Polyvinyl Chloride and Copolymers (PVC) Production

MACT Floor, Baseline, Reductions for Equipment Leaks

February 7, 2012

Worksheet Name

Cost Analysis

BTF Analysis

Emissions - Major

SubpartV Cost w Formulas-MC

P Option 1 - MC

V Option 1 - MC

C Option 1 - MC

PRD Wireless Monitoring
e and Copolymers (PVC) Production

eline, Reductions for Equipment Leaks

Description 

Analysis of MACT Floor Equipment Leak Costs

Analysis of BTF Options for Equipment Leaks

Emission 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 Wireless Monitoring Cost Estimate
ATTTACHMENT I/E: EQUIPMENT LEAK TESTING AND MONITORING COST ALGORITHM/BASELINE EMISSIONS ANALYSIS FOR EQUIPMENT 

LEAKS

02/08/2012

Equipment Leaks - MACT Floor Cost Analysis

Cost Summary for PRD Monitoring Systems

Capital Costs Annual Costs

Major Sources 188,913 26,897

Cost Summary for Equipment Leaks

Company 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) 

 Estimated 

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 - Pedricktown 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 system. 
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 Analysis[1] 

Type of Component Number of 

Components1

SubpartV Emission 

Factor 

(kg/hr/equipment)

Subpart UU Emission 

Factor 

(kr/hr/equipment)

Subpart V 

Emissions 

(Tons/yr)

Subpart UU 

Emissions 

(Tons/yr)

Emission 

Reduction 

(Tons/yr)

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

Agitators

 * 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 

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 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 

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 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 

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 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 

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 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

Type of 

Facility

No. of 

Pressure 

Relief 

Devices1

Facility Cost PRD 

Electronic 

Monitoring

(wireless)2

Annualized 

PRD Electronic 

Monitoring

(wireless)

Small 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_polymer_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