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iNlJl - i To: T. H. Huffman Interoffice Communication From: Date: Subject: D. C. Skokna September 25, 1991 ABERDEEN MONTHLY PROGRESS REPORT AUGUST, 1991 There were four first aid injuries reported during August. A new housekeeping program, Operation Cleansweep, began this month. Everyone was trained in housekeeping standards, and then cleanup of areas designated by natural teams was started. As of August 31, the plant's employees completed 4440 days (5,943,784 manhours) since the last lost time injury. FY1991 Kev Statistical Information 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 Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M 38.3 91.0 95.4 1.0412 5.7 98.3 1.4 84.9 < 19.5> < 87.5> 15.6 420.3 86.2 97.9 1 .0242 53.6 97.1 16.8 84.2 < 11.6> < 271.4> < 200.8> Operations The resin unit ran well. Some problems related to the new DCS in the New Module were encountered and corrected. Conversion of the Old Module is scheduled to begin in early October. The flexible compound schedule remains tight. Rates in the rigid unit were reduced to closely monitor quality and to produce the new Dayton product (RP152) which runs slower due to cooling limitations. Costs Variable efficiency variances were essentially at budget. Fixed costs were unfavorable due to MM&C charges related to the July turnaround and plant painting. -'"t- 4 i !" : =i VAB.0001189566 -F T. H. Huffman 9/25/91 Aberdeen Monthly Progress Report - August, 1991 Page 2 QMP The Compound "B" Shift presented their stabilizer spill reduction project to management, This project reduces the amount of this hazardous waste by 42% and reduces costs by $11,000 per year. Southwire's CEO visited the plant to present Vista Southwire's Excellent Supplier Award. Vista is the first and only Southwire supplier to receive this highest rating. I Nibco, a resin customer, performed an audit of the plant on August 6. Our quality system received a 98% rating, and we are now considered a "certified" supplier by Nibco. On August 27, a group of Nibco employees met with us to formalize communication channels, determine action on items of common interest, discuss D.O.E. for Nibco's priority quality concerns, and discuss pellet quality. Environmental Two VCM leaks occurred on August 16 and they were reported to the National Response Center, as a pre caution. The first incident, an approximate threepound leak, occurred when a drain plug in a recovery compressor vibrated out. The second, a leak of approximately forty-six pounds, involved a line rupturing at a weld spilling unstripped slurry. Results from DuPont Environmental Remediation Services (DERS) confirmed previously detected methylene chloride, acetone, etc. in groundwater samples were lab relics. VCM was again found in shallow groundwater south of the New Module. Additional sampling to determine the extent of VCM contamination south of the New Module is planned to begin in September. t- VAB.0001189567 ir T. H. Huffman 9/25/91 Aberdeen Monthly Progress Report - August, 1991 Page 3 Environmental - Continued m We provided Conoco an estimate of $1.8MM to reclaim the resin in old pond #2. m A contractor was selected to*' remove buried drums near the wastewater treatment plant. A plan for drum removal and site cleanup was submitted to MDEQ for approval. Work is scheduled to begin in October or November. D. C. Skokna Plant Superintendent rah VAB.0001189568 DISTRIBUTION COVER LETTER ENTIRE REPORT Hous ton J. D. Burns X R. T. Ferrell X T. H. Huffman X C. J. Matson X D. F. Harman X H. R. FI aminer X R. R. Smith X B. J. Bean X R. H. Gerlach X R. D. Gamblin X C. R. Miller X Aus tin R. L. Poe X H. J. Hall X Oklahoma Citv H. D. Garrison X LCVCM Plant P. D. Carrico X LCCP Plant J. Friend X LCLAB Plant J. W. Ware X Baltimore L. R. Bauer X Hammond J Pavao X Premiere P. L. Foote X Aberdeen RWS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, DAB, DAM , JEN, JDO, BLT VAB.0001189569 SAFETY - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Injuries bv Department Aug. 4 0 4 0 0 Fiscal Y.T.D. 1991 Fiscal Y.T.D. 1990 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries bv Type 1 2 1 0 0 0 4 Cuts and Abrasions Eye Injuries Burns S trains/Sprains Stings Other Totals Non-Occunational Injuries 3 0 1 0 0 0 0 4 Lost Workday Cases Days Lost Contractor Injuries First Aid Cases Medical Treatment Cases Lost Workday Cases Safety Record b 0 0 0 0 0 Last lost time injury - 7/5/79 Days since - 4,440 Employee hours since - 5,943,784 On August 30, 1991, the employees of the Aberdeen plant completed 4,440 days with no lost time injury. VAB.0001189570 r_J L . HM- | SAFETY - Continued Topics for plant safety meetings during the month included: Operation Clean Sweep. CPR and A new housekeeping program called Operation Clean Sweep began this month. All employees were trained in housekeeping skills for their August safety training. They then cleaned up their designated plant areas. An emergency drill involving a maintenance worker with a simulated heart attack went well. f Supervisors' brown bag safety lunches are going well. held. One per month is Routine dosimetry results for the month were: Chemical VCM Lead Total Particulates Monthly Injury Summary < PEL Number Percent 81 98.8 9 100.0 4 100.0 > PEL________ Number Percent 0 0 0 Iniurv Class FA FA FA FA Department Compound Maintenance Vinyl Compound Description First degree burn, upper right arm. Cut, left "ring" finger. Scratch, left elbow. Cut, left "middle" finger. VAB.0001189571 OTTAT.TTV MANAGEMENT PROCESS - T. J. Arbeiter All of the plant's natural teams met during August. teams' highlights for the month were: Some of the m Compound "B" Shift Natural Team made a presentation to management on August 28. The team presented results of their project to reduce the amount of stabilizer hazardous waste generation. The team described the action steps completed and procedures implemented that resulted in- a 42% reduction in stabilizer hazardous waste from the baseline period (second quarter 1988 to third quarter 1990) to the present period (fourth quarter 1990 to third quarter 1991). This 42% reduction positively impacts the environ ment , safety and productivity - as well as saving nearly $11,000 per year on stabilizer and disposal costs. Most of our teams were busy this month completing assignments for Operation Clean Sweep. Clean Sweep is a plant-wide housekeeping project with areas of the plant assigned to each natural team. i Southwire's management visited the Aberdeen Plant on August 1 to present our employees with the Southwire Excellent Supplier Award. In attendance from Southwire were: Roy Richards, President and CEO; Wayne McAmis, Senior Vice President and General Manager Wire and Cable Division; Melinda Jones, Supplier Excellence Manager; Jack McLendon, Purchasing Agent; Tom Robertson, Compound Develop ment Manager; and Wayne Posey, Plastics Blending Manager. In addition to approximately seventy-five plant personnel, Vista was represented by Jim Ball, Senior Vice President - Commercial; Wayne Hilgers, Manager - Quality Development; and Charles Matson, Manager of Marketing - Polymers Resins. Vista is the first and only Southwire Supplier to receive this highest rating in the Southwire program. On August 6, Lou Macakanja, Purchasing Quality Engineer for Nibco, Inc., conducted a Quality Systems audit of the Aberdeen Plant. Our Quality Systems received a rating in excess of 98% and are now considered "certified" by Nibco. TT VAB.0001189572 I QUALITY MANAGEMENT PROCESS - Continued On August 16, Southwire employees, Darrell Smith, Manufacturing Engineering Manager, and Steve Bohannon, Engineering Manager visited the Aberdeen Plant. The opuropose of their visit was to gam familiarity with our plant and processes and discuss areas of mutual interest with Aberdeen operations and engineering personnel. Nibco, Inc. visited the plant on August 27. Nibco attendees included John Rouch, Plastic Division Project Engineer; Richard Kauffman, Plant Services-Greensboro; Todd Nowicki, Director of Manufacturing; and Wil Pinto, Corporate Chemical Engineer. The purpose of the meeting was to formalize commun ication channels, determine action on items of mutual interest, discuss DOE application to priority quality concerns and discuss pellet quality. K COST VARIANCES - D. C. Skokna Variable Costs Product Efficiency PVC Flexible Compound Rigid Compound Plasticizer Total <$52.4> 12.2 10.3 45.5 $15.6 Resin Price $537.9 < 317.1> < 72.2> < 90.7> $ 57.9 Total $485.5 < 304.9> < 61.9> < 45.2> $ 73.5 Utility usage was above budget. Flexible and Rigid Compounds Efficiencies were essentially at budget. Plasticizer Raw material consumption was favorable. Major Price Variances: Variance - $M VCM Natural Gas Phthalic Anhydride Resin to Rigid Compound Resin to Flexible Compound Alcohols Plasticizers Other Price Variances Total $486.7 43.7 27.2 < 76.7> < 81.0> <130.6> <175.4> < 8.8> $ 57.9 Fixed Cost Variances m Payroll and Benefits MM&C Miscellaneous TI&D m Clearances Variance - $M Total $13.6 < 94.3> 3.8 < 7.8> < 2.8> <$ 87.5> Payrolland Benefits - A favorable payroll variance of $29.2M was partially offset by an unfavorable benefits variance of $15.6M. MM&C - Turnaround costs and contract painting caused the unfavorable variance. Year-to-date this category is $285.7M favorable. VAB.0001189574 11 .............................