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T. H. Huffman t From: Data: Subject; D. C. Skokna February 22, 1991 AIEEDKEH MOffTHLY PROGRESS REPORT JIUMH, 1991 There was one first aid case reported in January. As of January 31, 1991, the plant's employees have worked 4,228 days (5,647,049 manhours) since the last lost time injury. January 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, (EU1, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $M 38.2 84.9 98.9 1.0260 3.2 96.2 5.1 99.4 1.3 80.7 < 6.0> 84.3 23.0 253.2 88.3 98.7 1.0241 18.5 96.7 18.5 99.6 6.5 86.9 < 5.7> 59.8 < 17.6> Resin production was limited to 38MM pounds to reduce inventories. Training for the VCSM project commenced during the month with the first phase, switchover of the rotary dryers, planned for March. Flexible and rigid compound production was also curtailed to mini mize overtime and reduce inventories. MM&C expenditures were kept to a minimum resulting in a $79.3M favorable variance. This variance was partially offset by an unfavorable benefit clearance of $33.9M. Variable costs were close to budget due to a favorable product mix being offset by unfavorable yields in the PVC and plasticizer units. VAB.0001189815 T. H. Huffman 02/22/91 Abtrdatn Monthly Progress Kaport - January, 1991 Paga 2 95% of the plant's natural teams met during the month. The Stores Natural Team made a management tation recommending a change to Improve safety and productivity where capital project parts are stored. The Safety Director's Natural Team recommended changes In Industrial hygiene sampling procedures that will reduce costs and Increase surveillance of jobs with higher potential overexposures. Eagle Plastics, a rigid compound customer, visited the plant for a general orientation and to learn about dry blend production technology. The State issued a revised draft NPDES permit. A public notice, along with a press release on our renewal, was published In the local newspaper January 30. m Due to delays in obtaining groundwater samples and unsuccessful attempts to find buried drums, the final report on the remedial investigation will not be issued to the State until April. Estimated VCM emissions for CY1990 are 68.2M pounds versus 76.2M pounds in CY1989. This decrease was achieved while producing an additional 20MM pounds of resin. Environmental presentations were made to the Rotary Club and Garden Club. D. C. Skokna Plant Superintendent rah VAB.0001189816 Houston J. D. Burns X R. T. Ferrell X T. H. Huffman C. J. Matson D. F. Harman H. R. Flammer R. R. Smith B. J. Bean R. H. Gerlach R. D. Gamblln R. L. Poe X H. J. Hall H. D. Garrison LCVCM Plant R. A. Conrad LCC? Plant J. Friend J. W. Ware X L. R. Bauer X Blane J. Favao C. R. Miller X Premiere P. L. Foote Aberdeen RVS/DCS (File Copy), TJA, JBA, JEB, JME, SCH, MRK, DAB, DAM, RBN, JEN, JDO, REF, BLT X X X X X X X X X X X X X X mm UPVMPI phmhpi VAB.0001189817 - B. L. Trego First Aid OSHA Recordable Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases 1 1 0 0 Fiscal 6 _4 10 3 0 Fiscal 6 _3 9 2 0 Vinyl Operations Compound Operations Maintenance Laboratory Re c eiving/Warehouse Office Totals Cuts and Abrasions Eye Injuries Burns Bruises S trains/Sprains Stings Other Totals 01 13 05 00 00 0I 1 10 03 00 01 02 02 00 1 1 0 2 6 0 0 9 Lost Workday Cases Days Lost Last lost time injury - 7/5/79 Days since - 4,228 Employee hours since - 5,647,049 On January 31, 1991, the employees of the Aberdeen plant completed 4228 days with no lost time injury. Topics for the plant safety meetings during the month were "Hearing Con servation" and "Contractor Safety". VAB.0001189818 safety . Continued Routine dosimetry results for the month were: Chemical < PEL Nmrifr^r Percent VCM Lead Total Particulates 80 100.0 18 100.0 7 100.0 Fvfflbgj 0 0 0 Percent 0 0 0 Iniurv