Document aBQwe3NnXm85MnqzgobqjLoye
T. H. Huffman
IWT9rDflK9 CoamnunicaHon
From: Dote:
Subject:
D. C. Skokna October 26, 1992
ABERDEEN MONTHLY PROGRESS REPORT SEPTEMBER, 1992
* * ||
VIS1A
*
Safety
There were three first aid cases reported during September. For FY1992, there were four OSHA recordable (2 MTO and 2 RWC) cases reported; the best fiscal year ever for the plant. At month end, the plant's employees had worked 4836 days (6,485,734 employee hours) since the last lost time injury.
FY1992 Rev Statistical Information
tent.
Y.T.D.
PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M
38.8 93.9 96.0 1 0471
6.5 97.6
1.4 98.7
1.7 81.8
< 6.7> < 13.3>
0.8
447.2 87.3 97.1
1.0353 67.5 96.8 22.6 97.6 18.0 81.7
< 12.1> <418.1> <654.6>
Operations
transformer downtime The Vinyl Department was reduction in work force effective October 1.
A power failure
Compound rates were good during the month, but orders were lower than the previous month. Production of two compounds was moved from Line III to Line V which will provide additional capacity.
The rigid compound unit shut down on September 21, 1992. commissioning is in progress.
De
VAB.0001189105
T. H. Huffman 10/26/92 Aberdeen Monthly Progress Report - September, 1992 Page 2
Costs
Both fixed and variable costs were near budget for the month. Fixed costs included a $38.5M charge for the elimination of rigid compound line spare parts.
Xntex Plastics, a resin customer, visited .the plant for a tour and to review quality testing procedures.
Northwire, a flexible compound customer, visited the plant. They made a presentation of their operation and Vista's key role as a supplier. We agreed to work with them to improve our products so they can increase their production
The Senior Process Engineer's Team recommended a re duced reactor cleaning frequency based on heat trans fer data.
The Security Natural Team completed a procedures manual covering their job responsibilities.
OSHA Process Safety
m Policies were developed for Employee Participation, Process Safety Information Development, Process Hazards Analysis, Operating Procedures, Training, PreStartup Safety Review, Mechanical Integrity, and Man agement of Change.
m Management of Change procedures started in August and are proceeding smoothly.
Drafting standards for P.I.& D. are under review. P.I.& D. development is set to start in January, 1993.
Environmental
Data collection of the James Creek Modelling Project was completed. The modelling should be completed in October.
T. H. Huffman 10/26/92 Aberdeen Monthly Progress Report - September, 1992 Page 3
Environmental - Continued
m The MDEQ requested that we submit a detailed work plan for investigation of the VGM contamination of shallow groundwater. The plan was sent to the State in midOctober.
Reduction In Work Force
Because of the shutdown of the rigid compound unit and the need to improve plant profitability, twenty-four jobs were elimi nated; others were combined; a temporary pool was created to reduce contractor costs; two Operators were assigned to develop operating procedures as part of the OSHA Process Safety compli ance effort; and through transfers two new positions were filled. These changes resulted in nine employees being laid off. These changes were effective October 1.
