Document JvxGgGK4ZZdOm4bra6aQyJLQ6

SAFETY - A. H. Sather OCCUPATIONAL INJURIES Injuries Treated 1979 January 1979 Year-To-Date 1978 Year-To-Date First Aid Medical Cases Lost Time 22 00 00 5 1 0 Injuries By Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving Warehouse Office 22 3 00 0 00 3 00 0 00 0 0 0. 0 As of January 31, 1978, the plant operated 178 days or 236,249 manhours without a lost time injury. The plant record for total injury free operating time was increased to 69 days. Also, as of January 31, 1979, the longest period without a medical case injury had been increased to 115 days from the previous record of 99 days. INDUSTRIAL HYGIENE SEMINAR J. V. Uptain and A. H. Sather attended the Conoco Chemicals Industrial Hygiene Seminar held in Houston, Texas January 23 - 25, 1979. Also, the problems of lead handling and the Lead Industry approach to the new OSHA Lead Standard were discussed with National Lead representatives on the evening of January 22, 1979. LEAD STANDARD The Lead Standard Compliance Plan was completed and issued to G, G. Draper on January 31, 1979. Initial sampling as required by the Initial Determina tion of Exposure paragraph was initiated with preliminary results being returned in early February. This data indicates that we do have exposures in excess of the 50 Ug lead/ Permissable Exposure Limit (PEL). Initial work to reduce this exposure will be done in early Feburary with a rental air compressor which will be placed in captive service to the Building Ventilation System dust collector. This work should improve dust collector efficiency and therefore increase airflow rates through the system. Personnel sampling will be done concurrently with this change. The Department of Labor has issued several changes in the standard. They include a delay in the effective date of the standard to February 24, 1979 and a notice of reconsideration of the 3M disposable dust, mist, and fume respirator but have not deleted any of the requirements for quantitative face fit testing for concentrations of lead up to 500 Ug lead/ m^. DTH 000043824 f VCM COMPLIANCE Activity in this area for the reporting period was as follows: 1. Ninty-seven (97) percent of plant received VCM Compliance Training 2. The annual medical screening was initiated 3. Routine personnel monitoring (results are shown below) VCM Dosimetry Seventy-four (74) samples were taken during the reporting period. Twelve (12) of which indicated overexposures. The distribution of sample results are shown in the table below. Explanations for overexposures are also shown below. Range Number Percent 0.0 - 0.S 0.5 - 1.0 1.0 - 5.0 5,0+ 60 2 7 5 74 81.08% 2.70 9.46 6.76 100.00 Of the twelve (12) overexposures; one (1) occurred to an Operations Superintendent who was wearing a respirator during the change-out of seals on a pump, three (3) occurred to personnel hanging tarps around the V-ll Building and incinerator during normal operations, three (3) indicate no known reason, and the remaining five (5) are currently under investigation. DTH 000043825 ABERDEEN FIRST-AID CASES 12 MONTHS MOVING AVERAGE 50 45 40 35 30 25 20 1510 5 0 DTH 0000438261 Aug. ABERDEEN OS1IA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE 20 :rrr r: :: J Frequency Total OSHA Recordable Injuries X 12 Total Employees i- """ '!-- 15 ..------ -.1.... 10 -*-- ; 5 E 0 DTH 000043827' PERSONNEL _ J. L. Carter EMPLOYMENT During the month of January Aberdeen had one new hire - Mechanical Engineer. There was a total of three (3) casual labor employees on payroll during this month. Total hours worked were 268.25. The bulk of these employees were utilized for holiday coverage. TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTIONS Gary G. Draper, Plant Manager of the Aberdeen Plant, was transferred and promoted to Resin Product Manager in Houston, Texas. Curry L. Miller, Plant Manager of the Newark Plant, was transferred and promoted to Plant Manager of the Aberdeen Plant. RETIREMENTS None. TERMINATIONS None. DEATH/DISABILITY None. DTH 000043828 CONOCO Cl'I .MI CALS Aberdeen, Mississippi January 1979 "MONTIILirTI-:ilSONNLL REPORT ularied Employees : urly Employees ; tal Employees oloyecs (Hourly) New Employees * Terminations 70* 165 235* -0-0- 'PARTMENTS PAR # EMPLOYEES MIN. EMP. Minority Employees Salaried 3 If l\ 4% Hourly 66 40% Total 69 29% Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. -0-n-0-0- % MIN. NEK HIRES YTD TERM. YTD TURNOVER YTD rehouse 9 9 2 22 0 0 0 0 0 0 a. Plant 10 19 12 63 0 0 00 0 0 ..intenance 46 46 8 17 0 0 0 0 0 0 uooratory 22 22 3 14 0 0 0 0 0 0 impound 33 33 25 76 0 0 00 0 0 nyl 32 32 13 41 0 0 0 0 0 0 -asticicer 4 4 3 75 0 0 0 0 o 0 umber of Applicants: unth -Q- Year to Date _q_ PPLICANT BREAKDOWN: Minority -0- % Minority -0- remale % Female -0- *Includes one (1) Co-op Student. Hires (Hourly) : Month _q_ Year to Date _p Terminations (Hourly) : Month -0-______ Year to Date -0- Ovcrall Turnover -0- Projected Annual Turnover o DTH 000043829 o * t l IN O O 4* IN I IN o OI OI QI OI I I I I I fN 8oo # o s a uco> eC'J> en < a 3 -5 e / V H-ts DTH 000043830 MONTHLY HOURLY TURNOVER 1C 9 8 7 6 5 4 '3 ? 