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SAFETY - A. H. Sather OCCUPATIONAL INJURIES Injuries Treated January 1980 Year-to-Date 1979 Year-to-Date First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time 5 0 0 0 0 5 0 0 0 0 2 0 0 0 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 2 2 1 0 0 0 2 2 1 0 0 0 2 0 0 0 0 0 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 33 11 00 11 00 00 0 1 1 0 1 0 As of January 31, 1980, the plant operated 210 days or 276,154 manhours without a disabling injury. SAFETY AWARENESS The initial plant emphasis of safety awareness using the films noted in the November and December Supervisory Workshop progress reports was completed early in the reporting period. Materials for the "Win With Safety" campaign were reviewed, ordered, and received during the reporting period. The plant plans to utilize the sports themes and hazard emphasis from this program. To supplement the material from the campaign, numerous films were reviewed and reserved as appropriate to support the safety awareness topic of the month. EMPLOYEE SAFETY RESPONSIBILITIES PROGRAM The second issue of part 1 of the Employee Safety Responsibilities slide and tape program was received and reviewed. Comments were given to M. S. Reynolds in early February. Initial photographic work was initiated with several rolls of slide film being processed. 1- DTH 000043786 SAFETY (Cont.) LABORATORY FIRE PROTECTION The carbon dioxide (CO2) fire extinguishing system was installed in the laboratory chemical storage room. The system was tested for CO2 concentration over a ten (10) minute period and accepted by the Safety Director. An operating procedure was issued to all laboratory Supervisors and Safety personnel. LOSS CONTROL HOME STUDY COURSE To improve injury control methods in the plant, the International Loss Control Institute's home study course "Management Guide to Loss Control" was issued to the Plant Manager, Department Heads and Safety personnel. Current plans call for work requirements to begin in at the end of February. PHTHALIC ANHYDRIDE STORAGE TANK FAILURE At approximately 2:15 a.m. on January 8, 1980, T-100, Phthalic Anhydride (P.A.) storage tank failed. At the time of failure, GATX 14180 was in the final stage of unloading. An investigation team composed of L. D. Honeycutt, Yard Supervisor, J. R. McCrimon, Compound Operations Superintendent, and A. H. Sather, Safety Director, reviewd the incident and issued its findings and recommendations on January 18, 1980. All available evidence indicated the cause to be overpressure due to a plugged atmospheric vent. OSHA COMPLIANCE Numerous activities in the area of OSHA compliance occurred during the reporting period and include: A. VCM and lead training. B. Health testing by American Health Profiles. C. Ventilation improvements in the compound color weigh room were completed. D. Routine personnel monitoring, the results of which are shown below along with a brief explanation of overexposures. VCM Dosimetry - A total of 85 samples were analyzed for the reporting period with two (2) indicating overexposure. Below is a summary table of the results and a brief explanation of overexposure. Range (ppm) Number Percent 0.0 - 0.5 0.5 - 1.0 1.0 - 5.0 5.0+ 81 95.3 2 2.35 2 2.35 0 0.00 85 100.00 -2DTH 00004378 SAFETY (Cont.) OSHA COMPLIANCE (Cont.) Overexposures - The two (2) overexposures occurred to Vinyl Chief Operators. The source of one of the overexposures is undetermined at this time and the operator did not wear a respirator. The other operator indicated that he wore a respirator while working on recovery systems. Lead Dosimetry - The results for a total of twenty-one (21) samples were received during the reporting period all indicating exposures less than the permissible exposure limit (PEL). -3 DTH 000043768 VINYL - C. R. Miller Production Month Y.T.D. Budget 1. Total Production, MM#'s 2. Production Rate, M#'s/C.D. 3. Charges, Reactor Batches/C.D. 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average #'s/Hr. 7. Dryers, Stream Factor, % 8. Accounting Days 30.3 977 22.7 705 90.4 6243 93.1 31 30.3 977 22.7 705 90.4 6243 93.1 31 Vinyl department production for the month was 106% of budget at 30.3 MM pounds. This monthly total represents a new monthly production record which surpasses the previous record of 28.8 MM pounds set last October. Dryer performance was up from December with a 93.1% stream factor. The major items affecting the dryer performance were maintenance on the centrifuges (49 hours), and activators (38 hours) and the limitations caused by the large resin bagging requirements. Vibration studies and operating revisions were conducted in the new reactor module during January. Testing was completed on several steam nozzles. One of the more promising nozzles was installed in 741 reactor for longer term testing in normal service. A plant test run utilizing the new 5305 chain transfer agent was conducted during the month. Representatives of the Resin Development Group from Ponca City were on hand for the trials. Preliminary results were very favorable. The material produced is currently being processed into dry blend for customer trials. Resin bagging continued at maximum rates due to low inventory of empty hopper cars. Rates often exceeded 500 M pounds per day with a total of 12.5 MM pounds of resin packaged