Document yOGLDgKV8MEewxBeqZxyNKzn

CSCAMSIA PLANT INTEROFFICE MEMORANDUM To: Mr. E. A. Primeau From: D. H. Francke PVC Monthly Report July, 1976 Date Copies: 16 August 1976 J. T. Barr J. M. Diamond R. E. Jones W. R. Schofield Production for July, 1976 totaled 6,891M lbs. or 101.7% of budget. Production outages included 95 reactor hours or about 73M lbs. production due to startup time after the maintenance shutdown at the end of June. Off-grade production amounts to 0.36% of total production; and tails, sweeps, and PTS amounted to 0.2%. Personnel monitoring samples for July, 1976 showed 92% of the 8-hour TWA samples to be less than 1.0 ppm and 96% of the 15-minute TWA samples to be less than 5.0 ppm. VCM efficiency for July, 1976 was 95.9% vs. a budget of 95.5%. Total system variance from budget was $37M favorable. Production related variance was $18M favorable. Major favorable contributors for July were $27M in volume, $18M in off-grade credit, $23M in spending for services, and $18M in business system variance. Unfavorable variance contributors included ($16M) in maLntenance labor and materials, ($12M) in raw material conversion ($6M favorable VCM efficiency offset by high process chemicals at ($18M> unfavorable), ($8M) in utilities, ($7M) in increased depreciation, ($3M) in raw material cost, and {$27M) in business volume. JULY Production during July, 1976 totaled 6,891M pounds total production. Of this amount, 6, 818M pounds were prime grade resin, 25M pounds (. 36%) were off-grade due to contamination, and 48M pounds (.70%) were tails, sweeps and P. T. S. Production consisted of types PVC 1225, PVC 1230, PVC 1250, PVC 2160 and PVC 2250. Quality problems were minimal with the major point of interest remaining with the inherent viscosity analysis. Fluctuation continued although remaining within specifications. No significant cause has been seen for the fluctuations. The reaction temperature continues to be held 4 degrees low to maintain in specification I. V. analysis. This problem will continue to be studied to try and find an explanation. AP00041864 Mr. E. A. Primeau -2- 16 August 1976 JULY (coat'd) PVC 2250 production during July, 1976 remained low in bulk density despite recipe changes. The latex levels were dropped from 2,750 gms. per batch (9,000 pounds VCM) to 2,400 gms. Although no significant bulk density increase was seen, a slight increase in fisheyes was experienced. Further dropping of the latex level could lead to fisheye levels above the accepted limit. Residual VCM levels in the finished resins continued at about the concen trations experienced. In. recent months with the exception of PVC L225. Levels in both lot analysis and shipment composites were about 20 ppm higher on the average. A summary of all resin residual monomer levels Is below: Residual VCM in Finished Resin 1225 1230 1250 2160 2200 2250 Number Lots Avg. VCM 38 83 8 60 34 24 2 NA 8 9 NA 33 Number Shipments 8 21 1 NA 2 2 Avg. VCM 41 24 15 NA 8 27 Personnel Monitoring The personnel monitoring during July continued with the frequency being twice/month per man entering the PVC area. The sampling schedule is set up to monitor each person entering the PVC area during the month on an 8-hour TWA and a 15-minute TWA sample. The results for July showed that on 8-hour TWA samples, two samples were over 5 ppm. Of a total of 5 1 8-hour TWA samples, 76% were below 0. 5 ppm, 92% were below 1.0 ppm. Of a total of 52 15-minute TWA samples, 27% were below 0. 5 ppm, 54% were below 1.0 ppm and 96% were below 5.0 ppm. PPM Supervisor Senior Reactor Solution Recovery Finishing Utility Artisan Maintenance Subtotals % of Totals (51) < .5 5 4 4 1 2 2 3 3 15 39 76% 8-Hour Samples .5-1 1-3 3-5 1 1 1 2 2 1 8 16% 1 1 2 4% 5-10 1 1 2 4% 10-15 >15 AP00041865 Mr. E. A. Primeau Personnel Monitoring (cont'd) -3- 16 August 1976 15-Minute Samples < 5 .5-1 1-3 Supervisor Senior Reactor Solution Recovery Finishing Utility Artisan Maintenance 1 2 1 1 1 1 1 6 2 2 2 1 1 1 1 3 Subtotals % of Totals (52) 14 27% 14 27% 13 25% Area Monitoring 3-5 2 1 1 3 1 1 9 17% 5-10 10- 15 >15 11 2% 2% The current computer configuration worked well during the month except -or a period of about 3 days when the system was out of service. The cause of the