Document vkz4q0GMyDjVjy4Zza4RG7BZ

T. H. Huffman From: Data: Subject: D. C. Skokna August 22, 1991 ABERDEEN MONTHLY PROGRESS REPORT JULY, 1991 VcnA There were one first aid and one recordable Injuries reported during July. The recordable case Involved a vinyl operator who suffered a lacerated finger. On July 6, the plant's employees completed twelve years since the last lost time injury. At month's end, the plant's employees finished 4409 days (5,903,326 manhours) since the last lost time injury. FY1991 Kev % 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 July 24.3 58.3 98.0 1 .0236 5.6 95.0 3.2 98.3 1.4 87.2 < 14.5> < 131.4> < 1.5> Y.T.D. 382.0 85.7 98.2 1.0244 47.9 97.0 45.6 99.2 15.4 84.2 < 10.4> < 183.8> < 216.4> The New Module conversion to VCSM control was successfully com* pie ted. Conversion began on July 5 and full rate production was achieved on July 26. While down for the conversion, turnaround work was also completed. Product demand was strong in both compound departments. Rigid compound production was slowed due to close monitoring of product quality. A DOE was performed to determine the signifi cant factors which affect PLENEX melt flow. VAB.0001189603 T. H. Huffman 8/22/91 Aberdeen Monthly Progress Report - July, 1991 Page 2 Costs Fixed costs were $131.4M unfavorable due primarily to payroll which was over budget due to the turnaround, VCSM startup, holiday pay, vacation, and benefits. MM&C costs were also higher than budget due to the turnaround. Variable costs overall were essentially at budget. OMP The Vinyl "A" Shift Natural Team presented a project to management that will improve the safe access to rotary dryers. Compound "An shift presented their compound dicer Improvement project to management. This project reduces downtime caused by dicers and reduces dicer maintenance costs. The July closing required 357 manhours to complete. The problems that caused this excessive time requirement have been identified and corrective action has been started. D. C. Skokna Plant Superintendent rah DISTRIBUTION Houston J. D. Burns ggyER LBTT.gR X ENTIRE REPORT R. T. Ferrell X T. H. Huffman X C. J. Matson x D. F. Harman X H. R. Flammer X R. R. Smith X B. J. Bean R. H. Gerlach X x R. D. Gamblln C. R. Miller x x R. L. Foe X H. J. Hall X LCVCM Plant LCLAB Plant H. D. Garrison P. D. Carrico J. Friend J. W. Ware X X X X L. R. Bauer X Hammond J. Pavao X Premiere P. L. Foote RWS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, DAB, DAM, JEN, JDO, BLT 1 VAB.0001189605 SAFETY - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases Fiscal Fiscal 1 12 14 1-2-4 2 19 18 0 43 0 00 Vinyl Operations Compound Operations Maintenance Laboratory Rece iving/Warehouse Office Totals 13 05 19 00 00 0 2 Cuts and Abrasions Eye Injuries Bums Bruises S trains/Spralns Stings Other Totals 267 011 033 032 031 002 o. 2 Lost Workday Cases Days Lost 06 0 127 8 179 First Aid Cases Medical Treatment Cases Lost Workday Cases Safety Record 04 01 01 Last lost time injury - 7/5/79 Days since - 4,409 Employee hours since - 5,903,326 On July 31, 1991, the employees of the Aberdeen plant completed 4409 days with no lost time injury. VAB.0001189606 SAiEUf-i-T - Continued Topics for plant safety meetings during the month included: Inspection and Safe Use of Handtoo Is, CPR, Hand Safety, and Hazardous Chemical Exposure Prevention. The newly formed (as yet unnamed) safety organization in northeastern Mississippi started by our Safety Department is growing and already passing usable information