Document KzX9dwaNq5EgbQjXLkr5Zvw7X

Internal Correspondence To: R. J. Mitchell 3-07 Dnte: April 13, 1978 From: J. P. Kline 2-30 Copies; R. J. Johanson 3-04/F. E. Brandt 2-30 R. F. Henry/G. -Jakelsky - MVL L.J. Richards/H.T. Brode-Den Subject: P32-7 483 Ball Mill Dust Collector P54-7452 Silica Processing Dust Collector As we discussed, the F.A. Walsh dust collector installed at Denison (and being installed at Manville) is experiencing problems with inadequate damper sealing. This sealing problem is serious enough to prevent proper shake-down of the dirty bags. ' We expect that Frank Walsh will return to Denison within the next week to correct this problem. Upon satisfactory completion of his work at Denison he will go to Manville to make the same alterations to that unit. As he is ' scheduled to be at Manville for his routine maintenance checks soon,we are hoping to have both collectors modified within the next two to three weeks. We'll keep you informed of future developments. JPK/gcp. \ Johns-Manville ' Sales Corporation Ken-Caryl Ranch Denver. Colorado 80217 (303)979-1000 April 6, 1978 i Mr. Frank A. VJalsh, Sr. Frank A. Walsh & Sons 13000 Athens Avenue Cleveland, Oh. .44107 ' RE: J-M PO#X07-07592 Ball Mill Collector - Denison ' Dear Frank: As we agreed on April 4, I am attaching a print of the Ball Mill system at Denison (Dwg. No.14695-2) plus a copy of our dust control layout (Dwg. No. 47829-2) for the new collector just installed. Both prints are marked up with pressure and volume readings so you can familiarize yourself with the system design. . We maintain that the dust bags are not deflating in the new collector due to leaks around the dampers, shaker arm boots, doors, etc. As we have explained previously, the entire ball mill dust collector system operates under negative pressure, not positive. . We are in the position where neither the Denison'or Manville units (PO#X27-08155) will operate satisfactorily as you have supplied them. We will not agree to t'he installation of bleed-in dampers until each compartment is sealed tightly, preventing all airflow through the bags during the shake cycle. . Please do not delay in correcting this problem at both locations. We are assuming that whatever deficiencies are present in the Denison unit are also going to present themselves at start-up in Manville. We appreciate your prompt response to the problem thus far and thank you in advance for your continued cooperation. Staff Engineer Environmental Engineering Dept. Attachments JPK/gcp. CC: - R. Johanson 3-04/F.e. Brandt 2-30 ' C.C. Pascale 2-26 (P.0. #X27-07592 & X27-08155) L. Richards/H.T. Brode - Denison S. GiJlesnio 7-07/1?.J. Mitciv 11 7-07 Johns-Manville internal Correspondence To: S. B. Gillespie MAY 1 6 1377 DM0` Ma* 19"- From: E. J. Mitchell Copies: VI.. E. Volwi le r, /L. I. Richards/Denison,)AR File, file/clirono Subject: REPLACE BALL MILL DUST COLLECTOR-DENISON PLANT AR026-EC883R $111,900 This proposal would replace a collector which has been in service since 1958 and which would not be specified for a new installation of this type today. It is overloaded by present day standards and, as a consequence, cannot be maintained to meet J-M criteria for internal cleanliness, dust emissions and personnel exposure. . ' Bag-type dust collectors for- service in J-M asbestos cement pipe plants must have air-to-cloth ratios not greater, than " 2:1. They must be shaker type with access to bags on the clean air side. They must be continuous-automatic, meaning ' that they clean themselves on a time cycle without interruption to the process they serve.. And, they must be easily accessible - for internal inspection while in operation. ` Meeting all of the preceeding criteria means a larger' collector, which translates into high installation