Polyvinyl Chloride and Copolymers (PVC) Production

MACT Floor, Baseline Emissions, and Emission Reductions Analyses

Equipment Leaks

April 8, 2011

Worksheet Name Description 

Data Table Section 114 Survey Response Data

LDAR Cost Worksheet Summary of Baseline Emissions and Costs for Equipment Leaks

Cost tables for Memos Summary of Baseline Emissions and Costs for Equipment Leaks

Using Protocol Baseline Emissions Analysis for Equipment Leaks

factors- EPA sprdsht, emissions Emisison Factors
Section 114 Survey Data

Company Facility Process 

Unit ID

Has 

LDAR 

LDAR 1 LDAR 2 LDAR 3 LDAR 4

Formosa Delaware City P-1 Yes 40CFR63 UU

Formosa Delaware City P-2 Yes 40CFR63 UU

Formosa Baton Rouge P-1 Yes 40 CFR 61 Subpart F LAC 33:III.2122, LAC 33:III.5109

Formosa Point Comfort P-1 Yes 40CFR61 V OLD MACT 28CNTQ

Formosa Point Comfort SPVC P-2 Yes 40CFR61 V 28 MID

Georgia Gulf Aberdeen 1 Yes 40CFR61 V

Georgia Gulf Plaquemine P-1 Yes 40CFR63 UU 40CFR61 V 2122

OxyVinyls Pedricktown P-1 Yes 40CFR61 V N.J.A.C. 7:27-16.18(h)

OxyVinyls Pedricktown P-2 Yes 40CFR61 V N.J.A.C. 7:27-16.18(h)

OxyVinyls Pedricktown P-3 No

OxyVinyls Pedricktown P-4 Yes 40CFR61 V N.J.A.C. 7:27-16.18(h)

OxyVinyls Pedricktown P-5 Yes 40CFR61 V NJAC 7:27-16.18(h)

OxyVinyls Pedricktown P-6 No

OxyVinyls Pedricktown P-7 No

Shintech Plaquemine P-1 Yes 40CFR61 V LAC33:III.2122

Shintech Addis P-1 Yes 40CFR61 V LAC 33:III.2122

Shintech Freeport U-35 Yes 40CFR63 UU 40CFR61 V 30 TAC 115

Certain Teed Lake Charles P-1 Yes 40CFR61 V

Certain Teed Lake Charles P-2 Yes 40CFR61 V

OxyVinyls Deer Park sitewide Yes 40CFR61 V 30 TAC 115 Sub. D

OxyVinyls Pasadena sitewide Yes 40CFR61 V 28 LAER

PolyOne Pedricktown P-1 Yes 40CFR61 V 40 CFR Part 61, Subpart F

PolyOne Henry P-1 Yes 40CFR61 V 40 CFR Part 61.65 b 8 ii

PolyOne Henry P-11 Yes 40CFR61 V 40 CFR Part 61.65 b 8 ii

PolyOne Henry P-12 Yes 40CFR61 V 40 CFR Part 61, Subpart F

PolyOne Henry P-2 Yes 40CFR61 V 40 CFR Part 61.65 b 8 ii

PolyOne Henry P-3 Yes 40CFR61 V 40 CFR Part 61.65 b 8 ii

PolyOne Henry P-4 Yes 40CFR61 V 40 CFR Part 61.65 b 8 ii

PolyOne Henry P-5 Yes 40CFR61 V 40 CFR Part 61.65 b 8 ii

PolyOne Henry P-7 Yes 40CFR61 V 40 CFR Part 61.65 b 8 ii

PolyOne Henry P-9 Yes 40CFR61 V 40 CFR Part 61.65 b 8 ii

Dow Midland Vinyl Train Yes 40CFR61 V Subpart H

Dow Texax City P-1, P-2, P-3 Yes 40CFR61 V 63 EEEE (OLD MACT) 28 VHP and 30 TAC 115

Westlake Calvert City P-1 Yes 40CFR61 V

Westlake Geismar P-1 Yes 40CFR61 V LAC 51
LDAR Process

Subject to 

40CFR63UU

Subject to 

40CFR61V?

