Document rpbMKqBN61K38ENODkBNx1Rp0

l INTEH-OTFICE MFMQ TENNEGO CHEMICALS, INC. To W. Miring off j From J. T. Sweeney v SuBJtcr Flemington Monthly Report March, 1981 at Piscataway At Flemington Date April 1, 1981 Copy to P. Benn R. A. Donovan W. R. Fogelsanger G. Giordano D. M. Hershkowitz R. R. Neugold C. K, Newman R. B. Robertson G. I. Rozand W. Rupp R. A. Sloff Dr. W. Sorenson M. E. Wagshul Dr. L. Wigdor X. PRODUCTION 1. Production in March was 7.922 M Lbs. representing 100.1% of the monthly budgeted production rate and 93.9% of the standard pro duction rate. 2. Productivity delays encountered during the-month were as follows: a.) Partially set-up batch in R-10 (see item V-D) = 200 M Lbs. b.) CBS Type 318 trials involving space charging and other pro cessing delays = 150 M Lbs. c.) Elongated polymerization cycles resulting from operating reac tor on river cooling water vs. chilled cooling water in order to reduce electrical energy costs. = 150 M Lbs. The above items resulted in a total productivity loss of 500 M Lb.< II. QUALITY A. "RFT" "RFT" for March was 89.2% vs. 87.5% Y-T-D. B. GRADE III SUMMARY Grade III production in March was low at 1.9% (0.151 M Lbs.) The Grade III production resulted primarily from burnt resin contamination. TEN-FLEM 20038 TEN 4666 C. CUSTOMER RELATIONS The plant experienced one customer rejection in March. (Nixon - contamination). Lbs, rejected = Lbs. produced 0.04 M Lbs. - 7.922M Lbs. X 100 = 0.50% D. QUALITY IMPROVEMENTS 1. The slurry electromagnets are continuing to function well* The permanent purchase and installation of a larger revision of these electromagnets on both dryer lines, plus the purchase and installation of an elec tromagnet in "B" dry resin stream is expected to be completed by April 30. 2. Type 318 trials for CBS involving improved rheological properties were conducted in March. 3. An interim slurry tank blending system was installed by the plant at months end. III. YIELD Yield was below standard at 96.0 % (vs. 97.1% standard). Low yield resulted from: 1. Transfer of 45 M Lbs. of off spec recovered monomer to a railcar for disposal. 2. Loss of 15 M Lbs. of resin resulting from partial set-up in R-10. 3. Loss of 20 M Lbs. of resin resulting from the short-stop ping of two reactor batches due to control system malfunc tion. IV. OVERTIME Controllable overtime in March was high at 23.8%. Training cost for transferred employees, absentee coverage and overtime bagging were the major factors. TEN 4667 -3 - V. GENERAL OPERATION A. REACTOR BUILDING VCM LEVEL Reactor Building VCM level for March was low at 0.3 ppm. B. SAFETY 1. OSHA Days Away From Work Cases = 0 2. OSHA Restricted Duty Cases =0 -/ The plant has now worked 498 consecutive days without a lost time injury. C. EXPANSION 1. Construction on the overhead silo installation continued throughout the month. Startup date of this project is estimated at April 3, although some appurtenances will re main to be completed. As a continuing interim measure, resin is being loaded into trucks at Flemington and transferred into hopper cars at Ringoes, New Jersey. 2. Engineering is continuing to investigate the cause of intermit tent failures in the Water Addback Metering System. D. PARTIAL SET-UP - R & D On March 6 the plant experienced a partially set-up batch in R Si D, Early warning by the wattmeter system allowed short-stopping of the batch and the probable prevention of an entire set-up. The cause of the set-up is thought is be related to an impurity present in tf recovered monomer which is not measured by current analysis methods E. PERSONNEL 1. Mr. R. Kelly and Mr. G, Barboni were hired to fill two vacancie in the plant compliment. 2. Mr. C. Staniulis, Dryer Operator, retired March 24, 1981. TEN 4668 -43. Mr. S. Jones, Chief Boiler Operator, passed away on March 11, 1981. VI. SUMMARY - Attached VII. CAPITAL SPENDING STATUS REPORT - Attached VIII. MANUFACTURING COST PROJECTION - Attached D. M. Hershkowitz^J i/ TEN 4669