Document bBq2m4bO5jKYypGaVdE48Rke6

To: T. H. Huffman From: Dole: Subject: D. C. Skokna May 23, 1991 ABKRDESH MOHTHLY PROGRESS REPORT APRIL, 1991 There were no Injuries recorded during April. As of 4/30, the plant employees have worked 4,317 days (5,768,552 manhours) since the last lost time injury. FY1991 Kev FVC 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 Operations April 37.5 85.6 98.1 1.0074 4.7 98.6 5.3 98.9 1.3 80.4 < 10.2> 99.2 14.6 Y.T.P. 278.0 87.8 98.4 /f 02OJ 30.2 97.0 33.9 99.5 10.9 84.3 < 8.3> 153.1 < 85.8> The remaining rotary dryers and the fluid bed dryer were success fully converted to the new VCSM control system. The new water decalcification system was started up in the Old Module. Control of costs and inventory continued as high priority in the compound units. Costs Fixed costs were essentially at budget. Variable costs were favorable due primarily to low VCM consumption (likely caused by RCS scale problems giving inaccurate railcar weights). VAB.0001189711 T. H. Huffman 5/23/91 Aberdeen Monthly Progress Report Page 2 - April, 1991 am m Vista achieved Southwire's highest supplier rating. Excellent Supplier, for the period May 1, 1990 to April 30, 1991. m The Plant Accountant's Natural Team made its manage ment presentation. Their project will reduce mail costs to Houston by 55%, and also recommended other measures to reduce mail costs. The new NPDES permit covering the period to April 8, 1996 was received. It has two sections with more stringent limits becoming effective February 1, 1993. We are working with the USGS to prove that the tenyear, seven-day low flow in James Creek is not zero during winter months. This data could lead to less restrictive BOD limitations in 1993. i Vista and Conoco met with the State (MDEQ) to discuss the proposed plan to remove the resin in pond 2. MDEQ was very receptive and they plan to issue a letter of approval. D. C. Skokna Plant Superintendent rah m k % VAB.0001189712 Houston J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Garlech R. D. Gamblln R. L. Foe X H. J. Hall H. D. Garrison UfYQt Flint P. D. Carrico y?gg ,nm% LCLAB Plant J. Friend J. V. Ware X Hammond L. R. Bauer J. Pavao X X Blane C. R. Miller P. L. Foote Aberdeen RVS/DCS (File Copy), TJA, JBA, JEB, JME DAB, DAM. RBN. JEM. JDO. BLT A X X X X X X X X X X X X X X VAB.0001189713 JPPMVP T - B. L. Trego First: Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases April 0 0 0 0 Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 0 0 0 0 0 0 Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 0 0 0 0 0 0 0 Lost Workday Cases Days Lost Fiscal Fiscal Y.T.D. 1990 43 00 20 45 79 01 00 JL 15 35 11 23 32 31 02 2 15 16 Last lost time injury - 7/5/79 Days since - 4,317 Employee hours since - 5,768,552 On April 30, 1991, the employees of the Aberdeen plant completed 4317 days with no lost time injury. The main topic for the plant safety meetings during the month was "Respirator Training". * A drill was held on April 30 which featured a fire in the east warehouse. Response was excellent by involved workers. VAB.0001189714 gATKTT - Continued Routine dosimetry results for the month were: Chemical VCH Lead Total Particulates < Wt^nl?**T 79 5 4 100.0 100.0 100.0 >_________________________ Wtiwhftr 0 0 0 No injuries were reported. ooo A VAB.0001189715 T. J. Arbeltar All of the plant's natural teams met during April. Some of the natural team highlights for the month were: The Plant Accountant's Natural Team made a present ation to Management on April 10. The team's goal was to develop new mail procedures that would re sult in a reduction in mail costs without sacri ficing the needed level of service. The team recommended a change from routine over night delivery for Houston mail to Airborne two-day service. This change will reduce our mail cost to Houston by approximately 55%. Overnight delivery to Houston is still an option, but is to be used only in "emergencies". The team also identified cost savings by shipping packages under five pounds via