Document 5bMQ8J6jMNG3079voneL9eoX8
T. H. Huffman
Interoffice Communication
From:
Dcrte:
Subject.
D. C. Skokna April 27, 1992
ABERDEEN MONTHLY PROGRESS REPORT MARCH, 1992
VIS1A
Safety
There were four first aid injuries reported during March. At month end, the plant's employees completed 4,653 days (6,232,073 employee hours) since the last lost time injury.
FY1992 Kav Statistical reformation
PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. 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 Efficiency Variance, $M
Costs
Mar.
40.5 89.9 96.4 1.0375
5.3 97.0
2.0 99.2
1.4 83.6 < 11.6> < 136.3> < 64.9>
Y.T.D.
211.7 82.3 96.7
1.0351 30.7 96.5 11.9 97.4 8.8 78.7
< 16.3> < 321.4> < 443.1>
Variable costs were near budget for the month.
Fixed costs were above budget in the MM&C and Miscellaneous areas. Included was a $30M "warehouse loss" from the FY91 sale of excess propane at a price lower than it was purchased.
QMP
The Safety Supervisor's Natural Team completed writing six procedures for the Security Guards.
The Accounting Supervisor's Natural Team completed a project to put OASIS resource numbers on all packaged goods.
VAB.0001189318
T. H. Huffman 04/27/92 Aberdeen Monthly Progress Report - March, 1992 Page 2 Environmental
Removal of 145 burled drums was completed. The drums and excavated soil still need to be disposed. Conoco is evaluating disposal options.
i Reclamation of resin from Pond 2 began this month.
0. C. Skokna Plant Superintendent rah
VAB.0001189319
DISTRIBUTION
COVER LETTER
Houston
J. D. Bums
X
R. T. Ferrell
X
T. H. Huffman
C. J. Matson
H. R. Flammer
R. R. Smith
B. J. Bean
R. H. Gerlach
R. D. Gamblln
C. R. Miller
Austin
R. L. Poe
X
H. J. Hall
H. D. Garrison
LCVCM Plant
P. D. Carrico
LCCP Plant
J. Friend
LCIAB Plant
J. V. Ware
X
Baltimore
L. R. Bauer
X
Hammond Premiere
J. Pavao P. L. Foote
X
Aberdeen RWS/DCS (File Copy), JBA, JEB, JME, SCH, DAB, DAM , JEN, JDO, BLT
ENTIRE REPORT
X X X X X X X X
X X X X
X
A
VAB.0001189320
SAFETY - B. L. Trego
First Aid OSHA Recordable
Total Injuries
Number of Restricted Workday Cases Number of Lost Workday Cases
Injuries bv Department
Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office
Totals
Injuries bv Type
Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other
Totals
Mar.
4 4
0 0
Fiscal Y.T.D. 1992
8
11
2 0
Fiscal Y.T.D. 1991
33 03 15 00 00 0 J* 4 11
2
4 7 0 0
2
0 1 0 0 1
0. 4
Lost Workday Cases Days Lost
Contractor Injuries
First Aid Cases Medical Treatment Cases Lost Workday Cases
Safety Record
Last lost time injury - 7/5/79
Days since -
4,653
Employee hours since - 6,232,073
On March 31, 1992, the employees of the Aberdeen plant completed 4,653 days with no lost time injury.
VAB.0001189321
SAFETY - Continued
Topics for plant safety meetings during the month and "The Safe Operation of Lift Trucks'1.
"Off-the-Job Safety"
Routine dosimetry results for the month were:
< PEL Number Percent
> PEL Percent
VCH Lead Total Particulates
85 100.0 7 87.5 2 100.0
0 1 0
Monthly Injury Summary
Inlurv Class
Department
Maintenance
First degree bum of left hand (palm and fingers).
Vinyl
Cut of index finger of right hand.
Vinyl
Insect bite on right shoulder.
Vinyl
Cut of index finger of right hand.
