Document 6BNrK4eb3BMOR75KdVYJNxrw9

SAFETY - A. H. Sather OCCUPATIONAL INJURIES Injuries Treated June 1980 Year-to-Date 1979 Year-to-Date First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time 6 28 2 11 01 03 00 16 5 2 29 0 Injuries Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 4 12 09 4 17 02 00 00 8 2 9 6 0 2 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 4 19 04 13 3 10 04 22 7 3 7 5 3 0 As of June 30, 1980, the plant operated 361 days or 463,507 manhours without a disabling injury. SAFETY MEETINGS Topics for June safety meetings included the following: 1. Falls - The National Safety Council film "Down and Out" was shown. Follow up discussions included areas where falls could potentially occur in each department. 2. Hot Water Cleaning Cart - The hot water cleaning cart procedure was reviewed. The unit is used to remove slippery material from working surfaces. NEW EMPLOYEE ORIENTATION A temporary draftsman, Robert Richert, received new employee orientation. (1) DTH 000019179 SAFETY - (continued) OSHA COMPLIANCE Items relating to OSHA compliance were as follows: 1. Preliminary results of PVC dust sampling were received. The data indicates that all samples are all well below the 5 Ma/m3 respirable nuisance dust standard. More samples are planned when the plant returns to normal operating rates. 2. The results of VCM and lead dosimetry are shown below. VCM Range (ppm) Number Percent 0.0-0.5 0.5-1.0 1.0-5.0 5.0+ 76 92.68 2 2.44 4 4.88 0 0.0 100.00 Overexposures Four (4) overexposures to VCM occurred. One occurred to a Maintenance Mechanic working in the old reactor module. The specific cause is not known and he was not wearing a respirator. The second occurred to another mechanic who worked on a reactor and a recovered VCM receiver in the new module and was wearing a respirator. The third occurred to a Vinyl Supervisor who worked in the new reactor area and did not wear a respirator. The final overexposure occurred to a Mechanical Supervisor who worked on the inerts vent refrigeration system in the old module and did not wear a respirator. LEAD Number Greater than PEL Less Than PEL 3 2 5 Overexposures The three overexposures occurred to Compounders in the Compound Department. One occurred to the Color Weigh Room Compounder and the remaining two (2) occurred to line III Compounders. The samples were taken during May. Although the overexposures are currently under investigation, individual work habits are suspected. In each case, a respirator was worn. (2) DTH 000019180 VINYL - C. R. Miller Production 1. Total Production, MM Pounds 2. Production Rate, M Pounds/C.D. 3. Charges, Reactor Batches/C.D. 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average Pounds/Hr. 7. Dryers, Stream Factor, % 8. Accounting Days Month 13.7 456 10.6 317 52.4 5496 49.5 30 Y.T.D. 130.3 716 16.9 3060 72.7 5781 73.7 182 Budget 918 Vinyl Department production for the month was 49.7% of budget at 13.7 MM pounds. Reactor and Dryer stream factors were 52.4% and 49.5%, respectively. The major items affecting the Vinyl Department productivity are as follows: 1. Inventory control programs represented the majority of the reactor and dryer stream factor penalties (41.2% and 45.8%, respectively). The plant under went a total shutdown of all process units from June 16 to June 23, 1980. The new reactor unit was returned to operation on June 23. The old reactor unit remained down the remainder of June. 2. Three reactors required condenser cleaning in the new reactor module. This accounted for 1.7% of total reactor downtime. 3. Two reactors required seal repairs during June. The reactors were both in the old unit and represent a 1.2% stream factor penalty. 4. The new reactor module startup was hampered by condenser fouling and particle size control. All four reactor condensers required cleaning shortly after attempting startup. Initiator loadings were reduced during'this period to counteract the high cooling water temperatures. Several test runs were started or continued through the month. These included initial testing of a new suspending agent, testing of new lots of initiator for the dual initiator system on 5425, continuation of the agitator test on D-600 reactor, and the installation of the new high power agitator blades in 744 reactor. Resin Quality Summary Resin Type, 5305 5385 5425 5465 Sifter Overflow