U. S. Postal service and over five pounds by UPS or Airborne. Lastly, the team identified an annual savings of $1.2M by having payroll checks delivered on Monday versus Saturday. The team projects an annual mall cost reduction of $4M for Aberdeen with no sacrifice in efficiency. The team hopes other Vista locations will be able to identify similar savings. The Maintenance Superintendent's Natural Team continued work on their project to improve the stocking of critical spare parts. The Maintenance Electricians Natural Team selected their next project - improvement of the lighting in V-10 and V-ll buildings. The team is planning an experiment to test the longevity of various lights/ fixtures under high vibration conditions simulating those found in various locations of the plant. The Plant Manager's Natural Team has accomplished $50M of annual continuing cash flow improve] ient toward the goal of $1MM. The team is also visiting the past project of improving communica tions to employees. The team is gathering feedback from employees on the quality, frequency and over all effectiveness of communication from plant man agement .  Continued Vista has achieved Southwire's highest supplier rating, Excellent Supplier, for the rating period May 1, 1990 to April 30, 1991. Southwire management will present an award to the Aberdeen employees in the coming months to commemorate this achievement. \ VAB.0001189717 Product PVC Flexible Compound Rigid Compound Plasticizer Total $ 69.1 110.9 163.4 < 0.5> $342.9 $99.5 5.2 9.3 <14.8> $99.2 $627.7 < 263.0> < 169.4> < 60.2> <$135.1> Total $796.3 < 146.9> 3.3 < 75.6> $577.1 PVC - Consumption of VCM was below budget - this is likely due to inaccurate car weights provided by the KCS as the cars leave Lake Charles. Compound - Both rigid and flexible compound efficiency variances were essentially at budget. Raw material consumption was above budget. VCM i Natural Gas Pigments, Colors m Electricity i 601P to Flexible Compound Alfol* 610 m Resin to Flexible Compound m Resin to Rigid Compound Other Price Variances Total $667.4 14.7 < 18.1> < 30.8> < 33.2> < 62.2> < 71.7> < 133.9> $135.1 Fixed Cost Variances Payroll and Benefits MM&C Miscellaneous TI&D Clearances Total <$ 62.7> 45.6 29.7 2.8 < -Q.,8> $ 14.6 r VAB.0001189718 Continued Payroll,and Benefits - The benefit clearance was $27.5M unfavorable with hourly payroll being $40.2M unfavorable. Overtime in the Vinyl unit was high due to the VCSH startup. Due to a VMS problem, maintenance payroll has been overstated by approximately $100M Y.T.D. We are working with the Accounting Department to correct this problem. MM&C - Activity continues below budgeted levels to keep expenditures low. \V Outside Professional Services - <$16.5M> Processing Supplies - $11.6M Shipping Costs - $10.0M Warehouse Gain - $20.1M mm * VAB.0001189719 Wi -u- J. D. Olson, D. E. Inittig The Vinyl Department had no first aid case or OSHA recordable injuries during April. The monthly safety meeting topic was "Respirator Training." General 1. Dryers #6, #7, #8 and the fluid bed dryer were converted to the new VCSM system this month. Review of the reactor programs and training will begin next month. 2. The resin raw materials in the 744 account were valued at $307M. 3. The new decalcification system was started up in the Old Module. 4. A new rinse nozzle was installed in D-700 on May 2. The new nozzle is similar to the new D-745 rinse nozzle which has improved reactor cleanliness. Aoril - Production, MM Lbs. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime % 37.5 1249.4 97.9 884.0 29.5 85.6 91.6 81.9 98.1 Reactor Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts and inventory control). XX& 278.0 1311.3 102.7 6496.0 30.8 87.8 92.6 94.2 98.4 Hours 578 VAB.0001189720 - Cmtlnnad - cont. Maintenance downtime (repair ram valve on D745, D742 condenser cleaning, D500 , gearbox maintenance D745, dryer conversion to VCSM, evacuation jets in New Module, D300 dump valve, Decal start up, NM Sweco, D700 deluge line.) Drver Downtime Hours 460.5 % of Total Operational downtime (centrifuge plugs, dryer cleaning, flameouts). Maintenance downtime (centrifuge maintenance, dryer conversions to VCSM) . Reactor limited production. 