Document VGjLvN5MKOXB8O0Mykg75981Z

DownloadSearchable PDFRandom document
R. T. Ferrell Interoffice Communication From: Date: Subject: J. W. Ware September 17, 1987 ABERDEEN MONTHLY PROGRESS REPORT AUGUST, 1987 There were four first aid cases and one OSHA recordable injury recorded during the month of August. As of August 31, 1987, the plant had operated 2,979 days or 3,843,637 manhours without a lost time injury. PVC resin production for August was 32.3MM pounds. The major cause of downtime in the reactor areas was the old module * shutdown. Major work completed during this outage included replacement of 300 condenser, installation of reactor jacket expansion joints on 700, RQIP agitator and gear changes for 700, and hydroblasting and inspection of all old module reactors. Resin production year-to-date totaled 389.8MM pounds. The VCM efficiency for August was 1.04174 pounds of VCM per pound of PVC produced versus a 1.00208 standard. A portion of this unfavorable efficiency is due to a correction for a July accounting error. Investigation is continuing into other sources of the yield problem. Year-to-date VCM efficiency is 1.01039. Compound production for August was 5.6MM pounds. Line I and Line III operated thirty-one days and twenty-seven days, respectively, during the month. Line V operated four days. Downtime was taken on Line III and Line V to control inventory. Year-to-date compound production was 75.1MM pounds. Quality performance for flexible compounds was 3.4% off-grade of which 71.8% was due to mill scrap. "BC" production was 0.60%. Dry blend production was 4.7MM pounds for August and 50.9MM pounds fiscal year-to-date. Production was limited primarily by product changes. Quality performance for the month was 99.3% customer grade. The plasticizer unit produce 1.6MM pounds. 20.4MM pounds. operated twenty-nine days in August Year-to-date plasticizer production to is The Maintenance Department valve team presented their project to management during August. An improved design for valve-toactuator mounting brackets was developed and spare assemblies are now being built for inventory. The warehouse team working on product transfer efficiency has eliminated shipments to Prairie warehouses as a testto determine whether in-plant storage can accommodate routine inventory requirements. A plant-wide attitude survey was conducted in August. Feedback meetings will begin in September. VAB.0001191232 r < m ir- ^11 rt,! cHh-- i*^ ;> I-bps*** s*! .lipa rB-n-H + l >- f 144 j r*j-l>-^*p^rj"f.| > R. T. Ferrell 09/17/87 Aberdeen Monthly Progress Report Total energy consumption for August was 102.104 MMM BTUs. The energy consumption per pound of product was 2304 BTUs, resulting in an adjusted CMA reduction of 55.9%. The adjusted CMA reduction for fiscal 1987 year-to-date is 54.8%. w The total plant variable cost variance for August was $1508.8M unfavorable, resulting from an overall unfavorable price variance of $1366.1M and a net unfavorable efficiency variance of $142.7M. The total fixed cost variance for August was $1.9M unfavorable. * J. W. Ware rah ..................Tri'-HT i j. Itil .:M. !) ,t 1.3 VAB.0001191233 i Hr-'' - -rH U-IV*-- "-h ....................................................<- h 4 DISTRIBUTION COVER LETTER HOUSTON: J. D. BURNS X R. E. LEH40JHL R. T. FERRELL R. D. GAMBLIN J. J. LANGFORD X R. E. SWANTKDWSKI D, F. HARMAN X H. R, FLAKIER R. R. SMEffl S. K. SABQRSKY K. J. EGGERS D. H. SANDERS PONCA Cm: S. E. MOGUIEE R. L. POE H. J. HALL C. M. STARKS CKLAHCMA CHY: HARRY GARRISON LAKE CHARLES VCM PLANT: DICK CONRAD LAKE CHARLES CHEMICAL PLANT J. A. DEBEHNARDI T. H. HUFFMAN X LAKE CHARLES LAB PLANT: L. R. BAUER X BALTIMORE: R. W. SEYMOUR X HAMMOND: J. B. MAHER X ENTIRE REPORT COVER LETTER AM) QIP X X X X X X X X X X X X X X Safety Section and X HLANE POLYMERS PREMIERE POLYMERS: ABERDEEN E. L. KIESCHNICK P. L. FOOTE JF, JWW, DWH, PJK, TEL, RAF, KLF, RAM, VEM, HOC, CWT, REP, VLT, JEL, RBN h. H4t- - h -: ."j: '-J:- - -h*- nj-'ffp-i'. -i, 3 * VAB.OOOl 191234 ! 'i , L m *: ifj1 * I t SAFETY - K. L. Fogg, J. V, Uptain Occupational Inluries First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases August Fiscal Y.T.D. 1987 02 00 Fiscal Y.T.D 1986 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 5 4 11 0 1 _4 25 Injuries Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Non-Occupational Injuries Lost Workday Cases Days Lost 12 142 Safety Record Last lost time injury 7/5/79 Days since - 2,979 Manhours since - 3,843,637 On August 31, 1987, the employees of the Aberdeen plant completed 2979 days with no lost time injury. Topics for the plant safety meetings during the month included: Plant Power Failure Procedures, Safety Procedures for Clearing Bird Centrifuges, Chemical Hazards, Reviews of Recent Injuries, Eye and Face Safety, and Maintenance Weekly Safety and Job Reviews. P " RH-. .1--. f J -> ' - . --.VM f t ! 