Document x1gjp4B329wk55GD6Kx343zZ6

ABD00296624 l DISTRIBUTION: HOUSTON PONCA CITY OKLAHOMA CITY NEK'ARK LAKE CHARLES VCM PLANT BALTIMORE STAMFORD HAMMOND ABERDEEN _ J. D. Burns - W. H. Chamberlain - H. R. Flammcr - J. J. Langford - M. J. Fortier - B. li. A. Larsen - G. G. Draper - C. L. Sanderson _ D. H. Sanders - D. D. Tooman - A. J. Lundeen - John Friend - Paul Gowan (Safety Portion only) - J. A. DeBernardi - R. A. Darling (Cover Letter only) - R. W. Gerwig - J. B, Maher (Safety Portion only) - CRM, JRM, SJV, RAF, JLC, RBM, AHS, 4 ABD00296625 \I * SAFETY - A. 11. Sather OCCUPATIONAL INJURIES. Injuries Treated October 1979 Ycar-to-Date 1978 Ycar-to- First Aid Medical Cases Restricted Workday Cases Restricted Workdays Lost Time 4 32 18 02 0 29 01 42 8 1 10 1 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving and Warehouse Office 0 13 03 4 . 22 11 o- 0 02 16 15 18 5 0 1 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains and Sprains Other 1 0' 0 3 0 1 12 5 12 10 5 2 21 9 9 9 5 5 As of October 31, 1979, the plant operated 149,288 manhours or 118 days wit a disabling injury. SUPERVISOR'S WORKSHOP Pinal preparations were completed for the Supervisor's Workshop on Safety Awareness to be conducted during November. A number of films were reviewed with eight (8) being selected for- use. A new procedure was also prepared which stated the plant's position on accident and injury control with emphasis on methods of control. NEW COMPOUND LINE On October 8, 1979, a team of plant personnel conducted an 80 percent complete safety audit to identify safety and functionality items which should be corrected prior to startup. ABD00296626 FIRE PROTECTION IMPROVl-Ml-NTS - PHASE I The basis of bids piping package was received from CHD. Several changes were noted for revision prior to issue. The changes arc targeted to be complete during November with bid package issue shortly thereafter. EMPLOYJili SAFETY RESPONSIBILITIES PROGRAM Work on tlie new multi-part Employee Safety Responsibilities slide and tape pre sentation was initiated during the reporting period. The program is being designed such that it will fill' a number of needs specifically including new employee safety orientation and safety meeting emphasis. RIGGING TRAINING Final preparations were made to utilize the services of Crane Inspection and Certification fkn'cau (CICB) to conduct the rigging training program. The program is scheduled for December 10-17, 1979. Currently, the intent is to schedule all Mechanical Department personnel into the two (2), three (3)-day scssions. OSHA COMPLIANCE Activity in the area of OSHA compliance for the reporting period included: 1. "Hands-on" physicals for compound and lab personnel handling lead containing compounds and for plant personnel having worked with VCM for ten (10) years or longer. 2. Revisions to the annual Respiratory Protection Training program and conduct of several training classes. 3. Final layout review of the new air supply header to the building ventilation system dust collector. 4. Routine personnel monitoring for VCM and lead. The results of monitoring arc shown below along with a brief explanation of overexposures.. VCM Dosimetry Range, PPM Number Percent 0.0 - 0.5 .0.5 - 1.0 1.0 - 5.0 5.0+ A9 '8 : '.10 ` 2 69 71.01 11.60 14.49 2.90 100.00 ABD00296627 051IA COMPLIANCE (Cont.) VCM Ovcroxnosurcs Twelve (12) VCM overexposures occurred. Six (6) occurred to Vinyl Operations personnel, five (5) of which could not ifentify n source while one (1) indicated the source to be dispersing agent (PVA) makeup. Five (5) of the Mechanical Department personnel were overexposed. One (1) of them occurred to a mechanic entering D-600 and was wearing a respirator. The remaining Mechanical Department overexposures involved work on the valve actuator lubricators in the new unit recovery area (one), piping revision on 742 reactor N.O. kill piping (one), and two (2) mechanics performing work on the old module reactor gearboxes. The remaining overexposure occurred to a yard operator unloading VCM who was wearing a respirator. Le ad Number Percent Less than P13L Greater than I'LL S 0 S 100.0 0.0 100.0 ABD00296628 VINYL - C. R. Miller Product ion Month Y.T.D. Stand;) rd 1. Total Production, MM #'s 2. Production Rate, M tf's/C.D. 3. Charging, Reactor Batches/C.D. 4. Total Charges 5. Reactor Stream Factor, % 6. Drying Rates, Average fl's/hr. 7. Dryers, Stream Factor, % 8. Accounting Days 28.8 930 22.1 685 85.7 5984 92.3 31 264.9 871 21 .3 6464 88.5 5751 90.2 304 904 Vinyl department production for the month was 103% of budget at 28.8 MM pounds. This monthly total represents a new monthly production record which surpases the previous record of 28.7 MM pounds set last May. The reactor performance was down from September with a 85.7% stream factor. The major items which adversely affected reactor performance were as follows: 1. All four reactors in the old module required gearbox repairs during the month. (6% stream factor penalty) 2. Blade changes required for the agitation test run. An agitator