Document 2jXe3XQd0GXqo8ay27pego8da
Interoffice Communication
to G. L. Foshee From V. M. Fisher ate March 30, 1981 subject Impact of VOC Regulations on VCM Plant Expansion
The proposed EPA VOC regulations for control of fugitive emissions are applicable to any degree of expansion within a designated affected facility. However, an affected facility will not be subject to these regulations if there is not a net increase in overall VOC fugitive emissions due to the minor change or expansion. To avoid being subject to the stringent monitoring and recordkeeping requirements of these regulations a feasible alternative would be to reduce the uncontrolled VOC fugitive emissions from designated VOC fugitive emission sources within the existing facility to maintain the overall VOC fugitive emissions at their original level.
The reduction in uncontrolled VOC fugitive emissions in the VCM Plant could be accomplished through retrofitting and minor modifications of certain equipment. These equipment modifications are specified by the VOC regulations (except for the usage of rupture disks which is our most feasible interpretation for relief valves.)
Equipment which would require retrofitting and modification are pumps (on line and spares), compressors, pressure relief valves and sampling connections in VOC designated service. Emissions from both pumps and compressors occur at the seals. These emissions could be controlled by installing dual mechanical seals and a closed vent system to the incinerator. Emissions from safety/relief valves occur due to defects in valve seating surfaces, improper reseating after relieving, or process operation near the relief valve set point. Rupture disks could be installed upstream of the safety/relief valves to prevent the emissions of VOC through the valve scat during normal processing conditions. Fugitive emissions from sampling connections can be reduced by using a closed-loop sampling system. Once these modifications are made to a specific piece of equipment their emissions become controlled.
In contrast, valves are exclusively an uncontrollable source for VOC fugitive emissions. Reductions in valve emissions cannot be expected except in situations where the particular valve is retired from service (i.e. removed and replaced with either a spool piece, or capped or plugged). This presents a serious problem for the VCM Plant expansion because the VCM Plant can only utilize the reduction in the VOC uncontrolled fugitive emissions from pumps, compressors, and safety/relief valves in attempting to offset the expansion VOC emissions from similar equipment and new valves. The emissions for the number of valves in the expansion are greater than the sum of the emissions
---
'H'acf-vi
CCR 000017785
G. L. Foshee Page 2
from the expansion pumps, compressors and safety relief valves. In addition, the expected valve emissions comprise the majority of the total VOC fugitive emissions from the expansion and by themselves exceed the available offsets from the existing facility.
Attached are three tables, Table I- Controlled and Uncontrolled Fugitive Emissions in the Existing Plant, Table II - Net Increase in Controlled and Uncontrolled Fugitive Emissions due to Plant Expansion, and Table III Offsetting of Plant Expansion Emissions. These tables were compiled after a thorough investigation of the equipment list (Appendix A&B) for both the existing facility and the plant expansions for the number of pumps, compressors, sample connections, and safety/relief valves in VOC service. Furthermore, the expansion P&I diagrams were used to provide an estimation of the net increase of valves in VOC services. The equipment to be installed in the expansion will be installed with the specified controls, thus making them controlled fugitive emission sources.
The total expected VOC fugitive emissions increase from the VCM plant expansion is 34.178 lb/hr as detailed in Table II. However, the total available offset which could be provided in the existing facility is 23.350 lb/hr as detailed in Table I. The available offsets from the plant are deficient by 10.828 lb/hr which is equivalent to the removal of 492 valves in VOC service. This deficiency in available offsets would make the VCM Plant liable to the rigors of the VOC regulation after its anticipated final promulgation.
The financial impact of the VOC regulations on the expansion rest upon two conditions:
1) Compliance with only the equipment modification portion of the VOC regulation in order to offset the expansion's expected VOC fugitive emissions, defined in Table IV.
2) Total compliance (equipment modifications and a regimented monitoring program) if the expansion's expected VOC fugitive emissions cannot be offset, defined in Table V.
