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SAFETY - A. H. Sather OCCUPATIONAL INJURIES Injuries Treated March 1980 Year-to-Date 1979 Year-to-Dat< First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time 8 16 58 1* 1 33 00 6 1 1 4 0 Injuries By Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 26 37 6 10 22 00 00 4 0 2 0 0 2 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 7 11 12 12 25 24 23 2 2 2 2 2 0 * One of the medical cases reported during February required restricted work assignments during the reporting period. Injuries which required medical treatment included: a mechanic who slipped and fell when he stepped on a small oil slick in the Maintenance Shop; a development technician who cut his thumb while operating a paper cutter; a vinyl utility who suffered an avultion to his third right finger tip while changing a dryer sifter screen; a compound utility who suffered a back strain while performing product change work on Line III, and a "B" mechanic who struck his first left finger with a hammer while tightening the bolts on the D-400 reactor gearbox flange. As of March 31, 1980, the plant operated 270 days or 351,323 manhours without a disabling injury. FIRES Two (2) small fires occurred in the New Reactor Module, reactor section during welding operations. Both were extinguished promptly with 30 pound hand fire extinquishers. The first occurred on 3/4/80 when a leaky vinyl chloride charge valve on 741 reactor allowed VCM to enter the sewer during the routine draining of a reactor. The fire occurred where the main sewer line enters the under ground sewer. The other occurred on 3/6/80 at a leaking flange on the reactor recovery line as it leaves the reactor area going to the recovery area. DTH 00004390 -1- SAFETY - (cont.d) SAFETY MEETINGS The discussion topics for March Safety Meetings were: Hand traps, 1979 Safety Performance Review and the proper use and care of knives. STRIKE PREPARATION A considerable amount of time was spent preparing for plant safety and security in event of a work stoppage on March 19, 1980. Following acceptance of the contract offer, some time was dedicated collecting and consolidating strike preparation supplies and equipment into a central location. OSHA COMPLIANCE Activity in this area was limited to VCM and lead dosimetry. The results of sampling and an explanation of overexposures are shown below. VCM - A total of 83 samples were taken and analyzed. Of the results, two (2) indicated overexposure. Range, ppm VCM Number Percent 0.0 - 0.5 76 91.6 0.5 - 1.0 5 6.0 1.0 - 5.0 2 2.4 5.0+ 0 0.0 100.0 Overexposures - One overexposure occurred to a chief operator and the other, to an old module operator. The cause of overexposure is under investigation in each case. Neither of the above was wearing a respirator. Lead Number Less than PEL* Greater than PEL * Permissible exposure limit. 32 _o 32 DTH 000043903 -2- VINYL - C. R. Miller Production Month Y.T.D. Budget 1. Total Production, MM Pounds 2. Production Rate, M Pounds/C.D. 3. Charges, Reactor Batches/C.D. 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average Pounds/Hr. 7. Dryers, Stream Factor, % 8. Accounting Days 25.6 826 19.4 600 84.3 5536 88.8 31 82.2 903 21.0 1909 87.4 5889 91.3 91 Vinyl department production for the month was 90% of budget at 25.6 MM pounds. There were several major items that adversely affected overall production for the month. These items are as follows: 1. D-600 reactor required extensive downtime for repairs to the internal baffles and gearbox (99 hours). 2. Two reactor condensers were brushed during the month (74 hours). 3. Loss of the old unit slurry screener resulted in plugged slurry lines and pumps (92 hours). 4. Quality problems with 5425 production were corrected by elimination of one initiator but production rate was adversely affected. Experimentation with vendor and alternate suppliers is in progress. 5. Loss of an electrical transformer resulted in a 0.6% and 1.1% stream factor penalty in the reactor and dryer areas respectively. Resin Quality Summary Resin Type Prime Pounds "BC" Grade "H" Grade % of Total Production 5305 5385 5425 5465 Sifter Overflow 1,720,430 18,964,118 3,517,910 953,210 - 40,500 131,750 (2,250) - - - 284,135 6.9 74.6 13.7 3.7 1.1 TOTAL 25,155,668 170,000 284,135 100.0 Quality performance for the month of March was 98.2% customer grade with 0,7% "BC" grade and 1.1% "H" grade. The off-grade reported was due to sifter overflow. -3- DTH 000043904 VINYL - (cont.d) The variable cost variance for the vinyl department was ($199.7 M) with ($289.7 M) due to price and $90.0 M due to efficiency. The only major price variance was ($253.9 M) for VCM. The major efficiency variances were $9.9 M for VCM and $12.2 M for combined initiators. The initiator variance was a result of Lupersol 188 initiator not being utilized in 5425 production during the month. The raw material requirement for the month was 1.01777 pounds VCM/pound of PVC versus a 1.01960 standard. (Y.T.D. is 1.01560) -4- DTH 0000439') COMPOUND - J. R. McCrimon Compound Production Line I, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days Month 1,359 - 2,673 4,032 31 Daily Avg. 47 - 86 133 Y.T.D. 3,158 207 7,104 10,469 91 Line I operated 29 days during March at an average rate of 47 M pounds per day. Major items affecting production