- 111! 11 |q 11 - ll l 1-LI I H'l'li I .iIMi <: :jr t! | | 11. , ii ->41 ! . ii i'-t*1 H I * I :- f I|-.i|prni- :r -|!| iMUr- .4i-fjNl"-|:C|!ci1f2r!x! |!.'I'S- ilrtriHl MI i*s 1II f-i n ! .........;t| -!|i 11 iti 1111 ..!i-| .viMi* 11|.iiir N mjj^pmi h''lLrl!I'|14:-l +Jil ||ll|:|,iMMi>i . I:I: |li-rj =!-i il^lr!ji-jtf-lEj jj^1 j::e! Ii!"L 11 * iv|:n/'M i * VINYL - J. D. Olson, D. E. Knittig The Vinyl Department had no first aid case or OSHA recordable injuries during Augus t. The monthly safety meetings were concentrated on "Operation Cleansweep". Each shift was assigned specific plant areas for cleanup. General 1. VCSM project prepared for a late August conversion. The date was moved to October 4th due to inventory. The team focused on optimization and documentation. 2. The slurry dump line developed a leak while splitting a batch due to incorrect charge amounts. The line was repaired and procedures changed to eliminate this problem. 3. Preliminary testing of a closed dump system was completed. A full test is planned for mid-September. Aust. 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 % 38.3 1235.5 96.7 907.0 29.3 91.0 94.6 95.6 95.4 420.3 1254.6 98.4 9858.0 29.4 86.2 90.7 90.2 97.9 Reactor Hours Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, and dump conflicts). 471.0 Maintenance downtime (hydroblast D-700 condenser, New Module slurry dump line repairs, hydroblast D-742 condenser, low of steam due to boilerhouse trouble, D-300 rupture disc, polyvic valve on D-745, D-700 seal change, PM D-743 gearbox, change D-743 drive shaft, PM D-500 gearbox, change D-745 rinse nozzle, PM D-600 gearbox, and D-700 evacuation valve transition piece. 196.0 .I i---------M i | .L.K .H VAB.0001189575 VINYL - Continued Dryer Time m Operational downtime (centrifuge plugs, dryer cleaning, flameouts). - Maintenance downtime (dryer PM). Reactor limited production. % of Total Downtime 35.4 12.2 52.3 Key Maintenance Items - J. B. Autrey, S. A. Truitt 1. The reactor seal on D-700 was changed. Failure was due to the flush line plugging with resin. 2. Condensers on reactors D-700, D-742 and D-744 were drilled to control contamination. 3. The drive shaft on D-743 was replaced due to wear. 4. Annual rupture disc changeout on D-300 was completed. 5. The wet end boot of the #7 Bird centrifuge was badly worn and was replaced. 6. Trunions on dryers #4 and #6 were changed out. 7. The faulty low flow shutdown switch on the east incinerator was changed. 8. One maj or valve was changed in the vinyl unit. * . -4 ' : I".- !. I h. . |,M. r; -M##-;i :*j..:I ~r'L!~ l i V-K" VAB.0001189576 COMPOUND - S. C. Hillman, M. R. Kane Safety The Compound Department had no OSHA recordable injuries in August. General Orders remain tight on all production lines although there are some signs of lower orders on Line I. Close monitoring of dry blend product quality has caused hieher than normal downtime and slower than normal rates. Compound Production Operating Days Line I 31 Line III 31 Line V 10.5 Total % Prime Capacity Utilization Factor Month 1878 3267 513 5658 98.3 72.3 61 105 49 183 Fiscal Y.T.D. 18269 31541 3795 53602 97.1 62.5 Downtime Line I - Product Changes - One Dicer Offline - Miscellaneous Maintenance Line III - Product Changes - Miscellaneous Maintenance - Quality Line V - Product Changes - Miscellaneous Maintenance Hours 107 56 28 108 23 7 23 16 VAB.0001189577 COMPOUND - Continued Operating Days H Rigid Compound 30.5 % Prime Capacity Utilization Factor Month 3339 96.8 46.2 Avg./Day 109 Fiscal Y.T.D. 48895 99.0 72.1 Downtime - Quality Problems & Control - Running One Blender - Miscellaneous Maintenance - Product Changes Operating Days Plasticizer 31 % Prime Capacity Utilization Factor Hours 94 85 57 41 Production (M Lbs. Month Fiscal Y.T.D. 1406 84.9 63.4 16813 84.2 76.6 Key Maintenance Work - J. B. Autrey, S. A. Truitt 1. The bearings and shaft on the #1 boiler feedwater pump were replaced due to wear. 2. The #1 boiler feedwater pump was rebuilt and mechanical seals were installed to reduce leakage. i I- I*"?'1 P! I1 I (i*. -- - H |- I. VAB.0001189578 I I I > . ENGINEERING - J. E. Nickerson, M. L. Carter PROJECTS IN DEVELOPMENT - GENERAL VCSM Converting the Old Module equipment from the old control room to the DCS system is scheduled to start October 5. Initial loop checks for the Old Module are 85% complete. VCM monitors and other common equipment alarms have been switched over to the new system during the month. Dry Blend Oversize Problems A DOE was performed on the dry blend line to determine the effect of processing variables on ized particles. The response chosen was significant. Results from the DOE were used to plan another test run to determine the effect of transfer temperature on over sized particle formation. Low transfer temperature is responsible for impaired product rates. Vinyl Cooling Tower Performance Evaluation Performance testing of the vinyl cooling towers concluded in early August and the data is being evaluated. The results will be used to determine necessary changes to meet current and future cooling limitations. i -I - i-.ii 'll ' n %:li':. 