Document Em6dJNxodRbnbVqpeRdZ4QNgb

To: T. H. Huffman Interoffice Communication From: Date: Subject: D. C. Skokna July 18, 1988 ABERDEEN MONTHLY PROGRESS REPORT JUNE, 1988 There was one first aid case reported during the month. As of June 30, 1988, the plant had operated 3,283 days or 4,274,987 manhours without a lost time injury. On June 4, an Open House was held for employees and their families to celebrate the plant's 25th anniversary and to communicate SARA 313 Information. Approximately 480 people participated. Key Statistical Information PVC Production, M lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, lbs. Ah Conpound Production, MM Lbs. Coopound Quality, % Prime Dry Blend Production, ML lbs. Dry Blend Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Ehergy Use (CMA Reduction, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, Variable Cost Price Variance, $M Variable Cost Variance, $M Month 4 Y.T.D. 27.3 65.1 95.2 1.00257 7.3 96.5 5.5 98.6 2.0 96.6 46.8 (146.9) 43.1 (2250.5) (2207.4) 343.9 89.9 1.01425 (std 67.2 50.0 16.3 52.0 281.6 682.5 (17,216.1) (16,533.6) 1.00756) The primary cause of downtime in the vinyl unit was a VCM shortage. During the period of VCM shortfall, most of the annual old reactor module turnaround work was completed. In the compound unit. Lines I and XXX operated thirty days and Line V operated 26.5 days. Fixed costs were unfavorable due to several large maintenance projects and the old module turnaround clearing during the month. VAB.0001190851 jfcu ; - .vn"---);p k J.f| .if. < --r*v ;pi. -i'.jJ'Si f > ! :J ' OJ ........................ - -.Tl n i T. H. Huffman 7/18/88 Aberdeen Monthly Progress Report Page 2 - The plant participated in supplier audits for initiators and antioxidants -- Meetings were held with laboratory personnel to discuss calculating the cost of quality. -- The V-ll Dust and the 5265/5305 Contamination Teams met and progressed during the month. A Lead Abatement Team was formed to recommend ways to reduce lead exposures in the compound unit. -- The plant participated in a review of a prototype "Laboratory Information Management System" at the Lake Charles Chemical Plant. A team (the Plasticizer Improvement Team) was formed to improve quality, productivity and the environmental performance of this unit. In addition to plant members, this team has PED and R&D members. D. C Skokna Plant Superintendent rah VAB.0001190852 ABERDEEN CHEMICAL PLANT INJURIES SJtynrNI JO V38M1N s.j-: lyii-'! nip njf nr \t VAB.0001190853 >iqi Ilr.ll- i . t|.. . Jl-.--.. ..................... ... .. l. . t -i *' I snw I:;.*- i-F l-"Mr. i l^c < TM. t.i;!**: <1 i . .. fT- _ -"'.ii 4 t PLANT FIXED COSTS - D. C. Skokna Major Category Payroll and Benefits MM&C T&I Miscellaneous Variance vs. Budget June, 1988 , $M June YTD ($52.5) (115.6) 4.1 17.1 ($146.9) ($174.5) 187.7 86.0 182.4 $281.6 Payroll and Benefits - Overtime for Line V operation and a $26.1M unfavorable benefits clearance were the primary causes of the unfavorable variance. MM&C - Major extraordinary projects and the unscheduled old module turnaround caused the unfavorable variance. We forecast that MM&C expenditures will be approximately $80M favorable by year-end. Miscellaneous d - Travel and Entertainment - $11.1M unfavorable due to supplier visits and training related to the dry blend Orbitran replacement project. - Outside Professional Services - $9.0M unfavorable due to SARA 313 communications preparation (video, patnphlets). - Operating Supplies - $17.7M favorable - No major purchases were made during the month. - Shipping Costs - $10.6M favorable due to late clearing invoices. VAB.0001190854 l QUALITY MANAGEMENT PROCESS - D. W. Hollis, R. B. Newton 1) Participated in Employee Open House on June 4. 2) Dave Hollis and representatives from R&D, Purchasing, Aberdeen manufacturing and Oklahoma City manufacturing conducted audits of the initiator suppliers. Also, a site survey was done on the resin anti-oxidant supplier. 3) Dave Hollis, Harold Coleman and Dave Cox attended a presentation of the nBLISS,f software for lab data management at Lake Charles Chemical Plant. 4) A meeting was held with lab personnel to discuss calculating lab cost of quality. A 1 ' ' k II I 4: 't M.. I i'' ...I , . .[^3 a il ft-1-:ms j- VAB.0001190855 !: l-h . : ' I-*-J7.- * i : 1- VINYL - P. J. Kober, C. J. McDonald Safety There was one first aid injury in Vinyl this month. A General Helper burned his wrist while making a suspending agent solution. The monthly safety meeting topic was "Scott-Air Pak Training". All operators and supervisors practiced donning and using the Scott fresh air pak system. Quality Management Process The department's Natural Team met four times during the month to coordinate daily activities and to continue dlscusslons/actlons on the Quality Implementation Plan. There are three active employee involvement teams. A fourth, the Railcar Cleaning Team, has submitted an AFE designed to improve their process. The three active teams all met during the month. The V-ll Dust Team is testing some vendor equipment in addition to pursuing modifications to sifter deck equipment in the V-ll dryer room. The 5265/5305 Contamination Team continues to test various methods to reduce wall scale during low molecular weight resin production. To date, none have been successful. They are currently also soliciting help from R&D. 