Class FA Compound Smoke inhalation. A VAB.0001189819 - T. J. ArUitar Ninety-five percent of the plant's natural teams met during the month of January. Two teams did not meet due to funeral leave and a long-term illness. Team activity for the month included: The Maintenance Electrical Natural Team chose as their next project the improvement of lighting systems in the plant (to be further pinpointed at the next meeting). The Warehouse/Purchasing Supervisor Natural Team worked on the segregation of saleable and nonsaleable materials in excess inventory. The Stores Natural Team made a presentation to man agement on January 16. The team made a recommenda tion to relocate V-10 gate. They justified its relocation based upon perceived improvements in safety and productivity. The Plant Manager's Natural Team began selecting-in on their list of projects designed to increase Aberdeen cash flow by a sustainable $1MM per year. The Chief Process Engineer's Natural Team continued work on major process flows for the Engineering De partment . The Senior Process Engineer's (Hillman) Natural Team continued work on a DOE manual. m The Senior Process Engineer's (Kane) Natural Team completed their process flow for pre-startup review and began selection by another project. m The Safety Director's Natural Team finalized their sample reduction project and made their presenta tion to management on January 8, 1991. Based upon the frequency of historical overexposures during FY88, 89 and 90, the team recommended reductions in lead, total particulates and VCM sampling, saving approximately $3M per year in sampling costs. The team also chose as its next project respirator fit testing. Eagle Plastics, a major dry blend customer located in Hastings, NE, visited the plant on January 22. In addition to receiving general plant presentations and a walking tour, the Eagle representatives attended approximately four hours of instruction from the Compound, Quality Control, and Technical Service groups. The instruction was designed to assist Eagle in their upcoming venture to produce dry blend in-house. VAB.0001189820 -t 4 t COST VABTAMCTCg . d. C. Skokna Total PVC Flexible Compound Rigid Compound Plasticizer Total $ 33.8 15.5 77.4 0.3 $127.0 <$ 90.3> < 6.0> 21.7 < 29.4> <$104.0> <$1085.7> < 226.1> < 347.1> <$1733.7> <$1142.2> < 216.6> < 248.0> < IQ3,9> <$1710.7> PVC; Production of less than budgeted amounts of off-grade resin "penalized" the variance since off-grade has a higher C/lb. credit than the cost of its production. In addition to this effect, utilities were above budget. Flexible Compound: The efficiency variance was essentially at budget. Rigid Compound: A favorable Ti02 variance was the primary reason for the favorable efficiency variance. Raw material usage was high due to an unusually large amount of material being in a "slop oil" tank that is not accounted for in IPA calculations. Price VCM Resin to Rigid Compound Resin to Flexible Compound Alfol* 610 Plasticizers Phthalic Anhydride Natural Gas Other Price Variances Total <$ 969.5> < 338.7> < 118.8> < 42.6> < 45.1> < 29.8> < 22.8> < 166.4> <$1733.7> Fixed Cost Variances Payroll and Benefits MM&C Miscellaneous TI&D Clearances Total <$ 21.1> 79.4 18.1 10.5 < 2.6> $ 84.3 mmmmmmrnmm rnmmmmmmmmmm VAB.0001189821 T Cont limed An unfavorable benefits variance of $33.9M offset a favorable plant payroll variance of $12.8M. i' IL_M . & C. Activity was kept at a bare minimum to control costs. Outside Professional Services - $15.3M favorable. m Unclassified - $11.9M unfavorable. Freight on returned shipments caused this unfavorable variance. m Operating Supplies - $24.9M favorable. Processing Supplies - $25.5M unfavorable. An inventory error overstated consumption of the condensate corrosion inhibitor; this will be corrected in February. m Warehouse G/L - $15.9M favorable. L 1 VAB.0001189822 1 9 f Vfn, - J. D. Olson, D. E. Knlttlg The Vinyl Department had no first aid case or OSHA recordable injuries during January. The monthly safety eetlng topic was "Hearing Safety". 