Document wg4BZD14qrK5Gr0MM3JDNOJKB

ABD00282830 r- / VINYL - D. W. Hollis, J. M. Edwards Safety The Vinyl and Yard Departments had one first aid injury case in December. Shift safety meeting topic for the month was the Subpart V Compliance Training. 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 December 38.8 1251 948 30.6 94.1 9748 66.8 31 Y.T.D.(Fiscal 87) 107.6 1171 2665 29.0 89.1 10158 60.2 92 Vinyl Department production for December was 38.8MM pounds which sets a new production record. The previous record was 38.7MM pounds set in March, 1986. Reactors The reactor stream factor for December was 94.1%. Downtime in the reactor area occurred as follows: 1) Operational Downtime: Accounted for 84.0% of the total downtime and was due to reactor recovery scheduling conflicts, downtime due to rinsing the chem wash tank, waiting on particle size information before charging, reactor inspections for 5415 test runs and delays due to four 5415 coarse batches. 2) Maintenance Service Downtime: Accounted for no downtime because the cleaning of the reactor AMS injection ports and inert vent lines was accomplished while the reactors were normally down for other reasons. 3) Maintenance Repair/Revision Downtime: Accounted for 16.0% of the total downtime and was due to changing D-600 and 744 reactor agitator seals, cleaning the sewers in the old module, changing the new module dump Sweco screen and a major electrical short in a new module starter bank. Dryers The dryer stream factor for December was 66.8%. Downtime in the dryer area occurred as follows: 1) Reactor Limited Production: Accounted for 88.8% of the total down time. Dryers were shut down when possible for energy conservation. 2) Operational Downtime: Accounted for 5.0% of the total downtime and was due to centrifuge plugging, burner flameouts, dryer cleaning and transfer activator problems. A ABD00282831 VINYL - Continued Dryers - Continued 3) Maintenance Repair/Revision Downtime: Accounted for 6.2% of the total downtime and was due to repairing the fluid bed blower, welding on //7 outlet supports, working on #4 activator instrumentation, working on #5 exhauster and explosion door, preventative maintenance on the fluid bed south Bird centrifuge, and i\l activator valve replacements. Product Quality Summary Resin Type Prime % of Total "B" "H" Production 5265 5305 5385 5415 5465 Debox Off-Grade Sifter Overflow Pond Resin Total 2,273,116 3,816,440 23,179,058 6,207,369 1,800,860 - - - - 37,276,843 - - - - 998,360 176,220 - 223,580 1,398,160 _ - 98,888 - 98,888 5.9 9.8 59.8 16.0 4.6 2.6 0.5 0.2 0.6 100.0 Quality performance for December was 99.7% customer grade with 0.2% "H" grade production. A total of eleven railcars were shipped as "B" grade during the month which represented 9.6% of the 115 total resin hopper cars shipped. Load Date Ship Date Car No. Customer Product Reason 11/10/86 12/01/86 VIPX 45258 Intermax, TX Debox Quality 10/22/86 12/01/86 VIPX 45708 T. Brewer, PL Debox Quality 11/30/86 12/11/86 PLCX 43854 Wexford, CA Debox Quality 12/05/86 12/16/86 VIPX 45260 Vulcan Plastics, AL Debox Quality 11/26/86 12/16/86 ACFX 55814 Westernag, TX Debox Quality 12/16/86 12/29/86 VIPX 45261 Silverline, NC 5385 Cont. 11/17/86 12/29/86 VIPX 45782 Cont. Plast., CO Debox Quality 11/19/86 12/30/86 PLWX 44720 Wexford, CA Pond Resin Quality 12/01/86 12/31/86 PTLX 41841 Wexford, CA Debox Quality 12/10/86 12/31/86 PLWX 44291 Wexford, WI Debox Quality 11/15/86 12/31/86 PTLX 41592 Wexford, CA Pond Resin Quality ABD00282832 VINYL - Continued The Vinyl area received twenty short lead time emergency type orders comprising 7.4% of the 272 Aberdeen resin shipments in December. Monthly Variable Cost Performance Variable costs for the month were unfavorable at $487.3M resulting from an overall unfavorable price variance of $412.8M and an unfavorable efficiency variance of $74.6M. Resin variable cost for the month was 18.643 cents/lb. versus the budgeted 17.336 cents/lb. The $412.8M unfavorable price variance was primarily attributed to higher than budgeted pricing for VCM, $446.6M. The $74.6M unfavorable efficiency variance can be attributed mainly to the unfavorable efficiency variance of VCM, $67.7M; and calcium stearate, $16.2M. VCM efficiency for the month was 1.01402 lbs. VCM/lb. PVC versus the budgeted 1.00208 lbs. VCM/lb. PVC. YTD variable cost efficiency variances in the Vinyl Department totaled $103.3M unfavorable. Energy Performance/Progress 1. Plant energy performance for December was 2263 BTU/lb. General 1. Resin raw material in the 0744 account totaled $262.5M. 2. Commercial production of 5415 resin started in December using temporary facilities. A