P. 1


# OAR Box 1107 Prepped byOllie Stewart



## Document

Number: 

# 55 ) IV-B- 5 Docket Number: 

# A-81-2 1

Printed 4/11/20083:03:47

PM Sheet 55of 90P. 2 

# A-81-2 1
CORPORATIO N 

### IV-B- 5
MEMORANDUM DATE : Jul y

17 , 198 5 TO : Viny l Chlorid e Fil e FROM : Kare nK . Fidle r SUBJECT : Receip t o f Complianc e Informatio nfo r Formos a Plastic s in

Delawar e City , Delaware , fro m Regio nII I Attache dar e 10-day

complianc e report s fo r relie f valv e discharge s submitte db

y th e Formos a Plastic s PVC facilit y inDelawar e City , Delaware , t o Regio nIII . Copie s o f thes e report s wer e receive dfro m Mr . Ro nPatterso no f Regio nIII . Attachment s

Progres s Center/320 0 E
. Chape l Hil l Rd./Nelso n Hwy./P.O . Bo x13000/Researc h Triangl e Park , N.C
. 27709/(919)541-910 0P. 3



### . £ £" FORMOS APLASTIC S CORPORATIO NDELAWAR E V" P.O
. BO X320 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-457 5
CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D
Marc h20 , 193 5M[>r " • ; " "' * "
Rober t R . French , P.E . ** ! \ . Manager , Ai r Resource s Sectio n .AL;. > Stat e o f Delawar e Departmen t o f Natura l Resource s an d Environmenta l Contro l P . 0 . Box140 1 Dover , Delawar e 1990 3 RE : EMERGENCY RELIE F DISCHARG E OF VINY L CHLORID E MONOME R FROMRELIE F VALVE , FORMOS APLASTIC S CORPORATION , D E Dea r Mr . French : I n accordanc e wit hthe Stat e o f Delawar e Regulation s Governing th e Contro l o f Ai r Pollution , Chapte r XXI , Sectio n 13 , Subsectio n 3.2a.l , Formos a Plastic s i s submitting thi s writte n repor t o f an emergenc yrelie f dis

charg e o f viny l chlorid e monome r fro ma relie f valve . NATUR E AN

D CAUS E A t 150 0 hour s o n 3/10/85 , a n emergenc yrelie f discharg e o f viny l chlorid e monome r (VCM ) occurre d fro mVCMaccumulato r DT-303 , par t o f th e recovery systema t the E- 2 emulsio n plant . Th e discharge , actuall ytwo , one secon d discharge s fro

mthe relie f valve s o n DT-303 , wa s cause d b yan automati c v^lve whic hleake d VCMint o th e recoverysystema t E- 2 plan t fro mthe tan

k far m(VC Mstorag e area) . The caus e o f th e risin g leve l o f VCMi

n the accumulato r wa s no t immediatel yfound , an d operation s charge d recovere d monome r t o reactor s fro mth e accumulato r t o reduc e pressur e an

d level . Withou t th e knowledg e tha t th e automati c valv e wa s a t fault , the pressur e an d leve l in DT-30 3 continue d t o ris e leading t o a relie f valv e discharge . The secon d relie f valv e (spare ) o n DT-303 , wa s pu t int o servic e immediately , a t whic htime i t relieve d also . Dot h discharge s wer e observe d t o b e on e secon d duration . APPROXIMAT E TOTA

L VINY L CHLORID E MONOME R LOS S DURIN GDISCHARG E The approximat e tota l VCMlos s t o the atmospher e wa s 3 6 lbs .P. 4

Rober t R . French , P.L . Pag e 2 3/20/8 5

METHO D USE D TO DETERMINE VC MLOS S Orific e calculation s wer e mad e a s show n i n the attachment , base d on a two secon

d observe d discharge . ACTIONTAKE NT O PREVEN T DISCHARG E Whe n the accumulato r leve l wa s observe d t o b e increasing withou t goo d reason , operator s immediatel ybega n preparing a reacto r fo r charging an d looking fo r th e source . Additionally , the liqui d lin e fromthe recoverycondenser s t o the accumulato r wa s closed . Charging o f a reacto r fromthe accumulato r wa s initiate d withi n second s o f the release , thu s preventing a large r release . MEASURE S ADOPTE D T O PREVEN T FUTUR E DISCHARGE S I n additio n t o changing the fault yvalve , an analysi s o f th e system indicate d tha t additiona l interlock s o n the recoverysystemma yhav e prevente d the incident . Therefore , an interloc k systemwil l b e designe d an d installe d t o hel p preven t futur e discharge s fromthe VC Maccumulator . Sincerely ,

H . Alle n Wrigley , Vr-^H Environmenta l Manage r HAWjr/A B Attachments : cc : Ronal d Patterso n JosephJ . Hardman , P.E .P. 5 

## 7 ^ . Vr 7 

## Mr. Te- y /)/^„ cJr^k^j 

# dnl ik'P<-, ^?ft- " i UHO. 

## J?T3-J> veni*>»•>,%:>,cm cn 3//</<i'l 

# r'* c/'



## y\/ ^
_ * * 

# trf^ f*A c

£ ' ' ^ 5 

### 7 , Groa/u.-rf -/_-tf . van vaf"-!? „ •/«,, * c/. i „ A /-<•/•'<• t-j, S/'<r<f



## - /^_ > x / / y/-# - 7^/-? /

7 /^'- — "v<:.-_-j_-s.-*i A /
- fr?r.fcc^U/Z T . 

### - c , ^'_

2 

## -T " ~ _T5' V v£-•

• —3'/5 ' /C


# y y - C A QpJ^?

11



# - ($*7Xc>. 97X4'

*tX'i*7?xi

>•• H-/yi^/'t-
- re/xsc'J (?<//>.) (s/O

/ SfCi-.-x/

KH •*.•!< <-'\ 

# 7'i.k(££t 

# ^. = / £g

> n ^- 3 S's 

# hP. 6



### ,,-r - FORMOS APLASTIC S CORPORATIO NDELAWAR E s*dS P.O . BO X 32 0 • DELAWAR E CITY , DELAWAR E 1970 6 • TE L (302 ) 834-457 5

Octobe r 3 , 198 4

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D

Rober t R . French * P.E . Manager , Ai r Resource s Sectio n Stat e o f Delawar e Departmen t o f Natura l Resource s an d Environmenta l Contro l P.O . Bo x140 1 Dover , Delawar e 1990 3 RE : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E Dea r Mr . French : I n accordanc e wit hthe Stat e o f Delawar e Regulation s Governin g the Contro l o f Ai r Pollution , Chapte r XXI , Sectio n 13 , Subsectio n 3.2a.l , Formos a Plastic s i s submitting thi s writte n repor t o f a relie f valv e discharg e o f viny l chlorid e monomer . Nature , an

d Caus e A t 103 0 hour s o n 9/30/84 , a n emergenc yrelie f valv e discharg e o f viny l chlorid e monome r (VCM ) occurre d fro mCT-211 , the knockou t po t fo r the wastewate r strip

ping columns . Th e caus e o f the discharge , lasting fo r approximatel y1 5 seconds , wa s operato r error . Avalv e o n a drai n hos e fro mCT-12 4 VC Mtan

k t o th e waste wate r filte r po t upstrea mo f the VCM-ladc n wastewate r tank s CT-20 0 Aan d B wa s lef t open , allowing backflo wo f wate r int o CT-124 , filling th e syste mwit h water . Upo n restar t o f the system , CT-21 1 overpressured , causin g a ruptur e dis c failur e an

d the relie f valv e discharge . Approximat e Tota l Viny l Chlorid e Monome r Los s During Discharg e Th e approximat e tota l VC Mlos s t o the atmospher e during discharg e wa s 1. 2 lbs . VCM . 

# fccnVmP. 7

.. . -v-j._.c—P: J

Rober t R . French , P.E . -2
- Octobe r 3 , 198 4

Metho d Use d t o Determin e VC MLos s Orific e calculations , base d o n a 1 5 secon d discharg e resulte d i n 5 6 scf ma s air , which , wit ha 9/3 0 023 0 hour s wast e ga s analysi s o f 55. 4 mol e percen t VC Mrepre sent s a discharg e o f 1.1 6 lbs . o r 1. 2 lbs . VCM . Actio n Take n t o Preven t Discharg e Upo n learning o f th e systemhavin g backfille d wit hwater , nitrogenspargin g o f th e wate r ga s lin e t o the incinerato r wa s initiate d t o stri pVC Mou t o f th e line . Th e incinerato r wa s restarte d t o bur n th e VC Mstrippe d fro mtha t line , shortl yafte r whic htim e the pressur e o n CT-2 H reache d 1 5 psig , an d th e relie f valv e opened . Afte r the wast e ga s lin e t o th e incinerato r wa s cleared , a hos e wa s connecte d t o CT-21 0 an d th e wast e ga s lin e t o contro l pressur e unti l opera tion s wer e resumed . Measur e Adopte d t o Preven t Futur e Discharge s Operator s wer e instructe d t o shu t bot hvalve s o n th e wate r transfe r lin e whe n draining o f CT-12 4 ha s bee n completed . Further , a chec k valv e t o pre ven t backflo wo n tha t lin e ha s bee n installed . Awor k orde r ha s bee n initiate d t o mov e th e existing highpressur e alar m fro mthe carbo n treatmen t be d t o th e wastewate r treatmen t plan t contro l board . I f yo u hav e an

yfurthe r questions , pleas e d o no t hesitat e t o contac t me . Sincerel yyours ,

H ; Alle n Wrigley , tfx, Environmenta l Manage r HAW:1 1
cc : Ronal d J . Patterso n JosephJ . Hardman , P.E .P. 8



### "H^p^FORMOS APLASTIC S CORPORATIO NDELAWAR E ^<~y

p o B0 X32 0
. DELAWAR E CITY , DELAWAFP E 1970 6 •TE L(302 ) 834-457 5 Septembe r 12 , 198 4 CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Rober t R . French , P.E . Manager , Ai r Rosouice s Sectio n Stat e o f Delawar e Departmen t o f Natura l Resource s an d Environmenta l Contro l P . 0 . Box140 1 Dover . D E 1990 3 RE : VINY L CHLORID E MONOME R RELEAS E FORMOSAPLASTIC S CORPORATIOND E Dea r Mr . French : I n accordanc e wit hthe Stat e o f Delawar e Regulation s Governin g th e Contro l o f Ai r Pollution , Chapte r XXI , Sectio n 13 , Subsectio n 3.2a.l , Formos a Plastic s i s submitting thi s writte n repor t o f a relie f valv e discharg e o f viny l chlorid e monomer . NATUR E AN

D CAUS E A t 09C 0 hour s on 9/8/84 , a n emergencyrelie f v?lv e discharg e o f viny l chlorid e monome r (VCM ) occurre d fro mS-T . reacto r PR-410 . Th e caus e o f the discharge , lasting onl yfo r approximatel ycn e secon d during unseat ing an d immediat e reseating o f the relie f valvf- . i s unknown . Th e attach
e d batc hchar t indicate s tha t the reacto r came u p t o norma l temperatur e an d pressur e o f 166° F an d 18 0 psi;;* , respectivel ya t approximatel y060 0 hours , droppe d bac k t o 164° F an d 17 8 psi g wher e th e condition s hel d vir

tuall yconstan t fo r thre e hours . A t approximatel y090 0 hours , wel l be
lowthe pressur e rating o f the ruptur e disc , an d relie f valv e setting , the ruptur e dis c failed wit honl ya momentaryrelease . Pas t experienc e ha s show

n thi s typ e o f behavio r t o b e associate d wit hvorte xformatio n whic hcan caus e direc t contac t o f liqui d batc hcontent s agains t the rup tur e disc , resulting i n ruptur e dis c failur e v/el l belo wrane d value , wit h o r withou t a

n accompanying relie f valv e discharg e fo r shor t duration . Thi n discharg e ir . ver

yunusu.:] . i n t:hai ; al l condition s wer e i n steady-stat e fo r a n extende d perio d o f tim e prio r I.o tli

e ruptur e dis c failure . APPROXIMAT E TOTA

L VINY L CHLORID E .MONOME R LOS S DURIN

GDISCHARG E Th e approximat e tota l VC Mlos s t o the . atmospher e during discharg e wa s 1 7 lbs .P. 9

Rober t R . French. . .E . 1 \ 2 o f 2 H . Alle n Wrigley , Jr . Septembe r 12 , 198 4

METHO D USE D TO DETERMINE VC MLOS S Orific e calculation s wer e mad e a s show n i n the attachment , base d o n a on e secon

d observe d discharge . ACTIONTAKE NT O PREVENT DISCHARG E Immediatel yupo n discharge , batc hstripping wa s commenced , wit hn o othe r actio n required , sinc e the relie f valv e immediatel yreseated . MEASURE S ADOPTE D TO PREVEN T FUTUR E DISCHARGE S Thi s discharg e coul d no t b e attribute d t o a know n caus e wit hcertainty . Al l associate d system s wit hPR-41 0 wer e foun d t o b e normall yfunctioning .

HAW:jc c Attachment s Sincerely ,

H . Alle n Wrigley , W . Environmenta l Manage r

•••af-'
-P.1 0

^••xy.'H,^^'
* t* -> * ^ - i' ' /_.---' - 

# yxH xy.H:-\H'L y 

# H/HL —•lt O / / 

# j / - H,H-Hi^

• lA-A'--
- •AAA HH' H

-'HH

T 

# •"" "

•/\ l A - -vA^'A ^ : 

## A/tv: ^A: - -* ? 

# rixxXyHmHrn '^AA""

_ 

## ^^A--AAA' ' ^ < \.£ . 

# - A - A-• A AAA ^

A/ :



## .. yy\^--,H\yh.\\\.\Hfya? v

## / - y^8 : 

## 'xlX^H>-n'-- 

# Vv\\\ Y 

# 81tf«ISttS # 

# lif e ^%. A .:v



# M M

•\i\ I— j ''OP.'.' , ', - |O...I;U,l/, . l. p :; • , . ' 

# \idxMky\ AV;AA,;\\.

A •c : 

## V AA-* H \-\^:- : 

## ^'m
. < * 1706 6 A^^A'/ ^ » \ \ \ 'A- Y v

## \A' ^

AM>AA
. •AAA- ' A 7


## - / - A/ xA/A " //••/A Y/•••/• •/. ; 

# -: ; \.m\#;#>gs]5#A' ^ / YA/ yinHHy 

# \ ^Y \ AY^'YAAAAA AAAA'YYAA/^Y Y \\\- V - v\rX : x,- ' '.'•'--.; . /-s - .... w- p ,>• • V y••• /

X.~, ~ /. . /••,/ X / v••:/ .<•/•,/ , 

# Yy,"A /

;/-• / /,/V/'/ /
/ /'- . i . A .--. ' »^ - 

# -yyyW

1 

# '

• •- v / I,..- 

## ,-v.;\ .o»>v;'; ' 

## v

* . >, - >P.1 1



## . i ! i \

## jy- t /?/t ^ o 

## C<^J 1 . LI trir^ > tft"urp 1/» i u ^C~ ~

Ar. , \

<__A^ AA/< ? 

# P&y'oH&?
\A) 

# '= C K

# 'f

l P 1 • . ^ , 

## C ^ T?7
. ^ A



# ^-16 ^ 8<?o \Jo'sfkX ^ —,A^ ! 

# ;

/-<—«-*c 

## f 7 A - —"A' A^ Ac^

, 6 ^ • r 

## ocf7-- l

- 7 

# 7 5 " i C6^Y ( 

# ,UCc

_ot 

# r7?^ ^

C^L^ -

^ o 

# 6 u 

# r Yp^t - * v -r"*" vc -



# (/ Vvc,-. , - 5 ? 7 ^ 'H^ A

r * / t (- J *l ••-< c.^Jo:, X , v- ' 

### Wr*y.V..

—TA V 

# I A 

# \/ , 

# . A / s . <_<•. . 

# (s%n<r*Ut/t*S) :

# XXXx.X ( { 

# **~ <L

# )= : ,( 

# ^ |U 

# / " r f(J 

### lycw r 

### *. .r.ay,..?yP.1 2



### ~£; ~ FORMOS APLASTIC S CORPORATIO NDELAWAR E w' P.O
. BO X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-457 5 Septembe r 5 , 198 4 CERTIFIE D MAI L OfST^^"^^^" ! RETUR NRECEIP T REQUESTE D ^ fi» ^ ^" j v;

- ^ * 

### ,^H \ 

# 7^ 

# SE P15 W Rober t R . French , P.E . Manager , Ai r Resource s Sectio n T ,... - Stat e o f Delaware . ENFORCE^ , Ujj t Departmen t o f Natura l Resource s ACTlVHttS SECuON an d Environmenta l Contro l P . 0 . Box140 1 Dover , D E 1990 3 RE : VINY L CHLORID E MONOME R RELEAS E FORMOS APLASTIC S CORPORATIOND E Dea r Mr . French : I n accordanc e wit hth e Stat e o f Delawar e Regulation s Governin g th e Contro l o f Ai r Pollution , Chapte r XXI , Sectio n 13 , Subsectio n 3.2a.l , Formos a Plastic s i s submitting thi s writte n repor t o f a relie f valv e discharg e o f viny l chlorid e monomer . NATUR E AN

D CAUS E A t 231 5 hour s o n Augus t 29 , a n emergenc yrelie f valv e discharg e o f • viny l chlorid e monome r (VCM ) occurre d fromS- I reacto r PR-401 . Th e caus e o f the discharg e wa s directl ycause d b ya failur e o f the pressur e alar mdu e t o a plugge d pressur e pic , an d indirectl ythrougha n unnot iced , accompanying temperatur e ris e whic hhad occurre d fc r a perio d o f 4 5 minute s prio r t o the discharge . APPROXIMAT E TOTAL VINY L CHLORID E MONOME R LOS S DURINGDISCIL\P.G E Th e approximat e tota l VC Mlos s t o the atmospher e durin g discharg e wa s 110 2 lbs . METHO D USE D TO DETERMINE VC MLOS S Orific e calculation s wer e mad e a s show n i n tli

e attachment , base d o n a 1. 5 minut e disdiarge . ACTIONTAKE NT O PREVEN T DISCHARG E Upo n discoveryo f th o discharge , tli

e hatc hwa s kille d an d strippin g commence d using the recoverysystem .P.1 3

Rober t R . French , P.E . H . Alle n Wrigley , Jr . Septembe r 5 , 198 4 Pag e 2 o f 2

MEASURE S ADOPTE D TO PREVENT FUTUR E DISCHARGE S Investigatio n ha s bee n initiate d int o the feasibilit yo f providin g temper atur e alar

mcommo n t o the pressur e alar msystem s on al l 3 1 reactors , whic h i f implemente d woul d provid e alar mredundanc yi n the even t o f occurrance s simila r t o tha t describe d above . I f yo u hav e an

yfurthe r questions , pleas e d o no t hesitat e t o cal l m e a t (302 ) 836-2219 . Sincerely , 

# Xj,Gte&^ H . Alle n Wrigley , Environmenta l Manage r HAW:jc c Attachmen tP. M



## ?0- HO I - C Jtfll/-t j (/cliy-<—



# K-/ A 6 AA " 

# 5 ^ A-.'IT
- 7 1 

# -rXxix'r^

a 

# 7 3 * & H •v i r i~-2

_•• ? rA rv

—*•* c - *

* < „ 

### C-^ * 

# •rt^-€L ^ t i W C 

# t^W,=-.z 7 ' x ^zy / =/ d 

# yvc;l5 ' /Wf

c i ^ 

## /-—e_X.

<__ « *>.^.._ . Uv j « ? 

# , 

# /- v A - (/V) /

cv. < 

## D - / 

## 7-" ' --\
_ 

### A-y—C

, ^ /?f?roX

ISV-LA 

### CtZU~ 

# A 1 

# / , o~?A- M (-, A\ \H rv-> ; *"* ) 

## nr,"?

I 

# AP.1 5 

# Consolidated®

Conventiona l SafetyRelie fValv e 3- 2 Formul a Valv e Sizing 

# o

Formul a Symbol s A t Calculate d orific e area , sq . in. , a s determine d b y

formul a AValv e orific e area , sq . in. , Tabl e Apag e 3- 4 Gcm. Q Require d ga s capacit ySCF M @ 14. 7 psi a an d

G0° F V,.i,, WRequire d vapo rcapacity , Ibs/h r L«„ , LRequire d liqui d capacity , gp m a t70° F S G Spccili cgravit yo fga s (wit h referenc e l o ai r=

1 a tG0° F an d 14. 7 psia ) o ro fliqui d (wit h refer enc e t o wate rat 70°F , compressibilit yo fliqui d i s usuall yignored ) a t actua l discharg e tempera ture . M Molecula rweigh t(average ) P i Flowin g pressure , psi a = Se tpressur e + over pressur e + 14. 7 P
. Se tpressur e o fvalve , psi g Pb Flowin g bac k pressure , psi g T i Inle t temperatur e absolute , ° F + 46 0 T i Flowin g temperatur e absolute , ° F + 46 0 7 Compressibilit yfacto r Rati o o fspecifi cheats , C,./C
. unde rinle t'flo w conditio n ASM E Nozzl e ga s constant , pag e 3-2 3 U i AP I Nozzl e ga s constant , pag e 3-5 , 3-10 , o r3-2 3 P Density , lbs/ft J Ai r= 0.076 3 lbs/ft 3 a t14. 7 psi a an d 60° F B Vapo ro rga s correctio n facto rfo rconstan tbac k

pressure s abov e critica l pressures , pag e 3- 6 V i Vapo rcorrectio n facto rapplie s t o bellow s

valve s only , pag e 3- 7 l. i Liqui d correctio n facto rapplie s t o bellow s valve s only , pag e 3- 7 K
. Viscosit ycorrectio n factor , pag e 3-3 0 an d 3-3 1 S i Superhea tcorrectio n factor , pag e 4-1 2 K.
. Napie rfactor , fo rdr ysaturate d stea m a tse t

pressures , i s liste d i n th e Tabl e show n below
. Sect
. I VII I Ace
. 10' o IIP
. ler. s thn n 1*i- 1 V- ! 2- 1 K „ y.o" To " P
. Range ,

pr.i q 152 1 t o 310 0 1-i2-fto"?'*0 3 K „

C.-JIC
. TTk- " p , Ahov c N/ A 2303 t " 

### 1 K „ j 1. 0 |

„ _-190G

P K r —— ; 100 0 2292P . - 10G

1 tSc o Srclio n VIII , Appendi xXI , (o i equivalen tste.in i capacit y •o rcnl l th e t;tcloiy
. Nozzl e Ga s Constan t(C. ) —Avalu e obtaine d b ycom binin g th e r;a s constan t show n i n th e ASMi " Cod e wit h th e .05 0 No.-.*l e Flo wCoellicion t o fth e Consolidate d Valve , Ur e C , wit h th e AP I fomuik i an d C wit h th e ASW C formula
. Th e r..*ifv't

yiclic fvalve s ar o designed , constructed , an d teste d i n accordanc e wit h ASMI - Cod e Sectio n I o rVII I an d Ih e capacitie s ar o coililio d b yth e N.iliona l Board
. Th o AI M osilie o ,iioa s show n at o th e minimu m area s designate d lo rth e specihe d letto i orifice
. Sinc e th e no.'./l e HUM S ai o no l i n |! vt'V.ic t sam e p i one rtio n lo r Formul a Note s 1
. CAUTION : Us e onl yAP I lette rorific e area s i n th e AP I formul a an d onl yth e actua l (ASME ) area s I n th e ASMI : formula
. 2
. Appl yfactor s Sr , K n , B , Vf , K
. L , an d Z whe n applicable ; i fno t applicabl e us e facto ro f1
. Fo rSRV' s wit h bac k pressure : I ) no n bellow s wit h constan t b.p. , appl y"B " an d V , = 1 li ) bellow s wit h constan to rvariabl e b.p. , appl y"Vi " an d B = 1 3
. Compressibilit yfactor , Z applie s t o ligh t hydro carbons , se e Cod e Sectio n VIII , Appendi xXI
. 4
. AP I liqui d formula s ar e state d a s th e ASM E Cod e doe s no t cove rliqui d capacities
. 5
. Liqui d capacit ycorrectio n factor s fo roverpressure s othe rtha n 25 % ar e show n o n pag e 3-8
. 6
. Ga s Specifi cGravit y- —^ - ' • 28.9 7 

# O



# o

### £= £^ FORMOS APLASTIC S CORPORATIO NDELAWAR E P. O IJO X32 0 •DELAWAR E CITY , DELAWAR E 1970 G •TE L(302 ) B34-457 5

CERTIFIE D MAIL RETUR NRECEIP TREQUESTE D 

# P September 5 , 198 4

C P 

# 0* { Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Stat e o f Delawar e Departmen t o f Natura l Resource s an d Environmenta l Contro l P . 0 . Bo x140 1 Dover , D E 1990 3 * * * iM » 

## S i ^ 

# \$ A

^
- ^V v : -\\ ^

RE : VINY L CHLORID E MONOME R RELEAS E FORMOS APLASTIC S CORPORATIOND E Dea r Mr . French : I n accordanc e wit hth e Stat e o f Delawar e Regulation s Governin g th e Contro l o f Ai r Pollution,-Chapte r XXI , Sectio n 13 , Subsectio n 3.2a.l , Formos a Plastic s i s submitting thi s writte n repor t o f a relie f valv e discharg e o f viny l chlorid e monomer . NATUR E AN

D CAUS E A t 090 9 hour s o n 8/30/8 4 an d a t an unknown time durin g th e 1 2 t o 8 shif t on 9/2/8 4 th e S- 1 weig htan k PT-30 3 wa s overfille d du e t o fault y calibrate d weighcells , causing hydrostattin g an d emergenc yrelie f valv e discharge s c f viny l chlorid e monome r (VCM) .

» •nypy.rv v—\ fA ?PR p ••IAT E TOTAL VINY L CHLORID E MONOME R LOS S DURINGDISCHARG E Th e approximat e tota l VC Mlos s t o the atmosphere , durin g th e respectiv e discharge s wa s a s follows :

8/30/84 : 9/2/84 : 

# b

4 M lbs <2oc Unluiowi-r^auratio

n evidentl yfa r les s tha n 8/3 0 release , a s evidence d b ysmal l amoun t o f fros t o n relie f valv e whic hhad reseate d an d wa s holdin g whe n discovered . METHO D USE D T O DETERMINE VC MLOS S Th e 8/3 0 releas e o f 44 4 lb s wa s base d o n discharg e o f 6 0 gallon s b y eyewitnes s estimate . Th e determinatio n tha t the relie f valve , unseate d an d a discharge , occurre d o n 9/? . wa s base d o n presenc e o f smal l amoun t o f fros t o n the relie f valve .P.1 7

Rober t R . French , P.E . Septembe r 5 , 198 4 H . Alle n Wrigley , Jr . Pag e 2 o f 2

ACTIONTAKE NT O PREVENT DISCHARG E Weighcel l recalibratio n wa s immediatel yschedule d o n a priorit ybasis , a s i s remova l o f extraneou s piping . MEASURE S ADOPTE D T O PREVENT FUTUR E DISCHARGE S Extraneou s piping whic hmayhav e bee n interfering wit hweig hcel l operatio n wil l b e disconnected , an d a s describe d above , th e weig h cell s wil l b e recalibrate d befor e an d afte r remova l t o determin e i f piping wa s interfering wit hweighcel l operation . I f yo u hav e an

yfurthe r questions , pleas e d o no t hesitat e t o cal l m e a t (302 ) 836-2219 . 

