Document 0oQpwqwnyBr8D7QDmdDN09jb
VINYL - D. W. Hollis/M. L. Nathan
Safety
The Vinyl and Yard Departments operated with one first aid type injury in February. The injury involved a minor cut to a General Helper's finger.
Shift safety meeting topics for the month included review of the revised Power Outage Operating Manual and discussion of responses to emergency situations.
Production
February Y.T.D. (Fiscal 1985)
1. Production, MM Lbs. 2. Daily Production Rate, M Lbs./C.D. 3. Total Charges
4. Charges, Reactor Batches/C.D. 5. Reactor Stream Factor 6. Dryer Rate, Average Lbs./Hr. 7. Dryer Stream Factor 8. Accounting Days
31.5 1123.6
770.0 27.5 86.7
10521.9 55.6 28.0
172.8 1144.3
4170.0 27.6 90.3
10604.3 57.3
151.0
A
Reactors
The reactor stream factor penalty was 86.7%. Downtime in the reactor area occurred as follows:
1) Operational Downtime: Accounted for 39.7% of the total downtime and was due to reactor scheduling conflicts, winter operation periods, and processing VCM contaminated with caustic.
2) Maintenance Service Downtime: Accounted for 2.3% of the total downtime and was due to rupture disc changeout on 743 and cleaning reactor AMS injection ports.
3) Maintenance Repair/Revision Downtime: Accounted for 58.0% of the total downtime and was due to four reactor valve changeouts, condenser cleaning on 742, agitator seal replacements on 300, 741, 743, 744 and 745 reactors, reactor dump screener repair, and revisions to new module VCM charge system to aid in processing contaminated VCM.
Dryers
The dryer stream factor penalty was 55.6%. Downtime in the dryer area occurred as follows:
1)Reactor Limited Production: Accounted for 86.6% of the total downtime. Dryers were shut down when possible for energy conservation purposes.
VAB.0001187076
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VINYL - Continued
Dryers - continued
2) Operational Downtime: Accounted for 9.2% of the total downtime and was
due to centrifuge plugging, burner flameouts, dryer cleaning, and trans fer activator problems.
3) Maintenance Repair/Revision Downtime: Accounted for 4.2% of the total downtime and was due mainly to activator repairs, exhauster bearing replacement, and centrifuge repairs.
Product Quality Summary
Resin Type
Prime
% of Total "BC" "H" Production
5265 5305 5385 5425 5465 Sifter Overflow Pond Resin
Total
1,605,432 2,606,576 18,537,760 6,332,571 2,055,560
-
-
31,137,899
90,000 56,250
--
--
--
-
146,250
--
--
--
--
209,470 ( 33,200) 176,270
5.1 8.6 59.1 20.1 6.5 0.7 ( 0.1)
100.0
Quality performance for February was 99.0% customer grade with 0.5% "BC" duction and 0.5% MH" grade.
A total of two railcars werei shipped as " B" grade during the month which represented 1.8% of the 109 total resin hopper cars shipped.
Ship Date
Car No. Customer
Product
Reason
2/22/85
PTLX 41591 Grifco
Resifted Sifter Overflow
Quali ty
2/28/85
VIPX 45918 Si 1 verline 5425
Contamination
The Vinyl area received thirty-six short lead time emergency type orders comprising 16.1% of the 224 Aberdeen resin shipments in February.
Monthly Variable Cost Performance
Variable costs for the month were favorable $210.5M with $157.2M due to price and $53.3M due to efficiency. Resin variable cost for the month was 20.214 </lb. vs. the budgeted 20.887 /lb.
The $210.5M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $90.4M; lower than budgeted pricing for VCM freight, $30.5M;
lower than budgeted pricing for Lupersol 223 initiator, $31.2M; and lower than budgeted pricing in the utilities area, $13.4M.
VAB.0001187077
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VINYL - Continued
Monthly Variable Cost Performance - continued The $53.3M favorable efficiency variance can be attributed to lower than budgeted VCM efficiency, $39,5M; and lower than budgeted off-grade produc tion, $10.1M. VCM efficiency for the month was 0.99788 lbs, VCM/lb, PVC versus the budgeted 1,00500 lbs. VCM/lb. PVC. Year-to-date VCM efficiency is 1,00343, Year-to-date variable cost efficiency variances in the Vinyl Department totaled $305.4M favorable. Energy Performance/Progress 1. Plant energy consumption for the month totaled 2603 BTU/lb,
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2. A total of six steam leaks and seven steam traps were repaired during the month.
General 1. Packaging for the month totaled 683,950 pounds, 2. Resin raw material in the 744 account totaled $165,0M at month end.
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VAB.0001187078