1. Inventory control was implemented on D745 and D700 at the end of the month to meet the goal of 38.OMM pounds. 2. The first phase of VCSM training for operators and I&E technicians was completed. The basics of the DCS system were reviewed with the emphasis on our particular installation. 3. The resin raw materials in the 744 account were valued at $292.4M. - Production, MM Lbs. - Dally 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 % Downtlme Jan. 38.2 1232.8 96.6 898.0 30.0 84.9 92.5 97.3 98.9 mt 253.2 1340.3 105.1 3824.0 31.1 88.3 93.4 96.3 98.7 Hours Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts and inventory control). 911.0 Maintenance downtime (New Module hot water charge tank maintenance, torquing condenser on D744, hydroblasting D741, cleaning catalyst valve on D741/742, removing chem wash valves in Old Module, maintenance on D741 slurry valve, and D700 water controller maintenance). 213.0 VAB.0001189823 w vimyl - Continued % of Total Downtime Operational downtime (centrifuge plugs, dryer cleaning, flameouts). 25.9 Maintenance downtime (centrifuge maintenance, sparge pipe replacement, baghouse screwfeeder maintenance, screener maintenance, and pre ventive maintenance) . 25.7 Reactor limited production. 48.4 Kev Maintenance - J. B. Autrey, S. A. Truitt I Reactor 400 was brought down for hydroblasting due to suspected fouling. Reactor 741 was brought down for condenser drilling and hydroblasting to control hard particles. The motor on compressor 904 was replaced due to bad windings. New wire had to be pulled from the MCC to install the new motor because the old wire had crystallized and burned back up the conduit. After the new motor was installed, the compressor was aligned for startup. The inlet nozzle on the hot water tank in the new unit was replaced due to extensive leakage. The nozzle will be sent to GED for analysis of material failure. The "A" vacuum pump in the old unit was replaced due to a coup1ing/keyway failure that also damaged the shaft. The pump was r.ebuilt. The rebuild required replacing the case (worn very thin), shaft and cones. The motor on the fluid bed backmix blower was replaced due to bad drive-end bearings. Five major valves were replaced in the vinyl unit. COMPOUND - J.E. Nickerson, K.G. Akins Safety The Compound Department had no OSHA recordable injuries in January. The topic of the monthly safety meeting was "Hearing Conservation". General During the month of January, the three flexible compound lines and the dry blend unit were scheduled down as opportunities arose to control costs and/or inventories. As a result, combined flexible and rigid compound inventories fell 2.13MM pounds in January. Several maintenance problems during the month caused a larger than normal amount of downtime. Some of the problems included Line 1 blender gearbox. Line III mill electrical problems. Line III mill hood cleaning, and Line V Orbitran repair. A small insulation fire occurred on a plasticizer reactor on January 16. Replacement of the insulation necessitated the shutdown of two reactors for several days negatively impacting plasticizer rates. Operating Month Aft./Pav Fiscal Y.T.D. Line I 30.5 1331 Line III 17.5 1356 Line V 16.0 __4g], Total 3168 % Prime 96.2 Capacity Utilization Factor 39.8 44 78 104 6766 10851 931 18547 96.7 58.0 Downtime Line I - Product Changes - Miscellaneous Maintenance - Blender Maintenance - PLENEX Polymers Production - Banbury Seal Replacement - Quality Problems & Control 94 59 48 44 26 12 - Mill Roll Vent Hood Cleaning - Mill Roll Electrical - Startup/Shutdown - Product Changes - Miscellaneous Maintenance 63 43 40 26 24 cammtm - Continued Line V - Product Changes - Orbltran Maintenance - W-P Maintenance * Miscellaneous Maintenance - Quality Problems & Control - Startup/Shutdown Operating 55 55 23 11 6 8 Rigid Compound 27 % Prime Capacity Utilization Factor 5125 99.4 86.4 Downtime 190 18547 99.6 80.5 - Quality Problems & Control - Product Changes - Miscellaneous Maintenance - Screener Maintenance Operating 78 39 27 12 Month Plasticizer 30.5 1301 % Prime. 