Document MGmaXdKe4K7Xn4aXmZBV9XRLV

COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE PLAINTIFF'S EXHIBIT AL-1336 DATE: July 29, 1994 Enclosed you will find a copy of Composite Structures Divisions (CSD) responses to the ALCOA Corporate Audit that was performed by your team on May 4-6, 1994. On or before August 22, 1994, please review this and make any comments or corrections that you see that would assist Composite Structures Division in identifying, isolating and resolving a possible problem at the facility site.' If you have any questions after reviewing this data, please contact Adele Laikin or myself at extension 3250 or 3237 respectively. 1 C60699 0193 o 0 ft A^\ r^ (\> vT % 0 O 1<- 6 C60699 0194 CONFIDENTIAL ** The following situation and recommendation is a brief description of a potentially complex set of conditions. Readers who are not aware of the total situation should refrain from drawing conclusions. Environmental Review Composite Structures Division May 4-6,1994 ( ~~ AIR vf-..I >4iv<!:Aiiic'M'^n^-^^%Speclal:Sltuatlon.i:j:-sr:v,i- *' - Rule 1124 ComDliant Materials Manaaement Auditee Response and Action Plan: C60699 0195 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 D. ACTION ITEM: Rule 1124 Compliant Materials Management RECOMMENDATIONS: Develop and maintain a substance documentation file detailing how the VOC content of each paint, primer and mixture was derived and calculated. MSDS and VOC calculations are to be formally requested) using the purchase order system. PERSON RESPONSIBLE FOR ACTION ITEM: ^ ^ sjoc conierfr-cyprp Joel Feder (or designee) to get information ESH Department to maintain document files (3 weeks of temporary set up assistance required initially) 'v*x' Ccccr'^5 rynjcer* ESTIMATED COMPLETION DATE: or Start date: July 5, 1994 Completion: November 15, 1994 ESTIMATED COSTS: S500. for temporary assistance. Only labor hours will then be utilized to request and maintain a VOC log on calculations (40 hrs./yr). COMMENTS: 11 C60699 0196 CONFIDENTIAL ** The following situation and recommendation is a brief description of a potentially complex set of conditions. Readers who are not aware of the total situation should refrain from drawing conclusions. t Environmental Review Composite Structures Division May 4-6,1994 . AIR/-,*-.*. Special Situation -i - o. Current Alternative Emissions Control Plan (AECP) Status Auditee Response and Action Plan: U-V} k,^ -/er a/wf>y\ ^ uJj C60699 0197 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 C. ACTION ITEM: Alternate Emissions Control Plan (AECP) Status RECOMMENDATIONS: 1. Stop using more than 9 pounds/day in AECP paint booths. 2. Implement Rule 1610 "car scrapping program". 3. Void out AECP plan once Rule 1610 is in place. 4. Assemble and implement a Paint Booth Operational and Management Plan for compliance with the SCAQMD permit conditions. PERSON RESPONSIBLE FOR ACTION ITEM: 1. Tom Blecka and CSD painters are to monitor compliance with 9#/day VOC limit. vO'rO Va\\\ rv\o rules' 2. ESH department will continue to implement Rule 1610 program, (7 VLg 3. AECP plan will be voided out by ESH department once the Rule 1610 plan in is effect. 4. Frank Soldo, Tom Blecka and Mike Gigliotti (or designee) arethe^. , responsible individuals to review and assemble a Paint Booth Operational and Management Plan that is in compliance with \ -ferrrv<2PlV' SCAQMD permit conditions of 9#/day VOC. L ESTIMATED COMPLETION DATE: *>C cat- 1. 9#/day limit compliance has been implemented as of June 1, 1994 (completed). 2. Short term, the rule 1610 plan will be available for emissions usage by August 25, 1994. Long term, the plan will be reviewed and modified^ until December 23, 1999. ---------- -=4yi\i>r^>'rd roe-i-e/tT.7 -to 3. Upon implementation of rule 1610 (August 25,t1994) the AECP plan will be removed as a permit at the same time. posited1^ t{~as\ be C60699 0198 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 4. The Operational and Management of the (2) AECP plan paint booths will have to be implemented quickly on a day to day basis until the rule 1610 planjsjn effect. Star|/Xugust 30, 1994"apd completion October 30, 1994 - non ESTIMATED COSTS: 1. The 9#/day limit has no costs involved in implementation. 2. Emissions from rule 1610 have already been paid for and no additional costs will be incurred except minor labor costs (25 hrs.). 