24.8 48.9 26.3 f Mfrfwfcenance Work - J. B. Autrey, S. A. Truitt 1. The fluid bed demister pads-plugged and were changed out. A new set of demister pads is on order and expected to be delivered the first of June. 2. The fluid bed backmix and plugflow blowers were balanced during the shutdown. 3. The fluid bed Bird drain was increased to a six-inch line. 4. The resin transfer blower on the fluid bed dryer was rebuilt. 5. The seal oil pressure on reactor 500 dropped during a power outage and the seal had to be changed. The throttle bushing was found to be too tight and not allowing for adequate flow. 6. Reactor 742 was brought down for hydroblasting to control contamination and improve cooling. The tube-side of the condenser was hydrobiasted. 7. The motor on 6a cooling tower was replaced due to bad windings. 8. The motor on reactor 745 gearbox was repaired. The bearings had gone bad. The fluid coupling was changed and the unit aligned. ( 9. Bird gearboxes #7 and #8 were overhauled. VAB.0001189721 COMPOPHD - J.K. Nickerson, M. R. Kane Safety The Compound Department had no OSHA recordable Injuries in April. The topic of the monthly safety meeting was "Respirator Training". Control of costs and inventories continued to be a high priority during April. Lines were operated only on an as-needed basis and operators from shutdown lines were utilized to cover vacations and other absences to reduce overtime costs. Repairs to the Line I roll mill were responsible for some abnormal main tenance downtime. During the month, the fill in the cooling tower was replaced with some other minor repairs being done at the same time. The cooling tower maintenance did not cause significant downtime as the process was run with once-through cooling water during the shutdown. A major order of 1.6MM pounds of export flexible compound was received during the month. The compound utilized a plasticizer which is not typically used in our process. However, the required tankage changes were made and production has been successful so far. Linda Michels (Scheduler) and Mike Kane visited Kerr-McGee in Hamilton, MS. Operating Month Line I 23 Line III 30 Line V 6.75 Total % Prime Capacity Utilization Factor 1239 3151 266 4656 98.6 59.3 54 105 li 155 10731 17769 1735 30235 97.0 56.1 Downtime - Product Changes - Dicer Offline - Miscellaneous Maintenance - Quality Problems & Control - Waiting on Raw Materials - Mill Maintenance 112 31 12 7 7 7 VAB.0001189722 4 COMPOPHD - Continued - Product Changes - Waiting on Raw Materials - Miscellaneous Maintenance - Dicer Offline - Quality Problems & Control 72 28 23 19 9 Line V - Waiting on Raw Materials - Product Changes - Miscellaneous Maintenance - Quality Problems & Control 29 25 7 3 Operating Month Rigid Compound 30 % Prime Capacity Utilization Factor 5332 98.9 83.2 181 33915 99.5 81.2 Hours - Product Changes - Quality Problems & Control - Miscellaneous Maintenance - Waiting on Raw Materials 70 48 39 35 Operating Month Plasticizer 26 % Prime Capacity Utilization Factor 1304 80.4 69.2 10908 84.3 82.8 J. B. Autrey, S. A. Truitt The "B" blender gearbox on Line III was rebuilt. The gearbox was in need of repair from normal wear. Line I mill bushings, connection gears, dust caps and flow switches were replaced. The bearing failure is believed to have been caused when the lube oil became too cool and thick to circulate the lubricant as required. The new flow switches were installed for tamper resistance and better in dication of flow. Also, a new low temperature cutoff switch was added to shut down the mill, if the oil is not at the proper operating temperature. All lubrication equipment was cleaned and repaired as needed. VAB.0001189723 wrnmmmm f ' b h COMPOUND - Continued continued The compound cooling tower fill, drift eliminators, nozzles, and distribution control