Background Material: 1999-04-20 Fugitive Emissions from ... · Source Category: Fugitive Emissions...

Fugitive Emissions from Chemical Plants Last Revision 10/1/98F-1

Fugitive Emissions from Chemical Plants

Table I (1 of 2)Identification of Performance Standards

Source Category: Fugitive Emissions from Chemical Plants


Regulated Component Pollutant

BAAQMD Regulation 8-Organic BAAQMD Regulation 8-Organic BAAQMD Regulation 8-OrganicCompounds, Rule 18-Equipment Compounds, Rule 22-Valves and Compounds, Rule 28-Pressure ReliefLeaks. 1/7/98. flanges at Chemical Plants. Valves at Petroleum Refineries and

6/1/94. Chemical Plants. 6/15/94.

Leak Definitions: Conc. of total organic Conc. of total organic Conc. of total organic compounds,compounds, including compounds, including including methane, measuredmethane, measured above methane, measured above above background, expressed asbackground, expressed as background, expressed as methane and measured 1 cm ormethane and measured 1 cm methane and measured 1 cm or less from leak source; EPA Ref.or less from leak source; EPA less from leak source; EPA Method 21 “Method 21".Ref. Method 21 “Method 21". Ref. Method 21 “Method 21".

Major Gas Leak >100 ppm (valves, > 10,000 ppm > 10,000 ppmDefinitions: connectors)

>500 ppm (pumps &compressors, pressure reliefdevices)

Minor Gas Leak Same as Major > 10,000 ppm > 10,000 ppmDefinitions:

Major Liquid Leak Dripping of total organicDefinitions: compounds (TOC) at rate > 3

drops/min. and a conc. ofTOC > applicable leakstandard (gas leak definitions)







Minor Liquid Leak Same as majorDefinitions:

A. Leak Control VOCRequirements

A1. Gas leaks allowed(<200 components): N/A N/A N/A- Valves (V)- Pumps seals (P)- Compressors seals(Cp)- Pressure Relief Valves(PRV)- Hatches- Open ended lines(OEL)- Other components







A2. Gas leaks allowed N/A N/A N/A(>200 components):- Valves (V)- Pumps seals (P)- Compressors seals(Cp)- Pressure Relief Valves(PRV)- Hatches- Open ended lines(OEL)- Other components

B. Components ID VOC Yes Yes Yes

B1. All componentsphysically identified: - not specified - not specified - not specified

B2. Components - No - No - Noidentified on flowdiagrams:







C. OperatorsInspectionRequirements

C1. Audio-visual insp. - Daily (pumps & - None - None specified.compressors). If leakobserved, determine VOCconcentration.

C2. Hydrocarbon - Quarterly (valves, pressure - Quarterly (valves) - Quarterlyanalyzer Monitoring relief devices, pumps & - None specified for flanges(Method 21) - compressors)Accessiblecomponents:

C2. Hydrocarbon - For connectors opened - None specified N/Aanalyzer Monitoring during a turnaround, inspect(Method 21) - within 90 days after start-upThreaded Connections is completed.& Flanges:







C2. Hydrocarbon - Yearly (valves, pressure - Yearly (valves only) - None specifiedanalyzer Monitoring relief devices) (Note: PRDs(Method 21) - equipped with weephole shallInaccessible be inspected quarterly atcomponents: outlet of weephole if horn

outlet is inaccessible.)

C2. Hydrocarbon - Nothing specified - Nothing specified - Nothing specifiedanalyzer Monitoring(Method 21) - Unsafeto monitorcomponents:

C2. Hydrocarbon - 5 working days - N/A - Nothing specifiedanalyzer Monitoring(Method 21) - PRVafter a pressure relief:

C2. Hydrocarbon - Annually (valves) if: - Nothing specified - Nothing specifiedanalyzer Monitoring 1) leak free for 5 consecutive(Method 21) - quarters;Monitoring frequency 2) approval from APCO.extended for goodperformance:







C3. Tag all leaks Yes - use brightly colored Yes - tag leaking valves Yes - use brightly coloreddetected. weatherproof tags showing weatherproof tags showing date of

date of leak detection. leak detection.

D. MaintenanceRequirements

D1. Non-Essential Valves, Connectors, Pumps & - repair within 15 days. - repair within 15 days.Components - Repair Compressors:Gas Leaks Within: - minimize within 24 hours.

- repair within 7 days, 24hours if discovered by APCO.

Pressure Relief Devices:- minimize within 24 hours. - repair within 15 days, 7days if discovered by APCO.







