Document DMRNE7YDZvE32Y1jgJyXZ2aL5

T. H. Huffman From: Dale: Subject D. C. Skokna February 28, 1992 AB1XDEHI MOOT JABDARY, 1992 VISIA There was one first aid case reported in January. At month end, the plant's employees have worked 4,593 days (6,143,398 employee hours) since the last lost time injury. PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M Operations 33.2 80.3 98.7 1 .0194 4.8 97.6 2.2 98.4 1.2 68.4 < 18.3> < 25.0> < 32.6> 132.7 78.7 96.8 1.0330 21.0 96.8 8.5 97.2 5.9 77.4 < 16.2> < 305.2> < 367.2> FVC rates were restricted by hopper car availability and a power failure and subsequent failure of the backup power supply to the distributed control system. Lines I and III schedules were tight in flexible compound. Dry blend orders were slow during the month. The dry blend sample line will be available in February. Costs Both variable and fixed costs were near budget during the month. VAB.0001189390 T. H. Huffman 02/26/92 Aberdeen Monthly Progress Report - January, 1992 Page 2 OMP m John Griffin and Keith Pettus of Southwire visited the plant to receive instructions on the use of our torque rheometry equipment. Textileather, a resin customer, audited the plant on January 28. We received a 92% rating. Envlroiragmt-a 1 There were two NPDES violations during January. Both occasions were for exceeding the daily ammonia permit limit of 24.5 pounds per day. The violations that occurred on January 3 and January 8 were 39.7 and 25.8 pounds per day, respectively. The results of the Superfund site sampling and the upcoming drum removal and remediation project were discussed with the Community Advisory Panel. D. C. Skokna Plant Superintendent rah .. l+wp -F+' 1 " VAB.0001189391 DISTRIBUTION COVER LETTER ENTIRE REPORT Hous ton J. D. Burns X R. T. Ferrell X T. H. Huffman X C. J. Matson X H. R. Flammer X R. R. Smith X B. J. Bean X R. H. Gerlach X R. D. Gamblin X Austin C. R. Miller R. L. Poe X X Oklahoma Citv LCVCM Plant LCCP Plant LCIAB Plant H. J. Hall H. D. Garrison P. D. Carrico J. Friend J. W. Ware X X X X X Baltimore L. R. Bauer X Hammond J. Pavao X Premiere P. L. Foote Aberdeen RVS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, DAB, DAM , JEN, JDO, BLT X A ; .1 ; ;;r. - ;hirAHi-j*- ty. :. I- iii-rhi^k-'-tfr 'p^ .-. -: )?: VAB.OOOl189392 SAFETY - B. L. Trego Jan. Fiscal Y.T.D. 1992 Fiscal Y.T.D. 1991 First Aid OSHA Recordable Total Injuries Number of Restricted Workday Gases Number of Lost Workday Cases 0 0 2 0 3 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Rece iving/Warehous e Office Totals 00 13 03 00 00 0 1_0 16 Injuries bv Tyne Cuts and Abrasions Eye Injuries Burns Bruises S trains/Sprains Stings Other Totals 023 000 011 002 132 000 0 0 J> 1 6 10 Non-Occupational Injuries Lost Workday Cases Days Lost 0 3 Contractor Injuries First Aid Cases Medical Treatment Cases Lost Workday Cases 032 000 001 Safety Record Last lost time injury - 7/5/79 Days since - 4,593 Employee hours since - 6,143,398 On January 31, 1992, the employees of the Aberdeen plant completed 4,593 days with no lost time injury. VAB.0001189393 SAFhf - Continued The topic for plant safety meetings during the month was "Plant Emergency Duties" and "Injury Investigation Review". Routine dosimetry results for the month were: ____ < PEL- Number Percent VCM Lead Total Particulates 83 100.0 9 100.0 2 100.0 Monthly Injury Summary >_________________________ Number PEL 00 00 00 Inlurv Class FA Compound Description Muscle strain of left elbow. A 'I .................................... .'AHird -..-fc i'll f ..i. - i--- -|. h: f i.h , ::(rar;: :.n VAB.0001189394 OITAT.TTY MANAGEMENT PROCESS - T. J. Arbeiter All of the plant's natural teams continued work on projects and process Improvements. The average natural team score as of 1st quarter FY92 is 18.4. Several of the compound quality improvement teams presented their findings and recommendations to Bob Seymour and Charlie Hiller during the week of January 6. On January 13, John Griffin and Keith Pettus of Southwire visited the Aberdeen Plant to receive Instructions on the use of the Brabender. A brainstorming session was held on January 14 to compile.possible parameters for statistical process control in