Document EgRb4MLmwGZL70Xb6xRy63QN
Equipment Involve In November 20. 1987 VCL Release
1. Waste Water Stripping Column
Rupture Disc
- Size - 2 inch - Rupture Disc Relieving Pressure - 90 psig at 72F - Type - BV - Date Last Replaced - 8/10/87
Relief Valya
- Size - 2 x 3 - Type - Farris - Relief Valve Relieving Pressure - 75 psig - Date last checked and cleaned 8/11/87; 11/23/87 Arrangement: Dual assembly single disc gaydos R/V
2. Waste Water Holding Tank
Rupture Disc
- Size - 4 inch - Rupture Disc Relieving Pressure - Type - Carbon Disc - Date Last Replaced - No Record Arrangement: Dual Assembly Single Disc
100
psig at 72F
3. APRS "Burp" I(Tank
- Size - 4 inch - Rupture Disc Relieving Pressure - 105 psig at 72F - Type - BV - Date last replaced - West 9/1/85
East 10/21/86*
* Note - One side is only in service at a time. When the west is blown or a malfunction fouixi in R/D tlien the east is put in service.
Relief Valve
- Size - 4 x 6 - Type - Farris - Relief Valve Relieving Pressure - 120 psig - Date Last Checked and Cleaned 5/29/37 Arrangement: Dual Assembly Single Disc Gaydos R/V
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3 2Q. 19B7_WH5C. WWHT. AND BURP TANK
CORRECTIVE ACTION
STATUS.
1. The incident will be reviewed with all operational personnel in the Polymerization Area, and all emergency steps involving cooling water failure will be reviewed.
Complete
*2. Install a pressure switch to actuate closed all burp valves at Burp Tank pressure of 90 psig or in an event of a power outage.
Complete
3. The steam supply to the wastewater stripping column will be reviewed and modified to provide an automatic shutoff when a high pressure condition is determined in the stripper.
Complete
4. A review of the feed system to the waste water stripper and hold tank is to be done. The modification recommended from this review will be Implemented to prevent over pressuring the system.
Complete
5. The cooling water supply system will be reviewed and modifications will be made to ensure that the back-up cooling water supply can be actuated.
Complete
*6. Change present burp tank R/D to 120 psig/90%/120F
Complete
*7. A pressure switch will be installed on the two way burp tank valve (drain/recirculation) which will fail to recirculation side based on hold tank pressure of 13 psig.
Complete
Denotes corrective actions not reported to agency in ten day report.
NCC 01639
r u p t u r f d is c s PURP TANK BOTTOMS PUMP
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'.{uS TO &PA-&-0
INTER-ORGANIZATION CORRESPONDENCE
ro R. J.
FROM
K.J.
SUBJECT
Grahek Willings
Ftar> POINT OR DEPT, ft SLOG. NO FIELD POINT OR DEPT ft SLOG. NO.
DATE YOUR UTTER
DATE THIS LETTS?
4/3/87
SUPERFUND RELEASE REPOSTING
s s
All Superfund Reportable Releases are to be reported Immediately to the local emergency planning coordinator (Henry Fire Department and Marshall County ESDA). This will be followed up by a written report.
This is a change from past reporting requirements in that the calls are to be made immediately to the outside agency's with the best information available. The following points are to be covered during tl initial call.
1. Identify the Chemical (Use the Attached List)
2. An estimated quantity released
3. Time and duration (estimated) of release
4. Release went to the ground, air, or the river
5. Any known or anticipated acute or chronic health risks associate with the emergency
6. Proper precautions (example'. evacuation)
7. Name and telephone of contact at plant to be called.
To help us in reporting, I have attached a list of reportable chemicals, the quantities that when released trigger reporting and a forr for reporting.
rdra/S 118
Ken Willings
\GC 01645
FUOT PERSONNEL NUMBERS (HOME NUMBERS)
KEN "HILLINGS
(309) 274-4483
mike coyer
009) 364-3537
DIANA FRIESZ
(309) 246-2148
BOB AHEK
(309) 364-3433
ROB CALEER
(309) 364-3307
YOUR NAtS:
Mua
^ GO.
LOCATION OF PLANT:
J y 4LH*
-JL t-c.
