Document xdrpQXMezXrr9VEEddYRR31L1

CONOCO CHEMICALS Aberdeen, Mississippi _______February 1978________ MONTHLY PERSONNEL REPORT alaried Employees 71* Minority Employees # % lourly Employees 155 Salaried 4* 5% .'otai Employees 226* Hourly 56 36% mpljoyees (Hourly) Total 60* 26% New Employees Terminations -0-0- Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. -0-0-u- -0- DEPARTMENTS PAR # EMPLOYEES MIN. EHP. . % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse 9 9 2 22 0 0 00 0 0 Gen. Plant 11 11 4 36 0 0 00 0 0 Jaint nance 46 46 7 15- 0 0 0 0 0 0 L/Tatory 21 21 3 14 0 0 00 0 0 Compound 33 32 24 75 0 0 00 0 0 Vinyl Dryers 20 20 11 55 Vinyl Large Reactors Plasticizer 12 12 44 2 18 0 0 0 1 9% 9% 3 75 0 0 00 0 0 'iumbe of Applicants: 4onth -0- Year to Date 27 APPLICANT BREAKDOWN: # Minority -0- % Minority -0- # Femnle -0- % Female -0- * Include One (1) Co-op Student. Hires (Hourly) : Month ~0~_______ Year to Date -0- Terminations (Hourly) : Month Year to Date -1~ Overall Turnover -0- Projected Annual Turnover .6% DTH 000051490 MONTHLY HOURLY TURNOVER 10 9 8 7 6 5 4 I. 3 2 1 Zs Oa 76 78 DTH 000051491 DTH 000051492 VINYL - E. L. Kieschnick February had 28 accounting days (Y.T.D. is 59 accounting days). Production 1. Total Production, MM #'s 2. Production Rate, M #'s/C.D. 3. Charging, Rx B.A.'s/C.D, 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average #'s/Hr. 7. Dryers, Stream Factor, % Month 12.4 444 11.3 317 89.8 511 51.8 Y.T.D. 25.2 427 10.9 646 88.6 416 61.1 Standard Items which limited production for the month included: 1. A one day shutdown to make tie-ins for the Capacity Replacement Project and EPA related projects. 2. Time lost on D-600 to replace the agitator motor bearing, change the seal, and clean the reactor. 3. Time lost to replace the internal parts of the evacuation jets which had caused extended evacuation times. 4. Operation of two reactors on 5425, one on 5385, and one on 5305 for a two week period. Estimated production penalty versus normal 70-75% 5385 production is 6%. 5. Time lost to replace a leaking VCM charge valve on D-500 reactor. Resin Quality Summary Resin Type Prime Pounds "BC" Grade "H" Grade % Off Grade % of Total Production 5305 1,620,088 400 .02 5350 5385 5425 6,097,384 4,281,313 (26,650) (84,125) (1,700) (150) (12,700) (.44) (2.26) (0.01) (0.22) (0.78) 5446/5465 315,350 47,250 15.00 0.38 Sifter Overflow 191,130 100.00 1.54 TOTAL 12,314,135 (63,125) 176,580 0.91 Quality performance for the month of February was 99.01% customer grade with (.51)% "BC" and 1.42 % "H" grade. DTH 000051493 r^- The 1.54% sifter overflow reflects recovery of 30,000 pounds (0.32%) in resin spills due to a resin transfer line failure and to failure of a valve on a bulk loading silo. In addition, a coarse blend of 5305, due to an extended heat-up timei was also put in sifter overflow. The variable cost variance for the vinyl department was $274.4 M with $336.0 M due to price and ($61.6 M) due to efficiency. The major efficiency variances for the month were ($61,6 M) on VCM and $27.0 M on Lupersol 223 M. The $27.0 M on Lupersol 223 M is due to comparison with the standard unit per pound usage which is in error. The only major price variance is $332.7 M on VCM. The raw material requirement for the month was 1.04561 #'s VCM/# PVC versus a standard of 1.0147. The major losses in the department for the month were: 1. 0.0030 lb./lb. due to removal of resin heels from returning railcars and trucks. 2. 0.0014 lb./lb. (estimated) due to reactor foaming losses. 3. 0.0050 lb./lb. due to a coarse batch/reactor vent General rv 1. Total customer grade inventory decreased from 28.8 MM pounds to 24.2 MM pounds. 2. 5.3 MM pounds of 5385 resin were debagged during the month. DTH 000051494 COMPOUND - C. R. Miller February had 28 accounting days (Y.T.D . is 59 accounting days). Compound Production Month #'s/Day Y.T.D. 1) Line I, M pounds 2) Line III, M pounds 3) Total, M pounds 104 2859 2963 52 420 114 5211 106 5631 Line I operated three days during the month at an average rate of 52M pounds per day. Production included sample heating pad compounds 3711-27C and 3711-27E and a sample plug stock compound 3565-49. All samples produced were for Neco. Line III operated twenty-five days averaging 114 M pounds per day. Pro duction rates were affected by long blender dry times during the production of profile compound 18161 and specialty compound 44842. Production for the month also included 20 M pounds of 34533 Natural for Packard Electric. Quality performance for flexible compound was 1.76% "H" grade of which 92.3% was due to mill scrap. The remaining "H" grade resulted from black spec contamination in 15041 Cl Blue 50. "BC" production for the month was 3.4% of which all has been reblended. The "BC" production was largely due to white specs in 32 M pounds of 35441 Black. The raw material requirement for flexible compound was 0.99804#'s raw material/ # flexible compound versus a 1.01501 standard. (Y.T.D. is 1.00888). The low raw material requirement reflects the error made in resin inventory for January. The Variable cost variance for flexible compound was $27.2 M with $2.0 M due to price and $25.2 M due to efficiency. Variance due to product