Document jBpwg35XONdjXR1w7Gkq91aON
IntonfRtii t
T. H. Huffman To:
From: Date:
Subject:
D. C. Skokna August 21, 1992
ABERDEEN MONTHLY PROGRESS REPORT July 1992
Safety
There was one first aid case reported during July. On July 6, the plant's employees achieved thirteen years since the last lost time injury. At month end, the plant's employees had worked 4775 days (6,399,990 employee hours) since the last lost
time injury.
mm
PVC Production, MH 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
aEulY
39.2 92.1 97.5 1.0338
6.8 97.5
1.7 96.4
1.7 88.5
0.1 < 29.9>
45.5
y.T.p.
368.3 86.2 97.1
1.0354 53.9 96.6 19.7 97.6 14.5 80.8
< 13.2> <596.9> <577.5>
Costs
Variable costs were near budget for the month.
Fixed costs were overstated by $124M due to accrual errors which will be corrected in August.
Operations
In the Vinyl unit, annual inspections and rupture disk changeouts were completed in the New Module on reactors D-741, D-742 and D-743. Maintenance on #3 boiler limited rates for several days during July.
Inspection of the #3 boiler showed that its condition warrants extensive repairs or replacement. An AFE will be submitted during August.
VAB.0001189172
T. H. Huffman 08/21/92 Aberdeen Monthly Progress Report - July, 1992 Page 2
Operations - Continued
The flexible compound unit ran very well producing 6.8MM pounds. Line V and the rigid compound unit both operated with reduced
The plant scored 44% on a self-assessment done at Frestollte's request. A corrective action plan will be developed.
Environmental
We are working with a consultant, Tischler/Kocurek, to obtain a higher BOD limit on the new MPDES permit that takes effect on February 1, 1993. A meeting with the MDEQ is scheduled for October to review the results of the consultant's work. In addition to the work by the consultant, a parallel effort to develop a project to meet the tight BOD limit is in progress.
D. C. Skokna Plant Superintendent rah
VAB.0001189173
DISTRIBUTION Hous froft
Austin gfcMWiP City LCVCM Plant LCCP Plant LCLAB Plant Baltimore Hammond Premiere Aberdeen
*
COVER LETTER
J. D. Burns
X
J. R. Ball
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. Gamblln
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. W. Ware
X
L. R. Bauer
J. Pavao
X X
P. L. Foote
X
J. A. Autrey
J. E. Beall
X
J. M. Edvards
X
S. C. Hillman
D. A. Miller
J. E. Nickerson
X
J. D. Olson
B. L. Trego
X
R. W. Seymour/
D. C. Skokna (File Copy)
mm MMNW
m
ENTIRE REPORT
X
X
X
X
X X X X
X X X
X X X X
VAB.0001189174
4,
SAFETY - B. L. Trego
First Aid OSHA Recordable
Total Injuries
Number of Restricted Workday Gases Number of Lost Workday Cases
July
1 1
0 0
Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office
Totals
Injuries by Type
Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other
Totals
0 1 0 0 0 0 1
1 0 0 0 0 0 0 1
Fiscal
Fiscal Y.T.P. 1991
2
0
43 65 79 00 00
-1 19
96 01 43 13 33 10
Lost Workday Cases Days Lost
2 66
5 41 127
Contractor Injuries
First Aid Cases Medical Treatment Cases Lost Workday Cases
Safety Record
1 44 0 01 0 01
Last lost time injury - 7/5/79
Days since -
4,775
Employee hours since - 6,399,990
On July 31, 1992, the employees of the Aberdeen plant completed 4,775 days with no lost time injury.
VAB.0001189175
SAtilti - Continued
Topics for the plant safety meetings during the month included refresher training on Lockout/Tagout Procedures and CPR.
Routine dosimetry results for the month were:
O O -P"
VCM Lead Total Particulates
< PEL Nvmfrftir Percent
72 98.6 7 100.0 1 100.0
>_________________________
Number
1 0 0
Iniurv Class
Compound
Description
Minor laceration of right index finger.
VAB.0001189176
QUALITY MANAGEMENT PROCESS - E. E. Smith
The Aberdeen Plant scored 44% on a self-assessment questionnaire for Prestolite. A corrective action plan will be developed. Several natural teams have completed teem projects and are preparing for management presentations. 1993 Q-Scorecard preparation is underway.
