# Polyvinyl Chloride and Copolymers (PVC) Production

**MACT Floor, Baseline, Reductions for Equipment Leaks**
**February 7, 2012**

**Worksheet Name** Cost Analy sis BTF Analy sis Em issions - Major SubpartV Cost w Formulas-MC P Option 1 - MC V Option 1 - MC C Option 1 - MC PRD W ireless Monitoring

# Polyvinyl Chloride and Copolymers (PVC) Production
**MACT Floor, Baseline, Reductions for Equipment Leaks**

**Description** Analy sis of MACT Floor Equipment Leak Costs Analy sis of BTF Options for Equipment Leaks Em ission Estimates for Major Source Facilities Cost of Compliance with Subpart V for a Major Source Facility Cost of Compliance with Pump Requirements for Subpart UU Cost of Compliance with Valve Requirements for Subpart UU Cost of Compliance with Connector Requirements for Subpart UU PRD W ireless Monitoring Cost Estimate

# ATTTACHMENT I/E: EQUIPMENT LEAK TESTING AND MONITORING COST ALGORITHM/BASELINE EMISSIONS ANALYSIS FOR EQUIPMENT

LEAKS

02/08/2012



# Equipment Leaks - MA **CT Floor Cost A naly**  **sis**

**Cost Summary for PRD Monitoring Systems**

**Capital Costs An**  **nual Costs Ma**  **jor Sources** 188,913 26,897

**Cost Summary for Equipment Leaks**

**Com pany**  **LDAR Program [1]**  

# (A) PRV Monitoring **System Capital Cost ($)**  **(B) Annualize Capital Cost of PRV**  **Monitoring System ($)**  **Baseline**

**Emission[2] (Tons/yr)**  **Part 61**

**Allowable Emissions**  **(Tons/yr) Estim**  **ated**

**Emission Reductions**  **(Tons/yr)**
Formosa - Baton Rouge 40CFR61 V 188,913.00 26,897.00 14.64 14.64 Formosa - Delaware City 40CFR63 UU 188,913.00 26,897.00 8.10 14.64 Formosa - Point Comfort 40CFR61 V 188,913.00 26,897.00 14.64 14.64 Georgia Gulf - Aberdeen 40CFR61 V 188,913.00 26,897.00 14.64 14.64 Georgia Gulf - Plaquemine 40CFR63 UU 188,913.00 26,897.00 8.10 14.64 OxyVinyls - Pasadena 40CFR61 V 188,913.00 26,897.00 14.64 14.64 OxyVinyls - Pedricktown 40CFR61 V 188,913.00 26,897.00 14.64 14.64 PolyOne - Henry 40CFR61 V 188,913.00 26,897.00 14.64 14.64 PolyOne - Pedricktow

n 40CFR61 V 188,913.00 26,897.00 14.64 14.64 Shintech - Addis 40CFR61 V 188,913.00 26,897.00 14.64 14.64 Shintech - Freeport 40CFR61 V 188,913.00 26,897.00 14.64 14.64 Shintech - Plaquemine 40CFR61 V 188,913.00 26,897.00 14.64 14.64 Dow - Midland 40CFR61 V 188,913.00 26,897.00 14.64 14.64 Westlake - Calvert City 40CFR61 V 188,913.00 26,897.00 14.64 14.64 Westlake - Geismar 40CFR61 V 188,913.00 26,897.00 14.64 14.64 **Totals** 2,833,695.00 403,455.00 207 220

- [1] - LDAR program type reported by facility in August 12, 2009 information collection request. [2] - VOC assumed to equal total HAP. **Source Type PRD Monitoring Costs[1]** 

[1] - From South Coast Air Quality Management District "Proposed Amended Rule 1173 - Control of Volatile Organic Compound Leaks and Releases from Components at Petroleum Facilities and Chemical Plants". May 15, 2007 Includes device parts, installation, maintenance, and data retrieval sy stem.

# ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS

02/07/2012

**BTF Equipment Leaks Options Cost Summary**

Pumps - Option 1 5,948 972 209 1,181 Valves - Option 1 6,216 883 416 1,299 Connectors - Option 1 65,633 9,320 6,405 15,725 Total 77,798 11,175 7,030 18,205

**Cost Summary for Equipment Leaks**

**Company LDAR Program**  **[1]** 

# (A) Capital Cost Increase of **LDAR ($) (B) Annualized** 

**Capital Cost Increase of LDAR**  **(C) Annual Increase in LDAR Cost**  **(D) TAC ($) D=B+C**  **Baseline Emission[2]**

**(Tons/yr) Estimated** 

**Emission Reductions**  **(Tons/yr)** Formosa - Baton Rouge 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 Formosa - Delaware City 40CFR63 UU

- 8.10

- Formosa - Point Comfort 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 Georgia Gulf - Aberdeen 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 Georgia Gulf - Plaquemine 40CFR63 UU

- 8.10

- OxyVinyls - Pasadena 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 OxyVinyls - Pedricktown 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 PolyOne - Henry 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 PolyOne - Pedricktown 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 Shintech - Addis 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 Shintech - Freeport 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 Shintech - Plaquemine 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 Dow - Midland 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 Westlake - Calvert City 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 Westlake - Geismar 40CFR61 V 77,798 11,175 7,030 18,205 14.64 6.54 **Totals** 1,011,368 145,273 91,392 236,666 207 85 [1] - LDAR program type reported by facility in August 12, 2009 information collection request. [2] - VOC assumed to equal total HAP. **Component Capital Costs**  **Annualized Capital Costs**  **Annual Costs Total Annualized Costs** 

# ATTACHMENT E/C. BASELINE EMISSION ANALYSIS FOR EQUIPMENT LEAKS/BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS

02/08/2012

**Major Source Equipment Leaks Baseline and Emission Reduction A naly**  **sis[1]**

**Ty pe of Component**  **Number of Components**  **1** 

# SubpartV Emission **Factor (kg/hr/equipment)**  **Subpart UU Emission Factor**  **(kr/hr/equipment) Subpart V**  **Emissions (Tons/y**  **r) Subpart UU** 

**Emissions (Tons/y**  **r) Emission** 

**Reduction (Tons/y**  **r)**

Model 2 **Pump Seals**

* Light-liquid service 40 2.51E-03 6.95E-04 0.93 0.26 0.67 * Heavy-liquid service 5

**Valves** * Gas/vapor service 414 3.52E-04 2.03E-04 1.35 0.78 0.57 * Light-liquid service 1,179 3.90E-04 2.32E-04 4.26 2.53 1.72 * Heavy-liquid service 71

**Connectors** * Flanges - gas/vapor 0 3.07E-04 3.07E-04 0.00 0.00 0.00 * Flanges - light liquid 2,662 3.07E-04 1.62E-04 7.57 3.99 3.57 * Flanges -heavy liquid 0

