Document KJDZVqVeNyQnmkEJdEdyqxrDx

PLAINTIFF'S EXHIBIT :elanese plastics l specialties company Chemcel Plant Bishop , Texas TO: FROM : E unoz R. .T lu Bunklev RLB-51-79 September 25, 1 Quality Control Monthly Report August, 1979 CC : Dr. R. A. Daniel - Chatham M1 i. v. . J . *V . 3eltz Mr. A. R. Kurkowski Mv R. \s . Murphv Mv T"' &. \ O'Neill Dr. W T Druin (6) - Summit Mr. c. Gottfried Mv C\ , C. Abshier - Bishop Mv V . S. Allen V c. ns . Amond Mv G. Ar triDe Dr. H. L. Davis Mr. sj . C. Doeavns V D. L. Dotson Mr . R. D. Fuchs \r y. C. . Hammond Ms . . R. Hancock Mr T V Harvev Mv t H. D Hohon Vt w. T Merian Mv t K. Meyer Dr. M . Meisters Mr. F . B. McAndrew Mr, W . L. Shearer Mr. M . M. Wilson Mr. D . Zimmerman Summit Data Files Mr. A . B. Milam Ms . P . J. Moede Mr. R . G. Rothenberg Mr. J . D. Saladino Mr. A . G. Salinas Mr. P . N. Thomas Mr. D . Wallen Mr. V 1_4 . D. Wendler Mr. K . A. Wolf File: 3.017 301.014 501.009 Cen tral Files (3) - 003939 Product waivers for Ceicon^ production lots totalled 24.7" of the month's production cf 9.3Ml lbs. Quality waivers for'Natural Finishing produc tion were due mainly to out of specification melt index and natural color. The major quality variances in Special Products production were out of specifieation melt index, natural color, and off-size pellets. CelanexS quality waivers totalled 5.67, of the month's production of 1.9MM lbs. The major quality variances were failure of the flammability test and out of specification ash content on the filled products. A total of 55.77, of the Nylon Unit's production (1.4MM lbs.) for the month was waived due to quality variances. The major causes of quality variance being out of specification RV and volatiles content. i. celconS- A. Customer Complaints - Dotson/Tijerina/Hemandez 1. Arkless Switch complained (P-5554) that parts made with GC-25 from Polyplastics were brittle and did not mold as well as parts made with Bishop produced GC-25A. Since the material was not made at Bishop and no lot numbers or samples were available for further evaluation, no plant action was taken. Distribution was requested to send the customer onlv Bishop GC-25A production. (DLD-180-79) 2. Trico Products complained (P-5556) that metal contamina tion was found in a shipment of GC-25A black from lots 9041271, 9033011, and 9041671. A review of original shipping lot analysis, retain samples, and a sample of the returned shipment failed to find any indicating metal contamination. (DLD-179-79) At month's end four Celcon complaints are still pending. B. Manufacturing Support Evaluation of T-302 Stripping - Moede It was recommended to Production that stripping on T-302 reactor column be re-evaluated while continuing with plans for ordering the materials of construction for a cone bottom in the tower. A plant trial was initiated to deter mine the effects of increasing the trioxane concentration in T-302 residue on energy consumption, production capacity and raw material usage. The latent heat on the stripping section was reduced to a minimum. After sufficient data is collected, the latent heat will be returned and data will be collected for the stripping case. 003940 Proc :ction of C-2- with 3CI6: Allen 3CIc2"T co-stabilizer (a substitute for Elvamide 8063) was used in the production of C-244 from 3 ' 137 79 through 8/24/79. Previous studies at Summit had indicated that BCI637T would significantly reduce black speck formation. All C-244 was produced on the 8" extruders with no unusual processing difficulties. However, a significant number of black specks and/or burnt pellets were present in all lots produced. Future production of C-244 will be monitored to compare black speck generation during the use of Elvamide 8063 and BCI637T. C. Routine Analytical - Salinas Sample count, overtime hours, holiday overtime hours, and formaldehyde feed concentration for August are summarized in Table I. The overtime hours for