### Sincerely , 

# {Q&£ H . Alle n Wrigle y^/fr . Environmenta l Manage r HAWrjc cP.1 8



### . . „_ _FORMOS APLASTIC S CORPORATIO NDELAWAR E \_H£ ^ P O BO

X320 •DELAWAR E CITY , DELAWAR E 19/0 6 •TE L(302) 834-457 5 Augus t 13 , 198 4 CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Stat e o f Delawar e Departmen t o f Natura l Resource s an d Environmenta l Contro l P . 0 . Box140 1 Dover , D E 1990 3 RE : VINY L .CHLORID E MONOME R RELEAS E FORMOS APLASTIC S CORPORATIOND E Dea r Mr . French : I n accordanc e wit htli e Stat e o f Delawar e Regulation s Governing the Contro l o f Ai r Pollution , Chapte r XXI , Sectio n 13 , Subsectio n 3.2a.l. , Formos a Plastic s i s submitting thi s writte n repor t o f a relie f valv e discharg e o f viny l chlorid e monomer . NATUR E AN

D CAUS E At 004 5 hour s o n Augus t 5 , seve n ruptur e disc s o n tha following equipmen t i n the S- I viny l chlorid e monome r (VCM ) recoverysystemfailed du e t o hy
drostat s whic hoccurre d throughou t the system : PT300 B - Vacuu

mpum p sea l wate r tan

k PT301 A- Knockou t po t PT301 B - Knockou t po t PT310 A- Compresso r sea l wate r tan k PT310 B - Compresso r sea l wate r tan k PT31 3 (west ) - VC Maccumulato r PT31 5 - Wastewate r tan k Relie f valv e discharge s occurre d on PT300 B an d PT315 , wit hfugitiv e emission s following reseating o f th e valves . Th e immediat e telephoni c repor t t o th

e Stat e o f Delawar e wa s tha t discharge s occurre d fro mal l seven , but . late r interview s wit hplan t personne l indicate d tha t the re lie f valve s di d no t unsea t fro mthe othe r five vessels , no r di d fugitiv e emission s occur fro mthe m(valve s di d no t weep) . Th e cause , o f the abov e emission s wa s transfe r o f recovere d VC Mfro mthe E-1 1 plant , t o the S- I recover yaccumulato r (PT313 ) whic hwa s alread ynearl y full , du e t o a faultyleve l indicato r (L/l ) signal , whic hindicate d a fals e 20 % level .P.1 9

Rober t R . French , P.E . Augu s 3 , 198 4 VINY L CHLORID E MONOME R PLEAS E Pag e 7 H . Alle n Wrigley , Jr . APPROXIMAT E TOTA

L VINY L CHLORID E MONOME R LOS S DURIN GDISCHARG E (• Th e approximat e tota l viny l chlorid e monome r (VCM ) los s t o the atmospher e during discharg e was.a s follows : PT300 B vacuu

msea l wate r tan

k - 19 3 lb s PT31 5 wast e wate r tan k - 24 2 lbs METHO D USE D T O DETERMINE VC MLOS S Orific e calculation s wer e mad e a s show n i n th e attachment , base d o n a four minut e discharge . ACTIONTAKE NT O PREVEN T DISCHARG E Upo n discovery , the wast e wate r tan k wa s immediatel yblocke d in , an d upo n shut
of f o f the automati c sprinkle r system , the remaining ruptur e disc s whic hhad failed wer e found . Th e entir e S- I recoverysystemwa s thereupo n shu t down , an d the inle t lin e t o PT31 3 accumulato r fro mE-I I plan t RVC Mpum p statio n (DT303 ) wa s blocke d in . Afte r al l the remaining S- I recoverysystemtank s wer e blocke d in , an d th e "al l clear " signa l sounded , the are a wa s inspecte d an d maintenanc e crew s immediatel ybega n repair . MEASURE S ADOPTE D TO PREVEN T FUTUR E DISCHARGE S Adetaile d investigatio n wa s begun immediatel yb ymanagemen t wh o wa s i n th e plan t a t the time conducting anothe r investigation . I t wa s confirme d tha t th e L/ l o n PT31 3 accumulato r wa s fault yan d thi s wil l b e replaced . T o preclud e a discharg e fro moccurring i n the even t the L/ I a t PT31 3 shoul d fai l again , an interloc k i s being place d o n the systeminstrumentation , whic hwil l shu t th e accumulato r of f o n highpressure , i n additio n t o th e highpressur e shutof f whic halread yexist s o n the transfe r pump . A s an additiona l measure , th e accumulato r pressur e indicato r i s being relocate d t o a positio n whic hi s close r t o th e operator' s norma l fiel d o f visio n on the mai n contro l panel , an d th e transfe r procedur e wil l likewis e includ e monitoring o f the accumulato r pressur e a s a cross-check . I f yo u hav e an

vfurthe r questions , pleas e d o no t hesitat e t o cal l m e a t (302 ) 836
- 2219 . Sincerely ,

H . Alle n Wrigley , J t Environmenta l Manage r HAW:jc c Attachment sP.2 0



## r * 0 0 

## '£ • C.::-£~1~l 

## to: 

# CctosOi-ibriiin*

^ 

### UJ* C iS^rP Hr 62<S ~



# - 6^ ) f< * 0 C ,7C



# ^ ^ /3 

# ° ^ vT^T(

?r</c>)



## K * .^ TC <^___

_bat+e~-

trf !^_. » ..« ! 

## 5^-Z - >

bp-_c_swy_.r
. IP' T 

# ' 2 

# ^3J^A ^

" ^ V«*/-
. - I9Z

11*3 r^\. ^nnr,^ Y)f ) \(/0 y^i>h i/c t^\
7~>->y_,'K L 

## / f * z > c/ c7 3 5 cr

__>->/3 y j^jv ^ Uci-a^ r«-f

- ^ ^

L6TP4-O T^ - = . 0 ^

- ^ 

# ^ ,^37j r« 0 (,?o 7 

# ) (" c 

# 0 J x^— #-,3^ 7

CU
. c<x ^ >< <*• ' ' /- C / , Ve-lc^-.'H, / / 

# APPENDIXX I CAPACIT YCONVERSIONS FORSAFET YVALVE

S P.2 1

* UA-23 0 Th ecapacity o

f asafet y or relie f valvei nterm s o f a ga s or vapor other tha nth emediu mfo r whic hthe valv ewa s officiall y ratedshal

lb edclcnninc db

y appli
catio no f thefollowing formulas : ' Fo r steam. • W,= S\.SKAP Fo rAir : /A ? 

### w. CKAP^/H C=35 6 M =28.9 7 T= 52 0 whe

nW ai s therate dcapacity Fo r any ga s o r

vapor : /M W^CKAPA/Y wher c W,~ rate dcapacity , pound s o f stea mper hour W c = rate dcapacity , converte dt o pound s o f ai r per hour a t 6 0 degree s Fahrenheit , inlet tem peratur e W= flow o

f any ga s or

vapor , pound s per

hour C— constant fo r gn s o r vapo r whichi s afunction o f therati o o

f specific heats , k

— c f /c v(se e Fig . UA-230 ) A' = coefficien

t o f discharg e(se c UG-J3 1 (d ) an d (c) ) " A— actualdischarg eare ao f th esafet

y valve , squareinche s P~ (set pressurex1.10) plu s atmospheri c pres sure , pound s per

squareinchabsolute A/ = molecula

r weigh t T~ absolutetemperaturea t inlet (degree s Fahr
enheit plu s 460 ) Knowingiheonici:il ratint ; capacit yo f asafel yvalv e whic h i s Mampc

J o nili cvalve , i

l is possibl el o ilcicrniiu c (lienvnal l valin- o

f K.t ineithero

f ihefollowin p foumila s • ncases wher

eihevalueof

Ihcscindividua

l terms is not known : Ollieia l Killin gi nStea m. 51.51 ' Officia l RatinginAi r _•

_- "' •/ " KA 

### - cfr Tt i'. k , i ,;,'' " Xi,, " rfo rK'l

is thensulv-iiiuicd i

ntheahov cfor- >*\ to lU-icdiiin

e t [, ecapacit

yo f thewfetyvalvei

nIcnn s """•• * *l-a \or\aivr . Thes eformula s may als o b euse dwhenth erequire d flo w o f any gn s o r

vapo r i s know nan dit

i s necessary t o computeth erate dcapacity o f steamo r air . Molecula r weight s o

f someo f th ecommo ngase s an dvapor s ar c giveninTabi c UA-230 . Fo r hydrocarbo nvapors , whereth eactua lvalu eo f k i s no t known , theconservativ evalue , k = 1.00 1 ha s beencommonl y use dan dth eformul abecomes ,

Jr = 31 5 KAP T Whendesired , a s inth ecas eo f light hydrocarbons , th ecompressibility factor , Z , may b einclude di nth e formula s for

gase s an dvapor s a s follows : W=CKAP Example 1: Given : Asafet

y valv ebear s acertifie dcapacity ratin g o f 302 0 l b o

f steampe r

hou r for apressur e settin g o f 20 0 psi . Problem : What

i s th erelievin g capacity of tha t valv ei nterm s o

f ai r at 10 0 Ffor

th esamepressur e setting ? Solution : Fo r steam : W,= 51. 5 KAP 3020 = 51. 5 KAP
Fo r air : W B =CKAP 

# V -3S6KAP 

# V.

28.9 7 460+10 0


## = (356 ) (58.5 ) y ^

9 7 56 0
= 475 0 lb pe r

h r Example Given : It i s require dt o reliev e500 0 l b o f propan e per hou r fro mapressurevesselthroug hasafet y valv e se t t o reliev ea

t apressureo

f P„ pound s pe r

square , inch , an dwit

haninle t temperatur eo

f 12 5 F . 

# 0 32 7tio nof

th esyste mma y b eaulot r • o r manual . Ven t stack— Aven t

stac k i s th eelevate dvertica l terminatio nof

adisposa lsyste mwhic hdischarge s vapor s int o th eatmospher ewithou t combustio no r conversio no

f Hi erelieve dfluid . Type s o fpressur e relie fvalve s

GENERA L Severa l design s of

pressure-relie f

device s ca nb e certifie dan dapprove dunde r Sectio nVII Iof

th e ASM EBoile r

an dPressur eVesse lCod ecoverin g un file dpressur evessels . Thes einclud esprin g loade d direc t acting , pilo t

operated , an druptur edisks . Whe n th egovernin g cod ei s ANS IB31.8 , US AStandar d Cod efor pressur epiping , ga s transmissio nan ddis
tributio npipin g systems , man y type s o f pressur eent ilin g device s ar epermitted , suc ha s monitorin g regu lators , serie s regulators , weight-loade drelie f valves , liqui dseals , etc . Th ediscussio nbelo w i s limite dt o A.SMESectio nVII Itype s o f devices . CONVENTIONA LSAFET YRELIE FVALVE S I naconventiona lsafet y relie f valv eth einle t pressur el o th evalv ei s directl y oppose db y asprin g closin g th evalve , an dbac k pressur eo nth eoutle t of th evalv echange s th einle t pressur ea t

whic hth e valv ewil lopen . BALANCE D SAFET YRELIE FVALVE S Balance dsafet y relie f valve s ar ethos ei nwhic h th ebac k pressur eha s ver y littl eo r n o influenc eo n th ese t pressure . Th emos t

widel y use dmean s o

f bal
ancin g asafet y relie f

valv ei s throug hth eus eo f a bellows . I nth ebalance dbellow s valve , th eeffectiv e are aof th ebellow s i s th esam ea s th enozzl esea t are aan dbac k

pressur ei s prevente dfro mactin g o n th elo p sid eo

f th edisk . Thu s th evalv eopen s a t th e sam einle t

pressur eeve nthoug hth ebac k pressur e ma y vary .

• PILO TOPERATE D SAFET YRELIE FVALVE S Apilot-operate dsafet y relie f valv ei s adevic e consistin g o

f tw o principa lparts , amai nvalv ean d apilot . Inle t

pressur ei s directe dt o th eto p of th e mai nvalv episton , an dwit hmor eare aexpose dt o pressur eo nth eto p o

f th episto ntha no nth ebottom ; pressure , no t

aspring , hold s th emai nvalv eclosed . A t th ese t pressur eth epilo t

open s reducin g th e pressur eo nto p of

th episto nan dth emai nvalv e goe s full y open . A t extremel y lo w se t

pressures , pilot-operate d safet y relie f

valve s ar eavailabl ei nfrietionlcs s light
weigh t diaphrag mconstructio ni nplac eo f heav y pistons . RESILIEN TSEATE D SAFET YRELIE FVALVE S Whe nmetal-to-meta lseate dconventiona lo r bel
low s typ esafet y relie f valve s ar euse dwher eth e operatin g pressur ei s clos et o th ese t pressure , som e leakag eca nb eexpecte dthroug hth escat s of th e valv e(Refe r

t o AP IStandar d527 , "Commercia lSca t Tightnes s o

f Safet y Relie f

Valve s wit hMetal-to
Mcta l Scats") . Resilien t scat - afet y relie f

valve s wit heithe r O-Rin g sea t

sea l<» . plasti c sca t

suc ha s Teflo npro vid esea t

tightnes s belte r

tha nAP IStandar d527 . Limitation s o

f temperatur ean dchemica lcompatibil
it y of th eresilien t

materia lmus t

b econsidere dwhe n usin g thes evalves .

RUPTUR EDIS K Aruptur edis k

consist s of

athi nmeta ldiaphrag m hel dbetwee nflanges . Th edis k i s designe dturup tur ean dreliev epressur ewithi ntolerance s estab
lishe db y ASM ECode . Sizin g o frequire d orific e area s

GENERA L I t i s no t th epurpos eof

thi s sectio nl o discus s de
terminatio nof

individua lrelievin g rate s of safet y relie f valves . A nexcellen t referenc efo r

detenninin g individua lrelievin g rate s i s containe di nSectio n3 o f AP IRP521 , "Guid efo r Pressur eRelie f

an dDe
pressurin g Systems" . Afte r th erequire drelie f

ca pacit y of

asafet y relie f

valv eha s bee ndetermined , i t i s necessar y t o calculat eth eminimu morific eare a tha t th erelie f

valv emus t

contain . Method s of per formin g thes ecalculation s ar eoutline di nthi s section . Th esafet y relie f

valv emanufacturer s hav e standard s fo r

orific edesignatio nan dare aan dth e valv ebod y size s whic hcontai nthes eorifice s (AP I Standar d526 , "Flange dStee lSafet y Relie f Valve s fo r Us ei nPetroleu mRefineries) . Th estandar dori
fice s available , b y lette r designatio nan dare a-re : D Orific e EOrific e FOrific e GOrific e HOrific e JOrific e K Orific e LOrific e M Orific e NOrific e POrific e QOrific e ROrific e TOrific e However , inar. y smal lsafet y relie f valve s ar e manufacture dwit horific earea s smalle r tha n"D" , an dman y pilot-operate dtype s contai norific earea s large r tha n"T" . SIZIN GFO RGA S O RVAPO RRELIEF . SONI C O RCRITICA LFLO W Safet y relie f

valve s i nga s o r

vapo r servic ema y b esize db y us eof

on eof thes eequations : 0.11 0 0.19 6 0.30 7 0.50 3 0.78 5 1.28 7 1.83 8 2.85 3 3.6 0 4.3 4 6.3 8 11.05 16. 0 26. 0 s q sq s q sq s q s q sq s q s q s q s q sq i n i n i n i n i n i n i n i n i n i n i n i n sqi n sq . i n

A=

A= Wy/~T^ZT CKP , K

b y/W 

## V ,/T\fW\/T 6.3 2 C K

P , K „ (3.1 )
(3.2 ) 

# O



# o

o

3



# o

\ ,A= 

### VV'TVGVZ
- (3.3 ) 1.17 5 CKP , K„ W= flow throug hvalve , lb/h r V = flow throug hvalve , scf m C — coefficien t

determine db y th erati o of th e specifi c heat s of th ^ i*a s o r vapo r a t standar dcondi
tions . Thi s ca nb eaine dfro mFig . 3- 1 o r Fig . 3- 2 K = coefficien t

o f discharge , obtainabl efro mth e valv emanufacture r A— effectiv edischarg eare ao f th evalve , s qin . P , = upstrea mpressure , psia . Thi s i s se t pres sur eplu s overpressur eplu s th eatmospheri c pressur e

tc, n 0.4 1 0.4 2 0.4 3 0 4 4 0.4 5 0.4 6 0.4 7 0.4 8 0.4 9 0.5 0 0.5 1 0.5 2 0.5 3 0.5 4 0.5 5 0.5 6 0.5 7 0.5 8 0.5 9 0.6 0 0.6 1 0.6 2 0.6 3 0.6 4 0.6 5 0.6 6 0.6 7 0.6 S 0.6 9 0.7 0 c 219.2 8 221.5 9 223.8 6 226.1 0 228.3 0 230.4 7 232.6 1 234.7 1 236.7 8 238.8 3 240.8 4 242.8 2 244.7 8 246.7 2 248.6 2 250.5 0 252.3 6 254.1 9 256.0 0 257.7 9 259.5 5 261.2 9 263.0 1 264.7 2 266.4 0 268.0 6 269.7 0 271.3 3 272.9 3 274.5 2
' Intcrpolole d value s

Acetylen e Ai r Ammoni a Argo n Benzen e Carbo n Carbo n Corbo n Chlorin e Cyclol w Elhon e Ethylen e Heliu m Hcxan c disulphid e dioxid e monoxid e Kan e k , n

0.7 1 0.7 2 0.7 3 0.7 4 0.7 5 0.7 6 0.7 7 0.7 ? 0.7 9 0.8 0 0.8 1 0.8 2 0.8 3 0.B 4 0.8 5 0.8 6 0.8 7 0.8 8 0.8 9 0.9 0 0.9 1 0.9 2 0.9 3 0.9 4 0.9 5 0.9 6 0.9 7 0.9 8 0.9 9 1.0 0

, sinc e c

276.0 9 277.6 4 279,1 8 280.7 0 282.2 0 283.6 9 285.1 6 256.6 2 288.0 7 289.4 9 290.9 1 292.3 1 293.7 0 295.0 7 296.4 3 297.7 8 299.1 1 300.4 3 301.7 4 303.0 4 304.3 3 305.6 0 306.8 6 308.1 1 309.3 5 310.5 8 311.8 0 313.0 1 314.19 * 315.38 * C become s

Mo l w tCp/Cv 2 6 1.2 8 2 9 1.4 0 1 7 1,3 3 4 0 1.6 6 7 8 1.1 0 7 6 1.2 1 4 4 1.2 8 2 8 1.4 0 7 1 1.3 6 8 4 1.0 8 3 0 1.2 2 2 8 1.2 0 4 1.6 6 8 6 1.0 8 

### FI G

Value s o f k , n 1.0 1 1.0 2 1.0 3 1.0 4 1.0 5 1.0 6 1.0 7 1.0 8 1.0 9 1.1 0 1.1 1 1.1 2 1.1 3 1.1 4 1.1 5 1.1 6 1.1 7 1.1 8 1.1 9 1.2 0 1.2 1 1.2 2 1.2 3 1.2 4 1.2 5 1.2 6 1.2 7 1.2 8 1.2 9 1.3 0 c 316.56 * 317.7 4 318.9 0 320.0 5 321.1 9 322.3 2 323.4 4 324.5 5 325.6 5 326.7 5 327.8 3 328.9 1 329.9 8 331.0 4 -332.0 9 333.1 4 334.1 7 335.2 0 336.2 2 337.2 4 338.2 4 339.2 4 340.2 3 341.2 2 342.1 9 343.1 6 344.1 3 345.0 8 346.0 3 346.9 8 indeterminot e a s c i



### FIG . 3- 1 Coefficien t C ' k , n 1.3 1 1.3 2 1.3 3 1.3 4 1.3 5 1.3 6 1.3 7 1.3 3 1.3 9

. 1.4 0 1.4 1 1.4 2 1.4 3 1.4 4 1.4 5 1.4 6 1.4 7 1.4 8 1.4 9 1.5 0 1.5 1 1.5 2 1.5 3 1.5 4 1.5 5 1.5 6 1.5 7 1.5 8 1.5 9 1.6 0 he rn o rk 

### 3 - 2 c

347.9 1 348.8 4 349.7 7 350.6 8 351.6 0 352.5 0 353.4 0 354.2 9 355.1 8 356.0 6 356.9 4 357.8 1 358.6 7 359.5 3 360.3 8 361.2 3 362.0 7 362.9 1 363.7 4 364.5 6 365.3 9 366.2 0 367.0 1 367.8 2 368.6 2 369.4 1 370.2 1 370.9 9 371.7 7 372.5 5 approache s

Value s o fC fo rgase s c 34 5 35 6 35 1 37 7 32 7 33 8 34 5 35 6 35 2 32 4 33 9 33 7 37 7 32 4 C/3S 6

.96 9 1.00 0 .98 6 1.05 9 .91 9 .94 9 .96 9 1.00 0 .98 9 .91 0 .95 2 .94 7 1.05 9 .91 0 3 Hydrochlori coci d

Hydroge n . Hydrog c n sulphid e Iso-butan c Methan e Methy l Methy l alcoho l chlorid e N-butan e Natura l go s Nitroge n Oxyge n Penton e Propon e Sulphu r

- 3 dioxid e k , n 1.6 1 1.6 2 1.6 3 1.6 4 1.6 5 1.6 6 1.6 7 1.6 8 1.6 9 1.7 0 1.7 1 1.7 2 1.7 3 1.7 4 1.7 5 1.7 6 1.7 7 1.7 8 1.7 9 1.8 0 1.8 1 1.8 2 1.8 3 1.8 4 1.8 5 1.8 6 1.8 7 1.8 8 1.8 9 1.9 0 1.00
. c

373.3 2 374.0 9 374.8 5 375.6 1 376.3 7 377.1 2 377.8 6 378.6 1 379.3 4 380.0 8 380.8 0 381.5 3 382.2 5 382.9 7 383.6 8 384.3 9 385.0 9 385.7 9 386.4 9 387.1 8 387.8 7 388.5 6 389.2 4 389.9 2 390.5 9 391.2 6 391.9 3 392.5 9 393.2 5 393.9 1

Mo l w t Cp/C v 36. 5 1.4 0 2 3 4 5 8 1 6 3 2 1.4 0

1.3 2 1.1 1 1.3 0 1.2 0 50. 5 1.2 0 5 8 1 9 2 8 3 2 7 2 4 4 6 4 1.1 1

1.2 7 1.4 0 1.4 0 1.0 9 1.1 4 1.2 6 k , n

1.9 1 1.9 2 1.9 3 1.9 4 1.9 5 1.9 6 1.9 7 1.9 8 1.9 9 2.0 0 2.0 1 2.0 2 2.0 3 2.0 4 2.0 5 2.0 6 2.0 7 2.0 8 2.0 9 2.1 0 2.1 1 2.1 2 2.1 3 2.1 4 2.1 5 2.1 6 2.1 7 2.1 8 2.1 9 2.2 0

c 35 6 35 6 34 8 32 8 34 6 33 7 33 7 32 8 34 5 35 6 35 6 32 5 33 1 34 2 c 394.5 6 395.2 1 395.8 6 396.5 0 397.1 4 397.7 8 398.4 1 399.0 5 399.6 7 400.3 0 400.9 2 401.5 3 402.1 5 402.7 6 403.3 7 403.9 7 404.5 8 405.1 8 405.7 7 406.3 7 406.9 6 407.5 5 408.1 3 408.7 1 409.2 9 409.8 7 410.4 4 4 1 1.0 1 411.5 8 412.1 5

C/35 6 1.00 0 1.00 0 .97 8 .92 1 .97 2 .94 7 .94 7 .92 1 .96 9 1.00 0 1.00 0 .91 3 .93 0 .96 1 Rev
. 197 6P.2 4 

## Consolidated H ) 

## z-i Formul a Valv e c V>CP 1 

### bI Z 

## fet yRelie fValv e in g 

# 'o r
Formul a Symbol s A , A
. Gc„„ Q V„„ W Un, , L S G

M P
. P
. P b T
. T , 2 k C C . P

K
. Sr Calculate d orific e area , sq . in. , a s determine d byformul a Valv e orific e area , sq . in. , Tabl e Apag e 3- 4 Require d ga s capacit ySCF M @ 14. 7 psi a an d 60° F Require d vapo rcapacity , Ibs/h r Require d liqui d capacity , gp m a t70° F Specifi cgravit yo fga s (wit h referenc e t o ai r= 1 a t60° F an d 14. 7 psia ) o ro fliqui d (wit h refer enc e t o wate rat 70 C F , compressibilit yo fliqui d i s usuall yignored ) atactua l discharg e tempera ture . Molecula rweigh t (average ) Flowin g pressure , psi a —Se t pressure - + over pressur e + atmospheri cpressur e Se tpressur e o fvalve , psi g Flowin g bac k

pressure , psi g Inle ttemperatur e absolute , ° F + 46 0 Flowin g temperatur e absolute , ° F + 46 0 Compressibilit yfactor , pag e 3-2 1 Rati o o fspecifi cheats , C P/C vunde rinle tflo w conditio n ASM E Nozzl e ga s constant , pag e 3-2 3 AP I Nozzl e ga s constant , pag e 3-5 , 3-10 , o r3-2 3 Density , lbs/ft- 1 Ai r= 0.C76 3 lbs/ft 1 a t14. 7 psi a an d 60° F Vapo ro rga s correctio n (acto rfo rconstan tbac k pressure s abov e critica l pressures , pag e 3- 6 Vapo rcorrectio n facto rapplie s t o bellow s valve s only , pag e 3- 7 Liqui d correctio n facto rapplie s l o bellow s valve s only , pag e 3- 7 Viscosit ycorrectio n factor , pag e 3-3 0 an d 3-3 1 Superhea tcorrectio n factor , pag e 4-1 2 Napie rfactor , fc rdr ysaturate d stea m a t se t pressures , i s liste d i n th e Tabl e show n below
. Sect
. I V!! ! Acc
. 3 % 10 % I fP
. les s tha n 152 1 1<!2 4 K„ 1. 0 1. 0 P , Range ,

psi g 152 1 t o 310 0 "i42 4 •7290 3 K„

Calc
. Calc
. P , Abov e N/ A _903 f K„

/•»•* • 1. 0
•1906P , - 100 0 .2292P , - 106 1 fo requivalen t stea m capacit y tSc o Sectio n VIII , Appendi xI I o rcal l th e factory
. Nozzl e Ga s Constan t(C. ) —Avalu e obtaine d b ycom binin g th o ga s constan t show n i n th o ASM E Cod e wit h th e .9;i 0 Nozzl e Flo wCoefficien to fth e Consolidate d Valve
. Us e C , wit h th e AP I formul a an d C wit h th e ASM E formula
. Th e safet yrelie fvalve s ar e designed , constructed , an d teste d i n accordanc e wit h ASM E Cod e Sectio n I o rVII I an d th e capacitie s ar e certifie d b yth e Nationa l Board
. Th e AP I orific e area s show n ar cth e minimu m area s designate d fo rth e specifie d loite rorifice
. Sinc e th o nozzl e area s ar cno ti n th e exac tsam e propottio n fo r al l sizes , th e calculate d AP I capacit ywil l var yslightl y fro m th o ASM E figure
. Formul a Note s 1
. CAUTION : Us e onl yAP I lette rorific e area s i n th e AP I formul a an d onl yth e actua l (ASME ) area s i n th e ASM E formula
. 2
. Appl yfactor s St , K„ , B , Vr , Lt , an d K
. whe n applic able ; i fno t applicabl e us e facto ro f1
. Fo rSRV' s wit h bac k

pressure : i ) no n bellow s 'wit h constan tb.p. , appl y"B " an d V r= 1 ii ) bellow s wit h constan t o rvariabl e b.p. , appl y"Vr " an d B = 1 i. Compressibilit yfactor , Z applie s t o ligh t hydro carbons , se e Sectio n VIII , Appendi xII
. 4"
. AP I liqui d formula s ar e state d a s th e ASM E Cod e doe s no tcove rliqui d capacities
. 5
. Liqui d capacit ycorrectio n factor s fo roverpressure s othe rtha n 25 % ar e show n o n pag e 3-8
. 