mix was ($8.0 M). There were no major price or efficiency variances for the month. Dry Blend Month #1 s/Day Y.T.D. Total Production 2766 99 5277 The dry blend unit operated twenty-eight days during the month at an average rate of 99 M pounds per day. Production included 80172-B, 80273-G and 90281 dry blends. Major factors affecting rate were the packaging of 780 M pounds of dry blend, operation of only one Welex for several days due to mechanical difficulties and by unit downtime required to solve problem areas related to the new scale system. Quality performance for the month was 97.8% customer grade. Off-grade material continues to be reworked at a 3% rate. DTH 000051495 The raw material requirement for dry blend was 0.96788 #'s raw materials/ # dry blend versus a 1.00321 standard. (Y.T.D. is 0.97589) The low raw material requirement reflects a $17.3M variance for resin usage. The variable cost variance for dry blend was $68.9M with $5.8M due to price and $63.1M due to efficiency. The variance due to product mix was $47.9M. The only major efficiency variance was $17.3M for resin usage. There were no major price variances during the month. Plasticizer Month #'s/Day Y.T.D. Total Production, M Pounds 903 65 1478 The plasticizer unit operated fourteen days during the month averaging 65M pounds per day. Production included DOP, DIDP, 610-P and TOTM plasticizer. VRP production for the month was 44M pounds. The raw material requirement for the month was 1.21598 #'s raw materials/ # plasticizer versus a 1.10745 standard (Y.T.D. is 1.18799). The high raw material requirement reflects an error made in REP on the February month ending inventory. A correction will be made in March. The variable cost variance for plasticizer was $7.4M with $2.5M due to price and $4.9M due to efficiency.. Variance due to product mix was $8.6M. There were no major price or efficiency variances forthemonth. DTH 000051496 MAINTENANCE - K. W. Couch Vinyl 1. D-300 agitator seal failed early in the month after it had been changed in late January. Upon investigation, we found that the seal cavity had burs which nicked the seal O-ring when it was installed. The spacer between the gearbox and reactor bottom was removed and the seal cavity was machined to remove all burs. 2. Due to a buildup on D-600 agitator blades, the bottom bearing in the motor failed and the seal started to leak. The motor was sent out for repairs and our spare motor was installed. We also changed the mechanical seal. 3. Installed new nozzles in the evacuation eductors. 4. Replaced the mechanical seal in the east V.C.M. transfer pump. 5. Changed or rebuilt the following valves: A. D-500 VCM charge B. D-500 chem wash C. D-600 chem wash D. VCM pure receiver inlet 6. During a one day shutdown of the reactor area, 11 maintenance work orders were completed. Safety 1. Installed an escape ladder from the V-10 dryer sifter deck to the floor. 2. Completed the installation of safety latches on the new reactor Lenape manways. Projects 1. Aligned the equipment for the new slurry blend tank and the vent recovery project. 2. Installed and revised the debagging systems for dryer lines 1, 6, 8. 3. Installed larger motors, 15 HP, on the two small Corken compressors and removed unecessary piping in the transfer system from the bullets at the VCM storage area. Compound, Dry Blend, Plasticizer 5 Silos 1. Installed a new ram on Line I Banbury. Also installed hopper door seals. 2. Changed the motor and motor base for #6 air compressor. 3. Installed and removed the portable screeners under silos 412 and 413 due to problems with Kason screener. DTH 000051497 4. Replaced the drive bearings and coupling for #1 Welex unit in Dry Blend. 5. Rebuilt the 687 and 688 silo valves. 6. Completed overhaul of "A" feeder for Line III. Safety 1. Completed the installation of new steps and handrail on the platform on the south end of the plasticizer tank farm. 2. Rebuilt chain guards for the palletizer and #5 and 6 star valves for Line III. 3. Repainted the safety lanes in the hall by the Lab. 4. Installed quick connect fittings for the resin transfer system at the 600 series silos. (ESAR) Projects 1. Built a motor repair table in the I E Shop. 2. Removed the unused equipment for the atomite system in Dry Blend. 3. Installed a 3" transfer line from V-ll dryer building to the resin hook-up station. Utilities 1. Completed a major overhaul of #7 air compressor. 2. Repaired valves in #2, 3, 4, 5 and 8 air compressors. 3. Repaired the damaged parts for #9 air compressor and placed it on line. 4. Removed the suction strainer from the new Joy centrifugal compressor and repaired minor oil leaks. Safety 1. Insulated a section of #6 air compressor discharge line for personnel protection. 2. Repaired the safety shower at the lagoon area. Projects 1. Set up cooling tower pretreatment for the Capacity Replacement cooling tower. Instrument and Electrical 1. Completed the installation of the new Dry Blend control system and removed all unused panels and conduit. Completed the design fot the silo control panel. 