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T. H. Huffman 4I A rrom: Dole: Subject: D. C. Skokna December 18, 1989 ABERDEEN MONTHLY PROGRESS REPORT NOVEMBER, 1989 VISIA Safety There were two first aid and one recordable (RWC) cases reported during November. The recordable case involved a compound unit operator who severed the top of his right index finger when it was caught in the hinge side of a closing door. At month's end, the plant's employees had worked 3,801 days (5,037,551 manhours) since the last lost time injury. On November 6, the plant's employees reached 5,000,000 manhours without a lost time injury - a Vista record. Kev 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 November 37.9 90.1 95.9 0.99838 6.5 98.0 4.6 98.6 1.5 89.7 < 9.5> <107.1> 61.9 Y.T.D. 70.8 82.6 96.7 0.9978 13.0 97.9 8.1 99.1 3.0 90.1 < 6.9> <46.6> 136.7 Capacity Utilization Factors Resin Flexible Compound Rigid Compound Plasticizer 103.6 83.3 75.0 80.6 95.2 83.7 65.6 84.9 Waste Reduction Indices (%) Offsite, Hazardous Wastes Recycled, Hazardous Wastes Offsite, Non-Hazardous Wastes Vulnerable By-Products Total Waste Water Air and Water 157.7m 101.9(,) 79.2(,) 93.5n> 105.6n> 78.6(1> 194.1 117.6 91.1 106.4 118.0 85.9 (1) Three-month rolling average. VAB.0001190269 T. H. Huffman 12/18/89 Aberdeen Monthly Progress Report - November, 1989 Page 2 Operations Drying of 5415 resin was switched from rotary dryers to the fluid bed dryer to better match drying capacity to product mix. Results were good-acceptable rates were achieved and 5415 quality (contamination levels) has improved. A two-day test run of three reduced flame and smoke compounds was performed on Line 1. Results were encouraging. Costs Variable costs were favorable due to good raw material efficiencies in the resin unit, a favorable product mix variance in the flexible compound unit, partially offset by high raw material use in the rigid compound and plasticizer units. Fixed costs were unfavorable due to above budget payroll costs, maintenance material costs, and "Miscellaneous" costs. OMP 1. Sixty-three percent of the plant's natural teams met during November (the highest level for the plant). 2. Twenty-eight "SPC Expert" students were recognized for completing their training in this voluntary course. 3. Plant personnel participated in a meeting at Klockner to review work to date on the 5305 graininess problem. The 10 micron filtration trial did not eliminate graininess; a deionized water test run will be done in early 1990. Environmental 1. Presentation of 1988 SARA emissions were given to employees. 2. The NESHAPS 200 Valve Survey was completed - no leaks were found. Doug Skokna Plant Superintendent rah VAB.0001190270 DISTRIBUTION COVER LETTER ENTIRE REPORT Houston J. D. Burns X R. T. Ferrell X T. H. Huffman X C. J. Matson X D. F. Harman X H. R. FIamine r X R. R. Smith X B. J. Bean X R. H. Gerlach X Austin R. D. Gamblin R. L. Poe X X H. J. Hall X Oklahoma Citv H. G. Garrison X LCVCM Plant LCCP Plant R. A. Conrad J. Friend X X LCLAB Plant J. W. Ware X Baltimore L. R. Bauer X Hammond J. Pavao X Blane Premiere Aberdeen C. R. Miller P. L. Foote RWS/DCS (File Copy), PJK, JEN, MRK, DAM, JEB, HGC, JEL, REP, BLT, RBN, SCH X X VAB.0001190271 4 SAFETY - B. L. Trego, J. V. Uptain First Aid OSHA Recordable Total Injuries November 2 1 3 Fiscal Y.T.D. 1990 Fiscal Y.T.D. 1989 43 g0 63 Number of Restricted Workday Cases 1 1 0 Number of Lost Workday Cases 0 0 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Rec eiving/Warehous e Office Totals 00 11 24 00 00 01 36 0 0 3 0 0 0 3 Injuries bv Type Cuts and Abrasions Eye Injuries Burns Bruises S trains/Sprains Stings Other Totals Npn- 00 11 01 01 00 01 1 36 1 0 0 2 0 0 0 3 Lost Workday Cases Days Lost 00 32 59 1 14 Safety Record Last lost time injury - 7/5/79 Days since - 3801 Employee hours since - 5,037,551 On November 30, 1989, the employees of the Aberdeen plant completed 3801 days with no lost time injury. Topics for plant safety