Document oegwEmzJy4Z9yK5op6DEXYQjw
4
To: R. D. Gamblin
llllll Ulllif Communication
From: Date:
J W. Ware February 18, 1985
Subject: ABERDEEN MONTHLY PROGRESS REPORT JANUARY, 1985
One medical treatment case and three first aid cases vere reported in January. As of January 31, 1985, the plant had operated 2,036 days without a lost-time injury.
PVC resin production for January was a record 37.9MM pounds. The previous monthly production record was set in July of 1983 at 37.5MM pounds. Major downtime taken in the reactor area involved agitator seal repairs on 500, 600, 700, 742 and 743, cooling water jacket repairs on 742 and 743, and replacement of 745 agitator motor. Resin production year-to-date totaled 141.4M pounds. The VCM efficiency for the month was 1.01469 pounds VCM per pound of PVC versus a 1.00500 standard. Year--to--date VCM efficiency was 1.00467.
Compound production was 4.1MM pounds for January and 13.2MM pounds year-to-date. Used #7 rotors were installed in the Line III FCM during January and test runs were performed by the Fusion Task Force to produce compounds with low fusion delay. During the test runs products for several customers (Including AT&T) were produced at the desired low stock temperatures and rates over 5000 pounds per hour with only minor operating problems. All quality parameters, including fusion delay, were found to be acceptable for material produced with the new rotors. Quality performance for flexible compounds was 1.9% off-grade of which 100% was due to mill scrap. "BC" production was 0.2%.
Dry blend production for January was 4.7MM pounds and 15.0MM pounds year-to-date. Production limitations resulted primarily from product changes and intermittent master batching associated with rigid profile products. Quality performance for the month was 99.9% customer grade.
The plasticizer unit operated twenty-two days in January to
produce 1.3MM pounds. Year--to--date plasticizer production was 4.8MM pounds.
Total energy consumption for January was 123.352 MMM BTUs. The energy consumption per pound of product was 2575 BTUs resulting in an adjusted CMA reduction of 53.8%.
A
VAB.0001184189
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R. D. Gamblin 2/18/85 Aberdeen Monthly Progress Report Page 2
The total plant variable cost variance for January was $1013.6M favorable, resulting from an overall favorable price variance of $862. OM and a net favorable efficiency variance of $156.6M. VCM pricing contributed $717.4M to the favorable price variance. The fixed cost variance for the month was $73.3M favorable.
J. W. Ware rah
A
VAB.0001184190
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DISTRIBUTION HOUSTON
PONCA CITY
OKLAHOMA CITY LAKE CHARLES VCM PLANT LAKE CHARLES CHEMICAL PLANT BALTIMORE HAMMOND ABERDEEN
- J. D. BURNS - R. E. LUHMKUHL - R. D. GAMBLIN - J. J. LANGFORD - R. E. SWANTKOWSKI - G. G. DRAPER - D. F. HARMAN - H. R. FLAMMER - E. L. KIESCHNICK - S. K. SABORSKY - K. J. EGGERS
,, - D. H. SANDERS * - S. E. MCGUIRE . - R. L. POE . - H. J. HALL . - C. M. STARKS
- HARRY GARRISON
DICK CONRAD
R. T. FERRELL (COVER LETTER ONLY) J. A. DEBERNARDI (COVER LETTER AND
SAFETY PORTION) T. H. HUFFMAN J. B. MAHER (SAFETY PORTION ONLY) JF, JWW, DWH, PJK, CRS, RAF, AHS, JRW, WFH, RAM, REP, VEM, VLT, CWT
VAB.0001184191
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SAFETY - A H. Sather
4
Occupational Injuries
First Aid Cases Total OSHA Recordable Cases
Total Injuries Number of Restricted Workday
(RWC Rate) Number of Lost Workday Cases
(LWC Rate)
Injuries by Department
Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office
January
3
4 0
(0.0)
0
(0.0)
Fiscal 1985 Y.T.D.
7 _3
10
(11.22)
0
(0.0)
Calendar 1985 Y.T.D.
4 0 4
(00.0)
0
(0.0)
1 20
1 10
2 64
0 00 0 00 0 10
Cuts and Abrasions Eye Injuries Bums Bruises Strains and Sprains Stings Other
2 43
0 10 0 00
1 20
1 40 0 01 1 10
Non-Occupational Injuries
Lost Workday Cases Days Lost
0 0
On January 14, 1985, a General Mechanic "A" reported a back muscle strain that was a result of work on the installation of the number seven rotors on the FCM on Compound Line III. The injury occurred when the Injured and a fellow employee had to use a prybar on the rotor support system to clear an obstacle on the FCM table.
As of January 31, 1985, the plant operated a total of 2,036 days or 2,589,525 manhours without a disabling injury.
Safety Meetings
Topics covered in plant safety meeting included: 1984 Compound Safety Performance Review, Annual First Aid Training, Injury Reporting, Fall Protection, Steam Traps - Safety and Operation, and VCM Exposure.
A
VAB.0001184192
SAFETY - Continued
k
Action Requests
Calendar Year
Total Submitted Y.T.D
Completions Current Year Previous Year
1984 1985
55 46 20 2 00
Health
Activity for the month was limited to routine dosimetry.
Routine Dosimetry
VCM Lead Total Particulates
4 Number
89
12
9
PEL Percent
93.7 92.3
100.0
Number
6
1 0
PEL Percent
6.3 7.7
0.0
Three of the VCM overexposures were without respiratory protection. All others were with benefit of respiratory protection.
A
VAB.0001184193
f %
VINYL - J. W. Ware/M. L. Nathan
The Vinyl and Yard Departments operated with one first aid injury in January. The injury involved a puncture wound from a piece of wire on a valve handle.
Shift safety meeting topics for the month included "First Aid Training" and discussion of recent injuries and near-mis s incidents in the Vinyl Department.
