Document JJx9g5e36Xo017d7k3gRz956K

., UNION CARBIDE CORPORATION39 Old Ridgeburv Road Engineering, Manufacturing and Technology Services fADanbury, CT 06817-0001 TO: Mr. J. E. Sanders So. Chas., WV LOC. 511 DATE: February 17, 1987 SUBJECT: Recommended C & P Program - Asbestos Containing Materials The task group recommendation to phase out the use of asbestos containing materials in C & P locations, transmitted to me on October 14, 1986, is accepted. You should proceed to revise the appropriate engineering standards. BGP/pmc Attachment ,0LJZrtAt* B. G. Perry fv-f t'SCtP. UCC 0012732 * UNION * * * CARBIDE * * INTERNAL CORRESPONDENCE * Engineering, Manufacturing, and Technology Services Post Office Box B361 Central Engineering Building 2000 Technical Center South Charleston, WV 25303 October 14, 1986 RECEIVED TO: Mr. B. 6, Perry COPY TO: Mr. P. D. Franson Dr. P, R. Kavasmaneck Mr. W. G. Lilly, Jr. Mr. C. C. Neely Mr. S. W. Turlcchl SUBJECT: Recommended C&P Program - Phase-Out Use of Asbestos-Containing Materials In Workplace Bob: r 23 1986 S. W. IURICCHI RECEIVED OCT 2 0 1936 B. G. PERRTf In July of this year, you requested on behalf of the Manufacturing Council that a Task Group be assembled to evaluate the Implications for Chemicals and Plastics of continued use of asbestos-containing materials In the workplace. You should be aware that asbestos-containing Insulation materials were prohibited for new construction and for replacements beginning In 1976. The Task Group, headed by Mr. C. C. Neely, Corporate fellow - Engineering Mechanics, was comprised of the following Individuals and areas of expertise. L. E. Calvert S. W. Clark G. B. Elder R. W. Engle Maintenance Health/Safety Corrosion-Materials Valve and Piping Technology The Task Group has surveyed current and projected Industry practices with regard to the use of asbestos-containing materials and has evaluated current government regulations and made Judgements with regard to future regulations which could Impact on the use of and cost of use of asbestos-containing materials. Additionally, the Group evaluated the availability and cost effectiveness of substitute materials. UCC 0012733 Hr. B. 6. Perry Page 2 October 15, 1986 Based on available evidence that airborne asbestos In the occupational workplace has proven to be a carcinogen and that cost effective alternative materials are available, or can be developed with relative ease, the Team has recommended that CiP continue to phase out the use of asbestoscontaining materials with no purchase or Installation of asbestos-containing materials, without a formal variance, after January 1, 1989. Asbestoscontaining materials that are In use and retain their structural and functional Integrity need be replaced only If this Integrity Is compromised, or when normal maintenance occurs. Other recommendations are contained In the attached draft of the C&P Recommended Program. I want to thank the Task Group for their efforts In this study and for their breadth of Judgement as reflected In the recommendation. Please let me know of further work you require, or of any questions you may have. Very truly yours. JES:he Attachment 4701Y . E. Sanders UCC 0012734 UNION CARBIDE CORPORATIONP. 0. Box 6361 Engineering, Manufacturing, and Technology Services So. Chas., WV 25303 Central Engineering BUSINESS CONFIDENTIAL September 30, 1986 TO: Mr. J. E. Sanders COPY TO: Mr. L. C. Calvert Mr. S. W. Clark Mr. G. 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 Committee (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. CED'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. UCC 0012735 Hr. J. E. Sanders 2- - September 30, 1986 2. Belief that field testing of new gasket and packing materials will be required. Such testing will not be necessary since the plan at this time Is to accommodate most of the substitutions by broadening the use of materials already In use, materials such as reinforced Teflon and GRAFOILTM. This plan has not been broadly disseminated, and we can fully appreciate the reluctance to agree to a purchasing cut-off date for asbestos-containing products without knowing what the substitutes are. We also appreciate that, once this material substitute plan Is known, there will be a natural resistance due to the higher first cost of these substitute materials. 