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T. H. Huffman IllltfWMB Cowwunltallon From: Data: Subfact: D. C. Skokna March 25, 1991 ABEKDKEV MDITffiJ PROGRESS IDOKT FEBRUARY, 1991 There was one first aid and one recordable (MT) injuries reported in February. The recordable injury involved a mechanic who picked up a hot bearing heater and suffered minor second degree burns on two fingers. As of February 28, 1991, the plant's employees have worked 4,256 days (5,687,388 manhours) since the last lost time inj ury. 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 Operations Februarv 36.2 87.8 98.1 1.01995 3.9 96.5 4.0 99.9 1.5 80.7 < 13.8> 36.3 52.4 Y.T.D. 201.1 88.2 98.6 1.02338 22.4 96.7 23.0 99.6 8.0 85.8 96.0 34.8 A rH V Resin production was reduced to lower product inventories. The second phase of VCSM training was completed with the dryers being switched over to the new system planned for March. Both rigid and flexible compound production rates were reduced to lower product inventories. Improved steam stripping procedures in the plasticizer unit im proved the residual alcohol Cpk from 0.04 to over 1.0. Costs Fixed costs were $36.3M favorable primarily because of payroll which was $54.4M favorable, offset some by benefits clearance that was $31.7M unfavorable. The other categories were near budget. Variable costs (efficiency) were essentially at budget. VAB.0001189781 T. H. ftiffim 03/25/91 Abcrdatn Monthly Progress Report Pago 2 - February t 1991 m All natural teams net during February. m Vinyl "A" shift made their management presentation. Their efforts reduced nitrogen use 30%. i On 2/21, AT&T visited the plant to present us with their "Certified Quality Vendor" award. Vista is one of fourteen suppliers (out of 800 active suppliers) to receive this award. We met with the State to review the method used to set our new NPDES permit parameters. Also, we sent a letter stating that we felt the proposed 10 ppm BOD limit is too stringent. The State agreed to re evaluate the limit. A test run using "superbugs" started this month. These bacteria are more efficient in assimilating the contaminants present in our wastewater. The State approved the delay of the remedial investi gation as requested by DuPont. The report is now due April 26, 1991. A second geo-physical study success fully found the buried drums we could not locate during an earlier study. We met with the State on renewal of the air operating permits in particular about which VCM unit risk factor is correct. Our contractor, Clement Inter national, presented their work to determine the correct factor. The State agreed with Clement that the factor they were using was incorrect. The State wants to verify Clement's work with EPA and wait until the VCSM project is complete before they will renew our permit. D. C. Skokna Plant Superintendent rah VAB.0001189782 Hems ton J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin 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 Haaunond L. R. Bauer J. Pavao X X C. R. Miller Premiere P. L. Foote Aberdeen RVS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, HRK, DAB , DAM, RBN, JEN, JDO, REP, BLT X X X X X X X X X X X X X X A wmhmnmnwpmmpwhmmmv VAB.0001189783 ll^^i ii 1 SAFETY - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 1 1 2 0 0 Fiscal Fiscal Y.T.D. 1990 32 00 Vinyl Operations Compound Operations Maintenance H. Laboratory Re c e iving/Warehouse Office Totals 010 032 276 000 000 1 29 Cuts and Abrasions Eye Injuries Burns Bruises S trains/Sprains Stings Other Totals 03 00 12 02 13 00 a _2 2 12 2 1 2 1 0 1 Lost Workday Cases Days Lost Safety Rg^prd Last lost time injury - 7/5/79 Days since - 4,256 Employee hours since - 5,687,388 On February 28, 1991, the employees of the Aberdeen plant completed 4256 days with no lost time injury. Topic for the plant safety meetings during the month was "Health Training". VAB.0001189784 SAfEii - Continued Routine dosimetry results for the month were: Chemical <_________________________ Number ;> PEL Number Percent VCM Lead Total Particulates 70 98.6 1 6 100.0 0 6 100.0 0 The single VCM overexposure was with benefit of a respirator. Inlurv Class MT FA Department Maintenance Maintenance Bum - index and middle fingers of right hand. Strain - right wrist. A VAB.0001189785 * - T. J. Arbeitar All of the plant's natural teams met during the month of February. It was previously reported that two teams failed to meet during the month of January. In fact, only one team failed to meet. This was a three-member team scheduled to meet the last week of the month with two members absent the final week due to illness and funeral leave. The Vinyl A-Shift Natural Team made a presentation to management on February 25. The team studied nitrogen use in the plant and identi fied the sources of leaks. Through engineering and operational changes, nitrogen use in the plant has been reduced by 30% since August, 1990. The team recommends converting to bulk nitrogen when capital is available. This will further reduce nitrogen losses and eliminate the safety hazards associated with handling nitrogen cylinders. Other natural team highlights for the month included: The Vinyl C-Shift Natural Team continued work on their project to reduce VCM levels in discarded VCM filter packs. Initial results seem to indicate that procedures will allow for the disposal of the filter packs as non-hazardous waste. m The Vinyl Operations Supervisor's Natural Team is currently working on a project to update all of the vinyl operating procedures. This project is not only critical to dally operations, but will also allow for compliance with new OSHA regulations and ISO standards. The Senior Process Engineer's Natural Team (Steve Hillman) developed experimental design examples to be included in the DOE handbook they are preparing. The Senior Process Engineer's Natural Team (Mike Kane) began work on their latest project - the development of a statistical reference manual. The Plant Manager's Natural Team finalized the selection of cash flow improvement projects totaling $1.25MM annually and began work on these projects. The Safety Director's Natural Team finalized plans for the respirator fit testing project. The Warehouse/Purchasing Supervisor's Natural Team continued work on their inventory reduction project. The team selected vendors to be contacted on the sale of excess materials. iMUfflP VAB.0001189786 + Ht- On February 21, AT&T came to Aberdeen to present the plant with their "Certified Quality Vendor" award. Vista Aberdeen is on# of only fourteen AT&T suppliers to have achieved this quality vendor status (AT&T has 800 active suppliers). Aberdeen personnel and AT&T worked together through several audits to improve the quality systems at the plant. Vista supplies AT&T with 34862 grey compound used to make cable jackets. AT&T will no longer inspect incoming Vista compound. VAB.0001189787 HOST VABTAWC1M . D. PVC Flexible Compound Rigid Compound Plasticizer Total $ 43.3 < 37.2> 98.2 < 0-3> $104.0 $28.9 2.3 < 1.2> 22.4 $ 52.4 <$344.4> < 227.0> < 202.8> < 70.0> <$877.2> Total <$305.2> < 261.9> < 105.9> < 47.9> <$720.9> these products was close to budget. The overall efficiency variance for VRP yields were better than budget mainly because material not accounted for last month was recovered in February. Price VCM Resin to Rigid Compound Resin to Flexible Compound Alfol* 610 Plasticizers Phthalic Anhydride Colors Natural Gas Other Price Variances Total <$387.7> < 189.7> < 116.2> < 40.6> < 45.4> < 37.2> < 17.6> 24.9 < 67.7> <$877.2> Fixed Cost Variances Variance - SM m Payroll andBenefits MM&C i Miscellaneous TI&D m Clearances Total $ 22.7 8.2 < 0.5> 5.9 < 0> $ 36.3 Ik VAB.0001189788 HOST VABTAMCKfi - Continued Payroll and Benefits Payroll costs were $54.4M favorable while benefits were $31.7M unfavorable. MM&C This was essentially at budget. Removal of asbestos from two plasticizer reactors (caused by a small fire under the insulation) prevented us from having a larger favorable variance this month. Moving, Home Assistance - <$19.6M> ynclassified - <$10.2M> VAB.0001189789 * VIHYL - J. D. Olson, D. E. Knlttlg The Vinyl Department had no first aid case or OSHA recordable injuries during February. The monthly safety meeting topic was "Health Training". General 1. Inventory control was implemented to meet the production target of 37.0MM pounds. 