Production
J anuary Y.T .D. (Fiscal 1985)
1. Production, MM Lbs. 2. Daily Production, 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
37.9 1221.7
873.0 28.2 91.0
12768.0 49.8 31.0
141.4 1149.0 3400.0
27.6 91.1 10623.0 57.7 123.0
Production
Vinyl Department production for January was a record 37.9MM pounds
which was 102% of the Business Area's targeted production level of
37.0MM pounds*
The new record of 37.9MM pounds outpaced the
previous monthly production record of 37.5MM pounds set in July,
1983.
Reactors
Major echanical downtime during the month resulted from the following:
1. Agitator seal replacement on 500, 600, 700, 742 and 743* 2. Cooling water jacket repairs on 742 and 743. 3* Agitator motor replacement on 745. 4. Old module dump Sweco repair.
The agitator seal failure on 700 was the direct result of an associated bearing failure. A majority of the remaining failures have been attributed to freeze-up of the seal flush systems during cold weather conditions. Appropriate revisions to improve winterization of the seal flush systems have been accomplished. Valve change-out and repairs accounted for a stream factor penalty of 1.0% during January.
Operational downtime occurred as follows:
Cause
Factor Penalty
Recovery system scheduling conflicts No place to dump
. %3.0%
10
VAB.0001184194
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VINYL - Continued
11 "
Production was essentially reector limited during the month* Downtime in the dryer area occurred as follows:
Cause
Stream Factor Penalt
Energy conservation Dryer cleaning Centrifuge pluggage Activator problems Mechanical problems
44.3%
1*2% 0.6%
1.5%
1.6%
Product ualitv Summa
Resin Type
5265 5305 5385 5425 5465 Sifter Overflow Pond Resin
Total
Prime
2,298,229 2,806,864 25,269,342 6,199,069 1,211,080
37,784,584
"BC"
"H"
73,884 12,800 86,684
% of Total Production
6.1
7.4 66.7 16.4
3.2
0.2
100.0
Quality performance for January was 99.8% customer grade with 0.2% "H" grade production.
A total of month which shipped
four railcars were shipped as "B11 grade during the represented 2.6% of the 153 total resin hopper cars
Ship Date
Car No.
1/08/85
PTLX 41627
1/11/85
PLCX 43850
Customer
V
Wexford -i
Wexford
Product
Resifted Sifter Overflow
Pond Resin
Reason Quality
Quality
1/11/85
VIPX 45792
Osterman
Resifted Sifter Overflow
Quality
1/18/85
PLCX 43743
Vulcan
Resifted Sifter Overflow
Quality
The vinyl area received 20 short lead time emergency-type orders comprising 7.1% of the 280 Aberdeen resin shipments in January.
VAB.0001184195
#
VINYL - Continued
Monthly Variable Cost Performance
Variable costs for the month were favorable $787.9M with $794.9M due to price and ($7.0M) due to efficiency. Resin variable cost for the month was 18.802 c/lb. vs. the budgeted 20.887 c/lb.
The $794.9M favorable price variance was primarily attributed to lower than budgeted pricing for VCM $717.4M, lower than budgeted pricing for Lupersol 223 initiator $22.0M, and lower than budgeted pricing in the utilities area$30.5M.
The ($7.0M) unfavorable efficiency variance can be mainly attributed to an unfavorable variance in VCM efficiency ($64.6M). Actual silo level measurements could not be made during end of month inventory period due to hazardous weather conditions. Estimates were used which understated resin production and therefore overstated VCM consumption.
VCM efficiency for the month was 1.01469 lbs. VCM/lb. PVC vs. the budgeted 1.00500 lbs. VCM/lb. PVC Y.T.D. efficiency was 1.00467.
Y.T.D. variable cost efficiency variances in the Vinyl Department totaled $252.1M favorable.
Energy Performance/Progress
1. Plant energy consumption was 2575 BTU/lb.
2. A total of seventy-eight steam leaks, two air leaks, and thirty-three steam trap repairs were made during the month.
General
1. Packaging for the month totaled 576,884 pounds.
2. Resin raw material in the 744 account totaled $2234M at month end.
A
VAB.0001184196
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COMPOUND - P. J. Kober/S. B. Vick
A
Month
M Lbs./Day
Y.T.D.
Line I, M Pounds Line III* M Pounds Total, M Pounds Accounting Days
1714 2355 4069
31
63 100
--
--
4937 8239 13176
123
Line I operated 27.3 days during January at an average rate of 63M pounds per day. Major items affecting production efficiency were product changes 48.8 hours, charging delays 13*8 hours, Banbury seal changes 8.8 hours, dicing delays 7.8 hours, and blender conveyor bucket repairs 7.3 hours. Only one experimental compound, 0113-60, a reformulated version of 48562, was produced during the month on Line I.
Line III operated 23.5 days during January at an average rate of 100M pounds per day. Line III production was hindered by product changes 55.0 hours, #7 rotor installation 48.0 hours. Fusion Task Force trials 48.0 hours, and blender charging delays 6.0 hours. Experimental work on Line III during the month was conducted by the Fusion Task Force. The fusion study test runs were made on several products in an effort to achieve low fusion delay compound for several customers. Two products were produced for AT&T, 4986-90 and V0124-70; both products were successfully produced at stock temperatures below 320 F. and at average rates over 5000 pounds per hour. Other products produced during the tests included 18031 Cl B1 for CK Plastics, 34642 Nat. for Teledyne, 35851 Nat. for Universal and 38931 Nat. forv Woods Wire. On all the products, the desired stock temperature was achieved at normal rates with only minor operating problems. Quality as tested by the plant laboratory was acceptable by current parameters on all products. In addition, the fusion delay as measured by the PRS in Ponca City on the AT&T compounds was found to be acceptable.
Quality performance for flexible compounds was 1.9% off-grade of which 100% was due to mill scrap. "BC" production was 0.2%.