costs for structural modifications, conveyors and electrical work. An in-kind re- placement is estimated to cost $21,000 for the collector ($53,400, installed) versus $30,000 for. the proposed collector ($111,900, installed) which would meet all the criteria. There would be a cost reduction (though not sufficient to justify this expenditure in itself) of about $3000 per year. Other than routine inspections, no bag replacement or shaker maintenance would be contemplated for three to five years. This improvement in collector reliability should also result in some increase in ball mill operating time, hence improvement in production of ground silica (SILEX). ' RE: REPLACE BALL MILL DUST COLLECTOR-DENISON'PLANT AR026-EC-883R - $111,900 Page 2 - May 11, 1977 Intergrinding of A/C pipe waste material with sand should be a reality within two to three years at Denison. This would increase the potential of personnel exposure and release to atmosphere of hazardous materials (Silica and Asbestos). It therefore, seems prudent to up-grade this collector to the "state of the art" level rather than a replacement-in-kind which would not perform the job as best we know how nor give maximum protection against personal risk to maintenance and operating personnel. This is part of an item in the official 1977 CEP, under CR: "Improve Silica Classifier," for which $30,000 was originally planned. All work would be by outside contract.' Involvement of plant, workforces would be minimal. Approval is recommended. ' ma < WHA 0158. 16:04MDT DON 0042 16:24MDT 05/03/78 . <D0N 1074> . .* //23428LM// 5/03 H. BRODE ' . .. . ... *t 1 . . $' 'l . V , Vi*. ' 'r RE:- BALL MILL WITH THE ELECTRICAL CHANGES YOU ARE MAKING CAN.,,YOU,1 i' ;Tv r (PEN THE DAMPERS FROM.INSIDE THE COLLECTOR. ALSO'DO YOU.KKNNOOWW ' ` OF AANNYYBBOODDYY WHO REBUILDS DUST .COLLECTORS. IN THE FORT WORTH -..DALLAS-;., J^o/v AREAi.\ thanks.. /' '* ' 4- .. '... -. \ ,TTM P v% TMP. S> V- -I : i"ji ; v&,/;;'i&f. 7 >. is7; ..* "."MVP.:-' i'i :!u.j \ J' it' '! '1 Vi;./ . 1 .*' .if - WHF 0132,16.02MS.T/DON 0055 16.13MST 03/24/78 , ''' ' <DON 1 1 32>.. '* - . /" ' V* V i ; '. i.V V" . : /: V ' 1- -n '!!' . 77 i-y~-7/- wi/r : j.; /, ` 7- ' jS - f'VV ;?;>.-fr. //23428LM// 3/24 '\ > . . * Vv h.. brode; / . . 7- ... ` '/>;: * o-:- / v :vf-x'j : ......W"'-- RE: B-ll MILL DUST COLLECTOR PER .YOUR SUGGESTIONS I WILL RE-' AT , ' ' :: - ' ' ' l \ DENISON-ON TUE MARCH 28 AND WED MAR 29 WILL ARRIVE ABOUT 1:00 PM .', TUES REGARDS. /' 7 -V; / i ; ; .li. I *: 'JIM KLINE 2-30 . . , t. * ;-v* ' .. . ; `...i i'jhlr .... v.; . *. .-1..Jf.;,-.'-i /.. \ ` - - 'i'1- ; I' . : . - , 1 T": ` ;,-ij .!.iif.; l< . :' * * \ 7*j,$< ( /* -W V*f Y \f K * * >!&*+: ?.'** : * ,< I ,\ \ '1 .V..WH 0050 10132H0T o ocm't# r#f.\ * a *;- * * t* i.<( v vy ", - *, , ":^`,,'T :* .,,* '** . ' . 1<3* 47MDT 05/0A/7ef'fc ^ ' . *i\ * 1 <PON DON. 5050> * ! Vf ,:1 . * :v * f "-? -v^-. ?/V- " //04202AM// 5/4 t L RICHARDS H.BRQtyS i' . * rt?.'*' |r . -. '.rfc RE NEW BALL MILL DUST ' COLLECTOR --i/IS EVERYTHING, SATISFACTORY? '. , ` . V!, v ** . * . ' m . ** W NOT* PLS LIST THOE THINGS NEEDING ATTENTION. . .:i \/.v,- 5 . J\ ,, : ra. *** , . i'4iVr>f>^ <r;'\ ;: . ', (!'-.......S,"'. , ), t ,, . ' ' - 'i'l . `i ij: ';; 4tf* ' * . '. '.; : ? ?*' ^'V. ? .?v.' !U'; I*" ,. ^ ,*'*'*. * "': ito\J * * ' v ' * * 1 > ; ' t f '* A fiE //,') tuj )-**?& .Ujtut^:``I'pfr 1 ; r &+n/ie i***Z*R~: (ty: H M*v. mi* .. wr*''*><*,1 $ i'vh'HtJv ' . ;-.\ -m-*. r: ;^.v .! !'' H'<': v-Mv/ : \ i <JHQ 35>, /. , . . * !' i \ ; > 1 ' ' / 'y ) ; : . `fp ; :.rVv'?a ... i'.V. ;."i. . . :: . ' : | ' .... , , . iU-r-.' ;' if>.'. .' , .. .. ::=;? ` \' r . . ,ir& S. 05/05/78 jmitchell* e j; . - RE NEW BALL MILL DUST COLLECTOR - .AT THIS TIME EVERYTHING OK. ' . ; ' .' ; . : : , MY ONLY RESERVATIONS ARE . .. . . . .