outage was a lightning strike which burned out one board.. The recompilation program which was sent off to the Bristol Corporation for incorporating into our system was put on hold. This program change was designed to improve the output data from our current program, make the material balance functions operational, and permit the use of the access gate system. When compiled by Bristol the program load was about 11 M bytes too large for our current memory. Since the program, even if recompiled, would still not permit expansion in types of analysis or number of analysis units, the work was put on hold until further information could be received. This information involves the purchase of a completely new system capable of current functions, currently planned expansions and additional expansion of the functions If required later. Several alternatives are being investigated and it is hoped that by early September a decision will be made as to which direction to proceed. Area monitoring results for July, 1976 showed an average level for the reactor building to be 1.01 ppm. Weekly averages ranged from 0.70 to 1.33 ppm. AP00041866 Mr. E. A. Primeau -4- 16 August 1976 OSHA Work Continued upkeep and updating of OSHA related work resulted in costs of $6, 115 or 7.2% of the July maintenance costs. This cost is the total of the major items and does not necessarily include &1L costs. These items were as follows: Leak Patrol Computer Upkeep Updating of Vent System to Reduce Exposure Electrical Upgrading $1,068 $3,570 ($1,801 due to parts) $1, 271 $ 206 $6, 115 Maintenance Maintenance costs for July, 1976 were $16M over budget largely due to costs incurred during the shutdown at the end of June, charges too late to show in June. These items plus other major cost items are listed below: 1. Shutdown Work - $12,438 a) Instrument and electrical repairs during the shutdown resulted in $1, 553. b) Dryer repairs resulted in costs of $7, 508 for new coils and $1,265 for new steam traps. Both items have resulted in reduced steam usage and better drying rates. c) Repairs to the reactor jackets on four reactors resulted in costs of $2, 112. 2. Routine and preventive maintenance for lubrication, filter changes, instrument and electrical work totalled $6,791. 3. Repairs to reactors resulted in charges in excess of $3,300. A total cost of $2, 806 was Incurred with repairs to steam valves and work on No. 12 agitator shaft. 4. Installation of a second drop header to split the east and south strippers was made during July at a cost of $3,261. This was done to permit separate dropping and stripping of batches and should reduce charge and stripper lag. 5. Miscellaneous repairs to the strippers Including seal and rupture disc replacement totalled $1, 536. AP00041867 Mr. E, A. Frimeau -5- 16 August 1976 Maintenance 6. Replacement of the old sightglasses on the two (2) fresh monomer tanks resulted in costs of $2, 050. 7. Valve rebuilding costs totalled $1,216 while repairing of steam leaks totalled $1, 606. 8. Other charges of significance were $2, 180 for cooling tower cleanup, $1,434 for hydraulic oil pump repairs, $1,012 for No. 3 blend tank seal repairs, $1,049 Carrier refrigeration work, and $525 in revisions to VCM unloading pipe. These items totalled $38,398 or about 45% of the total maintenance dollars spent during July. DHF :fls Attachments (3) 1X-&L /J cUfcz, AP00041868 AP00041 00 On Prod. Eudcet - 6,777 Actual - 6, 391 A. Production Related Variance} I. Raw Material Convtuioii II. Volume a) Throughput b) Onstream c) Offgrade Total Volume HI. ( IV. Spending (Use) (at std. S/Ualt) a) Labor b} Maintenance Labor c) Maintenance Material d) Utilities c) Ocher Total Spending (Hie) Spending (Rate) a) Facility Services t Overheads b) Nonfacility Service* I, Overhead* c) Depreciation, Taxes L Insurance d) Labor, Salaries, Fringe Total Spending (Rate) TOTAL PRODUCTION RELATED VARIANCES B. V, Purchase Price Veriancee a) Raw Material b) Purchased Utilities c) Feedstock Mix d) Other (maiat. mail.,op. sup,, etc.) Total Purchase Price C. VI. Business Variances a) Volume b) Systems Variance c) Other Total Business Variances TOTAL PRODUCT COST VARIANCES PROM STD. VII. Budgeted Variances from Standard a) Raw Male rial Cost b) Purchased Utilities Cost e) Volume d) .