The raw material requirement for flexible compounds was 1.01043 pounds of raw material per pound of compound versus a 1.01172 standard. (Y.T.D. is 1.01085).
The variable cost variance for compound was $24.6M favorable with ($4.3M) due to price and $28.9M due to efficiency. The variance due to product mix was $19.9M. There were no major efficiency variances for the month. Total compound inventory decreased 0.44MM pounds from 7.29MM pounds to 6.85MM pounds.
Dry Blend
Month
M Lbs./Day
Y.T.D.
Production, M Pounds Accounting Days
4677 159 14976 31 - 123
Dry blend operated 29.5 days during January at an average rate of 159M pounds per day. Production Included 80273G, 90171, 90172B, XTRALIFE, RP-200, RP-200-T, 5426-129B, 140-115, 140-116, 140-117, 140-44, 140-57, 140-105, and 100-128.
VAB.0001184197
f
COMPOUND - Continued
Dry Blend - continued
Dry blend production was hindered by product changes 47.3 hours* tumhead replacement 33.3 hours* cooling blender delays 21.0 hours* quality control delays 15.5 hours* orbltran repairs 5.3 hours, resin availability 5.25 hours* and product blower belt replacement 5.0 hours. Quality performance for the month was 99.9% customer grade.
The raw material requirement for dry blend was 1.00241 pounds of raw material per pound of dry blend versus a standard of 1.00491. (Y.T.D. Is 1.00306).
The variable cost variance for dry blend was $125*5M favorable with $3.4M due to price and $122.1M due to efficiency. The variance due to mix was $121.3M. There were no major efficiency variances for the month
Plasticizer
Month
M Lbs./Day
Y.T.D.
Production* M Pounds Accoutlng Days
1251 31
57 4784 - 123
Plasticizer operated 22 days during January at an average rate of 57M pounds per day. Production Included 610P, 81OP and 108P.
VRP production totaled 133.9M pounds (11.6%).
The raw material requirement for plasticizer was 1.10220 pounds of raw materials per pound of plasticizer versus a 1.10827 standard. (Y.T.D. Is 1.08066).
The variable cost variance for plasticizer was $75.6M favorable with $68.0M due to price and $7.6M due to efficiency. Major price variances were Alfol 610 $30.5M and Phthalic Anhydride $36.3M. There were no major efficiency variances for the month. The variance due to product mix was ($5.6M).
Enersy
Compound Dry Blend Plasticizer
Actual Standard
1817.6 1927.3
684.8
760.0
1644.6 1642.1
A
VAB.0001184198
t
*
MAINTENANCE - C. R. Snowden
*
Vinyl
Reactors
There were four reactor seal failures in this period. In the old module, seals were replaced on D-500, D-600 and D-700 reactors. In the new module, the 743 reactor seal was replaced. Seal systems were upset in both modules from freezing conditions in this period.
The agitator drive motor was pulled and sent out for repair on the 745 reactor. Reactor jackets were repaired on the 742 and 743 reactors.
Major Valves
Major valves repaired or replaced in this period were the rinse valves on D-400, 500 and 600 reactors... five valves, 743 sewer valve, D-400 major dump valve and a suction valve on "B" vacuum pump.
Pumps and Compressors
Two pumps seals were replaced. The seals replaced were on the scrubber pump on the fluid bed dryer and the east slurry pump in the new module.
Miscellaneous
Major repairs and projects completed in the Vinyl dryer areas were to replace the inlet cone in the #8 exhauster fan, rebuild the #5 air sweep and to remove the test Bird unit from spot #4 and to reinstall the #4 Bird unit.
Several Corken compressors were rebuilt to control packing leaks. A high percentage of the maintenance manpower was used in this period repairing, tracing, insulating, working with operations on piping problems and on twenty-four hour coverage as required by weather con ditions.
Instrument and Electrical
Major work done during the month included modification to the new unit
reactor rinse system and centrate heat recovery system. Also, changes
made to the
regulators for numbers 4, 5, and 6 rotary dryers.
Three motors were repaired during the month (Sweco exhauster, 407 blend
tank slurry pump and HPSW pump).
Compound, Dry Blend, Plasticizer Silo Storage
Line III was scheduled down to install #7 test rotors. The liners were
also replaced in the hopper section at this time as were seals on the FCM unit.
VAB.0001184199
*
T
K4 MAINTENANCE - Continued
Compound, Dry Blend, Plasticizer, Silo Storage - continued
Major repairs to Compound Line I were to replace the Banbury seals and to rebuild a spare blender gearbox.
Dicer blade changes and repairs continue as high maintenance cost items on both compound lines.
Repairs were made to two roll doors in the compound area and a safety item to install a ramp over a transfer line on the compound roof was completed.
The dry blend unit was scheduled down to rebuild the turn head unit and to replace a section of the cooling water header to the cooling blenders.
The bowl and blade were replaced on the #1 We lex unit.
Repairs in the plasticizer unit were to change pump seals at tank 101 and 102 pumps and replace a seal and bearing in the north N2 blower. Two tubes were plugged in the R-4 condenser.
Instrumentation and electrical activities mainly consisted of replacement of motors on the #3 well, #8 air compressor and on compound cooling tower. Assistance was also provided for the Line Fusion Delay Task Force.
the the III
Utilities and Services
A major effort was made in this period to keep the plant running and prevent freeze problems. Additional manpower was scheduled on problem days. The plant went on propane fuel for sixteen hours on 1/20-21/85. PM inspection and chemical cleaning of the inerts and catalyst freezer unit was completed.
The automotive PM program remains on schedule, We have experienced the normal problems with batteries and starting equipment in cold conditions.
The pump supplying oil to the trackmoblle clutch failed and was replaced on an emergency basis by the area supplier.
Training
All of the mechanics and several from the mechanical engineering group attended an in-plant training session covering steam traps, how they work and how to check for proper operation. This training was conducted by the local service representative for Armstrong Traps.
