Document 609vmjrZmEapxeRV2ONGp12d

To: R. T. Ferrell r\ Interoffice Communication From: Date: Subject: J W. Were March 17, 1987 ABERDEEN MONTHLY PROGRESS REPORT FEBRUARY, 1987 There were no injuries recorded during the month of February. of February 28, 1987, the plant had operated 2,793 days 3,588,055 manhours without a lost time injury. As or PVC resin production for February was 33.7MM pounds. Mechanical downtime in the reactor areas was due primarily to agitator seal repairs on 400, safety disc replacement on 745 and miscellaneous reactor valve repairs. Resin production year-to-date totaled 177.8MM pounds. The VCM efficiency for February was 1.01638 pounds of VCM per pound of PVC produced versus a 1.00208 standard. Year-to-date VCM efficiency is 1.01065. Compound production for February was 6.8MM pounds. Line I and Line III operated twenty-eight days and Line V operated fourteen days during the month. Production was limited primarily by product changes, Banbury . maintenance and Line III mill maintenance. Year-to-date compound production was 35.4MM pounds. Quality performance for flexible compounds was 1.5% off-grade of which 100% was due to mill scrap. "BC" production was 1.2%. Dry blend production was 3.9MM pounds for February and 22.6MM pounds fiscal year-to-date. Production was limited primarily by product changes and quality control problems. Quality performance for the month was 99.8% customer grade. The plasticizer unit operated twenty-eight days in February to produce 1.6MM pounds. Year-to-date plasticizer production is 9.4MM pounds. Two of four active involvement teams have completed their projects. The vinyl team presented the results of their work to management and a miscellaneous capital project was approved to institute their proposal. Department steering teams have been formed and began regular meetings in February. Total energy consumption for February was 112.690 MMM BTUs. The energy consumption per pound of product was 2444 BTUs, resulting in an adjusted CMA reduction of 52.3%. The adjusted CMA reduction for fiscal 1987 year-to-date is 54.2%. VAB.0001191451 lh . -UJ * IfnPM . rl ) R. T. Ferrell 03/17/87 Aberdeen Monthly Progress Report Page 2 ; y The total plant variable cost variance for February was $277.4M unfavorable, resulting from an overall unfavorable price variance of $283.8M and a net favorable efficiency variance of $6.4M. The total fixed cost variance for February was $56.9M favorable. J. W. Ware rah A r>'-iu-kpy iifjH.... -ifm*-l-uuvr^i... v.- - t f!-' tj VAB.0001191452 DISTRIBUTION HOUSTON PONCA CITY OKLAHOMA CITY LAKE CHARLES VCM PLANT LAKE CHARLES CHEMICAL PLANT BALTIMORE HAMMOND ABERDEEN - J. D. BURNS - R. E. LEHMKUHL - R. T. FERRELL - R. D. GAMBLIN - J. J. LANGFORD - R. E. SWANTKOWSKI - D. F. HARMAN - H. R. FLAMMER - E. L. KIESCHNICK - S. K. SABORSKY - K. J. EGGERS - D. H. SANDERS - S. E. MCGUIRE R. L. POE - H. J. HALL - C. M. STARKS - HARRY GARRISON - DICK CONRAD - J. A. DEBERNARDI (COVER LETTER ONLY) - T. H. HUFFMAN (COVER LETTER AND SAFETY PORTION) - R. W. SEYMOUR (COVER LETTER AND SAFETY PORTION) - J. B. MAHER (SAFETY PORTION ONLY) JF, JWW, DWH, PJK, TFL, RAF, JVU, RAM, VEM, HGC, CWT, REP, VLT, PJR, JGC, RBN L f r J- .-si i dH I. . r-t-j '*. f .ffi : - 4. s 1' 1' n.-'S - 1 ...i i r Hr -m- . -f*>-i VAB.0001191453 +i SAFETY - J. V. UPTAIN Occupational Injuries Feb Fiscal Y.T.D. 1987 Fiscal Y.T.D 1986 First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases (RWC Rate) Number of Lost Workday Cases (LWC Rate) 0 0 0 0 (0.0) 0 (0.0) 4 1 5 0 (0.0) 0 (0.0) 12 2 14 1 (1.01) 0 (0.0) Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 3 3 5 0 0 _3 14 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 0 0 0 0 0 0 0 0 Non-Occupational Injuries Lost Workday Cases Days Lost 02 0 11 3 35 Safety Record Last lost time injury 7/5/79 Days since - 2,793 Manhours since - 3,588,055 Training Topics for the plant safety meetings during the month included: Housekeeping, Personal Responsibility to Act, Finding Cures for Accidents, The Team Approach to Safety, Review of 1986 Safety Performance, and Maintenance Weekly Safety and Job Review. One R&D employee and six contract personnel received plant safety orientation. A .--I-- ' " !-it ism tn-au . if. i wHfcfrijUMii j v j . i'E L,.j.rr- . . y.,.T IK^rK r- t!!*n h. i n-muq-i. ?'ngmmfP^FPir T' VAB.0001191454 t --.ns."--, ! Fwioqir , jo- wjv tmn *f*>^mtmininmBiniwiwnniFiffptiwarf f-jtii i- SAFETY - Continued Health Activity for the month included routine dosimetry (shown below) and the start of annual* medical health screening (van). V Chemical Number PEL Percent Number PEL Percent VCM Lead Total Particulates 77 16 7 100.0 88.9 100.0 0 0.0 2 11.1 0 0.8 The two lead overexposures occurred with respiratory protection. A , v-"- -i: v>:t- - ......................i!' J : -V- v |M n- " r|.. " I'!