and ideas on to one another. Over twenty members attend on a regular basis, including two customers (GenCorp and Southwire), one supplier (Kerr-McGee) and one competitor (North American Plastics). A housekeeping program (Operation Clean Sweep) is slated to begin in early August. This is another program which will include all employees. Routine dosimetry results for the month were: VCM Lead Total Particulates Monthly ----------< PEL______ Number Percent 75 100.0 5 100.0 1 100.0 _______> PEL Number Percent 00 00 00 MT Vinyl Laceration of right index finger. FA Maintenance Abrasion of left forearm. VAB.0001189607 - T. J. Arbeiter All of the plant's natural teams met during July. Some of the team highlights for the month were: m Vinyl A-shift made a presentation to Management on July 2. The team justified changes in the dryer inlet ladders that will reduce the safety risk of entering dryers. Previously, portable ladders on wheels were used for dryer entry. Their design made dryer entry hazardous because the ladder could roll out from under a person as he/she was making the transition from ladder to dryer or vice versa. The individual also had to step over the side railing to enter a dryer. The new ladders are designed expressly for dryer entry and should eliminate the safety hazards associated with the old ladders. *% m Compound A-shift made a presentation to Management on July 16. The team presented the results of their project aimed at increasing dicer efficiency, quality and safety. The team implemented several new procedures to accomplish their goal including: 1) Develop PM procedures for dicers, Including a PM sheet for recording maintenance; 2) Developed a method for tracking the number of pounds diced between blade changes, and; 3) Developed a more detailed main tenance downtime sheet to show the major causes of dicer downtime. The results of the team's efforts can be seen in the reduction in dicer downtime. Prior to the beginning of this project, Line I and Line III combined dicer downtime averaged just over twenty hours per month. Downtime for the period August, 1990 through March, 1991 averaged less than one hour per month. The Senior Process Engineer's Natural Team began planning their next project to improve time man agement skills for process engineers. The Synergy Team began listing barriers to effec tive QMP/Natural Team participation as perceived by plant employees. Product Total PVC Flexible Compound Rigid Compound Plasticizer Total PVC $ 1.3 22.9 63.0 < 88.7> <$ 1.5> $851.5 < 89.0> 40.6 < 38,5> $764.6 $852.8 < 66.1> 103.6 $ 763.1 Variable costs were essentially at budget. Compound and Plasticizer Production models are being audited and errors are being corrected. These variances may be a result of OASIS models not being correct. VCM Resin to Rigid Compound i Resin to Flexible Compound Natural Gas Phthalic Anhydride Pallets Electricity Ti02 Alfol* Alcohols Plasticizer Other Price Variances Total Fixed Cost Variances $837.0 59.5 65.9 29.3 14.0 < 15.4> < 15.8> < 19.6> < 58.2> <155.4> 21.8 $763.1 m Payroll and Benefits MM&C Miscellaneous TI&D Clearances Total <$116.9> < 33.6> 22.7 < 2.8> < 0.8> <$131.4> Payroll and Benefits - Operating payroll was $50.0M unfavorable due to the VCSM startup, turnaround, vacation and the holiday; benefits were $55.5M unfavorable. MM&C - Costs were above budget due to the New Module turnaround. VAB.0001189609 Continued Miscellaneous - Key variances were: Operating Supplies m Shipping Costs i Warehouse Gain/Loss <$34.6M> 10.4M 28.2M T.I.