A
VAB.0001184200
MECHANICAL ENGINEERING - R. E. Polk
Design
Design is in progress on the following projects:
- Dry Blend Improvements Phase II - Line I Modernization - Rotary Dryer Optimization
AFE Activity
Plasticizer Modernization Phase I - K. S. Allen
The jacketed piping and insulation is complete to the tie-in points. Tie-ins will be made during a plasticizer shutdown. All instrumen tation has been calibrated and electrical Installation is 98% com plete.
Normal Kill Solution Addition System - K. S. Allen
Initial project checkout was made for the old reactor module. A modified "liquid-full" method of charging the kill solution was developed and approved. Turnover documentation is complete and issued for approval.
Line I Modernization - K. S. Allen/C. Coym
The final drawing package from SO&A
plant
and Houston. GED is revising the definitive estimate to include
current local labor rates. The rates will be provided by the pla
before February 15. Confirmation of the Banbury rebuild estimate
in progress and scheduled for completion in February.
Centrate Heat Tank Exhaust Fan - K. S. Allen
Long lead time items have been ordered and received. Drafting is scheduled for completion mid-February. Construction is scheduled for completion by mid-April.
Dry Blend Improvements Phase II - J. L. White
Electrical and mechanical contracts have been awarded. Pre-shutdown work is scheduled to begin on February 11. Final equipment reloca tions and tie-ins are planned for the week of March 4.
Automatic Bagger Air Compressor - K. S. Allen
Design is scheduled for completion by mid--February. Construction is scheduled for completion by mid-March.
MECHANICAL ENGINEERING - Continued
AFE Activity - continued Ring Seal Water Filter Replacement - J. L. White Design Is complete and being reviewed. All material has been placed on order. Rotary Dryer Optimization - J. L. White
W
A pre-construction review meeting was held and comments Incorporated into the design. The contract for insulation work on dryers 4, 5, and 6 has been awarded. Work will begin In mid-February. The screw feeder for #6 dryer has been placed on order with delivery planned for late April.
VAB.0001184202
MECHANICAL ENGINEERING - R. E Polk
4
Design
Design is in progress on the following projects:
- Dry Blend Improvements Phase II - Line I Modernization - Rotary Dryer Optimization
AFE Activity
Plasticizer Modernization Phase I - K. S. Allen
The jacketed piping and insulation is complete to the tie-in points. Tie-ins will be made during a plasticizer shutdown. All instrumen tation has been calibrated and electrical Installation is 98% com plete.
Normal Kill Solution Addition System - K. S. Allen
Initial project checkout was made for the old reactor module. A modified "liquid-full" method of charging the kill solution was developed and approved. Turnover documentation is complete and issued for approval.
Line I Modernization - K. S. Allen/C. Coym
The final drawing package from SO&A
plant
and Houston. GED is revising the definitive estimate to include
current local labor rates. The rates will be provided by the pla
before February 15. Confirmation of the Banbury rebuild estimate
In progress and scheduled for completion in February.
Centrate Heat Tank Exhaust Fan - K. S. Allen
Long lead time items have been ordered and received. Drafting is scheduled for completion mid-February. Construction is scheduled for completion by mid-April.
Dry Blend Improvements Phase II - J. L. White
Electrical and mechanical contracts have been awarded. Pre-shutdown work is scheduled to begin on February 11. Final equipment reloca tions and tie-ins are planned for the week of March 4.
Automatic Bagger Air Compressor - K. S. Allen
Design is scheduled for completion by mid--February. Construction is scheduled for completion by mid-March.
December, 1964 Actual Accou..ang
ABHCEEl AIJrHORIZATIONS REPORT
AUTH. NO.
CAPITAL DESCRIPTION
DATE APPROVED
AUTH. AFE AH'.
9630 9730 9740 9760 9770 9591 %51 9661 9731 9751 9771 9791 9851 B5E2 D5H2 B5K2 A5L2 A5M2 A5N2 D5B3 B5D3 D5H3 D5H3 H5K3 C5G3 A5L3 D5M3 D5P3 G5N3 A5Q3 C5R3 H5A4 G5B4
Water Stripping
04/03/80
Qnp. line III Debottlenecking 10/16/80
Mod. To Moke Profile D.B.
10/27/80
Emergency AMS Kill System
11/15/80
Reactor Pressure Relief Mod.
11/25/80
Sifter Overflew Reclaim Sys.
03/20/81
Safety Equipment
06/08/81
Waste Water Treatment Rev.
06/19/81
Normal Kill Solution Addn. Sys. 09/01/81
fire Protection Phase IV
10/07/81
Recovery System Revisions
10/21/81
Oxnpound Line I Modernization 11/24/81
VCM Pump Pressure Relief
12/09/81
Plast. Area Gond. Collection
05/05/82
Bulk Storage & Handling of CEA 09/29/82
Energy Mon. Instrumentation
11/22/82
Plast. Modernization-Phase I
12/14/82
Dry Blend Inprovanents
12/16/82
Improved Dry Blend Screening
12/16/82
Safety Shower Revisions
03/08/83
Recovery System Revisions
04/08/83
Vinyl Reactor Interlock Rev. V-ll Roof Replacement
04/22/83 05/18/83
Dryer Centrifuge Conveyor Assy. 06/16/83
Instrument Air Dryer
06/02/83
Plasticizer Modernization-Ph II 09/28/83
Remote Operating Valves & Inst. 10/07/83
VCM Exposure Reduction
12/02/83
Imp. Compliance With EPA VCM Std 11/30/83
Dry Blend Improvements-Phase II 12/08/83
Bulk Storage & Handling of AMS 12/08/83
Miscellaneous AFE
01/26/84
Plant Sewer Revisions
01/26/84
810,000 1,350,000
200,000 335,000 560,000 200,000 106,000 560,000 93,000 160,000 402,000 1,800,000 58,000 55,000 160,000 80,000 240,000 41,000 74,000 * 50,000 147,000 44,000 221,000 47,000 90,000 20,000 130,000 100,000 103,000 200,000 75,000 200,000 180,000
EXPENDED OCMUTTED TO DATE TO DATE
FINAL TOTAL EST. GOST 0CMP.
