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ABD00311821 SArarY - C. M. Markerson/J. V. Uptain Dec. Fiscal Y.T.D. 1995 Y.T.D. 1994 First Aid OSHA Recordable Total Injuries 17 0, 1 18 6 3 9 Number of Restricted Workday Cases Number of Lost Workday Cases 0 0 0 0 1 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 01 13 03 00 00 01 18 0 4 2 1 2 0 9 Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 15 00 02 00 00 01 00 l8 5 0 1 2 1 0 0 9 Non-Occuoational Injuries Lost Workday Cases Days Lost 00 00 4 101 Contractor Injuries First Aid Cases Medical Treatment Cases Lost Workday Cases 00 00 00 1 0 0 Safety Record Last lost time injury Days since Employee hours since - 01/22/94 343 425,851 On December 31, 1994, the employees of the Aberdeen Plant completed 343 days with no lost time injury. Routine dosimetry results for the month were: Chemical < PEL Number Percent > PEL Number Percent VCM Lead Total Particulates 61 100.0 2 100.0 1 100.0 0 0 0 0 0 0 ABD003T1822 SAFKTI - Continued Monthly Tnjn-ry gimmary Injury Class FA Department Compound Description ; Cut finger. ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) TOTAL INJURIES OSHA RECORDABLE ABD00311823 COST VARIANCES - J. D. Olson Variable Costs Product PVC Flexible Compound Plasticizer Total _______Dec., 94 Variance. $M__________________ Efficiency Price Total 210.8 195.5 < 29.7> 376.6 <2593.3> < 451.3> < 54.3 <3098.9> <2382.5> < 255.8> < 84.0> <2722.3> PVC Resin The favorable efficiency variance for PVC was due to a favorable VCM efficiency on a total production basis. High off-grade pro duction resulted from an accounting adjustment made for seven railcars of resin produced in November. These seven railcars were down-graded from 5385 to off-grade due to contamination with a Barium stabilizer which was accidently added to the resin. Flexible Compound and Plasticizer The Compound negative price variance is due in part to higher than budgeted resin transfer prices and antimony oxide prices, and is offset by favorable aluminum trihydrate prices. The negative Plasticizer price variance is due to phthalic anhydride and alcohol pricing. Manor Price VaiH ann^ii _ VCM - Resin to Compound mv Antimony Oxide - Aluminum Trihydrate Filler . Phthalic Anhydride - Alcohol Variance - $M <2807.3> < 304.8> < 108.4> 68.8 < 43.5> < 60.5> VINYL - J. D. Olson, W. S. Carroll Safety The Vinyl Department had no injuries in December. The monthly safety meetings were held on shift. General December production was 49.8MM pounds of which 47.1MM pounds was prime grade resin. This is a new all-time monthly production record surpassing the previous record of 48.9MM set in October, 1994. Percent asset utilization was 92.5%. ABD00311824 VINYL - Continued General - continued Production of 2QFY95 was 145.7MM which is a new quarterly produc tion record surpassing the previous mark of 144.2MM set 1QFY95. Annual production for CY94 was 540.2MM. Dec. YTD _ Production, MM Lbs. - Reactor Stream Factor, % - Resin Quality, % Prime - VCM Efficiency, Lbs./Lb. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % % 49.8 95.2 94.6 1.0377 1605 111.6 1131.0 36.5 93.4 95.3 289.5 95.3 97.0 1.0369 1573 109.4 6515.0 35.4 95.9 97.4 Reactor Downtime Hours Operational downtime (recovery scheduling conflicts - 203 hours, hydroblast two reactors- 43 hours). Mechanical downtime (replace D-700 seal 18 hours, repair Old Module process water line - 17 hours, repair New Module hot water charge tank - 16 hours). 259.0 95.0 Drver Downtime Hours Operational downtime (cleaning, product changes, and centrifuge plugs). 78 - Mechanical downtime Reactor limited production 65 139 COMPOUND - S. C. Hillman Safety The Compound Department had no OSHA recordable injury during the month. General Compound prime production in December totaled 7.5MM pounds. This is the highest monthly production in Compound since April, 1989. Plasticizer production totaled 1.7MM pounds in December. ABD00311825 COMPOUND - Continued ComDound Production Operating Davs Production M (Lbs). Month Ava./Dav Fiscal Y.T.D. Line I 31 Line III 31 Line V 31 Total % Prime Capacity Utilization Factor 2006 4260 1279 7545 98.0 98.1 65 137 41 243 11717 24279 7138 43134 97.0 95.4 Downtime Hours Line I - Product Changes - Miscellaneous Maintenance - Quality 86 37 10 Line III - Product Changes - Miscellaneous Maintenance - Quality 57 30 9 Line V - Product Changes - Miscellaneous Maintenance - Quality Operating Days 33 39 29 Production (M Lbs.) Month Ava./Dav Fiscal Y.T.D. Plasticizer 31 % Prime Capacity Utilization Factor 1721 84.7 85.2 56 10928 85.5 91.1 ENGINEERING - J. E. Nickerson, T. R. Mackay, R. H. Sneed OSHA Process Safety Procedures Propane System procedures were completed and approved. HAZOPS The New Module HAZOP line-by-line analysis is complete. Com pletion of the New Module and SA Module HAZOPS is scheduled. ABD00311826 ENGINEERING - Continued Reactor Sight Glass Installation The design for the reactor sight glass has been changed from reactor 600 to reactor 741. This required a smaller flange than that required for