Document NGNrKwOLRv7810Lx3xJydnZwV

SAFETY - A. H. Sather Occupational Injuries Injuries Treated First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time 1980 May 4 0 0 0 0 1980 Year-to-Date 22 9 1 3 0 1979 Year-to-Date 12 1 2 29 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 28 29 0 13 02 00 00 7 1 5 0 0 2 Injuries by Types Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 2 15 14 02 17 04 00 3 3 5 4 3 0 As of May 31, 1980, the plant operated a total of 331 days or 429,960 manhours without a disabling injury. Safety Rulebook The Safety Rulebook was distributed to all employees beginning May 14, 1980. Essentially all of the employee acknowledgement sheets have been signed and returned to personnel for filing with individual personnel records. New Employee Orientation During the reporting period, new employee orientations were completed for John Dixon, Jr., Temporary Draftsman, Steve Hillman, Summer Process Engineer, and A1 Barfield , Process Engineer. Employee Safety Responsibilities Program The script has now been completed. A number of pictures remain to be taken and the show assembled. -1- DTH 000018986 SAFETY - (continued) Safety Meetings Topics covered during May Safety Meetings included the following: 1. Housekeeping - the film "Housekeeping Means Safekeeping" was shown and each supervisor discussed the housekeeping problems in their area of responsibility. 2. Lifting - the National Safety Council booklet "Lift Safely" was given to each employee to fill out. The acceptable methods for manual lifting were also reviewed by supervisors. 3. Practical Rigging Applications - The engineering group (Process and Mechanical) reviewed basic rigging practices and discussed several in-plant applications of rigging. Shutdowns A shutdown period was taken in each of the vinyl modules. During this period there were no injuries. OSHA Compliance Items relating to OSHA compliance during the reporting period were as follows: 1. The condenser top flanges on the seven (7) remaining reactors were machined to improve the seal. This should reduce the likelihood of employee exposure to VCM. (744 condenser top flange was machined during Apri1.) 2. The plant noise level survey was circulated for comment. 3. Routine VCM and lead dosimetry, the results of which are noted below. VCM A total of 66 samples were processed, one of which indicated overexposure. The results are shown below, along with an explanation of the overexposure Range (ppm) Number Percent 0.0-0.5 0.5-1.0 1.0-5.0 5.0+ 63 2 0 1 66 95.45 3.03 . 0.00 1.52 100.00 The overexposure occurred to a reactor operator who was changing recovered VCM filters. He was wearing a respirator. -2- IDTH. 000018987 SAFETY - (continued) Lead Greater then PEL Less Than PEL Number 0 6 6 -3DTH 000018988 VINYL - C. R. Miller Production Month Y.T.D. Budget 1. Total Production, MM Pounds 2. Production Rate, M Pounds/C.D. 3. Charges, Reactor Batches/C.D. 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average Pounds/Hr. 7. Dryers, Stream Factor, % 8. Accounting Days 13.7 443 11.1 344 49.1 5802 45.5 31 116.6 767 18.0 2742 76.7 5816 78.5 152 Vinyl department production for the month was 48% of budget at 13.7 MM pounds. Production levels continued to be reduced as part of the inventory control programs. Reactor and dryer stream factors were 49.1% and 45.5% respectively. The major items affecting these stream factors are as follows: 1. Inventory control programs represented the majority of reactor and dryer stream factor penalties. (45.6% and 49.6% respectively) The old reactor module underwent a fifteen (15) day turnaround and the new reactor module a seven (7) day turnaround during May. These shutdowns were utilized for new project tie-ins, mechanical repairs, leak repairs and for the plant's annual inspection. 2. Three reactors required seal repairs' or seal/gearbox repairs during May. This accounted for 2.1% of total reactor downtime. 3. Preventive maintenance and dust collector sock changes on two (2) dryers accounted for 1.3% of dryer downtime. Several test runs were conducted or continued through the month. These included testing of dual initiator systems for several initiators, utiliza tion of the chain transfer agent on 5305 resin, production of test blends produced with a new calcium stearate, an agitation test run on D-600, and revisions to steam stripping techniques in the new module. Resin Quality Summary Resin Type Prime 1 Pounds "BC" Grade "H" Grade % of Total Production 5305 5385 5425 5465 Sifter Overflow TOTAL \ 1,121,395 8,023,668 3,243,660 843,975 13,232,698 74,150 104,400 40,500 - - 219,050 76,500 ( 100) 41,150 - 163,280 280,830 9.3 59.2 24.2 6.1 1.2 100.0 /I DTH 000018989 VINYL - (continued) Quality performance for the month of May was 96.2% customer grade with 1.7% "BC" grade and 2.1% "H" grade. Of the "H" grade reported, 58% was due to sifter overflow. The variable