Document MNgQjrVDxmYwok25xN27oq97

SAFETY - A. H. Sather OCCUPATIONAL INJURIES Injuries Treated First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time Injuries by Department 1979 May 4 0 0 0 0 1979 Year-to-Date 12 1 2 29 0 1978 Year-to-Date 24 3 1 10 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office Injuries by Types 27 11 15 00 00 02 10 9 6 2 0 0 Cuts and Abrasions Eye Injuries Burns Bruises Sprains and Strains Other 13 03 35 04 03 00 12 3 5 4 .4 0 As of May 31, 1979, the plant operated 298 days or 393,167 man-hours without a disabling injury. TRAINING The plantwide lifting training program initiated in April was completed during the reporting period. Five (5) casual employees and three (3) engineers received new employee safety orientation. A. H. Sather attended the Managerial Grid Seminar May 6-11, 1979. PLASTIC VESSEL/SPLASH INVESTIGATION Two (2) in-plant teams conducted investigations regarding the use of plastic vessels and process hazards which could expose personnel to splash or spill hazards. Team members for each investigation are as follows: DTH 000019299 PLASTIC VESSEL/SPLASH INVESTIGATION (Cont.) Plastic Vessels - J. V. Uptain - Safety, F. W. Frantz - Maintenance, and V. L. Thornhill - Process Engineering. Splash/Spill Hazards - E. L. Kieschnick - Vinyl Operations, C. R. Miller Compound Operations, J. R. McCrimon - Process Engineering, and A. H. Sather - Safety. The reports were compiled and issued to C. L. Miller who assigned priorities for corrective action and distributed the final document to responsible personnel. OSHA INSPECTION On May 15, 1979, inspectors from the Occupational Safety and Health Adminis tration initiated an industrial hygiene inspection which was initially directed toward the handling of VCM. After the plant walk-around, some interest was shown with regards to lead handling in the compound area. The inspection lasted essentially seven (7) full days (May 16, 17, 22, 23, 24, 31 with half days on May 18 and 25, 1979). The initial activity involved a detailed review of personnel monitoring records to define sampling requirements for their inspection, and a brief review of overall plant safety procedures. Samples were taken on operators from two (2) separate shifts in each of the two (2) reactor modules, one dryer operator and a maintenance mechanic. The sampling for lead was limited to an 8-hour sample on a line III compounder during a Western Electric run. In all cases, the plant parallel-sampled the OSHA samples. Currently, the inspectors are awaiting the results of their sampling to deter mine if further sampling is required. The closing conference will be scheduled following that determination. FACTORY MUTUAL INSPECTION Factory Mutual Engineering conducted their semi-annual inspection on May 15, 16, 1979. The fire pumps were also tested and rated satisfactory. OSHA COMPLIANCE Lead - Activity in this area was limited to revising the process design for the building ventilation system baghouse air supply. The new design reflects air supply pressure requirements keyed to particulate loadings which normally would be found in that stream. Also, the forms for the finalized lead sampl ing plan have been received and the sampling procedures have been finalized. DTH 000019300 OSHA COMPLIANCE (Cont.) VCM - Seventy-four (74) samples were taken with six (6) indicating over exposure. The distribution of results and a brief explanation of over- are shown below: Range (ppm) Number Percent 0.0 - 0.5 0.5 - 1.0 1.0 - 5.0 5.0+ 61 7 5 1 74 82.43 9.46 6.76 1.35 100.00 Six (6) personnel received exposures to VCM of 1.0 ppm or greater. Job classifications, jobs, and respirator usage were as follows: a Mechanic working in the reactor area was overexposed from an unknown source; a Mechanic changed a reactor VCM charge valve and was wearing a respirator; a Yard Operator was unloading VCM cars and wearing a respirator ; a Reactor Operator was overexposed to an unknown source; a Mechanic was unplugging a 3/4 inch VCM line which contained liquid and was wearing a respirator; and a reactor operator was involved in clearing a plugged VCM charge line and wore a respirator. DTH 000019301 VINYL - E. L. Kieschnick May had 31 accounting days (Y.T.D. is 151 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, % 28.7 926 22.7 703 91,6 5860 94,0 123.6 819 20.7 3124 87.5 5519 88.2 The vinyl department production for the month was 28.7 MM pounds which represents a new monthly production record (old record 26.8 MM pounds in November, 1978). The 703 charges also represents a new record for 8 reactor operation. Items which contributed to the record production for the month were: 1. Utilization of dual initiators in 5425 production beginning May 4, 1979 which significantly reduced the 5425 polymerization times. 2. Continued success of the reduction in chem wash and swirl frequency in 5425 production and in elimination of swirl in 5385 production. 