Document JNG84jzdGvqqj5w4jaaGjejV6

SAFETY - A. H. Sather OCCUPATIONAL INJURIES Injuries Treated February 1980 Year-to-Date 1979 Year-to-Date First Aid 386 Medical Cases 440 Restricted Workday Cases 0 0 0 Restricted Workdays 0 00 Lost Time 000 Injuries by Department Vinyl Operations 243 Compound Operations 240 Maintenance 342 Laboratory 000 Receiving and Warehouse 0 0 0 Office 001 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 142 012 111 2 32 221 110 Injuries which required medical treatment included a General Helper who suffered a muscle strain while bagging resin, a General Mechanic who slipped on an icy area, a Mechanic "B" who bruised a finger tip while working on a pump in the shop, and a Yard Operator who sprained an ankle while climbing down from loading a resin railcar. The first two (2) were the result of injuries that occurred late in January which later required medical treatment. As of February 29, 1980, the plant had operated 239 days or 314,696 hours without a disabling injury. CHEMICAL'S INDUSTRIAL HYGIENE AND SAFETY CONFERENCE A. H. Sather attended the Chemical's Industrial Hygiene and Safety Conference held in Lake Charles, LA February 4-7, 1980. SAFETY MEETINGS The focal topic for February Safety Meetings was a detailed review of the plant Plugged Line Safety Procedures as they applied to the various departments. Personnel from the Laboratory, Receiving and Warehouse, and Process Engineering groups briefly covered the procedures noted above and viewed the film "28 Grams of Prevention." The materials for the "Win With Safety" campaign were distributed or posted. The campaign was announced in a general distribution memo from C. L. Miller dated February 13, 1980. 1- - DTH 000043709 SAFETY (Cent.) EMPLOYEE SAFETY RESPONSIBILITIES PROGRAM M. S. Reynolds and A. H. Sather discussed revisions to Part I of this program while attending the Industrial Hygiene Seminar mentioned above. The script was revised and returned by M. S. Reynolds at the end of the reporting period for review and comments. BREATHING AIR SYSTEM MODIFICATIONS Several discussions regarding the alternatives for the plant breathing air system modifications occurred between the plant Process Engineering Department and the Safety Department. In addition, J. J. Hall and T. G. Grumbles, Houston, discussed the alternatives during an introductory plant visit for Mr. Grumbles. He will provide an evaluation of one of the alternatives to assure continued OSHA compliance. OSHA COMPLIANCE Activities for the reporting period included: 1. Hands-on Physicals; and, 2. Dosimetry for VCM and lead. The results of analysis and overexposure explanation are noted below. VCM - A total of 75 samples were analyzed, one of which indicated overexposure. The results, by range, are summarized below: Range , ppm Number Percent 0.0 - 0.5 0.5 - 1.0 1.0 - 5.0 5.0+ 72 2 0 1 75 96.00 2.67 0.00 1.33 100.00 The overexposure occurred to a Yard Operator who was wearing a respirator while connecting and disconnecting VCM railcars. Lead Less than PEL* 31 Greater than PEL 1 * Permissible Exposure Limit The overexposure occurred to a Dry Blend Utility. The cause of overexposure is under investigation. DTH 000043710 -2- VINYL - C. R. Miller Production Month Y.T.D. Budget 1. Total Production, MM#'s 2. Production Rate, M#'s/C.D. 3. Charges, Reactor Batches/C.D. 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average #'s/Hr. 7. Dryers, Stream Factor, % 8. Accounting Days 26.3 906 20.8 604 87.6 5871 91.9 29 56.5 942 21.8 1309 89.1 6064 92.5 60 918 Vinyl department production for the month was 98.7% of budget at 26.3 MM pounds. The reactor and dryer stream factors were down from January at 87.6% and 91.9%, respectively. Items which impacted on the production for the month were: 1. The condensers on 741, 743 and 744 reactors were brushed during the month. 2. D-500 reactor required extensive downtime for repairs to the internal baffles (34 hours). 3. Reactor 742 was taken out of service for two days to make repairs to a defective reactor weld in the false bottom of the reactor. 4. Maintenance on the V-ll dryer activators resulted in a 1.9% stream factor penalty. Resin bagging was reduced to 140 M pounds per day to meet increased railcar orders. The empty hopper car inventory remained tight throughout the month which necessitated the continuation of the resin bagging. RESIN QUALITY SUMMARY Resin Type 5305 5385 5425 5465 Sifter Overflow TOTAL Prime Pounds 1,745,790 19,599,455 2,694,446 ( 7,600) - 24,032,091 "BC" Grade 4,000 1,713,945 2,250 - 1,720,195 "H" Grade _ 245,202 ( 40,500) 2,050 316,136 522,888 % of Total Production 6.7 82.7 10.1 - 1.1 100.0 Quality performance for the month of February was 91.5% customer grade with 7.1% "BC" and 2.4% "H" grade. The off-grade total reflects the high volumes of packaged resin during the month. -3- DTH 000043711 VINYL (Cont.) RESIN QUALITY SUMMARY (Cont.) The variable cost variance for the vinyl department was ($186.9 M) with ($434.8 M) due to price and $247.9 M due to efficiency. The major price variance was ($251.2 M) for VCM. The major efficiency variance was $48.5 M for VCM. The raw material re quirement for the month was 1.01072 pounds VCM/pound of PVC versus a 1.02000 standard. (Y.T.D. is 1.01462). -4- DTH 000043712 COMPOUND - J. R. McCrimon Compound Production Month M#'s/Day Y.T.D. Line I, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days 884 13 2,554 3,451 29 40 1,769 207 91 4,431 123 6,407 60 Line I operated 22 days during February at an average rate of 40 M pounds per day. Major items affecting production efficiency were: product changes (21.6 hrs.), dicing delays (20.3 hrs.), maintenance on star valves (5.8 hrs.), main tenance on pull roller (5.2 hrs.), adjusting blender scales (3.5 hrs.) and quality control (3.4 hrs.). Line I production was also hindered by operating a split shift on Line V. Line V operated 11 days during February with a Wemer-Pfleiderer engineer in the plant. Production included 48562 Blk. and 17461 Gry 545. Hard particles in the pellets is still the major operating problem on Line V. Wemer-Pfleiderer will conduct a test run the first week in March to obtain operating data on the unit. Line III operated 28 days during February at an average rate of 91 M pounds per day. Line III production was hindered by product changes (54.6 hrs.), quality control (10.7 hrs.), maintenance on the hydrotherm unit (5.0 hrs.), maintenance on the FCM conveyor (4.0 hrs.), and replacing Sweco motor (4.0 hrs.). Production was further hindered by running only one dicer for quality control for hard part icles (235 hrs.). Quality performance for flexible compounds was 2.4% off-grade of which 98% was due to mill scrap. "BC" production was 2.3%. The raw material requirement for flexible compounds was 1.02547 pounds of raw material per pound of compound versus a 1.01301 standard. (Y.T.D. is 1.00908). The variable cost variance for compound was ($30.5 M) with $9.6 M due to price and ($40.1 M) due to efficiency. The variance due to product mix was $2.3 M. Major efficiency variances were: ($16.2 M) for tribasic lead sulfate (coated) and ($13.9 M) for combined colors which are both a result of product mix for the month. There were two major price variances: ($23.1 M) for DIDP and $13.5 M for TOTM. The DIDP variance is a result of purchasing DIDP from Exxon during the month. DTH 000043713 -5- COMPOUND (Cont.) Dry Blend Month M#'s/Day Y.T.D. Production, M Pounds Accounting Days 801 67 2,664 29 60 Dry Blend operated 12 days during February at an average rate of 67 M pounds per day. Production included 80273G and 90171. Dry Blend production was hindered by: 2 shift operation, inventory control, maintenance on Orbitran (7.4 hrs.), quality control (6.9 hrs.), and transfer line plug (3.2 hrs.). Quality performance for the month was 99.99% customer grade. The raw material requirement for dry blend was 1.06854 pounds of raw material per pound of dry blend versus a standard of 1.00320. (Y.T.D. is 1.02269). The variable cost variance for dry blend was ($11.4 M) with $7.0 M due to price and ($18.4 M) due to efficiency. The variance due to mix was $25.1 M. There were two major efficiency variances: ($18.5 M) for Thermolite 101 stabilizer and ($13.8 M) for organotin stabilizers. Both variances are a result of an error in inventory count. There were no major price variances. Plasticizer Month M#'s/Day Y.T.D. Production, M Pounds Accounting Days 314 29 552 29 60 Plasticizer operated 11 days during February at an average rate of 29 M pounds per day. Production included D0P and DIDP. VRP production totaled 12.5 M pounds (4.2%). Production was limited by bag charging with flake phthalic anhydride. Installation of the molten phthalic anhydride tank has been completed. Use of molten phthalic anhydride will resume the first week in March. The raw material requirements for plasticizer was 1.28566 pounds of raw materials per pound of plasticizer versus a 1.08554 standard. (Y.T.D. is 1.25199). The variable cost for plasticizer was ($11.3 M) with ($6.1 M) due to price and ($5.2 M) due to efficiency. There were no major price variances. The variance due to product mix was $5.2 M. GENERAL Total customer grade compound inventory decreased to 4.5 MM pounds during February. Two sample compounds were produced during the month (JRT-3866-204 and Western Electric 757A). -6- DTH 000043714 MECHANICAL - S. J. Vincent VINYL There were two large reactor seal failures this month. The seal failures were to the D-600 reactor seal in the old module and to the 742 reactor in the new module. There were three large reactor condensers cleaned during this period. One of the condensers was on the D-500 reactor in the old module and the two condensers cleaned in the new module were on the 741 and the 743 reactors. All safety discs were changed on the 741 and the 743 reactors and condensers and the relief valves were tested. There were no large reactor gearbox problems this month. There were four other major problems resulting in production downtime. Three of the problems were in the old module and one in the new module. In the old module, a