2. Reivired the constant temperature room in the lab after the G.C. units were moved. DTH 000051498 3. Installed new switch gear and wire for the 15 HP motors on the two small Corken compressors at the VCM unloading rack. 4. Installed the pressure controller for the Joy centrifugal air system. 5. A great deal of the Instrument Technicians' time was spent on check out of the Capacity Replacement Project. Planner 1. Processed 21 Invoice Registers for contract repairs. 2. Supervising the update of the plant fixed assets inventory. 3. Worked with MED planning group to set up computor run for the relocation of the existing reactor control room and work to be accomplished in the existing reactor area. Micellaneous 1. The plant was on propane 17 hours during the month. 2. There were 596 maintenance, 11 revision, 10 safety and 17 service to operations work orders received during the month. The following is a breakdown on the maintenance work orders by priority. E 275 A 94 B 24 C 62 Shift Mechanic 141 Total 596 46% 16% 4% 10% 24% 100% 3. During the month, 615 maintenance, 24 revision, 23 safety and 19 service to operations work orders were completed. 4. The percentage of maintenance time spent on non-scheduled work was 29.3% for the month. 5. During the month, 10 safety work orders were received, 23 completed and we have a backlog of 2 work orders. 6. All maintenance employees completed the fork truck driver training. DTH 000051499 3. Installed new switch gear and wire for the 15 HP motors on the two small Corken compressors at the VCM unloading rack. 4. Installed the pressure controller for the Joy centrifugal air system. 5. A great deal of the Instrument Technicians' time was spent on check out of the Capacity Replacement Project. Planner 1. Processed 21 Invoice Registers for contract repairs. 2. Supervising the update of the plant fixed assets inventory. 3. Worked with MED planning group to set up computor run for the relocation of the existing reactor control room and work to be accomplished in the existing reactor area. Micellaneous 1. The plant was on propane 17 hours during the month. 2. There were 596 maintenance, 11 revision, 10 safety and 17 service to operations work orders received during the month. The following is a breakdown on the maintenance work orders by priority. E 275 A 94 B 24 C 62 Shift Mechanic 141 Total 596 46% 16% 4% 10% 24% 100% 3. During the month, 615 maintenance, 24 revision, 23 safety and 19 service to operations work orders were completed. 4. The percentage of maintenance time spent on non-scheduled work was 29.3% for the month. 5. During the month, 10 safety work orders were received, 23 completed and we have a backlog of 2 work orders. 6. All maintenance employees completed the fork truck driver training. DTH 000051499 PROCESS ENGINEERING - Douglas Michels A. Capacity Replacement Project Final operator training sessions were completed. Initial commissioning work was begun on February 20, 1978 with the cooling tower, process water system and duraseal systems being put into operation. The con struction contractor completed essential work on February 24, 1978. Full startup coverage was initiated. The period of February 24th to March 1st was used to flush all lines and equipment, leak test all systems and initially operate mechanical equipment. Preparations for initial charging were completed on March 1, 1978 with initial batch being produced on March 2, 1978. Plant process engineering coverage is continuing. Remaining problems are associated with automatic charge sequencing and recovery operation. Ponca City Process Engineers, A1 Peck, David Hester, and Pat Fetizanan, assisted as coordinators and trainers during startup. Their work was completed on March 6, 1978. Wally Sirmons of Oklahoma City provided overall startup coordination which also was completed on March 6, 1978. B. Dry Blend Weigh System The Orbitran sequencing, weighup and control system was put into operation. Initial debugging was completed and the system was turned over to operations. Final programming changes are now being defined. A meeting will be held with Orbitran in March to incorporate remaining changes into the system. C. Resin Silo Aeration The system was completed and put into operation. Air compressor operating instructions were written. Dryer operator training was conducted on the system. D. VCM Railcar Unloading The system was completed and put into operation, Process Engineering provided startup assistance. E. V-10 Dryer Startup Vernon Thornhill assisted operations in the initial startup on the V-10 dryers. F. P.A. Unloading The Engineering staff observed the unloading of several P.A. railcars. Railcar unloading procedures have been written. Minor mechanical revisions are still needed before the system is fully operational. DTH 000051500 G. QMS Addition System The process design for the OMS Addition System was completed and issued. The design is being reviewed by CED and PED. The plant is now developing a definitive estimate. H. Inert Gas Generator The process design for this project was completed and issued. The Plant is developing a definitive estimate for this project. I. Boiler Burner Replacement The process design for this project was issued by PED. The Plant is developing the definitive estimate. Plant process design review is complete. J. Specialty Compound Line A