Document QMqgJoGgokjrYobxqoavJ15Q7

EPA Inspection Report - Page 1 of 128 Region 6 - Enforcement & Compliance Assurance Division INSPECTION REPORT Inspection Date(s): Media Program: Regulatory Program(s) 09/24/2024 Air SIP, Title V, NSPS, NESHAP, MACT Company Name: Facility Name: Facility Physical Location: (city, state, zip code) Mailing address: (city, state, zip code) County/Parish: Facility Phone Number Facility Contact: Vopak Industrial Infrastructure Americas St. Charles, LLC Vopak Terminal St. Charles 335 LA Hwy 3142 Hahnville, LA 70057 2000 W Loop S Ste 1040 Houston, TX 77027 St. Charles (281) 832-9274 Kelly Phillips Environmental Engineer Kelly.Phillips@vopak.com FRS Number: Identification/Permit Number: Media Identifier Number: NAICS: SIC: 110071062771 AI # 227637 / Permit: 2520-00186-V1 AFS # 2208900186 493190 - Other Warehousing and Storage 4226 - Special Warehousing and Storage, Not Elsewhere Classified Personnel participating in inspection: Sophia Ong EPA Region 6, ECADAT Constantinos Loukeris EPA Region 5, AECAB Kara Allen EPA Region 6, ECADAT Colleen McCarthy EPA Region 6, ECADAT Benjamin Rosenthal EPA Region 6, ECADAT Victoria Nelson EPA Region 5, AECAB Karina Kuc EPA Region 5, AECAB John Penland EPA Region 6, ECADWSTEB Nathan Ward LDEQ Darren Duhe Vopak Kelly Phillips Vopak Armando Evangelisa Vopak Charles Patterson Vopak Dennis Fleming Think Environmental Physical Scientist Environmental Engineer Life Scientist Life Scientist Physical Scientist Environmental Engineer Environmental Engineer Senior Environmental Scientist Environmental Scientist Safety Health Specialist Environmental Engineer Dock Technician/Operator Shift Supervisor Site Supervisor EPA Lead Inspector Signature/Date SOPHIA ONG Sophia Ong Digitally signed by SOPHIA ONG Date: 2024.12.23 14:28:12 -06'00' Date Supervisor Signature/Date JAMES LEATHERS Date: 2024.12.23 15:04:46 -06'00' Digitally signed by JAMES LEATHERS James Leathers Date 6ENFORM-019-R8.2 (02/12/2020) 1 EPA Inspection Report - Page 2 of 128 Vopak Industrial Infrastructure Americas St. Charles, LLC / Vopak Terminal St. Charles Inspection Date 09/24/2024 Section I - INTRODUCTION PURPOSE OF THE INSPECTION EPA Region 6 inspectors Sophia Ong ("I"), Colleen McCarthy, Ben Rosenthal, Kara Allen, and John Penland and EPA Region 5 inspectors Constantinos Loukeris, Victoria Nelson, and Karina Kuc ("EPA inspectors") met with Vopak Industrial Infrastructure Americas St. Charles, LLC ("Vopak" or the "Facility") at 1:30 pm on September 24, 2024, for an unannounced inspection. We were accompanied by Nathan Ward from the Louisiana Department of Environmental Quality ("LDEQ"). We met with Vopak representatives Darren Duhe, Safety Health Specialist, and Kelly Phillips, Environmental Engineer, in Union Carbide Corporation's ("Union Carbide") conference room for the opening conference. Constantinos Loukeris presented his credentials to Ms. Phillips, and we informed them that this was an EPA inspection to determine compliance with the facility's Title V Air Permit and the Clean Air Act ("CAA"). The scope of the inspection was a partial compliance evaluation ("PCE") to evaluate the facility's compliance with the facility's Title V operating permit, Louisiana State Implementation Plan ("SIP"), and applicable CAA regulations. The inspection focused primarily on the National Emissions Standard for Hazardous Air Pollutants ("NESHAP") for Benzene Waste Operations at 40 Code of Federal Regulations ("CFR") Part 61, Subpart FF ("Subpart FF" or "BWON"). Inspector Penland also presented his credentials and informed them that he would be conducting an inspection at the Facility for compliance with the Resource Conservation and Recovery Act ("RCRA") under the authority of Section 3007 of RCRA. The RCRA inspection was conducted in conjunction with the CAA inspection. This inspection focused on the generation and management of the wastewater generated by operations at the Facility. FACILITY DESCRIPTION Vopak Industrial Infrastructure Americas St. Charles, LLC owns and operates the Vopak Terminal