Document VJkD33yq90d92JjbgLGkDDdLg
T. H. Huffman
*
umrovnn Communication
From: Date:
Subject:
D. C. Skokna September 23, 1992
AimnwM MONTHLY PROGRESS REPORT August, 1992
There were four first aid cases reported during August. At month end, the plant's employees had worked 4806 days (6,446,863 employee hours) since the last lost time injury.
PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime. Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EU1, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M
39.5 91.7 98.7 1.0225
7.2 97.2
1.5 97.4
1.8
88.2
< 4.9> 192.0
< 45.6>
407.8 86.7 97.2
1.0341 61.0
96.7
21.2
97.5 16.4
81.6
< 12.6>
<404.9>
<622.6>
Costs
Variable costs were above budget in the resin unit with near budget performance in the other units.
Fixed costs were favorable primarily due to correcting accrual errors that were made in July.
Operations
Annual inspections and rupture disk changeouts were done on reactors D744 and D745.
Production was very good in the flexible compound unit. Inventories increased during the month. Rigid compound pro duction was low. Plans are set to shut down the dry blend unit near the end of September.
/
VAB.0001189139
T. H. Huffman 09/23/92 Aberdeen Monthly Progress Report - August, 1992 Page 2 OMP
Cerro Wire and Cable (a resin and compound customer) visited and toured the plant. Discussions focused on ways they could Improve their compound production.
h The Vinyl nAM Shift Natural Team presented a project to improve access to blend tank valves during the winter.
Environmental We met with MDEQ to discuss our work plan to collect data for the James Creek flow modelling project. MDEQ made some comments and they will be incorporated Into the data collection plan. Data collection began in early September.
Plant Superintendent rah
VAB.0001189140
SAFETY - 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 by Type
Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains Stings Other
Totals
Fiscal Y.T.D. 1992
Fiscal Y.T.D. 1991
4 0 4
0 0
0 1 3 0 0 0 4
39 01 04 03 03 00
4
Lost Workday Cases Days Lost
08
3 ~ 49
6
127
Contractor
First Aid Cases Medical Treatment Cases Lost Workday Cases
0 44 0 01 0 01
Safety Record
Last lost time injury - 7/5/79
Days since -
4,806
Employee hours since - 6,446,865
On August 31, 1992, the employees of the Aberdeen plant completed 4,806 days with no lost time injury.
VAB.0001189141
4
4
SAFETY - Continued
Topics for the plant safety meetings during the month included "Lockout/ Tagout Training" and "Safe Work Permit Training".
Routine dosimetry results for the month were:
Chemical
VCM Lead Total Particulates
Number
74
6
1
Percent
100.0
100.0
100.0
Ntimhor
0
0
0
0 0 0
FA
Compound
Abrasion of right thumb.
FA
Maintenance
Abrasion of left elbow and
contusion of left hip.
FA
Maintenance
Puncture of left palm.
FA
Maintenance
Irritation of right forearm
(contacted AMS).
There were no emergency drills conducted during August.
m , U _ !_________
VAB.0001189142
OUAT.TTY
E. E. Smith
All natural teams continue to meet. Most are preparing team project presentations to management.
The Plant Manager's Natural Team and the Synergy Team brainstormed solutions to previously identified QMP barriers.
The Vinyl "A" Shift Natural Team recommended electric tracing on some transfer lines to improve safe access to blend tank valves during the winter. In the past, winterization shelters have made valve access difficult.
Cerro Wire and Gable visited the Aberdeen Plant on August 19. They received a resin and compound tour. They were looking at ways to improve their compounding operation.
A
VAB.0001189143
COST VARIANCES - D. C.
Variable Costs
Product
Aug*. 1992 Variance. $M
Efficiency
Erlfeft
X&&1
PVC Flexible Compound Rigid Compound Plasticizer
Total
<$44.2> < 11.2>
1*0 8.8 <$45.6>
<$506.0> < 69.7> < 18.1> < 37.8> <$631.6>
<$550.2> < 80.9> < 17.1> < 29.0> <$677.2>
PVC
4
Raw material use for all PVC (prime and non-prime) was slightly above budget for the month.
These units operated close to budget.
