Document bBBog5NYeMK7Lg5V808barejZ

T. H. Huffman Interoffice Communication jhir l*J-- From: Date: Subject: d. C. Skokna January 17, 1989 ABERDEEN MONTHLY PROGRESS REPORT - DECEMBER, 1988 Safety There was one first aid and one recordable case reported during December. As of December 31, the plant's employees had worked 3467 days or 4,539,724 manhours since the last lost time injury. Kev Statistical Information PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI %) Fixed Cost Variance, $M Variable Cost Variance, $M Variable Cost Price Variance, $M Variable Cost Efficiency Variance, $M Costs December 38.7 92.1 95.8 1.0182 6.6 96.7 5.6 99.9 1.7 97.7 (4.5) (57.4) 520.2 400.1 120.1 Y.T.D. 115.2 91.7 95.7 1.0165 19.0 94.2 16.8 99.9 5.3 94.5 (2.6) (136.2) 1420.8 1393.0 27.8 Fixed costs in December were above budget due to payroll, which was high due to holiday pay and staffing salaried positions sooner than was budgeted; MM&C, which was caused by early completion of some budgeted projects as well as completion of several unbudgeted projects; and moving/home assistance clearances. These were offset somewhat by lower than budgeted outside professional service charges. Variable efficiency costs were favorable due primarily to good operation of the dry blend unit. mmiinp--ffnittin........................................................................................................................................................................... VAB.0001190635 DISTRIBUTION COVER LETTER ENTIRE REPORT Houston J. D. Burns X R. T. Ferrell X T. H. Huffman X C. J. Matson X D. F. Harman H. R. Flammer X X R. R. Smith X K. J. Eggers X R. H. Gerlach X Ponca Citv S. E. McGuire X R. L. Poe X H. J. Hall X Oklahoma Citv H. G. Garrison X LCVCM Plant R. A. Conrad X LCCP Plant J. Friend X LCLAB Plant J. W. Ware X Baltimore L. R. Bauer X Hammond J. B. Maher X Blane C. R. Miller X Premiere P. L. Foote X Aberdeen RWS/DCS (File Copy), PJK, JEN, DWH, TFL, JEB, HGC, JEL, REP, BLT, RBN, SCH A VAB.0001190636 T. H. Huffman 1/17/89 Aberdeen Monthly Page 2 s Report - December, 1988 QMS Fifteen people group will goals. trained to be facilitators. This our teams in progressing on thei hosted a meeting of the Manufacturing The Aberdeen Plant Site Coordinators. involved in the 5305 Resin Several plant people were Quality Improvement Team. D. C. Skokna Plant Superintendent rah A Monthly disc/rah ***". .-dHIEi'l--: KU'h- r: -rt . . Olfei:: iL ... T t* me--------------- ---------------------- - VAB.0001190637 1 ' -I ir" 'p if ir m- I SAFETY - B. L. Trego, J. V. Uptain December Fiscal Y.T.D. 1989 Fiscal Y.T.D. 1988 First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 0 1 1 1 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 0 1 1 0 0 0 2 0 0 0 1 0 0 1 2 Non-Occupational Injuries Lost Workday Cases Days Lost 0 6 Safety Record Last lost time injury - 7/5/79 Days since - 3467 Manhours since - 4,539,724 On December 31, 1988, the employees of the Aberdeen Plant completed 3467 days with no lost time injury. Topics for the plant safety meetings during the month included: Winter Operation, Safe Use of Torque Wrenches, Yearly Review of Injuries, Planning for Safety, Hydroblasting Safety, and Maintenance Weekly Safety and Job Review. A i . 1KJ- 1*4 r.h: n:-- - ^IfiDronv' L-. E : --I r-fr-. ................-- f-, VAB.0001190638 A SAFETY - continued Chemical < PEL Number Percent > PEL________ Number Percent VCM Lead Total Particulates 73 100.0 16 100.0 3 100.0 0 0 0 0.0 0.0 0.0 Monthly Inlurv Summary Iniurv Class Department Description Compound Muscle strain, right upper back and shoulder. RWC Maintenance Fracture, 5th right finger. Hi i rii i-r . .ii-qUnJ +^ipi- irFi>pi = -KtUhPjUblH*11^11 : .<**-f'- VAB.0001190639 >..*11* Itk--1 I-.: |L, -.Y . .1^.: .{:r+. | .