Document yrJznZb3xr5526xwkd7YOOe5V
T. H. Huffman
From: Dote:
Sufaiech
R. V. Seymour June 24, 1991
Ainmni MONTHLY PROGRESS REPORT
MAY, 1991
There
Hvfa
Ln May. At: month's end, employees have worke<M#M*days (5,816,091 manhours) ist lost time injury.
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, (EUl, %) Fixed Cost Variance, $M Variable Cost Efficiency Variance, $ft
40.3 91.3 96.5 1.0390
6.1 99.0
4.5 99.0
1.6 81.8
6.6> 57.8 38.1
UEtPr
318.3 88.2 98.2
1.0241 36.3 97.4 38.4 99.5 12.6 84.0
< 8.1> 222.3
< 47.7>
The resin units ran well during the month. The first phase of reactor VCSM training was completed. Converting the New Module reactors to the VCSM is scheduled to begin July 5, 1991.
Both rigid and flexible compound production rates continued to be high as orders remain tight. Downtime due to maintenance was low.
Conversion to OASIS began June 1.
Variable efficiency costs were near budget in all units.
Fixed costs were $57.8M favorable due primarily to low payroll and low MM&C costs during the month.
VAB.0001189672
TUtt# fufaiLaftfmmiumi
6/24/91 Aberdeen Monthly Progress Report - Hay, 1991
Pass 2
OMP
All plant natural teams met In May.
m The Compound C-Shift Natural Team made a presenta tion on their project to improve safety and reduce transfer line length on dry blend by rerouting transfer lines.
m The Maintenance Area 11 Natural Team made a presentation on their project to improve the safety and efficiency of their work in the dry blend base ment.
i Customer visits this month were Inter Plastics (Corinth, MS) and Dayton Extruded Plastics.
i The first in-plant environmental newsletter was published.
m We sent the first load of office paper for recycle, consisting of ten thousand pounds of office paper and two thousand pounds of computer paper.
R. W. 'Seymour Plant Manager
rah
........mmwmm**
VAB.0001189673
F1
Hews ton
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. Gamblin
Austin
R. L. Poe
X
H. J. Hall
I
H. D. Garrison
ysyot ..Elfflfr
P. D. Carrico
J. Friend
J. V. Hare
X
Baltimore Hammond Blane
L. R. Bauer J. Pavao C. R. Miller
X X
P. L. Foote
RVS/DCS (Pile Copy), TJA, JBA, JEB, JME DAB. DAM. RBN. JEN. JDO. BLT
'l
X X X X X X X X
X X X X
X X
VAB.0001189674
B. L. Trego
First Aid OSHA Recordable
Total Injuries Number of Restricted Workday Cases Number of Lost Workday Cases
Mav
1 1
0 0
Fiscal Y.T.D. 1991
10 _6 16
4 0
Fiscal Y.T.D. 1990
13 _4 17
3 0
Vinyl Operations Compound Operations Maintenance Laboratory Rece iving/Warehouse Office
Totals
02
05
17 00 00
1
Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains Stings Other
Totals
036
011 13 3
032
03 1
00 2
-2
1 17
Lost Workday Cases Days Lost
06
0 127
6
119
First Aid Cases Medical Treatment Cases Lost Workday Cases
Safety Record
13 01 01
Last lost time injury - 7/5/79
Days since -
4,348
Employee hours since > 5,816,091
On May 31, 1991, the employees of the Aberdeen plant completed 4348 days with no lost time injury.
VAB.0001189675
a^suTT - Continued
during the month included Annual Awareness and Forklift Safety.
dosimetry results for the month
VCM Lead Total Particulates
...., .<;....fL .. Number Percent
78 100.0 5 100.0
2 100.0
WvnjKfr
0 0 0
0 0 0
Injury Class FA
Compound
First degree bums to both forearms.
VAB.0001189676
All of the plant's natural teams met during Hay.
Some of the natural team highlights for the month were:
m The Senior Mechanical Engineer's Natural Team worked on the documentation/quantification of their contractor evaluation project.
m The Maintenance Superintendent's Natural Team has reduced spare parts inventory by over $30M. Work continues to identify further reductions.
The Maintenance Area II Natural Team made a presentation to management on their latest project - dry blend basement improvements.
The team identified several solutions to the safety and productivity problems associated with the cramped working conditions and poor access in this area of the plant.
A monorail and hoist will be installed to lift equipment into and out of the basement, eliminating the carrying of heavy valves, etc. on the stairway. A scissor-type hydraulic lift table will also be purchased to facilitate the maneuvering of equip ment in the confined work areas present in the bas ement.
The Safety Supervisor' s Natural Team began documen tation of their latest project - rewriting the
laintenance call-in procedure.
m The Compound C-Shift Natural Team made a presenta tion to management on 5/31. The team justified re routing the dry blend boxing hopper lines based upon safety and efficiency considerations.