D. C. Skokna Plant Superintendent
rah
A
VAB.0001189107
DISTRIBUTION Houston
*
Austin Oklahoma Citv LCVCM Plant LCCF Plant LCLAB Plant Baltimore Hammond Premiere Aberdeen
J. R. Ball
COVER LETTER X
R. T. Ferrell
X
T. H. Huffman
X
B. M. Myers
C. J. Matson
H. R. Flammer
R. R. Smith
B. J. Bean
R. H. Gerlach
R. D. Gamblin
X
C. R. Miller
L. R. Kardos
M. J. Schneider
X
R. L. Poe
X
H. G. Coleman
H. D. Garrison
P. E. Markey
J. Friend
X
J. V. Hare
X
L. R. Bauer
X
J. Favao
X
P. L. Foote
X
J. A. Autrey
J. E. Beall
X
J. M. Edwards
X
S. C. Hillman
C. M. Markerson
D. A. Miller
J. E. Nickerson
X
J. D. Olson
R. W. Seymour/
D. C. Skokna (File Copy)
ENTIRE REPORT
X X X
-X
X X
X X
X X X
X X X X X
VAB.0001189108
A
SAFIlt1Y - J. V. Uptain
First Aid OSHA Recordable
Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases
Fiscal
Y.T.D. 1992
3 22
S Jt 3 26
02
00
Fiscal
5 0
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
1 1 1 0 0 0 3
1
2
0 0 0 0 0 3
Lost Workday Cases Days Lost
Contractor Injuries
0 0
First Aid Cases Medical Treatment Cases Lost Workday Cases
Safety Record
0 44 0 01 0 01
Last lost time injury - 7/5/79
Days since -
4,836
Employee hours since - 6,485,734
On September 30, 1992, the employees of the Aberdeen plant completed 4,836 days with no lost time injury.
VAB.0001189109
SAF^tt - Continued
Topics for the plant safety meetings during the month included: Safety, Plant Emergencies, and Handling of Chlorine and Caustic.
Driving
A lost time injury occurred on October 7, 1992, when a Maintenance Mechanic suffered multiple injuries, including bruised lungs while repairing a lift truck.
Routine dosimetry results for the month were:
Chemical
>m
Ntimha-r
VCM Lead Total Particulates
78
98.7
-1
7 100.0 0
1 100.0 0
1.3 0 0
The single VCM overexposure was without benefit of respiratory protection.
Monthly Injury Summary
Iniurv Class
Department
Description
FA
Maintenance
Cut of right index finger.
FA
Vinyl
610P plasticizer sprayed into
both eyes.
FA
Compound
Dust in right eye.
i
VAB.0001189110
QPAI.TTT mnAianiCTT rancma; . E. K. Smith
Intex Plastics visited the Aberdeen Plant on September 21 for a plant tour and demonstrations of laboratory tests.
Northwire visited the Aberdeen Plant on September 24. They made a presentation on the Aberdeen Plant's importance to Northwire.
The Senior Process Engineers Team justified reducing condenser cleaning frequency using batch condenser U-value data.
The Security Natural Team wrote an extensive procedures manual covering their many responsibilities (many of which are done infrequently).
k
VAB.0001189111
COST VARIANCES - D. C. Skokna Variable Costs
Product
_____Sept.. 1992 Variance. $M
Effipieppy
Price
Total
PVC Flexible Compound Rigid Compound Plasticizer
Total
$13.2 17.1
< 11.7> < 17.8>
$ 0.8
<$313.2> < 4.2> < 13.5> < 37.7> <$368.6>
<$300.0> 12.9
< 25.2> < 55.5> <$367.8>
Efficiencies In the PVC, Flexible and Rigid Compound Units were near budget for the month.
Plasticizer
Raw material use was above budget during September.
Maior Price Variances:
Variance - SM
VCM Debox Resin Credit Natural Gas AlcoholR Alcohols Plasticizer Micral 932 Electricity Other Price Variances
Total
<$273.0> < 43.4> < 39.5> < 39.2> < 33.7>
15.3 40.0
4.9 <$368.6>
Fixed Cost Variances
Payroll andBenefits MM&C Miscellaneous TI&D Clearances
Payroll & Benefits
Variance - SM
Total
<$ 2.6> 35.0
< 52.0> < 0.8>
7.1 <$13.3>
Results were essentially at budget. MM&C
Costs were controlled by minimizing contractor activity.
VAB.0001189112
k
COST VARIANCES - Continued
Miscellaneous
Assigned Vehicles: <$33.9M> - This corrects an August accrual error.
Unclassified: $21.8M - Transfer of test run costs to capital.
Moving, Home
$13.3M
pipeline repairs.
