Document zo7NB98rQ21Y0w1DDRLVqrEV6

ntwoflkt Communication To: From: Data: Subject: T. H. Huffman RECEIVED MUS 2 9. 90 D. C. Skokna March 26, 1990 WILLIAM L. McCLAlN ABERDEEN MONTHLY PROGRESS REPORT FEBRUARY, 1990 VIS1A Safety There were no injuries reported during February. At month's end, the Aberdeen plant's employees have worked 3891 days (5,168,371 manhours) since the last lost time injury. FY 1990 Kev Statistical Information February Y.T.D. 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 Canacitv Utilization Factors 36.5 92.5 95.3 1.0055 6.1 98.1 ' 4.3 99.4 1.3 91.0 < 17.0> 121.8 < 24.2> 179.5 84.8 96.5 1.0007 29.8 98.0 21.4 99.4 6.9 89.8 < 13.4> 141.2 243.8 Resin Flexible Compound Rigid Compound Plasticizer Operations 105.6 69.0 93.2 73.3 95.4 76.1 99.4 77.0 Initial testing of a proprietary clean wall agent in the resin unit was completed. Results are promising. Demand for flexible compound continued strong in February and production schedules were tight all month. Line I ran forty-eight hours on PLENEX polymers trials. On Line V, a test run was done to optimize screw configuration for rigid compound production. CCR 000006260 T. H. Huffman 3/26/90 Aberdeen Monthly Progress Report - February, 1990 Page 2 The dry blend unit set a new single day record on 2/1 producing 378.4M pounds; the previous record was 356.6M pounds. Dry blend orders continued to be strong during the month. A 10M-pound sample of foamed sheet dry blend was produced for Vycom. During the run, an experimental design (varying batch size and drop temperature) was done. Costs Variable costs were above budget, primarily due to product mix in compound and above budget raw material usage in the plasticizer .unit. Fixed costs were below budget due primarily to good results in the MM&C category and less than budget expenditures in some of the miscellaneous items. QMP 1. Ninety-five percent of the plant's natural teams met during February. 2. The Old Module Recovery Team made its management presentation. They recommended revisions that resolve some safety concerns experienced main taining the compressors and vacuum pumps in this system. A capital request ($60M) will be submitted in the third quarter to implement these recommendations. This team found very cost- effective ways to correct the safety problems. Previous estimates to correct the same problems were about $500M. 3. El Paso PVC (a division of Group Dekko) visited the plant on 2/9 to become familiar with our plant. They purchase 5415. 4. An experimental design was done in the dry blend unit to evaluate the effect of batch size and drop temperature on blowing agent dispersion in foamed sheet dry blend (for Vycom). ooooo^V CCS- T. H. Huffman 3/26/90 Aberdeen Monthly Progress Report - February, 1990 Page 3 QMP - continued 5, On Line III, an experimental design was done to determine how temperature and shear affect fusion delay. Doug Skokna Plant Superintendent rah CCr 0000626i DISTRIBUTION Houston J. D. Bums COVER LETTER X ENTIRE REPORT R. T. Ferrell X T. H. Huffman X C. J. Matson X D. F. Harman H,, R. FIaminer .--j. X X R. R. Smith * B. J. Bean X X R. H. Gerlach X R. D. Gamblin X K3E3?HcClal3 X J. P. Stokes X Austin R. L. Poe X H. J. Hall X Oklahoma Citv H. D. Garrison X LCVCM Plant R. A. Conrad X LCCP Plant J. Friend X LCIAB Plant J. W. Ware X Baltimore L. R. Bauer X Hammond J. Pavao X Blane Premiere Aberdeen C. R. Miller P. L. Foote RWS/DCS (File Copy), JEB, JME, SCH, MRK, JEL, DAM, RBN, JEN, JDO, REP, BLT X X ooooof*163 cc* SAFETY - B. L. Trego, J. V. Uptain February Fiscal Y.T.D. 1990 Fiscal Y.T.D. 1989 First Aid OSHA Recordable Total Injuries 0 - 0 66 JL 98 Number of Restricted Workday Cases 0 2 1 Number of Lost Workday Cases 0 0 0 Injuries bv Department Vinyl Operations Compound Operations Maintenance Laboratory Receiving/Warehouse Office Totals 0 0 0 0 0 0 0 Injuries bv Tyne Cuts and Abrasions Eye Injuries Bums Bruises Strains/Sprains Stings Other Totals 0 0 0 0 0 0 0 0 Non-Occupational Injuries Lost Workday Cases Days Lost 0 0 Safety Record last lost time injury Days since * 7/5/79 3891 Employee hours since - 5,168,371 On February 28, 1990, the employees of the Aberdeen plant completed 3891 days with no lost time injury. The main topic for plant safety meetings during the month was a review of the plant's new safety handbook. There was nearly 100% attendance to these meetings. CCR 00006^4 SAFETY - Continued Routine dosimetry results for the month were: Chemical VCK Lead Total Particulates _______< - PEL Huffbey Percent 69 100.0 11 100.0 5 100.0 > PEL_________ Number Percent 0 0.0 0 0.0 0 0.0 Monthly Injury Snnmtflrv There were no injuries reported. QUALITY MANAGEMENT PROCESS - M. R. Kane Ninety-five percent of the plant's natural teams met in February", some for the first time. The facilitator team is working with the teams to teach them team management techniques. t The departmental support scorecards were finalized so that each employee knows how their contribution affects the plant scorecard. Also, the Q-Scorecard was finalized and communicated to the plant. One customer visit occurred during the month. ElPaso PVC (a sub sidiary of Group Dekko) visited to tour the plant and learn a little more about PVC production. . TL. '}" ,,oooo6b CC* L COST VARIANCES - D. C. Skokna Variable Costs Product February. 