meetings during the month included Reviews of 1989 (Fiscal) Injury Statistics and Weekly Maintenance Safety Feedback Meetings. The Aberdeen Plant reached 5,000,000 manhours without a lost time accident on November 6, 1989. This is a Vista record that will set the standard foi other locations. Our new goal? Continued improvement! A nni mm m PM VAB.0001190272 SAFETY - Continued Routine dosimetry results for the month were: <________________________ Number VCM Lead Total Particulates 75 98.68 19 100.00 7 100.00 > PEL Number Percent 1 1.3 0 0.0 0 0.0 Monthly Injury Summary Injury Class FA Maintenance FA Maintenance RWC Compound Foreign object in left eye. Wood splinter in right palm. Amputation of distal half joint of right index finger. A compound worker allowed a door to close on his finger. This caused a break in the finger tip bone and the loss of flesh and skin from his finger tip when he pulled his hand out of the way through his reflex reaction. VAB.0001190273 i QUALITY DEVELOPMENT - M. R. Kane Twenty-eight SPC Expert students were recognized for completion of the course. This was the second full round of training that was given. In total, there are now forty employees who have been trained in basic and practical SPC techniques through the course. The next course will begin in January and will be revised based on student feedback. Progress was made in Identifying measurement and calibration standards which need to be traceable to the National Bureau of Standards. Weights used on the large product and raw material scales have been certified as NBS traceable as well as some of the primary standards in the lab (temperature and weight). The Plant Manager's Natural Team decided to emphasize and reinforce the team effort by developing some measures related to team progress. The two key measures are the number of teams meeting and the number of team meetings per month. Since effective facilitation is critical to success of inexperienced teams, it will be measured by having the facilitators report their progress to their department head each month. In addition, team leaders will report the progress of their team to their department head. Facilitators will be assigned to each natural team. The teams which have not been trained in team management will be trained as a team using a problem they pick as a case study. VAB.0001190274 t A COST VARIANCES - D. C. Skokna Variable Costs Product PVC Flexible Compound Rigid Compound Plasticizer 1989 Variance. $M Price Total $ 46.7 73.0 < 43.2> <-14,6> $ 61.9 $ 700.0 161.6 233.9 <15.3> $1080.2 $ 746.7 234.6 190.7 <29.9> $1142.1 PVC - Faborable raw material use (primarily VCM and initiators) , partially offset by above budget utility use, resulted in the overall favorable variance. Flexible Compound - The favorable variance was a result of product mix. Rigid Compound - The unfavorable variance was a result of above budget raw material use and product mix. Plasticizer - Raw material use was above budget. Price Variances - VCM - Resin to Rigid Compound - Resin to Flexible Compound - Electricity - Water > Natural Gas - 610P to Flexible Compound - Alfol Alcohols - Other Total $662.4 218.8 184.5 27.0 15.3 14.8 < 18.1> < 18.2> < 6.3> $1080.2 Fixed Cost Variances - Payroll andBenefits - MM&C - Miscellaneous - TI&D - Clearances Total $< 18.3> < 50.4> < 31.3> < 3.5> < 3.6> $<107.1> Payroll and Benefits - Salaried and hourly payroll costs were above budget, partially offset by a favorable benefits change, resulting in an overall unfavorable variance. M. M. & C, - Parts for incinerator repair caused an unfavorable variance. VAB.0001190275 COST VARIANCES - Continued Miscellaneous: - Travel expenses for VCSM project related training and expenses related to the continuous stripping technology assessment caused this item to be $15.2M over budget. - This is part of R. Mackey's relocation costs. Outside Professional Services - was $10.2M favorable. Unclassified - was $16.6M unfavorable due to VCSM related