2. The second phase of VCSM training for vinyl operators was completed. The dryer panel training included a review of the DCS dryer operation, operational programs, and "hands on" practice. 3. The resin raw materials in the 744 account were valued at $261.0 M. Feb. 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 % 36.2 1293.5 101.4 849.0 30.3 87.8 93.1 99.6 98.1 201.1 1330.9 104.4 4673.0 31.0 88.2 93.3 97.0 98.6 Reactor Downtime Hours Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts and inventory control). 354.0 Maintenance downtime (VC charge line plugged in Old Module, power outage, transformer problems, maintenance on D744 gearbox, D600 rupture disc and relief valve replacement, removing Old Module chem wash lines, hydro blasting D745, hydroblasting and drilling D744 condenser, and BUS-80 maintenance). 466.0 \ VAB.0001189790 VINYL - Continued Operational downtime (centrifuge plugs, dryer cleaning, flameouts). Maintenance downtime (centrifuge maintenance, baghouse screwfeeder maintenance, preventive maintenance, and exhauster work). Reactor limited production. 31.4 33.5 35.2 J. B. Autrey, S. A. Truitt All old chem wash valves were pulled out of the Old Module. The valves will be used in upcoming projects and as spares. m Since reactor 600 is not currently running low mole resin, the original relief valves and safety discs have been re installed. Temporary repairs were made to #6 dryer exhauster. Excessive vibration is causing balance problems. The exhauster will be changed out in March. The motor on #6 dryer had to be replaced because of bad windings and bearings. Reactor 745 was brought down for hydroblasting and acid cleaning on the water side of the condenser. Problems with contamination had developed, but were brought under control. Reactor 744 was also brought down for hydroblasting in an effort to control contamination. I&E personnel completed training on the UPS feed systems for the new vinyl control room. A VAB.0001189791 CQMFOmg) - J.E. Bickerson, K.6. AHn SUffttY The Compound Department had no OSHA recordable injuries in February. The topic of the monthly safety meeting was "Health Training". general Control of costs and inventories continued to be a high priority during February. Combined flexible and rigid compound inventories fell another 1.47MM pounds during the month. Lines were operated only on an as-needed basis and operators from shutdown lines were utilized to cover vacations and other absences to reduce overtime costs. Repairs to the Line I roll mill lubrication system and a Line III ribbon blender were responsible for some abnormal maintenance downtime. The use of new steam stripping procedures in the plasticizer unit have improved our residual alcohol Cpk's. Before the new procedures were in stituted, the Cpk was 0.04. The current Cpk is 1.0 and more improvement is possible. Operating Line I 27.5 Line III 21.5 Line V 9.0 Total % Prime Capacity Utilization Factor 1651 1911 301 3863 96.5 46.2 60 89 140 Downt ime Hours Line I - Product Changes - Hill Maintenance - Quality Problems &Control - Miscellaneous Maintenance 83 30 28 16 Line III - Product Changes - Miscellaneous Maintenance - Quality Problems & Control - Blender Maintenance 57 32 18 11 8417 12762 1232 22411 96.7 55.7 * VAB.0001189792 COMFOUHD - Continued Line V - Miscellaneous Maintenance - Product Changes - Startup/Shutdown - Quality Problems & Control 24 23 23 10 Operating Month Rigid Compound 23 % Prime Capacity Utilization Factor 3975 99.9 67.2 173 Downt ime Hours - Quality Problems & Control - Product Changes - Miscellaneous Maintenance 51 45 37 Operating JLJL. 23030 99.6 77.8 Plasticizer 28 % Prime Capacity Utilization Factor 1450 80.7 77.0 52 Key Maintenance Work - J. B. Autrey, S. A. Truitt 7951 85.8 84.4 Line X "B" blender gearbox seal was leaking and was replaced. The vacuum blower was pulled and cleaned. Pluggage was suspected when the system was not operating properly. The Line V CPU board was replaced in the Orbitran panel. VAB.0001189793 BKT1HBTWP. - R. R. Polk. 8. C. Hillman, M. R. KlM GioncAT. The Class "A" design was finalized. The project was submitted for approval as a part of the Third Fiscal Quarter 1991 Capital Budget. The project will replace the two existing Gump screeners with two sixty-two inch Kason screeners, resulting in significant improve ments in the ability to meet customer oversize particle specifica tions . The test of "superbugs" is continuing. Initial analysis results show single digit BOD values (8 ppm) , down from 30 ppm prior to the test. The impact of the "superbugs" has been positive; the test will continue through the middle of March. Current operation has centrate being sent to the sewer after having heat recovered and water stripper effluent going to the cooling tower. At present, the antis tat being used on the rotary dryers (wet calcium stearate) does not allow the centrate water to be re cycled to the cooling towers. The wet stearate fouls the towers and the equipment in the cooling water system. Until a suitable substi tute is Identified, the current operation mode will be used. Two HA20PS were issued for review in February. One was for the Incinerator Replacement Project and the other was for the Dry Blend Screener Project. Initial conversion of process equipment to the DCS was completed successfully. Dryer number 1 started up with no major complica tions. Conversion of the remaining rotary dryers will continue in March and should be completed by early April. Operator training and qualification testing is about fifty percent complete. Also, the DCS operating system software has been upgraded to version 10.0 which Is the latest version available. The project continues to progress as scheduled. A VAB.0001189794 h. ENSINEERIH6 - R.E, POU, 3.C. HILLHAN, R.R. KAK AIERKEM CHERICAL PLANT APPROVE) CAPITAL PROJECTS A AFE HMKR PROJECT OESCIIPTIW STATIS A8M *mn im nkuk CLOSE) TS FIELJ CHAtBCS. AS19 run tuciucK mp THE PROJECT MIL K ClttCI II FIEII CRAMES ill NK. AA49 nn. cwm.sma mkmbitiw tk ni mmm is m site, mmm if m mm is planki fii rmci am anil. A909 inn antHNncuiM IS11 rai utm MiinuTiM TW PROJECT HU K CUK II FIEII CIMMIS 1NMRCN. mm is samo n kin in mi. M29 rWMMMMMMI IBfMfll.fHmB I1fBtlMlMWIffItI CII9ltTIUfl INSTALLATION II CONFUTE EICEPT FN POWKIST ITEAS. FIELI CL8S8IE IS PLANKI FN MtCI. 0749 LEM RANHMI AM IIPMMI IflHfTIM imtalutim is a mmn im mmm planki fii macs. 1149 cmw life i mi-pi ummmuk ciTMcn is i mmm m planki fm cnputim in inch. )8S9 CMMM MU imiauaum is impute assn fm unmust item. 1)899 RAILCM CLMNNO MM mm is nmms. project cmpletion is planki fm nay. F699 LOO ROLECNLM IEIMT KSIH EXPANSIOH the project sill k assEi rs fieu csmses in mki. F779 MYERS NMAS COWMfNATION IEIUCT1IN ASIITIML PMHUSI ITEM ME UMtt COMIKIATION. 6159 Uffll rmM Uftft umiMiMKM i 1M M1IIMMMM IF MM II C0MU1C AM IK PROJECT MILL IE CLOSE* TO Fiai CNAMES IN APRIL. 5819 VCR SINT MAM KPtACEKMT CLOSE) TO FIEU CSMKS. 6039 PLAMT RATER HMOl TK PROJECT IIU K CLOSE) TO FIELI CHAISES IN AMIL. 1570 hi mu rnmnnsni tain KSIIN IS MMIEIEb IMTALUTIM IS PUMO FM 7/91. 1510 KtHBI M> Mr MUM KUEF KSIIN IS CflMUItfr IMTALLATION IS PUNK! FM 7/fl. 0180 PLASTICIZER L0A0IM AM MUAIIM KVISIOHS KSIIN IS IN PM0KI1 HITS CNPIET1QN PLANK) FN RAT. / FASO un win* in knctim comtmchm IS MflMKSS llfl CMPLETIIN PLANE) fm APRIL. FAAO KCALCIF1D M1KL MMTMOTM H IN PMMISSIITR CWPUTION PilMK) FM AWE. OSAO TC SPIU CDNTAIHNEHT INSTAUAT1M IS CIMIETE EXCEPT FN PUNCHLIST ITERS. SAID TC CORFUANCf PROJECT INSTALLATIN IS CMPLETI EXCEPT FOR PRNCKIST ITERS. 