D1. Non-Essential Leaks > 75,000 ppm:Components - Repair - repair within 15 days.Gas Leaks > 50,000ppmv Within:

D1. Non-Essential - minimize within 24 hoursComponents - Repair and repair within 7 days.Major Liquid LeaksWithin:

D1. Non-Essential - minimize within 24 hoursComponents - Repair and repair within 7 days.Minor Liquid LeaksWithin:







D2. Essential - Within 24 hours. - minimize within 15 days. - minimize within 15 days andComponents - For Non-Repairable Valves: - if still exceeded 10,000 ppm, repair at next scheduledMinimized Leaks 1) repair or replace within 5 repair at next scheduled turnaround.Within: years or at next scheduled turnaround but not longer than

turnaround, whichever first. 6 months.2) number awaiting repair notto exceed: 0.5% (valves) or1% (pressure relief devices,pumps & compressors) oftotal number of non-repairable equipment allowedor 1 piece of equipment.

Alternative to 2): - measure for mass emissionswithin 7 days after leakdiscovered. Mass emissionmeasurement must be lessthan: 0.1 lb/day (valves), 0.2 lb/day (PRDs, P & C).- facility total numberawaiting repair not to exceed:1% (valves), 5% (PRDs, P &C) - If any componentmeasurement is > 15 lb/dayTOC, repair within 7 days.(Note: This implies that







anything between 15 lb/dayand the mass emissionstandards above must usemethod 2).)

D2. Chronic Leakers:

D2. OEL and V Locatedat End of Lines:

D2. Hatches:

D3. Components - Within 24 hours - Within 3 months for valves. - None specified.inspected after repair or Nothing specified for flanges.replacement withMethod 21:

D4. Operator N/A N/A N/Amanagement plan:





Rule/Measure/Date

RACT Determination of SCAQMD Rule 1173. VCAPCD Rule 74.7. Fugitive Emissions of Fugitive Emissions of Fugitive Emissions ofVOCs from Oil and Gas Volatile Organic Reactive OrganicProduction and Processing Compounds. 5/13/94. Compounds (ROC) atFacilities, Refineries, Petroleum Refineries &Chemical Plants, and Chemical Plants. Pipeline Transfer Stations. 10/10/95.12/8/93. (Similar to RACT except

as noted)

Performance Standard

Leak Definitions: Conc. of total gaseous Conc. of gaseoushydrocarbons, including volatile organicmethane, measured compound, measuredabove background, above background,expressed as methane expressed as methaneand measured at and measured 1 cm orinterface of leak source; less from leak source;EPA Reference Method EPA Reference21 “Method 21". Method 21 “Method

21".

Major Gas Leak > 10,000 ppmv >10,000 ppmv (exceptDefinitions: PRD)

Minor Gas Leak >1,000 ppmv but >1,000 ppmv butDefinitions: <10,000 ppmv <10,000 ppmv (except

PRD)

Pressure Relief Device >200 ppmGas Leak Definitions:




Rule/Measure/Date


as noted)



Major Liquid Leak visible mist or dripping of liquidDefinitions: continuous flow of volatile organic

liquid. compounds at rate ofmore than 3 drops perminute.

Minor Liquid Leak Not a major leak and dripping of liquidDefinitions: drips liquid at a rate of volatile organic

more than 3 drops per compounds at rate ofminute. more than 3 drops per

minute.




Rule/Measure/Date


as noted)



A. Leak Control VOC - Any liquid leak orRequirements gas leak > 50,000 ppm

detected by Districtinspection constitute aviolation. - Any major gas leakdetected by Districtinspection, within anycontinuous 24-hourperiod, and numberingin excess of number ofleaks allowed,constitute a violation.




Rule/Measure/Date


as noted)



A1. Gas leaks allowed(<200 components): N/A- Valves (V) 1- Pumps seals (P) 2- Compressors seals 1(Cp) 1- Pressure Relief Valves(PRV)- Hatches- Open ended lines(OEL) 1- Other components




Rule/Measure/Date


as noted)



A2. Gas leaks allowed N/A(>200 components):- Valves (V) 0.5% of # inspected.- Pumps seals (P) 1% of # inspected.- Compressors seals 1(Cp) 1- Pressure Relief Valves(PRV)- Hatches- Open ended lines(OEL) 1- Other components

B. Components ID VOC




Rule/Measure/Date


as noted)



B1. All componentsphysically identified: - major, critical - major components

B2. Components - major, critical, & - minor componentsidentified on flow inaccessible except C &diagrams: F.

