Document 6wNq43YBaE86MGON4K6qowOGg

INDUSTRIES PPG INDUSTRIES, INC. CHEMICAL DIVISION U.S. P. 0. BOX 1000 LAKE CHARLES, LA. 70602 March 12, 1987 Mr. Tom Coerver Department of Environmental Quality Air Quality Division Office of Environmental Affairs P O Box 44096 Baton Rouge, LA 70804-4096 Dear Mr. Coerver: RE: LESHAP VCM Quarterly Report In accordance with Section 77.11 of the LESHAP regulations, PPG Industries' Lake Charles Complex submits the attached quarterly report for the period December 1, 1986 through February 28, 1987. Attached as Exhibit I is a record of emissions in excess of 10 ppm (averaged on a hourly basis) in the stack gases exiting the incinerator. There were 5 such incidents. Attached as Exhibit II is a record of emissions in excess of 10 ppm (averaged on an hourly basis) which resulted from temporary by-passes of incineration. An estimated 90 pounds of VCM were released as a result of these 6 incidents. Attached as Exhibit 111 is a record of sudden discharged of VCM which occurred during this reporting period. An estimated 8458 lbs of VCM were released as a result of these 4 incidents. Written notification of these incidents was made within 7 days of their occurrence. Next, in accordance with Section 61.65b of the NESHAP regulations, particularly subsection (8) leak detection and liminating PPG is hereby submitting (to the DEQ and, by copy of this report, to the EPA) the results of a performance leak test on 204 randomly selected valves in vinyl service which was p rformed at our VCM-II vinyl chloride unit on December 13 and 16, 1986. The leak check was performed in accordance with paragraph 61.245(b). A listing of the valves check d is attached as Exhibit IV. None of th valves was found t be leaking, cons quently th p rcentage of 1 aking valves in this SL 026403 Mr. Coerver Pag* 2 March 12, 1987 unit is demonstrated to ba less than 2.0 parcant. Accordingly this unit qualifies for exemption from paragraph 61.242(d), 61.242-7(a), (b) and (c), 61.246, and 61.247 of Subpart V. Based on these results, PPG intends to continue its LESHAP approved leak detection and elimination program in its VCM-II unit in lieu of Subpart V leak detection. Finally, PPG is hereby notifying you that our Mo. 4 incinerator located in our VCM-II vinyl chloride unit was started up on March 3, 1987 and is scheduled to operate approximately 14 consecutive weeks. This start-up has been required by the temporary shutdown of our Mo. 3 Incinerator which is being modified to meet EPA TSCA standards. Respectfully, James E. Rusnak Plant Environmental Liaison Foreman ce Attachments 026^4 EXHIBIT I OOHIIHUGMS STACK PCSSIOW RESULTS >10 PPM VCM Dec. 1, 1986 - Fab. 28, 1987 Data Stack Ho. Hour Ending Hourly Average (pm) COttflMttt 12/31/86 #1 8 #2 1600 10.9 Invastisatlon showed tha #2 Incinerator shutdown burning liquid wastes. Tha #1 Incinerator was burning vinyl vents and experienced no upsets. Tha VCM laval in tba stack is unexplained. 01/24/87 #1 * #2 1300 22.7 Tha #1 Incinerator tripped due to hot VOi-II vents. VCM-II vents got hot due to a lack of adequate coding Ira tba cooling tower. Power to one of tba cooling fans was being uaad by an axparinantal Helco trailer which increased tba dmands on tha systaw. 01/27/87 #1 a #2 2200 14.1 #1 Incinerator tripped due to a fine failure Alia switching vents frm tba #3 incinerator. 02/02/87 #1 & #2 1400 137.7 Investigation showed that tba #1 Incinerator was burning vinyl vents. Tha #2 Incinerator was burning liquid wastes. During tba introduction of Liquid notarial (non-vinyl) tba stack analyser indicated a high VCM level. The VCM level in tba stack is unexplained. 02/11/87 #1 & #2 1200 14.1 Tba #1 Incinerator was burning vinyl vmti. The #2 Incinerator was burning liquid wastes (nan-vinyl). During the Introduction of tba Liquid notarial tha atack analyser indicated a high VCM laval. Tha VCM lava! in tha stack is unexplained. SL 026405 EXHIBIT II BOW-iwciHERATicw of yen vans Dec. 1, ISM - Fab. 28, 1087 Data Tin Sources Hot Incinerated Estimated Quantity KM Vnta (lba) Cnunaut 01/08/87 0803 to TCH-II, CSS, VCH-I 17.6 01 Incinerator tripped duo to no natural saa proaaura. Snaeone mistakenly blockad in tho air supply to tbo natural Saa aupply (PCV) praaaura control valve Cor tha antlra complex. 