Document 6RZpL26wr7qnxjvKnYDGd8KM6
A
To: T. H. Huffman
Intoroffico Communication
From: Date:
Subject:
R. W. Seymour June 21, 1988
ABERDEEN MONTHLY PROGRESS REPORT MAY, 1988
There were two medical treatment cases during the month* One injury was a second degree burn from an uninsulated 3/4,r pipe plug
on a steam line and the other was a cut which required stitches* A
simulated a significant VCM leak and injury was conducted during the month. As of May 31, 1988, the
time injury.
manhours
PVC resin production for May was 39*5MM pounds with a reactor stream factor of 94.5%. Quality performance for resin in May was 97.1% prime. Resin production year-to-date totaled 316.6MM pounds. The VCM efficiency for May was 1.03390 pounds of VCM per pound of PVC produced versus a 1.00756 standard. Cumulative VCM efficiency was 1.01525 pounds per pound.
Compound production for May was 6.9MM pounds. Lines I and III operated thirty days during the month while Line V operated twenty-five days. Quality performance for May was 96.6% prime. Cumulative production totaled 59.9MM pounds of compound.
Dry blend production was 5.9MM pounds for the month. Quality performance in May was 99.4% prime. Cumulative dry blend production totaled 44.5MM pounds.
The plasticizer unit operated thirty days in May to produce 1.9MM pounds. Quality performance for May was 93.5% prime. Cumulative plasticizer production totaled 14.3MM pounds.
Team Management Training was completed for salaried personnel in May with another class planned for September to train new employees and a few who were unable to attend both parts of the spring session. Additional activities for May included formation of a maintenance team to resolve a ladder problem, plasticizer operators began charting both percent residual alcohol and color, and the railcar cleaning teamTs work resulted in preparation of a cost savings capital project to be submitted with the Fourth Fiscal Quarter Capital Budget.
Total energy consumption for May was 128.422MMM BTUs. The energy consumption per pound of product was 2370 BTUs, resulting in an adjusted CMA reduction of 53.0%. The adjusted CMA reduction for fiscal 1988 year-to-date is 52.4%.
VAB.0001190887
T. H. Huffman
6/21/88
Aberdeen Monthly Progress Report Page 2 The total plant variable cost variance for May was $2927.OM unfavorable, resulting from an overall unfavorable price variance of $2826M and an unfavorable efficiency variance of $101M. Year-todate plant price and efficiency variances were $14,964M unfavorable and $641M favorable, respectively. The total fixed cost variance for May was $1.0M unfavorable with the cumulative variance of $429M favorable.
R. W. Seymour Plant Manager rah
VAB.0001190888
DISTRIBUTION
HOUSTON:
J. D. BURNS
COVER LETTER X
ENTIRE REPORT
R. E. LEEMOIHL
X
R. T. EERRELL
X
T. H.HUFFMAN R. E. SWANIKOWSKI
X X
PONCA CEIY:
D. F. HAEMAN H. R. FLAEMER R, R. SMITH K. J. EQGERS D. H. SANDERS S. E. MCGUIRE R. L. POE
X
X X X X X X
H. J. HALL
C. M. STARKS
CKiAHCMA CTO:
H. G. GARRISON
TAKE CHARLES VQi PLANT
R. A. GGNRAD
LAKE CHARLES CHEMICAL PLANT: J. FRIEND
X X X X
LAKE CHARLES LAB HAST: BALTIMORE: HAMCND:
J. W. VttRE L. R. BAUER J. B. MAHER
X X X
ELANE POQMHS: PREMIERE POLYMERS: ABERDEEN:
C. R. MILLER
P. L. FOOTE
EWS/DCS (FILE OOP?), CWT, PJK, DWH, RAF, KLF, JEB, VEM, HOC, JEL, REP
X X
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VAB.0001190889
SAFETY - K. L Fogg, J. V. Uptaln
Occupational Injuries
First Aid OSHA Recordable
Total Injuries
Number of Restricted Workday Cases Number of Lost Workday Cases
Ma
1 __2
3
0 0
Fiscal Y.T.D. 1988
Fiscal Y.T.D 1987
6
A
12
2
0
Inluries bv Department
Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office
Totals
0 1 2 0 0 _0 3
Injuries by Type
Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other
Totals
2 0 1 0 0 0 _0 3
6
2
0 1
3 0 J)
12
Non-Occupational Injuries
Lost Workday Cases Days Lost
1 1
Safety Record
Last lost time injury
7/5/79
Days since -
3,253
Manhours since -
4,231,366
On May 31, 1988, the employees of the Aberdeen plant completed 3,253 days with no lost time injury.
Two injuries which resulted in medical treatment cases were reported. One involved a second degree burn from an uninsulated 3/4" pipe plug on a steam line and the other was a cut which required stitches.
The Local Emergency Planning Committee for Monroe County met in May.
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VAB.0001190890
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SAFETY - Continued
Hands-on physicals were completed in May*
A lead exposure abatement team was formed to further reduce exposure.
The plant executed an emergency drill. The drill simulated a significant VCM leak with an injury. A total plant evacuation was accomplished. Part of the drill also Involved a simulated television news crew, A critique was done after the drill and the general consensus was that the drill went well.