'V.i!',tillJ 111|>-.: I :i 1 :'H:!-:jiL- : -7nv;;iii:i|ir.'*h i: |+ll|--i-li-_ J| KJ- frini JM'H- "li .ii :i VAB.0001189579 * i* -. f \d4i ift ifiljAIDMy?" *4 ft 4 fth'J T 44 X- f**DT Vilft 4 If * ft * * a* 4 ftk 4 i.L t * 4 - L 1 * * I * a v : y- t* w *4 * ft ^ J * *I 1 UU * V *W *4 fca ^ 4 L. 1 1 J! ;.j1 1 * -v^ ,j j i f4 * : .1 VV 4 *4 v s* .P r- H- , V i d ' *V .TtS* 11 j p * 4^V -`)QQ - v Jw WV 4 "*ra 4 fi J W W^* -* A rt A 4 %d j k; Ij UH K * *J * *4 V <4 /***! 1 ^J -i^Vi 1 '4 A V** * Pi /1 v s*^ . 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"T> Ua 4 0 iX^ft A W V *i>Uw ; ki/d I 4 w **44 y **44 */ v\ woTli?r" OJATM???y Ayr^Tki ir.-T-r :TrAy7cy ':5?cut? ^ ^4 * V4 . 4* b ~rAS?TCT?E1l f.r4ST*5 t :vTAnTS('W*#*^ 4 4 l * U it *a J **V 4 4* a JI ^ *'nJ W * 4^ Si f + + -+r w t 'iAD si*!)l IST sr\ ?y:rA''T7 sapfr? *s utJUV J L U*44 ^VViiy v ^4 4 vO JIAUT'.^*f|Tjp' *ri*T ^ t lftT-r Ti|r * ** ^ * * *i p Itija v y W * tT Id V ^ulii 4 Wl^y.i Myaii1 , k y# at aSKB tile BHIDGE S1UIJ3 RAILCAE CaIK SACi L*it< A T ui/< l/4*^4*4f 4 305K vv SKI DUAL VCH SKUCTIO! :ixc;niD hath J8T283 S0.4 i 5 COJTMISATICS 3! i kf ^,- n r r wi i '-'OuMiuAtSTlilllT WSTKATSE INFLUENT EQUALIZATION *V ^wa- tASCp pjQJJJJ U i/k4^ 4i 4ih4 V V * V **V fc ta ^ < 4 tTrrjTi,^ 4^4>>*4**4(* A ^7 W 4 ^ * It * y i* 1 ^ * SSJi 15'iS 3AGH0U3E3 "ivm vr3 sv^r? #. dft 4 ''u* ity v i udid 'T f '. ,4 4 aATS2 STITSU ^X'TJT.Tt* * * ^W(* - ! 1 y T * ^ n.c ^ < a J4 ii?-? ;jaT4r7M?rw^d 4 4 *i U j i' At AmI * v1 * a^yi yU v w**y J * * ;u =0T'W 4dw iftdftildt 4 Ti Wpilf'MFST `ila Wa< 4 *4*` U *i^ 4 4*ili v> U*t 4 ?VC IIA3BGXIEPLAC2SSST `,.7if * * *U :v iha ) :ey' i ve shaft h!?l 1" i !* J - ^ rf )t * 444* U- rr a * 4 fl 444* *%. ^ 4i "" tY } J 1 I *ftr^T| .`.A Aijita*wT. '" *y * * w ''JtAWiTAA.Tjipi: t:TJ--TJSA7 4*41 * J y lyli 4 | ^ * it ftu ^ w t -1T * 4 V * 41 aa t *41 * ar * * 4d -4 V*44M>* 4 ^ t ^p w A 41 t \l * ^ . H , # * v V u v ft ~K ililfeT P1?7)j rfWr7T7^ u;" '/via* ytriftttw idllir - 4 i^*i *1**' ' ,T 4 iL^vfear * _,. T4 *w tfetv V at** *4 ^ V V 1 1" CONVERSION WAS HAS! IN JULY T'A - ?AWn'A1f i a i* ' yi4>ta 4 V fc* C-'pj?,'jTi s f I** 4 ^ rfW# PAD { vu fifT y^vl I :* it'?'} ? AP?3i9T?H R-^i !t,iPf!?vP r?r?v r''"r?" r'7 -i* : . ; ]|v i ct' r ^ * N* ^ ^ !.^ "PMfp-p ?r;? o_ai '*ss::mn ."AMDr.:?:-*: 4 * *d W *, l*ai iftftd 4 i 4/ * ** t/*N '7C7-78 sjrfiM T? 'K spngwc? viTia^T: -47; aypr *9 i+ ft ad*1 WtV JViiU ftd * ft ft ** V UlitU V *> 4 MU ft *dft*ft id iiU I y L .: ft* ^ ft * m ft v t* '.5^11 - ** k BA ILACiO IN OPERATION 5-91. lAHGETD fll" ; V - ft- f ^itivvf ft4 ^ :*7?i5 umt !S auAf-ijffc? : *r\ 7A" wtv ':`r>! -'i***M!, 'TMa'?l- ?*tfTtl MntAlJS rw 'QWrijft ;7iifii^f twiVU?i t* .*|.1 . ^:. *w4 r **3f w k4i a; * M4 4 .V * ftpyBiftri * *" Wldy ft* V A W i**J * # ft *' .-30CSSS :n ji t -ft i* w "-C1 '*' 4-' ft * !rl''7'77* * a >> ^ la 4 i#y ::I *h 7' *:*?? V',;; c* VV |1 ^ I V* *r ft *d wrnT^1*ty^rsT M u 4 * f aA * i W al 4 h 4 4 .* 4 # wt vrnrjTrjyrns? ^Vkrftft 4 V aa 4 4 J J % Kjwf Uli * M ay?f y ftdftdlf w*f MUft 4d * '*?? rns at? U 4 4i ft 4 ant** > kftAv a;?** W it 1 d vny 4 i w a# ar ^o.T!fT 3m htp4 J 1/ 4i U i *UiJ 41 yi' ^ iJ w" ftJ ft ip d . - \. ^ ^ W! t r ? ^ . ^ 1 w ; t w A ^1 * r ! r * d i iu*t dy y V 4 44 4 P 44 * 'LICK IS OPIBATIOS 8-31. TARGETED :^ * PrTI ]i yyv '"' ncnTT WuUwVMy w-j i* d 1 v 4. J WIak smss SCHEDULES TO BE IN PLANT S-PI ilCH. m iliCT DISI3S COUPLETS PROJECT IS TARGETED TO 3E PLACED IN OPERATION IS OCT 91 m FILTERS OS ORDER TARGETED COLLET IT! FOR 4TH ft mi^^ <4*4*1 -^* 1 4m PROJECT HAS BEEN CLOSED TO FIELD CHARGES 5-31 FINAL REPORT. PROJECT HAS BEES CCHPLOD AS1 ^ +* X4fcrfM*y-*!^ fH r* r' -. n ;* i V*V i^fti 4^ft J w >d D VAdw ^ ^ ' ft V ^X rr\ ju -TAM ii>i> tC ftyf ^!T A 4> . ! f` I . - K - * y id iib a* k> ft 4 'lar.T"?": * ift*1* i*4d 4 ftdlr 'Pt-iT'rt*' Vi diy4 1 <Uv -<'t*d * y w W fift ^ 4 PROJECT HAS BEES C03PLETED AND TARGETED r K *'Cl UAC n T'?rY ^'i iil# V^4J4 4 d* AJ r>^ v ftJ 4 *. ^1* rv FOR Ifl* 4T * J -r . " yyjy' ft* ft.