**Ag itators**  * Light-liquid service 3 2.51E-03 2.51E-03 0.07 0.07 0.00 * Heavy-liquid service 3

**Pressure Relief Devices** * Disks 45 0.00E+00 0.00E+00 0.00 0.00 0.00 * Disk holders, valves,etc. 45 NA NA

**Open-ended Valves** 141 3.33E-05 3.33E-05 0.04 0.04 0.00

**Sampling Connections** 35 0.00E+00 0.00E+00 0.00 0.00 0.00

**Compressor Vent** 2 2.28E-02 2.28E-02 0.42 0.42 0.00

**Totals 14.64**  **8.10 6.54**  [1] - Emissions estimated based on 8,400 operating hours per year

# ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS

02/07/2012

**Major Source Equipment Leaks - Subpart V Cost**

**Type of Component Number of**  **Components Initial** 

**Monitoring Fee or Unit**  **Cost ($/comp) Initial LDAR** 

**Costs ($/yr) (Capital)**  **Initial**

**LDAR Admin.**  **Costs Frequency** 

**of Monitoring**  **(times/yr) Subsequent** 

**Monitoring Fee ($/comp) or**  **Charge (%**

**) Annual**  **Monitoring Costs ($/yr)**  **Annual**

**Maintenance Costs ($/yr)**  **Initial Leak**

**Frequency (%**  **) Initial**  **Number of Leaks**  **Subsequent**

**Leak Frequency (%** 

**) Annual**  **Number of Leaks**  **Percent**

**Repaired OnLine**  **Repair**

**Time (hours)**  **Labor**

**Charge ($/hr)**  **Annual OnLine**

**Leak Repair Cost ($/yr)**  **Percent**

**Requiring Further**  **Repair Repair** 

**Time (hours)**  **Labor**

**Charge ($/hr)**  **Annual Offline Leak**  **Repair Cost ($/yr)**  **Monitoring to**

**Verify Repair ($)**  **Annual**

**Admin. Cost ($/yr)**  **Annual Misc.**

**Charges ($/yr)**

Model 2 **Pump Seals**

* Light-liquid service 40 23.80 

### 1979.78 12 1.50 1547.01 310.2 2.42 0.97 0.23 1.097 100 16.00 66.24 1162.87 0 80.00 66.24 0.00 1.65 248.15 * Heavy-liquid service 5 1.10 5.52

**Valves** * Gas/vapor service 414 23.80 

### 9960.24 2 1.50 1242.00 0.33 1.38 0.33 2.77 75 0.17 66.24 22.95 25 4.00 66.24 183.22 4.15 * Light-liquid service 1,179 23.80 

### 28365.03 2 1.50 3537.00 0.33 3.94 0.33 7.88 75 0.17 66.24 65.35 25 4.00 66.24 521.78 11.82 * Heavy-liquid service 71 1.10 78.38

**Connectors** * Flanges - gas/vapor 0 1.10 0.00 * Flanges - light liquid 2,662 1.10 2938.85 * Flanges -heavy liquid 0 1.10 0.00

**Agitators** * Light-liquid service 3 23.80 71.41 12 1.50 140.11 0.00 2.42 0.07 0.23 0.08 100.00 16.00 66.24 87.22 0 80.00 66.24 0.00 0.12 0.00 * Heavy-liquid service 3 1.10 3.31

**Pressure Relief Devices** * Disks 45 122.11 5494.78 0 2.00 0.00 109.90 219.79 * Disk holders, valves,etc. 45 6,374.29 286842.95 5.00 14342.15 11473.72

**Open-ended Valves** 141 140.92 19870.03 5.00 993.50 794.80

**Sampling Connections** 35 687.86 24075.01 5.00 1203.75 963.00

**Compressor Vent** 2 10526.21 21052.42 5.00 1052.62 842.10

**Replacement Pump Seals** 40 282.71 273.72 **Monitoring Instrument** 1 10,800 10,800 **Data Collection System** 1 14,500 14,500

hr/activity $/hr **Administrative and Reports** 250 92.72 23180.00 **Planning and Training** 320 92.72 29670.40

**TOTALS** 426311.44 29670.40 6466.12 18012.11 1338.39 705.00 17.73 23180.00 14541.56

Capital Costs 455,982 Capital Rec. Fac for Pump Seals and Rupture Disks 0.244

Capital Rec. Fac for All other Equipment 0.142

Annualized Capital Costs 65,338 Annual Expenses 64,261 Annual Fixed Costs ($/yr) 103,049 129,599 Annual Variable Costs ($/yr) 26,861

# ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS

02/07/2012

**Equipment Leaks - Pumps Option 1 Incremental Cost**

**Type of Component Number of**  **Component**

**s Initial** 

**Monitoring Fee or Unit**  **Cost ($/comp)**  **Initial LDAR**

**Costs ($/yr) (Capital)**  **Initial**

**LDAR Admin.**  **Costs Frequency** 

**of Monitoring**  **(times/yr) Subsequent** 

**Monitoring Fee**  **($/comp) or Charge (%)**  **Annual**

**Monitoring Costs ($/yr)**  **Annual**

**Maintenance Costs ($/yr)**  **Initial Leak**

**Frequency (%)**  **Initial**

**Number of Leaks**  **Subsequent**

**Leak Frequency**  **(%) Annual** 

**Number of Leaks**  **Percent**

**Repaired OnLine**  **Repair**

**Ti me**  **(hours) Labor**  **Charge ($/hr)**  **Annual OnLine Leak**  **Repair Cost ($/yr)**  **Percent**

**Requiring Further**  **Repair Repair** 

**Ti me**  **(hours) Labor** 

**Charge ($/hr)**  **Annual Offline Leak**  **Repair Cost ($/yr)**  **Monitoring**

**to Verify Repair ($)**  **Annual**

**Admin. Cost ($/yr)**  **Annual**

**Misc. Charges**  **($/yr)**

Model 2 **Pump Seals**

* Light-liquid service 40 0.00 

### 5724.65 12 1.50 1547.01 347.9 13.48 5.39 0.26 1.231 100 16.00 66.24 1304.21 0 80.00 66.24 0.00 1.85 278.32 * Heavy-liquid service 5 0.00 0.00

**Replacement Pump Seals** 40 282.71 1524.88 hr/activity $/hr **Administrative and Reports** 0 92.72 0.00 **Planning and Training** 0 92.72 0.00

**TOTALS** 7249.53 0.00 1547.01 347.90 1304.21 0.00 1.85 0.00 278.32

Capital Costs 7,250 Capital Rec. Fac for Pump Seals and Rupture Disks 0.244

Capital Rec. Fac for All other Equipment 0.142

Annualized Capital Costs 1,185 Annual Expenses 3,479

**Baseline Monitoring**

**Type of Component Number of**  **Component**

**s Initial** 

**Monitoring Fee or Unit**  **Cost ($/comp)**  **Initial LDAR**

**Costs ($/yr) (Capital)**  **Initial**

**LDAR Admin.**  **Costs Frequency** 

**of Monitoring**  **(times/yr) Subsequent** 

**Monitoring Fee**  **($/comp) or Charge (%)**  **Annual**

**Monitoring Costs ($/yr)**  **Annual**

**Maintenance Costs ($/yr)**  **Initial Leak**

**Frequency (%)**  **Initial**

**Number of Leaks**  **Subsequent**

**Leak Frequency**  **(%) Annual** 

**Number of Leaks**  **Percent**

**Repaired OnLine**  **Repair**

**Ti me**  **(hours) Labor**  **Charge ($/hr)**  **Annual OnLine Leak**  **Repair Cost ($/yr)**  **Percent**

**Requiring Further**  **Repair Repair** 

**Ti me**  **(hours) Labor** 

**Charge ($/hr)**  **Annual Offline Leak**  **Repair Cost ($/yr)**  **Monitoring**

**to Verify Repair ($)**  **Annual**

**Admin. Cost ($/yr)**  **Annual**

**Misc. Charges**  **($/yr)**

Model 2 **Pump Seals**

* Light-liquid service 40 0.00 

### 1027.60 12 1.50 1547.01 310.2 2.42 0.97 0.23 1.097 100 16.00 66.24 1162.87 0 80.00 66.24 0.00 1.65 248.15 * Heavy-liquid service 5 0.00 0.00

**Replacement Pump Seals** 40 282.71 273.72 hr/activity $/hr **Administrative and Reports** 0 92.72 0.00 **Planning and Training** 0 92.72 0.00

**TOTALS** 1301.32 0.00 1547.01 310.19 1162.87 0.00 1.85 0.00 248.15 Monitoring Repair Capital Costs 1,301 1,301.32 Capital Rec. Fac for Pump Seals and Rupture Disks 0.244

