Document 6556Op0egegMap4KjE70X5k5m

\> To: R. Do Gamblin A Interoffice Communication From: Dote: Subject: J. W. Ware April 18, 1985 ABERDEEN MONTHLY PROGRESS REPORT MARCH, 1985 Three first aid cases were reported in March. As of March 31, 1985, the plant had operated 2095 days without a lost time injury. PVC resin production for March was 36.1MM pounds. Major downtime in the reactor area involved four agitator seal replacements, replacement of 745 condenser lid gasket, rewiring of 700 agitator motor, and drilling of 743 condenser tubes. Resin production year-to-date totaled 208.8MM pounds. The VCM efficiency for the month was 0.98268 pounds of VCM per pound of PVC versus the 1.00500 standard. Year-to-date VCM efficiency is 0.99985. Compound production was 5.9MM pounds for March. This represents a new monthly production record for two-line operation. Year-to-date compound production totaled 23.8MM pounds. Major maintenance work accomplished during the month included repairs to the Banbury seals and FCM conveyor. Quality performance for flexible compounds was 1.4% off-grade of which 100% was due to mill scrap. "BC" production was 0.5%. Dry blend production for March was 5.1MM pounds and 25.4MM pounds year-to-date. Dry blend production was limited by a shutdown to complete the Dry Blend Improvement Project and replacement of the #2 Welex bowl. Quality performance for the month was 99.89% customer grade. The plasticizer unit operated 21 days during March to produce 1.3MM pounds. Year-to-date plasticizer production was 7.4MM pounds. Total energy consumption for March was 121.822MMM BTUs. The energy consumption per pound of product was 2517 BTUs resulting in an adjusted CMA reduction of 53.8%. The total plant variable cost variance for March was $411.0M favorable, resulting from an overall favorable price variance of $231.2M and a net favorable efficiency variance of $179.8M. VCM pricing contributed $80.1M to the favorable price variance. The total fixed cost variance for the month was $145.0M favorable. J. W. Ware VAB.0001184118 DISTRIBUTION HOUSTON PONCA CITY OKLAHOMA CITY LAKE CHARLES VCH PLANT LAKE CHARLES CHEMICAL PLANT BALTIMORE HAMMOND ABERDEEN - J. D. BURNS - R. E. LEHMKUHL - R. D. GAMBLIN - J. J. LANGFORD - R. E. SWANTKOWSKI - G. G. DRAPER - 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 4 - DICK CONRAD - R. T. FERRELL (COVER LETTER ONLY) - J. A. DEBERNARDI (COVER LETTER AND SAFETY PORTION) - T. H. HUFFMAN - J. B. MAHER (SAFETY PORTION ONLY) - JF, JWW, DWH, PJK, CRS, RAF, AHS, JRW, WFH, RAM, REP, VEM, VLT, CWT h VAB.0001184119 SAFETY - A. H. Sather Occupational Injuries Month First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases (RWC Rate) Number of Lost Workday Cases (LWC Rate) 3 0 3 0 (0) 0 (0) Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receivlng/Warehouse Office 1 1 0 0 0 1 Fiscal Y.T.D. 1985 14 3 17 1 (0.83) 0 (0) 4 2 8 1 0 2 Calendar Y.T.D 1984 7 0 7 0 (0) 0 (0) \ 1 1 5 1 0 0 Cuts and Abrasions Eye Burns Bruises Strains/Sprains Stings Other 16 12 03 02 04 11 01 Non-Occupational Injuries Lost Workday Cases Days Lost 08 7 251 Safety Record Last lost time injury 7/5/79 Days since - 2095 Manhours since - 2,661,272 4 0 1 0 1 1 0 0 0 Safety meetings for the reporting period were conducted on the following topics: 1985 Safety Program Planning, film "Gas Under Pressure"; Pro cedures for Working on Reactor Condenser; Chemical Handling-Material Safety Data Sheet video tape. Vinyl Job Safety Reviews; and Trackmobile Operations. 'y * A VAB.0001184120 SAFETY - Continued Fire Protection Number four fire pump engine was taken off line for overhaul Safety Action Requests (ESARS) Y.T.D. Total Submitted Current Year ESARs Completed Total Previous Year's ESARs C leted 1984 1985 55 3 46 1 20 3 Health Chemical VCM Lead Total Particulates 4 Number 87 6 5 PEL Percent 100.0 85.7 100.0 dosimetry as noted below > PEL Numb er Percent 0 0.0 1 14.3 0 0.0 No VCM overexposures occurred during the reporting period, One lead overexposure occurred to a Line I Compound (Mill) Operator, This Job normally requires no respiratory protection. The operator wore a 3M dust mask during the sampling period. VAB.0001184121 VINYL - D. W. Hollis/M. L. Nathan Safety The Vinyl and Yard Departments operated with one first aid type injury in March. The injury Involved a puncture wound from a frayed wire on a section of flexible conduit. Shift