*'"taT?fTMl 7 \r>yJidF vv w *4fti t * +* m vf t*< yI 4i|4 4 4-4d n* J k# ^ ! : ^^,01 4 1/ iv v ft FT 91 EDIFICATION OF HSSHASI BACKING IS SCHEDULE FOR OCT OUTAGE. f!l(lV I \ ) ' * * -j ' I .4 Jriik*^; ri ft ^ * 7 7 r*vif . Ct 1 di<u,, *;i TM'\ravi; CIVIL ASH SITE CONSTRUCTION IN PROGRESS "o SUUT?TM*?^ Pk ' -- * ** * W ^ a * f M1 ft 4 ^W 7ft 7- ^^ v J- *V t* - i* 4 rt "*Tfr -' v it * *V * INCINERATOR INSTALLED. PROJECT COMPLETION TAF.GE3D PC ** fe1* * 4 -^ * k -r V ft NSW TANK HAS BEEN INSTALLED. MINOR CAPO AUDI "'"VT JJVjryTr.^ - *i 4/4.iu*4 ^ il ft if U THE m GEARBOX HAS ARRIVED IN THE PLANT. "TR9MTLT VP w T ' i 7 T7K7 *BTiOC: *<`: a:--^'I a ^ ^ *ft* Id 4^ ft ft A d ' S# * -A ft 4' d I ^ a1 * t ^ hi a 44i* 4 # .J * v^ft ft fl ft** . kX J^ II 1^ ki 'IH* uky*E 1 id 4 1 I ft *f * i 4 r ' ft <ft it tP> t ft ^ -. *.* 4J \- * miA * ^ . I* ' - Ji4ti4I U n i ft .- i a d ^ i4 v * * i.* ------- tfi *- * ft ** * V ^ * :?^J7(7 >'i? srrcpnro ' 1 '. 1 i**ai(/ d V4 mW lift * *yr Iftfft/ * a 1 d ^ ^ a * * ft M-*Pr\rvTATr': * H* 4 4I X U J .VE?TWftdftJ-* ^ ftLfttidftr' 4 fti-vyyid4 '3T w ^Aii. Mi * * *b- hk*i*n J iT1 d- * *^ * ftft * '* ft. # ' *W ft. 1- !:: :|l!-,i MJ-'rt' k:jii:^M -| : ^ I . is--1:r :| iI-.i-li-i n -ns -i-i- 1 HHft 1 LpK-rfc.iaih|>^.i-i-| |c-.^|411 i-t^i^ thiit^^r|L|1< 1%||MJr |: - rnhr it::!-.rh ...............%!'- ?iJ ,,,J ' VAB.0001189580 ENVIRONMENTAL - K. G. Akins Vater All wastewater discharge parameters were met for the month of Augus t. Work continues on gathering information necessary for submitting the storm water permit application due November 18, 1991. We have five unpermitted storm water outfalls that will be covered by these regulations. A wastewater bypass occurred during testing of the Old Module deluge system on August 22, 1991. A process sewer west of V-10 overflowed to a storm sewer. The MDEQ was notified. Sunerfund Results from DuPont Environmental Remediation Services (DERS) resampling of the groundwater, soils, and sediments were received. The results confirmed that previous detections of methylene chloride, acetone, etc., were lab relics. VCM was still detected in the shallow groundwater south of the New Module. The concentration was 0.5 ppm versus 3.5 ppm during the first round of sampling. Phthalates were detected in every deep well during the last sampling. This contradicts the earlier sampling in which phthalates were present in only one deep well. DERS believes the water samples could have been contaminated by vinyl tubing that was mistakenly used during the second sampling. These wells will be resampled (at DERS' expense) the week of September 16, 1991. At the same time, further investigation will be done to determine the extent, if any, to which the shallow groundwater is contaminated with VCM south of the New Module. Aberdeen Process Engineering revised the estimate of the cost to Conoco for Vista drying resin excavated from Pond 2 using our existing resin reclaim system. The new estimate was $1.77MM with $107M required up front to prepare the system for operation as required for this project. ENSR was selected as the vendor to remove the drums buried near the wastewater treatment system. A work plan for drum removal and site clean up will be submitted to MDEQ for approval with work scheduled to begin in October or November. -y r I T` is -- t; t :(Jn-.-f I' Liv "I' I >........... I p VAB.0001189581 ENVIRONMENTAL - Continued GeneraI Two vinyl chloride leaks were reported to the National Response Center on August 16, 1991. Because these were leaks and not releases and posed no threat to anyone outside plant boundaries, we were not required to report. The reports were filed as a precau tion. The first incident involved a plug in a recovery compressor casing that vibrated out. Water saturated with approximately three pounds of VCM leaked from the casing plug before being stopped. The second incident involved a line rupturing along a weld spilling unstripped slurry containing about 46 pounds of VCM. During excavation for the new water plant, two drums were uncovered. The drums appeared to contain a heavy weight lube oil. The contents of the drums along with the contaminated soil were transferred to new drums. Conoco was notified that the drums would be held for disposal with other drums removed from the old drum burial site near the waste water treatment system. Waste There were no waste shipments during the month of August. * I- r' 1- *|- 01 ' L . . I `v *< 1 VAB.0001189582 ENERGY CONSERVATION - J. R. Ganc Aug.. 1991 Fiscal Y.T.D. I. Energy Conservation Data A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU < 21.0%> < 19.5%> 3047.2 149.1 < 12.4%> < 11.6%> 2803.1 1505.0 II. Boiler Operation Boiler Combustion Efficiency % Aug.. 1991 Fiscal Y.T.D. No. 1 No. 2 No. 3 83.2% 83.3% 82.6% 83.2% 83.4% 82.8% j- . . id- vHT..