Document J39EzyNjeE1E7zLLwrzDdOaBr

T. H. Huffman From: Date: Subject: D. C. Skokna March 26, 1990 ABERDEEN MONTHLY PROGRESS REPORT FEBRUARY, 1990 Safety There were no injuries reported during February. At month's end, the Aberdeen plant's employees have worked 3891 days (5,168,371 manhours) since the last lost time injury. February Y.T.D. 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 36.5 92.5 95.3 1.0055 6.1 98.1 4.3 99.4 1.3 91.0 < 17.0> 121.8 < 24.2> 179.5 84.8 96.5 1.0007 29.8 98.0 21.4 99.4 6.9 89.8 < 13.4> 141.2 243.8 Capacity Utilization Factors Resin Flexible Compound Rigid Compound Plasticizer 105.6 69.0 93.2 73.3 95.4 76.1 99.4 77.0 Operative? Initial testing of a proprietary clean wall agent in the resin unit was completed. Results are promising. Demand for flexible compound continued strong in February and production schedules were tight all month. Line I ran forty-eight hours on PLENEX polymers trials. On Line V, a test run was done to optimize screw configuration for rigid compound production. VAB.0001190167 T. H. Huffman 3/26/90 Aberdeen Monthly Progress Report Page 2 - February, 1990 The dry blend unit set a new single day record on 2/1 producing 378.4M pounds; the previous record was 356.6M pounds. Dry blend orders continued to be strong during the month. A 10M-pound sample of foamed sheet dry blend was produced for Vycom. During the run, an experimental design (varying batch size and drop temperature) was done. Costs Variable costs were above budget, primarily due to product mix in compound and above budget raw material usage in the plasticizer unit. Fixed costs were below budget due primarily to good results in the MM&C category and less than budget expenditures in some of the miscellaneous items. 1. Ninety-five percent of the plant's natural teams met during February. 2. The Old Module Recovery Team made its management presentation. They recommended revisions that resolve some safety concerns experienced main taining the compressors and vacuum pumps in this system. A capital request ($60M) will be submitted in the third quarter to implement these recommendations. This team found very cost- effective ways to correct the safety problems. Previous estimates to correct the same problems were about $500M. 3 El Paso PVC (a division of Group Dekko) visited the plant on 2/9 to become familiar with our plant. They purchase 5415. 4 An experimental design was done in the dry blend unit to evaluate the effect of batch s and drop temperature on blowing agent dispersion in foamed sheet dry blend (for Vycom). v> VAB.0001190168 mmip-r 9 rife T. H. Huffman 3/26/90 Aberdeen Monthly Progress Report - February, 1990 Page 3 OMP - continued 5. On Line III, an experimental design was done to determine how temperature and shear affect fusion delay. Doug Skokna Plant Superintendent rah mm VAB.0001190169 i * mmmm pigTmftVTIQN Hous ton J. D. Bums X R. T. Ferrell X T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin W. L. McClain J. P. Stokes Austin R. L. Poe X H. J. Hall Oklahoma Cltv H. D. Garrison LCVCM Plant R. A. Conrad LCCP Plant J. Friend LCLAB Plant J. W. Ware X Baltimore L. R. Bauer X Hammond J. Pavao X Blane C. R. Miller Premiere P. L. Foote Aberdeen RWS/DCS (File Copy), JEB, JME, SCH, MRK, JEL, DAM, RBN, JEN, JDO, REP, BLT ENTIRE REPORT X X X X X X X X X X X X X X X X VAB.0001190170 SAFETY - B. L. Trego, J. V. Uptain First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Injuries bv Vinyl Operations Compound Operations Maintenance Laboratory Re c eiving/Warehous e Office Totals Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 0 & 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Fiscal Fiscal Y.T.D. 1989 21 00 0 2 6 0 0. 