First, to retrofit and modify all existing pumps, compressors, sample connections and safety relief valves as defined in the VOC regulation for the VCM Plant the capital cost would be $700,000. This figure does not include the removal and replacement of the 492 valves (the estimated number of valves needed for a complete offset) with spool pieces. The cost which would be incurred here is $400,000. Thus the total additional cost for compliance with only the equipment modification portion of the VOC regulations would be $1.1MM.
On the otherhand, total compliance would not only include retrofitting and modification of all existing items as previously mentioned but a regimented monitoring system as well. Additional capital and operating cost would be
CCR 000017786
G. L. Foshee Page 3
incurred for the following:
1) Establishing a monitoring program. 2) Making all valves in VOC service accessible. 3) The operation of the monitoring program. 4) Maintenance cost for valves.
First, the establishing of a monitoring program for 2800 valves would require 15 to 20 man-days of engineering time and 250 to 300 man-days of drafting time. (Periodic minor revisions would require continuous drafting time in addition). The estimated cost for this would be in the range of $20,000.
Second, all valves must be accessible for monitoring purposes. It is estimated that 20% of the exisiting 1700 are inaccessible or not easily accessible. An order of magnitude capital cost to make these valves accessible was estimated to be $2.0MM.
Third, the operation of the monitoring program will require 10 additional personnel. It is reasoned that 6 full time persons (2nd class operators) would be required for monitoring the valves, 1 full time person for record keeping, 1 full time draftsman for' recording revision in the plant P&I diagrams and 2 extra full time maintenance persons. This estimated monitoring system operation cost for these additional personnel would be $239,000/year.
Fourth, there would be additional maintenance cost incurred due to leaking valves. For practical purposes the assumption is made that 4% of the2800 valves leak, and 10% of these will have to be changed out each quarter. Thus a capital cost of $640,000 will be incurred each year for new valves (excluding salvage valves).
The total capital and operating cost for total compliance with the VOC regulations would be $2.72MM and $879,000/year.
If reductions in uncontrollable emissions in the VCM Plant is insufficient to offset the net increase from the expansion, then gearing the planttowards total compliance would have to be considered. The expanded VCM plant is scheduled to go on line during the first quarter of 1983 by then the VCM Plant will have to begin implementation of the then promulgated VOC regulations. It is estimated that it would take 27 months lead time for engineering, design, procurement and construction to establish the changes needed for implementa tion of the VOC regulations.
iUiwjLi
Virgfl M. Fisher Process Engineer
br CC: JAD-JWW-DLD-MGH
JJH-JCL-GCB GJF
CC* 00
a?
OOOO^-
oo 50
03 CP
i
ABLE X, Conm.6i.uED amo Urtc*rr^oH-^i^Jfu$*Tit/e *M/55;^s IN
ST/ N <1
** TT
Equ/pmewt
No.
UnCO^TROLlEP Total-
Emission Factofz- 3
(JncoNTRULEP No.
Ptnso/oNs
l&A\r.
Control leo EmosfoN
Factor? LB/nr
^Vcw- 1///V /i. Purripi JN. ypc
50Z.P7CE . (Presentiy-,
EX/stiN<?\) ^
\ O' Z(&5
13.?&0
Non- V/oJYLPc/MPStN Voc Service
52* O'OF9
Iota l~x' Controlled Em/ssions
lb/hr
Fuomve" EMISSION Reduction ^/CoMTfZXK-lgD
Emissions
--
4./oe
Z&fZ
PytisriNqj M
SArnryferLiEF
Valves IN Voc Service
(Presently j EXI5DNJ Cy)
0. 353
Mo.Z&B
\
SAFETy/^ufp
Valves Im Vbc 5t'avjcc
4~Cp
0A4-<o
>?!(*
95 zz
(ftESENTpr
ExistimO~ . .1 1 ---------- 1 ---- -_X.... .. ............ .1
................ --
Note: i. Without Echup'ubnt Moi*icArMs . A* Spccificd ! im tvB; voe. Rb^ulatimis.