3. Improved reactor stream factor which was a result of: a. Maintenance of an optimum batch size to control foaming/condenser fouling. D-400 and 742 were the only reactors which required condenser cleaning for the month. b. Utilization of a new antifoam agent in all products beginning May 22. Approximately 1.7 MM pounds of resin were bagged during the month, primarily to meet export orders. Resin Quality Resin Type Prime Pounds "BC" Grade "H" Grade % of Total Production 5305 5385 5425 5465 Sifter Overflow 2,226,413 21,959,448 4,052,375 272,505 0 45,000 0 0 ( 3,000) (11,050) ( 2,250) ( 1,500) 169,090 (0.01) 0.12 (0.01) (0.01) 0.59 TOTAL 28,510,741 45,000 151,290 0.68 DTH 000019302 Quality performance for the month of May was 99.32% customer grade with 0.16% "BC" and 0.52% "H" grade. This represents the highest percent customer grade resin production since November, 1977. The variable cost variance for the vinyl department was ($340.4 M) with ($299 M) due to price and ($41.5 M) due to efficiency. The only major price variance was ($288.9 M) on VCM. The only major efficiency variance was ($59.0 M) on VCM. The raw material requirement for the month was 1.0339 pounds VCM per pound PVC versus a 1.01960 standard. General 1. A reactor opening loss test run was completed during the month. 2. A test batch of 5385 using PC-555, a liquid antioxidant replacement for BHT, was produced with samples being forwarded to PAL for evaluation. The material will provide for easier handling and a reduction in cost. DTH 000019303 COMPOUND - C. R. Miller May had 31 accounting days (Y.T.D. is 151 accounting days) Compound Production Month #1 s/Day Y.T.D. Line I, M Pounds Line III, M Pounds Total, M Pounds 1,870 60 7,686 3,092 100 14,533 4,962 160 22,219 Line I operated thirty-one days during the month at an average rate of 60 M pounds per day. Major items affecting productivity were the number of product changes (18 changes - 51 hours total) and maintenance on the blender scale system (24.3 hours). Line III averaged 100 M pounds per day. Production included several compounds for Tenex and Western Electric including a test run on Western Electric compound 34861 gray 536. Items affecting productivity during the month were number of product changes (17 changes - 44.6 hours total) and downtime due to contaminated resin (12.9 hours). The only major mechanical downtime resulted from a motor and bracket failure on the pellet classifier (Sweco), Quality performance on flexible compound was 2.8% of which 58% was due to mill scrap. The remaining off-grade was due to resin contamination (52 M #'s) and seal contamination (2.5 M #'s). "BC" production was 0.4% due to mis-charge. Reblending of "BC" grade compound totaled 330 M pounds. The raw material requirement for flexible compound was 1.01789 pounds raw materials/ pound of compound versus a 1.01298 standard. (Y.T.D. is 1.01082) The variable cost variance for compound was $7.4 M with ($23.3 M) due to price and $30.7 M due to efficiency. Variance due to product mix was $15.0 M. The only major efficiency variance for the month was $16.8 M for combined colors. The efficiency variance for the month was a result of ($20.4 M) variances due to off-grade production. Dry Blend Month #1 s/Day Y.T.D. Total Production, M Pounds 4,153 181 19,943 Dry Blend operated twenty-three days during the month at an average rate of 181 M pounds per day. Production included 80172-B, 80273-G and 80274 dry blends, Major items affecting productivity included mechanical downtime on the, Orbitran unit (22.3 hours), product changes (13.2 hours) and quality testing (19.0 hours). Quality performance for the month was 100% customer grade. reworked totaled 111 M pounds for May. Off-grade dry blend The raw material requirement for dry blend was 0,98924 pound raw materials/pound of dry blend versus a 1.00321 standard. (Y.T.D. is 0.99989) DTH 000019304 The variable cost variance for dry blend was $12.0 M with ($2.4 M) due to price and $14.4 M due to efficiency. The efficiency variance reflects a favorable product mix of $16.7 M. The only other major efficiency variance was ($10.6 M) for combined stabilizers. There were no major price variances for the month. Plasticizer Month #'s/Day Y.T,D. Total Production, M Pounds 1,398 74 5,497 Plasticizer operated nineteen days during the month at an average rate of 74 M pounds per day. The total monthly production of 1.49 MM pounds including VRP is a new record for the plasticizer unit on a five day operation. Production of plasticizers included DOP, 610-P and DIDP. VRP production for the month was 99 M pounds (7.1%). The raw material requirement for plasticizer was 1.13704 pounds raw materials per pound of plasticizer versus a 1.10744 standard. (Y.T.D. is 1.12913) The variable cost for plasticizer was ($29.6 M) with ($25.7 M) due to price and $3.9 M due to efficiency. The major price variances for the month were $22.1 M due to 2-ethyl hexanol and ($36.6 M) due to phthalic anhydride. There were no major efficiency variances for the month. General Total customer grade compound inventory increased from 6.5 MM pounds to 8.1 MM pounds during May. DTH 000019305 MECHANICAL - S. J. Vincent