$16.3M
Credit from Tenneco for gas
Warehouse Gain/Loss: <$41.7M> - Writeoff of Dry Blend Unit spare
*
VAB.0001189113
VxHYJL - J. D. Olson, D. E. Knittig
Safety
The Vinyl Department had no injuries in September.
The monthly safety meetings were held on shift.
General
A power failure caused by a city transformer problem caused thirteen hours of reactor downtime. We continue to modify and Improve our DCS system to control the reaction with limited effect on quality during these upsets.
2. We re-organized our department to prepare for the reduction in personnel completed on October 1.
September
TTD
- 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
%
38.8 1293.3
97.6 920.0
30.7 93.9 96.2 96.7 96.0
447.2 1221.9
92.2 10661.0
29.1 87.3 91.7 91.5 97.1
Reactor Downtime
Hours
Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts, and no blend tank space).
356.0
Maintenance downtime (D-741 condenser cleaning, D-742 steam leak, D-400 dump valve, D-300 charge valve, D-700 rinse nozzle, D-600 suspending agent ram valve, D-744 charge water valve, old module screener motor, PM D-742 agitator motor, D-400 catalyst ram valve, Old Module filter pack rinse valve, old module cooling water line, D-745 rinse nozzle, D-600 suspending agent valve, and D-300 high pressure service water line).
120.0
4*
VImiL - Continued
Dryer Time
% of Total
Operational downtime (centrifuge plugs, dryer cleaning, flameouts).
n Maintenance downtime (activator problems, centrifuge repair).
m Reactor limited production.
Key Maintenance Tram* - j. B. Autrey/S. A. Truitt
48.8 16.3 35.0
The "B" vacuum pump in the Old Unit was taken out of service. The case had a tiny hole from a casting defect that was leaking water. The casing is being repaired and pressure tested to be used for a spare.
Reactor 741 condenser was hydroblasted in an effort to control contamination.
Reactor 700 critical instrumentation PMs were completed. One major valve in Vinyl was changed.
The #4 cooling tower pump motor was pulled from service, sent out for repair and re-installed. The motor had bad windings.
Cooling tower #4B was reinforced for structural integrity. Excessive vibration was causing the east fan motor to shut down, and the shrouds were unlevel causing the blades to strike the shrouds periodically. Repairs included a new fan deck and repairs to one of the distribution valves.
The exhaust valves on #9 air compressor were replaced.
The PM was completed on the propane vaporizers.
The #1 boiler feedwater pump motor bearings were replaced.
Critical instrumentation on the water plant was completed.
A
VAB.0001189115
COMPOUND - S. C. Hillman, J. B. Hegwood
The Compound Department had no OSHA recordable Injuries in September. General
Orders continue to be down slightly on Line I and Line III. Production for the month was down 650M pounds from last month. This decrease can be attributed to an increase in product change and maintenance downtime. We have been given approval to move two Line III products to Line V by the customer. This has reduced the requirements of Line III and leaves room for additional production on Line III. The Business Area is developing new customers to use this addi tional production. The Dry Blend Unit operated only twelve days during the month. The Unit was shut down on September 21, 1992.
Compound Production
Operating Davs
Line I
30
Line III
29
Line V
20
Total
% Prime
Capacity Utilization Factor
Downtime
Line I
Production M (Lbs.)
Month
Fiscal YTTfp,
1943 3754
772 6469 97.60 84.25
65 129
38 232
20356 41465
5672 67493 96.77 73.22
Hours
- Product Changes - One Dicer Offline - Miscellaneous Maintenance - Quality
101 26
51
14
Line III
- Product Changes - Miscellaneous Maintenance - Quality
60 63 10
Line V
- Product Changes - Quality - Miscellaneous Maintenance
61
12 6
VAB.0001189116
COMPOPHD - Continued
Operating Dav
Rigid Compound
12
% Prime
Capacity Utilization Factor
Month
1411 98.66 27.99
118
22582 97.61 36.43
Downtime
- Product Changes Miscellaneous Maintenance - Quality
Operating Davs
Hours
13 18 15
Production (M Lbs.1) Month Avg,/Dav Fiscal Y.T.D.