valves (2) were replaced. The fan gearbox was also replaced. Hot water basin covers were added to prevent algae growth and additional internal supports. VAB.0001189724 ENGINEERING - R. S. Folk, S. C. Hillaan Resin dryer conversion to the new control system is complete. Software programming for reactor operation is being tested on a simulation panel in Kay. Operator training in the reactor panel operation will be conducted in late Hay and early June. The initial two weeks of HAZOPS of the Old Reactor Module are complete. The VCK tank farm, Old Module VCM receivers and charge systems, and half of the 0*300 piping were covered. Two to four additional weeks will be required to complete the Old Module. Several items were identified that should be addressed over the next year. An interim report on the findings to-date is being prepared. A new rotating nozzle was Installed in reactor 0-700. One had been installed in reactor 745 in mid-March and had performed well. These nozzles have reduced contamination and reduced frequency of having to hydroblast the reactor walls. The plasticizer area wastewater treatment tank, T-460, is a major source of the organic and high pH loading to the plant wastewater treatment system. A test was completed to slow drain plasticizer area wastewater from T-460. This test simulates the capital project to install a hold tank downstream of T-460 to reduce the daily organic and pH loading spike to the ponds. During the test, pH and COD at the ponds did not increase over non-dumping periods. This indicates that the hold tank should eliminate the need for H2S04 addition at the ponds for pH control except in abnormal situations. We are looking at converting to C02 addition for handling those abnormal situations to eliminate H2S04 from the plant altogether. VAB.0001189725 ENGINEERING - O.E. JOHNSON. S.C. HILLMAN MENKEN CHEMICAL PLANT APPROVED CAPITAL PROTECTS * AFE NUMBER A519 A649 A909 05H 0550 0749 0049 DB99 DB99 F551 F699 F779 6659 8839 0570 0580 0600 F650 F660 6560 6561 6610 6630 HSOO H510 H620 H501 H531 PROJECT DESCRIPTION STATUS PLANT ELECTRICAL UP8RAK VINYL CONTROL SYSTEM N08ERNI2ATI0N mm MNWAL N0BIF1CATT0N8 VCN UNL8MIN6 MOlFtGATIDM RAILCAR ACCESS PLATFORMS LEM HAMLINS AM EXPOSURE REDUCTION COMPQUM LINE 3 SERI-BULK LEAD HAN8LIN6 COHPOUM SILO BRISK SNEAKING RAILCM CLEANIM RACK DRY BLEND SCHEMER REPLACEMENT LOU NBLECULM HEISNT RESIN EXPANSION DRYERS NO.4 I 5 CONTAMINATION REDUCTION PLANT MATER RECYCLE OLD NODULE RECOVERY SYSTEM ACCESS RECOVERY VACUUM PUMP PRESSURE RELIEF PLASTICIZER UJMIN6 AND UNLOADIN6 REVISIONS 5305 RESIDUAL VCM ttOOCTION OECALCIFiaUATER TC SPILL comtaiment NASTENATER INFLUENT EQUALIZATION TC COMPLIANCE PROJECT REACTOR SLURRY STRIPPIN6 OPTIMIZATION PLANT MATER SYSTEM NEST IRCZRERATOR REPLACEMENT EAST INCINERATOR REPLACEMENT MISCELLANEOUS MWAL PROJECTS < 15M BOILER FEONATER TANK REPLACEMENT MILL CLOSE TO FIELD CHAR6ES IN NAY. DRYER CONVERSION COMLETE. MEM NOOULE CONVERSION PLANNED FOR JUNE PROJttT IS OPMftTNML, NQRIFICinOR PLANNED IN JUNE. sm.demon is screw,fi) to koin n NORKIM ON PUNCHLIST ITEMS. PROCESS EMMERIES IS MNITORIM NOTIFICATIONS. PLANNIM RODIFICATIORS IN NAY. COMPLETED, HILL * CLOSED TO FIELD CHARMS IN JUNE. IMMmlM CONTINUES, COMUETION PLANNED IN JUK. DESIBH IS SCHEMED TO DEBIB IN JULY. NHL K CLOSES TO FIELD CHARGES IN MAY. EMINB9IM6 IS IM PMSNESS ON HOOIFICATION. mi MODIFIED SOW SUE IN HAY. THE PROJECT Mia IE CLIMES TO FIELD CHARGES IN JUK. DESIGN IS C8HPLETE. INSTALLATION IS PLANNED FOR 7/91. DIBlON tS COMPUTE. INBYALLATION IS PLANNED FOR 7/91. INSTALLATION IS IN PROMCSS. COMPLETION PLANNED IN MY. V . j- * ' HU K OBE* TO FIRl MUSSES M JUUE. au uuBu camna, m mu coupijethiu pumd iu juue % HU KOBE} TO FIEL) (NAMES M JUUE. UESIBUIS IK FMHES8. OBSTHICTIOU PUSSES TO STSRT IS JUDE. SIU K (USE! TO FiEU CHIMES IS JUNE. MHFtCStnNB PUMM SUSlHI RI OUTAS IK JUNE. EMINpNip IN PM68IK. PORTIONS OUT FDR BID. PLANNED COMPLETION EARL' DELIVERED. PROJECT COMPLETION PLANNED FOR 7/91. rfe. -'i*- PROJECT COMPLETION PLANNED FOR 9/91. PROORfSS ON 7 PROJECTS. 