1 L(Tl:-il-f)?Mi- :y I VAB.0001191235 H > :niw: : : * SAFETY - Continued The Central Safety Committee met in August. K. L. Fogg met with the Mayor, Police Chief, and Fire Chief of Aberdeen to discuss community emergency preparedness. K. L. Fogg met with the Monroe County Board of Supervisors to discuss implementation of the community right-to-*know provisions of the SUPERFUND amendment. Two plant evacuation drills were conducted. Routine dosimetry results for the < Chemical Number onth are as follows: PEL Percent > Number PEL Percent VCM 82 100.0 Lead 16 94.1 Total Particulates 2 100.0 0 0.0 1 5.9 0 0.0 The single lead overexposure was with benefit of respiratory protection. 1 tt; T:v 'A Jiii `4 'it-" i-:a Tj -L- !J-=. VAB.0001191236 ill. ' .'C -tfin i k: -I.. . i + . ABERDEEN CHEMICAL PLANT INJURIES S3tkfnrNt JO U3UW1N '--*r '*!:.'i'-THjifji:: j; vi' |p llJ ;IN ** !:*l-ptJ4rtll ?cl !Xfl. N l>W|>i .U *iftr r> *+ OTAL INJURIESr + OSHA RECORDABLE VAB.0001191237 I !' I- :'1 j^TWi Hl+.tei- . . ks: .ii -'L , QUALITY IMPROVEMENT PROCESS - D. W. Hollis, R. B. Newton The valve team made their presentation to Management this month. They identified the ten most often replaced valves in the plant and are making completed and tested spare assemblies for inventory. This is projected to save 117 hours of vinyl reactor downtime per year. Cost of the project is approximately $12,000. The warehouse team working on reducing product transfer costs stopped all shipments to the Prairie warehouse. This is a test being used to determine our ability to store all products at the plant warehouse. A two-day SPC class was held for new employees. The CVR employee attitude survey was given to Aberdeen plant personnel. The employee feedback meetings began in September. The week of August 17 was Customer Visit Week. customer visits during the week. The plant hosted three * An initial meeting of the Lead Stabilizer Team was held August 12. The goals of the team were established at this meeting. A meeting was held in Houston with Vista Purchasing and representatives of Schenectady Chemicals to discuss long term supply of Isonox 132. Work was started to define a computer system that will allow the Aberdeen Plant to respond to customer requests for SPC analysis of lab data. .11 .1 H -J.H - :i-m. -IiT -iT. '-irr-jyi: . K-t-.:-.; J:l-1^- VAB.0001191238 r'-r* 15 : -41 > rJ I-J -I-. VINYL - P. J. Kober, J. M. Edwards Safety The Vinyl and Yard Departments worked without any reported injuries during the month of August. Shift safety meeting topics for the month were a review of the most recent accidents in the Vinyl Department and Emergency Procedures during power outages. Production 1. Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days August 32.3 1041 785 25.3 81.1 8781 61.8 31 Y.T.D.(Fiscal 87) 389.8 1164 9718 29.0 89.9 9776 62.4 335 Vinyl Department production for August was 32.3MM pounds. Reactors The reactor stream factor for August was 81.1%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 24.4% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size information before charging, lines plugging, reactor manway O-ring failures, power failures, bad weather, and the lack of blend tank room to dump a reactor. 2) Maintenance Service Downtime: Accounted for no downtime because the cleaning of the reactor AMS injection ports and inert vent lines was accomplished while the reactors were normally down for other reasons. 3) Maintenance Repair/Revision Downtime: Accounted for 75.6% of the total downtime and a majority of the time was due to the scheduled annual shutdown of the Old Module. The following major jobs were accomplished during the shutdown: Reactor 300 condenser was changed, reactor 700 jacket expansion joints added, Modicon manual mode was added, the north recovered VCM receiver condenser tube leaks were repaired, the agitation was changed in reactor 700 to match that of reactor 745, all Old Module reactors were hydroblasted and inspected, and the automatic chem wash system was installed. The safety discs were changed on reactor 744 and incinerator instrumentation problems caused some downtime during the month. i v: Ml Yri Ef t>^nf Ull r. 111.I' VAB.0001191239 JI. 1LI ritt -J |[. ill T3 9V'bPta'"?1'l '"Sippn-::............ ,, -u*i. r :s-yj-j 1 'J i(i hs i i + i*i ................... .... .... VINYL - Continued The dryer stream factor for August was 61.8%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 91.1% of the total down time. Dryers were shut down when possible for energy conservation. # 2) Operational Downtime: Accounted for 3.6% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems, and power failures. 