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* To: R. T. Ferrell Interoffice Communication From: Date: Subject: J W Were June 18, 1987 ABERDEEN MONTHLY PROGRESS REPORT MAY, 1987 There were no injuries recorded during the month of May, As of May 31, 1987, the plant had operated 2,885 days or 3,717,268 manhours without a lost time injury. PVC resin production for May was 38.1MM pounds. Mechanical downtime in the reactor areas was due primarily to drilling of 741, 742, 743 and 744 condensers, changing the condenser gasket on 400, changing the agitator motor on 700 and replacement of the agitator seals on 300 and 745. Resin production year-to-date totaled 284.9MM pounds. The VCM efficiency for May was 1.00172 pounds of VCM per pound of PVC produced versus a 1.00208 standard. Year-to-date VCM efficiency is 1.00825. Compound production for May was a new monthly record of 7.9MM pounds. The previous record was set in December, 1986 at 7.5MM pounds. Line I and Line III operated thirty-one days and Line V operated fourteen days during the month. Production was limited primarily by product changes. Year-to-date compound production was 57.9MM pounds. Quality performance for flexible compounds was 0.8% off-grade of which 100% was due to mill scrap. "BC" production was 0.3%. Dry blend production was 5.0MM pounds for May and 36.3MM pounds fiscal year-to-date. Production was limited primarily by product changes, quality control delays and transfer system maintenance. Quality performance for the month was 99.2% customer grade. v The plasticizer unit operated thirty-one days in May to produce 1.9MM pounds. Year-to-date plasticizer production is 15.2MM pounds. Six quality involvement teams are currently active in the plant. Control charts for major properties on all resins were issued to the regional sales offices for distribution to customers. The current plan is to issue updated charts on a quarterly basis. Total energy consumption for May was 116.458 MMM BTUs. The energy consumption per pound of product was 2202 BTUs, resulting in an adjusted CMA reduction of 57.4%. The adjusted CMA reduction for fiscal 1987 year-to-date is 54.3%. ft Gi<.r-;=W1i4HF ------ l-W A a ___ _ VAB.0001191343 I u iJa^i I IH1 i a fc a* -- h . . --__ . . y ^ ala a ' Oh. ' r+j j-:. c.m'j |:-! R. T. Ferrell 06/18/87 Aberdeen Monthly Progress Report The total plant variable cost variance for May was $593.0M unfavorable. resulting from an overall unfavorable price variance of $649.2M and a net favorable efficiency variance of $56.2M. The total fixed cost variance for May was $156.5M unfavorable. The major contributions to the unfavorable fixed cost variance were maintenance materials and contract costs ($71.6M), operating supplies ($27.2M), shipping costs ($20.3M), waste hauling ($23.3M) and moving/home assistance ($20.8M). J. W. Ware rah m-v. j.-rj-j |j-- -fl-plJ~lr ri ~ Tir-~~ VAB.0001191344 . fkj (**m. M.'|..b'4l Jl--I Ul DISTRXBlTriCIN HOUSTON: J. D. BURNS R. E. LEJMOJHL COVER LETTER X ENTIRE REPORT COVER LETTER AND QIP X R. T. FERRELL X R. D. GAMHLIN X J. J. LANGFORD X R. E. SWANEKCWSKI X D. F. HARMAN X H. R. FLAtMER X R. R. SMITH X S. K. SABCRSKY X K. J. 0GGERS X D. H. SANDERS X PONCA cm: S. E. MOGUIRE X R. L. POE X H. J. HALL X C. M. STARKS X OKLAHOMA Cm: HARRY GARRISON X LAKE CHARLES VCM PLANT DICK CONRAD X LAKE CHARLES CHEMICAL PLANT J. A. DEBEENARDI X T. H. HUFFMAN X BALTIMORE: HAtMOND R. W. SEYMOUR J. B. MAHER X X ABERDEEN JW, DWH, PJK, TEL, RAF, KLF, RAM, HGC, CWT. REP, VLT, JEL, JGC, RBN i-rfHittiiircuii-Fii-:. t-iTP f'1 '`.fur H will I r -L:4d^f VAB.OOOl 191345 i 4 SAFETY - K. L. Fogg, J. V. Uptain Occupational urles First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Fiscal Y.T.D. 1987 Fiscal Y.T.D 1986 02 00 2 0 A Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries by Type Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains Stings Other Totals Non-Occupational Injuries Lost Workday Cases Days Lost 6 66 Safety Record Last lost time injury 7/5/79 Days since - 2,885 Manhours since - 3,717,268 On May 31, 1987, the employees of the Aberdeen plant completed 2,885 days with no lost time injury. Topics for the plant safety meeting during the month included: Glassware Safety, Building in Safety During Process Design, Catalyst Handling Safety, Back Injury Prevention, "Hotwork" Control, Review of Accident Investigations, Department Injury Performance Review, The Importance of Safety Awareness and the Use of Personal Protective Equipment, and Maintenance Weekly Safety and Job Reviews. The Central Safety Committee met in May. procedures were adopted by the committee. Three proposed safety VAB.0001191346 ai:z*t`rv-wxnrrr-, :*t, -jr:33444*9^1:-Tlfc: r SAFETY - Continued Health activity for the month was limited to routine dosimetry; results of which are shown below: the Chemical VCM Lead Total Particulates Z_ Number 77 20 2 PEL Percent 96.2 100.0 100.0 / Number 3 0 0 PEL Percent 3.8 0.0 0.0 Two of the VCM overexposures were without respiratory protection. A . J.4-N3.. I II l-H-f IH-T-JPI- ^ . bk^.. i:4iii.