Document jykErynN8ywQq61EpkO17mq0p

SAFETY - A. H. Sather Occupational Injuries October 1980 Year-to-Date 1979 Year-to-Date Injuries Treated First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time 3 41 0 14 02 0 23 00 32 8 2 29 1 Injuries By Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 0 12 3 18 0 23 03 00 01 13 3 22 1 0 2 Injuries By Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 2 29 04 17 0 11 04 04 12 5 12 10 5 2 As of October 31, 1980, the plant had operated a total of 481 days or 623,504 manhours without a disabling injury. Safety Meetings The topic for October Safety Meetings was "Slips and Falls and Hand Safety". The film "Slips and Falls" (Conoco produced film) was shown and a National Safety Council - Petroleum Newsletter Article "Ten Safety Rules to Help Preserve All Ten of Your Fingers" were reviewed. Also, C. R. Miller, Plant Superintendent, and A. H. Sather conducted three (3) safety performance review meetings, one each for the Maintenance, Compound and Vinyl Departments. Personnel involved in these meetings included first and second level supervisors and department heads. Several topics were reviewed and discussed in each of the meetings. The topics included: 1980 year-to-date on and off-the-job safety performance, job planning, incident control and the effects of attitude. VCM Tank Car Derailment On October 15, 1980, C. R. Miller, Plant Superintendent and A. H. Sather, Safety Director, responded to a CHEMTREC assistance call for 3 derailed VCM cars near Strong, MS. The cars were found not leaking. The cars were re-railed without incident. 1- - DTH 000021629 SAFETY - (continued) Plant Noise Level Survey W. Guy Warren of CED conducted a noise level of the plant and plant boundaries October 7 through 10, 1930. Numerous suggestions were made regarding improve ments. Several of these improvements are currently being evaluated for implementation to reduce sound levels. Chemicals Industrial Hygienist T. G. Grumbles, Chemicals Industrial Hygienist, visited the plant October 14 through 16, 1980 to familiarize himself with the Aberdeen Plant, review chemical usage, review the plant Industrial Hygiene Program and to discuss the usage of the compound raw material. Antimony Trioxide. VCM Plant Turnaround J. G. Roberts, Safety Inspector, assisted W. V. Henry for the VCM plant turn around. His work activities in Lake Charles required him to be at the VCM plant from September 29 through October 23, 1980. OSHA Compliance Activity in this area included VCM and lead dosimetry, and a review meeting on lead compliance activities. The results of the dosimetry work are indicated below. A lead compliance plan review was conducted on October 16, 1980, and efforts were reinforced. VCM A total of 85 samples were taken and analyzed with six (6) indicating overexposure. The results are tabulated by range below. Overexposures are also explained. Range (ppm) Number Percent 0.0-0.5 0.5-1.0 1.0-5.0 5.0+ 75 88.24 4 4.71 4 4.71 2 2.34 85 100.00 Of the six (6) overexposures, one occurred to a Yard Operator who was connecting and disconnecting VCM railcars while wearing a respirator, one each occurred to a Reactor Operator and a Mechanic working in the old reactor module without respirators, one occurred to a Mechanic-Oiler who worked in several VCM process areas without a respirator, and two occurred to Mechanics who were working on recovery equipment seals while wearing respirators. -2- 000021630 dth SAFETY - (continued) Lead A total of twelve (12) samples were analyzed, the results are shown below with overexposure information. Number Greater than PEL* Less than PEL 2 10 12 Of the two (2) overexposures which occurred, one occurred to a color weigh room compounder and one to a line I compounder. Both of the overexposed employees were wearing dust respirators. -3^ DTH 000021631 VINYL - P. E. Markey Production Month Y.T.D. Budget 1. Total Production, MM Lbs. 2. Production Rate, M Lbs./C.D. 3. Charges, Reactor Batches/C.D. 4. Total Charges 5. Reactor Stream Factor 6. Drying Rates, Average Lbs./C.D. 7. Dryer Stream Factor, % 8. Accounting Days 26.5 853 21.0 650 87.9 5821 87.4 31 209.3 686 17.0 5176 73.5 5545 73.7 305 900 Vinyl Department production for September was 95% of budget at 26.5 MM pounds. Production levels for the first half of the month were reduced for inventory control purposes during which time advantage was taken by performing dis cretionary unit maintenance and available dryer line capacity was used to debag "BC" and "H" grade resin. Production target was increased mid month from 22.0 to 26.5 MM pounds. Reactor and dryer stream factors were 87.9% and 87.4% respectively. The major items affecting stream factor and production were: 1. Inventory control programs during the first half of October continued to represent substantial stream factor penalties in the reactor and drying areas (3.0% and 4.2%, respectively). 2. Steam limitations resulting from boiler downtime to install energy conserving economizers caused a 2.9% stream factor penalty. Resin Quality Summary Resin Type Prime Pounds "BC" Grade "H" Grade % of Total Production 5305 5385 5425 5465 Sifter Overflow 2,299,652 17,700,967 6,036,973 419,880 - 40,500 239,650 (335,250) - - 40,200 (174,850) ( 40,500) ( 40,300) 269,835 9.0 67.2 21.4 1.4 1.0 TOTAL 26,457,472 ( 55,100) 54,385 100.0 Quality performance for October was 100.0% customer grade with (0.2%) "BC" grade and 0.2% "H" grade. Debagging operations upgraded 672,050 M pounds to prime quality resin. 