P.1 

OAR Box 1107 

Prepped by Ollie Stewart 

Document Number: 

48) IV-E-4 

Docket Number: 

A-81-21 

Printed 4/11/2008 3:03:47 PM Sheet 48 of 90 
P.2 

RADIAN

 A " §J4~ 2 I 

CORPORATION i v i. t 

MEMORANDUM 

DATE: January 15, 1985 

TO: Leslie B. Evans, Chemicals and Petroleum Branch 

FROM: Karen K. Fidler, Radian Corporation 

SUBJECT: Meeting Report - Incinerator Bypass Discussion with Borden 

Chemical Representatives 

I. PURPOSE 

Representatives of Borden Chemical provided information on incinerator 

operations and incinerator bypass occurrences associated with their ethylene 

dichloride/vinyl chloride (EDC/VC) and polyvinyl chloride (PVC) production 

facilities. This information will be used to study the need for a control 

device bypass provision for the VC standard. The purpose of the meeting was 

to gain familiarity with both EDC/VC and PVC process incineration system 

design and operations. 

II. PLACE AND DATE 

U.S. Environmental Protection Agency 

North Carolina Mutual Building 

Durham, North Carolina 

January 3, 1985 

III. ATTENDEES 

Fred Dimmick, EPA/OAQPS/ESED/SDB 

Les Evans, EPA/OAQPS/ESED/CPB 

Bob Rosensteel, EPA/OAQPS/ESED/CPB 

Susan Wyatt, EPA/OAQPS/ESED/CPB 

Karen Fidler, Radian Corporation 

Jeff Shumaker, Radian Corporation 

Bailey Barton, Director, Environmental Affairs, Borden Chemical 

Chris Lunn, Technical Manager, Geismar Plant, Borden Chemicl 

IV. DISCUSSION 

Prior to the meeting, EPA provided the Borden representative with a 

list of information needs to serve as the basis for the meeting discussion 

(see letter from Evans, L. to Barton, B., December 5, 1984, Docket No. ). 

Borden's response to each of the discussion items is summarized below. The 

meeting discussion focused primarily on Borden's Geismar, Louisiana facility 

where both EDC/VC and PVC are produced. Incinerator operations at the 

Illiopolis, Illinois PVC facility also were discussed briefly. 

Progress Center/3200 E. Chapel Hill Rd./Nelson Hwy./P.O. Box 13000/Research Triangle Park, N.C. 27709/(919)541-9100 
P.3 

1 

Borden operated the following production units at their Geismar 

facility: 

- VCM-A unit produces VC monomer from acetylene 

- VCM-E unit produces VC monomer from ethylene via an air-based Stauffer 

process 

- PVC unit produces suspension PVC resin from VC in six large reactors 

Incinerator System Design and Operation 

Three incineration systems are currently operated at the Borden/Geismar 

facility. In 1976, two Trane-Thermal incinerators were installed to meet VC 

regulations. Of the two, the "primary" incineration system is equipped with 

a waste heat boiler and HCl scrubber and is designed to burn vent gases 

only. The "secondary" incinerator is vented directly to the HCl scrubber 

without a waste heat boiler. The secondary incinerator was originally 

designed to burn liquid waste along with vent gases, but since addition of a 

third incienrator system, it now serves only as a backup to the primary 

system. The third incineration system, manufactured by Rhone-Poulenc, was 

added in 1982. This so-called "VCR" incineration system includes a waste 

heat boiler and acid recovery system and is used to recover HCl from heavy 

chlorinated liquid wastes and vent gases. 

Design and operating parameters for the three incinerators include the 

following: 

- Design heat input rate (vent gas and natural gas combined 

Primary - 48 x IO6 Btu/hr 

Secondary - 28 x 10 Btu/hr 

VCR - proprietary, but similar to primary 

- Temperature 

Operating (all incinerators) - 2100°F 

Standby (secondary) - 2100°F 

- Steam production 

Primary - 40,000 lb/hr @ 200 psi 

Secondary - none 

VCR - 20,000 lb/hr @ 330 psi 
P.4 

Natural gas input 

Primary - 2100 scfm 

Secondary 

operating - 12,000 scfh 

standby - <12,000 scfh 

VCR - relatively small amount 

Liquid wastes and a portion of the vent gases (excluding the oxyvent) 

are burned in the VCR incinerator when it is operable. A pressure control 

valve on the VCR incinerator inlet controls the amount of vent gases that 

can be burned in the VCR system. The oxychlorination vent and any remaining 

vent gases are burned in the primary incinerator. When the "VCR" incinerator 

is not operable, all of the vent gases including the oxychlorination vent 

are burned in the primary incineration system. The secondary incinerator is 

used only when the primary system is down for repair or maintenance. The 

primary system is preferentially used because of its steam generation 

capabilities. 