01/08/87 1238 to 1240 VCM-II, CSS. KM-I 11.6 #1 Inclnarator tripped duo to a flame failure while t swapping vanta to the #3 Incinerator. Tho 03 waxto heat boiler was partially plugged which cauaad tho Clow to back up into tha 01 Incinerator and blow out tha flame. 01/24/87 1340 to 1400 KM-II, CSS. TOH 23.1 01 Incinerator tripped duo to bat KM-II vmu. KM-II vmjta sot hot due to a lack oC adequate cooling Cram tho cooling tner. Power to one oC the cooling Cana area bains uaod by an experimental Helco trailer which increaaod tha demands on tbo ayatn. 01/27/87 2104 to 2125 KM-II, CSS. KM-I 16.1 01 Inclnarator tripped due to a Claoo failure while vents wore switched from tha 03 Incinerator. 01/31/87 1724 to 1745 KM-II 14.0 Unknown computer problems at KM-II tripped off both OBC reactors and VQUI vents out of the incinerator. 02/18/87 0250 to 0254 KM-II, CSS, KM-I 4.6 A possible power surge cauaad VC vents to trip out of tha 01 Incinerator. SL 026406 EXHIBIT III suddct vcm discharges Dm. 1, 1SB6 - Feb. 20, 1807 Data Tina Duration Eetimated Quantity VCM Ralaaaad (Iba) 12/16/00 0142 to 0144 (2.5 min) 11 12/16/86 0913 to 1300 (3 bra, 43 min) 7455 01/26/07 0920 (2 aaconda) 7 02/02/07 0235 to 0620 (3 hra, 43 min) 903 Comment A corroaicm plnhola leak developed on tha VCM-II Hautrallzar drain llna. (Wrlttan notification waa mada 12/10/66). A hydraulic ahock in tha ayatam cauaad a SRV to lift and improperly raaaat on a VCM-II tranafar llna. (Written notification waa mada 12/19/06). A ahift atorate vent compreiaor at WCM-1I waa atartad up Incorrectly which cauaad lta SRV to raliava. (Wrlttan notification waa mada 2/2/87.) Tro plnhola corroalon laaka davalopad on tha bottom nozzle of tha Bo. 1 VCM Neutralizer. A aecond ralaaaa occurred whan an oraanlca boaa being used to drain tha neutralizer ruptured. (Wrlttan notification waa mada 2/0/87). st 0261,01 EXHIBIT IV The folloelnf operetora I rood the teetine ilvee: Heee Oery Sonniw mi t GAlLlDIIB Pete of Uu 1067 12/12/06 12/13/06 Jay Moon 916 12/12/06 12/13/06 Konny Bourgeole 016 12/12/06 12/13/06 Nolen Sleien 916 12/12/06 12/13/66 More Moreno 1067 12/12/06 12/1 /66 Tht follow!* valve* nrc ill checked aid found to have no vinyl liaki. EUfiC 1. S 2. 6 3. 14 4. IS .5. 19 6 32 7. 33 6. 35 9. 36 10. 40 11. 41 12. 45 13. 53 14. 56 IS. 60 16. 61 17. 63 18. 70 19. 73 20. 74 21. 82 22. 86 23. 89 24. 94 25. 100 26. 103 27. 107 26. 112 29. 114 30. 116 31. 118 32. 125 33. 129 34. 139 35. 150 36. 152 37. 162 36. 163 39. 165 40. 167 41. 168 42. ITS 43. 176 44. 180 45. 184 46. 189 47. 205 48. 212 49. 215 50. 218 Deacriatloo/locatlon 1" block valve oo 12 pan fl furnace going to vent header. 1" block valve on fl furnace fl pan going to vent header. Nitrogen supply block valve to body cavity of 12 furnace fl pan supervalve. f2 furnace fl .pan supervalve 3" dnp valve froo Qusnck Touar to 12 Dopp kettle. Block valve on pressure gauge on Biddle of bench Tonr. 6" block valve at Quaech Touar on reflux line. Block valve on pressure gauge at top of Quench Touar. 6" block valve on fl furnace feed line StV. Biddle block valve an aiddle Quench Toner SSf. 6" block valve oo unt SKI on Quench Toner vapor line. Quench Toner reflex floe control valve. 3" upstreae block valve on prod, still LCT on 0. Liq. Ik. 3" block valve next to gnench liquor tk. oo vea rework to Q.L.Tk. 1IT block valve on low pressure side of IT 3040 O.vapor to absorber. 1/2" block valve on high pressure side of FT 3040 O.vapor to Absorber. 3-wy valve on sn an Quench Liquor Tank. Saeple point block valve on suction of Quench Uqour puap. Discharge block valve on fl Quench liquor puap. 8" valve oo suction of Quench Liquor puap. 4" dowstreaa block valve for Quench Liquor to Stripper PCV 3042. 6" block valve oo vapor line out of fl Dopp Kettle, fl Dopp Kettle duap line where nitrogen is added. 1-1/2' block valve oo f2 Dopp Kettle fron entrainsent separator. 1-1/2" block valve at ground level on Dopp overhead seal loop. Block valve oo Quench Dopp Overhead tank bare nitrogen is added. 1-1/2" drain valve on vest gotten end of Q.D. Ovhd. drw. Upstreae block valve oo Q.D. Ovhd. drun PCV. 1-1/2" dowstreaa block valve for PV3455. l" block valve on saeple loop return to suction of Q.D.Ovhd pwps. 3" block valve oo section lien to south Q.D. Ovhd. pwp. 2" block valve for outlet of Q.D. Ovhd. filter. Upstraaa block valve on ft3B48:Quaach Dopp Ovhd. to Q.T. 1/2" block valve on high pressure tide of FT 3105. 