test run was held during October in the new reactor module with RSD and plant personnel. The results will be utilized to optimize agitation affects on resin properties and to provide scale-up information for future design work. Resin Quality Summary Resin Type Prime Pounds "BC" Grade "11" Grade % of Total Production 5305 5385 5425 5465 Sifter Overflow TOTAL 2,271,831 22,769,334 2,800,954 340,450 - 28,182,369 125,500 148,500 115,050 - - 389,050 43,000 20,250 - 206,365 271,615 8.3 79.6 10.2 1.2 0.7 100.0 Quality performance for the month of October was 97.7% customer grade with 1.35% "BC" and 0.95%' "H" grade reported, 76% was due to sifter overflow. The variable cost variance for the vinyl department was ($l,40S.l M) with ($1,507.5 M) due to price and $99.2 M due to efficiency. The major price variance was ($1,443.3 M) for VCM. The only major efficiency variance was $28.4 M for VCM. ABD00296629 1 'Hie raw material requirement for the month was 1.01298 pounds VCM/pound of PVC versus a 1.01960 standard. (Y.T.U. is 1.02514). General Approximately 6.1 million pounds of resin was bagged during the month to meet export requirements. ABD00296630 i. COMPOUND - J. R. McCrimon Compound Production Line I, M Pounds Line III, M Pounds Total, M Pounds Accounting Days Month 1,369 2,149 3,518 31 #1s/Dav 44 69 113 Y.T.D. 14,244 24,538 38.7S2 304 Line 1 operated 23 days during October at an average rate of 44 M pounds per dav Major items impeding productivity were the number of product changes (17 changes 45.2 hours), five (5) day operation, dicer problems (45.3 hours), pellet blower maintenance (5.4 hours), blender bucket drive clutch maintenance (4.2 hours) and skip hoist maintenance (2.7 hours). Line III operated 23 days averaging 69 M pounds per day. Production on Line III was hindered by five (5) day operation, product changes (12 changes, 33.2 hours) plugged FCM (12.5 hours), mill motor repair (25.8 hours), running only one dicer for quality control (SO hours), oil change on mill (4.0 hours), dicer problems (2.7 hours), star valve maintenance (2.5 hours), and blender ribbon repairs (2.2 hours). Quality performance for flexible compounds was 1.1% off-grade of which 65.3% was due to millscrap. "BC" production was 1.6%. The raw material requirement for flexible compounds was 1.00218 pounds raw material per pound of compound versus a 1.01297. (Y.T.D. is 1.008S0) The variable cost variance for compound was $20.3M with ($11.2 M) due to price and $31.5 M due to efficiency. The variance due to product mix was $19.1 M. The major price variance was ($19.2 M) for T0TM. Dry Blend Month #1 s/Day Y.T.D. Production, M Pounds Accounting Days 5,424 175 39,765 31 304 Dry Blend operated-25 days during October at an average rate of 175 M pounds per day. Production included 80172B, 80273G, and 90171. Dry Blend production was encumbered by Orbitran repairs (36.2 hours), running on one U'elex (44 hours), stabilizer pump repairs (4.5 hours), and load cell calibration (l.S hours). Quality performance for October was 99.99% customer grade. Tlie raw material requirement for Dry Blend was 1.01280 pounds raw materials per pound of dry blend versus a 1.00521 standard. (Y.T.D. is 1.00302) The variable cost variance for Dry Blend was ($86.8 M) with ($10.6 M) due to price and ($76.2 M) due to efficiency. The variance due to product mix was ($67.3 M). ABD00296631 Plasticizer Month fl's/Day Y.T.D. Production, M Pounds Accounting Days 864 28 9,092 31 304 Plasticizer operated 13 days during October averaging 66 M pounds per operating day. Production included 610P, DOP, and DTDP. VRP production totaled 101 M pounds 03.2%) . The raw material requirement for plasticizer was 1.06851 versus a 1.10872 standard. (Y.T.D. is 1.14099) 'Hie variable cost for plasticizer was ($18.7 M) with ($23.1) due to price and $4.41 M due to efficiency. Major price variances were ($22.2) for Alfol 610, $16.0 for 2-Bthyl hexanol, and ($11.1) for Tsodecyl. General Total customer grade compound inventory held steady at 6.9 MM pounds during October. ADD00296632 A M1ICI1ANTCA1, - S. J. Vincent There were three large reactor comlensors cleaned during this period. The condcnsors cl caned were on D-400 and D-500 in the old module and 744 condcnsor in the new module; Two large reactor mechanical seals were also replaced. Both of the seals were replaced in the old module on D-500 and D-400 reactors. There were three major reactor gear boxes overhauled this period. The D-600 gear box was rebuilt in the Prager Machine Shop and the lower bearing housing replaced along with extensive machine work. The D-400 and D-300 gear boxes were overhauled in our shop after both gear boxes experience top bearing failures. D-600 and D-400 gear boxes experienced high speed pinion gear failures after two weeks operation. 