Document DGR38GyJ5JbappVGQpv06VZp5
H. W. Hilgers
CoiMMUflllCCMOII
From:
Dote:
Subject:
D. C. Skokna January 25, 1993
Auamm mqwthly mows bspcks
DECEMBER, 1992
There wee one recordable case reported In December. A yard
operator received second degree bums to bis left hand. As of
December 31, the plant's
85 days <104,112
enployee hours) since
FTP
PVC Production, MM Lbs. Stream Factor, Frine
Ills.A *
%
Energy Use, (XU1, %) Fixed Cost Variance,
Cost
43.5 94.3 96.6 1.0382
6.0 98.4
1.6 89.8 < 9,l> <19.2> 33.4
118.1
92.5 97.2 1.0384 18.6 97.6
4.8 82.3 <n.5> 46.8 <71.3>
The December production is a record month for the plant, sur
passleg the
reco rd of 42.6 million pounds est in
Noveaber, 1990
Orders for Line 1 and LI a 111 products ware down. Line V orders held steady. Line [ was down nine days for an overhaul of the "Banbury" compoun? er. All lines were down for the
Christmas holidays.
le due to good energy i material use in resin and near
>lasticizer units.
Fixed costs were unfavorable due to payroll costs being above budget due to the holidays and heavy vacations. Operating supplies and outside professional services were favorable and partially offset the payroll variance.
VAB.0001188737
H. V. Hilger* 01/25/93 Aberdeen Monthly Progress Report - December, 1992 Fmge 2
OMP
Excel, a potential compound customer, visited the plant on December 15. They requested us to complete their "Quality System Survey" by January 15.
The Vinyl "A* shift recommended changes to hose trans fer stations to reduce resin cross-contamination and Improve safety.
u*.
m The Senior Process Engineer's Team found a potential $100,000 per pest cost saving* using eentrate water to proheat reactor charge water.
The M08Q sent us s draft permit of SOD limits for our new HDPES permit Chet btcamet effective on February 1, 1993 of 21 ppm in the vinter end 12*5 ppm in the summer, phis is -an improvement
Delineation ef the VCM plum began during the month. Conoco sent itS' cone penetrometer unit: end tame to do the neoeaaary shallow ground mater monitoring.
1A
Water use minimiratIon meetings were held with all employees. The response wae vary good with significant water use reduction realized.
Projects
Operating procedures for the new water plant ara
plate. Upon complotion, operator training will
problem with the mater proof coating system mss
was improperly applied. Ve are working with the
to problem was noted; out In the settling ponds.
does not Wo are working with
consultant to correct this problem.
design
The plasticizer unit steam ejector relocation project was completed.
*
/"""V
VAB.0001188738
*
B. V. Hilgers 01/25/93 Aberdeen Monthly Progress Report - December, 1992 Page 3
Procedure writing Is In progress using two vinyl operators and one shift supervisor. Drafting standards were developed for P&ID development.
D. C. Sfcokna Plant Superintendent rah
A
VAB.0001188739
i
DISTRIBUTION Houston
Austin
LSCP Plant LCLAB Flsnt ialtfsftrf JSdBBHftQSQUdl Premiere Aberdeen
J. R. Ball
X
H. V. Hllgers
B. M. Hyers
C. J. Hatson
H. R. Flamer
R. R. Smith
B. J. Bean
R. H. Gerlach
C. R. Hiller
L. R. Kardos
M. J. Schneider
X
H. G. Coleman
H. D. Garrison
J. V. Ware
X
J. Friend
X
F. J. Kober
X
P. E. Markey
X
J. Favao P. L. Foote
X X
J. B. Autrey
J. E. Beall
X
T. L. Cunnings
J. M. Edvards
X
S. C. Hillman
C, M. Harkerson
D. A. Miller
J. E. Nickerson
X
J. D. Olson
R. W. Seymour (File Copy)
T
e
r
X X X X X X X X X
X X
X X X X X X X
VAB.0001188740
SAFETY - C. M. Markerson/J. V. Uptain
First Aid OSHA Recordable
Total Injuries
Nuaber of Restricted Workday Cases Number of Lost Workday Cases
0 1 1
0 0
Vinyl Operations Compound Operations Maintenance
Race iving/Warehous e Office
Totals
Injuries bv Type
Cuts and Abrasions Eye Injuries
Bruises S trains/Spra ins Stings Other
Totals
1 0 0 0 0 0 1
0 0 1 0 0 0
ft
1
Fiscal
-Ip
1
2
1 0 1
0 1
2 2
0 0
-ft
5
Fiscal
2
0
0
2
3
0 0
-ft
5
2
0
1
0
2
0
Lost Workday Cases Days Lost
0 7
First Aid Cases Medical Treatment Cases Lost Workday Cases
0 03
0 10 0 00
Last lost time injury Days since Employee hours since -
10/7/92 85
104,112
On December 31, 1992, the employees of the Aberdeen plant completed 85 days with no lost time injury.