UNDER
EST.
(OVER) 0CMP.
AUIH. AMT. DATE
EST. CIOS. TATE
REMARKS
813,977 574,539 202,313 282,229 462,639 131,484 108,880 561,123
97,312 144,327 404,245 280,110 11,846 28,656 31,509 86,855 200,907 44,013 76,971 59,703 143,648 37,312 230,890 49,150 90,685 20,577 57,944 13,096
0 74,434
0 174,919 186,509
814,065 585,919 201,768 282,136 465,436 133,095 109,545 573,097
97,983 148,881 403,783 438,146
11,846 32,947 31,509 89,441 218,118 43,845 76,971 60,086 146,990 37,576 230,890 49,150 91,291 20,577 64,163 13,0%
0 91,405
0 177,017 187,373
815,000 705,000 203,000 285,000 560,000 131,000 109,500 573,000 98,000 149,000 404,000 1,800,000 58,000 55,000 160,000 89,000 240,000 44,000 77,000 50,000 147,000 44,000 230,000 49,000 91,000 21,000 130,000 100,000 103,000 200,000 75,000 175,000 187,000
( 5,000) 645,000 ( 3,000)
50,000 0
69,000 ( 3,500) (13,000) ( 5,000) 11,000 ( 2,000)
0 0 0 0 ( 9,000) 0 ( 3,000) ( 3,000) 0 0 0 (9,000) (2,000) (1,000) ( 577) 0 0 0 0 0 25,000 (7,000)
06/84 12/85 08/84 09/84 09/84 09/84 02/84 04/84 03/85 07/84 10/84 09/86 09/85 06/84 10/84 07/84 09/84 09/84 09/84 04/84 12/84 09/85 03/84 04/84 02/84 03/84 09/85 12/85 09/85 03/85 05/85 12/84 12/84
04/85 Closed to field charges. 02/85 Construction on hold. 04/85 Closed to field charges.
05/85 Closed to field charges.
04/85 Closed to field charges.
04/85 Closed to field charges. 04/85 Closed to field charges. 04/85 Closed to field charges.
05/85 Revisions in progress. 05/85 Closed to field charges.
05/85 Closed to field charges. 12/86 Engineering in progress. 12/85 Project on hold. 04/85 Closed to field charges 04/85 Closed to field charges. 04/85 dosed to field charges. 04/85 Construction in progress 04/85 Closed to field charges. 04/85 Revisions complete. 05/85 Closed to field charges. 05/85 Closed to field charges. 12/85 Revisions in progress. 05/85 Closed to field charges. 05/85 Closed to field charges. 05/85 Engineering in progress. 05/85 Closed to field charges. 12/85 Engineering in progress. 03/85 Closed to field charges. 12/85 Engineering scheduled. 05/85 Engineering in progress. 08/85 Closed to field charges. 03/85 35 projects approved. 03/85 Closed to field charges.
VAB. OOO1184204
auih. NO.
CAPITAL DESCRIPTION
H5G4 H5T4
H5E4
Miscellaneous AFE Fluid Bed Dryer Heating
Panel Bundles Dryer Centrifuge Conveyor
Assemblies
ABERDEEN A17JH0RIZATIGNS REPORT
December, 1984 Actual Accoun. ^
Ni
DATE APPROVED
06/06/84 05/18/84
Ainu. AFE AMT.
195.000 210.000
EXPEND'D GCMOTTED TO DATE TO DATE
109,978 198,083
126,454 198,274
FINAL TOTAL EST. COST COMP.
UNDER. EST. (OVER) OOMP. AlIIH. AMT. DATE
EST. CLOG. DATE
REMAFKS
110,000 210,000
95,000 0
12/84 05/85 14 Projects approved. 12/84 05/85 Engineering In progress.
03/20/84
150,000
0
0 150,000
0 12/86 03/87 Engineering scheduled.
VAB.0001184205
PROCESS ENGINEERING - R. A. Frohreich
A. Underwriters Insurance Review
Process designs were completed on several Items recommended by the plant's Insurance carrier.
B. Line I Modernization
A meeting was held to discuss the operation sequencing and inter locking requirements for the Line I project. Representatives from the plant operating and engineering groups and GED personnel were present.
C. Stormwater Run-Off Revisions
A class "A" design Is being prepared to redirect stormwater run-off south of the plasticizer operating area.
D. Plasticizer Catch Tank Pump Replacement
Economics were run to evaluate the payout of replacing the existing canned pumps with standard centrifugal pumps. The canned pumps have experienced a high frequency of maintenance. Assistance was given to the mechanical engineering group in selecting a new pump for this
E. Chem Wash Exposure Investigation
Process Engineering assisted in an investigation to evaluate chem wash (caustic) exposure hazards on the vinyl reactors when main tenance is needed on the equipment.
F. Reactor Rinse Optimization
Process Engineering is surveying all vinyl reactors on a routine frequency to ensure reactor cleanliness is being maintained.
G. Chem Wash Return Modification
A process design to decrease chem wash cycle time was prepared and given to the mechanical engineering group for estimating.