'Ihc main drive motor on the D-500 reactor gear box was replaced. Reactor valves repaired or replaced were the D-400 main dump, steam stripping and water charge valve, the D-500 sewer drain and VC charge valve and the VC charge valve on the D-600 reactor. The safety valves were tested on D-400 reactor and condcnsor, the south recovered receiver in the old module and the safety valve was replaced on the pull receiver in the new module. The only major mechanical problem in the vinyl dryer area was the shaft and bearing failure on the number seven exhauster. The exhauster was removed to the shop to repair the fan and to install a new shaft, bearings and drive shaft. Other dryer repairs included the replacement of the number two screener motor and minor repairs to sifter clamps and vibrators. There were nine mechanical seal repairs this month on small pumps and compressors. Six seal failures were in the old module and three in the new module. The south Corkin compressor was changed out and the old unit rebuilt. A new safety valve and stack was installed on the old module blowdown drum. The reactor agitator test run was completed using 744 reactor for the test. Mechanical manpower was scheduled for seven day twenty four hour coverage of the test run. A new fuel gas pressure readout was installed in the reactor control room. Compound, Dry Blend, Plasticizer, and Storage Silos Both the north and south blowers in the plasticizer unit were overhauled and case leaks repaired. The fan hub and blowers were replaced on the south compound cooling tower. The number one Kelcx main drive bearing failed. Repairs were made by installing the spare drive shaft and bearing. ABD00296633 Ut.i 1 ities and Servl ce Three air compressors were repaired this month. Valves and packing in number six and two and the crank bearings were replaced in number one air compressor. Ihe outlet cooling water lines were revised to increase cooling on the three V-10 air compressor aftcrcoolers. Heater elements were replaced in number one and number three air dryers. Planning The planner is still out due to illness and individual area supervisors are performing some of the planners duties along with the maintenance clerk. Miscellaneous The "B" mechanics completed four days of basis welding training. Twelve mechanics and one supervisor completed a two and one half day pump and seal seminar by Dupont Co. ABD00296634 PERSONNEL - J. L. Carter - EMPLOYMENT Randy Mamed, Electrical Engineer Steve Dobbs, Casual Labor TO/FROM LEAVE OP ABSENCE None TRANSFER/PROMOTION None RETIREMENT None TERMINATION James Sykes, Compound Utility Q. C. Townes, Compound Utility DEATH/DISABILITY None OTHER During the month of October there were four casual labor employee on payroll. Total hours worked were 704.75. The bulk of these employees were utilized for bagging resin. A ABD00296635' October 1979 MONTHLY PERSONNHL REPORT ialn^^d Employees 78 Minority Employees lour 1 y Employees 158 Salaried 5 6.4% i'otal Employees 256 Dourly 61 59* mployocs (Hourly)^ Total 66 New Employees Terminations Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 50! i-;paut: H.;: i s PAU " 1 -.MPlOYEES MI N. EMP. . % MIX. NEW 111 RES YTD TERM. YTD 'IV: W'OYER :td arehousc cn. Plant aintenancc aboratory ompound ' 1astici:cr 9 10 46 22 41 .32 5 9 n 45 21 36 32 4 2 22% 4 36% 7 15% 3 14% 29 80% 13 41% 3 75% 0 00 0 0 0 0 10 4 0 36% 0 00 1 0 2% 0 00 1 0 4.7% a 0 2 2 5% 5% 0 00 0 0 0 0 00 0 0 0 amber of Applicants: jnth 1 Year to Date 77 'PEI CANT BREAKDOWN: Minority 0 6 Minority 0 i'emu lo 1 % Ecmnlc 100% '''Includes two (2) tempoi'ary employees Hires (Hourly) : Month 6 Year to Date Terminations (Hourly) : Month 2 Year to Date Overall Turnover 1 .3% Projacted Annual Turnover 1 8 5% ABD00296636 K -H O o ao a a ll o v e rtim e e x c lu d in g o v e rtim e due to w o rkin g re g u la r hours on a h o lid a y and w o rk in g th e s ix th day in o p e ra tio n s . ABD00296637 A PROCESS ENGINEERING - R. A. Frohrcich A. Specialty Compound Line Mechanical construction of the project is proceeding. The operating manual for the line was prepared. The Orbitran control panel is scheduled . for shipment in the first week of November. Completion of the project is now scheduled for November 23, 1979. B. Fire Water Revisions The AFE request for Phase IX of the project was approved. C. Automatic Plasticizer Weigh-Dp System Installation of this project has been postponed until after startup of the new compound line. D. New Slurry Blend Tank and PVC Railcar Silo The Class "A" process design for this project is being revised to be consistent with the Expansion Project. E. Resin Expansion Project A review meeting covering the status ofthc project was held at the plant on 10/24/79. A partial AFE to cover engineering and equipment charges was .submitted and approved. F. Spare Incinerator An AFE request was submitted in late September for this project. G. Plant Dryer Debottlenecking The process design for this project is being revised to be consistent with the Expansion Project and the New Slurry Blend Tank and PVC Railcar Silo Project. H. Methoccl Charge Revisions The AFE request for this project was approved. I. In-Process Waste Water Stripping System An AFE request for this project was submitted in late September. J. Plasticizer Exposure