3. Some belief that Installers will need special training to handle the new gasket and packing materials. For reasons cited In (2), we do not believe this requirement will be significant. A. Perhaps lack of understanding that the January 1, 1989 date Is the cut-off date for the purchase of asbestos-containing materials except as approved by a variance. 5. "Is this really necessary" attitude. The Special Working Group believes that OSHA's recently revised exposure limit of 0.2 fibers per cubic centimeter of air {was previously 2.0 fibers per cubic centimeter) add significant impetus to Implement the proposed Recommended Program. According to Terry Hanning's September 5, 1986 memorandum (copy attached), labor union representatives do not believe that controlling the exposure limit to this lower level provides adequate protection. The above concerns notwithstanding, the Special Working Group decided to submit the subject Recommended Program to you with the January 1, 1989 date Included since we believe that, with proper communication with the key plant personnel responsible for Its Implementation, along with management support, this date Is realistic and achievable. We are submitting under separate cover a proposed CEO Technology Program which Includes request for funds to cover the Important communications aspect of the understanding, acceptance and Implementation process. Please let me know how we can be of further assistance regarding this matter. CCK:mr 43191 Attachment UCC 0012736 8/28/86 DRAFT RECOMMENDED POLICY CHEMICAL AND PLASTICS BUSINESS GROUP (C&P) SUBJECT; USE DF ASBESTOS-CONTAINING MATERIALS^ >IN 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 to 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 roan, 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 packing; 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 only the cost of mandatory work practices associ ated with the use of asbestos (e.g. wetting for removal or airborne fiber l1^"Asbestos-containing materials* Include but are not limited to Insulation, gaskets, packing, welding blankets, and building materials. UCC 0012737 DRAFT 2- - 8/28/86 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 scalability 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. POLICY 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 approved practices shall be employed for the Identification, removal, modification, and/or disposal of asbestos-containing mate rials. 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 policy 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 policy defined herein Is delegated as follows: To Central Engineering Department Develop and maintain engineering standards covering: - Identification of asbestos-containing materials; UCC 0012738 DRAFT B/28/86 -3 - Removal, modification and/or disposal of asbestos-containing mate rials; and - Use of asbestos-substitute materials. To Site Management Implement policies and practices for the Identification, removal, modification, and disposal of asbestos-containing materials. Use of CEO Standards covering asbestos substitute materials and the communication of service experience with these materials. To Manufacturing Services Monitor use of asbestos-substitute materials and the communication of service experience with these materials. To C&P HS&EA Audit compliance with governmental regulations and CED-developed standards relating to asbestos-containing materials and, where applicable, their substitutes. UCC 0012739 C. C. Neely 2073W <D H `"'x. UU. JUL 9 1987 Irju-/h.i~*r 4jf &Lt iS? = UNION CARBIDE CORPORATION P. 0. Box 8361 Engineering, Manufacturing, and Technology Services So. Chas., HV 25303 Central Engineering BUSINESS CONFIDENTIAL July 9, 