Document xj87zjZK8EDnJzERN5oqydRZy

SAFETY - A. H. Sather Occupational Injuries 1980 November Year-to-Date 1979 Year-to-Date Injuries Treated First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time 5 46 0 14 02 0 23 00 38 9 2 29 1 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving .& Warehouse Office 1 13 2 20 1 24 14 00 01 15 4 24 2 0 3 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 3 32 04 18 2 13 04 04 14 6 12 11 8 2 As of November 30, 1980, the plant operated 511 days or 660,622 manhours without a disabling injury. Safety Meetings A.H. Sather conducted the November Safety Meetings. The topics covered 1980 year-to-date safety performance, job planning for safety, incident control, attitude effects, and an open discussion of problem areas experienced by plant personnel. Employees were encouraged to suggest possible solutions to the problems they brought up. Management personnel present at the meetings included Department Heads, the Plant Superintendent or Manager, and second level Supervisors. New Employee Orientation Seven (7) new casual employees were given new employee safety orientation. Also, Steve Saborsky - Compound Business Area Manager was given an extensive orientation into chemical exposure controls and employee attitude concerns. -1- DTH 000021432 SAFETY - (continued) OSHA Compliance A significant amount of activity occurred in this area during the reporting period. The activities are listed below: A. A memo summarizing additional areas of lead related work was circulated for comment. This memo summarized the bases for future work including improved work practice controls, respirator requirements, engineering controls, labeling and others. B. Respirator training for all personnel who may have need to wear respirators was conducted. Makeup sessions were scheduled for the first week in December to train the remaining personnel. C. Routine VCM and Lead Dosimetry. The results of which are shown below. VCM A total of 77 samples were analyzed four (4) of which indicated overexposure. The results are shown below and overexposures explained. Range (ppm) Number Percent 0.0 - 0.5 0.5 - 1.0 1.0 - 5.0 5.0+ 70 90.91 3 3.90 1 1.29 3 3.90 77 100.00 Four overexposures occurred during the reporting period. One of them occurred to an old module operator who did not identify a source and was not wearing a respirator. Another occurred to a'dryer operator who was performing fire watch work in the new module. While performing a check for leaks, be crossed a VCM gas concentration escaping from the sewer during blowdown tank pumpout - he was not wearing a respirator. Another occurred to a new module operator who was performing a VCM filter change and was wearing a respirator. The remain ing overexposure occured to a mechanic who spent his monitoring period working on jobs in the vinyl unit. No source was isolated and he was not wearing a respirator. Lead A total of thirteen (13) samples were analyzed, two (2) of which indicated overexposure. The results and overexposure explanations are shown below: -2DTH 000021433 SAFETY - (continued) OSHA Compliance (continued) Lead Range Number Percent Less than PEL Greater than PEL 11 2 13 84.6 15.4 100.0 The two (2) overexposures occurred to Line III compounders while performing normal work including housekeeping. Both men were wearing respirators. -3- DTH 000021434 VINYL - P. E. Markey Production 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. Drying Rates, Average Lbs./C.D. 7. Dryer Stream Factor, % 8. Accounting Days 28.0 933 22.4 672 92.6 6019 92.3 30 245.0 731 17.5 5848 75.3 5779 75.3 335 Vinyl Department production for November was 103% of budget at 28.0 MM pounds. Reactor and dryer stream factors were 92.6% and 92.3% respectively. The major items affecting stream factor and production were: 1. A condenser cleaning on 743 reactor during which time advantage was taken by utilizing excess dryer capacity to upgrade material via de bagging and deboxing operations. This resulted in a penalty of 0.8% for the reactors and 1.1% for the dryers. 2. A number of routine smaller stream factor penalties comprised the balance. Resin Quality Summary Resin Type Prime Pounds "BC" Grade "H" Grade % of Total Production 5305 5385 5425 5465 Sifter Overflow 1,434,215 22,180,161 3,206,360 581,722 - _ 1,500 374,449 (140,302) -- -- - 374,680 5.1 80.0 11.5 2.1 1.3 TOTAL 27,402,458 374,449 235,878 100.0 Quality performance for November was 97.8% customer grade with 1.3% "BC" grade and 0.9% "H" grade. Cost The variable cost variance was $646.7 M favorable with $572.2 M due to price and $74.5 M due to efficiency. The major price variance was $574.5 M for VCM. Favor able efficiency variances were: $28.2 M for VCM, $37.8 for processing additives, and $10.6 M due to a different product mix. Variances due to off-grade were minimal. The monomer raw material requirement for November was 1.01456 lbs. VCM/lb. resin versus the 1.0196 standard. (Y.T.D. is 1.01818.) -3- DTH 000021435 VINYL - (continued) General 1. Resin packaging for November totaled 5,796,699 pounds. Resin debagging and deboxing totaled 140,302 pounds upgrading "H" grade resin to customer grade. 