efficiency were: Product changes (23 changes, 44.8 hours), dicers (41.3 hours), maintenance on No. 1 blender jacket (17 hours), and maintenance on the Banbury motor coupling (8.8 hours). Production was also hindered by Line V operation for 4 days during the month. Line V operated 4 days during March to experiment with screw configurations to work out hard particles in 17461 Gray 545. To date no configuration has been successful on this compound. More tests will be conducted in April. Line III operated 31 days during March at an average rate of 86 M pounds per day. Line III production was hindered by: Product changes (17 changes, 57.7 hours), quality control (12.5 hours), maintenance on mill Johnson joint (8.8 hours), and maintenance on Sweco (10.2 hours). Quality performance for flexible compounds was 2.0% off-grade of which 96.8% was due to mill scrap. "BC" production was 2.0%. The raw material requirement for flexible compounds was 1.02977 pounds of raw material per pound of compound versus a 1.01300 standard. (Y.T.D. is 1.01708) The variable cost variance for compound was ($14.6 M) with $40.6 M due to price and ($55.2 M) due to efficiency. The variance due to product mix was ($44.5 M). Major efficiency variances were: ($15.0 M) for resin, and $15.3 M for tribasic lead sulfate. There were two major price variances; $15.2 M for T0TM and $10.8 M for combined colors. Dry Blend Month Daily Avg. Y.T.D. Production, M Pounds Accounting Days 2,204 31 105 4,868 91 Dry Blend operated 21 days during March at an average rate of 105 M pounds per day. Production included 80273G, 80274G, and 80172B. Dry Blend production was hindered by: electrical failure on both Wei ex motors (51 hours on No. 1 Wei ex and 43 hours on No. 2 Welex), quality control (10.8 hours), maintenance on Orbitran (9.5 hours), and product changes (4.6 hours). Production was controlled by operating on a 5 day , 2 shift basis. -5- DTH 000043906 COMPOUND - (cont.d) Quality performance for the month was 99.99% customer grade. The raw material requirement for dry blend was 1.00915 pounds of raw material per pound of dry blend versus a standard of 1.00320. (Y.T.D. is 1.01657) The variable cost variance for dry blend was $41.5 M with $6.3 M due to price and $35.2 M due to efficiency. The variance due to mix was $45.3 M. There were no major price or efficiency variances. Plasticizer Month Daily Avg. Y.T.D. Production, M Pounds Accounting Days 1 ,292 56 1,777 31 91 Plasticizer operated 22 days during March at an average rate of 56 M pounds per day. Production included: D0P, 61 OP, and DIDP. VRP production totaled 67.6 M pounds (5.2%). The new molten phthalic anhydride system was successfully commissioned March 4, 1980. The raw material requirement for plasticizer was 1.11049 pounds of raw materials per pound of plasticizer versus a 1.11003 standard. (Y.T.D. is 1.15446). The variable cost for plasticizer was $8.5 with $37.2 M due to price and ($28.7 M) due to efficiency. Major price variances were : $12.3 M for isodecanol and $34.0 for phthalic anhydride. There were no major efficiency variances. The variance due to product mix was ($1.9 M). General Total customer grade compound inventory remained constant at 4.5 MM pounds during March. -6- DTH 000043907 MECHANICAL - S. J. Vincent Vinyl There were no large reactor seal failures this month. However, there were two reactor gear box failures. The gear box failures were to the D-400 and the D-600 gear boxes in the old module. Both failures were a result of plugged oil lines to the top gear box bearings. The D-600 motor was also repaired. There were three large reactor condensers cleaned in this period. Two of the condensers were in the old module on the D-400 and D-600 reactors and on the 744 reactor in the new module. Safety valves were tested on the D-400, D-600 and the 744 reactors. Safety discs were changed on reactors D-600 and 744. Both baffles were replaced in the D-600 reactor after they failed in an apparent similar fashion as D-500 reactor. Flow meters were installed in the oil lines feeding the top bearings on all of the old module reactor gear boxes. The seals were replaced in the D-400 and D-600 reactors as a part of the gear box repairs. Reactor system valves replaced this month were the steam stripping valves on the 744 reactor. Motors were repaired on the hot water charge pump, slurry pumps, the VCM charge pump, and the chem wash pump. There were ten mechanical seals repaired this month on pumps and compressors in the vinyl production area. Three of the seal failures were in the old module and seven were in the new module. The seals replaced in the old unit were the seal on the reactor rinse pump, the inboard seal on one emission recovery com pressor and the east recovered VCM return pump. The seals replaced in the new module were the outboard seals on the recovery compressors, the west VCM return pump, the south seal water pump, south service water pump and the west water charge pump. General repairs in the old module included cleaning the steam stripping heat exchanger on the recovery system, changing out of the steam sparger in the blowdown tank and the inspection of the incinerator quench system. Instrument repairs were made to the general monitors, controller on the knock out tank, reactor instrumentation, and the VCM charge