Document wgy5LBjjqMEyJEdq1mr5KqL0o
ABD00283051
VINYL - P. E. Markey/M. L. Nathan
Safety
The Vinyl and Yard Departments operated without an injury during February.
Shift safety meeting topics included "1983 Safety Performance/1984 Safety Goals", and sling air pack respirator training. The sling pack will phase out the use of the cannister masks.
Production
February
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 Steam Factor 8. Accounting Days
Production
34.1 1175.4
866.0 29.9 93.5
6667.0 81.6 29.0
66.9 1114.5 1721.0
28.7 90.8 6503.0 79.3 60.0
Vinyl department production for February was 34.1MM pounds which was 100% of the Business Area's targeted production level of 34.0MM pounds.
Reactors
1. Cooling water jacket repairs on 741 and D-700 reactors resulted in a stream factor penalty of 0.62%.
2. Replacement of D-500 agitator motor resulted in a 0.50% reactor stream factor penalty.
3. New module downtime associated with repairs to a seal oil line common to all the module reactor agitators resulted in a stream factor penalty of 0.26%.
4. Downtime on 742 reactor for steam stripping sparger installation re sulted in a 0.10% stream factor penalty.
5. Safety disc changes on 744 and 745 reactors resulted in a 0.13% stream factor penalty.
6. Downtime on D-700 to clean the rinse/chem wash sprayhead resulted in a 0.17% stream factor penalty.
7. Three valve changeouts and maintenance on reactor valves resulted in a 0.45% stream factor penalty.
8. Downtime due to recovery system scheduling conflicts resulted in a 3.10% stream factor penalty.
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ABD00283052
VINYL - Continued
Reactors - continued
9. Downtime associated with maintenance on the old reactor module recovery compressors resulted in a 0.33% stream factor penalty.
10. Downtime due to no place to dump slurry resulted in a stream factor penalty of 0.2%.
Dryers
1. Production was essentially reactor limited in February. Dryers were shut down as needed for energy conservation purposes. The associated stream factor penalty was 10.6%.
2. Downtime on #8 rotary dryer, as part of the dryer upgrade project main tenance items including dust collector sock change, drive alignment, etc., resulted in a 1.25% stream factor penalty.
3. Downtime on //2 rotary dryer for a dust collector sock change and various other maintenance items resulted in a stream factor penalty of 0.48%.
4. Routine dryer cleaning resulted in a stream factor penalty of 0.64%.
5. Dryer centrifuge pluggage resulted in a stream factor penalty of 2.55%. A concentrated effort is being made to reduce downtime in this area.
6. Downtime due to bottlenecks in the sifter and pneumatic transfer systems resulted in a 0.64% stream factor penalty.
7. Downtime due to dryer burner flameouts resulted in a stream factor penalty of 0.24%.
8. Maintenance on dryer centrifuges, sifters, activators, exhausters, etc. resulted in a 0.53% stream factor penalty.
Product Quality Summary
Resin Type
Prime
5265
1,229,425
5305
3,614,391
5385
17,995,886
5425
7,739,531
5465
3,324,170
Sifter Overflow
-
Pond Resin
-
"BC"
"H"
..
-
53,050
-
2,250
-
-
-
-
-
83,350 45,900
% of Total Production
3.6 10.6 52.9 22.8
9.8 0.2 0.1
Budget Prime Product Mix %
7.5 11.2 62.0 13.8
5.5
-
-
TOTAL
33,903,403
55,300 129,250
100.0
100.0
ABD00283053
VINYL - Continued
Product Quality Summary - continued
Quality performance for April was 99.5% customer grade with 0.2% "BC" pro duction and 0.3% "H" grade.
A total of eight railcars were shipped as MB" grade during the month which represented 6.61% of the 121 total resin hopper cars shipped.
Ship Date
Car No.
Customer
Product
Reason
2/24/84
PLCX 43103 Osterman
Resifted Sifter Overflow
Quality
2/24/84
CONX 45700
World of Plastics Resifted Sifter Overflow
Quality
2/24/84
PTLX 41643
World of Plastics Resifted Sifter Overflow
Quality
2/27/84
CONX 45788 Grifco
5385
Particle Size
2/28/84
CONX 45750 Grifco
5385
Particle Size
2/29/84
PTLX 41641
Continental Plast. Resifted Sifter Overflow
Quality
2/29/84
PTLX 41616 Extrusion Technology 5385
Contamination
2/29/84
PLCX 43713 Grifco
5385
Particle Size
The vinyl unit received nine short lead time emergency type orders comprising 4.4% of the 205 Aberdeen resin shipments in February.
Customer Service Performance
In February, there was a total of 137 days late in shipments for 205 total resin shipments or an average of 0.67 days late shipment.
Year-to-date average performance is 0.65 days late shipment.
Monthly Variable Cost Performance
Variable costs for the month were favorable $1.78MM with $1.73MM due to price and $0.05MM due to efficiency. Resin variable cost for the month was 21.949 c/lb. versus the budgeted 27.197 C/lb.
The $1.73MM favorable price variance was primarily attributed to lower than budgeted pricing for VCM, $1.65MM; lower than budgeted pricing for Lupersol 223 initiator, $18.9M; and lower than budgeted pricing in the utilities area, $69.6M.
ABD00283054
VINYL - Continued
Monthly Variable Cost Performance - continued
The $51.9M favorable efficiency variance can be attributed to favorable variances of $22.9M in VCM efficiency, and $57.2M due to lower than budgeted off-grade production.
VCM efficiency for the month was 1.00572 lbs. VCM/lb. PVC versus the budgeted 1.00860 lbs. VCM/lb. PVC. Year-to-date VCM efficiency is 1.00691. Year-to-date variable cost efficiency variances in the Vinyl Department totaled $56.6M favorable.
Energy Performance/Progress
1. Plant energy consumption for the month was 2712 BTU/lb.
2. A total of seventeen air steam and water leaks were repaired during the month.
General 1. Packaging for the month totaled 494,550 pounds.
2. Resin raw material in the 744 account totaled $187M at month end. 3. Research personnel were on hand to support additional CTA production
trials. The objectives of the program are to minimize reactor and condenser fouling in the production of the low molecular weight resin. A total of twenty-four batches of 5265 were produced with no evidence of condenser or reactor fouling.
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