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 Reactors June 27.3 909.3 633 21.1 65.1 8424 56.2 30 Y.T.D.(Fisc 343.9 1255 8130 29.7 89.9 9535 68.8 274 The reactor stream factor for June, 1988, was 65.1%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 9.9% 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, new module rinse/charge water conflicts, and holding recovery for Isonox 132 kill test, and reducing recovered VCM levels in the receivers to avoid using RVCM in 5305 production. 2) Maintenance Repair/Revision Downtime: Accounted for 14.1% of the total and was due to installation of a larger condenser on D600, replacing the agitator fluid drive coupling on D741, repairing new module F-50 charge meter, old module Modicon repairs, cleaning the D300 sewer, and checking the calibration on new module water meter and VCM meter temperature compensation. :!f i!` i^J-' M! V- L" VAB.0001190856 VINYL - Continued Reactors - continued 3) Other Downtime: Accounted for 76*0% of the total and was due to an Open House for plant employees and their families (6.2%), and a VCM shortage (69.8%). The downtime from the VCM shortage was used for maintenance normally done during the annual old module turnaround and some new module maintenance. Major old module turnaround items completed were: new bottoms were Installed on D400 and D500 reactor jackets, replaced bottom manway on D300, inspected recovery collect tank, inspected recovery seal water separators, inspected water charge tank, inspected fresh VCM receiver, inspected both recovery knock-out tanks, drilled recovery system subcoolers, drilled knock-out tank heat exchanger, inspected D700 VCM charge header. Installed new crossover cooling tower valve between D300/400 and D500/600 cooling tower, repaired fluid bed leaks, installed new VCM charge header, hydroblasted and dye-checked all old module reactors, and removed a relief valve from D300. In addition, new module reactors D743, 744 and 745 were hydroblasted. D742, 743 and 744 had their condensers drilled and D743 was dye-checked. Dryers The dryer stream factor for June, 1988, was 56.2%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 96.8% of the total. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 2.6% of the total downtime and was due to centrifuge plugging, dryer cleaning, activator transfer problems, power failures, and checking socks for leaks. > > 3) Maintenance Repair/Revision Downtime: Accounted for 0.6% of the total downtime and was due to repairs of leaking socks, activator repairs, and centrifuge and air sweep repairs on #7 dryer. Product Quality Summary Resin Type Prime % of Total "B" "H" Production 5325 5305 5385 5415 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 1,977,178 4,243,785 12,044,936 7,701,204 - -- -- -- -- 25,967,103 -- -- -- -- - 1,026,710 -- -- -- 1,026,710 -- -- - - 81,720 204,050 285,770 7.2 15.6 44.2 28.2 0.0 3.8 0.0 0.3 0.7 100.0 A -1I -1I -rii i: i-rjr | :i I r if-.tHiFpTJqfflhaT'** VAB.0001190857 Tij^e . ;;1.| :! n l.i P%1| .1. I..#:,- : f. 1 |H H- 1 1 MHlJ ' -f > J-lf. i--- | i '. i. ., VINYL - Continued * Monthly Variable Cost Performance Variable costs for the month were unfavorable at $1326.8M resulting from an unfavorable price variance of $1241.8M and an unfavorable efficiency variance of $85.OM. Resin variable cost for June, 1988, was 25.525 cents per pound versus the budget of 20.658 cents per pound. The unfavorable price variance was due to VCM pricing at $1299.1M unfavorable. VCM efficiency for the month was 1.00257 pounds per pound of PVC produced versus the budget at 1.00756 pound per pound. This resulted in a favorable variance of $25.4M. The lower VCM efficiency was a result of seasonal drying of pond resin. Initiator had an unfavorable variance of $85.3M. The variance is due to problems in accounting of inventory. We are currently trying to improve the initiator inventory accounting system. Energy Performance/Progress Plant energy performance for June, 1988, was 3197 BTU/lb. General The resin raw materials in the 744 account were valued at $245.3M. The Vinyl and Yard Departments participated in Open Houses for plant employees and their families, and local dignitaries,,and media. Vinyl also assisted R&D in a successful test run of IsonoxR 132 as a reactor kill agent. * * T.