Document kDNJVdpbdvJK3ZLjxLjdQvzxO

R. T. Ferrell ^JLuQ A Interoffice Communication From: Date: Subject: J. W. Ware November 18, 1987 ABERDEEN MONTHLY PROGRESS REPORT OCTOBER, 1987 There were two first aid Injuries recorded during the month of October. As of October 31, 1987, the plant had operated 3,040 days or 3,930,818 manhours without a lost time injury. PVC resin production for October was a record 40.7MM pounds. This surpasses the previous record set in December, 1986, at 38.8MM pounds. Major downtime in the reactor areas was due to completion of the new module shutdown and agitator seal changes on 700 and 743. The VCM efficiency for October was 1.00706 pounds of VCM per pound of PVC produced versus a 1.00905 standard. Compound production for October was 7.2MM pounds. Line I and Line III operated thirty-one days and Line V operated sixteen days during the month. Quality performance for flexible compounds wa$ 2.2% off-grade of which 71% was due to mill scrap. ,fBC" production was 0.43%. Dry blend production was 5.0MM pounds for October. performance for the month was 98.4% customer grade. Quality The plasticizer unit operated thirty-one days in October to produce 2.0MM pounds. i^ " r Advanced training on SPC charting was completed for compound personnel in October QMP discussions were held with Intex and Times Fiber during visits by these customers to en. t Attitude survey feedback meetings continued. One feedback group has evolved to a project team, bringing the involvement teaib total to twelve. Total energy consumption for October was 125.053 MMM BTUs. The energy consumption per pound of product was 2278 BTUs, resulting in an adjusted CMA reduction of 56%. The total plant variable cost variance for October was* $763.3M u unfavorable, resulting from an overall unfavorable price variance of $874.0M and a net favorable efficiency variance of $110.7M. The total fixed cost variance for October was $214.8M favorable. *H J. W. Ware ""ah 1 -1 I-I .r4ti*.j.v Tiifr HII^I !*!'*! Ill MI VAB.0001191159 .citJ *: !. 11 .: J_\i t :i !, i*. i; J&'ii- I-. J.UHV--,- i *-1 - I+.J i u -<. DISTOEBOTION COWER LETTER HOUSTON: J. D. BURNS X R. E. LEZMOJHL R. T. FERRELL J. J. LANGFORD X - R. E. SWANKCWSKI D. F. HARMAN X H. R. FLAEMER R. R. SMITH K. J. EQGERS D. H. SANDERS PONCA cm: S. E. MCGUIRE R. L. POE m X H. J. HALL C. M. STARKS OKLAHOMA 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 HAMCND: J. B. MAHER X ENTIRE REPORT COVER LETTER AND QIP X X X X X X X X X X X X Safety Section and X A BLANE POLYMERS PREMIERE POLYMERS ABERDEEN E. L. KEESCHNIOC P. L. HX7TE JF, JW, Tm, PJK, TEL, RAF, KLF, RAM, VEM, HOC, CWT, REP, VLT, JEL, REN r t l4!f 'f- Tl.............' PH' :-T tJ '-i'................. ,+r' p,l 1 jTfiff |^ff ptnwt: I'-MieL. * ' ' I > 141 J1 *M VAB.0001191160 ,-r l : i -+1. i - ....................... t v SAFETY - K. L. Fogg, J. V. Uptain Occupational Injuries First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Fiscal October Y.T.D. 1988 ^------------------------ 00 00 Fiscal Y.T.D 1987 --------- . 0 0 A 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 0 0 1 0 0 0 1 j Non-Occupational Injuries Lost Workday Cases Days Lost Safety Record Last lost time injury 7/5/79 Days since - 3,040 Manhours since - 3,930,818 On October 31, 1987, the employees of the Aberdeen plant completed 3,040 days with no lost time injury. Topics for the plant safety meetings during the month included: Maintenance Weekly Safety and Job Reviews, and Annual Fire Training. The Central Safety Committee met in October. V- ' Y 1 -T t.'if <A m. 'Mi-FM I,... ... | VAB.0001191161 -Hp c||. 4tr> t  SAFETY - Continued Routine dosimetry results for the month are as follows: Chemical Number VCM Lead Total Particulates 81 9 1 The single VCM overexposure was PEL Percent 98.8 100.0 100.0 s' Number 1 0 0 PEL Percent 1.2 0.0 0.0 benefit of respiratory protection. A I- -i ............. J'l : i. 'ia| h P'j `iis Li h! ' I | H : a'. '.Tfl *:* ti+3 h. 1" . VAB.0001191162 ^ . ... . t. ... hi..|. A S\7/b` )r\:f n H JWmir L:J : :Ki' i r.-rxp-'tm*!--'- *.........vim-.-: - .|j#%< *, - -- -pi .,r n ^ .j; .imi. VAB.0001191163 - . =N5*H=-s-- -- rli irtt.--i h;:H '**ntrv QUALITY MANAGEMENT PROCESS - D. W. Hollis, R. B. Newton A Rendell Newton and Dave Hollis attended an SPC seminar in Baton Rouge, Louisiana. Four companies gave presentations about their quality programs. Rendell Newton, Bob Miller, John Friend and Dave Hollis attended an "Excellence in Mississippi" seminar in Jackson, Mississippi. Companies from the State gave presentations. Some of the presentations attended Employee Enthusiasm, SPC, Involvement Teams, Measuring Productivity, Gain Sharing, Motivational Techniques. Paul Kober and Dave Hollis attended the Southwest Region Customer Appreciation Day at Toledo Bend. Intex Corporation came to Aberdeen and discussed our QMP activities. A presentation about QMP was given to Times Fiber during their customer visit. VAB.0001191164 < .41. . r- |H bi I:!)-: . i . IV i. \ S i t r! -!-f .p i; in j *:r J*-'"-TM * *:-< ^1-'' t so. 1 bl ' SC l" ^ ...Jr-. I -|. .. H .1. . ir.h .