Document wKKYyG2De9pMvmYexwBMk9EpJ

SAFETY A. H. Sather Occupational Injuries Injuries Treated Fi rst Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time Injuries By Department 1981 1980 May Year-to-Date Year-to-Date 2 17 02 00 00 00 22 9 1 3 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office Injuries By Type 13 05 18 01 01 01 8 9 13 2 0 0 Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 19 01 16 02 02 01 15 k 2 7 k 0 Near Miss Chem Wash Spill A mechanic suffered first and second degree chemical burns to the insides of his forearms as a result of chem wash contact during maintenance work on 7^1 reactor gearbox. The reactor had been chem washed extensively prior to turn ing it over to. maintenance for repair. The atmospheric vent valve was open during this cycle and the chem wash was vented to the atmosphere through this line. Evidence of chem wash material was found on all portions of the reactor as well as on the concrete below the reactor. The mechanic contacted the spilled chem wash while he was removing the universal joint guard. The chem wash procedures now prohibit having the atmospheric vent valve open during periods.; when chem wash is being supplied to reactor condensers. Future changes to the modicon controller are planned to prevent having the atmospheric vent valve open while chem wash is being supplied to the condenser. As of May 31, 1981, the plant operated a total of 698 days or 905,880 manhours without a disabling injury. (1) DTH 000019217 SAFETY - (continued) Safety Meetings Several topics were covered during May safety meetings. The topics included: April injury experience and preventive emphasis; proper use of hand tools; and characteristics and extinguishment of VCM fires. Safety Audit Field work for the 1981 safety audit was completed during the reporting period. All operating and maintenance areas were surveyed for safety hazards/problems and lighting. Training A total of ten (10) personnel received new employee orientation. Eight (8) of them were casual, one (1) a summer engineer and one (1) the plant accountant. A new Vinyl Chief Operator - R. S. Kilgore - received safety permit training. A total of 1** engineering and research personnel were given orientation regard ing work practices and other requirements prior to the vinyl reactor variability study. OSHA Compliance Activity for the reporting period was limited to routine sampling as noted below. The results and overexposures are shown below. Chemical Number 4. PEL Percent >PEL - Overexposures Number Percent VCM 75 95 4 Lead 25 100 0 Antimony 25 100 0 Total Particulates 6 100 0 5 0 0 0 Overexposures A total of four (4) overexposures to VCM were found. One occurred to a chief operator who did not wear a respirator and no specific cause identified. The remaining overexposures occurred to personnel who were wearing respirators. They occurred to: a mechanic who was repairing a VCM leak at the VCM tank farm, to a supervisor who was overseeing the dumping of a coarse batch, and to an "A" operator who was changing VCM filters in the new module. t (2) * DTH 000019218 VINYL P. E. Markey Month Year to Date 1. Total Production, MM Lbs. 2. Production Rate, M Lbs./C.D. 3. Charges, Reactor Batches/C.D. A. Total Charges 5. Reactor Stream Factor, % 6. Dryer Rate, Average Lbs./Hr. (on-stream) 7. Dryer Stream Factor 8. Accounting Days 25.3 816 20.2 625 87.1 5772 83.9 31 130.7 866 21.2 3200 88.3 5908 87.1 151 Vinyl Department production for May was 98% of budget at 25-3 MM pounds. Reactor and dryer stream factors 37.1% and 83.9%, respectively. Reactors 1. Shutdown work for reactor placement and tie-ins resulted in a 2.6% reactor stream factor penalty. 2. The April 30th power failure in which a number of reactors had to be killed in polymerization resulted in a stream factor penalty of 1.0% including the seal change on 7Al reactor which failed during the power outage. 3. Maintenance on agitator gearboxes resulted in a 1.8% reactor stream factor penalty. 4. Condenser cleanings resulted in a 1.1% stream factor penalty. 5. Recovery system and dryer imbalances resulted in a 5-A% reactor stream factor penalty. Dryers 1. Shutdown work for reactor placement and installation of a Sweco sifter on No. 8 dryer resulted in a 2.1% dryer stream factor penalty. 2. Maintenance and pluggage or dryer centrifuges resulted in a 33% dryer stream factor penalty. 3. Resin transfer system problems resulted in a 1.8% dryer stream factor penalty. 4. Normal dryer cleaning and line changes resulted in a 1.6% dryer stream factor penalty. i 5. Reactor/Dryer area imbalances resulted in a 2.5% dryer stream factor penalty. (3) DTH 000019219 VINYL - (continued) Resin Quality Summary Resin Type 5305 5385 5425 5465 Sifter Overflow Total Prime Pounds 1,522,976 15,600,997 4,678,956 2,030,650 - 23,833,579 "BC" Grade 121,650 314,100 7,500 - 443,250 "H" Grade 341,750 114,600 56,900 - 345,345 858,595 % of Total Production 7.9 63.8 18.9 8.1 1.3 100.0 Quality performance for May was 94.8% customer grade with 1.8% "BC" grade and 3.4% "H" grade. Due to business conditions and tight railcar availability no debagging or deboxing activities were conducted during the month. Cost The variable cost variance for May was favorable $837.2 with $951.