flexible compound operations. The original list of approximately forty parameters has been narrowed to twelve for consideration. As a result of recent color variation experienced in dry blend, the Rigid Raw Material Team traveled to Americhem's plant in Mansfield, Texas to discuss specifications and quality system elements relative to the production of color concentrates. Textileather Corporation, a resin customer, performed a quality audit of the Aberdeen Plant on January 28. The plant received a rating of 92%. VAB.0001189395 cn&T TABTAWRRg - D. c. Skokna Variable Costs Product Jan.. 1992 Variance. $M___________ Efficiency Prj.ce Total PVC Flexible Compound Rigid Compound Plasticizer Total $ 51.8 < 19.3> < 11.4> $ 32.6 <$ 62.1> < 99.1> < 66.8> < 3.5> <$231.5> <$ 10.3> < 101.4> < 78.2> 8.0 <$181.9> PVC Correction of previous accounting errors more than offset high electricity and natural gas consumption. The utility use was high due to cold weather and low rates. Compound Plasticizer Both compound and the plasticizer units operated near budgeted Major Price Variances: Variance - SM VCM Resin to Rigid Compound Resin to Flexible Compound Natural Gas Plasticizers Alfol Alcohols Vacuum Vent Dust Phthalic Anhydride Electricity Debox Resin Other Price Variances Total <$ 83.5> < 56.5> < 55.1> < 39.2> < 26.8> < 22.9> < 20.4> 13.5 19.3 26.1 < 14.0> <$231.5> Fixed Cost Variances Payroll and Benefits MM&C Miscellaneous TI&D Clearances Variance - $M Total $ 15.8 < 18.2> < 26.9> < 10.7> 15.0 <$ 25.0> h ^ yJL ; J. .* i " l^i-i # i ' fi' -' SaMJI i.: j i i 1,- i i 11 - W ^ - hi ::I VAB.0001189396 COST VARIANCE - Continued Maior Items January were: Warehouse Gain/Loss - <S40.2M>: This corrects an accounting problem from FY91 and also includes the write-off of obsolete spare parts for the dry blend screeners that were recently replaced. caused this item to be high. Purchases of cooling water chemicals Outside Clearance $14.3M: equipment and scrap. This is credit for the sale of surplus 4 , i- k , VAB.0001189397 VINYL - J. D. Olson, D. E. Knittig A The Vinyl Department had no first aid case or OSHA recordable injuries during J anuary. The monthly safety meetings were held on shift. 1. A power outage and subsequent UPS failure caused 152 hours of downtime. Another 147 hours was used to simulate the failure to identify needed repairs, but no problems were identified. DCS reboot problems associated with a power failure have been solved. The UPS system will be tested on-line weekly to look for an intermittent problem and check system reliability. 2. A majority of the downtime in the month was due to inventory control based on empty railcar availability. 3. Reactor maintenance overtime was minimized due to empty railcar availability. Jan. - 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 % 33.2 1070.4 80.8 800.0 25.8 80.3 86.2 91.7 98.7 Reactor Downturn** Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts, and inventory control). Maintenance downtime (D-500 cleanwall nozzle, D-700 reactor seal, PM D-741 gearbox, PM D-743 gearbox, PM D-600 gearbox, power failure, D-742 gearbox, D-700 Duraseal, low steam pressure, D-745 AMS safety disk, and D-600 AMS pot low level). YTD 132.7 1078.5 81.4 3234.0 26.3 78.7 87.2 82.7 96.8 Hours 627.0 838.0 '^-P- -1|.. .1.?*--<> i: . t-ff* 'ih;, vr !>-;. - h|-+ : : . f V . .... VAB.0001189398 VINYL - Continued Drve-r t-Iiba % of Total Downtime i Operational downtime (centrifuge plugs, dryer cleaning, flameouts). 19.5 Maintenance downtime (activator problems, centrifuge repair). 18.6 m Reactor limited production. 61.9 Key BafcntftTMHlCe - J. B. Autrey/S. A. Truitt 1. The demister pads in the fluid bed dryer were changed after they began to plug. 2. Reactor 700 seal was removed from service when some lubrica tion problems developed causing seal failure. The Duraseal oil system was thoroughly cleaned and the oil pump, pressure control valve and relief valve were replaced. The seal has been rebuilt for a spare. 3. Reactor 742 agitator gearbox experienced damage to the nose bearing which was detected on routine vibration analysis. The gearbox was pulled out of service and repaired before extensive damage occurred. 