Document dna1zVD3RODdKRwVO3XmZ4jjR

SAFETY A. H. Sather Occupational Injuries Injuries Treated December 1980 Year-to-l 1979 Year-to-Date First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time Injuries by Department 3 0 0 0 0 49 14 2 23 0 42 9 3 69 1 Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office Injuries by Type 2 0 1 0 0 0 15 20 25 4 0 1 16 6 25 2 0 4 Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 0 1 0 1 1 0 32 5 8 14 5 4 15 6 13 13 8 3 As of December 31, 1980, the plant had operated 542 days or 697,904 manhours since the last disabling injury. Also, at the close of 1980, the plant had operated 133 days without a medical case injury. Safety Meetings The topic for December Safety Meetings was "Consequences of Serious Injuries". A slide andtape presentation "The Convincer" was reviewed. Three important points were reviewed in the follow-up discussion, which were: 1. Always use your protective equipment; 2. Never work on energized (powered) equipment; and, 3. Always plan your jobs. New Employee Orientation Three (3) new casual employees received new employee safety training. -1- DTH 000021392 Safety - (continued) Third Radio Channel Gerry Sjoberg, Telecommunications - Ponca City, was requested to make application to the Federal Communications Commision for a third in-plant radio frequency assignment. The additional channel will be used by Dryer Operators, Yard Operators, and Laboratory Personnel to minimize disruptive communication on reactor channels and to improve overall safety in the above job classifications. The additional radio channel will allow for status checks by Supervisory Personnel on personnel working in isolated plant areas on off-shifts. These checks cannot be done under current operating conditions. OSHA Compliance A significant amount of activity occurred in this area during the reporting period. The activities were: 1. Due to an increase in the number of compounder exposures greater than the permissible exposure limit for lead, a new respirator, the 3M "Airhat", was purchased. All compound personnel were trained on its use, care, clean ing and basic maintenance procedures. This respirator has been very well received by personnel in that department. 2. The medical testing screen by Health Examinetics was set for February 3 through 10, 1981. The Screen will be preceeded by an introduction to the new Chemicals Contractor by T. G. Grumbles, Industrial Hygienist, Chemicals Houston, and W. W. Massad, Assistant Medical Director, Ponca City on January 21 and 22, 1981. 3. Routine dosimetry for VCM and lead. In addition, the results for Antimony and total dust will also be included in Aberdeen Safety Monthly Progress Reports. The results are shown below. VCM A total of 77 samples were analyzed for the reporting period, three (3) of which indicated overexposure. The results and overexposures are shown below: Range, (ppm) Number Percent 0.0-0.5 0.5-1.0 1.0-5.0 5.0# Overexposures 67 87.0 7 9.1 2 1.3 1 2.6 77 100.0 Of the three overexposures, one occurred to a Maintenance Mechanic who was rebuilding a plug valve in the shop and was not wearing a respirator. The second occurred to a Vinyl Utility who was working in the new reactor area and was not wearing a respirator. The last overexposure occurred to a yard operator who was connecting/disconnecting VCM railcars for off-loading and was not wearing a respirator. -2- DTH 000021393 SAFETY - (continued) Lead A total of twelve (12) samples were analyzed, none of which indicated exposures in excess of the permissible exposure limit. Antimony A total of twelve (12) samples were analyzed, none of which indicated exposures in excess of the 500 microgram per cubic meter OSHA standard. Total Dust A total of five (5) samples were analyzed, none of which indicated exposures in excess of the 5 milligram per cubic meter OSHA respirable dust standard. -3- DTH 000021394 VINYL P. E. Markey Production Month Y.T.D. 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 29.4 948 22.3 692 87.7 6233 90.6 31 274.5 750 17.9 6540 76.3 5826 76.6 366 Vinyl Department production for December was 104% of budget at 29.4 MM lbs. Reactor and dryer stream factors were 87.7% and 90.6% respectively. The major items affecting stream factor and production were: 1. Downtime in the reactor areas for tie-in items related to the Plant Expansion and Fire Water Improvement projects resulted in a 4.2% stream factor penalty. 2. Six month reactor rupture disc change-outs on D-300, D-400, and 744 reactors resulted in a reactor stream factor penalty of 0.4%. 3. Maintenance on the 744 condenser gasket resulted in a 0.4% reactor stream factor penalty. 4. Replacement of the Rotex sifters with the new Sweco sifters on #4, #5 and #6 dryers resulted in a 2.3% dryer stream factor penalty. 