Plasticizer
30
% Prime
Capacity Utilization Factor
1655 81.81 77.97
55
gey Maintenance Items - J. B. Autrey/S. A. Truitt
18046 81.65 65.06
The agitator seal in P-1 reactor R-4 was changed.
The seals in Line I Banbury were changed.
The Schenk filter was disassembled and cleaned.
Line I dicer hand/off/auto switch was revised to correct a safety hazard.
Line III reduction gearbox was replaced and rebuilt for a spare, and the motor was sent out for PM.
VAB.0001189117
ENGINEERING - J. E. Nickerson, T. R. Mackay, R. H. Sneed, I. L. Cartier
PROJECTS IN DEVELOPMENT - GENERAL
Water Plant
Water plant construction Is nearly complete and contractors are working on punchlist Items. Equipment testing has begun. Chlorine training and certification is in progress. Water plant startup will begin in the second week in October.
New Boiler
An unallocated AFE for $450M was approved. A specification and bid package for an 80,000 lb./hr. boiler will be sent out to selected vendors in mid-October. Plans are to place an order for a boiler in early November, Work has begun on a Class "A" design for the boiler installation.
Plastic*Expansion
An estimate for the plasticizer stripper was completed by GED; the
cost is $1.4MM. This estimate does not include tank and unloading
facilities. A Class "A" design of the "No Additional Tanks" option
of the plasticizer storage and transfer facilities was reviewed by
Operations and Mechanical Engineering.
A Class "A" design,
including additional tankage, will be completed shortly.
Capacity of all equipment and processes external to the plasticizer reactors were evaluated at expected production rates. The "No Additional Tanks" design is expected to increase capacity of the plasticizer unit to approximately 30MM lb./yr.
Special water sampling was extended into October. The test which added extra loadings to the ponds was stopped, but sampling will be continued until October 9 to observe changes in waste water effluent.
VCM Compressor Upgrade
Construction for upgrading the compressors and installation of safety equipment is in progress. Operating procedures have been completed and training will begin as soon as possible.
OSHA Process Safety
The following policies have been approved thus far: Employee Participation, Process Safety Information Development Plan, Process Hazard Analysis, Operating Procedures, Training, Pre-Startup Safety Reviews, Mechanical Integrity and Management of Change Procedure. Since implementation in August, Management of Change is proceeding smoothly at Aberdeen.
The plant is currently reviewing drafting standards for P&ID development. P&ID development should start January, 1993.
VAB.0001189118
ENGINEERING - Continued
Water Use Minimization
A team has been formed to look for ways to redu< plant. The team includes engineering, vinyl and < and maintenance. The team has started surveying compound and plasticizer areas.
As part of the External Steam Stripping Project, the plant has begun a dryer technology study. We received a budget estimate from Sulzer for a new 30,000 lb./hr. fluid bed dryer. We have received and re viewed technical information on UHDE's cyclone dryer. The techni cal information and cost estimates will be used to develop the scope for a Class "A" design.
5385/5395 Silo
A Class "A" design was completed for transferring resin from 281/282 silos to silo 676. This project provides a silo for loading trucks or railcars for a new customer, North American Plastics. Potential sales are 8MM to 20MM pounds per year.
Wastewater
The plant review of the aeration design for Pond 3 was completed. The estimate should be complete in October. The AFE will be sub mitted immediately upon budget approval.
Stream surveys of flow rates and oxygen levels were conducted on James Creek. Algae seems to be a major factor in the dissolved oxygen levels of the creek.
Fat-head minnows have been placed in Pond 5 for a test to determine if the pond is habitable for algae eating fish. After an adjustment period of one week, the fish appear to be doing well. Cooling Tower
Options for increasing cycles in the cooling towers are being looked into. This project has been focusing on quantifying blowdown. A plan for optimizing treatment will be determined after the new water plant comes on line.