& D. A $96.1M charge was taken as a result of a State audit of our sales and use taxes. This total represents what the State has found for 1989 and an estimate of possible liability for 1990 and 1991. Also included are interest charges. VAB.0001189610 VINYL - J. D. Olson, D. K. Knittig Safety The Vinyl Department had no first aid case or OSHA recordable injuries during July. The monthly safety meetings were open discussions with shutdown safety issues discussed and corrections made as needed. General 1. VCSM conversion of the New Module was completed. The conversion began on July 5, and the first reactor was brought on-line on July 24. The New Module was up to full production rates on July 26. 2. OASIS was used in parallel to the budget process. All production models were changed to match Fiscal 1992 budget. 3. The recovery line in the Old Module was inspected and repaired. Line inspection revealed many pits and thinning areas requiring replacement. - 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 Bad Dryer Stream Factor, % - Resin Quality, % Prime % July 24.3 783.9 61.5 585.0 18.9 58.3 71.1 38.7 98.0 235 382.0 1256.5 98.5 8951.0 29.6 85.7 90.3 89.7 98.2 Hours Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, and dump conflicts). 204.0 i Maintenance downtime (hydroblast D-743 condenser, Old Module recovery line repairs, hydroblast D-700 condenser, VCSM conversion, and loss of steam due to a gas company compressor failure). 2899.0 VAB.0001189611 VlwiL - Continued % of Total Operational downtime (centrifuge plugs, dryer cleaning, flameouts). Maintenance downtime (dryer PM). Reactor limited production 3.9 1.6 94.6 ggck - Jimmy Antrey, Sherry Truitt 1. Maintenance completed various tasks during the New Unit shutdown. .2 condenser contamination 3. The large reactor seal was rebuilt for a had failed the end of June. The seal 4. The new fluid bed dryer demister pads were installed during the turnaround. The old pads will be cleaned for 5 All New Module Instruments were checked and calibrated as required for the new DCS system during the shutdown. 6 The 15 kva cable from substation 101 to substation 102 was tested for high-potential loss during the New Module turnaround. Test results showed acceptable leakage. Also, the substation feeds were rewired so each substation can be isolated. 7. No ajor valves were replaced in the Vinyl unit in July. x WHH mmrnnf VAB.0001189612 COMPOUHD - J.K. Nickerson, M. R. Kane i The Compound Department had no OSHA recordable Injuries in July. General Orders remain tight on all production lines. Close monitoring of dry blend product quality has caused higher than normal downtime and slower than normal rates. A DOE was performed to determine the significant factors which affect the melt flow of FLEINEX. The results showed that a low stock temperature and short blender residence time will yield higher melt flow. Ted Nickerson visited Dekoron with the RFS team. Operating Line I 30 Line III 29 Line V 14 Total % Prime Capacity Utilization Factor Hontb 1865 3111 599 5574 95.0 69.2 igtti/Prr 62 105 43 186 yiacai y.t.d. 16391 28274 jm 47944 97.0 61.5 Downtime Hours - Product Changes - Miscellaneous Maintenance - One Dicer Offline Line III - Product Changes - Miscellaneous Maintenance - One Dicer Offline Line V - Product Changes - Miscellaneous Maintenance 81 43 36 54 42 16 33 9 t urn mmm mmpmmmmwmm VAB.0001189613 VMM + COjffQTO - Continued r Operating Rigid Compound 30 % Prime Capacity Utilization Factor Month 3179 96.33 47.9 