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ik- :i., To: T. H. Huffman / Q Interoffice Communication From: Date: Subject: D. C. Skokns August 21, 1989 ABERDEEN MONTHLY PROGRESS REPORT - JULY, 1989 Safety There were one first aid and three recordable injuries reported during the month. The recordable injuries were a mechanic who suffered a back muscle strain, a mechanic who got a particle in his left eye, and a mechanical engineer who suffered a laceration to his left wrist. On July 5, 1989, the plant's employees reached ten years without a lost time injury. As of July 31, 1989, the plant's employees completed 3,679 days (4,857,874 manhours) since the last lost time injury. Kev Statistical Information July___ 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 34.2 86.1 92.6 1.00299 4.0 97.6 5.3 100.0 1.5 90.0 < 7.8> 81.6 235.2 375.4 89.3 95.8 1 .00674 61.2 96.9 51.7 99.7 17.1 92.0 < 4.8> < 27.4> 1428.9 The annual old reactor module turnaround reduced resin production for the month. Flexible compound rates were reduced due to business conditions. Costs Fixed costs were favorable due to reduced contractor activity. Variable costs were favorable due to good VCM efficiencies and good efficiencies in the rigid compound unit. 1,1 - 11 w 1-'' .-S- ' p> --M I's-r-ttr r? I'fc rs."' * ' r.: v I ."Mi ^ . I I- . ;l| : J - -I I . .i ' -l( :*.!'!-1*1 1.(H- :| Tf'- M:' V n'|. v k-, ji! i-v VAB.0001190403 -ic : :ii. |.n:^fcl i: J. . H . . s h,, , K f| ... v .i . I T. H, Huffman 08/21/89 Aberdeen Monthly Progress Report Page 2 - July, 1989 OMP Forty-two percent of the plant's natural teams met during July. Seven natural teams have developed their mission The second round of "SPC Expert" training began. The first storeroom training session was conducted by the "Stores Team". Southwire (a 5415 customer) visited the plant to discuss their audit program. A team was formed to develop solutions for the 5305 "graininess" problem. Plant Superintendent rah VAB.0001190404 n | ZL-i r t DISTRIBUTION Houston J. D. Burns R. T. Ferrell COVER LETTER X X ENTIRE REPORT T. H. Huffman X C. J. Matson X D. F. Harman X H. R. Flammer X R. R. Smith X K. J. Eggers X R. H. Gerlach X R. D. Gamblin X Aus tin S. E. McGuire X R. L. Poe X H. J. Hall X Oklahoma Citv H. G. Garrison X LCVCM Plant R. A. Conrad X LCCP Plant J. Friend X LCLAB Plant J. W. Ware X Baltimore L. R. Bauer X Hammond J. B. Maher X Blane C. R. Miller X Premiere P. L. Foote X Aberdeen RWS/DCS (File Copy), PJK, JEN, MRK, DAM, JEB, HGC, JEL, REP, BLT, RBN, SCH * I- 1-r:1- |.*J | f - CThiJ ZM-1 1.1 r-i -'H |M T ir . -- ifT.........1-:............................... *............................11M :!.M!|| i-vl '& -t-4-H.'rll W*'irtftT!il1!Tvh^ip*TSp+.v::4v^rfcT:4.tiiww^ti*i'^-ir1 ,'kHi i. VAB.0001190405 ,^I.-u-aip-^: H'- n; .+,, -n.,., . !: ,n |. ' > . -if -Jr--, s ' ' hrsv n >:? ; ......... * SAFETY - B. L. Trego, J. V. Uptain First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Julv 1 3 4 1 0 Fiscal Y.T.D. 1989 13 9 22 3 0 Fiscal Y.T.D. 1988 9 4 13 0 0 Injuries bv Deoartment Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 02 04 3 13 01 00 12 4 22 3 2 7 1 0 0 13 Injuries bv Tvoe Cuts and Abrasions Eye Injuries Burns Bruises S trains/Sprains Stings Other Totals 14 22 06 04 14 00 0 _2 4 22 6 0 4 2 0 0 1 13 Non-Occupational Injuries Lost Workday Cases Days Lost 0 2 11 0 42 188 Safety Record Last lost time injury - 7/5/79 Days since - 3679 Employee hours since - 4,857,874 On July 31, 1989, the employees of the Aberdeen plant completed 3679 days with no lost time injury. Topics for the plant safety meetings during the month included: Electrical Safety, "Safety Seconds - Anatomy of a Rule-Breaker", Steam Safety, and Respirator Training. On July 5, 1989, the Aberdeen plant reached ten years without a lost time injury. Celebration banquets will be held in August. VAB.0001190406 I i 'T .. i. SAFETY - Continued Routine dosimetry results for the month were: Chemical < PEL Number Percent > PEL________ Number Percent VCM Lead Total Particulates 75 98.7 17 100.0 3 100.0 1 0 0 1.3 0.0 0.0 The single overexposure to VCM was with benefit of respiratory protection Monthlv Iniurv Summarv Injurv Class Denartment DescriDtion RWC MT Maintenance Maintenance Back muscle strain. Resin (or insulation?) in left eye. MT Mechanical Eng. Laceration of left wrist FA Maintenance Resin (or insulation?) in right eye. edfA* tw- r.'T*: v q i-.:.