Document x1yRgaD6wdgDQBJmjNxMmDkLm

SAFETY A. H. Sather Occupational Injuries Injuries Treated First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time February 2 0 0 0 0 1981 Year to Date b 0 0 0 0 1980 Year to Date 8 b 0 0 0 Injuries by Department Vinyl Operations Compound Operations Ma intenance Laboratory Receiving and Warehouse Office 0 1 1 0 0 0 0 2 2 0 0 0 1* b b 0 0 0 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 13 00 11 11 00 00 b 1 1 3 2 1 As of February 28, 1981, the plant operated 601 days, 783,995 manhours without a disabling injury. Also, the plant completed a six month period without a medical case on February 20, 1981. The total number of days of operating time without a medical case on February 28, 1981 , was 192 days. Safety Meetings The topic for plant safety meetings for the reporting period was "Chemical Safety". The Kodak "Chemical Safety" and plant produced "Dangers of Corrosive Materials" slide and tape shows were shown and discussed. Three safety meetings were conducted by A. H. Sather for contractor personnel. The first one was conducted on February 3, 1981 for contractors under the supervision of the plant Contract Supervisor, G. A. Morgan. The topics discussed were the plant safety rules and "The Convincer" slide and tape show. The remain ing two meetings were held with Energy Plant Constructors (EPC) personnel. The first of these meetings was conducted on February 5, 1981 for the supervisory personnel and Conoco Construction Engineer Wayne Bolar. This meeting focused on the operating safety philosophy, safety permits, and highlights of the plant safety rules. The other meeting was conducted on February 26, 1981 for all EPC personnel. A general safety meeting covering the highlights of the plant safety rules and operating safety philosophy was done for all personnel and a specific rigging safety meeting followed for rigger/ironworkers. -1- DTH 000043862 SAFETY - (continued) Fire Prevention and Emergency Plan The Plant Emergency Plan was revised, expanded to include fire prevention plan requirements mandated by the new OSHA Fire Protection Standard (Subpart L), and issued February 17, 1981. The plan will be the subject of March Safety Meetings. New Employee Orientations Four new casual employees and one process engineer - Steve Hillman received new employee orientations during February. OSHA Compliance Activity for the reporting period included: 1. Mobile Van Health Testing Several problems were encountered. They have been discussed with Health Examinetics personnel and hopefully resolved. 2. Portable Vacuum Cleaner For Lead A portable high volume vacuum cleaner was evaluated for a backup to the central system. The unit may also have other special uses. 3- Routine Air Samples Samples for VCM, Lead, Antimony, and total particulates were taken and analyzed. The results are shown below. Chemical _______ < PEL________ Number Percent PEL Overexposures Number Percent VCM Lead Antimony Total Particulates 73 92 19 95 20 110 8 100 68 15 00 00 Overexposures A total of seven overexposures occurred, one of which occurred to an employee who was not wearing a respirator. The overexposure that occurred without benefit of respirator occurred to a Chief Operator who worked near a leaking VCM recovery compressor seal. The remaining overexposures occurred to a Chief Operator and a Vinyl Shift Supervisor who were working near a leaking valve on the new module blowdown tank, to an "A" Operator who worked near a leaking VCM recovery compressor, to a Mechanic who was changing out a Corken VCM unloading compressor, and to an nA" Operator who changed VCM filters. The other overexposure occurred to the Color Weigh Room Compounder who was weighing lead compounds. -2- DTH 000043863 VINYL P. E. Markey Month Y.T.D. 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 23.0 821 20.1 562 84.8 5806 84.2 28 50.8 861 20.8 1226 86.3 5882 87.1 59 Vinyl Department production for February was 98.7% of budget at 23.0 MMpounds. Reactors and dryer stream factors were 84.8? and 84.2? respectively. The major items affecting production were: 1. Failure of a main electrical breaker combined with equipment freeze ups during the resulting downtime resulted in 5 agitator seal changes causing a 4.4? reactor stream factor penalty. 2. Air loss to the old unit recovery compressors caused major compressor casing failures in both recovery compressors and directly caused a 1.3% reactor stream factor penalty. Slower recovery cycles have continued as a result of running a single recovery train instead of two. 3- Maintenance on the old unit Sweco resulted in a 0.6? reactor stream factor penalty. 4. Condenser cleaning on 744 reactor resulted in a 0.8? penalty in reactor stream factor. 5- Drilling out a fouled new unit charge water preheater resulted in a 0.4? stream factor penalty. 