A
VAB.0001188741
SAFILTI - Continued
Topics for the plant safety nestings during the month included: General Safety Hazards, Personal Protective Equipmentt and Lifting Safety.
Eaergency Response and Fire Protection:
* Fuel for fire pumps and emergency generators was winterized. * Seni annual inspection on fixed systems. - Inspection of all smoke detectors. - All fire extinguieiiers were inspected. * All alr*paks were Inspected. - All safety showers and eyewashes were Inspected.
Routine dosimetry results for the nenth were:
VCH Lead Total Particulates
< PEL
yftlllfrtT Parcant
55 100.0 6 100.0
1 100.0
> PRL
Bsottua
0 0 0
0 0 0
Second degree burns of loft hand.
#
VAB.0001188742
B. B. Smith
Excel Hanufacturing Inc. , a potential customer, visited the Aberdeen Plant on Deca-ber 15. Th.y requested that we complete their "Quality System Survey Report" by January 15.
A Senior Process Engineer's natural team evaluated the potential cost savings of using eefitrate water to pre-heat reactor charge water. They estimated a potential cost sawings of $10QH/year.
A Vinyl "A" Shift natural team recommended some modifications to a hose transfer station to Improve safety and reduce resin crosscontamination potential.
h
r
VAB.0001188743
cnsr VARTAWCgs - D. G. Skokna
Product
Total
PVC Flexible Coapound(l) Plasticizer
Total
$51.8 < 7.6>
<$350.0>
100.8
<$257.0>
<$298.2> 93.2
<$223.6>
PVC Resin
High production rates t a record 43.5MN pounds, resulted in favorable utility consumption and raw material/by* products were also favorable.
Overall efficiencies were near budget.
Overall efficiencies were near budget.
m Resin to Compound m Electricity m PackagingSupplies m Initiators
VCM m Others
Total
$104.3 29.1
< 19.0> < 19.9> < 323.3> < 28.2>
<$257.0>
Payroll and Benefits MM&C Miscellaneous TI&D Clearances
Payroll and Benefits
Variance - SM
Total
<$85.7> 0.5
75.5 < 1.1> < 8.4>
<$19.2>
Operating and maintenance payrolls were high due to holidays, heavy vacations, and some extended absences.
M&C
*
This category was essentially at budget.
VAB.0001188744
COST VAttTANCES - Continued
Miscellaneous
Outside Professional Services m Operating Supplies
$23.7M $31.8M
Taxes and Insurance
This category was essentially at budget.
The unfavorable variance is a result of minimal activity in the old pond area #2 cleanout project.
VAB.0001188745
VXHYL - J. D. Olsonv V. S. Carroll
Safety The Vinyl Department had no Injuries in December. The monthly safety meetings were held on shift.
1. December production was 43.5 MM pounds. Tills is an Aberdeen Plant resin production record surpassing the old record of 42.6 MM pounds set in November, 1950.
J*
2. Rellear empty hoppers were in short supply near the end of December. This has resulted in significant reactor downtime in early January.
fttridtmr 2X0
Production, MM lbs. Daily Rata, M Lbe./C.D. Capacity Utilisation Factor, % Total Reactor Charges Charges/C.D. Raactor Stream Factor, % Rotary Dryer Stream Factor (#4-#8), Fluid Sod Dryer Stream Factor, % Resin Quality, % Prime
%
43.5 1403.2
104.3 1001.0
32.3 94.3 96.6 95.7 96.6
118.1 1283.7
95.4 2753.0
29.9 92.5 92.0 94.3 97.2
Hours
m Operational downtime (recovery scheduling conflicts, cherge/rinse water conflicts, D-600 rupture disc/PSV change, Q.C. data delays, dump conflicts, and no hlarnd tank spaca).