0 8 21 10 22 12 02 10 21 98 Lost Workday Cases Days Lost Safety Record 0 0 Last lost time injury - 7/5/79 Days since - 3891 Employee hours since - 5,168,371 On February 28, 1990, the employees of the Aberdeen plant completed 3891 days with no lost time injury. The main topic for plant safety meetings during the month was a review of the plant's new safety handbook. There was nearly 100% attendance to these meetings. A VAB.0001190171 SAFETY - Continued Routine dosimetry results for the month were: <_________________________ Number VCM Lead Total Particulates 69 100.0 11 100.0 5 100.0 >-- PEL Number Percent 0 0.0 0 0.0 0 0.0 There were no injuries reported. VAB.0001190172 QUALITY MANAGEMENT PROCESS - M. R. Kane Ninety-five percent of the plant's natural teams met in February, some for the first time. The facilitator team is working with the teams to teach them team management techniques. The departmental support scorecards were finalized so that each employee knows how their contribution affects the plant scorecard. Also, the Q-Scorecard was finalized and communicated to the plant. One customer visit occurred during the month. ElPaso PVC (a sub sidiary of Group Dekko) visited to tour the plant and learn a little more about PVC production. VAB.0001190173 i COST VARIANCES - D. C. Skokna Variable Costs Product Total PVC Flexible Compound Rigid Compound Plasticizer <$11.7> 90.5 <81.9> <$24.2> $C34.0 175.7 215.7 23.3 $1248.7 $822.3 266.2 133.8 2.2 $1224.5 PVC - Efficiencies were essentially at budget. Flexible Compound - Product mix ($76.3H favorable), raw material use ($15.2M favorable), and lower than budget off-grade ($11.OM favorable) were the contributors to the overall favorable variance. Product mix caused essentially all of the month's variance. Plasticizer - Raw material use was above budget. Price Variances - VCM - Resin to Rigid Compound - Resin to Flexible Compound - Alfol* 610 - Electricity - Ti02 - Other Price Variances Total Fixed Cost Variances $816.7 203.6 157.9 16.4 11.7 10.1 32.3 $1248.7 - Payroll and Benefits - MM&C - Miscellaneous - TI&D - Clearances Total SM $ 6.2 51.7 59.0 5.6 < 0.7> $121.8 Payroll and Benefits - These were essentially at budget. M. M. & C. - This category was favorable due to low activity levels. VAB.0001190174 \ * s COST VARIANCE^ - Continued 4 Miscellaneous: Major variances in this category were: Unclassified: $10.7M favorable - Physical exams were budgeted in the second quarter but will occur in March when the charges will clear. Contract. Operating: $12.2M favorable. Strike preparation costs of $30M were budgeted in the second quarter. Charges have not cleared (should clear in March or April). $10.1M favorable. $13.9M favorable. This month's invoice was late. / VAB.0001190175 i Tm VINYL - J. D. Olson, K. W. Birck The Vinyl Department did not have any first aid or OSHA recordable injuries during the month of February. The monthly safety meeting topic for the month was the new safety manual. General 1. Initial clean wall testing was completed during February. Results continue to look promising as reactor walls repeatedly and consistently coated with clean wall agent prior to charge have remained clean. Next month a new temporary test clean wall injection system will be used. This new system will be designed to provide better clean wall application. 2. Startup of the V-ll natural gas detectors was completed in February. This plant safety feature shuts down the dryer direct fired burners whenever a high level of natural gas is detected in the dryer building. 