Document 4ry2X6VkeRrwdmkD5yYba6kp

* ** * * ** * UNION * ** CARBIDE ** * * * * Purchasing Department Technical Center OM-on 7 d- INTERNAL LoSMaX. S\a}&AaJjL' R'W A. ffljyLVKJt $#%*** f`e*4K. Post Office Box 8361 /h/.J, Building 2000 South Charleston, WV 25303' TO: D. L. Kurle - 511-2000/0411 A. Means - 514/224 S. Murphree^X- 515/7 IT L. Newman - 512/330 J. R. Ruddle - 512/143 C. S. Tyson - 512/507 M. K. Wlsman - 514/224 COPY TO: <sT"b Elder^ S. E. Illlkalnen J. L. Lamar A. 1, Montero <7c. Neely)-^ sTTrnpowe DATE: SUBJECT: [XCEIVEO CCH March 16, 1987 Specialty Chemicals Division - Purchased Goods Quality Program Gasket Team The minutes of our meeting of March 5, 1987 are noted below. A. Steve Powe presented copies of stores gasket catalogs for Institute, South Charleston and Texas City. Service level Information for stores Items was not readily available. B. Sherry Murphree Indicated that the West Virginia locations spend about $312M/yr. on gaskets, gasket materials and packing. Packing accounts for only 5 or 10% of the total. Anticipated expenditures for the next two years are $800M/yr. The Increase Is due In part to the anticipated phase out of low cost gasket materials (1.e. asbestos). Report attached. C. A1 Montero (who was representing CED for Don Kurle) reviewed UCC and Industry specifications. It was noted that some UCC specifications referred to manufacturers who no longer manufacture/sell asbestos gaskets/materlals. A1 reported that the recommendations (of the EM&TS CED team) covering a C&P program for the phase-out of asbestos In the work place had been approved by C&P Management. Sherry Murphree will participate on the C&P team that will develop Implementation plans. (A copy of related correspondence Is attached). UCC 015879 2- - D. John Ruddle/Jeff Means presented their findings relating to Accident/Incident reports and Safety Signal reports. Because South Charleston does not file A/I reports In a central location, Jeff was unable to submit a suitable sample. E. The team spent a good deal of time discussing a flow chart that represents gasket utilization from specification thru Installatlon/start up. The copy attached represents the team consensus. This chart will serve as a tool for Identifying areas where Improvements are required. ' F. The following "Mini-Teams" were established to list the perceived "Problems" throughout the specification - Installation cycle. The teams will meet In person or via telephone conference call as appropriate. Specifications/ Installation/ Engineering D. L. Kurle* J. A. Means C. S. Tyson Information Exchange (Electronic) P. H. Day S. F. Powe* J. D. Ruddle Materials Management (Including Procurement, Vendors, Stores, Descriptions, Packaging, etc.) S. Murphree* R. L. Newman S. F. Powe M. K. Wlsman *For purposes of -the win 1-teams these members are Identified as team leaders. x A "mini team" consisting of P. H. Day and J. D. Ruddle was established to review Institute Accident/Incident reports and develop Pareto Charts If possible. \ 6. A preliminary attempt at .Identifying problems resulted In the following lists: Specifications: 1) UCC specifications not compatible with marketplace (materials no longer available) 2) New technologies not addressed 3) No procedure for variance review UCC 015880 -3- 4) Manpower shortage In engineering 5) Specifications are not linked to material codes (stores codes/MMC). 