during the month. Resin Quality Summary Resin IXP-e_ Prime Pounds 5305 1,332,690 5385 21,854,312 5425 4,455,805 5465 71,450 Sifter Overflow TOTAL 27,714,257 "BC" Grade "H" Grade ( 4,500) 1,481,250 42,750 - 1,519,500 79,750 535,250 201,750 ( 2,400) 225,160 1,039,510 % of Total Production 4.7 78.9 15.5 0.2 0.7 100.0 4- - DTH 0000437E9 VINYL (Cont.) Quality performance for the month of January was 90.8% customer grade with 5.5% "BC" and 3.7% "H" grade. The high "BC" and "H" grade reported results from resin moisture and revised particle size grading of bagged resin blends. This off-grade total reflects the increased packaging of resin from the budgeted 4 MM pounds to the actual 12.5 MM pounds packaged. The variable cost variance for the vinyl department was ($311.7 M) with ($517.8 M) due to price and $206.1 M due to efficiency. The major price variance was ($300.2 M) for VCM. The major efficiency variances were $12.6 M for VCM and $13.5 M for combined initiators. The raw material requirement for the month was 1.01801 pounds VCM/pound of PVC versus a 1.02000 standard. * -5DTH 000043790 COMPOUND - J. R. McCrimon Compound Production Month M #'s/Day Y.T.l Line I, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days 885 194 1,877 2,956 31 55 16 87 158 885 194 1,877 2,956 31 Line I operated 16 days during January at an average rate of 55 M pounds per day. Major items affecting production efficiency were product changes (28.7 hours), maintenance on blender scales (14.1 hours), dicing delays (8.9 hours), maintenance on pellet star valve (7.4 hours) and quality control (5.1 hours). Line I produced material for customer orders and to replenish packaged compound inventory. Line V operated 12 days during January at an average rate of 16 M pounds per day. Major items affecting production efficiency were maintenance on the Orbitran (31.6 hours), plugged pellet transfer line (34.5 hours), product changes (17.3 hours) and changing screw configuration (17.1 hours). Pro duction included 27121 Blk., 17461 Gry. 545, 34431 Nat., 18161 Gry 545, 18961 Gry. 545, 35441 Nat., 38551 Nat., and 48562 Blk. The major problem with product quality has been hard particles. Werner-Pfleiderer and PAL personnel have been assisting in the Line V operation. Line III operated 21 2/3 days during January at an average rate of 87 m pounds per day. Line III production was hindered by product changes (45.7 hours), maintenance on mill coupling (110.2 hours) and plugged sewer due to P.A. spill (7.0 hours). The FCM gearbox was also repaired during the down time required for the mill coupling replacement. Line III will be on a 7 day schedule during February. Quality performance for flexible compounds was 1.9% off-grade of which 71.7% was due to mill scrap. "BC" production was 4.2%. The raw material requirement for flexible compounds was 1.00984 pounds of raw material per pound of compound versus a 1.01299 standard. (Y.T.D. is 1.00984.) The lower raw material requirement is due to reworking Line V HBC" material on Line I. The variable cost variance for compound was $7.4 M with $7.3 M due to price and $0.1 M due to efficiency. The variance due to product mix was ($26.6 M). The only major efficiency variance was $11.7 M for resin which reflects re working of Line V "BC" material on Line I. There were no major price variances DTH 0000437:3 -6- COMPOUND (Cont.) Dry Blend Month M #'s/Day Y.T.D. Production, M Pounds Accounting Days 1,863 31 160 1,863 31 Dry blend operated 11 2/3 days during January at an average rate of 160 M pounds per day. Production included 80172B, 80273G, and 80274. Dry Blend production was reduced by the inventory control program. Quality performance for the month was 99.99% customer grade. The raw material requirement for dry blend was 1.00301 pounds of raw material per pound of dry blend versus a standard of 1.00318. (Y.T.D. is 1.00301.) The variable cost variance for dry blend was $35.2 M with $37.4 M due to price and ($2.2 M) due to efficiency. The variance due to product mix was $21.8 M. There was only one major price variance $33.4 M for organo-tin stabilizers and no major efficiency variances. Plasticizer Month M #'s/Day Y.T.D. Production, M Pounds Accounting Days 251 42 31 251 31 Plasticizer operated 6 days during January at an average rate of 42 M pounds per day. Production included 610P, DOP and DIDP. VRP production totaled 7.0 M pounds (2.5%). Production was limited by the failure of T-100 which was a molten phthalic anhydride storage vessel. Engineering is in progress for the installation of a new pressure vessel replacement for T-100. The new installation is scheduled for completion in late February. Due to sufficient inventory of 610P and DOP, bag charging with flake phthalic anhydride has been minimized. DIDP has been purchased from EXXON. The raw material requirement for plasticizer was 1.2116 pounds of raw material per pound of plasticizer versus a 1.09087 standard. (Y.T.D. is 1.21166.) The variable cost for plasticizeT was ($12.9 M) with ($1.4 M) due to price and ($11.5 M) due to efficiency. There were no major price or efficiency variances. GENERAL Total customer grade compound inventory decreased to 5.0 MM pounds during January. Three sample compounds were produced during the month: ADK-3972-134A; ERC 3711-75C; JRT-3866-195. 