Document zbbGQOY5XBmO0DJqQB0jyOKyR

ABD00311875 SAFETY - C. M. Markerson/J. V. Detain First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Iniuries bv DeDartment Sent. 3 1 4 0 0 Fiscal Y.T.D. 1995 7 1 8 0 0 Y.T.D. 1994 5 1 6 0 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Iniuries bv Tvoe Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 11 12 24 00 00 01 48 14 00 12 00 00 11 11 48 0 3 1 1 1 0 6 5 0 0 1 0 0 0 6 Non-OccuDational Iniuries Lost Workday Cases Days Lost 00 00 1 32 Contractor Iniuries First Aid Cases Medical Treatment Cases Lost Workday Cases Safetv Record 00 00 00 1 0 0 Last lost time injury Days since Employee hours since - 01/22/94 251 315,598 On September 30, 1994, the employees of the Aberdeen Plant completed 251 with no lost time injury. The topic for plant safety training during the month was Fire Training at the State Fire Academy in Jackson, Mississippi. ABD003T1876 SAFETY - Continued Routine dosimetry results for the month were: Chemical < PEL Number Percent > PEL Number Percent VCM Lead Total Particulates 64 97.0 4 100.0 2 100.0 2 0 0 3.0 0 0 One of the two VCM overexposures was with benefit of respiratory protection; the other without. Monthly Injury Summary In-iurv Class Department Description FA Maintenance Small metal splinter in left thumb. MT Compound Laceration of small finger of right hand, requiring stitches. FA Maintenance Wasp sting of left thumb. FA Vinyl Small areas of 1st degree bums to both hands. 12 October 1994 ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) TOTAL INJURIES OSHA RECORDABLE ABD00311877 QUALITY MANAGEMENT PROCESS - J. M. Edwards - Brenda Myers, Michael Harris, and Robin Thomas assisted Aberdeen personnel during the ISO 9002 - 1994 Pre-Assessment Audit which occurred September 14, 15, and 16, 1994. They took copious notes during all parts of the audit. - All of the ISO 9002 training for all Aberdeen personnel was com pleted in preparation for the pre-assessment audit. - All ISO related plant documents are being reviewed and revisions are being made where necessary in response to the recommendations made by the DNVI, Inc. Audit Team. COST VARIANCES - C. W. Turner Variable Costs Product Sept.. 94 Variance, $M Efficiency Price Total PVC Flexible Compound Plasticizer Total < 34.2> 68.5 11.7 46.0 <1701.1> < 158.4> < 46.8> <1906.3> <1735.3> < 89.9> < 35.1> <1806.3> PVC Resin The unfavorable efficiency variance for PVC was due to lower off-grade production resulting in a net unfavorable variance of $92.1M. This unfavorable variance was partially off-set by favorable variances in VCM ($22.3M) and Utilities ($58.9). Flexible Compound and Plasticizer The negative price variance in Compound is due primarily to higher than budgeted prices for resin and plasticizer. The negative price variance, in Plasticizer is due to higher than budgeted alcohol and phthalic anhydride prices. Major Price Va-ri anrPH Variance - $M - VCM - Plasticizer to Compound M Resin to Compound <1803.4> < 48.2> < 78.0> ABD00311878 VINYL - T. D. Olson, W. S. Carroll Safety The Vinyl Department had no injuries in September. The monthly safety meetings were held on shift. General September production was 47.9MM pounds of which 46.8MM pounds was prime grade resin. Percent asset utilization was 95.1% 9 (see attached chart). September production is a new monthly record for a 30-day month. This surpasses the old 30-day monthly production record of 44.5MM set in June, 1994. First quarter FY95 was 143.9MM which is a new quarter production record surpassing the old record of 133.8MM set 4QFY94. Sept. 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, % % 47.9 94.7 97.7 1.0274 1595 110.9 1064.0 35.5 96.4 98.0 143.9 95.8 97.6 1.0203 1564 108.8 3216.0 35.0 96.6 98.2 Reactor Downtime Hours Operational downtime (recovery scheduling conflicts - 135 hours, hydroblast and in spect four reactors - 145 hours). 320.0 Mechanical downtime. 59.0 Dryer nmwwtHina Hours _ Operational downtime (cleaning, product changes, and centrifuge plugs). 42.0 _ Mechanical downtime 43.0 Reactor limited production. 60.0 COMPOUND - E. T. Stouder Safety The Compound Department had one OSHA recordable injury during the month^ An Operator received stitches on his finger for a cut sustained while cleaning the Line V intensive cooler during a product change. ABD00311879 COMPOUND - Continued General Compound experienced a strong production month with 7.1MM pounds of finished compound produced. September production included a high volume of compound for AT&T due to increased demand by this customer. Orders for Lines I, III, and V continue to be very strong. For the second con secutive month, Aberdeen shipped in excess of 8.5MM pounds of prime finished compound. During this two-month timeframe, inventories of Agrade compound have been reduced by approximately 2.5MM pounds. Plasticizer production totaled almost 1.9MM pounds in September. For the first fiscal quarter 1995, plasticizer production is running at a 22MM pound rate. Comnnund Production Operating Davs Production M (Lbs). Month Ava. /Dav Fiscal Y Line Line Line I III V Total % Prime Capacity Utilization 30 30 30 