3. The resin raw materials in the 744 account were valued at $349.1H. - 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 % Reactor Downtime 36.6 1307.3 107.2 854.0 30.5 92.5 85.7 96.7 95.3 Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks. New Module rinse/charge water conflicts, no place to dump, 0-ring leaks, waiting on Q.C. data before charging, and inclement weather). Maintenance downtime (hydroblast reactors and drill condensers D700, replaced con denser base gasket on D741, drilled 741 condenser, replaced agitator seal on D400, repaired reactor jacket on D400, replaced reactor Lanape manway on D300 and miscella neous instrument and valve repairs) . 179.6 1189.5 97.6 4203.0 27.8 84.8 73.5 88.2 96.5 Hours 229.0 275.0 A VINYL - Continued Dryer Downtime Reactor limited production. Operational downtime (centrifuge plugs, check for dust collector leaking, clean dryers, activator transfer problems, and flameouts). Maintenance downtime (centrifuge repairs, replace north fluid bed centrifuge, shear pins, exhauster maintenance, hydroblast centrate line, sparge pipe replacement and Bird boot repairs). 66.7 16.5 16.8 - J. B. Autrey, J. B. Hegwood Reactor 400 was shut down during the month for repairs to the water jacket. A crack developed in the weld between the water jacket and the reactor vessel. Also during this time, the seal was changed out on the reactor because of an excessive oil leak. The seal was in service for nine months. The north fluid bed Bird centrifuge was changed out during the month because of a minor vibration problem. The vibra tion was caused by a calcium carbonate buildup. The Bird was replaced with a spare. The Bird that was removed will be re built and used as a spare. Reactor 741 was shut down during the month because of a leaking gasket on the condenser base. The gasket was replaced with a Flexitallic spiral wound gasket and the condenser was drilled because of cooling control problems. The "B" recovery compressor was changed out during the month due to decreased performance. It was replaced with a spare compressor. The #5 dust collector conveyor screw was changed out with a spare during the month. The screw shafts have been breaking because of an excessive torsional stress. Several options are being considered at this time to alleviate the problem. The #8 Bird centrifuge was taken out of service during the month, rebuilt and put back in service. Reactor 700 was shut down during the month for condenser drilling and hydroblasting as part of the contamination control program. Reactor 742 was shut down for condenser drilling during the month because of cooling control problems. VAB.0001190177 VINYL - Continued continued The north chem wash pump motor was changed out with a spare during the month because of bad bearings in the motor. The vinyl control room UPS unit was shut down for repairs on its systems control board and battery backup system. The systems control board was replaced along with three batteries. The old unit centrate exchanger was shut down for drilling and acid>cleaning because of an excessive calcium buildup. There were eight major valves changed out in the reactor area during the month. VAB.0001190178 COMPOUND - J. E. Nickerson, K. 6. Akins Safety The Compound Department worked without Injury In February. The new safety handbook was reviewed in the monthly safety meetings. Demand for flexible compound continued strong in February. Produc tion schedules remained tight throughout the month. Line I