cost variance for the vinyl department was ($438.5 M) with ($471.6 M) due to price and $33.1 M due to efficiency. The variance due to product mix was $9.5 M. The only major price variance was ($420.2 M) for VCM. The only major efficiency variance was ($31.3 M) for VCM. The raw material requirement for the month was 1.03104 pounds VCM/pound of PVC versus a 1.01960 standard. (Y.T.D. is 1.01627) The high VCM efficiency variance and raw material requirement is believed to be due to an inventory error for April utilization. April's VCM efficiency variance was $43.3 M favorable with a 1.00911 raw material utilization. General Resin packaging continued throughout the month with 1.8 MM pounds packaged. -5- DTH 000018990 COMPOUND - 0. R. McCrimon Compound Production Month #'s/Da.y Y.T.D. Line I, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days 1,485 - 3,001 4,486 31 58 - 100 150 6,072 207 12,862 19,141 152 Line I Operated 25 1/2 days during May at an average rate of 58 M pounds per day. Major items affecting production efficiency were: Line V operation (4 1/2 days), product changes (21 changes, 49.0 hours), dicers (29.0 hours), maintenance on blender bucket conveyor (16.6 hours), maintenance on blender scales (8.4 hours) and maintenance on sifter star valve (7.9 hours). Line V operated 4 1/2 days during May. Three different preblends were produced on Line V for tests in Werner-Pfleiderer labs in Ramsey, NJ and Stuttgart, West Germany. Tests were conducted on the pellet conveying system with a Werner-Pfleiderer engineer from Germany in the plant and were successful. Line III operated 30 days during May at an average rate of 100 M pounds per day. Major items affecting Line III production efficiency were: product changes (11 changes, 35.0 hours), maintenance on FCM (6.2 hours), maintenance on prefeeders (6.9 hours), maintenance on dicers (5.6 hours), maintenance on mill (16.3 hours) and maintenance on blenders (5.1 hours). Quality performance for flexible compounds was 2.0% off-grade of which 87.0% was due to mill scrap. "BC" production was 0.6%. The raw material requirement for flexible compounds was 1.01933 pounds of raw material per pound of compound versus a 1.01297 standard. (Y.T.D. is 1.01153) The variable cost variance for compound was $18.4 M with $14.0 M due to price and $4.4 M due to efficiency. The variance due to product mix was $11.1 M. There were no major efficiency variances. There was only one major price variance of $11.2 M for T0TM which reflects a decrease in transfer price. Dry Blend Month #' s/Da.y Y.T.D. Production, M Pounds Accounting Days 900 53 31 7,531 152 -6- DTH 000018991 COMPOUND - (continued) Dry Blend operated 17 days during May at an average rate of 53 M pounds per day. The unit operated 6 days on 2 shifts and 11 days on 1 shift. Production included 80273G, 80172B, and two experimental dry blends for trials in Austria: 3948-43A, 3948-43B. Also a sample was produced for Celanese. Dry Blend production was affected by: inventory control. No. 2 Welex motor out for repairs (16 days), blender limited due to No. 2 Helex out of service (9.4 hours), boxing limited (15.3 hours) and quality testing (7.9 hours). Quality performance for the month was 99.97% customer grade. The raw material requirement for dry blend was 1.00251 pounds of raw material per pound of dry blend versus a standard of 1.00320. (V.T.D. is 1.00868) The variable cost variance for dry blend was $12.6 M with $1.1 M due to price and $11.5 due to efficiency. The variance due to mix was $14.0 M. There were no major price or efficiency variances for May. Plasticizer Month #'s/Day Y.T.D. Production, M pounds Accounting Days 774 56 31 3,672 152 Plasticizer operated 16 days during May at an average rate of 56 M pounds per day. Production included: D0P, 610P, and DIDP. VRP production totaled 85.6 M pounds (11.1%). Production was limited by inventory control. The raw material requirement for plasticizer was 1.08671 pounds of raw materials per pound of plasticizer versus a 1.09718 standard. (Y.T.D. is 1.12940). The variable cost for plasticizer was ($60.7 M) with ($44.8 M) due to price and ($15.9 M) due to efficiency. Major price variances were: ($11.6 M) for Alfol 610, ($11.5 M) for 2 ethylhexanol; and ($20.3 M) for phthalic anhydride. The variance due to product mix was $1.8 M. General Total customer grade compound inventory increased to 6.0 MM pounds during May. Tests were conducted in the Werner-Pfleiderer lab in Ramsey, NJ during the week of May 26. Preblend from Aberdeen was processed through a 3-lobe, 5barrel KP-100 machine to obtain operating data for the Stuttgart test in June. Pellet samples from this test were analyzed in the Aberdeen lab and found to contain numerous hard particles (exceeding our normal specifications). -7- DTH 000018992 MECHANICAL - S. J. Vincent Vinyl There were three large reactor seal failures in this period. The