Malor Price Variances:
Yfyj&ngf.. - $M
VCM Natural Gas Aleoho1R Alcohols Plasticizers Resin to Flexible Compound Off-Grade Resin Credit Resin to Flexible Compound Micral 932 Electricity Other Price Variances
Total
<$478.6> < 52.8> < A6 * < 34.9> < 34.1> < 11.6> < 11.0>
12.6 24.1
0.8 <$631.62l.
Fixed Cost Variances
Payroll and Benefits MM&C m Miscellaneous TI&D m Clearances
Payroll & Benefits
Variance - $M
Total
$ 25.8 84.7 55.5 4.8 21.2
$192.0
Hourly payroll and benefits were both favorable; salaried payroll was above budge t.
MM&C
The favorable variance is due to correcting an $85M accrual error made
in July.
VAB.0001189144
L 1
cost mTAwas . Continued Miscellaneous
m Assigned Vehicles: $68.1M - This corrects a July accrual error. $12.6M
$16.2M ShlPP&Pg<$22.8M> - Delayed processing of a prior period
invoice overstated the actual August costs.
This favorable variance is due to a credit for the Pond 2 cleanout project.
k
VAB.0001189145
y t
VINYL - J. D. Olson, D. E. Knittig
The Vinyl Department had no injuries in August.
The monthly safety meetings were held on shift. A meeting with all supervisors was held to review revisions to the lockout/tagout procedure implemented last month.
General
1. Annual inspections and rupture disk changeouts were completed on reactors D>745 and D-744. The New Module inspections were completed in August.
.2 D-400's recovery line was replaced from the valve to the
condenser. The line developed a leak due to corrosion, All other recovery lines were inspected and reactors needing recovery line replacement were scheduled down. Reactors D-500 and D-600 were completed in August and D-742 was completed in early September.
August
YTD
- 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
39.5 1274.1
96.2 947.0
30.5 91.7 93.0 97.2 98.7
Reactor Downtime
407.8 1213.7
91.6 9741.0
29.0 86.7 91.3 91.0 97.2
Hours
Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts, and no blend tank space).
385.0
Maintenance downtime (D-745 annual inspection and condenser cleaning, D-400 recovery line, D-744 annual inspection, D-745 VCM charge valves, incinerator work, fluid bed dryer for cleaning, D-743 agitator gearbox and motor, D-600 recovery line, D-500 agitator PM, D-500 recovery line, D-300 evacuation valve, D-741 steam valve, D-500 suspending agent ram valve, D-300 catalyst pot disks, and RVCM charge meter New Module).
233.0
wmmmmmm
VAB.0001189146
VINYL - Continued
Dryer Tine m Operational downtime (centrifuge plugs,
dryer cleaning, flameouts). m Maintenance downtime
(activator problems, centrifuge repair). m Reactor limited production.
1 of Total Downtime
35,5
2.8
61.7
Kev Maintenance Items J. B. Antrey/S. A. Truitt
m Reactor 744 was prepared for annual rupture disc and die check. Relief valves were sent out for reconditioning.
m The Old Unit cooling tower, 4B gearbox seal on the input shaft, coupling, and grommets were all replaced. The tower has been experiencing some vibration due to the deck sagging.
i Recovery compressor "BK was pulled out of service and rebuilt for a spare.
m Emission recovery system compressor 706 was pulled out of service and rebuilt.
Reactor gearbox 743 coupling was changed and the unit realigned after rough vibration was detected on bi-weekly vibration checks.
The demister pads on the fluid bed dryer were changed, and a temporary patch put on the ductwork.
m Reactor 745 was prepared for hydroblasting. The .gearbox was pmrd while the reactor was down.
m Five major valves were changed in the Vinyl area.
Recovery lines that showed severe corrosion on reactors 400, 500, 600 and 742 were replaced.
Critical instrumentation P.M. was completed on the west and east incin erators, and reactors 744 and 500.
Boiler blowdown piping was completed.
m Air compressor #6 was rebuilt and is now on line.
m Boiler feedwater pump #5 had severe vibration in pump and motor. Both were rebuilt, aligned and placed back Into service.