-*- VAB.0001189583 * HPMMI RESOURCE REPORT AOGP8T- 1991 WMTWomml ~ J* E. Beall William Berlin Genetti - New Hire - Engineering Co-op Student. William Dwight McComb, Jr. - New Hire - Engineering Co-op Student. Proiotiona/Tyanaferg Amy E. Bagwell - Production Scheduler, transferred and promoted to Lab Supervisor replacing Billy Paul RBTIRBMB1W None. TBRMIHATIOH8/RB8IGNATIOM8 Holli Harris - Engineering Co-op Student returned to school. Michael Schneider - Engineering Co-op Student returned to school. TO/TPOM TYRAVE QF ABSENCE Allan Bodron - Engineering Co-op Student - Educational !L-d-:!i) rl" - ,-- L VAB.0001189584 MONTHLY 15 11 39 24 38 33 5 165 74 90 50 80 52 23 1 10 1 20 62 4 7 18 60% 45% 20.5% 20.8% 59% 30% 40% 37.6% 9.5% 0 0 0 8.3% 2.6% 3.0% 0 2.4% 24.3% 0 0 0 0 0 0 0 0 1 0 0 4 0 0 r M r !PI' '* i'."' Hi H' t VAB.0001189585 V a c a tio n 360 _ 316 128 128 552 180 o x* CM CO o 8 CM O' CO -Q - co ml i 4-* O H CM O e ro o 00 in CO o o in o c* ft ro CM o d ft ft 8 N* ft O' ft tn CO CM e rs na g to O i io o o oft o oft o oft o oft o Q o o ft 8 o o ft O o o O o o o 8 o o o ^3 IM KJ n S . Av E <0 CD (Du. o o o oft o oft o oft o oft o o o o 8 ft 8 ft 8 ft 88 ft ft o o o o o 00 ** O o O O O rg O 3-- o o o oooo o o oo d- <0 T3 BCL o oft oft oft o o ft o 4 o ft ooo ft l O (D o o o CO --3 OC M O o o o o 00 >o o ** fO CO CO X >* 33 -a Q 8 8 8 8o o o o o o ot oft oft oft oft o o ft o o ft ft ft oo o. o o o o o o o o 4> g CO s 8eg o 00i oft f o o o in jo ft ft oft o ft ft ft ft o oo O 8 ft ft o K "O s s 1C s 8 8CL flT (A o oft ft ft oo8o ft o ft o ft in o in >> ft s IAJ o in o CM to OO ae a: * 8 * O' O' co fr o }.............................. ............ *- -:i- A co AII II ac> 1Uoi CO U</I Ui 3E s sUI CO s2 oa CO h 3C Ui aU*i g SUi CO o IIIIII 4> gc rsi CO u CO CL <0 Oab> +o i: il.-.-* .I ' M .f . / " - " ' t ......................................... VAB.0001189586 2 UaJ uui (A UI UI (A UI -- uo S o O A i/% A O) C - ' i VAB.0001189587 .b ADMINISTRATIVE SERVICES - D. A. Barclay There were no reportable safety Instances this month. Quality All natural teams met in August OASIS Progress We are still experiencing problems with monthly closing of the OASIS system. Processed Invoices Working Fund Checks Written Cost Savings Through Bid Process Raw Material Purchase Orders Issued MRO/AFE Purchase Orders Issued Spare Parts Purchase Orders Issued Packaged Finished Goods Ending Inventory Month 1186 15 $5172 116 236 165 T.T.D. 10345 142 $28590 997 1986 1931 (Decrease) % July. 1991 Aug.. 1991 /Increase Change 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 Warehouse 3,580,700 96,292 329,086 151,348 87,278 509,092 244,754 485,306 100 161.533 5,745,489 4,309,548 85,626 365,738 182,848 117,408 537,998 356,699 731,450 100 172.939 6,860,354 728,848 < 10,666> 36,652 31,500 < 69,870> 28,906 111,945 246,144 0 11.406 1,114,865 20 <11> 11 21 <37> 6 46 50 0 7 19 * i VAB.0001189588 ADMINISTRATIVE SERVICES - Continued Bulk Finished Goods Ending Inventory July. 1991 Aug.. 1991 (Decrease) % /Increase Change Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade Total 1,119,270 177,500 2,850,600 1,112,560 10,450,500 1.385.100 17,095,530 643,615 177,500 2,984,939 1,112,560 11,179,589 1.775.473 17,873,676 <475,655> 0 134,339 0 729,089 390.373 778,146 0 5 0 7 28 4 i ... .i.. - I : ft- I L- Jf- .. !.; - : : ! ..fc V|' ' ft ! * k - JW .j.!. VAB.0001189589 4.. ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS AUGUST 1991 -SHIPMENTS BY PROOUCTS- PUBLIC RESIN-BULK RESIN-PACKAGED 19.007,510 578,837 FLEXIBLE COMPOUND-BULK FLEXIBLE COMPOUND-PACKAGED 232,010 3,254,581 NEU BUSINESS 8,016 RIGID COMPOUNO-BULK RIGID COMPOUND-PACKAGED RIGID COMPOUND-PELLETS 1,857,450 509,679 0 TOLLING - BULK TOLLING PACKAGED 0 0 PLASTICIZER 131,800 TOTAL 25,579,883 -SHIPMENTS BY MODEBULK : ................. AUGUST* RESIN FLEXIBLE COMPOUND RIGID COMPOUNO PLASTICIZER RAILCAR 148 11 7 5 TOTAL AUGUST 171 *YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUNO PLASTICIZER 1,706 114 217 28 TOTAL YTD 2,065 PACKAGED: AUGUST* RESIN FLEXIBLE COMPOUND RIGID COMPOUNO PLASTICIZER CUSTOMER PICKUP 3 24 1 0 TOTAL AUGUST *YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 28 35 270 10 0 TOTAL YTD MONTH IPT/ITC EXCH/TOLL 15,144,480 285,850 0 0 2,000,700 0 0 0 00 618,396 126,445 0 0 0 0 00 00 664,840 364,800 18,840,711 364,800 YTD PUBLIC IPT/ITC 212,334,182 139,105,110 3,260,833 2,341,950 6,660,895 15,117,540 33,567,247 832,470 135,575 0 33,742,280 4,303,941 38,022 6,893,996 906,801 0 00 00 951,390 2,609,610 294,994,365 167,807,477 CUSTOMER PICKUP COMMON CARRIER 35 53 05 0 34 06 35 98 425 0 27 