6A30 REACTM SLUM! STRIPPIM OPTIRIZATIOH IMTALLATIM IS CMPliTE AM TK STSTIS OPERATIONAL. FIEL) CLOSURE IS PLANK) FM APRIL. H500 PLANT jj-RA-Ti M STITEH HS10 KST 1KIKMTM IfFUCPENT EMINKIIM IS IN PMMISS. PROJECT CARPIETION IS PIANNM FM LATE-1991, KUHRT IF TK INQNEIATM IS PLANK) F9R 3/91. PROJECT CMPtETION IS PLANK) FM 5/91. HA20 EAST IKWIW KILACEKHT KLIKST OF TK HKMMIIM IS PLANK FIR S/ft. PROJECT C0RPLET10N IS PLANK) FOR 7/91. H501 iiisceumm (trim mnrs < tin EMINBIIM II IN FNNCSS ON IS PROJECTS. H521 REPLACE**! IIKKK VISC0I1TT ANALYZER i THE EIOJPNENJ Nil ION RECEIVE) AN) TIE PROJECT SILL BE CLOSE) TO FIEL) CHAISES IM MARCH. HS31 BOILER FIENATE! TAM KPIAKKNT mm IS SCKMLE) TO KOIN IH RARCH. VAB. OOO1189795 J* F. 6. Jeanion Water All wastewater discharge parameters were met for the month of February. We met with the State Water Quality Department to review the modeling procedure used to determine our permit limits. They agreed to run some additional ca**s of mur outfall'varying dissolved oxygen anil flow in James Creek. In addition, we talked about verifying the model with actual data that we would gather in the summer and what was involved in obtaining a winter 7Q10. A letter was sent to the State informing them that we feel the new 10 BOD permit limits in the revised draft NFD3SS permit are too stringent. The State responded verbally to our letter and said they war# re-evaluating the permit limits. The State was in the plant this month for their semi-annual inspection of our wastewater and stormwater samples. They collected samples from all four of our outfalls. A letter was sent this month notifying the State of two changes made to our boiler and cooling tower chemicals. A test run of superbugs" was started this month in our wastewater treat ment system. Some BOD reduction has occurred since we started. iii Superfund The State approved the delay of the remedial investigation final report as requested by DuPont Environmental DERS. A meeting was held with Conoco and DERS to discuss the test results from samples taken of and around the superfund sites. The final report for the remedial investigation Will be complete at the end of March. This report is due to the State on April 26, 1991. A second geo-physical study was completed to find the buried drums. This time it was successful. The drums were found fifteen feet below ground level. A drum removal clan is being out together bv DERS. An audit of Sun Polymers by Conoco and Vista was completed this month. Conoco is interested in evaluating the option of drying pond #2 resin here in Aberdeen. A meeting will be held next month to discuss all options. Waste Waste shipments during the month included: One bulk shipment of floor sweepings to CWM in Lake Charles, LA. m One bulk shipment of separator oil to M&M Chemicals in Gadsden, AL. VAB.0001189796 HUMP F. G. Jeanson - Continued A meeting was held with the State to discuss our operating permit renewal. The meeting was centered around the unit risk factor controversy. Our contractor, Clement Int. , presented the work he had done to determine the proper unit risk factor. After some discussion, the State agreed to the lower risk factor. The State wanted to verify Clement's work with EPA in Washington and wait until the Vinyl Control System Project was complete before they renewed our permit. They said our permit would stay in effect until that time. The annual Vinyl Institute environmental survey was completed. Once again we had 100% compliance. An environmental presentation was made to the 20th Century Club. I attended the annual legislative reception held for our Representatives and Senators. The resin claim dryer has been sold. p ayment. Sun Polymers made a 10% down The every four years TSCA report was completed and sent to EPA. This report summarizes the amount of certain types of plasticizer we manu factured in 1989. - J. &. Ganc A. Unadj ueted EUI <14.8%> B. Adjusted EUI <13.8%> C. BTU/Lb. Product 