7- DTH 000043792 MECHANICAL - S. J. Vincent VINYL There were no large reactor seal failures this month. There was one large reactor condenser cleaned during this period. The condenser was on the D-400 reactor. There was one gearbox failure this month. This failure was to the intermediate gear shaft on the D-400 gearbox. The safety discs were replaced on the D-400 reactor and condenser. There were several steam stripping tests conducted in the 742 reactor using steam dispersing nozzles drilled to various hole configurations. Various plant people followed the tests. The AMP meter was replaced on D-400 reactor. Reactor and recovery system valves replaced this month were the suction and discharge valve on "A" recovery compressor, the recovery valve on the 743 reactor and the kill valve on the 742 reactor. The VCM meter was cleaned in the old module. Several problems with the incinerator ignitor and water totalizer were repaired. There were ten (10) mechanical seals repaired this month on pumps and compressors in the vinyl production area. Six of the seals replaced were in the old unit and four (4) were in the new unit. The seals replaced in the old unit were the outboard seal on "B" vacuum pump, the inboard seal "A" vacuum pump, and the seal on the west VCM charge pump. The pump was overhauled and the seal replaced on the east VCM charge pump. The outboard seal on the "B" recovery compressor and the seal on the west VCM transfer pump were also replaced. Seals replaced in the new unit were the inboard seal on the 905 recovery compressor, and the seal on the west RVCM charge pump. A new vacuum pump was installed in place of the 902 vacuum pump and the old unit was overhauled for use as a spare. The inboard seal on the 904 recovery compressor was replaced. There were four P.M. inspections to the vinyl dryers and seven major repairs to vinyl dryer equipment. The dryers inspected were the numbers 2, 4, 5, and 8 units. Major repairs were completed as follows: the southwest trunion was re placed on #5 dryer, the Bird and gearbox were changed on #8 and a baffle rewelded in #8 dryer. The Bird and gearbox were changed on #2, the vibrator chute welded on #2, the #2 air lock rebuilt and the collector level alarm was repaired. Three Bird centrifuges were cleaned. The units cleaned were #1, 2, and 8. The spare Bird centrifuge was rebuilt. The engine was replaced in the vinyl fork truck. A new two inch vent header was installed from the new reactor area to the old unit blowdown tank. The drain piping on the old unit knockout drums was changed from 1" to 2" piping and valves. The receiver deluge line in the old reactor area was rerouted to provide better access to equipment. -8- DTH 000043793 MECHANICAL (Cont.) COMPOUND, DRY BLEND, PLASTICIZER AND SILO STORAGE There were three major repairs completed to compound line III during a plant shutdown this month. The repairs were to the FCM gear reduction unit, the drive coupling on the back mill roll and replacement of the front mill roll "0" ring. Other repairs completed during this down period consisted of minor leak repairs and replacing a section of cooling water return line and the overhaul of #5 vacuum pump. The gear reduction unit was sent to a Memphis machine shop for repair. All bearings were replaced and the line bore checked on the gear case. This unit has major gear problems and will require replacement in the near future. The drive coupling failed on the back mill roll. A replacement coupling would have required 22 weeks to manufacture. The plant machinists and a local machine shop fabricated an adapter to allow replacement of this coupling using a standard Falk coupling. The "0" ring replacement is a reoccuring problem associated with wear on the unit. The compound Lines I and V were operated on a limited basis and required no major repairs. Minor revisions to the cooling transfer line and the bag drop chute were completed as a part of the modifications and debugging of compound Line V. There were no major repairs this month m the dry blend and plasticizer units. Some repairs consisted of steam leak repairs, cleaning pumps, and rebuilding the phthalic anhydride charge pump. As a result of the failure of one of the phthalic anhydride storage tanks, six motors were repaired. There were several repairs in the silo storage area. The major repair was to the resin transfer unit. A clutch and one blower were replaced. Most of the other repairs were to unplug lines and to replace loading chutes. Several of the silo level indicators were repaired. UTILITIES AND SERVICE Major repairs to the plant air systems were completed as follows: valves were replaced in the #2 compressor and the motor was overhauled. The #5 compressor was overhauled and inspected and a head gasket leak repaired on #6 compressor. The new Joy air compressor, the second centrifugal unit, was checked out and placed in service. The new Deltech instrument air dryer was placed in service. The refrigeration mechanic changed out the #4 catalyst freezer compressor and repaired a leaking condenser tube on the Line III chiller. The propane system was tested three times and the plant operated on propane for 25 1/2 hours. MAINTENANCE PLANNER AND MISCELLANEOUS PROJECTS The planner issued 24 registers for contracted outside repair of equipment, processed 26 statements for payment, planned 52 work orders and ordered material for 17 of the planned