Document oDgjxOGz43rjgqKVeZGX1401E
A
T. H. Huffman
To
CommunlcoHon
From
Dole:
Subject:
D. C. Skokna June 23, 1992
ABERDEEN MONTHLY PROGRESS REPORT May, 1992
VIS1A
Safety
There were three first aid cases reported during May. At month end, the plant's employees had worked 4714 days (6,319,522 employee hours) since the last lost time injury.
PY1992 Key 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 Efficiency Variance, $M
Operations
May
42.4 93.5 98.1 1.0005
5.6 95.3
1.4 98.9
1.4 81.7
1.0 72.0 225.0
Y.T.D.
292.0 84.7 96.9
1.0329 41.5 96.3 16.3 97.8 11.5 79.6
< 14.0> < 359.6> < 431.1>
Resin production was good during the month. Changes to optimize operation of the fluid bed dryer were implemented.
Flexible compound production schedules were tight on Lines I and III. Rigid compound production was cut back to two shifts.
OMP
Flexible Technology (a flexible compound customer) audited the plant versus Ford's Q-l standard. We scored 135/200. Flexible Technology has a minimum target score of 120.
Environmenta1
The semi-annual bioassay wastewater test performed during April showed low reproduction rates in the test organism (fierifisiaphnia dubia). A followup test did not indicate any problems.
VAB.0001189245
T. H. Huffman 06/23/92
Aberdeen Monthly Progress Report Page 2
- May,
1992
Environmental - Continued
Reclamation of Pond 2 continued with no
problems.
Royal Plastics received the
recovered resin.
major first
operational railcar of
D. C. Skokna Plant Superintendent
rah
7
^
VAB.0001189246
DISTRIBUTION
COVER LETTER
Houston
J. D. Burns
X
R. T. Ferrell
X
T. H. Huffman
C. J. Matson
H. R. Flammer
R. R. Smith
B. J. Bean
R. H. Gerlach
R. D. Gamblln
C. R. Miller
L. R. Kardos
M. J. Schneider
Austin
R. L. Poe
X
H. J. Hall
Oklahoma Cltv
H. D. Garrison
LCVCM Plant
P. D. Carrico
LCCP Plant
J. Friend
LCLAB Plant
J. V. Hare
X
Baltimore Hammond
L. R. Bauer J. Pavao
X X
Premiere
P. L. Foote
Aberdeen RWS/DCS (File Copy), JBA, JEB, JME, SCH, DAB, DAM, JEN, JDO, BLT
ENTIRE REPORT
X X X X X X X X X X
X X X X
X
VAB.0001189247
SAFETY - B. L. Trego
First Aid OSHA Recordable
Total Injuries
Number of Restricted Workday Cases Number of Lost Workday Gases
Injuries bv Department
Hav
3 0 3
0 0
Fiscal Y.T.P. 1992
12
15
2 0
Fiscal Y.T.D. 1991
Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office
Totals
Injuries by Type
14 14 17 00 00
Q. 3 15
Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other
Totals
Non-Occupational Injuries
Lost Workday Cases Days Lost
Contractor Injuries
First Aid Cases Medical Treatment Cases Lost Workday Cases
Safety Record
Last lost time injury - 7/5/79
Days since -
4,714
Employee hours since - 6,319,522
On May 31, 1992, the employees of the Aberdeen plant completed 4,714 days with no lost time injury.
i
VAB.0001189248
SAFETY - Continued
Topics for plant safety meetings during the month included: Mill Roll Safety, Reviews of Recent Injuries, Hazard Communication, Substance Abuse, and OSHA Reporting Requirements.
Routine dosimetry results for the month were:
Chemical
< PEL Number Percent
> PEL
Number
Percent
VCM Lead Total Particulates
42 97.7 9 90.0 3 100.0
1 1 0
2.3 10.0
0
Both overexposures were with benefit of respiratory protection.
Summary
Inlurv Class
Department
Vinyl
First degree burn of thumb, "index finger", "middle" finger, and "ring" finger of right hand.
