Document 65BpYB6vja1x64GK6NBoZJnjo
To: T. H. Huffman
From: Dale:
Subject:
D. C. Skokna November 17, 1989
ABERDEEN MONTHLY PROGRESS REPORT OCTOBER, 1989
There were two first aid and one recordable cases reported during the month. The recordable case involved a mechanic who received a second degree bum to his chin. As of October 31, the plant's employees have worked 3,771 days (4,989,563 manhours) since the last lost time injury.
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
Capacity .Utilization Factors
Resin Flexible Compound Rigid Compound Plasticizer
Offsite, Hazardous Wastes Recycled, Hazardous Wastes Offsite, Non-Hazardous Wastes Vulnerable By-Products Total Waste Water Air and Water
(1) Three-month rolling average.
32.9 75.4 97.5 0.9972
6.6 97.9
3.5 98.6
1.5 90.6 < 3.9> 60.5 74.8
32.9 75.4 97.5 0.9972
6.6 97.9
3.5 98.6
1.5 90.6 < 3.9> 60.5 74.8
0.87 0.84 0.56 0.81
0.87 0.84 0.56 0.81
91.4<0 94.7n> 100.7<n 90.0n> 104.3(1> 78.6(1>
108.1 69.4
108.8 79.2
122.1 85.9
VAB.0001190302
T. H. Huffman 11/17/89 Aberdeen Monthly Progress Report Page 2
- October,
1989
The annual new module turnaround was completed during the month. Key work Included vessel Inspections, shutdown repairs, tie-in of the Plant Electrical Upgrade Project and installation of dryers #5 and #6 baghouses. The old module was down for three days to allow electrical tie-ins.
Variable costs were favorable due to good raw material efficiencies in the resin unit, a favorable product mix variance in the flexible compound unit, partially offset by above budget raw material consumption in the plasticizer unit.
Fixed costs were favorable due to lower than budget benefit charges, a favorable property insurance variance, partially offset by an unfavorable MM&C variance related to the new module turnaround.
1. Fifty-five percent of the plant's natural teams met during October.
AT&T (a flexible compound customer) audited the
plant.
We received an " adequate
with
recommendations" rating. Their audit is based on
the sixteen elements of the ASQC National Standard
for OQualityv Svysstteem Elements.
Three levels of
scoring are possible: Adequate, Adequate with
Recommendations, and Inadequate. The lowest rating
received in any element is the overall rating. We
received "adequate" ratings in eight elements and
"adequate - with recommendations" in eight
elements. The changes necessary to upgrade the
overall rating
not major. We plan to have
implemented the recommendations by mid-1990.
3. Uniroyal (a resin customer) performed an audit of the plant. We received an overall rating of 78.7% (considered to be "acceptable"). Uniroyal compli mented the plant on the consistency of the resin we sell them - they said that improvements made in 1989 have cut their scrap rate from 24% to 12%.
4. Exxon representatives visited the plant to discuss plasticizer quality and to tour the plasticizer unit.
T. H. Huffman 11/17/89 Aberdeen Monthly Progress Report - October, 1989 Page 3
OMP - continued
5. The Lab-Vinyl Team made its presentation to management. This team reduced delays that had been occurring from the time a resin railcar was loaded until it was approved for shipment. These improve ments will save over $30,000 per year in railroad switching charges. No investment is needed.
6. The Vinyl Operations Superintendent's Natural Team implemented procedural changes that reduced the amount of off-grade resin produced in October by 750,000 pounds (the reduction is based on FY1989 average off-grade production rates). This will generate about $15,000 in additional revenues (assuming off-grade sells for 2C/lb. less than prime grade). No investment was necessary.
7. Nine employees from the Aberdeen Plant participated in "Excellence in Mississippi" in Jackson, MS. The seminar, sponsored by the Association for Quality , featured presentations fro: Mississippi academic institutions about quality
1. All the new dryer baghouses are operational. Stack sampling shows particulate emissions being reduced from seven lbs./hour to 1.5 lbs./hour. This meets the design goal.