safety meeting topic for the month was "Job Safety Analysis". Operators on each shift presented a step-by-step description of one part of their job including safety aspects. Production March Y.T.D. (Fiscal 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 36.1 1163.3 907.0 29.3 93.1 8906.5 68.0 31.0 208.8 1147.5 5077.0 27.9 90.8 10315.1 59.1 182.0 Vinyl Department production for March was 36.0MM pounds which was 101% of the Business Area's targeted production level of 35.8MM pounds. Reactors The reactor stream factor was 93.1%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 54.4% of the total downtime and was due to reactor scheduling conflicts and processing caustic con taminated VCM. 2) Maintenance Service Downtime: Accounted for 1.9% of the total down time and was due to cleaning reactor AMS injection ports. 3) Maintenance Repair/Revision Downtime: Accounted for 43.7% of the total downtime and was due to two reactor valve changeouts, agitator seal replacements on 500, 700, 741, and 743 reactors, 745 condenser lid gasket replacement, 700 agitator motor rewiring and drilling/ brushing of 743 condenser. The dryer strea ) i factor was 68.0%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 84% of the total down time. Dryers were shut down when possible for energy conservation purposes. 2) Operational Downtime: Accounted for 11.8% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer clean ing, and transfer activator problems. VINYL - Continued Dryers - continued 3) Maintenance Repair/Revision Downtime: Accounted for 4.2% of the total downtime and was due to activator, centrifuge and screener repairs. Product Quality Summa Resin Type Prime mBC" % of Total *H Production 5265 5305 5385 5425 5465 Sifter Overflow Pond Resin 2,519,128 5,314,227 18,225,940 7,859,819 1,867,310 - 84,350 6,750 _________ 28,284 428,460 6.9 14.9 50.2 21.6 5.1 0.1 1.2 Total 35,786,424 91,100 456,744 100.0 Quality performance for March was 98.5% customer grade with 0.2% "BC" production and 1.3% "H" grade. A total of five railcars were shipped as "BM grade during the month which represented 3.5% of the 144 total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 1/28/85 3/18/85 PTLX 41606 Vulcan Resifted Sifter Overflow Quality 2/8/85 2/13/85 3/18/85 PLCX 42374 3/28/85 PLCX 43706 Vulcan Extrusion Techn. Resifted Sifter Overflow A Resifted Sifter Overflow Quality Quality 2/12/85 3/29/85 PLCX 42666 Vulcan Resifted Sifter Overflow Quality 3/01/85 3/31/85 PTLX 41646 Silverline 5385 Particle Size The Vinyl area received eight short lead time emergency type orders comprising 3.4% of the 237 Aberdeen resin shipments in March. Monthly Variable Cost Performance Variable costs for the month were favorable $266.3M with $154.4M due to price and $111.9M due to efficiency. Resin variable cost for the month was 20.139 <?/lb. versus the budgeted 20.887 $/lb. The $154.4M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $80.1M; VCM freight, $29.4M; Lupersol 223 initiator, $19.2M; and utilities, $19.9M. VINYL - Continued Monthly Variable Cost Performance - continued The $111.9M favorable efficiency variance can be attributed to lower than budgeted VCM efficiency, $141.2M and lower than budgeted usage in the utilities area, $29.9M. VCM efficiency for the month was 0.98268 lbs. VCM/lb. PVC versus the budgeted 1.00500 lbs. VCM/lb. PVC. Year-to-date VCM efficiency is 0.99985. Year-to-date variable cost efficiency variances in the Vinyl Department totaled $417.3M favorable. Ener Performance/Progress consumption for the month totaled 2517 BTU/lb .2 A total of thirty-nine steam leaks and twenty-two steam repaired during the month. General 1. Packaging for the month totaled 336,024 pounds. 2. Resin raw material in the 0744 account totaled $163.4M at month end. VAB.0001184124 COMPOUND - P. J. Kober Compound Production Month #'s/Day i Y.T.D. (fiscal 1985) Line I, M Pounds Line III, M Pounds Total, M Pounds Accounting Days 1908 3998 5906 31 64 129 8470 15290 23760 182 Line I operated 30 days during March at an average rate of 64M pounds per day. Major items affecting production efficiency were product changes 41.5 hours, Banbury housekeeping 32.5 hours, Banbury seal maintenance 31.5 hours, chiller repairs and delays 10.75 hours and lube oil system problems 6 hours. Three experimental products were produced in March, 1985; 0113-60 a reformulated version of 48562, 3934-130B