-; . 4 Jli rL. 0 . 'r ! spriH'*- VAB.0001190407 :.?*&> ip.-.1- rhni>T.WLFiJfH*ifl-irN-i:i 4 i-f !'CfF4ta1t*-tr*r--'I:-4.'' nv ft I 4 QUALITY DEVELOPMENT General The second course of SPC Expert training was started. The course includes six one-hour classes held over a twelve-week period. The first issue of the plant*s newsletter published by the new team was issued. Two teams were formed to plan the celebration for ten years without a lost time inj ury. The teams included members from all areas of the plant. Plant Manager The Plant Manager's Natural Team met twice in July and continued working on the identification step of the natural team process. The team has now identified its customers and suppliers. A calendar of events was developed for the Fall including safety recognition dinners, quality appreciation day, and a second round of Manager's Quality Meetings with supervisors. Vinyl Department The Vinyl Natural Team spent time developing team measures and reviewing process capabilities. Much time was also spent developing the operating plan to accommodate the old reactor unit shutdown. Laboratory Harold Coleman, Richard Williams, Billy Paul Sizemore and four shift technicians began attending the SPC Expert class in July. Administrative Services The Stores Team held the first storeroom education meeting with personnel from Vinyl and Compound attending. Southwire Southwire Company visited the plant for a tour and to discuss their vendor audit program. Contamination in 5415 is currently an issue with Southwire and was a major topic during the visit. VAB.0001190408 - :I i i -| i-1 ll-rti-r.fl.if-K-r " | -- 1 i 'i > COST VARIANCES - D. C. Skokna Variable Costs Product PVC Flexible Compound Rigid Compound Plasticizer Julv. 1989 Variance,. $M Efficiencv Price Total $195.7 11.0 37.7 < 9.2> $235.2 $1206.6 131.2 208.2 32.1 $1578.1 $1402.3 142.2 245.9 22.9 $1813.3 PVC - VCM usage continues below budget. Flexible Compound - Was essentially at budget. Rigid Compound - Low Ti02 use versus budget and product mix effect resulted in the favorable variance. Plasticizer - Was essentially at budget. Price Variances - VCM - Resin to Rigid Compound - Resin to Flexible Compound - AlfolR 610 - AlfolR 810AI - DIDP - 610P - Phthalic Anhydride - Other Price Variances Total Fixed Cost Variances $1198.9 190.9 89.3 34.4 19.1 13.4 12.5 <27.8> 47.4 $1578.1 - Payroll and Benefits - MM&C - Miscellaneous - TI&D - Clearances Total < 1.8> 56.0 36.5 5.3 <14.4> $ 81.6 A I r Kf>:i p : . >-l-i* . cut!Ms w;*! ....................................................................................................................................... ^ irtlTfIffl"- f. .. VAB.0001190409 I?*** t H.Bf'HlJi: jr.t- GOST VARIANCES - Continued Payroll and Benefits - were essentially at budget. M. M. & C. - was below budget due to low activity. Miscellaneous: - Outside Professional Services - Shipping Costs - Wastehauling $18.2M $14.2M $11.1M Favorable Favorable Favorable Clearances - The transportation, R&D, computer and inter-plant clearances were unfavorable. VAB.0001190410 OPERATIONS AND MECHANICAL DEPARTMENTS - P. J. Kober, D. A. Miller, J. E. Nickerson Operations/Mechanical Safety The Operations Departments did not have any first aid or OSHA recordable injuries during the month of July. The Mechanical Department had one restricted workday, two medical treatment cases and one first aid injury. The RWC involved a Mechanic who pinched a nerve in his back while attempting to remove a pump. One medical treatment case involved a project engineer who cut his wrist while inspecting a new dryer baghouse. The cut required six stitches. One medical treatment case involved a Mechanic who got either resin or fiberglass insulation in his eye while working in the fluid bed dryer area. The first aid injury involved a Mechanic who got either resin or fiberglass in his eye while working in the fluid bed dryer The topic of the Compound monthly safety meetings was electrical safety at work and at home. The Vinyl Department meetings covered on-the-job respirator training. * ir+'iiH HiHi . 411^ktf|-iXhv-*H+H - nr!' VAB.0001190411 l.:.|iifJr;: jtlKQ-L:" .:i m-1. -i ,,.i !