2. Stabilizer spill was accepted at Ghem Waste Management's Lake Charles facility.
Plant Superintendent
rah
Houston
Hammond
Blane
COVER LETTER
J. D. Burns
X
R. T. Ferrell
X
T. H. Huffman
C. J. Matson
r
D. F. Harman
H. R. Flammer
R. R. Smith
B. J. Bean
R. H. Gerlach
R. D. Gamblin
S E. McGuire
R. L. Poe
X
H. J. Hall
H. G. Garrison
R. A. Conrad
J. Friend
J. W. Ware
X
L. R. Bauer
X
J. B. Maher
X
C. R. Miller
P. L. Foote
RWS/DCS (File Copy), PJK, JEN, MRK, DAM, JEB, HGC, JEL, REP, BLT, RBN, SCH
X X X X X X X X X
X X X X
X X
mrnrnmmmmt
N
VAB.0001190305
SAFETY - B. L. Trego, J. V. Uptain
First Aid OSHA Recordable
Total Injuries
Number of Restricted Workday Cases Number of Lost Workday Cases
2 1 3
0 0
Fiscal
0 0
Fiscal Y.T.D. 1989
2
Q
2
0 0
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
00 00
22
00 00 1
33
0
0
2
0 0 0
2
00
1
00
0
11
0
11
1
00
o
11
0
0 0 _0
33
2
Lost Workday Cases Days Lost
Safety Record
00 27 0
Last lost time injury - 7/5/79
Days since -
3771
Employee hours since - 4,989,563
On October 31, 1989, the employees of the Aberdeen plant completed 3771 days with no lost time injury.
The topic for plant safety meetings during the month was annual fire training.
A
VAB.0001190306
SAFETY - Continued
Routine dosimetry results for the month were:
Chemical
>_________________________
NunAar
VCM Lead Total Particulates
79 98.7 15 100.0
3 100.0
1 0 0
1.3 0.0 0.0
The single VCM overexposure was without benefit of respirator protection.
Psggrirtiwi
FA
Maintenance
Contusion of third, right finger
FA
Engineering
Bee sting of right thumb.
MT
Maintenance
Bum to chin.
The medical treatment case occurred during annual fire training when a maintenance employee received a small second degree burn to his chin.
1
4
VAB.0001190307
J
t
M. R. Kane
General
Nine plant employees participated in "Excellence in Mississippi" in Jackson, MS. The seminar, sponsored by the Association for Quality Progress, featured presentations from Mississippi industries and academic institutions about quality efforts.
Plant Manager
The Plant Manager's Natural Team worked on developing measures for teams being formed and finishing to emphasize and encourage teams. Other measures which will be developed include a measure of employee development.
The Vinyl Natural Team met during the month and developed a list of team measures from which the most critical will be selected and base line data will be collected on those. Waste minimization was discussed and areas of potential reduction were discussed.
Uniroyal Plastics visited the plant during the month and conducted a quality audit. The audit score was 78.7% which represents an "acceptable" rating.
The Vinyl Department Head participated in a meeting with Southwire Executive Management in Houston. The meeting included signing of the Vendor Excellence Program by Vista and Southwire.
Compound
AT&T audited the plant.
We received an "adequate with
recommendations" rating. The audit was based on sixteen of the
elements of the ASQC National Standard for Quality Systems. There
are three levels of scoring possible: Adequate, Adequate with
Recommendations, and Inadequate. The lowest rating received in any
element is the overall rating. We received "adequate" ratings in
eight elements. The improvements required are not major and we plan
to be able to be re-audited (hiring 1990.
*****
mmmmpimmm
mm
mm
VAB.0001190308
WH
* wmmmmf
wmmmmmmmm
COST VARIANCES - D. C. Skokna
X2fil
PVC Flexible Compound Rigid Compound Plasticizer
$ 77.8 39.6 1.7
< 44.4> $ 74.8
$562.3 15.9 56.6
-<2$L,Z>
$614.1
$640.2 55.5 58.4
$688.9
PVC - Raw material (primarily VCM and initiator) use was below budget.
The favorable variance was a result of a favorable "product mix" variance.
Rigid Compound - Operations were essentially at budget.
Raw material use was above budgeted levels.
Price Variances
- VCM - Resin to Rigid Compound - Resin to Flexible Compound - Natural Gas - Alfol* Alcohols - 610P to Flexible Compound - Other Price Variances
Total
$541.2 50.5 43.8 27.9
<20.3> <44.1>
15-1 $614.1
F.L%d.Cgp Yfliiancafi
SM
- Payroll and Benefits - MM&C - Miscellaneous - TI&D - Clearances
Total
$34.0 < 39.7>
47.5 15.0
3r7 $60.5
Payroll and Benefits - Employee benefits were $23.7M favorable.
M. M. & C. - Costs were above budget due to new module turnaround charges.
Miscellaneous:
- Processing Supplies - Shipping Costs
$16.0M favorable $14.0M favorable (due to the plant shutdown)
T.I.& D. - Property insurance - $11.2 favorable.