Vinyl - Area I Two reactor condensers were cleaned during this month on D-400 and 742 reactors. Other work completed on D-400 included installation of equipment for reactor opening loss testing by PED and RD, Several valves were repaired on 742 reactor including the vent valve, catalyst injection valve, and the recovery valve. A major failure of the gasket under D-300 condenser required the condenser to be lifted for replacement of the gasket. A metal filled gasket was installed since this type of gasket has had promising results on some of the other reactor condensers. The agitator drive motor also had to be replaced when it failed during the changeout of the condenser gasket. Three condenser head gaskets had to be tightened because of leakage. The failure of a fuseable plug in one of the new unit fluid couplings is being investigated. Polymer restrictions in the old module VCM charge line required several cleanings and replacement of some sections of piping. On D-600 the VCM charge valve and operator were repaired while on 743 reactor the main dump valve had to be replaced. A new cooling water isolation valve was installed during the cleaning of the VCM charge line. A new rubber connector was installed on the new unit dump Sweco. Two new relief valves were installed on D-300 reactor condenser and on the vessel. The spare reactor gearbox was sent out to a machine shop to obtain an estimate of repair costs. The dampers were removed from number seven dryer exhauster. The gearbox was replaced on number two Bird centrifuge. A complete PM inspection of number four dryer was completed. Some other work completed on number four included the installation of a new fuel gas regulator and the installation of a new trial level probe in the activator. A fresh air supply line was routed to the top of the two large blend tanks. The rotex sifter bottom was replaced on number six dryer. A small slurry tank transfer pump motor was repaired. Electronic DP cells were installed on several of the small blend tanks. There were nine mechanical seals repaired on various pumps and compressors. Most of the seal failures were in the old module. Seven pumps and two compressors were overhauled and cleaned. A motor on the vacuum pump in the emission recovery system was repaired. One of the new unit knockout drums was opened for cleaning. The relief valve was checked on one of the old unit receivers and reset. A monorail for the removal of the Corken compressors was installed at the tank farm. Some minor repairs were completed on the incinerator. Most of the equipment for the TV cameras was installed and is presently being checked. Compound, Dry Blend, Storage Silos - Area II A nitrogen supply header was connected to one of the compound silo vibrators for testing. The Banbury and FCM seals were replaced. An overhaul of one of the Line I dicers was completed. One of the Line III dicers was also overhauled. A new transfer line was installed to number two bagger. The storage area exhaust fans were repaired. Motors were replaced on the Line I jump conveyor and the Line III Sweco. A new scale was installed on the palletizer. DTH 000019306 The number two Welex motor was removed and repaired. One Kason screen was replaced. Several sections of transfer line were repaired and some flexible hoses made for use. The blender relief valve discharges were routed to the sewer drains. The bearings were replaced in the north nitrogen blower. Two plasticizer reactor safety discs were replaced. The spare inert gas compressor was rebuilt. Several safety showers were relocated. The product transfer unit was given a major overhaul. The plant crane was sent out for boom repairs and has been returned to the plant. The boom on the plant truck was also repaired. Utilities and Services Five air compressor valve repairs were completed during this period. The desiccant was replaced in one of the V-10 air dryers. Number one boiler had a new front installed during the month. Improved performance has been realized with the percent excess air operating at about 3 to 4 percent. A PM and insurance inspection was also completed on this boiler. Number two boiler is presently shutdown for the same modifications. The refrigeration PM program is progressing. Several tubes in the Line III chiller had to be plugged because of internal leaks. Planning The planners work involved processing 26 invoices for payment and estimating 25 work orders. Material was purchased for 22 projects. There were 21 register tickets issued during the month. The plant shutdown list was updated several times. Miscellaneous The initial reports from MMS are being reviewed and checked. DTH 000019307 PERSONNEL - J. L. Carter EMPLOYMENT During the month of May, there were two permanent new hires, Thomas Docherty, Chemical Engineer and John Windham, Mechanical Engineer. Plus two temporaries, Gregory Ashby, Summer Engineer and Elbert Solomon, Co-op Student. Eight casual labor employees were placed on payroll during the month. Total hours worked were 341. The bulk of these