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To: R. T. Ferrell Interoffice Communication From: Date: Subject: J* W, Were June 17, 1987 ABERDEEN MONTHLY PROGRESS REPORT JUNE, 1987 There were two first aid cases recorded during the month of June. As of June 30, 1987, the plant had operated 2,917 days or 3,758,696 manhours without a lost time injury. PVC resin production for June was 34.8MM pounds. Mechanical downtime in the reactor areas was due primarily to drilling of 500 and 600 condensers, repair of the agitator seal on 742, installation of cooling jacket expansion joints on 742, 743 and 744, and Modicon software revisions for RQIP. Resin production year-to-date totaled 319.6MM pounds. The VCM efficiency for June was 1.01570 pounds of VCM per pound of PVC produced versus a 1.00208 standard. Year--to--date VCM efficiency is 1.00906. Compound production for June was 6.8MM pounds. Line I and Line III operated twenty-seven days and Line V operated sixteen days during the month. Line I and Line III were shut down on 6/27 for a planned ten-day outage to control inventory. Line V was shut down at month-end after producing some last minute orders. Year-to-date compound production was 64.7MM pounds. Quality performance for flexible compounds was 1.0% off-grade of which 99% was due to mill scrap. "BC" production was 0.7%. Dry blend production was 4.7MM pounds for June and 41.0MM pounds fiscal year-to-date. Production was limited primarily by product changes. Quality performance for the month was 99.4% customer grade. The plasticizer unit operated twenty-eight days in June to produce 1.7MM pounds. Year-to-date plasticizer production is 16.9MM pounds. A new operations involvement team was formed during the month. This team is composed of personnel from the Compound area and will work on improving product change procedures/equipment. Discussions with Houston Purchasing on raw material supplier quality programs were also initiated during the month. Total energy consumption for June was 108.293 MMM BTUs. The energy consumption per pound of product was 2251 BTUs, resulting in an adjusted CMA reduction of 56.4%. The adjusted CMA reduction for fiscal 1987 year-to-date is 54.5%. .1 ' " 1i 11 !. i qHii ii l- _ >v|jin if { - .Hr* VAB.0001191306 T . iiiwr^'T|rH~m-- -ri -t liij^fr^^iiainniiMrirEinitiHiwiir rTinupruiwi-- --------rtirif r"--rT----------*~*i--n-ir'-'t-1-- i l--'ll i rm irim lbrii-r-rmh--1--------------r--------------------nr-rr-i----------------------- R. T. Ferrell 07/17/87 Aberdeen Monthly Progress Report The total plant variable cost variance for June was $843.9M unfavorable, resulting from an overall unfavorable price variance of $778.1M and a net unfavorable efficiency variance of $65.8M. The total fixed cost variance for June was $20.9M unfavorable. J. W. Ware rah -,Jl ^ . HjfrlMii LMf| |H7M|i.rt hi^H^ |l Hj. lfta'rF-r+Ll1 -H BMjjqp VAB.0001191307 :rnf.- rgfiM-rrv^-T** DISEREBUTIiON COVER LETTER ENTIRE REPORT COVER LETTER AM) QIP HOUSTON: J. D. BURNS X R. E. LEHKUHL X R. T. FERRELL X R. D. GAMBLIN J. J. LANGFORD X X R. E. SWANIKOWSKI X D. F. HAFMAN X H. R. FLAFMER X R. R. SMITH X S. K. SABQRSKY K. J. EGGERS X D. H. SANDERS X PONCA Cm: S. E. MCGUIRE X R. L. POE H. J. HALL X C. M. STARKS X OKLAHOMA CTIY: HARRY GARRISON X LAKE CHARLES VCM PLANT: DICK CONRAD X LAKE CHARLES CHEMICAL PLANT J. A. DEBERNARDI Safety Section and X T. H. HUFFMAN X TAKE CHARLES LAB PLANT: L. R. BAUER X BALTIMORE: R. W. SEYMOUR X HAtMOND J. B. MAHER X ABERDEEN JF, JVW, DWH, PJK, TEL, RAF, KLF, RAM, VEM, HGC, CWT, REP, VLT, J1 JGC, REN A i ~ i n iiiiinir.r^Mr.f ! ii rja - r' nr rni'iiiTi ni|>riiiimn nunr ~ 11 i hi mi diwmfMfiiJMi...................... q-W-Mfta-r J. >-HWFUi imMI JlEW VAB.OOOl 191308 *1 Hl.i i nh innr ~ii r p>wii \ ipun.i|j.r \\j_r . ...... _r " QUALITY IMPROVEMENT PROCESS - R. B. Newton A team of operators in the Compound Department began meeting to discuss ways to improve the product change process. Plant personnel in the Compound and Engineering Departments worked with Bob Schettek of Purchasing to begin a quality improvement process with raw materials suppliers. iiJ IE-iVfc=i ' v .. bLi-.f. V-**' I. 1,^** Jet*, Himr -- JjiwJi. 141 iM-it-'y* f-AP VAB.0001191309 SAFETY - K. L. Fogg, J. V. Uptaln Occupational Injuries First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases June 0 0 Fiscal Y.T.D. 1987 2 0 Fiscal Y.T.D 1986 2 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Non-Occupational Injuries Lost Workday Cases Days Lost Safety Record Last lost time injury 7/5/79 Days since - 2,917 Manhours since - 3,758,696 On June 30, 1987, the employees of the Aberdeen plant completed 2,917 days with no lost time injury. Topics for the plant safety meetings during the month included: Reactor Emergency Kill Procedures, Job Safety Analysis, VCM and Lead Overexposure Controls, Emergency Alarms, Accident Investigation Procedures, Plant Safety and Health Policy, Safe Use of Manlifts, Employee Safety Action Request (ESAR) Program, Horseplay in the Workplace, Yearly