Document QX0Z5QOK0Y3QO299vLZDXxD04
PLAINTIFF'S EXHIBIT
I
UC-1091
\'
MEMORANDUM PLANT ASBESTOS PROJECT
By J. F. Schultz
Union Carbide Corporation Texas City Plant
July 19, 1985
UCTC 06788
Table of Contents
1. Foreward....................................................................................... 1
2. Introduction...............................................................
2
3. Summary......................................................................................... 3
4. Recommendations................................................... ................... 6
5. Discussion................................................................................... 9
6. Housekeeping.............................................................................. 11
7. Asbestos Identification....................................................... 11 '
8. Acknowledgement........................................................................ 12
9. Appendix
Cost Estimate
Identification of Piperack Priorities
UCTC 06789
PAGE 1 FOREMARD
\
The Texas City Plant is concerned about the potential health hazards of asbestos. Accordingly, development of an action plan addressing this concern was authorized. The primary objectives of the action plan are:
1. To ascertain the magnitude of asbestos insulation requiring repair and which therefore presents a potential for release of asbestos fibers to the environment.
2. To recommend corrective action which will eliminate, in-so-far as possible, asbestos contamination of the environment.
UCTC 06790
PAGE 2 INTRODUCTION
\
An assessment of the amount of exposed "asbestos suspect" insulation was completed for the entire plant (exclusive of office buildings, control rooms, laboratories and shops). This assessment was accomplished through site surveys performed by inspection teams appointed by the department heads. Valuable assistance was given these teams by hourly insulator craftsmen and leadmen and Industrial Hygiene departmental personnel. Cost estimates in the +30% range were made by the plant insulator group.
me 06791
PAGE 3 SUMMARY
\ Due to the weathered condition and to some degree damage to the insulation weather barrier, and to the insulation itself, significant amounts of exposed "asbestos suspect" insulation exists in the plant. Estimates of the quantity of asbestos suspect insulation requiring repair
.J
together with a cost estimate for correcting the exposed or damaged areas are tabulated below. The arrangement of the tabulation also prioritizes the problem areas in descending order.
UCTC 06792
PAGE 4
Estimated Insulation
Repair Required,
Priority
Location
Equipment(ftl)
Pipinq(Lin.ft)
Estimated Cost li$
1.
No. 2 Olefins
12,500
11,100
325.0
2.
Phenolic Resins
240
(B-176) and
Solvent Resins
Piperack
2,210
J
56.4
3. Bldg. 45
400
2,220
155.7
4. Acids & Esters
Bldg. 17
minor
Bldg. 21 and 24
2,818
Bldg. 54
none
690 80.2 305
5.
No. 3 Olefins
2,280
i2,764
465.2
6.
Plant Piperacks
none
16,171
402.4
7. 0X0 0X0 Syn Gas (B-139 etc.) Bldg. 79 Bldg. 83
3,410
189 530
47.0
8. E. 0. D. Bldg. 51 Bldg. 219
minor 700
720 3,300
20.6 65.7
9. Ethanol & OES minor
1,420
47.2
10. No.l Steam Plant
No.3 Steam Plant
140
719 68.2 295 18.2
11. In-plant Distribution
none
1,233
26.2
12. Pump Houses #4 #6 #7
105 35 13.1 27
Grand Total
1791.1
UCTC 06793
PAGE 5
The critera used when prioritizing the potential asbestos problem areas are as
follows:
^^
1. Potential exposure of asbestos to plant personnel.
2. Potential for contaminating the community.
3. Exposed insulation which is highly visible and easily seen by.the
casual observer.
'
UCTC 06794
PAGE 6
RECOMMENDATIONS \'
The overall action plan recommended is as follows:
1.As soon as possible (this year if possible) begin to correct the exposed asbestos containing insulation by, removing or covering the insulation using metal or mastic weather barriers at these "high
J
priority" locations: a. No. 2 Olefins 1) The Firebird, exhaust duct, and Waste Heat Boiler. Action: Remove. 2) The three columns and associated equipment from the old butadiene (vinyl acetate and acetone recovery) unit. Action: Remove 3) Flue gas breeching, cracking furnaces at building 105. Action: Remove. 4) Dead 1 1/2" and 2" acetylene lines in 5th Street piperack. Action: Remove. 5) Exhaust mufflers in building 103. Action: Mastic Coat. 6) Pipelines where the insulation is intact but weather barrier has deteriorated. Action: Mastic Coat.