VAB.0001189119
ABERDEEN CHEMICAL PLANT
MONTHLY PROGRESS REPORT
CAPITAL EXPENDITURE STATUS
M.L. CARTER SEPTEMBER REPORT
1992 F.Y. CAPITAL EXPENDITURES (MS)
VARIANCE
ACTUAL
BUDGET
MS %
Month
231.0
192.0
+ 39.0
+20.3%
4th Qtr.
482.5
479.0
+ 3.5
+ 0.7%
YTD
3337.1
3034.0
+ 303.1
+ 9.9%
Actua1 Expenditures - Expenditures in September were $39.OM more than the plant's budgeted expenditure forecast approved in the Fourth Quarter Budget submitted in June FY92.
September FY92 capital expenditures were 20.3% more than the plant's budgeted expenditure forecast, while overall expenditures for the Fourth quarter were 0.7% more than the 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.
Total Expenditures for FY92 were 9.9% more than the plant's forecast submitted in June FY92.
Quarter Budget - Current Quarter Expenditure Forecast as submitted and approved for the current quarter capital budget.
YTP Budget - Total of current and previous quarter approved budgets.
Forecasted Expenditures - The budget has been submitted for FY93 and 1st Quarter FY93, currently waiting for approval.
VAB.0001189120
ENVIRONMENTAL - K. G. Akins
Water
All wastewater discharge parameters were met for the month of September. Data collection for James Creek flow modelling was completed in September. This included water sampling for dissolved oxygen, BOD, and a time of travel survey to determine average stream velocities. The modelling should be completed in late October.
VCM Plume
The MDEQ requested that Vista submit a detailed work plan on further investigation of the vinyl chloride contamination of the shallow groundwater at the Aberdeen Plant. This work plan will be submitted for MDEQ approval in early October.
Waste
Waste shipments during the month included: Fifteen drums of stabilizer spill to Fisher Industrial Service in Gadsden, AL. m A bulk shipment of floor sweepings to Chemical Waste Management in Emelle, AL.
VAB.0001189121
ENERGY CONSERVATION J. A. Rodron
I. Energy Conservation Data A. Unadjusted EUI B. Adjusted EUI C. BTU/lb. Product D* Total Energy Consumption MMM BTU
II. Boiler Operation
No. 1 No. 2 No. 3
September 1992
(6.9)% (6.7)% 2763 134.7
Fiscal YTD
(13.0)%
(12.1)%
2909 1611.1
Combustion Efficiency %
September 92
Fiscal YTD
82.4% 83.4% 83.6%
83.3% 83.5% 83.3%
ABERDEEN ENERGY EFFICIENCY
3600
BTU/LB TOTAL PRODUCTION
3400
3200
3000 m
2800 i-- CD
2600
2400
2200
2000
JAN B7
JAN 88
JAN 89
JAN 90
JAN 91
JAN 92
JUL 87
JUL 88
JUL 89
JUL 90
JUL 91
JUL 92
MONTH
VAB.0001189122
*
k
ttttmam resource report
flRP^BlfBBR. 1992
PBRSOMBL - J. B. Beall
EMPLQYMBliT
None.
PROMOTIONS /TRANSFERS
Roger Crain - Engineering Department - Chemical Engineer transferred to Lake Charles LAB Plant as a Process Engineer.
Joseph Ganc - Engineering Department - Chemical Engineer transferred and promoted to Houston, Texas as a Process Engineer.
Timothy Arbeiter - Laboratory - Manufacturing Chemist transferred to Lake Charles Chemical Plant as a Group Leader - Control Laboratory.
Greg Norman - Engineering Department - Mechanical Engineer promoted to Project Engineer.
George Prillhart - Vinyl Department - Vinyl "A" Operator promoted to Vinyl Lead Operator.
Chris Gilreath - Vinyl Department - Vinyl "A" Operator promoted to Vinyl Lead Operator.
Ricky Clay - Compound Department - Compound Utility progressed to Compound Operator.