2. A large chem wash spill occurred in the old reactor module as a result of a chem wash valve failing to close on D-600 reactor during polymerization. When chem washing operations were begun on D-400 reactor, the resulting pressurization of D-400 and the chem wash retain header blew chem wash out of the tank. No one was injured as a result of the incident. -4- DTH 000021436 COMPOUND - J. R. McCrimon Compound Production Month #' s/Day Y.T.D. Line I, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days 710 49 12,303 662 33 1,630 2,277 99 28,910 3,649 126 42,843 30 335 Line I operated 14.6 days during November at an average rate of 49 M pounds per day. Major items affecting production efficiency were: product changes (32.6 hours). No. 1 blender gearbox repairs (19.9 hours), dicers (8.3 hours), skip hoist (6.5 hours), and quality control 8.7 hours). Line V operated 20.3 days during November at an average rate of 33 M pounds per day. Major items affecting production efficiency were: product changes (35.0 hours), cleaning equipment due to quality control (20.1 hours), Werner-Pfleiderer (18.4 hours), Orbitran (14.8 hours), plasticizer weighing (14.1 hours), putting up raw materials (12.9 hours), and maintenance on vibrators (5.5 hours). Line III operated 23 days during November at an average rate of 99 pounds per day. Line III production was affected by: product changes(47.1 hours), mill temperature control system (13.3 hours), FCM seal changes (10.6 hours), and steam leak repairs (10.5 hours). Line III was also down 135.5 hours for repairs to "B." blender gear box. Line I and V operated during the Line III outage. Quality performance for flexible compounds was 3.9% off-grade of which 55.9% was due to mill scrap. "BC" production was 4.0%. The raw material requirements for flexible compounds was 1.04086 pounds of raw material per pound of compound versus a 1.01301 standard. (Y.T.D. is 1.01700.) The variable cost variance for compound was ($25.8 M) with $42.1 M due to price and ($67.9 M) due to efficiency. The variance due to product mix was $10.3 M. The only major efficiency variance was ($32.0 M) for vinyzene SB-1 which is a result of an incorrect inventory in October and the use of vinyzene BP-5 (an equivalent, obsolete raw material). The IPA budget is based on SB-1; however, BP-5 is not pound per pound equivalent to SB-1. There were no major price variances for the month. Dry Blend Month #'s/Day Y.T.D. Production, M Pounds Accounting Days 2,881 30 175 22,418 335 -5- DTH 000021437 COMPOUND - (continued) Dry Blend - (continued) Dry Blend operated 16.5 days (based on 24 hour day) during November at an average rate of 175 M pounds per day. Production included 80172B, 80273G, 80274, 80174, and 90171. Dry Blend production was hindered by: product changes (11 changes, 10.1 hours), quality control (12.6 hours), putting up raw materials (7.1 hours), out of resin (5.3 hours), boxing limited (6.8 hours). Quality performance for the month was 99.3% customer grade. The raw material requirement for dry blend was 1.00056 pounds of raw material per pound of dry blend versus a standard of 1.00321. (Y.T.D. is 1.00421.) The variable cost variance for dry blend was $49.0 M with ($0.6 M) due to price and $49.6 M due to efficiency. The variance due to product mix was $57.3 M. There were no major price or efficiency variances for the month. Plasticizer Month #'s/Day Y.T.D. Production, M Pounds Accounting Days 922 64 30 9,074 335 Plasticizer operated 16 days during November at an average rate of 64 M pounds per day. Production included: D0P, 610P and DIDP. VRP production totaled 107 M pounds (10.4%). Production was limited by: steam curtailment due to boiler revisions, safety disc changes (4) and Schenk filter maintenance. The raw material requirement for plasticizer was 1.12481 pounds of raw materials per pound of plasticizer versus a 1.08233 standard. (Y.T.D. is 1.11123.) The variable cost for plasticizer was ($52.3 M) with ($41.5 M) due to price and ($10.9 M) due to efficiency. Major price variances were: ($10.4 M) for Alfol 610, and ($18.0 M) for 2-ethylhexanol. There were no major efficiency variances. The variance due to product mix was ($1.5 M). General Total customer grade compound inventory decreased from 6.0 to 4.8 MM pounds during November. -6- DTH 000021438 MECHANICAL - S. J. Vincent Vinyl There was one large reactor seal failure and one reactor condenser cleaned this month. The condenser cleaned was on the 743 reactor and the seal failure was on 741 reactor. Problems with the seal oil system was the cause of this seal failure. There were no reactor gearbox failures in this period. In the vinyl old module, four seal failures and two overhauls occurred to pumps and comperssors. The seals replaced were on the "A" vacuum pump, the west VCM charge pump, the south sphere pump and the recovered VCM charge pump. The "B" recovery compressor and the reactor rinse pump were overhauled. There were no repairs in the vinyl new module. Valves repaired or replaced in this period were the charge water valve on 743 reactor, D-600 dump valve, 742 main dump valve, D-500 dump valve and a new check valve was installed in