'* I j
?|
,'J:
1i
I
, 2. j With .1. &s?jUU?MEKr Me>f\''OATipyo.s As Spe&ipjeoiiN Tkc 14?c Refutations.
. 3. -Souece;.i tjUJpeUA/f $&i*
il
~T
Cojtrttx. of^ VocATii-B On^imc ft5fAiWu\ miss**w
I _i 1
fjg|e**| Sy*jfn4 611 CfciANic Otidweipi.
AN
rR Af*j<AfMF|ci^gW6 ^di-nOMcin/Tf. 1
A6LE IC. CoHTtt.6ilep AMO UncoMTfeeLugEmissions in E* 1 &ti*a$^TLa*jt.
Equipment
No.
Uncontrolled
Emission Factofz- 3
18/hk
Total. Unccntrcubo No. Em!$3/>NS>
Le/dfz
CoNTtZCLLEO Em133 /ON
Facto#.3 LB/d*>
M?V- t^A/^AS!a&pL/m $
dbNNEc 77 OA/S (hl-5H7LY
Ey/5r/N'6)
zo
Nod- Vldyu *SAMPL/Nt Connections CfkeseNrLY^ Exfsr/N O
(2o/>lpt-fyS0r5 id VoC
3tr#V/ca (fheseNTt-y j Ey/sr/NCp )
5
6.053
O.6C1
zo \ 4. 85 0
O
'Total.'' Controlled Emissions
lb/mk
Fiiomue' EuisstoM Reduction 'N/CoNtZCLIGP
Emissions
O 0.(^6? 1
Cpfnp^^scrs
oo30
IN \OC SEfLVtCZ
(Preset' a
. V/S77a/_)
A
5 ,2TI
J.85S
3.4-9 S'
000017789
Note
I. Wrrwou-rv Equipment
Z VVi-n-l [ 3. ISoU
j CpmipMEUt
IUIQEL
"T'o'T'a. l_
Z5-350
Mopi.pi4at:ipMs As spscciep IN TlJi VOC Ke,t*LATU>*t&.
|C|< AT||e>M5 As -Sb^tifsiep _ fJ T>je VOC IZ6ULA.TIOkiS.
Fuei-nye Em 1 as*cmos
ic. Qei*M tc yue*4i\Au i P<^Xt. K/ AKio tfesu*
PACTHKIAJ4
IP*4NT,
, )
fc[asl H.
