Document aBOed8Bq78QpBqxjNO696dmDa

SAFETY - A. H. Sather Occupational Injuries Injuries Treated January 1931 Year to Date 1980 Year to Date First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time 2 0 0 0 0 2 0 0 0 0 5 0 0 0 0 Injuries By Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 0 1 1 0 0 0 0 1 1 0 0 0 2 1 0 0 0 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 22 00 00 00 00 00 3 1 0 1 0 0 As of January 31. 1981, the Plant operated 573 days or 742,348 manhours without a disabling injury. Also, the Plant operated 164 days without an injury which required medical treatment. Safety Meetings The topics for January Safety Meetings were ''Hazards of Winter Operations" and "Fork Lift Truck Safety". The discussion of these topics included use of the sand and salt drums, repair of leaks, avoidance of water covered areas, and the effects of winter on fork lift truck operation. New Employee Orientation A total of four (4) new casual employees received new employee orientation. Health Testing Orientation T. G. Grumbles - Chemicals, Houston, and Dr. W. W. Massad - Medical Division, Ponca City conducted an orientation about the new health testing program. The new program will use Health Examinetics from White Plans New York for the clinical work and Dr. Massad will conduce the physicals. -1- DTH 000043747 SAFETY - (continued) First Aid Training V. A. Belk, Plant Nurse, conducted a review first aid course for the Laboratory Off Shift First Aid Staff during the reporting period. OSHA Compliance Activity for the reporting period was limited to routine dosimetry and a Lead Standard Compliance Status Meeting. The results of the dosimetry and overexposures are shown below. Results Chemical Less Than PEL Number Percent Greater or Equal to PEL Number Percent VCM Lead An timony Total Particulates 67 k 6 5 100 67 100 100 00 2 33 00 00 Overexposures Overexposures to lead occurred to compounders in the Compound Department. One occurred during the charging of blenders while the other occurred in the Color Weigh Room. "Airhat" respirators were being worn at the time of sampling. -2- DTH 000C)43r;,48 VINYL - P. E. Markey Month Year to Date 1. Total Production, MM Lbs. 2. Production Rate, M Lbs./C.D. 3- Charges, Reactor Batches/C.D. 4. Total Charges 5. Reactor Stream Factor, % 6. Dryer Rates, Average Lbs./Hr. (on-stream) 7. Dryer Stream Factor 8. Accounting Days 27.8 897 21.1 65** 87-7 5947 89-8 31 27.8 897 21.1 65** 87.7 5947 89.8 31 Vinyl Department production for January was 108?; of budget at 27.8 MM pounds. Reactor and dryer stream factors were 87.7? and 89.8? respectively. The major items affecting stream factor and production were: 1. Maintenance on reactor seals resulted in a 2.1? reactor stream factor penalty. 2. Condenser cleaning work on 7**3 and 7**** reactors resulted in a 1.4? reactor stream factor penalty. 3. Maintenance on reactor gearboxes resulted in a 0.9% reactor stream factor penalty. 4. During the above mentioned reactor downtimes, excess dryer capacity was used to perform maintenance on dust collectors and debag off-grade resin. The resulting dryer stream factor penalty was 2.0?. A number of smaller stream factor penalties comprised the balance of dryer downtime. Resin Quality Summary Resin Type Pr ime Pounds "BC" Grade "H" Grade ? of Total Product ion 5305 5385 1 ,868,591 14,632,479 181,450 54,750 35,250 6.9 71.6 5425 4,606,263 5465 955,130 Sifter Overflow - TOTAL 27,062,463 Quality performance for January was 97 1.6? "H" grade. 13,500 - 123,000 - 17.1 3-5 - 246,605 0.9 194,950 459,605 100.0 customer grade with 0,7? "BC" and -3- DTH 000043749 VINYL - (continued) Cost The variable cost variance for January was favorable $1,663 M with $1,709 M due to price and ($46 M) due to efficiency. The major price variance was $1,714 M due to monomer pricing. Unfavorable efficiency variances of $55-7 M for VCM and $21.3 M due to off-grade product ion were partially offset by a favorable combined additive variance of $28.8 M and $2.5 M due to product mix. The monomer raw material requirement for January was 1.02789 pounds VCM/ pound resin versus the 1.01936 standard. General 1. Resin packaging for January totaled 5-9 MM pounds. Debagging activities upgraded 65 M pounds to customer grade resin. 2. A limited test run was conducted to determine the feasibility of using 3% Methocel concentration versus the current 1.5% concentration levels. No problems were encountered. 