seal failures were all in the old module on reactors D-400, D-500, and D-600. All of the seal failures were attributable to material and weld slag getting into the seal during the unit shutdown. There were no gearbox failures this month. One large reactor condenser was brushed this month. The condenser cleaned was on the 744 reactor in the new module. Test blades were installed in the D-600 reactor. The old module was shut down for inventory control. The plant used this opportunity to make repairs and P.M. inspection to the equipment. The following is a listing of the major work completed in the downtime. The top flange on the condenser and condenser head gasket surfaces were machined to minimize VCM leakage from these areas. Flush water lines were installed to allow for back flushing the recovery condensers. The dump sweco was revised and a double screen installed. Both of the old module recovery condensers were cleaned. The safety valves in the old module were tested. Several process and steam leaks were repaired. Major P.M. and repair of motors and switchgear was completed. The plant was operating with all reactors in service at the end of the month. Reactor system valves repaired or replaced this month were the steam stripping valve on 742 reactor, the charge water valve on 741 reactor, D-500 evacuation valve, the D-600 condenser valve, a 4 inch valve on the bottom of the 401 receiver, the seal water valve on the emission recovery system, and the 6 inch main charge water header valve in the old module. There were four mechanical seals repaired this month on pumps and compressor in the vinyl production area. Two of the seals replaced were in the old module on the South emission recovery water pump and the North VCM sphere pump. The two seals replaced in the new module were on the south knockout circulating pump and the inboard seal on the 903 recovery compressor. There were five pumps in the vinyl area pulled and overhauled in the shop. The pumps overhauled were the south high pressure water pump and the rinse pump in the old module. The return condensate pump, service water pump, and the hydroquinone pump in the new module were overhauled. The electrical installation for the double block and bleed valving system was completed for the old module. The incinerator gas supply valve was repaired. The new 4160 volt motor was installed in the new vinyl cooling tower. There were three P.M. inspections completed this month on vinyl dryers. The dryers given a P.M. check were number 2, 5, and 6. Major repairs were completed on the bird effluent hopper and the exhauster stack on the number 5 dryer train. The wiring for number 1 and 2 dryers was revised in the CCR panel. All three manual baggers were repaired. Several anti chatter device repairs were made. -8- DTH 000018993 MECHANICAL - (continued) Compound, Dry Blend, Plasticizer and Silo Storage The major repairs to the compound lines were to one of the feeders and dicers on line three. The product blower and dicers in compound Line I were also repaired. The motors on number 5 and 9 dicers were repaired. The Line III mill controls were checked. The Line V compounder AMP meter was replaced. Guards were installed on the vent system blower shafts, and the sample port was revised on the Line V sweco. The number 2 welex motor was repaired and reinstalled in Dry Blend. Repairs in the plasticizer unit involved plugging a leaking tube in the inert gas heat exchanger and to blind reactors R-l and R-2 for MED inspection. Some minor repairs were made to the coil supports inside the plasticizer reactors as a result of this inspection. The number 1 fire pump engine was overhauled this month. The bulk of the mechanical manpower was used to take advantage of the vinyl area shutdowns to maximize the amount of work completed there. The operating personnel in the compound and dry blend areas did a good job by operating their units with a minimum of maintenance allowing the maintenance depart ment to concentrate on the work in the vinyl area. Utilities and Service There were three repairs to the plant instrument air system compressors this month. The number 9 air compressor was overhauled. The unloader valve on number 8 air compressor was repaired and the motor was repaired on the number 1 air compressor. With part of the vinyl operations shut down we were able to leave one of the Joy Centrifugal compressors down. With the air compressor shut down we were able to replace an 8 inch water valve on the east vinyl cooling tower. Completed a P.M. of the oil filters and guages on the Joy compressor. Planning The planner estimated 75 work orders and ordered material for 18 work orders. Thirty invoice registers were issued and twenty bills processed for payment. The relief valve log was updated and entries made for the valves tested in the vinyl areas. The history records were maintained and a listing