Document pm9BdzGeg2nq2N78Vbvqm2dGd

SAFETY - A. H. Sather OCCUPATIONAL INJURIES Injuries Treated First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time Injuries by Department 1979 April 1979 Year-to-Date 1978 Year-to-Date 17 2 1 10 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office Injuries by Types 8 5 5 2 0 0 Cuts and Abrasions Eye Injuries Burns Bruises Sprains and Strains Other 02 13 02 24 13 00 8 3 4 3 2 0 The doctor case which occured during the reporting period occured to a mechanic who sustained a fall while changing the mechanical seal on 741 reactor agitator. Another employee allegedly suffered a back injury while bagging compound on Line I. The injury occured following an unfavorable grievance reply. Following examinations by the local Company doctor and a neurosurgeon with no objective findings, the injury was reclassified to no injury. As of April 30, 1979, the plant operated 348,391 manhours or 267 days without a disabling injury. LIFTING TRAINING Due to the incidence of several back injuries to-date in 1979, the Safety Department prepared a lifting training program. Training methodology chosen involved the Safety Director training plant supervisors with a written outline, a lifting safety booklet, and a film. Once trained, supervisors presented the program to their personnel. As of the end of the month, 83 percent of the supervisors had received the training and 75 percent of the supervisors had completed their shift (crew) training responsibilities. The remainder of the training will be completed in May. DTH 000019143 1 RIGGING TRAINING The first phase of the Mechanical Department rigging training program was completed during the latter part of the reporting period and the first week * of May. Two films were shown. The first, "He Forgot,"was on crane safety and the second, "Rigging With Wire Rope Slings." Several comments by the Safety and Mechanical Department regarding plant practices were made follow ing each film. OSHA COMPLIANCE During the reporting period, comments on the lead sampling plan were received and the plan was altered accordingly. The new sampling data collection * forms have been sent out for printing. Initial write-ups of the Laboratory and Compound Department-Line I process descriptions were returned to the originators with corrections requested. Also, a process design for the Building Ventilation System Baghouse Air Compressor was issued by Process Engineering and circulated for review. VCM DOSIMETRY Sixty-four (64) samples were taken with three (3) indicating overexposure of 1.0 ppm or greater. The distribution of results and a brief explanation of overexposures are shown below: Range (ppm) Number Percent 0.0 - 0.5 0.5 - 1.0 1.0 - 5.0 5.0+ 60 1 2 1 64 93.75 1.56 3.13 1.56 100.00 One overexposure occured when a Vinyl Operator traced down a leak on 744 reactor condenser. He was wearing a respirator. A second overexposure occured to a Mechanical Supervisor who spent most of the day working near the resin storage silos. It has been concluded that the overexposure was due to VCM-contaminated air from the silos. The third overexposure occured to a Maintenance employee who spent most of the day repairing ah air conditioner on the Laboratory/Safety office area roof. The cause is still under investigation. ' DTH 000019144 VINYL - E. L. Kieschnick April had 30 accounting days (Y.T.D. is 120 accounting days). Production Month Y.T.D. Standard 1. Total Production, MM #'s 2. Production Rate, M #'s/C.D. 3. Charging, Rx B.A.'s/C.D. 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average #'s/Hr. 7. Dryers, Stream Factor, % 25.0 833 21.3 640 89.4 5470 90.6 94.9 791 20.2 2421 86.5 5424 86.7 904 The vinyl department production for the month was 25.0 KM pounds with the dryers continuing to perform well. The reactor performance for the month was down slightly from March as a direct result of a 3-5 minute power failure sustained on Tuesday, April 3rd. The plant was returned to normal operation without a VCM release after the power failure. However, the loss of power did result in seal damage to D-300, 400, and 600 reactors which had to be repaired. D-300 required significant agitator seal housing repair work. Items which have or will contribute to improved reactor production are listed below: 1. The D-300 condenser was brushed and chemically cleaned during the agitator seal housing repair. An improved seal water supply system was also installed. 