reactor 600. As a result, a smaller view window had to be used. The design and calculations have been approved by GED and the window assembly is being fabricated. New Module Recovery Observation Most of the equipment has arrived and arrangements have been made for the fabrication and installation of the piping. The wiring of cable for the camera is installed. Piping will be ready for in stallation at the end of this month. Calcium Stearate Addition Upgrade Dry calcium stearate is being used in the fluid bed dryer with 5385. Dry calcium stearate is also used in the rotary dryers as long as the bulk density remains above specification limits. If the bulk density falls below specification, then wet calcium stearate is used. Ways to allow continual use of dry stearate in the rotary dryers are being explored. VCM Vapor Lines Winterization Most of the heat tracing has been installed along with insulation. Power has not been connected due to delay in getting circuit breakers. All of the circuits except the one for the loading rack should be operational shortly after the arrival of the remaining equipment. P-1 Reactor Header Modifications and Control Valve Replacement The vacuum breaker for coil draining has been installed and tested on reactor 1. Modifications to the first reactor should be com plete for a startup sometime in February. The control valve re placement has already been completed for the first reactor. This project will reduce batch cycle times by as much as three hours by improving the heatup and cool down times. V-10 Slurry Transfer System Upgrade This project, funded by Conoco, will replace the slurry transfer pumps currently being used in the Pond 2 resin drying system. Other piping modifications will be completed to reduce downtime associated with plugged pipes and pump maintenance. The design and estimate were presented to Conoco and approval for the project has been obtained. ABD00311827 ENGINEERING - Continued New Module Charge Water System Upgrade This project will install a new hot water charge pump and associated piping in the New Module.- This will provide faster charges and allow simultaneous charge and rinse. Construction is mostly complete. Final tie-ins and programming will be completed during the DCS shutdown in late January. Economy Surplus Power Conversion Estimation of various plant loads is complete. A plant electrical curtailment plan is being drafted for potential temporary reduc tions in power. Contract negotiations with the Aberdeen Water and Light and TVA are in progress. Suspending Agent Charge Modifications A test run proposal to charge suspending agent into the water charge header has been approved. Mechanical design is in progress. Testing of the modifications is scheduled to begin in March, 1995. Recovery Compressor Addition for Old Module This project adds another compressor to the Old Module to decrease recovery times. Calculations show a production increase of 2.3MM lbs./year with the decreased recovery times. The project has been reviewed and turned in for AFE approval. Activator Rer>T arpmonh and Resin Tranafer Twprnvflmflnt8 This project replaces the activator on dryer #8 with a new dense phase transfer system. This system will require less air and will be able to transfer up to 25,000 lbs./hr. The feeder has been ordered. Reactor 600 Larger Batch Trial The larger batch trials have been switched to the New Module. The nuclear level gauge will be installed on reactor 741. The AFE has been approved. ENVIRONMENTAL - K. G. Akins Water The monthly average limit for chemical oxygen demand (COD) was exceeded for the month of December. Concentrations of COD in the discharge were within normal ranges, however, higher than average flows caused the mass limit to be exceeded. ABD00311828 ENVIRONMENTAL - Continued Water - continued BODs values for the same period were well within permitted values. The NPDES permit was modified in 1993 to increase the permit limits for BOD5/ but due to an oversight, the COD limits were not accordingly adjusted. The Aberdeen Plant submitted a proposed Toxicity Reduction Evacuation Plan to the DEQ on 1/10/95 to address whole effluent toxicity testing failures. Air On December 14 - 15, for the period of 22:00 to 1:00 hours, the incinerator stack gas chromatograph indicated the exhaust gas averaged 10.6 ppm VCM. Operating data indicated low flow rates, normal VCM content in feed, and firebox temperatures > 2000 degrees F. Based on the above operating data, it is highly unlikely that actual VCM concentrations in the stack were as measured. However, the incident will be reported on the quarterly NESHAPS report with an explanation. Wastes A bulk shipment of waste oil was shipped to Chemical Fisher Industrial Service in Gadsden, Alabama. KEY ENVIRONMENTAL COMPLIANCE DATA Stormwater Outfall Excursions Wastewater Outfall Excursions Reportable NESHAP Excursions Reportable non-NESHAP Air Excursions CERCLA/SARA Reportable Incidents Other Reportable Incidents Citations and NOV's Received MONTH 0 1 1 0 0 0 0 FYTD 0 ..2 1 0 0 0 0