Document X7Lbe0Y9ZYRx934y3Jko0616K

SAFETY - A. H. Sather Occupational' Injuries Injuries Treated 1979 March 1979 Year-to-Date 1978 Year-to-Date First Aid Medical Cases Lost Workday Cases (days) Lost Time Injuries By Department 0 1 1(4) 0 6 1 1 (4) 0 12 1 0 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 14 00 02 00 00 12 0 C 5 1 0 0 Injury Types Cuts and Abrasions Eye Injuries Bums Bruises Sprains Strains Other 12 02 02 02 12 00 5 n 3 3 o o Of the two doctor cases which occurred during the reporting period, one occurred while a compound utility was in a stable kneeling position during a propane fire training exercize. The resultant back muscle strain and subsequent light duty requirement was probably due to tension related overexertion as this was the injured's first fire training experience; the other injury (laceration and bruise) occurred when a vinyi operator caught his right thumb between a pipe wrench handle and a centrifuge gearbox housing while changing a shear pin. As of March 31, 1979, the Plant operated 310,407 manhours or 237 days without a disabling injury. On March 22, 1979, the Plant experienced its first medical case of 1979. This terminated a record of 166 days operating time without an injury which required medical treatment. Plant Fire Trainirig All plant fire training was initiated early in the reporting period. Training was temporarily suspended in order that a program on lifting be developed and completed in the plant. Fire training will resume upon completion of the lifting training program. A total of 121 employees have received training. DTH 000043672 * Lead Standard The plant progress with regards to the OSHA Standard on inorganic lead exposure continues per the plant's Compliance Plan. A sampling plan was developed and circulated for review and comment in early April. An AFE was submitted to upgrade the color weigh room and to improve the ventilation system per the recommendations of a ventilation consultant - John Kane, of Louisville, Kentucky. Several provisions of this standard have been stayed by the U.S. Court of Appeals for the District of Columbia. Provisions which remain in effect include: Permissible Exposure Limit, Exposure Monitoring, Respiratory Protection, Protective Clothing and Equipment, Housekeeping, Industrial Hygiene Facilities and Practices (except renovation and/or construction of new facilities). Medical Surveillance and Removal, Training, Recordkeeping, and Observation of Monitoring. VCM Compliance Activities with regards to cpmpliance include: Completion of Annual Medical Surveillance for all employees (including 138 blood lead tests), and routine personnel monitoring. A total of sixty-seven (67) samples were taken with six (6) indicating exposures of 1.0 ppm or greater. The distribution of results and a brief explanation of overexposures is shown below. Range (ppm) Number Percent 0.0 - 0.5 0.5 - 1.0 1.0 - 5.0 5.0+ 55 82.09 6 * 8.96 4 5.97 2 2.98 67 160.00 Of the six (6) overexposures, one occurred while a mechanic was working on a dryer centrifuge, one to a lead operator in the control room (see note below) and the four (4) remaining are under investigation. Two (2) of the employees whose overexposures are under investigation have indicated that they wore a respirator during the monitoring period. Due to transcient contamination of fresh air to the control room by VCM, an electrically operated damper has been installed in the fresh air inlet duct. .Whenever the Honeywell monitor senses VCM in the control room above 5 ppm, an alarm is activated and an operator manually operates the switch to close the damper. DTH 000043673 vinyl - E. L. Kieschnick March had 31 .accounting days (Y.T.D. is 90 accountingdays). . Production Month Y.T.D. Standard 1. Total Production, MM #*s 2. Production Rate, M #'s/C.D. 3. Charging, Rx B.A.'s/C.D. 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average #'s/Hr. 7. Dryers, Stream Factor, % 26.3 849 22.1 686 90.8 5698 88.7 69.9 777 19.8 1781 85.5 5406 85.5 The vinyl department production increased from 22.4 MM lbs. in February to 26.3 MM lbs. in March. The increase in production is a result of increased productivity from the reactors due to items described below. The dryer per formance continues to be good. a The increase in production is primarily a result of a reduction in chem'wash and swirl frequency on the 5425 and the elimination of swirl in the production of 5385. Reactor downtime was taken during the month to: 1. Brush the condensers on D-30Q, D-400, D-500, and D-600. The condenser was brushed on D-300 and D-500 while the reactors were down for a seal change and agitator gearbox repair, respectively. 