2. The condensers on 742, 744, and D-500 were brushed and chemically cleaned. 3. The reduction in chem wash and swirl frequently on 5425 and the elimination of swirl on 5385 continues with no adverse effect on resin quality. 4. A dual initiator test run for reduction in 5425 polymerization times was completed on 4/27/79 with results being quite favorable. The new initiator was ordered for delivery on 5/4/7? to coincide with final Ponca City PAL testing of the resin. 5. An improved initiator test run for reduction of 5465 polymerization times is scheduled for early May. 6. The Diamond Shamrock anti-foam agent, 160L, was tested and approved for use during the month. Delivery of the material is expected by mid-May. DTH 000019145 Resin Quality Summary Resin Type Prime Pounds "BC" Grade "H" Grade % of Total Production 5305 5385 5425 5465 Sifter Overflow 1*635,146 18,014,894 4,210,656 670,906 51,750 25,500 37,450 8,100 53,350 33,750 25,100 218,541 0.24 0.32 0.28 0.10 0.87 TOTAL 24,531,602 114,700 338,841 1.81 Quality performance for the month of April was 98.19% customer grade with 0.46% "BC" and 1.35% "H" grade. The "H" grade 5425 and 5465 were due primarily to contamination and gels. The 5305 was a result of high moisture. The variable cost variance for the vinyl department was ($264.1 M) with ($230.1) due to price and $6.0 M due to efficiency. The only major price variance was ($249.2 M) on VCM. The only major efficiency variance was ($17.0 M) on VCM. The raw material requirement for the month was 1.02416 pounds VCM/pound PVC versus a 1.01960 standard. DTH 000019146 COMPOUND - C. R. Miller April had 3.0 accounting days (Y.T.D. is 120 accounting days). Compound Production Month #'s/Day Y.T.D. Line I, M Pounds Line III, M Pounds Total, M Pounds 1,686 56 5,816 3,234 108 11,442 4,920 164 17,258 Line I operated thirty days during the month at an average rate of 56 M pounds per day. Major items affecting productivity were the number of product changes (20 products - 45.8 hours total), maintenance on the Banbury gate and seals (14.6 hours) and on the compound dicers (24.9 hours). Line III averaged 108 M pounds per day. Production included compounds for Tenex, Western Electric, Superior and Kaiser. Major items affecting pro ductivity were the number of product changes (12 changes - 29 hours) and maintenance on the FCM seals and clutch (23,1 hours). Total prime grade production for the month was 5.25 MM pounds, representing a new production record for a two compound line operation. This total includes 350 M pounds of "BC" inventory which was reprocessed into prime grade material. Quality performance on flexible compound was 1.6% of which 98.6% was due to mill scrap. "BC" production for the month was 1.7%. The raw material requirement for flexible compound was 1.01101 pounds raw materials/pound of compound versus a 1.01302 standard (Y.T.D. is 1.00877). The variable cost variance for compound was $44.0 with $9.6 M due to price and $34.4 M due to efficiency. Variance due to product mix was $31.1 M. There were no major efficiency variances for the month. The only major price variance was $16.0 M for combined colors. Dry Blend Month s/Day Y.T.D. Total Production, M Pounds 3,092 182 15,791 Dry Blend operated seventeen days during the month at an average rate of 182 M pounds per day. Dry Blend production was limited by sales and inventory control programs. Production included 80172-B, 80273-G, 90171 and a new formulation 80274. The 80274 dry blend utilizes off-specification 5425 and 5465 resins. Quality performance for the month was 97.4%. The off-grade for the month resulted from an operational error in stabilizer usage. Off-grade material continues to be reworked at a 3% level. The raw material requirement for dry blend was 1.00170 pounds raw materials/ pound of dry blend versus a 1.00319 standard (Y.T.D. is 1.00275), DTH 000019147 Dry Blend- (continued) The variable cost variance for dry blend was ($58.6 M) with ($2.4 M) due to price and ($56.2 M) due to efficiency. Variance due to product mix was ($31.2 M). The only major efficiency variance for the month was ($35.3 M) for combined 80172-B stabilizers. This variance reflects an inventory correction following a warehouse physical count. There were no major price variances for the month. Plasticizer Month # * s/Day Y.T.D. Total Production, M Pounds 1,127 71 4,099 Plasticizer operated sixteen days during the month at an average rate of 71 M pounds per day. Plasticizer production was limited by phthalic anhydride availability due to supplier shortages. Production of plasticizers included DOP, 610-P, and DIDP. VRP production for the month was ,79 M pounds (7%), The raw material requirement for plasticizer was 1.11072 pounds raw materials per pound of plasticizer versus a 1,10181 standard. (Y.T.D. is 1.12645). The variable cost for plasticizer was $5.0 M with $9.3 M due to price and ($4.3 M) due to efficiency. Variance due to product mix was ($7.9 M). There were no major price or efficiency variances for the month. General Total customer grade compound inventory increased from 5.1 MM pounds to 6.5 Ml pounds during April. DTH 000019148 MECHANICAL - S. J. Vincent Vinyl - Area I A major shutdown for D-300 reactor was completed during this period. Various problems had been encountered with this reactor including several mechanical seal failures, major gearbox repairs, and some major control problems with the process. When the unit was taken out of service the following major repair work was completed: The condenser was drilled and chemically cleaned on the shell side. Anew condenser spool piece was installed to eliminate congested piping and safety hazards on the top of the condenser. All of the associated control equipment had to be revised and major wiring revisions completed. All the switchgear and instrumentation went through preventative maintenance. The bottom drive gearbox was removed from the reactor and rebuilt in the maintenance shop. Major gear and bearings were repaired and the mechanical seal housing had to be sleeved installed at a local machine shop. New type square rupture disc holders were installed on this reactor also. The condenser spary head was also replaced. The other reactor condensers cleaned were on D-500, 742, and 744 reactors. The water side of these condensers was also chemically cleaned using sulfuric acid. All reactor condensers will be eventually chemically cleaned to reduce tube fouling so that better control of the reaction process will result. There were four major reactor mechanical seal failures. The reactor seals were replaced on D-300 as stated above and on D-400, D-600, and 741 reactors. Process valves that were either repaired or replaced were the VCM charge valve on D-400, the condenser, recovery, chemical wash, and both rinse valves on 742 reactor, and the rinse and recovery valves on 744 reactors. All of the rupture discs were replaced on 742 reactor. Numerous other safety discs were replaced based upon the weekly inspection list provided by process engineering. Various rotometers were installed in the old reactor area. The PVA tank temperature controller was calibrated. Several steam stripping valves were repacked in the old module also. One of the trunion bearings was repaired on number seven dryer along with replacing the drive sprocket and chain. An electric vibrator was installed on number six dryer inlet chute to evaluate its performance and durability in that service. Number four dryer torque indication was calibrated. One of the sensor heads on the newly installed anti-chatter devices failed and had to be replaced. Handrails and access ladders were installed on top of all seven of the dryer day collectors. There were ten mechanical seals replaced on various pumps and compressors. Major overhauls were performed on one of the recovery system vacuum pumps and one of the small Corken compressors, A new check valve was installed in the PVA system. The valve operator was rebuilt for one of the isolation valves on a recovery vacuum pump. Numerous problems in the old unit recovery system required an extended amount of troubleshooting and coverage. A committee was selected to review the system and provide recommendations for corrective action. DTH 000019149 The south knockout drum was blanked for cleaning in the new module. Both recovery condensers were cleaned in the old module. Platforms