9 PROJECTS COMPLETED DESIGN IS IN PROGRESS. VAB.OOOl189726 K. 6. Akins All wastewater discharge parameters were met for the month of April. We received the new NPDES water permit on April 18. This permit covers the period through April 8, 1996. The permitted period is divided in two sections with different effluent limitations for each period. The second set of limitations become effective February 1, 1993. Repairs to the Pond 6 outfall were completed in April. Water flow from a drainage ditch had eroded a large cavity under the outfall cascade. The cavity was filled and water flow redirected to prevent further erosion. We completed the EPA's Laboratory Performance Evaluation report. This program is designed to check the accuracy of the labs we use for our NPDES effluent testing. The EPA provides samples that are analyzed by our labs and the results are reported back to the EPA. Rendell Newton and I met with the USGS in Jackson to discuss proper methods for measuring flows in streams. We plan to collect flow data on James Creek to prove that the ten-year, seven-day low flow is not zero during the winter months. This data could be used to have our permitted BOD limitations raised in 1993. Frank Jeanson and I represented Vista at the Mississippi Manufac turers Association meeting with the MDEQ's Air Quality Division. This meeting was to discuss industry's concerns about the proposed changes to the state's air toxics regulations. The final revisions to the remedial investigation report were completed. The report was forwarded to Russell Smith of the MDEQ on April 25th. Vista and Conoco met with MDEQ on April 18 to discuss the proposed plan to remove the 20MM pounds of resin from Pond 2. The MDEQ was very receptive to the idea and plans to issue a letter in May approving this plan. Marcus Smith of Sun Polymers visited the plant and Aberdeen on April 10 to evaluate possible sites for a drying facility for Pond 2 resin. A VAB.0001189727 Continued Samples and certification forns were sent to Chemical Waste Management's Emelle facility to recertify our Pond 3/API sludge for disposal at Emelle. This certification expired in November, 1990. Waste shipments during the month included: Bulk shipment of floor sweepings to CWM in Lake Charles, LA. m Seven drums of stabilizer spill to TES in LaPorte, TX. Fourteen drums of dirt contaminated with sodium hydroxide to TES in LaPorte, TX. Nine gaylord boxes of VCM contaminated filter cartridges to TES in LaPorte, IX. Three drums of phthalic anhydride TES LaPorte VAB.0001189728 J. R. Gone A A. Unadjusted EUI <11.1%> B. Adjusted EUI <10.2%> C. BTU/Lb. Product 2733.8 D. Total Energy Consumption MMM BTU 133.5 < 8.8%> < 8.3%> 2754.1 964.1 No. 1 No. 2 No. 3 83.2% 83.5% 82.9% All three boilers operated during the month. 83.1% 83.4% 82.8% VAB.0001189729 mm ***** T None Beall Frank Jeanson - Senior Environmental coordinator transferred to Senior Environmental Specialist, Biomedical & Environmental Affairs - Houston Kenneth Akins -- Operations Engineer, Compound - promoted to Environmental Coordinator replacing Frank Jeanson. Michael Kane -- Senior Process Engineer -- assigned to Operations Engineer, Compound replacing Kenneth Akins. Randall Polk -- Senior Mechanical Engineer -- promoted and transferred to Mechanical Superintendent, Lakes Charles LAB plant. David Roberts - Maintenance Department - promoted from Electrician "B" to Electrician "A". William Parks - Compound Department - early retirement. None None VAB.0001189730 ^ r 'n*'^ A Hourly Temporary SUB TOTAL L.O.A. TOTAL 238 5 243 DEPARTMENTS #EMFLOYEES M WAREHOUSE GENERAL PLANT MAINTENANCE LABORATORY COMPOUND VINYL PLASTICIZER 15 9 i 12 5 40 8 23 5 36 22 33 10 52 F j 0 0 0 2 1 1 0 SUB TOTAL SALARIED 164 72 61 4 6 18 Salaried/Transfer Hourly Temporary TOTAL 0 0 0 0 1 1 %M 60% 42% 20% 21.7% 61% 30% 40% %F 0 0 0 8.6% 2.7% 3.0% 0 DEPARTMENT TURNOVER MO. YTD 00 0 p 0 0 0 00 12 00 00 37% 2.4% 8% 25% ANN. % 0 0 0 0 1.7% 0 0 Month YTD Minority Female i 00 00 00 00 Hourly Month YTD Salaried Month YTD UUMMeU mi 1 1.9% 2 3.7% 2 8.3% 5 2.1% VAB.00011S 7731 IA * * 5 oUl *2* co o* + 888 O O O V s83 o K mA * V A -- . _. . 