1 C VINYL - E: L. Kieschnick January had 31 accounting days (Y.T.D is 31 accounting days). Production Month Y.T.D. Standard 1. Total Production, MM #'s 2. Production Rate, M #'s/C. D, 3. Charging, Rx B. A.'s/C.D, 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average #'s/Hr. 7. Dryers, Stream Factor, % 21,1 681 17.3 537 81.4 5042 80.4 21.1 681 17.3 537 81.4 5042 80.4 904 Items which limited productivity during the month included: 1. A severe freeze up problem in both reactor modules beginning 1/1/79. The old and new reactor modules were brought back on stream 1/3/79 and 1/5/79, respectively. 2. Extended downtime on D-400 reactor gearbox (119.5 hours) due to equipment delivery delays resulting from inclement weather. 3. Propane vaporizer capacity on 1/7/79 and 1/9/79. 4. Time lost in the old reactor module to repair and troubleshoot the cause for repeated failures of the water charge turbine meter in the old module (118 hours). The cause was traced to steam leakage into a water supply header which in turn resulted in sporadic, destructive flow of vapor across the meter, 5. Replacement of the agitator blades in D-300 reactor (22 hours). 6. A high level of inerts in the recovered VCM from 1/19 to 1/22 which required a reduction in catalyst loading. Steps taken during the month to improve productivity were: 1. Installation of two centrifuge anti-chatter devices on 1/23 and 1/24. The current estimate for completion of the anti-chatter device installations is mid-February. 2. Implementation of a freeze protection program which resulted in normal operation during three additional days of temperatures below those which caused the shutdown. 3. Installation of an improved trial dust collector sock pulsing device on No. 6 dryer. The device is designed to keep the socks clean there by minimizing rate reductions to control maximum drying temperatures. DTH 000043832 Production - (cont.d) 4. Rental of an additional electric propane vaporizer until the new steam propane vaporizers can be installed in February. 5. Rental of an additional air compressor to increase the air pressure at the dryer activators which will reduce the frequency of activator induced rate reductions. This air compressor was received arid piped up in February. Resin Quality Summary Resin Type Prime Pounds "BC" Grade "H" Grade % of Total Production 5305 5385 5425 5465 Sifter Overflow 1,582,032 16,054,935 2,869,007 (11,450) 42,000 276,450 288,985 0 0 1.51 1.37 TOTAL 20,494,524 42,000 565,435 2.88 Quality performance for the month of January was 97.12% customer grade with 0.20% "BC" and 2.68% "H" grade. The major item affecting quality for the month was the production of contaminated 5425 which is reflected in the bag and bulk values listed above. The dryer cleaning frequency was increased and contamination guidelines prior to dryer shutdown and cleaning were tightened. The variable cost variance for the vinyl department was ($17.6 M) with $29.1 M due to price and ($46.7 M) due to efficiency. The major price variance was $51.8 M on VCM. The major efficiency variances were ($65.7 M) on VCM and $11.3 M on combined initiators. The raw material requirement for the month was 1.04053 pounds/pound PVC versus a 1.01960 standard. Two coarse batches contributed to the efficiency problem. DTH 00004383 COMPOUND - C. R. Miller January had 31 accounting days. Compound Production Month #1 s/Day Y.T.D. 1. Line I, M Pounds 2. Line III, M Pounds 3. Total, M Pounds 1,427 2,252 3,679 62 98 160 1,427 2,252 3,679 Line I operated twenty-three days during the month at an average rate of 62 M pounds per day. Production rates during the month were affected by mechanical downtime on the mill skip hoist. Line III operated twenty-three days averaging 98 M pounds per day. Production included several compounds including a new color formulation for 34431 grey 547 for Kaiser Electric. Major items affecting rates were the number of product changes and the blending cycle times required for the 34861 and 18031 compounds. Quality performance for flexible compound was 0.8% off-grade of which 96% was due to mill scrap. The remaining off-grade consisted of 2 M pounds due to burned seal material. The "BC" production for the month was 0.8%. The raw material requirement for flexible compound was 1.03083 pounds raw materiaIs/pound of compound versus a 1.01298 standard. The variable cost variance for compound was $17.1 M with $17.4 M due to price and ($0.3 M) due to efficiency. The major efficiency variances were ($10.9 M) due to resin and $20.0 M due to combined colors. There were no major price variances Dry Blend Month #1 s/Day Y.T.D. Total Production, M Pounds 6,550 211 6,550 Dry Blend operated thirty-one days during the month at an average rate of 211 M pounds per day. Production rates were limited by a 400 M pound production run of 90171 fittings dry blend to boxes. Rates were also affected by longer heat up times due to colder weather conditions. Quality performance for the month was 99.8% customer grade. The raw material requirement for dry blend was 1.00570 pounds raw materials/ pound