4- DTH 000021632 VINYL - (continued) The variable cost variance was $606.3 M with $542.6 M due to price and $63.7 M due to efficiency. The major price variance was $546.6 M for VCM. Favorable efficiency variances for VCM and processing additives totaled $39.3 M. Favorable variances in the off-grade category were $23.9 M. There was no variance due to product mix. The raw material requirement for October was 1.01785 pounds VCM/pound PVC versus the 1.01960 standard. (Y.T.D. is 1.01865) General 1. Resin packaging for October totaled 2,004,600 pounds. Resin debagging totaled 672,050 pounds upgrading "BC" and "H" grade resin to customer grade. 2. A test run was conducted 10/20/80 through 10/26/80 using the experimental J-48 Methocel. 48 batches were produced in the old reactor module producing 7 coarse batches, at which time testing was discontinued. Old module testing indicated J-48 produced a poorer coefficient of variation than our currently used F-50 Methocel and had a tendency towards higher gels. 2 batches were produced in the new module with better results, but with only 2 batches produced the results are best categorized as inconclusive. -5- DTH 000021633 COMPOUND - J. R. McCrimon Compound Production Month Day Y.T.D. Line I, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days 1,545 134 3,116 4,796 31 55 45 101 155 11,593 968 26,633 39,194 305 Line I operated 28 days during October at an average rate of 55 M pounds per day. Major items affecting production efficiency were: product changes (61.7 hours), maintenance on blender conveyor bucket (24.1 hours), dicers (19.4 hours), scale adjustments (12,5 hours). No. 1 blender gearbox failure (14.1 hours), and maintenance on skip hoist (10.3 hours). Line V operated 3 days during October at an average rate of 45 M pounds per day. Major items affecting production efficiency were: maintenance on the Orbitran (14.3 hours), pellet blower bearing failure (7.0 hours), and WernerPfleiderer temperature control problems (3.5 hours). Line III operated 31 days during October at an average rate of 101 M pounds per day. Line III production was affected by: product changes (50.5 hours), FCM clutch failure (20.5 hours), mill steam leak repairs (18.3 hours), and quality control (11.1 hours). Quality performance for flexible compounds was 3.1% off-grade of which 83.9% was due to mill scrap. "BC" production was 0%. The raw material requirement for flexible compounds was 0.'98083 pounds of raw material per pound of compound versus a 1.01300 standard. (Y.T.D. is 1.01475). The variable cost variance for compound was $54.7 M with $49,6 M due to price and $5.1 M due to efficiency. The variance due to product mix was ($20.0 M). Major efficiency variances were: $14.1 M for resin and $25.8 M for Vinyzene SB-1 which is due to the use of Vinyzene BP-5 in order to deplete the inventory of BP-5 (obsolete). Major price variances for the month were $10.9 M for T0TM and $14.1 M for colors. Dry Blend Month Day Y.T.D. Production, M Pounds Accounting Days 4,209 31 183 19,537 305 Dry Blend operated 23 days during October at an average rate of 183 M pounds per day. Production included 80273G, 80172B, 90171, and 3948-44-1. Dry Blend production was affected by: No. 1 Welex motor failure (43.0 hours), quality control (22.7 hours), Orbitran (11.5 hours), and boxing dry blend (8.3 hours). 6- DTH 000021634 COMPOUND - (continued) Dry Blend - (continued) Quality performance for the month was 99.99% customer grade. The raw material requirement for dry blend was 0.98941 pounds of raw material per pound of dry blend versus a standard of 1,00321. (Y.T.D. is 1.00471). The variable cost variance for dry blend was $107.0 M with $5.7 M due to price and $101.2 M due to efficiency. The variance due to mix was $91.4 M. The only major efficiency variance for the month was $16.6 M for resin. There were no major price variances for the month. Plasticizer Month Day Y.T.D. Production, M Pounds Accounting Days 1,122 65 8,152 31 305 Plasticizer operated 17 days during October at an average rate of 65 M pounds per day. Production included: DIDP, 610P, and D0P. VRP production totaled 101 M pounds (9.0%). Production was limited by: R-3 phthalic anhydride charge valve replacement, safety disc replacement on all 4 reactors, and steam restrictions (10/24 thru 10/31) due to boiler economizer installation. The raw material requirement for piasticizer was 1.08732 pounds of raw materials per pound of plasticizer versus a 1.08258 standard. (Y.T.D. is 1.10967) The variable cost for plasticizer was ($44.3 M) with ($28.3 M) due to price and ($16.0 M) due to efficiency. Major price variances were: ($12.4 M) for ALF0L 610, and ($12.5 M) for 2 EH. There were no major efficiency variances for the month. The variance due to product mix was ($2.3 M). General Total customer grade compound inventory decreased from 6.7 MM to 6.0 MM pounds during October. -7- DTH 000021635 MECHANICAL - S. J. Vincent Vinyl There were two large reactor seal failures in this period. The seal failures were both in the old module on the D-400 and D-600 reactors. There were two large