Document 5bxmjY7G5XXn2kRb2L2LpDyLN
ABD00282992
VINYL - J. W. Ware/M. L. Nathan
Safety
The Vinyl and Yard Departments operated with one medical case type injury in December. The medical case involved an injury to the right knee of an employee. The employee was attempting to open a valve from a ladder with a pipe wrench. The pipe wrench slipped causing the employee to lose his balance and fall from the ladder. The injury was classified as a restricted workday case.
Shift safety meeting topics for the month included "Respirator Training" and "Polyperoxides-Vessel and Line Cleaning Procedures".
Production
December
.1 Production, MM Lbs.
36.0
2. Daily Production Rate, M Lbs/C.D. 1161.2
3. Total Charges
871
4. Charges, Reactor Batches/C.tf.
28.0
5. Reactor Stream Factor
92.0
6. Dryer Rate, Average Lbs./Hr.
10966
7. Dryer Stream Factor
55.4
8. Accounting Days
` 31
Y.T.D. (Fiscal 1984)
103.5 1124.5 2527
27.4 91.2 9901 60.3 92
Production
Vinyl Department production for December was 36.0MM pounds which was 100% of the Business Area's targeted production level.
Reactors
1. Downtime for cooling water jacket repairs on 741, 742, 743 and 744 reactors resulted in a stream factor penalty of 0.8%.
2. Miscellaneous maintenance items including D-700 sprayhead adjust ment, reactor slow vent cleaning, and D-600 safety disc changeout resulted in a stream factor penalty of 0.9%.
3. A condenser cleaning on 745 reactor resulted in a stream factor pen alty of 1.1%.
4. Downtime due to recovery system scheduling conflicts resulted in a stream factor penalty of 4.0%.
5. Six valve changeouts and maintenance on reactor valves resulted in a stream factor penalty of 0.7%.
6. Downtime due to no place to dump the reactor slurry resulted in a stream factor penalty of 0.1%.
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ABD00282993
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VINYL - continued
Dryers
1. Production was essentially reactor limited during full production periods in December. Dryers were shut down when possible for energy conservation purposes. The associated stream factor penalty was 40.3%.
2. Dryer downtime for routine dryer cleaning resulted in a stream factor penalty of 1.0%.
3. Dryer centrifuge pluggage resulted in a stream factor penalty of
0.6%.
4. Downtime due to bottlenecks in the sifter and pneumatic transfer systems resulted in a stream factor penalty of 1.1%.
5. Downtime due to dryer burner flameouts resulted in a stream factor penalty of 0.3%.
6. Downtime for checking/replacing dust collector socks resulted in a stream factor penalty of 0.5%.
7. Maintenance on dryer centrifuges, screeners, activators, exhausters, drives, etc. resulted in a stream factor penalty of 0.9%.
Product Quality Summary
% of Total
Resin Type
Prime "BC" "H" Production
5265 5305 5385 5425 5465 Sifter Overflow Pond Resin
Total
1,840,687 2,621,754 23,128,845 5,614,285 2,564,560
35,936,751
61,673 166,620 228,293
5.1 7.3 64.2 15.6 7.1 0.2 0.5 100.0
Quality performance for December was 99.4% customer grade with 0.6% "H" grade production.
A total of four railcars were shipped as "B" grade during the month which represented 2.6% of the 151 total resin hopper cars shipped.
Ship Date
Car No.
Customer
Product
Reason
12/10/84 PTLX 41661 Osterman
5425
Derailed Material
12/20/84
VIPX 45805 Extrusion Technology
Resifted
Quality
Sifter Overflow
12/21/84 12/28/84
PLCX 42993 PTLX 41639
Osterman
5425
Extrusion Technology
Resifted
Sifter Overflow
Derailed Material
Quality
ABD00282994
VINYL - continued
The vinyl area received twenty-seven short lead time emergency type orders comprising 9.0% of the 297 Aberdeen resin shipments in December.
Monthly Variable Cost Performance
Variable costs for the month were favorable $651.5M with $534.5M due to price and $117.0M due to efficiency. Resin variable cost for the month was 18.563 c/lb. versus the budgeted 20.384 c/lb.
The $534.5M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $562.4M; and lower than budgeted pricing for Lupersol 223 initiator, $19.8M.
The $117.0M favorable efficiency variance can be attributed to lower than budgeted VCM efficiency, $49.4M; and lower than budgeted efficiency in the utilities area, $26.5M.
VCM efficiency for the month was 0.99701 lbs. VCM/lb. PVC versus the budgeted 1.00500 lbs. VCM/lb. PVC. Year-to-date VCM efficiency is
1.00100.
Y.T.D. variable cost efficiency variances in the Vinyl Department totaled $259.1M favorable.
Energy Performance/Progress
1. Plant energy consumption was 2491 BTU/lb.
2. A total of twenty-five steam leaks and ten steam traps were repaired/replaced during the month.
General
1. Packaging for the month totaled 308,073 pounds.
2. Resin raw material in the 744 account totaled $198.2M at month end.
3. The screen bowl centrifuge was installed and tested during the month. Acceptable levels of washing efficiency could not be obtained with the test centrifuge.
4. A mixed suspending agent test run was conducted during the month. Preliminary results are encouraging.
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