# o

Refe rt o pag e 3- 1 fo rValv e Sizin g Sequence s para . -2
.P.2 5



### f:' ^ FCmMO.'-j/. PLASTIC S CORPORATIO NDELAY/AR E ^H^v.c. no> : :i?

o • DEI.AWAH

_ CITY . DELAWAR

E19705 » TE

L(302 ) 834-157 5 Augus t IL, 198 4 CERTIFIE D MAI L RETUR NRKCK11' T REQUESTE D

, -7
- 7 " i Rober t R . French , P.E . '• ' . .. . •' , I'lHiiji^jy , Ai r Rer.omre s Sectio n f . ' . "' \ \^ > Stat e o f Delawar e ^ L Departmen t o f Natural . Resource s V . QJ^- . an,-. ! Environmenta l Contro l 0\ P • ' ' P . 0 . Bo x1401 . Dove?- , D E 1990 3 RE : VINY L CHLORID E MONOME R RELEAS E FORMOS APLASTIC S CORPORATIO ND E Dea r Mr . French : I n accordanc e wit hth e Stat e o f Delawar e Regulation s Governin g th e Control , o f Ai r Pollution , Chapte r XXI , Sectio n 13 , Subsectio n 3.2a. l Formos a Plastic s i s submittin g thi s writte n repor t o f a relie f valv e discharg e o f viny l chlorid e monomer . MATUR E AN D CAUS E A t 010 0 August.4 , 198 4 batc hS-406 4 wa s t o b e transferre d fro mS-I I reacto r SR-40 6 int o degassin g tan k ST41 3 fo r stripping . Th e operato r wh o va s t o perfor mthi s instea d transferre d th e batc hi n erro r t o anothe r reactor , SR41.0 , whic hwa s bein g readie d fo r CR T cleaning , an d therefor e ope n t o th e atmospher e vi a th e manwa yo n to p o f th e reactor . Th e entir e batc hwa s transferre d befor e th e erro r wa s discovere d an d corrected . Th e los s o f viny l chlorid e monome r t o th e atmospher e whic h occurre d wa s entirel ythroug hth e manwa ya s a direc t resul t o f operato r error , an d di d no t involv e a n emergenc yrelie f valv e discharg e o r rup tur e dis c failure . APPROXIMAT E TOTA L VINY L CHLORID E MONOME R LOS S DURIN GDISCHARG E 2» r vl 2 lbs . o f viny l chlorid e monome r wa s los t durin g th e discharge . METHO D USE D FO R DETERMININ C TH E VINY L CHLORID E LOS S Th e viny l c.lilorld

e los s wa s base d o n a los s o f al l viny l chlorid e i n th e vapo r spar e b o Tore , durin;* , an d afte r transfer , base d o n initia l VC M charge d and pe r cen t conversio n durin;*' , polymerisation . Sinc e ther e war . n o rupture - dis c failur e o r relie f valv e discharge , th e abov e basi s wa s use d wit ha vapo r pressur e calculatio n t o determin e th e averag e volum e fractio n o f VC Mi n solutio n remainin g i n th e converte d batc h al'U'.! ' livi s a t on e at.'-ospher c pressure . Calculation s an d batc hinforma

tio n a i * i ! attached . - n

• ^P.2 6

Rober t R . French. , <W. VINY L CHLORID E M

i li' R RELEAS E Augur - 1.4 , 198 4 Pap. e

ACTIO NTAKE NTO MINIMIZ E TH E RELEAS E Immediatel yupo n discovery , the batc hwa s isolate d b ysecurin g th e ope n manway , thu s preventing furthe r atmospheri c contac t b yth e batch . MEASURE S ADOPTE D T O PREVENT FUTUR E RELEASE S Th e abov e discharg e o f VC M t o the atmospher e wa s entirel yon e o f oper ato r erro r i n whic hvalv e position s wer e incorrectl yset . Th e opera to r involve d wa s discipline d an d retrained . I n the even t you hav e an yquestions , pleas e d o no t hesitat e t o call .

Sincerely ,

H . Alle n Wrigley , Jr . Environmenta l Manage r llAW:jc c Attachment s ' ^



## *-,H 

# <\*r.jX CC : JosephJ . Hardma n ,• - <'i' r ^J-" Ronal dJ . Patterso n2* 3 ' J>' fisV
& j0±>



# x-4

- 5t__-*i* 9 R6.METE R 151203 7
ilWUMU BP.2 7



### .„_-_VC*Vi . .

. ^d.&lo-cc- H-i/^ ^ ..Sl<?Ot . S 

## /y/s.9 -

.. . Z-oocr- p .((-.$ ..c^-cvrs ^ <2... . ^^T^. . cj^^xsi'<->^..r=. ...3.<y> &x>. .('a.-.-J_ ,

### J.c*A„..at. . : _^A. . 

### 4'. . .J"&HHIJ>\ 

### „ ._... ' , .._ty.<n—_..b^t4. . cJLoj-t \Q^^o^roXz^r<L_, G.C.. d 

### £;..rr>_ ^ S ! !?._£. ..Xs^^-l ^AP. Q^*f?-W^&^\. 

### vvi^ . axt~o*$^d

-fur- ^ f



### tA^ e£s^...&f~\Hyjyo^r-?~r?H3 fJ rs.^crH _ \<L$T..^..SrtnUs^. .:..._ : 

## £*?. . p =..„<2_-fr.._| r



## _..^..L_ ? C

_Jk r..T._

. -^.c
- S
-1-TcJjuVC- . CJV-. . /"ctAcv"v-~ e„ t^ecJ r "^fy . * C ve - C
- « - S.__?j^.'tfVr-«..„_L..<?rrLV.->-

_?-K... SS r~-k--«
- ^.....LZ. S .f^>r?..._ ^ .6.o :: f/> ! w._.y [ ..^••f-5.':! ^r'..-_C^C/^/c/^_-*-(^ ^ & 7 ^._\l?~fi£C. //. eJ?u^/*.c i Uo-/*/-e . ? . ...<5?-y

. „7l v WJi-rO., !


## o

- . 

## _4r-._
_

. C. 

### 8 J- " IH-H —-v- _„
„.. !
_ _<p , |. 3 o !.«**- ? O.I3J 

### f.£^- - -P,.Ht.Q. 1-.M
. ...O.jiT.7 - 

## i . e s o./6 c 

# \ 4 ..<D,9Q



## -QS?.. __X-o<J*c^

A



### ___V. p ..= .P-..?tl . C.o-A. . <aArr . z..r"?.*....t U....S.o.-.C-rPt I 

## _....<* * _.V.C

W..tfwVT ^ <f/r<»>

) ^.-.^•^fU/ ? 

## ^.. J NTVS... .


### .9«niji/o ^

• • • - ^ - • ^ / * . * N<.^.TK, S ,, 7 if, , j o 

## it * VC-*
-i . }• t in vii,|pji; i ,i.' r p / ci imi'tn mn I
I f

Vt

c. of .

1 «> > .0.'- '

„ -

-

-

~- . 

## c^" " 1 —

_ >

;

• • •

.

——————»•—
—• i i -

. • •

-
i j.. . 

# "

1

•

\*

"

V•* "

. » O t , V.l

o.f

e0
_ • Vwl-rr.*'ti^vi^p i o l pvlfmcr , I * t o Fij: . 5 . fwilubilit y c f

viny l rlilrinil ei npnly ( viny lcliWidc) .

<• : prcscn li nlli c .system . AVisltinashor t lim epolyme r

separate s out - l c for mnthir d pli.is c becaus ei t

i s totall y insolubl ei nth emonome r an dprecipitate s completely . Th e monome r i s solubl ei nth epolyme r l o a nexten t

a s show ni nFigur e5 wher e1 ' i s th e volum efractio no

f polyme r i nth eswolle nphas ean dp/p ui s th erati o o f th eactua lpres sureo f Ih eviny l chlorid et o th esaturatio nvapo r pressure . Thi s curv ei s fo r : i Icinpera
tnr c o f , r)0° C whic hi s : i typica lvalu ea t whic hpolymerizatio ni s carrie dout . Tli e solubility whe nexpresse da s ;i functio no f j'/jn , i s reasonabl y independen t o f tempera ture . Figur eGshow s severa lpublishe dret s o f data . (27-30 ) fo r

th evnpo r

pressur eof Ymy l chlorid ea s afunctio no f temperature . Th eful llin erepresent s wha t ar ebelieve d to b eth emos t

accurat edata , th emaximu mdeviation s o f othe r dat ainclude di: i th e d'mjjr.'irr. ar eo

f th eorde r

o f —10 % n t

C0°C . A nempirica l expressio nlia s bee nderive d fion t thes edata , th evapo r

pressure , p , bem;.* , ;;ivc u b y eipiatiui t -1 ,

' " '* • loR7»-f l + J;-M.7 aIo nr + c y ' 0 ) whereo « O. S 12

0 ••'.. • 

### 1 / - -nr.o. D C « ~0.00-.M1 5 • " p « vapo r

picssur c i natmospheres , nbsohile . . . V « * te.mpeiatui ei n* K

,

. Othe r physica lpropertie s o

f th emonome r

ar ej:ive ni nTabi c 10 . Muc hn f th eabov einformatio ni s take nfio mth enianufaeluiois ' technica llilcra
lut c (.'HI ) Mi dha s bi-ri i obtaine dfor tin : trchuira l r.iad c o

f viny lchloride , whic hi s onl y eWi l \\\).!i"/

(, pore . Th eimpuiitir s c^mprisr . .v.r.lyhiie , (onl y i l ft.- w part s pe r

millio ni

f thepolyim-malin ni s no t l o b ealfrcled) , aeetahlihyde , an dhi;;he r chlorinate dhydro
- (M\-cmsHth emonome r

h*„ * bee nmapufactun db y th echf-stea l mul evudn; ; acetylen eP.2 9

172 CnLO»OC\U))OXF. AM ) CJIi.t'JJ'.OliVDIi O " ' KUaW S

, ' Tid.fr
. ; . 1'liyi.io. l IV.n.i-iiir/ i
.. / Vinyl ' CI.UIil, :

» . tfirliiii," . |>oi/iI , * 0 . • . Jioilin r iinin'. , 7('.f

l m mI"j; , * C .trittifi c f;r.ivit y « , • ' 13.WC 20/r c • • '•'* . u p • • • tuifnr c Icftslon , nir , dyn/ci n• . . -30 C C ' , i • ' ~20' C ' .'<*. . ' -10' C • . ,'..*" • rptcifi c iir/it , cil/(j:)( e C ) . . " •••.•' ; liquid , 20° C ; .. . * ' • .-;.. • Vf.por , 25' C , ' ; • .•;'.."
- * Ctiticn lIcmacrntnrc , ° C '*"••
- ' • Ctilirc l pressure , .it m.•• • . .•'•.' ' 'dielectri c constant , J7;2 e C • • . IU-A Io f combustion , I.S'C , ronsf.-inl . pressure , keru/jj-mnlo . Ldtn l Jien t

o f tv.ijiorntion , cnl/ p ..b P. .. . . ' . : • .25' C : Ifttcn l lici t

of fusion , c-il/r

j flftslipoia l , . . . ope ntup , ° F' •, . •close dcup , " C

. f-clf-ifctiiliontemperature . * C ' • explosiv elimit s i nnir, * % b y vo l viocosity , liquid , cl ' . 

### , " -<o° c. '
' . ~30' O
• -20' C ' . . . r.* * ' -10' C ' . . - ^••'A . Vnpo r prcP-Mir o . . " •' . • •'

"C

* atm - 3 0 0.5 0 '-2 0 ' 0.V 7 - 1 0 • 0 1.1 7 1.7 0 1 0 2.4 3 °C

2 0 .1 0 '5 0 6 0 G O i

•* -l.*.3. 7

0.W2 ; .1.401 0 * •• 23.8 7 2?. . 2 7 20.R S . • •0.3 S '.0.20 3 }!>SA 52. 7 C.2 G 2S0.1 G .79.6 3 • ' 71.2 0 18.H , -10 3 .-7 S 47 2 4-2 0 0.333 0 0.302 G 0.27S D 0.250 3 aim 3.3 3 4.5 1 .0.0 4 7.8 0 0.0 3 * Tli einoi t

readil y ifcr.il.ibl c mixtur ei s lb.i l conl.iimnj ; 7 % viny l chlorid e(1) . pounds ) bnii £abou t

polymerization , thu s obscurin g thei r inLcrmediat c presence , findliiiidei'io** , t

lieii t'pi.iiiiilalivcsliidy . Wit hchlorine , viny l clilorid eform s U.IMiiehloroethane . (se c p . l.'iS) , an dwil h bromine , J-r.hloio-l.^-dibioiiioeLhnn e()) . I nth epresenc eof zin c chlorid eo nsilic a {*c!, hydroi'.c nchlorid ecomhiuc s wit hviny l chloride , a t abou t IfXrC . l o giv e1.1
- (lirhlnioilli.'ui e(se ep . MO) ; r. t roo mtemperatur enn din.ahsrnr o o f catalysts , hydii>;*c n iodide , in.•.iinilu

r fashion , form s l-chloro-l-iodoe l lunie . Sulfury l chloride . (SO.C'l : ) , it ) th epiesriic c o

f pyiidiue , read s wil hviny lchloride , a t ordinar y temperature , l o (•JV C 1,1,'.Mi•ieldoioi'lham
- nn d2,'J-dichlo i no l ban c st'lfony l ehloiide . JJvpochlorou s Acidimd\iny l chlorid etra dt o yiel dehloroacet.il.Ichyde , C*IC * 1T r C"1 1 ------- O (0,0) . ) u th epicseuc eo

f nnhydioti s rihiiuiiiuu t

ehloiide , viny lchlorid econdrme s wit h ctliy l rliloiide , nt

.'i0 n C , yieldin g th epioiliicls , l.l-diohloiorlhaii c an d1, 1 ,:bl : ic.htoro
lutlnne . (7) . A

t 0-6 o O , vii i.

v i chlorid eicae.l s wil hbciw.cnt: , i nIh o presenc eof ••himiuu mP.3 0 •a 

## .HS°HL )'i;i'.i;o:. A.'!
. S-I IV,X:

f .yC/iK U Yr\\..:\\ N'-j
. •p, p v ' ' •• ) '• <

p ^ ' ,.•••'•(:h a ro o C11fckojit*
. K;;aclo r Dro p Valv eClose dV<?S Slurr y lic.-i:1c: r

Valv eClose d' >

• • • Charge . Po t

Valve s Clone ds A* ; 1 i l« i I : or fu : a1 Pr

c s s ur e,,•»/,• ) . j? IY^C Glycerin ebeve l f_ AM S hot;Li ePul l nn dI nPlac eX— Jiat:c hChar Li nPlac ean dPens 7 Inkin g Tit C i nman . a t

fj * _/•___ . Oper a Lor : ___^-__r<___2__ _ ''.•'.'•ICl'l . . ^ a wMai ; o r j. o Is : Agitato r Spee d •/QQ&. •*c>i*I x(Soln.^o./^V^ ) / ^ ga l ' .tor (I ) A-f-.r

T ga l (II ) /fTf S a j . . >'lnnl ; Ques t e x 

## 3 l b

. 1 ii.;* ) nun Sulfat e diuir , Nitrit e 

## 5 l b

^ / ^ gra m l b litiato r /H_P ' /c l l b l b l b •c' d VC M rgi n VC M >orator : v . Hy(H'„, c,_, fPO QPQ - l b l b Batche s afte r Clea nhip , 

# .-^'^•_t' J Afte r Charg eCheckou t Set : I'oV.VTliMPKK'ATUltli : /3y/ Batcl i leve l Befor eHeat-Up : ,•<' Hig hPressur eSe t

Poin t Kuplur eDis c Statu s Operato r 

# XX

u.± s :> 

## ° F 

# I 1 

# " _psi g o

. J//rfitj?< UTcrtir l natio n 

## ( D
' (2 ) (3 ) . Additive. 1
* Operator :

« Droppin g C^-H^PS IPressur eDrop , o r ° FJacke t

Temper.• ! Cur e, o r Jiourj ; n t

pol y LeriL-i-vr

atvijv . 

# cs i ^r^c^rib ) biThi ?

# gfi

M -ovny . (gib )
Degassin g Tan k s<r ~ Dro p Valv eClose d 

## 4 

# £•/* /
/ ^ Slurr y Heade r

Valv eClosed ^ Operator : _£-• /H "



# Z£ mi n Strippin g Strippin g Tim e Strippin g Temperatur e ^{A'(L3 °^

- * Operator : LHlJ^yL Blendin g , ' •• - ' Blen d Tank ' ST
Blen d Numbe r ' S-

- • Sampl e t o La b ( 4 o>; . ja r o r plasti c bag ) Operator :

OPl-RATIN

C T l MI- ACTUA L (MIN ) f»T » (MIN ) HI-ASO NO F Mil.A

Y >s l Batc hDroppe d tf ; nt:; hPredu-c k 

# A. <,><r :CL ^.<X> : >\h; hH; : 0 . Pro.nt x /• : Other
- Ingredient s '•^• hVC

M J!£^J.^'2: '»>;'•'. . Hcu-u p lyV : _-/<
_ '^'•'• hPressur ei^.o p ^H^X'^ '
• n,;;l > Ten,*.'natio nf)'T Y?•"<* " ___ L 

# 3 ' JMtMry**X^X?^> / a 1 5

. cT; \ 

## r>

5P.3 1P.3 2


### "'£^: FORMOS APLASTIC S CORPORATIO NDELAWAR E \~H/ P.O
. RO

X320 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302) 834-457

5 Jul y20 , 198 4 CERTIFIE D KAI L RETUR NRECEIP T REQUESTE D |*> , rr.V. . 3 y.x- i 

# M-''y- '" ' Manager , Ai r Resource s Sectio n EJ^ ; C < :

- '"'.--.-•••*."> l Delawar e DNRE C fctflTiV^ '°- uUv ' ' Rober t R . French , P. E Manager , Ai r Resource s Sectio n P . 0 . Bo x140 1 Dover , D E 1990 3 RE : VINY L CHLORID E MONOME R RELEAS E FORMOS APLASTIC S CORPORATIO ND E Dea r Mr . French : I n accordanc e wit hth e Stat e o f Delawar e Regulation s Governin g th e Contro l o f Ai r Pollution , Chapte r XXI , Sectio n 13 , Subsectio n 3.2a. l Formos a Plastic s i s submittin g thi s writte n repor t o f a relie f valv e discharg e o f viny l chlorid e monomer . NATUR E AN D CAUS E A t 164 5 hour s o n Jul y10 , 1984 , th e relie f valv e o n wast e wate r knock
ou t po t CT-21 0 o n th e VCM-wast e wate r syste mwa s observe d discharging . Th e ruptur e dis c wa s foun d t o hav e faile d an d wa s immediatel yblocke d in . Th e estimate d duratio n o f discharg e wa s 4 5 minutes , a t 14.7 % viny l chlorid e monome r byanalysis . Examinatio n o f th e sequenc e o f event s Leadin g t o th e discharg e indicate d tha t probabl e caus e wa s wate r whic hentere d th e CC-12 0 compresso r caus in g a n overloa d an d subsequen t overheating . Thi s trippe d th e compresso r moto r out . APPROXIMAT E TOTA L VINY L CHLORID E MONOME R LOS S DURIN GDISCHARG E A n orific e calculatio n wa s mad e yieldin g 5 6 SCF Mflo wa s air , o r 6 0 lbs . a s viny l chlorid e monomer , a s follows :

cu.ft . lh^. (5 6 min.air ) (4 5 min. ) (0.1.47 ) (0.16 2 cu.ft. ) = 6 0 lbs . VC M ACTIO NTAKE NT O PREVEN T DISCHARG E Th e faile d ruptur e dis c and relie f valv e wa s immediatel yblocke d in . Ou r utilitie s departmen t ba s take n actio n to : (1 ) instal l a ne wtemperatur e contro l an d stea minjectio n syste mfo r CD-21 0 an d 211 , tb e strippin g col
umns ; and (!•" ) installatio n o f ne wtemperatur e control s o n th e CC-12 C compresso r moto r (moto r va s delivere d wit hincorrectly-size d temperatur eRober t R . French , P.E . H . Alle n Wrigley , Jr . Jul y20 , 198 4 pag e 2 o f 2

controls , o r "heaters" ) t o preven t a recurranc e o f prematur e moto r trip-out . Investigatio n o f feasibilit yo f compresso r CC-12 0 hook
u p t o the scan-alar

msystemi s als o bein g conducted .

Sincerely ,

H . Alle n Wrigley , Jr . Environmenta l Manage r HAW:jc cP.3 4

.r^r,*^*-*
- ._*-.* • 

## <py\ *~£" FORMOS APLASTIC S CORPOii/-.,-, , . . rNT 

### , r 

### „, i r 

### „. n T 

### , pt- / "• ' p y, t DF TAWARE

- ^ P.O . OO

X 31'0 •-DELAWAR

E CITY . DELAWAl

u, . . . VL.)*I\.W

*\i\L. / / ' « "tl . (30*" ) KM-45/ 5

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D

Jul y25 , 198 4 

## JU L ''-" ? --- •

Rober t R . French , P.E . Manager , Ai r Resource s SecLio n Stat e o f Delawar e Departmen t o f Natura l Resource s nn d Environmenta l Contro l P.O . Box140 1 Dover , Delawar e 1990 3 Dea r Mr . French : RE : Viny l Chlorid e Monome r Releas o Formos a Plastic s Corporation , p, , | • W/|f( i 

### P 2 8 < * -••«''-.' 3 

## {-^iCi-i^ r F0ruc_ : 

## i r ' i:f,..; j -\;A M N i l till * W KiW.M V t : ...-< • Ici v• '•".i"ij'iTn 

### iQH^I <o ^ <_ ^ ^ •^ > 

### ^* ^ <- _ rr'.iii f<.:•••.<) ~C^V^JL^_T-

_VCKQ.O ) 3~ i

In accordanc e wit hthe Stat e o f Del.-^..,, . o f Ai r Pollution , Cha p i s submitting thi s wr Nrt_tur e an d Caus e i

e Stat e o f De l tv

. pte r XX I S* 1

- ''''•'• ' Regulation s Governin g tbe Contro l •in-nr,Y,.'nr. ^ ,< n 1 • > Subsectio n 3. 2 a. l Formos a Plastic s " Viny l chlorid e monome r release .

th e reacto r int o the reacto r bui l • * ' \ VluV' l chlorid e monome r t o escap e fro m '>• >n\ d atmosphere . A n inspectio n o f the botto mvalv e *• > , , . valve togethe r ha

d sheare d off . -».. \ tll e studde d bolt s whic hhol d the t o n metallurgis t t o determin e the'^\ !:tUviii

- valv e an d valv e part s wer e sen t waiting fo r a writte n repor t fro n * »V! Ui? ° o f th ufailure . W e ar e currentl y However , indication s ar e tli e stud s ^ . ""Allergis t o n hi s determination .

" k " l ' ° over-torqued .P.3 5

Rober t R . French , P.E . -2
- Jul y25 , 198 4

Approximat e Tota l Viny l Chlorid e Monome r Los s Durin g Discbarg e 13,23 6 lbs . o f viny l chlorid e monome r wa s los t durin g th e discharge . Metho d Use d fo r Determinin g the Viny l Chlorid e Los s 3 A t 6 4 psig , PC-ILC 1 = 55. 5 lb./f t (assuming tan k vapo r spac e i s • saturate d wit hVCM ) ST-305 , accumulato r tank , capacit yi s 460 0 gallon s - Se e attache d equipmen t drawing . 460 0 gallon s ( 1 ft. 3 ) = 61 5 ft. 3 (7.4 8 gallons ) Therefore , ful l tan k hold s (55. 5 lb./ft 3 ) (61 5 ft. 3 ) = 34,13 3 lbs . Leve l indicato r showe d a 33 % increas e durin g th e incident . 34,13 3 lbs . x.3 3 = 11,26 4 lbs . came int o accumulato r durin g incident . Becaus e o f emergenc yequalizin g procedure , 4,50 0 lbs . o f th e abov e 11,26 4 lbs . came fro

mReacto r SR-403 , whic hwa s bein g charge d (an d weighed ) a t th e time . Therefore , the amoun t o f VC Mrecovere d fromSR-40 2 durin g th e inciden t wa s

11,26 4 lbs . - 4,50 0 lbs . = 6,76 4 lbs . o f VC M Therefore , amoun t los s (assuming negligibl e polymerization ) 20,00 0 -6,76 4 = 13,23 6 lbs . Actio n Take n t o Minimiz e th e Releas e O n Thursday , Jul y19 , 1984 , batc hS-373 4 wa s charge d i n Reacto r SR-40 2 a t approximatel y10:3 0 A.M . Th e batc hwa s i n it s heatu p cycl e an

d had reache d reactio n temperatur e an d pressur e a t 11:3 5 A.M . A t thi s poin t i n th e reactio n cycl e a lou

d nois e wa s heard b ythe operator s i n th e reacto r contro l room . Th e "A " Operator , Thelma Donovan , wa s chargin g viny l chlorid e monome r t o Reacto r SR-40 3 a t the tim

e o f th e incident . She had pumpe d i n approximatel y4,50 0 lbs . o f VCM . Upo n hearing the lou d nois e she immediatel yhi t the emergenc yshutdow n butto n o n the weightank . Thi s shu t dow n the VCMpumpin g t o Reacto r SR-403 . Th e ga s detectio n systemsounde d withi n second s o f the lou d nois e an

d the sprinkle r systemwa s activate d automaticall yb ythe ga s detectio n system .P.3 6

Rober t R . French , P.E . 

### -3
- Jul y25 , 198 4

Jerr yJohnson , the Are a Manager , wa s i n the SPVC- I reactio n are a a t th e time o f the incident . H e immediatel ywen t t o th e SPVC-I I contro l room . H e in

structe d th

e "B " Operato r t o do n hi s self-containe d breathin g apparatu s an d ente r the reactio n are a an d star t ventin g Reacto r SR-40 2 t o the VC Mrecovery system . Asecon

d "B " Operato r arrive d an d wa s instructe d t o equaliz e Reacto r SR-40 2 t o Reacto r SR-409 . Reacto r SR-40 9 wa s i n standby . Th e equalizatio n o f the tw

o reactor s wa s accomplishe d b yopenin g the VC Mcharg e valve s betwee n the tw o reactors . Sinc e the viny l chlorid e wa s bein g release d insid e th e reactio n area , the decisio n wa s mad e t o pul l the emergenc yven t o n the reacto r t o reduc e the pressur e o n the vesse l a s quickl ya s possible , thu s reducin g th e ris k o f fir e an d possibl e explosion . Th e emergenc yven t o n Reacto r SR-40 2 wa s i n th e ope n positio n for five minutes . A t approximatel y12:0 0 noo n the vent s t o tli e VCMrecoverysystemwer e close d an d the n reacto r wa s vente d t o th e evacuatio n jet . Onc e th e pressur e o n th e reacto r reache d 0 psig , the lowpressur e ven t systemwa s connecte d t o the reacto r t o preven t VC Mvapor s fro mbein g release d insid e the reactio n area . Usin g the Area s Continuing Monitorin g Systeman d Ga s Detectio n System , VC M level s i n the are a wer e monitore d an d onc e theyreache d th e saf e leve l the sprinkler s wer e turne d of f an d a n inspectio n mad e o f th e reactor . Additionally , the Plant' s Disaste r Pla n wa s implemented . Th e fir e departmen t wa s calle d i n t o stan d b yi n cas e o f a fir e o r explosion . Plan t personne l too k quic k actio n t o brin g the emergenc yconditio n unde r control . A s a precautio n unti l i t i s determine d wh ythe Pacifi c bal l valv e failed , w e ar e replacing al l Pacifi c bal l valve s i n reacto r service . Measure s Adopte d t o Preven t Futur e Release s Th e immediat e actio n take n wa s t o replac e the bal l valv e wit ha singl e bodie d valv e whereve r the

ywer e used i n th e bottomo f the Solid s Additio n Pots . Fu tur e measure s wil l depen d o n th e writte n repor t fro mth e metallurgis t o n hi s findings . Shoul d yo u hav e an

yquestion s o r nee d additiona l informatio n pleas e giv e m e a call . Sincerely , C . W . l'.ager ^ Operation s Manage r CWU-.l l Attachment s bec : Stephe n Herrmann , Esq ,P.3 7



# . ®

A5M EX\VI ' (,L)LVC\5-

> ft IIP , / ,^ , /



### . . * 

# V ^ 

# ^ J/Nd^v f 1 

### 1 ^ 4 McXE :

•/.J ? / I £;2o : i / X• ••: .

