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I To: R. T. Ferrell Interoffice Communication From: Date: Subject: J. W. Ware October 19, 1987 ABERDEEN MONTHLY PROGRESS REPORT SEPTEMBER, 1987 There was one first aid injury recorded during the month of September. As of September 30, 1987, the plant had operated 3,009 days or 3,890,107 manhours without a lost time injury. PVC resin production for September was 35.1MM pounds. The major cause of downtime in the reactor areas was the new module shutdown. Major work completed during this outage included installation of reactor jacket expansion joints on 745, hydroblasting and inspection of 741 and 745, replacement of condenser studs on 744 and Modicon revisions for RQIP. Resin production for the 1987 fiscal year was a record 425.0M pounds. The previous fiscal year resin production record was set in 1986 at 415.2MM pounds. The VCM efficiency for September was 0.99756 pounds of VCM per pound of PVC produced versus a 1.00208 standard. Year-to-date VCM efficiency is 1.00933. Compound production for September was 5.2MM pounds. Line I and Line III operated twenty-five days and twenty-nine days, respectively, during the month. Line V operated fifteen days. Downtime was taken on Line I and Line III to control inventory. Compound production for the 1987 fiscal year was also a new record at 80.3MM pounds. Quality performance for flexible compounds was 2.2% off-grade of which 71% was due to mill scrap. "BCM production was 0.43%. Dry blend production was 5.2MM pounds for September and 56.1MM pounds year-to-date. Production was limited primarily by product changes. Quality performance for the month was 99.4% customer The plasticizer unit operated nineteen days in September produce 1.0MM pounds. Year-to-date plasticizer production 21.4MM pounds. to is Feedback meetings for the plant attitude survey began during September. We expect some of the feedback groups to evolve into project teams as problems are identified. Eleven project involvement teams are now active. A -......... -Sr-- -lir-fv.-!. s'j.r :| 1 'J- il |^|J -si:- : -IpSI'J'TV E: |*- ! rf: fcb ! . I. -i .. "S. .j-; . :.. m-f,; VAB.0001191197 'I I R. T. Ferrell 10/19/87 Aberdeen Monthly Progress Report Page 2 Total energy consumption for September was 105.423 MMM BTUs. The energy consumption per pound of product was 2267 BTUs, resulting in an adjusted CMA reduction of 56.2%. The adjusted CMA reduction for fiscal 1987 year-to-date is 55%. The total plant variable cost variance for September was $1599.8M unfavorable, resulting from an overall unfavorable price variance of $1509.3M and a net unfavorable efficiency variance of $90.5M. The total fixed cost variance for September was $184.9M unfavorable. Year-to-date total fixed cost variance is $45.1M favorable. A rah VAB.0001191198 DISTRIBUTION COVER LETTER HOUSTON: J. D. BURNS X R. E. mtftCUHL R. T. FERREIL [ - R. D. GAMBUN J. J. LANGFORD X R. E. SWANIKDWSKI D. F. HAINAN X H. R. HAMER R. R. SMITH S. K. SABORSKY K. J. EQGERS D. H. SANDERS PONCA CITY: S. E. MCGUIRE R. L. POE X H. J. HALL C. M. STARKS OKIAHCMA CITY: HARRY GARRISON LAKE CHARLES VCM PLANT: DICK CONRAD LAKE CHARLES CHEMICAL PLANT: J. A. DEBERNARDI T. H. HUFFMAN X LAKE CHARLES LAB PLANT: L. R. BAUER X BALTIMORE: R. W. SEYMOUR X HftMDND: J. B. MAHER X ENTIRE REPORT COVER LETTER AND QIP X X X X X X X X X X X X X X Safety Section and X A BLANE POLYMERS: PREMIERE POLYMERS: ABERDEEN: E. L. K3ESCHNICK P. L. FOOTE JF, JWU, DWH, PJK, TEL, RAF, KLF, BAM, VEM, HOC, CUT, K VLT, JEL, BEN X X VAB.0001191199 h4 % -u i-#. t*fi-lf-T lH.iliJyrt'ii-f-h- -+ i-i-qi ; muhat.i,-: ifwiti = ' i i pih,. r>I - ' l-E1-'" * f r* : 1st R. i'.'Vi r * SAFETY - K. L. Fogg, J. V. Uptain Occupational Injuries Fiscal September Y.T.D. 1987 First Aid OSHA Recordable Total Injuries 1 _0 1 Number of Restricted Workday Cases Number of Lost Workday Cases 0 0 2 0 Fiscal Y.T.D 1986 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals Non-Occupational Injuries Lost Workday Cases Days Lost 0 0 Safety Record Last lost time injury 7/5/79 Days since - 3,009 Manhours since - 3,890,107 On September 30, 1987, the employees of the Aberdeen plant completed 3,009 days with no lost time injury. Topics for the plant safety meetings during the month included: Warehouse Walkway Safety and Annual Health Training (VCM, Lead, Noise, Asbestos and Respiratory Protection). A i, ri|-^i .Yi'ty t-7 f -I' ' 11 | -l' |-l- :iil- ' >>> -* * t : ... !>> fl|l' imnill'll VAB.0001191200 ......... J SAFETY - Continued The plant formed a quality team to plan a celebration in recognition of the eight years completed without a lost workday case. Three dinners were planned to accommodate the shifts. A second team selected a gift certificate for each employee in recognition of their accomplishments. R. E. Lehmkuhl, R. D. Gamblin, and R. T. Ferrell attended the steak dinners. Attendance was good and everyone had a good time. The Safety Department completed one attitude survey feedback session and one problem solving session. Phase I of the interim VCM/lead physicals was completed in September. The Central Safety Committee had its monthly meeting. Routine dosimetry results for the month are as follows: Chemical Number PEL Percent Number PEL Percent VCM 76 97.4 Lead 13 86.7 Total Particulates 2 100.0 2 2.6 2 13.3 0 0.0 Both of the lead overexposures and one of the VCM overexposures was with benefit of respiratory protection. VAB.0001191201 i ' `I 1H[ T'- -......... -I I'- : | - i . - Out. i - ' p -rw-*q - ; .