The primary and secondary incinerators are each capable of burning all 

of the vent gases (including the oxyvent) generated under normal process 

operating conditions. Under such conditions, the secondary incinerator 

would be operating at virtually full load while the primary incinerator 

would have about 50 percent excess capacity. When operating alone, the VCR 

incinerator can handle all of the vent gases with the exception of the 

oxyvent stream. When both the VCR and either the primary or secondary 

incinerator is operated, as is usually the case, excess capacity is 

available to handle some vent gas surges. However, in the past, oxyvent 

surges caused by unreacted ethylene vented from the oxychlorination reactor 

and surges in other headers caused by VC liquid in the lines have exceeded 

the capacity of the simultaneously operating VCR and primary incinerators. 

Incinerator temperature is the primary control parameter for each of 

the three incineration systems. High temperature signals trigger first a 

demand for more excess air. If this is not successful in dropping the 

temperature, the gas rate falls off. If less gas does not lower the temperature sufficiently, a high temperature trip will occur. The primary and 

secondary incinerators are capable of operating at 50 percent of their 

design heat input rate. 

Although the secondary incinerator is considered a standby incinerator 

(i.e., to be used only in the event the primary incinerator is down), it is 

currently maintained at minimum operating temperature (2100°F) when not in 

use. Prior to summer of 1984, Borden maintained the secondary incinerator 

at 1200°F standby temperature but recently raised the standby temperature in 

an effort to minimize incinerator bypass durations. 

Attachment A is a flow diagram of the three incineration systems and 

the vent headers feeding them. 
P.5 

Staged alarms provide operating personnel preliminary notice of process 

conditions that may lead to an incinerator bypass. With early warning, 

operators may be able to correct the process conditions and avoid a bypass. 

In other situations, early notice of process irregularities may allow the 

operators to selectively bypass the oxyvent to avoid an incinerator trip and 

subsequent bypassing of all gases. In addition, Borden's procedures require 

communications among operators prior to any loading or equipment purging or 

other venting operations. This reduces the possibility of incinerator 

bypasses from surges during these operations. Finally, flow meters are 

being installed in the vent header lines to allow operators to better 

predict and handle vent gas surges to the incinerators. Pressure sequencing 

of all three incinerators to automatically divide vent gases optimally among 

the incinerators was considered and rejected for economic reasons. 

Incinerator Malfunctions 

Malfunctions of the incinerator and associated equipment also 

contribute to the listed bypass incidents. For example, the incinerator 

tripped on occasions when the quench water flow was lost due to pump or 

valve failure. Switching vents from the primary to the secondary 

incinerator for maintenance and repair resulted in a relatively high number 

of bypasses. 

"First-out" indicators have been installed to indicate the initial 

cause of incinerator trips. This information is valuable in minimizing 

bypass durations. Also, the Borden/Geismar facility last summer reassigned 

one operator to perform the incinerator operations. An additional area 

supervisor overseeing incinerator operations was also assigned at this time. 

This was done primarily to reduce the frequency and duration of incinerator 

malfunctions and bypasses. 

Method for Estimating VC Emissions During Bypasses 

Borden estimates the amount of VC emitted to the atmosphere during 

incinerator bypasses based on the duration of the bypass and the 

representative concentration of VC in the bypassed streams. Samples are 

periodically taken under various operating conditions to establish the 

representative concentrations used to be used in the calculation. Borden 

reports the estimates bypassed VC emissions quarterly as required by the 

State of Louisiana. 

VC Monitoring 

VC is monitored in the HCl scrubber stack following the "VCR" 

incinerator and in the HCl scrubber stack following the primary and 

secondary incinerators. VC is not monitored in the emergency HCl scrubber 

stack. 
P.6 

Incinerator Bypasses 

A separate vent header transports VC-containing exhaust gases from each 

of the VCM-A, VCM-E and PVC production units to the incineration area. In 

addition, the oxychlorination reactor vent generated in the VCM-E unit is 

ducted in a fourth header to the incineration area. Each header is equipped 

with a control valve, which can divert the vent gases around the incinerators 

through an emergency HCl scrubber to the atmosphere. The control valves are 

activated automatically whenever the incinerator(s) trips. The control 

valves also may be opened to selectively vent one or more vent headers to 

the emergency scrubber when conditions in the vent stream are likely to trip 

the incinerator (i.e., streams are fuel-rich, fuel-lean, etc.). 