29 481 COMMON CARRIER 24 80 18 0 122 439 49 155 37 680 TOFC AIR/UPS 00 00 00 00 00 AIR/UPS 0 0 0 0 0 157 0 0 823 0 0 164 0 0 300 1,147 52 81 4 0 EXCH/TOLL 1,777,400 0 0 0 0 0 0 1,401,960 33,600 4,202,810 7,415,770 TOTAL TOTAL 27 104 19 0 150 244 1,174 178 3 1,599 CC: DAB.TLC,AEV,JRF VAB.OOOl189590 CL. cu Ii tn cn LU CJ j cn U H* CO a: - LU I-- cn cn cu cn cu UJ CU L-- ccej cc*n: LU LO lju Iii cn a: cu cn cn cc cu cn <r cn -- l- co cn cn tn cn & n O' o~ CM cm '7_> O' 4*"S o i o 1 r1 1 -a CM CP' --u m U'j CO O O O <o O o O ii I i JO Ct cn 40 tO hn rn w cn r* c-' L-.. )S3 ca ca <:*> Ci o CM M 04 o Oo cnl M3 t*3 ca *o CM rn 40 CM <r> CM <o CM CM CM CM CD* i IM CM CM CM CM CM CM CM CM CM CM 40 40 40 CP' 1*3 to 1 CO 1 o m 1 w*l i Oio tn i CM 1 CM 1 t ca i CD i 1O r-* CM 1 A1 CM M. --4 ii II co ii f**** ii tn ii - j*. II M II IMS cn era tn $sLU LU LU tn tn tn 9 tn LU tn tn tn uu LU LU =3 cn cn LU s cn tn LU cn CO CO CO S sca CO cu So ca CD o CO CD CO CO to O CO CO tn cn to O'* M3 I-- t". )I un hO CM cm r^ cn CM cm rn cn i CM < CM ;r- P'1 CM ci m Mi I CP' CM I CM ro M c> W~a Ml 41*1 in u*^ ~U M CJ cn cn c- C c CM -M U*1 p'% P'- 150 CO co CO PO CO M CO p*> -.o CP' Ml I TM CO co hn io UTj ca ca r^. CjU Cu xz an u *-* s tu UJ LU ac h*1 cn to cn 3 o "D CO LO JD ZO =r <r <C to oc CQ LO ctz ca JC <r --J ,.J __i Ii* 2s- UJ tn to cn *L *- co -E r ;r cn --j _i LU LU UL x CO i.n cn cn cn tn cn ca O cc JC v_/ CO t.1 CJl C.3 i.. CM CM CM O -O C ... p .. i : c CM `ii i t*J U.J LU l_*_ t_U O' cr** LU gj cn cn Ct. CU *"3 CU cn ~n VAB.0001189591 c (Thousands of lbs.) f FLEXIBLE & RIGID OFF-GRADE AUGUST '90 THRU AUGUST '91 1400 1200 1000 08/90 10/90 12/90 02/91 04/91 06/91 08/91 09/90 11/90 01/91 03/91 05/91 07/91 PKG'D PRODUCTS INVENTORY VAB.0001189592 * LABORATORY - J. M. Edwards m A. Safety There were no safety incidents in the Laboratory during Augus t. B. Customer Contacts Representatives from Southwire visited on 8/1 to present the Aberdeen Plant with the Excellent Supplier Award. Repre sentatives from Nibco visited the plant on 8/27 to discuss technical issues and partnership agreements. C. Customer O.C. Problem Reports and CNR*s 8/01 Flexible Technologies. Abbevlle. SC The customer complained of contami nation in 58031 Wat Cl 328 compound causing lumps and grainy appearance on hoses. The contamination re sembles crystallized Soya Epoxy. Samples are being analyzed in R&D Analytical. 8/01 Dayton fatniHad Plastics. Mlamisburg. OH The customer complained of poor com munication by Vista that a shipment of dry blend would not deliver on time. 1/06 Bee Wire & Cable. Whitten. CA 8/07 The customer complained that Visalia 2153 Natural compound had three UL failures. R&D Technical Service is investigating the problem. Cerro Wire & Cable. Hartsville. AL An Ergon truck driver mistakenly took a load of dry blend to a 5415 resin customer. A process was started which requires the driver to produce a bill of lading before picking up a shipment at the plant. 8/08 Thermal Industries. Pittsburgh. PA Due to the lack of raw materials, a product shipment had to be delayed. I : VAB.0001189593 IABORATORY - Continued C. Customer Q.C. Problem Reports and CNR*s - Continued 8/08 Davton BTtmrfftd Plastics. hnrg. oh The customer complained that the first truck of 489-116 WHT 140 (new product) produced pitting on window profile caused by oversized par ticles . 8/12 Uniroval Plastics. MlsImmItji. IN The customer complained of out of spec I.V.on three orders of resin. A process was started for lab release of bagged resin before any shipment is made. 8/13 Formtech. Bozart. GA 8/14 The customer complained of "shooting stars" in RP-91 WHT 110 finish pro file. This material had been re jected at the Stowe plant and rescreened at Aberdeen. Thermal Industries. Pittsburgh. PA The customer complained that they were charged for the gross weight on the shipment instead of the net weight of 489-136A. 8/15 Horthwire. Osceola. WI The customer complained of wood chips in the pellets of 38601 Black. Samples were received of the PVC and wood chips sandwiched together. 8/15 Thermal Industries. Pittsburgh. PA Again, Vista delayed shipment of this material (see CNR above) and was forced to pay overtime for help at the unloading dock to receive the shipment Friday night. I . |... . VAB.0001189594 LABORATORY - Continued C. Customer O.C. Problem Reports and CNR*a - Continued 8/16 Elecon. Venezuela The customer complained of 35451 which failed I.R. testing. This material was made in September of 1990 following a compound which had Soya Epoxy in it. Soya Epoxy is very detrimental to I.R. Thfe plant has started a flushout procedure Soya Epoxy is used so that the cross contamination in the plasticizer line will not harm wire and cable com pounds . 