-i -.) ' d Uj CQ T Q CC o o Uj cc CJ Uj Uj Q nr Uj o ..................... -- |li*f trO> Oo IODj O ID ^ O ^ ID O s>3idnrNi jo y i&wfiN VAB.0001191202 rrtl~^<p'fTtl , .T TlSTi ?i|. I -i;#?-. J^I| ^.. "H'-.-m: L-f-j:-j-=njifPimpa k . .h- j - h:-.i r'-'-i P::I:ij^.i. jupH.. . n iH-v; :S I-Wfe^- . .. P (J-i . h|iT^I-;...|, r-,y-Ma#l^W^i' ll = `jn-1 J QUALITY MANAGEMENT PROCESS - D. W. Hollis, R. B. Newton Quality Management activities (SPC charts, teams, training, etc.) will now be reported by each department in their section of the monthly report. This is being done to emphasize the idea that QMP is not a progra 1 but the new way of doing business. Rendell Newton attended the seven-day Team Performance training seminar in Houston. Several employee feedback meetings were held to discuss results of the CVR Attitude Survey. These meetings were mainly problem identification meetings with problem solving meetings to follow. VAB.0001191203 11 ,ppfc * f.% . -pi. '!! L-: - i-: ...................^ -i p n :- f i. * i: rvr I? L'l :ir-III jlJl-'i'i.-l'tljf Jl |. .--r.-r-r* r>- -? ft ' J 1 : I'l - . :\n : i!-._ ! I '.BfHfpPlr-.-4 r.y -T=-r'lfc"ftf'!n: i I l.-Ufi ler-i-t.. t -J : .r iifl.fl , I ;a E-:: : > 4J!1 :-n : * ;.... 1 hv: ftp.. |*.l- i , | i%.. r^,- -y -r z VINYL - P. J. Kober, J. M. Edwards Safety The Vinyl and Yard Departments worked without any reported injuries during the month of September. Shift safety meeting topic for the month was OSHA Compliance Health Training. Quality Improvement Process The CVR employee attitude feedback meetings continued in September for the Yard and Vinyl Departments. The meetings are presently in the problem identification stage. The Yard Department presently has one SPC team. This Railcar Team's objective is "to ship the best railcar possible to the customer*1'2. The team, which met three times in September, is in the recommendation stage of the problem solving process. Their main area of improvement involves cleaning, inspection and repairs to the cars before being released for filling and shipment. Production .1 Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. .5. Reactor Stream Factor 6 Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days September 35.1 1171 813 27.1 88.4 8737 69.8 30 Y.T.D.(Fiscal 87) 425.0 1164 10531 28.9 89.8 9691 63.0 365 Vinyl Department production for September was 35.1MM pounds. Reactors The reactor stream factor for September was 88.4%. reactor area occurred as follows: Downtime in the 1) Operational Downtime: Accounted for 25.1% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size information before charging, lines plugging, reactor manway O-ring failures, power failures, bad weather, and the lack of blend tank room to dump a reactor. 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. s I ^ h I T. -!! ( ' "I ^0 + : - = 1= ftt-l'i -- :: i?->: iI--.v-'i , .44 myrn-niJ *.:** iu -.M: Hi j f'" VAB.0001191204 VINYL - Continued Product Quality Summary - continued A total of thirteen railcars were shipped as "B" grade during the month which represented 9.2% of the 142 total resin hopper cars shipped. Load Date Ship Date Car No. 08/11/87 09/03/87 VIPX 43855 08/01/87 09/09/87 VIPX 45303 Customer Silverline, NC Shawnee, MS Product Reason 5385 Contamination 5415 Derailed 08/28/87 09/09/87 PLWX 44733 Apache Plast., CA Debox Quality 07/28/87 09/11/87 PLCX 43700 H&W, MS Debox Quality 08/26/87 09/11/87 PTLX 41014 Wexford, WI Debox Quality 09/01/87 09/11/87 VIPX 45855 Griffco Plast., MS Debox Quality 09/08/87 09/15/87 VIPX 45770 Custom Vinyl, TX Debox Quality 08/14/87 09/18/87 PLWX 44272 Kroy Indust., NE 5385 Contarn. 07/31/87 09/21/87 PLCX 43696 Gamma Mfg., CA Pond Quality Resin 09/16/87 09/22/87 PLCX 43869 Western Plast., OK Debox Quality 09/04/87 09/22/87 PLWX 44292 Apache Plast., CA Debox Quality 09/08/87 09/24/87 VIPX 45810 H. Heller, MS Pond Quality 09/22/87 09/24/87 PTLX 41609 Western Ag., TX Debox Quality Monthly Variable Cost Performance Variable costs for the month were unfavorable at $1453M resulting from an overall unfavorable price variance of $1411M and an unfavorable efficiency variance of $41.9M. Resin variable cost for the month was 22.429 cents/lb. versus the budgeted 18.119 cents/lb. The $1411M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $1402M, offset by favorable natural gas pricing of $26.3M. The $41.9M unfavorable efficiency variance can be attributed mainly to an unfavorable variance due to Calcium Stearate, $13.6M; Alcotex, $21.4M; and electricity, $12.6M; offset by a favorable Polyvic variance of $16.2M; and VCM, $23.7M. VCM efficiency for the month was 0.99756 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. YTD variable cost efficiency variances in the Vinyl Department totaled $696.0M unfavorable. VAB.0001191205 ................ ' -i! ir........................11- **!-+* Pl'frijmUfHi I rrKt*si\^ a iLJdna: * !! ti* t-i. 7 l-MV M.'' iJ!r iji r 7 : }nKi.::i:i A i i- = 0: ip. <T - 1 J * VINYL - Continued Reactors - continued 3) Maintenance Repair/Revision Downtime: Accounted for 74.9% of the total downtime and a majority of the time was due to the scheduled annual shutdown of the New Module. The following major jobs were accomplished during the shutdown: 745 jacket expansion joints added, Modicon manual mode was added, 741 and 745 reactors were hydroblasted and inspected, and the automatic chem wash system was installed. The safety discs were changed on reactors 741, 742 and 743. The condenser studs were changed on 744 condenser base. The safety discs were changed on D500 and D600 also. Dryers The dryer stream factor for September was 69.8%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 74.3% of the total downtime. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 11.5% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems, and power failures. A significant increase in the amount of operational downtime this month was caused by low air pressure. 3) Maintenance Repair/Revision Downtime: Accounted for 14.2% of the total downtime and was due to repairs to #4 and #6 star valves, #1 and //8 centrifuge belts, #7 Sweco motor, #7 Trunnion roller, #5 Bird and #6 gas valve. Product Quality Summary Resin Type Prime "B" "H" % of Total Production 5265 5305 5385 5415 5425 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 4,249,674 2,905,740 14,614,714 11,937,227 9,680 33,717,035 942,920 0 942,920 38,627 429,560 468,187 12.1 8.3 41.6 34.0 0.0 0.0 2.7 0.0 0.1 1.2 100.0 Quality performance for September was 98.7% customer grade with 1.3% "H" grade production. t r. .1 ..... j- - : - 'H.I ! h! ' Li *h+n : -hTIllMblUI-t ! : tf 11, 'll pi} * - 1 ' 1l# Cw1: m 1 STU SW SU VAB.0001191206 :> . '.'i In*-! i ! - : 1 VINYL - Continued Energy Performance/Progress 1. Plant energy performance for September was 2267 BTU/lb. General 1. Resin raw material in the 0744 account totaled $303.3M. 2. The New Module turnaround performance by maintenance, engineering, and operations was notable. At month end, the shutdown work was processing on schedule. A VAB.0001191207 COMPOUND - C. W. Turner, J. E. Nickerson Safety The Compound Department worked without injury in September* misses were reported. No near All compound operations personnel attended the training class conducted by the Safety Department. on proper use of respirator equipment. annual Health/Safety The training focused Compound Production Operating Days Month Production CM Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line V Line III Total 25 14.5 29 1426 572 3175 5173 57 39 109 26701 8770 44838 80309 Line I operated twenty-five days in September at an average rate of 57M pounds per day. Major items affecting production efficiency were: product changes, 81 hours; mill maintenance, 18 hours; dicing system problems, 13 hours; quality problems, 12 hours; Banbury maintenance, 10 hours; and housekeeping, 5 hours. Line I was down approximately five days for inventory control. This downtime was used for SPC school and re-packaging of some products. Line III operated twenty-nine days in September at an average rate of 39M pounds per day. Major items affecting production efficiency were: product changes and startup time, 74 hours; running line clean-out to remove streamers, 12 hours; dicing system problems, 7 hours; and mill maintenance, six hours. Line III was down Labor Day to control product inventory. Line V operated 14.5 days in September at an average rate of 39M pounds per day. Major items affecting production were: product changes and start-up time, 54 hours; transfer system problems, 5 hours; twin-screw problems and maintenance, 8 hours; and quality problems and rework, 4 hours. Quality performance for flexible compounds was 2.2% off-grade of which 71% was due to mill scrap. "BC" production was .43%. The raw material requirement for flexible compounds was 1.03276 pounds of raw material per pound of compound versus a 1.01203 standard CYTD is 1.00915). The variable cost variance for compound was $152.3M unfavorable with $88.8M unfavorable due to price and $63.5M unfavorable due to efficiency. The efficiency variance due to product mix was $28.8M unfavorable. The only major compound efficiency variance was for TOTM at $16.0M unfavorable. Total compound inventory fell 3.0MM pounds in September to 4.2MM pounds. A VAB.0001191208 ..........----------------------------------' 1 I ' 1 =-- '' " 1 s >r-------- I" ' >- L ' . i .. -||. I?fa1~,r1 -j\t (r = V--5 fcif-!'* -if- i ::: il Hirf'"* VI- |. 1""P . 