Document g2wKK51k2DGZk1YmXkM1mRGqQ

r To: T. H. Huffman A Interoffice Communication From: Date: Subject: P. J. Kober August 18, 1988 ABERDEEN MONTHLY PROGRESS REPORT JULY, 1988 There was one medical treatment case and one first aid case reported during the month. As of July 31, 1988, the plant had operated 3,314 days or 4,320,340 manhours without a lost time injury. On July 5, 1988, the Aberdeen Plant surpassed nine years without a lost time injury. On June 30, an Open House was held for the Aberdeen Terminal employees and their families as part of their annual picnic and to communicate SARA 313 information. Approximately 30 people participated. Key Statistical Information Month Y.T.D. PVC Production, m lbs. 32.6 Reactor Stream Factor, % 81.7 Resin Quality, % Prime 99.5 VCM Efficiency, Lbs./lb 1.01759 H Compound Quality, % Prime 95.8 Dry Blend Production, MM lbs. 2.4 Dry Blend Quality, % Prime 99.6 Plasticizer Production, Ml lbs. 1.7 Plasticizer Quality, % Prime 88.6 Ehergy Use (CMk Reduction, %) 51.6 Fixed Cost Variance, $M (52.9) Variable Cost Efficiency Variance, $M (60.8) Variable Cost Price Variance, $M (2866.9) Variable Cost Variance, $M (2927.7) 376.5 89.1 1.01454 73.9 52.4 18.1 51.9 228.7 621.7 (20,083.0) (19,461.3) Dcwntime in the vinyl unit was due to the continued VCM shortage and miscellaneous maintenance downtime. Dcwntime due to VCM shortage was used for mrint-gnaring. emA RQIP tie Ins. In the compound unit. Lines I and III operated thirty days and Line V operated 24.5 days. Dry Blend was down 14 days to install the new Univox control system. Fixed costs were unfavorable due to completion of several extraordinary projects and staffing of Line V for a three shift operation. VAB.0001190817 +- iiuu*tn!innpnimi *****urn mmm T. H. Huffman 8/18/88 Aberdeen Monthly Progress Report Page 2 QMP - Meetings were held with operations personnel to discuss calculating the cost of quality. - All natural teams met at least once during the month. - The Quality Coordinator participated in the company Quality Coordinators meeting in Galveston. - The plant continued efforts to define the needs for a data acquisition system. - The Railcar Cleaning Team received AFE approval to install a railcar cleaning system under the vinyl storage silos. A P. J. Kober Operations Superintendent - Vinyl tls VAB.0001190818 Hu i * DISTRIBUTION COVER LETTER ENTIRE REPORT COVER LETTER AND CMP HOUSTON: J. D. BURNS X R. E. LELMOJHL X R. T. FERRELL X T. H. HUFFMAN X C. J. MATSON X D. F. HARMAN X H. R. FLAMER X R. R. SMITH X K. J. EGGERS X D. H. SANDERS X PONCA CITY: S. E. MOGUIRE X R. L. POE X H. J. HALL X C. M. STARKS X OKLAHOMA CITY: H. 6. GARRISON X LAKE CHARLES VCM PLANT R. A. CONRAD X LAKE CHARLES CHEMICAL PLANT: J. FRIEND Safety Section and X LAKE CHARLES LAB PLANT: J. W. WARE X BALTIMORE: L. R. BAUER X HAMMOND: J. B. MAHER X BLANE POLYMERS: C. R. MILLER X PREMIERE POLYMERS: P. L. FOOTE X ABERDEEN: EWS/DCS (FILE COPY), JEN, PJK, DWH, TEL, JEB, VEM, HGC, JEL, REP, REN, SAFETY A ..........................-'T i' VAB.0001190819 ^ihirk i HU lima man P-:MI"I--I|iWPPPP i iiMIH ii i^-n nil a t PLANT FIXED COSTS - P. J. Kober Major Category Payroll and Benefits MM&C T&I Miscellaneous Variance vs. Budget July, 1988, $M July YTD (29.5) (46.8) 14.6 8.8 (52.9) (204.0) 140.9 100.8 190.9 228.6 Payroll and Benefits - This variance was due to operating Line V on a three shift schedule versus the two shift schedule that was budgeted and also other plant overtime. MM&C Miscellaneous This variance was due to completion of several extraordinary projects during the month. MM&C expenditures are forecast to be approximately $80M favorable at year end. - Outside Professional Services - $7.7M unfavorable due to SARA 313 video production costs. - Operating Supplies - $13.9 unfavorable due to low value items, equipment cleaning supplies (caustic for chem wash) and sampling supplies. - Shipping Costs - $24.4 favorable due to late clearing invoices, reduced drayage charges and not weighing empty railcars. A VAB.0001190820 SAFETY - J. V. Uptain Occupational Injuries First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Jul 1 __1 2 0 0 Fiscal Y.T.D. 1988 9 _4 13 0 0 Fiscal Y.T.D 1987 12 _7 19 2 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 34 21 79 12 02 _0 _1 13 19 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Non-Occupational Injuries 6 10 03 42 21 03 00 __1 0 13 19 Lost Workday Cases Days Lost Safety Record 10 6 174 55 Last lost time injury 7/5/79 Days since - 3,314 Manhours since - 4,320,340 On July 30, 1988, the employees of the Aberdeen plant completed 3,314 days with no lost time injury. A medical treatment injury occurred when an employee was struck in his eye by a railcar seal. An injury requiring only first aid happened when another employee tripped receiving minor abrasions and contusions. Two people attended the Texas A&M Fire School. A VAB.0001190821 AV ABERDEEN CHEMICAL PLANT INJURIES u> $ 3 2: o co + OSHA RECORDABLE u. N- <o a 5: O co "C *"3 TOTAL INJURIES <c 25 Us. $ a o Co <c s OlDOlDOlOOlOO ^ r) O <\j Cvj *-- *-- sjiunrNt jo v3&wnN VAB.0001190822 I ^ ^ .* rt .. r .: I< . .