of work in the maint enance backlog was sent to the area supervisor for reivew and priority assignments. -9- DTH 000018994 PERSONNEL - J. L. Carter EMPLOYMENT Alfred Barfield, Jr., Process Engineer John A. Dixon, Jr., Draftsman (Casual Labor) Steve Hillman, Process Engineer (Summer Employee) Johnny Sharp, Process Engineer (Co-Op Student) TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTION Michael F. Holman, Mechanical Engineer, transferred to the Lake Charles Chemicals Plant. Marvin C. Jernigan, Senior Process Engineer, transferred to the PED in Ponca City. RETIREMENT None. TERMINATION Alonzo McKnuckle, Casual Labor Bobby Trimble, Casual Labor Bernard Lloyd, Process Engineer (Temporary) Douglas Vogue, Casual Labor DEATH/DISABILITY None. OTHER During the month of May there were three (3) casual labor employees on payroll. Total hours worked were 225. -1 O- DTH 000018995 CONOCO CHEMICALS Aberdeen, Mississippi May 1980 MONTHLY PERSONNEL REPORT Salaried Employees Hourly Employees Total Employees Employees (Hourly) 78* 157 235* Minority Employees # Salaried Hourly Total ?** 62 69** % 9% 39% 29% New Employees Terminations 0 0 Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 0 0 0 DEPARTMENTS PAR # EMPLOYEES MIN. EMP. . % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse Gen. Plant 9 11 9 11 2 22% 0 0 00 0 0 6 54% 0 2 01 0 11% Maintenance 46 46 7 15% 0 0 00 0 0 Laboratory 22 20 3 15% 0 0 00 0 0 Compound 41 35 28 80% 0 0 0 2*** 0 l^lo Vinvl 32 32 13 41% 0 0 00 0 0 Plasticizer 4 3 75% 0 0 00 0 0 Number of Applicants: Month 31 Year to Date 78 Hires (Hourly) : Month 0 Year to Date 2 APPLICANT BREAKDOWN: # Minority 18 % Minority ^ Female % Female 58% 19% Terminations (Hourly) : Month 0 Year to Date Overall Turnover 0 3*** Includes two (2) temporary employees. Includes one (1) temporary employee. Includes one (1) retirement and is not counted in turnover rate. Projected Annual Turnover 1.3% -11- DTH 000018996 OVERTIME AND ABSENTEEISM CM ooo ** ** S'* o o o o o o r-- o o r-- o o o o o o o r-- <0 o CCOO o o o 01 ** E 0 -C E CT r *r *r-*s oi ** CM ** co Ol +-> <o .. to S- i- od \> sfr ID *a* o> 0) 4-> > CO o CcrO> oo o o o co CM 0C)l o ~0o3 sz 01 QJ sz o o V) u o oO <0 o oO o id cn r-' CSJ co t-- CM 0) E -O r- 01 1-- o O ID o O o ID ID ID o CM ID o tD l-x. M O x: 3 o> Ol o> CM Oi 0 CO CO CO C7I <-- to co 0 CO CO 10 CM CO co <0 r-* CO CM O ID VO i- 0 CO 10 0 r^. S- 3 +J O CO X r0 4-> QJ t- E QJ > +J o 0<y ) o X) VO .O 03 3 O O. i-- <y 4r->- C<D OJ 4-> o DTH 000018997 PROCESS ENGINEERING - R. A. Frohreich A. Breathing Air Modifications The Class "A" design for this project was issued and a review meeting was held. B. V-11 Water Stripper Tank Replacement The Class "A" design to replace the V-11 water stripper tank with a surplus tank was issued. C. Biodisc Study A process design for the installation of a pilot rotary biological disc unit to treat API effluent was issued. D. Initiator Injection Pot Replacement The Class "A" design to replace the existing initiator pots with pots having a higher design pressure and larger relieving area was issued. A design review meeting for this project was also held. E. Kemp Air Dryer Evaluation The Kemp air dryer service report was received. Recommendations include an inlet filter to remove entrained water, balance air flow to the dryers near V-11, replace purge piping, and upgrade electrical dryer controls. F. Groundwater Monitoring Two consulting firms visited the plant to give proposals on monitoring groundwater in order to determine if organics are leaching from the resin settling pond. One proposal has been received. G. Firewater Improvements - Phase III The Class "A" design for this project was issued in early June. H. Dual Steam Stripping Instrumentation The Class "A" design for this project was issued in early June. I. Fixed Point Monitor Data Computer and Warning Lights The Class "A" design for this project was issued, a design review meeting was held, and a revised Class "A" design was issued in corporating comments from the review meeting. J. Resin Debagging System A Class "A" design to debag 5.0 MM pounds per month of resin is being prepared. -13- DTH 000018998 PROCESS ENGINEERING - (continued) K. Underground Sulfuric Acid Line A design to install a new underground sulfuric acid line from the sulfuric acid tank near pond number 3 to number 5 and 6 ponds Was issued. This will provide the capability to add acid to control ph at the outfall. L. 1981 Capital Budget A consideral portion of the process engineering effort this month was devoted to the preparation of the 1981 Capital Budget. M. Resin Expansion Project All major equipment for the project has been ordered. P & I drawings and plot plans prepared by Litwin were reviewed. Assistance was provided Litwin electrical personnel who were in the plant obtaining field data. Review of the fluid bed dryer design is continuing. -14- DTH