| ; i; > vvtfIT"'', i wrt. in-? ; T1 ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) O InD - Ip O Ip sjtynrNt jo yjywnN W 5: O <o o CO VAB.0001190640 TOTAL INJURIES 0 OSHA RECORDABLE A QUALITY DEVELOPMENT - D. W. Hollis General Plant Facilitator training was given to fifteen people. provided for all teams to help the team leader. Facilitators will be The Aberdeen Plant hosted a meeting for the Manufacturing Site Coordinators to share ideas on past and future QMP methods. The Plant Manager's Natural Team met once during the month to continue working on removing barriers to QMP implementation. Administrative Services Jack Little met in Houston on December 6, 7, and 8, to participate in the "OASIS" software demonstrations. American Software, Inc. and Cullinet Software, Inc. were scheduled to demonstrate test scripts by various members of the "OASIS" team. Mike Swierc met with the CQIP team in Lake Charles on December 8. Pat Wells attended the facilitator training session. Compound The Compound Superintendent's Natural Team met in December. The meeting included a review of last year's performance and departmental goals for this upcoming year. Each shift supervisor's natural team met in December. The "B" shift supervisor's natural team traced out and identified product transfer lines. Lab SQC techniques were used to examine the 1988 RP-421 WHT 110 data on shipments to Vycom. The data was used to exhibit product consistency in a customer call. Four of the six lab's natural teams met in December. Mechanical The Mechanical Superintendent's Natural Team met once during the month. The topic was Project Team Updates and Team Facilitation. The Engineering Team process flow chart was revised and will be issued for review in February. Process Engineering The Department Heads' Natural Team met in December to discuss recruiting and department training needs. A m-h art* :FL~(....... pflII111l|mrWHU m L TiC ' |. ti VAB.0001190641 QUALITY DEVELOPMENT - Continued Process Engineering - continued Two days of in-depth PVC training was conducted by R&D for the plant. Several process engineers were involved in a one-day facilitator training class. Vinvl The department's natural team met twice during the month to coordinate daily operations, discuss Klockner quality issues and action steps, review employee action team progress, and to continue work on the Quality Implementation Plan. The Railcar Cleaning Team has completed their activity and construction will soon begin on the cleaning system. The 5265/5305 Contamination Team's activities have been taken over by the "full time" Klockner Contamination Team. The Alcohol/Plasticizer Team has completed the alcohol unloading portion of their problem and have begun work on the plasticizer portion. The V-ll Dustbusters are continuing with their work on modifying one of the Sweco/activator systems in the rotary dryer area. P. J. Kober attended a meeting with Klockner personnel on contamination. A presentation was made to Klockner regarding the work Vista has done and will be doing in short and long term to improve in this area. The presentation included personnel from Manufacturing, R&D, Business Area and Marketing. The presentation was well received by Klockner. A :,p. si j | Lii.L ... .. ii i >p-pL .r* 11- -m. rl FttW-ctm aqu^ttiat-sti : 11c-. : i..;.i;.1i, r:.j VAB.0001190642 'i'-l -Ji- !i--,-fc-- t- ' I'fll r!:TL'TrJqirPJ>fc:! :H^!JjKfH;Ti-|JfiTjm>ipi.c|.-m(|il COST VARIANCES - D. C. Skokna Variable Costs Product December 1988 Variance. $M Efficiency Price Total PVC Flexible Compound Rigid Compound Plasticizer $32.6 20.6 83.3 ( 16.5) $120.1 $354.5 ( 3.2) ( 17.9) 66,7 $400.1 $387.1 17.4 65.4 50.2 $520.2 PVC - Efficiencies were essentially at budget. Flexible Compound - The variance was primarily due to product mix. Rigid Compound - The favorable variance was primarily due to product mix and good Ti02 efficiencies. Plasticizer - The variance was primarily due to low VRP production. Price Variances Item $M VCM $393.0 Alfol 610 55.1 610P 34.4 Colorants 19.0 VCM Freight 17.7 Natural Gas (42.2) All Other Price Variances (76.9) Total $400.1 Fixed Cost Variances m Payroll and Benefits MM&C Miscellaneous TI&D Clearances Total ($29.6) ( 47.8) 10.5 2.9 6.6 ($57.4) Payroll and Benefits - was above budget as anticipated below par salaried staffing did not happen. Salaried staffing has been above budgeted level (budget -- 75, actual -- 78). Also, overtime was high due to the Christmas holiday. MM&C - Some maintenance projects were completed ahead of budget. ................................ vnm**mw*u*\W*i* 'W-j...... Hiivwitfi.iiiiWwmiiftiii mpipfriW iinumm* m IIJMWMWIIWI" VAB.0001190643 mimfmwn i m minima win WFHnn^iwuwwmiir. nuum****. COST VARIANCES - Continued Miscellaneous Outside professional services were $23.5M favorable as PL&D work for the DCS project and the air modelling study did not begin as budgeted. Contract-operating was $14.8M favorable due to not needing an operating contract for the Coker water test run. Shipping costs were $12.3M unfavorable due to late processing of an invoice. This rail switching invoice should have cleared in November. r J - -r- . -.v.-i*- .-LI. -w-T.- , p..i--H-rv; s-i; , r: i!-a. t r:J:. i: |. l. : --i|. .-y. -j-ji . -ip,., , TTi . | p-ri-i; v.tt(g.irii:: -'N": .1 !: it? iirihrtio-^! ! -* i VAB.0001190644 1. i-,. . .... P. . tj .-Hr 3 1 p|| < n ; ' : 1!- r I it . JJ af JJ.t.: ti -> OPERATIONS AND MECHANICAL DEPARTMENTS - P. J. Kober, Ted Lyon, Ted Nickerson Operations/Mechanical Safety There was one recordable injury resulting in restricted duty in the Mechanical Department in December. A General Mechanic suffered a lacerated and fractured finger while working on the #6 dryer centrifuge. The injury resulted when a belt guard was inadvertently dropped during maintenance work. There was one first aid injury in the Compound Department during the month which involved a pulled muscle suffered by a Plasticizer Operator. The Vinyl and Yard Departments worked without injury in December. Monthly safety meeting topics included: winter operations and hazards, hydroblasting and hydraulic torque wrench operation and hazardous wastes. The Compound Department experienced one first aid case in December. (Final classification of this injury has not been determined at this time.) An employee strained his back while operating a large valve. The December monthly safety meeting covered concerns associated with hazardous wastes and included RCRA training. A .l . i -I : <t* H >-t ic-rthK -"=i fetai-*-1 VAB.0001190645 JAH >-iKMk- s:t *f:i:.t. |*i| ' TrttI* -^-- VINYL - P. J. Kober, C. J. McDonald General 1. 5305 was made in reactor D744 for a week. The reactor walls remained clean. Reactor dump slurry contamination was lower than reactors D700 and D745. Three and three-fourths railcars were produced. 2. Additional test of Coker water as charge water was performed this month. The conclusion is still that no buffer is needed. This concluded testing of the Coker water. 3. Dryers #4 and #6 were hydroblasted as part of 5305 contamination reduction testing. We now clean the dryers every other day as standard procedure for low molecular weight production. 4. The resin raw materials in the 744 account were valued at $433.1M. December YTD - Production - Daily Rate, M Lbs./C.D. - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor(#4-#8), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime % Reactor Downtime 38.7 1249 924 29.8 92.1 83.1 97.5 95.8 115.2 1253 2735 29.7 91.7 85.4 96.5 95.7 Hours Operational downtime (recovery scheduling conflicts, power failure, downtime to rinse chem wash tanks, New Module rinse/charge water conflicts, waiting on particle size data before charging, precharge and dump preparations for Coker water test batches, false charging 5305 ingredients for D744 5305 test, and manual preparations for D744 5305 dumps). 348.7 Maintenance downtime (hydroblast D745 reactor shell and condenser, hydroblast D744 reactor shell and condenser, no place to dump while fluid bed dryer screw feeder was repaired, AMS emergency kill system repairs, change VCM receiver inert vent line, chem wash tank level indicator repair, new unit F50 meter repair, change relief valves on D744 for 5305 test, install line from D744 to low molecular weight dump line, and miscellaneous instruments & valves.) 237.5 VINYL - continued Reactor Downtime - continued Total downtime was 586.2 hours. Drver Downtime % of Total Downtime Reactor limited production 79.7 Operational downtime (centrifuge plugging dryer cleaning, activator transfer problems, checking dust collector socks for leaks, flameouts, checking sifter screens, dust collector back-ups, and power failure.) 8.3 Maintenance downtime (fluid bed screw feeder, hydroblast #4 and #6 dryers, fluid bed screener repairs, Star valve repairs on #6 and #8 dryers, install permanent calcium stearate feeder on #5 dryer, low molecular weight slurry feed pump, and various activator and centrifuge repairs.) 