Safety Performance, and Maintenance Weekly Safety and Job Reviews. A iM-i-* sr*"11* nil i " I11 dr "K|frt|*- VAB.0001191310 ' f-n jm^'uiijpmiiipjipi nil.li SAFETY - Continued Two four-hour sessions of CPR training were conducted for laboratory personnel. Malcolm McMullen and two insurance brokers from Jardin Glanill Ltd. inspected the plant in June. The Central Safety Committee met in June. A new procedure for personnel baskets and cranes was adopted. The new BLS standard was reviewed with the staff. Routine dosimetry results for the month are as follows: Vr Chemical z. Number PEL Percent Number PEL Percent VCM 79 100.0 Lead 15 93.8 Total Particulates 4 100.0 0 0.0 1 6.2 0 0.0 The single lead overexposure occurred with benefit of respiratory protection. ri -.**..* , L. ft,_. i - j-.m T _P VAB.0001191311 iwWM*'' 1 h+hp n pW*nwWjB(m \f ! Il I I BMUlllllHM II 1 ,h r--np,p. TK+Vrt-<.n-Ktn-nil*9C,r - ' Hs4j Mil t%**LV*p iruiHp^pi^a ABERDEEN CHEMICAL PLANT INJURIES sjthfnrNt jo yj&wriN VAB.0001191312 n lim-TTntj-r i r WiUmif^ron^togmji^a nt^iyiPii^ftnupin -mw-wh..,.. , r -rrnvnih*wiiwjimiimi ^-tftl.T^frir.1 4`|l '7i:lfeVHF t iy. i *hHi- VINYL - D. W. Hollis, J. M. Edwards A Safety The Vinyl and Yard Departments operated without any accidents in the month of June. Shift safety meeting topics for the month were Job Safety Analysis and Minimizing VCM Exposures. Production 1. Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days June 34.8 1159 834 27.8 87.3 9250 65.3 30 Y.T.D.(Fiscal 87) 319.6 1171 8037 29.4 90.9 9910 62.0 273 Vinyl Department production for June was 34.8MM pounds. Reactors The reactor stream factor for June was 87,3%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 34.5% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size information before charging, lines plugging, reactor manway O-ring failures, power failures and bad weather. 2) Maintenance Service Downtime: Accounted for no downtime because the cleaning of the reactor AMS injection ports and inert vent lines was accomplished while the reactors were normally down for other reasons. 3) Maintenance Repair/Revision Downtime: Accounted for 65.5% of the total downtime and was due to drilling D-500 and D-700 reactor condensers, changing the agitator seal on 742, installing reactor jacket expansion joints on 742, 743 and 744 reactors, Modicon software revisions and replacing miscellaneous reactor valves. Dryers The dryer stream factor for June was 65.3%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 91.1% of the total down time. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 6.3% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems. VAB.0001191313 i I- L: ; I(||-JfS'i!- |!^ir(1-l>-:t<Jl.frJ''to|ihrT.J ifi-M %tV t iTTlI--" T[ I*. I HI U'lr' || `t-t H'-h! lii-ph ill t K. '55 I i'-ihr ** + \*........ -> VINYL - Continued Dryers - Continued 3) Maintenance Repair/Revision Downtime: Accounted for 2.5% of the total downtime and was due to preventive maintenance to the fluid bed dryer, changing out //8 centrifuge, repairs to #6 dryer drive, change #6 Star valve and making insulation repairs to #5 dryer drum. Product Quality Summary Resin Type Prime 5265 5305 5385 5415 5425 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 2,205,784 3,238,020 17,621,971 10,258,031 33,323,806 "B" 1,090,820 173,620 1,264,440 "H" 64,806 128,460 193,266 % of Total Production 6.3 9.3 50.7 29.5 0.0 0.0 3.1 0.5 0.2 0.4 100.0 Quality performance for June was 99.4% customer grade with 0.6% "H" grade production. A total of twelve railcars were shipped as "B" grade during the month which represented 10.0% of the 120 total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 4/14/87 06/03/87 PTLX 41643 Vista: Bulk Serv. AL 5415 Derailed 04/14/86 06/11/87 VIPX 45704 G&M Agent, MS 5305 Derailed 05/15/86 06/12/87 PLWX 44733 G&M Agent, MS Pond Resin Quality 06/02/87 06/18/87 PLCX 43696 Silverline, NC 5385 Contamination 06/01/87 06/19/87 VIPX 45850 Wexford, WI Debox Quality 06/02/87 06/24/87 PLWX 44722 Western AG., TX Debox Quality 06/12/87 06/25/87 PLCX 43850 H&W, MS Debox Quality 06/17/87 06/25/87 PTLX 41840 H&W, MS Debox Quality 05/21/87 06/15/87 06/25/87 VIPX 45811 06/26/87 PLWX 44258 Gamma, CA Apache Plast. Pond Resin Debox Quality Quality 02/02/87 06/10/87 06/26/87 RTMX 580088 G&M, MS 06/30/87 PLCX 43745 H&W, MS Debox Debox Quality Quality VAB.0001191314 " III. * In-f-i a-' T--i'-.y- :rli Eft it i:tM i -***" IP nilttpwxW A r fH.s.--Hi **-**!?'km. .............. ... !> Ml. d.,L.