reactor gearbox failures this period. Both failures were in the old module with the high speed pinion shaft failing on D-500 and a high speed pinion gear failure on D-400. There were two condensers cleaned in the old module on the D-500 and D-600 reactors. In addition to cleaning the condenser, the safety valves were tested and all safety discs changed on the D-500 reactor. The universal joint on the 741 agitator experienced a bearing failure requiring a major overhaul of the unit. This was the same universal joint that was damaged during the summer by a resin accumulation inside of 741 reactor. Also the 741 reactor drive motor was replaced with the spare when it began making noise. There were 17 seal failures to pumps and compressors in this period, 8 of the seal failures were in the old module and 9 were in the new module. In the old module, seals were replaced on the 705 emission recovery compressor outboard seal, the east VCM charge pump, the recovered VCM charge pump, the east RVCM return pump, and the outboard seal was replaced three times on "A" vacuum pump. In the new module, seals were replaced on the east VCM charge pump, the west VCM charge pump, the 905 compressor inboard seal, the west chem wash pump, the PVA transfer pump, the 904 compressor inboard seal, the east RVCM return pump, the west RVCM return pump and the west RVCM charge pump. Pump and compressors overhauled in this period included the east hot water charge pump in the new module. In the old module the "B" recovery compressor, "B" vavuum pump, 706 emission recovery compressor, and the spare 1256 recovery compressor were all overhauled. A new compressor was installed on the inerts vent chiller system. The north and south seal water separator level controllers were calibrated in the new module. The deckwriter in the vinyl control room was repaired and re installed. The conversion from 110 volts to 24 volts on the blowdown tank controls was completed. In the vinyl drying equipment the #7 dryer was down to repair the oil seal on the drive gearbox, to repair the drive motor and to rework the day collector explosion door. The sock holders were replaced in #4 day collector. Belts were replaced on #6 exhauster. The #1 Bird was pulled for cleaning. The #8 Bird and gearbox were changed out twice for plugging and bearing failures. The resin blower transfer system controls were also revised. Repairs in the vinyl storage area included replacing two loading hoses and to rebuild one 690 Corken for a case repair and packing leaks. -8- DTH 000021636 MECHANICAL - (continued) Vinyl - (continued) A major effort was made to repair steam tracing leaks and repair insulation in both reactor modules. An intensified effort by several of the maintenance people completed these repairs in a timely fashion. Compound - Dry Blend - Plasticizer - and Silo Storage Repairs to the compounding equipment on line III were to replace the clutch unit to the FCM, change FCM seals twice, and to replace the spindle on #6 dicer. Minor steam and process leaks were also repaired. Repairs to line I consisted of minor adjustments to the conveyor and scale system. There was a failure of the #1 blender gearbox on the last day of the month. New controls were installed on the line III condensate pump. A new locking mechanism was installed on the pellet blower. Several start and stop switches were installed. The major repairs in dry blend included replacing the drive end shaft and bearings and replacing the drive motor and belts on #1 Wei ex unit. The Wei ex motor failed when water apparently entered it when a heavy rain came in through an open doorway. Repairs in the plasticizer unit included replacing bearings in the north blower. The safety disc on R-2 was replaced and the discs on R-l reactor were replaced twice. The PM inspection of the glycol unit in the plasticizer tank farm was completed. The final adjustments and revisions were completed and the new portable product transfer system was placed in operation. Utilities and Service There were five repairs to equipment in the plant air system in this period. Valves were repaired in #2, 7, 8 and 9 compressors and the motor repaired on #1 compressor. The fire pond overflow dike material was replaced with new red wood material. The D-500 and D-600 cooling tower distributer was repaired to control water loss. The gearboxes, supports and fan hubs were cleaned and coated with special paint on this cooling tower. All electrical switchgear and instruments were also inspected on this tower. One new bulk storage tank for the cooling tower chemicals was installed. Sight glasses were installed on both the new and existing bulk chemical tanks. Boiler repairs completed this period included having #2 and #3 boilers down to install economizers on them. With the unit down, the Drum baffles were pulled to wash the tubes. Three leaking tubes were repaired in the #2 boiler. -9- DTH 000021637 MECHANICAL - (continued) Utilities and Service - (continued) The propane system was test fired three times in this period. The machinist and tool room mechanic completed repairs or machine work on twenty-four pieces of equipment. Also all plant central heating systems were PM inspected. Planner The Planner estimated 105 work orders in this period and material was ordered for 28 