a reformulation of 17461, and 0113-55 a formula designed for Precision Trim. Line III operated 31 days during March at an average rate of 129M pounds per day. Line III production was hindered by product changes 53 hours, FCM conveyor problems 16 hours, orifice gate/hot oil system repairs 6 hours and mill oil pump maintenance 5 hours. One experimental product was produced for General Cable, V6003. The line ran well during the month. Quality performance for flexible compounds was 1.403% off-grade of which 100% was due to mill scrap. "BC" production was 0.5%. The raw material requirement for flexible compounds was 1.00334 pounds of raw material per pound of compound versus a 1.01203 standard. (Y.T.D. is 1.01036). The variable cost variance for compound was $6.8M unfavorable. The variance due to product mix was $11.0M unfavorable. The only significant raw material efficiency variance was 610F at $13.9M favorable. Total compound inventory decreased 0.3MM pounds to 6.9MM pounds. The 5.9MM pounds produced in March was a two-line total production record. Dry Blend Production, M Pounds Accounting Days Month 5078 31 s/Day 195 - Y.T.D. (fiscal 1985) 25429 182 Dry blend operated 26 days during March at an average rate of 195M pounds per day. Production included 80273G, 80174, 90171, 90172B, 90172C, RP-200T, XTRALIFE, RP-200 and 5426-129B. Dry blend production was hindered by shutdown for installation of Dry Blend Improvement Project 123 hours, replacement of #2 Welex bowl 75 hours, product changes 40 hours and Q.C. delays 21 hours. Quality performance for the month was 99.89% customer grade. The raw material requirement for dry blend was 1.00374 pounds of raw material per pound of dry blend versus a standard 1.00492. (Y.T.D. is 1.00372.) COMPOUND - Continued Dry Blend - continued The variable cost variance for dry blend was $72.1M favorable with $4.2M due to price and $67.9M due to efficiency. The efficiency variance due to product mix was $65.5M favorable. There were no major raw material efficiency variances. The Dry Blend Improvement Project was completed on schedule and the unit was started up with minimal problems and Impact on customers. Plasticizer Month s/Day Y.T.D. (Fiscal 1985) Production, M Pounds Accounting Days 1312 31 62 - 7,442 182 Plasticizer operated 21 days during March at an average rate of 62M pounds per day. Production included 610P, 810P and 108P. The raw material requirement for plasticizer was 1.14948 pounds of raw materials per pound of plasticizer versus a 1.10313 standard. (Y.T.D. is 1.09051). The variable cost variance for plasticizer was $79.3M favorable resulting from a favorable price variance of $83.7M and an unfavorable efficiency variance of $4.4M. Major price variances were Phthalic Anhydride at $51.1M favorable and Alfol 610 Alcohol at $23.7M favorable. There were no major efficiency variances. The variance due to product mix was $8.1M favorable. Compound Dry Blend Plasticizer Actual 1778.6 715.9 1541.1 Standard 1927.3 760.0 1642.1 A VAB.0001184126 ft MAINTENANCE - C. R. Snowden Vinyl Reactors There were four reactor seal failures in this period. Two were in the new module (741 and 743 reactors) and two were in the old module (D-500 and D-700 reactors) The 743 reactor condenser was drilled and brushed and the jackets welded on 741 and 743 reactors. The condenser lid gasket was changed twice on the 745 reactor to eliminate leaks. The seal oil pumps were also replaced in the 600 and 700 dura-seal units. Pump8 and Compressors There were three seal failures to pumps In the vinyl areas in this period. In the new module, both slurry dump tank pump seals were replaced and in the old module the seal was replaced in the south seal water pump. Two 407 blend tank pumps were repacked. One Corken compressor was changed out and rebuilt to control packing leaks. Major Valves Two major valves were replaced - a four-inch rinse and a six-inch slurry valve. Projects In the new module, the bases were rebuilt and the tank level alarms relocated on both dura-seal units. Piping revisions were made to improve safety when recovering and steaming fresh VCM filters. A new sample platform was Installed to collect resin samples from the reactor dump line. Other vinyl projects were to install 27 orifice plates in the blend tank aeration lines, install bleeder valves on resin transfer lines, strip down and clean the centrate