employees were utilized on the bagging and debagging operation. TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTION None. RETIREMENT None. TERMINATION None. DEATH/DISABILITY None. DTH 000019308 U U l\ O W W . ' -..V W/ V.Jl'? Aberdeen, Mississippi May 1979 MONTHLY PERSONNEL REPORT alaried Employees 77* Minority Employees # ourly Employees otal Employees imployees (Hourly) 161 238* Salaried Hourly Total 5** 63 68** 6.5%** 39% 28.6%** New Employees Terminations 0 0 Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 0 0 0 APARTMENTS PAR # EMPLOYEES MIN. EMP. . % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse 9 len. Plant 10 Maintenance 46 laboratory 22 Compound 38 'inyl 32 9 11 45 22 38 32 2 22% 0 00 00 5 45% 0 00 30 7 15% 0 00 10 3 14% 0 00 00 30 79% 0 00 00 13 41% 0 00 00 0 27% 2% 0 0 0 'lasticizer 4 4 3 75% 0 00 00 0 dumber of Applicants: Month 22 Year to Date 27 \PPLICANT BREAKDOWN: " Minority 10 % Minority 45% *Female % Female *Include 3 temporaries, 1 summer employee and two co-op students. **Include 2 temporaries, 1 summer employee and one co-op student. Hires (Hourly) Month n Year to Date 0 Terminations (Hourly) : Month 0 Year to Date 4 Overall Turnover Projected Annual Turnover 2.5% DTH 000019309 Department Warehouse Maintenance Laboratory Compound Vinyl Plasticizer Utility Boiler House General Plant Total OVERTIME AND ABSENTEEISM May 1979 Straight Time Hours Worked 1569.00 6983.25 3873.75 6809.25 6467.75 765.25 663.00 1063.00 28194.25 Overtime Hours Worked Controllable Li) Non-Control lableUl 131.50 40.00 533.75 16.00 327.75 115.75 490.25 442.00 629.00 216.00 23.50 8.00 123.25 56.00 84.75 -0- 2343.75 893.75 Overtime as % of Straight Time 10.9% 7.9% 11% 15.7% 15.1% 4% 27% 7.9% <s> Absence Hours Lost -0128 80 568 88 -0- 8 672 Absence as a % of Straight Time Sickness Other Total Year to Date -0- -0- -0- .2% 100% -0- 1.8% 1.2% 100% -0- 2% 4.1% 95.5% 6.5% 5.4% 5.2% 100% -0- 1.4% 1.7% -0- -0- -0- .2% -0- -0- -0- -0- 100% -0- .7% .5% 96.4% 3.6* 2.4% 2% Note: (1) Controllable Overtime - all overtime excluding overtime due to working regular hours on a holiday and working the sixth day in operations. (2) Non-Controllable Overtime - that overtime due to working regular hours on a holiday and working regular hours on the sixth day in operations. i DTH 000019310 PROCESS ENGINEERING - R. A. Frohreich A. Specialty Compound Line Crawford and Russel has completed the mechanical design for the project. Their only remaining work is to complete the mechanical catalogs. The contract for piping/structural has been awarded. The Contractor is to be on site June 19. Offsite piping will be complete the week of June 6. Electrical offsite work is presently awaiting shutdown for completion. The electrical and instrument bid package is out for bidding. Project mechanical completion is now projected for mid October. B. Fire Water Revisions - Phase I and Phase II Mechanical Engineering for the project is continuing. The underground piping basis of bids is expected to be received in the plant in June. A class "A" process design for phase II will be issued in June. C. Propane Vaporizer Replacement The electrical contractor has begun work. Completion is scheduled for late June. Startup will commence as soon as possible after completion. D. Plasticizer Exposure Abatement Mechanical Engineering is complete on the project and the contract has been awarded. The filter delivery is scheduled for mid July. E. Charge Water Heating Improvements System installation is complete and an operating procedure has been issued. Problems with the temperature controller have delayed using the new system. The controller is being repaired. F. Silo High Level Alarms The prototype sensing element is in operation and is being tested. Problems with panel alarm units are being investigated. G. Plant Dryer Debottlenecking 1. Remote Dryer Lighting Plant mechanical engineering is proceeding on the project. All major equipment has been received. A prototype instrument system has been tested. Project completion is expected by the end of July. 2. V-10 Transfer System Plant mechanical engineering is proceeding on the project. All major pieces of equipment have been ordered. Mechanical installation has begun. Project completion will be delayed due to a strike at the equipment manufacturer supplying the rotary air locks. DTH 000019311 H. Silo Isolation Valves The silo isolation valves have been received and will be installed. J. Automatic Plasticizer Weighup System The revised process design was issued. The panel drawings were approved for construction. Panel delivery is scheduled for the end of July. K. Emission Recovery System A definitive cost estimate was prepared for the modifications to the emissions recovery system to improve level control and to install an additional vacuum pump. An AFE request was submitted for the project. L. Plant Air System A study of the plant air system has been completed and reviewed. Process designs for three parts of the study have been issued and estimated. These designs include a new reactor