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R. T. Ferrell h Interoffice Communication From: Date: Subject: J. W. Ware May 15, 1987 ABERDEEN MONTHLY PROGRESS REPORT APRIL, 1987 One OSHA recordable and two first aid cases were recorded during the month of April. As of April 30, 1987, the plant had operated 2,854 days or 3,676,708 manhours without a lost time injury. PVC resin production for April was 34.8MM pounds. Mechanical downtime in the reactor areas was due primarily to drilling of condensers on 744 and 745, nozzle repairs on 300 condenser and new module Modicon software revisions. Resin production year-to-date totaled 246.8MM pounds. The VCM efficiency for April was 0.99630 pounds of VCM per pound of PVC produced versus a 1.00208 standard. Year-to-date VCM efficiency is 1.00926. Compound production for April was 7.3MM pounds. Line I and Line III operated thirty days and Line V operated sixteen days during the month. Production was limited primarily by product changes, quality problems and Line III mill maintenance. Year-to-date compound production was 50.0MM pounds. Quality performance for flexible compounds was 1.56% off-grade of which 72.5% was due to mill scrap. "BC" production was 3.6%, Dry blend production was 4.2MM pounds for April and 31.3MM pounds fiscal year-to-date. Production was limited primarily by product changes, quality control problems and an outage taken to install the master batch bulk resin weigh system. Quality performance for the month was 99.3% customer grade. The plasticizer unit operated thirty days in April to produce 1.9MM pounds. Year-to-date plasticizer production is 13.2MM pounds. A three-day training course for department heads and supervisors was conducted on team leader training during April. In addition, a four-day course on statistical design of experiments was conducted for department heads, engineers and supervisors. Two new involvement teams were formed: one in compound to work on product changes and one in the yard department to address problems which our customers have with railcars. Total energy consumption for April was 115.097 MMM BTUs. The energy consumption per pound of product was 2388 BTUs, resulting in an adjusted CMA reduction of 53.6%. The adjusted CMA reduction for fiscal 1987 year-to-date is 53.9%. + I p 'I r .l-.hnnwikHVi-pi-A- HIP .wfrpwiiI+ I-- - ..----------------------------- i iii m pnfiT~r~n ^ TT-rrfu^i-------r nrripr-nta--mhit--1r tip i n Tr 1111111111 i iiiniir-n girir-m h VAB.0001191378 h- ->.|>4 h1- l- r-.n.' ef'dnirmtn^vanTTKHiu-A-ruaP'Jii1 u ^lm nr ~ M,l~l fi i|i^ntm>T*-^<irp*ni n^iiri - rm T i ; .-.`j:-* i,i- >' Hf-H. r- f-hj-ti .1<TrB.-d,r. ' : J .D4I-0 R. T. Ferrell 05/15/87 Aberdeen Monthly Progress Report The total plant variable cost variance for April was $382.0M unfavorable, resulting from an overall unfavorable price variance of $416.7M and a net favorable efficiency variance of $34.7M. The total fixed cost variance for April was $65.5M favorable. J lOlObA Am.mm J. W. Ware rah VAB.0001191379 vrKrt:"' **+! v nrvt-*'"jji. .Ufci _ .. ..............................K f- 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 - R. R. SMITH - 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 - R. W. SEYMOUR (COVER LETTER AND SAFETY PORTION) (COVER LETTER AND SAFETY PORTION) - J. B. MAHER (SAFETY PORTION ONLY) - JF, JWW, DWH, PJK, TFL, RAF, KLF, RAM, VEM, HGC, CWT, REP, VLT, JEL, JGC, RBN KV" |H--! . i:--T' `frur- > -Hi | -h .vi4.i- I'ii-'-.V. i i . ;Tt L;: ! 1'iH- :> it- ihiH]*I* l|-fflJlP^UiUJ u it - ) VAB.0001191380 :ifc iJ-b- -r* r .................. P- |J- V- - 4- SAFETY - K. L. Fogg, J. V. Uptain Occupational Injuries First Aid OSHA Recordable Total Injuries Number of Restricted Workday Number of Lost Workday Cases Fiscal Y.T.D. 1987 Fiscal Y.T.D 1986 26 1 _6 3 12 8 _6 14 02 00 2 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Re ceiving/Warehouse Office Totals 12 01 16 01 12 0 J) 3 12 3 2 6 0 0 3 14 Injuries by Type Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains Stings Other Totals 16 02 00 11 13 00 00 3 12 4 1 3 0 3 0 3 14 Non-Occupational Injuries Lost Workday Cases Days Lost 02 0 11 6 61 Safety Record Last lost time injury 7/5/79 Days since - 2,854 Manhours since - 3,676,708 On April 30, 1987, the employees of the Aberdeen plant completed 2,854 days with no lost time injury. One medical treatment case was reported in April: suffered by a warehouse worker during March was recordable after medical treatment became necessary. An ankle sprain OSHA I'lir- ir-iT'ir-|v -.11 -m- -r K S**. 'wiln .............. -=1 VAB.0001191381 hr-.- i . J.. . 