training costs and physical exams. Operating Supplies - was $17.4M unfavorable, primarily due to performing a test using 10 micron raw material filters in the resin unit to evaluate the impact on 5305 resin quality. A VAB.0001190276 T VINYL - P. J. Kober, K. W. Birck Safety The Vinyl Department did not have any first aid or OSHA recordable injuries during the month of November. The topics of the monthly safety meeting were SARA, New Unit Turnaround, and Winter Safety Awareness. General Production of 5415 resin was switched from the rotary dryers to the fluid bed dryer during the month. This switch lessens rotary dryer bottleneck created bvy increased 5415 (and 5385) production. Results have been favorable: fluid bed rates have averaged between 19,350 to 23,650 pounds per hour and regular analysis for contamination has been below five average total contaminants. 2. Dryer #4 baghouse replacement was completed during the month. This was the last dryer to have its baghouse worked on as part of the Rotary Dryer Baghouse Replacement Project. 3. Production was reduced during the last part of the month to control VCM inventories. Minimum sphere levels were maintained to ensure an adequate VCM level to keep the plant operating during winter alert, had one occurred. 4. The resin raw materials in the 744 account were valued at $411.2M. November YTD - 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 % Reactor Downtime 37.9 1263.8 103.6 886.0 29.5 90.1 83.5 93.0 95.9 70.8 1060.8 95.2 1666.0 27.3 82.6 79.7 84.4 96.7 Hours Operational downtime (recovery scheduling conflicts, rinsing chem wash tanks, New Module rinse/charge water conflicts, no place to dump, 0-ring leaks, waiting on Q.C. data before charging, and inclement weather). 280.8 VAB.0001190277 VINYL - Continued Reactor Downtime - continued Maintenance downtime (hydroblast/drill reactors D700 and D745, drill condensers D741, D500 and D600, condenser lid torque/ gasket replacement on D744, changed safety discs on D743, and miscellaneous instruments and valve repairs). Other (inventory control due to VCM shortage). Hours 362.5 68.9 Reactor limited production. Operational downtime (centrifuge plugs, clean dryers, activator transfer problems, power outages (3), product change to 5415 in fluid bed dryer, leak checks and flameouts). Maintenance downtime (centrifuge repairs, shear pins, exhauster repairs, sparge pipes, screener repairs, and various other activator and centrifuge repairs). 53.9 31.7 14.4 Key Maintenance Woj:]p - J. B. Autrey, J. B. Hegwood Reactors 500, 600, and 741 were shut down during the month for condenser drilling due to cooling water control problems. Reactors 700 and 745 were also shut down for condenser drilling as part of the contamination control program. The seal on reactor 745 was changed out because of a plugged lip seal flush line. This seal had been in service for four months. The condenser lid gasket on reactor 744 was replaced due to a leakage problem. Numbers 1 and 8 Birds were removed and rebuilt during the month. The rupture disc on reactor 743 was changed out as part of the annual rupture disc program. The "A" vacuum pump was changed out during the month because of two seal failures. VINYL - Continued Kev Maintenance Work - continued The motors on #4 exhauster and on the north chem wash pump were replaced during the month. The #4 exhauster motor had a bearing failure and the north chem wash pump motor broke off of the foundation. There were ten major valves changed out in the reactor area during the month. A VAB.0001190279 COMPOUND - J. E. Nickerson, K. G. Akins A There was one restricted workday case in the Compound Department during November. A Compound Operator severed the tip of his right index finger when It was caught in the hinge side of a closing door. The accident team's investigation report is due December 22. The SARA Title 313 emissions from the Aberdeen Plant were reviewed during the November safety meetings. General We continued