Document q3Y20vnj91786v0dBJZyJVZME

(1) SAFETY - A. H. Sather Occupational Injuries Injuries Treated First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time March 3 1 0 0 0 1981 Year to Date 7 1 0 0 0 1980 Year to Date 16 8 1 3 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 0 0 2 1 1 0 06 27 4 10 12 10 00 Injuries by Type Cuts and Abrasion Eye Injuries Burns Brusies Strains and Sprains Other 2 0 0 0 1 1 5 11 02 12 15 14 13 As of March 31, 1981, the plant operated^ 635 days or 822,555 manhours without a disabling injury. The first medical case injury for the year occured March 6, 1981. This established a new record of 197 days of operating time between medical case injuries versus 177 days for the previous record. Safety Meetings The topic for March safety meetings was the new "Fire Prevention and Emergency Plan" for the Aberdeen Chemical Plant. One safety meeting was conducted for the plant expansion contractor. The topic of this meeting was "The Convincer" slide and tape show. Chemicals Safety Meetings A. H. Sather attended the Chemicals Safety and Industrial Hygiene Meetings held in the San Antonio, TX area, March 3"6, 1981 DTH 000019104 SAFETY - (continued) (2) Insurance Inspection John A. Krembs of Marsh and McLennan Protection Consultants (M MPC) con ducted an inspection of the Aberdeen Chemical Plant March 24, 25, and 26, 1981. Several minor items were noted for correction. He reviewed the plant fire water system and plans for the remaining portions of the fire water expansion. Also, he reviewed the plans for the emergency cooling water project and made recom mendations. OSHA Compliance Activity for the reporting period included scheduling for hands-on physicals and routine dosimetry as noted below. Sample Results Chemical <PEL Number Percent > PEL Overexposures Number Percent VCM Lead Antimony Total Particulates 83 95 22 100 22 100 7 100 45 00 00 00 Overexposures Four (4) VCM overexposures occured during the reporting period. One occured to a Vinyl operator who was wearing a respirator during a VCM filter pack change. The remaining overexposures to personnel who were not wearing a respirator. One occured to a Vinyl operator working in the old reactor module near a leaking vacuum pump seal flush line. The remaining overexposures occured to a Vinyl Oper ator and an instrument technician. No sources of overexposure were isolated. DTH 000019105 (3) VINYL - P. E. Markey Product ion Month Year to Date 1. Total Production, MM Lbs. 2. Production Rate, M Lbs./C.D. 3- Charges, Reactor Batches/C.D. 4. Total Charges 5 Reactor Stream Factor, % 6. Dryer Rates, Average Lbs./Hr. 7. Dryer Stream Factor, % 8. Accounting Days 28.3 913 22.6 702 90.7 5961 91.2 31 79.1 879 21.4 1928 87.8 5910 88.5 90 Vinyl Department production for March was 111.1% of budget and 99-5% of capacity at 28.3 MM pounds. Reactor and dryer stream factors were 90.5% and 91.2% respectively. The major items affecting production were: Reactors 1. Maintenance on D-300 reactor agitator gearbox and agitator motor failure resulted in a 1.0% reactor stream factor penalty. 2. Condenser cleanings were performed on D-300 and 743 reactors resulting in a 1.2% reactor stream factor penalty. 3. Tubeside pluggage in the new unit hot water preheater resulted in a 0.9% reactor stream factor penalty. 4. Maintenance on the old unit dump Sweco and dump line problems resulted in a 0.8% reactor stream factor penalty. 5. Recovery system and dryer imbalances resulted in a 5% reactor stream factor penalty. Dryers 1. Maintenance on dryer centrifuges and centrifuge plugging resulted in a 3.6% dryer stream factor penalty. .2 Normal dryer cleaning and line changes resulted in a 1.2% dryer stream factor penalty. 3- Slurry and valve pluggage resulted in a 0.7% dryer stream factor penalty. 4. During the period of excess dryer capacity advantage was taken to perform needed dust collector sock changes, resulting in a 0.4% dryer stream factor penalty. DTH 000019106 VINYL - (continued) Dryers - (continued) 5. Resin transfer system problems resulted in a 0.5% dryer stream factor penalty. 6. Reactor-dryer area imbalances resulted in a 0.8% stream factor penalty. Resin Quality Summary Resin Type Prime Pounds "BC" Grade "H" Grade % of Total Production 5305 5385 5425 5465 Sifter Overflow Total 2,276,229 18,239,771 6,804,694 1,124,570 - 28,445,264 (35,750) - - (35,750) ( 26,750) (250,950) (124,900) -- 301,990 (100,610) 7.9 63.4 23.6 4.0 1.1 100.0 Quality performance for March was 100.5% customer grade with (0.1%) "BC" grade and (0.4%) "H" grade. Cost The variable cost variance for March was favorable $1,752 M with $1,780 M due to price and ($28 M) due to efficiency. The major price variance was $1;757 M due to below budget monomer pricing. Unfavorable efficiency variances of ($105 M) for VCM were partially offset by $21 M in favorable efficiencies in the additives area. Product mix caused an unfavorable variance of ($3 M) and the variance due to packaged off-grade was favorable $59 M as a result of successful startup of a resifting system. The monomer raw material requirement for March was 1.03515 pounds VCM per pound PVC versus of 1.01936 standard. The unfavorable VCM efficiency was found to be a result of erroneous rail and truck scales. The plant rail and truck scales were found to read light 2% and 1% respectively. The truck scale was recalibrated and placed back in service. The rail scale remains out of service until scale system modifications can be completed and an ICG rail scale test car can be scheduled in for recalibration. All rail product movements are being weighed on out-of-plant scales. General 1. Packaging for the month was 577 M pounds. 