VAB.0001189322
OTTAT-TTY MANAGEMENT PROCESS - T. J. Arbelter
All plant natural teams continue to meet regularly and work on projects/team measures. The Safety Supervisor's Natural Team completed the writing of six procedures for the Security Guards. The Accounting Supervisor's Natural Team completed their project of putting OASIS resource numbers on all packaged goods. The Warehouse/Purchasing Supervisor's Natural Team is working on a project to ensure the cross-training of all non-exempt employees. The Stores Supervisor's Natural Team is working on a project to increase warehouse utilization. The Compound Operations Supervisor's Natural Team is continuing work on the writing of operating procedures. The Compound C-Shift Natural Team has begun charting of stock temperatures on the Farrell and Banbury. The Synergy Team set April 23 as the date for their presentation of barriers to QMP.
VAB.0001189323
COST VARTAKERS - D. C. Skokna
Variable Costs
Product
Mar.. 1992 Variance. $M__________
Efficiency
Price
Total
PVC Flexible Compound Rigid Compound Plasticizer
Total
$ 9.7 < 41.6>
5.8
< 39,8>
<$ 64.9>
<$461.8> < 65.1> < 16.1>
5.8 <$537.2>
<$452.1> < 106.7>
< 10.3>
< 33.0> <$602.1>
PVC
Operation was essentially at budget.
A
The unfavorable variance was primarily due to development of new PLENEX formulations. Production of off-grade PLENEX was high during the month.
Rigid Compound
Operation was essentially at budget.
Plasticizer
Raw material consumption was above budget.
Major Price Variances;
Variance - SM
VCM Resin to Flexible Compound Resin to Rigid Compound Vent Dust Credit Electricity Pond Resin Credit Debox Resin Credit Other Price Variances
Total
<$551.9>
< 62.6>
< 13.9>
< 11.7>
13.8 25.9
32.3 30.9
<$537.2>
Fixed Cost Variances
Variance - SM
Payroll and Benefits MM&C Miscellaneous TI&D
Clearances
Total
$ 5.2 < 39.7> < 85.4> < 13.9>
2.5
<$136.3>
VAB.0001189324
COST VARTANCF - Continued
Payroll & Benefits
These costs were near budget.
MM&C
Activity was above budgeted levels.
Miscellaneous
Variance - $M
i Unclassified m Operating Supplies Shipping Costs m Was tehaul ing m Warehouse Loss
<$17.3> <$13.9> <$13.5> <$13.4> <$30.0>
The warehouse loss was due to a FY91 sale of propane at a price lower than cost.
VAB.0001189325
VINYL - J. D. Olson, D. E. Knittig
The Vinyl Department had three first aid cases recorded during March.
The monthly safety meetings were held on shift and coordinated by the shift supervisors.
General
1. DCS software enhancements were completed this month. These changes were made to eliminate controller card failures. Controller card performance was improved through software changes to reduce peak and average load.
2. Reactor condenser cleaning was completed on five reactors for improved cooling prior to the summer season.
3. The Ultraclean Team started up the Condenser Cleanwall Project on D-745. Preliminary results look promising.
Mar.
YTD
- Production, MM Lbs. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4-#8) , % - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime
40.5 1306.5
98.6 957.0
30.9 89.9 94.1 99.1 96.4
211.7 1156.8
87.3 5056.0
27.6 82.3 89.4 87.4 96.7
Reactor Downtime
Hours
Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts, and no blend tank space).
411.0
m Maintenance downtime (D-700 seal replacement, D-745 condenser cleaning, D-743 condenser cleaning, D-600 seal replacement, D-742 condenser cleaning, D-745 rinse nozzle, D-745 cooling water valve, PM D-500 gearbox, D-500 condenser cleaning, D-600 catalyst ram valve, D-745 cleanwall program, and DCS software enhancement).
342.0
*
VINYL - Continued
VAB.0001189326
VINYL - Continued
Dryer Tine Operational downtime (centrifuge plugs, dryer cleaning, flameouts). Maintenance downtime (activator problems, centrifuge repair). Reactor limited production.
% of Total Downtine 48.9
34.7
16.4
gav
m
i
m
Xfttlff - J. B. Autrey, S. A. Truitt
Reactors D-600, D-742, D-743, and D-745 were hydroblasted. The safety disks were also changed on the annual program.