|. b VINYL - P. J. Kober, J. M. Edwards Safety The Vinyl and Yard Departments worked without any reported injuries during the month of October. Shift safety meeting topic for the month was Fire Fighting Training. Quality Improvement Process The CVR employee attitude feedback meetings continued in October for the Yard and Vinyl Departments. The meetings are still in the problem identification stage. The Vinyl and Yard Department Management Natural Team met once in October. This was our first meeting. The Yard Department presently has one SPC team. This Railcar Team's objective is "to ship the best railcar possible to the customer**. The team, which met three times in October, is in the design stage of the problem solving process. A process engineer has joined the team to help with the design. Production 4 October Y.T.D.(Fiscal 88) 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 40.7 1313 962 31.0 93.7 9749 70.2 31 40.7 1313 962 31.0 93.7 9749 70.2 31 Vinyl Department production for October was 40.7MM pounds. monthly production record. This is a Reactors The reactor stream factor for October was 93.7%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 55.5% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size information before charging, lines plugging, reactor manway O-ring failures, inspecting reactors, 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. A VAB.0001191165 't t Uu. - j |. : , - .nr | s ? 'I. i; `l.'i ! < I I' 1- - f .iniuiMtu .:p I-i': < -1 I tp ...w- r L -i VINYL - Continued Reactors - continued 3) Maintenance Repair/Revision Downtime: Accounted for 44.5% of the total downtime and a majority of the time was due to the scheduled annual shutdown of the New Module. The agitator seals were changed on D700 and 743 due to O-ring failures. A D700 safety disc was changed after a pressure check failure. The BPA kill line on 745 was enlarged to prevent plugging. Dryers The dryer stream factor for October was 70.2%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 79.8% of the total down time. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 7.0% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems. 3) Maintenance Repair/Revision Downtime: Accounted for 13.2% of the total downtime and was due to repairs to star valves, //I centrifuge belts, new ductwork, burner and screw feeder installation on #5 dryer, centrate manifold modifications and #4 exhauster motor and bearing repairs. Number six Bird was also changed out. Product Quality Summary Resin Type Prime 5265 5305 5385 5415 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 3,375,311 4,595,520 16,808,786 14,584,896 39,364,513 "B" 1,289,260 0 1,289,260 "H" 27,311 30,140 57,451 % of Total Production 8.3 11.3 41.3 35.8 0.0 3.1 0.0 0.1 0.1 100.0 Quality performance for October was 99.8% customer grade with 0.2% "H" grade production. A 4 -?1A"" `-"i .j fib n r -ri- k * r'r.v^^.r i--.** li.U !-S' I . t. VAB.0001191166 4 VINYL - Continued > Product Quality Summary - continued A total of eight railcars were shipped as "BM grade during the month which represented 5. 8% of the 138 total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 09/27/87 10/02/87 PTLX 41632 Customer Vinyl TX Debox Quality 09/18/87 10/04/87 10/14/87 10/13/87 09/23/87 10/22/87 10/19/87 10/06/87 VIPX 45822 Wexford, CA 10/12/87 PLCX 42670 Wexford, WI 10/19/87 RTMX 580102 Western Ag, TX 10/20/87 VIPX 45270 Silverline, NC 10/23/87 PLCX 43090 Gamma, CA 10/30/87 PLCX 43719 Wexford, WI 10/30/87 VIPX 45284 Apache Plast. CA Pond Quality Debox Quality Debox Quality Debox Quality Pond Quality Debox Quality Debox Quality Monthly Variable Cost Performance Variable costs for the month were unfavorable at $631.OM resulting from an overall unfavorable price variance of $704.6M and a favorable efficiency variance of $73.7M. Resin variable cost for the month was 23.705 cents/lb. versus the budgeted 22.102 cents/lb. The $704.6M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $756.8M, offset by favorable natural gas pricing of $15.3M and favorable freight pricing of $15.3M. The $73.7M favorable efficiency variance can be attributed mainly to a favorable variance due to VCM, $14.6M; Isonox $27.1M; and Polyvic, $15.6M; offset by an unfavorable L223 initiator, $11.2M; and Methocel, $11.6M. VCM efficiency for the month was 1.00706 lbs. VCM/lb. PVC versus the budgeted 1.00905 lbs. VCM/lb. PVC. Energy Performance/Progress 1. Plant energy performance for October was 2278 BTU/lb. General 1. Resin raw material in the 0744 account totaled $289.9M. 2. The New Module turnaround was completed on schedule at the beginning of the month. The startup proceeded without major problems. A VAB.0001191167 * COMPOUND - C. W. Turner, J. E. Nickerson A The Compound Department worked without injury in October. No near misses were reported. All shifts attended the annual fire school training. Quality Improvement Second round SPC training for all operators was completed in October. Operators are now developing control strategies for responding to out-ofcontrol points in the charts they are keeping. A new control chart was started by the plasticizer operators to monitor oxygen concentration in the inert gas stream. Too much oxygen in the inert gas causes plasticizer color problems. Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line III Line V Total 31 2256 73 31 4106 132 16 807 50 7166 2256 4106 807 7166 Line I operated thirty-one days in October at an average rate of 73M pounds per day. Major items affecting production efficiency were: product changes, 103 hours; quality problems, 17 hours; dicing system problems and maintenance, 15 hours; housekeeping, 8 hours; and plasticizer delivery system maintenance, 6 hours. Line III operated thirty-one days in October at an average rate of 132M pounds per day. Major items affecting production were: product changes, 23 hours; mill and hydro therm system maintenance, 14 hours; dicing system problems and maintenance, 13 hours; quality problems, 10 hours; and maintenance to the FCM control panel, 4 hours. Line V operated sixteen days in October at an average rate of SOM pounds per day. Major items affecting production efficiency were: product changes and startup, 46 hours; and quality problems and rework, 13 hours. Quality performance for flexible compounds was 1.7% off-grade of which 100% was due to mill scrap. "BC" production was 0.09%. The raw material requirement for flexible compounds was 1.00387 pounds of raw material per pound of compound versus a 1.01213 standard (YTD is 1.00387). The variable cost variance for compound was $55.1M unfavorable with $80.5M unfavorable due to price and $25.4M favorable due to efficiency. The efficiency variance due to product mix was $4.5M unfavorable. The only significant raw material efficiency variance was for TOTM at $11.4M unfavorable. Total compound inventory rose .6MM pounds in October to 4.8MM pounds. VAB.0001191168 ' r- -'si :j- t - -Si" -nrnf'H+l "? Hv .ii> V' f ' ' I | - IK In i,r te* -if'iis-i-fll: ;'t -- r .i-: ^ iJ -. 1 -s IJ. ;H| .iii-Jj-W ft A COMPOUND - C. W. Turner, J. E. Nickerson Safety The Compound Department worked without injury in October No near misses were reported. All shifts attended the annual fire school training. Quality Improvement Second round SPC training for all operators was completed in October. Operators are now developing control strategies for responding to out-ofcontrol points in the charts they are keeping. A new control chart was started by the plasticizer operators to monitor oxygen concentration in the inert gas stream. Too much oxygen in the inert plasticizer color problems. Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line III Line V Total 31 2256 73 31 4106 132 16 807 50 7166 2256 4106 807 7166 Line I operated thirty-one days in October at an average rate of 73M pounds per day. Major items affecting production efficiency were: product changes, 103 hours; quality problems, 17 hours; dicing system problems and maintenance, 15 hours; housekeeping, 8 hours; and plasticizer delivery system maintenance, 6 hours. Line III operated thirty-one days in October at an average rate of 132M pounds per day. Major items affecting production were: product changes, 23 hours; mill and hydrotherm system maintenance, 14 hours; dicing system problems and maintenance, 13 hours; quality problems, 10 hours; and maintenance to the FCM control panel, 4 hours. Line V operated sixteen days in October at an average rate of 50M pounds per day. Major items affecting production efficiency were: product changes and startup, 46 hours; and quality problems and rework, 13 hours. Quality performance for flexible compounds was 1.7% off-grade of which 100% was due to mill scrap. "BC" production was 0.09%. The raw material requirement for flexible compounds was 1.00387 pounds of raw material per pound of compound versus a 1.01213 standard (YTD is 1.00387). The variable cost variance for compound was $55.1M unfavorable with $80.5M unfavorable due to price and $25.4M favorable due to efficiency. The efficiency variance due to product mix was $4.5M unfavorable. The only significant major raw material efficiency variance was for TOTM at $11.4M unfavorable. Total compound inventory rose ,6MM pounds in October to 4.8MM pounds. VAB.0001191169 ^ .............. . .....y . |. -f -f, i.i i4h ... q- ;*-|!G-. i .. . i f 'i***- -H Nffr 4 .......................... t--i.pi 4 * ......... i, :x . ' i?:|i-.i'. i|- ;,i ..n .jk. .--i , : -s', i - H ' - i- . r-^|- v. : . . .r v t . . .s. | COMPOUND - Continued Dry Blend Production, M Pounds Operating Days Month 5024 31 Average Operating-Day Rate 162 Fiscal Y.T.D. 5024 31 Dry blend operated thirty days in October at an average rate of 162M pounds per day. Production included 80172C, 80273G, 90172D, RP-100, RP-203, RP-421, 186-139, 186-180, 245-53, 269-69, 269-151, 196-172, 269-192, 290-61, 317-104, 317-55, 317-91, A10-001, and RP-201T. Dry Blend production was hindered by; product changes, 67 hours; quality and lab problems and normal Q.C., 45 hours; Welex maintenance, 19 hours; transfer system problems, 13 hours; Orbitran problems and maintenance, 8 hours; filler system maintenance, 8 hours; and cooling blender maintenance, 8 hours. Quality performance for the month of October was 98.4% customer grade. The raw material requirement for dry blend was 1.00276 pounds of raw material per pound of dry blend versus a standard of 1.00443 (YTD is 1.00276). The variable cost variance for dry blend was $79.0M unfavorable with $88.6M unfavorable due to price and $9.6M favorable due to efficiency. The efficiency variance due to product mix was $2.0M unfavorable. There were no major dry blend raw material efficiency variances. Plasticizer Production, M Pounds Operating Days Month 2018 31 Average Operating-Day Rate 65 Fiscal Y.T.D. 2018 31 Plasticizer operated thirty-one days in October at an average rate of 65M pounds per day. Production included 61OP and 108P. VRP production totaled 164M pounds (8 .1%). The raw material requirement for plasticizer was 1.08227 pounds of raw materials per pound of plasticizer versus a 1.10162 standard (Y.T.D. is 1.108227). The variable cost variance for plasticizer was $1.7M favorable with $.3M unfavorable due to price and $2.0M favorable due to efficiency. There were no major plasticizer raw material efficiency variances. The efficiency variance due to product mix was $7.0M favorable. A t rI VAB.0001191170 h- '( i . L.