TOTAL Prime Pounds 887,301 9,334,142 2,571,957 641,635 - 13,435,035 "BC" Grade ( 650) - 162,000 - 161,350 "H" Grade 63,650 (40,500) ( 650) 52,660 75,160 % of Total Production 7.0 68.0 20.0 4.7 0.3 100.0 (3) DTH 000019181 VINYL - (continued) Quality performance for the month of June was 98.3% customer grade with 1.2% "BC" grade and 0.5% "H" grade. Of the "H" grade reported, 70% was due to sifter overflow. The variable cost variance for the vinyl department was $22.0 M with ($52.8 M) due to price and $74.9 M due to efficiency. The variance due to product mix was ($2.1 M). The only major price variance was ($50.7 M) for VCM. The major efficiency variances for the month were $26.2 M for VCM and $22.3 M for combined initiators. The initiator variance was due to reduced initiator loadings and low inventory level which allowed a more exact end of month count. The raw material requirement for the month was 1.01000 pounds VCM/pound of PVC versus a 1.01960 standard. (Y.T.D. is 1.01561) General Resin packaging continued throughout the month with 1.5 MM pounds packaged. (4) DTH 000019182 COMPOUND - J. R. McCrimon Compound Production Month #'s/Day Y.T.D. Line I, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days 1,309 57 7,381 -- 207 2,323 101 15,185 3,632 22,773 30 182 Line I operated 23 days during June at an average rate of 57 M pounds per day. Major items affecting production efficiency were: product changes (40.7 hours), dicers (28.5 hours), bag charging resin (12.0 hours), scales (6.4 hours), and plant shutdown (171 hours). Line III operated 23 days during June at an average rate of 101 M pounds per day. Major items affecting production efficiency were: product changes (22.1 hours), quality control (7.9 hours), bag charging resin (5.2 hours), and plant shutdown (171 hours). Quality performance for flexible compounds was 2.3% off-grade of which 80.5% was due to mill scrap. "BC" production was 0.4%. The raw material requirement for flexible compounds was 1.02019 pounds of raw material per pound of compound versus a 1.01301 standard. (Y.T.D. is 1.01293) The variable cost variance for compound was ($6.9 M) with $31.9 M due to price and ($38.8 M) due to efficiency. The variance due to product mix was ($11.3 M). There were no major price or efficiency variances. Dry Blend Month #'s/Day Y.T.D. Production, M Pounds Accounting Days 2,214 30 131 9,745 182 Dry Blend operated 17 days during June at an average rate of 131 M pounds per day. Production included 80172B, 80273G, and 90171. Dry Blend pro duction efficiency was affected by: product changes (5.9 hours), boxing dry blend (6.2 hours), quality control (7.2 hours), out of resin (13.9 hours), and plant shutdown (80 hours). Quality performance for the month was 99.99% customer grade. The raw material requirement for dry blend was 1.00329 pounds of raw material per pound of dry blend versus a standard of 1.00320. (Y.T.D. is 1.00744) The variable cost variance for dry blend was $44.4 M with $6.7 M due to price and $37.7 M due to efficiency. The variance due to mix was $33.1 M. There were no major price or efficiency variances. (5) DTH 000019183 COMPOUND - (continued) Plasticizer Month #'s/Day Y.T.D. Production, M Pounds Accounting Days 518 47 4,191 30 182 Plasticizer operated 11 days during June at an average rate of 47 M pounds per day. Production included: DIDP, 61 OP, and DOP. VRP production totaled 60.7 M pounds (11.7%). Production was limited by: inventory control and plant shutdown (120 hours). The raw material requirement for plasticizer was 1.22144 pounds of raw materials per pound of plasticizer versus a 1.10102 standard. (Y.T.D. is 1.14079). The variable cost for plasticizer was ($31.6 M) with ($22.0 M) due to price and ($9.6 M) due to efficiency. There were no major price or efficiency variances. The variance due to product mix was ($3.7 M). General Total customer grade compound inventory increased to 7.0 MM pounds during June. Tests were conducted in Werner-Pfleiderer's Stuttgart, West Germany lab during the month. Compound was produced on 5, 7, and 12 barrel machines with no success in eliminating hard particles from 17461 compound. A plant program to determine exactly what compounds can be run on Line V will begin in early July. (6) DTH 000019184 MECHANICAL - S. J. Vincent Vinyl There were three large reactor seal failures in this period. Two of