Document N2qBqBk1b8VD9Mn00E5OvrLEb

SAFETY - A. H. Sather OCCUPATIONAL INJURIES Injuries Treated October 1979 Year-to-Date 1978 Year-to-Date First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time 4 32 18 02 0 29 01 42 8 1 10 1 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 0 13 03 4 22 11 00 02 16 13 18 5 0 1 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 1 12 05 0 12 3 10 05 12 21 9 9 9 5 3 As of October 31, 1979, the plant operated 149,288 manhours or 118 days without a disabling injury. SUPERVISOR'S WORKSHOP Final preparations were completed for the Supervisor's Workshop on Safety Awareness to be conducted during November. A number of films were reviewed with eight (8) being selected for use. A new procedure was also prepared which stated the plant's position on accident and injury control with emphasis on methods of control. NEW COMPOUND LINE On October 8, 1979, a team of plant personnel conducted an 80 percent complete safety audit to identify safety and functionality items which should be corrected prior to startup. DTH 000021670 FIRE PROTECTION IMPROVEMENTS - PHASE I The basis of bids piping package was received from CED. Several changes were noted for revision prior to issue. The changes are targeted to be complete during November with bid package issue shortly; thereafter. EMPLOYEE SAFETY RESPONSIBILITIES PROGRAM Work on the new multi-part Employee Safety Responsibilities slide and tape pre sentation was initiated during the reporting period. The program is being designed such that it will fill a number of needs specifically including new employee safety orientation and safety meeting emphasis. RIGGING TRAINING Final preparations were made to utilize the services of Crane Inspection and Certification Bureau (CICB)' to conduct the rigging training program. The program is scheduled for December 10-17, 1979. Currently, the intent is to schedule all Mechanical Department personnel into the two (2), three (3)-day sessions. OSHA COMPLIANCE Activity in the area of OSHA compliance for the reporting period included: 1. "Hands-on" physicals for compound and lab personnel handling lead containing compounds and for plant personnel having worked with VCM for ten (10) years or longer. 2. Revisions to the annual Respiratory Protection Training program and conduct of several training classes. 3. Final layout review of the new air supply header to the building ventilation system dust collector. 4. Routine personnel monitoring for VCM and lead. The results of monitoring are shown below along with a brief explanation of.overexposures. VCM Dosimetry Range, PPM Number Percent 0.0 - 0.5 0.5 - 1.0 1.0 - 5.0 5.0+ 49 71.01 8 11.60 10 ' 14.49 2 2.90 69 100.00 DTH 000021671 OSHA COMPLIANCE (Cont.) VCM Overexposures Twelve (12) VCM overexposures occurred. Six (6) occurred to Vinyl Operations personnel, five (5) of which could not ifentify a source while one (1) indicated the source to be dispersing agent (PVA) makeup. Five (5) of the Mechanical Department personnel were overexposed. One (1) of them occurred to a mechanic entering D-600 and was wearing a respirator. The remaining Mechanical Department overexposures involved work on the valve actuator lubricators in the new unit recovery area (one), piping revision on 742 reactor N.O. kill piping (one), and two (2) mechanics performing work on the old module reactor gearboxes. The remaining overexposure occurred to a yard operator unloading VCM who was wearing a respirator. Lead Number Percent Less than PEL Greater than PEL 5 0 5 100.0 0.0 100.0 >TH 00002167 VINYL - C. R. Miller Production 1. Total Production, MM #'s 2. Production Rate, M #'s/C.D. 3. Charging, Reactor Batches/C.D. 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average #'s/hr. 7. Dryers, Stream Factor, % 8. Accounting Days Month 28.8 930 22.1 685 85.7 5984 92.3 31 Y.T.D. 264.9 871 21.3 6464 88.5 5751 90.2 304 Standard 904 Vinyl department production for the month was 103% of budget at 28.8 MM pounds. This monthly total represents a new monthly production record which surpases the previous record of 28.7 MM pounds set last May. The reactor performance was down from September with a 85.7% stream factor. The major items which adversely affected reactor performance were as follows: 1. All four reactors in the old module required gearbox repairs during the month. (6% stream factor penalty) 2. Blade changes required for the agitation test run. An agitator test run was held during October in the new reactor module with R$D and plant personnel. The results will be utilized to optimize agitation affects on resin properties and to provide scale-up information for future design work. Resin Quality Summary Resin Type 5305 5385 5425 5465 Sifter Overflow TOTAL Prime Pounds 2,271,831 22,769,134 2,800,954 340,450 - 28,182,369 "BC" Grade 125,500 148,500 115,050 - 389,050 "H" Grade _ 43,000 