Ara./PmT 106 Fiscal Y.T.D 45556 99.2 74.7 Downtime - Product Changes Miscellaneous Maintenance - Quality Problems & Control Operating Hours 59 49 45 Plasticizer 27 % Prime Capacity Utilization Factor 1381 87.2 63.9 15407 84.2 77.9 Work - J. B. Autrey, S. A. Truitt There were no major items this month. VNWf mmmm mm i VAB.0001189614  s ! * US - S. C. Hillman, M. L. Carter - CKWimAT. An enclosed dump system will potentially eliminate the evacuation step of the reaction cycle by preventing air from entering the reactor during dump and rinse. Piping and equipment modifications are being made to allow testing of a temporary system in October. The dry blend area is continuing to have problems with percent oversize particles in the screened products for several sensitive customers. The 3PQ91 Dry Blend Screener Replacement Project is scheduled to be installed in October, but additional improvements appear to be necessary. Plant engineering is investigating alter* natives to further reduce oversize due to linescale and agglomera tion of particles. A detailed list has been prepared of potential cost items associated with the removal of resin in old waste treatment Pond 2. This list is being forwarded to Vista Environmental to be considered in any contract arrangements with Conoco for Pond 2 cleanup by Vista. MSA catalyst is a potential replacement for pTSA in plasticizer pro duction. MSA may improve cycle time and reduce environmental loading to the wastewater treatment ponds. A month long trial beginning in mid-August is being coordinated with Operations to pin down cycle time and environmental benefits. An initial four-batch test run by PED in July showed no adverse quality or operational VAB.0001189615 t / ABERDEEN CHEMICAL PLANT APPROVED CAPITAL PROJECTS 3INEERING M.L. CARTER, S.C. HILLMAN NUMBER A519 A649 A909 C591 D511 DS50 D570 DS80 D600 D749 D849 D859 DB99 F551 F650 F660 F779 G560 G561 G610 G630 G659 G839 H500 H501 H510 H531 H541 H571 H581 H601 H620 PROJECT DESCRIPTION PLANT ELECTRICAL UPGRADE VINYL CONTROL SYSTEM MODERNIZATION INERTS REMOVAL MODIFICATIONS DRYBLEND SAMPLE LINE VCM UNLOADING MODIFICATIONS RAILCAR ACCESS PUT FORMS OLD MODULE RECOVERY SYSTEM ACCESS RECOVERY VACUUM PUMP PRESSURE REL. PLASTICIZER LOADING. UNLOADING. MOO. LEM) HANDLING AND EXPOSURE REDUCTION COMPOUND LINE 3 SEMI-BULK LEAD HANDLING COMPOUND SILO BRIDGE BREAKING RAILCAR CLEANING RACK DRY BLEND SCREENED REPLACEMENT 5305 RESIDUAL VCM REDUCTION DECALCIFIED WATER DRYERS NO.4 5 CONTAMINATION REDUCTION TC SPILL CONTAINMENT WASTEWATER INFLUENT EQUALIZATION TC COMPLIANCE PROJECT REACTOR SLURRY STRIPPING OPTIMIZATION NEW DRYER BAGHOUSES PUNT WATER RECYCLE PUNT WATER SYSTEM MISCELLANEOUS CAPITAL PROJECTS < S15M WEST INCINERATOR REPLACEMENT BOILER FEEDWATER TANK REPUCEMENT PVC GEARBOX REPUCEMENT D-745 RX DRIVE SHAFT REPL SPARE LARGE RX AGITATOR MOTOR GAS CHROMATOGRAPH UPGRADE EAST INCINERATOR REPLACEMENT STATUS A NEW 15 KV 600 AMP SERVICE TO SUB 101 WAS INSTALLED IN JULY. N.M CONVERSION WAS MADE IN JULY T/A - O.M. CONVERSION SCHEDULED FOR SEPT PROJECT IS OPERATIONAL, TARGETED FIELD CLOSURE AUGUST FY 91 PROJECT WAS APPROVED IN JULY FY 91 DESIGN PACKAGE IS IN PROGRESS, MATERIALS HAVE BEEN PLACED ON ORDER PUNCHLIST NEAR COMPLETION, TARGETED TO BE PLACED IN OPERATION AUG FY 91. DESIGN IS COMPLETE, INSTALLATION PLANNED FOR OLD MODULE OUTAGE IN SEPT N.M. WORK WAS COMPLETED JULY T/A - O.M. WORK PLANNED FOR SEPT T/A PUNCHLIST NEAR COMPLETION, TARGETED OPERATION AUG FY 91 PROCESS ENGINEERING IS MONITORING