5. The unit was dryer limited for the month and the reactor shutdown work resulted in a 2.0% dryer stream factor penalty due to no material to dry. Resin Quality Summary Resin Type 5305 5385 5425 5465 Sifter Overflow ' Prime Pounds 1,705,743 24,798,283 1,738,922 341,762 - "BC" Grade _ 466,000 - "H" Grade ( 1,500) 65,250 - - 324,845 % Of Total Production 5.8 86.0 5.9 1.2 1.1 TOTAL 28,584,710 466,000 383,595 100.0 Quality performance for December was 97.1% customer grade with 1.6% "BC" grade and 1.3% "H" grade. -4- DTH 000021395 VINYL - (continued) Cost The variable cost variance for December was favorable by $601.8 M with $642.6 M due to price and ($40.8) due to efficiency. The major price variance was $556.4 for VCM. Unfavorable variances of $57.6 M for VCM and $27.9 M due to off-grade production were partially offset by a favorable combined additive variance of $27.9 M and $17.9 M due to product mix. Variable cost variances for 1980 were favorable $799.5 M with $360.2 M due to price and $439.3 M due to efficiency. The monomer raw material requirement for December was 1.02949 pounds VCM/ pound resin versus the 1.0196 standard. (Y.T.D. is 1.0194) General 1. Several bulk quantities of 5305 were produced using a Chain Transfer Agent for American Hoechst trials. The testing was successful and from December 16 on, all 5305 production was made using the Chain Transfer Agent. The Chain Transfer Agent facilitates 5305 production at substantially lower operating pressures and reduces the chances of a VCM release. 2. Resin packaging for December totaled 6,500,050 pounds. No resin de bagging or deboxing activities were conducted during the month. 3. A new daily charge record of 28 charges was established 12/7/81, breaking the previous record of 27 charges set in January, 1980. -5- DTH 000021396 COMPOUND J. R. McCrimon Compound Production Month Per Day Y.T.D. Line I, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days 858 674 3,103 4,635 31 52 40 110 150 13,161 2,304 32,014 47,479 366 Line I operated 16.5 days during December at an average rate of 52 M pounds per day. Major items affecting production efficiency were: product changes (33.3 hours), skip hoist repairs (29.1 hours), Banbury gate repairs (12.0 hours), scales (9.9 hours), dicers (6.6 hours), and No. 2 blender gearbox (5.0 hours). Line V operated 17 days during December at an average rate of 40 M pounds per day. Major items affecting production efficiency were: quality control (equipment cleaning - 40.9 hours), product changes (36.5 hours), putting up raw materials (23.7 hours), and resin blower (5.4 hours). Line III operated 28.3 days during December at an average rate of 110 M pounds per day. Line III production was affected by: product changes (37.0 hours), quality control (mixed resin - 10.5 hours), and FCM conveyor (4.8 hours). Line III was down 66.0 hours for replacement of the FCM hopper liner; Lines I and V operated during this period. Quality performance for flexible compounds was 4.2% off-grade of which 77.2% was due to mill scrap. "BC" production was 5.6%. The raw material requirement for flexible compounds was 0.97652 pounds of raw material per pound of compound versus a 1.01300 standard. (Y.T.D. is 1.01307) The variable cost variance for compound was $18.0 M with $33.8 M due to price and ($15.8 M) due to efficiency. The variance due to product mix was ($37.7 M). Major efficiency variances were: $22.1 M for resin, $12.1 M for 610P and $12.2 M for colors. There were no major price variances for the month. Dry Blend Month Per Day Y.T.D. Production, M Pounds Accounting Days 3,500 31 175 25,918 366 Dry Blend operated 20 days during December at an average rate of 175 M pounds per day. Production included 80273G, 80274, 90171 and 80174. Dry Blend was affected by: out of resin (12.7 hours), quality control adjustments (11.6 hours), product changes (7.9 hours), putting up raw materials (6.5 hours), boxing limited (6.4 hours), resin silo star valve (7.5 hours) and Lab Brabender (6.3 hours). Quality performance for the month was 99.99% customer grade. -6- DTH 000021397 COMPOUND - (continued) Dry Blend - (continued) The raw material requirement for dry blend was 1.00121 pounds of raw material per pound of dry blend versus a standard of 1.00321. (Y.T.D. is 1.00378) The variable cost variance for dry blend was $84.2 M with ($1.9 M) due to price and $86.0 M due to efficiency. The variance due to product mix was $96.5 M. There were no major price or efficiency variances for the month. Plasticizer Month Per Day Y.T.D. Production Accounting Days 972 71 31 10,046 366 Plasticizer operated 15 days during December at an average rate of 71 M pounds per day. Production included: D0P, 610P and DIDP. VRP production totaled 101 M pounds (9.4%). Production was limited by: Schenk filter seals, rupture disc on R-3, and internal coil leak on R-2. The raw material requirement for plasticizer was 1.08608 pounds of raw materials per pound of plasticizer versus a 1.08930 standard. (Y.T.D. is 1.10878 versus a 1.10237 standard) The variable cost for plasticizer was ($35.6 M) with ($29.0 M) due to price and ($6.6 M) due to efficiency. Major price variances were: ($15.9 M) for Alfol 610 and ($14.6 M) for 2-Ethylhexanol. There were no major efficiency variances. The variance due to product mix was $0.8 M. General Total customer grade compound inventory increased from 4.8 to 5.8 MM pounds during December. -7- DTH 