work orders. The planner set up a system to review material on order working through the purchasing department. Shutdown lists were updated for each process area and the safety valve and safety disc records were reviewed and updated. A summary of reoccuring equipment repairs was compiled from the equipment history files and issued for comments. -9- DTH 000043794 MECHANICAL (Cont.) SAFETY PROJECTS AND ESAR ITEMS New lifting devices were installed on the plasticizer reactor to support the vent stacks when changing safety discs. New welding curtains were installed in the maintenance welding shops. The walkway to the V-ll dryer burner controls was decked to provide a dry work area when working on the controls. There were several projects completed involving relocation and the installation of lighting. The medical surveillance trailer was provided with utilities for operation. -10- DTH 000043795 PERSONNEL - J. L. Carter EMPLOYMENT Bernard Lloyd - Process Engineer (Temporary) Arthur Cunningham - General Helper (Reinstated) Douglas Vogue, Casual Labor Vemetta Peters, Casual Labor Daniel Darby, Casual Labor Alonzo McKnuckle, Casual Labor Aaron Dobson, Casual Labor William Caldwell, Casual Labor Michael Clopton, Casual Labor Larry Hubbard, Casual Labor Eugene Mays, Casual Labor TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTION John R. Williams, Lab Shift Supervisor, promoted to Quality Control Supervisor Billy P. Sizemore, Lab Lead Technician, promoted to Lab Shift Supervisor James D. Wells, "A" Lab Technician, promoted to Lab Lead Technician Robert E. Stone, Vinyl Lead Operator, promoted to Vinyl Chief Lead Operator J. D. Sims, Vinyl "A" Operator, promoted to Vinyl Lead Operator Cleveland Brown, Vinyl Utility, promoted to Vinyl "A" Operator Robert Newman, General Helper, promoted to Vinyl Utility RETIREMENT None. TERMINATION Robert McNabb, Casual Labor Terry Metcalf, Compound Utility Ricky Rea, Casual Labor Johnny Sharp, Co-Op Student James Sykes, Compound Utility DEATH/DISABILITY None. OTHER During the month of January there were 13 casual labor employees on payroll. Total hours worked were 1926. The bulk of these employees were utilized for bagging resin. DTH 0000437S -11- CONOCO U `..MiCALS Aberdeen, Mississippi January 1980 MONTHLY PERSONNEL REPORT"" alaried Employees lourly Employees ,'otal Employees Employees (Hourly) 78* 155 233* Minority Employees Salaried 7* Hourly 60 Total 67** 9%** 59% 29%** New Employees Terminations 2 Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 0 1 50% DEPARTMENTS PAR 1? EMPLOYEES MIN. EMP. . % MIN. NEW HIRESi YTD TERM. YTD TURNOVER YTD Warehouse 9 9 %2 22 0 0 00 0 0 Gen. Plant Maintenance Laboratory 10 46 22 9 45 20 4 44% 7 15% 3 15% % %0 0 1 1 11 11 0 0 00 0 0 0 0 00 0 0 0c*P 00 Compound .'invl lasticizcr 41 32 5 35 33 4 28 13 39% 3 75% 0 0 1 1 2.8% 2.8% 0 0 00 0 0 0 0 00 0 0 Number of Applicants: Month ___ 33 Year to Date 33 APPLICANT BREAKDOWN: s Minority 25 % Minority 76% i; Female 4____ % Female 12% *Includes two (2) temporary employees. **Includes one (1) temporary employee. Hires (Hourly) : Month -______ Year to Date _ __ Terminations (Hourly) : Month 2______ Year to Date 2 __ 1.3% Hourly - 0 - Salaried Overall Turnover ._9% Projected Annual Turnover 15% -12- PTH 000043797 o O 4uO-J C+U/-D> tH c3d e cd n *c^-d> u3O o-- Re* ^C uO ->H C O CO co o co e Xcd *3 cd o X +J co X H O CO X Xo cw tV3ol XO *4 H33 3 OVi TcDd w c H .X V* o 2 o X 3bO cd <d c o co C V3 O X s o 03> x> bO 0) C e H ,X Vl V. o <>L> 2 oo fcj) c TH33 To3J U os X o 4V->i o e O> o H O cd > O *3 cd o i a V. ao H > *-> u o oo 6 o XI o a V. oo V. o +-> c oo u 00 CD r00 o o o Eh G toi i PROCESS ENGINEERING - R. A. Frohreich A. Specialty Compound Line The specialty compound line operated intermittently during the month of January. Basic problems with the weigh-up system logic controller have been resolved by MED and plant maintenance personnel. The production of customer samples has been hindered due to a quality problem of hard particles in the finished compound. Variations in operating conditions and screw configurations have not yet solved the problem. Representatives from Werner-Pfleiderer Corporation and the PAL group in Ponca City will be in the plant in February to work on this problem. Plugging of the pellet transfer line from the pelletizer has also been encountered. Wemer-Pfleiderer has been advised of the problem and their recommendation on how to correct it is expected by the end of February. B. Resin Expansion Project The revised Class "A" process design for the PVC rail storage silos was issued. Representatives from Litiwin Engineers and Constructors, Inc. visited the plant. The review of bid tabulations for equipment items is continuing. C. Deltech Air Dryer Installation of the Deltech air dryer was completed and the unit started up in early January. Some mechanical problems have been encountered with the operation of the unit. Engineering is working with Deltech to correct the problems. D. Joy Centrifugal Compressor The new Joy centrifugal air compressor was started up and is operating smoothly. E. Dissolved Air Flotation Tests Dissolved air flotation tests on the effluent from the API separator are continuing. To date, dissolved air flotation has only reduced the BOD content by about 15%. F. Resin Reclaim System A test run to dry resin from the concrete