meters. There was one vinyl dryer PM this month to the #8 unit. The southwest trunion roller was replaced and several minor repair items repaired on the #8 dryer train. The Bird centrifuge was replaced in the #7 train with the new centrifuge unit and the old centrifuge was rebuilt for a spare. The star valves under the 281 silo were rebuilt and locking breakers installed. New locking mechanisms were installed on #1 and #2 dryer switchgear. Compound - Dry Blend - Plasticizer and Silo Storage The major repairs to the compound lines one and three were maintenance and repairs to the dicers and the replacement of the Banbury drive coupling. Some dicer electrical repairs were completed. Clean-out ports were installed in the line three bagging machines and a safety item to install cutting boards on the line three dicers was completed. A new heated plasticizer filter was installed for line three. A gate valve was installed on the filler drop line to the line five welex. The line five temperature zones were calibrated on the compounder. The west compound cooling tower pump and motor were overhauled. The dry blend -7- DTH 000043908 MECHANICAL - (cont.d) Compound - Dry Blend - Plasticizer and Silo Storage - (cont.d) unit ran with only minor mechanical problems. The major repair was to the welex motors. The repairs to the plasticizer unit were to overhaul the Glycol pump in the tank farm, repair of several steam leaks and minor process leaks. A project to run a new caustic line to tank 460 was completed this month. The Hoffman blower used for the dry blend and compound vacuum cleaning system failed and a replace ment unit is on order. Utilities and Service There were three repairs to the plant air system and air compressors. The valves were replaced in two air compressors and one air compressor was regrouted to the foundation. The aereator in the #5 lagoon was removed for repair and inspection. Leak Repair repaired 46 process steam leaks in the plant. One of the 1000 KVA transformers failed and was replaced at the chiller building motor control center. The plant air conditioning and compressor PM program is on schedule. The pressure control system was repaired on the deaerator. The magnetrol was replaced on number three boiler. Maintenance Planner and Miscellaneous Projects The planner issued 24 invoice registers for contracted repairs, estimated 93 work orders and ordered material for 26 of the planned work orders. There were 10 invoices processed for payment. The planner completed a listing of the plant safety valves and safety discs. The lists have been forwarded to the process area supervisors to help develop a plan for testing this equipment and to establish the necessary inspection interval. Miscellaneous The freeze protection tarps were removed from the vinyl operating area. The electric motor storage shed was rearranged. Installation of the control system for the double block and bleed system is in progress. -8- DTH 000043909 PERSONNEL - J. L. Carter EMPLOYMENT Willard Reed, Process Engineer Tony Smith, General Helper Verneta Peters, General Helper (Q. C. Townes - Reinstated) Douglas Vogue - Casual Labor TO/FROM LEAVE OF ABSENCE None. TRANSFER/ PROMOTION Charles E. Holcomb, Vinyl Chief Operator to Maintenance Helper RETIREMENT None. TERMINATION Eugene Mays, Casual Labor Larry Hubbard, Casual Labor Michael Clopton, Casual Labor William Caldwell, Casual Labor Aaron Dobson, Casual Labor Alonzo McKnuckle, Casual Labor Daniel Darby, Casual Labor Vernetta Peters, Casual Labor Willie Heard, Casual DEATH/DISABILITY None. OTHER During the month of March there were 14 casual labor employees on payroll. Total hours worked were 807.25. The bulk of these employees were utilized for bagging resin. -9- DTH 00004391 CONOCO QlMICALS Aberdeen, Mississippi March 1980_________ MONTHLY PERSONNEL REPORT Salaried Employees lourly Employees 78* 157 Minority Employees ft Salaried 7** "0 9%** Total Employees Employees (Hourly) New Employees Terminations 235 ______ 2 Hourly Total Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 2 100% 0 0 62 69** 39% 29%** DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound Vinyl Vlasticizer PAR ft EMPLOYEES MIN. EMP. 99 2 10 11 6 46 46 7 22 20 3 41 35 28 32 32 13 54 3 % MIN. 22% 54% 15% 15% 80% 41% 75% NEW HIRES YTD TERM. YTD TURNOVER 0 0 00 0 2 . 2_:,, 0 1 0 0 0 00 0 0 0 00 0 1 *** 0 0 2**** 0 0 0 00 0 0 0 00 0 YTD 0 11% 0 0 2.8% 0 0 Number of Applicants: Hires (Hourly) : Month 1 Year to Date 34 Month 0 Year to Date 2 APPLICANT BREAKDOWN: Terminations (Hourly) : ft Minority _____ ^ % Minority Q Month 0______ Year to Date 3**** Female 0 Female 0 Overall Turnover 0 includes two (2) temporary employees. Projected Annual Turnover 1 3% **Includes one (1) temporary employee. ***Indicates a reinstated employee and not considered as a new hire, ****Includes one (1) retirement and is not i unted in turnover rate. -10- DTH 000043E(11 & CO oo as LO as CO a* o O r>. o r>. O oo (-- CT> 1-- 1 as o as l o r-. oo 03 3: 01 +</J> uo -Q O O) fO CL OJ o Q. O >1 (DO >> rtJ JC X3 <D +J S3- O i- . o s >> #0 -o S_ o 2 >1 <0 o s: </o --t Ui Ui hz UJ VO o 00 CO < 00 o fO +J 0J -Oci <o +> s_ +- <U CO > o *+- o CM > o 5|' aoo* a* a* 3H? VO co c*- o *a- r-- i-- CO i. O * O o i0-1 o LO <D 3 TO oo uo o o O o o uo tn CM CM uo to UO o o r> r*** s CM CM UO O 00 