A total of 268 incinerator bypasses were reported by the Borden/Geismar 

facility during the period March through November 1984. All of the bypass 

occurrences during that period except one were less than 1 hour in duration. 

A breakdown of the causes of the 268 bypasses is as follows: 

Cause Percent 

Quench water flow s 11.2 

Liquid in vent 6.0 

High temperature trip 8.9 

Flame sensor trip 11.9 

Boiler level 8.9 

Switching incinerators 21.7 

Low temperature trip 5.2 

Oxychlorination reactor startup 1.5 

Low combustion air 1.9 

Vent flows 5.2 

Other 10.5 

Unknown 7.1 

Process Upsets 

Process upsets likely are responsible for many of the listed causes to 

which incinerator bypasses have been attributed. Bypasses due to the 

presence of liquid in the vent stream, high or low vent flows and problems 

during startup of the oxychlorination reactor are examples of incidents 

caused by process upsets. Further, in some cases, high and low temperature 

trips may be related to process upsets as when venting a column to the VCM-E 

utility line results in a fuel-rich stream to the incinerator and a 

resultant high temperature trip or when an oxyvent surge causes a low 

temperature trip due to a high level of inerts. In the past, high 

temperature trips have occurred when chlorine feed to the oxychlorination 

reactor was lost with the result that large amounts of unreacted ethylene 

were vented to the incinerator. Similarly, flame sensor trips may be the 

result of vent gas surges which may alter the flame pattern. 
P.7 

Impact of Oxychlorination Vent 

The oxychlorination reactor at the Borden/Geismar facility uses an 

air-based process to make VC monomer, and the vent steam containing >120 ppm 

VC must be incinerated to comply with the VC standard. (Although switching 

to an oxygen-based process has been considered, this modification has been 

rejected for economic reasons.) The oxyvent makes up 94 percent by volume 

of the total vent gases incinerated. However, the VC content of the oxyvent 

is only 2.5 percent by weight of the VC contained in all incinerated vent 

gases. Because of the relatively large volume and low VC content of the 

oxyvent, Borden reports that operation of their incinerators would be more 

stable if the oxyvent were not incinerated along with the other vent gases. 

At present, Borden is planning to modify their process (i.e., use different 

catalyst) to reduce VC in the oxyvent to about 50 ppm so that it need not be 

incinerated. Borden believes this will significantly reduce the frequency 

of incinerator bypasses. 

VC Emissions During Startup/Shutdown 

The oxychlorination reactor is vented to the atmosphere for approximately 

5 to 10 minutes during startup/shutdown. Because very little, if any, VC is 

vented during the startup/shutdown period, Borden does not include these 

periods when reporting incinerator bypasses. 

The startup/shutdown procedure for the rest of the plant normally does 

not result in increased incinerator bypass frequency. "Crash" shutdowns 

typically result in bypasses only when refrigeration is lost. 

Incinerator Bypass History 

Information on incinerator bypasses at the Borden/Geismar facility 

during the period March through November 1984 are summarized below. 

Mar-May Jun-Aug Sept-Nov 

Total lb of VC bypassed 

Number of bypasses 

Avg. amount of VC bypass 

Total bypass min. 

Percent bypass time 

Average minutes/bypass 

Further details on 10 ppm exceedences and incinerator bypasses during 

the period March through November 1984 are found in three quarterly reports 

submitted to the State of Louisiana. These reports are included as 

Attachment B. 

5,140 

86 

59.8 

1,408 

1.06 

16.4 

4,136 

101 

41 

968 

0.73 

9.6 

2,428 

81 

30 

676 

0.52 

8.3 
P.8 

Borden/Illiopolis PVC Plant 

Borden currently operates a 1.2 x 10 Btu/hr Trane-Thermal incinerator 

to burn VC-containing vents at their Illiopolis PVC facility. A backup 

incinerator is also available. Borden reports a 95 percent on-stream 

capability for the incineration system at the Illiopolis plant. Because of 

the low vent flow, the vent gases generated can be contained in an existing 

gasholder vessel during periods when the incineration system is down. 
P.9 

Attachment A 

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P.10 

Attachment B 

BORDEN CHEMICAL 

DIVISION OF BORDEN INC BORDtNl 

June 14, 1984 

CERTIFIED MAIL P 404 221 272 

Return Receipt Requested 

Mr. William H. Davis 

Chief, NESHAP Unit 

Department of Environmental Quality 

P. 0. Box 44066 

Baton Rouge, Louisiana 70804 

Dear Mr. Davis: 

In accordance with Louisiana Air Quality Regulations, Section 77.11, Borden 

herewith submits its quarterly report for the quarter ending May 31, 1984. 