8" auction valve to fl Freest puap. Swple point block valve an discharge of Upper Inner Cooler pop. 3-uay valve on hbaorber OV's. 4" block valve next to Absorber fra Preset Cooler. Top block valve on Leae QU to Absorber. Top block valve on Preset tray sight glass an Absorber. Top block valve on Absorber flaw to Preset Cooler. Top block valve on sight floss for Upper laser Cooler. 6" block valve nest to Absorber on Upper Inner Cooler. Loesr lwer Coolv floe to Aboorber aert to Aheortw. Bypow block valve on Loner loner Cooler PCV 3125. Top block valve on Absorber level traeenitter. 8" auction valve to fl Freest pop. Bypwo valve crowd Absorber Bottone to Stripper - LCV 3340 1" block valve on live fron diochirge of Upper lanercooler popA" block valve on discharge of spare Loner leaercoolar pwp. SL 026408 51. 219 S2. 221 S3. 222 54. 223 ss. 230 56. 236 S7., 240 SB. 242 S9. 243 60. 252 61. 263 62. 264 63. 267 64. 268 65. 269 66. 272 67. 280 66. 2B2 69. 2B4 70. 289 71. 298 72. 299 73. 304 74. 308 7S. 323 76. 326 77. 335 78. 336 79. 337 80. 342 81. 343 82. 346 83. 347 84. 348 85. 3S3 86. 359 87. 360 88. 367 89. 369 90. 373 91. 378 92. 381 93. 405 94. 406 95. 428 96. 429 97. 431 98. 432 99. 435 100. 438 101. 444 102. 452 103. 456 104. 463 11 Loner Innercoole pap suction block salve. 1/2" block valve on orifice up on FT 31*1 Stripper Overhead vapor hifh side. 1/2" block valve on orifice tap on FT 3141 - Stripper Overhead vapor los side. 4" block valve jtaper between Quench Liquor Feed and Absorber feed to stripper. High pressure nitrotai to Stripper next to Stripper. Product Still feed puep discharge line -4" valve that ties into DC rework header. *" block valve top of Product Still Feed tank on DC rework line. 2* block valve top of Product Still Feed tank. Top block valve on sight glass on Product Still Feed tank. 11 Product Still Feed pu*> discharge. 3-vay valve on Product Still SBV. Middle feed point block valve on Product Still leflui. Block valve on second fros top on Product Still feed point. Block valve on third froi top on Product Still feed point. Block valve on bottoe feed point to Product Still. Top block valve on float chaaber to Product Still. Dpetreaa block valve on Product Still Beflux FCV. Product Still reflux flow transiitter block valve on high pressure side. 1" block valve on Product Still top pressure gauge. 6" down streai block valve on Product Still FCV. 2" block valve on top of Product Still reflux tank. 1/2" block valve for Product Still reflux tank pressure gauge, famctreaa block valve on Product Still reflux tank FCV 3581. 3" block valve on upstreaa block valve on double block and bleed on rework line to neutralizers. Bypass around Product Still reflux tank LCV. 3/4" block valve on top of Husidifier. 1/2" block valve to pressure gauge on 3" product outlet line froa II neutralizer. 3" block valve on product outlet line froa II neutralizer. M/2" block valve on drain line to drain dna free II neutralizer. 4* valve on drain line on 12 neutralizer. Block valve on pressure gauge to top of 12 neutralizer. 3" valve on product outlet of 12 neutralizer. Product inlet block valve on |3 neutralizer. Pressure gauge block valve on 13 neutralizer. 4" block valve on drain line to neutralizer drain dna froa 13 neutralizer, l" block valve to pressure gauge on outlet of II VCM product filter. Product inlet block valve on |i product filter. 4" block valve down streai of VC product filters. Pressure gauge block valve on neutralize' drain dna. 3* top nozzle block valve on U3390 for neutralizer drain dna. 4* valve at the drain dna on the neutralize drain line. 4" block valve on suction line out of neutralize drain drun to neutralize sash puip. Block valve on bottoe of B-l level transaitte. 2" block valve for B-l high level probe. 3" valve on product rework recirculation on B-2. Block valve on B-2 high level transaitte. 2" block valve sith blind flange on B-2. 6" suction block valve on B-2 next to tank. Pinch valve on top of B-3 varec. Level transaitte top block valve. 3" rework recirculation block valve on top of B-3. B-4 top block valve on varec. 2' block valve for Ui-Ui pressure switch oo B-4. SL 0264oq T block valve uith blind flange on B-4. 105. 465 106. *66 107 . 467 106. 471 109. 474 110. 475 111. 462 112. 486 113. 493 114. 495 115. 499 116. 500 117. 504 118. 508 119. 524 120. 528 121. 529 122. 537 123. 541 124. 542 125. SO 126. 