oo r* 00 to <cf 00 00 00 o r-- LO r-- CM CO g-O p -2 UO o uo uo o o O o uo e' uo CM r- o o o CM en rl c- CM *rf- CM *a- r- to CO uo CO CM at r-* uo 00 <0 &_ S- 3 CO i-- VO uo CO uo CO UO uo uo CM M O OJ s_ -- u >5 0) o <U S- M CO to <T5 o TJ 3 C +J u >) o QJ <0 3 4J -c M S- o 4J <u c o CL t/> r~ s X) C TJ r-- & fO <0 2 5" --J O >O +J r> <D E QJ > o J-- ro U <D 0) > o a> S <o O O 4<-D> O DTH 000043912 PROCESS ENGINEERING - R. A. Frohreich A. Specialty Compound Line Tests utilizing new screw elements were conducted in the plant the first week in March to try to eliminate the hard particles in the finished compound. These test were not successful in eliminating the hard particles. A meeting with Werner-Pfleiderer Corporation personnel was held on March 13th to discuss the problem. It was decided a test using larger diameter screw elements would be conducted in the plant the first part of April. Also it was decided a test run would be conducted at Werner-Pfleiderer using a machine with a longer screw in May. This test has now been delayed until June due to delays in moving the W/P lab. B. Resin Expansion Project Plant review and approval of equipment purchases and drawings is continuing. A meeting was held with Niro to finalize the control scheme for the fluid bed dryer. A review of one line piping drawing prepared by Li twin was made during the month. Also the location of tie-in points for the expansion were shown to Li twin personnel. C. Resin Reclaim System A vacuum truck was used to remove and transport resin slurry from one of the concrete pits to a blend tank in the V-10 dryer building. The slurry will be dried and the quality of the dried resin will be evaluated as dryer time becomes available. The class "A" process design for the reclaim system utilizing a rotary dryer is being prepared. D. Calcium Stearate Addition System The AFE request for this project was submitted and approved. E. In-Line Methocel Analyzers The class "A" process design was issued for the project. Various concentration methocel solutions were sent to Anacon to determine if their refractive index instrument could be used for this application. The tests indicated the instrument to be accurate to within _+ 0.03 weight percent. F. Centrate Rinse Water System The test run using centrate water for rinse water has been delayed until after the hot water charge tank in the old module has been replaced. The class "A" design for the system is being prepared. G. Phthalic Anhydride Storage and Handling AFE requests to provide piping modifications and to provide a new storage tank were submitted and approved. -12- DTH 000043913 PROCESS ENGINEERING - (cont.d) H. API Clean Mater By-Pass An AFE request to divert clean water around the API separator and to install a continuous oil skimmer was prepared and submitted. I. Breathing Air Modifications The class "A" process design for installing a package water separator on the existing Nash compressors will be issued in April. A breathing air system using instrument air will be evaluated as an alternate to upgrading the existing systems. J. Compound Line III Debottlenecking The class "A" process design for the project will be issued the first of April. The review meeting for the design is scheduled for the second week of April. K. Compound Die Face Pelletizer The class "A" design for the addition of a die face pelletizer to compound line III will be issued in early April. Farrel and Buss-Condux have submitted their proposals for the project. Werner-Pfleiderer has not yet submitted their quote. L. Reactor Agitator Replacement The class "A" process design to replace the Philadelphia Gear agitators on D-500 and D-600 reactors with Mixco grade mounted agitators was issued in March. M. Boiler Economizers An AFE request to install economizers on the boiler stacks was submitted and approved. N. Old Module Hot Water Tank Replacement The old unit hot water tank was taken out of service due to chloride stress corrosion cracking. A design providing piping modifications to allow the use of the rinse tank as the charge tank was prepared. A process design to replace the tank with a 30,000 gallon lined carbon steel tank is being pre pared and will be issued in April. O. Vinyl Area Air Dryer The operating procedure for the Del tech air dryer was issued. P. Fixed Point Monitor Data Computer and Warning Lights The class "A" design for the project is being prepared. -13- DTH 000043914 Q. Plasticizer Backup Filter A process design providing a small backup filter to the new Schenk plasticizer filter was prepared. -14- DTH 000043915 ENVIRONMENTAL - V. E. Messick I. Particulates Particulate testing was conducted on three dryers to demonstrate com pliance with the emission limitations of the plant's operating permit. These tests were observed by personnel from the Mississippi Bureau of Pollution Control. The particulate emissions measured were within the limits of the permit. The compliance report is being prepared. II. Water BOD and COD levels were within the NPDES permit limits. Process Engineering assisted operations in the pump out and caustic treating of aqueous material in the underground storage tank, T-424. This underground tank is now being used to collect and store rag layer from the plasticizer operation. Ill. Vinyl Chloride The update of the OSHA Engineering