VAB.0001190309
* *
4
P. J. Kober, D. A. Hiller, J. . Nickerson
Safety
The Operations Departments worked without injury in
October.
The Mechanical Department had one medical
treatment case and two first aid cases. The medical
treatment case involved a mechanic who received a small
second degree bum to his chin during fire training. The
first aid injuries involved:
- A mechanic who pinched a middle finger lifting a pump impeller from its case.
An engineer who was stung by a wasp.
The monthly safety meetings were the annual fire fighting training.
A
VAB.0001190310
VINYL - P. J. Kober, K. W. Birck
General
1. Production was limited in both modules for seventy-two reactor hours to repair an electrical distribution problem. This was an unscheduled shutdown.
2. The annual New Module shutdown was completed this month. Routine vessel inspections) necessary repairs and capital tie-ins were performed during this shutdown. The Old Module was also shut down to complete necessary electrical tie-ins for the Plant Electrical Upgrade Project.
3. Dryers #5 and #6 baghouses were replaced during the month as part of the Rotary Dryer Baghouse Replacement Project. Dryer #4 is the last one to be replaced. Work is in progress to complete dryer #4.
4. During the month, there was an attempt to produce a batch of resin with 0.52 inherent viscosity (IV) resin. The actual IV came out to be 0.57. Though not on target, this batch provides important information for future ultra low resin inherent viscosity testing.
5. Produced this month in the Old Module was 5415.-
6. The resin raw materials in the 744 account were valued at $417.8M.
- 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
%
32.9 1061.0
87.0 780.0
25.2 75.4 76.1 76.1 97.5
Reactor
Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks, New Module rinse/charge water conflicts, no place to dump, changing filters, Waiting on Q.C. data before charging, and inclement weather).
32.9 1061.0
87.0 780.0
25.2 75.4 76.1 76.1 97.5
191
4 *
wmmm
UMM *
VAB.0001190311
VINYL - Continued
Reactor Downtime - continued
Maintenance downtime (hydroblast/drill D700 and D745, power outage to change coils on new electrical switchgear, D600 reactor jacket welding, D745 agitator gearbox repairs, D744 rupture disc replacement, low steam pressure and miscellaneous instrument and valve repairs).
New Module shutdown (including Old Module shutdown for electrical tie-ins).
Hours 237.1
1405.2
Reactor limited production.
Operational downtime (centrifuge plugs, clean dryers, activator transfer problems, check dust collector socks, and flameouts).
Maintenance downtime (repair activator valves, shear pins, burner maintenance #6, and various other activator and centrifuge repairs).
31.2 5.9
3.7
Other (not needed due to New Module shutdown and dryers #5 and #6 baghouse replacement).
59.2
Kev Maintenance Work - J. B. Autrey, J. B. Hegwood
The following major work items were completed during the New Reactor unit shutdown:
Rectors 741-745 were hydroblasted and dye-checked. There was a small crack found on the relief valve flange of reactor 744. The crack was directly below a bolt hole. The original bolt hole was drilled and tapped too deep which caused a weak spot at the bottom of the hole. The frequent removal and torquing of the relief valve eventually caused the crack. The crack was repaired and the bolt hole was re-drilled and tapped. There were no other problems found with the other reactors.
Reactor 745 gearbox was removed during the shutdown for repairs. The bearing on the input pinion shaft failed and was replaced. The input pinion gear set was replaced along with the shaft for the bull gear.
continued
The condensers on reactors 700 and 745 were drilled as part of the contamination control prograi
The condenser base gasket on reactor 742 was replaced due to the deteriorating condition of the existing gasket. A Flexitallic spiral-wound gasket was installed in place of the stainless steel jacketed gasket.
The 805 gearbox was replaced under reactor 741 with a new model 881 gearbox. The 804 gearbox will be sent out for inspection to determine if it can be repaired and used as a spare.
The relief valves on the sphere were refurbished during the shutdown.
All switchgear for the unit was cleaned and inspected as part of an annual inspection program.
The pressure vessels in the unit were internally inspected. The vessels were found to be in good condition.
Reactor 744 rupture disc was changed out as part of the annual rupture disc program.
The #4 dryer burner was changed due to it deteriorated condition. New Maxon gas valves were installed during this time.
The condenser shells were acid-cleaned on reactors 741-745. The slurry dump lines, 747 blend tank and the sewer lines in the unit were also acid-cleaned.