Compound
Abrasion of "middle" and "ring" fingers of right hand.
FA
Maintenance
Burn of left foot.
h
VAB.0001189249
All of the plant's natural teams continue to meet on a regular basis with a number of team projects nearing completion. The Plant Manager's Natural Team has begun work on the Synergy Team's recommendations for removing barriers to QMP. Four of the items requiring action from top management have been forwarded for consideration. Flexible Technologies conducted a quality audit of the Aberdeen Plant on May 28. The standard used was Ford Ql. Vista scored 135 out of a possible 200 points. Flexible Technologies has a minimum target score of 120 for their suppliers and a goal of 150.
VAB.0001189250
COST VAWTAWCKS - D. G. Skokna
Variable Costs
Product
PVC Flexible Compound Rigid Compound Plasticizer
Total
$195.7 15.4
< 5.3>
--1.9.2 $225.0
PVC
$387.7
< 12.6>
< 37.5>
14.3
$351.9
A prior accounting problem was corrected. Flexible Compound
Operations were essentially at budget. Rigid Compound
Operations were essentially at budget. Plasticizer
Raw material use was below budget.
Major Price Variances:
Variance - SM
VCM Debox and Pond Resin Credit Electricity Phthalic Anhydride Natural Gas Plasticizers Ti02 Other Price Variances
Total
$332.9 44.7 20.9 10.1
< 18.5> < 29.6> < 32.6>
24.1 $352.0
Fixed Cost Variances
Variance - $M
Payroll and Benefits MM&C
Miscellaneous TI&D Clearances
Total
$ 22.2 47.5
< 23.1> 1.2
24.2 $72.0
Tofraj
$583.4
2.8
< 42.8> 33.5
$576.9
A
VAB.0001189251
COST VARTAWCES - Continued
Payroll & Benefits
Overtime was near normal and hourly headcount was below budget for the month. Also, $5.7M was expended for the Pond 2 cleanup and was charged to Conoco.
MM&C Activity was below budgeted levels.
l*
Miscellaneous
Costs associated with the cleanup of Pond 2 totaled $20.7M in this category. This was credited in the "clearance" category.
Clearances
Credit, from Conoco, for costs associated with the Pond 2 cleanup caused the favorable variance.
VAB.0001189252
VXMYL - J. D. Olson, D. E. Knittig
Safety
The Vinyl Department had one first aid case during Hay. A Dryer Operator burned his fingers on a rotary dryer. The dryer inlet has been reinsulated.
The monthly safety meeting was "Electrical Hazards Survey".
General
1. Fluid bed dryer process changes have been implemented to Improve contamination performance of the dryer. Discussions with Niro, the fluid bed manufacturer, indicate we are making the necessary changes to improve performance.
2. Witco calcium stearate is being reevaluated due to poor flow qualities. Poor flow properties cause problems in our injec tion systems. Samples have been sent to Witco for testing.
Hay
- 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
%
42.4 1367.8
103.2 976.0
31.5 93.5 96.5 94.8 98.1
Reactor Downtime
ITD
292.0 1196.7
90.3 6960.0
28.5 84.7 90.9 88.9 96.9
Hours
Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts, and no blend tank space).
418.0
Maintenance downtime (TVA Power switching, D-743 baffle repair, D-400 sealn replace ment, D-600 pressure transmitter, and D-400 gearbox slurry valve).
66.0
VIHYL - Continued
Dryer Time
% of Total
Downtime
m Operational downtime (centrifuge plugs, dryer cleaning, flameouts).
69.2
m Maintenance downtime (activator problems, centrifuge repair).
26.1
Reactor limited production.
Ker Maintenance Items In Vinyl
4.7
Reactor 400 seal and oil circulator pumps were changed. The seal failure was caused by an oil pump failure.
The high pressure service water pump was rebuilt due to normal wear.
Replacement plans are in progress to repair the baffle that broke in reactor 743.
The Bird torque tests were performed on all V-ll dryer Birds.