4 I:: :t*i tv 'Ji h |*-u SAFETY - Continued Topics for the plant safety meetings during the month included: Annual First Aid Training, Reviews of Recent Injuries, Nitrogen Handling Safety and Maintenance Weekly Safety and Job Reviews (Lockout Procedures, Use of Personal Protective Equipment and Housekeeping). Keith Fogg attended a meeting of the Environmental Sub-committee of the Mississippi Manufacturer's Association to discuss the new SUPERFUND legislation. The May 17 notification under the SUPERFUND bill was completed as required. Health activity for the month included annual, VCM hands-on physicals and routine dosimetry (shown below): Chemical Z Number PEL Percent > Number PEL Percent VCM Lead Total Particulates 75 19 6 96.2 90.5 100.0 3 3.8 2 9.5 0 0.0 All of the overexposures occurred with benefit of respiratory protection. A VAB.0001191382 -i i iii iiit~ n umiiBn w^niiii| nm i n i i t' |-ls?fr*f. il vi'nl 'tn-tjrnLTur.- .y + jyn*................UP|-. . .<!! -I- ( - n I "P<1 l 4 N 4 NUMBER OF INJURIES TOTAL INJURIES ABERDEEN CHEMICAL PLANT INJURIES + OSHA RECORDABLE nm ' II r<h(" 'ffl 'll Hf+tHi! i^yj a : ip j `jr d|rf* . |j (; - m - - -M mj--------1_|-------i-------|_|J_ . AUI.IJJ -1-1--I J. ------ i i iMBfirmitT^umri i * TM }. ,-H -i-i j I ID* 'IP| VAB.0001191383 - E =--reEait.ilUHfrfttfMUgm?-T-I!KAtWIq^fttM^i KMHlTfffiBafcKW :< ^nniMtPH A QUALITY IMPROVEMENT PROCESS - R. B. Newton 0 Plant management and some supervisors attended a three-day course In Team Leader training. This class is being modified for use by the plant in training current and future team leaders. Department heads, engineers and supervisors attended a four-day Statistical Design of Experiments class taught by Bill McNeese. A new team was organized in the Vinyl (Yard) Department to address problems that customers have with railcars. The Compound Department is in the process of organizing a team to look at ways to reduce compound line downtime caused by product changes. There are currently about twenty-five process variables being charted plant wide. J pppri T rH'-V L- I. : i :b'. ' .p;|--,pfc| p jj " i- H .Jf+' rr iv.rifirf u|h : VAB.0001191384 i r,v-| i J-J. ,pg'i.1 11--^ Si..iiN-q-n ny-h-j-.m-h,--. VINYL - D. W Hollis, J M. Edwards A The Vinyl and Yard Departments had one accident which resulted in a bruised lip (first aid). Shift safety meeting topics for the month were CPR training, a film on hypertension, a review of recent accidents and some thoughts on safety awareness. Production April 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 34.8 1161 907 30.2 92.7 9143 66.1 30 246.8 1164 6253 29.5 91.3 10141 60.1 212 Reactors f The reactor stream factor for April was 92.7%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 44.9% 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 0-ring failures and downtime associated with test runs and reactor Inspections. 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 55.1% of the total downtime and was due to drilling 744 and 745 reactor condensers, changing the Lenape lid on D400, repairing the recovery nozzle on D300 condenser, software addition to new module Modicon and rebuilding the Polyvic valve on reactor 745. Dryers The dryer stream factor for April was 66.1%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 88.3% of the total downtime. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 3.3% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems. *++': - ^31 H, -I M->- T ' .WT' I'-Ti J-|l|if-r T^ink 1 * Ml. 11- q ,if.i Mr* 'WN |l' --- Sr ^ 1*CTW VAB.0001191385 VINYL - Continued Dryers - Continued 3) Maintenance Repair/Revision Downtime: Accounted for 8.4% of the total downtime and was due to changing out #4 and #6 centrifuges, #8 centrifuge sparge pipe and major repairs with improvements to #6 dryer. Product Quality Summary Resin Type Prime "B" "H" % of Total Production 5265 5305 5385 5415 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 3,119,716 2,593,708 15,858,751 10,301,625 1,349,530 -- -- 33,223,330 -- -- -- -- 944,720 169,420 -- 355,260 1,469,400 ** -- -- -- -- -- -- 133,201 -- 133,201 8.9 7.5 45.5 29.6 3.9 2.7 0.5 0.4 1.0 100.0 Quality performance for April was 99.6% customer grade with 0.4% "H" grade production. A total of seven railcars were shipped as "B" grade during the month which represented 6.8% of the 102 total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 03/25/87 04/08/87 PLWX 44722 Pacific Plast., CA Debox Quality 04/06/86 04/15/87 PLWX 44279 Gamma, CA 09/25/86 04/15/87 ACFX 52553 Klockner, VA Pond Resin 5305 Quality Quality 04/02/87 04/13/87 04/22/87 PTLX 41645 04/22/87 VIPX 45810 Wexford, CA Wexford, CA Debox Pond Resin Quality Quality 04/21/87 04/28/87 PLCX 43854 Silverline, NC 5385 Contamination 04/16/87 04/29/87 PLCX 43730 Vulcan Plast., AL Debox Quality The Vinyl area received thirty-three short lead time emergency type orders comprising 13.5% of the 244 Aberdeen resin shipments in April. A .................... *1- h- Jp- ' *... X . I p- H *+rPW*9**I'HWiflto 1C-||.. :I-V. : It . I. ip v'fcifr -.' .H rRT-rt.:-' I- j-, - "! < VAB.0001191386 .U ^rr'.^ki^.i ............ uli L T. ;t. : j-|,r ; .T-|fc'Qi ' . 1 1..'