291.0
Maintenance downtime (D-400 seal replacement, cooling water line old module, D-700 rinse line repair, D-700 seal replacement, 0-744 recovery valve maintenance, D-745 sprayhead, and D-743 gearbox PM).
134.0
VAB.0001188746
Continued
m Operational downtime (centrifuge plugs, dryer cleaning, flameouts). Maintenance downtime (activator problems asbestos removal). Reactor limited
Total % of
68.8
31.2
0.0
i i
Reactors 400 and 700 seals felled and were rebuilt for spares. Reactor 400 seal failed due to line pluggage, and reactor 700 seal failed due to overpressurlsation.
The #1 bird centrifuge was ro|m*talled. The Bird had been sent out for refurbishing after several months in service.
m. The north fluid bed Bird gearbox was changed out due to a seal leak.
Two major valves were changed out of the Vinyl unit.
i
m Two power supplies were replaced in the Vinyl control room after they were found to be faulty.
M The Gaitronies units in the Old and New Units were repaired to enhance
communications.
I I
m The test run on the propane system was conducted in preparation for winter alert.
The valves on #8 and #9 air compressors were repaired.
The west bio-disc bearing on the north end was replaced due to weal.
i
VAB.0001188747
m mmmmmmrnmm
CQMPCHJHD - S. G. Hillman, J. B. Hegwood
The Compound Department had no OSHA recordable Injuries during the month
General
Orders were down for the month on Line I and steady for the month. Production for the month was down pounds from last month. This decrease in production can
V production held 10GK
attributed to the
downtisie associated with the Christmas holidays and the Line 1 maintenance
downtime. The line 1 Banbury was shut down for nine days during the month due
to e gear failure. A complete overhaul of the Banbury was performed due to the
condition of the Banbury, Line I was started back up on January 9, 1992.
Operating
Line I Line ill
21 30
Line V
28
fetal
% Prime
Capacity Utilization Factor
Line I
- Product Chens#t - Miscellaneous Maintenance
Line 111
Product Changes - Miscellaneous Maintenance Quality
Line V
Product Changes - Quality - Miscellaneous Maintenance - Raw Material
1338 3486 1173 5**7 98.40 80.32
hfiMSd
63 116
42 221
id 273
3
104 41 28
23 11 26 17
4939 10314
3182 18437 97.42 82.21
i
VAB.0001188748
f
nnupomm - Continued
Operating
Month Ato./Pit
Plasticizer Capacity Utilization Factor
1552 89.75 84.55
55
4813 82.30 84.25
J 8. Autrey/S. A. Truitt
The agitator blades sere replaced in plasticizer reactor #1 after the blades broke during a charge.
A plugged regulator urns removed from the eater return line on the inert gas generator. The regulator was restricting water flow to the condenser, which resulted in water condensing into the compressor oil.
m The #6 dicer motor had bad windings.
A
i
VAB.0001188749
- J. K. Nickerson, T. &. Xtckay, R. H. Sneed, X. L. Carter
i
Bkfcnr Flenfc
Operating procedures for the water plant are near completion. Final approval is expected within the next few weeks. Operator training will take place after the operating procedures are approved.
Construction on the chemical feed system will begin in February, the boiler bid package was awarded te Nebraska.Boiler Company. The boiler design will be completed in January.
Wasteweter test run conferencs sail was held with FED, A final report la expected from FED seen.
Operator training ia almost senplate. Operator training will be finished in the first part of January.
Relocation end startup of the ejectors for R1 and R2 were completed during December. The ejectors were relocated to provide eesy main tenance access. Additional goals of the project were to reduce noise from tho ejector exhaust and eliminate the slipping hazard caused by the liquid in the exhaust. All goals were met by the project.
A miscellaneous capital project was submitted to install valves an the stema/weter lines to ejectors. These valves allow the ejectors to be "turned off" when vacuum is not required on the reactors. Justification ineludea $40M in amuital steam savings, reduced fouling in tho ejector secondary jets, and reduced process water use.
A draft of the Aberdeen Plant CAD standards has been prepared by Project Associates. These GAD standards will be used in P&ID development required by OSHA Process Safety.
A report was issued which highlights areas of potential water use reduction. Assignments were given for each item identified and the Water Use Minimization Team is working to inform all plant employees of the study and encourage their participation and help. Meetings were for all plant employees.
r
4
VAB.0001188750
EHGIHEKRIMC - Contlnuod
A test run has been performed on reactor R-l using both coils for heating and cooling. Preliminary results indicate a decrease in batch cycle tine of about two hours. The test run will be extended into January to collect more data.