3. No additional costs will be seen for the elimination of AECP plan (51 hrs.). 4. Only labor hours will be used to review and implement an PaintE Operational and Management Plan (40 hrs.). COMMENTS: l frn 10 C60699 0199 ** CONFIDENTIAL ** The following situation and recommendation is a brief description of a potentially complex set of conditions. Readers who are not aware of the total situation should refrain from drawing conclusions. Environmental Review Composite Structures Division May 4 -6,1994 Permitted VOC and Emissions Limits Auditee Response and Action Plan: C60699 0200 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 B. ACTION ITEM: SCAQMD Permit VOC Usage and Emission Limits -RECOMMENDATIONS: 1. Clear up SCAQMD permit conditions on limits of VOCs. 2. Stop using methylene chloride as a clean-up solvent in the paint booths. 3. Stop using over 40 pounds of 111 trichloroethane (TCA) per day in vapor degreaser, building B-1 main process line. 4. Track all TCA usages. 5. Review operational needs and ability to schedule and manage spray booth operations within the permit conditions. PERSON RESPONSIBLE FOR ACTION ITEM: 1. The ESH department will schedule a second meeting with the SCAQMD to review and modify the permit conditions for the CSD facility VOC limits (Consultant may be required)^\<=pJL 2. The area supervisors (T.B., S.G., R.P.) are responsible for keeping . methylene chloride out of paint/primer booths. cLDguV- gIm* VoOu>\U Vn'^>bc^cn't'-Cu^vi Cre.C&p 3. John Navan is to assign a Liaison Engineer a high priority task to identify and get approved a substitute paint, primer, and adhesivt primer clean-up solvent and gun cleaner that is acceptable to / ? SCAQMD regulations (to replace existing M-114M). ^ 4. The Department supervisor (Steve Gaudesi) and the Maintenance Supervisor (Dale Cortner) to insure that only (40) pounds of TCA is used daily and report any additional usages to ESH department. No additional material is to be added for any reason. 5. The ESH department will be responsible for the care and storage of the documents for a two year period. (?) rv^v We.TM 50 ^ *5 6. John Balicki and Steve Gaudesi in conjunction with Mike Gigliotti is to review the operational requirements of CSD and assemble a plan to manage the spray paint booths daily VOC requirements within the permit conditions. ~ V c'Wi- \JtiC, ro? -Sffcsj becta 5 C60699 0201 Ck be. enso*-12VOC- Lnii.}-- \t> ne+- exceeOei ^ pecrvu.4 ~fCA ^p\ac/WK>l - COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 7. Richard Stewart is to publish an internal memo to the manufacturing Supervisors defining the TCA limits, paint booth limits and the consequences and responsibilities of exceeding permit conditions (completed), -yj^yj cGooyr\ urf- <^o 'Vn'b-5> uuJJKWojAt pernnvf'e. hpV \o-e- reovcuxA- cA-A)) ck~ ^Lj ESTIMATED COMPLETION DATE: 1. The ESH department will initiate a meeting with the SCAQMD in August 29, 1994 with a estimated completion of the permit conditions limits of January 1, 1995. 2. The department supervisors are to eliminate the usage of methylene chloride (M-114M) from the paint booths by September ?n iafl4 and use other acceptable materials in the interim until a new clean^upV^ solvent can be identified that works better (by April 30, 1995). 3. Liaison Engineer is to start the identification of a new gun cleaning solvent by August 30, 1994 with an estimated acceptance of a new clean-up solvent being identified and implemented by April 30, 1995. s' ~'A ,---- - 5You-\^ Vcv-6_ eArte.4, UYVvejiiCtie-V-/ 4. As of Arne 1, 199^, only 40# of TCA will be used per day within the vapor d&greasSr 5. The ESH department will have an archival system for the storage of old files set up by December 30. 1995. -- 6. The Vapor Degreaser Operational Management Plan drafts will be available for review by CSD management by December 15, 1994 and be finalized by April 1, 1995. uJtyJo 7. Richard Stewart memo on TCA usage and VOC paint limits is to be published by June 15, 1994 (completed). ESTIMATED COSTS: 1. Establishing VOC limits in the paint booths will only require labor hours unless a consultant is contracted to resolve permit issues, which will then cost $2,500 (80 hrs.). 