6. The unit was basically reactor limited for the month. Advantage of excess dryer capacity was utilized to perform dust collector sock changes. Resin Quality Summary Resin Type 5305 5385 5425 5465 Sifter Overflow TOTAL Prime Pounds 1,154,080 14,153,874 6,013,258 387,517 - 21,708,729 -3- "B" Grade 293,250 375,400 79,500 - 748,150 "H" Grade ? of Total Product ion 23,350 55,250 92,000 164,780 6.4 63.4 26.9 1.7 0.7 545,380 100.0 DTH 000043864 VINYL - (continued) Quality performance for February was 94.9% customer grade with 3-1% "B" grade and 2.4% "H" grade. The variable cost variance for February was favorable $1,380 M with $1,433 M due to price and ($53 M) due to efficiency. The major price variance was $i ,419 M due to monomer pricing. Unfavorable efficiency variances of ($46 M) for VCM were partially offset by $30.5 M in favorable efficiencies in the additives area. Product mix caused an unfavorable variance of ($2.5 M) and the variance due to packaged off-grade was unfavorable ($34.9 M). The monomer raw material requirement for February was 1.02788 pounds VCM per pound PVC versus the 1.01936 standard. General Packaging for the month was 7,398,400 pounds. -4DTH 00004386 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 922 448 2,434 3,804 28 54 41 87 136 2,263 601 5,606 8,470 59 Line I operated 17 days during February at an average rate of 54 M pounds per day. Major items affecting production efficiency were: product changes (24.6 hours), plasticizer weighing slow (12.6 hours), dicers (9.2 hours), blender conveyor bucket (5.5 hours), and No. 1 blender gearbox failure (5-2 hours). Line V operated 11 days during February at an average rate of 41 M pounds per day. Major items affecting production efficiency were: quality control (16.7 hours), weighing plasticizer (9-4 hours), weighing resin (5.7 hours) and product changes (13.6 hours). Line III operated 28 days during February at an average rate of 87 M pounds per day. Line Ml production was affected by: product changes (30.6 hours), quality control (20.7 hours), and raw material elevator repairs (8.7 hours). Quality performance for flexible compounds was 4.5% off-grade of which 82% was due to mill scrap. "BC" production was 3-l%- The raw material requirement for flexible compounds was 0.95479 pounds of raw material per pound of compound versus a 1.01299 standard. (Y.T.D. is 0.99942). The variable cost variance for compound was ($11.1 M) with $38.0 M due to price and ($49-1 M) due to efficiency. The variance due to product mix was ($20.6 M). The only major efficiency variance for February was resin at $19*6 M favorable. Dry Blend Month Per Day Y.T.D. Production, M Pounds Accounting Days 3,495 28 175 6,965 59 Dry Blend operated 20 days during February at an average rate of 175 M pounds per day. Production included 80174, 80273G, 80244 and RP-100. Dry Blend production was affected by: quality control (30.3 hours), out of resin (14.0 hours), raw material elevator repairs (6.0 hours), stabilizer pump (6.0 hours), and product changes (5.0 hours). -5DTH 000043866 COMPOUND - (continued) Dry Blend - (continued) * Quality performance for the month was 99-99% customer grade. The raw material requirement for dry blend was 1.02743 pounds of raw material per pound of dry blend versus a standard of 1.00580. (Y.T.D. 1.02057) is The variable cost variance for dry blend was $69-8 M with $9.5 M due to price and $60.3 M due to efficiency. The variance due to mix was $77-3 M. There were no major price or efficiency variances for the month. Plasticizer Month Per Day Y.T.D. Production, M Pounds Accounting Days 1,149 28 57 2,276 59 Plasticizer operated 20 days during February at an average rate of 57 M pounds per day. Production included: 61 OP, DIDP, D0P, and 81 OP. The 81 OP was produced for use in Western Electric 757 compound. VRP production totaled 78 M pounds (6.8%). Production was limited by: PA charge pump seal change, R-3 steam valve, R-4 steam leak, Isodecyl charge pump and R-l safety disc change. The raw material requirement for plasticizer was 1.12670 pounds of raw materials per pound of plasticizer versus a 1.0528 standard. (Y.T.D. is 1.12625) The variable cost for plasticizer was $29.5 M with $38.6 M due to price and ($9-1 M) due to efficiency. Major price variances were: $13-0 M for 2 ethylhexanol and $15.0 M for phahalic anhydride. The only major efficiency variance was $14.9 M for phthalic anhydride. The variance due to produce mix was $5*3 M. General Total customer grade compound inventory increased from 6.2 to 6.3 MM pounds during February. -6DTH 000043867 MAINTENANCE S. J. Vincent Vinyl There were six large reactor seal failures in February. One reactor condenser was cleaned and there were no gearbox problems in this period. The seal failures were on the D-500 reactor in the old module and on the 741, 742, 743, 744 and again on 743 reactor in the new module. The seal failures were caused by the loss of the seal flush system. Several valves were replaced as a result of the freezing conditions that included three ten inch gate valves on the #2 vinyl cooling tower. Other repairs in the vinyl area included the cleaning of the charge water heat exchanger in the new module and cleaning the south recovery exchanger in the old module. Pump and compressors repairs this period included nine mechanical seals. One pump was overhauled. Problems with the old module recovery compressors included two major housing failures. The problem with the old module recovery system started when both "A" and "B" compressors ran blocked in, resulting in compressor case failures to both machines. One of the compressors was replaced with a compressor made up of salvage parts to get the unit back into operation. This compressor developed a leak and had to be replaced with a compressor from the new module. The other old compressor purchased from a surplus equipment dealer and the body