Document qazz0d6aggdEX56XEY327y5a5

UNION CARBIDE CORPORATION SILICONES A URETHANE INTERMEDIATES ENGINEERINC SOUTH CHARLESTON* WEST VIRGINIA MEMORANDUM April 17, 1985 TO: J. F. Dodd C. E. Fry /^ , P. D. Gossage 'X^_ J. G. Roy T G. Swanson P. G. West J. L. Worstell (Engineering Manager) (514 Health & Safety) (Maintenance Dept. Head) (Energy Systems Rep.) (Energy Systems Dept. Head) (Maintenance Dept. Rep.) (514 Environmental Protection) COPY: W. E. Ballard R. G. Hannon R. E. McEldowney P. B. Smith A. B. Williamson FROM: I. L. Beckett SUBJECT: Project Scope Document Safety/Health Insulation, No. 2 Powerhouse, Building 151 The following project scope has been prepared for acceptance by the above listed persons representing their department or group as noted. These approval signatures are required prior to Work Order Request submission. PROJECT SCOPE The objective of this project is to minimize hazards of airborne asbestos in the No. 2 Powerhouse. DESCRIPTION Much of the insulation in the No. 2 Powerhouse is asbestos and is in poor condition. Uncovered, unprotected asbestos insulation constitutes a health hazard to employees. This project will provide for the removal of asbestos insulation from idle facilities, replace damaged insulation with an approved type, or seal with metal cover, all remaining asbestos insulation. This will minimize personnel exposure to airborne asbestos which will result in a healthier working environment. UCC 003101 2- - BREAKDOWN OF WORK The work required for this project Is divided into Capital and Removal. The following is a description of items to complete this project. Capital Replace existing damaged asbestos insulation with an approved type in accordance with applicable UCC Insulation Standards. All piping which is not presently covered with metal jacketing will be jacketed with .016" thick, smooth aluminum with moisture barrier. Jacketing will be banded in place with 1/2" stainless steel bands on 12" centers. All 90 degree and 45 degree elbows will be covered with preformed aluminum covers. Existing ductwork and equipment will be covered with .040" thick stucco embossed box rib aluminum lagging. The lagging will be, attached to a subgirt system consisting of 18 gauge aluminized steel channel and 5/16" diameter self-welding studs with drive-on hat attachments. The studs will be welded to the duct stiffeners through holes cut in the insulation. Removals Asbestos insulation will be removed completely from all idle equipment and piping. SAFETY CONSIDERATIONS When the asbestos insulation is being removea or replaced. Safety and Health guidelines will be followed such as: installing rope barricades and clearing the area of plant personnel, posting of warning signs, assuring that proper bagging and disposal of insulation is adhered to, and monitoring of surrounding work areas. Since this work will be performed by Contractors, the following are additional guidelines which contract personnel must adhere to: if practicable, wet down the asbestos insulation before removal, wearing of appropriate respirators, wearing and disposal of proper protective clothing. ENVIRONMENTAL CONSIDERATIONS All OSHA and EPA regulations will be complied with. The Plant 514 Environmental Protection Department will be given ample lead time so that proper notification can be filed with the U.S. Environmental Protection Agency that removal of asbestos insulation will occur. UCC 003102 -3- ENGINEERING Engineering for this project will be performed by UI Design Engineering at South Charleston. PERFORMANCE OF WORK All asbestos insulation replacement, repairs, sealing, and removal work will be performed by Contractor!s). LOCATION This work will occur at the No. 2 Powerhouse. If approved funds are available after work is completed at this site, additional work will be done in the Water Treatment and Utility Distribution Departments. SCHEDULE The first phase of this project will cover the insulation work on the #16 and #15 boilers respectively. The #16 boiler is scheduled for shutdown from May 25, 1985 through June 8, 1985; therefore, insulation work will begin on this boiler first. The overall mechanical completion of the project is scheduled for December 31, 1985. ILB/bsh 08691 I. L. Beckett UCC 003103 -4- SAFETY/HEALTH INSULATION, NO. 2 POWERHOUSE, BUILDING 151 t APPROVAL SIGNATURES: I. L. Beckett (Project Manager) CtJ, Ot'. J. F. Dodd (Engineering Manager) (T P. D. Gossage (Mai%7 Dept. Head) 7,(f (/isCTL' T. G. Swanson (Energy Sys. Dept, head) P. G. Tiest (Maint. Dept. Rep.) r ^C`. y C. E. Fry Ti 51 14 Health & Safety) terns Rep.) ILB/bsh 08691 UCC 003104 INTERNAL * CORRESPONDENCE UNION CARBIDE CORPORATION SOUTH CHARLESTON PLANT Silicones and Urethane Intermediates P.O. BOX 8004, SOUTH CHARLESTON, WV 25303 rolNaTM' R. E. Peele Division w> $ Walker Location Area Copy to ___ ~ G. W. Bott P. D. Gossage s* B. P. Johnson, Jr. J. R. Soice J. L. Worstell EPD Staff (Circulate) Date May 30, 1984 Originating Oeot ENVIRONMENTAL PROTECTION Area Subject Asbestos Standards Applicable at 514 Plant The attached summarizes the NESHAP Standards for asbestos which apply to operations at Location 514. This summary is being