8/20 Flexible Technologies. Abbeville. SC The customer complained that 46801 Black compound did not adhere. R&D Technical Service investigated the problem and it was discovered that the solvent used at Flex Tech caused the problem. 8/21 Thermal Industries. Pittsburgh. PA The customer complained that a ship ment expected at 7:00 but delivered at 10:00 was not a problem this time, but could have been a big problem. Also, the next weights on the boxes of BGE product did not add up to the weight on the bill of lading. 8/21 Thermal Industries. Pittsburgh, pa The customer complained that Vista shipped only 13,000 pounds of BGE 347 against an order for 20,000. 8/23 Northwire. Osceola. BT 8/23 The customer complained of metal 38601 Black compound. Analysis samples showed the metal to aluminum. in of be Northwire. Osceola. ITT The customer complained of foreign material in 38601 Black compound. The sample looked like RTV (silicone sealant). it P * d VAB.0001189595 Continued Prswtasfc fftfrrftgg Customer Product Dayton 489-116 WHT 140 Dayton 489-116 WHT 140 Vycom RP-461 WHT 140 IfMon Color Color & Torque Rheometry 40 Mesh No. 3 H/T 2 H/T 2 H/T njfCM RVCM of The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages ex ceeded 400 ppm RVCM during the month of August, 1991. Number of Semples Average RVCM, ppm Reactor Slurries 904 71 Drier 5265 27 0.078 81 0.195 RVCM of Shipment Samples The following is a summary of the residual VCM analysis of shipment samples for the month of August, 1991. Product Number of Samples Averaee RVCM. xyom 5225 5265 5305 5325 5385 5395 5415 5465 Debox Pond Dry Blend 2 49 161 0 42 9 59 2 14 12 5 0.009 0.013 0.048 r 0.094 0.016 0.016 0.008 0.126 0.057 0.030 VAB.0001189596 Conttnued F. ReBln Process Capabilities (based on dryer "regulars") 5265 5305 5.311 mi 5415 Bulk Density Inherent Viscosity (vs. 0.64 - 0.67) (vs. 0.715 - 0.744) "L" Color "a" Color "b" Color % on Pan (vs. 2% max.) % thru 140 Mets I.R. (vs. 95% of Control) Hard Particles, (% > 10) Average Particle Size, Microns 0.81 0.80 0.20 -- 3.67 10.00 5.67 0.73 -- 0.91 -- ------------- ------------ 141 0.83 0.64 -- 0.44 2.67 3.11 6.00 0.93 -- 1.06 ---- -- -- 1.28 0.41 -- -- 2.67 -- 2.00 1.22 -- 1.69 ------------- ---- 6.9 1.17 2.00 -- -- 3.78 -- 2.17 1.81 -- 1.57 3.08 -- 0 1.36 0.37 -- -- 4.22 -- 3.00 2.83 0.33 3.72 4.95 2.38 2.9 144 166 152 174 6. Flexible Compound .flirt HIT ~ Hardness Color Hard Particles Heat Stability Contamination Dicing METS-IR Totals M Lbs. 26.0 51.7 <0.43> <0.85> 5.0 -- <0.08> -- 82.7 <1.36> M Lbs, ill ---* 12.5 11.6 1.5 15.6 30.0 71.2 - - -> - <0.21> <0.19> -- <0.02> <0.26> <0.49> <1.17> H. Rigid Compound Quality Summary Re lections M Lbs. (%} Torque Rheometry Torque Rheometry & Contamination Torque Rheometry, Contamination and Color Color Contamination Total 14.2 <0.45> 15.0 <0.47> 3.0 33.9 _JLJL 72.6 <0.09> <1.07> <0.20> <2.29> wm mummmm mmm emieui1 VAB.0001189597 LABORATORY - Continued I. Miscellaneous 1. All natural teams met once during the month. 2. The software to link lab data to the vinyl VAX was completed in the following area: A. RVCM data entry B. Viscosity data entry and auto report C. Regular Q.C. data entry Work is still needed for Regulars report and the RVCM report. 3. The Perkin-Elmer RVCM analysis instrument failed for two days and required an outside repairman. Assisted Administrative cumulative IPA terminal for OASIS. s to track down Also, helped set up a VAB.0001189598 SAMPLE SHIPMENTS AUGUST 1991 RESIN Ship Date 8/01/91 8/07/91 8/13/91 8/19/91 8/21/91 8/22/91 8/22/91 8/28/91 8/30/91 8/30/91 COMPOUND Ship Date 8/08/91 8/15/91 8/19/91 8/21/91 8/22/91 8/22/91 8/30/91 8/30/91 DRTBLEND Ship Date 8/16/91 Product 5395 5325 5225 5225 5415 5225 5325 5385 5385 5385 Pond * Product 16851 CB 50 35852 NAT 58162 BLK 462-143 BLK 462-34-B BLK 57121 WAT CL 487-5A NAT 487-5A NAT Product 378--143 Purge Amount 50 lbs. 10 lbs 100 lbs. 50 lbs. 100 lbs. 2 lbs * 2 lbs. 500 lbs. 50 lbs. 10 lbs. 50 lbs. Amount 100 lbs. 200 lbs. 100 lbs. 500 lbs. 500 lbs. 150 lbs. 5 lbs. 5 lbs Amount 50 lbs. Customer Baerlocher USA C. E. Shepherd Novatech Plasics Co. Congoleum American Thermo Hemisphere Eri Extrusion INEX S.A. DE C.V. Akzo Chemical Hawk Plastics Customer Vista - Austin Chicago Magnet Wire Corp. Vista - Austin Donnelly Corporation Donnelly Corporation Accurate Extrusions Essex Group Inc. Vista - Austin Customer Nibco, Inc. VAB.0001189599 * wrnmm TI ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) NUMBER OF INJURIES 7 PMNiffWi VAB.0001189600 tw ABERDEEN ENERGY CONSUMPTION T" mm PMHIH VAB.0001189601