|.| hb W>. }1Vk!<HlFu. *+ h "#TOI M | VAB.0001191347 H-rt+it i. pjwrtjird-!i h<' r* ii-H'-frMtvnp. * r*+.-, .:.'40t*t.. -jV+ i i in 11 i i~Iran it iT'ii'iifim mi inmiHmL i ABERDEEN CHEMICAL PLANT INJURIES sjtkjnrNt jo jjuwiiN II VAB.OOOl 191348 ti-fU **1 ifft-Ar: r*. hrNtM#4*Wefc 'LiMb +^m *U>t * YCfct^--t ijwmk i'h-niBihiiinu:j . *n anm rfi. _ p.l I- hi TOTAL INJURIES + OSHA RECORDABLE A QUALITY IMPROVEMENT PROCESS - R. B. Newton Information about the successes we've seen from the Quality Management Process was presented to the Board of Directors during their Aberdeen visit. A SPC course about the control charts Aberdeen has prepared for customers was presented to the Saddle Brook and Oak Brook offices. Control charts for major properties on all resins regional sales offices for distribution to customers. will be issued quarterly. were issued to the These control charts The following teams are currently active: 1. Railcar Team - Yard operators working on problems customers have with our railcars. 2. Material Handling Team - Warehouse employees working to improve product handling methods to reduce cost. 3. Transfers Team - Warehouse employees working to reduce transportation costs between the plant and the Prairie warehouses. r 4. Valve Team - Mechanics trying to reduce reactor downtime caused by valve maintenance. 5. Work Order Team - Maintenance supervision trying to make the work order system more efficient. 6. Time Card Team - Payroll department and Operations shift supervisors trying to simplify the time accounting system to reduce errors. T H'flLriV'i'IJ > -I'-U wn . !!:*'Hi 'I H4"- r: :ip shsft'ljrNtfcru'- "i-11 '*- : P : KHIifh4 I IMBU l 'dvi WIM"* I l|* n mi VAB.0001191349 .. ;r\siIhP+MI -I* + 1**4 l: dHK-1. W. If VINYL - D. W. Hollis, J. M. Edwards Safety The Vinyl and Yard Departments operated without any accidents in the month of May. Shift safety meeting topics for the month were Proper Catalyst Handling and Responsibilities of a "Firewatch". Production May Y.T.D.(Fiscal 87) 1. Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days 38.1 1228 950 30.6 91.8 8967 71.5 31 284.9 1172 7203 29.6 91.4 9991 61.6 243 Vinyl Department production for May was 38.1MM pounds. Reactors The reactor stream factor for May was 91.8%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 42.9% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size information before charging, lines plugging, reactor manway O-ring failures and downtime associated with test runs and reactor inspections. 2) Maintenance Service Downtime: Accounted for no downtime because the cleaning of the reactor AMS injection ports and inert vent lines was accomplished while the reactors were normally down for other reasons. 3) Maintenance Repair/Revision Downtime: Accounted for 57.1% of the total downtime and was due to drilling 741, 742, 743 and 744 reactor condensers, changing the condenser gasket on D-400, changing the agitator motor on D-700, changing the VCM valves on 741 and changing the agitator seals on D-300 and 745. Dryers The dryer stream factor for May was 71.5%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 87.5% of the total down time. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 2.5% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems. * 'HMWlJlPw* .................. .. VAB.0001191350 It*11.1 VINYL - Continued Dryers - Continued 3) Maintenance Repair/Revision Downtime: Accounted for 10.0% of the total downtime and was due to major repairs and insulation to #1 dryer inlet duct, changing the socks on #7, #8 and #5 dust collector, repairs to #8 air sweep and repairs to #6 star valve. Product Quality Summary Resin Type Prime "B" "H" % of Total Production 5265 5305 5385 5415 5425 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 4,005,618 2,321,590 16,067,536 14,262,424 - (43,360) -- - - -- 36,613,808 - -- -- - 846,900 - -- 846,900 -- -- - - -- - 88,505 532,980 621,485 10.5 6.1 42.2 37.5 0.0 (0.1) 2.2 0.0 0.2 1.4 100.0 Quality performance for May was 98.4% customer grade with 1.6% "H" grade production. A total of ten railcars were shipped as "B" grade during the month which represented 8.4% of the 119 total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 4/09/87 03/23/86 05/01/87 ACFX 36031 05/04/87 PLWX 44724 Silverline. NC Freedom, WI Debox Debox Quality Quality 05/04/86 05/07/87 ACFX 97124 Wexford, CA Pond Resin Quality 04/23/87 05/08/87 ACFX 36065 Vulcan Plastics, AL Debox Quality 04/22/87 04/30/87 05/07/87 05/08/87 VIPX 45871 05/13/87 VIPX 45793 05/28/87 PTLX 42025 Vulcan Plastics, AL Debox Western AG. , TX Debox Western