000021398 MAINTENANCE S. J. Vincent Vinyl There was one large reactor seal failure in this period. The seal failed on the D-600 reactor in the old module. There were no reactor gearbox failures and no reactor condensers cleaned this month. Safety valves were tested and all safety disc's were replaced on D-300, D-400 742 and 744 reactors. Flow meters were also cleaned on the old module reactors. In the old module, there were four mechanical seals replaced and one pump overhauled. The seals replaced were the outboard seal on the 705 emission recovery compressor, the outboard seal on "B" vacuum pump, the inboard seal on "A" recovery compressor, and the seal on the chemical wash pump. The "B" water charge pump was overhauled. In the new module there was one mechanical seal replaced. The seal replaced was the outboard seal on the 903 recovery compressor. The seal flush system for the new module reactors was checked through its control sequence and placed in full operation. There were two valves replaced this period. The valves replaced were the suction block valve on "A" compressor and the PVA charge valve on the 742 reactor. Major projects completed in this period were to revise the suction and discharge piping on the new module charge water pumps, hydro-blasting and chemical cleaning of the new module charge water pre-heat exchanger and steam leaks were repaired when the module was down for the expansion tieins. A new temperature indicator was installed to eliminate the resistance from the reactors to the control room. A test flow indicator was also installed in the unloading line at the VCM tank farm. Repairs to vinyl drying equipment were to change out and rebuild the #6 and #8 Birds. Rebuilt the exhauster stack damper on #4 dryer and replaced the Bird effluent hoppers on #4 and #6 Birds. The major project completed in the vinyl dryer area was to replace the rotex screeners with Sweco screeners on the #4, #5 and #6 dryers, along with, relocation of the acti vators arid piping. Three new pole mounted transformers were installed at the refrigeration building. The three that were in service had been recently checked and determined to be in poor condition. Compound, Dry Blend, Plasticizer and Silo Storage Major repairs to the compounding equipment were on line III. The FCM hopper section was pulled and new liners installed, the mill "0" rings were replaced, steam and water leaks repaired and gearboxes were opened, flushed and inspected. The spindle assembly was replaced on #5 dicer and the belt vacuum pump was repacked. The FCM motor was pulled and sent out for a PM check. -8- DTH 000021399 MAINTENANCE - (continued) Compound, Dry Blend, Plasticizer and Silo Storage - (continued) Repairs to compound line I were to replace and rebuild one blender gearbox. There were no major repairs to the #5 compound line in this period. Repairs in the plasticizer area included, the repairing of a coil leak in R-2 reactor, replacing the seals in the Schenk filter, and replacing reactor safety disc's. The dry blend unit had two gearbox problems, with gears being replaced in the "A" and "B" blender gearboxes and minor repairs to the transfer lines. The plant crane was inspected and the engine adjusted. Repairs were made to the swing brake and to the outriggers. The Plant Special Projects Crew completed repairs to general insulation in the vinyl production area. Utilities and Service Repairs to the plant air system were to repair valves in #2, #3, #5 and #7 air compressors and to overhaul the high pressure end of the #8 com pressor. The air dryer heater element was changed in the #1 dryer west tower. The motor on #3 air compresor was repaired. When #9 air compressor motor failed, the #8 motor was taken and installed to keep it running. The plant vaporizers were test run three times in this period with no problems. Major equipment repairs were to overhaul the API sump pump and to overhaul the east compound cooling tower pump. Projects completed were to install a skimmer unit in the API trap and to mount flue gas analyzers on all boilers. Planner The planner estimated 90 work orders and ordered material for 19 work order projects. There were 15 new invoice registers issued and 14 bills processed for payment. The equipment records were updated and work was started on revising the safety valve data records. -9- dm 000021400 MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved and Closed The following AFE's were submitted and approved during December: AFE No. Title Authorized 9780 9790 9800 9810 Centrate Heat Recovery Resin Reclaim System Plasticizer Irritant Control (Air) Replacement Gearbox for Farrell Mixer $300,000 727,000 80,000 73,000 The following AFE1 s were closed to field charges during December: AFE No. 9237 9519 9649 9510 9650 9580 9670 Title Heated Plasticizer Addition System Critical Spare Equipment Double Block Valves for VCM Charge Mi sc. Projects Under $10,000 Misc. Projects Under $10,000 Boiler Economizers Laboratory Equipment Authorized $ 37,000 175,000 182,000 150,000 150,000 140,000 32,000 There were no completion reports