rates were reduced by 48 hours of PLENEX polymer production and fiftyfour hours of roll mill maintenance. Line V was down for fortyeight hours during a test run to optimize screw configurations for production of rigid compounds. Work began on an experimental design on Line 111 to determine how temperature and shear affect fusion delay. On February 1, the dry blend unit produced 378,370 pounds a new one-day production record. The previous record was pounds set on January 6, 19900. As in January, the orders for rigid compound were heavy. A 10M pout nd sample of foamed sheet dry blend February. An experimental design was ction to determine the effect of batch size and drop temperature on blowing agent dispersion. Samples of p 80273G dry blend produced after the foamed sheet dry blend were sent to R&D to determine the extent, if any, of blowing agent con tamination of subseauentlv oroduced materials. Rates were slightly reduced in the plasticizer unit as two plasti cizer reactor agitator assemblies were replaced. The final two re placements will be completed in March. Operating Days___ Month Avg./Dav Line I 27 Line III 28 Line V 21 Total % Prime Capacity Utilization Factor 1733 3425 64 122 6058 229 98.1 .780 Fiscal Y.T.D. 9965 16576 3239 29780 98 .764 Downtime Hours Lino 1 - Product Changes - Mill Maintenance - PLENEX Polymer Testing - Miscellaneous Maintenance - Dicer Problems & Maintenance 81 54 48 19 14 COMPOUND - Continued Downtime - continued Line III - Product Changes - Miscellaneous Maintenance - Quality Problems and Control - Mill Maintenance 60 37 9 9 Line V - W-P Maintenance - Rigid Compound Test Run - Quality Problems & Control - Weigh System Maintenance - Product Changes - Miscellaneous Maintenance 52 48 44 42 36 17 Operating Month Production (M Lbs.) Fiscal Y.T.D Rigid Compound 28 5481 % Prime 99.4 Capacity Utilization Factor .930 196 22578 99.4 .754 Downtime - Product Changes - Quality Problems & Control - Miscellaneous Maintenance 82 40 26 Operating __Davs Plasticizer 28 % Prime Capacity Utilization Factor 1404 91.0 .679 7704 89.8 .752 Kev Maintenance Work - J. B. Autrey, J. B. Hegwood The Line V twin screw extruder was shut down during the month so that the lubrication system could be cleaned. The filters and oil tank were also cleaned. The Line I mill was shut down during the month for repairs to its gears. The gears were removed and flipped because of excessive wear on one side of the gear teeth. A new set of gears has been placed on order. VAB.0001190180 COMPOUND - Continued Maintenance Work - continued The front rotary joint on the Line III mill was re placed during the month and repairs were made to the hydrotherm line also. The rotary joint on the Line I Banbury gate was re placed during the month. The middle cooling tower pump was taken out of service because of bad windings in the motor. The motor is being repaired and the pump will be put back in service as soon as possible. The temperature control loop on R-2 plasticizer reactor was repaired during the month. A r wmmmmmmmmmm VAB.0001190181 I Mr J. B. Autrey, J. B. Hegvood The #5 water well was put in service on 2/19/90. The calcium carbonate levels in this well are significantly less than that of the other wells. Pond aerators #3, #4 and #8 were shut down for repairs during the month. The motors were replaced in aerators #4 and #8. Number three had a bad ground wire that was repaired. VAB.0001190182 ENGINEERING - R. E. Folk, S. G. Hillman, H. R. Kane PROJECTS IN DEVELOPMENT - GENERAL 5305 Decalcified Water Test The test run for removing calcium in 5305 charge