VAB.0001189177
I
*
COST VABTAWCKS . D. C. Sfcokoa
Variablft Coats
Frp4ug.lt:
PVC Flexible Compound Rigid Compound Plasticizer
Total
PVC
July. 1992 Variance. 8M
Total
$12.5 32.6
< 0.3> 0.5
$45.5
<$485.2> < 44.8> < 23.7>
< 37.0> <$590.7>
<$472.7>
< 12.2>
< 24.0>
<$545.2>
Operations were essentially at budget
Flexible Compound
Raw material use was below budget.
Variances:
Variance - $M
Electricity
$ 26.4
Micral 932
22.8
f
Resin to Rigid Compound
< 12.0>
Debox Resin Credit
< 14.0>
Natural Gas
< 21.1>
Plasticizers
< 27.0>
Resin to Flexible Compound
< 42.7>
Alfol* Alcohols
< 42.8>
VCM
< 474.9>
Other Variances
< - 5.4>
Total <$590.7>
Fixed Cost Variances
Payroll and Benefits MM&C Miscellaneous TI&D
Payroll & Benefits
Variance - SM
Total
$ 20.7 < 43.0> < 30.1>
1.2
____22.5 <$ 29.9>
An unfavorable payroll
due to the July holiday, long term
absences, and above budget salaried staffing levels was offset by
favorable benefits.
MM&C
An accrual error overstated this category by $85M.
VAB.0001189178
COST vartawces - Continued
Miscellaneous <$40.2M>
This Is due to a $39M accrual
Moving. Home Assistance: $16.6M Unclassified: $14.1M
<$17.07> <$12.0M> - This Is for the pond 2 cleanout and is offset by a clearance.
$12.1M
This Is primarily a credit for the pond 2 cleanout project.
VAB.0001189179
VINYL - J. D. Olson, D. E. Knittig
Safety
The Vinyl Department had no injuries in July.
The monthly safety meetings were presented by the Safety Department reviewing the Lockout/Tagout procedures.
General
1. Annual inspections and rupture disk changeouts were completed on reactors D-741, D-742, and D-743. The New module inspec tions should be completed in August.
A power failure on July 22 resulted in the early kill of four reactor batches. Downtime was minimal; however, resin quality particularly hard particles was adversely affected.
3. Low steam pressure due to boiler maintenance slowed production. Only one module could evacuate or recover at a time.
Julv
YTD
- Production, MM Lbs. - Dally Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime
%
39.2 1266.0
95.5 926.0
29.9 92.1 93.6 97.7 97.5
Reactor Downtime
368.3 1207.5
91.1 8794.0
28.8 86.2 91.1 90.4 97.1
Hours
Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts, low steam pressure, and no blend tank space).
394.0
Maintenance downtime (D-741 annual Inspection, D-742 annual inspection, D-743 annual inspection D-744 agitator motor work, D-741 PM, D-742 evacuation valve, D-500 agitator seal, D-700 agitator seal unit, D-600 catalyst ram valve, D-742 rinse valve, D-300 slurry valve, D-600 cooling water valve, D-700 steam eductor, and D-743 recovery line).
196.0
m mtrnmmmmmmmmmmmm
mmm PM
T
VAB.0001189180
A
VxBiiL - Cont inued
Dryer Time
Operational downtime (centrifuge plugs, dryer cleaning, flameouts). Maintenance downtime (activator problems, centrifuge repair). Reactor limited production.
% of Total
27.2
55.3
17.5
s
m Hie annual rupture disc changes and die Inspection were completed on reactors 742 and 743. Also, relief valves were sent out for reconditioning.
Compressors 903 and 905 were changed out due to poor per formance. The insides were severely pitted and worn.
i The reactor seal on reactor 500 was pulled out of service after five months of service. Failure was attributed to contami nated lubrication. The duraseal unit was disassembled and cleaned.
i The roller on the south end of dryer #1 was replaced. The roller broke and caused the dryer to come off track.
m Recovery piping on reactor 743 was replaced after a hole developed in the side of the pipe. All other small reactor new unit recovery lines were inspected. Reactors 744 and 742 recovery lines were also determined to be in poor condition and are scheduled to be replaced next month.
Three major valves were changed out of the vinyl unit.
Critical instrument PMs were completed on reactors 300, 600, 742, 743, dryer #4 and dryer #8. Critical instrument PMs were also completed on #3 boiler.
m The cooling water control valve on reactor 600 was replaced with a new style V-ball control valve.