issued during December. Design Design work is in progress on the following projects: - Fixed Point Montior Data Computer & Warning Lights - Compressor & Vacuum Pump Seal Flush Revisions - Breathing Airt Modifications - Kemp Air Dryer Modifications - Spare Inert Incinerator - Batch Water Stripping - Resin Reclaim System - Calcium Stearate Addition System - Reactor Pressure Relief Modifications AFE Activity 1. AFE 9689 - Diking of Sphere & Curbing of Drum Storage Areas - J. L. White This project is operational. A few minor items remain to be completed. -10- DTH 000021401 MECHANICAL ENGINEERING - (continued) AFE Activity - (continued) 2. AFE 9709 - Facilities for Multigrade Resin Production - S. Krause The preparation of the painting and insulation basis of bids is in progress. The remaining bulk pipe and fittings have been placed on order. 3. AFE 9729 - Fire Protection Improvements - Phase II - M. Ingle Part I piping installation is nearly complete. The part II piping installation work has been let. Bids have been requested for installation of the pump building. 4. AFE 9739 - Methocel Charge Revisions - J. L. White This project is operational. Insulation of piping is scheduled for January. 5. AFE 9530 - Spare Incinerator - D. Haub Overall project design is 65% complete. Preparation of bid packages for piping and structural steel are in progress. 6. AFE 9590 - Critical Spare Equipment - J. P. McKee Quotes and secrecy agreements have been received for construction of the spare reactor condenser. The quotes are being evaluated. 7. AFE 9610 - API Clean Water Bypass - M. S. Richards The skimmer installation was completed and is operational. Sewer con struction is scheduled to be completed in January. 8. AFE 9630 - Water Stripping - M. Ingle Overall project design is 95% complete. The piping and equipment erection bid package have been issued. Insulation and painting bid packages are being prepared. 9. AFE 9660 - Hot Water Charge Tank Replacement - J. P. McKee This project is operational. Insulation and painting remain to be completed. 10. AFE 9680 - Fixed Point Monitor Data Computer & Warning Lights - R. B. Harned Overall project design is 70% complete. We are awaiting a copy of the purchase contract from CSD in Ponca City. Parts for modification of the gas chromatograph have been received. -11- DTH 000021402 MECHANICAL ENGINEERING - (continued) AFE Activity - (continued) 11. AFE 80-395 - Interplant Communications - Phase III - R. B. Harned The Gaitronics equipment for the original contract has been received. Construction is in progress and is 50% complete. 12. AFE 9690 - Breathing Air Modifications - J. L. White Quotes have been received on the receiver and are being evaluated. Plan drawings have been distributed for review and comments. Construction - G. A. Morgan Three contracts were let during December for the following: 1. Part II of Piping and Equipment Installation for Fire Protection Improvements Phase II 2. Installation of Electrical Facilities for Fire Protection Improvements Phase II 3. Equipment Installation for Heated Plasticizer Addition System. The following projects became operational in December: 1. Hot Water Charge Tank Replacement 2. Methocel Charge Revisions Twenty-nine register tickets were issued during December. -12- DTH 000021403 (1) Thru November, 1900 Actual Accounting (2) Thru Oecember, 1980 ABERDEEN AUTHORIZATIONS REPORT auth. CAPITAL NO, description DATE Ainu. APPROVED ALU AMT, (1) EXPENDED TO DATE (2) COMMITTED TO DATE. FINAL TOTAL EST. COST COMP. UNDER (OVER) AUTII. AMT. EST. EST. COMP, CLOS, DATE DATE REMARKS 9237 9148 Heated Plasticizer Addition System Plasticizer Chemical Exposure Abatement 10/11/77 8/21/78 37,000 152,000 14,722 143,863 34.891 145,203 37,000 145,203 0 6,797 12/80 3/81 Closed to field charges. 9/80 12/80 Closed to field charges. 9519 Critical Spare Equipment 9559 Color Weigh Room Modifications 9589 Instrument Air Dryer 9609 Reactrr Inert Vent System 9629 Air Compressor 9639 Revisions to Emission Recovery System 2/6/79 4/19/79 5/30/79 6/28/78 7/9/79 7/12/79 175,000 25,000 110,000 90,000 340,000 100,000 162,725 164,446 18,552 19,647 90,468 96,238 14,394 17,895 267,637 278,143 65,190 78,731 166,000 25,000 110,000 90,000 340,000 100,000 9,000 0 0 0 0 0 12/80 3/81 1/81 4/81 2/81 5/81 12/81 3/82 3/81 6/81 3/81 6/81 Closed to field charges. Revisions in progress. Revisions in progress. Project on hold Revisions in progress. Revisions in progress. 9649 9669 9689 Double Block Valves for VCM Charge New Air Header Diking of Sphere & Curbing of Drum Storage Areas 7/18/79 8/15/79 9/15/79 182,000 25,000 170,000 147,532 169,835 17,963 19,286 124,427 132,723 170,000 25,000 170,000 12,000 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 Dryer Debottlenecking Facilities for Multiple Grade Resin Production 9/15/79 9/20/79 80,000 870,000 14,135 56,030 24,655 352,285 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 Fire Protection Improvements Phase II 9/10/79 10/1/79 850,000 490,000 11,421 829,021 53,592 224,371 850,000 490,000 0 8/81 4/81 Reactor vendor is off strike. 