section of one of the plant compressors were used to build up another recovery compressor. One new compressor case section was received and a second compressor was then rebuilt. When installed, the old compressor cracked at the inlet flange and the new case failed from what would appear to be a poor casting. At the end of the month two compressors were operating in each module with no spares on hand. There were six seals replaced in the old module. The "B" vacuum pump inboard seal twice, the inboard seal on both the east and west emission recovery com pressors, the seal on the south sphere pump and the inboard seal on the "A" compressor. In the new module seals were replaced on both VCM charge pumps and on the recovered VCM charge pump west. The rinse pump in the old module was pulled for overhaul after the pump shaft failed from ice in the pump. The north 490 Corken compressor was replaced with the spare unit. Installation of the instrumentation in the main control room for the batch water stripping project was started. The fabrication work for the VCM com pressor high temperature shutdowns was completed. A new liquid level probe was installed on 744 reactor. -7DTH 000043868 MAINTENANCE - (continued) Vinyl Dryers P.M. inspection was completed on the #7 dryer train. The exhauster fan shaft and bearings were replaced and the southwest dryer trunion was replaced on 1. The 2 centrifuge and gearbox were replaced and the units removed were reworked for spares. Belts were replaced on the #1 and #2 centrifuges after the units plugged. The project to reprocess sifter overflow was installed in the V-ll dryer building. Compound, Plasticizer, Dry Blend and Resin Storage Major repair to the compounding equipment included replacing the gearbox on Line I #1 blender, rebuilding both Line I blender dump valves and a complete overhaul of #6 dicer. Projects included installing a safety shower in the Line III area and a work platform on the Line V feeder. The digital readout for the Line III FCM temperature was repaired. In the dry blend area the major work accomplished was to break out concrete and install anchor bolts for "A", "B" and "D" blender gearboxes. The screen was replaced in the south Kason also. Repairs in the plasticizer unit were to repair process and steam leaks and to P.M. the Glycol heating system in the tank farm. A new alcohol charge meter was installed. Bearings were replaced on one lab mill. The new product transfer unit was serviced and the drive belts and coupling replaced. The automotive and fork truck repair work was heavy this month. Most of this work can be contributed to cold weather and starting problems with equipment. Utilities and Service There were nine repairs to the plant air system equipment, with valves being repaired in the #1, #6, 1 and #3 compressors, plugged a leaking tube in the #8 inter cooler and the heaters replaced in the east tower of the V--10 dryers. A base crack on #1 air compressor was repaired. A new safety valve was added to the plant air header to increase capacity. The west Joy centrifugal com pressor shutdown on high vibration, the compressor was opened and a major inspection completed. Bearings were replaced on the high speed shaft and all parts were cleaned. With the unit down the inter coolers were cleaned on the water side, the control system was revised and a second oil filter installed. The unit started up still showing a vibration of .45 - .55 mils. After 6 days of operation the compressor shutdown on high vibration again. The high speed shaft was pulled and sent to Joy for inspection and balancing. Baseline vibration data was obtained by MED on the east Joy air compressor. Additional data will be obtained when the west unit is returned to service. -8DTH 000043869 MAINTENANCE - (continued) Utilities and Service - (continued) The plant fire extinguisher locations were repainted and renumbered. Cooling water from the V-10 air compressors was repiped to return water to the cooling tower. The plant propane system was successfully tested twice this month. Planner There were 108 work orders planned and estimated. Material was ordered for 34 projects. 25 invoice registers were closed and 26 new registers were issued. 23 statements were processed for payment. -9DTH 000043870 MECHANICAL ENGINEERING J. A. Dixon AFE's Submitted, Approved, and Closed The following AFE's were submitted and approved during February: AFE No. Title Authorized 9551 9561 V-10 Centrate Heat Recovery (Energy) Cooling Tower Fan Controls (Energy) $125,000 ^0,000 Completion Reports were issued for the following AFE's: AFE No. S&k3 9010 Title Double Block Valves for VCM Charge Centrifuge Rotor Repair Authorized $182,000 20,000 The following AFE's were closed to field charges during February: AFE No. Title Authorized 9669 9739 New Air Header Methocel Charge Revision $ 25,000 66,000 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 Breathing Air Modifications Emergency AMS Kill System Sifter Overflow Reclaim Curbing for Gasoline and Diesel Tanks Centrate Heat Recovery Kemp Air Dryer Modifications AFE Activity 1. AFE 9709 ~ Facilities for Multigrade Resin Production - G. Kreutzer Foundation work is complete. Tank erection is in progress. The silo has been received. Erection of the structural steel is scheduled. -10- DTH 000043871 MECHANICAL ENGINEERING - (continued) AFE Activity - (continued) 2. AFE 9729 - Fire Protection Improvements - Phase II - M. Ingle Construction of the pump building is in progress. 