Document 6bO15dE2Yp6kvg3yRxNDEDBRg

To: T. H. Huffman <r $ An Received 4G 0 3. 90 WILLIAM L McCLAIN Interoffice Communication From: Dote: Subject: D. C. Skokna July 27, 1990 ABERDEEN MONTHLY PROGRESS REPORT JUNE, 1990 VIS1A Safety There were no reported injuries in June. At month's end Aberdeen plant employees had worked 4013 days (5,340,396 manhours) since the last lost time injury. FY 1990 Kev Statistical Information June Y.T.D. FVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M 37.4 92.0 98.9 C.99G42 5.8 98.5 4.6 99.8 1.4 85.6 < 3.2> < 12.0> 40,7 336.5 88.4 97.3 1.0013 54.4 98.3 44.3 99.6 13.6 87.1 < 7.7> 215.3 594.0 Operations Six railcars of low calcium 5305 were produced for Klockner. Installation of the permanent clean wall system began and will complete in August. Some 56 hours of Line I time were used for Plenex Polymers development. Rates in the ridgid compound unit were adversely affected by screener problems (136 hours of downtime). OCR 0000063H T. H. Huffman 7/27/90 Aberdeen Monthly Progress Report - June, 1990 Page 2 Costs Variable costs were favorable in the resin and compound units. Good efficiencies and low offgrade rates in these units and favorable product mixes caused the good results. Offsetting these variances was an unfavorable (high use of raw materials) variance in the plasticizer unit. A process change made earlier may be the cause of the inefficiency. OMP 1. 100% of the plant's natural teams met during June. 2- Overall, natural team scores for the 3rd quarter are up 46% from the previous quarter; an average score of 7.3 points. 3. The plant's estimated Q-Scorecard results as of June 1 are 10.3. 4. The Vinyl "B" Shift Natural Team made its management presentation. They recommended improved blend tank sparger design that benefits the environment, improves safety and quality, and reduces energy consumption. 5. AT&T (a compound customer) presented us their 5 Star Rating (the highest) as a result of our semi-annual vendor rating. Plant Superintendent rah CCR 000006372 DISTRIBUTION COVER LETTER ENTIRE REPORT Houston J. D. Bums X R. T. Ferrell X T. H. Huffman X C. J. Matson X D. F. Harman X H. R. Flammer X R. R. Smith X B. J. Bean X R. H. Gerlach R. D. Gamblin W. L. McClain X X X Austin J. P. Stokes R. L. Poe X X Oklahoma Ci tv LCVCM Plant LCCP Plant LCLAB Plant H. J. Hall H. D,, Garrison R. A. Conrad J. Friend J. W. Ware X X X X X Baltimore L. R. Bauer X Hammond Blane Premiere Aberdeen J. Pavao X C. R. Miller P. L. Foote RWS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, MRK, JEL, DAM, RBN, JEN, JDO, REP, BLT X X CCR 000006373 ABERDEEN CHEMICAL PLANT APPROVED CAPITAL PROJECT )/ AFE NUMBER PROJECT DESCRIPTION STATUS A8SB D818 A5i9 A649 A909 C919 0619 tm D749 D789 0049 0859 0899 F379 FMf F699 F7J9 F779 6369 0639 6719 6759 6819 6639 H679 H729 H769 H799 H829 H879 A540 S 6360 s H300 H310 H520 L330 ALTERNATE NATURAL BAS PIPELINE VINYL VALVE UP6RADE PLANT ELECTRICAL UPfiRAOE VINYL CONTROL SYSTEM HODERNUATION INERTS REMOVAL MODIFICATIONS NEH MATER NELL PROPANE 8T0RA6E AREA DELUBE SYSTEM COMPOUND REBLEKO TRANSFER SYSTEM LEAD HMDLINB AMO EXPOSURE REDUCTION INERT 6AS PUR6IN6 OF PA TANKS COMPOUND LINE 3 KN!