to build critical inventories during November. Flexible compound inventories rose from 4489M pounds to 5664M pounds in November. A two-day test run of reduced smoke and flame compounds, using licensed technology, was conducted on Line 1 at the end of the month. One insulation and two jacket formulations were produced. Problems continued with production of 80273G rigid compound. Based on some preliminary testing, segregation of the master batch may be occurring. Work continues to isolate the problem. We do not believe this is a new phenomena, but the new, more sensitive torque rheometry tests are able to detect it. We are viewing this as an opportunity to improve the quality of our dry blends. No customer problems have been reported. Operating Comoound Production Days ________Production (M Lbs. ) Month Avg./Day Fiscal Y.T.D Line I 28.5 Line III 28.0 Line V 20.5 Total % Prime Capacity Utilization Factor Downtime 2085 3415 960 6460 98. 0 * 833 73 122 47 Hours 4178 7064 1791 13033 97.9 .837 Line I - Product Changes - Quality Problems & Control - Miscellaneous Maintenance - Dicer Problems & Maintenance 80 11 39 4 Unp HI - Product Changes - Quality Problems & Control - Miscellaneous Maintenance 67 13 6 VAB.0001190280 COMPOUND - Continued Line V - Product Changes - W-P Maintenance - Miscellaneous Maintenance 40 20 9 Operating Month Rigid Compound 28 4600 % Prime 98.6 Capacity Utilization Factor .75 164 Downtime Hours - Quality Problems & Control - Product Changes - Miscellaneous Maintenance 96 44 36 Operating __Davs Month Plasticizer 29 % Prime Capacity Utilization Factor 1693 89.7 .806 Fiscal Y.T.D. 8072 99.1 .656 3374 90.1 .849 J. B. Autrey, J. B. Hegwood Line I Banbury was shut down for seal replacements during the month, A temporary fill chute was also made for the Banbury to assist with the experimental low smoke, low flame compound run. The 107 and 185 plasticizer pumps were shut down for the seal replacements and the motors were replaced on each. The motors on each were replaced due to bad bearings and windings. The Schenk filters were removed for cleaning during the month. Number two Welex was shut down during the month so that several badly worn seals could be replaced. The Line III condensate pump was rebuilt and the motor replaced. The motor was replaced because of bad bearings and windings. A VAB.0001190281 UTILITIES - J. B. Autrey, J. B. Hegwood Number one boiler was shut down for repairs because of a hot spot that developed on the outer skin. The inner skin had busted causing the hot spot. The boiler was repaired and put back in service. Number two boiler was shut down for a second inspection during the month because of deposits that were found on #3 boiler during its inspection. The same type of deposits that were found in #3 boiler were found in #2 boiler. Because of this finding, the tubes and firebox were hydrobias ted. A two-inch feed water line and the continuous blowdown line were replaced in the steam drum, also. VAB.0001190282 ENGINEERING - R. E. Polk, S. C. Hillman, C. J. McDonald PROJECTS IN DEVELOPMENT - GENERAL 5305 Graininess Work A meeting was held at Klockner to discuss work to-date on the graininess problem. Testing at BASF and Klockner showed that the ten micron filtration trial did not eliminate graininess. A D.I. water test run is being planned after the first of the year. TC Wastewater Compliance Several alternatives to reduce the total project cost are still being evaluated with results expected by late January. These are: - The initial trial of EVC clean wall technology. - A plant-wide test of stripping rinse water in small blend tanks. - An economic comparison of stripping columns versus UV oxidation. 5415 in the Fluid Bed Drver The fluid bed dryer has been converted from 5385 to 5415 service for a trial run. Alternatives to increase fluid bed rates with 5415 are being evaluated. 