1990 Variance. $M Efficiency Price Total PVC Flexible Compound Rigid Compound Plasticizer <$11.7> 90.5 <81.9> <21.1> <$26.2> $834.0 175.7 215.7 ____21a $1248.7 $822.3 266.2 133.8 2.2 $1224.5 PVC - Efficiencies were essentially at budget. Flexible Compound - Product mix ($76.3M favorable), raw material use ($15.2M favorable), and lower than budget off-grade ($11.OH favorable) were the contributors to the overall favorable variance. Rigid Compound Product mix caused essentially all of the month's variance. Plasticizer - Raw material use was above budget. Price Variances $M - VCM - Resin to Rigid Compound - Resin to Flexible Compound - Alfol8 610 - Electricity - Ti0a - Other Price Variances Total Fixed Cost Variances $816.7 203.6 157.9 16.4 11.7 10.1 32.3 $1248.7 - Payroll and Benefits - MM&C - Miscellaneous - TI&D - Clearances Total $ 6.2 51.7 59.0 5.6 < 0.7> $121.8 Payroll and Benefits - These were essentially at budget. M. M. & C. - This category was favorable due to low activity levels. CCR 000006267 COST VARIANCES - Continued Miscellaneous: Major variances in this category were: Unclassified: $10.7M favorable - Physical exams were budgeted in the second quarter but will occur in March when the charges will clear. Contract. Operating: $12.2M favorable. Strike preparation costs of $30M were budgeted in the second quarter. Charges have not cleared (should clear in March or April). Processing Supplies: $10.1M favorable. Switching Costs: $13.9M favorable. This month's invoice was late. r. i Tsv ;> -s.v* ' rvco jp* ooooo^8 ct* VINYL - J. D. Olson, K. W. Birck Safety The Vinyl Department did not have any first aid or OSHA recordable injuries during the month of February. The monthly safety meeting topic for the month was the new safety manual. General 1. Initial clean wall testing was completed during February. Results continue to look promising as reactor walls repeat edly and consistently coated with clean wall agent prior to charge have remained clean. Next month a new temporary test clean wall injection system will be used. This new system will be designed to provide better clean wall application. 2. Startup of the V-ll natural gas detectors was completed in February. This plant safety feature shuts down the dryer direct fired burners whenever a high level of natural gas is detected in the dryer building. 3. The resin raw materials in the 744 account were valued at $349.1M. Februarv YTD - Production, MM Lbs. - Daily Rate, M Lbs./C.D. - Capacity Utilization Factor, % - Total Reactor Charges - Charges/C.D. - Reactor Stream Factor, % - Rotary Dryer Stream Factor (#4-#8), - Fluid Bed Dryer Stream Factor, % - Resin Quality, % Prime % Reactor Downtime 36.6 1307.3 107.2 854.0 30.5 92.5 85.7 96.7 95.3 179.6 1189.5 97.6 4203.0 27.8 84.8 73.5 88.2 96.5 Hours - Operational downtime (recovery scheduling conflicts, rinsing chea wash tanks, New Module rinse/charge water conflicts, no place to dump, 0-rlng leaks, waiting on Q.C. data before charging, and inclement weather). 229.0 Maintenance downtime (hydroblast reactors and drill condensers D700, replaced con denser base gasket on D741, drilled 741 condenser, replaced agitator seal on D400, repaired reactor jacket on D400, replaced reactor Lanape manway on D300 and miscella neous instrument and valve repairs). 275.0 co? VINYL - Continued Drver Downtime Reactor limited production. Operational downtime (centrifuge plugs, check for dust collector leaking, clean dryers, activator transfer problems, and flameouts). Maintenance downtime (centrifuge repairs, replace north fluid bed centrifuge, shear pins, exhauster maintenance, hydroblast centrate line, sparge pipe replacement and Bird boot repairs). % of Total Downtime 66.7 16.5 16.8 Kev Maintenance Work - J. B. Autrey, J. B. Hegwood Reactor 400 was shut down during the month for repairs to the water jacket. A crack developed in the weld between the water jacket and the reactor vessel. Also during this time, the seal was changed out on the reactor because of an excessive oil leak. The seal was in service for nine months. - The north fluid bed Bird centrifuge was changed out during the month because of a minor vibration problem. The vibra tion was caused by a calcium carbonate buildup. The Bird was replaced with a