August were 272 compared to 509 in July. The significant decrease in overtime is due to the filling of a vacancy on "C" shift and a shorter reportin period. The sample count also decreased due to a shorter reporting period and less sampling from MH-2 and Nylon. The overtime hours are as follows: Technician vacation Sick relief Scheduled overtime Environmental Nucleant Production Safety Training PBT - Hi IV testing Total -- 72 38 -- 80 6 40 -- 12 24 272 CELAXEXS A. Customer Complaints: Dotson/Tijerina/Heraandez 1. Beatrice Foods Co. entered a precautionary complaint (P-5557) stating burnt and/or contaminated PBT chip in PBT shipments. The complaint indicated the customer uses the chip but is qualifying another source of supply. The plant has no control over the quality of the PBT originating from Shelby. Shelby Quality Control indi cated that a small level of contamination of the type indicated is inherent to their process. The complaint was referred to Shelby Quality Control for further resolution. (DLD-182-79) Two Celanex complaints remain unanswered at month's end. 003941 :\_r- s i- - J- Sectember Mar.ufacrurint Suooort -- "' 4 I Intrinsic Viscosity cf Ceianex - Moede Intrinsic viscosity determinations of Ceianex (PBT) have not been in agreement with the Fiber Industries Shelby plant determinations. This difference was due to the FII method basing the RV (relative viscosity) to IV conversions on PET solutions rather than PBT solutions. This results in a higher IV value by a factor of approximately 1.09. It was recommended that the Celanese Plastics and Specialties Co. continue to measure IV by the Celcon Method No. CL 1-69 and use the FII Method No. 5, Serial 1 RV to IV conversion table to make comparisons with Shelby. C. R.aw Material Evaluation Ceianex Fiberglass Qualification Trials - Allen JCF 419N911 AA, 3/16 inch glass from the new Amarillo plant was evaluated and qualified for use in Ceianex. This glass was used without processing difficulties in producing 25,245 pounds of VO grade Ceianex (3310 EF 3022). Physical properties and other Q.C. parameters met product release specifications and were within the normal range of Bishop production. OCF 419 BB, 1/8 inch fiberglass was re-evaluated for use in Ceianex formulations. This glass was originally qualified in 1977 but has not since been used at Celanese. No processing difficulties were encountered in producing 24,860 pounds of 3300 EF 2001 using this glass. Although all product release specifications were met, tensile strength was judged to be somewhat low compared to normal production. Therefore, addi tional trials will be held with this glass before requalifica- Customer Complaints - Dotson/Tijerina/Hemandez 1. Reynolds Metal Company entered a supplemental complaint to the original P-5552. This supplement indicated that the seal problems with gaylords of Nylon N-186 natural involved more material than originally indicated. A total of 18 gaylords instead of 11 out of a shipment of 30 were found with poor seals. In addition, an inspection of warehoused gaylords of N-186 disclosed 23 of 51 g*ylords with incomplete bagging seals. Photographs of the damaged seals were also included in the supplement. Investigation of the complaint revealed that liner sealing problems had occurred in the plant when packaging this material. A proper seal was not obtained due to creases and wrinkles in the box liners. This problem has been corrected. In addition, all packaging personnel have 003942 -5- ieDre~De: 3. Nvlon Nucleant Production - Saladino/Salinas The inventory status of the nylorf nucleant production is summarized below.