2. Remove a coarse batch from D-600 reactor. The problem was traced to the suspending agent charge system and has been resolved. Resin Quality Summary Resin Type Prime Pounds "BC" Grade Grade % of Total Production 5305 5385 5425 5465 Sifter Overflow 1,269,250 ' 21,262,707 2,858,485 496,620 42,750 74,250 40,350 274,660 0.16 0.28 0.15 1.04 TOTAL 25,887,062 157,350 274,660 1.63 Quality performance for the month of March was 98.37% customer grade with 0.59% "BC" and 1.04% "H" grade. Items completed during the month to improve quality were: 1. Installation of air filter in the air utilized to aerate the 5425 blend tank. This has improved the quality of air and removed a significant contamination source. DTH 000043674 2. Modification of the dryer operation procedures limiting the maximum inlet temperature. This has not only lowered the contamination but has also reduced'the. dryer cleaning frequency. 3. Installation of an improved blend tank aeration system in the blend tanks utilized for 5305 production which will lower the residual VCM in the dried product, > The variable cos.t variance for the vinyl department was $49.9 M with $49.6 M due to price and $0.3 M due to efficiency. The major price variance was $64.0 M on VCM. The only major efficiency variances were ($40.0 M) on VCM and $18.7 M on combined initiators. The raw material requirement for the month was 1.02981 pounds VCM/pound PVC versus a 1.01960 standard. Four coarse batches in the old module and a severe foaming problem from 742 reactor were the primary contributors. A modification to the suspending agent charge system in the old module will minimize the potential for coarse batches. The foaming from 742 is a result of shell'side fouling on the 742 condenser which will be chemically cleaned the first week in April', DTH 0000436 COMPOUND - C. R. Miller .March had 31 accounting days. Compound Production Month #'s/Day Y.T.D. Line I, M Pounds Line III, M Pounds Total, M Pounds 1,584 3,594 5,178 63 116 167 4,130 8,208 12,338 Line I operated twenty-five days during the month at an average rate of 63 M pounds per day. Major items affecting productivity were number of product changes. (20 products - 43 hours total), maintenance on the Banbury conveyor (12.4 hours) and a power outage on the control panel (10.4 hours). Pro duction included new compounds 35031 for ITT Automative and 34431 Black for Pirelli Cable. Line III operated thirty-one days averaging 116 M pounds per day. The only major item affecting productivity on Line III was the number of product changes (14 products - 28.2 hours). Quality performance for flexible compound was 1.9% of which 76% was due to mill scrap. The remaining off-grade consisted of 24 M pounds of 18031 Clear Blue for gels and resin contamination. "BC" production for the month was 0.9%. The raw material requirement for flexible compound was 1.00773 pounds raw materials/pound of compound versus a 1.01296 standard (Y.T.D. is 1.00789). The variable cost variance for compound was $29.8 M with $16.3 M due to price and $13.5 M due to efficiency. The only major efficiency variance for the month was $19.9 M due to combined colors. The only major price variance was $27.9 M for Synpron 1438. Dry Blend Month #1 s/Day Y.T.D. Total Production, M Pounds 1,483 212 12,669 Dry Blend operated seven days during the month at an average rate of 212 M pounds per day. Dry Blend production was limited by dry blend sales and inventory control programs. Production during the month included the reprocessing of 41 M pounds of off-grade dry blend. . Quality performance for the month was 100% customer grade. Reworking of off-grade material at a 3% level continued through March. * The raw material requirement for dry blend was 1.00406 pounds raw materials/ pound of dry blend versus a 1.00321 standard (Y.T.D. is 1.00301). The variable cost variance for dry blend was ($38.6 M) with $2.5 M due to price and ($41.2 M) due to efficiency. Variance due to product mix was ($14.7 M). The large efficiency variance reported reflects an error in the end of the month area inventory. A correction will be made next month. DTH 00004367 Plasticizer Month #1 s/Day Y.T.D. Total Plasticizer, M Pounds 936 62 .2,971 The plasticizer unit operated- fifteen days during the month at an average of 62 M pounds per day. Plasticizer production consisted of DOP, 610-P and TOTM plasticizers. VRP production for the month was 84 M pounds. The raw material requirement for plasticizer was 1.11616 pounds raw materials/ pound of plasticizer versus a 1.10482 standard (Y.T.D. is 1.13240). The variable cost for plasticizer was $1.2 M with ($1.6 M) due to the price and $2.8 M due to efficiency. The only major price variance was ($10.3 M) for phthalic anhydride. There were no major efficiency variances for the month. * DTH 000043677 MECHANICAL - S. J. Vincent Vinyl r Area- I The large reactor condensers that were cleaned this month were all in the old module. They were D^-300, D-400, D-500 twice, and D-600. Some of the other work completed in the old module follows. All rupture discs were replaced and the relief valves tested on D-300, 400, 500, and 600. The chem wash spray heads for D-400, 500, and 600 were removed and cleaned. The reactor seal on D-300 reactor failed and had to be repaired. Several reactor valves were replaced on D-400 and D-500 reactors. The valves