The west pump on #1 cooling tower sump was removed and sent out for repairs and reinstalled.
There were three major valves changed out in the reactor area during the month.
COMPOUND - J. E. Nickerson, K. 6. Akins
Demand for flexible compounds continued steadily in Oct
were able, however,
tdule longer production runs
inventory lost in September. Flexible compound inventory
3947M pounds to 4490M pounds
We
Orders were again light in October for rigid compound The dry
blend unit was down several days to control inventory
Some
problems were experienced during the month with 80273G production.
These quality control problems limited production for several days.
The final cause of the problems has not yet been completely
identified.
A test run to identify rigid pellet processing parameters was conducted on Line V. The test run used 90172D dry blend. Rigid pellets using slightly modified 90172D formulation will be produced on Line V in November.
A low-smoke, low-flame compound was produced on Line I. Samples of the compound were shipped to Prestolite for evaluation.
Operating
Month
Line I
29.5
Line III
29.5
Line V
20
Total
% Prime
Capacity Utilization Factor
2093
71
3649
124
831 42
6573
97.9
.842
2093 3649
-Jtl
6573 97.9 .842
A
- Product Changes - Quality Problems & Control - Miscellaneous Maintenance
Line III
- Product Changes - Hydro therm Maintenance - Miscellaneous Maintenance - Quality Problems & Control
- Product Changes - W-P Maintenance - We lex Problems A Maintenance - Miscellaneous Maintenance
94 13
8
71
22
15
8
63 36
20 20
mm m
mmmm
m
VAB.0001190314
COMPOUND - Continued
Operating
Month
Avg./Dav
Rigid Compound
25
3472
% Prime
98.6
Capacity Utilization Factor
.561
139
Downtime
- Quality Problems & Control - Product Changes - Miscellaneous Maintenance
116 61
12
Operating Davs
Month
Avg./Dav
Plasticizer
29
% Prime
Capacity Utilization Factor
1681 90.6 .806
3472 98.6
1681 90.6 .806
J. B. Autrey, J. B. Hegwood
The #4 VCM compressor was changed out and rebuilt because of a leak.
The east bio-disc pump was removed and rebuilt during the month.
- The south nitrogen blower was removed and rebuilt during the month.
mmummmm
mmmtmmrmm
VAB.0001190315
J. B. Autrey, J. B. Hegwood Number 3 boiler was shut down for inspection during the month. A buildup was noticed on the tubes and in the firebox during the inspection. Because of this, the tubes, firebox, steam and mud drums were hydroblasted. The water piping to the boiler was replaced in conjunction with a capital project, also. Several maintenance items were performed during this time. The relief valves were sent out for reconditioning and all of the boiler controls were inspected. Several maintenance items were taken care of in the boiler area during the steam outage for the electrical upgrade project. All instrumentation on #1 and #2 boilers was Inspected. The three
header valves were repaired, #2 boiler gas valve, the steam flow transmitter and block valves were replaced.
VAB.0001190316
- R. E. Polk, S. G. Hillman, C. J. McDonald
4 y
Testing for 5415 contamination sources Is complete,
The
recommendations that have been completed have lowered the upper
control limit for 5415 contamination below sixteen. The rest of the
team's recommendations are still needed to reduce the number of
statistically out-of-control points.
Dryer Dust Collectors
All the rotary dryer baghouses have been started up. Stack sampling shows particulate emissions have reduced to 1.5 lbs./hr. from 7 lbs. /hr.
VCg
VCSM (Vinyl Distributed Control System) engineers attended Taylor courses about ladder logic and Taylor control language.
Aberdeen process engineering participated in technology reviews with European FVC producers covering external slurry stripping and reactor clean wall technologies. EVC has a clean wall technology that has great potential. We are pursuing a licensing agreement which will include two test periods. Norsk Hydro and EVC both had external stripping technologies which looked promising. Operationally, the Norsk Hydro is preferred. However, Chisso Technology has yet to be reviewed.
During the technology trip, we also discussed the 5305 Klockner graininess problem with BASF. They feel it is a problem of foreign particles which is partially calcium. Some film imperfections, which may be graininess, were observed while calendaring 5305 on their lab calendar. This may be the graininess test we are looking for.
Two railcars were made for Klockner filtering charge water and VCM to ten microns absolute. It is hoped this will remove foreign contamination that may cause graininess. Samples have been sent to BASF and R&D for testing.
i .. Ml
VAB.0001190317
4
Continued
The D744 modified slurry stripping procedure test was completed. The new procedure reduced slurry RVGM by 40%. Reactor condenser fouling is still a question mark because two early kill batches foamed during the test. Low molecular weight reactors will try the new procedures next month which should clarify this issue.