2883.7 D. Total Energy Consumption MMM BTU 131.2 < 7.9%> < 7.1%> 2740.0 689.2 Boiler No. 1 No. 2 No. 3 83.4% 83.3% 82.9% 83.1% 83.3% 82.8% All three boilers operated all twenty-eight days of the month. VAB.0001189798 A None J. E. Beall Melvin Tallie, Development Technician, Laboratory Reduction in staffing - employee exercised seniority into Lead Technician position. Dave Gathings, Jr., Compound Operator, Compound Department - Promoted to Compound Shift Supervisor. Douglas Knittig, Process Engineer, Process Engineering Department - Promoted to Operations Engineer (replacing James Vinoski). None None None VPVMP wm j VAB.0001189799 15 12 40 23 37 33 5 165 75 90 50 80 62 21 1 10 1 20 61 4 6 18 60% 42% 20% 26% 57% 30% 40% 37% 8% 0 0 0 8.3% 2.7% 3.0% 0 0 0 0 0 1 0 0 2.4% 24% 0 0 0 0 1 0 0 iMJJiW*1 U*M*WT 9800 % A DEPARTMENT HOURS ANALYSIS REPORT /DISTRIBUTION LIST RNS, JFC, JVU, DEPARTMENT HEADS, FILE 2 4/91 THRU 3/ 3/91 cncoco <c fmm 4 Ul 8ui VAB. OOO1189801 O) s Cu SiXI & CJ oc WtS 5% <E:3<n>rn uw w to LU <cUoiMCnO / tiii iCn\* SP to (O CO s 5 NPW T\ VAB.0001189802 - D. A. Barclay There "were no reportable safety Instances this month. All natural teams met in February. Statistic* Processed Invoices Working Fund Checks Written Cost Savings Through Bid Process Packaged 944 12 $5277 62 $17497 (Decrease ) Compound "A" Grade PLENEX * Compound Off* Grade (BC) CompoundOff-Grade (H) MillscrapC*) Dry Blepd "A" Grade Dry Blexp Offgrade Resin Type I Resin Type *iC" Vacuum Qftst Total packaged Warehouse 3,960,418 80,945 889,372 57,750 116,100 449,495 50,074 367,470 36,950 6,310,588 * Include PLENEX millscrap and cleanout. 1* 1 kA iip Mp ifiEX w 4,035,813 64,682 734,449 73,172 132,457 312,968 44,605 636,800 37,600 327.141 6,399,687 75,395 < 16,263> <154,923> 15,422 16,357 <136,527> < 5,469> 269,330 650 89,099 i (Decrease) Compound "A" Grade Compound Offgrade Dry Blend *A* Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade Total 2,272,254 552,350 2,118,423 879,940 10,983,350 ___ lSd,100 16,962,417 1,774,593 368,450 1,550,810 1,057,260 5,926,210 ___ SSjhlSQ 11,257,573 < 497,661> < 183,900> < 567,613> 177,320 <5,057,140> ____424.150 <5,704,844> VAB.0001189803 1000 gWUHMLMk m 91 osno 03/90 06/90 10/90 12/90 03/90 07/90 01/90 11/90 01/91 PKGTD PRODUCTS INVENTORY VAB.0001189804 3 g gs tn to s Sf S IO CM tn i ii ll 8E to cn ss t "i s CM CM M K> CM CM CM CM m PT lO to IS to to to o .^ m cn ui cn cn to Ui UU UI ddd iiiii CL dL ^ dL a. CM SSSRIf-s HISSSI32S ss ?f I? ?N W M c ^ 4 r 5553SS S S & op s s opo^oo ^ ^ O' CO O' f ir g ^in i g 5 R s I oStSSSoSSc* K-- cu CD to I to cc s a as il cn to =3 t-1 DC m m mM3 CM CO m cd -- CM O CM CM *M CM CM CM uo no ? CM I Ol NO g ch m q o- CO irk op m cn i i NO co mH 5 25 9o o NO NO NO NO -4 m o NO rn NO NO NO NO NO NO NO NO NO NO CM 4T NO N*- NO NO NO NO a$s CM CM NO CM 3 O t*o HO O HO --4 NO CD CD HO CM CM NO CM NO CN* HO NO NO NO NO NO CM NO cn cn c0n0 cn ss St CM CM CM CM HO HO -M NO CM a M g g gj g "ui tn S3S8S m >tn a cn s cn CD HO MO NO CM CM HO NO CM -- *-- 3 Si 8 HO HO HO HO c* NO NO CD NO ZD HO CO CM UO 81 NO NO uO HO i7 S3! "38 iti CM CM CM M* Ml Ml CD 5 3) Mg CM CM CM CD UO CD HO O V -4 Ml CN C tt *o HO NO CM CM tI NO NO S NO II CCNMM OCCMM* I ts o o ? O Q ? O O r* 11 1 11i N* NO NO NO NO NO NO 9^ CN CM CM CM CM CM CM II CM I cn cn ss cn cn in cn U CJ HO UO MMWMPMHMV 8 cn cn 3 F4._ i CM CM Biisiliiii cn cn cn cn cn I a S8 IX cn 5: - *i CM CM CM CM CM CM CM CM CM CM at 83 tn Ui CnCM CM CM CM mrnmm tn CM Su mm C t.a BOXES A CO 3SS to to c a tJ CU CL uu 2 tt tfc fsS MO CM --* CM CM a aCM CM ~ & CO I NO II I ccmo <en po S S8 5 SCM CM N2N ** ^9 NO NO NO NO NO 3 HO CM NO NO !