JACKC7- , 

# C2/f^ AHoLL5 ,



# ' _L
_ 4SCU.-1 0 (TYi'. > 

# <B > . j^rrri^f^-4.
- —-V—Ti l-r ) (p ^ « < —->-

• p/Mr'i.r

i JA c 

### K/-:r
- / /

^'/ l 

## .'M(B ) ELEVATIO

NP.3 8



## •vQzr V FCRMOS A

## PLASTIC S CORPORATIO NDELAWAR E v H / P.O
. BO

X320 •DELAWARE" : CITV , DGtAWAR E 1970 6 •TE t (302 ) 834-4575
CERTIFIED MAI

L RETUR NRECEIPTREQUESTE

D Jul y 9 , 198 4



# RECEIVE D

Mr . Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Stat e o f Delawar e Departmen t o f Natura l Resource s an d Environmenta l Contro l P . 0 . lio

x140 1 

## JU L 12198 4 ENFORCEMEN TCAS E ACTIVITIE S SECTIO N

_>« J V n , 3 I' P r\ n RE : VINY L CHLORID E MONOME R RELEAS E

FORMOS APLASTIC S CORPORATIOND E * Dea r Mr . French : I n accordanc e wit hth e Stat e o f Delawar e Regulation s Governin g the Contro l o f Ai r Pollution , Chapte r XXI , Sectio n 13 , Subsectio n 3.2a.l . Formos a Plastic s i s submitting thi s writte n repor t o f a relie f valv e discharg e o f viny l chlorid e monomer . Natur e an

d Caus e A t 144 2 hour s o n Jun e 30 , reacto r SR-40 1 i n the S-I I plan t hydrostatted , causing failur e o f a ruptur e dis c a s wel l a s a discharg e fro mthe relie f valve , o f on e t o tw o second s duration . Atransfe r o f th e batc hwa s immed

iatel yinitiated . Subsequen t investigatio n reveale d errati c deionize d wate r (D/l ) mete r readings , whic hled t o batc hovercharge . Th e errati c reading s wer e cause d no t b yfaultyD/ I meters , bu t b ya partiall yclose d valv e o n the discharg e sid e o f the D/ I meter . Approximat e Tota l Viny l Chlorid e Monome r Los s During Discharg e The approximat e tota l viny l chlorid e monome r (VCM ) los s t o the atmospher e during discharg e wa s 17 6 Metho d Use d t o Determin e VC Mlos s A n orific e calculatio n wa s mad e base d o n a releas e o f two seconds , the duratio n o f discharge . Actio n Take n t o Preven t Discharg e Immediatel yupon discharge , th e "A " operato r initiate d transfe r o f the batc ht o the degassing tank , wit hthe late r assis t fro mthe foreman . Con
firmatio n o f the relie f valv e properl yreseating wa s the n made .P.3 9

Rober t R . French , P.E . Pag e 2 o f 2 H . A . Wrigley , Jr . Jul y9 , 198 4

Measure s Adopte d t o Preven t Futur e Discharge s Investigatio n i s bein g conducte d t o quantitativel ydetermin e the effec t o f valv e throttling upo n th e D/ I meter . Operator s ar e bein g give n additiona l training t o emphasiz e the effec t o f valv e setting s o n D/ I flowmete r performance . I f yo u hav e an

yfurthe r questions , pleas e d o no t hesitat e t o cal l eithe r Mr . Rober t Boye r a t (302 ) 836-221 0 o r mysel f a t (302 ) 836
- 2219 . 

# 6k&M H . Alle nWrigley" , Environmenta lManage r HAW:jc c CC : U . S . Environmenta l Protectio n Agenc y Regio n II I 6t han d Walnu t Street s Philadelphia , PA1910 1 ATTN : Mr . Ro n Patterso n 3AM2 2P.4 0



## G £>->e>e <

4 o •£<*

& w) uc 'A 

# vJ^CtftpJ- vYI



## p-*- x 

## ) 

# rt* - i/,os - *» . '" . 

# 7h' (SH

•> - - c; 2

__ . I<"- v



## \~1 io /bs > <_H- ^ ,v»^r * Sr*X

£ ^ ••£"

* „ 5 S <-"

* '**" , • 

## V Cl~\

Wn •^g.- W"hry-~ 

## 'own a r~iP.4 1 i'l) : uo; ; I'A. i I;KSO NOA N'.' ) 'Xh ^ I'OiiiM(.).'•; Ai' l Ml.TiC S CCdirO.- . .']H>l i D l i ;• • \vA11 K HJ H p o IJOX;i , v i » i j f

i '••./,' . > i .1 . oi l v . r- i i PPVVA Ini : . .p

. • i ; i (i n', , n u vri\. 

# - r 

# 'EIVt

.Januar y .'0 , lOb' l 

## APR2 ?98 4 SPECIA LCOMPLIANC

ESECTIOK

" EPA , REG/O NII I

Mr . Rober t

H . French , i'.h . Manager , Ai r

Re:iource. ; Sectio n Stat eo f

Delawar e Department , o f

Natura lReaource r a n dlrll V i !"'(

. > i IliUJ l il,.' i Ii ' i 'il l m l P.O . bo xI'lO l Dover , Delawar eIWi 

## * ' 'JA N 2 6198 4 •:_ii> . S\..-J

MAT E O F DELAWAR E U'. V O f li'VU'ONMENI- M C.ONIROt . V/ILMINCIO K

OhflC E l.i. : Vm y L''i : hii'n.u
- ! v;w i MIII . - c Releas e l'V;]-|li p i;i . i '• 'La . '•! . i i:.' . i \< l - | 'O i 'a L i O l /

\)\\. Dea r Mr . l-Venc h I naccordanc ewit hStat eH' U-I.-.WH V!. . y u la. ) ion: ; hovemln g tli eCon
tro l o f Ai r l'ol'lu l iuii , Chapte r X• . I, ."••• i i.. ni) , .

* "ul.»:*. i -i; l i < > ; i •i.^a.'.l. , l-'oi-imx- a Plastic; * l asubmittin g th!.
- wril.i t i , I-I-J-.I- Io r

..ye n(y i • Ii : •.

. • ! i;ii-f';o; ' fro m emergenc y relit:!. ' v . 1 1 v -:.* . wil hviny li -

JJI > • - •»• i
- • !•••. . i nU r

a i n• -.phf-iv , whic h occurre da t

I'^l' i liuiii';- , -

. J

_J.lanu.ar , Hi , lua' g \'<, I| . ' Wi i ; g I'ailui'p
- ol " bot h electi'ica l power ' r.uop.l y aa deiik-r . . - i i>- y I«'W< Iba.-kup .

- •" I Natur ean dCaiui e, ! ' A t 1.3'l' 3 hour u o nJanuar y I'.) , *.h'
- ! v 'lr.var.
- • " i t. y plant , a t

Kormoy aR'last l cr . experience dapowe r ''ai'lure , whic haim i d>...i ! al lpowe r i. u th eplant . l\me.r
genc y powe r

fo r th eS-1 . an. I.)•-: ' plan;..- , w.. . U.. Lava l lak hh.-.-.'nir.i ' th eemer genc y generator s supplyin g l.hur. epluui r li In.| . peri'-i'm . W i tli- . iiil . emergenc y powe r fo r agitation , th ebalch- k i I Ih r pr • • • > mn - i:: . ri ' ' 1 I')()'.; ' elT.'ctive . Althoug hoperator s Wer e.;ur.m:;:Tu l i nv.i'i. i Ii-.-.iu-' ; :;>-vi-raIr < ac ' or: : a t

hig h pressur et o empt y reactors , thu s e.lurin g lb
- numbe r o p release:; , seve nre - -actor s ble w rupture ' disks . Th eS- 1 emergenc y powe r i •< - nr.l-n r d i : sie c .;s ; u'My ..lart , bu t shu t hew n o nhig htempei'atur edu et o afault y i . raur.I'ei
- switch , '..h i hpr'eventu dsuppl y o f powe r t o th eemergenc y generato r cuiday ; ran . Th.-
- :'--. ' emergenc y "\>wer generato r

di dno t

star t du eL o afue liu • 1 iu-...**

• 1'auit , an. Iuvererauke dunti l th ebatten'ie s wen t

flat . Approximat e'J'ota l Viny lChlorid eI'-yijoiiipj ; J,ys s hiirlii r Ii i s diarg_ e Th eapproximat etota lviny l ehlm-hl en, > <inHH . - r (WM ) lo:'.. : t o th eatinuaplie n durin g discharg ewar, l.(>,uY. ' UJ: ; . Iikltvhliu ! lease s wer ear . I'ul . low:; :Huber t H . I'riua h .Januar y .-•>, 1'iH'

i Pa^ u 'J\u >

S-^_l'l;u} t V^'U-ti-j r No_ . VU-'

i I/'.;: ; (lbs. ) 

## P R''fid' ' ""'"•To'iy. T P R'10' i I'.lb. M P R 'io; - I'jkk. o S- 2 Plan t "Reacto r

do . VC

M ho:;: ; ( lbs. J SlHll O " ' ' ':>Ci?i"\J)"' S Riio i r.'Ci'.sy . ,- • SR'10 8 jOO'-S.' l SR'K Hi\ 00.0 Metho dUse dt o JX." . < • rmi.n o VC

M I,iy.• • Orific eea'h.:'11.'ii.ii'ti s wer emi. , v I'o r aJ'e leas eo f

on eminut edui'atiu n fro mrupLui'p ' dis!- ; ;' • iiur . l er.-ll«- r

valv ej'.-ri.a LJ'o r

eac hreacto r

i nit s respectiv esl.ag. e• >! ' reac t Lou . Ca! • aflat , i > -n s a nattached . Actio nTake nt o IV.-ve.n l P i :.; • h aeg . Th eproductio n-op . raker s I'uiluWe dth eprecedum . I» r I'oWe'i* Kai l ure . Terminatio npromicr. ' !'o r eac hbai-ri : u.iiic : Ai-'L'
- was , a.-.- , .i.-g lis.he dwithi nte n (10 ) minute s . Addition.ij.| y , th e< s nr;. 1 or s w.-rc - r.ucc . s s I, i Ii ntransferrin g nuteria l fro mIrij'j i pressur ebati'b s I.C Jempt y rcicter., , knu. ; reducin g th e numbe r oi ' releases . Concui'j'eni.l y will . Lb
- ub>v.
- i plVrts , aii di nu m- • 1 i . * t * . - i • / upo npowe r

failure , pi'Oductlo nan diinintena.uc c pe'r s • >ni:..- 1 worke dquickl y l o provid eemergenc y powe r and/o r rostui v norma ] powe r I. o lb
- plant . Measure s A-kipto dt o Preven t lAilsr . • Discharge s LimiodiaW
- inve. u igatiui i condii-tc dI. v tn-hnica l i-T.'-m: ; i nth' • plan t a t the
- tliix : ol ' powe r failur ereveale dapu ai.e-phas , k.iui t o nth' • K--

P- . undergroun. i I'c'p-der . 'I'hi s J'aulL , . i ; . ev.i.ien.- i dh

y w.ul.- r l.ikrusioi i o k

th e conduit , cause daDelunrv aPowe r an dLlg.n l riivui t

L nat.'. r

t o • > j ••

- 11 , shuttin g dow nal lpowe r

l o th eplant . Anodikicc ) L. nt o th ' syri..,-m , mc.-u l l y com - , . pleted , allowe dAsola t io no k th eI'aul i i ul'e.-de r lin e.' , alh'Wln
- m..loj',a
tl.Ol l o f powe r fro mDPM . t o Pee dr lin eI .Robei' LR . Drenc h

Januar y Pi) , l-.J-'S'

l Pag o Thl'o e

Afulf-se aL

o investigatio nwas , i im , u 'dia l eI.

V begun , resultin g no t onl y i nanalysi s an drepai r o k il-oiir . wiiic hwor ecausativ efactors , bu t atas k forc eassl.gui:n-n i t o impj'ov ebash : desig nok , an dprocedure s relatin g to , emergenc y powe r

equipment . Th epowe r

failur ewas . simi ! i r g • lb
- on elhat . occurre di nJovemb- r l l Ju. ' o nth eu u . lergmui r Iloa dline
- I'o r

ih eSP Warea . k'. v lik-nc eo f

simik a watei ' intrusio nint o th econdui t i uv. , '\\iXykailui v le dt o "hig hpot " testing , o f

al lou r

undergroun dlin> s i nSprin g " k '][)..]'

J tiwit hpassing , iv
- sults . l u thi s in s lance , no' , onl y will , ih ekaulle dlin el: e replaced , bu t th econdui t

thoroughl y sealed , an daweathe r hea dInstalle dtha t wa s no t par t oi ' th eorigina lInsta'Pla i ' . .,-i . Min

- P.-.' ' loa dan d.''.PV

C keede r

liner . Whic hWer elust.alL.- da t th es.in ek.lin . a s th etk, 1 I'eedei' , bu t whic hhav e no t failed , wil l b epurge dan dseale dalso . Specifi c mi i i iteiiaji o • Ituii s relaip.. dt o I'epai r an dupgrad etin. : syste m are a S- 1 o ri''Win d g i nej-a i o ro rpurchas e newgenerator ;

0 ch u i , .

• • ti-an : -

, l'e- r switc hJ'r-a

mfr i :•'. . b> aclutc ht o spring-loade d, elect ! b-a l l y L eI dl.yp . • ; S- 2 0 repai r

Pile.I . reservoir . Additionally , al l 1'uu r generator s i nth eplan t . v P I! l etie dtog...'ther , S O tha teve n"if

thro eed" th ePou r

g- - -ms-ai . >wtailed , wewoul dhav et.b : capabilit yoL'

supp ! y.iug'emergenc y p •>•;:• r t o .-.I Ir-acLo r

a,'; i Lat ors. . Ad

di tionally , wewil lha . v. - th ecan..!/ . !i i . - >| ' m-.-.l in g an, ; o r al l ge,, , ;-,- ( tors - unde r loa d i nnon-powe r

failur e(norm Psuisl./ ) cudltio no k tn . p'lanl . I f yo uhav ean y fui-thei ' q ; .e.s . iu:, . ..-• • . K.- : • i . 1 • > •....Mi l i ••*'•• : i nkerm dio n, pleas ed o no t

hes.ilai et o cal l ur, . ' ;Unc i rel y , /•/
. u: ' 1 p . ' 1 : > . '- a\

. ' 1 ) • II
. A l le n Wrigley , ,'lr
. l a i v1 roiin u 1 it a I M inar. i r 

### llAW/nia h Attachmen t/ ' • rK > <• i'

. / 

# A/A, - ) c 

# Q > 

# n (yxjj>) CtrnMlhatl

CX HH'AH- -IAI-C^



## d/.eJ/i...

'l^^K'' /..J.b''/'( i'C it <£«•** t. /H

/'• ..t~-x i-<'...« {•)) •-• C S I. /.. . 

# 0. . -vl '



## . ^ w • ;?* * / ^ • = j>/*/

:i 

## ?./'s/K C-^-H.A^y finely^uU^o jj.*<-,' 4$J. *¥>(•'%*f iX....y.H -£.<4•ti-CC-X-*£tr~ve. U 

### /-''{} . '%6f

C'Cj (

### , 

## /H /iitsct-hs fA'/to <\)a.o->. &?,&% (y/j 

## v

'2- - 

# A-- c,&- 

# xM
p - Q*>O+I.<}P){Q

## .fH/^xjoyfH,l^_...

" Z = ' *< f

^ 

# "f'XX'rX'* &'/, yy -3**'/



# \J ~CjJ X ty?7)(6t



# }y)C*o 9 

# ) ^_2ty Z._

- 11U>^3 t-i-\.- 

# (H,< y 

# t*A~ 

# (JAlhlJ/iySin^xl

.=

_ /^/? , * /^

# yiH

£o?d H . /.-/vD
Xcrr-f.H h(>

f ^' C^L^'/'C. (

4*,***..*«-

A7 " &•

xv >H H V )



# __._.. _JW . -..£**/*> x 

# 0- *Y.7P£ 

# ^

._.. _^.w^O m . ' fL'iH^^ /Hs:-j 1{X<'<^

XX, -&'7*

ff < : 

# <>



# . X*t X<^ («•* *>*•&-£>-. Yo

»:f Lie/;, JtJJ

J

- . . . HUM. C

"Lj Pft <fc 3 lx)^<L, 3-4

%-> 

# 4,

__ _XrA9f. ' _..

_. ' 

# -1- 

# c3$

# X\lX

(fid *) 

# _

_ 

# a .rr.iir^
__

. , fH. x^-t/^o/^

fX?-'- oc 

# >''// }£ 

# 'X-..-

__. _. ._ . f1 -~(6

<>>*'. *-*»%)

V 

# ' (•(?* t'X> 9& f_. 2 - .?, f £ .. . 

# X = /7t V'^£*£*£. U)-£ C/y/lr TZB



# - &$(*'/?)(*. XX^pX

faXfX)

... . ^ f'1<ffr ? 4 

# 'At - ,'r/r, Z. M



## /I^H 

# Jxt.^K

tl 

# fhn^ •[ tXuXX-

/':U\ tr Y : 

# y^ , /-/ ' yP.4 6

@ 

# yn^or cfy yg>



# . . CL 'A-^- 1 

# A^> ~ " C 5 ^'> A.. . ; iv V i 

# f CilH (.u,^(L„. K^/° /y ,.rr£y\-<-

<^ f *"'<' ' 

### S'oo ^ . ^ ? 

### ^/cL.. . ... •_ 

# C/*co,,V- . /ev,Al , /J^ . 3 X^- u> ^/ , . <A*A ^ ^ (Ai^yJ /w<aiX'l'-lu Cx^irCiX'iL- , %/-/ i/(In i't X AtaX^H

pfi<{••>*Ci/a^3 , ; 3 % „ . 

# K- M 7 ft~- 6>7fr LX

<=<- _ 

# C .-^.nr " f
_= = ^u ifi»)l ziiX]~ s^ <.y A ' t 

# '- 9, U T ^tob <^X . * n(> 0



# X 

# X-uXf 4



# = fe^^ri) ^ JJ?; ^f-W^j^ ; 

# fy.->eyyu - ixrA...tnn

#



# __.d ir 

# ^. . A"- ) < /

'-'•- ) .= - ,/rr.H * -^•- - 

## f/LV*"L-P.4 7



# XXf/b (y-KnX Coy^cLtX^($•'

/<<<X<LC



### X< ; 

### C /*-U-"- }



### /L*> "XHHXUX*

# •

' h'/°f- ^ A^-vu g ^^^"-^Vv.i:j ) finr^iV ' XH<XI



# i.tU^> /J-A^it^XI > ••<"/'/"

Y 

# un,X J 

# /Xl Agv u c^i^,fc£., (

# «^

> X t/cu., Xj^A Aty^X'

5/?9/t> fiO«A-. LJx^X* ''-ta/ik-,. . /cy. U<iH

I X^ t^y. A/^V. . X^^-Ls-X 

# Kx'-n / / -r - U-Of f 

# L fit ) C H >?X .. . ' •j 5 

# AQ)o V



# yH f 

# X/:^7 A7
- ^" 7 A^' ^ is - - ^ '• •" "•"" '



# A./A^ A*// ^

•=:- «Ap vlj 

# VnX 7 

# XXLHX / t,x --. 

# .{^:.HU 

# Xf(x?nny)- ?(>.•></& -/X'H'P.4 8



# _ ) 

# SfH'l (tf-ryo) Cv^r. AA A
. r

. <&- - A./.'/-
. -i ; 

## X*

f 

## (^6-''' ^ "X^A^X^Hl

* H('l°( : 

## (•CUtUv.Q.. /oX /^iHr.aX) 

## /A.s<
. ;p.«..-^iA y^/^7/V a 4«'C.J-A H 

## . ' AaA A-yr t 

## .o ? , 7 £ ~ •/<<•»•* ^ A' A
. ( A A^.o>yf ' A<- i A^'<i vCiy\-nrcXlJL-

. AAA*' - : f 

## y ^t-jrvtutyky^

..:."A k 

## " ' ^^^ V^^rC-C-H'- 

# H, r. 

# ixxxx- iff. X'*

xy X.H.-D1X. .^.H.Aof

/ 

# /^,v ww 

# , ^ 

# #^y. r

y

# j^rA'iO i ( '

& ^ ^lA^lr . ? £* r?
. - r 

## __o,fi L X f.RXf- -> AV - 

# ^H t-xr.xji 

# -*r- ^^xXC'^'Xt^x Z<A „


# ^ JXX^Ayl

^/h L 

# ._fy._>bXX (, 

# /n^P.4 9 

# x yX 

# ^/or 

# C *
- 

# '?<)

' r 

## /w 

# (f- ^U</.'Ai<
. AA- X£<-H

... ( J 

### ><AH -' 0. o.o. fHjt)

•"• H'/'l X'.'

0

### ^. -

.. . 6ra.'^i.ia\. n . ' /A>ncCi\ fl L . uA -x

/ -/*<- , < &&J!.. A ^ *'/_ > <*



## . . . X^X

XJ Xnn c^-ueXl

. . 0 

## /o tf L'O-'LX/

_fy^ ..sUac~Col/

'

C s/<C'ft>tf

/OOAi i / A 

## i2-<-^- n-\H,- v j* ^

.(/c-t'iHtilix

**• ii-*-- a • ' /

^-w . t^.-i^tCy;



# . /A.^; 7
. . . A~.//.*r. XX.. ($,y

C*x? 

# ")

• C. flyX 

# (j> - (?**1 '?*)M

.if://7- = A 7 /^ A
_ n ~XJ- * }}%\-IC/*.*

CXX^H^X'--- z^X ^Y^XfHfX :r ~jj\i*f:.?.ken*£-. - - 

# W : : C 

# ^X X 

# Xr I 'J

-I 

# (iXXii) u/x-xx^)../

^G

-u I 

# Ijojo i. I

'fyir ' '' ( %H,. 

# W

« V * 

# ._..(3*A A"'V^ - ) (



# I *" L) fX^X'

f/ 

# / - * / 7 

# " 'P.5 0



## .____Xvy^.y^X*' 1 

## '* & ' ( A H'A / " " X ^C fy-Lt>-y)i'\ 1).^X4 U A 

## X^^
- 

## ' ' V



## ' i > ' ; 

## ' / ' ' -«•*-*•• c


## . A' A^-
- i * r-stiJ-cA') F/e<»^• cpp«* >y j



## . ,Vi

, - . ., . /«/v7p-A^— . •»"' X<<f-< { 

## .o h pr(y hUiA 

## nyy^\\\*--. &-*-....- . A ^ % ^ A . hhl

X.- AJ^&ns. SA^HH



# _£.^A.* 7 

# yj - - //^ r,:,/A - <r>.^

^ % A " ) £.- - ?3 r f_..^
. ^ p^ -

. »<r-V . 

# _._H^(6^.^-^^AAA- t (/. v 

# x6o'/:) - -?^ A Z_J?.J>>.J.L
. 

# _„ _r_'.^> ^ r£

* AA 

# v = XM 

# t. 

# nxS &r yr H 

# H^f^nn °*Hx\ AlXyny *lt(°?^X> ----

- M>»'K

'At,. r 

# X'XxfQ H.HH, ;)oH'l ,/ • ) s 

## ./Y V

## w-y-j ;P.5 1



### ^'•^ X



### - FORMOS APLASTIC S CORPORATIO NDELAWAR E P.O
. BO X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 634-457 5 Apri l 4 , 198 4 CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Robert R . French , P.E . Stat e o f Delawar e Department o f Natura l Resource s an d Environmenta l Contro l P . 0 . Bo x140 1 Dover , Delawar e 1990 3 Dea r Mr . French :

RE : NESHA P Semiannua l Repor t o f Marc h14 , 1984 : Addendu mRepor t o f VC M Lea k fro mStorag e Spher e PT-103 , Octobe r 31 , 1983 , an d Reacto r Releas e Novembe r 4 , 198 3 Referenc e th e abov e lette r report o f Octobe r 31 , 198 3 sent t o yo u regardin g detectio n an d correctiv e actio n o f a VC M storag e spher e leak , an d releas e o n Novembe r 4 o f VC M fro mReacto r PR-403 , record s o f thos e report s wer e forwarde d t o Delawar e Environmenta l Contro l Offices , but inadvertentl yomitte d fro mth e semiannua l repor t issue d Marc h14 , 1984 . Thes e report s wer e issue d durin g th e interi mperio d o f employmen t o f previou s an d presen t environmenta l managers , an d hence , wer e no t include d i n file s reviewe d fo r th e NESHA P report . W e ar e als o forwardin g copie s o f th e origina l report s t o th e U.S . Environmenta l Protectio n Agency , Regio n II I offices . I f yo u hav e anyquestions , pleas e d o no t hesitat e t o cal l m e a t (302 ) 836-2219 . Sincerely ,

H . Alle n Wrigley , Jr . Environmenta l Manage r HAW/jc c CC : Josep hJ . Hardman , P.E . /*?_£*"" ' U S EP AThoma s Voltaggio** ^ ^O^** ' *••*
- £ ix _* * '*-*» , 

# *^«*A* *P.5 2



## Z^S ^ FORMOS APLASTIC S CORPORATIO NDELAWAR

E NCZ-/" ^ P.O
. BO

X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-4575

Octobe r

31 , 198 3

CERTIFIE D MAIL RETUR NRECEIP TREQUESTE D 

# yJ~V

Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Stat e o f Delawar e Departmen t o f Natura l Resource s and Environmenta l Contro l P.O . Bo x140 1 Dover , Delawar e 1990 3 

### tfl i_L > WS * i i VLc

_?_ ^ AP R 1 9. iy* M SPECIALCOMPLIANC E SECTION EPA , REGIO N II I Dea r Mr . French : RE : Exces s Emissio n Storag e Spher e PT-10 3 Octobe r 17, . 198 3 Formos a Plastic s Corporatio n Delawar e i s filing thi s writte n repor t coverin g th e abov e reference d exces s emission . O n Monday , Octobe r 17 , 1983 , ou r lea k technicia n foun d a pi n hol e leak i n th e 1 " balanc e lin e o n PT-103 . Thi s leak occurre d du e t o the carbo n stee l lin e corrodin g nea r th e to p o f th e storag e sphere . Th e lin e wa s electri c trace d and insulated . I t i s though t th e corrosio n rat e wa s accelerate d becaus e th e insulatio n wa s bein g watere d durin g summe r operations . I t ha s bee n standar d practic e t o ru n cit ywate r t o th e to p o f th e spher e and allo wth e wate r t o b e distribute d ove r th e surfac e o f th e spher e t o contro l th e vapo r pressur e durin g unloadin g operations . Afte r the leak wa s found , Formos a Plastic s Corporatio n Delawar e too k th e following action : a ) An attemp t wa s mad e t o isolat e th e leak . However , th e lea k wa s betwee n tli

e storag e spher e and th e firs t shut-of f valv e o n th e balanc e line . b ) Notifie d surroundin g neighbor s tha t w e ha d a lea k an d wha t actio n wa s bein g take n t o handl e th e situation . c ) Lea k technician s wer e assigne d t o provid e continuou s monitorin g fo r th e storag e area , fenc e lin e an d surroundin g neighbors .P.5 3

Mr . Rober t R . Frenc h-2
- Octobe r 31 , 198 3

d ) Notifie d th e Stat e o f Delawar e Ai r Resource s Sectio n o f ou r leak . e ) Fir e equipmen t wa s place d i n standb yi n cas e th e statu s o f th e lea k shoul d change . f ) Productio n supervisio n wa s schedule d around-the-cloc k t o supervis e th e emptyin g o f th e storag e sphere . I t i s estimate d tha t w e los t 57 6 pound s o f viny l chlorid e ove r a fou r dayperiod . Calculatio n 6 # VCM/hr . x2 4 hrs . x4 day s = 57 6 lbs.ACM . Th e following actio n i s bein g take n t o preven t a simila r occurrence : 1 ) Inspec t conditio n and thicknes s o f VC Moutle t lines . 2 ) Replac e pipin g fo r balanc e lin e usin g stainles s stee l 31 6 instea d o f carbo n steel . 3 ) Instal l support s fo r pipin g unde r storag e sphere . 4 ) Reconditio n hea t sensor s a s needed . 5 ) Spo t clea n and pain t sphere . 6 ) Inspec t al l insulate d pipin g a t dom e o f sphere . 7) . Remov e al l valve s and inspec t fo r prope r operation . 8 ) Send ou t relie f valve s fo r reconditionin g and setting . 9 ) Calibrat e LIT , PI T AND PI . 10 ) Chec k and clea n exces s flo wand fir e shut-of f valves . 11 ) Chec k thicknes s o f PT-103 . 12 ) Remov e al l insulatio n belo wcoolin g crown o n PT-103 . 13 ) Open , inspec t an d clea n storag e spher e PT-103 . 14 ) Unplu g 2 " evacuatio n lin e t o PT-103 .P.5 4

Mr . Rober t R . Frenc h-3
- Octobe r 31 , 198 3

I t i s fel t the abov e actio n wil l plac e th e storag e spher e i n goo d operatin g condition . Thi s typ e o f inspectio n wil l b e performe d periodicall y t o assur e the storag e spher e i s i n goo d operatin g conditio n a t al l times . I f yo u shoul d hav e an yquestion s o r nee d additiona l information , pleas e giv e m e a call . Sincerely ,

CWH/ma h 

# ^.VSN\C , C . W.. . H a ge r Administratio n Ma

TP.5 5



### " / 

### - ^ V

### FORMOS APLASTIC S CORPORATIO NDELAWAR E P.O
. BO X32 0 * DELAWAR E CITY
. DELAWAR E 1970 6 •TE L(302) 834-4575


### CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D
Novembe r 4 , 198 3
Josep hJ . Hardman , P.E . Stat e o f Delawar e Departmen t o f Natura l Resource s and Environmenta l Contro l Divisio n o f Environmenta l Contro l P.O . Bo x140 1 Dover , D E 1990 3 RE : Exces s Emissio n - Batc hP-636 2 Novembe r 4 , 198 3 Dea r Mr . Hardman : Formos a Plastic s Corporatio n o f Delawar e i s reportin g t o you r offic e a n estimate d los s o f 280 0 pound s o f viny l chlorid e t o th e atmospher e durin g th e heat-up o f thi s batc hi n reacto r PR-403 . Th e caus e o f thi s los s wa s th e prematur e failur e o f th e pressur e relie f system . Whe n th e pressur e reache d 18 5 psi g th e release.bega n an d laste d on e t o tw o minutes . Th e previou s batc hi n thi s reacto r reacte d a t 195-20 0 psi g with

ou t an yproblem . Th e ruptur e dis c and relie f valv e ar e bein g replaced . I f ther e ar e an

yfurthe r question s pertainin g t o thi s incident , pleas e fee l fre e t o contac t me . Sincerely , Car l E . Subric k ^'-*<-.V ? 