A preliminary design for carbon bed adsorption of VCM has been issued for estimation. Carbon bed adsorption of VCM stack emissions may be an alternative to external stripping to reduce plant VCM emissions.
A
fwmmm
mm * mm
mmmmmm
VAB.0001190318
DGiuniK- 8.1. poii, s.c. mm* c.j. c
&3
*
S3
w
I
*
VAB.OOOl190320
- u. u.DcinniK
pou, s.c. munu,
hcdouui
F. G. Jeanson
r
All wastewater discharge parameters were met for the month of October.
Results from the annual monitoring of our wastewater outfalls by the Mississippi DEQ were received this month. We received a 100% compliance rating. The testing was completed during the month of July.
A SARA team meeting was held this month. During this meeting, the four subteams decided on areas they would concentrate on. The four sub-teams are:
1. Employees and Families 2. Local Emergency Planning Committee 3. Community Relations 4. Schools and Education
The Aberdeen Plant video was updated. Pictures for the new brochure were taken. The brochure will be published in November.
A presentation for the employees at the Plant was put together to inform them of the 1988 SARA emissions and other environmental items. The department heads will give this presentation to their respective people during the month of November.
Waste
Waste shipments for the month of October included:
One bulk load of lead/antimony bags to Chemical Waste Management, Erne lie, Alabama.
- One bulk load of separator oil to Systech in Demopolis, Alabama.
Stabilizer spill was approved at CWM's Lake Charles, Louisiana facility. A shipment will be sent there in November.
The CMA waste survey was completed for wastes generated in 1988 and returned to the CMA.
I visited the Chemical Waste Management (CWM), Emelle, Alabama facility for their annual site tour and regulatory update meeting. CWM thinks they have a good chance to win the lawsuit they filed against Alabama for banning hazardous waste from certain states. They are still receiving nonhazardous waste from the banned states and do not foresee any problems with that.
mmmmmrnm
PMPN*
t *
VAB.0001190321
Continued
A meeting was held with the Mississippi DEQ to discuss permitting issues for the VCSM Project. This project would require a PSD permit if we remain a major stationary source. The State agreed that with our new baghouse project we could become a minor source. However, they specified that the permit limits in the air permit would have to be revised to be under the 100 tons/year limit.
We are currently evaluating the air permit to make the necessary revisions so that we can become a minor source. With minor source status, a PSD permit will not be required for the VCSM Project.
The Mississippi DEQ was here to do an inspection of air emission points this month after they received a complaint from a neighbor about particulates. 1 toured them around the plant and also showed them the new baghouses. I explained that we were in the process of starting up the new baghouses. Nothing else resulted from their visit.
Preliminary tests conducted on the new dryer baghouses indicate the baghouses are operating less than the guaranteed amount (2.4 lbs./hr.) but greater than the expected amount (0.6 lbs./hr.). Work is continuing to reduce the amount of particulate emissions so that the baghouses will operate at the expected amount.
The annual VCM valve and flange survey was completed this month. The New Module and sphere were surveyed. The total number of leaks found were twenty-one. These leaks were repaired and then rechecked.
Miscellaneous
I attended the 1989 Environmental Conference held in Jackson, Mississippi.
The waste minimization coordinators met in October to decide on a
measurement system for the monthly reports.
The measurement system
includes six categories which are listed on the following table. A waste
reduction index (WRI) is calculated for each of the categories and their main subheadings.
The percent waste reduction (% WRI) will be reported monthly on a three-
month rolling average basis versus FY1988 on a per unit of production basis. The formula is:
100 x 1
Most Recent 3 Months Lbs. of Production
FY1988 Total Lbs. of Production
We have also included a table on the type and pounds of each waste that are
included under each category.