12.0 Key Maintenance Work - D. A. Miller, J. B. Hegwood Reactor Area Reactor 744 was shut down for hydroblasting. The condenser which is normally drilled was also hydrobias ted. The hydroblasting of the condenser was done in order to evaluate the possibility of hydroblasting instead of drilling the condenser. It was determined that the reactor condeners could be hydrdoblasted effectively. This will reduce the amount of time required to do this job significantly. The old reactor unit rinse water pump was shut down for repairs due to a leaking seal. The shaft and bearings were replaced and the pump was put back in service. The old reactor unit's "B" recovery compressor was shut down for repairs on its shaft. The shaft was pulled, repaired and re-installed. The old reactor unit's "A" vacuum pump was changed out due to a leak in the case caused from excessive erosion. The new reactor unit's 901 vacuum pump was replaced due to a leaking case. New controls were installed in the vinyl unit control room for the new chem wash control system. The existing pneumatic temperature control system was replaced with a new electronic temperature control system. A --CP | p-.:hrt 3 * ! |I VAB.0001190647 VINYL - Continued Kev Maintenance Work - continued The chem wash backflush system was modified in order to optimize its performance. The Gould Modicon program was modified to prevent the reactor atmospheric vent valve from opening above 4 psig. This was done in compliance with an Employee Safety Action Request. There were ten major valves changed out in the reactor area during the month. A ' I" J-S.- I'Xjri ii:h .jriii .. . i.:, y.,!^ h. . |. t. -II-! !.. if. .tfltz iL ; i -f I** . , *#! Ki*-! -1 *1- :1- I^.T1 r i-(-.7: ;^.a :-.4 -!i- : VAB.0001190648 = 1- : i.- * '' I W;i. r> COMPOUND General All compound lines (including the dry blend unit and plasticizer) were down December 24-26 for the Christmas holiday. The first extended production of 38401 Orange compound took place on Line V. This production run extended over ten days and yielded approximately 400M pounds. Compound color was maintained consistently on target throughout the run. Operating Compound Production Davs Production fM Lbs.l Month Avg./Dav Fiscal Y.T.D. Line I Line III Line V Total 28 28 23 2092 3578 882 6552 75 128 38 6124 10422 2496 19042 Downtime Hours Line I - Product Changes - Transfer Problems & Limitations - Quality Problems & Control - Dicer Problems - Miscellaneous Maintenance Line III - Product Changes - Quality Problems & Control - Transfer Problems & Limitations - Mill Joint Repair - Miscellaneous Maintenance 59 12 10 10 8 Line V - W&P Maintenance - Product Changes - Orbitran Panel Maintenance - Miscellaneous Maintenance 41 32 20 9 A ntwxmmim Mumtmim wmwu^mi MmiliiiiEipij mmHI ........................................... .. VAB.0001190649 .... . ........................ . rtJ -Cry -I;:*. .!-.N- h. 1. I- -fc: 1 Ji|--C: J - i-rt- Iktft r-j * .L- .-V J H COMPOUND - Continued Operating Days Month Production (M Lbs.) Fiscal Y.T.D. Rigid Compound 28 5586 200 16790 Downtime Hours - Product Changes - Quality Problems & Control - Univox Problems - Miscellaneous Maintenance - Welex Problems 41 19 18 15 14 Operating Davs Month Production (M Lbs . ) Avg./Dav Fiscal Y.T.D. 1655 5340 Kev Maintenance Work - D. A. Miller, J. B. Hegwood - Several tubes that were leaking in the tank farm Glycol unit condenser were plugged to prevent further leaking. Also, the condensate line for the condenser was re-routed in order to separate the high pressure condensate system from the low pressure condensate system. This revision prevents the high pressure condensate system from leaking back into the Glycol heat exchanger. - A plate was installed around the charge station on Line III as part of a project initiated by the Lead Abatement Team. - After repeated seal failures on the phthalic anhydride transfer pump, a new bellows-type mechanical seal and steam jacketed gland were installed. To date, the new seal has performed well. - The Line V compounder was shut down by a failure of its DC drive control board. The DC drive control board was replaced and the Line V compounder was put back in service. - The blades in #1 Welex were changed due to normal wear. Utilities - The API separator was bypassed and drained in order to clean out as much of the settled particulates as possible. Number two boiler was painted and run on low fire periodically during the month. It was put back on line during the month and #1 boiler was put on standby. A ri+riMtli-'VrwJi SM'! ' '"f ' . sjl r i' "r> i . V vi " 'f ? ip. UU 1 l. mi-III: m V"- I VAB.0001190650 T:iI'-P-ifi . -d ;vK-tr:i.i.irf :S `Jh1- nlit COMPOUND - Continued Utilities - continued - After completion of the piping upgrades to the west propane storage tank and all of the mixed gas storage tanks, the plant was run on propane for approximately three hours in order to check the integrity of the upgrades. A * U :Lv ' M- t.rfF-n jHH'rN ^ *"! ssr+nttilwswttEBW Wrt^lUHtl l|rt> M VAB.0001190651 W*Usr*ci!