3. Testing was started to determine the potential cost savings of double flushing initiator to the reactors. -4- DTH 000043750 COMPOUND - J. R. McCrimon Compound Production Month Per Day Year to Date Line I , M Pounds Line V, M Pounds Line 111, M Pounds Total, M Pounds Accounting Days 1,341 153 3,010 4,504 31 48 51 97 145 1,341 153 3,010 4,504 31 Line I operated 28 days during January at an average rate of 48 M pounds per day. Major items affecting production efficiency were: Dicers (36.1 hours), product changes (36.0 hours), conveyor bucket (22.3 hours), quality control (16.0 hours), bag charging resin (12.9 hours), skip hoist (7-9 hours), Banbury (6.5 hours), and mill (5-3 hours). Line V operated 3 days during January at an average of 51 M pounds per day. Major items affecting production efficiency were: quality control (8.5 hours), and putting up raw materials (5-1 hours). Line III operated 31 days during January at an average rate of 97 M pounds per day. Line III production was affected by: product changes (55.2 hours), mill (18.5 hours), and quality control (12.0 hours). Quality performance for flexible compounds was 3.4% off-grade of which 70.2% was due to mill scrap. "BC" production was 1.9%. The raw material requirement for flexible compounds was 1.00194 pounds of raw material per pound of compound versus a 1.01301 standard. (Y.T.D. is 1.00194). The variable cost variance for compound was $58.6 M with $37-3 M due to price and $21.3 M due to efficiency. The variance due to product mix was $20.3 M. There were no major efficiency variances. The only major price variance was $10.4 M for D1DP which is due to DIDP cost less than budget by about $0.02 per pound. Dry Blend Month Per Day Year to Date Production, M pounds Accounting Days 3,470 31 158 3,470 31 Dry Blend operated 22 days during January at an average rate of 158 M pounds per day. Production included 80174, 80273G, and 90171- Dry Blend production was affected by: quality adjustments (46.6 hours), boxing limited (17.3 hours), transfer line pluggages (10.0 hours), product changes (5-6 hours), and scale vibrator (5.4 hours). Quality performance for the month was 99-98% customer grade. -5- DTH 000043751 COMPOUND - (continued) Dry Blend - (continued) The raw material requirement for dry blend was 1.01364 pounds of raw material per pound of dry blend versus a standard of 1.00580. (Y.T.D. is 1.01384.) The variable cost variance for dry blend was $34.9 M with $12.0 M due to price and $22.9 M due to efficiency. The variance due to mix was $33-9 M. There were no major price or efficiency variances for January. Dry Blend raw material, AC-629-A was found to produce long fusion times and low torque. A new raw material, Epolene E14P was substituted for the AC-629A to resolve quality problems in 80273G. PIasticizer Month Per Day Year to Date Production, M Pounds Accounting Days 1,126 31 59 1,126 31 Plasticizer operated 19 days during January at an average rate of 59 M pounds per day. Production included: DIDP, 610P, and D0P. VRP production totaled 143 M pounds (11.3^)- Production was limited by: safety disc change (R-2) and steam restrictions (boiler repairs). VRP production was higher due to implementing a new method of filtering rag layer to recover more plasticizer (VRP.) from the rag layer. The raw material requirement for plasticizer was 1.12580 pounds of raw materials per pound of plasticizer versus a 1.10500 standard. (Y.T.D. is 1.12580.) The variable cost for plasticizer was $43.2 M with $41.1 M due to price and $2.1 M due to efficiency. Major price variances were: $15-5 M for 2 ethylhexanol and $13-2 M for phthalic anhydride. Major efficiency variances for the month were $11.4 M for isodecyl and ($17-8 M) for phthalic anhydride. The variance due to product mix was ($0.95 M). General Total customer grade compound inventory increased from 5*8 to 6.2 MM pounds during January. -6- DTH 00004375 MAINTENANCE - S. J. Vincent Vinyl There were two large reactor gearbox failures. Four reactor seals failed and two reactor condensers were cleaned in this period. The gearbox failures were on the D-500 reactor in the old module and on the 741 reactor in the new module. Two seal failures were on the D-500 reactor in the old module and two on the 742 reactor in the new module. Both condensers were cleaned in the new module on 743 and 744 reactors. The safety valves were tested on 743 reactor and all safety discs were replaced. The actuator on 744 reactor dump valve sheared its retaining bolts and had to be repaired. There were six pump and compressor seals replaced this period. All seals re placed were in the old module - the "A" recovery compressor outboard seal, "B" water charge pump, rinse pump, RVCM charge pump and twice on the west RVCM return pump. Drum heater enclosures were fabricated for both modules. A new level controller was installed in the new module blowdown tank. In the vinyl unloading area both 490 Corken compressors were overhauled. Repairs to vinyl drying equipment included P.M. inspections that were completed