VAB.0001190322
HASTE REDUCTION INDEX SHEET October 1989
OVERALL
3 MONTH
%HRI
90 TCD
1989FY
104.30% 122.00%
95.03%
I. Offsite, Hazardous Wastes
91.36% 108.10% 122.77%
a. Land Ban Wastes b. Hazardous Solids c. Non-Hazardous Treated as Hazardous
II. Recycled Hazardous Wastes
90.90% 103.44%
86.42%
1 94.70%
0.00% 0.00% 153.79%
69.43%
63.20% 117.50% 125.72%
103.51%
III. Offsite, Non-Hazardous Waste
a. Recycled b. Non-Recycled
100.73%
108.81%
101.30% 100.71%
116.30% 108.65%
98.27%
98.48% 98.27%
IV. Vunerable By-Products
90.02%
79.24% 116.90%
V. Total Waste Water
104.32% 122.07%
95.01%
VI. Air & Water
a. SARA - Air b. SARA - Water c. Non-SARA - Air d. Non-SARA - Water
78.55%
85.90%
91.91%
89.04% 1126.67%
89.95% 66.12%
86.63% 1316.32%
79.52% 90.97%
86.25%
575.76%
96.30%
87.22% *
j
VAB.OOOl190323
A
f"N
WASTE REDUCTION INDEX SHEET October 1989
Offsite, Hazardous Wastes a. Land Ban Wastes.
1. Phthalic Anhydride
b. Hazardous Solids 1. Stabilizer Spill 2. Floor Sweep
c. Non-Hazardous Treated as Hazardous 1. Plast. Filter Cake 2. Lead Bags 3. API Sludge 4. Pit #1 Solids
Recycled Hazardous Wastes a. Recycled
1. Separator Oil 2. Safety Kleen Solvent
Offsite, Non-Hazardous Waste a. Recycled
1. Drums 2. Pallets 3. Aluminum Cans 4. Scrap Metal
*
b. Non-Recycled 1. Landfill
1988EY
259962 2412 2412
74821 12742 62079
182730 61670 11440 29620 80000
653226 653226 651700
1526
6699074 140601 49600 39000 0 52000
6558473 6558473
POUNDS
1989FY
90 YTD
324789 1551
1551
20695 0 0
89465 22425 67040
0 0 0
233773 56573 67880 29320 80000
20695 0
13900 0
6795
688080 688080 686210
1870
33397 33397 33180
217
3 Month
59594 550 550
19420 0
19420
39624 0
19460 0
20164
155224 155224 154790
434
6699373 140900 49600 39000 300 52000
6558473 6558473
536788 12041 4213 3312 100 4416
524747 524747
1693095 35739 12502 9830 300 13107
1657356 1657356
Vunerable By-Products a. PVC
1. Culls 2. Vacuum Vent Dust 3. Sifter Overflow 4. Pond Resin 5. Pit #2 Resin
3597456 3597456
471409 329460 801007 1915560
80000
4279372 4279372
533237 541016 504106 2621013
80000
209932 209932
21520 41706
9212 130699
6795
812589 812589
70587 121146
63270 537422
20164
Total Waste Water a. Effluent
1. Pond 6
4424987560 4278245861 397762756 1158280284 4424987560 4278245861 397762756 1158280284 4424987560 4278245861 397762756 1158280284
Air & Water a. SARA - Air
1. VCM
646617 73316 73316
604755 65843 65843
40905 4677 4677
127437 16379 16379
VAB.OOOl190324
fMMM
b. SARA - Water 1. VCM 2. Di-n-octyl Phthalate
c. Non-SARA - Air 1. Particulates 2. Sulfur Dioxide
d. Non-SARA - Water 1. BOD 2. TSS 3. COD 4. NH3
55 22 33
264206 263300
906
309040 43689 68392
195581 1378
324 21
303
264300 263300
1000
274288 46841 53152
173096 1199
54 2
52
15471 15390
81
20704 4458 3739
12466 40
156 6
151
59633 59393
240
51269 10653 10218 30237
161
i I
\
VAB.0001190325
ENERGY
D. A. Moore
A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU
-2.8% -3.9% 2532.0 112.9
-2.8% -3.9% 2532.0 112.9
(1) Plant electrical usage is an estimate because an additional meter was added during the Electrical Upgrade Project and was not read. This will be reconciled in the November energy numbers.
There were twenty-eight energy related items completed
in October, 1989. Six of these items were steam leak repairs. The remaining twenty-two were steam trap repairs.
No. 1 No. 2 No. 3
83.63% 83.51% 83.01%
83.63% 83.51% 83.01%
VAB.0001190326
J. E. Beall
Employment Debbl Lemons, New Hire
William Caldwell promoted from Lab Trainee to Lab "A" Technician.
Richard Face promoted from Lab Trainee to T-h "A" Technician.
Nathaniel Smith transferred from Lab Trainee to Compound Utility.
Janice Cullui Relations
Maintenance
Typist
Employee
Joe Ann Williams transferred and promoted from Employee Relations Assistant - Aberdeen plant to Employee Relations Assistant Baltimore plant.