UCTC 06795
PAGE 7
b. Phenolic Resin Unit - Building 176 1) Tanks and piping. Action: Remove. 2) No. 70 Column Flask Tank. Action: Remove. 3) Pipelines In piperack between buildings 122 and 176. Action: "Metal out" and/or Mastic Coat.
c. Building 45 Hydrogen Converters. 1) No. 3, 4, and 5 Hydrogenators. ActioVi: Remove asbestos and re-insulate with non-asbestos. 2) No. 1 and 2 Hydrogenators. Action: Install metal weather barrier. 3) Piping. Action: Use metal or mastic weather barrier where insulation in intact.
d. Building 24. 1) Acid Still Fore column. Action: Remove. 2) Acid Still. Action: Remove. 3) Acid Refining Column. Action: Remove. 4) No. 2 Esters Refining Still. Action: Remove asbestos Insulation and replace with non-asbestos. 5) Condensate Tank. Action: Remove asbestos insulation and replace with non-asbestos. 6) 4: Dead Oxide Line. Action: Remove.
UCTC 06796
PAGE 8 2. Each department including those not listed above will work out an action plan to correct the problem area$ irv their respective departments using the asbestos suspect survey data obtained by the inspection teams. The magnitude of the corrective work required for the entire plant precludes completion in one year. However department action plans should target for completion within a 2 to 4 year period. 3. Each department will include in their 1986 budget preparations funds for correcting their most obvious and/or greatest exposure potential areas. 4. Subsequent years budgets to include funds until resolution of the problem areas is completed.
UCTC 06797
PAGE 9
DISCUSSION
\
Included in the appendix of this report is a tabulation of cost estimates for the various departments. These cost estimates were developed by the plant insulator group and have a +30% accuracy.
When planning repairs to the exposed asbestos insulation, the following
J
guidelines are suggested.
1. Determine whether or not the insulation contains asbestos. If the insulation does not contain asbestos fibers, a decision to defer repair should be made. Economic considerations (energy conservation, production restraints, etc.) or safety considerations may result in a decision to go ahead with the repair anyway.
2. If the asbestos containing insulation is in poor condition (hanging loose, broken up, sagging, etc.), remove the old Insulation and replace with asbestos free material.
3. If the weather barrier is in poor condition (or essentially gone), but the insulation itself is in fairly good condition: a) Fill up the voids or breaks with non-asbestos filler if necessary. b) Cover straight runs of piping with metal and/or mastic weather barrier. c) "Mastic In" valves, 90 elbows, and other non-uniform sections. d) Use a combination of metal or mastic weather barrier or columns and other equipment.
4. If the weather barrier has breaks, is damaged, or missing over short reactions repair using a generous coating of mastic.
UCTC 06798
PAGE 10 5. If the insulation has "end or "edge" exposure, generously coat these exposed areas with an approved mastic. `This treatment should be
\
considered where "dead" or out-of-service piping or equipment has insulation which needs to be repaired. 6. If the asbestos containing insulation is in poor condition and is installed on "dead lines" or out-of-service equipment, remove and dispose this insulation. 7. Reference to the "Remarks" column of the inspection data sheets (Main Piperack Survey, Unit Equipment Survey, or Unit Piping Survey data sheets) will generally include comments on suggested repair. 8. Seek advice from the plant insulator group as required.
UCTC 06799
PAGE 11 HOUSEKEEPING
\
The entire plant places itself in a position of being open for censure from regulatory agencies when loose insulation is allowed to lie on the ground or has been left where it has fallen from equipment, piping, etc. Picking up and removing this insulation for disposal should be done on a continuing basis. ASBESTOS IDENTIFICATION Distinctive warning identification such as yellow adhesive backed film with black lettering is recommended for identifying asbestos containing insulation on equipment and pipe lines. Pipelines in piperacks should be thusly identified approximately every 100 150 feet.
UCTC 06800
PAGE 12
ACKNOWLEDGEMENT
\
The response by the plant to the request for "walk through inspections" of the operating areas and the plant piperacks was outstanding. Suitable recognition of everyone who participated may be impossible. However, recognition of the following for their commendable support and effort is in order because without
their help this project could not have gotten off the ground. ,
DEPARTMENT
INDIVIDUALS
Energy Systems
W. D. (Bill) Wilkins W. N. Parker R. A. Rivera C. R. Malveaux 0. B. Hayden
Ethylene Oxide Derivatives T. F. Hanrahan
No. 2 Olefins
T. W. Cates Henry G. Parker
Ethanol and DES
F. G. McWhorter J. A. McKenzie
Solvents and Acids
Frank L. Campbell J. L. Lamb J. B. Richards
In-Plant Distribution
J. L. Pedraza B. C. Wedhorn
UCTC 06801
PAGE 13
DEPARTMENT
INDIVIDUALS
Solvent Vinyls
D. B. Rygaard W. E. Benskin R. F. Garza R. J. Hadley R. Hernandez H. Martinez B. L. Nall J. Nunez E. K. Sumrall
Vinyl Acetate
Donald R. Kirkland
No. 3 Olefins
N. Dean Sharp Roy M Hughes O. T. Mallett Angel Echevarria
OXO and 0X0 Syn Gas
Marcie Laundrie Dan O'Neil J. D. Duston L. M Gonzalez
Industrial Hygiene
Kirk E. Martin C. W. Perry D. W. Harkreader
Also, the support and assistance received from the Insulator Craft group was
outstanding. Special thanks and appreciation is due these people:
J. E. Barnes H. P. Smith H. G. Kelly Jr. Keye Harding D. R. Labry P. J. Bartlett
UCTC 06802
<
ui 0010
"3D
Csj CM
o omo r>~
CO *3-
MO O MO
CM
cm co co co o m Ui .H UI vO CsJ f-s. *3* MO
OO-I
CM MO CMJ CMI CsJ CO CMJ
CM
<3- CO
vr O) CM
O
oMO to OM VO
U"> c VO CO MO
CT> r-s.