AG, TX Debox Quality Quality Quality 05/12/87 05/15/87 05/28/87 VIPX 45703 05/29/87 VIPX 45767 Silverline. NC Debox Pacific Plast., OR Debox Quality Quality 05/22/87 05/29/87 PLWX 44292 Vulcan Plastics, AL Debox Quality A VAB.0001191351 VINYL - Continued Monthly Variable Cost Performance Variable costs for the month were unfavorable at $750,2M resulting from an overall unfavorable price variance of $712.1M and an unfavorable efficiency variance of $38.0M. Resin variable cost for the month was 20.383 cents/lb. versus the budgeted 18.334 cents/lb. The $712.1M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $763.0M, offset by favorable freight pricing of $22.5M, a favorable natural gas pricing of $20.0M, and a favorable electricity pricing of $11.6M. The $38.0M unfavorable efficiency variance can be attributed mainly to the unfavorable efficiency variance due to off-grade9 $54.6M; and Alcotex, $20.6M; offset by a favorable Initiator 223 efficiency variance of $19.8M. VCM efficiency for the month was 1.00172 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. YTD variable cost efficiency variances in the Vinyl Department totaled $377.2M unfavorable. Energy Performance/Progress 1. Plant energy performance for May was 2202 BTU/lb. General 1. Resin raw material in the 0744 account totaled $248.9M. A -.3- -`if-iw:- VAB.0001191352 JL COMPOUND - P. J. Kober, J. E. Nickerson Compound Production Operating Days Month Production (M Pounds) Average Operating Day Fiscal Rate Y.T.D. Line I Line V Line III Total 31 2746 89 14 795 57 31 4362 141 7903 19530 6585 31798 57913 Line I operated thirty-one days in May at an average rate of 89M pounds per day. Major items affecting production efficiency were: product changes, 53 hours; housekeeping, 19 hours; dicer system problems and maintenance, 11 hours; quality problems, 9 hours; and Banbury maintenance, 7 hours. Line V operated fourteen days during May at an average rate of 57M pounds per day. Major items affecting production efficiency were: product changes and startup time, 29 hours; and maintenance to the single screw hot oil system, 2 hours. Line III operated thirty-one days during May at an average rate of 141M pounds per day. Major items affecting production were: product changes, 49 hours; preblend feeder maintenance, 14 hours; quality problems, 5 hours; transfer system problems, 5 hours; and dicer system problems and maintenance, 5 hours. Quality performance for flexible compounds was .80% off-grade of which 100% was due to mill scrap. "BC" production was .25%. The raw material requirement for flexible compounds was 1.01492 pounds of raw material per pound of compound versus a 1.01201 standard (YTD is 1.00919). The variable cost variance for compound was $11.8M favorable with $32.5M favorable due to price and $20.7M unfavorable due to efficiency. The efficiency variance due to product mix was $53.3M unfavorable. The efficiency variance for DIDP was $18.4M unfavorable due to correction of a previous accounting error. Year-to-date variance for DIDP is $10.0M favorable. The 7.9MM pounds of compound produced in May is a new monthly production record which exceeds the previous record (set in December, 1986) by .4MM pounds. Total compound inventory rose .5MM pounds in May to 7.9MM pounds. Dry Blend Month Average Operating-Day _______ Rate______ Fiscal Y.T.D. Production, M Pounds Operating Days 5000 31 161 - 36335 244 A -ijJK.ip'll 'I' M ?: friJin-V-: -ft** HP* p-rtMW sn "I-f|M-+ 11--nL jVr T ftp" - - 1). c f >cntJ I mwMHUgrtttmuwpi jp VAB.0001191353 COMPOUND - Continued Dry Blend - continued Dry blend operated thirty-one days during May at an average rate of 16XM pounds per day. Production included 80172C, 80273G, 90172D, RP-421, RP-440, RP-200, 269-192, 269-69, 269-151, 269-203 NAT, 186-74, 269-195, WCF3-2, 223-36, and 269-164. Dry Blend production was hindered by: product changes, 64 hours; delays associated with quality and lab problems and normal Q.C., 21 hours; transfer system problems and maintenance, 28 hours; cooling blender maintenance, 15 hours; Welex maintenance, 8 hours; and Orbitran weigh computer problems and maintenance, 8 hours. Quality performance for the month of May was 99.2% customer grade. The raw material requirement for dry blend was 1.00797 pounds of raw material per pound of dry blend versus a standard of 1.00489 (YTD is 1.01068). The variable cost variance for dry blend was $103.1M favorable with $16.8M favorable due to price and $86.4M favorable due to efficiency. The efficiency variance due to product mix was $75.1M favorable. There were no major dry blend raw material efficiency variances. Plasticizer Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Pounds Operating Days 1914 62 15152 31 245 Plasticizer operated thirty-one days during May at an average rate of 62M pounds per day. All