# OAR Box 1107 Prepped by Ollie Stewart



### Document

Number: 

# 57 ) IV-B- 7 Docket Number: 

# A-81-2 1

Printed 4/11/2008 3:03:47

PM Sheet 57 of 90 p. 1P. 2

A! 

# A-8I-2 I
IV-B- 7

MEMORANDU

M DATE : Jul y

22 , 198 5 TO : Viny l Chlorid e Docke t FROM : Kare nK . Fidler , Radia n SUBJECT : Relie f Valv e Discharg e Performanc e o f th e Formos a Plastic s

PV C Facilit y

i nDelawar e City , Delawar e Purpos e Recen t relie f valv e discharg e performanc e b y th e Formos a Plastic s PV C facilit y i nDelawar e City , Delaware , wa s evaluate dt o determin e whethe r th e plant' s performanc e woul d hav e exceede dth e propose dnumerica l limit s fo r relie f valv e discharge s unde r th e viny l chlorid e (VC ) standard . Thi s memorandu

m present s th e result s o f tha t evaluation . Backgroun d Formos a Plastic s i nDelawar e Cit y produce s PVC b

y two processes : suspensio nand disperson . Relie f valv e discharg e performanc e b y th e Formosa/Delawar e facilit y wa s th e objec t o f recen t enforcemen t actio nb y th e Stat e o f Delaware . Followin g proposa l o f numerica l limit s fo r relie f valv e discharges , publi c concer nwa s raise dtha t th e Formos a plant' s performanc e migh t no t hav e bee neligibl e fo r enforcemen t unde r th e revise dstandard . Finding s Informatio no nrelie f valv e discharg e occurrence s betwee nMa y 198 1 and Marc h198 5 a t th e Formosa/Delawar e facilit y wa s obtaine dfro

m 10-day complianc e report s (Ref . 1) . Durin g thi s period , a tota l o f 4 5 relie f valv e discharge s wer e reported . A summar y o f eac hdischarge , includin g th e date , estimate damount , source , cause , an dmeasure s take nt o preven t futur e recurrence , i s give ni nAttachmen t 1 . Th e propose drelie f valv e discharg e limit s ar e show ni nTabl e 1 . Fo r a PV C plan t producin g suspensio nresin , th e numbe r o f relie f valv e discharge s fro m suspensio nreactor s durin g a 12-mont hcomplianc e perio dma y no t excee d 0.03 5 batches/10 0 batche s o r 4 discharges , accordin g t o th e propose dlimits . Th e actua l numbe r o f suspensio nreacto r discharge s allowe dvarie s fro m plan t t o plan t dependin g o nth e numbe r o f suspensio nresi nbatche s produced . However , inno cas e i s a plan t allowe dmor e tha n4 suspensio nreacto r discharge s durin g a 12-mont hcomplianc e period .P. 3



### T o determin e th e numbe r o f actua l discharge s allowe db y a PV C plan t unde r th e propose ddischarg e limits , i t i s necessar y t o kno w th e numbe r o f batche s o f eac htyp e o f resi nproduced . Fro m th e 10-da y

complianc e report s submitte db

y th e Formosa/Delawar e plant , i t i s estimate dtha t thi s plan t produce s abou t 7,50 0 suspensio nresi nbatche s pe r yea r an d4,00 0 dispersio n resi nbatche s pe r year . Base do nthes e estimates , th e numbe r o f eac htyp e o f discharg e allowe dunde r th e propose ddischarg e limit s wa s determine da s show ni nTabl e 2 . Not e tha t fo r thi s plan t th e numbe r o f eac htyp e o f discharg e allowe db

y th e numerica l limit s i s les s tha nth e uppe r cap s i n Tabl e 1 . Tabl e 3 compare s th e Formosa/Delawar e plant' s performanc e wit hth e numbe r o f discharge s allowe d(give ni nTabl e 2) . A s indicated , exceedence s o f th e suspensio nreacto r limi t occurre ddurin g fiv e o f th e seve ncomplianc e periods . Th e dispersio nreacto r limi t wa s exceede ddurin g tw o o f th e seve n complianc e periods . Th e nonreacto r discharg e limit s wa s exceede ddurin g thre e o f th e seve ncomplianc e periods . O f th e 4 5 discharg e occurrence s durin g th e perio dinvestigated , 3 3 (1 3 percent ) woul db e considere di n violatio no f on e o f th e discharg e limit s durin g on e o r mor e o f th e over lappin g complianc e periods . Twelv e (2 7 percent ) o f th e discharg e occurrence s woul dno t b e subjec t t o violatio no f an y o f th e propose ddischarg e limits .