* ......................................... M VINYL - Continued Monthly Variable Cost Performance Variable costs for the month were unfavorable at $951.3M resulting from an overall unfavorable price variance of $823.6M and an unfavorable efficiency variance of $127.6M. Resin variable cost for the month was 21.189 cents/lb. versus the budgeted 18.334 cents/lb. The $823.6M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $883.2M, offset by favorable freight pricing of $18.4M, a favorable natural gas pricing of $28,3M, and a favorable electricity pricing of $11.9M. The $127.6M unfavorable efficiency variance can be attributed mainly to the unfavorable efficiency variance due to VCM, $73.OM; and Initiator 223, $26.9M. VCM efficiency for the month was 1.01570 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. YTD variable cost efficiency variances in the Vinyl Department totaled $504.9M unfavorable. Energy Performance/Progress 1. Plant energy performance for June was 2256 BTU/lb. General 1. Resin raw material in the 0744 account totaled $331.9M. A , j14, -rtr r--: r r i'i ip........,.|rr|-| I--Tr.l" Hqp. IIITr.JtT-' mm uphm1 whhii imhu VAB.0001191315 WlH.u-i .| 1,-H-M^r O, IUMH ff mTHT* fI i. ju , ^ 'Jrl-l .1 ri COMPOUND - P. J. Kober, J. E. Nickerson Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line V Line III Total 27 2102 78 16 936 59 27 3796 141 6834 21632 7521 35595 64748 Line I operated twenty-seven days in June at an average rate of 78M pounds per day. Major items affecting production efficiency were: product changes, 68 hours; blender maintenance, 20 hours; dicing system problems and maintenance, 19 hours; quality problems, 12 hours; and housekeeping, 10 hours* Line I was down three days for inventory control. Line V operated sixteen days during June at an average rate of 59M pounds per day. Major items affecting production efficiency were: product changes and startup time, 30 hours; twin screw compounder problems and maintenance, 5 hours; and downtime due to a power failure, 3 hours. Line V did not shut down at the beginning of the planned inventory control outage in order to complete some last minute orders. Line III operated twenty-seven days In June at an average rate of 141M pounds per day. Major items affecting production were: product changes, 32 hours; mill maintenance, 11 hours; and dicing system problems and maintenance, 4 hours. Line III was down three days for inventory control. Quality performance for flexible compounds was 1.0% off-grade of which 99% was due to mill scrap. "BC" production was .67%. The raw material requirement for flexible compounds was 1.01634 pounds of raw material per pound of compound versus a 1.01200 standard (YTD is 1.00995). The variable cost variance for compound was $52.4M favorable with $28.0M favorable due to price and $24.4M favorable due to efficiency. The efficiency variance due to product mix was $20.4M favorable. There were no major compound raw material efficiency variances. Total compound inventory rose .15MM pounds in June to 8.08MM pounds. All compound lines are scheduled to be down the first eight days of July for inventory control. Pry Blend Production, M Pounds Operating Days Month 4665 30 Average Operating-Day Rate 156 Fiscal Y.T.D. 41000 274 A I J r <*- i-- - I 'ir-|-Mlw7TiTTjf. .'HP- V"" ' f":n -I imi Qt H'frinnair n Ti VAB.0001191316 COMPOUND - Continued Dry Blend - continued Dry blend operated thirty days during June at an average rate of 156M pounds per day. Production included 80172C, 80273G, 90172D, RP-421, RP-203, 186-139, 269-69, 269-66, RP-100, 169-151, 269-192, and 269-164. Dry Blend production was hindered by: product changes, 67 hours; transfer system problems and maintenance, 33 hours; delays associated with quality and lab problems and normal Q.C., 29 hours; Welex maintenance, 9 hours; TiCL system problems and maintenance, 7 hours; and weigh computer problems, 4 hours. Quality performance for the month of June was 99.4% customer grade. The raw material requirement for dry blend was 1.00365 pounds of raw material per pound of dry blend versus a standard of 1.00490 (YTD is 1.00988). The variable cost variance for dry blend was $60.3M favorable with $20.0M favorable due to price and $40.4M favorable due to efficiency. The efficiency variance due to product mix was $25.3M favorable. There were no major dry blend raw material efficiency variances. Plasticizer Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 1715 28 61 16867 273 Plasticizer operated twenty-eight days during June at an average rate of 61M pounds per day. Production included 610P and 108P. VRP production totaled 8.2M pounds (.5%). The raw material requirement for plasticizer was 1.17395 pounds of raw materials per pound of plasticizer versus a 1.09877 standard (Y.T.D. is 1.10799). The variable cost variance for plasticizer was $5.4M unfavorable with $2.5M unfavorable due to price and $2.9M unfavorable due to efficiency. The efficiency variance due to product mix was $2.9M favorable. There were no major plasticizer raw material efficiency variances. Quality Improvement Charting of some laboratory results and process variables continues. Some SPC charts for hardness, gravity and insulation resistance are now being sent to select customers on a regular basis. An involvement team is now working on ways to improve the compound lines product change procedures. VAB.0001191317 ..... . |^.|U irmyru rtarfl tick mi 1 f ? j*l: Y.