the east charge water pump in the new module. Three loading hoses were replaced and the north Corken compressor was replaced with the spare compressor. General repairs and projects completed in the vinyl production area involved the quench section of the incinerator inspection and the cleaning of the spray heads. A work platform was installed at the new module charge water filter. Both seal oil system pumps were replaced in the new module. Two safety lifting cages were fabricated and installed in the recovery area of both modules. Third pens were installed on three new module recorders; one remains to be done. The level and pressure transmitters were calibrated for the old module middle re ceiver. Several flowmeters were cleaned and repaired. Repairs to vinyl drying equipment included the #2 Bird replacement and the spare bowl being overhauled. P.M. inspections were completed on the #2, #5 and #7 dryer trains, along with, minor repairs. Control panel wiring revisions were completed to dryer control sections. Compound - Dry Blend - Plasticizer - and Silo Storage Repairs to the compounding equipment involved a Line III shutdown to make re pairs to the "B" blender gearbox. With the unit down, the blender and mill vent hoods were cleaned and new sample ports were installed on the plasticizer charge lines. Also completed was repacking both blenders and repairing process leaks. The seals were changed three times on the FCM in this period. Repairs to the Line I compounding equipment were to overhaul the #3 dicer and to build up a spare blender gearbox. The compound product star valve was overhauled, the compounding boxing hopper transfer line was revised and a manway installed for cleaning the hopper. Lockouts were also installed on the Line I breaker panel. -7- DTH 000021439 MECHANICAL - (continued) Compound - Dry Blend - Plasticizer - and Silo Storage (continued) Major repairs in the dry blend unit were to overhaul "C" blender gearbox, re anchor the "B" and "D" gearboxes and repair chain guards. Some repairs were completed to the Orbitran controller and spares were checked. The only major repair in the plasticizer unit was to replace the phthalic anhydride charge pump seal. Utilities and Service There were some repairs to equipment in the pi ant air system in this period. The valves were repaired in #2 air compressor and the motor was rebuilt. The aftercoolers were repaired on the #5 and #7 compressor and the west heater replaced in the #3 air dryer. The new Joy air compressor motor was drawing high amps, so some tuning on the compressor controls was necessary to alleviate this problem. The propane vaporizers were test fired four times in this period with no problems. The #1 boiler was down to install the economizer and to wash tubes. Planner The Planner estimated 95 work orders and ordered material for 28 work order projects. There were 17 new invoice registers issued and 12 closed. There were 16 statements processed for payment. The Planner updated the Line III shutdown plan and worked with the Utility Supervisor to update the Utility Run Sheets. -8- DTH 000021440 MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approved, and Closed The following AFE's were submitted and approved during November: AFE No. Title Authorized 9750 9760 9770 9020 Rotary Dryer Insulation (Energy) Emergency AMS Kill System Reactor Pressure Relief Modifications Repairs to Line I Compounder $ 22,000 335,000 560,000 38,000 Completion reports were issued for the following AFE during November: AFE No. Title Authorized 9258 Dryer Operation Improvements $315,000 There were no AFE's closed to field charges during November. Design Design work is in progress on the following projects: - Fixed Point Monitor Data Computer & Warning Lights - Compressor & Vacuum Pump Seal Flush Revisions - Breathing Air Modifications - Spill Prevention Plasticizer Unloading Area - Crammer Feeder Access Platform - Sweco Installation - No. 4, 5 & 6 - Kemp Air Dryer Modifications - Fire Protection Improvements - Phase II - Multi grade Resin Production Facilities - Spare Inert Incinerator - Batch Water Stripping AFE Activity 1. AFE 9519 - Critical Spare Equipment - J. P. Windham Performance tests of the Colt-on transfer unit have been successful under some conditions and inconsistent under some conditions. Minor modifications and additional tests are scheduled for December. -9- DTH 000021441 MECHANICAL ENGINEERING - (continued) AFE Activity (continued) 2. AFE 9689 - Diking of Sphere & Curbing of Drum Storage Areas - J. L. White All exterior and interior walls are complete. Approximately 80% of the backfilling and grade work is complete. 3. AFE 9709 - Facilities for Multigrade Resin Production - S. Krause Overall project design is 90% complete. Bids have been requested for piping, structural steel, and equipment setting. Foundation work is in progress. 4. AFE 9729 - Fire Protection Improvements - Phase II - M. Ingle The design of this project is approximately 99% complete. Part Ipiping installation is nearly complete. Bids have been requested for part II piping, structural steel and equipment setting. 