Document yr1Yg61kE38Rn1e23Gk62BD06

ABD00311856 SAFETY - C. M. Harkerson/J. V. Uptain Oct. Fiscal Y.T.D. 1995 Y.T.D. 1994 First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 0 0 0 0 0 6 1 7 0 0 6 2 8 0 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 01 02 03 00 00 01 01 0 4 1 1 2 .0 8 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 04 00 02 00 00 01 0 _o 07 5 0 1 2 0 0 JD 8 Non-Occupational Injuries Lost Workday Cases Days Lost 0o 0o 3 58 Contractor Injuries First Aid Cases Medical Treatment Cases Lost Workday Cases 0o 0o 0o 1 0 0 Safety Record Last lost time injury Days since Employee hours since - 01/22/94 282 357,190 On October 31, 1994, the employees of the Aberdeen Plant completed 282 days with no lost time injury. The topic for plant safety training during the month was Fire Training. Routine dosimetry results for the month were: Chemical ________< PEL Number Percent > PEL Number Percent VCM Lead Total Particulates 65 97.0 9 100.0 6 100.0 2 0 0 3.0 0 0 ABD00311857 SAFETY - Continued Monthly Injury Summary There were no injuries reported. ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) NUMBER OF INJURIES -U- TOTAL INJURIES OSHA RECORDABLE ABD00311858 QUALITY MANAGEMENT PROCESS - J. M. Edwards - All ISO related plant documents were reviewed and revisions were made where necessary in response to the recommendations made by the DNVI, Inc. Audit Team during the September pre assessment audit. COST VARIANCES - P. J. Kober Variable Costs Product Oct. 94 Variance, $M Efficiency Price Total PVC Flexible Compound Plasticizer Total <409.2> 12.7 37.3 <359.2> <2422.5> 160.6 < 93.4> <2355.3> <2831.7> 173.3 < 56.1> <2714.5> PVC Resin The unfavorable efficiency variance for PVC was due to VCM <$334.6M>, catalyst usage <$28.2M>, and low off-grade produc tion <$56.5M>. The unfavorable variance was due to a correc tion for an inventory error in previous months. Flexible Compound and Plasticizer The Compound efficiency variance was due to a low rate of offgrade production. The positive compound price variance was due to lower than budgeted prices for flame retardants and non-Vista plasticizers partially offset by higher than budgeted resin prices. A portion of the positive variance for flame retardants and non-Vista plasticizers was due to raw material inventory ad justments . The negative price variance for plasticizer was attributable to higher than budgeted alcohol and P.A. prices. Major Price Variances - VCM - Plasticizer to Compound - Resin to Compound Variance - $M <2672.0> < 161.4> < 10.8> ABD00311859 VINYL - J. D. Olson, W. S. Carroll Safety The Vinyl Department had no injuries in October. The monthly safety meetings were held on shift. General October production was 48.9MM pounds of which 47.7MM pounds was prime grade resin. Percent asset utilization was 93. 8% (see attached chart) . October production is a new monthly record. This surpasses the old monthly production record Of 48. 2MM set in August, 1994. Oct. YTD - 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, % % 48.9 93.8 97.6 1.0673 1576 109.6 1105.0 35.6 94.9 96.2 192.7 95.3 97.7 1.0322 1567 109.0 4321.0 35.1 96.2 97.7 Reactor Downtime Hours Operational downtime (recovery scheduling conflicts - 112 hours, hydroblast and in spect two reactors - 66 hours). Mechanical downtime (planned turnaround 142 hours). 315.0 200.0 Dryer Downtime Hours Operational downtime (cleaning, product changes, and centrifuge plugs). 110.0 Mechanical downtime 57.0 Reactor limited production. 52.0 COMPOUND - E. T. Stouder Safety The Compound Department had no OSHA recordable injury during the month. ABD00311860 COMPOUND - Continued General Compound production in October totaled 7.2MM pounds. This total included 4.1MM pounds of compound for AT&T. Due to the continued strong demand from AT&T, several customers including Triangle and Cerro have been shifted to Mansfield. Compound off-grade produc tion totaled less than 60M pounds in October which represents a significant improvement from previous months. This improvement is due primarily to long production runs on all three lines and in creased experience with production of the various compounds for AT&T. Plasticizer production totaled 1.8MM pounds in October. For fiscal year 1995, the Plasticizer Unit continues to operate at a 22M pound per year rate. Compound Production Operating Davs ________Production M fT.vq) . Month Avq./Dav Fiscal Y.T.D. Line Line Line I III V Total % Prime Capacity Utilization 31 31 31 Factor 1934 4100 1215 7249 97.6 97.1 62 132 39 234 7875 16095 4626 28596 96.8 94.9 Downtime Hours Line I - Product Changes - Miscellaneous Maintenance - Quality 91 11 15 Line III - Product Changes - Miscellaneous Maintenance - Quality 72 24 4 Line V - Product Changes - Miscellaneous Maintenance - Quality 54 24 34 Operating Davs ___________Production (M Lba.l Month Avq. /Dav Fiscal Y.T.D. Plasticizer 31 % Prime Capacity Utilization Factor 1805 88.5 84.8 58 7310 86.4 83.8 ABD00311861 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. Bid