6) Training to use specifications and to Identify the availability of specifications Materials Management Stores: 1) Lack of familiarity with resources (CRT, Flsche, Catalogs) 2) Storage of material (damaged material) 3) Incomplete stores catalog 4) Stores order controls 5) Inconsistent descriptions and no maintenance 6) Lack of training - shortage of people " The next meeting will be April 6, 1987, Building 2000 (Tech Center), Room 2428 from 12:30 to 4:00 p.m. The agenda Is as follows: - Review of flow chart (revisions If required) - Report on the review of Institute A/I reports - P. H. Day/ J.D. Ruddle - "Mini Team" reports Engineering Specifications Information Exchange Materials Management - First pass at prioritization (l.e. hlgh/medlum/low benefits vs. hlgh/medlum/low efforts) PHD/cw Attachments 0556a UCC 015881 Estimate fox. N*xT Ttoo /&APS received MflR 13 1987 contracting t, eciu. PURCHASING LOCATION 306 -- STAR 380 SISTERSVILLE 510 -- SEADRIFT 511 -- TECH CENTER 512 -- INSTITUTE 514 SOUTH CHARLESTON 515 -- TEXAS CITY 519 - TAFT PLANT LOCATIONS FIRST YEAR SECOND YEAR * 5,000 5,000 30,000 15,000 140,000 150,000 45,000 95,000 5,800 5,800 34,800 17,400 162,400 174,000 52,200 110,200 TOTAL TOTAL VALUE 10,800 10,800 64,800 32,400 302,400 324,000 97,200 205,200 CONSTRUCTION LOCATIONS LOCATION FIRST YEAR SECOND YEAR TOTAL . VALUE 510 - SEADRIFT 511 - KANAWHA VALLEY 515 - TEXAS CITY 519 - TAFT 5,000 60,000 lQ-,000 10,000 5,800 69,600 11,600 11,000 ` - 10,800 129.600 21,600 21,600 TOTAL 183,600 GRAND TOTAL 1,231,200 OR $ 1,231M oo r^ o I--1 UCC 015882 - 1 -s: V \ 10 5* CO Z w o os o o 2 t--1 CJ c Pu, o 5S < * ! 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H CO z ONiO CJ r- n- m <t H iO iO CO CO co < Ol i CJ f"H fH r-l --1 (k m in Joo S3 CD H Z CCMOGOCMrJ OO 00 00 O' OO CUM' 'K < \0 vO vD iD vO Wcnncnnn H (s*. iv. n r**- S3 1 1 1 1 1 H cm c\l CM CM CM HH *"H *--t H in m in in m co o o o o o z i--i UCC 015883 CD o OS OS ww pa w o ZHZHo n pa h pa O NS O NS OS z co z co pa pa < pa < o U ffl J J ... S3 <z<zz zozo - pappao< zzz z > h pa o pa o o z ooo o z -< z z o H CO i--i O' O' CO vD pa oo h oo o' oo .-a'd-Mj-'tf'a-'d' ZOvOOvOvD < co co co co co Zn-n-r^-n-nOI l l l l 'S' MT MJ- 'i- MT 5C r--1 -H i--t h mmmmm zooooo o CO CO CO CO CO o o in * vD fee o o o CO 49- o o m i vO fee H pa NS CO < u z o o z o o H z c -a z O' wm >J O' -a m KH CM >m CO 1 zo pa oo H co co o M CO 00 CO o * i-H CO 00 fe* o o in CM 00 fee vico ON -d* fee o o o 00 rvf fee C/3 < H O H EXHIBIT "B" GULF COAST PLANTS EXPENDITURES - 8/1/82 THRU 12/31/85 COMMODITY CANADIAN ASBESTOS FILLED SPIROWOUND GRAFOIL FILLED METALLIC RING JOINT HEAT EXCHANGER TEFLON FILLED VENDOR CONTRACT NO . AUTH. CORPUS CHRISTI 0510-3918 18,634 LAMONS 0515-3915 0519-3971 17,336 35,000 SEPCO - 0519-3924 1,724 LAMONS 0306-3917 _ 4,310 R&W 0515-3921 0510-3920 0519-3922 10,000 8,000 1,000 CORPUS CHRISTI LAMONS 0510-3964 0515-3969 0519-3970 13,931 30,000 5,000 ' LAMONS CC GASKET 0515-3968 0519-3916 0510-3965 1,000 36,000 9,664 EXP. 20,534 13,623 43,914 1,609 3,561 4,015 269 3,794 20,015 4,572 26,456 13,603 TOTAL 191,599 155,965 UCC 015884 * ** * * UNION * * CARBIDE * ** ** * INTERNAL CORRESPONDENCE Engineering, Manufacturing,- and- Technology Services Post Office Box 8361 Central Engineering Building 2000 Technical Center South Charleston, WV 25303 October 16, 1986 TO: Mr. L. E. Calvert Mr. S. W. Clark / Mr. 6. B. Elder-/ Mr. R. W. Engle COPY TO: Hr. C. C. Neely SUBJECT: Recommended C&P Program - Phase-Out Use of Asbestos-Containing Materials In Workplace Gentlemen: Attached Is a copy of your recommendation covering asbestos usage which I transmitted to Bob Perry. Thanks for your Insights and efforts In pulling this together. I'll keep your team posted as the recommendation proceeds through the system. Very truly yours. JES:he Attachment 4704Y UCC 015885 UNION CARBIDE CORPORATION;P. 0. Box 8361 Engineering, Manufacturing, and Technology Services So. Chas., UV 25303 Central Engineering ... .. BUSINESS CONFIDENTIAL September 30, 1986 TO: Mr. 3. E. Sanders COPY TO: Mr. L. C. Calvert Mr. S. W. Clark Mr. 6. B. Elder Mr. R. W. Engle FROM: C. C. Neely SUBJECT: Final Draft of Recommended C&P Program Phase-Out Use of Asbestos-Containing Materials In Work Place Chemicals and Plastic Group Attached herewith on behalf of the Special Working Group Is a copy of the subject document