Document ykDbzX6wzxBNbEw9VXxV1jMR2

SAFETY - A. H. Sather Occupational Injuries First Aid Medical Case Restricted Workday Case Restricted Workdays Lost Time Injuries By Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office Injuries By Type September 2 0 0 0 0 1981 Year-to-Date 28* 3 0 0 0 1980 Year-to-Date 38 14 2 23 0 15 07 1 16 01 01 01 12 15 23 3 0 1 Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 1 14 02 1 12 02 02 02 27 4 6 11 4 4 * An incident which occurred during August was reclassified as a first aid injury. As of September 30, 1981, the plant operated a total of 818 days or 1,077,311 manhours without a disabling injury. Safety Meetings The topic for August Safety Meetings was Fire Safety. The "magic of fire" was shown and discussed. Also, special emphasis was placed on preparing winter home heating systems for use. This was done in preparation for Fire Prevention Week, October 4 - 10, 1981. Injury Investigation A. H. Sather acted as chair person for the investigation of the disabling injury which occurred on August 21, 1981 in the Lake Charles Chemical Plant. Back School Final preparations were made for Health Education Systems, San Francisco, CA to conduct a back injury prevention school in the Aberdeen Chemical Plant during October. DTH 000021512 SAFETY - (CONTINUED) Conferences A. H. Sather attended the Corporate Safety Meeting in Fort Lauderdale, Florida September 28 through October 1, 1981. J. V. Uptain attended a hearing conservation seminar in Jackson, MS on September 24, 1981. Health Activity for the reporting period was limited to routine dosimetry. The results and overexposure explainations are shown below. Chemical PEL Number Percent PEL Number Percent VCM Lead Antimony Total Particulates 86 92 5 100 4 100 4 100 78 00 00 00 Overexposures A total of seven (7) overexposures occurred, five of which occurred with benefit of respirators. The two (2) remaining overexposures occurred to a vinyl shift supervisor and an "A" reactor operator with no specific cause identified. One of the overexposures with benefit of respirator occurred to a mechanic who was cleaning VCM lines during a unit shutdown The remaining overexposures occurred to reactor "A" and chief operators who drained a knockout tank in the new unit, replacing a reactor lenape manhead "0" ring and checking a vacuum pump, and clearing a plug in the recovery system. DTH 000021513 VINYL - P. E. Markey 1. Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor, % 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor, % 8. Accounting Days September 21.2 706 520 17.3 76.6 5297 79.4 30 Y.T.D. 220.2 807 5453 20.0 85.6 5675 84.6 273 Vinyl production for September was 21.2 MM pounds or 89.5% of budget. The production volume was 118% of the Business Area designated target of 18.0 MM pounds. Reactor and dryer stream factors were 76.6 and 79.4, respectively. Planned unit shutdowns for inventory control purposes accounted for the vast majority of the downtime. Empty product hopper car availability became a critical factor early in the month. Adjusted unit stream factors removing the impact of planned outage were 92.5% and 97.0% for the reactors and dryers, respectively. Reactors 1. The major item affecting production in the reactor areas was a planned shutdown of the old reactor module 9/23 through the balance of the month for inventory control purposes. The reactor stream factor penalty associated with this outage was 13.5%. 2. Discretionary downtime was taken to install reactor relief valves on all the old module reactors. This completed the reactor relief valve installation program and now all of Aberdeen's reactors are equipped with reactor relief valves for improved EPA compliance. The resulting stream factor penalty was 2.4%. 3. A reactor agitator seal change on D-300 reactor resulted in a 1.7% reactor stream factor penalty. 4. Condenser cleanings on 743 and 744 reactors resulted in a 1.6% stream factor penalty. 5. VCM charge line pluggage in the old module resulted in a 0.8% reactor stream factor penalty. 6. Resin carry-over into the old module recovery system resulted in a 1.0% reactor stream factor penalty. 7. A number of smaller penalties comprised the balance of reactor downtime. DTH 000021514 VINYL - (CONTINUED) Dryers The vinyl unit was essentially reactor limited the entire month as described above. In order to maximize cost efficient operation some product lines were con verted to single initiator usage and initiator loadings were reduced as possible on other products. This resulted in extended polymerization times but saved over $21 M in initiator consumption. Maintenance costs were also reduced by discretionary reduction in overtime callouts on both reactor and dryer equipment when possible in light of reduced production requirements. Product Quality Summary Resin Type Prime Grade "BC" Grade "H" Grade % of Total Product i( 5265 5305 5385 5425 5465 Sifter Overflow 31,500 3,933,815 12,802,452 3,805,964 437,058 - -- ( 2,800) 40,500 30,000 - - -- 20,300 - 74,475 0.15 18.66 60.66 18.11 2.06 0.36 TOTAL 21,010,789 67,700 94,775 100.00 Quality performance for September was 99.2% customer grade with 0.3% "B" grade and 0.5% "H" grade. Variable Cost Performance Variable cost variances for September totalled $735 M favorable with $657 M due to price and $78 M due to efficient operation. The major price variance was $656 M due to below budget monomer pricing 20.584 d/lb. versus the budgeted 23.636 q/lb. Favorable efficiency variances of $78 M were comprised of $24.1 M for VCM, $34.2 for processing additives and $21.4 due to lower than budgeted offgrade production. An unfavorable variance of $2.1 M resulted from a product mix different than budget. VCM efficiency for September was 1.01458 lbs. VCM/lb. PVC versus the 1.01936 lb./lb. standard. Year to date VCM efficiency is 1.01973. Cummulative 1981 variable cost efficiency variances in the Vinyl Department total $492 M favorable. DTH 000021515 VINYL - (CONTINUED) General 1. Packaging activities for the month totalled 1.7 MM pounds. 