Document 4vV1KQgaw00RDoLgY1jdNQ8ve
VINYL - D. W. Hollis/M. L. Nathan
The Vinyl and Yard Departments operated without an injury in June
Shift safety meeting topics for the month included annual VCM Health Training, Noise Safety and Asbestos Training.
Production
.1 Production, MM Lbs.
2. Dailv 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
June
28.8 960.3 726.0
24.2 78.0 7443.0 67.2 30
Y.T.D. (Fiscal 1985)
309.2 1132.8 7546.0
27.7 89.1 9685.0 62.3 273
Vinyl Department production for June was 28.8MM pounds which was 103% of the Business Area's targeted level of 28.0MM pounds.
The reactor stream factor for June was 78.0%. Downtime in the reactor area occurred as follows:
1) Operational Downtime: Accounted for 89.9% of the total downtime and was due to reactor scheduling conflicts, no place to dump reactor slurry, downtime due to severe weather conditions, and a planned outage in the old module for inventory control purposes. The plant took advantage of the outage to complete shutdown type maintenance work. All old module reactors were hydroblasted and dye checked. The old module reactor condensers were also chemical cleaned.
2) Service Downtime
time and was due to cleaning reactor AMS
vent lines.
down
3) Maintenance Repair/Revision Downtime: Accounted for 8.8% of the total downtime and was due to nine reactor valve changeouts, agi seal replacement on 500, condenser cleaning on 744, and cooling water jacket repairs on 743 and 744.
Dryers
The dryer stream factor for June was 67.2%. Downtime in the dryer area occurred as follows:
1) Reactor Limited Production: Accounted for 80.6% of the total down time. Dryers were shut down when possible for energy conservation. The fluid bed dryer was shut down in conjunction with the old reactor module outage.
VINYL - Continued
Dryers - continued
2) Operational Downtime: Accounted for 12.0% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning* transfer activator problems* and downtime due to power outages.
3) Downtime: Accounted for 7.4% of the 1 downtime and was due to activator, centriruge ana screene
repairs. The fluid bed dryer hot water panels were reinstalled
during the month.
Product Quality Summar
Resin Type
Prime
5265 5305 5385 5425 5465 Debox Sifter Overflow Pond Resin
Total
1,727,791 4,589,950 14,388,501 5,467,988 1,597,010
*
-
27,771,240
"BC"
-
388,390 -
507,500
-
895,890
"H"
-- --
142,878 142,878
% of Total Production
6.0 15.9 51.3 19.0
5.5 1.8 0.5 100.0
Quality performance for June was 99.5% customer grade with 0.5% "H" grade production.
A total of five railcars were shipped as "B" grade during the month which represented 4.7% of the 107 total resin hopper cars shipped.
Load Date Ship Date Car No.
Customer Product
Reason
5/07/85 5/17/85 5/28/85 5/20/85 6/11/85
6/11/85 6/13/85 6/13/85 6/13/85 6/26/85
PLCX 42666 Gamma
ERLX 6192 United Plastics
VIPX 45833 Gamma
PLCX 43872 Grifco
PLWX 44292 Vulcan
Resifted Sifter Overflow
Resifted Sifter Overflow
Resifted Sifter Overflow
Resifted Sifter Overflow
Resifted Sifter Overflow
Quality Quality Quality Quality Quality
The vinyl area received sixteen short lead time emergency type orders comprising 7.5% of the 212 Aberdeen resin shipments in June.
Monthly Variable Cost Performance
Variable costs for the month were favorable at $1167.0M with $1262.9M due to price and ($95.9M) due to efficiency. Resin variable cost for the month was 20.032 c/lb. vs. the budgeted 24.103 <?/lb.
VAB.0001187057
VINYL - Continued
Monthly Variable Cost Performance - continued
The $1262.9M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $1235.2M; VCM freight, $22.8M; Lupersol 223M initiator, $13.6M; and utilities, $10.2M.
The $95.9M negative efficiency variance can be attributed to unfavorable VCM efficiency, $139.1M.
VCM efficiency for the month was 1.02841 lbs. VCM/lb. PVC versus the budgeted 1.0050 lbs. VCM/lb. PVC. Year-to-date efficiency is 1.00129.
Year-to-date variable cost efficiency variances in the Vinyl Department totaled $681.9M favorable.
Energy Performance/Progress
1. Plant energy consumption for the month totaled 2522 BTU/lb.
2. A total of seven steam leaks and one steam trap were repaired during the month.
General
1. Packaging for the month totaled 476,678 pounds.
Resin raw material in the 744 account totaled $194.0M at month end.
A
VAB.0001187058