C. OperatorsInspectionRequirements




Rule/Measure/Date


as noted)



C1. Audio-visual insp. - Every 8 hrs (P, Cp, - Every 8 hrs(RACT defn. of leak: PRV) (accessible P, Cp, PRVany liquid leak, a visible - Daily (P, Cp, PRV, & except for unmannedor audible leak, the PRSB at manned oil & oil & gas productionpresence of bubbles gas production fields fields and unmannedusing soap solns., or a and pipeline transfer pipeline transferleak identified by use of stations) stations)a vapor analyzer.) - Weekly (unmanned(Note: If vapor leak facilities)identified, measuredleak according toMethod 21.)




Rule/Measure/Date


as noted)



C2. Hydrocarbon - Quarterly except - Quarterly - Monthly analyzer Monitoring Threaded Connections(Method 21) - & Flanges Accessible components:

C2. Hydrocarbon - Immediately after - New, replaced oranalyzer Monitoring being installed and repaired fittings,(Method 21) - Threaded semi-annually thereafter including flanges &Connections & Flanges: threaded connections

shall be monitoredimmediately afterbeing placed intoservice or w/in 30 daysif necessary due toinstrumentationdesign.

C2. Hydrocarbon - Yearly - Yearlyanalyzer Monitoring(Method 21) -Inaccessiblecomponents:




Rule/Measure/Date


as noted)



C2. Hydrocarbon - Inspection plananalyzer Monitoring approved by EO(Method 21) - unsafe tomonitor components:

C2. Hydrocarbon - W/in 3 days - W/in 14 daysanalyzer Monitoring(Method 21) - PRVafter a pressure relief:




Rule/Measure/Date


as noted)



C2. Hydrocarbon - Yearly (all - Yearly (all - Quarterly (exceptanalyzer Monitoring components except P, components except P, flanges & threaded(Method 21) - Cp, PRV, & PRSB at Cp at facility if no connections - yearly) ifMonitoring frequency facility if no liquid leaks liquid leaks and no no major gas leak orextended for good and no major gas major gas any major liquid leakperformance: leaks > 0.5% of total leaks > 0.5% of total for 3 consecutive

components inspected components inspected monthly inspections.per inspection period per inspection periodfor 12 consecutive for 5 consecutivemonths.) (Note: Leaks quarters)from PRSBs are notincluded in total countof leaking componentsin the 0.5%determination.)




Rule/Measure/Date


as noted)



C3. Tag all leaks Yes - use brightly - None specifieddetected. colored weatherproof

tags showing date ofleak detection, tag notto be removed untilcomponent is repairedand reinspected.

D. MaintenanceRequirements

D1. Non-essential - 14 days (minor) - 14 days (minor)Components - Repair - 5 days (major) - 5 days (major)Gas Leaks within:




Rule/Measure/Date


as noted)



D1. Non-essential - 1 day** (onshore) - 1 dayComponents - Repair - 2 days (o/g productionGas Leaks > 50,000 or pipeline transferppmv within: stations)

- 5 days (offshore)

(**Note: unlessprohibited by CalOSHA standards or 29CFR 1910)




Rule/Measure/Date


as noted)



D1. Non-essential - 1 day** (onshore) - 1 dayComponents - Repair - 2 days (o/g productionMajor Liquid Leaks or pipeline transferWithin: stations)

- 5 days (offshore)

(**Note: unlessprohibited by CalOSHA standards or 29CFR 1910)

D1. Non-essential - 2 days** (onshore) - 1 dayComponents - Repair - 5 days (offshore)Minor Liquid LeaksWithin: (**Note: unless

prohibited by CalOSHA standards or 29CFR 1910)




Rule/Measure/Date


as noted)



D2. Essential - Immediately - not specifiedComponents -Minimized Leaks - Critical & unsafe towithin: monitor components:

minimized immediatelyand replaced w/ BACTduring shutdown orw/in 12 months,whichever occurs first.




Rule/Measure/Date


as noted)



D2. Chronic Leakers: - Components with 5 - Components with 5repair actions for major repair actions for agas or liquid leak within liquid leak or a major12 months: replaced gas leak within awith BACT. continuous 12 months

period: replaced withBACT or BART, orvent to an approvableair pollution controldevice.




Rule/Measure/Date


as noted)



D2. OEL and V - Sealed with a blindLocated at End of flange, plug, cap, or aLines: second closed valve

except duringoperations.(Note: Operationsinclude draining ordegassing operations,connection of temporaryprocess equipment,sampling of processstreams, emergencyventing, and othernormal operationalneeds.)