2. Installation of a resifting system was completed March, permitting debagging and deboxing without penalizing dryer stream factors. Debagging and deboxing activities for the month upgraded 813 M pounds of off-grade resin to customer grade for internal use at Aberdeen. DTH OOOOISXO'7' (5) VINYL - (continued) 3. Additional testing of Lucidol L-46 high productivity initiator was conducted during the month. A total of 16 batches were produced using the initiator. 4. A fresh monomer test run was conducted in the old module. The objective of the test run was to determine the effect of RVCM on particle size variabi1ity. 5. The two expansion reactors arrived at the plant March 14, 1981. dTH 000019108 (6) COMPOUND - J. R. McCrimon Compound Production Month Per Day Y.T.D. Line 1, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days 1,102 426 3,663 5,191 31 52.5 42.6 118.2 167,5 3,365 1,027 9,269 13,661 90 Line I operated 21 days during March at an average rate of 52.5 M pounds per day. Major items affecting production efficiency were: dicers (53-8 hours), product changes (35.9 hours), Banbury seal repair (15.0 hours), maintenance on skip hoist (11.5 hours), and maintenance on blender conveyor (10.3 hours). Line V operated 10 days during March at an average rate of 42.6 M pounds per day. Major items affecting production efficiency were: product changes (18.7 hours) and screw changes (8.8 hours). Line V set a daily production record of 81,000 pounds on 3/21/81. Line III operated 31 days during March at an average rate of 118.2 M pounds per day. Line III production was affected by: product changes (37.2 hours), maintenance on mill (20.0 hours), product star valve motor and gearbox replace ment (10.5 hours), and quality control (9.6 hours). Quality performance for flexible compounds was 4.9 % off-grade of which 54.3% was due to mill scrap. "BC" production was 1.7%. The off-grade was higher than normal due to packaging of bulk off-grade produced in 1980. The raw material requirement for flexible compounds was 1.01113 pounds of raw material per pound of compound versus a 1.01295 standard. (Y.T.D. is 1.00388.) The variable cost variance for compound was ($16.9 M) with $41.5 M due to price and ($58.5 M) due to efficiency. The variance due to product mix was ($1.25 M). There were no major efficiency variances. The unfavorable efficiency variance is due to higher than budgeted off-grade production. Compound production for March was 110% of budget. Dry Blend Month Per Day Y.T.D. Production, M Pounds Accounting Days 4,806 31 192.2 11,771 90 Dry Blend operated 25 days during March at an average rate of 192.2 M pounds per day. Production included: RP-100, 80273G, 80174, 90171, 80274. Dry Blend production was affected by: quality control (23-9 hours), out of resin (13.2 hours), product changes (10.3 hours), and maintenance on Welex diverter valve (9.3 hours.) DTK 000019109 (7) COMPOUND - (continued) Dry Blend - (continued) Quality performance for the month was 99-9% customer grade. The raw material requirement for dry blend was 1.00157 pounds of raw material per pound of dry blend versus a standard of 1.00580. (Y.T.D. is 1.01280.) The variable cost variance for dry blend was $75-8 M with $24.0 M due to price and $51.8 M due to efficiency. The variance due to mix was $54.6 M. Dry Blend production for March was 266% of budget. Plasticizer Month Per Day Y.T.D. Production, M Pounds Accounting Days 845 65 31 3,121 90 Plasticizer operated 13 days during March at an average rate of 65 M pounds per day. Production included: D0P, DIDP, and 61 OP. VRP production totaled 94.9 M pounds (10.0%). Production was affected by: R-2 coil repair, north catch tank, pump motor repairs and out of phthalic anhydride for a total of 9 days due to railcar deficiencies which would not allow safe unloading of phthalic anhydride. The raw material requirement for plasticizer was 1.05864 pounds of raw materials per pound of plasticizer versus a 1.10499 standard. (Y.T.D. is 1.10795.) The variable cost for plasticizer was $32.9 M with $24.6 M due to price and $8.3 M due to efficiency. Major variances were: $10.9 M for isodecanol and ($13*7 M) for phthalic anhydride. The phthalic anhydride variance is due to the I PA not accounting for P. A. consumption in RAE (VRP) production. The variance due to product mix was ($0.7 M). General Total customer grade compound inventory increased from 6.3 to 6.6 MM pounds during March. DTH 000019110 (8) MAINTENANCE - S. J. Vincent Vinyl There were no large reactor seal failures in this period. At this time all reactor seals were running using water flushes. D-300 reactor motor failed and was rebuilt. Two reactor condensers were cleaned and one reactor gear box failed. The condensers cleaned were on D-300 reactor in the old module and on 743 condenser in the new module. The