H. Colloid Filtering
A cartridge filter was installed in the new reactor module colloid transfer line. Performance of the filter is being evaluated.
t
*
PERSONNEL - R. A. MILLER
EMPLOYMENT
Satish K. Gianchandani, Electrical Engineer Virginia A. Belk, part-time Plant Nurse Earnestine Carter, recalled to General Helper
TRANSFER/PROMPTION
Kathaleen Johnson, from Adm. Services, Aberdeen, to ST, Houston, TX Helen Pruitt, from Lab Supervisor to Security Guard, due to reduction in force James Walker, from Drafter to Security Guard, due to reduction in force Ed Mize, from Electrician "A" to Gen. Mechanic "A", due to reduction in force John D. Hull, from Electrician "A" to Gen. Mechanic "A", due to reduction in force Lee R. Howell, from Gen. Mechanic "A" to Yard Operator "B", due to reduction in force Charles W. Holcomb, from Gen. Mechanic "A" to Lab Trainee, due to reduction in force Kenneth Killian, from Storekeeper MA,f to Compound Utility, due to reduction in force Thomas R. Staten, from Gen. Mechanic ''A11 to Compound Utility, due to reduction in fore Norman Clay, from Warehouse Worker "A" to Compound Utility, due to reduction in force Bernard Garth, from Yard Operator "B" to Compound Utility, due to reduction in force Jimmy Ashley, from Building Attendent to Compound Utility, due to reduction in force Jerry Crosby, from Gen. Mechanic MA'f to Compound Utility, due to reduction in force Larry Frye, from Gen. Mechanic "A" to Compound Utility, due to reduction in force Verneta Blanchard, from Utility to General Helper, due to reduction in force Gary Funderburk, from Utility to General Helper, due to reduction in force D. W. Clark, from Utility to General Helper, due to reduction in force William Davis, from Utility to General Helper, due to reduction in force Ralph D. Flippo, from Utility to General Helper, due to reduction in force Dave Gathings,Jr., from Utility to General Helper, due to reduction in force Homer Awtrey, from Utility to General Helper, due to reduction in force Jerry Jenkins, from Lab Trainee to General Helper, due to reduction in force Foster Fields, from Utility to "A" Operator, due to reduction in force Jerry Jenkins, from General Helper to Compound Utility
RETIREMENT
S. Howard Hill, Normal Retirement
TERMINATIONS
Curtis Lloyd, co-op returning to school Ricky Puckett, reduction in force 0. Joe Knight, reduction in force Dennis Knight, reduction in force Virginia A. Belk, reduction in force Charles E. Davis, reduction in force Coy Flynn, reduction in force Michael Skinner, reduction in force Needham Stahl, reduction in force Earnestine Carter, reduction in force
VAB.0001184207
f
PERSONNEL - R. A. MILLER (continued) TERMINATIONS (continued) Albert Gunn, reduction in force Paul Cogsdell, reduction in force Richard Metcalf, reduction in force Will Malone, reduction in force Daniel Loftin, reduction in force G. Freddy Phillips, reduction in force Richard Jones, Reduction in force William Earnest, reduction in force Reginald Evans, reduction in force Roland Covington, reduction in force Jimmy Ashley, resigned TO/FROM LEAVE OF ABSENCE NONE
j
VAB.0001184208
*
CONOCO CHEMICALS Aberdeen, Mississippi
A
January, 1985 MONTHLY PE NNEL REPORT
Salaried Employees
67
Minority Employees #
%
Hourly Employees Total Employees
156 223
Salaried Hourly Total
8
64 72
12
41 32
New Employees Terminations
0
1 **
Hourly Min. Hired % Min. Hired
Hourly Min Term. % Min. Term.
a &
a
DEPARTMENTS PAR # EMPLOYEES MIN. EMP. . % MIN. NEW HIRES YTD TERM. YTD TURNOVER
Warehouse
16
14
7 50 0 0 0 0 0
Gen. Plant Maintenance
11 53
12 39
6 50 0 0 0 0 0
*
7 18 0 0 0 0 0
L^^oratory
22
22
5 23 0 0 0 0 0
Compound
41
33
25
76
0
0 11
3%
Vinyl 36 32 13 41 0 0 0 0 0
Plasticizer
4
4
1 25 0 0 0
0
YTD 0 0 0 0 3% 0 0
Number of Applicants:
Month
a Year to Date
APPLICANT BREAKDOWN:
a
# Minority
0
% Minority
* Female 0 % Female
o
> P p
Hires (Hourly)
Month
0
Year to Date
Terminations (Hourly) :
Month
1
Year to Date
Overall Turnover
.6 &
Projected Annual Turnover
Includes one temporary part-time employee ** Employee resigned
0 1 7%
VAB.0001184209
j
OVERTIME AND ABSENTEEISM
WAREHOUSE ' MAINTENANCE
LAB COMPOUND VINYL PLASTICIZER UTILITY BOILER GENERAL PLANT
TOTAL
Stra.ght Tin
Houn Worked
2551.75 6123.25 4031.75 6606.00 6623.00 268.00 743.00 843.50 28290.25
I *
_____Overtime Hours Worked________ Controllable(1) Non-Controllable(2)
223.25 914.25 368.00 285.50 1015.25 17.50 169.SO 3.00 2996.25
24 . f)o
8.00
91.25 200.00 180.00 24.00 24.00
0 551.25
O)
overt,.. .
(2) --*-*u.u. 0vertw
exclu`,ln* -ta. *. to workin
Overtime as a %
Of Straight Time
9.69
15.06 11.39 7.35 18.05 5.40 26.04 .36
12.54V
Absence Hours
Lost
58 431
112
322
294 16
1
1239
Absence as a 1 of Straight Time
Sickness Other Total w
1.57
u
4.18 .89 2.85 2.54
0 0 0
43
2.86
7.04
1.89
2.78
2.03
4.87
1.90
4.44
2.08
2.08
.13 .13
.59 *.5C9Q*
1'.99SS
44..3388
3.34 7.50 3.59 8.41 .87 .14 .55 5.21
" due to uorki
* "*Ul*r l"TM on . hol<(|
r'*ul hour, on . holl. .
y "d
tl.o ,l,,h d
1,d*y "X1 *ng re(tu,ar
'y i,nn "WP*rroatt.1oonn,...
h,,,,ra ,,,, tk. sl,,th
1 y ln Peratlons.