3) Maintenance Repair/Revision Downtime: Accounted for 5.3% of the total downtime and was due to repairs to //6 dryer drive, repairs to #1 dryer air sweep, replacement of #5 dryer gas valves, and replacement of #8 centrifuge sparge pipe. The fluid bed dryer was shut down in conjunction with the Old Module shutdown during which time the outlet hot water manifold was replaced, the scrubber was cleaned and inspected, the backmix and plugflow sections were inspected and the centrifuges were serviced. Number six activator had a new inspection port installed. Product Quality Summary Resin Type Prime "B" 5265 5305 5385 5415 5425 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 1,627,752 3,032,600 15,968,651 9,787,970 -- (7,180) - -- - -- 30,409,793 -- -- -- - -- 1,128,150 511,620 - -- 1,639,770 "H" ** -- -- -- -- -- -- -- 117,886 108,700 226,586 % oV ^f TXVoWtaOXl Production 5.0 9.4 49.5 30.3 0.0 0.0 3.5 1.6 0.4 0.3 100.0 Quality performance for August was 99.3% customer grade with 0.7% "H" grade production. A total of eleven railcars were shipped as "B" grade during the month which represented 8.9% of the 123 total resin hopper cars shipped. Load Date Ship Date Car No. 07/20/87 08/10/87 PLCX 43701 08/01/87 08/11/87 PLWX 44275 08/07/87 08/13/87 ACFX 36024 08/02/87 08/13/87 PTLX 41603 Customer Con. Plast., CO Wexford, WI H&W, MS Silverline, NC Product Debox Debox Debox Debox Reason Quality Quality Quality Quality VAB.0001191240 VINYL - Continued Product Quality Summary - continued Load Date Ship Date Car No. Customer Product Reason 07/31/87 08/14/87 VIPX 45273 Apache Plast., CA Debox Quality 08/01/87 08/18/87 ACFX 52553 Wexford, CA 5385 Derailed 08/03/87 08/18/87 PTLX 41649 Western Ag., TX Debox Quality 07/13/87 06/16/87 08/24/87 08/25/87 PTLX 41645 Vulcan Plast., AL Debox PLWX 44279 Gamma Mfg., CA Pond Resin Quality Quality 08/12/87 09/19/87 08/26/87 08/26/87 PLCX 43738 Apache Plast., CA VIPX 45711 Capco Pipe, IN Debox Debox Quality Quality Monthly Variable Cost Performance Variable costs for the month were unfavorable at $1497M resulting from an overall unfavorable price variance of $1296M and an unfavorable efficiency variance of $200.5M. Resin variable cost for the month was 23.041 cents/lb. versus the budgeted 18.119 cents/lb. The $1296M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $1345M, offset by favorable natural gas pricing of $22.6M, and favorable electricity pricing of $10.4M. The $200.5M unfavorable efficiency variance can be attributed mainly to an unfavorable variance due to VCM, $194.8M; and Alcotex, $24.5M; offset by a favorable electricity variance of $42.6M. VCM efficiency for the month was 1.04174 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. YTD variable cost efficiency variances in the Vinyl Department totaled $654.1M unfavorable. Energy Performance/Progress 1. Plant energy performance for August was 2304 BTU/lb. General 1. Resin raw material in the 0744 account totaled $248.5M. 2. The Old Module turnaround performance by maintenance, engineering, and operations was notable. All jobs were executed safely without accidents or exposures. * VAB.0001191241 i - i : it h'T-i- t I'rii'r r|. -`l-a.i-.-M -.'T' i-H|-- IV:- -|4n-H 1.<. - ii, . -J-. ,-r- - v:- f"i ............... il - -4 VINYL - Continued General - continued 3. The plant conducted its second production run of Klockner Pentaplast recipe 5305 successfully with PED's assistance. 4. Ten operators attended a two-day in-house SPC training session which was taught by our Quality Department. A 'iiy in - 1-F-l :r^a ,%I-'.................... ,.| . I! I T1" <'i* 1 f . '.n. i-:t if.:. \ VAB.0001191242 I >t* : i| in .fi'.r COMPOUND - C W. Turner, J. E. Nickerson Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line V Line III Total 30 1898 63 4 218 55 27 3472 129 5588 25275 8198 41633 75136 Line I operated thirty days in August at an iverage rate of 63M pounds per day. Major items affecting production efficiency weres: product changes, 89 hours; quality problems, 21 hours; power outages , 13 hours; housekeeping, 11 hours; pig conveyor maintenance, 10 hours; dicer problems and maintenance, 8 hours; and Banbury maintenance, 5 hours. Line I was down one day for inventory control. The downtime was used to re-screen some material to check for metal contamination. Line V operated only four days in August due to inventory control and averaged 55M pounds per day. Major items affecting production efficiency were: product changes and startup time, 13 hours; and power outages, 2 hours. Line III operated twenty-seven days in August at an average rate of 129M pounds per day. Major items affecting production were: product changes, 62 hours; mill and hydrotherm system maintenance, 17 hours; power outages, 11 hours; and cooling water system maintenance, 9 hours. Line III was down four days for inventory control. The downtime was used to rescreen and/or repackage material with potential metal contamination. Quality performance for flexible compounds was 3.4% off-grade of which 71.8% was due to mill scrap. T,BCU production was .60%. The raw material requirement for flexible compounds was .98198 pounds of raw material per pound of compound versus a 1.01173 standard (YTD is 1.00753). The variable cost variance for compound was $27.8M unfavorable with $51.3M unfavorable due to price and $23.4M favorable due to efficiency. The efficiency variance due to product mix was $24.2M unfavorable. The efficiency variance for DIDP was $16.6M favorable due to correction of a previous accounting error. Total compound inventory fell .7MM pounds in August to 7.2MM pounds. VAB.0001191243 i-. :rs*;it-jvinJ t*1 r!J'=-;*TiyiET-<c- ------- ........................... . IITGI.'S. r: r,w.h.r : -- T f rrijr ! i\ I VI \ : i |- t : 1 H.: n'H |..| . . y r:., : .1. ! _ t It'- r'li-H--!