were revised to be used for the AMS addition system. The steam sparging pipe in the new unit blowdown tank was replaced. Several steam leaks were repaired through out the plant. A leak repair contractor repaired several major steam leaks without a steam shutdown. Compound, Dry Blend, Plasticizer, and Storage Silos - Area II The seals were changed on both the Banbury and FCM systems. Several dicer repairs were made to both lines. The drive shaft bearings on one of the Welex units was replaced. The screen was changed once on the Kason screener. An underground water leak on the east side of Line III was repaired. The new bag check scale was installed in the Automatic palletizer system. One of the laboratory mills was rebuilt. One of the Plasticizer blowers was disassembled and repaired. Various operational problems have caused erratic use of this unit. To provide more reliable service one stage was removed and a spacer installed per the manu facturers instructions. Major problems with the Phthalic Anhydride transfer system resulted in extensive repair downtime. In addition to line plugs, both unloading pumps had to be rebuilt. The silo sampler was re-installed for further evaluation. The resin transfer system for the large storage silos was repaired. Several silo level indicators were repaired. Some electrical revisions were continuing in the Dry Blend area. Utilities and Services Seven air compressor valve repairs were completed during this period. The safety office air conditioning compressor was replaced. The initial pressure checkout for the new propane vaporizer system was completed. Several process valves, safety valves, and tools were repaired. A new water meter was installed on the east plant main header. The SPI sump pump was rebuilt. Our spare Philadelphia gearbox was sent to a machine shop for major repairs. The gearbox will be dismantled, machine checked, inspected and then rebuilt. Planning The planners work involved processing 42 invoices for payment and processing 42 register tickets. The D-300 shutdown plan and arrow diagram was drawn up. The material for 12 projects was ordered, Miscellaneous The new Maintenance Management System was implemented at the beginning of April. There appears to be a smooth transition from the old system to MMS. DTH 000019150 PERSONNEL - J. L. CARTER EMPLOYMENT Donald F. Johnson, Vinyl Shift Supervisor and Samuel Vick, III, Process Engineer. TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTION None. RETIREMENTS None. TERMINATIONS Gary Faulkner, Vinyl Shift Supervisor. DEATH/DISABILITY None. DTH 000019151 CONOCO CHEMICALS Aberdeen, Mississippi APRIL 1979 MONTHLY PERSONNEL REPORT Salaried Employees 73* Minority Employees = Hourly Employees 161 Salaried 3 4% Total Employees Employees (Hourly) 234* Hourly 63 39% Total 66 38% New Employees Terminations -0-0- DEPARTMENTS PAR # EMPLOYEES MIN. EMP. Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. -0-0-0- ___ =b____ % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse 9 Gen. Plant 10 Maintenance 46 Laboratory 22 Compound 38 Vinyl 32 9 11 45 22 38 32 2 22% 0 0 0 0 0 0 5 45% 0 0 0 3 0 27% 7 15% 0 0 0 1 0 2% 3 14% 0 0 0 0 0 0 30 79% 0 0 0 0 0 0 13 41% 0 0 0 0 0 0 Plasticizer 4 4 3 75% 0 0 0 0 0 0 Number of Applicants: Month 2 Year to Date 5 APPLICANT BREAKDOWN: # Minority 0 % Minority 0 * Female 0 % Female 0 `Includes one co-op student and two other temporary employees. Hires (Hourly) : Month 0 Year to Date 0 Terminations (Hourly) : Month. 0 Year to Date 4 Overall Turnover 0 Projected Annual Turnover 2.5% DTH 000019152 (2) Non-Controliable Overtime - th a t overtime due to working re g u la r hours on a h o lid a y and working re g u la r hours on the s ix th day in operations. PROCESS ENGINEERING - R. A. Frohreich A. Specialty Compound Line Crawford and Russel has completed the mechanical design for the project. Their only remaining work is to complete the mechanical catalogs. The piping/structural basis of bids was completed and is presently out for bid. The mechanical completion as estimated by CED is now October 15, 1979, an extension of four weeks due to the delay in the issue of the electrical/instrumentation basis of bids. B. Fire Water Revisions - Phase I Mechanical Engineering for the projects is continuing. The