-. J ! -:*S...Ir i-.. VAB.0001190858 COMPOUND - C. W. Turner, S. C. Hillman Safety The Compound Department worked without injury in June, JuneTs monthly safety meeting topic was a review of general safety rules. Quality Management Process The Compound Department's Operations Superintendent Natural Team met in June, The meeting included all the compound shift supervisors. Topics covered included feedback from supervisor natural team meetings and status of the supervisor natural team projects. A Plasticizer Improvement Team has been formed to identify ways to improve quality, productivity, and environmental performance of the plasticizer unit. This team includes representatives from PED, plant Process Engineering, R&D, and plant lab. Coopound Production Operating Bays Month Production (M Pounds) Average Operating Day Fisca Sate Y.T.D line I Line III line V Total 30 30 26.5 2008 4019 1286 7313 67 134 49 20747 35002 11476 67225 Line I operated thirty days in June at an average rate of 67M pounds per day. Major items affecting production efficiency were: product changes. 111 hours; maintenance on Banbury seal and gate, 34 hours; quality problems, 22 hours; dicer problems and maintenance, 20 hours; and housekeeping, 7 hours. Line III operated thirty days in June at an average rate of 134M pounds per day. Major items affecting production were: product changes, 44 hours; housekeeping, 18 hours; dicer problems and maintenance, 13 hours; FCM seal maintenance, 12 hours; quality problems, 11 hours; and pull roller maintenance, 5 hours. Line V operated 26.5 days in June at an average rate of 49M pounds per day. Major items affecting production efficiency were: product changes, 43 hours; Welex intensive mixer problems and maintenance, 35 hours; pelletizer blade changes, 16 hours; microingredient conveyor maintenance, 10 hours; Orbitran problems, 4 hours; and housekeeping, 4 hours. Line V was scheduled down two days for maintenance on the Welex intensive mixer. !'**** '(* 1* -i ! 'I.............. -U' liiiJt" iiy. -r - -M l:k:*|-rT' 1 r*"- Tf|'- -I? ' V- i l - VAB.0001190859 r i COMPOUND - continued Quality performance for flexible compounds for June was 1.8% off-grade of which 84.0% was due to mill scrap* "BCn production was 1.5%. The raw material requirement for flexible compounds was 1.00472 pounds of raw material per pound of compound versus a 1.01192 standard (YTD is 1.00800). The variable cost variance for compound was $320.3M unfavorable with $433.5M unfavorable due to price and $113.2M favorable due to efficiency. The efficiency variance due to product mix was $213.8M favorable. The only major compound raw material efficiency variance was colors at $17.5M favorable. Total compound inventory rose 366M pounds in June to 9.43MM pounds. Dry Blend Month Operating-Day Rate Fiscal Y.T.D. Production, M Bounds Operating Days 5458 30 182 - 49967 274 Dry blend operated thirty days in June at an average rate of 182M pounds per day. Production included 80273G WHT 110, 80172C WHT 110, 90172D WHT 110, RP-100 WHT 142, RP-200 WHT 111, RP-203 BGE 322, RP-460 WHT 110, 186-139 WHT 111, 269-151 WHT 145, 290-61 WHT 121, 317-91 WHT 110, 317-166 WHT 144, 317-186 WHT 118, 317-196 WHT 111, 378-34 WHT 141, and 378-39 WHT 138. During June, 41.9% of production was fittings and other non-pipe dry blends. Dry Blend production was hindered by: quality control, 81 hours; product changes, 43 hours; waiting on blender transfers, 28 hours; screener inspection and cleaning, 23 hours; and blender inspection, 4 hours. Quality performance for the month of June was 98.6% customer grade. The raw material requirement for dry blend was 1.00526 pounds of raw material per pound of dry blend versus a standard of 1.00489 (YTD is 1.00490). The variable cost variance for dry blend was $497.4M unfavorable with $508.9M unfavorable due to price and $11.5M favorable due to efficiency. The efficiency variance due to product mix was $13.4M favorable. There were no major dry blend raw material efficiency variances. VAB.0001190860 - COMPOUND - continued Plasticizer Production, M Pounds Operating Days Month 2065 30 Average Operating-Day Rate 69 Fiscal Y.T.D, 16343 271 Plasticizer operated thirty days in June at an average rate of 69M pounds per day. Production included 61OP and 108P. VRP production totaled 68.6M pounds (3.3%). The raw material requirement for plasticizer was 1.07138 pounds of raw materials per pound of plasticizer versus a 1.10056 standard (Y.T.D. is 1.09304). The variable cost variance for plasticizer was $62.9M unfavorable with $66.3M unfavorable due to price and $3.4M favorable due to efficiency. The only major raw material efficiency variance was Alfol 610 alcohol at $18.7M favorable. The efficiency variance due to product mix was $0.1M unfavorable. * Compound Dry Blend Plasticizer Usage (BTU/Lb.) Actual Standard 2073 862 1878 1758.0 720.0 1550.6 h - ifc-lflqs'T VAB.0001190861 . i I -"r- l^| (^llr,7J. Jt I-.