meeting was held with Buss-Condux and Houston Management on this project. Buss-Condux was asked to supply updated cost information relative to the new line. Costs will sharply escalate due to dollar devaluation relative to the Swiss Franc. K. Plant Yield Improvement A report was written defining the magnitude and sources of VCM yield losses. A program was identified to further control and measure losses. Mr. Royce Robertson of PED was in the Plant. He reviewed the Plant's program and setup some of the sampling and calculation procedures. Measured losses during February were: 1. Dryer Dusting Losses 2. Centrifuge Centrate Losses 3. Rinse Losses to Sewer 4. Reactor Foaming Losses 5. Coarse Batch and Reactor Vent 1,200 lb./day 679 lb./day 1,196 lb./day 640 lb./day 33,600 lb./month 19,020 lb./month 33,482 lb./month 17,924 lb./month 63,000 lb./month Accounted for Losses 167,026 lb./month This is equivalent to .0135 lb./lb. PVC product. DTH 000051501 ENVIRONMENTAL HEALTH - Douglas Michels I. Compliance Plan Status A. Particulates No action steps were required during February. B. Water No action steps were required during February. The Plant was visited by the Mississippi Air and Water Pollution Control Commission during February. They inspected the Plant for compliance and conducted concurrent effluent sampling. Due to a secondary treatment system biological upset we expect the concurrent sampling to indicate a non-compliance condition. C. Vinyl Chloride We had no communications to or from the EPA during February. The recordkeeping program has been set up. II. Project Status A. Particulates We are awaiting construction bids on the resin bagging revisions project. B. Water We have received information that Exxon is using a process to re move irritating odors from plasticizer effluent. We are pursueing Exxon to get more detailed information. C. Vinyl Chloride Tabulated on Table I is the identification and status of projects related to vinyl chloride emissions which will be required by the EPA. Ill. Operating Status A. Particulates The recalibrated sampling probe on the RAC stacksampler was returned. Dryer particulate emission testing will resume when priorities permit. DTH 000051502 III. Project Status (Cont.d) B. Water During mid December the operation of Plasticizer Unit was curtailed because of market limiting conditions. Waste water flow from this unit to the secondary treatment system did not occur between December 20, 1977 and January 29, 1978. During this period our biological digestion lagoons apparently lost aclimatization. This was assisted by the cold weather conditions and a nutrient deficiency during the period. The subsequent result of this upset condition was a drastic increase in effluent BOD and a noncompliance condition. The State offices were notified. We will remain out of compliance until reaclimatization occurs. Nutrient additives are being used to expedite reaclimatization. During February there was also a major spill of alcohol apparently emanating from the railcar unloading area. Some of this material bypassed our treatment system and had to be collected by a pump truck and recycled. Revisions are planned to prevent bypassing a spill from the alcohol unloading area. Table II shows recent quality data on the Plant's effluent. C. Vinyl Chloride Inspection programs are in place for leak detection! double mechanical seals, and vessel rupture disks. Reactor slurry samples are being obtained each batch for VCM residuals. The February average for all samples was 417 ppm. Work continues on emphasizing procedures and repairing mechanical problems. DTH 000051503 TABLE I EPA COMPLIANCE ON VCM EMISSIONS ABERDEEN PVC PLANT PROJECT Vent Gas Emission Recovery System Purchase Order Issued Construction Started Installation Completed Compliance Achieved Vent Gas Incineration Purchase Order Issued Construction Started Installation Completed Compliance Achieved Process Water Stripping Purchase Order Issued Construction Started Installation Completed Compliance Achieved Reactor Exhaust Gases Purchase Order Issued Construction Started Installation Completed Compliance Achieved Reactor Opening Loss Purchase Order Issued Construction Started Installation Completed Compliance Achieved Exhaust Gas Discharge Purchase Order Issued Construction Started Installation Completed Compliance Achieved Sources Following Stipper Purchase Order Issued Construction Started Installation Completed Compliance Achieved COMPLIANCE PLAN AFE No. 9226 8/1/77 10/1/77 1/1/78 2/1/78 AFE No. 9057 9/1/77 4/1/78 5/15/78 8/1/78 AFE No. 9565 2/76 2/76 5/76 5/1/77 AFE No. 9275 .10/75 1/76 7/76 8/76 AFE No. 9055 3/31/77 4/30/77 7/31/77 8/31/77 AFE No. 9256 6/1/77 10/1/77 12/1/77 2/1/78 AFE No. 9055 3/75 4/75 9/75 6/30/77 ACTUAL 1/77 9/1/77 - - 7/1/77 - 2/76 2/76 5/76 5/77 10/75 1/76 7/76 8/76 3/75 4/75 9/75 5/1/77 9/1/77 12/1/77 - 3/75 4/75 9/75 6/30/77 DTH 000051504 TABLE I (cont.) PROJECT H. Unloading Lines Purchase Order Issued Construction Started Installation Completed Compliance Achieved I. Pump Seals Purchase Order Issued Construction Started Installation Completed Compliance Achieved J. Compressor Seals Purchase Order Issued Construction Started Installation Completed