Document 0gerQ11N5zB4N7ymEg59Y3XXn

To: T. H. Huffman * Interoffice Communication From: Date: Subject: B. C Skokna December 19, 1988 ABERDEEN MONTHLY PROGRESS REPORT NOVEMBER, 1988 Safety There was one first aid case reported in November, As of November 30, the plant's employees have worked 3,436 days or 4,500,865 manhours since the last lost time injury. Key Statistical Information November Y.T.D. PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb Flexible Compound Production, MM Lb s. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use (EUI %) Fixed Cost Variance, $M Variable Cost Variance, $M Variable Cost Price Variance, $M Variable Cost Efficiency Variance, $M 37.9 91.5 95.5 1.0146 5.6 92.9 5.6 99.8 1.8 92.3 ( 4.0) (60.8) 498.2 501.8 ( 3.7) 76.5 91.5 95.7 1.0158 12.5 92.9 12.5 99.8 3.7 93.1 ( 1.7) (78.6) 900.7 992.9 (84.9) Costs Fixed costs were above budget due to costs associated with the Coker water test run, holiday pay, and benefit clearances being higher than budget. Variable costs were essentially at budget. -ttv fliiii mm wmm mm m VAB.0001190668 T. H. Huffman 12/19/88 Aberdeen Monthly Progress Report Page 2 h - A task force, consisting of plant, PED, and R & D members, was formed to determine the causes of 5305 resin contamination. - A presentation was made to Purchasing and Manufacturing management concerning a revised raw material supplier partnership program. "p, C, s D. C. Skokna Plant Superintendent rah lipM 1-' 1 P-.,^P^ 'dH VAB.0001190669 y - .Ji,: W: K 3. ;i:-! -p1 :i.-: Vui:* <., <l --a?* DlSTOIBtrrijON HOUSTON: PONCA Cm: COVER LETTER J. D BURNS X R. T FERRELL X T. H HUFFMAN C. J MATSON D. F. HAFMAN H. R. FLAFMER R R. SMITH K. J. ROGERS R. H. GERLACH S. E. MCGUIRE R. L. POE H. J. HALL ENTIRE REPORT X X X X X X X X COVER LETTER AND QMP * OKLAHOMA CITY: H. G. GARRISON X LAKE CHARLES V(M PLANT R. A. CONRAD X LAKE CHARLES CHEMICAL PLANT: J. FRIEND Safety Section and X TAKE CHARLES LAB RANT: J. W. WARE X BALTIMORE: L. R. BAUER X HAMMOND: J. B. MAHER X BLANK POLYMERS: REM1ERE POLYMERS: C. R. MILLER P. L. FOOTE X X ABERDEEN: VMMiiiMmM' FWS/DCS (FILE COPY), PJK, JEN, DWH, TEL, JEB, VEM, HGC, JEL, E KBN, BIT I--rrw-vy*wn . lHHmi|UJUmrttMt^rh?<BMi|*UgK*Hti:rrv^r^ing>; r.!%--i!:i<- i:: -......... - -........... '1 S TTT^WVj IM VAB.0001190670 +?: *tt+ <1|- T* JJEh>M :|1 :.-,Lr*K`hSif!**si' V*f T"'- r : !i: .k: . h SAFETY - B. L. Trego Occupational Injuries November Fiscal Y.T.D. 1989 Fiscal Y.T.D 1988 First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 1 JO 1 0 0 3 0 3 0 0 3 0 3 0 0 Injuries by Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 00 00 13 00 00 00 13 0 0 2 1 0 0 3 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 01 00 00 12 00 00 00 13 1 0 0 2 0 0 0 3 Non-Qccupational Injuries Lost Workday Cases Days Lost 11 14 14 Safety Record Last lost time injury 7/5/79 Days since - 3,436 Manhours since - 4,500,865 On November 30, 1988, the employees at the Aberdeen Plant completed 3,436 days with no lost time injury. i Topics for the plant safety meetings during the month included: Contractor Safety, Annual Fire Training, Annual Health Training, and Maintenance Weekly Safety and Job Reviews. Annual health training and annual fire training were both completed during the month. p.. ... r I+| ^ | . Tfl|l . . . <i.* -i- l j-H-lc I tmjp lHu -- l' `i l: -I- Jut: t. n VAB.0001190671 i i:..- ..j--rL.-. .vs- U"MMK4i ^S-rip- n .n ;i +.1 7Trt,i: J! :l :v e -i i. , ; 11 . - SAFETY - Continued Routine dosimetry for the month were as follows: Chemical Number PEL Percent / Number PEL Percent VCM 78 100.0 Lead 18 100.0 Total Particulates 4 100.0 0 0.0 0 0.0 0 0.0 Monthly Injury Summary Injury Class Department Description FA Maintenance Bruise, right knee. h . i :i 'Li sir-l-4 in-fin-. + -vf ............ >*:<. VAB.0001190672 J m'* G in-s1W- -:SSi :. : -+?j9t `-rn TFTTnir'^^^^r^^i j-Ft,;Hj'|-`Hl-0|Fr. Ml li- -.. r:i r of)i|M|:=i->3nWfc Ki wmmiu.1 ^ -, s3jynrNt jo ujowrn VAB.0001190673 r - S |-^' - - rt'TlInfl | - - E 1 :. ::!!!?* I Tf t Tv |- c-r.|. ii-h. .. n. -Jii ill. : r 11 J i... t i|: |fi' Mmnmpfr: ni:-M ^ ,n. .. f' . I '-- .I,nil !