sent to you as primary contacts in order that you might pass the information on to the specific individuals that will ensure compliance with these standards. Normally, only maintenance and construction activities will be involved in the handling of asbestos. I would like to request a copy of any written procedures or if you should know of someone who has written procedures for the handling of asbestos, please forward this information to me by June 30, 1984. If you have any further questions or comments, please feel free to call me at X-2799. Truly yours. FASs/rls 0033A Attachment UCC 003105 NESHAP STANDARDS FOR ASBESTOS APPLICABLE AT 514 Title 40 of the Code of Federal Regulations, Part 61, Subpart M specifies the standards for handling and disposing of asbestos. Asbestos is considered a hazardous air pollutant due to its adverse health effects. Exposure to asbestos can cause fibrosis in the lungs leading to more serious illness like lung cancer. I. DEFINITION: Asbestos means the asbestiform varieties of serpentinite, riebeckite, cummingtonite-grunerite, anthophyllite, and actinolite-tremolite. As used here, the word asbestos includes asbestos, asbestos containing material, asbestos containing waste, and friable asbestos (i.e. can be pulverized) II. STANDARDS APPLICABLE AT 514 A. Roadways: No owner or operator of a roadway may deposit asbestos on that roadway. B. Demolition and Renovation: 1. Notification: The following information must be reported to the EPA Administrator: a) Name and address of the owner or operator b) Description of facility being demolished or renovated including size, age, and prior use. c) Estimate of the amount of asbestos removed. d) Location of the facility e) Schedule of demolition activity f) Nature and methods to be used g) Procedures to be used to comply with these regulations h) Name and location of the waste disposal facility used for the asbestos. The report should be made in one of the following manners: a) At least 10 days before demolition when the amount of asbestos is at least 80 linear meters (260 linear feet) on pipes or at least 15 square meters (160 square feet) on other equipment. b) At least 20 days before demolition when the amount of asbestos is less than 80 linear meter (260 linear feet) on pipes or at least 15 square meter (160 square feet) on other equipment. c) As early as possible before demolition when such demolition is ordered by a state or local agency due to danger of immediate collapse or unsoundness. At 514 Notifications will be made by EPD. UCC 003106 4 2. Emissions Control: a) Asbestos must be removed before demolition begins unless: i) It is encased in concrete or similar material ii) It is adequately wetted whenever exposed b) When a component with asbestos is taken out in sections: i) Adequately wet any asbestos exposed during disjoining operations ii) Carefully lower the sections to the ground, not dropping or throwing them. c) Adequately wet all asbestos before being stripped from the facility components unless: i) A request has been made to EPA not to wet the asbestos due to unavoidable equipment damage; and ii) EPA has approved the use of a ventilation and collection system that will prevent any emission. d) After a component with asbestos has been taken out: i) Adequately wet asbestos before stripping; or ii) Use a ventilation, collection system that will prevent any particulated asbestos emissions. e) For asbestos that has been removed or stripped: i) Adequately wet and keep wet until disposed. ii) Carefully lower to the ground not dropping or throwing it. iii) Transport via dust-tight chutes or containers when removed or stripped over 50 feet above ground. f) When the temperature is below 0 degrees C. (32 degrees F.): i) Remove components covered with asbestos as sections as much as possible, ii) Adequately wet asbestos before stripping and keep wet after removed until disposed. g) If the facility is being demolished because of an agency order: i) Wet the portions covered with asbestos during the demolition. UCC 003107 C. Insulating Materials: No owner or operator may install or reinstall any insulating materials that contain commerical asbestos if the materials are either molded or wet-applied. D. Disposal: 1. No visible emissions are allowed while collecting, packaging, transporting, and disposing asbestos: a) Treat asbestos with water: i) Mix asbestos from emissions control devices with water to form a slurry and adequately wet all other asbestos wastes. ii) No emissions must be discharged from collection, mixing and wetting operations iii) After wetting, seal all asbestos in leak-tight containers while wet. iv) Label all containers as follows: "CAUTION CONTAINS ASBESTOS Avoid Opening or Breaking Container Breathing Asbestos Is Hazardous To Your Health", or use the warning signs specified by OSHA. b) Process all asbestos waste so it can't be pulverized. i) Form into pellets or other shapes ii) Discharge no emissions while doing so c) After all the asbestos waste has been packaged; i) Complete a waste manifest and get EPD approval ii) Dispose of the waste at Goff Mountain Landfill FAS/rl s 0033A F. A. Sanchez 5/22/84 UCC 003108 *** ** * UNION ** CARBIDE * ** *** SILICONES & URETHANE INTERMEDIATES c. SPONDENCE Bldg. 3005 - 2 South Charleston, WV 25303 TO: FROM: CC: Mr. John Buzzard Mr. D. A. Gosselin Jirr-C. E. Fry Mr. R. L. Foster Dr. D. Liebeskind Mr. C. A. McNeill DATE: May 31, 1984 0RIG. DEPT: S&UI Safety and Health SUBJECT: Laundering Asbestos Contaminated Clothing Dear John: I have reviewed your letter (Attachment "A") concerning the laundering of asbestos contaminated clothing vis-a-vis the OSHA Standard 1910.1001 and have determined that while your approach is sound and appropriate, there appears to be one additional thing that must be done. Paragraph (d)(4)(iii)(b) of Section 1910.1001 (see boxed-in area on Attachment "B") states that "Any employer who gives asbestos-contaminated clothing to another person for laundering shall Inform such person of the requirement in paragraph (d)(4)(ill)(a) of this section to effectively prevent the release of airborne asbestos fibers in excess of the exposure." I suggest that a letter be written to Mr. Fauss, the owner of Vogue-Swift Cleaners, calling his attention to this paragraph In Section 1910.1001 of the code of Federal Regulations. For your general information, a temporary emergency standard (issued 11/4/83) of 0.5 fibers (longer than 5 micrometers) per cubic centimeter as on eight-hour time weighted standard is currently in effect. It could soon get tighter. In a proposed rule and notice of hearing published in the Federal Register on 4/10/84, OSHA announced its intent to permanently lower the eight-hour time-weighted average down to one of two alternative levels: 0.5 fibers/cc or 0.2 fibers/cc. OSHA seems to be leaning towards the 0.2 fibers/cc limit, but had Invited comments on the poroposed revisions to be submitted on or before 5/12/84. The informal rulemaking hearing is scheduled for 6/19/84 in Washington, D.C. UCC 003109 Mr. John Buzzard May 31, 1984 Page 2 Thank you for your Inquiry. I think you asked a worthwhile question. DAG/ero Attachments 0386A D. A/Gosselin Safety and Health Affairs Manager UCC 003110 4* 8O *. Q o C* rrifiiw ! ^5. 3uiS"o sSM cgS--9a g3s |83S Oft"_, - : cTMoc tauus *c; ' q*'5ft *C*o05O< :i ftt* *-J >i ft 41 <M iPj-^Oft ^^fQt V, i; 3 *Z XJ fftt oS f^t M 4r>> - w_ S*3tjtTX") C" tO3ciri oN cg0^JC3 42^(H *IOam, ^ "'D C asi^si gs-af SSfiisg C ^ T3 o sSjIM Js SV, IsSM ft id 10 U ft etf ft iu5SU`5f&0r. !;"3; IS :k ^ C S'rt | "32 fcis UCC 003111 'Ufta,, 3U-. a -a xi -!: ~ "g c th) h* nv) C^ c |2fS?|DHA'Si rt S > jt * ^ S l. og o, a <d 2 -a J3 . T*3Cl**11 : t- 0 t. c, " t,s ot, o ft K u y ^ft 3 Oft ^9 3J fat &5J fct ^Scl3ssp : q^ <u**.a ''Iff bgs|^ g|ft"I ^<HV< it tt UiN AwS Sift ft f0es`O2iofX5^3^ocfdt 3S|.g^b lisas;?* g g= "3 ftg^l a &28s: sjillfss, g5|fcga-oSo 53y`irgt'O1. oO.EaJrg5cSSogi r2t"fi1at^l:-D>cafi.S-oCJ=rg5?i!s*boJ5cPS-**S.J fSe^lla3 *ts3IS*3 /l li J ( ^ H INTERNAL CORRESPONDENCE RECEIVED MAY 2 2 1984 UNION CARBIDE CORPORATION ! jIL If a JNI : J t ! AN'I D- a. GOSSELIN L.H-IUCJNI aimi j ui (i r 11aiml ii-j i i i imi i .ha i i i11 i l ji JX l U( i. : ii:.i 11 i t:;vu i i_. wv .'l. I /L> MN^ei o^or, E<jLF4>LiLiI 1 A,^a Hr. 0. A. Gosselin Union Carbide Corporation Post Office Box 8361 Building 3005 South Charleston, West Virginia . 25303 n,,, ......... . a,,,.. Cop/ to t.1 -,i i t Hay 21, 1984 Purchasing , Cleaning of Insulators Clothing Dear Don: Confirming our recent phone conversation regarding the cleaning of Insulators clothing at Vogue-Swift Cleaners In Harietta, Ohio, the following Is a brief outline of the procedure used: (1) Purchase order Issued describing clothing as contaminated. Copy attached. (2) Clothing is put into special heavy black polyethylene bags imprinted with statement as follows: - CAUTION CONTAINS ASBESTOS FIBERS AVOID CREATING DUST BREATHING ASBESTOS DUST HAY CAUSE SERIOUS BODILY HARM (2-3/8" Letters) (1-5/8" Letters) (1-5/8" Letters) (1-5/8" Letters) (1-5/8" Letters) (3) We have talked to Mr. Mahlon Fauss, the Owner of Vogue-Swift Cleaners, by phone, and advised him how we are labeling the bags. Mr. Fauss agreed to inform his employees. Nothing has been sent to Vogue-Swift In writing regarding how to handle clothing. (4) Each time we send a bag of clothing a Special Shipping Order Is prepared. Our truck delivers bag to cleaner and our truck picks up cleaned clothing. Estimate clothing Is sent out for cleaning 2 to 3 days weekly. Please advise if we are meeting all OSHA requirements and any further obligations we might have to the vendor rendering this service. Thanks for your help. Very t J. R. Buzzard:lk Attachments Purchasing Agent UCC 003112 WINTERIZATION PREPARATION 1985 o NOW IS THE TIME TO BEGIN PREPARATION. o CHECK TRACER SYSTEMS FOR LEAKS AND BAD TRAPS. (1) PROVIDE LISTS OF DEFICIENCIES AND SHOP ORDERS TO AREA SUPERINTENDENTS. (2) AREA SUPERINTENDENTS WILL SCHEDULE AND COMPLETE TRACING DEFICIENCIES BY JULY 1. o SURVEY INSULATION FOR DEFICIENCIES. (1) PROVIDE LISTS OF DEFICIENCIES AND SHOP ORDERS TO AREA SUPERINTENDENTS. (2) EACH MAINTENANCE ZONE SUPERVISOR WILL BE RESPONSIBLE TO MAINTAIN THIS LIST - UPDATING THE STATUS OF COMPLETIONS AND ADDING TO THE LIST ANY INSULATION THAT IS REMOVED FOR MECHANICAL