Document OELEYvromLX56VXoJMRLaoJVw

SAFETY - A. H. Sather Occupational Injuries Injuries Treated First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time Injuries By Department September 1 0 0 0 0 1980 Year-to-Date 38 14 2 23 0 1979 Year-to-Date 29 6 2 29 1 Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 0 12 1 15 0 23 03 00 01 13 3 18 0 0 2 Injuries By Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 0 27 04 06 1 11 04 04 11 5 12 7 5 1 As of September 30, 1980, the plant operated a total of 450 days or 579,320 manhours without a disabling injury. Safety Meetings The topic for safety meetings during the reporting peri os was "Eye Safety". Several of the plant safety rules regarding eye and face protection and the film "Don't Push Your Luck" were reviewed. New Employee Orientation Six (6) new employees were given new employee orientation during the reporting period. Of the six (6) new employees, five were casual laborers and one was the new Vinyl Operations Superintendent, P. E. Markey. Training Programs Initial comments were given to M. S. Reynolds, Houston, regarding the expanded health effects of VCM exposure and medical records for the revised VCM slide and tape program. Several additional photographs were taken to complete the Employee Safety Responsibilities Program. -1- )TH 000021552 SAFETY - (continued) Corporate Safety Meeting A. H. Sather attended the Corporate Safety Meeting held in Houston September 28 through October 1, 1980. Departmental Supervisors Meetings Initial plans were made to conduct Departmental Supervisors Meetings to discuss areas of need and methods to improve safety performance. The meetings will be conducted during October, 1980. Chemical Exposure Activity for the month included monitoring for VCM and Lead exposure. Also, the results of the Aberdeen PVC Dust Sampling were compiled and reported. Monitoring results and overexposure explanations are noted below. VCM A total of 92 samples were taken with 5 indicating overexposure. Range (ppm VCM) Number Percent 0.0-0.5 0.5-1.2 1.0-5.0 5.0+ 85 92.39 2 2.17 4 4.35 1 1.09 92 100,00 Of the 5 VCM overexposures, 2 occurred to Mechanics who were blinding and opening the south knockout tank in the new unit and were wearing air line respirators; 1 occurred to a Mechanic who was changing gaskets in a VCM compressor and was wearing an air line respirator, 1 occurred to a Vinyl "A" Operator who was changing VCM filters and was wearing an air line respirator; the remaining overexposure occurred to a Vinyl Shift Supervisor who was not wearing a respirator. The source of the last overexposure is under investigation. Lead Number Less than PEL* Greater than PEL * Permissible Exposure Limit 2 0 2 PVC Dust Sampling A total of 41 samples were taken and analyzed. Of these samples, the first 5 were checked for particle size distribution, one was a blank, and the remaining 36 were analyzed for sample weight using matched-weight filters. The results of particle size analysis and time weighted average exposure -2DTH 00U021553 SAFETY - (continued) PVC Dust Sampling - (continued) analysis are shown below. Particle Size Size Range, Microns <2 2-5 5-10 >10 Percent, Total Particles* 4.5 26.1 26.9 42.5 * Particles were counted and sized using a scanning electron micro scope. All particles were counted. Time Weighted Average Exposure (TWA) Range (Mi 11igrams/M^) Number Percent 0.0-0.5 0.5-1.0 1.0-1.5* 29 80.56 4 11.11 3 8.33 36 100.00 * The largest TWA result was 1.4 mg/m^. The respirable dust standard (0SHA) is 5.0 mg/m3. -3- DTH 000021554 VINYL - P. E. Markey 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 Pound/Hr. 7. Dryer Stream Factor, % 8. Accounting Days 23.4 780 19.1 573 80.6 5699 81.5 30 187.9 686 16.5 4526 71 .9 4082 72.1 274 Vinyl Department production for September was 86.6% of budget at 23.4 MM pounds. Production levels continued to be reduced as part of the inventory control program. Reactor and dryer stream factors were 80.6% and 81.5% respectively. The major item affecting those stream factors and the overall production rates are as follows: 1. Inventory control programs continued to represent the majority of reactor and dryer stream factor penalties (10.3% and 10.2% respectively). 2. A total of 5 reactor condenser brushings were performed, resulting in a 2.8% reactor stream factor penalty. 