- Inventory 8/1/79 Inventory 3/31 '^9 Nucleant Produced m August Nucleant in Process Inventory 8/31/79 (16% KF) Inventory 8/31/79 (23% CaAcg) 15 drums 27 drums 12 dr''ms 14 drums 30 drums 18 drums INDUSTRIAL HYGIENE - Hancock, Pritchard A. Formaldehyde Survey The formaldehyde survey in the SH1/T01 area is partially complete. Sample results reveal several exposures to formaldehyde over the 1.5 ppm "action level". Those job descriptions exposed to formaldehyde above the action level were: 1 operator-gauger, 1 TO operator helper, 2 SH operator helpers, 1 SH operator. A leak, in the slop line from T02 could have contributed to some of the exDosures. The survey will continue, as will the follow up monitoring. A report will be issued. 3. Asbestos Survey Personnel were monitored for asbestos exposure during the August SEO production run in the Celanex Unit. The asbestos handling portion of the blending system had been modified. A report will be issued pending results from National Loss Control Laboratory, Long Grove, Illinois. Personnel were also monitored during the clean-up procedures after an asbestos spill in the Celanex unit (8-06-79). A rubber boot on V-1941 vacuum system was partially detached. Asbestos escaped from the system as the blend was dropped from MX-702 into the V-1941 feed tank. Personal and area samples were taken. The highest personnel exposure seen was 1.2 fibers/ cc. This was a short term (55 min.) sample. The highest concentration found (for the area samples) was 0.8 fibers/cc. This sample was taken on the third floor in the vicinity of the spill. The permissible exposure level (8 hr. time weighted average) for asbestos is 2 fibers/cc. C. Organic Vaoor Analvzer A "diluter kit" attachment for the OVA has been received. This attachment allows measurements in the 1000-10,000 ppm TOC range. A modification to the previously issued method of operation (ARH- 33-79'' will be written. 003944 R 51-79 -P- Seorember 2 Perscr.aL 53~ol.es for ETON exposure have been taken in the SHI, SH2 , and MK2 'units. Operators and operator helpers were monitored. Sample results indicate personnel exposures to ETON are 'under 1.0 ppm, 8 hr. tine weighted average. The highest -.cpcsures seen were under 5 ppm, while collecting samples. The survey will continue and should be complete in mid-October. A report will be issued. Analytical Load The OSKA/Environmentai analytical load, to date, is summarized below. , Month OS HA Environmental YTD OSHA Environmental SH1/T01 SH2/T02 MH2 Nat. Finishing Soec. Product Celanex Nvlon Chemical Co. 67 2 2 0 0 23 0 0 94 82 0 0 0 0 0 0 0 82 144 228 119 226 317 62 30 0 1,126 92 10 1 2 2 1 1 3 112 COLOR SERVICE - Artripe/Rothenberg/Harvey General Summary Color Service developed 27 color matches this month. The distribution of color match work for each market group was 16 Celanex, 6 Nylon, and 5 Ceicon; of this 5 Celanex, 3 Nylon, and 2 Celcon were reworked from existing formulations. 837 pounds of products were extruded and shipped. A total of 557 chips were sent out in the process of filling 21 sample requests for chips only. V."e have scheduled 25 color matches for September, leaving our backlog of unscheduled work at 42. There is 1 new marketing request on backlog. The remainder of the backlog is necessary due to pigment obsolescence, reformulation of Nylon vendor concentrates, and chip replenishment. Fisher Body Claret WPH 4887 now has full approval, Blue WPH 7130 was resubmitted to Fisher for UV testing. 13 match requests for Fisher 3ody 1981 model year were received this 003945 RL3-51 _ ;c Seo tender 25 R. Rother.bert ar.c L. Harvey visited Surrjr.it: and U.L. Laboratories to observe L'L ?L VO testing procedures. 'This was to identify any differences in testing procedures between U.L., Summit and Bishop Laboratories. Color Service work load remains very high, turnaround time per month was si rhtiv above la^t month. ft) OQ 1. Method Update - Rothenberg One physical property test method was revised and issued durin the month. The method was: Determination of Tensile Properti of Plastics (CL 2-22) . 