-i. ' t i M^kie^l I- i' -vk-H . . VINYL - P. J. Kober, K. W. Birck General 1. Production was limited in both modules for twelve hours due to an unscheduled shutdown to troubleshoot and repair an electrical distribution problem. The annual Old Module shutdown was completed this month. Routine vessel inspections, necessary repairs and capital tie-ins were performed during this shutdown, The New Module was also shut down for one day so that tie-ins to common utilities could be completed. 3. Produced this month in the New Module were 5395 and 5385. 4. The resin raw materials in the 744 account were valued at $308.OM. July YTD - Production, MM Lbs. - Daily Rate, M Lbs./C.D. - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4-#8), % - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime 34.2 1102 800 25.8 86.1 72.6 69.0 92.6 375.4 1239 8849 29.2 89.3 73.1 93.3 95.8 Reactor Downtime Hours Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks. New Module rinse/charge water conflicts, no place to dump, waiting on Q.C. data before charging and inclement weather). 349.9 Maintenance downtime (hydroblast D700 and D745, repair D745 agitator seals, an electrical distribution failure, drill D743 condenser and miscellaneous instru ment and valve repairs). 342.0 Old Module shutdown. 945.8 VINYL - Continued Drver Downtime ^--of Tota^, Downtime Reactor limited production. 72.5 Operational downtime (centrifuge plugs, clean dryers, activator transfer problems, checking dust collector socks, power outage, and flameouts). 9.6 Maintenance downtime (repair activator valves, replace centrifuge sparge pipes, shear pins, wash out dryers, and various other activator and centrifuge repairs). 2.3 Other (not needed due to Old Module shutdown). 15.0 Key Maintenance Work - J. B. Autrey, J. B. Hegwood The following major work items were completed during the old reactor unit shutdown. Reactors 300 - 700 were hydrobiasted and dye checked. There were no apparent problems found during the inspection. The cooling water jacket on reactor 600 was repaired. This was done because of stress cracking that had developed due to the thermal expansion during normal operation. The evacuation stack silencer was removed and repaired. Several holes in the stack were repaired - it was then sandblasted, painted, insulated and reinstalled. The support structure for reactor D700 was fireproofed to bring the reactor support structure up to insurance s tandards. The condenser shells were acid cleaned on reactors 300 and 400. The slurry dump lines and the sewer lines in the unit were also acid cleaned. The inerts removal system was shut down and several modifications were made to the system in order to improve its operating integrity. All switchgear for the unit was cleaned and inspected as part of an annual inspection program. The pressure vessels in the unit were internally inspected. The vessels were found to be in good condition. ' r --.. f 11 K -H . >! i|i VAB.0001190413 I r j iih 1h'; r|rr. .! I-; - -i.. tji . i.-rsiii! 47 r!,-i||^<L.'.I...-. . (. .Trf -ai:. r-.P VINYL ~ Continued Kev Maintenance Work - continued During the month, #1 and #4 Bird motors were changed out because of bearing failures. Reactors 700 and 745 were shut down during the month for hydroblasting and condenser drilling as part of the contamination control program. Reactor 743 was shut down during the month for hydroblasting and condenser drilling due to cooling control problems. Number one and number six Birds were shut down during the month due to vibration problems. The bushings and bearings were changed in each to correct this problem. During the month, a large and a small reactor seal were rebuilt in order to have an on-hand spare. The maintenance painting was completed on the seven silo resin dust collectors during the month. There were three major valves changed out in the reactor area during the month. VAB.0001190414 COMPOUND - J. E. Nickerson, K. G. Akins * All flexible compound lines adopted a three-shift, five-day schedule late in the month due to extremely reduced orders. Line V experienced higher than normal downtime this month due to problems with the Orbitran controller. The inability to start up after a long shutdown was attributed to corroded electrical connections. Several Decwriter (data entry device) failures necessitated running the unit in "manual" until new Decwriters could be delivered. The Plasticizer unit also experienced downtime for cooling water piping revisions, vacuum system repairs, and R-4 condenser replacement. Operating ComDound Production Davs Production fM Lbs.l Month Avg./Dav Fiscal Y.T.D Line I Line III Line V Total % Prime 23 23.5 14 1299 2229 482 4010 97. 