Document oDpbvZmrQgQ55Zj1yEqGRQpZE

To: T. H. Huffman Interoffice Communication From: Date: Subject: R. W. Seymour May 18, 1988 ABERDEEN MONTHLY PROGRESS REPORT APRIL, 1988 There were no injuries recorded during the month of April. As of April 30, 1988, the plant had operated 3,222 days or 4,189,521 manhours without a lost time injury. PVC resin production for April was 39.6MM pounds with a reactor stream factor of 93.9%. Resin production year-to-date totaled 277.1MM pounds. The VCM efficiency for April was 1.00822 pounds of VCM per pound of PVC produced versus a 1.00756 standard. Cumulative VCM efficiency is 1.01259 pounds per pound. Compound production for April was 7.96MM pounds. Lines I, III and V all operated thirty days during the month. Cumulative production was 53.0MM pounds of compound. Quality performance for the month was 1.4% off-grade all of which was mill scrap. There was no "BC" production. Dry blend production was 6.15MM pounds for the another consecutive monthly production record. production was 38.5MM pounds. Quality performance 99.2% customer grade. month setting Year-to-date for April was The plasticizer unit operated twenty-eight days in April to produce 1.67MM pounds. Cumulative plasticizer production was 12.4MM pounds. During the month, the three-day part of the Team Management Training for salaried personnel was completed. Several Natural Teams met in April and a team of plant employees made a customer visit to Comm/Scope's communication cable production plant in Catawba, North Carolina. Total energy consumption for April was 127.932MMM BTUs. The energy consumption per pound of product was 2310 BTUs, resulting in an adjusted CMA reduction of 54.0%. The adjusted CMA reduction for fiscal 1988 year-to-date is 52.4%. VAB.0001190926 !H: -i-l i y-r-v + *r=T"- h. n Jl =' T. H. Huffman 5/18/88 Aberdeen Monthly Progress Report Page 2 The total plant variable cost variance for April was $2090.3M unfavorable, resulting from an overall unfavorable price variance of $2333.1M and a favorable efficiency variance of $242.8M. Year-to-date plant price and efficiency variances were $12,139.7M negative and $740.5M positive, respectively. The total fixed cost variance for April was $6.7M unfavorable with the cumulative variance of $429.5M favorable. R. W. Seymour Plant Manager rah VAB.0001190927 * distribution COVER LETTER ENTIRE REPORT COVER LETTER AW) CMP HOUSTON; J. D. BURNS X R. E. LEHMKUHL X R. T. FERRELL X T. H. HUFFMAN X^ R. E. SWAN3KOWSKL X D. F. HARMAN X H. R. FLAKIER X R. R. SMITH X K. J. EGGERS X D. H. SANDERS X PONCA cm: S. E. MCGUIRE X R. L. FOE X H. J. HALL X C. M. STARKS X CKLAHCMA CITY: H. G. GARRISON X LAKE CHARLES VCM PLANT R. A. CONRAD X LAKE CHARLES CHEMICAL PLANT J. FRIEND Safety Section and X LAKE CHARLES LAB PLANT J. W. WARE X BALTIMORE: L. R. BAUER X HAFMOND: J. B. MAHER X BLANE POLYMERS: E. L. K3ESCHNICK X PREMIERE POLYMERS: ABERDEEN: P. L. FOOTE DCS, COT, PJK, DWH, TEL, RAF, KLF, VEM, HGC, J -* R EBN, FILE X _ . p-trrr. ..r, I ,d ' |ia :r^ m-'Hqa?*-: i k-J I ^1V, ............. ..... f' 1* l^k.iri rr ! 1; f' ' VAB.OOOl190928 SAFETY - K. L. Fogg, J. V. Uptain Occupational Injuries First Aid OSHA Recordable Total Injuries Nuofeer of Restricted Workday Cases Nunber of Lost Workday Cases April 0 0 0 0 0 Fiscal Y.T.D. 1988 Fiscal Y.T.D 1987 6 _6 12 2 0 Injuries by Department Vinyl Operations Cooopound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 0 0 0 0 0 0 0 Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains Stings Other Totals 0 0 0 0 0 0 0 0 Non-Occupational Injuries Lost Workday Cases Days Lost 1 14 Safety Record Last lost time injury 7/5/79 Days since - 3,222 Manhours since - 4,189,521 On April 30, 1988, the employees of the Aberdeen plant completed 3,222 days with ro lost time injury. Topics for the plant safety meetings during the month included: Annual First Aid Training, Vessel Entry, Safety Performance Reviews, and Maintenance Weekly Safety and Job Reviews. VAB.0001190929 SAFETY - Continued The local Bnergency Planning Committee for Monroe County met in April. First aid training was conducted in April. The Central Safety Coondttee net in April. Keith Fogg met with the Monroe County Board of Supervisors to discuss SARA activities. April was an injury-free month for the Aberdeen Plant. Hands-on physicals utilizing two local physicians started in April. Routine dosimetry results for the month are as follows: Chemical PEL Number Percent > PEL Nimber Percent VCM 69 98.6 Lead 7 100.0 Total Particulates 2 100.0 1 1.4 0 0.0 0 0.0 Hie single VOl over-exposure was with benefit of respiratory protection. VAB.0001190930 i H- --T-fiKih *r1ntt-***a*T - r:ar H I- II ; ' I|J.' . VAB.0001190931 ABERDEEN CHEMICAL PLANT INJURIES o O era , i- OO ro 01 roo NUMBER OF INJURIES t . Co O i TOTAL INJURIES + OSHA RECORDABLE PLANT FIXED COSTS - R. W. Seymour Fixed costs for April were $1,283.1M versus a budgeted $1,276.4M for an unfavorable variance of $6.7M. The following is an analysis of this months variances: Major Category Variance vs. Budget April, 1988, $M April YTD Payroll and Benefits MM&C T&I Miscellaneous (69.0) 46.0 16.7 ( 0.4) ( 6.7) ( 89.0) 250.8 64.2 203.5 429.5 Payroll and Benefits are unfavorable due to benefits charges for the month being at 25.9% of total payroll (budget was 15.9% of base payroll) and overtime due to the operation of Line V on a full time basis with budget basis being a two-shift operation. MM&C expenditures are favorable due to lower than budgeted maintenance materials and several extraordinary contract projects. The Miscellaneous category was essentially at budget for April. 