80.7 Capacity Utilization Factor 69.1 Work - J. B. Autrey, S A. Truitt 6501 86.9 86.3 The oil seals on the Line I Banbury were changed due to external leakage. The vent hoods on Line III mill were pulled out of service and steam cleaned because buildup was interfering with proper air flow and causing product contamination. m Blender "B" gearbox was re-anchored to the floor. Two of the old bolts had broken and the others have pulled out of the floor. Thirteen buckets on the Line V conveyor were replaced that had been broken off. m All of the heaters for #1 and #2 dry blend Velexes were replaced to meet National Electric Code requirement. - The motor on the transfer pump for plasticizer tank #187 was replaced due to bad windings. mcTwmTWc - r. g. Polk, S. G. Hillman, M. ft. Kano - rngnaii. A meeting was held with the Mississippi DEQ in Jackson to discuss the plant's upcoming operating air permit renewal in March. Results from air modeling studies and an evaluation of various Unit risk factors were presented to the State. The MDEQ will our current operating air permit for apprimclikhtely nine months during which time they will verify the information we gave them. A Patco brand antis tat is being evaluated which could potentially improve dryer centrifuge performance and reduce dryer particulate emissions. A trial was conduct#* on the fluid bed dryer On 5415 resin as a replacement for dry CaSt. The Patco was able control the static, but application levels made it an uneconomical substitute. Additional testing is being planned to see if Patco will be feasible for controlling static of 53S5 inrotary dryers. j; Engineering is underway to convert unused fern valves mounted on the bottom of reactors 741-744 to useias initiator charge valves. The conversion will require some rerouting of Initiator charge heedets at each reactor. When completed^ those reactors can be converted to automated Isonox-only kill. All other reactors have been using Isonox-only kill for several mouths. The class "A" design has been completed and issued. The project will replace the two existing Gump screeners with two sixty-inch Kason screeners. The new screeners will utilize thirty-four mesh screens. The project will provide significant improvements in the ability to meet customer oversize particle specification. Wastewater Test Run Biological organisms which are specific to the nature of the plant waste streams are being added to supplement the activity of the existing bug population. The test will continue for thirty days and then the results will be evaluated. A class "A" design has been issued which will provide better equal!zation of the waste system influent and therefore better BOD removal. The project includes using an existing tank as a surge tank to allow the major organic source to dribble into the system continuously. ENSINEER1NI - R.E. POLK, S.C. HILLRAN, N.R. IAK AMMO CNEIICAt PLANT mmm mm mucus AFE NMKR MSI AS If AM9 Afff 1511 1A29 1749 JMf SfSf )lff FA99 F77T SASf 6117 6139 9S7I ISM SAM FASI FAAI 6SAI 6All 6A3I H5N KS1I RAZI HS01 H521 PRtlECT KSCRIPTIM STATUS altemme min* m pipeline TIE PtMECT RILL IE CLI II FIELI CMMES M FEIIMRl. runoppM mmsnmmmwmvim rA-ZT-i INERTS HRMII MUfKATTMS m INfALUTMft * TIE MIERMM FEOO IS MMOIMftMilfi CNPIETIM mmmmm is H im. csMttsnME msmbiis piano mutci am