**FORM A -1** 

**COMPA NY INFORMA**  **TION**

**I. Parent Company / Legal Corporate Owner Information**

1. Legal Parent Company / Legal Corporate Name Example Resins 2. Mailing Address 123 Example Resins Rd 3. City Any town 4. State North Carolina 5. Zip Code 28590 6. County Any County

501-750 7. Size of Com pany

(approximate number of employees including all subsidiaries, branches, and related establishments owned):



### Page 1 of 1 **DRA FT** PVC Section 114 Survey Part 1 06/23/2009**FORM A -2** 

**FA CILITY INFORMA** 

**TION**

**II. Polyvinyl Chloride and Copolymers (PVC) Production Facility Information**

1. Facility

Name Example Resins Sometown Facility Address a. Street 123 Any Road W ay b. City Som etown c. State Louisiana d. Zip Code 70767 e. County Any Parish Facility Coordinates (Decimal Degrees to the 5th decimal place) f. Latitude 35.72154 g. Longitude -79.17732

2. Number of employees attached to the PVC production facility: 175

**III. Technical Contact**

1. Name John Doe 2. Technical Contact Title Environm ental Manager 3. Telephone 1-234-567-8910 4. Facsimile 1-234-567-8910 5. Em ail John.Doe@ExampleResins.com

**IV. Other**

1. Is the facility

a major source of HAP? Yes

2. If No, did the facility

take a limit of its potential HAP em issions to avoid classification as a major source?

3. If the facility

took a limit of its potential HAP

em issions to avoid classification as a major source, provide the date on which the limit was taken (MM/DD/YYYY).

4. Does the facility

manufacture other products in addition to PVC resin? Yes

5. If Yes, list the other products manufactured at the facility

. Ethylene Dichloride, Vinyl Chloride Monom er

6. Are there any

HAP em issions associated with any co-located facilities? Yes



### Page 1 of 1 **DRA FT** PVC Section 114 Survey Part 1 06/23/2009**FORM F-1 CONTROL DEVICES - ABSORBER** 

**Instructions**

1. Complete the form for each absorber used as a control device within the PVC production facility, or for any absorber that emits directly to atmosphere. 2. Refer to "Enclosure 1" for additional instructions and details.

**1** Type of Equipment or Device Control Device **2** Equipment of Device ID C-1 **3 Type of Absorber**  Packed bed **4** If other, provide a description: **5** Gas inlet flow rate (dscfm): 2300 **6** Gas inlet temperature (°F): 170 **7** Pressure drop (in H 2O): 10 **8** Liquid-to-gas ratio (gal/10 3acfm): 18 **Inlet scrubbing liquor 9**  Liquor used: Water **10** pH: 6.5 **11** Percent solids: 7 **12** Type of alkali added, if any: NaOH **13** Addition rate (lb/gal): 0.01 **14** Wastewater generation rate (gal/min): 10

**15** Year Equipment Installed: 1985 **16** Equipment Currently Regulated Under (cite regulations): 40 CFR 61 Subpart F

Page 1 of 1 **DRAFT**PVC Section 114 Survey Part 1 06/23/2009**FORM F-2 CONTROL DEVICES - THERMAL OR CATALYTIC OXIDIZER** 

**1** Control Device ID: C-2 **2** Number of operating hours per year (hours/year): 8400 **3** Is this emergency equipment? No **4 Type**  (Thermal Oxidizer or Catalytic Oxidizer) Thermal Oxidizer **5** Oxidizer Inlet Flow Rate (dscfm): 2300 **6** Average percentage of total flow originating from the production facility: 10