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PLANT FIXED COSTS - R. W. Seymour
Fixed costs for May were $1,277.4M and were within $1,051 of the budget. The following is an analysis of this month's variances:
Major Category
Variance vs. Budget
May, 1988, $M
Mav
YTD
Payroll and Benefits MM&C T&I Miscellaneous
(33.0) 52.5 17.6
. )(38.1)
( 10
(121.9) 303.3 81.8 165.3 428.5
Payroll and Benefits are unfavorable due to a $14.4M negative variance vs. budgeted benefits and operation of Line V on more shifts than the two-shift operation budgeted. MM&C expenditures are favorable due to lower than budgeted maintenance material expense and delayed execution of several extraordinary contract projects. T&I continues under budget. An analysis of major variances in the Miscellaneous category is given below:
Miscellaneous Category
Travel and Entertainment Moving and Home Assistance Outside Professional Services Warehouse Gain/Loss
Variance vs. Budget
May, 1988, $M
Mav
YTD
(14.4) (19.2) (13.0)
(11.2)
(15 1) 48 3
23.3
0.2
Travel and Entertainment was above budget for May because of unbudgeted trips for two engineers and a maintenance supervisor to Fisher schools in preparation for the dry blend DCS installation, visits to several compound customers, two quality seminars and a quality control delivery time visit to a supplier. The Outside Professional Services category this month includes a recruiting fee and the fee for the SARA Title III communications videotape production. Warehouse Gain/Loss is negative because of a $10.4M loss on sale of an obsolete raw material.
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QUALITY MANAGEMENT PROCESS - D. W. Hollis, R. B. Newton
1. Four sessions of Team Management Training were completed in May. Another training session is planned in Septen&er for any salaried personnel who did not attend the May sessions.
2. Assisted in planning an Open House to celebrate the plant's twenty-five years of operation and communicate emissions as part of our SARA Title III communications effort.
3. Attended a meeting of R&D, Purchasing and plant personnel to discuss needs from our Initiator suppliers to prepare for the upcoming supplier audits.
4. Rendell Newton attended a three-day ASQC quality convention in Dallas.
5. Rendell Newton attended a one-day Sheller-Globe symposium on Statistical Design of Experiments - Taguchl Methods.
VAB.0001190893
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VINYL - P. J. Kober, C. J. McDonald
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Safety
The Vinyl and Yard Departments worked without an injury during May, 1988.
The monthly safety meeting topic was "First Aid". nurse, demonstrated common first aid techniques.
Ginny Belk, plant
Quality Management Process
The Department Natural Team met three times during the month to coordinate daily activities and to continue discussions/actions on the Quality Implementation Plan. All salaried employees in the department completed the five-day Team Management Training course during the month.
There continue to be four active employee involvement teams. The teams are at various stages in solving the problem they chose to work on. All teams are making good progress.
Production
1. Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days
39.5 1274
952 30.7 94.5 9777 67.9
31
Y.T.D.(Fiscal 88)
316.6 1297 7497 30.7 93.0 9672 70.3 244
Reactors
The reactor stream factor for May, 1988, was 94.5%. Downtime in the reactor area occurred as follows:
1) Operational Downtime: Accounted for 61.8% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size data before charging, power failures, severe weather, new module rinse/charge water conflicts, and holding reactors to test Isonox 132 kill.
2) Maintenance Repair/Revision Downtime: Accounted for 38.2% of the total and was due to gearbox replacement of reactor D744, agitator seal change to reactor D600, hydroblasting reactors D700 and D745, and miscellaneous valve repairs and replacements.
Dryers
The dryer stream factor for May, 1988, was 67.9%. Downtime in the dryer area occurred as follows:
1) Reactor Limited Production: Accounted for 91.0% of the total. Dryers were shut down when possible for energy conservation.
VAB.0001190894
VINYL - Continued
Dryers - continued
2) Operational Downtime; Accounted for 6.0% of the total downtime and was due to centrifuge plugging, dryer cleaning, activator transfer problems, changing Sweco screens, and power failures.
3) Maintenance Repair/Revision Downtime: Accounted for 3.0% of the total downtime and Included activator maintenance, dust collector repairs, changing socks, replacement of slider rings, and replacing screener motor on fluid bed.
Product Quality Summary
Quality performance for resin May was 97.1% prime.
Resin Type
Prime
5265 5305 5385 5415 5465 Debox Off-Grade Sifter Overflow Pond Resin
Total
3,161,863 4,609,670 15,846,304 14,734,472
-- --
38,352,309
Monthly Variable Cost Performance
"B"
-- -- -
1,080,110
-- --
1,080,110
"H"
-- -- -- -- --
65,390
--
65,390
% of Total Production
8.0 11.7 40.1 37.3
0.0 2.7 0.0 0.2 0.0 100.0
Variable costs for the month were unfavorable at $2017.2M resulting from an unfavorable price variance of $1909.0M and an unfavorable efficiency variance of $108.2M. Resin variable cost for May, 1988, was 26.853 cents per pound versus the budget of 21.579 cents per pound.
The unfavorable price variance was due to VCM pricing at $1939.7M unfavorable.
VCM efficiency for the month was 1.03390 pounds per pound of PVC produced versus the budget at 1.00756 pound per pound. This resulted in an unfavorable variance of $192.4M. The team formed to investigate this problem continues to be active but have not determined any major or obvious cause. Higher suspending agent concentrations to control particle size resulted in an unfavorable variance for Alcotex 72.5 and Methocel F-50 of $17.2M. The higher concentrations were a result of maximum production rates. Initiator had a favorable variance of $59.5M due to inventory correction.
Energy Performance/Progress
Plant energy performance for May, 1988, was 2769 BTU/lb.
General
The resin raw material in the 744 account was valued at $350.7M.
Two lots of dual suspending agent 5385 were produced and bagged this
month for testing in flexible applications.
VAB.0001190895
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COMPOUND - C. W. Turner, S. C. Hillman
Safety
There was one medical case In the Compound Department during May. A Dry Blend Utility Operator suffered a laceration to his forearm while coupling a flex hose at a hookup station. The accident was reviewed by an Investigation team and a report was issued on May 24 with recommendations to eliminate the cause and prevent future occurrences. There were no other injuries in the Compound Department in May.