3 AFE 9530 ~ Spare Incinerator - J. L. White Overall project design is approximately 89% complete. The basis of bids for piping and structural steel were issued late this month. Foundation work is in progress. 4. AFE 9630 ~ Water Stripping - M. Ingle Foundation work is complete. The vessels have been set and piping fabrication is in progress. 5. AFE 9680 - Fixed Point Monitor Data Computer & Warning Lights - R. B. Harned The cabinet, connecting cables, and stands for the printer and display terminal are on order. Shipment of the computer to Aberdeen from Ponca City is scheduled for April 15. 6. AFE 80-395 ~ Interplant Communications - Phase I I - R. B. Harned This project is operational and the original scope of work on the contract is complete. Minor revisions remain to complete this project. 7 AFE 9660 - Hot Water Charge Tank Replacement - J. P. MeKee Insulation and painting work on the charge tank was completed during February. 8. AFE 9690 ~ Breathing Air Modifications - J. L. White Construction drawings have been approved. A basis of bids for installation is being prepared. 9- AFE 9730 ~ Compound Line III Debottlenecking - R. B. Harned The half lined, segmented chamber for the #9 FCM is onorder. Shipment is scheduled for October, 1981. Specifications for the weigh-feeders are being written. 10. AFE 9760 - Emergency AMS Kill System - J. L. White The long lead valves have been placed on order. Quotes for the remaining valves have been received. Preliminary plan drawings for the new unit have been distributed for approval. Preliminary plan drawings for the old unit are nearly complete. -11- DTH 000043872 MECHANICAL ENGINEERING - (continued) AFE Activity - (continued) 11. AFE 9770 - Reactor Pressure Relief Modifications - J. L. White Plan drawings for both modules have been completed and distributed for approval. Installation drawings are in progress. 12. AFE 9800 - Plasticizer Irritant Control - R. B. Harned The aerators and the motor control center are on order. The motor control center will ship in May, 1S81. 13* AFE 9321 - New VCM Rail spur - Herzog-Hart Corp. The topography and soil boring work is in progress. Construction - G. A. Morgan The following projects were completed during February: 1. Methocel Charge Revisions 2. Hot Water Charge Tank Replacement 3. Main Break Room Extension 4. New Air Dryer Shed The following contracts were issued during February: 1. Foundation work for Spare Incinerator 2. Modification to Kemp Air Dryers 3. Walkway Bridge between 280 and 600 Series Silos 4. New Rail spur for PVC Expansion Project 5. Painting of Piping and Structural for Hot Water Tank Project 6. Electrical Facilities for PVC Expansion Project Eighteen register tickets were issued during February. -12- DTH 000043873 0) Thru January, 10*^ * Actual Account ini: (2) Thru February, 1931 AMuiH.r-N Aim!oiu:.vni).\s uimur Atmi. CAPITAL NO. DFSCRTl'TrON 9237 9519 Heated Plasticizer Addition System Critical Spare Equipment 9559 Color Weigh Room Modifications 9589 Instrument Air Dryer 9609 Reactor Inert Vent System dvit Mini. AlTUOVlUl All. AMI. (1) fiXIT.NWn TO tv\ll o coMMirnn to ivvir. F 1\'AI, roru i:st. COST COMP. UNm-R lOVI-R) ,M*m. AMT. l:$T. 1ST, COMP. ci.os. inn-: 1>A IT: lil.M.Ml K.S io-n-77 37.000 15,367 36,073 37,000 0 12-80 3-81 Closed to field charges. 2-06-79 175.000 165,130 166,442 166,465 8.535 12-80 3-81 Closed to field charges. it-19-79 25,000 19.817 22,525 25.000 0 1-81 4-81 Closed to field charges. 5-30-79 110,000 92,653 100,042 110,000 0 4-81 7-81 Revisions in progress. 6-28-79 90,000 14,541 14,541 90,000 0 12-81 3-82 Project on hold. 9629 9639 Air Compressor Revisions to Emission Recovery System 7-09-79 7-12-79 340,000 100,000 278,653 77,399 289,153 81,474 340,000 100,000 0 0 3-81 6-81 3-81 6-81 Revisions in progress. Revisions in progress. 9669 New Air Header 9689 Diking of Sphere 5 Curbing of Orum Storage Areas 9699 Plant Dryer Debottlenecking 9709 9719 Facilities for Multiple Grade Resin Production Aberdeen RVC Resin Expansion 9729 Fire Protection Improvements - Phase 11 9739 9759 Methocel Charge Revision Aberdeen PVC Resin Expansion 9510 Miscellaneous Projects Under $10,000 9530 Q5SQ 9560 Spare incinerator "P.A. Handling Improvement Safety Equipment 9570 Replace T-100 P.A. Tank 9580 Boiler Economizers 9590 Critical Spare Equipment 9600 Calcium Stearate Addition System 9610 API Clean Water Bypass 9630 Water Stripping 9650 Miscellaneous Projects Under $10,000 9660 Hot Water Charge Tank Replacement 9670 Laboratory Equipment 9680 Fixed Point Monitor Data Computer and Warning Lights 9690 Breathing Air Modification 9700 Compound Fines & Streamers Removal 9710 Fire Protection - Phase II 9720 Reactor Agitator Replacement 9730 Compound Line III Debottlenecking 97*10 Modifications to Make Profile Ory Blend 9750 Rotary Dryer Insulation (Energy) 9760 Emergency AMS Kill System 8-15-79 9-15-79 25.000 170,000 18,025 132,239 19,633 133,853 25,000 170,000 9-15-79 9-20-79 80,000 870,000 20,660 109,255 58,930 573,605 80,000 870,000 9-10-79 10-01-79 850,000 490,000 11,421 175,972 860,000 375,331 860,000 490,000 10-03-79 66,000 39,758 41,781 66,000 12-10-79 11,150,000 3,623,000 8,498,600 11,150,000 1-3-80 150,000 126,609 161,898 150,000 1-23-30 3-03-80 3-12-80 3-27-80 3-26-80 3-26-80 2#--02-80 l|-15-80 4-30-80 5-30-80 650,000 63,000 25,000 119,000 140,000 59,000 84,000 23,000 810,000 150,000 88,105 28,177 7,846 62,720 144,894 11,410 429 17,851 144,451 114,630 324,319 33,967 28,908 62,473 145,389 60,386 11,062 18,106 334,291 173.802 650,000 63,000 28,908 119,000 145,389 60,386 84,000 23,000 810,000 150,000 6-04-80 7-09-80 9-04-80 160,000 32,000 113,000 108,701 31,587 1,238 137,856 32,447 38,210 160,000 32,447 113,000 9-09-80 10-01-80 10-14-80 10-14-80 10-16-80 10-27-80 21,000 95,000 385,000 420,000 1.350,000 200,000 11-10-80 11-13-80 22,000 335,000 1,264 0 0 0 0 0 5,265 0 0 191,268 69,500 23.633 21,000 95,000 385,000 420,000 1,350,000 200,000 0 27,391 27,391 0 14,392 335,000 0 2-81 5-81 Closed to field charges. 