on 2 and #6 dryer trains. The stack was replaced on the #4 exhauster, the #2 day collector star valve was rebuilt, the north 407 slurry pump was overhauled and the large 281 transfer blower was replaced. Belts were replaced on the #1 and #6 Birds. Several blend tank level transmitters were calibrated. The remote lighting system was repaired on #2 and #5 dryer controls. Compound - Plasticizer - Dry Blend and Resin Storage Major repairs to the compounding equipment included replacing the conveyor drive gearbox on line I and repairing steam leaks on line III. The line III orifice gate temperature was calibrated. Projects in the compound area were to fabricate three tote bin racks, build a platform to pull the twin screws on line V and to replace the 36" conveyor belt on the automatic bag stacker. In the plasticizer unit new seals were installed in the Schenk filter and steam leaks were repaired. The safety discs were replaced on R-l, 3 and 4 reactors. Repairs in the dry blend unit were to patch the #2 Wei ex bowl and weld cracks on the south Kason unit. The dry blend product transfer blower was replaced, along with, the star valve under "A", "B" and "D" blenders. Bearings were replaced in the "B" blender gearbox and new supports were installed to reanchor "A" and "D" blender gearboxes. During the repair work on the Welex bowl, panel wiring changes were completed and all motor starters were placed in the switchgear room. -7- DTH 000043753 MAINTENANCE - (continued) Utilities and Service There were five repairs to the plant air compressors. Valves were repaired in the #5 and #6 compressors, the low stage end on #8 compressor was overhauled and leaking inter cooler tubes plugged. The oil pump was replaced on the west Joy compressor. The outlet valves were replaced on the Del tech air dryer. Four pumps were overhauled in the utility area. The #2 boiler was down to repair a tube. Oxygen analyzers were installed on all three boilers. The 350 HP expansion cooling tower motor was installed and is performing satisfactorily. Planner There were 103 work orders planned and material ordered for 28 projects, eighteen invoice registers were closed and twenty new registers were issued, eighteen statements were processed for payment. The equipment history and safety valve records were updated. Mi seellaneous Two 1000 KVA transformers that had previously been removed were returned to the city of Aberdeen. -8- DTH 000043754 MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved, and Closed The following AFE's were submitted and approved during January: AFE No. Title Authorized 9511 9521 9531 9541 Miscellaneous Projects Under $10,000 New VCM Rai1 spur Vinyl Initiator Charge Pots VCM Tank Farm Modifications $170,000 11,000 165,000 90,000 A completion report was issued for the following AFE: AFE No. Title Authorized 9148 Plasticizer Chemical Exposure Abatement $152,000 The following AFE's were closed to field charges during January AFE No. Title Authorized 9559 9010 Color Weigh Room Modifications Centrifuge Rotor Repair $ 25,000 20,000 Design Design work is in progress on the following projects: Fixed Point Monitor Data Computer and Warning Lights - Spare Inert Incinerator Batch Water Stripping Resin Reclaim System Reactor Pressure Relief Modifications Emergency AMS Kill System Plasticizer Irritant Control Breathing Air Modifications AFE Activity 1. AFE 9709 ~ Facilities for Multigrade Resin Production - G. Kreutzer Design is complete. Painting and insulation bid packages are being issued. Construction is in progress. 2. AFE 9729 - Fire Protection Improvements - Phase II - M. Ingle Underground piping is complete. The contract has been let for construction of the pump building. -9- DTH 000043755 MECHANICAL ENGINEERING - (continued) AFE Activity - (continued) 3. AFE 9530 ~ Spare Incinerator - J. L. White Overall project design is 75% complete. The concrete package is out for bids. 1*. AFE 9590 ~ Critical Spare Equipment - J. P. McKee The condenser is on order and delivery is June, 1981. 5. AFE 9630 ~ Water Stripping - M. Ingle Design work is complete The piping and equipment erection work has been let and construction is in progress. 6. AFE 9680 - Fixed Point Monitor Data Computer & Warning Lights - R. B. Harned Design is 70% complete and we are awaiting details on the computer to gas chromatograph wiring. Software development is in progress. 7. AFE 80-395 ~ Interpiant Communications - Phase III - R. B. Harned Construction has continued in a limited way during January. Weather conditions have slowed the trenching for conduit runs. All material has been received for this project. 8. AFE 969O - Breathing Air Modifications - J. L. White The vessel has been placed on order and plan drawings are being reviewed. 