underground piping basis of bids is expected to be received in the plant in late May. C. Propane Vaporizer Replacement Electrical bid packs have been issued. D. Plasticizer Exposure Abatement Mechanical Engineering is complete on the project and the plant has received the bid packages. Issue of the bid packages has been delayed because of late delivery of the filter. E. Charge Water Heating Improvements System installation is being completed. Start-up is estimated for mid May. An operating procedure for the project has been issued. F. Silo High Level Alarms The prototype sensing element is in operation and is being tested. G. Plant Dryer Debottlenecking 1. Remote Dryer Lighting Plant mechanical engineering is proceeding on the project. All major equipment has been received. A system will be installed and tested. Project completion is expected by the end of July. 2. V-10 Transfer System Plant mechanical engineering is proceeding on the project. All major pieces of equipment has been ordered. Mechanical completion is projected to be the end of July. DTH 000019154 H. SiloIsolation Valves Valves are on order. Installation will proceed as soon as the valves are received. J. Automatic Plasticizer Weighup System The revised process design was issued. Hie panel drawings were approved for construction. Panel delivery is scheduled for the end of July. K. Emission Recovery System A definitive cost estimate was prepared for the modifications to the emission recovery system to improve level control and to install an additional vacuum pump. An AFE request was submitted for the project. L. Plant Air System A study of the plant air system has been completed and reviewed. Process designs for two parts of their study have been issued for review and estimating. These designs include a new reactor area instrument air dryer and a new centrifugal air compressor for plant air. M. VCM Receiver Back-Up High Level Alarm Two test sensors have been ordered. These include a capacitance type and a sonic type. The capacitance probe type sensor has been received. Installation is scheduled for first shutdown on the new unit. N. Reactor Inert Vent Design A class A process design for this project has been issued. The design is presently being cost estimated. O. QMS Addition System A revised process design has been issued for this project. A cost estimate is being prepared. P. New Slurry Blend Tank A process design was issued for a new 150f000 gallon slurry blend tank for use in multigrade resin production. The design has been sent to CED for cost estimation. DTH 000019155 ENVIRONMENTAL HEALTH - J. R. McCrimon I. Particulates The exhausts from one of the resin dryers was sampled for particulates. The rental vacuum cleanup system has been evaluated and found to work well. A purchase order was issued for the unit. Engineering is underway to add options to the unit. The remaining' equipment should be in the plant by late June. II. Water BOD and COD levels were within NPDES permit limitations in April. An application for renewal of our current NPDES permit was submitted and storm water runoff sources were included. The quarterly NPDES report was submitted to the Mississippi Air and Water Pollution Control Commission. PED personnel were in the plant to run a source sampling program to define flow rates and loadings from the various areas of the plant. This data will be used to determine the effect of increased plasticizer production and resin expansion on the plant waste water treatment system. Methods of eliminating the pond irritant are being investigated. Aerators operated 24 hours per day all of this period. III. Vinyl Chloride PED personnel were in the plant to discuss methods to improve EPA compliance. Efforts have been intensified to come closer to compliance 100% of the time. In-plant emission testing and leak checking are continuing as specified in the Compliance Manual. The "Leak Detection Program" was revised and updated. DTH 000019156 Flow GPM Jan. - Ave. Max. 788 948 Feb. - Ave. Max. 756 773 Mar. - Ave. Max. kfir. - Ave. Max. 669 760 743 930 May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sbpt. - 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. Diss. 02 26 246 37 307 63 589 94 781 19 170 6.9-7.3 31 279 30 272 43 380 17 134 24 184 