3. Debagging operations were undertaken towards the end of September, resulting in a 2% dryer stream factor penalty. Testing of extended Methocel addition times was begun in September. Additional testing is planned for October. Resin Quality Summary Resi n Type Prime Pounds "BC" Grade "H" Grade % of Total Producti on 5305 5385 5425 5465 Sifter Overflow 1,604,190 18,268,239 2,880,505 404,400 - ( 50) 203,250 13,500 - - - (286,450) - 244,900 6.9 79.2 11.2 1.7 1.0 TOTAL 23,157,334 216,700 ( 41,550) 100.0 Quality performance for September was 99.2% customer grade with 0.9% "BC" grade and (0.1%) "H" grade. Debagging operations upgraded 286 M pounds to prime quality resin. -4DTH 000021555 VINYL - (continued) The variable cost variance for the Vinyl Department was $339.3 M with $314.1 due to price and $25.2 M due to efficiency. The variance due to product mix was $8.6 M. The major price variance was $320.2 M for VCM. The major efficiency variance was ($57.7 M) for VCM, but was partially offset by a favorable $51.3 M in processing additives. The raw material requirement for September was 1.03200 pounds VCM/pound PVC versus the 1.01960 standard. (Y.T.D. is 1.01876) General Resin packaging for September totaled 2,827,885 pounds, Resin debagging totaled 286,450. -5- DTH 0000215& COMPOUND - J. R. McCrimon Compound Production Month Day Y.T.D. Line I, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days 1,127 51 10,048 214 31 834 2,831 98 23,517 4,172 144 34,400 30 274 Line I operated 22 days during September at an average rate of 51 M pounds per day. Major items affecting production efficiency were: product changes (35.5 hours), adjusting and repairing scales (30.2 hrs,), dicers (16.0 hours), conveyor clutch and bucket repairs (15.8 hours), and maintenance on the pull roll gearbox. Line V operated 7 days during September at an average rate of 31 M pounds per day. Major items affecting production efficiency were: putting raw materials in use bins (19.9 hours), product changes (15.0 hours), maintenance on the Orbitran (7.1 hours) and maintenance on the plasticizer scale system (5.5 hours). Line III operated 29 days during September at an average rate of 98 M pounds per day. Line III production was affected by: product changes (41.4 hours), repairs to FCM and conveyor (19.9 hours), and quality control (11.1 hours). Quality performance for flexible compounds was 3.0% off-grade of which 92.6% was due to mill scrap. "BC" production was 1.3%. The raw material requirement for flexible compounds was 1.03410 pounds of raw material per pound of compound versus a 1.01303 standard. (Y.T.D. is 1.01994) The variable cost variance for compound was ($8,0 M) with $44,1 M due to price and ($52.2 M) due to efficiency. The variance due to product mix was ($4.8 M). The only major efficiency variance was ($12.9 M) for resin which was due to an inaccurate inventory count on bagged resin, There were no major price variances for September. Dry Blend Month Day Y.T.D. Production, M Pounds Accounting Days 1,645 30 84 15,323 274 Dry Blend operated 19 days during September at an average rate of 84 M pounds per day. Production included 80172B, 80273G, 80274G, 80175 and 3948-43A, Dry Blend production was affected by: inventory control. No. 2 Welex blade change (16.0 hours), maintenance on product blower (15.6 hours), quality control (14.2 hours), boxing dry blend (11.5 hours), dust collector/use bin repairs (9.7 hours), and product changes (8.3 hours). Quality performance for the month was 99.99% customer grade. -6- DTH 000021557 COMPOUND - (continued) Dry Blend - (continued) The raw material requirement for dry blend was 1.02031 pounds of raw material per pound of dry blend versus a standard of 1.00319. (Y.T.D. is 1.00890) The variable cost variance for dry blend was $26.0 M with $8.5 M due to price and $17.5 M due to efficiency. The variance due to product mix was $32.9 M. There were no major price or efficiency variances for the month. Plasticizer Month Day Y.T.D. Production, M Pounds Accounting Days 1,026 30 51 7,030 274 Plasticizer operated 20 days during September at an average rate of 51 M pounds per day. Production included: 610P, DIDP, and D0P. VRP production totaled 68.2 M pounds (6.7%). Production was limited by: R-2 cooling coil acid cleaning and rupture disc replacement (twice). The raw material requirement for plasticizer was 1.12148 pounds of raw materials per pound of plasticizer versus a 1.07823 standard. (Y.T.D. is 1.11325) The variable cost for plasticizer was ($55.7 M) with ($34.2 M) due to price and ($21,6 M) due to efficiency. The only major price variance was ($17.0 M) for 2-Ethylhexanol and there were no major efficiency variances. The variance due to product mix was ($0.9 M). General Total customer grade compound inventory decreased from 7.2 to 6.7 MM pounds during September. -7- DTH 000021558 MECHANICAL - S. J. Vincent Vinyl There were no large reactor seals or gearbox failures in this period. There were five condensers cleaned this month with three condensers being cleaned in the new module and two in the old module. Those condensers cleaned in the new module were on the 742, 743, and 744 reactors. In the old module, condensers were cleaned on the D-300 and D-400 reactors. The safety valves were tested on 741 and 744 reactors. Mew safety discs were installed on these reactors also. New agitator blades were installed in the new module reactors 741, 742 and 743. Several major valves were repaired or replaced in the vinyl production area in this time period. The slurry dump valves on 742 and D-300 reactors were replaced. The recovery system bypass and inlet valve to the north knock-out drum