Capital Rec. Fac for All other Equipment 0.142

Annualized Capital Costs 213 212.71 Annual Expenses 3,270 1,548.86 1,473.07

**Incremental Capital Costs 5948.21**  **Incremental Annual Costs 1181.47** 

# ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS

02/07/2012

**Equipment Leaks - Valves Option 1 Cost Analysis**

**Type of Component Number of**  **Components Initial** 

**Monitoring Fee or Unit**  **Cost ($/comp)**  **Initial LDAR**

**Costs ($/yr) (Capital)**  **Initial**

**LDAR Admin.**  **Costs Frequency** 

**of Monitoring**  **(times/yr) Subsequent** 

**Monitoring Fee**  **($/comp) or Charge (%)**  **Annual**

**Monitoring Costs ($/yr)**  **Annual**

**Maintenance Costs ($/yr)**  **Initial Leak**

**Frequency (%)**  **Initial**

**Number of Leaks**  **Subsequent**

**Leak Frequency**  **(%) Annual** 

**Number of Leaks**  **Percent**

**Repaired OnLine**  **Repair**

**Ti me**  **(hours) Labor**  **Charge ($/hr)**  **Annual OnLine Leak**  **Repair Cost ($/yr)**  **Percent**

**Requiring Further**  **Repair Repair** 

**Ti me**  **(hours) Labor** 

**Charge ($/hr)**  **Annual Offline Leak**  **Repair Cost ($/yr)**  **Monitoring**

**to Verify Repair ($)**  **Annual**

**Admin. Cost ($/yr)**  **Annual**

**Misc. Charges**  **($/yr)**

Model 2 **Valves**

* Gas/vapor service 414 0.00 

### 2279.30 2 1.50 1242.00 7.24 29.98 0.51 4.19 75 0.17 66.24 34.75 25 4.00 66.24 277.41 6.28 * Light-liquid service 1,179 0.00 

### 4341.26 2 1.50 3537.00 4.84 57.09 0.51 11.93 75 0.17 66.24 98.95 25 4.00 66.24 790.01 17.89 * Heavy-liquid service 71 0.00 0.00 hr/activity $/hr **Administrative and Reports** 0 92.72 0.00 **Planning and Training** 0 92.72 0.00

**TOTALS** 6620.56 0.00 4779.00 0.00 133.69 1067.42 24.17 0.00 0.00

Capital Costs 6,620.56 Capital Rec. Fac for Pump Seals and Rupture Disks 0.244

Capital Rec. Fac for All other Equipment 0.142

Annualized Capital Costs 940 Annual Expenses 6,004

**Baseline Monitoring**

**Type of Component Number of**  **Components Initial** 

**Monitoring Fee or Unit**  **Cost ($/comp)**  **Initial LDAR**

**Costs ($/yr) (Capital)**  **Initial**

**LDAR Admin.**  **Costs Frequency** 

**of Monitoring**  **(times/yr) Subsequent** 

**Monitoring Fee**  **($/comp) or Charge (%)**  **Annual**

**Monitoring Costs ($/yr)**  **Annual**

**Maintenance Costs ($/yr)**  **Initial Leak**

**Frequency (%)**  **Initial**

**Number of Leaks**  **Subsequent**

**Leak Frequency**  **(%) Annual** 

**Number of Leaks**  **Percent**

**Repaired OnLine**  **Repair**

**Ti me**  **(hours) Labor**  **Charge ($/hr)**  **Annual OnLine Leak**  **Repair Cost ($/yr)**  **Percent**

**Requiring Further**  **Repair Repair** 

**Ti me**  **(hours) Labor** 

**Charge ($/hr)**  **Annual Offline Leak**  **Repair Cost ($/yr)**  **Monitoring**

**to Verify Repair ($)**  **Annual**

**Admin. Cost ($/yr)**  **Annual**

**Misc. Charges**  **($/yr)**

Model 2 **Valves**

* Gas/vapor service 414 0.00 

### 105.16 2 1.50 1242.00 0.33 1.38 0.33 2.77 75 0.17 66.24 22.95 25 4.00 66.24 183.22 4.15 * Light-liquid service 1,179 0.00 

### 299.48 2 1.50 3537.00 0.33 3.94 0.33 7.88 75 0.17 66.24 65.35 25 4.00 66.24 521.78 11.82 * Heavy-liquid service 71 0.00 0.00 hr/activity $/hr **Administrative and Reports** 0 92.72 0.00 **Planning and Training** 0 92.72 0.00