spare. The Bird that was removed will be re built and used as a spare. Reactor 741 was shut down during the month because of a leaking gasket on the condenser base. The gasket was replaced with a Flexitallic spiral wound gasket and the condenser was drilled because of cooling control problems. The "B" recovery compressor was changed out during the month . due to decreased performance. It was replaced with a spare compressor. The #5 dust collector conveyor screw was changed out with a spare during the month. The screw shafts have been breaking because of an excessive torsional stress. Several options are being considered at this time to alleviate the problem. The #8 Bird centrifuge was taken out of service during the month, rebuilt and put back in service. Reactor 700 was shut down during the month drilling and hydroblasting as part of the control program. for condenser contamination - Reactor 742 was shut down for condenser drilling during the month because of cooling control problems. CCR 000006270 VINYL - Continued Key Maintenance Work - continued The north chem wash pump motor was changed out with a spare during the month because of bad bearings in the motor. - The vinyl control room UPS unit was shut down for repairs on its systems control board and battery backup system. The systems control board was replaced along with three batteries. The old unit centrate exchanger was shut down for drilling and acid-cleaning because of an excessive calcium buildup. - There were eight major valves changed out in the reactor area during the month. ; ,~a: 00006g7l COMPOUND - J. E. Nickerson, K. G. Akins Safety The Compound Department worked without injury in February. The new safety handbook was reviewed in the monthly safety meetings. Demand for flexible compound continued strong in February. Produc tion schedules remained tight throughout the month. Line I rates were reduced by 48 hours of PLENEX polymer production and fiftyfour hours of roll mill maintenance. Line V was down for fortyeight hours during a test run to optimize screw configurations for production of rigid compounds. Work began on an experimental design on Line III to determine how temperature and shear affect fusion delay. On February 1, the dry blend unit produced 378,370 pounds to set a new one-day production record. The previous record was 356,554 pounds set on January 6, 1990. As in January, the orders for rigid compound were heavy. A 10M pound sample of foamed sheet dry blend was produced for Vycom in February. An experimental design was conducted during this production to determine the effect of batch size and drop temperature on blowing agent dispersion. Samples of 80273G dry blend produced after the foamed sheet dry blend were sent to R&D to determine the extent. If any, of blowing agent con tamination of subsequently produced materials. Rates were slightly reduced in the plasticizer unit as two plasti cizer reactor agitator assemblies were replaced. The final two re placements will be completed in March. Operating Conroound Production Davs _________Production (K Lbs . > Month Ave./Dav Fiscal Y.T.D. Line I 27 Line III 28 Line V 21 Total % Prime Capacity Utilization Factor Downtime 1733 64 3425 122 900 Jil 6058 229 98. 1 780 Hours 9965 16576 3239 29780 98.0 .764 Line I - Product Changes - Mill Maintenance - PLENEX Polymer Testing - Miscellaneous Maintenance - Dicer Problems & Maintenance 81 54 48 19 14 CCR 0ooq6272 COMPOUND - Continued Downtime - continued Line III - Product Changes Miscellaneous Maintenance - Quality Problems and Control Mill Maintenance j. Line V Hours 60 37 9 9 - W-P Maintenance - Rigid Compovind Test Run " - Quality Problems & Control - Weigh System Maintenance - Product Changes J Miscellaneous Maintenance 52 48 44 42 36 17 Operating Davs Month Production (M Lbs.)_____________ Avg./Day Fiscal Y.T.D. Rigid Compound 28 5481 % Prime 99.4 Capacity Utilization Factor .930 196 22578 99.4 .754 Downtime Hours - Product Changes - Quality Problems & Control - Miscellaneous Maintenance 82 40 26 Operating Days Month Production (M Lbs.^_____________ Avg./Day Fiscal Y.T.D. Plasticizer 28 % Prime Capacity Utilization Factor 1404 91.0 .679 50 7704 89.8 .752 Key Maintenance Work - J. B. Autrey, J. B. Hegwood The Line V twin screw extruder was shut down during the month so that the lubrication system could be cleaned. The filters and oil tank were also cleaned. The Line I mill was shut down during the month for repairs to its gears. The gears were removed and flipped because of excessive wear on one side of the gear teeth. A new set of gears has been placed on order. CCR 00006273 COMPOUND - Continued Kev Maintenance Work -continued - The front rotary joint on the Line III mill was re placed during the month and repairs were made to the hydrotherm line