MODIFICATIONS. MODIFICATIONS HAVE BEEN MADE, A TEST RUN IS SCHEDULED FOR AUGUST FY 91. COMPLETED, PROJECT WILL BE CLOSED TO FIELD CHARGES IN AUG FY 91 i '. i PUNCHLIST ITEMS REMAIN, TARGETED FOR OPERATIONS AUG. FY 91 SCREENERS ON ORDER, MECN. DESIGN 98% COMPLETE ELECTRICAL 85% COMPLETE PROJECT WILL BE CLOSED TO FIELD CHARGES IN AUG, FY 91. NEW FILTERS ON ORDER TARGETED COMPLETION FOR 4TH QTR. FY 91 PROJECT WILL BE CLOSED TO FILED CHARGES IN AUG. FY 91 PROJECT WILL BE CLOSED TO FIELD CHARGES IN AUG. FY 91. CONSTRUCTION IS IN PROGRESS, TARGETED OPERATIONAL MID SEPT. FY 91 TARGETED TO BE CLOSED TO FIELD CHARGES 4TH QTR. FY 91 WORK WAS COMPLETED DURING RX OUTAGE IN JULY, TARGETED TO CLOSE IN 4TH QTR PROJECT IS BEING MONITORED, MODIFICATION OF MEMBRANE BACKING IS SCHEDULED PROJECT WILL IE CLOSED TO FIELD CHARGES AUG. FY 91 ENG. IN PROGRESS, CIVIL AND SITE CONSTRUCTION IN PROGRESS 32 PROJECTS APPROVED, 16 COMPLETED, ENG.IS IN PROGRESS ON 16 PROJECTS. INCINERATOR DELIVERED. PROJECT COMPLETION TARGETED FOR 9/91 NEW TANK HAS BEEN INSTALLED, MINOR ITEMS REMAINING THE NEW GEARBOX IS SCHEDULED TO ARRIVE IN THE PUNT MID AUGUST. CURRENTLY WORKING WtTH VENOORS ON PRICING CURRENTLY WORKING WITH VENDORS ON PRICING PROJECT WAS APPROVED IN JULY FY 91 INCINERATOR DELIVERED. PROJECT COMPLETION PLANNED FOR 10/91. VAB.0001189616 K. 6. Akins Confirmatory tests for the bioassay testing that we did not pass in June failed to confirm the presence of any toxicity in our wastewater. During software testing of the new vinyl distributed control system on July 20, 1991, a wastewater bypass occurred. A cooling tower basin overflowed during testing with emergency cooling water. The overflow contained approximately a 50-50 mixture of cooling tower water and water from wastewater treatment pond #5. The MDEQ was notified. Recent problems with low pH in the wastewater treatment system have necessitated modification of operating procedures for our incinerators. Control system modifications to limit the amount of time the incinerators are in high fire will stabilize pH by balancing hydrochloric acid production throughout the day from VCM incineration. DuPont Environmental Remediation Services completed resampling of the groundwaters, soils, and sediments as recommended in their site assessment. Preliminary results should be available near the end of Augus t. Negotiations continue with Conoco on the reclamation of resin from Pond 2. Royal has tentatively agreed to Conoco*s counteroffer of 4.5 cts./lb. U.S. funds for the Pond 2 resin. Conoco and Vista are now working out the details of how the material will be dried using Aberdeen's existing pond resin reclaim equipment and cost accounting. Bids for remediation of the buried drum site were due in Houston or August 2, 1991. Remediation vendors were presenting work plans August 12th - 13th. Work is expected to begin in September. General The MDEQ approved our proposal to use a reactor as a batch water stripper. This will allow us to keep four New Module reactors running with the fifth acting as the stripper during the Old Module shutdown in September. The batch water strippers are located in the Old Module and will be switched over to the new control system during the shutdown. h VAB.0001189617 Continued General - continued Work continues with AT&T on recycling of PVC scrap from their wire and cable operation in Omaha. The next step is to get several gaylords of the scrap to Aberdeen for testing. If an acceptable product can be made from the scrap alone or blended with