^pCrjWC,^P,AMs!oM
(JtJcabtrtCLLEO fu*TII/ vu/9S1ON S t>UB'^^
Equipment
No-
Uncontrolled
Emissioh Factor
ib/Hr
Total-
Uncontrolled No, Ew$3tOM2> L6AiX
Controlled Emio3/on
ac.to&lb/h*
//W- VtNyu Pubifo 1*4 V`0 C SlRytCE
PtrAf/T
zz. 0.0^9
Total- ' Controlled Emissions
l%k
Fud/nv'G" EmissioM REDUCTION) ^/CoNfraou-ED
uissionJS
\h?5
O
//6A/- Vjfi/YL~
Satett/ReuEF
Va Lv&y in YOC
Off
Pt-Awr Z.XPAf/^iVNJ
i/tNYL
Com presso& s IM VOC -Service (,Pfec>M RLanjt
oo30 Ner Increase
41 o.f4&
5.9$&
o
Co (O.ZTl
o
Ofei-i TM 00
(M VOC -Stv4t.- 93d
CR?OM "Pt-AN T
O 02JZ
2QM5-C*
o
StpAMSJpH^
A/;ErJNC*eA^
vInyuVAi-veslM^VO'C -5f^Wc<F5?cM^ JPUmt
/?>
C?. oz%
4.keb
*
- - j--------
___i_ _:.
J-QTAU ;k 1. soiAexJS 1
11* ^
W,' ` ^ 1
<&u/ocuAjfi denies :
- < j MJ
USE
Co^imot, FVoiArn/e OeAANTZR^tTTffEMi*** ms
Beom SV^tMEtic, OCtoAMic. CV+fc^icAL. Poi-rA<r*, A^D
ft # j| di * . * * ^ * MM , ft > I
A . , * ^ M ' *
~Ta ale JXL
Qf^FSETTlHG? OP flAMT' P/FANsjoN
Mi 33/oNS
-0A/et Coa/tCo/.LC ANQ
UAJrOA/7&OUE> FmsCIN$ !n CA FAS E P/Po^f
.-34\ /?a L%tz
|
Pi A NT P.KPAAiS-iOAi
(FbomTablE XT> ReOUCT(0A//A/
Unclontaolle &
fuo/rn/F pMissioM
'TaIAou 6 M&bjriAAfloAj afr Exist/Nq
23.$*>OUfa
IzQmEMlNT fiksuETMt)
_n; 0.^17
(F ?McxCMiS>JoAJ^
IabuB t. )
^; / >JPs
'/ p/tj/zst c>a/$
nJ Of-mr-
PaCM c ', :r/,'/, ^ //.'
/&. 32 8 L%&
\
0000
;. i, 1 .' . I1 : !
1
1 ; I !1 J_L 1.I.J, ___
i i
1 ________
_
-u ____
j_
l
i.
\
"Ueu-
;
r?/v/,nci.<*l. clmpact c;/r
compliance:
WITH. Cf-<uV TW` GQUiPMLUT /UOOIf=/CA'UOI4
p 0 Ct -/a tj OF* the vtoc.
*>U LAT/ 0\4 w
cr-p'ST purposes .
j / .Mopf &,>cA~r tON&
i
l
e-CutPMCM / ! ( // 6 "^7a ^^5, Coupxl &Cqp~c,
i aSAAu-a. OwNhcriosis&SAf&'r IpLLl U~' VADJ&& /W V'C O
| /<r . lA&cfi CaLT' ! MCA&Ct'D ')
I
Afc'wn/u <:/' 7'<?:n
I a'.". ;.' ^ / t-P. t~l.Pt!AC .Y*
i ,'/r" a 7i
PiLas
C<pc yAcys^/S' tN
teSTP-iA'CSJ Msm&~ AC. PC Hot. Aa/<$Ui\-'AIlNT
Oi-PCCLT CP T'PG. VCJP
HA M r iypA f-4 do fJ VC C,
Has in t'A Arabic cl
TOTAL
Capital Coz.'T # y-OG,OCHO
4 rf-cc, occ
$ !/ooyocc
+ r ---r
. .4~
I* - - t t
F- !
II
000017792 OCR
rY/WC/AL jC^APACT CF TerrA L. ComPuAKvA
OF 7~H 1/OC g6CfCAriD^o(j.t< EoPiFfJLUrl MODtrtCATl 0<4O Arlp A^^aj iTEjtf i m<5 P(U&3AHfy\
j JfcisG U LA rfeN Uc-MAMO0
. ieCliiPMFNT Moot ftCAT/O A/S E&TA&UNfG A M&Nt7l>(lrN4
CsrST
Ctftapital f opb Eating yoo, 00 0 *2.0, 00cd
1
i
(IS'tbZG rn&Sidtctfr
* et'Ainetful * k2s$ 19if)0,-] Xr\e/n </;.
tdl i'jfi/rtrr "Vw<0
.
7^AiN&AU- VALV?> /a/
sez\//ce
Accessible , zc% Q-f
i
-
^2/ 000,000
"i
-tf:& lrOd VAil!'Z are {n neec'vry blc* ) THE OpEMT/OA/ OiF
i
7AIe Mas/rrec /a/<?