+ lA.Kll, - r-, K. uI MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - D. A. Miller Safet There were no injuries to Mechanical Department personnel during the month. The monthly safety meeting topic was "Respirator Training". The Maintenance Shop Utilization Team was formed and had two meetings during the month. Vinyl Due to an unscheduled shutdown of the old module because of VCM supply problems, the unit was cleared and annual shutdown work completed. The following is a list of the major work completed: - Rupture discs were changed on all old module reactors. - All old unit reactors were hydroblasted and die-checked. No problems were found. - The D-300 bottom manway was replaced. - The bottom closure ring on the D400 and D500 reactor jackets were replaced due to leaks caused by water--side norrosion. - The fresh VCM receiver, knockout pots, seal water separators, hot water tank, and collect tank were inspected. - The knockout pot water cooler and ring seal water coolers were cleaned. - The VCM charge header was replaced. - All reactor agitator rotating equipment was inspected and lubricated. - The D500 vinyl chloride charge valves were replaced. - Several leaking valves were replaced in the old unit steam system. - The old dump Sweco screens were replaced. - The D600 cooling water control valve was replaced with a larger valve. VAB MECHANICAL DEPARTMENT - continued Vinyl - continued The following instrument and electrical work was performed during the month: - The VCM turbine meters were PM'd. - The VCM receiver level and pressure instrumentation was calibrated. - The power supply to the old module Modicon I/O racks was modified to allow isolation of each rack. - A floating ground was repaired in the Foxboro spec 200 system. The D600 chem wash and rinse system was revised to eliminate pressure drop and unnecessary valving during the condenser replacement. Reactor condensers 741, 742, 743 and 744 in the new module were drilled due to tube side fouling. Reactors 743 and 744 were hydroblasted and die-checked. Reactor 745 was hydroblasted in preparation for a low mole resin run. The D744 condenser lid was replaced with a new lid due to cracked cladding. The old lid will be repaired and will be installed on D742 which also has a lid with cracked cladding. The following mechanical seals were replaced: - D300 agitator seal - Old unit south chem wash pump - 903 compressor inboard and outboard - North fluid bed scrubber recycle pump The following major valves were replaced: - D700 main dump valve - D700 sewer valve - D742 main dump valve - D744 condenser cleaning valve - D300 sewer valve - D300 primary VCM valve - D400 slurry dump valve - D600 recovery valve h ' rfr: ' . t. .`r i -:rt- lb tjr.:*: ilfftJHW'tf- f * VAB.0001190863 ........................ ' H 1 ' : T'-J i:-h r.Jl-r ( i+lr-T'-l- ' (' MECHANICAL DEPARTMENT - continued Dryer Area The #1 Bird centrifuge overhaul was completed and installed in preparation for a pond resin run. During the old unit shutdown, the following work was performed on the fluid bed dryer: - The bed plate was resealed. - The heating panel door gaskets were replaced. - The scrubber was chemically cleaned and the demister pad replaced. - Revisions were made to the centrate hopper discharge piping. Compound, Dry Blend, Plasticizer The Line I Banbury seals and hydraulic pump were replaced. The Line III FCM Visco seals were replaced and the rotors were inspected. No abnormal rotor wear was noted. A vibration problem on the Line V Welex deck was investigated. All rotating parts associated with the intensive mixer were dynamically balanced. Vibration of the platform has not decreased. Investigation into structural problems is continuing. Only routine maintenance was performed in the dry blend and plasticizer units. Utilities The #3 boiler annual Inspection was completed; repairs were completed: the following - Minor firebox refractory repairs. - Repaired the burner damper linkage and controls. - The magnetrol level system wiring was replaced. - The relief valves were reconditioned. The east Joy centrifugal compressor motor was overhauled on a scheduled basis. The Joy compressor vibration instrumentation was recalibrated. The supply and return piping to #2 cooling tower was sandblasted and painted. VAB.0001190864 MECHANICAL ENGINEERING - R. E. Polk AFE F596/A717 - Reactor Heat-Up Loop This project Is complete and operational. closed to field charges In July. The project will be AFE F786/F557 - Resin Quality Improvement Concrete work Is 97% complete and in progress. Fireproofing and minor paving remains. Mechanical work is complete except for punchlist items. I/E work is 50% complete and in progress. Painting, roofing and siding are in progress. Project completion is targeted