5. AFE 9739 - Methocel Charge Revisions - J. L. White Construction is in progress and is scheduled to be operational in December. 6. AFE 9530 - Spare Incinerator - D. Haub Piping isometrics are 75% complete. The concrete bid package is to be issued in December. Instrumentation drafting is in progress. 7. AFE 9580 - Boiler Economizers - J. L. White All three economizers have been installed and are operational. Painting and insulation remain to be completed. 8. AFE 9590 - Critical Spare Equipment - J. P. McKee Quotes have been requested from qualified vendors for construction of the spare reactor condenser. 9. AFE 9610 - API Clean Water Bypass - M. S. Richards Sewer construction is in progress and the skimmer equipment has been set in place. Completion is scheduled for December. -10- DTH 000021442 MECHANICAL ENGINEERING - (continued) AFE Activity (continued) 10. AFE 9630 - Water Stripping - M. Ingle Overall project design is 85% complete. The construction of the founda tion and sewer is in progress. 11. AFE 9660 - Hot Water Charge Tank Replacement - J. P. McKee Concrete work is complete. The piping and electrical contracts were let and work is in progress. This project is scheduled to be operational in December. 12. AFE 9680 - Fixed Point Monitor Data Computer & Warning Lights - R. B. Harned Overall project design is 55% complete. A draft of the purchase contract has been submitted to the vendor. Projected delivery is sometime in February, 1981. Debugging of software in Ponca City will require approximately one month. Modifications of the Gas Chromatograph are being handled by MED/ISD. 13. AFE 9690 - Breathing Air Modifications - J. L. White Quotes have been requested for the air receiver and long lead items. 14. AFE 9720 - Reactor Agitator Replacement - M. S. Richards The agitators have been placed on order. MED has been requested to study the feasibility of removing one of the eight reactor supports for more accessible placement of the agitators. 15. AFE 8395 - Interplace Communications - Phase II - R. B. Harned The installation contract has been let and construction is scheduled to start in December. Equipment delivery is scheduled in January. Construction - G. A. Morgan Nine contracts were let during November. They were for: 1. Piping, Structural and Equipment Setting for Hot Water Charge Tank Replace ment. 2. Electrical Installation for Hot Water Charge Tank Replacement. 3. Piping, Structural and Instrumentation for Methocel Charge Improvements. 4. Installation of Phase II Interplant Communications. -11- f*TH 000021443 MECHANICAL ENGINEERING - (continued) Construction - (continued) 5. Insulation of New Air Dryer. 6. Installation of Spill Containment Trench. 7. Insulation of Vinyl Rotary Dryers. 8. Extension of Main Plant Breakroom. 9. Phase III of Concrete Work and Underground Facilities for Plant Expansion. Twenty-seven (27) register tickets were issued during November. -12- DTH 000021444 1) Thru October, 1980 Actual Accounting 2) Thru November, 1980 ABnnnm-N Airriinuir.vnoNS km'okt Aurii. Capital NO, MscRirnoN' 9237 Heated Plasticizer Addition System D:\TF. /Mini. AITROVK!) Ai l-: AMT. 10/11/77 37,000 CD FINAL i:xri:\H!:n comm mm Torn, i:st. to inn. PUL__ COST COMP. UNPr.u tovuo \UTH. AMT. 1ST. LST. COMP. Cl.OS. inn: ill'll Rl MARKS 13,135 15,494 37,000 0 12/80 3/81 Design in progress. 9143 Plasticizer Chemical Exposure Abatement 8/21/7S 152,000 143,863 145,203 145,203 6,797 9/80 12/80 Closed to field charges. 9519 9559 Critical Spare Equipment Color Weigh Room Modifications 2/6/79 4/19/79 175,000 25,000 107,874 18,552 161,480 19,443 163,000 25,000 12,000 0 12/80 3/81 Revisions in progress. 1/81 4/81 Revisions in progress. 9589 9609 Instrument Air Dryer Reactor Inert Vent System 5/30/79 6/28/78 110,000 90,000 90,134 13,483 95,229 17,895 110,000 90,000 0 12/80 3/81 Revisions in progress. 0 3/81 6/81 Project on hold. 9629 Air Compressor 7/9/79 340,000 263,856 276,730 340,000 0 3/81 6/81 Revisions in progress. 9639 Revisions to Emission Recovery System 7/12/79 100,000 62,991 73,359 100,000 0 12/80 3/81 Revisions in progress. 9649 Double Block Valves for VCM Charge 7/18/79 182,000 144,765 169,793 182,000 0 12/80 3/81 Project operational. 9669 New Air Header 8/15/79 25,000 17,423 18,566 25,000 0 12/80 3/81 Revisions in progress. 9689 Diking of Sphere & Curbing of Drum Storage Areas 9/15/79 170,U00 112,427 129,782 170,000 0 3/81 6/81 Construction in progress. 9699 Plant Dryer Debottlenecking 9709 Facilities for Multiple Grade Resin Production 9719 Aberdeen PVC Resin Expansion 9729 Fire Protection Improvements Phase II 9739 Methocel Charge Revision 9759 9510 Aberdeen PVC Resin Expansion Miscellaneous Projects Under 110,000 9530 Spare Incinerator 9550 P.A. Handling Improvement 9560 Safety Equipment 9/15/79 9/20/79 80,000 870,000 6,775 43,740 24,615 337,145 80,000 870,000 9/10/79 10/1/79 850,000 490,000 11,421 23,062 824,900 172,846 850,000 490,000 10/3/79 66,000 12/10/79 11 ,150,0G0 1/3/80 150,000 8,814 35,369 66,000 1,582,079 5,430,600 11 ,150,000 102,514 126,359 150,000 1/23/80 3/3/80 3/12/80 650,000 63,000 25,000 2,659 25,352 1,854 221,552 33,914 7,843 650,000 63,000 25,000 0 3/81 6/81 Construction in progress. 0 3/81 6/81 Construction in progress. 