Rule/Measure/Date


as noted)



D2. Hatches: - Keep closed exceptduring sampling,adding process matl., orattended maintenanceoperations.

D3. Components - Within 30 days - Within 30 daysinspected after repair orreplacement withMethod 21:

D4. Operator N/A N/Amanagement plan:

Table II (1 of 2)Identification of Performance Standards



Rule/Measure

BAAQMD Regulation 8- BAAQMD Regulation 8-Organic BAAQMD Regulation 8-OrganicOrganic Compounds, Rule 18- Compounds, Rule 22-Valves and flanges Compounds, Rule 28-Pressure ReliefEquipment Leaks. 1/7/98. at Chemical Plants. 6/1/94. Valves at Petroleum Refinery and

Chemical Plants, Bulk Plants and BulkTerminals. 6/1/94

Exemptions

Visual Inspection Exemption: Leak/Repair Standards Exemption:- not apply to days when - any pressure relief valve on storagefacility not staffed. tanks.

Inspection, Identification setpoint of the pressure relief valve.Exemption:- equipment handling organicliquids having initial boilingpoint > 150 C (302 F)o o

- the static upstream pressure exceeds the

Inspection, Identification and Leak/Repair Standards and InspectionRecord Keeping Exemption: Exemption:- research and development - emissions from the pressure relief valveplants which produce only non- is vented to a vapor recovery or disposalcommercial products solely for system that is at least 95% efficient.research and dev. purposes. - the pressure relief valve is protected by a- equipment in vacuum service. rupture disk.



Rule/Measure




Rule Exemption:- Controlled seal systems andpressure relief devices vented tovapor recovery or disposal systemwhich reduces emissions oforganic compounds from theequipment by 95% or greater(exemption from rule except forprovision on the determination ofcontrol efficiency).- Small facilities-facilities whichhave less than 100 valves or lessthan 10 pumps and compressors(these facilities are subjects toRegulation 8-22).- Bulk plant and terminal loadingracks-connections at the interfacebetween loading rack and thevehicle being loaded.- Storage tanks-appurtenances onstorage tanks including pressurerelief devices, which are subject toRegulation 8, Rule 5 Storage ofOrganic Liquids.

Rule Exemption: Rule Exemption:- Low vapor pressure-valves or flanges - pressure relief valves handling onlywhich handle only organic liquids with a organic liquids with a vapor pressure lessvapor pressure less than 2.6 mmHg (0.05 than 2.6 mmHg (0.05 psia) at 20 oC (68psia) at 20 oC (68 oF) or exhibit a 10% oF) or exhibit a 10% evaporation pointevaporation point > 150 oC (302 oF) greater than 150 oC (302 oF) according towhen using ASTM D-86. appropriate test method.- Natural gas-valves or flanges handling - research or development facilities whichonly commercial natural gas. produce only non-commercial products for- Research and development facilities research and development purposes.which produce only non-commercialproducts for research and dev. purposes.- Large facility-valves or flanges inchemical plants having 100 or morevalves, which are subject to Reg. 8, Rule18-Valves and connectors at PetroleumRefineries, Chemical Plants, Bulk Plantsand Bulk Terminals.



Rule/Measure




Applicability

Leaking equipment at Valves and flanges at chemical plants Pressure relief valves on any equipmentpetroleum refineries, chemical that has less than 100 valves. handling organic compounds at petroleumplants, bulk plants and bulk refineries and chemical plants.terminals including but notlimited to: valves, connectors,pumps, compressors, pressurerelief devices, diaphragms,hatches, sight-glasses, fittings,sampling ports, meters, pipes &vessels.

Comments

Note: Rule 18 - Valves andConnectors at PetroleumRefinery complexes, chemicalPlants, Bulk Plants and BulkTerminals and Rule 25 - Pumpand Compressor Seals atPetroleum Refinery, ChemicalPlants, Bulk Plants and BulkTerminals has beenconsolidated and renamed:Rule 18 - Equipment Leaks,1/7/98.



Rule/Measure




Definition: Definition: Definition:- Petroleum Refinery: Any - Chemical Plants: Any facility engaged - Chemical Plant:facility that processes in producing organic or inorganic and/or - Rupture Disc: The thin metal diaphragmpetroleum products as defined manufacturing products by chemical held between flanges.in Standard Industrial processes. Any facility or operation that - Background:classification Manual as has 28 as first digits in their StandardIndustry No. 2911, Petroleum Industrial Classification (SIC) Code asRefining. det. from the SIC Manual. May include,- Chemical Plants: but not limited to the manufacture of:

industrial inorganic and organicchemicals; plastic and synthetic resins,synthetic rubber, synthetic and other manmade fibers; drugs; soap, detergents andcleaning preparations, perfumes,cosmetics and other toilet preparations;paints, varniches, lacquers, enamels andallied products; agricultural chemicals;safflower and sunflower oil extracts; re-refining.