REPAIRS. (3) AREA SUPERINTENDENTS WILL BE RESPONSIBLE FOR SCHEDULING THE LISTED REQUIREMENTS FOR COMPLETION BY NOVEMBER 1. o BEGINNING NOW WILL ENABLE US TO: (1) COMPLETE NECESSARY WORK PRIOR TO WINTER. (2) SPREAD THE COSTS OF WINTERIZATION WORK THROUGHOUT THE SUMMER MONTHS. (3) COMPLETE AS MUCH OF THE WORK AS POSSIBLE ON STRAIGHT TIME. (i|) TAKE ADVANTAGE OF MORE DAYLIGHT HOURS WHERE OVERTIME IS REQUIRED. (5) HAVE WORK PLANNED SO THAT BETTER UTILIZATION OF "SWAP" PEOPLE CAN BE REALIZED. (6) KEEP YOU UPDATED ON THE STATUS OF WINTERIZATION REQUIREMENTS. UCC 003113 I UNfON CARBIDE CORPORATION P. O. BOX B004, SOUTH CHARLESTON, W. VA. 35303 Silicones and Urethane Intermediates South Charleston Plant To: Mr. J. F. Dodd Copy to: Mr. W. E. Ballard Mr. I. L. Beckett Mr. L. T. Brannon Mr. J. R. Dean Mr. G. F. Painter Mr. E. C. Powell Mr. T. G. Swanson Mr. W. L. Thomas Mr. P. G. West From: J. G. Roy Date: March 27, 1985 Subject: Plant Project to On February 21st W. L. Thomas called a meeting to kick off the first phase of a project to eliminate asbestos exposure in the plant. The minutes of that meeting issued by Ira Beckett reflect the general agreement reached on how the project should proceed. A time table was also established in the above meeting indicating that a rough draft of the WOR would be ready for review by February 27th with submittal to Danbury in sufficient time to ob tain a May 1 approval. Inasmuch as the No. 2 Steam Plant was to be starting point I was re quested to work with Paul West and develop a strategy. To this end a meeting was held with a local insulating contractor that included Operations, Maint., and Engineering representation. It was agreed that a modified version of my asbestos elimination plan would serve as a beginning point for specific project definition. It was my understanding that this activity was to provide specific bid packages which would enable the plant to implement the project upon approval. There was no decision or agreements that contractor Input was to serve as the basis for WOR preparation. After reviewing and walking through the Energy Systems plan, the contractor began a more detailed study of the situation. We agreed that re moval of insulation on idle facilities would provide the biggest return on our overall objective and that this should be done early in the project ex ecution. Next with the contractor's input a manageable piece of work with finite boundaries was established together with the repair methodology. UCC 003114 Mr. J. F. Dodd March 27, 1985 Page 2 Through discussions with the contractor and Engineering the section of the steam plant from the north side of No. 15 Boiler to the south wall of Building 151 was selected as the first increment of the repairs. This selection was made because much of the work on the boilers can only be done during shut down. Boilers 15 and 16 come down at the end of May with back-to-back outages extending to the end of June. We planned to work the insulation contractors on off-shift hours to minimize congestion around the boilers during turnaround. This piece of work is the only one that will need tight scheduling to get the work done. Under the February 21st agreements this did not present a problem. In asmuch as fixed price contracting was the way elected to proceed and the overall plant project will far exceed the funds to be requested in 1985, our contract preparation activities can move parallel to the WOR approval procedure. However, 1 understand that there has been a shift in direction which was not communicated to Energy Systems. Ira Beckett has informed me that current plans do not in clude the use of maintenance estimates for the WOR preparation. Rather, the contractor currently estimating the work will be requested to proceed to other sections of the steam plant and beyond as necessary until the desired 1985 level of spending is identified. A ten percent estimate going into the WOR phase make sense for a conventional project. A conventional project is normally geared to job completion rather than the spending of a limited amount that will knowingly not achieve the total results. The ten percent estimate also serves as an audit tool in conventional projects for cost control purposes. The asbestos project is anything but conventional. Since the monies in volved in the WOR request will not even reach the halfway mark of that identified in the maintenance estimate, there is no risk in over-committing funds for this phase. The alternative to this project is do nothing or the limited amount that can be completed with maintenance forces. With health and safety at issue I doubt that such an alternative would be acceptable to plant and divisional management. On the issue of cost control,there is absolutely no risk in the agreed to competitive bid approach. A series of fixed price competitively bid contracts will insure that the specified work is completed in a cost effective manner. Incremental completions towards the overall project will provide a much higher degree of accurcy in later funding requests. In view of the above I recommend that we return to the original strategy and use the maintenance estimate for