work order projects. The Planner closed 16 invoice registers and issued 17 new registers. There were 20 statements processed for payment and 692 work orders closed for the month. The history and safety valve records were brought up to date at the end of the month. -10- DTH 000021638 MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved, and Closed The following AFE's were submitted and approved during October: AFE No. Title Authorized 9700 9710 9720 9730 9740 Compound Fines & Streamer Removal Fire Protection Improvements - Phase III Reactor Agitator Replacement Compound Line III Debottlenecking Modifications to Make Profile Dry Blend $ 95,000 385,000 420,000 1 ,350,000 200,000 Completion reports were issued for the following AFE's during October: AFE No. Title Authorized 9297 9158 9228 9248 9769 Automatic Plasticizer-Stabilizer Weigh-Up System Fire Protection Improvements - Phase I Dry Blend Silo Alarms Silo Isolation Valves Automatic Setback Thermostats $ 60,000 176,000 25,000 25,000 3,000 There were no AFE's closed to field charges during October. Design Design work is in progress on the following projects: - Replacement of Hot Water Charge Tank - Methocel Charge Revisions - Reactor Inert Vent System - Interplant Communications - Phase II - Spare Reactor Condenser - Multi grade Resin Production Facilities - Water Stripping - Fire Protection Improvements - Phase II - Spare Inert Incinerator - Breakroom Extension - Sweco Installations AFE Activity 1. AFE 9629 - Air Compressor - M. S. Richards Conversion of the old Joy compressor to dual control is scheduled for November. -11- DTH 000021639 MECHANICAL ENGINEERING - (continued) AFE Activity - (continued) 2. AFE 9689 - Diking of Sphere and Curbing of Drum Storage Area - J. L. White All exterior walls are complete. Backfilling and final grade work is in progress. 3. AFE 9709 - Facilities for Multigrade Resin Production - S. Krause Overall project design is 30% complete. The contract for concrete and site work has been let. 4. AFE 9729 - Fire Protection Improvements - Phase II - M. Ingle Overall project design is 97% complete. The piping and concrete drawings are undergoing final revisions. 5. AFE 9739 - Methocel Charge Revisions - J. L. White Design is complete. Bulk material is being quoted. Bids have been requested for installation of piping. 6. AFE 9530 - Spare Incinerator - D. Haub Overall project design is 54% complete. Piping plans are complete. Concrete basis of bids to be issued in November. 7. AFE 9550 - P. A. Handling Improvements - J. P. Windham The new jacketed unloading line is complete and operational. Instrumenta tion design work is in progress. 8. AFE 9580 - Boiler Economizers - J. L. White The economizers have been installed on number 2 and 3 boilers and are operational. 9. AFE 9590 - Critical Spare Equipment - J. P. McKee The drawings have been reviewed and approved and are ready to be mailed out for bids. 10. AFE 9610 - API Clean Water Bypass - M. S. Richards Sewer design is complete and construction work is scheduled. 11. AFE 9630 - Water Stripping - M. Ingle Overal project design is 70% complete. Piping drawings are undergoing final revisions. -12- DTH 000021640 MECHANICAL ENGINEERING - (continued) AFE Activity - (continued) 12. AFE 9660 - Hot Hater Charge Tank Replacement - J. P. McKee Concrete and site work is in progress. Bids have been requested for installation of the piping and electrical. 13. AFE 9680 - Fixed Point Monitor Data Computer & Warning Lights - R. B. Harned Overall project design is 35% complete. Computer Services Division in Ponca City is negotiating the purchase of the computer for this project. 14. AFE 8395 - Interplant Communications - Phase II - R. B. Harned Design is complete. All major equipment is on order. Bids have been requested for the equipment installation. Construction - G. A, Morgan The foundation for the new hot water charge tank was completed. Bids have been requested for piping, equipment, structural and electrical installation on this project. A proto-type loading chute for the resin silos was installed and approved. Two boiler economizers have been installed and the third is scheduled for early November. Repairs to the Lagoon Aerators was completed during the period. Installation of the new back-up plasticizer filter was completed. Six contracts were let during the period. They were for: 1. Boiler Economizers Piping and Equipment 2. Boiler Economizer Structural 3. Concrete work for Silos, Cooling Tower, Blend Tanks and Initiator Storage 4. Piping for Part I of Fire Protection Improvements - Phase II 5. Concrete, Demolition and Sewer Line Installation for Batch Water Stripping 6. Maintenance of Plant Two-Way Radios and Closed Circuit Television Nineteen (19) register tickets were issued during October. -13- DTH 000021641 1) Thru September, 1980 Actual Accountinq 2) Thru October, 1980 ABERDEEN AUTHORIZATIONS RT I'OU 1' Aivni. Capital NO. description PATE AUT11. APPROVED AH; AMT. 0) EXPENDED TO DATE (2) COMMITTED TO DATE FINAL TOTAL EST. COST COMP. UNDER (.OVER) All III. AMT. EST. EST. COMP. CI.OS. DATE DATE REMARKS 9237 Heated Plasticizer Addition System 10/11/77 9143 Plasticizer Chemical Exposure Abatement 8/21/78 9258 Dryer Operation Improvements 12/14/78 9519 Critical Spare Equipment 2/6/79 9559 Color Heigh Room Modifications 4/19/79 9589 Instrument Air Dryer 5/30/79 9609 Reactor Inert Vent System 6/28/78 9629 Air Compressor 7/9/79 9639 Revisions to Emission Recovery System 7/12/79 37,000 152,000 315,000 175,000 25,000 110,000 90,000 340,000 100,000 13,090 143,513 14,691 145,005 287,958 107,281 18,552 90,134 13,488 260,090 60,726 324,848 161,214 19,346 91,694 17,895 266,368 72,445 37,000 152,000 324,848 163,000 25,000 110,000 90,000 340,000 100,000 0 2,842 12/80 3/81 Design in progress. 