'r- * h f - I1 *^1 -i- I' T !! ' VAB.0001190932 m . 1, ... S I , ...... :e-i -w-i:- : ! 1 -------iT*- ! 1 1 --'i- t 'ifflsl * QUALITY MANAGEMENT PROCESS - D. W. Hollis, R. B. Newton 1. Completed two three-day sessions of Team Management Training for salaried personnel. The remaining two days of the training will be given in May. 2. Assisted Marketing in making a video of the Quality Management Process in Aberdeen. ** Assisted in planning of open houses to communicate emissions required by SARA Title III. J -f' i ir- VAB.0001190933 VINYL - P. J. Kober Safety The Vinyl and Yard Departments worked without an injury during April, 1988. The monthly safety meeting topic was "First Aid Training". instruction was provided to all personnel by the Plant Nurse. Quality Management Process The The Department Superintendent's Natural Team met in April. Topics discussed included the purpose of a natural team. Quality Implementation Plan action steps, and team recognition. Plans were laid out for a customer visit. There are four active employee involvement teams in the department. Each team met at least once during the month and all teams are making good progress on their projects. The Railcar Cleaning Team is preparing their presentation for Plant Management to request funds to purchase and install a cleaning system. The 5265/5305 Contamination Team is trying various methods of reactor cleaning to reduce wall scale buildup on D700 and D745. The V-ll Dust Team is pursuing repairs and modifications to the equipment on the sifter deck in the V-ll dryer room and the Plasticizer Team is proceeding with designs to limit spillage and contamination in the unloading area. Production April Y.T.D.(Fiscal 88) 1. Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges 4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days 39.6 1321 935 31.2 93.9 9784 70.3 30 277.1 1300 6545 30.7 92.8 9657 70.6 213 Reactors The reactor stream factor for April, 1988, was 93.9%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 69.2% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size data before charging, power failures, inclement weather, blend tank availability, and new module rinse/charge water conflicts. * in " '"I BIT-: -Jf." : t*.- t - sHiiUrf**'* VAB.0001190934 .V.fl U": 7. ! f" ...r. 1: SMJIBURk-L '< ;> ' VINYL - Continued Reactors - continued 2) Maintenance Repair/Revision Downtime: Accounted for 30.8% of the total and was due to hydroblasting D700 and D745 reactors, replacing D300 chem wash line, repairing new module water line, vent line repair, maintenance to recovery vacuum pumps and compressors, and miscellaneous valve repairs and replacements. Dryers The dryer stream factor for April, 1988, was 70.3%. dryer area occurred as follows: Downtime in the 1) Reactor Limited Production: Accounted for 88.9% of the total downtime. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 7.9% of the total downtime and was due to centrifuge plugging, dryer cleaning, activator transfer problems, burner flame-outs, and pulsing baghouse socks. 3) Maintenance Repair/Revision Downtime: Accounted for 3.2% of the total downtime and included activator maintenance, sock replacement/ repairs, repairs to the fluid bed hopper, installing screw feeder switches, and maintenance of rotary effluent lines. Product Quality Summary Resin Type Prime 5265 5305 5385 5415 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 3,167,765 5,563,370 16,177,324 12,171,309 - -- -- - -- 38,278,588 Monthly Variable Cost Performance "B" -- -- -- 1,155,780 -- -- -- 1,155,780 "H" -- -- -- -- -- -- 83,411 108,980 192,391 % of Total Production 7.9 14.0 40.8 30.7 3.2 2.9 0.0 0.2 0.3 100.0 Variable costs for the month were unfavorable at $1342.3M resulting from an unfavorable price variance of $1333.3M and an unfavorable efficiency variance of $9.0M. Resin variable cost for April, 1988, was 25.086 cents per pound versus the budget at 21.579 cents per pound. The unfavorable price variance was due to VCM pricing at $1398.3M unfavorable. VAB.0001190935 h VINYL - Continued Monthly Variable Cost Performance - continued VCM efficiency for the month was 1.00822 pounds per pound of PVC produced versus the budget at 1.00756 pound per pound. This resulted in an unfavorable variance of $6.0M. Above budget initiator concentrations resulted in an unfavorable variance of $58.4M. The higher concentrations were used in an effort to maximize production. Energy Performance/Progress ** Plant energy performance for April, 1988, was 2723 BTU/lb. General The resin raw material in the 744 account was valued at $279.5M. VAB.0001190936 hi. r II.Wk*. ..j.. K> n.'m |-i * ^ '-r i !t^ ' t r ?nn . i fli' ' i I h>" COMPOUND - C. W. Turner, S. C. Hillman Safety The Compound