the WOR. This will allow us to develop competitive bids for the removal of asbestos from idle facilities and first increment of repair work. Ira passed on the verbal cost numbers he received for the segments currently under consideration. Frankly, I believe that we are going to find them to be on the high side when all the bids are tallied. Use of these numbers could lead us to a project scope which is less than the plant currently has in mind. JGR:kab UCC 003115 INTERNAL CORRESPONDENCE UNION CARBIDE CORPORATION p.o. 25303box bsbi, south charleston, wv INVESTMENT RECOVERY DEPARTMENT ' To INemei, Divition Location Anee Mr. L. Pierce, Jr. Controller Silicones and Urethane Inter. Danbury K1454 Copy co -- Mr. W. E. Ballard ^Mr. J. C. Cogar Mr. R. L. Foster Mr. R. G. Link Mr. T. G. Swanson Mr. K. C. Watkins Mr. W. R. Yerkey . March 11, 1985 Originating Dept Ana* sobmcc Surplus Property Declaration Asbestos Removal No. 1 Steam Plant Dear Leonard: .The enclosed Surplus Property Declaration is the first of a series of three for the dismantling and removal of the old Number 1 Steam Plant located within the South Charleston Plant. This Surplus Property Declaration is for the first phase, removal of all asbestos and other insulation from the equipment and piping. Since the steam plant has been shut down for some time, the insulation has deteriorated and requires immediate attention. The estimated cost is $147M, and the work will be performed by an outside contractor specializing in asbestos removal. It is our intent to begin the work by no later than April 1, 1985, after proper notification of the Environmental Protection Agency by the plant. We therefore would appreciate approval from the division as soon as possible. Very truly yours, WRY/JEK/pk/6813C Enclosure UCC 003116 SURPLUS PROPERTY DECLARATION LOCATION: _ 57 (UMTCOOCj 514 HOC. NO I Silicone & Urethane Intermediates (DMt*ON NAME) South Charleston West Virginia (CITY) (TATE) TO BE COMPLETED AT ORIGINATING LOCATION Facility: No. 1 Steam Plant Building Number 47~56~78 Dept/Sys. 043100 Owning Division stJI Protit Center _ 001 Date Available 1st Quarter 1985 Gross Fixed Investment___ 31,818.00 Net Book Value______ as of 1/84 Estimated Location Costa: Shutdown and cleaning; preparation for removal (Show procedures on the beck) Engineering ____________________ Labor 10,000 includes fire watch Material 15,000 include asbestos disdo Overhead__ 0- Total 25,000 Est By _ j- G. Roy GENERAL DESCRIPTION OF FACILITY: (Attach eddftlonel eheeitt needed) Removal of insulation (asbestos) from Mainland Powerhouse facility, buildings 47, 56 and 78 only. No mechanical equipment to be removed at this time. . HAZARDOUS MATERIALS PRODUCED OR HANDLED (Del by Name) Estimated 6200 ft.^ asbestos insulation. REASON FOR SHUTDOWN: Steam plant idled in 1982 with no foreseeable need to operate. ESTIMATED BY INVESTMENT RECOVERY DEPARTMENT: Equipment Reuse (NBV) Equipment Income Other Income Dismantlement Proceeds Total Recovery 0- 0- 0- 0- - . -_Q-- Decontamination Cost Dismantlement Cost Invest, Recovery Dept. Total Costs By WRY Date $147M -0____3M_ $150M 3/11/85 DISTRIBUTION: Value of Associated Stores (e.g.. 701. 703.704.720, 723. 740) (See beck of lorm) ROUTE FOR APPROVAL AS SHOWN BELOW: DATE APPROVALS 1. Originator 2. Plant Surplus Equipment Coordinator fyh 3. Plant Manager 4. Investment Recovery Dept P O. Box 0361 So. Charleston, WV 25303 rt" % 5. Div. Controller obtains Dlv. and other approvals: WO-3-1*70 (R*. HU, AD 3 7* 6. Investment Recovery Dept distributes copies to originating plant and others as needed. UCC 003117 UNION CARBIDE CORPORATION SILICONES t URETHANE INTERMEDIATES ENGINEERING SOUTH CHARLESTON, NEST VIRGINIA MEMORANDUM February 25, 1985 TO: W. E. Ballard J. A. Bowyer J. R. Dean C. R. Gillsepie J G. Roy T. G. Swanson W. L. Thomas P. G. West COPY: J. F. Dodd R. G. Harmon A. B. Wi11iamson FROM: I. L. Beckett SUBJECT: Minutes of Meeting - Asbsestos Insulation Replacement Project, Phase I A meeting was held on February 21, 1985 to discuss the subject project. The purpose of the meeting was to accomplish the following: Develop a scope that meets the J900M cash flow objectives for 1985. Determine who will perform the work. Develop an action plan for WOR submittal by March 31 , 1985. The opening discussion was led by Mr. Ballard and centered around the magnitude of the project and the limits as to the amount of funds to be expended in 1985. It was determined that the Maintenance Department would be the sponsor for this project. The following are discussions of each item listed in Mr. Thomas' suggested agenda. SCOPE A presentation by Mr. Dean showed the approximate hours required for repairs/replacement of asbestos insulation in each department at the South Charleston Plant. These figures were developed from a site survey conducted by Mr. W. B. Spurlock and Mr. T. G. West, Maintenance personnel. It was decided that asbestos repairs/replacement would be started first in the SUI Division. The following six departments were chosen since it was felt that UCC 003118 W. E. Ballard, et al. Page Two February 25, 1985 their combined total costs would more closely fall within the $900M limit set for 1985: Water Treating, No. 2 Steam Plant, Utility Distribution, Polyols, Specialty Catalyst, and Maintenance. PERFORMANCE OF WORK It was determined that the majority of this work should be done by contractors since the Maintenance and Construction departments would not have adequate manpower to complete the project on time. Maintenance or Construction could, however, do selected parts of the project. It was pointed out by Mr. Roy that some contractors could be used for estimating portions of the project prior to WOR approval. It was pointed out by Mr. Dean and Mr. Roy that asbestos insulation is not easily identified. There are some personnel within the plant that can identify this type of insulation, however, would not be available to go into each department to mark each line or piece of equipment requiring repairs/replacement. It was suggested by Mr. Ballard that Mr. Paul West would develop expertise in this area and would work with one appointed representative from each department to make these identifications. Each item must be identified in order to obtain contractor bids. WORK ORDER REQUEST A rough draft of the Work Order Request will be available for review by February 27, 1985. Four weeks will be allowed for local approval, while approval by Danbury is expected by May 1, 1985. ILB/bsh 07511 I. L. Beckett UCC 003119 * UNION A * * ENVIRONMENTAL PROTECTION SOUTH CHARLESTON PLANT * CARBIDE * ** *** February 28, 1984 TO : J .->R. Dean P. D. Gossage A. B. Williamson CC : R. L. Foster S. Rossi EPD Circulate SUBJECT: Asbestos Capital Project Felipe Sanchez will be the EPD rep for the proposed capital project for asbestos removal. JLW:cp 0191W J. L. Worstell UCC 003120 UCC 003122 2,154,600 25,020 239,400 oOoo oooo 00 o #1 V A o O O o <3 ooo o CO LO AA LO AA o o o o O O ol ooooOOo CO a CM A CM A co A CO A LO A =jA P -bO- o CM LD 00 CM <n fl3 CO Cn f-- CO CO CM 00 CM LO cn cn LO LO co r-- 00 r" 1 --1 < o cr LU <U DC o CM O <3- o o o 10 O CM o o LD o O o CM o CO o co o CM o CM o o LO Qd </> CM o CO LD LO CO d" an A a oo AA r-* Lf> co 00 L_ CO Ol r~ t-- r-- |--- o rc 00 UJ cn 00 <c O" o o o o O o o o O L,~J O o o o o o 0J o o o o O o o o ooooooo o; CM CO o CO CM LO CM 00 CO CM CM LO CO r-^ o CO LO LO CO s- CM cn m o o F". F-'. LO co 1-- r~ o o o o o o o o LO 'd- LO CM LO 00 LO PV* sfO: cn 00A COA cn 00 PO cnA cn 1-- COA CO ooooooo CO CM LO LO LO CO cnA cn cn cn A 1--- o < UHJ" Z* cDC < ut O" DCCD CO </> CM CO CM CO CO CO CO CM 'M' CO CO CO CO Z 3- t- rn to or O LU I-- Cl. LO CLOU <to cr QJ o o o O o o o o o o o o O O O Qd LO LO CM LO CO LO CO CM LO LO <r LO LO LO i-- CO LO CO r*" CM on S_ 3: 26,880 224 ESTIMATE FOR ASBESTOS REQUIREMENTS 4,480 36,305 TOTAL PLANT 00 00 z O Cd LU CT CL) LO O O O o o o o o o o o o o o o o00 LU LU Q- C 03 LU h ad LO CM LO oO cn A cn r-- CO CO o <d- LO . LO CO A r-- LO r-. o LO A CO co c r=) sC O'LU zc, LO o o o o o LO r-*. =1* cn CM 00 cn *3" AAAA LO DC on cn c >> P T3 on 1-- r- p T3 C <--i rO C P sc rd -P P on C i--i O res (j o c OJ 1-- fl5 c: t-- <ts on 5 3 c-- u CU ro a i-- c on >> LO TD p g c laJ S- n-- on o 4|-- C <u P 1-- -o 3 C AS s H* O. i--i c (/) o c: on r-- <C CL> c i--t-- p cn res QJ *1-- o fa O) i-- ' 0J eQd s- c &- f-- Od p u O r-- 0) 5- p < CD <D <13 r-- ,i-- <u c 3 r U Pc Cl. E P O) *r* X Q. r- <C t-- i-- CL) "O r" on j-- r" LU ra r3 P P *r-- Q_ rtS > O 'i-- o Q. *r- X *r" 3 03 10 z s: oO !3 oo zo s: CL LO to D_ LO Q CQ 21 UCC 003123 UCC 003124 ASBESTOS REPAIR PLAN - 1985 o CAPITAL PROJECT o IRA BECKETT - PROJECT MANAGER o PAUL WEST JERRY ROY DEPARTMENT CONTACT o ENERGY SYSTEMS POLYOLS SPECIALTY CATALYST UCC 003125 UCC 003126 / -//-es- UCC 003128 UNION CARBIDE CORPORATION SILICONES AND URETHANE INTERMEDIATES Engineering South Charleston, West Virginia MEMORANDUM February 11, 1985 TO: ' W. E. Ballard J. A. Bowyer mmamm C. R. Gillespie J. G. Roy T. G. Swanson P. G. West COPY TO: J. F. Dodd FROM: W. L. Thomas SUBJECT: Asbestos Insulation Replacement Project - Phase I Please attend a meeting on Thursday, February 21, 1985 In Building 82-320 at 1:30 p.m. to plan this project. It Is proposed that discussions center around the following: Select a scope that satisfies the $900M cash flow objective for 1985. Ascertain who does what work. Develop an action plan for WOR submittal by March 31, 1985. Attached for your advance reading Is a proposal by Jerry Roy. WLTijjv Attachment 48950 W. L. Thomas UCC 003129 I r UNION CARBIDE CORPORATION P. O. BOX 8004, SOUTH CHARLESTON. W. VA. 25303 Silicones and Unethane Intermediates South Charleston Plant 1 To: Mr. T. G. Swanson Copy to: Mr. W. E. Ballard Mr. J. R. Dean Mr. C. E. Fry Mr. D. G. Moshier Mr. R. A. Ream ES Routings List 2 From: Date: J. G. Roy ! December 27, 1984 Subject: No. 2 Steam Plant Asbestos Insulation Replacement fiEc;v w JAN'0l3SR 0EP1. One of my MOP1 s for the 4th Quarter is the development of a program to phase out asbestos from the steam plant. I understood from Bob Ream at the time X was given the assigment that special budget provisions were being made to kick this off in 1985. This apparently came about during budget presentations to SUI division management. Attached is my proposal to