-* : \:-h- ?r- UjL. LlidDLIn-L.. M.4J:il..J-------'|l U.W l^. >> I J--i 'K "' I*'- tf Wl>W n n *+*** --.V' F VAB.0001191455 QUALITY IMPROVEMENT PROCESS - R. B. Newton A one-day training course for involvement teams and problem solving techniques was prepared. It is scheduled to be given to the Vinyl Department the first two weeks of March. Two of the four active teams completed their projects. The team of operators presented their solution to the problem of cross-contamination to management. A miscellaneous AFE request is approved to implement their recommendations. vinyl resin being The maintenance team that was preparing the Preventative Maintenance Program for the new plant crane completed its work. A presentation to management scheduled for early March. An additional involvement team was formed in the Maintenance Department to address the problem of valve actuator mounting brackets. Each department in the plant has formed a steering team to keep the quality improvement effort moving forward. These teams began meeting regularly during February. l,ir,r* 7 pTU+rB-flrtI/-1 -nKi- -H'y* '+ --J- V ^i-t. Itfarin r-i i H Irt^ I1^ >' rrl . r(>-( r-: r.j. '-I-1*'1"'..........- ! "m ilMMHaiWWHUPfSf :-S mi*: - VAB.0001191456 VINYL - D. W. Hollis, J. M. Edwards Safety The Vinyl and Yard Departments operated without an injury in February. Shift safety meeting topic for the month was Accident Prevention and a review of the plant s first aid and medical cases which resulted from accidents in recent years. Production February Y.T.D.(Fiscal 87) 1. Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days 33.7 1202 854 30.5 94.8 10616 59.0 28 177.8 1190 4431 29.3 90.6 10407 59.2 151 Vinyl Department production for February was 33.7MM pounds. Reactors The reactor stream factor for February was 94.8%. reactor area occurred as follows: Downtime in the 1) Operational Downtime: Accounted for 71.3% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size information before charging, reactor manway O-ring failures and downtime associated with test runs. 2) Maintenance Service Downtime: Accounted for no downtime because the cleaning of the reactor AMS injection ports and inert vent lines was accomplished while the reactors were normally down for other reasons. 3) Maintenance Repair/Revision Downtime: Accounted for 28.7% of the total downtime and was due to changing the agitator seal on D-400, changing D-300 and 745 primary VCM valves, changing various chem wash and rinse valves on D-500, D-700 and 745, changing the safety discs on 745 and changing the inboard seal on B-compressor. Dryers The dryer stream factor for February was 59.0%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 92.8% of the total down time. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 3.8% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems, and the fluid bed scrubber plugging. A . H L+ > |.. Tta *;. .bT<; p--Ki P * L 4 - | ||1J.iw',i^ii-l^d4.^ in ir; >-ij.. up* ii-`h;-I i + Vt - ' l|4 Ep VAB.0001191457 ? VINYL - Continued Dryers - Continued 3) Maintenance Repair/Revision Downtime: Accounted for 3.4% of the total downtime and was due to changing out #7 centrifuge, changing out the fluid bed exhauster sheave, #5 activator problems, #6 star valve problems and the #8 tumbler seals. Product Quality Summary Resin Type Prime % of Total "B" "H" Production 5265 5305 5385 5415 5425 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 1,483,273 2,899,270 17,691,415 7,270,740 1,828,830 1,388,600 -- -- -- -- 32,562,128 -- -- - -- - 1,038,080 20 -- 2,000 1,040,100 -- -- -- -- -- -- -- 55,703 - 55,703 4.4 8.6 52.6 21.6 5.4 4.1 3.1 0.0 0.2 0.0 100.0 Quality performance for February was 99.8% customer grade with 0.2% "H" grade production. A total of six railcars were shipped as "B" grade during the month which represented 5.6% of the 108 total resin hopper cars; shipped. Load Date Ship Date Car No. Customer Product Reason 01/21/87 02/02/87 RTMX 580054 Cont. Plast. Co. Debox Derailed 12/14/86 02/03/87 VIPX 45811 Wexford, CA Pond Quality 01/27/87 02/09/87 PLCX 43730 Wexford, WI Debox Quality 02/04/87 02/23/87 VIPX 45871 Wexford, CA Debox Quality 01/28/87 02/25/87 VIPX 45793 Wexford, WI 5385 Contamination 02/20/87 02/27/87 VIPX 45713 Griffco. MS Debox Quality The Vinyl area received fifty-nine short lead time emergency type orders comprising 22% of the 269 Aberdeen resin shipments in February. Monthly Variable Cost Performance Variable costs for the month were unfavorable at $269.3M resulting from an overall unfavorable price variance of $247.8M and an unfavorable efficiency variance of $48.5M. Resin variable cost for the month was 18.996 cents/lb. versus the budgeted 18.086 cents/lb. A -*ri - - -I .. -- i i*i: \., Hi i- r- i. H. . tj|l |>p Pr- 1 It** . niifViis' : ns--'iiv - r<-- VAB.0001191458 t 1 VINYL - Continued Monthly Variable Cost Performance - (Continued) The $247.8M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $342.1M. The $48.5M unfavorable efficiency variance can be attributed mainly to the unfavorable efficiency variance of VCM, $72.7M. This was partially offset by a favorable efficiency variance in Polyvic, $10.3M. VCM efficiency for the month was 1.01638 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. YTD variable cost efficiency variances in the Vinyl Department totaled $223.6M unfavorable. Energy Performance/Progress 1. Plant energy performance for February was 2444 BTU/lb. Resin raw material in the 0744 account totaled $209.7M. 4 CI,I I,-#.:- -I- 1-H -- -t *.' 