*8ULK LEAD HANDL1N6 COMPOUND SILO IRIOBE IREAKINS RAILCAR CLEAN!N8 RACK COMPOUND BOTINS HOPPER HA6NET8 COMPOUND LINE 3 HEATED PLA8TICI2ER LON MOLECULAR NEI8HT RESIN E1PARBIQN DRYER NO.8 CONTAMINATION REDUCTION DRYER NO.4 CONTAMINATION REDUCTION DRYBLENO 01V.VALVE ANI CHUTE REPLACEMENT NEB DRYER BABHOUBES COT*iO SEVER REVISIONS Ml OIL REDUCTION VCN 6I8HT BLASS REH.ACEHENT PLAHT HATER RECYCLE PLASTICIZER REACTOR A8ITAT0AB TDRSUE RHEOMETER REPLACEMENT PLANT OIVERTER VALVE REPLACEMENT H1BHNAV 23 LAND PURCHASE RECOVERY SYSTEM COMPRESSOR - SPARE ROOF UPBRADE REDUCED FLAME k SMOKE COMPOUND PROJECT TC SPILL CONTAINMENT PLANT HATER SYSTEM VEST INCINERATOR REPLACEMENT MISCELLANEOUS CAPITAL PROJECTS < DISH FURNITURE AND OFFICE E0U1PHENT . THE SYSTEM HAS SEEN 8TARTE0 UP AND IS OPERATIONAL. PUNCHLIST ITEMS ARE IN PRQ6RES6. INSTALLATION IS IN PR0BRES8 AND PLANNED FOR COMPLETION IN AUGUST. CONSTRUCTION 18 951 COMPLETE AND IN PR06RES8. PROJECT COMPLETION IS PLANNED FOR !?. EN6INEERIN8 IS IN PR0SREB8, CONTROL ROOM CONSTRUCTION IS IN PRDBRE88 NITH COMPLETION ftWSNEI m SEFTEflKS. CONSTRUCTION IB IN PROBRESS NITH COMPLETION SCHEDULES FOR AUGUST. CONSTRUCTION IB COMPLETE EXCEPT FOR PUNCHLIST ITEMS. COMPLETION IS PLANNED FOR APRIL. INSTALLATION MILL BE COMPLETED IN RAY. INSTALLATION IS COMPLETE EXCEPT FOR PUNCHLIST ITEMS. INSTALLATION IS IZ PR06RE88 MITH COMPLETION PLANNED FOR JIM. THE PROJECT HILL BE CLOSEO TO FIELD CHAR8CB IN APRIL. LONS LEAD ITEMS HAVE SEEN PLACED ON ORDER. PROJECT COMPLETION IS PLANNED FOR M/TO. LONS LEAD ITEMS HAVE KEN PLACED ON ORDER. COMPLETION IS PLANNED FOR 10/90. mm IS IN PROBRESS. PROJECT COMPLETION IS PLANNED FOR 11/90. THE PROJECT MILL K CLOSED 10 FIELD CHAR6EB IN APRIL. ENBINEERIN6 IS IN PROBRESS. PROJECT COMPLETION IB PLANNED FOR JULY. INSTALLATION IS IN PR08RE8B NITH COMPLETION PLANNED FOR JULY. THE PROJECT MILL IE CLOSED TO FIELD CHAR6E8 IN APRIL. A CHAKBE ORDER HAS SEEN APPROVED FOR MODIFICATIONS TO IS DRYER. DF9IBN IB IN PROBRESS. PROJECT COMPLETION IS PLANNED FOR JULY. MODIFICATIONS TO THE INLET AIR BAFFLES ARE KINS TE8TE0. INSTALLATION IS IN PROGRESS NITH COMPLETION IN JULY. INSTALLATION IS IN PR06RE88 NITK COMPLETION PLANNED FOR APRIL. QESI6N U tN PROBRESS. PROJECT COMPLETION IS PLANNED FOR JULY. DEB16N IS IN PROBRESS. PROJECT COMPLETION II PLANNED FOR OCTOKR. THE PROJECT MILL K CLOSED TO FIELD PARKS IN APRIL. THE PROJECT HILL K CLuBEO TO FIELD CHAR8ES IN APRIL. INSTALLATION IS COMPLETE EXCEPT FOR PUNCHLIST ITEMS. NESOT1ATION8 ARE UNKRHAY. THE PROJECT MILL K CLOSED TO FIELD CHARGES IN APRIL. THE PROJECT NHL K CLOSEO TO FIELD CHARK8 IN APRIL. INSTALLATION OF THE BANBURY ROTOR C0QLIN8 P1PIN6 IS PLANNED FOR 5/1. 0ES1BN IS IN PROBRESS ON V-ll DRYER AREA ITEMS. ENS1NEERINS IB IN PROBRESS. PROJECT COMPLETION 18 PLANNED FOR NIO-I99I. ENBINEERINB 18 IN PR06REBB. SPECS HAVE KEN ISSUED TO T-THERHR PPR RIVIEN. ENGINEERING IB IN PROBRESS ON 25 PROJECTS. EQUIPMENT IS KINS QUOTED. s t9 0 0 0 0 0 ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were met for the month of March. Bioassay testing was also completed on our wastewater outfall. No toxicity was found in this test. The Mississippi Department of Environmental Quality (MDEQ) was in the plant during the month to collect samples from our wastewater and storm water outfalls. Results should he issued next month. Samples from the EPA were received for the annual lab performance eval uation. Results from the lab analysis of the samples will be sent to EPA next month. A baffle was installed in the biodisc to help increase this unit's efficiency to remove wastewater contaminants. Wastewater parameters will be evaluated in the coming month to determine if this baffle has made a significant difference In the blodlsc operation. The blodisc consists of three rotating biological contractors which are highly aerated and remove a large part of the wastewater contaminants. 