-' = BiPMTrttW rtn tai vHtitlit h-: 11 I COMPOUND Continued Compound Dry Blend Plasticizer Usage (BTU/Lb.) Actual Standard 1790.6 750.2 1557.4 1783.0 730.0 1833.5 A j|-r. M-sHi-rn-AW >! di--i.: ^s-11 -fl. =Hni] :<ii itiM ^ bi f.iiri-tili =l-i ?P I M 4 11......"r "lh~iTlnrnTirrr~~~r- ir-m^|fiir<l|^n 'n--i untni- i i ^TlHt MUlJWiWPlUiPiUH.lL VAB.0001191318 H IWWmWWMWCilWfflitJ19 =r- ttflh KTitn.i ii|i i i ii ij-- unm ' ii-K-sii i 1.1.. I MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - D. A. Miller, G. A. Morgan Safety There were two first aid injuries to Maintenance Department employees during June. The injuries were to General Mechanics; one was a thermal burn from steam trap condensate and the second was an abrasion of the neck from a metal sliver. Vinyl The D-742 reactor agitator seal was replaced with a rebuilt spare. Reactors 742, 743 and 744 were hydroblasted and die penetrant inspected during the downtime caused by the cooling water jacket expansion joint installation. The D-500 and 700 reactor condensers were drilled and brushed. The new module recovery condensers were drilled and brushed. Thirteen major valves were replaced during the month, six of those valves were reactor valves. The west cell fan in no. 2 cooling tower failed during the month. A blade broke causing extensive gearbox and mounting pedestal damage. Repairs will be completed in July. One Corken VCM unloading compressor was replaced with a spare. The following mechanical seals were replaced in June: - "B" vacuum pump inboard seal - t,B" compressor inboard seal - "A" vacuum pump inboard seal - 706 compressor inboard and outboard seals - Old unit RVCM pump seal - 704 vacuum pump outboard seal - 905 compressor outboard seal - Old unit rinse pump seal - New unit blowdown tank south transfer pump seal The east incinerator downcomer pipe was replaced. The old module dump box was acid cleaned to remove a carbonate build-up. Dryer Area Preventive maintenance work on the fluid bed dryer centrifuges, fans and transfer blowers was completed during an outage taken to clean the bed plate in the back-mix section. Pr 3 rvr(T t. [J'Jpir.Cf VAB.0001191319 t MECHANICAL DEPARTMENT - Continued Dryer Area - continued The no. 8 dryer centrifuge rotating element was replaced with a rebuilt spare. The Trunion bushings and one Trunion shaft were damaged causing excessive vibration. The centrifuge centrate water line was hydroblasted to remove carbonate and calcium stearate build-up. The insulation on the outlet section of the no. 5 dryer drum was replaced. The numbers 4 and 6 dryer dust collector Star valves were replaced. Instrumentation and Electrical Assistance was provided to complete control room work for RQIP Phases I and II. The 903 and 905 recovery compressor seal water flowmeters were overhauled. The no. 6 dryer Sweco motor was replaced. All cooling tower fan vibration switches were tested and repaired as The low oil pressure switch, relay and timer for the Frick system compressor were replaced. The RVCM meters in both reactor modules were replaced. The terminal strips in the D-743 junction box were replaced due to corrosion. An electrical outage in substation 9 (new module substation) was taken to allow tie-ins to the new RQIP Phase I and II motor control center. Compound, Dry Blend and Plasticizer The following work was completed on Compound Line III during the month: - The FCM water end bearing housing, wearplate and seal bushings were replaced. - The Line III mill oil cooler was replaced. - The blender shaft packings were repacked. The compound wet ventilation system exhauster was cleaned, overhauled and its base was regrouted. Plasticizer tanks 183 and 188 were cleaned and inspected; no problems were noted. iil-p.ii Mill II UiiMW ilM'WWBHlWIPiliiKiWIMUl ' ' +***r*f- : VAB MECHANICAL DEPARTMENT - Continued Compound, Dry Blend and Plasticizer - continued A leaking tube was plugged in the R-4 reactor condenser in the plasticizer building. The blender drive sprockets for the west Line I ribbon blender were replaced and a spare blender drive gearbox was overhauled. The bearings were replaced in the #2 Welex motor in the dry blend unit. The power supply and controls were replaced for the Titanium Dioxide feed system. Utilities The pond #3 sulfuric acid storage tank was repaired. nozzles were removed and one replaced. Two corroded The annual no. 3 boiler inspection was completed. Minor revisions were made to the blowdown piping to improve alkalinity and conductivity control. No significant problems were noted. The east aerator in pond 5 was replaced with a spare due to gearbox damage. Valves were replaced in no. 5 air compressor and the unloader was overhauled on no. 9 air compressor. A new engine was installed in forklift no. 13354. Training Welder training and recertification on carbon steel was completed for three General Mechanics. lire,-tUtH li].. ' I' -S- ' ' F * ' . hi" II I I I I 111 H I Ifl I \IW * Plf^llll I1 Hl| I I II i UMIllH |W I I K. ''3`Mev V- ttmn \nwWtrjM- WJ^miWUHP**-***#***--*****1 * VAB.0001191321 -H- r-? < 'V.