Document v1an3mZmJjV3ev5jQ77VJprLq

To: T. H. Huffman Interoffice CowimunlcoHon From: Date: Subject: D. C. Skokna May 27, 1992 ABERDEEN MONTHLY PROGRESS REPORT April, 1992 There was one first aid case reported during April. At month end, the plant's employees had worked 4683 days (6v272,852 employee hours) since the last lost time injury. **1992 Apr. TiTtP. PVC Production, MM Lbs. 37.9 249.6 Reactor Stream Factor, % 89.8 83.4 Resin Quality, % Prime 96.6 96.7 VCM Efficiency, Lbs./Lb. 1 .0577 1 .0385 Flexible Compound Production, MM Lbs. 5.2 35.9 Flexible Compound Quality, % Prime 96.9 96.5 f t Rigid Compound Production, MM Lbs. 2.9 14.8 Rigid Compound Quality, % Prime 99.0 97.7 Plasticizer Production, MM Lbs. 1.3 10.1 Plasticizer Quality, % Prii 83.5 79.3 Energy Use, (EUI, %) < 14.9> < 16.1> Fixed Cost Variance, $M < 110.2> < 431.5> Variable Cost Efficiency Variance, $M < 131.4> < 627.4> Operations The L-9 suspending agent replacement test run was completed. The replacement material was not suitable for our charge temperatures. The fluid bed dryer was shut down for repairs, replacing the scrubber impingement plate, and installation of additional backmix heating coils. Line I and Line III production schedules were tight all month. Dry blend rates were low due to close quality control monitoring and higher than normal downtime. Dry blend will go to a twoshift operation beginning in early May. QMP The Laboratory nDN Shift presented the results of their project to reduce the amount of resin wasted due to excess sample size. The new procedure results in 28,000 lbs./year less resin downgraded. VAB.0001189282 T. H. Huffman 05/27/92 Aberdeen Monthly Progress Report Page 2 - April, 1992 OMP - Continued The Vinyl nDn Shift presented a project to reduce blend tank overflow. When fully implemented, their recommendations will save $41,000 per year by reducing off-grade resin. m ALSCO (a resin customer) visited the plant for an overview of our process and to gain a better under standing of the quality control testing done on the resin they purchase. AT&T (a flexible compound customer) conducted a Quality System Audit of the plant. Overall, the results were favorable. Recommendations include better documentation of procedures, completing the Quality Manual revisions, and attaining ISO certifi cation. Rmrf raniental * The semi-annual bioassay test resulted in a failure. Results of a followup test will be available in May. Reclamation of the resin for Pond 2 continued, The first) r&ffbar recovered resin was shipped. D. C. Skokna Plant Superintendent rah DISTRIBUTION COVER LETTER Hous ton J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson H. R. FIaminer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblin C. R. Miller L. R. Kardos M. J. Schneider Austin R. L. Poe X H. J. Hall Oklahoma City H. D. Garrison LCVCM Plant P. D. Carrico LCCP Plant J. Friend LCLAB Plant J. W. tfare X Baltimore L. R. Bauer X Hammond J. Favao X Premiere P. L. Foote Aberdeen RtfS/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.0001189284 SAFETY - B. L. Trego AEL*. Fiscal Y.T.D. 1992 Fiscal Y.T.D. 1991 First Aid OSHA Recordable Total Injuries 1 0 1 Number of Restricted Workday Cases 0 2 4 Number of Lost Workday Cases 0 0 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 03 2 034 16 7 000 000 0 _2 1 12 15 Injuries by Type Cuts and Abrasions Eye Injuries Burns Bruises Strains/Sprains Stings Other Totals 1 0 0 0 0 0 0 1 Non-Occupational Injuries Lost Workday Cases Days