Tube leaks on #3 boiler were repaired after a tube failure. The boiler tubes were then acid-cleaned and additional tube leaks found were repaired. The annual insurance inspection was completed and the annual relief valve reconditioning was also completed.
i
VAB.0001189181
m mpuMMIVM
/'"n
COMPOUND - S. C. Hillman, J. B. Hegwood
t
Safety
The Compound Department had one first aid injury during the month. A Compounder received a cut on his index finger.
General
Orders continue to be tight on Line 1 and Line III. Production for the month is up 1000M pounds from last month due to a significant decrease in total downtime. Line V and Dryblend continue to operate at reduced staffing. Efforts are being made to move some production to Line V which would alleviate some congestion on Lines I and XII. This additional production on Line V would also allow us to go to three production shifts and hopefully increase production on Lines I and III by further reducing downtime.
Operating
Ifanrii
Line I
31
Line III
31
Line V
16
Total
% Prime
Capacity Utilization Factor
2095 4178
532 6805 97.50 92.68
Hours
68
135 33
236
Fiscal T.T.D.
16211 33310
4348
53869
96.61 69.82
- Product Changes - One Dicer Offline - Miscellaneous Maintenance - Quality
line III
- Product Changes - Miscellaneous Maintenance - Quality
Line V
- Product Changes - Quality - Miscellaneous Maintenance - Coverage for Other Lines
90 15 26 14
50 23
8
46 3 4
10
VAB.0001189182
COMPOUND - Continued
Operating
Days
Rigid Compound
21
% Prime
Capacity Utilization Factor
Production CM Lbs.) uplift
1682 96.44 31.30
19714 97.55 38.02
ppwasfm?
Hours
- Product Changes - Miscellaneous Maintenance - Quality
49 10 75
Operating
Plasticizer % Prime Capacity Utilization Factor
flODSB
1651 88.47 74.94
14545 80.80 60.76
J. B. Autrey/S. A. Truitt
The leaking transfer line to Line I boxing hopper was replaced.
Line III "AH blender ribbon was repaired.
Tests were performed on all alarms on Line V panel.
VAB.0001189183
ENGINEERING - J. E. Nickerson, T. R. Mackay, R. H. Sneed, M. L. Career
PROJECTS IN DEVELOPMENT - GKWFBAT.
Water Plant:
Operator training has begun. Equipment check-out will begin in midAugust. Persistent equipment delays have pushed startup to late August or early September.
Centrifuge Pool Depth Tests - Rotary Dryer Debottlenecking
The centrifuge pool depth test run is complete. A lower pool depth in the centrifuge lowers the moisture in the resin wetcake entering the dryer. The test run showed that rotary dryers can be operated at higher flow rates and low inlet temperatures if centrifuges are run at lower pool depth. This helps quality and fuel savings and makes capacity increases possible. The drawback is a higher resin concentration in the centrate water.
New Boiler
The plant is pursuing the design of a new boiler to replace boiler #3 which is in need of repairs. It was decided to purchase a new boiler based on the economics of repairing boiler #3. Bids are being solicited from several manufacturers.
PXtraclean
Equipment was ordered and modified to run Syntron resin contami nation tests under a UV light. It is hoped that the UV Syntron test will detect baghouse fibers and resin particles that have poor heat history.
New Gortex bags have been ordered and upon delivery will be installed in the baghouse of dryer #8. This test, using the new Gortex bags, will hopefully reduce the number of polyester fibers in our resins.
Compound Prodscti^tf
An economic analysis was done to determine if using returnable bins instead of Gaylord boxes for shipping compound would save money. The results showed that a switch would not save money, due mainly to the cost of shipping the empty bins back to Aberdeen.
Wastewater
The Wastewater Team had its first meeting and decided to focus on oxidation and water recycle, along with continuing aerator design efforts and regulatory relief work. Another action step from the meeting was to minimize water use. A plant water balance will be completed in August.
A
ENGINEERING - Continued
Plasticizer Expansion
A HAZOP of the Plasticizer Stripper Class "A" design was completed and then sent to GED for a definitive estimate. The stripper plot plan was approved in a plant meeting. Existing equipment relocation issues will be resolved before estimation begins in early August.
Storage and unloading facilities, the second phase of the expansion, were evaluated to determine current capacity and future require ments. The operability of models predicting equipment use and capacity will be confirmed with operations In early August.