6 56 95 34 19843 32871 8517 61231 96.9 Downtime Hours Line I - Product Changes - Mill Maintenance & Repairs - Miscellaneous Maintenance - Dicer Problems & Maintenance 51 43 40 38 Line III - Product Changes - Mill Maintenance & Repairs - Dicer Problems & Maintenance - Miscellaneous Maintenance 71 23 23 23 Line V - Orbitran Problems & Maintenance - Product Changes - Miscellaneous Maintenance - Quality Problems & Control 48 38 14 4 Operating Davs Rigid Compound 27 % Prime Month Production (M Lbs. > Avg./Dav Fiscal Y.T.D. 5274 99.98 195 51664 99.7 VAB.0001190415 11 J-.-. 1-rL I?- -1 J-i. h - :j 4 4 ' |- li'- + ' Ih'-TJ ! iht v,` *-'** MiwrffrrF'n!. - t-n iQHUrb-iViiurV .fin !. ^--iBiii'iKftfr-Micp;ik- i^cpj.1.^1 ^ ;p.|i f.<-n >s r- --+ >> 1 >-I -- h p'1 p-A* - COMPOUND - Continued Downtime - Product Changes - Quality Problems & Control - Miscellaneous Maintenance - Univox Problems & Maintenance - Welex Problems & Maintenance Hours 45 25 14 10 6 Operating Davs 26 % Prime Month Production (M Lbs.) Ave./Day Fiscal Y.T.D 1451 90.0 56 17053 92.0 Maintenance Work - J. B. Autrey, J. B. Hegwood The Line I Banbury was shut down during the i onth due to a coupling failure, The coupling between the gearbox and the Banbury failed due to normal operational wear. The coupling between the motor and gearbox was changed out also. The Line I Banbury was shut down during the month in order to replace the pump on the hydraulic system. Plans are being made to install filters on the system in order to protect the important system components. The Line III mill was shut down during the month on two different occasions; once due to a coupling failure and once due to a Johnson joint failure . The coupling on the back mill roll was replaced and the Johnson joint on the front mill roll was replaced. The compound cooling tower was shut down during the month due to pump problems. The west pump was removed and sent out for repairs and reinstalled. The east pump was then removed and sent out for repairs. It has not been reinstalled as of this time. The Line V Decwriter was changed out during the month three times. \ i., VAB.0001190416 ENGINEERING - R. E. Polk, S. C. Hillman, C. J. McDonald PROJECTS IN DEVELOPMENT - GENERAL Compound Lead Projects Status Meeting A meeting was held with Operations, Safety and Environmental Departments to discuss progress on defined lead exposure and waste reduction projects. Some additional items needing engineering assistance were identified. Plasticizer Process Improvements A meeting was held with PED and plant personnel to discuss design considerations and plan additional work needed to evaluate batch neutralization with sodium carbonate instead of caustic soda. PED is planning additional testing and equipment evaluations to develop a capital project for the second fiscal quarter, 1990. Environmental White Paper Meeting Plant engineering participated in a plant meeting with Paul Gowan of the Special Projects Group concerning an environmental white paper being prepared. Future environmental projects were listed and prioritized for use by Paul in developing this paper. City Water Usage Meeting A meeting with the Mayor of Aberdeen, city utility representatives, and plant personnel was held on July 28 to discuss the plant's current water needs and the city's supply capabilities. Plant demand for city water has increased due to supply problems with the plant's water wells. A capital project to install a new water well at the plant is being prepared. Recruiting Career fairs at three schools and on-campus interviews at eight schools are being scheduled for the Fall recruiting effort. Chief Process Engineers' Meetings Rendell Newton attended the Chief Process Engineers' annual meeting on July 26 and the Engineering Presentation to Management meeting on July 27. A ........''if r-*ti ltii,H,rtreh!v.. VAB.0001190417 h*1 J-hti mi urai: St*. h.i Hit-ih'H-ll+l-iii-r+r j .jr)l .