The quarterly PM program was completed on the west incinerator.
A new relief valve was installed on the discharge line of #6 compressor.
The load test was performed on #2 boiler. The water controls were checked and adjusted as needed. During the load test, the #1 and #2 water valves were determine to be undersized.
A fifth utility man began duties 5/18/92.
- S. C. Hillman, J. B. Hegwood
The Compound Department had no OSHA recordable injuries in May.
General
Orders continue to be tight on Line 1 and Line III. Dryblend production has been cut back to two shifts.
fiMPPWt PirodgctiPfr
Operating
Production M (Lba.l
____fisxi__ Month Avg./Dav Fiscal Y.T.D.
Line I
31
Line III
31
Line V
16
Total
% Prime
Capacity Utilization Factor
1703 3455
490 5648 95.27 74.90
55 111
31 182
12366 25873
3304 41543 96.34 66.60
Downt ime
Hours
Line I
- Product Changes - One Dicer Offline - Miscellaneous Maintenance - Quality
121 25 13 6
Line III
- Product Changes - Miscellaneous Maintenance - Quality
93 37
3
Line V
- Product Changes - Quality - Miscellaneous Maintenance - Coverage for Other Lines
33 1
37 33
VAB.0001189255
COMPOUND - Continued
Operating Days
Rigid Compound
18
% Prime
Capacity Utilization Factor
Production Of Lbs.) Avg./Pav Fiscal T.T.D
1449 98.86 28.10
81
16264 97.81 39.20
Downtime
Hours
- Product Changes - Miscellaneous Maintenance - Quality - Coverage for Other Lines
58 14 39 10
Operating P*V8
Plasticizer
30
% Prime
Capacity Utilization Factor
Production (M Lbs.)
Month
Fiscal T.T.D.
1425 81.68 59.80
11497 79.58 58.42
Key Maintenance Items - J. B. Autrey/S. A. Truitt m Regular PM on #1 dicer was completed. m Line I "B" blender motor was replaced due to bad windings.
VAB.0001189256
ENGINEERING - J. E. Sickerson, T. R. Mackay, R. H. Sneed, M. L. Carter
PROJECTS IN DEVELOPMENT - GENERAL
Water Plant
Construction is proceeding and startup is scheduled for the middle to end of July.
Debottlenecking - Prverg
A new air line was connected to dryer #8 activator to improve compressed air flow rates, eliminate flow restrictions and make higher resin transfer rates possible. Centrifuge torque evaluation data has been compiled. The Bird Company will study the data and make recommendations.
Resin buildup and burning are causing a problem with the fluid bed dryer. Niro, the fluid bed vendor, has been contacted for advice.
Improvements in the plant wet air system are being evaluated in order to improve compressed air supply to activators.
Semi-Bulk Lead
A third supersack of lead stabilizer was successfully run on the Line III semi-bulk lead system.
OSHA Process Safety
A meeting presented by OSHA was attended in Houston. In this meeting, OSHA stressed their expectations that industry make a "good faith effort" to comply with the regulation. OSHA defined a "good faith effort" as having as many process safety documents generated and implemented as possible by the May 26, 1992 deadline.
Also, Reed Mackay, Rodger Collins and Steve Carroll attended an Operating Procedure Writing Class in Lake Charles. This class was presented by the personnel at LCCP and detailed their efforts toward compliance of the operating procedures element of OSHA Process Safety.
A model was developed to calculate plant total steam demand from the
state of valves and meters in steam service. Historical data from
the unit was then fit to steam flow rates recorded at the boilers to
determine f
:eam through each piece of equipment, From
this, peak and average steam demand for each process area was
determined.
A
mm
VAB.0001189257
m
ENG1HKKRJLHG - Continued
Wastewater
Work on the plant wastewater system is proceeding in three areas: aeration in Fond 3, algae removal in ponds 5 and/or 6, and chemical oxidation for BOD reduction. Work has begun on an aeration design for Pond 3. Information on algae eating fish has been obtained. A fish study is targeted for July. Oxidation information is being sent to us and some water samples have been mailed out to Carruss Chemical Company for oxidation tests.