A
VAB.0001189147
Cfflfponup - S. C. Hillman, J. B. Hegwood
The Compound Department had one first aid injury during the month. A Compounder received an abrasion to his thumb.
General
Orders were down slightly on Line X and Line III during the month. Production for the month was up 300M pounds from last month. This increase can be attributed to a continued decrease in downtime and more efficient scheduling. Efforts are still being made to move two products to Line V to relieve congestion on Lines X and XXX. At this time, we have received approval to move one product to Line V. The second product has been shipped and we are awaiting approval from the customer.
CoMPOund
Operating
Manggi
Line X
31
Line III
31
Line V
15
Total
% Prime
Capacity Utilization Factor
2202 4400
552 7154 97.20 96.12
71 142
37 250
18413 37711
4899 61023 96.68 72.22
Downtime
Hours
- Product Changes - One Dicer Offline - Miscellaneous Maintenance - Quality
Line III
- Product Changes - Miscellaneous Maintenance - Quality
Line V
- Product Changes - Quality - Miscellaneous Maintenance - Coverage for Other Lines
91 17 29 15
43 55
5
46 3 5
60
i
VAB.0001189148
--r
k. 1
COMPOUND - Continued
Operating Days
Rigid Compound
18
% Prime
Capacity Utilization Factor
Production (H U.) Month Ayg./Day Fiscal T.T.D
1456 97.40 28.96
81
21171 97.54 37.19
Hours
- Product Changes - Miscellaneous Maintenance - Quality
38 24 32
Operating Para
Plasticizer
31
% Prime
Capacity Utilization Factor
1845 88.20 95.16
16391 81.63 63.89
Key Malntenime*
- J. B. Autrey/S. A. Truitt
Line I "AM blender gearbox was replaced. The old gearbox was rebuilt for a spare.
Line III auger for the bulk lead system was replaced. The old auger will be repaired for a spare.
Line V Welex starter had bad contacts and was replaced.
Line III bearings.
totors were repaired. Both motors had worn
A
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mmm
r
VAB.0001189149
ENGINEERTNG - J. E. Nickerson, T. R. Mackey, R. H. Sneed, M. L. Carter
PROJECTS IN DEVELOPMENT - GENERAL
Equipment checkout is nearly complete and operator training is continuing. Filter media installation is also complete. A DOE jar test to determine water plant chemical addition levels is in progress. Startup is scheduled for the third week in September.
New Boiler
m
An unallocated AFE for $45011 was submitted to Houston. These funds will allow fabrication of a new boiler to begin immediately. An 80,000 lb./hr. boiler was recommended as the size that would give the plant the best flexibility and efficiency.
Flame Arrestor Lid
A new lid, with a higher pressure rating, was Installed on the incinerator flame arrestor. A pressure transmitter and a feed block valve were also installed to protect the arrestor from over pressure. Startup is complete and the system was turned over to Operations.
Plasticizer Efrlltflift-ion
An estimate of the Stripper Class "A" design is expected within the week. Equipment relocation issues have been resolved.
A Class "A" design of storage and transfer facilities for the stripper will be issued in early September. The Class "A" design will cover the capacity of the existing facilities and additional capacity gained by adding the steam stripping column. A model of our plasticizer production was developed to gredict how VRP and RAE handling affect final annual capacity.
Operations ended the wastewater test run July 28 after having a truck of 610P rejected for cloudiness. Loadings to ponds 3 and 4 have increased over the test run, but remained below expected levels. COD samples were taken around P-1 and downstream of the API to evaluate the contribution of the dribble tank, T-470, to overall loadings. Sampling will continue through mid-September to evaluate loadings as operating conditions return to normal.
Centrate Pool Depth Tests
Sample ports are being installed on all centrate basins to deter mine if considerably higher concentrations of resin in centrate water will occur with lower pool depth. A test run on all cen trifuges will be done once the sample ports are in place.
ENGINEERING - Continued
VCM Compressor Upgrade
Construction for upgrading the compressors and installation of
safety equipment are in progress.
Construction completion is
targeted for the end of September. Operating procedures have been
completed and training will begin as soon as possible.
OSHA Process Safety
The following policies have been approved by plant management: Management of Change Procedure, Operating Procedure Development and Control Plan, Pre-Startup Safety Review and Process Safety Informa tion Development Plan.