'PHI' ,-t faMBla#**. | |L-||U il.-iRVipiJ I M *! tj*-' h lv-i- |vW VAB.0001191459 r ,U;1 ^ ' -S-i 11 r COMPOUND - P. J. Kober, J. E. Nickerson Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line V Line III Total 28 2142 77 14 827 59 28 3860 138 6829 11904 4268 19219 35391 Line I operated twenty-eight days during February at an average rate of 77M pounds per day. Major items affecting production efficiency were: product changes* 73 hours; Banbury maintenance and seal changes, 41 hours; ribbon blender maintenance, 11 hours; housekeeping, 11 hours; quality problems and Q.C., 14 hours; dicer problems and maintenance, 6 hours; and Modicon reprogramming, 6 hours. Line V operated fourteen days during February at an average rate of 59M pounds per day. Major items affecting production efficiency were: product changes and startup, 33 hours; quality problems, 4 hours; and plasticizer system problems and maintenance, 3 hours. Line III operated twenty-eight days during February at an average rate of 138M pounds per day. Major items affecting production were: product changes, 40 hours; mill drive shaft gear replacement, 16 hours; dicing system problems and maintenance, 6 hours; hydrotherm system maintenance, 5 hours; and transfer system problems and maintenance, 5 hours. A test run to investigate rigid PVC production on Line III lasted approximately 11 hours. Quality performance for flexible compounds was 1.5% off-grade of which 100% was due to mill scrap. "BC" production was 1.2%. The raw material requirement for flexible compounds was .99658 pounds of raw material per pound of compound versus a 1.00993 standard (YTD is 1.00462). The variable cost variance for compound was $46.4M unfavorable with $59.5M unfavorable due to price and $13.1M favorable due to efficiency. The efficiency variance due to product mix was $8.4M unfavorable. There were no major compound raw material efficiency variances. Total compound inventory fell .4MM pounds in February to 7.8MM pounds. Dry Blend Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 3926 28 140 22561 151 A 1 'i !*hpU-. ! r J `F in ^wlnym npii^frfp -!W V lumwwiWU|iBmH n.-umi UPPIP Iiifujy-Fsm in VAB.0001191460 f COMPOUND - Continued Dry Blend - continued Dry blend operated twenty-eight days during February at an average rate of 140M pounds per day. Production included 80172C, 80273G, 90172D, RP-200T, RP-421, 186-74, 186-139, 223-36, 196-198, 223-57, 245-53, 269-12, 269-67, 269-66, 269-63 and 269-43. Dry Blend production was hindered by: product changes, 53 hours; delays associated with quality and lab problems and normal Q.C., 38 hours; transfer system problems and maintenance, 15 hours; filler system problems and maintenance, 8 hours; Welex diverter valve maintenance, 8 hours; screener maintenance, 8 hours; and Welex maintenance, 5 hours. Quality performance for the month of February was 98.4% customer grade. The raw material requirement for dry blend was 1.00744 pounds of raw material per pound of dry blend versus a standard of 1.00489 (YTD is 1.01018). The variable cost variance for dry blend was $51.2M favorable with $14.9M favorable due to price and $36.3M favorable due to efficiency. The efficiency variance due to product mix was $38.3M favorable. Plasticizer Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 1624 28 58 - 9372 151 Plasticizer operated twenty-eight days during February at an average rate of 58M pounds per day. Production included 61OP and 108P. VRP production totaled 142M pounds (9,6%). The raw material requirement for plasticizer was 1.11239 pounds of raw materials per pound of plasticizer versus a 1.09848 standard (Y.T.D. is 1.11520). The variable cost variance for plasticizer was $14.1M favorable with $8.6M favorable due to price and $5.5M favorable due to efficiency. There were no major plasticizer raw material variances. The efficiency variance due to product mix was $1.7M favorable. Quality Improvement Charting of process variables is being practiced on all lines. The continuing monitoring of plasticizer reaction rate has demonstrated a statistical increase in rate and reduction of reaction time since the charting began. A quality information bulletin board was started in the production area. Customer problems and positive responses are posted on the board to help the operators grow more familiar with the customer and his concerns and to provide feedback for our quality effort. l I -.1 I I II L-"|.J*u, . .IH-W -1C. i:n"J - r u-H -H- 11' ,t ii*'.n;; .. Ml. "'1 , p*p v^>i i n ift -1 u 2 s im i* U. jj j sr. 'infill :.-r .r`i#''r- -I-:-I- Y|.tH?. At.- 4 i.: -I t -Sj+..j-.: .Jlrirt-I i- t : r r VAB.0001191461 COMPOUND Continued Enersy Compound Dry Blend Plasticizer ________ Usage (BTU/Lb.)