Document RpKxZe6ky5v4zB2e3eNpQxjyk

To: T. H. Huffman (nttroffka Communication From: Date: Subject: D. C. Skokna July 23, 1992 ABERDEEN MONTHLY PHOGKESS REPORT June, 1992 There were two first aid and one OSHA recordable injuries reported in June. The recordable injury (MTO) Involved a Compound Operator who fell and sprained his wrist. At month end, the plant's employees had worked 4744 days (6,359,937 employee hours) since the last lost time injury. FY1992 Kev Statistical Information 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 Costs June 37.1 91.8 98.1 1.0563 5.9 97.5 1.8 96.2 1.6 81.6 < 8.4> <207.4> <153.2> Y.T.D. 329.1 85.5 97.0 1.0356 47.1 96.5 18.0 97.7 12.9 79.8 < 13.3> <567.0> <585.4> The unfavorable efficiency variance is primarily due to above budget VCM consumption. Fixed costs were above budget due to accruing all accounts for the RWE year-end closing, a correction of a mis-accrual of the May payroll, trackmobile and OSHA Operations PVC ran at full production during June. New agitator blades in D-745 resulted in improved 5385 resin quality and the batch size was increased by 5000 pounds. VAB.0001189208 T. H. Huffman 07/23/92 Aberdeen Monthly Progress Report Page 2 - June, 1992 Operations - Continued The flexible compound unit ran at high rates on Lines I and III. Rates on these lines increased some as fever product changes were taken as compared to previous months. Line V and the dry blend unit both operated with reduced staffing. The plant received Southwire's Quality Supplier Award. Environmental A meeting was held with MDEQ and EPA remediation activities at the plant. presentations, the EPA representative sampling was not needed. to discuss progress on After listening to our indicated that further We met with MDEQ to discuss progress in meeting the more stringent BOD limits contained in the 1993 NPDES permit. MDEQ requested a followup meeting this Fall. Cleanout of Pond 2 continued with satisfactory progress being made. D. C. Skokna Plant Superintendent rah VAB.0001189209 f \ DISTRIBUTION Hous ton J. D. Burns J. R. Ball COVER LETTER X X R. T. Ferrell X T. H. Huffman C. J. Matson H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblln C. R. Miller L. R. Kardos M. J. SchneIder Austin R. L. Foe X H. J. Hall Oklafrpma City H. D. Garrison LGVCM Plant P. E. Markey LCCP Plant J. Friend LCLAB Plant J. V. Hare X Baltimore L. R. Bauer X Hammond J. Pavao X Premiere P. L. Foote Aberdeen RVS/DCS (File Copy), JBA, JEB, JME, SCH DAB, DAM , JEN, JDO, BLT ENTIRE REPORT X X X X X X X X X X X X X X A VAB.0001189210 SAren - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals June 2 i 3 0 0 0 2 0 0 0 1 3 2 0 0 0 1 0 0 3 Fiscal Y.T.D. 1992 14 _4 18 2 0 Fiscal Y.T.D. 1991 11 _6 17 4 0 4 6 7 0 0 _1 18 9 0 4 1 3 1 Ji 18 Lost Workday Cases Days Lost 0 66 0 11 127 First Aid Cases Medical Treatment Cases Lost Workday Cases Safety Record 034 00 1 00 1 Last lost time injury - 7/5/79 Days since - 4,744 Employee hours since - 6,359,937 On June 30, 1992, the employees of the Aberdeen plant completed 4,744 days with no lost time injury. i VAB.0001189211 safety - Continued Annual first aid review was given to Lab Technicians during the month. The June safety training topic was "Electrical Hazards" which culminated with employee involvement in a plant-wide electrical hazards survey. Routine dosimetry results for the month were: Chemical > PEL__________ Number Percent VCH Lead Total Particulates 76 98.7 6 100.0 5 100.0 1 1 0 Both overexposures were with benefit of respiratory protection. Monthly Injury Summary Xnlurv Class FA Department Process Engineering FA Compound MT Compound Description Contusion of left shoulder; abrasion of left arm, left lower leg, and left side of forehead. Abrasion and contusions of upper back, right mid-back, and forearm. Strain of left wrist. 