of dry blend versas a 1.00322 standard. The high raw material consumption reported reflects an overcharge of omyalite 90-T to dry blend. A correction will be made in February. * The variable cost analysis for dry blend was ($37.3 M) with $7.7 M due to price and ($45.0 M) due to efficiency. The variances due to efficiency reflects the use of T-101 stabilizer for 90181 fittings dry blends. This usage is a DTH 00004383-1 Dry Blend - (Cont.d) result of a revision to the formulation after preparation of the budget. There were no major price variances for the month. Plasticizer Month #'s/Day Y.T.D. Total Production 1,009 63 1,009 The Plasticizer unit operated sixteen days during the month averaging 63 M pounds per day. Plasticizer production consisted of DOP, 610-P, DIDP, and TOTM plasticizers. VRP production for the month was 63 M pounds. The raw material requirement for plasticizer was 1.16981 pounds raw materials/ pound of plasticizer versus a 1.11641 standard. The high raw material require ment reflects the usage of budgeted formulations which included efficiency savings from two capital projects which were not completed in January. The variable cost for plasticizer was C$3.7 M) with $14.3 M due to price and ($18.0 M) due to efficiency. There were no major price or efficiency variances for the month. DTH 000043835 MECHANICAL - S. J. Vincent Vinyl - Area I The condensers that were cleaned were D-300, D-400, D-500 twice, and D-600. Some of the other work completed on D-300 involved changing the safety discs and cleaning the spray head on the chem wash system. The agitator blades on D-300 also had to be replaced when some PVC residue damaged them. The gearbox on D-400 was rebuilt along with the slurry dump valve and the spray head for the chem wash system. Oil failure switches were also installed on D-300 and D-400 gearboxes. The agitator drive motor on D-500 was replaced because of bearing failures, the spray head for the chem wash system was pulled and cleaned twice, and the vent valve was rebuilt. The D-600 reactor seal was replaced and the spray head for the chem wash system was pulled and cleaned twice also. Several flow meters and back pressure controllers were repaired because of freeze damage. The VCM turbine meter was rebuilt several times. The condensers in the new module were not cleaned during this period. However, leaks on the water jacket for 741 and 742 reactors were repaired. Weld failures on these two jackets are now beginning to reappear in some of the spot weld repairs previously performed. Complete weld repairs to the jackets will probably require major downtime for each reactor. The spray head for the chem wash system was also cleaned for 742 reactor and twice for 744 reactor. The safety discs were replaced on 743 reactor. The reactor seal on 744 reactor was replaced with the spare. Extensive damage to this seal required machine shop repairs and the purchase of a new bearing housing. The .recovery condensers in the old module were cleaned, each two times. A low fire switch was installed for the incinerator. The new unit cooling tower pump motor was returned to the manufacturer due to problems with the oil system. One of the area cooling towers was serviced. Some major work was performed on the dryer system. The exhauster motor on number one dryer was replaced along with the drive belts. The gearbox was changed on number two dryer centrifuge, the drive belts were replaced, and a PM inspection completed. An anti-chatter device was installed on two dryer centrifuges. Dryers number four and six were given a PM inspection. A revision to the pulsation system on number six dryer day collector was installed and appears to be functioning well. A burner control box was also installed on this dryer system. The blowback motor on number eight dryer pulsing system was repaired. The seal was replaced in the west VCM charge pump in the old module. Several other seal repairs were made to some of the equipment in the new unit that included the recovery compressor, vacuum pump, water charge pump, and the VCM charge pump. Most of the seal failures experienced were a result of freeze problems. The emission recovery compressor and the hot water charge pump had to be rebuilt. An inspection of all pumps in the new unit was completed. The two large Corken compressors were refurbished. Several hoses were also changed on the unloading stations. DTH 000043836 Compound, Dry Blend, Plasticizer, and Storage Silos - Area II In the compound area several steam tracing leaks were repaired on the lines to both compound systems. The rotors for the FCM unit were returned to Parrel for an estimate to refurbish them. A new pump was installed on the compound feed tanks. The compound cooling tower return pump and motor were repaired and re-installed. A drainage trench was installed under the line one scale system. Both Welex gate operators were repaired in the dry blend unit. The drive end bearings on number one welex were replaced and temporary repairs were made to the shaft and coupling. One screen change was made on the Kason system and a dump valve was