_ L -LUU'i QUALITY DEVELOPMENT - D. W. Hollis General Plant The Plant Manager's Natural team met twice during the month. The members of the team are doing a time study to identify areas that can he changed to be able to devote more time to QMP. Bob Schettek and Dave Hollis made a presentation to Purchasing and Manufacturing management concerning a revised raw material supplier partnership program. Administrative Services No QMP activity was reported this month. Compound The Compound Supervisor's natural team met in November. The meeting included review of Ford's Failure Mode and Effects Analysis (FMEA) program and a discussion of possible ways to implement this system. The metal detectors upstream of the dicers on Lines I and III were placed in operation. These instruments will shut down the dicers upon detection of metal thus preventing dicer teeth damage. Lab SPC charts were sent to Southwire for their 1220-06X compound. covered the fourth fiscal quarter of 1988. The data All six Lab Natural Teams met in November. Mechanical There are three active project teams in the Mechanical Department. The Mechanical Superintendent's November Natural Team meeting topic was "How to Remove Barriers that Inhibit Project Team Progress". The Maintenance Engineer collected team data during November in preparation for the December Commodities Quality Improvement Team meeting in Lake Charles. Software supplied by our water treatment vendor is being analyzed for on-line water treatment variable charting. VAB.0001190674 -T Zr- - i j= Crt.- -ill #li=,l*sP : k. sr"n .|,ri- <,[, re i-l.lh: t >. - -f I :i i; i. . it** QUALITY DEVELOPMENT - Continued Vinyl The Department Natural Team met twice during the month to coordinate day-to-day operations, brainstorm ideas and provide support to the Klockner Contamination Team, discuss involvement teams and to continue work on the Quality Implementation Plan. Four Employee activity teams continue to be active in the department: The 5265/5305 Contamination Team continues to be active in pursuing a resolution to the contamination problem and are contributing to the "full time" technical team that was organized in November to pursue a more timely resolution to the problem. The V-ll Dustbusters are in the process of upgrading one of the five screeners to demonstrate that their proposed solutions will be effective and thus justify further expenditures. The Plasticizer Loading/Unloading Team did not meet during the month and f,CM Shift met with PED-Houston to complete the hook-up station design for the low molecular weight expansion design. Process Engineering Natural Teams met five times during this month. In two of the meetings J.E. Nickerson, Operations Superintendent, and T.F. Lyon, Mechanical Superintendent, spoke to the Process Engineers on "What Do I Expect From a Process Engineer?" These talks were recommended by V. E. Messickfs Natural Team. An experimental design was conducted to optimize Dryblend transfer rates from the blenders to storage. This design showed that transfer system improvements and correct operating conditions have allowed a 40% decrease in transfer times and eliminated the transfer system bottleneck to bulk silos. * S'lMi-bi I - r n IH r : H i|'' VAB.0001190675 ! ........ ...................... ............. nmk nmu hh m\inm mm* him mum COST VARIANCES - D. C. Skokna Variable Costs Product PVC Flexible Compound Rigid Compound Plasticizer Total November, 1988 Variances - $M Efficiency Price Total $16.6 (32.2) 38.6 (26.7) $(3.7) $403.4 6.8 30.4 61.2 $501.8 $420.0 (25.4) 69.0 34.5 $498.1 PVC Variances - Efficiencies were essentially at budget. Flexible Compound - The variance due to product mix was an unfavorable $28.5M, with other variances near budget. Rigid Compound - The product mix variances ($21.OM favorable) and TiO variances ($21.7M favorable) were the primary contributors to the overall variances. Plasticizer - Alcohol and phthalic anhydride consumption were both above budget. It is believed that this is due to underestimating the plasticizer (610P and 108P) usage in flexible compound. The low estimate causes an unfavorable variance in Plasticizer with an offsetting variance in flexible compound. The total effect (Plasticizer variances plus the 610P and 108P variance in the compound) is slightly favorable. * i </> Price Variances VCM (including freight) Alfol 610 Polyvic 5202 TiO? 610P D1DP Other Price Variances Total Fixed Cost Variances Payroll & Benefits M. M. & C. Miscellaneous T. I. & D. Clearances Total $396.4 61.4 15.0 13.1 12.9 (10.0) 13.0 $501.8 $M $(69.4) ( 4.4) 20.8 ( 4.5) ( 3.3) $(60.8) VAB.0001190676 -|i |3 .a h m j -">-h i1.ii.v.hli hbrnd-M COST VARIANCES - continued Payroll and Benefits Overtime costs due to the two day Thanksgiving holiday and a higher than budget benefits clearance rate caused the unfavorable variance, M.M. & C. costs were essentially at budget. Miscellaneous - Moving/Home Assistance - Outside Professional Services - Unclassified - Operating Supplies - All Other Miscellaneous Items Total $M $14.2 26.3 (30.5) 13.6 ( 2.8) $20.8 VAB.0001190677 t " 41 .jx.. : _ -|i -t:. **:m |> iti! | ;h|- * ' ir-N'-J | . ,i j.. ; r,+: '=^4 Fi: . -t-I-: *.:|r:.''"S*?i............ ..i*| bkli4.ll .-i| I'M--4 3 ILI K- - ! N^-i OPERATIONS AND MECHANICAL DEPARTMENTS - T. Lyon, P. Kober, J. Nickerson OPERATIONS/MECHANICAL SAFETY There was one injury to a Mechanical Department employee requiring first aid. A General Mechanic suffered a bruised knee after tripping on some coiled cable. The Vinyl, Yard and Compound Departments worked without injury in November. The monthly safety meeting topics for all departments were health training and fire training. A VINYL - P. J. Kober, C. J. McDonald GENERAL 1. A test run using the Coker water as charge water was conducted this month. No buffer addition was needed. 2. An improved temperature controller (like the controller on D745) was installed on D700. 3. The resin raw materials in the 744 account were valued at $472.9M. November YTD Production, MM lbs Daily Production Rate, Mlbs/c.d. Total Reactor Charges Charges, Reactor Batches/c.d. Reactor Stream Factor, % Rotary Dryer Stream Factor (#4-#8), Fluid Bed Dryer Stream Factor, % Resin Quality, % Prime % 37.9 264 905 30.2 91.5 85.3 95.0 95.5 76.5 1254 1811 29.7 91.5 86.6 95.9 95.7 Reactor Downtime Hours - Operational Downtime (recovery scheduling conflicts, power failure, downtime to rinse chem wash tanks, new module rinse water/charge conflicts, waiting on particle size data before charging, flushing lines and false charging for Coker water test, inclement weather, unplugging BPA line to D745, inspecting D700 and D745 as part of Klockner contamination work, cleaning small blend tanks for Klockner contamination work, and no place to dump.) 292.7 i p r ^ , lh :*-hr.!+ : -tUltf M| i WW v* |J VAB.0001190678 II n . |it - - |i | pir| i - . I.*, f : ii .. z -it- i t VINYL - Continued Reactor Downtime Hours - Maintenance Downtime (hydroblasting and drilling condensers on reactors D700, D745, D741, D742, polyvic charge system repairs, replacement of transformer, repairs to D743 jacket, change agitator seal on D745, commissioning chem wash backflush filters, new unit recovery system repairs, and miscellaneous instruments and valves.) 316.8 Total Downtime 609.5 Dryer Downtime (does not include dryers #1 [pond] and #2). % of Total Downtime - Reactor limited production 64.9 - Operational downtime (centrifuge plugging, dryer cleaning, activator transfer problems, checking dust collector socks for leaks, flameouts, checking sifter screens, dust collector backups, lining up small blend tanks to dry 5305 [part of Klockner contamination testing], and a power failure.) 12.5 - Maintenance Downtime (dryer #8 air sweep, trunion roller on dryer #7 fluid bed exhauster, dryer #8 star valve, changing fluid bed screens, repairs to the fluid be screeners, replace broken socks on #8 and #4 dust collectors, and various activator and centrifuge repairs.) 22.6 Key Maintenance Work - D. A. Miller, J. R. Hegwood Reactor Area -- Reactors 700, 741, and 742 were shutdown for condenser drilling. Condenser drilling has increased in order to decrease the contamination level of the resin. - Reactor 745 was also shut down for condenser drilling, during which time the condenser base was hot bolted and Belleville washers were installed. The installation of these washers are part of the Reactor Bolted Joint Program started to improve the integrity of our reactor bolted joints. A new hydraulic torque wrench was also trialed for use by maintenance personnel for the rector bolted joints. Also during the month, the reactor agitator seal was changed due to an external oil leak through the weep hole. p< Kylsr! :|;-s !^= i J:.r ;;.cji+..................... r,fii-i .. -i* '!'.:p p-' VAB.0001190679 h _ l i:*i r'l ... j. . . f >11 h . ->^14 h C0`: c-7. + 'e-.fr-i 1 . r' . -it: VINYL - Continued A Reactor Area f. *1 - The chem wash backflush filters were repaired and put in service. - A small water leak in reactor 743 jacket caused by a cracked circumferential weld was repaired. - A new 881 reactor agitator gearbox was purchased as a replacement for an 805 gearbox due to high repair costs. - Silo 281 resin blower was replaced due to a split in the case of the old blower. - As an on-going part of winterization several shelters were installed around vulnerable areas in the vinyl unit. Several steam leak repairs have also been made along with the replacement of some old insulation in the vinyl unit. - Training for instrument technicians on the