The boxing lines currently run across the silo deck walkway creating a tripping hazard. The team also estimates the lines can be shortened 70 to 80 feet as a result of their proposed re-route.
Intex Plastics (Corinth, MS) visited the plant on May 21. The Intex visitors included Terry Emmons - Quality Control Manager; Sherry Parikh - Process Development Manager; and Jerry Hight - Resource Manager.
The purpose of the Intex visit was to review specifications, discuss unloading problems at Intex, review laboratory procedures and give Intex an overview of our safety programs. Intex was also given general plant, operations and QMP overviews, as well as a plant tour.
an*#** mmm
pph wmmmm****m
Continued Dayton Bxtruded Plastics (Springboro, OH) visited the plant on May 21 & 22. Dan Preston - Material Manager, represented Dayton. Hie agenda for the Dayton visit included discussion of dry blend formulation and current and proposed specifications for resin and
ry en . Dan was also treated to our usual dose of overview and tours.
VAB.0001189678
- D. C. Skokna
Product
PVC Flexible Compound Rigid Compound Plasticizer
Total
$ 55.8 132.5 15.9
< 0.5> $204.7
$40.9
< 7.6>
< 12.7>
17.5
$38.1
variable CQgfrg; Operation of all units was near budgeted levels.
Price Variances:
$520.2 < 300.6> < 105.9> < 81.3>
$ 32.4
Total
$616.8 < 175.7>
< 102.6>
VCM m Natural Gas m Phthalic Anhydride Pigments, Colors Plasticizers Resin to Flexible Compound m AlfolR Alcohols m Resin to Rigid Compound m Other Price Variances
Total
$465.3 34.3
< 18.4>
< 20.7>
< 38.8> < 62.2>
< 68.6>
< 74.5>
$ 32.4
Fixed Cost Variances
Payroll and Benefits MM&C Miscellaneous TI&D m Clearances
Total
$ 22.0
33.0
< 12.7>
7.1
<
$ 57.8
unfavorable
variance
MM&C - Activity continues below budgeted levels to conserve cash.
Miscellaneous - Contract cost-operating, an unfavorable $33.9M variance, appears to be due to incorrect entry items not in this category. However, there is $11M in software maintenance for the VCSM project.
s I
-ft
VAB.0001189679
VINYL - J. D. Olson, D. E. Knittlg
SifetY
The Vinyl Department had no first aid case or OSHA recordable Injuries during May. The monthly safety meeting topic was "Fire Training."
1. Phase 1 of VCSM reactor training was completed.
This
training focused on the complete system. Phase 2 will
emphasize specific reactor programs.
2. The resin raw materials in the 744 account were valued at $303M.
3. OASIS training was completed and all production models modified as needed to open the month of June.
4. A new rinse nozzle was installed in D700 on May 2. The nozzle in D745 was replaced due to a construction defect. The reactors remain clean.
Mav
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
%
40.3 1300.4
101.9 948.0
30.6 91.3 90.9 96.0 96.5
m
318.3 1310.0
102.7 7444.0
30.8 88.2 92.4 94.4 98.2
Operational downtime (recovery scheduling conflicts, charge/rinse water conflicts, Q.C. data delays, dump conflicts and inventory control).
Hours 449
Maintenance downtime (repair steam valve on D741, D745 condenser cleaning, D700 rinse nozzle, gearbox maintenance D741, D744 seal, VC valve OM, D743 main charge, valve, D700 condenser cleaning.)
195.5
VINYL - Continued
Drver Downtime
% of Total
Operational downtime (centrifuge plugs, dryer cleaning, flameouts).
Maintenance downtime (centrifuge maintenance, dryer PM, #5 baghouse screwfeeder motor).
Reactor limited production.
24.5 22.3 26.3
y ifaintMatiea Wofft - J. B. Autrey, S. A. Truitt
1. The fluid bed dryer wetcake feed screws were changed out when one end of a screw broke off.
2. A VC compressor in the old unit was replaced due to wear. The old compressor is being rebuilt for a spare and will be completed in June.
3. Reactor 744 seal failed due to normal wear after being in service for twenty-seven months. The old seal has been rebuilt for a spare.
4. A defective gasket (reactor 700 seal) was replaced.
5. The screw and bearings on the #7 dryer inlet screw feeder were worn and had to be replaced. The old screw is repair able and will be reinstalled in June.
6. Reactors 700 and 745 condenser tubes were hydroblasted to aid in contamination control.
7. Two major valves were changed out in the Vinyl unit this month.
f
GQMPOOHD - J.E. Nickerson, If. R. Kan
The Compound Department had no OSHA recordable injuries in Hay. The topic of the monthly safety meeting was "Fire Training".