*>, ... .j.i.? i. QUALITY MANAGEMENT PROCESS - D. W. Hollis, R. B. Newton 1) A meeting was held to discuss data acquisition for the entire plant. This included planned distributed control systems and the lab data management system. 2) Attended a meeting with Operations Department Heads about how to implement cost of quality accounting in their area. 3) Administrative Services held a meeting with S&T personnel to develop a freight carrier evaluation program. Plans are to evaluate carrier performance on inbound and outbound shipments. 4) Rendell Newton attended Quality Coordinators meeting in Galveston. 5) Two natural team meetings were held in Administrative Services. The Plant Accountant Team and the Warehouse Supervisor Teams met to communicate the Quality Implementation Plans to their departments. 6) Administrative Services held a conference with AT&T representatives to discuss options for upgrading the quality of the phone system. A 'p - '.n-mraiiitu. *--1^ i-if- r.f ifcfWgc tel FMtF r MJKPfBKPi : PWHW* W* - -I -w-in VAB.0001190823 MV > INM I"1 !H9 'i'Hh. m r\T-*M*r+ h-- -- VINYL - P. J. Kober, C. J. McDonald Safety There was one medical treatment injury in vinyl this month Operator suffered an eye injury while retrieving his safety had slipped off. A Yard which The monthly safety meeting topics were Burns and Vacation safety. A film on burns, "It Could Happen To You", was shown. Also, safety hazards of vacation travel and summer recreation were discussed. Quality Management Process The Department Natural Team met five times during July to coordinate daily activities and to continue the quality implementation process. There are three active employee involvement teams in the department. A fourth, the Railcar Cleaning Team has received approval for an AFE to improve their process. The three active teams all met during the month. The V-ll Dust Team continues to test improved Vendor equipment and is designing sifter deck equipment modifications. The Plasticizer Unloading Team is preparing their formal presentation of recommendations to plant management. The 5265/5305 Contamination Team is being reorganized to include personnel from other parts of the company. R&D and PED will become part of this team. Production .1 Production, MM lbs July 32.6 Y. T.D. (Fiscal 88) 376.5 2. Daily production rate, M lbs/c.d . 1052.1 3. Total charges 793 4. Charges, reactor batches/c.d. 25.6 5. Reactor stream factor 81.7 6. Dryer rate, average lbs/hr 8160 7. Dryer stream factor .8 Accounting days 67.2 31 Reactors 1234.3 8923 29.3 89.1 9395 68.6 305 The reactor stream factor for July was 81.7%. Downtime in the reactor area occurred as follows: 1. Operational Downtime: Accounted for 20.3% of the total and was due to recovery scheduling conflicts, downtime to rinse the chem wash tank, waiting on particle size data before charging, new module rinse/charge conflicts, no place to recover to, no place to dump, inclement weather, reactor Inspections, plugged recovery and dump lines and power outages (excluding blown transformers included in maintenance downtime). A VAB.0001190824 '! ' .......... a.|f<PJIU|1H l`JW --j-i-iriflMri niii 1ti 11 jmi* ;: I a-f- I-. J,- ,iT-unpi:DP* `"H "IHii.-rii- * VINYL - Continued * Reactors - continued 2. Maintenance repair/revision downtime: Accounted for 61.0% of the total and was due to installation of a new condenser lid on D744, drilling the D741 condenser, repairs to D742 agitator gear box, repair and later replacement of transformer 7B, drilling the condenser and hydroblasting D745 to control low molecular weight contamination (it was hydrobiasted twice), repairs to D300 emergency kill system, changing D744 agitator seal, repairs to reactor evacuation lines, and miscellaneous valve and instrumentation repairs. 3. Other downtime; Accounted for 18.7% of the total and was due to a shortage of VCM. When possible, downtime was used for maintenance. Dryers The dryer stream factor for July was 67.2%. occurred as follows: Downtime in the dryers 1. Reactor limited production: Accounted for 90.0% of the total. Dryers were shut down when possible for energy conservation. 2. Operational downtime: Accounted for 5.4% of the total and was due to centrifuge plugging, dryer cleaning, activator transfer problems, power failures, checking socks for leaks, checking screeners for leaks, and flame outs. 3. Maintenance repair/revision downtime: Accounted for 4.6% of the total and was due to repairs of leaking socks, activator repairs, centrifuge repairs on several dryers, maintenance on #7 dryer air sweep, screener maintenance, and repairs and replacement of transformer 7B. Product Quality Summary Resin Type Prime 5265 5305 5385 5415 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 1,141,683 3,487,390 14,253,658 12,272,933 - -- - -- - 31,155,664 "B" -- -- -- 940,430 -- -- -- 940,430 "H" -- -- -- -- -- 57,687 462,500 520,187 % of Total Production 3.5 10.7 43.7 37.6 0.0 2.9 0.0 0.2 1.4 100.0 ^ VAB.0001190825 VINYL - Continued Monthly Variable Cost Performance Variable costs for the month were unfavorable at $2008.8M resulting from an unfavorable price variance of $1909.8M and an unfavorable efficiency variance of $99.0M. Resin variable cost for July, 1988, was 26.713 cents per pound versus the budget of 20.663 cents per pound. The unfavorable price variance