Compliance Achieved K. Reciprocating Compressors Purchase Order Issued Construction Started Installation Completed Compliance Achieved L. Relief Valve Leakage Purchase Order Issued Construction Started Installation Completed Compliance Achieved M. Equipment Opening Purchase Order Issued Construction Started Installation Completed Compliance Achieved N. Samples Purchase Order Issued Construction Started Installation Completed Compliance Achieved COMPLIANCE PLAN AFE No. 9256 6/1/77 11/1/77 2/28/78 4/1/78 AFE No. 9525, 9495 9/30/76 11/30/76 8/31/77 10/31/77 AFE No. 9525, 9495 9/30/76 11/30/76 8/31/77 10/31/77 AFE No. 9505 9/1/77 11/1/77 3/1/78 5/1/78 AFE No. 9276 6/30/77 8/31/77 10/31/77 11/30/77 AFE No. 9266 5/31/77 8/31/77 11/30/77 2/1/78 AFE No. 9485, 9535 12/76 1/77 4/30/77 5/31/77 ACTUAL 5/1/77 10/1/77 2/15/78 - 9/76 11/76 8/31/77 10/31/77 9/76 11/76 8/1/77 8/1/77 5/15/77 10/1/77 2/15/78 2/77 8/31/77 10/31/77 11/30/77 2/77 6/1/77 11/30/77 2/1/78 12/76 1/77 5/15/77 5/31/77 NOTE: Dates shown are as agreed to by the Plant and the EPA DTH 000051505 Jan. - Ave. Max. Flow GPM 627 798 Feb.- Ave. Max. 606 745 TABLE II WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB/DY. 26 205 34 240 COD PPM LB/DY. 54 434 72 508 Sus. Solids PPM LB/DY. 14 117 17 163 Dlsr 7.2-7.6 ph 7.6-7.7 69 515 100 894 123 906 154 1377 11 79 7.9-9.6 7.6-8.1 12 107 NPDES Ave. Max. - 32 386 43 520 - 1390 - 1940 - 605 >6.0 - 909 6,0-8.5 DTH 000051506 ENERGY CONSERVATION - Douglas Michels I, Plant Operations Total energy consumption for February was 45.24 MM BTU's. The energy consumption per pound of product decreased from 2797 BTU/ Lb. in January to 2377 BTU/Lb. during February. II. Plant Energy Conservation Program A. Energy Audit Booklet The energy audit booklet was completed and issued. B. Boiler Burner Replacement The Class "A" design for conversion of the boiler burners to allow fuel oil firing was issued for plant review, C. Steam Leaks 19 of 19 reported steam leaks were repaired during February. DTH 000051507 ITEM Production, MM Lbs. Control Period Resin Plasticizer Compound Dry Blend TOTAL Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU Propane Consumption, M Gal. Conversion, BTU/Gal, Energy Consumption, MMM BTU Electricity Consumption, MM KWH Conversion, BTU/KW Energy Consumption, MMM BTU Total Energy Consumption, MMM BTU BTU/Lb. Boiler Operating Date No. 1 No. 2 No. 3 ENERGY CONSERVATION DATA FEBRUARY, 1978 1977 1978 Accounting Month Accounting Month 15.23 0.27 1.62 2.87 19.99 12.40 0.90 2.96 2.77 19.03 5021 1020 5.121 11000 1020 11.220 360.829 92000 33.196 294.533 92000 27.097 2.698 3413 9.208 2.029 3413 6.926 47.525 2377 45.243 2377 Ave. Stack Temp. 1977 1978 394 395 419 420 410 410 Ave. % Excess Air 1977 1978 96 70 114 95 120 95 DTH 000051508 MECHANICAL ENGINEERING - S. J. Vincent AFE's Submitted, Approved, and Closed The following AFE's were submitted for approval during the month of February: Resin Moisture Analyzers Laboratory Equipment Safety Equipment Miscellaneous Projects Under $10,000 $ 17,000 $ 50,000 $ 14,000 $225,000 AFE approvals for the month of February were as follows: AFE No. Title Authorized 9038 9048 9058 9068 9078 Maintenance Equipment Resin Moisture Analyzers Laboratory Equipment Safety Equipment Miscellaneous Projects Under $10,000 $ 18,000 $ 17,000 $ 50,000 $ 14,000 $166,000 There was one AFE closed to field charges in February: AFE No. Title Authorized 9246 Dry Blend Control Revisions $ 75,000 Design The electrical design for the Emergency Lighting System has been completed. A basis of bids was compiled and issued for quotes. Installation is scheduled to begin in March. The design and material procurement for the Dry Blend Production Expansion is being handled by CED. The goal date for start-up of this project still remains at June 1, 1978. CED anticipates completion of their design in April. The only significant change made to date has been the relocation of the Dry Blend Screener. No apparent design problems or delays have resulted. Basis of bids were issued for the Inert Vent Incinerator involving the concrete, underground piping, structural, and piping and equipment installation. Most of the materials have been purchased by the Plant. Partial receipt of the incinerator from Trane Thermal occurred at the end of the month. The remainder of the incinerator should be shipped during March. Construction The following major construction activity occurred during February: A. The mechanical installation of the Additional Slurry Blend Tank was completed. Insulation and painting remain to be completed. The system is now ready to be placed in operation. DTH 000051509 Construction (Cont.d) B. The construction work fpr the Vapor Emission Recovery project is complete for startup checkout. Some mechanical changes and insulation work remain to be completed. C. The VCM Unloading Area Revisions project was installed during a shutdown. Some minor items remain to be adjusted, but VCM is being transferred through the system. D. The Dry Blend In-Line Screener was relocated to eliminate vibration problems for the new Dry Blend Weigh System. E. Preliminary work for site clearing and various tie-ins for the Inert Vent Incinerator were done. DTH 