for completion in early August, 3-4 weeks ahead of schedule. AFE F587 - Laboratory Addition The lab was completed the week of May 16. Punchlist items are in progress and scheduled for completion by 7/15. The project will be closed to field charges in August. Installation by Texas Automatic is 85% complete and in progress. Completion is planned for the week of 7/4. The project will be closed to field charges in August. AFE A538 - Reactor Condenser Revisions Installation of the new condenser on D600 was successfully completed in early June. Retubes for D500 and D400 5are planned for mid-July and mid-August, respectively. AFE D608 - Dryblend Orbitran Replacement Software development and checkout are complete. Pre-shutdown field work is 80% complete and in progress. Installation is planned for the period of 7/10-20. AFE B548 - Plasticizer Lighting Upgrade All scope work is complete including punchlist items. The project will be closed to field charges in July. AFE D638 - Boilerhouse MCC Replacement Bids have been requested and are due in early July. Installation is planned for completion by 10/1. AFE F598 - Line I Screeners Installation is 20% complete and in progress. planned for 9/1. Completion is h VAB.0001190865 r PROCESS ENGINEERING - V. E. Messick Dry Blend OrbItran Replacement Univox configuration and software checkout was essentially completed in June. The operations training manual was also completed. Training classes for operations and I&E personnel were conducted. Railcar Cleanout Team An AFE for a new railcar cleaning system was submitted by the team and has been approved. Plant Air System Modification This project was included in the fourth fiscal quarter budget. An AFE request was written and submitted for this project. Compound Silo Bridging Problem A report from Jenike and Johnson was received containing recommendations to correct the bridging problem. It was reviewed and major equipment costs are being determined. SARA The Section 313 forms were approved and issued to the EPA and State. Titanium dioxide was removed from the Section 313 list. Chem Wash Optimization A letter was written describing work to date on backflush filters, problems encountered and recommendations to correct. An estimation was completed on proposed solutions. Plant Water System A meeting was held with PED, R&D, plant personnel and a hydrologist to discuss alternate charge water testing. An estimate was completed on charge water testing costs. The AFE request for the Coker aquifer test was prepared and submitted. Steam Trap Survey All of the steam traps in the new and old modules were tagged and documented. Well Water Safety Items A design was completed to provide additional relief capacity to the well water system and to provide instrumentation to start the city water booster pump during periods of low pressure in the well water system. VAB.0001190866 . r: v PROCESS ENGINEERING - continued Well Water Safety Items A design was completed to provide additional relief capacity to the well water system and to provide instrumentation to start the city water booster pump during periods of low pressure in the well water system. Pond #3 pH Control A design was completed to provide improvements to the current acid addition system. An alternative to sulfuric acid is also being evaluated. RQIP Construction continues in all areas. A pre-completion audit was held in June. FED people are developing the operating procedures with plant input. Manuals will be in the plant for review in July. Assistance to the construction group is ongoing and continuous. D600 Condenser The new extended-length condenser was Installed on D600 reactor. Several batches of 5385 were made at 7 and 8 gallons of initiator. Testing will continue in July. Shutdown Assistance Process Engineering provided assistance during the recent shutdown of the V-ll reactor module. Information was gathered on all rupture discs which were changed out during the shutdown. Plasticizer Filtering Problem A design was completed to electric heat trace soya epoxy lines in order to eliminate hard particle formation. Designs were also completed to install better plasticizer filters on Line I, III and V. Plasticizer Discoloration Problem A design was completed to install an oxygen analyzer on the inert gas system that will alert operators of excess oxygen. Dryer Dust Collectors A consultant was in the plant to gather information and observe both the existing dust collector system and a proposed new dust collection system. * n p mi r l ~ ii i tnwvnr t t chh- .