dated 9/29/86. It Is a slightly fine-tuned version of the 8/28/86 version which was transmitted to you under my transmittal also dated 8/28/86. The changes that have been made are of a clarifying rather than substantive nature. At this point, we have not made an effort to obtain broad, formal review of the subject program. However, Larry Calvert has discussed It briefly with the Maintenance APM's and Maintenance Managers. In addition, Stan Clark arranged for Its review by the Safety, Health Advisory Cown-lttee (SHAC), and your staff has reviewed It. Feedback Indicates these groups to be supportive of the concept, but some have expressed concern regarding the January 1, 1989 date specified for the discontinuance of the purchase of asbestos-containing materials, believing It to be optimistic. Some of the concern relates to the following: 1. CEO's ability to revise and reissue the V&P Specifications and the Valve Manual In time to support the deadline. The responsible CEO specialists have carefully reviewed this matter and believe that reissuance of these Manuals by July 1, 1988 Is realistic. This date has not been published, however. f UCC 015886 RECttvtu UNION CARBIDE CORPORATION ' crp 101986 str PR kavasmaneck ENGINEERING. MANUFACTURING AND TECHNOLOGY SERVICES DEPARTMENT ' HEALTH. SAFETY AND ENVIRONMENTAL TECHNOLOGY SOUTH CHARLESTON. WEST VIRGINIA MEMORANDUM September 5, 1986 TO: Mr. S.W. Clark Mr. O.A. Gosselln Mr. V.H. Johnkoskl Dr. P.R. Kavasmanecki^" Mr. J.A. Leonard Mr. J.B. Leverton FROM: T.E. Hanning SUBJECT: Asbestos Update For Your Information Hr. C.P. Maxwell Mr. J.E. Neff Mr. M.A. Patel Mr. T.P. Raby Mr. H.W. Wegert " kGriVEn' SEP 2 9 195u Labor union representatives are currently endorsing a pro posed asbestos ban by the Environmental Protection Agency. The unions contend that OSHA's permissible exposure limit of 0.2 fibers per cubic centimeter of air, effective July 21, provides insuf ficient worker protection. The proposed EPA rule would ban completely, five asbestos products that have effective substitutes. These products are: roof ing felts, flooring felts, vinyl-asbestos floor tile, asbestos clothing, and asbestos/cement pipe and fittings. Other asbestos uses would be phased out over 10 years. TEH/db 6209D Terry E. ^laannlng Extension' 5903 f UCC 015887 9/29/86 DRAFT RECOMMENDED C&P PROGRAM CHEMICAL AND PLASTICS BUSINESS 6R0UP (C&P) 60AL: PHASE-OUT USE OF ASBESTOS-CONTAINING MATERIALSH)lN THE WORK PLACE PURPOSE/BACKGROUND The Corporate Charter (1.1) contains the following commitment to employees: "To provide working conditions, programs of training and education, and persistent review and appropriate modifi cation of facilities and practices ^0 protect the health and safety of employees." It also contains a social commitment to conduct business "In accordance with all the applicable national and local laws and regulations." As a result of available evidence that airborne asbestos In the occupa tional environment had proven to be carcinogenic In man, all C&P Insulation Standards were revised In- 1976 to specify only asbestos-free Insulating materials; and new or replacement Installations of these materials have sub sequently been selected accordingly. Additionally, a Safety/Health Standard designated SH-256 was prepared covering the safe removal and handling (In cludes disposal) of asbestos-containing Insulating material during renova tion and demolition. The requirements of this Standard equal or exceed those of current applicable government standards. OSHA's rule-making efforts relative to asbestos usage In the work place are mired In controversy. Hearings on the latest EPA proposal which In cludes the phaseout of all asbestos over a ten-year period are now In prog ress. The proposal states: "EPA Is considering banning the manufacture. Importation, and processing of asbestos construction products and asbestos