the seal failures were in the old module on the D-300 and D-500 reactors. In the new module the seal failed on the 743 reactor. There were no gearbox failures this month. The test set agitator blades were installed in the 74A reactor. There were four reactor condensers brushed this month. All of the condensers cleaned were in the new module with the condenser on the 741 and 743 reactors being cleaned twice in this period. The east VCM charge pump motor was repaired in the new module. The old module was held down most of this period for inventory control. In this down period the double block and bleed system was installed in the VCM charge header. Several steam and water leaks were repaired in the old module. The electrical portion of the double block valves for the VCM charge project was completed. Reactor system valves repaired this month were the eight inch VCM charge pump suction valve on the east pump, the D-300, D-400 steam stripping check valves were removed and the gasket faces remachined. The south steam stripping valve on the 742 reactor was rebuilt. The old unit Sweco dump valve was rebuilt and the inlet and outlet bypass valves were replaced on the new module RVCM filter. There were six mechanical seal failures to pumps and compressors in the vinyl production area. All of the seal failures were in the old module. The seals repaired were the outboard seal on the 705 emission recovery compressor, the outboard seal on the A vacuum pump, the seals on both RVCM transfer pumps, the outboard seal on the 706 emission recovery com pressor, and the seal was replaced in the north sphere pump. There were seven pumps and compressors removed from the units for complete overhauls. Two compressors, the 705 emission recovery and the north recovery compressor in the new module were overhauled. The pumps over hauled were the east RVCM charge pump, and the east chem wash pump in the new module. The chem wash pump "B" hot water charge pump, and the rinse pump in the old module were overhauled. The vinyl incinerator was down for a general inspection. The downcomer and quench nozzles were replaced. The only major repair to the vinyl dryer equipment was to pull and rebuild the number five Bird unit. Compound, Dry Blend, Plasticizer and Silo Storage Repairs to the compounding equipment involved changina the FCM seals, rebuilding the outlet valve on "B" blender and repairing several steam and water leaks. Dicer repairs were also completed. (7) DTH 000019185 MECHANICAL - (continued) In the dry blend unit, the belts were replaced on both Wei ex units and the boots were replaced on the Kason screeners. The "C" blender motor was repaired. There were six loading chutes replaced on the storage silos. Two lab mills were removed to the shop for complete overhaul. The number two fire pump engine was overhauled and the four fire pumps were repacked. A new high level instrument was installed in the phthalic anhydride charge tank. Utilities and Service There were three repairs to the plant instrument air system. Valves were repaired in the number eight and three air compressors and the heater elements were replaced in the west V-10 air dryer. The three plant boilers were shutdown and opened for the annual insurance inspection. No problems were found and new certificates are expected. New safety valves were installed on the air system drums to increase the relievino capacity of the system. The inboard seal was replaced in the south fresh air system compressor. The north lagoon aerator in pond five was removed and inspected. Planner The planner estimated 62 work orders and ordered material for 28 work orders. There were 16 new invoice registers issued for equipment repair and 15 bills processed for payment. The equipment history and safety valve records were maintained for this period. (8) JDTM 000019186 PERSONNEL - J. L. Carter EMPLOYMENT Glendale D. Richards, Process Engineer Robert Rickert, Draftsman (Temporary) TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTION J. W. Lowe, Maintenance Helper, promoted to General Mechanic "B". RETIREMENT None. TERMINATION Coleen Williams, Steno Clerk OTHER During June there were two casual labor employees on payroll. Total hours worked were 320. (9) DTH 000019187 CONOCO CHEMICALS Aberdeen, Mississippi June 1980 MONTHLY PERSONNEL REPORT Hourly Employees Total Employees Employees (Hourly! _Z1 157 236* Minority Employees # Salaried ^ Hourly 62 Total 69 8.9% 39% 29% New Employees Terminations 0 0 Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 0 0 0 DEPARTMENTS PAR # EMPLOYEES MIN. EMP. . % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse 9 9 2 22% 0 0 00 0 0 Gen. Plant 10 11 6 54% 02 01 0 11% Maintenance 46 46 7 15% 0 0 00 0 0 Laboratory 22 20 3 15% 0 0 00 0 0 Compound 37 35 28 80% 0 0 0 2** 0 2.,81 Vinyl 32 32 13 41% 0 0 00 0 Jl_ Plasticizer .5 4 3 75% 0 0 00 0 0 Number of Applicants: Month 2 Year to Date 80 APPLICANT BREAKDOWN: ft Minority 1 % Minority 50% # Female ^ % Female 0 *Includes two (2) temporary employees. Includes one retirement and is not counted in turnover rate. Hires (Hourly) : Month 0 Year to Date 2 Terminations (Hourly) : Month 0 Year to Date Overall Turnover 0 3** Projected Annual Turnover 1.3% (i o> E>TH OOOOISHLSQ OVERTIME AND ABSENTEEISM (2) N on-C ontrollable Overtime - th a t overtim e due to working re g u la r hours on a holiday and working re g u la r hours on the s ix th day in operations. cn co vo 10 --. o oo oo * oo oo CO CO O CM O CO i" CM >> (OO cn as 0) 4-J > CO o 4CL) c3 00 o o o o CO r-- I-- CM r*v in C<LD.n 0> E &_ CD > o CD E T5 - <y l-- t. M O -c 3 CTt r- in fO iS- 3 +- o CO X Lf) o o o in LO co cr cf cn in O o r^. CM o o CM O 1-- Oh CM r-- CO LO 00 r-* CO CM CO <3* om o r- CM in l> r- O in CM in Oh CO to 1 0) ErsQJ > o Cl) X) to O oo DTH 000019189 PROCESS ENGINEERING - R. A. Frohreich A. 1981 Capital Budget The majority of the process engineering effort this month was devoted to preparation of the 1981 Capital Budget. A total of 26 process designs were issued. Economics and capital budget write-ups were also prepared. B. Resin Debagging System The class "A" design for this project was issued and a review meeting was held. C. Fixed Point Monitor Data Computer and Warning Lights A meeting was held with CED to discuss the differences between the Perkin-Elmer System and the Spec Physics-Dec System. Further evalua tion will be necessary in order to make a decision. D. Rupture Disc Survey A survey of rupture discs in VCM service has been completed. The type of disc, type of holder, and material of construction of the disc and holder has been noted for each disc assembly. As a result of the survey, disc assemblies in critical service will be upgraded. E. Batch Water Strippers Tie-in points for the project were determined and shown to the mechanical design group of CED. F. Expansion Project A meeting was held with Li twin to discuss relocation of the slurry blend tanks and piping in the slurry storage area. The first civil package was issued by Li twin. Review of control panel layouts and instrument specifications are underway. Review of piping and layout drawings is continuing. (12) DTH 000019190 ENVIRONMENTAL - V. E. Messick I. Particulates One dryer was tested for particulates and found to be within allowable 1imits. II. Water Effluent BOD and COD concentrations were within NPDES permit limits in June. The NPDES quarterly report was prepared. III. HAZARDOUS WASTE MANAGEMENT The form for notification of hazardous waste activity has been reviewed. Work has begun to gather the necessary information to complete the form. (13) X)TH OOOO19191 Flow GPM Jan. - Ave. Max. 810 941 Feb. - Ave. Max. 645 802 Mar. - Ave. Max. 595 743 Apr. - Ave. 628 Max. 877 May - Ave.' 304 Max. 480 June - Ave. 670 Max. 804 July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. TABLE I - WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB./DY. COD PPM LB./DY. Sus. Solids PPM LB./DY. 43 131 436 1342 6 42 8 56 29 220 36 314 21 147 30 232 86 851 216 2214 15 116 24 171 66 502 95 828 54 378 67 519 11 103 13 143 10 79 13 125 11 74 14 94 12 86 13 129 16 69 32 184 6 49 11 84 53 197 74 426 40 316 51 367 10 40 14 81 12 98 15 145 Diss. 02 6.8-8.5 6.7-7.9 6.6-8.3 6.4-8.3 6.7-7.3 6.7-7.3 NPDES - Ave. Max. 32 387 43 520 1390 1940 - 605 - 909 > 6.0 ph 7.7-8.0 7.1-7.8 7.1-7.8 7.5-8.4 7.2-7.9 7.5-7.9 6.0-8.5 (14) DTH 0000X9X92 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for June was 67.97 MMM BTUs. The energy consumption per pound of product decreased from 3918 BTU/lb. to 3365 BTU/lb. in June. II. Plant Energy Conservation Program A. Steam Leaks Fourteen (14) steam leaks were repaired in June. B. Boilers Economizers Mechanical design of the project is continuing