-h- |i + ir -.iF^r * J, . .. .1- Y^! lit* itv .. -I I- =i - |fi '<ri - i - . i f. rfu--rri iJ ........................... ' --"'I ft ' --1> -- VAB.0001190867 HUMAN RESOURCE REPORT PERSONNEL - J. E. Beall EMPLOYMENT Wayne L. Cadden, New Hire Charles R. Clay, New Hire Thomas A. Madigan, Rehire Bernard McGee, New Hire Nathaniel Smith, New Hire Rory H. Sneed, New Hire PROMOTIONS/TRANSFERS Paul E. Allman promoted from General Helper to Compound Utility. Paul Cook from Compounder to Compound Operator. Lee Roy Howell promoted from General Mechanic MBM to General Mechanic "A". David Nolen from General Mechanic "A" to Instrument Technician "B". James D. Wells promoted from Maintenance Helper to General Mechanic "B". RETIREMENTS None TERMINATIONS/RESIGNATIONS Jeffrey B. Popp TO/FROM LEAVE OF ABSENCE None * VAB.0001190868 h Aberdeen* Mississippi Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations DEPARTMENTS Warehouse Gen. Plant Maintenance Laboratory Compound Vinyl Plasticizer PAR 16 ia_ 40 24 40 32 5 78* 171 242 JUNE* 1988 MONTHLY PERSONNEL REPORT Minority Employees #, % Salaried 7 9% Hourly 68 40% Total 4 Hourly Min. Hired 2 % Min. Hired 50% 0 Hourly Min. Term. 0 % Min. Term. # EMPLOYEES MIN. EMP. ` % MIN. NEW HIRES YTD TERM. YTD TURNOVER 16 7 44 0 000 0 17 7 41 . 4 _g_ 0 o 0 38 9 24 0 * 00 0a * m 24 6 25 0 00Q 0n 39 27 69 0 00o 0o 32 10 31 0 000 00 5 2 40 0 000 0 Number of Applicants ** Hires (Hourly): Month 10 Year to Date 23 Month 4 Year to Date APPLICANT BREAKDOWN: Terminations (Hourly) * // Minority // Female 2 0 % Minority % Female 20 0 Month 0 Year to Date Overall Turnover 0 Projected Annual Turnover * Includes 1 temporary employee. 2 Co-op Engineers and 1 Summer Engineer. 8 3 3.5% VAB.0001190869 ?! -I 1 '1,. .-I-; M \ 1 i j '. i:: i a I. r -i k '+ ' i|- 1* - + ..............1: ---I: :p.-l i . : dir- .i.hipj p- I *- OVERTIME AND ABSENTEEISM !1> hJ * Lj H* 44 >* XI &u 0< >o OS CO sO CO CO o T--* CM CO o CM CM CM <r o H o CM rH CO CM CO <d fH CO 44 44 CO o H o M H Of X CO 44 o 10 <0 o i--| X uo O uo o o os O * CM # X O as ON sO o o S0 CO CM UO PIi r** o 00 X OS o uO o o m O o Mfr CM CO V0 o o CO 01 00 a Oft d Of Of QQ .3 Xa O o CO o SO o O o o o CM sO CO sO no o o o CO lo| CO H Mf uo -a- *4 D O 4f *J O QQ co Of m3 CO x< 00 00 CM sO co <r OH co co o> ma td H ocdn j4s4 x Of *H *u8H * u M CO at I CO o OS CO o 00 CO 00 U0 o NO o CO o o CO <r ON 00 00 CO o sO rH iH pH CM CM iH 00 N 41 uo 44 fu d0 u co 1 d lM o o2 : s 4f 4i ux 0) $H 0 u 44 d o a oooo oo ooo ** GO VO o o H 00 00 00 iH 1 1 o 1o 1o *1 * -o 1 CM CM I CO \1 ** UO O UO O UT ICS uo U0 CM m o N CM CM CM uo K *#**4* ** CM Os Os os NO CO MT 00 sO OS CM CO U0 iH 00 iH i-j OS vO 00 iH pM <H iH UO Of 8 "O Of H M u X9 00 *H QQ Cd Li Lt d Vwi O SB o uo O o UO fv oO UO uo O uo ** rH o Os CO sO uo CM CO iH CM <* 'O CM Os os UO UO OS CM NO OS ON 00 uo CO 00 NO OS CM 04 fUad w04 Xfad 8c 44 g M X e c M frlj 3 8 I* CO 3 aat * 0 IwD c o H 44 a mMw o< o d H >s CO g Ji a X H 00 a; X 00 c *H X LOal co CO >s d TO QQ d moJ 4J cd u Of CL o c H >* CO TJ X 44 X 11 00 Of X c o QQ Ll d o X d 0 d 00 at Li 00 a s a o "a as >s d CO o M CO d CO 00 Qt a Ini o 00 QQ eU Mu d o X o u m odo 0) d L 00 a> d B u li 0>) o 00 c Of H d d tt 8 X 0t u 8 at > o U 0) d >X o I CO Q> I at 6 H 4-1 <5 U Of Of 01 CO o K 44 e ou 0 o 4J 1 dc oo o2 CM VAB.0001190870 : n r !- ^ - ! < v ENERGY CONSERVATION - F. G. Jeanson I. Plant Operations Total energy consumption for June was 109.816 MMM BTUs. Energy consumption increased to 2608 BTU/lb. from 2370 BTU/lb. in May. An adjusted CMA reduction of 46.8% was obtained for the month. The adjusted CMA reduction for fiscal 1988 is 52.0%. II. Plant Energy Conservation Program Maintenance There were twelve energy related items completed in June. Ten of these items were steam leak repairs. The remaining two were steam trap repairs. HI. Boiler Operation Boilers No. 1 No. 2 No. 3 83.6 83.3 83.4 Note: (1) Boiler umber two was operated eleven days during the month (2) Boiler ruber three was operated sixteen days during the month. * VAB.0001190871 Month ENERGY CXKSEKVATION DATA 1988 June Production, MM Ubs. Resin Dry Blend Compound Plasticizer TOTAL 27.3 5.5 7.3 2.0 42.1 Natural Gas Consumption, MSCF Conversion, BIU/SCF Ehergy Consunption, ltd BIU Ehergy Consumption, BTU/lb. 51448 1020 52.477 1246 Electricity Consumption, Iti KWH Conversion, BTU/KWH Energy Consunptlon, ltd BIU Energy Consumption, BTU/lb. i - 5.7339 10000 57.339 1362 Propane Consumption, M Gal. Conversion, ETU/Gal. Energy Consumption, ltd BTU Ehergy Consumption, BTU/lb. 0 92000 0 0 Total Energy Consumption, BTU/lb. 2608 Ehergy Consumption, ltd BTU Actual Unadjusted Actual Adjusted 1972 Base Period 109.816 91.936 172.879 Oft Reduction (%) Adjusted Unadjusted Fiscal 1988 Year^to-Date Performance 52.0% Adjusted 42.3% Unadjusted 46.8 36.5 1987 June 34.8 4.7 6.8 1.8 48.1 49343 1020 50.330 1046 5.7963 10000 57.963 1205 '0 92000 0 0 2251 108.293 88.615 203.082 56.4 46.7 * V l.i U'-, -! 'I I :i i.'3: . VAB.0001190872 ENVIRONMENTAL - R. A. Frohreich Water All wastewater discharge parameters were within NPDES limits in June. RCRA Additional information on wastewater was provided to the State for the 1987 Hazardous Waste Biennial Report. A VAB.0001190873 i l.i 'SL: H:KlRMHv !