4. The 905 VC recovery compressor was replaced. The rotor had a hole in it; cavitation in the ring water seal is suspected. The old one was rebuilt for a spare. The 904 VC recovery compressor had an outboard seal replaced. 5. Both vinyl turbine meters in the old unit were replaced. 6. The UPS System in the vinyl control room was tested to deter mine possible causes of an earlier weekend failure. During the test, no failures occurred. Other possibilities are still being investigated. COMPOUND - S. C. Hillman, R. H. Sneed A The Compound Department had one first aid case, but no OSHA recordable injuries in January. General Orders are tight on Line I and Line III. Close monitoring of dry blend product quality continues to cause higher than normal downtime and slower than normal rates. Operator training has begun on the new dry blend sample line. production should begin soon. Sample Compound Production Operating Line I 31 Line III 30 Line V 9 Total % Prime Capacity Utilization Factor Downtime Line I Production M Ohs.) Month Fiscal T.T.D 1536 3068 180 4784 97.61 61.56 50 102 _20 154 6258 13268 1482 21003 96.76 67.05 Hours - Product Changes - One Dicer Offline - Miscellaneous Maintenance - Quality 104 66 7 41 Line III - Product Changes - One Dicer Offline - Miscellaneous Maintenance - Quality 74 54 25 13 Line V - Product Changes I--! h -J i: i c . j -- i-; h% -i.^i - VAB.0001189400 COMPOUND - Continued Operating Davs Production (M Lbs.) gfrfttfr Avg./Day Fiscal Y.T.D. Rigid Compound 26 2234 86 8462 % Prime 98.44 97.16 Capacity Utilization Factor 43.67 39.51 Hours - One Welex (Half Rates) - Quality - Product Changes - Miscellaneous Maintenance - Waiting on Raw Materials 74 43 89 40 23 Operating Days Production (M Lbs.^ Month Ayg./Day Fiscal Y.T.D. Plasticizer 30 1233 % Prime 68.35 Capacity Utilization Factor 43.82 5924 77.44 58.13 Key Maintenance Work - J. B. Autrey, S. A. Truitt 1 The compressor was obsolete and not cost effective to repair. The 2 Leaking steam and water coils in plasticizer reactors 3 and 4 were patched. VAB.0001189401 A ENGINEER TUG - J. E. Nickerson, K. R. Kane, T. R. Mackey, M. L. Carter PROJECTS IN DEVELOPMENT - GENERAL New Mater Treatment Plant Boiler conversion from the old boiler control room to the new water plant control room began this month. The number one boiler was converted. Boilers two and three will be converted in February. As part of the new Water Plant Project, the boiler controls are moved from the existing location to the new water plant facility. Having the boiler controls and the water plant controls together permits one operator to do both jobs. A schedule for training has been issued with operator training scheduled to begin in April. The operator manual is being written and will be issued in early March. Construction is progressing well and should be complete in late April with startup targeted for midMay. Wastewater System Improvements A model of the wastewater system was done in 1987. The model is being updated for any differences in current operating conditions. The potential plasticizer expansion has an impact on the wastewater loading and must be accounted for when deciding what improvements are necessary to meet the lower 1993 wastewater limits. The new model will allow the decisions to be based on the most updated data. Incinerators The new east incinerator replacement was installed and cured this month. Field checks and startup were also completed. Completion of punchlist items is in progress. Plasticizer Work is beginning on a design for a plasticizer expansion. Engineering is looking into using a stripper to remove alcohol from plasticizer. This will reduce reactor cycle by almost half. Dry Blend Sample Line Dry blend sample line project is complete. Operator training and equipment startup is complete. System is operational and functioning. AT&T Fluff Test runs making compound from AT&T fluff have been successful. Initial samples are being evaluated by potential customers. A large scale test run, producing a truckload of product instead of a few boxes, is planned for the near future. Engineering is working on a design for producing AT&T fluff on a regular basis. VAB.0001189402 ... i..N .!