** M due to price and ($114.3) due to efficiency. The major price variance was $933.4 M due to below budget monomer pricing. Monomer pricing was 20.045 /lb. versus the budgeted 23.636 </1b. Unfavorable efficiency variances of ($63.2 M) for VCM, ($73-6) due to off-grade production and ($4 M) due to product mix were partially offset by a favorable variance of $26.4 M in the additives area. The monomer raw material requirement for May was 1.02992 pounds VCM per pound PVC versus a 1.01936 standard. The largest single item of the shortfall continues, to be weight discrepancies on incoming monomer shipments. Check weighing of incoming cars has shown: No. of Cars Scale Used Average Overage of (shortfall) Lbs./Railcar 76 Aberdeen Plant 1,801 20 Rai1 road 1,740 A more extensive weighing program is being coordinated with the VCM plant, May's 97.1% PVC/VCM efficiency would improve to at least 98.1% (budget 98.1%) removing the effect of incoming monomer weight discrepancies. General t 1. Packaging for the month totalled 5.4 MM pounds, 2. The plant expansion reactors were lifted and placed in position in both reactor modules on May 18th and 19th. Safety considerations dictated a one day shutdown in each reactor module for the reactor placements. (4) DTH 000019220 VINYL - (continued) General - (continued) 3. Additional testing of Lucidol's L-46 initiator was conducted in May. Testing indicated potential reduction in polymerization times of five to ten percent. 4. Additional testing of Naugard 492 as an antioxidant replacement for Conoco1s PC-555 was conducted in May. Extended testing on 5385 resin indicated heat stabilities and colors to be equivalent to standard. 5. An extensive reactor variability test run was conducted at the Aberdeen Plant from May 26 to June 4, 19S1. The goal of the program is to determine the underlying causes of batch to batch particle size variation. 1 (5) DTH 000019221 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 1,362 52 6,443 171 34 1 ,221 2,787 90 14,856 4,320 139 22,520 31 151 Line I operated 26 days during May at an average rate of 52 M pounds per day. Major items affecting production efficiency were: product changes (24.3 hours), skip hoist (17.3 hours), dicers (16.3 hours), blender scales (10.1 hours), mill (5.5 hours), Banbury seals (5*4 hours) and blender conveyor (5.0 hours). Line V operated 5 days during May at an average rate of 34 M pounds per day. Major items affecting production efficiency were: product changes (11.5 hours) and quality control (7-5 hours). Line III operated 31 days during May at an average rate of 90 M pounds per day. Line III production was affected by: product changes (47.6 hours), qua 1 ity control (27.5 hours) and mill maintenance (8.0 hours). duality performance for flexible compounds was 5-7% off-grade of which 47-7% was due to mill scrap. "BC" production was -6.0%. The raw material requirement for flexible compounds was 1.03038 pounds of raw material per pound of compound versus a 1.01300 standard. (Y.T.D. is 1.00949.) The unfavorable raw material variance is due to production of two compounds which were not budgeted for I98I. The variable cost variance for compound was ($49.5 M) with $41.7 M due to price and ($91.2 M) due to efficiency. The variance due to product mix was $0.95 M. Major efficiency variances were: off-grade ($66.7M) and resin ($14.7 M). The only major price variance was $10.7 M for colors. Dry Blend Month Per Day Y.T.D. Production, M Pounds Accounting Days 4,074 157 19,682 31 151 Dry Blend operated 26 days during May at an average rate of 157 M pounds per day. Production included RP-100 BW, 90171, 80174, 802730 and purge compound. Dry Blend production was affected by: quality control (70.6 hours), product changes (13.6 hours), out of resin (9-9 hours), master batch feeder (7.8 hours), and product blower (6.7 hours). i Quality performance for the month was 33.31% customer grade. The raw material requirement for dry blend was 1.01045 pounds of raw material per pound of dry blend versus a standard of 1.00525. (Y.T.D. is 1.01293)- (6) DTH 000019222 COMPOUND - (continued) Dry Blend - (continued) The variable cost variance for dry blend was $54.7 M with $16.4 M due to price and $38.3 M due to efficiency. The variance due to mix was $39.1 M. There were no major price or efficiency variances for the month. PIasticizer Month Per Day Y.T.D, Production, M Pounds Accounting Days 1,129 61 5,280 31 151 Plasticizer operated 20 days during May at an average rate of 61 M pounds per day. Production included: DOP, 610P, DIDP, and 810P. VRP production totaled 84 M pounds (7.4%). Production was limited by reactor instrument repairs (12.5 hours), safety disc changes (18.0 hours), and out of P.A. (54.5 hours). The raw material requirement for plasticizer was*1.15033 pounds of raw materials per pound of plasticizer versus a 1.10529 standard. (Y.T.D. is 1.11754;) The variable cost for plasticizer was $6.3 M with $13-9 due to price and ($7-6 M) due to efficiency. The only major price variance was$15.6 M for P.A. and the only major efficiency variance was ($17*2 M) for P.A. which was due to un budgeted production of 81 OP and to the I PA not accounting for P.A. consumption in RAE (VRP) production. General Total customer