settling basins will be conducted in late February. The process design for the proposed resin reclaim systen is being prepared. G. Calcium Stearate Addition System The Class "A" process design for this project is being prepared and will be issued in February. -14- DTH 00004379S PROCESS ENGINEERING (Cont.) H. Inline Methocel Analyzer The Class "A" process design for installing a continuous analyzer on the methocel charge tank in each module is being prepared and will be issued in February. I. Dryer Remote Lighting Operating Procedure The operating procedure for the dryer remote lighting system was issued in January. J. Centrate Rinse Water System A test run using centrate water for rinse water in the reactors is planned for late February. K. Boiler Economizers The Class "A" process design to install economizers in the boiler stacks is being prepared and will be issued in February. L. Phthalic Anhydride Handling Improvements The Class "A" process design for this budget item is being prepared. M. API Clean Water By-Pass A process design to divert clean water now going into the API separator is being prepared. Decreasing the flowrate through the API separator will decrease the organic loading on the secondary waste treatment system. N. Reactor Vibration Tests Process Engineering is assisting the operations department in measuring reactor vibration during steam stripping. Various steam injection nozzles and steam flow rates are being tested. -15- DTH 000043800 ENVIRONMENTAL - V. E. Messick I. Particulates Two (2) dryer exhausts were sampled for particulates and were with allowable limits. II. Water BOD and COD levels in the plant waste treatment outfall exceeded the limits of the NPDES permit once during the month. The excursion resulted from a phthalic anhydride tank rupture. Phthaiic anhydride from the spill entered the secondary waste treatment system through the process sewers biologically overloading the system. Results of a December bioassay test showing compliance with the NPDES permit were forwarded to the state. III. Miscellaneous The Spill Control and Countermeasure Plan for the plant was updated and issued. -16- DTH 000043801 Flow GPM Jan. - Ave. Max. 810 941 Feb. - Ave. Max. Mar. - Ave. Max. Apr. - Ave. Max. May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Oct. - Ave. Max. Nov. - Ave. Max. Dec, - Ave. Max, TABLE I - WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB./DY. COD PPM LB./DY. Sus. Solids PPM LB./DY. 43 436 131 1342 86 851 216 2214 11 103 13 143 Diss. 02 6.8-8.5 NPDES - Ave. _ Max. _ 32 387 43 520 - 1390 - 1940 - 605 - 909 >6.0 ph 7.7-8.0 6.0-3.5 -17- DTH 000043802 ENERGY CONSERVATION - V. L. Thornhill I. plant OPERATIONS Total energy consumption for January was 114.09 MMM BTU's. The energy consumption per pound of product increased from 3058 BTU/Lb. to 3214 BTU/Lb. but was 9.9% lower than in January, 1979. II. PLANT ENERGY CONSERVATION PROGRAM A. Steam Leaks Twenty-seven (27) steam leaks were repaired in January. B. Energy Reporting The energy report for the 4th Quarter of 1979 was completed and issued in January. The plant had a 27.0% energy savings compared to the 1972 base year. After adjusting for EPA and OSHA projects, the plant energy savings were 40.3% compared to the 1972 base year. -18- DTH 000043803 ITEM Control Period Production, MI-1 Lbs. Resin Dry Blend Compound Plasticizer TOTAL Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Total Energy Consumption, MMM BTU Energy Consumption , BTU/Lb. Boiler Operating Data No. 1 No. 2 No. 3 ENERGY CONSERVATION DATA 1979 January 21.1 6.6 3.6 1.1 32.4 1980 January 30.3 1.9 3.0 0.3 35.5 56200 1020 57.324 4.867 10000 48.670 91.700 92000 8.436 59554 1020 60.745 5.1456 10000 51.456 20.544 92000 1.890 114.430 3532 114.091 3214 Ayi- Stack Temp. 1979 1980 423 389 410 413 463 418 Avg. % Excess Air 1979 1980 98 19 105 20 121 22 -19- DTH 000043804 MECHANICAL ENGINEERING - J. A. Dixon AFE'S SUBMITTED, APPROVED AND CLOSED The following AFE's were submitted and approved in January: AFE No. Title 9510 9520 9530 Miscellaneous Projects Under $10,000 Replacement Phthalic Anhydride Tank Spare Incinerator Authorized $150,000 75,000 650,000 The following AFE's were closed to field charges during January: AFE No. Title Authorized 9208 9029 9069 Spare Recovery Vacuum Pump Repair of Steam Tracing fj Insulation Centrifuge Rotors Repair $ 14,000 62,000 47,000 A completion report was issued during January for the following AFE: AFE No. Title Authorized 9197 Dryer Area Noise Abatement $ 45,000 DESIGN Contracts were let for insulation of the new dryer ducts, painting of the new Joy compressor and piping, and rental of IBM copier. Design work is in progress on the following projects: Replacement Phthalic Anhydride Tank, Diking of Sphere and Curbing of Drum Storage Areas, Line V Modifications, Reactor Vibration Monitoring, Line III Weigh System, Methocel Charge Revisions, Double Block Valves for VCM Charge, and Reactor Inert Vent System. CONSTRUCTION 1. The new 800 HP Joy air compressor project was placed on stream during the period. 2. The plant winterization projects were completed. 3. The new instrument air dryer project was placed on stream during the period. 4. The air header for the building ventilation system is complete. 5. The concrete repair work in the old module is complete. -20- DTH 000043805 MECHANICAL ENGINEERING (Cont.) CONSTRUCTION (Cont.) 6. A roof drain was installed for the guardhouse. 