CHEMICAL RELEASED: tJlO
Puc at..ol4y
ESTIMATED QUANTITY RELEASED:
S'L? O <1
TIME AND DURATION: Date
C?
TIjib
n o . o &
Hou Long "2. rm w .
"3 14
(LOiOTAtWiiJA
0
LOCATION OF RELEASE
VENTED AIR
HENRY, IL
SPILLED ON GROUND
MARSHALL COUNTY
ON WAY TO RIVER
AREA OF PLANT
73
(EXAMPLE:
lAL fOD S
NORTHEAST OF PLANT SITE)
-to
k
ANY KNOW OR ANTICIPATED
HEALTH EFFECTS:
(GET THE ISES DATA)
PRECAUTIONS--
(USE THE MSES DATA)
ANY INJURIES BEYOND FIRST AID tJ o b
PLANT CONTACT
NAME
PHONE NUMBER JjOcf - 3 C~4
_________ (YOUR NAME)
5 f Z. (YOUR PHONE NUMBER)
(TELL THEM HOW DONG YOU WILL BE THERE AND TO CONTACT KEN HILLINGS AFTER THAT TIME)
CALL THE FOLLOWING OUTSIDE PERSONNEL TO REPORT THE INCIDENT: '3Co 4' 36^
1. HENRY FIRE DEPARTMENT - 364-2341
TIME CALLED ALlI^TALKED TO
^4^
2. ILLINOIS ESDA - (800) 782-7860
TIME CALLED
pA- ~ QlC<C- Pot TALKED TO f(\(kX 'fefevj
Me /VlATiHesotM
3. NATIONAL RESPONSE NUMBER (600) 424-8802 TIME CALLED <L2 TALKED TO
W.R. GBACE MR. BILL STAEEL MR. BILL MILLER
(309) 364-2361 (309 ) 364-2274 (309) 364-3265
NGC016J6
MY NAME IS TITLE)
Mi
s
V V
AT THE BFGOODRICH COMPANY,
tiT AM THE
^, A4
(JOB
HENRY, ILLINOIS PLANT AN
I AM REPORTING A RELEASE OF A REPORTABLE QUANTITY OF A HAZARDOUS MATERIAL.
NGC 01647
The BFGoodrich Company
Chemical Group
MANUFACTURING PROCEDURE
PROCESS STEP Pearl Charge Procedure (Troubleshooting Guide)
PRODUCT(S)
PtANT Henry, Illinois
DEPr NAgfS8
PROCEDURE NO. PCH 12
Section 25-0
OATE 07/10/87
REFERENCE NO. PCH-11
TOOUBLESHOOTING GUIDE
____Ol
WP
In any process a nunber of abnormalities can occur which require immediate action to prevent the situation from becoming more serious. Because of the seriousness of venting Vinyl Chloride to the atmosphere, every precaution must be taken to prevent a release - If a problem in a reactor occurs which is unfamiliar and there is a question about the proper procedure, the charge should be shortstopped and contained in the poly until a Tech Man can be consulted. Since the Blowdown Tank is rated at a lower pressure and has no cooling capacity, an abnormal charge should be contained in the poly until it is under control. Also during normal operation a charge should not be dropped to a Blowdown Tank unless the recovery system is operating properly.
The following procedure outlines the proper steps to control a temperature or pressure rise situation:
A. TEMPERATURE RISK
1. Anytime a temperature rise occurs it should be confirmed
that the poly is receiving full cooling water flow to the
jacket.
If it is not, this should be corrected
immediately.
2. Anytime the poly temperature increases 3F. above the reaction temperature before the last hour of the reaction, the Foreman is to be notified.
3. For reactions which are run to a pressure drop, the temperature may be allowed to rise as long as the pressure is holding steady or dropping.
;VC 01648
The BFGoodrich Company
Chemical Group MANUFACTURING PROCEDURE
PfK>CeSf4aPl Charge Procedure (Troubleshooting Guide)
f*eooocT(s
PROCEDURE NO. PCH 12
Section 25-0
PCANT Henry, Illinois
DATE 07/10/87
DEPT. NAMBNO. 5536
REFERENCE NO. PCH-11
p*g* 2
. o<__
WP Fo
4 4. With the exception of Polys 1 & 2t a charge reaching a
10 F. tailpeak in the last hour is to be dropped and
recovered early.