Construction has begun on the aeration project. Water samples of pond 3 inlet and effluent will be taken before project startup and after it is running. This will quantify benefits gained by the
A chemical feed and automatic
design is near complex
tion. Work continues on identifying and quantifying blowdown fron
each cooling tower.
Several air modeling programs word ovaluated fog with Responsible Care goals and for future use in mooting clean air
The SPILLS model was selected due to its
and ability to handle the chemicals we use at this mation is being collected for s base case sample modsl
A
wmmmmmmmmm
VAB.0001188751
ABERDEEN CHEMICAL PLANT
M.L. CARTER DECEMBER REPORT
Month 1st QtTf YTD
ACTUAL 73.4
374*5 374.5
94.0
330.0 3435.0
lift - 20.6 <4* 44.5 -3360 5
....%.... --21.9% +13.5% -49 .1%
Actual : than
in December ware November FY93.
6 K lower in the
more
the
- Dec . 1 Fir
were $44.5 M
- Current Quarter Expenditure Forecast as submitted
the current
capital budget.
budgets
- Total of current and previous quarter approved
- Total Expenditures for the Second Quarter
FY93 are forecasted at $775 M while January expenditures
forecasted at $130 H.
VAB.0001188752
KHVIftOWMEHTAT. - I. G. Aldns Veter All wastewater discharge parameters were met for the month of December. A draft permit was received in December modifying the permit limitations that were to go into effect February 1, 1993. Vinter limits are 22 ppm BOD and summer limits are 12.5 ppm BOD. Hie dissolved oxygen limit was raised to 7 ppm. Horizontal delineation of the VCM plume in the shallow groundwater began in December. this work is expected to be completed in January. Waste Waste shipments during the month included:
A bulk shipment of API Sludge to Laldlaw Environmental Services in Chattanooga, TV.
VAB.0001188753
ENERGY CONSERVATION
J. A. Bodron
A Unadjuatcd BUI B. Admitted BUI C. BtuAb. ftoduct D. Total EnergyCootumptioo MMM Btu
IL Boiler Operation
Haul No. 2 Nfc.3
December 15192
(98%) (9.1%) 29249 150J8
Fiscal Y.T.D.
(12.1%) (113%) 29705
4265
- -U
83.7% 829% 839%
BOBciaosjr % fflWtf TiTr*>
835% 829% 83.1%
1
Mvt
mn
xahm
tn.m
ui
m.
mhn
ivlm
MONTH
mmm
mn
mrr
VAB.0001188754
*
%
A
MMOMBK. - J. E. Beall None. Heme. Hone. Hone. R. Danny FI ippo - Vinyl Department - Union Leave of Abeence. Holli Harris - Engineering Department - Educational Leave of
Absence.
nwmvpMgj
Ml
VAB.0001188755
HAftSaOCISE
I
GENERAL PLANT 1
MMmmc* |
laboratory
COMPOUND VINYL PLASTICIZER
I I
1
SUB TOTAL SALARIED
13 I 7
13 7
34 7
IS 3
30 22 31 10
5 12
145 59
78 6
0 53.8%
0
0 1 53.8%
0
0 20.6% 0
1 16.6%
5.5%
1 I 73.3% 1 3.3%
2 1 32.2%
6.5%
0 I 40%
0
4 41% 2.8%
is
7.7%
23.1%
VAB.0001188756
n\
FAMMUtt rd Mttl Mpcri
TOTAL 0/T L, 15,575*75
r ira.oo
TOTAL non
ino.ro
10.75
Ultp
I.NI.IS
1101*00
son.oo
C* tab
10,454*40
anus
nlMr*
.N
tabmaaa
UrlH.79
1115.00
l.m.N
44.75
MlOMtOt tab
0,110.00
750*50
f liad
f,110.10
450*50
VMl
M.l*t.*S
mh.i
Rorl mm. n#R
1 --I-Y|-PP- '.' 'I-I- 7-T .N 0,41.00
|; ,
1 V
X
14^ ..
I l 1 U^.H 1074*15
1 n,m*n
htM kHm Puwitff 17, 1,01.