0 8/81 4/81 Reactor vendor on strike. 0 6/81 9/81 Construction in progress. 0 2/81 5/81 Construction in progress. 0 9/81 12/81 Foundation work in progress. 0 12/80 3/81 Fifty-one projects approved. 0 6/81 9/81 Engineering in progress CEO. 0 2/81 5/81 Unloading line complete. 0 3/81 6/81 Smoke detection portion complete. 9570 Replace T-100 P.A. Tank 3/27/80 119,000 9530 Boiler Economizers 3/26/80 140,000 9590 Critifcal Spare Equipment 3/26/80 59,000 9600 Calcium Stearate Addition System 4/2/80 84,000 9610 API Clean Water Bypass 4/15/80 23,000 9630 Water Stripping 4/30/80 810,000 9650 Miscellaneous Projects Under $10,000 5/3G/80 150,000 9660 Hot Water Charge Tank Replacement 6/4/30 160,000 9670 Laboratory Equipment 7/9/80 32,000 9680 Fixed Point Monitor Data Computer and Warning Lights 9/4/80 113,000 9690 Breathing Air Modifications 9/9/30 21,000 9700 Compound Fines & Streamers Removal 10/1/80 95,000 9710 Fire Protection - Phase III 10/14/30 385,000 9720 Reactor Agitator Replacement 10/14/30 420,000 9730 Compound Line III Debottlenecking 10/16/80 1 ,350,000 9740 Modifications to Make Profile Ory blend 10/27/80 200,000 57,877 62,311 44 0 4,665 15,671 68,216 62,366 119,000 138,767 140,000 11,486 59,000 420 84,000 16,682 23,000 220,244 810,000 127,838 150,000 1,606 1,063 0 115,364 30,533 9,683 160,000 32,000 113,000 0 0 21,000 0 0 95,000 0 0 335,000 0 190,890 420,000 0 0 1 ,350,000 0 o' 200,000 0 12/80 3/81 Project on hold. 0 12/80 3/81 Project operational. 0 12/80 3/81 Condenser quotes requested. 0 5/81 8/81 Engineering scheduled. 0 12/80 3/81 Sewer construction in progress 0 4/81 7/81 Sewer construction in progress 0 12/80 3/81 Forty-one projects approved. 0 2/81 5/81 Construction in progress. 0 12/80 3/81 Analyzer purchased. 0 9/81 12/81 Engineering in progress. 0 3/81 6/81 Engineering in progress. 0 10/81 1/82 Engineering scheduled. 0 10/81 1/82 Engineering sched.lcd CED. 0 10/81 1/82 Agitators on order. 0 10/81 1/82 Engineering scheduled. 0 10/31 1/82 Eng i neor i ng sc hod., 1 ed. 9750 Rotary Dryer Insulation (Energy) 11/10/80 22,000 0 27,391 27,391 ( 5,301) 2/81 3/HI Contract let. -13- DTH 000021445 Ainu. Capital NO. description ARHUDi-nN authorizations report 1DATE Airni. iapproved AM: amt. U) expended to date C) committed to n,\ it: FINAL TOTAL EST. COST COMP. UNDER (OVER) AUIH, AMT. EST. 1ST. COMP. CI.OS. DATE DATE 1REMARKS 9760 Emergency AMS Kill System 11/15/80 335,000 0 0 335,000 0 8/81 11/81 Engineering Scheduled. 9770 Reactor Pressure Relief Modifications 11/25/30 560,000 0 0 560,000 0 12/81 3/32 Engineering in progress. 8395 Interplant Communications - Phase II 1/22/S0 55,000 0 20,183 55,000 0 6/81 9/81 Construction in progress Expense 9010 Centrifuge Rotor Repair 9/19/80 20,000 0 0 20,000 0 2/81 5/81 Repairs in progress. 9020 Repairs to Line I Compounder 11/24/80 38,000 0 0 38,000 0 11/81 2/82 Parts to be ordered. -14- DTH 000021446 PERSONNEL - J. L. Carter EMPLOYMENT Charles A. Clark, Senior Drafter TO/FROM LEAVE OF ABSENCE None. TRANSFER/PROMPTION Darnell Perry, Compound Utility, transferred to Vinyl Utility. RETIREMENT None. TERMINATION Clarence Johnson, Compound Utility OTHER During November there were 13 casual labor employee on payroll. Total hours worked were 2150.50. -15- DTH 000021447 CONOCO CHEMICALS Aberdeen, Mississippi November 1980 MONTHLY PERSONNEL REPORT Salaried Employees 79* Minority Employees # Hourly Employees Total Employees Employees (Hourly) New Employees Terminations 155 234* 0 1 Salaried Hourly Total Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 Q 1 100% 6 58 64 DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound Vinvl PAR # EMPLOYEES MIN. EHP. . % MIN. 99 2 22% 10 11 4 36% 46 46 7 15% 22 20 3 15% 37 33 26 79% 32 32 13 40% NEW HIRES YTD 00 0 !4: 00 00 00 00 TERM. YTD TURNOVER YTD Q0 0 0 0 2 0 16.6% 0 0 __J2 D___ 0 0 ___ Q _ _Q___ 1 4** 3% Q* 0 1 ___0_____ 31-- Plasticizer 5 4 3 75% 0 0 0 0 0 0 Number of Applicants: Month 4 Year to Date 212 APPLICANT BREAKDOWN: # Minority 0 % Minority 0 # Female 2 % Female 50% *Includes three (3) temporary employees. **Includes one (1) retirement and is not counted in turnover rates. Hires (Hourly) : Month Q Year to Date 4 Terminations (Hourly) : Month 1_______ Year to Date 7** Overall Turnover .6% Projected Annual Turnover 4.5% -16- 000021448 dth CfDT> O o o -s -c* Q7T --I (DCL 3 "5 03> o o CO --* -- 3 cr z 00 o CO -5 4*CO 4* CO o o5-S -L i- OVERTIME AND ABSENTEEISM DTH 000021449 PROCESS ENGINEERING - R. A. Frohreich A. Expansion Project The concrete package for the Fluid Bed Dryer Area was awarded during November. Field work is continuing in the V-ll and CRD reactor areas, slurry blend tank areasand silo area. A trip was made to Bird Machine Company to discuss operation of the centrifuges. Major pieces of the dryer package were received. Assistance was given to Litwin personnel who were in the plant for field work. B. Resin Reclaim A revised process design incorporating comments from CED and PED was issued. An AFE request was submitted in November. C. Reactor Area Drum Storage The process design to provide a curbed drum storage for each reactor area was issued. D. Fuel Storage Tank