Staffing
Two new process engineers started June 1. Kelly Wood and Michael Harvey are both graduates of the University of Arkansas.
Plastic*
Design reviews with project engineering and operations have led to re-evaluation of column/condenser pressure control schemes. Alter natives to the original design were suggested and evaluated. Re design of the condenser will be completed in early June. Specifica tions on all major equipment, except the condenser and decanter, are with vendors for confirmation and quotes. Class "A" re-issue is planned for mid-June.
ABERDEEN CHEMICAL PLANT
MONTHLY PROGRESS REPORT
CAPITAL EXPENDITURE STATUS
M.L. CARTER MAY REPORT
1992 F.Y. CAPITAL EXPENDITURES (MS)
VARIANCE
Month 3rd Qtr. YTD
ACTUAL 259.7 485.3 2603.3
BUDGET 262.0 791.0
3362.0
M$ - 2.3 - 305.7 - 758.7
% - .8% -38.6% -22.5%
h
Actual Expenditures - Expenditures in May were $2 3M less than the plant's budgeted expenditure forecast approved in the Third Quarter Budget submitted in March FY92.
Mays FY92 capital expenditures were 0.8% less than the plant's
budgeted expenditure forecast. 16 of the 19 projects which are
active came within +/- 10% of the forecasted expenditure amounts
for May.
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 3rd Quarter Capital Budget calls for expenditures of $791.0M and June expenditures of $280.0M.
i
VAB.0001189259
nm
VAB. OOO1189260
APPROVED CAPITAL PROJECT STATUS
G561 WASTE WATER INFLUENT EQUALIZATION
6SN 04/92
80 81 -1 MINOR ITEMS REMAIN - TARGETED CLOSURE 7-92
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APPROVED CAPITAL PROJECT STATUS
A
VAB.0001189261
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VAB.0001189262
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VAB.0001189263
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VAB.0001189264
ENVIRONMENTAL - K. G. Akins
Water
All wastewater discharge parameters were met for the it onth of May.
Confirmatory bioassay testing on the Ceriodaphnia dubia did not
indicate any toxicity in our wastewater.
Ceriodaphnia dn^-ja
reproduction was lower than the controls on the first test conducted
in April.
Pond 2
Pond 2 reclamation continues with no major operational problems. The first railcar of Pond 2 resin was received by Royal Plastics in May. We have not received any feedback on the processing of this material as yet.
Waste
Waste shipments during the month included:
m A bulk shipment of waste oil to Fisher Industrial Services in Gadsden, AL.
VAB.0001189265
ENERGY CONSERVATION - J. R. Ganc
Kay.. 1992
Fiscal Y.T.D.
A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU
II. Boiler Operation
< 1.6%> 1.0%
2646.0 137.6
Boiler
No. 1 No. 2 No. 3
Cortwtlon
MiY* l*9Z
82.7% 83.9% 83.3%
< 16.5%> < 14.0>
2983.0 1084.3
83.3% 83.3% 83.0%
VAB.0001189266
A
mnrai MtaonacK hkpoht
MAY. 1M
PWPgfl-- T.
J< Ea B6&11
Hollie Harris - Rehire - Co-op Student Engineer.
Berlin Genetti - Rehire - Co-op Student Engineer.
Dwight McComb, Jr. - Rehire - Co-op Student Engineer.
PROMPTXOHS/TRANSFERS
Joseph Hegwood - Transferred from a Mechanical Engineer to Operations Engineer replacing Rory Sneed.
r
Gary Sanders - Compound Utility progressed to Compound
Dale Barr - Reduction-in-Force - Compounder moved back to Compound Operator.
Willie White - Reduction-in-Force - Compounder moved back to Compound Operator.
Denton Cunningham - Reduction-in-Force - Compound Utility moved back to General Helper.
None.