0*T. x or
It
11.04
7*45
! M. .Mfc
00UMT MU MQf ... 0MW
ooo.ai
10*0.00
0*00
0.00
MUMP 9WM
1U.N
0.00
( amki 1 t or im
1 t,Tf
s o.oo
tt.ii tt-H
. t.u IS.
Ml
i.ao
no.oo i
fVwiM
-i *7.
0.00
' Mtt.M 08*0.00 ' 000*00 100.00 4WM* 0*0^00'
' U.15 1
itt.il *tt.n
1
I
1
1
'..J*s"L [
o.n **7t
*.i* 0.40
t,*t t.7
I.H u.ti 11.10
*11*5# ' IM.tt
i . Mt.M /l tt,n
* 4. | '04.0.|0L
N.tl
' 4000.00
owpw o-pno
1 . 1 0. 00 I .00
50.00 1*04.00
0004*15 1 *.*
_.**. .^ : / r I
m.ts
S
1i 1*.? 1 WMt
fM.M . ltt>Tf
f ^'
f .r
17M*.*
.`.-.J*.
1
: lio.tt
I >
I s. .
si
10.00 0.00 0.00
544.00 H.M
ttttt 0.00 4.M
0*00 ' M.M
m.M 0.00
li ' 1 i i' * h r 004^4#
UfHHAL OOMW 0.00 0.00 0*00 00.00 004.00 0.00 0.00 0*00 0*00 100*00 100.00 ato.oo 4.00
I m**m
PtATW n WMOX 00*00 0*00 04*00 UI.M 100.00 0.00 *1.00 0.00 0.00 10.00 400.00 UO.OO **,00
MSMSLm 0,00 0*04 0*00
054.00 400.00
H.M
J
1*4. N 0.00 0.00
400*00 1454*00 7000.00 UH.tt
1 mm*m ^
TOTAL Alt.
s or ft
1*40
VACATI0* 1500
0.00
0
14
1.54
11,014
5*00
4,400
1*45
014
1.40
1754
1.40
044
.11 11*0
0*01
1000
5.01
7000
14.41
401
11.00
1010 j
4101
/
VAB.0001188757
i?, im.
I
>
:....................^
, tm jm
l ,ii
tv* 1. . t*00
1 1 [
** 1. * [ ***, i, 1 [ I.1N
1 1[ .1 1I l
E *.* 1 B.
O' '
1
--fj
[ .*
['
it
0*00
0.00 ***
I.N
-* I.M i3i ,i
Ml "
MTIOtil tww
| ; o.oo
n*n n KMStY
9.00
uam-mx Kioitm
0.00
TOTAL A1S. x or ft/T
0.00
0*00
o.oo
0.00
0.00
0.90 1[ 0.00 1| 0.00
N.M 1 [ B.M j 1 I.H
o* oo ri^ j
.
9.00 j 1 .
00.00 0.00
1
][ _
..
0.00 0.00
1.00 .05
0.00 1.59 9.99 0.00
0.90
9.99
999.90
j [ 0*09
J I 0,99
1 o.oo
I 9.M
1'-
1 ^
E ..
I.M
l|K
...
-ii1.
[
1:j I:.. .J
0.00
.r
K
j(; .^*tt , i I M* " : I 419*09
hi-'
7.59 0.70 Ml
i
I t.M
VACATION 100 110 700 204 00 100 40 m 990 000 50
[0* 9000
]
i t 4 *
VAB.0OO1188758
i
4 I
ACCOPTIBG - T. L. Caaalags
There were no reportable safety instances this month.
.' *
The Accounting Natural Team met once in December for a safety meet ing and an audit.
07 *005 07-006 AFK/MRO
Dlai<ount;a
07-005 AFE/lffiO LTL
Month 176 126 542
YTD 638 452 1341
$405 $5
$2059 $2565 $26,90
A
VAB.0001188759
J
M. A. Swierc
There were no reportable safety instances this month.
All teams met in December to review progress on their projects.
Natural Gas
KTD
$0
Processed
Cost Savings Through Bid Process MRO/AFE Purchase
Parts Purchase Orders Issued
no
Calm/(Loss!