area instrument air dryer, a new centrifugal air compressor for plant air and a new air header to the building ventilation baghouse. An AFE request for the instrument air dryer has been submitted. The AFE requests for the compressor and air header will be submitted in June. M. VCM Receiver High Level Alarms Two test sensors, a capacitance type and a sonic type, have been ordered. The capacitance probe has been received and will be installed during the first shutdown of the new unit, N. Reactor Inert Vent Design An AFE request for this project has been submitted. O. QMS Addition System A revised process design has been issued for this project. A cost estimate is being prepared. P. New Slurry Blend Tank A process design was issued for a new 150,000 gallon slurry blend tank for use in multigrade resin production. The CED cost estimate has been completed. Work is underway to submit an AFE request. Q. New PVC Railcar Silo A process design was issued for a new 200,000 lb. capacity railcar silo for use in multigrade resin production. The design has been sent to CED for cost estimation. DTH 000019312 R. Water Treatment Revisions A process design for part one of this project has been issued and is being estimated. Part one includes installation of stormwater settling pits. S. Capital Budget Work is proceeding on preparing the 1980 Capital Budget, DTH 000019313 ENVIRONMENTAL HEALTH - J. R. McCrimon I. Particulates The exhaust from one of the resin dryers was sampled for particulates. A meeting with the Mississippi Air and Water Pollution Commission was held to discuss the expansion permits. II. Water BOD and COD levels were within NPDES permit limitations in May. III. Vinyl Chloride In-plant emission testing and leak checking are continuing as specified in the Compliance Manual. Plant, R&D, and PED personnel conducted an extensive reactor opening loss test run on D-400 reactor. Results will be published in June. OSHA inspectors visited the plant and conducted a survey pertaining to the VCM and lead standards. DTH 000019314 Flow GPM Jan. - Ave. Max. 788 948 Feb. - Ave. Max. Mar. - Ave. Max. Apr. - Ave. Max. May - Ave. Max. 756 773 669 760 743 930 730 881 June - Ave. Max. July - Ave. Max. Aug, - Ave. Max. Sdpt. - 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. Diss. 02 26 246 37 307 63 589 94 781 19 170 6.9-7.3 31 279 30 272 43 380 73 656 95 840 27 241 6,9^7.9 34 315 17 134 24 184 6 55 9 73 61 490 81 621 33 295 42 446 26 214 6,9-7,6 45 367 10 85 6.9-7.3 16 130 12 101 18 149 44 374 61 504 11 95 6.6-7.4 14 129 NPDES - Ave. Max. - 32 387 43 520 - 1390 - 1940 - 605 - 909 6.0 Ph 7.5-8.2 7.7-8.0 7.3-7.9 7.3 7.3-7.9 6.0-8.5 DTH 000019315 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for May was 115.2 MMM BTUs. The energy consumption per pound of product decreased from 3272 BTU/Lb, in April to 2908 BTU/Lb. in May. II. Plant Energy Conservation Program A. Steam Leaks 10 of 10 reported steam leaks were repaired during May. B, Charge Water Heating Improvements Installation of hot water preheater was completed in May. Use of the system has been delayed due to problems with the temperature controller. The controller is being repaired. C. Boiler Burner Replacement Installation of new front on one of the 40,000 lb./hr. boilers has been completed and the unit has been started up. Initial operation of the burner shows favorable results with the boiler operating at an average of 20% excess air. DTH 000019316 ITEM ENERGY CONSERVATION DATA 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 Avg. Stack Temp. 1978 1979 No. 1 No. 2 No. 3 388 409 371 421 429 464 1978 MAY 25.1 4.1 4.1 1.0 34.3 51401 1020 52.429 4.675 10000 46.750 1979 MAY 28.7 4.3 5.1 1.5 39.6 61055 1020 62.276 5.2896 10000 52.896 99.179 2892 115.172 2908 Avg. % Excess Air 1978 1979 70 54 74 100 82 120 DTH 000019317 MECHANICAL ENGINEERING - J, A. Dixon AFE's Submitted, Approved, and Closed The following AFE's were submitted and approved during May: AFE No. Title Authorized 9569 9579 9589 9599 Misc. Projects Under $10,000 Additional Office Space Instrument Air Dryer Reactor Jacket Modifications One additional project was submitted for AFE approval during May: $125,000 12,500 110,000 21,000 Title Reactor Inert Vent System The following AFE's were closed to field charges during May: AFE No. Title 9048 9198 Resin Moisture Analyzers Debottlenecking - Centrifuge Anti-Chatter Devices Authorized $ 90,000 Authorized $ 17,000 70,000 A completion report was issued for the following AFE during May: AFE No. Title Authorized 9058 Laboratory Equipment $ 50,000 Design Bids were requested for the following projects: Reactor Jacket Modifications, Piping - Equipment Installation Plasticizer Chemical Exposure Abatement, Piping Equipment Installation Dryer Operation Improvements, Electrical - Silo High Level Alarms, Installation of Dust Collectors - Resin Debottlenecking, the Mechanical Installation for the New Compound Line, and Electrical - Propane Vaporizer Replacement. The contract was let for the New Compound Line Mechanical installation. Definitive estimates were completed for the following: Waste Water Revisions Part I, Reactor Inert Vent System, Plant Air System Addition, Building Ventilation Air Compressor, and the Vinyl Area Air Dryer. DTH 000019318 Design work is in progress on the following projects: Dryer Operation Improvements, Monorails for Blenders and Welex Equipment, Silo High Level Alarm, Resin Transfer Debottlenecking, Dryer Noise Abatement and Vinyl Area Air Dryer. Construction 1. Insulation work on the propane vaporizer project is complete. 