**TOTALS** 404.63 0.00 4779.00 0.00 88.30 705.00 15.96 0.00 0.00

Capital Costs 405 Capital Rec. Fac for Pump Seals and Rupture Disks 0.244

Capital Rec. Fac for All other Equipment 0.142

Annualized Capital Costs 57 Annual Expenses 5,588

**Incremental Capital Costs 6215.93**  **Incremental Annual Costs 1298.68** 



# V Option 1 - MC I-1

# ATTACHMENT C: BEYOND THE FLOOR ANALYSIS FOR EQUIPMENT LEAKS

02/07/2012

**Equipment Leaks - Connectors Option 1 Cost Analysis**

**Type of Component Number of**  **Components Initial** 

**Monitoring Fee or Unit**  **Cost ($/comp) Initial LDAR** 

**Costs ($/yr) (Capital)**  **Initial**

**LDAR Admin.**  **Costs Frequency of** 

**Monitoring (times/yr)**  **Subsequent**

**Monitoring Fee ($/comp) or**  **Charge (%**

**) Annual**  **Monitoring Costs ($/yr)**  **Annual**

**Maintenance Costs ($/yr)**  **Initial Leak**

**Frequency (%**  **) Initial**  **Number of Leaks**  **Subsequent**

**Leak Frequency (%** 

**) Annual**  **Number of Leaks**  **Percent**

**Repaired OnLine**  **Repair**

**Time (hours)**  **Labor**

**Charge ($/hr)**  **Annual OnLine Leak**  **Repair Cost ($/yr)**  **Percent**

**Requiring Further**  **Repair Repair** 

**Time (hours)**  **Labor**

**Charge ($/hr)**  **Annual Offline Leak**  **Repair Cost ($/yr)**  **Monitorin**

**g to Verify Repair ($)**  **Annual**

**Admin. Cost ($/yr)**  **Annual**

**Misc. Charges**  **($/yr)**

Model 2 **Connectors**

* Flanges - gas/vapor 0 23.80 0.00 0.20 2.50 0.00 0.36 0.00 0.36 0.00 75 0.17 66.24 0.00 25 2.00 66.24 0.00 0.00 * Flanges - light liquid 2,662 23.80 63778.96 0.25 2.50 1663.75 0.36 9.58 0.36 2.40 75 0.17 66.24 19.88 25 2.00 66.24 79.35 5.99 * Flanges -heavy liquid 0 0.00 0.00

hr/activity $/hr **Administrative and Reports** 50 92.72 4636.00 **Planning and Training** 20 92.72 1854.40

1663.75 0.00 19.88 79.35 5.99 0.00 0.00 **TOTALS** 63778.96 1854.40 1663.75 0.00 19.88 79.35 5.99 4636.00 0.00

Capital Costs **65,633** Capital Rec. Fac for Pump Seals and Rupture Disks 0.244

Capital Rec. Fac for All other Equipment 0.142

Annualized Capital Costs **9,320** Annual Expenses **6,405**



# C Option 1 - MC I-1

# ATTTACHMENT I: EQUIPMENT LEAK TESTING AND MONITORING COST ALGORITHM

02/07/2012

**PRD Wireless Monitoring Cost Estimate**

Option 4

Ty pe of Facility No. of

Pressure Relief
Devices 1 

# Facility

Cost PRD Electronic Monitoring (wireless) 2 

# Annualized

PRD Electronic Monitoring (wireless) Sm all 57 $113,116 $16,105 Average 134 $188,913 $26,897 Large 275 $290,803 $41,404 1. Table 2-1 http://www.epa.gov/ttnnaaqs/ozone/ctg_act/198403_voc_epa450_3-83-006_leaks_poly me r_equipment.pdf 2. From South Coast Air Quality Management District "Proposed Amended Rule 1173 - Control of Volatile Organic Compound Leaks and Releases from Components at Petroleum Facilities and Chemical Plants". May 15, 2007 Includes device parts, installation, maintenance, and