0 6-81 9-81 Revisions in progress. 0 8-81 11 -81 Construction in progress. 0 8-81 11-81 Construction in progress. (10,000) 0 8-81 11-81 6-81 9-81 Reactors to ship ^-4--81. Construction in progress. 0 2-81 5-81 Closed to field charges. 0 9-81 12-81 Piping contract let. 0 12-80 3-81 Closed to field charges. 0 6-81 9-81 0 12-81 3-82 ( 3,908) 3-81 6-31 Construction in progress. Project on hold Construction in progress. 0 12-81 3-82 Project on hold. ( 5,389) 12-80 3-81 Closed to field charges. ( 1,386) 3-81 6-81 Condenser to ship 6-8). 0 5-81 8-81 Engineering in progress. 0 3-81 6-81 Project operational. 0 6-81 9-81 Construction in progress. 0 12-80 3-81 Closed to field charges. 0 ( 447) 0 4-81 7-81 12-80 3-81 9-81 12-81 Proj ect ope ra tiona1. Closed to field changes. Engineering in progress. 0 5-81 8-81 Engineering in progress. 0 10-81 1-82 Engineering scheduled. 0 10-81 1-82 Engineering scheduled CEO 0 10-81 1-82 Agitators to ship 5**81. 0 10-81 1-82 FCM barrel to ship i0-8l. 0 10-81 1-82 Engineering schedu ed. ( 5,391) 0 4-81 7-81 8-81 II-81 7S% complete. Engineering in progress. DTH 000043874 AHI-KOITN \\UlMIU^.VnONS 1I1TO!? I' (1) Thru January, 1981 Actual Accounting (2) Thru February, l'j8l Aum. CAPITAL NO. niiSOKin ion 9770 Reactor Pressure Relief Hodif icetions DAT!: Aimi. Al'i'UOt ill) AH: AMT. 11-25-80 580.000 m i:xn:\ni:n Tu ivva. (.:) ccMurm:i> to dati: FINAL TOTAL LSI'. tost comp. a 235.078 560,000 MNUliR (OVPK) AUIU, AMT. l:Sl'. liST. COMP. Tins. iun: MAH: 0 12-81 3-82 KIMAUkS Engineering in progress. 9780 9790 9300 Centrate Heat Recovery Resin Reclaim System Plasticizer Irritant Control (Air) 12-08-80 12-14-80 12-15-80 300,000 727,000 80,000 0 0 0 5,264 300,000 0 727,000 27,950 80,000 0 3-82 6-82 Engineering In process. 0 J-82 6-82 Engineering in progress CEO 0 9-81 12-81 Engineering In progress. 98)0 Replacement Gearbox for Farrell Mixer 12-18-80 73.000 0 69,400 73,000 0 9-81 12-81 Gearbox to ship 9*31 9511 Miscellaneous Projects Under $10,000 1-09-81 170,000 0 30,758 170,000 0 12-81 3-82 Ten projects approved. 9521 New VCM Rail spur 1-30-81 11,000 0 15,800 11,000 0 5-81 8-81 Engineering In progress. 9531 Vinyl Initatior Charge Pots 95)11 VCM Tank Farm Modifications 80-395 Interplant Communication Phase 111 1-21-81 1-21-81 1-22-80 165,000 90,000 55,000 0 0 0 0 0 21,755 165,000 90,000 55,000 0 11-81 2-82 Engineering scheduled. 0 1-82 4-82 Engineering in progress. 0 6-81 9-81 Project operational. 955) 9551 V-IO Centrate Heat Recovery (Energy) 2-17-80 Cooling Tower Fan Controls (Energy) 2-17-80 125,000 40,000 0 0 0 125,000 0 40,000 0 5-82 8-82 Engineering scheduled. 0 11-81 2-82 Engineering scheduled. EXPENSE 9020 Repairs to Line 1 Compounder 11-24-80 38,000 0 0 38,000 0 11-81 2-82 Parts ordered in Jaiuary. -14- DTH 000043875 PERSONNEL J. L. Carter EMPLOYMENT Foster Field - Casual Labor Earnestine Carter - Casual Labor Needham Stahl - Casual Labor TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMOTION L. T. Gathings, Warehouse Worker "B", transferred from Conoco Chemicals Department to Surface Transportation. Terry Edwards, General Helper, promoted to Compound Utility. Samuel D. Brown, General Mechanic "A", transferred to Instrument Technician "B". Deevie Rambus, General Mechanic "B" promoted to General Mechanic "A". William Davis, General Helper, promoted to Compound Utility. RETIREMENT None. TERMINATION Dave Gathings, Casual Labor Jeffery Shields, Casual Labor Ralph Flippo, Casual Labor OTHER During February there were 15 casual labor employees on payroll. Total hours worked were 2315- -15- DTH 000043876 CONOCO CHEMICALS Aberdeen, Mississippi February 1 981 MONTHLY PERSONNEL REPORT Salaried Employees 80* Minority Employees # Hourly Employees 155 Salaried 6 7-5% Total Employees 235' Hourly 57 37% Employees (Hourly) New Employees Terminations 0 0 Total 63 27% Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 U 0 0 DEPARTMENTS PAR # EMPLOYEES MIN. EMP. . % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse 9 8 1 1 2% 0 0 0 0 0 0 Gen. Plant Maintenance Laboratory 11 46 22 10 45 21 3 30% 0 2 0 0 0 JL_ 7 15% 0 0 0 0 0 _Q__ 3 1 b% 0 0 0 0 0 _Q_ Compound Vinyl Plasticizer 37 32 4 35 32 -4 as LTV r**> 27 77% 0 0 0 0 0 JL_ 13 40% 0 0 0 0 0 JL_ 3 0 0 00 0 0 Number of Applicants: Month 55 Year to Date _______ APPLICANT BREAKDOWN: ft Minority % Minority 73% # Female ^ % Female M.5% ,vlncl udes two (2) temporary employees . Hires (Hourly) : Month 0 Year to Date 2 Terminations (Hourly) : Month 0_____ Year to Date ____ 0 Overall Turnover 0 Projected Annual Turnover 0 -16- DTH 000043877 ON> sO OVERTIME AND ABSENTEEISM CT\ O4>) t*o- i3V<>_u. _o -- -!J- -- i: s o o oo oo o *o c I 1 DTH 000043876! PROCESS ENGINEERING R. A. Frohreich A. Expansion Project Concrete work in the reactor areas and slurry blend tank areas is complete. Concrete work is continuing in the Fluid Bed Dryer and Cooling Tower areas with total completion expected in March. The electrical package bids were received and the contract is being signed. Instrumentation bid packages have been sent out to contractors. Reactor steel erection is underway in both modules and pipe fabrication has begun. The change order for the V-ll chem wash system was submitted and approved. Equipment for this system is being purchased. B. Reactor Emergency Cooling System Process Engineering is continuing to provide assistance to PED. C. Plasticizer Initiator Handling System Process Engineering is planning a test run using solid initiator as a replacement for the liquid PTSA presently used. The test run is scheduled for March. D. Capability to Receive OKC Resin The revised class "A" design, incorporating review meeting comments, was issued. E. Rigid Pelletized Compound Production - Line V The class "A" design for this project is being prepared. F. Compound Line I Modernization The class "A" design is underway. A letter outlining the project basis and direction was issued for plant review. G. Line III Mill Temperature Control Work on the process design for this project continues. H. Reactor Agitator Replacement - D/300 and D/400 The agitator manuafacturer is still looking for a shaft coupling which will meet the height requirement underneath the reactors. I. Plasticizer Spill Containment The class "A" design to install mechanical seals on the plasticizer transfer pumps ?s being prepared. -18- DTH 000043879 PROCESS ENGINEERING - (continued) J. Donnelly Mirror Compound Testing The process design to fill "Super Sac" containers with compound is underway. K. Reactor High Level Alarms A new probe has been installed on reactor 7^** for testing. L. Resin Automatic Bagging Work has begun on the class "A" design to convert the compound automatic bagging system to resin service. M. Recovery System Revisions The class "A" design for this project is being prepared. Revisions include improved solids removal, increasing knockout pot water recirculation rate, and instrumentation for the recovery system. N. Rag Layer Reduction Tests without carbon black on 6-10 plasticizer gave good color without the use of sodium borohydride as was previously planned. Other plasticizers will be tested without carbon black. O. Explosive Mixture Monitor The class "A" design to install explosive mixture monitors in the dryer burner area was issued and the design review meeting was held. P. Slurry Delumper The class "A" design to install a delumper in the old module to reduce oversize material from coarse batches was issued and the design review meeting was held. Q. Normal Kill Solution Addition System The design review meeting for this project was held. Comments from the review meeting are being incorporated in the design. R. VCM Flexible Hose Evaluation An evaluation of flexible hoses used in VCM service was issued. S. Sifter Overflow System Operating procedures for the temporary sifter overflow system were written. Process Engineering assisted in the start-up of this project. -19- DTH 000043880 PROCESS ENGINEERING - (continued) T. Diverter Valves for 490 Series Silos The class "A" design to replace the flexible hose on the 490 series silos is being prepared. U. Caustic Addition to the Recovery System The class "A" design to add caustic in the recovery system to reduce corrosion is being prepared. V. Plasticizer Waste Water Stripping Revisions The class "A" design to install organic level sensors on the plasticizer waste water tanks and a condenser on T-460 is being prepared. W. Pressure Relief for Recovery Compressors A design to install pressure relief for the recovery compressors in both modules was issued. X. Lake Charles Water and Centrate Rinse Water Test Runs A letter defining preparations for the Lake Charles Water and Centrate Rinse Water test runs was issued. -20- DTH 000043881 ENVIRONMENTAL V. E. Messick Particulates Three dryers were sampled in February for particulates and all were within allowable 1imits. Water All effluent parameters were within NPDES limitations in February. VCM Process Engineering is continuing to work with operations and maintenance to verify that all leaks found in the comprehensive VCM survey are repaired. Hazardous Waste Management A total of 138 drums of waste material were shipped to Chemical Waste Management s Alabama site for disposal. Manifests for three earlier shipments of hazardous wastes were received. The RCRA Contingency Plan is being prepared. The groundwater monitoring AFE request was submitted in early March. Other The Aberdeen Chemical Plant Pollution Control Manual is being prepared. -21- DTH 000043882' Flow GPM Jan. - Ave. 1069 Max. 1297 Feb. - Ave. Max. 757 819 Mar. - Ave. Max. 