2. No major costs differences will be incurred. M114M costs will diminish as usage goes down and new solvent costs I increase as usage goes up. , be 7 C60699 0202 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 3. Minor costs will be involved in the identification of a new solvent that would be acceptable to the SCAQMD and the prime contractor. These costs would be in the form of labor hours for the Liaison Engineer and minor costs for additional testing of the material at CSD (120 hrs.). 4. An unknown costs would be incurred when the limit of 40# of TCA is enforced. This would be in the form of more hand wiping of the parts_hu^ yj\*^ instead of vapor degreasing. This can be off-set by eliminating the ul* > parts that do not require degreasing by specification, alkaline ` cleaning, and switching to Brulin 815GD (Boeing). 5. Minor costs would be seen by the additional storage of documents within the ESH department. Costs would be in the form of filing cabinets and floor space ($75). 6. The vapor degreaser operational management plan would not cost a lot, only in the one time labor hours that it would take to assemble the plan (180 hrs.) 7. No additional financial costs would be required to write and publish a memo by Richard Stewart (5 hrs.) COMMENTS: 8 C60699 0203 ** CONFIDENTIAL ** The following situation and recommendation is a brief description of a potentially complex set of conditions. Readers who are not aware of the total situation should refrain from drawing conclusions. Environmental Review Composite Structures Division May 4-6, 1994 r-'.-1- ' : < ' 3" ---"AIR'.------ - Special Situation SCAQMD Rule 109 Recordkeepina Reauirements Auditee Response and Action Plan: - 'UwTM! 5,5^ Ae . at ie^oit*rvJnb in rvS- -) oWn 5c. 4 Qnol) f C60699 0204 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 II. ISSUE: AIR EMISSIONS A. ACTION ITEM: SCAQMD Rule 109 Record keeping Requirements 1. Solvent clean-up or wash-up quantities are not tracked or recorded. 2. Keep all records for two years. 3. Comply with all parameters on permit conditions (recordkeeping, I usage, materials, PM programs...). \I RECOMMENDATIONS: 1. Start to track solvent clean-up and wash-up materials used in the paint, primer and adhesive booths per Rule 109 including paints, primers and adhesive primes. 2. Keep all records (TCA) for (2) years minimum. -- crA-) 1 CA "T 3. Review conditions and parameters on all permits for compliance. 4. Buy a computer based system for VOC compliance (1 in a new pain mix cage). 5. Implement a PM program for permitted equipment. ^ ^ PERSON RESPONSIBLE FOR ACTION ITEM: 1. Tom Blecka for the (5) paint/primer booths in Building B-2, D & E for record keeping. Steve Gaudesi for (2) adhesive primer booths in Building B-1 for record keeping. Ron Padilla for (1) adhesive primer booth in Building "U" for record keeping. 2. ESH Department will be responsible for maintaining the paint records for a minimum of two years, ^nb> Tk_ tecord poU<-^ ttscAcn 3. The ESH Department will review all permit conditions for compliance to SCAQMD parameters. 4. Lee Kemble will be responsible for the maintaining and Preventative ' ^ Maintenance (PM) of the paint, primer, adhesive booths, scrubbers _all_other permitted equipment. cl i rVj 5. Adele Laikin will buy the computer software program (completed). "tvV} Ws \foc G^c<iS3 ^ C60699 0205 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 6. Lee Kemble to assemble a paint mix cage (fence & power). 7. All supervisors will report on the daily solvent usage. ESTIMATED COMPLETION DATE: 1. The documentation of solvent clean-up and wash-up quantities will be D started by October 30, 1994 in all coating booths and continues from C now on including facility wide documentation by September 1, 1994.0 WVuA tedVny ? 2. Record retention for two years is currently being done in 90% of the facility and 100% as of October 30, 1994. \on\ -- ibnrts - -J 3. Review of all permit conditions will start as of October 30, 1994 and be completed by January 30, 1995. -- 'ooV-t 4. PM programs will be evaluated and a draft program assembled by December 1, 1994 with a formal PM program completed by June 1, t995. Implementation of PM program is estimated for February 7, 1995.--vv>Wi tao \oioAj -for 5. VOC software program to be bought by June 30, (completed! and be operational by August 28, 1994. -- HoJ Ji'\ 6. Paint mix room is estimated to start by September 15, 1994 and be completed by December 30, 1994.