'f ,, ! COMPOUND - Continued Dry Blend Production, M Pounds Operating Days Month 5205 30 Average Operating-Day Rate 173 Fiscal Y.T.D. 56135 364 Dry blend operated thirty days in September at an average rate pounds per day. Production included 80172C, 80273G, 90172D, RP-440, 186-139, 269-69, 269-66, 269-185, 269-151, 269-164, 317-30, 1960172, 317-91, and A10-001. of 173M RP-421, 290-61, Dry Blend production was hindered by: product changes, 79 hours; delays associated with quality and lab problems and normal Q.C., 53 hours; master batch feeder maintenance, 13 hours; transfer system problems, 7 hours; TiO,, system problems and maintenance, 5 hours; elevator maintenance, 5 hours; screener maintenance, 4 hours; and Welex maintenance, 4 hours. Quality performance for the month of September was 99.4% customer grade. The raw material requirement for dry blend was 1.00355 pounds of raw material per pound of dry blend versus a standard of 1.00491 (YTD is 1.00731). The variable cost variance for dry blend was $14.5M favorable with $6.0M favorable due to price and $8.5M favorable due to efficiency. The efficiency variance due to product mix was $15.4M favorable. The efficiency variance for Liquid Methyl-Tin Mercaptide stabilizer was $15.0M unfavorable. Plasticizer Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 1024 54 21381 19 350 Plasticizer operated nineteen days in September at an average rate of 54M pounds per day. Production included 61OP and 108P. VRP production totaled 59.4M pounds (5.8%). The raw material requirement for plasticizer was 1.09354 pounds of raw materials per pound of plasticizer versus a 1.10192 standard (Y.T.D, is 1.10184). The variable cost variance for plasticizer was $8.8M unfavorable with $15.2M unfavorable due to price and $6.3M favorable due to efficiency. There were no major plasticizer raw material efficiency variances. The efficiency variance due to product mix was $2.3M favorable. -t- nI l ,i i >< VAB.0001191209 it- r:: c? Mfi-i J Jm*. -I" p. d* \lii- ih-v i COMPOUND - Continued Quality Improvement Compound and dry blend operators are now plotting critical Q.C. results on individual's charts which reflect deviation of results from target. This makes it possible to use a single, continuous chart for all products. Second-round SPC training (with emphasis on charts currently in use) has been completed by half of the compound personnel. The remaining people will complete the class next month. The product change project team has completed initial work to identify equipment and procedures to improve product change. The team plans to collect data during product changes using the new procedures to measure improvement and determine what additional work might be needed. Energy Compound Dry Blend Plasticizer Usage (BTU/Lb.) Actual Standard 1960.5 782.3 2045.9 1783.0 730.0 1833.5 A VAB.0001191210 i i+,h. %j-- -1-t. ? -I mil-. . 'i i-i f ......................................... ... iL i : !>-- - ......... 1 MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - D. A. Miller Safety There were no injuries to Maintenance Department personnel during the month. The monthly safety meeting topic was the annual VCM, Lead, Noise and Respirator Training. Vinyl The annual safety disc change for reactors 500, 600, 741, 742 and 743 was completed. The D744 reactor agitator seal was replaced during the month. failure was due to an 0-ring deterioration. The The annual new module shutdown was completed in late September. following major work was completed: The - D741 and 745 reactors were hydroblasted and die-penetrant inspected. No problems were found. - The recovery system subcoolers and seal water coolers were cleaned. - The following vessels were opened, cleaned and inspected; blowdown tank, fresh VCM receiver, east recovered VCM receiver, recovery system knockout pots, hot water charge tank and 747 blend tank. - D744 reactor condenser was removed and the attachment stud bolts were replaced. A non-metallic gasket was used on the condenser base and Belleville spring washers were installed. No leaks have been reported since startup. - The evacuation jet had a new second stage venturi installed. - A pinhole leak was repaired in the bottom of the D741 reactor jacket. - A plant steam outage was taken to replace a ten-inch valve in the main steam header. During the outage, three pole mounted PCB contaminated transformers were replaced at the boiler house. - Eight relief valves were overhauled and tested. - A bus stab in #9 MCC was replaced. This was identified as a hot spot during an infrared inspection. - The VCM turbine meters were inspected. - The 903 and 905 compressor seal water flow meters were repaired. - The catalyst Day freezer alarms were calibrated. "'fUfwM*" 1 vr ' - ' 111 fir-1 Wir *" i. . L^q: r;:- -.if \> .