- Q CM S3X08 3 tn ^CJ CM NO CN* CM X CM o auu M 8 II R HO 8 8 z> tn s II NO I I-*- nk I HO i i CM CO NO HO O l O O* II CD CD NO NO CO O g> tn cu tn UU tn u cn w cn u cu CD i cn CJI tJ tUni tUni Ou Ct UO HO UO VAB.0001189805 CM CM CM CM mm ABERDEEN CHEMICAL PLANT SNIPPING ANALYSIS FEBRUARY 1991 -SNEPMEMTS BY PRODUCTS- PUBLIC RESIN-BULK RESIN-PACKAGED 18,790,220 201,638 FLEXIBLE COMPOUND-BULK 843,530 FLEXIBLE COMPOUND-PACKAGED 2,743,789 NEW BUSINESS 500 RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED 3,803,040 391,923 TOLLING - BULK TOLLING - PACKAGED 0 0 PLASTICIZER 43,720 TOTAL 26,818,360 *SHIPMENTS BY NODE BULK: FEBRUARY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER RAILCAR 162 8 24 3 TOTAL FEBRUARY 197 YTD* RESIN FLEXIBLE CONPOUNO RIGID COMPOUND PLASTICIZER 834 53 114 11 TOTAL YTD 1,012 PACKAGED: FEBRUARY* RESIN FLEXIBLE CONPOUNO RIGID COMPOUND PLASTICIZER CUSTOMER PICKUP 5 28 1 0 TOTAL FEBRUARY 34 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 20 108 6 0 TOTAL YTD 134 MONTH IPT/ITC EXCH/TOLL 14,972,710 296,300 167,600 0 888,800 81,846 0 0 00 531,800 9,000 0 0 00 00 89,400 554,450 16,869,856 722,050 PUBLIC 97,738,994 974,183 3,640,990 13,219,148 33,353 16,818,700 1,764,234 0 0 648,670 134,838,272 CUSTOMER PICKUP 56 0 12 0 68 CARRIER 37 3 3 3 46 224 181 0 15 16 61 29 20 269 277 CARRIER 14 55 10 0 79 TOFC AIRAIPS 00 00 00 00 00 AIRAJPS 6 9 1 0 16 60 0 0 334 0 0 63 0 0 1 00 458 0 0 28 56 3 0 87 YTD IPT/ITC 69,161,470 1,134,600 5,930,200 711,002 0 2,869,350 521,706 0 0 630,070 80,958,398 EXCH/TOLL 1,413,500 0 0 0 0 0 0 1,401,960 33,600 2,722,110 5,571,170 TOTAL 255 11 39 6 311 1,239 68 191 60 1.558 TOTAL 25 92 12 0 129 108 498 72 1 679 VAB.0001189806 TABOBATOBT - J. M. Edwards, Jr. A There were no safety incidents in the Laboratory during February The monthly safety meeting topic was "Annual Health Training". B Customer Contacts Representatives from A&T visited the Aberdeen Plant on 2/21/91. Ms. Cheryl Cincetti with AT&T made a presentation to an assembly in the Plant and awarded us the "Certified Quality Vendor" award. 02/04 Customer complained of contamination in 38552 NAT compound, lot 10B10. During the production of this material, there was an Incident of contamination in the product, Several boxes were downgraded and the problem material was assumed to be isolated. A procedural change was made to downgrade product boxes on either side of the discovered out-of-spec material. 02/04 Customer complained of contamination in com partment CB of 5305 railcar #46436. The compartment was transferred to their B-Grade silo. All samples, including the samples sent from Klockner of the contaminated compartment showed to be within specification. No further action is planned. 02/06 Customer complained of significant drop in Cpk values for 5415 shipments in the 4CQ90 for IV, contamination and percent moisture. A letter of explanation was written by Process Engineering. 02/08 Customer complained of difficulty unloading two recent 5385 railcars. The Aberdeen Yard Department assisted (via phone) to solve the problems. mm&mi - Continued Continued Customer complained of difficulty breaking down 384FR compound. Nothing definite was discovered to explain the difference. The Technical Service Group will followup on this problem. 02/22 AT&T. Customer complained of receiving underloaded railcars. AT&T has asked that our cars be filled at least 180,000 pounds. More dis cussion is planned to resolve this issue. 02/22 Customer complained of various types of con tamination plugging 5305 silo outlet sifters. Some of the contamination origi nated at the CSX terminal. The same type of contamination was found in Oxy resin which uses the same terminal. Samples of the con tamination have been sent to Austin R&D and CSX for further study. Another trip has been scheduled to talk with Mirrex and the CSX terminal. Customer complained of bad smelling pallets in a shipment of 452-106A NAT, 89A compound. Investigation is underway. Customer complained of contamination in six railcars of 5305. A majority of the contam ination was line scale that resembled "onion skin" Four of the cars were Vista's. One of the cars was from Pac West and one of the cars was a competitor s. All of the samples looked the ie. Samples have been for warded