The wastewater test run is in progress.
Early environmental
problems with the test run were compensated with operational
changes. These changes and the steam problems at the plant have
hindered the test run. The high acid values are difficult to obtain
and are causing considerable problems with VRP handling. To date,
there is no indication the test run has increased loading to the
ponds.
The Plant Hazards Analysis Policy is complete and approved by plant
management.
This plan provides the necessary procedures for
performing process hazard analysis at the Aberdeen Plant. Training
on the Process Hazards Analysis Policy was given to the Process
Engineering Department.
Management of change and pre-startup safety review procedure training of supervisors has started. Supervisor training will be complete August 13.
t
VAB.0001189185
ABERDEEN CHEMICAL PLANT
MONTHLY PROGRESS REPORT
CAPITAL EXPENDITURE STATUS
M.L. CARTER JULY REPORT
1992 F.Y.
Month 4th Qtr. YTD
ACTUAL
326 6
326.6
*
3181.2
BUDGET 105.0 479.0 3841.0
VARIANCE
M$.
+ 221.6
___1___
+211.0%
- 152.4
-31.8%
- 659.8
-17.1%
Actual Expenditures - Expenditures in July were $221*6M more than the plant's budgeted expenditure forecast approved in the Fourth Quarter Budget submitted in June FY92.
July's FY92 capital expenditures were 211.0% more than the plant's budgeted expenditure forecast. It should be noted that the capital expenditures associated with project H612 Pond 2 Resin Drying are not accounted for in the reported actual above due to the accounting procedures and contract agreement with Conoco.
Quarter Budget - Current Quarter Expenditure Forecast as submitted and approved for the current quarter capital budget.
YTD Budget - Total of current and previous quarter approved budgets.
Forecasted Expenditures - The submitted 4th Quarter Capital Budget calls for expenditures of $479.0M and August expenditures of $182.0M.
*
wV
wmmm
5*
VAB.0001189186
ENVIRONMENTAL - K. G. Akins
Water
All wastewater discharge parameters were met for the month of July.
We are working with the consulting firm of Tischler/Kocurek on an effort to obtain higher BOD limitations for the second part of the NPDES permit. The new limits are currently scheduled to take effect on February 1, 1993. We will be gathering hydraulic data on James Greek as well as analyzing for BOD, DO, temperature, nitrogen compounds. This information will be used in a computer model to determine allowable BOD discharge levels. The MDEQ has expressed a willingness to use the computer model proposed by Tischler/Kocurek.
We will meet with the MDEQ in October to review the .results of the stream survey and modelling results.
We are also looking at chemical oxidation or filtration of our effluent as a means of meeting the stricter permit limitations in the event stream modelling does not provide us with higher allowable discharge limitations.
Waste shipments during the month included:
A bulk shipment of floor sweepings to Chemical Waste Management in Emelle, AL.
i A bulk shipment of empty lead bags to Chemical Waste Management in Emelle, AL.
EHEELCY CONSERVATION - J. R. Ganc
I. Energy Conservation Data
A. Unadjus ted EUI B. Adj us ted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU
JitlT. 1992
< 0.3%>
0.1%
2576.0 127.5
Fiscal Y.T.P.
< 14.3%> < 13.2%>
2935.0 1340.5
No. 1 No. 2 No. 3
July. 1992
83.7% 83.5% 83.6%
83.4% 83.4% 83.1%
*
/
VAB.0001189188
HUMAN RESOURCE REPORT JULY. 1992
PERSONNEL - J. E. Beall EMPLOYMENT None.
Erik B. Smith ~ Engineering Department - Employee transferred from Process Engineer to Quality Management coordinator.
Charles R. clay - Compound Department - Compound utility temporarily transferred to compound Operator covering for Verneta Young (on sick leave)
Larry Frye - Maintenance Department - Employee progressed from General Mechanic "B" to General Mechanic A"
RETIREMENTS None. TERMIHATIOM8/RESXGMATXOM8 None.
TO/FROM LEAVE OF ABSENCE R. Danny Flippo - vinyl Department - vinyl Lead Operator
- Union Leave of Absence.
VAB.0001189189
Printed
8/05/92
DEPARTMENTAL SUMMARY HOURS REPORT
.............. YEAR TO DATE ................