heat exchanger and Install crank case vents on the Corken compressors. Instrument and Electrical Major work performed during this period was the repair or replacement of motors on the following equipment: - Old unit south seal water pump - South Kason motor (fluid bed) - Hydroquinone pump - NaOH addition pump - D500/600 cooling tower fan The 5KV wiring to the D-700 agitator motor was replaced. Is. VAB.0001184127 n MAINTENANCE - Continued Compound. Pry Blend, Plasticizer. Silo Storage Compound Units I and III - Major repairs completed on compound Line I were to install built-up seals in the Banbury unit and replace sheaves on the skip hoist. Repairs on Line III were to change the FCM conveyor belt twice and to make repairs for process leaks. The compound cooling tower fan gearbox was overhauled. In the dry blend unit, seals were replaced in the #2 Welex unit and the outlet section of the intensive cooler was covered with stainless steel cladding due to mechanical wear. Modifications were completed on the Gump screeners for improved mechanical integrity. Repairs in the plasticizer unit were to change the R-2 reactor seals and to change safety discs on R-3. A new pump, motor and base were installed on the south catch tank. Repairs in the silo and storage area were to rebuild the feeder valve on the 282 silo and to install a new pump, motor and base at the 108F tank. Instrument and Electrical Construction and startup assistance were provided to support the Dry Blend Improvement Project. A remote alarm for Deltech air dryer failure was installed in the boiler house and the east Joy air compressor controller was repaired. Utilities and Services The #3 B.F.W. pump was pulled for overhaul and a new mechanical seal Installed. A VAB.0001184128 MECHANICAL ENGINEERING - R. E. Polk Design Design is in progress on the following projects: - Old Module Rinse Meter - Line I Modernization - Rotary Dryer Optimization - Deluge System Revisions - Warehouse Lighting Revisions - Centrate Tank Exhauster - Vessel Entry Documentation AFE Activity a Normal Kill Solution Addition System - K. S. Allen Initial project checkout was made for the old reactor module. A modified "liquid-full" method of charging the kill solution was developed and approved. Checkout for the new reactor module will be complete by the end of May. Commission of the system will follow the checkout. Line I Modernization - K. S. Allen/S. K. Glanchandanl The Banbury rebuild estimate has been completed and issued to GED. The pre-shutdown tle-ln list has been reviewed and a preliminary outage plan approved. The plant will be responsible for all pre shutdown tie-ins except the plasticizer lines. These will be made by the piping contractor once he has moved on site. A project status meeting was held with GED and plant personnel. The proposed shutdown schedule, revised estimate, equipment storage and plasticizer charging system were reviewed. Centrate Heat Tank Exhaust Fan - K. S. Allen Bids have been received and contracts awarded. Construction is scheduled for completion in April. Dry Blend Improvements Phase II - J. L. White/S. K. Gianchandani Construction is complete and the system is operational. Agreements with Conoco to modify Orbitran software for the TiO addition system proved to be unacceptable. MIT Services of San Diego has been con tacted to determine if they can modify the Orbitran program. A quo tation is expected by the end of April. Automatic Bagger Air Compressor - K. S. Allen Construction is complete except for punchlist items. The system will be operational by the end of April. MECHANICAL ENGINEERING - Continued AFE Activity - continued Ring Seal Water Filter Replacement - J. L. White A contract for installation of the new filters has been awarded. Completion of the system is scheduled for mid-May. - J. L. White Insulation work on dryers 4, 5# and 6 is complete. Fabrication of the hopper for dryer #4 is complete and is being Teflon coated at Pfaudler/Eldon. Hoppers and the screw conveyor for #6 dryer have been placed on order with delivery expected within ten weeks. A shutdown for #4 dryer is planned for mid-April. Plasticizer Catch Tank Pump - K. S. Allen Funds were approved to replace the canned pump for the north catch tank. A centrifugal replacement was placed on order and expected to be delivered in April. ~ "^visions - K. S. Allen Materials have been ordered to revise