Document pmLx2NOV5EyzDjvV8Zz1g5Q2w

SPECIALTY CHEMICALS DIVISION SISTBRSVILLB PLANT ENGINEERING June 25, 1986 TO: J. F. Dodd (2) tf. V. Summers G. W. Wulfert CC: W. D. Bradbury, Jr. R. P. Leichliter W. C. Nycz SUBJECT: Sistersville Plant Insulation Upgrade Attached is the Draft Outline of Project for the subject project for your review and comments. Highlights are: Project Cost <1,500,000 Capital, <600,000 Expense over next three years. Advance funding is not available, so expenditure in 1986 is estimated at <150,000. Estimate is based on detailed takeoff of Maintenance Department survey. Maintenance to supervise field construction. Project will meet all OSHA and EPA Standards. Please return comments to me, or I will schedule a meeting if there are significant comments to resolve. LGM/kcs 0723k UCC 006447 SISTERSVILLE PLANT ENGINEERING SPECIALTY CHEMICALS DIVISION OUTLINE OF PROJECT SISTERSVILLE PLANT INSULATION UPGRADE SISTERSVILLE. WV DRAFT JUNE 23, 1986 UCC 006448 OUTLINE OF PROJECT SISTERSVILLB PLANT INSULATION UPGRADE TABLE OF CONTENTS I. INTRODUCTION II. SUMMARY III. SPONSOR'S OBJECTIVES IV. FACILITIES V. ENVIRONMENTAL PROTECTION/OCCUPATIONAL HEALTH AND SAFETY CONSIDERATIONS VI. SUPPORTING FACILITIES VII. PROJECT PLAN VIII. SCHEDULE IX. COST ESTIMATE A. SUMMARY B. BASIS FOR ESTIMATE C. CASH FLOW 1 1 1 2 3 3 4 4 5 UCC 006449 I. IHTRODUCTIOM Much of the insulation in the Sistersville Plant is asbestos and is in poor condition. The exposed asbestos presents a safety and health hazard associated with airborne particulate asbestos. II. SUMMARY The asbestos insulation throughout the Sistersville Plant must be upgraded to comply with the Occupational Safety and Health Administration (OSHA) standards. The plan is to remove asbestos from idle equipment, replace asbestos insulation, where necessary, with an approved type, and cover asbestos insulation with an approved covering. This cost of the proposed project is: Capital (+ 15%) $1,500,000 Mon Capital 600,000 The justification of this project is Occupational Health. The present OSHA Asbestos Standard, 1910.1001, specified two fibers/cc as the maximum allowable exposure over an eight-hour period. The figure refers to fibers greater than five micrometers in length and would amount to about 16 million fibers in that time period. Because there is no evidence in occupational studies to show that there is threshold level below which there are no adverse effects. OSHA is pressing for a lowering of the level to 0.2 fibers/cc. III. SPOMSOR'S OBJECTIVE The basic objective of this project is to upgrade the asbestos insulation throughout the Sistersville Plant to comply with OSHA Standards. Completion This Insulation Upgrade Project to be complete by June 1989. Project is high priority and must be executed on a continuous basis over the three-year period with only curtailment during the bitter cold winter months. UCC 006450 -2 Safety/Health All Division Safety/Health Guidelines must be followed during asbestos removalrepair, land covering. Government Regulations Plant will be in compliance with all applicable OSHA and U.S. Environmental Protection Agency (EPA) Regulations at project completion. IV. FACILITIES This project will replace asbestos insulation and jacketing in many areas of the Plant in accordance with the following area priority list: 1. Intermediates Area 2. Environmental Protection Area 3. Small Scale ProductionArea 4. Polymers II 5. Silanes Reactor Tower 6. Polymers I 7. Miscellaneous areas; including Maintenance, Laboratory. Warehouse, etc 8. Energy Systems area This project will provide total replacement of an estimated 50 per cent of the asbestos insulation currently installed in the Sistersville Plant. The remaining asbestos insulation will be addressed by another project of approximately the same cost as this one, to be executed in 1989, 1990, and 1991. In the execution of this project non-asbestos type insulation will also be repaired or replaced to provide for an economical and complete project. Mon-asbestos insulation work will consititute 15 per cent, or less, of the total project cost. UCC 006451 -3- V. ENVIRONMENTAL PROTECTION/OCCUPATIONAL HEALTH AND SAFETY CONSIDERATIONS This project will correct an Occupational Health concern by replacing or sealing exposed asbestos insulation throughout the Plant. When the insulation is being replaced or removed. Safety and Health Guidelines will be followed which includes: installing rope barricades and clearing the area of plant personnel, posting of warning signs, proper bagging and disposal of insulation, and monitoring of surrounding work areas. In addition, assuring that contractor personnel adhere to guidelines such as: wet clean-up, wearing of appropriate respirators, wearing and disposal of proper protective clothing, etc. This project will be in compliance with all applicable OSHA and EPA Regulations. The EPA will be notified that the removal of asbestos insulation could occur at the Sistersville Plant. VI. SUPPORTING FACILITIES A. Distribution The project will have no effect on Distribution facilities. B. Energy Systems The project will have no effect on Energy Systems requirements. However, Energy Conservation will be improved with this insulation upgrade. C. Safety and Environmental Considerations See Section V above. UCC 006452 -4- VII. PROJECT PLAM The project survey, or scope, was prepared by the Maintenance Department ov$r the last year. The priority of work is 'Shown in the Facilities Section on page 3. Insulation specification consultation will be supplied by Engineering. Field construction will be done by the Plant Maintenance Department, an outside contractor, or the Central Engineering Construction Group, and will be supervised by the Maintenance Department. Project Management, including cost control and reporting, will be provided by Plant Engineering. The project organization follows: Steering Committee Assistant Plant Manager Maintenance Superintendent General Project Manager W. V. Summers G. W. Wulfert J. F. Dodd Project Team Maintenance Contractor Foreman Maintenance Coordinator/Supervisor Project Manager J. E. Boley W. C. Mycz C. A. Eddy VIII. SCHEDULE Key dates are: Outline of Project Approval CBP Approval Mechanical Completion July 1986 September 1986 June 1989 UCC 006453 -5- COST ESTIMATE A. Summary Capital Construction Labor Materials * Engineering* Contingency $1,109,000 241,000 50,000 100,000 Total $1,500,000 Removals Expense $554,000 21,000 12,000 13,000 $600,000 * Insulation specification consultation, project management and field coordinator of contractor. B. Basis for Estimate The estimate for the work is based on a detailed scope provided by an insulation survey of each unit. The total man-hour estimate is 30,000 hours of work. C. Cash Flow 1986 1986 1988 1989 150,000 500,000 500,000 350,000 UCC 006454