were replaced. The evacuation and recovery valves were replaced on 741 reactor and rewired for panel control, along with both steam stripping valves. The D-400 chemical wash valve was replaced. The polarity was reversed on the new module large reactor control valves. This was done to prevent the possibility of these valves failing open should there be a wiring problem. There were seven seal failures to pumps and compressors in this period. One failure was in the new module and six were in the old module. In the new module the seal was replaced in the east VCM return pump. In the old nodule seals were replaced in the south emission recovery return pump, the emission recovery compressor, the inboard and outboard seal on "B" recovery compressor, the inboard seal on the "A" recovery compressor and the inboard seal on "B" vacuum pump. In the old module the rinse pump was overhauled and a new seal water pump was installed. Two Corken compressors were removed to repair case leaks. New safety discs and safety disc holders were installed under the VCM sphere safety valves. The Bird centrifuge and gearbox were changed twice in the #5 dryer unit. The Bird centrifuge and gearbox were changed in the #4 unit. The Sweco feeder valve was changed on #2 dryer and the exhauster damper was reworked on the #6 exhauster. A separate power source was installed to the large silo lights. The lights previously were shut off whenever a blower was locked out. Compound, Dry Blend, Plasticizer, and Silo Storage The compound lines I, III, and V were operated this month with line I and V alternating. The bulk of the repairs to the compounding equipment were dicer maintenance, along with minor steam and process leaks. The resin diverter valve to line I and V was replaced and the line I scales were over hauled. Repairs were made to #6 dicer motor. The compound cooling tower level control was repaired. The line one product blower was relocated and rewired. -8- DTH 000021559 MECHANICAL - (continued) Compound, Dry Blend, Plasticizer, and Silo Storage - (continued) In dry blend, the blades were changed in the #2 Helex. The dump gate was rebuilt on #1 Wei ex. The overflow dump valve was replaced on the south Kason screener. Isolation valves were installed on the bottom of the 412 and 413 silos. A blender motor was repaired due to a leaking oil seal. A major problem was experienced with the north plasticizer blower that involved bearing failures, case leaks, and rotor problems. The unit has been completely overhauled and returned to service. The coil in R-2 reactor was chemically cleaned. Safety discs were replaced on all plasticizer reactors. The safety valves were tested on the four fire pumps. One development lab mill was rebuilt. The new 800 horsepower Joy air compressor motor was installed along with the new control system. Power was run to three waste analysis trailers. The installation of two electric operated doors was completed on the warehouse. Utilities and Service There were three repairs to the plant air system this month. Valves were replaced in the #6 and #9 air compressors and the heater elements were replaced in the east tower of #3 air dryer. The air conditioning and air compressor P.M. programs are proceeding. The compressor on the safety department air conditioning unit was replaced. The machinist repaired or completed machine work on 24 major items. The tool room mechanic maintained the tool room and rebuilt valves to be returned to stock and tested safety valves. The well pump header safety valve was tested and reset to 120 psig. A new temperature control thermostat was installed in the I & E shop. Planner The planner estimated 87 work orders. Material was ordered for 35 projects. Closed 12 registers and issued 20. Processed 17 statements for payment. The equipment history and safety valve records were maintained. -9- DTH 000021560 MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved, and Closed The following AFE's were submitted and approved during September: AFE No. Title Authorized 9680 9690 9010 Fixed Point Monitor Data Computer and Warning Lights Breathing Air Modifications Centrifuge Rotor Repair $113,000 21,000 20,000 Completion reports were issued for the following AFE's during September: AFE No. Title Authorized 9098 9549 9659 9520 9540 9640 New Compound Line Safety Equipment P. A. System Modifications Replacement Phthalic Anhydride Tank Laboratory Equipment Shed For Drum Storage Area $2,050,000 15,000 35,000 75,000 45,000 14,000 The following AFE 's were closed to field charges during September: AFE No. Title Authorized 9297 9148 9258 9228 9248 9769 Automatic Plasticizer-Stabilizer Weigh-Up System Plasticizer Chemical Exposure Abatement Dryer Operations Improvements Dry Blend Silo Alarms Silo Isolation Valves Automatic Setback Thermostats $ 60,000 T52,000 315,000 25,000 25,000 3,000 Design Design work is in progress on the following projects: - Replacement of Hot Water Charge Tank - Methocel Charge Revisions - Boiler Economizers - Reactor Inert Vent System - Walkway From 600 to 200 Series Silos - Interplant Communications Phase II - Spare Reactor Condenser - Fire Protection Improvements - Phase II - Spare Inert Incinerator - Multigrade Resin Production Facilities - Water Stripping -10- DTH 000021561 MECHANICAL ENGINEERING - (continued) AFE Activity 1. AFE 9629 - Air Compressor - M. S. Richards The new motor and control system for the new Joy air compressor were installed. 