- id-k . i,. . . *T ENGINEERING - Continued Rftcmitlng All plant trips for college recruits were completed this month. We ade six offers to spring graduates. Semi-Bulk Lead System A semi-bulk lead system test (super sack quantities) was performed using Atomite (a filler). A test using lead is in progress. The personnel exposure seems to be very minimal, if not non-existent, although the dosimetry results have not yet been completed. The major issue will be if exposure can be kept low when the empty super sack is handled. Vinvl Debottlenecking Work has begun to determine the baseline drying capacity by doing a series of tests. The dryer system limitation will be identified and targeted for improvement. AT&T Scrap Recycle A design is being completed to allow the recycle wire insv from AT&T to be used on Line V to make a black saleable scrap compound. The scrap insulation will be shipped from AT&T in railcars at the rate of about 80H pounds per month. 1 r VAB.0001189403 A ABERDEEN CHEMICAL PLANT MONTHLY PROGRESS REPORT CAPITAL EXPENDITURE STATUS M.L. CARTER, W.C. ENGLISH JANUARY REPORT Month 2nd Qtr YTD ACTUAL 306.0 306.0 1525.0 BUDGET 317.0 1190.0 2571.0 0 H H 1 VARIANCE MS % - 3.4% - 884.0 -74.2% -1046.0 -40.6% Expenditures in January were $ ll.OM less 'khan the plant's budgeted expenditure forecast approved in the Second Quarter Budget. - Current Quarter Expenditure Forecast as submitted and approved for the current quarter capital budget. YTD Budget - Total of current and previous quarter approved budgets. Forecasted Expenditures - The current approved quarter forecast calls for 2nd quarter expenditures of $1190.0 M. i H-i : . lll-i h I- ill - a .k VAB.0001189404 . CO if* cl to o 8 o in in oo $ UI-l 1o1c1 UJ i3 5 Ul if* % if* lAl 2M 8Sl (A Ul CNJ rvi olli Ul CO a ac Ul T| a. z Q %o UJ h Ul a.UJ tt BUl UJ sa. Z U CO CO o oou Ul Ui Ul *1 ooo CL CL <L o. APPROVED CAPITAL PROJECT STATUS a! ft oac UJ co u Ul u ooc rsi i uUJ a. I oUl u. co O) ou a. i Z' z Ul ISi Ul tart y CO CO ui Ui o oc CQ 8 mJ in CL Ul a. o Ul ui m CL in 2 CO Ul Ul CL 2 3 CO Ui "* O 1 ui u_ Ul 2 Ul o tart iD cc tart tart u u CL 00 CO --1 Ui 3< 2 o O CJ < UJ 2 Ui Ul UJ 2 o _J Ul o 00 in O o if* 3 CL > Kl < UJ Q CL in 32 in >o O ty in in u. AB$001$9405 i </> (A ^ O* Ui O Cl gO UI CD u- O </> Ui Ui in Ui 2 a. tn s UJ (O g g CL ui 8 s SR in u s Ui inOL CL o in UuI 5 go OL in UJ (9 O <n Ui g ui O Ui ui o uui .8! IN UI 33 5 UI 3g Oz g Ui g oo Ui ui 3 uUi Z UI od UI Ui S 2 oo ft * in ui m o. g oc o 2a. (9 Ui iinn 3 aui 2 iUi 8o $ ui u 1 Ui Ui g ui 1 in s 3 g0 SX o DC O Ck Ui (A U. UO (A CL in ui in ui u ui ii 3" ot O oa sg H? U 2 o Ui 00 u Ui o CM CMM) CM 8 88 p CM in m m in Ui CO in Ui CL CL CL <9 00 uj KJ APPROVED CAPITAL PROJECT STATUS a uj o 8^ ci Cl u. uuii Ui J I 1-- 1 M1 1-- 1 t h- i O UJ o! OL i a. i 4 1 OL * Ui 5CD < : 2i < Ui i < UJ Cl u Ui CL CL Ui n ss CD 3C UJ (A (A ae UJ K --* a o in sc CO CD CO u UI UuJ CL Ui p'.................. ......... .... ' -'-MVI Q < <J aI CD CM II II II II II II II i __l < U CO M iit 1TM 1 o O CM CM in <! VA^.CfOO11^406 II i - J'-t .... CO CO o oa Ul ui </> oui o sc m V) 3 u c/> CL (/) Ui UI 2 I2 s CJ <o aOC s OU3I 1 OC CO t OC Ui o 3 1 Ui Ui 5 1 1 o a * 00 CO a. CO o Ui UUII a. u oo UI V) s Iu ui oc UI a. Ui i- s8 O u> CO 8 ai z s- u uai co s 3 OC W ui oc at ag o CO Ui UI cl ^ OC OC UI u 8o to CM IA to O fM in CM 3 C\l OJ Ui OC 3 CO CO UI OC 8Ui CJ OC 3 uuii ui CO UoI o o " CJ 1L 28 i < UI CL & aOC ui o uCO CJ I CO CO o Ui 8 o oo OC Sf OC OC a. CL a. & CL CL s S OC OC Q. Ui UI a. Ui Ui Ui Ui oa CO CO CO CO $3 UI UI UI Sto CM 00 CM *o s CKM 5 CM 33 o X 3 CO APPROVED CAPITAL PROJECT STATUS CO CO CO ac u CO tl II <J II 8CO Ui OC 3 Ui OC Ui a UXI UI II o II II OC CL IIII a. Ui OC s OC Ui CO UI CO CJ CO soUI UI OC UJ II fM IIIIII II II 111s OC CO CJ UI 5 oUI UI OC 8o UJ *u4 CO UJ CO CO II II CJ II CO II II II 8o CJ CO 3 OC 00 33 CO CJ UI 5 cj UI CL o UI 35 CO II II IIIIIIfI s U00J Ui riCnoM iConM CM in CM in CM rvj CM in 'O eo 8 in in IA in ao CJ Ui VAB.0001189407 CO T (A i/% r\i i u tA 44A0 in Ui O U ki* A APPROVED CAPITAL PROJECT STATUS 1 t UJ t _J 1 1-- h- I 1-- 1 Ul UI i *1 o tt < a * oc > UI i CD i ac uj i ll. i t it i/% II it II n o II H UJ II II H II o II II DC II II CL N II N It H II n It < II II II II i It II tl i II It II H II H II o II II II It II II o II H II U II H Of II II C3 If i >r. i- ' -ft:* ii-F:li^i-fc"(`Mf.