OOOOXSSSQ ENVIRONMENTAL - V. E. Messick I. Particulates Two dryers were tested for particulates and found to be within allowable limits. II. Water Effluent BOD and COD concentrations were within NPDES permit levels in May. A 24 hour static bioassay test was conducted by Applied Biology of Atlanta on pond number 6 effluent. Results were 100% survival in 100% effluent. III. Hazardous Waste Management Samples of API solids, rag layer, and the phthalic anhydride were sent to Chemical Waste Management for a cost estimate for disposal at their Alabama site. -15- DTH 000019000 Flow GPM Jan. - Ave. Max. 810 941 Feb. - Ave. Max. 645 802 Mar. - Ave. Max. 595 743 Apr. - Ave. 628 Max. 877 May - Ave.' 304 Max. 480 June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. TABLE I - WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB./DY. COD PPM LB./DY. Sus. Solids PPM LB./DY. 43 131 436 1342 6 42 8 56 29 220 36 314 21 147 30 232 16 69 32 184 86 851 216 2214 15 116 24 171 66 502 95 828 54 378 67 519 53 197 74 426 11 103 13 143 10 79 13 125 11 74 14 94 12 86 13 129 10 40 14 81 Diss. 02 6.8-8.5 6.7-7.9 6.6-8.3 6.4-8.3 6.7-7.3 NPDES - Ave. Max. _ _ '32 387 43 520 - 1390 - 1940 - 605 - 909 >6.0 ph 7.7-8.0 7.1-7.8 7.1-7.8 7.5-8.4 7.2-7.9 6.0-8.5 -ip- DTH 00019oo ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for May was 78.4 MMM BTUs. The energy consumption per pound of product increased from 3282 BTU/lb. to 3918 BTU/lb. in May. II. Plant Energy Conservation Program Steam Leaks Thirty-five steam leaks were repaired in May. -17- DTH 000019002 ITEM ENERGY CONSERVATION DATA 1979 Production, MM Lbs. May Resin Dry Blend Compound Plasticizer Natural Gas TOTAL 28.7 4.3 5.1 1.5 39.6 Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Electricity 61055 1020 62.276 Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Propane 5.2896 10000 52.896 Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Total 0 92000 0 Energy Consumption, MMM BTU Energy Consumption , BTU/Lb. Boiler Operating Data 115.172 2908 No. 1 No. 2 No. 3 Av- Stack Temp. 1979 1980 409 370 421 424 464 414 Avg. % Excess Air 1979 1980 54 22 100 21 120 26 1980 May 13.7 0.9 4.5 0.9 20.0 35887 1020 36.605 4.1446 10000 41.446 3.42 92000 .315 78.366 3918 -78- DTH 000019003 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 9640 9650 Shed For Drum Storage Area Miscellaneous Projects Under $10,000 $ 14,000 $150,000 The following AFE's were closed to field charges during May: AFE No. Title Authorized 9619 9620 Waste Water Revisions - Part I Cooling Tower Motor Replacement $140,000 $ 17,800 Completion reports were issued for the following AFE's during May: AFE No. Title Authorized 9749 9049 Improved Rupture Disc Holders Repairs to Dryer Inlet Ducts $ 27,000 $ 25,000 Design Design work is in progress on the following projects: Replace T-100 P. A. Tank Automatic Plasticizer-Stabilizer Weigh-Up System Replacement of Hot Water Charge Tank API Clean Water Bypass Replacement of Emission Recovery Line from the VCM Tank Farm Contracts were let for the following projects: Double Block Valves for VCM Charge in the Old Module Electrical Installation of Dry Blend Silo Alarms Diking of Sphere and Curbing of Drum Storage Areas AFE Activity 1. AFE 9158 - Fire Protection Improvements - Phase I - J. P. McKee Construction is in progress. 2. AFE 9228 - Dry Blend Silo Alarms - J. L. White The contract was let for installation of silo alarms. -19- DTH 000019004 MECHANICAL ENGINEERING - (continued) 3. AFE 9649 - Double Block Valves for VCM Charge - M. S. Richards The construction contract was let for installation in the old module. Prefabrication of piping is in progress. 4. AFE 9689 - Diking of Sphere & Curbing of Drum Storage Area - J. L. White Bids were received and evaluated. The bonding procedure for the low bidder is in progress. 5. AFE 9707 - Facilities for Multigrade Resin Production - CED Revised P & I drawings were received from Litwin for review and approval. Piping design is in progress. 6. AFE 9729 - Fire Protection Improvements - Phase II - CED Piping design is in progress. Tie-ins to existing piping have been identified. 7. AFE 9739 - Methocel Charge Revisions - J. L. White The studding outlet flanges were installed in the old reactor module. 8. AFE 9570 - Replace T-100 P.A. Tank - J. P. Windham The design has been reviewed and is complete. The storage tank was received during the period. 9. AFE 9580 - Boiler Economizers - J. L. White Quotations were received and evaluated. A purchase order has been issued for the economizers. Construction The installation of the studding outlets for the methocel revisions project was completed.