replaced were the condenser valve, the recovery valve, the evacuation valve, the main dump valve, and the VCM charge valve on D-400 and then on D-500 the chem wash valves to the reactor and the condenser valve were replaced. The fresh VCM receivers level device was calibrated. The control instrumentation for D-500 was calibrated and they were calibrated twice on D-600. There was a coarse batch in D-600 reactor at the end of the month with a significant accumulation of resin in the reactor. Extensive work was required to prepare, clean, and place this reactor back in service. There were no large reactor condensers cleaned in the new module. The rupture discs were replaced and the relief valve was pressure tested on 741 reactor. The chem wash spray head for 744 was removed and cleaned. The evacuation, recovery, and catalyst valves were replaced on 741 reactor. The evacuation and recovery valves were replaced on 744 reactor. A major problem developed with the new unit seal oil system. The flow could not be maintained through the filters with the gear pumps subsequently over heating and failing. The seal oil system was bypassed and service water was placed on all the seals on March 19. Several panel lights were repaired in the control room. The Sweco exhaust fan motor was removed and repaired. The vinyl dryers continue to operate satisfactorily after the installation of the new anti-chatter devices. The rotating assembly and gearbox were replaced on number two dryer. The units removed on changeout were rebuilt. The exhauster drive motor was replaced on number two dryer, also. Two dryers were given PM checks. The trunion roller and bearings were replaced on number four. A new process sampler was also installed on number four dryer sifter. Electric power was installed on a new vibrator for number six chute. The motor on one of the small blend tanks was repaired. Several silo level indicators and blend tank level transmitters were repaired and calibrated. The torque controllers on two'dryers were calibrated. A safety guard rail was installed on the roof around the collectors in the V-10 dryer building. The installation of the day collector handrails was completed for all dryers. \ One of the emission recovery system compressors was rebuilt with a new shaft and mechanical seals. Mechanical seals were replaced on three recovery compressors. One of the old module vacuum pumps was dismantled and cleaned. Motors were removed and repaired on one vacuum pump and two compressors in old recovery system. Two of the 490 Corken compressors were rebuilt. The mechanical seals were replaced in both of the VCM transfer pumps at the tank farm. The suction screens were pulled and cleaned twice on both VCM charge pumps in the old module. The mechanical -seals wer.e also replaced in .the old ' '' ' DTH 000043678 unit RVCM pump and one of the slurry pumps. All the valves going into the "A" vacuum pump were replaced to try to define continuing problems in this . recovery system. Both of the tecoyery condensers in the old unit were cleaned. A new drain bypass line was installed in the emission recovery system. The knockout drums and receivers were opened to remove resin restrictions. Numerous rupture discs continue to be replaced throughout the unit. A three way control valve was replaced on the incinerator. All Honeywell monitoring points were checked and verified. Compound, Dry Blend, Plasticizer, and Storage Silos - Area II The cooling water piping to the Line III product blower was revised. The top roller on the Line III scrap conveyor was replaced. The mechanical joints on the two laboratory mills had to be rebuilt. The dump valve on one of the line I blenders was repaired. A steam leak list was developed for compound and the leaks corrected. The motor on one of the dicers was removed and repaired. The service water piping to the dry blend basement was rerouted. The service elevator corftro'ls were relocated for the installation of the new access ramp for raw materials. The dry blend basement sump pump was rebuilt. A vacuum cleaning connection was installed on the' screener deck. A new stub shaft was installed on the drive end of one of the blenders. During the dry blend shutdown, five motors were also pulled and repaired. The two plasticizer blowers were rebuilt. The mechanical seal was replaced in the phthalic anhydride transfer pump. The catch tank was revised to hold filter socks. The rupture disc was replaced on one of the reactors. The inert gas generator installation was completed. An air purging system was installed on the alcohol unloading lines. A coil leak in one of the reactors was also repaired. A new water line was installed to the truck scale. The fresh air piping to the VCM unloading rack was revised. An engine was replaced in one of the plant fork trucks. The new silo sampler was installed on one of the truck loading resin silos. Several painting projects were completed. The manway covers were repaired on three large silos. One knife valve was