-- -flv -p.vr: | wt". * : COMPOUND - Continued Blend Production, M Pounds Operating Days Month 4717 31 Average Operating-Day Rate 152 Fiscal Y.T.D. 50930 336 Dry blend operated thirty-one days in August at an average rate of 152M pounds per day. Production included 80172C, 80273G, 90172D, RP-200, RP-421, 186-74, 186-139, 168-180, 269-69, RP-100, 269-185, 269-151, 269-192, A10-006, 290-60, 290-61, 317-30, 371-58 and 317-71. Dry Blend production was hindered by: product changes, 68 hours; delays associated with quality and lab problems and normal Q.C., 33 hours; transfer system problems and maintenance, 15 hours; Welex maintenance, 13 hours; and Orbitran weigh-computer maintenance, 5 hours. Quality performance for the month of August was 99.3% customer grade. The raw material requirement for dry blend was 1.00131 pounds of raw material per pound of dry blend versus a standard of 1.00492 (YTD is 1.00772). The variable cost variance for dry blend was $43.5M favorable with $6.2M favorable due to price and $37.3M favorable due to efficiency. The efficiency variance due to product mix was $33.9M favorable. Several raw materials, including weatherable impact modifiers and T-137 stabilizer, had unfavorable efficiency variances due to correction of an accounting error which overstated production in July. The efficiency variance for titanium dioxide was $43.9M favorable. This variance is currently unexplained as investigation continues. Plasticizer Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 1636 56 20357 29 331 Plasticizer operated twenty-nine days in August at an average rate of 56M pounds per day. Production included 61OP and 108P. VRP production totaled 88.8M pounds (5.7%). The raw material requirement for plasticizer was 1.12278 pounds of raw materials per pound of plasticizer versus a 1.09971 standard (Y.T.D. is 1.10227). The variable cost variance for plasticizer was $27.6M unfavorable with $24,8M unfavorable due to price and $2.9M unfavorable due to efficiency. There were no major plasticizer raw material efficiency variances. f v=--r . M ! 1' r 1 '1 -t -;:; !*; 1"l 1i>B- I 14-.. V.M I;, h-i*: ' ^^ = ; r:. F : 1 =<> ?.! VAB.0001191244 * ................................... |: H|Tf- ^l- f'.i 4'i* COMPOUND - Continued The product-change team is continuing to function. Some recommendations from the team have been implemented. The team is currently specifying tools (brushes, scrapers, etc.) to be ordered or built to improve the blender cleaning process. Second-round SPC training for all operators, originally scheduled for August, has been rescheduled for late September and early October. Energy Compound Dry Blend Plasticizer Usage (BTU/Lb.) Actual Standard 1444.4 558.1 1614.7 1783.0 730.0 1833.5 VAB.0001191245 MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - D. A. Miller, G. A. Morgan A There were four injuries during the month; three requiring first aid and one requiring medical treatment. The three first aid injuries were first degree thermal bums. The first occurred when a boiler Mflashed back" during startup and the Utility Technician received minor facial burns and the second and third first aid cases involved bums to the forearm while working on a boiler level control and a reactor PVA valve. The medical treatment case involved a second degree bum to an Instrument Technician's forearm while working on a boiler level controller. An accident investigation will be completed in early September. Vinyl The annual Old Reactor Unit turnaround was completed during the month. Major work items included the following: - All reactors were hydroblasted and die-penetrant inspected. problems were found. No - The condenser on 300 reactor was replaced with a spare. This required extensive reactor mounting nozzle modifications. A new style gasket is being tested on the 300 condenser lid. Preliminary results are promising. - A new flush mounted manway was installed in the 300 reactor bottom head. - The 700 reactor agitator blades and gearbox ratio were modified to allow for 5305 production. - Two leaking tubes were plugged in the north recovered VCM receiver overhead condenser. - Reactor cooling jacket expansion joints were installed on 700. - The following vessels were opened and inspected: - South batch water stripper - Fresh VCM receiver - South recovered VCM receiver - Hot water charge tank - Recovery system knockout pots - The following major valves were replaced during the month: - 745 auto AMS kill valve - 741 recovery/evacuation valve - 400 atmosphere vent valve - Old unit chem wash recycle valve r. ^ - * m. >;. I -IX XI rv. VI I- `I I- : . , l( -j: !j. : i-*. * H .| j |iiJ -1 .h- ny c|-r. --i VAB.0001191246 <!