7. Demolition work of the phthalic anhydride storage tanks is complete. 8. The two rental air compressors were returned to the vendors during the period. 9. The repair of the middle railroad lead is complete. 10. The mapping of the cracks in the new reactor support structure was completed by CED. 11. The hydroquinone back pressure controller was installed. 12. The installation of the concrete receiving dock steps was completed. 13. The jacketed piping for the new phthalic anhydride tank was completed. 14. T-400 phthalic anhydride charge tank was inspected to determine the extent of the repair work required. 15. Construction is in progress on the following projects: compound dock exten sion, color weigh room modification, phthalic anhydride tank replacement, handrails for plasticizer building, compound roof handrails, repair of T-400 charge tank, modification of Line V cyclone screen, repair of Line I wall, pipe bracing and support modifications in the new module, installation of vibration monitors, air sparging of blend tanks 646 and 647, dryer operation improvements, new air compressor, instrument air dryer, and silo isolation valves. 16. Ten annual time and material contracts were issued during January. 17. Forty-eight register tickets were issued in January. -21- DTH 000043506 Vru January, 1MMI Aimi. CAPITAL NO. DOSOUPTION 9237 9247 9297 Heated Plasticiser Addition System Farrel Mixer Feeders Automatic Plasticiter-Stabiliier Weigh-Up System 9307 9098 9148 Compound Project Conveying Lines New Compound Line Plasticizer Chemical Exposure Abatement 9158 Fire Protection ImprovemcntsPhase I 9178 Propane Vaporizer Replacement 9188 Railcar Resin Heel Clean-Up System 9208 Spare Recovery Vacuum Pump 9228 Dry Blend Silo Alarms 9248 Silo Isolation Valves 9258 Dryer Operation Improvements 9519 Critical. Spare Equipment 9S29 Miscellaneous Projects Under $10,000 9539 Laboratory Equipment 9549 9559 Safety Equipment Color heigh Room Modifications 9569 Miscellaneous Projects Under $10,000 9589 Instrument Air Dryer 9609 Reactor Inert Vent System 9619 Waste Water Revisions-Part I 9629 Air Compressor 9639 Revisions to Emission Recovery System 9649 Double Block Valves for VCM Charge 9659 P.A. System Modifications 9669 New Air Header 9679 9689 Plant Winterization Diking of Sphere 6 Curbing of Drum Storage Areas 9699 Plant Dryer Debottlenecking 9709 Facilities for Multiple Grade Resin Production 9719 Aberdeen PVC Resin Expansion (Partial) 9729 Fire Protection Improvements Phase II 9530 Spare Incinerator Aberdeen authorizations report DATE Aim I. APPROVED AFE AMT, (1) (2) FINAL EXPENDED COMMITTED TOTAL EST. TO DATE TO DATE COST COMP. UNDER EST. EST. (OVER) COMP. CI.OS. AUTU. AMT. DATE DATE REMARKS 10/11/77 11/21/77 37,000 47,000 13,090 42,412 13,518 42,426 37,000 42,426 0 4,574 3/80 6/80 Design in progress. 11/79 3/80 Closed to field charges, 12/14/77 60,000 S6.293 56,731 60,000 0 3/80 6/80 Installation scheduled. 12/14/77 SO,000 49.287 49,369 49,369 4/17/78 2,050,000 2,065,821 2,08S,494 2,101,962 8/21/78 152,000 134,112 140,351 152,000 631 (51,962) 0 11/79 3/80 Closed to field charges. 12/79 3/SO Closed to field charges. 4/80 7/80 Revisions in progress. 9/19/78 176,000 73,798 107,985 176,000 0 6/80 9/80 Evaluating bids. 9/21/78 175,000 10/12/78 5S.000 12/5/78 14,000 12/13/78 25,000 12/14/78 25,000 174,051 33,970 0 4,392 21,156 174,051 41,951 14,633 4,602 22,244 174,0S1 SS.000 14,633 25,000 25,000 12/14/78 2/6/79 2/15/79 31S.OOO 17S ,000 125,000 233,373 248,979 35,697 116,337 120,786 122,231 315,000 175,000 122,231 949 0 (633) 0 0 0 0 ' 2,769 10/79 3/80 Closed to field charges. 4/80 7/80 Project operational. 1/80 3/80 Closed to field charges. .4/80 7/80 Purchases proceeding. 5/80 8/80 Eighteen of twenty-one valves installed. 3/80 6/80 Installation proceeding. 3/80 6/80 Purchases proceeding. 12/79 12/80 Closed to field charges. 3/27/79 3/26/79 4/19/79 5/8/79 31,000 15,000 25,000 125,000 24,441 31,410 5,232 658 56,520 14,933 IS,460 127,397 31,410 15,000 25,000 127,397 .5/30/79 6/28/79 7/3/79 7/9/79 7/12/79 110,000 90,000 140,000 340,000 100,000 79,526 2,913 135,352 51,054 14,359 81,927 8,460 137,131 223,993 18,350 110,000 90,000 140,000 340,000 100,000 (410) 0 0 (2,397) 7/79 T4/80 Closed to field charges. 10/79 6/80 3/80 7/80 12/79 3/80 Closed to field charges. Installation in progress. Closed to field charges. 0 2/80 5/80 Project operational. 0 6/80 9/80 Engineering in progress. 0 1/80 4/80 Project Operational 0 6/80 9/80 Project operational. 0 6/80 9/80 Engineering in progress. 7/18/79 7/10/79 8/15/79 9/5/79 9/15/79 182,000 35,000 25,000 64,000 170,000 20,550 15,796 3,9S3 60,138 0 64,983 21,760 13,3S3 60,138 0 182,000 35,000 25,000 64,000 170,000 9/15/79 9/20/79 80,000 870,000 0 0 80,000 0 0 870,000 9/10/79 850,000 11,421 829,021 850,000 10/1/79 490,000 0 0 490,000 0 6/80 9/80 Installation in progress. 0 6/80 9/80 Engineering in progress. 0 4/80 7/80 Installation proceeding. 0 3/80 6/80 Priority items completed. 0 6/80 9/80 Engineering in progress. 0 . 3/80 6/80 Engineering in progress CEO. 0 9/80 12/80 Engineering in progress CEO. 0 9/80 12/80 Equipment on order. 