was due to VCM pricing at $1936.6M unfavorable. VCM efficiency for the month was 1.01759 pounds per pound of PVC produced versus the budget at 1.00756 pound per pound. This resulted in a unfavorable variance of $59.8M. Possible causes for the poor efficiency are being studied and may be related to accounting of resin used by compound/dryblend. Alcotex had an unfavorable variance of $13.6M. The variance is due to product mix and the quality of the alcotex caused it to be less efficient as a suspending agent. Polivic S-202 had a favorable variance of $15.9M. The variance is due to reduction of low molecular weight resin production caused by downtime to hydroblast D700 and D745 reactors and the problems with transformer 7B. Energy Performance Plant energy performance for July, 1988, was 2876.3 BTU/pound. General The resin raw aterial in the 744 account was valued at $356.2M * - h-- Si--1 -- T"....... VAB.0001190826 IUP 14MtH U lT***** T>r r !>. :-j i:l-- it ]|'-p !n.' ji [i.>t -fi--i i COMPOUND - J. E. Nickerson, S. C. Hillman Safety The Compound Department worked without injury in July. The July monthly safety meeting topic concerned safely handling hot molten chemicals. Quality Management Process The Compound Department's Operations Superintendent Natural Team met in July. The meeting included all the compound shift supervisors. Topics included reduction of offgrade production and charting progress. The compound Shift Supervisor Natural Teams all met in July. Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. line I Line III line V Total 30 30 24.5 1973 3503 1159 6634 66 117 47 22720 38505 12634 73859 All three compound lines were shutdown for the July 4th holiday Line I operated thirty days in July at an average rate of 66M pounds per day. Major items affecting production efficiency were: product changes, 69 hours; maintenance on Banbury seals , 11 hours; dicer problems and maintenance, 10 hours; plasticizer pump maintenance, 7 hours; quality problems, 5 hours; preblend feeder problems and maintenance, 5 hours; conveyor maintenance, 5 hours; and construction of new air wipes, 4 hours. Line III operated thirty days in July at an average rate pounds per day. Major items affecting production were: changes, 87 hours; quality problem, 6 hours; resin problems, 5 hours; and conveyor maintenance, 4 hours. of 117M product weighup Line V operated 24.5 days in July at an average rate of 47M pounds per day. Major items affecting production efficiency were: product changes, 13 hours; twin screw compounder problems and maintenance, 10 hours; Welex mixer maintenance, 7 hours; and quality problems 6 hours. Line 5 was scheduled down two days for twin screw compounder maintenance and 3.5 days for inventory control in July. T TH'HII HimmpUFH VAB.0001190827 t COMPOUND - continued Quality performance for flexible compounds for July was 2.1% off-grade of which 93.9% was due to mill scrap. "BC" production was 1.1%. The raw material requirement for flexible compounds was pounds of raw material per pound of compound versus a standard (YTD is 1.00888). 1.01752 1.01194 The variable cost variance for compound was $522.3M unfavorable with $546.9M unfavorable due to price and $24.6M favorable due to efficiency. The efficiency variance due to product mix was $175.5M favorable. The major raw material efficiency variances were Jayflex 366 plasticizer at $118.7M unfavorable and Uvasorb 3C at $17.2M unfavorable. Both of these are new raw materials that were not budgeted in fiscal 1988. Total compound inventory decreased 533M pounds in July to 9.04MM pounds. Dry Blend Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 2413 17 142 - 52381 291 Dry blend operated seventeen days in July at an average rate of 142M pounds per day. Production included 80273G WHT 110, 80172C WHT 110, 90172D WHT 110, RP421 WHT 110, RP440 WHT 110, 186-139 WHT 111, 317-91 WHT 110, and 317-104 WHT 110. Dry blend was shut down for 14 days to install the new Univox control system. Dry Blend production was hindered by: Dry blend startup, 91 hours; product changes, 20 hours; Maintenance on masterbatch blower, 13 hours; waiting on blender transfers, 9 hours; quality control, 8 hours; waiting on resin transfer, 8 hours; and transfer line pluggage problems, 7 hours. Quality performance for the month of July was 99.6% customer grade. The raw material requirement for dry blend was 1.03026 pounds of raw material per pound of dry blend versus a standard of 1.00490 (YTD is 1.00607). The variable cost variance for dry blend was $186.1M unfavorable with $217.2M unfavorable due to price and $31.2M favorable due to efficiency. The efficiency variance due to product mix was $53.6M favorable. There were no major dry blend raw material efficiency variances for dry blend in July. r|-- -,.7-. il.u | HI tiff* 7 VAB.0001190828 "wiimiiuii>iiwhh|ihhnwrw--mm* nm+n r : "vt ** h'h it t1 i J COMPOUND - continued Plasticizer Month Operating-Day Bate Fiscal Y.T.D. Production, M Pounds Operating Days 1710 55 18052 31 302 Plasticizer operated thirty one days in July at an average rate of 55M pounds per day. Production included 108P and 610P. VRP production totaled 202.5M pounds (11.4%). The raw material requirement for plasticizer was 1.18309 