Lost 1 4 Contractor Injuries First Aid Cases Medical Treatment Cases Lost Workday Cases Safety Record 032 00 1 00 1 Last lost time injury - 7/5/79 Days since - 4,683 Employee hours since - 6,272,859 On March 31, 1992, the employees of the Aberdeen plant completed 4,683 days with no lost time injury. VAB.0001189285 SAFETY - Continued The main topic for plant safety meetings during the month was "Hazard Communication". Routine dosimetry results for the month were: Chemical < PEL Number >_________________________ Number EEL VCM Lead Total Particulates 64 98.5 1 12 92.3 1 8 100.0 0 1.5 7.7 0 Summary Description Maintenance Scratched chin. h VAB.0001189286 QUALITY MAHAGEMEHT PROCESS - T. J. Arbelter All of the plant's natural teams continue to meet on a regular basis. Some of the team highlights during the month were: The Laboratory D-Shift Natural Team presented the results of their project to reduce wasted resin due to excess sample size. New procedures implemented by the team have resulted in a 28,000 pound annual reduction in the amount of resin the lab dumps to debox. This project saves Vista $2,000 per year. The Vinyl D-Shift Natural Team presented their project to reduce blend tank overflow. The team made four specific specifications: 1) Institute regular PM on level transmitters; 2) Put operators on existing valves and tie into the DCS; 3) Program the DCS to close blend tank valves at 87% full; and 4) Transfer blend tanks until empty. At the current pond resin: prime resin differential, these recom mendations would save $41,000 per year. The project would also save 300 manhours per year spent cleaning spilled slurry, will extend the life of the membrane roof on V-ll and will enhance safety, the environment and product quality. m The Synergy Team presented its list of barriers to QMP to the Plant Manager's Natural Team on April 23. The Plant Manager's Natural Team will begin developing an action plan to deal with these barriers. Alsco (purchases 5385) visited the plant on April 7. The primary objective of the visit was to gain a better understanding of the Q.C. testing performed on the resin they purchase. Alsco was also given a plant overview and tour. AT&T conducted a Quality System Audit of the Aberdeen Plant on April 21 and 22. The AT&T auditor reported "The overall conclusion re garding the Vista quality system are of a positive nature". He also stated "Vista has a strong management commitment to quality". Recommendations for improvement included developing more written documentation of work procedures, completing the quality manual revision and considering the attainment of ISO registration. VAB.0001189287 i- i nngT VARTAHCES - D. C. Skokna Variable Costs EgQjftiMr.t PVC Flexible Compound Rigid Compound Plasticizer Total <$ 91.8> < 30.2> < 17.1> 7.6 <$131.4> 1221 Price $387.3 < 29.4> < 8.9> $354.8 Total $295.5 < 59.6> < 26.0> 13.4 $223.4 PVC VCM use was above budget. This is most likely due to an accounting problem. We are investigating. Raw material use was above budget. Resin and plasticizer consump tlon accounted for most of the variance. Rigid Compound Operation near budgeted levels. Plasticizer Operation was near budgeted levels. Malor Price Variances: Variance - $M VCM Debox Resin Credit Electricity Vacuum Vent Dust Credit Ti02 Plasticizers Other Price Variances Total $329.4 45.0 30.5 < 11.2> < 15.0> < 52.9> ____29, Q $354.8 Fixed Cost Variances Payroll and Benefits MM&C Miscellaneous TI&D Variance - SM Total <$ 42.1> < 53.3> < 