Document gbYYymxvrRMDja6nLm20GbjDa

, ABD00311893 SAFETY - C. U. Markerson/J. V. Uptain First Aid OSHA Recordable Total Injuries August 3 0 3 Fiscal Y.T.D. 1995 4 0 4 Y.T.D. 1994 2 1 3 Number of Restricted Workday Cases Number of Lost Workday Cases Injuries bv Department 0 0 0 0 0 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 00 11 22 00 00 0 1. 34 0 2 1 0 0 3 Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 23 00 11 00 00 00 0 _o 34 2 0 0 1 0 0 0 3 Non-Occupational Injuries Lost Workday Cases Days Lost 00 00 1 17 Contractor Injuries First Aid Cases Medical Treatment Cases Lost Workday Cases 00 00 00 0 0 0 Safety Record Last lost time injury Days since Employee hours since - 01/22/94 221 279,722 On August 31, 1994, the employees of the Aberdeen Plant completed 221 days with no lost time injury. The topic for plant safety meetings during the month was "Respiratory Protection. ABD00311894 SAFETY - Continued Routine dosimetry results for the month were: Chemical < PEL Number Percent > PEL Number Percent VCM Lead Total Particulates 63 100.0 9 90.0 7 100.0 0 1 0 o 10.0 o The single lead overexposure, the first seen in 25 months, was with benefit respiratory protection. Monthly Iniurv Summary Iniurv Class FA Department Compound Description Cut of thumb of right hand. FA Maintenance Cut of middle finger of right hand. FA Maintenance Bun of left upper arm. 13 September 1994 ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) TOTAL INJURIES OSHA RECORDABLE ABD00311895 QUALITY MANAGEMENT PROCESS - J. M. Edwards - Most of the ISO 9002 training for all Aberdeen personnel was com pleted in August. - ISO plant Tier II and Tier III documents are being copied onto to the official "controlled document" paper in preparation for the pre-assessment audit September 14, 15, & 16, 1994. _ Quality Team Activity 1. The Computer Resources Allocation and Management Team made its presentation to the Plant Manager's Natural Team. They pro posed procedures for optimizing the use of existing and new personal computers in the Aberdeen Plant. 2. All natural teams that met in August were trained in ISO 9002 1994 standards and how the standards complement the natural teams and the total quality management process. COST VARIANCES - C. W. Turner Variable Costs Product Aug., 94 Variance, $M Efficiency Price Total PVC Flexible Compound Plasticizer Total 251.6 < 66.1> < 64.5> 121.0 <1054.6> < 110.1> < 33.2> <1197.9> < 803.0> < 176.2> < 97.7> <1076.9> PVC Resin The favorable efficiency variance for PVC was due to a favorable VCM efficiency of $224.9M. The favorable VCM efficiency was due to an accounting error associated with data entry into OASIS. Flexible Compound and Plasticizer The negative efficiency variance in Compound was due primarily to higher than budgeted off-grade production and unfavorable resin efficiency variance due to an accounting error associated with data entry into OASIS. The negative price variance in Compound was due to higher than budgeted resin and plasticizer prices. The negative price efficiency in Plasticizer was attributable to higher than budgeted P.A. and alcohol prices. ABD00311896 COST VARIANCES - C. W. Turner - continued Major Price Variances - VCM - Plasticizer to Compound - Resin to Compound Variance - $M <1181.4> < 63.5> < 17.9> VINYL - J. D. Olson, W. S. Carroll Safety The Vinyl Department had no injuries in August. The monthly safety meetings were held on shift. General August production was 48.2MM pounds of which 47.0MM pounds was prime grade resin. Percent asset utilization was 92.5%. August production is a new all-time monthly record and prime production record. Aua. _ Production, MM Lbs. - Reactor Stream Factor, % - Resin Quality, % Prime - VCM Efficiency, Lbs./Lb. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % % 48.2 96.3 97.5 1.0052 1556.0 108.2 1082.0 34.9 96.7 97.0 YTD 96.1 96.3 97.6 1.0167 1550.0 107.8 2152.0 34.7 96.6 98.2 Reactor Downtime Hours Operational downtime (recovery scheduling conflicts - 137 hours, hydroblast and inspect three reactors - 89 hours). _ Mechanical downtime. 242.0 33.0 Drver Downtime Hours _ Operational downtime (cleaning, product changes, and centrifuge plugs). 74.0 - Mechanical downtime 26.0 - Reactor limited production. 45.0 ABD00311897 COMPOUND - E. T. Stouder Safety The Compound Department had one first aid injury during the month. An operator cut his finger while cleaning the Line V intensive mixer. General Compound experienced a strong production month with 7.15MM pounds of finished compound produced. Production was positively impacted by long runs on line III of compound for AT&T, Times Fiber, and Donnelly. Pro duction of BC compound in August was higher than normal due primarily to problems with plasticizer cross-contamination in AT&T compounds. Several action steps have been implemented to eliminate these problems. Orders for Lines I, III, and V continue to be very strong. Compound shipped over 8MM pounds of prime finished compound during the month. Correspondingly, inventories of "A" grade compound were reduced by almost 1.3MM pounds in August. Plasticizer production was down slightly for the month due to VRP production and mechanical downtime. For fiscal year 1995-to-date, plasticizer production is running at a 22MM pound rate. Additional studies continue with the objective of further increasing plasticizer production. Comnound Production Operating Days Production M (Lbs). Month Ava./Dav Fiscal Y Line Line Line I III V Total % Prime Capacity Utilization 31 31 31 Factor 2090 3914 1145 7149 96.4 93.3 67 126 37 230 4072 7964 2243 14279 96.6 94.3 Downtime Hours Line I - Product Changes - Miscellaneous Maintenance - Quality 85 6 12 Line III - Product