also. The rotary joint on the Line I Banbury gate was re placed during the month. - The middle cooling tower pump was taken out of service because of bad windings in the motor. The motor is being repaired and the pump will be put back in service as soon as possible. The temperature control loop on R-2 plasticizer reactor was repaired during the month. i CCfc ooooo*" UTILITIES - J. B. Autrey, J. B. Hegvood The #5 water well was put in service on 2/19/90. The calcium carbonate levels in this well are significantly less than that of the other wells. Pond aerators #3, #4 and #8 were shut down for repairs during the month. The motors were replaced in aerators #4 and #8. Number three had a bad ground wire that was repaired. q&'r i:..; CCR 00006275 ENGINEERING - R. E. Polk, S. C. Hillman, M. R. Kane PROJECTS IN DEVELOPMENT - GENERAL 5305 Decalcified Water Teat: The test run for removing calcium in 5305 charge and rinse water will begin the week of March 12. The test will involve diverting charge and rinse water for 5305 made in 745 reactor through a water softening bed. Samples will be sent to BASF for calendaring evalu ation. If BASF sees an improvement in graininess, a car will be offered to Klockner for evaluation. EVC Clean Vail Technology The closed reactor temporary addition system for 745 was completed March 7. The system is being tested. Results from the testing will be used to design a permanent addition system for all vinyl reactors. "' - TC Waste Water Compliance A class "A" design is being prepared to provide instrumentation and equip-ment to improve the reliability of the batch water strippers. This will be needed to meet TC waste water limits. Interaction Management Engineering, department heads and supervisors attended Interaction Management seminars conducted at the Best Western. Plasticizer BOD/COD Reduction Baffling of the existing biodisc has been identified as a way to improve BOD/COD performance from the biodisc. A baffle will be in stalled between the second and third cell in mid-March, after which sampling will be increased to determine the amount of BOD/COD reduc tion that can be achieved. Of the four offers made for permanent process engineers, three have declined. CCR 000006276 AFE NUMBER PROJECT DESCRIPTION AB5B DBIS A319 A6H A909 C9I7 D6I? D629 07D9 D78? DB4? DB59 F579 F66? F699 F73? F77? 636? 6657 67J7 675? 681? 6839 H677 H729 H76? HB27 HB7? A54Q H500 H5I0 H520 L530 ALTERNATE NATURAL BAS PIPELINE VINYL VALVE UP6RA0E PLANT ELECTRICAL UP6RADE VINYL CONTROL SYSTEN MODERNIZATION INERTS RENOVAL NOD1HCATIONS NEW MATER NELL PROPANE STORAGE AREA SELU6E SYSTEN CONFOUND REBLEND TRANSFER SY5TEN LEAO HANDLING AND EXPOSURE REDUCTION INERT 6AS PUR6IN6 OF PA TANKS CONFOUND LINE 3 SEMI-BULK LEAD HANDLIN6 CONPOUND SILO BRID6E BREAKING CONPOUNO BOXING HOPPER NA6NETS CONPOUND LINE 3 HEATED PLASTICIZER LON MOLECULAR HEIGHT RESIN EXPANSION DRYER NO.0 CONTAMINATION REDUCTION DRYER NO.A CONTAMINATION REDUCTION DRYBLENU OIV.VALVE AND CHUTE REPLACEHENT NEN DRYER BA6HOUSES CONPOUND SEWER REVISIONS HASTE OIL REDUCTION VCR SI6HT GLASS REPLACENENT PLANT HATER RECYCLE PLASTICIZER REACTOR AGITATORS TORQUE RHEOMETER REPLACENENT PLANT DIVERTER VALVE REPLACEHENT RECOVERY SYSTEN COMPRESSOR - SPARE ROOF UPGRADE REDUCED FLAME b SHORE COMPOUND PROJECT PLANT HATER SYSTEM NEST INCINERATOR REPLACEMENT MISCELLANEOUS CAPITAL PROJECTS < MSN FURNITURE AND OFFICE EQUIPMENT ABERDEEN CHEHICAL PLANT APPROVED CAPITAL PROJECTS STATUS THE SYSTEM HAS BEEN STARTED UP AND IS OPERATIONAL. PUNCHLIST ITEMS ARE IN PR06RES5. INSTALLATION IS IN PR06RESS AND PLANNED FOR COMPLETION IN APRIL. CONSTRUCTION IS ?5X COMPLETE AND IN PR06RE9S. PROJECT COMPLETION IS PLANNED FOR MARCH. ENBINEER1NB IS IN PR06RESS. CONTROL ROOM PRE-HORK ITEMS ARE SCHEDULED FOR COMPLETION IN MARCH. DESIGN IS IN PROGRESS KITH COMPLETION SCHEDULED FOR MARCH. CONSTRUCTION IS COMPLETE EXCEPT FOR PUNCHLIST ITEH9. COMPLETION IS PLANNED FOR MARCH. INSTALLATION HILL BE COMPLETED IN APRIL. INSTALLATION IS CONPLETE EXCEPT FOR PUNCHLIST ITEMS. INSTALLATION IS IN PR06RESS NITH COMPLETION PLANNED FOR HAY. INSTALLATION IS CONPLETE EXCEPT FOR PUNCHLIST ITENS. LONG LEAD ITEMS HAVE BEEN PLACED ON ORDER. PROJECT COMPLETION IS PLANNED FOR 7/1. LONG LEAO ITENS HAVE BEEN PLACED ON ORDER. INSTALLATION IS PLANNED FOR COMPLETION IN JUNE. INSTALLATION IS COMPLETE EXCEPT FOR PUNCHLIST ITEMS. ENGINEERING IS IN PROGRESS. PROJECT COMPLETION IS PLANNED FOR HAY. INSTALLATION IS IN PR06RESS NITH COMPLETION PLANNED FDR NAY. THE PROJECT HILL BE CLOSED TO FIELD CHARGES IN HARCH. A CHANGE ORDER HAS BEEN APPROVED FDR MODIFICATIONS TO 15 DRYER. DESIGN IS IN PR06RESS. PROJECT COMPLETION IS PLANNED FOR APRIL. REDESIGN OF THE BA6H0USE SCREH FEEDERS IS IN PROGRESS. INSTALLATION IS IN PR06RESS KITH COMPLETION IN NAY. INSTALLATION