amil. TNI IMIRT iSU M CIMO IS FIELI OMMM M IARCf; MMM MUMO ! KSM M MV. I EM iMMl ii QMRME KMCTIM CNFNM Lid 3 SttIHNII LEM MMUM cmnw sai Mim mmm WtttEM OIMM m KSIIEIPAWIM MiiRsnmis mmmtmmmm lNNMUNM M MMIIM BV) EM UNMIS! ITEM. FIELI CLMME IS PUMEI FN RARER mmmm is mmmmm cmputim firmer fm rarer. UMTMCT1M IS 1RFIMIEM AIR FUHRO FM CMPtiTIM M MRU UBIAUAHM IS CMFUTE EXCttT FM PNOUST ITERS. MSIM IS M FMSHMIr FRRJCCT MMlETIM IS FLAMER FN RARCR. tie mmmmwm tr ?ieli vmmm ma. mmm mmm lm mi mrm cnmenvin. NEI Mitt UNMNS vci Sim mmmm piiit MTU M SISTER ACCESS MIMML SMFI IF RHI IS CMFUTE m WE FMIICI SILL K CLISEI IS FIELI CMMES IN RARCF mmmmmmmmfm cramb mfimrmt. mmnmmmm mmmmm is fumes m harm imni m mmm* mmmmn fiamm fm 7/fi. RECMERT VAMM fVM MiSMI RELIEF HUM IS CRMII1I. INWUIIM II ftAMD FN 7/91. PLAITICttEt UMBS Ml VN.RMIM RE91SIIM mm IS IS PMMHI RHR CMFUT1M RMM AFR1L. sirs mmmmmmnm is mmmm m cmpiitim mm fm mcci i' Ii:i" mmmmmmmm mm mmmmnmm fm me ic mucmhmh * I'-* TC IMMUJIIM IIIMRSM BKfPtfM PMNLISI ITEM. INKALUUM IS CIMUIt OtOT FN 9VNCMST ITERS. tEACTM 9PTIRIZATIM UHAURINi lt CHPIIlE AM ME STITtt RKRATIVNIl. FIELI CLISVRE IS PLANNEI FN FEMRART. v Niovmv mmmmmw win mf^nnPn VEST INClRMAiSR IEPLACERENT EAST INCHOAtM SEPLACEKNT MSCELLNMRS CAPITAL PROJECTS < I15R REPLACENENT INHERENT VISCRSITT ANALYZER EMMORMR tf lR MMMM. FMMCI CMFIETIM IS PLANNEI FM RIHffl. KLIMR! IF TNI MHMMMI It FUMKI FM 3/91. PMXCT CflNPlETIH IS PUMO FM 5/91. KLJVttT IF TNI rmmm IS PIAMEI FN S/fl. PMJCCT CMPLETIM IS PIANO FM 7/9!. EMNBltM IS IN FMMOIM1S PMJECTS. IRE EMIFNERT MS SOI RICEIVEI AM IRE PREFECT RILL IE CLISEI TO FIELI CIMSES IN NMCN. VAB.0001189828 4 I F. 6. JuntOD SftSfiX All wastewater discharge parameters were met for the month of January. The State issued a revised draft NPDES permit this month, The draft permit was reviewed and comments were given to the State, The State issued a public notice on the renewal of our permit. The public notice was in the Aberdeen newspaper on January 30, 1991. A press release was included in the same paper to help explain the permit renewal process. A meeting was also held with city officials to explain the nei A Due to delays in obtaining groundwater samples and unsuccessful attempts to find the buried drums * the final report on the remedial investigation (RI) will not be issued to the State until April. The State approved the delayed schedule. An audit of Sun Polymers by Conoco and Vista will be held February 11. If all things work out. Sun Polymers will dry pond #2 resin and ship to Royal Plastics in Toronto. Waste shipments during the month included: m Eight gaylord boxes of VCM contaminated filter cartridges to TES in LaPorte, TX. Eight drums of stabilizer spill to TES in LaPorte, TX. Estimated VCM emissions for 1990 were 68,202 pounds compared to 76,212 pounds for 1989. This decrease is especially significant since we made an additional 20MM pounds of resin. A meeting was set up with the State to discuss our operating permit renewal in February. Our contractor has met with EPA on the unit risk factor and written a letter summarizing his work to date on this subject. The contractor is also working on the risk assessment for the area surrounding the plant. He expects to be complete with this in early February. I attended the Vinyl Institute Environmental committee meeting this month. Environmental presentations were made to the Rotary Club and the Garden Club. Potential buyers for the resin reclaim dryer were in the plant this month. VAB.0001189829 h . Unadjusted EUI <20.7%> B. Adjusted EUI < 6.0%> C. BTU/Lb. Product 3009.7 D. Total Energy Consumption MMM BTU 143.9 < 19.7%> < 5.7%> 2604.0 557.0 Lower than average production coupled with a record total energy consumption resulted in poor energy numbers for the month. II. I No. 1 No. 2 No. 3 December. 