*iHi 4> Lb-il-.-. I '44riKk^HniK-r.Lk-Mi:bHhiir> ENGINEERING - R. E. Polk, S. C. Hillman, V. L. Thornhill Projects In Development - General The Klockner Contamination Team completed Its investigation of contamination sources. A meeting involving the plant, Business Area, PED and R&D was held to establish goals for reducing contamination. Team findings and plans for improvement were presented to Klockner on December 20. 5305 In 744 Test Run Test production of 5305 resin in 744 reactor was successfully completed and a report Issued. The test showed that 5305 made in small reactors will meet our 5305 specifications. Customer trial of the resin still needs to be done. Lead Handling and Exposure Reduction A program has begun to reduce the amount of lead the color weigh room operator handles by rounding compound batch sizes to even bag weights of lead where possible. Thus far, twenty-six formulas have been rounded off to reduce color weigh room lead handling. Coker Water Test Run Two additional runs were tested in reactors 741 and 742 to evaluate the effects of chem wash on the sodium levels on the resin. Testing is complete and the test system will be dismantled and returned. A water balance is being prepared for designing the new Coker water supply system. Vinvl DCS A meeting was held with GED and plant personnel to review the timeline for engineering tasks needed to determine system costs. Chlorine Gas Monitoring System A design to install a chlorine gas monitoring system at the chlorine ton cylinder storage area was issued for plant review. Recruiting By the end of December, nineteen process engineering and thirteen mechanical engineering plant interviews had been completed. There has been one process engineering job acceptance and two mechanical engineering acceptances. All are scheduled to start work in midJ anuary. A THE Sft MODULE IS OPERATIONAL IWTH PUNCHLISTITEMS IN PR06RESS. DELIVERY OF THE REMAINING ITEMS ARE EXPECTED INJANUARY. CLOSED TO FIELD CHARGES IN JANUARY. CLOSED TO FIELD CHAR6ES IN JANUARY. cn cLUn uj x LU CO 3 UJ r-H UJ LU cn co o: o <c <n a ctnn cn uj cn & <x m ui cn cn uj txi or lu cn * UJ o cj cn uj uj co co cn i cj cn cn CD LU cn o cn cn rsi a or cn lu cn UJ CD h-- cj cn * or co cn to cn LU o uj cn UJ LU O WD (D D O scn OL CseD a(XCLDT cn hcn* g u xc UJ =3 cn ) UJ co c 3 ^ UJ cn a. cn mLU DC <LCUDL cn x . - -ii uj s 3Mfe cn Cl xc <3C a sc cn UJ cn or lu CD a UJ CD ui LJJ x UJ UJ LU 9*C LU cn cn m cn cn uj ^ LU LU cn LU or 3E LU CO * LU cn LU CO cn oc or cn LU LmUJ Cl. cn fll 1 cz o CD r LU oCDr CD CD c>n f 11 LU or xc UJ UJ 03 cn U, -Ji m CD LU DC CD cn UJ H* LUi CL XT O CD ULi fr--** UJ a*. CD LLUUJ OL. CXDT CD or co CD or iL. LU or CO CD or a* XC u a cn cn u cn uj cn x in ^ ac <=> Ui cn Z (O CL cn cn cn cn CD cn cn CO oLUr XQT, 3 Of <x sc sc cMn DC cMn SC Mcn y cn sc CMO sc <n cn u cn cn cn cn cn cl cn ca cn ci uj co CD cn LU LU O CD CD CD CD co cn co U) <t lu or cn u set uj cn cn cn cn co lu cd ae lu cn u) ax cn z d z cn sc cn cn cn cn cn *--* co cn a a. cn co lu LU CO cn CO cn LU CO cn or lu irs cn cn cn cj cn cd cn cn ILL CLUO tn LU CO ^5Hz LoD(UOr Ku-< uuj c>n cn 3c i cn CD LU CO CL i UJ cn CD CO K CL co UJ oc c>n~ cn cn >- to cn cn cn CJ cn XT XT cn cn cn cn CO CD UJ in im ui o 'i_____ ,, cn to LU UJ DD or CD cn cd cn lu o cr or io UJ ^ Ui lu in ui x; o cn uj OIX o > to a a. or LU UJ DD or Cl. in cn uj uj xr RESIN QUALITY IMPROVEMENTPROJECTS CRITICAL SPARE EQUIPMENT PROPANE TANK FARM REMOTEOPERATED VALVES PA FLUF CONTAINMENT F786/F557 H636 D667 6677 in -o CSI o in m OD LO ........ .. p -r '! * T !