2. ,\'ew Test Method - Rothenberg Test method CL 2-27, Visual Evaluation of Color Differences of Opaque Materials was issued (RGR-74-79). This method describes the general procedure to be used in the visual evaluation of color differences in molded Celcon, Celanex!, and Nylon. The method covers spectral, photometric, and geometric characteristics of light sources, illuminating and viewing conditions, and specimens. This method is to be used for critical color matching. 3. PCB's in Pigments - Rothenberg Effective July 1, 1979, EPA imposed a ban on any form of phthalocyanine blue and green pigments and diarylide pigments containing more than 50 ppm of Polychlorinated Bi Phenyls (PCB's). L:e currently use five (5) pigments classified as phthalocvanines and have been informed by the manufacturers that we are in compliance with the new regulation (RGR-71-79). V. Color Formulation for NSF Approval - Rothenberg Complete formulation data on a Celcon FDA-grade blue concentrate was furnished to A. Serle. This information was needed to comnlete material formulation confidential reports for NSF* (RGR-73-79). PERSONNEL Martha Escobar joined Celanese as a Lab Technician assigned to the Color Lab on August 13. Marianne Thompson, Color Lab Technician, was transferred to the Specification Lab on August 13. 003946 RLS-51-79 -5- September 25, 1979 K. A. Rose Analvtzical Grout* Leader, resigned effective August 2L. ` Kenneth Pratt was transferred from the Specification Lab to the Chemical Co. Lab on August 29. RL3:sih Attachments 003947 III i m i vo J co O1 o1 o, <r CM | -----------------\ uo ' - O <r o,o ; Ni ,0 in i cn * ^f -- j ZJ l/l -- a; 2. CL - >v o h~ m -- --- --. ---T3) <o i ZJ i 1 0) 3c -J 33 -VD-____ O 1 O >~ A --* S. ~ -i * 0 1 ., j; 'l mantes HC' ,O'<in"^'CN'0CiA 'S O '-H o 'O n- --. CO MO') CO o o 0. 0. ooh i oo oo a) a; <> c> -a ccjj -aoa> oo 'j cn <t r^ Qi r^O r-* | in co co >* CM CM CM O CM CM 2! CM J , ^ 23 23 < --1< *--1 u 2) *--i p 2C r--i 0 Vo > -V^ -- o Gross Production Total Packaged Off Specification Quality Waivers p n- ( TABLE II Cel eon Quality Summary AUGUST M Lbs Percentag&e 9247.1 100.0 Year to Date M Lbs Percentage 58411.7 100.0 2643.7 ' 22S6.2 28.6 24. 7 17328.6 14378.1 29.7 24.6 TABLE III Celcon Experimental Products 'roduct C234A C243 C244 C267 C273 C300 C301 Production 62400 209900 599100 30530' 5400 333300 125100 Releases 62400 209900 471100 30530 5400 290100 125100 003949 Cel;;r, Releases - ^----* ?.e leases U C r. Z Z Z'-' (y. ibs ATG V7C1 AL'G Y70 Quar. zrtv (M Lbs) AL'G YTD AL'G M9 0C0 "lake "lake M2'?:: "lake :-;j 5 3 1 T a cur" ' M2S0- Natural M251- Natural M9 30- Natural Mill- Natural Mr-::i: Natural .Ml-1 1- Natural Cl-5 Tarural Ml'::- Natural U1C11 Nvat^ural -- 3 , *-- \^C *. 0 r M22- Cclor : - coiaz ;:?!! Icier MJ21B Natural XvlS- Color Ml-11C Color Cl-i Color Millie Color MC"1C3 Color M253- 5lac.-: M90 7- Slack M9C14 Slack Cl-3 Slack M2"10- Slack M2 7011 Slack _ 31 c c e GC25A Natural IC23A Slock vC ^ ~ ^ - M? 11" 5 lac - i ..r *t rscofir u.^` f "* *JW i C1 -1 22-1 C2 -1 22 -- _ 15 ^ v1z 2 C25C2oo C2 5 " Cell 13TALC 0 39 3. 9 6 0 0 0 2 -0 e ^ 651.3 US.123.2 110?.S 922 . 5 60C.5r 6 0 27.0 0 0 0 53.3 23. S 43.9 2. S 33.9 0 51.2 112.6 102.3 117.2 30.9 o 362.3 Q '1_6 o 135.6 0 62.4 c c 209 9 171. 1 \0r-j r. 6 0 30.5 5.1 292.1 125. 1 26.3 1396.2 21 9 831.1 1596.3 25.7 24S72.9 279^ 173.6 172.3 3239.3 2717.9 1733.3 139.6 73 56.0 1603.3 ?^ 98.3 ^ 3Q 2 315.1 93.1 1^9 0 113.0 26C.1 159 2 2507,2 551.5 236.2 380.6 30.9 65.2 303.5 1613.2 225.9 215 e 1175.3 12 e ~ 96-.3 503.6 61.7 615.1 3275.9 387.6 176.1 12.6 iL--5*> .-0^ 50.9 5.1 ICC'.5 512.6 9C99.1 5 396". 1 0 3e 0 0 0 0 27 13 5 1 10 6 6 0 0 0 1 0 0 0 4 2 6 1 10 0 2 7 8 " 2 6 21 0 5 0 10 0 4 0 0 6 0 0 0 0 0 3 1 3 1A. 211 3 113 2 17 23 1 206 640.1 31 109. " 6 54.9 2 38 - 394.2 20 267.1 25 116.0 13 2 3 143 3.2 9 15 18 23.3 t 21 9.7 1t 42 8. " 15 74 25 17.5 16 16.1 17 53.4 2 16.4 5 60 141.5 71 64 ^c 85 5 35 4 4 T * 100.4 33 3C3.1 8 411.1 1045.3 7001.3 360.2 85.1 589.4 335.5 341.1 412.7 35.9 272.4 1.9 14.2 177.3 34.9 2.6 86.6 92.0 373.4 270.7 16.1 69.7 16.4 302.6 12.7 35.3 143.0 93.3 18.2 262.6 622.6 285.6 \ 1 1 51 5.4 5.4 10 5 137" 2236.2 1437S.1 S 3 2 4'v T l O 2 1 i i 3 A 9 l 1 43 J,_2dl22? rr^NL crCr.x : *- .