-iP i t tri r:..................... * >n-m VAB.0001189408 't EHVIROHMENTAL - K. 6. Akins There were two NPDES permit violations during the mo: We exceeded permit limitations for the daily maximum January 3 and January 6 with easurements of 39.7 lbs./day lbs./day, respectively. Our permitted limit is 24.5 lbs.. Ammonia levels returned to normal on January 13 and we did not have above normal levels of ammonia measured during the remainder of January or early February. Supeyfund Sites We held a meeting with the Community Advisory Panel on January 13th to discuss the results of the superfund site sampling. We also discussed the upcoming drum removal and remediation project to be conducted by ENSR. This is scheduled to begin by early March. The third topic of discussion was the removal and recycling of resin from pond 2 also scheduled to begin in early March. Waste Waste shipments during the month included: A bulk shipment of floor sweepings to Chemical Waste Management in Emelle, AL. m A bulk shipment of waste oil to Fisher Industrial Service in Gadsden, AL. Thirteen gaylords of filter cartridges to Laidlaw Environmental Services in LaPorte, TX. i One drum of phthalic anhydride spill to Laidlaw Environmental Services in LaPorte, TX. Four drums of stabilizer spill to Environmental Services in LaPorte, TX. Laidlaw m Seven drums of VCM contaminated soil to Laidlaw Environmental Services in LaPorte, TX. A VAB.0001189409 ENERGY CONSERVATION - J. R. Ganc January 1992 Fiscal YTD I. Energy Conservation Data A. Unadjusted EU1 B. Adjusted EUI C. BTU/lb. Product D. Total Energy Consumption MMM BTU -21.5% -18.3% 3104 128.5 -18.6% -16.2% 3020 514.0 II. Boiler Operation No. 1 No. 2 No. 3 ------Combustion Efficiency % JtTtt fZ Flacal YTD 83.0% 83.0% 82.5% The boiler outlet oxygen analyzer was inoperative this month, and so no efficiencies could be calculated. A I' !!!- I/ .t lnlri-'K? I "i -Ml!-: t ll Tir1. l I'f I I'.'l1 -fi ------ r. I*. SI SsH1 : . h;-l i Ur pjfg,n ,|y.e qc.i-hi '-1 - VAB.0001189410 HOMAN RESOURCE REPORT JANUARY- 1992 PERSONNEL - J. E. Beall EMPLOYMENT None, PROMOTXON8/TRAMSFBR8 Rodger A. Collins - Transferred from Vinyl Shift Supervisor to Operations Supervisor (new position) . Roland D. Covington, Jr. -- Vinyl Chief Operator promoted to Vinyl Shift Supervisor (replacing Rodger Collins). Thomas - General Mechanic "B" promoted to General Mechanic "A" in the Maintenance Department. RETIREMENTS None. TERMIMATIONS/RESIGMATIOMS William Berlin Genetti - Co-op Student - Engineering Department. Returning to school. TO/FROM T.KAVR OR ABSENCE None. VAB.0001189411 A K VAB.0001189413 UJ gIM o in <0 o so UJ 1 I <IA/J) gUJ iw UJ 00 uo C0>L P rin te d 2/06/92 U u> </> (U UJ Ocl CO Y CO O o e CM CM "inO i AJ CM :8 CM DEPARTMENTAL SUMMARY HOURS REPORT ............ MONTHLY .............. T o ta l X H o lid a y H o lid a y h r Non P a id Absence J u ry Hour o f S/T Worked Hr Not worked Hours X o f S/T D uty V N a tio n a l Death In Long*term Guard Fam ily D is a b ility 00*0 OO'O 00*08 oo NO 8 o in 8 N oin 3 79.75 79.75 462.75 124.00 24.00 11.70 17.64 12.25 9.50 9.11 2.50 22.50 64.00 400.75 788.25 71.50 5.61 15.74 13.60 15.25 48.00 24.00 21.25 0.00 5.50 271.50 27.00 00*09 00*91 00*96 Oo a o So oo o 12.00 1.10 0.00 00*0 40.00 0.00 256.00 65.50 1.66 8.00 0.00 0.00 00*8* 00*91 8 3 oO* Oo oo oo oo o 3 176.00 39.75 1.72 0.00 O tn* 0.00 0.00 oo K1 0.00 00*0 00*0 00*8 00*0 8 In OO* oo O CM 8 o oo 3 0.00 0.00 40.00 2.00 0.00 0.00 68.00 0.00 368.00 0.00 in CM 336.00 124.50 12.00 oo o 21.00 3.25 8 oo Oo oO oo* Oo 00*0 00*0 00*0 1" " r 00*0 0.00 0.00 0.00 64.00 0.00 288.00 00*0 00*0 00*0 00*0 ADMINISTRATIVE SERVICES - D. A. Barclay d A There were no reportable safety instances this month. Quality All five teams met during January and reviewed progress on their respective projects. Statistics Processed Month FY92 Y.T.D. Processed Invoices Working Fund Checks Written Cost Savings Through Bid Process Raw Material Purchase Orders Issued MRO/AFE Purchase Orders Issued Spare Parts Purchase