0 6/81 9/81 Construction in progress. 9739 9759 Methocel Charge Revision Aberrippn PVC Resin Expansion 10/3/79 66,000 12/10/79 11 ,150,000 20,270 o nnq non c 37,079 66,000 ?nn 11 icn Aftn 0 2/81 5/81 Construction in progress. A ft/fll t r /on 9510 Miscellaneous Projects Under $10,000 9530 Spare Incinerator 9550 P. A. Handling Improvement 9560 Safety Equipment 9570 Replace T-100P.A. Tank 9580 Boiler Economizers 9590 Critidal Spare Equipment 9600 Calcium Stearate Addition System 9610 API Clean Water Bypass 9630 Water Stripping 9650 Miscellaneous Projects Under $10,000 9660 Hot Water Charge Tank Replacement 9670 9680 Laboratory Equipment Fixed Point Monitor Data Computer and Warning Lights 9690 Breathing Air Modifications 9700 Compound Fines 4 Streamers Removal 9710 Fire Protection - Phase III 9720 Reactor Agitator Replacement 9730 Compound Line III Debottlenecking 9740 Modifications to M.iko Profile Dry LI end 1/3/80 150,000 1/23/80 3/3/80 3/12/80 3/27/80 3/26/80 3/26/80 4/2/80 4/15/80 4/30/80 5/30/80 650,000 63,000 25,000 119,000 140,000 59,000 84,000 23,000 810,000 150,000 6/4/80 7/9/80 9/4/80 160,000 32,000 113,000 9/9/80 21,000 10/1/80 95,000 10/14/80 335,000 10/14/80 420,000 10/lG/.i() 1 .3r,n,TM 10/27/80 200,000 106,283 158,906 150,000 7,465 238,632 650,000 25,352 33,914 63,000 1,854 9,985 25,000 58,068 62,356 119,000 115,091 143,916 144,000 10,390 11,486 . 59,000 0 8,037 84,000 5,380 17,100 23,000 32,099 246,693 810,000 78,042 154,409 150,000 14,917 30,533 708 121,758 32,447 13,205 160,000 32,000 113,000 0 1,434 21,000 0 0 95,000 0 0 305,000 0 no.uso 420,000 0 n,m l , VjU,000 0 0 200,000 0 12/80 3/81 Closed to field charges. 0 0 0 0 ( 4,000) 0 0 0 0 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 CEU. Project on hold. Walkway quotes requested. Project on hold. Closed to field charges. Condenser quotes requested. Engineering in progress. Sewer construction in progress. Sewer construction in progress. Closed to field charges. 0 2/81 5/81 Project operational. 0 12/80 3/81 Closed to field charges. 0 9/81 12/81 Engineering in progress. 0 3/81 6/81 Engineering in progress. 0 10/81 1/82 Engineering scheduled. 0 10/81 1/82 Engineering scheduled CEO. 0 10/81 1/82 Agitators on order. 0 10/UI 1/82 Engineering schedu 1 . 0 10/81 1/82 Engineering scheduled. -13- DTH 000021404 ABERDEEN AUWORTCATrONS REPORT Airni. CAPITAL NO. DESCRIPTION DATE Aimi. APPROVED AFE AMT. CD expended TO DATE (2) COMMITTED TO DATE FINAL TOTAL EST. COST COMP. UNDER COVER) AUTU. AMT. EST. EST. COMP. CLOS. DATE PATE REMARKS 9750 Rotary Dryer Insulation (Energy) 11/10/80 22,000 0 27,391 27,391 ( 5,391) 2/81 3/81 Insulation In progress. 9760 Emergency AMS Kill System 11/15/80 335,000 0 0 335,000 0 8/81 11/81 Engineering scheduled. 9770 Reactor Pressure Relief Modifications 11/25/80 560,000 0 0 560,000 0 12/81 3/82 Engineering in progress. 9780 Centrate Heat Recovery 12/8/80 300,000 0 0 300,000 0 3/82 6/82 Engineering scheduled. 9790 Resin Reclaim System 12/14/80 727,000 0 0 727,000 0 3/82 6/82 Engineering in progress CED 9800 Plasticizer Irritant Control (Air) 12/15/80 80,000 0 0 80,000 0 9/81 12/81 Engineering scheduled. 9810 Replacement Gearbox for Farrell Mixer 12/18/80 73,000 0 0 73,000 0 9/81 12/81 Updated quote received. 80-395 Interplant Comnunication - Phase III 1/22/80 55,000 0 21,683 55,000 0 6/81 9/81 Construction in progress. EXPENSE 9010 Centrifuge Rotor Repair 9020 Repairs to Line I Compounder 9/19/80 11/24/80 20,000 38,000 16,500 0 0 20,000 0 38,000 0 2/81 5/81 Repairs in progress. 0 11/81 2/72 Parts to be ordered in Jan. ) -14- DTH 000021405 CONOCO CHEMICALS Aberdeen, Mississippi Salaried Employees Hourly Employees Total Employees 79* 155 234* Employees (Hourly) New Employees ____1 Terminations ____1 December 1980 MONTHLY PERSONNEL REPORT Minority Employees # Salaried 6 Hourly 58 Total 64 Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 1 100% 1 100% 7.6% 37% 27% DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound Vinvl PAR # EMPLOYEES MIN. EBP. . % MIN. 6^ CNI CM 99 2 10 10 3 30% 46 46 7 15% 22 21 3 14% 37 33 27 82% 32 32 13 40% NEW HIRES YTD 00 15 00 00 00 00 TERM. YTD TURNOVER YTD nn 13 On 10% 30% 00 0 0 00 0 0 0 4** 0 9% 0 1 0 3% Plasticizer 5 4 3 7570 0 0 0 "0 0 0 Number of Applicants: Month 13 Year to Date 225 APPLICANT BREAKDOWN: # Minority 3 % Minority 33% $ Female ^ % Female 38% *Includes three (3) temporary employees. '"'Includes one (1) retirment and is not counted in turnover rates. Hires (Hourly) : Month 1_______ Year to Date 5 Terminations (Hourly) : Month 1_______ Year to Date 8** Overall Turnover .6% Projected Annual Turnover 4.5%, -16- DTH 000021406 PERSONNEL - J. L. Carter EMPLOYMENT Gail Edwards, General Helper TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTION Gail Edwards, General Helper, to Compound Utility Dwain Lucas, Compound Operator, to Lab Trainee RETIREMENT None. TERMINATION Arthur Cunningham, General Helper OTHER During December there were 18 casual labor employees on payroll. Total hours worked were 2654.50. -15- DTH 000021407 <r to <t ct\ o ^ fcS O<fn''*tvoooco o<foooooo vO sOi- O CTv O o_ ooo Mi- CM 3 3 CO 00 CM CM CM Mt OOv P? 15 S S) fe R CM .