IS IN PR06RESS H1TH COMPLETION PLANNED FOR APRIL. DESIGN 15 IN PROGRESS. PROJECT COMPLETION IS PLANNED FOR APRIL. DESIGN JS IN PROGRESS. PROJECT COMPLETION IS PLANNED FOR JUNE. INSTALLATION IS SCHEDULED FOR COMPLETION IN MARCH. THE PROJECT HILL BE CLOSED TO FIELD CHARGES IN HARCH. INSTALLATION IS COMPLETE EXCEPT FOR PUNCHLIST ITEMS. THE COMPRESSOR IS SCHEDULED FOR DELIVERY IN APRIL. THE PROJECT N1LL BE CLOSED TO FIELD CHARGES IN MARCH. DESIGN IS IN PROGRESS TO PROVIDE C00UN6 MATER TO THE BANBURY ROTORS. ENGINEERING IS IN PROGRESS. PROJECT COMPLETION IS PLANNED FOR HID'1991. EN6INEERIN6 IS IN PROGRES9. SPECS HAVE 8EEN ISSUED TO T-TKERMAL FOR REVIEN. ENGINEERING IS IN PR06RESS ON 23 PROJECTS. EQUIPMENT IS BEING QUOTED. ii290oooc voo ENVIRONMENTAL - F. G. Jeanson Water All wastewater discharge parameters were met for the month of February. Bioassay testing was also completed on centrate containing the new clean wall agent. Results were favorable. Mr The new air permit for our plant will be reviewed by the Mississippi Department of Environmental Quality (MDEQ) Board on March 13. We should have a new air permit shortly after that date. SARA The Section 312 report was completed and issued to the State, the Local Emergency Planning Committee (LEPC), and the fire department.' The 1988 Section 313 report was sent to us by EPA to be proof-read. The report was proof-read and returned to EPA. Waste The RCRA Biennial Report was completed and issued to the MDEQ. Waste shipments for the month included: - One bulk load of separator oil to Systech in Demopolis, AL. - One drum load of stabilizer spill to Technical Environmental System in LaPorte, TX. Chemical Waste Management will stabilize all loads going to the Lake Charles facility at the Emelle, AL facility. All of our drum loads of waste can now go to Emelle to be stabilized. From there, they will be transferred to Lake Charles. There will be an additional charge for the transfer; however, the total cost will be less than what we currently pay for transportation. Reports Completed - Monthly NPDES - EPA questionnaire on latitude/longitude of NPDES outfalls - Vinyl Institute Environmental awards questionnaire CCR 000006278 ENVIRONMENTAL - Continued Suoerfund A meeting was held with EPA (Region IV) to discuss the NUS Report and recommendations. A meeting was also held with Conoco representatives to review the NUS Report and look over the sites. A letter was completed with four tables summarizing the results listed in the NUS Report. Miscellaneous Joe Ledvina and I visited M&M Chemical, a waste oil blender, to qualify them as an option for recycle of burnable residuals. I attended a seminar on the Third Third Land Ban conducted by Chemical Waste Management. jj, ^ - :r. . I took the Certified Hazardous Materials Manager's exam this month. Bob Seymour and I attended a legislative reception in Jackson for the area representatives and senators, which was sponsored by the...:'. Aberdeen-South Monroe County Chamber of Commerce. CCR 000006279 ENERGY CONSERVATION - D. A. Moore February. 1990 I. Energy Conservation Data(t> A. Unadjusted EUI <16.8%> B. Adjusted EUI <17.0%> C. BTU/Lb. Product 2888.0 D. Total Energy Consumption MMM BTU 139.38 Fiscal Y.T.D < 13.1%> < 13.4%> 2791.0 663.67 II. Plant Energy Conservation Program A. Maintenance There were thirty-five energy related items completed in February, Twenty-nine of these items were steam leak repairs. The remaining six were steam trap-repairs. III. Boiler Operation Boiler Combustion Efficiency % .. Feb.. 90 Fiscal Y.T.D No. 1 No. 2 No. 3 83.3% 83.1% 83.0% 83.44% 83.32% 83.02% (1) Total energy usage is an estimate due to the plant electrical upgrade project being under construction. CCR 000006280 HtJKAN RESOURCE REPORT FEBRUARY, 1990 Personnel - J. E. Beall Employment: None Promotions/Transfers John D. Olson - Transferred from Lake Charles Chemical Plant, Operations Superintendent, to Operations Superintendent Aberdeen. Charles McDonald - Transferred from Senior Process Engineer - Aberdeen to Process Superintendent - Oklahoma City. Dvain Lucas - Transferred from Lab Lead Technician to Lab "A" Technician (due to Mike Gray returning to Lab) William Holcomb - Promoted from Storekeeper "B" to Storekeeper "A". None TERMINATIONS /RESIGNATIONS None TO/PROM LEAVE OP ABSENCE None CCR 000006281 ABERDEEN, MISSISSIPPI Salaried Employee* Hourly Employees Total Employee* FEBRUARY. 