gear box failure was on the D-300 reactor in the old module. The high speed and intermediate gears, bearings, and shafts were replaced. The condenser top gasket was replaced on the 744 condenser. Only one major valve was replaced in this period which was the 6" suction valve on the "A" vacuum pump. Pumps and compressors repairs in this period were to replace seven seals and overhaul two compressors and one pump. In the new module, seals were replaced in the west VCM charge pump, the out board seal in the 904 compressor, the seal in the east chemical wash pump, and the seal in the east VCM charge pump. Seals replaced in the old module were in the west VCM return pump, the outboard seal in the 706 emission recovery compres sors, and the seal in the east VCM charge pump. In the old module the "A" and "B" recovery compressors were rebuilt to replace leaking compressor cases. In the old module the south K.O. drum circulating pump was overhauled and the pump case replaced. The north and south recovery condensers in the old module were cleaned. The charge water pre heater in the new module was hydroblasted and chemically cleaned. Repairs to the vinyl dryer were to change out the #2 centrifuge and >gear box twice. The belts were replaced on the #2 and #6 centrifuges. Minor repairs were made to the dryer door and exhauster stacks on the #4 and jfS dryers. The Honey well gas bottle racks were relocated for the construction of the fluid bed dryer. The torque controls for #4, #5, and #8 dryers were calibrated. Compound - Dry Blend - Plasticizer and Resin Storage Operation in this period was to operate Line Three full time and run Line One or Line Five as required by product demand. With Line One down several steam leaks were repaired, along with, dicer repairs and changing banbury seals. Line Three was down twice for a product change. The F.C.M. seals and rotary joints were replaced and the coupling on the sout.h mill roll motor was replaced. Two electric vibrators were installed on the Line V scales. The bulk of the repairs in the plasticiizer unit involved steam leaks. In the dry blend unit the belts were replaced twice on the intensive cooler. The Sprocket was repaired on "D" blender drive. The Welex Diverter Valve was repaired. dth oooo:l :l x (9) MAINTENANCE - (Continue) Utilities and Service There were four repairs to the Plant Air system. Valves were repaired in #5 and #6 compressor. #1 Compressor was overhauled after the piston failed. The major repair in this period was to remove the west Joy air compressor and return the unit for new gears to be installed and a general inspection at the Joy factory. A project to pipe treated water to the boiler feed pump packing was completed to help improve boiler water control. Utilities were piped to the new safety valve test stand in the Maintenance shop. The main break area was repainted. The removal of unused switchgear from the refrigeration building to provide air compressor access was completed. Planner There were 115 work orders planned and estimated and material ordered for 30 projects. Twenty invoice registers were closed, 25 new registers were issued. The revised Safety Valve and Safety Disc Log Book was completed. DTH 000019112 (10) MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved, and Closed The following AFE's were submitted and approved during March: AFE No. Title 9571 9581 9591 9601 9611 9621 9631 Centrifugal Air Compressor Repair Dryer Building Ventilation Sifter Overflow Reclaim System Compliance With EPA VCM Standard (Air) Recovery System Revisions Laboratory Equipment Ground Water Monitoring (Solid) The Following AFE's were closed to field charges during March AFE No. Title 9589 9610 Instrument Air Dryer API Clean Water Bypass Completion reports were issued for the following AFE's: AFE No. Title 9237 9519 9669 9739 Heated Plasticizer Addition System Critical Spare Equipment New Air Header Methocel Charge Revision Design Design work is in progress on the following projects: Fixed Point Monitor Data Computer and Warning Lights Spare Inert Incinerator Resin Reclaim System Reactor Pressure Relief Modifications Emergency AMS Kill System Sifter Overflow Reclaim Contrate Heat Recovery Fire Protection Improvements - Phase III VCM Tank Farm Revisions Cent rate Heat Recovery System Calcium Stearate Additon System Authorized $ 45,000 23,000 200,000 72.000 30.000 42.000 30.000 Authorized $110,000 23,000 Authorized $ 37,000 175,000 25,000 66,000 OTH 000019113 (11) MECHANICAL ENGINEERING - (continued) AFE Activity 1. AFE 9709 ~ Facilities for Multigrade Resin Production - 6. Kreutzer Erection of structural steel and fabrication of slurry blend tanks is in progress. 2. AFE 9729 ~ Fire Protection Improvements - Phase II - M. Ingle Excavat ion work is complete. Forming and pouring of concrete for the pump building is in progress. 3. AFE 9530 ~ Spare Incinerator - L. Roussel Overall project design is approximately 32% complete. Foundation work is in progress. The structural steel fabrication work has been let. Bids were requested for piping, equipment installation and pneumatic instrument ation. 4. AFE 9600 - Calcium Stearate Addition System - M. Richards Electrical design and equipment purchasing is in progress. 