### REFERENCE S

1 . Memorandu

m fro m Fidler , K. , Radian , t o file . Jul y 16 , 1985 . Receip t o f Complianc e Informatio nfro m Regio nIII .P. 5

TABL E 1 . PROPOSE D NUMERICAL LIMIT S ON RELIE F VALVE DISCHARGE S A T PV

C PLANT S
Categor y Numerica l Limi t (1 ) Discharge s fro

m PVC plant s (suspension , dispersion , latex , bul k processes )

- Reactor s

- suspensio nresi nproces s

- dispersio nresi nproces s (includin g late xresin )

- bul k resi nproces s

- Nonreacto r source s (2 ) Discharge s fro

m PV C plant s (solutio nan

dothe r continuou s processes ) 0.03 5 discharges/10 0 batches , no t exceedin g 4 discharges/y r 0.03 5 discharges/10 0 batche s 0.03 5 discharges/10 0 batche s 0.02 5 discharges/10 0 batches , no t exceedin g 3 discharges/y r 1 discharge/y rP. 6

TABL E 2 . NUMBE RO F DISCHARGE S ALLOWE D BYNUMERICAL LIMIT S A T

FORMOSA/DELAWAR E PLAN T

Discharg e Categor y Numerica l Limi t A Estimate d No .

o f Batches/Yea r B No . o f Discharge s

Allowe d A xB Suspensio nreacto r Dispersio nreacto r

Nonreacto r 

### 0
0
0 .03 5 discharge s 10 0 batche s .03 5 discharge s 10 0 batche s .02 5 discharge s 10 0 batche s 7,50 0
4,00 0
11,50 0 Numbe r o f allowabl e discharge s i s determine d b y roundin g dow

nt o neares t whol e integer .TABL E 3 . COMPARISON O F PLAN T PERFORMANC E WIT H PROPOSE D NUMERICA L LIMIT S

8/8 1 - 7/8 2 2/8 2 - 1/8 3 8/8 2 - 7/8 3 2/8 3 - 1/8 4 8/8 3 - 7/8 4 2/8 4 - 1/8 5 8/8 4 - 7/8 5 Suspensio nReacto r Plan t performanc e (No . o f discharges ) No . o f discharge s allowe d b y propose dlimit s Exceedanc e o f limits ? 

### Ye s N

o Ye

s 1

1

Ye s Ye

s Ye

s N

o Dispersio nReacto r Plan t performanc e (No . o f discharges ) No . o f discharge s allowe d b y propose d limit s Exceedanc e o f limits ? 

### N o 0

1 N o 2

1 Ye s 3

1 Ye s 1

1 N o 0

1 N o 0

1 N o Nonreactor Plan t performanc e (No . o f discharges ) No . o f discharge s allowe d b y propose dlimit s Exceedanc e o f limits ? 

### Ye s 1

2 N o 2

2 N o 1

2 N o 1

2 N o 6

2 Ye s 6

2 Ye sP. 8



### ATTACHMEN T 1 SUMMAR YO F RELIE F VALVE DISCHARGE SRV

D Performanc e - Formosa/Delawar e Cit y
Dat e Amoun t

(l bVC ) Sourc e Caus e Preventiv e Measure s 3/10/8 5 3 6

9/30/8 4 1. 2

9/8/8 4 1 7

9/2/8 4 20 0
8/30/8 4 44 4
8/5/8 4 19 3 V C accumulato r o f recover y

system

Wastewate r strippe r knockou t po t

Suspensio nreacto r 8/29/8 4 1,10 2 Suspensio nreacto r

Weig htank
Weig htank

Vacuu m pum p sea l wate r tank i n V C recover y

tan k Accumulato r overfille d

becaus e automati c valv e leake dV C int o recover y system ; 2 discharge s occurre dbefor e lea k wa s discovere d V C wa s remove dfro