4- VAB.0001189212 QUA~LXTY MAWACTMFHT PROCESS - E. E. Smith The plant natural teams continue to meet on a regular basis. The Vinyl Department and support groups received the Southwire Quality Supplier Award for 1992. The Aberdeen Plant continues to work hard to obtain and maintain an "Excellent Supplier Award" rating from Southwire. No customer audits were conducted in June. VAB.0001189213 1 * cost VARTANCKS - D. C. Skokna Variable Costs Product June. 1992 Variance. SM Efficiency Price Total PVC Flexible Compound Rigid Compound Total <$159.5> < 35.2> 6.5 35.0 <$153.2> <$24.3> < 11.7> < 37.0> 14.5 <$58.5> <$183.8> < 46.9> < 30.5> 49.5 <$211.7> PVC VCM consumption was above the unfavorable variance. We believe it is due to accounting errors not found before the submittal of the final IPA. Flexible Compound Raw material use was above budget Rigid Compound Operations were essentially at budget Plasticizer Raw material use was below budget. Malor Price Variances: Variance - SM Debox Resin Credit PVC Reactor Initiators Electricity Phthalic Anhydride Rigid Compound "BC" Grade Credit Resin to Rigid Compound Natural Gas Resin to Flexible Compound VCM Other Price Variances Total $45.6 21.1 17.6 12.2 < 13.1> < 18.7> < 26.3> < 37.1> < 76.9> ____17.1 <$58.5> Fixed Cost Variances Payroll and Benefits MM&C Miscellaneous TI&D Clearances Variance - $M Total <$ 69.6> < 50.2> < 83.3> < 8.3> 4^2 <$207.4> VAB.0001189214 COST variances - Continued Payroll & Benefits Salaried payroll was $18.3M unfavorable due to above budget engineering staffing. Hourly payrolls were $50.2M unfavorable due primarily to not accurately accruing the Hay payroll and the overtime to cover a high number of people out on either leave of absences or long term illness. MM&C The $50.2M unfavorable variance is due primarily to accruing all work. In addition, there were approximately $20M of accruals related to the pond 2 cleanout that will be paid by Conoco in July. m T&E - S12.4M Unfavorable - Accruals of current travel and costs associated with moving the Compound Customer Service Representa tive function to Aberdeen caused this unfavorable variance. - Extensive repairs to the plant's trackmobile caused most of the unfavorable variance. - Contract designers were brought in to document electrical equipment labelling and VCSM documentation. We expect this category to be $50M favorable at year-end. that were paid in June This is due to two May cars back to the plant so that the resin could be bagged. Tlfrfi - This category was $8.3M unfavorable due to insurance ($4.2M unfavorable); FICA taxes <$16.2M unfavorable); and advalorem taxes ($2.5M unfavorable). VAB.0001189215 VINYL - J. D. Olson, D. E. Knittig The The monthly safety meetings were held on shift led by the shift supervisor General 1 Fluid bed dryer process changes have improved contamination performance of the dryer since the installation of the additional heating panels. progress. We will continue to monitor its 2 New agitator blades were installed in D-745 to improve hard particles and increase batch size. D-745 could only produce type IIIlIl 5385 due to hard particles but with the new blades produces type I resin. The batch size was increased by 5000 pounds per batch. Testing has not been completed to fully evaluate the benefit to low molecular weight resins. June - 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 37.1 