Curbing The design to curb the plant's fuel storage tanks was issued. E. Line III Mill Temperature Control A process design to install a new mill heating system is underway. F. Emergency AMS Kill System The AFE request for this project was submitted and approved. G. Reactor Emergency Cooling System The AFE request for the project was approved in November. H. Reactor Agitator Replacement The Class "A" design to replace the D-300 and D-400 reactors' agitators is being prepared. I. Heat Recovery System The AFE request for recovering heat from the V-ll centrate water and the batch water strippers (Part I) was submitted. The conomics were calculated for recovering heat from the V-10 centrate water (Part II). -18- DTH 000021450 PROCESS ENGINEERING - (continued) J. Process Water Filter Replacement Economics for replacing the process water filters with a different type filter to reduce filter replacement costs were calculated. Process Engineering is working with the Mechanical Group to reduce the capital costs of the project by installing vertical filters rather than horizontal ones. K. VCM Tank Farm Revisions The revised Class "A" design to add liquid detectors, a VCM knockout pot, and make other revisions to the VCM unloading area was issued. L. Hot Water Charge Pump Problem A report was issued on the hot water charge pump problem. The main problem appears to be improper suction piping. M. High Level Alarms for Recovered VCM Receivers The Class "A" design for this project has been completed. N. Improved Rupture Disc Holders The Class "A" design for this project is being prepared. O. Cooling Tower Blowdown Bypass The Class "A" design for this project is being prepared. This project will collect blowdown from all plant cooling towers (including the compound cooling tower) and send the water directly to No. 6 pond. P. Sifter Overflow Reclaim The Class "A" design for this project is being prepared. Q. Normal Kill Addition System The Class "A" design for this project is being prepared. R. Dry Blend Production Process Engineering is assisting Operations in increasing dry blend production rates. Observations to date indicate that problems with the weigh-up and transfer systems have been a significant cause of lower rates. -19- DTH 000021451 PROCESS ENGINEERING - (continued) S. Rag Layer Reduction Process Engineering is examining the possibility of eliminating carbon black from plasticizer production to reduce the rag layer and reduce disposal costs of the filter cake material. T. Schenk Filter Start-Up Process Engineering assisted Operations in starting up the Schenk filter and retraining the operators. U. Irritant Reduction The AFE request to reduce irritant by installation of submerged aerators in No. 4 pond and making modifications in the plasticizer waste water treatment system was submitted. V. Line V Color Test Run Process Engineering assisted operations in the test run to reduce color problems on Line V. Favorable results were obtained by adding filler later in the Wei ex cycle. W. Reactor Slurry Residual VCM Testing A slurry sampler has been fabricated and tested to sample slurry during reactor steam stripping. The slurry will be sampled and analyzed for residual VCM when the reactor is cooled to 180 F during the cooldown period of the steam stripping cycle. -20- DTH 000021452 ENVIRONMENTAL - V. E. Messick Particulates Two dryers were sampled for particulates in November and were within allowable 1imits. Water All effluent permaters were within NPDES limitations in November. A sample for pesticides and PCB's which is required for the NPDES renewal permit was collected and sent for analysis. The permit application will be submitted upon receipt of the analysis. Process Engineering assisted the waste water trailer in obtaining T-460 material for shock testing. The tests with the waste water trailer are nearing completion. The trailer is scheduled to leave the week of December 15. VCM The comprehensive survey of all VCM piping and equipment is nearing completion. Points with high VCM concentration have been reported to operations via the plant's Leak Detection and Elimination Plan for corrective action. Hazardous Waste Management The RCRA permit application for treatment, storage, and disposal of hazardous wastes was submitted. A report on the plant's compliance with RCRA was issued. Other Preparations are being made for the incompany environmental audit to be conducted in December. Another vendor has been located to purchase the waste oil. The oil will be sold in December. -21- DTH 000021453 Flow GPM Jan. - Ave. Max. 810 941 Feb. - Ave. Max. 645 802 Mar. - Ave. Max. 595 743 Apr. - Ave. 628 Max. 877 May - Ave.' 304 Max. 480 June - Ave. 670 Max. 804 July - Ave. 696 Max. 813 Aug. - Ave. 698 Max. 753 Sept. - Ave. 679 Max. 767 Oct. - Ave. 956 Max. 1066 Nov. - Ave. 1032 Max. 1076 Dec. - Ave. Max. TABLE I -WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB./DY. COD PPM LB./DY. Sus. Solids PPM LB./DY. 43 131 436 1342 86 851 216 2214 11 103 13 143 6 42 8 56 29 220 36 314 21 147 30 232 15 116 24 171 66 502 95 828 54 378 67 519 10 79 13 125 11 74 14 94 12 86 13 129 16 69 32 184 6 49 11 84 53 197 74 426 