88 Am W *in O 5 mo * V 8 INi fc. 88 Ui 83 3 (A i/% (A SUI 8 & f8 8 i W U s II ? INI 1 C<3 *8 CL VAB.0001189732 h !tf) 1 s' I 2 ! 3s U o VAB.0001189733 w D. A. Barclay There were no reportable safety Instances this month. All natural teams met in April. 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 1103 12 $2899 100 199 166 7234 81 $20396 535 1232 1170 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 4,091,582 74,019 736,079 82,772 69,916 309,147 42,805 574,450 37,500 326.223 6,344,493 * Includes PLENEX millscrap and cleanout. (Decrease) 4,011,348 88,592 464,049 46,460 41,432 258,968 124,737 649,200 37,500 ___291.362 6,013,648 < 80,234> 14,573 <272,030> < 36,312> < 28,484> < 50,179> 81,932 74,750 0 <330,845> Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade Total 1,422,788 177,500 2,185,510 873,660 11,365,508 17,214,116 (Decrease) 1,039,762 177,500 1,316,662 594,860 8,067.700 12,385,634 < 383,026> 0 < 868,848> < 278,800> <3,297,808> <4,219,582> VAB.0001189734 A* % f 06/90 07/90 09/90 11/90 01/91 09/91 PKQ'D PRODUCTS INVENTORY ** * i+ wmmmmnmm 4" WfWPtlWNIItwifi i| i wmm VAB.0001189735 ABBdMESM CHEMICAL PLANT SHIPPING ANALYSIS APRIL 1991 -SHIPMENTS IY PRODUCTS- PUBLIC RESIN-HUU RESIN-PACKAGED 21,404,730 384,931 FLEXIBLE COMPOUND-SUU 541,860 FLEXIBLE COMPOUND-PACKAGED 3,842,360 15,605 RIGID RIGID -SULK -PACKAGED 4,907,900 317,488 TOLLING BULK TOLLING PACKAGE 0 0 PLASTICIZER 0 TOTAL 31,414,874 SHIPMENTS BY NODE SULK: APRIL* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER RAILCAR 131 8 31 4 TOTAL APRIL 194 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 1,144 m68 18 TOTAL YTD PACKAGED: APRIL* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 1,lf9 CUSTOMER PICK# 0 38 0 0 TOTAL APRIL 38 YTD* RESIN FUXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 22 167 6 0 TOTAL YTD 195 MONTH YTD IPT/ITC EXCN/TOLL PUBLIC IPT/ITC 11,352,150 164,050 0 0 139,415,484 91,028,420 1,590,614 1,424,950 1,079,950 40,500 0 0 4,920,260 19,153,329 7,740,450 751,502 00 58,680 0 885,100 0 0 0 25,819,790 2,483,179 4,100,050 521,706 00 00 00 00 387,910 370,400 779,150 1,102,420 13,909,660 `CUSSOORR ' PICKUi P 47 0 2 0 370,400 r cStCR 50 4 9 1 194,220,486 106,669,498 49 64 - 299 266 0 24 24 74 29 26 352 390 common rare AIR/UPS AIR/UPS 17 0 0 92 0 0 15 0 0 1 00 7 8 1 0 125 0 0 16 86 0 0 480 0 0 93 0 0 200 37 69 4 0 661 0 0 110 EXCN/TOLL 1,777,400 0 0 0 0 0 0 1,401,960 33,600 3,652,160 6,865,120 TOTAL 24S 12 42 5 307 1,709 92 267 73 2,141 TOTAL 24 138 16 1 179 145 716 103 2 966 CC: Ml.TIC.AEV, JRF * f VAB.0001189736 2 * W cn 3S ii ii I S33 cn L ssss r ills 5 8SSS w w CM CM CM CM CM CM CM CM CM CM OO O CO -MJ CM CD CO OO O M*> M W hO CM CM CM CM CM CM m -> cm CM *1*% ro i hn o in CM cn O II o o- o oo cn mm CuMn cn cn cn cn Ul UJ UU Ui 2222 m <in9 Om iQn Om i m co un o S S J? m O l mifi'l imim rn fO m wm m r*n r-n m i CJ CO *X* CO ^2 - n CO lO CO rn r*n 'i i s sm m oo 3 i cm r-4 i1 1 O' O' CH i CM o o o CM hO m CP 4^4 Sfe fe & U O U Li cn s* cn cn ua. aXu. aa. Ss CD cn 222 UJ Ui Ul cn acn ccnj uco aon V? * 33 cn Uu in in u') o => o Ul UJ UJ oc a: cu lu VAB.0001189737 04/18/91 SQUTHNIRE 6A, CARROLLTOM RESIN 1842-12 5415 GAC173409 BULK 93,300 01342 04/02/91 892347-092 2232250 BROKEN HINGE PIN ON A CONPT --< CN OB cn S8888 IIttI Bgui Q gS gB mi mi 5aSS35 CM 8 r- r*- r O <** C*- C** pk fv*) M cn cn cn s-a iS cun/ cn sss *r cn i ii 22222 31 i 11 i PP VAB.0001189738 A T-ARORAttiby - J. M. Edvards, Jr. A. Safetv There were no safety incidents in the Laboratory during April. The monthly safety meeting topic was "Respiratory Protection" taught by Bruce Trego. There were two customer contacts made during the month. Several representatives from Nibco's residential products division visited the Aberdeen Plant on 4/9/91. The Nlbco group was given the plant "Quality Presentation" and a tour. Afterwards, technical and business discussions were exchanged. On 4/17/91, representatives from Gencorp in Columbus, MS visited the Aberdeen Plant to discuss MSP-80 and MSP*90 compound properties and applications at their plant. 