^|r|>. FI *1' * 03 re oa * a *--i c/a era i-3 c/a m >-3 <-a Ctafll co co as s 9 $2 POM, S.C. HILLHAH, C.J. HcDOlULD KHGIMKIRIHG - M . VAB.0001190418 : ENVIRONMENTAL - F. G. Jeanson Water The pH on Outfall 002 (storm water discharge) was above the daily maximum one time during the month. This pH excursion was reported to the State, The excursion was caused by run-off water from a construction site. All other wastewater discharge parameters were within NPDES limits for the month of July. The Mississippi Department of Environmental Quality (MDEQ) was here during the month to do their annual monitoring of our wastewater outfalls. This year they are also doing bioassay testing. Results are expected in midAugus t. Permits Written approval was received from the Mississippi Department of Environmental Quality (MDEQ) for the Low Molecular Weight Project. This project provided for an additional VCM emission source (blend tank addition) and a NESHAP authorization was submitted to have this approved by the MDEQ. However, in their correspondence with the EPA (Region IV), the EPA said a NESHAP authorization was not needed for this project because total plant emissions were not increased and therefore the project could be completed. A letter of application for a new water well into the Eutaw aquifer was sent to the MDEQ. A new water well in the Eutaw is needed to replace capacity lost from our current well operation. The MDEQ reviewed the application. A public notice was published in the Aberdeen Examiner. The MDEQ permit board will meet on August 11, 1989 to discuss approval of the permit. Waste/Off-Grade Management July waste shipments included: One drum shipment of plasticizer filter cake and stabilizer spill to Chemical Waste Management. One bulk load of lead/antimony bags to Chemical Waste Management. A program was started this month to recycle aluminum cans. During construction work to replace the containment dike around the sulfuric acid tank, the dirt underneath the dike was found to be a hazardous waste. The dirt was considered hazardous due to its corrosive nature because of acid contamination. Samples were taken of the dirt and sent to the hazardous waste landfill for approval. The dirt was approved at the hazardous waste landfill and will be removed in August. A meeting was held with Sun Polymers to discuss Pond 2 and stormwater pit resin sale. A 'I1 I*-*--' .-1 [ .. . tiavp* s ll*+ r *i^Ji*lr i- i4--' jPVftt Jr- h |: i rfl ? i- ' v4p 1"M!: VAB.0001190419 lr-1^ /i.tUunttrlJiiJ-- - /p WiK" *nrn tr-* 'i -"i f-|;[ Wihf t il .-i-t;.- N' ^ .t: r . `P ^idMPJIi -ri 1\1?;r:ir ENVIRONMENTAL - Continued SARA A meeting of the SARA team was set up in August to develop a plan for continuing community relations. Superfund The groundwater monitoring wells were resampled during the month by CH2M Hill. Results are expected in mid-August. Air The annual VCM flange and valve survey was completed in the Old Module before shutdown. Two leaks were found and they were both fixed during the shutdown. Miscellaneous An environmental audit was done on the Prairie Transport Terminal. The Mississippi Department of Natural Resources has changed its name to the Mississippi Department of Environmental Quality. I coordinated a meeting here in the plant with Paul Gowan to discuss environmental issues in this plant's future. A meeting was held with the City to discuss our water usage requirements and bring them up to date on our Coker water project. t VAB.0001190420 i U ;l -i'.>ih|i||-ili jfiTfrit-.-i.im, b:ij'-ji;; r- -!*..ir I - -I'-iM. ' M- ENERGY CONSERVATION - D. A. Moore July. 1989 I. Energy Conservation Data A. Unadj us ted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU -6.90% -7.76% 2612.30 117.26 This corresponds to an adjusted CMA of and an unadjusted CMA of 49.61% 37.53% Fiscal Y.T.D. -3.82% -4.75% 2535.44 1280.90 51.41% 39.87% II. Plant Energy Conservation Program A. Maintenance There were six energy related items completed in July, 1989. All of these items were steam leak repairs. Ill. Boiler Operation Boiler Combustion Efficiency % July. 89 Fiscal Y.T.D. No. 1 No. 2 No. 3 (1) 83.54% 83.20% 83.71% 83.48% 83.16% Boiler number one was not operated during the month. * ... -mfrwEMBHWH-W-h