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 69 888 106 1650 43 382 56 479 7 93 9 114 7 65 10 86 Diss. 02 8.5-10.4 8.9-9.8 ph 7.4-7.8 7.5-7.9 NPDES - Ave. Max. - 32 387 4 3 520 - 1390 - 1940 - 605 >6.0 - 909 6.0-8 5 -22- DTH 000043883 ENERGY CONSERVATION J. F. Perez-Velasco I . Plant Operations Total energy consumption for January was 108.755 MMM BTU's. The energy consumption per pound of product increased to 3^8 BTU/Lb. as compared with 3209 BTU/Lb. for January. I I . Plant Energy Conservation Program A. Steam Leaks Thirty-six steam leaks were repaired in February, three of which were steam trap repairs. B. Dryer Insulation Installation of additional insulation on the rotary dryers is 751 complete. C. Continuous Oxygen Analyzers Continuous excess oxygen analyzers were installed on the boilers. Calibration was completed on two and they are presently in operation. D. Energy Reporting The yearly energy report for 1980 was completed and issued in February. Energy savings ideas generated from Carl Spangler's plant visit were evaluated. Three projects were found to be economically attractive at this time. They included two-speed motors on the reactor agitators, air-to-air heat exchangers on the rotary dryers and high efficiency motor replacement. -23- DTH 000043884 ITEM ENERGY CONSERVATION DATA 1981 1980 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 February 23.0 3.5 3.8 1 .2 31.5 56345 1020 57.472 5.1283 10000 51.283 0 92000 0 February 26.3 0.8 3.5 0.3 30.8 54266 1020 55.351 4.8480 10000 48.480 0 92000 0.558 Energy Consumption, N4M BTU Energy Consumption , BTU/Lb. Boiler Operating Data 108.755 3448 104.389 3385 No. 1 No. 2 No. 3 o CO cr\ CO cr> Avg. Stack Temp. 25k 4oo 288 419 218 428 Avg. % Excess Air 1981 1980 27 33 30 34 26 37 -24- DTH 000043885 LABORATORY R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Report By Northwi re Inc. Taylor Cable Corp. Whitaker Cable Corp. Permafit Corporation 39032 Black 34431 Natural 5425 90171 B1 istering, Rough Surface Rough Surface, Lumps Grainy Surface Processing RDJ Under Invest Under Invest Under Invest WAIVERS RECEIVED Date 1 dentification Product Customer Reason Waived By 2/13 2/20 2/20 2/23 2/25 C0NX 45308 PTLX 41657 PLCX 42681 PTLX 41834 Bag Blend 02981 PRODUCT SERVICE 6 DEVELOPMENT 5305 5385-3 5385-3 5385-3 5305 N. J. Terminal World of Plastics World of Plastics Rehau Export - Eurpoe Viscosity RNG "B" Color ELK "B" Color ELK Bulk Density ELK Particle Size ELK Sample Shipments Ship Date Product Amount (lb v). Customer Requested By 2/2 2/4 2/4 2/4 2/6 2/9 2/10 2/10 2/10 2/12 2/12 5385-1 5385-3 SD 5385-3 5385-1 5385-1 5465 5465 5425 5425 5385-3 35351 Natural 35851 Natural 50 1 ,000 200 2,000 50 50 2 ,000 50 50 250 10 1 ,000 Fritz Airfreight A1sco - Anaconda Diamond Shamrock Corp. Carstab Corp. Ethyl Technical Center Hoover Universal Inc. Dayco Electric Hose Leon Plastics Behring International Conoco, Ponca City Dielectric Materials JPM COEDS COEDS COEDS HJH COEDS MR MR COEDS JLI COEDS -25- DTH 0000438)36 LABORATORY - (continued) Sample Shi pments Ship Date Product 2/12 2/13 2/13 2/16 2/17 2/18 2/18 2/18 2/19 2/25 2/25 2/25 2/27 14741 Natural 61 OP 5305 5305 5305 5465 34501 Black 48562 Black 38931 Natural 38601 Natural 38671 Natural 5385-1 5465 5305 5425 80273 DB Special Compound Testing Amount (Lbs.) 100 5 gal. 2,250 50 50 1 250 50 50 50 50 100 100 50 100 100 Custome r Lavanture Uni royal Chemical Varssallo Inc. Fritz Airfreight Jo Anna Western Mills Kohkoku, USA ITT Royal Electric Plastex, Inc. Runzel Wire S Cord Tiger Flex Corp. Rehau Plastics, Inc. Ferro Corp. Fritz Airfreight Requested By COEDS JLI COEDS JPM MFM RTM COEDS WBS MFM COEDS RNG JTW JPM Western Electric specification tests were run on 2 production lots of 36861 Natural and on 1 lot of 34861 Gray 546. Plasticizer content and flammability were measured on 5 railcar samples from these lots. Packard Electric specifi cation tests and extensive extrusions were run on 1 lot of 34533 Natural. Color Matching A color match was made for 34431 Gray 547, using a combination of the lighter VCP-5082 gray color concentrate and black color concentrate. A lab Welex batch of 34711 Natural was made and shipped to Avecor Midwest for them to use in preparing a color concentrate to match 3471 1 Gray 550. Customer Assistance and Complaint Investigation Melt flow tests were run on two samples of vinyl wall covering from Intex, Corinth, MS. They were experiencing physical property problems with the thin (3 mil) film and not with the thicker film (A mil). The two samples were found to be significantly different in melt flow and it was suggested to Intex that the processing conditions were different. -26- DTH 000043887 LABORATORY - (continued) Customer Assistance and Complaint Investigation - (continued) As the result of a complaint from Packard Electric on 34533 Natural 5D04 5D06, returned samples were extruded and gave a poor appearance. Plasticizer extractions on selected portions of the sample showed a wide variation in plasticizer content. A report summarizing this work has been written. QUALITY CONTROL TESTING Resin Regular Samples = 324 Bag Samples = 191 Other In-Process Samples = 3135 Bulk Shipments = 134 (Railcars = 62, Trucks = 72) Dry Blend Blenders Produced = 325 Blenders Tested = 321 Blenders Adjusted = 12.3% Other In-Process Samples = 278 Bulk Shipments = 62 (Railcars = 17, Trucks = 46) Compound Blenders Produced = 553 Blenders Adjusted = 2.9% Line V Production = 262 skids; 8 boxes, 80 M lbs. bulk Other In-Process Samples = 902 Bulk Shipments = 23 (Railcars = 6, Trucks = 17) Resin Heat Stabi1 ity Fifty (50) samples of resin were tested for oven heat stability. These were: 5385 5425 5305 5465 21 Samples 16 Samples 10 Samples 3 Samples The heat