Management of Change and Pre-Startup Safety Review training for all supervisors and engineers was completed. Management of Change and Pre-Startup Safety Review were implemented plant-wide on August 26. The new system is proceeding smoothly so far.
Bids were received for P&ID development.
BA1HSE
A plant water balance was completed and issued this month. Currently, we are still identifying ways to reduce water use.
The Class
design for a new diffused air aeration system to pond
3 is complete and is in review.
The regulatory relief work has led to a meeting with the State and a stream survey for James Creek is being conducted. The oxidation test results were not positive and this has been dropped. Pond 6 water is being tested for characteristics to determine if it can be recycled.
A
VAB.0001189151
ABERDEEN CHEMICAL PLANT MONTHLY PROGRESS REPORT CAPITAL EXPENDITURE STATUS
M.L. CARTER AUGUST REPORT
1992 F.Y. July-August
Month 4th Qtr. YTD
251.5 251.5 3106.1
287.0 479.0 3841.0
- 55.6 - 227.5 - 734.9
-12.3% -47.4% -19.1%
Actual Expenditures - The General Ledger for August indicates a large negative actual expenditure for the month. The General Ledger was overstated in July due to the VMS not accepting actual expenditures for July and posted accruals. Houston has indicated that the problem has been rectified in the August General Ledger. The plant has therefore added expenditures in July to those in August to report an actual expenditure of $251.5M for the JulyAugust months (shown above). Expenditures for July-August were $ 55.6M less than the plant's budgeted expenditure forecast approved in the Fourth Quarter Budget submitted in June FY92.
July-August FY92 capital expenditures were 12.3% 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.OM and September expenditures of $192.OM.
VAB.0001189152
s 1
K. G. Akins
Water
All wastewater discharge parameters were met for the month of Augus t.
We met with the KDEQ in August to discuss the work plan for data collection for James Greek flow modelling. Comments by MDEQ were incorporated into the work plan. Data collection will begin in early September.
Air Permit
The MDEQ air division informed us that little or no activity is taking place on air permit renewals. They are working on new source reviews only. They are allowing companies to run on expired per mits. We believe the MDEQ will not take any action on our permit application that was submitted September/ 1990.
a&s
Waste shipments during the month included:
m A bulk shipment of waste oil to Fisher Industrial Service in Gadsden, AL.
A
VAB.0001189153
I "mmmmmmmmmmmmrnmmmmmp
ENERGY CONSERVATION - J. A. Bodron
I. Energy Conservation Data A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU
II. Boiler Operation
Aqftt. 1992
< 4.8%> < 4.9*>
2694.0 134.8
Fiscal T.T.P.
< 13.5%> < 12.6%>
2915.0 1476.4
No. 1 No. 2 No. 3
83.3% 84.6% 85.0%
83.4% 83.5% 83.3%
VAB.0001189154
HOMAN RESOURCE REPORT AUGUST* 1992
personnel - j. E. Beall
+
EMPLOYMENT
Keith Bailey - Engineering Department - New hire Co-op Student.
Thaer Abudiab - Engineering Department - Rehired Co-op Student.
Allen Bodron - Engineering Department - New hire Chemical Engineer (removed from Educational Leave of Absence).
PROMOTIONS/TRANSFERS
None.
RRTTPRMBHTO
None.
Berlin Genetti - Engineering returning to school.
Dwight McComb - Engineering returning to school.
Holli Harris - Engineering returning to school.
Department - Co-op Student Department - Co-op Student Department - Co-op Student
TO/PROM LEAVE OF ABSENCE
R. Danny Flippo - Vinyl Department - Vinyl Lead Operator Union Leave of Absence.
Holli Harris - Engineering Department - Co-op Student placed on Educational Leave of Absence.
A
VAB.0001189155
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VAB.0001189156
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DEPARTMENTAL SUMMARY HOURS REPORT
................ YEAR TO DATE ..................