27.3> < 0.7> 13.2 <$110.2> f VAB.0001189288 COST VARTAHHE - Continued Payroll & Benefits There were an unusually high number of long term absences during April. These absences and the holiday caused Operating Payroll costs to be significantly above budget. MM&C Two large maintenance projects, repair of the fluid bed dryer centrifuge, and replacing the Line III mill D.C. drive controller, caused expenditures to be above budget. Miscellaneous Most categories were near budget. There was an unfavorable variance in the Operating Contract category due to the charge for the annual service contract for the data gathering and analysis software used in conjunction with the resin DCS. VAB.0001189289 VINYL - J. D. Olson, D. E. Knittig The Vinyl Department had no first aid case or OSHA recordable injuries during April. The monthly safety meeting was Annual Respirator Training. General 1. The L-9 alternate suspending agent test was completed. The L-9 is not compatible with our current charge temperatures. Several of the test batches were coarse due to L-9's sensi tivity to our warmer charge water temperatures. 2. Reactor condenser cleaning was completed on three reactors for improved cooling prior to the summer season. 3. The Fluid bed dryer was shutdown for installation of actuated air dampers, water scrubber impingement plate, and extra backmix heating coils. Apr. 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 % 37.9 1263.3 95.3 928.0 30.9 89.8 94.4 91.4 96.6 249.6 1171.8 88.4 5984.0 28.1 83.4 90.1 88.0 96.7 Reactor Downtime i Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts, and no blend tank space). flours 384.0 Maintenance downtime (D-700 seal replacement, D-500 condenser cleaning, D-300 condenser cleaning, D-744 seal replacement, D-400 condenser cleaning, D-745 rinse nozzle, PM D-600 gearbox, D-742 seal replacement, Fluid Bed work, L-9 suspending agent test run, Hot water tank repair). 352.0 A VAB.0001189290 VINYL - Continued Dryer Tine % of Total Downtime Operational downtime (centrifuge plugs, dryer cleaning, flameouts). 33.2 Maintenance downtime (activator problems, centrifuge repair). 47.7 Reactor limited production. 19.1 J. B. Autrey/S. A. Truitt m Six reactor seals failed in April. Reactor 741 failed after thirty-five months in service; reactor 400 failed after twenty-five months in service; reactor 700 failed after eleven months in service; reactor 742 seal after only two months in service. Reactor 700 had two seal failures. The seal failures on reactor 700 are associated with failures of the dura-seal lubrication system. i Reactors 300, 400 and 500 were blanked and hydroblasted for contamination control. The Bird centrifuge #8 was pulled out of service because of high vibration. The bushings were worn and the bowl assembly is in need of extensive machining. Dryer exhauster #7 drive shaft bearings were replaced and the fan was balanced after a noticeable increase of vibration was detected. The screw in the #7 screw feeder conveyor under the dust collector was replaced when the screw broke. The broken screw was later linked to shavings in the product. The VCM condensers in the New Unit were acid cleaned. Outside heating panels were installed on the fluid bed dryer. Demister pads were changed. Switches on the Maxon gas valves were also changed. The #6 exhauster motor was changed out due to bad bearings. The switches on the silo aeration valves were replaced as continuing modernization program. Two major valves in the Vinyl unit were