. i-f 1 . I- -1 4 VINYL - Continued Monthly Variable Cost Performance Variable costs for the month were unfavorable at $473.2M resulting from an overall unfavorable price variance of $456.2M and an unfavorable efficiency variance of $17.OM. Resin variable cost for the month was 19.758 cents/lb. versus the budgeted 18.334 cents/lb. The $456.2M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $607.2M, offset by favorable freight pricing of $105.8M and favorable natural gas pricing of $21.1M. The $17.OM unfavorable efficiency variance can be attributed mainly to the unfavorable efficiency variance of Initiator 939, $10.4M; and Alcotex, $10.3M, offset by a favorable VCM efficiency variance of $31.OM. VCM efficiency for the month was 0.9963 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. YTD variable cost efficiency variances in the Vinyl Department totaled $339.2M unfavorable. Energy Performance/Progress 1. Plant energy performance for April was 2388 BTU/lb. General 1. Resin raw material in the 0744 account totaled $247.9M. - ,|: li-f i1 I,.. .. 1-1- .!IA .1*^1 "L 1 1 fcT J 11 L IF i ^i-'f hi i i M milii i Mil pb<I ipiii phi -** VAB.0001191387 ' |nr* -.lift iris 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 30 2484 83 16 825 52 30 4011 134 7319 16785 5790 27436 50011 Line I operated thirty days in April at an average rate of 83M pounds per day. Major items affecting production efficiency were: product changes, 87 hours; dicer system problems and maintenance, 13 hours; housekeeping, 12 hours; quality problems and testing, 10 hours; running transfer line cleanout to remove streamers, 5 hours; and maintenance to the weigh computer, 4 hours. Line V operated sixteen days during April at an average rate of 52M pounds per day. Major items affecting production efficiency were: product changes and startup time, 22 hours; quality problems (primarily testing and reworking compound with high hard particle count), 37 hours; and downtime due to elevator maintenance, 3 hours. Line III operated thirty days during April at an average rate of 134M pounds per day. Major items affecting production were: product changes, 45 hours; mill and hydrotherm system maintenance, 16 hours; quality problems (primarily due to hard particles), 13 hours; and dicer systems problems and maintenance, 9 hours. Quality performance for flexible compounds was 1.56% off-grade of which 72.5% was due to mill scrap. ''BC" production was 3.6%. The raw material requirement for flexible compounds was .99682 pounds of raw material per pound of compound versus a 1.01066 standard (YTD is 1.00828). The variable cost variance for compound was $19.2M favorable with $8.3M favorable due to price and $10.9M favorable due to efficiency, efficiency variance due to product mix was $13.2M unfavorable, The The efficiency variance for DIDP was $32.0M favorable primarily due to correction of an accounting error which left last month unfavorable. The TOTM efficiency variance was $24.4M unfavorable. Most of this variance was also due to correction of an accounting error from the previous month. Total compound inventory fell .5MM pounds in April to 7.5MM pounds. Dry Blend Production, M Pounds Operating Days Month 4202 29 Average Operating-Day Rate 145 Fiscal Y.T.D. 31335 213 A UJUKrFV--"IT-I >>iii uw I M< f1 m In . mJ i 6 r 111 VAB.0001191388 Ti----rrr "I" ~ "Til r H' A COMPOUND - Continued <r Dry Blend - continued Dry blend operated twenty-nine days during April at an average rate of 145M pounds per day. Production included 80172C, 80273G, 90172D, RP-421, 186-139, 186-180, RP-203, 269-69, 269-113, RP-100, 269-148, 269-145, 269-185, 269-151 and 269-169. Dry Blend production was hindered by: product changes, 58 hours; delays associated with quality and lab problems and normal Q.C., 29 hours; transfer system problems and maintenance, 27 hours; Orbitran weigh computer problems and maintenance, 12 hours; and Welex maintenance, 8 hours. The dry blend unit was down for forty hours for scheduled Installation of the master batch bulk resin weigh system. Quality performance for the month of April was 99.3% customer grade. The raw material requirement for dry blend was 1.01909 pounds of raw . ).material per pound of dry blend versus a standard of 1.00488 (YTD is 1 01110 The variable cost variance for dry blend was $33.3M favorable with $13.8M favorable due to price and $19.5M favorable due to efficiency. The efficiency variance due to product mix was $39.1M favorable. There were no major dry blend raw material efficiency variances. Plasticizer Month Average Operating-Day Rate Fisca Y.T.D Production, M Pounds Operating Days 1872 62 13238 30 -- 214 Plasticizer operated thirty days during April at an average rate of 62M pounds per day. Production included 61OP and 108P. VRP production totaled 152M pounds (8.1%). The raw material requirement for plasticizer was 1.09072 pounds of raw materials per pound of plasticizer versus a 1.09877 standard (Y.T.D. is 1.10403). The variable cost variance for plasticizer was $38.8M favorable with $17.5M favorable due to price and $21.3M favorable due to efficiency. There were no major plasticizer raw material efficiency variances. The efficiency variance due to product mix was $2.9M favorable. Quality Improvement Key personnel, including the operations superintendent, operations supervisor, operations engineer and one shift supervisor, attended the three-day team/leader training held in Aberdeen. A problem solving team led by the trained shift supervisor will be formed soon. Charting of process variables or product characteristics measured in the lab continues on all lines. VAB.0001191389 |; j j |.l 11-7! : ' r.: 11 ..