repaired. Motor repairs were necessary for one of the Kason units. A cylinder operated valve was installed on the boxing hopper. The bearings and seals in one of the nitrogen blowers were replaced, The old bypass lines were removed from the reactors. Repairs were made to the Phthalic Anhydride unloading piping after being damaged by a railcar. The caustic tank was repainted. The resin silo sampler being evaluated by the plant was removed and returned to the vendor for further design changes. Several silo chutes and valves were repaired. The turbo blowers on the four diesel fire pumps were repaired, Electric alarms are being tested on the compound area forklifts. The V-10 plastic strip door was replaced. Some of the abandoned conduit was removed from the Chiller area. The laboratory compound mill was rebuilt. The power supply was revised to the lab brabenders. A new brabender was installed in the lab, Utilities A rental LPG vaporizer was installed at the propane system to help supplement plant needs while operating on propane. A new refrigeration compressor was installed on one of the catalyst freezers and the old unit was sent out for repairs. A complete cylinder overhaul of number one air compressor was made and the motor repaired. Six compressors had valve repairs during this period. Chain hoist inspections were completed throughout the plant. The refrigeration and lubrication programs are continuing. The installation of an emergency shutdown for the propane vaporizers was completed. Control valve repairs were also completed on one of the boilers. General As a result of freeze problems, mechanical coverage was provided continuously for three days in the vinyl unit. A local explosion and fire at the Aberdeen telephone office required continuous mechanical coverage for eight days. DTH 00004383'7 Planning The planners work involved processing twenty-six invoice registers for contract work, forty-one bills were processed for payment, and twenty-seven registers were closed. Material was ordered for twenty-three projects and estimates completed for twenty-one work orders. The year end closings were completed and the work backlog was updated. Arrow diagramming was also completed for the installation of the day collector pulser revisions. Miscellaneous There were 622 maintenance, 41 revision, 3 safety, and 97 service to operations work orders received during the month. The following is a breakdown of the maintenance work orders by priority: Number Percent E A B C Shift Mechanic 393 .63 128 21 71 69 11 25 4 TOTAL 622 100 During this reporting period 583 maintenance, 35 revision, 4 safety, and 100 service to operations work orders were completed. 50.3% of the time was spent on non-scheduled work. There is a backlog of 7 safety work orders with 3 safety work orders being received and 4 being completed. DTH 000043838 PROCESS ENGINEERING - R. A. Frohreich A. Specialty Compound Line The plant is continuing to work with Crawford and Russell and CED on the mechanical design of the project. Engineering is 75% complete. Crawford and Russell and CED personnel were in the plant to discuss construction of the control panel and other engineering questions in early January. Project, completion is now scheduled for September 15, 1979. B. Fire Water System Revisions - Phase I CED was in the plant January 11th to discuss the process design for the project with the plant Safety and Engineering Departments C. Propane Vaporizer Replacement The vaporizers and mixers will be delivered to the plant in mid February. Foundation and piping work is in progress. Project completion is scheduled for April 1. D. Plasticizer Exposure Abatement CED is preparing the bid package for the installation of the filter. The bid package is expected in the plant in late February. E. Railcar Resin Cleanup The rental unit has been evaluated. The unit works well arid a purchase order has been issued for the machine. F. Charge Water Heating Improvement Mechanical Engineering for the project is continuing. G. . Silo High Level Alarms One of the radiating frequency alarm probes has been purchased and will be evaluated prior to ordering the remaining alarms. H. Plant Dryer Debottlenecking 1. Anti-Chatter Device Two of the anti-chatter devices were received and installed. Centrifuge performance has improved with the addition of the devices. The remaining five units are expected in the plant in mid February and will be installed when received. DTH 000043839 H. Plant Dryer Debottlenecking - (Cont.d) 2. Dryer Feed Control The new one inch slurry feed valves are being installed as opportunities arise to make the change without taking downtime for this purpose. 3. Remote Dryer Lighting Mechanical design for the project is in progress. Estimated completion date for the project is June 1. 