Department worked without injury in April, 1988. April's monthly safety meeting was a review of first aid and CPR training. Quality Management Process During April, a team of plant employees visited Comm/Scope's communication cable production plant in Catawba, NC. Trip participants were a compound shift supervisor, a compounder, a compound operator, a compound utility, the quality control supervisor, the lead warehouseman, and the compound operations superintendent. The objective of the trip was to strengthen the supplier/customer relationship with Comm/Scope and discuss the use of our compound at their facility. The Compound Operations Superintendent Natural Team met in April. The meeting included all compound shift supervisors. The main topics included control charting progress and changes, utility training procedures, and ways to reduce off-grade production. The shift supervisors will be generating new charts for use in compound and dry blend. The Chris Turner visited two dry blend customers, Dayton Extruded Plastics and U-Brand Corporation, during April to discuss dry blend performance and our quality program. A presentation was made to U-Brand supervisors and operators about Aberdeen's dry blend process and quality management and safety programs. Conpound Production Operating Days Month Production <M Pounds) Average Operating Day Fisca Rate Y.T.D Line I Line LEI line V Total 30 2300 30 4059 30 1605 7964 77 135 53 16662 27249 9113 53024 Line I operated thirty days in April at an average rate of 77M pounds per day. Major items affecting production efficiency were: product changes, 92 hours; quality problems, 15 hours; dicer problems and maintenance, 15 hours; and transfer line pluggage problems, 8 hours. Line III operated thirty days in April pounds per day. Major items changes, 53 hours; quality proble s system maintenance, 19 hours. at an average rate of 135M production product 20 hours; and mill lube u , '-S -7 'V'.-pH'-JfcF -i'.: I. ' L ' VAB.0001190937 COMPOUND - continued Line V operated thirty days in April at an average rate of 53M pounds per day. Major items affecting production efficiency were: ts, 31 hours; quality problems, 23 hours; and chute pluggage problems, 5 hours. Quality performance for flexible compounds was 1.4% off-grade of which 100% was due to mill scrap. "BC" production was 0.0%. The raw material requirement for flexible compounds was 0.99695 pounds of raw material per pound of compound versus a 1.01197 standard (YTD is 1.00627). The variable cost variance for compound was $289.4M unfavorable with $453.0M unfavorable due to price and $163.6M favorable due to efficiency. The efficiency variance due to product mix was $78.0M favorable. Major compound raw material efficiency variances were 61 OP at $31.4M favorable, color concentrate at $13.7M favorable, 610TM at $11.3M favorable, and Thermoguard WE at $10.7M favorable. The favorable variance in color concentrates is due to continued rise of concentrates that are more efficient than budgeted. Total compound inventory rose 1.70MM pounds in April to 8.59MM pounds. Dry Blend Month Average Operating-Day Rate Fiscal Y.T.D. Production, M Founds Operating Days 6151 30 205 - 38556 213 Dry blend operated thirty days in April at an average rate of 205M pounds per day. Production included 80273G WHT 110, 80172C WHT 110, 90172D WHT 110, RP-100 WHT 142, RP-201T NAT 101, RP-421 WHT 110, 180-31 WHT 138, 269-151 WHT 145, 269-185 WHT 144, 290-61 WHT 121, 378-06 WHT 141, 378-09 WHT 141, 317-91 WHT 91, 317-129 WHT 110, and 317-206 WHT 110. The April, 1988 production of 6.15MM pounds surpasses the previous monthly production record of 5.88MM pounds set in March, 1988. Production of rigid profiles comprised 33% of the April, 1988 product versus 36% in March, 1988. Dry Blend production was hindered by: blender transfers, 60 hours; product changes, 40 hours; scale problems and maintenance, 26 hours; quality control, 21 hours; screener inspections and maintenance, 11 hours; transfer system pluggage and maintenance, 11 hours; star valve maintenance, 9 hours; and Welex maintenance, 5 hours. VAB.0001190938 COMPOUND - continued Dry Blend - continued Quality performance for the month of April was 99.2% customer grade. The raw material requirement for dry blend was 0.99986 pounds of raw material per pound of dry blend versus a standard of 1.00481^ (YTD is 1.00590). The variable cost variance for dry blend was $392.2M unfavorable with $489.5M unfavorable due to price and $97.3M favorable due to efficiency. The efficiency variance due to product mix was $73.OM favorable. The only major raw material efficiency variance was liquid stabilizer at $25.9M favorable. Plasticizer Production, M Pounds Operating Days Month 1672 28 Operating-Day Rate 56 - Fiscal Y.T.D. 12363 211 Plasticizer operated twenty-eight days in April at an average rate of 56M pounds per day. Production included 61OP and 108P. VRP production totaled 59.2M pounds (3.5%). The raw material requirement for plasticizer was 1.11561 pounds of raw materials per pound of plasticizer versus a 1.10133 standard (Y.T.D. is 1.09198 ). The variable cost variance for plasticizer was $66.3M unfavorable with $57.4M unfavorable due to price and $9.0M unfavorable due to efficiency. The only major raw material efficiency variance was Alfol 610 Alcohol at $11.0M favorable. The efficiency variance due to product mix was $4.3M favorable. Energy Compound Dry Blend Plasticizer Usage (BTU/Lb.) Actual Standard 1663 682 1705 1758.0 720.0 1550.6 ^ ..!!' p ->H .N.Hi t VAB.0001190939 s*.