1236.7 93.2 908.0 30.3 91.8 90.1 95.1 98.1 Reactor Downtime Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts, and no blend tank space). YTD 329.1 1201.1 90.6 7868.0 28.7 85.5 90.8 89.6 97.0 Hours 353.0 Maintenance downtime (D-741 annual inspection, D-744 condenser cleaning, D-400 seal replace* ment, D-600 PVA ram valve, D-742 steam line, new module slurry pumps, D-742 condenser cleaning, D-700 rinse supply valve, D-745 agitator blade changeout, D-741 PM, D-742 PVA ram valve, D-742 jacket weld, D-400 jacket weld, and D-745 rinse nozzle). 236.0 k VAB.0001189216 t VINYL - Continued Dryer Time % of Total Downtime Operational downtime (centrifuge plugs, dryer cleaning, flameouts). m Maintenance downtime (activator problems, centrifuge repair). m Reactor limited production. 25.2 8.2 66.6 J. B. Autrey, S. A. Truitt The fluid bed dryer pick heater was removed from service and rebuilt. Reactor 741 gearbox PM schedule was completed. Spray nozzle on reactor 700 was changed and reactor 745 was changed twice. Failure was due to no lubrication in the gear section. The new test blades on the agitator were installed in reactor 745. Reactors 742 and 744 were hydroblasted and agitator gearboxes were PM'd. The old unit rinse pump was removed from service, sent to Gould's to be rebuilt, and re-installed. Normal wear due to some cavitation was reason for rebuilding. Critical instrument PMs were completed on the following systems: a. Reactor 400 b. Reactor 742 c. Reactor 744 d. Reactor 745 e. Dryer #1 Cooling tower 4B fan motor was removed from service to replace the bearings. The east bio-disc blower motors were sent out for repair due to bad bearings. VAB.0001189217 COMPOUND - S. C. Hillman J. B. Hegwood b. The Compound Department had one OSHA recordable Injury for the month. A Compound Operator Incurred a sprained wrist due to an accidental fall. The Compound Department also had a restricted work case during the month, but this was deemed a none work related accident and was not considered OSHA recordable. General > Orders continue to be tight on Line I and Line III. Production for the month is up slightly from last month due to a decrease of downtime from product changes. Line V and Dryblend continue to operate a reduced staffing. Operating Line I 30 Line III 30 Line V 18 Total % Prime Capacity Utilization Factor Production II (Lbs.3 MSOtil 4TC/Pt7 Fiscal Y.T.D. 1815 3554 528 5896 97.50 72.47 60 118 29 197 14116 29132 3815 47064 96.48 67.28 Downtime Hours Line I - Product Changes - One Dicer Offline - Miscellaneous Maintenance - Quality 106 29 33 18 Line III - Product Changes - Miscellaneous Maintenance - Quality Line V 72 29 5 - Product Changes - Quality * Miscellaneous Maintenance - Coverage for Other Lines 42 11 10 36 VAB.0001189218 COMPOUND - Continued Operating Rigid Compound 18 % Prime Capacity Utilization Factor Production Of Lbs.) Avtt./Dav F1C1 T.T.P. 1782 96.20 35.17 99 18033 97.65 38.76 Downtime - Product Changes - Miscellaneous Maintenance - Quality Operating P*TS Plasticizer % Prime Capacity Utilization Factor Hours 36 11 25 Konsb 1590 81.63 65.33 ^fgi/Pty IrTtlh 12894 79.82 59.19 Key Maintenance Items - J. B. Autrey, S. A. Truitt m PMs were completed on the following: - #5 cooling tower - #5 and #6 dicers - Grove crane The new hydraulic pump on Line 1 Banbury was replaced. The system had been running on a rental unit since the old unit failed. The south nitrogen blower in P-1 was overhauled due to bad vibration. m Line 111 #6 dicer motor was replaced and repaired. Bad windings were responsible for the motor failure. VAB.0001189219 ENGIWKEWtwc . j. E. Nickerson, T. R. Kackay, R. H. Sneed, M. L. Carter PROJECTS IN PEVKUOFMENT - CENERAT. Staffing Erik Smith was transferred to Quality Management Coordinator starting July 1. Water Plant i Equipment delivery delays continue to push back startup dates. Startup is scheduled for mid-August. The first issue of the pond 3 and 4 bottom aeration design is complete. An oxidant test run will be scheduled later in the year. Test results would be more applicable if the test was after the summer months. A wastewater team has been formed to speed project execution and pursue parallel avenues of solutions. Plasticizer Expansion Discussions with consultants and vendors confirmed the overhead condenser design. A pressure control scheme was confirmed with the process controls group in Houston. Preliminary quotes have been received on all major equipment. Class "A" design passed a plant review and will be given to estimating after a Process Hazardous Analysis in early July. Ultraclean Rinse segregation, dumping slurry and rinse water to separate blend tanks, was trialed for five days. Segregation and processing rinse water separate from prime showed promising results. An improvement in dry resin contamination of 15-25% was noted. Discussions continue with a vendor of an alternate reactor cleaning machine. This machine has an externally driven spray head and should require less maintenance than the existing reactor cleaning machines. A new initiator dispersion test was proposed this month. Instead of charging initiator to the reactors with water, the initiator will be pulled out of the charge pot with an eductor. Better dispersion can be accomplished in this manner. Scheduling for the test has been delayed until the new agitator blades in reactor 745 are evaluated. Plant StMif SiiqdIt Preliminary economics for improving the reliability of the plant's steam system were developed. Options include retubing boiler #3 and buying a new boiler. The most attractive options were buying a new 60M lb./hr. boiler and repairing #3 as necessary to keep it in VAB.0001189220 mm rnmmmmmmmmmmm EBGIHEKRIHG - Continued OSHA Process Safety A Process Safety Management Team was formed. The team is developing and implementing a management program to comply with OSHA regula> tions. The Employee Participation Plan is completed. The Document Approval and Control Policy is completed. The purpose of this policy is to ensure all process safety management documents are reviewed and approved in a timely manner. The Process Hazards Analysis Execution Policy and the Operating Procedure Development Policy were both issued for review. Inert Gas Dryer Startup complete; the dryer is running with no problems. Blend Tank T-501 Sparger RevIs ions A Class "A" design was submitted to revise spargers and the cleanout system for blend tank T-501. The design will Improve aeration and reduce cleanout times. This project is targeted for first fiscal quarter 1993. A preliminary economic analysis indicates that buying concentrated lead in supersacks may save an estimated $41M per year. A similar economic study is now underway to determine if using reusable boxes instead of gaylords has benefits. Centrifuge pool depth effects on wet cake moisture have been studied, tests on effluent are underway, results show possible improvements on drying rates and resin quality. A Class "A" design is underway for activator load cells. s VAB.0001189221 ABERDEEN CHEMICAL PLANT MONTHLY PROGRESS REPORT CAPITAL EXPENDITURE STATUS M.L. CARTER JUNE REPORT 1992 F. Y. CAPITAL EXPENDITURES (M$l ____VARIANCE ACTUAL BUDGET _ M$ ___ Month 3rd Qtr. 