0 10/80 1/81 Engineering in progress CEO. 1/23/80 650,000 0 0 650,000 0 1/81 4/81 Engineering in progress CEO. -22- DTH 000043807 AUTll. CAPITAL (Cont.) NO. D---E--S--C--RIP|"T.ION ABTHPl.rS AUTHORIZATIONS RETORT DATE Ainu. APPROVED AFC AMT. (1) (2) FINAL EXPENDED como into TOTAL F.ST. TO DATE TO DATE COST COMP. UNDER (OVER) AUTH, AMT. ESI. EST. COMP. CLOS. DATE DATE REMARKS 9739 Methocel Charge Revision 9749 Iop roved Rupture Disc Holders 97S9 Aberdeen PVC Resin Expansion 9769 Automatic Setback Thermostats 10/3/78 66,000 10/22/79 27,000 12/10/79 11,150,000 12/31/79 3,000 9510 Miscellaneous Projects Under $10,000 1/3/80 150,000 9S20 Replacement Phthalic Anhydride Tank 1/17/80 75,000 0 0 66,000 0 24,613 27,000 0 1,1S3,794 11 ,150,000 0 0 3,000 0 7,587 150,000 0 23,709 75,000 0 6/80 9/80 Engineering in progress. 0 4/80 7/80 Safety heads on order. 0 7/81 10/81 Engineering in progress. 0 6/80 9/80 Thermostats on order. 0 12/80 3/81 Thirteen projects approved. 0 6/80 9/80 Fabrication in projrass. -23- I)TH 000043808 M3 Til. fXPLVSE description (11 Thru (H'cenSer 197-1 Actual Accounting (2) Thru January, 1980 ABERDEEN AllliK)U lATUlNS REIMI'T DATE Ainu. APPROVED AJ-E AMT, (1) expended to dvm; (2) .ximmiited io uvn: FINAL TOTAL r.ST. COST COMP. UNDER IOVER) AlHIl. AMT. ESI. ESI. COMP. C1.0S. DATE DATE REMARKS 9019 Repairs to Large Reactor Gearbox 7/7/79 $029 Repair of Steam.Tracing S Insulation 9/5/79 9049 Repairs to Oryer Inlet Ducts 9/13/79 90o9 Centrifuge Rotors Repair 9/13/79 9079 Cooling Tower Motor Repair 10/22/79 9059 Vibration Study-Capacity Replacement Reactors 10/29/79 925S Compound Line I Roof Collapse 12/13/78 27.000 62,000 25,000 47,000 17,800 50,000 44,000 23,598 68,054 16,140 21,312 0 2,898 43,75D 25.59S 6S.054 18,604 53,282 0 10,441 43,739 23,593 63,054 25,000 53,282 17,800 50,000 43,739 Cl,598) (5,954) 0 (6.282) 0 0 12/79 3/B0 Closed to field charges. 1/80 4/SO Closed to field charges. 3/80 6/80 Insulation in progress. 2/80 5/80 Closed to field charges. 4/80 7/80 Motor being repaired. 3/80 7/80 Prototype testing in progress 261 1/80 3/80 Closed to field charges. DTH 000043809 Date 1/4 1/8 1/11 1/11 1/11 1/15 1/15 1/17 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Report By Tridyn Carlon, IA 5385 5305 Moisture Moisture-Frozen Resin Under Investigation Under Investigation WAIVERS RECEIVED Identification Product Customer Reason Waived By PLCX 42674 PLCX 42904 CONX 45309 PLCX 43703 PTLX 41827 PTLX 41600 CONX 45258 PTLX 41624 5425 5385 5385 5385 5385 5385 5425 5385 Intex Charlotte Pipe Charlotte Pipe Houston Terminal Houston Terminal LCP Southwire Can-Tex Viscosity Particle Size Particle Size Particle Size Particle Size Particle Size Particle Size Color ELK CLS ELK ELK ELK ELK ELK CLS PRODUCT DEVELOPMENT AND SERVICE Ship Date 1/15 1/15 1/17 1/21 1/22 1/24 1/22 1/29 1/29 1/30 1/31 Product 38931 Nat. 34431 Nat. 34641 Nat. 38931 Nat. 90171 DB 5385-1 5305 5305 5385-1 5385-III 5425 5465 5425 5385-1 5305 5425 5305 5385-1 5425 5465 Quantity (Lbs.) 50 100 50 50 40 100 2 300 300 300 300 300 10 5 50 50 50 50 50 50 Customer The Okonite Co. Medgenco Cairo, Egypt Conoco, Inc Genesco St. Regis Paper Co. Conoco Chemicals Co. Export Export Export Export Triangle PWC Inc. Tarola International Uniroyal - Chemical Div. Carol Cable Fritz Airfreight Requested By RNG CLS CJM JFN NTH RNG RTM NTH NTH JPM -25- DTH 000043810 LABORATORY (Cont.) COMPOUND DEVELOPMENT AND SERVICE Special Compound Testing Western Electric specification tests were run on 3 lots of 34861 Gray 546 and on four (4) lots of 36861 Natural. Two (2) lots of 34533 Natural for Packard Electric were tested for hardness and tensile properties. Oven aging tests were run on two (2) shipments of 35851 Natural to Phelps-Dodge. New Compounds Quality control specifications and standards were prepared for an experimental compound - JRT-3866-204. The same was done for a dry blend formula - 3948-30. Compound Development Complete physical properties were measured on the first production lots of three (3) new experimental compounds. They were ERC-3711-75C, ADK-3972-134A, and JRT-3866-195. Dry Blend Development New quality control standards were prepared for 80172B, 80273G and 80274. QUALITY CONTROL TESTING Resin Regular Samples = 346 Bag Blends - 310 Other In-Process Samples = 3328 Bulk Shipments 119 (Railcars = 81; Trucks = 38) Dry Blend Blenders Produced - 191 Blenders Tested = 138 Blenders Adjusted = 12.0% Other In-Processing Samples =116 Bulk Shipments = 12 (Railcars = 8; Trucks = 4) Compound Blenders Produced = 465 Blenders Adjusted = 1.9% Other In-Process Samples = 340 Bulk Shipments = 12 (Railcars = 7; Trucks = 5) -26- DTH 0000438:..! LABORATORY (Cont.) QUALITY CONTROL TESTING (Cont.) Resin Heat Stability Forty-one blends of resin were tested for oven heat stability as shown below: 5385 5425 5305 5465 20 Blends 12 Blends 8 Blends 1 Blend The heat stability of the 5385 resin appears to have deteriorated slightly this month. Other types of resin appeared normal. Raw Material Testing Fifty-eight (58) lots of plant raw materials were tested and approved for use. SPECIAL PROJECTS RVCM of Shipments A total of 93 samples of bulk resin were tested for RVCM content. Below is a summary of those results: Product538554255305 Average RVCM No. Samples 2.6 48 0.4 15 2.5 30 RVCM of Slurries A total of 664 samples of slurry were tested for RVCM in January (96% of the batches produced). The overall average was 276 ppm. Due to vibration problems in the new unit relating to the steam