4703 Customer complained that the 489*98 WHT 125 dry blend shipment was too low in "L" value; color was too dark. Material was experi* mental and all 35,000 pounds were returned. 4/04 Castle. PK Customer complained that 5265 railcar PLWX 44376 inherent viscosity was too high- The Aberdeen lab agreed that the l.V. value was bumping the upper spec limit. American Mirrex used the car with some process ad* j us tments. 4/05 Conductors Customer complained of 5415 processing differently. After further discussions with Technical Services, the customer was satis* fied with the material. 04/98 Morthwire. Osceola. VI Customer complained of late shipment of 34551 Natural compound. There was a basic lack of communication which caused this problem. VAB.0001189739 Continued 4/08 ContInued Customer complained of a pallet nail found in a box 38601 Black compound. Apologies were made and preventative measures taken to lessen the chances of future occurrences. 04/08 The customer complained of a weight dis crepancy on a railcar of 5415. A letter of explanation about our scale control charts was sent to Essex. 04/08 Customer complained of 38601 Black compound causing bumps on wire and producing a dull appearance. Samjple sent from Northwire of the screen paks showed undispersed calcium carbonate. The raw material supplier va** notified and a complaint was filed. 04/08 Customer complained of "fisheyes" in lab prepared samples made from a 5415 and 5305 polymer blend for "Polystar". The samples sent to Aberdeen were inconclusive. Eric Stouder will follow-up with a visit. 04/11 Customer complained of receiving a 5415 railcar with the compartment MA" hatch open. Customer complained of cardboard contamina tion in a lot of 38601 Black compound which plugged their screen paks. Customer complained of processing incon sistency between two lots of 45541 Natural compound. The shipment was made up of material made from Lines I and III. The Line III material was removed and their problems went away. * .-****> VAB.0001189740 - Continued Continued 04/11 Customer complained of overdue C of A's for 5385 truck shipments. We explained to Dan Preston about the timing of running truck shipment analyses and that some tests (i.e., viscosity) take twenty-four hours to run. Also, he complained of too much material on the 200 mesh particle size analysis. A specification of 10% max on 200 mesh was agreed on for further shipments. 04/11 Customer complained of excessive oversized material in two compartments of a RP-151 dry blend car. Samples sent from Dayton showed high on the 40 mesh. 04/12 Worth. TX Customer complained that a 6,000 pound order for 36451 Natural was undershipped by 15%. The discrepancy has since been resolved. 94/1$ PaTton Extruded.Plastics. Davton. OH Customer complained of burnt compound particles and gravel plugging screen paks in RP-151 service. 04/18 ed that one box compound was labeled with two numbers on it. 04/22 Klockner- Custoner complained of finding ion exchange resin in their calendared rigid sheet made from 5305. Ion exchange resin particles were found in 5305 and 5415 production re tains starting around the third week in March. The plant's charge water polishing filter failed to contain the ionic exchange resin leakage. LABORATORY - Continued Continued Customer complained of excessive amounts of grey streamers in a box of 58991 Natural compound. Ted Nickerson is responding. Blane is complaining of finding grass, wood and other contamination in 5595 resin. John Olson is responding. 04/26 Customer complained of specks in 38552 Natural compound which was isolated to one box of lot 31F06. Samples were received at Aberdeen. Specks could not be found. We called Northwire and asked questions; they said they would get back with the answers. 