`hThilctt'l. Ll = i - !**! Hf'.............t' lltltilPC J II b] -fH- '-."ll- -. . -Hi- . : .| Jl: ................... TABLE I WATER QCMPLIANCE WITH NPDES PEEWIT PARAMETERS Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. Jan. - Ave. Max. Feb. - Ave. Max. Um. Ave.rlUT* * Max. Apr. - Ave. Max. May - Ave. Max. June - Ave. Max. July - Ave. Max. Aug. - Ave. Max. Sept. - Ave. Max. Flow GEM 1229 1264 1222 1430 1083 1146 1326 1431 1521 1562 1206 1507 1076 1312 757 882 611 722 BOD FRi lb. Aw. 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 7 56 11 85 0QD PEM IB. /TO. 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 33 263 48 373 Sus. Solids PEM LB./DY. 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 15 122 23 174 Dias. 0Z 8.4 8.6 7.4 7.9 7.6 8.2 7.5 7.7 8.4 8.8 1 7.8 8.8 8.3 8.8 8.t) 8.7 7.9 8.8 ML LB./D7. 1.8 2.9 1.4 1.7 9.5 17.6 2.0 2.8 3.3 5.6 7.2 21.8 5.1 6.2 9.4 15.9 1.2 2.6 _E*L 7.5 7.9 7.5 7.8 7.6 7.8 7.5 7.7 7.5 7.7 7.5 7.8 . 7.7 7.7 7.5 7.7 7.6 8.0 NTOES Permit Units - Decenber 1 through April 30 Ave. Max. - 32 431 43 800 - 1462 - 2713 NTOES Permit Limits - Novenber 30 Ave 26 357 - 1212 Max 40 744 - 2523 674 13% 7 6.0 13 6.0 - 9.0 28 674 13% > 6.0 13 6.0 - 9.0 28 VAB.0001190874 t .! ..... .  I LABORATORY - H. G. Coleman A. Safety The Laboratory operated without a safety incident this month. Hands-on respirator training was provided by the Safety Department. B. Customer Relations Customer Contacts -- There were no customer visits by Lab personnel in June. Requests for Corrective Action There were no RCA's received this month. Customer Problem Reports Date Customer Product Reason 6/01/88 flexible Tech. Abbeville* SC 17121 WAT. OR. Soya epoxy contamination. i STATUS: Project to install new filters is In engineering. 6/03/88 National Extrusions 18162 GEY 563 El fteso* TX STATUS: Samples sent to FRS for analysis. Slow extrusion rates. * h 06/10/88 Master Halco Olney, ILL 45541 NAT n STATUS: Customer used material. RESOLVED Stringers. 6/15 Mid-American Menphis, TN 80172C STATUS: NSF to retest sanples. High tin content as tested NSF. 6/17 Athol Mfg. Butner* NC 5415 Slew plasticizer take-up. STATUS: Drytimes and CPA's looked good* sanples sent to PRS. VAB.0001190875 I-Ji -' = Cf, : :t >* . Hr lift 11-- IV' ||li TWfirf7s.fr r*i : f- Hlrf+wiit ^i-P* .sfdj ife-Hfe ' !* -I 'fd ? f!!. "H 'tJfzjlS1 'n.c- ]!' :*i ir J tin.!. i ............. ?\t: 1'I --^+'F- (I-,!^ .M- sfi,r .^-i t it i' LABORATORY - Continued Customer Problem Reports - continued Product 6/23/88 m Automotive Brownsville, TX 35031 NAT Low hardness values STATUS: Lab tested product CEt, ITT to check procedure 6/23/88 Klockner Gcrdonsvllle, VA 5305 Higher contamination STATUS: One ccnpartment sold at reduced price. RESOLVED 06/29/88 Dayton Extruded Plastics Dayton, GH 269-151 VHT 145 Metal chunks STATUS: Post-Gump screens Installed. RESOLVED 06/29/88 Vinyl Building Products Oakland, NJ 290-61 WHT 121 Contamination. STATUS: Contaminants are line scale; customer's first bulk shipment; monitor future runs. 06/30/88 Premiere Polymers 5415 Jefferscntown, KY Contamination. STATUS: Filter media; working with S&T to solve problem. Waivers Received Customer Product Reason No. Athol IPC Nibco 5415 5415 5305 Bulk density Bulk density Static flow 4 HT 1 RC 1 HT Premiere Polymers 5415 Bulk density 1 RC Uhlroyal 5305 Static flow 1 HT VAB.0001190876 LABORATORY - Continued C. RVCM Sungary * RVCM of In-Process Samples The following is a suninary of residual VCM results on in-process samples. Nona of the reactor dally averages exceeded 400 ppm during the month of June* 1968, Reactor Slurries 5265 5305 Number of Samples Average ppm, RVCM 631 132 27 0.5 64 0.2 RVCM of Shipment Samples The following is a summary of the residual \CM analysis of shipment mmplgg for the ncnth of June, 1988. Product 5265 5305 5385 5415 5465 No. of Saiples 39 93 28 27 Average RVCM, ppm 0.0 0.1 0.1 0.1 1 0.0 ResjIn Process Capabilities 5265 5305 i 5385 5415 Bulk Density 1.56 1.17 1.01 0.57 Inherent Viscosity 0.16 1.05 0.52 0.77 "L" Color Value 2.75 5.08 2.40 3.17 "A" Color Value 3.33 4.17 -- 35 0.1 Pond Debooc 0 24 0 0.0 "B" Color Value 1.17 % on Pan (vs. 2% max.) 1.13 % thru 14CM 0.39 Drytime Mets I.R. (vs. 95% of Control) _ Hard Particles (% > 10) 2.67 3.25 0.71 1.50 0.97 0.64 0.67 3.3 1.83 1.25 0 0.66 0.56 1.75 0.88 0 VAB.0001190877 usamuEtx - E. Conprand Quality Smnary Hardness Color/Clarity Hard Particles Heat Stability Contamination Dicing Total MUbs. (%) 32.5 (0.44) -- ---- 10.0 (0.14) ---- 42.5 (0.58) Rejections MUbs. 10.4 43.3 7.8 70.5 17.0 149.0 (0.14) (0.59) (0.11) (0.96) (0.23) (2.04) Color 40 Mesh Stability/Torque Stability/Color Rision Torque Stability Total 17.8 10.6 24.1 10.4 5.1 3.8 71.8 (0.33) (0.19) (0.44) (0.19) (0.09) (0.07) (1.32) 1. Dally testing for residual alcohol of a standard (0.2%) 610P aanple was begun in June to determine the precision of this test. 2. Harold Guianan and Dave Cox visited the LOCP with Dave Hollis to look at a prototype laboratory Information Management System (LIMS). A UMS tauld enable us to automate certificates of analysis and to provide customers with SBC charts. 