20,250 - 206,365 271,615 % of Total Production 8.3 79.6 10.2 1.2 0.7 100.0 Quality performance for the month of October was 97.7% customer grade with 1.35% "BC" and 0.95% "H" grade reported, 76% was due to sifter overflow. The variable cost variance for the vinyl department was ($1,408.1 M) with ($1,507.3 M) due to price and $99.2 M due to efficiency. The major price variance was ($1,443.3 M) for VCM. The only major efficiency variance was $28.4- M for VCM. DTH 000021673 The raw material requirement for the month was 1.01298 pounds VCM/pound of PVC versus a 1.01960 standard. (Y.T.D. is 1.02514) General Approximately 6.1 million pounds of resin was bagged during the month to meet export requirements. DTH 000021674 COMPOUND - J. R. McCrimon Compound Production Line I, M Pounds Line III, M Pounds Total, M Pounds Accounting Days Month 1,369 2,149 3,518 31 #'s/Day 44 69 113 Y.T.D. 14,244 24,538 38,782 304 Line I operated 23 days during October at an average rate of 44 M pounds per day. Major items impeding productivity were the number of product changes (17 changes, 45.2 hours), five (5) day operation, dicer problems (43.3 hours), pellet blower maintenance (5.4 hours), blender bucket drive clutch maintenance (4.2 hours) and skip hoist maintenance (2.7 hours). Line III operated 23 days averaging 69 M pounds per day. Production on Line III was hindered by five (5) day operation, product changes (12 changes, 33.2 hours), plugged FCM (12.5 hours), mill motor repair (25.8 hours), running only one dicer for quality control (80 hours), oil change on mill (4.0 hours), dicer problems (2.7 hours), star valve maintenance (2.5 hours), and blender ribbon repairs (2.2 hours). Quality performance for flexible compounds was 1.1% off-grade of which 65.3% was due to millscrap. "BC" production was 1.6%. The raw material requirement for flexible compounds was 1.00218 pounds raw material per pound of compound versus a 1.01297. (Y.T.D. is 1.00880) The variable cost variance for compound was $20.3M with ($11.2 M) due to price and $31.5 M due to efficiency. The variance due to product mix was $19.1 M. The major price variance was ($19.2 M) for T0TM. Dry Blend Month # * s/Day Y.T.D. Production, M Pounds Accounting Days 5,424 175 39,765 31 304 Dry Blend operated 25 days during October at an average rate of 175 M pounds per day. Production included 80172B, 80273G, and 90171. Dry Blend production was encumbered by Orbitran repairs (36.2 hours), running on one Welex (44 hours), stabilizer pump repairs (4.5 hours), and load cell calibration (1.8 hours). Quality performance for October was 99.99% customer grade. The raw material requirement for Dry Blend was 1.01280 pounds raw materials per pound of dry blend versus a 1.00321 standard. (Y.T.D. is 1.00302) The variable cost variance for Dry Blend was ($86.8 M) with ($10.6 M) due to price and ($76.2 M) due to efficiency. The variance due to product mix was ($67.3 M). DTH 000021675 Plasticizer Month #'s/Day Y.T.D. Production, M Pounds Accounting Days 864 28 9,992 31 304 Plasticizer operated 13 days during October averaging 66 M pounds per operating day. Production included 610P, DOP, and DIDP. VRP production totaled 101 M pounds (13.2%). The raw material requirement for plasticizer was 1.06831 versus a 1.10872 standard. (Y.T.D. is 1.14099) The variable cost for plasticizer was ($18.7 M) with ($23.1) due to price and $4.41 M due to efficiency. Major price variances were ($22.2) for Alfol 610, $16.0 for 2-Ethyl hexanol, and ($11.1) for Isodecyl. General Total customer grade compound inventory held steady at 6.9 MM pounds during October. DTH 000021676 MECHANICAL - S. J. Vincent There were three large reactor condensors cleaned during this period. The condensors cleaned were on D-400 and D-500 in the old module and 744 condensor in the new module. Two large reactor mechanical seals were also replaced. Both of the seals were replaced in the old module on D-300 and D-400 reactors. There were three major reactor gear boxes overhauled this period. The D-600 gear box was rebuilt in the Prager Machine Shop and the lower bearing housing replaced along with extensive machine work. The D-400 and D-300 gear boxes were overhauled in our shop after both gear boxes experience top bearing failures. D-600 and D-400 gear boxes experienced high speed pinion gear failures after two weeks operation. The main drive motor on the D-500 reactor gear box was replaced. Reactor valves repaired or replaced were the D-400 main dump, steam stripping and water charge valve, the D-500 sewer drain and VC charge valve and the VC charge valve on the D-600 reactor. The safety valves were tested on D-400 reactor and condensor, the south recovered receiver in the old module and the safety valve was replaced on the pull receiver in the new module. The only major mechanical problem in the vinyl dryer area was the shaft and bearing