Subject to 

other Federal 

Federal LDAR 

Regulation

Yes

Yes

N/A No No Yes 40 CFR 61 Subpart F

No Yes Yes OLD MACT

Yes

Yes

Yes Yes No

Yes

Yes

Detected by daily operator inspections and maintenance notifications

Yes

Yes

Ammonia sensor alarms, operator rounds; repaired via work orders

Leaks detected on operator rounds and repaired via work orders

No Yes No 40 CFR 61.65

No Yes No 40 CFR 61.65

Yes Yes No

No Yes No

No Yes No

No Yes No

No Yes No

No Yes Yes 40 CFR Part 61, Subpart F

No Yes Yes 40 CFR Part 61.65 b 8 ii

No Yes Yes 40 CFR Part 61.65 b 8 ii

No Yes Yes 40 CFR Part 61, Subpart F

No Yes Yes 40 CFR Part 61.65 b 8 ii

No Yes Yes 40 CFR Part 61.65 b 8 ii

No Yes Yes 40 CFR Part 61.65 b 8 ii

No Yes Yes 40 CFR Part 61.65 b 8 ii

No Yes Yes 40 CFR Part 61.65 b 8 ii

No Yes Yes 40 CFR Part 61.65 b 8 ii

No Yes Yes Subpart H

No Yes Yes 63 EEEE (OLD MACT) 

Yes

No Yes No
Subject to 

other state State LDAR Regulation Total LDAR Cost ($)

$ 10,000.00

$ 10,000.00

Yes

LAC 33:III.2122, 

LAC 33:III.5109 CBI

Yes 28CNTQ $ 43,675.00

28 MID

Yes 2122 $ 155,000.00

Yes N.J.A.C. 7:27-16.18(h) $ 5,800.00

Yes N.J.A.C. 7:27-16.18(h) $ 5,800.00

Yes N.J.A.C. 7:27-16.18(h) $ 3,400.00

Yes NJAC 7:27-16.18(h) $ 1,000.00

Yes LAC33:III.2122 $ 17,000.00

Yes LAC 33:III.2122 $ 14,000.00

Yes 30 TAC 115 cost incurred internally

No $ 20,000.00

No $ 6,000.00

Yes 30 TAC 115 Sub. D $ 29,093.94

Yes 28 LAER $ 85,277.00

$ 20,000.00

No $ 240.00

No $ 240.00

No $ 240.00

No $ 240.00

No $ 240.00

No $ 240.00

No $ 240.00

No $ 240.00

No $ 240.00

No $ 20,000.00

Yes 28 VHP and 30 TAC 115 $ 105,000.00

No $ 10,000.00

Yes LAC 51 $ 16,525.00
Attachment E1 - Baseline Emissions Analysis for Equipment Leaks

Company Facility LDAR Program 

Type (by Survey) Facility Type

Baseline 

Emissions (TPY) 

[1]

Certain Teed Lake Charles 40CFR61 V Bulk 16.5

Formosa Baton Rouge 40CFR61 V Other 59.29

Formosa Delaware City 40CFR63 UU Dispersion 8.1

Formosa Point Comfort 40CFR61 V Other 59.29

Georgia Gulf Aberdeen 40CFR61 V Other 59.29

Georgia Gulf Plaquemine 40CFR63 UU Other 8.1

OxyVinyls Deer Park 40CFR61 V Other 59.29

OxyVinyls Pasadena 40CFR61 V Other 59.29

OxyVinyls Pedricktown 40CFR61 V Other 59.29

PolyOne Henry 40CFR61 V Other/Dispersion 59.29

PolyOne Pedricktown 40CFR61 V Dispersion 59.29

Shintech Addis 40CFR61 V Other 59.29

Shintech Freeport 40CFR63 UU Other 8.1

Shintech Plaquemine 40CFR61 V Other 59.29

Dow Midland 40CFR61 V Other 59.29

Westlake Calvert City 40CFR61 V Other 59.29

Westlake Geismar 40CFR61 V Other 59.29

[1] 59.29 from "PVC_eqlk_baseline_er_estimate_102610" Worksheet "Using Protocol" For subpart V, medium 

/small complexity plant. 8.1 from Worksheet "factors-EPA sprdsht, emissions" US, Level 2, 

medium/small complexity plant
Attachment K - Equipment Leaks

Company Facility

LDAR 

Program 

Type (by 

Survey)

Facility 

Reported LDAR 

Cost ($) 

2006 

Capacity 

1,000 US 

Tons

Facility LDAR 

Cost 

$/1,000Ton 

Facility LDAR 

Cost by Using 

Average Cost of 

40CFR61V x 2006 

Facility LDAR Cost 

by Using Average 

Cost of 

40CFR63UU x 2006 

Increase in 

LDAR Cost 

from V to UU 

PRV Cost 

Reduction TAC 

[1]

PRV Cost 

Reduction TCI 

[1]

TCI per 

Facility ($)

TAC per 

Facility 

($/year)

Certain Teed Lake Charles 40CFR61 V $26,000 240.3 $ 108 $55,860 $64,595 $8,736 $ 16,105 $ 113,116 $ 113,116 $24,841

Formosa Baton Rouge 40CFR61 V - 458.6 - $106,595 $123,265 $16,670 $ 26,897 $ 188,913 $ 188,913 $43,567

Formosa Delaware City40CFR63 UU $20,000 71.7 $ 279 $16,655 $19,260 $0 $ 26,897 $ 188,913 $ 188,913 $26,897