___________ Actual Standard 1716.5 720.1 1792.0 1783.0 730.0 1833.5 A i h nil. . ifi iii ~-j< t- weirin' r VAB.0001191462 il-1-.h-i- w vl. 1 + h' -H MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - G. A. Morgan, D. A. Miller There were no injuries to Maintenance Department personnel during the month. Vinyl The D-400 reactor agitator seal was repaired during the month. Four agitator seals have been replaced through the first five months of fiscal 1987. Ten reactor valves were replaced. The following work was accomplished on pumps and compressors: - The seal was replaced in the old module east VCM charge pump. - The seal was replaced in the old module north chem wash pump. - The south VCM sphere pump was replaced with a spare. - The impeller was replaced on the fluid bed dryer scrubber pump. - The seal was replaced in the old module high pressure service water pump. - The outboard seal was replaced in the 706 emission recovery compressor. All mercury manometers on the reactors were replaced with vacuum The annual replacement of the D-745 reactor rupture discs were completed. The #6 dryer exhauster was replaced with a spare due to high vibration. The #7 dryer Bird centrifuge was replaced with a spare due to high vibration. Twenty-three steam leaks were repaired. The control room batteries and inverter system was PMTd. The new unit seal water separator temperature controller was replaced. A - '.L ,^| =! :tiru ii *:ai iw . M! -H i<11|T Ii ilM TT II i 11 ii i ............ill iwiiiJiaiiip smij|||uI l ! . < it-i .Kyinr.--.k ^jy .,r, VAB.0001191463 r MECHANICAL DEPARTMENT - Continued Compound, Dry Blend, Plasticizer The Line I Banbury seals were replaced and two seal yoke cylinders were replaced. The Line I B-blender gearbox was replaced. The Line I A-blender ribbon shaft was repaired in the outboard bearing area. New chain guards were installed on both blenders. The Zone I Line III hydrotherm system pump was replaced. The dry blend unit #1 Welex mixer drive motor was replaced with a A rebuilt gearbox was Installed on the north gump screener. The Line I Banbury inlet chute and Ram housing was modified to eliminate excessive dusting and a potential lead exposure hazard. The Line V single screw hot oil system was overhauled. The Line I pro-batcher weigh controller was repaired. Utilities Dredging on pond #3 was completed and a subsurface aerator was installed. A new sulphuric acid day tank was installed at pond #3. The hydrazine based oxygen scavenger for the boilers was replaced with a hydroquinone based product to eliminate potential employee exposure hazards. . it y.t: .U '':rj 'J fP"'Ji : rKI " ^ " :*i.r "T ',- T" ' t: -s i: a?i!rs.rj^tr.|: n :r-p VAB.0001191464 r A im..' . Ni, ,wi,m .r. MECHANICAL ENGINEERING-(R.E. POLK) CO cn u CO iiii i i u cn ii in O k. at Iff 3 C= *0 a ai tii at in rf >*+ iff ai u am L. o u U 4J at ai Iff ii itii ii ii ii tiii ii ii cn it it ii ii ii ii ii it ttii iitt ii ii ii ii ii ii ii It it it it it ii ii i ii at iff in M in Iff ro m cn II cn II II II II cn M it ii ii in ii ii in A# c o tJ d <0 at a. TE3 o ai LJ iff Ql Li a at 01 4J cs o at ad m Iff c o at o o mp4 <c o * at cu o tz u cr * at Ol 4J c Ol H fe c cn at X3 o +J > 0 at 4 <a ai > iff O "O Iff o o u lj at at as lj ai at iff u ia at u ai ai at at o in aa iff at in m nd at oo CM Iff at Iff at at at at 0t a at o at as oo u at iff ^ iff ui LJ =n o ut in at c L. O ui at o LJ in in ui at o **4 o U -W d O u at ui iInff K> at at u at o III UI UI at o Oi ._o at c C #4 m at m in in iff in in CM in cn cn cn UJ cn ui LLl in at iff o u ^3 Pih4 ai J3 ai .O d .-4 ai u* ns a UI at at iff at lj cn in 04 CM ui in cn m 04 VAB.0001191465 .......... :| - it 4*--.. +ifW.-l .* J, flf l ^ ^MCnw+lriTirfl.;-j* -'.(th "!!> M* |||l| ii->. M> - h . 4i-,,. l**11- II |I1 11tff Mil l||l JlHHIH II. tl.lW I JHI|I|I|| | t Hu--mammn ht**-*1 '1 f' -KP-- .'4 k ............ * - mii - J i i r. i c .r: 'xji.: r ^ j- Un) iII i-- ii <r m ii cn h m ii rt _ ii ii ii r_i M n < ii h ti it tn it ixi ii a it LU ca ii ii LU t A _ ii x ti LU n n LU ii n n W* H n ii era ii un Oa ut HI o ui i. .#4 rtf OJ O Oi cr u^ o OJ Xo3j mr in OJ OJ OJ u* in oi o OO C O OJ o Xo> CJ U Of c u in x OJ OJ OJ *o c X OJ O OI tt 0 l. ~0 Ok ui in U1 OJ in oino OJ oo oj o -- -- Oj UI m O o OJ OJ oi o OJ uo u in m k. o in m in oi m UI CM O O MO Of rtf mo in u in m CM GO to LcUn i LU CO LU A MECHANICAL UoiNEEftIN6-(R.E. POLK) 4H-! 'Tttiu r?! f*" i>h 'tM n- *<*rt tnms!i-wtv I..............iWi I iijlWH|1||f|r " 'II i~~nr*iv rJ IT"i wrpI ri'IIHhiii gin ii I Will 'i^lfHiiiN^ y i4^juh'THir-mi ' VAB.0001191466 T i*i^iNTWWy:m.nHHH!;nimipn ifcMwMfcW--|UnHiiHUlUUhuiiummhi MECHANICAL ENGINEERING - Continued Contracts A total of twenty-five register tickets and one construction contract were issued during the month of February. h -i.i-it Mil.'/ TH'-: t* h. I i hfrttT *-**"-1 1 ra:r-7F<! n'-ij: . -r-n -h-vttf-rwwfasif mm VAB.0001191467 r IIWW* + npnr-ik "WlW t- n.