- - * MECHANICAL DEPARTMENT - T. F. Lyon MAINTENANCE - D. A. Miller Safety There were no reported injuries to Mechanical Department personnel during the month. Quality Management Process The Engineering Project Report was issued to all plant employees. This report is intended to keep employees up-to-date on current engineering projects and priorities. The Maintenance Training Team completed interviews of all hourly maintenance employees. The data retrieved during the interviews will be used to develop a "Skill Needs Assessment". Seven Mechanical Department employees attended three days of team management training. Vinyl Reactors D700 and D745 were hydroblasted during the week of April 11 in preparation for a 5305 run. The chem wash and rinse piping on reactor D300 was replaced due to external corrosion. The piping arrangement was simplified and two automatic valves were eliminated. The recovered VCM condensers in the old module were cleaned. The north condenser required a code weld repair to the shell. The centrate heat recovery trim heater required cleaning due to tube side fouling. The following major valves were changed: - D300 sprayhead flush block valve - D744 chem wash return valve - D700 polyvic ram valve - D745 polyvic ram valve - D700 catalyst ram valve The following rotating equipment repairs were performed: - Mechanical seals were changed in the following pumps and compressors: o ERS north seal o New module east VCM charge pump o Alcotex charge pump o New module east chem wash pump o East fluid bed hot water pump o Old module "B" vacuum pump VAB.0001190940 ** MECHANICAL DEPARTMENT - continued Vinyl - continued - "B" vacuum pump in the old module was replaced with a spare due to gland corrosion and poor performance. - The agitator shaft in the BPA make-up tank was replaced. - The west new module cooling water pump motor was changed due to rough bearings. Instrument technicians assisted in the installation and checkout of the instrumentation associated with the Reactor Heat-up Loop Project and the temperature compensated VCM meters. Dryer Area The north and south fluid bed dryer rotary air locks were replaced and rebuilt. The following work was performed on #6 dryer: - The dust collector explosion vent was repaired. - A gas supply line blind was installed. - The inlet screen was repaired. - The dust collector air surge pot was re--gasketed. The #8 centrifuge main radial bearings were replaced. Motors were replaced on the #5 dryer Sweco and star valve, and on the debox Sweco. The exhauster bearings were replaced on 747 blend tank. Compound, Dry Blend, Plasticizer The 412 silo cyclone separator was repaired due to erosion. The 479 silo rotary airlock was overhauled. The spare laboratory two-roll mill was rebuilt. The quarterly weigh scale calibration was completed. VAB.0001190941 MECHANICAL DEPARTMENT - continued Compound, Dry Blend, Plasticizer - continued The following major work was completed on Line III: - New vacuum filters for the Line III pellet transfer system were installed. - The spindle assembly for #6 dicer was overhauled. - The zone 1 hydrotherm pump motor was replaced. - The lube oil for the Line III mill was changed. - The front mill roll rotary union was replaced. The Line V plasticizer weigh tank heating coil was repaired and a permanent steam supply line installed. Only minor maintenance was performed on Line I. The following work was completed in the Dry Blend unit: - A new rotary airlock was installed under "C" blender. - The D-scale 50-lb. load cells were replaced with 200 lb. load cells. Necessary Orbitran progra: changes were made to allow the change. - Screens were replaced in the south Gump and south Kason The following work was accomplished in the Plasticizer unit: - T-400 fPA charge tank) was inspected, new supports installed and the asbestos insulation removed and replaced with mineral wool. - A strainer was installed up-stream of the alcohol charge meter. - The R-l agitator motor and gearbox pinion oil seal were replaced. - Minor steam leaks were repaired. - The PA charge pump was overhauled. - The PA vent collection blower bearings were replaced. - The R-3 safety discs were replaced. KT' pt-^hn i-rl !<!>.' 1..'- :J-*- (' VAB.0001190942 VJ Tii-..; v.