*t `mr ---ni '-*vra u MECHANICAL ENGINEERING - R. E. Polk M AFE H636 - Critical Spare Equipment All items Identified in the original scope have been received Including the spares for the Line III FCM. A balance of approximately $40M remains which will be utilized to purchase critical items for Line V. These items will be identified and placed on order by 8/15, AFE F537 - Dry Blend Transfer Lines Design is complete and the basis of bids issued to contractors for review. Bids are due on 7/20. Construction Is scheduled to begin by 7/27 with complete by mid-September. AFE F786 - Resin Quality Improvement Construction is in progress for Phases I and II with completion scheduled for the week of 7/13. Procurement for Phases III and IV is on schedule. Quotations have been received on most of the major equipment and tabulations reviewed by this plant and GED. Design for Phases III and IV is approximately 15% complete. AFE D756 - Reactor Expansion Joints Installation of joints on reactors D-742, D-743 and D-744 has been completed. Joints for reactors D-700 and D-745 will be Installed during their module outages in August and October, respectively. AFE A567 - Rotary Dryer Duct Upgrade Design is 95% complete and in progress. Quotations for the duct will be issued the week of 7/13. The basis of bid for the mechanical installation will be issued by 8/1 with bids due by 8/15. Completion is scheduled for mid-December. AFE F587 - Laboratory Addition All major equipment has been quoted and will be placed on order by 7/20. Development of the building floor plan will be completed by 7/13. Detailed design is scheduled to begin by 8/1. Construction is planned for completion by 12/1. AFE F537 - Dry Blend Boxing Hopper Binsert Jenneke and Johansen Inc. has begun detailed design for the binsert. Approval drawings are scheduled for completion the week of 7/6. Installation is planned for completion in September. AFE A657 - Roof Upgrade Phase II Bids have been received and a contract will be awarded by 7/13. Installation is scheduled for completion by 9/15. -r- cprr .-hii-i'ii* r-v% ' "Hi -..-.ji. i-.i*.. n .. v.. 11J a `I .-i M'-t VAB.0001191322 ' It-it lll.fc.WlMlfcttiTTRlHlFFJfSj t ETV-r'-iM *< tyi-Kif.-i it : '1 1* . I V L MECHANICAL ENGINEERING - Continued A AFE F596 - Chem Wash Automation Design for the New Module is 98% complete and in progress. Completion is planned by the week of 7/20, Construction for the Old Module is 20% complete and in progress. Completion is scheduled for 9/1. CONSTRUCTION - C. A. Clark A total of six construction contracts, thirty-four General Service Contracts and twenty-four register tickets were issued during the month of June. -|. h.Hs^ . =-UJ-Ti.:h 1'^ !** II +1 ^ I v^fm. '**W V.- tze .r ii* :J* nsarni i-"iMtffcc '-JrliHnkn .>-,v$4 j b ^ri|ftinrR?w t-it.'rrdF^f'^.d 1i1-7it|M44pQp*4 ,riTdl =-r: *-*tM fflim * ll^^^^*f^fl^$^^Ttl^^,^ 1 - VAB.0001191323 f rtt-tK f r - ; 'h h- :. fc r- -pgc^p: r-rT*r .^|n i < ~r' - PROCESS ENGINEERING - V. E. Messick Resin Quality Improvement Project A. Rigid Resin Permanent Facilities - Phase I and II Operator training classes were held on the Phase I and II additive systems with the assistance of PED personnel. Programming changes to the old module Modicon were made to allow recipe specific charging. Check-out and commissioning of the systems are in progress with start-up scheduled for early July. B. Resin Permanent Facilities - Phase III and IV Equipment and instrument selection continued throughout the month. A field trip was made by Litwin to determine site elevation information and underground information. Further review of equipment arrangement and surrounding area revealed the need to relocate several firewater lines and the refrigeration compressors for the initiator storage freezers. C. Flexible Resin Technology Final status reports were issued on Flexible Resin Technology team activities. The team was disbanded at the end of the month. Rigid Calendering Team Activities Results from the BASF calendering trial were issued by L. G. Haefner. E. J. Meyer and J. G. Cole issued trip reports. K. W. Birck issued the results of the 5305 experimental design. A meeting was scheduled for July 7 to determine the Klockner and Hoechst trial plan and recipe. D. S. Cox issued a report detailing his work to reduce inherent viscosity test variation. The configuration of the new temperature controller for D-745 has been finalized after review with operations. A letter was issued which detailed possible causes of inconsistency between D-745 and D-700 production. 5305 resin will be produced in D-700 in July. Distributed Control System The plant and GED have finalized the information to be presented in the project scope document. The project scope and justification is scheduled to be issued in July and a review meeting will be held on July 28. Plasticizer Area Relighting Project The class "A" process design for relighting the plasticizer building and surrounding areas was issued and reviewed in the plant. Southwire IR Problem Process engineering participated in discussions and test runs associated with quality problems at Southwire1s compounding facilities. Test runs included studying the effect of different raw materials on the electrical properties of the compound. Results showed that the anti-stat used on the resin was detrimental at higher concentrations to electrical properties. Resin produced with an alternative anti-stat resulted in improved electrical properties of the compound. VAB.0001191324 r M1 11 . -a P- -| i^p JL'l-T ' : i.