2. Resifting activities for the month totalled 49 M pounds. 3. A total of 6 railcars of special 5385 with high calcium stearate levels were produced for siding customers. The higher calcium stearate levels are designed to minimize static formation and improve customer processing rates. 4. A single batch of the new 5265 resin was produced and packaged for customer samples. Samples were also forwarded to PAL for further testing. 5. A test batch of 5305 resin was produced using the new L-54 initiator, preliminary results show a desirable heat release curve. The blend was packaged and samples were forwarded to PAL and R&D for further tesing. R&D small reactor testing of L-54 has indicated good potential for polymerization time reduction over the currently used initiators. 6. A slurry blend tank aeration test run was conducted on 5305 resin to determine the optimum aeration time required to attain residual monomer content of 10 ppm or less in the dried resin. It was determined the minimum aeration times were in the 3 - 3.5 hour range in the small blend tanks equipped with ring spargers and specification residual content could not be attained in the large blend tanks without prior aeration in smaller blend tanks equipped with ring spargers. 7. On 9/16/81 the plant experienced a reportable VCM relief valve discharge estimated to be approximately 20 pounds. The release was a result of thermal expansion on a VCM filter in the old reactor module. This is the first such release since April, 1980. DTH 000021516 COMPOUND - J. R. McCrimon Compound Production Line I, M Pounds Line V, M Pounds Line III, M Pounds Total, M Pounds Accounting Days Month 825 289 2,365 3,479 30 Per Day 53 28 82 Y.T.D. 10,120 3,277 25,042 38,439 273 Line I operated 15.5 days during September at an average rate of 53 M pounds per day. Major items affecting production efficiency were: product changes (25.7 hours), pull roll (5.0 hours), No. 1 Blender (11.9 hours), scales (3.3 hours), dicers (2.9 hours), and Banbury thermocouple (2.5 hours). Line V operated 10.5 days during September at an average rate of 28 M pounds per day. Major items affecting production efficiency were: quality problems with hard particles/gels (24 hours), Werner-Pfleiderer instruments (6.6 hours), knife blade change/adjustments (5.5 hours) and Werner-Pfleiderer (4.0 hours). Line III operated 29 days during September at an average rate of 82 M pounds per day. Line III production was affected by: product changes (37.1 hours), mill (13.0 hours), quality control (7.0 hours), hydrotherm steam leak repair (8.0 hours), FCM (5.8 hours), and plugged transfer line (3.5 hours). Quality performance for flexible compounds was 3.4 % off-grade of which 85.5% was due to mill scrap. "BC" production was 2.9%. The raw material requirement for flexible compounds was 1.00290 pounds of raw material per pound of compound versus a 1.01297 standard. (Y.T.D. is 1.00810) The variable cost variance for compound was $31.4 M with $34.1 M due to price and ($2.7 M) due to efficiency. The variance due to product mix was ($5.1 M). The only major efficiency variance was $12.6 M for resin, and there were no major price variances for the month. Dry Blend Month Per Day Y.T.D. Production, M Pounds Accounting Days 5,150 184 38,079 30 273 Dry Blend operated 28 days during September at an average rate of 184 M pounds per day. Production included: 80273G, 80174, 90171, 80274, and RP-100 RW. Dry Blend production was affected by: quality control (15.6 hours), product changes (15.5 hours), out of resin (11.2 hours), RP-100 BW quality control (11.1 hours). No. 1 Welex shaft replacement (7.5 hours), Welex drive belt replacement (7.0 hours), and dust collector sock changes (7.2 hours). Quality performance for the month was 99.99% customer grade. DTH 000021517 COMPOUND - (CONTINUED) Dry Blend - (Continued) The raw material requirement for dry blend was 1.00892 pounds of raw material per pound of dry blend versus a standard of 1.00577. (Y.T.D. is 1.00952) The variable cost variance for dry blend was ($54.0 M) with $25.2 M due to price and ($79.3 M) due to efficiency. The variance due to mix was ($80.3 M). There were no major efficiency variances for September. There were two major price variances for the month: $24.5 M for Organo-tin stabilizer and $10.1 M for Methyl-tin stabilizers. Plasticizer Month Per Day Y.T.D. Production, M Pounds Accounting Days 663 44 9,088 30 273 Plasticizer operated 15 days during September at an average rate of 44 M pounds per day. Production included: D0P, DIDP, and 610P. VRP production totaled 29.7 M pounds (4.5%). Production was limited by: rupture disc replacement on R-l, R-3 and R-4, inert gas compressor failure and R-l condenser tube leak repairs. The raw material requirement for plasticizer was 1.01991 pounds of raw materials per pound of plasticizer versus a 1.10500 standard. (Y.T.D. is 1.10092) The variable cost for plasticizer was ($5.5 M) with ($7.7 M) due to price and $2.2 M due to efficiency. There were no major price