St. Charles facility, a for-hire bulk terminal, near Hahnville, Louisiana. Vopak is collocated with Union Carbide's St. Charles Operations and supports Union Carbide's operations. Vopak stores raw material, product, and wastewater for Union Carbide. The wastewater stored at Vopak is generated by chemical manufacturing process plants, including ethylene production units, at Union Carbide. Other chemical and petroleum products are transferred in and out of terminal tankage for external customers via marine vessel, tank truck, and/or railcar. The Facility was previously owned and operated by Union Carbide. Ownership of the terminal was transferred to Vopak on December 1, 2020. On January 14, 2021, Vopak requested the transfer of CAA Title V permit 3175-V0 from Union Carbide to Vopak. On May 4, 2021, LDEQ confirmed the transfer of the permit and issued an effective date of December 1, 2020. Vopak currently operates under CAA Part 70 Operating Permit No. 2520-00186-V1 issued by LDEQ on August 31, 2022, which expired on July 18, 2024. A Title V permit modification and renewal application 2 EPA Inspection Report - Page 3 of 128 Vopak Industrial Infrastructure Americas St. Charles, LLC / Vopak Terminal St. Charles Inspection Date 09/24/2024 was submitted to LDEQ via email on January 18, 2024. A copy of Operating Permit No. 2520-00186-V1 and a copy of the January 2024 renewal application are found in Appendix 2 and 3, respectively. Section II - OBSERVATIONS EPA inspectors met with Vopak representatives Mr. Duhe and Ms. Phillips in Union Carbide's conference room to discuss the scope of the inspection and planned inspection activities. We shared our intent to tour of the facility and conduct interviews with facility personnel. After the opening conference, EPA Inspectors Sophia Ong, Constantinos Loukeris, Kara Allen, and John Penland ("we") entered the Vopak facility at 1:49 pm. Mr. Duhe and Ms. Phillips accompanied us to the Facility. The other EPA inspectors, Colleen McCarthy, Ben Rosenthal, Victoria Nelson, and Karina Kuc, did not join the facility tour. Constantinos Loukeris operated a FLIR Gx620 Optical Gas Imaging ("OGI") camera to image equipment for hydrocarbon emissions while in the field. Kara Allen conducted EPA Method 21 monitoring using a Thermo Scientific Toxic Vapor Analyzer ("TVA"), Model 2020, equipped with a flame ionization detector ("FID") to detect the total volatile organic compounds ("VOCs"). OGI videos taken during the inspection are found in Appendix 1. At 2:00 pm, we arrived at Vopak's Dock 1 with Mr. Duhe and Dennis Fleming, a Leak Detection and Repair ("LDAR") technician and site supervisor with Think Environmental, Vopak's contracted LDAR company. At the dock, we met Armando Evangelisa, Dock Technician/Operator. Mr. Evangelisa explained that Vopak, at a minimum, unloads naphtha, dripolene and propylene from barges to the Facility. Vopak indicated they load approximately two barges per month of dripolene. We observed piping labeled crude butadiene, dripolene, EPD, naphtha, propylene LD, and propylene UNIC at the dock. Mr. Evangelisa provided clarification stating EPD is also known as EOB, Union Carbide's wastewater treatment plant. Dock 1 is equipped with a thermal treatment unit for loading dripolene barges. In addition, Vopak blows down the hose lines that load the barges with air into the barge itself. While at the dock, Mr. Evangelisa stated he was waiting for a barge to load crude butadiene. Inspectors monitored two sump covers, six manhole covers, valves, and connectors on the dripolene vapor line and propylene lines with the FID at Dock 1. Inspectors also observed the same equipment with the OGI camera. No detectable emissions were observed at Dock 1 with the FID or hydrocarbons imaging with the OGI camera. As we were departing from the dock at 2:34 pm, we observed a Kirby barge arriving at Dock 1. At 2:55 pm, we arrived at four external floating roof ("EFR") storage tanks (TK 1301, TK 1311, TK 1321, and TK 1331) and met Charles Patterson, Vopak Shift Supervisor. Vopak stores benzene-containing wastewater generated by the collocated Union Carbide chemical manufacturing plants into the four EFR tanks. 