-i-s-m-ff, 11 fpMWFUtfrfafrT* HI I ||||f BPIjll. Iff.I affirm .......... Ik ^ >|M!l flij , , PROCESS ENGINEERING - V. E. Messick Resin Quality Improvement Project A. Flexible Resin Technology - Three experimental designs were run during normal production this month to determine causes of 5415 particle size variability. In the first experimental design, the volume of recovered VCM, the on-charge temperature, the VCM density, and the time in the cycle that the steam was started to the jacket were varied to determine which were significant. Only the recovered VCM volume was determined to be a significant cause of particle size variability. A second experimental design showed a significant difference in recovered VCM in the new module depending on whether 5305 or 5265 was being produced in 745 reactor. The third experimental design was run to determine the batch-to-batch 5415 particle size variation when 5305 was being produced in 745 reactor. The test was also designed to determine the colloid amount necessary to counteract this particle size shift. B. Rigid Resin Permanent Facilities - A piping review meeting of the D-700 pump system was held at the plant with GED and PED people in attendance. The kick-off meeting between Vista and Litwin for Phases III and IV was held with work starting on the building layout. Review of "For Construction" packages of piping and I&E continues as they are issued. A sample of Methocel was sent to Westphalia for centrifuge testing and evaluation. Operating procedures and training were provided on the use of the Compound P system. Initial testing shows favorable results from injecting the Compound P into the A Compound Lines I and V Magnets The final issue of the class "A" design was issued to install magnets on Compound Lines I and V. Miscellaneous capital was requested to fund this project. Residual VCM Reduction Team Activities The residual VCM reduction methods already in place for 5265 resin implemented on 5305 resin. These include twelve-hour blend tank aeration, twenty-four hour silo aeration and charting residual VCM data on the blend tanks and dryer outlet. Steam injection to the blend tanks was tested to determine the effect on residual VCM removal. On 5265 resin, an additional 30% removal was obtained over normal aeration. On 5305, no additional removal was seen. Interpersonal Skills Management School F. G. Jeanson attended Interpersonal Management Skills on February 19 and 20 in Houston. 5305 Particle Size Variability The plant along with R&D tested separate Compound P makeup to determine the effect on particle size. Separate Compound P makeup gave more consistent particle size control. Compound P is now made up separately from the F-50/GH-20 solution for all 5305 production. T- rrl + .................. t^ii -r >---^+4 - " H*-........................f|--------' >T T'TFIf' I lM*ir flfl P | .1 " ^ RHUMB--1 % VAB.0001191468 -r>, .Mihr-si.i.-wf il^ np-aff-Tw*i"i**trrrTtr-pi 1* PROCESS ENGINEERING - Continued A Influence Management School J. G. Cole attended Influence Management School on February 16, 17, and 18 in Houston. Reactor Data Acquisition System Vendor quotes were received for the hardware, software and configuration for this project. An estimate is now being completed. Additional Pond Aeration Dredging of pond #3 was completed during the month and the aerator was installed and put into operation on 2/11. Subpart V Compliance Project The final issue of the class "A" design was issued after incorporating comments from the review meeting. An AFE request has been written and is being reviewed. RQIP Environmental Team Activity An organic loading estimate was prepared during the month based on projected recipe formulations. The peak loading estimate will be used in a simulation program to determine the capability of the plant's wastewater system under increased organic loading. Southwire Customer Trial Samples of 35852 were produced on Lines I and III for customer trials at the Osceola, Arkansas plant, Results of the trials indicated that the material produced at higher stock temperatures ran better. A possible lead dispersion problem was discovered during analysis of samples by R&D. PVC In-Depth Seminar Brett Bass attended the PVC In-Depth Seminar in Ponca City during the month. Dry Calcium Stearate Addition System Resin static control testing at the plant has been completed. R&D is analyzing samples of different resin types for effects on downstream processing. The review issue of the class ''A" design has been completed and is being reviewed. --> -- r ,1^ -J' VAB.0001191469 r- j I ;i!