5. AFE 9630 ~ Water Stripping - M. Ingle Nearly all the piping and valves have been received. Installation of instru mentation work in the control room is in progress. Bids have been requested for installation of the electrical and instrumentation work. 6. AFE 9680 " Fixed Point Monitor Data Computer and Warning Lights ~ R. B. Harned The stand for the CRT and printers have been received. Installation drawings are in progress. 7. AFE 9730 ~ Compound Line III Debottlenecking - R. B. Harned The class "A" design for this project is being revised. Some equipment specifications were firmed up and a suggested bidders list was compiled. 8. AFE 9760 - Emergency AMS Kill System -J. L. White Plan drawings have been approved and drafting is in progress. 9. AFE 9770 ~ Reactor Pressure Relief Modifications - J. L. White Plan drawings have been approved and installation drawings are in progress. 10. AFE 9780 - Resin Reclaim System - J. P. McKee All major equipment except the tank is on order. Drafting is in progress. D1H 0000191A^ (12) MECHANICAL ENGINEERING - (cont.) AFE Activity - (cont.) 11. AFE 9790 " Resin Reclaim System - P. Meiers A kick-off meeting was held with the plant, CED and contract engineering personnel on 4-3-81. Some equipment bid tabulations have been reviewed and approved. 12. AFE 9800 - Plasticizer Irritant Control (AIC) - R. B. Harned The aerators have been received. Certified drawings of the motor control center have been received and it is scheduled to ship in May. 13* AFE 9521 - New VCM Rail spur - Herzog - Hart Corp. The topography and soil boring work is complete. Progress prints and a draft of the specificiations were received for review and approved. 14. AFE 9541 - VCM Tank Farm Modifications - R. B. Harned Purchasing of equipment and instrumentation is in progress. Quotes for the knock-out pot have been received and are being evaluated. The struc tural and foundation drawings are complete and piping design is in progress. 15. AFE 9591 - Sifter Overflow Reclaim System - J. P. Windham A temporary system was completed in March and is operational. Construction - G. A. Morgan The following projects were completed during March: 1. Relocation of Air Cannons on 410 Silo. 2. Installation of Lighting in the Drum Storage Shed. 3. Replacement of Ladder Rungs on 282 Silo. 4. Interplant Communication - Phase II. The following contracts were issued during March: 1. Fireproofing of the New Reactor Structure. 2. Insulation of the Batch Water Stripping Project, 3. Installation of Structural Steel for Spare Incinerator. 4. Collection and Disposal of Scrap Metals. Twenty register tickets were issued during March: X>TFi 0000 19 11 (2) Tnru March, 198' Actua Accounting AUTH. CAPITAL NO. DESCRIPTION ABERDEEN AUTHORIZATIONS REPORT DATE Airm. AMT.APPROVED AFli CD EXPENDED TO DATE (2) COMMITTED TO DATE FINAL TOTAL EST. COST COMP. UNDER (OVER) AUTII. AMT. fc$T. EST. COMP. CLOS. DATE PATE REMARKS (13) 9559 9589 9509 9529 9539 9689 9699 9709 9719 9729 Color Weigh Room Modifications 6/19/79 Instrument Air Dryer Reactor Inert Vent System 5/30/79 6/28/79 Air Compressor Revisions to Emission Recovery Sys. Diking of Sphere *, Curbing of Drum Storage Areas 7/9/79 7/12/79 9/15/79 Plant Dryer Debottlenecking Facilities for Multiple Grade Resin 9/15/79 9/20/79 Aberdeen PVC Resin Expansion Fire Protection Improvements - Phase 11 9/10/79 10/1/79 25.000 110,000 90,000 360,000 100,000 170,000 80,000 870,000 850,000 690,000 22,901 96,623 16,561 282,168 77,665 132,398 23,090 100,259 16.561 292,203 81,606 136,500 32,305 179,365 63,595 589,595 11,621 175,972 860,000 376,696 23,090 100,259 90,000 360,000 100,000 170,000 80,000 870,000 860,000 690,000 1,910 9,761 0 0 0 0 i/bi 6/81 3/81 6/Bl 12/81 3/82 5/81 8/Pl 5/81 8/81 6/81 9/81 Closed to field charges. Closed to field charges. Project on hold. Revisions in progress. Revisions In progress. Revisions in progress. 0 8/81 11/81 Construction in progress. 0 8/81 11/81 Construction in progress. ( 10,000) 0 S/Sl 6/81 11/81 Reactors received 3/1*1/81. 9/81 Construction in progress. 9759 Aberdeen PVC Resin Expansion 12/10/79 11,150,000 6,630,680 9,071,800 1 1,150,000 9510 Miscellaneous Projects Under $10,000 1/3/80 150,000 163,362 159,788 150,000 9530 9550 9560 9570 9580 Spare Incinerator P. A. Handling Improvement Safety Equipment Replace T-101 P.A. Tank Boiler Economizers 1/23/80 3/3/80 3/12/80 3/27/80 3/26/80 650,000 63,000 25,000 119,000 160,000 99.907 32,386 10,923 62,720 166,896 368,503 33,612 29,015 62,720 165,389 650,000 63,000 28,908 119,000 165,389 9590 Critical Spare Equipment 3/26/80 59,000 11,610 60,386 60,386 9600 Calcium Stearate Addition System 6/2/80 86,000 629 12,068 86,000 9610 API Clean Water Bypass 6/15/80 23,000 18,203 18,511 18,511 9630 Water Stripping 6/30/80 810,000 215,911 361 ,167 1 810,000 9650 9660 Miscellaneous Projects Under $10,000 Hot Water Charge Tank Replacement 5/30/80 6/6/80 150,000 160,000 127,715 110,789 172,530 139,016 150,000 160,000 9670 Laboratory Equipment 7/9/80 32.000 31,587 32,667 32,667 9680 Fixed Point Monitor Data Computer and Warning lights 9/6/80 113.000 1,631 39,716 113,000 9690 Breathing Air Modification 9/9/80 21,000 1,266 6,869 21,000 9700 Compound Fines Streamers Removal 10/1/80 95,000 0 0 95.000 9710 Fire Protection - Phase III 10/16/80 385,000 0 600 385,000 9720 Reactor Agitator Replacement 10/16/80 620,000 0 191,268 620,000 9730 Compound Line HI Debottlenecking 10/16/80 1 ,350,000 0 69,500 1,350,000 9760 9750 Modifications to Make Profile Dry Blend Rotary Dryer Insulation (Energy) 10/27/80 n/io/ao 200,000 22,000 69 0 23,975 27,391 200,000 27,391 9760 Emergency AMS Kill System 11/15/80 335,000 0 59,063 335,000 9770 Reactor Pressure Relief Modifications 11/25/80 560,000 263 235,708 560,000 9780 Centrate Heat Recovery 12/8/80 300,000 673 62,518 300,000 9790 Resin Reclaim System 12/16/80 727,000 167 167 727,000 9800 Plasticizer Irritant Control (Air) 12/15/80 80,000 0 28,305 80,000 9810" Replacement Gearbox for Farrel Mixer 12/18/80 73.000 0 69.600 73,000 9511 Miscellaneous Projects Under $10,000 *1521 New VCM Rati spur 7 ^ -953T-- Vinyl initiator Charge Pots 1/9/81 1/30/81 1/21/81 170,000 11,000 165,000 9,760 0 0 53,983 15,800 0 170,000 11,000 165,000 9561 VCM Tank Farm Modifications 1/21/81 90,000 0 13.769 90,000 80-395 Interplant Communication - Phase II 1/22/80 55,000 0 21,755 55,000 9551 V-IO Centrate Heat Recovery (Energy) 2/17/81 125,000 0 0 125,000 9561 Cooling Tower Fan Controls (Energy) 2/17/81 60,000 0 0 60,000 9571 Centrifugal Air Con.pressor Repair 3/11/81 65,000 0 62,975 65,000 9581 Dryer Building Ventilation 3/20/81 23.000 0 0 23,000 9591 9601 Sifter Overflow Reclaim System Compliance With EPA VCM Standard 3/20/81 3/25/81 200,000 72,000 0 0 0 200,000 0 72,000 0 9/81 12/81 Construction in progress. 0 12/80 3/81 Closed to field charges. 0 6/81 9/81 Construction in progress. 0 12/81 3/82 Project on hold. ( 3,908) 6/81 7/81 Construction in progress. 0 12/81 3/82 Project on hold. ( 5,389) 12/80 3/81 Closed to fie Id charges. ( 1,386) 3/81 6/81 Condenser to ship 6/81. 0 5/81 8/81 Engineering in progress. 6,689 0 3/81 6/ai 6/81 9/Cl Closed to field charges. Construction in progress. 0 12/80 3/81 Closed to field charges. 0 6/81 7/81 Project operational. ( 667) 12/80 3/81 Closed to field charges. 0 9/81 12/81 Engineering in progress. 0 5/81 8/81 Engineering in progress. 0 10/81 1/82 Engineering scheduled. 0 10/81 1/82 Engineering In progress. 0 10/81 1/82 Agitators to ship 5/81* 0 10/81 1/82 FCM barrel to ship 10/81. Q 10/81 1/82 Engineering scheduled. c 5,391) 0 0 6/81 7/81 751 complete. 8/81 11/81 Engineering in progress. 12/81 3/82 Engineering in progress. 0 3/82 6/82 Engineering In progress. 0 3/82 6/82 Engineering in progress. CEO 0 9/81 12/81 Engineering in progress. 0 9/81 12/81 Gearbox to ship 9/81. 0 12/81 3/82 Twenty projects approved. 0 5/81 8/81 Engineering in progress. 0 11/81 2/82 Engineering scheduled. 0 1/82 6/82 Engineering In progress. 0 6/81 9/81 Project operational. 0 5/82 8/82 Engineering scheduled. 0 11/81 2/82 Engineering scheduled. 0 6/81 7/81 Compressor operational. 0 9/81 12/81 Engineering scheduled. 0 3/e2 6/82 Engineering in progress. 0 12/81 3/82 Engineering scheduled. 9611 9621 9631 Recovery System Revisions Laboratory Equipment Ground Water Monitoring (Solid) 3/25/81 3/25/81 3/26/31 30,000 62 ,000 30,000 0 0 0 0 30,000 0 62.000 0 30,000 0 12/81 3/82 Engineering scheduled. 0 R/Rl 1 l/ftl FqnifMwnt 9 tnd . 0 10/81 1/82 Engineering In progress. 9020 EXPENSE Repairs to Line 1 Compounder 11/26/80 38,000 0 0 33,000 DTH 000019116 0 11/81 2/82 Parts ordered in January. PERSONNEL - J. L. Carter EMPLOYMENT Ralph D. FIippo - General Helper Dave Gathings - General Helper Jeffery Shields - General Helper John White - Casual Labor (Transportation) Howard Sykes - Casual Labor (Transportation) Hanna Word - Casual Labor (Transportation) TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMPTI ON Jeffery Shield, General Helper, transferred to Building Attendant. Eddie M. Smith, Head Building Attendant, transferred to Lab Trainee. Robert L. Williams, Building Attendant, promoted to Head Building Attendant. Jerry R. Crosby, Lab Technician "A", transferred to Maintenance Helper. RETIREMENT Sara F. Jones, Payroll Clerk Earnest R. Long, General Mechanic "A" TERMINATION Ulas Nabor - Casual Labor Georgia Elliott - Casual Labor David Elliott - Casual Labor Jerry McCulloum - Casual Labor (Transportation) David Thompson - Casual Labor (Transportation) OTHER During March there were 15 casual labor employees on payroll. Total hours worked were 1429. DTH 000019117 CONOCO CHEMICALS Aberdeen, Mississippi 05) March 1981 MONTHLY PERSONNEL REPORT Salaried Employees 79* Minority Employees # % Hourly Employees Total Employees Employees (Hourly) 157 236* Salaried Hourly Total 6 58 64 7.6% 37% 27% New Employees Terminations 3 ]** Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 1 33.3% 0 0 DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound PAR # EMPLOYEES MIN. EHP. . % MIN. 9 8 1 12% 11 12 4 33% 46 45 7 15% 22 21 3 14% 37 35 27 77% NEW HIRES YTD 00 35 00 00 00 TERM. YTD TURNOVER 000 YTD 0 000 1 ** 1 ** 0 0 0 000 0 000 0 Vinyl 32 32 13 Plasticizer 4 4 3 40% 0 0 0 0 0 0 75% 0 0 0 -o 0 0 Number of Applicants: Month ' 1 Year to Date 74 APPLICANT BREAKDOWN: # Minority 5 % Minority ^ Female 9 % Female 45% 82% *lncludes two (2) temporary employees. **lncludes one retirement. Retirements are not included in turnover rates. Hires (Hourly) : Month 3 Year to Date 5 Terminations (Hourly) : Month 1 ** Year to Date Overall Turnover 0 ] ** Projected Annual Turnover ____ 0 DTH 000019118 OVERTIME AND ABSENTEEISM o o<oK o 00 --o <T\ O V0 s>? <"/> o <0 a: r*. co <n K e "o ri- .x O) *--<o 1u/1 +L*. 