section of the steam stripping header ruptured, the VCM line to D-300 plugged, and a baffle came loose in the D-500 reactor. Both the baffle and steam line sections have been sent to MED for analysis. En the new module, a crack developed in the false bottom in the 742 reactor. The installation of this bottom section is being reviewed to ascertain if the thickness of this section is a problem. No metal coupons were taken since the mode of failure was determined to be improper initial installation. Reactor and recovery system valves replaced this month were the jacket steam valve on the D-400 reactor and the steam stripping check valve on the D-500 reactor. New controllers were installed on the old module blowdown tank. A flexible line on the incinerator was replaced. There were seven mechanical seals repaired this month on pumps and compressors in the vinyl production area. Five of the seals replaced were in the new module and two were in the old module. The seals replaced in the new unit were the inboard seal in 903 recovery compressor, the north knockout circulating pump seal, and the east VCM return pump. The seals were replaced and the pumps overhauled on the south knockout circulating pump and the south seal water pump. The seals replaced in the old module were the inboard seal on the "B" vacuum pump and the outboard seal on the "A" vacuum pump. One of the 690 corken compressors was replaced with the spare compressor. The east RVCM receiver was opened for cleaning and a standpipe installed in the water drain. There were no P.M. inspections to the vinyl dryers during this period. Major repairs completed were as follows: the activator and the Bird centrifuge were replaced on the #5 dryer train; the bearings were replaced on the #4 exhauster and the sifter gearbox was replaced on the #7 sifter. The star valves under the 281 and 282 resin silos were pulled and rebuilt and the large transfer blower was replaced. -7- DTH 000043715 MECHANICAL (Cont.) COMPOUND/DRY BLEND/PLASTICIZER AND SILO STORAGE There were no major repairs to the compounding lines this month. The seals were replaced on the FCM and the #6 star valve on Line III was replaced. The bag drop photo eye and pellet transfer blowers were revised on the Compound Line V. External resets were installed on the Line V Orbitran panel. The dry blend unit operated with no major mechanical problems. The Orbitran cont rol panel spares for dry blend were checked. The inert gas compressor in the plasticizer unit failed and was replaced. The major repairs required in the silo storage area were to replace loading chutes, repairs to level indicators, and resin transfer line leaks. The maintenance project crew fabricated the platform and steam piping for the phthalic anhydride storage project. The spark-arrestor mufflers were replaced on the four fire pump engines. A new one inch dry air header was installed to supply dry filtered air to the vinyl area Honeywell units. This line will also maintain the required air pressure to operate the units. UTILITIES AND SERVICE Some major repairs to the plant air system were completed. The aftercooler was repaired on the #2 air compressor. The heater element on the east tower on the #2 air dryer was replaced. The east propane pump vanes were replaced and the propane system test fired four times. pH control problems in the plant lagoon system developed this month and the utility department and the engineer ing department are working to resolve the problems. The dew point indicator was repaired. MAINTENANCE PLANNER AND MISCELLANEOUS PROJECTS The Planner issued 29 invoice registers for contracted repair of equipment. During this period, the Planner processed 29 statements for payment, planned and estimated 61 work orders, and ordered material for 18 mechanical repairs All of the mechanical department mechanics and supervisors completed the inplant Fork Truck Training Program. The vibration study in the new reactor area is continuing. -8- DTH 00004371 PERSONNEL - J. L. Carter EMPLOYMENT None. TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTION None. RETIREMENT Essie B. Eubanks, Compound Operator Will E. Ridings, Head Security Guard TERMINATION Tony Smith, Casual Labor Douglas Vogue, Casual Labor DEATH/DISABILITY None. OTHER During the month of February there were 13 casual labor employees on payroll. Total hours worked were 2289.75. The bulk of these employees were utilized for bagging resin. -9DTH 000043717 CONOCO li i Ml CALS Aberdeen, Mississippi February 1980 MONTHLY "PERSONNEL REPORT Salaried Employees iourly Employees 77* 15 4 Minority Employees Salaried 7** 9%** iotal Employees 231* Hourly 59 3 3% imployees (Hourly) Total 66** 2 8%** New Employees Terminations 1(Retired) *** Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 0 *** 100%*** DEPARTMENTS PAR # EMPLOYEES MIN. EHP. . % MIN. NEW HIRES YTD TERM. YTD TURN0VE R YTD Warehouse 99 2 2 2% 0 0 0 0 0 0 Men. Plant 10 9 4 44% 0 0 0 1 0 11% Maintenance 46 45 7 15% 0 0 0 0 0 0 Laboratory 22 20 3 15% 0 0 0 0 0 0 Compound 41 34 27 79% 0 0 2 * * * 2 * * * 0 2 . 