with purchase of the economizers in May. (15) DTH 000019193 ITEM Production, MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Total Energy Consumption, MMM BTU Energy Consumption , BTU/Lb. Boiler Operating Data No. 1 No. 2 No. 3 ENERGY CONSERVATION DATA 1979 June 27.2 3.6 3.9 1.1 35.8 57137 1020 58.280 4.9248 10000 49.248 0 92000 0 107.528 3004 Avg. Stack Temp. 1979 1980 397 357 419 409 451 412 Avg. % Excess Air 1979 1980 22 27 31 24 102 23 1980 June 13.8 2.2 3.6 0.6 20.2 32079 1020 32.721 3.525 10000 35.250 0 92000 0 67.971 3365 06) DTH 000019194 MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved, and Closed The following AFE was submitted and approved during June : AFE No. Title Authorized 9660 Hot Water Charge Tank Replacement $160,000 The following AFE's were closed to field charges during June: AFE No. Title Authorized 9188 Railcar Resin Heel Clean-Up System $ 55,000 9519 Critical Spare Equipment $175,000 9659 P. A. System Modifications $ 35,000 9520 Replacement P.A. Tanks $ 75,000 Completion Reports were issued for the following AFE's during June: AFE No. Title Authorized 9679 Plant Winterization $ 64,000 9089 Vibration Study-Capacity Replacement Reactors $ 50,000 Design Design work is in progress on the following projects: Automatic Plasticizer-Stabilizer Weiph-uo System Replacement of Hot Water Charge Tank API Clean Water Bypass Boiler Economizers Seal Flush Revisions Spare Inert Incinerator Fire Protection Improvements - Phase II Multigrade Resin Production Facilities Water Stripping Contracts were let for the following projects: Drum Storage Area Shed Electrical for Fire Protection Improvements - Phase I Diking of Sphere and Curbing of Drum Storage Area (17) DTH 000019195 MECHANICAL ENGINEERING - (continued) AFE Activity 1. AFE 9158 - Fire Protection Improvements - Phase I - J. P. McKee Construction is in progress and approximately 95% complete. 2. AFE 9228 - Dry Blend Silo Alarms - J. L. White Eight of the twelve silo alarms are now operational. 3. AFE 9649 - Double Block Valves for VCM Charge - M. S. Richards The installation of piping is comnlete and the project is operational. 4. AFE 9689 - Diking of Sphere and Curbing of Drum Storage Area - J. L. White The contract was let and construction is in progress. 5. AFE 9707 - Facilities for Multigrade Resin Production - CED Piping and foundation design is in progress. 6. AFE 9729 - Fire Protection Improvements - Phase II - CED Piping, architectural and electrical design is in progress. 7. AFE 9570 - Replace T-100 P.A. Tanks - J. P. Windham Drafting is complete. Material purchasing is in progress. 8. AFE 9580 - Boiler Economizers - J. L. White Structural and pipe drafting is in progress. 9. AFE 9729 - Fire Protection Improvements - Phase II - CED Drafting and architectural work will be complete in August. 10. AFE 9709 - Facilities for Multigrade Resin Production - CED Engineering and design is in progress. 11. AFE 9530 - Spare Inert Incinerator - CED The incinerator and flame arrester have been placed on order. 12. AFE 9610 - API Clean Water Bypass - M. S. Richards Drafting is complete and ready for review. 08) DTH 000019196 MECHANICAL ENGINEERING - (continued) 13. AFE 9630 - Mater Stripping - CED Concrete, structural design and pipe drafting is in progress. 14. AFE 9660 - Replacement of Hot Water Charge Tank - J. P. McKee Engineering design and drafting is in progress. Construction - G. A. Morgan The piping installation for the VCM Double Block Valves in the old module was completed. The foundations, electrical and mechanical work for the Vapor Emissions System Revisions was completed. Concrete curbing for the two drum storage areas was installed. Structural repairs to second lagoon aerator was completed. Installation of the Phase I Fire Protection Improvements is in progress. Repairs to the third lagoon aerator is underway. There were three contracts and twenty-five register tickets issued for contract work during the period. (19) DTH 000019197 (1) Thru May, 1980 Actual Accounting (2) Thru June, 1980 AUTH. CAPITAL NO. DESCRIPTION ABERDEEN AUTHORICATIONS REPORT DATE Airm. APPROVED afe amt. 0) (2) FINAL EXPENDED COMMUTED TOTAL EST. TO DATE TO DATE COST COMP. UNDER COVER) AUTH, AMT. EST. EST. COMP. CLOS. DATE DATE REMARKS 9237 9297 9098 9148 9158 9188 9228 9248 Heated Plasticizer Addition System Automatic Plasticizer-Stabilizer Weigh-Up System New Compound Line Plasticizer Chemical Exposure Abatement Fire Protection Improvements Phase I Railcar Resin Heel Clean-Up System Dry Blend Silo Alarms Silo Isolation Valves 10/11/77 12/14/77 37,000 60,000 13,090 56,293 13,518 59,163 37,000 60,000 4/17/78 2,050,000 2,089,993 2,089,993 2,089,993 8/21/78 152,000 141,921 147,116 152,000 9/19/78 176,000 130,219 173,763 176,000 . 