-tit :t* ?! "I MECHANICAL DEPARTMENT - continued Utilities Two water well pressure regulating valves were rebuilt. The boiler house deaerator was inspected by Vista and our insurance carrier. No problems were found. The coupling was replaced on #4 boiler feedwater pump. The Deltech air dryer alarms were modified to indicate a compressor shutdown. Motors were replaced on //2 aerator and pond #3 and #6 aerator on pond #4. VAB.0001190943 MECHANICAL ENGINEERING - R. E. Polk AFE F596/A717 - Reactor Heat-Up Loop Construction is complete including punchlist items. Start-up and commissioning is planned for the week of 5/09/88. AFE F786/F557 - Resin Quality Improvement Concrete work is 51% complete and in progress. The first floor of the SA building has been poured. Steel erection is complete and decking for the second floor started. Piping and mechanical Installation is 31% complete and in progress. Electrical installation is planned to commence in mid-May. AFE F587 - Laboratory Addition Final painting and trim work is completed. Mechanical equipment installation is in progress. Project completion is planned for the week of 5/16. AFE D707 - VCM Unloading Fire Protection All construction is complete except for the Texas Automatic Sprinkler piping and final painting. Texas Automatic is scheduled to be completed by 7/1. Project completion is planned for 8/1. AFE A538 - Reactor Condenser Revisions Delivery of the new condenser is planned for the week of 5/16. Installation of this condenser on D-600 is planned for early June. Project completion is planned for 9/1. AFE D608 - Dryblend Orbitran Replacement Software development is in progress and planned for completion in mid-May. An initial checkout of the Fisher Univox was completed in Austin. It was shipped to Houston for final staging at Puff er-Swieven. Shipment to the plant is planned for 6/6. Installation is tentatively planned during a Dry Blend outage scheduled for 7/5-14. AFE B548 - Plasticizer Lighting Upgrade Bids have been requested on the lighting installation. All equipment has been received. Construction is planned to begin the week of 5/16 with completion in mid-June. AFE D638 - Boilerhouse MCC Replacement The design has been completed and all major equipment placed on order. Basis of bids preparation is in progress. Installation is planned for completion in August. VAB.0001190944 MECHANICAL ENGINEERING - continued AFE F598 - Line I Screeners Design is 90% complete and in progress. Major equipment items are on order and scheduled for delivery in mid-May. Construction is planned for completion in August. "`ii VAB.0001190945 PROCESS ENGINEERING - V. E. Messick Resin Quality Improvement Project All field tie-ins were reviewed for reactor downtime requirements. Assistance to construction activities continue on an "as needed" basis. Review of the I&E design package for the Atmer feeders was* completed in April. 5415 Production in the Old Module Modifications to the out-of-service fluid bed dryer heating panels have begun. A meeting was held with the manufacturer of the steam injection water heating unit to discuss system limitations. These efforts are directed toward higher 5415 drying rates. VCM Storage and Handling Information Team Areas covered in April included fire protection systems and VCM leak handling. Resin Debottlenecking Work is underway to develop an overall schedule of debottlenecking efforts and manpower requirements. Alternate Natural Gas Supply A meeting was held with GED, PED, Purchasing and the plant to review the project scope and cost estimates received for the pipeline. Boiler Safety Team A presentation by the team was given to plant management outlining the team's recommendations. Priorities will be assigned to the various suggested items. Dryer Baghouses A summary of a study to investigate dryer baghouse problems was issued. Preliminary recommendations Include replacing existing baghouses with larger, easier to maintain collectors. Railcar Cleanout Team A class "A" design was issued for the railcar cleaning system. Team and process design review meetings were held. The project will be budgeted for the fourth fiscal quarter 1988. VAB.0001190946 PROCESS ENGINEERING - continued Dry Blend Orbitran Replacement Project - Kenny Akins completed two weeks of Univox Configuration school at Fisher in Austin, Texas. He also assisted GED with construction of time sequence diagrams. More review meetings were held with Operations to discuss displays, proposed unit operation, etc. Dry Blend Rate Improvements The damaged variable speed drive unit was replaced. A new small star valve was installed on "C" blender. PA Scrubber Modifications - Modifications were completed and operating procedures issued. PA Fluff Containment The operating procedures for the desublimation box were Issued for review. Reactor Heat-Up Loop Preliminary reactor heat-up loop start-up to check the mechanical equipment was completed. The operating manual and the start-up procedure to heat-up a reactor charge were issued for review. Line III Vacuum Filters The new Line III blower vacuum filters were installed and are operational. Alloy Project Carl Tomanek sent the new alloy recipes to the plant for review. MSDSf s are being received for approval to bring new raw materials into the plant for a trial run of the new alloys. Lead Bag Disposal A customer has been found who will take PVC bags with residual lead. A truckload of lead in PVC bags was ordered for a trial at the plant. Bird Rinse Water Modifications The rinse water modifications to a Bird centrifuge for a test at the plant were approved. Our centrifuge at Bird Machine is being modified to run rinse water. Shipment is expected near the end of May. Metal Detectors - Line III Troubleshooting