grade compound inventory increased from 1.2 MM to 8.3 MM pounds during May. 1 (7) DTH 000019223 MAINTENANCE S. J. Vincent Vinyl There were two large reactor seal failures, three reactor condensers cleaned, and four reactor gearbox problems in this period. The seal failures were on the D-400 reactor in the old module and on the 741 reactor in the new module. The condensers cleaned were on the 741, 743, and 744 reactors in the new module. Two of the gearbox failures were in the old module on the D-300 and D-400 reactors. Both failures were a result of intermediate gear and bearing failure. In the new module the 741 reactor gearbox was pulled and inspected. No addi tional problems were found. After the low speed pinion and low speed gears failed, the 742 reactor gearbox required a major overhaul. The safetydiscs were changed and all safety valves tested on the D-500 and 741 reactors. There were sixteen safety discs replaced on pumps and drums in the vinyl area in this period. There were six seal failures and one pump overhauled in the vinyl area. In the new module, pump seals were replaced on the east and west chem wash pump, the condensate return pump, high pressure service water pump, and the west water charge pump. In the old module the seal was replaced on the west VCM charge pump and the north water charge pump was overhauled. There were three major valves replaced in this period. A new 6" emergency dump valve was installed in the old module dump line, the 6" inlet valve to the old module fresh filter was replaced and in the new module the 742 slurry dump valve was replaced. There were some projects completed in the vinyl area. The charge water pre heater in the new module was acid cleaned and the south RVCM receiver was opened for cleaning in the old module. Three large Corken compressors were overhauled for the VCM tank farm unloading area. Repairs to the vinyl dryers were to change out the Bird centrifuge bowl and gearbox on the #6 dryer twice and once on the 5 dryer. These units were plugged with resin. The Day collector star valve was rebuilt on the #8 dryer. The air lock valve was replaced on the #1 dryer. A major project completed in the dryer area was to install the new Sweco screener on #8 dryer train. Compound, Dry Blend, Plasticizer and Resin Storage There were no major repairs to compound Line I. Several steam leaks were repaired and PM inspection of the skip hoist was completed. Repairs to the Line III equipment were to overhaul the #6 vacuum pump and both chilled water pumps. Acid cleaning of the FCM barrel was successfully completed along with the changeout of the FCM seals. The rebuilt FCM gear drive and barrel was disassembled and returned to Farrel for further evalua tion. (8) DTH 000019224 MAINTENANCE - (continued) Compound, Dry Blend, Plasticizer, and Resin Storage - (continued) In the plasticizer area the Schenk filter was opened and pulled for cleaning. There were no major repairs to dry blend equipment in this period. Other projects completed were to install a new steam regulator on the deaerators at the boiler house, replaced the governor on the Colt-on transfer unit, painted three drums for asbestos disposal and to replace the brushes in the plant sweeper. Utilities and Service There were five repairs to equipment in the plant air system. Valves were repaired in the #1, #3 and #7 air compressors. The main breaker was replaced on #8 compressor, the heater element was replaced on the west tower of the 2 air dyrer, and the desicant was replaced in both V-10 dryers. The Plant ran 7-5 hours on propane to allow Mississippi Valley Gas Company to relocate the main gas line. The tool room mechanics tested 25 safety valves for the new expansion. Planner There were 88 work orders estimated and material ordered for 36 projects. There were 28 registers closed and 30 invoice registers issued for contracted repair of equipment. The safety valve, safety disc, and equipment history were updated for the month. i (9) J)TH 000019225 MECHANICAL ENGINEERING J. A. Dixon AFE's Submitted, Approved and Closed The following AFE was approved during May: AFE No. Title 9641 Slurry Delumper The following AFE was closed to field charges during May: AFE No. Title 9560 Safety Equipment Authorized $35,000 Authorized $25,000 Completion reports were issued for the following AFE's: AFE No. Title Authorized 9589 9580 9610 Instrument Air Dryer Boiler Economizers API Clean Water Bypass $110,000 140,000 23,000 Design work is in progress on the following projects: Spare Inert Incinerator Resin Reclaim System Reactor Pressure Relief Modifications Emergency AMS Kill System Sifter Overflow Reclaim System Centrate Heat Recovery Fire Protection Improvements Phase III VCM Tank Farm Revisions V-10 Centrate Heat Recovery System Vinyl Initiator Charge Pots AFE Activity 1. AFE 9639 ~ Revisions to Emission Recovery System - J. L. White Retubing of the vapor knockout condensers is scheduled to be completed in June. 2. AFE 9729 ~ Fire Protection Improvements - Phase II -M. Ingle S J. P. McKee The backfi11ing and grounding work is completed for the pump house. Th$ pumps and drivers have been set in place and construction of the pump house walls are in progress. 