^ Lifting lugs and new baffles were installed in D-500 reactor. D-300 catalyst injection nozzle revision was completed. Condensor flange surfaces in the old module were machined during the period. Repairs to the plant effluent outfall box were completed. Fire protection improvements at the propane tank farm were completed. The new replacement phthalic anhydride storage tank was received. The dump piping on the plasticizer filter was revised. There were three contracts and 32 register tickets issued for contract work during the period. -20- DTH 000019005 (1) Thru April, l''R(l Actual Accounting (2) Thru May, 1980 AW Shl ! N AimiOltl .'VnuN'S lill'Olil' AUUI. CAPITAL Nil._ m sluiI*i ION hath. ahiu. MTKPVliP AIHLV[L`- ID to n.vn: u> FINAL awMimo TOTAL HST. to inn:__ COST COMP. UNPliR lOVKU) AUDI. AMT. rsT. HST. COMP. CI.OS. PATH PATH KI-MAUKS 9237 9297 Heated Plasticizer Addition System Automatic Plasticizer-Stabilizer Wetgh-Up System 10/11/77 12/14/77 37,00(1 60,000 13,090 56,293 13,518 57,944 37,000 60,000 0 6/80 9/80 Design in proqress. 0 6/80 9/80 Design in progress. 9098 9148 New Compound Line Plasticizer Chemical Exposure Abatement 4/17/78 2 ,050,000 2.090.35S 2,090,358 2 ,090,358 8/21/78 152,000 141,802 147,103 152,000 (40,358) 12/79 6/80 Closed to field charges. 0 8/80 11/80 Revisions in progress. 9158 Fire Protection Improvements * Phase I 9/19/78 176,000 105,028 166,522 176,600 0 8/80 11/80 Installation in progress. 91 S3 9228 9248 Railcar Resin Heel Clean-Up System Dry Blend Silo Alarms Silo Isolation Valves 10/12/78 12/13/78 12/14/78 55,000 25,000 25,000 42,970 4,392 21,327 43,311 16,392 22,244 55,000 25,000 25,000 9258 Dryer Operation Improvements 9519 Critical Spare Equipment 9549 Safety Equipment 12/14/78 2/6/79 3/26/79 315,000 175,000 15,000 261,363 98,051 15,094 286,860 159,192 15,094 315,000 175,000 15,094 0 6/80 9/80 Project operational. 0 7/80 10/80 Installation in progress. 0 6/80 9/80 Eighteen of twenty-one valves installed. 0 9/80 12/80 Project operational. 0 6/80 9/80 Purchases proceeding. (94) 10/79 6/80 Closed to field charges. 9559 Color Weigh Room Modifications 4/19/79 25,000 16,676 17,335 25,000 0 7/80 10/80 Project operational. 9589 Instrument Air Dryer 5/30/79 110,000 90,763 91,334 110,000 0 9/80 12/80 Winterization design in progress. 9609 Reactor Inert Vent System 6/28/79 90,000 9,204 9,339 90,000 0 10/80 1/81 Engineering in progress. 9619 Waste Water Revisions - Part I 7/3/79 140,000 128,109 136,489 140,000 0 5/80 8/80 Closed to field charges. 9269 Air Compressor 7/9/79 340,000 231,304 240,489 340,000 0 8/80 11/80 Project operational. 9639 Revisions to Emission Recovery System 7/12/79 100,000 36,980 55,432 100,000 0 8/80 11/30 Installation in progress. 9649 Double Block Valves for VCM Charge 7/18/79 182,000 70,790 94,564 ' 182,000 0 8/80 11/80 Installation in progress. 9659 P. A. System Modifications 7/10/79 35,000 26,571 33,339 35,000 0 6/80 9/80 Project operational. 9669 New Air Header 8/15/79 25,000 15,727 16,789 25,000 0 6/80 9/80 Project operational. 9679 Plant Winterization 9/5/79 64,000 60,029 60,931 60,931 3,069 3/80 6/80 Closed to field charges. 9689 Diking of Sphere 4 Curbing of Drum Storage Areas 9/15/79 170,000 0 1,077 170,000 0 9/80 12/80 Bids being evaluated. 9699 Plant Dryer Debottlenecking 9/15/79 80,000 0 0 80,000 0 12/80 3/81 Engineering in progress CED. 9709 Facilities for Multiple Grade Resin Production 9/20/79 870,000 0 197,014 870,000 0 12/80 3/81 Engineering in progress CED. 9719 Aberdeen PVC Resin Expansion (Partial) 9/10/79 850,000 9729 Fire Protection Improvements Phase 11 10/1/79 490,000 9739 Methocel Charge Revision 10/3/79 66,000 9759 Aberdeen PVC Resin Expansion 12/10/79 11 ,150,000 9769 Automatic Setback Thermostats 12/31/79 3,000 9510 Miscellaneous Projects Under $10,000 1/3/80 150,000 9520 Replacement Phthalic Anhydride Tank 1/17/80 75,000 9530 Spare Incinerator 1/23/80 650,000 9540 Laboratory Equipment 2/6/80 45,000 9550 P. A. Handling Improvement 3/3/80 63,000 9560 Safety Eqinpttrnt 3/12/80 25,000 9570 Replace T-100 P. A. Tar.k 3/27/80 119,000 9500 boiler Economizers 3/26/80 140,01k) 11,421 817,600 850,000 0 76,350 490,000 0 16,207 66,000 280,300 2,161,700 11 ,150,000 128 2,397 3,000 46,971 94,073 150,090 75,072 0 0 17,295 0 10,957 0 81,326 0 41,604 20,148 1,630 r>0 ,'r.Yt 2,099 84,090 650,000 45,000 63,C00 ?rj,0r)0 no/.'jQ 140,000 0 9/80 12/80 Equipment on order. 0 10/80 1/81 Engineering in progress CED. 0 8/90 11/80 Engineering in progress. 0 7/81 10/81 Engineering in progress. 0 6/80 9/80 Project operational. 0 12/80 3/81 Forty-Eight projects approved (9,000) 7/80 10/30 Project operational. 0 1/81 4/81 Enaineerino in progress CED. 0 8/80 11/80 Purchases procc-ediro. 0 12/80 3/80 Ciwineerino in pronreAS. 0 9/80 12/80 Purchases proceeding. 0 %'RO 12/80 rug inner inn in progress. 0 10/80 1/81 tnnineerinq in prcpm'.*'.. -21- PTH OOOO19006 Ainu. CAPITAL - (continued) SO. oisonri ins 9590 9600 9610 9620 Critical Spare Equipment Calcium Stearate Addition System API Clean Water Bypass Cooling Tower Motor Replacement 9630 Water Stripping 9640 Shed For Drum Storage Area 9650 Miscellaneous Projects Under $10,000 aiii:ui)i:i:n aihiu>i!i.:ai ions itn'our (1) Thru April, 1980 Actual Accountinq (?) Thru May. 1980 n.vni AUTII. Aiviiovi-n Al'ii AMT. 3/26/80 59,000 4/2/80 84,000 4/15/80 23,000 4/28/80 17,800 4/30/80 810,000 m 12) PINAL i:\ii:\nrn i:oMMrm:n TOTAL 1ST. to p\it. TU IWTI: COST (UM!