-,k k-iin-dV 4. ,1^11^1; *r Wianll -m-Jft jjof H`: ** *>S**T"* I.BU-il.l'ltM' H tt'T COMPOUND Continued Compound Dry Blend Plasticizer Usage (BTU/Lb.) Actual Standard 1755.4 747.0 1673.5 1783.0 730.0 1833.5 A i p. ii.-- % . - ii > kr `Tjn----- it-= VAB.0001191390 nf-ir^|ii^Sftt in' ' III i Ti il ]' jfc. ||U|itei<W>jmJ |<11 f nliTTi FTPS PTI1I1 .f-w^pav^ *,1b\ MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - G. A. Morgan, D. A. Miller There was one first aid injury to a General Mechanic during the month. The mechanic received minor bruises and contusions after falling over the trailer tongue of a solids transfer system. Vinyl One reactor agitator seal failed during the month. The D743 seal was changed due to an external leak. The seal had been in service only three days. An inspection revealed a burnt rotating face. There was no apparent reason for the failure. There have been nine seal failures fiscal year-to-date. The 743 reactor agitator gearbox was removed from service and inspected during the month. The low speed helical gear set shows signs of accelerated wear. Action steps to develop a plan for corrective action are in progress. The D743 condenser to reactor gasket failed during the month. A new gasket was installed. Both D745 and D744 condensers were drilled and brushed. Cracks in the D745 jacket were repaired. Eight major reactor valves were replaced during the month. The recovery nozzle on D300 condenser cracked at the shell weld during the month. An inspection indicated that the crack was probably a low cycle fatigue failure. The reactor was safely recovered and the nozzle was repaired. The D400 Lenape manway was replaced. The defective manway was sent out to be reconditioned. Mechanical seals were replaced in 703 vacuum pump, 903 vacuum pump and "Bn compressor. The old module west slurry transfer pump was overhauled. Dryers Numbers 4, 6 and 8 centrifuges were overhauled during the month. All three required new trunnion shafts and bushings. Number 6 had a failed thrust bearing. A rebuilt 15 unit was received from Bird during the month. A 9 single flight centrifuge scroll was hard surfaced to serve as a for the resin reclaim dryer. A Til - P** . i ,, VhTl'.+i- rn **" I--fr <1^ --c . , m' VAB.0001191391 -i :-1*1* 'T.f <mr- .. !> ^ : i rr.n j**.. MECHANICAL DEPARTMENT - Continued Dryers - Continued Number 6 centrifuge effluent boot was replaced. Number 6 dryer burner was replaced and internal modifications were completed to reduce the potential for contamination Numbers 1 and 2 dryer inlet ductwork was removed due to severe deterioration from corrosion. Replacement of number 1 dryer ductwork is in progress and will be complete in early May. The spare rotary dryer exhaust fan was overhauled. Compound, Dry Blend, Plasticizer The Line III Zone I hydrotherm pump was overhauled. Two scissor lift tables were assembled and delivered to the Compound Department The Line V Welex blades and seals were replaced. A spare Welex bowl and blades were sent out for lining and coating repairs. q Electrical repairs were made to both Line I and Line III elevators. A spare process controller was installed in the dry blend Orbitran. A new positioner was installed on the Line III FCM orifice gate. Utilities Number 2 air compressor was overhauled. The piston, rings and valves were replaced. A test run was conducted by Betz and plant personnel to determine the performance of several neutralizing amines in the plant steam system. Results of the testing will be available in late May. Rotating equipment alignment training was attended by all mechanics. A VAB.0001191392 T *'Lk'"' '1 '`r i-k-t.ry- ' 1 -k ' Ijpi'1 s-t--hnrii.INI Ktigjiip-si CAPITAL PROJECT STATUS - R. E. Polk AFE A5L2 - Plasticizer Modernization Phase I Installation of additional cleanout nozzles has been completed. Materials to tie-in the south PA tank are on order and due by 5/29. Installation is scheduled for completion by 6/12. The project will be closed to field charges in June. AFE C566 - Master Batch Bulk Resin Handling Installation of new weigh bin was completed the week of 4/20 and the system is operational. Safety audit and punchlist items will be completed in May. The project will be closed to field charges in June. AFE D606 - Propane Tank Farm Electrical Revisions r Electrical construction is in progress and planned for completion by 6/1. AFE D756 - Reactor Jacket