Document Jrz1JmoRgDJpyjbbnLG6v4jDe
ABD00282883
VINYL - D. W. Hollis/M. L. Nathan
Safety
The Vinyl and Yard Departments operated without an injury in January.
Shift safety meeting topics for the month included a review of vinyl safety performance for 1985 and discussion of the 1986 Vinyl Safety Program.
Production
.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
January Y.T.D,(Fiscal 86)
38.2 1232.8
926 29.9 91.7 10496 61.2
31
145.5 1182.7
3579 29.2 90.2 9977 61.9
123
Vinyl Department production for January was a record 38.2MM pounds. The previous record was 37.9MM pounds set in January, 1985.
Reactors
The reactor stream factor for January was 91.7%. Downtime in the reactor area occurred as follows:
1) Operational Downtime: Accounted for 47.7% of the total downtime and was due to reactor scheduling conflicts, no place to dump reactor slurry, and downtime to check AMS emergency kill systems during freezing weather.
2) Maintenance Service Downtime: Accounted for 3.3% of the total downtime and was due to cleaning reactor AMS injection ports and slow vent lines.
3) Maintenance Repair/Revision Downtime: Accounted for 49.0% of the total downtime and was due to agitator seal replacement on 700, repair work on agitator seal oil systems, condenser cleaning on 745, cooling water jacket repairs on 741, 742, and 744, and four reactor valve changeouts. Some reactor downtime was also taken for tie-in of BASF additive systems.
Dryers
The dryer stream factor for January was 61.2%. Downtime in the dryer area occurred as follows:
1) Reactor Limited Production: Accounted for 87.0% of the total downtime. Dryers were shut down when possible for energy conservation.
ABD00282884
VINYL - Continued
Dryers - continued
2) Operational Downtime; Accounted for 4.5% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning, transfer activator problems, and screener repairs.
3) Maintenance Repair/Revision Downtime: Accounted for 8.5% of the total downtime and was due to activator, centrifuge and screener repairs, and dust collector sock changes.
Product Quality Summary
Resin Type
Prime
5265 5305 5385 5425 5465 Debox Sifter Overflow Pond Resin
Total
5,175,666 1,445,710 24,390,604 4,696,636 1,723,750
-
-
6,600 37,438,966
"B"
_ -
691,160
-
691,160
"H"
_
-
86,665
-
86,665
% of Total Production
13.5 3.8
63.8 12.3
4.5 1.8 0.3 0.0 100.0
Quality performance for January was 99.8% customer grade with 0.2% "H" grade production.
A total of twelve railcars were shipped as "B" grade during the month which represented 7.6% of the 158 total resin hopper cars shipped.
Load Date Ship Date Car No.
Customer
Product
Reason
11/10/85
1/09/86 PLCX 42994 Wexford
Debox
Quality
12/28/85
1/13/86 PLWX 44292
Vulcan Plastics
Debox
Quality
12/07/85
1/13/86 VIPX 45870
Vulcan Plastics
Debox
Quality
12/05/85
1/13/86 PTLX 41621 Osterman
Debox
Quality
01/06/86
1/21/86 VIPX 45253 Grifco
Debox
Quality
12/29/85
1/24/86 VIPX 45708 Vulcan
Debox
Quality
12/15/85
1/27/86 VIPX 45284
Continental Plastics
Debox
Quality
12/18/85
1/28/86 VIPX 41857
Extrusion Technology
Debox
Quality
ABD00282885
4*
VINYL - Continued
Load Date 01/21/86 01/13/86
Ship Date 1/30/86 1/30/86
Car Number Customer PTLX 41841 Grifco PLCX 42993 Grifco
Product Debox Debox
Reason Quality Quality
12/23/85
1/30/86
PLCX 43850 Continental Plastics
Debox
Quality
12/18/85
1/31/86
PTLX 41631 Vulcan Plastics
Debox
Quality
The vinyl area received twenty-one short lead time emergency type orders comprising 7.8% of the 270 Aberdeen resin shipments in January.
Monthly Variable Cost Performance
Variable costs for the month were favorable at $750.2M resulting from an overall favorable price variance of $870.9M and a net unfavorable efficiency variance of $120.7M. Resin variable cost for the month was 17.415 c/lb. versus the budgeted 19.419 C/lb.
The $870.9M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $583.6M; VCM freight, $40.9M; and utilities, $239.0M.
The $120.7M unfavorable efficiency variance can be attributed mainly to unfavorable VCM efficiency, $110.3M. Off-grade efficiency was favorable by $74.7M.
VCM efficiency for the month was 1.01811 lbs. VCM/lb. PVC versus the budgeted 1.00050 lbs. VCM/lb. PVC. Year-to-date VCM efficiency is 1.00292.
Year-to-date variable cost efficiency variances in the Vinyl Department totaled $208.3M unfavorable.
Energy Performance/Progress
1. Plant energy consumption for January was 2493 BTU/lb.
2. A total of twenty-five steam leaks and seven steam traps were repaired during the month.
General
1. Packaging for the month totaled 343,915 pounds.
2. Resin raw material in the 744 account totaled $294.9M at month end.
3. A production run of 5305 using BASF technology was begun in January but had to be delayed to clean the condenser and shell on 745 reactor. Some particle size control problems occurred but were solved in early February.
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