Non Paid
Hours .0 2
Holiday
Worked t
1 4 4 .0 0
7 2 .0 0 4 8 .0 0
2.50
6 0 3 .5 0 6 2 0 .0 0
3 6 .0 0
os g CO
i:
i!
q *0 3C
. MM
oo
_
1^
- CO rlVl ^ M-- >o
fVUl KLm
21
S; 'O
8
to o
s
J3
in , CM to CM
a A di
a A n
j
jo
$
ts
M" M-
M *a
to
o m
s
o m
s
a
3
s
8
in CM
o m
10
10
10
w JVi Mk 41 A a av A
5o
o JS
t-> JO
K.
o 40 Mr CM CM to
L
s s s s3s88 88Q88
M.
%
N
o
o N
40 K
3
3
d tn
w
c; o j
O'
. 4
.
to
00*0
s
3
tn CM
88
V
o
3
:
O tn
3
CM
.-
VCh o CM tn oo
CM to
in in
3
''
3
o*
to to
A A M
A
4
C\l o to
40 to N CM 0 O
a
O
ic 8 8in
o
IA CM
lA
3
3
tn CM
m CM
10
in
a aA
in d in 40
R 3 3<o *4$o in n
3to
i
CM CM in
to
to m
O
i i
ft!
2P
cm
to
LU Q.
CO
AIfIIIfIIIl
01
c
1 41
\
sc
Ui
cc
o
o
LU c/> CO
UJ
o
LU
8 CO lu
Ui
u
or
$
$
g
CO
o
o
u
O'
MUi
3 fsj
u
Ol 41
^r
So CL
O <0 CL
VAB.0001189190
i
4i
i
DEPARTMENTAL SUMMARY HOURS REPORT
.......... MONTHLY ............
tno O
s
*0
8
ft
3
8
8
CM $
ft in
ft
N
ooo*
88
O
3
8
O 8
8 to
8
8 to
ftto-
N> to
K> toto
OdOoo
CM
.
i +
00*0
O O 'O
00*0 00*0
00*0 00*0
8 3 $ Oo
8
O
1 6 8 .0 0
0 .0 0
0 .0 0
8
#
8#
8
O oO
88
3
8
8
$38 to
8 to
8
Jttoo
8 to
8to
O O O O ft ft O
8i8
O#
j
O
8 O
8
O
ut i'
ir
O. to
8
d
8
qtfo
8
ottoo
8
d
8 to
O
88 to to.
OiO
i
8 88
O
8O
8O8
Oooto
<5to o .; O
8too
8 to
Oio
to
1
8 to
: Ti
8
O|o d
.< i>
i
CM
V
oo ow
8
O
tA
3t8o
8 to
o
8 to
8
Otto
oo d
83 to to
.
CM
CMto
ttoo
CM
pJ
ft
04
8
O
8
oV
Ointo o
CM
8 gto iO
8
to
o
O8. to
8to O
8to o
ft ft
ft 58
8
8
:
8 to
8to
8to
O 3 o
SBto g
8to
8
8to Jg
8**ttoo
8
to
ft
8
toto t8o
8tVo 41[s] 3
"
88
CO
8O
8
CM
8
d
3
8to O
JOV
8to O
8
j
8
O
i
8
3
8
s
8
ft
ftV
CM
8 O
IOA
CO
hto
CM
3* 1 ato o* co
04
to o
ftto
8
d
fc M
JO
ft N
8
d
1*-
CM CM
1C
*
8 O
om d
<r
1C
h*
CO
* 8
ft
toOj
ft tVo
5
oon
*
in
CM
co
8 rg
in
CM0to
ion
o'
m
d~ d
co
N
&
*o
CM
g g
to
g >
m
VAB.OOOl 189191
Printed
8/05/92
4*
K
DEPARTMENTS
#EMPLOYEES
WAREHOUSE GENERAL PLANT MAINTENANCE LABORATORY COMPOUND VINYL PLASTICIZER SUB TOTAL SALARIED
15 10 36 22 36 32
5 156
80
M
9 5 8 4 24 11 2 63 6
4
F
0 0 0 1 1 2 0 4 19
%M %F
60% 50% 22.2% 18.2% 66.7% 34.4% 40% 40.4% 7.5%
0 0 0 4.5% 2.8% 6.3% 0 2.6% 23.8%
DEPARTMENT TURNOVER
MO. FYD 00
02
03
01
02
02
00
ANN. %
0 24% 10% 5.5% 6.7% 7.5%
0
VAB.0001189192
A ADMTWTSTRATIVK SERVICES - D. A. Barclay
There were no reportable safety Instances this month
Quality
All teams met during July to review progress on their projects
Futures
MTD Galn/(Los)
YTD
Natural Gas
$0 <$34,092.64>