9/80 12/80 Closed to field charges. ( 9,848) 9/80 12/80 Closed to field charges. 12,000 12/80 3/81 Revisions in progress. 0 1/81 4/81 Project operational. 0 12/80 3/81 Revisions in progress. 0 3/81 6/81 Project on hold. 0 3/81 6/81 Revisions in progress. 0 12/80 3/81 Revisions in progress. 9649 9669 9689 Double Block Valves for VCM Charge New Air Header Diking of Sphere & Curbing of Drum Storage Areas 7/18/79 8/15/79 9/15/79 182,000 25,000 170,000 143,075 17,084 97,375 167,026 18,296 127,330 182,000 25,000 170,000 0 12/80 3/81 Project operational. 0 12/80 3/81 Revisions in progress. 0 1/81 4/81 Construction in progress. 9699 9709 Plant Dryer Debottlenecking Facilities for Multiple Grade Resin Production 9/15/79 9/20/79 80,000 870,000 5,805 28,560 24,205 330,305 80,000 870,000 0 3/81 6/81 0 3/81 6/81 Engineering in progress CED. Construction in progress. 9719 9729 Aberdeen PVC Resin Expansion Fire Protection Improvements Phase II 9/10/79 10/1/79 850,000 490,000 11,421 19,953 817,600 166,185 850,000 490,000 0 1/81 4/81 0 6/81 9/81 Equipment on order. Piping contract let. 9739 rietnocel Charge Revision 10/3/79 66,000 8,732 21,119 66,000 0 12/80 3/81 Bids requested on piping. 9759 Aberdeen PVC Resin Expansion 9510 Miscellaneous Projects Under $10,000 9530 Spare Incinerator 9550 P. A. Handling Improvement 9560 Safety Equipment 9570 Replace T-100 P.A. Tank 9580 Boiler Economizers 9590 Critical Spare Equipment 9600 Calcium Stearate Addition System 9610 API Clean Water Bypass 9630 Water Stripping 9650 Miscellaneous Projects Under $10,000 9660 Hot Water Charge Tank Replacement 9670 Laboratory Equipment 9680 Fixed Point Monitor Data Computer and Warning Lights 9690 Breathing Air Modifications 9700 Compound Fines & Streamers Removal 9710 Fire Protection - Phase III 9720 Reactor Agitator Replacement 9730 Compound Line III Debottlenecking 9740 Modifications to Make Profile Dry Blend 12/10/79 11 ,150,000 1,272,679 5,062,100 11,150,000 1/3/80 150,000 94,951 120,361 150,000 1/23/80 3/3/80 3/12/80 3/27/80 3/26/80 3/26/80 4/2/80 4/15/80 4/30/80 5/30/80 650,000 63,000 25,000 119,000 140,000 59,000 84,000 23,000 810,000 150,000 1,036 214,455 25,093 33,914 1,711 7,843 57,782 62,366 4,365 132,676 44 11,486 00 4,628 5,039 12,501 76,926 67,370 115,630 650,000 63,000 25,000 119,000 140,000 59,000 84,000 23,000 810,000 150,000 6/4/80 7/9/80 9/4/80 160,000 32,000 113,000 200 67,772 160,000 151 30,529 32,000 0 8,800 113,000 9/9/80 21,000 10/1/80 95,000 10/14/80 385,000 10/14/80 420,000 10/16/80 1,350,000 10/27/80 200,000 0 0 21,000 0 0 95,000 0 0 385,000 0 0 420,000 0 0 `l,350,000 0 0 200,000 -14- 0 9/81 12/81 Foundation work in progress 0 12/80 3/81 Forty-Eight projects approved. 0 6/81 9/81 0 2/81 5/81 0 12/80 3/81 0 12/80 3/81 0 12/80 3/81 0 12/80 3/81 0 5/81 8/81 0 12/80 3/81 0 4/81 7/81 0 12/80 3/81 Engineering in progress CEO. Unloading line complete. Smoke detection portion complete Project on hold. Two economizers operational. Engineering in progress. Engineering scheduled. Sewer construction in progress. Sewer contract let. Thirty-eight projects approved. 0 2/81 5/81 Bids requested for piping. 0 12/80 3/81 Analyzer purchased. 0 9/81 12/81 Engineering in progress. 0 3/81 6/81 Engineering scheduled. 0 10/81 1/82 Engineering scheduled. 0 10/81 1/82 Engineering scheduled CED.. 0 10/81 1/82 Updated quotes requested. 0 10/81 1/82 Engineering scheduled. 0 10/81 1/82 Engineering scheduled. DTH 000021642 (1) Thru September, 19SQ Actual Accounting (2) Thru October, I9o0 ABERDEEN AU'i'IICM?! "ATIONFS REPORT Ainu. Capita) NO. description DATE AUTll. APPROVED AEE AMT. (1) EXPENDED TO DATE (2) COMMITTED TO DATE FINAL TOTAL EST. COST COMP. UNDER (OVER) All'll!. AMT. EST. EST, COMP. CEOS. DATE DATE REMARKS 8395 Interplant Communications - Phase II 1/22/80 55,000 0 8,142 55,000 0 6/81 9/81 Equipment on order. 9010 Expense Centrifuge Rotor Repair 9/19/80 20,000 0 0 20,000 0 12/80 3/81 Repairs in progress -15 DTH 000021643 PERSONNEL - J. L. Carter EMPLOYMENT None TO/FROM LEAVE OF ABSENCE None TRANSFER/PROMOTION None RETIREMENT None TERMINATION None OTHER During October there were five casual labor employees on payroll. Total hours worked were 868. -16- DTH 000021644 CONOCO CHEMICALS Aberdeen, Mississippi October 1980__________ MONTHLY PERSONNEL REPORT Salaried Employees Hourly Employees Total Employees Employees (Hourly) 78* 156 234 Minority Employees # Salaried 6 Hourly 59 Total 65 0'0, 7.7% 38% 28% New Employees Terminations 0 0 Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 U 0 n DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory PAR # EMPLOYEES MIN. EHP. - % MIN. 99 2 22% 10 11 4 36% 46 46 7 15% 22 20 3 15% NEW HIRES YTD 00 04 00 00 TERM. YTD TURNOVER 00 0 YTD 0 02 0 16.6% 00 0 0 00 0 0 Compound 37 35 Vinvl 32 31 28 80% 0 0 0 3** 0 6% 12 39% 0 0 0 1 0 3% Plasticizer 5 4 3 75% 0 0 0 0 0 0 Number of Applicants: Month 92 Year to Date 208 APPLICANT BREAKDOWN: If Minority 57 % Minority # Female 21 % Female 52% 23% *Includes three (3) temporary employees. **Includes one (1) retirement and is not counted in turnover rates. Hires (Hourly) : Month 0______ Year to Date 4 Terminations (Hourly) : Month 0______ Year to Date 6** Overall Turnover 0 Projected Annual Turnover 3.2% -17- DTH 000021645 OVERTIME AND ABSENTEEISM - 18- <u CO *3- vo ro 5-y 5-3 O VO i4-> r-- OO <TJ 4- o O h- o-3 0-3 S-S r> r- to vo sj- cm O cm ro ro!VO O CM 0000 o <D O C CD to JtOo to CD <c C oo CO cn 5-3 oo coo-3 oo oo _X <_) 00 C\i CD O X> rtj CD r-- o o to i- to 3O c o o o to CD o o o o to CD to 0 o3 0 co1 z CD o0 VO O O O 0 VO 0 oVO CM O to vo to r*. 