J*
$0
FT93
$384.34 154 178
$6,486.60 517 520
Compound "A" Grade FLBKSX Compound Off-Grade (BC) Compound Off-Grade (H) Millscrap Dry Blend "A* Grade Dry Blend Offgrade Resin Type I Resin Type *BC* Vacuum Dust
Total Packaged W/house
4,857,628 212,176 467618 167,395 120,694 430,931 87,092
1,429,450
100
7,978,473
Dec.*91
(Decrease)
/Tfio.r^aee
%
5,324,822 202,596 501,508* 160,2620* 67,073 253,694 45,423
1,583,200
100
8,270,193
467,194 < 9,580>
33,890 < 7,133> < 53,621> <177,237> < 41,669>
153,750
0
291,720
9.62 < 4.52>
7.25 < 4.26> <44.43>
<41.13> <47.84>
10.76
0
<3f .97> 3.66
Compound MA" Grade Compound Offgrade Rigid "A" Grade Rigid Offgrade Resin Type I Resin Offgrade
Total
2,080,528
0
212,552
0
10,268,050
13,458,930
1,194,146
0
172,700
0
15,671,627
19,015,723
(Decrease)
%
/Increase JBttgi
<166,382>
0
< 39,852>
0
5,403,577
5,556,793
< 8.00>
0
<18.75>
0
52.63 40.04
41.29
* Includes PLENEX (BC) ** Includes PLENEX (H)
VAB.0001188760
mm wmmmmm
mmmm
ABERDEEN CHEMICAL PLANT SNIPPING ANALYSIS DECEMBER 1992
'SHIPMENTS BY PRODUCTS-
RESIN'BULK RESIN-PACKAGED
FLEXIBLE COMPOUND-BULK FLEXIBLE COMPOUND-PACKAGED
NEU BUSINESS
RIGID COMPOUND'BULK RIGID COMPOUND-PACKAGED RIGID CGMPOUMD-PELLETS
AUTOMOTIVE - BULK
Atmuoirm - packaged
PLASTICIZER
TOTAL
TOTAL MONTH
SHIPMENTS
33,883,230 758,790
2,810,230 2,354,931
9,530
62,540 218,906
0
780,370 71,450
mooe
41,478,777 'Pi
12:09 PM 14-Jan-93
YTD
SHIPMENTS
102,117,940 2,292,141
7,300,026 8,396,020
36,868
491,230 517,491
0
1,467,178 252,866
* * .* 4
* #-*
124,421,214
'SHIPMENTS BY MODE BULK:
********
DECEMBER* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
TOTAL OECtMRCn
BASLCAR
185
17 0 3
205
CMMONRR'. SAMliiR
8 14 0 12 02 00
8 28
1i t
TOTAL
207 29 2 3
141
YTD* RESIN FLEXIBLE IlOMFININD RIGID GQMfttJND PLASTICIZER
TOTAL YTD
PACKAGED:
RESIN FLEXIBLE COMPOUND BIGIB COMPOUNO PLASTICIZER
TOTAL DECB4KR
548 43
1
9
CtlPSNBI
4 14 4
0
22
37 59
0 28 08 02
***
22 74
4 0
MO
TMPC
MPiMN a* *****
AtR/UPt
****** ******
00 00
00 00
1 3 0 0
**********
******* *;* *
* * * -m m m m * * w
B0
4
444
71 9
11
27 91
8 0
126
YTD* RESIB FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
TOTAL YTD
m'-mm + m*
6 40
7 0
+
13
*****
76 260
10 i 2
348
1
0 0 0 0
0
0 0 0 0
0
4 6 0 0
.. !
to
86 306
17
2
411
CC: TLC,MAS,AEV,JRF
N
VAB.0001188761
*
VAB.0001188762
ft
LABORATORY - J. M. Edwards, J. &. Williams A. SafetY
There were no safety incidents in the Laboratory during December.
Sandy Joiner, David Hawks and Donna Parrish of Excel visited the Aberdeen Plant on December 16, 1992, to tour and audit the processes.
The customer complained of high gel count In 52,000 remaining pounds of 5415 In their silo.
were faxed to the customer. Closer in i spection of the resin showed it to be better than the competition's.
12/10
The customer complained of rough surface on the wire Jacket made with 38552 Natural compound. The bumps were caused bp 400-500 micron calcium carbonate crystals. This raw mate riel should be lees than 5 microns particle site.
12/22
i-
The customer complained of white pellets mixed In with 48451 Black compound. Samples were never re ceived from the customer end all remaining boxes in inventory were inspected. The customer used the compound.
12/23
The customer complained of resin
cross contamination In a 5385
railcar.
