Document emkEekZdDjbqLmdOMp3BX8V8G

ABD00282784 VINYL - D. W. Hollis/M. L. Nathan Safety The Vinyl and Yard Departments operated without an injury in September. Shift safety meeting topic for the month was Job Safety Analysis. Operating procedures, including safety aspects of several jobs in the Vinyl area, were discussed. 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 September 31.1 1034.6 785.0 26.2 83.9 9642.0 55.9 30 Fiscal 1985 411.7 1128.0 10087.0 27.7 89.2 10010.0 60.1 365 Vinyl Department production for September was 31.1MM pounds. Reactors The reactor stream factor for September was 83.9%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 15.2% of the total downtime and was due to reactor recovery scheduling conflicts, no place to dump reactor slurry, and downtime due to severe weather conditions. 2) Maintenance Service Downtime: Accounted for 2.6% 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 22.6% of the total downtime and was due to eight reactor valve changeouts, agitator seal replacements on 700 and 741, condenser cleanings on 742 and 745, and rupture disc replacement on 741. 4) New Module Turnaround: Accounted for 59.6% of the total downtime and was needed to complete preventive maintenance and maintenance repair work of a shutdown nature. Dryers The dryer stream factor for September was 55.9%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 91.1% of the total down time. Dryers were shut down when possible for energy conservation. Rotary dryers were shut down in conjunction with the new module outage. A ABD00282785 VINYL - Continued Dryers - continued 2) Operational Downtime: Accounted for 5.1% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning, transfer activator problems, and downtime due to power outages. One bundle of hot water panels was removed from the fluid bed dryer due to leaks. 3) Maintenance Repair/Revision Downtime: Accounted for 3.8% of the total downtime and was due to activator, centrifuge and screener repairs. Product Quality Summary Resin Type Prime 5265 5305 5385 5425 5465 Debox Sifter Overflow Pond Resin Total 1,863,893 3,823,514 15,716,789 6,917,065 824,790 - - 167,920 29,313,971 "BC" 107,140 1,082,460 - 451,760 - 1,641,360 "H" _ - 82,548 - 82,548 % of Total Production 6.0 12.7 54.1 22.3 2.7 1.5 0.2 0.5 100.0 Quality performance for September was 99.7% customer grade with 0.3% "H" grade production. A total of fifteen railcars were shipped as MB" grade during the month which represented 11.0% of the 136 total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 8/22/85 8/25/85 8/26/85 9/03/85 PTLX 41598 Wexford 9/12/85 PTLX 41619 Vulcan 9/12/85 VIPX 45709 Vulcan Debox 5385 5385 Quality Contamination^ Contamination (2) 8/15/85 8/06/85 8/31/85 8/29/85 8/01/85 9/13/85 9/13/85 9/17/85 9/18/85 9/19/85 PTLX 41596 Extrusion Debox Technology PLWX 44294 Extrusion 5385 Technology PLWX 44291 Silverline 5385 ERLX 6239 Grifco 5385 VIPX 45795 Vulcan 5385 Quality Contamination (2) (2) Contamination Contamination ^ (2) Contamination A ABD00282786 VINYL - Continued Product Quality Summary - continued Load Date Ship Date Car No. Customer Product Reason 9/02/85 8/28/85 9/10/85 9/20/85 9/20/85 9/23/85 PLCX 43019 Extrusion Debox Technology PLCX 42994 Extrusion 5385 Technology VIPX 45748 Wexford 5385 Quality Contamination ^ ^ Contamination (2) 9/05/85 8/07/85 9/23/85 9/30/85 PTLX 41841 Wexford Debox VIPX 45260 Silverline 5385 Quality Contamination ^ ^ 9/18/85 7/28/85 9/30/85 9/30/85 ACFX 53415 Continental Debox PLCX 43701 Grifco 5385 Quality Contamination (2) (1) Contamination due to operating problem with fluid bed dryer. (2) This material was used for dryer cleanout. The vinyl area received thirteen short lead time emergency type orders comprising 5.5% of the 236 Aberdeen resin shipments in September. Monthly Variable Cost Performance Variable costs for the month were favorable at $1970.9M resulting from an overall favorable price variance of $2139.9M and a net unfavorable efficiency variance of $169.0M. Resin variable cost for the month was 18.203 C/lb. vs. the budgeted 24.605 <?/lb. The $2139.9M favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $2065.9M; VCM freight, $27.5M; process additives, $16.4M; and utilities, $30.0M. The $169.OM unfavorable efficiency variance can be attributed primarily to unfavorable VCM efficiency, $177.7M. Favorable efficiency variances included natural gas, $28.6M. VCM efficiency for the month was 1.03195 lbs. VCM/lb. PVC versus the budgeted 1.00500 lbs. VCM/lb. PVC. Fiscal year 1985 efficiency was 1.00311. The poor efficiency experienced for September is under investigation. Fiscal year 1985 variable cost efficiency variances in the Vinyl Department totaled $746.3M favorable. Energy Performance/Progress 1. Plant energy consumption for September totaled 2432 BTU/lb. 2. A total of nineteen steam leaks and one steam trap were repaired during the month. ABD00282787 Vinyl - Continued General 1. Packaging for the month totaled 421,898 pounds. 2. Resin raw material in the 744 account totaled $245.8M at month end. 3. A vibration study was performed on the fluid bed dryer on 10/2 to determine the cause of the cracks in the water panels. The cracks are being caused by a low frequency/high magnitude vibration. A design will be proposed by the vendor to modify the panel support structure in order to reduce the vibration. A