Reactor seals were changed out from D-600 and D-700. Both failures have been linked to failures in the seal oil unit.
The #8 Bird centrifuge has been changed out twice because of high vibration. The high vibrations were due to wear of the Trunion bushings.
The #1 Bird centrifuge was installed after it came back in from repair on pond resin drying.
The #7 dryer baghouse screw broke and was changed.
Centrate heat exchanger tube bundle gaskets were changed due to leakage and the unit was acid-cleaned.
The #4 and #5 VCM compressors were pulled out of service and replaced. The old compressors will be rebuilt for spares.
The #5 Bird motor was replaced due to bad windings and bearings. The breaker was also changed when a wiring problem was discovered before the motor was pulled.
*
VAB.0001189327
COMPOUND - S. C. Hillman, R. H. Sneed
k
The Compound Department had no injuries in March.
Orders continue to be tight on Line I and Line III. Close monitoring of dry blend product quality continues to cause higher than normal downtime and slower than normal rates.
Compound Production
Operating ______ Production M (Lbs.^
Dsts
Month Avtt./Pav Fiscal Y.T.P.
Line I
31
Line III
31
Line V
15
Total
% Prime
Capacity Utilization Factor
1498 3342
436 5276 97.01 68.11
48 108
29 170
9174 19367
71
30712 96.45 65.39
Downtime
Hours
Line I
- Product Changes - One Dicer Offline - Miscellaneous Maintenance - Quality
84 133
56 16
Line HI
- Product Changes - One Dicer Offline * Miscellaneous Maintenance - Quality
72 25 17 14
Line V
- Product Changes - Quality - Miscellaneous Maintenance
39 5
19
VAB.0001189328
COMPOUND - Continued
Operating PftTff
Rigid Compound
21
% Prime
Capacity Utilization Factor
Month
1959 99.15 41.19
Y.T.D.
11899 97.41 37.96
Rpwntljpe
- Product Changes - One Welex (Half Rates) - Miscellaneous Maintenance - Quality - Waiting on Raw Materials
Operating !>*
Plasticizer
30
% Prime
Capacity Utilization Factor
Hours
49 11
8
35 4
Month
1377 83.62 61.14
46
8804 78.68 58.97
Key Maintenance Work - J. B. Autrey, S. A. Truitt The Schenk filter was disassembled and cleaned. The #6 dicer motor bearings were bad; the motor was sent out for repair. Line I Sweco motor had bad bearings and was also sent out for repair. i The exhaust valves on the #8 air compressor were replaced. The leak on the front of #2 boiler was repaired.
VAB.0001189329
ENGTWEgRTNG - j. E. Nickerson, T. E. Mackay, M. L. Carter PROJECTS IN DEVELOPMENT - GENERAL Resin Debottlenecking Test runs for L-9 antifoam suspending agent were completed this month. Difficulties getting the correct particle size with L-9 ended the test run. A design basis meeting for debottlenecking the reactor recovery systems was held. The most economical design basis is for a third recovery system common to both units. Economics were reviewed of the closed dump design. The economic return for this option is borderline. Staffing Steve Carroll, an experienced hire, started work Harch 23. Kike Kane, Senior Process Engineer, transferred to the LCLAB Plant. Rory Sneed, Operations Engineer, was promoted to Senior Process Engineer. We had one new hire acceptance, Kelly Wood. He will start the first of June. Water Treatment Plant Work continues with the State for approval of start-up discharge. Work is continuing in developing a start-up plan. Construction continues steadily with completion expected in Hay. Pond 2 Resin Reclaim Reclaiming buried resin from Pond 2 began this month. AT&T Scran Recycle
The estimate for Class "A" design for permanent AT&T fluff recycle project was $170M. This project is on hold until other wire recycling issues are resolved through the FVC recycling team.
?ser Survey A preliminary plant steam balance is complete. Rates of specific users have been measured. During the next month, engineering will try to determine peak load usage and frequency.