May18 monthly safety meeting was concerning forklift safety and maintenance.
Quality Management Process
Shift supervisors held natural team meetings with personnel on their shifts in May. These meetings focused on identifying quality concerns that each shift can work on.
Plasticizer operators began charting plasticizer finished product percent residual alcohol and color during May.
Ccnpound Production
line I line III line V Total
Operating
30 30 25
Production (M Pounds)
Month
Operating Day Rate
Fiscal Y.T.D.
2077 3734 1077 6888
67 120 43
18739 30983 10190 59912
Line I operated thirty days in May at an average rate of 67M pounds per day. Major items affecting production efficiency were: product changes, 103 hours; quality problems, 26 hours; dicer problems and maintenance, 33 hours; and housekeeping, 18 hours.
Line III operated thirty days in May at an average rate of 120M pounds per day. Major items affecting production were: product changes, 71 hours; miscellaneous construction work, 11 hours; dicer problems and maintenance, 10 hours; housekeeping, 9 hours; FCM/mill maintenance, 7 hours; and quality control problems, 6 hours.
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VAB.0001190896
COMPOUND - continued
Line V operated twenty-five days In May at an average rate of 43M pounds per day. Major Items affecting production efficiency were: product changes, 56 hours; no mlcroingredlent bags available, 20 hours; quality control problems, 18 hours; and housekeeping, 12 hours
All three compound lines were down for inventory control and cost savings on Memorial Day.
Quality performance for flexible compounds for May was 96.6% prime. There was 1.6% off-grade of which 98.6% was due to mill scrap. "BC" production was 0.8%.
The raw material requirement for flexible compounds was 1.02468 pounds of raw material per pound of compound versus a 1.01196 standard (YTD is 1.00839).
The variable cost variance for compound was $431.9M unfavorable with $387.5M unfavorable due to price and $44.4M unfavorable due to efficiency. The efficiency variance due to product mix was $240.4M favorable.
Major compound raw material efficiency variances $23.1M unfavorable and TOTM at $14.6M unfavorable. variances are inventory corrections from April.
were 610P at Both of these
Total compound inventory rose 426M pounds in May to 9.10MM pounds.
Dry Blend
Month
Operating-^tay Bate
Fiscal Y.T.D,
Production, M Pounds Operating Days
5952
192 44509
31 -
244
Dry blend operated thirty-one days in May at an average rate of 192M pounds per day. Production included 80273G WHT 110, 80172C WHT 110, 90172D WHT 110, RP-200 WHT 111, RP-440 WHT 110, RP-421 WHT 110, 269-151 WHT 145, 269-185 WHT 144, 186-139 WHT 111, 290-61 WHT 121, 317-91 WHT 110, 317-196 WHT 111, 317-204 GRY 152, and 378-34 WHT 141.
Dry Blend production was hindered by: product changes, 49 hours; blenders behind, 46 hours; screener inspection and maintenance, 32 hours; quality control, 22 hours; feeder and valve maintenance, 11 hours; hand dropping TiO, 9 hours; Welex problems and maintenance, 8 hours; and transfer system maintenance, 5 hours.
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VAB.0001190897
COMPOUND - continued
Dry Blend - continued
Quality performance for the month of May was 99.4% prime.
The raw material requirement for dry blend was 0.99813 pounds of raw material per pound of dry blend versus a standard of 1.00491 (YTD is 1.00484).
The variable cost variance for dry blend was $419.8M unfavorable with $456.1M unfavorable due to price and $36.3M favorable due to efficiency. The efficiency variance due to product mix was $22.6M unfavorable. Major raw material efficiency variances were TiO? at $57.3M favorable and Omyacarb filler at $10.7M unfavorable.
The large favorable variance for TiO for May is due to problems with inventorying the bulk Ti0 silo. The May cu variance of $72.3M is believed to be due to using less than budgeted Ti0 when using the bulk weight system.
Plasticizer
Production, M Pounds Operating Days
Month
1915 30
Average Operating-Day
Rate
62 -
Fiscal Y.T.D.
14278 241
Plasticizer operated thirty days in May at an average rate of 62M pounds per day. Production Included 610P.
Quality performance for May was 93.5% prime and VRP production totaled 124.4M pounds.
The raw material requirement for plasticizer was 1.12255 pounds of raw materials per pound of plasticizer versus a 1.10200 standard (Y.T.D. is 1.09618 ).
The variable cost variance for plasticizer was $58.1M unfavorable with $73.3M unfavorable due to price and $15.2M favorable due to efficiency. The only major raw material efficiency variance was Phthalic Anhydride at $10.6M favorable.
The efficiency variance due to product mix was $9.4M favorable. Energy
Compound Dry Blend Plasticizer
Usage (BTU/Lb.)
Actual
Standard
1697.4 686.4
1767.4
1758.0 720.0
1550.6
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VAB.0001190898
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MECHANICAL DEPARTMENT - T. F. Lyon
MAINTENANCE - D. A. Miller
There was one first aid injury and one injury requiring medical treatment in the Maintenance Department, The first aid case was a minor cut to the hand of a Building Attendant. The medical treatment injury was a small second degree burn to the forearm of a Mechanic. The burn occurred as a result of contacting a bare plug on a steam line while working on a reactor valve, An investigation was conducted and completed.
The monthly safety meeting topic was a review of the crane personnel basket procedures, basic equipment rigging and signaling.
Quality Management Process
The Engineering Project Team met during the month and developed a process flow diagram outlining the engineering process. Members of the team solicited feedback from their customers concerning the "role" of engineering in the plant.
A team of Maintenance mechanics and the I&E Supervisor developed a plan to resolve the "ladder problem". The plan was presented to Mechanical Department management and approved.