repaired. Utilities . The air dryer heater elements were replaced in one of the V^IO air dryers. One of the rental diesel air compressors was returned to the supplier. An air filter was installed on the air supply to one of the large blend tanks. All the plant air receiver relief valves were tested and also the relief valVe on the water softeners. A new water meter was installed on one of the main city supply lines to the plant. The air conditioning and refrigeration program the history, and equipment vibration program, and the lubrication program are continuing. A sonic testing device is being used to develop data for a leak detection program primarily for process valves. Nineteen valves were rebuilt for the vinyl unit. Several tools were repaired. Several bicycle repairs were completed. The installation of the new steam fired vaporizers is continuing with an estimate of completion.in April. DTH 000043679 New cable and a new motor were installed on the polishing pond aerator. Number six air compressor motor was removed and repaired. One of the water.valves .in the boiler system was rebuilt.. Planning The planners work involved processing 42 inyoice registers and processing 31 invoices for payment. Planning work and material was ordered for 31 separate projects. The change over of all backlog work to th.e new Maintenance Management System was completed. Supervisory coverage was also provided by the planner. Miscellaneous There were 520 maintenance, 23 revision, no safety, and 68 service to operations work orders received during the month. The following is a breakdown of maintenance work orders by priority; E A B C Shift Mechanic TOTAL Number 262 160 9 56 33 520 Percent 50 31 2 11 6 100 During this reporting period 625 maintenance, 36 revision, 4 safety, and 91 service to operations work orders were completed. 30.5% of the time was spent on non-scheduled work. Preliminary work has been completed for implementation of the MMS at Aberdeen. Supervisory meetings were conducted to familiarize employees with the program. The official changeover to MMS will occur on April 1, 1979. . DTH 000043680 PERSONNEL - J. L. Carter EMPLOYMENT During March there were two temporary new hires, Debra Lindsey, Steno Clerk and Clyde Rhea, Temporary Contractor Guard. TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMPTION None. RETIREMENTS None. TERMINATIONS. Two hourly employees, Willie C. Burley, Painter-Insulator-Carpenter "A", and Percy Carothers, General Helper. DEATH/DISABILITY None. OTHER - CASUAL LABOR There was one (1) casual labor employee on payroll during this month. Total hours worked were 55.75. DTH 000043681 . Aberdeen, Mississippi March 1979__________ MONTHLY PERSONNEL REPORT Salaried Employees Hourly Employees Total Employees Employees (-Hourly) . 72*. 161 233* . Minority Employees - Salaried Hourly Total 3 63 66 4% 39% 28% New Employees Terminations -02 Hourly Min. Hired -0- % Min. Hired -0- Hourly Min. Term. -2- % Min. Term. 100% DEPARTMENTS PAR # EMPLOYEES MIN. EHP. % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse Gen. Plant Maintenance Laboratory Compound _S_ 10M22-- 18_ 9 11 45 22 38 2 22% 0 0 0 *0 0 0 5 45% 0 0 13 9% 27% 7 15% 0 0 1 1 2% 2% 3 14 0 0 0 0 0 0 30 79% 0 0 00 0 0 Vinyl Plasticiser 32 4 32 4 13 41 0 0 0 0 0 0 3 75 0 0 0 0 0 0 Number of Applicants: Month 3 Year to Date 3. APPLICANT BREAKDOWN: # Minority -0- % Minority -0- *6 Female ______2 % Female 66.6% *Includes one Co-Op Student and two other temporary employees. Hires (Hourly) : Month -Q- Year to Date Terminations (Hourly) : Month 2 Year to Date Overall Turnover Projected Annual Turnover _q. 4 13% DTH 000043662 0 PROCESS ENGINEERING - J. R. McCrimon A* Specialty Compound Line The plant is continuing to work with Crawford and Russell andCED on the mechanical design of the project. Construction began on March 20, 1979. Current estimated mechanical completion date is September 15, 1979. B. Fire Water Revisions - Phase I Mechanical Engineering for the project is continuing. A request for engineering services from Texas Automatic Sprinkler Co. is being prepared. C. Propane Vaporizer Replacement Mechanical installation of the project was begun in late February. Project completion is still scheduled for mid April, D. Plasticizer Exposure Abatement Mechanical Engineering is continuing. E. Charge Water Heating Improvement Installation is underway and completion is scheduled for the end of April. F. Silo High Level Alarms A prototype was installed on silo 479 and tested. Problems with the Ronan alarm panel in the control room ard being investigated. G. Plant Dryer Debottlenecking 1. Centrifuge Slurry Feed Control The new one inch control valves have been installed on all the dryers except Dryer No. 7. 