WskfrSGrtT ItK! *4**: lujiljafrjpilpitifcutrttPi.fr annwi 'iamu VAB.0001190421 -ho:I -n-1- ;i+:T'r^ ai-t: hrr :t *-.t rft `firm- n.aei- v HUMAN RESOURCE REPORT JULY. 1989 Personnel - J. E. Beall Employment: None PromptIons/Transfers Kenny Akins from Process Engineer to Compound Operations Engineer Ken Birck from Process Engineer to Vinyl Operations Engineer. Mike Gray from Lead Technician to Maintenance Helper. Phillip Hall promoted from Compound Utility to Compound Operator. Frank Jeanson promoted from Environmental Coordinator to Senior Environmental Coordinator. Charles McDonald promoted from Vinyl Operations Engineer to Senior Process Engineer. Reed Mackay transferred from Process Engineering Houston, TX to Process Engineer Aberdeen. Anthony Pritchett promoted from Compound Utility to Compound Operator. Retirements None William A. Earnest Vernon L. Thornhill, Jr. None VAB.0001190422 ABERDEEN. MISSISSIPPI Salaried Employees Hourly Employees Total Employees Employees (Hourly) New Employees Terminations JULY, 1989 MONTHLY PERSONNEL REPORT 79* Minority Employees #, % 173 Salaried 7 9% Hourly 66 38% Total 73 29% 0 Hourly Min. Hired 0 0 % Min. Hired Hourly Min. Term. 0 % Min. Term. 0 Warehouse 16 Gen. Plant 13 Maintenance 41 Laboratory 24 Compound 40 Vinyl 33 Plasticizer 3 16 8 16 5 41 10 23 ___5____ 39 26 33 10 52 50. 0 0 0 0 31 0 7 0 0 2.4 0 ___ L 0 0n 30 _________ 0 0 40 0 0 0 0 00 00 00 00 0 0 ao Number of Applicants: Month 0 Year To Date 21 APPLICANT BREAKDOWN: # Minority 0 % Minority 0 # Female % Female Hires (Hourly): Month Year To Date 7 Terminations (Hourly): Month Year To Date Overall Turnover .6% 2 Projected Annual Turnover 1^1 * Includes 2 Co-op Engineers and 2 Summer Engineers. VAB.0001190423 K-*-'--it -: Tilr^rr ' a ii^t i. :t|'. |'+V - - }* t - r jCftpr. pi'ttir;. i' M i * ON OO rH i--4 cn cn OO 1--* m 1--1 aO cn CM -O' OO H CM CM 5-1 * 4 p * * * * >H f- m --4 i--i ON i--i CM i *i ills. od -r4 i <o 1-->n sO CTs 00 a> o o r-s ^ i to i a> CM rH CM oo 00 o o CM Ml iJI * * * * ft * iO| Ol =-l pH m rH m CM r^. cn *1 A^ I -f ^5) 0H i 3 1 uj w1 f-t CM > mD CM H m vO CM "4 CM X rH <? OO O o o o o o O O h XI C3 I u e C0O1 ax;i.*! i W. r^. cn CTs <T> CM OO * CM # CM X C O X <9 i | CJ uo c01 o >s (C *3 X X X u 3 ir 4Ji o n- CJ\ CO 'J XI m fH CM <r v ^J H CM ^X * <i rH 00 o o m Cs* <T XJ tH IM sm? Ei CJ fr*| I X 4*1 mfr -iri vO <J\ ON m O Ofll <Ti inv5 1--( iH 'sO m IN a\ rH 1--t E <91 m oO ** m 00 00 x) * 00 H rH rH rH H 1m CO <u O> UOjl V co 00 X C31-1 U. 0 3u 0 "nO* 3 5 1Ou-O <T3 coc V i )4 3o*9 oC -o c <0 X l-i 3 0 c>ar "O u 3 LU CO BQ < a CM < <y LU pO *tl "3 o 41 Uc 0 L> x| c1 Ui O 3 o oo 0<30- \oorDH ir*n> O4 111t11\l1 Oo* vO v--f i\\iiiiii oo<CMr* Iiliiit\i m <ccnnr4 3 <0 00 ua e o 00 c X H H 3 O oiM 3 o C3U i--010na-)10ji at c00 4J H Hai > Q 3 o o in m o m m O o o o o CM CM m CM CM o o o m * CM o 00 m M3 in cn cn cn iO cn m cn <r 00 m o 00 rH MT fN* MT CM O0 <u *H 3 TJ -o 3 pH 0) ct E X rH 01 41 a> 0u1 s> o aa -tj h * HM wo -3 2 00 wCO uat -i ci CO S| o m* o in m ion4 o o in CM* om# o o * o o o o# m CM * rH m m cn rH m m <<rt vO cn cn N Cr^M m a\ OfMv m 00 o vO o o vO o CM m 0a0s cn cn CM uas w as < c ge 2< u Wz CO > O as eW 44 as < Uz3 H W (9 >< ao* s oo U4 CM o Q a. IH o H H CO 3 a* --S 1-4 H w uz C3 o H 01 I 5m 0J CO > O \ CO ai l E 4--1 *4aH1 U 0u1 > o 0J QJ > 0 XI CO 01 JO nj Uo 4J o c 0 Jm o 4i 1 co c o CM VAB.0001190424 l AnMTWTSTRATIVE SERVICES - J. E. Little There were no safety instances this month. "Forklift Maintenance". The safety topic for July was Cost Savings Savings due to competitive bidding were $14-,161 for the month, and $121,554 for FY1989. Savings due to prompt payment discounts were $1780 for the month, and $19,799 for FY1989. Warehouse - Finished Goods Inventory Total packaged inventories decreased 707M pounds; from 6083M pounds to 5376M pounds. Although still a problem, off-grade inventories decreased 94M pounds - 802M pounds to 708M pounds. The Stores Team conducted their first training session July 27, 1989. Attendees were Albert Barr, James Howell, Terry Noland, Bill Davis, Charles Worlow, Don Johnson, Pat Wells, and Mike Swierc. Meetings The month of July was replete with budgeting and making plans to close the transportation terminal. 