1987 TO: L, E. Calvert S. W. Clark G. B. Elder R. H. Engle S. S. Murphree H. G. Clem, Jr. R. S. Holmes D. L. Kurle R. W. Light C. R. Morris J. A. Reynolds J. J. Polomskl K. C. Schmidt COPY TO: E. M. Bartrug, Jr. D. J. Dickson P. D. Franson G. E. Garrett J. D. Griffith T. E. Hanning T. E. Martin Carey Neal J. E. Neff C. JU Pelanne cJU E, Sanders FROM: C. C. Neely SUBJECT: Second Task Group Meeting July 23, 1987, from 1:00 p.m. to 6:00 p.m. Phaseout Use of Asbestos-Containing Materials In the Work Place* I Chemicals and Plastics Group The agenda for the subject meeting Is attached. Please note the full agenda, including presentations by two GRAFOIL" gasket experts from the UCC Specialty Products Group to help us settle some Issues regarding style of GRAFOILTM gasket versus service conditions. As you will also note, this will be a long meeting, and In appreciation for this extended effort, the agenda Includes repairing directly to a restaurant of our choice (consensus) for a period of relaxation and dinner of your choice. I personally look forward to our meeting and hope your schedule wtll allow you to attend as currently planned. See you there. CCN:aa Attachment 43551 UCC 0012740 AGENDA SECOND TASK GROUP MEETING PHASEOUT USE OF ASBESTOS-CONTAINING MATERIALS IN WORK PLACE CHEMICALS AND PLASTICS GROUP TECHNICAL CENTER. BUILDING 2000, ROOM 4505 JULY 23. 1987 1:00 P.M. TO 6:00 P.M. 1. Call to Order. 2. Adoption of Agenda. 3. Announcements. 4. Funding for Task Group Work Beyond Scope of T&S Programs (CCN). 5. Home for Asbestos-Phaseout Program Document (CCN). 5.1 See J. E. Sanders' June 22, 1987 memorandum (attached). 5.1.1 Assignment to prepare generic Summary Statement. 6. GRAFOIL" Gasket Selection vs. Service Conditions and Other Considerations. 6.1 Leakage and Blowout Test Results for Various Grades of 1/16" thick GRAFOILTM Gaskets vs. 1/16" thick Asbestos Composition Gaskets (KCS/OJP). . 6.1.1 Grade GKE (metal Insert, tanged). 6.1.2 Grade GHR (metal insert, adhesively bonded foil). 6.1.3 Grade GHP (polyester Insert, adhesively bonded). 6.1.4 Grade GHL (no Insert). 6.2 Other Pertinent Comparative Test Data, Above Gaskets (KCS/JJP). 6.3 Field Experience with Above Gaskets (KCS/JJP/GBE/OTHER). UCC 0012741 2- - 6.3.1 Finger Cutting Problems with Grade GHE. 6.3.2 Leakage. . 6.3.3 A11ied/Dow/Monsanto <GBE). 6.4 Cost Considerations, above Gaskets (KCS/JJP/SSM). 6.4.1 Type 316 Metal Insert. 6.4.2 Other Insert Alloys (e.g., Hastelloy C-276). 6.5 Delivery Considerations, above Gaskets (KCS/JJP/SSM). 6.6 Stock Inventory Considerations With Multiple Grades of GRAFOIL" Gaskets (LEC/SSM). 6.7 Quality Problems with Grade GHE. 6.7.1 Type 316 vs. Other 300 Series Grades of Stainless Steel. 6.7.2 Thickness of GRAFOILTM Sheet. 6.8 Review of Service Conditions and Action Plans to Date, above Gaskets. 6.8.1 Piping (RWE). 6.8.2 Machinery (JAR). 6.8.3 Pressure Vessels (DUO. 6.8.4 Control Systems (CRM). 6.9 Preliminary Matching of GRAFOIL" Gasket Grades with Service Conditions (ALL). 7. Fiber Exposure Data When Installing/Removlng Asbestos Composition Gaskets/Packing (RSH). 8. Fire Safety Considerations. 8.1 TeflonTM, Tef1on"-f111ed Spiral Wound Gaskets. 8.2 Nonasbestos Substitute Materials. UCC 0012742 -39, Action Plan Development - Asbestos-Containing Materials Other than . Gaskets and Packing. 9.1 We will use attachment to CCN's June 15, 1987 memorandum entitled "Background Data" as outline for this discussion (copy attached). 10. Asbestos In Mastics Used for Insulation Weather Barriers <HGC/GBE). 11. Status Report - Visual Identification Coding of Weather Barriers Installed Over Asbestos-Free Insulation (HGC). C. C. Neely July 9, 1987 43551 UCC 0012743 UNION CARBIDE CORPORATION ENGINEERING, MANUFACTURING, AND TECHNOLOGY SERVICES Central Engineering South Charleston, West Virginia UCC BUSINESS CONFIDENTIAL June 22, 1987 TO: COPY: C. C. Neely L. E. Calvert S. W. Clark G. B. Elder R. W. Engle P. D. Franson W. G. Lilly S. S. Htirphree - RECEIVED JUN 22 1987 CCN FROM: J. E. Sanders SUBJECT: Phaseout of Asbestos Containing Materials Clyde: Your April 6, 1987 transmittal of the Task Group Meeting Minutes asked that I provide advice concerning the permanent home for the asbestos usage phaseout documents and standards. 