-t i: mo o r-* o o cB 00 Mfr CsMf m r- 00* 00 co mT m OLOv omm o o CM CM m 0VO0 CT\ r-H <? ov 3 Mp-f m m CM Ov O T5 m r-. 8 8 o m O m o m m r*-. m r-. m r**- H CO 2 b5 <3* ov CM i--1 8 in r-> o VO CM 3 m in m 3 m i--i m CO CO r- Ov 00 00 o> I--1 co S 6 - U i--<3< *H aH <2 ^4-> t&4 CO i-M 5Dm *Dd 5 u<U JQ DTH 000021408 PROCESS ENGINEERING R. A. Frohreich A. Expansion Project Field work is continuing in the V-ll and CRD reactor areas, slurry blend tank area, and silo area. Review of instrumentation and electrical packages is underway. Bids on the mechanical package have been received and the contract will be awarded in January. B. Reactor Area Drum Storage A revised process design incorporating review comments was issued. C. Line III Mill Temperature Control Work on the process design to provide a new mill heating system continues. D. Reactor Emergency Cooling System Process Engineering is assisting PED in obtaining field information on this project. E. Reactor Agitator Replacement The class "A" design to replace D-300 and D-400 reactor agitators was issued. F. Donnelly Mirror Compound Testing Process Engineering is investigating the requirements for providing compound in 2,000 pounds bulk sack containers to Donnelly Mirror. G. Plasticizer Initiator Handling System A class "A" design to provide a new catalyst charge system to the plasticizer reactors was issued. H. Plasticizer Spill Containment The class "A" design for this project is being prepared. I. Normal Kill Solution Addition System The class "A" design for this project is being prepared. J. Rag Layer Reduction An evaluation of replacing carbon black with sodium borohydride in plasticizer operation was issued. The letter also recommends a testing procedure to evaluate the effectiveness of sodium borohydride in reducing color in plasticizer. -18- DTH 000021409 PROCESS ENGINEERING - (continued) K. Compound Line III Production Process Engineering is assisting operations in improving compound production rates. L. Dry Blend Production Rates Process Engineering has been studying the dry blend operation and have given operations several recommendations for improving dry blend production rates. M. Sifter Overflow Reclaim System The class "A" design for this project was issued and a review meeting was held. N. Improved Rupture Disc Holders The class "A" design for this project was issued. O. Recovered VCM Receiver High Level Alarms The class "A" design for this project was issued. P. VCM Tank Farm An ultrasonic liquid detector is being tested in the VCM unloading line to determine if it can be used to indicate when the railcars are unloaded. Q. Heat Recovery System - Part II The AFE request to use V-10 centrate water to preheat boiler feedwater was submitted. -19- DTH 000021410 ENVIRONMENTAL V. E. Messick Particulates One dryer was sampled for particulates in December and was within allowable 1 i mi ts. Water All effluent parameters were within NPDES limitations in December. Results of the PCB and Pesticide fraction sample showed no PCB's or pesticides in the plant effluent. The waste water trailer finished the biodisc study and left the plant on December 17. The consolidated NPDES permit application was submitted to the Mississippi Bureau of Pollution Control. Results of a second serial BOD were transmitted to the Mississippi Bureau of Pollution Control to aid them in establishing the BOD limit for the new permit. VCM Only a few flanges remain to be samples in the comprehensive VCM survey. Points with high VCM concentration have been reported to operations via the plant's Leak Detection and Elimination Plan for corrective action. Hazardous Waste Management Drums of waste phthalic anhydride, API solids. Acetone, Isoprene, and plasticizer/ phthalic anhydride were moved into the drum storage area. Contracts with Chemical Waste Management to dispose of phthalic anhydride, API solids. Acetone, and Isoprene have been signed and sent back to Chemical Waste Management. A procedure to filter the plasticizer rag layer using the Schenk filter was written and distributed for comment. This will be attempted as soon as VRP storage space becomes available. Groundwater monitoring proposals from several firms are being reviewed. Other An in-company environmental audit was conducted on December 16 and 17. -20- DTH 000021411 Flow GPM Jan. - Ave. Max. 810 941 Feb. - Ave. Max. 645 802 Mar. - Ave. Max. 595 743 Apr. - Ave. 628 Max. 877 May - Ave.' 304 Max. 480 June - Ave. 670 Max. 804 July - Ave. 696 Max. 813 Aug. - Ave. 698 Max. 753 Sept. - Ave. 679 Max. 767 Oct. - Ave. 956 Max. 1066 Nov. - Ave. 1032 Max. 1076 Dec. - Ave. 1064 Max. 1214 TABLE I - WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB./DY. COD PPM LB./DY. Sus. Solids PPM LB./DY. Diss. 02 43 131 436 1342 86 851 216 2214 11 103 13 143 6.8-8.5 6 42 8 56 29 220 36 314 21 147 30 232 15 116 24 171 66 502 95 828 54 378 67 519 10 79 13 125 11 74 14 94 12 86 13 129 6.7-7.9 6.6-8.3 6.4-8.3 16 69 32 184 6 49 11 84 53 197 74 426 40 316 51 367 10 40 14 81 12 98 15 145 6.7-7.3 6.7-7.3 14 112 19 145 7 56 9 