Statistics Pppftftwd
FY92 Y.T.P,
Processed Invoices
Working Fund Checks Written
Cost Savings Through Bid Process
$
Raw Haterial Purchase Orders Issued
MRO/AFE Purchase Orders Issued
Spare Parts Purchase Orders Issued
1,139 11
,466.22 110 163 177
10,713 165
$30,891.98 995
1901 1917
Packaged Finished Goods Ending
June. 92
(Decrease)
%
Compound "A" Grade
3,440,831
PLENEX
159,878
Compound Off-Grade (BC)
463,256
Compound Off-Grade (H) Millscrap
270,429 341,660
Dry Blend "A" Grade
534,150
Dry Blend Offgrade
327,276
Resin Type I
598,200
Resin Type "BC"
100
Vacuum Dust
Total Packaged W/house 6,346,386
Bulk Finished
3,757,133 139,263 402,946 107,117 155,418 607,206 278,130 950,750
100
192-058 6,590,121
Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade
Total
June.*92 Julv. *92
499,675 0
1,335,580 598,930
12,588,021 1.983.802
17,006,008
448,765 0
1,321,300 269,870
9,605,310 1.591.012
13,236,257
316,302 < 20,615> < 60,310> <163,312> <186,242>
73,056 < 49,146>
352,550
0
< 18.548> 243,735
9.19 <12.89> <13.02> <60.39> <54.51>
13.68 <15.02>
58.94
0
< 8.81> 3.84
(Decrease) /Increase
%
Change
< 50,910> 0
< 14,280> < 329,060> <2,982,711> < 392.790> <3,769,751>
<10.19> 0
< 1.07> <54.94> <23.69> <19.80> <22.17>
/""N
VAB.0001189193
~7
V
VAB.0001189194
A8ER0EEN CHEMICAL PLANT
PRODUCT RETURNS
JULY 1992
*
Ul
3
IA
VAB.OOOl 189195
V
r
VAB.0001189196
ABERDEEN CHEMICAL P U N T
PRODUCT RETURNS
JULY 1 9 %
gg
IU
N
CM CM
*n O
ti
s 8 4A
1C
VAB.0001189197
ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS
JULY 1992
-SHIPMENTS BY PRODUCTS-
PUBLIC
MONTH 1PT/ITC
EXCH/TOLL
PUBLIC
YTD
IPT/ITC
07:33 AM 11-Auq-92
EXCH/TOLL
RESIN-BULK RESIN-PACKAGEO
13,628,509 22,267,830
515,200
308,250
0 0
160,731,029 176,319,510 5,129,505 3,248,700
0 0
FLEXIBLE COMPOUNO-BULK
1,201,480 3,366,310
4- FLEXIBLE COMPOUND-PACKAGED 2,573,918
103,828
0 0
4,685,920 20,441,160
30,366,219
334,581
0 0
NEU BUSINESS
20,955
00
155,789
00
RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED RIGID COMPOUND-PELLETS
TOLLING - BULK TOLLING - PACKAGED
960,980 711,418
0
0 0
306,100 0 0
0 0
0 0 0
i
0 0
11,198,860 4,325,357 0
0 0
5,533,050 181,850 0
0 0
0
0
0 0
PLASTICIZER
TOTAL
SHIPMENTS BY MODE BULK:
JULY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
0 512,400 19.,612,460 26,864,718
0
0
RAILCAR
196 20 5 3
CUSTOMER PICKUP
3 0 15 0
COMMON CARRIER
22 28
0 0
165,060 5,606,660
236,757,739 211,665,511 iimmim!