new SA module Modicon program using Compaq personal computers was completed. - Reactors 700 and 745 microprocessor based temperature control system was completed. This was done to improve the temperature control and consistency of the inherent viscosity for 5305 resin. - There were two major valves changed out in the reactor area during the month due to leaks. COMPOUND - J. E. Nickerson, J. B. Autrey General A new record for production of 90172D (326,323 lbs.) was set in Dry Blend on November 1. This is also a post-Univox installation record for Dry Blend. A second successful run of Chisso E2303 Black was completed on Line V in November. Flexible Compound Operating Days Production (M Pounds) Average Operating Day Fiscal Month Rate Y.T. Line I Line III Line V Total 29 1736 60 29 3056 105 21 804 38 5596 4032 6844 1614 12490 .I .fia>- ........... urr VAB.0001190680 K MhO-l-th40}, i . :."4<-infl-i-F.-i^n... f. . , ..... p :.p*j*nP-hP +41+11..* COMPOUND - Continued Downtime Hours Line I - Product Changes - Quality Problems and Control - Dicer Problems - Miscellaneous Maintenance - Transfer Problems and Limitations - Banbury Gate Repair 132 45 15 14 13 12 Line III - Product Changes - Quality Problems and Control - Transfer Problems and Limitations - Sweco Star Valve Motor Replacement - Mill Coupling Repair - Dicer Problems - Miscellaneous Maintenance 76 26 24 21 19 18 8 Line V - W&P Maintenance - Product Changes - Cooling Water Pump Repair - Transfer Problems andLimitations 72 55 7 6 Rigid Compund Operating Days Production - M lbs Month Avg./Day YTD Dry Blend Unit 28 5566 199 11204 Downtime Hours - Product Changes - Quality Problems and Control - Transfer Problems and Limitations - Miscellaneous Maintenance - Univox Problems 56 16 8 8 6 Operating Days Production - M lbs Month Avg./Day YTD Plasticizer 1818 63 3685 Key Maintenance Work - D. A. Miller, J. B. Hegwood - The Line V Werner and Pfleiderer compounder was shut down for repairs to its gearbox. The left pinion shaft splines that connect it to the compounder had become excessively worn and the shaft was in need of replacement. All bearings, bushings, and seals were replaced along with the left pinion shaft. VAB.0001190681 1 ! ' ' - !. i.": . W+J 1 -d : H 'i t I ll |||UK J-| J ir*la A1 i. > . 14 Nli-iwiijr-. 1 rll . ;(. COMPOUND - Continued Key Maintenance Work - The Line V cooling water pump for the Werner and Pfleiderer compounder was replaced due to severe corrosion. The old pump was replaced with a new Gould's standard ANSI pump. - Line III was shut down for repairs to the roll mill coupling. The roll mill back roll inboard coupling half failed. It was removed and replaced with a new coupling. - The Line I Stewart Bolling mixer discharge door hydraulic actuator failed. The actuator was rebuilt and reinstalled. UTILITIES - D. A. Miller, J. B. Hegwood - The west propane storage tank and all of the mixed gas storage tanks were cleared for inspection and installation of a capital project to upgrade the piping to current NFPA standards. Also, the relief valves were recorditioned. - The annual inspection and certification of the maintenance crane was performed and a one-day training course was held for maintenance personnel. - On November 22, 1988, transformer 7C failed causing a plant outage. The critical equipment to operate the plant was temporarily fed from Motor Control Center 7B1 and 7B2, and a rental transformer was located and installed on November 29, 1988. Testing of the old transfomer revealed a winding short that affected the turns ratio on one leg and would require the transformer to be rewound. It will take approximately six weeks for the rewinding of the transformer. - Three underground storage tanks at the Plasticizer building were filled with sand in compliance with new federal EPA regulations. - Repairs to #2 boiler were completed and all tubes were mechanically cleaned to remove any deposits. - Temporary repairs to a natural gas leak at the boiler house were made due to pin-hole leaks caused by galvanic corrosion. A new section of pipe is being fabricated and will be installed with cathodic protection. - Winterzation of the boilers and propane system was completed. VAB.0001190682 -1 . -p+gtth- 1 ENGINEERING - R. E. Polk, R. B. Newton, S. C. Hillman PROJECTS IN DEVELOPMENT GENERAL Coker Water Test Run Seven PVC reactor batches have been successfully produced using Coker water. There appear to be no significant problems with using this water. Design of the permanent water treatment facilities and wells for use of Coker water will