Associated Indemnity Corp. v. Dow Chemical Co.

814 F. Supp. 613, 1993 U.S. Dist. LEXIS 2207, 1993 WL 49935
CourtDistrict Court, E.D. Michigan
DecidedJanuary 11, 1993
Docket1:85-cv-10398
StatusPublished
Cited by8 cases

This text of 814 F. Supp. 613 (Associated Indemnity Corp. v. Dow Chemical Co.) is published on Counsel Stack Legal Research, covering District Court, E.D. Michigan primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
Associated Indemnity Corp. v. Dow Chemical Co., 814 F. Supp. 613, 1993 U.S. Dist. LEXIS 2207, 1993 WL 49935 (E.D. Mich. 1993).

Opinion

CHURCHILL, District Judge.

MEMORANDUM OPINION

The parties in this action are (1) Dow Chemical Company (Dow) and its wholly owned subsidiary, Dow Chemical Company of Canada, Inc., (Dow Canada), the insured, (2) Associated Indemnity Corporation and The American Insurance Company (collectively Fireman’s Fund, the primary insurer and (3) Underwriters at Lloyds London and Insurance Companies Subscribing to Policy K 25298 (London Insurers), the excess insurers. This is one of a series of lawsuits to determine the rights of Dow and its subsidiaries to indemnity and defense of products liability claims under Dow’s liability insurance program in effect during the decade of the 70’s. The products liability claims in this lawsuit arose from production and sale of gas pipe resin by Dow Canada for the extrusion of pipe to be used in a large rural gasification program in rural Alberta. The gas lines leaked and were eventually replaced at a cost of approximately $30 million (Canadian). The specific issue under consideration is the number of occurrences issue.

In the early 1970’s the Province of Alberta, Canada undertook the Rural Gas Program, the purpose of which was to deliver natural gas service to a significant portion of rural Alberta. The system would consist of steel and aluminum high pressure lines and plastic low pressure service lines. Service areas would be organized as co-operatives (co-ops). The low pressure lines were to be constructed with polyethylene pipe which was somewhat flexible and could be plowed into the ground in a single operation. The Alberta Department of Telephones and Utilities (T & U) was the Alberta agency responsible for implementing the program.

DOW CANADA’S PRODUCT

The necessary polyethylene gas pipe resin for production of the low pressure pipe was purchased from a number of sources, including Dow Canada. Dow Canada produced 4.8 million pounds of high density polyethylene resin for use in the program. The Dow Canada resin was known as N5303. The pipe made from N5303 was known as PE3306. Dow Canada’s resin had been certified by the Canadian Standards Association as suitable in 1969 for gas pipe under the designation EP237. The Canadian Standard Association recertified the resin in 1973 in anticipation of its use in the Rural Gas Program.

PRODUCTION AND DELIVERY OF N5303 GAS PIPE RESIN

In 1973 T & U obtained gas pipe resin from Canada Industries, Ltd. (CIL). CIL *615 obtained resins from a number of sources to produce gas pipe resin by a blending process.

In late 1973, T & U determined that CIL could not provide enough gas pipe resin to cover its 1974 projected demand. T & U agreed to help Dow Canada obtain ethylene feedstock. Dow Canada agreed to produce five million pounds of polyethylene gas pipe resin.

Dow Canada’s gas pipe resin N5303 was produced by blending a mixture of Dow Canada’s base resin with carbon black master-batch in a ratio .of 9:1. Carbon black master-batch was made from carbon black and a low density polyethylene carrier.

Gas pipe was manufactured from N5303 by two different processes.

1. Dow Canada, acting through independent contractors, referred to as compound-ers, melted, extruded, cooled, pelletized and packaged a mixture of Dow Canada’s base resin and carbon black masterbatch. The product was shipped to one of four entities referred to collectively as the “Alberta ex-truders” who would form the pipe.

2. Dow Canada would provide an uncompounded resin known as N5303 Natural and carbon black masterbatch by an Alberta ex-truder that had the equipment necessary to mix the base resin and carbon black master-batch and extrude the resulting mixture into gas pipe in a single operation. This method of manufacturing gas pipe was known as the “salt and pepper” method. Some cost savings were involved. Approximately 17% of the 4.8 million pounds of resin sold by Dow Canada was N5303 Natural.

TROUBLES GALORE

Neither Dow Canada’s resin nor the pipe formed from it were completely homogeneous products. Six entities participated in the compounding of N5303. Four entities were involved in extruding the pipe. Some entities had better quality control than did others. Some N5303 had excessive moisture and excessive foreign materials. Some N5303 contained off-spec materials. It was transported and stored in different ways.

The pipe was installed by different co-ops in variable soils and in different weather conditions. The co-ops had different designs and had installers who followed different installation techniques.

Some pipe was difficult to install. Some pipe segments developed leaks. Some of the leaks may have occurred during the installation process. Other leaks developed after installation. The leaks in the pipe took different forms.

If there was a pattern of distribution of pipe from different sources to selected coops, it does not appear in the record. PE3306 was used by 38 co-ops. Some co-ops had very little apparent difficulty with PE3306. Others had a great deal of apparent trouble.

At first it was believed that the problems could be solved. If an apparent or possible cause of difficulties was identified, steps were taken to eliminate it. When leaks were discovered, they were repaired. The troubles, however, did not end. Leaks continued to develop. Difficulties were experienced with pipe made from resins from other sources, but difficulties with PE3306 were more persistent.

In 1976 the Province of Alberta imposed a moratorium on the installation of PE3306. In 1978 the province decided to offer a program of grants and loans to all co-ops to replace all of the PE3306 with a different kind of pipe. Eventually, under some pressure from the province, all of the co-ops went along with the replacement program. 1

THE REASON FOR THE REPLACEMENT PROGRAM

It is an undisputed fact that the decision to encourage the co-ops to replace all PE3306 pipe was precipitated by the 16-page report of Frank G. Rice, P. Eng., entitled “Report On Evaluation of Pipe Quality and Forecast of Serviceability of PE3306 Polyethylene Gas *616 Piping Laid Under the Rural Gasification Program of the Government of the Province of Alberta During 1974 to 1976.” After briefly stating that the report was based upon data set forth in prior reports and upon new data from a recently conducted testing program, the report drew the following conclusions:

1. Even the best pipe made from Dow N6303 is deficient for use in the rural gasification program, particularly at the licensed MOP of 80 psi. It lacks toughness necessary to withstand this operating pressure when additionally subjected to installation stresses and environmental loads.
2. Service life of undamaged pipe can be prolonged by the reduction of operating pressure(s)....
3. Service life of already damaged pipe is unlikely to be significantly prolonged by reduction of operating pressure and will continue to show a high failure regardless of any ameliorative measures.
4.

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814 F. Supp. 613, 1993 U.S. Dist. LEXIS 2207, 1993 WL 49935, Counsel Stack Legal Research, https://law.counselstack.com/opinion/associated-indemnity-corp-v-dow-chemical-co-mied-1993.