VAB.0001189330
ABERDEEN CHEMICAL PLANT
MONTHLY
CAPITAL EXPENDITURE STATUS
M.L. CARTER MARCH REPORT
1992 F.Y
M1
VARIANCE
ACTUAL
BUDGET
MS %
Month
182.7
375.0
- 192.3
-51.2%
2nd Qtr.
899.0
1190.0
- 291.0
-24.4%
YTD
2118.0
2571.0
- 453.0
-17.6%
- Expenditures in February were $192.3M than the plant's budgeted expenditure forecast approved in the Second Quarter Budget submitted in November FY92.
Second quarter FY92 capital expenditures were 24.4% less than the plant's budgeted expenditure forecast approved in the Second Quarter Budget submitted in November FY92. It should be noted that this reported underrun does not take into account circumstances which were uncontrollable by the project group, i.e., delayed delivery of forktrucks accounted for $40.OM, movement of personnel/project reassignment accounted for - Inert Gas Dryer $25.OM, VCSM Project - control room modifications $25.OM, and delayed billing on completed work on the Water Plant Project accounted for $50.OM of the reported $291.OM underrun. Incorporating these items into the actual data depicts that the plant underran the 2nd quarter forecasted capital expenditure by 14.4%.
Quarter Budget - Current Quarter Expenditure Forecast as submitted and approved for the current quarter capital budget.
X2D__fivflget - Total of current and previous quarter approved budgets.
Forecasted Expenditures - The submitted 3rd Quarter Capital Budget calls for expenditures of $791.OM and April expenditures of $249.OM.
VAB.0001189331
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VAB.0001189334
Msmwnmi, - * g. Akin.
Water
All wastewater discharge parameters were met for the month of March.
The MDEQ had asked us to test our NPDES outfall for lead. The testing was completed and results submitted. Because there were no appreciable levels of lead present, the MDEQ will not include lead limits in future permits.
We asked the MDEQ for permission to put start-up water from the new water plant to a nearby storm sewer. The MDEQ said we would have to meet State water quality criteria which would require dechlorination of the water before discharging.
Drum Excavation
Excavation of the buried drums was completed in March. A total of 145 drums were removed from the excavation site. All of the drums had apparently been crushed during the burying. The drums contained plasticizer filter cake. Conoco is now evaluating their disposal options for the drums and contaminated soils.
Air Permit
A meeting was held with the MDEQ in March to review the latest air permit application. They now want us to submit information on emissions of particulate matter under 10 microns (PM10) in size. The permit application will be revised and submitted in April.
Waste
Waste shipments during the month included:
A bulk shipment of floor sweepings to Chemical Waste Management in Emelle, AL.
i A bulk shipment of waste oil to Fisher Industrial Services in Gadsden, AL.
Thirty-two drums of plasticizer filter cake to Fisher Industrial Services in Gadsden, AL.
t
i
^
VAB.0001189335
ENERGY CONSERVATION - J. R. Ganc
Mar., 1992
Fiscal Y.T.D.
A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU
II. Boiler Operation
< 15.0%> < 11.6%>
2968.0 147.3
< 18.8%> < 16.3%>
3040.0 804.6
Boiler
No. 1 No. 2 No. 3
19M Flacal Y.T.D.
83.7% 83.2% 82.9%
83.3% 83.1% 82.7%
h
i
VAB.0001189336
HUMAN RESOURCE REPORT MARCH. 1992
PERSONNEL - J. E. Beall
EMPLOYMENT Victoria F. Turman - New Hire - Analyst/Maintenance
replacing Carolyn Wigginton. William S Carroll - New Hire
PROMOTIONS/TRANSFERS Debra R. Lemmons Analyst/Payroll promoted to Production
Scheduler replacing Linda Michels. Timothy J. Arbeiter - Transferred from Quality Coordinator
to Manufacturing Chemist replacing David S. Cox. Carolyn V. Wigginton - Analyst/Maintenance promoted to
Analyst/Payroll replacing Debra Lemmons.
RETIREMENTS William Browning - Maintenance Department - Electrician "A"
- early retirement. Artis B. Jones - Laboratory - Lab Technician "A" - early
retirement.