Formosa Point Comfort40CFR61 V $43,675 782.6 $ 56 $181,929 $210,380 $28,451 $ 26,897 $ 188,913 $ 188,913 $55,348

Georgia Gulf Aberdeen 40CFR61 V - 500.4 - $116,332 $134,524 $18,193 $ 26,897 $ 188,913 $ 188,913 $45,090

Georgia Gulf Plaquemine 40CFR63 UU $155,000 599.7 $ 258 $139,393 $161,192 $0 $ 26,897 $ 188,913 $ 188,913 $26,897

OxyVinyls Deer Park 40CFR61 V $29,094 275.6 $ 106 $64,059 $74,077 $10,018 $ 26,897 $ 188,913 $ 188,913 $36,915

OxyVinyls Pasadena 40CFR61 V $85,277 1050.5 $ 81 $244,194 $282,383 $38,189 $ 26,897 $ 188,913 $ 188,913 $65,086

OxyVinyls Pedricktown 40CFR61 V $16,000 175.3 $ 91 $40,742 $47,113 $6,371 $ 26,897 $ 188,913 $ 188,913 $33,268

PolyOne Henry 40CFR61 V $2,160 62.8 $ 34 $14,606 $16,890 $2,284 $ 26,897 $ 188,913 $ 188,913 $29,181

PolyOne Pedricktown 40CFR61 V $20,000 65.0 $ 308 $15,118 $17,482 $2,364 $ 26,897 $ 188,913 $ 188,913 $29,261

Shintech Addis 40CFR61 V $14,000 312.0 $ 45 $72,515 $83,856 $11,340 $ 26,897 $ 188,913 $ 188,913 $38,237

Shintech Freeport 40CFR63 UU - 1598.3 - $371,544 $429,649 $0 $ 26,897 $ 188,913 $ 188,913 $26,897

Shintech Plaquemine 40CFR61 V $17,000 650.4 $ 26 $151,180 $174,823 $23,642 $ 26,897 $ 188,913 $ 188,913 $50,539

Dow Midland2

40CFR61 V $20,000 10.8 $ 1,852 $2,511 $2,903 $393 $ 26,897 $ 188,913 $ 188,913 $27,290

Westlake Calvert City 40CFR61 V $10,000 400.1 $ 25 $93,014 $107,560 $14,546 $ 26,897 $ 188,913 $ 188,913 $41,443

Westlake Geismar 40CFR61 V $16,525 286.6 $ 58 $66,622 $77,040 $10,419 $ 26,897 $ 188,913 $ 188,913 $37,316

Total $ 446,457 $ 3,135,724 $ 3,135,724 $ 638,073

[1] EPA supplied cost factors from "PVC_PRV_Cost_reductions_110310" option 4, average facility 40CFR61 V 232.5

[2] Non CBI production data - Capacity information not available 40CFR63UU 268.8

Average $/KTon
Attachment E2 - Baseline Emissions Analysis for Equipment Leaks

Factors from protocol

simple medium complex Control Factor Control Factor Subpart V US, Level 2 Subpart V US, Level 2

Pump Seals

 * Light-liquid service 15 40 56 0.0199 Monthly (10,000ppm) 0.00617Monthly (1,000ppm) 0.00488 2.28 1.81 0.86 0.68 0.48 0.18

 * Heavy-liquid service 0 5 36 0.00862 none 0.00862 none 0.00862 0.40 0.40 0.00 0.00 0.00 0.00

Valves

 * Gas/vapor service 77 414 1,379 0.00597 Monthly (10,000ppm) 0.00078Quarterly (500 ppm) 0.00035 2.97 1.33 0.55 0.25 1.64 0.31

 * Light-liquid service 380 1,179 1,980 0.00403 Monthly (10,000ppm) 0.00084Quarterly (500 ppm) 0.00038 9.16 4.14 2.95 1.33 5.02 1.62

 * Heavy-liquid service 0 71 1,272 0.00023 none 0.00023 none 0.00023 0.15 0.15 0.00 0.00 0.00 0.00

Connectors

 * Flanges - gas/vapor 0.00183

 * Flanges - light liquid 731 2,662 7,410 0.00183 None 0.00180 annual (500) 0.00013 44.33 3.20 12.17 0.88 41.13 11.29

 * Flanges -heavy liquid 0.00183

Pressure Relief Devices

 * Disks 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

 * Disk holders, valves,etc. 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Open-ended Valves 33 141 424 0.0017 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Sampling Connections 8 35 106 0.015 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Compressor Vent 0 2 8 0.228 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Total 59.29 11.03 16.53 3.14 48.27 13.40

Equipment counts from Subpart VV analysis provided by EPA

Emission 

reduction (simple 

complexity) (tpy)

Type of Component

Number of Components

Emission Factors From Protocol (kg/hr/source)