Factor 1869 4031 1168 7068 96.3 93.8 62 134 39 236 5941 11995 3411 21347 96.5 94.1 Downtime Hours Line I - Product Changes - Miscellaneous Maintenance - Quality 80 29 22 Line III - Product Changes - Miscellaneous Maintenance - Quality 68 7 9 Line V - Product Changes - Miscellaneous Maintenance - Quality 73 23 25 Operating Davs Production (M Lbs.) Month Ava./Dav Fiscal Y.T.D Plasticizer 30 % Prime Capacity Utilization Factor 1898 87.7 88.4 63 5500 85.7 83.5 ABD00311880 ENGINEERING - J. E. Nickerson, T. R. Mackay, R. H. Sneed PROJECTS IN DEVELOPMENT - GENERAL EXPRESS We participated with GED in evaluating engineering companies for Phase I. Bid packages for major equipment will be ready in early October. The estimate for Phase I will be complete in mid-October. OSHA Process Safety Process Safety Information Work is finished on locating and developing equipment specifi cations and documentation for the New Module. Equipment docu mentation for the S.A. Module should be completed next month. New Module relief systems documentation is continuing. Procedures Procedures for New Module and SA Module are in the review process. Procedures for the boilers are complete. HAZOPS The Old Module HAZOP is scheduled to begin in October. New Blades for Reactor 600 New larger blades for reactor 600 have been ordered. This is part of the larger batch that is on-going. When the production schedule allows, the new blades will be installed. R&D and the plant can then continue the larger batch development work that has been taking place. Reactor Level Indication A nuclear level gauge for reactor 600 has been ordered. It will be evaluated for use as high level and continuous level indication for the reactors. A trial is planned for reactor 600 as part of the larger batch development work. P-1 Reactor Header Modifications The AFE for this project was submitted and approved. This project will increase plasticizer production by reducing batch times with improved heat-up and cool down times. A test run will be con ducted in October to determine if vacuum breakers can be used to drain the coils rather than installing actuated valves. ABD00311881 ENGINEERING - Continued PROJECTS IN DEVELOPMENT - GENERAL - continued Calcium Stearate Addition Upgrade Replacing wet calcium stearate in 5385 with dry calcium stearate addition has the potential of saving $160M a hear in raw material costs. It will also require less operator manpower. Positive results were obtained during the first test substituting dry cal cium stearate for wet calcium stearate in 5385. Testing will con tinue with an extended run where dry calcium stearate is used exclusively. VCM Vapor Lines Winterization This project will reduce fugitive VCM emissions in the VCM tank farm area. VCM condensation in lines leading to the railcar un loading compressors is suspected of causing fugitive VCM emissions. Heat tracing these lines will prevent this from happening. This project is included in the 2QTR95 budget submittal. RVCM SuhgQQler Addition This project is another way of reducing recovery times. Reducing the temperature of the recovery VCM lowers the back pressure in the receivers. Reduced back pressure in the receivers increases re covery compressor rates. The Class "A" design has been reviewed and the project is currently being estimated. Boiler Feedwater Softener Replac**TM**TM**- 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. The softener's capacity will also be increased to meet expected post pony EXPRESS steam require ments. Class "A" will be completed in November. Resin Quality Control This project helps align product quality testing with production units. This realignment of lab testing is driven by quicker feed back for operators and combining job tasks for manpower savings. This project purchases new lab equipment to run the moisture, con tamination, static flow, and bulk density tests. V-10 Slurry Trannfer System Upgrade 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 verbal approval for the project has been obtained. ABD00311882 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 installs an additional deaerator and deaerator feed pump to help meet post EXPRESS steam requirements. Class "A" to be completed in November. 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. Suspending Agent Charge Modifications Work has begun on a test run proposal to charge suspending agent into the water charge header. Charging S.A. into water header should increase the efficiency of the SA and reduce SA charge amounts by aiding in the dispersal and dilution. RMVTRQMMEMTAL - K. G. Akins Water All wastewater discharge parameters were within permitted limits for the month of September. Groundwater Groundwater tracer tests began this month to determine flow rate of the aquifer. This data will be used in the final design of the bio and pump and treat remedial systems. Wastes Seventy-six drums of plasticizer filter cake were shipped to Fisher Industrial Service in Glencoe, Alabama. A bulk load of API sludge was shipped to Laidlaw in Chattanooga, Tennessee. 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 0 0 0 0 0 0 0 0 0 0 0 0 0