1 agree with your Task Group's recommendation that the program reside within the CED sponsored THS system. Recognizing that program statements and specifications for nonasbestos containing material will need to be addressed In several of the THS Manuali recommend that suitable summary statements be Included In all technology manuals that are Impacted by the Asbestos Phaseout Program. The complete text of the C&P Asbestos Phaseout Program should be located In the Safety/Health Technology Manual - Section 8. - The approach outlined above will accomplish two key objectives. First, the asbestos phaseout Is a wide ranging program affecting several skill areas and a variety of users. Maximum publicity of the phaseout rationale and approved substitute materials Is essential to ensure consistency and to reduce confusion. Second, any changes to the agreed-to program, handling of variances, etc. should be consistent within the THS program. Therefore, Including reference to the Phaseout Program In the relevant THS manuals will require that the responsible Manual Managers have U/A on all standard revisions. (DSafety/Health Technology Valve/Piping Technology Process Vessel Technology Insulation Technology Machinery Technology Materials Technology Others? UCC 0012744 Mr. C. C. Neely June 22, 1987 Page Two Please let me know should you or the Task Group members have any question or need further dialogue. JES:csn 5008Y E. Sanders UCC 0012745 UNION CARBIDE CORPORATION P. 0. Box 8361 Engineering, Manufacturing, and Technology Services Central Engineering June 15, 1987 So. Chas., HV 25303 BUSINESS CONFIDENTIAL TO: L. E. Calvert S. W. Clark G. B. Elder R. H. Engle S. S. Murphree COPY TO: E. M. Bartrug, Jr. D. J. Dickson P. D. Franson G. E. Garrett T. E. Martin J. A. Reynolds J. E. Sanders FROM: C. C. Neely SUBJECT: Background Data Next Task Group Meeting July 23, 1987 As mentioned In my May 18, 1987 transmittal to you, one of the agenda Items for our July 23 meeting will be action plan development for asbestos-containing materials other than gaskets and packing that are used In the C&P work place. The attached listing published by the Alternative Materials Institute will hopefully provide a fairly complete listing by categories of the various products that we must consider in our action plan development. This will supplement the article entitled "Alternatives to Asbestos" that Larry recently submitted to us. As discussed with some of you, l have arranged to have Karl Schmidt from the Cleveland GRAFOIl" factory participate In our meeting and lead a discussion of the various GRAFOIL" gasket products and their limitations. Karl Is an Application Representative and should be able to help us factually address questions regarding the trade-offs associated with their various gasket products as a function of service conditions. By copy of this memorandum, Messrs. Bartrug, Dickson, Garrett and Martin are requested to send a representative or representatives to this meeting to participate In the GRAFOIL" gasket style trade-off discus sions. The action plans that I hope will result from the discussions led by Karl Schmidt are ones relating to the use of GRAFOIL" gaskets In: UCC 0012746 Memo -2- June 15, 1987 pumps and other commonly used machinery Items; and control systems equipment. As requested earlier, please transmit meeting agenda Items to me by.Monday, July 6. Many thanks. CCN;aa Attachments 49171 Neely UCC 0012747 APPENDIX I fM 11 ALTERNATIVE MATERIALS INSTITUTE AMERICAN SUPPLIERS OF NON-ASBESTOS PRODUCTS December 17, 1986 NOTE The attached list of questions and products was prepared by ICF, the contractor doing EPA's economic analysis related to the asbestos rulemaking. AMI is providing this list as a service to its members, but in doing so, AMI does not suggest that all of the information requested should be shared among the members of the Institute. Some of ICF's questions relate to product prices, costs, market shares and the like. Although the information is needed by EPA, such data should not be shared among the members for antitrust reasons. We are currently developing mechanisms by which members may provide this information to EPA without sharing it with one another. AMI018LQP 60S Fourteenth Street. UW, Suite 900, Washington, OC 20005 Telephone 202 737-1419 UCC 0012748 , . g . 