+-. .c rL,c..pi -.: QI- -.ii- -..ji -i MECHANICAL DEPARTMENT - Continued Vinyl - Continued The following mechanical seals were replaced during the month: - 705 compressor outboard seal - North chem wash pump seal in the old unit The safety discs were changed in D-744 reactor. Control room work was completed for the remote operated valves project and chem wash automation project. The #1 Bird centrifuge, used in pond resin service, was overhauled. A rebuilt, hard surfaced, scroll was installed. Compound, Dry Blend, Plasticizer The Line I pellet classifiers were modified for removal of fines from finished product. A magnet was installed on the outlet of the Line I resin bin and boxing hopper. Number 6 dicer was removed from service and shipped to Henion Brothers to be overhauled. A rental dicer was installed in its place. Sightglasses were installed in the dry blend stabilizer bins. Sixty feet of cooling water piping for the inert gas generator was replaced. The laboratory hard particle mill was replaced with a rebuilt spare. Utilities The east pond #5 aerator was changed out due to gearbox damage. Assisted in startup of the catalyst freezer compressors following relocation for RQIP. Two fork truck engines were overhauled during the month. A VAB.0001191247 - r| w-iv iii%f.n.|nf:|p:i, V-'l? ','"4 fc'HIl-I*:*" 1 -HI ^ i'.i; S. f i.. lEf-I ?-T'i'Jv:-PftroL: -ill- ii-- n I !: 1-? I -.il . .'-u rr.- !l :l ! ; ,, --Ih- 11- jr r -r- - JF MECHANICAL ENGINEERING - R. E. Polk A AFE F537 - Dry Blend Transfer Lines / .Installation Is 50% complete and In progress. Completion is scheduled for 11 1 AFE F786 - Resin Quality Improvement Design at Litwin is 39% complete and in progress. Procurement of in-line instrumentation is complete. Drawing packages for site preparation, pipe rack structural steel, and piping plans for off-sites and the first floor of the SA module have been received and are being reviewed. AFE D756 - Reactor Expansion Joints Installation of joints on reactors 700, 742, 743 and 744 has been completed. The joints for 745 will be installed during the New Module outage late in September. AFE A567 - Rotary Dryer Duct Upgrade Phase II Design is complete and the ductwork placed on order. Delivery is scheduled for 9/15. Installation is planned for completion by 11/15. AFE F587 - Laboratory Addition All major equipment has been placed on order. Engineering is 5% complete and in progress with completion scheduled for 11/1. Construction is planned for completion by 1/1. AFE A657 - Roof Upgrade Phase II All mechanical pre-work has been completed. Membrane installation is 5% complete and in progress. Completion is planned for 11/1. AFE F596 - Chem Wash Automation Installation in the Old Module was completed during the module August. Startup and de-bugging of the control system is in Installation for the New Module is in progressand will be during the module outage in September. outage in progress. completed AFE D606 - Propane Tank Farm Electrical Revisions Electrical construction is complete and the system operational. An operational check will be completed in September as a part of normal winter preparation. PCB Transformer Replacement Two pad-mounted transformers have been retrofilled. Nine of the thirty-two pole mounted units have been replaced. All work is scheduled for completion by 12/31/87. Construction - C. A. Clark A total of two construction contracts, four general service contracts and thirty-eight register tickets were issued during the month of August. VAB.0001191248 -j-J !*!1 4-[ill k Ji. , ..r. .J. + PT-.'rfcJ ''Tfc r +H - r i-r-'-M- T - 1 I ? L PROCESS ENGINEERING - V. E. Messick A Resin Quality Improvement Project A. Rigid Resin Permanent Facilities - Phases I and II A critique of the project was held in Aberdeen with plant, PED, GED and construction participation. A list of ideas was generated to be used on Phases III and IV. B. Resin Permanent Facilities - Phases III and IV Field trips by Litwin's piping and instrument groups were made to the plant. Operator training on the new Modicon programming was completed during August. Equipment inquiries were completed with review of vendor data in progress. Review of the one-line piping plans for the chiller area and kill solution make-up and storage area was completed. Instrument selection is still underway. Information on work to be completed during the upcoming New Module shutdown was provided to the construction group. Reactor Heat-Up Loop The class "A" design for the Reactor Heat-Up Loop Project was completed and reviewed in the plant during the month. This project will provide increased productivity to the four smaller reactors in the New Module. First Fiscal Quarter 1988 Capital Budget The First Fiscal Quarter 1988 Capital Budget was completed during the month and submitted to Houston for approval. Annual VCM Leak Survey The Annual VCM Leak Survey was completed. September. A report will be issued in Rigid Calendering Resin Team Activities * - -H ,, The second production run of the Klockner and Hoechst trial resin was completed. Response from Klockner of their trial of the July-produced resin has been favorable. SARA - Right-to-Know Regulations Regulations were reviewed to determine plant hazardous chemicals that will be included with the Hazardous Chemicals Inventory Form and the Toxic Release Form. Fixed and Variable Costs Budget Preparation *- Steve Hillman assisted in preparation of Variable Cost Budget in Houston. the Manufacturing Fixed and Distributed Control System The budget estimate, which was prepared jointly by the plant and GED, was completed. This project