Document 0JBMRzd136n3y9L98ONR9KzVd

To: From: Re: Gkmuxtj& CSCAMVfA PLANT INC. INTEROFFICE MEMORANDUM E. A. Primeau D . H . F rancke PVC Monthly Report, July, 1975 Dote: Copies: 15 August 1975 J. T. Ba r r J. M. Diamond R. E. Jones Summary: Production for July, 1975 was 4. 79MM lbs. of prime or 72. 97a of budget. Production was below budget primarily because of stripper limitations (1.4MM lbs. ) and tests on PVC 2250 resin (. 3MM lbs. ). Work on OSHA Projects continued with, progress being seen on the Washout System and the Access Control System. Personnel monitoring for the month showed 75.5% of the 8 hr. TWA samples to be below 1.0 ppm with 53. 37o being below 0, 5 ppm. Of the 15 minute TWA samples, 93. 67o were below 5. 0 ppm and 53. 17o were below 1. 0 ppm. System variance for the month was $43. 3M favorable. The variance was primarily due to favorable variances of $15. 0M in spending, $8.4M in raw material efficiency and $92.8M favorable price variances in monomer and utility costs. They were offset in part by unfavorable variances of ($44. 8M) processing efficiency, ($10. 5M) volume variance and ($11. 8M) sales variance. AP00041508 EXPLANATION OF MAJOR VARIANCES Escambia PVC Plant, July, 197 5 Non-Controllable Controllable Total Explanation of Major Contributors 1. Manufacturing Var iance $64.7M from Budget ($21.4M) $43.3M a. Spending b. Raw Material Efficiency $ B.7M $ .5M 0 $ 8.4M $' 9.2M ($1,750) ($2,400) ($1,285) $6,751 $17,607 ($1,953) $1,6l8 ($3,513) $ 8.4M ($58, 000) $9, 114 Salary premium pay high primarily due to coverage for vacations & illness and from high purchased labor. Utility usages higher than budgeted. Bagging costs high due to mainte nance &c materials. Chemical cleaning favorable due to good DMF efficiency. Favorable depreciation, $18. 0M, taxes $1.8M and Plant O/H, $4. 9M offset by unfavorable insurance, ($4. 9M) and amorti zation ($2. 2M). Unfavorable professional services due to OSHA-VC1 physicals. Favorable process chemicals of $1,276 and effluent chemicals of $342. Unfavorable laboratory ($585), effluent control, ($1, 085) and materials and supplies, ($1,843) Utility and overhead variance VC1 efficiency at 95. 3% vs. 94. 5% budget. AP00041509 EXPLANATION OF MAJOR VARIANCES Escambia PVC Plant, July, 1975 Page 2 Non-Cont-rollable Controllable b. R.M. Efficiency (continued) c. Process Efficiency n. a. ($44, 8M) Volume Variance ($10. 5M> Sales Variance ($11.8M) Total Explanation of Major Contributors $1,276 ($2, 633) Good process chemicals usage Offgrade credit ($44, 8M) ' ($29, 503) ($15,417) Low PVC 2200 rates due to increased cleaning frequency needed to maintain quality Low PVC 1230 rates caused by excess reactor time not requiring minimum cycles. ($10.5M) ($10, 500) Low production rates due to extended stripping requirements for low monomer content. ($11.8M) ($5, 024) ($6,785) Low bagging volume due to low sales of bagged material. PVC22 50 test runs alleviate GS & Plastics supply problems caused several reactors to be out of service. AP00041510 I EXPLANATION OF MAJOR VARIANCES Escambia PVC Plant, July, 1975 Page 3 Non-Controllable Controllable 4. Price Variance $81,171 Total Explanation of Major Contributors $81, 171 $76, 171 $16, 600 VCM price variance Utility price variance due to ethane/methane usage. AP00041511 PVC Monthly Report, July, Page 2 D. H. Francke 1975 Production, for July consisted of PVC 1225, PVC 1230, PVC 1250, PVC 2200 and PVC 2250. Except for an early contamination problem, all resin types were basically without quality problems during the month. Early contamination problems were traced to a buildup primarily in one of the weigh tanks. Cleaning the weigh tanks eliminated the problem, PVC 1230 production was normal throughout the month with very few problems, There was one batch of PVC 1230 which was mischarged and resulted in about 1, 500 lbs. of BBs and chunks. This appeared to be caused by a slow