Control of costs and inventories continued to be a high priority during May. Lines were operated only on an as-needed basis and operators from shutdown lines were utilized to cover vacations and other absences to reduce overtime
A test was run to determine the feasibility of producing a natural rigid compound (without titanium dioxide) . The entire dryblend system was cleaned thoroughly prior to production. Although the results are not conclusive, the initial feedback from the customer is that the compound still contained too much pigment. The business is being evaluated to determine future direction.
High priority was placed on producing rigid profile compounds that would meet the 40 mesh spec. Procedures were established to help prevent off spec material due to 40 mesh. Included in the procedures are Items such as inspection of the screeners once per shift and loading and testing of each railcar compartment as it is produced. Of particular importance has been RP"151 for Dayton Extruded Plastics. The extra precautions have caused a reduction in rates, but they are considered absolutely necessary.
Operating
Month Avg./Dav
Line I Line III Line V
Total
31 31 11
% Prime
Capacity Utilization Factor
1894 3805
-Ml
6088 99.0 73.5
61 123
-11
196
12625 21574
2124
36322 97. 58.
Dpvmtlms
Line I
- Product Changes - Quality Problems & Control - One Dicer Offline - Miscellaneous Maintenance - Waiting on Raw Materials - Mill Maintenance
Hours
102 28 21 13 12 7
VAB.0001189682
COMPOPHD - Continued
Line III
- Product Changes - Waiting on Raw Materials - One Dicer Offline - Quality Problems & Control - Miscellaneous Maintenance
68 20 20
9 7
- Product Changes - Miscellaneous Maintenance - Waiting on Raw Materials Orbitran Problems
39 6 3 2
Operating Para
Month Awe./Daw
Rigid Compound
31
% Prime
Capacity Utilization Factor
4523 99.0 68.5
146
38438 99.5 79.6
Hours
- Product Changes - Quality Problems & Control Miscellaneous Maintenance - Waiting on Raw Materials
130 74 35 9
Operating
Month
Plasticizer
31
% Prime
Capacity Utilization Factor
1644 81.8 71.3
12552 84.0 81.3
Kew Malpt?lp|>rfr? WffTfr - J. B. Autrey, S. A. Truitt
m The #5 air compressor is being reworked. It locked up while in service and when disassembled it was found that the head and cylinder needed to be reworked and some bearings replaced. The expected completion of rebuild is July when the last parts arrive.
The #3 air compressor head and cylinder are also being reworked. Expected completion is July.
VAB.0001189683 mm
1
COMPOUND - Continued continued
The "A" blender gearbox was replaced due to bad bearings The motor on #9 dicer was replaced due to bad bearings. The auto greaser on Line I Banbury was installed. The old greaser only lubricated when the gate opened, but the new greaser is on a timer and is much more reliable.
A
VAB.0001189684
S. C. Hillaan, M. L. Career
VCSH
Operator training on reactor software programs was conducted in late May and early June.
The turnaround for conversion of the new reactor module has been rescheduled to begin July 5 due to resin production demands.
The old and new reactor module systems were put into service in early May and mid-June, respectively. In April, there were problems with ion exchange resin contamination of low mole products from the temporary system. A change order has been issued to install an additional filter downstream of the decalcifier vessel in each module for the permanent systems.
Ultraclear 5305
The plant and FED are working on ways to improve 5305 quality for our rigid calendaring customers. The focus of efforts has been on reducing black/brown contamination, fibers, and streamers. Investi gative work is being done to identify and classify sources of these contaminants.
Several projects are being evaluated for debottlenecking the PVC
One project will be to eliminate the evacuation step by enclosing the dump systems to prevent air from entering the reactor. Slurry culls were sampled to determine the capacity requirements of basket strainers for replacing the dump Sweco. A test of enclosed dumping is being planned for July or August.
Performance testing of the cooling towers will be conducted in July to help determine ways to increase cooling capacity. Summertime cooling capabilities are marginal now with production improvements due to cleanwall.