6 55 9 73 73 656 95 840 61 490 81 621 33 295 42 446 27 241 6.9,7.9 34 315 26 214 6,9-7,6 45 367 10 85 6.9-7.3 16 130 NPDES - Ave. Max. - 32 387 43 520 - 1390 - 1940 - 605 - 909 6.0 Ph 7.5-8.2 7.7-8.0 7.3-7.9 7.3 6.0-8.5 DTH 000019157 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for April was 111.9 >*4M BTUs. The energy consumption per pound of product decreased from 3308 BTU/lb. to 3272 BTU/lb. in April. II. Plant Energy Conservation Program A. Steam Leaks 17 of 18 reported steam leaks were repaired during April. B. Charge Water Heating Improvements Installation of hot water preheater was started, in April. Initial start-up should begin next month. C. Boiler Burner Replacement Equipment arrived at the plant in April. Installation will start in mid-May. DTH 000019158 ITEM ENERGY CONSERVATION DATA 1978 1979 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. 1978 1979 392 416 405 428 436 463 April 20.3 3.0 3.7 1.1 28.1 47791 1020 48.747 4.429 10000 44.290 April 25.0 3.1 4.9 1.2 34.2 60481 1020 61.691 5.0208 10000 50.208 93.037 3311 111.899 3272 Avg. % Excess Air 1978 1979 102 100 80 94 86 120 DTH 000019159 MECHANICAL ENGINEERING - J. A. Dixon AFE'.s Submitted, Approved and Closed The following AFE was submitted and approved during April: AFE No. Title Authorized 9559 Color Weigh Room Modification $ 25,000 The following projects were submitted for AFE approval during April: Title Authorized Miscellaneous Projects Under $10,000 $125,000 Additional Office Space $ 12,500 The following AFE's were closed to field charges during April: AFE No. 9187 9267 9287 Title Emergency Reactor Vent Control Dry Blend Production Expansion Plasticizer Yield Improvement Test Authorized $ 33,000 $200,000 $ 6,000 There were no completion reports issued in April. Design Bids were requested for the Inert Gas Generator Shed, Emergency Lighting Generator Shed, Miscellaneous Painting Projects, Electrical for Hot Water Charge Improvements, Sprinkler System for Safety and Maintenance Offices, Installation of Silo 282 Dust Collector, Silo Rescue Davits, Line III Take-Off Conveyors, and Specialty Compound Line Piping, Instrumentation, Equipment and Steel Structure. Design work is in progress on the following projects: Dryer Operation Improvements, Resin Transfer Debottlenecking, Fire Protection Improvements, Office Expansion, Propane Vaporizer Replacement Electrical, Boiler Burner Replace ment, Dry Blend Silo Alarms, and High Level Alarms for VCM Storage Vessels. Construction 1. Installation of isolation damper in fresh air system to the control room is complete. 2. The piping and vessel modifications for the Propane Vaporizer Replacement project is complete. DTH 000019160 Construction - (continued) 3. The plugged portion of the VCM charge line was replaced. 4. The damaged underground conduit for line III was disconnected and installed above grade. 5. The rail switch on the scale lead was repaired. 6. The concrete and site work for the Schenk filter is complete. 7. Work on the following projects is in progress: Dryer Operation Improvements, Insulation of Propane Vaporizer Project, TV Monitor Installation, Hot Water Charge Improvements, Inert Gas Generator, Dry Blend Silo Alarms, Plasticizer Chemical Exposure Abatement, Offsites Piping and Electrical for Specialty Compound Line, and Foundation for New Compounder and Building, DTH 000019161 (1) Thru March, 1979 Actual Accounting (2) Thru April, 1979 ABERDEEN AUTHORISATIONS REPORT AUTH. CAPITAL NO. DESCRIPTION DATE AUTH. APPROVED AFE AMT. CD (2) FINAL UNDER EST. EST. EXPENDED COWIITTED TOTAL EST. (OVER) COMP. CLOS. TO DATE TO DATE COST COMP. AUTH. AMT. DATE DATE REMARKS 9529 Miscellaneous Projects Under $10,000 2/15/79 125,000 21,120 74,293 125,000 0 12/79 3/80 Twenty-nine projects approved, 9559 Laboratory Equipaent 9549 Safety Equipaent 3/27/79 3/26/79 31,000 1 15,000 0 0 0 31,000 0 15,000 0 10/79 1/80 Purchases proceeding. 0 10/79 1/80 Quotes being obtained. 