550 127. 553 128. 556 129. S70 130. S73 131. 577 132. 584 133. 587 134. 588 135. 589 136. 590 137. 596 138. 600 139. 601 140. 614 141. 615 142. 617 143. 624 144. 629 145. 659 146. 660 147. 674 148. 675 149. 677 150. 681 151. 690 152. 691 153. 692 154. 696 155. 698 156. 699 157. 702 158. 706 6' block valve on bottoo of B-4 on line to product reuork p*p. 2* block valve aitb blind flanfe on fe-4. 1' equalizing line on 6" line to/fron vat storage spheres, l* floating line to 6" product transfer header to S1/S2 area. Block valve on product pusp discharge line into product transfer header. 3/4" block valve on floating line (roe alternate transfer header (South) to suction line of product transfer puip. 8-5 bottoe block valve on LI. Product inlet line block valve on B-5. 2" valve uith blind flange on B-5. 10" suction valve for 12 product transfer piap. 10" suction isolation block valve on product transfer punp. 1" floating line on auction of product transfer puap. 1" valve on auction of reuork pup sanple point. 1" sanple rig oo product reuork pop discharge line block valve. 2" inlet valve to shift storage vent condenser free shift storage vest cospressor. Bottoe block valve on H.F. vent condenser knock out dna level tranaitter. Bottoe block valve on H.P. vent condenser knock out dna sight glass. 1/2" orifice tap block valve (high side) on FT 7026 vent flow off of 8.P. vent condenser receiver. Shift storage vent cospressor pressure control valve (PCV 7426). Shift storage vent cospressor block valve domstrean of PCV 7426. Shift storage vent cospressor block valve bypass around PCV 7426. 3" block valve oo Product line into D-l. D-l block valve on pressure gauge. 3-vay valve under SKV's on D-l. 3* botton block valve on pressure trnnsnitter on D-2. 4" block valve for recirculation into D-2. 3-ay valve for SBV on top of D-2. 4" drain valve on uest end of botton of D-2. 3" block valve oa product inlet to D-2. Block valve on reuork recirculation line into D-3. 4" recirculation block valve froo Certainteed transfer puip to 0-3 or D-4. 4" block valve on recirculation to D-3. 6" block valve on botton of D-3 oo suction line to Certainteed transfer pusp. 3* botton block valve on level transmitter on D-4. 3" block valve on product inlet to D-4. 4" recirculation valve in piperack on walkway on top of daytanks between D-l and D-8. M/2" equalizing line in piperack between D-l and D-8. 3" block valve oa product linn in pipe rack between D-l and D-8. 3/4" block valve on Certainteed transfer equalizing line. 6" suction valve at Certainteed transfer pusp. 1-1/2" block valve on equalizing line to D-8. 1-1/2" block valve snder pressure gauge oo D-8. 1/2" block valve under pressure switch on D-7. 6" 3-way valve on D-7 for SKV's. 6" block valve to transfer punp suction bender under D-7. 3" block valve oa product line into D-6. 6" block valve to transfer punp suction header under D-6. 4" block valve to suction header for reuork punp under D-l. 4" block valve uith blind flange under D-6. 4" block valve on recirculation header to D-5. 1/2" block valve to pressure switch on D-5. 6" 3-way valve oa D-5 for SKV's. 6" block valve oa D-5 to suction header for transfer pusps. 2" block valve at 5-1. SL 026*10 15V. 710 160. 712 161. 714 162. 728 163. 731 164 . 759 165. 766 166 . 769 167 . 771 168. 777 169. 785 170. 789 171. 792 172. 793 173. 795 174 . 796 175. 800 176. 805 177. 807 178. 80s 179. 827 180. 833 181. 837 182. 844 183. 845 184. 850 185. 863 186. 867 187. 879 188 . 881 189. 883 190 . 885 191. 886 192. 889 193. 891 194 . 901 195. 906 196. 908 197. 910 198 . 924 199. 927 200 . 929 201. 931 202. 934 203. 935 204 . 943 0* 3-way valve on $-1 for SRV's 3* block valve on bottoe nozzle of varec of S-l. 4" check valve on recirculation line to S-l. i" auction block valve on fi tank car loading puap. 1/2" block valve on tanple rig off of suction of tank car loading pops. 6" block valve on suction header to barge loading paps under S-3. 1/2" block valve on top of saiple rig of S-3 loading paps. 4* block valve on discharge of fl barge loading pap at S-3. 6* block valve on suction of #2 barge loading pap at S-3. 6" bypass valve around FCV 6005/lncinerator vent valve fros C-6. 1-1/2" drain valve on bottos of T-4. 6" block valve out of E-l. 6" block valve on discharge line of lov tesp VC transfer punp into line to/frce area. 6" block valve upstrem of ICV out of 1-2. 