Team leader training of all salaried personnel was completed during the month.
Vinyl
There was one reactor agitator seal failure. The D600 seal failed to reseat following a power failure. There have been six reactor agitator seal failures during fiscal 1988.
Reactors 700 and 745 were hydroblasted in preparation for a 5305 run.
An overhauled reactor agitator gearbox was installed under D744. The original gearbox was excessively noisy due to gear and bearing wear. The old gearbox will be overhauled and retained as a spare.
The 903 recovery compressor in the new module was replaced with a new compressor. The old compressor will be overhauled and retained
The old unit high pressure service water pump was replaced with a
The new module recovery condensers were drilled during the month.
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VAB.0001190899
MECHANICAL DEPARTMENT - continued
Vinyl - continued The following major valves were replaced during the month:
- 744 condenser valve (replaced a ball valve with a plug valve). - D300 chem wash return valve. - Old module main chem wash supply valve.
- D745 shell, condenser and main chem wash/cleaning valves. The power supply for the batch water stripper Modicon PLC I/O rack failed and was replaced.
All control room work for the reactor heat-up loop project was completed.
One 490 series and one 690 series Corken compressor at the VCM tank farm was changed out and overhauled. Dryer Area
Work began to overhaul the pond resin centrifuge. The conveyor flites were repaired and flame sprayed. The centrifuge will be returned to service in June.
Revisions to two fluid bed dryer heating panels began. The revisions are aimed at eliminating contamination problems with four heating panels installed.
The fluid bed dryer hot water recirculation pump was replaced. A new style high level alarm was installed on dryer #4 dust collector. To date, it has outperformed the old instrumentation and new level detectors will be installed on the remaining four collectors.
Miscellaneous transfer line leaks were repaired. The silo rotary valve was replaced with a spare. Compound, Dry Blend, Plasticizer
Line I
- The head on #1 dicer was overhauled. - In-line screen spools were installed in the compound resin
silo transfer stations.
VAB.0001190900
MECHANICAL DEPARTMENT - continued
Compound, Dry Blend, Plasticizer - continued
Line III
- The zone 1 hydrotherm pump motor was replaced.
- The FCM speed controller was repaired.
Only minor maintenance was performed in Dry Blend and Plasticizer. Utilities
The west Joy centrifugal air compressor was overhauled on its scheduled two-year cycle. The following work was completed:
- Two radial bearings were replaced on stages 1 & 3.
- Revisions to allow more efficient filter elements were made to both the motor and compressor air filter housings.
- The motor was disassembled, inspected and repaired. radial bearings were repoured.
The
- All compressor control and shutdown instrumentation was recalibrated.
- The interstage coolers and lube oil coolers were chemically cleaned.
- The lube oil was changed.
- Vibration data was taken on shutdown and start-up. appreciable change was noted.
No
Pressure control valves were installed on #2 and #4 water well pumps.
The power cable to the west aerator on pond //5 was replaced due to a ground fault.
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MECHANICAL ENGINEERING - R. E. Polk
AFE F596/A717 - Reactor Heat-Up Loop
Startup and commissioning are complete. closed to field charges in June.
Both projects will be
AFE F786/F557 - Resin Quality Improvement
Concrete work is 87% complete and in progress. Slabs for the second and third floors of the SA module have been poured. All major steel work has been completed. Piping installation is 64% complete and in progress. The I&E contractor has moved on site. Electrical field and control room work is 3% complete.
AFE F587 - Laboratory Addition
All work has been completed except for punchlist items. These are in progress and scheduled for completion by 7/15.
AFE D707 - VCM Unloading Fire Protection
All construction is complete except for the Texas Automatic Sprinkler piping and final painting. Texas Automatic is scheduled to be completed by 7/1. Project completion is planned for 8/1.
AFE A538 - Reactor Condenser Revisions
The new condenser has been received. Installation is planned for the week of 6/6 on reactor D600. Re-tubes for D500 and D400 are scheduled for completion by 7/25 and 9/1, respectively.
AFE D608 -- Dryblend Orbitran Replacement
Software development is complete. Checkout is in progress and planned for completion in early June. Field work is scheduled to begin in the control room the week of 6/6. Installation is planned during a dry blend outage scheduled for 7/10-20.
AFE B548 - Plasticizer Lighting Upgrade
Installation is in progress and scheduled for completion by 7/1.
AFE D638 - Boilerhouse MCC Replacement
Basis of bids preparation is in progress. Bids will be requested the week of 6/20. Installation is planned for completion in August.
AFE F598 - Line I Screeners
Design is complete and all major equipment items have been received. Basis of bids preparation is in progress. Bids will be requested by 6/20. Installation is planned for completion in August.
VAB.0001190902
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PROCESS ENGINEERING - V. E. Messlck
Resin Quality Improvement Project
Assistance to construction activities continue on a "as needed" basis. Review of the Modlcon software for the make-up and transfer of the suspending agents and kill solution was held in Aberdeen. Review of the charge sequences will be held in July. Meetings were held with vendors to outline design work for a deluge system in the building and smoke detection for the second floor control room.
Resin Debottlenecking
An overall scope and schedule was issued to plant management for review.
5305/5265 Capacity Expansion
A letter outlining environmental operating guidelines was issued to plant personnel for review.
Reactor Heat-Up Loop
The reactor heat-up loop startup, safety audit, and operator training were completed. Normal use of the heat-up loop is suspended until minor safety audit revisions are complete.
Dry Calcium Stearate Addition - Fluid Bed
Both the main and spare calcium stearate screw feeders were made operational and recalibrated. A trial using dry calcium stearate on the fluid bed was started at the end of the month.