90 83.1% 83.5% 82.8% U,B: 83.0% 83.3% 82.8% Boiler #2 was operated twenty-seven days during the month VAB.0001189830 J. E. Beall William Bariin Genetti student. New Hire - Engineering Co-Op John Sutton, Jr. - Maintenance Department - Employee promoted from General Helper to General Mechanic HBM. Thomas Staten ~ Maintenance Department * Employee promoted from General Helper to General Mechanic "B". Albert Barr - Compound Department. James M Vinoski resigned. Operations - vinyl Department Hone. VAB.0001189831 * I- 15 12 40 23 38 33 5 166 74 9 i 5 8 6 22 10 2 0 0 0 2 1 1 0 62 4 5 18 60% 42% 18% 26% 58% 30% 40% 37% 6.8% 0 0 0 8.3% 2.4% 3.0% 0 2.4% 23.7% VAB.0001189832 m VAB.0001189833 mmm* cntntn ^ <c -*; M n n kib i.I m ,kttARI CM ML HOURS ANALYSIS REPORT on list jfc, jvu, department waps, file oo CM CCi * <Of*\ tf; X2 % 2 Ss U UQCi to *55-j a? a s CO rj cn tip. Vi 1-* <L* irnj4 s tw tin 4 w 4 mm * o fc Nm m in $ ino r** mnpOD $ CACAO s v VAB.0001189834 h D. A. Barclay There were no reportable safety Instances this month. The Stores Natural Team made a management presentation in January for the relocation of the gate on the south side of V10. Processed Processed Invoices Working Fund Checks Written Cost Savings Through Bid Process Month 1047 11 $2285 T.T,D. 4179 50 $12270 Compound "A" Grade PLENEX Compound Off-Grade (BC) Compound Off-Grade (H) Mlllscrap(*) Dry Blend "A" Grade Dry Blend Offgrade Resin Type I Resin Type MBCH Vacuum Dust Total Packaged Warehouse 4,372,735 83,079 745,902 68,255 93,101 468,404 58,662 482,270 36,950 311.279 6,720,637 * Include PLENEX millscrap and cleanout. (Decrease) 3,960,418 80,945 889,372 57,750 116,100 449,495 50,074 367,470 36,950 302.014 6,310,588 <412,317> < 2,134> 143,470 < 10,505> 22,999 < 18,909> < 8,588> <114,800> 0 <-9.265> <410,049> (Decrease) Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade Total 4,168,186 1.177.850 2,271,460 1.055.850 14,637,704 ____429.400 23,740,450 2,272,254 552,350 2,118,423 879,940 12,135,950 18,224,217 <1,895,932> < 625,500> < 153,037> < 175,910> <2,501,754> <- 164.100> <5,516,233> i VAB.0001189835 2 2 to 2to Cl CO J 2tn CO 2222 iMi CO CO I ss 2 at*i* U2i 2Ul 2Ui2111 o et CO fc 3 3S SoIT* s 8 i rs N M M 3S sss?: ? ? ? ?????2> C5* Il k s " S3SS ||5 3Ss 2 r% s 2s sssS SEES OSNN ss 3A aR ro pO as :s <N 1 *I 1 Ri 4 I I I I I j1 i | i_ S_ |I SK|> I I t I t t I j3 H H II it J i JCO CO CO CO in sgi* 2222 s ill iii 2u Si 2 2* i i tir* CN 1^ <N M 3 ss2 2 2 II rrr? ??tt SSSS ir in 2 CO S C3 2 CO 2 ill co rn <o b *s 22 22 2Cu o to CO sis to cn S3 3 to cn to to to LJ U to CO g g S cn 22 2 Si ac CO CO CO CO 2 222 2222 l|HM DM mmmmmmmmmm :l VAB.0001189836 mm RB8IN Ship Date 1/04/91 1/07/91 1/11/91 SAMPLE SHIPMENTS JANUARY 1991 Product 5265 5305 5225 5415 Aaount 780 lbs. 716 lbs. 50 lbs. 500 lbs. 1/18/91 1/18/91 1/18/91 1/23/91 1/24/91 1/28/91 1/30/91 5385 5415 5385 5415 5385 5415 5265 5385 5415 5266 5305 5325 5366 5398 5415 5395 5385 10 lbs. 10 lbs. 100 lbs. 100 lbs. 100 lbs. 100 lbs. 100 lbs. 200 lbs. 200 lbs. 100 lbs. 50 lbs. 50 lbs. 50 lbs. 50 lbs. 100 lbs. 50 lbs. 200 lbs. 1/30/91 5385 200 lbs. 1/30/91 5385 200 lbs. 1/30/91 5385 200 lbs. 1/30/91 1/31/91 1/31/91 coaram Ship Date 1/02/90 1/10/91 5385 5386 5415 5385 Product 4S2-93B NAT 462-93C NAT 452-94A NAT 17462 BLK <0G> 200 lbs. 5 lbs. 5 lbs. 200 lbs. Aaount 200 lbs. 200 lbs. 200 lb>. 