3 EPA Inspection Report - Page 4 of 128 Vopak Industrial Infrastructure Americas St. Charles, LLC / Vopak Terminal St. Charles Inspection Date 09/24/2024 EPA inspectors Constantinos Loukeris and John Penland observed the floating roofs of the following wastewater tanks from the platform at the top of the tanks' stairwells: TK 1301, TK 1311, TK 1321, and TK 1331. No emissions were observed with the OGI camera from TK 1301, TK 1311, and TK 1331. EPA Inspector Constantinos Loukeris observed hydrocarbon emissions with the OGI camera from the floating roof seal of wastewater tank TK 1321 (Videos 1-2). [AOC 1] EPA inspector Kara Allen conducted EPA Method 21 monitoring at the pumps and quench piping associated with the wastewater tanks. Mr. Fleming accompanied the EPA inspection team to conduct concurrent Method 21 monitoring. Mr. Fleming informed EPA inspectors that Think Environmental conducts Method 21 monitoring on an annual basis at Vopak, typically in the third quarter of the calendar year. The EPA inspection team did not observe detectable emissions at the pumps and quench lines associated with the wastewater tanks with the FID. At 3:52 pm, EPA Inspectors Constantinos Loukeris, Kara Allen, and Sophia Ong observed dripolene storage tank, TK 6200, with the OGI camera from the platform at the top of the tank's stairwell. EPA Inspector Constantinos Loukeris observed hydrocarbon emissions with the OGI camera from the seal of the floating roof on TK 6200 (Video 3). [AOC 2] Charles Patterson stated material in TK 6200 can be routed back to Union Carbide's Olefins 1 Unit. At 4:13 pm, we arrived at the naphtha storage tanks area. We observed two naphtha tanks, TK 3100 and TK 5101, and their associated pumps and piping from the ground. TK 3101 was out of service at the time of inspection. Mr. Patterson stated the naphtha tanks have been static with no movement of product for the past three years. We concluded our site tour at 4:48 pm. We returned to Union Carbide's conference room with the other EPA inspectors who did not join the Vopak facility tour. Section III - AREAS OF CONCERN EPA Inspectors Constantinos Loukeris, Colleen McCarthy, and Sophia Ong, conducted a virtual closing conference on October 25, 2024, at 9:00 am, for the inspection. Facility representatives Alex Ledet, Technical Manager; Kory Pourciau, Terminal Manager; Gerard Zeringue, Manager; and Kelly Phillips were present for the closing conference. During the closing conference, we summarized the facility tour and presented our observations, including the Areas of Concern ("AOC") 1 through 3. AOC 4 and 5 were determined after the closing conference. The facility made no claims of confidential business information regarding the videos taken on-site. The facility was informed that copies of the videos would be made available to the facility following the inspection. 1) EPA Inspectors observed hydrocarbon emissions from TK 1321 using the OGI camera. This indicates the tank may not be meeting the applicable design, operational, and maintenance standards. 4 EPA Inspection Report - Page 5 of 128 Vopak Industrial Infrastructure Americas St. Charles, LLC / Vopak Terminal St. Charles Inspection Date 09/24/2024 2) EPA Inspectors observed hydrocarbon emissions from TK 6200 using the OGI camera. This indicates the tank may not be meeting the applicable design, operational, and maintenance standards. 