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ABD00311839 SAFETY - C. H. Markerson/J. V. Uptain First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Nov. 0 0 0 0 0 Fiscal Y.T.D. 1995 6 1 7 0 0 Y.T.D. 1994 6 3 9 1 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 01 02 03 00 00 () X 01 0 4 2 1 2 0_ 9 Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 04 00 02 00 00 01 .0 J) 07 5 0 1 2 1 0 0 9 Non-Occuoational Injuries Lost Workday Cases Days Lost 00 00 3 78 Contractor Injuries First Aid Cases Medical Treatment Cases Lost Workday Cases 00 00 00 1 0 0 Safety Record Last lost time injury Days since Employee hours since 01/22/94 312 391,841 On November 30, 1994, the employees of the Aberdeen Plant completed 312 days with no lost time injury. The topic for plant safety training during the month was Personal Protective Equipment. ABD00311840 SAFETY - Continued Routine dosimetry results for the month were: Chemical < PEL Number Percent VCM Lead Total Particulates 57 100.0 * * Monthly Injury Summary There were no injuries reported. > PEL Number Percent 00 ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) TOTAL INJURIES -+- OSHA RECORDABLE ABD00311841 COST VARIANCES - S. C. Hillman Variable Costs Product _______Nov.. 94 Variance, SM Efficiency Price Total PVC Flexible Compound Plasticizer Total PVC Resin <36.6> 95.8 34.4 93.6 <2650.0> < 490.2> < 94.4> <3234.6> <2686.6> < 394.4> < 60.0> <3141.0> The unfavorable efficiency variance for PVC was due to VCM <$217.1M> which was due primarily due to high off-grade pro duction. The high off-grade production resulted in a favorable efficiency variance of $103.9M. The efficiency variance for catalyst was also favorable at $70.5M. High off-grade production resulted primarily from an unfavor able product mix. Flexible Compound and Plasticizer The Compound favorable efficiency variance was due to use of a less costly alternative supply of antimony oxide. Major Price Variances Variance - $M VCM Resin to Compound DIDP/TOTM Plasticizers Antimony Oxide Aluminum Trihydrate Filler Phthalic Anhydride Alcohol <2633.9> < 193.3> < 187.8> < 114.2> 98.7 < 43.0> < 61.9> VINYL - J. D. Olson, W. S. Carroll Safety The Vinyl Department had no injuries in November. The monthly safety meetings were held on shift. General November production was 47.0MM pounds of which 45.4MM pounds was prime grade resin. Percent asset utilization was 92.3%. ABD00311842 VINYIj - Continued Nov. - Production, MM Lbs. - Reactor Stream Factor, % - Resin Quality, % Prime - VCM Efficiency, Lbs./Lb. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % % 47.0 95.3 96.6 1.0554 1567 109.0 1063.0 35.4 97.4 98.2 Reactor Downtime Operational downtime (recovery scheduling conflicts - 222 hours, hydroblast and inspect D-500 reactor - 33 hours). Mechanical downtime YTD 239.7 95.3 97.5 1.0367 1567 109.0 5384.0 35.2 96.4 97.8 Hours 336.0 25.0 Drver Downtime - Operational downtime (cleaning, product changes, and centrifuge plugs). _ Mechanical downtime _ Reactor limited production Hours 89 16 0 COMPOUND - E. T. Stouder Safety The Compound Department had no OSHA recordable injury during the month. General Compound production in November totaled 7.OMM pounds. Compound off-grade production totaled less than 40M pounds. The off-grade production rate for the past two months has averaged 0.7% (versus the FY94 rate of 1.8%). Plasticizer production totaled 1.9MM pounds in November. For fiscal year 1995, the Plasticizer Unit is operating at a 22M pound per year rate. ABD00311843 COMPOUND - Continued Compound Production Operating Days _______Production M (Lbs) . Month Ava./Dav Fiscal Y.T.D. Line I 30 Line III 30 Line V 30 Total % Prime Capacity Utilization Factor 1836 3924 1233 6993 96.8 94.5 61 131 41 234 9711 20019 5859 35589 96.8 94.8 Downtime Hours Line I - Product Changes - Miscellaneous Maintenance - Quality 124 13 11 Line III - Product Changes - Miscellaneous Maintenance - Quality 75 22 6 Line V - Product Changes - Miscellaneous Maintenance - Quality 29 14 42 Operating Davs __________Production (M t Month Ava./Day Fiscal Y.T.D. Plasticizer 30 % Prime Capacity Utilization Factor 1897 82.8 83.3 63 9207 85.6 83.7 ENGINEERING - J. E. Nickerson, T. R. Mackay, R. H. Sneed PROJECTS IN DEVELOPMENT - GENERAL EXPRESS We participated with GED in evaluating outside engineering companies for engineering procurement and construction of EXPRESS. Work has progressed in putting together a scope package that can be taken to a contractors office for work to begin. Prepared and reviewed bid packages for major equip ment. Reviewed estimate for Phase I. ABD00311844 ENGINEERING - Continued Boiler Feedwater Deaerator Addition This design is part of Phase II EXPRESS. This design upgrades deaerator equipment feeding the boilers. Upgrading this equipment will improve its stream factor. This design in stalls an additional deaerator and deaerator feed pump to help meet post EXPRESS steam requirements. Class "A" design is currently being reviewed. OSHA Process Safety Process Safety Information Work is finished on locating and developing equipment specifications and documentation for the New Module. Procedures Approximately 20% of the New Module Procedures have been approved. HAZOPS The New Module HAZOP Team completed the line-by-line analysis. Completion for the New Module and the SA Module is scheduled for March, 1995. Reactor Sight Glass Installation The design for the reactor sight glass is complete. Purchase orders have been placed for the fabrication of the sight glass and all other components. This sight glass will be used to detect foaming during the upcoming larger batch test