-**+* i"-1' J' j, ns-vj-A WPfPliniiW WhWCH r 4 PERSONNEL - R. A. Miller EMPLOYMENT None PROMOTIONS/TRANSFERS R. C. Towery from Lead Operator to Vinyl Chief Operator Jeffery C. Shields from "A" Operator to Vinyl Lead Operator RETIREMENTS None TERMINATIONS Sammie L. Stokes, employee resigned TO/FROM LEAVE OF ABSENCE None ii- h i i r+-<,+i r- rtf". `I ` I i.t. IL+- , .Hi.......... H VAB.0001191470 r .1,^. i \ + ihrf 1 Aberdeen, Mississippi n c' h' -n-' i. . FEBRUARY, 1987 MONTHLY PERSONNEL REPORT Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations 72* 169 241_ 0 0 DEPARTMENTS Warehouse PAR mm 14 # EMPLOYEES 16 MIN. ElfP. 7 Minority Employees # Salaried Hour1y 7 65 10% 38% Total 72 30% Hourly Min Hired % Min. Hired Hourly Min Term. % Min. Term. a 0 a a % MIN. NEW HIRES YTD TERM. YTD TURNOVER 44 0 0 0 0 0 YTD 0 Gen. Plant 14 15 6 40 0 7 0 0 0 0 Maintenance 39 38 8 0 Laboratory 22 24 5 21 0 Qn 0 0 __ . * 0 _ 0__ 0 Compound 33 40 m 0 0 0 0 Q ... Vinyl 32 31 9 21 0 0 0 0n Plasticizer 4 5 2 40 0 0 0 0 0 0 Number of Applicants: Month 5 Year to Date APPLICANT BREAKDOWN: # Minority 1 % Minority * Female % Female 5 20 20. Hires (Hourly) : Month 0 Year to Date 7 Terminations (Hourly) : Month 1 Year to Date Overall Turnover .6% 1 Projected Annual Turnover 3.6% * Includes 1 temporary employee and one Co-op Engineer IIHU. rtirii4t,iv 'H l> l,+- |. *pn.|. -.rf*-. ,a...Vhri * -f - -.1 v -J-l-............ *p ! I . . J,.. -.1 VAB.0001191471 - I-'-' t T-n-bJ-w lj m tncr _.-hllr ~J "T * tit-1 * s- - d:.H n-i +-. -! L' H OVERTItC AND ABSENTEEISH 0 > Csl CN Ox co H E--* m CN r-% O *<T 4 0 0 >0 pH co CN co CN * CO 0 <r * 0* as iH SO Csl iH co 0 0 ui 0 0 co ui 0 * Uii 0 CN *O 1--| 04 b * 0 m ao Cs| as 11 XuH 0 co (-H *0 Csl Ch 0O Vu c (ft 01 to tft 0 0 O CN CN cn Xe 0 0 co m sO < u (/> m0 Csl 0 CO ** uo Csl un 0 O 0O * * 0 0 Csl 0 0 CO m CN 00 CN t-H sO CO * CN OS k 3 O 01 m S3 as o m SO on so on H 0 as O sO sO I tn Ck as SO k sO sO 'O r**- 1-4 00 CN 0 CN CN CN CN O as * m 4J <U k CO of>t* 1o*4 CN * M4) S k t) k 9 O X \8 k O tn uo 0 0 CN 0 * * * o r-*> Csl LTV CO CO m tn r*. * CO CO O O * <T m Csl * CO LO 00 iH as uo 1--I CO rH CO CO fH 1--1 tn I H k o O 0 * tn 0 p"- 0 m r*^ * O O oft ,* ^ CN tn r^. as CO as sO CN O in U9 k9 tn CN fH m cn sO CO sO ^ XO un 0 O *r-* 0 O 00 0 sO X sO CN CO sO tn CN CN rH tO CS| X txj lu W CO X W tN Oca a3, 8c kXl u X s X U3 H s 3 o g? >- 2 U *h to 5 H>- 4 H uj z LU o o H 0 -> i- w<v~: HMmqw**rumt.J ikg*tiimuM^ngmiwi w=3*"^^n-ia^iiy- h :-mb*+h* ..................-1'tJ,r-- >?* . A tn c O U 0 k iC>L O e >s 0 3 g w X **4 to JS k c 3 wo 9 9 >* 0 'a S m k '3 3 u 3 X 0 k 00 c k S * 1ft 0 k faolJ c !k 0 X to co w k 3 O 3 00 4) k 00 c k s m >s 0 eo E 3 O 01 k -3 00 X Zc k kO (U >o oco 01 3 -o "O 3 XH U K 0 k X 0>J O k 0>o) 0X 1 o> k01 at o> X 0 V o 0k k o e o k0 kco 1 e o CJ <N \ *W.--!rtf. -4 VAB.0001191472 -.I..-11 .-WF.J -1---f-it|i(i>tMlHfi^tjTirigiii-------tin------rn- i:re-|i. ENERGY CONSERVATION - F. G. Jeanson I. Plant Operations Total energy consumption for February was 112.690 MMM BTUs. Energy consumption decreased to 2444 BTU/lb. from 2495 BTU/lb. in January. An adjusted CMA reduction of 52.3% was obtained for the month. The adjusted CMA reduction for fiscal 1987 is 54.2%. II. Plant Energy Conservation Program A. Maintenance There were twenty-two energy related items completed in February. Twenty of these items were steam leak repairs. The remaining two were steam trap repairs. B. Steam Trap Survey III. The survey for the vinyl and plasticizer areas identified three steam trap items for repair. i Boiler Operation Boilers Combustion Efficiency % February, 1987 February, 1986 No. 1 No. 2 No. 3 84.2 83.5 83.2 (l) 83.7 83.6 Note: (1) Boiler number one was not used during the month. (2) Boiler number one was operated three days during the month. A tup*TM .fq-'Ht;--* -- 1 Ji ,|h:^^<Ka ---^1 r If I .'Ir ii i.". i i i!* 5rt .H! 11 ' :-U-* VAB.0001191473 r J? i Month ENERGY CONSERVATION DATA 1987 February Production, MM Lbs, Resin Dry Blend Compound Plasticizer TOTAL 33.7 3.9 6.8 1.7 46.1 Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, Energy Consumption, MMM BTU BTU/lb. 58137 1020 59.300 1286 Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, Energy Consumption, MMM BTU BTU/lb. 4 5.3390 10000 53.390 1158 Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, Energy Consumption, MMM BTU BTU/lb. 0 92000 0 0 Total Energy Consumption, BTU/lb. 2444 Energy Consumption, MMM BTU Actual Unadjusted Actual Adjusted 1972 Base Period 112.690 93.673 196.290 CMA Reduction (%) Adjusted Unadjusted Fiscal 1987 Year-to-Date Performance 54.2% Adjusted 44.5% Unadjusted 52.3 42.6 1986 February 35.2 4.7 5.5 1.3 46.7 58758 1020 59.933 1283 5.2236 10000 52.236 1119 0 92000 0 0 2402 112.169 85.882 197.026 56.4 43.1 A ||. t i > f J|H :| i-.- Lit i I; Iff*-: I*. "WII+Ht-MB' I -**-*1- ti .. m VAB.0001191474 . n -vi !- IC lp-'f -I . -|-fTt>THK-TifM-lf HM|l '.pJI:1 ENVIRONMENTAL - F. G. Jeanson Water One minor wastewater bypass occurred on February 12 as a result of a process sewer backing up during a deluge test and overflowing to a storm sewer. The State was notified of the bypass. All other wastewater discharge para eters were within NPDES permit limits during February. Waste Management Two truckloads of waste oil were shipped to Stauffer Chemical Company in Baton Rouge, Louisiana. A 1 ,, ...I n Writ 1 r_ l wljTI ..'{il' . |- "t 1c M!