000051510 LABORATORY - R. B. Martin CUSTOMER COMPLAINTS Type Complaint Customer Product Date Received Status End of Month Marketing Quality Quality Quality Service Quality/ Service Quality Industrial Plastics Variform Ross 8 Roberts Reynolds Metal LCP Plastics Lone Star Grinnel Compound 90281 Dry Blend 5385-Resin 38631-Compound 5385-Resin 80273-G Dry Blend 5305-Resin 2/2/78 2/6/78 2/13/78 2/27/78 2/27/78 2/27/78 2/27/78 Marketing Complaint Report by CRM Report by RBM Under Investigation Under Investigation Under Investigation Under Investigation WAIVERS REQUESTED Date Shipment Type Product Customer Reason Waived By 2/13 2/24 2/28 Miller Transportation 5425 PTLX 41828 5425/5385 T 2321 5305 General Cable Western Textile Hatco Particle Size Off Grade Particle Size TGS TGS TGS QUALITY CONTROL TESTING In-Process Testing - Routine Resin - 323 regular samples with 2135 in-process testing. Bulk shipments were 166 (42 railcars and 124 trucks). Compound - 411 blenders tested with 2.9% requiring adjustment. Bulk shipments were 16 (4 railcars and 12 trucks). Dry Blend - 565 blenders tested with 14.2% requiring adjustment. Bulk shipments were 25 (10 railcars and 15 trucks). Plasticizer - 48 batches were tested. 2 alcohol tank samples tested. 4 in coming alcohol shipments and 1 incoming plasticizer shipment were tested. 1 outgoing plasticizer shipment was also tested. The month of February set a record for bulk shipments tested in the resin area. This record has not been exceeded since December, 1976. The total bulk shipments tested were 208 which included 166 resin bulk shipments. Resin Oven Heat Stability Sixty-seven (67) blends of resin were tested for heat stability. 5385 5425 5305 5446 34 Blends 22 Blends 10 Blends 1 Blend DTH 000051511 Resin Oven Heat Stability (Cont.) One blend of 5385 was 15 minutes poorer than the control. All the other blends met the heat stability specification. An increase to 7 gallons of catalyst in 5385 resin did not lower heat stability for that product. RVCM Testing of Shipments The RVCM content of 58 railcars was measured during February. The averages by product are as follows: Product 5385 5425 5446 5305 Dry Blend Average # Samples 2.0 29 0.4 0.3 15.8 0.5 15 1 6 7 Raw Material Testing Seventeen (17) lots of plant raw materials were tested and approved for use. A sample of Glowmax LL clay from the Georgia Kaolin Company was tested as a possible substitute for SP-33 clay. The color of the Glowmax LL was excellent, but it did not give an acceptable high value for volume resistivity. COMPOUND DEVELOPMENT AND SERVICE Compound Property Verification The program to evaluate non-routine properties of compounds was continued by testing four (4) additional electrical compounds as well as new compound (16542X). The program was expanded to include oven aging tests on all electrical compounds used for primary insulation. Quality Control Standards New color and heat stability standards were prepared for six (6) compounds. Color plaques and heat stability buttons were submitted to the Quality Control Laboratory. New Compound Formulas Plant formulas, specifications and quality control standards were prepared for four (4) new experimental compounds - 3711-27C, 3711-27E, 16542X, and 3565-41 (using reworked 90826). Customer Complaints Reynolds Metal - In order to investigate a complaint from Reynolds, tensile properties were measured on four (4) samples of 35441 and two (2) samples of 38631. These properties were normal as tested in our plant laboratory. DTH 000051512 Customer Complaints ( Cont.) Sometco - Melt flow tests were run on three (3) lots of 18161 and portions of the samples were sent to Ponca City for evaluation. This work was prompted by a report that Sometco was experiencing low extrusion rates on these materials. There were some variations in the flow rate as measured by this test but coorelation to the processability of the compounds is questionable. PRODUCT DEVELOPMENT AND SERVICE Product Type Pounds Customer 37121 Wht. Std. Compound 50 Bata Shoe Company Salem, IN 47167 18961 Wht. 366 Compound 50 Pan-Am Plastics Corp. Chicago, IL 60616 5385-1 Resin 10 Continental Plastics Inc. Avene1, NJ 07001 5385-1 Resin 50 U.S. Gypsum Research Des Plaines, IL 60016 80172B Dry Blend 200 Extrudyne Omityville, NY 11701 27121 Blk. 28131 Blk. Compound Compound 100 Brierwood Molding 100 Littletown, PA 17340 14331 Clear 28831 Nat. Compound Compound 50 Armorlite, Inc. 50 Sam Marcos, CA 90269 18161 Nat. 14331 Cl. Bl. 50 15041 Cl. Bl. 50 Compound Compound Compound 50 Vinyl Plastics, Inc. 50 Sheboygan, WI 53081 50 5385-1 Resin 50 Sherwin Williams Co. Chicago, IL 60628 5385-1 Resin 5 Cerro Wire Cable Co. Maspeth, L.I., N.Y. 11378 5465-1 5305-1 Resin Resin 5 Thiskol Corp. 5 Brigham City, Utah 84302 90171 5385-1 Dry Blend Resin 2,250 Multi-Fittings Wolverine Aluminum Jackson, MI 49203 DTH 000051513 SPECIAL PROJECTS High VR 5425 Resin Volume resistivity (VR) tests were run on four (4) experimental blends of 5425 resin produced in cooperation with a Ponca City VR improvement program. The VR results were in good agreement with values measured in Ponca City. This data has been reported to PAL. RVCM of Slurries A total of 300 slurry samples were tested