2nd Fiscal Quarter 1990 Capital Budget The 2nd Fiscal Quarter 1990 Capital Budget was completed and sent to Houston on 12/8/89. Railcar Hazardous Materials Spill Response Training Jim Edwards attended an American Association of Railroads seminar on management of hazardous materials spills from railcar accidents. He is one of four people at the plant trained to respond to such a spill. A VAB.0001190283 HGI1KKEIIG - k.E. .POLK, S.C. fllLUAl, C.J. 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CQUTBCtm IS II PMNBSS MITH CRPUTIOI II DKfiW. ramniH is n pknrss. piojict cqrutim is purs ioi use. nsuiuim is u Brass win coririoi puns idi nnun. uruuiioi is orpub kxcept mi nkuir itbs. piojict coRuim is pubs mi ruoaiy IBUlLATIM IS II PM6RSS. PIOJICT CORUTIOI IS PUHS Ml JtfUH. DBI6K IS 11 M06RSS. PB0JICT CORUTIOI IS PUHS MI JtfUH. URUUIIOI IS ORKHI1IC1PT Ml FOKHLIST IBU. PIOJICT CORUTIOI IS PUHS Ml JASSY. nRiiunoi n scums to ran n juuh nn coririoi ii fibduy. nsriiunn is n noons nn corutioi furs mi jamah. ram is n prams, psoject corutioi is pubs mi rbrah. ram is n prams. piojict corutioi is pubs ioi jure, all piojict nn n ranois mi corutioi ii raran. cuss to nra cram. IIRA1UTI0I IS ORPUB EXCEPT Ml POICHIIST ITUS. TB AGITATORS UR BU lECEIBD. IISTALLATI01 IS PUBS Ml CORUTIOI IIISKUH. IRSIAlUim IS ORPUB EXCEPT MI P0KHLIST ITBS. IB PB0JKCI WILL U CUSS TO FIELD CHARGES II JAMAH. IISTALLATI0I IS PURS TO BEGIB IX JAMA1T 9ITH CORUTIOI II BHUH. CUSS TO IBU CURB. TB C0RBSS01 IB SCBOOLS 701 DIUBH 11 IBIOAH 1990. eras to nra cunis'. IIRILUTIOI IS MS CRP1R1 AS II PIOGIESS. CORUTIOI IS PUBS Ml DICUBEE. aoss to nra anra. BQIBSIM IS II PBJ6BSS. PIOJICT CRFUTIOI IS PUBS Ml MID-1991. EMIIBHM IS II PI06BSS. B6UBIIW IS II PM6RSS 01 7 P10JECTS. 100IMBT IS BIB GORED. VAB. OOO1190284 H 4 F. G. Jeanson Water All wastewater discharge parameters were met for the month of November. However, we did have a wastewater bypass. The bypass occurred on Sunday, November 19, when an estimated 500 gallons of untreated wastewater went to the storm water system. The bypass was caused by a plugged process sewer. The State was contacted about the incident. SARA Presentations on the 1988 SARA emissions were given to all employees at the plant by their respective department head. Waste Waste shipments for the month of November included: Ten drums of stabilizer spill were sent to Technical Environmental Systems in LaPorte, Texas. From this storage facility, the waste will be shipped to Chemical Waste Management's (CWM) Lake Charles facility. Two bulk loads of API sludge were sent to CWM's Erne lie, Alabama facility. Two bulk loads of separator oil were sent to Systech in Demopolis, Alabama. A The NESHAP 200 Valve Survey was completed during the month. No leaks were found. Results from this survey will be reported to EPA in the next NESHAP quarterly report. Fiscal year residual VCM numbers were tabulated for 1988 and 1989. The total pounds emitted from slurry and the average ppm/batch are listed below: Total Pounds Avg. Total Pounds Emitted PPM/Batch Production FY88 FY89 73,317 65,841 164 145 446.6MM 454.2MM This represents a 12% decrease in VCM emissions, even though more PVC was produced in FY1989. The rotary dryer baghouse project was completed this month. Emissions testing was completed on the baghouse stacks and submitted to the State. The emissions tests were completed on two of the five baghouses. Both baghouses were operating below the manufacturer's emission guarantee. An application for a new air permit was completed this month. This new permit, if approved by the State, would allow us to become a minor source. This permit was reviewed with plant management and will be submitted to the State next month. VAB.0001190285 ENVTBONMgMTAT- - Continued Toxjjg.ity I discussed with the State the effect this regulation would have on our plant and Inquired about an extension for wastewater. The State said they did not have the authority to grant an extension beyond what was called out In the regulation. Miscellaneous I attended the Mississippi Manufacturers Association Environmental