03 in x r0-v\ vO vO -- Is* <n i/\ i**-* -a- in c o I/I co <u0 <0 4a). l_ o 4Q)_ c o c > to v ><o0 X4-> X X in X 4) I/I X X4> o or m c -Xu O o c(0 10 3Oi 4> >H to *o or c Xo !ix_ o to 3 c T3 oC <0 in 4. 3 o *<>o0 <0 o X Ol <0 4) c o on m c jL*. o o X 2 0 o 3Dl V 3> ic .X U. o 4>o) 3 O O) cS 5 o u X0) i 0) 0> o 4(-01 > o X4J 1 I I o 4>) o 4) X>0 4) Xo to -- <D (16) DTH 000019119 (17) PROCESS ENGINEERING - R. A. Frohreich A. Expansion Project All concrete work has been completed except for the Chem Wash area. Erection of the west cooling tower has begun with completion of both towers expected in May. Erection of the slurry blend tanks is proceeding. Dryer steel erection and equipment setting in this area has begun. Instrumentation bid packages have been received and selection will be made in April. All major equipment for the Chemical Wash system has been ordered. B. Reactor Emergency Cooling System A revised class "A" design is being prepared for this project. C. Compound Line I Modernization The class "A" design for this project is being prepared. D. Plasticizer Spill Containment The class "A" design for this project was issued. A design review was held and the comments were incorporated in the design. E. Donnelly Mirror Compound Testing The design is being revised to incorporate "Super Sac" containers with a longer service life. F. Automatic Resin Bagging The class "A" design to convert the compound automatic bagging system to resin service is underway. G. Dryer Vacuum System Work has begun on the class "A" design to install a vacuum clean up system for the dryer buildings. H. Recovery System Revisions During review of this design, it was decided that additional field data needs to be taken to verify the flow rates through recovery system that were used as a basis for equipment sizing. I. Slurry Delumper The class "A" design incorporating comments from the design review meeting was issued. DTH 000019120 (18) PROCESS ENGINEERING - (Continue) J. Caustic Addition System The class "A" design to add caustic to the recovery systems to reduce corrosion is being prepared. K. Line III Production Improvement A report proposing a test run on line III to determine rate limitations for several compounds is being prepared. L. Pressure Relief on Recovery Compressors The class "A" design to install pressure relief on the recovery compressors was issued. The AFE request for this project was submitted and approved. M. Pressure Relief on Pumps in VCM Service A survey of the relief capacity on pumps in VCM service was conducted. A design to provide adaquate relief for these pumps is being prepared. N. Evaluation of Vinyl Emergency systems operability The MSPW and new module seal oil emergency systems are being evaluated for operability and capacity to determine if these systems are adaquate. O. Plasticizer Caustic Charge Pump A design to replace the plasticizer caustic charge eductor with a pump to reduce the amount of water that needs to be treated was issued. P. Sifter Overflow Reclaim System The AFE request for this project was submitted and approved. DTH 000019121 (19) ENVIRONMENTAL - V. E. Messick Pa rticulates Two dryers were sampled in March for particulates and were within allowable limits. Water The ph for outfall 002 exceeded allowable limits with a value of 10.0. All other effluent parameters were within NPDES limitations. A proposed compliance schedule to meet lower effluent limitations by the installation of biodisc was submitted to the State of Mississippi A draft NPDES permit was received from the state in early April. VCM All leaks found during the comprehensive VCM survey have been repaired and verified. Hazardous Waste Management The Groundwater Monitoring AFE request was approved. A meeting was held with the contractor to plan work on the plant's closure and post-closure plan and the groundwater monitoring study. All manifests on previous shipments of hazardous wastes have been received. The RCRA Training Manaul is being prepared. DTH 000019122 Flow GPM Jan. - Ave. 1069 Max. 1297 Feb. - Ave. 757 Max. 819 Mar. - Ave. 753 Max. 790 Apr. - Ave. Max. May - Ave Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sdpt. - 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. 39 504 57 887 11 95 18 154 10 90 11 103 69 888 106 1650 43 382 56 479 36 330 51 466 7 93 9 114 7 65 10 86 11 93 17 139 Diss. O2 8.5-10.4 8.9-9.8 8.3-8.9 (20) ph 7.4-7.8 7.5-7.9 7.6-7.7 NPDES - Ave. Max. - 32 387 43 520 - 1390 - 1940 - 605 >6.0 - 909 6.0-8.5 DTH 000013123 (21) ENERGY CONSERVATION - J. F. Perez-Velasco 1. Plant Operations Total energy consumption for March was 112.653 MMM BTU's. The energy consumption per pound of product decreased to 2873 BTU/lb as compared with 3^8 BTU/lb. for February. I 1. Plant Energy Conservation Program A. Steam Leaks Twenty-six (26) steam leaks were repaired in March, two of which were steam trap repairs. In addition, Leak Repair Inc. made twenty eight (28) on-line steam leak repairs. B. Light Survey Westinghouse conducted a plant-wide light survey and will send