was moved from the First Fiscal Quarter to the Third Fiscal Quarter of the 1988 Capital Budget due to manpower limitations. VAB.0001191249 1 i r s Jrf- -:! c 4-- iv ru .. a I . Hr-: J Tr- ' r + PERSONNEL - R. A. Miller EMPLOYMENT None * PROMOTIONS/TRANSFERS Jonathan G. Cole, promoted to Process Superintendent and transferred to LCVCM Plant Donald F. Johnson, promoted from Vinyl Shift Supervisor to Vinyl Operations Supervisor Bobby Jenkins, from Lead Technician to Development Technician Artis B. Jones, from Lab Technician "A11 to Lead Technician RETIREMENTS None TERMINATIONS Catherine M. Bonsanti, summer student returned to school Allison H. Russell, summer student returned to school TO/FROM LEAVE OF ABSENCE None A 1- '"'P'l' " Ilf : "I ' =" . ,4 . , " i iL . . I *,; . . i VAB.0001191250 : i !2 ' v ',r .. - l-|.|-L3._..-- ... ... Aberdeen, Mississippi A Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations 73 * 170 243 0 DEPARTMENTS Warehouse Gen. Plant Maintenance boratory Compound Vinyl Plasticizer PAR # EMPLOYEES 16 16 38 22 24 40... 32 32 5 ______ AUGUST. 1987 MONTHLY PERSONNEL REPORT Minority Employees # EHP Salaried Hour1y 66 10% Total 74 3% Hourly Min. Hired % Min. Hired Hourly Min Term. % Min. Term. 0 % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD 7 kk 0 0 0 47 0 8.... 21 0 5 21 0 n 28 n 2 40 0 0 0 00 Number of Applicants: Month Year to Date APPLICANT BREAKDOWN: # Minority 0 % Minority * Female % Female 0 Hires (Hourly) : Month 0 Year to Date Terminations (Hourly) : Month Year to Date Overall Turnover 0 Projected Annual Turnover 9 2 Includes 1 temporary employee and one Co-op Engineer. : : . frFS u c yinf. y_ VAB.0001191251 !i 1 r r"1!' -r ' " ' ^ ,b,: v ......... i. i: i'iw. r 'T 2 1 OVERTIME AND ABSENTEEISM o * CM in 00 n CM H* * CM ** CM CM CM in O' CM rH n rH m o O' o O' ** in CM --t rg tJU in o O' 00 rH vO O cn CO H 6* n <y*i rH CO 4J 5O H IUQ w Jl * 00 o * m O' * vO 1^ i--t Mf O o O Of u c tn a tn in CO CM o eO 6 vO * CM O' o *4# u ITI iH CM rH CM 4A *n 'sd O' ** cO co <N o rH in o C"* ** o O' o o 00 m 6*m CM CO CM u 3O 4J tn in O' soO O' CoO> u o co c pj in < m 00 vO 00 O' M2 *H 3X o n CM H CO CM m rH 6C rH * oo 6 CO vO 4 CM n ** O rH o * K <o O' tri vO CM CO CO o css HU rH rH rH U CO V> ** oo CM X4 2 aJ '4 u I 9 O I 8 u 0) o% o n in L/Y o in O o o in CM CM ** o CM in o m ** * ** CM rH O' rH <T in CM O' m 2 00 rH in CM \0 CM n CM N CM ^H r^. CM U CM 6 a 8 O H 1* O in o in o O o o o 60 MD O'3 inu tn u 9 o * vO CO CO CM r O CO O' o * in n <r CO CM * O' in in v> m * o n in rH o <r CM u0 * O>n)' v> CM CM to a: u fe w W to 1 HI & o & cc HM3 j 3 A< U& H to B Jj w 2 8 3 ft* s (9 tn co to cG ItQ* & (Q t- OD- Oo. CQ c o X v: K o> to & co 60 C tun w o3 3o u 3 IQ C 3 O6J0 o t* T? 60 C 3rt g *3 C C3 >mn o o 3 60 co 60 C tun H ki 3O o Jm (Q 3 60 2 6U1 *3 60 2C Xu o >O 3 60 C 61 3 3 -a 3 U2 K *H 2 at > o u (0 o CQ 2 J 4J 8 8? 4Ui O U3 o> V to JO 4oMJ *o- C0 u 4J 1 c 5 Xeo CS| VAB.0001191252 % r ! -i- i -* I=- rflc^^fJi. i t *. f . *- ^ - . r ** f 4.1 ; I . ,1-; i.:s.|K u r -U .j T- ' ft. : i .fii .^.pflifir.; ^ T*`a-.. 1 r^> | ! : ! . i* S'! ::H'. *tt l-n:-v --.n.-.............,.> ENERGY CONSERVATION - F. G Jeanson I. Plant Operations Total energy consumption for August was 102.104 MMM BTUs* Energy consumption Increased to 2304 BTU/lb. from 2263 BTU/lb. In July. An adjusted CMA reduction of 55.9% was obtained for the month. The adjusted CMA reduction for fiscal 1987 is 54.8%. Note: The total energy consumption for August, 102.104 MMM BTUs, is an estimate due to a problem with the electric meter. This problem will likely be resolved with the Aberdeen Electric Department in September and the energy numbers will be adjusted. II. Plant Energy Conservation Program Maintenance There were thirteen energy related items completed in August. Twelve of these items were steam leak repairs. The remaining one was a steam trap repair. III. Boiler Operation Boilers Combustion Efficiency % August, 1987 August, 1986 No. 1 No. 2 No. 3 83.4 (1) 83.3 83.7 (1) 83.3 Note: (1) Boiler number two was not used during the month. A <... . - + VAB.0001191253 'i : i:ji# . M.HP. iij^i jj. . --rl" ! ,-ipi- j& V = I'i,! vA ! TH T "JIT i Month ENERGY CONSERVATION DATA 1987 Augus t Production, MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL 32.3 4.7 5.6 1.7 44.3 Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 50271 1020 51.276 1157 Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 5.0828 10000 50.828 1147 Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 0 92000 0 0 Total Energy Consumption, BTU/lb. 2304 Energy Consumption, MMM BTU Actual Unadjusted Actual Adjusted 1972 Base Period 102.104 81.933 185.916 CMA Reduction (%) Adjusted Unadjusted Fiscal 1987 Year-to-Date Performance 54.8% Adjusted 45.0% Unadjusted 55.9 45.0 1986 August * 27.3 4.9 5.7 1.6 39.5 44136 1020 45.019 1140 5.2492 10000 52.492 1329 0 92000 0 0 2469 97.511 77.542 163.687 52.6 40.4 A VAB.0001191254 ENVIRONMENTAL - R. A. Frohreich Water Wastewater discharge parameters were within NFDES limits in August. One wastewater bypass did occur. The Bureau of Pollution Control has asked us to continue the chronic bioassay testing on a monthly basis for the next six months. They have opted to continue testing rather than to issue a compliance order at this time. Waste Management One tanker load of waste oil was shipped to Stauffer Chemical Company. General A truckload of building vacuum dust was sold to Surplus Chemicals Marketing. A truckload of reactor culls was sold to Sun Polymers. A . i i .