2. The piping and electrical work for the Hot Water Charge Improvement Project is complete. 3. The installation of the silo rescue davits is complete. 4. Installation of the number 1 and 2 Boiler Burner Replacement is complete. 5. The fabrication of the offsites piping for the new compound line is complete. 6. A new cyclone was installed on the bagging hopper. 7. Air conditioning and electrical for the Additional Office Space is complete. DTH 000019319 (1) Thru April, 1979 Actual Accounting (2) Thru May, 1979 AUTH. CAPITAL NO. DESCRIPTION 9126 PVC Reactor Capacity Replacement ABERDEEN AUT!k)Rl NATIONS REPORT DATE AUTH. APPROVED AFE AMT. (n (2) EXPENDED COMITTCD TO DATE TO DATE FINAL TOTAL EST. COST COMP. UNDER (OVER) AUTH. AMT. EST. EST. COMP. CLOS. DATE DATE REMARKS 7/8/76 8,577,000 8,147,787 8,194,505 8,194,505 382,495 12/78 6/79 Closed to field charges. 9276 Relief Valve Vent Containment 12/10/76 39,000 34,499 34,499 34,.499 4,501 12/78 6/79 Closed to field charges. 9286 Additional Slurry Blend Tank 12/7/76 9057 Vent Gas Incineration 4/1/77 9087 Resin Silo Aeration 5/16/77 9147 Phthalic Anhydride Exposure Reduction 6/30/77 9187 Emergency Reactor Vent Control 9/29/77 290.000 275,000 280,000 45,000 33,000 283,537 275,876 242,054 40,290 32,547 285,823 275,876 242,336 44,039 33,720 285,823 275,876 242,336 44,039 33,720 4,177 12/78 6/79 Closed to field charges. (876) 12/78 5/79 Closed to field charges. 37,664 12/78 6/79 Closed to field charges. 961 11/78 6/79 Closed to field charges. (720) 5/79 7/79 Closed to field charges. 9197 Dryer ARea Noise Abatement 9/29/77 45,000 30,916 32,671 45,000 0 9/79 12/79 Installation proceeding. 9227 Plant Emergency Lighting System 10/10/77 65,000 50,441 63,475 65,000 0 6/79 9/79 To be closed. 9237 Heated Plastici2eT 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 20,934 21,143 47,000 0 6/79 9/79 Mill take-off conveyors purchased. 9257 Resin Transfer Debottlenecking 11/16/77 56,000 31,879 54,111 56,000 0 9/79 12/79 Collectors to be installed. 9267 Dry Blend Production Expansion 9277 Truck Loading Safety Revisions 11/23/77 11/28/77 200,000 16,000 202,942 6,306 202,815 6,306 202,815 16,000 (2,815) 5/79 8/79 0 6/79 9/79 Closed to field charges. Installation proceeding. 9287 Plasticizer Yield Improvement Test 12/5/77 6,000 3,544 3,544 6,000 2,456 5/79 6/79 Closed to field charges. 9297 Automatic Plasticizer-Stabilizer Weighup System 12/14/77 60,000 873 43,718 60,000 0 9/79 12/79 Design in progress. 9307 Compound Project Conveying Lines 12/14/77 50,000 24,274 26,271 50,000 0 6/79 9/79 Installation proceeding. 9018 Critical Spare Equipment 1/31/78 63,000 60,855 63,502 63,502 (502) 12/78 6/79 Closed to field charges. 9028 Miscellaneous Items Under $10,000 1/31/78 50,000 42,002 49,083 49,083 917 12/78 7/79 Closed to field charges. 9038 Maintenance Equipment 2/3/78 18,000 18,213 18,213 18,213 (213) 12/78 7/79 Closed to field charges. 9048 Resin Moisture Analyzers 2/24/78 17,000 13,729 13,729 13,729 3,271 5/79 7/79 Closed to field charges. 9058 Laboratory Equipment 2/24/78 50,000 48,617 48,659 48,659 1,341 10/78 6/79 Closed to field charges. 9078 Mis. Projects Under $10,000 2/24/78 166,000 156,349 160,131 160,131 5,869 12/78 7/79 Closed to field charges. 9088 Replacement Inert Gas Generator 3/28/78 44,000 31,920 40,647 44,000 0 6/79 9/79 Installation proceeding. 9098 New Compound Line 4/17/78 2,050,000 9S7,520 1,496,233 2,083,934 (33,934) 12/79 3/80 Concrete work complete. Most tie-ins complete. Engineering 98% complete. 9108 Boiler Burner Replacement 5/12/78 170,000 1,469 166,968 170,000 0 7/79 10/79 Installation proceeding. 9138 Plant Guardhouse Improvement 8/14/78 19,000 18,540 18,S40 18,540 460 11/78 6/79 Closed to field charges. 9148 Plasticizer Chemical Exposure Abatement 8/21/78 152,000 7,399 111,874 152,000 0 7/79 10/79 Piping contract let. 9158 Fire Protection Improvements-Phase 1 9/19/78 176,000 2,494 24,097 176,000 0 9/79 12/79 Engineering in progress by CKO. 9168 Misc. Projects Under $10,000 9/21/78 59,000 43,772 52,117 52,117 6,883 12/78 7/79 Closed to field charges. 9178 Propane Vaporizer Replacement 9/21/78 175,000 99,020 128,787 175,000 0 9/79 12/79 Installation proceeding. 9188 Railcar Resin Heel Cleanup System 10/12/78 55,000 3,643 41,523 55,000 0 7/79 9/79 Fabrication of Satellite hopper in progress. 9198 Debottlenecking - Centrifuge Anti-Chatter Devices 11/7/78 70,000 65,085 65,085 65,085 4,915 5/79 6/79 Closed to field charges. 