1990 MONTHLY PERSONNEL REPORT 76* Minority Employees #, % 172 Salaried 6 81 248 Hourly 66 38Z Employees (Hourly! New Employees 0 Terminations _______^ ____12______ --ME-- Hourly Min. Hired % Min. Hired Q 0J Hourly Min. Term.. Q -- - % Min. Term. 0 DEPARTMENTS PAR #EMPLOYEES MIN, EMpL %MIM. NEW HIRES YTD TERM. YTD. TURNOVER YTD. Warehouse 16 Gen. Plant 13 Maintenance 41 laboratory 24 Compound 40 Vinyl 33 Plasticizer 5 15 16 41 24 38 33 5 8 ' 53 ' Q 0 0 'o 5 31 Pw 00 10 24 P 0 9 0 5 22 P 0 0 0 26 67 P 0 0 0 10 30 0 0 0 0 2 40 0 _0_ 0 0 0o 00 00 0 00 00 00 Number of Applicants: Month 0 Year To Date 0 APPLICANT BREAKDOWN: # Minority 0 % Minority 0 * Female 0 % Feosle 0 * Includes L Co-op Student Hires (Hourly): Month 0 Year To Date ___0 Terminations (Hourly): Month 0 Year To Date Overall Turnover o 0 Projected Annual Turnover 0 CCR 0006282 ro CO IM s> O O O O r.'i O 11 O' o u * < eeava ........................... ahwvj ni Hivaa moj SWnOH INVId 1V101 eo*e ....... Aina ihmwmm ivnouvn moj BBnOH INVId 1V101 oe*89 ..................................... Aina Anr moj sanoH iNVid ivioi ee*0OA ez'E 62* 29*0 fl*0 B9'2 ee*ceei bsmi 2*i90 eo*e 0*992 INVid 1V101 ee*0 00*0 |00'0 00*0 00*0 00*0 00*0 00*0 00*9 09*0 00*0 SM3dl3H 1VM3N3D 00*21 2*9 |9'9 6C*0 00*0 92*9 00* IS 2*9 0'2 00*0 00*692 H3ZIDIiSV1d 00*081 9* 06*1 02*0 00*1 02*0 2*H 98*9 2*609 00*0 09*9l 9E*E 0* 1 aro S9*e 00*0 0S*E9 49*91 2*6101 00*0 00*99 E9*0 00*0 00*0 00*0 00*0 00*0 18*91 0*2t 00*0 6*626 0S*8I9 O0*2C6 1ANIA awiodwaa aH3i5 m 00*0 2*0 00*0 00*0 eo'o 00*0 00*0 6*6 0*96 00*0 00'26 8V1 lN3HdD13A3a 00*91 21*1 E*0 EE'0 00*0 00*0 00*1 6* 00*21 00*0 OO'VOE S3M01S 00*0 66*6 9B*8E 00* 1 eo'o 9B'2 0*69 20*91 2*Zt 00*0 52*056 3SnOH3MVfl 00*8 S2*0 00*0 00*0 00*0 00*0 00*0 2'l 2*9 00*0 00*21 SMOlINVr 00*94 E9*2 29*0 29*0 00*0 00*0 00*21 91* 2*291 00*0 00*2282 0V1 Db ee*9sz 20*S 21*9 EE* 1 6s*e 12*2 2*922 0E*21 2*699 00*0 2*6E9 33NVN31N1VH 00*0 99*2 EE'EE 00*0 00*0 EE'EE 00*891 00'2 0*98l 00*0 06*965 uiinn 00*26 99*1 00*0 00*0 ee*e 00*0 OO'O 28*E1 2*021 00*0 00*22I sanoH 31VQ 1V10I aiVdNON aivd SS3NMIS 1S01 SMH 3HI1 HIS TOHIN03 "KJHIN03NON aXHN SMH N0I1V3VA -01-MV3A 831 ID 33N3S8V JO I V SV sunoH 3H11M3A0 3HU MIS 3HUM3A0 _____ 3HH.iH3WVlSJQ.?.S-SVJ3H3SSS_____ __ SMOQH.3HU83AO__ 1 OMVA ld3fl 0661 `'Hvnam 6/9 /Z HI 06/S /Z HU 'SflVBH iH3Hiayd30 'nAr *Djr 'snu l., Nounaiaisia lU0d3M S1SATVNV SMflOH 1VlN3HiMVd3a INVId *1 V 3 1 H 3 H 3 N 3 3 0 M 3 8 V ABERDEEN CHEMICAL PLAN! DEPARTMENTAL HOURS ANALYSIS REPORT DISTRIBUTION L^T RUS, JFC, JVU, DEPARTMENT HEADS, FILE Id/ 2/8? THf 13/ 4/90 DEPT YARD UTILITY STR TIME HRS URKD HWERTTfOBORS OVERTIME HOURS NONCONTROL CONTROL ----------fiBSEHCrfiS'fi'rorSTRAICflT TIRE--------- OVERTIME AS A X OF ABSENCE OTHER YEAR-TO- VACATION: SIR TIME HRS LOST SICKNESS PAID N0NPA1D TOTAL DATE HOURS 0721.75 252.00 704.75 15.13 91.75 0.00 6.54 0.83 1.36 1.46 668.80 3236.50 144.00 050.50 24.78 252.00 7.80 0.60 0.00 7.80 7.44 '248.00 MAINTENANCE 27171.00 307.75 4487.25 17.05 1303.00 3.83 0.35 0.84 5.02 5.07 2440.00 QC LAB JANITORS 14987.00 1915.00 324.00 0.00 710.00 78.75 0.90 4.11 332.25 5.00 1.12 0.00 0.08 0.00 1.02 0.26 2.22 0.26 2.43 0.25 784.00 208.00 WAREHOUSE 5204.00 0.00 424.25 8.00 540.25 9.35 0.46 0.57 10.38 9.99 472.00 STORES 1504.75 0.00 50.58 3.01 28.25 0.00 0.00 1.01 1.81 1.72 124.00 DEVELOPMENT LAD 4554.50 00.25 423.08 10.74 27.25 0.53 0.00 0.07 0.60 0.57 536.00 DRY BLEND 4980.75 30.00 420.50 9.27 33.00 0.00 0.00 0.66 0.66 0.63 388.00 COMPOUND VINYL PLASTICIZER 32005.75 32257.50 4048.50 240.00 1152.00 00.00 2835.00 3204.75 140.75 9.59 13.09 4.9? 1857.50 519.25 153.75 2.40 0.48 2.3B 0.35 0.31 0.00 0.55 0.82 1.43 3.30 1.61 3.81 3.34 1456.00 1.54 1000.00 4.52 248.00 GENERAL HELPERS 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 TOTAL PLANT 130759 2512750" 14208755 12714 4455725 57T5 5727 5774 37T5 1720 9371755 TOTAL PLANT HOURSFORJURY DUTY............................................ 08.00 TOTAL PLANT HOURSFOR NATIONAL GUARD/RESERVE DUTY......... 12.00 TOTAL PLANT HOURSFORDEATH IN FAMILY............................ 300.00 o o p o oo O' rj 03 ADMINISTRATIVE SERVICES - J. E. Little Safety There were no safety Instances this month. Safety handbooks were distributed followed by a presentation from the Safety Department. Cost Savings Savings due to competitive bidding were 8,625 for February, and $71,464 for FY1990. Savings due to prompt payment discounts were $1,641 for February, and $10,517 for FY1990. Warehouse - Finished Goods Inventory Slow moving inventories are still a major concern. A revised listing of old compounds will be given to Fred Williams. ......... ' Flexible Compounds Rigid Compounds Slow Moving Compounds 811,474 101.120 912,594 Fred Williams was advised that approximately twenty-five percent of our packaged inventory was either slow moving or off-grade. '" Development Three employees attended Interaction Management Class at the Aberdeen Best Western: Fat Wells and Tommy Cummings, 2/14 - 2/16; and Mike Swierc 2/26 - 2/28. Ruth Morris was in Aberdeen 2/08 - 2/09 to work with Judy Frossard on the PMS conversion to PC application. Final conversion from the main frame is estimated to be 3/31/90. Several employees attended forklift training class on 2/27. Addi tional hands-on training is scheduled for March. Meetings 2/01 Supervisor meeting at the Best Western. 