-- Hr; ^ . WTiH^Krii^NIEni m :t !WI*uhi i m- i ................................ Jffruitffiwmt* iWP^ Hi.-.-L-f Ift-yr*; r ........ * PROCESS ENGINEERING - Continued Water Management Project Work associated with the project to identify alternative water sources and to define water conservation/recycle items included: 1) Issuing a report on interviews with five hydrologists to discuss the purpose of pursuing an alternative water supply and to answer questions on project specifics. 2) Issuing trip reports on visits to several locations in areas that have water supply from another water aquifer. The iron removal systems at these locations was observed. 3) Obtaining samples of water from existing aquifer and from alternative aquifer for R&D. R&D will check buffering capability of each water supply. 4) Developing a preliminary project timeline with target dates. A r 1 ` . !`l |t lf|<l |> HI'- ' VAB.0001191325 PERSONNEL - R. A. Miller EMPLOYMENT James M. Vinoski, New Hire Catherine M. Bonsanti, New Hire Thomas A. Madigan, Rehire Jeffrey P. Sykes, New Hire William S. Caldwell, New Hire PROMOTIONS/TRANSFERS K. Stan Allen, promoted to Senior Mechanical Engineer and transferred to LCCP RETIREMENTS None TERMINATIONS Jeffrey B. Popp, Co-op Student returned to school TO/FROM LEAVE OF ABSENCE None A > i L4.*jr:t+l| . 1fl'f-'-lJ IT-* !-T 14*4.1 . (ffl h:F|i :-pn ii r r-ttsu :!v.if)(a(t.i'!.imirt`i-#>--nit--4iMvtPiM4nna -"-1 f'J .J'-4^4-^ VAB.0001191326 111 " 1 i|VfL-> r . v 'V7^:lBW`(4yk4h y, .I Aberdeen, Mississippi A Salaried Employees Hourly Employees Total Employees 77* 170 New Employees Terminations 2 2 DEPARTMENTS PAR # EMPLOYEES Warehouse Gen. Plant 16 Maintenance Laboratory Compound 22 22 Ik Ml Vinyl 32 hi Plasticizer 5 ________ JUNE, 1987 MONTHLY PERSONNEL REPORT Minority Employees # 0 Salaried Hourly 2 66 10% 29% Total 74 30% Hourly Min. Hired % Min. Hired Hourly Min Term. % Min. Term. 1 o o EHP % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD 1 M 2 02 1 22 2 21 2 28 0 0 1 22 2 2 02 0 22 2 40 0 02 0 Number of Applicants: Month 2 Year to Date APPLICANT BREAKDOWN: 22 # Minority 2 % Minority 2 * Female o % Female 0 Hires (Hourly) : Month 2 Year to Date 9 Terminations (Hourly) : Month 0 Year to Date Overall Turnover 2 Projected Annual Turnover 2.4% summer VAB.0001191327 A t s l-i-ir. :?KH' s * VAB.0001191328 M HU vi>:" sn.^^TTir^^tiUf^rfiii.t! --niwmav****#?**'< F ---m -=tf -^-^jfj-jtf,-<mW*]1i-^HrilfW HHHBM i-MFfrUfl wailiBMMWW*5^ :*ri-^Ki .j =5* i*^.- * ENERGY CONSERVATION - F. G. Jeanson I. Plant Operations Total energy consumption for June was 108.293 MMM BTUs. Energy consumption increased to 2251 BTU/lb. from 2202 BTU/lb. in May. An adjusted CMA reduction of 56.4% was obtained for the month. The adjusted CMA reduction for fiscal 1987 is 54.5%. II. Plant Energy Conservation Program Maintenance There were seven energy related items completed in June. All of these items were steam leak repairs. III. Boiler Operation Boilers Combustion Efficiency % June, 1987 June, 1986 No. 1 No. 2 No. 3 83.6 83.3 83.4 (2) (3) (1) 83.7 83.9 Note: (1) Boiler number one was not used during the month. (2) Boiler number two was operated six days during the month. Boiler number three was operated twenty-four days during the month. A i-r- -ijrSrt*!LHT=4i- H:'1 i >.f. 11 | i I in rn *i .^i Hjiiiiii VAB.0001191329 h : i Month ENERGY CONSERVATION DATA 1987 June Production, MM Lbs. Resin Dry Blend Compound Plasticizer Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Energy Consumption, BTU/lb. Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Energy Consumption, BTU/lb. Propane Consumption, M Gal. Conversion, BTU/Gal Energy Consumption, MMM BTU Energy Consumption, BTU/lb. Total Energy Consumption, BTU/lb. Energy Consumption, MMM BTU Actual Unadjusted Actual Adjusted 1972 Base Period CMA Reduction (%) Adjusted Unadjusted Fiscal 1987 Year-to--Date Performance TOTAL 34.8 4.7 6.8 1.8 48.1 49343 1020 50.330 1046 5.7963 10000 57.963 1205 0 92000 0 0 2251 108.293 88.615 203.082 54.5% Adjusted 44.8% Unadjusted 56.4 46.7 1986 June 33.5 4.6 4.8 1.5 44.4 48096 1020 49.059 1105 5.5237 10000 55.237 1244 k 0 92000 0 0 2349 104.296 82.757 187.379 55.8 44.3 \* -r Kt'Hf I'-T. IPiirwrHP>pt|*W'l LflWh|llBll||f iMl H l|, 'l| *L EJtlWM HMJi'lH* :I 1-r>l:|!M I- vt mWlUpi-^ .c .>. :vr.MM*.i I Wl Bl.HW'H VAB.0001191330 i III rr.ri2 'I all .* ai... *, .