70 5 42 7 64 9 110 17 217 16 196 33 390 20 256 28 374 39 322 78 597 32 270 42 380 22 168 27 248 27 316 45 576 28 347 45 531 39 499 75 1038 11 88 14 no 15 126 24 187 7 44 14 89 7 78 11 119 11 131 23 272 6 80 7 102 6.6-7.3 6.5-6.9 6.2-6.7 6.1-7.3 7.2-7.5 8.1-10.4 ph 7.7-8.0 7.1-7.8 7.1-7.8 7.5-8.4 7.2-7.9 7.5-7.9 7.3-8.0 7.6-7.9 6.5-7.9 7.6-8.0 7.4-7.8 7.6-7.8 NPDES - Ave. Max. _ 32 387 43 520 1390 - 1940 605 - 909 >6.0 6.0-8.5 DTH 000021412 ENERGY CONSERVATION J. F. Perez-Velasco I. Plant Operations Total energy consumption for December was 120.8 MMM BTU's. The energy consumption per pound of product decreased to 3131 BTU/lb. as compared with 3193 BTU/lb. for November. II. Plant Energy Conservation Program Steam Leaks Sixteen (16) steam leaks were repaired in December. Other Energy conservation pamphlets were ordered for distribution to plant personnel. -22- DTH 000021413 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 1980 December 1979 December 29.4 4.6 3.5 1.1 38.6 65263 1020 66.569 5.4024 10000 54.024 2.799 92000 0.256 120.849 3131 26.5 5.5 2.8 0.5 35.3 57020 1020 58.160 4.9632 1000 49.632 1.717 92000 0.158 107.950 3058 Avg- Stack Temp. 1979 1980 387 279 421 284 425 267 Avg. % Excess Air 1979 1980 21 27 21 26 30 29 -23- DTH 000021414 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Report By Novatech Permafit Alcan Cable Tenex Charlotte Pipe 80273G 90171 34641 Blk. 18031 CB 50 5385 Processing Contamination, Processing Contamination Air in Pellets Moisture JRW JRM JRM RDJ PEM WAIVERS RECEIVED Date Identification Product Customer Reason Waived By 12/14 12/16 12/18 T-2868 T-101 T-2810 5305 80273G 802736 Intex Columbia Uni-Mac Viscosity Long Stability Long Stability RDJ JRW JRW PRODUCT DEVELOPMENT & SERVICE Sample Shipments Ship Date Product Amount (Lbs.) Customer Requested By 12/3 5385-1 300 American Vinyl COED 12/3 5385-1 500 Hamel in Industries JFN 12/5 5305 5385-3 5425 50 Angus Fire Armour 50 50 PCM 12/11 5425-1 50 Fritz Airfreight (Export) JPM 12/11 5305 5 Wilson Products Co. RNG 12/11 5305 5385-1 5425 5465 50 Goodyear Tire & Rubber Co. 50 50 50 JTW 12/19 5385-1 100 Associated Lead Inc. COED 12/22 5305 50 Sheller-Globe MFM 12/22 45541 Brn 259 5 Conoco, Ponca City ERC 12/23 5425 50 Witco Chemical Corp. JLI 12/23 18551 Blk 100 Satellite Plastics JFN -24- DTH 000021415 LABORATORY - (continued) PRODUCT DEVELOPMENT & SERVICE - (continued) Special Compound Testing Complete specification tests were run on three samples of 34861 Gray 546 and on two samples of 36861 Natural for Western Electric. Color Matching A gray color was matched for Electri-Flex and sample plaques were submitted for customer approval. It was assigned the number 18961 Gray 551. Melt Flow Tests Melt flow tests were run on 3 samples of 48562 produced on Line V and on 16 samples of 18031 from Line III. The 18031 gave high values for melt flow; however, when 5425 resin was substituted for 5385 the values dropped well below the maximum allowable value. Dry Blend Development Laboratory Wei ex batches of 80273G were made for use as a quality control standard. QUALITY CONTROL TESTING Resin Regular Samples = 349 Bag Samples =163 Other In-Process Samples = 3299 Bulk Shipments = 152 (Railcars = 94; Trucks = 58) Dry Blend (Rigid) Blenders Produced = 377 Blenders Tested = 301 Blenders Adjusted = 9.2% Other In-Process Samples = 315 Bulk Shipments = 44 (Railcars = 11; Truck - 33) Compound (Flexible) Blenders Produced = 574 Blenders Adjusted = 4.0% Line 5 Production = 343 Skids; 48 Boxes; approximately 80 M bulk Other In-Process Samples = 925 Bulk Shipments = 21 (Railcars = 13; Trucks = 8) -25- DTH 000021416 LABORATORY - (continued) QUALITY CONTROL TESTING - (continued) Resin Heat Stability Oven heat stability tests were run on twenty-eight (28) samples of resin from production. 5385 5425 5305 5465 14 samples 6 samples 4 samples 4 samples In addition to these, one railcar sample of high color 5305 was tested and found to have inferior heat stability. All samples of production resin were acceptable, except for one lot of 5465 produced early in the month. Late month production of 5465 was better than the control resin. RVCM of Shipments A total of 134 shipment samples were tested for residual VCM. A summary by product is listed below. Product 5305 5385 5425 5465 Dry Blend Average RVCM ppm Number of Samples 1.2 37 1.3 85 0.1 3 1.5 1 0.2 8 Inherent Viscosity Viscosity continues to be run on all railcar compartments of resin and on all shipments of 5305. A total of 640 samples were tested in December. Raw Material Testing Fifty three (53) lots of plant raw materials were tested. One shipment of SP-33 clay was rejected for giving a low value for volume resistivity; and another shipment will be rejected if it is not needed to keep the plant running. There was a meeting with representatives of the supplier regarding the recent drop in clay quality. One shipment of Hydra! 