0 10 VO p-- CO CO 0 00 0 cn CM CM CD r-- 0 CM vo CM VD CO <3- CD ^3- CM CD E -a I- 0) h- -J*: 0 to vo 0 10 O 0 0 10 oS_ to r-. r-~ LO I-- O 0 to h- CD r-- 10 ro i_ 0 tn CM VO CD CO pv. r-. co vo co VO to CM O CO CO vo VO vo VO 0 CO r- p-. cn co 4S-J- O3 VO X tCoD S- ro CL CD O CD VO 3 O X 1--(D 4C-> CD i- 03 U >> CD O <-- cro V_ o N CO Ct. C <D <T3 3 O io- o9- J3 E ro O _J O > Cl to o ro s_ CO CD c Q. O O c <0 CD *foD CoL x: x >> 1- ro to *o CD sz +J X CD to c r- CD i. _+CJ o 3 *o co c to ro i- >> O foO S- tO O JZ 3 CD rC (D CD to $3o j*: so- 2 J- *0 ra cr0 3 CD >1 CD rO TD CD -- CO TO o 2 o c o +J to CD 3 3O *d -C CD tro S- CD CD CD > S- O CD -o _x s_ 3o 3 U X CD CD -3a <D CD o> <D > ro O QJ E 4-> I CD CD > O JrOO CD DTH 000021646 PROCESS ENGINEERING - R. A. Frohreich A. Expansion Project Basis of bids for the new railroad spur was issued to contractors. The second concrete package which includes the silos, slurry blend tanks, cooling towers, and initiator storage freezer was awarded and field work has begun. Concrete work is continuing in the CRD and V-ll reactor areas. Review of piping, electrical, and instrumentation layout continues. Preliminary layout of equipment and piping for chem wash system was reviewed and comments returned to CED. B. Heat Recovery System The revised class "A" design incorporating comments from the review meeting was issued. The project will be AFE'd upon completion of the cost estimate. C. Emission Recovery System Compressor Problem New casings were installed on the east compressor which improved performance. Process Engineering is also examining the cost versus the benefit of installing compensated seals. D. Process Water Filter Replacement A design to reduce filter replacement costs by the installation of a different type of water filter was issued. E. Fire Protection Improvements - Phase III A revised process design for this project is being prepared. F. Kemp Air Dryer Modifications The class "A" design to add coalescing filters, replace purge piping, upgrade wiring, and make other modifications in order to correct the dew point problem in the Kemp air dryers was issued. G. VCM Tank Farm Revisions The design to add liquid detectors, a VCM knockout pot, and made other modifications in the VCM unloading area was issued and a review meeting was held. H. Fixed Point Monitoring Data Computer and Warning Lights Process Engineering issued a report for CCD giving detailed requirements for the operation of the data computer. -19- DTH 000021647 PROCESS ENGINEERING - (continued) I. Hot Water Charge Pump Problem Process Engineering has determined that the main cause of hot water charge pump failure is improper suction piping. A sketch showing proper suction piping configuration was given to operations. The possibility that the pumps might also be experiencing some cavation is being investigated. J. Resin Reclaim A revised process design incorporating comments from CED and PED is being prepared. K. Rotary Dryer Insulation A report evaluating potential energy savings from insulating various sections of the rotary dryers was issued. An AFE request for insulating the uninsulated portion of the dryers was submitted. L. Plasticizer Initiator Handling The Class "A" design to improve plasticizer initiator handling is underway. M. Reactor Drum Storage Areas The design to provide a curbed drum storage area for each reactor module is being prepared. N. Resin Silo Aeration The class "A" design to provide additional aeration in the Series 600 resin silos was issued. O. RVCM Receiver High Level Alarms The class "A" design for this project is being prepared. P. Line III Mill Temperature Control An evaluation on the temperature control scheme of the Line III mill was made. A letter was issued on the condition of the existing heating system. t20- DTH 000021648 ENVIRONMENTAL - V. E. Messick Particulates Two dryers were tested for particulates in October. Water All effluent parameters were within NPDES limitations in October. NPDES Laboratory Performance Evaluation samples were received, analyzed, and the information was transmitted to the EPA contractor. A meeting was held with the State Bureau of Pollution Control to discuss waste water limitations for the renewal of the plant's NPDES permit. VCM A comprehensive leak survey of all piping and equipment in VCM service has begun. Areas with higher than normal VCM concentration are being reported to operations for corrective action. Hazardous Waste Management A visit was made to the Chemical Waste Management disposal site