ENGINEERING - H.L. CARTER. S.C. HILLMAN *
I
ABERDEEN CHEMICAL PLANT APPROVED CAPITAL PROJECTS
A
AFE NUMBER
A519 A449 A909 D5U D550 DS70 D5B0 mo D749 D849 D859 D899 F551 F650 F440 F499 F779 6340 6341 6410 6430 6459 6839 H500 H501 H510 H531 H571 H420
PROJECT DESCRIPTION
PLANT ELECTRICAL UPORABE VINYL CONTROL SYSTEM MODERNIZATION INERTS REMOVAL MODIFICATIONS VCN UNLOADING MODIFICATIONS RAILCAR ACCESS PLATFORMS OLD HODOLE RECOVERY SYSTEM ACCESS RECOVERY VACUUM PUMP PRESSURE REL. PLASTICIZER LOADING, t UNLOADING. HOD. LEAD HANDLING AND EXPOSURE REDUCTION COMPOUND LINE 3 SOW-BULK LEAD HANDLING CQNPOUNO SILO BRIM BREAKING RAILCAR CLEANING RACK BRY BLEND SCRE8KR REPLACEMENT 5305 RESIDUAL VCM REDNCTION DECALCIFIED NAUR LON NOLECULAR HEIGHT RESIN EXPANSION ORVERS NO.4 4 5 CONTAMINATION REDUCTION TC SPILL CQMTAXNHEKT HASTEHATER INFLUENT EQUALIZATION TC COMPLIANCE PROJECT REACTOR SLURRY STRIPPING OPTIMIZATION NED DRYER 8A6HQUSES PLANT HATER RECYCLE PLANT HATER SYSTEM MISCELLANEOUS CAPITAL PROJECTS < *13H VEST IMCIHERATOR REPLACEMENT BOILER FEEDWATER TANK REPLACEMENT d-745 rx Drive shaft repl EAST INCINERATOR REPLACEMENT
STATUS
PROJECT NAS CLOSED TO FIELD CHARGES IN HAY FY 91. FINAL REPORT MEN NODULE CONVERSION PLANKS FOR JULY T/A. PROJECT IS OPERATIONAL. TARGETED FIELD CLOSURE 4TH QTR.91 A PRELIMINARY DESIGN REVIEN NEETIMG IS SCHEDUUD FOR JUNE WORKING ON PUNCHLIST ITEMS, TARGETED COMPLETION JULY FY91. OESION IS CONPLETE, INSTALLATION PUUNEI FOR OLD NODULE OUTAGE 00# IS PLANNED FOR JULY T/A PUNCH LIST ITEK REMAINING. TAfHETED CDNPLETIDN 4TH 0TR.FY91 PROCESS ENGINEERING IS NMITORIK MODIFICATIONS. MODIFICATIONS AMD TEST RON IS SCHEDULED FOR JUNE COMPLETED. HILL BE CLOSES TO FI&D CHARGES IN JUNE. CQNRTRUCTlON CONTINUES. CDNPLETIDN PLUMED IN JUNE. SCREMERS WILL BE PLACED ON MIM IN JOK. DESIGN HILL BE6IN IN JUNE PROJECT MILL K CLOSM TO FIELD CHARGES IN 4TH OTR. FY91. OLD NODULE COMPLETED. NENHOBULE CQHPLCTION PLANNED IN JUNE. PROJECT NAS CLOSED TO FIELD CHARGES IN MAY FY91. FINAL REPORT ENGINEERING IS IN PROGRESS ON MODIFICATION. PROJECT HILL BE CLOSED TO FIELD CHANBES IN 4TH OTR. FY91. OESION IS IN PROORGGG. CONRMKTION PLANNED TO START IN JUNE. TARGETED TO K CLOSEB TO FIELD CHRRBES 4TN OTR. FV9I MODIFICATIONS PLANNEB BURINS R1 OUTAGE IN JULY. NEN MODIFIED SCREMS HAVE ARRIVED. PROJECT IS KING MONITORED. PROJECT MILL K CLOSED TO FIELD CHARGES 4TH QTR.FY91 EOS. IN PROGRESS. BIDS DUE BACK IN JUNE. TARGETED COHPL. EARLY-92. ENGINEER016 IS IN PMGRESS ON 7 PROJECTS. 9 PROJECTS COMPLETED. INC1KIATQR DELIVERED. PROJECT COMPLETION PLANNED FOR 8/91 NOOK IS PLANNED FOR JHK/JULY STEAM 0MTA8E. CURRENTLY NQRKIMB NITH VENDORS ON PRICING INCINERATOR IELIVIREI. PROJECT COMPLETION PLANNED FOR 10/91.
VAB.0001189686
- K.G. Akins
All wastewater discharge parameters were met for the month of May.
The new NPDES permit requires us to monitor for total lead and hardness once per month in the water we discharge from the plant into James Creek. Based on the data collected, the State has the option to modify our permit to Include Mississippi's Water Quality Criteria limits on lead. We have been testing our outfall for total lead and hardness once per week to get a quick idea of where we stand with regard to lead in our wastewater discharge. Based on data collected to date, we are far below the State limits.
A process sewer was found to be leaking oils from the plasticizer unit into a storm sewer. The leak began during a period of above normal flow in the process sewer due to cooling tower repairs. The leak was repaired and the oils trapped with sorbent booms before it left the plant.
A kick-off meeting was held in May to discuss items necessary to comply with the new storm water regulations. Work will begin on the application in June and July.
Vista, Conoco, and DuPont Environmental Remediation Services (DERS) met with the MDEQ on May 6 to discuss the final Remedial Investiga tion report. The state agreed with the DERS recommendation to conduct some resampling. the MDEQ will probably not issue final comments on the report until the results from the resampling are available. Resampling work is scheduled for June.
Vista, Conoco, and DERS met in Houston to discuss removal of the buried drums at Aberdeen. DERS plans to subcontract the job and is getting bids from local contractors.
The MDEQ ruled the resin in Pond 2 is a product and not a waste. This will clear the way for removal of the resin.