8% .'i nyl 32 32 13 39% 0 0 0 0 0 0 ;J1 asticizer 5 4 3 75% 0 0 0 0 0 0 Number of Applicants: Month Q_____ Year to Date 33 APPLICANT BREAKDOWN: ' Minority 0 % Minority 0 ' Female 0 % Female _0 *Includes two (2) temporary employees. **Includes one (1) temporary employees. ***Includes one (1) retirement and is not counted in turnover rate. Hires (Hourly) : Month Q Year to Date 0 Terminations (Hourly) : Month 1 * * * Year to Date 3*** Overall Turnover 0 Projected Annual Turnover 1.3% -10- DTH 000043718 o 4B> -XHbO 00 M C\ o> on > OS < V n 5 4oh +-> t4O-> SO & o XO3 oa Eo c OVERTIME AND ABSENTEEISM -C o n tro lla b le O vertim e - th a t o ve rtim e due to w o rkin g re g u la r hours on a h o lid a y and w orking re g u la r hours on th e s ix th day in o p e ra tio n s . 0) X OQ C H o3 "ee3j \fi o 00 X u Xo3 urt McHbO O5 3 oo *3 >o c* c > o <D 24o- DTH 000043719 PROCESS ENGINEERING - R. A. Frohreich A. SPECIALTY COMPOUND LINE A representative from Wemer-Pfleiderer Corporation was in the plant and tests were conducted on the unit to try to eliminate the hard particles in the finished compound. The various screw configurations and operating conditions tested did not solve this problem. Werner-Pfleiderer Corpora tion personnel will be in the plant in early March to present their recommen dation on how to correct the hard particle problem. They will also make recommendations to eliminate the plugging problem with the pellet transfer system. B. RESIN EXPANSION PROJECT Plant review and approval of equipment purchases and drawings are continuing. C. JOY CENTRIFUGAL COMPRESSOR Relief valves providing adequate relieving capacity for the plant air system were specified. D. Resin Reclaim System A detailed description for the test run to dry resin collected in the concre settling pits was issued. The test run is scheduled to begin in mid-March. Economics of drying the resin presently being collected in settling pits compared to disposal of the resin at a hazardous waste disposal site or a sanitary land fill were prepared. E. CALCIUM STEARATE ADDITION SYSTEM The class "A" process design for the system was issued and reviewed. F. INLINE METHOCEL ANALYZERS The class "A" process design for the project will be issued in early March. Methocel samples are being prepared and will be sent to the manufacturer of the refractive index instrument for testing. G. CENTRATE RINSE WATER SYSTEM The test run using centrate water for rinse water in the reactor has been delayed due to problems with one of the hot water charge tanks in the old module. H. PHTHALIC ANHYDRIDE HANDLING IMPROVEMENTS The class "A" process design was issued and an AFE request was submitted for the project. -12- DTH 0000437 PROCESS ENGINEERING (Cont.) I. API CLEAN WATER BY-PASS A design to reduce water flow through the API separator by diverting clean water now entering the separator was issued. By reducing the flow from the API separator, the organic loading on the secondary waste treatment system will be decreased. J. SPILL CONTAINMENT A process design to contain spills which may occur at the plasticizer truck loading and unloading stations is being prepared. K. BREATHING AIR MODIFICATIONS The class "A" process design for installing a package water separator for the existing seal ring breathing air compressors is being prepared. A breathing air system using instrument air is being evaluated as an alternate to upgrading the present system. L. COMPOUND LINE III DEBOTTLENECKING A class "A" process design for the project is being prepared. M. COMPOUND DIE FACE PELLETIZER A class "A" process design for the installation of a dry face pelletizer on Compound Line III is being prepared and will be issued in March. Meetings with the various vendors who can supply the pelletizer will be held in the plant in March. N. REACTOR AGITATOR REPLACEMENT The class "A" process design to replace the Philadelphia Gear agitators on D-500 and D-600 reactors with Mixco grade mounted agitators is being prepared and will be issued in March. -13 DTH 000043721 ENVIRONMENTAL - V. E. Messick I. PARTICULATES Two (2) dryer exhausts were sampled for particulates and were within allowable limits. The renewed operating permit for the plant for air emission equipment was received in February. Compliance testing on three dryers will begin on March 10. A stack sampling procedure review meeting was held February 28 with the State of Mississippi Bureau of Pollution Control. II. WATER BOD and COD levels were within allowable limits during February. The pH in the plant outfall exceeded allowable limits once during the month. To prevent other pH excursions in the ponds, we have updated our procedures for controlling pH. Also, the capability to add acid in #6 pond has been provided. DTH 00004372 Flow GPM Jan. - Ave. 810 Max. 941 Feb. - Ave. Max. 645 802 Mar. - Ave. Max. Apr. - Ave. Max. May - Ave.' Max. June - Ave. Max. 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. 43 436 131 1342 6 42 8 56 86 851 216 2214 15 116 24 171 11 103 13 143 10 79 13 125 Diss. 02 6.8-8.5 6.7-7.9 NPDES - Ave. _ Max. . 