and rinse water will begin the week of March 12. The test will involve diverting charge and rinse water for 5305 made in 745 reactor through a water softening bed. Samples will be sent to BASF for calendaring evalu ation. If BASF sees an improvement in graininess, a car will be offered to Klockner for evaluation. EVC Technology The clos March 7. be used temporary addition system for 43 was completed The system is being tested. Results fro the testing will to dJ esign a permanent addition system for all vinyl TC Waste Water Compliance A class "A" design is being prepared to provide instrui equip-ment to improve the reliability of the batch wat This will be needed to meet TC waste water limits. t Interaction Management Engineering, department heads and supervisors attended Interaction Management seminars conducted at the Best Western. Plasticiser BOD/COD Reduction Baffling of the existing biodisc has been identified as a way to improve BOD/COD performance from the biodisc. A. baffle will be in stalled between the second and third cell in mid-March, after which sampling will be increased to determine the amount of BOD/COD reduc tion that can be achieved. Recruiting Of the four offers made for permanent process engineers, three have declined. VAB.0001190183 r 1 CA s a 5f sss cn S i is Sf <A s mt g f si 5 k * a! SS s s lis"Sl sli. sLU m S u *8 CD sSS u s UJ jJ O U1 cn 01 cn sf cn cl. m cn ~5 cn sa o> * if i iu sasaga^S g % i?s SS g S ^^isZSs&ss cn cn s & cn SS s Sags! uj cn S 0> ISII M.K S cn cn w CIS1S aa^i u cn _______ mSSoiSSSSSS || 2 w 2 m cn cn -j cn cn cn cn cu -*S*=iS35Sss ~s~ m"-3e Si;iiiiilaa= 352 O O) K uj M cn S UJ UJ UJ si g g S g * S i IS S S & 5 S S S S IS g g I, I eg SS S ssss VAB.0001190184 i m-* rnmmmm wm f ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were met for the month of February. Bloassay testing was also completed on centrate containing the new clean wall agent. Results were favorable. The new air permit for our plant will be reviewed by the Mississippi Department of Environmental Quality (MDEQ) Board on March 13. We should have a new air permit shortly after that date. SARA The Section 312 report was completed and issued to the State, the Local Emergency Planning Committee (LEPC), and the fire department. The 1988 Section 313 report was sent to us by EPA to be proof-read. The report was proof-read and returned to EPA. Waste The RCRA Biennial Report was completed and issued to the MDEQ. Waste shipments for the month included: - One bulk load of separator oil to Systech in Demopolis, AL. - One drum load of stabilizer spill to Technical Environmental System in LaPorte, TX. Chemical Waste Management will stabilize all loads going to the Lake Charles facility at the Emelle, AL facility. All of our drum loads of waste can now go to Emelle to be stabilized. From there, they will be transferred to Lake Charles. There will be an additional charge for the transfer; however, the total cost will be less than what we currently pay for transportation. Reports Completed - Monthly NPDES - EPA questionnaire on latitude/longitude of NPDES outfalls - Vinyl Institute Environmental awards questionnaire $ VAB.0001190185 Continued Sunerfund A meeting was held with EPA (Region IV) to discuss the NUS Report and recommendations. A meeting was also held with Conoco representatives to review the NUS Report and look over the sites. A letter was completed with four tables summarizing the results listed in the NUS Report. Miscellaneous Joe Ledvina and I visited M&M Chemical, a waste oil blender, to qualify them as an option for