Chem Wash Conductivity Probe
M*
The chem wash conductivity probe and monitor were installed and calibrated. Data was collected and the operators trained on its use. Planned optimization of the chem wash system will include use of the monitor to insure adequate chem wash strength.
Line III Metal Detectors
Startup problems with the metal detectors have been corrected. The metal detectors are operating as designed. The wiring to shut down the dicers on detection of metal will be installed early next month.
Line III Vacuum Filters
New blower filters providing easier and quicker cleaning were installed on Line III and are in use.
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VAB.0001190903
PROCESS ENGINEERING - continued
Baghouse #4 Solids Level Svitch
A new level switch was installed on the #4 baghouse for a trial* The switch worked well and new level switches were ordered for the other baghouses* This project was completed through a joint effort of the Process Engineering, Mechanical Engineering, and Maintenance Departments.
Bird Rinse Water Modification
The rinse water equipment modification was finalized and the Instructions given to Bird. Delivery of the modified centrifuge is expected within two months.
Compound Alloy Production
All MSDS's on new raw materials were received and approved for use at the plant. Trial production of the alloys is scheduled for next month.
Lead Bag Disposal
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Lead contained in PVC bags was trialed on Line I to determine handling and exposure problems. The trial confirmed that use of PVC bags for lead is not a favorable option. A letter will be issued discussing the problems with PVC bags. A customer was found who will purchase the empty PVC bags.
Lines I, III and V Boxing Hopper Magnets
The final design for all three lines was completed and estimated. Miscellaneous AFE requests for funding the projects were also completed.
Recovery System Vacuum Pumps
Testing performed on the new unit vacuum pumps indicate that their motors are sized too small for the peak loads caused by periodic high Interstage pressure. Work on a design to solve the vacuum pump "kick-out" problem is underway.
Interlocks
A report was issued discussing our dryer safety interlocks. The purpose of this study was to insure that our dryer systems conformed to dryer industry standards. Several dryer
experts were consulted. Many of the recommendations stated in the report have already been completed.
New Unit System Interlocks
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PROCESS ENGINEERING - Continued
SARA
Section 313 forms were completed and Issued for review. Employee meetings were held to explain emissions.
Pond #3 pH Control
A design to replace the acid feed pumps with a pressurized tank and control valves was completed and issued for review.
Dryer Dust Collectors
Process and Mechanical Engineering and Vinyl operations representatives attended a demonstration of Steelcraft's mode "S" dust collectors at the vendor's production facility in Memphis. A similar trip to Kerr-McGee's plant in Hamilton, Mississippi, is planned for next month to see some new technology baghouses in operation.
Alternate Plant Water Supply
Meetings were held with the U.S. Geological Service and the Mississippi State Bureau of Land and Water Management to discuss results of pilot well. The analysis of the data indicate the Coker formation to be very promising. A design for the test was issued. Bids were received for the test well. The AFE request was prepared.
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VAB.0001190905
HUMAN RESOURCE REPORT
PERSONNEL - J. E. Beall
EMPLOYMENT Brian G. Aftergut, New Hire Deborah L. Tollison, New Hire William C. English, New Hire Joseph B. Hegwood, New Hire
PROMOTIONS/TRANSFERS Earnestine Carter promoted from General Helper to Vinyl "A" Operator. Michael G. Langford promoted from Instrument Tech "A" to Compound Shift Supervisor. Charles J. McDonald transferred from R&D Ponca City, to Operations Engineer, Aberdeen. Douglas C. Skokna transferred from Baltimore to Plant Superintendent, Aberdeen. Willie J. Wilson promoted from Compound Operator to Compounder.
RETIREMENTS Randolph Rye
TERMINATIONS/ RESIGNATIONS
Earnest L. Randle Kerry L. Lewis
TO/FROM LEAVE OF ABSENCE None
+
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VAB.0001190906
Aberdeen, Mississippi
A
Salaried Employees Hourly Employees Total Employees Emplo
New Employees Terminations
77 * 167 244
0 0
DEPARTMENTS PAR
Warehouse
16
Gen. Plant
13
Maintenance 40
Laboratory Compound Vinyl
2L-
40 32
Plasticiser 5
EMPLOYEES
16
Ik
24 38
5
MAY
MONTHLY PERSONNEL RE
Minority Employees #
Salaried Hourly Total
7
66
21
Ml
EHP
Z
2
6
10
Hourly Min. Hired % Min. Hired
Hourly Min Ten. % Min. Term.
0 0 0 0
% MIN. NEW HIRES YTD TERM. YTD TURNOVER
44 0 0
0
4
24 0
0
25 4 4
68 0
o
40
YTD
0 0
0
0
40 o 0 0 0 0
Number of Applicants:
Month
0 Year to Date 13
APPLICANT BREAKDOWN:
# Minority
0 % Minority 0
* Female
0 % Female
* Includes 1 temporary employee.
Hires (Hourly) :
Month
0
Year to Date
4
Terminations (Hourly) :
Month
2
Year to Date
3
Overall Turnover
Projected Annual Turnover
2.9%
summer
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VAB.0001190907
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VAB.0001190908
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ENERGY CONSERVATION - F. G. Jeanson
-i
I. Plant Operations
Total energy consumption for May was 128.422 MMM BTUs. Energy consumption increased to 2370 BTU/lb. from 2310 BTU/lb. in April. An adjusted CMA reduction of 53.0% was obtained for the month. The adjusted CMA reduction for fiscal 1988 is 52,4%.
II. Plant Energy Conservation Program
Maintenance
There were seven energy related items completed in May. All seven of these items were steam leak repairs.
in
Boilers
No. 1 No. 2 No. 3
83.2
83.3 83.4 83.1
Note: (1) Boiler amber two ms operated two days during the month.