on the Line III metal detectors was completed. The metal detector installation has been revised in the field. Rebuilt sub--panels are to be received in early May. VAB.0001190947 ' * f in- *!. PROCESS ENGINEERING - Continued Dry Calcium Stearate Addition The fluid bed main screw feeder has been calibrated. Review of the I&E design package for the remaining feeders was completed. Preliminary start-up tests were completed. The operating manual first draft is being revised. The rotary dryer CaSt designs are being revised to decrease space requirements. Lab Ventilation Team The team presented a solution to the Brabender fume problem to Management. A miscellaneous capital AFE request to build and install the team designed vent hoods was approved. Chem Wash Conducting Probes The conductivity probe and monitor was received and pressure checked. Installation is expected next month. SARA Calculations to determine section 313 emissions were completed. A summary table was issued to T. G. Grumbles for an executive briefing. Also worked with contractor hired to do modeling study. Winter Safety Showers Four options were evaluated and presented to the Central Safety Committee meeting. The committee decided to install one winter safety shower at the sulfuric acid tank area. A miscellaneous AFE request was written to complete this project. Alternate Water Supply Samples from the pilot well were collected and analyzed. Electric logs were also obtained. The information shows the Coker aquifer to be good. VAB.0001190948 HUMAN RESOURCE REPORT PERSONNEL - J. E. Beall EMPLOYMENT Sonya L. Hill, New Hire PROMOTIONS/TRANSFERS Joe Beall promoted and transferred from Employee Relations Representative LCCP, to Director of Employee Relations Aberdeen. Robert A. Miller promoted and transferred to Director of Employee Relations LCCP. William Parks from Compounder to Lab Trainee. David Plunkett promoted from General Helper to Vinyl A Operator. Charles Smith from Compound Shift Supervisor to Maintenance Supervisor Nathaniel Wilson promoted from Vinyl "A" Operator to Chief Operator. RETIREMENTS None TERMINATIONS James Hill, Jr. Norma Springfield, resigned TO/FROM LEAVE OF ABSENCE None VAB.0001190949 Aberdeen, Mississippi h APRIL, 1988 MONTHLY PERSONNEL REPORT Salaried Employees Hourly Employees Total Employees Employees (Hourly) 71* 170 m Minority Employees tt Salaried 7 Hourly Total 67 74 99 10% New Employees Terminations o DEPARTMENTS PAR tt EMPLOYEES MIN. EHP Hourly Min. Hired % Min. Hired Hourly Min. Term. % Min. Term. 0 2 % MIN. NEW HIRES YTD TERM. YTD TURNOVER YTD Warehouse Gen. Plant J- 13 Maintenance 40 Laboratory Compound 2L. Jt_ Vinyl 32 Plasticizer 5 16 7 12 7 39 9 6 39 27 mA 2 52 M0 00 42 00 0 0 00 0 25 0 00 0 0 0 00 0 0 00 40 0 0 0 0 Number of Applicants: Month 13 Year to Date 13 APPLICANT BREAKDOWN: tt Minority 7 % Minority 54 * Female % Female 8 Hires (Hourly) : Month Year to Date Terminations (Hourly) : Month 1 Year to Date Overall Turnover .6% Projected Annual Turnover Includes 1 temporary employee end 1 Co-op Engineer. 4 t . -ijf i i i* * ..r. tioWiiK t? n*. M-.-tY*. : P'!. s?;i ' 'Is1! -I-'-:: VAB.0001190950 l ri'. J f I1 r-L-^ii hi . i ,11'C I- -: .i-n : n 4 4) s * _| H 4J JS Cl 00 cud ra XJ on o H i*-i o Li MV _e d 4J O to cd 41 to O GO C 41 01 c UQ CJ < H CO rH cn m CO m 00 in o <r o o 4 ON * as* as 4 m o o p--4 sO 4* 44 m CM CM m cn CM r-^ X> cn X) o as i--i O o 00 a\ as c-* in o C- 4 s CO CM CM r- x> cn m o CM o <T O r--i oo 00 CM *H in o o s 44 *4 4 o oO mo Om o o i--l ** 4 X) 4 * o * o 4 s CM CM CM to c 4o CO G nw Cd w u LI 4> utd CL O ai owa* c >> *H cc >% cd ,UrC+ X CO X 4) to .1. -H* i + 41 CO c o Li 3 O X a> LI o CO co hJ to XI < CM s CO cn c*. s CM CM 00 CO cu CO CM *H M u 3 o o 3 Ll cd TJ c3 C3 0tu0 Li CO 4) Ma 00 C iH cd H -X Li CO L cd J3 o CO Of 004> x> in coa cd Li uo COW LI Li CO 41 r> m 00 to * M0 00 c T3 o3 (d CO u >> 3 *d o n CO 6 o h-I u Ed Ed cd z Cd CO 3 cd 00 U41 e o CM 41 fH 4 ed -o o M4u) o 3 Li LI B UO 1 to c Li o 3X O X 4) H B 4i LUI H 4 V cd fH fH o Li LI 3 0 O 1 1\ 1 I l \ 1\ \l 1 i 1 1 1 1 1 1 1 l l\ i i l l 1 1 1 1 1 1 1 l l 1 1 l i 1 1 1 i i l1 i l 1 l i l l l l i 1 1 1 o n in n o n n n o o in r^- CM o r-^ CM oo oo in as iH CM n as r** CM n r-* O ao s<* 4 cn as v # CM * o as oo iH CM 00 to cd Li M 3 O Li O 3 u cd o LI 3 00 4-mmJj 4) Li T> 00 4B> c LI u Ll o 41 * > O 0dmm0 4> 3 TW1 TD 3 4> Ua a) Li 0) 4> S> O 4B1 *3 H 41 H^ Ll LI O *c 3 00 H CO cd Li Li 3 LI O in o n O O CM 4 in CM n <r 4 as o 4 CM n o 4 o UO * v cn H n CM 1-M rH 00 M" 00 cn cn o rM cn oo m 00 CM X> v s ON 00 UO CM u 4) cd > o I an) 41 l <u Li a 4) H Ll Li 4) cu > Xcd) 4) UJ CO C0 4) X E4 LC4i 1 41 a U o CxJ 55 Ho 2 Si 3o PS Ed H x Ed O 4-4 CM CO PU O >4 2 E- 5 2! CO Ed 3 as H Ed Pm O * O 4Jcd Li 3 uo 0 O c 1 3 oO o Csl VAB.0001190951 * * ENERGY CONSERVATION - F. G. Jeanson I Plant Operations Total energy consumption for April was 127.932 MMM BTUs. Energy consumption decreased to 2310 BTU/lb. from 2397 BTU/lb. in March. An adjusted CMA reduction of 54.0% wa^ obtained for the month. The adjusted CMA reduction for 1988 is 52.4%. II Plant Ener Conservation Program Maintenance There were twenty-two energy related items completed in April. Nineteen of these items were steam leak repairs. The remaining three were steam trap repairs. HI. Boiler Operation Boilers No. 1 No. 2 No. 3 Coobustion Efficiency % April, 1988 April, 1987 83.7 (2) 83.2 (1) 83.4 83.2 Note: (1) Boiler nunber one was not operated during the month. (2) Boiler lumber two was not operated during the month. t - * ^i.1- h.. k. r VAB.0001190952 p.