customer grade production was 610P. VRP production totaled 171M pounds (8.9%). The raw material requirement for plasticizer was 1.07102 pounds of raw materials per pound of plasticizer versus a 1.09900 standard (Y.T.D. is 1.09989). The variable cost variance for plasticizer was $42.1M favorable with $13.7M favorable due to price and $28.5M favorable due to efficiency. The efficiency variance due to product mix was $5.7M favorable. Quality Improvement Compound operators continue to chart hardness and gravity for all compounds produced on Lines I and III. Some of these charts will be distributed to specified customers starting next month. A volunteer team of operators has been formed to Improve our product-change process. Data gathering, generally using charting techniques, continues for several projects such as the dicer blade wear study, the plasticizer reaction rate investigation, etc. A a . rtit:: 't.1 (--Iv ..i . .q.-Li: VAB.0001191354 COMPOUND - Continued Compound Dry Blend Plasticizer Usage (BTU/Lb.) Actual Standard 1697.3 616.6 1567.3 1783.0 730.0 1833.5 A |s,|. fT'irih," I i-r- I I ? '1=1 ' I-Lj: 4 21 il' .It- . Fir-' ft-Ci-q-srt-^t;|!itrtH.fSfin|wri-^ *.|4i|-!r.'tii|l J -Wi|iT^-.-.r|-juiLi|-w=i| ibum- * VAB.0001191355 J. < MUI11 F iHlUT lHHH d - - I MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - D. A. Miller, G. A. Morgan There were no injuries to Maintenance Department personnel during the month. The monthly safety meeting included a review of recent accidents, accident investigations and a review of personal protective equipment. Vinyl The D745 and D300 reactor agitator seals were replaced. The seals ran twelve and nine months respectively before failure. The condensers on reactors D741, 742, 743 and 744 were drilled and brushed. The D744 condenser-to-reactor gasket failed and was replaced during the month. One of forty studs was broken off during the work and will be repaired during the October new module shutdown. The cladding on the D743 condenser lid was inspected after drilling was completed and several cracks in the cladding were noted. A spare lid was installed and repairs to the damaged lid are being planned. Cracks were also noted in the 741 condenser lid. They were not severe enough to require immediate repairs, but will be repaired when the spare lid is re-clad. The D400 condenser lid gasket failed and was replaced. A new jacket eductor was installed in D743 reactor. Eight major valves were repaired in the Vinyl reactor area. Dryer Area The #7 dryer induced draft fan was replaced during the month with a spare. The fan failure was due to a failed bearing that caused shaft damage, resulting in excessive vibration. A new flex boot was installed on #8 dryer centrifuge. A new pump case was installed on the west fluid bed hot water recirculation pump. The original carbon steel case was destroyed due to corrosion caused by pH excursions in the fluid bed heating system. The 281/282 silo transfer system large blower was overhauled. Instrumentation and Electrical The motor was replaced on the south fluid bed resin blower. The D743 agitator motor bearings failed and were replaced. A LP>>*-iAit|-4Nh . . ..................................- VAB.0001191356 i -.T ll- MECHANICAL DEPARTMENT - Continued * Instrumentation and Electrical - continued The D700 agitator motor was overhauled and its power wiring was replaced back to the starter due to a ground fault. Motors were replaced on both the #7 dryer Sweco and the old module dump Sweco. Compound, Dry Blend, Plasticizer A new vacuum pump was Installed in the Compound Line I dicer house. The Line I Banbury seals were changed. The dry blend intensive cooler shaft was repaired and the outboard bearing was replaced. Tanks 184 and 185 in the plasticizer tank farm were cleaned and inspected. No problems were noted. The Schenk filter was disassembled and cleaned. The plasticizer building #2 reactor agitator seal was replaced. Quarterly preventive maintenance was performed on the Line V and dry blend process controllers. Completed repairs and modifications to the Line III FCM orifice gate controller. The Line III //6 dicer motor was rewound. Utilities New power factor correction capacitors were installed. capacitors were disposed of. The old PCB The annual #1 boiler inspection was completed. The back wall of the fire box was replaced and new relief valves were installed. Capital Project Status - R. E. Polk AFE A5L2 - Plasticizer Modernization Phase I Materials to tie-in the south PA tank have been received. Installation is scheduled for completion by the end of June. The project will be closed to field charges by 7/15. AFE D756 - Reactor Jacket Expansion Joints Installations on D742, D743 and D744 are planned for the weeks of 6-8, 6-15 and 6-22, respectively. Joints for reactors D700 and D745 are to be installed during their respective module outages in August and October. VAB.0001191357 v-ip.!