Document o9gbqQBrbVea0Ny68VgODjEwr

To: T. H. Huffman ..J * pron,. Dol: Subject: D. C. Skokna January 22, 1991 ABERPEEM MONTHLY PROGRESS REPORT DECEMBER, 1990 There was one recordable injury reported in December. The injury was suffered by a mechanic when his right forearm contacted an ex posed steam tracer causing a second degree burn. As of December 31, 1990, the plant's employees have worked 4,197 days (5,600,536 manhours) since the last lost time injury. December Y.T.D. PVC Production, MM Lbs. Reactor Stream Factor, % Resin Quality, % Prime VCM Efficiency, Lbs./Lb. Flexible Compound Production, MM Lbs. Flexible Compound Quality, % Prime Rigid Compound Production, MM Lbs. Rigid Compound Quality, % Prime Plasticizer Production, MM Lbs. Plasticizer Quality, % Prime Energy Use, (EUI, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M 42.5 90.9 99.1 1.01422 4.4 96.6 3.6 99.6 1.8 84.7 < 3.2> < 21.4> 63.3 126.6 89.4 98.6 1.02355 15.4 96.8 13.9 99.6 5.2 88.2 < 3.1> < 24.5> < 40.6> Operations were smooth in the resin unit. Some planned downtime was taken in the flexible and rigid compound units to reduce inventories. There were twenty-two hours of PLENEX polymers development on Line I. A second, longer Vistel 9102 run was made on Line V producing pellets for a trial at UBrand. Fixed costs were essentially at budget. Variable costs were favorable primarily due to the product mix run in the rigid compound unit. VAB.0001189847 T. H. Hnffain 01/22/91 Aberdeen Monthly Progress Report - December, 1990 Page 2 OMP All of the plant's natural teams met during the month. D. C. Skokna Plant Superintendent rah VAB.0001189848 DISTRIBUTION Houston J. D. Bums R. T. Ferrell X X T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin Cohen Austin J. P. Stokes R. L. Poe H. J. Hall LCVCM Plant H. D. Garrison R. A. Conrad LCLAB Plant J. Friend J. V. Ware X Hammond Blane L. R. Bauer J. Pavao C. R. Miller X X P. L. Foote RWS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, MRX, DAB, DAM, RBN, JEN, JDO, REP, BLT X X X X X X X X X X X X X X X K VAB.0001189849 SAFETY - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 0 1 1 0 0 Fiscal Fiscal 31 00 Vinyl Operations Compound Operations Maintenance Laboratory Rec eiving/Warehouse Office Totals 0 10 022 1 54 000 000 01 I97 Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains Stings Other Totals 031 001 111 021 020 001 Q. 19 Lost Workday Cases Days Lost Safety Record 0 4 Last lost time injury - 7/5/79 Days since - 4,197 Employee hours since - 5,600,536 On December 31, 1990, the employees of the Aberdeen plant completed 4197 days with no lost time injury. Topic for the plant safety meetings during the month was "Back Safety" presented by Ginny Belk, Plant Nurse. * VAB.0001189850 SAJ^T| - Continued Routine dosimetry results for the month were: VCM Lead Total Particulates r 71 100.0 10 100.0 2 100.0 WliHK*`r 0 0 0 ooo Maintenance Second degree bum, right forearm A came burn exposed steam tracer causing VAB.0001189851 All of the plant's natural teams met during the month of December. Many of the teams are in the process of brainstorming new team measures/projects. The Plant Manager's Natural