in Alabama. The RCRA permit application for treatment, storage, and disposal of hazardous wastes is being reviewed prior to submittal. -21- DTH 000021649 Flow GPM Jan. - Ave. Max. 810 941 Feb. - Ave. Max. 645 802 Mar. - Ave. Max. 595 743 Apr. - Ave. 628 Max. 877 May - Ave.' 304 Max. 480 June - Ave. 670 Max. 804 ' July - Ave. 696 Max. 813 Aug. - Ave. 698 Max. 753 Sept. - Ave. 679 Max. 767 Oct. - Ave. 956 Max. 1066 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. Diss. O2 43 131 436 1342 86 851 216 2214 11 103 13 143 6.8-8.5 6 42 8 56 29 220 36 314 21 147 30 232 15 116 24 171 66 502 95 828 54 378 67 519 10 79 13 125 11 74 14 94 12 86 13 129 6.7-7.9 6.6-8.3 6.4-8.3 16 69 32 184 6 49 11 84 53 197 74 426 40 316 51 367 10 40 14 81 12 98 15 145 6.7-7.3 6.7-7.3 14 112 19 145 7 56 9 70 5 42 7 64 9 110 17 217 39 322 78 597 32 270 42 380 22 168 27 248 27 316 45 576 11 88 14 no 15 126 24 187 7 44 14 89 7 78 11 119 6.6-7.3 6.5-6.9 6.2-6.7 5.9-7.3 NPDES - Ave. Max. 32 387 43 520 1390 1940 - 605 - 909 > 6.0 > *-- i -n 00 Ph 7.7-8.0 7.1-7.8 7.5-8.4 7.2-7.9 7.5-7.9 7.3-8.0 7.6-7.9 6.5-7.9 7.6-8.0 6.0-8.5 -22- dtH 000021650 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for October was 112.5 MMM BTUs. The energy consumption per pound of product decreased from 3215 BTU/lb. to 3066 BTU/lb. 11. Plant Energy Conservation Program Steam Leaks Forty-six (46) steam leaks were repaired in October. Boiler Economizers Installation of economizers on two of the plant's three boilers was completed in October, with the installation of the third economizer to be completed in November. -23- DTH 000021651 ITEM ENERGY CONSERVATION DATA 1979 1980 Production, MM 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 Avg. Stack Temp. 1979 1980 365 392 404 483 407 406 28,8 5,4 3,4 0.9 38,5 56582 1020 57.714 5.0496 10000 50.496 0,601 92000 .055 108.265 2812 26.5 4.2 4.8 1.2 36.7 57964 1020 59,123 5.3398 10000 53.398 0 92000 0 112.521 3066 Avg. % Excess Air 1979 1980 27 22 26 24 27 31 -24- DTH 000021652 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Report By Kaiser Aluminum Packard Electric World of Plastics 34641 Blk. 34533 Nat. 5385 Undispersed material Poor processing Resin streamers RDJ RDJ CRM WAIVERES RECEIVED Date Identification Product Complaint Reason Waived By 10/7 10/3 iCONX 45705 iCust. Truck 5385 VRP Charlotte Pipe Heritage Particle size EKL Color Customer PRODUCT 1DEVELOPMENT & SERVICE Amount Ship Date Product (Lbs.) Customer Requested By 10/1/80 18031 CLBL50 50 PMS 10/1/80 14431 CLBL50 50 PMS 10/1/80 15041 CLBL50 50 PMS 10/1/80 16851 CLBL50 50 PMS MAS MAS MAS MAS 10/7/80 5305 50 Amoco Chemicals MAS 10/7/80 10/7/80 10/7/80 15041 CLBL50 34533 Natural 48562 Black 10 5 2 Conoco Inc. Conoco Inc. Conoco Inc. ERC ERC ERC 10/7/80 5385-3 5 W. R. Grace Co, MFM 10/8/80 5305 100 Dayco - 10/8/80 34501 Black 5 Conoco Inc. ADK 10/10/30 5385-3 50 General Binding Corp. MFM 10/10/80 5305 50 Fritz Airfreight JPM 10/14/80 VRP 1 gallon Heritage International Inc. WR 10/14/80 10/14/80 5385-1 5425 50 Electric Hose & Rubber Co. MFM 50 Electric Hose & Rubber Co. MFM 10/16/80 10/16/80 5385-1 5425 50 Sheller Globe 50 Sheller Globe MFM MFM 10/22/80 5385-1 50 Fritz Airfreight -25- JPM DTH 000021653 LABORATORY - (continued) PRODUCT DEVELOPMENT & SERVICE - (continued) Amount Ship Date Product (Lbs.) Customer Requested By 10/22/80 27121 Black 100 Standard Mirror JTW 10/22/80 17461 Natural 50 Tafco Corp. MFM 10/22/80 5465 10 Kalex Chemical Co. RNG 10/22/80 5305 5 Wilson Products RNG 10/24/80 27121 Natural 50 PMS Consolidated MAS 10/27/80 10/27/80 10/27/80 10/27/80 5305 5385-1 5425 5465 50 Diamond Shamrock 50 Diamond Shamrock 50 Diamond Shamrock 50 Diamond Shamrock JTW JTW JTW JTW 10/29/80 5305 50 Uniroyal Chemical Division NTH Special Compound Testing Complete specification tests were run on 2 samples of 36861 Natural for Western Electric, and selected critical tests were run on 2 other samples. Oven aging tests were run on 2 shipments of 38601 to Phelps Dodge and one shipment of 35851. One shipment of 34641 to Kaiser was subjected to oven aging tests. Customer Color Samples Sample plaques of 6 gray colors available in electrical compound were prepared and sent to Electri-Flex. QUALITY CONTROL TESTING Resin Regular Samples = 403 Bag Samples = 53 Other In-Process Samples = 3020 Bulk Shipments = 202 (Railcars = 87; Trucks = 115) Dry Blend Blenders Produced = 452 Blenders Tested = 400 Blenders Adjusted = 12.4% Other In-Process Samples = 541 Bulk Shipments = 61 (Railcars = 4; Trucks = 57) -26- DTH 000021654 LABORATORY - (continued) QUALITY CONTROL TESTING - (continued) Compound Blenders Produced = 737 Blenders Adjusted = 2.4% Line 5 Production = 71 skids; 0 boxes Other In-Process Samples = 573 Bulk Shipments = 24 (Railcars = 5; Trucks = 19) Resin Heat Stability Fifty two (52) lots of resin were tested for oven heat stability using the Metrastat oven. 5385 5425 5305 5465 20 lots 20 lots 10 lots 2 lots Heat stabilities were acceptable, except for one sample of 5335 which was marginal. RVCM of Shipments A total of 159 shipment samples were tested for residual VCM in October None of the samples exceeded 10 ppm. A summary of this data is below. Product 5305 5385 5425 5465 Dry Blend Number of Samples Average RVCM, ppm 71 54 27 2.6 0.8 0.1 2 0,1 6 0.4 Inherent Viscosity A