**7** Combustion chamber temperature (°F): (please note if temperature

measurement is not in chamber) 1800

**8** Excess air (%): 25 **9** Nominal residence time (s): 1.5 **Heat recovery 10**  Recuperative, percent heat recovery **11** Regenerative, percent heat recovery **12** Design Capacity (Heat Input) (MMBtu/hr): 5 **13** Fuel Basis for Design Capacity: Fuel Gas **14** Heat Release Rate (Btu/scf): 792 **15** Is the unit subject to NSPS? No **16** If yes, indicate the year: **Start-up Fuel/Material 17**  Start-up fuel: Fuel Gas **18** Number of start-ups per year: 2 **19** Typical length of time for start-up (hours): 16 **20** Higher heating value (HHV): 792 **Fuels/Materials Combusted During Normal Operations (include solid, liquid, and gas waste streams) 21**  Fuel 1: PVC Vent **22** Hours used per year: 8400 **23** Higher heating value (HHV): 421 **24** Fuel 2: EDC/VCM Vent **25** Hours used per year: 8400 **26** Higher heating value (HHV): 1600 **27** Fuel 3: Fuel Gas **28** Hours used per year: 8400 **29** Higher heating value (HHV): 792 **30** Fuel 4: Natural Gas **31** Hours used per year: 10 **32** Higher heating value (HHV): 993 **33** Fuel 5: **34** Hours used per year: **35** Higher heating value (HHV):

**36** Year Equipment Installed: 1985 **37** Equipment Currently Regulated Under (cite regulations): 40 CFR 61 Subpart F

Page 1 of 1 **DRAFT**PVC Section 114 Survey Part 1 06/23/2009**FORM F-3 CONTROL DEVICES - CONDENSERS** 

**Instructions**

1. Complete the form for each condenser used as a control device within the PVC production facility, or for any condenser that emits directly to atmosphere. 2. Refer to "Enclosure 1" for additional instructions and details.

**1** Type of Equipment or Device **2** Equipment of Device ID **3 Type of Condenser**  **4** If other, provide a description: **5** Is the condenser refrigerated?

**6** Describe the materials condensed:

**7** Describe the fate of the non-condensed gas stream:

**8** Describe the fate of the condensate outlet stream:

**9** Gas inlet flow rate (dscfm): **10** Gas inlet temperature (° F): **11** Gas outlet temperature (° F): **12** Liquid outlet for rate (gpm):

**15** Year Equipment Installed: **16** Equipment Currently Regulated Under (cite regulations):

Page 1 of 1 **DRAFT**PVC Section 114 Survey Part 1 06/23/2009**FORM H EQUIPMENT LEAKS** 

**Instructions**

1. Submit a copy of the leak detection and repair procedures for the PVC production facility and provide responses to the questions below. 2. Refer to "Enclosure 1" for additional instructions and details.

**Table 1. LDAR Program**

Yes

Yes No

No

$10,000

**Table 2. Equipment Counts**

**In Source Category**  **Subtotal of Equipment Associated**

**with Closed Vent System(s)** (Subset of count in source category)

50 13 5 0

20 0 4 0

100 25 10 0

1 0 10 0

75 15 5 0 100 10 10 0 10 2 80 21 In heavy liquid service In gas, vapor, and light liquid service Connectors

In heavy liquid service In gas, vapor, and light liquid service Agitators

In liquid service

In gas and vapor service Pressure Relief Devices

Open ended valves and lines Sampling connection systems Compressors Instrumentation systems Valves

In heavy liquid service

In light liquid service Pumps 40 CFR Part 61, Subpart V Other Federal LDAR Regulation Specify: State LDAR Regulation Specify: Provide the total cost to your facility for conducting the LDAR program at this process unit in 2013:

**Equipment**

In heavy liquid service In gas, vapor, and light liquid service Is there an equipment leak detection and repair (LDAR) program for all equipment at your facility included in the source category? If "No," how are equipment leaks detected and repaired?

If "Yes," is the equipment subject to the requirements of: 40 CFR Part 63, Subpart UU

Page 1 of 1 **DRAFT**PVC Section 114 Survey Part 1 06/23/2009**FORM K-1**

**TA NKS, VESSELS A** **ND PORTA BLE CONTA** **INERS USED FOR FEEDSTOCK STORA GE, PRODUCT STORA** **GE, VENT GA S STORA** **GE, HOLDING, A ND WA**  **STEWA TER** 

**Instructions** 1. Complete this form for 2013 only. 2. Provide copies of estimation worksheets and any other relevant documentation. 3. Complete this form for individual equipment, including equipment that is not assigned an equipment ID (e.g., portable containers). 4. Do not include gas holders on this form. Complete Form K-2 for gas holders. 4. Refer to "Enclosure 1" for additional instructions and details.