Team chose as their next project the improvement of cash flow by a sustainable $1MM per year. The Administrative Services Natural Team chose report reduction as their next project. The Senior Process Engineer's Natural Team continued development of their project to improve DOE knowledge and resources. The plant's quality coordinator attended a DOE at LCCP the week of December 3. Thanks to Pete Markey and Dave Hollis for the oppor tunity. The Aberdeen Plant conducted its first self-audit against ISO 9002. The quantified results were: Manual - 72%; Actual Practice - 85%. The average natural team score for the first quarter of FY91 is 11.77. The Aberdeen Q-Score as of December 31, 1990, is 5.2 - not including linkage (not available at the time of calculation). VAB.0001189852 Variable Costs t SM__ PVC Flexible Compound Rigid Compound Plasticizer Total $59.7 < 96.4> 135.1 $63.3 <$1427.9> < 123.4> < 117.3> 3.7 <$1664.9> <$1480.2> < 219.8> 17.8 < 31.4> <$ 161.6> PVC: The favorable variance is primarily due to a favorable product mix, offset some by producing 49% less off-grade (debox) resin than budgeted. Since debox is credited at a higher value than variable cost, the plant suffered a negative variance. In December, this "penalty" was $16.4M. Compound: The unfavorable variance was primarily due to product mix. The favorable variance was due to product mix and favorable raw material consumption. This month's variance corrects an overstatement made in November. VCM Resin to Rigid Compound Resin to Flexible Compound Phthalic Anhydride 610P to Flexible Compound AlfolR 610 Other Price Variances Total <$1434.9> < 105.9> < 79.7> < 49.3> < 15.5> 42.0 <$1664.9> Fixed Cost Variances m Payroll and Benefits MM&C m Miscellaneous TI&D <$ 69.4> 67.0 < 8.0> #- Total <$ 21.4> VAB.0001189853 Continued Payroll costs were above budget due to the plant having three holidays in December. M. M. & C. There was less than budgeted activity. All items were near budgeted levels. TI&D Underbudgeting "ad-valorem" taxes caused the unfavorable variance. VAB.0001189854 - J. D. Olson, J. K. Vinoski Safety, 4- The Vinyl Department had no first aid case or OSHA recordable injuries during December. The monthly safety meeting topic was "Lifting Techniques". 1. Production of 5415 resin was temporarily switched from the New Module to the Old Module to improve hard particle results. The regul&r New Module dump header configuration is the suspected cause of high hard particles in resin made in reactors D741 through D744. Modifications to the header are planned for February. 2. A site acceptance test was performed on the computer control equipment by Vista and Aberdeen personnel as part of the VCSM Project. The equipment was accepted as delivered and programming work is underway. 3. The resin raw materials in the 744 account were valued at $282.3M. - 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, % Pri Dec. 42.5 1370.4 107.4 989.0 31.9 90.9 93.7 96.2 99.1 YTD 126.6 1376.5 107.9 2926.0 31.8 89.4 93.7 95.9 98.6 Operational downtime (recovery scheduling conflicts, New Module rinse/charge water conflicts, Q.C. data delays, O-ring leaks dump conflicts). Hours 434.0 Maintenance downtime (D600 agitator shaft replacement, D500 gearbox replacement, unplugging of D500 lip seal flush, D700 hydroblasting and condenser drilling, D500 seal change, D500 condenser lid gasket replacement, D700 seal change, Old Module charge line repair, cleaning BUS-80 nozzles). 