-- huJ cjixeSS Not- ESTIMATED COSTS: 1. Documentation of solvent usage will only be minor labor costs (3 hrs/yr). 2. Retention of documents only requires minor labor and minor storage facilities (5 hrs/yr, $70 - equipment). 3. Review of permit conditions will require (12) hours of labor. 4. PM programs could cost S35.000 in software and (80) manhours to review. 5. $752. for (1) computer system. 6. $4,000 for paint mix room. COMMENTS: C60699 0206  CONFIDENTIAL ** The following situation and recommendation is a brief description of a potentially complex set of conditions. Readers who are not aware of the total situation should refrain from drawing conclusions. Environmental Review Composite Structures Division May 4-6,1994 'lX- ` ' jrSpecial Situation.v>\v:Sjr': yrN.:;-.' A'-V.. Preventative Maintenance Proaram Auditee Response and Action Plan: C60699 0207 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 -#-AQflONTreM: ~~ OtherSeAQMD Peimit Conditiens-(Freventative Maintenance) -RECOMMENDATIONS: Develop a formal PM Program Obtain "old' permit applications PERSON RESPONSIBLE FOR ACTION ITEM: Lee Kemble will be responsible for the maintaining and Preventative Maintenance (PM) of the paint, primer, adhesive booths, scrubbers and all other permitted equipment. ESH department to review the SCAQMD archives and obtain permit application copies. ESTIMATED COMPLETION DATE: PM programs will be evaluated and a draft program assembled by December 1, 1994 with a formal PM program completed by February 1, 1995. 'mplpmffn*3*"TM nf PM Pmiram fill r^hUHiy 7t-4qq5 Obtain permit copies by November 15, 1994 ESTIMATED COSTS: PM programs could cost $35,000 in software and (80) manhours to review. $2,000.00 for the permit copies (+40 hrs.). COMMENTS: c(J^CULCL a^(L<W.VP rrefiVal p*TM + "J>c.voA<^prv-e^V drf- 5-e.V o^ <3-^Lprwy"W~ ^ rnrv^. , CiD/vi l4i- AO rv'--r1v2),"' <^~Lt~. f*Jc*^*CaCic pvLK C60699 0208 ** CONFIDENTIAL ** The following situation and recommendation is a brief description of a potentially complex set of conditions. Readers who are not aware of the total situation should refrain from drawing conclusions. Environmental Review Composite Structures Division May 4-6,1994 r f- .?. -v- - Special Situation Evaluation of Reporting Requirements Auditee Response and Action Plan: C60699 0209 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 G. ACTION ITEM: Evaluation of Reporting Requirements t (Self reporting of exceeding SCAQMD1-ganitatforr; ERA, RWQCB peimit -5 t4onVsl'\ ool^ Q.C.'reSSOi uL>e^vfc So rvxcm.'j v~e.c-enL ercur-Sicns} RECOMMENDATIONS: Contact ALCOA legal Department and Environmental Control Department for review and assistance. PERSON RESPONSIBLE FOR ACTION ITEM: Dave Rittichier to evaluate issue.-- uinxVi "BO ESTIMATED COMPLETION DATE: "VnlS Issue pending. r cxdret> O-iaA. (i>Ucv/ Co Vn? h f* ot a. cW^ prtx_*kAF4. qA 15 C60699 0210 CONFIDENTIAL** The following situation and recommendation is a brief description of a potentially complex set of conditions. Readers who are not aware of the total situation should refrain from drawing conclusions. Environmental Review Composite Structures Division May 4-6, 1994 ' - ' ^ v' ' v AiR ~~ . ^Special Situation - - *" i, Ozone Deoletina Chemical Manaaement Auditee Response and Action Plan: C60699 0211 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 I. ACTION ITEM: Chloroflurocarbons (CFC's), Ozone Depleting Chemicals 1. Audit CFC Contractors for compliance with^rLGOA standard. Ko-V 2. Revise purchase orders to include CFC servicing to be in accordance with SCAQMD and EPA regulations. 3. Update files to include documentation that previous work was in accordance with regulations. PERSON RESPONSIBLE FOR ACTION ITEM: 1. The auditing of CFC contractors operations and facilities will be done by the ESH department. 2. Joel Feder (or designee) will revise purchase order wording to include compliance with SCAQMD and EPA regulations.---5-5^1 b-e.-speof-'-c* 3. Lee Kemble to contact his contractors to update the files on the compliance of past contractors with the regulations (certificates, notifications, training, permits...). ESTIMATED COMPLETION DATE: 1. Auditing of contractors will start on January 15,1995 and be completed by March 15, 1995. (. 