2. Remote Dryer Lighting Equipment has been ordered. Mechanical Engineering is continuing. Projected completion is projected for the end of July. 3. V-10 Transfer System Mechanical Engineering is proceeding on the mechanical design for this project. Equipment is'on order. Project completion is scheduled for the end of July. . DTH 000043684 H. Silo Isolation Valves The valves for this project are on order. I. Plant Yield Study The use of the continuous sampler to determine the amount of resin in the effluent to the plant waste treatment system is continuing. J. Automatic Plasticizer Weighup System The process design for this project has been modified to incorporate changes in the sequencing operation. The need for these changes are necessary to better define tie-ins to the existing system. Panel delivery is scheduled for the end of July. K. QMS Addition System The process design for an automatic OMS addition system for the new module was completed and reviewed. A cost estimate will be made for the project. L. Emission Recovery System A process design for the installation of an additional vacuum pump and to improve liquid control in the system was prepared. A definitive estimate is being prepared by the Mechanical Engineering Group. M. Plant Air System A process design for an additional air compressor 'is being prepared. , DTH 000043685 ENVIRONMENTAL HEALTH - J. R. McCrimon I. Particulates . The exhausts from two of the resin dryers were sampled for particulates. The rental vacuum cleanup system has been evaluated and found to work well. A purchase order was issued for the unit. Engineering is underway to add options to the unit. II. Water BOD and COD levels were within NPDES permit limitations in March. An application for renewal of our current NPDES permit was submitted and storm water runoff sources were included. PED personnel were in the plant to run a source sampling program to define flow rates and loadings from the various areas of the plant. This data will be used to determine the effect of increased plasticizer production and resin expansion on the plant waste water treatment system. Methods of eliminating the pond irritant are being investigated. Aerators operated 24 hours per day most of this period. III. Vinyl Chloride PED personnel were in the plant to discuss methods to improve EPA compliance. The plant received a ''show cause" notice from the EPA concerning the two VCM releases from D-300 reactor which occurred in February, A control room isolation damper was installed in the fresh air duct to the vinyl control room. In-plant emission testing and leak checking are continuing as specified in the Compliance Manual. The EPA semi annual report was submitted as required by the regulation. Efforts have been intensified to come closer to compliance 100% of the time. The Engineering and Work Practice Control Plan was updated and reissued. IV. General A permit to construct the specialty compound line was granted by the state and construction is in progress. DTH 000043686 Flow GPM Jan. - Ave. Max. 788 948 Feb. - Ave. Max. 756 773 Mar. - Ave. Max. 669 760 Apr. - Ave. Max. May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sdpt. - Ave. Max. Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. TABLE I WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB./DY. COD PPM LB./DY. Sus. Solids Diss. PPM LB./DY. o2- 26 246 63 589 37 307 94 781 19 170 6.9-7.3 31 279 30 272 43 380 17 134 24 184 73 656 95 840 61 490 81 621 27 241 6.9-7.9 34 315 26 214 6.9-7,6 45 367 NPDES - Ave. Max. - 32 387 43 520 - 1390 - 1940 - 605 - 909 6.0 ph 7.5-8.2 7.7-8.0 7.3-7.9 6.0-8.5 % , DTH 00004368r7 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for March was 112.1 MMM BTU's. The energy consumption per pound of product increased from 3265 BTU/lb. to 3308 BTU/lb. in March. II. Plant Energy Conservation Program A. Steam Leaks 18 of 22 reported steam leaks were repaired during March. B. Charge Water Heating Improvements Mechanical design is continuing. Installation of equipment will begin in April. C. Boiler Burner Replacement Fabrication and testing of burner units by the vendor was completed in March with shipment pending. DTH 000043688 ENERGY CONSERVATION DATA ITEM 1978 1979 Production, MM Lbs.' March March Resin Dry Blend Compound Plasticizer 19.3 3.5 2.9 0.5 26.3 1.5 5.2 0.9 TOTAL 26.2 33.9 Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU 47758 1020 48.713 61659 1020 62.892 Electricirty Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Propane 4.262 10000 42.620 4.9243 10000 49.248 Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU 6.60 92000 0,607 0 92000 0 Total Energy Consumption, MMM BTU Energy Consumption , BTU/Lb. 91.940 3509 112.140 3308 Boiler Operating Data No. 1 No. 2 No. 3 .. Stack Temp. 1978 1979 389 425 412 406 428 452 Avg. % Excess Air 1978 1979 115 100 105 110 61 . .115 DTH 000043689 MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved, and Closed The following AFE's were submitted and approved during March: AFE No. Title Authorized 9539 9549 Laboratory Equipment Safety Equipment $31,000 $15,000 There were no AFE's closed to field charges or completion reports issued in March. Design Bid packages were prepared for insulation on the Propane Vaporizer Project and underground conduit for the Dryer Operation Improvement Project. Silo isolation valves are on order. All major equipment for the Dryer Operation Improvement Project is on order. Contracts were let for the concrete work for the Plasticizer Chemical Exposure Abatement and New Compound Line Projects. Design work is in progress on the following projects: Dryer Operation Improve ment, Resin Silo Debottlenecking, Plasticizer Chemical Exposure Abatement, Fire Protection Improvements, Vinyl Communications System and Office Expansion. Construction 1. The Inert Gas Generator Project is complete and ready for startup by the manufacturer's representative. 