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VINYL - P. E. Markey/M. L. Nathan
Sa fety The Vinyl and Yard Departments operated without an injury during October.
Shift safety meeting topics included: "Chainsaw Safety'*1 2fo3r4 all shifts; and "Forktruck Training" which included classroom as well as field training for
two Vinyl/Yard shifts. The remaining two shifts will tae trained in early
November.
A meeting was held with all vinyl shift supervisors to discuss the 1984 Safety Program. A safety audi t checklist for each operator classification was prepared and implemented during the month.
Production
October
Y.T.D.
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
32.8 1057.4
776 25.0
77.5
7851 62.4 31
325.2 1068.5 7782
25.6 82.9
7182 68.9 304
Production
Vinyl Department production for October was 32.8MM pounds which was 95.3% of the budgeted production volume.
Reactors
1. The new module was down from 10/22 until the end of the month for inventory control. During this shutdown, capital project work and various other main tenance items including eighteen valve changeouts were performed. The re sulting stream factor penaTty was 16.6%.
2. Replacement of D-600 agitator seal resulted in a 0.19% reactor stream factor penalty.
3. Reactor jacket welds on D-743 and D-700 reactors resulted in a stream factor penalty of 0.83%.
4. Two valve changeouts and maintenance on reactor valves during normal produc tion periods resulted in a stream factor penalty of 0.19%.
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VAB.0001186894
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VINYL - Continued
Reactors - continued
5. Miscellaneous maintenance items including D-600 steam eductor cleaning, D-500 safety disc changeouts, and D-300 agitator coupling changeout re sulted in a reactor stream factor penalty of 0.4%.
6. Downtime, due to recovery system scheduling conflicts, resulted in a stream factor penalty of 2%.
7. Downtime due to pluggage of the old module slurry dump line resulted in a stream factor penalty of 0.78%.
Dryers
1. Production was essentially reactor limited in October. Dryers were shut down as needed for energy conservation purposes. The associated stream factor penalty was 22.2%.
2. Dryer downtime, due to a shortage of material as a result of the new module shutdown, contributed 13.5% to the monthly dryer stream factor penalty.
3. Dryer downtime, due to a shortage of material as a result of pluggage in the old module slurry dump line, contributed 1.39% to the monthly dryer stream factor penalty. During this period, the fluid bed dryer was cleaned.
4. Routine dryer cleaning resulted in a stream factor penalty of 0.75%.
5. Dryer centrifuge pluggage resulted in a stream factor penalty of 0.39%.
6. Downtime due to bottlenecks in the sifter and pneumatic transfer systems resulted in a stream factor penalty of 0.52%.
7. Downtime, due to dryer burner flameouts, resulted in a stream factor penalty of 0.24%.8
8. Maintenance on dryer centrifuges, sifters, activators, etc. resulted in a stream factor penalty of 0.57%.
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VAB.0001186895
VINYL - Continued
Product Quality Summary
Resin Type
Prime 11BC" "H"
% of Total Production
Budgeted Prime Product Mix %
5265 5305 5385 5425 5465 Sifter Overflow Pond Resin
TOTAL
2,154,432 2,291,896 21,625,644 5,194,156 1,398,400
-
-
32,664,528
49,150
-
-
49,150
--
-
66,845
-
66,845
6.7 7.0 66.1 15.8 4.2 0.2
-
100.0
12.5 11.25 57.5 13.75
5.0
--
--
100.0
Quality performance for October was 99.7% customer grade with 0.1% "BC" produc tion and 0.2% "H" grade.
A total of four railcars were shipped as off-grade during the month which repre sented 4.16% of the 96 total resin hopper cars shipped.
Ship Date
Car No.
Customer
Product
Reason
10/18/83 C0NX 45293 10/25/83 PTLX 41589 10/25/83 PTLX 41632 10/31/83 PTLX 41650
Continental Plastics Continental Plastics Continental Plastics Continental Plastics
Resifted Sifter Overf1ow
Resifted Sifter Overflow
Resifted Sifter Overf1ow
Resifted Sifter Overf!ow
Qua!ity Quality Quality Qua!ity
The vinyl area received thirty-three short lead time emergency type orders com prising 16.0% of the 206 Aberdeen resin shipments in October.
Monthly Variable Cost Performance
Variable costs for the month were favorable $958.3M with $702.5M due to price and $255.8M due to efficiency. Resin variable cost for the month was 22.329 <t/lb. vs.
the budgeted 25.258 </lb.
VAB.0001186896
VINYL - Continued
Monthly Variable Cost Performance - Continued
The $702.5M favorable price variance was primarily attributable to lower than budgeted pricing for VCM, $328.5M; lower than budgeted pricing for VCM freight, $257,8M; lower than budgeted pricing for Lupersol 223 initiator, $41.8M, and lower than budgeted pricing in the utilities area, $59.5M.
The $255.8M favorable efficiency variance can be attributed to favorable variances of $74.1M in VCM efficiency, $84.6M in the utilities area, $25.2M due to deviation from the budgeted product slate, and $72.7M due to lower than budgeted off-grade production.
VCM efficiency for the month was 1.00199 lbs. VCM/lb. PVC vs. the budgeted 1.01277 lbs. VCM/ lb. PVC. Year-to-date VCM efficiency is 1.00466.
Year-to-date variable cost efficiency variances in the Vinyl Department totaled $1.75MM favorable.
Energy Performance/Progress
1. Plant energy consumption for the month was 2474 BTU/lb.
2. A total of thirty-five steam leaks and six air leaks were repaired in the plant during October. Seven steam traps were also replaced.
3. The recently installed cold water rinse project was started up in October. The project is expected to save 6MMM BTU/yr in energy usage.
General
1. Packaging for the month was 795,375 pounds.
2. Research and PED support were on hand during the month for additional produc tion trials of a new chain transfer agent (CTA) for use in low molecular weight resin production. Some problems were encountered with poor particle size distribution in the experimental resin production. This completed the first phase of the test program with additional plant runs scheduled for November.
3. Resin raw material inventory in the 744 account totaled $187.1M at month end.
4. A total of three coarse batches were produced during October. Two of the batches were associated with the new chain transfer agent (CTA) test run and the third was caused by a faulty colloid addition valve on 744 reactor.
5. Ken Taylor with Management and Training Systems was in the plant during October to conduct a training heeds survey'in the vinyl area. The purpose of the survey was to identify any training deficiencies and define a training program for all Vinyl/Yard Department operations personnel. The plant has received a copy of the training audit along with a proposed operator training program. This con tractor was used wiith a high degree of success at the Lake Charles LAB plant.
VAB.0001186897
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