3. AFE 9689 ~ Diking of Sphere S Curbing of Drum Storage Areas - J. L. White Bids were requested for completion of the curbing of the drum storage areas. Construction is scheduled for June and July. (10) DTH 000019226 MECHANICAL ENGINEERING (continued) AFE Activity - (continued) 4. AFE 9530 ~ Spare Incinerator - L. Roussel & J. White Project design work is complete. Erection of structural steel is in progress. 5. AFE 95&0 ~ Safety Equipment - J. P. McKee The overhead walkway between the 200 and 600 series silos is installed and operational. 6. AFE 9630 ~ Water Stripping - M. Ingle 6 J. White Construction is in progress. Project is scheduled to be operational in mid June. 7. AFE 9660 - Hot Water Charge Tank Replacement - J. P. McKee A sparger pipe was designed and installed in the inlet nozzle of the charge tank. This appears to have eliminated the vibration problem. 8. AFE 9680 - Fixed Point Monitor Data Computer & Warning Lights - R. B. Harned The contracts for assembly of the relay cabinet and the electrical installation have been let. 9. AFE 9690 - Breathing Air Modification - J. L. White Construction is scheduled for June. 10. AFE 9710 - Fire Protection Improvements - Phase III - T. Blazek A schedule has been issued and design work is in progress. 11. AFE 9720 - Reactor Agitator Replacement - M. S. Richards A change order was written to purchase two speed electic motors. A viking pump has been installed in a refurbished duraseal unit for a test run. 12. AFE 9740 - Modifications to Make Profile Dry Blend - J. P. Windham The new boxing silo and the weigh system were placed on order. Bids were requested for the boxing scale and use bin. Installation of the Acrison feeders is in progress. 13. AFE 9760 ~ Emergency AMS Kill System - J. L. White Drawings for the old module are being checked and drafting is in progress for the new module. 14. AFE 9770 ~ Reactor Pressure Relief Modifications - J. L. White The studding outlets for the old module are scheduled for installation in mid June. (11) DTH 000019227 MECHANICAL ENGINEERING - (continued) AFE Activity - (continued) 15. AFE 9780 - Centrate Heat Recovery - J. P. McKee Equipment location drawings are being reviewed for approval. All the major equipment is on order. 16. AFE 9790 ~ Resin Reclaim System - P. Meiers Overall project design is 10% complete. Purchasing of major equipment is in progress. 17. AFE 9521 - New VCM Rail spur - Herzog Hart Corp. Construction bids have been requested. Bids are due 6-11-81. 19, AFE 9531 ~ Vinyl Initiator Charge Pots - S. Jones Drafting is in progress. Bids have been received for the initiator pots. A studding outlet required for this project on D-300 will be installed during the next shutdown. 19. AFE 95^1 ~ VCM Tank Farm Modificiations - R. B. Harned The knockout pot has been inspected by MED. Foundation work is complete. Materials have been purchased to pre-fabricate the spool pieces for tie-ins. 20. AFE 9551 ~ V-10 Centrate Heat Recovery - S. Jones Bids have been requested for purchase of major equipment. An equipment location drawing is being reviewed for approval. 21. AFE 9581 - Dryer Building Ventilation - J. P. Windham All major equipment is on order and drafting is in progess. 22. AFE 9611 - Recovery System Revisions - J. P. McKee The rupture discs and safety heads have been placed on order. The new relief valves have been received. Drafting is in progress. 23. AFE 9631 ~ Ground Water Monitoring - V. E. Messick The ground water monitoring study has been received from the .icontractor and is being reviewed. The closure plan has been reviewed and was sent to the contractor for corrections. Construct ion - G. A. Morgan The following projects were completed during May: 1. Roadway for fork lift access to Corken compressors. 2. Boiler economizer insulation. 3- Chemical cleaning of new module preheater. k. Chemical cleaning of Line III FCM barrel. 5. Installation of piping for Centrate and Lake Charles water charge tests. (12) DTH 000019228 MECHANICAL ENGINEERING - (continued) Construction - (continued) 6. Installation of overhead walkway from 282 silo to rail silos. The following contracts were issued during May: 1. Incinerator painting 2. Installation of Chem-wash piping and equipment 3. Painting of piping and equipment - PVC expansion project 4. Installation of electrical facilities - Fixed point monitor data computer and warning lights Twenty six register tickets were issued during May. i (13) DTH 000019229 (1) Thru April, I98I Actual Accounting (2) Thru May, 1981 AUTH. CAPITAL NO. DESCRIPTION ABERDEEN AlfTUORIZATIONS REPORT DATE AUTH. APPROVEDi AFE AMT. CD EXPENDED TO DATE (2) COMMITTED TO DATE FINAL. TOTAL EST. COST COMP, UNDER (OVER) AUTH, AMT. EST. EST. COMP. CL0S. DATE DATE REMARKS 9559 9609 9629 9639 9689 9699 9709 9719 9729 9759 9530 9550 9560 9570 9590 9600 9630 9660 9670 9680 9690 9700 9710 3720 9730 9760 9750 9760 9770 Color Weigh Room Modifications Reactor Inert Vent System Air Compressor Revisions to Emission Recovery Sys. Diking of Sphere & Curbing of Drum Storage Areas 6/19/79 6/28/79 7/9/79 7/12/79 9/15/79 25,000 90,000 360,000 100,000 170,000 26,065 16,561 292,068 78,168 136,671 26,065 16,561 302,586 95,307 135,095 26,065 90,000 360,000 100,000 170,000 Plant Dryer Debottlenecking 9/15/79 80,000 36,665 69,360 