failure on the number seven exhauster. The exhauster was removed to the shop to repair the fan and to install a new shaft, bearings and drive shaft. Other dryer repairs included the replacement of the number two screener motor and minor repairs to sifter clamps and vibrators. There were nine mechanical seal repairs this month on small pumps and compressors. Six seal failures were in the old module and three in the new module. The south Corkin compressor was changed out and the old unit rebuilt. A new safety valve and stack was installed on the old module blowdown drum. The reactor agitator test run was completed using 744 reactor for the test. Mechanical manpower was scheduled for seven day twenty four hour coverage of the test run. A new fuel gas pressure readout was installed in the reactor control room. Compound, Dry Blend, Plasticizer, and Storage Silos Both the north and south blowers in the plasticizer unit were overhauled and case leaks repaired. The fan hub and blowers were replaced on the south compound cooling tower. The number one Welex main drive bearing failed. Repairs were made by installing the spare drive shaft and bearing. DTH 000021677 Utilities and Service Three air compressors were repaired this month. Valves and packing in number six and two and the crank bearings were replaced in number one air compressor. The outlet cooling water lines were revised to increase cooling on the three V-10 air compressor aftercoolers. Heater elements were replaced in number one and number three air dryers. Planning The planner is still out due to illness and individual area supervisors are performing some of the planners duties along with the maintenance clerk. Miscellaneous The "B" mechanics completed four days of basis welding training. Twelve mechanics and one supervisor completed a two and one half day pump and seal seminar by Dupont Co. DTH 000021678 PERSONNEL - J. L. Carter EMPLOYMENT Randy Hamed, Electrical Engineer Steve Dobbs, Casual Labor TO/FROM LEAVE OF ABSENCE None TRANSFER/PROMOTION None RETIREMENT None TERMINATION James Sykes, Compound Utility Q. C. Townes, Compound Utility DEATH/DISABILITY None OTHER During the month of October there were four casual labor employee on payroll. Total hours worked were 704.75. The bulk of these employees were utilized for bagging resin. DTH 000021679 Aberdeen, Mississippi October 1979 MONTHLY PERSONNEL REPORT Salaried Employees 78* Minority Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations 158 236 * 0 2 Salaried Hourly Total Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 0 1 50% 5 61 66 (6.4% 39% 28% DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound Vinvl PAR # EMPLOYEES MIN. EMP. . % MIN. 99 2 22% 10 11 4 36% 46 45 7 15% 22 21 3 14% 41 36 29 80% 32 32 13 41% NEW HIRES. YTD 00 01 00 O' 0 00 00 TERM. YTD TURNOVER YTD 000 0 i o\ 04 0 36 010 2% 010 4.7% 2 2 5% 5% 000 0 Plasticiser 5 4 3 75% 0 00 0 0 0 vumber of Applicants: Eonth 1 Year to Date 77 APPLICANT BREAKDOWN: i Minority : Female 0 % Minority 0 1 % Female 100% *Includes two (2) temporary employees. Hires (Hourly) : Month 0 Year to Date Terminations (Hourly) : Month 2 Year to Date Overall Turnover 1.3% Proiected Annual Turnover 1 8 DTH 000021680 0 a j- 1M0 o rt VrtI 0) oo Cl oc V) < in\ O _J c X3 < o E c\ l/i HH 03 QJ X4C-3>X) H W +H-> 4f-n> fl> CO > O *MO tcw-c* >o O rX--Ji ctJ n43> o h o Xu3O o E H 4-> O > o X4f-cT>O auH CO CD oa o o o o Q PROCESS ENGINEERING - R. A. Frohreich A. Specialty Compound Line Mechanical construction of the project is proceeding. The operating manual for the line was prepared. The Orbitran control panel is scheduled for shipment in the first week of November. Completion of the project is now scheduled for November 23, 1979. B. Fire Water Revisions The AFE request for Phase II of the project was approved. C. Automatic Plasticizer Weigh-Up System Installation of this project has been postponed until after startup of the new compound line. D. New Slurry Blend Tank and PVC Railcar Silo The Class "A" process design for this project is being revised to be consistent with the Expansion Project. E. Resin Expansion Project A review meeting covering the status of the project was held at the plant on 10/24/79. A partial AFE to cover engineering and equipment charges was submitted and approved. F. Spare Incinerator An AFE request was submitted in late September for this project. G. Plant Dryer Debottlenecking The process design for this project is being revised to be consistent with the Expansion Project and the New Slurry Blend Tank and PVC Railcar Silo Project. H. Methocel Charge Revisions The AFE request for this project was approved. I. In-Process Waste Water Stripping System An AFE request for this project was submitted in late September. J. Plasticizer Exposure Abatement The plant engineering staff assisted PED in operator training and startup