240.0 vjjiijl. - Continued drrer Pflwfitlm* r Operational downtime (centrifuge plugs, dryer cleaning, flameouts). 38.7 Maintenance downtime (screw valve and centrifuge repair, sparge pipe replace* ment, exhauster, screw feeder, screener maintenance). 42.0 Work - J. B. Autrey, S. A. Truitt Reactor seals on 700 and 500 were changed due to plugged throttle bushing flush. The top condenser gasket on reactor 500 was replaced because the old gasket was leaking. The agitator shaft on reactor 600 broke and was replaced. A crack was discovered In the false bottom of reactor 500. The crack was repaired. Reactor 745 was hydrobiasted because of contamination problems. The gearbox on reactor 500 was pulled out of service to be repaired on PM schedule. The recovery compressor was changed out due to wear. A motor on #5 Bird was replaced. The old motor's windings and bearings were damaged. VAB.0001189856 RnMWHfllD - J.E. Nickerson, K.G. The Conpound Department had no OSHA recordable injuries in December. The topic of the monthly safety meeting was "Back Injuries". The three flexible compound lines and the dry blend unit were scheduled down for the three-day Christmas holiday. As other opportunities arose, downtime was scheduled to control costs and/or inventories. The plasticizer unit operated all thirty-one days this month due to the continued strong external demand for plasticizer. Following the successful trial of VISTEL 9102 samples at U-Brand, a longer production run to produce compound for a 1OH-pound order and to further evaluate Line V capabilities was completed December. Hore customer feedback as well as NSF approval is expected in January. Several shifts were taken to reprocess some compartments of AT&T's 34862 GRY546 compound on Line III. The compound had been offgraded due to hard particles not detected during initial production but found in railcar samples prior to shipping. Operating Month Line I 28 Line III Line V Total 28 9.5 % Prime Capacity Utilization Factor 1605 2778 4419 96.6 54.9 57 99 __4 158 5435 9495 449 15379 96.8 64.1 Dgyntlag Hours - Product Changes - PLENEX Polymers Production - Miscellaneous Maintenance 67 22 22 - Product Changes - Quality Problems & Control - Miscellaneous Maintenance - Quality Problems & Control 57 25 20 * DM mm VAB.0001189857 mmm wfNmm COMPOUHD - Continued - Product Changes - Miscellaneous Maintenance Operating 19 15 Rigid Compound 20 % Prime Capacity Utilization Factor 3617 99.6 60.8 181 13930 99.6 78.5 Downtime Hours - Product Changes - Miscellaneous Maintenance - Quality Problems & Control - Screener Maintenance 42 29 14 10 Operating Month Plasticizer 31 1761 % Prime 84.7 Capacity Utilization Factor 93.5 5200 88.2 92.0 J. B. Autrey, S. A. Truitt PM work was completed on the #1, #2 and #5 dicers. -"V L VAB.0001189858 ENGINEERING - R. E. Polk. S. C. Hillman, M. R. Kano The Taylor DCS system is in place and site acceptance has been completed. Configuration and system checkout are on schedule. The first phase of operator training is being conducted in January. An open house for the neW control room will be held the week of January 21. 