80,000 Facilities for Multiple Grade Resin 9/20/79 Aberdeen PVC Resin Expansion 9/10/79 870,000 850,000 326,950 873.776 621,810 887,171 725,000 887,171 Fire Protection Improvements Phase II 10/1/79 690,000 278,796 376,696 690,000 Aberdeen PVC Resin Expansion Spare incinerator 12/10/79 11,150,000 5,502,000 9,668,000 10,650,000 1/23/80 650,000 153,238 626,882 550,000 P.A. Handling Improvements 3/3/80 63,000 32,386 32,687 63,000 Safety Equipment 3/12/80 25,000 10,939 29,299 29,299 Replace T-101 P.A. Tank 3/27/80 119,000 62,720 62,720 119,000 Critical Spare Equipment Calcium Stearate Addition System 3/26/80 6/2/80 59.000 86,000 11,610 11,330 60,386 13,368 60,386 86,000 Uater Stripping Hot Uater Charge Tank Replacement 6/30/80 6/6/80 810,000 160,000 332,798 160,316 369,652 161,905 510,000 160,000 Laboratory Equipment Fixed Point Monitor Data Computer and Warning Lights 7/9/80 9/6/80 32,000 113,000 31,587 37,739 32,667 67,703 32,667 113,000 Breathing Air Modification Compound Fines 6 Streamers Removal 9/9/80 10/1/80 21,000 95,000 2,519 Q 9,872 29,526 , 21,000 95,000 Fire Protection - Phase Ml 10/16/80 385,000 1.707 ' 1,707 385.000 Reactor Agitator Replacement 1C/16/C0 420,000 S5.WC 131,672 420,000 Compound Line Ml Debottlenecking Modifications to Make Profile Dry Blend Rotary Dryer Infulatlon (Energy) Emergency AMS Kill System Reactor Pressure Relief Mod. 10/16/30 1,350,000 10/27/80 200,000 11/10/80 11/15/80 11/25/80 22,000 335,000 560,000 23,519 16,310 69,500 68,301 1,350,000 200,000 0 65,097 6,669 27,391 89,716 302,671 27,391 335,000 660,000 9780 Centrate Heat Recovery 12/8/80 9790 Resin Reclaim System 12/16/80 9800 Plasticizer Irritant Control (Air) 12/15/80 9810 Replacement Gearbox for Parrel Mixer 12/18/80 9511 Miscellaneous Projects Under $10,000 1/9/81 9521 New VCM Railsnur 1/30/81 9531 . Vinyl Initiator Charge Pots 1/21/81 9561 VCM Tank Farm Modifications 80-395 Interplant Communication-Phase M 1/21/81 1/22/80 9551 V-I0 Centrate Heat Recovery (Energy) 2/17/81 9561 Cooling Tower Fan Controls (Energy) 2/17/81 5371 9581 Centrifugal Air Compressor Repair Dryer Building Ventilation 3/M/81 3/20/81 9591 Sifter Overflow Reclaim System 3/20/81 9601 Compliance With EPA VCM Standard (Air) 3/25/81 9611 Recovery System jlevlslo.is 3/25/81 9621 laboratory Equipment 3/25/81 9631 Ground Uater Monitoring (Solid) 3/26/81 9661 Slurry Oelumper 5/16/81 300,000 727,000 80,000 73,000 170,000 11,000 165,000 90,000 55,000 125,000 60,000 65,000 23,000 200,000 72,000 30,000 62,000 30,000 35,000 11,276 12,050 25,319 0 66,258 9.808 0 201 0 0 0 62,972 0 0 0 60,992 177,050 28,305 69,600 128,227 15,723 1,186 23,792 21,755 680 19,860 62,972 7,516 16,511 12,636 . 300,000 727,000 80,000 73,000 170,000 20,000 165,000 90,000 55,000 125,000 60,000 65,000 23,000 200,000 72,000 0 9,916 30,000 0 37,236 62,000 0 16,872 30,000 0 0 35,000 955 0 0 0 0 1/81 6/81 12/81 3/82 8/81 11/81 8/81 11/81 6/81 9/81 Closed to field charges. Project on hold. Revisions in progress. Revisions In progress. Revisions in progress. 0 165,000 ( 37.171) 0 8/81 8/81 8/81 6/81 11/81 11/81 11/Cl 9/81 Construction in progress. Construction in progress. Reactors received 3/14/81. Construction in progress. 700,000 -100,000 0 ( 6,299) 0 ( 1,386) 0 300,000 0 ( 667) 0 9/81 12/81 6/81 9/81 12/81 3/82 5/81 8/81 12/81 3/82 6/81 9/81 8/81 11/81 6/81 9/81 6/81 9/81 12/80 3/81 9/81 12/81 Construction in progress. Construction in progress. Project on hold. Closed to field charges. Engineering In progress. Condenser to ship 6/81. Engineering in progress. Construction in progress. Project operational. Closed to field charges. Contract let. 0 7/81 10/81 Construction scheduled. 0 10/81 1/82 Engineering scheduled. 0 10/81 1/82 Engineering in progress; CED. 0 10/31 1/82 Agitators to ship 6/61. 0 6/82 9/82 FCM barrel to ship 10/3). 0 10/81 1/82 Engineering In progress. C 5.391) 0 100,000 0 0 0 0 0 C 9,000) 0 0 0 0 0 0 0 0 0 7/81 10/81 8/81 11/81 12/81 3/82 3/82 6/82 3/82 6/82 9/81 12/81 9/81 12/81 12/81 3/82 8/81 11/81 11/81 2/82 1/82 6/82 7/ei 10/81 5/82 8/82 11/81 2/82 6/81 7/81 9/81 12/81 3/82 6/82 12/81 3/82 80% complete. Engineering in progress. Engineering in progress, nozzle Installation scheduled. Engineering in progress. Engineering in progress; CED. Engineering in progress. Gearbox to ship 10/81. Fifty-three projects approved. Bids requested. Engineering in progress; CEO. Foundation installed. Revisions in progress. Engineering In progress; CED. Equipment on order. Closed to field charges. Engineering in progress. Engineering in progress. Engineering in progress. 0 12/81 3/82 Equipment on order. 0 8/81 11/81 Equipment on order. 