and Work Practice Control Plan was issued in March. -15- DTH 0000439J Flow GPM Jan. - Ave. Max. 810 941 Feb. - Ave. 645 Max. 802 Mar. - Ave. Max. 595 743 Apr. - Ave. Max. May - Ave Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max, TABLE I - WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB./DY. COD PPM LB./DY. Sus. Solids PPM LB./DY. 43 436 131 1342 6 42 8 56 29 220 36 314 86 851 216 2214 15 116 24 171 66 502 95 828 11 103 13 143 10 79 13 125 11 74 14 94 Diss. 0~ 6.8-8.5 6.7-7.9 6.6-8.3 NPDES - Ave. _ Max. _ 32 387 43 520 - 1390 - 1940 - 605 - 909 >6.0 ph 7.7-3.0 7.1-7.8 7.1-7.8 6.0-8.5 -16- DTH 000043917 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for March was 110.3 MMM BTUs. The energy con sumption per pound of product decreased from 3378 BTU/lb. to 3332 BTU/lb. II. Plant Energy Conservation Program A. Steam Leaks Leak Repair, Inc. was called in to repair leaks on stream in key areas that could not be shut down. Seventy-two (72) leaks were repaired in March. B. Boiler Economizers The AFE for the installation of economizers on the Plant's three boilers was submitted and approved in March. -17- PTH 000043918 ITEM ENERGY CONSERVATION DATA 1979 1980 Production, MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Total Energy Consumption, MMM BTU Energy Consumption , BTU/Lb. Boiler Operating Data No. 1 No. 2 No. 3 Avg. Stack Temp. 1979 1980 425 384 406 408 452 414 26.3 1.5 5.2 0.9 33.9 25.6 2.2 4.0 1.3 33.1 61 ,659 1,020 62.892 57,691 1,020 58.845 4.9248 10,000 49.248 5.1456 10,000 51.456 0 92,000 0 0 92,000 0 112.140 3,308 110.301 3,332 Avg. % Excess Air 1979 1980 100 19 110 19 115 21 -18- DTH 000043919 MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved and Closed The following AFE's were submitted and approved during March: AFE No. Title Authorized 9550 9560 9570 9580 9580 Phthalic Anhydride Handling Improvement Safety Equipment Replace T-100 Phthalic Anhydride Tank Boiler Economizers Critical Spare Equipment $ 63,000 25,000 119,000 140,000 59,000 The following AFE iwas closed to field charges during March: AFE No. Title Authorized 9679 Plant Winterization $ 64,000 Completion reports were issued for the following AFE's during March: AFE No. Title Authorized 9307 9208 9238 9178 9529 9569 Compound Project Conveying Lines Spare Recovery Vacuum Pump Compound Line I Roof Collapse Propane Vaporizer Replacement Miscellaneous Projects Under $10,000 Miscellaneous Projects Under $10,000 $ 50,000 14,000 44,000 175,000 125,000 125,000 Design Contracts were let for the Foundations, Piping and Equipment, and Electrical Modifications for the Vapor Emissions Recovery System Revisions project. Design work is in progress on the following projects: Replacement Phthalic Anhydride T-100 Storage Tank Instrument Air Dryer Winterization Diking of Sphere and Curbing of Drum Storage Area Double Block Valves for VCM Charge Methocel Charge Revision Seal Flush Revisions Line III Weighup System -19- DTH 000043S20 MECHANICAL ENGINEERING - (cont.d) AFE Project Activity 1. AFE 9148 - Plasticizer Chemical Exposure Abatement - M. S. Richards Revisions to the seal flush system are in progress. Design of steam tracing system and piping modifications are in progress. 2. AFE 9158 - Fire Protection Improvements - Phase I - J. P. McKee Additional bids are due in early April. 3. AFE 9519 - Critical Spare Equipment - J. P. Windham A Colt-on portable resin transfer unit has been purchased on a guaranteed performance basis. 4. AFE 9619 - Waste Water Revisions - Part I - J. L. White The design of the sampling weirs and outlet piping is complete and ready for construction bidding. 5. AFE 9629 - Air Compressor - M. S. Richards All of the revisions to the compressors will be scheduled when all of the material is received. 6. AFE 9639 - Revisions to Emission Recovery System - J. L. White The contracts for concrete, piping and equipment, and electrical installation have been let. 7. AFE 9649 - Double Block Valves for VCM Charge - M. F. Holman All design work is complete. Bid packages for installation are being prepared. 8. AFE 9749 - Improved Rupture Disc Holders - M. F. Holman Installation of the improved holders is in progress. 9. AFE 9759 - Aberdeen PVC Resin Expansion - M. F. Holman The inhibitor injection system and the cooling towers have been purchased. Preliminary piping and equipment layout drawings were revised with Litwin. The fluid bed dryer general arrangement, reactor, and miscellaneous vessel drawings were reviewed. -20- JJTH 000043921 MECHANICAL ENGINEERING - (cont.d) 10. AFE 9570 - Replace T-10Q Phthalic Anhydride Tank - J. P. Windham T-1000 was placed in operation early this month. The design for the replacement of T-100 is in progress. Construction - G. A. Morgan The installation of the vessel, piping and insulation for the new phthalic anhydride tank 1000 was completed. Repairs to the phthalic anhydride charge tank T-400 were completed. A removable screen was fabricated and installed in the line five pellet cooler. The installation of the baffles and baffle supports for D-600 reactor was completed. Air spargers were installed in 646 and 647 blend tanks. Insulation of number 4, 5, and 6 dryer inlet ducts was completed. -21- DTH OOOC 5; 5922 A0ERDEBH AUTHORIZATIONS REPORT (1) Thru February, 1980 Actual Accounting (2) Thru March, 1980 Airm. CAPITAL NO. DESCRIPTION DATE Ainu. APPROVED AFE AWT. (1) (2) PINAL EXPENDED COSMITTED TOTAL EST. TO DATE TO DATE COST COMP. UNDER (OVER) AUTH. AMT. EST. EST. COMP, CLOS. DATE DATE REMARKS 9237 Heated Plasticizer Addition System 9247 Farrel Mixer Feeders 9297 Automatic Plasticizer-Stabilizer Ueigh-Up System 9098 New Compound Line 9148 Plasticizer Chemical Exposure Abatement 10/11/77 11/21/77 12/14/77 37,000 47,000 60,000 13,090 42.412 56,293 13,518 42,667 57,944 37,000 42,667 60,000 4/17/78 2,050,000 2,088,233 2,101,962 2,101,962 8/21/78 152,000 140,587 146,013 152,000 0 4,333 0 6/80 9/80 11/79 3/80 6/80 9/80 Design In progress. Closed to field charges. Installation scheduled. (51,962) 12/79 4/80 0 4/80 7/80 Closed to field charges. Revisions in progress. 