HDPE Daily Report

09-Jan-18

Plant Load (MT/Hr.) : 23.5

PRODUCTION : Production Prime % NP % Utility %
Qty Day Month Year Month Year Month Year Month Year
Month Target MT
Grade B5004
Actual Powder Prodn. MT 348 6957 174451
MT
Actual Pellet Prodn. 348 6957 174397 6957 148912 0 24487 0 998
Standard Production : MT 1068
% of Standard 33% 100.00% 85.39% 0.00% 14.04% 0.00% 0.57%
Shortfall for the Day MT
Reason for shortfall
Low polymer bagging 441 bags 7 MT 47.94 LP Monthly (MT) POLYMER WASTE
CONSUMPTION CUMULATIVE PRODUCTION Day Month
Sp. Actual Sp. Production Production Yearly
Day Grade Target M/c waste 0.0 9.0000
Consumption Consumption monthly (MT) (MT)
Waste
Ethylene (MT) 393.0000 1.0890 1.1293 M6008 0 0 8045 1.0 11.2000
powder/pellet
Propylene (KG) 0.0000 0.0000 0.0000 B6003 0 1209 49455
Butene-1 (KG) 0.0000 0.0259 0.0000 B5004 3300 223 2211
Hydrogen (Nm3) 1694.0000 0.4464 0.4375 B55H03 4400 0 13812 Down time
Power (MW) 197.9000 0.3618 0.5687 F52H04 6500 0 55534 GRADE B5004
HP steam (MT) 0.0000 0.1030 NA** R5504 3900 5524 16056
MP Steam (MT) 84.8800 0.1040 0.2439 M5306 0 0 Poly Down Time (hrs) 6.00
LP steam (MT) 68.6700 0.1820 0.1973 M5618 0 0 0
DM water (MT) 226.7100 0.6000 0.6515 P4402 0 0 0 Extruder Down
Time(hrs) 12.00
Nitrogen (Nm3) 49629.2500 38.4000 142.6128 P50H03 7600 0 11291
20% Caustic (m3) 7.0400 0.0088 NA** P51H10 0 0 465 Plant load at
06:00(mt/Hrs) 23.50
Service water (MT) 10.9700 0.3600 0.0315 P4402U 0 0 0
Instrument Air (m3) 14168.5000 54.0000 40.714 Y5808 0 0 1282 Yesterday's Plant Load
@ 06:00 Hr. 0.0
Plant Air (m3) 22594.7500 9.5000 64.927 F5010 0 0 4802
CW supply (MT) 199916.0000 228.0000 NA** Y5008 3300 0 10446 Rated Production Rate 44.50 MT/Hr.
EXPORT : Utility 0 0 998
Condensate Return (MT) 368.21 0.292 1.058

Catalyst & Chemicals

RZ Catalyst (KG) 12.65 0.042 0.036 Total 29000 6957 174396
Teal Co - Catalyst (KG) 35.00 0.08 0.101
Calcium Stearate(HA) (KG) 840 1.5 2.414
Irganox 1010/ Eunox 10
0 0 0.000
(AE)
I-168 (AK) 445 0.7 1.279
UE 0
Irganox 1076 / Anox PP 18
0 0 0.000
(AF)
Pep-36 (AN) 0

Remarks:
* Plant Status
> Plant Load 23.5 MT/hr, Grade:B5004
> RR-201/RR-221 Catalyst feeding done at 11hrs/14hrs respectively, RR-201/RR-221 Ethylene feeding done at 12hrs/15hrs respectively
> EE-224B Circuit boxed up done, leak test also done. N2 PDP is u/p.
> Extruder Started at 17:30hr, Load: 24.5 MT/hr.
Concern
*
Concern Action Plan* Action By Target Date
Dryer chest pressure High on higher load. EE-301cleaned but no improvement found.
MM not
Additive stock critically low. Technical Evaluation Completed. Materials
confirmed
1) Expedite Approval and PO.
RR-201 & RR-221 Teal flow meter not working Instrumentation
2) To install flowmeter after receipt.
Steam leakages arrested in Shutdown. New Instrumentation/M
B/L HP Steam Flowmeter showing higher value
leakage developed. DP increased due to ech
Elutriator system not working properly SECL to consult with Vendor for modification SECL

Additive & Chemical Stock Silo Status

RZ Catalyst 4,330 Powder Silo (MT) Pellet Silo (MT)
TE Catalyst 1,420 SILO GRADE QUANTITY SILO GRADE LOT NO. QUANTITY
TEAL 0 TH-400 B5004 21 TI-453 R5504 180140010 7
TI-401A TI-461 B5004 180140022 103
Calcium Stearate(HA) 34,000 TI-401B TI-451A R5504 180140020 56
DLTDP (AA) 0 TI-402 B5004 25 TI-451B B5004 180140021 120
BHT (AB) 0 TI-451C
Irgafos 168 (AK) 12,760 TI-451D
AL (I 3114) 0 TOTAL Powder 46 TOTAL Pellet 286
Irganox 1010 (AE) 2,000 rz 50
Irganox 1076 (AF) 36,500 pz 25
DSTDP (AD) 1,500
AN (PEP 36) 480
HB 0
DHT 4A (HD) 0
HG (Calcium Carbonate) 0
Zinc Stearate(HF) 0
EB 17,320
Tinuvin-326 (UC) 1,080
Tinuvin-770 (UD) 600 PURE Hx TANK TT - 702 (MT) 358.9
Tinuvin 622 (UE) 5,720 TT - 702 Pumpable Amount Balance(MT) 234.45

NA** : Totalizer not working properly( HP steam B/L flowmeter showing high value due to high pressure drop)
** Detail action plan submitted by Maintenance seperately.