variances or efficiency variances for the month. The variance due to product mix was $1.8 M. General Total customer grade compound inventory increased from 11.2 MM to 11.6 MM pounds during September. Line I started up September 10 after the seals were replaced on the Banbury, and a controlled test on mill scrap production from the seals resulted in a 64 pound per day rate. The total mill scrap for September was 102 M pounds which consists of the following makeup: Vacuum Dust Mill Scrap Mill Scrap Mill Scrap 21 M pounds 13 M pounds 56 M pounds 12 M pounds (Produced in August, but not counted until September inventory.) (Produced in September.) (Cleanout pellets downgraded in September.) DTH 000021518 COMPOUND - (CONTINUED) General - (Continued) Of the 56 M pounds produced in September it is estimated that 5 M pounds resulted from railcar heel cleanout prior to loading. A total of 20 railcars (both compound and dry blend) required heel cleanouts due to the low inventory of hopper cars and switching the products carried in the cars. DTH 000021519 MECHANICAL - S. J. Vincent Vinyl The old module was shut down in the latter part of this period for inventory control. A significant amount of the maintenance effort was devoted to repairs and cleaning in this module. There was one seal failure and one gearbox failure in this period. Both of the failures were in the old module. The seal failed on the D-300 reactor. The top bearing failed on the D-500 gearbox requiring a major overhaul of this gearbox. Two reactor condensors were cleaned in this period. They were on the 743 and 744 reactors in the new module. Major valves replaced in the vinyl area in this period were the chemical wash valves on 742 and 744 reactors, 741 charge water valve, 743 atmospheric vent valve, D-500 recovery valve and the chemical wash header valve in the new module. One of the turbine meters was replaced in the new module and the other one repaired. Several instrument transmitters were repaired. The counter weights were reset on the new module Sweco screener. Several control and area lighting repairs were completed. There were five seal failures to pumps in this period with seals being replaced on the condensate return pump, east recovered VCM return pump, east recovered VCM charge pump and the south knockout tank recirculating pump in the new module. The seal was also replaced on the south sphere transfer pump. In the old module the "A" vacuum pump was pulled and test material used to repair the case and then the unit was overhauled. In the new module the 902 vacuum pump and 904 recovery compressor were overhauled. Major projects worked on in the vinyl production areas included the final work on the reactor pressure relief modifications for the old module reactors . This included all of the old module reactor safety valve and safety disc being replaced. The downcomer and lower section was replaced on the plant incinerator. Nineteen new safety discs and holders were installed on various pieces of vinyl equipment. Some of the modicon relay wiring was revised for the expansion project. Several new "go" switches were installed. Instrumentation was installed in the control room for the spare incinerator. The dryer area work was primarily to PM and calibrate instrumentation. Compound-Dry Blend-Plasticizer and Resin Storage The major overhaul of the Line I Banbury was completed and the unit returned to operations. New blender valves were installed on Line I blenders. Major repairs to the compound Line III equipment were to replace the mill and FCM rotary joints, along with, repairs to steam and water leaks. DTH 000021520 MECHANICAL - (CONTINUED) The drive shaft bearings were replaced on the compound Line V Welex. In the dry blend area belts were replaced on number one and number two Welex units. Repairs in the Plasticizer Unit were to replace safety discs on the R-l and R-4 reactors. The Schenk filter was pulled and disassembled for cleaning. The bearing was replaced on the north nitrogen blower. A new compressor was installed on the inert gas unit. Utilities and Services Repairs to the plant air system in this period were to overhaul the top section of #3 compressor and to repair valves in the #6 and #7 compressors. The heater element was replaced in the #2 air dryer and the inlet and outlet valves were rebuilt. Two new boiler chemical feed pumps were installed at the boiler house. The compressor on the vinyl unit control room air conditioner was replaced. The //2 boiler was shut down for a tube failure. After the tube was plugged, several tube roll leaks were found on the mud drum. A total of eight tubes were plugged and the boiler was returned to service. The outlet piping on "A" water softener developed a leak and the softener was removed from service to perform repairs. Planner There were over 700 work orders processed in this period. Material was ordered for 13 work order projects and 96 work orders were planned. There were 23 invoice registers processed for payment and 21 new registers issued for equipment repair. DTH 000021521 MECHANICAL ENGINEERING - J. A. Dixon The following AFE was submitted and approved during September: AFE No. Title Authorized 9741 Plasticizer Catalyst Handling System $38,000 The following AFE was closed to field charges during September: AFE No. Title Authorized 9750 Rotary Dryer Insulation (Energy) $22,000 There were no completion reports issued in September. Design Design work is in progress on the following projects: Resin Reclaim System Compound Line III Debottlenecking Fire Protection Improvements - Phase III V-10 Centrate Heat Recovery Vinyl Initiator Charge Pots Reactor Seal Access Platform Centrate Heat Recovery Emergency AMS Kill System Slurry Delumper Calcium Stearate Addition System Reactor Agitator Replacement Emergency Cooling for Reactors Waste Water Treatment Revisions AFE Activity 1. AFE 9570 - Replace T-101 P. A. Tank J. P. Windham Pipe fabrication and installation is in progress. 