40 316 51 367 10 40 14 81 12 98 15 145 14 112 19 145 7 56 9 70 5 42 7 64 9 110 17 217 16 196 33 390 39 322 78 597 32 270 42 380 22 168 27 248 27 316 45 576 28 347 45 531 11 88 14 no 15 126 24 187 7 44 14 89 7 78 11 119 11 131 23 272 Diss. O2 6.8-8.5 6.7-7.9 6.6-8.3 6.4-8.3 6.7-7.3 6.7-7.3 6.6-7.3 6.5-6.9 6.2-6.7 6.1-7.3 7.2-7.5 NPDES - Ave. Max. 32 387 43 520 1390 - 1940 _ 605 - 909 >6.0 ph 7.7-8.0 7.1-7.8 7.1-7.8 7.5-8.4 7.2-7.9 7.5-7.9 7.3-8.0 7.6-7.9 6.5-7.9 7.6-8.0 7.4-7.8 6.0-8.5 -22- DTH 000021454 ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for November was 113.4 MMM BTUs. The energy consumption per pound of product increased from 3066 BTU/lb. to 3193 BTU/lb. II. Plant Energy Conservation Program Steam Leaks Nine (9) steam leaks were repaired in November. Boiler Economizers Installation of the third and final economizer was completed. Initial results indicate a total average heat recovery of 1.3 MM BTU per hour from the three units. Energy Reporting The third quarter energy performance report was issued in November. The plant showed an unadjusted energy savings of 23.6% compared to the 1972 base year. -23- DTH 000021455 ITEM 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 ENERGY CONSERVATION DATA 1979 NOVEMBER 1980 NOVEMBER 26.7 4.9 2.7 1 .1 35.5 28.0 2.9 3.6 1.0 35.5 55314 1020 56.420 59512 1020 60.702 4.9824 10000 49.824 5.2063 10000 52.065 3.5 92000 0.322 6.475 92000 0.596 106.566 3010 113.363 3193 Avg. Stack Temp. 1979 1980 395 285 417 290 421 269 Avg. % Excess Air 1979 1980 30 33 28 38 52 32 -24- DTH 000021456 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Report By Kaiser Aluminum 34641 Blk. Undispersed Material RDJ WAIVERS RECEIVED Date Identification 11/5 11/7 11/14 11/17 11/21 11/24 11/25 11/26 11/26 CPU CONX 45309 T-2220 CPU PLCX 43229 PLCX 43872 CPU PLCX 42672 PLCX 43220 Product VRP 5385-3 5385-3 80273G 5385-3 5385-3 80172B 5385-3 5385-3 Customer Heritage Charlotte Pipe Certain-Teed Air Products Carl on Charlotte Pipe Columbia Plastics Charlotte Pipe Can--Tex Reason Waived Jl___ Color CJM Particle Size ELK Particle Size RDJ Eq. Torque JRW Particle Size ELK Particle Size ELK Long Stability JRW Particle Size ' CJM Particle Size CJM PRODUCT DEVELOPMENT & SERVICE Sample Shipments Ship Date Product 11/5 5385-1 5425 5465 Amount (Lbs.) 5 5 5 Customer General Tire & Rubber Co. Requested _i1 PCM 11/7 17461 Blk 50 Gama International MFM 11/7 5385-1 50 Hal stab Company MR 11/11 5385-1 5425 50 Uni royal Chemical 50 JLI 11/12 5385-3 5 Eslon Thermoplastics, Inc. PCM 11/12 5305 50 Gossen Inc. MR 11/17 NPD-1 Resin 10 Carlon CJM 11/17 5385-1 2 P.C.I. Industries PCM 11/17 5305 100 Conoco Inc. TAT 11/17 5425 50 Fritz Air Freight (Export) JPM -25- DTH 000021457 LABORATORY - (continued) PRODUCT DEVELOPMENT & SERVICE (continued) Amount Ship Date Product (Lbs.) 11/17 38963 Wat. Cl. 200 38551 Nat. 200 Customer Grayline., Inc. Requested By MM 11/17 5305 5385-1 50 Crown Wire 50 NTH 11/17 38611 Nat. 50 Trio Products JTW 11/18 5385-3 50 General Binding Corp. MFM 11/18 5385-1 5X5 Crane Plastics JTW 11/19 18031 Cl. Bl. 14331 Cl. Bl. 15041 Cl. Bl. 16851 Cl. Bl. 50 50 50 50 PMS MED COMPOUND DEVELOPMENT AND SERVICE Special Compound Testing Complete Western Electric specification tests were run on one lot of 34861 Gray 546 and on two lots of W.E. 536-C1 Gray 546. A limited number of tests were run on two more samples of 34861 Gray 546 and on one sample of 36861 Natural. Oven aging tests were run on two shipments of 35851 Natural compound to PhelpsDodge. New Compounds Quality control specifications and standards were prepared for a new compound (35341) which was received under the experimental designation ADK 4184-99A. Color Matching A color match was prepared for 38551 Brown 5. The Quality Control Laboratory was supplied with the formula and a color standard. Melt Flow Tests Melt flow tests were run on production samples of 18031 Cl. B1. 50 for Tenex. -26- DTH 000021458 LABORATORY - (continued) QUALITY CONTROL TESTING Resin Regular Samples = 344 Bag Samples = 141 Other In-Process Samples = 3,666 Bulk Shipments = 201 (Railcars = 82; Trucks = 119) Dry Blend (Rigid) Blenders Produced = 309 Blenders Tested = 298 Blenders Adjusted = 8.4% Other In-Process Samples = 425 Bulk Shipments = 40 (Railcars = 4; Trucks = 36) Compound (Flexible) Blenders Produced = 462 Blenders Adjusted =4.5% Line V Production = 371 Skids; 32 Boxes Other In-Process Samples = 619 Bulk Shipments = 21 (Railcars = 4; Trucks = 17) Resin Heat Stability Thirty-seven (37) lots of resin were tested for oven heat stability. 