of plasticizer filter. DTH 000021682 K. Phthalic Anhydride Tank Replacement A process design to replace the phthalic anhydride tank was issued. L. Propane Operating Manual The propane operating manual was issued for internal review. M. Recovery System Modifications The Recovery System Modifications process design was issued for internal review. This design regulates the seal water flow to the vacuum pumps and compressors. N. Plant Air Dryers Non lubricated switching valves for dryers #2 and #3 (V-10) are due to be shipped November 14. Kemp sales representative recommended increasing plant pressure to achieve dryer air. Monitoring of dryer performance continues. O. Oxygen Analysis of Vapor Space in Emission Recovery System A report on the Emission Recovery System oxygen analysis test was issued in October. P. Operating Procedures for Emergency Power System Operating procedures for the emergency power system are being prepared. Q. Plasticizer Waste Water Several plasticizer waste water streams were analyzed for BOD to see if these streams can bypass the API. Air floatation tests will be conducted beginning in December. DTH 000021683 ENVIRONMENTAL - V. E. Messick I. Particulates The exhaust from one of the resin dryers was sampled for particulates and was within allowable limits. Mechanical problems with the stack sampler prevented more samples from being taken. II. Water BOD and COD levels were within the NPDES limitations during all of October. Arrangements have been made to clean the API separator. The solids in the separator will be trucked to Rollins Environmental Service and be disposed of by them. III. Vinyl Chloride The Honeywell continuous monitoring systems received preventative maintenance service by the vendor during October. DTH 000021684 O 00 1 r*- Flow GPM Jan. - Ave. Max. 788 . 948 Feb. - Ave. Max. 756 773 Mar. - Ave. Max. 669 760 Apr. - Ave. Max. 743 930 May - Ave. Max. 730 881 June - Ave. Max. 670 722 July - Ave. Max. 780 840 Aug. - Ave. 972 Max. 1123 Sept. - Ave. Max. 711 867 Oct. - Ave. Max. 671 823 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 30 272 43 380 17 134 24 184 6 55 9 73 63 589 94 781 73 656 95 840 61 490 81 621 33 295 42 446 19 170 6.9-7.3 31 279 27 241 6.9-7.9 34 315 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 10 75 19 143 25 196 44 332 20 154 6.9-7.9 28 234 11 98 14 126 31 347 75 788 41 387 60 590 63 707 143 1502 14 128 6.6-7.2 30 295 8 89 6.2-7,5 11 116 15 128 24 192 6 50 11 80 48 410 65 519 25 203 37 286 14 122 6.3-8.0 22 229 9 75 6,8-7.4 15 148 NPDES - Ave. Max. - 32 387 43 520 _ 1390 - 1940 605 > 6.0 - 909 ph 7.5-8.2 7.3-7.9 7.3 7.3-7.9 7.6-8.0 7.8-8.5 6.6-8.0 7.5-7.7 7.7-8.0 6.0-8.5 DTH 000021685 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for October was 108.3 MMM BTU's. The energy consumption per pound of product decreased from 2896 BTU/lb. to 2812 BTU/lb. II. Plant Energy Conservation Program A. Steam Leaks Twenty-three steam leaks were repaired in October. B. Energy Reporting The Third Quarter Energy Report was issued in October. The plant had a 30.7% energy reduction compared to the 1972 Base Year. With adjustments for OSHA and EPA energy usage the energy reduction was 44.8%. DTH 000021686 ENERGY CONSERVATION DATA ITEM 1978 1979 Control Period Production, MM Lbs. ' October October Resin Dry Blend Compound Plasticizer ' . 24.1 6.7 3.2 0.9 28.8 5.4 3.4 0.9 TOTAL 34.9 38.5 Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU 54816 1020 55.912 56582 1020 57.714 Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU 4.646 10000 46.460 5.0496 10000 50.496 Propane Consumption, MGal. Conversion, BTLI/Gal. Energy Consumption, MMM BTU None 0.60 92000 0.055 Total Energy Consumption, MMM BTU Energy Consumption , BTU/Lb. 102.372 2933 108.265 2812 Boiler Operating Data No. 1 No. 2 No. 3 Avg. Stack Temp. 1978 1979 421 365 415 404 427 407 Avg. % Excess Air 1978 1979 102 27 98 26 125 27 DTH 000021687 MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved, and Closed The following AFE's were submitted and approved during October: AFE No. Title Authorized 9729 9739 9749 9079 9089 Fire Protection Improvements Phase II Methocel Charge Revision Improved Rupture Disc Holders Cooling Tower Motor Repair Vibration Study - Capacity Replacement Reactors $490,000 66,000 27,000 17,800 50,000 The following completion reports were issued during October: AFE No. Title Authorized 9286 9187 9287 9048 9108 Additional Slurry Blend Tank Emergency Reactor Vent Control Plasticizer Yield Improvement Test Resin Moisture Analyzers Boiler Burner Replacement $290,000 33,000 6,000 17,000 170,000 The following AFE's were closed to field charges during October: AFE No. Title Authorized 9197 9257 9277 9178 9218 9549 9039 Dryer Area Noise Abatement Resin Transfer Debottlenecking Truck Loading Safety Revisions Propane Vaporizer Replacement Charge Water Heating Improvement Safety