4. Dryer Slurry Feed Strainers Plans are to purchase and install one system for evaluation purposes. i I. Silo Isolation Valves Mechanical design of this project is in progress. J. Plant Yield Study A continuous sampler is being used to determine the amount of resin in the effluent to the plant waste treatment system. K. Blend Tank Aeration The spargers for blend tanks 648, 649, 650 and 651 have been fabricated and will be installed. L. Automatic Plasticizer Weighup System Plant Process Engineering is working with the Orbitran Co. on the construction of the panel and the sequence of operation. A trip was made to.Orbitran in January to discuss final details on the sequencing operation. M. QMS Addition Systems A process design for an automatic OMS addition system for the new module is being prepared. N. Emission Recovery System A process design to provide an additional vacuum pump and to improve tank level control in the emission recovery system is being prepared. O. Plant Air System A rental air compressor will be used to supplement the present plant air system. A study to define the amount of additional air required is in progress. A process design for an additional compressor will be prepared after the requirement is defined. DTH 000043840 ENVIRONMENTAL HEALTH - R. A. Frohreich I. Particulates The exhausts from two of the resin dryers were sampled for particulates. The rental vacuum cleanup system was evaluated and found to work well. A purchase order was issued for the unit. The application for a permit to construct the specialty compound line is being prepared for submission to the Mississippi Air and Water Pollution Control Commission. II. Water BOD and COD levels were within the permit limitations in December. Methods of eliminating the Pond Irritant are being investigated. III. Vinyl Chloride In-plant emission testing and leak checking is continuing as specified in the Complaince Manual. DTH 000043841 Flow GPM Jan. - Ave. Max. 788 948 Feb. - Ave. Max. 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. 26 246 37 307 63 589 94 781 19 170 31 279 Diss. NPDES - Ave. Max. 32 387 43 520 - 1390 - 1940 - 605 - 909 6.0 oh 7.5-8.2 6.0-8.5 DTH 000043842 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for January was 114.4 MMM BTU's, The energy consumption per pound of product increased from 3013 BTU/lb, in December to 3535 BTU/lb. in January. II. Plant Energy Conservation Program A, Energy Reporting An energy consumption analysis for January was completed (See following sheet). A change has been made in the calculation of electrical usage. The conversion factor for electrical energy has been changed from 3413 BTU/KWH to 10000 BTU/KWH which is used in the plant's MCA reporting procedure. B, Steam Leaks 18 of 18 reported steam leaks were repaired in January. C, Boilers Equipment for the Boiler Burner Replacement Project is scheduled to arrive in late February. DTH 000043843 ENERGY CONSERVATION DATA ITEM Production, MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Total Energy Consumption, MMM BTU Energy Consumption, BTU/Lb. Boiler Operating Data No. 1 No. 2 No. 3 - Avg. Stack Temp. 1978 1979 422 423 422 410 433 463 January 1978 January 1979 12.9 2.5 2,7 0.6 18.7 21.1 6.6 3.6 1.1 32,4 29906 1020 30.504 56200 1020 57.324 3.139 10000 31.390 4.867 10000 48.670 118.749 92000 10.925 91.700 92000 8.436 72,819 3894 114.430 3532 Avg. % Excess Air 1978 1979 70 98 90 105 90 121 DTH 000043844 MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved and Closed There were no AFE's submitted, approved, or closed to field charges during the month of January. Completion Reports were issued for one AFE in January: AFE No. Title Authorized 9226 Vapor Emission Recovery System $ 260,000 Design Bid packages were prepared for the following: Steel Structure and Foundations for the Propane Vaporizer project, the Fork Lift Ramp and Canopy for the Dry Blend Production Expansion project. Design work is in progress for the Propane Vaporizer, Slurry Blend Tank Sparger System, Hot Water Charge System, Resin Samplers, Electrical for Acrison Feeders, and Vent Line from Incinerator to VCM Bullets, Design work by CED is in progress on Plasticizer Chemical Exposure Abatement, and Fire Protection Improvement - Phase I. Basis of Bids were issued for concrete work for the new compound line. All major electrical, instrumentation, and mechanical equipment is on order for this project. Construction 1. The live bottom on the 410 silo was removed and a new cone section with air .pads was installed. 2. The emergency items were completed on the winter insulation schedule. 3. The leaks were repaired on the Phthalic Anhydride Unloading System. 4. The centrifuge chute modification on number 1 and 6 noise abatement project was completed. 5. The insulation of the soya epoxy line was completed. 6. New spargers were fabricated for the old and new blowdown tanks. 7. The electrical remote controls for Silo-Aeration is complete. 8. The piping on the Compound Conveying Lines project is complete. 9. Construction to divert all process flow from number 2 to number 1 lagoon is complete. DTH 000043845 Construction - (Continued) 10. Electrical work for the new inert gas generator was completed during the period. 11. A new duct with an electric vibrator was installed for the dry blend B scale. 