9. AFE 9760 ~ Emergency AMS Kill System -J. L. White Quotes have been received on long lead items. A vessel drawing is being circulated for approval. 10. AFE 9770 ~ Reactor Pressure Relief Modifications - J. L. White The relief valves, safety head, rupture discs and studding outlets are on order. Drawings of studding outlet locations are being circulated for approval. Construct ion - G. A. Morgan The alcohol unloading spill prevention project was completed the last week in January. Fifteen contracts were let during January. Nine of these were for annual time and material contracts. Six contracts were let for the following: -10- DTH 000043756 MECHANICAL ENGINEERING - (continued) Construction - (continued) 1. Fire Protection Improvements Phase II Pump Building 2. New Air Dryer Shed 3. PVC Resin Expansion Piping, Equipment and Structural Installation A. Batch Water Stripping Piping, Equipment and Structural Installation 5- Disposal of Hazardous Chemical Waste 6. Plant Vegetation Control The following projects became operational in January: 1. The Alcohol Unloading Spill Prevention Project 2. The API Clean Water Bypass Project Thirty-six register tickets were issued during January. -11- DTH 00o04 (1) Thru December, 1980 Actual Accounting (2) Thru January, 1981 ABERPEF.N AUTHORIZATIONS RETORT AllTIl. CAPITAL NO. DESCRIPTION DATE Ainu. APPROVED AFE AMT. (1) (2) FINAL EXPENDED COMMITTED TOTAL GST. TO DATE TO DATE COST COMP. UNDER (OVER) AUTII. .AMT. EST. EST, COMP. CL0S, DATE DATE REMARKS 9237 9519 9559 9589 9609 Heated Plasticizer Addition System Critical Spare Equipment Color Weigh Room Modifications Instrument Air Dryer Reactor Inert Vent System io/u/77 2/6/79 6/19/79 5/30/79 6/28/79 37,000 175,000 25,000 110,000 90,000 15,098 163,081 18,853 91,967 16,561 36,992 166,665 20,268 99,888 16,561 37.000 166,665 25,000 110,000 90,000 0 8,535 0 0 0 12/80 3/81 12/80 3/81 1/81 6/81 2/81 5/81 12/81 3/82 Closed to field charges. Closed to field charges. * Closed to field charges. Revisions in progress. Project on hold. 9629 9639 96*19 9669 9689 Air Compressor Revisions to Emission Recovery System Double Block Valves for VCM Charge New Air Header Diking of Sphere & Curbing of Drum Storage Areas 7/9/79 7/12/79 7/18/79 8/15/79 9/15/79 360,000 100,000 276,563 283,077 76,587 78,517 182,000 25,000 170,000 168,083 18,003 127,567 168,083 19.369 132,768 360,000. 100,000 0 3/81 6/81 Revisions in progress. 0 3/81 6/81 Revisions in progress. 168,083 25,000 170,000 13,917 0 0 12/80 3/81 2/81 5/81 3/81 6/81 Closed to field charges. Revisions In progress. Construction in progress. 9699 9709 Plant Oryer Debottlenecking Facilities for Multiple Grade Resin Production 9/15/79 9/20/79 80,000 870,000 16,570 81,840 58,630 568,075 80,000 870,000 0 8/81 11/81 Construction in progress. 0 8/81 11/81 Construction in progress. 9719 9729 Aberdeen PVC Resin Expansion Ffre Protection Improvements Phase 11 9/10/79 10/1/79 850,000 690,000 11,621 135,698 860,000 237,623 860,000 690,000 ( 10,000) 0 8/81 11/81 Reactors to ship 3/VSl. 6/81 9/81 Construction in progress. 9739 9759 9510 Methocei Charge Revision Aberdeen PVC Resin Expansion Miscellaneous Projects Under $10,000 10/3/79 66,000 39,376 61,662 66,000 12/10/79 n,150,000 2,959,579 7,232,300 u,150,000 1/3/80 150,000 115,378 156,110 150,000 0 2/81 5/81 Project operational. 0 9/81 12/81 Piping contract let. 0 12/80 3/81 Closed to field charges. 9530 9550 9560 9570 9580 9590 9600 9610 9630 9650 9660 9670 9680 9690 9700 9710 9720 9730 9760 9750 9760 Spare Incinerator P. A. Handling Improvement Safety Equipment Replace T-100 P.A. Tank Boiler Economizers Critical Spare Equipment Calcium Stearate Addition System API Clean Water Bypass Water Stripping Miscellaneous Projects Under $10,000 Hot Water Charge Tank Replacement Laboratory Equipment Fixed Point Monitor Data Computer and Warning Lights Breathing Air Modifications Compound Fines & Streamers Removal Fire Protection - Phase 111 Reactor Agitator Replacement Compound Line III Debottlenecking Modifications to Hake Profile Ory Blend Rotary Dryer Insulation (Energy) Emergency AMS Kill System 1/23/80 3/3/80 3/12/80 3/27/80 3/26/80 3/26/80 6/2/80 6/15/80 6/30/80 5/30/80 650,000 63,000 25,000 119,000 160,000 59,000 86,000 23,000 810,000 150,000 6/6/80 7/9/80 9/6/80 160,000 32,000 113,000 9/9/80 21,000 10/1/80 95,000 10/16/80 385,000 10/16/80 620,000 10/16/80 1.350,000 10/27/80 200,000 11/10/80 11/15/80 22,000 335,000 15,392 279,537 28,030 33,966 7,866 11,185 58,167 62,366 166,695 166,701 10,798 60,386 629 1-1,062 16,667 17,690 71,708 322,202 95,866 171,918 650,000' 0 63,000 0 25,000 0 119,000 0 166,701 ( 6,701) 60,386 ( 1,386) .86,000 0 23,000 0 810,000 0 150,000 0 6/81 9/81 12/81 3/82 3/81 6/81 12/81 3/82 12/80 3/81 3/81 6/81 5/81 8/81 3/81 6/81 6/81 9/81 12/80 3/81 Engineering in progress CED Project on hold. Evaluating bids. Project on hold. Closed to field charges. Condenser to ship 6/31. Engineering in progress. Project operational. Construction in progress. Closed to field charges. 