10/12/78 12/13/78 12/14/78 55,000 25,000 25,000 42,970 4,483 21,327 43,311 16,449 23,444 55,000 25,000 25,000 9258 9519 9549 9559 9589 Dryer Operation Improvements Critical Spare Equipment Safety Equipment Color Weigh Room Modifications Instrument Air Oryer 12/14/78 2/6/79 3/26/79 4/19/79 5/30/79 315,000 175,000 15,000 25,000 110,000 274,895 107,249 15,094 16,676 90,085 285,450 159,192 15,094 17,301 90,596 315,000 175,000 15,094 25,000 110,000 9609 Reactor Inert Vent System 6/28/79 90,000 9619 Waste Water Revisions - Part I 7/3/79 140,000 9629 Air Compressor 7/9/79 340,000 9639 Revisions to Emission Recovery System 7/12/79 100,000 9649. Double Block Valves for VCM Charge 7/18/79 182,000 9659 P. A. System Modifications 7/10/79 35,000 9669 New Air Header 8/15/79 25,000 9689 Diking of Sphere & Curbing of Drum Storage Areas 9/15/79 170,000 9699 Plant Dryer Debottlenecking 9/15/79 80,000 9709 Facilities for Multiple Grade Resin Production 9/20/79 870,000 9719 Aberdeen PVC Resin Expansion (Partial) 9/10/79 850,000 9729 Fire Protection Improvements Phase II 10/1/79 490,000 9739 Methocel Charge Revision 10/3/79 66,000 9759 Aberdeen PVC Resin Expansion 12/10/79 11,150,000 9769 Automatic Setback Thermostats 12/31/79 3,000 9510 Miscellaneous Projects Under $10,000 1/3/80 150,000 9520 9530 Replacement Phthalic Anhydride Tank Spare Incinerator 1/17/80 1/23/eo 75,000 650,000 9540 Laboratory Equipment 2/6/80 45,000 9550. P. A. Handling Improvement " 3/3/80 63,000 9560 Safety Equipment 3/12/80 25,000 9570 Replace T-100 P. A. Tank 3/27/80 119,000 9580 Boiler Economizers 3/26/80 140,000 12,329 133,059 12,862 136,489 231,645 41,304 241,026 55,856 90,000 140,000 340,000 100,000 89,869 136,800 27,411 33,419 16,957 16,957 1,585 118,314 182,000 35,000 25,000 170,000 0 3,061 0 197,014 80,000 870,000 11,421 817,600 850,000 9,358 76,987 490,000 857 18,743 66,000 472,000 2,421,900 11,150,000 2,389 2,389 3,000 67,488 101,010 150,000 75,072 0 445 18,112 1,711 12,906 0 81,326 0 41,604 18.797 1,711 52,648 55,020 81,326 650,000 45,000 63,000 25,000 119,000 140,000 0 9/80 12/80 Pesion in proaress. 0 9/80 12/80 Desian in nrcpress. 139,993) 12/79 7/80 Closed to field charaes. 0 8/80 11/80 Revisions in nrooress. 0 8/80 11/80 Installation in progress. 11,689 6/80 9/80 Closed to field charaes. 0 7/80 10/80 Installation in proaress. 0 8/80 11/80 Eiqhteen of twenty-one valves Installed. 0 9/80 12/80 Project operational. 15,808 6/80 9/80 Closed to field charges. (94) 10/79 6/80 Closed to field charaes. 0 7/80 10/80 Project operational. 0 9/80 12/80 Winterization desian completed. 0 10/80 1/81 Engineering In oronress. 3,511 5/80 8/80 Closed to field charaes. 0 8/80 11/80 Project operational. 0 8/80 11/80 Installation in progress. 0 8/80 11/80 Project operational. 1,581 6/80 9/80 Closed to field charaes. 0 9/80 12/80 Project operational. 0 9/80 12/80 Contract let. 0 12/80 3/81 0 12/80 3/81 Engineering in progress CED. Engineerina in progress CED. 0 9/80 12/80 Equipment on order. 0 10/80 1/81 Engineerina in proaress CED. 0 8/80 11/80 Engineerina in progress. 0 7/81 10/81 Engineerina in proaress. 0 7/80 10/80 Project operational. 0 12/80 3/81 Forty-Eiaht projects approved (6,326) 6/80 9/80 Closed to field charaes. 0 1/81 4/81 Enaineerina in proaress CED. 0 8/80 11/80 Purchases proceedfnn. 0 12/80 3/80 Engineerina in pronress. 0 9/80 12/80 Purchases proceeding. 0 9/80 12/80 Engineerlno in oronress. 0 10/80 1/81 Economizers on order. (20) PTH 0000191-98 Ainu, CAPITAL - (continued) NO. 1M St'RimON 9598 Critical Spare Equipment 9600 Calcium Stearate Addition System 9610 API Clean Water Bypass 9620 Cooling Tower Motor Replacement 9630 Water Stripping 9640 Shed for Drum Storage Area 9650 Miscellaneous Projects Under $10,000 9660 Hot Water Charge Tank Replacement APiuim-i-N authorizations hi-port (1) Thru May, 1*W0 Actual Accnuntinq (2) Thru June, 19H0 ivvir Airni. Arrnovnn Mil AMT. (n 1 INAL UNPliR liST. liST, i:\Pii\nr i I'OMMMTTU TOTAL 1ST. (OVIilO aimp. CLOS. to ha n- TO lv\ II; COST COMP. AUTII. AMT. PATIi DATf! UliMAKKS 3/26/80 4/2/80 4/15/80 59,000 84,000 23,000 0 0 59,000 0 1,148 84,000 0 3,189 23,000 0 10/P0 1/PI Update ouotes reouested. 