2. AFE 9630 - Water Stripping M. Ingle & J. L. White Piping and instrumentation revisions are in progress. 3. AFE 9680 - Fixed Point Monitor Data Computer and Warning Lights R. B. Harned Contract work is essentially complete except for minor revisions. The computer was powered up and checked during the period. Final hookup and check out is scheduled for October. 000021522 dth MECHANICAL ENGINEERING - (CONTINUED) AFE Activity - (Continued) 4. AFE 9710 - Fire Protection Improvements - Phase III J. Elkins/W. Modica Engineering is approximately 95% complete. Drafting is approximately 97% complete. Design completion is scheduled for October. 5. AFE 9720 - Reactor Agitator Replacement M. S. Richards Mechanical design began this month. Drawings for the seal oil tank were sent out for bids. The gearboxes and mounting bases are slightly larger than the available area for installation. We have requested a design modification of the mounting base from Lightnin Inc. so that installation car. be made without requiring foundation modifications to the reactors. 6. AFE 9730 - Compound Line III Debottlenecking J. Tomek Structural design is on hold pending receipt of equipment outline drawings. A budget estimate is being prepared for an alternate silo location. 7. AFE 9760 - Emergency AMS Kill System J. L. White A design review was held on 9/10/81. Drafting changes are being incorporated. Quotes are being requested for bulk material items. 8. AFE 9770 - Reactor Pressure Relief Modifications J. L. White This project is operational and complete except for painting and modification of two spare 6x8 relief valves. 9. AFE 9790 - Resin Reclaim System P. Meiers & M. Richards The design is approximately 70% complete. Levingston Engineers made a field trip this month to determine final measurements necessary to complete the design. Equipment selection is in progress. 10. AFE 9800 - Plasticizer Irritant Control R. B. Harned The underground conduit and switchgear for the new aerators have been installed. Design of the wastewater stripping equipment is in progress. 11. AFE 9531 - Vinyl Initiator Charge Pots S. Jones Instrumentation engineering is 97% complete with 85% of the drafting finished. 12. AFE 9541 - VCM Tank Farm Modifications R. B. Harned Piping and structural steel installation is complete. Electrical installation is in progress. DTH 000021523 MECHANICAL ENGINEERING - (CONTINUED) AFE Activity - (Continued) 13. AFE 80-395 - Interplant Communications - Phase II R. B. Harned Seven additional stations were installed and are operational. 14. AFE 9551 - V-10 Centrate Heat Recovery S. Jones Engineering and drafting is complete. Basis of bids are being prepared. 15. AFE 9561 - Cooling Tower Fan Controls R. B. Harned The drawings and specifications are complete. The installation contract has been let. 16. AFE 9601 - Compliance With EPA VCM Standard R. B. Harned Installation of the improved safety heads is in progress. 17. AFE 9631 - Ground Water Monitoring V. E. Messick Drilling of the water wells is scheduled for October. 18. AFE 9641 - Slurry Delumper M. S. Richards The drawings are complete. Installation is scheduled for October. 19. AFE 9661 - Haste Water Treatment Revisions D. Pace & J. L. White Quotations for all mechanical equipment have been received and purchasing is proceeding. A plot plan was sent to the plant for approval. Under ground piping and concrete design is in progress. Engineering and drafting is approximately 35% complete. 20. AFE 9671 - Hew VCM Railspur G. A. Morgan Construction is proceeding and completion is scheduled.for October. 21. AFE 9691 - Reactor Agitator Two Speed Motors M. S. Richards The motors have been purchased with a delivery of 14 to 18 weeks. 22. AFE 9721 - Emergency Cooling for Reactors D. Pace A project kick-off meeting was held in August. Piping and mechanical drawings are complete and being checked by plant personnel. Bid packages are being prepared. Instrumentation and electrical sections are ready to start drafting. DTH 000021524 MECHANICAL ENGINEERING - (CONTINUED) Construction - G. A. Morgan The following projects were completed in September: 1. Reactor Pressure Relief Modifications 2. Interplant Communication - Phase II 3. Removal of resin from lagoons NPD-3 and NPD 1-B 4. Rotary Dryer Insulation 5. Replaced NPD-3 Lagoon Outlet Piping The following contracts were issued in September: 1. Construction of Shed Over Oil Drum Storage Area 2. Electrical Installation for Cooling Tower Fan Controls 3. Drilling of Ground Water Monitoring Wells Twenty-eight register tickets were issued during September. WH 0000215 (I) 'Ihru Auj-.ust, 1981 Actual Accounting CD Thru So pi ember, 1981 Aiu mu i n Airmoiuzvi ions ki.i'ijut Ainu. NU. 9609 9629 9639 9689 CAPITAL in:s(;i' i i'TioN DATE AUTH. AITUOVT.I) Al l. AMT. Reactor Inert Vent System Air Compressor Revisions to emission Recovery Sys. Diking of Sphere 6 Curbing of Drum Storage Area 6/28/79 7/9/79 7/12/79 9/15/79 90,000 340,000 100,000 170,000 ri) to da ii: f2) FINAL OJMMf i ll-D 10TAL LST. 'io n.'