Orders Issued 1242 15 $3872.33 100 205 216 4416 78 $15753.22 361 779 750 Packaged Finished Goods Ending Inventory Dec.. '91 Jan.. 92 (Decrease) /Increase % Change Compound "A" Grade PLENEX Compound Off-Grade (BC) Compound Off-Grade (H) MilIscrap Dry Blend "A" Grade Dry Blend Offgrade Resin Type I Resin Type "BC" Vacuum Dust Total Packaged W/house 5,117,947 119,840 382,763 239,293 262,183 575,785 564,966 1,131,350 100 32.610 8,426,837 4,509,544 141,628 285,721 261,448 184,310 643,221 269,678 1,055,035 100 ____81,525 7,432,210 <608,403> 21,788 < 97,042> 22,155 < 77,873> 67,436 <295,288> < 76,315> 0 48.915 <994,627> < 11.89> 18.18 < 25.35> 9.26 < 29.70> 11.71 < 52.27> < 6.75> 0 150.00 < 11.80> Bulk Finished Goods Ending Inventorv Dec.. '91 Jan.. '92 (Decrease) /Increase % Change Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade Total 2,772,902 0 2,834,070 1,092,760 22,269,775 2.279.450 31,248,957 1,667,658 0 2,661,679 959,860 13,531,633 1.817.850 20,638,680 < 1,105,244> 0 < 172,391> < 132,900> < 8,738,142> < 461.600> <10,610,277> <39.86> 0.00 < 6.08> <12.16> <39.24> <20.25> <33.95> December and January futures loss is $33,889.79. Aberdeen's percentage of future gain or loss is 8.4%. VAB.0001189414 ? .| : i : ''(ill iiV| :L-^L ."I* .in i t :rS-V * V ABERDEEN CHEMICAL PLANT SKIPPING ANALYSIS JANUARY 1992 -SHIPMENTS BY PRODUCTS- PUBLIC MONTH IPT/ITC EXCH/TOLL PUBLIC YTD IPT/ITC 02:46 PH 20-Feb-92 EXCH/TOLL RESIN-BULK RESIN-PACKAGED 22,646,915 21,142,030 660,356 231,650 0 0 71,281,410 1,822,106 58,582,680 830,250 0 0 FLEXIBLE COMPOUND-BULK FLEXIBLE COMPOUND-PACKAGED 136,940 3,254,985 3,086,750 18,000 0 0 701,160 10,921,516 8,357,350 172,011 0 0 NEU BUSINESS 7,550 00 38,512 00 RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED RIGID COMPOUND-PELLETS 743,400 750,600 0 1,253,100 0 0 0 0 0 2,896,410 1,842,805 0 2,959,700 6,500 0 0 0 TOLLING BULK TOLLING - PACKAGED 0 00 0 00 0 00 0 00 PLASTICIZER 38,240 445,710 0 61,300 1,817,750 917,400 TOTAL =3EESSXSX13B3XaSSSSBEaXSS -SHIPMENTS BY MOOEBULK: JANUARY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 28,238,986 RAILCAR 183 17 9 2 26,177,240 CUSTOMER PICKUP 21 0 0 0 0 COMMON CARRIER 47 3 13 4 89,585,239 72,726,241 mmmmummmmmm 917,400 TOTAL 251 20 22 6 TOTAL JANUARY 211 21 67 299 *YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 579 52 173 49 0 21 25 2 42 13 0 9 804 70 69 22 TOTAL YTD 666 54 245 PACKAGED: JANUARY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER CUSTOMER PICKUP 3 21 5 0 COMMON CARRIER 26 88 11 0 TOFC AIR/UPS 00 00 00 00 AIR/UPS 0 3 0 0 TOTAL 29 112 16 0 TOTAL JANUARY 29 125 0 0 3 157 *YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 12 75 0 0 88 301 0 0 9 46 0 0 0 000 0 6 1 0 87 395 56 0 TOTAL YTD 109 422 0 0 7 538 88CSSCES8B8B8883BS8iaiSS3SI I3Z88IBIIII8SE88SS88S8388U8888I88S8388383883838888H88II8888838S888388S8888338888383 CC: DAB,TLC,AEV,JRF i VAB.0001189415 A w *i o -- z& or 04 C^ o Uj Cm c-* si <5r>? un w s*" O w r* cn co co i5Q r-- oo CS Cm M fM O CO fH cm *T^% CM 4 oo 5 **> r*> ioT> 3 1^ o o CM O 1o oip o Iw *. i Csl CM o t w* p--1 CM i Cm CM i i a a i * S3 CO CO CO co CO CO S3 CO *4 *4 o 44 (O II OO tl II It CM 11 at n ii ia 4t CO ***> r^j U*1 V ^ -* oo r-n m CO Cti r*> r-n *#'# in MO ro'/ m u*3 ro KJ -+~t i f O CM 11 -o 'O O1oc W) CO uocj ucci UU I.U a c~ m a cn co ctr OCi co CO CD CO tn to a* co --. <c <JT cu UJ oc CO 3K 3C Qu *-- (__ cn cn <t <C j Cu Cu <r <r 4"^- K" CU UJ cm cm _i y K 3* * co uu LU O Cu Cc. 4JU UJ 14 CcT cc -- a-- *_ *-+'^ a: UJ cu -U j cn sn i!.rf cn cn am CJi C-J cn d> __ 4 co CO cu CU cm cm ctr UJ cn kw| Cl, Cl, I--- CM C-4CT' O' 0^1 CM O- c*' CM o Cm CM co CM CM CM CM -S-- I s : y. |]|[ rfcl. Mtf?. J" J?.i-I|. a---"? |.- J.i- ` r|iL|u L; > Ja. ! I -i H-'i 1 " "`-f |!,B"i^:-l l~t|4HrtRffl+- t^sHPr rrrl 11 HIJKfpn? 3 `llft'-tli*: (-di :' -!IM * 'V -I * * n *.lrr1. iWU '! -*.*# iJJ .t f r^nr| |j| :.; .>.*!. . r J:it. *ltj| r.tr: : 1:.-v . . VAB.0001189416 ousands of lbs.) . . J.