TBRMIMATIOMS/RESIGMATIOMS None. TO/FROM LEAVE OP ABSENCE R. Danny Flippo - Vinyl Department - Vinyl Lead Operator
- Union Leave of Absence.
VAB.0001189337
4
h
DEPARTMENTS
#EMPLOYEES
M
WAREHOUSE GENERAL PLANT | MAINTENANCE || LABORATORY I COMPOUND 1 VINYL I PLASTICIZER
I SUB TOTAL
SALARIED
15 11 35 23 38 31
5 158
78
9 5 8 5 23 10 2 62 7
F
0 0 0 2 1 1 0 4 18
%M %F
60% 45% 22.9% 21.7% 60.5% 32.3% 40% 39.2% 9.0%
0 0 0 8.7% 2.6% 3.2% 0 2.5% 23.1%
DEPARTMENT TURNOVER
MO. FYD 00
00
13
00
00
00
00
ANN. %
0 0 17.2% 0
0
0
0
Printed
4/07/92
DEPARTMENTAL SUMtART HOURS REPORT
Total
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VAB.0001189339
VAB.0001189340
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Printed
4/07/92
DEPARTMENTAL SUMMARY HOURS REPORT
.............. TEAR TO DATE ................
4
A
4
ADMINISTRATIVE SERVICES - D. A. Barclay
i
There were no reportable safety instances this month.
OttalitY
All teams met during March to review progress on their projects
Futures
MTD
YTD
Natural Gas
$279.73
<$33,610.00>
Statistics
Processed
Processed Invoices Working Fund Checks Written Cost Savings Through Bid Process Raw Material Purchase Orders Issued MRO/AFE Purchase Orders Issued Spare Parts Purchase Orders Issued
1192 14
$2867.60 80
191 228
FT9 2 UtB,t
6830
102
$20753.19 531
1168 1168
Packaged Finished Goods Ending Ttnranfcore
Compound NAn Grade PLENEX Compound Off-Grade Compound Off-Grade Millscrap Dry Blend "A" Grade Dry Blend Offgrade Resin Type I Resin Type "BC" Vacuum Dust
W/hous
Bulk
Feb.. *91
n
4,291,913 129,476 420,012 159,135 210,612 709,511 269,678
1,131,050
100
112.085 7,433,572
3,626,224 144,775 367,114 218,074 271,872 495,345 286,639
1,521,450 100
141.091 7,072,684
Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade
Total
1,438,084 0
2,431,602 790,510
12,685,666
1..282.750 19,328,612
Mr.. *92
641,591 0
1,519,735 790,510
10,352,795 1.606.650
14,911,281
(Decrease)
%
<665,689> 15,299
< 52,898> 58,939 61,260
<214,166> 16,961
390,400 0
29.006 <360,888>
<15.51> 11.82
<12.59> 37.04 29.09
<30.19> 6.29
34.52
0.00
25.88 < 4.85>
(Decrease) /Increase
< 796,493> 0
< 911,867> 0
<2,332,871> < 376.100> <4,417,331>
% Change
<55 39> 0.00
<37.50> 0.00
<18.39> <18.97> <22.85>
VAB.0001189341
i V
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03/91 05/91 07/91 09/91 11/91 01/92 03/92 04/91 06/91 08/91 10/91 12/91 02/92
PKG'D PRODUCTS INVENTORY
VAB.0001189342
ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS MARCH 1992
vil 1 rrlCN 1 d Dl rn^UUw 1 w
PUBLIC
MONTH IPT/ITC
EXCH/TOLL
PUBLIC
YTD IPT/ITC
09:55 AM 09-Apr-92
EXCH/TOLL
RESIN-BULK RESIN-PACKAGED
21,770,430 22,123,160
696,401
300,650
0 0
112,635,790 99,881,050 2,916,107 1,350,150
0 0
FLEXIBLE COMPOUND-BULK
213,420
FLEXIBLE-COMPOUND-PACKAGED 4,050,816
2,365,200 0
0 0
1,089,020 12,330,800
18,032,237
189,175
0 0
NEW BUSINESS
19,648
00
98,364
00
RIGID COMPOUND-BULK RIGID COMPOUNO'PACKAGED RIGID COMPOUND-PELLETS
Aw
TOLLING - BULK TOLLING - PACKAGED
2,499,240 427,176 0
0 0
373,950 0 0
0 0
0 0 0
0 0
6,128,150 2,480,064