52,368 31,587 708 136,155 32,667 38,020 160,000 32,667 113,000 ( 0 667) 0 2/81 5/81 Project operational. 12/80 3/81 Closed to field charges. 9/81 : 12/81 Engineering In progress. 1,266 0 0 0 0 0 5,265 0 0 190,890 0 13,967 21,000 95,000 385,000 620,000 1 ,350.000 200,000 0 3/81 6/81 Engineering in progress. 0 io/8! 1/82 Engineering scheduled 0 10/81 1/82 Engineering scheduled CED. 0 10/81 1/02 Agitators to ship 5/3 0 10/81 1/82 Engineering Scheduled 0 10/81 1/82 Engineering scheduled. 0 27,391 00 27,331 335,000 ( 5.391) 0 2/81 3/8l Insulation in progress. 8/81 11/81 Engineering In progress. i/L'i-i UC0043758 12- (1) Thru December, 1980 Actual Accounting (2) Thru January, 1931 Airm. CAPITAL NO. description ABERDEEN AUTHORIZATIONS REPORT DATE Ainu. APPROVED AFE AMT. (1) EXPENDED TO DATE (2) FINAL COMMUTED TOTAL ESI. TO DATE COST COMP. UNDER (OVER) auth. AMT. EST. EST. COMP. CEOS. DATE DATE REMARKS 9770 9780 9790 9800 9810 Reactor Pressure Relief Modifications Centrace Heat Recovery Resin Reclaim System Plasticizer Irritant Control (Air) Replacement Gearbox for Farrell Mixer u/25/80 12/8/80 12/14/80 12/15/80 12/18/80 560,000 300,000 727,000 80,000 73,000 0 226,194 00 00 00 0 69,400 560.000 300,000 727,000 80,000 73,000 0 12/81 3/82 Engineering in progress. 0 3/82 6/82 Engineering scheduled. 0 3/82 6/82 Engineering in progress CED. Q 9/81 12/81 Engineering in progress. 0 9/81 12/81 Gearbox to ship 9/Sl. 9511 Miscellaneous Projects Under $10,000 1/9/81 170,000 0 3,829 170,000 0 12/81 3/82 Three projects approved. 9521 New VCM Rail spur 1/30/81 9531 Vinyl Initiator Charge Pots 1/21/81 952*1 VCM Tank Farm Modifications 1/21/81 80-395 Interplant Communication - Phase III 1/22/80 11,000 165,000 90,000 55,000 00 00 00 0 21,683 11,000 165,000 90,000 55,000 0 5/81 8/81 Engineering in progress. 0 11/81 2/82 Engineering scheduled. 0 1/82 4/82 Engineering scheduled. 0 6/81 9/81 Construction in progress. 9010 9020 EXPENSE Centrifuge Rotor Repair Repairs to Line 1 Compounder 9/19/80 11/24/80 20,000 38,000 16,650 0 16,650 0 16,650 38,000 ' 0 1/81 4/81 Closed to field changes. 0 11/81 2/72 . Parts ordered in January. -13- DTH 0000437b9 J. L. Carter - Personnel EMPLOYMENT Charles E. Morris - General Helper William J. Davis - General Helper James Curlee - Casual Labor Cal lie Tallie - Casual Labor Craig Miller - Casual Labor Homer Awtry - Casual Labor TO/FROM LEAVE OF ABSENCE Steve C. Hillman - Process Engineer TRANSFER/PROMOTION Donald G. Bennett promoted from Lab Trainee to Lab Technician "A" RETIREMENT Quinton Thompson, General Mechanical "A" TERMINATION Lexie Williams, Casual Labor OTHER During December there were 21 casual labor employees on payroll. Total hours worked were 2726.75- -14- DTH 000043760 CONOCO CHEMICALS Aberdeen, Mississippi January 1981 MONTHLY PERSONNEL REPORT Salaried Employees Hourly Employees Total Employees 80* 156 236* Minority Employees # Salaried 6 Hourly 58 % 7.5% 17% Employees (Hourly) New Employees Terminations 2 0 Total Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 0 0 0 Sti 27% DEPARTMENTS PAR # EMPLOYEES MIN. EHP. . % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse Gen. Plant Maintenance Laboratory 9 10 46 22 9 12 45 21 2 3 7 ___ 3 22%__ 25% ]5% ]k% 0Q_ 2_____ _2_ 00 00 0 _Q_ 00 1 ** 1 ** 00 0 0 0 0 0 0 0 Q_ CM Compound 37 33 82% 0 0 0 0 0 0 Vinyl 32 32 13 ko% 0 0 0 0 0 0_ Plasticizer 5 k 3 75% 0 0 0 0 0 0 Number of Applicants: Month 8 Year to Date 8 APPLICANT BREAKDOWN: # Minority 2 % Minority 25% # Female 0 % Female ___ 0_ includes three (3) temporary employees. **lncludes one (l) reti.rement (effective December 1980) and is not counted in turnover rates. Hires (Hourly) : Month 2 Year to Date Terminations (Hourly) : Month 1** Year to Date Overall Turnover 0 Projected Annual Turnover 2 1 ** 0 -15- DTH 000043761 OVERTIME AND ABSENTEEISM e* NO 00 O O NO O o cn Q10 J+c=*r I TO P- 00 <m*? <r**<>- &--e -- -- -- \\ &CT$N M *J u cn ft) > 4- 0*e9r-\ o o 0C0T\ ft) E -o -- a> H .X k. cn o o o cn o. o o o 4J o r-*- o m o r- o o o o CTjc 3C -- <o TO U i- 3 r-*. cn <r\ nO rn. NO nO m <N o ON cn -3" NO o r^. VO -- r-N NO in r- cn o O o f-s. cn f-** wo fsj cn x to c o to c o <u0 ft) T3>- ro O. O c M X T>O* in XI to x: *-j cn to a) _x Ou2 c *o o cTO to i_ 3 > O <D0 X <0 O XT TO 3cn a> C oo c to .x 3u O 2 IV *D C IV cn 0) T>O- *3 a> co _x v. ID O 2C o O to i_ 3 o i <0 *3 O ft) > fut). o cn cn c c T9 lx u 3o 5 O XO ft) a> E a) > o IV -C V ft) > o X) 0) XITIJ O oo 4) 4-1 zO I vO DTH 