begin in December. Low Molecular Weight Resin Expansion A field trip was made by GED to gather information for the estimate planning packages. Estimates are to be completed in early December for review and approval before the next budget issue. The project is expected to cost approximately $1.5MM. Klockner Contamination Team The team has concentrated on identifying contamination sources in the existing systems. A meeting is scheduled for December 13 to discuss results to date. Alternate Natural Gas Pipe Line A project design meeting with Gulf Fuels, Inc. is scheduled for December at the plant. A steam stripping test run was completed in November. The new steam stripping procedures reduced residuals by 30-40% from 120 ppm average to 80 ppm average. Steam consumption increased by 16%. Implementation of these new procedures will begin in January after operator training is completed. Noise Reduction Project An engineering services contract has been signed with a consultant to evaluate plant noise data to determine possible methods for noise reduction. Recruiting Campus recruiting has been completed. Plant trip offers have been extended to prospects. All plant interviews will be completed by late February. A fiH f|R + -`M'-f - :|. ' .up-'* ^r.. . :Hriv.M^Yj|r*w,(Hrl j,5rl ^4Dp||Kf. ihlIAh|^pfA^p4- pilUfrtUrp-lJ-ni*1 unqryir'fMfrMi^lHP n IS.: fi i M I rti.r-ll^v-wp kApE Wt -L<VHirf1-liji^r-Uh<:--'`{>:h VAB.0001190683 IItt cn it ii Si it UJ it tt M 8 IIfI II I! 8 II It II II II II CL SI II M II tl II U4 II II (I II It M II II II II If If Mtl It II tt Iu I tt cn S CD P tt IS cn =3 3 UM U UJ UJ 2tt UJ #-- tt =3 tt UJ s s s! d cn cn OC UJ St cn 3: m k S cn U cn cn ac UJ cn ccnn tt i ffi t uj gc s uB S3 3 oe u a UJ tt DC SBtt St u sm u z tn u cn s m Is <C UJ ui n z; d uj *- o <n S S iti S UJ t-4 UJ M p >* S ze h t **s "2"a *- cn UJ ** d t= uj as S a? a a uj cp uj cn UJ cn wB ai a ox c0n4 sr 09 U_ * * a cn s as ^ X UJ - UJ sh cn cn a 5 2 s cn cn j m uj 3 cn E cn i S! S8 ~ sss UJ cn cn cn cn UJ cn cn UJ SISI Q 5 S cn sc ~ s s 3 a acn a Huj I ~ cn cn a st s * sI . 5KmK _ fc--* Ob* ft* SC <C UJ Srn UJ a <n w x cn 3E w o> cn u cn cn &% uj ae z -J <n. , - ut cn uj z cn QO-UJUJUJUIKUJUJ o a s aoisSuiSDIuoSttl cn ~ S ai fe lt5a-lg cn cn *H CD XS OS UJ D S cn u cn % ses - cn 3UJ s s*- tf U-. UJ S S Eo u cn cn a; o cn cn cn uj K C x cn ae x x cncMn cwn Mcn ^cncnMcn cn US Zm cn Uccnn cn X*-* cn cn UJ (N cn cn ccnn j|ogUuJ i|^|gQeaQ^SKM UJ . mP ^n** * CD U * cn g tt UJ U O) r:d cn s s S UJ 2 & tt S s uS|2Sg d j-i Cui OK UJ (J XKOxuiSZ^KXKa,cn isdiiislii SS uZj tt S U U Q cn m co dsil cn c B cn cd uj U OL m U h- OQ UJ UJ UJ uu il cn cn cn u t-- UJ ii & M cn <c 3 u cn fe cn cn u cn ae: uj in in cn cn cn S 2 H- S cn cn sa cn u a cn uj cn g '"Bo & n* .... cn =z cn __i o- 2c2n I aSBB1 .iiS Suj u3 cn a s"-as *- cn as 5 cn cn cn cn sot uj cn cn O LU n dZ> KxCZD Of aex M *-4 UJ $ cn UJ cn u UJ Z uj uj 3E tt &; S S &i CD O UJ r* t iettci u = ae m m SS tt 55 * <c GU UJ ft- B -i c uj yj uj uj Z *" Ss g S cn 2 in r<4 UJ (J p Ny u-* Xh* uj UJ u_ uj ac - uj uS. <--cJ uj <_ci u-x q: cn a cn uj in uj a cn uj M h- UJ s 8 ti cn cn u cn u ENBINEERIN6 - R... POLK, R.B. NEWTO ,N S.C. HILLMAN in 3 -o -o in CM k> oo ^ m ^ 'oOo U. iOnO U. ^OD CO N'O CD QCON CD CD 0hO9 iCnM in in iinn in CmM VAB.0001190684 A ENVIRONMENTAL - F. G. Jeanson Water Permit excursions occurred at our pond #6 outfall on November 2 and 4 when we discharged 45.4 and 64.4 pounds of ammonia to James Creek. Our daily limit is 27.9 lbs. per day. Ammonia vapor is added to our ponds as a nutrient. The excursions occurred due to an overfeed of ammonia to our ponds. The problem arose when a flow meter was replaced in our ammonia addition system. The flow meter that was installed was not for ammonia service. Once the high concentrations were discovered in the ponds, the flow meter was found to be the problem and was replaced. We also reported to the State and the National Response Center that we spotted a sheen of oil from our outfall 003. This sheen resulted from rainwater runoff from the fire training grounds. Diesel is used in this area for fire training and apparently had been spilled on the soil. The soil in this area was cleaned up to prevent this from happening again. All other wastewater discharge parameters were within NPDES limits. Air Three-fourths of the completed this month. farm will be surveyed. annual VCM flange and valve survey was The new module, old module, and VCM tank Waste Management November waste shipments included: - One load of separator oil to Stauffer