pounds of raw materials per pound of plasticizer versus a 1.10156 standard (Y.T.D. is 1.10142). The variable cost variance for plasticizer was $210.6M unfavorable with $193.1M unfavorable due to price and $17.5M unfavorable due to efficiency. The only major raw material efficiency variance was Alfol 610 alcohol at $18.4M unfavorable and phthalic anhydride at $22.4M unfavorable. The efficiency variance due to product mix was $5.5M favorable. Epergy Compound Dry Blend Plasticizer Usage (BTU/Lb.) Actual Standard 1877.2 804.8 2836.3 1758.0 720.0 1550.6 A VAB.0001190829 --iMIr-rv il IF' + Ii j. MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - D. A. Miller Safety There was one first aid injury in the Mechanical Department during the month. A general mechanic bruised his hand while moving a relief valve on a boiler. The topic of the monthly safety meeting was "Rigging and Lifting Equipment." Quality Management Process There are three active project teams in the mechanical department. The "Shop Utilization Team" met once during the month. The "Maintenance Training Team" completed a general mechanic skills inventory and the Valve Team began assembly of valves for stock. Vinyl There was one reactor agitator seal failure in July. The D-744 seal was changed due to an internal leak following a 10 month run. There were two unscheduled power outages during the month due to failures of 15KV bushings on a 1500KVA, 12.47KV/480V transformer in substation 7. The transformer was removed from service and a rental unit installed. The damaged transformer will be refurbished and returned to service during a scheduled electrical outage in late September. The condenser on D-500 reactor was replaced with a retubed and the chemwash and rinse piping, and control system modified. D-745 reactor condenser was drilled and brushed, and the reactor shell hydroblasted. The recovery system condensers in the new module were cleaned due to tube side fouling. The fan and gearbox for the new module cooling tower west cell was overhauled. The following mechanical seals were replaced during the month: - new module north and south blowdown tank transfer pumps - 903 recovery compressor outboard - 706 emission recovery compressor - old module east collect tank pump The D-742 reactor main dump valve was replaced during the month. A VAB.0001190830 I- MECHANICAL DEPARTMENT - continued Dryer Area A refurbished 9 centrifuge equipped with rinse nozzles was installed in the No, 8 location. A test run was conducted to evaluate centrifuge performance while rinsing. A shell leak and several tube leaks were repaired in the centrate heat recovery trim heater. This exchanger is badly deteriorated and specifications are being prepared for replacement. The two uninstalled fluid bed heating panels were modified to allow better resin movement between plates. The panels will be installed in late September for testing. The south Kason Star Valve was replaced with a rebuilt spare during the month. Compound, Dry Blend, Plasticizer The following work was accomplished on Line V during the month: - Rebuilt blades were installed in the Line V Welex - A structural engineer was consulted on a Line V Welex deck vibration problem. Flexibility in the Welex support structure has resulted in a high amplitude low cycle vibration. Structural modifications will be required to resolve the problem. - The compounder planetary gear reducer was overhauled due to excessive bearing noise. During this work, the compounder drive gearbox was inspected. Severe wear on the left hand pinion output splines was discovered. A major overhaul of the gearbox will be required to correct the problem. Parts requirements are being investigated. - The tach generator on the compounder drive motor was replaced. The following work was completed in the dry blend area during the outage for installation of the Univox control system: -- A new air lock was installed on the masterbatch blender - A filter bag screen and gasket was installed on the Bin 2 dust collector - A new star valve was installed on the Bin 1 discharge chute. -- The Titanium Dioxide star valve and aftercooler were removed and cleaned. VAB.0001190831 'r.l'lL.T Ptt -ftfrt! "f nmm**+'*H*<* MECHANICAL DEPARTMENT - continued - The dry blend cooling blenders were refurbished. New structural steel legs were installed, the blenders and drives were regrouted and all cooling water piping replaced. The blender jackets were painted and reinsulated. Only routine maintenance was required on Lines I & III, and the plasticizer unit during the month. Utilities Number 2 boiler was shutdown for inspection after discovering a hot spot on the burner front. Major refractory damage was noted. Temporary repairs were made by filling voids in the refractory with a pumpable grout. No. 2 boiler will be used in emergencies only, until permanent repairs can be made. A new dewpoint chart recorder was installed on the Deltech Air Dryer. The Pall Air Dryer purge air control valve was rebuilt and the purge air electric heater controls were replaced. A test run to evaluate C02 for ph control at Pond 3 was completed during the month. Preliminary data indicates that C02 is not a good substitute for H2 S04 in our