0 11/80 2/81 Enoineerino scheduled. 0 8/80 11/80 Engineerina in nronress. 4/28/80 17,800 16,595 16,595 17,425 375 5/80 8/80 Closed to field charges. 4/30/80 810,000 0 0 810,000 0 4/81 7/81 Engineering in progress. 5/8/80 5/30/80 14,000 150,000 0 13,486 14,000 0 56,178 150,000 0 8/80 11/80 Contract let. 0 12/80 3/81 Five projects approved. 6/4/80 160,000 0 0 160,000 0 12/80 3/81 Engineering in progress. (21) DTH 000019199 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint P.eoort B.v Natural Vinyl Products World of Plastics Material Control Corp. ITT Royal Central Plastics Alcan Cable Alcan Cable Alcan Cable Natural Vinyl Products Columbia Plastics 5385 5385 18831 Cl B1 5425 18161 Blk. 34641 Blk. 34641 Blk. 34641 Blk. 5385 80273G Shipped wrong type resin Contamination - gasket Cross contamination Contamination - pink powder Paper contamination Contamination - foreign Cross contamination Fines and streamers Baq weights Contamination - foreign CRM CRM JRM RDJ JRM JRM JRM JRM CRM RDJ WAIVERS RECEIVED None PRODUCT DEVELOPMENT AMD SERVICE Ship Date Product Quantity (lbs.) Customer Requested R.y 6/2 6/2 6/4 6/12 6/23 6/24 6/24 6/24 6/24 6/24 6/25 6/25 6/25 6/25 5385-1 5385-1 80273G 18551 Blk. 38601 Nat. 5425-1 5385-1 26421 Nat. 17461 Wht. 35441 Nat. 39032 Blk. 17461 Nat. 18161 Nat. 18961 Nat. 100 300 grams 200 5 10 10 50 50 100 100 50 100 100 100 Fritz Airfreight Fritz Airfreight Thermo Plastics Conoco Inc. Okonite Wire & Cable Weymouth Art Leather Packard Electric Div. J. V. Components, Inc. Crane Plastics Interstate Bel den Corp. Polyvinyl Co., Inc. Polyvinyl Co., Inc. Polyvinyl Co., Inc. JPM JPM - JAP RNG NTH JTVf NTH JTW - MAS - - - Special Testing 15 samples of 17461 material returned from Werner Pfleiderer test run were tested for hard particle count. Special Compound Testing Three production lots of compound were tested and found to meet customer specifications. They were: 34861 Gray 546 - Western Electric 36861 Natural - Western Electric 35851 Natural - Phelps-Dodge (22) DTH 000019200 LABORATORY - (continued) Compound Property Verification Property testing is complete on 20 compounds and is nearly complete on 3 others. Another group of compounds will be tested in July. Dry Blend Development Plant formulas and quality control standards were prepared for 3 experimental low cost single screw dry blend compounds. A new quality control standard for 80172B was prepared. Metrastat Oven Work has continued toward establishing uniformity of temperature and reproducibility of results in the Metrastat oven. Prospects of success appear good. Blown Film Tower A new blown film tower has been received to go with the laboratory extruder, and is ready for a test run. It will then be possible to run the Western Electric blown film test on their compounds, and will be suitable for test ing all compounds for dispersion, hard particles, gels, etc. Resin Volume Resistivity Six blends of 5425 and 5465 resin were tested for volume resistivity. Five of the samples gave uniform, high values for VR while one blend of 5465 was rated acceptable to good. QUALITY CONTROL TESTING Res i n Regular Samples = 237 Bag Blends = 39 Other In-Process Samples = 1167 Bulk Shipments = 109 (Railcars = 51; Trucks = 58) Dry Blend Blenders Produced = 243 Blenders Tested = 176 Blenders Adjusted =5.3% Other In-Process Samples = 83 Bulk Shipments = 41 (Railcars = 2; Trucks = 39) (23) DTH 000019201 LABORATORY - (continued) Compound Blenders Produced = 602 Blenders Adjusted = 2.8% Other In-Process Samples = 107 Bulk Shipments = 18 (Railcars = 10; Trucks = 8) Resin Heat Stability Twenty-seven (27) blends of resin were tested for oven heat stability. Product No. Tested 5385 5425 5305 5465 12 Blends 8 Blends 4 Blends 3 Blends All samples met heat stability specifications, and there was a slight improvement for all types of resin. Raw Material Testing Thirty-nine (39) lots of raw materials were tested and approved for use. RVCM of Shipments A total of 102 shipment samples were tested for residual VCM. Five of the samples (5305) were rejected and not shipped due to high residuals. A summary of RVCM data on resin shipped is below: Product 5305 5385 5425 5465 