Chemical - One load of lead bags to Chem Waste - One bulk load of reactor culls to Sun Polymers Samples of pit #1, pit #2 and pond #2 were given to Sun Polymers for evaluation. Miscellaneous On Thursday, November 10, an eighteen wheeler carrying liquid stabilizer overturned in Starkville. The accident ruptured one of five 400-gallon containers. Vista personnel were quick to respond to this emergency, even though we had no responsibility. The result was the spilled liquid stabilizer was cleaned up and disposed of safely without any harm to the environment. The three underground storage tanks in the plant were filled with sand and permanently closed. An audit was conducted this month by a representative from the Bureau of Explosive. VAB.0001190685 I attended the Mississippi Manufacturers Association Environmental Committee meeting. "| ; s rjr|.i :ii. ... | . .. 1" r- I. f'. rj'l ..h * * -I ENERGY CONSERVATION - D. A. Moore I. Energy Conservation Data November, 1988 Fiscal A. Unadjusted EUI % (4.0) (1.7) B. Adjusted ElU % (5.2) (2.4) C. BTU/Lb. Product 2535 2472 D. Total Energy Consumption WM BTU 128.8 256.5 This corresponds to an unadjusted % CMA of 39.6% and an adjusted % CMA of 50.6%. A. Maintenance There were ten energy related items completed in November. Nine of these items were steam leak repairs. The remaining one was a steam trap repair. Steam The survey for the vinyl and plasticizer areas identified fifty steam trap items for repair. III. Boiler Operation Boilers Combustion Efficiency % Nov., 1988 F5C89 Y.T.D. No. 1 83.5 No. 2 (1) No. 3 83.1 83.5 Note: (1) Boiler number two was not used during the month. (2) Boiler number one was operated two days during the month. (3) Boiler number three was operated twenty-eight days during the month. <-im'!.4Pi.|c.Lh|sl-t*l-i>MPJI4tu.4 av-db-rJt^n lyrKyr,>s,vvH,rr.KP^^v,|: ,,m vi\tu rtgtefrUf yyUfjHot-HUMi imrtl|i||HBH>!H|lHl 'Ml H L-wfUf -T* * ** l>i- . jb.JT' VAB.0001190686 w ENERGY USAGE o cn cnj <r> BTU/LB tr> Zo > < u, UJ ^ '-"I ^ til r*~> 'X m amJ** V - r --hi i.,i 11 I Monthly 12-Month Moving Average * .-I-.- ..-1 ---J --"rTrL.~ ----------- --------------------------------1 j ~LI|- Tjll I.' 4" I'-KIV* i =g-.<-iMnFTw ufraw|w^PMPiF*w^^lH#w<4in VAB.0001190687 HUMAN RESOURCE REPORT PERSONNEL - J. E. Beall EMPLOYMENT Amy E. Vernon, New Hire PROMOTIONS/TRANSFERS None RETIREMENTS Willie B. Nails TERMINATIONS/RE SIGNATIONS None TO/FROM LEAVE OF ABSENCE None ... -.- -ii-i ir-'ifUi-vrr '-^r^HfT|^|3]4d!^pa<rKfl||. 99mm WIMflUPMl VAB.0001190688 ip-fL4ii7.fAf.p4M41. j |i ..-I i d ...L.. Aberdeen, Mississippi NOVEMBER, 1988________ MONTHLY PERSONNEL REPORT Salaried Employees Hourly Employees Total Employees Employees (Hourly) 78* 170 248 Minority Employees #, Salaried Hourly Total 7 6b 73 29% New Employees Terminations DEPARTMENTS PAR ______ 0 0 Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 0 0 0 # EMPLOYEES MIN. EMP. % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse Gen. Plant Maintenance Laboratory Compound Vinyl Plasticizer 16 13 41 24 40 33 5 16 14 39 24 39 33 5 7 44 0 0000 0 7 50 0 10 0 0 0 0 10 25 0 0000 0 4 17 0 0000 0 26 65 0 _Q D 0 0 0 10 30 0 0000 0 2 40 0 0000 0 Number of Applicants: Month 0 Year to Date APPLICANT BREAKDOWN: // Minority 0 % Minority // Female a % Female 35 0 Q. Hires (Hourly): Month Q Year to Date ]_p Terminations (Hourly): Month Q Year to Date 5 Overall Turnover p Projected Annual Turnover 3.2% * ' : -1 f'-H!' Iih r.^1. , .JH.. 1 . . 1 | i :.!f - s l": t VAB.0001190689 J *. If*"' ,F : ,j. ... k- s'l J S3 !jh y--,m -l" -T ,"iur.. . , ...................... OVERTIME AND ABSENTEEISM 4 0) Q mJ * L-l ,_i un CM 00 O Ov o Os HL >< 4-1 m -cr -o- i-H *a iH < on on 00 00 o >0a aaaaa on CM X Em 00 *i-4 to iH L--j- CO 4J .u CO o H 1--1 \o a un 00 a rH ,h on a o- <r o a un O on a r^* a CM O iH a o o a o o a on on a CM CmI o m K 01 o CM on on X v> un O on i-H rH O rH o o O o CM on CO 4-1 * * a * * a a a a a o CO to 0u1 <0 CO c CL) o o oJJ c pO CJ < on GO 00 o un un SO -4* a aa a iH on MT vO O o o i-H sO o O aaa a CM CM JO u n o X 01 4-1 u CO co 0) i-3 CA X < CT. Os *'0* so m 1--1 o o 00 CM on rH CM OS o CM CM i--4 01 6^ E 03 CO CO X 00 o o o vO <Ts on 00 CO OS as 1--( O Os i--l CM un 0) H * a 4 * *a E to 1--1 ^-| & 04 00 on HU 1--1 iH i--l rH T~\ 1--1 CM i--i 01u CO > o CM 0) X) Cfl ~o o Q> X x: 4J uc o0 u 1 C0 c lM o 3Z O X 0) & H 0) H 1- JO 0) to o> iH o u 4J c o o o o un o un o O o o CM o CM o o a Baaaa <T 00 un CM Os 00 00 r^ on Os CM <r i--i iH on io im i* io i iH i OS un un o un o un o o un CM CM m CM rs un CM un un r*. a