Expansion Joints The three small joints for reactors 742, 743 and 744 have been received. Joints for 700 and 745 are due by 6/1. Installation of the joints will begin in June with completion In October based on reactor availability. AFE F786 - Resin Quality Improvement - Permanent Rigid Construction for Phases I and II is in progress and scheduled for completion by 7/1. A P&ID review for Phase III was held in Houston with attendance by GED, PED, Litwin and the plant. Control panel options for the vinyl control room and the S.A. building are being evaluated. A selection will be made in May. CONTRACTS - C. A. Clark A total of two construction contracts, twenty-five general service contracts and twenty register tickets were issued during the month of April. A f> 1 v+ -v-^--I-H -I I , IjKjl iTV^-fr .! ^ -ft VAB.0001191393 fflfi m\nw\wm*iff ~J`-1 i*iv<*--.1-.r:-;-*-. r t- PROCESS ENGINEERING - V. E. Messick Resin Quality Improvement Project A. Flexible Resin Technology - Software changes on the Modicon were completed to allow Alcotex injection in the polymerization mode for reactors 741 through 744* Operating procedures were issued for these changes. Testing established that a larger Alcotex quantity injected during polymerization reduced foaming. To date, those changes have allowed a batch size increase equal to 60% of the original production loss Incurred with implementation of 5415 technology. Testing on larger batch sizes continues. Testing with ALFOL 610 being injected from the bottom of the reactor as an antifoam agent does not appear successful. A report on the Alcotex make-up temperature testing was issued. Recommendations for maintaining a final make-up temperature below the cloud point are being prepared. B. Rigid Resin Permanent Facilities -- Equipment Inquiries for the vessels, pumps and agitators were reviewed. Visits by all the agitator vendors to observe colloid make-up were completed in April. Plant personnel attended a flow sheet review of all Phase III and IV systems. Information is being gathered on tie-in points and existing equipment for Litwln's use. Experimental Design Class J. G. Cole and M. L. Nathan attended a four-day class on experimental design and evolutionary operations. Rigid Calendering Team Activities An experimental design was completed in which twelve batches of 5305 resin were produced for future trial to determine those variables significantly affecting calendering performance. Samples from these twelve batches were shipped to BASF in West Germany and to Ponca City. Plans are to test these samples on BASF's pilot plant. Master Batch Bulk Resin Handling The Master Batch Bulk Resin Handling System was commissioned. Minor punchlist items remain. Preliminary operating procedures were issued and operator training was completed. Line V Operation Consistency A report is being prepared detailing the causes of processing inconsistencies observed on Line V. A list of action steps to address the inconsistencies is also included. Most of the steps have been completed to date. Several options for blender installation on Line V were drawn up for estimation by GED. A ..IT*--- -v . .j.,- :'i! 7 i-ct i* ' *(**:--fist-att: `it--: - swi-miip-i VAB.0001191394 n. : p:***. ;hMrrUfti -a:j* :;u sx-wn- v * ii.1 i>iicr*j*.n. r A PROCESS ENGINEERING - Continued Process Water Header Distribution System A study was conducted on the process water system during the month to determine the best method of operation with the recent installation of the backflow prevention project. The conclusion of the study was that all four water well pumps must be operational in order to minimize city water usage. The system is being evaluated to determine methods to reduce the large fluctuations in pressure due to reactor charging and rinsing. Pond Resin Residual VCM (RVCM) Removal An experimental design was formulated to determine which factors significantly affect RVCM removal from pond resin. This design is part of the overall TCLP study to reduce VCM levels in our products and wastes to levels that will make these materials non-hazardous. Recovery System Seal Water Filter Stud A report was written during the month outlining process and filter media changes to the seal water filter systems in the plant's three recovery systems. These changes are required in order to reduce the RVCM content of the filters to a level which will make these items non-hazardous by TCLP, RQIP Environmental Team A sampling plan was initiated during the month to gather operating data for each pond in the plant's wastewater system. The data will be used to formulate a mathematical model to simulate the wastewater systems performance with increased organic loading due to RQIP. Dry Calcium Stearate Addition Project The plant worked with R&D in pursuing customer trials for resins produced with dry calcium stearate as the antistat. R&D will work with Marketing in setting up trials for customer evaluation. An investigation was made into discrepancies of calculated calcium stearate concentrations during testing and values measured by R&D. It was discovered that the bulk density of the calcium stearate varies and causes changes in flow through the screw feeder. The bulk density difference explained the calculated versus measured j *-''ll 'I--. 