Vista and Conoco met with Royal Plastics in May to discuss reclaiming the resin from Pond 2. It appears the resin could be hauled offsite and dried at a Royal facility to be located in Prairie and operated by Sun Polymers.
VAB.0001189687
Continued
The Bureau of the Census Survey of Pollution Abatement Costs and Expenditures for 1990 was completed in May.
We issued an environmentally focussed issue of the plant newsletter in May.
The Aberdeen Chemical Plant's Industrial Toxics Project (ITP) voluntary emissions reduction plan was prepared and submitted to corporate environmental.
1 attended a three-day environmental regulation course in Houston May 13-15.
Rendell Newton and I attended the Mississippi Environment 1991 seminar in Jackson on May 30.
Recertification forms were submitted to renew our Alabama Disposal Approval Number (DAN) for our empty lead/antimony bags. The DAN expired in January, 1991.
The Aberdeen Plant shipped its first load of office and computer paper for recycle in May. We collected 10,000 pounds of office paper and 2,000 pounds of computer paper.
Waste shipments during the month included:
Bulk shipment of reactor culls to Sun Polymers in Baton Rouge, LA.
Two drums of stabilizer spill to TES in LaPorte, TX.
Bulk shipment of waste oil to M&l Chemical in Attalla, AL.
A
VAB.0001189688
v
J. R. Ganc
A. Unadjusted EUI B. Adjlisted EUI C. BTU/Lb. Product D. Total Energy Consumption MMM BTU
< 7.62> < 6.62>
2673.0 140.5
< 8.70%> < 8.12%>
2744.0 1104.7
Boiler
No. 1 No. 2 No. 3
83.2% 83.4% 82.7%
83.1% 83.4% 82.8%
VAB.0001189689
a .. i
Allan Bodron - Engineering Department - Rahire Employee returned to work ae a Co-op Engineer.
Michael Schneider - Engineering Department - Rehire Employee returned to work ae a Co-op Engineer.
Franklin D. Andrews - Maintenance - Promoted from Instrument Technician "An to Maintenance Supervisor.
Artis Jones -- Lab -- Reduction in force -- employee exercised seniority into Laboratory "A" Technician position - Article VIII, Section 3.
Donald Whatley -- Compound -- Employee promoted from Compound Utility to Compound Operator.
None.
William Berlin Genetti - Engineering Department Employee returned to school.
Coleman Haynes - Compound Department - Returned to work from military leave of absence to the Persian Gulf.
VAB.0001189690
IQMUI RSOU0 Report
May, 1991
Ptgt 2
j -# l*i i *
Robert Hamilton - Compound Department - Returned to work from military leave of absence to the Persian Gulf.
Charles Reed - Compound Department - Returned to work from military leave of absence to the Persian Gulf.
James Gray - Laboratory - Returned to work from military leave of absence to the Persian Gulf.
James 0. Howell - Compound Department - Returned to work from military leave of absenOe to the Persian Gulf.
VAB.0001189691
b
CM
-
#EMPLOYEES
15
39* 24 39 33
5 167
74
M
9 5 8 5 23 10 2 62 7
F
0 0 0 2 1 1 0 4 18
%M 60%
%F 0
TURNOVER MO. YTD
10
0
M
00
0
__
_
_
20.5% i
20.8% 59%
0 8.3% 2.6%
0
0
4
0
0 0 1.2%
30%
3.0*
0
0
40%
00
0
37.1*
2.4%
9.5*
24.3%
.i
hHHMPMWM
s Ul
(A f*
.1
s*l
|S %1
2
5
CL
-M
il
i
8
N*
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e
0 0 *0
0 .0 0
P'"
8
'1 .4
0
:
*
8
8
* * ft
8 ft
CMt o* *+ O Ci VJ8
8
8 8
8
85 1
*
0
;8
8
8 8
8
*
:
OOHN
> 5
it c IS
%
S
B
3 8
I
9
VI
I: I i.
: t\
8
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CM
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S1 11
3i
a.
VAB.0001189693
i
DEPARTMENTAL NUMMARY HOURS REPORT
............. TEAR TO DATE.................
Non Paid
Hours
15.00
UN *8
3
*
9H
i i. 4
8
*
O
8
O
* IA
8
ft
8
8 8
3
8
*
<
8
8 N
8 ft
8 ft
8
e
8
*
18
3 ft
8 ft
8
t
8
8
ft
8 3
8
8 ft
3
ft
CM
3i
s sRl
U8l
gs s
52a3
o
._ .i- .fi *-
a.
VAB.0001189694
Printed
6/06/91
tf
- D. A. Barclay
Safety There were no reportable safety Instances this month.
All natural teams met in Hay. The accounting group natural team made a management presentation on * I ail cost reduction. Savings is estimated at $10M.