04/29 Customer complained that Vista did not maintain minimum Inventories of 16851 compound. Charlie Miller responded to the complaint. Customer complained of late delivery of a 58162 Grey compound sample for line testing. The color formulation work, raw material ordering and delivery and production of the sample could not be accomplished in the time frame promised to the customer. D. Product Waivers SttSoggy Eagle Product 80273G WHT 110 Reason Esu Eq. Torque & 40 Mesh 1 R/C Eagle 80273G WHT 110 40 Mesh 1 R/C Rustique Rustique RP-123 WHT 111 RP-123 BGE 322 40 Mesh 40 Mesh 1 H/T 1 H/T VAB.0001189742 laboratory - Continued A The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of April, 1991. Reactor Number of Samples Average RVCM, ppm 25 0.627 71 0.314 The following is a summary of the residual VCM analysis of shipment samples for the month of April, 1991. Erodest ffvafrgr Samples Average RVCM. ppm 5265 5305 5325 5385 5395 5415 Debox Dry Blend 26 108 9 70 11 42 12 20 0.152 0.125 0.103 0.289 0.035 0.028 1.015 0.024 (based on dryer regulars") 5265 5305 mi 5395 Bulk Density Inherent Viscosity (vs. 0.64 - 0.67) (vs. 0.715 - 0.744) L Color A Color B Color % on Fan (vs. 2%, max.) % thru 140 Mesh Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle size, microns 1.25 2.60 0.40 -- 5.83 8.33 6.33 15.67 -- 8.46 -- -- ---- 162 1.33 1.67 -- 0.93 2.00 9.33 7.33 7.67 -- 3.13 *---- -- 159 1.50 0.42 ------- 3.44 .... 1.67 5.11 3.00 -- 9.6 181 1.87 0.74 ---* ---- 3.89 .... 4.67 4.89 -- 4.03 1.76 .... 0 1.63 5415 1.41 0.37 --- -- .... 3.78 .... 2.50 5.11 1.78 5.67 4.81 2.31 4.5 187 VAB.0001189743 LABORATORY - Continued Hardness Color Hard Particles Contamination Dicing Total 42.0 <0.89> 10.0 <0.21> 52.0 <1.11> 6.0 24.0 11.2 13. 3 54.5 <0.13> <0.51> <0.24> <CLZ$> <1.16> Color 40 Mesh Mischarge Re lections M Lbs. ill 14.3 4.2 37.2 55.7 <0.27> <0.08> <0.70> <1.05> 1. Assistance was given to Administrative Services developing software for the timecard and payroll summary. 2. The hardware installation is half complete and software development is underway to link the lab Q.C. output to the DEC computer at Vinyl. Target date for completion of this data link is mid-July. 3. Assistance was given to the OASIS implementation team to help set up the training terminals. 4. All natural teams met once during the month. The Chief Plant Chemist's Natural Team completed their project, but have not presented it to Management yet. 0 i VAB.0001189744 A SAMPLE SHIPMENTS APRIL 1991 RESIN Ship Date 4/10/91 4/11/91 4/11/91 4/12/91 4/15/91 4/18/91 4/22/91 4/25/91 4/29/91 Product 5415 5325 5395 5225 5385 5415 5416 5265 5305 5385 6415 5325 Amount 50 lba. 50 lba. 50 lba. 100 lba. 2 lba. 2 lba. 50 lba. 50 lba. 50 lba. 50 lba. 5 lba. 100 lba. Customer Baerlocher USA Intex Plastics Novatech Plastics A Chemical Company Oary Corporation Essex Group Erie Extrusion Inc. Robbins Tire Gary Corporation Po1ycast/Uniroya1 mj : i UND Ship Date 4/04/91 4/04/91 4/04/91 4/05/91 4/10/91 4/17/91 4/22/91 4/22/91 Product 55041 NAT 419-50-C NAT 02 54941 BLK MSP-80 MSP-90 MSP-80 17462 BLK (OG) 419-50-A NAT 02 419-50-A NAT 02 419-50-A NAT 02 419-50-C NAT 02 Amount 300 lbs. 200 lbs. 100 lbs. 975 lbs. 1500 lbs. i lb. * lb. 300 lbs. 400 lbs. 300 lbs. 200 lbs. Customer Plasticraft Mfg. Co. F Signal Cable Co. Precision Trim Gencorp Polymer Products - RCM International Signal Cable Co. Amphenol; Spectra-Strip Alcatel N.A. Inc. VAB.0001189745 S&aple Shipments/April 1991 Page 2 COMPOUND (Cont.) Ship Date Product Amount Customer 4/22/91 57462 NAT MSP-80 100 lbs. 200 lbs. Flexible Technologies 4/22/91 17462 BLK (OO) 1 lb. 17462 ORY 546 (OO) 1 lb. 17462 WHT (OO) 1 lb. 38531 WHT 818 (OO) 1 lb. 57462 NAT (OO) 1 lb. 48562 BLK (OO) 1 lb. 38931 WHT 810 (OO) 1 lb. H. Heller Company DKTBLEND Ship Date 4/19/91 Product RP-28 WHT 122 Amount 100 lbs. Customer Montage MISC. Ship Date 4/08/91 Product Vent Dust Amount 2 lbs. Customer Vista Chemical - Austin VAB.0001189746 ER OF IN ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) 30 VAB.0001189747 ABERDEEN ENERGY CONSUMPTION sVnis VAB.0001189748