12. Work is in progress on Dryer Noise Abatement, Maintenance Insulation, Inert Gas Generator, Compound Conveying Lines* Farrel Mixer Feeders, Truck Unloading Safety Revisions, Railcar Resin Heel Cleanup SysfenH New Contractor Shed, Offsites Electrical-Specialty Compound Line, Plant Emergency Siren, and Plant Emergency Lighting System. DTH 000043846 LABORATORY - R. B. Martin CUSTOMER COMPLAINTS Customer Product Type Complaint No. Status Resin Ross Roberts Tridyn Mastic Elm Coated Elm Coated Tridyn World of Plastics 5305 5385 5385 5385 5385 5385 5385 Contamination Moisture Contamination Contamination Gels 8 Contamination Moisture Moisture ARP-122078 ARP-011079 ARP-122178 ARP-011279 ARP-011079 ARP-011779 ARP-011079 Report by RBM Under Investigation Under Investigation Report by RBM Report by RBM Under Investigation Under Investigation Compound Central Plastics 18961 Central Plastics 18161 Central Plastics 17461 Superior 15041 American Electrical 34641 American Electrical 34641 Cross Contamination Rough Profile Cross Contamination Sticky Product Contamination Scheduling '- ACP-121578 ACP-121578 ACP-011179 ACP-011279 ACS-011179 ACS-011079 Report by CRM Report by CRM Report by CRM Under Investigation Under Investigation Under Investigation Dry Blend Permafit Corp. 90171 Agglomerates ACP-011279 Under Investigation WAIVERS RECEIVED Date Car Material Customer Reason Waived By 1-4 1-5 1-5 1-8 1-10 1-11 1-15 1-16 1-17 1-17 1-17 1-18 1-25 1-25 1-25 1-26 1-24 1-31 1-31 1-31 PTLX-41597 PLCX-42680 T-2320 00292 Bags T-2319 T-2419 T-2809 T-2351 PLCX-43227 PTLX-41622 T-2320 PTLX-42040 Miller Transport PTLX-41860 PTLX-41640 Bagged PLCX-43235 PLCX-43199 PTLX-41826 PTLX-41565 5425 5465 5425 5425 5425 5425 5425 5385 5385 5305 5385 5385 VRP 5305 5305 5385 5385 5305 5385 5385 Hat co Industrial Plastics Hatco Whittaker Athol Athol Uniroyal Robin Tech CarIon Carlon Robin Tech World of Plastics Triple R Flexi-Flo Flexi-Flo Export Tridyn Industries Carlon Simpson- Ore Tridyn Industries Volatiles Volatiles Volatiles Dry Time Static Static Gels Static Residual VCM Residual VCM Particle Size Particle Size Acid Value Residual VCM, Particle Size Residual VCM Dry Time Particle Size Residual VCM, Contamination Particle Size Moisture CLS CLS RDJ CLS RBM CLS CLS RBM GGD GGD RDJ RBM RBM NJF ^ NJF $ CLS g RBM o HRF t* GGD g GGD ^ QUALITY CONTROL TESTING Resin - 521 regular samples, 2860 other in-process resin samples. Bulk resin shipments total 132 (62 railcars, 70 trucks). Dry Blend - 614 blenders plus 346 boxes produced in January, 353 blenders checked plus 77 boxes tested. Adjustment rate for Dry Blend blenders was 1.8%, (boxes 0.3%). There were 339 other Dry Blend in-process samples during January. Bulk shipments total 54 (29 railcars, 25 trucks). Compound - 598 blenders produced and tested. 429 other in-process samples. Adjustment rate was 2.2% of total blenders produced. Bulk shipments total 18 (11 railcars, 7 trucks). RVCM in Shipments A total of 127 shipment samples were tested for RVCM in January, A summary of these results are listed below. Product 5385 5305 5425 Dry Blend (including 90171) Average RVCM # Samples 2.5 35 14.0 14 0,4 11 ' 2.9 36 Resin Heat Stability Oven heat stability tests were run on forty-two (42) blends of resins. 5385 5425 5305 5465 16 Blends 16 Blends 8 Blends 2 Blends Two blends of 5425 were rated 15 minutes poorer than the control and one blend was more than 15 minuters poorer. Raw Material Testing Sixty-two (62) lots of plant raw materials were tested. One railcar of 2-Ethyl hexanol was rejected for high acid heat and phthalate ester color. The phthalate ester color was run for the first time in January and will be used when acid heat colors indicate poor quality alcohol. Color Concentrates Custom Chemicals Co. green color concentrate CVG-258M was tested as a replacement for Americhem 11866-R3 and was found unacceptable. DTH 000043848 QUALITY CONTROL TESTING (CONT.D) Lead Stabilizers A sample of special non-dusting Tribase XL was tested. It dispersed well and was equivalent to the regular Tribase XL as a stabilizer. Titanium Dioxide A plant sample of New Jersey Zinc RF-1 titanium dioxide was tested. This coarse particle size and less expensive grade did not adversely affect the Brabender properties of dry blend. Date Shipped 1-10 1-11 1-24 1-25 PRODUCT DEVELOPMENT AND SERVICE Quantity Product Customer Requested By 100 lbs. 50 lbs. 50 lbs. 50 lbs. 18031 CL BL 50 5385 III 5385 III 27121 Unique Plastic Graphics M T Chemicals Inc. GAF Inc. ACME Boot Co. EAS RNG RNG JFN COMPOUND DEVELOPMENT AND SERVICE Special Compound Testing The specification physical tests and extrusion quality were measured on 5 railcar shipments of 34861 Gray 546 and 1 truck shipment of 36861 Natural for Western Electric. The materials all met Western Electric's specifications and were released. Color Formulas Gray 547 Color formulas and quality control standards were prepared for 34431 Gray 547 to enable the plant to make this compound color. Gray 544 17461 Gray 544 was matched using a solid block color concentrate in place of a paste color concentrate. Extension Quality Tests / During the month 20 compound samples were extruded to evaluate quality. They included