2. AFE 9689 - Diking of Sphere and Curbing of Drum Storage Area - J. L. White Construction of the concrete wall is 80% complete. 3. AFE 9709 - Facilities for Multi grade Resin Production - CED (S. Krase) Overall project design is 75% complete. All major electrical and instrumen tation items have been purchased. Concrete bid packs were sent out for quotes. 4. AFE - 9729 - Fire Protection Improvements - Phase II - CED (M. Ingle) Overall project design is 92% complete. Part I of the underground piping is out for bids. Bids are due 10/10/80. 5. AFE 9739 - Methocel Charge Revisions - J. L. White Overall project design is 90% complete. The strahman ram valves have been received. 6. AFE 9530 - Spare Incinerator - CED (D. Haub) Overall project design is approximately 45% complete. Structural design and pipe drafting are in progress. Concrete and plot plan drawings are being revised to reflect the new location of the incinerator. 7. AFE 9550 - P. A, Handling Improvements - J. P. Windham Installation of the jacketed unloading line is 90% complete. Project completion is scheduled for 10/15/80. 8. AFE 9560 - Safety Equipment - J. P. McKee Structural design of walkway between the 600 and 200 series silos has been reviewed and is ready for bidding. 9. AFE 9580 - Boiler Economizers - J. L. White Structural steel and equipment installation contract has been let. The piping bid packs are out for bids. 10. AFE 9590 - Critical Spare Equipment - J. P. McKee The drawing for the spare condenser is ready for bidding. -11- DTH 000021562 MECHANICAL ENGINEERING - (continued) AFE Activity - (continued) 11. AFE 9610 - API Clean Water Bypass - M. S. Richards The skimmer has been received. Sewer design is in progress. 12. AFE 9630 - Water Stripping - CED (M. Ingle) Mechanical design is 74% complete. Quotes on structural steel have been received and tabulated. Concrete and sewer bid pack with the revised sewer location have been issued. 13. AFE 9660 - Hot Water Charge Tank Replacement - J. P. McKee The concrete work has been let and is in progress. Construction - 6. A. Morgan Bids were received for the D-300 reactor jacket repair. Construction has started on the new hot water charge tank. The plant water wells were inspected for flow, mechanical condition and water quality. The foundations for the boiler economizers were completed. The new motor and controls for the new Joy air compressor were installed. Bids have been requested for part I piping of the Fire Protection Improve ments Phase II project, A smoke detection system was installed for areas which normally have no traffic during off hours. Six contracts were let during the period. They were for: 1. Insulation of Vapor Emissions Recovery System 2. Insulation of New Phthalic Anhydride Unloading Line 3. Insulation of Piping for Double Block Valves for VCM Charge 4. Lease of the Amory Rail Lead for Car Storage 5. Repairs to Plant Trackage 6. Foundations for New Hot Water Charge Tank. Thirty-two (32) register tickets were issued during September. -12- DTH 000021563 (1} Thru August, 19110 Actual Accounting (2) Thru September, 1980 ABERDEEN AtmiOUi:.\,nONS REPORT Aum. CAPITAL NO. m-SCIUPTlON 9237 9297 Heated Plasticizer Addition System Automatic Plasticizer-StabilIzer Weigh-Up System DATE AUTIl. APPROVED Ai;i:. wrr. 10/11/77 37,000 12/14/77 60,000 Cl) EXPENDED TO DATE U) COMMITTED TO DATE FINAL TOTAL LST. COST COMP. UNDER (OVER) AUT11. AMT. EST. LST. COMP. CI.OS. DATE DAH: REMARKS 13,090 13,589 37,000 0 12/80 3/81 Design in progress. 56,263 59,163 60,000 837 9/80 12/80 Closed to field charges. 9148 Plasticizer Chemical Exposure Abatement 8/21/78 152,000 142,245 149,158 152,000 2,842 9/30 12/80 Closed to field charges. 9158 Fire Protection Improvements Phase I 9228 Dry Blend Silo Alarms 9248 Silo Isolation Valves 9258 Dryer Operation Improvements 9519 Critical Spare Equipment 9559 Color Weigh Room Modifications 9589 Instrument Air Dryer 9609 Reactor Inert Vent System 9629 Air Compressor 9639 Revisions to Emission Recovery System 9/19/78 176,000 144,560 179,595 182,600 12/13/78 25,000 12/14/78 25,000 12/14/78 315,000 2/6/79 175,000 4/19/79 25,000 5/30/79 110,000 6/28/78 90,000 7/9/79 340,000 7/12/79 100,000 16,490 16,580 21,629 22,577 287,749 325,140 107,249 160,097 17,849 18,552 90,134 90,645 13,245 17,895 249,327 261,749 60,065 69,664 25,000 25,000 326,000 163,000 25,000 110,000 90,000 340,000 100,000 ( 6,600) 8/80 11/80 Closed to field charges. 8,420 9/80 12/80 Closed to field charges. 2,423 9/80 12/80 Closed to field charges. ( 11,000) 9/80 12/80 Closed to field charges. 