7 Waste ' : - - .. J" ' - i Waste shipments for the month included: v. - Two bulk loads of separator oil to Systech in Demopolis, AL. - One bulk load of lead bags to CWM in Emelle, AL. - One bulk load of API sludge to CWM in Emelle, AL. One drum of phthalic anhydride spill to CWM in Lake Charles, LA. Sludge from pond #3 of our wastewater treatment system was sampled and analyzed for toxicity using the new toxicity characteristic leaching procedure. No toxicity was found in the samples using this test. Air The MDEQ did not review the air permit application that we submitted to become a minor source. Instead, they decided to take a different approach. They wanted us to change our air permit application to a con struction permit application for the VCSM project. When this was con sidered by their permit board, we would get both an operating permit with minor source status and a construction per: it for the VCSM project. The construction permit application, since it calls for an increase of emissions of a toxic air pollutant, will have to go through a thirty-day public notice period. The public notice will be issued in April and we expect the new permits in May. 0006352 Continued Air - continued The new operating air permit v:.ll have limits on all of our pollutants. In previous permits, the boilers and particulates were the only things listed. The new permit will include limits on vinyl chloride, plasticizer, alcohol, VOC's on the dryers and incinerators, and all combustion pollutants. A NESHAP authorization for the VCSM project was also submitted to the MDEQ. This authorization is necessary since we are modifying our plant and increasing the potential for vinyl chloride emissions. Superfund Interviews were conducted with employees and contractors to determine what was buried on site. A file search was conducted to find any additional items of information on the sites, geo-technical information or ground--r water monitoring results. A second meeting was scheduled with Conoco for April. During this meeting, we will also meet with a contractor who is interested in re claiming the resin in old pond #2 for recycle. Miscellaneous A notice was published in the paper for the Coker water wells. publication was sent to the MDEQ. Proof of .r I attended a meeting of industry and State MDEQ representatives during the month. We discussed the State air toxics program. CCR 000006353 - B. L. Trego June Fiscal Y.T.D. 1990 Fiscal Y.T.D. 1989 First Aid OSHA Recordable Total Injuries 0 13 12 ) 4 6 0 17 18 Number of Restricted Workday Cases 0 3 2 Number of Lost Workday Cases 0 0 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 00 05 0 10 01 00 0a 0 17 2 4 10 1 0 -1 18 Injuries bv Type Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains Stings Other Totals 0 01 03 02 01 02 (J _Z 0 17 3 0 6 4 3 0 _2 18 Non-Occuoational Injuries Lost Workday Cases Days Lost 06 14 133 2 42 Safety Record Last lost time injury - 7/5/79 Days since - 4013 Employee hours since - 5,340,396 On June 30, 1990, the employees of the Aberdeen plant completed 4013 days with no lost time injury. The major topics for June safety meetings