-i . -.,syr VAB.0001191211 P I - I' i. '-1 V MECHANICAL DEPARTMENT - Continued Vinyl - Continued The following mechanical seals were replaced during the month: - 705 ERS compressor inboard and outboard seals. - 905 compressor inboard seal. - Old unit north chem wash pump seal. The following major valves were changed out: - D300 main chem wash valve. - Primary VCM charge valve on D600. - D741 recovery valve. - D600 main rinse valve and shell rinse valves. - D600 atmospheric vent valves. - D742 and 744 main charge and dump valves. A Daniels service technician assisted in a calibration and PM check on all gas chromatographs. The following major work was completed in the vinyl dryer area: - New Maxon gas valves were installed on the #6 dryer burner system. - The pond resin slurry transfer pump was overhauled. - A Trunnion roller on #7 dryer was replaced. - A spare Pick heater was installed for the fluid bed dryer hot water system. - Replaced the case on the fluid bed dryer hot water pump. - The 5415 transfer blower from 281 silo was overhauled. - Number six dust collector was overhauled. Compound, Dry Blend, Plasticizer The back roll driveside bushing was replaced on the Line I mill. New labyrinths were installed and the lube oil system was cleaned and rebuilt. The Line I Banbury seals were changed. The east conveyor belt for the east Line III mill takeoff conveyor was replaced. VAB.0001191212 -| r I I -1'-< i-V n ^ .> ,,v lull'd m/1 1 I | -y-\r h -:i i . *f.H! 1.': -e . i-iL. . I \x |i H'+ ` i - i - 'if 4 MECHANICAL DEPARTMENT - Continued Compound, Dry Blend and Plasticizer - continued - Pressure gauges were installed on the supply water piping for the plasticizer reactor condensers. - The Line III #5 dicer motor was rewound. - Repaired a ground fault in the Line V compounder control panel. Utilities The main process water header ruptured near the rail scale in the southeast corner of the plant property. The line was spliced with a Dresser coupling. The annual inspection of #2 boiler was completed. The inspection revealed one leaking tube which was plugged and removed. A hot spot in the back wall was repaired. All the boiler burner management systems were tuned during the month. The dessicant and prefilter was replaced for the Pall plant air dryer. The seals were replaced in the south fresh air compressor. Corroded piping was refrigeration system. replaced for the VCM receiver condenser Completed the quarterly crane P.M. and replaced the boom cylinder bushings and right rear outrigger holding valve. The bio-disc inlet sump was cleaned of solids. Quality The Valve Team has completed fabrication of eight of the ten prototype valve assemblies. Design drawings of these assemblies have been completed. In addition, several of the team members designed valve kits for the plug valves purchased for the Subpart V Compliance Project. Plans for the near future will include building eighteen valves for stock and selection of a vendor for valve/actuator mounting kit fabrication. A team has been formed to investigate the safety aspects of the boiler house from an operations, maintenance and administrative point of view. The team includes members of the Maintenance Department, Utilities, Process and Mechanical Engineering and the Safety Department. 1 p I- -:: - V-.-: e-..::. j: itr- .4. .f r 1 -v ............................... sin " -i ' HH: l-l-?. bl*- Cl -jhi-Htj" tW-;! VAB.0001191213 cf.nis -.-i - rili*..jh- i-t.-fl r>r:i^ih: i; ,"1'? ^ 'i.-, : h-f!: Ji rh-': M ;v t t+i MECHANICAL ENGINEERING - R. E. Polk AFE F537 - Dry Blend Transfer Lines Installation is 85% complete and in progress. Completion is scheduled for 11/1. AFE F786/F557 - Resin Quality Improvement Design at Litwin is 56% complete and in progress. Procurement of in-line instrumentation is complete. Drawing packages for electrical grounding, SA module control room layout and Modicon rack layout have been received and are being reviewed. AFE D756 - Reactor Expansion Joints Installation of joints on all reactors has been completed. Painting and minor punchlist items remain. The project will be closed to field charges in November. AFE A567 - Rotary Dryer Duct Upgrade Installation is planned for dryers #4 and #5 in October. Ductwork installation for dryer #8 will be coordinated with dryer shell repairs to minimize downtime. This is tentatively scheduled for late November. AFE F587 - Laboratory Addition All major equipment except the MCC has been placed on order. This will be requisitioned by 10/15. Design is 85% complete and in progress. Completion of design is scheduled for 11/1. Construction is planned for completion by 1/1. AFE F657 - Roof Upgrade Phase II All mechanical pre-work has been completed. Membrane installation is 50% complete and in progress. Completion is planned for 11/1. AFE F596 - Chem Wash Automation Installation in the Old Module was completed during the module outage in August. Startup and de-bugging of the control system is in progress. Installation for the New Module is in progress and will be completed by 10/19. AFE D606 - Propane Tank Farm Electrical Revisions Electrical construction is complete and the system operational. An operational check will be completed in October as a part of normal winter preparation. PCB Transformer Replacement Two pad-mounted transformers have been retrofilled. thirty-two pole mounted units have been replaced. Nine of the VAB.0001191214 i -i 1 : * --1*1*1!" -* " ' 4 ' i -i'l- }Nirr = --J.I-j h-J::ib-!- j. I**'*: v-:%- .