-b-iff-. di . ' . + --It* ir-r^-fP -t,- 'I 7 i I -fli-ti-lii -I rj.'. - -Li.':! 'Ij J- '-i U ' I. P'rj'- : ~t 11! II COMPOUND Continued Enefgy Compound Dry Blend Plasticizer Actual 1687.7 700.1 1574.6 (BTU/Lb.) Standard 1758.00 720.0 1550.6 A * i- ThT -sr i-iw mp i -,'f s - ri: r 1 ^l--1 I. : :! \ * ir-.*4j-J ;+ VAB.0001191171 i '1 -arp'1 fa- * <vclk,' k |-.: :-(d-q<,'r. ;-,i i:htj.:_: , jjini a1= - : V - :\t . j-;-- - ri-M-B-- M-r-'-'r" - r '1 :j " MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - D. A. Miller Safety There were no injuries to Maintenance Department personnel during the month. The topic for the monthly safety meeting was a review of 1987 fiscal year injuries. Vinyl Two reactor agitator mechanical seals were changed. The 700 seal was changed following a sixteen-month run and the 743 seal failed after a three-month run. The following major valves were replaced during the month - Manual block valve - old unit chem wash system - 743 rinse water supply - New unit chem wash supply - Spare 700/745 catalyst ram valve -745 chem wash return valve The annual safety disc change was completed on 400 reactor. A reactor shell safety disc was changed on 700 following a failure during a pressure test. Run indication was provided in the Vinyl control room for the recovery system vacuum pumps and compressors. Additional emergency lights were installed in the Vinyl control room. Assisted with the software installation and startup of the new unit automated chem wash system. The old module normal kill pump was replaced. The following pump seals were replaced in the Vinyl unit: - Old unit "Btf compressor outboard seal - Old unit "A" compressor inboard seal - 501 slurry pump seal - Old unit north chem wash pump seal - Old unit south chem wash pump seal - New unit Alcotex transfer pump seal The following major work was completed in the Vinyl dryer area: -- The #6 dryer centrifuge rotating element and gearbox were replaced. Both were rebuilt and stored as spares. A r .> I -Ifli-: .1 i -rj-,- j- "f. \ (r1 ' I' `ii*** i: VAB.0001191172 " fi + . jf' i-t!.1! Ltj H:r? :kt. 1-r- f h MECHANICAL DEPARTMENT - Continued Vinyl - Continued - The #1 dryer centrifuge Trunion bushings were replaced. - The north fluid bed dryer Kason screener feeder valve was replaced with a rebuilt spare. - The #4 dryer exhauster was removed due to a driveshaft failure. A rebuilt spare was installed. - The fluid bed dryer pick heater was rebuilt. - The fluid bed dryer east hot water circulation pump case was replaced. - Assisted in startup and checkout of #5 dryer following installation of the new air filter, ductwork, screwfeeder and seals. - New Maxon gas valves were installed on #5 dryer. The 1987 winterization work began in October. Most of the wind break shelters have been installed. Insulation and steam leak repairs are in progress. Compound, Dry Blend, Plasticizer Only minor maintenance was performed on Lines I, III and V during the month. The following work was done in the Dry Blend unit during the month: - Drive belts were replaced on the #1 Welex mixer and intensive cooler. - Number two Welex mixer sheave was repaired. The sheave and drive shaft will be replaced in November. - Repaired A and B blender diverter valve. - Overhauled the north Gump screener gearbox. - Changed out "B" blender star valve. - Replaced "A" blender drive chain. - Calibrated all dry blend scales. Leaking tubes were plugged in the R-l condenser in the plasticizer unit. A cracked nozzle was repaired in the R-l olasticizer reaetnr VAB.0001191173 t j:x-: . , ... ... . H `I -+ + 1 ......................... [t ^M PBW'NHI' .-JJU-TJ <.|+. : p" p^rN | : i ! 7"; i : :L-* | ':h - i *|i t-1- iH-" : - r-r- ;.i- .-i i- MECHANICAL DEPARTMENT - Continued Utilities The shaft, impellers, bearings and packing were replaced in #1 boiler feedwater pump. The drive motor was replaced for #1 boiler feedwater pump. The level controls and magnetrols were recalibrated on //I and #2 boilers. Completed checkout of the propane vaporizers. The Pall air dryer dessicant was replaced and switching valves overhauled. The #3 catalyst freezer compressor was replaced. The new unit west chest freezer compressor was replaced. The Yard tractor was retrofitted from a tandem axle design to a single axle design. The annual crane certification was completed. A ' -.......................................... I ! :rF( -!g.- r. >h I V 7f.LrK.T7' . * ^ F : I n <1 `I VAB.0001191174 -1 i ^m ^ Jf11 -i-iEl( N- K.Li-'f'A . .l-.