clothing soon after the rule's promulgation with the category of asbestos friction products banned about five years later, and other asbestos products banned at a later time." Gaskets and packing that contain asbestos are In the category of "other asbestos products" that would apparently be banned after ten years. No peer company that we are aware of has a target date for removal of existing asbestos-containing Insulation, gaskets, or paektng; however, one major chemical company has recently discontinued the purchase of asbestos-containing gaskets and packing. A cost analysis of pipe-size gaskets shows that GRAFOIL*, probably the most expensive of the acceptable gasket substitute materials. Is, in fact, cost effective when the cost of mandatory work practices associated with the use of asbestos (e.g. wetting for removal or airborne fiber f l')"Asbestos-containing materials" Include but are not limited to Insulation, gaskets, packing, welding blankets, and construction products. UCC 015888 DRAFT -2- 9/29/86 exposure monitoring during removal, placing In labeled plastic bags after removal, landfill disposal, and record keeping) Is considered. The same conclusion Is drawn relative to valve packing when the additional considerations of Improved service life and sealablllty are Included. Consistent with the aforementioned commitments and the economic use of materials, C&P has concluded that positive actions relative to asbestos-con taining materials^) should be taken. RECOMMENDED C&P PROGRAM . Except as otherwise provided by applicable law. Chemicals and Plastics Business Group will: Continue to phase out the use of asbestos-containing materials: Asbestos-containing Insulation shall be replaced with asbestos-free materials as required to maintain structural and functional Integ rity. - No asbestos-containing materials shall be purchased after January 1, 1989. C&P Standard Practices shall be employed for the Identification, removal, modification, and/or disposal of asbestos-containing mate rials; and for use of asbestos-substitute materials. Evaluation of asbestos-substitute materials shall Include considera tion of health effects as well as suitability for Intended service and cost. A variance approval procedure shall be employed to cover considera tion of uncommon circumstances. Approval must always Include en dorsement of C&P HS&EA management. SCOPE This Recommended Program applies to all C&P operated/hosted facilities. Other components of the Corporation will be apprised of Its content. . DELEGATION The assignment of duties and authority to carry out the Recommended C&P Program defined herein Is delegated as follows: To Central Engineering Department Develop and maintain C&P Standard Practices covering: - Identification of asbestos-containing materials; UCC 015889 DRAFT 9/29/86 -3~ - Removal, modification and/or disposal of asbestos-containing mate rials; and - Use of asbestos-substitute materials. To Line Operations Management Implement C&P Standard Practices for the Identification, removal, modification, and disposal of asbestos-containing materials. Implement C&P Standard Practices covering asbestos substitute material applications, and communtcate the service experience with these materials. To Manufacturing Services Monitor use of asbestos-substitute materials and communicate the service experience with these materials. - To C&P HS&EA Audit compliance with governmental regulations and C&P Standard Practices relating to asbestos-*contatn1ng 'materials and, where applicable, their substitutes. f UCC 015890 C. C. Neely 2073W FLOW CHART GASKETS PRODUCTION ENGINEERING PRODUCTION PURCHASING REQUISITION/ISSUE/SHOP ORDER/BM OTHER LOCATIONS HISTORY ------- --------------------SAM/VENDOR STOCK C BUYER ) GOV'T. REGS 3/5/87 0636a RECEIVING INVOICE AUDITING TRANSPORTATION US ER ^ ^(training) INSTALLATION T TEST/STARTUP/RUN UCC 015891