Western Electric shipment samples, customer complaint samples, and plant quality evaluations. DTH 000043849 SPECIAL PROJECTS Resin Volume Resistivity Volume resistivity measurements were made on 4 blends of 5425 resin produced during the month. These values were all normal for 5425 resin. RVCM in Slurry A total of 458 slurry samples were tested for RVCM out of a total of 498, The daily average exceeded the 400 ppm limit on 7 days (23% of the days were over 400 ppm RVCM). The overall average of all samples for the month of January was 324 ppm. RVCM of 5305 Drier Samples The Laboratory continues to monitor 5305 RVCM on samples from the drier. A total of 31 samples were tested with an average RVCM of 25 ppm. RVCM of Waste Water The GC lab continues to monitor blowdown drain water taken by production for RVCM. Problems with the emission recovery system continued to cause high VCM levels in the blowdown effluent. A summary of January's results is as follows: Old Blowdown Tank New Blowdown Tank Average ppm RVCM No. of Samples 190 21 131 28 Special Samples for Aberdeen Engineering Sampling continued from the blowdown tanks for % solids. This month 22 samples were tested for the yield project. The other continuing project for Aberdeen Engineering is the special sampling of slurries and waste water for VCM content. There were 48 of these samples in January. Dry Blend Rheometer A new torque rheometer was put into service and sensitivity curves plotted. Due to field problems with 80273 H work was concentrated on this dry blend. It was found that stabilizer errors as analyzed on the torque rheometer would not respond to major changes in concentration. The new instrument operates quite well and work will be donw to determine if the torque totalizer (integrator) is capable of routine plant usage. DTH 000043850 SPECIAL PROJECTS (CONT.D) Anacon Moisture Monitor Work continued on verification and calibration of the Anacon Moisture Monitors. Anacon results were compared to the standard percent moisture by oven, Problems of mechanical reliability have developed as two of the three units are now out of service. A data letter will be issued concerning the precision and accuracy of the units in early February. PRC Color Test The phthalate reflux color method was set up using the run lab equipment and three alcohol samples were checked. One sample of 2-ethyl hexanol had very poor color. The other incoming shipment was marginal. This test will be used to monitor incoming alcohol shipments which fail the routine acid heat color specification. DTH 000043851 ORDER ENTRY AND TRANSPORTATION WAREHOUSE - J. C. Coffman J . E. Mays Shipment by Product- M/Lbs. January, 1979 Year-to-Date Resin Plasticizer Dry Blend Compound TOTAL 17 ,291 82 5 ,471 3 ,997 26 ,841 17,291 82 5,471 3,997 26,841 Number of Shipment by Mode R/C O.T, C.C. C.O.T. TOFC CPU TOTAL Resin - Bulk Package Export Aberdeen Plasticizer - Bulk 68 65 5 62 3 45 6 * 138 7 7 22 54 22 Dry Blend - Bulk Package 24 11 3 2 1 12 49 37 Compound - Bulk Package 87 27 2 1 15 32 62 Export - Package Back Hauls for January 2 103 166 11 12 7 1 2 7 56 351 12 Number of Shipment by Month - Y.T.D R/C O.T. C.C. C.O.T. TOFC CPU TOTAL January 103 166 12 7 7 56 351 Material Handling Report M/Lbs. T/L Packaged Resin From Production Packaged Compound, Dry Blend From Production Transferred From Main to Prairie Transferred From Prairie to Prairie Reverse Transfer Resin to Plant Reverse Transfer Compound to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Main 486 2,066 648 0 486 0 5,467 2,066 1,782 13,001 12 51 16 0 12 0 135 51 44 321 - DTH 0000438 LOCATION MAIN-East S TOTAL M SQ. FT. 48 CONOCO TRANSPORTAT ion ABERDEEN WAREHOUSE ' CONTENTS Compounds Dry Blend Export Resin Conoco Resin 2.8 ___ .2 .3 // ' ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 3.9 5.6 9.5 Prairie 12-1 12-2 12-3 12 22 * 21 . 12-4 12-5 22 21 e 12-6 12-7 fu 21 21 12-8 21 Compound Compound Dry Blend Como 0.6. Raw Materials Conoco Resin Conoco Resin Resin O.G. Mill Scraps Cmpd 0. G. Dry Blend 0. G. Sifter Overflow Resin 0. G. Conoco Resin Conoco Resin .Chrysler Resin Chrysler Resin ` Conoco Resin .3 1.2 1.5 1.2 .1 1.3 2.2 3.5 .5 .2 .7 2.8 3.5 1.1 .9 . .7 .4 .1 ..- 2`Q. _JUii Ar" ; - 3.5 1.0 2.2 .3 ____ZUL_ 3.5 3.5 1.4 . 1.2 .1 ____Id.- 1.3 2-JL 2.2 3.5 3.5 Total Sub-Total __ 34*5. , (Plug Aisles) * -. 20.9 13.1 21.4 34.5 DTH 000043853 Off-Grade In Storage Material M/Lbs. T/L Sifter Overflow Resin "BC" Resin "H" Mill Scraps Compound "B" Compound "H" Dry Blend "O.B," TOTAL 160 1,025 675 72 1,040 185 448 3,605 4 25 17 2 26 5 11 90 Chrysler Storage Balance, January, 1979 Transferred during month TOTAL 2,974 334 2,640 73 8 65 D. F. Operation During the month of January we experienced another drop in our resin inventory. We had an export order for Eximplast that amounted to 2 MM lbs. Our total inventory is the lowest since 1974 with only 13 MM lbs. We now have 3 empty warehouse buildings at Prairie ready for future use. DTH 000043854 (1) Thru December, 1978 Actual Account in (2) Thru January, 1979 ABERDEEN AUTHORIZATIONS REPORT Aim*. CAPITAL HO. DESCRIPTION DATE Ainu. APPROVED AFE AMT. Cl) (2) FINAL EXPENDED COMMITTED TOTAL EST. TO DATE TO DATE COST COMP. UNDER (OVER) AUTII. AMT. EST. EST. COMP. CL0S. DATE DATE REMARKS 9126 PVC Reactor Capacity Replacement 7/8/76 8,577,00(5 8,102,089 8,180,029 8,190,029 386,971 12/78 3/79 Closed to field charges. 