-^ppfii t: i ..V Month ENERGY OBSERVATION DATA 1988 Production, Ml lbs. Resin Dry Blend Compound Natural Gas Consumption, MSCF Conversion, ETU/SCF Energy Consmption, Mfl BTU Energy Consumption, BTU/lb. Electricity Consumption, Ml KWH Conversion, BTU/KWH Energy Consumption, MW BTU Ehergy Consumption, BTU/lb. TOTAL 39.6 6.2 8.0 1.6 55.4 66353 1020 67.680 1222 6.0252 10000 60.252 1088 Consmption, M Gal. Conversion, BTU/Gal. Energy Consmption, Mfl BTU Ehergy Consumption, BTU/lb. 0 92000 0 0 Total F ergy Consmption, BTU/lb. 2310 Bnergy Consmption, Mfl BTU Actual Unadjusted Actual Adjusted 1972 Base Period 127.932 106.510 231.397 CMA Reduction (%) Adjusted Unadjusted n -1 52.4% Adjusted 42.7% Unadjusted 54.0 44.7 1987 34.8 4.2 7.3 1.9 48.2 56481 1020 57.611 1195 5.7486 10000 57.486 1193 2388 115.097 95.229 205.221 53.6 43.9 i. - * L-.. VAB.0001190953 ENVIRONMENTAL - R. A. Frohreich Water All wastewater discharge parameters were within NPDES limits in April, RCRA The 1987 Hazardous Waste Biennial Report forms were completed and submitted to the State. One truckload of drummed waste and one truckload of floor sweepings were shipped to Chemical Waste Management. Two truckloads of reactor culls were purchased by Sun Polymers. One truckload of building ventilation dust was purchased by Surplus Chemicals Marketing. General VCM emission data was provided to Scott Environmental Technology. Scott will use the information to perfon a dispersion air modeling study. VAB.0001190954 t-l h.**' 'I ; V Si ' TABLE I WATER CCMPLIANCE WITH NPDES PERMIT PARAMETERS Oct. - Ave. Max. Nov. - Ave. Max. Dec. - Ave. Max. Jan. - Ave. Max. Feb. - Ave. Max. Mar. - Ave. Max. Apr. - Ave. Max. May - Ave Max June Ave Max July - Awe Max Aug* - Ave Max - Ave Max Flow GFM 1229 1264 1222 1430 1083 1146 1326 1431 1521 1562 1208 1507 1076 1312 BOD PEM LB./DY. 5 77 7 100 15 212 22 378 8 106 12 155 19 311 25 426 11 201 14 262 12 179 15 211 6 80 9 112 GOD pm LB./DY. 28 433 39 553 43 607 65 1117 35 468 51 659 68 mi 87 1476 45 818 51 955 55 824 75 1052 38 508 53 662 Sus. Solids PPM LB./Dy. 10 147 15 215 22 310 25 370 14 191 20 264 13 213 18 307 12 228 16 295 23 342 34 473 18 237 27 336 0 8.4 8.6 7.4 7.9 7.6 8.2 7.5 7.7 8.4 8.8 7.8 8.8 8.3 8.8 NH)ES Permit Limits - Decenber 1 through April 30 Ave. Max. 32 431 43 800 - 1462 - 2713 NPDES Permit limits - Novenber 30 Ave. Max. 26 357 40 744 - 1212 674 - 13% 674 - 13% y 6.o y 6.o r LB./DY. ^ * 1.8 7.5 2.9 7.9 1.4 7.5 1.7 7.8 9.5 17.6 7.6 7.8 2.0 7.5 2.8 7.7 3.3 7.5 5.6 7.7 7.2 21.8 7.5 7.8 5.1 7.7 6.2 7.7 13 6.0 - 9.0 28 13 6.0 - 9.0 28 VAB.0001190955 I -J 'I' !J ' LABORATORY - H. G. Coleman Safety A. Safety There were no safety incidents in the Laboratory this month. The safety meeting was four-hour first aid training review given by V. A. Belk. B. Customer Relations Customer Contacts 4/26 Richard Williams visited Comm/Scope as part of an Aberdeen manufacturing team organized by Chris Turner to express our commitment towards quality. 4/26 - Harold Coleman accompanied Mike Nathan and Virgil Fisher to discuss the quality of toll-produced 80273G. 4/27 - Harold Coleman visited Hoechst Celanese along with Tom Davis and Leland Haefner to discuss quality issues and product testing. 4/28 - Harold Coleman accompanied Tom Davis and Diana Fenton to Klockner to discuss quality concerns. Requests for Corrective Action Date Customer 04/03/88 Poly-Tex Company Customer Problem Reports Product 169-185 WHT 144 Reason Gloss; impact; production rates. Date 04/05/88 Customer Precision Tri Boaz, AL Product 14941 Reason Rough extrusion. Production Return Notifications Date Customer Product 04/04/88 Astro Plastics Covington, PA RP-201T NAT 101 Amount Reason 10,400 lbs. Color 04/26/88 Macklenburg Duncan 18961 WHT 366 Oklahoma City, (X 04/28/88 Prestolite Port Huron, MI 35031 NAT 16,890 lbs. Heat Stability 40,000 lbs. Streamers 04/25/88 Trim Plastics Springville, AL 17462 GEY 545 7,950 lbs. Processability VAB.0001190956 t .. :I . V|' -K :-r f I" W"* "W- r Iy.p. . : r' .;+: * Jl.fi'-ii'-iniifl! i" I' LABORATORY - Continued B. Customer Relations - continued Waivers There wte no product waivers for April. C. RVCM Smeary The following is a sumnary of residual VCM results on in-process sanples. None of the reactor daily averages exceeded 400 ppm during the month of April, 1988. Reactor Slurries ________ Dryer 5265_________ 5305 Number of Samples Average ppm* RVCM 936 151 34 0.4 60 0.5 RVCM of Shipment Samples The following is a sumnary of the residual VCM analysis of shipment sanples for the month of April, 1988. Product 5265 5305 5385 5415 5465 Dry Blend Pond Debax No. of Sanples 42 133 37 51 Average RVCM, ppm 0.1 0.2 0.2 0.1 6 0.2 52 0.1 4 32 3.4 0.2 D. Resin Process Capabilities 5265 5305 5385 5415 5465 Bulk Density 1.29 1.25 1.88 0.60 3.19 