` ' v ! ' t ' ' : , 5?^ ' "* '*' ' : . , f '. ' . rlk . ' i . : ' > :>. 4>' . ' .f.. , .... I. HOW LONG WILL.THE DAMPERS LAST IN THE HOT ENVIRONMENT. 2. - HOW WILL THE SILICA TRANSPORTING ' PERIOD OF. DAMP. WEATHER . ERODE : " ' LINE WORK IN AN EXTENDDEEDD;;//!!;- .; ; ./ i 1 ;' ` -V . . . '! i . > i-f ../. '* t. r:-.; .;..V !r^. \W0-$P-:: v I; , Jl -vlf wkP WMP AITROV.C dliTf: ' t. flIffjjnncct rfivaet W.E. RdUSh--0eitH3OI> 0:r. E*>v. fug. r; Hillffir i-v. 2 KSrMi?P2.iSK Hgr. W.A. Sells s. o;r.profit fun ^fo TgfaaY 3. mac c/c S.B. Gillespie -7-.--V-J---.F-ur.8IctSSnq.Ssrv. M. SlVettl 4. c;~ w.l.^Gregory - APPROPRIATION REQUEST No. Q26-EC-.883-R 'wdocATiCN DSN I SON division I&PPM cept N-*ME TRANSITS dept no. 070 TITLE: RBPT.ACE BALL MILL DUST COLLECTOR..................................................................' I.PURPOSE: To provide a new dust collector for the Ball Mill classifier system* tt*present"FACILITIES: The present dust collector is a- two-compartment auto * mat t'c~REESE "dust collector. It was installed 18 yrs. ago; The shaker mechan- ` ism requires constant maintenance and the bags bleed through so there are . several inches of dust on the floor in each compartment. The collector does .. not meat company guidelines of 'art air-to-cloth ratio of 2'sl. The dust collec tor is necessary to prevent ground silica from being discharged into the atmos phere. Portions of the classifier system are being replaced in AR026-R-868. III.PROPOSED FACILITIES: A new dust collector will be purchased and installed. TEe"uriit will be a 4-compartment continuous-automatic dust collector, shaker type, 3,500 CFM, and gross air-to-cloth ratio of 2:1. Engineering of project will be by General Environmental Engineering. (GEE) . . ESTIMATED COST: Life Systems . Capital Item. Description . Cost Yrs. Dust Collector . $ 30TMo IS Account /4l5~ 1112 Par, 3.A.2 Conveyor & Rotary valve 5,00C 15 2415 . 3.A.2 Wiring & Controls ' 5,003 15 2415 3. A. 2 Installation Labor 50,503 15 2415 3.A.2 Spare Parts . 1,000 15 ` 2415 . 3.A.2 Engineering ' 9,000 15 2415 3.A.2 ' '7 Total Capital . $1^0,500 Expense ' ^Taxes " Total Expense Sub-total ' 2,400 2,400 fl'02,800 012 2.B * ,, '/ Contingency TOTAL APPROPRIATION 9,000 $111,90'? ' ' ' X' ' *. v.BENEFITS OR SAVINGS: The new dust collector will reduce emissions of silica from the ball mill classifier system, reduce exposure of maintenance personnel!1. to silica dust and reduce maintenance costs. ' VI.OTHER INVESTMENT:' . None. ' . ' ' VII.DISPOSITION OF PROPERTY: .Retire :.ust Collector Q26-RP-884 ` : 111. LABOR" fi UTILITY REQUIREMENTS: Nom IK.REMARKS: . . . 1. Job "Order No. 6846 3. Work to be done by outside contractor ' 2. Cost Estimate J. P. Kline, GES, 2-11. C Ye* O No. Meat reqmt*. of C 331*1, 331*2, 332*1? (3 Yc? O No. On olfic. cp. project* list? P 331*3 13 Ye? No. RETIREMENT PROPOSAL, attached? O Yes C3.No BOCGET AODiTiON requested for expense ' pertion? * FINANCIAL ANALYSIS/CERTIFIC^nON: itRt..mnnF -- rv *7 --'' . Approusl autiwizai exped. of .. -------- O Ye* Qno. Ctrp. Finance OK? ONot amenable to FA REFS3 TO SYSTEM? ?U FIR REQUIRED APPROVAI LEVEL i TITLE jlHtTIAL I[ 'K3?f55ms6>t?*Et!T.}----------'-------------- Y^xse Y.P. FIN. & AOM. (S2QCM) 1 I SB. VJ>. PRGO. & EN. IS7SWJ ' jSR. VJ>, CQRP. MKT. iSSCM & S/FI "TT-T ! 1 SR. VJ, J-M CORF. I050M1 Jj12 OAT1. TITLE V.P. J-tft CORF. (S33M OIV. GEN. MSB. (SZSlil felV. PROD. MOlft. teflRi""...................... , . ~ri RES. DIR. IS2MJ DIR. GEN. SERV. IS5MI FLT. or MINE MGR. ISM) INITIAL . DATE ^ L____.____ vmmmwi , > DENISON AR026-EC-883-R Replace ball mill dust collector ?AGE 2 - 5/5/77 IX. REMARKS: (cont.) 4. Capital Commitment 12 35,000 m 10,000 Capital Spending: 12 3 7,400 4 34 10,000 56 7 - 45,000 14,500 56 7 - 42,000 30,000 'Nil*