3) EPA Inspectors indicated that the wastewater streams that are being received by Vopak from Union Carbide may be subject to the control standards for BWON and thus Vopak may not be maintaining those streams as controlled by not complying with the BWON requirements as specified in 40 C.F.R. 61 Subpart FF. 4) Vopak may be misrepresenting the Facility's federal Clean Air Act applicability. EPA inspectors identified a letter dated June 6, 2023, sent from Vopak to LDEQ documenting the nonapplicability determination of the Facility to BWON. The letter states, "[t]he St. Charles Terminal does not contain facilities that treat, store, or dispose of benzene-containing hazardous waste from chemical manufacturing plants, coke by-product recovery plants, or petroleum refineries. As of December 1, 2020, the St. Charles Terminal was no longer an affected facility subject to BWON." Vopak does receive and store benzene-containing waste from chemical manufacturing plants. A copy of the letter can be found in Appendix 4. In a permit renewal application received by LDEQ on January 18, 2024, Vopak requests to remove applicability to 40 C.F.R. 61 Subpart FF. The application states, "The Vopak Terminal is not a chemical manufacturing plant, coke by-product recovery plant, or petroleum refinery. Additionally, it is not a hazardous waste treatment, storage, or disposal facility that treats, stores, or disposes of hazardous waste generated by a chemical manufacturing plant, coke byproduct recovery plant, or petroleum refinery." Vopak does receive and store benzenecontaining hazardous waste generated by chemical manufacturing plants. In the permit application, Vopak represents the four EFR tanks, 1301, 1311, 1321, and 1331 with potential to store wastewater or dripolene. Upon review of the emission calculations provided in the permit application, tanks 1301, 1311, 1321, and 1331 have not been identified as dedicated wastewater storage tanks. In their response to our records request, Vopak stated Subpart FF quarterly inspection records were no longer maintained since 2023 and Total Annual Benzene ("TAB") reports were not prepared since 2022, for calendar year 2021. They also stated that since the EPA inspection they have directed that such quarterly inspections and TAB reports should be resumed. The TAB report for 2021 and quarterly Subpart FF reports for 2021 submitted by Vopak include conflicting information. In the 2021 TAB report, Vopak states they are subject to the control requirements since the TAB was previously greater than 10 megagrams per year ("Mg/yr"). They indicate that they elect to follow the provisions of 40 CFR 61.342(e) also known as the "6 BQ" option. In the actual report for 2021, they claim the TAB is 0.03 Mg/yr and only identify one point of generation. The point of generation identified is labeled "Quench Oil/T68 and soil" which appears to be multiple points and may not be the location where the material exits the process. 5 EPA Inspection Report - Page 6 of 128 Vopak Industrial Infrastructure Americas St. Charles, LLC / Vopak Terminal St. Charles Inspection Date 09/24/2024 5) Vopak may be operating hazardous waste storage tanks without a permit and without meeting the permit exemption requirements for hazardous waste generators. Vopak receives wastewater from Union Carbide's St. Charles Operations Olefins units which exceeds 5.0mg/L of benzene and is a hazardous waste demonstrating the toxicity characteristic for benzene (D018). This wastewater is accumulated in tanks 1301, 1311, 1321, and 1331 before being returned to the Union Carbide for additional treatment. As tanks being used for the accumulation of hazardous waste, they would normally fall under the RCRA tank requirements for hazardous waste generators codified at 40 CFR Part 262. However, these tanks are claimed by Vopak as exempt from the RCRA generator standards under the exemption for units subject to the Clean Water Act. However, as noted in AOC 4, in their Clean Air Act permit application they can use these tanks for the storage of both wastewater and product/intermediate materials. The wastewater treatment unit exemption claimed for the four tanks requires that the tanks are dedicated to the management of wastewater. Therefore, since these tanks are not dedicated solely for the management of wastewater, they may not qualify for the wastewater treatment unit exemption from RCRA permitting. Section IV - FOLLOW UP On October 29, 2024, EPA Inspector Sophia Ong requested the following records after the closing conference from Vopak: 1. For tanks 1301, 1311, 1321, 1331, 3100, 3101, 4101, 5101, and 6200, provide the following: a. Most recent seal gap measurement inspections; b. Most recent API 653 inspections; and c. All repair and maintenance records from date of ownership to present. 