4 Preparation is being made to meet with the Mississippi Department of Environmental Quality in early February to discuss our air permit application. Data from air dispersion modeling done at the plant and information furnished by C1ements International Company are being compiled for this meeting. Clements International Conipapy is in the process of reviewing the VCM unit risk factor with the EPA in Washington to determine the possibility of getting the EPA to re* evaluate the unit risk factor given to the State. Compound Line v A second trial run was made in December to further evaluate Line V equipment's ability to make Vistel 910& in full production. Although some mechanical problems were experiexi ingredient conveyor, the line ran well overall. U-Brand has run into problems using Vistel 9102 rigid pellets made on compound Line V during the initial trial in November. RAD is evaluating formula changes to address these problems. Test runs to date have shown that double screening of profile products can be effective in reducing oversize particles below the spec of 0.1% on the 40 mesh. Design work is being completed to provide reliable double screening. Most likely, the project will provide replacement of the Gump screeners with Kason screeners. Wastewater Test Run Centrate water is being recycled to the cooling towers replacing fresh make-up water. The impact of reduced hydraulic loading on the ponds is unclear due to pH excursions during the test which resulted in killing bugs. The major organic loading source, T-460, is being monitored closely to ensure complete reaction of the major BOD con stituent. EKBlJKCiiN - X.E. POLK, S.C. HILLNN, K.l. KANE ife HU *51* AH* milMfwf Ml* M2* >71* )M* mr iro FM* Fil* F77* AM* BAS* HI* AM* >57* I5H MH FJ*f FAM FAM 65AI BAH BAM MH Hit 152* M2* HB1 < pmm mmm alienate mmm. m fipeuk ||M| M|| MH VrvUPK-' PUMK EUCUBUi WMK vmroMr HU ** ,, mmutir IkKVH SEMI UHIAHIJB AH HNHH ffffffff Lis i ohu ieai mmm cmpm mmmmmm ~ USB IHMSftSS IRICK S.B I 5 pusiiciza BEXHUMHi ' : 11 BEHCTIN wmaienkn nenical mm capital pnjects stain nrmjtn nu k an n fiqj awtei u mmii. CUB n FIOIOMB. apyina f nr ammt raw u u mu m nmam carumui w me. iotbiw HW--I ! ,- . T'~ cusiumi oarTFM maun nm~- - -B -At IMIHMi U MEEK EXCEPT FH PWOLI5T ITEH. FIEU CUSNE IS PLANO FNFOMT MStSUitt VIU MLETIN PLANO FN MS*. LMIttl 1T NK KN PLACO N BM. PIUECT CBSLCIIN IS PLANE! FN MU MSiSSi U MSS EXCEPT FBB PMLIST ITEH. purer Miens is piano fh fenbait. mmm atm m mpmlisi iteh. is stbtu sen places uts mm K OHO TB FIEU NARKS IN Mill. m ob mmin ruMwamiL. INK IS CNPIETE AN TK PHJECT SILL IE CLOSE! TB FIEU HANES IN FEItNIT mtttl CNPUIIN IS PIAM FN MMI rV PtIKCT OKUTIN IS PLANO FN -' mItNsmKli NrIMMSi mMSsB MMMMM MrSSMirUrTl BUI NNKI SMI* HUN ACCfH OSNUIIN IS PIANO FN 7/*l. J l'* * 4* _ * L Bf * * -- .