Charges in Polys 1 k 2, with a 10*F.
tailpeak, must be shortstopped with BPA if the pressure i3
rising with the temperature.
Before dropping a charge
early, the Downstairs Recovery Operator must be contacted
to insure that the Blowdown Tank: is empty.
5. Before the last hour of the reaction a small temperature
rise may be controlled by opening the quick fill valve full
open.
If this is done, constant attention must be
maintained at the poly to prevent the charge from going
hydroful.
6. When the temperature alarm sounds or the temperature rises 10 F. before the last hour of the reaction, the charge should be immediately shortstopped with BPA. If the charge is "killed" the temperature will drop and then the jacket temperature will rise. The charge should not be dropped to the Blowdown Tank until the jacket temperature starts to rise.
7. If the pressure and temperature continues to rise, the charge should be shortstopped with N.O. at 155 psi or at the pressure alarm point. Anytime the pressure alarm is in the abnormal position, the charge must be under constant supervision.
8. If the shortstopping fails to control a charge, it may be set up to equalise to another poly which is on vacuum or is waiting to be charged.
9. As a last resort, a portion of the charge may be dropped to
a Blowdown Tank.
If this is done the pressure on the
Blowdown Tank must be monitored to prevent overpressuring
the tank.
10. Anytime a temperature rise occurs the Super Baffle filters must be checked for a restriction.
NGC 01649
The BFGoodrich Company
Chemical Group
MANUFACTURING PROCEDURE
PROCESSwSTEsP * Charge Procedure (Troubleshooting Guide)
psooucrp)
r_-------------------------------------------Henry, Illinois
PROCEDURE MO. PCH 12
Section 25-0
DATE 07/10/87
REFERENCE NO. PCH-11
2_____oi _3
WP Fo*
11. Any X500 charge that ia shortstopped with BPA or Nitric Oxide oust be put to the 1C Blend Tank.
B. FRESSURK RISE
1. A pressure rise may be caused by an agitator failure. This
should be the first thing checked when a pressure rise
occurs.
If the agitator cannot be restarted, the
controller should be turned to full oooling and the charge
shortstopped through the agitator seal with Nitric Oxide.
2. If a poly goes hydroful during heatup or the first hour of reaction, vent the poly momentarily to the recovery system and shut off the steam sparge. The poly should then be bombed with BPA and handled as a discharge. When adding the BPA, monitor the pressure closely to insure the poly doesn't go hydroful again.
3. If there is a pressure rise between the 2nd and 4th hour
not accompanied by a temperature rise, shut off the quick
fill, reduce water flow to the agitator seal to 0.3 gpm,
and vent momentarily to the recovery system.
If the
pressure continues to rise, shortstop the charge and. handle
as a coarse charge.
<
REASON FOR ISSUE
New Procedure
A ManufacturtnoVPfodycUon Marvagaf
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NGC 01650
! ORIGINATED 0Y
| Procedure Review Team
0ATE 07/10/87
mmAlx?
>7
i
_1
} QWEE COOLING WATER VMLVfc UPLRA I'I ON
Iwa valve actuators have been installed on the 24" and c2" gate vajve located in the pit outside Building 731 off j.ce. These actuators will be used to open and close the valves during normal and emergency operations. These actuators are driven by electric motors and the switches -for operation are located on a post just West of the pit. These acutators will shut off automatically in the full open and full closed position, this is done by counting the number of revolutions of the valve shaft and as a safety feature the valve will stop when a sufficient amount of torque is seen by the motor.
The actuators will open or close the valves in 3--4 minutes and it takes 177 revolutions of the valves stem to go from full open to full close Dr vise versa. Due to the location of the valves it is some what difficult to view the rotation of the valve stem. If entry to the cooling water valve pit is needed and entry permit will have to be issued. DO. NOT. ENTER PI.T WITHOUT AN ENTRY PERMIT*..
Due to the size of these valves there will be a tremendous amount of force on one side of the gate if you do not have equal pressure on both the tower and chilled water systems. In order to have the valves work, these pressures should be near equal, so the valves will work easily.
The following is a step by step procedure to follow when switching cooling and chilled water valves.