changed. VAB.0001189291 COMPOUND - S. C. Hillman, R. H. Sneed A The Compound Department had no OSHA recordable injuries in April. General Orders continue to be tight on Line I and Line III. Close monitoring of dry blend product quality continues to cause higher than normal downtime and slower than normal rates. Dryblend production will be reduced to two shifts beginning the first weekend of May. Operating Hgn]| Line I 30 Line III 30 Line V 16 Total % Prime Capacity Utilization Factor 1489 3051 5183 96.91 65.79 50 102 40 173 10663 22418 2814 35895 96.52 65.44 Downtime Hours Line I - Product Changes - One Dicer Offline * Miscellaneous Maintenance - Quality 109 23 47 19 Line III - Product Changes - Miscellaneous Maintenance - Quality 65 92 13 Line V - Product Changes - Quality - Miscellaneous Maintenance VAB.0001189292 COMPOUND - Continued Operating __BUI Rigid Compound 27 % Prime Capacity Utilization Factor 2916 98.96 57.79 108 14815 97.71 40.79 Downtime Hours - Product Changes - One Welex (Half Rates) - Miscellaneous Maintenance - Quality Waiting on Raw Materials 64 29 27 53 24 Operating Month Plasticizer 28 % Prime Capacity Utilization Factor 1268 83.49 53.72 10072 79.28 58.22 Key Maintenance Items - J. B. Autrey/S. A.Truitt The hub fan assembly was replaced on the compound cooling tower. The old fan assembly was obsolete and had a cracked blade. Line I hydraulic pump failed and is being replaced by a rental unit. A new pump and filter system are on order. Line III hydrotherm three-way control valves were replaced. The motor on "A" blender was replaced due to bad windings. The old one was repaired for a spare. Line III mill motor DC controllers were replaced. One controller had major component failure. Parts were not available because the units are obsolete. % VAB.0001189293 t ENGINEERING - J. E. Nickerson. T. R. Mackay, M. L. Carter PROJECTS IN DEVELOFMEHT - GENERAL Rater Plant Construction is proceeding. There have been several construction delays due to material and equipment late deliveries Startup has slipped to iddle-to-late July, State approval for startup water is targeted for early June. Operator training July. R&D expertise is being utilized. Rotary and FBP FBD: Spare heating panels were installed when blower damper actuators and extra scrubber plates were Installed. Some problems with resin building and burning in backmlx section have hopefully lined out. Rotary: Centrifuge capacity evaluation is in progress. Dryers which are activator limiting (i.e. , #8) could run at considerably higher rates if activator air supply is increased. Line III Separate Addition System Class "A" design for a Line III separate liquid stabilizer addition system was completed and approved. This design will provide for more accurate and automated liquid stabilizer addition. A purge system is also included to reduce contamination resulting from product changes. This project will improve quality and reduce stabilizer usage PSHA Process A written implementation plan to comply with the new OSHA regula tions has been prepared for the Aberdeen Plant. This plan sets forth the procedures , action steps, resources and timing for com pliance with the thirteen elements of OSHA PSM. Draft procedures for process hazard analyses, management of change and pre-startup safety reviews have also been written and are in routing for review. An employee participation plan has been written and approved for the Aberdeen Plant. Plasticizer Expansion The plasticizer stripper class "A" design has been issued for review. Design reviews were held with Operations and Project Engineering. A revised class "A" will be issued pending response from vendors on exchanger, condenser and tower designs. VAB.0001189294 EHGIHEERIHG - Continued Wastewater System Evaluation A wastewater model for the Aberdeen system was made using the sampling data. A pilot filter unit was tested and initial results show BOD reductions, but not as much as was anticipated. The filter study also proved R&D's theory that the system has a significant amount of algae. Current developments include better aeration in Fond 3, oxidizing Pond 4, and algae removal in Ponds 5 & 6. Steam Survey Information from equipment In steam service was historized using the DCS. This information Included flow through meters, percent travel for analog valves, and on/off state for other actuated valves. This historical data will be compared to total steam flow from the boilers during the same time periods to determine absolute flow rates through each device. Materials were ordered to replace the steam meter in the Old Unit. VAB.0001189295 MONTHLY PROGRESS REPORT CAPITAL EXPENDITURE STATUS M.L. CARTER APRIL REPORT 1992 F.Y VARIANCE ACTUAL BUDGET MS % Month 225.6 249.0 - 23.4 -9.3* 4P tn H 1 3rd Qtr. 225.6 791.0 - 565.4 YTD 2343.6 3362.0 - 453.0 -30.3% Actual Expenditures - Expenditures in April were $23.4M less than the plant1s budgeted expenditure forecast approved in the Third Quarter Budget submitted in March FY92. April's FY92 capital expenditures were 9.3% less than the plant's budgeted expenditure forecast. Twelve of the fourteen projects, which funds were forecasted to be expended in April, exceeded the forecast. Both the VCSM Project and Gas Chromatograph Project accounted for the underrun. 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 .OM and May expenditures of $262.OM. VAB.0001189296 oUJ UI o> fOM' in <A ac ui ^ Ui oUI S o g S3 3 * I CJ Ui Ui U UJ ac UJ IA <A UaJ Iu-i aui I= uo CO 3 ac ui a. a <y rvi o in in ! S g <5 3 o 4000 4210 -210 MINOR PUNCH LIST ITEMS IN CONTROL ROOM REMAIN, ALL CONCRETE HAS BEEN POURED, WATER PLANT ELECTRICAL IN PROGRESS, WATER PLANT CONSTR IS 95% COMPLETE APPROVED CAPITAL PROJECT STATUS JBH Ui CJ Ui oot uaci CD mmm CO u UJ o ac CL u mmmm U o* oin in o UJ Q. "i" Ui Ui UI CA Kl PLANT WATER SYSTEM CUOI (A (9 CO 5 UI c* in o VAB^OOl189297 cO\i lil CC Uoci g u, o CL o (A 3S o s o o UI u o UJ < o at scl UJ 8 L> UJ UJ Os Sm CoM* So c~o "O i3 CJ uj ro 5K UJ u $2 UJ s s8o o CO IAJ UI u* o CQ UJ Oo UJ <o UJ o o CO UJ g s UJ 3 5 S! ocUJ %n uj 5 uj (A oc a g CO UJ o CO /> s o UJ s so m -- uj co ^ Qas uj IA CM IA O CO CM tOn J* 0 CM o in 40 30 10 PROJECT HAS BEEN INSTALLED WITH MINOR PUNCH LIST ITEMS A JBH c<o3 c<Do O FLUID BED DRYER IMPROVEMENTS o CO V^.0001^9298 CaOt UJ Q uj a O uj u uT a E UJ si UJ CO CO UJ 3 O X a3. uj UJ CO CQ CO 2 2 O Sf 2 NCO ^o - Osf CMM CM CIO APPROVED CAPITAL PROJECT STATUS CO UflCJ Ul a UJ UJ CM in in UCOJ CO H O MH UJ M MHMn H N HN H 8Ooe N n a. n uH g It NNR HH H H HIt s s 8co -I 1HHU4 CCOO _l CO mM M H N IMnt H8HH IHt H IIIIUIIItIt H M H It O it MNINHt a H HHIt H 1" M ICaAM* a VAB.0001189299 A* ENVIRONMENTAL - K. 6. Akins Water All wastewater discharge parameters were met for the month of April. Problems were encountered with the semi-annual bloassay test conducted on the wastewater outfall. The Cerlodaohnla dub Ia did not reproduce In sufficient quantities to pass the test. A second bloassay was conducted as a