Document jmYvqNq1Zb5D97e7K69bOeZz9

To: R. T. Ferrell Interoffice Communication From: Date: Subject: W. Were March 17, 1987 ABERDEEN MONTHLY PROGRESS REPORT FEBRUARY, 1987 There were no injuries recorded during the month of February. As of February 28, 1987, the plant had operated 2,793 days or 3,588,055 manhours without a lost time injury. PVC resin production for February was 33.7MM pounds. Mechanical downtime in the reactor areas was due primarily to agitator seal repairs on 400, safety disc replacement on 745 and miscellaneous reactor valve repairs. Resin production year-to-date totaled 177.8MM pounds. The VCM efficiency for February was 1.01638 pounds of VCM per pound of PVC produced versus a 1.00208 standard. Year-to-date VCM efficiency is 1.01065. Compound production for February was 6.8MM pounds. Line X and Line III operated twenty-eight days and Line V operated fourteen days during the month. Production was limited primarily by product changes, Banbury maintenance and Line III mill maintenance. Year-to-date compound production was 35.4MM pounds. Quality performance for flexible compounds was 1.5% off-grade of which 100% was due to mill scrap. "BC" production was 1.2%. Dry blend production was 3.9MM pounds for February and 22.6MM pounds fiscal year-to-date. Production was limited primarily by product changes and quality control problems. Quality performance for the month was 99.8% customer grade. The plasticizer unit operated twenty-eight days in February to produce 1.6MM pounds. Year-to-date plasticizer production is 9.4MM pounds. Two of four active involvement teams have completed their projects. The vinyl team presented the results of their work to management and a miscellaneous capital project was approved to institute their proposal. Department steering teams have been formed and began regular meetings in February. Total energy consumption for February was 112.690 MMM BTUs. The energy consumption per pound of product was 2444 BTUs, resulting in an adjusted CMA reduction of 52.3%. The adjusted CMA reduction for fiscal 1987 year-to-date is 54.2%. VAB.0001031584 r R. T. Ferrell 03/17/87 Aberdeen Monthly Progress Report The total plant variable cost variance for February was $277.4M unfavorable, resulting from an overall unfavorable price variance of $283.8M and a net favorable efficiency variance of $6.4M. The total fixed cost variance for February was $56.9M favorable. A J. W. Ware rah VAB.0001031585 ? L DISTRIBUTION HOUSTON PONCA CITY OKLAHOMA CITY LAKE CHARLES VCM PLANT LAKE CHARLES CHEMICAL PLANT BALTIMORE HAMMOND ABERDEEN A - J. D. BURNS - R. E. LEHMKUHL - R. T. FERRELL - R. D. GAMBLIN - J. J. LANGFORD - R. E. SWANTKOWSKI - D. F. HARMAN - H. R. FLAMMER - E. L. KIESCHNICK - S. K. SABORSKY - K. J. EGGERS - D. H. SANDERS - S. E. MCGUIRE - R. L. POE - H. J. HALL - C. M. STARKS - HARRY GARRISON - DICK CONRAD - J. A. DEBERNARDI (COVER LETTER ONLY) - T. H. HUFFMAN < - R. W. SEYMOUR (COVER LETTER AND SAFETY PORTION) (COVER LETTER AND SAFETY PORTION) - J. B. MAHER (SAFETY PORTION ONLY) - JF, JWW, DWH, PJK, TFL, RAF, JVU, RAM, VEM, HGC, CWT, REP, VLT, PJR, JGC, RBN VAB.0001031586 SAFETY - J. V. UPTAIN Occupational Injuries First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases (RWC Rate) Number of Lost Workday Cases (LWC Rate) Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Feb. 0 0 0 0 (0.0) 0 (0.0) Fiscal Y.T.D. 1987 4 1 5 0 (0.0) 0 (0.0) Fiscal Y.T.D 1986 12 2 14 1 (1.01) 0 (0.0) Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Non-Occupational Injuries Lost Workday Cases Days Lost 0 0 Safety Record Last lost time injury 7/5/79 Days since - 2,793 Manhours since - 3,588,055 Training Topics for the plant safety meetings during the month included: Housekeeping, Personal Responsibility to Act, Finding Cures for Accidents, The Team Approach to Safety, Review of 1986 Safety Performance, and Maintenance Weekly Safety and Job Review. One R&D employee and six contract personnel received plant safety orientation. A VAB.0001031587 f SAFETY - Continued Health Activity for the month included routine dosimetry (shown below) and the start of annual, medical health screening (van). Chemical < Number PEL Percent *> Number PEL Percent VCM Lead Total Particulates 77 16 7 100.0 88.9 100.0 0 0.0 2 11.1 0 0.8 The two lead overexposures occurred with respiratory protection. A VAB.0001031588 i. A QUALITY IMPROVEMENT PROCESS - R. B. Newton A one-day training course for involvement teams and problem solving techniques was prepared. It is scheduled to be given to the Vinyl Department the first two weeks of March. Two of the four active teams completed their proj operators presented their solution to the cross-contamination to management. A miscellaneous approved to implement their recommendations. . The team of vinyl problem of AFE request is being The maintenance team that was preparing the Preventative Maintenance Program for the new plant crane completed its work. A presentation to management is scheduled for early March. * An additional involvement team was formed in the Maintenance Department to address the problem of valve actuator mounting brackets. Each department in the plant has formed a steering team to keep the quality improvement effort moving forward. These teams began meeting regularly during February. r" 4 ' -+ 4 h - -.p-. . -4 .. ,, VAB.0001031589 fi VINYL - D. W. Hollis, J. M. Edwards A Safety The Vinyl and Yard Departments operated without an injury in February. Shift safety meeting topic for the month was Accident Prevention and a review of the plant's first aid and medical cases which resulted from accidents in recent years. Production February Y.T.D.