1. Determine the need, do not delay. 2. Have a entry permit issued as soon as you see the need, you will probably need to enter the pit. Set up communication with the upstairs control room to monitor system pressure. 3. lf_ one system is. down and one is running you will have to equalize the pressure on both sides of the valve do this by shutting down the system that, is running. 4. One man should enter the pit now with one man outside to operate the switches. 5. Activate the switches located beJow the open and close buttons, push buttons to open or close valves, valve indicator 1iqhts are RED UPEN, GREEN CLOSED, and both lights when valve is in travel. 6. Check, with man in pit to see j+ valve stems are rotating. 7. If valve stem s are not rotating shut of f_ switches and have the man in the pit operate the valves manually just enough to get the gate off the seats. Once this is done activate the switches again and push open or close b ut tons. B. WhiJe these valves are actuating, open or close the manual valves on the chilled water system which have hand wheel Located on too of the cooling water pit
cover. Monitor building cooling water- pressure.
''GC 01651
9. After 3-4 minutes the actuators will shut off, the
valves will be -fully open or fully closed, a light is
located near the switch, RED is open GREEN is. c 1 osed.
10. Once the valves are open the cooling pumps can be
started, if they were shut down at any time during the
switch. Once per week pen. shift} these valves should be
tjssted, this, will give everyone, a chance to operate the
valves and uncover possi bl e probl ems whi ch may ar i se.
-from the. values. To do the test si mpl y open the valve
unti1 it is off the seats and then close aqain. The electrical breakers are located in the Poly Building MCC
and these breakers are powered by the Poly Building
emergency generator during a power failure. If you have
a problem with the valve actuators you will need to
notify either an electrician or general maintenance for
repairs and adjustments. FyEN_EN_BER A VESSEL. ENTRY WILL
BE NEED DURING PI T ENTRY BY ANY PERSONNEL."
.........................
NGC 01652
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COOLING WATER PIT VALVE PROCEDURE SWI TCHING VALVES: SWITCHING FROM CHILLED WAT ER IU T UWER waIRK
1. I URN ON POWER SUPPLY SWITCHES LULA IhD BELOW OPEN AND
CLOSE BUTTONS GREEN L i GH I SHOULD BE LI I 2. PUSH OPEN BUI TUN UN bUlH VALVES BOTH RED AND GREEN
LIGHIS SHOULD BE Li I 3. CHECH. OPERA 1 I UN OR VALVES IF ENTRY IQ PIT IS NEEDED
A VESSEL ENTRY PERM I I IS REQUIRED 4. IF THE VALVES ARE NUT ACTUATING 1 HE VALVES WILL NEED
1U BE OPENED ENOUGH MANUALLY SO THE ACTUATOR CAN OPERATE I HIS CAN BE DUNE BY USING THE HAND WHEEL.S 5. WHEN TOWER VALVES ARE OPEN RED LIGHT LIT SHUT OFF POWER SWITCHES 6. SHUT DOWN CHILLER UNITS /. CLUSE CHILLER VALVES A I Pi I 0. SHUT DOWN ONE '.l) LHC l F K SERVILE PUMP 9. LHbLT OPERA I ION UT I UWER PUMPS ANw r> I HR I NT iu-'- V HUMPS
NCC 01654
i BFGoodrich
Goon Vinyl Otvltlon Specialty Polymer* 6 Ctwnlc*l* OM*kx\
R.R 1. Box 15 Henry, IMInoU 61537 309*364-2311
IU Gfthtk punt Maneger
December 21, 1987
*
Illinois Environmental Protection Division of Air Pollution Control 5415 North University Peoria, IL 61614
Agency
Attention: Mr. Richard Jennings, Regional Manager
SUBJECT:
EMERGENCY RELIEF VALVE/RUPTURE DISC DISCHARGE REPORT
Dear Mr. Jennings:
In accordance with the requirements for 40 CFR 61.65 (a) the National Emission Standard for Vinyl Chloride, the BFGoodrich Company is reporting an emergency relief valve/rupture disc discharge at its Henry, Illinois facility.
of
Should you have any questions concerning this report, please contact Mr. Kenneth J. Willings, of my staff, at (309)364-2311, extension 214.