system. The Pond 5 east aerator was rebuilt during the month. VAB mm pm PUMP mmmm iiu+inhi MECHANICAL ENGINEERING - R. E. Polk AFE F786/F557 - Resin Quality Improvement Concrete work is 99% complete and in progress. Remaining items consist of fireproofing punchlist items. Mechanical work is complete except for final process tie-ins and punchlist items. I&E work is 81% complete and in progress. Completion of remaining items is scheduled for the week of 8-22. Project start-up is planned for mid-September. AFE F587 - Laboratory Addition This project is complete and operational. field charges in August. It will be closed to AFE D707 - VCM Unloading Fire Protection This project is complete and operational. field charges in August. It will be closed to AFE A538 - Reactor Condenser Revisions The retubed condenser for D-500 was successfully installed. Installation for D-400 is planned for completion by 9-9. AFE D608 - Dryblend Orbitran Replacement The Univox Control System was successfully installed and is operational. Punchlist items are in progress and scheduled for completion by 11/1. AFE D638 - Boilerhouse MCC Replacement Pre-shutdown work is in progress. The MCC will be energized during a plant steam outage scheduled for the week of 9-19. Project completion is planned for early November. AFE F598 - Line I Screeners Installation is approximately 75% complete and in progress. Completion has been delayed until late September due to unfavorable delivery of transfer piping. AFE A678 - Dryblend Transfer System Improvements Installation was completed in conjunction with the outage to install the Univox control system. The transfer system is complete and operational. Punchlist items are in progress and will be completed by 10-1. A * `piilrihfMini'r VAB.0001190833 iTf.i-x.ij t I .-r F n r 1 wtr:rr.-ti'a*iJfc MECHANICAL ENGINEERING - continued AFE P628 - Compound Resin Supply Valves All original scope items are complete and operational. Punchlist items are in progress and scheduled for completion by 9-15. The project will be closed to field charges in September. AFE D648 - 745 BME Addition System Modifications Mechanical Installation is complete and the system is operational. Punchlist items are in progress and will be complete by 10-1. MISCELLANEOUS ITEMS Development of a VCM/Chem wash piping spec for Aberdeen has been completed with the assistance of GED. It will be issued to the plant in August. Capital expenditures (XRQIP) year to date are $2.6MM, 122% of the total for fiscal 1987 and 88% of the fiscal 1988 goal of $2.9MM. W^rpwHiriW|||| UfH'HillM fc| ***- HWHH-1*** '*ln ' - mmm VAB.0001190834 H- .............. r7i -^-nn-Mmnmin nimm-- Win........ mi n i mm .mim?- PROCESS ENGINEERING - V. E. Messick RQIP Review of the operating manuals was completed with a meeting held in the plant to communicate comments. Commissioning plans are being developed by PED with plant input. Assistance is being given to the construction group as required. Low Molecular Weight Resin Expansion A kick-off meeting was held to discuss project scope and major issues. Assistance is being given to PED to outline work. A meeting was held to discuss problems with a relief valve simulation model used to determine relief valve requirements for the small reactors in low molecular weight resin production. Dry Blend Orbitran Replacement Ken Akins was on shift for startup of the new dry blend control system. Dry Calcium Stearate System Construction of the systems for the rotary dryers is underway with completion in September. A problem with the injection point into the fluid bed dryer was resolved. The system is operating on the fluid bed dryer on a trial basis. Problems with the stearate particle size and flowability are being investigated. Boiler Safety Team Work was begun on modifications to the boiler feedwater system to resolve a potential over-pressure situation. BME Addition System The new D745 chain transfer agent addition system was installed. Operators were trained in its use and the system started up This new system replaced the old temporary system and provides a safer system that reduces operator exposure to foul BME odors. The operating manual was also issued. Installation of a pressure switch, its interlocks, and safety audit items are all that remains to be completed. Rinse Water Test Run A test was conducted to determine the feasibility of rinsing resin in the dryer centrifuges. Resin's ability to insulate wire is directly related to the quantity of ions (chiefly sodium) that the resin contains. Lab tests have shown that it is possible to rinse the ions from resin using deionized water. The purpose of this test was to determine if performing the resin rinse using regular process water as the rinse fluid in our centrifuges is possible. Results of the favorable and future testing using water with less ions is planned. VAB.0001190835 H. <--i:-ta-neiiti-r*w i7 -uhtlpP' K vUMH'S-iiR**- .8***r 4it4 p i i-q ri ............................................................................................ PROCESS ENGINEERING - continued Recovery System Pressure Control Design The class "A" design of the recovery system pressure control system was issued for plant-wide review. This design will improve recovery system performance and compressor life expectancy by reducing compressor cavitation. Compressor cavitation is one of the most significant causes of compressor deterioration that we have seen. Rotary Dryer Debottlenecking A letter was issued outlining the direction of dryer debottlenecking work. Included in this letter were action steps, estimated action step start date, and the range of expected dryer rate improvement. Historical dryer data was also presented graphically to show use trends and potential future problem areas. Pond Aeration Optimization A design was done to improve the aeration and mixing in pond #4, thus increasing our total BOD removal by up to 10%. Inert Gas System New hose connections were installed to prevent anyone from accidentally hooking up to an inert gas line. Dryer Dust Collectors Finished evaluating the different types of dust collectors that are on the market at this time. Plant personnel decided on DCE 5/8/15 model dust collector. BHA (baghouse consultants) issued their findings and recommendations in a written report. BHA commented that ''The system now in use is significantly undersized and, in our opinion, not adequate for this application". A review of a design to implement new collectors was completed and has been sent to the Mechanical Department for estimating. Alcohol Tanks Static Protection Completed a review issue of a design. This design has been submitted to the Mechanical Department for estimation. propane stem Kevisions - Deluge bystem A review issue of a design to install a fixed spray system on the storage tanks in the propane system was completed during July, 1988. This design will be submitted for budgeting in the second fiscal quarter of 1989. A 1. 1 uni-' VI': li VAB.0001190836 ^Fr MU+irt- TWH'IMlW ' PROCESS ENGINEERING - Continued Old Module Charge Water Temperature Control Improvements A review issue of a design to provide increased flow of cold water to the reactor charge pumps was completed in July, 1988. This design will be submitted for budgeting in the second fiscal quarter of 1989. Plant Water System Two iron treatment vendors were invited to the plant to present their respective iron treatment capabilities and methods of operation. PED, R&D, the hydrologist, and the plant met with each vendor to evaluate the iron treatment system proposed. Two local iron treatment facilities were visited during the month; Leau Claire at the Weyerhauser plant in Columbus and Xnfilco at the East Lowndes water treatment plant. Boiler Water De-alkalization Options were evaluated for de-alkalization. findings was issued. A letter giving Pond #3 pH Control A 48-hour carbon dioxide test run was completed. The results are being analyzed. Chlorine Alternatives Sodium hypochlorite was evaluated and recommendations were issued for review. Plasticizer Improvements Several test runs have been made and samples have been taken which has identified several areas for improvement to the plasticizer unit. A VAB.0001190837 A I| HUMAN RESOURCE REPORT PERSONNEL - J. E. Beall EMPLOYMENT None PROMPTIONS/TRANSFERS Frank Jeanson from Process Engineer to Environmental Coordinator. John E. Nickerson promoted from Senior Process Engineer to Compound Operations Superintendent. Chris Turner promoted and transferred from Compound Operations Superin tendent to Alcohol Superintendent, LCCP. RETIREMENTS None TERMINATIONS/RESIGNATIONS Ernest "Brett" Bass TO/FROM LEAVE OF ABSENCE None <hhiipji]ihiwiwwh ........................... --n VAB.0001190838 miml--winffffmwn--i>.n>iinm.i>BiiiiMi A Aberdeen, Mississippi Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations DEPARTMENTS Warehouse jen. Plant Maintenance Laboratory Compound Vinyl Plasticizer PAR 16 13 40 24 40 32 3* 76* 171 247 JULY, 1988 MONTHLY PERSONNEL REPORT Minority Employees //, % Salaried Hourly Total 7 68 75 9% 40% 30% 0 Hourly Min. Hired 0 0 % Min. Hired 0 Hourly Min. Term. 0 % Min. Term. 0 # EMPLOYEES MIN. EMP. % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD 16 7 44 0 0000 0 17 7 41 0 8000 0 38 9 24 0 0000 0 24 6 25 0 0000 0 39 27 69 0 0000 0 32 10 31 0 0000 0 5 2 40 0 0 Q 0 0 _Q_ Number of Applicants : Month 12 Year to Date APPLICANT BREAKDOWN: # Minority # Female 4 2 % Minority % Female 35 33 16 Hires (Hourly): Month 0 Year to Date 8 Terminations (Hourly): Month 0 Year to Date Overall Turnover 0 3 Projected Annual Turnover 3.0% * Includes 1 temporary employee, 2 Co-op Engineers and 1 Summer Engineer. VAB.0001190839 P- .q t. -J.i-r.-H; .1 ,,i:,l - I : : - -'--N pi!- 1 .mfc ..I-. i-'l-i. i:ji-p..a| -- 1 >P ii. .i.i.| J..7I .| .;..i . .i. ii-iJ 11 -. . "I'l. '|. : ' :| ..u :'H. I -' i i 3 f H --i I : 11- i fc i V'V r -- P -H0aH) pC4CwC1HHMOJ0i 4o-4 IK > (0 Q* H>-l (** rH4HC0-O1 pOUM4dJ <C0M* CM 0r-0.* 00 4 vOO <T OO* oo CM rH vLOA C0O0 CtnM CM co - oO0rHN\* n0O0 CO oNO COMN OCMN CO UvOO <r rCHM CM C1--O1 CrHO oo oo4 oo oiH oo* oo NrHO CO OUN04 m M<4O6C<OU> C(V0O J*coHnj Oo oo CO oCO OiHN O 00 CrHM OO oo oo rH* aCuo3eO -<Coe<CoDOD r4(oH0J ON o mCCMO <CLO?r\ CcCMoM oCOo m 0a) 1-i (0 H CcdO <0HD p4ocMHdJdc U u <ur-nr*# 0CM0* CM oCrHM4 rCC-MM41 0O0N* rH CrHM4 i-H nO LA* n0CrHO0>* OCMN* CrtrOHHM U0) CO > Nm oo OVERTIME AND ABSENTEEISM MTuV3 o CO V 3 noc prOcHd 4OUJ CCOJ oo* 00 uCMo 4 MCCMM3 Ouo4 -iCOTO ouo4 ronHD omrH ON UO P-H4 oNO trCC-nMM^ Ouo* vO Oin OrHN4 uCMo 0CO04 CO E4a-H) X*i44bcHnH--d>1o tp&QkOo^4J 3CuO3dO Oo ui--ntt ooo0oiH0* 0uCu<HSM0oo*t Oou0OCM0oN* UO CO N<Oo uCCC0uMOOo0o4 mCCMM4 OOoNnOO4 oonNUOOO* oCUOOCCMOOONN4 ow4 wco noPQ wosc |- i ri H | - lr - 'll- ?