- Hr M|| i-tW-rv i? *+* r* nljWi.HW. VAB.0001191475 t !lx* IIJl'l*-'. < t . wntflivjiLp1 h A TABLE I WATER COMPLIANCE WITH NPDES PEFMIT PARAMETERS Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. Jan. - Ave. Max. Feb. - Ave. Max. Mar. - Ave. Max. Apr. - Ave. Max. May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Flow GEM 1010 1207 1031 1075 987 1350 1062 1300 858 900 BOD FFM LB./DY. 6 77 10 120 15 183 17 213 23 268 46 373 15 194 20 310 14 142 26 266 a PEM lb./dy. 26 311 33 404 33 406 42 527 71 846 110 1284 53 662 57 775 42 431 75 766 Sus. Solids PEM LB./DY. 14 165 23 281 23 281 37 464 13 179 24 302 18 231 28 434 10 99 13 140 Diss. oz 7.4 8.0 8.2 9.1 7.6 8.6 9.6 10.3 10.0 10.6 ML LB./DY. 2.7 7.3 0.1 0.1 2.0 4.7 2.1 4.6 4.9 9.3 PH 7.6 8.0 7.6 7.8 7.3 7.8 7.7 7.8 7.7 8.0 NPDES Permit limits - ril 30 Ave. Max. 32 431 43 800 - 1462 - 2713 NTOES Permit Limits - May 1 througjh Novenber 30 Ave. Max. - 26 357 - 40 744 - 1212 - 2523 674 13% ? 6.0 13 6.0 - 9.0 28 674 13% ,> 6.0 13 6.0 - 9.0 28 if'. . 'M * |- -||p: |. . y.. .f. y.}- T !' M-'h'fc l-pvidl-t** :f HHrmiK- * irif-iHI-: Ti: up it --.I'- rts.4' ".-ViIhIJ. -1 . .j . N it . '-s f.- t-f r -rk ||X1rr.^.j ^ - l.r-.- VAB.0001191476 iE'A.IM[ * If : rf-toi pi & 1>^T.-r P|v? *rp-^| bf t ; uiw an T: i' 1 we A LABORATORY - H. G. Coleman/J. R. Williams Safety A. Safety There were no recordable first aid or medical cases for the month. As of February 21, the lab completed two years without any such incidents. B. Customer Relations Customer Contacts Southwire - Samples were exchanged for a correlation study of test methods (contamination and moisture) in an effort to reach an agreement on a 5415 resin specification for this customer. All testing is complete and the results are being analyzed. Southwire representatives visited the plant and received a lab tour on 2/26. Future reporting of SPC charts for compound was discussed. General Cable - In response to several recent complaints, B. J. Harrison visited this customer along with C. E. Hoover and Ken Walker. Brian will give extra plant attention to compound made for General Cable to prevent recurrence of past problems. Requests for Corrective Action Date 2/06 Customer Chicago Magnet Wire Product 35851 NAT Reason i The customer experienced burning during wire extrusion. Adhesion also fluctuated widely. 2/18 General Binding Corp. 5385-3S Customer experienced surging in the extruder and a grainy surface on the final product (notebook binders). Particle size was the suspected cause. Customer Problem Reports Date Customer Product Reason 2/03 General Cable 46001 NAT Spark failures 2/05 Southwire - Osceola, ARK. 35852 NAT Excessive streamers 2/06 Southwire - Osceola, ARK. 35852 NAT Spark failures; "oily appearance" 2/11 Times Fiber 38601 BLK Blistering; rough extrusion 2/13 Southwire - Carrollton, GA. 35852 NAT Spark failures 2/17 Harvey Hubble 38901 GRY Contamination - aluminum chips vl,m>irn;v,,-: t--*- .tiN'. !- `Jars '.if' I a V-lTlf* ! p t-r-.iJ ll*|fcfhn0T`r I l(OTrT-a?T`I't!1' VAB.0001191477 p 1 11' l = t. i^F.yirv ..JU. i-li hy-i -ct.i Wl*a<J i |WiL I II LABORATORY - Continued C. Quality Control Testing Resin Regular Samples Total Batches Bag Blends Bulk Shipments 398 850 17 260 (Railcars - 117; Trucks - 143) Dry Blend Blenders Tested - Blenders Adjusted - Bulk Shipments - 608 0% 26 (Railcars - 17; Trucks - 9) Compound Blenders Produced - 1090 Blenders Adjusted - 3.1% Bulk Shipments 28 (Railcars - 20; Trucks Waivers Issued Customer Product b Reason No. Uniroyal 5305 Static Flow 1 HT Uniroyal 5415 Static Flow 1 HT D. Development Lab Summary RVCM of In-Process Samples The following is a summary of residual VCM results on in-process samples. None of the reactor daily averages exceeded 400 ppm during the month of February, 1987. Reactor Slurries 5265 Drier 5305 Number of Samples 851 34 Average ppm, VCM 190 1.1 52 0.3 RVCM of Shipment Samples The following is a summary of the residual VCM analysis of shipment samples for the month of February, 1987. Product 5265 5305 5385 5415 Debox 5425 5465 Dry Blend No. of Sanples 26 66 50 26 27 RVCM, ppm 1.2 0.2 0.6 0.1 0.6 12 0.3 8 0.1 15 0.9 'i- : vvr-.-j. j-1 I'-Jt 1H M! * H- y I $ 1 -A h : +1^ 4H ^ i' 1 : I * i - !*h <1 -1 - I w-r-j#-.. f .i `.-I 4-q.p-JUJ: M:1 4t*Fr.' '< f sJ t THifc1 .. " It'I" ;h'1 |l -7 1hVI -1 * VAB.0001191478 wtmgHeTffwrn.?;rrntf^;.3 l* .............. ...............................................................................i -- -i--,itrrtnrim i^im lji^li-iin..jj.ii-..' .i, .um.. LABORATORY D. Development Lab Testing - Continued Other The Development Lab ran 138 non-routine COD tests on plant wastewater in February. Resin Process Capabilities (CPK) - Regular (Dryer) Samples Bulk Density 5265 0.91 5305 * 0.03 5385 2.00 5415 1.56 5465 2.48 Inherent Viscosity 1.29 1.19 0.70 0.81 0.67 "L" Color Value 1.43 3.93 4.22 3.08 4.44 "A" Color Value 1.33 8.67 3.00 -- -------- -- "B" Color Value 1.56 0.89 3.89 1.83 4.33 % on Pan (vs. 2% max.) 0.94 2.80 2.31 4.56 6.67 (1.83) (1.67) % thru 140m 0.88 1.02 0.67 2.14 7.19 Dry time -- -- -- 0.67 1.17 Mets IR (vs. 95% of control) -- ------ --- 0.86 1.19 Hard Particles (% > 10) 2.2 9.3 17.9 * 5305 bulk density CPK is unusually low due to elimination of antistat from dryer outlet (to satisfy Hoechst Celanese). F. Compound Quality Summary - M Lbs. Adjustments (%) Rejections (%) Hardness 15.0 (0.22) 1.5 (0.02) Color/Clarity 196.1 (2.86) 39.5 (0.58) Hard Particles Dispersion Dicing Total 0.0 ( - ) 0.0 ( - ) 0.0 ( - ) 211.1 (3.08) 31.4 36.8 11.3 120.5 (0.46) (0.54) (0.16) (1.76) A -Hi i rrt. PP'1' I" VI VAB.0001191479 t j I -rsnrr1'.i:-j.': ?f! r:n"n-.rV"e* a i-ni: P*ll* ?