*:: , FLEXI LE & RIGID OFF-GRADE JAN.'91 THRU JAN.'92 02/91 04/91 06/91 08/91 10/91 12/91 PKG'D PRODUCTS INVENTORY VAB.0001189417 A LABORATORY - J. M. Edwards A. Safety There were no safety incidents in the Laboratory during J anuary. B. Customer Contacts Representatives from Textileather visited the Aberdeen Plant to audit, tour and discuss technical issues concerning 5385 resin. Customer 0 .C. Problem Reports and CNRr 01/02 Thermal Industries The customer complained that lot 41L19 of RP-159 BGE 347 fused faster than typical material which caused dimens ional instability. The Q.C. was made more sensitive to detect this variation in the future. ire. Nashville. TH The customer complained of a late delivery of 2153A NAT 03 compound. This lot was delayed by the lab because of low METS values on the first blenders. 01/03 Klockner-Pentaplast. Gordonsville. VA The customer complained that a hatch was open on a 5305 railcar when received. The risk of contamination necessitated that the car be returned to the plant. 01/07 Available Plastics - Himstville. AL The customer complained that a shipment arrived three weeks early. This was a miscommunication of a change order. 01/07 American Mirrex. New Castle. DE The customer complained of high con tamination in two compartments of a 5305 railcar. Samples sent from the terminal confirmed that the resin was high in contamination from the top of the compartments. The car was re routed to a less critical applica tion. . a| , : 'I* 1 H--JI !l - L-j .' ip. -1 - t s-l -i -il-'- k-: > 't" : r'! I-Cf... t ll i ^ .. I Jrl -I' i . P f. - J. VAB.0001189418 j-|k : . I M -V-tSWH I *i 1*>1 -p LABORATORY - Continued C. Customer O.C. Problem Reports and CNR* - Continued 01/13 Essex. Marion. IN The customer complained that a truck shipment of 5416 was released from the lab with an out of spec dry time. Two errors were made to cause this complaint, The original suited in a 4.9? anda it was released even though the specification was a 4.5 maximum. The sample was rerun after the complaint and the value was actually 4.4 which was in spec. Ql/13 Essex. Pauline. KS Customer complained of lumps in the resin. Samples from Essex showed the contamination in the 5415 to be 93% FVC and 7% lead and cadmium. 01/13 Textileather The customer complained of a high number of lights or brown contam ination in 5385. Technical dis cussions, plant visits with business and marketing involvement will solve this issue. We are not capable (statistically) of meeting their needs at this time. 01/15 Sttnliftaii NBCO. Bav Springs. MS The customer complained of metal in 38931 WHT compound. Samples sent to R&D showed the metal was stainless steel. It Is undetermined where the metal originated. 01/17 Intex Plastics. Corinth. MS The customer complained of 11.25% moisture in compartment "A" of a 5385 resin railcar. The compartment was returned to Aberdeen. The moisture was 0.12% in the returned material. VAB.0001189419 l LABORATORY - Continued 01/22 Flexible The customer complained of compound de livered on 1/21/92 rather than 2/10/92. A communication error was made concerning a change order. fil/21 Payton Extruded Plastics. f oh 01/29 The customer complained that a compartment of a railcar of RP-152 was "too blue". It is apparent that their color target has shifted yellow. Tliee Fiber. Canada 01/30 The customer complained of loss of diameter control when they switched from 38525 NAT to 38525 Blit. Samples of the material are being analyzed to find out why the material processed so differently. * Marley Mouldings. Marion- IN 01/31 The customer complained of 5305 being too fine. They measured 6% fines on the pan. The same sample was analyzed in Aberdeen as 3% on the pan. The people at Harley were asked to check their 200 mesh screen for signs of wear or any holes. Essex. Anaheim. CA 01/31 The customer complained of flow problems with 5415 resin causing a rough surface on their wire. The problem was found in Essex's process and the investigation was dropped a week later. V1C0A The customer complained that box 3 of lot 42Q03 of RP-34B WHT 180 processed poorly. Samples returned showed that the stability time was 28% shorter than control material. The investigation continues. A j'! i | m :i !' w`i*!. > l:;;m "P-"';! ............rr.x -ii-m- WrviffcaiLV u#hfh>kiUp* = * -T n i*i -7 : 1-1-I -i* M ftKS h il s sui;l; VAB.0001189420 LABORATORY Continued The customer complained that a railcar vent