-.-.-... . .O- . Lw y.c r.rr ,,. 23 5 . 22 -- ,C' --~ >/ - Y 't'*N 5. w _/ 3. 33 ** -C' * c CCACITY VAINERS MONT:: 25 . 1 YTC 24 4 YTD 9 15 55 1C 3 6 $ 15 n 2~ 7 ,, 10 6 / 2 10 12 1 1 1 -1 '"k 1 3 5 3 9 -- A 260 003950 TABLE V Ar. a 1 v 5 iso Ceicor. Packaeed Off Soeci ------------------------ r* cation La Defect: Me It Index Discolored Tellers 31ack Specks Stabilizer Content Ash Content Natural Coror Ext. HCHO 10X Melt Index Kc Volatiles Off Size Pellets Aug'us t Lots Quantity M Lbs. 14 1015.0 6 329.3 1 192.4 4 249.8 00 6 346.9 1 43.2 0 '0 3 169.6 C0 G0 t; of Total Natural 12.4 4.0 2.3 3.0 0 4.2 0.5 0 2.1 0 0 of Quantitv Total )tS M Lbs.' Natural 83 7202.0 25 1169.2 33 2971.6 19 1113.4 1 28.3 23 1964.9 5 152.0 3 56.1 6 532.1 60s 205. S 914.6 15.4 2.5 6.4 2.4 0.1 4.2 0.3 0.1 1.1 0.4 2.0 Soecial ?: Augus t Defect it Index discolored Pellets Color Match Off Size Pellets Colored Pellets (Contamination) Voiatiles Stabilizer Content Slack Specks Tensile Strength Datura! Color (Glass Filled) Ash Content Lots 11 4 5"/ 1 011 10 0 1 9 0 TABLE v\rr Ouantitv M Lbs . 120.8 43.7 18.1 62.3 2.8 0 17.5 58.2 0 20.1 141.5 0 ?o of Total S .P . 11.6 4.2 1.7 6.0 0.3 0 1.7 5.6 0 1.9 13.6 0 Lots 84 20 21 50 Quantity M Lbs . 1209.7 206.0 136.7 650.1 6 25.2 10 143.7 13 424.4 29 177.7 1 9.4 21 299.1 25 349.8 5 38.4 % of Total S.P. 10.3 1.7 1.1 5.5 0.2 1.2 3.6 1.5 0.1 2.5 3.0 0.3 003951 C ^ ' -n "Y r'uaiitv Summary M lbs august Percentage 1905.7 100.0 406.6 1P,7 ? 21.3 5.6 Yea to Date M Lbs Percentage 16086.4 100.0 1435.5 884.5 in 8.9 TA3LH VIII Celar.ex Experimental Products Frodu; :240 Produc tion 4450 Releases 4450 003952 CELANEX September Status Report - N.A. Rollins Celanex A scrap recovery system has been designed that will recover Celanex Phase I material. By using the energy off of the existing fluid bed dryer, negligible energy will be required to recover an estimated $126,000/yr. of scrap product. Payback will be less than two months. A qualification trial was conducted using a modified binder in OCF fiberglass. Physical properties were all on-spec and no opera tional problems were encountered. 40,000 pounds of J-189 were produced with no operational pro blems. The material was on-spec. Asbestos Monitoring - Swinler Obtained large volume air sampler from CCTC for use in predict ing potential loading to atmosphere from Celanex warehouse dust collector. Modifications to air sampler will be required to fulfill our obligation. The maintenance department is currently fabricating required adapters. One dozen three piece 0.8/U. filter cartridges are on order from Clayton labs for use in a particle size distribution study to be undertaken for the warehouse dust col 1ector-construction permit. Ten samples will be taken and analysed for particle size. Additiona one sample will be examined for free asbestos. "J" Number Support - Swinler No new "J" numbers were received this month. A process hazard analysis was undertaken for <3-197. The salt and pepper blending of Foam-Kon 23 with 3300 was found safe providin proper safeguards are implimented for the storage and handling of Foam-Kon. Ref: GSS-10-77. 004086 NYLON MS-383 Safety Audit - Swinler < Audit complete. Preliminary report out shortly. Nylon - Ro11ins/Swin1er Another trial was conducted on MS-383, producing 1503 bl&ck with the SC-60 screw and a temporary cooling system on zone 1. Good temperature control was attained across the barrel but feed ing problems halted the test after nine hours of successful produc tion. The trial is being analyzed, A bowed screw and/or improper surfacing of the feed flights is suspected to have caused the feed ing problems. After less than 30 hours production time using SC-5 up to .030" wear on the flights has been found. 004087