9238 EXPENSE Coapound Line I Roof Collapse 12/13/78 44,000 0 0 44,000 0 6/79 ' 7/79 Insurance claia filed. Hi i \ DTH 000019162 LABORATORY - R. B. Martin CUSTOMER COMPLAINTS Customer Product Complaint Type Complaint No. Status Resin None Compound Kaiser Aluminum Sometco 34431 Compound Dicing Problems `Poor Pallets ACP-040679 Answer by CRM ACS-032679 Under Investigation Dry Blend None Date 4/2 4/3 4/4 4/5 4/5 4/5 4/5 4/6 4/6 4/9 4/10 4/16 4/16 4/17 4/18 4/19 4/19 4/23 4/23 4/23 4/23 4/26 4/26 4/30 4/30 4/30 TOTAL Identification WAIVERS RECEIVED Product Customer Reason Waived by.. PLCX 42984 PTLX 41863 80473G 5305 Bags 00339 29147 PLCX 43197 PTLX 42031 5385 5385 5385 5385 PLCX 43218 5465 Miller T/T T-2 T-2481 Bags 00570 PLCX 43040 PLCX 43214 Bag 00586,00587 00590,00591 PLCX 42664 T-2809 T-2479 PTLX 41828 CONX 45291 CONX 45701 PLCX 43235 Bags 00601,00602 PLCX 43221 Bags 00609 PLCX 43208 PLCX 43198 PTLX 41862 26 VRP 5385 80172B 5305 5385 5385 5385 5385 5385 5385 5385 5385 5385 5385 5385 5385 5425 5385 5305 5385 5385 Can-Tex Mineral Wells Carlon Expost-New Zealand Export-New Zealand Simpson, WA World of Plastics, Florida Inmont Heritage Certain-Teed Can-Tex Uniroyal Simpson, WA Tridyn Eximplas Eximplas Simpson, ORE Jet Stream, IA Jet Stream, IA Tridyn Simpson, ORE Charlotte Pipe LCP Eximplas Southwire Eximplas C E Terminal Simpson, ORE Simpson, WA Fursion Torque Residual VCM Dry Time Dry Time Particle Size Particle Size Contamination, Particle Size Color Particle Size Stability Time Particle Size Particle Size Particle Size Particle Size Particle Size Particle Size Particle Size Particle Size Particle Size Particle Size Particle Size Particle Size Particle Size Contamination Particle Size Moisture Particle Size Particle Size RDJ Customer J. Stone GGD GGD GGD GGD GGD Customer RDJ RDJ RBM RDJ CLS CLS CLS RDJ GGD RDJ RDJ GGD GGD GGD GGD RDJ RDJ GGD GGD GGD DTH 000019163 QUALITY CONTROL TESTING Resin - Regular Samples - 686 Bulk Resin Shipments - 170 Other In-Process Resin Samples = 2234 (Resin Railcars = 91) (Resin Hopper Trucks * 170) Dry Blend - Blenders Produced * 345 Belnders Tested = 175 Blenders Adjusted = 2.6% Other In-Process Dry Blend Samples =112 Dry Blend Bulk Shipments - 36 (Dry Blend Railcars = 12) (Dry Blend Hopper Trucks = 24) Compound - Blenders Produced = 842 Blenders Adjusted = 1.8% (Compound Railcars = 12) Other In-Process Compound Samples = 259 Compound Bulk Shipments = 26 (Compound Hopper Trucks = 14) Resin Heat Stability Oven heat stability tests were run on forty-four (44) blends of resin. 5385 - 16 Blends 5425 r 17 Blends 5305 - 6 Blends 5465 - 5 Blends All the blends passed the test. Residual VCM in Shipments A total of 86 samples from bulk shipments were tested for RVCM in April. The summary by product is listed below: 5385 5305 5465 5425 Dry Blend Average, RVCM # Samples 0.8 62 4.5 0.1 20 3 0.2 0.4 13 8 Raw Material Testing Fifty (50) lots of assorted plant raw materials were tested. Another shipment of Tribase lead stabilizer was rejected this month for poor dispersion. Three lots of Methocel F-50 were rejected because they failed to meet the specification for solution viscosity. Monsanto was approved as a supplier of phthalic anhydride after acceptable property values were measured on a sample of their product. PRODUCT DEVELOPMENT 8 SERVICE Date Shipped Quantity Product Customer 4/2 50# 38233 Blk. Belden Corp. 4/3 50# 5425 LCP Plastics 4/3 50# 5305 Thermoclad Requested Shipped by ____ MAS HAP JTW HAP JTW HAP ' DTH 000019164 Date Shipped 4/3 4/3 4/4 4/5 4/8 4/12 4/29 4/29 PRODUCT DEVELOPMENT SERVICE (CONT.) Quantity Product Customer Requested Shipped by by 50# 18031 Cl. Bl. 50 Wilson Spoorting MAS HAP Goods R 8 D 50# 15041 Cl. Bl. 50 50# 5385 General Cable Corp. RDJ HAP 50# 5305 Norsk Hydro Research GGD HAP 50# 5385 Norsk Hydro Research GGD HAP 50# 5425 Norsk Hydro Research GGD HAP 50# 5465 Norsk Hydro Research GGD HAP 5# 5305 Sylvania Chemical RNG JRN 5# 5385 Sylvania Chemical RNG JRW 5# 5425 Sylvania Chemical RNG JRW 50# 26831 Blk. Source Plastics MAS JRW 50# 18031 Cl. Bl. 50 Vinyl Plastics, Inc. MAS JRW 50# 28831 Blk. Uniflair, -Inc. RNG JRW COMPOUND DEVELOPMENT AND SERVICE Special Compoud Testing Western Electric specification tests were run on 2 lots of 34861 Gray 546 and 4 lots of 36861 Natural. Customer Service Brittle point tests were run for Southwire on 6 of their experimental compounds. SPECIAL PROJECTS Resin Volume Resistivity Volume resistivity measurements were made on 4 lots of 5425 resin and 1 lot of 5465 resin. All samples gave typical values for VR. Chrysler Gel Test Resin with different gel ratings by the