recommendations. C. Energy Reporting Calculation of weekly plant energy efficiencies was begun in March. D. Continuous Oxygen Analyzers Installation and calibration of the excess oxygen analyzers was com pleted in March and they are in full operation. DTH 000019124 (22) ENERGY CONSERVATION DATA ITEM 1981 1980 Control Period March March Production, MM Lbs. Resin Dry Blend Compound Plasticizer TOTAL Natural Gas 28.3 4.8 5.2 0.9 39.2 25.6 2.2 4.0 1.3 33.1 Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU 59178 1020 60.361 57691 1020 58.845 Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU 5.2291 10,000 52.291 5.1456 10,000 51.456 Propane Consumption, M Gal . Conversion, BTU/Gal. Energy Consumption, MMM BTU 0 92000 0 0 92000 0 Total Energy Consumption, MMM BTU Energy Consumption, BTU/Lb. 112.653 2873 110.301 3332 Boiler Operating Data Avg. Stack Temp. 191 1980 Avq. % Excess Air 1981 1980 No. 1 No. 2 No. 3 260 384 37 280 408 30 270 414 18 19 19 21 DTH 000019125 (23) LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Charlotte Pipe Packard Electric Lubonyl WAIVERS RECEIVED Product 5358 34533 Natural 5385 Complaint Moisture Processing , Lumps Contamination Report By PEM CRM CRM Date Identification Product 3/7 3/9 .3/11 3/23 3/23 3/23 3/24 3/24 3/24 T-2479 P-1261 PTLX-41833 CONX-45770 CONX-45757 PTLX-41600 PLCX-43710 PTLX-41640 PTLX-41651 5425 80273G 5385-3 5385-3 5385-3 5385-3 5425 5305 5305 PRODUCT SERVICE S DEVELOPMENT Customer Reason Southwire Ari Products World of Plastics World of Plastics World of Plastics World of Plastics Uniroyal Intex N. J. Terminal Gels Low Torque Viscosity Viscosity Viscosity Viscosity Viscosity Viscosity Viscosity Wa ived By RDJ RDJ ELK ELK ELK ELK ELK ELK ELK Sample Shipments Ship Date 3/6 3/9 3/9 3/12 3/13 3/13 3/16 3/16 3/17 3/17 Product 5385-3 5385-1 18031 CLBL50 5305 18831 CLBL50 I896I Natural 5305 38761 Black 5385-1 35851 Natural 34431 Natural 38551 Natural Amount (lb.) 8x2 200 900 250 200 50 1 5 50 50 50 Customer Vydel Corp. of America Hamel in Industries Tenex Corp. Mitsui & Co. (USA) Inc. Astro Plastics Lavanture Innovative Sensors, Inc. Conoco, Ponca Ci ty Dart Industries Wrap-On Co. Inc. Requested By MFM COEDS COEDS COEDS COEDS COEDS RTM ERC RNG MFM DTH 000019126 (24) LABORATORY - (continued) Sample Shipments - (continued Ship Date Product Amount (lb.) 3/23 3/25 3/25 3/25 3/25 3/25 3/26 3/26 3/31 3/31 3/31 3/31 3/31 27121 Natural 14331 Water Cl . I896I Natural' 28831 Natural 200 200 200 100 18031 CLBL50 100 5425-1 50 5305 100 5385 5425 5 5 5305 5385-1 5425 5465 10 10 10 10 26421 Natural 50 5385 2 x 500 90171 100 35851 Natural 150 5385-3 50 5385-3 50 5425 5 Special Compound Testing Customer Quimsanto Industrial C.A. Requested By COEDS Ruvan Plastics Royal Plastics LTD Genova 1nc. Abboth Industries, Inc. Fritz Airfreight COEDS COEDS COEDS NTH JPM Fritz Airfreight Conoco, Inc. LCP Plastics Inc. Whitaker Cable Corp. American Pipe & Plastics Pro Tochem Inc. Fritz Airfreight JPM COEDS COEDS COEDS NTH COEDS JPM Complete Western Electric specification tests were run on three production batches of 34861 Gray 546, on one batch of 36861 Natural, and on one batch of 38761 Black'. In addition, plasticizer extraction and flammability tests were run on six rail- car samples. The 38761 Black exhibited poor extrusion flow characteristics arid was rejected for shipment. New Compounds Quality control specifications and standards were prepared for 3711-65C White a new Neco heating pad formula. The color was ajusted to match the Neco standard. Dry Blend Development Welex batches of four dry blend compounds were prepared for use as control standards. DTH 000019127 (25) LABORATORY - (continued) Customer Complaints As the result of a complaint from Taylor Cable, melt flow tests were run on the complaint sample of 34431 Natural and on production retains. There was no significant difference in the melt flows of the two materials. QUALITY CONTROL TESTING Resin Regular Samples = 413 Bag Samples - 18 Other In-Process Samples = 3,257 Bulk Shipments = 204 (Railcars = 123; Trucks = 8l) Dry Blend Blenders Produced = 446 Blenders Tested * 446 Blenders Adjusted = 16.4? Other In-Process Samples = 555 Bulk Shipments = 57 (Railcars =11; Trucks = 46) Compound Blenders Produced = 762 Blenders Adjusted = 2.1? Line V Production = 256 skids Other In-Process Samples = 940 Bulk Shipments = 30 (Railcars = 14; Trucks = 16) Resin Heat Stability Resin heat stability was good during March, with only one sample approaching the unacceptable level. Forty-six (46) samples were tested, as follows: 5385 5425 5305 5465 16 samples 16 samples 8 samples 6 samples Raw Material Testing Eighty-three (83) lots of plant raw materials were tested and released. A report has been issued regarding variations in the volume resistivity of clays. Tests indicated that problems with dispersion of the clays has been responsible for very low VR readings, and the sample preparation technique has been revised. Preliminary test results have indicated that Compound Line III gives good clay dispersion and acceptable values for VR of electrical compounds. DTH 000019128 (26) LABORATORY - (continued) Raw Material Testing - (continued) A sample of XM-39^1V Gray color concentrate from Avecor Midwest was