9158 Fire Protection Improvements Phase I 9/19/78 176,000 95,728 95,728 176,000 0 6/80 9/80 Re-bidding in progress. 9188 Railcar Resin Heel Clean-Up System 10/12/78 55,000 42,970 42,970 55,000 0 4/80 7/80 Project operational. 9228 Ory Blend Silo Alarms 9248 Silo Isolation Valves 9258 Dryer Operation Improvements 12/13/78 12/14/78 25,000 25,000 4,392 21,156 9,368 22,244 25,000 25,000 12/14/78 315,000 249,629 264,169 315,000 0 5/80 8/80 Purchases proceeding. 0 5/80 8/80 Eighteen of twenty-aie valves installed. 0 4/80 7/80 Project operational. 9519 Critical Spare Equipment 9539 Laboratory Equipment 2/6/79 3/27/79 175,000 31,000 97,127 24,467 158,269 30,721 175,000 30,721 0 6/80 9/80 Purchases proceeding. 279 7/79 4/80 Closed to field charges. 9549 9559 Safety Equipment Color Heigh Room Modifications 3/26/79 4/19/79 15,000 25,000 12,326 16,257 14,933 16,589 15,000 25,000 0 10/79 6/30 Closed to field charges. 0 5/80 8/80 Installation in progress. 9589 Instrument Air Dryer 5/30/79 110,000 89,183 91,197 110,000 0 6/80 9/80 Winterization in progress. 9609 Reactor Inert Vent System 6/28/79 90,000 5,326 8,460 90,000 0 6/80 9/80 Engineering in progress. 9619 Haste Hater Revisions - Part I 9629 Air Compressor 9639 Revisions to Emission Recovery System 9649 Oouble Block Valves for VCM Charge 7/3/79 7/9/79 7/12/79 7/18/79 140,000 340,000 100,000 182,000 126,209 127,989 117,212 235,293 15,619 45,945 53,915 77,037 140,000 340,000 100,000 182,000 0 5/80 8/80 Project operational. 0 6/80 9/80 Project operational. 0 6/80 9/80 Installation In progress. 0 6/80 9/80 Installation in progress. 9659 P. A. System Modifications 9669 New Air Header 9679 Plant Hinterizatlon 7/10/79 8/15/79 9/5/79 35,000 25,000 64,000 16,758 15,727 56,059 32,445 13,299 61,944 35,000 25,000 61,944 0 0 2,056 6/80 9/80 6/80 9/80 3/80 6/80 Project operational Project operational. Closed to field charges. 9689 Diking of Sphere 6 Curbing of Drum Storage Areas 9699 Plant Dryer Debottlenecking 9/15/79 170,000 9/15/79 80,000 0 0 170,000 r 0 0 80,000 0 6/80..9/80 Engineering in progress. 0 9/80 12/80 Engineering in progress CED. 9709 Facilities for Multiple Grade Resin Production 9/20/79 870,000 0 0 870,000 0 9/80 12/80 Engineering in progress CED. 9719 Aberdeen PVC Resin Expansion (Partial) 9/10/79 850,000 9729 Fire Protection Improvements Phase II 10/1/79 490.000 9739 Methocel Charge Revision 10/3/79 66,000 9749 Improved Rupture Disc Holders 10/22/79 27,000 9759 Aberdeen PVC Resin Expansion 12/10/79 11,150,000 9769 Automatic Setback Thermostats 12/31/79 3,000 9510 Miscellaneous Projects Under $10,000 1/3/80 150,000 9520 Replacement Phthalic Anhydride~J*nk 1/17/80 75,000 9530 Spare Incinerator 1/23/80 650,000 9540 Laboratory Equipment 2/6/80 45,000 11,421 829,021 850,000 0 0 490,000 0 10,640 66,000 23 24,636 27,000 41,328 1,779,372 11,150,000 128 1,872 3,000 12,508 62,604 150,000 23,590 0 0 77,738 0 38,344 84,000 650,000 45,000 0 9/80 12/80 Equipment on order. 0 10/80 1/81 Engineering In progress CED. 0 6/80 9/80 Engineering in progress. 0 4/80 7/80 Installation in progress. 0 7/81 10/81 Engineering in progress. 0 6/80 9/80 Thermostats received. 0 12/80 3/81 Thirty-five projects approved. (9,000) 6/80 9/80 Installation In progress. 0 1/81 4/81 Engineering in progrss; CED. 0 8/80 11/80 Purchases proceeding. -22- DTH 000043925 Aimiv CAPITAL NO, DESCRIPTION 9550 P A Handling Improvement 9560 Safety Equlpment 9570 Replace T-100 P A Tank 9580 Boiler Economizers 9590 Critical Spare Equipment ABERDEEN AUTHORHATIONS REPORT (1) Thru February, 1980 Actual Accounting (2) Thru March, 1980 DATE AUTO. APPROVED AFE AWT. CD EXPENDED TO DATE C2) COMMITTED TO DATE FINAL TOTAL EST. COST COMP. UNDER (OVER) AUTO. AMT. EST. EST. COMP. CLOS. DATE DATE REMARKS 3/3/80 3/12/80 3/27/80 63,000 25,000 119,000 0 18,000 63,000 0 1,630 25,000 0 0 119,000 0 12/80 3/80 Engineering in progress. 0 9/80 12/80 Purchases proceeding. 0 9/80 12/80 Engineering In progress. 3/26/80 3/26/80 140,000 59,000 0 0 140,000 0 0 59,000 0 10/80 1/81 Engineering in progress. 0 10/80 1/81 Update quotes requested. EXPENSE 9029 9049 Repair of Steam Tracing & Insulation 9/5/79 Repairs to Dryer Inlet Ducts 9/13/79 ' 9069 Centrifuge Rotors Repair 9/13/79 9079 Cooling Tower Motor Repair 10/22/79 9089 Vibration Study-Capacity Replacement Reactors 10/29/79 62,000 25,000 47,000 17,800 50,000 69,369 16,548 53,302 0 18,164 69,369 19,012 53,302 0 18,562 69,369 25,000 53,302 17,800 50,000 (7,369) 1/80 4/80 Closed to field charges. 0 4/80 7/80 Insulation in progress. (6,302) 2/80 5/80 Closed to field cha'ges. 0 6/80 9/80 Motor being repaired. 