* SL hJm '+ * ICNM VAMPNFFKNIR BELIEF PLABflCUn UHJN IS BSBAM SVttM UMEflilN JNMLUIIN IS PLANO FH 7/*l. N MLETIN FLANO FN FISNART. ^* t#inHs# MIIIIIIMHII SVSHSfrdRSSISMNNVSMIMNl SUBeH Bin MLETIN PLANO FN FENNNT KaUVIOMO ANSCNNLE1 MLETIN IN MNT. LON LEM ITEN AN BN MEI itvnraBiBM INNltllN It CANUTE EXCEPT FH PONHLIST ITEN rcaauBFMBt new wm triform amauim Pw MLAmN MtHItaMUmI VI4VMI nr -- hi-- EXCEPT FBI PNCNIST ITEN IS IN SISTERIPEIATIINL. FIEU CUM IS FUNNO I h o mmm. mm cnpiehs is pum fn hum s mrnmmrn is piano is mu mm muetis o fum MU iooubb arm nuni < tm CUKIH FIEU HANKU CtfMloSf CHNCFisMEEPM^MfMSs MHVBIAJKMQCIKMnVI NOSS S STIWSSm IS FIANNO FH S/91. FRSJECT MLETIN IS FUND mu inn iwb Willi noon < tm MSN ON I PIIJECTS. VAB.0001189860 EHVdOMflgrTAL - F. 6. Jeanson All wastewater discharge parameters were met for the month of December. The draft NPDES operating permit was received from the State. Many permit limits were reduced from our existing permit limits. A meeting was held with the State to discuss the changes from our existing permit limits. Negotiation with the State resulted in some higher limits and additional testing on our part to determine whether the stricter limits are justi fied. The State will issue a revised draft permit in January. The remedial investigation (RI) on-site work was completed. All samples have been taken. Results from the samples should be received in January. The final report on the RI will be issued to the State in February. Some investigation was also started on the site containing the buried drums. Three holes were dug where the geophysical survey showed the drums to be located. No drums were found in these three areas. DERS is eval uating plans on how to proceed with the remediation of this site from this information. No hazardous waste shipments during the month. - A new compactor was installed for disposal of lead bags. 1 attended a waste minimization conference sponsored by the Mississippi DEQ and the Mississippi Technical Assurance Program. The NESHAPS quarterly report was issued during the month. The annual 200 valve survey and incinerator feed line inspection was also completed during the month. After investigation into the unit risk factor for VCM by our contractor, discrepancies were found in the data that supports the higher (new) unit risk factor. These discrepancies are being pursued with EPA in Washington. The semi-annual SPCC Plan Survey was completed during the month. An offer of $45M was received for our resin reclaim dryer. buyers will be in the plant next month to look at the dryer. Potential J. R. Ganc A. Unadjusted EUI <4.2%> B. Adjusted EUI <3.2%> C. BTU/Lb. Product 2656.7 D. Total Energy Consumption MMM BTU 138.68 < 3.3%> < 3.1%> 2603.8 413.07 No. 1 No. 2 No. 3 83.0% ........... 82.7% Boiler #2 was not operated during the month. 