12,000 10/80 1/81 Revisions in progress. 0 11/80 2/81 Project operational. 0 11/80 2/81 Revisions in progress. 0 12/80 3/81 Engineering in progress. 0 3/81 6/81 Revisions in progress. 0 12/80 3/81 Revisions in progress. 9649 Double Block Valves for VCM Charge 9669 New Air Header 9689 Diking of Sphere & Curbing of Drum Storage Areas 7/18/79 8/15/79 9/15/79 182,000 25,000 170,000 135,479 17,084 64,194 147,290 17,284 127,244 182,000 25,000 170,000 0 10/80 1/81 Project operational. 0 12/80 3/81 Revisions in progress. Q 11/80 2/81 Construction in progress. 9699 Plant Dryer Debottlenecking 9709 Facilities for Multiple Grade Resin Production 9719 Aberdeen PVC Resin Expansion 9729 Fire Protection Improvements Phase II 9739 Methocel Charge Revision 9759 Aberdeen PVC Resin Expansion 9769 Automatic Setback Thermostats 9510 Miscellaneous Projects Under $10,000 9530 Spare Incinerator 9550 P. A. Handling Improvement 9560' Safety Equipment 9570 9580 Replace T-100 P. A. Tank Boiler Economizers 9590 Critical Spare Equipment 9600 Calcium Stearate Addition System 9610 API Clean Water Bypass 9630 Water Stripping 9650 Miscellaneous Projects Under $10,000 9660 Hot Water Charge Tank Replacement 9670 9680 Laboratory Equipment Fixed Point Monitor Oata Computer and Warning Lights 9/15/79 9/20/79 80,000 870.000 5,365 23,380 23,595 271,080 80,000 870,000 9/10/79 10/1/79 850,000 490,000 11,421 817,600 15,994 99,465 850,000 490,000 10/3/79 66,000 7,096 20,621 66,000 12/10/79 11 ,150,000 1,033,079 4 ,897,400 11 ,150,000 12/31/79 3,000 2,419 2,557 3,000 1/3/80 150,000 89,303 119,290 150,000 1/23/80 3/3/80 3/12/80 3/27/80 3/26/80 3/26/80 4/2/80 4/15/80 4/30/80 5/30/80 650,000 63,000 25,000 119,000 140,000 59,000 84,000 23,000 810,000 150,000 164 213,578 23,982 28,927 1,711 7,703 57,782 62,366 2,019 109,663 0 11,486 0 1,148 3,216 4,727 6,270 38,509 47,699 107,524 650,000 63,000 25,000 119,000 140,000 59,000 84,000 23,000 310,000 150,000 6/4/80 7/9/80 9/4/80 160.000 32,000 113,000 200 40,243 160,000 151 30,529 32,000 0 0 113,000 0 3/81 6/81 0 3/81 6/81 Engineering in progress CEO. Engineering in progress CED. Q 1/81 4/81 Equipment on order. 0 6/81 9/81 Bids requested on Part I piping. 0 12/80 3/81 Engineering in progress. 0 9/81 12/81 Foundation work in progress. 443 9/80 12/80 Closed to field charges. 0 12/80 3/81 Forty-Eight projects approved. 0 3/81 6/81 Engineering in progress CED. 0 12/80 3/80 Construction in progress. 0 12/80 3/81 Smoke detection portion complete 0 12/80 3/81 Project on hold. 0 12/80 3/81 Installation in progress. 0 12/80 3/81 Engineering in progress. 0 11/80 2/81 Engineering scheduled. 0 11/80 2/81 Engineering in progress. 0 4/81 7/81 Engineering in progress. 0 12/80 3/81 Thirty-three projects approved. 0 12/80 3/81 Foundation contract let. 0 12/80 3/81 Analyzer purchased. 0 9/81 12/81 Engineering in progress. 9690 Breathing Air Modifications 9010 EXPENSE Centrifuge Rotor Repair 9/9/80 21,000 9/19/80 20,000 0 0 21,000 0 -13- 0 20,000 0 3/81 6/81 Engineering scheduled. 0 12/80 3/81 Repairs in progress. DTH 000021564 PERSONNEL - J. L. Carter EMPLOYMENT Phil Carson, Casual Labor William Davis, Casual Labor Charles Morris, Casual Labor Randy Otts, Casual Labor Stevie Troupe, Casual Labor TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTION John Coffman, Plant Accountant, promoted to Management Information System Analyst, Houston. Pete Markey, Assistant to the Vice President-Operations, Houston, promoted to Operations Superintendent, Aberdeen. Vernon Thornhill, Process Engineer, promoted to Senior Process Engineer. Earnest Randle, General Helper, promoted to Compound Utility. Hansel Baughn, Lab Trainee, transferred to Compounder. RETIREMENT None. TERMINATION Lester Danner, Compound Operator OTHER During September there were five casual labor employees on payroll. Total hour worked were 702.25. -14- DTH 000021565 CONOCO CHEMICALS Aberdeen, Mississippi September 1980 MONTHLY PERSONNEL REPORT Salaried Employees 77* Minority Employees # Hourly Employees 156 Salaried 6 7.8% CO CO ci-S Total Employees 233* Hourly 59 Employees (Hourly) Total 65 28% New Employees Terminations Hourly Min. Hired % Min. Hired Hour1y Min. Term. % Min. Term. 0 0 n m DEPARTMENTS PAR It EMPLOYEES MIN. EMP. . % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse 9 9 2 22% 0 0 00 0 0 Gen. Plant Maintenance 10 46 11 46 4 36% 7 15% 0 4 02 0 0 0 00 0 16.6% 0 Laboratory 22 20 3 15% 0 0 00 0 0 Compound 37 35 28 80% 0 0 1 3** 3% 6% Vinyl Plasticizer 32 5 31 4 12 39% 3 75% 0 0 01 0 0 0 0 -0 0 3% 0 Number of Applicants: Month 2 Year to Date 116 APPLICANT BREAKDOWN: It Minority 1 % Minority 50% ^ Female 0 % Female 0 includes three (3) temporary employees. **Includes one (1) retirement and is not counted in turnover rates. Hires (Hourly) : Month 0 Year to Date 4 Terminations (Hourly) : Month 1 Year to Date Overall Turnover .6% 6** Projected Annual Turnover 5% -15- DTH 000021566 OO oo CCOO co cn o3 o .c s- KOI OVERTIME AND ABSENTEEISM QEJ -O i-- c q| DTH 000021567 