251.3 736.6 280.0 791.0 - 28.6 - 54.4 -10.2% - 6.8% YTD 2854.6 3362.0 - 758.7 -15.0% Actual Expenditures - Expenditures in June were $28.6M less than the plant's budgeted expenditure forecast approved in the Third Quarter Budget submitted in March FY92. Total capital expenditures for the 3rd quarter were $736.6M, 6.6% less than the plants budgeted expenditure forecast. June's FY92 capital expenditures were 10.2% less than the plant's budgeted expenditure forecast. It should be noted that the capital expenditures associated with project H612 Pond 2 Resin Drying are not accounted for in the reported actual above due to the accounting procedures and contract agreement with Conoco. Quarter Budget - Current Quarter Expenditure Forecast as submitted and approved for the current quarter capital budget. YTD Budget - Total of current and previous quarter approved budgets. Forecasted Expenditures - The submitted 4th Quarter Capital Budget calls for expenditures of $479.0M and July expenditures of $105.0M. VAB.0001189222 Ul o Ui CM fid Os Cd a s uc/>i O) Ul auci ui X gf c/> 5 8 u </> Ui XA Ul D Ui r8 Uu.l omm sUi o < 3E UJ CM p- 8 (ft 3 (A in COMs COMs CoM> CaM oOC CL O<. <az/ uz--i z<(/9 ua.i Ul Uol oOC a. aueoci 2a i(nJ iAn o* SAO iiunn_ m `VAB.0001189223 UUJi in UJ u. in ac g UJ uj in -OJ. UacJ L> UJ o* a. <a a UJ o o CM (UOOAJf u UofJi a. a uj 2g tn u. UJ UJ UJ O UJ u CJ ofUI ion of o 35 u (A UJ UJ UJ soac o CL CJ KJ t CATIONS BEING MADE TO THE CURRENT MONITORING SYSTEM A CON.J O UJ CJ UJ VAB.0001189224 f iA u o D liJ aIII aOUfl g g CJ Ho> o UJ (A ui s 0 1 g Z Ul 01 o s Ul u Ui o> ooc Ki u 2 (A (o<ADc CO So 2 *S Ol CO aui uUJ s 3- fsJ O' 3o u s U<0J s 5Ui 6 oS 3Ou fM SO ra rxj i rcu* rov*i APPROVED CAPITAL PROJECT STATUS oUcl oc UJ -<j CJ CO (A oo CM CM in CJ VAB.0001189225 2O APPROVED CAPITAL PROJECT STATUS ocnc ui a- o 8 SS MO 8 (VJ </> *$ cn " --oLri (uAi OC U(AI X s 3DC Q in CM CJ CM 8 CM o* UI K UJ o ccnn UJ ui u 8 tfk* 5 Ol 3! UJ UJ Ui n Uai o 8 CJ o ui CJ UJ 8 uCaDti CJ UoJ u UJ OOC oc UJ o UJ Ucni 2 ui 8 $ co l < 8CcnO UJ oc cn QoC UJ cn cn g UaJ s ui UJ CJ a. a UJ a o Q. UJ cn I cn ao ucn " S5 o 8 Scn cn Ui a UJ OC CJ CJ *u- 3a o UcOnJ u s 8* 3 u UJ UJ CJ UJ su o ooc UJ cn o o $ UJ a. CM $ a. 0I0 00 oq CM KCMl 00 3 CM UJ UJ 00 8 CM CM CM CM COM COM cn o UoJ U~JJ CM o> 8 COM CJ CJ cn C9 cn cn oc CJ cn UJ UocJ u Ui UJ X UI cn cn o 3 8UJ g Ui OC 1 8 cn CJ oc UJ Ui 1 1 UJ k CJ UocJ cn OC 1 4*4 1 CJ UJ IL **4 3oc ec cn J ooc o 1 ^4 o1 1 UJ Ui CJ < w UJ tt o CO 1 3 s1 CJ 8 a UJ 5 CO 3 oc UJ cn 1 i1 CL o u. GO t CM in UJ VAB.0001189226i CM o i in CM vO CM CoMo 4 in in in tn o1Q uoi * o * CM C* in o CM O *oo cn f Ai UJ 33 k CL iA OUJ 3 iA <A O< S in O in mCM O <0 APPROVED CAPITAL PROJECT STATUS iA M II U IIII H N II IHI CM H & HIIIt II <s H II II iA II II II II II H H H II HN IHMt iA U IU H NK IHHI H HH UH 8 NIHf o $ $mCM CM ton CM CM UJ VAB.0001189227 ENVIRONMENTAL - K. G. Akins Water All wastewater discharge parameters were met for the month of June. A meeting with the Industrial Wastewater Control Division of the Mississippi Department of Environmental Quality (MDEQ) was held on June 3 to discuss Vista's progress on meeting the more stringent BOD limits contained in the 1993 permit. The MDEQ requested a second meeting in the Fall to update them again. Superfund A meeting was held with the MDEQ and EPA on June 13 to discuss progress on remediation activities at the Aberdeen plant site. Based on our presentation, the EPA said they do not intend to pursue further sampling at this time. Waste Waste shipments during the month included; A bulk shipment of API