* i 4-- | ** a --a |. -1" h. - --I-- ^ aiai-.ri. ENVIRONMENTAL - R. A. Frohreich Water All wastewater discharge parameters were within NPDES limits during June. The acute bioassay testing completed in June indicated that polyvinyl alcohol is not causing the toxicity observed in the chronic bioassay tests. The cause of the toxicity has not yet been determined. Air The application for the renewal of the plant Operating Permit was submitted to the Bureau of Natural Resources. Waste Management Five truckloads of waste oil were shipped to Stauffer Chemical Company. One truckload of reactor culls was shipped to Sun Polymers. One truckload of drummed waste was shipped to Chemical Waste Management. NESHAPS The Leak Detection and Elimination Plan was revised to satisfy the requirements of Subpart V and was submitted to the Bureau of Pollution Control. Comments were given to Keller and Heckman pertaining to EPATs suggested revisions to the vinyl chloride standard. The NESHAPS quarterly report was prepared and submitted. A Si- !.PrM 1 *... 'I h--I- *flj rj -.i: t*i n .'It! "VlP-t . `t VAB.0001191331 .: c. j. .'(I ShRTl'T-'sUprli: C|H P- Vi tf : t A TABLE I WATER COMPLIANCE WITH NEDES PEEWIT PARAMETERS Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. Jan. - Ave. Max. Feb. - Ave. Max. Mar. - Ave. Max. Apr. - Ave. Max. May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Flow GEM 1010 1207 1031 1075 987 1350 1062 1300 858 900 903 970 990 1177 1049 1243 979 1021 BOD PEM lb./dy. 6 77 10 120 15 183 17 213 23 268 46 373 15 194 20 310 14 142 26 266 11 119 21 217 8 93 10 121 8 104 11 116 6 71 8 98 00D PIM LB./DY. 26 311 33 404 33 406 42 527 71 846 110 1284 53 662 57 775 42 431 75 766 38 409 50 541 42 505 56 680 31 384 40 515 27 350 40 480 Sus. Solids PEM LB./DY. 14 165 23 281 23 281 37 464 13 179 24 302 18 231 28 434 10 99 13 140 19 206 35 362 33 407 78 986 8 101 11 142 14 167 21 257 Dies. or 7.4 8.0 8.2 9.1 7.6 8.6 9.6 10.3 10.0 10.6 8.8 10.5 9.1 11.0 7.7 7.8 7.0 7.3 NIL LB./DY. 2.7 7.3 0.1 0.1 2.0 4.7 2.1 4.6 4.9 9.3 4.0 7.6 2.5 6.1 8.8 17.8 6.9 14.2 PH 7.6 8.0 7.6 7.8 7.3 7.8 7.7 7.8 7.7 8.0 7.8 8.3 8.0 8.3 8.0 8.6 7.7 7.9 NEDES Permit Limits - Decenber 1 through April X Ave. Max. 32 431 -- 43 800 1462 - 2713 NEDES Permit Limits - May 1 through Novenber X Ave. Max. 26 357 -- 40 744 1212 -- 2523 674 -- 1396 674 -- 1396 rr -d: 1^.^;.^'!*-gw-wn-"r:T~r*.|*HT`T'ii>ilMtUW, M*f+! 'y "Hhc-tr.tr|'1^i:nm-rJitf j..! riUMtHh HitJv iHufi"*1 i5(n*rt^i-rtr^?*atfrt-,f4KhS' ...... if TM> th.- ^wm:t<a"ntriWMWdfciM.-i,w:-: --'artfrfr*iWW?lW-^W^ai!i|ft3l:o ^ 6.0 ~7 6.0 f 13 6.0 - 9.0 28 13 6.0 - 9.0 28 VAB.0001191332 J . ... mW|. . i -frtT'..i../..j...|....i.....i....*..- Vi!-: + . y-ji.JJ.; ' N . .'-i. ;p^j .-^Ce. ttfc ir 4 i h, LABORATORY - H. G. Coleman Safety A. Safety There were no injuries to laboratory personnel during the month. An R&D technician suffered a minor burn while working on a mill. The second degree burn required routine first aid and is being classified as a medical treatment case, charged to R&D. The safety training for the month was a First Aid/CPR refresher course given by Corporate Nurse, Susan Smith. B. Customer Relations Customer Contacts Alsco - B. J. Harrison visited this customer who began toll supplying 80273G this month. He provided technical input to the start-up of the toll blending operation. Requests for Corrective Action Date 6/25 Customer Prestolite Sidney, NE 6/25 6/24 Northwixe, Inc. Osceola, WI Allied Extrusions Deerfield Beach, FL Product 35031 34551 NAT Reason B conpartment of PTLX 41650 was contaminated with black streamers. Bolt damaged extruder. 269-164 WHT 112 Gray streaking on extruded product. Customer Problem Reports Date 6/04 Customer Allied Extrusion Product Reason 269-164 WHT 112 Gray streaking. 6/09 Novatec (Honduras) Waivers Issued Customer Product Oolmbia Plastics 5385-3P Hoechst Celanese 5305 Nibco 5265 Nibco 5305 Western Textile VRP 80273G Kheometry uniformity; product toll blended by Intamix. Reason Contamination Static Flow Static Flew, PSD Static Flow Color No. 1 HT 2 EC 1 HT 6 HT 2 TT ' dfc-r ( >:| lm*.. LM' i `iSf.ers.-rtft T*EH= .aHf*fe1Hirtl b=: v.ftf -IHjq-w* BT^fff.TtllFlfcJ m VAB.0001191333 II -rr^riir'-r--*HTt rttH(JJ| Hijp^i^Tm';-rrirrrTjirrfllllrin ' ~T t Ctfntifrt iTi'm i < )ir H|. nr nT .' jiJJ'HI!E-p<'-i!li'. ipjn: n ij.pWH .-Mr*'.-. !Xih*i< : i. 11 mi>. . LABORATORY - Continued C. Development lab Summary Die following is a sunnary of residual VCM results on in-process sanples. None of the reactor daily averages exceeded 400 ppm during the month of June, 1987. Nunber of Sanples Average ppm, VCM Reactor Slurries 831 258 42 1.3 Blend Tanks 5265 5305 43 29.8 RVCM of Shipment Sanples Die following is a stannary of the residual VCM analysis of shipment sanples for the month of June, 1987. Product 5265 5305 5385 5415 5465 Debax Dry Blend Pond No. of Sanples 50 83 42 50 Average RVCM, ppm 0.5 0.2 0.2 0.1 0 0 32 0.4 40 0.2 4 1.9 5265 Bulk Density 0.65 Inherent Viscosity 0.39 "L" Color Value 0.86 "A" Color Value 0.48 "B" Color Value 1.08 % on Pan (vs. 2% max.) 0.42 % thru 140m 0.77 Drytime ------------ Mets IR (vs. 95% of control) Hard Particles (% / 10) 5305 * 0.33 0.57 6.00 8.33 0.67 7.00 1.90 -- -- 5385 1.40 0.48 5.83 -- 3.33 6.33 2.38 0.44 -- 5415 0.67 0.58 2.92 -- 4.00 4.22 (0.89) 2.90 0.67 0.63 (0.35) 1.1 7.7 * No antistat added at dryer. No 5465 production this month. rtl' V*"" ' .