-Ti: COST COMP. U.NIM.U (UVHKJ AIII1I. AMT. HST, iiST, COMP. ci.os. DATI: UA'iii REMARKS 14,541 303,416 87,992 150,993 14,541 308,119 89,467 166,078 90,000 308,119 89,467 170,000 0 31,881 10.533 0 12/81 3/82 6/81 10/81 7/81 10/81 10/81 1/82 Project on hoLd. Closed to field charges. Closed to field charges. Revisions to field charges. 9699 9709 Plant Dryer Debottlenecking 9/15/79 Facilities for Multiple Grade Resin 9/20/79 80,000 870,000 55,340 541,825 75,105 683,410 80,000 738,000 9719 9729 9759 9530 9550 9570 9590 9600 9630 9680 Aberdeen PVC Resin Expansion Fire Protection Improv.-Phase II Aberdeen PVC Resin Expansion Spare Incinerator P. A. Handling Improvements Replace T-101 P. A. Tank Critical Spare Equipment Calcium Stearate Addition System Water Stripping Fixed Point Monitor Data Computer and Warning Lights 9/10/79 850,000 10/1/79 490,000 12/10/79 11,150,000 1/23/80 650,000 3/3/80 63,000 3/27/80 119,000 3/26/80 59,000 4/2/80 84,000 4/30/80 810,000 9/4/80 113,000 887,200 887,200 399,621 400,524 7,713,400 9,629,900 443,216 489,493 32,470 39,633 68,573 110,623 63,447 63,476 17,012 17,731 411,361 412,506 52,098 81,342 887,200 490,000 10,450,000 550,000 63,000 119,000 63,476 84,000 510,000 113,000 9690 Breathing Air Modification 9/9/80 21,000 14,540 15,543 21,000 9700 9710 9720 Compound Fines & Streamers Removal Fire Protection - Phase III Reactor Agitator Replacement 10/1/80 10/14/80 10/14/80 95,000 385,000 420,000 2,227 1,707 192,900 31,751 1,707 194,608 95,000 385,000 420,000 9730 Compound Line III Debottlenecking 10/16/80 1,350,000 135 173,745 1,350,000 9740 9750 Modifications to Make Profile D.B. Rotary Dryer Insulation (Energy) 10/27/80 11/10/80 200,000 22,000 27,027 20,000 55,719 27,391 200,000 27,391 9760 9770 9780 9790 9800 9810 9511 Emergency AMS Kill System 11/15/80 Reactor Pressure Relief Mod. 11/25/80 Centrate Heat Recovery 12/8/80 Resin Reclaim System 12/14/80 Plasticizer Irritant Control (Air) 12/15/80 Replacement Gearbox for Farrell Mix. 12/18/80 Miscellaneous Projects Under $10,000 1/9/81 335,000 560,000 300,000 727,000 80,000 73,000 170,000 96,335 348,838 61,538 187,013 28,932 0 160,820 111,159 396,902 83,568 285,242 46,285 69,400 194,894 355,000 460,000 300,000 727,000 80,000 73,000 170,000 9531 Vinyl Initiator Charge Pots 1/21/81 9541 VCM Tank Farm Modifications 1/21/81 80-395 Interplant Communication-Phase II 1/22/81 9551 V-10 Centrate Heat Recovery (Energy) 2/17/81 9561 Cooling Tower Fan Controls (Energy) 2/17/81 9581 Dryer Building Ventilation 3/20/81 9591 9601 Sifter Overflow Reclaim System Compliance with EPA VCM Std. (Air) 3/20/81 3/25/81 9611 Recovery System Revisions 3/25/81 9621 . Laboratory Equipment 3/25/81 9631 Cround Water Monitoring (Solid) 3/24/81 9641 Slurry Delumper 5/14/81 9651 Safety Equipment 6/8/81 9661 Waste Water Treatment Rev. (Water) 6/19/81 9671 New VCM Rail spur 6/30/81 9681 Miscellaneous Projects Under $10,000 7/31/81 9691 Reactor Agitator Two Speed Motors 7/2/81 9701 9711 Mlsc. F.ncrgv Savings Projects liuler 910,000 Plast ic i;'cr Spill Containment 7/13/81 7/27/81 9721 Emergen*v Cooling for Reactors 7/30/81 9731 Normal Kill Solution Addition Sys. 9/1/81 9 741 Plasticizer Catalyst Handling Sys. 9/21/81 165,000 90,000 55,000 125,000 40,000 23,000 200,000 72,000 30,000 42,000 30,000 35,000 106,000 560,000 194,000 145,000 40,000 25,000 42,000 190,000 93,000 33,000 7,962 40,666 28,235 18,755 78 3,567 15,569 12,179 17,236 37,974 501 21,537 01 1,060 3,737 2,646 0 0 75,971 58,297 31,755 41,449 29,104 17,137 16,123 18,700 19,054 38,866 28,550 23,019 0 145,097 189,512 38,190 4,568 0 0 1,139 0 0 0 4,782 0 0 165,000 90,000 55,000 125,000 40,000 23,000 200,000 72,000 30,000 42,000 30,000 35,000 106,000 560,000 194,000 145,000 40,000 25,000 42,000 190,000 93,000 38,000 0 132,000 (37,200) 0 700,000 100,000 0 0 ( 4,488) - 300,000 0 12/81 3/82 12/81 3/82 7/81 10/81 12/81 3/33 12/81 3/82 12/81 3/82 12/81 3/82 12/81 3/82 7/81 10/81 12/81 3/32 12/81 3/82 10/81 1/32 Construction in progress. Construction in progress. Closed to field charges. Construction in progress. Construction in progress. Construction in progress. Engineering in progress. Construction in progress. Closed to field charges. Engineering in progress. Revisions in progress. Construction in progress. 0 0 0 0 0 0 ( 5,391) 0 100,000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 8/81 11/81 Closed to field charges. 4/82 7/82 Engineering scheduled. 5/82 8/82 Engineering in progress CED. 12/81 3/82 Engineering in progress. 6/82 9/82 Engineering in progress. 4/82 7/82 Engineering scheduled. 9/81 12/81 Closed to field charges. 12/81 3/82 12/81 3/82 3/82 6/82 Engineering in progress. Construction in progress. Engineering in progress. 3/82 6/82 Engineering In progress CED. 11/81 2/82 Construction in progress. 10/81 12/81 Gearbox to ship 10/81. 12/31 2/82 11/81 2/82 Sixty-two projects approved. Engineering in progress CED. 1/82 4/82 10/81 1/82 5/82 8/82 11/81 2/82 10/81 1/82 3/82 6/82 12/81 3/82 12/81 3/82 8/81 11/81 Construction In progress. Revisions in progress. Engineering in progress CED. Contract let. Project Is operational. Engineering in progress. Engineering In progress. Revisions in progress. Closed to field charges. 10/81 1/82 2/82 5/82 6/82 9/82 9/82 12/82 12/81 3/82 12/81 3/82 4/82 7/82 12/81 3/82 Construction scheduled. Engineering in progress. Engineering scheduled. Engineering in progress CED. Construction in progress. Twenty-two projects approved Motors purchased 10/1/81. Engineering scheduled. 0 1/82 4/82 Engineering scheduled. 0 4/82 7/82 Engineering in progress CED. 0 7/82 10/82 Engineering scheduled. 