'i'Tii. n.-Kwinei ivireiitMMf `t: T VAB.0001191395 r................................................................................................ -kip !M r.^qiT. I j >141 I,-:I PERSONNEL - R. A. Miller EMPLOYMENT None PROMOTIONS/TRANSFERS None RETIREMENTS None TERMINATIONS None TO/FROM LEAVE OF ABSENCE None A W*'-U* Jinn "'H I'-T 11" ::il. ItK-:- ' l|l~nfrft ~l I I|IPI I I pj| H l| |l |l <1 'ij I- >-N I--". ! 7 t J. .JT-Bl-1- l-Ui-J I- .1 l3_-rT--BJ-aV^ + t Ijfcfrf! |lfi *| :..! i> ( Tr.'.'^r H :H : V VAB.0001191396 : '-`PMfJi.I.lll'tJM.hi . t.Hk ~*..rE[- 11: u |- `l i-fi1- I: :-| r Jl Aberdeen, Mississippi A Salaried Employees 74** APRIL MONTHLY PERSONNEL REPORT Minority Employees # 0o Hourly Employees Salaried 8 11% Total Employees 242 Hourly 65 ii% Employees (Hourly) Total 73 30% New Employees Terminations 0 0 Hourly Min. Hired % Min. Hired Hourly Min Term. % Min. Term. 0 Q. Q. 0 DEPARTMENTS Warehouse PAR # EMPLOYEES MIN. EHP. 14 16 7 % MIN. 44 NEW HIRES * 0 YTD 0 TERM YTD TURNOVER 0 YTD 0 Gen. Plant Maintenance Laboratory Compound Vinyl 16 39 22 33 32 13 ____ 6_____ ..4j_ 0 70 a & __G 0 n 5 Q_ 0 0 Q. 4Q 23 m __0 0 Q. Q. 32 1 28 0 0 8 0 a a a a Plasticizer 4 5 2 40 0 0 0 ao Number of Applicants: Month IQ Year to Date 17 APPLICANT BREAKDOWN: # Minority ^ % Minority _10 * Female __ 0 % Female 0 Hires (Hourly) : Month Q m Year to Date _____ 7 Terminations (Hourly) : Month 0______ Year to Date _____ 2 Overall Turnover 0 Projected Annual Turnover 3.6% * Includes 1 temporary employee and one Co-op Engineer. *'" ' I1-1*- l.L'= -''J "1 .;ir ------- Ll- Tf1-^ -| 1.J .hLT ;ip:-n J'-'i- : -- VAB.0001191397 -1 l " 1 tflf !: fllTlH- Ji'UbLltb A 4 > / * -ri D-l 'T'MInT .Klj. VAB.0001191398 H* 1 ENERGY CONSERVATION - F. G. Jeanson I. Plant Operations Total energy consumption for April was 115*097 MMM BTUs. Energy consumption decreased to 2388 BTU/lb. from 2434 BTU/lb. in March. An adjusted CMA reduction of 53.6% was obtained for the month. The adjusted CMA reduction for fiscal 1987 is 53.9%. II. Plant Energy Conservation Program Maintenance There were fifteen energy related items completed in April, Thirteen of these items were steam leak repairs. The remaining two were steam trap repairs. III. Boiler Operation Boilers No. 1 No. 2 No. 3 Combustion Efficiency % April, 1987 April, 1986 (1) 83.4 83.2 (1) 83.6 83.5 Note: (1) Boiler number one was not used during the month VAB.0001191399 ''i U .hr: : i . . .. ii-.'fl TPUi-r -r I'MAUkj ilim::-fr if im :vi k m ^n-.iBiHissiHepssitTwmiwn kWuftffr .) h*2"*** w - ^ * 'u i: . " -t#*" - '*r h Month ENERGY CONSERVATION DATA 1987 April Production, MM Lbs. Resin Dry Blend Compound Plasticizer Natural Gas 4 TOTAL 34.8 4.2 7.3 1.9 48.2 Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 56481 1020 57.611 1195 Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 5.7486 10000 57.486 1193 Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 0 92000 0 0 Total Energy Consumption, BTU/lb. 2388 Energy Consumption, MMM BTU Actual Unadjusted Actual Adjusted 1972 Base Period 115.097 95.229 205.221 CMA Reduction (%) Adjusted Unadjusted Fiscal 1987 Year-to-Date Performance 53.9% Adjusted 44.1% Unadjusted 53.6 43.9 1986 April 32.5 4.6 5.2 1.4 43.7 51695 1020 52.729 1207 5.1986 10000 51.986 1190 0 92000 0 0 2397 104.715 83.414 183.792 54.6 43.0 -fiifi*u-ni |.- t-fiiwr- 1 - Lt.'f >- : ftf i. ********* iifil .ccrl- v llNib-: I ; -i m* H-Ul. nv+4+VwiW' i W* --.j ii.ss- -a 1^1 -I -4 VAB.0001191400 itsF^invzi rswilnu ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were within NPDES limits during April. March bioassay results were issued to the State. Our 100% effluent showed a significant amount of mortality. This test will be re-run in April. Waste Management One truckload of reactor culls was shipped to Sun Polymers. Reporting The quarterly progress report for the compliance plan was completed and issued. The EPA laboratory performance evaluation was completed and issued. A letter was written to the State explaining a manifest discrepancy with a shipment of spent solvent. Other Federal and State EPA personnel conducted a compliance plan inspection on April 29 and 30. A ir .ii ri'mu'.-i-M.a' i'-iiivm-- i;!-pei?- X2*7- -TP" irnIP^ :A ? .f*WH ! i^l Wl" I fi VAB.0001191401 n- . . _1 .J.lJAl-. II - LL'i. * ..iV',r^rrs4EfmiAi-' .r ;-ur hiiwinic^i . mi.oumu-.. ^ . vr F- TABLE I % WATER OCMPLIANCE WITH NFDES PEEMTT PARAMETERS Oct. - Ave. Max. Nov. - Ave. Max. 1 Dec. -- Ave. Max. Jan. -* Ave. Max. Feb. -- Ave. Ifex. Mar. -- Ave. Max. Apr. -* Ave. >fex. 