32 387 43 520 - 1390 - 1940 - 605 - 909 >6.0 nh 7.7-8.0 7.1-7.8 6.0-8.5 -15- DTH 000043723 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for February was 104.4 MMM BTU's. The energy consumption per pound of product increased from 3,214 BTU/lb. to 3,378 BTU/lb. This is a 3.5% increase over February, 1979. H. PLANT ENERGY CONSERVATION PROGRAM A. Steam Leaks Leak Repair, Inc. was called in to repair leaks on-stream in key areas that could not be shut down. Twenty-six leaks were repaired in February. B. Energy Reporting The yearly energy report for 1979 was completed and issued in February. The plant had a 25.8% energy savings compared to the 1972 base year. After adjusting for EPA and OSHA projects, the plant energy savings were 39.0% compared to the 1972 base year. C. Boiler Economizers The class "A" design for the installation of economizers on the plant's three boilers was issued in February. DTH 000043724 ITEM Control Period 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 February 1980 February Avg. Stack Temp. 1979 1980 408 400 418 419 463 428 22.5 4.7 3.5 1.1 31.8 26.3 0.8 3.5 0.3 30.9 55,308 1,020 56.414 54,266 1,020 55.351 4.368 10,000 43.680 4.848 10,000 48.480 39.44 92,000 3.628 6.069 92,000 0.558 103.722 3,262 104.389 3,378 Avg. % Excess Air 1979 1980 92 33 92 34 107 37 -17- DTH 00004372 MECHANICAL ENGINEERING - J. A. Dixon AFE'S SUBMITTED, APPROVED AND CLOSED The following AFE was submitted and approved during February. AFE No. Title Authorized 9540 Laboratory Equipment $ 45,000 There were no AFE's closed to field charges during February. Completion reports were issued during February for the following AFE: AFE No. Title Authorized 9019 Repairs to Large Reactor Gearbox $ 22,000 DESIGN Contracts were let for the following: New Module Pipe Supports, New Phthalic Anhydride Tank Insulation, Installation of Double Block and Bleed Valves in New Module, and Plant Pest Control for 1980, 1981 8 1982. Design work is in progress on the following projects: Replacement of Phthalic Anhydride T-100 Storage Tank, Reactor Inert Vent System, Double Block Valves for VCM Charge, Diking of Sphere and Curbing of Drum Storage Area, and Methocel Charge Revisions. AFE PROJECT ACTIVITY Automatic Plasticizer Stabilizer Weigh-Up Systems - R. B. Hamed 8 J. P. Windham The estimate to complete this project has been made and is ready for review. Plasticizer Chemical Exposure Abatement - M. S. Richards Additional revisions are needed to complete this project. The revisions are as follows: revise dump outlet and valve; increase temperature of funnels installed on reactors; and revise seal flush system and reactor piping. Fire Protection Improvements - Phase I - J. P. McKee The initial bids for installation were too high for the available funding. Re-bidding is in progress to attempt to complete the project within current authorized funding. Dryer Operation Improvements - M. F. Holman The piping revisions have been completed for all vinyl dryers. A work order has been issued to revise the control room wiring for the remote burner control -18- I)TH 000043726 MECHANICAL ENGINEERING (Cont.) AFE PROJECT ACTIVITY (Cont.) Critical Spare Equipment - J. P. Windham Additional specifications were issued for vendors to quote quaranteed per formance rates for the portable resin transfer unit. Quotes are ready for evaluation. Color Weigh Room Modifications - J. P. McKee This project is operational. Installation of the new 150 HP motor for the building ventilation system is scheduled. Instrument Air Dryer - M. S. Richards This project is operational. A design is in progress for overall winteriza tion of the unit. Waste Water Revisions - Part I - J. L. White This project is operational. The design of the final items, sampling weirs and outlet piping are in progress. Air Compressor - M. S. Richards This project is operational. Additional design is required for the following items: converting the old Joy compressor to dual oil filters and dual control motor, coupling, and control panel change for the new Joy compressor. Revisions to Emission Recovery System - J. L. White Engineering is complete. Bid packages for installation are being prepared for mailing. Double Block Valves for VCM Charge - M. F. Holman The mechanical and electrical installation is in progress for the new module. The mechanical and electrical design for the old module is near completion. Phthalic Anhydride System Modification - J. P. Windham The installation of the replacement for T-1000 storage tank and piping were completed during this period. Startup is scheduled for 3/3/80. The design of the replacement for T-100 and piping is in progress. Aberdeen PVC Expansion - M. F. Holman The selection of cooling tower pumps and miscellaneous process pumps have been approved. Review of the dryer, reactor and cooling tower are in progress. -19- DTH 000043727 CONSTRUCTION - G. A. Morgan Temporary repairs were completed for the damaged D-500 baffles. The crack in the 742 reactor bottom was repaired. The inlet line to Line V Welex was modified. A