- Inaccessible Pressure Relief Valve:



Rule/Measure




Definition con’t:- Inaccessible: not in an accessiblelocation as defined by Title 8, Section33207, General Industrial Safety Ordersof CAL OSHA 1986.- Small Chemical Plant: any plant thathas less than 100 valves.




Rule/Measure

Rule/Measure

RACT Determination of SCAQMD Rule 1173.Fugitive Emissions of VOCs Fugitive Emissions offrom Oil and Gas Production Volatile Organicand Processing Facilities, Compounds. 5/13/94. Refineries, Chemical Plants,and Pipeline TransferStations. 12/8/93.

Exemptions

Visual Inspection Exemption:- PRV, P & Cp equippedwith closed-vent systemcapable of capturing andtransporting any leak tovapor control system.



Rule/Measure

Rule/Measure



Inspection Exemption:- Components exclusivelyhandling commercial naturalgas.- Components buried belowground.- Components, except those atgas processing plants,exclusively handling fluids witha VOC concentration of 10% bywt. or less, as determined byappropriate test methods; orcomponents exclusivelyhandling liquid, if the wt%evaporated is 10% or less at 150C (302 F), as determined byo o

appropriate test methods.- **Components at oil and gasproduction facilities, or pipelinetransfer stations, handling liquidof less than or equal to 20 APIo

gravity after point of primaryseparation.



Rule/Measure

Rule/Measure



Inspection Exemption con’t.:- **Components at oil andgas production facilities, orpipeline transfer stations,handling liquid between 20and 30 API gravity whicho

are located either:1)downstream of a wellheadequipped with a casing vaporrecovery system, providedthat the vapor recovery is at apressure of less than 10 psig;or 2)after the point ofprimary separation of oil andgas, provided the separationvessel is equipped with avapor recovery system and isoperated at a pressure lessthan 25 psig.



Rule/Measure

Rule/Measure



Inspection Exemption con’t.:(**Note: (1)Components locatedat offshore oil platforms shall bevisually inspected on a quarterlybasis. If leak detected, measureaccording to Method 21. Quarterly visual inspection maybe changed to annual, except P,Cp, PRV, & PRSB, if no liquidleaks and no major gas leaks >0.5% of total componentsinspected per inspection periodfor 12 consecutive months. Leaks from PRSB not includedin total count of leakingcomponents. (2)Componentslocated at onshore facilities shalleither be subject to (1) or thatany leak, from components notsubject to an inspection programthat are detected by the District,may constitute a violation.)



Rule/Measure

Rule/Measure



Rule Exemption: Rule Exemption:- one-half inch and smallerfittings which have beendemonstrated to the APCO tobe leak-free based on aninitial inspection inaccordance with Method 21.

Applicability (PRV), diaphragms, hatches, plants, oil and gas production

Components including but Valves, fittings, pumps,not limited to valves (V), compressors, pressure reliefflanges (F), fittings (C), devices, diaphragms,pumps (P), compressors hatches, sight-glasses, and(Cp), pressure relief devices meters at refineries, chemical

sight-glasses, and meters at fields, natural gas processingrefineries, chemical plants, plants, and pipeline transferoil & gas processing plants stations.including offshore platforms,and pipeline transfer stations.



Rule/Measure

Rule/Measure



Comments

Comp. classifications:- Major: >4" V, >5-hp P, anyCp, and >4" PRV.- Minor: not a major.- Critical: require unitshutdown if component takenout of service.- Inaccessible: >15' aboveground when access requiredfrom ground; >6' away fromplatform when accessrequired from platform.- Unsafe: as defined byOSHA standards or inprovisions for worker safetyfound in 29 CFR 1910.



Rule/Measure

Rule/Measure



Definitions:- Unmanned Facility: remotefacility which has nopermanent sited personneland is greater than 5 milesfrom the closest mannedfacility.

Background Material: 1999-04-20 Fugitive Emissions from ... · Source Category: Fugitive Emissions...

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Transcript of Background Material: 1999-04-20 Fugitive Emissions from ... · Source Category: Fugitive Emissions...