Equipment Repair of Storm Drains $ 45,000 56,000 16,000 175,000 32,000 15,000 25,000 Design Design work is complete for the New Air Header and piping for Emission Recovery Revisions. Design work is in progress on the following projects: New Air Compressor, Double Block Valves for VCM Charge, Improved Rupture Disc Holders, Dryer Operation Improvements, Emission Recovery Revisions, Reactor Inert Vent System, Phthalic Anhydride System, Automatic Plasticizer-Stabilizer Weighup System and Portable Pneumatic Transfer Unit. Contracts were let for the following projects: Installation of Piping and Equipment for the Instrument Air Dryer, Color Weigh Room Modifications, and Foundations for the New Air Compressor. DTH 000021688 Construction 1. The painting of the lagoon chemical tanks, plasticizer tank 460, light poles and new reactors was completed during the period. 2. Concrete repair work behind the plasticizer building was completed. 3. The area west of V-ll was leveled during the period. 4. The shed for the inert gas generator is complete. 5. The replacement of the cabinet for the laboratory is complete. 6. The installation of the air cannons on 410 silo is complete. 7. The last four dust collectors were installed on the Resin Transfer Debottlenecking project. 8. The concrete stairway for the VCM railroad lead is complete. 9. The platform extension for the old unit turbine meter was completed. 10. A high level alarm was installed on the VCM receiver in the old module. 11. The new line III mill take-off conveyors were installed during the period. 12. The hot tap on the natural gas line for remote read-out was completed. 13. The construction of number 2 resin settling pit is complete. 14. Construction is in progress on the following projects: Resin Settling Pits, Dryer Operation Improvements, Repairs to Dryer Inlet Ducts, Plasticizer Safety Improvements, Additional Dust Collectors, Silo Isolation Valves, Instrument Air Dryer, Additional Air Compressor, Installation of VCM Level Indicators, Double Block Valves for VCM Charge and Drains for the lagoon electrical pits. 15. Twenty-six register tickets were issued for contract work during October. DTH 000021689 (1) Thru Sept ember , 1979 Actual Account i in; (2) Thru October, 1979 AIJMI. CAPUA!. NO. descri p 11 on Aberdeen Ammki.'.AnoNs m E(tri_ DATE AU'IH. APPROVED APE AMT. (\) i \n \ni:n TO P \ !T. U) COMM I H i D 10 DA IE i:in\i, TOEA!. 1ST. COST COM!'. uxw u (OVER) AUIH. AMI. J-ST. nsv. COMP. CEOS. DATE DATE REMARKS 0126 I'VC Reactor Capacity Replacement 7/8/76 ,577,000 0286 Additional Slurry Blend Tank 12/7/70 290,000 9087 Resin Silo Aeration 5/16/70 280,000 9147 phthalic Anhydride Exposure Reduction 6/30/77 45,000 9187 emergency Reactor Vent Control 9/29/77 33,000 9197 Dryer Area Noise Abatement 9/29/77 45,000 922? Plant Tnergency Lighting System 10/10/77 65,000 9237 Heated Plasticizer Addition System 10/11/77 37,000 9247 Farrell Mixer Feeders 11/21/77 47,000 9257 Resin Transfer Debottlenecking 11/16/77 56,000 9267 Dry Blend Production Expansion 11/23/77 200,000 9277 Truck Loading Safety Revisions 11/28/77 16,000 9287 Plasticizer Yield Improvement Test 12/5/77 6,000 9297 Automatic Plasticizer-Stabilizer Weighup System 12/14/77 60,000 9307 Compound Project Conveying Lines 12/14/77 50,000 9028 Miscellaneous Items Under $10,000 1/31/78 50,000 9048 Resin Moisture Analyzers 2/24/78 .17,000 8,151,116 8,194,505 8,194,505 287,084 287,0S4 287,084 242,054 242,034 242,054 40,290 44,039 44,039 32,547 32,547 32,547 41,011 44,654 45,000 56,925 56,990 56,990 8,350 12,704 37,000 32,152 35,712 47,000 45,902 55,596 56,000 203,706 203,706 203,706 14,929 14,929 16,000 3,544 3,544 3,544 49,660 56,557 60,000 37,632 44,070 13,729 42,878 50,000 44,070 ' 44,070 13,729 13,729 382,495 12/78 12/79 Closed 1o field charges. 2 ,916 12/78 10/79 Completion report issued. 37,946 12/78 12/79 Closed to field charges. 961 11/78 10/79 Completion report issued. 453 5/79 12/79 Completion report issued. 356 10/79 2/S0 Closed to field charges. 8,010 6/79 12/79 Closed to field charges. 0 3/SO 6/80 Design in progress. 0 11/79 2/80 Conveyor installation scheduled. 0 10/79 12/79 Closed to field charges. (3,706) 5/79 12/79 Closed to field charges. 1,071 10/79 12/79 Closed to field charges. 2,456 5/79 10/79 Completion report issued. 0 3/80 6/80 Installation scheduled. 0 5,930 3,271 n/79 2/80 Installation scheduled. 12/78 12/79 Closed to field charges. 5/79 10/79 Completion report issued. 9078 9088 Miscellaneous Projects Under $10,000 2/24/78 Replacement Inert Gas Generator 3/28/78 166,000 44,000 160,248 43,783 160,248 43,984 160,248 43,984 5,752 12/78 12/79 Closed to field charges. 16 8/79 2/80 Closed to field charges. o CO ro 9098 New Compound Line 4/17/78 2.,050,000 1,761,117 1,965,144 2,076,622 (2f,622) 12/79 Concrete work complete. Structural erection work proceeding. Engineering complete. 