Average RVCM ppm No. of Samples 2.3 44 0.8 38 0.1 0.1 96 SPECIAL PROJECTS RVCM in Slurry A total of 296 slurry batches were checked for residual VCM in June. None of the daily average exceed 400 ppm. The overall average for the month was 183 ppm. RVCM of 5305 Regular Drier Samples A total of 23 samples of 5305 taken from the regular 0C sample were tested for residual VCM. The overall average for June was 6.2 ppm VCM. (24) DTH 000019202 LABORATORY - (continued) RVCM of Blowdown Tank Water A total of 61 water samples drained from the blowdown tanks were tested for VCM. The monthly average was 9.4 ppm VCM. Viscosity The inherent viscosity was measured on 128 slurry samples, 201 shipment samples and 51 regular drier samples. The Schott viscosity instrument continues to perform very well. Instrument Evaluation D. Cox visited the L & N Plant in Tampa Florida to evaluate an instrument to rapidly measure resin particle size in both wet and dry samples. An AFE has been submitted toward the purchase of this instrument. (25) DTH 000019203 TRANSPORTATION - J. E. Stark Shipment by Product - M/Lbs. June Year to Date Resin Plasticizer Dry Blend Compound TOTAL 13,398 121 2,501 2,872 18,892 96 ,398 362 11 ,419 21 ,002 129 ,181 Number of Shipments by Mode Resin - Bulk - Package - Export Plasticizer Dry Blend - Bulk - Package - Export Compound - Bulk - Package - Export TOTAL O.T. O.T. R/C Bulk Van C.O.T. C.C. TOFC CPU Total 45 26 2 98 32 7 3 78 19 7 55 36 136 0 4 15 90 68 98 33 37 42 7 3 15 3 13 35 7 7 0 74 308 Back Hauls for June 22 Number of Shipments by Month - Y.,T.D. R/C Bulk Van C.O.T. C.C. TOFC CPU Total January February March April May June 104 53 72 0 4 2 36 273 111 83 66 0 21 4 35 320 130 95 64 1 37 0 48 375 69 43 84 0 5 0 29 230 42 41 75 0 3 0 30 191 55 36 136 0 7 0 74 308 Material Handling Report M/Lbs. T/L Packaged Resin from Production Packaged Compound, Dry Blend from Production Transferred from Main to Prairie Transferred from Prairie to Prairie Reverse Transfer Resin to Plant Reverse Transfer Compound to Plant Shipment from Warehouses Special Packaging Transferred from Prairie to Main TOTAL 1,823 1,944 1,580 0 527 81 5,924 4,374 1,984 18,266 45 48 39 0 13 2 147 108 49 451 (26) DTH 000019204 'TRANSPORTATION - (continued) % LOCATION MAIN-East TOTAL M SO. FT. 48 Prairie 12-1 12-2 12-3 12 22 21 12-4 12-5 22 2i 12-6 21 12-7 12-8 12-9 21 21 21 tal 209 CONOCO TRANSPORTATION ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco Resin Resin Resin Export Resin Conoco Export Resin 42 3 .8 ___ i,,5- 1 -1 .8 .7 1 .5 " i .6 Conoco Resin 4 .4 Resin O.G. Mill Scraps Cmpd 0. G. Dry Blend 0. G. ... *9 ... -1 Sifter Overflow Resin 0. G. .8 Compound .1 Resin 3 .0 Raw Material .2 Resin 0. G. 4 .0 Conoco 4 .5 ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 5 .8 _ 4-2 1... 1 4 10.0 1.5 1.5 2 -0 3.5 2.1 1 .4 3.5 * 4 *4 3.5 1-8 7. _ 2.5 3.3 * 4.0 * 4.5 ____i2_ 3.5 3.5 3.5 Conoco Resin Sub-Total (Plug-Aisles) -2-.-4__ * 2-4 1 -T_ 3.5 -2.4 Total Conoco I27T 30.9 10.0 40 .9 DTH 000019205 TRANSPORTATION - (continued) Off-Grade In Storage Material Sifter Overflow Resin "BC" Resin "H" Mill Scrap Compound "B" Compound "H" Dry Blend "O.G." TOTAL M/Lbs. 72 4,988 1,785 10 799 82 90 7,826 T/L 2 123 44 n 20 2 2 193 D.F. Operation During the month of June the D.F. was extremely busy handling rush export orders. All vessel dead lines were met even though we had short lead time. Total packaged inventory dropped approximately 3.5 MM pounds during the month. This drop was primarily due to resin shipments. We still have one outside warehouse rented. A safety meeting was held during the month to discuss the safe and efficient way to operate forklifts in a congested area. (28) DTH 000019206 ABERDEEN FIRST-AID CASES 12 MONTHS MOVING AVERAGE 50 45 40 35 30 25 20 15' 10 5 0 DTH 000019207 ABERDEEN OSHA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE ( C c e DTH 000019208 MONTHLY HOURLY TURNOVER DTH 000019209 ENERGY USAGE c- c c c L Monthl'^ 0000ig210 12 Month Moving Average ABERDEEN PLANT PRODUCTION I UN MM POUNDS 'HL 1980 CUMULATIVE 35 30 25 20 15 6 60 5 50 4 40 3 3D 2 1 6 5 4 3 2 1, 2 I 0 ----------- ACTUAL ----------- CUMULATIVE DTH 000019211 ABERDEEN PLANT QUALITY PERFORMANCE STANDARD 1.35 DTH 000019212 ABERDEEN PLANT EFFICIENCY 1980 POUNDS OF RAW MATERIAL/POUND OF PRODUCT DTH 000019213 ABERDEEN PLANT INVENTORIES DTH 000019214