for RVCM in February. The overall average was 414 ppm. It should be noted that 58.1% of the samples were below 400 ppm. Personnel VC Measurements Work was done on a new VCM monitoring device. The "REAL" minimonitor, a device that uses activated carbon, was tested for possible use as a replacement for the air bag monitoring we now do. A method for using the F-42 head space analyzer to measure the VCM absorbed on the carbon was developed. Effective March 1st, all monitoring work will be evaluated using the new system. RVCM Testing on Bagged Resin As part of the current program to remove the cancer label from bagged resin, work was done to check the VCM exposure of workers while debagging. A report is to be issued on these results by March 17. The first portion of this project involved the testing of air trailer space for VCM while unloading bagged resin. DTH 000051514 ORDER ENTRY 8 TRANSPORTATION WAREHOUSE - J. E. Stark, J. C. Coffman Shipment by Product M/Lbs. February, 1978 Year-To-Date Resin Plasticizer Dry Blend Compound TOTAL 14,888 44 3,363 3,066 21,361 28,701 131 6,824 5,879 41,535 Number of Shipment by Mode R/C O.T, C.C. C.O.T, TOFC CPU TOTAL Resin -Bulk -Package -Export Aberdeen -Export Hattisburg 35 89 4 32 36 17 13 29 2 162 48 78 13 Plasticizer -Bulk 11 Dry Blend -Bulk -Package 14 14 10 1 28 2 13 Compound -Bulk -Package 6 10 24 4 12 20 18 54 Export -Package 55 183 1 84 29 1 27 378 Number of Shipment by Month - Y.T. D. R/C O.T. C.C. C.O.T T0FC CPU TOTAL January February 72 140 36 55 183 84 1 29 0 35 284 0 27 378 Material Handling Report M/Lbs. T/L Packaged Resin from Production Packaged Compound, Dry Blend From Prod. Transferred From Main to Prairie Transferred to Hamilton from Main Transferred From Prairie to Main Transferred From Prairie to Prairie Reverse Transfer Resin to Plant Reverse Transfer Cmpd. to Plant Shipment From Warehouses Special Packaging Shipment From Hattiesburg 891 2106 567 0 5670 0 5467 202 6075 3726 526 25,232 22 52 14 0 140 0 135 5 150 92 13 623 DTH 000051515 LOCATION KAIN-Eaat TOTAL M SO. FT. 48 HAMILTON 11 PRAIRIE 12-1 12-2 12 t ` 22 12-3 22 12-4 22 12-5 21 12-6 12-7 12-8 12-9 12-11 21 21 21 21 21 12-12 HATTIESBURG 22 18 TOTAL CONOCO TRANSPORTATION ABERDEEN WAREHOUSE CONTENTS ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL Compound JLL Dry Blend Export Realn Conoco Realn III Realn Raw Material Compound __ iZ. JJL JLZ. .2 Compound JLxL Dry Blend _U. Chryaler Realn Raw Materials Conoco Resin 2.6 .3 4.7 4.8 1 .4 _L4____ .6 .1 ____ 2J&____ .7 3 4 .1 -- 9.:5____ 2.0 1.5 3.5 3.5 Conoco Realn Realn O.G. Mill Scraps Cmpd O.G. l 2 .9 Dry Blend O.G, --d. Sifter Overflow .4 Realn O.G. Conoco Realn -UL * 1.9 4.5 Conoco Realn __dL Export Realn * .1 Chryaler Realn Exp Realn * 4.5 * _____ 3_-l- .6 .6 3.4 .3 3.5 2.5 3.5 3.5 3.5 3.5 Cmpd. O.G. Conoco Realn t Conoco Realn Exp Resin Sub-Total 6 .8 2 .7 3.5 3.2 .3 3.5 1.8 1 .2 ____3J>._ 50.0 (Plus Aisles) i DTH 000051516 36 . 61S. 4 - JLlD.52,0 Off-Grade In Storage Material M/Lbs. T/L Sifter Overflow Resin "BC" Resin "H" Mill Scraps Compound "B" Compound "H" Dry Blend "O.G." 348 1183 51 40 219 49 382 9 29 1 1 5 1 9 TOTAL 2232 54 Chrysler Storage Balance, February 1 7224 178 Transferred during month TOTAL 347 6877 8 170 Export Shipments Special Packaging 3726 92 Other During the month of February we had a drop in our packaged inventory. This drop was due to debagging resin for shipments and several large export orders. We have released two of our outside rental buildings as of the first of April. DTH 000051517 (11 Thru January, I9"8 Actual Accounting (2) Thru February, 1978 rtlilL CAPITA! NP. DESCRIPTION DATE Ainu. APPROVED* AFU AMT. O) U'l FINAL UNDER EST. EST. EXPENDED COMMUTED TOTAL liST. (OVER) COMP. CLOS, TO DATE TO DATE COST COMP. AUDI. AMT. DATE DATE REMARKS 91C 1 Blender Vent Systca 8/20/74 50,000 28,782 23,782 28,782 1,218 9/77 3/78 Closed. Credit due. 9E 2 Replacement of VCM Equip Seals 12/19/75 36,000 12,418 15,818 13,818 22,132 12/77 4/78 Closed to field charges. 962 - Building Ventilation Syston 12/31/75 344,000 311,347 322,316 344,000 0 4/78 7/78 Painting in progress. 91C Dry Blend In-Line Screcner 6/29/76 20,000 16,547 16,384 16,384 3,616 S/77 4/78 Closed. Credit due. 912 PVC Reactor Capacity Replacement 7/8/76 8,577,000 6,958,222 7,80S.273 7,950,208 626,792 3/78 6/78 Unit being started. 91 > Revisions to the Manual Baggers 9/7/76 62,000 9,599 9,999 62,000 0 6/78 9/78 Bids requested. 91V 2 Area Vacuum Cleanup System 10/11/76 25,000 34,324 33,951 33,951 18,951) 9/77 4/78 Closed. Credit due. 9U : Plant Communication System 10/21/76 38,000 36,662 36,662 36,662 1,358 7/77 3/78 Closed to field charges. 9:i , Maintenance Equipment 11/2/76 33,000 33,296 35,366 33,366 (366) 12/77 4/78 Closed to field charges. 922 Vapor Emission Recovery System 11/4/76 260,000 153,776 204,460 260,000 0 3/78 6/78 Construction in progress. sc* Dry Blend Control System 11/4/76 75,000 72,902 81,353 81,353 (6,353) 3/78 5/78 Closed to field charges. 9Ri > Railcar Unloading Area Compliance 12/2/76 220,000 119,247 193,869 220,000 0 3/78 6/78 Painting scheduled. 9*t> Vessel Purging System 12/10/76 43,000 33,352 37,138 38,000 5,000 3/78 6/78 Changes to be aade. 977 : Relief Valve Vent Containment 12/10/76 39,000 26,073 27,500 39,000v 0 3/78 6/78 Installation in progress. 