9208 Sparc Recovery Vacuum Pump 9218 Charge Water Heating Improvement 12/5/78 12/8/78 14,000 32,000 0 17,740 14,633 34,976 14,633 34,976 (633) 8/79 11/79 Vacuum pump on order. (2,976) 9/79 12/79 Installation proceeding. 9228 Dry Blend Silo Alarms 9248 Silo Isolation Valves 9258 Dryer Operation Improvements 12/13/78 25,000 12/14/78 25,000 12/14/78 315,000 3,991 0 4,037 4,287 15,589 138,795 25,000 25,000 315,000 0 8/79 12/79 Prototype installed. 0 7/79 10/79 Installation scheduled. 0 10/79 1/80 Piping and equipment contract lot. DTH 000019320 I AUTH. CAPITAL NO. DESCRIPTION' 9519 Critical Spare Equipment 9529 Misc. Projects Under $10,000 9539 Laboratory Equipment 9549 Safety Equipment 9559 Color Weigh Room Modifications 9569 Misc. Projects Under $10,000 9579 Additional Office Space 9589 Instrument Air Dryer 9599 Reactor Jacket Modification EXPENSE 9238 Compound Line I Roof Collapse (1) Thru April, 1979 Actual Accounting (2) Thru May, 1979 ABERDEEN AUTHORIZATION'S REPORT DATE AUTH. APPROVED AFE AMT. 2/6/79 175,000 2/15/79 125,000 3/27/79 31,000 3/26/79 15,000 CD EXPENDED TO DATE (2) COMMITTED TO DATE FINAL TOTAL ESI. COST COMP. UNDER (OVER) AU'IU. AMT. EST. EST. COMP. CLOS. DATE DATE REMARKS 0 115,165 175,000 0 11/79 2/80 Purchases proceeding. 32,415 82,571 125,000 0 12/79 3/80 Forty projects approved. 0 9,648 31,000 0 10/79 1/80 Purchases proceeding. 0 3,429 15,000 0 10/79 1/80 Purchases proceeding. 4/19/79 25,000 0 0 25,000 0 10/79 1/80 Engineering in progress. 5/8/79 5/11/79 125,000 12,500 0 25,665 125,000 0 0 12,500 0 12/79 3/80 Twelve projects approved 0 8/79 11/79 Installation in progress 5/30/79 110,000 0 0 110,000 0 12/79 3/80 Quotes being obtained. 6/4/79 21,000 0 0 21,000 0 8/79 11/79 Modifications scheduled. 12/13/78 44,000 0 0 44,000 0 6/79 7/79 Insurance claim filed. DTH 000019321 Date 5/3 5/8 5/8 5/10 5/11 5/15 5/21 5/21 5/25 5/29 5/29 5/29 5/30 5/30 5/30 LABORATORY - R. B. Martin CUSTOMER COMPLAINTS CUSTOMER PRODUCT COMPLAINT TYPE NO. STATUS Resin Uniroyal 5425 Streamers ARP-051679 Under Study Compound NECO 38963 Off-Color Pellets ACP-050479 Report by CRM Anchor 15041 Metal Contamination ACP-051479 Under Study Identification PTLX 41829 PLCX 43193 PLCX 43191 PTLX 41660 PLCX 43233 PTLX 41645 PTLX 41821 T-2811 00641 00654 00656 00657 00662 00662 00666 WAIVERS RECEIVED Product Customer Reason 5385-3 5385-3 5385-3 5385-3 5385-3 5425 5425 5425 5385 5385 5385 5385 5385 5385 5385 Simpson - OR Simpson - WA World of Plastics; LCP LCP Southwire C E Terminal Athol Eximplas Eximplas Eximplas Eximplas Eximplas Eximplas Eximplas Particle Size Particle Size Particle Size Color Contamination Dry Time Dry Time Dry Time Particle Size Dry Time Dry Time Dry Time Particle Size Contamination Particle Size Waived . by GGD RDJ RDJ GGD GGD GGD RBM GGD GGD GGD GGD GGD JRW GGD RBM QUALITY CONTROL TESTING Resin Regular Samples = 686 Other In-Process Samples = 3311 Bulk Shipments = 190 (Railcars = 123; Trucks = 67) Dry Blend Blenders Produced = 418 Blenders Tested = 274 Blenders Adjusted = 6.2% Other In-Process Samples = 296 Bulk Shipments = 42 (Railcars = 20; Trucks = 22) Compound Blenders Produced = 900 Other In-Process Samples = 196 Blenders Adjusted = 1.0% Bulk Shipments = 18 (Railcars = 11; Trucks = 7) DTH 000019322 QUALITY CONTROL TESTING (Cont.) Resin Heat Stability Fifty-four (54) blends of resin were tested for oven heat stability. This included some experimental blends. All of the samples showed good heat stability. 5385 - 20 Blends 5425 - 22 Blends 5305 - 10 Blends 5465 - 2 Blends Residual VCM - Shipments A total of 142 samples were analyzed for RVCM which related to bulk resin shipments. The summary by product is listed below: Product Average ppm Number of Samples 5305 2 30 5385 0.7 82 5425 0.2 13 5465 0.2 2 Dry Blend 0.2 15 Raw Material Testing Cyastab 523, tribasic lead sulfate stabilizer, was evaluated and approved for use in the Western Electric 34861 compound. Ninety (90) lots of various plant raw materials were tested. There were no rejections during the month. Dow Chemical Co. has agreed that the lots of Methocel F-50 rejected in April give low values for solution viscosity and has agreed to accept return of these lots. On the other hand, Ponca City pilot plant tests have indicated that the low viscosity lots are more efficient than lots of Methocel with viscosities near the top of the spec ification range. Variations are the concern in operations. PRODUCT DEVELOPMENT SERVICE Date Shipped 5/8 5/8 5/15 5/16 5/21 5/23 5/29 5/29 Quantity 50# 50# 50# 50# 50# 100# 2# 2# 50# 50# 100# 50# Product Customer Requested by 5385-1 Hartz Mountain Corp. 5425-1 27121 Wht. Perez 8 Jacard 28831 Blk. 26831 Blk. Perez Jacard 15041 Commercial Plastics Co. Cl. Bl. 50 5385-1 Kohkoku 5305-1 5425-1 Geauga Plastics 26421 Nat. Tiga 5385-1 Sherwin-Williams Co. 14331 Vinyl Plastics, Inc. Cl. Bl. 50 RNG CLS CLS MAS RTM JTW AMP MAS MAS Shipped by JRW JRW JRW HAP HAP JRW JRW HAP HAP DTH 000019323 COMPOUND DEVELOPMENT AND SERVICE Special Compound Testing Western Electric specification tests were run on 4 lots of 34861 Gray 546 and on 3 lots of 36861 Natural. Compound Verification Tests