Committee meeting this month. The Aberdeen Plant contributed $1500 toward their hazardous waste public education campaign. A guide for training requirements for environmental coordinators was completed. I surveyed other manufacturer's methods of storage for EPA required documents (disc or hardcopy) for VCSM team. Surveys and Reports Completed - CMA survey of wastes shipped to Alabama - Monthly NPDES report Waste Minimization 1 attended a waste minimization conference held by MISSTAP (Mississippi Technical Assistance Program). The waste minimization three-year plan was completed. SARA-air) decreased due to the completion WRI for last three months. 52.85% WRI for FY90) A waste paper baler was included in the third quarter capital budget. Approximately 10-15% of our solid non-hazardous waste, in the form of waste paper and cardboard, will be recycled when this baler is installed. A project to reduce slurry residual VCM by 50% was also included in the fourth quarter capital budget. A VAB.0001190286 -i A Nov-89 WASTE REDUCTION INDEX SHEET OVERALL EXCLUDING "TOTAL WASTE WATER"1 NON-RECYCLED WASTE RECYCLED/SOLD WASTE 3 MONTH 90.96% 85.41% 94.85% %HRI 90 YTD 103.54% 96.94% 108.17% 1989FY 103.51% 94.96% 109.51% I. Offsite, Hazardous Wastes 157.71% 194.12% 100.68% a. Land Ban Wastes b. Hazardous Solids c. Non-Hazardous Treated as Hazardous 0.00% 125.84% 169.80% 0.00% 40.66% 246.65% 244.74% 111.19% 95.77% II. Recycled Hazardous Wastes 101.86% 117.64% 103.51% III. Offsite, Non-Hazardous Waste a. Recycled b. Non-Recycled 79.18% 91.15% 95.95% 77.28% 109.35% 89.09% 95.37% 98.39% 95.03% IV. Vunerable By-Products 93.50% 106.36% 111.36% V. Total Waste Water VI. Air & Water a. SARA - Air b. SARA - Water c. Non-SARA - Air d. Non-SARA - Water 105.55% 118.00% 95.01% * 76.92% 75.10% 91.90% 87.13% 1139.94% 67.37% 82.46% 87.41% 1274.36% 52.85% 90.99% 88.05% 592.12% 96.30% 87.24% VAB.0001190287 4 A Nov-89 WASTE RECTION INDEX SHEET Offsite, Hazardous Wastes a. Land Ban Wastes 1. Phthalic Anhydride b. Hazardous Solids 1. Stabilizer Spill 2. Floor Sweep c. Non-Hazardous Treated as Hazardous 1. Plast. Filter Cake 2. Lead Bags 3. API Sludge 4. Pit #1 Solids Recycled Hazardous Wastes a. Recycled 1. Separator Oil 2. Safety Kleen Solvent 1988FY 321409 2412 2412 79068 16989 62079 239930 61670 68640 29620 80000 653226 653226 651700 1526 POUNDS 1989FY 90 YTD 329304 6006 6006 98907 0 0 89465 22425 67040 5097 5097 0 233833 56573 67880 29380 80000 93810 0 13900 66540 13370 688080 688080 686210 1870 121815 121815 121340 475 3 Month 124902 0 0 24517 5097 19420 100385 0 13900 66540 19945 163946 163946 163340 606 Offsite, Non-Hazardous Waste a. Recycled 1. Drums 2. Pallets 3. Aluminum Cans 4. Scrap Metal b. Non-Recycled 1. Landfill Vunerable By-Products a. PVC 1. Culls 2. Vacuum Vent Dust 3. Sifter Overflow 4. Pond Resin 5. Pit #2 Reain Total Waste Water a. Effluent 1. Pond 6 VI. Air & Water a. SARA - Air 1. VCM 2429430 247201 49600 145600 0 52000 2182229 2182229 2357718 247500 49600 145600 300 52000 2110218 2110218 351053 42853 10950 22812 400 8690 308200 308200 473996 58446 10950 34032 500 12964 415550 415550 3597456 3597456 471409 329480 801007 1915560 80000 4076656 4076656 330521 541016 504106 2621013 80000 606575 606575 26520 84297 24836 457552 13370 828835 828835 57180 124847 38561 587302 19945 4424987560 4278245861 827694426 1150836733 4424987560 4278245861 827694426 1150836733 4424987560 4278245861 827694426 1150836733 646617 73316 73316 604682 65694 65694 76981 122547 10159 15740 10159VAB.OO$g?388 + A Nov-89 WASTE RECTION INDEX SHEET 1988FY POUNDS 1989FY 90 YTD 3 Month b. SARA - Water 1. VCM 2. Di-n-octyl Fhthalate c. Non-SARA - Air 1. Particulates 2. Sulfur Dioxide d. Non-SARA - Water 1. BOD 2. TSS 3. COD 4. NH3 55 22 33 264206 263300 906 309040 43669 66392 195581 1378 333 21 312 264290 263300 990 274364 46750 53140 173276 1199 112 4 108 22136 21965 171 44574 11659 8530 24304 81 155 6 150 43858 43606 252 62794 15346 11527 35779 142 VAB.0001190289 ENERGY CONSERVATION - D. A. Moore November. 