0 9/82 12/82 Engineering scheduled. 9020 EXPENSE Repairs t< Line I Compounder 11/24/80 38,000 23,699 25,854 38,000 0 9/81 12/81 Closed to field charges. DTH 000021526 PERSONNEL - R. A. Miller EMPLOYMENT Albert Gunn, General Helper Paul Cogsdell, General Helper Richard Metcalf, General Helper Richard Gamer, General Helper Will Malone, General Helper TO/FROM LEAVE OF ABSENCE Willard Reed, Process Engineer - To Leave Patrick Thompson, Process Engineer - To Leave Robert Milner, Electrical Engineer - To Leave TRANSFER/PROMOTION Terry Edwards, Compound Utility, transfer to Lab Trainee George Carnathan, Electrician "B" promoted to Electrician "A" Robert Williams, Lab Trainee, transferred to Head Building Attendant Gordon Ostoroski, Head Building Attendant, transferred to Building Attendant RETIREMENT None TERMINATION John P. McKee, Mechanical Engineer Charlotte Lowe, Casual Labor Willie Nails, Casual Labor Q. C. Townes, Compound Utility OTHER During September there were eight (8) casual labor employees on payroll. Total hours worked were 213.75. DTH 000021527 CONOCO CHEMICALS Aberdeen, Mississippi September 1981 MONTHLY PERSONNEL REPORT Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations 81* 165 246* 5 1 Minority Employees # Salaried 6 Hourly 61 Total 66 Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 2 40% 1 100% q0, 37% 27% DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound Vinyl Plasticizer PAR # EMPLOYEES MIN. EMP: . % MIN. 11 9 11 19 '1 11% 8 42% 52 47 22 21 8 17% 4 19% 37 33 25 76% 40 32 13 40% 44 2 50% NEW HIRES YTD TERM. YTD TURNOVER 0 JL- 0 0 ___Q 5 15 0 0 0 00 0 1** 0 0 1*** 0 0 0 0 0 0 00 11 00 o -o 0 3% 0 0 0 0 0 0 3% 0 0 Number of Applicants: Month 0 Year to Date APPLICANT BREAKDOWN: # Minority ~ % Minority ^ Female _____ ~ % Female 103 *Inludes foux^ (4) temporary employees **Includes one (1) retirement. Retirements are not included in turnover rave. ***Indludes one (1) reinstatement. Reinstate ments are not included in new hires. Hires (Hourly) : Month Year to Date Terminations (Hourly) : Month 1 Year to Date Overall Turnover Projected Annual Turnover 15 3** DTH 000021528 O o r4 Q) 3 cr O o G O o U r-r (6 3 G C H- CL O &J 0) nN * 3 n O ror| O<_J M >j O' js U O Ui U)Gn |- O' O' 'j vO O 05 O' GJ vO O U) Ln Ui GJ i-* h- H- 05 O GnGn O NJ hO 'J O to Gn Gn ui O Gn C X 05 0 rt C >1 i CD CO H* 00 SC 30 cr ?** H ft H- a i(0 N> M t-- I--* Gn ho gj oo ho w ho I-* so VO 00 u> Gn JN u* SO KjNJ-sjvjOOhOGnN) GnGnGnGnQGnGn rr * O DJ O <: O* -i It 52 o crj cn Gn ho (-- P* to P- Gn 00 gj ^ o P' o co ro so N> o o ooo o o o ooo cr ft heso O o mO' O' O H> o < cn ft rt r< i rr Oj p. 4> h5 3 .JQ. n> 5T rt Q) (o H m. e, ft h* Pi *t3 H n pi so so 00 OVERTIME AND ABSENTEEISM EC o c VO o o o SO o O SO O t--* oOo oo he he he h4 he > CT* cn ft 3 on o o fOtjsO he o o o o Nh o he rt P* it H he cn to he H heI-- 3-4 OO H* M h* 3- GJ r- to he Oo rt *-h he gj o O ~j ro r-* p* o rr H he he h he he O e-- OGn he 3 Oj rt> rr It DTH 000021529 PROCESS ENGINEERING - R. A. Frohreich A. Expansion Project Work is continuing in all areas. Line flushing and equipment checkout has begun in the Fluid Bed Dryer area. Operator training has started for the Fluid Bed Dryer. Tie-ins to existing process lines in the old reactor module are being made during shutdown of the module. Installation of the chem wash system is nearing completion with startup expected in October. B. Line I Modernization The class "A" process design and cost estimate for the project were completed. An AFE request is being prepared. C. Firewater Improvements - Phase IV An AFE request for the project was submitted. D. 1982 Captial Budget A revised 1982 Capital Budget was prepared using new depreciation methods and submitted to Houston. E. Firewater Improvements - Phase III Piping drawings were reviewed and comments returned to CED. F. Plasticizer Initiator Handling System An AFE request for this project was submitted. G. 10-8 Plasticizer Production The AFE request for the project was submitted. Revisions to the class "A" design are being made. H. Calcium Stearate Addition System The class "A" design for this project was issued and a review meeting held. Comments from the review meeting are being incorporated in the design. I. Recovery System Modifications The AFE request for this project was submitted. J. Methocel Make-Up Revisions A design to install an eductor system on the methocel make up tank to improve methocel dispersion is being prepared. DTH 000021530 PROCESS ENGINEERING - (CONTINUED) K. Schenk Filter Problem Assistance was given in starting up the Schenk filter again. A rental pump was used to precoat the filter at a higher flow rate. A small amount of filter aid is being added to each batch. Performance to date has improved. L. Temperature Controller on Line V Process Engineering provided assistance in getting the temperature controller on compound Line V adjusted. M. Line V Air Slide Several venders were contacted concerning an air slide on Line V. A quote was obtained and a work order to install the air slide was submitted. N. Sampling Program for IR Problem A sampling program for the 5425 resin manufacturing process has been developed to determine what is necessary to improve the IR property of the resin. The sampling program will be conducted in October. DTH 000021531 ENVIRONMENTAL - V. E. Messick Particulates Two dryer exhausts were sampled for particulates and were within allowable limits. The procedure for sampling the fluid bed dyrer for particulate emissions was reviewed. A longer