2. Revision of Purchase Orders will be started by November 30, 1994 and be completed by February 30, 1995. 3. Existing and past contractor compliance and recordkeeping will be started bv June 15, 1994 to verify past projects compliance and documentation and be completed by October 30 1994 (est, 54 hrs.). OtLeij') oi- C\ rCCofCi_ ESTIMATED COSTS: ^ <rnDu'`t- te&rdv, ocqa There are no significant costs associated with any of the (3) items mentioned above, only labor hours. COMMENTS: & 17 C60699 0212 CONFIDENTIAL ** The following situation and recommendation is a brief description of a potentially complex set of conditions. Readers who are not aware of the total situation should refrain from drawing conclusions. Environmental Review Composite Structures Division May 4-6, 1994 ' -- AIR;-- ^ * A*"**3* s- ' * _ I x f ~ *1 * v '*- - V. Special Situation Asbestos Manaaement Plan Auditee ResDonse and Action Plan: ^ V . .V.>` v T.< * ^: C60699 COMPOSITE STRUCTURES DIVISION 801 ROYAL OAKS DRIVE MONROVIA, CALIFORNIA 91016 H. ACTION ITEM: Upgrade of Existing CSD Asbestos Compliance Plan RECOMMENDATIONS: CSD has received an updated version of the ALCOA Asbestos Plan and CSD will revise the current plan to reflect the newly revised ALCOA standards. &\ccm fc> v\J2uAu^ revise* PERSON RESPONSIBLE FOR ACTION ITEM: Greg Emanuelson ESTIMATED COMPLETION DATE: Start Date: October 15, 1994. Completion Date: December 15, 1994 ESTIMATED COSTS: Minor costs involved in the revision (est. 10 hrs.). COMMENTS: q-- )cc&rd. '-Pc 16 C60699 0214 Inter-Office Communication From: AdeleLaikin To: John Gay Date: January 4, 1994 Subject: HAZARDOUS WASTE DISPOSED OF FOR THE MONTH OF DECEMBER The total amount of Hazardous Waste manifested and disposed of the month of December 1993 is 23.853 pounds (liquid and solid) and was transported by The Patterson Group to Norris Environmental Services and by Rollins Chem-Pak to Rollins/Deer Park, Texas. Chemical Waste Management transported to Chem. Waste OSCO Facility. Manifest No. 93306875 *93306875 93167863 *93167863 93187185 00197398 *00197398 *93361709 *93361709 *93361709 *93361709 Description Amount Acid Brick 750# Acid (Sulfuric) Dirt 250# Ferric Chloride 8,340# Mixed Acids 2,793# Asbestos (building "C") 20# Flammable Solids 4,400# Paint Sludge 3,600# Lab Pack 200# Grease 500# Solvents 1,000# Oil Absorbent 2.000# Total: 23,853# Disposed Chem Waste Chem Waste Norris Environmental Norris Environmental BKK Landfill Rollins, Tx. Rollins, Tx. Rollins (OPC) Rollins (OPC) Rollins (OPC) Rollins (OPC) Total Effluent Excursion = 0 * = Waste Accumulated From 10/1/93 to 12/30/93 cc: R. Stewart D. 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SHssfS 5.1 nn sassssfggass sss?? spSHprpp ppsapsa ssppsps n <1 n n <( n sppppp nn ps pp sp ppHV. * HsHsa -* *0 <0 e* n rt aps "^2 |iiIs|iilllPliiiii!iiiiii!iiiiil|ii||Ililisiil!iiiiiiIliiiiii mini IISPIIII|II = IIilIIIII|||I|IHIISI|lll|pH = IIIiIIPPIIIIiriHIIllI sisisisisiiiiiiiiiSi-fbi5i2iSii;!l-i-;iSiSii:5ii!-f.-l-i-i-Sii5lSiSii-l-Ii-l-lli.lSii5iSliSilSi S-".S...2.21|,^Sll:l!IlSllSl! C60699 0218 li let I !i if 33335i IssilsSiHSg I iiiinninnnnnnznnnnnHHfniimfxzll^nnnhnlnnnz FROM: KAREN L. WAECHTER ENVIRONMENTAL AUDIT GROUP PITTSBURGH OFFICE - AB 19 TO: JAMES S. BOYT PITTSBURGH OFFICE - AB 1995 February 01 RE: COMPOSITE STRUCTURES (CSD1 ENVIRONMENTAL AUDIT RESPONSE I have reviewed the environmental audit response with Composite Structure's Environmental Manager as part of the response review process. The response for the special situation titled "Permitted VOC and Emissions Limits" did not clarify which daily facility VOC emission limit (54 gallons or 27 gallons) CSD would comply with until daily facility VOC emission permit revisions were made. After conversations with the South Coast Air Quality Management district, the attached letter was submitted to the agency by CSD. I believe this letter and CSD's action address the special situation in its entirety. CSD's response and action plan will effectively address the special situations and recommendations identified in the audit report. If you have any questions regarding the response, please do not hesitate to contact me on ext. 4044. Karen L. Waechter Attachment KLWrmht (COMP6S6.DOC) cc: Ft. B. Kelson - Pittsburgh, AB 30 C60699 0129