compared with Wilson 32-GY-16. The Avecor sample appeared to be an acceptable color match, however* the pigment dispersion was very poor. RVCM of Shipments A total of 166 shipment samples were tested for RVCM in March. The following is a summary of these results. Product 5305 5385 5425 5465 Dry Blend PPM RVCM Number Samples 1.6 60 1.6 59 0.2 30 0.1 8 0.1 9 Viscosity A total of 807 samples were tested for sol ut ion v iscosity. This gives an average of 26 samples per day for 31 days. MISCELLANEOUS PROJECTS 5385 Resin Molecular Weight This project was undertaken because of a proposal to reduce the molecular weight of 5385 from a minimum inherent viscosity of 0.90'to 0.88. Laboratory batches of two critical melt flow compounds (18031 and 3^861) were prepared using the two resins and tested for melt flow. Compounds containing the 0.88 l.V. 5385 flowed much faster than the same compounds made with 0.93 l.V. resin. The low molecular weight resins would not appear Suitable for 18031 or 3^861 based on these laboratory comparisons. Computer/LSN In order to make reactor slurry particle size data from the Leeds and Northrup more meaningful to the Vinyl Department, a new program has been prepared for the lab computer. This program stores the last sixty data points and graphs the results to show trends in particle size performance. This information is transmitted to the Vinyl Control Room several times during a shift. RVCM in Slurry A total of 669 slurry samples were checked for RVCM. The overall average ppm RVCM for March was 212. The daily average exceeded 400 ppm on one day. RVCM of 5305 Dryer Samples The dried 5305 samples were tested for RVCM. A total of 57 samples were tested with a monthly average of 2.6 ppm RVCM. DTH 000019129 (27) LABORATORY - (continued) RVCM of Blowdown Tanks A total of 165 blowdown tank water samples were tested for RVCM in March. The overall average was 7 ppm VCM. Special A total of 100 non-routine samples were analyzed for the Processing Engineering Department. Most of these were for COD testing. Dosimetry A total of 86 VCM dosimetry samples and 25 plasticizer in air samples were tested. Technical Service A visit was made by the Plant Chief Chemist to Phelps Dodge, Starkville, MS concerning particle size analysis differences. The problem at this customer's plant was found to be processing related and it was recommended that PAL be called in to monitor the situation. DTH 000019130 (28) TRANSPORTATION - J. E. Stark Shipments By Product - M/Lbs. March Year-to-Date Res i n Plasticizer Dry Blend Compound Number of Shipments By Mode 27,336 164 5,401 4,560 37,461 69,814 409 12,628 12,646 95,497 O.T. O.T. R/C Bulk Van C.O.T. C.C. TOFC CPU Total Resin - Bulk - Package - Export Plasticizer Dry Blend - Bulk - Package - Export Compound - Bulk - Package - Export Back Hauls for March Number of Shipments by Month 104 48 3 3 167 14 1 14 13 5 12 12 2of 132 ~TT 4 1 1 6 27 179 1 48 174 44 3 43 61 1 5 12 12 3 30 19 18 50 9 5b 6 74 539 27 1 4 32 R/C Bulk Van C.O.T. C.C. TOFC CPU Total January February March Material Handling Report 91 48 200 91 55 172 132 65 208 2 0 6 91 0 55 487 40 0 58 416 54 0 74 539 M/Lbs. T/L Packaged Resin From Production Packaged Compound, Dry Blend From Production Transferred From Main to Prairie Transferred From Prairie to Prai rie Reverse Transfer Resin to Plant Reverse Transfer Compound to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Main 1,134 3,159 1,903 0 770 283 10,246 7,776 6,359 31,630 28 78 47 0 19 7 253 192 157 78T DTH 000019131 TRANSPORTATION - (continued) Off Grade In Storage Material Sifter Overflow Resin "BC" Resin "H" Mi 1 1 Scrap Compound "B" Compound "H" Dry Blend "O.G." M/Lbs. 1,379 3,043 750 133 1,687 70 366 7,428 (29) T/L 34 75 18 3 42 2 9 TSJ DTH 000019132 LOCATION MAIN-East l >V TOTAL M J SQ. FT. 48 Prairie 12-1' l 12-2 12-3 12 22 21 12-4 22 12-5 ... 21 12-6 21 12-7 12-8 12-9 12-12 21 21 21 21 - ... Total 251 ^ CONOCO TRANSPORTATION ABERDEEN WAREHOUSE CONTENTS Compounds 4.4 Dry Blend .2 Export Resin .2 Conoco Resin .2 HDPE .3 Dry Blend .2 Conoco Resin 1.4 ` Conoco .3 Export Resin .7 Conoco Resin 4.4 Resin O.G. Mill Scraps Cmpd O.G. .1 1.0 Dry Blend O.G. .2 Sifter Overflow .7 Resin O.G. .3 Compound Resin .1 3.0 Raw Material .3 Resin O.G. Conoco Resin 3-4 4. 5 Conoco Resin 2.3 Dry Blend O.G. S.O. . 6 Comp. O.G. .7 Mill Scarp Sub-Total (Plug-Aisles) Total Conoco ESTIMATED MM POUND! ON FLOOR OPEN TO 5.0 5.0 10.0 -.5 1.0 1.5 1.4 3.1 3.5 ! '1 1.0 2 .5 3.5 * 4.4 3.5 2.3 .2 2.5 - 3.4 3.4 * 4.5 2.3 .1 3.5 .1 3.5 3.5 1.2 3.5 ' 1.3 1 20. 5 J>.2 14.4 3.5 42.0 1,9 43. q DTH 000019133 MONTHLY HOURLY TURNOVER DTH 000019134 ABERDEEN CHEMICAL PLANT INJURY PERFORMANCE C c c oo >oz Ui o' c. e FREQUENCY TOTAL INJURIES (FA OR MC) X 12 TOTAL EMPLOYEES DTH 000019135 ENERGY USAGE C ( c c Monthly 12 Month Moving Average DTH 000019136 MM POUNDS ABERDEEN PLANT PRODUCTION MM POUNDS 60 50 40 30 20 10- 40 35 30 25 20 15 10 5 7 25 20 15 10 5 .......... BUDGET --------- ACTUAL ---------- CUMULATIVE DTH 000019137 ABERDEEN PLANT QUALITY PERFORMANCE STANDARD 1.35 DTH 000019138 ABERDEEN PLANT EFFICIENCY 1981 STANDARD 1.01936 STANDARD 1 .01300 STANDARD 1 .00580 STANDARD 1.10500 MONTHLY CUMULATIVE DTH 000019139 ABERDEEN PLANT INVENTORIES MM 1981 3 DTH 000019140