Document V31xkopXMamp1VwNK3gzVM7m4
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VINYL - D. W. Hollis/M. L. Nathan
Safety
The Vinyl and Yard Departments operated without an injury in May.
Shift safety meeting topics for the month included "Chemicals Handling". Discussion included personnel protection required when handling chemicals, treatment if contacted by a chemical, and need for knowing about chemicals used in the Vinyl area.
Production
May 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
34.8 1121.2
853.0 27.5 85.9
7765.4 75.2 31
280.4 1154.1 6820.0
28.1 90.5 9962.1 61.7 243
Vinyl Department production for May was 34.8MM pounds.
Reactors
The reactor stream factor for May was 85.9%. Downtime in the reactor area occurred as follows:
1) Operational Downtime: Accounted for 53.6% of the total downtime and was due to reactor scheduling conflicts, no place to dump reactor slurry, and downtime due to severe weather conditions. Downtime occurred in the old module as a result of shutdowns of the fluid bed dryer to inspect and remove the heating panels.
2) Maintenance Service Downtime: Accounted for 4.1% of the total down time and was due to cleaning reactor AMS injection ports and slow vent lines.
3) Maintenance Repair/Revision Downtime: Accounted for 42.3% of the total downtime and was due to nine reactor valve changeouts, agitator seal replacements on 500, 742 and 744 reactors, and repair of the new module dump screener.
Dryers
The dryer stream factor for May was 75.2%. Downtime in the dryer area occurred as follows:
1) Reactor Limited Production: Accounted for 79.3% of the total downtime. Dryers were shut down when possible for energy conservation purposes.
2) Operational Downtime: Accounted for 14.1% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning, and transfer activator problems.
VAB.0001187061
VINYL - Continued
Dryers - continued
3) Maintenance Repair/Revision Downtime: Accounted for 6.6% of the total downtime and was due to activator, centrifuge and screener repairs. The fluid bed dryer hot water panels were removed during the month.
Product Quality Summary
Resin Type
Prime
5265 5305 5385 5425 5465 Debox Sifter Overflow Pond Resin
Total
3,763,903 3,502,760 17,929,445 6,600,548 1,669,230
--
-
33,465,886
"BC"
42,750
903,620 -
946,370
"H"
...
--
--
45,644 45,644
% of Total Production
10.9 10.3 52.0 19.2
4.8 2.6 0.2
-
100.0
Quality performance for May was 99.8% customer grade with 0. 2% "H" grade
production.
A total of five railcars were shipped as "B" grade during the month which represented 4.2% of the 120 total resin hopper cars shipped.
Load Date Ship Date Car No.
Customer Product
Reason
4/27/85
4/09/85 5/13/85
4/29/85 4/28/85
5/23/85
5/24/85 5/28/85
5/29/85 5/29/85
VIPX 45718
VIPX 45276 PLCX 42866
PTLX 41606 PLCX 42993
Wexford Resifted Sifter
Overflow
Wexford
5425
Extrusion Resifted Sifter
Tech.
Overflow
Silverline 5385
Silverline 5385
Quality
Viscosity Quality
Cont. Cont.v '
(1) Viscosity for this material was out of specification range due to a raw material problem.
(2) This material was contaminated as a result of leaking hot water panels in the fluid bed dryer.
The vinyl area received twenty-one short lead time emergency type orders comprising 9.6% of the 218 Aberdeen resin shipments in May.
Monthly Variable Cost Performance
Variable costs for the month were favorable $1323.3M with $1148.0M due to price and $175.3M due to efficiency. Resin variable cost for the month was 20.258 c/lb. vs. the budgeted 24.103 c/lb.
VAB.0001187062
VINYL - Continued
Monthly Variable Cost Performance - continued
The $1148.0M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $1095.7M; VCM freight, $28.8M; Lupersol 223M initiator, $15.AM; and utilities, $12.1M.
The $175.3M favorable efficiency variance can be attributed to higher than budgeted VCM efficiency, $82.5M; process additives, $29.1M; utilities area, $61.2M; and off-grade production, $38.2M.
VCM efficiency for the month was 0.99339 lbs. VCM/lb. PVC versus the budgeted 1.0050 lbs. VCM/lb. PVC. Year-to-date efficiency is 0.99850.
Year-to-date variable cost efficiency variances in the Vinyl Department totaled $777.7M favorable.
Energy Performance/Progress
1. Plant energy consumption for the month totaled a record low of 2338 BTU/lb. The previous record was set last month at 2339 BTU/lb.
2. A total of five steam leaks and one steam trap were repaired during the month.
Gene ra1
1. Packaging for the month totaled 364,844 pounds.
2. Resin raw material in the 744 account totaled $232.7M at month end.
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VAB.0001187063