921: Additional Slurry Blend Tank 12/7/76 290,000 189,236 236,556 290,000 0 . 3/78 6/78 Construction proceeding. 901 i Misc. Capital Items Less Than $2500 1/12/77 25,000 25,758 25,758 25,758 (758) 7/77 3/78 Closed to field charges. 90* ; Cooling Water Circulation Revision 3/2/77 105,000 56,786 64,094 105,000 0 4/78 7/78 Waiting for shutdown to complete 9Ci Vent Gas Incineration 4/1/77 275,000 8,508 138,192 275,000 0 7/78 10/78 Bids requested. Resin Silo Aeration S/16/77 280,000 196,764 207,998 207,998 72,002 4/78 7/73 Construction in progress. Jli. Compound Plasticizer Tank Farm 6/6/77 45,000 14,900 23,840 45,000 0 4/78 7/78 Insulation to complete. 91: ? Misc. Capital Items Less Than $2500 6/30/77 10,000 9,090 9,141 10,000 0 1/78 4/78 Closed to field charges. 9U' Phthalic Anhydride Exposure Reduction 6/30/77 45,000 8,937 15,887 45,000 o- 3/78 6/78 Work in progress. 91 ' Boiler Feedwater Treating System 6/30/77 49,000 0 34,476 49,000 0 4/78 7/78 Waiting on equipment. 9H ' Farrel Mixer Rotors 6/30/77 38,000 0 35,735 38,000 0 3/78 6/78 Ordered. 911 Laboratory Equipment 7/19/77 21,900 1,429 20,295 21,000 0 3/78 6/78 Some equipment received. 91 f 7 Emergency Reactor Vent Control 9/29/77 33,000 100 100 33,000 0 6/78 9/78 Design proceeding. 915 / Dryer Area Noise Abatement 9/29/77 45,000 0 0 45,000 0 10/78 12/78 Design proceeding. 92 C? Safety Equipment 9/29/77 7,000 1,361 5,488 5,488 1,512 1/78 4/78 Closed to field charges. 922; Plant Emergency Lighting System 10/10/77 65,000 3,221 16,80S 65,000 0 4/78 7/78 Bids requested. 92: ? Heated Plasticizer Addition System 10/11/77 37,000 1,863 4,183 37,000 0 4/78 7/78 Installation proceeding. 924 7 Farrel Mixer Feeders 11/21/77 47,000 0 12,476 47,000 0 5/78 8/78 Feeders purchased. 92 $2t; Resin Transfer Debottlenecking Dry Blend Production Expansion 11/16/77 11/23/77 56,000 200,000 0 29,871 2,163 47,539 56,000 200,000 0 5/78 8/78 CED handling project. 0 7/78 10/78 Design in progress. 92 w Truck Loading Safety Revisions 11/28/77 16,000 0 0 16,000 0 4/78 7/78 Scheduled. 92 f-: Plasticizer Yield Improvement Test 12/5/77 6,000 0 0 6,000 92! r Automatic Plasticizer-Stabilizer 12/14/77 60,000 0 0 60,000 Wcighup System 0 6/78 9/78 Design in progress. 0 12/78 3/79 Waiting on design. 9Ji : 911 : S ^*^911 ju : Compound Project Conveying Lines Critical Spare Equipment Misc. Items Under $10,000 Maintenance Equipment 12/14/77 1/31/78 1/31/78 2/3/78 SO,000 63,000 50,000 18,000 0 0 50,000 0 52,764 63,000 0 1,919 50,000 0 3,870 18,000 0 11/78 2/79 Scheduled. 0 12/78 3/79 Equipment Ordered. 0 12/78 3/79 Purchases proceeding. 0 9/78 12 / V 8 Equipment Ordered. DTH 000051518 MilL CAPITAL NO. DESCRIPTION 91C i Blender Vent System 9E 2 Replacement of VCM Equip Seals 962 i Building Ventilation Systom 91C Dry Blend In-Line Screcner 912 PVC Reactor Capacity Replacement 91 > 91V 2 Revisions to the Manual Baggers Area Vacuum Cleanup System (11 Thru J.muarv, I9"8 Actual Accounting (2) Thru February, 1978 ABERDEEN AUTHOR 1'At IONS REIVIIT --- PATE autii. APPROVED' aee A>rr. O) FINAL EXPENDED COMMUTED TOTAL liST. TO DATE TO DATE COST COMP. UNDER (OVER) Mini. AMT. liST. EST. COMP. CLOS, DATE DATE REMARKS 8/26/74 30,000 28,782 28.782 28,782 1,218 9/77 3/78 Closed. Credit due. 12/19/75 36,000 12,418 13,818 13,818 12/31/75 344,000 311,347 322,316 344,000 6/29/76 20,000 16,547 16,384 16,384 7/8/76 8,577,000 6,958,222 7,80S,273 7,950,208 22,182 0 3,616 626,792 12/77 4/78 4/78 7/78 S/77 4/78 3/78 6/78 Closed to field charges Painting in progress. Closed. Credit due. Unit being started. 9/2/76 10/11/76 62,000 25,000 9,599 34,324 9,999 33,951 62,000 33,951 0 6/78 9/78 (8,951) 9/77 4/78 Bids requested. Closed. Credit due. ' (1) Thru January, l'.i'a Actual Accounting (2) Thru Feburary, 1978 ABERDEEN AUTHORIZATIONS REPORT AU'iil. EXPENSE $2.... DESCRIPTION DATE Airni. APPROVED AFU AMT. (11 (2) FINAL EXPENDED COiNITTED TOTAL EST. TO DUE TO OATE COST COMP. UNDER (OVER) AUTH. AMT. EST. EST. COMP. CLOS. DATE DATE REMARKS 9 s T. fl> 90 : SI 92 J Revisions to Corken Compressors 12/22/75 PVC Reactor Capacity Replacement (OHS 17/8/76 Repairs to V-11 Dryer Roof 5/17/77 Laboratory Modifications (OMS) 5/31/77 Maintenance Painting Projects 9/29/77 22,000 175,000 18,000 10,000 85,000 7,354 S3,916 12,926 33,062 72,214 6,874 6S ,025 21,428 35,449 81,595 6,874 175,000 21,428 35,449 85,000 15,126 S/77 4/78 Closed. Credit due. 0 3/78 6/78 Unit being started. (3,428) 4/78 7/78 Construction proceeding 4,551 1/78 4/78 Closed to field charges 0 3/78 6/78 In progress. DTH 000051519 ABERDEEN PLANT EFFICIENCY 1978 Monthly Cumulative Standard 1.0147 Standard 1.0150 Standard 1.0032 Standard 1.13992 DTH 000051520 MM Pounds ABERDEEN PLANT PRODUCTION 1978 MM Pound Monthly Cumulative 350 300 250 200 150 100 50 0 50 40 30 20 10 0 80 60 40 20 0 12 10 8 6 4 Z 0 DTH 000051521 ABERDEEN PLANT INVENTORIES DTH 000051522 Off Grade ABERDEEN PLANT QUALITY PERFORMANCE 1978 EUG ENE D IETZO E N CD, /\ PAPER 4.0 W 3.0 2.0 1.0 4.0 3.0 2.0 I o<- in r 1.0 a zy UJ 15 > "5 D uj > 5 4.0 Goiiip >und- u pr-gra, je--: 3.0 2.0 1.0 Monthly Cumulative 19 78 Standard 0.35 Standard 0.79 Standard 2.2 DTH 000051523