None
None
None
VAB.0001190327
A
4
f
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VAB.0001190328
ABERDEEN, MISSISSIPPI
Salaried Employees Hourly Employees Total Employees
79* 172 251
Nev Employees Terminations
0
0
Warehouse 16
Gem. Plant 13
Maintenance 41
Laboratory 24
Compound
40
Vinyl
33
Plasticizer 3
41 23 39 33
5
10
5 26
10
2
report
Minority Employees #, %
Salaried
6
8%
Hourly
66 38%
Total
72 29%
Hourly Min. Hired ____ 0 % Min. Hired ____ Q
Hourly Min. Term. 0 % Min. Term. 0
Number of Applicants:
Month
0
Tear To Date 21
APPLICANT BREAKDOWN:
# Minority 0 % Minority 0
# Female
0 % Female 0
* Includes 2 Co-op Engineers.
Hires (Hourly)
Month 0
Tear To Date
Terminations (Hourly)
Month 0 Tear To Date
Overall Turnover
0
Projected Annual Turnover
7
2
VAB.0001190329
wmmmm
A4
iuttfi! cuucu puit siippik Mums OCTOin 1989
-SIIMDRS 1! PHMCT3-
IISIIBOLI usii-mcugid
rmici
11,514,15! 371,572
ioiti
IPT/ITC i 10,1(2,010
199,990
p
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0 0
IU1IIU CMMD-NU
1,212,310 1,474,299
ruiuu ccvom-Picutu 3,212,113 113,972
9 9
II8IB COHPMID-NU inn comm-picusn
4,342,810 512,535
125,100 9
0 0
PUSTICIIII
131,210 599,990
9
totu
21,021,25! 12,115,102
9
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19,394,959 19,147,919 371,572 199,999
9 0
1,272,319 1,424,200 3,212,113 113,972
0 9
4,342,010 312,335
125,100 9
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139,299 500,000
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20,020,25! 12,015,002
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25 99 13 1 ___yABiiDOl190330
135
LABORATORY - H. G. Coleman
A. Safety - There were no safety incidences in the Laboratory this month. Richard Williams coordinated the monthly safety meeting a discussion on holiday safety, changing weather conditions, and safety at the workplace.
10/10-11 - The Lab participated in an audit by AT&T, represented by Cheryl Cincetti.
10/17
- Exxon visited the plant to observe our
plasticizer operation;
D. C. Cox
participated.
10/19
- Uniroyal Plastics Company performed an audit of the Aberdeen Plant. Uniroyal representatives were Lynn Bakker and Fay Karpuleion.
10/24
- H. G. Coleman visited Dayton Extruded Plastics in Springboro, Ohio, to discuss resin specifications and rigid compound consistency.
10/9
10/23 & 10/30
Southwire Company rejected one compartment of 5415 railcar 41147 for excessive contamination.
Uniroyal Plastics rejected two bulk
trucks of 5385 Type I resin for foreign
contamination.
Contamination was
determined to be from material caked
on the walls of commercial carriers
prior to loading.
American Mirrex Blane Polymers Eagle Plastics Eagle Plastics Essex
Essex Essex Rustique UTA
5265 5415 80273G WHT 110 80273G WHT 110 5415
5415 5415 RP-123 WHT 111 5415
Viscosity Static Flow % on 40 Mesh Short Stability Average Microns
Low % on Pan Static Flow % on 40 Mesh Static Flow
r*'
No.
1 R/C 1 H/T 2 R/C 1 R/C 1 H/T
2 R/C 1 H/T 1 H/T 1 R/C
VAB.0001190331
* t
p
LABORATORY - Continued
A
The following is a summary of residual VGM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of October, 1989.
Reactor
Number of Samples Average RVCM, ppm
786 133
26 0.927
61 0.801
The following is a summary of the residual VCM analysis of shipment samples for the month of October, 1989.
5265 5305 5385 5395 5415 5465 Dry Blend Debox Pond
26 86 36
0 58
0 51 12
0
0.335 0.499 0.371
0.205 0 0.224 0.377 0
E. (based on dryer "regulars")
5265
im
mi
5415
Bulk Density Inherent Viscosity
(vs. 0.715 - 0.744) L Color A Color B Color % on Pan
(vs. 2%, max.) % thru 140 Mesh Drytime Mets I.R.