50 lbs. 1/10/91 1/14/91 1/16/91 1/21/91 17462 BLK (OG> 50 lbs. 461-120A VAT CL(OG) 50 lbs. 34662 GRY 546 (OG) 50 lbs. 58162 BLK 3000 lbs 48451 BLK 100 lbs. 1/2S/91 1/25/91 1/25/91 1/25/91 1/28/91 462-78A 462-78B 462-78C 57462 BLK 57462 BLK 58162 BLK 57462 BLK 58162 BLK 34431 VHT 1000 lbs 1000 lbs 1000 lbs 300 lbs. 300 lbs. 300 lbs. 300 lbs. 300 lbs. 50 lbs. Custoaer PVC Container PoljreMt Toeh. Corp. PIRELLI CABLE LTD. (Cttada) Firestone Bldg. Products COMPOFLKX (Chile) PANICHBM (Chile) INTERNATIONAL TRADEX (Chile) Furon Coapeny Essex Oroup PD NTR GUATEMALA (Guateaala) CONDUCOMER (Costs Rice) COCISA (Chile) TIE (Panaaa) ECHOSA {Hondurss) Shawnee Chesicsl GENERAL TRADING (Venesuela) Custoaor Mecklenburg-Duncsn Prototype Plastic Extrusion Co., Inc. Superior Insulated Wire Corp. Polychea Alenco ITV PLASTIOLIDS (Csnsds) Automotive Industries Vytron Corporation Betterbilt Aluainua (AZ) Betterbilt Aluainua (TN) INPACO S. A. (Paraguay) PLASTICIZER Ship Date 1/24/91 Product 108P Aaount 1 drua Custoaor Vista RAD - Austin VAB.0001189837 ABERDEEN CHEMICAL PLANT SHIPPING ANALYSIS JANUARY 1991 -SHIPMENTS BY PRODUCTS- PUBLIC RESIN-BULK RESIN-PACKAGED 20,778,114 350,649 FLEXIBLE COMPOUND*BULK 1,214,290 FLEXIBLE COMPOUND-PACKAGED 2,654,719 NEW BUSINESS 14,530 RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED 4,117,900 524,196 TOLLING - BULK TOLLING - PACKAGED 0 0 PLASTICIZER 49,570 TOTAL 29,703,968 SHIPMENTS BY MODE BULK: *JANUARY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER RAILCAR 159 12 27 4 TOTAL JANUARY 202 YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 672 45 90 8 TOTAL YTD 815 PACKAGED: *JANUARY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER CUSTOMER PICKUP 6 28 3 0 TOTAL JANUARY 37 *YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER 15 80 5 0 TOTAL YTD 100 MONTH IPT/ITC EXCH/TOLL 12,416^650 170,600 530,000 0 909,350 209,012 0 832,550 0 0 0 0 0 0 0 0 0 0 203,920 554,550 14,742,082 1,084,550 CUSTOMER PICKUP CARRIER 73 55 07 0 22 02 73 86 168 0 4 29 201 COMMON CARRIER 11 70 9 1 91 46 279 53 1 379 144 12 58 17 231 TOFC AIR/UPS 00 00 00 00 00 00 00 00 00 00 YTD PUBLIC IPT/ITC 78,948,774' 54,188,760 772,545 838,300 2,797,460 10,475,359 5,041,400 629,156 32,853 0 13,015,660 1,372,311 2,337,550 512,706 00 00 604,950 540,670 106,019,912 64,088,542 AIR/UPS 14 14 0 0 28 22 47 2 0 71 EXCH/TOLL 1,245,900 0 0 0 0 0 0 1,401,960 33,600 2,167,660 4,849,120 TOTAL 287 19 49 6 361 964 57 152 54 1,247 TOTAL 31 112 12 1 156 83 406 60 1 550 VAB.0001189838 FLEXIBLE & RIGID OFF-GRADE m01/90 09/90 09 07/90 00/90 11/90 01/91 02/90 04/90 0/90 09/90 10/90 12/90 PKGD PRODUCTS INVENTORY VAB.0001189839 - J. M. Edwards, Jr. There were no safety incidents in the Laboratory during January. The monthly safety meeting topic was "Hearing Conservation" taught by Bruce Trego. Representatives from Eagle Plastics visited the Aberdeen Plant on 1/22/91. Pete Konen, David Schnase, Mike Vengler and Jeff Armstrong from Eagle accompanied Nick Vafiadls to learn about aking 80273G dry blend. JL 01/03 A truck of low (out of spec) viscosity 5305 was shipped to Uniroyal. The I.V. analysis of the truck was completed after the truck had been unloaded into the customer's silo. Uniroyal was contacted and told about the low viscosity resin. They were able to run the material by lowering their process teniperatures. The customer complained of low fusion torque for two truck shipments of RP-151. The trucks were T-2479 and T-2810 shipped on 1/6/91. The material was also contaminated with "gravel-like particles1' on the 40 mesh 01/14 Payton Extruded The truck delivery of RP-151 on 1/14/90 was rejected for "undispersed wax pearls" as well as a "high amount of line scale." 01/14 Cablec Utility Cable Co.. DuOuoin. IL The customer reported ifiinnading a pipe clamp in the bottom of a box of 38611 compound. The clamp came from steam lines hanging above the box staging area. A plan of action is in place now to prevent recurrence of this particular problem. Continued Continued 01/22 Customer complained of lumps on jacketing made with two lots of 34501 beige compound (lots 30Y21 and 30Y18). R&D Aberdeen is investigating. Customer complained of white streaking in RP-91 WHT 110. Their part reject rate was 3 to 7 parts rejected per five minutes of running. During