< :P---1^ . -I- fc': ' i ' 1 1 * ^ 1" , - -- .'h 1 M ..l? "A i 1 PROCESS ENGINEERING - V. E. Messick Resin Qualit rovement Pro Review of engineering design packages continues. Those included equipment and pipe rack foundations, structural steel, control panel layouts, and site preparation drawings. A trip was made to Houston to meet with Vista GED personnel and review piping plans for the suspending agent building. The operator interface unit which allows the operator to verify recipes in the programmable controller was put into operation. The "manual mode" programming was activated during the CRD module turnaround. Also, several tie-ins to the plant1s utilities (steam, process water, cooling water) were made during the turnaround. Breathing Air, Bottled Nitrogen, and Plant Air Systems Survey Surveys were conducted of these systems to identify any system cross-contam ination or improper tie-ins. A report on results was Issued. Subpart V - VCM Valve Leak Survey A random leak survey of 200 valves in VCM service was completed. No leaks were found. A letter on results was issued. AFE's Submitted The AFE requests for Reactor Heat-up Loops, Line III Metal Detectors, VCM Unloading Area, Fire Protection Improvements, Recovery System Compressor and Furniture and Fixtures were issued. SARA - Right-to-Know Frank Jeanson attended a CMA workshop on estimating fugitive emissions and an environmental coordinators meeting concerning SARA. Compilation of data for the SARA reDorts is beine eathered. 745 BME Addition System Modifications A design was issued to modify the 745 BME Addition System for operator exposure to BME vapors and adding interlocks for safety. system will be similar to the existing D700 BME Addition System. meeting is scheduled. reducing The new A review 5415 IR Problem A relationship was identified between dry CaSt levels on 5415 resin and IR performance in Southwlre 1201 formulation. Due to this, limits were set on the amount of dry CaSt applied to 5415 and IR performance has improved. Fusion Tea A proposal for an experiment design on Line I was Issued for review. This design will vary Banbury batch size and drop temperature to determine the effect on fusion. Reactor Temperature Control A proposal for revisions to the test reactor control system on reactor 745 was Issued. A review meeting was held with operations. The revised control scheme will be tested during the October 5305 production run. VAB.0001191215 "* r*t"-:1' i:- r-. i | :-.vi -is-ij|ii ./ >t. i-11. f.. .a-r" r- ii * h. . i. 'I- :i -1j : : -n.-. |i >' - . PERSONNEL R. A. Miller EMPLOYMENT Jeffrey B. Popp, Rehire PROMOTIONS/TRANSFERS Daniel A. Miller, promoted to Maintenance Superintendent Charles A. Clark, promoted to Maintenance Supervisor Gilbert A. Morgan, from Maintenance Supervisor to Contract Supervisor 0. C. Pace, promoted to Vinyl Shift Supervisor Mike Nathan, promoted to Product Supervisor and transferred to Timberway Paul Cogsdell, from Lab Trainee to Lab Technician "A" Robert E. Stone, from Vinyl Chief Operator to Maintenance Helper Freddie Franks, from Vinyl "A" Operator to Maintenance Helper Kenneth Campbell, from General Helper to Vinyl "A" Operator Steven C. Wilkes, from General Helper to Vinyl "A" Operator I RETIREMENTS Jerry L. Horstman Samuel L. Kennedy TERMINATIONS Satish K. Gianchandani Thomas A. Madigan, Co-op Student returned to school TO/FROM LEAVE OF ABSENCE - t VAB.0001191216 i rtr -r i s s TMi'' - ' "'a- i:"iw ::a=-i ;<\- ' i , P^fT : i -- -I Hd-! n> II .IvlTfjm-- f :ir- -p r : ill'!-;:*. fc I-1 \? > . -ir i,-h. c- k- - . .Jh,.-, .. . J-i*-. -tv" Mir !:Ctt ilf;. .cNT i-e-*| . . i. H --Vll > - Aberdeen, Mississippi Salaried Employees 71 * MONTHLY PERSONNEL REPORT Minority Employees # 0 Hourly Employees Total Employees 168 239 Salaried Hourly 8 66 n% Employees (Hourly) Total 74 31% New Employees Terminations 0 Hourly Min Hired % Min. Hired Hourly Min Term. % Min. Term. o a DEPARTMENTS PAR EMPLOYEES MIN. EHP % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse Gen. Plant JA. -L6_ 16 Z 44 1a 00 0 Maintenance 12L 22 boratory 2L. 1 a Compound XL 22 m a Vinyl 22- 31 a a a a Plasticizer 52 o0 Number of Applicants: Month Year to Date APPLICANT BREAKDOWN: # Minority * Female 2 0 % Minority % Female 0 Hires (Hourly) Month Year to Date 9 Terminations (Hourly) : Month 0 Year to Date Overall Turnover 0 Projected Annual Turnover 1.6% * Includes 1 temporary employee and one Co-op Engineer 11 l i- == :: : a i hi ~^ \'s if s ' tt.:. .lira VAB.0001191217 . : - I1; j; i.`l i-.i III IA iJ- Tl- 1 t. i:- ; i~.i ?l h \ ..................... h I OVERTIIC AND ABSENTEEISM ... I ...V -T- : It >1. M^i Wfriii Jh- r .'i.ip =i ` l-H VAB.0001191218 n-Hi ' r M>Lw''i l-: ' : * !.> . > ! ' r V1:"1! 1 'I'1 ,lVr,, 'h-i- . i-i i-. -< n > .i ENERGY CONSERVATION - F. G. Jeanson I. Plant Operations Total energy consumption for September was 105.423 MMM BTUs. Energy consumption decreased to 2267 BTU/lb. from 2304 BTU/lb. In August. An adjusted CMA reduction of 56.2% was obtained for the month. The adjusted CMA reduction for fiscal 1987 Is 55%. II. Plant Energy Conservation Program Maintenance There were twenty-seven energy related items completed in September. Twenty-six of these Items were steam leak repairs. The remaining one was a steam trap repair. III. Boiler Operation Boilers No. 1 No. 2 No. 3 Combustion Efficiency % Sept * 9 1987 Sept 9 1986 83.9 (1) 83.5 83.9 (1) 83.3 Note: (1) Boiler number two was not used during the month. VAB.0001191219 > +' -ii n *I : 'l.jfl I: + ak'- I uJnIjUL : -..t. -JFK . .:|rlT-I. j U^l: : . 