the conveying system on Line III in order to provide improved performance for low fusion delay material. Completion is planned for the end of April. Catalyst Freezer Alarms - S. K. Gianchandani Construction is complete and the system operational. * Air Dryer Power Failure Alarm - S. K. Gianchandani Construction is complete and the system operational. Heat Tracing Revisions - J. L. White Installation of remaining pilot lights is complete. The original scope of work is complete and operational. February, 1965 Actual Accounting . + r. ABERDEEN AIHH0RIZATICN5 REPORT ALTTH. NO. CAPITAL DESCRIPTION DATE APPROVED AUIH. AFE AMT. 9630 9730 9740 9760 9770 9591 9651 9661 9731 9751 9771 9791 9851 R5E2 D5H2 B5K2 A5L2 A5M2 A5N2 D5B3 B5D3 D5E3 D5H3 H5K3 C5G3 A5L3 D5M3 D5P3 G5N3 A5Q3 C5R3 H5A4 G5B4 H5G4 H5F4 H5E4 Water Stripping 04/03/80 Qqp. line 111 Debottlenecking 10/16/80 Mod. To Hake Profile D.B. 10/27/80 Bnergency AMS Kill System 11/15/80 Reactor Pressure Relief Mod. 11/25/80 Sifter Overflow Reclaim Sys. 03/20/81 Safety Equipment 06/06/81 Waste Water Treatment Rev. 06/19/81 Normal Kill Solution Addn. Sys. 09/01/81 Fire Protection Phase IV 10/07/81 Recovery System Revisions 10/21/BI Compound line 1 Modernization 11/24/81 VCM Pump Pressure Relief 12/09/81 Plast. Area Cand. Col lection 05/Q5/B2 Bulk Storage & Handling of CIA 09/29/82 Energy Mon. Instrumentation 11/22/82 Plast. ModernizatlonrPhase 1 12/14/82 Dry Blend Improvements 12/16/82 Improved Dry Blend Screening 12/16/82 Safety Shower Revisions 03/08/83 Recovery System Revisions 06/06/83 Vinyl Reactor Interlock Rev. 04/22/83 V-ll Roof Replacement 05/18/83 Dryer Centrifuge Conveyor Assy. 06/16/83 Instilment Air Dryer 06/02/83 Plasticizer Modenxizatlon-Ph II 09/28/83 Remote Operating Valves & Inst. 10/07/83 1AM Exposure Reduction 12/02/83 Imp. Ccnpliance With EPA VCM Std 11/30/83 Dry Blend IoprOTements--Phase II 12/08/83 Bulk Storage & Handling of AMS 12/08/83 Miscellaneous AFE 01/26/84 Plant Seuer Revisions 01/26/84 Miscellaneous AFE Fluid Bed Dryer Heating 06/06/84 Panle Bundles 05/18/84 Dryer Centr ^e Conveyor Assenblik^ 03/20/84 810,000 1,350,000 200,000 335,000 560,000 200,000 106,000 560,000 93,000 160,000 402,000 1,800,000 58,000 55,000 160,000 80,000 240,000 41,000 74,000 50,000 147,000 44,000 221,000 47,000 90,000 20,000 130,000 100,000 103,000 200,000 75,000 . 200,000 180,000 195,000 210,000 150,000 oowrrrED TO DATE TO DATE 813,977 588,310 202,313 282,229 462,639 131,484 106,880 561,116 97,312 144,327 404,245 406,996 11,846 28,656 31,509 86,855 201,039 39,877 76,003 58,006 145,334 39,990 230,890 49,150 92,080 20,577 57,944 ' 13,096 0 118,559 0 175,075 186,509 125,172 814,065 589,484 201,768 282,136 465,436 133,095 109,545 573,097 97,983 148,881 403,783 491,688 11,846 32,805 31,509 89,441 216,584 41,310 77,003 60,086 146,242 40,025 230,890 49,150 92,022 20,577 64,163 13,096 0 133,735 0 175,164 187,373 137,634 198,374 0 198,656 FINAL TOTAL ESI. COST COMP. UOER EST. (OVER) OCMP. AUIH. AMT. DATE EST. CL0S. DATE REMARKS 815,000 705,000 203,000 285,000 560,000 131,000 109,500 573,000 98,000 149,000 404,000 1,800,000 58,000 32,000 32,000 89,000 240,000 44,000 77,000 58,000 147,000 44,000 230,000 49,000 91,000 21,000 130,000 32,000 103,000 200,000 0 176,436 187,000 110,000 ( 5,000) 645,000 ( 3,000) 50,000 0 69,000 < 3,500) (13,000) ( 5,000) 11,000 ( 2,000) 0 0 23,000 128,000 ( 9,000) 0 ( 3,000) ( 3,000) ( 8,000) 0 0 (9,000) (2,000) (1,000) ( 577) 0 87,000 0 0 0 25,000 (7,000) 95,000 06/84 12/85 08/84 09/84 09/84 09/84 02/84 04/84 04/85 07/84 10/84 09/86 09/85 06/84 10/84 07/84 09/85 09/84 09/84 04/84 12/84 09/85 03/84 04/84 02/84 03/84 09/85 12/85 09/85 06/85 05/85 12/84 12/84 12/84 04/85 dosed to field charges. 02/85 Construction on hold. 04/85 Closed to field charges. 05/85 Closed to field charges. 04/85 Closed to field charges. 04/85 Closed to field charges. 04/85 Closed to field charges. 04/85 Closed to field charges. 07/85 Closed to field charges. 05/85 Closed to field charges. 05/85 Closed to field charges. 12/86 Engineering in progress. 12/85 Engineering in progress. 04/85 Closed to field charges 04/85 Closed to field charges. 04/85 Closed to field charges. 04/85 Revisions in progress. 04/85 Cloaed to field charges. 04/85 Closed to field charges. 05/85 Closed to field charges. 05/85 Closed to field charges. 12/85 Revisions in progress. 05/85 Cloaed to field charges. 