9108 Boiler Burner Replacement 5/12/78 170,000 9148 Plasticizer Chemical Exposure Abatement 8/21/78 152,000 9158 Fire Protection Improvemcnts-Phase I 9/19/78 176,000 9178 Propane Vaporizer Replacement 9/21/78 175,000 9188 Railcar Resin Heel Cleanup System 10/12/78 55,000 9198 Debott1enecking-Centrifuge Anti-Chatter Devices 11/7/78 70,000 9208 Spare Recovery Vacuum Pump 12/5/78 14,000 9218 Charge Water Heating Improvement 12/8/78 32,000 9228 Dry Blend Silo Alarms 12/13/78 25,000 9248 Silo Isolation Valves 12/14/78 25,000 9258 Dryer Operation Improvements 12/14/78 315,000 9519 Critical Spare Equipment 2/6/79 175,000 9529 Miscellaneous Projects Under $10,000 2/16/79 125,000 9539 9549 9559 Laboratory Equipment Safety Equipment Color Weigh Room Modifications 3/27/79 3/26/79 1/19/79 31,000 15,000 25,000 9569 Miscellaneous Projects Under $10,900 5/8/79 125,000 9679 Additional Office Sonet* 5/11/70 12,500 9589 Instrument. Air Dryer 5/30/70 110,000 168,640 107,487 168,640 124,250 168,640 152,000 29,998 161,968 3,643 65,943 38,624 172,136 41,951 65,961 176,000 175,000 55,000 65,971 0 14,633 34,906 35,222 4,392 4,602 15,593 21 ,238 184,576 229,515 19,123 116,337 108,905 116,139 19,300 31,156 3,573 14,887 4 53 1 1 ,4 33 48,894 70,314 11 ,657 1 1 ,974 0 76,013 14,633 35,766 25,000 25,000 315,000 175,000 125,000 30,773 15,000 25,000 125,000 11 ,974 110,000 1 ,360 0 8/79 10/79 Completion report issued. 12/79 3/80 Installation proceeding. 0 12/79 3/79 Drawings being revised. 0 10/79 1/80 Closed to field charges. 0 12/79 3/80 Test run scheduled. 4,029 5/79 10/79 Closed to field charges. (633) 11/79 2/80 To ship in November. (3,766) 10/79 12/79 Closed to field charges. 0 12/79 3/80 Prototype test in progress. 0 12/79 3/80 Sixteen of twenty valves install 0 3/80 6/80 Installation proceeding. 0 3/80 6/80 Purchases proceeding. 0 12/79 3/80 Forty projects approved. 277 7/79 10/79 Closed to field charges. 0 10/79 1/80 Closed to field charges. 0 12/79 3/80 Contract awarded. 0 12/79 3/80 Thirty projects approved. 526 8/79 11/79 Closed to field charges. 0 12/79 3/80 Inst .'il lat ion proceed in;;. DTH 000021690 (1) Thru September, 1979 Actual Account ing (2) Thru October, 1979 Aum. CAPITA!, fcontinued) NO. description AN TPJTX A.'ij.Ll'-.l!!!IZVITUNS KM OR]' DATE Ainu. APPROVED AEH AMT. m EXPENDED j0.DMT_ (-1 FINU. COMMIT! ED K'i\l, EST. Tojmr____ CuS i i.XlMR . UNDER (OVER) All Vi!. AMI. ESI . EST. COMP. CEOS. Dvn; DA IT REMARKS 9599 9009 9619 9629 9639 Reactor Packet Modification 6/1/79 Reactor Inert Vent System 6/28/79 Waste Water Revisions-Pnrt I 7/3/79 Air Compressor 7/9/79 Revisions to Emission Recovery System 7/12/7;) 21,000 90,000 140,000 310,000 100,000 1S,906 0 57,332 3,133 225 21 ,000 Q cniQ 121,763 141,622 11,413 21 ,000 90,000 140.000 340,000 100,000 0 8/79 11/79 Closed to field charges 0 3/80 6/80 Engineering in progress 0 12/79 3/80 Installation proceeding 0 12/79 2/SO Purchases proceeding. 0 2/80 5/80 Engineering in progress 9649 Double Block Valves for VCM Charge 7/18/79 1S7.000 0 38,033 182,000 0 1/80 3/80 Engineering in progress 9659 1* A System Modifications 7/10/79 35,000 15,413 21,777 35,000 0 11/79 2/80 Engineering in progress 9669 New Air Header 8/15/79 25,000 1,031 4,169 25,000 0 12/79 3/80 Engineering in progress 9679 Plant Winterization 9689 Piking of Sphere and Curbing of Drum Storage Areas 9/5/79 9/15/79 64,000 170,000 0 15,000 64,000 0 0 170,000 0 12/79 3/80 Installation proceeding 0 3/80 6/80 Engineering in progress 9699 9709 Plant Dryer Debottlenecking Facilities for Multiple Grade Resin Production 9/15/79 9/20/79 80,000 870,000 0 0 80,000 0 3/80 6/80 Engineering in progress 0 0 870,000 , 0 9/80 12/80 Engineering in progress 9719 Aberdeen PVC Resin Expansion (PaTtial)9/10/79 850,000 0 0 850,000 0 9/80 12/80 Equipment quotes being < 9729 Fire Protection Improvements Phase II 10/1/79 490,000 9739 Methocel Charge Revision 10/3/79 66,000 9749 Improved Rupture Disc Holders 10/22/79 27,000 0 0 490,000 0 0 66,000 0 0 27,000 0 10/80 1/81 Engineering in progress 0 6/80 9/SO Engineering in progress 0 4/80 7/80 Engineering in progress (1) Thru September, 1979 Actual Accounting (2) Thur October, 1979 AUTII. EXPENSE NO. DESCRIPTION ABERDEEN AUTHORIZATIONS REPORT DATE AUTH. APPROVED AFE AMT. (1) EXPENDED TO DATE (2) COMMITTED TO DATE FINAL TOTAL EST. COST COMP. UNDER (OVER) Ainu. amt'. EST. EST. COMP. CLOS. DATE DATE REMARKS 9238 Compound Line I Roof Collapse 12/13/78 44,000 9019 Repairs to Large Reactor Gearbox 7/7/79 22,000 9029 Repair of Steam Tracing $ Insulation 9/5/79 62,000 9039 Repair of Storm Drains 9/11/79 25,000 9049 Repairs to Dryer Inlet Ducts 9/13/79 25,000 9059 Repairs to Dumpster Storage Area 9/13/79 20,000 9069 Centrifuge Rotors Repair 9/13/79 47,000 9079 Cooling Tov.