00004 rn PROCESS ENGINEERING - R. A. Frohreich A. Expansion Project The mechanical contract for the project was awarded to Energy Plant Constructors of Houston, Texas. A set-up crew for the contractor is already on site. Concrete work in all areas continues with the reactor areas and slurry blend tank area nearing completion. Review of V-11 chem wash system piping, electrical and instrumentation has begun. B. Reactor Emergency Cooling System Process Engineering is continuing to provide assistance to PED on this project. C. Donnelly Mirror Compound Testing A test run was held at B.A.G. Corporation to determine the size of the discharge opening needed for the "Super Sac" containers. Work has begun on a process design for filling the continers. D. Plasticizer Initiator Handling System A review meeting was held on this design. Process Engineering is planning a test run using a solid initiator as a replacement for the liquid PTSA presently used. E. Capacity to Receive OKC Resin The class "A" process design to handle pond resin from the Oklahoma City plant was issued. A review meeting on the design was held and comments are being incorporated in the design. F. Rigid Pelletized Compound Production - Line V The class "A" design to produce rigid compounds on Line V is underway. G. Compound Line I Modernization The, class "A" design on this project is underway. H. Reactor Agitator Replacement - D-300 and D-400 A review meeting on this project was held and review comments were incorporated in the design. I. Line III Mill Temperature Control Work on the process design to provide a new mill heating system continued. J. Plasticizer Spill Containment The class "A" design for the project is being prepared. -17- DTH 000043763 PROCESS ENGINEERING - (continued) K. Cooling Tower Blowdown Bypass The class "A" design to divert any cooling tower blowdown directly to number six pond was issued. L. Recovery System Revisions The class "A" design on this project is In progress. Revisions include increasing knockout pot water circulation, rate improving solids removal, and recovery system instrumentation. M. Dry Blend Production Rates Recommendations on improving dry blend rates were issued. Follow-up on these items continues. N. Rag Layer Reduction A test run using sodium borohydride instead of carbon black to remove color in plasticizer has been planned. Process Engineering is working with production to complete the test. O. Rag Layer Filtration Filtration of Rag layer to produce VRP was successful. Rag layer will continue to be filtered as allowed by the plasticizer production schedule. P. Explosive Mixture Monitor The class "A" design to monitor the dryer burner area for explosive mixtures of natural gas is being prepared. Q. Slurry Delumper The class "A" design to install a delumper to reduce oversize materail from coarse batches is being prepared. R. Normal Kill Solution Addition System The class "A" design for this project was issued. S. Compound Sewer Revisions A design to eliminate the possibility of spilled plasticizer entering the storm sewer is being prepared. T. VCM Flexible Hose Evaluation An evaluation of flexible hoses used in VCM service is being prepared. U. Variabi1ity Test Run Process Engineering is providing support for the variability test run. -18- DTH 000043764 PROCESS ENGINEERING - (continued) V. Sifter Overflow System Process Engineering assisted the Mechanical Group in the design of a temporary sifter overflow system. -19- DTH 000043765 ENVIRONMENTAL V. E. Messick Particulates One dryer was sampled for particulates in January and was within allowable limits. Water Effluent parameters for BOD exceeded allowable limits on January 14 and January 21 due to high loadings on the waste treatment system. Sludge was removed from the API separator to allow more residence time for the organics to separate. The suspended solids from storm water effluent 002 exceeded allowable limits. This settling pit was cleaned out to allow more residence time for sol ids to settle. The Quarterly NPDES Discharge Monitoring Report was issued. VCM The comprehensive VCM survey was completed and issued. Hazardous Waste Management A total of 232 drums of waste material was shipped to Chemical Waste Management's Alabama site for disposal. Waste material profile sheets for plasticizer filter cake were sent to Chemical Waste Management in order to receive approval to dispose of this waste at their site. The RCRA Contingency Plan is being prepared. Other The Aberdeen Chemical Plant Pollution Control Manual is being prepared. The updated OSHA Engineering and Work Practice Control Plan was issued. -20- DTH 000043766 Flow GPM Jan. - Ave. 1069 Max. 1297 Feb. - Ave. Max. Mar. - Ave. Max. Apr. - Ave. Max. May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. TABLE I - WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB./DY. COD PPM LB./DY. Sus. Solids PPM LB./DY. 39 504 57 887 69 888 106 1650 7 93 9 114 Diss. 02 8.5-10.4 ph 7-4-7.8 NPDES - Ave. Max. 32 387 43 520 - 1390 - 1940 - 605 >6.0 - 909 6.0-8.5 -21- DTH 000043767 ENERGY CONSERVATION - J. F. Perez-Velasco I . Plant Operations Total energy consumption for January was 119.383 MMM BTU's. The energy consumption per pound of product increased to 3209 BTU/lb. as compared with 3131 BTU/lb. for December. I * Plant Energy Conservation Program Steam Leaks Fifteen (15) steam leaks were repaired in January. Dryer Insulation Installation of additional insulation on the rotary dryers was started in January. -22- DTH 000043768 ITEM Production, MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Propane Consumption, M Gal, Conversion, BTU/Gal. Energy Consumption, MMM BTU Total Energy Consumption, MMM BTU Energy Consumption , BTU/Lb. Boiler Operating Data No. 1 No. 2 No. 3 ENERGY CONSERVATION DATA 1981 January 1980 January 27.8 3-5 4.7 1.3 37-2 30.3 1.9 3.0 0.3 35.5 67042 1020 68.383 5.0888 10000 50.888 59554 1020 60.745 5-1456 10000 .51.456 1.224 92000 0.113 20.544 92000 1.890 119.383 3209 114.091 3214 Avg. Stack Temp. 1981 1980 264 389 30 4 *13 260 418 Avg. % Excess Air lsSl 1980 26 19 29 20 25 22 -23- DTH 000043769 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Report By Master Fence 45541 Natural Burning During Processing RDJ WAIVERS RECEIVED Date Identification Product Customer Reason Waived By 1/20 PTLX 41856 5305 Intex Viscosity RDJ 1/20 CONX 45737 5465 3M Contamination ELK PRODUCT SERVICE AND DEVELOPMENT Sample Shipments Ship Date Product Amount (Lbs.) Customer Requested By 1/6 5305 50 Genova, Inc. JFN 1/8 5425 5465 5 Product Specialties 5 KJQ. 1/9 VRP 3 gal. Heritage International WR 1/9 5385-1 200 Conoco Inc. PAS 1/13 5385-3 1000 Certain Teed COEDS 1/15 DIDP 1 gal . Diamond Shamrock SKS 1/16 5385-1 100 Anderson Corp. MED 1/17 35441 Nat. 50 Lenz Electric Mfg. Co. MFM 1/18 5425-1 10 Bata Shoe RNG 1/20 5385-1 200 General Binding COEDS 1/20 5385-1 4 Conoco Inc. PAS 1/21 1/21 DIDP DOP 27121 Nat. 44461 Blk. 48562 Blk. 3 x 55 gal. 2 x 55 gal. 50 50 50 Conoco Inc. Conoco Inc. MG LW 1/22 1/30 5425-1 5385 4500 1000 Essex Wire & Cable Conoco Inc. -24- JFN PEM DTH 000043770 LABORATORY - (continued) PRODUCT DEVELOPMENT AND SERVICE - (continued) Special Compound Testing Complete specification tests were run on 2 samples of 36861 Natural, 1 sample of 648-B Natural and 2 samples of 34861 Gray 546 for Western Electric. Plasticizer content and f1amroabi1ity were tested on another railcar of 34861 Gray 546. Tests were run on one sample of 34533 Natural for Packard Electric. New Compound Specifications were established and standards were prepared for a new compound (4184-82), proposed as a replacement for 38551. Dry Blend Development Wei ex batches of 80174 were prepared for use as a quality control standard. QUALITY CONTROL TESTING Resi n Regular Samples = 387 Bag Samples = 149 Other In-Process Samples = 3428 Bulk Shipments = 183 (Railcars = 79; Trucks = 104) Dry Blend Blenders Produced = 393 Blenders Tested = 328 Blenders Adjusted = 10.9% Other In-Process Samples = 519 Bulk Shipments = 50 (Rai1 cars = 11; Trucks = 39) Compound Blenders Produced - 734 Blenders Adjusted = 1.5% Line V Production = 18 skids; 126 boxes Other In-Process Samples = 834 Bulk Shipments = 20 (Railcars = 9; Trucks = 11 ) Resin Heat Stability Fifty seven (57) resin samples tested for oven heat stability. 5385 5425 5305 5465 23 Samples 21 Samples 11 Samples 2 Samples The 5385 resin averaged slightly poorer than the control; the other resins averaged slightly better. 5305 resin was inconsistent with respect to heat stability. -25- DTH 000043771 LABORATORY - (continued) QUALITY CONTROL TESTING - (continued) RVCM of Shipments A total of 145 shipment samples were tested for residual VCM in January. Only one shipment, a 5305 truck, was found to be greater than 10 ppm and had to be off loaded. A summary by product is below. Product 5305 5385 5425 5465 Dry Blend Average RVCM, ppm 2.7 1.4 0.4 0.1 0.4 Number of Samples 66 49 15 5 10 Inherent Viscosity The viscosity sample load continued to be high in January. A total of 709 samples were tested. MISCELLANEOUS PROJECTS Plasticizer Analysis Routine analysis of plasticizer tank samples revealed severe cross contamina tion of the DIDP. Much work was done to identify where the contamination started and stopped in finished compound. Raw Material Testing One hundred two (102) lots of raw material were tested during January. The SP-33 clay continues to give problems with low volume resistivity, and two truck loads were rejected. One