VAB.0001190909
Month
ENERGY OBSERVATION MIA 1988 Mgr
Production, MM lbs.
Resin Dry Blend Ccopound Plasticizer
TOTAL
39.5 6.0 6.9 1 #8
54.2
Natural Gas
Consunptim, M9CF Conversion, BIU/SCF Energy Gonsunption, M*1 BIU Energy Consumption, BIU/lb.
67904 1020
69.262 1278
Electricity
Consunptlon, MM KWH Conversion, BIU/KWH Energy Ccosunption, M BTU Ehergy Consumption, BTU/lb.
5.9160 10000
59.160 1092
Propane
Consunptlon, M Gal. Conversion, BIU/Gal. Energy Consunptlon, M BIU Ehergy Consunptlon, BTU/lb.
Total
Energy Consunptlon, BTU/lb.
0 92000
0 0
1
2370
Energy Consunptlon, MtM BIU Actual Itaadjusted Actual Adjusted 1972 Base Period
128.422 106.635 226.996
(MA Reduction (%)
Adjusted Unadjusted Fiscal 1988 Year-to-Date
Performance
4
52.4% Adjusted 42.8% Unadjusted
53.0 43.4
1987
MSL
38.1 5.0 7.9 1.9
52.9
54906 1020
56.004 1059
6.0453 10000
60.453 1143
0 92000
0 0
2202
116.458 95.345 223.742
57.4 47.9
VAB.0001190910
ENVIRONMENTAL - R. A. Frohreich
Water
All wastewater discharge parameters were within NPDES limits in May.
A representative from the State Bureau of Pollution Control and one from the Atlanta EPA office conducted a wastewater inspection on May 5, 1988. Several recommendations resulting from the inspection are being implemented.
General
Scott Environmental Technology completed the dispersion air modeling of VCM from the plant. The highest predicted annual average VCM concentration outside the plant boundary was 3.2 ppb based on 1987 emissions.
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VAB.0001190911
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TABLE I WATER COMPLIANCE WITH
mXS PEfMIT PARAMETERS
i
Oct. - Ave. Max.
Nbv. - Ave. Max.
Dec. - Ave. Max.
Jdn * Ave. Max.
Feb. - Ave. Max.
Mar. - Ave. Max.
Apr. - Ave. Max.
May - Ave. Max.
June - Ave. Max.
July - Ave. Max.
Aug. - Ave. Max.
Sept. - Ave. Max.
Flow (3M
1229 1264
1222 1430
1083 1146
1326 1431
1521 1562
1208 1507
1076 1312
757 882
BOD PtM LB./TO.
5 77 7 100
15 212 22 378
8 106 12 155
19 311 25 426
11 201 14 262
12 179 15 211
6 80 9 112
9 81 11 116
OOD FEM LB* /eRT*
28 433 39 553
43 607 65 1117
35 468 51 659
68 1111 87 1476
45 818 51 955
55 824 75 1052
38 508 53 662
42 379 52 550
Stl8. Solids
HEM LB./DT.
10 147 15 215
22 310 25 370
14 191 20 264
13 213 18 307
12 228 16 295
23 342 34 473
18 237 27 336
17 152 18 175
r
Diss.
oz
8.4 8.6
7.4 7.9
7.6 8.2
7.5 7.7
8.4 8.8
7.8 8.8
8.3 8.8
8.0 8.7
NEL LB./DT.
PH
1.8 7.5 2.9 7.9
1.4 7.5 1.7 7.8
9.5 17.6
7.6 7.8
2.0 7.5 2.8 7.7
3.3 7.5 5.6 7.7
7.2 21.8
7.5 7.8
5.1 . 7.7 6.2 7.7
9.4 15.9
7.5 7.7
NPDES Permit Limits - December 1 through April 30
Ave. Max.
- 32 431 43 800
- 1462 - 2713
NPDES Permit Limits -- May 1 through Novenber 30
Ave. Max.
- 26 357 40 744
- 1212 - 2523
674 1396
> 6.0
13 6.0 - 9.0 28
674 1396
13 6.0 - 9.0 28
VAB.0001190912
; .-i :* n:
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LABORATORY - H. G. Coleman
A. Safety
There were no safety Incidents in the Laboratory this month. The safety meeting was "Change of Seasons", a taped show from the weather channel about thunderstorms and safety precautions to prevent Injuries caused by them.
B. Customer Relations
Customer Contacts
5/04 - Brian Harrison attended a technical conference at Vycom. Both companies' needs and concerns were discussed.
5/10 - Brian Harrison re-visited Vycom to witness a run of Chem Cut blue foamed sheet and to Investigate a "white specking" problem.
5/23 - Harold Coleman accompanied John Levardsen and Alan Butler to GM to discuss the specification for compounds sold to our window incapsulation customers (Dott, Donnelly, Lamar).
Requests for Corrective Action
There were no RCA's received this month.
Customer Problem Reports
Date
Customer
Product
Reason
05/02/88
Comn/Scope Cata&a, NC
38401 BLK
Streamers; unlnttHlng difficulties.
4
-
STATUS: Product returned to Aberdeen. RE9QLVTD
05/06/88 05/16/88
Hoechst Gelanese Delaware City, DE
5305
Foreign ocntaninatlon.
STATUS: Gontaodnatlon found not to be plant-related; suspect problems at i-awtrfnai.
RESOLVED
05/06/88
Trim Plastics Springville, AL
17462 GEY 545 Surge problems.
STATUS: Formllation problem; not plant-justified. RESOLVED
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VAB.0001190913
LABORATORY - Gontiiued
Customer Problem Reports - continued
Date
Customer
Product
Reason
05/18/88
Master Halco Olney, 1L
45541 NAT
Color/stability.