Sincerely,
THE BFGOODRICH COMPANY Geon Vinyl Division
ENV1:sfm cc: Chris Roraaine
Robert J. Grahek, Plant Manager
NGC 0165?
THE BFGOODRICH COMPANY HENRY. ILLINOIS
VINYL CHLORIDE RELEASE REPORT t40 CFR 61.65 fa) 1
Type of Release: Day/Time >f Relea^ e:
Quantity of Vinyl Chlorine Re! -tas-'d; Source /Na tare:
Rupture Di^c/Relief Valves
Tuesday. December 15. 1987; !)74S - :*755 ho`rs
25,4+C i bs . (Se- attached ca 1 cula Li<.ns )
Emergency relief pressure in Poiymerizer No. 3 L. i vifrri?:er N`> 4 f . yiv-r i :e.`` ^ 15 Ct- ii'piJtg .-nui No. I -ipping ' I'lttn No. L . and tiowdown Tank No. 10 M-nually Vanning.
NCC 01656
Emergency Discharge Chronology of Events:
1) On Tuesday, December 15, 1987 at approximately 06:50 hours, power provided to the plant from CILCO, the local Dtility Company, failed during snow/ice storm. This failure also resulted in steam and cooling water loss.
2) BFGoodrich personnel preparing for shift change were held over. This enabled the Polymerization Building to have a larger than normal personnel staff to try to combat the emergency situation.
3) Immediately the plant personnel implemented the electrical power outage procedure.
4) Operating personnel immediately started to shortstop the reaction occurring in the polymerizers. Without agitation, complete mixing of the shortstop reagent with unreacted vinyl chloride monomer is ineffective. Thus, the charge will continue converging and thereby increasing pressure and temperature when no cooling water is available.
5) The emergency power generator that supplies agitation to the polymerizers, building floor lights, and building exhaust, failed to start.
6) The operating personnel used empty, available polymerizers and the available Recovery System as an attempt to lower and equalize pressures from the reacting polymerizers. *#
7) Portions of the reacting polymerizers were dropped to blow down tanks (holding tanks) to help control pressures.
8) At approximately 07:45 - 07:55 hours Poly 1*3, 4, and 16 rupture discs relieved.
9) At approximately 07:50 hours columns #1 and #2 safety relief devices relieved.
10)
To control the pressure build-up in the recovery system and to prevent the loss of entire contents of the remaining reactors, seven polymerizers were manually vented. The venting relieved pressure from the system and enhanced the chances of the shortstop to react with the vinyl chloride raonomer.
\1)
At approximately 07:50 hours blowdown tank **10 safety relief device relieved.
NGC 01657
12)
At approximately 08:40 hours the emergency generator was started, but it failed to engage in the electrical system.
13)
Power was restored to the plant at approximately 16:20 hours through one of the two supply legs. Alternative back-up power was restored to the second leg at approximately 05:00 hours on December 16, .1987.
ENV2:sf
NGC 0K)5
BFGoodrich has taken the following steps #rior to* discharge to prevent occurrences:
1) Operators and area supervisors responsible for the operation of the equipment have been trained with respect to procedural steps for controlling releases and emergency conditions.
2) Relief valves are removed and pressure checked as a part of a preventative maintenance program.
3) Rupture discs are replaced after a specific length of service to protect their integrity.
4) The emergency back-up generator which operates critical equipment (i.e., poly agitation, building floor lights, and building exhaust) is checked and started on a weekly basis, put under load on an annual basis, and is placed on an active PM program. The emergency back-up generator which operates critical equipment in the polymerization building carried the load with no malfunctions onCftoveraber 2cT, 1987^ when power was discontinued in order to make an electrical tie-in.
5) A shortstop system is in place and inspected on a routine basis for empty cylinders, plugged hoses, arid a sufficient back-up supply of shortstop reagent.
6) The plant's electrical power is provided by CILCO from two supply loops, a main leg and an alternate secondary back-up leg. Both are chocked periodically by CILCO to insure their operational quality.
Cause of Discharge?
1) The incident, upon further review, was caused by the loss of electrical power to CILCO's Marshall Substation which feeds the BFGoodrich Plant and the inability to engage the emergency back-up diesel generator which provides poly agitation.
