Document baXRazy9Rbkwan1jK4ow4KqvZ

S,, J. SPELL MECHANICAL ENGINEERING February 19, 1973 ' ) - TO MESSRS. F, P, BERGERON H A. LOWER. G. V,, HUTTON ' D. D. MeGREGOR J, LEMEZIS . H Vo FKAKSEEN ' . ; W, B HOWELL G. R. EARNSTM , J. P. FECK ' E. 8. PARKER ' - B. Me STARKER . PEPAimsirr head e.c.r. AREA.INDUSTRIAL ENGINEER l.G.N. - AREA ELLCTRICAL ENGINEER R.L.B. ' AREA MECHANICAL ENGINEER S.J.S RE; AUtaOmATION APPROVAL __________ - .. ' '- '' Attached for your review is an informational copy of Dust Collection for Mafinite Machining_______ _ If you have any questions, comments, or suggested changes, please contact,______ H. .W-_Ex.anse.en___ '____ hY - Wgdnesday^ If no unxesolvable problems are encountered by Wednesday, February 21____ , this authorization will receive a final review at the next regular authorization . meeting on Thursday,' February 22, 1973 - at 9:00 a.in.. Following this review, all final drafts of the R.F.A. will be signed and mailed to-Pittsburgh. The probability of success of this project has been estimated by the following individuals to be: .- ~ ....... Technical Success: ' Savings Success: Originator Production Supt. Industrial Engr. Othe r ' S. J. Spell E. b. Remaley m ". 98% TS'sr -' . - N.A. N.A, r- . ' . ' ' . These probabilities have been taken into account in the economic evaluation. If you are unable to attend this meeting, please sign,the R.F.A. beforehand or send an authorized representative to the meeting. . S. J. SPELL SJS:ND Attachment .; - . '' ' ' , ' . . > . . . ' r ; V ' . WEN 108233 Q ALCOA REQUF^T FOR AUTHORIZATION 1 Date 2/19/73 - Req. No. _____ Name of Company ALUMINUM COMPANY OF AMERICA Works Location ROCKDALE. WORKS Auth. No. Total Cost . ^ Estimate $ 104,700o00 Brief Description -. DUST COLLECTOR. AND FACILITIES FOR MARIHITE MACHINING Approval is recommended by: Location Manager President of Subsidiary Co Division General Manager Pittsburgh Review by; - Date PRIMARY REASON FOR EXPENDITURE Profit Adding: . [ j Cost Reduction 1 I Profit Maintaining (Sustaining Operations) I | Add'l. Capacity I I Research & Development r~| Cost Reduction & Add'l. Capacity Combined Environmental I | Other ' (Explain) ACCOUNTING DEPARTMENT USE ONLY When completed, cost will be charged as follows: Capital Expenditures Comm, .4 Facilities Planning Comm. SF 4461 (Rev. 3-72) , WEN 108234 By_______________________________ Date GENERAL EXECUTIVE APPROVAL Name Date Name _________________________ Date Name FINAL APPROVAL Date c ts u j. urt 3.y x 7 $ x ? t iwuivua j j SUMMARY STATEMENT This Request for Authorization is for $104,700 to' purchase and install a dust collection system and other related equipment for fabrication of marinite parts, mixing trough lining materials and removing trough linings. These facilities are necessary to put our operation within the guide lines for asbestos and silica emission levels outlined by O.S.H.A. .. DETAILED STATEMENT In the processing of molten aluminum in the Ingot Plant and at the Propers! casting unit, materials such as marinite, which contains asbestos and silica, are used. Marinite is used in continuous casting molds and materials containing silica are used to line the troughs which convey the metal to a casting unit. Asbestos-free materials have been tried as replacements for marinite and this work is continuing but none have been successful to date. The marinite is purchased in 4 feet by 8 feet sheets. These sheets are cut on a band saw into one of many shapes and machined on either one or more of the following: lathe, drill press, end mill, and/or hand held saber saw. The pieces are then assembled into the mold or trough. Assembling can require some hand work, with a rasp or file. Although trough linings no longer contain asbestos fibers, unless they are made of marinite, they do contain other materials such as silica. The lining material must be mixed in a mixer for installation in the troughs. After the troughs have failed, the linings must be removed so that a new lining can be installed. The above mentioned operations all generate airborne dust containing asbestos or silica beyond the limits set by O.S.H.A. We are presently performing these operations at four separate locations which have varying degrees of inadequate dust collection. Our personnel have submitted a grievance demanding that we provide a working environment with safe dust levels. In order to meet these demands and needs, we propose the purchase and installation of a dust collection system with pickup points at each dust generating operation, heated make-up air unit, band saw, mixer and trough tear-out facilities in one isolated area of the Machine Shop at a cost of $104,700* The area is to be isolated with new wall systems. ' These facilities will allow us to machine marinite and work troughing materials while keeping the exposure level to our personnel'below the limits set by O.S.H.A. This will also eliminate an area where an inspector representing 0.S.H.A, could issue us a citation and a fine, WEN 108235 rs_reoruary ty, ry/3 ' ) PROJECT COST. ESTIMATE SIMSARY Description Dust Collector Hake Up Air Unit and Heat Building Modifications Equipment Modify and Rearrange Existing Equipment Portable Vacuum Unit tSub-Total: ' Tax.: Contingency: (15%) TOTAL: Eockcaaie worts ) rage \i:ntee Material Labor Total $ 15,740 9,700 5,696 11,105 3,770 5,050 $ 25,550 $ 41,290 3,430 13,130 5,000 10,696 1,200 12,305 3,220 6,990 - 5,050 $ 51,061 $ 38,400 $ 89,061 1,600 13,639 $104,700 WEN 108236 PROTECT COST ESTIMATE SUMMARY I: ' : Detail the estimated major cost elements separately. Cost Estimate fs Considered (jj ) Accurate ( ) Preliminary Prepared By_____________________ S. J SPELL Recommended by Works Personnel CJUef .Engineer Total Requested $104a70000 n,.e 2/19/73 Works Accounting WEN 108237 ALCOA ECONOMIC EVALUATION & PLANNED FINANCIAL PERFORMANCE Answer all questions appropriate to this project: Capital Expenditure Forecast No. RSTC0003 product Title INGOT & D,,C. PRODUCTS Product Code No. 21 Est. Time Required to Complete Auth. 12 Months PROPOSED EXPENDITURE S CHEDULE (! ;000 Omittec1) ____ 19 73 19 19 19 Total Capital Expense Total Auth. 797 10.0 89.7 . 15.0 - 15.0 94.7. ' 10.0 104.7 L State number of employees to be increased or decreased after completion?________________ __________ 2. Is any equipment or other facility being replaced? No If so, will it be sold, scrapped or transferred?" What is its original cost? - Present Book Value?"Estimate Present Market Value? . " 3. Will any equipment be transferred from another plant? Present Book Value?"___________________________ Nojf so, what is original cost?,________________________ ~ . 4; What disposition will be made of spare parts for. equipment being retired? NA ; 5. Has any work been done or material requisitioned for the job?No: Was prior approval given? - By whom?______________________________________________________________________________ 6. Will this project eliminate other projects from the Capital Expenditure Budget? If yes, give the Budget numbers of the projects being deleted:' _____ No ~' __________ - 7. Estimated Useful life 17 Years____________ . 8. Terminal Value of Capital Items N0A 9. Net Present ValueN/A . 10. Cash Rate of Return N/A .________ . . 11. Cash Payback Years (Discounted)N/A 12. Cash Payback Years (Undiscounted) N/A . . Economic & Financial Evaluation Prepared by ; Date .1 . WEN 108238