MSP80, bulk shipments of scrap would be possible. This testing will be done on Line X. 1 attended a Hazardous Materials Transportation course July 15th - 19th. This course Included instruction on the new HM-181 regulations that will significantly impact transportation and packaging of hazardous materials and wastes beginning in 1992. Wlftfeg Waste shipments during the month included: Bulk shipment of floor sweepings to Chemical Waste Management in Emelle, AL. Bulk shipment of waste oil to Fisher Industrial Service in Gadsden, AL. Thirteen boxes of VCM filter cartridges and three drums of stabilizer spill to TES in LaPorte, TX. I 4 VAB.0001189618 - J. R. Ganc A. Unadjusted EUI B. Adjusted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU < 15.2%> < 14.5%> 2782.6 96.0 < 11.1%> < 10.4%> 2767.8 1352.0 h No. 1 No. 2 No. 3 83.3% 83.4% 82.9% F1cal Y.T.D. 83.1% 83.4% 82.8% Boiler #1 operated twenty-four days during the mqnth. Boiler #2 operated twenty-five days during the month. VAB.0001189619 None 1 Erik Smith - Process Engineer, PED - Houston, transferred to Aberdeen as a Process Engineer. Theron Reed Mackay - Process Engineer, Aberdeen promoted to Lead Process Engineer, Aberdeen. RendeXl B. Newton - Chief Process Engineer, Aberdeen, transferred and promoted to Chief Process Engineer, Lake Charles. Larry E. Frye * Maintenance Helper, Maintenance Department, promoted to General Mechanic "BW. Charles L. Smith - Maintenance Supervisor Department Maintenance Paul D. Cook Compound Operator Compound Department. Hone. None. T mu *mi\M VAB.0001189620 15 11 39 24 38 33 5 165 74 9 0 I 60% 00 50 45% 00 8 0 20.5% 1 0 0 5 2 20.8% 8.3% 0 23 1 59% 2.6% 1 10 1 30% 2 0 1 40% 3.0% 0 0 0 62 4 37.6% 2.4% 7 18 9.5% 24.3% 0 1 0 0 3 0 0 21 4 \ s; K: >* i I g 1i g$99* .. A OOO IKK/1I. N- <KKV 1 QOQA ! O841 88 8 i 8O O8 8i 0 8# O8 N8* ~O8*~ T" a 0 IT m ~8a~ "T# 0 ' T8O O TO41 "O8 " 0 8: S s35^: 3 s8 9 (A (A 1 1; &28 ? 1 5 S 's u :i 3 VAB.0001189622 3t; in B *N> * 38 a aV E -* il -1 Q 1ill O ill 53 m 2 JjL g 00'0 00*0 88 O 88 O OaP V 8 V N 0 * 4 1 A * ? 3 s*5 sS8 3 5281 M3 I$ S U s 4> CL CL VAB.0001189623 Safety There were no reportable safety instances this month. Qualify All natural teams met in July. We are still experienci|ig problems with monthly closing of the OASIS system. A great deal of work still needs to be done on the models. Although July closing was smoother than June's, 357 manhours were required for closing in July. 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 986 16 $1354 122 175 200 T.T.P. 9159 127 $23418 881 1750 1766 (Decrease) % Compound "A* 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 Warehouse 3,905,357 127,883 317,385 111,174 43,765 587,556 254,608 620,950 100 6,202,661 3,580,700 96,292 329,086 151,348 187,278 509,092 244,754 485,306 100 5,745,489 <324,657> < 31,591> 11,701 40,174 143,513 < 78,464> < 9,854> <135,644> 0 < 72.350> <457,172> < 8%> < 25%> 3% 36% 328% < 13%> < 3%> < 22%> 0 < 31%> < 7%> ; VAB.0001189624 Jum. 1991 .flfply- (Dtertu*) t /Iner--i> ^yQgl Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin nAn Grade Resin Offgrade Total 1,039,762 177,500 3,222,540 1,157,610 16,353,509 23,932,971 752,156 177,500 2,850,600 1,112,560 10,450,500 16,728,416 < 287,606> 0 < 371,940> < 45,050> <5,903,009> < 596.950> <7,204,555> <28%> <11%> < 4%> <36%> <30 <30ft> VAB.0001189625 ABERDEEN CHEMICAL PLANT SHIPPIRE ANALYSIS July 1991 -SHIPMENTS BY PRCOUCTS- PUBLIC MONTH IPT/IYC EXCM/TOLL PUBLIC YTD IPT/ITC EXCH/TOLL RESIN-BULK RESIN-PACKAGED 17,894,178 