stability of the 5305 was much more uniform this month and averaged slightly better than the control. The 5465 resin was also better than the control, while the 5385 and 5425 resins were slightly poorer than control. RVCM In Shipments A total of 115 shipment samples were tested for RVCM in February. A summary of these results is below. Product Average RVCM, ppm Number of Samples 5305 4.2 64 5385 1.8 26 5425 0.2 20 5465 0.1 5 -27- DTH 000043868 LABORATORY - (continued) Viscosity A total of 537 resin samples were checked for viscosity in February. MISCELLANEOUS Raw Material Testing Sixty six lots of plant raw materials were tested. The most recent shipment of SP-33 clay from Freeport Kaolin gave an acceptable value for volume resistivity, and it appears that the product may have been improved. Clay from Burgess and Engelhard Minerals was no better than SP-33- Variables in the VR test and in different types and lots of clay are under investigation. The low-dusting Tribase EXL Special from Associated Lead was retested for dispersion and compared with Cyastab 56** and Halbase 100 EP for stabilizing efficiency and volume resistivity. This second sample of Tribase EXL Special showed excellent dispersion and appeared slightly better than the other two stabilizers in heat stability and volume resistivity. RVCM In Slurry A total of 549 batches were tested in February for RVCM. The overall average was 236 ppm. The daily average exceeded 400 ppm for three days during the month. RVCM of Regular 5305 Drier Samples A total of **3 5305 regulars were tested for RVCM. The overall average ppm RVCM for 5305 was 4.9. Residual VCM of Blowdown Tank Water A total of 137 samples of water from the blowdown tanks were tested for RVCM. The overall average was 6.7 ppm. 90% of the samples were below 10 ppm. Dosimetry A total of 73 VCM carbon badges were tested for PPM VCM TWA. A total of 30 filters were checked for plasticizer in a new monitoring program. Particle Size - L 6 N Microtrac A total of 550 reactor slurries were examined on the L & N microtrac. A plot of the particle size was made for February. In addition the QC technicians generated microtrac data on regular samples to allow guidelines to be developed. These guidelines were incorporated into the minicomputer program developed to plot the L N particle size data. Special Sample The special sample load was very high in February. A total of 110 special samples were tested, 8l of which were COD samples. -28- DTH 000043889 TRANSPORTATION J. E. Stark Shipment by Product - M/Lbs. Res i n Plasticizer Dry Blend Compound TOTAL February 19,347 123 4,128 3,747 27,345 Y.T.D. 42,478 245 7,227 8,086 58,036 Number of Shipments by Mode R/C O.T. Bulk O.T. Van C.O.T. Resin - Bulk - Package - Export 73 41 9 1 121 PIasticize r Dry Blend - Bulk - Package - Export Compound - Bulk - Package - Export TOTAL 11 4 3 3 79 18 18 91 55 172 0 Back Hauls for February 32 Number of Shipments by Month - Y.T.D. R/C O.T. Bulk O.T. Van C.O.T. January February 91 48 200 2 91 55 172 0 Material Handling Report M/Lbs. Packaged Resin From Production Packaged Compound, Dry Blend From Production Transferred From Main to Pra i r ie Transferred From Prairie to Prairie Reverse Transfer Resin to Plant Reverse Transfer Compound to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Ma i n TOTAL 23- 7,816 2,795 5,143 0 122 283 7,411 5,751 2,714 32,035 C.C. T0FC CPU Total 26 140 4 13 122 33 2 41 58 14 3 5 21 7 9 34 18 40 0 58 416 3 35 C.C. 91 40 T0FC CPU 0 55 0 58 T/L Total 487 416 193 69 127 0 3 7 183 142 67 791 DTH 000043890 TRANSPORTATION - (continued) Off-Grade In Storage Materia1 Sifter Overflow Resin "BC" Resin "H" Mi 11 Scrap Compound "B" Compound "H" Dry Blend "O.G." TOTAL M/Lbs. , 1,100 3,293 1,194 146 1,309 98 348 7,576 T/L 29 81 30 4 32 2 9 187 -30- DTH 000043891 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 12-8 12-9 12-12 21 21 21 21 % Total ' 251 CONDO) ~RANSP0RTATI0N ABERDEEN WAREHOUSE CONTENTS ESTIMATED MM POUNDS ON FLOOR OPEN TOT Compounds 4. 5 Dry Blend .3 Export Resin .6 Conoco Resin .2 5 . 6 4 .4 10.0 HDPE Compound Dry Blend .3 .. 2 2 . 7 .8 1.5 Conoco Resin 3. 1 3 .1 .4 3.5 Conoco .3 Export Resin 3. 5 * 3.8 3.5 Conoco Resin 4. 4 Resin O.G. * 4.4 3.5 Mill Scraps .1 Cmpd 0.6. .9 Dry Blend O.G. .1 Sifter Overflow .7 Resin O.G. Compound .8 .1 * 2.6 2.5 Resin 3. 3 Raw Material .3 * 3.7 3.5 Resin O.G. 3. 6 * 3.6 3.5 Conoco Resin 4. 5 * 4.5 3.5 Conoco Resin 2. 9 2 .9 .6 3.5 Dry Blend O.G. Conoco Resin S.O. Comp. O.G. Mill Scarp Sub-Total (Plug-Aisles) Total Conoco .7 2.8 3.5 .4 ____ J. . DTH 000043892 __________ 25-j.fi...... 3.5 42.0 _ 2. 6 44* 6 ABERDEEN CHEMICAL PLANT C c INJURY FREQUENCY X 100 L L FREQUENCY TOTAL INJURIES (FA OR MC) X 12 TOTAL EMPLOYEES DTH 00004389 MONTHLY HOURLY TURNOVER 9 a 7 6 5 4 3 2 1 DTH 000043894 Mar. ENERGY USAGE ________ Monthly ------------ 12 Month Moving Average DTH 000043895 ABERDEEN PLANT PRODUCTION 1981 MM FOUNDS CUMULATIVE 35 30 25 20 15 6 60 5 53 4 1 40 3 30 2 20 1 130 3 40 3 35 6 E 30 5 E 25 4 E 20 3 z 15 2 E 13 1. E 5 i 2 I 0 -------- BUDGET ---------- ACTUAL ---------- CUMULATIVE DTH 000043896 ABERDEEN PLANT QUALITY PERFORMANCE STANDARD 1.35 V DTH 000043897 ABERDE1.N PLANT EFFICIENCY 1981 STANDARD 1 .01936 0 1.020 1.010 1.000 STANDARD 1 .01300 STANDARD 1.00580 STANDARD 1.10500 CUMULATIVE DTH 000043898 ABERDEEN PLANT INVENTORIES DTH 000043899