0 6/80 9/80 Prototype testing in progress -23- DTH 000043924 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Report By Cerro Wire & Cable Athol Carl on Permafit Western Electric 5385 5425 5305 90171 36861 Nat. Gels Delayed Shipment Moisture Particle Size Contamination-Plasticizer RDJ CRM RDJ RDJ JRM/RDJ WAIVERS RECEIVED Date Identification Product Customer Reason Waived By 3/4 3/4 3/4 3/5 3/11 3/19 3/19 3/20 3/20 3/20 3/20 3/21 3/25 3/26 3/26 3/27 T-7769 T-1056 T-101 PTLX-41845 PLCX-43744 CONX-45282 T-2481 T-2351 T-2479 PLCX-43750 PLCX-43204 PTLX-41648 T-2481 PLCX-43732 PLCX-43747 PTLX-41603 5385-1II 80273G 80172B 5305 5305 5385-1II 5385-1II 5305 5385-1II 5385-III 5385-1II 5385-1II 5305 5385-III 5385-1II 5385-1II Can-Tex Ari Products Columbia Plastics Tyler Pipe N. J. Terminal Charlotte Pipe Can-Tex American Hoescht World of Plastics World of Plastics Can-Tex Can-Tex American Hoescht Carl on Simpson LCP Particle Size Fusion Torque Equilibrium Torque Particle Size Viscosity Color "b" Value Color "b" Value Particle Size Particle Size Particle Size Color "b" Value Color "b" Value Color "b" Value Moisture Moisture Color "b" Value JRW JRW RDJ CLS RNG CJM CJM CJM RDJ ELK ELK ELK CRM CRM CRM CLS TOTAL 16 PRODUCT DEVELOPMENT AND SERVICE Ship Date Product Quantity (Lbs.) Customer Requested By 3/4 3/5 3/5 3/5 3/5 3/5 3/6 3/7 3/11 5425 5465 5305 5425 5465 5385 38611 Nat. 5385 17461 Gry 545 150 5 200 200 200 900 100 50 50 Fritz Air Freight Ciba-Geigy Corporation Conoco Chemicals Company Conoco Chemicals Company Conoco Chemicals Company Conoco Chemicals Company Electri-Flex Vinyl Plastics Plastics Profiles JPM RNG - - - - - MAS MAS -24- DTH 000043925 LABORATORY - (cont.d) PRODUCT DEVELOPMENT AND SERVICE - (cont.d) Ship Date Product Quantity iLbs-JL Customer Requested By 3/12 3/18 3/19 3/19 3/19 3/19 3/19 3/19 3/19 3/19 3/19 3/19 3/21 3/21 3/25 3/25 3/25 3/25 3/27 3/28 3/31 34431 Nat. 20 5305 50 35851 Nat. 300 34551 Nat. 100 34431 Nat. 100 38931 Nat. 100 35851 Nat. 250 34551 Nat. 250 35851 Nat. 100 34641 Nat. 100 39032 Nat. 100 17461 Blk. 50 14431 Cl B1 50 100 15041 Cl B1 50 100 34641 Nat. 1 5385 1000 34641 Nat. 100 16851 Cl B1 50 100 5385 10 34551 Nat. 10 5305 10 Conoco Inc. Polymer Service, Inc. ITT Royal Electric ITT Royal Electric ITT Royal Electric ITT Royal Electric Chester Cable Operations Chester Cable Operations North Wire Inc. North Wire Inc. North Wire Inc. Homestead Plastics Atcoflex Inc. Atcoflex Inc. Universal Mfg. Co. Superior Dixie Wire Co. Anchor Wire Decorative Products Conoco Inc. Inmont Corporation JAP RNG - - - - - - - JFN - - RNG - JFN JFN NTH - - Special Compound Testing Western Electric specification tests were run on three lots of 36861 Natural and on two lots of 34861 Gray 546. All the lots met the specifications. One lot of Packard Electric 34533 Natural was tested. One lot of 34431 Gray 547 and one lot of 34641 Black were tested and were found to meet Kaiser specifications. Compound Property Verifications Compound property tests are complete on seven compounds and are complete except for oven aging on four other compounds. New Compounds Quality control specifications and standards were prepared for two new compounds., They were JLI 3934-26B and 3711-82B. -25- DTH 000048926 LABORATORY - (cont.d) QUALITY CONTROL TESTING Resin Regular Samples = 362 Bag Blends = 25 Other In-Process Samples = 1941 Bulk Shipments = 238 (Railcars = 110Trucks = 128) Dry Blend Blenders Produced = 240 Blenders Tested = 195 Blenders Adjusted = 7.5% Other In-Process Samples = 75 Bulk Shipments = 26 (Railcars = 6Trucks = 20) Compound Blenders Produced = 657 Blenders Adjusted = 3.5% Other In-Process Samples = 62 Bulk Shipments = 28 (Railcars = 10 Trucks = 18) Resin Heat Stability Forty-five (45) samples of resin were tested for oven heat stability. They consisted of: 5385 5425 5305 5465 19 Samples 16 Samples 8 Samples 2 Samples The 5385 and 5305 resins continue to give erratic values for heat stability and average poorer than the controls. The 5425 resin was good except for one very poor blend. The 5465 blends were better than the control. Three of the 5385 samples were railcars and had high Gardner "B" values. They were acceptable with respect to heat stability. Raw Materials Fifty-six (56) lots of plant raw materials were tested for quality. One small lot of SP-33 clay was rejected because it gave a low value for volume resistivity. One lot of Cyastab 523 stabilizer was rejected because dispersion was unacceptable. The other raw materials were released. -26- DTH 000043927 LABORATORY - (cont.d) RVCM .of Resin Shipments A total of 185 samples of resin for bulk shipment were tested during March. Below is a summary of these results. Product 5385 5305 5425 5465 Average RVCM, ppm Number of Samples 3.2 71 5.9 61 0.4 12 0.1 3 Due to some high values all 5305 shipments were tested prior to release. Any values greater than 10 ppm were rejected for shipment. Ninety-nine (99) 5305 samples were tested for shipment. The average RVCM on all shipment samples, including rejections was 10.4 ppm. SPECIAL PROJECTS RVCM of Slurries A total of 592 batches (99.7% of the batches dumped) were tested for RVCM. The overall monthly average was 293 ppm. Six days during March the daily average exceeded 400 ppm. RVCM of Blowdown Tanks A total of 140 samples of