Conoco test were run by the Chrysler gel test. It appeared that Chrysler will continue to require a Type I gel level. Residual VCM in Slurry A total of 607 samples out of 635 batches produced were tested for RVCM in April. The overall average was 216 ppm with only one day being above 400 ppm. The daily average tanged from 112 ppm to 335 ppm (excluding the one day above 400 ppm). Residual VCM in 5305 Dryer Samples The samples of 5305 taken from the dryers dropped in RVCM levels during the month. The maximum RVCM concentration in April was 68 ppm. DTH 000019165 SPECIAL PROJECTS (CONT.) Waste Water Test Run Die waste water test program was completed in April with 44 samples being tested for COD, % solids and ph. All data was transmitted to Louis Evans in Ponca City. This data will be used to project future needs in the waste treatment system. Western Electric Complaint As a result of a complaint from Western Electric concerning the contamination of DIDP with DOP, a research project was conpleted to monitor DOP in DIDP. The initial data showed high levels of DOP in routine DIDP production. Tfye new test method has been used to resolve the source of this problem. Production batches are now under examination with this test method. DTH 000019166 ORDER ENTRY AND TRANSPORTATION WAREHOUSE - J. C. Coffman J. E. Mays Shipment by Product - M Lbs. Agril Year-to-Date Resin Plasticizer Dry Blend Compound 21,312 86 3,081 3.700 69,690 419 16,191 16,992 TOTAL 28,179 103,292 Number of Shipments by Mode R/C O.T. C.C. C.O.T. TOFC CPU TOTAL Resin - Bulk - Package - Export - Aberdeen 96 68 9 1 58 6 4 174 3 6 18 59 Plasticizer - Bulk 22 Dry Blend - Bulk - Package 10 11 5 2 11 34 49 Compound - Bulk - Package 10 14 26 ll7 T5T" 3 11 1 1 24 1 15 46 4 42 366 Back Hauls for April 25 25 Number of Shipments by Month - Y. T.D. R/C O.T. C.C. C.O.T. TOFC CPU TOTAL January February March April 103 166 101 119 110 145 117 191 12 10 21 11 7 0 2 1 7 56 351 3 36 269 8 49 335 4 42 366 Material Handling Report Packaged Resin From Production Packaged Compound, Dry Blend From Prod Transferred From Main to Prairie Transferred From Prairie to Prairie Reverse Transfer Resin to Plant Reverse Transfer Compound to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Main M/Lbs. 2,916 2,714 1,499 283 203 648 4,779 2,349 1,417 16,808 T/L 72 67 37 7 5 16 118 58 35 715 DTH 000019167 LOCATION MAIN-East CONOCO TRANSPORTATION f // ABERDEEN WAREHOUSE TOTAL H B. CONTENTS 0 Compounds Dry Blend Export Resin Conoco Resin ESTIMATED MM POUNPS ON FLOOR *. . OPEN TBTAL 00 (*) .7 __ -2 .5 5.2 4.3 9.5 Prairie 12-1 12-2 * .12-3 12 22 * 2.1 12-4 12-5 22 21 12-6 21 Conoco Compound Dry Blend t Comp O.G. Raw Materials Conoco Resin Conoco Resin Resin O.G. Mill Scraps Cmpd 0. G. Dry Blend 0. G. Sifter Overflow Resin 0. G. Conoco .1,3 ..... ,1 .2 2. 1. 1 - ,8 .3 .2 1.0 1.0 _____ Li_JLA__3.5 .7 2-8 3.5 2.4 1.1 3.5 ___LJL__L2__-2.5 as 3.5 12-7 12-8 * 21 21 , Conoco Conoco Total on Hand Chrysler Resin a 5 3.5 3.5 3.5 11.0 23 .0 34.0 (- 2.0 ) . Total 20.9 _____ Total Conoco___ '__ 9.0 DTH 000019168^ Off-Grade In Storage Material M/Lbs. T/L Sifter Overflow Resin "BC" Resin "H" Mill Scraps Compound MB" Compound "H" Dry Blend "O.G." 165 839 1,154 57 710 62 296 3,283 4 21 28 1 18 2 7 81 Chrysler Storage Balance, April Transferred during month 1,954 0 1,954 48 0 48 D. F. Operation During the month of April sales and production balanced themselves out and warehouse inventory remained the same as previous month. We had an Eximplast order at the end of the month 2.2 M pounds of 5385 type I and type III resin. Since we do not have a great amount of type I resin, hopefully production will come through and we can meet the deadline of May 9. DTH 000019169 INJURY FREQUENCY* X 100 ABERDEEN FIRST-AID CASES 12 MONTHS MOVING AVERAGE DTH 000019170 ABERDEEN OSHA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE 20 15 10 5 0 June DTH 000019171 MONTHLY HOURLY TURNOVER IQ 9 8 7 6 5 4 3 7 1 C IM Pounds r*+ ' : i,> : ',ABERDEEN PLANT PRODUCTION 1979 Ml Pounds POUNDS OF RAW MATERIAL/POUND OF PRODUCT DTH 000019174 % Off Grade PLANT Q'JA^ITY ?5R?0.?LVAVC." ' 1979 '***`r? '4 * v * ; ' "v-:;v .' : Standard 0.40 Standard 0.739 Standard 2.0 ' DTH-, 00019175 ./ ABERDEEN PLANT INVENTORIES 1979 ' DTH 000019176 QNC YEAR DV MONTHS