=: . r- <> ifJ-- -IT-... I-, . . rfJ v. . .................. h -c : ^:j-..Lkd(!:v .............. ... J h- I l]|ri' I 'M 1-K# - - p UD sO CD CD m cm CcnD m in * IT3 in in in in in in VAB.0001190653 li't^i'PTF'. .ir r -r n iT Hip: I-H : !-!!! n |* l(- s* :Tfr -i I'll > 1^.. ---- !-H 1- ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were within NPDES limits for the month of December. Air The annual VCM flange and valve survey was completed. A list of all the leaks found and their locations was issued. Seventy-one leaks were found. A bagging study was completed by Emissions Control Services. Twenty-one of the leaks found in the annual survey were bagged. An additional sixteen components (flanges, valves, etc.) were bagged as non-leakers or zeros. All of the data from these bagged components will be used to develop fugitive emission factors for the components in our plant. These fugitive emissions factors will then be used to calculate the total fugitive emissions for the plant. We are required to report fugitive emissions annually under SARA Section 313. A bleeder valve survey was conducted in the New Module area. Two bleeders were found to be without the required plugs. About one-third of the bleeder valves were repainted. Waste Management December waste shipments included: - Two bulk tanker loads of separator oil to Stauffer Chemical - One dump truckload of floor sweepings to Chem Waste Management - One truckload of reactor culls in super sacks to Sun Polymers In addition to these shipments, the API separator was bypassed and the solids/sludge was cleaned out of this pit. One roll-off container (20 cubic yards) was filled with the solids/sludge and shipped to Chem Waste Management. Gaylord box samples of pond #2 resin, stormwater pit #1 solids and stormwater pit #2 solids were sent to Sun Polymers and KREO Company in an effort to sell this material. We currently have about 20MM pounds of pond #2 resin and about 175M pounds in each of the stormwater pits. Annual RCRA training was completed for all four compound shifts. In calendar year 1988, 867M pounds of hazardous waste was disposed of at a cost of $52M. Miscellaneous Coordinated and attended In-Depth PVC Training course held at the plant. A VAB.0001190654 r :r*j|. I ENVIRONMENTAL - continued Updated and re-issued the Spill Prevention Control and Countermeasure (SPCC) Plan. Also, completed semi-annual inspection of dikes and trenches around potential oil spill areas which is required by the SPCC Plan. A <Xi * 't-= Vv. kj:j .ia LL I , IV .Y J ! .Ijll^P Jfr-' tfWWM h VAB.0001190655 Htfjunuy i H ib -tr I ->*?. 4r "n+sHtoitm' :f - irr i Kr nnT*if.*FTjiMfr;jJ*i tc- iukkit- t&VTXimmvr'* J-1 >u ENERGY CONSERVATION - D. A. Moore December 1988 Fiscal Y.T.D. I. Energy Conservation Data A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU -4.52% -4.18% 2543.96 133.48 -2.63% -2.23% 2496.13 389.94 This corresponds to anadjusted CMA of and an unadjusted CMA of 51.25% 39.44% 51.92% 40.56% II. Plant Energy Conservation Program A. Maintenance There were ten energy related items completed in December, 1988. Nine of these items were steam leak repairs. The remaining one was a steam trap repair. Ill. Boiler Operation Boiler Combustion Efficiency % Dec..88 Fiscal Y.T No. 1 No. 2 No. 3 83.44% (1) 83.20% 83.55% 83.57% 83.20% (1) Boiler #2 was not operated during the month * A VAB.0001190656 L'.t :CilMA<PI Ik*1 *** ................. ^ipinnuTT^Jr'l -- -- - -- t l o o o DC CD < - .......................... i :i::. i -t" -`Tj .vii HJ| II ' 11 HJ Qi/nB --ill-- i4iAi*p<*tr-:|-;. . . rr mf ui MONTH ------- 12 MONTH AVERAGE VAB.0001190657 HUMAN RESOURCE REPORT PERSONNEL - J. E. Beall EMPLOYMENT None PROMOTIONS/TRANSFERS Dale Barr promoted from Compound Operator to Compounder. Ricky Clay promoted from General Helper to Compound Utility. Maurice Evans promoted from Compound Utility to Compound Operator Phil Hall promoted from Compound Utility to Compound Operator. RETIREMENTS None TERMINATIONS/RESIGNATIONS Brian Aftergut Todd Haley Lee Lusk TO/FROM LEAVE OF ABSENCE None A ... fJ._ .. VAB.0001190658 ^ 1-`I- fc-i J'I HI T-H+Itr.p-Htsn-k| I -I- ' - 11 I -..Vi'i-!D*I! I- ! |-J 'I*! fc- v A Aberdeen, Mississippi Salaried Employees Hourly Employees Total Employees Employees (Hourly) New employees Terminations DEPARTMENTS Warehouse en. Plant Maintenance Laboratory Compound Vinyl Plasticizer PAR 16 13 41 24 40 33 5 78* 169 ZA1 DECEMBER, 1988 MONTHLY PERSONNEL REPORT Minority Employees Salaried Hourly 7 66 Total % 21 39% 2Q1 0 Hourly Min. Hired 0 0 % Min. Hired ___Q_____ Hourly Min. Term. 0 - .. % Min. Term. 0 # EMPLOYEES MIN. EMP. % MIN. NEW HIRES YTD TERM. YTD TURNOVER 16 7 12 7 39 10 24 4 40 26 33 10 52 44 __ 0 0 00 58 0 10 0 00 25 _Q 00 00 17 _ _ Q 00 00 65 _ 0___ 00 00 >i 30 0 00 00 40 0 00 00 Number of Applicants Month 0 Year to Date APPLICANT BREAKDOWN: // Minority 0 % Minority # Female 0 % Female 35 0 0 * Includes 2 Co-op Engineers '* ! t^Hi 1^.1 I ! .i-pwi-- r. II-I ; .