6" dounstrean block valve on ICV out of E-2. 14" block valve on suction header for P-1 (Orbit valve). 6" check valve on discharge of P-3. 6" block valve on discharge of P-4. 6" Durco block valve used to cross-over froa discharge of P-1/P-2 into discharge of P-3/P-4 into sphere storage. 12" suctioo block valve on P-l loading pap. 2" block valve on discharge of P-6; after check valve on line to 1-7. 1-1/2* block valve on bottos leg of sight glass on T-3. 1-1/2" block valve under rupture disk/SBV for T-3. 2" block valve out of 1-3 (going to 1-7). 2" block valve on vent line out of 1-4 to T-4. 6" block valve between vapor line froe docks and the back-pressure control valve. 2" bypass valve around dryer on drain line to T-7. 3/4" bottoe bleed valve on bottoe of T-6 (Deriaing water drain tank). 2* block valve between deriving dryer D-l and T-7. Bottoe block valve on level transaitter on T-7. 2" block valve on top of T-7 on line froe P-5 and P-6. 1" block valve on recirculation line on top of T-7. 1-1/2" block valve on pressure switch on T-7. Nitrogen sake-up regulator block valve on T-7. 6* block valve on vapor line fore loading dock going into 1-3 and1-4. 1" LCV6223 on H-i vaporizer off of 14" T-l and T-2 suction lines. Block valve on top of T-l varec. 4* block valve on top of T-l (cooldown line). 8" block valve on vent line on top of T-l. Nitrogen autcnatic valve on top of T-2. Block valve on bottoe of theraal SBV on 4" recirculation line froe dock. 6" block valve on recirculation line on top of T-2. 1-1/2" block valve on top of T-2 to PV-6429 and PCV-6439 (nitrogen aake-up). 1-1/2" block valve on line to PT6482 on top of T-2. 8* block valve on vapor line out of the top of T-2 at tank. 8" isolation (air operated) valve for ship vapor return. SL PPG INDUSTRIES,INC CHEMICALS P.O. BOX 1000 LAKE CHARLES. LA. 70602 Dec. 12, 1986 Mr. Gus Von Bodungen Department of Environmental Quality Air Quality Division Office of Environmental Affairs P. 0. BOX 44096 Baton Rouge, LA 70804-4096 Dear Mr. Von Bodungen: Re: LESHAP VCM Quarterly Report In accordance with Section 77.11 of the LESHAP regulations, PPG Industries' Lake Charles Complex submits the attached quarterly report for the period September 1, 1986 through November 30, 1986. Attached as Exhibit I is a record of emissions in excess of 10 ppm (averaged on an hourly basis) in the stack gases exiting the incinerator. There were four such incidents. Attached as Exhibit II is a record of emission in excess of 10 ppm (averaged on an hourly basis) which resulted from temporary by-passes of incineration. An estimated 67 pounds of VCM were released as a result of these 12 incidents. Attached as Exhibit III is a record of sudden discharges of VCM which occurred during this reporting period. An estimated 31 lbs of VCM were released as a result of these two incidents. Written notification of these incidents was made within 7 days of their occurrence. Finally, in accordance with Section 61.65b of the NESHAP regulations, particularly subsection (8) leak detection and elimination, PPG is hereby submitting (to the DEQ and, by copy of this report, to the EPA) the results of a performance leak test on 200 randomly selected valves in vinyl service which was performed at our Tri-Ethane' ' II vinyl chloride unit on November 26, 1986. The leak check was performed in accordanc with 1*61.245(b). A listing of the valves checked is attach d as Exhibit IV. Non of the valves was found to be leaking, SL 026412 Mr. V n Bodungen 2 Dec. 12, 1986 consequently the percentage of leaking valves in this unit is demonstrated to be less than 2.0 percent. Accordingly this unit qualifies for exemption from |>61.242-1 (d), 61.242-7(a), (b) and (c), 61.246, and 61.247 of Subpart V. Based upon these results, PPG intends to continue its LESHAP approved leak detection and elimination program in its Tri-Ethane1*' II unit in lieu of Subpart V leak detection. The results of a similar test in PPG's VCM-II unit, scheduled for December, will be submitted in the next quarterly report. Respectfully, lr Attachments BAii 9/6/86 10/8/86 10/9/86 11/9/86 Stack &SU 4 81 8 2 83 81 t 82 EXHIBIT I Continuous Stack Emission Results > 10 ppm VCN September 1, 1986 November 30, 1986 Hour Ending 0800 Hourly 10.3 0900 0300 1300 11.3 13.3 S69.2 Cornwni Investigation showed no process upsets or unusual circuastances leading to the incident. The cause of excursion is not known. The incinerator stack OC's calibration was cheeked for accuracy. Mo trips or upsets occurred during this time. The VC level In stack is unexplained. No trips or upsets occurred during this tine. The VC level in stack is unexplained. Investigation showed that the 83 incinerator shut down duo to failure of the absorber bottoms pump. Par/Tri vents (non-vinyl vents) were switched from 83 incinerator to #2 Incinerator. 