^prndinf! ) System Total Budgeted Variances TOTAL VARIANCES FROM BUDGET a) Production Related , b) Purchased Price Variances c) Business Variance JULY VARIANCE FORECAST PVC - ESCAMDIA PLANT Jure 30th 1 5th 28th Actual 21 - __z. 21 . (5) (5) - 1 (12) 21 ' 23 (10) 31 S (S) (18) (9) (5) (13) 17) - - <B) 10 10 23 (21) 4 2 (9) (7) 14 ' _ 1 . 1 2. (91 " .20 () . . (45] (10) 14 (10) 14 19 (21) 2 (9) -- 02) 4 (7) ~ 34 - -a - (10) 14 (8) (3) <ro> (13) (27) 18 (9) 12 (57) 19 (3) 15 (26) 45 (2) (57) 19 13) 15 ' (26) 5 4 (57) 19 (3) 15 (26) 16 (2(3) (56) 19 (3) 15 (25) 37 18 3/10/76 Variance Esolanation 28th - fav, efficiency offset by chemical costa. Act. - high initiator levels offset in part by ISM 1st. YGM efficiency. 28th - production above std. Act. - downtime during first first of July from startup. 28th (c) - unit charged with two shipments in June. downgraded to affgrade in July. 28th - shutdown charges at and of June, charge -in July. 26th - low service group usage. 2Bch - increased depreciation due to east stripper. 28th - product mix change volume effect. material balance escambia pvc plant" MONTH ENDING 31 JUL 7b PMBU15 ;. r ____ A. LHS sub-total LRS TOTAL * OF VCL CHARGE' SUB-TOTAL TOTAL VCl. USED BASFD ON BILLING .WEIGHTS ._ ___ ___ 7*185*956, -- 100.00 ___ B. PVC OUT TO PRODUCT " ---- . - . . . ----------- ~6 * 890 *850 9b. 89 1. PVC PRIME 2. PVC OFF-GRADE 6.618*000 72*650 94*86 1.01 C'"PVC LOSS'eSZ.ZZZ' .J.,>2G_39T. .Z..... ............. .... . .59 1. PVC TO DUMP AS SCRAP ______ 2..DRYER DISCHARGE _ __________ ........ . SOUTH LINE ______167 ____ _ NORTH LINE _____ 283 ________3... PVC...IN FFLUENT_WATER______ 36*806 *51 ______ 450................. ..................... .01 5.139 ,07 ____ P ,_VCL LOSSES_________ _____________________________________ _______________ 31*234________ ... ;........ 1. ;_____________ _ 2. ^! ' _____ * ,` 3. 4* 5. 6 7. . . e. 9. DRYEH~DISCHARGE ~ SOUTH LIME _______________1*43o' NORTH LINE 560 STRIPPER EVACUATION NORTH _ ... 11*094 SOUTH 2.43d VCL IN EFFLUENT WATER VCL F0* OPEN REACTORS VCL VCL VCL VCL VCL FROM BLEND TANK VENT FROM CONDENSER VENT FROm reactors VENT _ FROm.PURIFICATION COLUMN WEIGHT DIFFERENCE 1*990 1Z ~Z......Z"#03" ______ '___________ J___' 13*532 *19 3*294 41*567. 95 9.829 39.073- ..... .. .05 SB ou 14 .00 #00 54" .43 TOTAL ACCOUNTED FOR OUTTOTAL UNACCOUNTED FOH......... 6*964.481 ' 221*475 96.91 3.09 AP00041870 MATERIAL BALANCE ' ESCAHhJiA PVC PLANT Y T D ENDING 31 JJL 7ft PMrtUlS ------------------ ..................................... LBS ------------- ' SUB-TOTAL' A _VCL._USED. 8ASED_0N_B];lLING.. WEIGHTS.. ,. ' LBS % OF V.CL CHARGED TOTAL SUB-TOTAL total ____65*383*950. .. 100.00 6 PVC OUT TO PRODUCT___ . v7_62*82X*250 ......... .. . 1. PVC PRIME 60*827*000 93.03 2. PVC OFF-GRADE1*994?50,,........... .................................3.05. 96.OB c. _PVC LOSSES ~ ................................................. ......... :__ 1'." .480*821 ______ , ____ 1. PVC TO DUMP AS SCRAP 328*907 .50 2. DRYER DISCHARGE__________________________ 4*081. .01 SOUTH LINE _________2*181 __ NORTH LINE _______ 1*900_________ ........... ................... ........ _. _________________ __________ _3 *_PVC IN_ EFFLUE.nT_WATER_____ ___________ 147*833 .23 .74 D _.VCL. LOSSES._________________________________________________ 290*2.05.________________ .44 1. 2. 3. 4* 5. 6. __7 , 8. 9. DRYER DISCHARGE.116*229______________________________ ____________________ .18 SOUTH .LINE________ 79.157___________ ______________.... NORTH LINE 37*072 STRIPPER EVACUATION 54*890 *08 NORTH34*387 ___________________________________ _____________________________ _______ SOUTH . ____ _ 20*503 ______ . ___ __________ _____ VCL IN EFFLUENT WATER __ 6*916............. ................................ .01 VCL FROM OPEN REACTORS 271*393 ______ ___________________ .42 VCL FROM BLFNO TANK VENT ~ 3*955 .01 VCL FkOm CONDENSER VENT Hb*367 .13 VCL FROM REACTORS VENT ____________ 10*000______________________ _____ .02. VCL from purification COLUMN _ _____ ____ ____ _ .. .00 VCL WEIGHT DIFFERENCE 259*645- .40- TOTAL ACCOUNTED FOR OUT TOTAL UNACCbUNTEb"FbR.'7`_____ __ _ .. " __ 63*592*276 --''l *791*674 97.26 ~ 2.74 AP00041871 AP00041872