CO Ol Or o UO fs. CD MO co O to CO CM o
cm cn oo co vj-
O *3* MO CO O VO CO
OM rH
H
UO Q) o Ohhi/IO r*v
CM O CM OnCM^T Vf co
CH C O CM rH
CXI
r-H co
V CO CO rH h o CM CM fH MO in CO co CM
o> 0) CM
OM ^3* MO
c
OM ^ ^ o MO -H
C- O co .h rH o CM
OUlHH rH UO to -- CM CM (MH CM
co CM
CO
o c
co MO co
Ol CM f*v. UO CO MO MO HH
Nc0o1
PUNT ASBESTOS PROJECT
(1) Escalated la b o r co st by 30X f o r s c a ffo ld in g , asbestos d isp o sa l and co n tin g a n cle s.
a? 3 Of iC *-i
N 0> 0 -4 O CM
Ol rv in oivt UO
UCOO
VO
CO *H
CO
UO Oi
*H
VcOo
UO N fH
VO rH O O CM CM f-H
CHM
CM CM
UO
0cr) UO NVOOIOHH vf
fH
o c
CD
co
VO co vo co VO *l- --l --1
co
00
CM
rH
-J
M
OUfi J--
4
<cco mi
oc 3
<
HOas--f: <
Q.
UQi
oo O co UO o o o 00 CM oi 1 ^ Vf r*N
CO 00 H rH CM
*H CM
cHo
*-H CM
H
OO
cn
4J r* o co UO UO UO o
CM
c o c
CM
fooiooo
orHHo
4-> 4->
cc
40 40
JChi-
o a. a.
4*0-
E
6
VI 01
O 40 40 VI
a*- o4->
o 4-
3 o
Q- UO 00 3S
cHtn a
sCzOzOo3.
ai rH *H UO CM
Ol Ol *o *o # r""" CO CO
ME
4Q->*
VI
i>n>
o
>o>i
ia.>
c
o
Ui
U0 O' fH OO
Ol o> -o -o r* r** CO CO
H CsJ CM UO
o> cn Ol o> *o "O *o *o r-- r- r* r* CQ 00 CO CO
Ol rH
cn x> r-- CO
5
*
VI* oo
c UJ
f- Q
p4~1 pa1a
Oo
CM
c 1C uz
2OC
4- Ui
*o c 40 VI U V) c4> *of >O ft--Oo
c or4J -43-1 rC4~0 -fUOQ. 4-> *CH1 HOV-I
Of rH rH
a. rH
0 8
vo O 1^. rH rH H
* C7I cn *o o
r---- 00 00
pV>I VI
>cr-1
+> P40
ct--
> 4O> 4>
4-* C O
C p>Qf> COO
e-- >1 Cr-- >*
CO
o 2;
VI C. VI 0) 40 4J CO u
2
c CO O w' (J to Ol CO CM vtUIrsOOGO 3- CM
Ol Ol Ol Ol Ol fo p-Oa p"Oa *f 0 -pOa 00 0Q 00 OO 00
V)
o a
2
co
VI C4O0 t/1
1 X0 0
UCTC 06803
Identification of Piperack Priorities
ooo
INTERNAL CORRESPONDENCE
UC 4*- z
P. O. BOX 471. TEXAS CITY. TEXAS 77590
July 19, 1985
TO: P. D. Balmert L. E. Calvert
''S. 0. Footer R. W. Klein R. A. Mendez F. S. Provenzano D. R. Reem
Gentlemen:
Attached is a copy of my memorandum "Plant Asbestos Project" for your comment and approval.
Very truly yours
J. F. Schultz
UCTC 06787