STATUS: Future production will be closely monitored for color consistency. RESOLVED
05/19/88
Soutlwire Ccnpany 1220-6X UT & AR building wire plants
VW-1 bum test failures.
STATUS: Formulation problem; not plant-justified. RESOLVED
05/25/88
Hoechst Celanese Delaware, DE
5305
Contandnatlan.
STATUS: Sanples tested verified contamination; resin shipped to less critical customers. RESOLVED
05/26/88
Chicago Magnet Wire 35851 NAT Elk Grove Village, IL
Burning on screen pack.
STAKES: Stability retested CK; formulation problem, not plant justified. RESOLVED
05/31/88
Hoechst Celanese Delaware City
5305
Low X.V. one roipiitnwnf,
STATUS: Sample sent by D&S was in spec (.745); evaluating sample from Hoechst. Resin will be shipped elsewhere, if necessary. RESOLVED
Production Return Notifications
Date
Customer
05/20/88 Comm/Scope Catas&a, NC
05/24/88 Comm/Scope Catawba, NC
05/25/88 Donnelly Corp. Holland, MI
Product 38401 BLK 38401 BEK
48562 GRY
Amount 988 lbs.
Reason Hard particles.
7520 lbs.
Streamers, fines.
2250 lbs.
Wrong product (color) shipped.
VAB.0001190914
LABGRAKXff - Continued
B. Customer Relations - continued
Waivers
Customers
Product
Utibco
5305
TVitchell
5415
C. RVCM Stannary
Amount 1 HT 2 RC
Reason Static flow I.V.
The following Is a sunmary of residual VCM results on in-process sanples. None of the reactor daily averages exceeded 400 ppm during the month of May, 1988.
Reactor Slurries
5265
5305
Nunber of Samples Average ppm* RVCM
948 128
42 0.4
55
0.2
KVCM of Shipment Samples
The following is a sunmary of the residual VCM analysis of shipment sanples for the month of May* 1988.
Product
5265 5305 5385 5415 5465 Dry Blend Pond Debax
No. of Sanples
54 106 28 64
Average RVCM* ppm 0.1 0.1 0.1 0.1
1 0.1
39 0.1
0 24 0 0.1
Resin Process Capabilities
5265 5305 5385 5415
Bulk Density
1.67 0.83 1.22 0.78
--
Inherent Viscosity
1.28 0.81 0.76 0.73
"L" Color Value
5.67 5.00 4.11 3.17
"A" Color Value
6.67 8.33
"B" Color Value
1.17 1.33 1.17 2.00
% on Pan (vs. 2% max.)
4.44
4.67
3.89
2.33 0.33
% thru 140M
1.19 1.15 2.02 1.47
Drytime
Mets I.R. (vs. 95% of Control)
0.44
--
---------------------------
0.42
m
1.25 0.65
Hard Particles (% 10)
2.8 1.7
VAB.0001190915
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LABORATORY - continued
4
Hardness Color/Clarity Hard Particles Heat Stability Contamination Dispersion Dicing Streamers Metal
Total
Adjustments MUbs. (%)
93.0 (1.35) ---- ---- 4.8 (0.07)
----
----
----
---- -- 97.8 (1.42)
Rejections M lbs. (%)
3.2 33.1 52.3
--
1.3 18.0 13.1 4.5
1.5 127.0
(0.05) (0.48) (0.76) --* (0.02)
(0.26) (0.19) (0.07) (0.02) (1.84)
Color Color/Bheometzy Rheometry Partial Box
Total
3.9 13.5 12.6
1.2 31.2
(0.07) (0.23) (0.21) (0.02) (0.52)
G. QuaUty Manaaanent Process
1. Harold Coleman, Richard Will isms, Brian Harrison and Dave Cox completed the five-day Team Management Training; Billy Paul Sizemore oust attend make-up.
2. Quarterly SFC charts on 1201 confound were Issued to Soutlwire.
3. Dave Cok completed an evaluation of a new digital hardness tester. A rnrtrgll angina capital request to purchase a unit with two heads was written. A report summarizing our findings will follow.
4. Analysis of dally batch plasticizer samples for percent residual alcohol was begun.
5. Dave Cok modified the shipment KMCM report to calculate KVCM to three Animal places, effectively giving the answer in parts per billion.
6. Harold Coleman updated the Mets IR data base on 5415 shipments and issued a report.
7. 5415 Control Resin (lot 04169) Testing?
n
Moisture Dry Time Particle Size - 60 mesh
80 mesh 100 mesh 120 mesh 140 mesh 200 mesh
Pan
63
0.160
0.037
29 4.99 0.46
62
1.20
0.49
62 31.13
4.85
62 33.22
1.42
62 20.85
2.61
59 7.27 1.36
62 5.14 2.16
62 1.16 0.51
VAB.0001190916
LABORATORY - Continued
7. 5415 Control Resin (Lot 04169) Testing: (cont.)
Bulk Density Color - L
A B Flow Time Hard Particles, 7 Min. Inherent Viscosity
H. Miscellaneous
nX3
31
0.5155
0.0050
49 100.465
0.335
49 -0.126 0.147
49
2.382
0.319
31 7.33 0.70
57 7.16 2.75
28
1.0031
0.0102
1. Harold Coleman, Richard Williams and Dave Cox attended various gggnpnfa of the Product Liability Presentation by Tom Grunbles and Mil McClain; Brian Harrison to attend make-up session at another location.
2. Brian Harrison oonpleted color matches for Intek and Coreloex.
3. Brian Harrison approved Superflex 100 as a secondary source of fine-grind CaOCL.
4. Dave Cox prepared thirty sanples of 5305 in the 1-100 ppb range and *ni- them to Hoechst for a correlation study. Results will be presented in June.