PROCESS ENGINEERING - R. A. Frohreich A. Expansion Project Basis of bids for the second concrete package which includes the silos, cooling towers, initiator storage freezer, and slurry blend tanks were issued to contractors. In the V-ll area the reactor pad and piers are in place. In the CRD area the reactor piers have been placed. Con struction of the electrical substations is underway. Review of piping and electrical layout continues with plant assistance to Litwin field personnel as needed. B. Agitator Replacement The AFE request for this project was submitted. C. Modifications to Make Profile Dry Blend The revised class "A" design for this project was issued and the AFE request was submitted. D. Compound Fines and Streamer Removal The revised class "A" design for this project was issued and the AFE request was submitted. E. Resin Reclaim System The class "A" design was issued, a review meeting was held and the revised class "A" design incorporating comments from the review meeting was issued. F. Heat Recovery System The class "A" design was issued and a review meeting was held. Comments from the review meeting are being incorporated. G. Automatic Cooling Tower Fan Controls The AFE request for this project was submitted. H. City Water Usage City water usage is down as a result of starting the forth well water pump and resetting the setpoint on the well water relief valve, I. Emission Recovery System Compressor Problem Several trouble shooting tests were run on the Nash compressors as suggested by Nash with negative results. A Nash Service Representative will be here in October to determine why the compressors will not put up the proper head. -17- DTH 000021568 PROCESS ENGINEERING - (continued) J. Process Water Filter Replacement This design to reduce filter element expenses will be issued in October. K. Fire Protection Improvements - Phase III The AFE request for this project was submitted. L. API Clean Water Bypass Revised drawings routing the clean water from the plasticizer building around the API were issued and reviewed. M. Cooling Water Blowdown Bypass The class "A" design to bypass cooling water blowdown around the bioponds is being prepared. N. Rotary Dryer Insulation An evaluation of energy savings by insulating various sections of the rotary dryers is being prepared. O. Kemp Air Dryer Modifications The class "A" design to add coalescing filters, replace purge piping and electrical, and make other modifications in order to correct the dew point problem in the Kemp air dryers is being prepared. P. VCM Tank Farm Revisions A design to correct problems and allow for better unloading of VCM is being prepared. Q. Biopond Aerator Replacement The class "A" design to replace existing aerators with smaller submerged ones to reduce the aerosol effect is being prepared. R. Compound Sewer Revisions The design to eliminate process contact streams from the compound area that now enter the storm water sewer is being prepared. S. Emergency AMS Kill System PED completed the class "A" design for this project and a review meeting was held at the plant. T. Double Rupture Disc Replacement A review meeting of PED's class "A" design for replacing the double rupture disc/relief valves systems was held at the plant. -18- DTH 000021569 ENVIRONMENTAL - V. E. Messick Particulates Two dryers were tested for particulates in September. Water Effluent BOD and COD concentrations were within NPDES limitations in August. The Quarterly NPDES Discharge Monitoring Report was issued. The pilot study of the biodisc is proceeding on schedule. Preliminary results show about 65% COD reduction with the biodisc. Hazardous Waste Management The plant is negotiating with Chemical Waste Management about contract language for disposal of six items. Work has begun on the Part A of the Permit Application which is due November 19. -19- DTH 000021570 Flow GPM Jan. - Ave. 810 Max. 941 Feb. - Ave. 645 Max. 802 Mar. - Ave. 595 Max. 743 Apr. - Ave. 628 Max. 877 May - Ave.' 304 Max. 480 June - Ave. 670 Max. 804 July - Ave. 696 Max. 813 Aug. - Ave. 698 Max. 753 Sept. - Ave. 679 Max. 767 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. 0" 43 131 436 1342 86 851 216 2214 11 103 13 143 6.8-8.5 6 42 8 56 29 220 36 314 21 147 30 232 15 116 24 171 66 502 95 82 8 54 378 67 519 10 79 13 125 11 74 14 94 12 86 13 129 6.7-7.9 6.6-8.3 6.4-8.3 16 69 32 184 6 49 11 84 53 197 74 426 40 316 51 367 10 40 14 81 12 98 15 145 6.7-7.3 6.7-7.3 14 112 19 145 7 56 9 70 5 42 7 64 39 322 78 597 32 270 42 380 22 168 27 248 11 88 14 110 15 126 24 187 7 44 14 89 6.6-7.3 6.5-6.9 6.2-6.7 NPDES - Ave. Max. 32 387 43 520 1390 1940 - 605 - 909 >6.0 >*-- i -n oo ph 7.7-8.0 7.1-7.8 7.5-8.4 7.2-7.9 7.5-7.9 7.3-8.0 7.6-7.9 6.5-7.9 6.0-8.5 DTH 000021571 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for September was 97.1 MMM BTUs. The energy consumption per pound of product decreased from 3425 BTU/lb. to 3215 BTU/lb. in September. II. Plant Energy Conservation Program Steam Leaks Nineteen