### &. D TemporaryAssociat e Regulator y„ D 

### Affair s Specialis t ^ K ] 2 ]%q CES:1 1 

# ^sssrP.5 6

/ 

## I^3S ^ FORMOS APLASTICS CORPORATIO NDELAWAR

E \j£/ P.O . BO

X320 •DELAWAR E CITY . DELAWAR E 1&70 6 •TE L (302) 834-457

5

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D nr . r . r * Decembe r 22 , 198 3

•a-.- : ;* t •- . ->

• .--^ s »"**? K Rober t R . French , P.E . flCWl^-i i to C^i^J Manager , Ai r

Resource s Sectio n/A/>* \. Delawar eDepartmen t o f Natura lResource s APR1 1 1MW 4 0 '!)£"•- " an dEnvironmenta lContro l H TM L L l3C H/ P.O . Bo x140 1 Dover , Delawar e1990 1 SPECIA LCOMPLIANC

ESECTIO N EPA , REGIO NII I R E : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E Dea r Mr . French : Formos a Plastic s Corporatio n Delawar e i s filin g thi s writte n repor t regardin g a n emergenc yreleas e t o th e atmospher e o f approximatel y38 8 pound s o f reactan t containin g a n estimate d 10 9 pound s o f viny l chlorid e monomer . N o discharg e occurre d t o th e atmospher e fro ma manua l ven t valv e o r relie f valve . Natur e an d Cause : Approximatel ytw o hour s int o th e batc hreactio n i n reacto r SR407 , th e agitato r shaf t couplin g failed . Th e batc hwa s immediatel ykilled , however , th e shortsto p w a s no t totall yeffectiv e du e t o a tota l lac k o f agitation . I n orde r t o preven t a relie f valv e discharge , a slo wtransfe r o f th e batc ht o th e ST41 3 degassin g tan k started , durin g whic htim e a gasket*o n Gorato r SG400 Wfailed . Correctiv e actio n wa s immediatel ytaken , bu t no t befor e th e heade r partiall yde
- pressure d fro m12 0 psig . Dat e an d Time : Saturday , Decembe r 17 , 198 3 a t 104 5 hours . Approximat e Tota l VC MLos s Durin g Discharge : A n estimate d 10 9 lbs . o f viny l chlorid e monome r wa s release d i n th e immediat e vicinit yo f a Bacharac hsensor , activatin g th e sprinkle r System .Rober t R . French , P.E . 

### -2
- Decembe r _ , 198 3

Metho d Use d fo r Determining VC MLoss : Calculation s ar e attached . Actio n Take n t o Preven t Discharge : Prio r t o the Gorato r gaske t failure , a slo wtransfe r o f th e shortstoppe d batc h wa s attempte d t o preven t runawaypolymerizatio n an d a n accompanyin g relie f valv e discharge . N o dis k ruptur e occurre d du e t o immediat e actio n b yth e op erators ; however , the transfe r wa s prematur e i n tha t th e transfe r wa s attempte d abov e the Gorato r operating pressur e ratin g o f 10 0 psig . Measure s Adopte d t o Preven t Futur e Discharge : Th e abov e inciden t wa s ultimatel ycause d b ya mechanica l failur e o f the agitator , an d i s considere d a highl yunusua l occurrenc e whic hled t o a n unavoidabl e re lease . Operator s hav e bee n cautione d t o no t attemp t suc hcorrectiv e actio n unti l th e reacto r pressur e i s a t o r belo w10 0 psig . Correctiv e maintenanc e wa s performe d o n bot hth e agitato r an d th e Gorator . I f yo u hav e an

yfurthe r questions , pleas e d o no t hesitat e t o contac t m e a t 836
- 2219 . Sincerel yyours,^\\ y 

# fliy2^c^<HX^ H . Alle n Wrigley , Jr . Environmenta l Manage r HAW:1 1 Attachmen t

cc : JosephHardman , P.E .

# X?/'7/f3 ..__.; _ 

# xXxlrx '£\.tfJt^^.„S&^cJ*rt:. Ccraior ® 3)u.ra-Ji K



# fiy2 &£.. ..tfh*,h**4
_

* J.S1.. 4h*W&/.„-. .._. __ l/C/kf „JuL*feJI. A4n4U*Zf_% 

# lA)^cU^XX)l^k A'Xc+L

-6r 

# —- r "r-Ais * A

- _!rri_e» . . 0.fi.**!.t

> . ' y *f""

. 

## H/.ti'f 

# ..-^J^*. ^

~ ^ fi *%&

£
M<^L^K_. (Tv^y4^-Q. - »_?_%_

_(<_*feu___^<__>?=

### -
_..rJlx^apd p^y-.^sCtc^U. K 

### X(/}IU.-./VLAJXC-*- &4/



# _SR^X^at-dXai-. iXUL . . &J^_._.^. ^ X^uX< ,. . _. .A^_r„ . 

# '„J(CH fe&com(LP.5 9 

# 6>< * r*<j3'*+ FORMOSA PLASTIC S CORPORATIO NDELAWAR E P.O . BO X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L (302 ) 834-457 5 CERTIFIE

DMAI L RETUR N RECEIP T REQUESTE

D 

# RE C i _ " • ' : * * t

_:.

_».p * November 23 , 198 3 

# AP R1 1 1984 Ar, - SPECIA L COMPLIANC

ESEC . IO N EPA , REGIO NII I 

# 6 rX SIAWOf -**** * 

# tf Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Delaware Department of Natura l Resource s an dEnvironmenta l Contro l P.O . Bo x140 1 Dover , Delaware 1990 3 

### Dear Mr . French : r. - : 

### .--•• • •X'H. H 

### I'. . 

### Mi l 

# DEC ! 198 3
i ! • \ • u I 1 T ti'A ,.N_ I: .- t_..i ; .•JNJitO L RE : Viny l Chlorid

e Monomer Releas e Formos a Plastic s Corporatio nD E 'I naccordanc e wit hNationa l Emissio nStandard s fo

r Hazardou s Ai r Pollutants , Part 6 1 of Chapter I , Titl e 40 , Sectio n61.65(a ) Relie f Valv e Discharges , Formos a Plastic s Corporation , Delaware make s th e followin

g repor t concernin

g th e abov e reference

drelease . Th e addres s of th

e source : Formos a Plastic s Corporation , Delaware P.O . Bo x32 0 Schoolhous e Roa

d Delaware City , Delawar e 1970 6 Sourc e of Release : Suspensio nPlant SPVC- I A . Natur e o

f Cause : Batc hP-663 2 wa s charge da t 01:4 5 hour s o

nNovember 20 , 198 3 inReactor PR-403 . I nreviewin g th e batchchart , th

e reactio

npressur e ros e an

d levele dof f a t 18 4 psig . A

t approximatel y

03:3 0 hours , th

e rupture dis c faile

dan dth e relie f valv

e opene dan drelease

da mixtur e o f water , suspendin

g agen t an dviny l chlorid

e to th e atmosphere . A ninvestigatio

nwa s made an

dit wa s determlnne dth e ruptur e dis c faile d prematurely

a t 18 4 psi g base

do npressur e PI C an

dloca l gauge readings .P.6 0

Rober t R . French , P.E . Viny l Chlorid e Monome r Releas e Pag e Tw o

B . Dat e an

d Time o f Release : Sunday , Novembe r 20 , 198 3 a t 03:3 0 hour s C . Approximat e Tota l Los s o f Viny l Chloride : Nin e hundre d thirty-fou r (934 ) pound s o f viny l chlorid e release d D . Metho d Use d t o Determin e Amount : Avisua l observatio n o f th e reacto r content s indicate d tha t approximatel y thre e fee t wer e lost . Normall yth e amoun t o f th e releas e ca n b e calcula
ted base d o n the amoun t o f viny l chlorid e recovere d i n ou r recoverysys te man d the amoun t o f viny l chlorid e converte d t o Polyviny l Chloride . Sinc e th e leve l i n th e recoverywa s a t th e zer o leve l mark , w e wer e un abl e t o us e thi s method . Ou r calculatio n o f the los s i s a s follows : Safet yvalv e size : 4 " x6 " Orific e Area : 6.3 8 inches 2 W-CKAP 

## \JZ T (0/Hour ) k
- CP/C Nfo r C 2 H C L -1. 2 C » 33 5 K - 0.9 7 A - 6.3 8 P - (193+164)/ 2 + 14. 7 - 193. 2 M - 62. 5 Z = 0.9 2 !•

_152° F - 612° R f
__ _f «

= OJ.

_K I " ' W - (335 ) (0.97 ) (6.38 ) (193.2 ) / 62. 5 V (0.92)(612 ) 133448. 8 #/hr . - 22240/minut e



### E . I t i s estimate d tha t the safet yvalv e wa s opene d fo r 1 minute . Th e amoun t o f viny l chlorid e charge d t o th e reacto r i s equa l t o 42 2 o f tota l ingredient s charged . (2224#/min. ) ( 1 minute ) (0.42 ) - 93 4 lbs . o f viny l chlorid e release d Actio n Take n t o Minimiz e Discharge : 1 . Batc hwa s terminate d 2 . Stripping operation s starte d t o recove r monome r 3 . Relie f valv e reseate dP.6 1

Rober t R . French , P.E . Viny l Chlorid

e Monome r Releas e Page Three
F . Measure s Adopte dt o Prevent Future Discharges : 1 . Configuratio

nof reactor change d 2 . Contacte

dmanufacturer of rupture dis c an dthe y recommende

dthat operatin

g condition s shouldnot excee d90 % o f ruptur e dis c desig n pressure
I f there are further questions concernin g thi s matter , pleas e contac t me . Sincerely , 

# ^5)\oT ^ C . W . Hage r Administratio

nManage r CWH:1 1P.6 2



### FORMOSA PLASTIC S CORPORATIO NDELAWAR E P.O . BO X32 0 •DELAWAR E CITY . DELAWAR E 1970 6 •TE L (302 ) B34-4575
CERTIFIE D MAI L RETUR NRECIEP T REQUESTE D ^ aaso i ••"'J* : .*• - \vtfi'

Octobe r 7 , 198 3

Rober t R . French , P.E . Manager , Ai r

Resource s Sectio n Stat eo f

Delawar e Departmen t

o f Natura lResource s an dEnvironmenta lContro l P.O . Bo x140 1 Dover , Delawar e1990 3 •s, *w*^ -*-••" " .^ - •:*

* " "•

" :i --"'"*" 1

m '-<UE ? L-C-i^ . i i
_ " • 

## AP R 1 1 It o 

# D

i'tt-i'. * 

## XW< £Oc r13, * 3

UA_*
. OHUJU

SPECIALCOMPLIANC E SECTION EPA , REGIO N II I

RE : Exces s Emissio n- Batc hS-519 5 Octobe r 4 , 198 3 Dea r Mr . French : Formos a Plastic s Corporatio n o f Delawar e i s reporting t o your offic e an estimate d los s o f 100 0 pound s viny l chlorid e t o atmospher e during the transfe r o f thi s completel ypolymerize d batc hfro mreacto r SR-40 5 t o degassing tan k ST-41 2 fo r the stripping operatio n t o remov e the remaining unreacte d viny l chloride . Th e caus e o f thi s los s wa s bot hthe failur e o f the operato r t o clos e the ED C valv e an d the leaking througho f a secon d valve . Thi s valv e i n questio n ha s bee n repaired . Also , the operato r wh o mad e the erro r i s being give n disciplinary action . I f ther e ar e furthe r question s pertaining t o thi s incident , pleas e fee l fre e t o contact - me . 

### Sincerely , 

# CUM~#- fa Charle s A . Markowit z Associat e Regulatory Affair s Specialis t CAM:1 1P.6 3 

# -_S N FJRMOS APLASTIC S CORPORATIO NDELAWAR E .'.O
. BO X320 •DELAWAR E CITY , DELAWAR E 1970 6 •TE LJ302) 834-457 5

Jun e 30 , 198 3

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D

Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Delawar e Dept . o f Natura l Resource s an d Environmenta l Contro l P.O . Bo x140 1 Dover , D E 1990 1 Dea r Mr . French : RE : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E I n accordanc e wit hNationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Delawar e City , Delaware ; th e addres s fo r thi s source : P . 6 . Bo x32 0 Schoolhous e Road Delawar e City , D E 1970 6 Sourc e o f Release : Suspension-I I Are a A . Natur e o f Cause : Batc hS-330 3 wa s charge d i n reacto r SR-41 0 a t 5:4 5 a.m . o n Jun e 21 , 1983 . A t approximatel y7:4 5 a.m. , the reactor' s relie f valv e opene d becaus e o f highpressur e an

d discharge d abou t 1/ 5 o f the batc hint o th e atmosphere . Th e caus e o f thi s discharg e wa s a fault ypressur e transmitte r whic hdi d no t war n operating personne l o f the fac t tha t highpressur e wa s present . B . Dat e an

d Time : Tuesday , Jun e 21 , 198 3 a t 074 5 hours . 

# ^ 

# \m > 

### Pi / D^Ar»ni-. ^

"' ' " : * -'X- '!* • 

# %X



# v . "<> MLS1383

\ \

*

" ' " ' .'u
- ; ; • ••• ; p •-.. . • : , - , .. . ,, u % / ^P.6 4

Rober t R . French , P.E . -2
- Jun e 29 , 198 3

C . Approximat e Tota l Los s o f Viny l Chloride : Tw o thousan

d four hundre d eigh t (2,408 ) pound s o f viny l chlorid e discharge d t o atmosphere . D . Metho d Use d t o Determin e Loss : Fromth e time tha t th e discharg e too k place , i t i s estimate d tha t 30 % conversio n too k place . Observatio n o f th e liqui d leve l remainin g i n th e reacto r indicat e abou t 20 % o f th e batc hwa s los t t o atmosphere . 17,20 0 - Lbs . VC Mcharge d i n reacto r 5,16 0 - Lbs . VC Mconverte d t o PVC 12,04 0 - Lbs . VC Munreacte d i n reacto r 2,40 8 - Lbs . VC Mdischarge d t o atmospher e 9,63 2 - Lbs . VC Mi n reacto r afte r discharg e 30 % - conversio n VC Mt o PVC E . Actio n Take n t o Preven t Discharge : Instrumen t failur e di d no t war n operatin g personne l o f highpressur e condition s i n orde r t o tak e correctiv e actions . F . Measure s Adopte d t o Preven t Futur e Discharges : 1 , Pressur e transmitte r ha s bee n repaired . 2 , Operatin g personne l an d supervisor s hav e bee n advise d t o thi s inci

den t an d t o examin e batc hoperatin g condition s fo r simila r instrumen t failur e an d t o tak e necessarycorrectiv e actions . 3 , Th e operating procedur e fo r contro l o f ho t batche s wil l b e reviewe d an d change d t o mee t th e presen t need s o f th e plant . I f ther e ar e furthe r question s pertainin g t o th e informatio n submitted , pleas e fee l fre e t o contac t me . Sincerely ,
Charle s A . Markowit z Associat e RegulatoryAffair s Specialis t CAM/mahP.6 5



### FORMOS

A PLASTICS CORPORATIO NDELAWAR

E P.O
. BO X320 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-457 5
Jul y 8 , 198 3 

## R E C VA , 

## v CERTIFIE D MAI L RETUR NRECEIP TREQUESTE D 

# miI

# 5 I Q til

Rober t R . Frenc h Manager , Ai r Resource s Sectio n Delawar e Dept . o f Natura l Resource s an d Environmenta l Contro l P.O . Bo x140 1 Dover , D E 1990 1 Dea r Mr . French : 

# EPA , REGi u { 

### 'iiill &:>/.'( 

# RECEIVE D JU L 

## I \ 198 3
OFFICEO f RE6I0HA L

RE : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n Delawar e I n accordanc e wit hNationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Delawar e City , Delaware ; th e addres s fo r thi s source : P.O . Bo x32 0 Schoolhous e Road Delawar e City , D E Sourc e o f Releases : Releas e No . 1 : Suspension-I I Plan t Releas e No . 2 : Emulsion-I I Plan t 1970 6

A , Natur e o f Caus e ; Releas e No.-l : Batc hS-344 7 wa s charge d a t 213 0 hour s Jun e 30 , 198 3 i n reacto r SR-409 . A t approximatel y2 33 0 hours , a viny l chlorid e releas e o f shor t duratio n too k plac e throughth e relie f valv e becaus e o f highpressure . Reacto r char t indicate d tha t batc htemperatur e di d no t pas s 100° . F no r batc hpressur e abov e 14 0 psig . Investigatio n o f

. instrumentatio n afterward s indicate d tha t the pressur e pi k flui d ha d leake d an

d temperatur e calibratio n wa s off . 

# PH n> . - ' ! t 

# r ML 1 5 

## WQ3 Ali i t 'nuofwiiv. ^ 

# B M mtnXiX

nti)P.6 6

Mr . Rober t R . Frenc h-2
- Jul y8 , 198 3

Releas e No . 2 : Batc hD-161 8 wa s charge d a t 133 0 hour s o n Jul y3 , 1983 , i n reacto r DR-408 . Pressur e ris e continue d pas t 20 0 psi g o n batc hchart . Examinatio n o f ruptur e dis k indicate s tha t it wa s onl ycracked , thereb y considerabl yconstrictin g an yreleas e whic hwoul d hav e occurred . Loca l pressur e gaug e a t th e tim e o f releas e wa s 24 5 psig . Observation s o f ven t pip e o f DR-40 8 wa s that cream-lik e materia l coul d b e see n bein g emitted . B . Dat e an d Tim e o f Release : Releas e No . 1 : Thursday , Jun e 30 , 198 3 a t 2 3 3 0 hour s Releas e No . 2 : Sunday , Jul y3 , 198 3 a t 141 0 hour s C . Approximat e Tota l Los s o f Viny l Chloride : Releas e No . 1 : Les s tha n on e hundre d *(100 ) pound s o f viny l chlorid e release d t o atmosphere . Releas e No . 2 : Les s tha n on e hundre d (100 ) pound s o f viny l chlorid e release d t o atmosphere . D . Metho d Use d t o Determin e Amount : Releas e No . 1 : Becaus e o f th e shor t duratio n ( a fe wseconds) , th e fact s tha t reactio n liqui d leve l wa s unchange d an d n o slurr ycoul d b e see n i n th e area , i t i s estimate d tha t les s tha n 10 0 lbs . o f VC M wa s lost . Releas e No . 2 : Becaus e o f th e ruptur e dis k havin g onl ya smal l crac k an d th e visua l observation s o f release , it i s estimate d tha t les s tha n 10 0 lbs . o f VC Mwa s lost . E . Actio n Take n t o Minimiz e Discharge : Releas e No . 1 : (1 ) Onc e hig hpressur e conditio n wa s realized , batc hwa s terminated . (2 ) Strippin g operatio n t o reduc e pressur e wa s then , immediatel ystarted . Releas e No . 2 : (1 ) Reacto r DR-40 8 batc hwa s partiall ytransferre d t o a n empt yreacto r DR-40 1 t o reduc e pressure .P.6 7

Mr . Rober t R . Frenc h -3
- Jul y8 , 198 3

F . Measure s Adopte d t o Preven t Futur e Discharges: . Releas e No . 1 : (1 ) Instrumentatio n on'thi s reacto r wa s repaire d an d recalibrated . (2 ) Th e pressur e tes t procedur e i s bein g modifie d t o includ e a chec k o f th e loca l pressur e gaug e vs . instrumen t pressur e t o confir minstrumen t accuracy . (3 ) Al l othe r reacto r instrumentatio n ha s bee n inspecte d an d recali

brate d fo r prope r operation . (4 ) Operator s hav e bee n reinstructe d a s t o th e prope r settin g o f hig hpressur e se t poin t alarm . Releas e No . 2 : (1 ) Ruptur e dis k ha s bee n sen t bac k t o th e supplie r fo r inspection . (2 ) Th e catalys t tha t wa s use d wil l b e checke d fo r activit ybefor e i t i s use d i n production . I f ther e ar e furthe r question s concernin g thi s matter, ' fee l fre e t o contac t me . Sincerely ,



# d/*^.f. ^^Wj f Charle s A . Markowit z •<=_r- ' Associat e Regulator yAffair s Specialis t CAM/ma h cc : Mr . Mr . Mr . Mr . Sta nLeskowski , EP A Jo e Hardman , D E DNRE C Yen-H o Huang , FP C N J Rober t Boyer , FP C D EP.6 8 

# (fcXX iV

^^^ . FORMOS APLASTIC S CORPORATIO NDELAWAR E \ & S P.O
. BO X320 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-457 5 

# $et>^

Augus t 26 , 198 3

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D 

# RECEIVE D AUG 9



### - 9 198

3 EPA , REGIO

NII I mi O fRtGlOii M AOMINISIRAT

M
Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Delawar e Departmen t o f Natura l Resource s an d Environmenta l Contro l P.O . Bo x140 1 Dover , Delawar e 1990 1 Dea r Mr . French : RE : Viny l Chlorid e Monome r Releas e Formos a P I istic s Corporatio n D E I n accordanc e wit hNationa l Em;ssio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Delawar e City , Delaware ; the addres s fo r thi s source : P.O . Bo x32 0 Schoolhous e Road Delawar e City , D E 1970 6 Sourc e o f Release : Emulsion-I I Plan t A . Natur e o f Cause : Batc hD-210 9 wa s charge d a t 113 0 hour s o n Augus t 17 , 198 3 i n reacto r DR-401 , An examinatio n c f th e batc hchar t a t 170 0 hour s indicate d tha t the batc hhad stoppe d polymerizing . Thi s brough t abou t a n investigatio n o f th e catalys t charg e system . Fo r emulsio n batches , tw o solution s R1 0 (acid ) an

d C 2 (peroxide ) ar e introduce d concurrentl yint o th e reacto r whic har e use d t o initiat e th e reaction . I t wa s foun d tha t th e R1 0 lin e wa s plugged . Tw o increment s o f h lb . R1 0 wa s adde d followe d b yh lb . an

d 1 lb . t o hel p tr

yt o star t th e reaction . A t the time th e R1 0 tank wa s bein g remade , the ruptur e dis k ble wan d relie f valv e lifte d dischargin g n I C 

# RECEIVE D SEP 0 8 198 3 AI R MOMTORIN G 

# RECEIVE D RECEIVE D AU G 3 1 198 3 EPA-FNVihO^.-^ L SERViCt S DiVtSiO N 

## SE P 

## 1 5 198

3 SPECIA LCOMPLIANC E SECTIO H 

### EPA , REGIO N II IP.6 9
/ / J

Rober t R . French , P.E . -2
- Augus t 26 , 198 3

viny l chlorid e t o atmosphere . Batc hpressur e indicatio n wa s onl yshowin g 14 0 ps i a t th e tim e o f discharg e an d onl yincrease d t o 15 5 psi g befor e droppin g of f t o zer o whe n th e batc hwa s terminate d an d strippe d off . B . Dat e an d Tim e o f Release : Wednesday , Augus t 1 7 a t 193 0 hours . C . Approximat e Tota l Los s o f Viny l Chloride : Thre e hundre d thirt y(330 ) pound s o f viny l chlorid e release d t o atmosphere . D . Metho d Use d t o Determin e Amount : Avisua l observatio n o f reacto r solutio n indicate s tha t 2 S fee t wer e lost . Thi s i s equivalen t t o 53 0 gallon s (7. 8 lb./gal. ) o r 4,13 0 lbs . o f solutio n o f whic h60%i s wate r an d 40 % VCM , PVC , soa p (1,65 3 lbs.) . I t i s estimate d tha t th e batc hconversio n wa s 60 % whic hwoul d amoun t t o 66 0 lbs . unreacte d viny l chlorid e monomer , o f whic hi t i s estimate d tha t one-hal f wa s discharge d t o th e atnipspher e an d th e othe r hal f t o th e recover ysystem . E . Actio n Take n t o Minimiz e Discharge : (1 ) Onc e hig hpressur e conditio n wa s realized , batc hwa s terminate d wit h-methylstyren e (AMS) . (2 ) Strippin g operatio n t o reduc e pressur e wa s immediatel ystarted . F . 'Measure s Adopte d t o Preven t Futur e Discharges : (1 ) Instrumentatio n o n thi s reacto r wa s repaire d an d recalibrated . (2 ) Operatio n o f catalys t chargin g ha s bee n change d t o specif ytha t bot hC 2 an d R1 0 mus t b e introduce d together . I f ther e i s a n interruptio n o f flo wfo r eithe r C 2 o r R10 , the n th e othe r on e wil l b e halte d unti l th e proble mca n b e solved .P.7 0

Rober t R . French , P.E . -3
- Augus t 26 , 198 3

I f ther e ar e furthe r question s concernin g thi s matter , fee l fre e t o contac t me .