-er Motor Repair 10/22/79 17,800 9089 Vibration Study-Capacity Replacement 10/29/79 Reactors 50,000 43,739 5,206 6,818 21,708 6,090 17,118 21,312 0 0 43,739 17,651 51,882 21,708 15,223 17,118 21,312 0 0 43,739 22,000 62,000 25,000 25,000 20,000 47,000 17,800 50,000 261 8/79 10/79 Closed to field charges. 0 10/79 12/79 To be received in October 0 12/79 3/80 Installation proceeding. 0 10/79 12/79 Closed to field charges. 0 3/80 6/80 Installation scheduled. 2,882 10/79 12/79 Closed to field charges. 0 12/79 3/80 One rotor repaired. 0 1/B0 4/80 Motor being repaired. 0 1/80 4/80 Engineering by CED, MED ti DTH 000021691 LABORATORY - R. D. Jackson Customer Resin Carlon Cerro Wire Cable Cerro Wire 5 Cable CUSTOMER COMPLAINTS Product Complaint 5305 5385 5385 Contamination Fusion Time Streamers WAIVERS RECEIVED Number Status ARP-092879 ARP-101679 ARP-101679 Report by CRM Report by RDJ Report by CRM Date Identification 10/1 10/3 10/3 10/4 10/4 10/4 10/5 10/5 10/5 10/5 10/9 10/9 10/10 10/12 10/12 10/15 10/15 10/16 10/17 10/18 10/19 10/22 10/22 10/24 10/25 10/30 10/30 CONX 45290 T-l 7-2481 T-l T-2479 T-l PTLX 41654 PTLX 41624 T-l T-7768 01105 Bags T-7769 T-7769 CONX 45254 PLCX 43716 PLCX 43101 PTLX 41843 PTLX 41611 PTLX 41656 PLCX 43235 Nine Bag Lots PTLX 42016 PLCX 43743 PTLX 41608 00838/00839 Bags 00152 Bags 01214 Bags TOTAL 27 Product 5305 5385 5385 5385 5385 5385 5385 5305 5385 5385 5385 5305 5305 5385 5385 5385 5385 5385 5425 5305 5305 5385 5385 5385 5385 5305 5425 Customer Reason Carlon RVCM Certain-Teed Particle Size World of Plastics Particle Size Certain-Teed Particle Size Certain-Teed Particle Size Certain-Teed Particle Size World of Plastics Particle Size Carlon RVCM Certain-Teed Particle Size World of Plastics Particle Size Eximplat Dry Time Intex RVCM Intex Bulk Density LCP Bulk Density/Particie Size World of Plastics Particle Size LCP Particle Size LCP Particle Size World of Plastics Bulk Density Uniroyal Contamination Carlon RVCM Export Carlon RVCM Particle Size Charlotte Pipe Particle Size Charlotte Pipe Particle Size Implavin Particle Size Uniroyal Viscosity Nylex Dry Time Waived by GGD RDJ RDJ RDJ RDJ RDJ GGD GGD RDJ RBM GGD GGD GGD GGD GGD RDJ RDJ GGD GGD GGD GGD GGD CLS CLS CLS CLS CLS DTH 000021692 PRODUCT DEVELOPMENT AND SERVICE Ship Date Product Quantity (Lbs.) Customer Requested by 10/2 10/2 10/9 10/10 10/10 10/10 10/16 10/16 10/23 10/23 10/25 10/30 10/30 10/30 10/31 10/31 5305 10 36861 Nat. 2 VRP 1 Gal. J-50 Methocel 100 5385- I 10 5425 10 44461 Black 100 5305 50 35851 Nat. 100 34431 Nat. 1000 35851 Nat. 1000 90171 50 5425 50 5465 50 5385- 1 5 5425 5 5465 5 5465 50 15041 C1.B1..50 50 16851 C1.B1..50 50 D.G. Shelter Products Conoco, Ponca City Diecks 8 Diecks Conoco, Ponca City PMC Incorporated Orange Products, Inc. Conoco, Ponca City Fritz Air Freight Phelps-Dodge Cable 8 Wire Conoco, Ponca City General Cable Corp. Vinylex of Tennessee O'Sullivan Corp. Bel den Corp. Burgundy Plastics Wiman Corp. PCM JRT CLS DW JFN RNG T. Tuckett JPM CLS RBM NTH PCM PCM MAS MAS MAS COMPOUND DEVELOPMENT AND SERVICE Special Compound Testing Two.(2) production lots of 34861 Gray 546 and one lot of 36861 Natural were tested and released for shipment to Western Electric.One production lot of 34533 Natural was approved for shipment to Packard Electric. New Compounds and Colors Specifications and quality control standards have been established for ADK-3972-134A experimental compound for Material Control and Superior Plastics. Electri-Flex has accepted a new gray color submitted to them. It uses astandard Wilson gray color concentrate and will be supplied to them in experimental compound JRT-3866-195 Gray 550. Dry Blend Development Multiple laboratory Welex batches of 80172B and 90171 were made for use as quality control standards. Tests were run to see if 80274 dry blend can be worked off at 10% in 80172B and/or S0273G. The blends varied sufficiently from the control compound that when combined with normal production variations the blends might not meet specifications. Wheii 30% 5465 was used with 70% 5385 in the 80273G formula, the Brabender properties were very close to the control 80273G properties. DTH 000021693 QUALITY CONTROL TESTING Resin Regular Samples = 696 Bulk Shipments = 185 (Railcars = 92, Trucks = 93) Other In-Process Samples = 3178 Dry Blend Blenders Produced = 569 Blenders Adjusted =0.5% Bulk Shipments = 58 (Railcars = 22, Trucks = 36) Blenders Tested = 311 Other In-Process Samples = 88 Compound Blenders Produced = 584 Blenders Adjusted = 6.0% Bulk Shipments = 25 (Railcars = 6, Trucks = 19) Other In-Process Samples = 50 Resin Heat Stability Thirty-six blends of resin were tested for oven heat stability. They were distributed as follows: 5385 - 16 Blends 5425 - 12 Blends 5305 - 8 Blends While one (1) blend of 5385 was 15 minutes poorer than the control, all types averaged better than their controls. RVCM of Shipments A total of 105 bulk shipments were tested for RVCM in October. A summary by product is listed