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 858 900 903 970 990 1177 BOD FEM LB./D5T. 6 77 10 120 15 183 17 213 23 268 46 373 15 194 20 310 14 142 26 266 11 119 21 217 8 93 10 121 OCX) PEM LB. AW. 26 311 33 404 33 406 42 527 71 846 110 1284 53 662 57 775 42 431 75 766 38 409 50 541 42 505 56 680 Sus. Solids PEM LB. Aw. 14 165 23 281 23 281 37 464 13 179 24 302 18 231 28 434 10 99 13 140 19 206 35 362 33 407 78 986 NPDES Permit Umlts - Decenber 1 through April 30 Ave. Max. 32 431 43 800 - 1462 - 2713 NPDES Permit Limits - May 1 through Nbvenber 30 Ave. Max. - 26 357 40 744 - 1212 - 2523 674 1396 674 1396 - -i jiji ............... ?'!n !! v t ! " T'i'i r*'v v* r'j^ v 'tr.'B ij .1: jk Dlss. oz 7.4 8.0 8.2 9.1 7.6 8.6 9.6 10.3 10.0 10.6 8.8 10.5 9.1 11.0 NEL lb. fm. 2.7 7.3 0.1 0.1 2.0 4.7 2.1 4.6 4.9 9.3 4.0 7.6 2.5 6.1 PH 7.6 8.0 7.6 7.8 7.3 7.8 7.7 7.8 7.7 8.0 7.8 8.3 8.0 8.3 > 6.0 13 6.0 - 9.0 28 > 6.0 13 6.0 - 9.0 28 VAB.0001191402 t+'isn H A. - I.JlIp-'q-hDlWTl-l-ttH- ! 'Tf WWHfti 1! -.L- H 1 * : retail .if LABORATORY - H. G. Coleman/J. R. Williams A Safety A. Safety There were no recordable first aid or medical cases for the month. B. Customer Relations Customer Contacts The following customers visited the plant during customer week (April 6-10). H. G. Coleman gave the standard laboratory presentation and tour: * Uniroyal Chemical Company, Inc. * Diversitech General Southwire Company f Better-Bilt Aluminum Available Plastics, Inc. f * Included a vendor survey by these customers. Poly-Tex Company - B. J. Harrison accompanied R. D. Jackson to this account on 4/15 to investigate continuing problems with 223-204, lot 47C23. A formula correction was made (269-185) to increase the amount of paraffin and colorant and the blue-white specification (WHT 144) was revised. Dayton Extruded Plastics - B. J. Harrison visited this customer with R. D. Jackson on 4/16 where it was learned that we were using the wrong color specification. A new WHT 145 color code has been issued and the colorant level increased. Requests for Corrective Action Date Customer Product Reason 4/06 Donnelly Corporation Holland, MI 48562 Customer received miscuts and streamers in bags of conpound. 4/06 Donnelly Corporation Holland, MI 48562 Customer identified hard particles In conpound produced on Tire V. 4/06 Donnelly Corporation Holland, MI 48562 Returned 1700 lbs. due to Inproper colorant dispersion. 4/07 m Automotive Brownsville, TX 35031 Returned 1700 lbs. of unusable conpound - hard particles on Line V. 4/06 DOIT Manufacturing Deckerville, MI 48562 Inproper dispersion of conpoun made on line V; caused surface appearance problems. VAB.0001191403 wi-y-i ii.:':i>ispr;isi ik I'.- rtf*.-: tin ru ..m, ihm--aii--j-it 1 r-irins f: jH-rnanism-u cf: "T c; i 'f" ' e M J-L--I- LABORATORY - Continued * Customer Problem Reports Date Customer Product Reason 4/03 Dayton Extruded Plastics Springboro, CH 269-12 WHT 142 Elision torque; color not blue enough. 4/03 UTC Automotive Mt. Airy, NC RP-200T WHT 111 Too glossy. 4/03 Columbia Plastics Coluabla, TN 4/oe United Thermal Plastics Philadelphia, PA 5385 269-67 Stones in storage silo. Plate-out; variable bulk density 4/13 Dayton Extruded Plastics Springjboro, OH 269-12 lT 142 Color not blue enough* (Railcar conpartment rejected.) 4/14 Soutlwire Canpany Osceola, AR 4/21 TVitchell Dothan, AL 240-98 * 5415 Spark failures; vfoite powder contamination on screen paks. Rough extrusion due to gels/hard particles. Waivers Issued Customer Product Reason No. Anchor Wire 15041 CB50 1 H/T Colby Plastics 80172C Eq. Torque 1 R/C Nlbco 5305 Static Flow 1 H/T United Technologies 5415 Static Flow 2 H/T C. 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 April, 1987. Reactor __________Drier Slurries52655305 Number of Samples Average ppm, VCM 907 180 42 2.7 50 0.59 A ...........................+ ' M >- 'll :n ,ft -II f.-fi T *' u " *"*' \ .....................iiw -au VAB.0001191404 v-............. H |itth!WMm--*r",'^r:-ff>^iL|L|^nt!0|. : 11' 4S- ->i ffH:: L--f.ur I?- mir1'mms |J.-t Rp-t| jftlt'i-v : H- ' LABORATORY C. Development Lab Sumnary - continued A The foliating Is a sumnary of the residual TCM analysis shipment samples for the month of April, 1987. Product 5265 5305 5385 5415 5465 Debax No. of Saaples 82 73 38 42 Average KVCM, ppm 1.1 0.2 0.3 0 1 7 20 0.1 0.6 42 0.6 D. Resin Process ihhab (Dryer) Saaples 5265 5305 5385 5415 5465 Bulk Density 0.88 0.14 2.44 1.39 3.39 Inherent Viscosity 1.61 0.64 0.56 0.63 0.78 LHt If Color Value Aft A ft Color Value If-Bnf"f Color Value 2.61 0.81 1.22 6.78 4.33 1.50 3.33 -- 3.33 3.25 -- 4.00 7.00 -- 4.33 % on Pan (vs. 2% max.) 2.00 3.67 6.00 3.42 6.50 (0.92) (1.50) % thru 140m Dry time 1.89 1.70 2.04 0.44 2.25 r, 0.83 3.26 2.67 Mets IR (vs. 95% of control) 1.55 1.06 (0.77) (0.63) Hard Particles > 10) 6.5 16.8 5.3 antistat at Hoechst's request. an effort to minimize E. Compound Quality Summary Hardness Color/Clarity Hard Particles Contamination Dispersion Dicing Total Adjustments M Lbs. (%) No Adjustments This Month 0.0 (0.0) Rejections M Lbs. (%) 7.20 29.51 70.13 4.80 1.50 13.05 126.19 (0.10) (0.41) (0.97) (0.07) (0.02) (0.18) (1.74) VAB.0001191405 -i ^i nuf*nHiLi>rrM*ui *&> tr-% ............... ......................................................................................................... +--r-J---F-.s-.r 'I | ip- : MUf-trAi-ilpd-t..' h I LABORATORY F. D Blend Quality Summary Color _______ Rejections M Lbs. (%) 27.11 (0.65) Total 27.11 (0.65) G. Miscellaneous 1. Training - Harold Coleman attended the three-day Team Leadership Training Course April 21-23. Brian Harrison and Dave Cox attended the four-day Experimental Design Course April 28 - May 1; Harold Coleman and Richard Williams received only the one-half day orientation. 