Abatement The plant engineering staff assisted PED in operator training and startup of plasticizer filter. ABD00296638 V A K. Phthalic Anhydride Tank Replacement A process design to replace the phthalic anhydride tank was issued. L. Propane Operating Manual The propane operating manual was issued for internal review. M. Recovery System Modifications The Recovery System Modifications process design was issued for internal review. This design regulates the seal water flow to the vacuum pumps and compressors. N. Plant Air Dryers Non lubricated switching valves for dryers 2 and 3 (V-10) are due to be shipped November 14. Kemp sales representative recommended increasing plant pressure to achieve dryer air. Monitoring of dryer performance continues. O. Oxygen Analysis of Vapor Space in Emission Recovery System A report on the Emission Recovery System oxygen analysis test was issued in October. P. Operating Procedures for Emergency Power System Operating procedures for the emergency power system arc being prepared. Q. Plasticizer Waste Water Several plasticizer waste water streams were analyzed for BOD to see if these streams can bypass the API. Air floatation tests will be conducted beginning in December. ABD00296639 ENVIRONMENTAL - V. E. Mcssick I. Particulates The exhaust, from one of the resin dryers was sampled for particulates and was within allowable limits. Mechanical problems with the stack sampler prevented more samples from being taken. IT. hater BOD and COD levels were within the NPDES limitations during all of October. Arrangements have been made to clean the API separator. The solids in the separator will be trucked to Rollins Environmental Service and be disposed of by them. III. Vinyl Chloride The lloneywel1 continuous monitoring systems received preventative maintenance service by the vendor during October. w Flow GPM Jan. - Ave. Max. 788 948 Feb. - Ave. Max. 756 773 Mar. - Ave. Max. 669 760 Apr. - Ave. Max. 743 930 May - Ave. Max. 730 881 June - Ave. Max. 670 722 July - Ave. Max. 780 840 Auc. - Ave. 972 # Max. 112 3 Sept. - Ave. Max. Oct. - Ave. Max. Nov. - Ave. Max. 711 867 671 823 Dec. - Ave. Max. ABD00296640 TABU- 1 WATER COMPLIANCE WITH NPDHS PERMIT PARAMETERS BOD PPM LB./DY. 26 246 37 307 30 272 43 380 17 134 24 184 6 55 9 73 12 101 18 149 COD PPM LB./DY. 63 589 94 781 73 656 95 840 61 490 81 621 33 295 42 446 44 374 61 504 Sus. Solids PPM LB./DY. 19 170 31 279 27 241 34 315 26 214 45 367 10 85 16 130 11 95 14 129 Dj.ss. o- 6.9-7.3 6.9-7.9 6,9-7.6 6.9-7.5 6.6-7.4 10 75 19 143 25 196 44 332 20 154 6.9-7.9 28 234 - 11 98 14 126 31 347 75 788 41 387 60 590 63 707 143 1502 14 128 6.6-7.2 30 295 8 89 6.2-7.5 11 116 15 128 24 192 6 50 11 80 48 410 65 519 25 203 37 286 14 122 6.3-S.O 22 229 9 75 6.8-7.4 15 148 NPDES Ave. Max. 32 387 43 520 1390 1940 605 ;>6.o 909 ph 7.5-8.2 7.7-8.0 7.3-7.9 7.3 7.5-7.9 7.6-S.O 7.8-8.5 i 6.6-8.0 7.5-7.7 7.7-8.0 6.0-8.5 ABD00296641 J' ENERGY CONSERVATION - V. L. Thornhill I. Plant Operations Total energy consumption for October was 108.3 MMM BTU's. The energy consumption per pound of product decreased from 2896 BTU/lb. to 2812 BTU/lb. 1I. Plant Energy Conservation Program A. Steam Leaks Twenty-three steam leaks were repaired in October. B. Energy Reporting The Third Quarter Energy Report was issued in October. The plant had a 30.7% energy reduction compared to the 1972 Base Year. With adjustments for OSHA and EPA energy usage the energy reduction was 44.8%. i ITEM ABD00296642 ENERGY CONSERVATION DATA 1978 1979 Control Period Production, MM Lbs. Resin Dry 11] end Compound Plasticizer TOTAL Natural Gas October 24.1 6.7 3.2 0.9 34.9 October 28.8 5.4 3.4 0.9 38.5 Consumption, MSCP Conversion, BTIJ/SCI7 Energy Consumption, MMM BTU H1cctricity 54816 1020 55.912 56582 1020 57.714 Consumption, MM KL'Il Conversion, BTU/KW1I Energy Consumption, MMM BTU Propane. ' 4.646 10000 46.460 5.0496 10000 50.496 Consumption, M Gal. Conversion, BTU/Gnl. Energy Consumption, MMM BTU Tota 1 Energy Consumption, MMM BTU Energy Consumption , BTIJ/Lb. Boiler Operating Data None 102.372 2933 0.60 92000 0.055 10S.265 2812 No. 1 No. 2 No. 3 Avg. Stack Temp. 1978 1979 421 365 415 404 427 407 Avg. % Excess Air 1978 ;1979 102 27 98 26 125 27 A ABD00296643 ) MECHANICAL ENGINEERING - J. A. Dixon AFE's Submitted, Approvcd, and Closed The following AFE's were submitted and approved during October: AFE No. Title Authorized 9729 9739 ' 9749 9079 9089 Fire Protection Improvements Phase II Methocel Charge Revision Improved Rupture Disc Holders Cooling Tower Motor Repair Vibration Study - Capacity Replacement Reactors $490,000 66,000 27,000 17,800 50,000 The following completion reports were issued during October: AFE No. Title 9286 9187 9287 9048 9108 Additional. Slurry Blend Tank Emergency Reactor Vent Control Plasticizer Yield Improvement Test Resin Moisture Analyzers Boiler Burner Replacement The following AFE1 s were closed to field charges during October: Authorized $290,000 33,000 6,000 17,000 170,000 AFC No. 9197 9257 9277 9178 9218 9549 9039 Title Dryer Area