\ UNOI-R (OVIili) All 111. AMI'. 1ST. liST, COMP. a.us. HATH DAT!-: KI-MARKS 0 0 59,000 0 10/80 1/81 Update quotes requested. 0 0 84,000 0 11/80 2/81 Engineering in progress. 0 3,189 23,000 0 8/80 11/80 Engineering in progress. 0 17,425 17,425 37? 5/80 8/80 Closed to field charges. 0 0 810,000 0 4/81 7/81 Engineering in progress. 5/8/80 5/30/80 14,000 150,000 0 0 14,000 0 27,808 150,000 0 8/80 11/80 Bids being evaluated. 0 12/80 3/81 Five projects approved. 9089 EXPENSE Vibration Study-Capacity Repalcement Reactors 10/29/79 50,000 27,299 27,433 30,000 20,000 6/80 9/80 Project complete. -22- DTH 000019007 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Western Electric Wiman Corp. Charlotte Pipe Northerri Electric World of Plastics 36861 Nat. 5385 5385 38671 White 5385 Stabilizer Agglomerates Gels, hard particles Sled caps missing Cross contamination Late Shipment WAIVERS RECEIVED Date Identification Product Customer Reason 5/5 5/9 5/12 5/18 TOTAL PTLX-41860 PLCX-42035 PTLX-41827 T-2810 4 5385-3 5385-3 5385-3 5385-1 Charlotte Pipe Particle Size World of Plastics Particle Size Charlotte Pipe Particle Size Cerro Wire $ Particle Size Cable PRODUCT DEVELOPMENT AND SERVICE Ship Date Product Quantity (lbs.) Customer 5/1 5/3 5/3 5/7 5/7 5/7 5/14 5/20 5/20 5/21 5/21 5/21 5/21 5/21 5/27 5/28 5/28 5/28 5/28 5/28 5/28 5/29 5/29 5/29 5/29 5385-1 18031 Cl. 14331 Cl. 5425 5385-1 34641 Pond Resin 5425 5385-1 35851 Nat. 34641 Nat. 26421 Nat. 5305 36861 Nat. 27121 Blk. 3948A-DB 3948B-DB VRP 18031 Cl. 14331 Cl. 5385-3 5385-1 ERC-3711-82B 5425 5385-1 3 x 50 50 50 4 x 50 2 x 50 10 5 2x3 10 50 50 50 50 50 100 4 4 1 gal. 10 10 4 x 50 500 grms. 50 4 x 50 4 x 50 Fritz Airfreight USCI USCI Fritz Airfreight Fritz Airfreight Conoco Inc. Heritage International Conoco Inc. Harte & Co. American Bosch American Bosch Fritz Airfreight Bel den Corp. Engineering Polymer Fritz Airfreight Conoco Inc. Conoco Inc. Heritage International Zapata Industries Zapata Industries Fritz Airfreight Fritz Airfreight Belden Corp. Fritz Airfreight Fritz Airfreight Report By RDJ RDJ CRM JRM CRM Report By CJM ELK ELK ELK Requested By JPM CLS CLS JPM JPM JAP CRM ERC RNG JFN JFN JPM MAS CLS JPM RBM RBM DS RNG RNG JPM JPM MAS JPM JPM -23- DTH 000019008 LABORATORY - (continued) Special Compound Testing One lot each of 34861 Gray 546 and 36861 Natural were tested for compliance with Western Electric specifications, and released. One lot of Kaiser 34431 Gray 547 was tested and found acceptable. One lot of 34533 Natural for Packard Electric was tested and released. Compound Property Verification Property testing is complete on 18 compounds and testing has been started on 5 additional compounds. New Compounds A formula, specifications and quality control standards were prepared for 18551 (ADK 4184-42), a new compound for exterior automotive applications. New Dry Blend Formulas Plant formulas were prepared for 3 special dry blends, one was 80273 for Celanese and 3948-43A and 3948-43B were for trial runs at Actual (Austria). QUALITY CONTROL TESTING Resin Regular Samples = 232 Bag Blends = 44 Other In-Process Samples = 1974 Bulk Shipments = 87 (Railcars = 46; Trucks = 4}) Dry Blend Blenders Produced = 130 Blenders Tested = 118 Blenders Adjusted = 17.7% Other In-Process Samples = 166 Bulk Shipments, = 14 (Railcars = 2; Trucks = 12) Compound Blenders Produced = 682 Blenders Adjusted = 1.3% Other In-Process Samples = 255 Bulk Shipments = 18 (Railcars = 10; Trucks = 8) -24- OTH OOOOASOOS LABORATORY - (continued) Resin Heat Stability Forty-nine (49) samples of resin were tested for oven heat stability, as follows: 5385 5425 5305 5465 21 Samples 17 Samples 7 Samples 4 Samples Two (2) samples of 5425 resin were significantly poorer than the control. Raw Material Testing Seventy (70) lots of raw materials were tested and released. One lot of Hydral 710 was marginal with respect to dispersion and was not released. A trial quantity of Thermoguard WE was rejected for poor dispersion. One (1) lot of 32-GY-16 Gray color concentrate was found to contain particles of red pigment that do not disperse properly, and it was rejected. A complaint has been filed with the supplier. A sample of American Cyanamid's new stabilizer, Cyastab 800, was tested and compared with Tribase and Halbase 10. The Cyastab 800 dispersed satisfactorily and was better than Halbase 10 and Tribase in an oven heat stability test. A sample of T0TM form BASF was tested and approved as a compound raw material. RVCM in Shipments A total of 68 bulk shipments were tested for RVCM in May. Below summary: Product 5305 5385 5425 5465 Average ppm RVCM 3.9 0.7 