steam leaks were repaired in September. Other R. A. Conrad, Carl Spangler, and Bob Vruggink were here to survey the plant for potential energy savings projects. Recommendations will be made by the survey team to the plant for evaluation. -21- DTH 000021572 ENERGY CONSERVATION DATA ITEM 1979 1980 Production, MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL September 28.3 3.7 3.0 1 1 36,1 September 23.3 1.6 4.2 1.1 30.2 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 54285 1020 55.371 4.7232 10000 47.232 21.095 92000 1.941 49322 1020 50.380 4.680 10000 46.800 0 92000 0 Total Energy Consumption, MMM BTU Energy Consumption , BTU/Lb. 104.544 2896 97.108 3215 Boiler Operating Data No. 1 No. 2 No. 3 Avg. Stack Temp. 1979 1980 377 382 413 464 409 421 Avg. -a Excess Air 1979 1980 26 29 28 22 33 22 -22- DTH 000021573 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Report By Rehau Plastiks Charlotte Pipe O'Sullivan Corp. 5385 5385 5385 Contamination - Fused Resin Contamination - Fused Resin Contamination - Fused Resin CRM CRM JRW WAIVERS RECEIVED Date Identification Product Customer Reason Waived By 9/16 9/22 PTLX 41657 CONX 45298 5385-3 5385-3 Charlotte Pipe Charlotte Pipe Particle Size Particle Size JRW CJM PRODUCT DEVELOPMENT & SERVICE Ship Date Product Amount (Lbs.) Customer Requested By 9/3 9/10 9/10 9/10 9/16 9/16 9/16 9/16 9/16 9/16 9/17 9/16 9/16 9/24 9/24 9/24 9/24 9/24 9/24 9/24 9/24 9/24 9/26 9/26 9/26 9/26 38601 Natural 2 34641 Black 50 34641 Natural 50 5385-1 50 x 4 14952 Natural 100 15241 Natural 100 18161 Natural 100 35851 Natural 50 34431 Natural 50 38551 Natural 20 Unitane 0R-450 5 36861 Natural (EXP) 5 34861 Gray (EXP) 5 5305 50 34501 Black 200 34501 Black 250 5305 50 5425 50 5305 50 5385-1 50 5425 50 5465 50 48562 Black 2 38601 Natural 5 kg 34431 Natural 5 kq 5425 5 kg Wilson Products Co. Eaton Corp. Eaton Corp. Fritz Airfreight Runzel Cord & Wire Runzel Cord & Wire Formtech Dielectric Materials Dielectric Materials Norton Company Conoco Inc. Conoco Inc. Conoco Inc. Uni royal Chemical Div. Lorraine Ind. Cable Superior Cable Amoco Chemicals Mitsui & Co., Inc. Morton Chemical Co. Morton Chemical Co. Morton Chemical Co. Morton Chemical Co. Conoco Inc. Fritz Airfreight Fritz Airfreight Fritz Airfreight ERC JTW JTW JPM MAS MAS JTW MM MM JTW JAP ERC ERC NTH WBS PM MAS JPM MFM MFM MFM MFM ERC JPM JPM JPM -23- DTH 000021574 LABORATORY - (continued) PRODUCT DEVELOPMENT & SERVICE - (continued) Special Compound Testing Complete specification tests were run on 2 production lots of 34861 Gray 546 and 1 lot of 36861 Natural for Western Electric. In addition, critical property test are run on every shipment. Specification tests were also run on an experimental lot of Western Electric 646-B. U. L. oven aging tests were run on 2 lots of 35851 Natural and 1 lot of 38601 Natural shipped to Phelps-Dodge. Two lots of 34641 black for Kaiser were subjected to U. L. oven aging tests. QUALITY CONTROL TESTING Resi n Regular Samples = 301 Bag Blend Samples = 73 Other In-Process Samples = 2351 Bulk Shipments = 138 (Railcars = 94, Trucks = 44) Dry Blend Blenders Produced = 220 Blenders Tested = 184 Blenders Adjusted = 13.2% Other In-Process Samples = 126 Bulk Shipments = 31 (Railcars = 3, Trucks = 28) Compound Blenders Produced (Line 1 & 3) = 515 Blenders Adjusted = 5.4% Line 5 Production = 120 skids; 9 boxes Other In-Process Samples = 295 Bulk Shipments = 28 (Railcars = 14, Trucks = 14) Resin Heat Stability Forty (40) lots of resin were tested for oven heat stability. 5385 5425 5305 5465 16 lots 11 lots 9 lots 4 lots The 5425 and 5465 resin were consistently good; however, the 5385 and 5305 samples gave a wider range of results with occasional samples being marginal to poor in heat stability. Heat stability tests are now run in the Metrastat oven. -24- DTH 000021575 LABORATORY - (continued) QUALITY CONTROL TESTING - (continued) RVCM of Shipments A total of 139 shipment samples were tested for VCM. Below is a summary of this data. Product 5305 5385 5425 5465 Average RVCM Number of Samples 1.3 61 0.7 69 0.1 0.1 72 Viscosity The Schott viscosimeter continues to function well. A total of 619 resin samples were checked for inherent viscosity. Raw Material Testing Forty-eight (48) lots of plant raw materials were tested. Dispersion quality of Hydral 710 continues to be erratic, and 1 truckload (2 lots) were rejected. We have finally obtained cooperation of the supplier in solving the problem. Dry Blend Development Quality control standards were prepared for monitorinq production of 80172B, 80175, 80273G, 80274 and 90171. SPECIAL PROJECTS Metrastat Oven The initial Metrastat oven development program has been completed and a report is being prepared. Other potential applications will be investigated. Compound Property Verification The compound property verification program is approaching completion for 1980. Blown Film Tower Additional runs have been made with the extruder blown film tower. Progress has been made, but additional work