*-: -aLLPX-fi^nfr-iJ* 7 MM IF>v!ritF^4ib4?WilJrJl bl % -I .V =i ft Ms Hn-TenwIWifB^fiarWijfci|piinpipn|rnptim||| IMjjty+t-: 'l AWTiHW *nr. MECHANICAL DEPARTMENT - Continued Capital Project Status - continued AFE C566 - Master Batch Bulk Resin Handling Materials to complete punchlist and safety audit items are due by 6/12. Completion of all items is planned for 6/30, The project will be closed to field charges in July. AFE D606 - Propane Tank Farm Electrical Revisions Electrical construction is 80% complete and in progress. Materials to replace the sequence controllers on the vaporizers are due by 6/15. Installation is planned for completion by 7/1. The project will be closed to field charges in July. AFE F537 - Dry Blend Transfer Lines Design is 90% complete and in progress. Completion is scheduled for the week of 6/15. Construction is planned to begin in July with completion by 9/1. AFE F786 - Resin Quality Improvement - Permanent Facilities Construction for Phases I and II is in progress and scheduled for completion by 7/1. Modicon software will be Installed during the week of 6/15. Detail design for Phase III has begun at Litwin. Options to resolve MCC locations are being investigated by the plant and GED. A resolution is planned for June. Contracts - C. A. Clark A total of seven general service contracts and forty-two register tickets were issued during the month of May. iHWWfr-al lei ivmt rfWMirl WtT1 " -i rif-xi die VAB t wnNvifiM mwK+mi.jiinnar-iiNBtrn m nwini nmtnMw--** utma/mhtm- PROCESS ENGINEERING - V. E. Messick Resin Quality Improvement Project A. Flexible Resin Technology - A test run was conducted to optimize the amount and time of Alcotex injection in order to increase 5415 batch size with good hard particle results. The 5415 batch size is now equal to the old 5425 batch size. A test run was also conducted to evaluate alternatives to bottom addition of Alcotex. A letter was issued that outlined recommendations for handling Alcotex solution cooldown during hot weather. The dryer temperature control instrumentation Is being reviewed with GED to determine if revisions will help reduce hard particle formation. B. Rigid Resin Permanent Facilities - Equipment and instrument inquiries are being reviewed. Information on specialty items, piping specifications, tie-ins, and equipment asset numbers were given to GED personnel in Houston. Review of the area plot plans and general arrangement of the building was held in Aberdeen. Assistance was given to the construction group to outline final tie-ins to be made during a vinyl area shutdown in June. Rigid Calendering Team Activities Twelve 5305 resin samples were trialed BASF's laboratory scale calender, Eight of these samples were from an ental design and four samples had specific recipe changes. The results re being compiled by L. G. Haefner, R&D, and will be used to determine the effect of resin processing variation on calender operation and film quality. Trip reports are being issued by J. G. Cole and E. J. Meyer. SPC charts begun on six process variables in 5305 production and issued. Line III Metal Detectors The Class "A" design for metal detectors on Line III was issued and reviewed in the plant. The metal detector will detect both ferrous and non-ferrous metals. Several customer complaints have resulted from metal contamination. Blown Film Equipment The blown film equipment was started up and film was blown from 5305 Currently, cross-contamination measurement procedures are being determined Baseline cross-contamination data will be established before the 700 and 745 reactor dumplines are operational. Rigid Calendering Resin Antistat Addition System A Class "A" design for installing an Atmer 129 antistat addition system for 5305 resin was issued for plant review. Atmer 129 eliminates the calender processing variation seen with calcium stearate. Emergency Power to Initiator Freezers Operating procedures and operator training were completed for the system supplying emergency power to the initiator freezers. A .rt. fH-l J Bt'S!* !! V.-SI ! ' ' Pd iTTiinnurn ii i 11 j mm wiipPi piiimi|ipiiimi Him* 11 im mi iipii i 1 miwii mii VAB.0001191359 j .............................................................................................................................. -|>1 --n.S-.f- PROCESS ENGINEERING - Continued A Water Management Project The Water Management Project was Initiated during the month. Plant process engineering will work with PED to define alternative water sources as well as water conservation and recycle options. RQIP Environmental Team The sampling program to quantify organic loadings and performance of the plantTs wastewater system was started during the month. The goal of the program is to develop a working model of the wastewater system in order to predict the effect of Increased organic loading due to RQIP. WlUPIHiNE 5-pj' VAB.0001191360 JL, PERSONNEL - R. A. Miller EMPLOYMENT Allison H. Russell, New Hire Kenneth G. Akins, Rehire PROMOTIONS/TRANSFERS None RETIREMENTS None TERMINATIONS None TO/FROM LEAVE OF ABSENCE None A ! ht- r+rf^' i>:,ii if'i i-r1 T"* i .J i ii i i mi ............. i ........... ... ii mi i i i ii i i mii in mi ii i immiMi i m unm i^miiii nnm i i i n 11 m him h hi i i i *-,+.