917,400 91*7,400
TOTAL
221
48
20
3
TOTAL JULY
224 16 50
292
*YTD*
RESIN FLEXIBLE COMPOUND i 1 RIGID COMPOUND PLASTICIZER
1,664 118 70 34
126 339 0 114 18 112 0 16
2,129 232
200
50
TOTAL YTD
nnawiamMMnaBiM
PACKAGED:
JULY* RESIN FLEXIBLE COMPOUNO RIGID COMPOUND PLASTICIZER
1,886
144 581
immiWNiMnamiiutiiiimmmmnmMHiawMMn
CUSTOMER PICKUP
COMMON CARRIER
TOFC AIR/UPS
AIR/UPS
1 26 0 0 18 68 0 0
4 11 0 0 0 000
0 0 0 0
2,611
TOTAL
27
86
15
0
TOTAL JULY
23 105 0 0
0
128
YTD* RESIN ft/" FLEXIBLE COMPOUND RIGID COMPOUND
i
PLASTICIZER
> a-
4- TOTAL YTD
umm**mm*semmmssmns
29 241 192 836
19 120 00
240 1,197 KSSSSSaSBKMB &SS38SBS8BBSKSRX
0 0 0 0
0
0 0 0 0
0
5 23
1 0
29
1,051 140
0
1,466
II
II It II
H
II
*It
M
II
II
II
n II
H
II II
H
u 0 II
*
DAB,TLC,MAS,AEV,JRF
VAB.0001189198
4
TABORATORY - J. M. Edwards, J. R. Williams
A. Safety
There were no safety incidents in the Laboratory during July.
B. Customer Contacts
Richard Williams visited the AT&T Phoenix Works to learn about 757-D compound special testing.
7/08 Tandy
2/M
The customer complained of rough surface on extruded wire using 34711 Natural compound. Analysis of the bumps on the wire showed natural unpigmented compound with the same composition as the normal covering except a little harder.
Alsco. Olive Branch. MS
7/14
The customer complained of a hard-toopen bottom outlet valve on a 5385 railcar.
Chicago Magnet Wire. Elk Grove Village. XL
The customer complained of a loss of bond strength between 35851 Natural compound and copper wire. Analysis of the plasticizer showed 10% cross contamination of DIDP in TOTM in the compound.
I/M Flexible Technologies. Abbeville. SC
The customer complained of gels in 58031 Water Clear compound in vacuum cleaner hose application. Analysis showed the lumps to be the same com position as the rigid PVC support ring in the hose.
7/14 Flexible Technologies. Abbeville. SC
The customer complained of lumps and pits in wire coating made with 46801 compound. The lumps were caused by harder pellets mixed in the compound.
4
ft
IAROBATORY - Continued
C. Customer O.C. Problem Report* end CMR*s - continued
1/M ?ffC,CqiKIlftK. SfttOBtgMI..*U
The customer complained that a 5305 truck was delivered 2 1/2 hours late. The 5305 resin delivered was off color and contained foreign contam ination.
7/21 Formtech. Bogart. GA
Shipped a box of purge material to Formtech in Stow instead of Bogart.
Q7/ZZ Savannah Wire and Cable. Pembroke. GA
The customer complained of out of round wire made with 35852 compound. TSL suggested some process changes to make and the problem went away.
P.7/22 AT&T. Omaha. NK
The customer complained of a sticky yellow substance in a railcar com partment of 34862 GRY 546 compound. Austin analyzed the substance and found it contained lead stabilizer and aluminum trihydrate held together with plasticizer. The most likely source is undispersed raw material.
P7/25 Vlcoa. Glassuort. PA
The customer complained of a green tint to boxes of RP-34 dry blend. The "A" color value dropped slightly at the end of the production run. We are waiting for the boxed material to return for further testing and spec revision.
D. Product Waivers Issued
Customer
Ensolite Formtech Style Crest
Product
5385 RP-91 WHT 110 RP-17 WHT 113
Reason
Wo.
Particle Size 1 R/C
Fusion Torque 1 H/T
Color & Fusion 1 R/C Torque
VAB.0001189200
LABORATORY - Continued
D- Product Welders limed - continued
Customer
Product
Tandy Wire
54332 CB 50
Color
Vycom
RP-461 WHT 110
Color
Western Ag.
80273G WHT 110
Eq. Torque
Ho. 1 H/T 2 H/T 1 R/C
The following is a summary of residual VCH results on in-
process samples.
None of the reactor daily averages
exceeded 400 ppm RVCM during the month of July, 1992.
Number of Samples Average RVCM, ppm
Reactor
Sjurrleff
923 65
Dryer______
23 0.217
79 0.096
F. RVCM of Shipment Samples
The following is a summary of the residual VCM analysis of shipment samples for the month of July, 1992.