Changes - Miscellaneous Maintenance - Quality 61 35 12 Line V - Product Changes - Miscellaneous Maintenance - Quality 84 41 30 ABD00311898 COMPOUND - Continued Operating Davs Plasticizer 31 % Prime Capacity Utilization Factor Production (M Lbs.) Month Ava./Dav Fiscal Y.T.D. 1756 84.9 79.2 57 3602 84.7 81.0 ENGINEERING - J. E. Nickerson, T. R. Mackay, R. H. Sneed PROJECTS IN DEVELOPMENT - GENERAL EXPRESS The plant continues to work with PED in defining the scope. We participated with GED in evaluating outside engineering companies for engineering procurement and construction of the cyclone dryer. A dryer bid package, including the Basic Engineering Package and certain items from the Outside the Battery Limits Design, was completed and given to GED. PED and plant engineering completed the HAZOPs for all Phase I a designs. I OSHA Process Safety Process Safety Information Work is progressing on locating and developing equipment specifications and documentation for the New Module. New Module relief systems documentation are also started. Procedures Procedures for New Module and SA Module are in the review process. Procedures for the boilers are 75% complete. HAZOPS The Old Module HAZOP study is complete. The report is currently in review. RVCM Reduction Efforts The "Hot Air to Blend Tanks" project AFE is approved. RVCM levels this summer have been lower than last year. The hot air supply to Tank 407 has not caused quality problems. The remainder of the project will be installed before winter. New Blades for Reactor 600 New larger blades for reactor 600 have been ordered. This is part of the larger batch study that is on-going. When the production schedule will allow, the new blades will be in stalled. R&D and the Plant can then continue the larger batch development work that has been taking place. ABD00311899 ENGINEERING - Continued PROJECTS IN DEVELOPMENT - qhnbRAL - continued Reactor Level Indication Nuclear level indication is being evaluated for use as high level or continuous level indication of the reactors. A trial is planned for reactor 600 as part of the larger batch development work. Iron Sludge Disposal Ramnyal A pilot-scale sludge drying bed was tested during the month of August. Several test runs were made, variables being studied were the amount of polymer addition and degree of loading. In formation gathered from these tests will be used to design a per manent sludge drying system. P-1 Reactor Header Modifications The AFE for this project was submitted and approved. This project will increase plasticizer production by reducing batch times with improved heat-up and cool-down times. A test run will be conducted in September to determine if vacuum breakers can be used to drain the coils rather than installing actuated valves. Bullets for Inerts Pressure Reduction An unallocated AFE was submitted to put the bullets back in service. This project has the potential of greatly improving reactor recovering times. Calcium Stearate Addition Upgrade A project to upgrade the wet calcium stearate system is listed in the 3QTR95 Capital Budget. Before designing a new wet calcium stearate bulk system, begins the feasibility of using dry calcium stearate in 5385 resin which is being explored. Currently, only 5385 type resin uses the wet calcium stearate system. Using only dry stearate offers the following advantages: material cost savings, quality improvement, and easier material storage. Testing dry calcium stearate in 5385 resin will take place in September. VCM Vapor Lines Winterization This project will reduce fugitive VCM emissions in VCM tank farm area. VCM condensation in lines leading to the railcar unloading compressors is suspected of causing VCM fugitive emissions. Heat tracing these lines will prevent this from happening. This project is included in the 2QTR95 budget submittal. Activator Reliability improvementa This project improves dryer production by reducing activator cycle times. Improved activator control will be achieved by moving the controls from the field to the DCS. ABD00311900 ENGINEERING - Continued Fluid Bed Feed Conveyor RevifLon Niro, the manufacturer of the fluid bed, has submitted a design and price for vibrating conveyor feeders. Their estimate and design are being compared to one from Flo-Dynamics Company. RVCM Subcooler Addition This projects will install a heat exchanger between the RVCM condensers and RVCM receivers in each module. Chilled water will be used to farther cool the VCM before it enters the receivers. Lower back pressures in the receivers will improve recovery times. This project is an alternative to venting inerts to the bullets. Boiler Feedwater Softener Replacement Class "A" design work was started to replace existing water softeners with new ones. This project will save an estimated $45M annually in regenerative salt costs. Resin Quality Control a This project helps align product quality testing with production" units. This realignment of lab testing is driven by quicker feedback for operators and combining job tasks for manpower savings. This project purchases new lab equipment to run the moisture, contamination, static flow, and bulk density tests. ENVIRONMENTAL - K. G. Akins Water All wastewater discharge parameters were within permitted limits for the month of August. Wastes A bulk load of empty lead bags was disposed of at Waste Management's Prairie Bluff Landfill in Houston, Mississippi. KEY ENVIRONMENTAL COMPLIANCE DATA MONTH FYTD Stormwater Outfall Excursions Wastewater Outfall Excursions Reportable NESHAP Excursions Reportable non-NESHAP Air Excursions CERCLA/SARA Reportable Incidents Other Reportable Incidents Citations and NOV's Received 0 0 0 0 0 0 0 0 0 0 0 0 0 0