-v-p K---T ; 11' i i*i |r - - -:j*A I* h-- MECHANICAL ENGINEERING - R. E. Polk A AFE F537 - Dry BlAtid Transfer Lines Installation is complete except for punchlist items. These are scheduled for completion by 11/20. The project will be closed to field charges during the month of December. AFE F786/F557 - Resin Quality Improvement Design at Litwin is 69% complete and in progress. The concrete basis of bids is scheduled for issue in early December. The mechanical basis of bids is scheduled for issue prior to Christmas. Installation of the screw feeder on dryer #5 was completed. The feeder for #4 dryer is scheduled for the week of 11/2. Installation of the feeder on #8 dryer will be coordinated with dryer shell repairs to minimize downtime. AFE D756 - Reactor Expansion Joints Installation of joints on all reactors has been completed. Painting is scheduled for completion by the end of November. The project will be closed to field charges in December. AFE A567 - Rotary Dryer Duct Upgrade ? Installation of ductwork for #5 dryer has been completed. The ductwork for #4 dryer is scheduled for the week of 11/2. Installation of #8 dryer is being coordinated with dryer shell repairs to minimize downtime. This is tentatively scheduled for late December. AFE A657 - Roof Upgrade Phase II Membrane installation is 70% complete and in progress. planned for 12/1. Completion is AFE F596 - Chem Wash Automation Construction is complete and the systems are operational in both modules. Punchlist and safety audit items are in progress and planned for completion in November. AFE F587 - Laboratory Addition Approval drawings were reviewed with Laboratory personnel and Process Engineering. Basis of bids will be issued by 11/20. Construction is planned to commence in early December. PCB Transformer Replacement Two pad-mounted transformers have been retrofilled. Nine of thirty-two pole mounted units have been replaced. Three were sampled and found to be non-PCB. An additional ten samples have been taken. These results are due in early November. VAB.0001191175 i -I.--* |i. i| :r r: ^ ;:i> .1 k 1 HUJ^L -h'-cl -'r;:d n -H i-... t - nr; r. Mp* .i: ...i'..:... . .i r! :p j in PROCESS ENGINEERING - V. E. Messick A Resin Quality Improvement Project Design work on the Polyvic system for D745 is in full swing. Information on the instrumentation and electrical scopes of work was given to GED. Review of piping/structural/civil packages was completed. On-going review of all Litwin design work on Phases III and IV of the Resin Quality Improvement Project continues. Reactor Condenser Revisions The AFE for this project was prepared for submittal. This project will provide two-foot extensions to the condensers on reactors D400, D500 and D600. Water Management A hydrologist was selected to evaluate the groundwater situation in Aberdeen. The Coker aquifer and the Gordo aquifer are being evaluated for possible alternate aquifers for plant water supply. Dry Calcium Stearate Addition A revised Class "A" design was issued and a review meeting held. This project will add dry calcium stearate to the rotary and fluid bed dryers. Lines I and III Resin Supply Valves A revised Class "A" design was issued and a review meeting held for this project to replace the supply valves below the resin silos for compound. Lines I and III Preblend Magnets A Class "A" design was issued and a review meeting held for a project to improve magnet systems downstream of the blenders for Compound Lines I and III. This design is part of an overall plan to reduce metal contamination in compound product. New Module Chem Wash Automation Operating procedures were issued for the new module chem wash automation system. Assistance was given on startup of the system. In-depth PVC Training An in-depth PVC training session was taught in Aberdeen by Richard Quy of R&D. Plant process and mechanical engineering, safety, and maintenance personnel were in attendance. Section 312/313 Reporting A review of all hazardous chemicals for toxic components was completed. Calculations for VCM fugitive emissions were made. Information for the March SARA report is nearing completion. f..... " rr-j- : - --..tt.ij M . i'h Flrf r,|| ::j: :T:-|i......................... , -s.p l: .+. fr I lT*l,-| i*l -dj C 3l W * ? fT .*. , "r- `P- VAB.0001191176 ..................V Jllr-'U . PERSONNEL - R. A. Miller EMPLOYMENT None PROMOTIONS/TRANSFERS John Ray Hamilton, promoted from Instrument Technician "A" to Maintenance Supervisor Kerry Lewis, promoted from General Helper to Vinyl "A" Operator RETIREMENTS None TERMINATIONS None TO/FROM LEAVE OF ABSENCE None A 1 i. t. 141.|j u Mfa.ijd i < .. Li. JiJiu.l|l |!. ci. - i . < tiJi .^:n :ir ' i.h=i ' |i tj| -C -i p i t.: ... ' iTM! > VAB.0001191177 f. l. i. .. <.. . . . , Aberdeen, Mississippi A Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations 72 141 239 4 o DEPARTMENTS Warehouse Gen. Plant Maintenance \boratory Compound Vinyl Plasticizer PAR # EMPLOYEES 16 16 13 40 33 24 40 40 32 32 55 OCTOBER. 1987 MONTHLY PERSONNEL REPORT Minority Employees # Salaried 8 ill EHP Hourly 44 40% Total 74 111 Hourly Min Hired % Min. Hired Hourly Min Term. % Min. Term. 0 a 4 a % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD 7 M 0 0 40 0 2 49 44 23 0 40 4 3 21 0 4 28 00 40 3 26 0 40 4 2 40 0 0 0 00 Number of Applicants: Hires (Hourly) : Month 0 Year to Date 23 Month 0 Year to Date 9 APPLICANT BREAKDOWN: Terminations (Hourly) : # Minority 0 % Minority 0 Month Year to Date 2 * Female 0 % Female 0 Overall Turnover 0 Projected Annual Turnover 1.4% Includes 1 temporary employee and one Co-op Engineer *............................ -1-...........> . .ft"! nn-it V r 1 St:?- ?:: -.c*' - i: y- - -!--,r- :--: - -| c 1 Vit : : ;:tli V-.. .;i.i'^si.iusi. iH! VAB.0001191178 M Jj mH mm u x *mv4 momUq <t vo* on o> o iH * vO CM* 00 v> * o> fH CM * m H v> r- m * m o rH 4J 4J u cn Is 4- CM t O s.s o m m ^o X3 to A vO sa CM iO v> X r-* cn X. 1--1 CM M W*v V# U ^3 in CM O m vO C"> \o iH m fs* 0 v> s O V CM MT *a* r*. 'd- vD iTt CM * oc kJ .........^';r s-iTF" i-' irr *-- i *4 f .< -- i C*1f . . -|.s-N s Jf p I v- i'! ............. i r , -i ii. " It* :u- VAB.0001191179 ENERGY CONSERVATION - F. G. Jeanson I. Plant Operations Total energy consumption for October was 125.053 MMM BTUs. Energy consumption Increased to 2278 BTU/lb. from 2267 BTU/lb. In September. An adjusted CMA reduction of 56.0% was obtained for the month. II. Plant Energy Conservation Program Maintenance There were eighteen energy related items completed in October. All of these items were steam leak repairs. III. Boiler Operation Boilers No. 1 No. 2 No. 3 Combustion Efficienc Oct.. 1987 Oct., 1986 (2) 83.7 83.6 (3) 83.3 83.9 (1) 83.3 Note: (1) Boiler number two was not used during the month. (2) Boiler number one was operated thirteen days during the month. (3) Boiler number two was operated eighteen days during the month. A ...... WF/m JilBflQHr ' -t-sa i: i -z^i.:. -.t-. -q :r, w =' r VAB.0001191180 rii .v, 11 : .. .i j,|i. i .i i Month ENERGY CONSERVATION DATA 1987 October Production, MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL 40.7 5.0 7.2 2.0 54.9 Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Energy Consumption, BTU/lb. f 63680 1020 64.329 1172 Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 6.0724 10000 60.724 1106 Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 0 92000 0 0 Total Energy Consumption, BTU/lb. 2278 Energy Consumption, MMM BTU Actual Unadjusted Actual Adjusted 1972 Base Period 125.053 102.595 232.999 CMA Reduction (%) Adjusted Unadjusted Fiscal 1988 Year-to-Date Performance 56.0% Adjusted 46.3% Unadjusted 56.0 46.3 A 1986 October 31.8 4.4 6.6 2.0 44.8 47196 1020 48.140 1075 5.4480 10000 54.480 1216 i 0 92000 0 0 2291 102.620 83.358 189.076 55.9 45.9 i f *- .................... l t-c.-fc- =!!: ........................* VAB.0001191181 -n 1- .-yY ;+ i :!|-v WfMI 1 * | if* ' >' `ii'-- ! ENVIRONMENTAL - R. A. Frohreich Water All wastewater discharge parameters were within NPDES limits in October. Two wastewater bypasses did occur. Two chronic bioassay tests were conducted in October. Test organisms were the fat head minnow and the water flea. No toxicity was detected in either test. General On truckload of building ventilation dust was purchased by Surplus Chemicals Marketing, Inc. Arrangements were made for the sale of surplus BHT which is no longer used in the plant. A f t- 1V ! ..j< -i. >>,. . 'I r- r!t v VAB.0001191182 .t-m. -4- |r-n-s P. I '1h T ^ `Mi r ' -t : -r ~^*r tT ' s rT A TABLE I WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS Oct. - Ave Max Nov. - Ave Max Dec. - Ave Max Jan. - Ave Max Feb. - Ave Max Mar. - Ave Max Apr. - Ave Max May - Ave Max June - Ave Max July - Ave Max Aug. - Ave Max Sept. - Ave Max Flow GEM 1229 1264 BOD PEM LB./DY 5 77 7 100 OOP PEM LB./DY. 28 433 39 553 Sus. Solids PEM LB./DY 10 147 15 215 Digs or 8.4 8.6 ML LB./DY. 1.8 2.9 jeS 7.5 7.9 NPDES Penult Limits - Deceaber 1 through April 30 Ave. Max. 32 431 43 800 - 1462 - 2713 NEPES Permit limits - May 1 through November 30 Ave. Max. 26 357 40 744 - 1212 - 2523 674 - 1396 674 13% > 6.0 6.0 13 6.0 - 9.0 28 13 6.0 - 9.0 28 VAB.0001191183 1 `I- .. -i; p 3 '1 ' :;'.T I!- .. .. . ..v ./ * LABORATORY - H. G. Coleman A A. Safety There was one first aid case in October. A technician suffered a small laceration to the forehead when he bumped his head on a temperature recorder. The safety topic for the month was a film on AIDS, a question and answer program conducted by the Surgeon General. Of concern was the possibility of contracting AIDS when administering first aid. B. Customer Relations Customer Contacts ITW Meritex - Julius Acker of Merltex visited Aberdeen on 10/19 to review our production facilities and quality control techniques. Harold Coleman gave the standard Laboratory presentation. General Plastics - Brian Harrison, along with C. 0. Yoder and Fat Haugen, visited this . dry blend customer on 10/5. Color requirements were discussed and color swatches were provided. Chrysler - Brian Harrison, along with C. 0. Yoder and Pat Haugen, visited Chrysler on 10/6 to discuss color specifications for their white dry blend. Requests for Corrective Action Date Customer Product Reason ? Foimtech, Stow, OH 317-91 VHT 110 Inconsistent color (T1D,, levels). Customer Problem Reports Date Customer Product Reason 10/06 Times Fiber Chatham, VA 38601 Black Spark failures. 10/08 Royal Electric Pawtucket, RI 34551 Natural IR failures 10/10 Vinyltherm Bloomington, MN 245-53 WHT 140 Color - too ' 'white''. 10/12 10/28 NortJwire 38601 Black Dayton Extruded Plast. 