(Fiscal 87) 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 33.7 1202 854 30.5 94.8 10616 59.0 28 177.8 1190 4431 29.3 90.6 10407 59.2 151 Vinyl Department production for February was 33.7MM pounds. Reactors The reactor stream factor for February was 94.8%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 71.3% 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, reactor manway O-ring failures and downtime associated with test runs. 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 28.7% of the total downtime and was due to changing the agitator seal on D-400, changing D-300 and 745 primary VCM valves, changing various chem wash and rinse valves on D-500, D-700 and 745, changing the safety discs on 745 and changing the inboard seal on B-compressor. Dryers The dryer stream factor for February was 59.0%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 92.8% of the total downtime. Dryers were shut down when possible for energy conservation. Operational Downtime: Accounted for 3.8% of the total downtime and 4 was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems, and the fluid bed scrubber plugging. VAB.0001031590 r VINYL - Continued Dryers - Continued 3) Maintenance Repair/Revision Downtime: Accounted for 3.4% of the total downtime and was due to changing out #7 centrifuge, changing out the fluid bed exhauster sheave, #5 activator problems, #6 star valve problems and the #8 tumbler seals. Product Quality Summary Resin Type Prime % of Total "B" "H" Production 5265 5305 5385 5415 5425 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 1,483,273 2,899,270 17,691,415 7,270,740 1,828,830 1,388,600 -- -- -- - 32,562,128 -- - - -- -- -- 1,038,080 20 -- 2,000 1,040,100 -- - -- -- - -- -- 55,703 -- 55,703 4.4 8.6 52.6 21.6 5.4 4.1 3.1 0.0 0.2 0.0 100.0 Quality performance for February was 99.8% customer grade with 0.2% ,fH" grade production. A total of six railcars were shipped as "B" grade during the month which represented 5.6% of the 108 total resin hopper carsi shipped. Load Date Ship Date Car No. Customer Product Reason 01/21/87 02/02/87 RTMX 580054 Cont. Plast. Co. Debox Derailed 12/14/86 02/03/87 VIPX 45811 Wexford, CA Pond Quality 01/27/87 02/09/87 PLCX 43730 Wexford, WI Debox Quality 02/04/87 02/23/87 VIPX 45871 Wexford, CA Debox Quality 01/28/87 02/25/87 VIPX 45793 Wexford, WI 5385 Contamination 02/20/87 02/27/87 VIPX 45713 Griffco. MS Debox Quality The Vinyl area received fifty-nine short lead time emergency type orders comprising 22% of the 269 Aberdeen resin shipments in February. Monthly Variable Cost Performance Variable costs for the month were unfavorable at $269.3M resulting from an overall unfavorable price variance of $247.8M and an unfavorable efficiency variance of $48.5M. Resin variable cost for the month was 18.996 cents/lb. versus the budgeted 18.086 cents/lb. A VAB.0001031591 VINYL - Continued Monthly Variable Cost Performance - (Continued) The $247.8M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $342.1M. The $48.5M unfavorable efficiency variance can be attributed mainly to the unfavorable efficiency variance of VCM, $72.7M. This was partially offset by a favorable efficiency variance in Polyvic, $10.3M. VCM efficiency for the month was 1.01638 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. YTD variable cost efficiency variances in the Vinyl Department totaled $223.6M unfavorable. Energy Performance/Progress 1. Plant energy performance for February was 2444 BTU/lb. General 1. Resin raw material in the 0744 account totaled $209.7M. A VAB.0001031592 r 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 28 2142 77 14 827 59 28 3860 138 6829 11904 4268 19219 35391 Line I operated twenty-eight days during February at an average rate of 77M pounds per day. Major items affecting production efficiency were: product changes, 73 hours; Banbury maintenance and seal changes, 41 hours; ribbon blender maintenance, 11 hours; housekeeping, 11 hours; quality problems and Q.C., 14 hours; dicer problems and maintenance, 6 hours; and Modicon reprogramming, 6 hours. Line V operated fourteen days during February at an average rate of 59M pounds per day. Major items affecting production efficiency were: product changes and startup, 33 hours; quality problems, 4 hours; and plasticizer system problems and maintenance, 3 hours. Line III operated twenty-eight days during February at an average rate of 138M pounds per day. Major items affecting production were: product changes, 40 hours; mill drive shaft gear replacement, 16 hours; dicing system problems and maintenance, 6 hours; hydrotherm system maintenance, 5 hours; and transfer system problems and maintenance, 5 hours. A test run to investigate rigid PVC production on Line III lasted approximately 11 hours. Quality performance for flexible compounds was 1.5% off-grade of which 100% was due to mill scrap. f,BCn production was 1.2%. The raw material requirement for flexible compounds