0.1 0.1 No. of Samples 30 25 8 5 SPECIAL PROJECTS RVCM in Slurry A total of 326 samples were tested for RVCM in May. The overall average was 193 ppm. The daily averages were low with 90% of them being less than 300 ppm and only one daily average greater than 400 ppm. RVCM of Blowdown Tanks A total of 89 samples of water from the blowdown tanks were tested for RVCM. The overall average was 9.6 ppm. -25- DTH 000019010 LABORATORY - (continued) A total of 25 samples of 5305 taken from the regular drier samples were tested for RVCM. The overall average was 12 ppm. Customer Service Because of a question from Phelps-Dodge of low retention of elongation on 35851, a sample of 1S28B10 was aged and tested. The sample gave typical (acceptable) values for retention of elongation and tensile strength. Samples of Teknor-Apex and B. F. Goodrich compounds submitted by Siegel Roberts Co. were compared with 48562 for hardness. The Teknor-Apex compound hardness was the same as 48562 and the Goodrich compound was harder. Viscosity Testing The new Schott viscosity instrument permitted increased testing of resin molecular weight. In May a total of 135 shipment samples, 109 regular drier samples, and 75 reactor slurry samples were analyzed for inherent viscosity. In addition, a precision check was done by running the ASTM sample daily. The precision obtained on this sample during May was 0.5% relative (0.005 absolute). Technical Conference R. Jackson attended the SPE Annual Technical Conference in New York, May 5-8, 1980. -26 DTH 0000X9011 TRANSPORTATION - J. E. Stark Shipment by Product - M/lbs. May Year-to-Date Resin Plasticizer Dry Blend Compound Total 7,733 42 1,365 3,969 13,109 82,997 241 8,918 18,130 110,286 Number of Shipment by Mode R/C O.T. C.O.T C.C. TOFC CPU TOTAL Resin - Bulk Package Export - ABR Plasticizer - Bulk 29 32 4 34 1 61 49 34 1I Dry Blend - Bulk 21 12 15 Package 71 4 12 Compound - Bulk 11 .8 19 Package 25 1 9 35 Export- Pkg Back Hauls for May 42 5 116 ` 0 26 Number of Shipment by Month-year-to Date ` O.T. O.T. R/C Bulk Van 30 C.O.T. o o 5 30 191 26 TOFC CPU TOTAL January February March Apri 1 May 104 53 72 111 83 66 130 95 64 69 43 . 84 42 41 75 0 0 1 0 0 4 2 36 273 21 4 35 320 37 0 48 375 5 0 29 230 3 0 30 191 -27- DTH 000019012 TRANSPORTATION, - (continued) 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 12-9 Total . --- ----.........-- -- - 21 21 21 209 CONOCO TRANSPORTATION ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco Resin Resin 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 Resin Raw Material Resin 0. G. Conoco Conoco Resin Sub-Total (Plug-Aisles) Total Conoco -- 4.0 .4 .8 .5 1.2 1.9 1.5 3.1 .4 4.4 8 .1 .2 .7 .1 -a-o 2 4.0 4.5 1-9 ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 5.7 4 . 3 10.0 1.2 3 1.5 3 4 1 3.5 3. 5 3.5 *-4,U-- 3.5 1. 8 7 2.5 3-3 * 4.0 * 4.5 _____ 3.5 3.5 3.5 1.9 33.7 3.5 _3JL_ _ 2.4 7.2 ___4Q -9_________ DTH 000019013 TRANSPORTATION - (continued) SAFETY REPORT Lost Time Accident Doctor Cases First-Aid Cases Man Hours Worked MAY 0 0 0. 239T 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 1701 2592 1417 0 446 162 3645 1579 446 11988 LABOR REPORT Total regular Hours Total Overtime Hour Total Worked Paid but not Worked Total 1771 125 1896 176 *2072-- Labor Efficiency equals 2.0 MM/Lbs. - Hours Worked Overtime % 6323 S.0% Y.T.D. GRAND TOTAL SINCE L.T.A. 9579 151344' Ilk 42 64 35 Q 11 4 90 39 11 295 -29- DTH 000019014 TRANSPORTATION - (continued) FOUIPMENT REPORT Lift Truck Hours Worked 258 Gal of Fuel Consumed 325 Gals/Hrs 1.3 Lift Truck Efficiency Equals 12.0 MM/Lbs. - Hours Worked -46,465 Lbs./hr OFF-GRAOE IN STORAGE MATERIAL M/Lbs. Sifter Overflow 136 Resin "BC" 4827 Resin "H" Mills Scraps Compound "B" Compound "H" Dry Blend "O.G." Total 1803 22 695 107 74 7664 .. _IZk 3 119 44 1 17 3 2 189 D.F. OPERATION Total packaged inventory for the month remained about the same. There was. also very little change in the shipments for the month. We still have one outside warehouse rented. Safety The subject for the safety meeting was proper lifting and handling of stacking packaged product on pallets. -30- DTH 000019015 ABERDEEN FIRST-AID CASES 12 MONTHS MOVING AVERAGE c c o o X c *>u z 034 O' 04 C B. >aooz *--i c c DTH 000019016 ABERDEEN OSHA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE 20 15 10 5 0 DTM 000013017- Jan. MONTHLY HOURLY TURNOVER 9 8 7 6 5 4 o 2 1 ENERGY USAGE C C (Monthlyot,, 000019019 12 Month Moving n 11 1i ABERDEEN PLANT PRODUCTION 1980 35 30 25 20 15 6 5 4 ..b^4^=.-.. 3 2 1 MM POUNDS CUMULATIVE bz... 60 50 ----------j 40 30 20 10 6 5 4 3 2 1. TOSTiCIZhrT rfc 2 I 0 19 80 25 20 15 10 5 --------- BUDGET ----------- ACTUAL ----------- CUMULATIVE DTH 000019020 % OFF GRADE ABERDEEN PLANT QUALITY PERFORMANCE 1980 STANDARD 0.41 STANDARD 1.02' i STANDARD 1.35 DTH 000019021 ABERDEEN PLANT EFFICIENCY 1980 DTH 000019022 ABERDEEN PLANT INVENTORIES DTH 000019023