5385 5425 5305 5465 16 lots 12 lots 6 lots 3 lots All the samples were within specifications for heat stability. RVCM of Shipments A total of 124 shipment samples were tested for residual VCM in November. None of the samples exceeded 10 ppm. A summary of this data is below. Product 5305 5385 5425 5465 Dry Blend Number of Samples Avg. RVCM, ppm 48 48 16 4 1.3 1.2 0.1 0.1 8 0.4 -27- DTH 000021459 LABORATORY - (continued) QUALITY CONTROL TESTING (continued) Inherent Viscosity A total of 599 samples were analyzed in November. All railcar shipments and 5305 truck shipments were tested for inherent viscosity. Raw Material Testing Seventy-two (72) lots of plant raw materials were tested and approved for use. Several lots of SP-33 clay were rejected for giving low values for volume re sistivity. Apparently, Freeport Kaolin is encountering problems with starting up new calciners. Shipments of Hydrol 710 (hydrated alumina) continue to be spotty in dispersibility. Samples of Alcoa paper grade and Alu Chem AC-714 hydrated alumina were tested and found to disperse well; however, comments from Western Electric personnel indicate that they will not be approved in their compounds. MISCELLANEOUS PROJECTS Resin Volume Resistivity Samples of 5425 and 5465 resin tested for volume resistivity gave values equivalent to the control resin. Residual VCM in Slurry A total of 667 slurry samples were tested for RVCM. The overall average was 163 ppm. There were no cases of the daily average exceeded 400 ppm. RVCM of Blowdown Tanks A total of 150 samples of blowdown tank water were tested for RVCM. The overall average was 1.7 ppm. RVCM of 5305 Regular Samples A total of 31 samples of 5305 taken from the regular Q.C. sample were tested for RVCM. The monthly average was 3.0 ppm. Personnel Dosimetry There were 146 analysis of VCM dosimeters reported to the Safety Department in November. -28- DTH 000021460 LABORATORY - (continued) MISCELLANEOUS PROJECTS (continued) L & N Particle Size Tester A precision study was done on the L & N Microtrac Particle Size Tester in November. The short term precision was good at + 1% relative (for average particle size value) but the long term test results were unsatisfactory. In the long term (2 week) test samples run by 12 Q.C. Technicians showed relative variation to + 20%. A check by one operator using best known technique shows the long term reproducibility to be +3.5% relative. The factory representative reported that their long term study showed 3% relative error. Retraining and retesting of technicians precision is the next step toward optimum utilization of the L & N Microtrac. -29- DTH 000021461 TRANSPORTATION ---J. E. Stark Shipment by Product - M/lbs. November Year-to-Date Resin Plasticizer Dry Blend Compound Total 21420 80 2751 4705 . 28956 184884 809 24874 42363 252930 Number of Shipment by Mode R/C O.T Bulk O.T Van Resin - Bulk : Package Export Platicizer Dry Blend - Bulk - Package - Export Compound - Bulk - Package Export Other Antifreeze A1umina 75 51 ,, . 3 2 11 14 ' 87 Back Hauls for November__ _ i 67 Number of Shipment by Month--Year-to--Date 4 73 .3 11 19 7 .. 11731 January February March April May June July August SeDtember October November *. R/C 104 111 130 69 42 55 57 79 102 128 87 Bulk 53 83 95 43 41 36 41 51 53 76 67 Van 72 66 64 84 75 136 52 65 62 107 117 C.O.T. 4 4 1 C.O.T. 0 0 1 0 0 0 0 0 0 1 4 C.C. TOFC 39 1. 2 2 2 '13 - ' , 59 0 2 C.C TOFC 42 21 4 37 0 50 30 70 20 12 0 72 43 0 59 0 CPU TOTAL 16 179 13 18 75 22 30 37 14 11 27 22 58 7 84 418 34 CPU TOTAL 36 273 35 320 48 375 29 230 30 191 74 308 64 222 89 296 53 279 116 471 84 418 -30- . DTH 000021462 TRANSPORTATION - (continued) Material Handling Report M/Lbs. T/L Packaged Resin from Production Packaged Compound, Dry Blend from Prod. 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 TOTAL 5670 3483 4090 0 162 0 6764 3767 1417 25353 140 86 101 0 4 0 167 93 35 262 Off-Grade in Storage Material Sifter Overflow Resin "BC" Resin "H" Mills Scraps Compound "B" Compound "H" Dry Blend "O.G." TOTAL D. F. Operation M/Lbs. 1073 2286 703 52 1077 137 271 5599 T/L 27 56 17 1 27 3 7 138 This month's inventory showed a gain of 2.3 MM lbs. of finished product. Export orders for the month were higher due to a 1000 MT order for Hooker. There were several compound and dry blend orders for export also. -31- DTH 000021463 LOCATION MAIN-East TOTAL M SQ. FT. 48 Prairie 12-1 12-2 12-3 12 22 21 12-4 12-5 22 21 12-6 ... 21 12-7 12-8 12-9 12-12 21 21 . 21 21 ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco Resin HDPE Dry Blend Res i n Export Resin Conoco Export Resin . . 3-5 3 1-0 6 - -3 .2 4 -3 .4 3-4 Conoco Resin Resin O.G. Mill Scraps Cmpd 0. G. Dry Blend 0. G. Sifter Overflow Resin 0. G. Compound Resin Raw Material Resin 0. G. Conoco Resin Conoco Resin Conoco Resin 4.4 1 1-4 _ -1 - .8 9 1 2-8 2 3-4 .4-5 3.6 ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL .5-4 . -5 4-6 10.0 1-0 1.5 * 4.3 3.5 * 3-8 * 4.4 3.5 3.5 * 3.3 2.5 3.1 3.4 * 4.5 * 3.6 .4 3.5 1 3.5 3.5 3.5 3 3.5 Total 230 Sub-Total (Plug-Aisles) Total Conoco -32- 42.0 3.9 36 3 9 6 45 9 DTH 000021464 ABERDEEN FIRST-AID CASES 12 MONTHS MOVING AVERAGE 50 45 40 35 30 25 20 15 10 5 0 DTH 000021465 ABERDEEN OSHA RECORDABLE INJURIES 12 MONTH MOVING AVERAGE 20 15 10 5 0 DTH 000021466 MONTHLY HOURLY TURNOVER DTH 000021467 ENERGY USAGE B TU /LB . DTH 000021468 Monthly 12 Month Moving Average ABERDEEN PLANT PRODUCTION 1980 MM POUNDS CUMULATIVE 35 30 25 20 15 6 5 4 3 2 1 6 5 4 3 2 1, 2 i: 0 ----------- actual ----------- CUMULATIVE DTH 000021469 ABERDEEN PLANT EFFICIENCY 1980 POUNDS OF RAW MATERIAL/POUND OF PRODUCT DTH 000021470 ABERDEEN PLANT INVENTORIES DTH 000021471 OFF GRADE ABERDEEN PLANT QUALITY PERFORMANCE 1980 STANDARD 0.41 STANDARD 1.02 ' STANDARD 1.35 DTH 000021472