VAB.0001184210
ENERGY CONSERVATION - S. C. Hillman I Plant Operations Total energy consumption for January was 123.352 MMM BTUs. Energy consumption increased to 2575 BTU/lb. from 2491 BTU/lb. in Decem ber. An adjusted CMA reduction of 53.8% was obtained for the month. The CMA values for fiscal 1985 are 54.5% adjusted and 39.8! unadjusted.
II Plant Ener Conservation Program A. Maintenance There were one hundred seventeen energy related items completed in January. Seventy-eight steam leaks were repaired and thirty-three steam trap repairs were made. Also, two air leak repairs and four energy related insulation repairs or improve ments were made. B. Steam Trap Survey The survey for the vinyl area identified ten steam trap items for repair.
VAB.0001184211
ENERGY CONSERVATION DATA
1985
1984
Month
J anuary
J anuar
Production, MM Lbs.
Resin Dry Blend Compound Plasticizer
TOTAL
37.9 4.7 4.1 1.3
48.0
32.8 3.5 4.7
1.0
42.0
Natural Gas
Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Energy Consumption, BTU/lb.
68158 1020
69.522 1451
69557
1020
70.948 1690
Electricity
Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Energy Consumption, BTU/lb.
5.2497 1000
52.497 1096
5.2902
1000
52.902 1260
Propane
Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Energy Consumption, BTU/lb.
14.489 92000 1.333 28
0 92000
0 0
Total
Energy Consumption, MMM BTU Energy Consumption, BTU/lb.
123.352 2575
123.850 2950
CMA Reduction (%)
Adjusted Unadjusted Fiscal 1985 Year-to-Date
Performance
54.5% Adjusted 39.8% Unadjusted
53.8 39.3
44.8 31.1
Boiler Combustion Efficiency (1)
NOTE:
(1) Combustion efficiencies were not calculated for January due to the boiler excess oxygen analyzer being out of service.
VAB.0001184212
* t
4 ENVIRONMENTAL - V. E. Messick Water All wastewater parameters were within NPDES permit limitations during January. Consent Decree The first draft of responses to questions on relief valve discharges is nearing completion. Work is continuing on the rest of the responses to the Section 114 questions. Revised Vinyl Chloride Standard The proposed revisions to the vinyl chloride standard have been reviewed. Evaluation of the impact on the plant is in progress. Comments to be given to the EPA are being prepared.
VAB.0001184213
V 1
TABLE I
HATER COMPLIANCE WITH
It
f"
Flow GPM
Jan. - Ave. 941 Max. 1189
NPDES PERMIT PARAMETERS
BOD PPM LB./DY.
13 158 22 298
COD PPM lb./dy.
30 352 36 474
Sus. Solids PPM LB./DY.
*
13 156 16 190
Diss
NH3
02 LB./DY
8.4 10.4
1 J 7.7 3.7 7.9
Feb. - Ave. Max.
Mar. - Ave Max
Apr. - Ave Max
May - Ave Max
June - Ave Max
July - Ave. Max.
"-Aug. * Ave. Max.
Sept. - Ave. Max.
Oct. - Ave. Max.
Nov. - Ave. Max.
M
Dec. - Ave. Max.
NPDES Permit Limits - December 1 throuqh April
Ave.
32 431
1462
Max.
43 800
2713
NPDES Permit Limits - May 1 through November 30
Ave.
26 3S7
- " 1212
Max.
40 744
2523
-
674 > 7.0 1396
674 >7.0 1396
13 6.0-8.5 28
13 6.0-8.5 28
Mu " '
VAB.0001184214
*
LABORATORY - J. R. Williams
RCAs Entered During Januar
AJP 1-9-85
Thermo Compound
5385-3S
Hard Particles
Waivers Received
Customer
Product
Reason
Carlon
5385-3
Contamination
Charlotte Pipe
5265
Particle Size
Columbia Plastics
5385-3
Particle Size
Compression Polymers
5426-129B
Fusion Torque
HAW Plastics
5385-3S
Bulk Density
Intex
5305
Particle Size & Viscosity
ITT Grlnnel
l
Southwire
5265 5425
Viscosity Particle Size
Tyler Pipe
5265
Particle Size
United Tech
5465
Viscosity
Quality Control Testing
Resin
Regular Samples - 380 Total Batches Tested - 865 Bag Blends - 13 Bulk Shipments - 291 (Railcars - 167;
Trucks - 124)
Dry Blend
Blenders Produced - 675 Blenders Tested - 429 Blenders Adjusted - 2.2% Bulk Shipments - 41 (Railcars - 20;
Trucks - 21)
Compound
Blenders Produced - 677 Blenders Adjusted - 0,6% Bulk Shipments - 9 (Railcars - 9;
Trucks - 0)
No. 2 RC 1 RC 2 HT 1 RC 2 HT 1 RC 1 RC 1 HT 1 RC 1 RC
b
VAB.0001184215
LABORATORY - Continued
RVCM of In-Process Samples
The following is a summary of residual VCM results on in-process samples. None of the reactor dally averages exceeded 400 ppm VCM during the month of January, 1985.
Number of Samples Average ppm, VCM
RVCM of Shipment Samples
Reactor Slurries
891 233
_______Drier
5265
5305
36 13.6
49 3.1
The following is a summary of the residual VCM analysis of shipment samples for the month of January.
Product No. of Samples Average ppm
5265 47
9.3
5305 55
2.0
5385 110
1.4
5425 28
0.2
5465 6 0.1
VAB.0001184216
Administrative Services-W. F. Higeinbotham
Shipment by Product - M/lbs.