0 10/81 1/82 Contract let. 0 2/82 5/82 Quotes being obtained. EXPENSE 9020 Repairs to Line 1 Compounder 11/26/80 38,000 0 0 38,000 0 11/81 2/32 Parts ordered In January. (H) DTH 000019230 PERSONNEL - R. A. Miller EMPLOYMENT Mary Conn - Drafter Donna Cambre - Process Engineer (Summer) Alice James - Process Engineer (Co-Op) Weldon Higganbotham - Plant Accountant Albert Gunn - Casual Labor Paul Cogsdell - Casual Labor Richard Metcalf - Casual Labor Will Malone - Casual Labor David Volz - Casual Labor Frank Brewer - Casual Labor Annie Everett - Casual Labor Richard Garner - Casual Labor Mildred Thompson - Casual Labor TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTION Larry Frye, Chief Operator, transferred to Maintenance Helper. Thomas Staten, Lab Technician "A", transferred to Maintenance Helper. RETIREMENT None. TERMINATION Annie Everett, Casual Labor Chris Wing, Process Engineer OTHER During May there were 12 casual labor employees on payroll. Total hours worked were 1611. (15) DTH 000019231 CONOCO CHEMICALS Aberdeen, Mississippi Mav 1981 MONTHLY PERSONNEL REPORT Salaried Employees 83* Minority Employees # % Hourly Employees 159 Salaried 7 8% Total Employees 242* - Hourly 58 36% Employees (Hourly) Total 65 27% New Employees Terminations 0 0 Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 0 0 0 DEPARTMENTS PAR # EMPLOYEES iMIN. EMPT . % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse Gen. Plant Maintenance Laboratory 9 11 52 22 8 ' 1 10 3 48 8 20 4 12% 0 0 0 0 0 0 30% 0 7 0 0 0 0 \7% 0 0 0 1** 0 0 20% 0 0 0 0 0 0 Compound 37 36 26 72% 0 0 0 0 0 0 Vinyl 32 13 ko% 0 0 0 0 0 0 Plasticizer 4 5 3 60% 0 0 0 ~0 0 0, - Number of Applicants: Month 16 Year to Date APPLICANT BREAKDOWN: # Minority 3 % Minority # Female 4 % Female 99 m 25% *lncludes five (5) temporary employees. **lncludes one (1) retirement. Ret irements are not included in turnover rates. Hires (Hourly) : Month 0 Year to Date 7 Terminations (Hourly) : Month 0 Year to Date 1 ** Overall Turnover 0 Projected Annual Turnover 0 (16) DTH000019232 &9 SO OVERTIME AND ABSENTEEISM <N> -- <W -- vO ** O o lcAn c<ow LA CO cn Ol f0 " d-P ** <3M> <M> O -- so - -3* -- CM *-- CN -- 4) 4- > </> >ID* o f>D- *o o\ -- (A a o> 4) *o oo oo \0 CO \0 -- tN -- -- CM CM or- ---- LA LA ao> 4) CM NO 4) > o O2 cn 4O-1 8 -o *-- 4-1 II -- 0) h- -* o LA O LA LA O O o LA J LA CM O CM CM LA o o r-. cn -- n <o L. CM CM CM LA CA r* CO \0 CM LA cn LA CM LA r-. CO CM OO o -T LA o o so o o 00 i-* vr> CO *uj oa CM 2. 7. J E ci O -- ; 4) 0--cfl --10 C-O* a. *j >- _ -- 4) --4- C<D 4>> o 4) > o 4) CO 'o 44-1) s O-- DTH 000019233 PROCESS ENGINEERING R. A. Frohreich A. Expansion Project Installation of the product rail silos is continuing. Both reactors have been set in place. The instrumentation contractor has moved into the plant and has begun work. Plans are to set the reactor condensors in June. Deluge system drawings are being reviewed. B. Plasticizer Catalyst Handling The class "A" design for this project is being prepared. C. Spare Cooling Tower Pumps A process design to provide spare cooling tower pumps on two of the vinyl reactor cooling towers was issued. D. New Boiler Deaerator A process design to provide a new boiler feed water deaerator was issued. E. Line III Mill Heating System The class "A" design to provide a new heating system for the Compound Line III roll mill was issued. F. Variabi1ity Study Process Engineering provided assistance to Ponca City R&D in setting up the reactor area variability test run. G. Automatic Resin Bagging The class "A" design to convert the automatic bagging system from compound to resin service was issued. H. Recovery System Revisions The class "A" process design for this project was issued. I. Batch Water Stripping Project The Batch Water Stripping Operating Manual was issued and operator training is in progress. Process Engineering will provide startup assistance. J. Waste Water Treatment Revisions The AFE request for this project was submitted. (18) DTH 000019234 PROCESS ENGINEERING - (continued) K. Plasticizer Waste Water Stripping Revisions The design review meeting for this project was held and the class "A" design incorporating comments from the review meeting was issued. L. Caustic Addition to Recovery Systems The class "A" design for this project was issued. M. Safety Projects and Equipment The AFE request for this project was submitted. This project includes the combustible monitor for the dryer burner area and the diverter valves on the 470 and 490 series silos. N. Lake Charles Water and Centrate Rinse Test Runs Process Engineering worked with a PED representative and operations to perform test runs on Lake Charles Water and Centrate Rinse. O. Additional Expansion Silo The class "A" design for an additional expansion silo is being prepared. P. I98I Capital Budget Much of the engineering effort during the month was directed toward designs for projects to be included in the 1982 Capital Budget. (19) DTH 000019235 ENVIRONMENTAL V. E. Messick Particulates One dryer exhaust was sampled in May for particulates and was within allowable 1imits. Water The total suspended solids from outfall 002 exceeded allowable permit limits on the sample taken on May 20. All other parameters were within permit 1imitat ions. A draft NPDES permit incorporating plant comments was received in early June. Hazardous Waste Management The closure plan was received from the contractor and was reviewed. The closure cost estimate was sent to the insurance division who is assisting in obtaining insurance as required by RCRA. The Groundwater Monitoring Study was received from the contractor and is being reviewed. Hazardous waste management training as required by RCRA was completed. A letter ammending the plant's hazardous waste permit application to delete "Rag Layer" treatment and storage facilities was sent to the Mississippi State Board of