Noise Abatement Resin Transfer Debottlenecking Truck Loading Safety Revisions Propane Vaporizer Replacement Charge Water Heating Improvement Safety Equipment Repair of Storm Drains Authorized $ 45,000 56,000 16,000 175,000 32,000 15,000 25,000 Design Design work is complete for the New Air Header and piping for Emission Recovery Revisions. Design work is in progress on the following projects: New Air Compressor, Double Block Valves for VCM Charge, Improved Rupture Disc Holders, Dryer Operation Improvements, Emission Recovery Revisions, Reactor Inert Vent System, Phthalic Anhydride System, Automatic Plasticizer-Stabilizer h'eighup System and Portable Pneumatic 'transfer Unit. Contracts were let for the following projects: Installation of Piping and Equipment for the Instrument Air Dryer, Color Weigh Room Modifications, and Foundations for the New Air Compressor. ABD00296644 Construction 1. The painting of the lagoon chemical tanks, plasticizer tank 460, light poles and new reactors was completed during the period. 2. Concrete repair work behind the plasticizer building was completed. 3. The area west of V-ll was leveled during the period. 4. The shed for the inert gas generator is complete. 5. The replacement of the cabinet for the laboratory is complete. 6. The installation of the air cannons on 410 silo is complete. 7. The last four dust collectors were installed on the Resin Transfer Debottlenecking project. 8. The concrete stairway for the VCM railroad lead is complete. 9. The platform extension for the old unit turbine meter was completed. 10. A high level alarm was installed on the VCM receiver in the old module. 11. The new line III mill take-off conveyors were installed during the period. 12. The hot tap on the natural gas line for remote read-out. was completed. 13. The construction of number 2 resin settling pit is complete. 14. Construction is in progress on the following projects: Resin Settling Pits, Dryer Operation Improvements, Repairs to Dryer Inlet Ducts, Plasticizer Safety Improvements, Additional Dust Collectors, Silo Isolation Valves, Instrument Air Dryer, Additional Air Compressor, Installation of VCM Level Indicators, Double Block Valves for VCM ChaTge and Drains for the lagoon electrical pits. 15. Twenty-six register tickets were issued for contract work during October. ABD00296645 i 1 t) Mini '-i |.i (.) Thru M. r , 19 `9 V I ii 11 A. i inn : in.- . im SO. i'l St I'.ll'l 1>'N .mv. : -,D\ l\ MM" M ID\S n |V';l iw 11: VMM. aitudyit' M i v:i. 1 11 I \it : o TO DM! l.'l lOVM hid I'l DMI 1 !.\l. I.HAI 1 S 1 . ('DO i."|P, UNT'l I! (DU R) .VMM. \'li. I'l. 1 -;t. (.''ti', I IDS, IHI,_ DMI isi'iv:"- 9i7o I'Vl! Reactor ('opacity lu-placcacnt 7/8/76 8,.577,000 5,151,116 8,194,503 8,1 ' 1, M'S 58 2.495 17/V 8 12/79 Closed to field charges. 92sp Additional Slurry Hloinl Tan). 12/7/76 290,000 287 ,081 78.', 1)8-1 287.084 2 ,91 r. 12/78 10/79 Compict ion report issued. 90s: ni-17 Kes in Silo Aria tion 3/K./70 1'bthalic Anhydride exposure Reduction 6/30/77 2S0,000 4.6. not) 242,051 40.290 247,OM 14 ,039 2 13 ,05 1 4 t ,(>-> 37,9 16 961 12/78 12/79 Closed to I*i* 1 *1 t'lnr.ys. 11/78 10/79 Completion r.-p.'i-t issued, 918` 1 metj'.cncy Reactor Vent Control 9/2-1/77 53.0J0 32,317 52.517 52,517 453 5/79 12/79 ferapi c t ion report i sited. '.) 19 7 Dryer Area Poise Abatement 9/29/77 45,090 44.01) -14 ,654 45,000 556 10/79 2/80 Closed to field cl.,-.: yes. `>227 Plant emergency l.i gh: ing System 10/10/77 (.5,000 56,925 56,990 56,990 S ,010 6/Tp 12/79 Closed to field ch.-.r-fo. 9237 Heated. I'last ici ror Addition System 10/11/77 37,000 8.350 12,701 37,01)0 0 3/80 6/SO Design in progress. 9247 Carrel 1 Mixer feeders 11/21/77 47,600 32,152 33,712 47,000 0 11/79 2/SO Convevor insta 1 I at i,-n schcdulr '9257 Resin Transfer Debottlenecking 11/16/77 56,000 45,902 55,596 56,000 0 10/79 12/79 ClnseJ to field charges. 9267 Dry Blend Production expansion 11/2.3/77 20(1,01)0 203,706 203,706 203,70o (3,706) 5/79 12/79 Close.! to field charges. 9277 Truck bonding Safety Revisions 11/28/77 16,000 14,929 1-1,929 16,000 1 ,07) 10/79 12/79 Closed to field charges. 9257 Plasticizer Yield Improvement Test 9297 Automat ic I'l ast >r i rcr-Stnbj 1 i ror Keighirp System 12/3/77 '12/14/77 6,000 60,000 3,514 49,600 3,5-14 56,557 3,544 60,000 2,456 0 5/79 10/79 Couplet iost report issued. 13/80 6/S0 nsta 1 l.it ion scheduled. 9307 Compound Project Conveying bines 12/14/77 50,000 37,632 42,878 50,000 0 11/79 2/S0 Installation scheduled. 9028 Miuccl l.ancous Items HttJer $10,000 1/31/78 50,000 44,070 4-1,070 41,070 5,930 12/78 12/79 Closed to field ch-rges. 9048 P.esin Moisture Analyzers 2/24/78 .17,000 13,729 13.729 13.729 3,271 5/79 10/79 Completion report issued. 9078 mw Miscellaneous Projects Under $10,000 2/24/78 Replacement Inert (las Ccnerator 3/28/78 166,000 44,000 Sew Compound bine 4/17/78 2,,030,000 160,248 43,783 160,248 ' 160,245 43,984 43.9S-1 1,761,117 1 ,965,144 2,0-6,622 5,752 16 12/78 12/79 Closed to field charges. 