1989 Fiscal Y.T.D. I. A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU -9.1% -9.5% 2689.0 135.8 -6.1% -6.9% 2615.0 248.8 (1) Plant electrical usage is an estimate because an additional meter was added during the Electrical Upgrade Project and was not read. This will be reconciled in the December energy numbers. j II. Plant Energy Conservation Program A. Maintenance There were sixteen energy related items completed in October, 1989. Ten of these items were steam leak repairs. The remaining six were steam trap repairs. III. Boiler Operation Boiler No. 1 No. 2 No. 3 83.3% 83.3% 83.1% 83.5% 83.4% 83.1% VAB.0001190290 w NQVBMPEfti 1999 J. E. Beall Employment None Promptions/Transfers None None A wmmmtmmmmmmmmmmrnmmmmmmmm wmp VAB.0001190291 mu -Ti m cn K) N3 DoO oCD D oDQ> MP UPMHMf l w^ow 04 >o m fO o ae m Om tn^o cn 4 VAB.0001190292 - * ABERDEEN, MISSISSIPPI Salaried Employees Hourly Employees Total Employees NOVEMBER, 1989 MONTHLY PERSONNEL REPORT 79* Minority Employees #, % 172 Salaried EL 251 Hourly 66 Total 72 29% A New Employees 0 Hourly Min. Hired 0 Terminations 0 % Min. Hired 0 Hourly Min. Term 2 % Min. Term 2 DEPARTMENTS PAR #EMPLOYEES MIN. EMP. %MIH. NEW HIRES YTD TERM. YTO. TURNOVER YTP. Warehouse i 6 Gen. Plant 13 Maintenance 41 24 Compound 40 Vinyl 33 11 16 41 23 39 33 aa a 5 31 7 7 0 0 0 12 24 0 0 0 2 00 2 26 67 0 0 0 0 0 2 10 30 0 0 0 0 0 0 Plasticiser 5 5 1 40 2 0 0 0 0 0 Number of Applicants: Month 0 Year To Date APPLICANT BREAKDOWN: # Minority 2 % Minority # Female 0 % Female Hires (Hourly): Month Year To Date Terminations (Hourly): Month __q Year To Date Overall Turnover 2 Projected Annual Turnover Z Z VAB.0001190293 Safety There were no safety instances this month. Cost Savings Savings due to competitive bidding were $44,179 for November, and $44,482 for FY1990. Savings due to prompt payment discounts were $1831 for November, and $4215 for FY1990. Warehouse - Finished Goods Inventory Offgrade inventories remain a serious problem; Fred Williams. will discuss with FY1988 FY1989 November Flexible Compound Rigid Compound Resin 142.7 49.7 28.6 477.0 64.4 83.7 566.3 120.7 52.0 Meetings 11/02/89 11/03/89 Judy Frossard attended the Payroll Team Meeting in Houston. Discussion Included conversion to VMS, PMS conversion to software, direct deposits, etc. MMS PC 11/28/89 Mike Swierc attended a CQIP meeting in Hous ton. Focus was primarily stainless steel gate globe, and check valve testing. VAB.0001190294 4 Ullllll CIUICU PLAIT SlIPPIR IIIITSIS 107IBM III) SOffTI -SHPKIITS 1! PMMCT8- PlllIC in/m IICI1NI ttsuiiu usunciuit 11,411,111 7,997,299 919,199 9 9 IU11IU C0BF9IIM9U 1,374,556 fUlIIU CMPMU-PICKMO 2,912,217 929,499 111, HI 1 9 tun couom-iiu Hill CORPMH-PICIMII 2,197,431 14,111 111,111 12,999 9 9 A 7T9 PVIMC IfT/ITC I1CUMI 99,999,479 19,994,949 749,974 111,HI 9 9 1,141,HI 2,999,999 9,114,999 291,129 9 9 1,111,141 4M.S1I 999,199 11,IH 9 9 PUSTICISI1 lii.iii 114,111 9 997,999 II1.4N 9 TOTAL 27,919,961 1,141,411 9 13,111,111 11,SSI,411 9 -SHNIITS I! MR- Bill: *10711111* mil KillIII C0IP09II mu comm ruiiiciiii UllCil CRTOIII CWM PICtIP cutiit 122 22 78 12 3 9 19 2 19 1 94 TOW 229 15 29 5 TOTAL I0TKHIII 151 27 99 269 tim mu PMI1UK COIPOIIB IIG1I COIPOIIB pusTicim 258 52 145 26 3 5 99 7 29 4 97 455 34 69 11 mu in 927 92 177 HI NCUlil: Ofllltt* mil ruirni COOPOWI mu etiNm PU6TIC11II lomiotuiii CKTOIII P1C1IP CHIN cmitt 9 14 23 95 04 99 32 93 tore comtiu ill/IFS 99 19 91 99 5 3 9 9 11 1 TOTAL m 29 92 5 9 125 *!!l* ^ mil IMIIMI COHPOIII mn mrom runiciui .i * Tom TTI 13 28 9 9 49 143 l 9 i 18 9 1 9 9 99 53 187 1 m 12 4 1 1 53 188 18 1 VAB.00(#fe0295 lI Il Hi i HII II fIlI Ittl 1 II II1 II tiiiII iiiIIi i Mi i r--* w "T LABORATORY - H. G. Coleman A. Safety - The Laboratory operated injury-free in November. Harold Coleman led the monthly safety meeting which included a review of FY89 safety statistics, the Vista/Aberdeen film, and a SARA presentation. B. Customer Contacts - None. Customer O.C. Reports 11/8 Chicago Magnet Wire Corporation reported failure of their strip force adhesion test with 35851, lot 39N02. The problem was traced to something which affected melt flow; 42,000 pounds of material were returned - another 51,000 pounds in inventory were downgraded. 