removable screen was installed on the pellet cooler cyclone. The removal of the damaged phthalic anhydride storage tanks and piping was completed. The Line III dock extension was completed. The installation of the vibration monitors for the new reactor module is complete. -20- DTH 000043728 AW'nm:'N AtmiQRt:\T!ONS report 11) Thru January, 19S0 Ajiuat Account v (2) Thru February, 1950 Aimi. CAPITAL NO. DESCRIPTION' 9237 Heated Plasticizer Addition System 9247 Farrel Mixer Feeders 9297 Automatic Plasticizer-Stabilizer Heigh-Up System DATE Mm i . APPROVED AFE AMT. 10/11/77 37,000 11/21/77 47,000 12/14/77 60,000 cn (2) FINAL EXPENDED COMMiriEP TOTAL EST, TO PA H: TO DATE COST COMP. UNDER (OVER) Alim. AMT. EST. es r. COMP, CL0S. DATE DATE REMARKS 13,090 13,518 37,000 0 3/80 6/80 Design in progress. 42,412 42,426 42,426 4,574 11/79 3/80 Closed to field charges. 56,293 57,944 60,000 0 3/80 6/80 Installation scheduled. 9307 Compound Project Conveying tines 9098 New Compound Line 9148 Plasticizer Chemical Exposure Abatement 12/14/77 50,000 49,336 49.9S9 49,989 4/17/78 2,050,000 2,0S2,337 2,101,962 2,101,962 8/21/78 152,000 136,476 143,216 152,000 11 (51,962) 0 11/79 4/80 12/79 4/80 4/80 7/80 Closed to field charges. Closed to field charges. Revisions in progress. 9158 9178 Fire Protection Improvements Phase 1 Propane Vaporizer Replacement 9/19/78 176,000 95,558 95,558 176,000 9/21/78 175,000 174,135 174,217 174,217 0 6/80 9/80 Re-bidding in progress. 783 10/79 4/80 Closed to field charges. 9188 Railcar Resin Heel Clean-Up System 9208 Spare Recovery Vacuum Pump 9228 Dry Blend Silo Alarms 9248 Silo Isolation Valves 10/12/78 12/5/78 12/13/78 12/14/78 55,000 14,000 25,000 25,000 33,970 14,542 4,392 21,156 41,951 14,542 9,368 22,244 55,000 14,542 25,000 25,000 9258 Dryer Operation Improvements 9519 Critical Spare Equipment 9529 Miscellaneous Projects Under $10,000 12/14/78 2/6/79 2/15/79 315,000 175,000 125,000 241,398 253,957 315,000 35,697 116,337 175,000 122,259 122,259 122,259 0 .. 4/80 7/80 Project operational. (542) 1/80 3/80 Closed to field charges. 0 4/80 7/80 Purchases proceeding. 0 S/80 8/80 Eighteen of twenty-one .. valves installed. 0 4/80 7/80 Project operational. 0 3/80 6/80 Purchases pToceecing. 2,741 12/79 4/80 Closed to field charges. 9539 Laboratory Equipment 3/27/79 51,000 24,441 31,410 31,410 (410) 7/79 4/80 Closed to field charges. 9S49 Safety Equipment 9559 Color Weigh Room Modifications 9569 Miscellaneous Projects Under $10,000 3/26/79 4/19/79 S/8/79 15,000 25,000 125,000 12,076 6,124 64,249 14,683 15,711 128,987 15,000 25,000 128,987 0 0 (3,987) 10/79 6/30 3/80 7/80 12/79 4/80 Closed to field charges. Installation in progress. Closed to field charges. 9589 Instrument Air Dryer 9606 Reactor Inert Vent System 9619 Waste Water Revisions - Part I 9629 Air Compressor 9639 Revisions to Emission Recovery System 5/30/79 6/28/79 7/3/79 7/9/79 7/12/79 110,000 90,000 140,000 340,000 100,000 88,703 90,258 3,849 8,460 126,230 128,010 72,7S2 225,846 14,687 25,412 1X0,000 . 90,000 140,000 340,000 100,000 0 4/80 7/80 Project operation;! . 0 6/80 9/80 Engineering in progress. 0 4/80 7/80 Project operational. b 6/80 9/80 Project operational. 0 6/80 9/80 Bids requested. 9649 Double Block Valves for VCM Charge 9659 P. A. System Modifications 9669 New Air Header 9679 Plant Winterization 9689 Diking of Sphere 6 Curbing of Drum Storage Areas 7/18/79 7/10/79 8/15/79 9/5/79 9/15/79 182,000 35,000 25,000 64,000 170,000 53,238 16,166 6,949 56,039 0 74,040 32,015 13,285 61,944 0 182,000 35,000 25,000 64,000 170,000 0 6/80 9/80 Installation in progress. 0 6/80 9/80 Project operational. 0 4/80 7/80 Project operational. 0 3/80 6/80 Project operational. 0 6/80 9/80 Engineering in progress. 9699 9709 Plant Dryer Debottlenecking Facilities for Multiple Grade Resin Production 9/15/79 9/20/79 80,000 870,000 0 0 80,000 0 0 870,000 0 9/80 12/80 Engineering in progress CED. 0 9/80 12/80 Engineering in progress CED. 9719 Aberdeen PVC Resin Expansion (Part ial) 9/10/79 850,000 n ,421 829,021 850,000 0 9/80 12/80 Equipment on order. 9729 Fire Protection Improvements Phase II 10/1/79 490,000 0 0 490,000 0 10/80 1/81 Engineering in progress CED. 9739 9749 9759 Methoccl Charge Revision ImproveJ Rupture Disc Holders Aberdeen PVC Resin Expansion 10/3/79 66,000 10/22/79 27,000 12/10/79 11,150,000 0 10,640 66,000 0 24,613 27,000 12,211 1,750,258 11 ,150,000 0 6/80 9/BO Engineering in progress. 0 4/80 7/80 Safety heads on order. 0 7/81 10/81 Engineering in progress. -21- DTH 00004372S ABERDEEN AUTIUUI NATIONS REPORT (1) Thru January, 1980 Actual Accounting (2) Thru February, 1980 AUTH. CAPITAL SO. DESCRIPTION' DATE AUTH. APPROVED AFE AMT. (1) EXPENDED TO DATE (2) FINAL COMMITTED TOTAL EST. TO DATE COST COMP. UNDER (OVER} AUTH. AMT. FST. EST. COMP. CLOS. DATE DATE REMARKS 9769 Automatic Setback Thermostats 9510 Miscellaneous Projects Under $10,000 12/31/79 1/3/80 3,000 150,000 128 5,1S2 2,001 23,850 3,000 150,000 0 6/80 9/80 Thermostats on order. 0 12/80 3/81 Sixteen projects approved. 