agitator setting. One railcar of PVC 1230 was produced using a Methocel K-35 recipe. This material was within a specification and was shipped for evaluation. If there are no processing problems at customer locations, a longer run of PVC 1230 using a Methocel K-35 recipe is anticipated. Use of Methocel K-35 in place of a PVC'Tween suspension system is desirable for several reasons. These include having only one type of solution for general purpose resin suspensions, reducing the number of raw materials, and having the capability to filter solutions when both PVC 1230 and PVC 1225 are made at the same time. Several batches of special PVC 2250 runs were made during July using a Geon Latex 450X3 additive. These tests involved using both full and reduced space charges and were limited to one stainless and one glass reactor to help limit the number of variables. Both lots of material made were tested by the customer and this material was accepted as good material. Future plans for production include the use of a latex additive. Which latex will be decided after laboratory testing of different latex additives since Geon 450X3 has such a short shelf life. These tests resulted in a loss of 300M lbs. of production due to out of service reactors. The residual monomer levels for lot and shipment composites dropped significantly for the PVC 1230 resin made during the month. No particular changes in operation were instituted. Following is a table of the monomer content, by type, for all shipments and lots during the month; AP00041512 PVC Monthly Report, July, Page 3 D. H. Francke 1975 PVC 1225 PVC 1230 PVC 1250 PVC 2200 PVC 2250 Average VCM Lot Composite a Shipment Composites 29. 2 14. 8 36. 6 20. 9 22.4 12. 3 14. 7 4.7 30. 5 No shipments There were no major maintenance problems during July which caused production outages. Work on the weigh tanks for cleaning and other work resulted in the loss of about 65M lbs. of production, or 7.6 batches. To eliminate the reoccurrence of the problems due to buildup, the use of a standpipe in the recovered monomer tanks was started. This will permit the separation of a water layer which can be removed prior to charging to the weigh system. In addition, a filter and caustic bed are planned for the charge system. The Nash Compressor continued causing problems during the month. The Nash representatives visited the plant and recommended a reduction in the seal water flow rate be made to stop the noisy operation. This was done along with a revision to the separator system and the noise problem ended. Shortly after that, a noticeable reduction in capacity was observed. After a full check of the control systems, a compressor test was made which indicated compressor problems. The compressor was removed and torn down revealing a worn outlet core. The part 1b in transit as of this writing. There is no positive cause for the worn part. The new steam generator was installed during the month replacing the old condensate hold tank. Along with the elimination of a three horsepower motor for condensate transfer, there should be an increase in the condensate credit to PVC, During July, 1975 sodium nitrite was used almost exclusively as short stop. There were no problems encountered with this material and it was found to be on good shortstop.* No deterioration of the inhibiting effect was seen even in reactors held for extended periods of time. Further use is planned to determine whether it will replace AMS as our shortstop. AP00041513 PVC Monthly Report, July, 19*75 Page 4 D. H. ` Francke VC1 Exposure Programs a. Personnel Monitoring The personnel monitoring during July continued with the frequency being twice/month per man entering the PVC area. The sampling schedule is get up to monitor each person entering the PVC area during the month on an 8 hour TWA and a 15 minute TWA sample. The result for July showed that on 8 hours only one sample was over 3 ppm. Of a total on 45-8 hr. TWA samples, 53. 