384,680 9,696,940 253,150 0 0 193,326,672 123,960,630 1,777,400 2,681,996 2,056,100 0 FLEXIBLE COMPOUND-BULK 170,420 FLEXIBLE COMPOUND-PACKAGED 3,129,121 2,151,500 0 0 0 6,428,885 13,116,840 30,312,666 832,470 0 0 NEW BUSINESS 15,483 00 127,559 00 RIGID COMPOUMD^BULK RIGID CONPUlJlG>PMXAGED RIGID COMPOUND*PELLETS 1,795,590 584,613 38,022 1,155,800 80,600 0 0 0 0 31,884,830 3,794,262 38,022 6,275,600 780,356 0 0 0 TOLLING - BULK TOLLING PACKAGED 0 00 0 00 0 0 1,401,960 0 0 33,600 PLASTICIZER 40,440 464,240 0 819,590 1,944,770 3,838,010 TOTAL 24,052,547 13,802,230 0 269,414,482 148,966,766 7,050,970 -SHIPMENTS BY NODE BULK: JULY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER RAILCAR 124 13 13 2 CUSTOMER PICKUP 25 0 1 0 COMMON CARRIER 28 6 22 4 TOTAL 177 19 36 6 TOTAL JULY 152 26 60 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 1,558 103 210 23 390 386 0 44 27 121 29 31 2f334 147 358 TOTAL YTD 1.894 446 PACKAGED: JULY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER CUSTOMER PICKUP 3 24 1 0 CARRIER 20 78 20 0 TOFC AIR/UPS 00 00 00 00 AIR/UPS 2 5 0 0 TOTAL 25 107 21 0 TOTAL JUNE 28 118 0 0 7 153 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER TOTAL YTD 32 133 0 0 246 743 0 0 9 146 0 0 0 300 52 81 4 0 287 1,025 0 0 137 217 1,070 159 3 1.449 CC: DAB,TLC,AEV,JRF VAB.0001189626 % m ae: A, X f/J cn <1: cc ccmo u- I ! OU c/i cn C/1 CD cn iO ^ j rir m S in Ll'*> U~> r_> O- *-C> uo M3 o rO ro <z> 3 i o o o U*i i irk OK CM * t ** hn t l> CO wo M. ro ^ 2 i PQ (O CM CO cu 1.0 f'**C*'/*-> co 1 sO 1 ol CO t CO 1 -o t 4) 'p- 1 O' *- 1 -- I I I 1 iXi MO II II HO II o II CO t! >4 m rII Ml* * CO o1*0 in Ml MO ro sO HO CM CM in m CO ro m S> m c-i CP <p CO CO o o- to Cv hs o o CP o o ih*i 3C C7t CP H* CO 3C 3C JC mJ -rtJ 5e m m. LU LU CP O cn CcmO i,,r]i C.1 55 ..J H--i c--Zu'Ji % iPWWPIM PWWUHP f * VAB.0001189627 iAMBATOttT - j. m. Edwards A. SafetT There were no safety incidents in the Laboratory during July. The monthly safety meeting was "CPR Recertification" taught by Ginny Belk. Jim Edwards and Ted Nickerson visited Dekoron in Aurora, Ohio for technical and product availability discussions. The meeting was very productive. Customer O.C. 7/01 I. P- S. A. The customer complained of rough surface on PVC coated wire made with 34643 compound. The lumps under the surface were analyzed at Austin R&D. The lumps were unpigmented PVC compound. 7/01 The customer complained that an order for 34862 GRY 546 for 10,500 pounds was shorted; only 9,158 pounds were shipped. im The customer complained that the Vista MSDS sheet for compound lists the lead and chromium contents in excess of what 38611 compound actually contains. This causes problems when complying with SARA 313 emission reporting. The custo________t__________________________ for 48451 Black compound was shipped five days late. The customer complained that box #15 of lot 31H12 of 38601 Black compound contained wood chips in the pellets. TriUKltfiATfffiiT ~ Continued Continued The customer complained of gray con tamination in 48451 Black. The gray contamination was long, four-inch wide strips of line streamers. The customer suspects wide variation in 5415 molecular weight. Control charts were sent showing S.Q.C. of 5415 inherent viscosity. The customer prefers to have the three-board type of pallet used instead of the four-board type. The customer complained of poor fusion, blue-white contamination and white streaking in RP-91 brown window profiles. The customer complained that the weights on boxes of 58 and 59 