#*m- . .. . . mi;- pi-i i;e rt = nr ^ maim- ( | ' ' :t,! :,r ` !,p' ' i'l-H'l1;' l-; j-; i-. ! : l-s* ! : -|l- srr-". -- :ri rTirpM*l VAB.0001191255 'V =- t I- TABLE I MATER COMPLIANCE WITH NPDES PEEWIT PARAMETERS A Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. Jan. - Ave. Max. Feb. - Ave. Max. Mar. - Ave. Max. Apr. - Ave. Max. May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Flow GEM 1010 1207 1031 1075 987 1350 1062 1300 858 900 903 970 990 1177 1049 1243 979 1021 1150 1300 %5 1230 BOD PEM LB./DY. 6 77 10 120 15 183 17 213 23 268 46 373 15 194 20 310 14 142 26 266 11 119 21 217 8 93 10 121 8 104 11 116 6 71 8 98 4 55 5 66 5 61 8 118 OOD PEM LB./DY. 26 311 33 404 33 406 42 527 71 846 110 1284 53 662 57 775 42 431 75 766 38 409 50 541 42 505 56 680 31 384 40 515 27 350 40 480 45 618 60 797 39 474 50 744 Sus. Solids PEM LB./DY. 14 165 23 281 23 281 37 464 13 179 24 302 18 231 28 434 10 99 13 140 19 206 35 362 33 407 78 986 8 101 11 142 14 167 21 257 14 194 26 344 10 145 12 168 Dies. <r 7.4 8.0 8.2 9.1 7.6 8.6 9.6 10.3 10.0 10.6 8.8 10.5 9.1 11.0 7.7 7.8 7.0 7.3 7.1 7.4 7.2 8.0 NIL LB./DY. 2.7 7.3 0.1 0.1 2.0 4.7 2.1 * 4.6 4.9 9.3 4.0 7.6 2.5 6.1 8.8 17.8 6.9 14,2 1.4 1.6 1.7 2.2 7.6 8.0 7.6 7.8 7.3 7.8 7.7 7.8 7.7 8.0 7.8 8.3 8.0 8.3 8.0 8.6 7.7 7.9 7.9 8.1 7.3 7.8 NPDES Pfer Ml It Limits - Decenher Ave 32 431 Max 43 800 NPDES Permit Limits - Ave. Max. 26 357 40 744 - 1462 - 2713 Novenber 30 - 1212 - 2523 - 674 - 13% > 6.0 13 6.0 - 9.0 28 674 - 13% 6.0 13 6.0 - 9.0 28 VAB.0001191256 I ... t^ P. . . .. -.fj-,..-i TiP- j - > :..:i .................I| fTj | H r '1 n I - I r r . i-. r -|i c !I Jc-y! -? 'j ' '! It'i! i fl t .. : hU!Yi/i it! |J: r . .1' LABORATORY - H. G. Coleman Safety There were no injuries during August. This month's safety meeting included a film, ''Health Hazards of Chemical Exposure". Procedures for introducing new chemicals into the plant and MSDS's were discussed. B. Customer Relations Customer Contacts The following customers were hosted during Customer Visit Week, August 17-21: - Sanderson Plumbing - United Thermal Plastics - Alsco Standard laboratory presentations and tours were given. Dayton Extruded Plastics - B. J. Harrison visited this customeron8/13;topics discussed were colorimeter correlation, color standard, PVC flammability and an off-color railcar. Requests for Corrective Action There were no RCA's received this month. Customer Problem Reports Date Customer Product Reason 8/21 Formtech 317-58 WHT 110 Pewter flow (dry blend). 8/21 Soutfoire SW1201 NAT Metal contamination. 8/25 Mid-American 80172C Poor flow, varying wall thickness. 8/27 Flexible Technologies 17121 CB50 "Bine streaks" on finished product. Product Return Notifications Date 8/24-25 Customer Southwire Product SW1201 NAT Amount 12,000 lbs. Reason i1 Metal contamination. l `1 "-f ! . r*; r ' -! I ' -* i-K-'r- : ?i- - ' t f.j |n-? : . n |: krtt-IlSi-TTf-? -Sf'i: ''I : Uh- U(=-f . s-l -B m-lit ^ >,,^11 VAB.0001191257 C.. "t? - .j,; - P .1-. ........ .P ........ ... I-- - LABORATORY - Continued B. Customer Relations - continued Waivers Issued Customer Product Reason No. Mbco 5305 Niboo 5305 Uhiroyal 5305 C. Development Lab Sungary Static Flow Particle Size Static Flow 5 HT 1 HT 1 HT RVCM of In-Process Sanples Hie following Is a summary of residual VCM results on in-process sanples. None of the reactor dally averages exceeded 400 ppm during the month of August, 1987. Number of Samples Average ppm, VCM Reactor Slurries 781 234 Dryer 5265 5305 Blend Tanks 5265 5305 21 4.32 59 38 2.34 63.4 62 35.6 RVCM of Shipment Sanples The following is a summary of the residual \M analysis of shipment sanples for the month of August, 1987. Product 5265 5305 5385 5415 5465 Debax Dry Blend Pond No. of Sanples 29 65 41 40 0 28 Average RVCM, ppm 0.50 0.19 0.13 0.11 - 0.26 31 0.12 2 0.1 Resln Process Capabilities Bulk Density 5265 0.80 5305 0.46 5385 1.33 5415 * 0.15 Inherent Viscosity 0.73 0.60 0.44 0.56 "L" Color Value 1.30 2.33 4.00 4.11 "A" Color Value 1.33 2.33 -- -- "B" Color Value 1.11 1.17 1.67 2.17 % on Pan (vs. 2% max) 0.52 4.44 2.92 2.47 (0.47) i HTl- |J ' VAB.0001191258 1 ' !