stripping, many of the new unit samples were over 400 ppm. They were balanced by the old unit samples most of which were below 100. As a result, only three (3) daily averages were above 400. RVCM of Blowdown Tanks A total of 151 samples were tested for RVCM in January. The overall average was 9.9. RVCM of 5305 Dryer Samples A total of 30 batches of 5305 were tested for RVCM. The samples were taken from the regular dryer product. The overall average was 12 ppm VCM. -27- DTH 00004381 LABORATORY (Cont.) SPECIAL PROJECTS (Cont.) Plant Process Engineering Support A total of 35 special samples for Process Engineer's support were tested. These samples were for COD (25), % solids (5), ppm VCM (5). Lab Computer Project The debugging of the quality control data programs was completed in January. There are still two (2) printers out of service - one (1) Dec (sent to factory) and the other a Heath (sent to factory). Customer Complaints Follow-Up Phelps-Dodge has complained that they are measuring low values for retentions of elongation on 35851 coated on wire. Oven aging tests were run of molded sheets from two production lots and were found to give typical values for re tention of elongation. Samples of their wire coating appeared to be borderline. Samuel Moore Co. complained that a sample of 34551 Natural failed to pass oven aging tests; however, tests in the Aberdeen Laboratory have indicated that the sample material passes the tests. Line V Startup At least 40 melt flow tests were run on various compound samples from Line V as a part of the quality control program. Extrusion tests were run on several Line V compound samples that were rejected for "hard particles." These were also found in the extruded strips. Volume resistivity tests were run on three (3) electrical compounds that had been made on Line V and were compared with the same compounds made on Line I or Line III. The Line V material was at least as good as the Line I and Line III products. Particle Size Method Comparison All shipments during January were tested using both the lOOg. test method and the 49g + lg. MgCOj method. A report was issued on results of the December data from these methods. -28- DTH 000043813 SURFACE TRANSPORTATION' ABERDEEN DISTRIBUTION WAREHOUSE JANUARY ACTIVITY REPORT, 1980 Shipment h.y Product - M/lbs. Resin Plasticizer Dry Blend Compound Total JANUARY 16693 43 2193 2855 21784 Year-to-Date 16693 43 2193 2855 ' 21784 Number of Shipment by Mode R/C O.T. " C.C. C:O.T -------TOFC CPU TOTAL Resin - Bulk Package Export - ABR Plasticizer - Bulk Dry Blend _ Bulk Packaae Compound - Bulk Package 82 12 10 Special Export - Package Bulk Package Back Hauls for January 104 34 7 40 3 5 17 5 16 127 21 Number of Shipment by Month-Year-To Date . January O.T. R/C Bulk 104 55 O.T. Van 72 1 2 `. 1 40 117 2 9 20 40 11 6 18 3 15 20 38 5 16 2 36 273 c.c; c.o:t........ tofc cpu total 40 2 36 273 -29- DTH 000043814 LOCATION MAIN-East TOTAL M SQ. FT. 48 Prairie 12-1 12-2 12-3 12 22 21 12-4 . 12-5 22 21 12-6 21 12-7 12-8 21 21 Total 209 CONOCO TRANSPORTATION ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco Resin Resin 4-3 -7 -5 4 .9 Resin Export Resin 2*. 7 Conoco Export Resin 3.6 Conoco Resin Resin O.G. 3- 6 Mill Scraps .1 Cmpd 0. G. .7 Dry Blend 0. G. .1 Sifter Overflow . 1: Resin 0. G. .7 Compound Resin Raw Material .9 .3 Resin 0. G. 3.5 Conoco 3.6 ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 5-9 4-1 10.0' 9 .6 1.5 2.7 .8 3.5 3.6 3.5 3.6 3..5 - 1.7 . 8 2.5 . 1. 2 3. 5 3. 6 2.3 3.5 3.5 3.5 Sub-Total (Plug-Aisles) -30- . Total Conoco -* DTH 000043815 26. 7 8.6 35.0 .3 35. 3 SAFETY REPORT . Lost Time Accident Doctor Cases First-Aid Cases Man Hours Worked JANUARY 0 0 0 2892 MATERIAL HANDLING REPORT M/Lbs. Packaged Resin From Production Packaged Compound, Dry Blend From Prod. Transferred From Main to Prairie Transferred From Prairie To Prairie Reverse Transfer Resin to Plant Reverse Transfer Cmpd. to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Main 12312 1944. 11624 0 81 121 3848 1822 365 32,117 LABOR REPORT Total regular Hours Total Overtime Hour Total Worked Paid but not Worked Total 2043 249 2292 222 "2514- Labor Efficiency equals 32.1 MM/Lbs. - Hours Worked 14,013 Overtime % 9.9 Y.T.D. 0 0 0 2892 GRAND TOTAL SINCE L.T.A 144,567 T/L 304 48 . . 287 0 2 3 95 45 9 >93 -31- DTH 000043813 EQUIPMENT REPORT lift Truck Hours Worked Gal of Fuel Consumed Tials/Hrs 598 1033 1-7 Lift Truck Efficiency Equals 32.1 fW/Lbs. - Hours Worked -53707 Lbs./hr CFF-6RA0E IN STORAGE MATERIAL tt/Lbs. Sifter Overflow 110 Resin "BC" 2671 Resin "H" Hills Scraps Compound "B" -"Compound "H" Dry Blend "O.G." Total 1304 85 541 - 0. 62 TTn----------- T/L 2 66 32 2 13 0 2 ~* TT7 D.F. OPERATION Total material in inventory increased from 16.5 MM/lbs. to 26.7 MM/lbs. during January, this build-up is from packaged resin. We are still waiting on two large export orders to be released. These orders contain approx 3MM/lbs of 5385 -I 9 high and 5425 - I six high. Hopefully in February we will be able to ship this material. -32- DTH 000043817 INJURY FREQUENCY* X 100 cn 12 MONTH MOVING AVERAGE CC ( INJURY FREQUENCY* X 100 (( DTH 000043:18 MONTHLY HOURLY TURNOVER 1C 9 8 7 6 5 4 3 2 1 DTH 000043819 O t-i N) m w ft tn O' N) W ft t/1 O' -- to N> W CM i/i o oi o tn ABERDEEN PLANT PRODUCTION gl r>H* o"Co ABERDEEN PLANT EFFICIENCY MONTHLY CUMULATIVE