-.r. I^r r-r-Tf: I r :*on- i:> j VAB.0001191334 LABORATORY E. Conpound Adjustments M Lbs. (%) Rejections M lbs. (%) Hardness Specific Gravity Color/Clarity Hard Particles Heat Stability Contamination Dispersion Dicing Total 15.00 (0.22) -- 7.00 (0.10) --- 5.08 (0.07) -- --- -- 27.08 (0.39) - 3.20 7.80 8.60 17.27 37.50 5.35 79.72 -- (0.05) (0.12) (0.13) -- (0.25) (0.55) (0.08) (1.18) F. Dry Blend Quality Summary Rejections M Lbs. (%) Contamination Color/Long Stability Total 20.54 (0.44) 6.%_____ (0.15) 27.50 (0.59) G. Miscellaneous1 1. B. J. Harrison visited various manufacturers of rheometers and colorimeters to decide upon equipment for the new Applications Lab. Purchase orders for all of the necessary equipment were Issued. 2. TCLP data was generated by D. S. Cox for 5305 and experimental 5265, albeit at high (12-20 ppm) RVCM levels. Results were similar to other Mnon~5265" resins. Porous resins at 2 ppm or less can be expected to pass the TCLP test. 3. An experimental design was performed in the I.V. test. Sample concentration, cook time and balance selection were found to have an insignificant effect on variability. A 4. A report was Issued on all precision testing performed to-date at Aberdeen. Based on feedback, certain tests will be selected for precision improvement. 5. B. J. Harrison completed color matching for the following customers: NB00, Available Plastics and Thermal Industries. B. J. Harrison conpleted a torque study of 269-113 lot 47F26 for Vinyl Building Products. All box within specification. An evaluation of 80273G sanples returned from Novatec shewed very poor quality and uch variability. mils product toll-blended by Intandx.) ' J' :! : . 3 rrw1-1" . ! H"*"1 -ir in "fcHdi'-ii' > -Hs.WiLJN- iWW-' lu 'H IH Hapii H IT-1J If r W ^ y 1"jl ' --li A VAB.0001191335 i-h rTt t^-i**?mw" t SHIPMENTS BY PRODUCT - M LBS. JUNE. 1987 FISCAL YEAR-TO-DATE A RESIN PLASTICIZER DRYBLEND COMPOUND 27,558 432 5,243 6,887 243,458 6,561 41,699 64,952 TOTAL 40,110 356,670 NUMBER OF SHIPMENTS BY MODE: 1 RAILCAR VISTA TRUCK TRAILER ON COMMON CUSTOMER BULK VAN A FLAT CAR CARRIER PICK-UP CONTAINER TOTAL RESIN-Bulk 12Q 1 Package * t 2 Export 3 3 103 67 1 266 18 4 PLAST.-Bulk Package 2 2 4 DRYBLEND-Bulk Package 83 12 14 Export COMPOUND-Bulk Package Export 18 5 36 30 37 2 23 103 2 TOTAL JUNE 165 60 49 6 41 152 473 OCTOBER NOVEMBER DECEMBER JANUARY FEBRUARY MARCH APRIL MAY 166 41 51 2 52 160 422 146 64 39 2 64 135 450 133 46 29 1 48 133 390 193 68 44 3 89 147 544 154 50 45 3 56 143 451 181 60 56 64 129 3 493 150 53 46 4 44 140 1 438 162 60 44 54 139 459 ----------------------1................ , VAB.0001191336 V*-f-Mf?rtfMfff'T- E| fW !fT-| "S'Ti'l! "1^nWUMK(p^rTv3pil*ujil|yjrij ENERGY USAGE A con CNJ CO BTU/LB in 2O (j) > Q 'XI o Z) o ID to Z - Oft > UJ ** T uj < u. LlJ >D ^ UJ cn ^ IAJ ir4t Mo n th1y --------- 12-Month Moving Avg i- .' i *-' i +. iit-pr.i-iiHk-Ofri frr-* > r* ^ -Tfr-:+!:!-an^i j?Tii ti t -rtr n < ijiiir-1 ni v rmi mpTininfrfptf' f |.r. 11 lint ' im iu; i.h i|. . iLih. f| iiJ>n In!!. <jii .i j.i.nM;.i.iii|.iH^ijiM<ii. ~*ld VAB.0001191337 n;FjhP!ii^ ;ii> iHHMy mJLf Tft-dfr 5^" * -''-`--i v. i'mrrp :im? t iuitrtf*fcifnrrr:s if!-nrnifntumnir hi i iirt r4 h-i - i --iK MONTHLY HOURLY TURNOVER A i ' !-- - .v-- + HI-J? <ih-j J. i I- Iiv.il 1-1 J I |rjrr- II IT 1- I* T r #..l--|-i-niT*iii!ii- -i^i7'l|LdN.-il4>K<i.qh'i*T*al- I J- V->. -liPP*-''?! \-,mrm T-'l-'!|E)!::if -KifcSI IPJWP^PJ^*)f^ippS',T i* rt*" TLP.p^-|!; t' ::)ir Jfcjlll [(v; h. IhH-aic VAB.OOOl 191338 k I *f 1i V 6.0 5.0 4.0 3.0 2.0 1.0 0 % OFF-GRADE 1.00 Q75 050 25 0 4.0 3.0 2.0 1.0 0 Oct. ABERDEEN PLANT QUALITY PERFORMANCE 10/01/86 - 09/30/87 Jan. Feb. Apri 1 ip 86/0? June A Sept.i Oct. in*': f** r L| 1 -4>htilh i- r> - ^ ***' si wii*friMi*H<rvl:J.^r ^<ir HW h . -friMiw WWttr'fmtfH. UMI Tlih1 ril* K- !; ; iifjaffjf Hh*t:h r -*fl --1 p'Wklhj '! T'l VAB.OOOl 191339 % i-i!: i - L.-iTr!: nv.. 'I re I- f-< ^ r^-T lll tn^m -"t-rnHF ` -upi-i ihi!-*' t POUNDS PRIME ABERDEEN PLANT INVENTORIES 10/01/86 - 09/30/87 A 1.0 0.5 0 & r--r hi p:fi 9' 1- V t If l4t rv HmU'ii *-| . :rjTp^ .i>4c-jns m>yyiiiiA-.f>-:TVf.-.nT<. i KnnvnMiumitiw l*h-h- r gliV-tlthik-lj p >p4j "HP'.p VAB.0001191340 *PI i-! u `'Htfel!' HTTP*? -T- aH^IF WHt'T' *! r MM POUNDS V MONTHLY 40 35 30 25 20 E 15 8 6 4 2 V 6 5 4 3 2 1 2 1 0 Oct. ABERDEEN PLANT PRODUCTION 10/01/86 - 09/30/87 A MM POUNDS CUMIOTW Dec. i Jan. -- --- - - -- - -- T - --------* Ma r. 1 - --- ... Apri 1 May t i i i jJune i ... July 20 4- i 15 *1*':t ;1*i1 1 " 11 10 1\it! 5 1 : i | \i Aug. I Sept.1 Oct. j Budget Actual Cumulative VAB.0001191341 ML == ................ m infmif. Bfr^ri (**" 4 'N ABERDEEN PUNT EFFICIENCY 10/01/86 - 09/30/87 POUNDS OF RAM MATERIAL/POUND OF PRODUCT A 19.86/87 wert'l"r!> pp.ih*tfr-wrT*l .rc+w VAB.0001191342 j, *-> i+Tit j tN ;..!! W.'urlu