9276 Relief Valve Vent Containment 9286 Additional Slurry Blend Tank 12/10/76 12/7/76 39,000 290,000 33,203 281,706 34,499 285,922 34,499 285,922 4,SOI 4,078 12/78 3/79 12/78 4/79 Closed to field charges. Closed to field charges. 9057 Vent Cas Incineration 4/1/77 275,000 273,794 274,284 274,284 716 12/78 4/79 Closed to field charges. 9087 Resin Silo Aeration 5/16/77 280,000 229,525 241,989 241,989 38,011 12/78 3/79 Closed to field charges. 9147 Phthalic Anhydride Exposure Reduction 6/30/77 45,000 40,290 44,039 44,039 961 11/78 3/79 Closed to field charges. 9187 Emergency Reactor Vent Control 9/29/77 33,000 24,640 31,118 33,000 0 3/79 6/79 Testing. 9197 Dryer Area Noise Abatement 9/29/77 45,000 12,763 25,245 45,000 0 6/79 9/79 Installation proceeding. 9227 Plant Emergency Lighting System 10/10/77 65,000 42,052 45,648 65,000 0 4/79 7/79 Installation proceeding. 9237 Heated Plasticizer Addition System 10/11/77 37,000 7,628 8,057 37,000 0 9/79 12/79 Installation proceeding. 9247 Farrell Mixer Feeders 11/21/77 47,000 14,321 17,321 47,000 0 3/79 6/79 Feeders to be installed. 9257 Resin Transfer Debottlenecking 11/16/77 56,000 28,142 31,444 56,000 0 5/79 8/79 tkist collector purchased. 9267 Dry Blend Production Expansion 11/23/77 200,000 165,313 179,374 200,000 0 4/79 7/79 Some items to complete. 9277 Truck Loading Safety Revisions 11/28/77 16,000 1,147 3,095 16,000 0 3/79 6/79 Installation proceeding. 9287 Plasticizer Yield Improvement Test 12/S/77 6,000 3,041 3,544 6,000 0 3/79 6/79 One test complete. 9297 Automatic Plasticizer-Stabilizer Weighup System 12/14/77 60,000 873 41,778 60,000 0 9/79 12/79 Design being dore. 9307 Compound Project Conveying Lines 12/14/77 50,000 11,131 20,563 SO, 000 0 4/79 7/79 Installation proceeding. 9018 Critical Spare Equipment 1/31/78 63,000 56,665 63,502 63,502 (S02) 12/78 3/79 Closed to field charges. 9028 Wise. Items (Aider $10,000 1/31/78 50,000 24,138 47,273 47,273 2,727 12/78 3/79 Closed to field charges. 9058 Maintenance Equipment 9048 Resin Moisture Analyzers 9058 Laboratory Equipment 9078 Mi sc.. Projects Under 510,000 9088 Replacement Inert Gas Generator 9096 New Compound Line 2/3/78 18,000 2/24/78 17,000 2/24/78 50,000 2/24/78 166,000 3/28/78 44,000 4/17/78 2,050,000 7,737 17,899 17,899 13,148 13,148 17,000 48,617 48,659 48,659 132,512 158,374 166,000 25,490 28,703 44,000 340,980 1,037,230 2,050,000 9108 Boiler Burner Replacement 5/12/78 9158 Plant Guardhouse Improvement 8/14/78 9148 Plasticizer Chemical Exposure Abatement 8/21/78 9158 Fire Protection Improvements-Phase I 9/19/78 9168 Misc. Projects Under $10,000 9/21/78 9178 Propane Vaporizer Replacement 9/21/78 9188 Railcar Resin Heel Cleanup System 10/12/78 9198 Debottlenecking-Centrifuge AntiChatter Devices 11/7/78 9208 Spare Recovery Vacuum Pump 12/5/78 9218 Charge Mater Heating Improvement 12/8/79 9228 Dry Blend Silo Alarms 12/13/78 9248 Silo Isolation Valves 12/14/78 9258 Dryer Operation Improvements 12/14/78 EXPENSE 9238 Compound Line 1 Roof Collapse 12/13/78 170,000 19,000 152,000 176,000 59,000 175,000 55,000 70,000 14,000 32,000 25,000 25,000 315,000 44,000 1,183 18,496 2,038 166,525 18,540 73,122 170,000 18,540 152,000 0 10,540 0 0 0 0 50,511 88,941 3,613 60,876 176,000 59,000 175,000 55,000 70,000 0 0 14,000 0 11,198 32,000 0 0 - 25,000 0 0 25,000 0 0 315,000 0 0 44,000 101 12/78 3/79 Closed to field charges. 0 3/79 6/79 Analyzers in service. 1,341 10/78 2/79 Closed to field charges. 7,626 12/78 3/79 Closed to field charges. 0 4/79 7/79 Equipment to be installed. 0 12/79 3/80 Offsites electrical being installed. 0 6/79 9/79 Burners on order. 460 11/78 3/79 Closed to field charges. 0 7/79 10/79 Purchases proceeding. 0 9/79 12/79 Engineering in progress by CEt 0 12/78 3/79 Closed to field charges. 0 9/79 12/79 Engineering in progress. 0 5/79 8/79 Trial unit being tested. 0 2/79 5/79 Equipment being installed. 0 8/79 11/79 To be purchased 0 5/79 8/79 Purchases proceeding. 0 5/79 8/79 Engineering in progress. 0 7/79 10/79 Engineering in progress. 0 10/79 1/80 Engineering in progress. 0 2/79 S/79 Insurance claim being filed. DTH 000043855 ABERDEEN PLANT EFFICIENCY 1979 POUNDS OF RAW MATERIAL/POUND OF PRODUCT Standard :r < 1.01960 Pi ri ' 3 Lf Ll Standard 1.01300 Standard 'J 1.00320 Standard 1.12080 DTH 000043856 C M C Y L A R r2Y M O N T % `Off Grade ABERDEEN PI,ANT QUALITY PERFORMANCE 1979 Standard 0.40 Standard 0.739 Standard 2.0 4M Pounds Monthly Production E&& iln ABERDEEN PLANT PRODUCTION 1979 MM Pounds Cumu1ativo Production 40 35 30 25 20 15 10 5 0 Em tpouri# 8 7 6 5 4 3 -Meric 350 300 i 250 200 150 100 50 0 50 40 .30 20 10 0 5 4 3 2 1 0 Pis StlC12 er 2 80 60 40 20 0 15 12 9 16 0 0N1 k Hv#nAx T MAtCK A^tlL MAV >UN( *uowit tiATtMiia ucioaia novemc* etctMtr* 3 0 1 9 79 DTH 000043858 ONE. YEAR SY M O N TH S MM Pounds ABERDEEN PLANT INVENTORIES 1979