confirmatory test. Results will be available in mid-May. The reclamation of resin from Pond 2 continued throughout the month. The first railcar of Pond 2 resin was shipped on April 30th. RVCKs remain in the 20-50 ppb range and no major operational problems have been encountered in recovering the resin. Waste shipments during the month included: m A bulk shipment of floor sweepings to Chemical Waste Management in Emelle, AL. m Eight drums of stabilizer spill to Fisher Industrial Services in Gadsden, AL. i A bulk shipment of empty lead/antimony bags to Chemical Waste Management In Emelle, AL. VAB.0001189300 ENERGY CONSERVATION - J. &. Ganc I. Energy ConserratIon Data A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU Aor.. 1992 < 17.3%> < 14.9%> 2980.0 141.8 Fiscal Y.T.D. < 18.6%> < 16.1%> 3031.0 946.4 Boiler No. 1 No. 2 No. 3 82.7% 83.7% 83.8% 83.2% 83.2% 82.8% 1 VAB.0001189301 --nnmn BMmiBfW VVMBV J^sSE^siBfl^^^^MBiBESESRESEiBlQCflBLiMpJBE&fisE^sSRuBi 3MPRII., 1992 firWiUTil- - J. E. Beall None. Kenneth 6. Akins * Environmental Coordinator - promoted to Senior Environments1 Coordinator. Rory H. Sneed - Operations Engineer - promoted to Senior Process Engineer replacing Michael Kane. Phillip Hall - Compound Operator - bid to Vinyl "A" Operator. Phillip Drake - Compound Operator - bid to Vinyl "A" Operator. Jimmy Brewer - Yard Operator "A" - bid to Utility Technician "B". George Phillips - Compound Operator - bid to Yard Operator "B" replacing Jimmy Brewer. Debbie Johnson - Process Engineer - transferred to Process Engineer at Lake Charles VCM Plant. Michael Kane - Senior Process Engineer - transferred to Senior Process Engineer at Lake Charles LAB Plant. PBTTPignMTfi None. TEBKXMiaXQ"* ^TamaB None. TO/WtOM LEAVE OP ABSEMCB R. Danny Flippo - Vinyl Department - Vinyl Lead Operator - Union Leave of Absence. VAB.0001189302 15 9 36 22 37 34 5 158 77 90 50 80 41 24 1 11 2 20 63 4 6 19 60% 55.6% 22.2% 18.2% 64.9% 32.4% 40% 39.9% 7.8% 0 0 0 4.5% 2.7% 5.9% 0 2.5% 24.7% 0 2 1 1 1 0 0 0 2 3 1 1 0 0 VAB.0001189303 4 i h X 5 g IM JO N8 tVo a jo CK g8 to s 8 Wto N 3 a to 8 tVo O T 88 88 t* * oO3O * 8888 to * 'to to OO$O *i 8 8 8X V to to tVo oOoo DEPARTMENTAL SUMMARY HOURS REPORT O Off UWCtl a. at xu Uul CJ Ui $ GO 3 u a 1A 8 Ul (UAl S CO Ui Ul aot T* && >o CM 5- 2 ? O autj ISI C 40 "8 41 Ol C/I Cl0 * VAB.0001189304 P rin te d 5/05/92 s ftU <A Ui O o S $ i UoJ (M 8^ CO l/* pmimmm n( o* \ r\ <$* $ VAB.0001189305 * ADMINISTRATIVE SERVICES - D. A. Barclay Safety There were no reportable safety Instances this month. Quality All teams met during April to review progress on their projects Futures MID YTD Natural Gas Statistics <$482.58> <$34,092,64> FY92 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 996 19 $1512.00 114 157 208 Packaged Finished Goods Mar. 92 Compound RAn 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 3,626,224 144,775 367,114 218,074 271,872 495,345 286,639 1,521,450 100 Ml, Oil 7,072,684 3,563,400 162,973 391,041 229,824 285,228 675,280 297,598 1,270,450 13,600 ...167 JP8 7,057,202 Bulk Finished Goods Ending Inventory Mar.. *92 Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade Total 641,591 0 1,519,735 790,510 10,352,795 _1.606.650 14,911,281 704,762 0 2,009,200 790,510 8,789,158 1.718.501 14,012,131 7826 121 $22265.19 645 1325 1376 (Decrease) Increase % < 62,824> < 1 18,198 12.57 23,927 6.52 11,750 5.39 13,356 4.91 179,935 36.33 10,959 3.82 <251,000> <16.50> 13,500 13500.00 .,-26.717 18.94 < 15,482> < 0.22> (Decrease) % 