Res i n Plasticizer Dry Blend Comoound
Total
Jan. 1985
32,629 429
3,983 4.520 41,561
Number of Shipments by Mode:
Resin - Bulk Package Export
Plasticizer Dry Blend - Bulk
- Package *. m
- Export Compound - Bulk
- Package - Exoort
ICG- 176 BN- 0
Number of Shipment by Month-Year-to Date :
JANUARY
176 69
Year-to Date
242,160 2,332
15,870 275,693
417 '
VAB.0001184217
ADMINISTRATIVE SERVICES - continued
Material Handling Report
Packaged Resin from Production Packaged Compound, Dry Blend from Prod Transferred from Main to Prairie Transferred from Prairie to Prairie Transferred from Prairie to Main Reverse Transfer Resin to Plant Reverse Transfer Cmpd. to Plant Shipment from Warehouses Special Packaging
Off-Grade In Storage
Material
Sifter Overflow
Resin "BC"
Resin "HM Mill Scraps
<%
Compound "BC"
Compound "H"
Vacuum, Dust Collector, Vent Dust
Dry Blend "0. G."
Volumes - Month 8,8 - Y.T.D. 8,8
M/Lbs.
460 3033
824 200 178 131 3959
578?
M/Lbs.
63 24
31 162
47 60 112 459
T/L
11 76 22
4 4 3 99
FT?
T/L
2 1
1 4 1 1 3 13
VAB.0001184218
ADMINISTRATIVE SERVICES - continued
Aberdeen Warehouse
Location Main-East
Prairie 12-1
12-2
12-3 12-4 12-5
Total M Sq. Ft.
48
12 22 21 22 21
Contents
Cmpd. Bags 3.3
Cmpd. Boxes 2.8
Dry Blend
.1
Compound
1.2
Dry Blend
.7
Resin
.2
Vacuum Dust Mill Scrap
J
ol
Estimated MM Pounds
On Floor Open p
Total
6.1 1.4 7.5
.1 1.4 1.5
1.2 2.3 30 5 .7 2.8 3.5 .2 3.3 3.5
Sifter Overflow .]
12-6
12-7
Cmpd. O.G.
.2
Dry Blend O.G.
21 Compound-Hold
Re sin-HoId D.B. - Hold
.4
.2
Raw Material .4
21 Resin
.5 2.0 2.5
-
1.0 2.5 3.5
12-8
Compound
^9
21 Maintenance
Storage
PIugged Aisle
? 3.2 3.5 3.5
3.5 3.5
TOTAL 209
10.0
22.5
32.5
*
VAB.0001184219
*
<o0T4>
CO VO
ABERDEEN CHEMIC-A"L -P-LANT INJURY PERFORMANCE
i -........... - '
i-
<*i
tLAJI
Frequency =_ 12 MONTH
INJURIES (FA or MCJ
TOTAL EMPLOYEES
VAB.OOOl184220
*
5000 4500 4000 3500 3000 2500
2000
1500
ENERGY USAGE
Monthly 12-Month Moving Avg
VAB.0001184221
MONTHLY HOURLY TURNOVER
VAB.0001184222
MM
W? POUNDS
40.C
20.C
4.0
3.0
2.0 1.0
0. --
-
v>
10.0 8.0 6.0
2.0
1.0
0
ABERDEEN PLANT INVENTORIES
10/1/84 - 10/1/85
K
ii
f --------.y
VAB.OOOl184223
ABERDEEN PLANT QUALITY PERFORMANCE
10/1/84 - 10/1/85
%
OFF-GRADE
i k
r i mi
r i an raj
n 11
---
M \--*
1
Wl --
\+iit.lii i - J-1 "
~
[ J.
"
----!--rr--
1_
__
_r
1
_________________
-1 J A J
6.0
5.0 4.0 3.0
11 --.
1
' TM " 1,1
-1 r
"
-------------------
------------
:-d .. ------------------------------ h
----------------------- - -------------
,,---- -------------------------- ---------------- ---- --
-- r _________ - -- i
' '
--- -------- - - -------- ---------- -- --..... --------- -------------- - -
|___________________ _______ -- ------------ --*----------- ---
I q .,
> -- --------------- -
______
------------ - -
-- - - - ------------------------ - ------ -----
.... ---
--^
-------- -
--~~ -- rr
[_______
--- -- ' - --- - - - --------------------' *--
1 ________
-- - - - - ------------[ ~ ____ __ ^
______________ __
--
"j
r
II 1
- ------------ ---------------------------- - .
---- -----------------------------------
2.0 1.0
0
pl - 1 "m
11
]
1 "
r ..
LU_ ----- r........................ -.rq _ r--_-_--_-_--_-_--_--_-_- _*_--_--_--_-_-_-_--_-_--
1----------------------1
-------------------- :
"---------- : : .
n :
J. 1
....
. .J n
i
1
i i __________ _ __________
..-- .
* -------------- ,
1
1
1
J. .
_______________ _________
j
I
_. . .
------------------------------------------- 1
1. i
... .....
l
r i^ih
4.0
*
3.0
-
--
2.0
1.0
0
f*-
- - . I--
K
4.0 3.0
2.0 1.0
0 Oct. Nov. Dec. Jan. Feb.
84/85
VAB.0001184224
%
/ MM POUNDS > p MONTHLY
'--
~
t~~
>y .
,*
4
25
20
15
ABERDEEN PLANT PRODUCTION
10/1/84 - 10/1/85
MM POUNDS CUMULATIVE
.
*
m
.. -
1
'
60 50 40 30
20 10
70 60 50 40 30
20 10
20
15
1 10
5
o Oct. Nov. Dec. Jan. Feb. Mar. Apr. May June July Aug. Sent. Oct.
19 84/85
i - Budget - Actual Cumulative
VAB.0001184225
\ *
t
l I
ABERDEEN PLANT EFFICIENCY
10/1/84 - 10/1/85
POUNDS OF RAW MATERIAL/POUND OF PRODUCT
1.200 1.150
1.100 1.050
iq 84/85
Monthly Cumulative