8/79 2/80 Closed to field Chiracs. (2(,6?2) 12/79 3/SO Concrete t-orl. coupUtcStructural erect io:. work proceeding. I ngi-ieering completc. 9108 Boiler Burner Replacement 5/12/78 17(1,000 108,640 168,640 168,640 1,360 8/79 10/79 Completion report issued. 9118 Plasticizer Chemical l-xposurc Abatement 8/21/78 152,000 107,487 12-1,250 152,000 0 12/79 3/S0 Installation proceeding. 9188 lire Protection Improvement s-l'hasc J 9/19/78 176,000 29,998 38,624 176,000 0 12/79 3/79 Drawings being revised. 9178 Propane Vaporizer Replacement 9/21/78 175,000 161,968 172,156 175,000 0 10/79 1/50 Closed to field charges, 9188 Railcar Resin Heel Cleanup System 10/12/78 5S.000 3,643 41 ,951 55,009 ' 0 12/79 3/80 lest run sclicdiiled. 9198 Ocbot 11 cnecki tig-fcut t i fuge Anti-Chat ter Devices 11/7/78 70,000 65,943 65,961 65.971 4 ,029 5/79 10/79 Closed to field charges. 9208 Spare Recovery Vae.uui? I'unp 12/5/78 1-1,000 0 M .633 11,633 (633) 11/79 2/80 To ship in fUwcrabvr. 9218 Charge Vinter Healing, Improvement 12/8/78 52,000 31,906 35,277 35.766 (3.766) 10/79 12/79 Closed to field charges, 9228 Dry lilcnd Silo Alarms 9248 Silo Isolation Valves 92t>R Dryer Operation 1 nproviuv-n t s 12/13/78 75,000 12/14/78 25,1)00 17/14/78 355 ,<M)9 4,397 4 ,602 15,593 21,738 184,576 229,5)5 25 ,<KKl 25 .OOii M3 .DIM) 0 12/79 3/80 i'roiof/pe test in j-egresv. 0 12/79 3/S1' Sixteen of twenty -.Ives inst.i 10 3/R0 0/p.n ;ista: lat i on proceeding. 9.ri 19 Critical -pare IVpiipir-nl 2/6/79 Hi sccl 1 Vciects Under $l,tn)( 2/13/79 1/3,9(10 125,non 19,123 108,605 116,357 11 (..139 175,000 1 25,001) 1) 3/80 6/8(1 Purchases proceeding, 0 1.779 -V'V) forty [.r<jt- appr-.e-d. 9339 l.ah'-raU-.-y lipjip:.' nt 3/27/79 31 ,601) 19,500 3) .156 30,773 277 7/7!) 10/79 Clos'd to fi-ld cl.ar.'/->. 93 19 Safety l.'jui|im<:nt .3/26/79 13,1)0(1 3,573 14,8X7 15.001) 0 10/70 1/80 Uo'.'-l to field eh':,/.'., w9393 Color heigh I'ooi:i Modifications 4/19/79 Miscellaneous Projects Under $|O,000 3/8/79, Addi ti on 11 Of'firc Riia-c 3/11/79 95X9 Iir;i rum-nt Air Dryer 5/30/79 25,000 125,000 12,300 ! 111,000 153 48,891 11 .657 11,153 70,314 1 1 ,071 7i., ('13 25,000 1 75.000 1 1 ,97-1 1 0 12/70 5/-U) fontract awni-.l-d. 0 12/79 5/30 Thirty piojc. t . nj ; .-`-.od. 5 26 8/7`i ll/7o Close-! to l i-!.! ibi-,-/. . 12/ lust -i 11-it ion pro. !:ng. ABD00296646 |]| Nil n .vi't i'wl'i ! , ];'!> -\c 111 >1 \ (.`I 'Hint (>. , f'7!> ..nt tug AW i;in I \ A"!!1 > i \| tnv. i;i ivr I AIHII. m ^|);l CAP ITU. (cont i iiih'.I ) I1' Si Kll'l TON Reactor Jacket Mod i t`i cat ion <TOO? tUvactov Inert Vent System I'MI. Al'lll. .VTluiVI 1' ah cal'. (./t/79 6/28/79 .'1 ,000 90,000 in r \fi m : o 10 l>\l! TO' 1 il o IO I'MI 1 ISM TOi'.l I'M, O' 1 n',iP. UNIT U (ini k; Milll, '.'11, 1 si, I'M. i ir:;, 1 IMS. I'M- I'MI R!'Hits 18,91.6 0 21,000 9,999 .'1 ,OD0 90,000 0 S/70 1 )/7' Closed to fi vlJ ch.uges. 0 3/SO (/Ri) Engineering in piegress. oo 9 haste I'atcr I'uvis ious-Part 1 7/5/79 l Ht.ooo 5? , 337 171 ,7(i5 1 10,000 0 12/-9 3/80 ln-t.il lal ioi proceeding. 11629 Air Compressor 7/9/79 3 10,000 3,133 1 1 ! ,67.' 340,OO0 0 12/-P 7/80 Pu:chases pr<iccecire. 91.39 Revisions to Finis:.ion Recovery System 7/12/79 ll'O.IKOl 2r. 1 1 ,4 13 100,000 0 3/8;' S/80 ling;:.erring in progress. 91.19 Double IHock Valves for Vt`*1 Charge 7/18/79 182,000 0 35 ,033 182,000 0 1/9.' 3/80 l.nginewinp in progress. 9(..r.P P A System Modi f ical ion? 7/10/79 3S,I10U ir.,-113 71 ,7"'7 3S.OO0 0 11/'9 7/80 FRgii.ee ring in p:og-:s. 9609 New Air Header 8/19/79 rs 1 ,031 4,le? 23,000 0 12/-9 3/80 Engineering in pteg-esj. 967? Plant Winteritation 9/9/79 1.1 ,000 0 IS,000 61,000 0 12/79 5/80 Inst a 11 at iei proceeding. 96S9 Mi 1;ilift of Sphere and Curbing of Drum Storage Areas 9/19/79 170,000 0 0 170,000 0 3/fO 6/80 Engineering in pr`gross. 5U.09 Plant Dryer Pebot 11enecking 9/1 S/79 80,000 0 0 60.000 0 3/60 6/SO V.ngineeving in pogtrsr-. 9709 Facilities for Multiple Grade Resin Production 9/20/79 870,000 0 0 670,000 0 9/ff 12/S0 Engineering in progress. 9719 Aberdeen PYC Resin expansion (Partial)9/JO/79 850,000 0 0 830,000 0 9/50 12/SO Equipment quotes being obtai 9729 Fire Protection Improvements Phase 11 10/1/79 490,000 0 0 190,000 0 10/60 1/M llngireering in progress. 97 W Methocel Charge Revision 10/3/79 60,000 0 0 66,000 0 6/SP 9/R0 Engineer i njj in progress. 9749 Improved Rupture Disc Holders 10/22/79 27,000 0 0 27,000 0 1/80 7/60 Engineering in picyt.'ss. {11 Thru September, 1979 Actu.il tcc.nmting (2) Thttr October, 1979 aih:nin.HN' ahihokilvi tons urt out AM i ll. EXPENSE VO, niisciumos DAT C ADI 11. APPROVED ALL AMI. (') EXPENDED TO HAIL (?) PINAL CD.'i'ii i n n TOTAL LSI, TO f'VTI. _ OTM COMP, UNM'i.: CU'.T-Kj All ill. AMIN LSI . l!ST. C(V/>, n.us. DATT n.tu; RL'-IA'TKS 9238 9019 9029 9039 9049 9059 9069 9079 9069 Compound Line I Roof Collapse 12/13/76 Repairs to Large Pxactor Gearbox 7/7/79 Repair of Steam Tracing 6 Insulation 9/5/79 Repair of Storm Drains 9/11/79 Repairs to Dryer Inlet Ducts 9/13/79 Repairs to HvstpstcT Storage Area 9/13/79 Centrifuge Rotors Repair 9/13/79 Cooling lover Motor Repair 10/22/79 Vibration Study-Capacity Replacement 10/29/79 Reactors 44,000 22,000 62,000 25,00(1 25,000 20,01)0 47,00(1 17,600 SO,000 43,739 S, 206 6,61ft 21,708 G, 090 17,118 21 ,312 0 0 43,739 17,651 51,ft&2 21,708 15,223 17,118 21,317 0 0 43,739 22,000 62,000% 23,000 25,000 20,000 47.000 17,800 50,000 261 0 0 0 0 2,882 0 0 0 8/79 10/79 Closed to field charges. 