Document XRnbaevo35k099Bbpr8j48KBy

ABD00311910 SAFETY - C. M. Markerson/J. V. Uptain July Fiscal Y.T.D. 1995 Y.T.D. 1943 First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 1 0 1 0 0 1 0 1 0 0 2 0 2 0 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 00 00 00 00 00 11 11 0 1 1 0 0 0. 2 Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 11 00 00 00 00 00 0 .0 11 2 0 0 0 0 0 _0 2 Non-Occupational Injuries Lost Workday Cases Days Lost 00 00 1 3 Contractor Injuries First Aid Cases Medical Treatment Cases Lost Workday Cases 00 00 00 0 0 0 Safety Record Last lost time injury Days since Employee hours since - 01/22/94 190 242,952 On July 31, 1994, the employees of the Aberdeen Plant completed 190 days with no lost time injury. ABD00311911 SAFETY - Continued Routine dosimetry results for the month were: Chemical VCM Lead Total Particulates Monthlv In-iurv Summarv < PEL Number Percent 66 100.0 6 100.0 3 100.0 > PET. Number Percent 00 00 00 Iniurv Class Deoartment Descriotion PA Quality Small puncture, middle finger of right hand. 9 August 1994 ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) S3 30 cc 3 25 "5 20 o 15 cc LU OQ 3 I 1 I I 1 1 I I \--y\ I I 1 ITV 1 I I--rTTTTTTTTTTTl--I I I I J 0 J'92 A J 0 J'93 A J O J'94 A J MONTH TOTAL INJURIES OSHA RECORDABLE ABD00311912 QUALITY MANAGEMENT PROCESS - J. H. Edwards - The Aberdeen ISO 9002 Training Manual was completed. Training sessions will occur in August during the natural team meet ings . - 90% of all ISO plant Tier III documents are complete; 80% of all Tier II documents are complete. _ The Compound Raw Material Spec Book was completed and issued. - Natural Team Activity 1. The Compound Operations Supervisor's Natural Team is working on the elimination of gaylord box strapping. 2. The Compound "A" Shift is working to upgrade the color weigh staging area. 3. The Compound "B" Shift is working to improve the mill scrap reporting/labeling. 4. The Compound "C" Shift is completing eliminating powder and oil leaks. its project on 5. The Compound "D" Shift is working on a justification for a second drum pump. 6. The Compound Superintendent's Natural Team project is reducing inventories of obsolete raw materials. They are still collecting data and monitoring the progress on reducing off-grade compound inventories. 7. The QC Supervisor's Natural Team is collecting data on gas cylinder usage. 8. The Vinyl Superintendent's Natural Team project is reducing offgrade resin. 9. The Vinyl Operations Supervisor's Team is working on RVCM pump evaluation, recovery system cooling supply and the fluid bed plenum recycle line. 10. The Vinyl "B" Shift is working on replacement of the replacement of reactor ram valves. 11. The Vinyl "C" Shift is working on revising power supplies to the 281/282 transfer systems. 12 . The Vinyl "D" Shift is working on improving the procedures for clearing the ERS seal water exchangers. 13. The Yard Supervisor's Natural Team is working on the cleanout of compound railcar heels. ABD00311913 COST VARIANCES - C. W. Turner Variable Costs Product ________July# 94 Variance, $M Efficiency Price Total PVC Flexible Compound Plasticizer Total 96.0 <27.8> <11.8> 56.4 <719.3> 1.1 < 28.6> <746.8> <623.3> < 26.7> < 40.4> <690.4> PVC Reain The favorable efficiency variance for PVC was due to a favorable catalyst efficiency of $73.3M and a favorable energy efficiency (electricity and natural gas) of $49.4M. The favorable catalyst efficiency was due to inventory swings associated with catalyst delivery timing. The favorable energy efficiency resulted from high production and hot weather. Flexible Compound r>d Plasticizer The negative efficiency variance in Compound is primarily due to higher than budgeted off-grade production. The negative price variance in Plasticizer is primarily due to higher than budgeted costs related to 610AI alcohol. Major Price Variances Variance - $M - VCM - Plasticizer to Compound _ Resin to Compound <720.9> < 10.5> 9.7 720.1 VINYL - J. D. Olson, W. S. Carroll Safety The Vinyl Department had no injuries in July. The monthly safety meetings were held on shift. General .1 July production was 47.9MM pounds of which 46.7MM pounds was prime grade resin. Percent asset utilization was 91.9%. July prime production is a new all-time monthly record. ABD00311914 VINYL - Continued July - Production, MM Lbs. - Reactor Stream Factor, % - Resin Quality, % Prime - VCM Efficiency, Lbs./Lb. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % % 47.9 96.3 97.7 1.0284 1543.9 107.4 1070 34.5 96.5 99.3 Reactor Downtime _ Operational downtime (recovery scheduling conflicts - 157 hours, plugged recovery line - 43 hours). - Mechanical downtime (D-300 gearbox - 14 hours). Dryer Downtime - Operational downtime (cleaning, product changes, and centrifuge plugs). _ Mechanical downtime _ Reactor limited production. YTD 47.9 96.3 97.7 1.0284 1543.9 107.4 1070.0 34.5 96.5 99.3 Hours 226.0 50.0 Hours 54.0 17.0 66.0 COMPOUND - E. T. Stouder Safety The Compound Department had no OSHA recordable injuries during the month. General Orders for Lines I, III, and V continue to be very strong. Several customers have been shifted back to Aberdeen from Mansfield (Tri-angle, Pirelli, Cerro) to take advantage of more favorable freight economics. In all likelihood, these customers will be shifted back to Mansfield once Aberdeen begins production of 757C for AT&T Phoenix. Production volumes were positively impacted in July due to long product runs on Line III. Production was impacted nega tively in July by product change downtime and quality problems on Line V associated with the initial production of several AT&T compounds. These quality problems have since been resolved. ABD00311915 