63,171 0 489,465 0 <1,563,637> 111.851 < 899,150> 9.85 0.00 32.21 0.00 <15.10> 6.96 < 6.03> VAB.0001189306 ABEROEEN CHEMICAL PLANT SHIPPING ANALYSIS APRIL 1992 # -SHIPMENTS BY PRODUCTS- PUBLIC MONTH IPT/ITC EXCH/TOLL PUBLIC YTD IPT/ITC 08:25 AN 15-May-92 EXCH/TOLL RESIN-BULK RESIN-PACtCAGED 21,226,470 17,687,050 399,728 477,500 0 0 133,862,260 117,568,100 3,315,835 1,827,650 0 0 FLEXIBLE COMPOUND-BULK 363,100 FLEXIBLE COMPOUND-PACKAGED 3,185,034 1,493,500 1,500 0 0 1,452,120 13,824,300 21,217,271 190,675 0 0 NEW BUSINESS 13,350 00 111,714 00 RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED RIGIO COMPOUND-PELLETS 2,080,070 307,285 0 019,700) 0 0 0 0 0 8,208,220 2,787,349 0 3,879,600 175,850 0 0 0 TOLLING BULK TOLLING - PACKAGED 0 00 0 00 0 00 0 00 PLASTICIZER 0 698,650 0 81,300 3,640,540 917,400 TOTAL -SHIPMENTS BY MODE BULK: *AnPrRPATIL* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 27.575,037 20,238,500 0 RAILCAR 174 8 8 4 CUSTOMER PICKUP 15 0 0 0 COMMON CARRIER 33 8 15 0 171,036,069 141,106,715 917,400 BX8B3C SSBsacBSttSSMBSMBM TOTAL 222 16 23 4 TOTAL APRIL 194 15 56 265 *YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 1,116 80 50 23 100 262 0 41 3 90 0 11 1,478 121 143 34 TOTAL YTD 1,269 SSSSS8BBSSSSXSSSSSSSSSttSENB8BSBSBSSSSSSSt; PACKAGED: CUSTOMER *AAPr WRK A1LL* PICKUP RESIN 3 FLEXIBLE COMPOUND 18 RIGID COMPOUND 2 PLASTICIZER 0 103 COMMON CARRIER 21 90 12 0 404 1,776 ISfBSSSSSSSESSSttSStCNaESS&EfitSSBSBBBSsssssasassnsi TOFC AIR/UPS 00 00 00 00 AIR/UPS 1 5 0 0 TOTAL 25 113 14 0 TOTAL APRIL *YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 23 123 0 0 22 145 0 0 152 572 0 0 12 86 0 0 0 000 6 4 21 1 0 152 171 745 99 0 TOTAL YTD 186 803 0 0 26 1,015 CC: DAB,TLC,AEV,JRF VAB.0001189307 cn cn cn cn cn cn cu A cn cn 3 5 3 cn VAB.OOOl189308 (Thousands of lbs.) FLEXIBLE & RIGID OFF-GRADE APRIL '91 THRU APRIL '92 1600 1400 1200 1000 600 400 200 " 04/91 06/91 08/91 10/91 02/92 04/92 05/91 07/91 09/91 1 /91 01 /92 03/92 3 INVENTORY VAB.0001189309 \ TAMHtATORY J. M. Edwards a. $+f*pr There were no safety incidents in the Laboratory during April. B. Customer Contacts AT&T audited the plant on 4/21 and 4/22. There were no unacceptable items found. A formal report is expected in May. Customer O.C. 4/06 The customer complained of a late delivery of 57121 VC compound. Material was delivered late in the day instead of the morning when it was scheduled. 4/P6 AT&T. Omaha. MB The customer complained of minor contamination from 34862 compound on their screen pak. The contamination was analyzed to be an agglomerate of lead and aluminum trihydrate undis persed in the compound. 4/06 Tenex. Elk Grove. IL The customer complained of a late delivery of 18033 compound by fortyeight hours after a two-week order lead tii 4/06 Royalite. Warsaw. IN 4/16 The cus tomer complained of a miscommunication of a change in the delivery time of a shipment of 5305 in bags. Wexford International. Houston. MS The customer complained of four wet dry blend overs boxes shipped to them. i VAB.0001189310 LABORATORY - Continued C. Customer Q.C. Problem Reports and CWRrs - Continued Qft/21 Rollex. Elk Grove. IL The customer complained of RP-23 WHT 120 plating out during processing. The eight boxes returned showed that the fusion time was longer than the control using new conditions on the lab Brabender developed by the TS lab. 04/27 The customer complained of small specks on wire insulation and lighter color in 38601 BLK compound. As a result of this complaint, the