Statlatics
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
1103 18
$2899 111 206 181
7234 99
$20396 646
1438 1359
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
4,111,348 88,592
464,049 46,460 41,432
258,968 124,737 649,200
37,500
6,344,493
* Includes PLENEX millscrap and cleanout.
(Decrease)
4,008,228 97,949
317,645 49,787 76,730
517,995 167,586 636,250
100
6,013,648
< 92,306> 9,357
<146,404> 3,327
35,298 259,027
42,849 < 12,950> < 37,400> < 64.267> <330,845>
Compound "A" Grade Compound Offgrade Dry Blend "A" Grade Dry Blend Offgrade Resin "A" Grade Resin Offgrade
Total
1,039,762 177,500
2,185,510 594,860
8,067,700
12,254,482
(Decrease)
752,156 177,500 2,592,530 816,160 8,509,718
14,808,014
< 287,606> 0
407,020 221,300 422,018 ____770.800 1,533,532
VAB.0001189695
m mmm
Hl
* *1
1000
05/90 07/90 06/90 11/90 01/91 03/91 05/91 05/90 06/90 10/90 12/90 02/91 04/91
PKG'D PRODUCTS INVENTORY
VAB.0001189696
\
ABERDEEN CHEMICAL PLANT SNIPPING ANALYSIS NAY 1991
-SHIPMENTS SY PRODUCTS-
PUBLIC
MONTH IPT/ITC
EXCH/TOLL
PUBLIC
YTD IPT/ITC
EXCH/TOLL
RESIN-SULK resin-packaged
21 ,456,810 10,394,080
330,990
155,700
0 0
160,872,294 101,422,500 1,777.400
1,929,604 1,580,650
0
FLEXIBLE COMPOUND-BULK FLEXIBLE COMPOUND-PACKAGED
902,770 4,497,035
1,254,900 0
0 0
5,823,030 23,650,364
8,995,350 751,502
0 0
NEW BUSINESS
34,606
00
93,288
00
RIGID COMPOUND-BULK RIGID COMPOUND-PACKAGED
1,045,260 349,629
666,050 178,050
0 0
27,665,050 2,832,808
4,766,100 699,756
0 0
TOLLING - BULK TOLLING - PACKAGED
0 00 0 00
0 0 1,401,960 0 0 33,600
PLASTICIZER
0 378,110
0
779,150
1,480,530 3,652,160
TOTAL
29,425,102 13,026,890
0
223,645,588 119,696,388 6,865,120
-SHIPMENTS BY NODEBULK:
MAY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
TOTAL NAY
RAILCAR
161 10 15 2
i
IBB
CUSTOMER PICKUP
42 0 2 0
44
COMBI CARRia
39 8 12 1
60
TOTAL
242 18 29 3
292
*YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
TOTAL YTD
1,305 78
184 20
4
1,587
341 0
26 29
396
305
32 a 27
1,951 110 296 76
2.433
PACKAGED:
MAY* RESIN FLEXIBLE COMPOUND RIGID COMPOUND PLASTICIZER
CUSTONER PtOfiUP
3 26
1 0
CQNNON CARRIER
12 113
19 1
TOTC AIR/UPS
00 00 00 00
AIR/UPS
12 2 0 0
TOTAL
27 141
20 1
TOTAL MAY
YTD* RESIN FLEXIBLE COMPOUND RIGID COMPOUNO PLASTICIZER
TOTAL YTD
30 145 0 0
14
25
98 0
0
193 593 0 0
7 112 0 0
0 30 0
49 71
4 0
225 806 0 0 124
189
172 857 123
3
1,155
&CC TLC,AEV,JRF
VAB.0001189697
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VAB.0001189699
TAWiaATOBT - j. m. Edwards
A
There were no safety incidents in the Laboratory during May. The monthly safety meeting topic was "Fire Fighting" taught by the Safety Department.
There were four customer contacts made during the month.
A meeting was held at Intex in Corinth, MS on 5/12 with Mark Manion, Eric Stouder, Harold Coleman and Jim Edwards to discuss 5415 product specifications and to help solve a "window" problem in thin flexible film applications.
On 5/20, Dan Preston with Dayton Extruded Plastics, visited the Plant to discuss 5385 and RP-151 specifications.
On 5/21, several representatives from Intex visited the Plant. The Intex group was given the Plant "Quality Presen tation" and a tour. Environmental and safety subjects were discussed. Proposals for 5415 resin specifications were negotiated also.
On 5/29, a representative from NAPCO and a consultant visited the Plant. The two were given the Plant "Quality Presentation" and the NAPCO representative was given a plant tour. NAPCO is interested in purchasing dry blend for siding manufacturing and eventually resin for their own blending unit.
05/03
The customer complained that 45541 Natural compound ran inconsistent. Variation from two lots of material made on two different lines caused the variability. Line I material was preferred over Line III material.
Customer complained of greater than
10% on the 200 mesh sieve analysis
for a 5385 truck shipment.