10/`9 12/79 To be received in Crtober 12/79 3/80 ' Installation piocee-ing. 10/79 12/7? 63/87 /RO Closed to field charges. Installation scheduled. 10/79 12/7? Closed to field charges. 12/79 3/80 One rotor teptiveJ, 1/50 4/60 1/86 1/SO Motor being repniici. fingirrering by ('I'D, MED t * ' ) ABD00296647 LABORATORY - R. D. Jackson Customer Res in CarIon Cerro Wire Cerro Wire Cable Cable CUSTOMER COMPLAINTS Product CompInint S305 53S5 5385 Contamination Fusion Time Streamers WAIVERS RECEIVED Number Status ARP-092879 ARP-101679 ARP-101679 Report by CRM Report by RDJ Report by CRM Date Identification Product 10/1 CONX 45290 5305 10/3 T-l 5385 10/3 7-24S1 5 385 10/4 T-l 5385 10/4 T-2479 5385 10/4 T-l 5385 10/5 PTLX 41654 ' 5385 10/5 PTLX 41624 5305 05 T-l T-7768 5385 5385 10/9 01105 Bags 5385 10/9 T-7769 5305 10/10 T-7769 5305 10/12 CONX 45254 5385 10/12 P'LCX 4 3716 5385 10/15 PLCX 43101 5385 10/15 PTLX 41S43 5385 10/16 PTLX 41611 5385 10/17 PTLX 41656 5425 10/18 PLCX 43235 5305 10/19 Nine. Bag Lots 5305 10/22 PTLX 42016 5385 10/22 PLCX 43743 5385 10/24 PTLX 41608 5 385 10/25 00S58/00S39 Bags 5385 10/30 00152 Bags 5305 10/30 01214 Bags 5425 TOTAL 27 Customer Reason Carlon RVCM Certain-Teed Particle Size World of Plastics Particle Size Certain-Teed Particle Size Certain-Teed Particle Size Certain-Tced Particle Size World of Plastics Particle Size Carlon RVCM Certain-Teed Particle Size World of Plastics Particle Size Eximp 1 at Dry Time Intex RVCM Intex Bulk Density LCP Bulk Density/Particle Size World of Plastics Particle Size LCP Particle Size LCP Particle Size World of Plastics Bulk Density Uniroyal Contamination Carlon RVCM Export RVCM Carlon Particle Size Charlotte Pipe Particle Size Charlotte Pipe Particle Size Implavin Particle Size Uniroyal Viscosity Nylcx Dry Time Waived by CCD RDJ RDJ RDJ RDJ RDJ GGD GGD RDJ RBM GGD GGD GGD GGD GGD RDJ RDJ GGD GGD GGD GGD GGD CLS CLS CLS CLS CLS ABD00296648 PRODUCT DEVELOPMENT AND SERVICE Ship Date 10/2 10/2 10/9 10/10 10/10 10/10 10/16 10/16 10/23 10/23 10/25 10/30 10/30 10/30 10/31 10/31 Product Quantity C Lb s .) 5505 10 36861 Nat. 2 VRP 1 Gal. J-50 Methoccl 100 5385-1 10 5425 10 44461 Black 100 5305 50 35851 Nat. 100 -34431 Nat. 1000 35851 Nat. 1000 90171 50 5425 50 5465 50 5385-1 5 5425 5 5465 5 5465 50 15041 Cl.Bi .50 50 16851 C1.B1 .50 50 Customer D.G. Shelter Products Conoco, Ponca City Diecks 8 Diecks Conoco, Ponca City PMC Incorporated Orange Products, Inc. Conoco, Ponca City Fritz Air Freight Phelps-Dodge Cable 8 Wire Conoco, Ponca City General Cable Corp. Vinvlcx of Tennessee O'Sullivan Corp. Bcldcn Corp. Burgundy Plastics Wiman Corp. Requested by PCM JRT CLS DW JFN RNG T. Tuckett JPM CLS RRM NT! 1 PCM PCM MAS MAS MAS - COMPOUND DEVHLOPMENT AND SERVICE Special Confound Testing Two (2) production lots of 34861 Gray.546 and one lot of 36861 Natural were tested and released for shipment to Western Electric. One production lot of 34533 Natural was approved for shipment to Packard Electric. New Compounds and Colors Specifications and quality control standards have been established for ADK-5972-134A experimental compound for Material Control and Superior Plastics. Elcctri-Flex has accepted a new gray color submitted to them. It uses a standard Wilson gray color concentrate and will be supplied to them in experimental compound JRT-3866-195 Gray 550. Dry Blend Development Multiple laboratory Welcx batches of 80172B and 90171 were made for use as quality control standards. Tests were run to see if 80274 dry blend can be worked off at 10% in S0172B and/or 80273G. The blends varied sufficiently from the control compounds that when combined with normal production variations the blends might not meet specifications. When 30% 5465 was used with 70% 5385 in the 80275G formula, the Brabendcr properties were very close to the control 80273G properties. ABD00296649 i QUALITY CONTROL TP.STINC Resin Regular Samples = 096 Bulk Shipments = 185 (Railcars = 92, Trucks = 93) Other In-Process Samples = 3178 Dry Blend Blenders Produced = 569 Blenders Adjusted - 0.5% Bulk Shipments = 58 (Railcars = 22, Trucks = 36) Blenders Tested = 311 Other In-Process Samples = 88 Compound Blenders Produced = 584 Blenders Adjusted = 6.0% Bulk Shipments = 25 (Railcars = 6, Trucks = 19) Other In-Process Samples = 50 Resin Heat Stability Thirty-six blends of resin were tested for oven heat stability. They were distributed as follows: 5385 - 16 Blends 5425 - 12 Blends 5305 - 8 Blends While one (-1) blend of 5385 was .15 minutes poorer than the control, all types averaged better than their controls. RVCM of Shipments A total of 105 bulk shipments were tested for RVCM in October. A summary by product is listed below. Product . 