82.9% 83.0% 82.8% VAB.0001189862 Nona J. E. Beall Curley Payne - Maintenance Department - Employee bid from General Mechanic "A" to Lead Warehouse Worker (replaced JCL). David Moore - Process Engineer -- Transferred to Lake Charles VCM plant as Process Engineer. None Michael Schneider - Engineering Co-op Student - Returned to school. Coleman Haynes - Compound Department - Military Leave of Absence to Persian Gulf. Robert Hamilton - Compound Department - Military Leave of Absence to Persian Gulf. Charles Reed - Compound Department - Military Leave of Absence to Persian Gulf. James Gray -- Laboratory -- Military Leave of Absence to Persian Gulf. VAB.0001189863 15 12 40 23 38 33 5 166 76 90 50 70 62 22 1 10 1 20 61 4 6 18 60% 42% 18% 26% 58% 30% 40% 37% 7.9% 0 0 0 8.3% 2.4% 3.0% 0 1 0 1 0 0 0 0 2.4% 23.7% 2 4 2 1 1 1 1 VAB.0001189864 A R s in -- 1 1 t I <* $1$ AA M 1 o 1 1 1 1 SIS M IW ? I 1 1 J 1 tin V' * IW 1 1 1 1 ft T CM * CM in DEPARTMENTAL HOURS ANALYSIS REPORT DISTRIBUTION LIST MS, JFC, JVU, DEPARTMENT HEARS, FILE 12/ 3/90 THRU 12/30/90 December, 1990 ! $ $SB VOA 11 l a 1 4 P i CM 1 <*> CM ti1 r-o 1 11 in t 1 it ijn id> u 1 CM 2l~ mum VAB.0001189865 P f mpn m $ 3 Ol Pi <CJJ CO Pm PM PMMMlimiM i i* to CM ICM $ CM cn 3t a! VAB.0001189866 ADMINISTRATIVE/PURCHASING PROGRESS REPORT ^ DECEMBER 1990 JANUARY 10, 1991 A Safety There sere no reportable safety Instances this month. A "walk-thru" safety audit was performed in the storeroom, raw materials, and finished goods warehouses in December. Quality All five natural teams met in December* The stores natural team is expected to complete their project and make a management presentation in January. Statistics Processed invoices Working fund checks written cost savings through bid process Month 1,082 7 $4,576 YTD 3,132 39 $9,985 Packaged Finished Qoods Sadias Invamtorv (DECREASE) MOTEMMER 9 O DECEMBER /increase Compound A grade Compound Ofrgrade Compound Offgrade compound MSP - 90 Millss'crap(*) Dryblend A grade Dryblend Ofrgrade Resin Type I Resin Type "BC" Vacuum Dust (BC) (H) 4,183,774 573,177 64,755 89,576 165,786 453,257 21,199 644,320 36,950 301.903 4,455,814 745,902 68,255 0 93,101 468,404 58,662 482,270 36,950 272,040 172,725 3,500 (89,576) (72,685) 15,147 37,463 (162,050) 0 Total Packaged Warehouse 6,534,697 6,720,637 185,940 NOTE: (*) INCLUDES--PLENEX MILLSCRAP AND CLEANOUT. FLEXIBLET& RIGID OFFGRADE DEQ.WIHNU oec.*9o A VAB.0001189867 ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS DECEMBER 1990 -SHIPMENTS BY PRODUCTS- RESIN-BULK RESIN-PACKAGED MONTH PUBLIC JPT/ITC EXCH/TGLL 13.614,610 20,018,730 68,920 201,550 CvJ*LWW , l.'iA *0 YTD PUBLIC JPT/ITC EXCH/TOLL 58,170.660 41,772,110 421,896 667,700 715,900 0 FLEXIBLE COMPOUND-BULK 106,740 FLEXIBLE COMPOUND-PACKAGED 2,n 221,526 NEN BUSINESS 1, 550 RI6ID COMPOUND-BULK RIGID COMPOUND-PACKAGED 3,661,280 213,255 905,850 333, 907 0 813, 050 221,506 0 0 0 0 0 1,583,170 7.820,640 4,132,050 p < 420,144 18,323 fi 8,897,760 848,115 1,505,000 512,706 o f+l 0 0 0 TOLLING - BULK TOLLING - PACKAGED 0 00 0 00 0 0 1.h 401, 960 0 0 33,600 PLASTICIZER 214,960 174,100 533,330 555,380 336,750 1,613,110 TOTAL 20,102,841 22,668,693 1,059,530 78,315,944 49,346,460 3, 764,#570 :ss:s::::33U8?nsmtss;:s:ss:s:::ssssssssim*t8s5sS5scssss9mass::Bstqtnssssras:::3t$:isxs -SHIPMENTS BY MODE- BULK s 1DECEMBER! RESIN FLEXIBLE COMPOUND l RIGID COMPOUND PLASTICIZER TOTAL DECEMBER RAILCAR CUSTOMER PICKUP COMMON CARRIER 176 25 22 6 02 26 1 5 3 45 211 30 34 TOTAL 223 8 32 12 1 111 275 tYTDt RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 513 95 89 33 0 5 63 4 36 4 29 15 697 38 103 48 TOTAL YTD 613 128 145 