-*+**- VAB.0001191361 Aberdeen, Mississippi A Salaried Employees Hourly Employees Total Employees 76 * 168 244 _________MAY, 1987 MONTHLY PERSONNEL REPORT Minority Employees # Salaried 8 Hourly 65 0O 11Z 391 Employees (Hourly) Total 101 New Employees Terminations 0 0 Hourly Min Hired % Min. Hired Hourly Min Term. % Min. Term. o o DEPARTMENTS PAR # EMPLOYEES MIN. EHP. % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse 14 16 7 44 a o Gen. Plant 16 13 6 46-- o 7 0 Maintenance .aboratory 39 22 38 _ 24 a. 5 21 o o n 4 21 0 Compound m Vinyl Plasticizer 33 32 4 40 _ 32 5 28 9 2 70 28___ > * 40 a o n o o 0 0 0 0 Number of Applicants: Month 6 Year to Date 23 APPLICANT BREAKDOWN: # Minority 4 % Minority 67 # Female 1 % Female 17 Hires (Hourly) : Month 0 Year to Date Terminations (Hourly) : Month 0 Year to Date Overall Turnover 0 Projected Annual Turnover Z 2 2.9% * Includes 1 temporary employee, one Co-Op Engineer and 1 Summer Engineer. 1................................. -.-I*-nTi-._ ;irt *fl * I* n<rm------< T-*f" Tf|- iftf Hi I Ml lUll'l mil I'll IM lHIWBjgp* ..........II HI I Inn U IMM <1 I |i an 4ffi i imim mmUi i am uni il VAB.0001191362 ! 1 frtTNJ jyi i.irtrtr.rjanKnnif mwepamBainmii niiwnliiiitwida in dun i tI t OVERT11C AND ABS L'j .. r\' h. pfrUjr ij h r fihi -4 j .-*1^'H *i m-. iv hHAwmafa mufr^Ttoij i H m w i ii i up I mnmyjjfc.wmnhiciiiirniFwi= **(:wttrti-a u*k 1 ***?-. mOCWUJUCaiJJUlfiB't'ICiMMHiHfUNitiiiiP * VAB.OOOl 191363 ENERGY CONSERVATION - F. G. Jeanson I. Plant Operations Total energy consumption for May was 116.458 MMM BTUs. Energy consumption decreased to 2202 BTU/lb. from 2388 BTU/lb. In April. An adjusted CMA reduction of 57.4% was obtained for the month. The adjusted CMA reduction for fiscal 1987 Is 54.3%. II. Plant Energy Conservation Program Maintenance There were six energy related Items completed In May. All six of these items were steam leak repairs. III. Boiler Operation Boilers No. 1 No. 2 No. 3 Combustion Efficiency % May, 1987 May, 1986 8311 (1) 83.5 83.4 Note: (1) Boiler number one was not used during the month (2) Boiler number one was operated fourteen days during the month (3) Boiler number two was operated seventeen days during the month. Pi iar"! hi- r>rj'wrn--v `-t*- p-f-iitiftit ihinwiiMatt+r-n- k- -infN|v.it|BSf imitewyri1 ,t* " ' VAB.0001191364 'imam ' k- .31. 4.' "n v. Month ENERGY CONSERVATION DATA 1987 Production! MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL 38.1 5.0 7.9 19 52.9 Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 54906 1020 56.004 1059 Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU Energy Consumption, BTU/lb. Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU Energy Consumption, BTU/lb. 6.0453 10000 60.453 1143 0 92000 0 0 Total Energy Consumption, BTU/lb. 2202 Energy Consumption, MMM BTU Actual Unadjusted Actual Adjusted 1972 Base Period 116.458 95.345 223.742 CMA Reduction (%) Adjusted Unadjusted Fiscal 1987 Year-to-Date Performance 54.3% Adjusted 44.6% Unadjusted 57.4 47.9 1986 36.5 5.9 5.4 2.0 49.8 53091 1020 54.154 1087 5.3856 10000 53.856 1081 0 92000 0 0 2168 108.010 84.776 207.984 59.2 48.1 A V-CT i-.-pt- Life hllh ..irt' f. KUI H* ifl-i'lvr-: =rm" ' Ii U-MT' wf - 4 1 rt+.vrl!- VAB.0001191365 ,,J^r weniiiiiuliu iitflfwwtwir' nT ! m ENVIRONMENTAL - R. A. Frohreich Water All wastewater discharge parameters were within NPDES limits during May. The Bureau of Pollution Control sampled all four discharge points. They will check the samples to determine if NPDES discharge limits are being met. The April chronic bloassay results were issued to the State. A significant mortality was found in the 50% and 100% effluent. Additional acute bioassay testing will be conducted in June to try to determine what is causing the toxicity. Air The application for the renewal of the plant Operating Permit is being prepared. Waste Management One truckload of waste oil was shipped to Stauffer Chemical Company One truckload of reactor culls was shipped to Sun Polymers. Miscellaneous The annual environmental meeting was attended this month. A 1 T* | fw|r p .