5225 5265 5305 5325 5385 5395 5415 5416 5465 Debox Pond Dry Blend
0 38 103
3 79
8 75
0 4 16 1 2
G. Flexible Compound Otian^y
Hardness Color Hard Particles Heat Stability Dicing Mischarge METS-IR
Adjustments
M Lbs. %
21.7 <0.32> 45.0 <0.65> ...............................
---------------
...............................
---------------,--,i
66.7 <0.97>
0
0.091 0.071 0.067 0.166 0.068 0.041
0
0.013 0.135 0.030 0.018
Rejections
M Lbs. J&l
------15.4 31.3
54
45
25.3
--7k
90.6
<0.22>
<0.46> <0.09> <0.08> <0.37>
<0.11>
<1.32>
/*
VAB.0001189201
lABOBATOBY - Continued
Rigid Compound
Torque Rheometry Torque Rheometry & Color Torque Rheometry, Color & Cont. Color
Total
Rejections M Lbs. <S>
4.6 3.9 8.4 3.9 20.8
<0.27> <0.23> <0.50> <0.23> <1.24>
t
VAB.0001189202
I
3 E> S 8
oi t-- o c\i
co cm
>r- IQ
I** IN* e>
h- CM
I I
143 152 153 165 142 176
Average Particle Size, Microns
I Bm
3
EE 5 IO Is-
#
i&m
4t +.:ll
mmm
VAB.0001189203
SAMPLE SHIPMENTS JULY 1992
RESIN Ship Date
7/10/92
7/13/92 7/16/92
7/22/92
7/23/92 7/24/92 7/30/92
COMPOUND Ship Date 7/08/92
Product 5395 5415
5415
5385 5395
5385 5305
5415
5395
5225 5265
Product 6085 BLK
7/13/92 7/14/92 7/17/92 7/27/92 7/27/92 7/29/92
18033 CB 50 18033 CB 50
6085 BLK 48562 BLK 39014 WHT 380 35852 NAT
Amount 5 lbs. 5 tbs.
50 lbs.
10 lbs. 10 lbs.
50 lbs. 50 lbs.
50 lbs.
3000 lbs.
50 lbs. 50 lbs.
Customer Bayshore Vinyl Compounds
Ship Mode UPS
M. E. Inc. O'Sullivan Corp.
Airborne UPS
Harcro's
Airborne
M. E. Inc. North American Plastics
Global Products
Airborne CC UPS
Amount 100 lbs.
100 lbs. 50 lbs. 100 lbs. 50 lbs. 1500 lbs. 1500 lbs.
Customer PROCESADORA INDUSTRIAL
de PLASTICOS
Ship Mode Airborne
REKO Company
Airborne
REKO Company
Airborne
H. Heller
UPS
Standard Plaque
UPS
Sunbeam-Northern Co.
CC
Southwire
CC
VAB.0001189204
SAMPLE SHIPMENTS JULY 1992
DRYBLEND
Ship Date 07/17/92
Product RP-461 WHT110 RP-421/RP-442
7/21/92
378-143 Purge
7/22/92
RP-421/RP-442 RP-421/RP-442
RP-461 RP-461
MISC.
Ship Date 7/27/92
Product 610-P Halbase 10EP
Amount 4X5 lb*.
5 lbs.
100 lbs.
30 lbs. 20 lbs. 50 lbs. 20 lbs.
Amount 5 gal.
25 lbs.
Customer H. Heller
Formtech H. Heller
Page 2
Ship Mode UPS
Airborne J. Stark Pick-up
Customer R&D - Austin
Ship Mode UPS
VAB.0001189205
NUMBER OF INJURIES
A
ABERDEEN CHEMICAL PLANT INJURIES
(Twelve Month Running Totals)
MONTH
TOTAL INJURIES
OSHA RECORDABLE
VAB.0001189206
ABERDEEN ENERGY EFFICIENCY
BTU/LB TOTAL PRODUCTION
3600
3400 -
3200
3000
2800
C-h
PQ 2600
2400
2200
2000
I J .1 l 1i J i
. .. .1 t
AA *A i i iJJ
1I tI
I I I I I I I I I 11.................... I . . . . . J . j I 1 . 1___I 111
til
,i
JAN 87
JAN 88
JAN 89
JAN 90
JAN 91
JAN 92
JUL87
JUL88
JUL89
JUL90
JUL91
JUL92
MONTH
VAB.0001189207