m recover y system t o reactors ; Valv e repaired ; additiona l inter lock s o nrecover y

system adde d
Operato r error ; drai nhos e Operator s instructe do nprope r valv e fro

m V C tank t o wastewate r strippin g syste m wa s lef t ope n causin g system

t o overpressur e Prematur e ruptur e dis c failur e Batc hoverheate dbu t wa s no t detecte dbecaus e high pressur e alar

m faile d Weig htank overfille d du e t o fault y

calibrate d weig h cell s (repea t incident ) Weig htank overfille d du e t o fault y

calibrate d weig h cell s Fault y leve l indicato r o

n recover y accumulato r allowe d syste

m t o b e overfille d wit hrecovere d V C procedure ; chec k valv e adde d t o preven t backflow ; high pressur e alar

m installe d

Non e Additio no f hig htemperatur e alarm s considere d Weig hcel l recalibratio nwa s reschedule donpriorit y basi s Weig hcel l schedule d recalibratio n

Leve l indicato r replaced ; interloc k adde dt o shutof f accumulato r onhighpressure ; accumulato r pressur e indicato r relocated ; transfe r procedure s modifie dt o includ e cros s chec k o f accumulato r pressur eRV D Performanc e - Formosa/Delawar e Cit y Amoun t Dat e (l bVC ) 8/5/8 4 24 2 7/10/8 4 6 0

6/30/8 4 17 6

1/10/8 4 1,61 9 Source

Wastewate r tank i n VC recover y

tank Wastewate r knockou t pum p inwastewate r strippin g syste

m Suspensio nreacto r
Suspensio nreacto r Caus e Preventiv e Measure s

1/10/8 4 1/10/8 4 1/10/8 4 1/10/8 4 1/10/8 4 1/10/8 4 11/20/8 3 1,51 6

1,55 2 2,62 4 2,657 , 3,00 3 3,10 0 

### 93 4 Suspensio n

Suspensio n Suspensio n Suspensio n Suspensio n Suspensio n Suspensio n reacto r

reacto r reacto r reacto r reacto r reacto r reacto r Same a s previou s

Compresso r overheate d an d faile d afte r wate r cause d overloa d
Batc hovercharge d becaus e valv e onwate r mete r wa s partiall y

close d causin g fault y mete r reading s Powe r failur e - emergenc y powe r generator s wer e inoperabl e

Sam e a s previou s Same a s previou s Same a s previou s Same a s previou s Sam e a s previou s Same a s previou s Prematur e ruptur e dis c failur e Same a s previou s
New temperatur e control s installed ; new

stea m injectio n syste m fo r strippin g column s installe d Operator s instructe d oneffec t o f valv e setting s o

ncharg e mete r performanc e Maintenanc e procedure s fo r emergenc y

generator s improved ; Emergenc y

generator s tie d togethe r t o provid e acces s t o al l reacto r agitator s Sam e a s previou s Sam e a s previou s Same a s previou s Same a s previou s Same a s previou s Sam e a s previou s Wil l no longe r operat e reactor s a t ove r 90 % o f ruptur e dis c desig npressur eRV

D Performanc e - Formosa/Delawar e Cit y

Amoun t Dat e (l bVC ) Sourc e Caus e Preventiv e Measure s 8/17/8 3 33 0

7/3/8 3 10 0 Dispersio nreacto r

Dispersio nreacto r

6/30/8 3 10 0 Suspensio nreacto r

6/21/8 3 2,40 8 Suspensio nreacto r
4/19/8 3 2,02 5 V C storag e tan k
3/8/8 3 2,21 1 Suspensio nreacto r