sludge to Chemical Waste Management in Emelle, AL. A 550-gallon shipment of stabilizer spill to Fisher Industrial Services in Gadsden, AL. m A 35-gallon shipment of waste paint solvent to Fisher Industrial Services in Gadsden, AL. An 880-gallon shipment of plasticizer filter cake to Fisher Industrial Services in Gadsden, AL. EHKRGY CONSERVATION - J. R. Ganc I- Energy Conservation Date A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU II. Boiler Operation June. 1992 < 11.9%> < 8.4%> 2861.0 130.2 Fiscal Y.T.D. < 15.9%> < 13.3> 2970.0 1214.5 Bellar No. 1 No. 2 No. 3 .Twm 1992 84.1%. 84.0% 84.3% 83.3% 83.3% 83.1% VAB.0001189229 HUMAN RBSODRCK REPORT JUNE. 1992 PERSONNEL - J. E. Beall EMPLOYMENT Michael L. Harvey - New Hire - Chemical Engineer. Kelly D. Wood - New Hire - Chemical Engineer. Jason A. Edwards - New Hire - Mechanical Engineer. PRQMOTION8/TRAN8FBRS None. RETIREMENTS Cleveland Brown - Vinyl MAM Operator - Vinyl Department - Incapacity Retirement. TBBMIMMTIOMS/RK8JQMATION8 William E. West - Vinyl Lead Operator - Vinyl Department - TO/FROM LEAVE OF ABSENCE R. Danny Flippo - Vinyl Department - Vinyl Lead Operator - Union Leave of Absence. f VAB.0001189230 DEPARTMENTS #EMPLOYEES WAREHOUSE GENERAL PLANT MAINTENANCE LABORATORY COMPOUND VINYL PLASTICIZER SUB TOTAL SALARIED 15 10 36 22 36 32 5 156 80 M 9 5 8 4 24 11 2 63 6 F 0 0 0 1 1 2 0 4 19 %M %F 60% 50% 22.2% 18.2% 66.7% 34.4% 40% 40.4% 7.5% 0 0 0 4.5% 2.8% 6.3% 0 2.6% 23.8% TURNOVER MO. FYD 00 02 03 01 02 20 00 ANN.! 0 26.6% 11.1% 6.0 7.4% 8.3% 0 Month FYD Minority Female Hourly Month FYD Salaried Month FYD 1.7% 5.1% 8.3% VAB.0001189231 t o 40 O rsi CM rsi N 4* o CM 03 Kl CM DEPARTMENTAL SUMMARY HOURS REPORT ............... YEAR TO DATE .................. P rin te d 6/30/92 atoc UI lii aa>. o UJ aUi CO u 03 O<oc ucoi BX </> ui UXi o Ui ui Uo 5 CO UJ u5 MHIMMMPWi It IIIItt a* UJ N g u 41 to CL CL mmrnmm VAB.0001189232 t DEPARTMENTAL SUMMARY HOURS REPORT ........... MONTHLY ............. 41 S r l H- JS <H T] CB O. CA L II s 8 5N o in ** * o O j s 8 8e o n dVi A * o 40 O i l\l i 8 QC * 1C11l s 8CD to UI UJ oae 8IAJ 8oo auci 5 to UI UI to <8M: *V S3 o Cm ^5 AHH i H If H 3rDC 4> UI JM O to 3 VAB.0001189233 P rin te d 6/30/92 APMTHTSTRATIVE SERVICES - D. A. Barclay There were no reportable safety instances this month. Quality All teams met during June to review progress on their projects. Futures MTD YTD Natural Gas $0 <$34,092,64> Statistics fcfifisaAfid Wwtito FT92 Processed Invoices 947 Working Fund Checks Written 20 Cost Savings Through Bid Process $6,160.57 Raw Material Purchase Orders Issued 160 MRO/AFE Purchase Orders Issued 241 Spare Parts Purchase Orders Issued 170 9574 154 $28,425.76 885 1738 1740 Packaged Finished MfrT- Compound "An Grade 3,547,042 PLENEX 144,053 Compound Off-Grade (BC) 581,047 Compound Off-Grade (H) 231,324 Millscrap 291,642 Dry Blend "A" Grade 720,154 Dry Blend Offgrade 266,442 Resin Type I 1,175,100 Resin Type "BC" 13,600 Vacuum Dust 180.246 Total Packaged W/house 7,150,650 June. 92 3,399,031 159,878 463,256 270,429 341,660 534,150 327,276 598,200 100 .$06 6,304,586 (Decrease) /Increase <148,011> 15,825 <117,791> 39,105 50,018 <186,004> 60,834 <576,900> < 13,500> 30.360 <846,064> % hjB&& < 4.17> 10.99 <20.27> 16.90 17.15 <25.83> 22.83 <49.09> <99.26> 16.84 <11.83> Bulk Finished Goods Ending Inventory Compound nAn Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "AM Grade Resin Offgrade Total Hit. 