886 "V PACKAGED: IDECEMBER! RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTIC HER . TOTAL DECEMBER IYTDI RESIN FLEXIBLE COMPOUND RIGID COMPOUND RAST1CIZER TOTAL YTD CUSTOMER PICKUP COMMON CARRIER L 10 18 55 0 13 00 20 78 TOFfc- CONTAINER AIR/UPS ,0 *1 0^ 0 0 0> 10 y 5 1 1*1 `tw 0 9 9 35 52 .209 2 44 00 00 00 00 00 8 33 2 0 / TOTAL 294 48 0 394 ==Ai&B.OOOl 189868 *-* u"> K-- Ui LU iI 3E 3E to to I CC OU UJ on <X <r __t -o ro r'j 0-4 uu Ui LU CJl CJI cE <C CJ LU Cl. \ <r <r <i x CO CO CO tZoD CD CD h- -- -X Cc CD cn CL LU UJ r^i cn LO t cu cu iJtZ txz to to tit Cu cu *'E <1Z *X *vX <E l K" h-- W CtZ tn to to cn pPf^w^+4 DC cn to i1 rx: ::c ii 1^4 LU X I 1 oc co co co or CO I-- to to U C^ CJ cn CO CkJ o cu ctr QU <E Cv CO --* CO :>- 4 " it> tXt LU Ui UJ Cc~ Cr: ct.: cu cu a: CO CD cn UJ UJ UI Ui UJ UJ S Si tn tn rn era o 1X5 3ft =D X5 K* ** CD U- LU to t.rj r.O UJ UJ X5 CD cc cu ,.* . .t i_ji CJ 04 04 CO 04 -40 JJ CO CO t-o ri wu m nr* r'.i Ch Oh ---4 UTj U-J o- l>- CP* O 4 04 O4 C'*4 04 CM 04 0-4 cm 04 04 0*4 C*4 0*4 CM rvi 04 0 4 r 4 C*4 *-0 Cr- 04 OO 04 CM e 4 04 n4 in rN ^ O* ro 04 04 O O O 04 CM o <D , CD O** CO O 04 04 tn cr* lilt I i I 1 1 I CO r-. * no *o o- CO 04 m 04 04 1*0 -*o 4S CD ftO CO CD CO CO CD CD o Sg CD <t> oo* 04 04 tn r*4 1*0 $c Ch o -'"s 0-4 04 o 0-4 CM 0*4 M3 o CO r*o 1*0 OM 49^ 45 41 C*M CO r-O ro 1*0 04 CM r-o ho 0-4 ro -Q -<J ro % m -o fO 1*0 r-i -O 1*0 SB) ho in tn *r> wt* CO CD O 0-4 04 o* 1 1o m 1 4^ CD 1 CD 1 *< CD 1 CO ro 1 to o 1 o1o u-> rvo 1 1 U*5 t*r 1 UT& 1 t ps *o i IM3 |i. 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LU LU E cj cu a: oc lJ __ i luU >-- j,, Ui Ji1, UJ t-- UJ i ftp UJ 1________ .rtl ~>- CP*to to 3C 3ft CD O cu CC CD CD 1_______ -tx. _ -J -J <1Z _ ILO 3E se sc c:i uui UJ cu 3p CD JC 3C 1-- vs 3E 3E 1-- cn cn &3? tn tn cn CD L.3 (-5 CD CD s CD 3ft vk*** "3* S5* CD Ou Cu tn CD > <r <X <C xc /CC i1 LU LU / 1 CD CD D cn cn i CU cu cu j cn CD tu CU CD Lu LU ^n 3D i i to X ><< cn cn H*C UJ UJ cu cu UJ 3* S to tn CD o O o CD m CP* CP* Ch CP* O"* CP* Ch- "'t M-J ho h* 04 04 l>4 CN CN 04 CN CNl%H*. h's*i 04 0*4 CN CN 'v*. UJ ! H to LU 3E <X to Vi JCPD* 1-- to 4C i CU h-- CU CD 1 cn ou CD U- LU c> CP* cn CN A VAB.0001189869 TAMttATOttY - j. m. Edwards, Jr. A. Safety .A- There were no safety incidents in the Laboratory during December. The monthly safety meeting topic was "Back Strain Prevention" taught by Cinny Belk, Plant Nurse. Jim Edwards accompanied Rendell Newton, Mike Kane and Mark Eramo to Southwire in Starkville, MS. A presentation was made to the Starkville staff in support of the Mets I.R. test. Evidence was given to improve the credibility of the test results as perceived by the Starkville staff. 