |
Careful
attention to the Dry End process assures each bag or
drum packed is as good as the last. |
| 83 |
Art
depicting "war on weeds" |
And
that's what quality control really means--making products
that will win the war against weeds |
| 84 |
Credit
slide. |
(Music
up.) |
| 85 |
Art:
"A Training Center Production" |
(Music
fade.) |