below. Product5385542554655305Dry Blend Average RVCM 1.5 No. of Samples 63 0.7 2.1 71 8.0 18 1.0 17 Raw Material Testing Thirty-two (32) lots of plant raw materials were tested and released. There were no rejections. DTH 000021694 SPECIAL PROJECTS Volume Resistivity of Resins Recent production blends of 5425 and 5465 resin have given acceptably high values for volume resistivity. Blends of 5385 resin stabilized with PC-555 anti-oxidant gave volume resistivity values close to the 5385 control resin. RVCM of Slurrys The results of RVCM analysis on reactor slurry samples were good in October. The daily average did not exceed 400 ppm during the month. A total of 668 slurry sample were tested out of 682 batches made. This represents 97.9% of the batches tested. RVCM Dryer Samples (5305) During October 92 dryer and 5305 resin samples were tested for RVCM. The average for these samples was 16 ppm. RVCM of Blowdown Tank Water A total of 195 samples were tested for RVCM. The average for October was 3 ppm RVCM. Lab.Computor Programming is essentially complete. We have encountered a circuit board defect and are working with the manufacturer to resolve the problem. DTH 000021695 SURFACE TRANSPORTATION ABERDEEN DISTRIBUTION WAREHOUSE OCTOBER ACTIVITY REPORT, 1979 Shipment by Product - M/Lbs. Resin Plasticizer Dry Blend Compound Total Number of Shipment by Mode Resin - Bulk Package Export - ABR R/C 75 Plasticizer - Bulk Dry Blend - Bulk Package Compound - Bulk Package 23 8 Export - Package Back Hauls for October 106 October 22792 164 5153 3347_ '31456 O.T. 50 3 162 C.C. 17 2 15 19 2 14 5 255 18 1 2 4 6 47 1 -Year-To Date R/C O.T. C.C. January Febuary March April. May June July August September October 103 166 101 119 no 145 117 191 148 153 154 143 120 65 132 131 125 227 106 255 12 10 21 11 14 13 '1 2 48 47 Year-to- date 210555 870 41883 39111 292419 C.O.T TOFC 1 1 CPU TOTAL 25 167 7 13 177 4 14 57 4 26 19 30 69 478 C.O.T 7 0 2 1 1 0 0 '0 0. 0 TOFC 7 3 8 4 10 2 2 0 8 1 CPU 56 351 36 269 49 335 42 366 40 366 34 346 43 231 77 342 92 500 69 478 I DTH 000021696 SAFETY REPORT Lost Time Accident Doctor Cases First-Aid Cases Han Hours Worked OCTOBER 0 0 0 2195 . Y.T.D. 23646 GRAND TOTAL SINCE L.T.A. 136962 .MATERIAL HANDLING REPORT M/Lbs. Packaged Resin From Production Packaged Compound, Dry Blend From Prod. Transferred From Main to Prairie Transferred From Prairie To Prairie Reverse Transfer Resin to Plant . Reverse Transfer Cmpd. to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Main 6480 1660 . 2835 0 365 81 , 8869 7169 1215 28674 LABOR REPORT Total regular Hours Total Overtime Hour Total Worked Paid but not Worked Total 1553 162 1715 0 T71F Labor Efficiency equals 28.7 KM/Lbs. - Hours Worked 16720 Overtime % 10.6 . T/L 160 41 70 0 9 2 219 177 30 708 DTH 000021697 'EQUIPMENT REPORT Lift Truck Hours Worked 379 Gal of Fuel Consumed 500 Gals/Hrs 1.3 N Lift Truck Efficiency Equals 28.7 MM/Lbs. - Hours Worked - 75657 Lbs./hr. OFF-GRADE IN STORAGE MATERIAL Sifter Overflow Resin "BC" Resin "H" Mill Scraps Compound "B" M/lbs. 135 468 524 50 448 T/L 3 12 13 1 11 Compound "H" Dry Blend "O.G." ^ TOTAL 46 21 1692 1 ......... r 42 , CHRYSLER STORAGE Balance, October Transferred during month TOTAL 936570 669100 267470 t 23 17 6 D.F. OPERATION Our packaged goods inventory dropped 1.2 MM/lbs. during the month. The reason for this is that export shipments were slightly higher than the month before. We were shipping as fast as resin production was packaging material. t DTH 000021698 I LOCATION MAIN-East TOTAL M SQ. FT. 48 Prairie 12-1 12-2 12-3 12 22 21 12-4 12-5 22 21 12-6 21 12-7 12-8 21 21 Total 20.9 CONOCO TRANSPORTATION ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco Resin Compound Resin Export Resin Conoco Export Resin Conoco Resin Resin O.G. Mill Scraps Cmpd 0. G. Dry Blend 0. G. Sifter Overflow Resin 0. G. Compound Dry Blend Raw Material Resin 0. G. Conoco Total on Hand Chrysler Resin 5.3 .2 .3 .2 .2 1.3 .3 .1 .2 .4 .1 % 2 .2 .6 Total Conoco ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 6. 0 4 0 ' 10.0 .2 1 3 1.5 1 .3 2 .2 3.5 .3 3 .2 3.5 .3 3 .2 3.5 ..5 2 . 0 2.5 . 4 3 . 1 3.5 . 6 2 . 9 3.5 3 . 5 3.5 9 . 6 25 . 4 35.0 ( \3 ) I 9 i.j-- DTH 000021699 ABERDEEN OSIIA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE 20 15 10 5 0 DTH 000021700 ABERDEEN FIRST-AID CASES 50 45 40 35 30 25 20 15'10 5 0 DTH 000021701 MONTHLY HOURLY TURNOVER DTH 000021702 A 46 0780 iTS r S w y !* " 7.61 f h 46 0780 8Z.6I DTH 000021703 ABERDEEN PLANT PRODUCTION 350 500 250 200 150 100 50 o (J 7. < Li U) W N. J- 3 Li 0 wz 5< 60 50 40 30 20 10 0 a4 70 n <x 60 -h u Qz ij >: 50 L'J > f 4 QJ 40 :i l>j 30 ^u C4 J oz 20 a n 10 j0 20 15 10 5 0 BUDGET ACTUAL DTH 000021704 ABERDEEN PLANT EFFICIENCY 1979 POUNDS OF RAW MATERIAL/POUND OF PRODUCT % Off Grade ARHRnHK.V PLANT QUALITY PERFORMANCE 1979 MM Pounds 1979 a o o 0 00 0 o. o0 0 ,0 DTH 000021707