a * B * a aa4 o 00 00 o vO <r 1--1 00 r- un Os vO vO vO un CM Oh iH rH un vO 00 00 rH <3- on a u c ao CO -T41 c 4-1 o to *H l-i 4J 0) Cfl Cl HO OJ Cl> c O H c *H tO -o CO -C TD ml Imk, X +T-* 4-1 in X H V CO OJ e o GC CO cX X o3 o 5u CO T3 C3 CO 00 0) Sn w cO *t3 oo *H c *1-1 X o to > C o *co to CO )-l 3 to O o *H X CO 3 to GO <U 3 o 00 CO cX *x 3 o M O u (0 a 00 tu QJ 3 l-i TJ 00 a<U c *H X 4-1 Uo 01 z > o 00 c OJ *H a o T3 013 rH oa X 0) u 0) 0) E> *H o O) e -a H <D E-* X W 4-1 O oo *H cO X u3 4-1 O CO SC c & t(o- 0) Ci O O O o un CM un CM o un o un O O o o O o O un a CM <1- Os rH r*- on on Ml* 00 CM T--| V un iH CM un 00 CM O CM OO o o 00 Os <3* 1^ v on m o on W CO o o X w Sg w CJ 2 < s lc <GO a6oozpoa xi >z1-4 <X0HGawGIuHHOO-n GObXIHOJ H3hIXIHH) C<HHZu -J 5uzLOU2a H*HO-<3 0) to > O I to 01 i 4-> 01 U Bo *H 4-1 6> 1*4 0) 01 > o to o> o CO 1-1 4-1 c o0 lM o 4-1 1 cc oo CJ> CSJ I .h K--,,. -fe. -: T-. --|+lj-|- - " i'l> ;]. i-. : 11 I.'. r A,; . I' rt ** ** ^ :.-|4^^l9rl rp a A * f i f* VAB.0001190690 L4 r-F- hi, J, -i *; T- ADMINISTRATIVE SERVICES - J. E. Little Safety There were no safety instances this month. Safety meetings included a review of outstanding ESAR's and disposition of same. Personnel/Training Amy Vernon started work November 7, 1988. She spent two weeks of on-the-job training with Linda Michels. Linda was released November 28, 1988, to assume her new duties as Production Scheduler. Cost Savings Savings due to competitive bidding were $5,042 for the onth, and $11,864 for FY1989. Savings due to discounts were $2,468 for the month, and $4,062 for FY1989. Meetings Dave Tarantino, LCCP - OASIS Manufacturing Representative, was in Aberdeen November 9 and 10 to develop test scripts for planned vendor demonstrations. Participants included Jimmy Autrey, Pat Wells, Linda Michels and myself. .`l 1 ! ,^i M |al jir HilH T-f.' >n ty 'fT: JC; d jLaU&ttJfcjfciWIIB h . r ^ L .ll-i^.-CLOl VAB.0001190691 Ml JJ -k.1 . H4. ku- i i .. _ - VK-c l' * A SHIPMENTS BY PRODUCT - M LBS. RESIN PLASTICIZER DRYBLEND COMPOUND TOTAL Nov. 1938 28,400 1,052 4,479 7,353 41,284 FI SCAL YEAR-TO-DATE 55,271 1,504 9,210 15,082 81,067 NUMBER OF SHIPMENTS BY MODE: i RAILCAR VISTA BULK RESIN-Bulk 122 51 - Package TRUCK VAN 1 TRAILER ON A FLAT CAR COMMON 1 CUSTOMER CARRIER PICK-UP CONTAINER 5 86 11 7 TOTAL 264 19 Export PLAST.-Bulk 1 Package 5 3 DRYBLEND-Bulk 19 5 _. Package 5 1 1 20 .. 6 9 1 30 25 Export COMPOUND-Bulk l&ckage Export TOTAL N0V OCT. 11 r 157 152 2 29 2 61 37 59 62 1 1 1 60 5 104 61 46 145 141 14 135 7 504 475 A VAB.0001190692 *J, LABORATORY - H. G. Coleman A. Safety There were no safety incidents in the Lab this month. The monthly safety meeting was the annual training provided by the Safety Department on VCM and lead. B. Customer Relations Customer Contacts 11/03 - Brian Harrison visited Vinyl Building Products in Oakland, New Jersey, to discuss dry blend colors. 11/03 - Brian called on Silverline in Plainfield, New Jersey, to discuss plate-out and Q.C. equipment. 11/10 - Brian visited Polytex in Pittsburgh, Pennsylvania, and discussed fines and moisture. 11/11 - Brian met with Thermal Industries in Pittsburgh to discuss formulation and color preferences. Requests for Corrective Action There were no RCATs received in November. Customer Problem Rej>orts Date Customer Product Reason 11/02 Hoechst Celanese Delaware City, DE 5305 Contamination. STATUS: Contamination confirmed; diverted to customer where contamination was not critical. 11/10 Klockner Gordonsville, VA 5305 Contamination. STATUS: Car re-routed to Hoechst. 11/11 United Thermal Plastics 269--66 BGE 346 Philadelphia, PA Brown streaking. STATUS: Could not duplicate problem on mill; suspect customer processing problem. 11/15 U-Brand Upper Sandusky, OH 90172D Fittings failed burst strength. STATUSi Prepared sample with KM-653 for evaluation; suspect segregation a problem with BTA-753. -T L-" .-i,.-: |.:*i -WrtfJ- VAB.0001190693 (.L-i'lJr.ti::---.'- ;si : r* 'i-pt t:-:- -.i-il- --r-|H I 'H ! . K-" r! 11. t 'WtH .i ti .p r> LABORATORY - Continued B. Customer Relations - cont. Customer Problems Reports - cont Date Customer Product Reason 11/17 United Thermal Plastics Philadelphia, PA 269-192 WHT 141 Static. STATUS: Another example of the lumping problem we recently attributed to a bad raw material. 11/18 Universal Manufacturing Gallman, MS 35852 NAT Excessive fines and streamers. STATUS: Product returned. 11/21 Uniroyal Mishawaka, IN 5385 Contaminant. STATUS: Related to glassies problem in October. 