probe required for sampling the dryer stack was placed on order. Water All wastewater parameters were within NPDES limitations in September. The renewal NPDES permit was received from the Bureau of Pollution Control. VCM The comprehensive VCM leak survey has been completed. All leaks have been repaired. Hazardous Waste Management The Groundwater Monitoring Plan was reviewed with State Hazardous Waste Authorities on September 17. The monitoring wells will be installed in October. Other The update of the OSHA Engineering and Work Practice Controls was issued. DTH 000021532 Flow GPM Jan. . Ave. 1069 Max. 1297 Feb. Ave. Max. 757 819 Mar. _ Ave. Max. 753 790 Apr. Ave. 946 Max. 1200 May Ave.' 846 Max. 1200 June ' July Ave. Max. Ave. Max. 739 917 746 922 Aug. Ave. 753 Max. 1212 Sdpt. _ Ave. 739 Max. 1146 Oct. Ave. Max. Nov. _ Ave. Max. Dec. Ave. Max. TABLE I - WATER COMPLIANCE WITH NPDES PERMIT PARAMETERS BOD PPM LB./DY. 39 504 57 887 11 95 18 154 . 10 90 11 103 10 118 20 253 12 125 14 163 COD PPM LB./DY. 69 888 106 1650 43 382 56 479 36 330 51 466 31 360 41 519 43 470 54 629 Sus. Solids PPM LB./DY. 7 93 9 114 Diss. 0- 8.5-10.4 7 65 8.9-9.8 10 86 11 93 8.3-8.9 17 139 13 151 8.2-8.9 19 240 13 138 7.4-8.4 17 198 20 183 34 314 12 107 16 130 9 81 11 131 56 502 79 729 39 339 53 420 36 347 38 428 18 157 6.2-8.2 27 249 22 190 6.2-7.5 28 209 25 237 6.0-7.4 35 378 8 68 14 148 25 208 42 443 17 143 6.6-7.5 36 380 NPDES Ave. Max. - 32 431 43 800 -- 1462 - 2713 _ 674 - 1396 6.0 Ph_._ 7.4-7.8 7.5-7-9 7.6-7.7 6.9-8.1 7.3-8.0 7.6-7-9 7.7-8.0 7.5-7.8 7.5-7.7 6.0-8.5 DTH 000021533 ENERGY CONSERVATION - J. R. Perez-Velasco I. Plant Operations Total energy consumption for September was 92.115 MMM BTU's. The energy consumption per pound of product increased to 3021 BTU/lb. as compared with 2959 BTU/lb. in August. II. Plant Energy Conservation Program Steam Leaks One steam trap and eighteen steam leaks were repaired during September. Boilers The natural gas flow meter was recalibrated. DTH 000021534 ENERGY CONSERVATION DATA ITEM 1981 1980 Production, MM Lbs. September September Resin Dry Blend Compound Plasticizer . 21.2 5.2 3.5 0.7 23.3 1.6 4.2 1.1 TOTAL 30.6 30.2 Natural Gas Consumption, MSCF Conversion, BTU/SCF Energy Consumption, MMM BTU 43237 1020 44.101 49322 1020 50.380 Electricity Consumption, MM KWH Conversion, BTU/KWH Energy Consumption, MMM BTU 4.801 10000 48.014 4.680 10000 46.800 Propane Consumption, M Gal. Conversion, BTU/Gal. Energy Consumption, MMM BTU 0 92000 0 0 92000 0 Total Energy Consumption, MMM BTU Energy Consumption ,BTU/Lb. 92.115 3021 97.108 3215 Boiler Operating Data No. 1 No. 2 No. 3 Avg. Stack Temp. 1981 1980 312 382 300 464 289 421 Avg. % Excess Air 1981 1280 18% 29 15% 22 20% 22 DTH 000021535 LABORATORY - R. D. Jackson CUSTOMER COMPLAINTS Customer Product Complaint Report By Essex Group Alcan Cable Industrial Plastics 5465 34641 Black 14331 CB Oversize clumps Metal Contamination Poor Clarity PEM JRM RDJ WAIVERS RECEIVED Date Identification Product Customer Reason Waived By 9/3 9/8 9/8 9/9 9/9 9/15 9/15 9/23 9/25 9/25 9/25 T-2479 PLCX 43750 CONX 45809 CONX 45303 PLCX 43872 PTLX 41651 CONX 45794 CONX 45725 CONX 45715 PTLX 41646 CONX 45762 5385 5385 5385 5305 5385 5385 5385 5385 5425 5305 5385 Uniroyal Uniroyal Carlon Intex Carlon Carlon Carlon Bird & Sons Intex O'Leary Term. Carlon Particle Size Particle Size Viscosity Viscosity Viscosity Particle Size Particle Size Viscosity Particle Size Viscosity Particle Size JRW JRW JRW ELK ELK RDJ JRW JRW ELK ELK ELK PRODUCT SERVICE & DEVELOPMENT Ship Date Product Amount (Lb s.) Customer Requested By 9/3 9/3 9/4 9/8 9/8 9/8 9/11 9/15 9/15 9/15 9/16 9/16 9/17 9/18 9/21 34431 Natural 38552 Natural 90171 DB 5385-3 RP 100 DB RP-100 DB 5385-1 5385-1 5385-1 5385-1 5425-1 5465 5385 5425 VRP 5425 5385-1 5305-1 5425 5465 2,250 1,000 1,000 100 1,000 1,000 1,000 2,250 150 5 5 2,250 3x5 2x5 5 gal. 5 50 50 50 50 Northwire Inc. Northwire Inc. Proto Corp. Hammond Lead General Plastics Technical Plastics Eslon Thermoplastics General Binding Synthetic Products Co, Panasote Corp. Charlotte Pipe & Foundry Cerro Wire & Cable Wexford International Great American Chem. Co. E. I. DuPont de Nemour and Co. COEDS COEDS COEDS MAS COEDS COEDS COEDS COEDS COEDS JCL COEDS JCL WR RDJ COEDS DTH 000021536 LABORATORY - (CONTINUED) PRODUCT SERVICE & DEVELOPMENT - (CONTINUED) Ship Date 9/23 9/24 9/24 9/25 9/25 9/28 9/29 9/29 Product Amount (Lbs. ) 80273G DB 17461 Natural 5425 80273G DB 5385-3S 80274 DB 34711 Wht. 366 RP 100 DB 10 2,250 50 1,000 11,250 1,000 1,000 1,000 Customer Requested By Mitsui & Co. USA Weed Corp. Fritz Airfreight Winnebago Drainage System Certain-Teed Corp. Novatec Atcoflex Inc. General Plastics. JPM COEDS JPM COEDS COEDS COEDS COEDS COEDS Special Compound Testing One production lot of 34862 gray 546 was tested to verify that it met Western Electric specifications. Plasticizer content and flammability tests were run on the two railcar samples from this run. New Compounds Quality control specifications and standards were prepared for two experimental compounds - 4276-53B and 4276-53C. Color Matching A color formula was developed for 34711 White 366. Compound Property Verification Compound properties have been measured on thirty-one (31) compounds. These are the compounds which have been made during 1981. Tests will be repeated on some compounds which gave atypical results. Dry Blend Development Welex batches of 80174, 80273G and 90171 for the QC laboratory to use as control standards were prepared. A formula has been issued for 