**Table 1.**

VCM Storage Bullets

25 50 65

**Table 2.**

**Vapor Pressure Total Emissions**  (in H2O) Minimum Maximum Average **(pounds)** Vinyl chloride 1391 99 100 99.1 0 (select HAP) (select HAP) (select HAP) (select HAP) (select HAP) (select HAP) (select HAP) (select HAP) (select HAP) (select HAP) VCM Storage Bullet - pressure vessel

Feedstock storage

If Other, please specify, being as descriptive as possible: Source Process Equipment ID (if applicable): Equipment Description: If not provided in the equipment description above, describe the tank, vessel, or container and indicate (if applicable) if the tank is a fixed, floating internal, or floating external roof.

Select the purpose of the equipment:

If Yes, How Are The Emissions Controlled? Displaced vapor during filling is routed to VCM recovery system.

**Concentration (ppmvd @ 3% O2)** How is the HAP Concentration Determined? Equipment is VCM storage - all material stored is HAP. Are HAP Emissions Controlled? Yes

**Individual HA P Present**  Source Equipment Type:

Number of turnovers: Equipment volume (m 3 ):

**Notes** Storage Temperature (°F)

Page 1 of 1 **DRAFT**PVC Section 114 Survey Part 2 06/23/2009**FORM L STARTUP, SHUTDOWN, AND MALFUNCTION** 

**Instructions**

1. Complete this form for 2013 only. 2. Submit with your response to this survey, copies of all records of emissions during periods of process startup, shutdown, and malfunctions for 2013 only. 3. Refer to "Enclosure 1" for additional instructions and details.

Yes

Startup Shutdown 32 24

For a malfunction:

Yes Yes

No No

40 CFR Part 61 Subpart F 40 CFR Part 61 Subpart F

Control equipment (thermal oxidizer and scrubber) is brought online before startup begins. Control equipment (thermal oxidizer and scrubber) is kept online until plant is completely shutdown.

Vinyl chloride (pounds) 0.02 0.02 Hydrochloric acid (pounds) 0.05 0.05 Methylene chloride (Dichloromethane) (pounds) 0.01 0.01 (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) (select HAP) (pounds) **Total Emissions During Startup, Shutdown, or Malfunction Event**  Were all of the emissions control devices operating for the entire duration of the startup, shutdown, or malfunction event? Startup, Shutdown or Malfunction?

If startup or shutdown, what was the duration (hours):

Provide a short description of the malfunction and the circumstances:

If No, which control devices were not operating (Control Equipment ID), for how long, and why:

Were permitted emissions limits exceeded?

Provide a description of the procedures used to alert the owner/operator that the malfunction occurred. If the malfunction resulted in a release of emissions, describe any indicators used to signal and/or measure the release. Is there a written startup, shutdown and/or malfunction plan for the process unit?
Provide a description of the systems and equipment in place that function to notify operators that a malfunction **is occurring**

. Pressure monitors on reactors with high, high-high alarms. All PRDs are "backed" by rupture disks - vapor space between is monitored for pressure and alarms when > atmospheric detected. Thermal oxidizer bypass has a flow detector which alarms to operator whenever flow is detected in the bypass.

Applicable standard or regulation:

Describe what actions, if any, were taken to minimize emissions to the atmosphere:

Page 1 of 1 **DRAFT**PVC Section 114 Survey Part 1 06/23/2009**FORM P**

**PROCESS VENT EMISSIONS TESTING DA TA** 

**Instructions**
1. Copy this worksheet as necessary for pollutants/compounds sampled on different dates. 2. For multiple control devices, users may copy this worksheet within this workbook.