Non-routine properties are being measured on seven (7) compounds in order to verify that they agree with published specification and typical values. All active compounds will be tested during the year as time permits. SPECIAL PROJECTS Waste Treatment Test Run A total of 55 samples of waste water were tested for COD, % solids, and Ph. This project is in support of work done by L. Evans of Ponca City on our waste water system and is a follow-up to the April test run. Reactor Opening Test Run During the month, a test run was held to measure reactor vapor space concen tration prior to dump and to. evaluate vapor space steam purging. A total of 52 bomb samples, 29 bag samples, 47 syringe samples, and 65 slurry samples were tested for VCM concentration during the run. Analytical Research supported the effort with people and equipment. Yield Study A total of 11 samples of #1 pond inlet water were tested for % solids in May as part of the continuing yield loss program. A new composite sampler was also checked out and is now in routine usage on our yield sampling program. RVCM - Slurry Samples Of the 703 batches produced in May, 691 were tested for residual vinyl chloride monomer. The average RVCM for all batches tested was 182 ppm. The highest daily average was 262 ppm RVCM and the low daily average was 126 ppm. RVCM - Dryer Samples - 5305 A total of 75 samples of 5305 from the dryers were checked. These averaged 3.7 ppm RVCM with a maximum of 28 ppm. During most of the month, 5305 truck shipments were released prior to analysis for residual VCM due to low VCM concentrations in dryer samples. DTH 000019324 ORDER ENTRY AND TRANSPORTATION WAREHOUSE - J. C. Coffman $ J. E, Mays Shipment by Product - M Lbs. May Year-to-Date Resin Plasticizer Dry Blend Compound TOTAL 24,344 41 4,602 3,989 32,976 90,034 460 20,793 20,981 136,268 Number of Shipments by Mode R/C 0.T, C.C. C.O.T. T0FC CPU TOTAL Resin - Bulk 117 50 9 - Package 5 - Export - Aberdeen 1 53 176 8 4 17 54 Plasticizer - Bulk 11 Dry Blend - Bulk - Package 21 10 2 11 42 2 Compound - Bulk - Package 95 14 26 5 1 2 24 58 - Export Package 2 148 153 14 2 1 10 40 366 Number of Shipments by Month - Y.T. D. R/C O.T. C.C. C.O.T. TOFC CPU TOTAL January February March April May 100 166 12 101 119 10 110 145 21 117 191 11 148 153 14 7 7 56 351 0 3 36 269 2 8 49 335 1 4 42 366 1 10 40 366 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 1,836 2,876 1,093 1,134 364 446 5,103 2,228 1,174 16,281 46 71 27 28 9 11 126 55 29 402 DTH 000019325 Location MAIN-East TOTAL M SO. FT. 48 ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco Resin .5 .2 ___ dL ESTIMATED MM POUNDS OH FLOOR OPEN TOTAL ' * 5.7 3.8 9.5 u > CO r o PO Prairie 12-1 12-2 * 12-3 12 Conoco Jl i_____ _______ 1.0 22 Compound .1 resin .1 Dry Blend ___dL * . .3 3.5 21 Comp 0.6. Raw Materials .2 12-4 12-5 22 21 - Conoco Resin Conoco Resin Resin O.G. Mill Scraps Cmpd 0. G. Dry Blend 0. G. Sifter Overflow _______dL :.3. 1.7 .......... 2-Q -1-5 LL_______ .5 :_3_ 3.5 3.5 12-6 21 Resin 0. G. -Compound Raw Materiel 1.2 .1 .9 1 .3 % 1 _ 2.5 2.2 3.5 12-7 21 12-8 21 Conoco Conoco 3 5 3.5 ______ 3.5 Total on Hand 10. 4 23 .6 34.0 * Citrysler Resin (.--1,6- ) 40 P4- * 20.9 Total Conoco 8.8 DTH 000019326 Off-Grade In Storage Material M/Lbs. T/L Sifter Overflow Resin "BC" Resin "H" Mill Scraps Compound "B" Compound "H" Dry Blend "O.G." 36 635 1,169 30 506 328 2,740 1 16 29 1 12 8 67 Chysler Storage Balance, May Transferred during month 1,954 336 1,618 48 8 40 D. F, Operations We met the May 9, deadline on the 2.2 MM lbs, Eximplast order. They also entered a new order for the same amount at the end of May for June 6, dead line. This order will only give us seven working days to complete and deliver to the wharf This material will have to come out of current production which has to be made. Our total packaged inventory still remains about the same as previous month. DTH 000019327 50 .. 45 40 35 ABERDEEN FIRST-AID CASES 12 MONTHS MOVING AVERAGE 4- -- -Freqtiency =--Totaj--Firrst--Aid (lases-X 12 4 'otalEmployees i--r -j------------ -4-------- (- x 30 25 20 15 10 5 0 19. 78 ~w 19. 80 DTH 000019328 20 -t--f 15 ABERDEEN OSHA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE -HI---- t-- Frequency = Total OSHARecordab Injuries X Total Employees 3 _l--,-- ---- 1- 4- -- 4- - 10 5 Jan. June 0 19_ 78 19. 79 19. 80 DTH MONTHLY HOURLY TURNOVER 10 9 8 7 6 5 1 3 7 1 r DTH 000019330 ABERDEEN PLANT PRODUCTION 350 300 250 200 150 100 50 ou 0 7. < hd 2 Q< 60 MUl l 50 40 30 20 10 0 l a. 70 -* viIn- 60 > oz 50 40 a 30 .J az 20 u r) 10 .j 0 20 15 10 5 0 BUDGET ........................... ACTUAL _____ _________ _ dtH 000019331 KM Pounds 1979 On C year dy DTH 000019332 % Off Grade " ........ | ..........i-----------1---------q nKCrc*.}i1MN finIR/'iMi UrnKA/MnJnll -- _ .0 0 0-- 00 0 0 0 0 0 c 0 o. 0 1979 . --- -- -- Standard 0.40 Standard 0.739 Standard 2.0 DTH 000019333 POUNDS OF RAW MATHRIAL/POUND OF PRODUCT Standard 1.01960 Standard 1.01300 Standard 1.00320 Standard 1.12080 DTH 000019334 (fc . * ENERGY USAGE DTH 000019335