-Mr*'"***- " lft-iHH I "`I T T~ [tt1~r 'i ^ri-tr i 1 ' i)ilT 1 r r r ini i.ft iSUhimMl IlftlldfflM'iiUntun IflU-1 *li` I fillJli Mill Hi i in rlT<fc.d-<H - '"lrathimlmi Ldl VAB.0001191366 Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. Jan. - Ave. Max. Feb. - Ave. Max. Mar. - Ave. Max. Apr. - Ave. Max. May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. TABLE I WATER OCMPLIANCE WITH NFDES PERMIT PARAMETERS Flow GEM 1010 1207 1031 1075 987 1350 1062 1300 858 900 903 970 990 1177 1049 1243 BCD FEM lb./ot. 6 77 10 120 15 183 17 213 23 268 46 373 15 194 20 310 14 142 26 266 11 119 21 217 8 93 10 121 8 104 11 116 GOD FEM lb./dy. 26 311 33 404 33 406 42 527 71 846 110 1284 53 662 57 775 42 431 75 766 38 409 50 541 42 505 56 680 31 384 40 515 Sus. Solids pat LB. /TO. 14 165 23 281 23 281 37 464 13 179 24 302 18 231 28 434 10 99 13 140 19 206 35 362 33 407 78 986 8 101 11 142 A Dies. or 7.4 8.0 8.2 9.1 7.6 8.6 9.6 10.3 10.0 10.6 8.8 10.5 9.1 11.0 7.7 7.8 ML LB. Ah . 2.7 7.3 0.1 0.1 2.0 4.7 2.1 4.6 4.9 9.3 4.0 7.6 2.5 6.1 8.8 17.8 pH 7.6 8.0 7.6 7.8 7.3 7.8 7.7 7.8 7.7 8.0 7.8 8.3 8.0 8.3 8.0 8.6 Ave 32 431 - 1462 Max 43 800 - 2713 NPDES Permit Limits - May 1 through Novenfeer 30 Ave. Max. - 26 357 40 744 - 1212 - 2523 :h - ttj-' inn* = Ijr ml-;. 4#J J I. -IM MULJ*mE -irtttflr i m nni"Mi ............ . m mi inpim mi murn Wife-W. 674 13% > 6.0 13 6.0 - 9.0 28 674 13% > 6.0 13 6.0 - 9.0 28 VAB.0001191367 lUABMkfl -.m***-p 1.1 :.meJJMipimicJafllHI'. +? $11;J !-Sl;-t > . r . i . N JiTirlj h_l. 1 LABORATORY - H. G. Coleman Saf et A Hlril-irilHF' --M1-1 There were no Injuries reported during the month. D. S. Cox led this month's safety meeting; the topic was ''Safe Handling of Glassware". B. Customer Relations Customer Contacts Southwlre Company - The problems with SWC's dry time test method have been resolved. They were actually using a lower charge volume and a higher plasticizer addition temperature than their procedure indicated. We are running their dry time test on each shipment along with their volatiles test (45 minutes at 105C). A correlation will be developed with our standard tests. Twitchell - Twitchell's application (fiber coating) appears to be very sensitive to hard particles. We will attempt to select low HP resin for them and will check HP's on each compartment. Requests for Corrective Action There were no RCA's received in May. Customer Problem Reports Date Customer Product Reason 5/074 5/22 Times Fiber Chatham, VA 38601 Black High hard particles. 5/21 Precision Trim 14941 Black Pitting and burning. bill Dayton Extruded Plastics Springboro, CH 269-151 WHT145 Color too yellow; high torque. bill Flexible Technologies Abbeville, SC 17121 CB50 18031 CB50 Gels; "crow's feet". Stringers. Waivers Issued Customer Product Reason No. H8W Plastics 5385 Bulk Density 1 HT Hoechst Celanese 5305 Static Flow 5 SC IPC (Intex) 5305 Static Flow 1 RC Nibco 5305 Static Flow 2 HT ifcummwm fm .............................................................. .... VAB.0001191368 JL+*+ '!UvtttJlHtb4i uFHPIIHhJL, J'-NJVk fc*- i-tf Hi - * i .-*.-pw1 LABORATORY - Continued C. Development Lab Sumaiy nj The following Is a summary of residual VCM results on in-process samples. None of the reactor daily averages exceeded 400 ppm during the month of May, 1987. Reactor Slurries Drier 5265 5305 Blend Tanks 5265 5305 Number of Samples Average ppm, VCM 960 212 65 1.7 49 1.0 85 18.7 30 6.4 RVCM of Shipment Samples The following Is a summary of the residual VCM analysis of shipment samples for the of May, 1987. Product 5265 5305 5385 5415 5425 Debox Dry Blend Pond No. of Samples 69 65 35 50 Average RVCM, ppm 0.6 0.3 0.2 0.1 3 20 0.1 0.4 39 0.3 12 0.5 Resin Process Capabilities (CHC) - Regular (Dryer) Samples Bulk Density 5265 0.70 5305 * 0.13 5385 1.57 5415 1.21 5465 Inherent Viscosity 0.41 0.92 0.46 0.67 "L" Color Value 2.24 6.56 3.25 4.22 "A" Color Value 2.17 8.33 -- -- "B" Color Value 1.22 1.50 3.33 4.00 % on Pan (vs. 2% max.) 1.33 4.56 4.11 4.22 No (0.89) Production % thru 140m 1.33 1.18 1.21 3.04 Drytime -- Mets IR -------- (vs. 95% of control) -- ____ 0.33 0.67 1.15 (0.69) Hard Particles (% y io) -- -- 2.6 12.5 * 5305 bulk density is low because of an effort to reduce antistat at HoechstTs request A I -v- J.1 1-.|:- : f. . 1*1 rpiL1 n^l'4-.t-W^TIi *W- * : r|-L.n<-.|*4* f,.7 ^ | JfHHffWlflWl Hfljf-I ."i I * -.iMMrf* :| 1 * R* *' V**?*-*-"-f - --* I T ` +i*lM***?!*fll' VAB.0001191369 r T rtiwa I PJU.1 (mi #+*wi*r^- ttttdwi LABORATORY E. Conpomd Hardness Specific Gravity Color/Clarity Hard Particles Heat Stability Contamination Dicing Metal Total Adjustments M Lbs. (%) b 21.00 (0.27) 7.00 (0.09) - (" ) - (- ) 5.00 (0.06) - (- ) - (- ) -- (- ) 33.0 (0.42) Rejections M Lbs. (%) 26.74 - 4.50 12.00 - 3.00 22.63 7.50 (0.34) (~ ) (0.06) (0.15) (- ) (0.04) (0.29) (0.09) 76.37 (0.97) A _____ Rejections M Lbs. (%) Stability Partial Box Color Rision Torque Wise, (oonbinatiens) 3.9 0.5 13.0 9.9 11.4 (0.06) (0.01) (0.26) (0.20) (0.23) Total 38.7 (0.78) G. Miscellaneous 1. Beginning this month, we are reporting hard particles at five and seven minutes rather than three and seven. All three--minute results for the past six months have been "50+". It is hoped that the five-minute results will prove to be more useful and meaningful. 