to Austin R&D for chemical analysis. A meeting has been scheduled at Klockner the week of March 25. A letter has been sent to Klockner explaining what we have found thus / VAB.0001189808 tjutoattwy - Continued Cmstumer Dayton Essex Group H&W Stylecrest Product RP-151 WHT 145 5415 5385 RP-27 WHT 113 Reason Color Particle Size Static Flow 40 Mesh Ho. 1 R/C 1 H/T 1 H/T 2 R/C The following is a summary of residual VCM results on in> process samples. None of the reactor dally averages exceeded 400 ppm RVCM during the month of February, 1991. Reactor 530 Number of Samples Average RVCM, ppm 30 0.186 49 0.186 The following is a summary of the residual VCM analysis of shipment samples for the month of February, 1991. Product Average RVCM. ppm 5265 5305 5325 5385 5395 5415 5465 Dry Blend Debox Pond 40 53 3 74 1 40 3 17 8 6 0.093 0.107 0.096 0.282 0.008 0.045 0.091 0.070 0.707 0.255 A VAB.0001189809 TABQATPBY - Continued r (based on dryer "regulars") 5265 5305 5385 5395 Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle size. microns 1.20 1.57 -- 3.72 7.67 3.017 1.43 -- 1.00 -- -- 136 0.46 0.69 0.18 1.87 9.00 3.50 1.13 -- 0.68 -- -- 140 1.15 0.62 2.00 2.50 1.25 -- 1.05 ---- 71.5 161 *_ -- ---------- * -- -- - -- -- 5415 1.06 0.53 4.00 5.33 2.06 0.39 2.54 5.06 2.29 0 170 Hardness Specific Gravity Color Hard Particles Heat Stability Contamination Dicing Cross Contamination Mischarge Total H I^bs. XU 5.0 5.0 175.0 <0.12> <0.12> <4.34> 185.0 <4.59> 34.5 50.4 7.8 34.0 10.5 4.7 14.9 156.8 <0.86> <1.25> <0.19> <0.84> <0.26> <0.12> <0.37> <3.89> There were no rejections for the month. I. Miscellaneous 1. All six natural teams met during the month. 2. The new resin viscosity instrument was installed. and 3. The Coulter particle size analyzer was put in Q.C. service on February 25 measuring all in-process samples. Con currently, shipment particle size analysis was switched from wire mesh screens to precision screens. 4. Dave Cox completed the IPA software program to run on PC's. VAB.0001189810 SAMPLE SHIPMENTS FEBRUARY 1991 RESIN Ship Date 2/06/91 2/08/91 2/12/91 2/15/91 2/18/91 2/18/91 2/22/91 Product 5265 5265 5305 5415 Sifter Overflow "Coarse" 5385 5415 5385 5415 5265 2/25/91 2/27/91 2/28/91 2/28/91 5415 Control 5265 5305 5385 5415 .5385 5415 Aaount 300 lbs. 50 lbs. 50 lbs. 50 lbs. 5 lbs. 1 kg. 1 kg. 1 kg 1 kg. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 100 lbs. 100 lbs. Custoaer Nibco (KY) Kenrich Petrocheaical Inc Ethyl Corporation Shawnee Chemical FADALTEC (Colombia) FACOMEC (Colombia) INDUSTRIAL ENVAMEX S.A. (Mexico) Vista - OKC IND. PLASTICAS INTERNACIONALES INDUSTIAS CONELEC ETERPLAST S.A.(Ecuador) COMPOUND Ship Date 2/04/91 2/06/91 2/07/91 2/08/91 Product Vistel 9102 WHT 449-78 WHT 110 18162 BLK (OG) 419-50-C NAT 02 419-79-C NAT 02 17462 WHT(OG) 38931 WHT(OG) Amount 3200 lbs 2840 lbs 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs Custoaer U-Brand H. Heller Coapany Akzo Engineering Plastics Gentry Manageaent VAB.0001189811 COMPOUND (Cont.) Saaple Shipaenta/February 1991 Page 2 Ship Date 2/08/91 Product 462-34A BLK 462-34AX2 BLK 462-34B BLK Amount 50 lbs. 50 lbs. 50 lbs. Customer Vista - Austin 2/12/91 462-34AX1 BLK 50 lbs. Vista - Austin 2/15/91 2/15/91 MSP-80 419-79-C NAT 02 100 lbs 50 lbs. Vulcan Metals Vista - Austin 2/21/91 57462 NAT 57561 NAT 58561 NAT 300 lbs 300 lbs 300 lbs Vytron Corp. 2/21/91 419-68 NAT 1400 lbs. Tines Fiber 2/21/91 17561 NAT(06) 17462 GRY 545(00) 18162 GRY 545(OG) 1 lb 1 lb 1 lb Prototype Plastic Extrusion Co, Inc. 2/21/91 461-120A WAT CL(OG) 50 lbs. Renee Products Corp. 'l DRYBLEND Ship Date 2/07/91 2/12/91 2/13/91 Product Amount RP-151 WHT 145(OG) 1210 lbs. RP-151 WHT 145(OG) 1500 lbs. 80172C WHT 110 100 lbs. Customer Stylecrest Western Ag Sales Co., Inc. THE BRUNA CORP. MISC. Ship Date 2/18/91 Product Vent Dust Amount 5 lbs. Customer fr Able Plastics VAB.0001189812 A TOTAL INJURES OSHA RECORDABLE VAB.0001189813 ABERDEEN ENERGY CONSUMPTION f mrn i#ni VAB.0001189814 *