CAM/ma h cc : Mr . Leskowsk i EPA , Regio n II I 

# ^_wi-^.^?a«^ C Charle s A . Markowit z Associat e RegulatoryAffair s Specialis tP.7 1



### ^ S ^ FORMOS

A PLASTICS CORPORATIO NDELAWAR

E ^^£s P.O
. BO

X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302) 834-457

5 CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Augus t 13 , 198 4

Mr . Ronal d J . Patterson , 3AM2 2 U.S . Environmenta l Protectio n Agency , Regio n II I Sixt han

d Walnu t Street s Philadelphia , Pennsylvani a 1910 6 Dea r Mr . Patterson : Pleas e fin

d enclose d a cop

yo f our Jul y25 , 198 4 repor t issue d t o the Stat e o f Delaware , Departmen t o f Natura l Resource s an d Environ

menta l Control , Ai r Resource s Section . Thi s wa s apparentl yno t for
warde d t o you r offic e during m yabsenc e fromthe plant . Als o attache d i s a cop yo f the metallurgica l repor t mentione d i n the penultimat e paragrapho f the Jul y2 5 report , receive d subsequen t t o tha t date , an

d forwarde d t o Mr . JosephHardma n today . I f yo u hav e an

yquestions , pleas e cal l m e a t (302 ) 836-2219 . Sincerely ,

H . Alle n Wrigley , Jr . Environmenta l Manage r HAW:e k Attachmen t c c . JosephJ . Hardman , P.E. , Delawar e (Ai r Resource s Section )P.7 2



## XX FORMOSAPLASTICS CORPORATIO NDELAWAR

E Xt/ ' P.O
. BO

XSIX ) •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302) 834-4S7

5

CERTIFIED MAI

L _RETUW*

_JUXE_ir_

T.J}Ji_y_iiSTE

D

Jul y 25 i198 4

Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Stat e o f Delawar e Departmen t o f Natura l Resource s nn d Environmenta l Contro l T.O . Box140 1 Dover , Delawar e 1990 3 Dea r Mr . French : RE : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n Delawar e I n accordanc e wit hth e Stat e o f Delawar e Regulation s Governin g th e Contro l o f Ai r Pollution , Chapte r XXI , Sectio n 13 , Subsectio n 3. 2 a. l Formos a Plastic s i s submitting thi s writte n repor t o f a viny l chlorid e monome r release . Natur e an

d Caus e O n Thursday , Jul y19 , 198 4 hatc hS-373 4 wa s charge d i n Reacto r SR-402 . a t approximatel y10:3 0 A.M . Th e batc hva s i n it s heatu p cycl e an

d had reache d reactio n temperatur e an d pressur e a t 11:3 5 A.M . A t thi s poin t i n the re actio n cycl e the bottomvalv e o n the . Solid s Additio n Po t failed . Thi s valv e failur e allowe d water , PVC resi n an d vinyl , chlorid e monome r t o escap e from th e reacto r int o the reacto r buildin g an d atmosphere . A n inspectio n o f the bottomvalv e showe d the studde d bolt s whic hhol d th e valv e togethe r had sheare d off . Th e studs , valv e an d valv e part s wer e sen t t o a metallurgis t t o determin e the caus e o f the failure . W e ar c currentl y waitint* . ft*" " n writte n repor t fro mthe metallurgis t o n hi s determination . However , indication s ar c th e stud s wer e ovcr-torqucd .P.7 3

Rober t R . French , P.E . -2
- Jul y25 , 198 4

Approximat e Tota l Viny l Chlorid e Monome r Los s Durin g Discharg e 13,23 6 lbs . o f viny l chlorid e monome r wa s los t durin g th e discharge . Metho d Use d fo r Determinin g the Viny l Chlorid e Los s 3 A t 6 4 psig , PC„H„C 1 =55. 5 lb./f t (assuming tank vapo r spac e i s saturate d wit hVCM ) ST-305 , accumulato r tank , capacit yi s 460 0 gallon s - Se e attache d equipmen t drawing . 460 0 gallon s ( 1 ft. 3 ) = 61 5 ft. 3 (7.4 8 gallons ) Therefore , ful l tan k hold s (55. 5 lb./ft 3 ) (61 5 ft. 3 ) = 34,13 3 lbs . Leve l indicato r showe d a 33 % increas e durin g th e incident . 34,13 3 lbs . x.3 3 = 11,26 4 lbs . came int o accumulato r durin g incident . Becaus e o f emergenc yequalizin g procedure , 4,50 0 lbs . o f th e abov e 11,26 4 lbs . came fro

mReacto r SR-403 , whic hwa s bein g charge d (an d weighed ) a t th e time . Therefore , the amoun t o f VC Mrecovere d fromSR-40 2 durin g th e inciden t wa s

11,26 4 lbs . - 4,50 0 lbs . = 6,76 4 lbs . o f VC M Therefore , amoun t los s (assuming negligibl e polymerization ) 20,00 0 -6,76 4 = 13,23 6 lbs . Actio n Take n t o Minimiz e the Releas e O n Thursday , Jul y19 , 1984 , batc hS-373 4 wa s charge d i n Reacto r SR-40 2 a t approximatel y10:3 0 A.M . Th e batc hwa s i n it s heatu p cycl e an

d had reache d reactio n temperatur e an d pressur e a t 11:3 5 A.M . At thi s poin t i n th e reactio n cycl e a lou

d nois e wa s heard b ythe operator s i n tli e reacto r contro l room . Th e "A " Operator , Thelm a Donovan , wa s charging viny l chlorid e monome r t o Reacto r SR-40 3 a t the tim

e o f the incident . She had pur.ipe d i n approximatel y4,50 0 lbs . o f VCM . Upo n hearing the lou d nois e she immediatel yhi t the emergenc yshutdown butto n o n the weightank . Thi s shu t dow n th e VCMpumpin g t o Reacto r SR-403 . The ga s detectio n systemsounde d withi n second s o f the lou d nois e an

d th e sprinkle r systemwa s activate d automaticall yb ythe ga s detectio n system .P.7 4

Rober t R . French , P.E . 

### -3
- Jul y25 , 198 4

Jerr yJohnson , th

e Are a Manager , wa s i n the SPVC- I reactio n are a a t the time o f the incident . H e immediatel ywen t t o the SPVC-I I contro l room . H e in

structe d th

e "B " Operato r t o do n hi s self-containe d breathin g apparatu s an d ente r the reactio n are a an d star t ventin g Reacto r SR-40 2 t o the VC Mrecovery system . Asecon

d "B " Operato r arrive d an d wa s instructe d t o equaliz e Reacto r SR-40 2 t o Reacto r SR-409 . Reacto r SR-40 9 wa s i n standby . Th e equalizatio n o f the two reactor s wa s accomplishe d b yopenin g the VC Mcharg e valve s betwee n the tw o reactors . Sinc e th e viny l chlorid e wa s bein g release d insid e th e reactio n area , the decisio n wa s mad e t o pul l the emergenc yven t o n the reacto r t o reduc e th e pressur e o n th

e vesse l a s quickl ya s possible , thu s reducin g th e ris k o f fir e an d possibl e explosion . Th e emergenc yven t o n Reacto r SR-40 2 wa s i n th e ope n positio n fo r five minutes . A t approximatel y12:0 0 noo n the vent s t o th e VC Mrecoverysystemwer e close d an d the n reacto r wa s vente d t o th e evacuatio n jet . Onc e th e pressur e o n th e reacto r reache d 0 psig , th e lo wpressur e ven t syste mwa s connecte d t o th e reacto r t o preven t VC Mvapor s frombein g release d insid e the reactio n area . Using the Area s Continuin g Monitorin g Systeman d Ga s Detectio n System , VC M level s i n the are a wer e monitore d an d onc e theyreache d th e saf e leve l the sprinkler s wer e turned of f an d a n inspectio n mad e o f th e reactor . Additionally , the Plant' s Disaste r Pla n wa s implemented . Th e fir e departmen t wa s calle d i n t o stan d b yi n cas e o f a fir e o r explosion . Plan t personne l too k quic k actio n t o brin g th e emergenc yconditio n unde r control . A s a precautio n unti l i t i s determine d wh ythe Pacifi c bal l valv e failed , w e ar e replacing al l Pacifi c bal l valve s i n reacto r service . Measure s Adopte d t o Preven t Futur e Release s Th e immediat e actio n take n wa s t o replac e th e bal l valv e wit ha singl e bodie d valv e whereve r theywer e use d i n th e bottomo f the Solid s Additio n Pots . Fu tur e measure s wil l depen d on the writte n repor t fromthe metallurgis t o n hi s findings . Shoul d yo u hav e an

yquestion s o r nee d additiona l informatio n pleas e giv e m e a call . Sincerely , C . W . Hager^ \ Operation s Manage r CW11:1 1 Attaclinient s 

## f^^^XX^—^, k£ . ,tt^Ma/M-S ** •(**-*-:P.7 5



# . ® (fYQfH )


# "X| : 

# T® J/\£v;£ T
Fini s 5 ~ v rA'!>••/• , r

crt fS
. « <

* v l-l CAP A



# ±„ 43CM.-1 0 

# (B ) rrTTP^S-i - —-Y—/t

_rf)

- A— A fi^-«i__^-^^-3 \• / / j ^ • < ^- ^

p/Mf'tf i -JACK/;!- - / / £'/> V t 

## •M(S ) ELEVATIO N

•I,I:.(>- I 

### "\'|V,,..,*.,•••••
. , * ,••- , * T

### ... \ ,\,~~.. ~wnnnVr7"yy\~}\r~,., ,\t?~n~i- cr

# i r 

# —i

n

.. . 402 0 NE WCASTL E AVENUE'P. O f"O X1M 1 •WILMINGTON
. DELAWAR E 1989 9 •302-&SS-73^ 0



### Augus t 6 , 198 4 FORMOS APLASTIC S CORPORATIO N Schoolhous e Roa d Delawar e City , DE . 1970 6 ATTENTION : MR . KE NKERN S REFERENCE : P.O . No . 0733 6 Lehig hProjec t No . 786-8 4 Dea r Mr . Kerns : W e hav e examine d a 3 " cas t stainles s stee l bal l valv e whic hyo u recentl ydelivere d t o th e laborator yt o determin e tn e reaso n fo r failure . I t wa s reporte d tha t th e valv e faile d durin g servic e whe n eigh t stu d bolt s attachin g a flang e t o on e en d o f th e valv e faile d suddenl y, an d apparentl ysimultaneously . Th e valv e wa s locate d o n to p o f a viny l chlorid e reacto r operatin g a t 13 0 ps i pressure , an d 180°F , a t th e tim e o f failure . I t i s use d t o charg e ra wmaterial s t o th e reacto r i n a batch-typ e operation . Failur e o f th e valve , whic hresulte d i n complet e separatio n o f th e to p flange d joint , allowe d som e portio n o f th e chemica l reactant s t o spil l int o th e surroundin g atmosphere . Th e followin g repor t describe s th e result s o f th e laborator y examinatio n o f th e faile d valv e components . EXAMINATIO NO F VALV E BODY : Th e faile d sea t ring s th e valv e bal l plug , floo r nex t den t appa r als o dent e i s fitte d hav e t o b e b e ejecte d wer e comp l valv e bodyi s show n i n F

, an d portion s o f th e br o faile d a t th e flange , in t an d th e tw o Teflo n seat s t o th e reactor . Th e ba l entl ycause d b

ya n impac t d an d deforme d byth e fa i t o th e shaf t b

ya n elong a rotate d t o a closed , o r throug hth e faile d en d o etel ybroke n a s shown . 

### i k gur e e n s erna l

.r-l

. 

### 1 t T h 

### wa s T h ure . e d s near l 

### t : 

### th e 1 , w i tud s a pres s es e w c dama g e Tef l Bec a lot , t yc l o s valv e t htw o Teflo n n d nuts . Whe n ur e ejecte d th e r e foun d o n th e e d bya dee p o n ring s wer e us e th e bal l plu g h e valv e woul d e d position , t o

. Al l eigh t stud s Figur e 2 i s a sid e vie wo f th e valv e showin g th e botto mflang e (th e sid e closes t t o tlie reactor ) stil l intact , an d "hard " agains t th e mid-bod yo f th e valve . Non e o f th e stud s fo r th o botto mflang e wer e broken , an d al l wer e a t leas t finge r handlin g tight .P.7 7



### FORMOS APLASTIC S CORPORATIONAug . 6 , 190 4 LehighProjec t N

c 786-8 4 2

Th e 3BA1-1 0 i s a foundrypatter n number. " I n addition , al l thre e cas t component s wer e marke d with.th e materia l identification , CF8M , fo r 18- 8 stainles s stee l wit hmolybdenum , whic hi s th e cas t equivalen t o f wrough t Typ e 31 6 stainles s steel . Figur e 3 i s a sid e vie wo f on e o f th e broke n stud bolts . Th e bolt s ar e 7/16 " dia , 1 4 thd./in . size , 18- 8 typ e stainles s steel . Th e bol t wa s elongate d b yth e failur e a s ca n b e see n fro mth e stretche d thread s on eac hsid e o f th e fracture . Th e failur e appear s t o b e a typica l ductil e tensil e fractur e fo r thi s typ e o f material . EXAMINATIONO F STUD NUTS : . Clos e examinatio n o f th e 18- 8 stainles s stee l nut s remove d fro m th e broke n stud s showe d evidenc e o f over-tightening . On e o f th e nuts , representativ e o f thos e examine d from th e faile d flange * i s show

n i n Figure s 4 and 5 . Not e tha t th e washe r face , whic hi s th e contac t surfac e o f th e nu t agains t th e flange , i s severel yscore d and mechanicall ygouged , a s i f from heav yturnin g pressure . Als o not e tha t th e flat s o n th e sid e o f th e nu t ar e mashe d fromheav ywrenc hpressure , and ar e upset , o r crushe d a t th e bottomcorners . DISASSEMBL Y O F BOTTOMFLANGE : Durin g th e examination , th e bottomflang e wa s disassemble d from th e mid-bod

ypiece . Th e write r wa s no t presen t whe n th e flang e wa s removed . However , i t wa s reporte d tha t th e nut s wer e no t visibl yloose . Ther e wa s a fla t Teflo n ring gaske t betwee n th e flang e an

d mid-body , whic hfi t int o a ring groove . A s measure d wit hth e flang e face s superimposed , bu t no t bolted , and re-using th e ol d gasket , ther e wa s a clearanc e o f n o mor e tha n 0.00 8 betwee n th e super-impose d flang e faces . Th e ring groov e wa s 0.102 " deep , an d th e reuse d gaske t wa s 0.110 " thick . Th e smal l clearanc e mayb e th e resul t o f "cold-set " o f th e Teflo n durin g service . W e di d no t hav e a ne wgaske t fo r thicknes s comparisons . EXAMINATIONO F UNFAILE D NUTS : Th e eigh t nut s remove d fromth e unfaile d flang e ar e show n i n Figure s 6 and 7 . Not e tha t th e washe r fac e surface s and th e flat s ar e distorte d an d mashe d b

yheav ytorquin g pressures .

### FORMOS APLASTIC S '

LehighProjec t Nc 'O R PO RATION 786-8 4 Aug . 3 6 , 190 4

EXAMINATION S O F UNFAILE D STUDS : Th e thread s on th e eigh t unbroke n stud s showe d threa d stretching simila r to , bu t no t a s sever e a s tha t o n th e broke n stud s a t th e opposit e end . I n Figur e 8 , a 7/16 " dia . , 1 4 thd./in.tap i s positione d nex t t o on e o f th e stretche d studs . Fo r approximatel ytwo-inche s o f expose d thread , th e stud ha s been'elongate d b

yth e pitc ho f on e thread . Th e elongatio n i s 0.070" , o r 3.5 % o f tota l threa d exposed . EXAMINATIONO F UNFAILE D FLANGE : Th e to p surfac e o f th e flang e i n contac t wit hth e flang e nut s i s show n i n Figur e 9 . Not e tha t th e bol t hol e surface s ar e mashe d and score d b ycontac t pressur e o f th e nuts , durin g tightening o n th e studs . HEAT TEST S O F TEFLONRINGS : Figur e 1 0 show s on e o f th e Teflo n sea t ring s found o n th e floo r afte r th e failure . Th e ring i s ben t int o a a permanen t ova l shap e an

d i s no longe r fla t . I t als o i s deepl yindented . Laboratorytest s wer e ru n t o determin e th e temperatur e require d fo r thi s kin

d o f damage . I t wa s found tha t a ne wTeflo n ring , provide d b ya valv e maintenanc e service , coul d b e damage d i n a simila r manne r b y heatin g 20 0 t o 300°F , i n a controlle d laborator yoven , followe d b

ybendin g and squeezin g wit hpliers . DISCUSSION : CUrsoryevaluatio n o f th e faile d component s migh t lea d t o th e conclusio n tha t failur e wa s cause d b yinterna l detonation . However , th e detonatio n woul d hav e t o b e substantia l t o caus e simultaneou s ruptur e o f eigh t bol t wit hminimumtensil e strength s o f 75,00 0 ps i (Refe r t o ASTMA193 , Clas s B 8 fo r Typ e 30 4 stainles s steel) . Asaf e boltin g stress , accordin g t o handbooks , shoul d be no highe r tha n abou t 10 % o f th e ultimat e tensil e strengt ho f th e bolt . O n th e othe r hand , i f th e bolt s had bee n inadvertentl yover-tightened , an d stresse d clos e t o breaking , failur e woul d com e wit hlittl e additiona l loading . I t appear s tha t over-tightening , an d abnorma l highbol t stresses , wer e principall yresponsibl e fo r failur e durin g service . Assumin g tha t th e bolt s wer e clos e t o breakin g whe n th e valv e wa s place d int o service , act s norma l t o th e operatio n o f th e reacto r migh t be sufficien t t o "touch-off " failure . I t coul d be no mor e than opening , o r closing th e valve . O r ther e coul d hav e bee n some othe r incrementa l stres s on th e pipe , o r reactor . Ther e coul d eve n hav e bee n a smal l

### FORMOS APLASTIC S 1PORATIO NAug . 6 , 198 4 LehighProjec t No . 786-8 4 4

detonation , no t normall ya problem , unles s th e bolt s wer e alread yclos e t o failur e fro mover-stressing . W e understan d tha t th e reactor s occasionall yexperienc e smal l detonation s durin g start-u

p charging . Ther e i s evidenc e o f over-tightenin g wher e th e nu t washe r face s ar e heavil yscored , an d th e flats , i n contac t wit ha wrench , ar e mashed . I t shoul d b e note d tha t th e bottomflange , i n Figur e 2 , i s "hard " agains t th e mid-bodysection . Whe n th e flang e wa s removed , th e bolt s wer e noticeabl yelongated , a s i f fro mover-tightening . I f th e bottom flang e bolt s ha d bee n stretche d b

ya detonation , w e woul d expec t th e botto mflange , an d nut s t o b e visibl yloose . Th e valv e manufacture , i n privat e conversations , ha s note d tha t thi s particula r bal l valv e shoul d b e assemble d usin g torque s o f 4 5 t o 6 0 in.-lbs . fo r 7/16 " dia. , 1 4 thd./in . studs . Th e recommende d torqu e a t thes e value s shoul d no t caus e th e nut s t o upse t an

d mas ha s describe d i n th e report . Th e valv e manufactur e als o state d tha t ne wvalve s o f thi s styl e n o longe r us e fla t Teflo n flang e gasket s lik e thos e i n th e faile d valve . Th e recommendatio n i s t o us e a "chevron-packing " typ e gaske t o f alternatin g Teflo n and stainles s steel , whic hi s muc hlik e a flexitalli c design . CONCLUSION : Base d o n th e result s o f ou r examination , i t i s ou r opinio n tha t th e bal l valv e faile d a s a resul t o f over-tightene d stud bolt s a t th e faile d flange . I t appear s tha t th e stud bolt s wer e i n a highl ystresse d condition , an d clos e t o failure , prio r t o som e fina l unknow

n event , whic hcause d th e fina l fracture s b ysom e smal l amoun t o f additiona l bol t loading . Th e fina l even t coul d hav e bee n inheren t t o th e operatio n o f th e valve , and/o r reactor . I t coul d als o hav e bee n a smal l low-leve l detonatio n inheren t t o chargin g th e reactor , an d which , t o ou r knowledge , ha s no t previousl ycause d an yseriou s problem . Th e rathe r small , clearanc e o f 0.008 " betwee n th e flang e face s coul d be par t o f th e problem . W e d o no t know , a t thi s time , whethe r th e smal l clearanc e i s cause d b y"cold-set" , o r whethe r th e gaske t wa s under-size d whe n installed . I f th e gaske t wer e to o thin , i t woul d mak e i t difficul t t o ge t a leak-tigh t join t withou t dange r o f over-torquing .P.8 0



### FORMOS APLASTIC S ' '<PORATIO NAug . 6 , 19 8 4 LehighProjec t No . 786-8 4 5

W e hop e tha t w e hav e answere d question s concernin g th e caus e o f valv e failure . I f additiona l explanation s ar e required , o r i f mor e wor k shoul d be done , d o no t hesitat e t o contac t us . Verytrul yyours , LEHIGH TESTINGLABORATORIES , INC . Lewi s H . Reid , P.E . Consultin g Metallurgis t LHR;cj- s Enclosure s LT L letter s an

d report s appl yonl yt o th e specifi c materials , products , o r processe s tested , examined , surveyed , inspected , o r calculated ; an

d ar e no t necessaril yindicativ e o f th e qualitie s o f apparentl yidentica l o r simila r materials , products , o r processes . Th e liabilit yo f Lehig hTestin g Laboratories , Inc. , wit hrespec t t o th e service s rendere d herein , shal l b e limite d t o th e amoun t o f th e consideratio n pai d fo r suc hservice s an d shal l no t includ e an yconsequentia l damages .

### Formos a Piastre s Corp

Lehig hProj e . No . 786-8 4 P.8 1



### AAA..AA-AAAAA-AA-,A A"",.-,, '- ^ / yJ , |
•'Hi : 

# ''X

. • • *. . -r;A • - . ' = - r - 

# •:: 1

• 3 £.;••':• • .:.''•*• '

:
. < .'••-,• • 

# r#v \ i : 

## ^> ; 

## . 

# fe ; 

# *.VHf£t_w
_ .' v/ /

•'• •/ /

•

• ; . //"• • Tjr. . *y . :. ' r t(__5li*~ . pp-'.* * •. • : ' . N' • • -*- v*" . • • V" , : / "'* • * •

V.* « 

### • •• - •'• • • • -'-'x m

. • :'"••.'*'•'-*"'•*.•• ' • *t. y,*'. ' y - '-^.r.p. ; .v." . . ;.v.• . •. : \\; y y • ..-^ i 

### Figur e 1 : Component s o f faile d valv e receive d

a t th e laboratory

• • 

# p - v-» . r

_U.-_A_T. . . ....-w»»—-^p i

^ : • • • - \ .:>'y j *rfe*fc*'A./-t4^_»o ] ..... . «.. . __ti»_K_5t-t'-^---?-___ £ ,^_._.:.__«A"-.'-Wiu."_.*L:*r

_J.v U 

### Figur e 2 : Sid e vie wo f faile d valv e

Magnification: . 0.5 X

### Formos a Plastic s Cor p

LehighProj c . No . 786-8 4

/•

• / *

.

1 ,• '


### } 

# c

{ ( 

# I { { 

# k < 

# V c

/•-* •

•• , 

# c —-• ^

.— r7f c •J.-I *? ;

l -^.'-
_

.. . .p.p.'..^. - ">*i^

•<3't •.". " PP.'P«M V / -••-rr-.:. ;*
_

—v_C^ - rAtfc. .

f .V^^J^ 3 " *

_.-.-i** ii( W

< < •""••'• - " ' •<"-' -

> v 

# ..., ' 

# ^ : 3

^.i»;;_i.ii j

. ^

_.I'l l m > TM I *H- I r •••*• * -



### Figur e 3 : Sid e vie wo f broke n stu d a t faile d en

d o f valv e Magnification : 3 X

### Formos aPlasHc s Cor p

Lehig hProje , No . 786-8 4

& * 

# ^s; :



# ^ t 

# ..y . • . 

# 1 ,;

**W>l> r •* • >«

_-**_ . _-_-_i_- . _-_J'?_. * --.-•-• h _ /

• *>il>__-T-iA_l|_M_*ri * 

### Figur e 4 : Vie wo f washe r fac e (contac t face )

o f nu t fromfaile d stud Magnification : 3 X



# [xyryxpV' H.'."•• .



### Figur e 5 : Vie wo f crushe d fia t o n sid e o f nu t i n

Fir mr e 4

### Formos a Plas'*'c s Corp

LehighProjc \ No . 786-8 4

/ 

# V ^

' / 

# .1 

# /' .
J ; / '

Figur e 6 : Vie wo f washe r fac e surface s o n nut s

remove d fromunfaile d en d Magnification : I X

.-. v p * , -.. . /



### Fiqur e 7 : Vie wo f mashed ' flat s o n nut s i n Figur e 6

Magnification : I XP.8 5



### Formos a 'Plastic s Cor p LehighProj ' . No . 786-8 4

> > > > > _ y 7 > > > >

> • V

Li i -p u I I
_ _II' I l i H i •*" ! - I ' •i i II'I I '. ri< r 

### J
Figur e 8 : Vie wo f stu d a t unbroke n en

d o f valve , compare d t o a standar d threa d ta p Magnification : 2 X .P.8 6



### Formos a Plastic s Cor p LehighProjec t No . 786-8 4


## Hi

~~ 1

.,. «

•'••n a

* p'r—jj/.i ' _A ' •1 _ . .... . v**«i*..>^ p^ j *__9__82___S]!_3___S2_ i 

### Figur e 9 : Vie wo f unfaile d flang e showin g mashe d

bol t hole s Magnification : 1.25 X

,V7,lTl ' *<*#ju»m

M •* • f (KVA " "»•«•'»" ' i_^i"*i*wmj

_*^'HJP>*«-M' * ••**-»'• » w.wi^- i w > ipi.iii- * rf-^ , wr.'"wT.(-« v



### Fiaur e 10 : Teflo n sea l ring fromfaile d valv e

Magnification : 0.75 X' / P.8 7



### " / 

### £ ^ FORMOS APLASTIC S CORPORATIO NDELAWAR E

~ >S ^l£f P.O . BO

X320 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L (302) 834-457

5 Apri l25 , 198 3
CERTIFIED MAI

L RETUR NRECEIPTREQUESTE

D

rtJV... . 

### tio n' ' 

# |\PR29«8

3 j 2 8 1??3 

# 1

s,Ar f< * oaAw ,

r.n,' . -,7 AT E 9 ' r ;.',' 1 , \.'CONTRO L ,yw~i^>* - c ' .i u Rober t R , French , P,E . Manager , Ai r

Resource s Se c Delawar eDept , o f

Natura lResources, , <_, . an dEnvironmenta lContro lW > P,0 . Bo x140 1 Dover , D E1990 1 Dea r Mr . French : RE : Viny l Chlorid e Monome r Release s Formos a Plastic s Corporatio n Delawar e I n accordanc e wit hNationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t th e Delawar e City , Delaware ; the addres s fo r thi s source :

P.O . Bo x32 0 Schoolhous e Roa d Delawar e City , Delawar e 1970 6 Sourc e o f Releases :

Releas e ill: Carbo n Be d Are a Releas e 112 : Emulsio n Tank Farm A . Natur e o f Cause : Releas e ill: Aviny l chlorid e (VCM ) lea k occurre d o n a VC Mwast e storag e ga s bulle t CT-100C . 