recycle of burnable residuals. I attended a seminar on the Third Third Land Ban conducted by Chemical Waste Management. I took the Certified Hazardous Materials Manager's exam this month. Bob Seymour and I attended a legislative reception in Jackson for the area representatives and senators, which was sponsored by the Aberdeen-South Monroe County Chamber of Commerce. VAB.0001190186 ENERGY CONSERVATION - D. A. Moore Energy u> A. Unadjusted EUI <16.8%> B. Adjusted EUI <17.0%> C. BTU/Lb. Product 2888.0 D. Total Energy Consumption MMM BTU 139.38 Fiscal Y.T.D. < 13.1%> < 13.4%> 2791.0 663.67 Plant A. Maintenance III. There were thirty-five energy related items completed in February. Twenty-nine of these items were steam leak repairs. The remaining six were steam trap repairs. frailer No. 1 No. 2 No. 3 Combustion Efficiency % E,br. 9Q Fiscal Y.T.D. 83.3% 83.1% 83.0% 83.44% 83.32% 83.02% (1) Total energy usage is an estimate due to the plant electrical upgrade project being under construction. VAB.0001190187 Personnel - J. E. Beall None John D. Olson Operations Aberdeen. Transferred fro Lake Charles Chemical Plant f Superintendent, to Operations Superintendent Charles McDonald - Transferred from Senior Process Engineer Aberdeen to Process Superintendent - Oklahoma City. Dwain Lucas - Transferred from Lab Lead Technician to Technician (due to Mike Gray returning to Lab) a" William Holcomb - Promoted from Storekeeper "B" to Storekeeper nAM. RgTTttBMgHTS None None None VAB.0001190188 ABERDEEN, MISSISSIPPI Salaried EBpIoynt Hourly Employees Total Employeea 172 1222 FERSOHOn. REPORT Minority Employees #, % Stlariid Hourly & 66 Total 22 Ntv Enployeas Terminations 2 0 Hourly Min. Hlrad % Min. Hlrad 2 Hourly Min. Tarn % Min. Tazm ngPARTunrrg pa* mwMwrums wnt emp. *mtw. kwb htbts ytd term. ytd. turnover ttd. Varahouse 16 53 Gan. Plant Maintananca 41 31 0 0 24 2 22 Conpound 40 67 Vinyl 33 Flaatlcizar 5 33 5 10 30 0 0 0 0 0 0 2 40 0 0 0 0 0 0 Nunbar of Applleanta Month 0 Taar To Data 0 APPLICANT BREAEDOVN # Minority 0 % Minority__ 0 # F la 0 % Fanala 0 * Includes 1 Co-op Student. Hiraa (Hourly) Month 0 Taar To Data 0 Tarnlnatlons (Hourly) Month 0 Taar To Data 0 Overall Tornortr 2 Pro1acted Annual Turnover 0 VAB.0001190189 DEPARTMENTAL HOURS ANALYSIS REPORT DISTRIBUTION LIST RVS, JFC, JVU, DEPARTMENT HEADS, FILE 2/ 5/90 THRU 3/ A/90 IS QO s ro CM OY in ON CM PQ W fa s 00 in in s in in 3 CM mtncn sis! f VAB.OOOl 190190 ft A Q H CO P** U) 2 3 3 uoUel (OU co5^ ^Cl o v> rn aJ5 CM Ui mmmmmmmmam CM n CM ro* pmmmnmrn cm CM s s s CM $s 3 CM a $ IA 5 CM *n conto *5 si m MMH VAB.0001190191 J. E. Little Safety There were no safety instances this month. Safety handbooks were distributed followed by a presentation from the Safety Department. Cost Savings Savings due to competitive bidding were $8,625 for February, and $71,464 for FY1990. Savings due to prompt payment discounts were $1,641 for February, and $10,517 for FY1990. Warehouse - Finished Slow moving inventories are still a major concern. A revised listing of old compounds will be given to Fred Williams. Flexible Compounds Rigid Compounds Slow Moving Compounds 811,474 912,594 Fred Williams was advised that approximately twenty-five percent of our packaged inventory was either slow moving or off-grade. Three employees attended Interaction Management Class at the Aberdeen Best Western: Pat Wells and Tommy Cuimaings, 2/14 - 2/16; and Mike Swierc 2/26 - 2/28. Ruth Morris was in Aberdeen 2/08 - 2/09 to work with Judy Frossard on the PMS conversion to PC application. Final conversion from the main frame is estimated to be 3/31/90. Several employees attended forklift training class on 2/27. Addi tional hands-on training is scheduled for March. Meetings 2/01 Supervisor meeting at the Best Western. 