cap was found in their silo after unloading 5385. The cap was identified as a competi tor's (Quantum) vent gate from a railcar. D. Product Waivers Issued Customer Product Vycom RP-461 WHT 110 E. RVCM of ln-Procftgg sfples Reason 40 Mesh Ho^ 1 H/T The following is a summary of residual VCM results on in- process samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of January, 1992. Reactor Slurries Number of Samples Average RVCM, ppm 788 49 F. RVCM of Shipment- sples Drier 5265 5305 49 0.100 55 0.189 The following is a summary of the residual VCM analysis of shipment samples for the month of January, 1992. Product Number of Samples Average RVCM. mm 5225 5265 5305 5325 5385 5395 5415 5416 5465 Debox Pond Dry Blend 2 72 100 10 48 0 58 4 1 12 1 1 0.003 0.029 0.049 0.061 0.134 ** v ** _ . 0.012 0.008 0.017 0.110 0.040 0.014 VAB.0001189421 ( G- Process Capabilities (based on drrer "regulars"^ 5265 5305 5385 5415 54165 Bulk Density Inherent Viscosity (vs. 0.64 - 0.67) (vs. 0.715 - 0.744) "L" Color "a" Color wb" Color % on Pan (vs. 2% max.) % thru 140 Hard Particles, Average 5 Minutes 7 Minutes Mets I.R. (vs. 95% of Control) Average Particle Size, Microns 0.87 0.77 0.27 --- ----------------------- 4.73 7.67 5.33 1.76 -- 1.84 -- ---------- ------ 147 0.67 1.22 1.41 1.00 1.21 0.58 0.81 0.38 0.94 2.27 2.67 2.83 0.97 1.74 ** __ 1.72 -- 1.11 1.30 1.33 2.11 5.67 1.26 0.15 3.33 2.47 2.17 0.77 0.92 --- _ WMV^ 25.00 8.00 8.00 2.00 4.18 2.03 7.00 2.00 1.36 0.59 147 166 181 156 H. Flexible Compound Qualify gumma rv Hardne s s Color Hard Particles Contamination Dispersion Dicing Cross Contamination Streamers METS I.R. Totals Adjustments M Lbs. 27.0 25.0 <0.55> <0.51> 52.0 <1.06> Rejections M Lbs ill 4.3 32.3 50.5 4.6 16.0 6.9 15.2 5.9 1.5 137.2 <0.09> <0.66> <1.03> <0.09> <0.33> <0.14> <0.31> <0.12> <0.03> <2.79> Torque Rheometry Torque Rheometry & Color 40 Mesh Color Total M Lbs. i%l 3.9 9.1 2.8 7.8 23.6 <0.17> <0.41> <0.13> <0.35> <1.06> A I , I I ... -ft ....................................... IF 1!"!' ifosi-fl- S:i: = - r i. . rjv.r ii i. i-s. .jI vl VAB.0001189422 ' -iiy :ii.r t f SAMPLE SHIPMENTS JANUARY 1992 RESIN Ship Date 01/09/92 01/15/92 01/15/92 01/21/92 01 /21 /92 01/22/92 01/23/92 01/23/92 01/29/92 01/30/92 01/31/92 Product 5305 5225 5225 5265 5265 5265 5305 5265 5225 5325 5415 Pond 5225 Amount 2 lbs. X 3 100 lbs. 5 lbs. 5 lbs. 5 lbs. 5 lbs. 5 lbs. 2 lbs. X 3 10 lbs. X 3 10 lbs. X 3 50 lbs. 5 lbs. 100 lbs. Customer Keysor-Century Corp. Vista - Austin R&D IPS Ship Mode UPS UPS UPS Keysor- Century Corp. Rockland React-Rite UPS UPS Keysor-Century Corp. Kappus Plastics Armstrong World Industries Witco Corporation Osterman & Co. Vista - Austin R&D UPS UPS UPS UPS UPS UPS COMPOUND Ship Date 01/09/92 01 /15/92 01/22/92 Product 462-34A BLK 462-121B1 BLK 48562 BLK 6085 BLK 2153A NAT (OG) 2153A NAT 03 (OG) Amount 50 lbs. 50 lbs. 50 lbs. 1 lb. 10 lbs. 10 lbs. Customer Premier Polymers Ship Mode UPS Gencorp Polymers Corp. Judd Wire UPS Airborne VAB.0001189423 A SAMPLE SHIPMENTS JANUARY 1992 Page 2 COMPOUND (Cont) Ship Date 01/23/92 Product 452-181A BLK 452-181B BLK 01/23/92 58162 BLK 01/28/92 452-182AWHT 452-183 WHT 01/29/92 35031 NAT Amount 1500 lbs. 1500 lbs. 100 lbs. 500 lbs. 500 lbs. 200 lbs. Customer Alenco Ship Mode CC Florida Central Extrusions Sunbeam Home Comfort UPS CC Tandy Wire & Cable Co. CC DRYBLEND Ship Date 01/09/92 01/30/92 Product 378-143 BL 170 80273G WHT110 Amount 50 lbs. 50 lbs. Customer Extrutech Plastics Ship Mode UPS PLASTICOS OMEGA (Mexico) Airborne '!' -T IK :. I "3 ||i L<| iU' f: >.' r '' `tL- i*+: L- L'dl^fcr-i <| b S-*r1 ' ... ............ I A- - ' Jr1 ' 1 I-' VAB.0001189424 t ! T||vd :l p: -- NUMBER OF INJURIES ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) 30 25 20 15 10 5 0 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I | | I | I I |T | | I J S N J'89 M M J S N J'90 M MJSNJ'91MMJS NJ'92 MONTH TOTAL INJURIES --OSHA RECORDABLE VAB.0001189425 B T U /L B ABERDEEN ENERGY CONSUMPTION BTU/LB O MONTHLY MONTH --------- 12 MONTH AVERAGE 'till r-t rfe-' H: -ta-rji'. i| t- i - i-1 > ... ..................................... ...... f - H| VAB.0001189426 .1- --!. - It ........................... . .. .J. y ncpl**"'