710 was rejected for poor dispersion MISCELLANEOUS PROJECTS Resin Volume Resistivity Volume resistivity tests were run twice this month - each time on 4 blends of 5425 resin. In both sets there were wider than normal variations in VR - all on the low side of the control. This property is being monitored frequently in attempt to find the reason for the low values. Samples of resin giving low values are being sent to Ponca City to confirm test values. -26- DTH 000021417 LABORATORY - (continued) MISCELLANEOUS PROJECTS - (continued) Residual VCM of Slurry A total of 673 reactor slurry samples were tested in December for residual VCM. The overall monthly average was 161 ppm with no daily averages exceeding 400 ppm. Residual VCM of Blowdown Tank Water A total of 146 samples of blowdown tank water were tested for RVCM. The monthly average was 1.6 ppm. Residual VCM of 5305 Dryer Samples A total of 37 dryer samples of 5305 resin were tested for ppm RVCM. The overall average was 14.5 ppm, however, only two samples exceeded 10 ppm. The average for the other 35 samples were 2.5 ppm. Personnel Dosimetry A total of 55 carbon dosimetry samples were tested in December. L & N Microtrac Particle Size Tester Quality Control Personnel were instructed on the revised operation and cleaning procedures for the particle size tester. A two week test was done to determine the effectiveness of the additional training. The resulting precision between multiple technicians was comparable with data obtained by a single operator using the L & N and screens. A single operator testing control resin previously gave a median particle size of 148.9 microns with a standard deviation 2.7. The QC technicians, over a similar time frame, testing the same sample, gave a median size of 148.8 microns with a standard deviation of 4.0. Additional improvements in precisions are expected by changing to a heated water supply during cold conditions in order to prevent fogging of the sample cell. 1 Continued use of the instrument should also improve operator skills. -27- DTH 000021418 TRANSPORTATION J. E. Stark Shipment by Product - M/lbs. Resin Plasticizer Dry Blend Compound Total December 25,148 82 2,584 3.324 31,138 Year-to-Date 210,032 891 27,458 46.687 284,068 Number of Shipment by Mode R/C O.T Bulk O.T Van Resin - Bulk Package Export Platicizer Hvm/ D1 riru^ _ Dili!/ Compound Other - Package - Export - Bulk - Package - Export - Antifreeze - Alumina Back Hauls for npppmhpr 79 25 75 87 * 94 37 Number of Shipment by Month-Year-to-Date 1 204 3 3 11 4 226` 16 C.O.T. 4 4 1 C.C. TOFC CPU TOTAL 30 1 11 1 11 V ' *' 4 - 10 2 26 15 138 12 215 2 39 3 3 15 41 4 54 0 : 57 472 4 21 R/C Bulk Van January February March Apri 1 May June July August September October November December Total per Year 104 111 130 69 42 55 57 79 102 128 87 94 1058 ' 55 83 95 43 41 36 47 51 53 76 67 37 684 72 66 64 84 75 136 52 65 62 107 117 226 1126 C.O.T. 0 0 1 0 0 0 0 0 n 1 4 4 10 -28- C.C 4 21 37 5 3 7 2 12 7 43 59 54 254 TOFC CPU TOTAL 2 36 273 4 35 320 0 48 375 0 29 230 0 30 191 0 74 308 0 64 222 0 89 296 2 53 279 0 116 471 0 84 418 0 57 472 8 715 3855 DTH 000021419 TRANSPORTATION - (continued) Material Handlinq Report Packaged Resin from Production Packaged Compound, Dry Blend from Production Transferred from Main to Prairie Transferred from Prairie to Prairie Reverse Transfer Resin to Plant Reverse Transfer Compound to Plant Shipment from Warehouses Special Packaging Transferred from Prairie to Main Off-Grade in Storage Material Sifter Overflow Resin "BC" Resin "H" Mill Scraps Compound "B" Compound "H" Dry Blend "O.G." TOTAL M/Lbs. 7,776 2,754 2,146 0 162 122 11,218 8,951 2,795 35,924 M/Lbs. 1,053 2,544 649 132 1,332 108 261 6,079 T/L 192 68 53 0 4 3 277 221 69 887 T/L 26 63 16 3 33 3 6 150 -29- DTH 000021420 \ LOCATION MAIN-East TOTAL M SO. FT. 48 Prairie 12-1 12-1 12-3 12 22 21 12-4 12-5 22 91 h. a '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 B1end Conoco Resin Conoco Export Resin Conoco Resin Resin O.G. Mm4 1il1 wwi upj Cmpd 0. G. Dry Blend 0. G. Sifter Overflow Resin 0. G. Compound Resin Raw Material Resin 0. G. Conoco Resin 3.6 .3 .6 .7 .3 .2 4.0 .2 2.5 4.4 .1 1.4 .1 .8 .9 ' .1 3.0 .2 3.1 4.5 ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 5.2 4.8 10.0 .5 1.0 1.5 * 4.0 3.5 2.7- 8 3.5 * 4.4 3.5 *3.3 2.5 3. 3 3. 1 *4.5 . 2 3.5 . 4 3.5 3.5 Conoco Resin Conoco Resin S.O. Comp. 0. G. Sub-Total (Plug-Aisles) Total Conoco -3.2 .2 .1 3.2 3 DTH 000021421 34 . 5 . 3 3.5 3 ..2. 3.5 42.0 3* 2 10. 7 45 2 ABERDEEN OSHA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE 20 Frequency Total OSHA Recordable Injuries X 12 Total Employees r 15 10 5 0 i9_78. 19. 79 c% 8 oy 80 DTH 000021422 ABERDEEN FIRST-AID CASES 12 MONTHS MOVING AVERAGE C ( oo X * c uzw ow' oc n* >2DO hH c c DTH 000021423 MONTHLY HOURLY TURNOVER DTH 000021424 ENERGY USAGE B T U /L B . DTH 000021425 Monthly 12 Month Moving ABERDEEN PLANT PRODUCTION 'UNI MM POUNDS HL' 1980 CUMULATIVE 35 30 25 20 15 6 5 4 3 2 1 6 5 4 3 2 1. 2 25 20 i: 15 10 o5 ----------- ACTUAL ----------- CUMULATIVE DTH 000021426 0'Q. OFF GRADE ABERDEEN PLANT QUALITY PERFORMANCE 1980 STANDARD 0.41 STANDARD 1.02 ' STANDARD 1.35 DTH 000021427 ABERDEEN PLANT EFFICIENCY 1980 POUNDS OF RAW MATERIAL/POUND OF PRODUCT DTH 000021428 ABERDEEN PLANT INVENTORIES 000021429 DTH