9520 9530 9540 Replacement Phthalic Anhydride Tank Spare Incinerator Laboratory Equipment 1/17/80 1/23/80 2/6/80 75,000 650,000 45,000 2,101 0 0 77,297 0 .34,975 84,000 650,000 45,000 (9,000) 0 0 6/80 9/80 Installation in progress. 1/81 4/81 Engineering in progress CED, 8/80 11/80 Purchase proceeding. 9029 9049 9069 9079 9089 9238 BPENSE Repair of Steam Tracing 6 Insulation 9/5/79 Repairs to Dryer Inlet Ducts 9/13/79 Centrifuge Rotors Repair 9/13/79 Cooling Tomct Motor Repair 10/22/79 Vibration Study-Capacity Replacement Reactors 10/29/79 Compound Line I Roof Collapse 12/13/78 62,000 25,000 47,000 17,800 50,000 44,000 69,270 16,548 53,302 0 5,059 69,270 19,012 53,302 0 34,264 43,739 43,739 69,293 25,000 53,302 17,800 50,000 43,739 (7,293) 0 (6,302) 0 0 1/80 4/80 3/80 6/80 2/80 5/80 4/80 7/80 3/80 7/80 Closed to field charges. Insulation in progress. Closed to field charges. Motor being repaired. Prototype testing in progress 261 1/80 3/80 Closed to field charges. -22- DTH 000043730 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Celanese Piping Charlotte Plastics Western Electric LCP Plastics Runzel Cord Wire Product 5305 5305 36861 Nat. 5385 34641 Nat. Complaint Moisture High ViscosityContamination Moisture/Frozen Resin Wrong Product Report By RDJ RDJ RDJ Under Investigat Under Investigat WAIVERS RECEIVED Date Identification 2/5 2/5 2/6 2/8 2/8 2/8 2/13 2/13 2/18 2/18 2/20 2/20 2/22 2/24 2/25 2/27 2/27 2/27 2/27 2/27 2/28 2/28 2/29 T2481 PTLX 41623 PTLX 41652 PTLX 42027 T2811 PLCX 43736 CONX 45280 PLCX 42962 PLCX 43205 PTLX 41598 PTLX 41651 PLCX 43216 PLCX 42660 T2811 PLCX 43742 PLCX 43015 PLCX 43007 PLCX 43704 PLCX 43228 T2479 T2811 T2869 CONX 45708 TOTAL 23 Product 5385-1II 5385-III 5 385-III 5385-III 5425 5425 5465 5425 5385-III 5385-11I 5385-III 5385-III 5385-III 5385-1II 5385-1II 5385-III 5385-III 5385-III 5305 5305 5385-III 5385-III 5385-III Customer Reason Waived By World of Plastics Charlotte Pipe Charlotte Pipe Simpson Intex Uniroyal Inmont Intex World of Plastics World of Plastics World of Plastics Simpson Simpson Can-Tex World of Plastics World of Plastics LCP Simpson Intex Celanese Pipe Can-Tex Mastic Simpson Static Flow Color "b" Value Particle Size Particle Size Gels Dry Time Gels Gels Particle Size Particle Size Particle Size Particle Size Particle Size Static Flow Particle Size/Color Color "b" Value Particle Size Particle Size Particle Size Static Flow Static Flow Static Flow Particle Size JRW ELK ELK JRW ELK ELK HRF HRF ELK ELK CLS CLS ELK JRW ELK ELK ELK ELK ELK JRW JRW JRW ELK 723- DTH 000043731 LABORATORY (Cont.) PRODUCT DEVELOPMENT AND SERVICE Ship Date Product Quantity (Lbs.) Customer Requested By 2/4 2/5 2/13 2/13 2/13 2/13 2/14 2/15 2/19 2/26 2/26 2/26 2/29 2/29 35031 Nat. 5385-1 5385-1 5385-1 5425 5305 5305 17461 Wht. 80172B 5425 5425 5385-1 48562 Blk. 5385-1 15041 Cl. Bl. 17461 Nat. 18031 Cl. Bl. 18961 Nat. 50 50 200 10 100 100 100 s 5 50 5 5 10 50 200 300 100 100 100 100 Dixie Wire Co. Rubbermaid Specialty Products Glyco Chemical Co. Fritz Airfreight CSI-Coating Systems,Inc. Intex Plastics Crane Plastics Can-Tex Phelps-Dodge Western Electric Mfg. Co. Ferro Chemical Siegel Robert Co. Kohkoku, USA Lavanture Products JFN PCM RNG JPMc NTH JFN JTW JFN NTH RNG JTW GCC - AHH COMPOUND DEVELOPMENT AND SERVICE Special Compound Testing Western Electric specification tests were run on one lot of 34861 Gray 546, on two lots of 36861 Natural and on one lot of 38761 Black. One lot of 34533 Natural for Packard Electric was tested. Line V Startup Melt flow tests were run on fifteen (15) compound samples to provide information for Line V operation. Compound Property Verification A report was issued which gave physical property values measured on all active compounds during 1979. The 1980 compound property verification program has been started on ten (10) compounds. -24- DTH 000043732 LABORATORY (Cont.) QUALITY CONTROL TESTING Resin Regular Samples = 387 Bag Blends = 137 Other In-Process Samples = 3,129 Bulk Shipments = 220 (Railcars = 105; Trucks = 115) Dry Blend Blenders Produced = 109 Blenders Tested = 101 Blenders Adjusted = 15.6% Other In-Process Samples = 112 Bulk Shipments = 10 (Railcars = 2; Trucks = 8) Compound Blenders Produced = 548 Blenders Adjusted = 4.6% Other In-Process Samples = 264 Bulk Shipments = 24 (Railcars = 9; Trucks = 15) Resin Heat Stability Forty-two (42) samples of resin were tested for oven heat stability. 