TERMTHATIOMS/RESIGNATIONS
Thaer Abudiab - Co-op Student Engineer returned to school.
Michael Schneider -- Co-op Student Engineer returned to school.
TO/FROM LEAVE OF AB8EMCE
R. Danny Flippo - Vinyl Department - Vinyl Lead Operator - Union Leave of Absence.
W mm m
VAB.0001189267
r
EMPLOYMENT Salaried Hourly Temporary
SUB TOTAL
77 158
3
238
ABERDEEN PLANT
MONTHLY PERSONNEL REPORT
MAY. 1992
NEW HIRES Salaried/Transfer Hourly Temporary
TOTAL
MO
0 0
2
2
D
6 0
4
10
DEPARTMENTS
#EMFLOYEES
M
WAREHOUSE GENERAL PLANT MAINTENANCE LABORATORY COMPOUND VINYL PLASTICIZER SUB TOTAL SALARIED
15 10 36 22 36 34
5 158
77
9 5 8 4 24 11 2 63 6
F
0 0 0 1 1 2 0 4 19
%M %F
60% 50% 22.2% 18.2% 66.7% 32.4% 40% 39.9% 7.8%
0 0 0 4.5% 2.8% 5.9% 0 2.5% 24.7%
DEPARTMENT
TURNOVER
MO.
FYD
00
02
03
01
12
00
00
ANN.%
0 30% 12.5% 6.8% 8.4%
0 0
VAB.0001189268
Printed
&/03/92
DEPARTMENTAL SUMMARY HOURS REPORT
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VAB.0001189269
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VAB.0001189270
r
Printed
6/03/92
DEPARTMENTAL SUMMARY HOURS REPORT
.............. TEAR TO DATE ................
i
ADimTTSTRATIVE SERVICES - D. A. Barclay
Safety
+
There were no reportable safety Instances this month.
Quality
All teams met during Hay to review progress on their projects
Futures
HID Gain/(Loss^
YTD
Natural Gas
$0
Statistics
Processed
Processed Invoices Working Fund Checks Written Cost Savings Through Bid Process Raw Material Purchase Orders Issued MRO/AFE Purchase Orders Issued Spare Parts Purchase Orders Issued
Inventory
<$34,092,64>
Month
801 13
$0.0 80
172 194
FY92 Y.T.P.
8627 134
$22,265.19 725
1497 1570
Anr.. 92
Mav.. 92
(Decrease)
%
Compound "An Grade PLENEX Compound Off>Grade (BC) Compound Off-Grade (H) Millscrap Dry Blend "A" Grade Dry Blend Offgrade Resin Type I Resin Type "BC" Vacuum Dust
Total Packaged W/house
3,563,400 162,973 391,041 229,824 285,228 675,280 297,598
1,270,450 13,600
167.808 7,057,202
3,547,042 144,053 581,047 231,324 291,642 720,154 266,442
1,175,100 13,600
180.246 7,150,650
talk Finished Goods Ending Inventory
Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade
Total
Apea. '9Z MfT-,, *9Z
704,762 0
2,009,200 790,510
8,789,158 _ 1.718,501 14,012,131
567,672 0
1,003,050 598,930
16,216,208 1.486.101
19,871,961
< 16,358> < 18,920>
190,006 1,500 6,414
44,874 < 31,156> < 95,350>
0 12.438 93,448
< 0.46> <11.61>
48.59 0.65 2.25 6.65
<10.47> < 7.51>
0 7.41 1.32
(Decrease) /Increase
% Change
< 137,090> 0
<1,006,150> < 191,580>
7,427,050 < 232.400>
5,859,830
<19.45> 0
<50.08> <24.23>
84.50 <13.52>
41.82
VAB.0001189271
I
ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS MAY 1992
-SHIPMENTS BY PROOUCTS-
PUBLIC
MONTH IPT/ITC
EXCH/TOLL
PUBLIC
YTD IPT/ITC
03:07 PM IO-Jun-92
EXCH/TOLL
RESIN-BULK RESIN-PACKAGED
18,603,650 16,924,950
622,120
456,000
0 0
152,465,910 134,493,050 3,937,955 2,283,650
0 0
FLEXIBLE COMPOUND-BULK