82 incinerator was burning natural gas at ttae of switch. The 81 incinera tor was burning VC vents. The VC level in the stack is unexplained. ST S IV 9 Z 0 'IS Pete 9/2/86 9/15/86 9/20/86 10/3/86 10/8/86 10/10/86 IO/n/86 10/17/86 Tine 4 Minutes between 1326 1 1334 1747 to 1752 0751 to 0758 1633 to 1638 0107 to 0110 1452 to 1459 1511 to 1522 0911 to 0913 EXHIBIT II Hon-Incineration of VCH Vents Sept water 1, 1986 November 30, 1986 Sources Hot Incinerated VC II VC 11, CSS VC 11, CSS VC 11, CSS VC II VC II, CSS VC II, css VC 11, CSS Estimated Quantity VCH Vented fibs) 1.7 3.1 4.4 2.1 1.0 5.8 3.9 0.7 Coaaeent VC 11 vents were tripped out of #4 Incinerator due to operator errors while switching vents to 8*1. Operator was counseled on his actions. *1 incinerator tripped due to hot VC II vents. Hot vents resulted from the venting of a ship In prepara tion for loading. #1 Incinerator tripped due to hot EDC vents. Hot vents resulted from ethylene rich vents from the EDC process of shutting down. *1 incinerator tripped due to hot vents from VC 11 while they were in the process of starting up. VC II vent was tripped out of it Incinerator In order to prevent the incinerator fron tripping off. Vents were "hot" due to the startup of the VC II EOC plant. #3 Incinerator tripped due to a failure of the steam drum level transmitter. The level transmitter was replaced. #3 Incinerator tripped due to an excessive buildup of rust in the system causing the steam drum level transmitter to fall. The problem was remedied by flushing the system several times. Vents were tripped out of #3 Incinerator due to operator error. Operator tripped the wrong switch. Operator was counseled. 1 Pit! 10/20/86 10/20/86 11/21/86 11/22/86 Time 1112 to 1116 1330 to 1334 1310 to 1314 201S to 2039 EXHIBIT II Hon-Incineration of VCH Venta September 1, 1986 - November 30, 1986 Sources Not instntrstrt VC II, CSS VC 11, css. VC 11, css VC i VC (1, css VC i Estimated Quantity VCH Vented fibs) 2.6 2.6 12.5 26.5 Cfflsasm 81 Incinerator tripped due to high natural gas pressure when hot vents caused a valve completely close. Cause of the problem was not discovered until second trip occurred. See below. 81 Incinerator tripped due to high natural gas pressure when hot vents caused a valve to completely shut off. A stop was put on the regulator to prevent the vatve from compl tety closing. 81 incinerator wee tripped due to operator error. Wrong incinerator was shut down by mistake. Operator was counseled on his action. 81 Incinerator tripped due to high temperature condition caused by burning liquids. SL 026416 2 SL 026417 Bau 10/5/86 11/14/86 T ie Duration 0800 to 0807 (7 afnutea) 0730 to 0740 (10 alnutea) exhibit in SWPEH VCM DISCHARGES Sept. 1, 1986 - Nov. 30, 1986 Eetlaated Quantity VCM ftOlOWSf UfrU Cowwent 25 A imII teak developed in the seal flush tubing on the TE II VC/KCl Still Reflux punp. (Written notification was made 10/10/86). 6 A seall hole developed in a feed line going to the VCM II 82 VC Oopp Kettle. (Written notification waa ade on 11/21/86). EXHIBIT IV The following valves were checked on 11/26/86 by J. E. Neely using HNU #1074 (last calibrated 11/24/86 . No readings in excess of 2,000 ppm were found. - r'r XEiiW PM 7. R v A i_ v c. INT VALVE TO THE VENT HEADER . -- rAii INT VALVE TO THE 'VENT j-iEADER 0 THE x-UENCH TONES D. TOM 0ALVE i VAL'.'E 'jL.h;4 B'jT 0 . M VALVE c-- iT ;*nf ;*T GLASS TOP VA L V E x v . S -0 V T rt DOFF NETTLE VAPOR RETURN VALVE .NORTH DOrF KETTLE VAPOR RETURN vAlve . S v-1 -J T H ' 5 T F AMMAN` VE AT THE 0QUENCH TOWER X 7 .NORTH ' S7F AMMAN1 VALVE AT THE GUfNCH TOWER 1 .NO.i. PASS O'UTLET PRESSURE TRANSMITTER VALVE .NO.0 PASS ET PRESSURE TRANSMITTER VALVE . .1 VAL/E TO THE ATMOSPHERIC VALVE . NO . C PASS ALVE TO THE ATMOSPHERIC VALVE I '3 .QUENCH LIO UOR REFLUX VALVE AT THE QUENCH TOWER i 9 . FL'OAT CHAM;5ER BOTTOM VALVE C0>. FLOAT CHAMBER TO? VALVE _Q 1 NO . -- -M MF UPS 7 REA m -v AL t - -- NO . 