-I.- |b 1 | 1 iufl h = -rl ^lr+. n* Tl- '* Hires (Hourly): Month Q Year to Date 10 Terminations (Hourly): Month l Year to Date 6 Overall Turnover .6% Projected Annual Turnover 3.6% i 1. ' .p-IUH-h i ^h r.l. , t- . i*.:. --n..k i VAB.0001190659 ?(-T. .............I * M-r-M 'hi' I1 1^ Bhili rf^^l ijt 1 1 -LA-nt .-i. w OVERTIME AND ABSENTEEISM E01 H Ui a H ><* ov vrv --i vcDn cn mf-H cn Oo> 0o0 CN cvn cn 00 CN Oo CCNN CN oa fl3 U to ui U HoCO a\ CN CN CN ruvn m CcOn fH in ccnn CN v mlO| o lu OJ oCN> CN ruvn ccnn mm om mcn Oo oo 0o0 CQ CN cn flfl ov c Oo OO OO 0iv0 o00 oo oo CN oo m 2U < -H CN l CO CT lu 3 O X 0) 4U u CO so m CN cCnN o> oo omo CN V m 01 X in XI < rv m 11 E MU CO E- cn Ui eo J= OX 01 E to tU lu CrvTv oo ON vcTn fXN) >wa- mCN CCNN o mf-t 01--01 oCN aun\ ci-Hn i--| <mr H un 0rrvv0 LlcuJn u 0O1J O><u LHo3xu . 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I't-' VAB.0001190660 d'lU: >* I1;' ULilar,. ADMINISTRATIVE SERVICES - J. E. Little There were no safety instances this month. Safety meetings stressed offthe-job injuries and extra caution during holidays. Cost Savings Savings due to competitive bidding were $8995 for the month, and $20,859 for FY1989. Savings due to prompt payment discounts were $1912 for the month, and $5974 for FY1989. The switchover to the new AT&T switch was completed December 29, 1988. Thanks to Judy, and pre-planning by AT&T, this was a smooth transition. Judy Frossard and Jack Little will attend an AT&T sponsored class on the new System 75 January 16-20, 1989. Internal Audit Vista's internal auditors arrived December 5, 1988, to conduct their scheduled operations audit - two weeks. An exit interview was held with them on December 16, 1988. The auditors should have a draft of their audit exceptions prepared by late January. We will review and comment before the final report is issued. A iL-.-f ---.r. |>: I-1 -i p L ' ' -T*- I"!: I| . u! ft"! 1/! 1 E1!' -tiY-ii- niiy *! ... ."I- :l- -! :: r.tib - vNCHiHnlji? "Ml m -N- in-- t fr f.'Hbn'-tffllK.rK't ijJJ'Ihl'ia- 1 ! |l "#1; :i VAB.0001190661 :l, - -I'l .(. J'-. L- .f. t.."f > . ir:> !::: ir -j -i. | . .||irt I SHIPMENTS BY PRODUCT - M LBS. RESIN PLASTICIZER DRYBLEND COMPOUND NUMBER OF SHIPMENTS BY MODE: TOTAL Dec. 1988 27,272 631 4,213 6,552 38,668 RESIN-Bulk FISCAL YEAR-TO-DATE 82,543 2,135 13,423 21,634 119,735 A TOTAL TOTAL DEC. OCT. NOV. . ti p- -.-i ^ l,JVI T "f FF 'i-- T i ' 'i- VAB.0001190662 P i ' IL. ;! ( ir LABORATORY - H. G. Coleman A. Safety - The Lab operated Injury-free this month. There were no Incidents the entire calendar year. The monthly meeting, presented by H. G. Coleman, included a review of the FY89 Safety Statistics for the plant and a "Safety Seconds" film entitled Pre-Flight Your Job. B. Customer Relations Customer Contacts 12/1 - Brian Harrison visited Vinylex in Knoxville, TN, along with M. C. Manion, M. Washington, and C. 0. Yoder. Topics discussed included color and dry blend Q.C. 12/8 - Brian Harrison accompanied Tom Davis to Vycom to discuss product consistency of RP-421 and Aberdeen's production and Q.C. operations. 