5385 5425 5465 5505Dry Blend Average RVCM No. of Samples 1.5 63 0.7 2.1 7 .1 8.0 IS 1.0 17 --Raw Ma-te rial Testingo . Thirty-two (32) lots of plant raw materials were tested and released. There were no rejections. ABD00296650 \ SPECIAL PROJECTS Vplume Resistivity of Resins Recent production blends of 5425 and 5465 resin have given acceptably high values for volume resistivity. Blends of 5385 resin stabilized with PC-555 anti-oxidant gave volume resistivity values close to the 5385 control resin. RVCM of Slurrys The results of RVCM analysis on reactor slurry samples were good in October. The daily average did not exceed 400 ppm during the month. A total of 668 slurry sample were tested out of 682 batches made. This represents 97.9% of the batches tested. RVCM Dryer Samples (5305) During October 92 dryer and 5305 resin samples were tested for- RVCM. The average for these samples was 16 ppm. RVCM of Blowdown Tank Water A total of 195 samples were tested for RVCM. The average for October was 3 ppm RVCM. Lab Computor Programming is essentially complete. -We have encountered a circuit board defect and are working with the manufacturer to resolve the problem. ; ABD00296651 SURFACE TRANSPORTATION abeko-en distribution warehouse OCl^R ACTIVITY REPORT, 1979 Shipirant by Product -ll/lbs Resin Plasticizer Dry Blend Compound Total Number of Shipment by Mode October 22792 164 5153 3347 31456 Resin - Bulk Package Export - ABR Plasticizer - Bulk Dry Blend - Bulk Package Coin^uRd - Bulk Package Back Rauls for October R/C O.T. C.C. 75 50 17 32 162 - 15 23 19 2 8 14 5 1 2 4 6 106 255 47 18 1 Number cf Shipment by Month- Year-To Date R/C O.T. C.C. January Pebuary Ma rch April May June July August September October 103 101 110 117 148 154 120 132 125 106 166 119 145 191 153 143 65 131 227 255 12 10 21 11 14 13 '1 2 48 47 Year-to- date 210555 870 41883 39111 292419 C.O.T TOFC 1 1 CPU TOTAl 25 167 7 13 177 44 14 57 4 26 19 30 69 478 C.O.T 7 0 2 1 1 0 0 0 0_ 0 TOFC- 7 3 8 4 10 2 2 0 8 1 CPU TOTAL 56 351 36 269 49 335 42 366 40 366 34 346 43 231 77 342 92 500 69 478 i \ SAFETY REPORT Lost Time Accident Doctor Cases First-Aid Cases Man Hours Worked ABD00296652 . OCTOBER ~0 '0 Q___ 2195 ______ 23646 GRAND TOTAL SINCE L.T.A. 136962 .MATERIAL HANDLING REPORT M/Lbs. Packaged Resin From Production Packaged Compound, Dry Blend From Prod. Transferred Freni Main to Prairie Transferred From Prairie To Prairie Re'Apo Transfer Resin to Plant Re\Wse Transfer Cmnd. to Plant Shipment From Warehouses Special Packaging Transferred From Prairie to Main 6480 1660 . 2835 0 365 81 , 8859 7169 1215 28674 LABOR REPORT Total regular-Hours Total Overtime Hour Total Worked Paid but not Worked Total 1553 162 1715 0 "1715- Labor Efficiency equals 28.7 MM/Lbs. - Hours Worked 16720 Overtime % 10-6 i T/L 160 41 70 0 9 2 219 177 30 708 i^iOj^ku]jLUiQ!Lt ABD00296653 Lift Truck Hours Worked 379 Gal of fuel Consumed 500 G^^Oirs 1.3 Lift Truck Efficiency Equals 28.7 HM/Lbs. - Hours Worked - 75657 Lbs./hr. PIT-GRADE HI STORAGE MATERIAL Sifter Overflow Resin "BC" Resin "If Mill Scraps Compound "B" M/lbs. 135 468 524 50 448 T/L 3 12 13 . 1 11 Compound "If Dry Blend "O.G." . CI1RYSLER STORAGE TOTAL 46 ?-l 1692 , 1 ......... I' 42 , . Balance, October 936570. 23 Transferred during month TOTAL 669100 267470 17 6 D.E. OPERATION . Our packaged goods inventory dropped 1.2 MM/lbs. during the month. The reason for this is that export shipments were slightly higher than the month before. We were shipping as fast as resin production was packaging material. - ^CATION MAI II-East TOTAL M SQ. FT. 48 Prairie 12-1 12-2 12-3 12 22 21 12-4 A ^ 12-5 22 21 12-6 21 12-7 12-8 21 21 Total 20.9 ABD00296654 CONOCO TRANSPORTATION ABERDEEN WAREHOUSE CONTENTS Compounds Dry Blend Export Resin Conoco Resin Compound Resin Export Resin Conoco Export Resin 5.3 .2 .3 .2 .2 1.3 .3 Conoco Resin Resin O.G. Mill Scraps Cmpd 0. G. Dry Blend 0. G. Sifter Overflow Resin 0. G. Compound Dry Blend Raw Material Resin 0. G. Conoco Total on Hand Chrysler Resin .1 .2 .4 .1 % .2 .2 .6 A ESTIMATED MM POUNDS - ON FLOOR OPEN TOTAL 6-0 4 -0 ' 10-0 .2 1 .3 1.5 1 .3 2 .2 3.5 .3 3 .2 3.5 .3 3 .2 3.5 2 .0 2.5 .4 .6 9.6 ( -3 3 . 1 3.5 2 . 9 3.5 3 . 5 3.5 25 . 4 ) 35-0 . Total Conoco 9/3 Ahl.RIM.i.N OSiIN00KI1.5 12 MONTH MOVING AVI-RAW: 20 15 10 5 0 l 12 MONTHS MOVING AVHKAGH so 45 40 35 30 25 20 15' 10 5 0 months 46 3 2 9 0 ' < % ABD00296657 MONTHLY DOURLY TURNOVLR ABD00296658 Vvj it / MM Pounds Monthly 50 25 20 15 10 5 0 7 6 5. 4 3 2 1 0 7 6 5 4 3 2 3. 0 .0 .5 .0 .5 0 ABD00296659 ABI-RDHIiN PLANT PRODUCTION 1979 MM Pounds Cuiiui 1 at i. vc A 350 500 250 200 150 100 50 0 io 79. BOUGHT ACTUAL 70 60 50 40 50 20 10 0 20 15 10 5 0 A U l. U1 >jAlBDDQg9666q ' H!! l.MCV >M 1970 POUNPS 01' RAW MATRRlAL/POUNP 01: PRODUCT A 06 04 02 Stamla nl 1.01960 00 06 04 02 00 03 0201 00 PLASH Cl ZI:R RAW MATMRIAL CONSUMPTION 20 13 Standard 10 1.120S0 03 00- n n u t Mi'if [D ocrnpi Din-iM u> 79. 4f -,Vk_A t Off Cr;ulc Al'l l.l'l f.,' ' 197 f) Stnndnrd 0.40 Standard 0.730 Stnndnrd 2.0 MM Pounds 1.1 UM l.i 197!) N'lOIll l:N A