3% were below 0. 5 ppm, 75. 5% were below 1.0 ppm and 97.7% were below 3.0 ppm. Of a total of 47 - 15 minute TWA samples, 34.0% were below 0. 5 ppm, 53. 1% were below 1. 0 ppm, 89. 3% were below 3. 0 ppm and 93. 6% were below 5.0 ppm. AP00041514 PYC Monthly Report, July, L975 Page 5 D. H. Francke PPM <.5 Supervisor Senior Reactor Solution Recovery Finishing Utility Artisan Maintenance 5 2 2 1 3 3 2 2 4 Subtotals 24 % of Totals (45) 53.3 8 HOUR SAMPLES . 5-1 1 -3 3-: 5-10 10-15 >15 0 20 0 0 0 0 11 00 0 1 20 0 0 0 2 10 0 0 0 0 10 0 0 0 1 00 0 0 0 1 20 0 0 0 1 00 0 0 0 4 10 00 0 10 10 1 0 0 0 22.2 22.2 2.2 0 0 0 15 MINUTE SAMPLES Supervisor Senior Reactor Solution Recovery Finishing Utility Artisan Maintenance Subtotals % of Total (47) 5 3 0 2 0 1 0 1 4 16 34.0 1 1 0 1 0 1 2 1 2 9 19.1 1 1 3 2 4 0 3 1 2 17 36.2 0 0 0 0 0 1 0 0 1 Z 4.3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 2 4. 3 0 0 0 0 0 0 1 0 0 1 2.1 AP00041515 PVC Monthly Report, July, Page 6 D. H. Francke 1975 YC1 Exposure Programs (cont'd) b. Area Monitoring System The area monitoring system operated throughout the month with only a portion of the sample points giving good analysis. On about the seventh of the month it was discovered that all of the sample tubing from the reactor building had degraded to the point of cracking open. When this problem was found, it was possible to make repairs to only some of the sample points due to tubing availability. The repairs were made and the plant ran on area monitoring for the second and third floors only during the rest of the month. The problem seemed to be at least two fold. First, it was found that a lower priced poly-propylene tubing had been used originally since it was available. This was clear (unpigmented) tubing and it was discovered, after the bad tubing was found, that unpigmented poly-propylene tubing has poor sunlight resistance. This is being corrected by replacement with black tubing. The second problem was the close proximity of one group of sample lines to a steam traced line. The added heat factor seemed to increase the degree of degradation. Further investigation indicated that all of the pigmented tubing inside the building was good and there should be no problem, with pigmented poly-propylene tubing outside. The alarming sequence was quickly reprogrammed to alarm and light based only on the good sample points and adequate coverage was maintained. c. OSHA Projects Work continues on the OSHA Projects CEA. Delivery of the access control turnstiles is expected at the end of August and installation will follow. The washout header system installation continues and it should be in use by the end of August. AP00041516 PVC Monthly Report, July, Page 7 D. H. Francke 1975 VC1 Exposure Programs (cont'd) d. Breathing Air System Two vessels were located in July for use as carbon beds and the drawings should be issued in the first part of August. These tanks require only slight modification and they can be piped up for use. e. Second South Stripper Approval for the second south stripper was received and the vessel has been purchased. Engineering has begun on the foundation drawings and layout. AUGUST Production for August, 1975 is projected at 5. 3MM lbs, or 80. 6% of budget. This will result in a volume variance of ($60.8M) unfavorable. Maintenance should be at budget. Favorable variances from VC1 efficiency and non-controliables should account for $16. 6M and $17. 6M favorable respectively. Total system variance is projected at ($26. OM) unfavorable. Future Plans The future plans for the Escambia PVC Plant include the following items: 1. Complete debugging of the Bristol/Bendix System to improve reliability and to simplify programming will begin in August. This will give more credibility to all of the analysis including the material balance numbers and will make debugging of the access control system easier when it is set into operation. 