269-151 WHT 145 Springboro, OH Calcium carbonate dispersion. Calcium stearate lumps. VAB.0001191184 LABORATORY - Continued B. Customer Relations - continued A Customer Problem Reports - continued Date Customer Product Reason 10/28 Formtech Stow, CD 317-91 WKT 110 Poor die flow. 10/30 Vinylex Corp. Knoxville, TN 5415 GEM Lunps on clear tubing Product Return Notifications Date Customer Product Amount Reason 10/02 10/07 General Cable Taipa, EL Southwire Carrollton, GA 46311 war 1201 NAT 30,000 lbs. 10,500 lbs. Customer on strike Lew IR values. 10/13 Formtech Stow, OH 317-91 WHT 110 16,645 lbs. Inconsistent color i Waivers Issued Customer Blane Polymers Product 5305 Reason Static Flow No. 1 HT / Nibco 5305 Static Flow 1 HT Uhiroyal 5305 Static Flow 1 HT United Technologies 5415 Mets IR 1 RC Vulcan Metal 5415 Static Flow 1 HT Sanle Shipments Resin Ship Date Product Amount Reason 10/12/87 5415 100 pounds United Tech. /Essex 10/14/87 5415 2250 pounds Colonial Rubber Works 10/27/87 5415 15 pounds Zoecon Industries VAB.0001191185 1 r.ui. !=.. .. : :, B-.1i-Aa r:V-\- *: - * --h : '= -T !tT. I-" ' . \ :i * !I "p'^a-1-l-si- : :. v 1-: # 4t'fa l sta. ; ~-di. ..imc.: *. -j-. j ihi .`11(- . 1 i!r. .|i:s .'Niii i: ... ..-jK i lj-,1 .. . h. li i - .. . lu .1.. j i. ... . .. LABORATORY B. Customer Relations - Continued A Sample Shipments - continued Compound Ship Date Product Amount Reason 10/09/87 271-99A NAT 271-99C NAT 300 pounds 300 pounds Celvmve Systems, Inc. 10/12/87 39031 BLK 1500 pounds Cablec Corporation 10/12/87 17462 GRY 545 18162 GRY 545 25 pounds 25 pounds Lasko Metal Products 10/14/87 186-74 WHT 112 100 pounds Americhem, Inc. 10/14/87 150-6A NAT 50 pounds Wilson Fiberfil 10/15/87 38631 VHT 2250 pounds Flexible Technologies 10/19/87 259-99B BLK 1600 pounds Corns Scope 10/20/87 18031 CB 50 50 pounds All-Wire Inc. 10/21/87 35852 NAT 50 pounds Vista (Ponca City) 10/21/87 34642 NAT 50 pounds Blane Polymers 10/22/87 17462 GRY 545 100 pounds Lasko Metal Products 10/30/87 18961 GRY 545 100 pounds Ihermoid 10/30/87 240-105B GRY 1400 pounds Marine Industrial Cable Dry Blend 10/16/87 90172D 50 pounds United Plastics (Export) Other 10/28/87 Dythal XL 1/2 gal. Vista (Ponca City) 10/29/87 Cyasorb UV 531 5 pounds Vista (Ponca City) C. Development Lab Sunmaiy RVCM of In-Process Samples The foHewing is a summary of residual VCM results on in-process samples. None of the reactor daily averages exceeded 400 ppm during the month of October, 1987. Reactor ________ Dryer Slurries52655305 Number of Samples Average ppm, VOI 928 237 39 1.2 67 0.2 VAB.0001191186 ' r.L- . ............................................................. . : . | l-'| -.1- 'll. 1-^- M ............................ ............ If-' j1, ,j; i r~ i njfrT|ii * . A i*. p> " . n-r h r-rJir. -u-lrffritii- < !- n :q TH* T'l Kill1-*" .+< -h-p---- -iT :^'-i :|i i r> , 4t.->T It 4. - ^ LABORATORY - Continued C. Development Lab Summery - continued A The following is a summary of the residual TCM analysis of shipment samples for the month of October, 1987. Product 5265 5305 5385 5415 5465i Debase Dry Blend Pond No. of Samples 42 104 34 76 0 Average KVCM, ppm 0.40 0.10 0.20 0.10 - 28 0.1 33 0.20 0 0 Resin Process Capabilities 5265 5305 5385 5415 Bulk Density 0.55 0.40 1.35 0.09 Inherent Viscosity 0.19 0.67 0.46 0.67 ,fL,r Color Value 1.55 4.50 3.78 4.00 "A" Color Value 1.67 4.00 "B" Color Value 1.22 1.17 3.00 4.00 % on Pan (vs. 2% max.) % thru 14CM 0.69 1.13 1.33 0.86 4.33 4.44 (kid 2.94 3.64 Drytime 0.83 0.56 Mets I.R. (vs. 95% of Control) 0.51 (0.27) Hard Particles (% > 10) 6.00 8.10 No 5465 production this month. E. Coapound Quality Sumary Adjustments MIbs . (%) Hardness Color/Clarity Hard Particles Heat Stability Contamination Dispersion Dicing Cross Contamination Metal Contamination Total 58.5 (0.82) ---- ---- ---- ---- ---- ---- ---- ---- 58.5 (0.82) Rejections M lbs. ( 16.4 4.5 58.6 6.8 1.5 4.5 6.5 6.8 14.0 119.6 (0.23) (0.06) (0.82) (0.09) (0.02) (0.06) (0.09) (0.09) (0.20) (1.67) VAB.0001191187 -v - I "I I '! ' .............................. '!=- ' " -"!?!! : - ` | r- . : .J. ... ! | Eft-fU. i -! f (Hr W h -r-..-lt;-. .i L- lL . . I ! '4 i!'r-r I*' |l Ir . JIbI .1. k :. | _:n - jirt - !-***, .H I;. i-i - - y r + : , 1 :iL| i i ar !'. ..............................ir i is LABORATORY - Continued F. Dry Blend Quality Stannary Rejections M lbs. co Color Stability Color High Fusion Torque Contamination Particle Size Total 12.5 24.2 3.9 8.4 27.6 76.6 (0.25) (0.48) (0.08) (0.17) (0.55) (1.52) G. Quality Development 1. The second REACT meeting was held in Aberdeen on 10/7. SFC data on control resin testing vras compared. 2. Primarily through the efforts of Rod Harmons (Ponca City) and Gary Fritch (Aberdeen), significant discoveries were made about the Mets l.R. test: a. Milling two samples consecutively adds significant variability to the results. This was eliminated as of 10/12 by running one sample at a time. b. High levels of dry CaSt on the resin drastically reduce Mets values in the 1201 formula. Differences between two CaSt suppliers were Insignificant. c. After fifteen minutes equilibration time In the water bath, Mets values are constant. Up to that point they Increase, probably due to temperature. Mets l.R. values are very dependent upon the formulation being used. For example, lab batches of our best 5415 resin give values of about 9000 In the SW 1201 formula, but only 2500 In the 34551. 