were CPR and Respirator Training. CCR 000006374 SAFETY - Continued David C. Sheffield of International Loss Control Institute, conducted a plant-wide safety audit during the week of June 25, 1990. A. report of the findings is expected from ILCI during July. Routine dosimetry results for the month were: VCM Lead Total Particulates < PEL Number Percent 77 98.72 18 94.74 7 100.0 > PEL Number Percent 1 1.28 1 5.26 0 0.0 Both overexposures were benefit of respiratory protection Monthly Injury Summary Inlurv Class Department ho injuries reported during June. Description 00000fc375 OCR NUMBER OF MJURIES J-ST8* MAMJJASON QI'OBF MAMJJASON QJ'OSF MAMJJASON QJ-9CF M A U J TOTAL INJURIES O QSHA RECORDABLE CCR 000006376 QUALITY MANAGEMENT PROCESS - T. J. Arbeiter Q3FY90 Natural Team scores are in! The Aberdeen Plant team activity resulted in an average score of 7.3 points, up 46% from the previous quarter. Our Natural Teams and facilitators deserve great credit for the accomplishment. These "points" represent a lot of good work done by our teams. The Vinyl "B" Shift Natural Team made a presentation to management on June 20th. The team recommended changes to sparger design aimed at benefiting the environment, improving safety and the quality of our products, and reducing energy consumption. The Aberdeen Q-Scorecard score as of June 1st is 10.3. Our progress by line item is as follows: Item 1990 Card Submission 1991 Card Submission Average Natural Team Score Safety Cost Control Quality Waste Minimization Linkage Score 10 10* 10 12 12 10* 13 4 * Assumed CCR 000006377 COST VARIANCES - D. C. Skokna Variable Costs Product PVC Flexible Compound Rigid Compound Plasticizer June, 1990 Varfance. $M______ Efficientix msa Total $74.0 38.9 11.3 ( 83.5) $ 40.7 ($65.5) ( 21.4) ( 1.6) 44.4 ($ 44.1) $ 8.5 17.5 9.7 n9.n $( 3.4) PVC - $74.OM favorable. VCM consumption was below budget:, and product mix was favorable. Offgrade production was 70% below budgeted levels. Flexible Compound - $38.9M favorable. Raw material use was slightly above budget ($20.1H), product mix was $49.3M favorable, and variance due to offgrade was $10.6M favorable. Millscrap production was 62% below budget. Rigid Compound - $11.3M favorable. Operation was essentiallv at budget. Plasticizer - $83.5M unfavorable. Raw material use was significantly above budget. Investigation indicates that a switch to soda ash neutralization (done to reduce the amount of BOD going to the wastewater system) may be the cause of this month's and recent month's inefficiencies. To evaluate further, use of caustic has been resumed. Price Variances - $44.1M unfavorable ____SM . - Alfol 610*Alcohols - 610P to Flexible Compound - VCM - AllOther PricesVariances Total $ 31.9 28.9 ( 68.9) ( 36.0") ($ 44.1) Fixed Cost Variances - $12.0M unfavorable - Payroll and Benefits - MM&C - Miscellaneous - TI&D - Clearances _Sil Total $ 24.2 42.5 62.5 < 137.2) ( 4.0) ($ 12.0) CC* 00637e COST VARIANCES - Continued Payroll and Benefits - Payroll was essentially at budget while benefits clearances were $179M favorable, M. M. & C. - Activity was below budgeted levels. Miscellaneous - Most items in this group were favorable; the most favorable item was "packaging supplies" - $26.2M favorable. T.I. & D. - An unexpected city tax clearance caused this category to be significantly unfavorable. We are trying to determine why this happened. o00006*19 ccfc