2/05 Jack Little and Mike Kane - Finalize Q-Support card. 2/08 2/13 Jack Little, Mike Swierc and Pat Wells - Develop procedure for handling Gold Bond raw materials. Jack Little met with Dale Reynolds from Exxon to review exchange balance. PJMH m VAB.0001190192 Continued Meetings - continued 2/14 Bob Seymour and Jack Little met to review FY90 goals. * 2/21 Teresa Pounders and Linda Michels attended a vendor appreciation presentation (Union Camp) in Lafayette, LA. 2/27 Jack Little met with Yellow Freight to review LTL discounts. Numerous negotiations/preparation meetings for the 3/19/90 contract expiration. A VAB.0001190193 m m mmmm m ABIIDHR CUBICAL PLABT SHIPPING HALTSIS llimn 1991 -SI1PIIITS BT PIODICTS- PIBLIC HOffTI IPT/ITC IIC11NI PIBLIC TTB IPT/ITC UCUKI IISIR-BILK 1ISIB-PACIAGID 11,112,061 9,103,040 0 471,054 221,200 866,150 91,757,802 48,000,110 1,234,900 i,m,ioo 1,167,950 0 FLIIIBLI COIPOMB-BIU 1,011,010 fillIlll COtPOm-PAClACIO 3,061,805 739,050 425,950 0 0 T,200,200 4,217,210 14,024,040 1.00T.0T0 0 0 BIB BOSIIISS 1,500 00 6,864 00 1IBID COVMIMIU uni comm-ncum 4,174,090 1,000,000 201,OOT 4,200 0 0 11,698,280 2,952,650 1,030,321 17,000 0 0 PLASTIC1III TOTAL 170,920 20,440,020 0 11,030,000 0 000,100 000,100 1,223,000 364,000 135,786,219 58,585.788 1,598,900 -SIINIITS IT mu- BILK: tnniuT* IISIB fUIlllI COttONI mu comm nuiiciiii TOTAL PIBBVIBT IA1LCAI CDSTOHKH COMOB P1C10P Cllllll 153 11 36 11 0 6 21 3 27 0 04 105 14 73 - TOTAL 290 17 51 4 2T2 *TTBt RIS1B FLIIIBLI COHPOIIO mu comm FUIT1CIIII TOTAL III 706 124 2T0 56 3 22 103 13 81 9 0 14 876 140 392 1,105 83 197 23 1,408 PACIASID: triuiAiK IIS IB iiuiiu cornno mu comuo runiciui TOTAL FIBBIAIT CI8T0MI ncior COMOB Cllllll 5 15 19 76 08 00 24 90 tok coniuit lii/irs 00 00 00 00 13 4 0 0 00 17 TOTAL 33 99 8 0 140 tTTB* urn iuiiili comm mu comm PLASTICIIII TOTAL TTD 23 66 0 0 98 357 2 0 6 35 0 1 0 1 00 127 459 2 1 37 12 1 1 51 126 469 43 2 VAB.(f4(9l 190194 - J. M. Edwards, Jr. Safety - There were no safety incidents in the Laboratory for February. The monthly safety meeting topic was the "Vista Safety Handbook" with Billy Paul Sizemore in charge of the meetings. Customer Contacts - ElPaso, a PVC division of Group Dekko, made a plant visit to learn about our process. Vista supplies them 5415. Customer Q.C. 2/01 When the customer sampled this car, they found very high quantities of contamination. This was communicated to the plant and when the plant inves tigated the origin of the contamina tion, it was discovered that the car was loaded from a start-up silo. It was quickly decided then to pull this car out and divert it to another customer less sensitive to contamina tion. 2/06 - Condutel. Mexico - The customer re ported finding green pellets and black and grey contamination in 34501 BGE. Samples have been received at the plant and are being analyzed. - The corrective action requested was how to prevent future occurrences of contam ination in shipments of 34862 BGE 10 compound. The contamination was de termined to be "paper fibers" and the corrective action was to use only sharp knives when opening raw material bags as they are introduced to the system. Customer Product B. P. Performance 5415 Capito1/Guardian 5415 Essex Group 5415 Export 5265 Reason Static Flow Static Flow Static Flow Moisture No. 1 R/C 1 R/C 1 R/C 1 R/C VAB.0001190195 LABORATORY - Continued F. RVflM Sinmnarv { The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of February, 1990. Reactor Slurries ________Drier 525 5305 Number of Samples Average RVCM, ppm 851 116 38 0.926 75 0.835 RVCM of The following is a summary of the residual VCM analysis of shipment samples for the month of February, 1990. Product 5265 5305 5385 5395 5415 5465 Dry Blend Debox Pond Number of 46 96 54 0 62 0 61 12 14 verage RVCM. ppm 0.733 0.565 0.680 0 0.053 0 0.124 0.854 2.350 Resin Process Capabilities (based on dryer "regulars") 5265 Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Drytime Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle size, microns 1.94 0.67 -- 8.11 6.33 3.17 2.33 ----0.66 -- -- -- -- 142 5?05 2.50 0.35 0.18 2.53 3.83 2.83 1.21 -- 0.68 -- -- ------- -- 138 5385 2.03 0.75 -- 3.25 ------------ ------- 2.67 2.58 -- 1.64 2.00 - ----- -- 7.9 160 5415 1.08 1.14 7.17 7.00 6.17 1.17 5.33 2.00 3.33 2.07 1.2 173 i VAB.0001190196 Continued Flexible Hardness Color Hard Particles Heat Stability Dicing Cross Contamination Streamers Totals 7.0 <0.11> 7.0 <0.11> M Lbs. Ill 11.4 20.8 53.1 8.0 8.4 1.4 10.8 113.9 <0.19> <0.34> <0.87> <0.13> <0.14> <0.02> <0.18> <1.86> tt LfrS,___L41 Color Total 33.8 <0.61> J. Miscellaneous The HS 100 gas chromatograph used for RVCM testing was down for 2 1/2 days until repairs could be made. Perkin-Elmer had been called prior to the instrument failure. It took six days for Perkin-Elmer to respond with a repairman. 2. Dave Cox, Billy Paul Sizemore and Richard Williams attended a three-day course in Interaction Management. 3. Five of six natural teams met once during the month. "Team Meeting Planning and Management" was taught to each natural team by their respective facilitators. 4. The IBM PC used for faxing certificates of analysis was down two days for repair. This computer had been in service five years without major repair. 5. A newer and better version of SQC software was used to report SPC charts of resin shipments this month. * VAB.0001190197 RESIN Ship Date 2/06/90 2/06/90 2/07/90 2/07/90 2/08/90 2/08/90 2/08/90 2/09/90 2/13/90 2/14/90 2/19/90 2/20/90 2/20/90 2/21/90 2/23/90 2/23/90 2/28/90 COMPOUND Ship Date 2/01/90 2/05/90 2/07/90 2/09/90 SAMPLE SHIPMENTS FEBRUARY 1990 Product 5415 Control Pond Resin Pond Resin Pond Resin Pond Resin Pond Resin Pond Resin Pond Resin Pond Resin Debox Resin 5395 5265 5305 5385 5305 5415 5415 Amount 50 lbs. 50 lbs. 5 lbs. 50 lbs. 10 lbs. 200 lbs. 200 lbs. 1 lb. 5 lbs. 1 lb. 50 lbs. 100 lbs. 50 lbs. 200 lbs. 15 lbs. 50 lbs. 400 lbs. Product 48562 BLR 34311 NAT PLENEX 419-50D 34431 NAT 35852 NAT Amount 5 lbs. 200 lbs. 200 lbs. 100 lbs. 100 lbs. Customer Vista - Ok. City Conex of Georgia VCLA - Houston PARAGON TRADING Osterman IMP. & EXP. JOREGA SA DE CU QUIMPAC CIA. LTDA. Ravago Company Rare Plastics Osterman ^ Decorative Coverings Morton International GLASSIDUR S. A. Premier Polymers Gassen Corporation DuPont Polymer Products INYECCIONES INDUSTRIALES Customer Premier Polymers - LGH Superior Cable Fluorocarbon CONDUCEN, S. A. >- VAB.0001190198 COMPOUND (cont.) Ship Date Product 2/12/90 34311 NAT 38631 WHT 2/12/90 35852 NAT 2/27/90 39012 BLK 2/27/90 452-32A BLK Sample Shipments/Feb. 1990 Page 2 Amount 200 lbs. 200 lbs. 500 lbs. 200 lbs. 1500 lbs Customer ELEC TROCONDUC TO RE S ITT A. E. P. D. Superior Cable Times Fiber VAB.0001190199 ABERDEEN CHEMICAL PLANT INJURIES (TweMe Month Running Totals) J'S7F MAMJJ A S 0 N DJ'QBF MAMJJASON OJ'B9F MAMJJ ASON DJ'90F TOTAL INJURIES OSHA RECORDABLE VAB.0001190200 ABERDEEN ENERGY CONSUMPTION * 01/018 VAB.0001190201 rT MONTHLY -------- 12 MONTH AVERAGE