4 1 rl.. :. If -1.. -4. . tijs t) j ..fc^ ...................................................... ..... ............ rl I -qftfl ( . J-l-lj !j .L If 1.; "'iH' !'!.. II- 14 ; pir I Month ENERGY CONSERVATION DATA 1987 September Production, MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL 35.1 5.2 5.2 1.0 46,5 Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 47656 1020 48.609 1045 Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 5.6815 10000 56.815 1222 Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 0 92000 0 0 Total Energy Consumption, BTU/lb. 2267 Energy Consumption, MMM BTU Actual Unadjusted Actual Adjusted 1972 Base Period 105.423 85.197 194.544 CMA Reduction (%) Adjusted Unadjusted Fiscal 1987 Year-to-Date Performance 55.0% Adjusted 45.1% Unadjusted 56.2 45.8 1986 September 34.4 4.3 6.5 1.8 47.0 48907 1020 49.885 1061 5.5768 10000 55.768 1187 0 92000 0 0 2248 105.653 83.212 199.580 58.3 47.1 h VAB.0001191220 ENVIRONMENTAL - R. A. Frohreich Water All wastewater discharge parameters were within NPDES limits in September. One wastewater bypass did occur. NESHAPS An emission test of 200 valves in vinyl chloride service was conducted during the month. No leaking valves were found. The test was required as one of the provisions of the waiver of compliance granted for a portion of Subpart V. Waste Management One shipment of waste was made to Chemical Waste Management at Emelle, Alabama. The shipment included PCB oil switches and PCB capacitors. h h' 1 ii" "I............... ! T I ^k' ^I -H- . - >11 ?-!*'! VAB.0001191221 I' ; rfr+"!3 --:Tr-P V i -*--n i .. j... ;| |., in 4>j v >' i JJiL-i . if- *. -l'"-I ' T : i- 1- ! iTf . . .1 TABLE I WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS A 'V Oct. - Ave. Max. Nov. - Ave. Mac. Dec. - Ave. Max. Jan. - Ave. Max. Feb. - Ave. Max. Mar. - Ave. Max. .ipr. - Ave. tfex. May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Flow GFM 1010 1207 1031 1075 987 1350 1062 1300 858 900 903 970 990 1177 1049 1243 979 1021 1150 1300 %5 1230 1132 1188 BOD PEM LB./dy. 6 77 10 120 15 183 17 213 23 268 46 373 15 194 20 310 14 142 26 266 11 119 21 217 8 93 10 121 8 104 11 116 6 71 8 98 4 55 5 66 5 61 8 118 3 45 5 68 GOD PEW lb./dy. 26 311 33 404 33 406 42 527 71 846 110 1284 53 662 57 775 42 431 75 766 38 409 50 541 42 505 56 680 31 384 40 515 27 350 40 480 45 618 60 797 39 474 50 744 28 427 49 660 Sus. Solids PPM LB./DY. 14 165 23 281 23 281 37 464 13 179 24 302 18 231 28 434 10 99 13 140 19 206 35 362 33 407 78 986 8 101 11 142 14 167 21 257 14 194 26 344 10 145 12 168 8 121 14 185 Diss. 0 7.4 8.0 8.2 9.1 7.6 8.6 9.6 10.3 10.0 10.6 8.8 10.5 9.1 11.0 7.7 7.8 7.0 7.3 7.1 7.4 7.2 8.0 7.7 8.2 NPDES Permit Limits - Deoenber 1 through April 30 Ave. Max. 32 431 43 800 - 1462 - 2713 NH)ES Permit Limits November 30 Ave. Max. 26 357 40 744 - 1212 - 2523 674 - 1396 > 6.0 674 - 13% > 6.0 NHL LB./DY. 2.7 7.3 0.1 0.1 2.0 4.7 2.1 4.6 4.9 9.3 4.0 7.6 2.5 6.1 8.8 17.8 6.9 14.2 1.4 1.6 1.7 2.2 2.4 4.3 7.6 8.0 7.6 7.8 7.3 7.8 ' 7.7 7.8 7.7 8.0 7.8 8.3 8.0 8.3 8.0 8.6 7.7 7.9 7.9 8.1 7.3 7.8 8.0 8.4 13 6.0 - 9.0 28 13 6.0 - 9.0 28 VAB.0001191222 .. r ' i I r- ; s. :* -. - 4r. jf ':: . . /;!Fr - ?H"*" : :!' ! 'I ' !--. !----J13 :! \?4.n V*' t r> - !*! Jn jjJ; .I'ljil^.r. .'. t !'V r- . + ^-:J th-. H^f: % . ,, ............ Vff^lPL11:: . .V'J.'b' .W^ 1 < * ' Jl ' - . j-i i ;..--s. - i.u-.iM} LABORATORY - H. G. Coleman Safety A, Safety There were no injuries during September. The safety topic for this month was the annual respirator training, provided by the Safety Department. B. Customer Relations Customer Contacts United Technologies Essex - Harold Coleman accompanied Pat Haugen on a visit to UTC's research center September 15. The remaining open issues on UTC's specification for 5415 resin were discussed. Uniroyal Chemical Company - Harold Coleman and Randell Jackson visited Uniroyal in Painesville, Ohio on September 16. Basically, they agreed to accept our 5305 manufacturing specifications as their raw material specifications. sts for Corrective Action Date 9/02 9/02 Customer Abitibi-Price Corp. Mlddlebury, IN Central Plastics McPherson, KS Product 5385 17462 Reason Roughness In finished extruded profile. Surface defects on profiles. Customer Problem Reports Date Customer Product Reason 9/01 Dayton Extruded Plast. Dayton, CH 259-151 WHT 145 High, Inconsistent fusion torque 9/24 Hi Tech Cable Corp. Starkville, MS Product Return Notifications 35851 NAT Unknown foreign material (streamers). Date 9/15 9/22 9/28 Customer Flexible Technologies Central Plastics Northern Electric Co. Product 17121 CB50 17462 27251 BKN Amount 1,077 lbs. 950 lbs. 5,950 lbs. Reason Contamination. Profile surface defects Pigment instability. i ii'. i s VAB.0001191223 LABORATORY - Continued Customer Relations - continued Waivers Issued Customer Blane Polymers Gossen Hoechst Celanese Nlbco Southwlre Tteitchell Product 5415 5265 5305 Exp. 