5385 5425 5305 18 Blends 16 Blends 8 Blends All types of resin averaged poorer than the control on heat stability; however, they improved during the last two weeks of the month, and heat stability was about normal the last week. RAW MATERIAL TESTING Forty-nine (49) lots of plant raw materials were tested. One (1) shipment of SP-33 clay was rejected because it gave a low value for volume resistivity. Th other materials were accepted. SPECIAL PROJECTS RVCM of Shipments A total of 106 shipment samples were tested for RVCM in February. Due to many factors, the RVCM of the shipments are higher. Truck shipments of 5305 were tested for RVCM on a call-in basis prior to release. -25- DTH 000043733 LABORATORY (Cont.) RVCM of Shipments (Cont.) Product No. Samples Average ppm RVCM % of Samples over 10 ppm 5385 69 3.4 7.2% 5425 6 0.3 0.0 5305 27 21.0 66.7 Dry Blend 4 0.0 0.0 RVCM in Slurries A total of 595 slurry samples were tested for RVCM in February. The overall average was 298 ppm VCM. The pound weighted average exceeded 400 ppm on four (4) days during the month. RVCM of Blowdown Tanks A total of 126 samples of blowdown water were checked for RVCM in February. The overall average was 12.2 ppm. Most of the samples were below 10 ppm but a few high samples raised the overall average. RVCM of 5505 Dryer Samples A total of 48 samples were tested from the regular Q.C. sample taken at the beginning of each batch. The average was 18 ppm. These results look rather low when compared to the shipment samples and would seem to indicate that the dryer samples were not representative of the entire production. SPECIAL WORK Plant Process Engineering Support The following samples were tested in support of work done by the Process Engineers: 10 incinerator samples for VCM. 6 #1 pond samples for % solids. 6 API water samples for COD. 5 Inert gas samples for composition. 1 Sulfuric acid sample for purity. Miscellaneous Work was done to try to quantitatively measure the % plasticizer in compound. Reproducibility at present is +_ 5% relative. Much repair work was required to keep the F-42 running. Repair parts are on order. -26- DTH 000043734 SURFACE TRANSPORTATION ABERDEEN DISTRIBUTION WAREHOUSE February ACTIVITY REPORT, 1980 Shipment by Product - H/lbs. Resin Plasticizer Dry Blend Compound Total Number of Shipment by Mode Resin - Bulk Package Export - ABR Plasticizer - Bulk Dry Blend Compound - Bulk Package - Bulk Package R/C O.T. 93 71 1 31 9 7 9 12 26 Export- Pkg Back Hauls for February _____ 111 '1 149 24 Number of Shipment by Month-year-to Date O.T. R/C Bulk January February 104 55 111 83 FEBRUARY 20634 < 0 2127 3998 26759 Year-to-Date 37327 43 4320 6853 48543 C.O.T C.C. TOFC CPU TOTAL 14 24 178 7 14 31 2 3 O' 21 1 10 1 17 4 35 19 8 23 46 1 323 O.T. Van 72 66 C.O.T 0 0 C.C. 4 21 TOFC 2 4 CPU TOTAL 36 273 35 320 -27- DTH 000043735 \ LOCATION MAIN-East TOTAL M SQ. FT. 48 Prairie 12-1 12-2 12-3 12 22 21 12-4 12-5 22 21 12-6 21 12-7 12-8 21 21 Total 209 CONOCO TRANSPORTATION ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco Resin Resin Resin Export,Resin Conoco Export Resin 3.6 .6' .2 .4 .7 3.2 4.0 Conoco Resin Resin O.G. Mill Scraps Cmpd 0. G. Dry Blend 0. G. Sifter Overflow Resin 0. G. Compound Resin Raw Material Resin 0. G. Conoco 4.5 .7 .1 2 .6 .1 2.7 .2 3.8 4.6 Bub-Total (Plug-Aisles) Total Conoco -28- ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 4.8 5.2 10.0 .7 .8 1.5 3.2 .3 3.5 * 4.0* 4.5 3.5 3.5 1.6 -9 2.5 3.0 * 3.8 * 4.6 .5 3.5 3.5 3.5 ... * 35.0 .2,9 30.2 7.7 37 . 9 DTH 000043736 SAFETY REPORT Lost Time Accident Doctor Cases First-Aid Cases Man Hours Worked MATERIAL HANDLING REPORT fghruary 0 0 _______ Q 2265 Y. T. D O' 0 _______ 0 5157 Packaged Resin From Production Packaged Compound, Dry Blend From Prod. Transferred From Main to Prairie Transferred From Prairie To Prairie Reverse Transfer Resin to Plant Reverse Transfer Cmpd. to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Main LABOR REPORT Total Regular Hours Total Overtime Hours Total Worked Paid But not Worked Total 1638 '147. 1785 .40 TS2S M/lbs. 6521 1539 6480 0 364 40 3969 .1296 365 "20F77T Labor Efficiency Equals 20.6 MM/Lbs. - Hours Worked Overtimed 8-0/o T/L 161 38 160 0 9 1 98 32 9 W GRAND TOTAL SINCE L.T.A. 146832 -29- DTH 000043737 EQUIPMENT REPORT Lift Truck Hours Worked Gal of Fuel Consumed Gals/Hrs 340 541 1.6 Lift Truck Efficiency Equals 20.6 MM/Lbs. - Hours Worked 60512 Lbs./hr OFF-GRADE IN STORAGE MATERIAL Sifter Overflow M/Lbs. 196 Resin "BC" 4106 Resin "H" Mills Scraps Compound "B" Compound "H" Dry Blend "O.G." Total 1807 44 580 0 63 T7M T/L 5 101 45 1 14 .0 2 168 D.F. OPERATION Total, material in inventory increased this month from 26.7 MM/1bs. to 30.2 MM/lbs. this increase was due to packaged resin. Compound inventory dropped approximately .5 MM/lbs during February. Our export order for China for 5425-1 was completed in February. At the present we do not have any export orders. -30- I)TH 000043738 ABERDEEN RAIL CAR REPORT SURFACE TRANSPORTATION DEPT. AS 2/29/80 LIMITS LOCATION LOADED VCM 35 IN PLANT 10 25 MONROE LEAD 40 20 BINFORD ICG DOWNTOWN TEXICO TRACK SLSF ACROSS BRIDGE STRONG 30 PRAIRIE 50 EGYPT . OTHER 160 TOTALS 50 EMPTY HOPPERS 10 15 LOADED HOPPERS 28 2 21 8 * 11 7 33 69 OTHER LOADS 2 '6 - 8 TOTAL 50 63 21 - 19 7 160 RECAP FOR MONTH 2/8/80 2/15/80 2/21/80 2/25/80 31 35 78 36 40 69 31 32 76 41 35 78 7 151 7 152 7 146 8 162 -31- DTH 000043739 A8Li<DLl.N OSI'A RECORDABLE INJURIES DTH 000043740 MONTHLY HOURLY TURNOVER c cocr\>j oo VO {/> oZ co > 5" x< CO jE d zo u& Ui/Ji V>fflw'.O DTH 000043741 ENERGY USAGE C c ( c Average o ou-> orr c*0 on ci-- ABF.ROliCN PLANT PRODUCTION >CJ U3 cCC {- =3 7. ^ O;z u3 o oooo ftsoi ro* --lo< o --i oin DTH 00004374.3 ABERDEEN PLANT QUALITY PERFORMANCE