0
0 0
3,999,300 175,850 0
0 0
0
0
0 0
PLASTICIZER
0 316,850
0
81,300 2,941,890
917,400
TOTAL
29,677,131 25,479,810
0
143,461,032
BBBIBBlBISimiBUMIXBBBUt[vnaBBxass&utxivssssiai 1NSIX18S3I3 SS38BSSS383XSCSSSSSSS8SS
-SHIPMENTS BY MODEBULK;
RAILCAR
CUSTOMER PICKUP
COMMON CARRIER
120,868,215
PlAKUn
RESIN FLEXIBLE COMPOUND RIG10 COMPOUND PLASTICIZER
*
*
TOTAL MARCH
192 14
11 2
219
16 29 05
0 21 00
16 55
917,400
I3SBIB18883
TOTAL
237 19 32
2
290
*YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
942 85 229 72 0 33 42 3 75 19 0 11
1,256 105
120 30
' TOTAL YTD
1,075
88 348
1,511
SSSSSESlNVSSBSSSBBSCSSSfiSGBB
PACKAGED:
CUSTOMER
SBBSBSBBaXSSB BSIBSSSSSSB S38333333G33S353S&S8333S S3SSSBBSS33S3SS SSSSSBSSSS
COMMON
*MARCH*
PICKUP
CARRIER
TOFC AIR/UPS
AIR/UPS
TOTAL
RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
6 27 0 0 23 106 0 0
1 16 0 0 0 000
2 8 0 0
35 137
17 0
TOTAL MARCH
30 149 0 0
10
189
*YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
19 124 0 0 134 482 0 0
10 74 0 0 0 000
3 16
1 0
146 632
85 0
TOTAL YTD
163 680 0 0
20
663
8BBBBBBBB83SS8SBBB 8SXBBB8S38BBB8BS83S3BBSB SE3SZ3C3SBBKB 3ES3SS5S 33ES33ISX33 53BE8B3838e338S3338S 33388&3B3SSS8BBS33
CC: DA8,TLC,AEV,JRF
VAB.0001189343
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VAB.0001189344
LABORATORY - J. M. Edwards
A. Safety
There were no safety incidents in the Laboratory during March.
B. Customer Contacts
Jim Edwards, Steve Hillman and Mike Quackenbush visited Vycom to discuss RP-421 quality issues and the surface appearance of rigid sheet.
Jim Edwards and John Olson visited Sunbeam in Bay Springs, MS to discuss voids in wire made with Vista compound and metal and paper contamination issues.
C. Customer Q.C. Problem Reports and CHR's
P3/Q3 Northwire. Osceola, ffl
The customer complained rough* sandy surface during extrusion of 34551. Aberdeen Q.C. could not find any problems with the two returned boxes of product. R&D is investigating.
3/13 Premiere. Jeffersontown. KY
The customer complained of broken bags of 5325 resin in a truck ship ment.
3/13 Sunbeam Home Comfort. Bay Springs. MS
The customer complained of voids in the surface of three conductor extruded cords made with 38931 compound. Investigation of the wire showed the voids were formed by un dispersed Ti02 and some were formed by something volatile like water. Steps have been taken in Aberdeen to help eliminate the undispersed Ti02 problem.
03/19 Essex. Areola. IN
The customer complained that a railcar of 5415 arrived with four hatches open.
laboratory - Continued
C. Customer O.C. Problem Report8 end CNRf s - Continued
03/20 Sunbeam Home Comfort. Bar Springs. MS
A trial of 35852 compound at the Bay Springs plant showed the compound had a lot of fines and streamers which resulted in a less than optimum surface to the wire. This material was made on Line III.
03/22 RKrn mi ton Head. SC
The customer complained of contami nation in Black MSP80 that clogs their screen paks. The contamination was "blowing agent", rigid compound and miscellaneous "junk".