*>: -JlPt-. T --11 * r-tfl r-.* P -vi.v .r : t1- - i -r VAB.0001190840 Hi-s . ' | s'. ; t \ *1 rf- :r5*ilLT:- J I ENERGY CONSERVATION - D. A. Moore I. Plant Operations Total energy consumption for July was 111.511 MMM BTUs. Energy consumption decreased to 2570 BTU/lb. from 2608 BTU/lb. in June. An adjusted CMA reduction of 51.6% was obtained for the month. The adjusted CMA reduction for fiscal 1988 is 51.9%. Maintenance There were twenty-nine energy related items completed in July. Twenty-seven of these items were steam leak repairs. The remaining two were steam trap repairs. III. Boiler Operation Boilers ________Contoustion July, 1988 July, 1987 No. 1 No. 2 No. 3 83.4 83.4 83.3 83.4 (1) 83.2 Note: (1) Boiler nunber two was not used during the month. A ......... .. - t,v- VAB.0001190841 MUfCLklj. Month ENERGY CONSERVATION DATA 1988 July Production, fcM lbs. Resin Dry Blend Compound Plasticizer TOTAL 32.6 2.4 6.6 1.8 43.4 Natural Gas Consumption, MSCF Conversion, BTO/SCF Energy Consumption, vm BTU Energy Consumption, BTU/lb. 55986 1020 57.106 1316 Electricity Consuiption, PM KWH Conversion, BTU/KWH Energy Consumption, MM BTU Energy Consumption, BTU/lb. 5.4405 10000 54.405 1254 Propane Consumption, M Gal. Conversion, BTU/Gal, Energy Consumption, MM BTU Energy Consumption, BTU/lb. 0 92000 0 0 Total Energy Consumption, BTU/lb. 2570 Energy Consumption, E*M BTU Actual Unadjusted Actual Adjusted 1972 Base Period CMA Reduction (%) 111.511 91.559 189.073 Adjusted Unadjusted Fiscal 1988 Year^to-Date Performance 51.9% Adjusted 42.2% Unadjusted 51.6 41.0 1987 July 37.9 5.2 4.8 1.8 49.7 52205 1020 53.250 1071 5.9261 10000 59.261 1192 0 92000 0 0 2263 112.511 91.240 209.872 56.5 46.4 A i. . .. ^ |j ! ' -Il'^h-IIT^ 4H- ***--* Mn-li+'v.!!..-* VAB.0001190842 mmrn * + !** '"''jy, -I .W---.J: -I. ..- i l| ^| |B| in,l|| Q_|| J.,II miHPiWHlHlWI !,, t -iWfert ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were within NPDES limits in July. Waste Management One truckload of waste oil was shipped to Stauffer Chemical Company. One truckload of reactor culls was shipped to Sun Polymers. One truckload of floor sweepings was shipped to Chemical Waste Management. One truckload of drummed waste was shipped to Chemical Waste Management A < .................... H i- i .1I J + h --|hi*-p il-i* in {. .L VAB.0001190843 A TABLE I WATER COMPLIANCE WITH NPDES PEEWIT PARAMETERS Oct. - Ave, Max. Nov. - Ave. Max. Dec. - Ave. Max. Jan. - Ave. Max. Feb. - Ave. Max. Mar. - Ave. Max. ! I- Apr. - Ave. Max. May - Ave. Max. June - Ave. Lfex. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Flow aw 1229 1264 1222 1430 1083 1146 1326 1431 1521 1562 1208 1507 1076 1312 757 882 611 722 677 733 BOD pm LB./Eff. 5 77 7 100 15 212 22 378 8 106 12 155 19 311 25 426 11 201 14 262 12 179 15 211 6 80 9 112 9 81 11 116 7 56 11 85 6 51 10 82 OOD pm LB. An. 28 433 39 553 43 607 65 1117 35 468 51 659 68 mi 87 1476 45 818 51 955 55 824 75 1052 38 508 53 662 42 379 52 550 33 263 48 373 37 298 48 394 Sus. Solids pm lb. An. 10 147 15 215 22 310 25 370 14 191 20 264 13 213 18 307 12 228 16 295 23 342 34 473 18 237 27 336 17 152 18 175 15 122 23 174 17 115 14 150 Dies. 0z 8.4 8.6 7.4 7.9 7.6 8.2 7.5 7.7 8.4 8.8 7.8 8.8 8.3 8.8 8.0 8.7 7.9 8.8 7.3 7.7 I TO NPDES - December 1 through April 30 Ave. Max. 32 431 -- 43 800 1462 -- 2713 NEDES Permit Limits - May 1 through November 30 Ave. ifex. 26 357 40 744 1212 -- 2523 mm 674 -- 13% 674 -- 13% > 6.0 y 6.o ML LB./ro. 1.8 2.9 1.4 1.7 9.5 17.6 2.0 2.8 3.3 5.6 7.2 21.8 5.1 6.2 9.4 15.9 1.2 2.6 2.4 5.2 pH 7.5 7.9 7.5 7.8 7.6 7.8 7.5 7.7 7.5 7.7 7.5 7.8 7.7 7.7 7.5 7.7 7.6 8.0 7.7 7.8 13 6.0 - 9.0 28 13 6.0 - 9.0 28 VAB.0001L ............... ft-sK- :*. iy* il IlKtluu- - > PM* Mmt+JWtlp. -\m*m :i innwuii mnppiptp : 'Wl A LABORATORY - H. G. Colenan A, Safety There were no safety incidents in the laboratory this month. The safety meeting topic was the safe operating procedures for the lab mill oil heaters, presented by B. J. Harrison. B. Customer Relations Customer Contacts 7/21 - HGC visited Klockner to discuss quality problems with 5305 contamination and graininess in thin film applications. Requests for Corrective Action Date Customer Product Reason 7/11/88 Master Halco -Olney, IL 45541 Nat Stringers Customer Problem Reports r lV.VMJ,., Date Customer Product Reason 7/7/88 Times Fiber -Chatham, Va 39012 Blk Spark failures STATUS; Retested retains for 20 sec. hard particles - looked good; samples in Ponca City for analysis* 7/12/88 STATUS: Southwire -Osceola, AR 1220-06X Low on wire IRs. R&D investigating; QC records indicate no problems. 7/15/88 Available Plastics -Huntsville, AL 80273G Metal fragment STATUS: Metal does not appear to have come from our plant. RESOLVED 7/25/88 Vinyl Building Products -Oakland, NJ 290-61 Wht 121 Burning; yellow streaks. STATUS: All QC data and follow-up testing looks normal and consistent: BJH to visit them. A ..............P- 1 bi|>i.