2. TCLP Testing - Zero headspace extractors were received and some preliminary precision testing was performed by J. L. Cox of R&D. Receipt of tumbling devices is expected in early May. 3. All quality letters of certification were typed onto a computer disc. Use of the IBM PC will not only make a neater letter, but it will be much quicker and easier to make revisions. Also, we began reporting actual values for I.V. and RVCM on all resin railcar shipments. 4. Design work on Aberdeen1 s new dry blend color lab will begin soon. Brian Harrison is compiling a list of required utility hook-ups and is proceeding with equipment specifications and quotations. 5. RQIP Wastewater Studies - The lab is supporting T. W. Heller's program by running about ten COD measurements per day. A .ni .. _ i -iTf L -|' -I- : rr;*: i = r? - r I I-'! I l-H -.h J nl' M'w--slJ': " - *- VAB.0001191406 k SHIPMENTS BY PRODUCT - M LBS. RESIN PLASTICIZER DRYBLEND COMPOUND TOTAL APRIL 1987 24,350 1,005 4,458 7,985 37,798 FISCAL YEAR-TO-DATE 189,108 5,448 31,918 50,617 277,091 sA \ NUMBER OF SHIPMENTS BY MODE: VISTA TRUCK TRAILER ON COMMON CUSTOMER RAILCAR BULK VAN A FLAT CAR CARRIER PICK-UP CONTAINER TOTAL RESIN-Bulk Package 103 34 3 1 i 90 52 228 11 Export PLAST.-Bulk 4 6 - 1 11 Package DRYBLEND-Bulk Package 23 1 11 4 r 3 2 92 36 18 Export COMPOUND-Bulk Package Export TOTAL APRIL 20 1 2 1 39 150 53 46 * 4 1 23' 46 1 2 44 140 1 23 109 2 438 OCTOBER NOVEMBER DECEMBER JANUARY FEBRUARY MARCH 116 146 133 193 154 181 41 51 64 39 46 29 68 44 50 45 60 56 2 2 1 3 3 52 160 64 135 48 133 89 147 56 143 64 129 3 422 450 390 544 451 493 1!f P . i r^n Ti? 1 r .-drJ.prj i-H* .+!. .. < ><* *3ip;i-.*4.:qfck b-""H gw^r.!!!* W H i+h j4r |H LIf Ltiviih>. kun.i. ijs- |4*i--H^*sfnf1Wrr. * + <i VAB.0001191407 ENERGY USAGE A s SI I -t- Us1?. p Cl 1 Monthly --------- 12-Month Moving Avg .flp-* - rq.'I,-rr> 7 hfT-f-rt t .AiH.-i-.-pf->#artMfl r* VAB.OOOl 191408 ^jc.nwiif.MjnnitPf Hi iUJ| i iliUm Wi ||ii|jrriFftBirrrijitrfliiPP*i|Wi- nttWEffEiiT^i3rr?g*rH .vr.-i-. 1N1P' 'W'T %P ^ rm f| r-w I-. E--iy.rftf*t*hPi|. 71NH <??>! MONTHLY HOURLY TURNOVER A iim. uq- \>>iw o'-rtvTfcjT |: .M....l|ttrj? -h it * p. -it^mlinc1 Kmmti'nw............ .... r. * VAB.0001191409 a .-..r.Lrfi.. *4f Tfri*.! ^ifil-b . - -^h- ^ ' i-'lO^ -Hi. -it asq.~<P,miitTT|pnqpPtL *nfp#rfrrfi=rHi**H- r-i i^iinnLil|t I *+ ABERDEEN PLANT QUALITY PERFORMANCE 10/01/86 - 09/30/87 % OFF-GRADE 1 / I r v 3.0 2.0 1.0 0 Oct. Nov tt t Dec Jan Feb. Mar April May 1^86/07 June July Aug Sept.i Oct. s..-. ...r. jr.rhw- ! rFk*J'i: VAB.OOOl 191410 h-n-N -|r 1 - ..vrl4Wm li A_ll III' k .. -lit** ^ Ti-'^T-: *< ,r ND9H&:--! . llttHS+lfT 1 WHj.IL1 |I U-lUCHKJ MM POUNDS PRIME ABERDEEN PLANT INVENTORIES 10/01/86 - 09/30/87 *& , + --- -! --H------------------------------------- ------------------------------------- 1------------------------------------ -- * ~ I _k l + -- ;;i --------------------- ----------------------------------------- 1> - .- i - ........................... 1 1 1 1 "" 1' 1 t ^ 1 i Oct. Nov. j Dec. i Jan. 1 Feb. Mar. Apr. May June July Aug. Sept, i Oct. i iq 36/87 J . >;. UI ... J*-:- 1-nU I Kfcil i^r i.. i . Il|*:-*_ -4ff-irC ! fiM grjsfc ; 'l:|' VAB.OOOl 191411 11 |AI*J il|l>iMftmba^tifcH||J| |jPPF^iliqHIL4p.'!l-IMT-'+-!r-r ' i n'r ! ml i initHniyHmHi|FlfriPHITiimiHI^Hlin inilf nin--IMH!Pm MM POUNDS MONTHLY ABERDEEN PLANT PRODUCTION ' II l " > I 10/01/86 - 09/30/87 , MM POUNI OWn^T ------------- , 2 20 t----- 1 ----------------------------------------------------------------------------------------1 i T r - + r----^-- : 0i * * -i U| | -- : I1 f F + - - ^ f - }- 111 -- ____ _ --i t - -- ______ \ ----- f i t ' -" 1 t ! r _ _ _ _^_ . Oct. Nov. Dec. Jan. Feb. j i i la f r. Apri 1 May 15 \ j ! j i t 1 J u ne i t . _ --- . July Aug. i 4 * i Sept.;Oct. 10 ' i 51 i f i i 1 ; i n 11 :^F-TT * -*N1i L :-*TSlr"'H-s.. 'ltfrtTiihp**<iHJ*A1 ^*-|* rM-PW--* v1- -------------- Budget - - - - Actual Cumulative 'rAL-^*r` VAB.OOOl 191412 I! "WmilhftWliriiil f Pfri * mtif 'i*n*M' - 1.020 1.015 1.010 1.005 1.000 0.995 ABERDEEN PLANT EFFICIENCY 10/01/86 - 09/30/87 POUNDS OF RAM MATERIAL/POUND OF PRODUCT --- - -- 1.200 1.190 1.100 1.050 . i: . 19 86/87 wni9 lima ii n ^iwmumpin ii iHMium il.iijuj.i pipmwui r:f - *wnHllH]E.i'<i| I VAB.0001191413