^+fr* !- -n LABORATORY Summary Rejections % Long Heat Stability 27.3 (0.7) Color 23.4 (0.6) Contamination 4.9 (0.1) Total 55.6 (1.4) H. Miscellaneous 1. B. J. Harrison received six days of training in Ponca City on rigid compound testing. 2. H. G. Coleman and B. J. Harrison participated in week-long PVC In-Depth Training program in Ponca City. Precision testing on the RVCM headspace analyzer (HS-100) at sub-ppm levels was completed and a report was issued by D. S. Cox. Summarizing the data: Sample Avg. RVCM (PPB) 3 Sigma Limits Relative Error (%) Resin, 5385 682 70 10.3 Resin, 5425 220 48 21.8 Resin, 5305 85 35 41.2 Resin, 5415 26 6 23.1 Std Gas/lg Water 65 20 30.8 Std Gas/4g Water 16 3 18.8 The old Spectra Physics 4000 integrator used in the development lab for all chromatograph integrations died and could not be resurrected. A new SP4290 was ordered as a replacement. 5. It was decided that some TCLP testing will be done in Aberdeen. An AFE was submitted for the necessary equipment. Even though the Federal Register specifies a "purge and trap" analysis for VCM in the leachate, it was felt that our headspace analysis was sufficient for generating internal data. A L I . -Hr Jk i .!:. > j. -f -`ft -:i: /c m j' `tinirisT'ii ** .iiirii i- bauj.-H-e-' r) 41.| . rr h rill!-..! - JP if- VAB.0001191480 r PAUL RIESENBERG - PLANT ACCOUNTANT SHIPMENTS BY PRODUCT - M LBS. Resin Plasticizer Dryb1end Compound TOTAL NUMBER OF SHIPMENTS BY MODE: OT R/C BULK OT VAN FEB. 1987 26,922 803 3,780 7,363 TOFC CC A FISCAL YEAR-TO DATE 135,167 3,419 22,435 35,045 195,066# CPU AIR TOTAL NUMBER OF SHIPMENTS BY MONTH-YEAR-TO R/C Bulk Van October November December January February March April May June July August September 116 146 133 193 154 41 51 64 39 46 29 68 44 50 45 TOFC 2 2 1 3 3 CC CPU AIR 52 160 64 135 48 133 89 147 55 143 1 TOTAL 422 450 390 544 451 il I--!:---f--*4K-fl,||!-i.- i Jtxj- < Ir1 ri-UP.?. !: ; j >jjr2i->`-> ii '! JJ ,=" M ..... .................................................................................................................................... . VAB.0001191481 lL1|;.., ....^ ABERDEEN CHEMCAL PLANT INJURY PERFORMANCE A INJURY FREQUENCY X 100 Frequency Jir fn* i , h'*-* i- uB> fiUh.. fr+fj.u +f gnw iUftniw irrixi m+ . .f im-.- ... P-1 - -i.tarti in -li. k.". I * + Mfchh UH- VAB.OOOl 191482 F ,J m ,i liJf^jw 'TfHrlii ^ h i--i-`fJr 'Ll TJ!rtl'i|l>.iTF~^^1^>1 iu^.n-1- ,. + > ENERGY USAGE A 001 C\J CO <<o BTU/LB in oZ -- > Q (/> o o X in X H oZ ou X Linii >n UJ 4CD a:cn -J Ui < Ll. >Lii u. D *Ui CO 2000 / t 4- r-- ftir \ i \ ji i 1500 ZQ1> . -- -- ^ ^ Th. ^ ^ ^ -^5 ^ X3 i * -V - f` \ > U ~ d - ^ -Ml >3 "y -4 _ ^ W C -S' -- 3- -- ^ r T ,-* -* -i < -n 3 Z H " U 33 ^ -C: ,,86 i ,, 8/ : 11 Monthly 12-Month Moving Avg. VAB.0001191483 = -Tl^r rt L-. - :| HJI, ||--,L fi .. qx >: *> i4ti i;i.w-i;->?tvtnffiui pnu^-n^-i,; -"Kr>. I-H-I'-ir- * ' r- -p ^ ^jTTinhtTU- .it ~ =.: j lh P L'i-r 'JIjT ': .................:r* MONTHLY HOURLY TURNOVER A o<j* CM CO VO <n oZ 35 QJ 3l "TM" UJ x8 u> * jEo OzSB" > ill cc<nr ^uj, UJ Up ^ U1 ro SAJ + : L .1 r ' ! : I. t: In- HI........... Lrm^i. i T -i- ! I ` p; Jh; ec H 4-fi- -ht nprj^Pf | iirR? 4fjLr!i ><W. i Wi-r- ..Lu-r|-|.r||.' e > i .-Iplu.1 :: |P h-u .ii<uj ]:.- lit! . -I 1ii r r t--.* -*> - -it.:../.i-i,i.. VAB.0001191484 S*m ***-** ^ iv- ">Firj j|n-i-Mk -. hi-Mrs i^riPVihsutfMn -i it ABERDEEN PLANT QUALITY PERFORMANCE 10/01/86 - 09/30/87 OFF-GRADE , - .-IE- -I :1 i . !-W I1' ITt f.'Hi:' '( ' ri: " --S- :h J. -* -|Imvv -.iqi.-?- Tr|f:i i ikfk-..!-'.. -- *- r-1 -Z` r s I is _-v.:! !i |rJ>|irtl^M.lN> I- .lull. 1I -J JT - --II y ||j mipii |^| mi^ii 111 I I II III ^ II I I -4 4aL VAB.0001191485 \ t 1.020 1.015 1.010 1.005 1.000 0.995 ABERDEEN PLANT EFFICIENCY 10/07/86 - Q9/30/87 POUNDS OF RAW MATERIAL/POUND OF PRODUCT * " 1.200 1.150 1.100 1.050 r= i Mar. Apr. May 19 86/87 i* 1 1 iJune 1 1 :July 1- ' -- i Aug. Septi Oct. 1 '"* '-1*1 - -'1 I' ' -* - J. "Iflfr't- : t i^!.:-:H?HJ >ttr,,. .. I t h,., h : :|'fc|ri-11 i^tt+P-HHM^r-H-G I- Mfj - 1 T 1 'r' '-fK ''r-.'-r ' rr:... , -, r-w* m !--^ j! ip -.M li iT*n--*n r r VAB.0001191486 A1. ABERDEEN PLANT INVENTORIES 10/01/86 - 09/30/87 * r L ............ r - - . ^ i- I'-k-r-iK-e-*- |-T+ -r .f, ^Vi ^ _ _ . .. ,T: .......... -u^f fcrtr: !?<! v'.r-.jUrTi 1W i-**:: f -ff -mit. * :h't i p--iu^ nr ^ ....................1--'i --4s . in - - r r VAB.0001191487 MM POUNDS ABERDEEN PLANT PRODUCTION 10/01/86 - 09/30/87 0 A MM PO 2 1 0 Oct, Nov. | Dec. iJan. ! Feb. Mar. April June Sept.iOct. ---------------- Budget - - - - Actual Cumulative i .. +' mi "T *- !" *f3S-. in"i * i . . .'*p J ir , T n- VAB.OOOl 191488