80281 - a dry blend for outdoor furniture. QUALITY CONTROL TESTING Resin Regular Samples = 339 Bag Samples = 47 Other In-Process Samples = 3127 Bulk Shipments = 131 (Railcars = 82; trucks = 49) dth 000021537 LABORATORY - (CONTINUED) QUALITY CONTROL TESTING - (CONTINUED) Dry Blend Blenders Produced = 604 Blenders Tested = 559 Blenders Adjusted = 5.0% Other In-Process Samples = 698 Bulk Shipments = 50 (Railcars = 18; trucks = 32) Compound Blenders Produced = 479 Blenders Adjusted = 1.5% Line V Production = 158 skids; 80 M pounds bulk Other In-Process Samples = 1,085 Bulk Shipments = 4 (Railcars = 4; trucks -- 0) Raw Material Testing Sixty-one (61) lots of plant raw materials were tested and released. One shipment of Ross Wax 145 was rejected because it had formed large, hard lumps which could not be used. One lot of Advawax 280 was rejected for black contamination. Resin Heat Stability Forty-four (44) samples of resin were tested for oven heat stability. All of the samples passed the test. The 5385 and 5425 resins continue to average slightly poorer than the controls, while 5465 was slightly better and 5305 was significantly better than the controls. RVCM Of Shipment Samples A total of 124 shipment samples were tested for RVCM in September. Below is a summary of these results. Sample Type 5305 5385 5425 5465 Dry Blend Average ppm RVCM Number of Samples 1.7 0.7 0.5 0.2 67 48 5 4 0.3 32 MISCELLANEOUS PROJECTS Resin Volume Resistivity Volume resistivity tests were run on 5425 and 5465 resins. The results were lower than normal. DTH 000021538 LABORATORY - (CONTINUED) MISCELLANEOUS PROJECTS - (CONTINUED) RVCM of Process Samples Below is a listing of the RVCM of in process samples. Sample ID Overall Average RVCM Number of Samples Reactor Slurry Stripper Water 5305 Drier Samples 193 4.7 2.6 516 119 86 The daily average for reactor samples exceeded 400 ppm one time during the month of September. Inherent Viscosity A total of 677 resin samples were checked for inherent viscosity in September. Other Service The following indicates the number of samples tested as a service to Process Engineering and Safety Departirent. Sample Type Number of Samples Waste Water COD Well Water Conductivity Waste Water Percent Solids Air Bags ppm VCM Carbon - CTA ppm Carbon - VCM ppm 94 12 12 5 14 79 DTH 000021539 TRANSPORTATION - J. E. STARK Shipment by Product - M/lbs September Year-to-Date Resin Plasticizer Dry Blend Compound Total 15825 41 3820 33Q672992 169467 826 34245 33062 237600 Number of Shipment by Mode O.T. O.T. R/C Rulk Van C.O.T C.C. TOFC CPU TOTAL Resin - Bulk Package Export Plasticizer Dry Blend - Bulk - Package - Export Compound - Bulk - Package - Export Other - Antifreeze - Alumina Back Hauls for September 74 3 H 7 ____ 95 28 2 8 38 9 28 5 13 35 3 93 34 10 1 21 4 3 11 0 3 0 47 1 Number of Shipment by Month-Year-to-Date R/C Bulk Van C.O.T. C.C. TOFC CPU 102 19 33 1 40 9 13 7 49 3 276 35 Total January February March April May June July August September 91 48 200 2 91 0 55 487 91 55 172 0 40 0 58 416 132 65 208 6 54 0 74 539 96 38 181 0 11 0 69 395 111 49 120 0 3 0 68 351 123 55 74 0 5 0 50 307 104 60 80 0 7 0 47 298 87 65 87 0 8 0 44 . 291 95 38 93 0 3 0 47 276 DTH 000021540 TRANSPORTATION - (CONTINUED) MATERIAL HANDLING REPORT Packaged Resin from Production Packaged Compound, Dry Blend from Prod. Transferred From Main to Prairie Transferred from Prairie to Prairie Transferred from Prairie to Main Reverse Transfer Resin to Plant Reverse Transfer Cmpd. to Plant Shipment from Warehouses Special Packaging OFF-GRADE IN STORAGE MATERIAL Sifter Overflow Resin "BC" Resin "H" Mill Scraps Compound "BC" Compound "H" Vacuum,Dust Collector Dry Blend "0. G." Total M/Lbs. 2268 4495 3199 1094 1377 284 81 2916 1782 17496 M/Lbs. 200 2452 766 103 1480 77 100 175 5346 T/L 56 111 79 27 34 7 .2 72 44 432 T/L 5 61 19 3 36 2 2 4 132 DTH 000021541 LOCATION MAIN-East TOTAL M SO. FT. 48 Prairie 12-1 12 12-2 22 12-3 21 12-4 22 12-5 21 12-6 21 12-7 21 12-8 21 12-9 21 Total 230 \. ti i^BERDEXN WAR EHOUSE CONTENTS Compounds. 6.9 Dry Blend .3 Export Resin Conoco Resin HDPE --i_L .4 Dry Blend Conoco Resin 1. 9 Compound (A) Dry Blend 3 .1 Conoco Resin .4 Export Resin Compound (A) .1 Conoco Resin Resin O.G. Mill Scraps .1 Cmpd O.G. 1. 0 Dry Blend O.G. .8 Sifter Overflow Resin O.G. .2 Compound Resin 2. 9 Raw Material .3 Resin O.G. 3. 2 Conoco Resin Conoco Resin 3.- 7 .5 Sifter Overflow --Z Compound (A) --5. Compound O.G. ___^5 D.B. O.G. .2 Mill Scrap .1 Sub-Total (Plug-Aisles) Total Conoco m t .j,ea.tfim3ar & .ESTIMATED MM POUNDS ON FLOOR OPEN TOTAL 7.3 2. 7 10.0 . 4 1.5 2.3 1 .2 3.5 CM *4.4 1.1 3.5 3.5 1. 8 .7 2.5 3 .2 3 .2 * 3 7___ . 3 3.5 . 3 _JL5___ * 3.5 2. 1 1.4 3.5 38.5 1.1 30 .8 ___ fiLJL 39:__ DTH 000021542 ABERDEEN CHEMICAL PLANT INJURY PERFORMANCE 8 6 k 2 0 kO 30 20 10 0 REQUENCY = T0TAL INJURIES (FA OR MC) X 12 TOTAL EMPLOYEES DTH 000021543 MONTHLY HOURLY TURNOVER 10 9 3 7 6 5 4 3 2 1 DTH 000021544 ENERGY USAGE 4000 3500 3000 2500 2000 Monthly 12 Month Moving Average DTH 000021545 ABERDEEN PLANT PRODUCTION I Ui\ MM POUNDS 'HL 1981 CUMULATIVE 35 30 25 20 15 6 5 4 3 2 1 40 35 6 30 5 25 4 20 3 15 2 10 1. 5 2 25 20 i: 15 10 05 --------- BUDGET ---------- ACTUAL ---------- CUMULATIVE DTH 000021546 ABERDEEN PLANT QUALITY PERFORMANCE 1981 STANDARD 1.35 V, DTH 000021547 3Aii\nnwnD A1ILLX0N 08500' l ayvaNVis 1861 ADN3IDI333 INVTd N33Qd3aV C OSO'I OOT' I OSI' I 002' T(^ 0S2 ` I OOO'I 010*1 020' T c TO'I 20' I 0*1 frO'T SO'I -90*1 10*1 20' I 0*1 DTH 000021548 ABERDEEN PLANT INVENTORIES DTH 000021549