03/23 Master
Olnev. IL
The customer complained of a late truck delivery of 45541 NAT compound.
03/26 Abitlbi. Middleburv. IN
The customer complained of a late truck delivery of 5385 resin.
D. Product Waivers Issued
Customer
Product
Reason
No.
Formtech
RP-91 WHT 110
E. RVCM of In-Proeo fifpT
Color
1 H/T
The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of March, 1992.
Number of Samples Average RVCM, ppm
Reactor
Slurries
5265
38 0.240
5305
73 0.271
LABORATORY - Continued
F. RYCM of Shipment-
The following is a summary of the residual VCM analysis of shipment samples for the month of February, 1992.
Product
Number of Samples
Average RVCM. nnm
5225 5265 5305 5325 5385 5395 5415 5416 5465 Debox Pond Dry Blend
22 54 99
4 65 16 85
0 4 21 10 6
1. 608 0. 094 0. 102 0. 783 0. 209 0. 154 0. 030
0 0. 018 0. 207 0. 058 0. 043
G. Resin Process Capabilities (based on dryer "regulars"}
5225 26 5305 5385 5395 5415
Bulk Density Inherent Viscosity
(vs. 0.64 - 0.67) (vs. 0.715 - 0.744) "L" Color "a" Color "b" Color % on Pan (vs. 2% max.) % thru 140 Hard Particles, Average 5 Minutes 7 Minutes Mets l.R. (vs. 95% of Control) Average Particle Size, Microns
2.56 0.85 --
--
1.44 2.50 2.50 0.38
0.85
0.88 1.81 0.19
4.11 8.67 7.00 1.76
1.84
0.43 1.00 -- 1.00 2.47 4.67 3.50 1.10
1.46
1.02 0.55 -- ---2.75 -- 2.17 1.86
2.26
1.33 0.48 *-- ---- ------2.33 *-*2.33 3.08
3.33
1.45 1.11 ----------
3.25 -----
6.00 3.33 0.83 5.33
-----------
-- -- ----
-- 30.00 - - - - 13.00 --
6.00 2.00 3.24
8.00 2.00 4.69 2.49
150 146 145 166 155 176
VAB.0001189347
LABORATORY - Continued
H. Flexible CoapcwniH oAlitT Summary
Adjustments M Lbs. %
Hardness Specific Gravity Color Hard Particles Contamination Dicing Cross-Contamination Streamers METS-IR
Totals
45.0 <0.82> --.....................
........................ 45.0 <0.82>
x- Rigid Compound Quality Summary
There were no rejections for this month.
h
Rejections M Lbs, m
1.6 <0.03> 3.2 <0.06> 24.3 <0.44> 68.4 <1.25> 93.9 <1.72> 7.8 <0.14> 1.6 <0.03> 7.5 <0.14>
6.0<0.11> 214.3 <3.92>
* mmrnmmmmmmmmmmmmmmmm
f wpwm
VAB.0001189348
SAMPLE SHIPMENTS MARCH 1992
RESIN Ship Date 03/09/92 03/10/92 03/16/92 03/17/92 03/19/92
3/19/92
03/24/92
03/26/92 03/27/92 03/30/92
Product
5415
5415
5415
5305
5305 5385 5415
5225 5305 5325 5385
5385 5415
5385
5265/5305 OG
5225
COMPOUND Ship Date 03/04/92 03/05/92 03/06/92
Product 34501 NAT 462-34-01 BLK 58162BLK
Amount
Customer
2000 lbs.
Trioxide Canada, Inc.
50 lbs.
Akzo Chemical
50 lbs.
Sarnafil
2 lbs. X 3
Keysor Century
2 lbs. 2 tbs. 2 lbs.
American Art Clay Co.
5 lbs. 5 lbs. 5 lbs. 5 lbs.
Electroca!
50 lbs. 50 tbs.
Gen-Corp
25 kg. TECHNIPLAST (Dorn. Republic)
1 lb. Global Products
3 lbs.
PCI Industries
Amount 10 lbs. 3000 lbs. 100 lbs.