Health. The "Rag Layer" is now processed to VRP with the aid of a filtration step. Other The "Notification of Hazardous Waste Site" as required by the Superfund Regulation was transmitted to the EPA. (20) DTH 000019236 Flow GPM Jan. - Ave. 1069 Max. 1297 Feb. - Ave. 757 Max. 819 Mar. - Ave. 753 Max. 790 Apr. - Ave. 946 Max. 1200 May - Ave.' 846 Max. 1200 June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. TABLE I - WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB./DY. 39 504 57 88/ COD PPM LB./DY. 69 888 106 1650 Sus. Solids PPM LB./DY. 7 93 9 114 Diss. 02 8 .5-10.4 11 95 18 154 10 90 11 103 10 118 20 253 12 125 14 163 43 382 56 479 36 330 51 466 31 360 41 519 43 470 54 629 7 65 8 9-9.8 10 86 11 93 8 3-8.9 17 139 13 151 8 .2-8.9 19 240 13 138 7 .4-8.4 17 198 NPDES - Ave. Max. - 32 387 **3 520 - 1390 - 19*0 - 605 - 909 >6.0 ph 7.4-7.8 7.5-7.9 7.6-7.7 6.9-8.1 7.3-8.0 6.0-8.5 (21) DTH 000019237 ENERGY CONSERVATION - J. F. Perez-Velasco I. Plant Operations Total energy consumption for May was 108.860 MMM BTU's. The energy consumption per pound of product increased to 3130 3TU/1b. as compared with 2940 BTU/lb. for April. 11. Plant Energy Conservation Program Steam Leaks Fourteen (14) steam leaks were repaired in May. Boiler Adjustment A1 Thomas and Johnny Click of MED made a survey of the boiler controls during a two day period. Suggestions were given to plant. (22) DTH 000019238 ITEM Control Period ENERGY CONSERVATION DATA 1981 Hay 1980 May 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. 1^81 I98O N/A 370 N/A 424 N/A 414 25.2 4.1 4.3 1.2 30* 13-7 0.9 4.5 0.9 20.0 52111 1020 53-154 5.4312 10000 54.312 15.164 92000 1.395 108.860 3130 35887 1020 36.605 4.1446 10000 41.446 3.42 92000 0.315 78.366 3918 Avg. % Excess Air I98I 1980 27 22 27 21 24 26 (23) DTH 000019239 LABORATORY R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Report By Lawrencevi1le Ind. 34431 Natural Master Fence Fittings 45541 Natural Permafit Corp. Southwire Co. World Of Plastics 90171 5425 5385 Product not ready. Received unapproved Line V material. Material burned. Contamination. Moisture. JRM JRM RDJ RDJ PEM WAIVERS RECEIVED Date 1 dentification Product Customer Reason Waived By 5/1 5/1 5/1 5/1 5/5 5/12 5/13 5/18 5/28 5/28 5/28 5/28 02891 Bags CONX 45726 PLCX 43857 CONX 45749 03126 Bags PLCX 43863 PTLX 41361 PLCX 43728 03222 Bags CONX 45729 PLCX 43737 PLCX 43859 5425 5835-3 5385-3 5425 5305 5385-3 80174 5385-3 5305 5425 5425 5425 Nylex World or Plastics World of PIastics Southwire Uniroyal World of Plastics Mid American LCP Inmont Intex Intex Intex Dry Time Bulk Density Particle Size Viscosity Particle Size Particle Size Eq. Torque Particle Size Bulk Density & Viscosity Viscosity Viscosity Bulk Density ELK ELK ELK ELK ELK ELK CJM ELK CRM ELK ELK ELK PRODUCT SERVICE 6 DEVELOPMENT Sample Shipments Ship Date Product Amount (Lbs.) Customer Requested By 5/1 5/7 5/8 5/8 5/8 5/8 5/13 5385-3 5385-1 61 OP 14741 Natural 5385-1 5425 5385-1 61 OP 15041 CLBL 5 1,000 5 gal. 100 50 50 5 1 gal. 50 COCHEM El son Thermoplastics Bel den1 Corp. Industrial Plastics Flexible Tubing M T Chemicals Robinson Electronics AHH COEDS MED JFN PCM JLI RTM (24) DTH 000019240 LABORATORY - (continued) PRODUCT SERVICE 6 DEVELOPMENT - (continued) Sample Shipments - (continued) Ship Date Product 5/14 5/15 5/18 5/19 5/19 5/22 5/22 5/22 5/22 5/27 5/27 5/27 5385 5305 5385-1 5425 VRP VRP 15071 Natural 28831 Natural 44171 Black 5385-3 15041 CLBL 15071 Natural VRP 61 OP RP-100 Amount (Lbs.) 100 150 2,250 2,250 1 gal . 1 gal . 10 10 10 50 100 50 1 gal . 5 gal. 20 Customer Sherwin Wi11iams Conoco - Ponca City Gary Chemical Requested By COEDS PEM COEDS Heritage International Marketing Tech. Services Conoco - Ponca City WR WR SKS Petrolite Corp. Advanced Plastics Corp. La van tu re Heritage International Belden Corp. Crane Plastics CSS MFM JFN WR MED CJM Special Compound Testing Complete Western Electric specification tests were completed on seven (7) lots of thei r compounds, as follows: 34861 Gray 546 34862 Gray 546 36861 Natural 36862 Natural 38761 Black 2 lots 1 lot 1 lot 2 lots 1 lot Plasticizer content and flammability tests were run on nine (9) railcar or trailer samples from these lots. New Compounds Quality control standards and specifications were prepared for 27651 Black a new injection molding compound for automotive applications. (25) DTH 000019241 LABORATORY - (continued) PRODUCT SERVICE & DEVELOPMENT - (continued) Customer Complaints Precision Molding has complained that their profile, extruded from 18961 Black, is not as black as molding extruded by Custom Molding from a competitor's compound. Tests have indicated that the problem is not con centration or type of carbon black, but is caused by differences in filler content. 