### V > \ J v

Releas e #2 : An overpressuring o f viny l chlorid e (VCM ) storag e bulle t DT-102 B occurre d whic hresulte d froma n operato r erro r during the un loading operatio n o f a VCMtan k car . Line-u

p o f valve s wa s suc htha t th e Abulle t wa s bein g emptie d whil e B bulle t wa s fille d unti l VC M pressur e exceede d 20 0 psi . Ruptur e dis k ble wan d relie f valv e lifte d fo r approximatel y4 5 second s causing a VC Mdischarg e t o atmosphere ./ Rober t R . Frenc h-2
- Apri l 25 , 198 3

B . Dat e an

d Tim e o f Release : Releas e #1 : Monday , Apri l 18 , 198 3 a t 140 0 hour s t o 184 5 hours . Releas e #2 : Tuesday , Apri l 19 , 198 3 a t 030 0 hours . C . Approximat e Tota l Los s o f Viny l Chloride ; Releas e #1 : Les s than on e hundre d (100 ) pound s o f viny l chloride released . Releas e #2 : Tw o thousand twenty-fiv e (2025 ) pound s o f viny l chloride discharge d t o atmosphere . D . Metho d Use d t o Determin e Amount : Releas e #1 : Condition s o f CT-100 C

V = 30,00 0 gallon s (4010. 7 cu.ft. ) P = 5 0 psi g Volum e o f ven t ga s 5 0 14. 7 x4010. 7 = 13641. 8 Weigh t o f ven t ga s (densitya t 45 % VCM= 0.1 1 ^j ) o f th e 982"lbs . VCMi n th e tank , i t i s estimate d tha t onl y 5 % o f th e VC Mwa s discharged . Therefore , les s tha n 10 0 lbs . i s estimate d t o b e release d t o atmosphere . Releas e #2 : I t i s estimate d fro mthe pum

p curve s tha t 27 0 gallon s viny l chlorid e wer e discharge d during th e time tha t th e relie f valv e lifted . E . Actio n Take n t o Preven t Discharge : Releas e #1 : (1 ) Onc e th e leak wa s recognized , a wate r hos e wa s pu t o n th e lea kt o minimiz e th e fir e an d explosio n hazard . (2 ) Incineratio n rat e fro mthi s tan

k wa s increase d t o hel p reduc e VC M pressur e i n th e tank . (3 ) Al l venting fro mth e reacto r plant s t o thi s storag e tan k wa s stopped . (4 ) Recoverysystem s fro mreacto r plant s wer e utilize dt o hel pfurther reduc e pressure . (5 ) Leak wa s fixe d b yplugging wee p hol e wit htappe d pip e an dvalve .Rober t R . Frenc h-3
- Apri l 25 , 198 3

Releas e #2 : (1 ) A s soo n a s th e operato r becam e awar e o f th e highpressure , charg e pump s wer e shu t off , stopping VC Mfrombein g pumpe d int o B bulle t and thereb yhaltin g th e discharge . F . Measure s Adopte d t o Preven t Futur e Discharge : Releas e #1 : (1 ) A t th e presen t time , viny l chlorid e wast e storag e ga s bulle t CT-100 C i s bein g take n ou t o f servic e an d welds , valves , an d gasket s ar e being replace d o r repaired , a s required . (2 ) Avalv e ha s bee n connecte d t o eac hwee p hol e and lef t opene d s o tha t i f a simila r leak occur s i n a flang e weld , th e valv e onl yha s t o b e close d i n orde r t o stop th e leak . Releas e #2 : (1 ) Operator s an

d foreme n wil l b e reinstructe d a s t o th e correc t operating procedures . Operator s wil l b e retrained , i f necessary . Severa l ke ysafet yissue s wil l b e stressed . (2 ) Safet yinterlock s wil l b e designe d int o th e systemt o preven t thi s fromoccurring again . (3 ) Mechanica l defect s associate d wit hth e selecto r switc hwil l als o b e corrected . I f ther e ar e furthe r question s pertaining t o th e informatio n submitted , fee l fre e t o contac t me . Sincerely ,
Charle s A . Markowit z «— ^ Associat e RegulatoryAffair s Specialis t CAM:ma h cc : Mr . Pete r N . Bibc o Mr . WilliamG . Razo rP.9 0

v

### FORMOS APLASTIC S CORPORATIO NDELAWAR E _ £ •P.O
. BO

X320 •DELAWAR E CITY , DELAWAR E 1970 6 « •TE L(302) 834-4575


### Marc h18 , 198 3

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D 

# RECEIVE D Rober t R , French , P.E . Manager , Ai r Resource s Sectio n Delawar e Departmen t o f Natura l Resource s MA R ? 4 19 8 i an d Environmenta l Contro l P.O . Bo x140 1 Dover , Delawar e 1990 1 

### EPA-FNV!K

_ vivitNVA L SERViCh S DiViSlO N Dea r Mr , French ; RE : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E I n accordanc e wit hthe Nationa l Emissio n Standar d fo r Hazardou s Ai r Pollu
tants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) - Relie f Valv e Discharge , Polyviny l Chlorid e Plan t locate d a t Delawar e City , Delaware ; the addres s fo r thi s source :

P.O . Bo x32 0 Schoolhous e Road Delawar e City , D E 1970 6 Sourc e o f Release :

Suspension-I I Are a A , Natur e o f Cause : Batc hS-120 7 wa s charge d i n reacto r SR-40 7 a t 8:1 5 p.m . o n Marc h8 , 1983 . A t 10:1 5 p,ra . the plan t experience d a powe r interruptio n whic hcause d a numbe r o f motor s t o fail . Al l motor s tha t faile d wer e restarte d excep t fo r a Worthingto n ai r compresso r whic hsupplie d th e plan t wit h instrumen t air . Th e los s o f instrumen t ai r cause d the following thing s t o happen : 1 ) fai l ope n o f the cooling wate r valves , 2 ) los s o f batc htemperatur e an d pressur e informatio n i n the contro l rooms , an d

A-6P.9 1

Rober t R , Frenc h-2
- Marc h18 , 198 3

3 ) th e wate r delug e system s t o activat e i n th e S- 2 reacto r building , warehous e an

d S- I third recoverysystem , Sinc e powe r wa s returne d almos t immediately , n o actio n wa s take n t o terminat e batches . Loca l pressur e gauge s wer e checke d periodically . A t thi s time i t wa s apparen t ther e wa s highpressur e i n SR-40 7 an d the terminatio n pro cedur e wa s started , During thi s time , reacto r SR-40 7 wa s als o vente d t o SR-40 2 t o hel p furthe r reduc e the pressure , ' Bot hstep s wer e no t enought o brin g the reacto r unde r contro l s o a s t o preven t th e blowin g o f the ruptur e dis k an d a VC Mreleas e t o atmosphere , B , Dat e an

d Time : Tuesday , Marc h8 , 198 3 a t 223 0 hours . C , Approximat e Tota l Los s o f Viny l Chloride : Two thousan

d tw o hundre d eleve n pound s o f viny l chlorid e los t t o atmosphere , D , Metho d Use d t o Determin e Loss : Fromlevel s i n reactor s SR-40 7 an d SR-402 , i t i s estimate d tha t 20 % o f th e batc hwa s VC Mlos t _

frac t pound s batc h o f th e batc hwa s lost , Th e following determinatio n i s made : / ,-,./„ '

tio n o f f

VC Mcharge d _/ reactio n time a t discharge ) / VC M)J hlos t V

pound s Tota l Pol yTime , charge d 0,2 0 (17,20 0 - ( 2.5 ^ (17200) ) hour s

7 

### "HH 

### -H.,,

= 2,21 1 lbs , VC Mrelease d t o atmospher e Actio n Take n t o Preven t Discharge : 1 ) <=\-methy

l styren e (2 % gallons ) wa s adde d t o batch . 2 ) Batc hwa s vente d t o empt yreacto r SR-40 2 t o hel p reduc e pressure . 3 ) Stea

mwa s manuall yshu t of f t o th e plant .P.9 2

Rober t R , Frenc h-3
- Marc h18 , 198 3

F , Measure s Adopte d t o Preven t Futur e Discharges : 1 ) Upo n a los s o f instrumen t air , al l pol ybatche s wil l b e terminate d promptly , 2 ) Auxiliaryai r wil l b e mad e availabl e an d checke d o n a dail ybasi s s o a s t o b e abl e t o restar t ai r compressors . I f ther e ar e furthe r question s concerning th e informatio n submitted , fee l fre e t o contac t me , Sincerely ,



# (%*&, &. foM^*^. Charle s A . Markowit z Associat e Regulatory Affair s Specialis t CAM:mah cc : Pete r Bibk o U.S . EP AP.9 3 

# XS N FORMOS APLASTIC S CORPORATIO NDELAWAR E P.O
. BO X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-457 5 :Q

### A- iooo?>
Marc h4 , 198 3

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D

Rober t R , French , P.E , Manager , Ai r Resource s Sectio n Delawar e Departmen t o f Natura l Resource s an d Environmenta l Contro l P.O . Bo x140 1 Dover , D E 1990 1 Dea r Mr , French : RE : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E I n accordanc e wit hth e Nationa l Emissio n Standar d fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61,6 5 (a ) - Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Delawar e City , Delaware ; the addres s fo r thi s source : . . P.O . Bo x32 0 Schoolhous e Road Delawar e City , D E 1970 6 Sourc e o f Release :

Emulsion-I I Are a Natur e o f Cause : Batc hD-34 8 wa s being charge d i n reacto r DR-40 3 a t th e E-I I Plant . Whe n agitato r wa s turne d o n t o star t batc hreactor , pressur e quickl yincrease d unti l ruptur e dis k ble wan d relie f valv e lifte d causing a viny l chlorid e monome r releas e t o atmospher e whic hlaste d approximatel ylh minutes . Th e majo r caus e o f releas e wa s D/ I wate r valv e leaking throughwhic hresulte d i n the batc hbein g overcharge d an d hydrostating . I t als o shoul d b e note d tha t operato r di d no t chec k reacto r leve l befor e turning o n agitator . 

# RECEIVE

D iE i EI¥ED RE:c 

# EfVE D ' MA R 0 9 198 3 EPA-ENVIRONMENTA L SERVICE S DiViSlO N !••?$ £



### . " 3 rZH SECT'O X MA R- 8 |9 f i 3 

### EPA , KEGIO

Ni n 

# **§am mam • 4 3P.9 4

Rober t R . Frenc h-2
- Marc h4 , 198 3

B , Dat e an

d Time o f Release : Thursday , February25 , 1983 , a t 212 5 hours . C , Approximat e Tota l Los s o f Viny l Chloride : Tw o thousan

d forty(2040 ) lbs , viny l chlorid e monome r wa s discharge d t o atmosphere . D , Metho d Use d t o Determin e Loss : Th e amoun t o f viny l chlorid e los t t o atmospher e wa s determine d fromth e % solid s i n th e batch , 19.5% , vs . an averag e o f 26,9 % solid s i n th e othe r batches . I t i s als o assume d tha t ther e wa s 10 % mor e wate r i n tha t batc h an d sinc e the stripping operatio n wa s starte d immediatel yo n the reacto r a n extr a 100 0 lbs . VC Mmor e tha n norma l wa s recovered .

Lbs , VC Mcharge d = 18,00 0 Lbs . Lbs . VC Mconverte d t o PVC = 11,96 0 Lbs . Lbs , VC Mrecovere d = 4,00 0 Lbs . Lbs . VC Mrelease d t o atmospher e = 2,04 0 Lbs . E , Actio n Take n t o Preven t Discharge : .. . - -. . - —- 1 , Stripping operatio n wa s starte d immediatel yt o remov e unreacte d viny l chlorid e i n orde r t o lowe r reacto r pressure . 2 , Batc hwa s als o place d i n ful l cooling . F , Measure s Adopte d t o Preven t Futur e Discharge : 1 , Disciplinaryactio n ha s bee n give n t o th e tw o operator s involve d i n charging o f thi s batch . 2 , Deionize d wate r valv e ha s bee n repaired . 3 , Al l E- 2 (emulsion plant ) A-operator s wil l b e retraine d a s t o th e importanc e o f checking reacto r level s a t certai n time s durin g th e charg e procedure .P.9 5

Rober t R . Frenc h-3
- Marc h3 , 198 3

I f yo u nee d additiona l informatio n o r hav e an yquestions , fee l fre e t o contac t me , Sincerely , ,
Charle s A . Markowit z Associat e Regulatory Affair s Specialis t CAM:mah cc : Mr , Pete r Bibko , Administrato r Regio n III , EP AP.9 6 

# >_3 S FORMOS APLASTIC S CORPORATIO NDELAWAR E P.O
. BO X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-457 5


### January14 , 198 3 CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D

Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Delawar e Departmen t o f Natura l Resource s an d Environmenta l Contro l P.O . Bo x140 1 Dover , Delawar e 1990 1 Dea r Mr . French :

RE : VINY L CHLORID E MONOME R RELEAS E FORMOS APLASTIC S CORPORATION , D E I n accordanc e wit hth e Nationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Delawar e City , Delaware ; th e addres s fo r thi s source :

Sourc e o f Releases : P.O . Bo x32 0 Schoolhous e Roa d Delawar e City , D E 1970 6
Releas e #1 : Releas e #2 : Carbo n Be d Are a

Emulsio n Plan t EPVC-I I A . Natur e o f Cause : Releas e #1 . Aviny l chlorid e (VCM ) leak occurre d o n a VC M wast e storag e ga s bulle t CT-100C . Pressur e o n th e bulle t a t th e time o f th e lea k wa s 6 0 psi g wit ha concentratio n o f 35 % VCM . Releas e #2 . An unauthorize d openin g o f reacto r DR- 4 0 5 occurre d whe n a mechani c pulle d a stea mspargin g spoo l o n a reacto r whic hhad a batc ho f terminated , bu t no t completel ystripped , late xi n it .P.9 7



### ROBER T R . FRENCH , P.E . -2
- JANUARY 14 , 198 3

B . Dat e an

d Tim e o f Releas e Releas e #1 : Thursdayt o Friday , January6-7 , 198 3 a t 233 0 hour s t o 130 0 hour s Releas e #2 : Thursday , January13 , 198 3 a t 114 5 hour s C . Approximat e Tota l Los s o f Viny l Chlorid e Releas e #1 : Les s tha n on e hundre d (100 ) pound s o f viny l chlorid e release d Releas e #2 : Les s tha n on e hundre d (100 ) pound s o f viny l chlorid e release d D . Metho d Use d t o Determin e Amoun t Releas e #1 : Condition s o f CT-100 C V=3000 0 gallon s (4010. 7 cu . ft. ) P=6 0 psig . Volum e o f ven t ga s

6 0 

### x4010. 7 = 1637 0 ft. 3 

### 14. 7 Weigh t o f ven t ga s 1637 0 x0.101 5 = 1661. 6 lbs . - (581. 6 lbs . VCM ) O f th e 581. 6 lbs . VC Mi n th e tank i t i s estimate d tha t onl y 15 % o f the VC Mi n th e tank wa s discharged . Th e remainin g VC Mi n th e tank wa s eithe r incinerate d i n th e boiler s o r vente d t o othe r VC Mstorag e tanks . Releas e #2 : I t i s estimate d tha t 2 fee t 2 inche s o f reactio n mixtur e wa s los t t o th e drain . I t i s estimate d tha t 2 % o f th e 150 0 lbs . PV

C los t wa s viny l chlorid e whic hwoul d calculat e ou t t o b e 3 0 lbs . VCM . E . Actio n Take n t o Preven t Discharg e Releas e #1 : • (1 ) Onc e th e leak wa s recognize d th e sprinkle r systemwa s turne d o n t o minimiz e th e fir e an d explosio n hazards .P.9 8



### ROBER T R . FRENCH , P.E . -3
- JANUAR Y 14 , 198 3

(2 ) Incineratio n rat e fro mthi s tan k wa s increase d t o hel p reduc e th e pressure . (3 ) Thi s wast e ga s bulle t wa s als o vente d t o othe r storag e tank s t o hel p reduc e pressure . - (4 ) Al l ventin g fro mth e reactio n plant s t o thi s storag e tan k wa s stoppe d (5 ) Recover ysystem s fro mreacto r plant s wer e utilize d t o hel p reduc e pressur e Releas e #2 : (1 ) Whe n spargin g spoo l wa s plugged , spoo l wa s reassemble d t o sto p discharg e (2 ) Disciplinar yactio n wil l b e take n (3 ) Mechani c wil l b e retraine d i n thi s operatio n F . Measure s Adopte d t o Preven t Futur e Discharg e Releas e #1 : A t th e presen t tim e eac hviny l chlorid e wast e ga s storag e bulle t i s bein g taken.ou t o f servic e an d suc hvalve s an d gasket s ar e bein g inspecte d an d replace d a s required . Releas e #2 : Mechani c involve d wil l b e give n additiona l training . I f ther e ar e furthe r question s concernin g th e informatio n submitte d pleas e d o no t hesitat e t o contac t me . Sincerely ,
Charle s A . Markowit z Associat e Regulator y Affair s Specialis t CAM:1 1 cc^Mr . Pete r N . Bibc oP.9 9



### , TM FORMOS APLASTIC S CORPORATIO NDELAWAR E xj£ / P.O
. 30 X320 •DELAWAR E CITY , DELAWAR E 1970 6 •7i" L(302) 834-4575

Octobe r 9 , 198 4

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D

Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Stat e o f Delawar e Departmen t o f Natura l Resource s an d Environmenta l Contro l P.O . Bo x140 1 Dover , Delawar e 1990 3 RE : Resi n Spil l Dea r Mr . French : Formos a Plastic s Corporatio n Delawar e hereb yconfirm s a spil l o f resi n Octobe r 7 , reporte d b

ytelephon e t o Mr . JosephHardma n o n Octobe r 9 , a s pe r condition s o f AP C Permi t 82/266 , paragraph3 , an d Delawar e Code , Chapte r 7 , Sectio n 6006 , Reporting Emissions . A t approximatel y120 0 hour s o n Octobe r 7 , a spil l o f approximatel y300 0 lbs . o f resi n fro

mSil o DT601 B occurre d du e t o sil o overfill. . Operation s ha s cite d th e blo wtan

k weig hscal e calibratio n a s the cause , an d ha s submitte d a correctiv e maintenanc e wor k order . Cleanu p o f th e spille d resin , confine d t o the inuredinue are a o f th e silos , wa s promptl yinitiated . I f yo u hav e an

yquestion s or nee d additiona l information , pleas e d o no t hesitat e t o telephon e me a t (302 ) 836-2219 . 

### Sincerely , _ ^ 

# '(Qxut MUH 

# sa-- . , v H . Alle nWrigle ^ Jr . . * • tf£h$L Environmenta lManage r . • ^n r A%. v^

M HAW:1 1 cc : JosephJ . Hardman , P.E . Ronal d Patterso np. 1


# >5£ y FORMOS APLASTIC S CORPORATIO NDELAWAR E P.O . BO X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L (302 ) 834-457 5 

### Decembe r 2 , 198 2 CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D

Mr . Rober t R , French , P.E . Manager , Ai r Resource s Sectio n Delawar e Departmen t o f Natura l Resource s & Environmenta l Contro l P . 0 . Bo x140 1 Dover , Delawar e 1990 1 Dea r Mr . French : RE : VINY L CHLORID E MONOME R RELEAS E FORMOS APLASTIC S CORPORATION , D E I n accordanc e wit hNationa l Emissio n Standard s fo r hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.6 5 (a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a f Delawar e City , Delaware ; th e addres s fo r thi s source :

Pos t Offic e Bo x32 0 Schoolhous e Roa d Delawar e City , Delawar e 1970 6 Sourc e o f Release : SPVC-I I Plan t A . Natur e o f Caus e

Aviny l chlorid e (VCM ) releas e occurre d fro m reacto r SR-40 6 becaus e o f th e additiona l amoun t o f catalys t adde d t o counterac t th e *< -methy l styrene , a shor t sto p presen t i n th e recovere d viny l chlorid e monomer . Durin g previou s da yo f operation , a powe r outag e ha d occurre d a t th e plan t whic hresulte d i n al l suspensio n batche s bein g immediatel y terminate d with K -methy l styren e (AMS) . Sinc e al l thes e batche s ha d t o b e strippe d aOBunreacte d viny l chlorid e recovere d ha d AM S presen t i n it , i t wa s believe d tha t mor e catalys t the n norma l woul d b e require d i n orde r t o reac t thi s monomer . On e batc hwa s charge d i n bot hth e SPVC- I and SPVC-I I plan t a t th e increase d catalys t levels . Bot hbatche s wer e observe d closel yand upo n seein g hig hpressur e rise , AM S wa s immediatel y adde d t o tha t reacto r bu t pressur e ris e continue d unti l releas e t o > V X atmosphere . Th e batc hi n th e S- I Plan t wa s brough t unde r control , bu t \ ^ * \ v th e batc hi n th e S- 2 Plan t wa s no t controlle d eve n afte r ventin g t o ^ ^ anothe r reacto r an d th e recover ysystem . <P%f~ /T+f^i\ t T~f^<t"

V V / " b.V 

# RECEIVE D DE C 

## - 6 198

2 

## * % <P. 2

Mr . Rober t R . French , P.E . - 2 - Decembe r 2 , 198 2 B . Dat e an

d Tim e o f Releas e Thursday , Novembe r 25 , 198 2 a t 010 0 hours . C . Approximat e Tota l Los s o f Viny l Chlorid e

Si xthousan

d fiv e hundre d (6,500 ) pound s viny l chlorid e wa s estimate d t o b e discharge d t o atmosphere . D . Metho d Use d t o Determin e Los s

17,50 0 = lbs . VC Mcharge d i n SR-40 6 4,50 0 = lbs . VC Mrecovere d i n accumulato r estimate d fromleve l

indicator s befor e an d afte r batch . 3,50 0 = lbs . VC Mconverte d t o PVC assumin g 20 % conversion ;

estimate d frombatc hcar d condition s - temperature , reactio n time and pressure . 3,00 0 = lbs . VC Mremainin g i n batc hestimate d fromsharp decreas e

i n pressur e afte r releas e o r transferre d t o othe r reactor , 6,50 0 = lbs . VC Mdischarge d t o atmosphere * E . . Actio n Take n T o Preven t Discharg e

1 . AM S wa s adde d t o reactor . 2 . Manua l stea

mt o reacto r wa s blocke d in . 3 . Reacto r wa s vente d t o reacto r SR-40 3 an d tw o degassin g tank s i n a n attemp t t o lowe r pressure . F . Measure s Adopte d T o Preven t Futur e Discharge s

1 , Catalys t amount s i n futur e charge s wer e considerabl yreduce d •< « far. 4 r\a . 2 , Unde r simila r conditions , suc hincrease d amoun t o f catalys t wil l no t b e used again . I f ther e ar e an

yfurthe r question s concerning th e informatio n submitted , d o no t hesitat e t o contac t me . Sincerely ,
Charle s A . Markowit z Associat e Regulatory Affair s Specialis t .CAM/ctvP. 3



### FOR2VIOS APLASTIC S CORPORATIO NDELAWAR E P.O
. BO X320 •DELAWAR E CITY , DELAWAR E 19706 » TE L(302 ) 834-457 5 > 'yi- / /

Septembe r 24 , 198 2 

# RECEIVE D 

# *£ ,

c ^

"**&»// / 

# eo CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Mr . Rober t R . French , P.E . Manager , Ai r Resource s Sectio n Delawar e Departmen t o f Natura l Resource s & Environmenta l Contro l P.O . Bo x140 1 Dover , D E 1990 1 Dea r Mr . French : Re : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E I n accordanc e wit hNationa l Emissio n Standard s fo r hazard
- ' ou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Delawar e City , Delaware ; th e addres s fo r thi s source : Pos t Offic e Bo x32 0 Schoolhous e Roa d Delawar e City , Delawar e 1970 6 Sourc e o f Release : EPVC-I I Plan t OC T4 iQ Q 

## •3 2 AI R& WASTEMANAGEMEN T r r ; DIVISION mt m EPAREGIO NUl

A . Natur e o f Caus e Aviny l chlorid e (VCM ) releas e o f shor t duratio n occurre d fro m Accumulator , DT-303 , becaus e o f a hydrostat . B . Dat e and Tim e o f Releas e



# SEP 

# 3 0 

# E 198 2 Thursday , Septembe r 16 , 198 2 a t 144 5 hours . Approximat e Tota l los s o f Viny l Chlorid e Tw o hundre d fift y(250 ) pound s viny l chlorid e wa s discharge d t o atmosphere . Metho d Use d t o Determin e Los s Observation s o f liqui d leve l i n th e accumulato r indicat e tha t ther e wa s n o los s o f liqui d VCM . Becaus e o f tha t fac t and th e shor t duratio n o f thi s release , i t i s estimate d tha t n o mor e tha n tw o hundre d fift ypound s o f VC Mwa s lost .

• • . - ' K 

# a ...Ai 

# I t^X .Viny l Chlorid e Monome r Releas e Septembe r 24 , 198 2 Pag e 2
E . Actio n Take n t o Preven t Discharg e 1 . Upo n discoveryo f thi s problem , operato r switche d t o th e othe r ruptur e disc . 2 . Recoverysystem s wer e als o shu t dow n t o reduce , pressur e build-up . F . Measure s Adopte d t o Preven t Futur e Discharge s Leve l Indicato r (L.I. ) fo r DT-30 3 wil l b e repaired . I f ther e ar e furthe r question s concernin g th e informatio n submitted , fee l fre e t o contac t me .

CAM/cam Sincerely ,
Charle s A . Markowit z Associat e Regulatory Affair s Specialis t

CC . Mr . Pete r Bibc o (EP ARegio n III )P. 5

JOP.VOS APLASTi'bb S CORPORA/r.O NDI.b., AVvAib ^ P.O
. BO X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-457 5 Augus t 31 , 198 2
CERTIFIE D MAI L . RETUR NRECEIP T REQUESTE D
Mr . Pete r N . Bibc o Regiona l Administrato r U . S . Environmenta l Protectio n Agenc y Regio n III , Sixt han d Walnu t Street s v l "\j Philadelphia , Pennsylvani a 1910 6 ^ ' l Dea r Mr . Bibco : ' ^ ^y^

RE : VINYL CHLORID E MONOME R RELEAS E FORMOSAPLASTIC S CORPORATIO NDELAWAR E I n accordanc e wit hth e Nationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.6 5 (a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Delawar e City , Delaware ; the addres s o f thi s source : Pos t Offic e Box32 0 Schoo l Hous e Road Delawar e City , Delawar e 1970 6 Sourc e o f Release : SPVC-I I Plan t A . Natur e o f Caus e Viny l Chlorid e Monome r (VCM ) wa s release d fromreacto r SR-41 0 becaus e o f operato r error . I n the transfe r o f ethylen e dichlorid e (EDC) , a n organi c solven t use d t o clean dirtyreactors , fro mreacto r SR-40 9 t o PT-206 , th e operato r mistakenl yaligne d reacto r SR-41 0 whic hhad a polymerizatio n reactio n i n it . Th e resul t wa s a releas e o f VC Mfro mSR-41 0 t o PT-206 , an ED C storag e tan k t o atmosphere . B . Dat e an

d Time o f Releas e Monday , Augus t 23 , 1982 , a t 090 0 hour s C . Approximat e Tota l Los s o f Viny l Chlorid e I t i s estimate d tha t fifty-si xhundre d ten (5,610 ) pound s o f viny l chlorid e monome r (VCM ) wa s release d t o atmosphere . 