the followup conversation with Formtech, it was learned that the problem was short lived. Aberdeen R&D is following up. The customer complained of "yellow streaked" contamination in the bottom of VIPX 45252 shipment of RP-151. Compartment "B" was contaminated with RP-91 which was in the silo before being filled with RP-151. Com partment "A" was contaminated with "blue waxy balls" and CB had a large amount of "overs" on the 40 mesh screen test. 01/23 Customer complained of hard particles in eleven boxes of 18161 GRY 545 compound. Central has agreed to trial various boxes of hard particle values to help us determine the correct specification. Customer complained of cross contamination in an RP-20 railcar number FPAX 890181. Records show that the silo the RP-20 came from and the dry blend unit both previously contained 80273G. The sample from VBP tested like 80273G using the torque rheo meter and colorimeter. mum nm PUMP WPPV TAxnaATnmv . Continued 01/30 Continued Customer complained of contamination in a 108P plasticizer car. Samples received in Aberdeen of the complaint material showed a high freezing point contamination as well as some rust particles. This may explain why the bag filters were suffering damage at the terminal and why the material was "hard to pump." The sample has been forwarded to Austin R&D to determine the identity of the high freezing point liquid contaminant. 01/30 The wrong off-grade 34862 compound was shipped to REKO. They received the "fiber contaminated" material instead of the "glowing" pellet material. 01/30 Special test compounds, 462-78 A, B & C, arrived twenty-four hours late which caused scheduled machinery and operators to be idle. Customer Blane Blane Columbia Dayton Essex (KS) Essex (IN) Stylecrest Uniroyal Product 5395 5395 5385-3P RP-151 WHT 145 5415 5415 RP-27 WHT 113 5305 Reason Inherent Viscosity Bulk Density Range Contamination Color Particle Size Avg. Microns Particle Size Avg. Microns % on 40 Mesh Bulk Density No. 1 R/C 1 R/C 1 H/T 1 R/C 1 R/C 1 R/C 1 R/C 1 H/T A4 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 January, 1991. Reactor Number of Samples Average RVCM, ppm 25 0.261 62 0.237 The following is a summary of the residual VCM analysis of shipment samples for the month of January, 1991. Product Average RVCM. ppm 5265 5305 5325 5385 5395 5415 Dry Blend Debox Pond 50 101 6 68 1 56 19 12 0 0.113 0.088 0.096 0.322 0.015 0.026 0.099 0.335 (based on dryer "regulars") 1165 1201 5385 5395 5415 Bulk Density Inherent Viscosity (vs. 0.715 - 0.744) L Color A Color B Color % on Pan (vs. 2%, max.) % thru 140 Mesh Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle size, microns 1.56 1.44 5.75 4.00 1.78 1.11 -- 0.38 -- 133 0.67 1.33 0.78 1.67 9.33 3.17 1.57 ---- 1.05 -- 134 0.91 0.79 2.50 2.50 0.93 -- 1.14 ---- 68.3 160 *v -- -- ------ - - ------ 0.98 0.62 3.00 5.33 3.00 0.50 3.45 3.69 1.70 2.6 167 i VAB.0001189843 --**^**^mmmm**"***mrnm*^^TM^v 1 -- ----- ------------- ----- ---....... ...... *......... . TiMiiiwT . Continued Hardness Color Hard Particles Heat Stability Contamination Dicing Cross Contamination Total Adjustments ILUlio. ill 10.0 15.0 ------- 10.0 <0.31> <0.46> -- <0.31> ---- ---- 35.0 <1.08> -*-* 15.6 44.1 -- <0.48> <1.36> 7.6 24.9 8.0 100.2 <0.23> <0.77> <0.25> <3.09> Torque Rheometry Color Total 6.5 <0.13> 14.3 <0.28> 1. All six natural teams met during the month. 2. The I. V. analyzer failed four times during the month. 3. The Coulter particle size analyzer was moved into the resin testing area of the Q.C. lab. Training was started on this instrument for use in the routine analysis of our resin. VAB.0001189844 T MHMM F ER OF 30 25 20 4 15 10 5 0 M M J S N J*89 M M J S N J'90 M M J S N J'91 MONTH TOTAL INJURES OSHA RECORDABLE VAB.0001189845 ABERDEEN ENERGY CONSUMPTION 4 4 VAB.0001189846 4