Deevie Rambus - Maintenance Department - General Mechanic "A" transferred to Instrument Technician "B"
RETIREMENTS
None.
VAB.0001189123
Human Resource Report: X992
TERMINATIONS/RESIGNATIONS
Virginia Belk - Plant Nurse - Termination due to reduction-inforce.
Marvin L. Keaton - Compound Department - Deceased.
TO/PROM r.mm ny ABSENCE
R. Danny Flippo - Vinyl Department - Vinyl Lead Operator Union Leave of Absence.
VAB.0001189124
ABERDEEN PLANT
gHPl'TOTOT Salaried Hourly Temporary
SUB TOTAL
L.O.A. TOTAL
234 236
DEPARTMENTS
#EMPLOYEES
WAREHOUSE GENERAL PLANT MAINTENANCE | LABORATORY 1 COMPOUND I VINYL I PLASTICIZER 1 SUB TOTAL 1 SALARIED
15 10 36 22 35 32
5 155
77
MF
9 5 8 4 22 11 2 61 6
0 0 0 1 1 2 0 4 18
. 1992
NgW HIRES Salaried/Transfer Hourly Temporary
TOTAL
FYD
%M
s
60% 50% 22.2% 18.2% 62.9% 34.4% 40% 39.4% 7.8%
%F
0 0 0 4.5% 2.9% 6 3%
.
0 2.6% 23.4%
n
DEPARTMENT TURNOVER
MO. FYD
0
0
02
03
01
13
02
00
-
ANN.%
0 20% 8.3% 1 4.5% 8.6% 6.3% 01
APPLICATIONS U Month
FYD | Minority 1 Female
No. i 00 00 00 00
PLANT TURNOVER Hourly Month
FYD Salaried Month
FYD
No i
1 6.5%
7 4.5% 4 5.2% 6 7.8%
VAB.0001189125
mmivipmh
VAB.0001189126
P rin te d
10/06/92
AII O)
II C
ii ?41
DEPARTMENTAL SUMMARY HOURS REPORT
........... MONTHLY .............
V
i i
P rin te d
10/06/92
DEPARTMENTAL SUMMARY HOURS REPORT
............... YEAR TO DATE ..................
CM | 1
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VAB.0001189127
f r
ADMINISTRATIVE SERVICES - D. A. Barclay
Safety
There were no reportable safety Instances this month.
Quality
All teams et during September to review progress on their projects.
Futures
YTD
Natural Gas
<$34,092.64>
Statistics
Processed
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
Month
1,060 7
$471.47 80 61
197
FT9 2 Y.T.P.
12,783 181
$34,028.58 1158 2140 2310
Packaged Finished Goods Ending Inventory
Sent.r 92
(Decrease) /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 W/house
3,995,394 144,706 312,000 63,607 84,469 632,625 261,850
1,222,700
100
242.701 6,960,152
4,425,368 163,134 333,521 51,829 27,617 477,492 88,737
1,337,050 100
180.553 7,085,401
429,974 18,428 21,521
< 11,778> < 56,852> <155,133> <173,113>
114,350 0
< 62.148> 125,249
10.76 12.73
6.90 <18.52> <67.31> <24.52> <66.11>
9.35 0
<25.61> 1.80
Bulk Finished Goods Ending Inventory
im-t'W
Bent..*92
(Decrease)
%
/Increase Change
Compound "A" Grade Compound Offgrade Rigid "A" Grade Rigid Offgrade Resin Type I Resin Offgrade
Total
858,815
0
876,709 56,050
8,280,950 924.750
10,997,274
1,330,021 0
801,942 0
10,688,058 2.379.251
15,199,272
471,206
54.87
0 0.00
< 74,767> < 8.53>
< 56,050> <100.00>
2,407,108
29.07
1.454.501 157.20
4,201,998
38.21
VAB.0001189128
ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS SEPTEMBER 1992
-SHIPMENTS BY PRttUCTS-
PUBL1C
RES1N-BULK RESIN-PACKAGED
12,404,400 684,394
FLEXIBLE COMPOUND-BULK
492,660
FLEXIBLE COMPOUND-PACKAGED 3,085,334
NEW BUSINESS
14,328
RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED RIGID COMPOUND-PELLETS