2. The new fork lift ramp is complete. 3. Installation of an electrically operated damper in the control room fresh air system is complete. 4. Installation of the Plant Emergency Siren System is complete, 5. Installation of the Gaitronics Communication System is complete. 6. The API separator was cleaned during the period. 7. The Phthaiic Anhydride rail spur extension is complete. 8. The railroad bed was repaired on the west spur. 9. Work on the following projects is in progress: Dryer Noise Abatement, Propane Vaporizer Replacement, Dry Blend Silo Alarms, Emergency Lighting System,'Charge Water Heating Improvements, Offsite Electrical and Piping for the New Compound Line. DTH 000043690 (1) Thru February, 1979 Actual Accounting (2) Thru March, 1979 ABERDEEN AUTHORIZATIONS REIWE MJTH. CAPITAL NO. DESCRIPTION 912b PVC Reactor Capacity Replacement 111 DATE AUTII. APPROVED AFE AWT, (1) (21 FINAL EXPENDED COMMiTED TOTAL EST. TO DATE TO DATE COST COMP. UNDER (OVER) AUTM. AMT. EST. EST. CLOS. DATE REMARKS 7/8/76 8,5^7,000- S,130,704 8,189,896 .8,189,896 387,104 , 12/78 3/79 Closed to field charges. t 9276 9286 Relief Valve Vent Containment Additional Slurry Blend Tank 12/10/76 39,000 12/7/76 290,000 34,499 34,499 282.S46 285,823 34,499 285,823 4,501 4,078 12/78 3/79 12/78 4/79 Closed to field charges. Closed to field charges. 9057 Vent Gas Incineration 4/1/77 275,000 275,876 275,876 275,876 (876) 12/78 4/79 Closed to field charges. 9087 Resin Silo Aeration S/16/77 280,000 242,054 242,336 242,336 37,664 12/78 3/79 Closed to field charges. 9147 Phthalic Anhydride Exposure Reduction 6/30/77 45,000 40,290 44,039 44,039 961 11/78 2/79 Closed to field charges. 9187 9197 Eaergency Reactor Vent Control Dryer Area Noise Abatement 9/29/77 9/29/77 33,000 45,000 26,331 25,004 33,136 32,629 33,136 45,000 (136) 4/79 6/79 0 6/79 9/79 Installation complete. Installation proceeding. 9227 Plant Emergency Lighting System 10/10/77 65,000 46,056 46,122 65,000 0 6/79 9/79 Installation proceeding. 9237 Heated Plasticizer Addition System 10/11/77 37,000 7,628 8,057 37,000 0 9/79 12/79 Installation proceeding. 9247 Farrell Mixer Feeders 11/21/77 47,000 17,599 20,730 47,000 0 6/79 9/79 Conveyors to be installed. 9257 Resin Transfer Debottlenecking 11/16/77 56,000 28,756 43,147 56,000 0 7/79 10/79 Dust collectors purchased. 9267 Dry Blend Production Expansion 11/23/77 200,000 180,159 197,877 200,000 0 4/79 7/79 Installation complete. 9277 Truck LoadingSafety Revisions 11/28/77 16,000 2,495 4,009 16,000 0 6/79 9/79 Installation proceeding. 9287 Plasticizer Yield Improvement Test 12/5/77 6,000 3,544 3,544 6,000 0 4/79 6/79 One test complete. 9297 Automatic Plasticizer-Stabilizer Weighup System 12/14/77 60,000 873 43,718 60,000 0 9/79 12/79 Design in progress. 93G7 Compound Project Conveying Lines 12/14/77 50,000 20,942 22,211 50,000 0 6/79 9/79 Installation proceeding. 90X8 Critical Spare Equipment 1/31/78 63,000 60,855 63,502 63,502 (502) 12/78 3/79 Closed to field charges. 9028 Misc. Items Under $10,000 9038 Maintenance Equipment 9048 Resin Moisture Analyzers 9058 Laboratory Equipment 9078 Misc. Projects Under $10,000 9088 Replacement Inert Gas Generator 9098 New Compound Line 1/31/78 50,000 2/3/78 18,000 2/24/78 17,000 2/24/78 50,000 2/24/78 166,000 3/28/78 44,000 4/17/78 2,050,000 30,510 48,422 48,422 18,213 17,899 17,899 13,148 13,148 17,000 48,617 48,659 48,659 138,545 158,943 1S8.943 29,668 39,870 44,000 737,710 1,422,669 2,050,000 9108 9138 9148 9158 9168 9178 9188 Boiler Burner Replacement 5/12/78 Plant Guardhouse Improvement 8/14/78 Plasticizer Chemical Exposure Abatement 8/21/78 Fire Protection Improvements-Phase I 9/19/78 Misc. Projects Under $10,000 9/21/78 Propape Vaporizer Replacement 9/21/78 Railcar Resin Heel Cleanup System 10/12/78 170,000 19,000 152,000 176,000 59,000 175,000 55,000 9198 Debottlenecking - Centrifuge Anti-Chatter Devices 9208 Spare Recovery Vacuum Pump 9218 Charge Water Heating Improvement 9228 Dry Blend Silo Alarms 9248 Silo Isolation Valves 9258 Dryer Operation Improvements 11/7/78 70,000 12/5/78 12/8/79 12/13/78 12/14/78 12/14/78 14,000 32,000 25,000 25,000 315,000 9529 Miscellaneous Projects Under $10,000 . 2/15/79 125,000 1,183 18,540 2,670 166,789 18,540 92,298 170,000 18,540 152,000 0 36,927 8,411 3,643 15,194 52,770 105,306 41,523 176,000 52,770 175,000 ssiooo 19,374 63,122 70,000 0 3,263 331 0 0 14,633 31,152 4,201 15,589 74,703 14,000 32,000 25,000 25,000 315,000 0 59.183 125,000 1,578 12/78 3/79 Closed to field charges. 