Inherent Viscosity 0.76 1.27 0.58 0.45 0.42 "L" Color Value 4.67 4.00 2.53 3.33 3.42 ''A" Color Value 3.33 8.33 -- "B" Color Value 1.17 1.00 1.17 1.83 2.00 (% on Pan) (vs. 2% max.) 2.67 2.67 1.52 1.94 0.28 3.67 0.33 % thru 14CM 1.44 1.62 1.64 2.47 2.22 Drytime 0.33 0.44 0.44 Nets I.R. (vs. 95% of Control) Hard Particles (% > 10) 2.13 1.15 3.86 2.06 3.1 2.6 21.2 VAB.0001190957 i H . |- '> LABORATORY - Continued E. Conpound Quality Sunmary M Lbs. (%) Rejections MIhs. (%) Hardness Color/Clarity Hard Particles Dispersion Dicing Total 79.0 (0.99) 14.0 (0.18) ---- ---- ---- 93.0 (1.17) 6.8 12.9 44.9 17.9 6.4 88.9 (0.09) (0.16) (0.56) (0.22) (0.08) (1.12) F. Dry Blend Quality Summary Rejections M Lbs* (%) Color Total 48.0 48.0 (0.78) (0.78) G. Quality Development 1. Harold Coleman* Richard Williams and Brian Harrison attended the first three days of Team Management Training. 2. Harold Coleman attended Experimental Design in Houston April 18-21. 3. 5415 Control Resin (Lot 04169) Testing Results: Moisture Drytime, min. Particle Size - 60 Mesh - 80 Mesh - 100 Mesh - 120 Mesh - 140 Mesh - 200 Mesh - Pan Bulk Density Color - L a b Flow Time Hard Particles Inherent Viscosity n__ X 3 (T~ 58 0.157 0.03 30 5.07 0.33 60 1.20 0.46 60 31.40 4.31 60 33.67 1.17 60 20.63 2.54 60 6.94 1.51 60 4.78 2.19 48 1.25 0.60 30 0.5124 0.0178 58 100.556 0.261 58 -0.138 0.131 60 2.416 0.350 29 7.42 0.71 60 6.97 3.46 28 1.0036 0.0157 H. Miscellaneous 1. Brian Harrison visited Americhem (colorant supplier) on 4/6 to discuss color matching, unstabilized concentrates and Q.C. procedures. 2. Brian Harrison instituted the switch from stabilized to unstabilized color concentrates In dry blend production. Also, the switch was made from KM-330 to KM-334 Impact modifier and DuPont's Edgenixnvproduced TOIL was approved. 'Mft-U:.!'" r. fo-.C'jr-H.. i' .lit- 4?- *' tV- ] '*114 LABORATORY - continued H. Miscellaneous - continued 3. Raw material specification sheets were updated by Dave Cox on disk and circulated internal 1 y for approvals. 4. Harold Coleman attended Quality Expo TIME in Chicago on April 12-13. Of interest were seminars on precision testing plus exhibits of new Q.C. equipment. 5. Brian Harrison completed six color matches for Omega Plastics, Aluminum Products, Comm/Scope (2), Corelmex, and National Extrusions. 6. Brian Harrison attended the Dry Blend New Product Definition Team Meeting in Menphis on 4/26/88. VAB.0001190959 A SAMPLE SHIPMENTS RESIN Ship Date 4/04/88 4/14/83 4/15/88 4/15/88 4/21/88 APRIL 1988 Product 5385 5415 5265 5385 5415 5385 5415 Amount- 50 lbs. 50 lbs. 2250 lbs. 1000 lbs. 50 lbs. 5 lbs. 5 lbs. Customer m1 Davidson Technology Cent Arlington Mills Gold Bond Crane Plastics Borden Chemicals COMPOUND Ship Date 4/11/88 4/15/88 4/21/88 4/26/88 4/26/88 4/29/88 4/29/88 Product 34642 NAT 38401 BLK (BC) 18162 NAT 18031 CB 50 38931 NAT 17121 WAT CL 17121 WAT CL 4/29/88 18162 NAT Amount 100 lbs. 50 lbs. 1500 lbs. 10 lbs. 50 lbs. 5 lbs. 100 lbs. 50 lbs. Customer Atlas Wire Polychem Electronics Gossen Corp. Compression Polymers Rayton Electric Ltd. Protomold California Insulated Wire & Cable Fiberchem TtHYRT .KWP Ship Date 4/29/88 Product 186-74 WHT 112 Amount 100 lbs. Customer Americhem Inc. v p. t -" - ; it * \ r 4|- <? i !- MV f. ............-r-W' - si: .. I!-*** 11 II H- VAB.0001190960 I-ij: .*.. r -If- l*' j. -.M >3 Fjrvijvrtt SHIPMENTS BY PRODUCT - M LBS. April 1988 FISCAL YEAR-TO-DATE RESIN PLASTICIZER DRYBLEND COMPOUND TOTAL 29,441 484 5,4 79 6,407 41,811 212,506 4,517 37,225 49,158 503,4(^6 NUMBER OF SHIPMENTS BY MODE: RESIN-Bulk r RAILCAR 128 VISTA TRUCK TRAILER ON COMMON CUSTOMER BULK f VAN A FLAT CAR CARRIER PICK-UP CONTAINER TOTAL 48 3 95 274 Package 1/ / 20 Export PLAST.-Bulk Package DRYBLEND-Bulk n 25 - 3 - S n r 8 5 2 4 Package 4 12 1 17 Export COMPOUND-Bulk Package Export TOTAL 15 170 4 35 63 44 1 19 33 30 98 i 67 58 141 6 483 b * r VAB.0001190961 3000 2900 2800 o cn oCMo 2700 2600 BTU/LB 2500 W 2400 0 01 Q cn x " 2300 in Ed z0 F Ji in v>- iuni in j tr ul < u. 2200 Ul lL IUM C 2100 2000 ENERGY USAGE Monthly 12-Month Moving Average j4,.t n 13 p**s--f: > **<>n ' " VAB.0001190962 -- : *V . .. S.I -4*TM,-- n- MM POUNDS MONTHLY ABERDEEN PLANT PRODUCTION 10/01/87 - 09/30/88 f* MM POl..jS CUMULATIVE 450 80 8 70 60 6 50 40 4 30 2 lO 70 60 50 40 30 20 10 f k ------------------------ ,________ Budget Actual Cumulative VAB.0001190963 i & 1.020 1.015 1.010 1 .005 1.000 0.995 1.030 1.025 1.020 1.015 1.010 1.005 1.000 1.020 1.010 1.000 990 1.200 1.150 1.100 1.050 ABERDEEN PLANT EFFICIENCY 10/01/87 - 09/30/83 POUNDS OF RAW MATERIAL/POUNDS OF PRODUCT * t?-. nail t IfKi* - i ............ , . !M|A -^rri . VAB.0001190964 cl-h -1,..* -<- 6.0 5.0 4.0 3.0 2.0 1.0 0 c/1o/ OFF-GRADE I'.OO .75 .50 .25 0 4.0 3.0 2.0 1.0 0 ABERDEEN PLANT QUALITY PERFORMANCE 10/01/87 - 09/30/88 r P'- .:* -Sk-t.' -u-.j. . n p* ............. .-r. hi VAB.0001190965 -i- -i- irH< ly-.i-h.. - .. i (/.:> MM POUNDS ABERDEEN PLANT INVENTORIES 1O/Ol/87-09/30/88 A 10o0 1.0 0o5 0 4 f1 i i 4<p tt f tt t t I4f * June ! July Aug |. ...I, VI J-l: : ^h'|- t:^HH=r.J-|ll ^ VAB. OOO1190966 fJ MtiPik . Lj J.S k. -Il nf--+. '['i-l.r i-A-Ul.l --L-- -il- .4-1 Jk: K^s-ll y `u.n.- . ur