522,040
FLEXIBLE COMPOUND-PACKAGED 3,508,313
1,809,700 40,078
0 0
1,974,160 15,634,000
24,725,584
230,753
0 0
NEW BUSINESS
21,720
00
133,434
00
RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED RIGID COMPOUND-PELLETS
1,420,010 485,113 0
710,300 0
0
0 0 0
9,628,230 3,272,462
0
4,589,900 175,850 0
0 0
TOLLING - BULK TOLLING - PACKAGED
0 00 0 00
0 00 0 00
PLASTtCIZER
0 527,930
0
81,300 4,168,470
917,400
TOTAL
25,182,966 20,468,958
0
196,219,035 161,575,673
917,400
SESSESSsSS2ZSSSBOCB22SClBEZBSSSSItSSSSNEEZESECSBSIBMBBtttSSUBCBBCZZCSXSSaitS8X8flSSBB3SfiSXSCI*8S8&SSCSS8C!BSBCSXttttKZSS
-SHIPMENTS BY M00E-
BULK:
CUSTOMER
COMMON
HMnAIY*
RAILCAR
PICKUP
CARR1ER
TOTAL
RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
163 17 25 10 0 13 10 0 13 3 01
205 23 23 4
TOTAL MAY
186 17 52
255
*YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
1,279 90
60 26
117 287 0 54 3 103 0 12
1,683 144
166 38
TOTAL YTD
1,455
120 456
RSSB388SU SSCS33SSSCCS3SS3BISSSBSCCSSSS.3SSSZCSSSSSZS SCSZZSSZZZSZZZZZS csccscssszzzcsssccc
PACKAGED:
CUSTOMER
COMMON
nMnAYi *
PICKUP
CARRIER
TOFC AIR/UPS
AIR/UPS
RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
4 30 0 0 9 112 0 0
2 10 0 0 0 000
0 2 0 0
M
II
II
tl
H
H
K
II
U
It II
II
2,031 B3S3SXS3333S
TOTAL
34 123
12 0
TOTAL MAY
15 152 0 0
2
169
*YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
26 175 0 0 161 684 0 0
14 96 0 0
0 000
4 23
1 0
205 868
111 0
TOTAL YTD
201 ES32Z3CfiSCSI
955 0 0 ssBcscssscccscass:
28
1,184
CC: DAB,TLC,AEV,JRF
1
mm mm
VAB.0001189272
m
t
t 71
FLEXIBLE & RIGID OFF-GRADE
MAY '91 THRU MAY '92
1800 (]
1600
1400
i 1200 o <0 1000
"D i CO
CO
3 O
05/91 07/91 09/91 11/91 01/92 03/92 05/92 06/91 08/91 10/91 12/91 02/92 04/92
PKG'D PRODUCTS INVENTORY
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VAB.0001189273
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VAB.0001189274
TABQRATORY - J. M. Edvards
A. Safety
There were no safety incidents in the Laboratory during May.
B. Oustoier Contacts
Jim Edwards and John Olson visited Intex in Corinth, MS to discuss resin specifications. Specs were set for 5385, 5415 and 5305.
Fred Williams, Mike Quackenbush and Jim Edwards visited Vycom in Scranton, PA to discuss product quality, Q.C. testing and other Business Area concerns.
Richard Williams and Dean Honeycutt visited Marley Mouldings in Marion, VA to discuss 5305 particle size specifications and advise them about resin unloading equipment.
C. Customer Q.C. Problem Reports and CHR's
5/06 Times Fiber. Chatham. VA
The customer co plained of having difficulty unloading 38601 BLK compound from a railcar. It is sus pected that the calcium stearate was not added to help the material trans fer process.
5/07 Rovalite. Warsaw. IN
The customer complained of a miscommunication concerning the delivery time of a 5305 bag shipment. The production was delayed but the ship ment was expedited to arrive as scheduled.