lab will test the color of all compounds, and specifications will be set after enough data has been collected. A4/2P Iwtcx. Corinth. MS The customer complained of high con tamination in a railcar of 5385 and 5305. A trip was planned to Intex in Hay to develop and revise specifica tions for these two products. D* Product Waivers Issued Customer Product Reason Vycom RP-461 WHT 110 E. RICH of In-Process Samples Color 1 H/T The following is a summary of residual VCM result in- process samples, None of the reactor daily exceeded 400 ppm RVCM during the month of April, 1992. Number of Samples Average RVCM, ppm Reactor Slurries 926 55 Drver______ 5265 5305 23 0.111 82 0.203 LABORATORY - Continued ftypy pf The following is a summary of the residual VCM analysis of shipment samples for the month of April, 1992. Product Average RVCM- ppm 5225 5265 5305 5325 5385 5395 5415 5416 5465 Debox Pond Dry Blend 0 41 132 0 55 1 64 0 2 16 8 6 0 0.079 0.087 0 0.093 0.006 0.027 0 0.025 0.344 0.088 0.017 G. Resin Process Capabilities (based on drver "regulars"^ 5265 5305 51M 5415 Bulk Density Inherent Viscosity (vs. 0.64 - 0.67) (vs. 0.715 - 0.744) "L" Color "a" Color "bw Color % on Pan (vs. 2% max.) % thru 140 Hard Particles, Average 5 Minutes 7 Minutes Mets I.R. (vs. 95% of Control) Average Particle Size, Microns 1.50 1.20 0.30 5.92 8.00 6.67 1.89 2.19 -- -- -- 145 0.50 0.67 -- 0.42 1.89 4.50 3.50 1.11 -- 1.46 0.98 0.80 -------------- -- 2.33 ------------- 2.17 3.33 --- ------- ---- 3.23 -- --------- -- -- 17 4 -------------- -- 143 172 1.38 0.74 ---- --- 2.67 - --~ 1.89 2.60 0.60 5.33 7 2 4.36 2.22 178 A VAB.0001189312 1ABORATORY - Continued H. Flexible Compound Oualitr Summary Adjustments M Lbs. Hardness Color Hard Particles Contaaination Dicing Mischarge METS-IR 16.0 178.4 Totals 194.4 <0.30> <3.37> <3.67> i. Rigid, Cowporod Rejections Color Total 8.5 <QAl> <0.11> Re1ections M Lbs, m 53.4 25.8 7.2 1.5 17.3 <1.01> <0.49> <0.14> <0.03> <0.33> 109.7 <2.08> t VAB.0001189313 * SAMPLE SHIPMENTS APRIL 1992 RESIN Ship Date 4/01/92 4/02/92 4/13/92 04/22/92 04/23/92 04/24/92 04/30/92 04/30/92 04/30/92 04/30/92 Product 5415 5415 5385 Pond 5385 5305 Debox 5395 5325 5385 5395 5465 5415 k Amount 5 lbs. X 3 10 lbs. X 2 100 lbs. 2lb8. 50 lbs. 50 lbs. 2 lbs. X 8 10 lbs. 10 lbs. 10 lbs. 10 lbs. 10 lbs. 10 lbs. Customer Leon Plastics Southwire Co. Witco Corporation H. Heller & Co. Crane Plastics Alcan Building Products Keysor Century Buiftrite Corporation O'Sullivan Corporation Ship Mode UPS UPS UPS Airborne UPS UPS Airborne UPS UPS Polysar Rubber Corp. UPS COMPOUND Ship Date 4/02/92 4/05/92 4/09/92 Product 48451 BLK 46801 BLK 6085 BLK Amount 100 lbs. 1500 lbs. 2 lbs. X 2 Customer Standard Plaques Inc. Flexible Technologies T & T Marketing Ship Mode Airborne CC UPS wnMppipi VAB.0001189314 SAMPLE SHIPMENTS APRIL 1992 COMPOUND (Cont.) Ship Date 4/20/92 Product 58031 WTCL 328 04/24/92 48562 BLK 46234A BLK 462-121B1 BLK 04/29/92 58162 NAT Amount 300 lbs. 100 lbs. 100 lbs. 100 lbs. 50 lbs. Customer Hall Industries Standard Plaque Page 2 Ship Mode UPS Air UPS Florida Central Extrusions Airborne DRYBLEND Ship Date__________ Product___________ Amount________________ Customer_____________ Ship Mode 04/23/92 80273G WHT110 5 lbs. Vista R&D - Austin UPS VAB.0001189315 * ABERDEEN CHEMICAL PLANT INJURIES (Twelve Month Running Totals) NUMBER OF INJURIES OJ'88 A OJ'89 A OJ'90 A OJ'91 A OJ'92 A TOTAL INJURIES OSHA RECORDABLE VAB.0001189316 ABERDEEN ENERGY CONSUMPTION BTU/LB 81/018 VAB.0001189317 *