2. In-Plant TCLP testing began in May. Initial results indicate that our resins should pass the TCLP limit of 50 ppb maximum in the extract. The limit on 5265 appears to be in the 10-15 ppm range (dry resin), while all other resins tested fall in the 2-2.5 ppm range. Apparently, VCM diffuses more readily during the leaching process from the more porous resins. Work will continue in June. 3. The saturation level of water in 108P plasticizer was determined to be 0.098% at 75 F, which is less than our specification of 0.1%. Colder temperatures reduced the solubility, but the extent was not quantified. Work was initiated this month to collect some background data on resin (specifically 5305) blown film analysis. Initial indicate that cross-contamination is currently a problem (no startling revelation!) and that one must a clean, new container to gather samples. tflF-! -S ----------------------------- -------- ------- -------------- - --------- -----------if 'Hr......... .. | II ....... ................................................... ................................. MVHMMiVtoto. VAB.0001191370 r SHIPMENTS BY PRODUCT - M LBS. MAY 1987 FISCAL YEAR-TO-DATE A RESIN PLASTICIZER DRYBLEND COMPOUND TOTAL 26,792 681 4,538 7,448 39,459 215,900 6,129 36,456 58,065 316,550 NUMBER OF SHIPMENTS BY MODE RAILCAR VISTA TRUCK TRAILER ON COMMON CUSTOMER BULK i1 VAN A FLAT CAR CARRIER PICK-UP CONTAINER TOTAL RES IN-Bulk Package Export PLAST.-Bulk Package DRYBLEND-Bulk Package Export | 118 4 . 22 37 2 15 2 1 _ ......................... 3< 9 1 "1 1 4 2 1 13 1 7 38 COMPOUND-Bulk Package Export TOTAL MAY 18 162 6 _ _. + 38 60 44 30 34 1 54 139 26 102 1 459 OCTOBER NOVEMBER DECEMBER JANUARY FEBRUARY MARCH APRIL 116 41 51 2 52 160 422 146 64 39 2 64 135 450 133 46 29 1 48 133 390 193 68 44 3 89 147 544 154 50 45 3 56 143 451 181 60 56 64 129 3 493 150 53 46 4 44 140 1 438 m VAB.0001191371 J' HUH* B-UilwiW l. - T*l. * -j-p m -,^,,**4- ENERGY USAGE A o <x> CM CO <> BTU/LB in zo in > Q* oo =* MJ . . Cl in h0 Z 0S cn > uj m* tqn: _di St >3 ro ^ w jl 'i r 1,J?^'-H+tradjHJ'hBTWBpnH' -ihj i^Uc Kill-1 IVKk I fI-|T-J Monthly Moving Avg EH*****1 ^|IH'**!'|M! *> in ipi upMimtimT 4,:'^^'flWrU^tfl^^T'l1^Tt^<!|^^1^t '=m :ii-^:iT>r.- +- rnWtftl fir- ='** KHW* + ** 'nwa^wff--**mun-,jwijni VAB.0001191372 iferafrflHumilliNHPwm--u>. iM.a.Ti-qrwji^ffiriT:i jiwm'i ii-n-rt-.- MONTHLY HOURLY TURNOVER o oCVoJ KD A in Zo cn > O <A O E X LO < CD <a W cr u>< UuJ. Il UDi ro ^ P#I :.n - 4-i- -P- . -H? fir hui- K VAB.0001191373 i i 'T1" l l | l ' ir ' iTrm rnm imiTITIfyil |l ll .................fci .: i --------------- j--~"-ni-rii wtu'i i~ht~t~t "^[TiiiiiiiWfiTir"rr"irnErHnnniifcrmtni i----------------------------- ' mi in~nrnin unrun wmii 'nirurmnnir n imm n ` 1 ~ 111 ` 111 1111 i`i i `ill `fctil i bti>.ii i ii nMrtHliBi i uiui.fi' i.hiVJJvli *- ^ 1- % t M** 6.0 5.0 4.0 3.0 2.0 1.0 0 % OFF-GRADE 1.00 h- 0,75 Qj50 25 0 ABERDEEN PLANT QUALITY PERFORMANCE 10/01/86 - 09/30/87 4.0 3.0 2.0 1.0 0 Oct. , Nov Dec Jan. Feb. Mar. April May 19 mm June July Aug. Sept. Oct. `-Ml-- f'l 'Fn t T.i' '-H Fit: 1:^l' .1 i-J^i U. LSh'l IWi . n:k4-^-i-. f VAB.0001191374 .1FLF I'lFFi^^ ^TT^irmTr-ii-ri - rl ir --trJ--J1J~`,~I"T" - r - - inina-inMiiiiii^imiiiB m hi i i iiiiiiiiniimt~ L1 -H-i-aMUA '*w ii-jH >ai I! < c^h r-v. H'ir--hmr iid-aPMi 3 Lii P--H P j dl>Ui ABERDEEN PLANT INVENTORIES 10/01/86 - 09/30/87 4 -fa A 3* 1 0 :--:------ 1 ......... |f* .... *^* f i Oct. Nov. Dec.i i * T t t Jan. " --- - > i - ------------ Feb. -- Mar. ! ----------------------------------------------- u~n--r- Apr. Hay iq 86/87 i! June July Aug. Sept, i Oct. i 1 ' .fr'P< ? -.V -.r I. J 1 ' +, (r-'LV'n U. Id L T*- h- !: ,r t+,i-nl`` -I|ii 4^ T* VAB.OOOl 191375 t MM POUNDS * t MONTHLY ABERDEEN PLANT PRODUCTION 10/01/86 - 09/30/87 v h MM POUN! CM 400 350 300 250 200 150 100 50 80 t 70 60 50 40 30 20 10 h 2 1 0 Oct. Dec. i Jan. April O June -------------- Budget - - - - Actual Cumulative Sept. 20 15 10 5 VAB.0001191376 pw b rfj-ar'fih 'rt I!-.; Tfcrvar- A i.JlSr l!H__||>i*-***"i H-iAi !t-raf.m Biinr.^iBWW-r' ~iiil ff ITri irniiiiirfrn ifmiwi* mist WlPlifet* N-pil-n- 1l?p r U V. F^JJ14 * #( * ABERDEEN PLANT EFFICIENCY 10/01/86 - Q9/30/87 POUNDS OF RAW MATERIAL/POUND OF PRODUCT 1.200 1,190 1.100 1.050 Dec. i Jan iq 86/87 r +* i *i I ir-- SeptJ Oct --ir*s mi i jiF Hkti' IK il !i,Tt ti!1.. Iiu` CF-V^i* 4MV4t *mmn* '^-fW K & ! *>h. tt.-mnr: VAB.OOOl 191377 d^i-^uii]--n--|-- I -jrTT'Ti i|--r~tprtTrttr1ijininiiji [ ............................................. n ^nn I ulMH-" TllJ-J-*. :>^KU'''-h+`r-br u'jL j^v \4 I l r-'i'*-1 -- -M-