# RECF*Vb ~

n ii\ •« * i\.. . E P A.?>:.•#<>.:;. Il lP. 6

Mr . Pete r N . Bibc o Pag e 2 Augus t 31 , 198 2
D . Metho d Use d t o Determin e Los s Visua l observatio n o f the batc hafte r releas e indicate s tha t approximatel y one-third o f th e reactor' s content s wa s discharged , I t i s assume d tha t a t the time"o f discharg e ther e wa s 1 % conversio n o f VC Mt o polyviny l chlorid e (PVC ,

17,00 0 lbs . VC Mcharge d i n reacto r SR-41 0 17 0 lbs . VC Mconverte d t o PVC 5,61 0 lbs . VC Mdischarge d t o atmospher e 11,22 0 lbs . VC Mremaining i n reacto r E . Actio n Take n t o Preven t Discharg e Plan t foreman close d ED C lin e whe n reacto r wa s foun d t o b e discharging t o PT-206 . F . Measure s Adopte d t o Preven t Futur e Discharg e 1. Operato r wa s retraine d a s t o th e correc t ED C transfe r procedure . 2 . Th e operato r wa s als o give n disciplinarytime of f becaus e o f hi s carelessness . I f ther e ar e question s pertaining t o the informatio n submitted , fee l fre e t o contac t me . Sincerely ,
Charle s A . Markowit z Associat e Regulatory Affair s Specialis t

CAM/ 1 t g cc : Mr . Rober t Frenc hP. 7



### - ^ V

### - '.-.?.VOS APLASTIC S COPJ "

P.O
. BO X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-457 5 

### Jul y17 , 198 1
CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Mr . Jac k Schramm , Reg . Administrato r U . S . Environmenta l Protectio n Agenc y Regio n III , Sixt han d Walnu t Street s Philadelphia , PA1810 6 Dea r Mr . Schramm : Re : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E I n accordanc e wit hthe Nationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) - Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Delawar e City ; th e addres s fo r thi s source : P . 0 . Bo x32 0 Schoolhous e Roa d Delawar e City , D E 1970 6 Sourc e o f Release : SPVC- I Plan t A . Natur e o f Caus e

Aviny l chlorid e (VCM ) releas e occurre d fromreacto r PR-40 7 a t approximatel y131 5 hour s o n Jul y8 , 1981 , becaus e o f highpressur e resulting frominsufficien t cooling o f the batch . Whe n instrumentatio n calle d fo r cooling , wate r wa s shor t cir

cuite d ou t the suctio n lin e bac k t o th e tower . Thi s wa s mad e possibl e b

ya chec k valv e staying ope n an d th e recirculatin g pum p no t starting . Also , becaus e o f a ba d transmitter , th e pressur e pic k i n the contro l roomdi d no t accuratel yindicat e the existing highpressur e i n the batc hs o tha t mor e promp t correctiv e actio n coul d hav e bee n take n t o preven t thi s release . B . Dat e an

d Time o f Releas e Wednesday , Jul y8 , 1981 , a t 131 5 hours . C . Approximat e Tota l Los s o f Viny l Chlorid e

Twenty-seve n hundre d seve n (2,707 ) pound s viny l chlorid e \^ \ discharge d t o atmosphere .P. 8



### Mr . Jac k Schramm , Reg . Administrato r Jul y16 , 198 1 Pag e 2
D . Metho d Use d t o Determin e Los s I t i s estimate d fro mth e 1 % hou r reactio n tim e a t increase d reactio n temperatur e tha t 30 % o f th e VC Mwa s converte d t o polyviny l chloride . Lbs . VC MCharge d t o Reacto r % Conversio n Lbs . VC MEmitte d t o Atmospher e Lbs . VC MRemainin g i n Batc h 11,60 0 30 % 2,70 7 5,41 3 Visua l observatio n fro mlevel s i n th e reacto r showe d tha t approximatel y1/ 3 o f reacto r content s wer e discharge d t o th e atmosphere . Som e o f th e batc hcontent s wer e als o transferre d t o reacto r PR-403 . E . Actio n Take n t o Preven t Discharg e 1 . Tw o shot s o f a-methylstyren e (AMS ) wer e adde d t o moderat e batc htemperature . 2 . Recirculatin g pump wa s manuall yplace d i n ful l chill . 3 . Batc hwa s equalize d wit hPR-403 , a n empt yreactor . 4 . Th e strippin g operatio n wa s starte d t o reduc e pressure . F . Measure s Adopte d t o Preven t Futur e Discharge s 1 . Al l recirculatin g pump s ar e no wbein g operate d i n manual . ,2 . Th e pressur e transmitte r ha s bee n repaired . 3 . Pump s wil l b e rewired , s o a s t o activat e whe n pressur e reache s 4 ps i o n th e Moor e Controller . I f ther e ar e furthe r question s concernin g th e informatio n submitted , fee l fre e t o contac t me . Sincerely ,
Charle s A . Markowit z Associat e Regulator yAffair s Specialis t CAM:cd r cc : Rober t R . Frenc h Rober t Tagger tP. 9

PLASTIC S DIVISIO N 

## Stauffe

r 

# Stauffe rChemica l Compan y P.O
. Bo x32 0 /

Delawar e City , Delawar e 1970 6 / Telephon e (302 ) 834-457 5 

### Ma y 14 , 

### 198 1 

### CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D 

# ! h 

# NJV ) Mr . Thoma s Voltaggio , Acting Directo r U.S . Environmenta l Protectio n Agenc y Enforcemen t Divisio n Sixt h& Walnu t Street s Philadelphia , P

A1910 6 Dea r Mr . Voltaggio : B ythi s letter , Stauffe r Chemica l Compan y(th e transferor ) an d Formos a Plastic s Corporatio n US A(th e transferee) , hereb y infor mthe Unite d State s Environmenta l Protectio n Agenc ytha t o n o r aroun

d Ma y14 , 198 1 operationa l contro l an d ownershi p o f the Stauffe r Chemica l Compan yPolymer s Plant , P.O . Bo x320 , Delawar e City , Delawar e shal l b e transferre d t o Formos a Plastic s Corporatio n USA , headquartere d a t 6 6 Hanove r Road , FlorhamPark , Ne wJersey07932 . A s a resul t o f the chang e i n operationa l contro l an d owner ship , bot hStauffe r Chemica l Compan yand Formos a Plastic s Cor
poratio n US Aagre e tha t the responsibilit yt o compl ywit hth e Nationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 4 0 - Viny l Chlorid e Standar d shoul d b e transferre d t o Formos a Plastic s Corporatio n USA . I f yo u hav e an

yquestion s concerning thi s matter , fee l fre e t o contac t m e a t (302)834-457 5 extensio n 285 . Sincerely , Charle s A . Markowit z < 

### ~ ^ Associat e RegulatoryAffair s

Specialis t CAM/p j ^ 

# t -P.1 0

7 •'.. 

## ^^^FORMOS APLASTIC S CORPORATIO NDELAWAR ERECE

j ' / tlL) P.O
. BO X32 0 •DELAWAR E CITY
. DELAWAR E 1970 6 •TE L(302 ) 834-457 5 Augus t 26 , 198 2 

## SE PG 1 AI R 

### & W A Lb\- : '.. • • Mr . Pete r N . Bibc o EPAivbCv< • .... Regiona l Administrato r Certifie d Mai l U . S . Environmenta l Protectio n Agenc yRetur n Receip t Requeste d Regio n III , Sixt han d Walnu t Street s Philadelphia , PA1910 6
Dea r Mr . Bibco : RE : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n Delawar e I n accordanc e wit hthe Nationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.6 5 (a ) Relie f Valv e Discharges , Polyviny l Plan t located a t Delawar e City , Delaware ; the addres s o f thi s source : Pos t Offic e Box32 0 Schoo l Hous e Road Delawar e City , Delawar e 1970 6 Sourc e o f Release : SPVC- I Plan t A . Natur e o f Caus e Viny l Chlorid e (VCM ) releas e occurre d fro mreacto r PR-40 4 becaus e o f failur e t o ad

d premi xsolutio n t o batch . Highpressur e conditio n wa s als o no t accuratel ydetermine d becaus e o f partiall yplugge d pressur e gauge . Operato r wa s therefor e unawar e o f highpressur e conditio n and , therefore , di d no t perfor mnecessarycorrectiv e actio n t o terminat e batch . B . Dat e an

d Time o f Releas e Wednesday , Augus t 25 , 1982 , a t 150 0 hours . C . Approximat e Tota l Los s o f Viny l Chlorid e I t i s estimate d tha t two hundre d (200 ) pound s o f viny l chlorid e monome r (VCM ) wa s release d t o the atmosphere . D . Metho d Use d t o Determin e Los s

- ^ Relie f Valv e discharg e onl ylaste d a coupl e o f seconds . N o chang e i n liqui d leve l wa s observe d i n reactor . Two hundre d pound s VC Mi s onl y a roug hestimate .P.1 1

Pete r N . Bibc o Pag e Two
E . Actio n Take n t o Preven t Discharg e Becaus e o f malfunctio n o f pressur e gauge , operato r wa s no t awar e o f highpressur e problemunti l releas e had alread yoccurred . N o pre ventiv e actio n wa s therefor e taken , a-methylstyren e wa s adde d immediatel yonc e the existing highpressur e conditio n wa s realized . F . Measure s Adopte d t o Preven t Futur e Discharg e 1 . Th e operato r wa s retraine d a s t o the charging procedure . 2. Th e operato r wa s als o give n disciplinarytim e of f becaus e o f hi s carelessness . I f ther e ar e an

yothe r question s pertaining t o th e informatio n submitted , fee l fre e t o contac t me . Sincerely ,
Charle s A . Markowit z Associat e Regulatory Affair s Specialis t CAM:al pP.1 2



### FORMOS APLASTIC S CORPORATIO NDELAWArU : P.O
. BO X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-457 5


### Octobe r 7 , 198 1

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Mr . Pete r N . Bibc o Regiona l Administrato r U . S . Environmenta l Protectiv e Agenc y Regio n II I 6t h& Walnu t Street s Philadelphia , P A1910 6 Dea r Mr . Bibco : Re : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E I n accordanc e wit hth e Nationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.6 5 (a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Delawar e City , Delaware ; th e addres s fo r thi s source : Pos t Offic e Bo x32 0 Schoolhous e Roa d Delawar e City , D E 1970 6 Sourc e o f Release : EPVC-I I Tan k Farm . A . Natur e o f Caus e Operato r wa s unloadin g tan k ca r an d recyclin g t o DT102 B storag e bullet , whe n h e go t a hig hleve l i n DT102B . H e switche d th e unloadin g line s t o DT102A , bu t faile d t o switc h th e recycl e line . Th e tan k continue d t o fil l an d hydrostated , blowin g th e ruptur e disk . B . Dat e an d Tim e Wednesday , Septembe r 29 , 198 1 a t 150 0 hours . C . Approximat e Tota l Los s o f Viny l Chlorid e *


### -, t Si xhundre d (600 ) pound s o f viny l chlorid e release d t o th e atmosphere . V v 

# 1 ^ 5P.1 3



### Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E Octobe r 7 , 198 1 Pag e 2 o f 2
D . Metho d Use d t o Determin e Los s I t i s estimate d tha t th e relie f valv e lifte d fo r 2 0 second s befor e receding . Th e loadin g rat e o f th e pump i s approximatel y150 0 lbs/min . Becaus e o f th e hig hpressur e conditio n tha t estimate d rat e o f discharg e wa s increase d by 20 % o f th e pump flo wrate . E . Actio n Take n t o Preven t Discharg e 1 . Upo n notificatio n fro mhig hpressur e alarm,operato r wen t t o tan k far mt o ope n recycl e valv e t o DT-102 C storag e vessel . 2 . Forema n shu t of f charg e pump . Thes e tw o action s allowe d pressur e t o equaliz e t o DT10 2 A& C an d th e 12 % o f VC Mwa s recycle d fro mDT102 B t o DT-102 C t o lowe r th e liqui d leve l i n DT-102B . F . Measure s Adopte d t o Preven t Futur e Discharge s 1 . Operato r wa s reinstructe d i n th e correc t unloadin g procedur e fo r VC M cars . 2 . Operato r wa s give n 3 day s disciplinar ytim e of f (DTO ) I f ther e ar e anyfurthe r question s pertainin g t o th e informatio n submitted , pleas e d o no t hesitat e t o contac t me . Sincerely , 

# c^^ ^ (2. Charle s A . Markowit z Associat e Regulator y Affair s Specialis t

CAM:p dP. M

P.O
. BO X32 0 •DELAWAR E CITY
. DELAWAR E 1970 6 •TE L(302 ) 834-457 5


### Augus t 28 , 198 1

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Mr . Jac k Schram

m Regulator yAdministrato r U . S . Environmenta l Protectio n Agenc y Regio n III , Sixt han d Walnu t Street s Philadelphia , Pennsylvani a 1810 6 Dea r Mr . Schramm : Re : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E I n accordanc e wit hth e Nationa l Emissio n Standard s fo r hazard
ou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Delawar e City , Delaware ; th e addres s fo r thi s source : Pos t Offic e Bo x32 0 Schoolhous e Roa d Delawar e City , Delawar e 1970 6 Sourc e o f Release : EPVC-I I Plan t A . Natur e o f Caus e Aviny l chlorid e (VCM ) releas e occurre d fro m Accumulato r DT-3 0 3 a t approximatel y170 0 hour s o n Augus t 19 , 1981 , becaus e a n LP V valv e opene d durin g th e strippin g o f a batc hi n reacto r DR-406 . Ai r wa s subsequentl ypulle d int o th e system , caus in g pressur e t o ris e i n DT-30 3 t o ove r 10 0 p.s.i . an d blo wth e ruptur e disc . B . Dat e an d Tim e o f Releas e Wednesday , Augus t 19 , 1981 , a t 170 0 hours . C . Approximat e Tota l Los s o f Viny l Chlorid e Les s tha n fift y(50 ) pound s viny l chlorid e wa s \ v 

### discharge d t o atmosphere . ^ V 

# VP.1 5



### Viny l Chlorid e Monome r Releas e Augus t 28 , 198 1 Pag e 2

D . Metho d Use d t o Determin e Los s Du e t o th e shor t duratio n o f thi s releas e an d th e fac t tha t n o los s i n the accumulato r coul d b e determined , i t i s estimate d tha t les s tha n fift y(50 ) pound s o f VC M wer e discharged . Also , n o highlevel s wer e picke d b y the continuou s monitoring systemi n th e plant . E . Actio n Take n t o Preven t Discharg e Releas e too k plac e s o quickl ytha t n o preventiv e actio n wa s possible . Withi n second s th e 1s t stag e o f recovery system kicke d ou t becaus e o f th e highpressur e an d th e 2n d stag e shu t down . F . Measur e Adopte d t o Preven t Futur e Discharge s 1 . Ruptur e dis k wa s replace d o n accumlator . 2 . Eac hoperato r o n tha t shif t wh o ma yhav e bee n res ponsibl e fo r thi s erro r wa s retraine d a s t o th e importanc e o f checking an d rechecking suc hprocedure s an d preventing suc hdischarges . 3 . An investigatio n o f thi s inciden t coul d no t definitel y pinpoin t thi s erro r t o a specifi c operator . I f ther e ar e furthe r questio n concerning th e information , fee l fre e t o contac t me . Sincerely , Charle s A . Markowit z Associate . Regulatory Affair s Specialis t CAM:al sP.1 6 

# ^S X P.O
. BO X32 0 •DELAWAR E CITY
. DELAWAR E 1970 6 •TE L(302 ) 834-457 5



### Septembe r 25 , 198 1

CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Mr . Pete r N . Bibc o Regiona l Administrato r U . S . Environmenta l Protectio n Agenc y Regio n III ; Sixt hand Walnu t Street s Philadelphia , P A1910 6 Dea r Mr . Bibco : Re : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E I n accordanc e wit hth e Nationa l Emissio n Standard s fo r hazard
ou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) Relie f Valv e Discharges , Polyviny l Chlorid e Plan t locate d a t Dela
war e City , Delaware ; th e addres s fo r thi s source : Pos t Offic e Bo x32 0 Schoolhous e Roa d Delawar e City , D E 1970 6 Sourc e o f Release : SPVC- I an d SPVC-I I Plant s A . Natur e o f Caus e Viny l Chlorid e (VCM ) release s occurre d fro mnin e reactor s an d thre e strippin g tank s i n th e tim e perio d o f 013 0 t o 030 0 hour s o n Septembe r 16 , 1981 . Th e cause s o f thes e release s ar e listed : 1 . A t 005 7 hours , th e Delawar e Cit yPlan t experience d a powe r outage . Th e area s affecte d wer e th e SPVC- I an d SPVC-I I Plants .P.1 7



### Viny l Chlorid e Monome r Releas e Septembe r 25 , 198 1 Pag e 2 2 . I t wa s als o discovere d a t 012 0 hour s tha t

a Worthingto n Ai r Compresso r ha d shu t down . Los s o f ai r pressur e prompte d th e terminatin g o f al l suspensio n batche s tha t wer e reacting . 3 . A t 013 0 hour s bot hth e S- I and E- I emer genc ygenerator s shut-dow n an d wer e re started . Th e caus e o f thi s shut-dow n wa s overheatin g becaus e o f a n excite r circui t fus e blowin g o n th e S- I generator . I n bot hcases , th e generato r engine s worke d properly . However , overheatin g cause d bot hunit s t o b e inoperable , sinc e bot h Th e S- I an d E- I emergenc ycoolin g fan s operat e of f o f th e outpu t o f th e S- I generator . 4 . Los s o f powe r i n th e S- I plan t prevente d agitator s fro mbein g operated , causin g batche s t o hea t up , buil d pressures , blo w ruptur e disc s an d lif t valve s releasin g t o th e atmosphere . Du e t o thes e emergenc ygenerator s no t operating , th e ai r compressors , whic h ar e o n emergenc ypower , coul d no t b e utilized . Los s o f thi s ai r pressur e i n th e S- I an d S-I I plant s als o reduce d th e amoun t o f cit ywate r pressure . Eve n wit hagitator s runnin g i n th e S-I I plant , reduce d coolin g cause d batche s t o ge t ou t o f control , buil d u p pressure , and releas e t o th e atmosphere . B . Dat e an d Tim e o f Releas e Wednesday , Septembe r 16 , 1981 , fro m013 0 t o 030 0 hours . C . Approximat e Tota l Los s o f Viny l Chlorid e I t i s estimate d tha t twenty-eigh t thousan d si x(28,006 ) pound s viny l chlorid e monome r (VCM ) wa s release d t o th e atmosphere . D . Metho d Use d t o Determin e Los s Fo r al l nin e batche s release d t o th e atmosphere , a n estimat e a s t o ho wmuc ho f th e batc hwa s los t wa s mad e fro mvisua l observation s and ho wmuc hviny lP.1 8



### Viny l Chlorid e Monome r Releas e Septembe r 25 , 198 1 Pag e 3 chlorid e (VCM ) wa s converte d t o polyviny l chlorid e

(PVC ) durin g th e reaction . I n th e S-I I plan t i t i s estimate d tha t 16,50 0 pound s o f VC M i s converte d ove r a 4. 5 hou r poly-reactio n tim e t o 15,00 0 pound s PVC , leavin g 1,50 0 pound s o f VC Munreacted . I n th e S- I plant , 11,50 0 pound s o f VC M wa s converte d t o 10,00 0 pound s o f PV C ove r a 7 hou r poly-reactio n time . Usin g th e informatio n available , th e attache d formul a i s derived , an d informatio n fo r eac ho f th e batche s i s se t fort hi n th e attache d tabl e (Appendix) . E . Actio n Take n t o Preven t Discharg e 1 . Severa l attempt s wer e mad e t o restar t emer genc ygenerator s whe n overheatin g wa s takin g place . 2 . a-methy l styren e (AMS ) wa s adde d t o terminat e al l reactin g suspensio n batches . 3 . Sprinkler s wer e turne d o n i n bot hplant s t o reduc e fir e hazar d an d t o provid e coolin g fo r reacto r domes . F . Measure s Adopte d t o Preven t Futur e Discharge s 1 . Operator s hav e bee n re-instructe d a s t o th e .prope r terminatio n o f reactin g batche s upo n a powe r outage . 2 . Amount s o f AM S adde d t o terminat e reactin g suspensio n batche s wil l b e increase d depend
in g o n th e exisitn g conditons . Also , othe r terminator s wil l b e examine d t o determin e thei r effectivenes s i n killin g th e poly
merizatio n reaction . / 3 . Emergenc ydrill s wil l b e conducte d withi n *th e nex t tw o week s simulatin g a powe r outage . 4 . Fan s o n th e emergenc ygenerator s wil l b e pu t o n separat e circiut s s o a s t o eliminat e th e inter-dependenc yo f on e generato r o n another . 5 . Th e existin g weekl ygenerato r check s wil l includ e a simulate d powe r outage . Thi s wil l enabl e u s t o chec k al l function s o f th e emer genc ysystem , i.e. , moto r operation , gener ato r operation , automati c powe r transfe r switc hoperation . \P.1 9



### Viny l Chlorid e Monome r Releas e Septembe r 25 , 198 1 Pag e 4 6 . Productio n foreman wil l b e re-instructe d i n

the prope r troubl e shooting procedure s fo r the emergenc ygenerators . I f ther e ar e furthe r question s concerning th e informatio n submitted , fee l fre e t o contac t me . Sincerely ,

/Pran V . T I/Tirwrl c. ' 

### ''Fran k JyDoyl e Plan t Manage r FJD/dr k Attachmen t

### -APPENDIX -

— 

### VC MLOS T POUND S

REACTO R NUMBE R PR-40 1 PR-40 2 PR-40 4 PR-41 0 PR-41 1 SR-40 1 SR-40 3 SR-40 4 SR-41 0 PT-41 5 PT-41 6 PT-4 ] 1 7 =



### BATC H NUMBE R P-434 1 P-434 3 P-434 2 P- 4 3 4 5 P-434 4 S-413 6 S--413 1 S-413 4 S-413 5

-

-

- 

### FRACTIO NO F

BATC H LOS T

- 

### FRACTIO NO F i BATC H LOS T 0.5 0 0.5 0 0.5 0 0.7 5 0.6 7 0.3 3 0. 0 0.2 0 0.7 5

-

-

- 

### VC MCHARGED ,

POUND S
/CM CHARGED , POUND S 1150 0 1150 0 1150 0 1150 0 1150 0 1650 0 1650 0 1650 0 1650 0

-

-

- - 

### REACTIO NTIME , HOUR S A T DISCHARG E TOTA L POL Y TIM E REACTE D A T DISCHARGE , HOUR S 4.7 5 4.2 5 3.7 5 2. 0 2. 5 3.2 5 4. 5 4. 5 2.7 5

-

-

- 

### TIM E , HOUR S POUND S VC M CONVERTE D TOTA L NC R POL Y TIME , VC MLOST , HOUR S POUND S 7. 0 7. 0 7. 0 7. 0 7. 0 4. 5 4. 5 4. 5 4. 5

-

-

- 

### 235 7

271 4 307 1 648 2 531 2 187 0 *10 0 30 0 550 0 *10 0 *10 0 *10 0 TOTAL : 2 3,00 6 *Fo r Vessel s SR-403 , PT-415 , PT-41 6 and PT-417 , n o visibl e losse s wer e observed , Sinc e batche s ha d bee n terminated , 10 0 pound s o f VC Mi s th e estimate d loss .P.2 1
C - c••

' ,»' J-,(.'•:" C-s>


### bOFMCS APl.ASrC S CORPORATIO NDELAWARE P.O
. BO X32 0 •DELAWAR E CITY , DELAWAR E 1970 6 •TE L(302 ) 834-457 5


### Jun e 30 , 198 1
CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Mr . Jac k Schramm , Req . Administrato r U.S . Environmenta l Protectio n Agenc y Regio n III , Sixt han d Walnu t Street s Philadelphia , PA1810 6 Dea r Mr . Schramm : Re : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n D E I n accordanc e wit hth e Nationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) - Relie f Valv e Discharges , Polyviny l Chlorid e locate d a t Delawar e City ; the addres s fo r thi s sourc e is :

P.O . Bo x32 0 Schoolhous e Roa d Delawar e City , D E 1970 6 Sourc e o f Release : SPVC- I Plan t A . Natur e o f Caus e Aviny l chlorid e (VCM ) releas e occurre d fromPT-306 , a viny l acetat e (VAM ) accumulator , a t 181 0 hour s o n Jun e 23 , 1981 . Eve n thoug

hvalve s betwee n the knockou t po t an d the VC Mrecovery systeman

d the VA

Msystem

wer e closed , ther e wa s enoughleakag e throug hthes e valve s fo r the ruptur e dis c t o fai l an d it s relie f valv e t o lift . Ruptur e dis c ha d apparentl yfaile d becaus e o f excessiv e flexing an d relie f valv e di d no t hav e prope r pressur e rating . B . Dat e an

d Time o f Releas e Tuesday , Jun e 23 , 198 1 a t 081 0 hours . C . Approximat e Tota l Los s o f Viny l Chlorid e I t i s estimate d tha t les s than on e hundre d (100 ) pound s o f \ i viny l chlorid e wa s release d t o the atmosphere . , W 

## fy kf 3 

# V »P.2 2



### Mr . Jac k Schramm , Reg . Administrato r Jun e 30 , 198 1 Pag e 2 D . Metho d Use d t o Determin e Los s Becaus e o f the shor t duratio n o f thi s discharg e an d the possibl e presenc e o f some viny l acetate , i t i s estimate d tha t les s than on e hundre d (100 ) pound s o f viny l chloride , wa s los t t o the atmosphere . E . Actio n Take n t o Preven t Discharg e 1 . Releas e wa s stoppe d b yequalizing pressure s i n Aan d B recoverysysteman d restarting B- l vacuu m pump . F . Measure s Adopte d t o Preven t Futur e Discharge s 1 . Suc hvessel s wil l b e blinde d of f whe n no t i n use . 2 . Prope r relie f protectio n wil l b e installe d o n PT-306 . I f ther e ar e an

yfurthe r questions , fee l fre e t o cal l me .

Sincerely , Charle s A . Markowit z Associat e RegulatoryAffair s Specialis t

CAM/b j cc : R . Frenc h R . Tagger tP.2 3
' . . 

# ^SN . : n ~ r.- r 

### v- : P.O
. BO X32 0 •DELAWAR E CITY
. DELAWAR E 1970 6 •TE L(302 ) 834-457 5



### May27 , 198 1
CERTIFIE D MAI L RETUR NRECEIP T REQUESTE D Mr . Jac k Schramm , Reg . Administrato r U . S . Environmenta l Protectio n Agenc y Regio n III , Sixt han d Walnu t Street s Philadelphia , PA1810 6 Dea r Mr . Schramm : Re : Viny l Chlorid e Monome r Releas e Formos a Plastic s Corporatio n US A I n accordanc e wit hth e Nationa l Emissio n Standard s fo r Hazardou s Ai r Pollutants , Par t 6 1 o f Chapte r I , Titl e 40 , Sectio n 61.65(a ) - Relie f Valv e Discharges , Polyviny l Chlorid e locate d a t Delawar e City ; th e addres s fo r thi s sourc e is : P . 0 . Bo x32 0 Schoolhous e Road Delawar e City , D E Sourc e o f th e Release : SPVC-I I Plan t 1970 6
A . Natur e o f Caus e Batc hS-178 9 wa s charge d a t approximatel y073 0 hour s i n reacto r SR-407 . A t 093 5 hour s a B operato r mistakenl ypulle d th e emergenc yven t fo r SR-40 7 instead o f reacto r SR-40 5 tha t h e wa s spra

yrinsing . Areleas e o f reactio n mixtur e (viny l chloride , polyviny l chloride , an d water ) t o th e atmospher e too k plac e fo r les s tha n 3 0 second s unti l th e operato r realize d hi s erro r an d close d th e vent . B . Dat e an

d Time o f Releas e Monday , May18 , 198 1 a t 093 5 hour s C . Approximat e Tota l Los s o f Viny l Chlorid e Fou r hundre d eight yfour (484 ) pound s viny l chlorid e release d t o th e atmosphere .P.2 4



### Mr . Jac k Schramm , Reg . Administrato r Ma y27 , 198 1 Pag e 2 D . Metho d Use d t o Determin e Los s Lbs . VC M Charg e t o Reacto r 17,00 0 % Conversio n 25 % Lbs . VC M Emitte d t o Atmospher e 48 4 Lbs . VC M Remaining i n Batc h12,26 6 Lbs . VC M Converte d t o PV C 4,25 0 VC MVapo r Discharge d - Assumin g 50 0 gallon s vapo r spac e a t 15 0 psi a an

d T - 135° F = 595°R ; z = . 8 (compressibilit y factor) ; densit yVC M = 0.161 6 lbs./ft. 3 

### a t 70° F - 1 at m

, 1 ,530°R , . 50 0 gallons . ,.,., - lbs . .15 0 psi a . _ - i o- j 1Kc 

### . TTPM 

### (OTSO ) ( 

### 595°R > ( 7 

### .48 l gallons * ( 

### ' 161 6 

### ft" ^ IttlpelJ " 12 3 lb S 

### \ ^ ftT 3



### —vapo r VC MLiqui d - Approximatel ysix-inc hlos s o f reactio n mixtur e wa s estimate d fro

mvisua l observatio n t o hav e bee n discharge d t o th e atmosphere . 17.5 ' i s the dept ho f th e tota l reactio n mixture . ,12,62 7 lbs . VC M . , 0.5' , _„,- , , . „_ „ ,,„„,, , ( . . . . . ) (T-=—r r 36 1 lbs . VC M Liqui d 

### 'remainin

g i n mixture ' v 

### 17.5' ' ^ Lbs . VC M Release d = 36 1 + 12 3 = 48 4 lbs . E . Actio n Take n t o Preven t Discharg e A s soo n a s mistak e wa s realized , emergenc yven t wa s closed . F . Measure s Adopte d t o Preven t Futur e Discharg e 1 . Operato r ha s bee n retraine d a s t o th e prope r procedur e o f venting a reacto r an d bee n give n disciplinarytime of f fo r no t following procedure . 2 . Emergenc yven t knob s hav e bee n numbere d o n fron t o f th e knob . I f ther e ar e furthe r question s fee l fre e t o cal l me . Sincerely , Charle s A . Markowit z Associat e RegulatoryAffair s Specialis t CAM:cd r