05/85 Closed to field charges. 05/85 Cloaed to field charges. 05/85 Clbaed to field charges. 12/85 03/85 Closed to field charges. 12/85 Engineering scheduled. 08/85 Construction in progress 08/85 Closed to field charges. 03/85 Closed to field charges. 03/85 Closed to field charges. 05/85 Closed to field charges. 210,000 150,000 0 12/84 05/85 Construction in ness. VAB.0001184131 0 12/86 03/87 Engineering sch e* * H5A5 F5C5 B5D5 H5B5 H5G5 Miscellaneous AEE Low Rislon Delay Manufacture - Phase I Rotary Dryer Optimization Lab Equipment Miscellaneous AEE 10/25/84 12/07/84 12/11/84 11/24/84 02/27/85 75,000 45,000 65,000 36,000 75,000 9,297 42,933 54 0 0 10,265 42,500 4,265 33,060 0 0 0 10/85 12/85 22 Projects approved. 0 0 04/85 07/85 Construction in progress. 0 0 12/85 03/86 Engineering in progress. 0 0 04/85 07/85 Engineering in progress. 0 0 10/85 12/85 Projects under review. VAB.0001184132 mum mm PROCESS ENGINEERING - R. A. Frohreich Reactor With the assistance of PED and R&D personnel, samples of the reactor head space were taken. Additional sampling will be conducted In April. Line I Modernization Engineering is continuing to provide assistance to the Mechanical Engineering group on this project. Compound Rate Improvements Work is continuing on the compound improvement project blender charge sizes for several products were calculated and instituted. Changes to the Line III FCM conveyor were made. Line I cycle time was investigated and work is ongoing with the Mechanical Group about cycle time revisions. Plant Stormwater Revisions The AFE for this project was submitted for approval. PA Fluff Containment Operating Procedures The operating procedures for this project are being prepared. I Reactor Rinse Optimization All reactors were checked for cleanliness and summaries of findings were issued. Line III Pellet Coating System The design to provide a permanent pellet coating system for Line III is being prepared. % VAB.0001184133 PERSONNEL - R. A. MILLER EMPLOYMENT None TRANSFER/PROMOTION Vemeta Blanchard, from General Helper to Compound Utility A.C. Pettus, from Lead Operator to "A" Operator William J. Davis, from General Helper to Compound Utility Norman Clay, from Compound Utility to General Helper Dave Gathings, from General Helper to Compound Utility Ralph D. Flippo, from General Helper to "A" Operator RETIREMENT Aubrey Sanders TERMINATIONS None TO/FROM LEAVE OF ABSENCE None CONOCO CHEMICALS Aberdeen, Mississippi March 1985 MONTHLY PE EL REPORT Salaried Employees Hourly Employees Total Employees 67 154 ** 221 Minority Employees # % Salaried 8 12 J Hourly 64 42 Total 72 33 New Employees Terminations 0 0 Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 b u 0 DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound Vinyl 1 * ' J, - * * Plasticizer PAR * EMPLOYEES MIN. BMP. . % MIN. 16 14 7 50 11 11 6 55 53 39 22 21 7 18 + 5 24 41 33 26 79 36 32 12 38 44 1 25 NEW HIRES YTD 00 TERM. YTD TURNOVER 00 0 0 0 00 0 0 0 00 0 0 0 00 0 0 0 00 0 0 0 0 1 3% 0 0 0 JO 0 YTD 0 0 0 0'-- 0 3% 0 Number of Applicants: Month 0 Year to Date APPLICANT BREAKDOWN: # Minority 0 % Minority * Female 0 % Female 0 0 0 > Hires (Hourly) Month 0 Year to Date Terminations (Hourly) : Month 0 Year to Date Overall Turnover 0 Projected Annual Turnover 0 2 5.2 & * Includes one temporary part-time employee dr * One employee retired VAB.0001184135 OVERTIME AND ABSENTEEISM rtaient WAREHOUSE maintenance LAB COMPOUND VINYL PLASTICIZER UTILITY BOILER GENERAL PLANT TOTAL Stra.ght Time Hour) Worked 2256.00 4966.75 3227.50 5707.25 5618.00 564.50 659.00 592.00 23591.00 Overtliee Hours Worked Controllable(1) Non-Controllable(2) 327.75 0 609.25 0 326.75 0 229.00 0 619.50 31.25 48 0 13.25 0 1.00 0 2157.75 48 Overtime as a Z Of Straight Time 14.53 12.27 10.12 4.01 11.88 5.54 2.01 .20 9.35 Absence Hours' Lost 0 165 159 130 38 4 13 0 509 Absence as a X of Straieht Time Sickness Other Total Fiscal Y T*D 0 00 4.88 2.90 .42 3.32 3.13 4.83 .09 4.93 6.41 1.47 .81 2.28 3.60 .21 .46 .68 6.54 0 .71 .71 .86 0 1.97 1.97 1.92 0 0 0 .60 1.68 .48 2.16 4.47 (1) Controllable Overtime - all overtime excluding overtime due to working regular hours on a holiday and working the sixth day in operations. (2) Non-Controllable Overtime - that overtime due to working regular hours on a holiday and working regular hours on the sixth day in operations * 4MI l * VAB.0001184136 ENERGY CONSERVATION - S. C. Hillman