(vs. 95% of control) Hard Particles, (% > 10)
1.67 1.29
--
3.19
3.00
2.67 1.25
--
0.56
--
-- -- --
1.56 0.50 0.22 3.08 3.67 4.67 1.67 ----
0,77
-- --
-------
2.17 0.73 ....
6.33
....
2.67 2.20 ------
1.59 2.33 --~------
0.3
1.03 0.57 ---
6.50 __
6.33 1.57 0.14 2.26 2.67 2.38 1.43 6.0
Average particle size,
microns
135 141 166 168
m
pMW
mmm
m
VAB.0001190332
LABORATORY Continued
Hardness Color/Clarity Hard Particles Dicing Heat Stability Cross Contamination Streamers
Totals
M Lbs, ill
54.0 ------------------10.0 ------------64.0
(0.82) -------------------
(0.15) -------------
(0.97)
M Lbs. (%)
1.5 38.6 13.8 18.4
6.3 7.6 12.8 99.0
(0.02) (0.59) (0.21) (0.28) (0.10) (0.12) (0.19) (1.51)
4
Torque Rheometry Color 40 Mesh Retention Mischarge
Total
29.9 7.7 3.6
JLJL
48.8
(0.86) (0.22) (0.10) (0.22^ (1.41)
1. Our new Brabender PL2000 torque rheometer was received and installed. Precision testing is being performed by D. S. Cox prior to commission.
2. The new Sintech tensile tester was installed and serviced by a factory representative. It is temporarily located in the Tech Service Lab while we review the operation of our constant temperature/constant humidity room.
3. H. G. Coleman participated in the annual Southwest Region Customer Interaction Program.
J. R. Williams and Gary Fritch attended the seminar on October 13.
5. H. G. Coleman attended a presentation by Pennwalt (Lucidol)
on October 31.
Their SPC program and charting were
discussed.
*
RESIN Ship Date 10/04/89 10/09/89 10/12/89 10/12/89 10/18/89 10/23/89 10/23/89 10/30/89 10/30/89 10/31/89
SAMPLE SHIPMENTS OCTOBER 1989
Product 5415 5416 Pond Resin 5265 5415 5386 Pond Resin 5385 5385 5265
Aaount 400 lbs. 50 lbs. 2 lbs. 2 lbs. 50 lbs. 50 lbs. 1249 lbs. 100 lbs. 100 lbs. 100 lbs.
Custoaer C ITOH A CO ANDROMEDA INTERNATIONAL Jin Beightol Oatey Coapany Wirekraft Witco Corporation ANDROMEDA INTERNATIONAL NISSHO IWAI CORP. Argus Cheaical Morton International
COMPOUND Ship Date 10/02/89
10/04/89
10/04/89 10/06/89 10/06/89 10/13/89 10/25/89
10/26/89
10/26/89
Product
2163 NAT 36851 NAT 35852 NAT
2153 NAT 38601 NAT
151-176 CB 50
48562 BLK
35852 NAT
419-66-1 NAT
38201 GRT 573 38901 GRT 573
16841 NAT (BC) 17461 NAT (BC) 17561 NAT (BC)
416-74-1 NAT
Aaount
400 lbs. 400 lbs. 400 lbs.
2745 lbs. 3000 lbs.
300 lbs.
500 lbs.
25 lbs.
200 lbs.
500 lbs. 500 lbs.
5 lbs. 5 lbs. 5 lbs.
500 lbs.
Custoaer TELMAG S.A. DE C.V.
i
Encore Wire Corporation
Deckerville Plastics TREMPEX AB Vista - Austin Superior Optics P. W. Pipe
Conex of Georgia
Prestolite Wire Corp.
A
*
DRTBLEND Ship Date 10/10/89
Product 802730 WHT 110
Aaount 100 lbs.
Custoser AHI PLASTICS LTD.
PLASTICIZER
Ship Data
Product
10/18/89
610P
Aaount
55 Ral.
wmmmmmmmmamm
Customer
CHISSO PETROCHEMICAL
HMPMPMMV^NMHMiJMJlPPPJWPPPVfMMVIVWV^MViM........ ...................
*
VAB.0001190334
ABERDEEN CHEMICAL PLANT INJURIES
(Twelve Month Running Totals)
V
JS7F MAMJJASON DJ'WF MAMJJASON DJ'89F MAMJJASO
TOTAL INJURIES
O OSHA RECORDABLE
NUMBER OF INJURIES
VAB.0001190335
W#***
A
ABERDEEN ENERGY CONSUMPTION
MWP
mmmm
en/ruM
VAB.0001190336
dir