11/29 Vycom/Compression Polymers Various Dry Blends Poor extrusion. Scranton, PA STATUS: Brian Harrison to visit in December. Waivers Issued Customer Product Reason No. BP Performance 5415 Viscosity 1 R/C Essex 5415 Viscosity 1 R/C Essex 5415 Particle Size 1 H/T PVC Compounders 5415 Viscosity 1 H/T Southwire 5415 Viscosity 1 R/C Uniroyal 5415 Bulk Density 1 R/C C. RVCM Summary RVCM of In-Process Samples The following is a summary of residual VCM results on in process samples. None of the reactor daily averages exceeded 400 PPM RVCM during the month of November, 1988. Reactor Slurries 5265 Dryer 5305 Number of Samples Average, RVCM 905 133 28 0.4 76 0.6 A VAB.0001190694 jaiTlt+H'-* V LAB - Continued 4 C. RVCM Summary - continued RVCM of Shipment Samples The following is a summary of the residual VCM analysis of shipment samples for the month of November, 1988. Product 5265 5305 5385 5415 5465 Dry Blend Pond PeboK No. of Samples 46 107 34 74 0 Average RVCM, ppm 0.1 0.2 0.2 0.0 40 0.1 D. Resin Process Capabilities 5265 5305 5385 5415 Bulk Density 1.22 2.25 2.27 0.41 Inherent Viscosity 0.67 0.83 0.48 0.57 "L" Color Value 3.67 6.89 6.50 7.00 "A" Color Value 2.83 7.67 ?,B" Color Value 1.00 1.11 1.83 2.67 % on Pan (vs. 2% max.) 7.00 3.25 2.83 4.00 (0.67) % thru 14QM 2.22 1.01 1.77 3.36 Drytime 0.67 0.83 Mets l.R. (vs. 95% of Control) 0.78 (0.30) Hard Particles (% 10) 8.0 0.8 E. Compound Quality Summary Adjustments M IBs. (%) Hardness Specific Gravity Color/Clarity Contandnation Hard Particles Dicing Cross Contamination Metal Total 96.5 (1.72) 15.0 (0.27) 40.0 (0.71) 151.5 (2.70) Rejections M Lbs.. (%) 45.8 34.2 217.6 10.5 6.8 4.5 319.4 (0.82) (0.61) (3.89) (0.19) (0.12) (0.08) (5.71) 'I mr .4.' . :j Fl i*: ilt |.|iU4f|F*p- | :v . "IF I `p-i - ' . VI VAB.0001190695 +r- -5-i I|. ^4.....IV. r 4 LAB - Continued F. Dry Blend Quality Simnary Torque/Color 40 Mesh Partial Box TOTAL G. CoEopound SPC Test Results Rcj ectlons M Lbs. (%) 6.3 (0.11) 2.3 (0.04) 0.6 (0.01) 9.2 (0.16) 38401 - Hardness Specific Gravity Hard Particles (20") 56 81.1 1.28 55 1.375 0.005 56 25.5 4.7 35031 - Hardness Specific Gravity Hard Particles (2') 57 49.7 0.65 57 1.372 0.008 57 5.2 2.2 Mill Tenperature 57 326.8 2.9 Oven Tenperature All readings 204C H. 5415 Control Resin Test Results nX 3 Moisture Dry Time Particle Size - 60M - 8CM - 10CM - 12CM - 140M - 20CM Pan Bulk Density Color - L A B Flow Time Hard Particles, 7 Min. Inherent Viscosity 59 0.160 0.026 30 5.05 0.37 60 1.53 1.06 60 29.72 3.40 60 33.93 1.06 60 21.01 2.01 60 7.41 1.33 60 5.18 1.57 60 1.22 0.45 30 0.5051 0.0050 29 100.63 0.377 29 -0.17 .476 29 2.38 0.753 30 7.83 0.69 60 4.78 2.62 28 1.007 0.012 I. Miscellaneous 1. Harold Coleman and Dave Cox attended the Plasticizer Planning Meeting in Aberdeen on Novenber 9. 2. Harold Coleman participated in the VCM Specification Team meeting on November 29. 3. A malfunctioning even tenperature controller was found to be a source of variation on the inherent viscosity test. 4. Brian Harrison completed two dry blend and one ccnpound color match this month for VHP, Thermal Industries and Calvex. VAB.0001190696 I'P-'l.".............. ' T H H TP'M- . II l;:: -IT.r. .....................W'-Li I y.' +.KH H**#1 2 3 4 Htsp** stufii.--_*r J '1= ' J'?: : ":: '-n - -1 => * - .1. naq, .. . s,,. *::r l;^4f-l|r + +*-- : J * " ft 'i.. . ^ _ +. ;rt. u<- lb-'iU * 1 l" v.l. . i* L..ABO*RATORY - continued I. Miscellaneous 5. Brian Harrison attended Flustrated Total Internal Reflectance (FEtR) training in Ponca City on Novenfcer 2. 6. Brian Harrison attended PlA's Plastics Extrusion Seminar in Chicago on November 16-17. A . .......... . :n :i;i-|ui : -f- -n -- - II r-i;i4-4e 'i rwpr:1 !"-r -*{| -r i VAB.0001190697 vn #r--- SAMPLE SHIPMENTS RESIN Ship Date 11/08/88 11/08/88 11/14/88 11/14/88 11/14/88 11/14/88 11/22/88 11/29/88 11/30/88 COMPOUND Ship Date 11/01/88 11/04/88 11/07/88 11/15/88 11/29/88 NOVEMBER 1988 Product 5305 Sifter Overflow Labscrap Pond Resin 5385 5265 5305 5385 5415 5415 5415 5415 Amount 5 lbs. 2 lbs. 2 lbs. 2 lbs. 5 KG. 15 lbs. 15 lbs. 2 KG X 5 2 KG X 5 5 lbs. 10 lbs. 50 lbs. Product 39012 BLK 271-159B BLK 46851 BLK 46851 BLK 18031 WAT CL Amount 1500 lbs. 720 lbs. 100 lbs. 50 lbs. 200 lbs. Customer Polysar Rubber Wexford Int'1. H. Heller International Polymers Chisso Corporation T. C. L. Marketing JTF Elastomerics Capital Wire & Cable Johnson & Johnson Customer Tandy Wire & Cable Comm-Scope J. C. Levardsen Keeler Brass United Tech. Corp. \ OTHER Ship Date 11/03/88 Product 610P Plast. Amount 1 qt. Customer Sarnafil, Inc. Jk VAB.0001190698 i t- * .......................... .. h ` T- .k;!