12/9 - Brian and Tom visited United Thermal Plastics to discuss several processing problems this dry blend customer was having. Requests for Corrective Action Date Customer Product Reason 12/5 Master Halco 45541 Natural Stringers, zippers Customer Problem Reports There were no customer problem reports received this month! Waivers Issued Customer Product Reason No. Essex 5415 Bulk density 1 R/C Hayes Dockside 80273G 40 mesh 1 R/C Southwire 5415 Bulk density 1 R/C RVCM Summary RVCM of In-Process Samples The following is a summary of residual VCM results on inprocess samples. None of the reactor daily average 400 ppm RVCM during the month of December, 1988. A <!' rt - : - f4 **41.4 I IMil i Jib'Ll -t-| tTn-. -nr fmhi rptcwi<HHWMKif.rur. ifHwnHhhw*immmwi > =L-tjLM.n.Hi|y > VAB.0001190663 l* s m V uWWHUli^iPliiWXi. imi ai w** LABORATORY - continued C. RVCM Summary - continued Reactor Slurries Drier 5265 5305 Number of Samples Average RVCM, ppm 923 133 25 0.400 96 0.315 RVCM of Shipment Samples The following is a summary of the residual VCM analysis of shipment samples for the month of December, 1988. Product Number of SamDles Average RVCM. ppm 5265 5305 5385 5415 5465 Dry Blend Debox Pond 20 117 55 61 0 23 23 0 0.178 0.143 0.313 0.059 -- 0.084 0.141 -- D Resin Process Capabilities 5265 5305 5385 5415 Bulk Density Inherent Viscosity L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Drytime Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) 1.28 0.24 3.05 1.78 1.83 4.44 -- 0.92 -- -- -- ----------- ---- E Compound Oualitv Summary 2.00 0.76 6.89 4.00 2.33 4.89 1.37 -- -- -- -- 2.52 0.77 6.17 -- 2.00 3.89 -- 1.83 0.67 -- -- 13.2 0.39 0.67 4.44 -- 2.67 4.00 0.67 3.56 1.67 1.62 0.90 1.2 Adjustments M Lbs. Hi Hardnes s Color/Clarity Hard Particles Dicing Cross contamination Total 7.0 -- -- -- -- 7.0 (0 Ml) -- -- -- (0 .11) Rejections M Lbs. I%1 ----_ 24.4 56.8 12.8 2.3 96.3 - - * (0.37) (0.87) (0.20) (0,Q4) (1.47) A M4i i.ni* bn- v.n ^IrcT^Mrriristf.'-rrfiaf-t*TY|^j1pr^i!rq;j||pjTTi: ||>r,ir i-;ir"T|`^ ' , ;|JI -*! -lyju,..., hk-rsin.- VAB.0001190664 '- - ^-.|.^*ir. ir*rl 1H: i .-ji|t*.. kt COMPOUND - continued F. Drv Blend Quality Summary Rejections M Lbs. (%) Long stability 4.2 fO.08^ Total 4.2 (0.08) Compound SPC Test Results A n X 3 (i 38401 - Hardness - Specific Gravity - Hard Particles (20") 52 52 52 82.7 1.376 22.3 0.97 0.008 4.4 35031 - Hardness - Specific Gravity - Hard Particles (2') 50 48 51 49.7 1.373 4.9 0.74 0.007 1.9 Mill Temperature Oven Temperature 52 325.5 1.2 All readings 204 degrees C. 5415 Control Resin Test Results A n X 3<r~ Moisture 61 0.156 0.024 Drytime 31 5.02 0.51 Particle Size - 60 mesh 56 1.24 0.52 - 80 mesh 62 30.11 6.16 - 100 mesh 62 34.12 1.13 - 120 mesh 62 20.86 2.25 - 140 mesh 62 7.12 0.95 - 200 mesh 62 5.12 1.37 Pan 62 1.10 0.40 Bulk Density 31 0.5051 0.0042 Color - L 31 100.43 0.50 A 31 -0.12 0.37 B 31 2.20 0.61 Flow Time, sec. 31 7.95 0.68 Hard Particles, 7 min. 61 5.31 2.22 Inherent Viscosity 18 1.0122 0.0143 I. Miscellaneous 1. Richard Williams, Billy Sizemore and Dave Cox attended both the rigid and flexible compound training classes at the Best Western on 12/7-8. Harold Coleman attended the rigid class only. Brian Harrison presented his color training presentation as part of the rigid class. mu*-**m-wii. = gfffrUBwnnmft-fiafcatggniiffT line VAB.0001190665 LABORATORY I. Miscellaneous - continued 2. Brian Harrison prepared 80273G controls, including +/-20% of master batch, for Premiere Polymers to use on their new dry blend unit. 3. Brian Harrison completed an evaluation of Kemira OR-450 and OR-460 and approved them as substitutes for CR-834/R-101 in all non-weatherable applications. Awaiting PRS results of QUV testing for approval in weatherable applications. Brian Harrison completed the color match for Lamar's experimental charcoal gray formulations. He also worked on reducing the cost of the orange colorant used in 38401 0RG61 for Corelmex from 7.4 to 0.95 cents per pound. 5. This was "meeting month". Brian attended the Rigid Compounds Steering Committee meeting on 12/15. Harold Coleman attended a CTTC meeting on 12/6, a Resin Business Team meeting on 12/8 and a 5305 Quality Improvement (Klockner) meeting on 12/13. Richard Williams gave a Lab SPC presentation at the Site Coordinators meeting on 12/13. * VAB.0001190666 f- I X!_#i: .. ji i i j i i'i :i: vl. 'L. ii r ?: j H " . -i- t - %.jp. ;>>. , * 1 ruSiDin Ship Date 12/02/88 12/06/88 12/06/88 12/06/88 12/12/88 12/15/88 12/16/88 DECEMBER 1988 Product 5415(OG) 5415(OG) 5415(OG) 5415(OG) 5415 DEBOX Resin 5415 Amount 2X2 lbs. 2 lbs. 2 lbs. 2 lbs. 50 lbs. 2 lbs. 5 lbs. Customer Hoffman Plastics Tecknor Apex Color Rite Central Syntech Decorative Coverings Osterman & Co. JPS Elastomerics COMPOUND Ship Date 12/07/88 Product 48562 BLK Amount 50 lbs. Customer ACF Industries DRY BLEND Ship Date 12/19/88 Product 180-31 WHT 138 Amount 1300 lbs. Customer Astro Plastics VAB.0001190667