101 12/78 3/79 Closed to field charges. 0 4/79 7/79 Analyzers in service. 1,341 10/78 2/79 Closed to field charges. 7,057 12/78 3/79 Closed to field charges. 0 4/79 7/79 Installation proceeding. 0 12/79 3/80 Offsites electrical being installed. Most material on order. 0 6/79 9/79 Burners shipped. ^ 460 11/78 3/79 Closed to field charges. 0 7/79 10/79 Site work in progress. 0 9/79 12/79 Engineering in progress by CED. 6,230 12/78 3/79 Closed to field charges. 0 9/79 12/79 Installation proceeding. 0 5/79 8/79 Fabrication of Satellite hopper in progress. * 0 4/79 7/79 Equipment being installed. 0 8/79 1 1/79 Vacuum pump on order. 0 S/79 8/79 Installation proceeding. 0 5/79 8/79 Prototype installed. 0 7/79 10/79 Valves purchased. 0 10/79 1/B0 Engineerng and purchasing in progress. 0 12/70 3/HO Twenty-two project:; approved'. DTH 000043691 MJTtt. EXPENSE NO. DESCRIPTION 9258 Compound Line I Roof Collapse (1) Thru February, 1979 Actual Accounting (2) Thru March, 1979 ABERDEEN AUTHORIZATIONS REPORT DATE APPROVED ' Cl) (2) FINAL Aim). EXPENDED COMMITTED TOTAL EST. AFE AMT. TO DATE TO DATE COST COMP. UNDER COVER) Aim). AMT. EST. EST. ' COMP. CLOS. PATE DATE REMARKS 12/13/78 44,000 0 0 44,000 0 4/79 7/79 Insurance clain being filed I DTH 000043692 LABORATORY - R. B. Martin ' CUSTOMER COMPLAINTS Customer Product Type Complaint No. Status Resin Rehau 5385 $ Wet Resin ARP-030579 Report by ELK Compound Tenex Tenex Tenex Croft Emico Tenex Louisiana Wire 8 Cable 18031 19041 15041 17461 14551 18031 34641 Processing Color Streaks Off-Color Processing Off-Color Gassing Cold Bend Test ACP?021579 ACP-021479 ACP-021679 ACP-021479 ACP-020279 ACP-032179 ACP-022879 Report by CRltf Report by RBM Report by RBM Report by RBM Report by RBM Report by RBM Under Investigation WAIVERS RECEIVED Date Identification Product Customer Reason 3-1 3-1 3-1 3-1 3-1 3-2 3-2 3-2 3-2 3-2 3-5 3-12 3-18 3-19 3-19 3-21 3-22 3-22 3-26 3-27 3-27 3-27 3-28 3-28 3-28 3-29 3-30 T-2351 C0NX-45706 Bags 00517/00518 PLCX-43216 PTLX-41644 PTLX-42022 Bags 00519 T-2811 T-2479 T-2321 T-2320 PLCX-42680 T-2809 T-2320 CONX-45291 Bags 00518 Miller Truck PLCX-43011 T-2809 C0NX-45268 T-2811 PTLX-41836 PLCX-43231 PTLX-41855 T-2481 T-2810 PLCX-43081 Total 27 5305 Carlon 34431 Gry547 Kaiser 5305 Export 5385 III Simpson 5425 Uniroyal 5305 Carlon 5305 Export 5385 III World of Plastics 5305 Carlon 5305 LCP 5465 Industrial Plast. 5425 Uniroyal 5425 5305 5385 III 5305 VRP 5425 5305 5385 III 5305 80273G 5385 80273G Athol Hat co Tridyn Uniroyal Heritage Southwire Carlon Charlotte Pipe CarIon Can-Tex Charlotte Pipe Central Foundry 5305 5305 5385 Celanese Piping Uniroyal Simpson Residual VCM W. Howell Mixed Color, Fines CLS Residual VCM GGD Particle Size RDJ Contamination GGD Residual VCM GGD Residual VCM GGD Particle Size GGD Residual VCM GGD Residual VCM Customer/GGD Dry Time GGD ` Contamination, GGD No-flow static Contamination RBM Residual VCM GGD No-flow static ELK Residual VCM GGD Color GGD Contamination GGD Residual VCM Color "b" value * GGD GGD Residual VCM RBM Fusion Torque RBM Particle Size RDJ Fusion Time, Torque HJH/GGD Stability Time Residual VCM Customer/WH Residual VCM RBM Particle Size RDJ - ' * ` . DTH 000043693 QUALITY CONTROL TESTING Resin - 612 regular samples, 2716 other in-process'resin samples. Bulk resin shipments total 210 (106 railcars, 104 trucks) Dry Blend - 147 blenders produced with 92 blenders tested. Adjustment rate for all dry blend was 3.4%, There were 184 other dry blend inprocess samples. Bulk shipments total 25 (railcars 4, trucks 21) Compound - 826 blenders produced and tested. 233 other in-process samples were received. Adjustment rate for blenders was 1.6%. Bulk shipments total 37 (railcars 16, trucks 21) Residual VCM in Shipments A total of 131 shipment samples were tested for RVCM in March, A summary of these results is below: Product ,5385 5425 5305 Dry Blend Average ppm VCM 1.1 0.4 12.3 Number of samples 88 10 30 0.9 3 Resin Heat Stability Fifty-five (55) blends of various resin types were tested for over heat stability. 5385 5425 5305 5465 22 Blends 20 Blends 8 Blends' 5 Blends Heat stability of all types were good. Raw Material Testing Fifty (50) lots of plant raw materials were tested. One shipment of Tribase lead stabilizer was rejected for poor dispersion quality, Harwick VCP-5217 black powder color concentrate was approved as a replacement for the Harwick 90-PC-02 black paste color concentrate. PRODUCT DEVELOPMENT AND SERVICE Date Shipped Quantity Product Customer 3-14 3-14 3-14 3-21 3-21 3-21 3-21 3-30 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 17461 Black 14431 CLBL 50 15041 CLBL 50 5305 5385 I 5425 5465 5385 I Donnelly Mirror, Atcoflex, Inc. Atcoflex, Inc. Vinatex England Vinatex England Vinatex England Vinatex England M 8 T Chemicals Inc. CJM CJM CJM AMP AMP AMP AMP HJH , DTH 000043694 COMPOUND DEVELOPMENT AND SERVICE Special Compound, Testing * Specification tests were run on 7 lots of compound for Western Electric 5 lots of 34861 Gray 546 and 2 lots of 36861 Natural. Dry Blend t Quality control standards were prepared for KGM-3400-172C, a new experimental dry blend. Customer Complaints A United Cable (Louisiana Wire and Cable) complaint that 34641 did not pass the cold bend test was investigated. A brittle point test indicated that the shipment was typical of this compound and should have passed the cold bend test when coated on wire. * Croft Metals complained'that 17461 3A01 gave extrusion problems. The material performed satisfactorily in the laboratory extruder. A Tenex complaint concerning 18031 Clear Blue 50 claimed gas bubbles and poor profile surface were present in their extruded product. Laboratory extruded strips showed many gel-like imperfections; however, the surface was not rough and no gas bubbles could be seen. SPECIAL PROJECTS RVCM in Slurries A total of 635 batches out of a possible 672 produced were tested for RVCM. The overall average for the month was 212 ppm VCM with only 1 day exceeding the 400 ppm limit. This month, March, is the best with respect to RVCM since the new reactors were put into service. Residual Vinyl Chloride in 5305 Drier Samples A total of 34 samples of 5305 from the drier were tested for RVCM. The over all average was 18 ppm VCM. EPA-Reactor Opening Study As part of the reactor opening study and related EPA testing the following samples were analyzed: Slurries for RVCM Waste Water for RVCM Reactor Opening Air Bag for VCM Incinerator Air Bags for VCM 140 samples 42 samples 51 samples 6 samples DTH 00004369 SPECIAL PROJECTS (CONTINUED) Yjeld Test Run In support of the Yield Test Run percent solids were measured on 12 total waste water composites 9 blowdown tank samples. Waste Treatment Study In support of the waste water program conducted by engineering in Ponca a total of 84 samples were tested for COD, Ph, and percent solids. In addition 7 samples were tested for BOD by an outside laboratory. DTH 000043396 % ORDER ENTRY AND TRANSPORTATION WAREHOUSE - J, C. Coffman S J. E. Mays Shipment By.Product - M Lbs. March Vear-to-Date Resin Plasticizer Dry Blend Compound TOTAL 15,709 83 4,906 . 5,222 25,920 48,378 333 13,110 13,292 75,113 Number of Shipments by Mode R/C O.T. C.C. C.O.T. TOFC CPU TOTAL Resin - Bulk - Package - Export - Aberdeen Plasticizer - Bulk 75 85 7 12 11 7 171 8 4 26 i3 22 Dry Blend - Bulk - Package 19 9 2 13 41 57 Compound - Bulk - Package 15 22 16 3 2 37 25 46 Export - Package Back Hauls for March 2 110 145 14 21 2 2 8 49 335 14 Number of Shipments by Month - Y.T .D. R/C O.T. C.C. C.O.T. TOFC CPU TOTAL January February March 103 166 101 119 110 145 12 10 21 7 0 2 7 56 351 3 36 269 8 49 335 Material Handling Report M/Lbs- T/L 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 Compound to Plant Shipment From Warehouses < Special Packaging Transferred From Prairie to Main , 1 ,823 1 ,579 567 932 567 121 3 ,281 162 405 9 ,437 45 39 14 23 14 3 81 4 10 233 DTH 00004369 , LOCATION MAIN-East TOTAL M SO. FT. 48 CONOCO TRANSPORTATION I ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco. Resin 3.1 i.-n .2 .7 {1 ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 5-Q 4.5 9.5 Rnjirie 12-1 12-2 12-3 12 22 21 12-4 12-5 22 21 12-6 12-7 12-8 21 21 21 Compound Dry Blend 1.5 .1 Comn O.G. 2 Raw Materials .2 Conoco Resin . Conoco Resin .5 Resin O.G. 2.2 Mill Scraps . Cmpd 0. G. .6 Dry Blend 0. G. . .5 Sifter Overflow .2 Resin 0. G. . Conoco Conoco Conoco 1.5 1.5 1A___LS___ A5 .4 3.1 3.5 2.7 .ft 3.5 1A_____L2_____ LI 3.5 3.5 3.5 3.5 3.5 Total on Hand '' ' T1 .0 ` 23.fi___ 34.5 Chrysler Resin (-2.0 ) Total 2D. 9. Motftl Conoco -:___________________ ________________ - : ' . -. DTH 000043698 Off-Grade In Storage Material Sifter Overflow Resin "BC" Resin "H" Mill Scraps Compound "B" Compound "H" Dry Blend "O.G." M/Lbjs, 200 1,108 1,142 41 1,111 140 375 Ilk 5 27 28 1 . 27 4 __ 9 TOTAL 4,117 101 Chrysler Storage Balance, March Transferred during month 2,291 337 56 8 ' TOTAL 1,954 48 D. F. Operation It now appears that our inventory has reached a low level and we are shipping approximately what production is producing. We presently have 4 empty storage warehouses available for future storage. Plans are to have a fifth warehouse empty next month by regrouping some products together. DTH 000043699 ABERDEEN FIRST-AID CASES I 12 MONTHS MOVING AVERAGE 50 45 40 35 30 25 20 15' 10 5 0 ,DTH 000043700 Feb. ABERDEEN OSHA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE 20 15 10 5 0 DTH 000043701 MONTtfl-Y HOURLY TURNOVER 1C 9 8 7 6 5 4 3 2 1 r ' !#i Pounds ABERDEEN PUNT PRODUCTION 1979 MM Pounds 350 300 250 200 150 100 50 0 60 50 40 30 20 10 0 70 60 50 40 30 20 10 c 20 15 10 5 0- ABERDEEN PLANT EFFICIENCY 1979 Standard 1.01960 Standard 1.01300 Standard 1.00320 Standard 1.12080 DTH 000043704 u u l 'JC L H E T Z G E N C Q . M A D E IN U. S. A. % Off Grade ' 'rjm QUALITY. PERFORMANCE 1979 ABERDEEN PLANT INVENTORIES 1979 CMC S tE T Z S C N CO.