4. 5415 Control Resin (Lot 04169) Testing nX3 Moisture Drytime Particle Size - 60 Mesh - 100 Ifesh - 140 Mesh Pan Bulk Density Color - L A B Flow Time Hard Particles, 7 Min. Inherent Viscosity 60 0.138 0.284 62 5.01 0.27 31 0.77 0.34 30 33.85 1.13 29 6.60 1.71 31 1.06 0.55 61 0.5032 0.0073 46 100.400 0.320 62 -0.147 0.332 62 2.298 0.583 39 8.23 1.19 60 7.00 3.68 28 1.0047 0.0099 A f " :i ' I ** H -LiMli*-!-' .. j-' ' 4-- ' *-- "it.. ie-: 1J iNf 1 -i : -'rrlt * i- VAB.0001191188 -p- 1C: El-fi! .'j'lf- LABORATORY - Continued H. Miscellaneous 1. Dave Cox, Richard Williams and Billy Paul Sizemore attended Rick Quy's seminar on VCM polymerization technology on 10/14/87. 2. Brian Harrison issued a report rejecting a new TifL from DuPont (WH>-701). It gives a grayer color when substituted for R-101. 3. Brian Harrison prepared beige, ivory and gray color matches for General Plastics and presented them to GP on his 10/5 visit. He also finalized a color match for dry blend purge* 317-115 HLU 170. 4. Dave Cox's revision of Aberdeen's test methods continued this month. Thus far, twelve resin methods have been revised and approved. 5. Brian Harrison investigated complaints from Formtech and Nbvatech. Causes were identified as varible TiO^ levels in 317-91 WHT 110, and inconsistency of 80273G toll-blended by Intandx, respectively. 6. Brian Harrison Issued a memo on eliminating stabilizer from dry blend colorants. A minor cost savings is involved. 7. Brian Harrison attended the SPE Color and Appearance Division seminar in Atlanta on 10/14-15. He also attended extrusion trials at Ponca City on 10/7-8. 8. Brian Harrison accompanied Virgil Fisher to Alsco on 10/22 to discuss their Q.C. procedures for toll-produced 80273G. A ir I :;| 'A .11 i || L VAB.0001191189 1A: Vi'-I: SHIPMENTS BY PRODUCT - M LBS. OCTOBER 1987 FISCAL YEAR-TO-DATE RESIN PLASTICIZER DRYBLEND COMPOUND 30,294 779 5,237 ___ 6,619 30,294 779 5,237 6,619 TOTAL 42,929 42,929 NUMBER OF SHIPMENTS BY MODE: 9 i RAILCAR VISTA TRUCK TRAILER ON 1 COMMON CUSTOMER BULK I VAN A FLAT CAR [ CARRIER PICK-UP CONTAINER TOTAL RES IN-Bulk 138 52 1 11 99 290 Package 2 1 16 4 13 Export PLAST.-Bulk 4 2 ' 6 Package ! 1 DRYBLEND-Bulk Package Export 25 3 8 1 1 1 13 8_ 2 36 .24 _ COMPOUND-Bulk Package Export TOTAL 15 182 5 . 45 _ 1 62 56 j 1 30 1 2 51 32 145 20 107 13 1 499 * VAB.0001191190 ENERGY USAGE A <oJ) C\J 00 <x> BTU/LB to z o t/) Q* o ^* X^ LD Hz 0 0^2: *Ujii > UJ ^tE d_J J<jJ uLl. rn * J-irl Monthly --------- 12-Month Moving Avg : l:` * i* A VI- f- HM) A 1*1- n-I -J< =:::- : "I jprilF.'":: n-:.: '1 - - fj-I- ri-t -1-:=^' . p"1-; 1 T VAB.0001191191 T -'tL, - 3*Ph'-H -i :< o CM CO VD uz) o V) Oo * LU x3 (/> 6 z 0^ KUi vW >- LlI tqo: d, <u. yj Ll >^. 3UJ CO ^ Hf 2C MONTHLY HOURLY TURNOVER A 100 r-- - + 90 --------------------1-' r 80 ----------------t,. + -r 4----------------------- ----------------------> -- 70 + ------------------+ k............ --r --------------------t- 60 ---------------------|_ -~.J-- 50 ----------------------k- f -- -+-- r- f - i- ~V 1 t --r M- ... .T f.. ,--t- U -------- - '* -r1 ti ---------------------------------------------- i + i 4---------------------------------------p- +---------------------------t--* --. --------T + ------------------------- ----- -I.. ---------------- 4. 4 - 4 +--------------- 4--------------------- *-- - - " *-------------T +-- rr I 4- 4- 4 r 4- j ----------------------- h f -4-- -r i--4 1--f 1--r r t* T 1--1--> i--r tr 1-- + -- 40 -0----------, i-- -t-- 30 20 ----------r T --- f T -K1 r or 1 + -j- 4- - 41 T 4- - t + i------ h 10 0 < O<c0 <u flj 0c31Q. >, tab +Q--. t \ 3 <3 X 8 O> 01 19 87 ----------------------r -i4. T 4 -*----------------- <4u2 CTJ Q. .13 198.8 oo Q. <3 <2 8 >O 3 A3 4) 4li- - - - - - 4- <a 0c1 <SP </) 1982 1 VAB.0001191192 t HP .H .I- :-H - -.1 -.'.5: . . 1. ; ^|. *.M -H-. h. r' -W-, : , 1-' . -T ? -: --Si: :tfi; , . y i: -\ .'=.-a. * 1: MM POUNDS MONTHLY ABERDEEN PLANT PRODUCTION 10/01/87 - 09/30/88 A MM POUNDS CUMULATIVE 450 i'l r V '-3: *-h 1 i-: n- 11 - i-.-* Budget Actual Cumulative VAB.0001191193 ? -I--' 1 L ":f, f' ' K: * 1.020 1.015 1.010 1.005 1.000 0.995 ABERDEEN PLANT EFFICIENCY 10/01/87 - 09/30/88 POUNDS OF RAM MATERIAL/POUNDS OF PRODUCT ^_____ ____ ____ _____ A 1.030 1.025 1.020 1.015 1.010 1.005 1.000 1.020 1.010 1.000 .990 t 1.200 1.150 1.190 1.050 Oct.iNov i - i t4- r- +I 4 4 i May iJune July Aug. I Septij I VAB.0001191194 i 4 I- - 4 "`1 A--M. ' ^r :i F .-I T| 'r. rj I I, . I-|! 'I i TH |^-i J W >r v C . J . : J.*J J+.ii-- ? If-- i -f*- II . .1 1: i 4 I V 6.0 5.0 4.0 3.0 2.0 1.0 L*- 0; % OFF-GRADE l'.OO .75 .50 .25 0 4.0 3.0 2.0 1.0 30 ABERDEEN PLANT QUALITY PERFORMANCE 10/01/87 - 09/30/88 A I ' "I r-i . .. i. .. r ii. i -. I r : ' s. .' ..h:I ..............Jt, J. ,n . i . - I . . - : VAB.0001191195 v MM POUNDS PRIME 20 10 0 10/01/87 - 09/30/88 A 0.8 0.6 0.4 0.2 0 10.0 v 8.0 6.0 1.0 0.5 -- * --1 t , ------------------ > -- t f i t 1 -- _i : ' 2____________________________________________________ ____________________________________________ __________________ _______________________________________ t ---------------- -- -- =rt f~. r rr r T 0r -i t t 1 Oct. Nov. Dec. Jan. Feb. Ma r. Apr. | May | June ! July Aug. Sept. 19 87/38 P ]. js, .1-.^ : ,1fir pr|f, t h4 ! - I ' .v l|fih^i VAB.0001191196