packages were prepared and reviewed for major equipment, and the estimate for Phase I was reviewed. Boiler Feedwater Deaerator Addition and Instrument-, Air Dryer These designs are part of Phase II EXPRESS. This design upgrades deaerator equipment feeding the boilers. Upgrading this equipment will improve its stream factor. This design installs an additional deaerator and deaerator feed pump to help meet post EXPRESS steam requirements. Class "A" designs will be completed in November. OSHA Process Safety Process Safety Information Work is finished on locating and developing equipment specifications and documentation for the New Module and the SA Module. Procedures Procedures for New Module and SA Module are in the review process. HAZOPS The New Module HAZOP Team began work in October. Work is progressing well. 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 completed. An in quiry was sent to Boardman Company requesting a fabrication estimate. An estimate is expected the first of November. This sight glass will be installed in place of the Lanape. It will be used to detect foaming during the upcoming larger batch test runs. Reactor Level Indication New larger agitator blades were installed in reactor 600. These blades will be used for larger batch testing. ABD00311862 ENGINEERING - Continued 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. Plasticizer Reactor Header Modifications Vacuum breaker tests were successfully completed in October. They will be used to drain the coils instead of an actuated vent valve. Modificationsto the first plasticizer reactor should be completed sometime in December. This project will reduce batch cycle times by 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, using dry calcium stearate, started on November 17 and has continued. Thus far, positive results have been obtained. VCM Vapor Lines Winterization This project will reduce fugitive VCM emissions in the tank farm area. VCM condensation in 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 happening. Installation is scheduled for December. RVCM Subcooler Addition This project is another way of reducing recovery times. Re ducing the temperature of the recovered VCM lowers the back pressure in the receivers. Reduced back pressure in the receivers increases recovery compressor rates. The Class "A" design has been reviewed and an AFE was submitted. Boiler Feedwater Softener Replacement Class "A" design work was started to replace existing water softeners with new ones. This project will save an estimated $45M annually in regenerative salt costs. Class "A" will be completed in November. ABD00311863 ENGINEERING - Continued PROujsltx'S IN DEVELOPMENT - GENERAL - continued V-10 Slurry Tranafer flyqh^TTi TTpqraHft This project will replace the existing 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. Economy Surplus Power Conversion The plant is currently pursuing conversion to TVA's Economy surplus power electrical power rate structure. An energy consulting firm has been retained to provide assistance. ESP has the potential to reduce electricity costs $500M - $900M per year at our current power consumption level. Estimate of various plant electrical loads is in progress. A plant cur tailment plan is being drafted for potential temporary reduc tions in power under the new contract. Contract negotiations with TVA and Aberdeen Light and Water should begin in late November or early December. Suspending Agent Charge Modifications A test run proposal to charge suspending agent into the water charge header has been completed. The proposal will be issued in November for review. 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. Recovery Compressor Addition for Old Module This project adds a compressor to the Old Module to decrease recovery times. Calculations show a production increase of 2.3MM lbs./year with the decreased recovery times. The design and estimate will be done by mid-November. Activator Replarament anH Resin T-ranafpr Improvements This project replaces one activator with a 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. ENVIRONMENTAL - K. G. Akins Water All wastewater discharge parameters were within permitted limits for the month of October, ABD00311864 ENVIRONMENTAL - Continued Sampling conducted by the MDEQ has indicated that our wastewater is exhibiting some degree of chronic toxicity. The MDEQ has re quested that Vista submit a plan to identify the cause of the toxicity by January 17. Groundwater Groundwater tracer tests were completed this month. Lab testing has confirmed that naturally occurring bacteria at the site can biodegrade TCE to DCE. However, further degradation of the DCE is slower than expected. Possible enhancements are being in vestigated before a field study begins. Wastes A bulk shipment of waste oil was shipped to Fisher Industrial Service in Glencoe, Alabama. KEY ENVIRONMENTAL COMPLIANCE DATA 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 MONTH 0 0 0 0 0 0 0 FYTD 0 0 0 0 0 0 0