total of 681 samples were analyzed for a daily average of 22 samples per day. All railcar shipments during October were tested for inherent viscosity. Dry Blend Controls Wei ex batches of 80273G and 80172B were prepared as quality control standards. Raw Material Testing Fifty-eight (58) lots of plant raw material were tested and released. One lot of Hydral 710 (hydrated alumina) and four lots of Thermaguard S (antimony oxide) were rejected for poor dispersion. -27- DTH 000021655 LABORATORY - (continued) MISCELLANEOUS PROJECTS Resin Volume Resistivity Volume resistivity was measured on 4 recent samples of 5425 resin and 2 recent samples of 5465 resins. All the samples gave values that were equal to or better than the control. Compound Property Verification The compound property verification program is complete unless the plant should make additional compounds for the first time in 1980. Residual VCM in Slurry A total of 639 slurry samples were tested for RVCM. The overall average was 179 ppm. There were no days where the average exceeded 400 ppm. RVCM of Blowdown Tanks A total of 149 samples of blowdown tank water was tested for RVCM. The overall average was 4.7 ppm. RVCM of 5305 Regular Samples A total of 63 samples of 5305 taken from the regular QC drier samples were tested for RVCM. The overall average was 3.6 ppm. Personnel Dosimetry There were 94 analyses of VCM dosimeters reported to the Safety Department during October. L & N Particle Size Tester The startup of the L & N particle size tester is complete after many problems. Most of the startup problems were electronic which the L & N service people worked on. In addition we found several operation parameters which were much more critical than expected. One such item is lazer alignment. A test program to define the short term and long term precision is in progress. The precision study will be completed during November. -28- DTH 000021656 TRANSPORTATION - J. E. Stark Shipment by Product - M/lbs. October Year-to-Date Res i n Plasticizer Dry Blend Compound Total 24742 83 4423 5566 34814 163464 729 22123 -326.58. 223974 Number of Shipment by Mode R/C O.T Bulk O.T Van Resin - Bulk Package Export Platicizer Dry Blend - Bulk - Packaqe - Export Compound - Bulk - Package - Export Other - Antifreeze - Alumina Back Hauls for October 112 47 6 67 10 16 * 128 76 Number of Shipment by Month-Year-to-Date 5 37 10 13 31 11 107. 33 C.O.T. 1 1 1 ' c.c. 16 TOFC 1 3 1 3 19 CPU TOTAL 43 218 7 12 43 12 44 60 1 12 13 29 20 71 11 43 0 116 471 2 36 January February March April May June July August September October R/C Bulk Van C.O.T. C.C TOFC CPU TOTAL 104 53 72 111 83 66 130 95 64 69 43 84 42 41 75 55 36 136 57 47 52 79 51 65 102 53 62 128 76 107 0 0 1 0 0 0 0 0 0 1 4 2 36 273 21 4 35 320 37 0 48 375 5 0 29 230 3 0 30 191 7 0 74 308 2 0 64 222 12 0 89 296 7 2 53 279 43 0 116 471 -29- DTH 000021657 TRANSPORTATION - (continued) Material Handling Report M/Lbs. T/L Packaged Resin From Production Packaged Compound, Dry Blend From Production Transferred From Main to Prairie Transferred From Prairie to Prairie Reverse Transfer Resin to Plant Reverse Transfer Compound to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Main 2,470 4,415 2,187 0 769 203 5,427 2,471 2,389 61 109 54 0 19 5 134 61 __ M TOTAL 20,331 502 Off-Grade In Storage Material M/Lbs. T/L Sifter Overflow Resin "BC" Resin "H" Mill Scrap Compound "B" Compound "H" Dry Blend "O.G." 519 3,983 1,735 183 930 114 110 13 98 43 5 23 3 ____ 2 TOTAL 7,574 187 D. F. Operation Total packaged inventory for the month remained the same. Production for packaged compound and resin was up for the month, but shipments were high, therefore the inventory remained approximately the same. Export shipments were up for the month. Total shipments for the month was the highest this year. -30- DTH 000021658 \ 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 12-9 21 21 21 Total 209 CONOCO TRANSPORTATION ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco Resin HOPE Resin Export Resin Conoco Export Resin 3 -6 2 1 -0 .5 .4 3 .0 .1 .3 3.6 Conoco.Resin Resin O.G. Mill Scraps Cmpd 0. G. Dry Blend 0. G. Sifter Overflow Resin 0. G. Compound Resin Raw Material Resin 0. G. Conoco Conoco Resin Sub-Total (Plug-Aisles) Total Conoco 4. 4 .2 1. 1 .1 .5 1- o .1 2- 6 .2 3. 0 4. 5 3. 7 ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 5. 3 .4 4.7 1.1 10.0 1.5 3.1 .4 3.5 * 3- 9 * 4-4 3.5 3.5 *2-9 2.5 2-9 3 -0 * 4-5 fi_ 3.5 . 5_ 3.5 3.5 3.7 Hr DTH 000021659 3.5 " 38,5 2.9 34,1 ____7,3__ . -a ABERDEEN FIRST-AID CASES 12 MONTHS MOVING AVERAGE 50 45 Frequency = Total First Aid Cases X 1 Total Employees 40 35 30 25 20 15 10 5 0 DTH 000021660 ABERDEEN OSHA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE 20 15 10 5 0 DTH 000021661 MONTHLY HOURLY TURNOVER DTH 000021662 ENERGY USAGE B TU /LB . Monthly 12 Month Movin DTH 000021663 Average ABERDEEN PLANT PRODUCTION 1980 MM POUNDS CUMULATIVE 35 30 25 20 15 6 5 4 3 2 1 : 40 \ 35 6 l 30 5 i 25 4 3 2 1. 2 I 0 ----------- actual ----------- CUMULATIVE DTH 000021664 ABERDEEN PLANT QUALITY PERFORMANCE 1980 STANDARD 1.02 STANDARD 1.35 DTH 000021665 1.01 ABERDEEN PLANT EFFICIENCY 1980 POUNDS OF RAW MATERIAL/POUND OF PRODUCT STANDARD 1.01960 STANDARD 1.01300 MONTHLY CUMULATIVE DTH 000021666 ABERDEEN PLANT INVENTORIES DTH 000021667