3. Dave Cox Is participating on a plasticizer team Healing with quality and productivity improvements. 4. 5415 Control Resin (Lot 04169) Testing: n X 3(P Moisture Dry Time Particle Size - 60M - 80M - 10CM - 1201 - 14GM - 2001 Pan Bulk Density Color - L A B Flow Time Hard Particles, 7 Min. Inherent Viscosity 60 .161 .029 27 4.99 .52 60 1.22 .78 60 30.99 3.84 60 33.35 1.41 60 20.72 2.69 60 7.22 1.17 60 5.29 1.53 60 1.20 .71 29 .5147 .0052 55 100.438 .274 54 -0.101 .224 57 2.412 .563 29 7.597 1.33 15 1.0105 .0106 VAB.0001190878 LABORATORY - Continued H. Miscellaneous 1. The new applications lab was conpleted and Brian Harrison moved in this month. Melvin Tallin was gg<Hgn*d full time technician duty In the new lab. 2. Resin samples were sent to Hoechst Celanese for comparative RVCM readings in the ppb range* Testing differences made this first exchange meaning! ess; further work is planned. 3. Dave Cox finished writing a program for compound Q.C. data storage; working on sane for dry blend and awaiting hardware necessary to complete project. 4. Brian Harrison developed "reduced HO-" femulations for Vycom's color applications and performed color matches for National Extrusions Inc. 5. Brian Harrison visited Hitax Corporation and discussed applications for "buff1' no2. niece la potaitlal cost re&ictlm used In beige and bran colors. Brian Harrison attended Influence Management training June 1-3 in Houston and product liability/technical service meetings at Premiere Polymers on June 17. He also attended the National Plastics Exposition in Chicago on Jtne 20-22. h * VAB.0001190879 4. RESIN Ship Date 6/06/88 6/16/88 6/30/88 JUNE 1988 Product 5305 5385 5385 5415 5465 5385 5415 Amount 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 2 lbs. 2 lbs. Customer Product Specialties Chisso Petrochemical Corporation Stahl Finish Co. COMPOUND Ship Date 6/01/88 6/02/88 6/03/88 Product 34551 NAT 34431 NAT 17461 BLK 6/13/88 6/21/88 6/27/88 6/29/88 17462 NAT 18961 NAT 18162 NAT 34451 NAT 35852 NAT 271-152A BLK 271-152B NAT Amount t 5 lbs. 1500 lbs. 100 lbs. 150 lbs. 150 lbs. 100 lbs. 50 lbs. 50 lbs. 200 lbs. 200 lbs. Customer Southwire Company Multiflex Tubular Protection of America Superior Rubber Co. National Extrusion Quintex Alcatel NA Inc. OTHER Ship Date 6/15/88 Product Hubercarb Q6 Amount 200 lbs. Customer Vista - Ponca City VAB.0001190880 I SHIPMENTS BY PRODUCT - M LBS. JUNE 1988 FISCAL YEAR-TO-DATE RESIN PLASTICIZER DRYBLEND COMPOUND NUMBER OF SHIPMENTS BY MODE: TOTAL 24,079 1,010 5,133 7,051 37,273 265,290 6,232 46,885 62,667 381,074 RES IN-Bulk Package Export RAILCAR 102 VISTA TRUCK TRAILER ON CQNMON CUSTOMER BULK 1 VAN A FLAT CAR CARRIER PICK-UP CONTAINER TOTAL 56 69 227 52 98 - 24 PLAST.-Bulk 53 8 Package DRYBLEND-Bulk Package ________ Export 22 4 9 10 12 36 21 COMPOUND-Bulk Package 12 2 36 i 49 ' 14 132 Export 11 TOTAL JUNE 141 65 50 2 71 134 463 OCT 1987 NOV 1987 DEC 1987 JAN 1988 FEB 1988 MAR 1988 APR 1988 MAY 1988 182 62 56 173 72 50 154 88 38 155 88 45 178 97 50 211 46 37 170 63 44 159 61 51 2 1 1 5 2 2 1 51 145 1 499 61 142 499 85 161 1 528 77 139 3 512 68 168 563 82 160 538 58 141 6 483 62 149 1 483 J| '1?^^r.r .--l'ft '`tr1- I- + <L"-d Phj'. |u^.,f VAB.0001190881 *. *1 I- I : a- o(T> C\J 00 BTU/LB zo c/i tn (<f)r < Ui Wuu. > m *j ENERGY USAGE f Monthly 12-Month Moving Average VAB.0001190882 MM POUNDS m 4 MONTHLY 40 35 30 25 20 P 15 ABERDEEN PLANT PRODUCTION 10/01/87 - 09/30/88 * MM POUNDS CUMULATIVE 450 400 350 300 250 200 150 100 r0 -47T 1 : ! IttlffiSfUt- 25 20 15 10 5 m 8//80 ------------------------ Budget Actual Cumulative 4 VAB.0001190883 1 -h I- !' 1 ' ' I" ' J- { ' :^iij '* \oc . ' or.' HJ.V i : !!.'< n-.i! 1.020 1.015 1.010 1.005 1.000 0.995 1.030 1.025 1.020 1.015 1.010 1.005 1.000 1.020 1.010 1.000 .990 1.200 1.150 1.190 1.050 ABERDEEN PLANT EFFICIENCY 10/01/87 - 09/30/88 POUNDS OF RAW MATERIAL/POUNDS OF PRODUCT A 19 87/88 r tJ-MllI- i -ii ri- + *:p,,ch VAB.0001190884 ABERDEEN PLANT QUALITY PERFORMANCE 10/01/87 - 09/30/88 s * 6.0 5.0 4.0 3.0 2.0 1.0 0 % OFF-GRADE 1-.00 .75 .50 .25 0 4.0 3.0 ++- 2.0 Oct. 1 Nov.i Dec.' Jan.i Feb. Fla r. Apr. May j June io37/83 1 < JI - 1III 1t i ij t 1 Aug. Sent i t i j\ 4 t L l t 4 i ii r 1 i 4:,;! .'-.Ifll,-* ,1 Miq.HfcTThr1 'M tfJ! i'-V -j, r r t. 1 '4' .......................... 1 VAB.OOOl190885 C-4) MM POUNDS PRIME * I ABERDEEN PLANT INVENTORIES 10/01/87 - 09/30/88 ' ............ . ; '..................... I I- ; .e i-kj-;*- . f,. us it-.b i- j. VAB.0001190886