12/17 The customer reported having quality problems with two boxes of 48562 compound in their injection molding process. Chemical analysis of the compound showed TOTM plasti cizer was used instead of DIDP. 12/12 The customer reported having heat stability problems with two railcars of 5415 resin. The car numbers were 41161 and 73412. R&D in Austin is investigating the complaint. John Blum with American Mirrex reported a change in fusion characteristics in a ship ment of 5305. American Mirrex lab showed the Vista sample took longer to fuse and longer to reach equilibrium. The suspect material was one of three railcars. R&D in Austin is analyzing the samples. Central Plastics Tandy Cable 17462 WHT 34431 BLK Heat Stability Hard Particles 7 Boxes 1 H/T /-n VAB.0001189870 LABORATORY - Continued k 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 December, 1990. Reactor Number of Samples Average RVCM, ppm 11 0.151 85 0.286 The following is a summary of the residual VCM analyses of shipment samples for the month of December, 1990. 5265 5305 5325 5385 5395 5415 Dry Blend Debox Pond 10 113 0 99 21 48 15 8 0 0.091 0.138 0.360 0.048 0.068 0.042 0.979 -- ^-- (based on dryer "regulars") mi Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle size, microns 1.40 3.56 7.56 8.00 3.00 2.27 0.55 ---- 128 mi 0.83 1.53 0.87 2.58 9.33 3.17 1.38 *--- 0.72 -- 135 5385 1.23 0.75 3.44 1.17 1.38 ---- 1.22 ---- 48.3 159 mi 0.94 0.67 5.83 2.50 2.00 1.57 2.05 0 150 0.86 0.69 4.00 2.83 2.47 0.47 3.09 2.29 1.07 4.8 163 mm m wmmm IMMIPMiiPIIIII VAB.0001189871 mm & T.ABQBATORY - Continued Hardness Color Hard Particles Heat Stability Contamination Dicing Cross Contamination Total 21.4 -- -- -- ----- --. 21.4 <0.44> ------- ----- -- -- ... * <0.44> 4.9 6.0 178.1 4.8 4.5 3.2 1.5 203.0 <0.10> <0.12> <3.65> <0.10> <0.09> <0.07> <0.03> <4.33> Color Cross Contamination Mischarge Total I. Kieceilaneous 12.2 23.8 9.6 45.6 <0.34> <0.66> <Q.27> <1.27> 1. All six natural teams met during the month. Dave Cox spent most of his time preparing a database program on PC to create the plant IPA report. 3. The I. V. analyzer failed during the Christmas holidays. Samples sent to Oklahoma City for analysis were delayed three days. The instrument was repaired in the meantime and the retains were run instead. The reliability of this instrument is still decreasing. VAB.0001189872 A RESIN r Ship Date 12/07/90 12/10/90 12/10/90 12/12/90 12/12/90 12/14/90 12/28/90 COMPOUND Ship Date 12/03/90 12/07/90 12/11/90 12/12/90 12/18/90 12/21/90 12/28/90 12/28/90 SAMPLE SHIPMENTS DECEMBER 90 Product 5415 5385 5385 5305 5415 Pond 5385 5265 5385 Amount 5 lbs. 1 kg. 7500 lbs. 5 lbs. 5 lbs. 100 lbs. 200 lbs. 50 lbs. 50 lbs. Product 34862 GRY 546 OG 27251 WHT 366 OG 34862 GRY 546 OG 45541 NAT 35451 NAT 38631 NAT 085 38552 NAT 18031 WAT CL(OQ) 18031 WAT CL(OG) 461-120A 35031 NAT 03 2153A NAT 03 38525 NAT 02 Amount 100 lbs. 50 lbs. 300 lbs. 1000 lbs. 200 lbs. 200 lbs. 200 lbs. 20 lbs. 20 lbs. 20 lbs. 500 lbs. 1000 lbs. 200 lbs. Customer D. K. Enterprises HELM AG (GERMANY) Dayton Extruded Plastics Henkel Corporation PANICHEM S. A. M O AIR INTERNATIONAL CABLEC Customer Carol E. Chatham Gentry Management Carol E. Chatham DE ACERO EXPORT c/o HAYES DOCKSIDE Reko Company Dixie Wire Company Tandy Wire VAB.0001189873 f DRYBLEND Ship Date 12/12/90 * 12/16/90 12/31/90 Product 426-90 WHT 110 489-75A WHT 123 489-79A WHT 111 Sample Shipments/December 1990 Page 2 Amount 50 lbs. j 1300 lbs. 1300 lbs. Customer IFER DOMINICANA Premier Polymers Montage / VAB.0001189874 NUMBER OF INJURIES VAB.0001189875 ERDEEN ENERGY CONSUMPTION 01/nj.s VAB.0001189876 i-**K Mpmmi T B