18961 contains considerable calcium carbonate filler while the Custom Molding compound is unfilled. Dry Blend Development Approximately ten laboratory Welex batches of dry blend compound were prepared for use and quality control standards. QUALITY CONTROL TESTING Res in Regular Samples = 388 Bag Samples = 137 Other In-Process Samples = 3,275 Bulk Shipments = 164 (Railcars = 106, Trucks =58) Dry Blend Blenders Produced = 479 Blenders Tested = 478 Blenders Adjusted = 23.6% Other In-Process Samples = 612 Bulk Shipments = 66 (Railcars =11, Trucks = 55) Compound Blenders Produced = 690 Blenders Adjusted = \ .7% Line V Production = 93 skids, 14 boxes Other In-Process Samples = 461 Bulk Shipments = 15 (Railcars = 14, Trucks = 1) Resin Heat Stabi1ity Forth nine (49) lots of resin were tested for oven heat stability. All the lots were within the specification limits for this property and all types of resin averaged equal to or better than the controls. (26) DTH 000019242 LABORATORY - (continued) QUALITY CONTROL TESTING - (continued) Raw Material Testing Sixty three (63) lots of plant raw materials were tested and released. Two lots of Halbase 100 EP lead stabilizer were held up due to marginal dispersion but were subsequently accepted because it is not used in compounds where dis persion is very critical. One lot of Ongard 2 was rejected for poor dispersion. Another lot of Ongard 2 sent as a replacement was also questionable but was accepted because better material was not available. It is a relatively new raw material specified by Western Electric. We had previously notified Western of potential dispersion problems when Ongard 2 was specified. Five samples of various color concentrates from three suppliers were evaluated as replacements for Wilson color concentrates. The Wilson concentrates we are now using have been showing poor pigment dispersion and color variations. Replacements are now approved for all but one of the Wilson color concentrates. RVCM of Shipments A total of 168 shipment samples were tested for RVCM in May. A summary of this data is below. Product 5305 5385 5425 5465 Dry Blend PPM RVCM No Samples 4.7 1.1 86 44 1.8 0.1 17 12 0.2 9 Analytical Work The following samples were tested in the analytical lab in May. Sample Type Analysis No. of Samples Res i n Plasticizer Waste Water Air Bags Western Electric Compound Carbon Dosimetry Compound Viscosity Purity % Solids PPM VCM Plasticizer Purity Mg. VCM Resin Viscosity 670 13 45 4 4 92 2 (27) DTH 000019243 LABORATORY - (continued) QUALITY CONTROL TESTING - (continued) RVCM of In Process Samples A total of 829 process samples were tested for RVCM. A summary of in process sample analysis is below. Sample Average RVCM, PPM Number of Samples Reactor Slurries Blowdown Tank Water 5305 Drier Samples 193 4.7 9.4 619 162 48 One slurry daily average exceeded 400 ppm. MISCELLANEOUS The Chief Chemist attended the Marketing/Business Area/Research Meeting in Houston June 18 and 19, 1981. (28) DTH 000019244 TRANSPORTATION J. E. Stark Shipment by Product - M Lbs. May Res i n Plasticizer Dry Blend Compound TOTAL 17,637 37 4,043 3,241 29,958 Number of Shipments by Mode O.T. O.T. R/C Bulk Van C.O.T. Resin - Bulk - Package - Export Plasticizer Dry Blend - Bulk - Package Compound - Bulk - Package - Export 92 40 5 3 77 85 11 11 1 26 1 111 49 120 0 Back Hauls for May 22 Number of Shipments by Month - Y.T. D. R/C Bulk Van C.O.T. Janua ry February March Apri 1 May 91 48 200 91 55 172 132 65 208 96 38 181 111 49 120 2 0 6 0 0 Material Handling Report M/Lbs. Packaged Resin from Production Packaged Compound, Dry Blend from Product 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 5,387 2,876 4,293 40 121 284 2,309 3,159 2,389 20,858 Year to Date 105,029 520 20,165 20,066 145,780 C.C. 1 2 3 1 T0FC CPU Total 133 6 11 80 11 51 64 11 12 10 38 1 o "5F 351 23 C.C. T0FC CPU Total 91 0 55 487 40 0 58 416 54 0 74 539 11 0 69 395 3 0 68 351 T/L 133 71 106 1 3 7 57 78 59 515 (29) DTH 000019245 TRANSPORTATI ON - (continued) Off-Grade In Storaqe Material Sifter Overflow Resin "BC" Resin "H" Mill Scraps Compound "B" Compound "H" Dry Blend "OG" M/Lbs. 881 2,405 1,113 83 1,288 93 522 085 T/L 22 59 28 2 32 2 13 T5F (30) DTH 000019246 LOCATION MAIN-East # ) TOTAL M / SQ. FT. 48 Prairie 12-1 12 12-2 12-3 ' 22 21 12-4 22 12-5 21 12-6 21 - ** 12-7 21 12-8 ' 21 12-9 21 12-12 , 21_ total 251 CONOCO TRANSPORTATION May 31, 1981 ABERDEEN WAREHOUSE CONTENTS ESTIMATED MM POUNDS ON FLOOR OPEN TOT Compounds 5. 3 Dry Blend .1 Export Resin .4 Conoco Resin HDPE Dry Blend .2 .3 .1 6 .0 4.0 10.0 .... : -i 4' ` 1.1 1.5 Conoco Resin Conoco 2.3 .3 2. 3 1 .2 3.5 Export Resin Conoco Resin Resin O.G. Mill Scraps 6 4.4 .1 9 2.fi 3.5 * 4.4 3.5 Cmpd O.G. 1.0 Dry Blend O.G. .3 Sifter Overflow .2 Resin O.G. Compound .2 .1 1.8 .7 2.5 Resin 2.5 Raw Material Resin O.G. Conoco Resin .2 3.3 4.0 2.8 3.3 * 4.0 .7 3.5 .2 3.5 . 3.5 Conoco Resin .2 .2 3.2 3.5 Dry Blend O.G. ,1 S.O. .8 Comp. O.G. Mill Scarp Sub-Total (Plug-Aisles) Total Conoco .5 v4 - TYTH 000019247 ' 1,4 2.1 3.5 .. ..42 J?. 27.5 15. 9 1.4 43.4 ABERDEEN CHEMICAL PLANT INJURY PERFORMANCE c c o co >o 3 c e FREQUENCY TOTAL INJURIES (FA OR MC) X 12 TOTAL.EMPLOYEES DTH 000019248 MONTHLY HOURLY TURNOVER DTH 000019249 ENERGY USAGE Monthly 12 Month Moving Average DTH 000019250 ABERDEEN PLANT PRODUCTION 1981 MM POUNDS CUMULATIVE 35 30 25 20 15 6 5 4 3 2 1 40 35 6 30 5 25 4 20 3 15 2 10 L5 2 I 0 -------- BUDGET --------- ACTUAL --------- CUMULATIVE DTH 000019251 OFF-GRADE C ABERDEEN PLANT QUALITY PERFORMANCE 1981 STANDARD 1.33 c C" STANDARD 1.35 V DTH 000019252 ABERDEEN PLANT EFFICIENCY 1981 STANDARD 1.01936 STANDARD 1 .01300 STANDARD 1.00580 1 STANDARD 1.10500 MONTHLY CUMULATIVE DTH 000019253 ABERDEEN PLANT INVENTORIES DTH 000019254