**Control Equipment ID:** Indicate whether the inlet to the control device is from the PVC process only ("dedicated") or from the PVC process and another process unit (non-PVC) ("combined"):

**Parameter**

Test Date (mm/dd/y

y) **Required Operating Parameters During Test** Total Heat Input (MMBtu/hr) Fuel 1 Feed Rate HHV Fuel 2 Feed Rate HHV Fuel 3 Feed Rate HHV Flow Rate Temperature Moisture O2 CO2 Number of PVC resin grades being produced during sampling Number of PVC resin grades being produced (as percentage of all resin grades produced by facility) **Testing Data** Compound Benzene Chloroethane Chloroform Chloroprene 1,1-Dichloroethane 1,2-Dichloroethane n-Hexane Methylene chloride Toluene 1,1,1-Trichloroethane 1,1,2-TrichloroethaneVinylidene chloride

Acetophenone Bis(2-ethylhexyl) phthalate (DEHP) 1,4-Dichlorobenzene 2,4-Dinitrophenol Hexachlorobutadiene Hydroquinone Naphthalene Phenol 1,2,4-Trichlorobenzene Acetaldehyde 1,3-Butadiene Chlorobenzene Chloromethane Cumene Ethylbenzene Ethylene glycol Formaldehyde Methanol 1,1,2,2-Tetrachloroethane 2,2,4-Trimethylpentane Vinyl acetate Vinyl bromide Xylenes (isomers and mixtures) Vinyl chloride Methane (CH4)C-2

Combined

**CA S Number**  **Run #1 Run #2**  **Run #3 Units** 
Enter the CAS number for each pollutant/compound. Do not include dashes. Select appropriate unit from list.

4/1/2014 4/1/2014 4/1/2014

19.6 17.1 15.9 MMBTU/hr Natural Gas Natural Gas Natural Gas

19.6 17.1 15.9 MMBTU/hr 337 337 337 BTU/scf

MMBTU/hr BTU/scf

MMBTU/hr BTU/scf 8790.1 8867.3 8930.8 dscfm 451 447 457 deg F 15.1 14.9 14.5 % 6.7 5.9 7.05 % 8.7 8.9 8.7 % 1 1 1 20 20 20 %

CAS Number 71432 0.02 0.02 0.02 ppm vd @ 3% O2 75003 0.005 0.005 0.005 ppm vd @ 3% O2 67663 0.05502 0.00429 0.55921 ppm vd @ 3% O2 126998 0.47091 0.84152 0.48407 ppm vd @ 3% O2 75343 0.34632 0.22430 0.63035 ppm vd @ 3% O2 107062 0.23618 0.10824 0.31487 ppm vd @ 3% O2 110543 0.61394 0.00318 0.04897 ppm vd @ 3% O2 75092 0.28723 0.77804 0.74157 ppm vd @ 3% O2 108883 0.08046 0.05573 0.30012 ppm vd @ 3% O2 71556 0.16892 0.95882 0.95167 ppm vd @ 3% O2 79005 0.32749 0.35141 0.42412 ppm vd @ 3% O2 Enter numerical value only.

Enter numerical value only

.75354 0.31693 0.34155 0.02419 ppm vd @ 3% O2

98862 0.46181 0.89753 0.21937 ppm vd @ 3% O2 117817 0.73100 0.84955 0.84679 ppm vd @ 3% O2 106467 0.76541 0.38040 0.60674 ppm vd @ 3% O2 51285 0.02045 0.12233 0.15984 ppm vd @ 3% O2 87683 0.44470 0.85413 0.92067 ppm vd @ 3% O2 123319 0.03777 0.56408 0.40106 ppm vd @ 3% O2 91203 0.78022 0.00196 0.80266 ppm vd @ 3% O2 108952 0.26708 0.18864 0.19807 ppm vd @ 3% O2 120821 0.40474 0.39410 0.81911 ppm vd @ 3% O2 75070 0.95814 0.35858 0.46405 ppm vd @ 3% O2 106990 0.09809 0.74534 0.87695 ppm vd @ 3% O2 108907 0.09093 0.29692 0.92321 ppm vd @ 3% O2 74873 0.56775 0.35855 0.13606 ppm vd @ 3% O2 98828 0.67384 0.28638 0.23619 ppm vd @ 3% O2 100414 0.23047 0.93697 0.09574 ppm vd @ 3% O2 107211 0.65432 0.42177 0.24037 ppm vd @ 3% O2 50000 0.89907 0.94252 0.35415 ppm vd @ 3% O2 67561 0.16015 0.99542 0.78944 ppm vd @ 3% O2 79345 0.18766 0.64299 0.27044 ppm vd @ 3% O2 540841 0.94718 0.64250 0.78853 ppm vd @ 3% O2 108054 0.59784 0.89953 0.09221 ppm vd @ 3% O2 593602 0.36167 0.72758 0.28526 ppm vd @ 3% O2 1330207 0.98577 0.41794 0.58376 ppm vd @ 3% O2 75014 0.03283 0.84356 0.75999 ppbvd @ 3% O2 74828 1.22400 0.99840 1.11340 ppm vd @ 3% O2**Run # 1 Detection Run # 2 Detection**  **Run # 3 Detection**