460,980 371,789
0
TOLLING - BULK TOLLING - PACKAGED
0 0
PLASTICIZER
85,680
TOTAL
17,599,565
-SHIPMENTS BY MODEBULK:
SEPTEMBER* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
RAILCAR
157 13 7 1
TOTAL SEPTEMBER
178
MONTH
IPT/ITC EXCH/TOLL
16,668,650 342,250
0 0
2,231,100 60,835
0
0 0
0
981,600 83,221 0
0 0
0 0 0
0 0
291,300
0
20,658,956
S3S
CUSTOMER PICKUP
COMMON CARRIER
10 21 0 12 27 07
12 47
07:50 AM 14-0ct-92
YTD
PUBLIC
IPT/ITC
EXCH/TOLL
207,341,609 213,653,410 6,489,640 3,899,150
5,834,580 25,740,590
36,419,077
495,177
0 0
0 0
196,208
1,981
0
12,581,590 4,993,751 0
6,941,250 760,945 0
0 0
0 00 0 00
250,740 6,948,680
917,400
274,107,195 258,441,183
917,400
SZ=S=SSSBSSS3SCS&Stt3SSSSSSSSSSSSSSS3
TOTAL
188 25 16 8
m
237
*YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
TOTAL YTD
PACKAGED:
SEPTEMBER* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
1,998 147 83 40
155 402 0 144
20 133 0 28
2,268
175 707
E3I333S3838WSfe 33883888X3X3 S3S8883333S 88833333333 3SS3388S38S3338S83388833
CUSTOMER PICKUP
COMMON CARRIER
TOFC AIR/UPS
AIR/UPS
2 36 0 0 18 77 0 0
4 11 0 0 0 100
0 0 0 0
2,555 291 236 68
3,150
TOTAL
38 95 15
1
TOTAL SEPTEMBER
24 125 0 0
0
149
YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
36 301 0 0 229 991 0 0
27 150 0 0 0 100
7 23
1 0
344 1,243
178 1
TOTAL YTD
292 1,443 0 0
31
1,766
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(Thousands o f lbs.)
10/91 12/91 02/92 04/92 06/92 08/92
PKG'D PRODUCTS INVENTORY
wmmmmrn
VAB.0001189B1
#
laboratory - J. M. Edwards, J. R. Williams
. Safety
There were no safety incidents in the Laboratory during September.
B. Customer Contacts
Jeff Almendinger and Wayne Crandell from Northwire visited the Plant for a tour and technical discussions.
C. Customer O.C.Problem Reports and CBR's
9/02 Armor Bond. Sardis, MS
The customer complained of red and lavender colored resin in a railcar of 5385 resin.
9/07 Triangle Wire & Cable. Slkeston. MO
The
customer complained
of poor
dispersion of raw materials and
pluggage in screen paks using the
35852 compound.
Analysis of the
samples showed the contaminants to be
lead, calcium, clay and titanium.
9/09 Klockner Pentaolast. Gordonsville. VA
The
customer complained
of high
levels of contamination in a railcar
of 5305 resin using a slurry test
method. The contamination was within
specification using the syntron test
method.
9/16 Donnelly Corporation. Holland. MI
9/18
The customer complained that bulk shipments of 48451 compound were sent without a co*shipment sample. One shipment had two lot numbers and another shipment had no lot number.
Silyerline Plastics. Ashyille. NC
The customer complained of finding a chunk of die cast aluminum in a debox resin shipment. The piece of aluminum was from a truck accident.
VAB.0001189132
LABORATORY - Continued
C. Customer Q.C. Problem Reports and CNR's - continued
9/24 Bnsolite. Mishawaka. IN
The customer complained of fisheyes and glassies in a railcar shipment of 5385 resin.