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VAB.0001189157
P rinted
9/01/92
r
EMPLOYMENT Salaried Hourly Temporary
SUB TOTAL
L.O.A. TOTAL
81 156
2
239
2 241
DEPARTMENTS
#EKPLOYEES
WAREHOUSE GENERAL PLANT
MAINTENANCE LABORATORY COMPOUND VINYL PLASTICIZER SUB TOTAL SALARIED
15 10 36 22 36 32
5 156
81
ABERDEEN PLANT
MONTHLY PERSONNEL REPORT
AUGUST. 1992
NEW HIRES Salaried/Transfer Hourly Temporary
TOTAL
HO 1 0 0
1
FY 13 0 4
17
MF
90 50 80 41 24 1 11 2 20 63 4 6 19
%M %F
60% 50% 22.2% 18.2% 66.7% 34.4% 40% 40.4% 7.4%
0 0 0 4.5% 2.8% 6.3% 0
4
"2.6% 23.5%
DEPARTMENT TURNOVER
MO. FYD 00
02
03
01
02
02
00
ANN. %
0 21.8%
6.1% 5.0% 6.1% 6 8%
.
0
APPLICATIONS Month FYD Minority Female
No. i 00 00 00 00
PLANT TURNOVER. Hourly Month
FYD Salaried Month
FYD
No I 00 6 4.2% 00 5 6.7%
VAB.0001189158
I 4
ADMINISTRATIVE SERVICES - D. A. Barclay
There were no reportable safety Instances this month.
All teams met during August to review progress on their projects.
Futures
YTD
Natural Gas
<$34,092.64>
Statistics
Month
Processed Invoices
ly010
Working Fund Checks Written
9
Cost Savings Through Bid Process
$2,666.11
Raw Material Purchase Orders Issued
83
MR0/AFE Purchase Orders Issued
178
Spare Parts Purchase Orders Issued
196
Packaged Finished Goods
FY92 Y.T.P.
11,723 174
$33,557.11 1078 2079 2113
h
July. p?
Compound "A" Grade PLENEX Compound Off-Grade (BC) Compound Off-Grade (H) Millscrap Dry Blend "A" Grade Dry Blend Offgrade Resin Type I Resin Type "BC" Vacuum Dust
Total Packaged W/house
3,757,133 139,263 402,946 107,117 155,418 607,206 278,130 950,750 100
. 19?i,058 6,590,121
Bulk Finished Goods Ending Inventory
Compound "A" Grade Compound Offgrade Rigid "A" Grade Rigid Offgrade Resin Type I Resin Offgrade
Total
448,765
0
1,321,300 269,870
9,605,310 1.400.551 13,045,796
3,995,394 144,706 312,000 63,607 84,469 632,625 261,850
1,222,700
100
242.701 6,960,152
(Decrease) /Increase
% Change
238,261 5,443
< 90,946> < 43,510> < 70,949>
25,419 < 16,280>
271,950 0
50.643 370,031
6.34 3.91 <22.57> <40.62> <45.65> 4.19 < 5.85> 28.60
0 26.37
5.61
Aug..*92
(Decrease) /Increase
% Change
858,815
0
876,709 56,050
8,280,950 924.750
10,997,274
410,050
0
< 444,591> < 213,820> <1,324,360> < 475.801> <2,048,522>
91.37
0.00
<33.65> <79.23> <13.79> <33.97> <15.70>
VAB.0001189159
m m mm
w
i
A
1800-rl 1600
1
s 1200 S 1000
08/91 10/91 12/91 02/92 04/92 08/92 08/92 09/91 11/91 01/92 03/92 05/92 07/92
PKG'D PRODUCTS INVENTORY
VAB.0001189160
ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS AUGUST 1992
-SHIPMENTS BY PROOUCTS-
PUBLIC
MONTH IPT/ITC
EXCH/TOLL
PUBLIC
YTD IPT/ITC
09:33 AM 09-Sep-92
EXCH/TOLL
RESIN-BULK RESIN-PACKAGED
14,206,180 675,741
FLEXIBLE COMPOUND-BULK FLEXIBLE COMPOUND-PACKAGED
656,000 2,967,524
20,665,250 308,200
3,068,330 99,761
0 0
0 0
194,937,209 196,984,760 5,805,246 3,556,900
5,341,920 23,509,490
33,333,743
434,342
0 0
0 0
NEW BUSINESS
26,091
1,981
0
181,880
1,981
0
RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED RIGID COMPOUND-PELLETS
TOLLING - BULK TOLLING - PACKAGED
921,750 296,605
0
0 0
426,600 495,874
0
0 0
0 0 0
0 0
12,120,610 4,621,962 0
0 0
5,959,650 677,724 0
0 0
0
0
0 0
PLASTICIZER
0 1,050,720
0
165,060 6,657,380
917,400
TOTAL
-SHIPMENTS BY MOOEBULK:
AUGUST* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
19,749,891 26,116,716
0
256,507,630 237,782,227
917,400
ISBiaWtlVBS SBBBBBBISBSBBBSSSSSXBtBSCGSBKSBBESGBGBaBBBVtDBSBmmxmwmmnmMmmm* 8SS8BSBSSS
RAILCAR
177 16 6 5
CUSTOMER PICKUP
COMMON CARRIER
19 42 0 18 0 14 05
TOTAL
238 34 20 10
TOTAL AUGUST
204 19 79
302
YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
1,841 134 76 39
145 381 0 132
18 126 0 21
2,367 266 220 60
TOTAL YTD
2,090
163 660
a
2,913
PACKAGED:
AUGUST* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
CUSTOMER PICKUP
5 19
4 0
COMMON CARRIER
24 78 19
0
TOFC AIR/UPS
00 00 00 00
AIR/UPS
f
2 0 0 0
TOTAL
31 97 23
0
TOTAL AUGUST
28 121 0 0
2
151
*YTD*
RESIN
FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
34 265 0 0 211 914 0 0
23 139 0 0 0 000
7 23
1 0
306 1,148
163 0
TOTAL YTD
268 1,318 0 0
31
1,617
CC: DAB,TLC,MAS,AEV,JRF
*
VAB.0001189161
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VAB.0001189162
LABORATORY - J. M. Edwards, J. R. Williams
A. Safety
There were no safety incidents in the Laboratory during Augus t.
B. Customer Contacts
Jim Edwards, Amy Bagwell and Terry Edwards went to Intex in Corinth, MS to offer training in resin testing.
C. Customer O.C. Problem Reports and CHR's
8/Q3 Abitlbl. Mlddleburv. IH
The customer complained that the wrong sample being shipped to them for evaluation.
8/04 Kappua Plastics Hampton. HJ
The customer complained of 5465 con tamination in 5265 bagged resin. The problem was caught during blown film testing of the 5265. The contamina tion occurred in the bagging process.
8/08 AT&T. Omaha. HE
The customer complained of abnormal
screen change frequencies using 34862
Gray 546 compound. Analytical tests
showed the yellow and black contami
nation to be aluminum trihydrate,
lead stabilizer and calcium carbo
nate .
""
8/10 Thermal Industries. Pittsburg. PA
The customer complained of poor
finish and poor surface results with
RP-159 Beige 347.
R&D Technical
Service is investigating.
8/10 Armor Bond. Sardis. MS
The customer complained of a 5385 resin car arriving with one unload ing spout missing and taped with duct tape.
LABORATORY - Continued
C. Customer O.C. Problem Reports and CHR's - continued
8/11 Simbeam-
The customer complained of a 27251 compound color shift at the end of a lot. The product was a little too yellow.
8/11 Inter
The customer complained of having problems unloading a 5305 resin car. We suspect that the resin was too dry and too high in static.
8/18 Centrallft. Clearnore. OK
The customer complained of two collapsed boxes of 34431 compound. The pallet design is presently being reviewed as the main cause of stacked box failures.
8/21 Tandy Wire, Ft. Worth. TX
The customer complained of rough surface on wire insulated with 34711 compound. The lumps were unpigmented and slightly harder compound.
93/21 Marlev Moulding. Marion. VA
The customer complained several compartment samples from a 5305 railcar were above the 3.0% on the pan speci fication. The plant is working at coarsening the 5305.
P8/21 Triangle. Sikeston. MD
The customer complained of contamina tion on their screen pak using 35852 compound. The contamination analyzed to be mostly lead with smaller amount of calcium and titanium.