2/05 Jack Little and Mike Kane - Finalize Q-Support card. 2/08 2/13 Jack Little, Mike Swierc and Pat Wells - Develop procedure for handling Gold Bond raw materials. Jack Little met with Dale Reynolds from Exxon to review exchange balance. CCR 000006285 ADMINISTRATIVE SERVICES - Continued Meetings - continued 2/14 Bob Seymour and Jack Little met to review FY90 goals. 2/21 Teresa Pounders and Linda Michels attended a vendor appreciation presentation (Union Camp) in Lafayette, LA. 2/27 Jack Little met with Yellow Freight to review LTL discounts. Numerous negotiations/preparation meetings for the 3/19/90 contract expiration. CCR 0oo62S6 , ABZIDIII C8ZHICAL PLAIT SIIPPIIG ARALTSIS flBRRAtt 1999 -SIIPHHTS BT PRODUCTS- POBIriC SORTS 1PT/ITC IXCIAKI PUBLIC TTD IPT/ITC 2ZCHA8GI IISII-BOLI IISII-PACZAGID 18,852,060 9,163,540 0 471,054 221,200 886,150 91,757,892 48,000,110 1,234.909 1,770,156 1,167,950 0 FUIIBLI COHPO0BD-BDLI 1,507,510 FLIZIBLI CQHPQ08D-PACIAGIB 3,061,605 m BOSIIZSS 1,500 739,050 425,950 0 0 0 0 7,289,290 14,624,546 6,864 4,217,200 1,007,878 0 0 0 0 RIGID COKPOUSD-BOtil RIGID COHPOOU-PACIAGID 4,174,090 1,056,650 201,887 4,200 0 0 18,698,280 2,952,650 1,030,321 17,000 9 9 PLASTKIIll 170,920 00 608,680 1,223,000 364,000 TOTAL 28,440,626 11,630,590 886,150 135,788.219 58,565.788 1.598,900 -SIIPHHTS BT I0DI- B0LI: tflBEOABI* IISII FLIZIBLI COMM RIGID COHPOOID PLASTICIXII torn FIBIDA1I RAILCAR COSTOHII COHHOI P1CI0P CARRIER 153 11 36 11 0 6 21 3 2T 1 04 185 14 73 TOTAL 299 17 51 4 272 MTD* IISII FLIZIBLI COHPOOID RIGID COHPOOID PLASTICIZII TOTAL TTD 706 124 2T5 58 3 22 103 13 81 9 0 14 CCR 000006287 876 140 392 1,105 83 197 23 1.408 FACUGKD: tflBIUTO IISII FLIZIBLI COHPOOID RIGID COHPOQHD PLAST1CIZIB COSTOHII F1CI0P COIHOI CARRIER 5 IS 19 76 98 80 tore C08TA1RII AII/OPS 00 09 09 09 13 4 9 9 TOTAL 33 99 8 9 TOTAL FIB80AIT 24 99 0 0 17 140 *TTD mu FLIZIBLI COHPOOID RIGID COHPOOID PLASTICIUB TOTAL TTD 23 66 0 0 98 357 2 0 6 35 0 1 0 1 00 127 459 2 1 37 12 l 1 51 126 469 43 2 640 LABORATORY - J. M. Edvards, Jr. A. Safety - There were no safety incidents in the Laboratory for February. The monthly safety meeting topic was the "Vista Safety Handbook" with Billy Paul Sizemore in charge of the meetings. B. Customer Contacts - ElPaso, a FVC division of Group Dekko, made a plant visit to learn about our process. Vista supplies them 5415. C. Customer O.C. Problem Reports 2/01 _ - Klockner-Pentanlast. Gordonsville . GA - When the customer sampled this car, they found very high quantities of contamination. This was communicated to the plant and when the plant inves tigated the origin of the contamina tion, it was discovered that the car was loaded from a start-up silo. It . was quickly decided then to pull this car out and divert it to another customer less sensitive to contamina- .. tion. -- 2/06 - Condutel. Mexico - The customer re ported finding green pellets and black and grey contamination in 34501 BGE. Samples have been received at the plant and are being analyzed. D. Requests for Corrective Action 2/08 - AT&T Technologies. Omaha. NE - The corrective action requested was how to prevent future occurrences of contam ination in shipments of 34862 BGE 10 compound. The contamination was de termined to be "paper fibers" and the corrective action was to use only sham knives when opening raw material bags as they are Introduced to the system. E. Product Waivers Customer Product Reason No. B. P. Performance 5415 Static Flow 1 R/C Capito1/Guardian 5415 Static Flow 1 R/C Essex Group 5415 Static Flow 1 R/C Export 5265 Moisture 1 R/C CC 000006288 LABORATORY " Continued F. RVCM SiiTTffnar-v RVCM of In-Process Samples The following is a summary of residual VCM results on inprocess samples. None of the reactor daily averages exceeded 400 ppm RVCM during the month of February, 1990. Reactor Slurries _________Drier 5265 5305 Number of Samples Average RVCM, ppm 851 116 38 0.926 75 0.835 RVCM of Shipment Samples The following is a summary of the residual VCM analysis of shipment samples for the month of February, 1990. Product Number of Sanmles Average RVCM. 5265 5305 5385 5395 5415 5465 Dry Blend Debox Fond ' -- 46 96 54 0 62 0 61 12 14 0.733 0.565 0.680 0 0.053 0 0.124 0.854 2.350 Resin Process Caoabilities (based on dryer "regulars") 5265 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 Mesh Drytime Mets I.R. (vs. 95% of control) Hard Particles, (% > 10) Average particle size. microns 1.94 0.67 .... 8.11 6.33 3.17 2.33 -- 0.66 -- -- -- -- 142 2.50 0.35 0.18 2.53 3.83 2.83 1.21 .... 0.68 -- .... -- -- 138 2.03 0.75 -- 3.25 .... 2.67 2.58 .... 