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O 41 o> w B b g a O Ci CO Z U 9 41 u 4> *> XI 3 O0 m <o V 9V 9 b. bi O U B o bi B JS B b> B * o bi bi 51 2 UCC 0012753 A o id b bi O i* bi O' f t x jf C oatings t Cements C e llu lo s e F ib e rs Polyethylene F ibers C lay, Talc What percentage o f the ro o f c o a tin g s or cement market is asbestos-free? Are there o th e r s u b s titu te s being used? 4a9o> E E3 0 kd wM no 0 m cS *> yID a * -* tn 5 2 2 #3 ss !i*3 U j<3_JHo V E O a W i0u <M "*OH 0 3 +>>1 x4ii oa *O1 *1*0 XJ -.pH* --y< u41mtH . a n <o at *i E e3 -H * <4-1 *> I n S1 uo UCC 0012754 V1I Document I3039D * UNION * * * * CARBIDE ** * * * INTERNAL CORRESPONDENCE Engineering, Manufacturing, and Technology Services Central Engineering Technical Center Post Office Box 8361 Building 2000 South Charleston, WV 25303 Febuary 19, 1987 TO; Mr, B. 6. Perry COPY TO: Mr. P. D. Franson Mr. W. G. Lilly, Jr. Mr. C. C. Meely Mr. S. W. Turlcchl SUBJECT: Asbestos Usage Bob: We are proceeding to establish plans to Implement the phase-out of asbestos-containing materials from C&P facilities. I have asked Clyde Neely to lead this effort which will require resources and Input from Maintenance groups. Purchasing, Safety and Health as well as Engineering Technology skill centers. Clyde will, In the next couple of weeks, develop a plan out lining the general steps required for this program between now and January 1989. We'll keep you posted on progress. .Very truly yours, JES:he 4898Y{4) J. E. Sanders UCC 0012755 UNION CARBIDE CORPORATION ENGINEERING, MANUFACTURING, AND TECHNOLOGY SERVICES Central Engineering South Charleston, West Virginia UCC BUSINESS CONFIDENTIAL June 22, 1987 TO: C. C. Neely COPY: L. E. Calvert S. W. Clark G. B. Elder R. W. Engle P. D. Franson W. G. Lilly S. S. Murphree FROM: J. E. Sanders SUBJECT: Phaseout of Asbestos Containing Materials Clyde: Your April 6, 1987 transmittal of the Task Group Meeting Minutes asked that I provide advice concerning the permanent home for the asbestos usage phaseout documents and standards. I agree with your Task Group's recommendation that the program reside within the CED sponsored TMS system. Recognizing that program statements and specifications for nonasbestos containing material will need to be addressed In several of the TMS HanualsO), I recommend that suitable summary statements be Included In all technology manuals that are Impacted by the Asbestos Phaseout Program. The complete text of the C&P Asbestos Phaseout Program should be located In the Safety/Health Technology Manual - Section 8. The approach outlined above will accomplish two key objectives. First, the asbestos phaseout Is a wide ranging program affecting several skill areas and a variety of users. Maximum publicity of the phaseout rationale and approved substitute materials Is essential to ensure consistency and to reduce confusion. Second, any changes to the agreed-to program, handling of variances, etc. should be consistent within the TMS program. Therefore, Including reference to the Phaseout Program In the relevant TMS manuals will require that the responsible Manual Managers have u/A on all standard revisions. ^)Safety/Health Technology Valve/Piping Technology Process Vessel Technology Insulation Technology Machinery Technology Materials Technology Others? UCC 0012756 Hr. C. C. Neely June 22, 1987 Page Two Please let me know should you or the Task Group members have any question or need further dialogue. JES:csn 5008Y E. Sanders UCC 0012757