of 38611 compound did not have the corresponding weights on the bill of lading. They were billed for more material than was shipped. The customer complained that the last bulk truck of RP-91 had four-inch white clumps of line scale plugging their transfer line. mmm wmmmm mrn--mmmpm IP Tiimw VAB.0001189629 LABORATORY - Continued D. Product fftlieri Customer Available Plastics Columbia Plastics Hayes Dockside Marley Moulding Uniroyal E. g^mmarv Product Reason 80273G WHT 110 Torque Rheometry 5385 Static Flow 5385 5305 5385 Particle Size Metal Particle Size 2 H/T 1 H/T 1 R/C 1 R/C 1 H/T The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages ex ceeded 400 ppm RVGM during the month of July, 1991. Reactor Slurries _____ 5265 225 Number of Samples Average RVCM, ppm 29 0.245 69 0.154 The following is a summary of the residual VCM analysis of shipment samples for the month of July, 1991. Product 5265 5305 5325 5385 5395 5415 Debox Pond Dry Blend 48 89 0 35 0 23 13 0 5 . ppm 0.054 0.072 0.084 0.045 0.117 0.025 VAB.0001189630 mmm TABOttATOttY - Continued (besed on dryer "regulars"> 5385 mi Bulk Density Inherent Viscosity (vs. 0.64 - 0.67) (vs. 0.715 - 0.744) "L" Color "a" Color "b" Color % on Pan (vs. 2% max.) % thru 140 Mets I.R. (vs. 95% of Control) Hard Particles, (% > 10) Average Particle Size, Microns 0.89 1.33 0.54 -- 5.17 7.67 6.67 5.11 -- 3.25 -- -- -- 161 0.70 0.72 1.07 0.40 3.73 0.28 0.70 0.50 0.36 2.50 4.17 6.33 0.86 -- 0.87 ----------- -- -- ** ... 2.50 12.33 ------------------------ 2.00 1.41 -- 53.33 2.89 -- 1.78 -- -- 2.28 0 -- 7.6 ----------- 0 _*__ 4.11 -- 2.83 1.48 1.11 2.23 5.91 3.23 2.8 81 168 140 176 Color Hard Particles Dicing Cross Contamination Moisture Totals 70.0 <1.23> __________________ 70.0 <1.23> 20.5 130.0 9.4 3.2 3.6 166.7 <0.36> <2.29> <0.17> <0.06> <0.06> <2.94> Torque Rheometry and Color 40 Mesh Moisture Total M Lbs. HI 3.6 15.6 3.9 23.1 <0.09> <0.37> <0.09> <0.55> A VAB.0001189631 \ \ 1. All natural teams met once during the month. 2. Software Is still being revised to communicate Q.C. data to the new vinyl computer data base. 3. Assistance was given to Administrative Services to help prepare the annual plant budget software. >. tl VAB.0001189632 * h a4ft SAMPLE SHIPMENTS JULY 1991 RESIN Ship Date Product 7/03/91 5385 7/05/91 5416 7/10/91 5415 7/15/91 5385 5415 7/15/91 5415 7/16/91 5416 7/17/91 5465 7/19/91 /*--- 5265 5305 7/24/91 5465 7/25/91 5385 7/25/91 5385 Amount 400 lbs. 20 lbs. 5 lbs. 50 lbs. 50 lbs. 150 lbs. 50 lbs. 50 lbs. 10 lbs. 10 lbs. 50 lbs. 100 lbs. 100 lbs. Customer QUILMES (Argentina) Dayton Extruded Plastics Wexford International TUBOFLEX CONDUCTORES LATINCASA Blane Polymers Essex Group C. E. Shepherd Intex Plastics Vista Chemical Far East Eri Extrusion COMPOUND Ship Date 7/05/91 7/05/91 7/05/91 7/05/91 7/11/91 7/12/91 Product 35851 NAT 35851 NAT 462-34A BLK 419-50-C NAT 02 419-50-A NAT 02 48562 BLK 419-73-A Amount 50 lbs. 500 lbs. 1478 lbs. 10 lbs. 10 lbs. 100 lbs. 50 lbs. Customer Wirekraft Dixie Wire Company LOF Tech. FIOS E CABOS PLASTICOS (Brazil) Omega Plastics Vista - Austin R&D 7/19/91 57462 NAT 200 lbs. Flexible Technologies VAB.0001189633 mam m mmm MI SC. Ship Date 7/03/91 Product Vent Dust Sample Shipments/July 1991 Page 2 Amount 2 gals* Customer RFC Plastics VAB.0001189634 ABERDEEN CHEMICAL PLANT INJURES (Twelve Running Totals) 30 25 /> 20 15 R OF IN 10 5 0 MMJ S N J*89 M M J S NJ90M M J S NJ'91M M J MONTH TOTAL NJURES OSHA RECORDABLE VAB.0001189635 \ r* m ABERDEEN ENERGY CONSUMPTION ai/nis f VAB.0001189636