'M June. *92 567,672 0 1,003,050 598,930 16,216,208 1.983.802 20,369,662 499,675 0 1,335,580 598,930 12,588,021 _1.591.012 16,613,218 (Decrease) Increase % Change < 67,997> 0 332,530 0 <3,628,187> < 392.790> <3,756,444> <11.98> 0 33.15 0 <22.37> <19.80> <18.44> VAB.0001189234 A ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS JUNE 1992 -SHIPMENTS BY PRODUCTS- PUBLIC MONTH IPT/1TC EXCH/TOLL PUBLIC YTD IPT/ITC 01:39 PM 10-Jul-92 EXCH/TOLL RESIN-BULK RESIN-PACKAGED 14,636,610 676,350 FLEXIBLE COMPOUND-BULK 1,510,280 FLEXIBLE COMPOUND-PACKAGED 3,066,717 19,558,630 656,800 1,440,850 0 0 0 1 0 0 167,102,520 154,051,680 4,614,305 2,940,450 3,484,440 17,074,850 27,792,301 230,753 0 0 0 0 NEW BUSINESS RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED RIGID GOMPOUtN)-PEL LETS 1,400 609,650 341,477 0 0 637,050 6,000 0 0 0 0 0 134,834 10,237,880 3,613,939 0 0 5,226,950 181,850 0 0l 0 0 TOLLING - BULK TOLLING - PACKAGED 0 00 0 00 0 00 0 00 PLASTICIZER 83,760 925,790 0 165,060 5,094,260 917,400 TOTAL 8C| SA JL -SHIPMENTS BY MOOE BULK: JUNE* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 20,926,244 RAILCAR 189 8 5 5 23,225,120 CUSTOMER PICKUP 6 0 0 0 0 COMMON CARRIER 30 32 R 9 4 217,145,279 184,800,793 917,400 ttMunnanmnanua>(*& TOTAL 225 40 14 9 TOTAL JUNE 207 6 75 288 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 1,468 98 65 31 123 317 0 86 3 112 0 16 1,908 184 180 47 TOTAL YTD KS8M*VSlMimmtS PACKAGED: JUNE* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER II II H It It II II fItfi 1 *a ! IT! : 8- s II 3 1,662 CUSTOMER PICKUP 2 13 1 0 126 COMMON CARRIER 40 84 13 0 531 TOFC AIR/UPS 00 00 00 00 2,319 tmmmmmmmwmtI8888mVI8IBIStI888tSI8l AIR/UPS 1 0 0 0 TOTAL 43 97 14 0 TOTAL JUNE 16 137 0 0 1 154 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 28 215 0 0 174 768 0 0 15 109 0 0 0 000 5 23 1 0 248 965 125 0 TOTAL YTD 217 1,092 0 0 29 1,338 888I8BS8I8BB8888U8SBUBSssaaabisbbbibbiI8I88B8I88III8IV8U88B8jmummmmmmmmmmmm bbkbibbxbi[SSSBBBBSIS8NSIflBBBIKtSl DAB,TLC,MAS,AEV,JRF i VAB.0001189235 IjU <n r- CM o w- C* o -tr> o 1 O1 <3i * ^SJ* 1 oi CM CO r-. r- r^, _r*4 r-'i *rr* nr* cm O' O' cr- O wl o *o O* 'w* o o li1 cm CM Cm CM CM O' O' O' <r* CO *r o --* w CM in ^ *r Cl -JO <* o o o -o s cm r-- CO no CD O cm rM oo O' o CoM 2 r> c> ocm iT> CD rCO CO r'- (K 4 t I r-- i nr t i i t co O CM CM M'i ^ s o* ud OQ : CJ SC QC CM u ir* M^> w> M*1 v> CO Ui ro 5i *n CO w pvi in ro iT> CO M*G-* CO MO O O h*i tO O' o> O' CO |M (M <^*% ^1. *4 1 > O' ho o lO MTi *o 1C 3C ZX cn <3 5 o CU esi Cu 4jU UJ 1C oc cc CJ u CD CU cn 3C 3: ca 3 ae aie Ml M CD cn U.i g oc :v*: <c i i cn O CJ UJ CO . to J(*i *s, -*. Crt co ae ic ** *,, J CD 1C <Ui CM CM CM CM CM O*^' C*" > O' --. O" UJ CM >< 0*4 CM "fcv^. 4C %o MD -hO -o mo Oo CD VAB.0001189236 Ar ousands of lbs.) 1800 1600 1400 1200 1000 06/91 06/91 12/91 02/92 04/92 06/92 07/91 09/91 11/91 01/92 06/92 06/92 PKG'D PRODUCTS INVENTORY VAB.0001189237 "P w- h LABORATORY - J. H. Edwards A. Safety There were no safety incidents in the Laboratory during June. B. Customer Contacts There were no "on the road1* customer contacts made in June. C. Customer O.C. Problem Reports and ClIB/s 6/08 Flexible t The customer complained of gray pellets and white resin contamina tion in one box of 46801 Black compound. This product run followed a 34862 Gray run on Line III. 6/08 Athol. Manufacturing. Butner. NC The customer complained of a miscommunlcation concerning the delivery time of a 5415 hopper truck. It was scheduled for 6/22 but was delivered on 6/8. km The customer complained of a 5385 railcar that arrived with a hatch open. Rain through the hatch wetted the resin. A bolt on the hatch had come loose. kill Triangle Fire & Cable. Sikeston. MO The customer complained of clogged screen paks after running only 22 hours on 35852 compound. They normally run 72 hours on one screen pak. Blending procedures were changed on Line III for 35852 to solve the poor dispersion problem. 