5/27 Horthwire. Osceola. WI
The customer complained of wire size reduction, rate reduction and quality problems using 38601 BLK compound. The problem coincides with using suspect VRP plasticizer in the formu lation.
UMtATOBY - Continued
D. Product Waivers Issued
Customer
Product
Reason
Ho.
Hayes Dockside
80273G WHT 110
Short Fusion Time; High Eq. & Fusion Torques
1 R/C
Hayes Dockside
80273G WHT 110
Long Stability Time; High Eq. Torque
1 R/C
E. RVCM of In-Process Samles
The following is a summary of residual VCM results on in-
process samples.
None of the reactor daily averages
exceeded 400 ppm RVCM during the month of May, 1992.
Reactor Slurries
Drver
5265
5305
Number of Samples Average RVCM, ppm
F. RVCM of Shipment Samples
34 0.119
95 0.352
The following is a summary of the residual VCM analysis of shipment samples for the month of May, 1992.
Product
Number of Samples
Average RVCM. mm
5225 5265 5305 5325 5385 5395 5415 5416 5465 Debox Pond Dry Blend
7 59 152
5 56 11 75
0 6 12 2 1
1.270 0.067 0.116 0.077 0.114 0.120 0.029
0 0.036 0.192 0.134 0.018
VAB.0001189276
1
taboratopy - Continued
G. Flexible Conoound Quality Smwmrv
Adjustments M Xbs. _i_
Hardness Specific Gravity Color Hard Particles Heat Stability Mischarge
Totals
297.0 7.0
22.0 ----------------........... 326.0
<5.34> <0.13> <0.40> --------------------.............. <5.86>
OualltY
Rejections M Lbs. <i>
40 Mesh Total
3JI 3.9
<0.27> <0.27>
Rejections M Lbs.
------3.2
32.1 43.1
6.4 17.0 101.8
------<0.06> <0.58> <0.77> <0.12> <0.31> <1.83>
A.
VAB.0001189277
CM w
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VAB.0001189278
*
A
r-V SAMPLE SHIPMENTS MAY 1992
RESIN Ship Date 5/05/92 5/05/92 5/08/92 05/14/92 05/15/92 05/18/92 05/20/92 05/27/92 05/28/92
Product 5385 5385
5305 (Derailed) 5415 5305 5265 5395 5265
5225 OG
Amount 50 lbs.
Customer Penetron
5 lbs.
Quantum Chemical
5 lbs. X 8
Keysor Century
4500 lbs.
Johnsonite
50 lbs.
Electrocai
500 lbs.
PVC Container Corp.
500 lbs.
United Technologies Auto.
50 lbs.
Trinidad Concrete Co. Ltd.
50 lbs.
H. Heller & Co.
Ship Mode UPS UPS
Airborne CC
Fed. Express CC CC
Airborne 2nd Day UPS
COMPOUND
Date 5/04/92
Product PLENEX1200 PLENEX 1275 PLENEX 1250 N734
5/11/92
PLENEX 1275
48562 BLK
5/22/92
48562 BLK
Amount 200 lbs. 200 lbs. 200 lbs.
200 lbs
1500 lbs
1500 lbs.
Customer Intercomp
Ericsson Cable AB Davis Standard Co. The Standard Products Co.
Mode CC
Airborne CC CC
DRYBLEND
Date 05/19/92
05/21/92
Product 90172D WHT110
489-145B WHT 128 RP-43 WHT 128
Amount 50 lbs
990 lbs. 980 lbs.
Customer Fiberchem Inc.
Berllnex Polymers (CANADA)
Mode UPS CC
VAB.0001189279
NUMBER OF INJURIES
ABERDEEN CHEMICAL PLANT INJURIES
(Twelve Month Running Totals)
J
1
MONTH
o .rae a
TOTAL INJURIES
OSHA RECORDABLE
VAB.0001189280
A
aT/rua
VAB.0001189281