was .99658 pounds of raw material per pound of compound versus a 1.00993 standard (YTD is 1.00462). The variable cost variance for compound was $46.4M unfavorable with $59.5M unfavorable due to price and $13.1M favorable due to efficiency. The efficiency variance due to product mix was $8.4M unfavorable. There were no major compound raw material efficiency variances. Total compound inventory fell .4MM pounds in February to 7.8MM pounds. Dry Blend Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 3926 28 140 22561 151 A VAB.0001031593 t COMPOUND - Continued Dry Blend - continued Dry blend operated twenty-eight days during February at an average rate of 140M pounds per day. Production included 80172C, 80273G, 90172D, RP-200T, RP-421, 186-74, 186-139, 223-36, 196-198, 223-57, 245-53, 269-12, 269-67, 269-66, 269-63 and 269-43. Dry Blend production was hindered by: product changes, 53 hours; delays associated with quality and lab problems and normal Q.C., 38 hours; transfer system problems and maintenance, 15 hours; filler system problems and maintenance, 8 hours; Welex diverter valve maintenance, 8 hours; screener maintenance, 8 hours; and Welex maintenance, 5 hours. Quality performance for the month of February was 98.4% customer grade. The raw material requirement for dry blend was 1.00744 pounds of raw material per pound of dry blend versus a standard of 1.00489 (YTD is 1.01018). The variable cost variance for dry blend was $51.2M favorable with $14.9M favorable due to price and $36.3M favorable due to efficiency. The efficiency variance due to product mix was $38.3M favorable. Plasticizer Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 1624 28 58 - 9372 151 Plasticizer operated twenty-eight days during February at an average rate of 58M pounds per day. Production included 610P and 108P. VRP production totaled 142M pounds (9.6%). The raw material requirement for plasticizer was 1.11239 pounds of raw materials per pound of plasticizer versus a 1.09848 standard (Y.T.D. is 1.11520). The variable cost variance for plasticizer was $14.1M favorable with $8.6M favorable due to price and $5.5M favorable due to efficiency. There were no major plasticizer raw material variances. The efficiency variance due to product mix was $1.7M favorable. Quality Improvement Charting of process variables is being practiced on all lines. The continuing monitoring of plasticizer reaction rate has demonstrated a statistical increase in rate and reduction of reaction time since the charting began. A quality information bulletin board was started in the production area. Customer problems and positive responses are posted on the board to help the operators grow more familiar with the customer and his concerns and to provide feedback for our quality effort. A VAB.0001031594 f fc 4 COMPOUND - Continued Compound Dry Blend Plasticizer Usage (BTU/Lb.) Actual Standard 1716.5 720.1 1792.0 1783.0 730.0 1833.5 A * ... | + -i i i- b n.- VAB.0001031595 r MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - G. A. Morgan, D. A. Miller There were no injuries to Maintenance Department personnel during the month, Vinyl The D-400 reactor agitator seal was repaired during the month. Four agitator seals have been replaced through the first five months of fiscal 1987. Ten reactor valves were replaced. The following work was accomplished on pumps and compressors: - The seal was replaced in the old module east VCM charge pump. - The seal was replaced in the old module north chem wash pump. - The south VCM sphere pump was replaced with a spare. - The impeller was replaced on the fluid bed dryer scrubber pump. - The seal was replaced in the old module high pressure service water pump. - The outboard seal was replaced in the 706 emission recovery compressor. All mercury manometers on the reactors were replaced with vacuum The annual replacement of the D--745 reactor rupture discs were completed. The #6 dryer exhauster was replaced with a spare due to high vibration. The #7 dryer Bird centrifuge was replaced with a spare due to high vibration. Twenty-three steam leaks were repaired. The control room batteries and inverter system was PM*d. The new unit seal water separator temperature controller was replaced A VAB.0001031596 F i MECHANICAL DEPARTMENT - Continued Compound, Dry Blend, Plasticizer The Line I Banbury seals were replaced and two seal yoke cylinders were replaced. The Line I B-blender gearbox was replaced. The Line I A-blender ribbon shaft was repaired in the outboard bearing area. New chain guards were installed on both blenders. The Zone I Line III hydrotherm system pump was replaced. The dry blend unit #1 Welex mixer drive motor was replaced with a A rebuilt gearbox was installed on the north gump screener. The Line I Banbury inlet chute and Ram housing was modified to eliminate excessive dusting and a potential lead exposure hazard. The Line V single screw hot oil system was overhauled. The Line I pro-batcher weigh controller was repaired. Utilities Dredging on pond #3 was completed and a subsurface aerator was installed. A new sulphuric acid day tank was installed at pond #3. The hydrazine based oxygen scavenger for the boilers was replaced with a hydroquinone based product to eliminate potential employee exposure hazards. A VAB.0001031597 f