1 01 MF / A I-, v E -- - NO' * 1 D - ?F X E T T TL_ J" 7* s, 4f f'cj ET V A L V E J, -4 NO --`. MP UFST REA M ' AL VE _c NO . *- r.r ME VALV - 6 1 \'J - - DO p p KETT ! f* IN L VALVE OLE" Sri 7 ON DEN SER /CUE .* H LI OU OR TAN 7 OU EN CH CON DENS ER DR A IN TO TH 28.QUENCH CON DENSER EWALICING VALVE 29.QUENCH TOW ER VAPOR LINE EQUALISING VALVE 30.QUENCH LIQUOR TANK. x - V A V V A L V E T1 SR V ' =? 31.QUENCH LIOUOR TANK VAPOR VALVE TO' VC/HCL STILL 32.VC REWORK VALVE AT THE QUENCH LIQUOR TANK 33.FURNACE FEED VALVE AT THE QUENCH LIQUOR TANK 34.QUENCH LIQU OR TANK SUCTION' VALVE OS.NO.l OUENC LIO UOR PUMP SUCTION OS.NO.C OUENC:m LIQUOR PUMP SUCTION 3~.NC.l CUENO:h LIQUOR PUMP DISCHARGE 35.N0.C OUENC LIQUOR PUMP DISCHARGE x z> . QUENCH TOW Eft REFLUX .QUENCH T WEF7 REFLUX . .WENCH T OW irs x 7 x :v UPSTREAM VALVE IV by-pass valve IV ,F-10x, WENCH tr, ?EFLU> .QUENCH T y*i CD D DDT ! ;- IV DOWNSTREAM VALVE IV DR A Iri VALVE . O'JEN CH LIO XlJi' RUM UPSTREAM VALVE .QUENCH LIQ :0'R DRUM LCV 5Y-PASS VAiLVE SL 026418 'WENCH Li'q -iOR DRUM l:v hi it! QUENCH LIQUOR I RUM LCV DOWNSTREAM VALVE QUENCH LIQUOR DRUM LCV 'DRAIN VALVE -4 . NO , 1 QUEN1. :h LIQUOR PUMP DRAIN 1 .* . 1 i ' . _ OUEN :h LIQUOR PUMP DRAIN " I . 1 4 - , 1 QUEN' :h liquor PUMP DISCHARGE ELEED 5 2 * N 0 . _ QUEiV ,`H LIQUQR PUMP DISCHARGE BLEED 3 3 . O'JEN CH LI*' CJOR PUMP DISCH ARGE PRESSURE INDI .0 _ QUENCH LIQUOR PUMP DISCHARGE PRESSURE INDIJATCr V A L '< BLEED quench liQuor sample point vhlq'E) ndh LIO -n 'ANK LEVEL TrANSMITlEP EOT' . rt _ - USN-CH LIQUOR TANK LEVEL TRANSMITTER TCP VALVE QUENCH UCR TANK TRANSMITTER BOTTOM BLEED QUENCH LI DCS TANK TRANSMITTER TOP BLEED- VrtLVE Ov QUENCH LID PJC-R TANK rPARr, LEVEL TRANSMITTER BOTTOM VALVE QUENCH l r; UOR TANK SPARE LEVEL TRANSMITTER TOP VALVE 'jUENCK LI1. UOR TANK SPARE LEVEL TRANSMITTER bottom' ELEED V ALV QUENCH LID UOR TANK SPARE LEVEL TRANSMITTER TO? BLEED VALV :/HDL STILL: . 7C/HCL L-L LIQUID FEED 30TTIM > . VC/HCL STI LL LIQUID FEEEEDL MIDDLE VALVE .VC / HCL STI LL LIQUID FEE TOP VAL'Vs . VC,- HCL STI LL VAPOR FEED OTT DM VALVE . VC/HCL STI LL VAPOR FEED MIDDLE VALVE .VC/HCL STI LL VAPOR FEED TOP VALV'i . VC ' HCL STI LL REFLUX INLET VALVE i "'l . VC/HCL STT LL 3-WAV VALVE Sr.7 ' s | 72 . VC/HCL STI LL 3-WAV VALVE SRV'3 SyUTH BLEED VALVE 73 .VC/HCL STI LL 3-WAV VALVE SPV1 3 NyRTH BLEED .Hi. v ; 74 VC/HCL STI LL LEVEL TRANSMITTER BOTTOM VALVE 75 , VC/HCL STI LL LEVEL TRANSMITTER TOP VALVE 76 . VC/HCL STI LL LEVEL TRANSMITTER BllEED VALVE ' 77 VC/HCL STI LL SPARE LEVEL TRANSMITTER BOTTOM VALVE og VC/HCL STI LL SPARE LEVEL TRANSMITTER TO? VALVE 7 9 VC/HCL STI LL SPARE LEVEL TRANSMITTER ELEED VALVE S| VC 'HCL STI LL REBOILER OVERFLOW V/jiLVE 31 VC, HTL STI LL REBOILER UNDERFLOW 'j'ALVE --1 / VC/HCL STI LL REFLUX DRUM LCV BV-^ASS VALVE M 1 VC/HCL LL REFLUX DRUM LDV UPSTREAM VALVE 34 v'C / HCL ST I LL REFLUX DRUM LCV UPSTREAM BLEED VALVE LL REFLUX DRUM L L-IE-" NIL -- njr,* 3 3 VC/HCL 9 i VC HCL ST LL 3TI ,, L STI --> Imt 37I -L REFLUX REFLUX REFLUX REFLUX DRUM D RUM DRUM DRUM LDV LOWfi'STREAM VALVE W.NST REAM BLEED VAq * r- SPARE :-- --4U'r UPSTREAM VALUE SPARE LCV BV-PASS VALVE n. VC/HCL STI -L REFLUX DRUM SPARE LCV bleed value 02 61.19 SL 026420 91 VC/HCL STILL . Yiu a. 29 VC/HCL STILL EEFLl / -1_ ia i j. P PCI ' LI DU ID V Liim' j 6 - " \ ur. i a ._afL_ ;; m INLET VjVL . nu:'! T- - * 7 . t ^ S- IS ,,nARGE v'AL t a a VC,HCL LL REFLUX D' R U X I - X A V ' _ # a r ^ r o r. rl'Z VC/HC L ST I LL REFLUX DRUM 3-WA YjhLVE N--'R i H VC/HCL STJ LL F.EFLV: DRUM _-WAYY VALVEUS-U TH LIQUID VC IME SRV DISCHARGE DRUM 4'-} VC/HCL LL REFLUX CRUM LEVEL : HANSMITTER TCP . VC - HCL ST1 ILL REFLUX DRUM LEVEL XRANSMITTER ?'. VA f '.'E- AATT HE TANK. I 01.LIQUID Vv iLr..J . THa LaVEL " j\ANSMI TTER 102.VC/HCL STILL PT7C-T "Y DRUM LEVEL TRANSMITTER B0 TTOM ELEED VALVE 103.VC/HCL STILL REFLUX DRUM LEVEL TRANSMITTER TO ? BLEED VALVE 10*.VC/HCL STILL REFLUX DRUM SPARE VSVEL TRANSMIT TER BOTTOM VALVE 105.VC/HCL STILL REFLUX DRUM SPARE T-EVEL TRANSMIT TER TOP VALVE 106. VC/HCL SlIlLL REFLUX DRUM SPARE LEVEL TRANSMIT TER EOTTOM BLEED VALVE 1 07 VC /HCL w* a ILL RE FLU;< DRUM 5 :op BLEE D VAL V r LEVEL TRANSMIT 1 06 VC /HC*L ST ILL REFLV;< DRUM S 1 ** ?* VC /HC'L ST ILL RarLUI0 DRUM /AL 7E AT * HE RANSM r ,;N VALVE fpANSMITTER PC T. 'M 1 t i. 11 1 12 1 13 1 1a NO . 