11/14 Intex Plastics reported a bridging prob1em trying to unload a 5305 railcar. No moisture or res in flow discrepancies were found. 11/29 Blane Polymers rejected a 5395 railcar for metal contamination. This car was produced during a previously identified problem. We have begun testing railcars for metal prior to shipment. D. Requests for Corrective Action - None. E. Product Waivers Customer Product Reason No. H&W - Export Rustique 5385-3 435-30 WHT 111 Contamination 40 Mesh 1 R/C 1 H/T mm RVCM of In-Process Samples 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 November, 1989. Number of Samples Average RVCM, ppm & Reactor Slurries 888 138 ________Drier 5265 5305 29 0.527 70 0.595 VAB.0001190296 LABORATORY - Continued RVCM of Shipment Samples The following is a summary of the residual VCM analysis of shipment samples for the month of November, 1989. Product Average RVCM. ppm 5265 5305 5385 5395 5415 5465 Dry Blend Debox Pond 33 98 41 0 62 0 61 13 8 0.150 0.247 0.324 0.153 0 0.084 0.350 5.114 G * (based on dryer "regulars") 5265 530? Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Dryt ime Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) 1.52 0.78 -- 5.75 6.00 2.67 1.93 -- 0.74 -- -- -- -- 1.33 0.90 0.43 3.08 3.50 2.50 1.72 -- 0.79 -- -- -- -- Average particle size, microns 134 136 H. Flexible Compound Quality Summary 5385 2.67 0.93 4.11 ---2.50 2.67 -- 1.70 1.67 -- 21.8 157 5415 1.37 0.55 ------------------- ------- 4.33 -- 6.33 4.00 0.67 3.69 2.00 1.93 1.10 2.6 174 Hardness Color/Clarity Hard Particles Contamination Dicing Totals Adjustments M Lbs. . m 7.0 -------- -- 7.0 (0.11) -- -- -- -- (0.11) Rejections M Lbs 4.5 24.1 46.4 4.5 25.5 105.0 (0.07) (0.37) (0.72) (0.07) (0.39) (1.63) A VAB.0001190297 LABORATORY - Continued Torque Rheometry Total 26.0 (0.57^ 26.0 (0.57) 1. Our new Brabender PL2000 torque rheometer was commissioned for service this month. All rigid compound Q.C. technicians were trained. 2. H. G. Coleman participated in an Open House for the Aberdeen High School teachers. This was a kick-off for the Aberdeen/Vista Partners in Education Program. 3. Effective 12/1/89, Harold Coleman is being transferred to R&D in Austin as Senior Group Leader for PVC resins. Richard Williams will handle the duties of Chief Chemist until a replacement is named. VAB.0001190298 A RESIN r Ship Date 11/02/89 11/03/89 11/07/89 11/19/89 11/14/89 11/14/89 11/16/89 # 11/22/89 11/28/89 11/28/89 11/30/89 SAMPLE SHIPMENTS NOVEMBER 1989 Product 5415 5415 5305 5385 5415 Pond Resin 5305 Pond Resin 5415 Pond Resin Pond Resin Amount 100 lbs. 100 lbs. 5 lbs. 10 lbs. 100 lbs. 5 lbs. 50 lbs. 5 lbs. 50 lbs. 2X5 lbs 50 lbs. Customer ELECTRO CONDUCTORES C.A. ELECTRO CONDUCTORES C.A. General Cable Co. Carter Footwear Co. Twitchell Sun Polymers * GLASSIDUR, S. A. Sun Polymers INYECCIONES INDUSTRIALES Wexford International JOSE M. TELLES COMPOUND Ship Date 11/02/89 11/03/89 11/09/89 11/10/89 11/16/89 11/16/89 11/28/89 Product 35451 NAT 35451 NAT 416-74-1 NAT 38525 NAT 38525 blk 240-183C NAT 240-184 NAT 38201 GRY 573 38901 GRY 573 Amount 100 lbs 300 lbs. 50 lbs. 250 lbs. 300 lbs 150 lbs. 150 lbs. 200 lbs. 200 lbs Customer ELECTRO CONDUCTORES C.A. ELECTRO CONDUCTORES C.A. Vista - Austin Times Fiber Comm'ns Inc. Communication Cable Inc. Prestolite Wire Corp. Carlon Company DRYBLEND Ship Date 11/28/89 Product RP-200 WHT 111 Amount 50 lbs. Customer OMNI PRODUCTS VAB.0001190299 'i A A9tRDttN CHEMICAL PUNT INJURIES (Twelve Month Running Totals) 40 35 30 25 NUMBER OF INJURIES 15 10 s. O J*B7F MAMJJASON OJ'SBF MAMJJASON DJ`B9F MAMJJASON TOTAL INJURIES O OSHA RECORDABLE VAB.0001190300 ERDEEN ENERGY CONSUMPTION en/ma VAB.0001190301 MONTHLY --------- 12 MO