The
Aberdeen lab analyzed the truck to be
9.6% on the 200 mesh. DEP accepted
and used the shipment without
problems.
TARQBATOBT - Continued
Continued
5/06
The customer complained of receiving RP-34 WHT 142 instead of RP-34 WHT 141 as ordered. Apologies were made and the customer was able to use the material anyway.
The customer complained of high per centage on 40 mesh, "Blue Waxy Ball" contamination and low fusion torque readings on three compartments of RP151 railcar VIPX 45290. They were returned.
2/flZ
5/09
The customer complained of unmelted wax and excessive contamination in RP-151 railcar VIPX 45200. Also, UTCX 46587 had two compartments with high percentages on the 40 mesh. The material was returned to the Plant.
The customer complained of leaves, bark and polyethylene contamination in a hopper truck shipment of 39032 BIX compound.
05/13
The customer complained that RP-151 railcar 44676 was too yellow. In vestigation showed that Vista1 s color targets were different than DEP's re quirements. An adjustment was made in formulation to correct this difference.
The customer complained of high per
centage on the 40 mesh of compartment
NAM and undispersed wax prills in RP-
151 railcar PLWX 44676.
This
material was returned.
Htp mmmmm
VAB.0001189701
TJLBOBATOMT - Continued
Continued
05/13
The customer complained that all bolts on the railcar compartment bottom outlets were frozen from corrosion on PLUX 44676. During the investigation, the originator could not be found to answer questions concerning why the bolts had to be loosened.
05/16
The customer complained that 5415 lot 19720 caused a lumpy finish on coextruded flexible compound. Retains and samples sent to Aberdeen showed low hard particles. Aberdeen and DEP suspect raw (unplasticized) resin leakage in the DEP process that caused the problem.
05/16
The customer complained of burning and sticking with undispersed blowing agent in RP-461 UHT 110 railcar UTGX 46505. The material in this car was manufactured at the same time several trucks of RP-461 were made which ran great. It is suspected that this material is very sensitive to trans-
Railcar material is subjected to more material handling than truck shipments.
The customer complained of boxes collapsing of RP-34 WHT 142 when stacked three high. They ask that we only put 1300 pounds net in each box. These are the Premiere boxes and they are not as strong as the Aberdeen boxes.
VAB.0001189702
m
\
TABABATORY - Continued
05/21
Continued
The customer complained that because of lower than contract inventories of 30611 BLK in Aberdeen, 7485 pounds were shipped instead of a 42,000 pound order. Customer ran out of material.
05/28
The customer complained of line scale from 5305 railcar VIPX 45864. This line scale problem is the same one discussed at the last Plant meeting with Mirrex.
05/28 Chelsea
The customer complained of an experi mental car of 489-100A WHT 144 that had two compartments which ex perienced "rat holing" while emptying the car. R&D Is investigating.
05/28
The customer complained that 5305 railcar UTCX 48070 produced "grainy film". Calcium analysis of retains showed high calcium concentrations. This resin was made through the old decalcification system just before it was shut down permanently. It is suspected that a manual valve turning sequence was misaligned.
05/29 Flexible
The customer reported "grainy" finish
on vacuum cleaner hoses.
High
moisture content in 57121 WT CL 327
was the cause. Several boxes were
returned to Aberdeen because of
cloudy-looking
(high
moisture)
pellets.
VAB.0001189703
LABORATORY - Continued
05/29
Continued
The customer complained that the last six trucks of 80273G has not . processed as well and has a different color (not as white) as material they use to get. Ted Nickerson is investlgating.
The customer complained of streamers in a hopper truck of 35031 Natural. A formal written explanation was sent.
The customer complained of lower gloss and lower impact strength than typical RP-20 WHT 121.
Dayton Extruded Plastics
RP-151 WHT 145 "L" Color
1 R/C
Electriflex H&W Plastics
Intex Stylecrest Vinyl Building
Products
58661 GRY 550
Hard Particles
1 H/T
5385-3P
Static Flow &
2 H/T
Contamination
5305
Inherent Viscosity 1 R/C
RP-27 WHT 113
40 Mesh & F. Torque 1 R/C
RP-20 WHT 121
Stability
1 R/C
Vycom
RP-461 WHT 110
40 Mesh
2 H/T
*
VAB.0001189704
umbatmt - Continued
'""N
The following is a sunaary of residual VCH results on inprocess samples. None of the reactor daily averages ex ceeded 400 ppm RVCM during the month of Hay, 1991.
Reactor
Number of Samples Average RVCM, ppm
947 41
0
98 0.491
The following is a summary of the residual VGK analysis of shipment samples for the month of May, 1991.
5265 5305 5325 5385 5395 5415 Debox Pond Dry Blend
3 123
0 61
1 68 16
4 13
0.050 0.121
0.301 0.011 0.050 0.449 0.045 0.041
F. (based on dryer "regulars")
5305
5385
5415
Bulk Density Inherent Viscosity
(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
0.92 0.69 0.31 0.96 2.67 0.87 3.83
----
2.43
...