accomplish the overall objectives. I've not attempted to quantify the project into monetary blocks (Bob indicated that guideline established was $250,000 expenditure per year) but have presented it in pieces as a control measure. I believe the approach outlined will provide the greatest return both from a health and economic standpoint. By copy to the department staff I would appreciate their re view of both the approach and the individual work list. The most successful projects are those with the most thorough and up front work. JGRikab Attachments J. G. Roy UCC 003130 ASBESTOS ELIMINATION PROGRAM Building 151 General: . As an energy conversion facility constructed in large part during its first twenty years (1933-1953), the No. 2 Steam Plant insulation was originally all asbestos, While rebuilds of pre cipitators and 25 Boiler together with SCESUP additions incorporated non-asbestos materials the majority of the insulation is still asbestos. In reviewing the health related issues involved in steam plant operation asbestos exposure has to be viewed as one of the critical few. There are several approaches which can be taken to the resolu tion of this problem. One is to continue the phasing out of asbes tos by attrition i.e. repairs with non-asbestos material. Asbestos can also be rendered harmless by sealing the surface to prevent fiber migration into the atmosphere. The ultimate solution is a total replacement of all asbestos material. The program outlined in this proposal is aimed at elimination rather than control. Realizing that the project cannot be accomplished overnight so to speak, a phased approach incorporating discrete pieces of work (shown on attached listing) is recommended to proceed in the following manner. Schedule/Funding The precautions and health monitoring required for asbestos re lated work is very intensive in comparison to other types of work. For this reason it's important that specific task be started and completed in a timely fashion. Full replacement of all asbestos UCC 003131 ____ . j --- 2- - has been roughly estimated to be in excess of one million dollars. / The magnitude of the project almost dictates a phased approach not only from the monetary standpoint but to avoid chaos in the normal operation and maintenance activities. For this reason the attached list of work has been arranged in a quasi prioritized order. You will note that the first part deals with the removal only require ments. This of course offers the greatest return on expenditure. The remaining individual items are arranged to make significant contributions with emphasis on places where exposure is most likely. For instance the last item is the 25 Boiler feed water lines. These were fairly well sealed during SCESUP. Also work around the turbine generators should coincide with the scheduled overhaul of these machines. Funding is visualized at a rate of 150-250M$ pwer year and be comes a budgeted item until the project is completed. I believe that the distribution of work outlined below will produce a high level of efficiency to keep the overall cost well below the original estimate. Work Assignments There's plenty of work for everyone 1 However keeping in mind the need for timely execution coupled with costs, the project seg ments can be best accomplished by various groups. I visualize the use of demolition contractors, insulation contractors, and UCC Construction as well as Plant Maintenance. Each of these work groups offers unique skills that can expedite as well as minimize the costs for various pieces of the project. Demolition Contractors; These people are geared to removal work UCC 003132 , .hi -3- and can strip idle facilities very quickly at reasonable costs. Insulation Contractors: Traditionally, UCC insulation projects have been overdone in the sense that we do a better job than is needed. Of course our costs are higher as a result. We almost universally use the block and wire approach with fabric coatings on large flat surfaces when other systems such as mineral wool on impaling wires and metal lagging are much more prevelent in the industry. Con tractors having to meet stiff competition have developed systems that are sufficiently sturdy but minimize both material cost and labor. A case in point is the system we bought from Riley Stoker for the No. 25 Boiler rebuild. This project scoffed at by a number of construction people at the time, appeared to be flimsy. The entire insulation and lagging is supported on the impaling wires with no use of stand-offs and angle iron frames to mount the metal lagging. The bottom line is that it works and the cost is lower. For this reason I recommend that major equipment such as boiler ducts and breechings be insulated by contractors. UCC Construction; For the most part it will be virtually impossible to isolate steam and hot boiler feed water headers for stripping and reinsulation. From a health, safety and economic standpoint, it is important that long segments of header be stripped with re insulation following closely. Construction's manpower availability is suited to this kind of activity. Maintenance; There is a definite need to address miscellaneous