1.64 2.00 .... -- 7.9 160 1.08 1.14 7.17 7.00 6.17 1.17 5.33 2.00 3.33 2.07 1.2 173 CCR 000006289 Continued H. Flexible Compound Quality Summary Adjustments MJUfefj. jCH Hardness Color Hard Particles Heat Stability Dicing Cross Contamination Streamers Totals 7.0 <0.11> 7.0 <0.11> I. Rigid Compound Quality Summary Rejections M Lbs. XU 11.4 20.8 53.1 8.0 8.4 1.4 10.8 113.9 <0.19> <0.34> <0.87> <0.13> <0.14> <0.02> <0.18> <1.86> \ M Lbs. (%) Color Total 33.8 <0.61> 33.8 <0.61> J. Miscellaneous ~ "-.L 1; The HS 100 gas chromatograph used for RVCM testing was down for 2 1/2 days until repairs could be made. Perkin-Elmer had been called prior to the instrument failure. It took six days for Perkin-Elmer to respond with a repairman. 2. Dave Cox, Billy Paul Sizemore and Richard Williams attended a three-day course in Interaction Management. 3. Five of six natural teams met once during the month. "Team ... Meeting Planning and Management" was taught to each natural " team by their respective facilitators. 4. The IBM PC used for faxing certificates of analysis was down two days for repair. This computer had been in service five years without major repair. 5. A newer and better version of SQC software was used to report SPC charts of resin shipments this month. CCR 000006290 RESIN Ship Date 2/06/90 2/06/90 2/07/90 2/07/90 2/08/90 2/08/90 2/08/90 2/09/90 2/13/90 2/14/90 2/19/90 2/20/90 2/20/90 2/21/90 2/23/90 2/23/90 2/28/90 COMPOUND Ship Date 2/01/90 2/05/90 2/07/90 2/09/90 SAMPLE SHIPMENTS FEBRUARY 1990 Product 5415 Control Amount 50 lbs. Customer Vista - Ok. City Pond Resin 50 lbs. Conex of Georgia Pond Resin 5 lbs. VCLA - Houston Pond Resin 50 lbs. PARAGON TRADING Pond Resin .. 10 lbs. Osterman Pond Resin 200 lbs. IMP. & EXP. JOREGA SA DE CU Pond Resin Pond Resin Pond Resin 200 lbs. ~"T`lb. ' ~5 lbs. QUIMPAC CIA. LTDA. Ravago Company Kare Plastics Debox Resin 1 lb. Osterman 5395 .50 lbs. j. Decorative Coverings 5265 100 lbs. Morton International 5305 50 lbs. GLASSIDUR S. A, 5385 200 lbs. Premier Polymers 5305 5415 15 lbs. "V 50 lbs. Gassen Corporation DuPont Polymer Products 5415 400 lbs. INYECCIONES INDUSTRIALES Product 48562 BLK 34311 NAT PLENEX 419-50D 34431 NAT 35852 NAT Amount 5 lbs. 200 lbs. 200 lbs. 100 lbs. 100 lbs. Customer Premier Polymers - LGH Superior Cable Fluorocarbon CONDUCEN, S. A. CCR 000006291 COMPOUND (cont.) Ship Date Product 2/12/90 34311 NAT 38631 WHT 2/12/90 35852 NAT 2/27/90 39012 BLK 2/27/90 452-32A BLK Sample Shipments/Feb. 1990 Page 2 Amount 200 lbs. 200 lbs. 500 lbs. 200 lbs. 1500 lbs. Customer ELECTROCONDUCTORES ITT A. E. P. D. Superior Cable Times Fiber ------ --------------------------- - ;--------------------- -------------P---------T--------- . ------------ ----- - ---------------- - -------------------- '. - . ; -------- -- . - -... .......----- ----------- - ----- ----------------------- 1\ 000006Z92 cca ABERDEEN CHEMICAL PLANT INJURIES NUMBER OF NJURIES TOTAL INJURIES O OSHA RECORDABLE cc* 00006 293 3300 ABERDEEN ENERGY CONSUMPTION BTU/LB 3200 3100 3000 2900 an/rus 2800 2700 2600 2500 2400 ccr 000006294 2300 2200 JAN 87 JUL 87 JAN 88 JUL 88 JAN 89 JUL 89 JAN 90 MONTHLY MONTH --------- 12 MONTH AVERAGE S6Z900000 a UJ > UJ o UJ cc LT3 CCR 0 0 0 0 0 6 2 9 6 VISTA 5415 RVCM 2ND Q FV90 POLYMERS 04-03-1990 Individuals LCL=-.077B MEAN=0.0505 UCL=0.1789 USING TABULAR CONSTANTS, BASED ON 102 TO 329 1.0 0.80.6- CCR 0 0 0 0 0 6 2 9 7 VISTA 5415 RVCM 2ND Q FY90 POLYMERS Individuals LCL=-.O770 MEAN=0.0505 UCL=0.1789 04-03-1990 227 5415 RVCM 2ND Q FY90 VISTA POLYMERS IndividuaIs 04-03-1990 CO O' C4 sO oo * Moving range, n=2 LCL=-- MEAN=0.0483 UCL=0.1576 ucl 329 662900000 ttDD 0 in ri 0) CD CD CD CM o CM O) to CM o CM cn O) 0) > H in in n o in o in Ol o O) O) CD 44 4 *o o O ri CO ri o 44 r-l o ri H ri 1 1 >* 0 BIB n D B B CD 1 B B B 01 4-1 CD H 0 D) ri ri M ri U 09 u CD U a> CJ -rl CL 4- u CD u 09 Cd 09 a. cn cn CD a. OL cn CD Q. o. cn CO CO 1 cn co C. c. 3 cn cn CD CD M C. cn cn o *. | CL O) O. 3C U CD 3 o 09 ID * o o CO c O rt CL o *< r-i > .e o 1--1 4- 1-- > o o 49 c CD c CD cn o. o. c. .o 3 3 09 3 09 09 c_> U U N rj *<c CO O < CO O CO f- to D- CT) r- CD oo cn to r--. cn cn CM ri in cn r-. 'cr CO CD ri CO cn ri cn in 00 O 4 CD 4 r-i 4 O) 4 o 4 o o o o O CM in ri 44 m o> On) B c c c. ri CO 8 B o i cn o *o CM o> n. e O ^i 3 1 ri O. CD O CD o- n o > CD CD > H CD CD 0) o e c_ 3 3 c 1-4 o> CO rl cn > ri CD > r-l CD > cn ri cn o ri 09 4 09 C. 09 > cn CD 09 09 cn 3 c_ a> O" +- 0) > Ll 4 C. cn D _ 09 CD <u 0-1 *--i CM X CD c f-l m o o t--1 < ri r-i CD r c R L> 4 CD O) -4-* (D cd ri cn O H cn UJ Cd o 4-1 cn 4 CD X c. a> -ri 09 C 4-1 CD 3 .X 09 o 09 DC x: cn CJ> *3 o CD o cr 5 3 8 5 RVCM 2ND X (n L 0) E > i--i 1 ' 1 2.6261 2.4368 2.2515 2.0641 1.6768 1.6895 1.5021 1.3148 1.1275 0.9401 0.7528 0.5655 0.3781 0.1906 0.0035 HH-i TT T-TTTT CT*-> TT7T C\J TTTTT