9/25 Essex Croup. Llthonia. GA
The customer complained of experi encing a drop in pressure in their process and a grainy surface on wire made with 5415 in UTCX 46492.
9/28 Northwlre. Osceola. WT
The customer complained that a box of 35852 Natural was shipped instead of the order for 38552 Natural.
D. Product Waivers Issued
Customer
Available Plastics
Product 80273G WHT 110
Reason Torque Rheometry
No. 1 H/T
Vista Performance Polymers - Mansfield
5395
Particle Size
1 R/C
E. RVCM of In-Process Samples
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 September, 1992.
Reactor Slurries
Drver
5265
5305
Number of Samples Average RVCM, ppm
924 47
29 0.165
72 0.133
k
VAB.0001189133
LABORATORY - Continued
F. RVCM of Shtcaent Samples
The following is a summary of the residual VCM analysis of shipment samples for the month of September, 1992.
Product
Umber of Samples
Average RVCM. ppm
5225 5265 5305 5325 5385 5395 5415 5416 5465 Debox Pond Dry Blend
12 53 122 16 36 24 74
0 0 0 0 0
0.692 0.083 0.079 0.069 0.087 0.030 0.039
G. Flexible Compound
SmMimrv
Adjustments M Lbs.
Hardness Color Hard Particles Heat Stability Contamination Dicing Mischarge Metal
32.0 175.0
5.0 Totals 212.0
<0.05> <2.66>
<0.08> <3.23>
H. Rigid Compound Quality
Rejections
M Lbs a
81.1 31.7 34.2
3.4 3.0 6.0 6.0 9.0 174.4
<1.23> <0.48> <0.52> <0.05> <0.05> <0.09> <0.09> <0.14> <2.65>
Torque Rheometry & Color Total
Rejections M Lbs. <%>
3.8 3.8
<0.27> <0.27>
t
VAB.0001189134
VAB.0001189135
SAMPLE SHIPMENTS SEPTEMBER 1962
RESIN Ship Date
9/14/92
9/16/92 9/25/92
Product 5225 5305 5385 5415 5416
5395
5385
Amount 101be. 10 lbs. 10 lbs. 10 lbs. 10 lbs.
50 lbs.
20 lbs.
COMPOUND
Ship Date 9/02/92
Product 35852 NAT
9/09/92
38401 BLK
9/09/92
57121 WC 327 58831 CB 50
9/06/92
57462 BLK 58031 WC 328 58831 CB 50
9/10/92
PLENEX 1275
9/10/92
PLENEX 1200 PLENEX 1250
9/22/92
56961 BLK
9/24/92
PLENEX 1200 PLENEX 1250
Amount 50 lbs.
50 lbs.
50 lbs. 50 lbs.
100 lbs. 50 lbs. 50 lbs.
100 lbs.
100 lbs. 100 lbs.
1500 lbs.
50 fbs. 50 lbs.
PLAST.
Ship Date 9/29/92
Product 61 OP
Amount 2 X 55 gal.
Customer EVC AMERICAS INC.
Intax AKZO Chemical
Customer R&D - Austin CommScope Inc. SunSoft Corp.
-
Terhorst Mfg.
BICC Cables Corp. Wallingford Wire & Cable
Winders & Gelst ALLWIRE
Customer Conex of Georgia
Ship Mode Airborne
UPS UPS
Ship Mode UPS UPS UPS UPS
CC CC CC Airborne
Ship Mode CC
VAB.0001189136
SAMPLE SHIPMENTS SEPTEMBER 1992
MfSC.
Ship Date________ Product
9/09/92
Vent Dust
Amount_______________ Customer_________
2 lbs.
Lakeland Chemical & Plastics
Page 2
Ship Mode UPS
VAB.0001189137
NUMBER OF INJURIES
A
ABERDEEN CHEMICAL PLANT INJURIES
(Twelve Month Running Totals)
MONTH
TOTAL INJURIES --OSHA RECORDABLE
VAB.0001189138