6/1? Freedom Plastics. Janesville. WI The customer complained that a 5385 railcar shipment was very fluffy. The Aberdeen Lab data showed that V this was the finest particle size shipment ever sent to them. The specification was changed to tighten the percent through the 140 mesh. VAB.0001189238 LABORATORY - Continued C. Customer O.C. Problem Reports and CHR's - continued 6/19 AJLsco. Olive Branch. MS - continued The customer complained that a 5385 railcar had very hard to open bottom outlet valves. The valves will be inspected when the car returns. 6/29 American Melted and fused clumps of resin were caught in the unloading screen at the terminal while unloading two 5305 railcars. The customer complained of dried clumps of 5265 resin causing problems during resin unloading and compound blending. 6/29 The customer complained of bills of lading arriving out of sequence and pre-shipment samples arriving late. A conference call was made to Donnelly to explain how shipping compound trucks from the plant instead of the terminal would affect the process including bills of lading, certificates of analysis, and samples. They were satisfied. D- Product Waivers Issued Customer Product Essex 5415 E. RVCM of In-Process Samples Reason Viscosity Mo. 1 R/C The following is a summary of residual VCM results on in- process samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of June, 1992, Number of Samples Average RVCM, ppm Reactor Slurries 907 49 _____Dryer 5265 5305 38 0.092 69 0.128 LABORATORY - Continued F. RVCM of Shipment Samples The following is a summary of the residual VCH analysis of shipment samples for the month of June, 1992. Product Humber of Samnles Average RVCM. ppm 5225 5265 5305 5325 5385 5395 5415 5416 5465 Debox Pond Dry Blend 20 60 129 4 67 5 80 0 6 27 4 2 0.818 0.067 0.078 0.084 0.095 0.048 0.018 0 0.017 0.169 0.035 0.024 G. Flexible Compound Quality StrmnmM-r^ Hardness Color Hard Particles Heat Stability Dicing Mischarge METS-IR Adjustments M U. 241.0 150.5 <4.02> <2.51> 5.0 <0.08> Totals 396.5 <6.62> M Lbs t m 5.9 31.5 34.2 4.8 4.6 33.4 10.5 124.9 <0.10> <0.53> <0.57> <0.08> <0.08> <0.56> <0.31> <2.09> H. Rigid Compound Color Total Rejections M Lbs. <%> 59_J> 59.5 <3.34> <3.34> * VAB.0001189240 Ed 8 8 id id o 5 ^ *^ 88 * it CM 00 ir- o O IO IO CD o CM o CM id IOO IO CD r VAB.0001189241 m m SAMPLE SHIPMENTS JUNE 1992 RESIN Ship Date 6/01/92 6/01/92 06/10/92 6/22/92 6/24/92 Product 5305 5325 5305 5325 5395 5416 5385 Amount 500 50 4X5 lbs. 10 lbs. 10 lbs. 10 lbs. 5 tbs. Customer Alcan Building Products Intex Plastics Corp. American Mirrsx Color Custom, Inc. Ship Mode CC UPS Airborne UPS Willamette Co. Airborne COMPOUND ,' Ship Date 9/09/92 Product 35852 NAT Amount 20 Ibe. 6/12/92 6085 BLK 10 lbs. 6/24/92 55041 CB 50 58162 NAT 100 lbs. 100 lbs. 6/25/92 34862 GRY 546 (OG) 2 X 5 lbs. Customer Vista R&D - Austin Enterplast, Inc. Pyramid Plastics Inc. REKO Company Ship Mode UPS Airborne Airborne UPS DRYBLEND Ship Date 06103192 06/11/92 6/25/92 Product 80273GWHT 110 378-143 Blue 170 RP-34WHT 141 Amount 50 lbs. 200 lbs. 300 lbs. Customer BOUGRAFOS Y LAPICES SA NOVATEC Formtech Enterprises Inc. Ship Mode Airborne Airborne CC VAB.0001189242 ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) c oU. 15 CD 0 t--i--i--i--i--i--i--r J*90 A J o i i--i--r JS1 *t--r A MONTH T---I--I I I " I I I i--r r i J O J*82 A TOTAL INJURIES -H-- OQHA RECORDABLE VAB.0001189243 aa/nia VAB.0001189244