I. Plant Operations Total energy consumption for March was 121.822 MMM BTUs. Energy consumption decreased to 2517 BTU/lb. from 2603 BTU/lb. in February. An adjusted CMA reduction of 53.8% was obtained for the month. The CMA values for fiscal 1985 are 53.8% adjusted and 39.5% unadjusted. II. Plant Energy Conservation Program A. Maintenance There were sixty-one energy related items completed in March. Thirty-nine steam leaks were repaired and twenty-two stea trap repairs were made. B. Steam Trap Survey \ The survey for the vinyl area identified one steam trap item for repair. The majority of the traps were not in service. VAB.0001184137 ENERGY CONSERVATION DATA Month Production, MM Lbs. 1985 March 1984 March Resin Dry Blend Compound Plasticizer Natural Gas TOTAL 36.1 5.1 5.9 1.3 48.4 36.5 4.5 5.1 1.2 47.3 Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Energy Consumption, BTU/lb. Electricity 63993 1020 65.273 1349 69152 1020 70.536 1490 Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Energy Consumption, BTU/lb. Propane 5.6549 1000 56.549 1168 5.4699 1000 54.699 1155 Consumption, M Gal. Conversion, BTU/Gal.ft Energy Consumption, MMM BTU Energy Consumption, BTU/lb. Total 0 92000 0 0 0 92000 0 0 Energy Consumption, MMM BTU Energy Consumption, BTU/lb. CMA Reduction (%) 121.822 2517 125.234 2645 Adjusted Unadjusted Fiscal 1985 Year-to-Date Performance 53.8% Adjusted 39.5% Unadjusted 53.8 40.2 50.8 37,7 Boilers Combustion Efficiency % Mar .> 1985 Mar., 1984 No. 1 No. 2 No. 3 -- (1) 83.5 83.5 83.9 83.8 83.6 Note (1): Boiler no. 1 was not used during the month. VAB.0001184138 ENVIRONMENTAL - V. E. Messick Water All wastewater parameters were within NPDES permit limitations during March A State performance audit Inspection of permit sampling and analytical procedures was performed at our request as a check of our outside wastewater laboratory. No plant problems were noted. The State will Issue a report Including recommendations for improvement at the wastewater laboratory. Consent Decree Several draft responses to section 114 questions were Issued and reviewed Hazardous Waste Management The impact of the recent RCRA amendments on the plant was evaluated and documented. City Water Backflow Prevention The Mississippi State Board of Health reviewed the proposed design to Improve backflow prevention between the city water supply and the plant process water supply. They have requested that we supply them additional information. * ii& fr~* lir-i. . . 'j .... VAB.0001184139 TABLE I -HATER COMPLIANCE WITH * A Flow GPM Jan. - Ave. 941 Max. 1189 Feb. - Ave. 878 Max. 1327 Mar. - Ave. 903 Max. 1016 NPDES PERMIT PARAMETERS BOD PPM LB./DY. 13 158 22 298 14 157 20 228 COD PPM LB./DY. 30 352 36 474 29 328 39 444 Sus. Solids PPM LB./DY. 13 156 16 190 12 133 18 195 9 93 10 122 30 330 38 464 13 144 19 204 Diss. NH3 o2 LB./DY Ph 8.4 10.4 1.7 7.7 3.7 7.9 9.1 11.2 1.2 8.Q 1.4 8.2 8.9 9.5 1.1 8.0 1.2 8.2 Apr. - Ave. Max. May - Ave.' Max. June - Ave. Max. * July - Ave. Max. t h. ig. - Ave. Max. Sdpt. - Ave. Max. Oct. Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. NPDES Permit Li mi ts - December 1 through April 30 Ave. Max. NPDES Ave. Max. - - Permit - 32 43 Limits 25 40 431 800 - May 1 357 744 through - 1462 2713 November 30 1212 2523 - 674 7.0 1396 674 >7.0 1396 13 6.0-8.5 28 13 6.0-8.5 28 VAB.0001184140 LABORATORY - W. H. McNeese i RCAs Entered During March: ACP-Donnelly AJP-022685-UTC ACP-030885 Donnelly Corp. United Tech. Corp. Master/Halco 48562 Blk. 5425 45541 Nat. Mixed Material Wet Resin/Hard Particles Streamers Waivers Received Customer Product Reason No. American Hoechst 5305 Particle Size 1 R/C 1 H/T American Hoechst 5305 Bulk Density 1 H/T Athol 5425 Static Flow 3 H/T Carlon 5385-3 Particle Size 5 R/C Charlotte Pipe 5265 Particle Size 1 R/C Columbia Plastics 5385-3 Static Flow 1 H/T Conductor Products 5425 Static Flow 2 H/T DAS Terminal 5305 Bulk Density A Particle Size 1 R/C DAS Terminal 5305 Particle Size 3 R/C DAS Terminal 5305 Viscosity 1 R/C Diversitech General 5385-1 Particle Size 1 R/C Ecodyne 5385-3 Particle Size 1 H/T Excel 5465 Static Flow 1 H/T Genova Inmont Intex 5265 5305 5305 Particle Size & Viscosity Particle Size Particle Size 1 R/C 1 B/B 2 R/C Macklinburg-Duncan 5425 Static Flow 1 H/T Nib co 0*Leary Terminal Tenex Uniroyal Vulcan 5305 5385-1 15041 CB50 5305 5385-3 Particle Size 3 H/T Color 1 R/c Hard Particles 