Blowdown tank water were tested for RVCM. The monthly average was 9.7 ppm VCM. RVCM of 5305 Dryer Samples Samples of 5305 were taken from the regular resin sample caught at the driers. A total of 43 samples were tested for an over all average of 13.0 ppm VCM. Resin Volume Resistivity Volume resistivity tests were run on four lots of 5425 resin and two lots of 5465 resin. The samples showed greater than normal variations in volume resistivity. While none of the values appear dangerously low, another series of samples will be tested soon. NEW EQUIPMENT A new Metrastat oven has been received for use as a replacement for a conventional forced draft oven. It will provide heat stability comparisons through the total exposure period and requires less technician time during the exposure period. The oven performance was unacceptable, as received, due to poor temp erature uniformity in the front section. After extensive tests the reason was discovered, and modifications have been made which greatly reduce temperature variations. Tests are underway to compare the Metrastat and conventional forced draft.oven. -27- DTH 000043928 LABORATORY - (cont.d) NEW EQUIPMENT - (cont.d) The lab minicomputer operated without problem during March. PLANT PROCESS ENGINEERING SUPPORT The following special samples were tested: COD's Incinerator Exhaust Pond Solids Special Water for VCM 19 samples 2 samples 2 samples 6 samples PROFESSIONAL CONFERENCE Manufacturing Chemist, Dave Cox spent two days at the Conference of Analytical Chemistry (Pittsburg Conference). -28- DTH 000043929 SURFACE TRANSPORTATION ABERDEEN DISTRIBUTION WAREHOUSE MARCH ACTIVITY REPORT, 1980 Shipment by Product - M/lbs. Resin Plasticizer Dry Blend Compound Total Number of Shipment by Mode R/C O.T. Resin - Bulk Package Export - ABR Plasticizer - Bulk 116 80 6 7 Dry Blend Compound - Bulk Package - Bulk Package Export- Pkg Back Hauls for MARCH 61 14 8 14 37 130 159 '20 Number of Shipment by Month-year-to Date O.T. R/C Bulk MARCH 24732 . 0 2420 3890 31,042 Year-to-Date 62059 43 6740 10743 79,585 C.O.T C.C. TOFC CPU TOTAL 4 24 3 8 228 12 21 7 -0 . `2 18 18 25 2 16 24 8 54 1 37 11 0 48 O.T. Van " C.O.T.C.C. TOFC 375 CPU TOTAL January February March 104 55 111 83 130 95 72 66 64 0 0 1 4 2 36 * 273 21 4 35 320 37 0 48 375 -29- DTH 000043930 \ LOCATION MAIN-East > TOTAL M SQ. FT. 48 Prairie 12-1 12-2 12 22 ...^12-3 . " .... ' " 21 12-4 12-5 22 21 12-6 .21 12-7 12-8 21 21 CONTENTS Compounds Dry Blend Export Resin Conoco Resin Compound Resin Export Resin Conoco Export Resin 3.5 .3 .2 .4 .6 -3.2 3.9 Conoco Resin Resin O.G. Mill Scraps . 4-5 ; Cmpd 0. G. t Dry Blend 0. G. .7 .1 Sifter Overflow .4 Resin 0. G. .6 Compound .1 Dry Blend 2. 7 Raw Material .3 'Resin 0. G. 4. 0 Conoco 4.5 Sub-Total (Pluq-Aisles) ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 4.4 5.6 .6 .9 10.0 1.5 3.2 .3 3.5 3-9 4.5 - 3; 5 3.5 . 18 . 7 2.5 3. 1 4. 0 ** 4. 5 4 3.5 3.5 3.5 35.0 2.9 Total 209 Total Conoco -30- 30.0 7. 9' 37.9 DTH 000043931 SAFETY REPORT Lost Time Accident Doctor Cases First-Aid Cases Han Hours Worked MARCH 0 0 0 2016 MATERIAL HANDLING REPORT Packaged Resin From Production Packaged Compound, Dry Blend From P Transferred From Main to Prairie Transferred From Prairie To Prairie Reverse Transfer Resin to Plant Reverse Transfer Cmpd. to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Main LABOR REPORT Total regular Hours Total Overtime Hour Total Worked Paid but not Worked Total 1434 102 1536 0 1536 Labor Efficiency equals 10.5 MM/Lbs. - Hours Worked 6,855 Overtime % 6.6% M/Lbs. 1296 2349 1336 0 770 40 3604 283 851 . Y.T.D. GRAND TOTAL SINCE L.T.A. 7173 148848 T/L 32 58 33 0 19 1 89 7 21 -31- DTH 00004393; EQUIPMENT REPORT Lift Truck Hours Worked Gal of Fuel Consumed Gals/Hrs 262 437 1*7 Lift Truck Efficiency Equals 10.5 MM/Lbs. - Hours Worked -40,187Lbs./hr OFF-GRADE IN STORAGE MATERIAL Sifter Overflow Resin "BC" Resin "H" M/Lbs. ; 306,053 4,313,000 1,615,000 Mills Scraps 57,600 Compound "B" , 609,000 Compound "H" Dry Blend "O.G." Total 3,000 24,275 6,927,928 _IZL 8 106 40 .1 15 0 1 171 D. F..Operations Total Overall inventory of packaged material remained about the same for the month. Compound and dry blend shipments were above average for the*month. Warehouse-space still remains tight. Safety meeting held during the month with D.F. personnel on safety of storing and removing of packaged material out of storage racks. 32- DTH 000043933 I ABERDEEN RAIL CAR REPORT SURFACE TRANSPORTATION DEPT. AS OF LIMITS LOCATION LOADED VCM 35 IN PLANT 25 MONROE LEAD in 27 20 BINFORD ICG DOWNTOWN TEXICO TRACK SLSF ACROSS BRIDGE STRONG 30 PRAIRIE - 50 EGYPT OTHER 160 TOTALS 37 EMPTY HOPPERS 9 23 32 LOADED HOPPERS 24 1 12 OTHER LOADS -2 3 - 9 9 55 5 TOTAL 45 54 12 - 9 9 ... 129- RECAP FOR MONTH 3/24/80 3/17/80 3/10/80 3/3/80 2 28 29 34 27 37 37 29 62 ` 63 71 73 7 99 5 131 7 142 8 147 PAT WELLS -33- DTH 000043934 i-- O Ui O INJURY FREQUENCY* X 100 >-- v* Vi O VI C Oj -u Oi G -t. ui '-n G ABERDEEN F IR S T -A ID CASES ABERDEEN OSHA RECORDABLE IN JU R IE S DTH 00004393f MONTHLY HOURLY TURNOVER DTH 000043936 ENERGY USAGE < c c c DTH 000043937 Monthly 12 Month Moving Average ABERDEEN PLANT PRODUCTION F2 ~< ~z> C/1 CO co o r- -o >o -i <= I MONTHLY CUMULATIVE N) -t. O' Oo -* N) t/i -U Oo O o III !t o? ? . ig O Oo * ' r-V ABERDEEN PLANT INVENTORIES