runs. RX-600 Larger Batch Trial An application for a Radioactive Materials License was submitted to the Mississippi State Department . of Health, Division of Radiological Health. This license is necessary prior to install ation of a nuclear source on the reactor. The project was estimated and an AFE was submitted for approval. New Module Recovery Observation An AFE has been issued for the installation of a sight glass and camera in the New Module Recovery building. Control room operators will be able to observe the VCM recovery header for foaming during recovery. This will help prevent quality problems and equipment problems as work continues to speed up recovery times. Equipment, which includes the flow indicator and the camera, has been ordered. ABD00311845 ENGINEERING - Continued P-1 Reactor Header Modifications The vacuum breaker was permanently installed on R-l. Modifications to the first reactor should be complete for a start up sometime in January. This project will reduce batch cycle times by as much as three hours by improving the heat up and cool down times. Calcium Stearate Addition Upgrade Replacing wet calcium stearate in 5385 with dry calcium stearate addition has the potential of saving $160M a year in raw material costs. It will also require less operator manpower. A test run on the fluid bed dryer demonstrated that dry CaSt can successfully be used. However, the rotary dryers still require wet CaSt due to addition limitations. VCM Vapor Lines Winterization This project will reduce fugitive VCM emissions in the VCM tank farm area. VCM condensation in the lines leading to the railcar unloading compressors is suspected of causing fugitive VCM emissions at the compressors. Heat tracing these lines will prevent this from occurring. Installation began in early December and should be completed by the end of the month. RVCM Subcooler Addition This project will help further reduce reactor recovery times during the summer months. The subcooler will reduce the temperature of the recovered VCM as it enters the receiver, which will subse quently lower the back pressure in the receivers. Reduced back pressure in the receivers will significantly improve reactor recovery rates. The Class "A" design has been reviewed and the AFE submitted for approval. Boiler Feed Water Softener Replacement The Class "A" Design to replace existing water softeners is com plete. This project will save an estimated $42M annually in regenerative salt costs. The softener's capacity will also be increased to meet expected post Pony EXPRESS steam requirements. V-10 Slurry Transfer System Upgrade This project will replace the slurry transfer pumps currently being used in the Pond 2 resin drying system. Other piping modifications will be completed to reduce downtime associated with plugged pipes and pump maintenance. The design and estimate were presented to Conoco and approval for the project has been obtained. ABD00311846 ENGINEERING - Continued New Module Charge Water System Upgrade This project will install a new hot water charge pump and associated piping in the New Module. This will provide faster charges and allow simultaneous charge and rinse. Construction and programming are nearly complete. Some downtime will be required for start up. Economy Surplus Power Conversion The plant is currently pursuing conversion of its electrical supply to TVA's Economy Surplus Power rate structure. Estimates of various plant electrical loads is in progress. A plant curtailment plan is being drafted for potential temporary reductions in power under the new contract. Contract negotiations with TVA and Aberdeen Water and Light should begin in December. Conversion to ESP should occur in January or February. Selection of a power monitoring system, which is required with ESP, is complete and design work is in progress. Suspending Agent Charge Modifications A test run proposal to charge suspending agent into the water charge header has been completed. This test run will determine if SA charge amounts can be reduced and if particle size variability can be improved by charging SA into the charge water header. The test run will also be used to determine if higher on-charge temper atures can be achieved without sacrificing quality. Recovery Compressor Addition for Old Module This project adds another compressor to the Old Module to decrease recovery times. Calculations show a production increase of 2.3 MM lbs/year with the decreased recovery times. The design and esti mate are complete with a review meeting scheduled for mid-December. Activator Replacement and Resin Transfer Improvements This project replaces the activator on Dryer #8 with a new dense phase transfer system. This system will require less air and will be able to transfer up to 25,000 lbs/hr. A consignment feeder will be installed first. The consignment design has been reviewed and an AFE has been submitted. ENVIRONMENTAL - K. G. Akins Air Stack testing for particulates on dryers and silos was con ducted in November to assess the plant's status as a major or minor source. Final results will be available in mid- December . ABD00311847 ENVIRONMENTAL - Continued Wastes A bulk shipment of floor sweepings was shipped to Chemical Waste Management in Emelle, Alabama. A bulk shipment of empty lead/antimony bags was shipped to Chemical Waste Management in Sulphur, LA. KEY ENVIRONMENTAL COMPLIANCE DATA MONTH FYTD Stormwater Outfall Excursions Wastewater Outfall Excursions Reportable NESHAP Excursions Reportable non-NESHAP Air Excursions CERCLA/SARA Reportable Incidents Other Reportable Incidents Citations and NOV's Received 0 1 0 0 0 0 0 0 1 0 0 0 0 0