7/17/89 We met with Bob Seymour to discuss dispatching. During the interim, the plant will arrange packaged shipments while the terminal will handle bulk loads. 7/21/89 We visited the terminal to identify any equipment/furniture that could be used by the plant. Transfers should be finalized in August. 7/24/89 Dean Honeycutt, Johnny Williams, Jack Little and John Farrier visited Ergon's offices in Jackson, MS. This was a get-acquainted session, review their operations and iron out details of the new contract bulk carrier. 7/25/89 Ergon was in Aberdeen to meet plant personnel and discuss bulk operations. 7/25 & 7/26 Jack Little was in Houston for the "OASIS" presentation. Presentations were made by Marcam and System 2000. * -rnn j- viurt.jr* . - r>.: f --k.i 1: - . : | f.il! i.| f ..p*!:!--|p | 45r I - i-tfe-T Jtfr ' ..1 .1 :| ;': I tb VAB.0001190425 * r -'-I i|.- ..--.-H. i: \ 1 i; 1. : .. \\w -*i jqi . i. ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS JULY 1989 -SHIPMENTS BY PRODUCTS- PUBLIC MONTH IPT/ITC EXCHANGE RESIN-BULK RESIN-PACKAGED 17,931,587 455,764 4,318,250 47,150 FLEXIBLE COMPOUND-BULK 512,070 FLEXIBLE COMPOUND-PACKAGED 2,931,904 730,200 0 RIGID COMPOUND-BULK RIGID COMPOUND-PACKA6ED 3,720,880 220,272 0 0 PLASTICIZER 176,670 533,750 185,550 TOTAL 25,949,147 5,629,350 185,550 I1I II II II II II II II IIIt II II II II II II II 1 II II It II II II II II II -SHIPMENTS BY NODE- tII lII It II II II II II ttIllt IIII II YTD PUBLIC IPT/ITC EXCHANGE 174,977,717 104,913,579 5,342,150 413,600 13,319,680 11,B66,190 37,439,226 1,067,646 39,369,460 3,867,950 5,169,420 1,551,971 1,966,350 1,559,500 2,749,450 277,584,003 125,240,436 2,749,450 IItI It II II II II II II II .t II II II II ItII ItIt It II It H II II It It II II II tIlI II II II It1 II tIlI IIII It IIIt II II IIII It It H 11 It tl H II It II II 11 II II M II It II It II IItttl II II ttIitttt II It II II IIII II II It II IIII II II II II II It It It II II It II II II II II II II II II II II BULK: (JULY! RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTiciZER TOTAL JULY tYTDt RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER RAILCAR 115 6 18 4 143 VISTA CUSTOMER COMMON PICKUP CARRIER 31 24 6 1 02 2 10 0 04 34 25 12 1,278 135 226 24 447 761 27 27 0 5 66 32 5 15 0 32 TOTAL 176 9 21 8 214 2,513 167 329 71 TOTAL YTD PACKAGED: (JULY! RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER TOTAL JULY 1,663 555 793 69 VISTA CUSTOMER COMMON PICKUP CARRIER TOFC CONTAINER AIR/UPS 1 5 80 36 19 29 1 10 0 7 0 0 10 00 00 47 24 44 1 0 10 3,080 TOTAL 24 85 17 0 126 tYTDt RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER TOTAL YTD II II It II II H IIII 40 4B 97 0 367 2B6 410 1 84 8 117 0 0 0 30 491 342 627 1 II II II IIIt It IIII II II II 0 40 225 3 14 1,081 2 0 211 0 03 5 54 1,520 ---____-_j.VAB.0001190426 1 II IB It II II II IIII II II II II 1 IIII IIIIIttttt It IIIt II II II LABORATORY - H. G. Coleman A. Safety - There were no safety incidents in the Lab this month. H. G. Coleman coordinated July's safety meeting which featured a video tape entitled "Hazards of Steam" and a safety seconds film, "Anatomy of a Rule-Breaker". B. Customer Relations Customer Contacts 7/19/89 Southwire representatives were hosted. Our standard presentation was given and they were given a Syntron vibrating tray for measuring resin contamination. Work continues in an effort to resolve the contamination issue with 5415 resin. 7/20/89 Harold Coleman participated on a conference call with John Helwig of Essex and J. C. Levardsen concerning Essex's proposed 5415 specification. A subsequent memo was written summarizing our recommendations. 7/25/89 Richard Williams visited BP Performance Polymers in Visalia, CA, to discuss quality control methods, specifications and plasticizer cross-contamination for Vista flexible compounds. C. Product Waivers Customer Chelsea Building Products Product RP-166 WHT 144 Reason__________________________ % Retained on40 Mesh 1 RC Dayton Extruded Plastics RP-151 WHT 145 % Retained on 40 Mesh 1 RC Vycom RP-421 WHT 110 % Retained on 40 Mesh 1 RC D. RVCM Summary RVCM of In-Process Samples The following is a summary of residual VCM results on process samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of July, 1989. Reactor Slurries Drier 5265 5305 Number of Samples Average RVCM, ppm 