COMPOUND - Continued Plasticizer production continued to run at almost a 23MM pound per year rate. Additional studies will be conducted in August in an attempt to further increase plasticizer production. The possi bility of outside sales of 610P is also being investigated due to growing plasticizer inventories. Compound Production Operating Dava Production M (Lbs) ._____________ Month Avq./Day Fiscal Y.T.D. Line I 31 Line III 31 Line V 31 Total % Prime Capacity Utilization Factor 1982 4050 1098 7196 96.9 95.3 64 131 35 230 1982 4050 1098 7196 96.9 95.3 Downtime Hours Line I - Product Changes - Miscellaneous Maintenance - Quality 119 4 16 Line III - Product Changes - Miscellaneous Maintenance - Quality 66 29 6 Line V - Product Changes - Miscellaneous Maintenance - Quality 100 29 49 Operating Days Production (M __________ Month Avq. /Dav Fiscal Y.T.D. Plasticizer 31 % Prime Capacity Utilization Factor 1846 84.5 82.9 60 1846 84.5 82.9 ENGINEERING - J. E. Nickerson, T. R. Mackay, R. H. Sneed PROJECTS IN DEVELOPMENT - GENERAL EXPRESS The plant is working with PED to redefine the scope of the Aberdeen EXPRESS Project. A new expanded scope was turned into GED estimating at the end of July. The new scope in cludes the addition of two more large reactors in the Old Module. ABD00311916 ENGINEERING - Continued PROJECTS IN DEVELOPMENT - GENERAL - continued EXPRESS - continued Cyclone dryer P&IDs and equipment specification sheets were received from UHDE as part of the Basic Engineering Package. Instrument specifications are expected in early August. A plant process hazards analysis was completed on the dryer portion of the EXPRESS Project. OSHA Process Safety Process Safety Information Work is progressing on locating and developing equipment specifications and documentation for the New Module. New Module relief systems documentation are also started. Procedures Procedures for New Module and SA Module are in the review process. Procedures for the boilers are 75% complete. HAZOPS The Old Module HAZOP study is complete. currently in review. The report is RVCM Reduction Efforts The "Hot Air to Blend Tanks" project APE is approved. RVCM levels this summer have been lower than last year. The hot air supply to Tank 407 has not caused quality problems todate. The remainder of the project will be installed before winter. New Blades for Reactor 600 New larger blades for reactor 600 have been ordered. This is part of the larger batch study that is on-going. When the production schedule will allow, the new blades will be in stalled. R&D and the Plant can then continue the larger batch development work that has been taking place. Plant: Wet Aj t- and Instrument Air Work on the Class "A" design and definitive estimate continues. An alternate compressor has been identified with the possibility of reducing operating costs by $60M per year. Iron Sludge Disposal Removal Gravity Flow Systems Inc. is expected to be in Aberdeen midAugust to perform a test run using their sludge dewatering system. ABD00311917 ENGINEERING - Continued P-1 Reactor Header Modifications A definitive estimate has been completed. An AFE submittal form has been completed and sent to Houston. Boiler 4 Addition Project Design calculations by the fabricator for the new blowdown flash tank were approved by GED. Fabrication of the vessel should be complete in mid-August and installation of the vessel complete by September. Boiler Blowdown Heat Recovery Construction is in progress. August. Start-up is scheduled for Cascade Boiler Blowdown A miscellaneous capital request was approved for piping revisions to circulate hot boiler blowdown from the on-line boilers to the off-line boiler. This project will provide for faster start-up of Boiler 1 or 2 and will provide protection from corrosion when the boiler is not in use. Bullets for Inerts Pressure Reduction An unallocated AFE was submitted to start getting the bullets put back in service. This project has the potential of greatly improving reactor recovering times. Calcium fifcflarate Addition Upgrade A project for upgrading calcium stearate addition to 5385 is currently being redesigned based on the suggestions from the preliminary review. Activator Reliability Improvements This project moves the activator controls from the field to the DCS. Operators will be able to reduce activator cycle times through optimization. The Class "A" design has been issued and an estimate is scheduled for the end of August. CRC Replacement for Catalyst Freezers This project will replace the existing catalyst day freezers with industrial grade freezers equipped with non-regulated HFC refrigerant. This project will also replace the old water cooled refrigeration units for the walk-in catalyst freezers with new air cooled units. All the walk-in units will finally be equipped with non-regulated HFC refrigerants. ABD00311918 ENGINEERING - Continued Fluid Bed Feed Conveyor Revisions The Niro Company is working on a proposal to replace the existing single fluid bed feed screw conveyor with two vibrating bin conveyors. The system will reduce downtime and make repairs easier and less costly. ENVIRONMENTAL - K. G. Akins Water All wastewater discharge parameters were within permitted limits for the month of July. flrmindwater Field work began in July on the TCE plume bioremediation pilot study. KEY ENVIRONMENTAL COMPLIANCE DATA MONTH FYTD Stormwater Outfall Excursions Wastewater Outfall Excursions Reportable NESHAP Excursions Reportable non-NESHAP Air Excursions CERCLA/SARA Reportable Incidents Other Reportable Incidents Citations and NOV's Received 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ABERDEEN ENERGY EFFICIENCY BTU/LB TOTAL PRODUCTION BTU/LB MONTH