VAB.0001190917
-1
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RESIN Ship_Date 5/03/88 5/03/88
5/09/88
5/20/88
S AMFL E SHIPMENTS MAY 1988
>
Product
5385
5305 5385
5265 5305
5265 5305
Amount
300 lbs.
5 lbs. 5 1 bs.
50 lbs. 50 lbs.
50 lbs. 50 lbs.
Customer Lonza Incorporated Emery
Belden Corporation
Oatey Company
r
COMPOUND Ship Date 5/02/88 5/03/88 5/03/88 5/06/88 5/11/88 5/16/88 5/18/88 5/24/88
5/26/88 5/31/88
Product 35851 NAT 259-161 BLK 48451 BLK 27251 BLK 151-69E NAT 35852 NAT 35852 NAT 48451 BLK 48562 BLK 322-76C BLK 35852 NAT
DRYBLEND Ship Date 5/03/88
Produc t 90172D WHT 110
PLASTICIZER Ship Date 5/17/88
Produc t DIDP
,
Amount
1500 lbs.
10 lbs.
1500 lbs.
50 lbs.
200 lbs.
1600 lbs.
1600 1bs.
1400 lbs. 1400 lbs.
1
150 lbs.
100 lbs.
Customer * AT&T Technologies Wire & Cable Vista -- Ponca Lamar Industrial PTasbict, Cord Specialties Omega Plastics Universal Manufacturing Central Industries Excel of Tenessee Inc.
Precision Trim, Inc. Storm Products
Amount 100 lbs.
Customer
Tubular Protection of America
Amount 5 Gal .
Customer Vista - Ok C i
0001190918
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SHIPMENTS BY PRODUCT - M LBS.
MAY 1988
FISCAL YEAR-TO-DATE
RESIN PLASTICIZER DRYBLEND COMPOUND
28,705 705
4,527 6,458
241,211 5,222
41,752 55,616
NUMBER OF SHIPMENTS BY MODE:
TOTAL
40,395
343,801
RESIN-Bulk
RAILCAR 123
VISTA TRUCK TRAILER ON COMMON CUSTOMER BULK I VAN"" A FLAT CAR CARRIER PICK-UP I CONTAINER TOTAL
52
3 101
279
Package Export PLAST.-Bulk Package
34
'
7
,
&
1
13
7
1
DRYBLEND-Bulk Package
20
1
10
10 12 1
31 23
Export
COMPOUND-Bulk I
* J3
Package
Export
TOTAL MAY
159
4_
40
61 51
.
38 62
31 149
17 109
1 1 483
*
OCT 1987 NOV 1987 DEC 1987 JAN 1988 FEB 1988 MAR 1988 APR 1988
182 62 56 2 173 72 50 1 154 88 38 1
155 88 45 5
178 97 50 2 211 46 37 2 170 63 44 1
51 145 61 142 85 161 77 139
68 168
82 160 58 141
1 499
499
1 528
3 512 563
538
6 483
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VAB.0001190919
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SHIPMENTS BY PRODUCT - M LBS.
MAY 1988
FISCAL YEAR-TO-DATE
RESIN PLASTICIZER DRYBLEND COMPOUND
28,705 705
4,527 6,458
241,211 5,222
41,752 55,616
NUMBER OF SHIPMENTS BY MODE:
TOTAL
40,395
343,801
VISTA TRUCK TRAILER ON COMMON CUSTOMER A FLAT CAR CARRIER PICK-UP f CONTAINER TOTAL
RESIN-Buik
COMPOUND-Bulk
Export
TOTAL MAY
OCT 1987 NOV 1987 DEC 1987 JAN 1988 FEB 1988 MAR 1988 APR 1988
182 173 154 155 178 211 170
62 56 72 50
88 38 88 45
97 50 46 37 63 44
2
1 1
5
2 2
1
51 145 61 142 85 161 77 139
68 168
82 160 58 141
483
1 499
499
1 528
3 512 563 538 483
VAB.0001190920
F
0
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CC\OJ
UD
BTU/LB
LzoD
in
Xo
J
in
U<J
u. u.
XUS
IM ft
3C
ENERGY USAGE
Monthly 12-Month Moving Average
p
VAB.0001190921
MM POUNDS MONTHLY
40 35 30 25
20
15 j
ABERDEEN PLANT PRODUCTION
10/01/87 - 09/30/88
MM P0U'' CUMULAT
450 400 J350 300 250
200
150
100
50 80
70
GO 50 40
30
20 '
/u
60 50 40 30 20 10
/ ~-
4*
25
20 15
1 __ -
Oct.
i-----------rt-----------t:---------- }
'i
ii_^__m____ _t; _- -__- -_-___(f_- ______-_1t[-<_-___-_-----1 i
Nov. - Dec. Jan. i Feb.
-- i -- - |
-
liar. - Apr. May June 4 re 87/80
i -
July
--:--1------------>;-----------*1li -- . -. _- |I i Aug. Septj,
10
5
----------------- Biidget - - - - - Actual
Cumulative
VAB.OOOl190922
-h! -
1.020
1.015
1.010
1.005
1.000
0.995
1.030 1.025
1.020
1.015
L
1.010 1.005
1.000
1.020
1.010
1.000
.990
1.200 1.150 1.190 1.050
6.0 5.0 4.0 3.0 2.0 1.0
0
%
OFF-GRADE
KOO
.75 .50 .25
0
ABERDEEN PLANT QUALITY PERFORMANCE
10/01/87 - 09/30/88
J
4
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t
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VAB.0001190924
ABE RIES
10/01/87 - 09/30/88
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VAB.0001190925