798 158 34 0.322 57 0.595 No. VAB | |l. *'Sf h,. r.L..! j_. j;-* I -11 LABORATORY - Continued D. RVCM Summary - continued RVCM of Shipment Samples The following is a summary of the residual VCM analysis of shipment samples for the month of July, 1989. Product 5265 5305 5385 5395 5415 5465 Dry Blend Debox Pond Number of Samples 37 88 45 8 51 0 58 42 8 Average RVCM. ppm 0.122 0.135 0.179 0.031 0.046 0 0.043 0.350 0.736 E. Resin Process Capabilities (based on dryer "regulars ") 5265 5305 5385 5395 5415 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) 1.17 0.83 -- 5.25 5.33 4.67 1.72 -- 0.70 -- -- -- 0.29 1.60 0.93 3.25 7.33 1.89 2.33 -- 0.89 * *----------- -- -- ---------- --------------- 1.31 1.00 ----------- --------------- 4.00 -- 2.17 2.07 ---------- --------------- 1.40 2.33 -- -- 0.8 1.07 0.89 -- 12.33 -- 2.83 1.61 --*- 0.99 1.17 3.43 -- ---- 1.23 1.05 -- 6.33 -- 2.83 1.89 0.22 2.33 3.00 3.04 2.06 7.7 Average particle size, microns 138 146 161 152 174 VAB.0001190428 LABORATORY - Continued F. Flexible Compound Qualit Summary Adiustments M Lbs. (%) Hardness Color/Clarity Hard Particles Dicing Heat Stability Totals 5.0 15.0 ----- ------------------- 14.0 34.0 (0.12) (0.37) ----- ------------------ (0.35) (0.85) Rejections M Lbs. (%) ..... 34.6 10.1 16.9 - ---------------- 61.6 -- (0.86) (0.25) (0.42) -- (1.54) G. Rigid Compound Quality Summar 40 Mesh Retention Total Reiections M Lbs. (%) 5.2 (0.10) 5.2 (0.10) H. Flexible ComDound SPC Test Results n X 3a 38401 - Hardness - A Scale - Specific Gravity - Hard Particles - 20 sec. 34 34 34 83.82 1.376 21.00 0.94 0.013 3.68 35031 - Hardness - D Scale - Specific Gravity - Hard Particles - 2 min. 34 34 34 49.88 1.374 6.15 0.63 0.010 3.29 Mill Temperature, F Oven Temperature, C All Readings All Readings 325F. 204C. I. 5415 Control Resin (Lot 04169) Test Results n X 3a Moisture Drytime Particle Size Bulk Density Color - L - 60 mesh - 80 mesh - 100 mesh - 120 mesh - 140 mesh - 200 mesh Pan 12** 62 62 20* 20* 62 62 62 61 30 62 0.155 4.75 2.08 42.41 23.79 18.00 7.25 5.14 1.28 0.4998 100.32 0.036 0.29 0.53 3.45 1.00 2.13 1.02 1.35 0.45 0.0059 0.27 * 1 'll. . nn.H 4 VAB.0001190429 > mmfnrr-.iwstoTt::-: i-r::-:vt- Fintiafi|4^i^ibf4v-!i|ue;i4iK^'-! rW s* r-^*!ini n^ri' i- ivi'i n | f-- s. i. .n*^k LABORATORY - Continued I. 5415 Control Resin (Lot 041691 Test Results - continued nX 3(7 Color A B Flow Time, Hard Particles, 7 min Inherent Viscosity 43 -0.03 0.25 45 1.91 0.50 31 7.26 0.39 60 6.15 2.43 29 1.0120 0.0056 * New 80 mesh screen installed on 7/22. ** Moisture analyzer recalibrated 7/26. J. Miscellaneous 1. D. S. Cox and Coulter service representatives started up the R&D particle size analyzer. D. S. Cox issued a memo summarizing an initial variability study. Work continues in monitoring each reactor for particle size control. 2. H. G. Coleman and D. S. Cox participated in a Plasticizer Improvement meeting on July 25. VAB.0001190430 t RESIN Ship Date 7/06/89 7/06/89 7/12/89 7/12/89 7/12/89 7/12/89 7/13/89 7/18/89 7/19/89 7/19/89 7/24/89 COMPOUND Ship Date 7/06/89 SAMPLE SHIPMENTS JULY 1989 Product Pond Resin 5385-1 5415 Pond Resin 5385 5 385 5385 5265 Pond Resin Pond Resin 5305 Amount 2 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 450 lbs. 100 lbs. 50 lbs. 500 lbs. Product 38931 NAT Amount 10 lbs. 7/10/89 7/13/89 7/24/89 7/27/89 7/27/89 DRYBLEND Ship Date 7/21/89 7/24/89 18162 GRY 545 15072 NAT 34502 NAT 34431 NAT 18162 NAT 18961 NAT Product RP-91 WHT 110 90172D WHT 110 300 lbs. 250 lbs. 200 lbs. 100 lbs. 1600 lbs. 1500 lbs. Amount 1300 lbs. 2600 lbs. Customer RESINAS Y MATERIALES ANDROMEDA INTERNACIONAL Polimex EDCO FORWARDING ICC TRADING (TAIWAN) LTD. I.C.C. (HONG KONG) JOHN CROWLEY INTERPLAST PLASTICOS DEL PACIFICO DIDESA BASF AKTIENGESELLSCHAFT Customer Precision Electrical Products National Extrusion Aeroquip Corporation Tandy Automate Aeroquip Corporation Customer Elixir Industries U-Brand 7/24/89 378-143 BL 170 (Purge) n.p i|k. - 1500 lbs. Mid-American Ind. vab.0001190431 ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) J r'l * J'87 FMAMJJASOND J`S8 FMAMJJ ASOND J`89 F M A M J J TOTAL INJURIES O OSHA RECORDABLE VAB.0001190432 i- lit . A ABERDEEN ENERGY CONSUMPTION 12 MONTH AVERAGE ai/rus VAB.0001190433 rhiif:nF?i :n l|.:c<.-.!ttifp,L,xi::..|J n--i..