2) It was later found, upon investigation, that the reason for the generator not to engage was a faulty battery lead caused by a loose battery clamp. A blown Field exciter fuse resulting from the effort to jump start the generator during the power failure prevented the generator from engaging after it was started.
3) The failure to deliver electrical power to the poly agitators and the loss of cooling water due to the plant power outage caused high pressure on the polymerizer as well as on the recovery system.
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\Ct"01660
BFGoodrich, will initiate the following actions to prevent recurrence:
1) BFGoodrich has taken steps to initiate a meeting with a CILCO representative to reiterate the importance of immediate notification of any power supply malfunctions.
2) A check list will be constructed and performed when testing of emergency back-up diesel generator is done on a weekly bas is.
3) Technical personnel will review and revise shutdown procedures in the recovery area of the polymerization process.
4) Battery leads on emergency back-up diesel generator will be replaced.
5) We will investigate the possibility to use a gasoline power `pony engine" as the starting supply power to emergency back up diesel generator instead of two 12-volt batteries.
6) R&D will investigate possible alternative shortstop which will perform better when no agitation conditions exists than present type available.
i
>
C 01661
Method used in determine the amount of vinyl chloride monomer released from polymerizers rupture disc assembly:
EOLY- NUMBER 3.
1) Vinyl Chloride Monomer Charged = 12,600 pounds
2) At this point in the reaction the charge had initiated to 50% conversion; therefore, 50% of the release is vinyl chloride monomer.
3) Pounds of Vinyl Chloride Monomer Released:
(12,600 lbs)(.50) = 6,300 lbs
PQLY NUMBER A
1) Vinyl Chloride Monomer charged = 12,600 pounds
2) At this point in the reaction the charge had initiated to 35% conversion; therefore, 65% of the release is vinyl chloride monomer
3) Pounds of Vinyl Chloride Monomer Released:
(12,600 lbs) (.65) = 8,190 lbs
EQLY NUMBER 16. 1) Vinyl Chloride Monomer Charged = 8,500
2) At this point in the reaction the charge had initiated to 60%
conversion; therefore, 40%*of the release is vinyl chloride
monomer
*
3) Pounds of Vinyl Chloride Monomer Released:
(8,500 lbs)(.40) = 3,400 lbs
NGC
Method .used to determine the amount of vinyl chloride released from stripping column number 1 and stripping column number 2 safety relief device:
Assumption:
1) Approximate duration of release for stripping column #1; 30 seconds
2) Approximate duration of release for stripping column #2; 1 minute
3) Vessel pressure in psig = 55 psig
4) Vapor temperature - 220 degrees F = 680 degrees R
5) Orifice area = 18.60 square inches
Equation used:
W = (C)(.851)(A)(PI)( Jd_ ) BVf ( ZTa )
Note: BVf =1.0
W = f30QU.8511 (18.60) (70W .
62.5_
) 1.0
, ( (.88) (680) )
W = 107,425 lb/hr
For a 1.5 minute release:
(107.425 lb/hr) f 1 hr W1. 5 min) = 2,686 pounds of vinyl
(60 min)
chloride
NGC 01663
Method i.or determining VC1 discharge from blowdown tank number 10 safety relief device:
Assumption:
f
1) Approximate duration of release - 1 minute
2) Vapor temperature = 180 degrees F. = 640 degrees R
3) Vessel pressure in psig = 175 psig
4) Vinyl Chloride Molecular Weight = 62.5
5) Orifice area = 2.138 square inches
Equation used:
W = (C)(.851)(A)(PI)(
) BVf where:
( ZTa )
C= A= Pl=
M= Z= Ta= B=
Vf=
W=
ASME nozzle gas constant Orifice area in square inches System pressure = gauge pressure plus
atmospheric pressure Molecular weight of vinyl chloride Compressibility factor System temperature Vapor correction factor for constant back pressure above critical pressure Vapor correction factor applies to bellow valves Vapor mass flow
Note:
For non-bellows with constant back pressure apply "B* and Vf = 1.0
W = (316) (. 851) (2. 138) (190) (
62.5 _ ) (1. 0)
( (.75 ) (640) )
W =39,418 lbs/hr
For 1.0 minutes release:
(39,418 Ibs/hr)
(1 roin) =
(60 roin)
Pounds of Vinyl Chloride released = 657 pounds