Identify the status of measured values relative to the detection

levels Identify the status of measured

values relative to the detection

levels Identify the status of measured

values relative to the detection

levels

BDL BDL DLL BDL BDL BDL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADLADL ADL ADL

ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL ADL**An alysis M**  **ethod Used Note(s)** 

Wh ere applicable, select the analysis method

used. For all pollutants/compounds, provide any other information supporting information you think is necessary about this test report.

SW-846 Method 8260B Reporting average concentration; runs #1 and #2 are BDL. SW-846 Method 8260B All 3 runs are BDL. SW-846 Method 8260B SW-846 Method 8260B SW-846 Method 8260B SW-846 Method 8260B SW-846 Method 8260B SW-846 Method 8260B SW-846 Method 8260B SW-846 Method 8260B SW-846 Method 8260BSW-846 Method 8260B

SW-846 Method 8270D SW-846 Method 8270D SW-846 Method 8270D SW-846 Method 8270D SW-846 Method 8270D SW-846 Method 8270D SW-846 Method 8270D SW-846 Method 8270D SW-846 Method 8270D US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18 US EPA Method 18**FORM Q**

**TOTA L HYDROCA** **RBON 30-DA Y MONITORING** 

**Instructions**
1. For multiple control devices, users may copy this worksheet within this workbook. 2. Add additional rows as necessary to provide 30 days of monitoring data.

**Control Equipment ID:**

**Date and Time THC Reading**  **CH4 Reading O2 level in exhaust gas** 

MM/DD/YYYY HH:MM (ppmvd as propane @ 3% O2) (ppmvd @ 3% O2) (% by volume, dry)

04/01/2014 15:00 27.4 1.56 8 04/01/2014 15:15 30.2 1.24 10 04/01/2014 15:30 40.5 1.33 5 04/01/2014 15:45 20.6 1.78 6 04/01/2014 16:00 20.3 1.15 8 04/01/2014 16:15 28.9 1.14 9 04/01/2014 16:30 35.1 1.67 10 04/01/2014 16:45 30.2 1.63 8 04/01/2014 17:00 32.7 1.64 6 04/01/2014 17:15 25.4 1.27 5 04/01/2014 17:30 29.4 1.23 10 Indicate whether the inlet to the control device is from the PVC process only ("dedicated") or from the PVC process and another process unit (non-PVC) ("combined"):C-2

Combined

**Moisture in exhaust gas**  **PVC Type PVC Grade**  **Control Device Temperature** 

(% by volume) (e.g., suspension, dispersion/emulsion, bulk, etc.) (e.g., GP, HMW , LMW , etc.) (degF)

17 Suspension HMW 469 18 Suspension HMW 473 12 Suspension HMW 461 16 Suspension HMW 494 13 Suspension HMW 455 10 Suspension HMW 480 11 Suspension HMW 452 13 Suspension HMW 450 20 Suspension HMW 459 13 Suspension HMW 470 17 Suspension HMW 488**Control Device**

**Operations Indicator THC Monitoring**  **Operations Indicator** (note periods of start-up, Shutdown, malfunctions, or normal operation) (note periods of abnormal operations)
Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal Normal