* ! ' .1 I- -fi ' :l. ` i :r-nrt -,t\ .3 v' v : A :- > . i:l - LABORATORY D. Resin Process Capabilities - Continued 5265 5305 5385 5415 % thru 140M 0.79 0.75 0.80 1.74 Drytime ---- 0.44 0.56 Mets IR (vs. 95% of control) -- -- -- 1.28 (0.83) Hard Particles (Z y 10) 1.4 2.4 * Effective this month, spec is 0.480 - 0.540. No 5465 production this month. Compound Quality Summary Hardness Color/Clarity Hard Particles Heat Stability Con tamination Dispersion Cross Contamination Streamers Metal Contamination Total Adjustments M Lbs . os) 55.77 -- -- -- -- -- -- -- -- 55.77 (1.02) -- -- -- -- -- -- -- -- (1.02) Rejections M Lbs. (Z) 22.20 8.00 9.95 3.65 8.40 24.75 1.30 1.30 20.25 99.80 (0.40) (0.15) (0.18) (0.07) (0.15) (0.45) (0.02) (0.02) (0.37) (1.82) Dry Blend Quality Summary Rejections M Lbs. (Z) Long Stability Color/Fusion Torque Stability Total 0.97 13.67 11.40 26.04 (0.02) (0.29) (0.24) (0.55) G. Quality Development 1. Daniel Loftin and Paul Cogsdale received SPC training; all technicians have now completed this basic training in SPC techniques. A round robin testing program on dry resin RVCM was started this month as a follow-up to the REACT meeting in July. A 1 . r: i I i! h 'Pin-iJt *!: I!' H I .1 |- '1- - r..:' I- ;; f. .I| 1 . . .. . || 11 ; J-: % T- VAB.0001191259 iri si : , i - : f -i I LABORATORY - Continued H. Miscellaneous 1. Confirmation letters for sample requests were started this month. Copies are sent to the customer, product manager and sales/service representative when a sample is shipped. Richard Williams was responsible for instituting this program. 2. TCLP tests were performed by Dave Cox on ground culls. threshold limit appears to be 10 ppm RVCM. The 3. Inconsistencies in Amerlchem's blue-white colorant strength were discovered. Brian Harrison worked with this supplier to develop new tolerances in a visit on 8/14. 4. A trial run of Amerlchem's extra strength blue-white colorant, 5405-T1, was very successful. The plant will begin using 5405-T1 exclusively, reducing colorant costs by 65% (approximately $75M annually). Brian Harrison had project responsibilities. i 5. Brian Harrison finalized a color match for 317-55 Beige 323 for Elixir. Color specifications and standards were Issued. 6. Brian Harrison investigated "gray streaking" problem experienced by Allied Extrusion on 269-164 WHT 112. Raw material substitution is the suspected cause. A .... .. = > ' Hi '( t - t . -I- J : I , .-T;, -u- - - s \l3Lf,ptJL>UAi^MAL. 1 ft V-: ' ' .-I- T'.'u.r .. I |_!l VAB.0001191260 V ! 0 t***-'?^lGfc'' 1 1 LIhi I-1- fLHJ.' ' tfcK F' SHIPMENTS BY PRODUCT - M LBS. AUGUST 1987 FISCAL YEAR-TO-DATE RESIN PLASTICIZER DRYBLEND COMPOUND 27,507 977 4,936 6,299 301,586 8,203 51,667 76,502 TOTAL 39,719 437,958 NUMBER OF SHIPMENTS BY MODE: RESIN-Bulk RAILCAR 120 VISTA TRUCK TRAILER ON COKMON CUSTOMER BULK VAN A FLAT CAR CARRIER PICK-UP I CONTAINER TOTAL 109 283 Package A PLAST.-Bulk DRYBLEND-Bulk Export COMPOUND-Bulk Package Export TOTAL - Aug. 159 OCTOBER NOVEMBER DECEMBER JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY 116 146 133 193 154 181 150 162 165 178 117 47 160 4 504 52 160 64 135 48 133 89 147 56 143 64 129 44 140 54 139 41 152 45 145 422 450 390 544 451 3 493 1 438 459 473 2 476 -i.. ' -I I ........................... < ' i i :s . ie > : VAB.0001191261 ? :s f-rJ tc l J. ]i . r -r ThJJrjfwi-i . .. -J 3500 . i... - <oT> CM 00 . r - b- + BTU/LB. 3500 10 Zo in > D< C<l in oX I- z o o q: u, x > X u CQ 35 in Ct -i u >< dj Ll Ll UJ co 2000 ENERGY USAGE t 4- - + 1 -------------------------- ------------------------------ ^ 1 * | +i 4 T 4n* - < *-------- fI i iI r +- t TI 1" r- H I* 4 -------- ^ 4i I * h- 4-- i * - I l t < ............................... ...... I ...................... .. ............. imwi 1,1 T I t t 1 1r A 1i j1 4 I 1500 Mon th1y --------- 12-Month Moving Avg. ' ' ' 1 +? - . I- i|s L - ->Mf :#JH-''f " "HU'.i.J.............................. .. 'fll.r-". i :. i. .. . i. -i. |.'.|. .j: -\n$p-l-. .. A. 3p*l cl L...J! 4,: + j *-.j^ . VAB.0001191262 TJJrS-ii -t t\' v1*1 : I " --1 n * i'": I:; . I-m r\|i -J'.||n' iir; J iM i*1- MONTHLY HOURLY TURNOVER I . , .11. '* . i* ' - " ' : i i >!: ''ll m i ;i :t. +> i h :JJ fcurr' p '***' ) ' I'f-'d:. it: , . L. :j IMi.KJ f t- i; I- r VAB.0001191263 .---fc:: .. * ;:r- . ( .-!> ABERDEEN PLANT QUALITY PERFORMANCE 10/01/86 - 09/30/87 A T 4* V % OFF-GRADt 1 N. y 4.0 3.0 2.0 1.0 0 Oct Nov. Dec Jan. Feb. Ma r. April May i June July Aug. 4 Sept.i Oct VAB.OOOl 191264 F i l+f -+ ' F- it V'|.:|- . pi L-. il. ' -ijij sA Jn --li-riv:'" /.v'T. i .v -w j:. - - -- I* kT'!! -1_ i ; ti 1 ' ' ^ j. + ** MM POUNDS PRIME ABERDEEN PLANT INVENTORIES 10/01/86 - 09/30/87 COMP' HMJGJK -- . 1 t" -- -- + - 0 - - - - - - - - - - - 1:- - - - - - - - - - - t! 0 t. t: i Oct. Nov.| --*:- - - - - - - - : . . . . . .... r* - -- - - - -' *t 11 t Dec.' Jan. Feb. - .. . - -- - - - - -- - Mar. API"- May 19-86/87 1 -. . . ** 1 1 t June July i!i ; .! - ; ;T T| !i 1'! Aug. ISept. j Oct.i *!- r^- > 1_r |i ^ :ir r-ivii-. 1H - li, h . . > s i. |.| Mt - - T*-!r' -: , m f VAB.0001191265 I I' ;| b. h , I-S-* If . I- -T . MM POUNDS I' i ABERDEEN PLANT PRODUCTION ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 10/01/86 - 09/30/87 ,A ^ MM POUNDS * -------------- Budget - - - - Actual Cumulative VAB.OOOl 191266 ' ir-'H- j-. ; f . '-i fcSmlw :+ i >*1: . -=i #-Lir, .. .;v j. 1-if^-IH!- 4' |ll i i:|: '.-'i- uf r-; hr.'^r- ti i-y- -v = : i - -k., Ul T -I m VI t 1.020 1.015 1.010 1.005 1.000 0.995 1.030 1.025 1.020 1.015 1.010 1.005 1.000 V 1.020 1.010 1.000 .990 1.200 1.190 1.100 1.050 ABERDEEN PLANT EFFICIENCY 10/01/86 - Q9/30/87 POUNDS OF RAW MATERIAL/POUND OF PRODUCT A A 'N f *1 li J 1 ft-vi. -! 1 VAB.0001191267 ' il">` h"--. - /* T