Pi'(ZodrCftAf (u*t 11 rccpifz,
/C de'drfiwaf personnel:
*23%ooo/y
(0 7\v/7- hfriH, t_ H'TortS ^ir IVcm/rihU l /Mii- hm? person-ftr rettirL-
11l
J
Ireepuicj
1
( dr.i-ksnian Tvr
Ktcprd'na revisions in
; -dr- pkef p{p. p,aaramc-
2i
e'x1rre-
r .; t
ixi(-7
-* l
marni'/-, i/>ce
persons '
*1
1:1
1f i
i
Ma/msea/as/ce cost FOR. VALVES ( Jtf'
I 4% Or ii'C?$(7)
/n.ihrr.'i
u)t(! be rzpMrn each nitxier)
fc4-0,000/z0ir
: ~total
2,$2* 0,000 *'8r c COo/jn
4
I --fi - -
I
f
OOOOX7793 OCR
APPENDIX A. EXISTING EQUIPMENT IN VOC SERVICE
P-102 A/B P-103 A/B P-104 A/B P-105 A/B P-106 A/B P-109 P-110 A/B/C P-112 P-211A P-402 P-405 P-450 P-451 A/B P-452 P-108 'P-115 P-255 P-425 P-435 P-453 P-454 P-460 P-504 P-505 P-506 P-507 P-604
Caustic Wash
L. E. Column Feed
L. E. Column Reflux
H. E. Column Feed
H. E. Column Reflux and Product Transfer
EDC Tar Still Bottoms
Water Wash Recycle
EDC Transfer
Tar Still Bottoms EDC
L. E. Transfer
EDC Tar Transfer
EDC Transfer
Pure EDC Transfer
EDC Transfer
EDC Tar Still Overheads
Oil Pump (BL-301)
EDC Circulating Pump
EDC Unloading
EDC Tars
Wet Crude EDC Rerun
T-453 Water Pumpout
Slop Tank Transfer
Tretolite Pump
Chemical Feed
Chemical Feed
Chemical Feed C-500 Transfer Pump
OOOOITT?* CCR
APPENDIX A (CONTINUED)
P-605 A/B P-606 A/B P-607 A/B P-625 P-902 A/B/C/D
BL-410 A/B BL-602 A/B BL-501
Lube Oil Consol Main Oil Pump (BL-501) Main Oil Pump (BL-605) EDC Loading Liquid Feed to Incinerators
Freon Freon Propylene
Sample Connections S-309 EDC S-309 Water S-307 EDC S-306 EDC H-201A H--201B C-204 Reflux Vaporizer Feed R-101 EDC R-102 EDC C-203 Bottoms T-101 EDC C-102 EDC Feed C-102 EDC Bottoms C-103 EDC Reflux
T-103A EDC P-110A, B, and C Discharge T-102 EDC R--103
CCR 00001T795
APPENDIX B EXPANSION EQUIPMENT IN VOC SERVICE
NP-150 NP-151/152 NP-153/154 NP-155/156 NP-157/158
NP-106 C/D NP-109B NP-131 A/B NP-132 A/B NP-301 A/B NP-302 A/B NP-451C NBL-304 NBL-305 A/B/C NBL-501A NBL-413A NBL-413B NBL-414A NBL-414B
R-150 Purge Pump R-150 Reflux Pumps R-150 Product Pumps EDC Product Pumps uent Condensate Pumps
Heavy Ends Column Product and Reflux Pumps EDC Tar Still Bottoms Pump Water Wash Feed Pumps EDC Tar Still Overhead Pumps Oxy EDC Pumps Oxy Water Pumps
Recycle Compressor Ethylene Recovery Compressors Propylene Refrigeration Compressor Tank Farm Vent Compressor Spare Tank Farm Vent Compressor BLR Vent Compressor Spare BLR Vent Compressor
000017796
CCR