|j | Ht-.i .rH-ihf! I l ..j-j,. -| II--H!1 ! Ii* 'V. J; 't t*.j -tofcffc VAB.0001190845 w EttM+qH11 h |df| I ! I ,it4 * LABORATORY - Continued m Customer Problem Reports - continued Date Customer Product Reason 7/29/88 Corelmex -Mexico 38401 Orange 61 Light color STATUS; Color rematched by B. J. Harrison. RESOLVED Waivers Issued Customer Product Reason No. Essex Group 5415 Bulk Density 3 RC C. RVCM Sunmary A Hie following is a summary of residual VCM results on in-process samples. None of the reactor dally averages exceeded 400 ppm during the month of July, 1988. Reactor Slurries ________ Dryer 5265 5305 Number of Samples Average, RVCM 788 135 8 0.5 58 0.3 RVCM of Shipment Samples The foHewing is a summary of the residual VCM analysis of shipment samples for the month of July, 1988. Product 5265 5305 5385 5415 5465 Dry Blend Pond Debax No. of Samples 10 61 37 47 0 Average RVCM, ppm 0.1 0.1 0.1 0.0 D. Resin Process Capabilities 16 12 20 0.0 0.9 0.3 5265 5305 5385 5415 Bulk Density 2.33 0.25 0.93 0.50 Inherent Viscosity 0.93 1.22 0.44 0.57 "L" Color Value 4.47 1.80 1.33 1.42 "A" Color Value 6.33 3.67 "B" Color Value % on Pan (vs. 2% max.) 1.67 6.67 0.47 3.25 0.40 0.67 1.57 1.89 (0.22) nm> nmnmwt iwi*m ihimmfcircpiimmimr `"^r w miWMHIWIIffTH^iWW^WHI wmpMmm iwiiiMl I VAB.0001190846 ,,nH(ii#w^!..k W'1 -11*4*4ttfr "O i 31.Hi iT*li |. ' LAB - Continued D. Resin Process Capabilities - continued 5265 5305 5385 5415 % thru 14CM 1.10 0.85 0.70 1.25 Drytime ------- ------- 0.11 0.33 Mets I.R. ------- (vs. 95% of Control) 1.14 0.61 Hard Particles (%> 10) ------- ------- 16.7 2.0 E. Oamound Quality Sumary Adjustments M Lbs. (%) Rejections MIbs. (%) Hardness Color/Clarity Hard Particles Heat Stability Contamination Dicing Cross Contamination Total 40.0 (0.60) 17.0 (0.26) 57.0 (0.86) 17.0 7.5 55.6 36.5 20.4 4.8 7.5 149.3 (0.26) (0.11) (0.84) (0.55) (0.31) (0.07) (0.11) (2.25) F. Dry Blend Quality Suninary Rejections MIbs. (%) 40 Mesh Total 9.0 9.0 (0.37) (0.37) G* 1. The (JMP video vos shewn and Aberdeen's Quality Implementation Plan was explained to all Laboratory employees at department meeting this month. 2. Rinds were approved for a new balance and an electronic durameter, which will iaprove the precision and accuracy of the I.V. and hardness tests, respectively. The equipment is expected in August. 3. Quarterly SPC charts on 1220-06X compound were issued to Southwire. 4 Cox completed a program to input, store and print our compound and diyblend a on an HM PC. The data will be used for C^MP purposes and quickly relayed s control room. Project coupletion is expected in August. 5. 5415 Control Resin (Lot 04169) Testing: A i I f ............. i VAB.0001190847 irf i'.'i : LABORATORY - Continued Moisture Dry Time Particle Size - 6GM - 80M - 10CM - 1201 - 1401 - 2001 Pan Bulk Density Color - L A B Flow Time Hard Particles, 7 Min. Inherent Viscosity n 61 .168 14 5.15 39 1.97 59 30.42 60 33.13 59 20.88 61 7.34 65 5.31 61 1.16 30 .514 19 100.62 19 -0.05 19 2.05 31 7.71 55 4.51 26 1.007 .029 .38 1.14 5.60 1.75 2.59 1.65 2.06 .68 .011 .25 .24 .60 1.11 3.72 .0136 H. Miscellaneous 1. D. S. Cck participated In an audit of the Exxon plasticizer plant In Baton Rouge, LA on 7/26. 2. Brian Harrison evaluated and reconmended two replacements for Sunolite 160 ground wax Sunolite 160 prill form and Rheolnb 165-010. 3. Brian Harrison completed several color matches for NECO, Premier Polymers, Vytron, and Superior Rubber. ~`~^rri i iirr^nTTw^ninr"TTnr^riTiiiiBiiiiiMiiMiBiiir-------------- r VAB.0001190848 rnm i BWItmMMHv^ RESIN Ship Date 7/06/88 SAMPLE SHI I PMENTS JULY 1988 Product 5265 5305 5385 Amount 2 lbs. 2 lbs. 2 lbs. Customer Witco Corporation COMPOUND Ship Date 7/01/88 7/01/88 7/01/88 7/05/88 7/12/88 7/12/88 7/15/88 7/19/88 7/20/88 7/25/88 7/26/88 7/28/88 Product 35852 NAT 17121 WAT CL 18031 WAT CL 38601 NAT 38551 WHT 38601 NAT 34551 NAT 38601 NAT 34551 NAT 16851 CB 50 48451 BLK 16851 CB 50 34711 GRY 550 847 GRY 561 18162 GRY 545 34862 BGE 10 (BC) 46200 -31 NAT 17121 WAT CLR Amount 1500 lbs. 100 lbs. 100 lbs. 1500 lbs. 300 lbs. 50 lbs. 50 lbs. 100 lbs. 100 lbs. 50 lbs. 1500 lbs. 50 lbs. 2 lbs. 2 lbs. 2 lbs. 5 lbs. 100 lbs. 50 lbs. Customer Westwire Vytron Corp. Gehr Industries Inc. BRIntec Corp. Advance Group Storm Plastics Kasouni Mfg. Siegel Robert Inc. Plastics Techn. Inc. REKO Polychem (REKO) Proto Mold A ai .......fr- 1 - i I: P VAB.0001190849 1 ! SHIPMENTS BY PRODUCT - M LBS. JULY 1988 FISCAL YEAR-TO-DATE ESIN PLASTICIZER DRYBLEND COMPOUND 26,262 564 4,519 7,021 291,552 "6,796 51,404 69,688 TOTAL 38,366 419,440 NUMBER OF SHIPMENTS BY MODE: RESIN-Bulk RAILCAR 117 VISTA TRUCK TRAILER ON COMMON CUSTOMER BULK I VAN A FLAT CAR CARRIER PICK-UP CONTAINER TOTAL 52 103 272 Package 31 3 2 9 Export PLAST.-Bulk 25 /r Package 11 DRYBLEND-Bulk 20 5 7 32 Package 8 51 14 Export COMPOUND-Bulk 13 4 Package h 35 2 38 1 41 17 116 Export 1 56 TOTAL - July 152 66 46 3 48 154 5 474 Oct 1987 Nov 1987 Dec 1987 Jan 1988 Feb 1988 Mar 1988 Apr 1988 May 1988 Jun 1988 182 62 56 2 51 145 1 499 173 72 50 1 61 142 499 154 88 38 1 85 161 1 528 155 88 45 5 77 139 3 512 178 97 50 2 68 168 563 211 46 37 2 82 160 538 170 63 44 1 58 141 6 483 159 61 51 62 149 1 483 141 65 50 2 71 134 463 A VAB.0001190850