D. Product Waivers Issued
Customer
Product
Reason
Stylecrest
RP-27 WHT 113
40 Mesh
Mfr Ml
up
mrnmmmm
m
LABORATORY - Continued
E. RVCM of In-Pro<*g Mmoles
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 August, 1992.
Reactor Slurries
Number of Samples Average RVCM, ppm
33 0.090
79 0.137
F. RVCM of Shipment Sammies
The following is a summary of the residual VCM analysis of shipment samples for the month of August, 1992.
Product
5225 5265 5305 5325 5385 5395 5415 5416 5465 Debox Pond Dry Blend
Humber of Samples
0 60 98
2 53
9 77
0 6 4 0 0
Average RVCM. ppm
0.038 0.077 0.049 0.080 0.015 0.040
0.007 0.019
G. Flexible Compound Quailtv Summary
Hardness Color Hard Particles Contamination Dicing Cross-Contamination Mischarge Metal METS-IR
Totals
Adjustments" M Lbs. J_ 20.0 <0.28> 30.0 <0.42>
5.0 <0.07>
55.0 <0.76>
Rejections M Lbs. (X'i
------13.7 5.2 1.3 13.6 11.2 17.2 15.5 9.0 86.7
----------<0.19> <0.07> <0.02> <0.19> <0.16> <0.24> <0.21> <0.12> <1.20>
k
*
VAB.0001189165
LABORATORY - Continued
H. Rigid Compound Owht
Torque Rheometry & Color Color Contamination
Total
Rejections M Lbs. <%>
3.9 11.7 15.6
<0.27> <0.80> <1.07>
4
VAB.0001189166
r*
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138 144 148 163 140 174
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Average Particle Size, Microns
VAB.0001189167
*
SAMPLE SHIPMENTS AUGUST 1992
RESIN Ship Date
8/04/02 8/05/92 8/12/92 8/18/92
8/21/92 8/20/92 8/24/92 8/25/92 8/25/92
8/25/92
8/26/92
Product 5385
5385
5305
5265 5385 5415
5325
5305
Pond
Pond
5225 5305
5225 5305 5415
5325
Amount 50 lbs.
Customer Vista R&D - Austin
Ship Mode UP8
50 lbs.
Alcan Building Products
UPS
500 lbs. GRUPOIMPORTADOR JALISCO Burlington Northern Air
10 lbs. 10 lbs. 10 lbs.
REHAU AG + CO
Airborne
50 lbs. 2 lbs.
Ferro Chemical Shawnee
UPS Airborne
50 lbs.
H. Heller
J. Stark Pick-up
5 lbs.
Carton
Airborne
5 lbs. 5 lbs.
Teknor Apex
Airborne
1 lb. Osterman 1 lb. 1 lb.
Airborne
50 lbs.
O'Sullivan
UPS
1 COMPOUND
8/14/92 8/19/92 8/19/92 8/21/92
8/27/92
58961 NAT
48451 BLK
419-128A NAT
48562 BLK 48451 BLK 462-121B1 BLK
35852 BLK
100 Ibe.
100 lbs.
2 lbs.
1500 lbs 1500 lbs 1500 lbs
200 lbs.
Customer Winders and Geist Inc.
Excel of Kentucky Furon - Macromeric Div.
LOF Tech.
Modified Tubular Products
Mode UPS Airborne Airborne
CC
Airborne
VAB.0001189168
f ''SAMPLE SHIPMENTS
AUGUST 1892
DRYBLEND
Ship Date 08/08/92
Product 489-188A NAT 489-188B NAT 489-188C NAT 489-188D NAT
Amount 335 lbs. 348 lbs. 354 lbs. 349 lbs.
Customer Abitibi-Price Corp.
MISC.
Ship Date
Product
8/12/92 Penn Color 83B1479
Amount 5 lbs.
Customer Vista R&D - Austin
Page 2 Ship Mode
CC
Ship Mode UPS
i1-.
VAB.0001189169
NUMBER OF INJURIES
/""Ns
ABERDEEN CHEMICAL PLANT INJURIES
(Twelve Month Running Totals)
30
MONTH
TOTAL INJURIES --*- OSHA RECORDABLE
VAB.0001189170
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VAB.0001189171