2. Quarterly Visual Inspection records from date of ownership to present; 3. Annual Total Annual Benzene (TAB) reports and all supporting documents from date of ownership to present; 4. No detectable emissions testing/monitoring data as required by 40 CFR 61.356(h) from date of ownership to present; 5. Engineering Design Documentation for each waste management unit and treatment process required by 40 CFR 61.356(d); 6. BWON Manual and/or BWON training; and 7. Initial Notification and Notification of Compliance Status for Part 63 Subpart EEEE. Vopak provided records to EPA on November 15, 2024. Section V - LIST OF APPENDICES Appendix 1 - Video Log - 3 FLIR videos taken 09/24/2024 Appendix 2 - Operating Permit No. 2520-00186-V1 Appendix 3 - Title V Operating Permit Renewal Application January 2024 Appendix 4 - Vopak's Letter to LDEQ of Non-applicability of Subpart FF 6 EPA Inspection Report - Page 7 of 128 Vopak Industrial Infrastructure Americas St. Charles, LLC / Vopak Terminal St. Charles Inspection Date 09/24/2024 Appendix 1 Video Log EPA Inspection Report - Page 8 of 128 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Video Log Appendix 1 Location: Vopak Industrial Infrastructure Americas St. Charles, LLC / Vopak Terminal St. Charles City: Hahnville County: St. Charles State: Louisiana Video 1 Video File Name: Date of Video: Time of Video: Videographer: Description: FLIR00196.mp4 09/24/2024 15:28 Constantinos Loukeris Hydrocarbon emissions observed from TK 1321. Video 2 Video File Name: Date of Video: Time of Video: Videographer: Description: FLIR0197.mp4 09/24/2024 15:30 Constantinos Loukeris Hydrocarbon emissions observed from TK 1321. Video 3 Video File Name: Date of Video: Time of Video: Videographer: Description: FLIR0198.mp4 09/24/2024 16:01 Constantinos Loukeris Hydrocarbon emissions observed from TK 6200. Page 1 of 1 EPA Inspection Report - Page 9 of 128 Vopak Industrial Infrastructure Americas St. Charles, LLC / Vopak Terminal St. Charles Inspection Date 09/24/2024 Appendix 2 Operating Permit No. 2520-00186-V1 LDEQ-EDMSEPDAoIncsupmecetniotn1R3e4p5o5r2t 6- 0P,aPgeag10e 1 of o1f21805 LDEQ-EDMSEPDAoIncsupmecetniotn1R3e4p5o5r2t 6- 0P,aPgeag11e 2 of o1f21805 LDEQ-EDMSEPDAoIncsupmecetniotn1R3e4p5o5r2t 6- 0P,aPgeag12e 3 of o1f21805 LDEQ-EDMSEPDAoIncsupmecetniotn1R3e4p5o5r2t 6- 0P,aPgeag13e 4 of o1f21805 LDEQ-EDMSEPDAoIncsupmecetniotn1R3e4p5o5r2t 6- 0P,aPgeag14e 5 of o1f21805 LDEQ-EDMSEPDAoIncsupmecetniotn1R3e4p5o5r2t 6- 0P,aPgeag15e 6 of o1f21805 LDEQ-EDMSEPDAoIncsupmecetniotn1R3e4p5o5r2t 6- 0P,aPgeag16e 7 of o1f21805 LDEQ-EDMSEPDAoIncsupmecetniotn1R3e4p5o5r2t 6- 0P,aPgeag17e 8 of o1f21805 LDEQ-EDMSEPDAoIncsupmecetniotn1R3e4p5o5r2t 6- 0P,aPgeag18e 9 of o1f21805 LDEQ-EDMSEPDAoIncsupmecetniotn1R3e4p5o5r2t6-0P,aPgeag19e o1f01o2f8105 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Permit Renewal Application LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag11e61oof f132808 LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag11e72oof f132808 LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag11e83oof f132808 LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag11e94oof f132808 LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag12e05oof f132808 LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag12e16oof f132808 LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag12e27oof f132808 LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag12e38oof f132808 LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag12e49oof f132808 LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag12e51o0f o1f28308 LDEQ-EDMSEPDAoIncsupmecetniotn1R4e1p3o1r8t 2- 2P,aPgeag12e61o1f o1f28308 EPA Inspection Report - Page 127 of 128 Vopak Industrial Infrastructure Americas St. Charles, LLC / Vopak Terminal St. Charles Inspection Date 09/24/2024 Appendix 4 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