Emissions, medium 

complexity (tpy)

Emission 

reduction 

(medium 

Uncontrolled complexity) (tpy)

Baseline (subpart V) US, Level 2

Emissions, simple 

complexity (tpy)

Using Protocol 7
Factors from "emissions" tab of EPA spreadsheet (A7:C11) or "final estimates" tab

simple medium complex Control Factor Control Factor Subpart V US, Level 2 Subpart V US, Level 2

Pump Seals

 * Light-liquid service 15 40 56 0.0199 Monthly (10,000ppm) 0.00251Monthly (1,000ppm) 0.000695 0.93 0.26 0.35 0.10 0.67 0.25

 * Heavy-liquid service 0 5 36 0.00862 none 0.00862 none 0.00862 0.40 0.40 0.00 0.00 0.00 0.00

Valves

 * Gas/vapor service 77 414 1,379 0.00597 Monthly (10,000ppm) 0.000352Quarterly (500 ppm) 0.00020 1.35 0.78 0.25 0.14 0.57 0.11

 * Light-liquid service 380 1,179 1,980 0.00403 Monthly (10,000ppm) 0.00039Quarterly (500 ppm) 0.00023 4.25 2.53 1.37 0.82 1.72 0.56

 * Heavy-liquid service 0 71 1,272 0.00023 none 0.00023 none 0.00023 0.15 0.15 0.00 0.00 0.00 0.00

Connectors

 * Flanges - gas/vapor 0.00183

 * Flanges - light liquid 731 2,662 7,410 0.00183 None 0.00031 annual (500) 0.000162 7.56 3.99 2.08 1.10 3.57 0.98

 * Flanges -heavy liquid 0.00183

Pressure Relief Devices

 * Disks 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

 * Disk holders, valves,etc. 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Open-ended Valves 33 141 424 0.0017 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Sampling Connections 8 35 106 0.015 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Compressor Vent 0 2 8 0.228 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Total 14.64 8.10 4.05 2.15 6.54 1.89

Equipment counts from Subpart VV analysis provided by EPA

Emission 

reduction (simple 

complexity) (tpy)

Type of Component Number of Components Emission Factors From Protocol (kg/hr/source) Emissions, medium 

complexity (tpy)

Emission 

reduction 

Uncontrolled (medium 

Baseline (subpart V) US, Level 2

Emissions, simple 

complexity (tpy)

Using Protocol 8
Using Protocol 9
Using Protocol 10
simple medium complex Control Factor Control Factor Subpart V US, Level 2 Subpart V US, Level 2

Pump Seals

 * Light-liquid service 15 40 56 0.0199 Monthly (10,000ppm) 0.00251Monthly (1,000ppm) 0.000695 0.93 0.26 0.35 0.10 0.67 0.25

 * Heavy-liquid service 0 5 36 0.00862 none 0.00862 none 0.00862 0.40 0.40 0.00 0.00 0.00 0.00

Valves

 * Gas/vapor service 77 414 1,379 0.00597 Monthly (10,000ppm) 0.000352Quarterly (500 ppm) 0.00020 1.35 0.78 0.25 0.14 0.57 0.11

 * Light-liquid service 380 1,179 1,980 0.00403 Monthly (10,000ppm) 0.00039Quarterly (500 ppm) 0.00023 4.25 2.53 1.37 0.82 1.72 0.56

 * Heavy-liquid service 0 71 1,272 0.00023 none 0.00023 none 0.00023 0.15 0.15 0.00 0.00 0.00 0.00

Connectors

 * Flanges - gas/vapor 0.00183

 * Flanges - light liquid 731 2,662 7,410 0.00183 None 0.00031 annual (500) 0.000162 7.56 3.99 2.08 1.10 3.57 0.98

 * Flanges -heavy liquid 0.00183

Pressure Relief Devices

 * Disks 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

 * Disk holders, valves,etc. 2 45 76 0.104 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Open-ended Valves 33 141 424 0.0017 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Sampling Connections 8 35 106 0.015 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Compressor Vent 0 2 8 0.228 no leaks 0 no leaks 0 0.00 0.00 0.00 0.00 0.00 0.00

Total 14.64 8.10 4.05 2.15 6.54 1.89

Equipment counts from Subpart VV analysis provided by EPA

Factors from "emissions" tab of EPA spreadsheet (A7:C11) or "final estimates" tab

Emission 

reduction 

(simple 

complexity) (tpy)

Type of Component

Number of Components

Emission Factors From Protocol (kg/hr/source)

Emissions, medium 

complexity (tpy)

Emission 

reduction 

(medium 

Uncontrolled complexity) (tpy)

Baseline (subpart V) US, Level 2

Emissions, simple 

complexity (tpy)

factors- EPA sprdsht, emissions 11