2/25/8 3 2,04 0 Dispersio nreacto r Plugge d charg e lin e Mad e repairs ; institute d ne w require d alteratio ni nprocedure s i ncas e o f chargin g chargin g procedure s whic hmalfunctio n apparentl y

led t o discharg e Batc hoverpressure d causin g ruptur e dis c t o crac k

Batc hoverpressured ; temperatur e an

d pressur e instrumentatio nfault y Fault y pressur e transmitte r Operato r error ; valv e misalignmen t durin g tank ca r unloadin g Powe r interruptio ncause d los s o f instrumen t air ; batc hoverpressur e wa s no t detecte d i ntime Batc hwa s overcharge d becaus e o f leakin g charg e wate r valve ; operator s di d no t follow

standar d operatin g procedur e befor e startin g agitation . Ruptur e dis c returne d t o supplier fo r inspection ; catalys t activit y

checke d befor e use d agai ni

n productio n Instrumentatio nrepaired ; maintenanc e an

d operatio n procedure s fo r pressur e sensor s upgrade d Repaire d pressur e transmitter ; operatin g procedure s fo r con trollin g ho t batche s improve d Correc t operatin g procedure s reemphasized ; safet y inter lock s adde d Operatin g procedure s change d t o requir e immediat e batc h terminatio nwhe ninstrumen t ai r i s los t Valv e repaired ; operator s disciplined ; reemphasize d correc t operatin g procedure sRV D Performanc e - Formosa/Delawar e Cit y
Dat e Amount

(l bVC ) Sourc e Caus e Preventiv e Measure s 11/25/8 2 6,50 0 Suspensio n reactor
9/16/8 2 25 0

8/25/8 2 20 0

9/29/8 1 60 0

9/16/8 1 2,71 4 9/16/8 1 3,07 1 9/16/8 1 6,48 2 9/16/8 1 5,31 2 9/16/8 1 1,87 0 Accumulato r
7/8/8 1 2,70 7 Suspensio n reactor

Suspensio

n reactor

V C storage tan

k 9/16/8 1 2,35 7 Suspensio n reactor

Suspensio

n reactor Suspensio

n reactor Suspensio

n reactor Suspensio

n reactor Suspensio

n reactor Batc

hoverpressured becaus e to o muchcatalys t wa s adde d Hydrosta t i

n accumulato r becaus e o f fault

y leve l indicato

r Batc hoverpressure

d becaus e o f coolin

g wate r syste m failure ; pressur e transmitte r malfunctioned Batc hoverpressure

d becaus e o f failur e to ad d premixsolution ; pressur e indicato

r plugge

d Operator erro r whil e unloadin

g tan k car Power failure ; emergenc y power generator s faile d du e t o overheatin

g
Sam e a s previou s Sam e a s previou s Sam e a s previou s Sam e a s previou s Sam e a s previou s Reduce d catalys t amount i n batc hrecip e Repaire d leve l indicator

Coolin g wate r recirculatio n pumps switche

d to manua l operation ; pressur e transmitte r repaire d - Operator discipline d an d retraine

d

Operator discipline d an d retraine

d Emergenc

y generato r testin

g procedure s improved ; batc h terminatio

n procedure s reemphasize

d Sam e a s previou s Sam e a s previou s Sam e a s previou s Sam e a s previou s Sam e a s previou sRV D Performanc e - Formosa/Delawar e Cit y
Dat e Amoun t

(lbVC ) Sourc e Caus e Preventiv e Measure s 9/16/8 1 10 0 9/16/8 1 30 0 9/16/8 1 5,50 0 9/16/8 1 10 0 9/16/8 1 10 0 9/16/8 1 10 0 8/19/8 1 5 0

5/18/8 1 48 4

6/23/8 1 10 0 Suspensio n reactor Suspensio

n reactor Suspensio

n reactor Strippin

g tan k Strippin

g tan k Strippin

g tan k V C accumulator

Suspensio

n reactor
Viny l acetat e accumulator Sam e a s previou s Sam e a s previou s Sam e a s previou s Sam e a s previou s Sam e a s previou s Sam e a s previou s Operator error ; valv e opene d durin g strippin

g cause d ai r t o b e pulle d into V C recover

y syste m Operator error ; wron g emergenc

y vent wa s opene d Leakage throug

hvalve s an d improperly

size d relie f valv

e Sam e a s previou s Sam e a s previou s Sam e a s previou s Sam e a s previou s Sam e a s previou s Sam e a s previou s Operator s retraine

d

Operato r discipline d an d retraine

d
Installe

d prope r relie f valve ; modifie

d procedure s to blin d of f accumulator s when not i

n us e