-----
172
1.16 0.41
---
1.93
----
1.44 7.83
----------
4.10
--- ...
10.2
180
1.33 0.64
----
2.83
----
2.50 7.83 2.83 7.17 4.51 2.16 4.2
190
There was no 5265 or 5395 produced during May.
'L
I
VAB.0001189705
TAiMBATngT - Continued
M Lbe. %
Hardness Color Hard Particles Contamination Dicing Cross Contamination Streamers Metal
Totals
327.8 <5.26>
__________________ 327.8 <5.26>
Summary
Color 40 Mesh Moisture
Total
M Lbs. XU
5.6 14.3 12.9 32.8
<0.12> <0.32> <0.29> <0.73>
M Lbs.
6.0 <0.10> 10.9 <0.17> 123.4 <1.98>
2.1 <0.03> 12.0 <0.19>
1.6 <0.03> 3.2 <0.05> l* 8 <Q. 162.0 <2.60>
1. All natural teams met once during the month.
2. Assistance was given to the OASIS implementation team to help set up hardware.
3. Hardware connections are now complete and the software for lab data entry in the Vinyl VAX computer is continuing.
4. A precision study of the resin viscosity instrument was completed which showed almost all variation currently is due to the instrument (+ .0075 for 3 signa control limits). Work is underway to reduce this variation.
VAB.0001189706
\
RESIN Ship Date 5/01/91
5/01/91 5/01/91 5/03/91 5/03/91
5/03/91
5/03/91
5/03/91
5/07/91 5/08/91
5/06/91
5/13/91 6/15/91 5/17/91 5/17/91 5/20/91 5/20/91 5/22/91
SAMPLE SHIPMENTS MAY 1991
Product
5415
5385
5305
5385
5265 5305
5265 5305
5265 5305 5385
5265 5305
5385
5385 5395 5415
5385 5415
Pond Resin
5305
5265
5415
5385
5415 Control
5385
Amount
1 kg.
5 kg.
50 lbs.
50 lbs.
10 kg. 10 kg.
10 kg. 10 kg.
3 kg. 3 kg. 3 kg.
10 kg. 10 kg
10 kg.
5 lbs. 5 lbs. 5 lbs
10 kg. 10 kg.
2 lbs.
100 lbs.
200 lbs.
50 lbs.
5 kgs
50 lbs.
50 lbs.
Customer FABRICA ARGENTINA DE
ALPARGATAS SAIC PEVECE S.A. (Argentina) Alcan Building Products PLASTIGAMA (Ecuador) ANIONS S.A. (Argentina)
VINISA FUEGUINA (Argentina)
PAVCO (Columbia)
PRINCZ S.A. (Argentina)
NEOPLAX S.A. (Argentina) RJF International Corp.
NEOPLAZ S. A. (Argentina)
H. Heller and Co. AGRICOMINSA PVC Container Corp. Gary Corporation IND. E COM. CARDINALI Vista - OKC INTERNACIONAL PROCURACIONES
VAB.0001189707
RESIN (Cont.)
Ship Date 5/22/91
5/23/91 5/28/91
Product
5265 5415
5325
5385
5/29/91 5/29/91
5265 5305
5385
Sample Shipments/May 1991
**** `
Amount 50 lbs. 50 lbs. 100 lbs. 5 kg
50 lbs. 50 lbs. 50 lbs.
Customer CONDUCOMER
Polycast FIOS E CABOS PLASTICOS
(Brazil) Eri Extrusion Inc.
Synthetic Products
COMPOUND Ship Date 5/02/91 5/06/91
Product 34311 NAT 419-73-A NAT 02
5/07/91 5/10/91
5/16/91 5/17/91 5/30/91
54431 CB 50
416-194-1 419-103-C NAT 02
18831 WTCL
46234A BLK
35852 NAT 02
Amount 200 lbs. 400 lbs.
100 lbs. 500 lbs. 500 lbs. 100 lbs. 600 lbs. 1500 lbs.
Customer Tandy Wire & Cable Arizona Electric
Fabricators Inc. Tandy Wire & Cable Furon Company
Florida Central Extrusion LOF Savannah Wire A Cable Co.
DRYBLEND Ship Date 5/02/91 5/06/91 5/29/91
Product 489-106A NAT 489-108A WHT 144 489-116 WHT 145
Amount 1300 lbs. 4200 lbs. 1300 lbs.
Customer General Binding Corp. Chelsea Building Products Dayton Extruded Plastics
VAB.0001189708
*i
NUMBER OF
i i i i i TTTTTTT
M M J S N J'89 M M J S N J'90 M M J S N ^91 M M
MONTH
TOTAL INJURES
OSHA RECORDABLE
VAB.0001189709
n/fiu
VAB.OOOl189710