truck load of Hydral 710 was rejected because it did not disperse properly. One lot of Ongard 2 was also rejected for poor dispersion. A sample of Satintone No. 2 clay was tested and compared with SP-33- Results indicate that Satintone No. 2 will give a higher volume resistivity than current SP-33> and it was recommended that the plant buy some of this clay. The SP-33 is slightly better in color. The oiled version of DS-207 (dibasic lead stearate) disperses satisfactorily and appears to perform as well as the unoiled version. Due to the high dust levels of unoiled DS 207, the oiled version will be purchased in the future. Samples of epoxidized soybean oil from two suppliers (Union Carbide Flexol EP0, Viking Vikoflex 7170) were tested and found equivalent to the ES0 currently used in compounds. RVCM of Slurry A total of 657 slurry batches were tested for RVCM in January. The overall average was 188 ppm. There were no daily averages over 400 ppm. -26- DTH 000043772 LABORATORY - (continued) MISCELLANEOUS PROJECTS - (continued) Residual VCM of Blowdown Tank Water A total of 144 samples of water from the blowdown tanks were tested for VCM. The January average was 2.8 ppm, only 3 samples exceeded 10 ppm. Personnel Dosimetry A total of 108 carbon badge samples were tested for VCM in January. Water Qua! ity A total of 59 COD's were run in January due to problems with the plant outfa11. L & N Microtrac The problem of very cold water experienced in December was solved by installing a warm water line. Since 1/23/81 each reactor batch has had the particle size measured on the Microtrac. The reactor to reactor variation has been measured. QC people are running parallel analysis on regular sample using Microtrac and screens. The data will be used to obtain necessary information to set plant guidelines for the Microtrac. -27- DTH 000043773 TRANSPORTATION - J. E. Stark Shipment by Product - M/Lbs. January Year to Date Res i n Plasticizer Dry Blend Compound TOTAL 23,131 122 3,099 4,339 30,691 23,131 122 3,099 4,339 30,691 Number of Shipments by Mode 0.T. O.T. R/C Buik Van C.O.T. C.C. T0FC CPU TOTAL Resin - Bulk - Package - Export 74 34 3 166 60 168 3 10 16 167 Plasticizer Dry Blend - Bulk - Package - Export Compound - Bulk - Package Backhauls for January 2 9 98 20 "9T TS- 200 35 10 21 44 2 9 4 21 14 21 57 91 55 W 7 44 Number of Shipments by Month Year to Date O.T. O.T. R/C Bulk Van C.O.T. C.C. T0FC CPU TOTAL January 91 48 200 91 0 55 487 Material Handling Report M/Lbs. T/L Packaged Resin From Production Packaged Compound, Dry Blend From Production Transferred From Main to Prairie Transferred From Prairie to Prairie Reverse Transfer Resin to Plant Reverse Transfer Compound to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Main 5,791 3,726 2,795 40 446 162 9,801 7,087 3,321 33,169 143 92 69 1 11 4 242 175 82 W\3 -28- DTH 000043774 TRANSPQRTATI ON - (continued) Off-Grade In Storage Material Sifter Overflow Resin "BC" Resin "H" Mill Scraps Compound "B" Compound "H" Dry Blend "O.G." M/Lbs. 857 2,907 910 183 1 ,262 86 161 6,366 T/L 21 72 22 5 31 2 k 157 -29- DTH 000043775 V LOCATION MAIN-East TOTAL M SQ. FT. 48 Prairie 12-1 12- 2 12-3 12 22 21 12-4 22 12-5 21 12-6 21 - 12-7 12-8 12-9 12-12 21 21 21 21 Total 251 ABERDEEN WAREHOUSE .CONTENTS Compounds Dry Blend Export Resin Conoco Resin HDPE Dry Blend Conoco Resin Conoco Export Resin ... 4-3 .5 .5 .4 .3 .2 3.8 .2 .9 Conoco Resin Resin O.G. Mill Scraps Cmpd 0. G. Dry Blend 0. G. Sifter Overflow Resin 0. G. Compound Resin Raw Material Resin 0. G. Conoco Resin 4.4 .1 1.0 .1 .7 .8 ' .1 3.0 .2 3.4 4.5 Conoco Resin Conoco Resin S.O. Comp. 0. G. Sub-Total (Plug-Aisles) -3.1 .4 .. .4 Total Cnnnro ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 5.7 4.3 10.0 .5 1.0 1.5 3.8 3.5 1.1- 2.4 3.5 4.4 3.5 2.6 2.5 - 3.3 .2 3.5 3.4 .1 3.5 4.5 3.5 3.1 .4 3.5 -8 2-7 3.5 42.0 2. 3 DTH 000043776 ?? 9 111 AA 7 ABERDEEN CHEMICAL PLANT INJURY PERFORMANCE c c c oo >o z LU o' UJ cc >CC z c 0 FREQUENCY TOTAL INJURIES (FA OR MC) X 12 TOTAL EMPLOYEES DTH 00004377'? monthly hourly turnover 10 9 8 7 6 5 4 3 2 1 DTH 000043778 ENERGY USAGE C C c JO CO \ c c Monthly 12 Month Moving Average ABERDEEN PLANT PRODUCTION UNI 'HL' 1981 35 30 25 20 15 MM POUNDS CUMULATIVE 6 5 4 3 2 1 6 5 4 3 2 1, 2 1 0 JaNUAM riMUABT MABCM AM1 HAT U JUIT 19 81 AUDUST OCICat* hOV{MBC OtCCHit* 25 20 15 10 5 BUDGET DTH 000043730 ----------- ACTUAL ----------- CUMULATIVE OFF-GRADE l 6.0 5.0 4.0 ( 3.0 2.0 1.0 0- ABERDEEN PLANT QUALITY PERFORMANCE 1981 c STANDARD 1.33 V" STANDARD 1.35 DTH 000043781 ABERDEEN PLANT EFFICIENCY 1981 STANDARD 1 .01936 1.020 1.010 1.000 STANDARD 1 .01300 STANDARD 1.00580 STANDARD 1.10500 MONTHLY CUMULATIVE DTH 000043782 POUNDS ABERDEEN PLANT INVENTORIES DTH 000043783