is required before the unit can be con sidered operational. RVCM in Slurry A total of 542 slurry samples were tested in September for residual VCM. The overall average was 205 ppm. There were no days where the daily average exceeded 400 ppm. -25- DTH 000021576 LABORATORY - (continued) SPECIAL PROJECTS - (continued) EPA Testing - RVCH A special test on slurry was done to generate data for an EPA variance request on storage of samples prior to analysis for RVCM. Personnel Dosimetry A total of 80 personnel dosimetry tests were run in support of the Safety Department. RVCM of 5305 Regular Samples A total of 39 samples of 5305 taken from the regular drier sample was checked for RVCM. The overall average was 5.8 ppm. One sample tested 67 ppm. RVCM of Blowdown Tank Water A total of 134 water samples were tested for RVCM. The overall average was 4.5 ppm. In September, 94% of the samples were below 10 ppm RVCM. -26- DTH 00002157? TRANSPORTATION - J. E. Stark Shipments by Product - M/lbs. Resi n Plasticizer Dry Blend Compound TOTAL Number of Shipments by Mode 0 .T. O.T. R/C Bulk Van Resin - Bulk - Package - Export Plasticizer Dry Blend - Bulk - Package - Export Compound - Bulk - Package - Export Other - Antifreeze 89 5 8 37 2 1 4 12 1 12 34 10 2 TOTAL 102 53 62 Back Hauls for September 16 Number of Shipments by Month - Y.T D. R/C Bulk Van January February March April May June July August September 104 53 72 111 83 66 130 95 64 69 43 84 42 41 75 55 36 136 57 47 52 79 51 65 102 53 62 Material Handling Report 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 Transfered from Prairie to Main -27- September 15,768 80 2,506 4,723 23,077 Year-to -Date 138,722 646 17,700 _____32? 092 189, 160 C.O.T. 0 C.C. 4 1 2 7 1 TOFC CPU TOTAL 130 9 12 1 22 25 34 1 13 1 20 2 16 54 10 2 2 53 279 17 C.O.T. 0 0 1 0 0 0 0 0 0 M/Lbs. 3,038 2,308 3,038 0 446 364 3,402 486 769 13,851 C.C. 4 21 37 5 3 7 2 12 7 TOFC CPU T0TA1 2 36 273 4 35 320 0 48 375 0 29 230 0 30 191 0 74 308 0 64 222 0 89 296 2 53 279 T/L 75 57 75 0 11 9 84 12 19 342 DTH 000021578 TRANSPORTATION - (continued) Off-Grade In Storage Material M/Lbs. T/L Sifter Overflow Resin "BC" Resin "H" Mill Scrap Compound "BC" Compound "H" Dry Blend "O.G." 218 4,768 1,392 127 922 39 106 7,572 5 118 34 3 23 1 3 187 D. F. Operation Total packaged inventory for the month increased approximately 1.2 MM pounds during September. Compound shipments for the month were above average. We had a decrease in compound inventory by approximately .5 MM pounds. Bagged resin inventory gained approximately 1.2 MM pounds. Export shipments for the month were extremely low. -28- DTH 000021579 V LOCATION MAIN-East 11 I 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 21 21 21 ital 209 CONOCO TRANSPORTATION ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco Resin HDPE Resin Export Resin Conoco Export Resin 3-6 4 6 9 4 2.2 .3 3 .6 V Conoco Resin "" 4.4 Resin O.G. Mill Scraps .2 Cmpd 0. 6. 1 .0 Dry Blend 0. 6. .1 Sifter Overflow .2 Resin 0. G. `Compound 1 .7 .1 Resin 3.0 Raw Material .2 Resin 0. G. 4.0 Conoco 4.5 Conoco Resin Sub-Total (Plug-Aisles) 3.8 Total Conoco _29_ * ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL __ 5;. 5 . 4.5 LA__ l.i__________ 10.0 1.5 2 . 2 __ 1:. 3_____2.5 * -3 9 *4.4. 3.5 3.5 2.2 2.5 3- .3. . * 4 Q.. * a 5 *3.8 * .2 3.5 3.5 3.5 3.5 -2L5.. 3.1 34. 2 7.4 41 . 5 DTH 000021580 ABERDEEN FIRST-AID CASES 12 MONTHS MOVING AVERAGE C c o o X ( *>u2w ctu/ Uh >H *"3 i--i c DTH 000021581 ABERDEEN OSHA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE 20 15 10 5 0 DTH 000021582 MONTHLY HOURLY TURNOVER DTH 000021583 ENERGY USAGE DTH 000021584 Monthly 12 Month Moving Average ABERDEEN PLANT PRODUCTION UlNI MM POUNDS 'HL' 1980 CUMULATIVE 35 30 25 20 15 6 5 4 3 2 1 6 5 4 3 2 1, 2 I 0 ----------- ACTUAL ----------- CUMULATIVE DTH 000021585 OFF GRADE ABERDEEN PLANT QUALITY PERFORMANCE 1980 STANDARD 0.41 -------- ----J--------------- ------- hi iMi'XJ LINtt- rHn-GRADE --------..-------:---1r----.--------------------- ' -------------- 1 -------------1 --------------- ----------------J --------------- ----------------J - ** -- " - .. . . -- -4 ---------------1 - -JV- ______ -- L-------------- --- 1---------- "'7/' ------ L ,i -- \ X1-------- . -------------- .......-f- -- i - - --l] -- p- J- 1 y`~ N/....... _____ __ -~~TT L-------- ----- -- * - -J -- -------- ---- -- ---- -- ------------- _____ I'll - -_____ ' ;__ __ ; _ . ... ------- V -- -- \--f ~ .............. -1 bt-.. ________ V --* -- ............ 1 '' ~ -------------------- -- -- -------------------- -- .-.-.-.-.-..-.-.-.-.-.--- .. . -----------.-- _______ _ __________ ' - -- --- -- -- L------------- -- ----- -------- -------- ---- ..-- ---- t__________ _________ _ ________ _ L_ .... - " '- . __ ______ -- ' .. . STANDARD 1.35 w*Uiwr 1 MASCM E-IL Htr JUNE -- AUGUST $ CB1CM Bf OCTQttB HOVfMfllJj OECCMltB O ; 00 0! DTH 000021586 ABERDEEN PLANT EFFICIENCY 1980 POUNDS OF RAW MATERIAL/POUND OF PRODUCT DTH 000021587 ABERDEEN PLANT INVENTORIES DTH 000021588