1 R/c Bulk Density & Particle Size Particle Size 1 R/C 1 B/B 2 R/C LABORATORY - Continued Quality Control Testing Re 8 in Regular Samples - 413 Total Batches Tested - 878 Bag Blends - 6 Bulk Shipments - 248 (Railcars - 163; Trucks -85) Dry Blend Blenders Produced - 796 Blenders Tested - 531 Blenders Adjusted 1.8% Bulk Shipments - 45 (Railcars 22; Trucks - 23) Compound Blenders Produced - 939 Blenders Adjusted - 1.0% Bulk Shipments - 21 (Railcars - 15; Trucks - 6) RVCM of In-Process Samples The following is a summary of residual VCM results on in-process samples. None of the reactor dally averages exceeded 400 ppm during the month of March. Number of Samples Average RVCM, ppm RVCM of Shipment Samples Reactor ________ Drier Slurries52655305 847 69 161 156 5.5 1.4 The following is a summary of the residual VCM analysis of shipment samples for the month of March. Product Number of Samples Average RVCM, ppm 5265 5305 5385 0.6 0.8 5425 5465 7 0.3 VAB.0001184142 Administrative Services - W. F. Higginbotham Shipment by Product - M/lbs. Resin Plasticizer Dry Blend Compound Total 28*739 666 5*061 6*179 40*645 of Shipments by Node Resin - Bulk Plastic Dry BY Compou 0*T, SO O.T Year-to Date 293*089 . 3,528 26,117 26*162 348*896 CPU CTR Total 6 Number of Shipment by*Month-Year-to Date January February March April May June July August Sept ember October November December 176 69 147 47 172 77 150 65 185 82 168 68 CPU CTR Total 62 10 18 48 7 20 59 15' 17 82 417 75 1 345 32 3 375 K 64 9 28 52 3^ 41 9 23 80 420 37 11 19 91 394 VAB.0001184143 Activity Report - Finished Goods David Whitaker MARCH 31, 1985 MATERIAL. HANDLING REPORT Packaged Resin from Production Packaged Compound, Dry Blend from Prod. Transferred From Main to Prairie Transferred from Prairie to Prairie Transferred from Prairie to Main Reverse Transfer Resin to Plant Reverse Transfer Cmpd. to Plant Shipment from Warehouses Special Packaging OFF-GRAPE IN STORAGE MATERIAL Sifter Overflow Resin "BC" Resin "HM Mill Scraps Compound MBCN Compound NHN Vacuum,Dust Collector,Vent Dust Dry Blend "0. G.M Volumes - Month Y.T.D. n.8 136.2 TOTAL M/Lbs. 542 3,625 2,665 121 420 233 ---- 4,207 -- ---- 11,813 13 90 67 3 11 6 105 * 295 M/Lbs. 289 23 62 535 12 77 93 1,091 T/L 7 1 * 2 13 2 2__ 27 LOCATION TOTAL SO. FT. * MAIN -p h PRAIRIE 12-1 48 12 12-2 12-3 12-4 12-5 22 21 22 21 > 12-6 21 12-7 12-8 21 21 TOTAL 209 ABERDEEN WAREHOUSE CONTENTS CMPD A CMPD(BC) DRY BLEND CMPD CMPD DRY BLEND P CMPD VACCUM DUST MILL SCRAP SIFTER OVERFLOW CMPD O.G. DRY DLEND O.G. COMPOUND-HOLD RESIN-HOLD DRY BLEND-HOLD RAW MATERIAL 4 RESIN A COMPOUND COMPOUND / { .1 .3 5 1. 4 .8 1.5 .1 .1 ,3 .2 .1 1 * .3 .1 .3 3 1.7 .3 DATE MARCH 31.1985 4 % ESTIMATED POUNDS ON FLOOR OPEN TOTAL . 4 7a 7.S .5 1.4 .8 1. 5 1 -0 2.1 2.7 2.0 1.5 3.5 { 3.5 3.5 .8 1.7 2.5 7 i 1-1 2*4 3.5 1 # / 1 *K 3.5 .3 3.2 3.5 8.5 24.0 32.5 * VAB.0001184145 j + * ABERDEEN CHEMICAL PLANT INJURY PERFORMANCE f Wl I o a CN CO *0 * 4A Si tKfi uj, X T+ t 30 ** * 4 4* %* ' 4 * * ! V i I +1 *-- 1 ----------- k ------ 1 > + ................ < * ; i 44 t VAB.0001184146 mhp-1. -? - HMf rfc 1 5000 4500 4000 3500 3000 2500 2000 1500 ENERGY USAGE II I I ! 'M 1 Monthly 12-Month Moving Avg K\ * t VAB.0001184147 MONTHLY HOURLY TURNOVER VAB.0001184148 MM POUNDS 10.0 8.0 2.0 1.0 0 VAB.OOOl 184149 % OFF-GRADE 5.0 4.0 3.0 b 2.0 1.0 0 4.0 3.0 2.0 1.0 0 4.0 3.0 2.0 1.0 r* 0 10/1/84 10/1/85 VAB.0001184150 t * MM POUNDS MONTHLY 40 35 30 25 20 15 6 5 4 3 2 1 6 5 4 3 2 1 2 1 0 Oct. ABERDEEN PLANT PRODUCTION A) MM POUNDS CUMUUTNE Dec. Jan. 60 : 50 40 3 30 20 10 70 60 50 40 30 20 10 20 15 10 5 Mar. 19 84/85 June July Sent. Oct. ----------- Budget - - - - Actual Cumulative VAB.0001184152 t. 1.03 1.02 1.01 ABEROEEN PLANT EFFICIENCY POUNDS 1.06 1 1.05 1.04 1.03 1.02 1.01 1.020 1.010 1.000 3fSTTmmmmm 1 L l Ls "?' i jmPMMH *m i mmumm ^j!l1 *.. mmmmmmtmmrnmmmm mm mm mm*m 'rM#tll1'if"fM1I1 vpmm\nmrn "+t *Ul! mm ^ Mim ********* rnmmrn^mm **** mm(*4fr*^*pj***#^^ m Mf *m+ mmmmm mm ***** mmmmmrmmmrnmmmm M*WW **** *p w *** *f *11 ^*1 ***** i*M* mm fM*N mmmmrnmmtum NMh mm rt* JMM* ***** mmmm mmrnmm 4w * I w ** wMlfiapW - ihM* r h P1 ***** t ****#*< ***** H** rr . .... ... ... . - mm*** 4Wtt n. --------------------- i ii i r 3____________ mm vfa U*H 1Awn -- >-- -'-* " -- ---- -- . Tr - ~ --i. ^ . ' 1i | 1.200 1.150 1.100 1.050 m+m i -ir. .* _ ijlltl-.i. ._ i9 61/85 Monthly Cumulative i VAB.0001184153