Customer Akzo Engineering Plastics
Donnelly Corporation Modified Tubular Products
Ship Mode CPU UPS UPS UPS UPS
Airborne
Airborne
Airborne Airborne
UPS
Ship Mode UPS CC UPS
VAB.0001189349
4
JAMPLE SHIPMENTS MARCH 1992
COMPOUND (Cont)
Ship Date
Product
03/06/92
PLENEX1250
03/10/92
55072 NAT
03/10/92
6085 BLK
03/11/92
452-189B BLK
03/11/92
PLENEX 1250
03/12/92
35852 NAT
03/13/92
6085 BLK
03/16/92
PLENEX 1200 PLENEX 1250
03/17/92
PLENEX 1200 PLENEX 1250
03/13/92
18033 CB 50
03/18/92
18033 CB 50
03/19/92
6085 BLK
03/20/92
27251 BLK
03/23/92
27251 BLK 35852 GRY 562
03/23/92
PLENEX 1275
03/24/92
PLENEX 1200 PLENEX 1250
03/25/92
MSP 80
mm
mmrnmmmmmmmmmmmmmm
Page 2
Amount
Customer
Ship Mode
100 lbs. 100 lbs. 100 lbs. 992 lbs.
Remee Products Corp. Modified Tubular Products ARCOS ELECTRICA S.A. de C.V.
Alenco
Airborne UPS Air Airborne
CC
300 lbs.
200 lbs.
50 lbs.
400 lbs. 500 lbs.
Furon Company Sunbeam-Northern Co.
J. V. Components Arizona Elec. Fabri. Inc.
CC CC Airborne CC
350 lbs. 200 lbs.
Lynn Electronics Corp.
CC
50 lbs. 50 lbs. 100 lbs. 50 lbs. 500 lbs. 500 lbs.
Fiberchem (Denver, CO)
Airborne
Fiberchem (Wheatridge, CO)
Airborne
ALAMBRES DOMINICANOS C. POR Airborne
Emerald Electronics
Fed. Expres
Packard Electric
CC
100 lbs.
100 lbs. 150 lbs.
Remee Products Corp. Ideal Wire Products Inc.
Airborne CC
50 lbs.
J. V. Components
Airborne
VAB.0001189350
mmmrnmmmmmmmmmm
*
SAMPLE SHIPMENTS MARCH 1992
COMPOUND (Cont.)
Ship Date
Product
Amount
03/26/92
PLENEX 1275
100 lbs.
03/27/92
PLENEX1200
100 lbs.
03/27/92
6005 BLK
50 lbs.
03/31/92
PLENEX 1250 PLENEX 1250 NAT 734
300 lbs. 300 lbs.
DRYBLEND Ship Date 03/02/92
Product Offgrade
Amount 2 lbs.
OTHER Ship Date 3/19/92
Product
108 P Halbase 10EP
Amount
1 gal. 2 lbs.
Page 3
Customer Teledyne Thermatics Inc. Comm-Scope Company
Bazflex Canada Ltd. Eastman Wire & Cable
Ship Mode UPS UPS
Airborne Burlington
Customer H. Heller & Co., Inc.
Ship Mode Airborne
Customer Penn Color, Inc.
Ship Mode UPS
VAB.0001189351
ABERDEEN CHEMCAL PLANT INJURIES
(Twelve Month Running Totals)
40 35
in 30
LxJ
C
25
o 20 O'
& 15
10
5
0
S0NB88M M J S NJ'89M M J S NJ'90M M J S NJ'91M M J S NJ'92M
TOTAL INJURIES -**- OSHA RECORDABLE
i
VAB.0001189352
BTU/LB
ABERDEEN ENERGY CONSUMPTION
3300
BTU/LB
3200 -
3100 -
3000 -
2900 -
2800
2700 -
2600
2500
2400 -
2300
2200
pn..I I I |
JAN 87 JUL 87 JAN 88 JUL 88 JAN 89 JUL 89 JAN 90 JUL 90 JAN 91 JUL 91 JAN 92
MONTHLY
MONTH 12 MONTH AVERAGE
VAB.0001189353