lines and equipment that while limited in scope are more time con suming. The nature of work it lends Itself to an intermittent pro gression of this type of work and should aid in the overall plant UCC 003133 -4- scheduling of this manpower short craft. The following is a suggested assignment of the attached items to the various resources described above. Demolition Contractors - 1 through 10 Insulation Contractors - 11 through 18 UCC Construction - 19 through 37 514 Maintenance - 38 through 49 Project Control Unless tight control is exercised for a project of this type monies have a way of being spent without a whole lot to show for it. It is important that all changes accrue to a single account and be reviewed on a monthly basis. Additionally a file must be maintained to measure progress of the overall effort. Some time ago a program was undertaken to identify all asbestos with stickers. 1 understand that stickers were placed on just about every insulated surface and I've heard insulators say that many non asbestos surfaces were eroneously labeled. Also due to dirt con ditions many stickers failed to stay in place. Perhaps a more effective way to start the project would be to identify all of the insulation that is non-asbestos. There has been a lot of insulating done since 1972 and with our knowledge of project timing etc. it should not be difficult to pin down the majority of non-asbestos material. Identification with a stencil and spray paint would be a good first step leading into the overall project. UCC 003134 ASBESTOS ELIMINATION PROGRAM Building 151 i, Removal From Idle Factilities 1. No. 14 I.D. fan and breeching to the south stack 2. Nos. 12 and 13 precipitator hoppers 3. No'. 12 I.D, fan 4. No. 14 Boiler air ducts, drum heads, feed water lines, and steam header to the main header isolation valve 5. No. 12 precipitator inlet breeching and duct 6. No. 12 Boiler air heater, ducts, feed water lines, drum heads, and steam header to the isolation valve at the main header 7. No. 12 bubar ash collector 8. No. 12 pulverizer coal ducts from feeders 9. No. 13 pulverizer coal ducts from feeders 10. No. 13 hot air ducts to the coal feeders Remove and Replace With Non-Asbestos 11. South stack breeching serving Boilers 15 and 16 12. No. 15 I.D. fan and precipitator hoppers ` 13. No. 16 I.D. fan and precipitator hoppers 14. No. 16 precipitator inlet breeching 15. No. 16 Boiler air heater, ducts, drum heads, feed water piping, boiler headers and steam header to isolation valve at the main header 16. No. 15 Boiler, air heater, air ducts, drum heads, feed water piping, boiler headers and steam header to isolation valve at main header 17. No. 15 precipitator inlet breeching 18. No. 13 Boiler air heater, air ducts, feed water piping, drum heads, and steam header to the isolation valve at the main header UCC 003135 2- - Remove and Replace With Non-Asbestos (Continued) 19. No. 25 atmosphericflash tank 20. No. 25 deaerator 21. No. 25 high pressureheater 22. South end 10 psi flash tank and associated headers 23. No. 3 deaerator 24. 200 psi flash tank and headers 25. 10 psi steam header from north end to No. 3 deaerator, south end feed water pumps and on to the 200*10 psi reducer; section behind 14 Boiler is OK s. k\ 26. No. 2 deaerator and headers on that level 27. North 600-200 psi (Hagen) reducing station and all steam headers in that area 28. All deaerated boiler water lines below No. 2 deaerator on operating level 29. North end 200-10 psi reducing station and associated headers 30. South end blowdown recovery heat exchanger and associated piping 31. South end high pressure feed water heater and associated piping 32. All steam and feed water piping associated with Nos. 4 and 5 boiler feed water pumps 33. Ducts between the coal feeders and pulverizers serving Boilers 15 and 16. 34. Boiler feedwater headers serving all boilers 35. Main 200 and 600 psig headers through basement 36. West process steam header 37. North end boiler feedwater pump steam and water lines 38. Atmospheric flash tank and associated piping at No. 8 turbine generator 39. No. 8 turbine generator inlet and exhaust steam headers 40. All remaining miscellaneous lines and equipment at the basement level UCC 003136 -3- Remove and Replace With Non-Asbestos (Continued) 41. All remaining miscellaneous lines and equipment on the operat ing level ' 42. All remaining miscellaneous lines and equipment at the 3rd level . 43. All remaining miscellaneous lines and equipment at the 4th level 44. All remaining miscellaneous lines and equipment in the bunker and east roof level 45. All remaining miscellaneous lines and equipment on the main precipitator platform 46. All remaining miscellaneous lines and equipment on the 25 precipitator platform and I.D. fan area 47. Steam header serving 25 high pressure heater and all water piping associated with both the high pressure heater and the deaerator 48. All remaining miscellaneous lines and equipment in the struc ture located on the north side of 25 Boiler ' 49. All water lines and miscellaneous steam tracer supply headers in the north yard area and around the north residue manifold JGRoy:kab 12/28/84 UCC 003137