2. Plans for setting up data summary programs using the data generated by the OSHA related functions are being made. This data, if summarized correctly, can probably lead to the identification of some problem areas but will, at least, tell us how we are operating with respect to government regulations. AP00041517 PVC Monthly Report, July, Page 8 D. H. Francke 1975 A series of tests on PVC 1230 using a MethocelK-35 suspending system will be made during August to see if a switch to this system is practical. The use of a latex additive is to be tested in PVC 2200 production in August to determine if it is useful in reduction in fouling and/or fisheyes. Production of PVC 2250 for customers is already planned for a latex system. DHF/cd Attachments iiJ-r -- D. H. Francke AP00041518 EXHIBIT I Statistics Prime Production, M lbs. % of Budget July, Actual 4, 790 75. 1 1975 Budget 6, 381 Year to Date Actual Budget 52, 993 61,058 86. 8 Off Grade Homopolyme r Tails Sweeps & PTS 88 37.5 84 96.7 8 28. 1 Total Production % of Budget 4, 970 76.0 6, 543 55,400 B8. 4 62,641 Off Grade, % of Total Bulk Production, % Prime VCM Efficiency VCM Accountability Reactor Availability 3. 6 96.5 95.3 97.4 68.6 94. 5 4. 3 82. 3 96. 0 98. 6 72. 6 94. 5 Type 1250 2250 1230 1225 1230 2350 2200 Production Sequence. North Line Hours Batches 37 5 58 4 60 5 237 19 429 36 87 6 2, 607 203 3, 515 276 July. 1975 Type 1225 1230 1225 1250 South Line Hours 525 2, 608 562 522 Batches 49 219 45 43 Type 122 5 1230 1250 2160 2200 2250 M LBS, July 890 2,217 321 - 1,295 67 Production Summary - Prime YTD July LBS. /HOUR Budget % Budget 6, 552 672 646 104. 1 28,366 716 822 87. 1 557 574 - - 946 - 663 - 14,386 497 685 72. 5 2, 190 462 400 115.5 Lb. /Annual Gallon Actual Budget L, 364 1, 311 1, 543 1,669 1, 165 - - 1,425 1, 069 1,473 993 860 AP00041519 MATERIAL BALANCE ESCAMGI A PVC PLANT MONTH ENDING 31 JULY 1975 PMB015 LBS - SUB-TOTAL & VCL USED BASED ON BILLING WEIGHTS LBS TOTAL % OF VCL CHARGED SUB-TOTAL total 5,213,433 100.00 B PVC' OUT TO PRODUCT 1. PVC PRIME 2. PVC OFF-GRADE 4,790,000 180,000 4,970,000 91.88 3.45 95.33 C PVC LOSSES I. PVC TO DUMP AS SCRAP 2- DRYER DISCHARGE SOUTH LINE NORTH LINE 3* PVC IN EFFLUENT WATER 452 81 22,640 533 3,324 26,497 .43 ._o_i___ .51 .06 in * o M i D VCL LOSSES 1. DRYER DISCHARGE SOUTH LINE 843 i NORTH LINE 2. STRIPPER EVACUATION 800 I NORTH 4t 736 , SOUTH ..5 _797 i 3. VCL !N EFFLUENT WATER r 4. VCL FROM OPEN REACTORS 5. VCL FRUM BLEND TANK VENT i\ 6. VCL FROM CONDENSER VENT 7. VCL FROM REACTORS VENT 8. VCL FROM PURIFICATION COLUMN 9. VCL WEIGHT DIFFERENCE 1.643 10,533 344 25,136 75 13*274 28.896 79.901 .03 .01 .48 .00 *25 .00 .00 ,.55. f3TAL ACCOJNTED FOR OUT I0T&L^J'N ACCOUNT EO^FOR - --- - 5,076,398 Z~7A377^ 3.5 .--2 t.S.3. 97.37 rC \ ,1_ i A r i \ X v ri 1 AP00041520 MATERIAL BALANCE E S C A MB I A"P VC "P L ANT Y T D ENOING 31 JULY 1975 PMB015 -- L8S SUB-TOTAL A VCL USED BASED ON BILLING WEIGHTS LBS TOTAL 57,702,103 % OF VCL CHARGED SUB-TOTAL TOTAL 100.00 B PVC OUT TO PRODUCT 1. PVC PRIME 2. PVC OFF-GRAOE 55,401,600 52,993,100 2.408,500 91.84 4. 17 96.01 PVC LOSSES L. PVC TO DUMP AS SCRAP 2. DRYFR DISCHARGE SOUTH LINF 104*515 NORTH LINE 17,842 3. PVC IN EFFLUENT WATER 424,344 122*357 48,861 595,562 .74 .21 .08 1.03 , P VCL LOSSES X^3A L. ..ORYER 0 [SCHARG6190*444. 33. NORTH LINE 93*682 2. STRIPPER EVACUATION NORTH26*200 59.489 .10 __________________________________________ SOUTH_3_3* 289 ,,3. _VCL IN EFFLUENT WATER 12,998.02. 4. _ VCL FROM OPEN REACTORS __ 178,503.31 5. VCL FROM BLEND TANK VENT 44,811 .OB 6. VCL FROM CONDENSER VENT 68,430 .12 7. VCL FROM REACTORS VENT39,_0j>_0,.0.7. 8._VCl FROM PURIFICATION ..COLUMN,00. _9>__VCL_.WE I GHT_DINFERENCE3 0 3,82.9.. 53. r i *1 1 1 1 I TOTAL ACCOUNTED FOR OUT ------------ ----- 56,894,666 ..... ---- ----96.60 QTAL UNACCOUNTED FOR _B0X*_43i L.AQ_ AP00041521