1 VC /H DL R a FLUX NO . 2 /H CL o EFLUX NO- . 1 VC /H DL R EFLUX NO 9 VC /H CL EFLUX VC /HC L RE FLUX PUMP PUMP S u PUMP S u ptJJrfC V PUMP S u SUCTIO N v A aa VALVa DRAIN VALVi DRAIN VAL7: a VALVE 1 15 NO . 1 VC/H CL R EFLUX PUMP D I a VALVE 1 16 NO .2 VC/H DL R EFLUX PUMP DDIISCHARGE VALVE 1 17 NO . 1 VC/H DL R EFLUX PUMP C I 1 18 NO .2 VC/H DL R EFLUX PUMP D I BLEED VA a v : ELEED V A UV! 119.VC/HCL REPLUX PUMP DISCHARGE SAMPLE VALVE 120.VC REWORK LINE VALVE AT THE PUMFj'S 121 .LIQUID VC TO VC I I r a v a PS I REAM 7 1 n n LIQUID VC TO VC I 7 FC V EY-PASS VA 1 23 LIQUID VC TO VC I r* V UPSTREAM V vLVE BLEED LIQUID VC TO VC I I FC V . F - 141 X " c LIQUID VC TO VC I I FC V DwWNSTREAM valve bleei 1 26 LIQUID VC TO VC I T1 FC V DOWNSTREAM l 27 LIQUID VC TO VC I T R V BL'j'.K vAlv' 1 28 VC/HCL REl 'LUX FC V Ur STREAM VALVE 1 29 VC/HCL 'LUX FC V 5L a ED VALVE I J- 'J VC/HC L RE LUX FC V ' F -1^6 1 31 VC/HCL RE 'LUX FC V 0^ aiiair.EAM v A a 1 J, VC/HCL RES 'LUX SA FE TV DRYER BY-PA VC/HCL 3 2 LUX SA FE TV DRYER INLET 1 ^ * VC/HCL REl LUX SA FE TV DRYER INLET r i a a a a '.hi. v a t 1 ^ c VC/HCL RE;flux SAFETY DRYER V .-\L,'V!L 136, VC/HCL F.E FLUX SAFETY CRYER - ~7 X w> ' VC/HCL P.E FLUX FCV BY-PASS I BLEED 1 .-1 l, v E 1 33 , V C / H 3 L RE FLUX SAFETY DRYER CUTLET BLEED VALVE 1 -.9 VC/HCL RE rLUX SAFETY CRYER PI VALVE 1-0.VC/HCL F:E F1 UX SAFE TY DRYER OUTLET VALVE 1^1.VC/HCL NO . 1 FILTER INLET VALVE 142.VC/HCL NO . 1 FILTER TOP BLEED VALVE i-3.VC/HCL *iNr'._"-* . 1 FILTER ri BLimD v.4_/yE 1 i+4 . VC/HCL NO . 1 FILTER rl VALVE 145.VC/HCL NO . 1 FILTER OUTLET VALVE 1-6.VC/HCL NO . j. FILTER INLET VALVE i^+ 7 . VC/ HCL NO . FILTER T 0 P BLEED VA4VE _L ^ 6 . y v / Hv Li NO . jL FILTER PI BLEED 'vALV'E 1-9.VC/HCL NO FILTER PI VALVE 1 SO.VC/HCL NO . j. FILTER CUTLET VALVE j 151.VC/HCL FI LT ER3 INL ET BLEED VALVE 152.VC/HCL NO 1 FILTER OUTLET BLEED VALVE 153.VC/HCL NO . -1 FILTER OUTLET BLEED i VALVE VC/HCL ST ILL PCV UPSTREAM VALVE 155 . VC/HCL ST ILL PCV BLEED VALVE 156 VC/HCL ST ILL FCV (P-156; 157 VC/HCL ST ILL PCV DOWNSTREAM VALVE 153 VC/HCL ST ILL PCV (HIC; UPSTREAMjVALVE 159 VC/HCL ST ILL PCV (HIC; 3LEED VAlivE 160 VC/HCL ST LL PCV (H-15-; 161.VC/HCL ST iLL PCV (HIC) DOWNSTREAM VALVE :E REACTOR: Sh 026421 162.DCE REACTOR FEED MAIN VALVE ! 163.DOE REACTOR FEED SE SPARGER FEED* VALVE 164.DCE REACTOR FEED 3W SPARGER FEE!) VALVE lfrS.DCE REACTOR PEED NE SPARGER FEED VALVE 166.DCE REACTOR FEED NW SPARGER FEED VALVE 167.NO.1 DCE REACTOR RECIRCULATION PUMP SUCTION VALV 168.NO.1 DCE REACTOR RECIRCULATION rfUMP SUCTION VALV (AIR OPERATED: 169.N0.1 DCE REACTOR RECIRCULATION rjvMP SUCTION BLEE VALVE 170.no.1 dce Reactor RECIRCULATION RUMP DISCHARGE BL VALVE ( 1/21*) 171.N0.1 DCE REACTOR RECIRCULATION PUMP DISCHARGE .A OPERATED) 172 .NO. 1 DCE .RECIRCULATION FjUMP DISCHARGE BL VALVE (1" 5 173 NO. 1 DCE REACTOR RECIRCULATION PUMP DISCHARGE 1^4 . NO . 2 DCE RECIRCULATION PUMP SUCTION VALV -i. / D . N 2.2 iO-w & RECIEMULATION PUMP SUCTION VALV (AIR 2PEP.A ED; 176 . NO. 2 DCE VALVE RECIRCULATION FjUMP SUCTION BLEEl I i~7.no.2 dce Reactor RECIRCULATION PUMP DISCHARGE BL; VALVE jttj l i j ; ! j ! t 4 I I I U ill 178.NO.2 DCE REACTOR 5T "TP- - VLAT ior/ PUMP DIOCHARGE .AIR OFERA7ED) 179.:JO. 2 DCE REACTOR RECIRC ,'LATION PUMP DISCHA.RGE 180.NO.3 DCE 2 1 ^ , f*1 RE ""IR C Jlaticn p'JMP 5UO'71 ON VALVE 181.NO.3 DCE REACTOR RED IRC jLATICN PUMP SUCTION 7AL JE '..AIR OPERi \TED 182.NO.3 DCE REACTOR EEC IRC OVATION PUMP SUCTION BLEED VnLVE 183.NO.3 DCE REACTOR REC IRC JL A TION RUMP CISCHARIE BOLE VALVE 18-+. NO. 3 DCE R E AO TO'R RECIRC ,'LAT 10 .N IrUMr DISCHARGE -AIR OPERATED) 185.NO.3 DCE REACTOR RE CIRC _ L A T1 N PUMP DISCHARGE 130.NO.2 DOE REACT OR COOLER INLET /Klve 137.NO.2 DCE REA J TOR COOLER OUTLET BLEED VALVE 188.NO.2 DCE REACTOR COOLER OUTLET VALVE 189.NO.2 DCE REACTjR COOLER OUTLET fI VALVE 190.NO . 1 DCE REACTOR 'COOLER INLET VALVE 191.N0.1 DCE REACTOR CO'OLER OUTLET BLEED VALVE' 192.H0.1 DCE REACTOR COOLER OUTLET Valve 193.NO.1 DCE REACT OR COOLER OUTLET PI VALVE l FRIMARY) 19-+ . NO . 1 DCE REACTOR COOLER OUTLET FI VALVE (SECONDARY HCL STILL SAN PLE POINT VALVES: 195.VC/HCL 198.VC/HCL 19".VC/HCL 198.VC/HCL 199.VC/HCL 200.VC/HCL ST ILL ST ILL ST ILL ST ILL ST ILL ST ILL SAMPLE SAMPLE SAMPLE SAMPLE SAMPLE SAMPLE POINT-TRAY POINT-TRAY PO'INT-TRAY POINT-TRAY PCI N'T-TRAY POINT-TRAY #7 if8 #12#22 #27 #31 SL 026422