Their torque rheometry
testing of the resin showed a lower
molecular weight contamination. The
Aberdeen lab confirmed their suspi
cion. Operations is working on the
resolution.
A
VAB.0001188763
LABORATORY - Continued
D. Product Waivers Issued
There were no waivers for the month.
E. RVCM of In-Process Samples
The following is a summary of residual VCM results on inprocess samples. Rone of the reactor daily averages exceeded 400 ppm RVCM during the month of December, 1992.
Reactor
.^^r^porr
Number of Samples Average RVCM, ppm
1001 64
60 0.372
51 0.331
The following is a summary of the residual VCM analysis of shipment samples for the month of December, 1992.
JCvGisflBBSuE
5225 5265 5305 5325 5365 5395 5415 5416 5465 Debox Pond
0 116 117
0 61 12 63
0 0 16 0
0.141
0.147
0
0.207 0.026 0.059
0 0
0.420
0
4
Hardness Color Hard Particles Heat Stability Contamination Dicing Streamers Klscharge
METS-1R
Totals
mmntt
LUb. _i_
12.5 14.5
--
7.5 ,
-- -- ... -
----
34.5
<0.21>
<0.24> <0.12>
<0.57>
l.tgHnn
M U>. m
4.5 56.5 27.0
4.5 6.3 8.4 4.5 3.2
7.5
124.4
<0.07>
<0.94>
<0.45> <0.07> <0.14> <0.14> <0.07> <0.05>
<0-12>
<2.07>
'I
VAB.0001188764
SAMPLE SHIPMENTS DECEMBER 1992
A
Ship Dale 12/07/92 12/10/92 12/16/92
12/18/92 12/28/92 12/28/92
Product 5416
5385
5265 5305 5385 5415 5465
5265 5305
Pond
5265
I COMPOUND Ship Date 12/02/92 12/03/92 12/03/92 12/03/92 12/03/92 12/07/92
12/09/92 12/10/92 ~N 12/11/92 12/16/92 12/29/92
Product 38561 BLK 58031 WC 328 58033 CB 50
801424A CL 606)5 BLK 568i|l NAT 57462 NAT 34642 NAT 811-53-A
34642 NAT 34431 NAT 48451 BLK
Amount 100 lbs.
150 lbs. 50 lbs. 50 tbs. 50 lbs. 50 lbs. 50 lbs. 2 lbs. 2 lbs. 5 lbs.
lOtbs.
Amount 5 lbs.
700 lbs 3200 lbs
1500 lbs 50 lbs. 100 lbs. 100 lbs. 200 lbs 50 lbs. 200 lbs 50 lbs 50 lbs
Customer BAERLOCHER GMBH
VISTA Chemical Europe
NALCO Chemical
Ship Mode Airborne
Airborne
Airborne
Keysor-Century Corp.
Heritage Plastics OTEXCo.
Airborne
Airborne UPS
Customer Connect All, Inc. FIberchem Inc.
Tenex Corp Flexible Technologies
ENTERPLAST Inc. Macklanburg-Duncan
CENTRIUFT Berk-Tek
FACOMEC S A (Columbia) Vista Chemical - Austin Brock Plastics
Mode UPS CC CC CC Airborne Airborne
UPS UPS Airborne UPS UPS
VAB.0001188765
Resin Process Capabilities
Bulk Density
Inherent Viscosity (vs. 0.64 >0.67) (vs. 0.715-0.744)
"L" Color
'a* Color
"b" Color
% on Pan
(vs. 2% max.)
% thru 140
Hard Particles, Average 5 minutes 7 minutes
MET8IR (vs. 99% of Control)
Average Particle Size, Microns
(based on dryer "regulars")
5225
5255
5305
1.93 1.67 1.21
0.07
1.37 0.30
0.63 0.63
4.44 3.50 3.89
4.87 3.83 8.00
4.33
2.83
6.00
0.23 1.72 1.25
0.26
0.54
0.61
5385 2.30 1.24
3.67
2.00 2.67
1.72
16 3
December 1992
9395 1.10 0.96
5415 1.21 0.55
5416 11.00 0.57
3.08 6.17 12.33
2.17 5.33 14.17
0.88 3.78 2.78 0.44
0.61 3.21 0.77
b
13 6 3 621
5.52 5.55 3.18
132 132 141 152 140 171 132
IP W HUP
VAB.0001.188766