5305 5415 5415 Reason Bulk Density Viscosity Viscosity Static Flow mets m Bulk Density No. 1 R/C 1 R/C 1 R/C 2 H/t 3 R/C 1 R/C C. Development Lab Stannary RVCM of Inr-Process Sacples The following is a summary of residual VCM results on in-process samples. None reactor daily averages exceeded 400 ppm during the month of Septenber, 1987. the Number of Samples Average ppm, VCM Reactor Slurries 827 220 Dryer 5265 5305 60 1.9 32 0.2 Blend Tanks 5265 5305 84 17.3 44 7.3 RVCM of Shipment Samples The following is a stannary of the residual VCM analysis of shipment samples for the month of September, 1987. Product 5265 5305 5385 5415 5465 Debax Dry Blend Pond No. of Sanples 67 81 36 59 0 20 Average RVCM, ppm 0.40 0.10 0.20 0.10 -- 0.4 46 0.10 14 0.8 Resin Process Capabilities Bulk Density 5265 0.88 5305 0.37 5385 1.74 5415 0.13 Inherent Viscosity 0.18 0.64 0.37 0.49 "L" Color Value 2.67 2.94 3.78 2.92 * VAB.0001191224 4 LABORATORY D Resin Process Capabilities - Continued "A" Color Value 5265 2.50 5305 4.17 5385 -- 5415 -- "B" Color Value 1.22 % on Pan (vs. 2% max) 1.89 % thru 140M 2.15 Drytime -- Mets IR (vs. 95% of control) -- Hard Particles (% > 10) No 5465 production this month. 1.00 3.58 0.85 -- -- 1.67 2.60 1.02 0.50 -- 2.17 3.33 (0.83) 2.69 0.56 1.28 (0.88) 4.2 2.3 E Compound Quality Summary Hardness Color/Clarity Hard Particles Heat Stability Contamination Dispersion Dicing Metal Contamination Total F Dry Blend Quality Summary Adjustments M Lbs. (%) 22.0 (0.43) -- -- ---- 20.0 (0.39) ---- ---- ---- ---- 42 0 (0.82) M Lbs . (%) 9.1 3.2 -- 16.6 2.3 7.5 11.8 50.5 (0.18) (0.06) -- (0.32) (0.04) (0.15) (0.23) (0.98) Color Rejections M Lbs. (%) 31.0 f0.60,i G Miscellaneous Total 31.0 (0.60) 1. The revision of Aberdeen's test methods began this month. Dav Cox is coordinating this proj ; methods will be stored on th computer for ease of revision ) .! - L- i, 4 . i. . VAB.0001191225 -r| f I- ...... .. .***},). 11 .....................I -T -h-f-4il:N:1. :ui .-'Mft-:i%'* ' r {. . :*' M| ;-|l : - i; - P ' i 1 .-rl,li f .-..j : if . . ,i is-.' --jl-.?'. -::r 1 LABORATORY - Continued G. Miscellaneous 2. As part of our Resin Analytical Capability Team efforts, dry resin samples were sent to Ponca City and Oklahoma City for comparative RVCM analysis. Again, Dave Cox is coordinating; samples will be sent every two weeks. 3. Brian Harrison completed color matches for Condutel (ivory) and Marine Industrial Cable (gray). 4. Brian Harrison attended the Effective Writing Workshop in Houston on September 14-15. 5. Harold Coleman attended The Management Process in Houston September 20-25. ' * |- I = IS:, m , A I*:.': WM1P "ft -rt; S . J-IS+I PJ1 f i **-'<- VAB.0001191226 .... ~ .. .....jK-ffvcjJVTi l- ? !I I .. -if.! II: :r+*M 'kh i.h|.,. . ...., .. .u-JHTIM i- : - ir-M I1! I ' M. (....,1- 4JJ-; .ri 1 ! ................... JS. SHIPMENTS BY PRODUCT - M LBS SEPT. 1987 FISCAL YEAR-TO-DATE AES IN PLASTICIZER DRYBLEND COMPOUND 30,612 591 5,215 8,274 332,198 8,794 56,882 84,776 TOTAL 44,692 4S2,650 NUMBER OF SHIPMENTS BY MODE: 1 RAILCAR VISTA TRUCK TRAILER ON C0M40N CUSTOMER BULK 1 VAN 1 A FLAT CAR | CARRIER PICK-UP CONTAINER TOTAL RESIN-Bulk 140 45 I1 94 Package 5 1 10 9 r Export PLAST.-Bulk 3 2 25 "S. 5 Package DRYBLEND-Bulk Package Export 26 6 8 1 s 5 - 38 16 COMPOUND-Bulk Package 18 6 40 64 | 38 24 142 Export 1 12 TOTAL-SEPT. OCTOBER NOVEMBER DECEMBER JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST 187 116 146 133 193 154 181 150 162 165 178 159 59 53 41 51 64 39 46 29 68 44 50 45 60 56 53 46 60 44 60 49 60 44 68 63 1 59 172 2 52 160 2 64 135 1-- 48 133 89 147 5 56 143 64 129 4 44 140 54 159 6 41 152 0 1 45 145 3 47 160 1 532 422 450 390 544 451 5 493 i 438 459 473 2 476 504 * A VAB.0001191227 ..MM POUNDS ABERDEEN PLANT PRODUCTION 10/01/86 - 09/30/87 MM POUNDS --------- Budget - - - - Actual Cumulative VAB.OOOl 191228 i i'^4 . *!*- .->F i'***-KljtF+fJl I !^d--P'V'hf r1 .. i iT.F. r. . . ;-u K :S --.-t t hl?; I V ' .? l :lli I . T<-rr'. >i .1^!J .. <j m. . .. in: -u J ** * V 1.020 1.015 1.010 1.005 1.000 0.995 1.030 1.025 : 1.020 1.015 1.010 1.005 1.000 v 1.020 1.010 1.000 990 1.200 1.190 1.100 1.050 ABERDEEN PLANT EFFICIENCY 10/01/86 - Q9/30/8? POUNDS OF RAW MATERIAL/POUND OF PRODUCT /. 042, HI 'T Nr+ M \ ft -- kij- ' | i ' |, + . ! .-rt rfT-.Tj-ji i v /> . s:fakiF|-,Njri-n+iF' - .. i i l' 1,1 '*lll -r.l-i. VAB.0001191229 I TI ABERDEEN PLANT QUALITY PERFORMANCE 10/01/86 - 09/30/87 0/0 OFF-GRADf 1 4.0 3.0 2.0 1.0 0 '1-\ \-=?t '* i H.i.r H.-f -.4 HV ' A" rtw jifl i r 3 :h r| ^ I M -tV "I VAB.OOOl 191230 *4 ' ........................... .. MM POUNDS PRIME ABERDEEN PLANT INVENTORIES 10/01/86 - 09/30/87 v Ml Ml, ------ * " - ^ f. - > - ------ --- -----------------1-------Tm-- ---------r--h-...--...... ` ^ - ! -- 1 * !' "------------------- L t .. L \ 1\ 1 * + I1 ; -- -f r ** i :; t: -t; : nrr-" -1 t: -- -- -- i --. j ^ t _____j -! ^ - 1 !i T t ;i t* 1i! I: Oct, Nov, I Dec.i Jan. Feb. Mar. Apr. Ma.V June July Aug. Sept, j Oct. i VAB.0001191231 i -T+.H--H*! r i ... .. i4d.,.i> |l " :*H - -.M'-.V rf :iik-" : .v ?-> id ii'iuriMUfcj#.. .i-, -. . ...:. -.* - ..-