Should you have any questions concerning this report, please contact 

David T. McLemore or me. 

Sincerely, 

BORDEN CHEMICAL 

DIVISION OF BORDEN, INC. 

W. P. 

Compl 

jonard 

II Manager 

WPL:ft 

cc: 0. A. Sandberg 

J. C. Lunn 

M,JlL-Bi«**ea, 

•"CUTT . McLemore^ 

L. L. Bird 

W. B. Barton 

H. A. Rosenzweig 

Director, Enforcement Division 

EPA, Region VI 

1201 Elm Street 

Dallas, Texas 75270 

POST OFFICE BOX 427 • GEISMAR. LOUISIANA • TELEPHONES: (504) 673-6121 (504) 367-5101 
P.11 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

DATE 

TIME 

START CAUSE 

3-04-84 

3-04084 

3-12-84 

3-17-84 

3-19-84 

3-21084 

3-21-84 

3-22-84 

2230 

2330 

0030 

0130 

0230 

1335 

1525 

1625 

1725 

1800 

1200 

0535 

0635 

2055 

2155 

2255 

2355 

0055 

0155 

0330 

0430 

0530 

0630 

0730 

Occurred while burning VCM-A waste liquid. The temperature of 

the incinerator was increased and the emissions were reduced. 

Ditto 

Ditto 

Ditto 

Ditto 

Occurred while washing the light ends column. 

Ditto 

Ditto 

Ditto 

Occurred while clearing the quench line to the absorber sump. 

Primary incinerator tripped due to flame sensor problem 

Occurred while clearing the unit for a turnaround. 

Ditto 

Occurred during unit start-up after turnaround. 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 
P.12 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

DATE 

TIME 

START CAUSE 

3-22-84 

3-23-84 

3-24-84 

3-25-84 

3-27-84 

4-02-84 

0830 

0930 

1030 

1130 

1800 

1900 

2000 

2100 

2200 

0415 

2240 

0600 

0700 

0800 

0900 

1000 

1100 

1200 

0500 

1950 

2050 

2150 

2250 

2350 

Occurred during unit start-up after turnaround. 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Primary incinerator tripped due to high temperature. 

Primary incinerator tripped due to flame sensor problem. 

Occurred while washing out caustic dryers to change caustic 

charge. 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Primary incinerator tripped due to low boiler water level. 

Steam stripper down for maintenance. 

Ditto 

Ditto 

Ditto 

Ditto 
P.13 

DATE 

4-03-84 

4-03-84 

4-04-84 

4-06-84 

4-18-84 

4-20-84 

4-21-84 

5-02-84 

5-05-84 

TIME 

START 

0050 

0150 

0250 

0350 

0450 

1520 

0945 

1045 

1145 

1343 

1443 

1130 

1250 

1500 

0630 

0810 

1030 

1445 

1630 

2145 

1045 

1200 

1010 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

CAUSE 

Steam stripper down for maintenance. 

Ditto 

Ditto 

Ditto 

Ditto 

Unknown 

Primary incinerator tripped two times due to vent flow valve 

malfunction. 

Ditto 

Ditto 

Primary incinerator tripped due to low quench water flow and 

due to low boiler water level. 

Ditto 

Primary incinerator tripped due to low boiler water level. 

Ditto 

Ditto 

Primary incinerator tripped due to flame sensor problem. 

Ditto 

Primary incinerator tripped due to low boiler water level 

Primary incinerator tripped due to low flow to quench 

Primary incinerator tripped due to flame sensor problem. 

Ditto 

Primary incinerator tripped, cause unknown. 

Secondary incinerator tripped due to low temperature. 

Occurred due to a high vent rate. 
P.14 

DATE 

TIME 

START 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

CAUSE 

5-06-84 

5-09-84 

5-11-84 

5-12-84 

5-13-84 

5-14-84 

5-15-84 

5-16-84 

5-17-84 

1115 

1215 

1500 

1800 

0900 

1500 

1935 

2045 

1500 

1020 

1115 

1215 

1440 

1540 

1640 

1740 

1840 

1035 

1445 

1545 

0834 

0934 

1505 

1605 

1015 

Primary incinerator tripped due to high temperature. 

Primary incinerator tripped due to variation in vent flow. 

Occurred while acidizing the incinerator vent scrubber to 

reduce the dp. 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Clearing lines. 

Vents tripped out of the incinerator due to an electrical 

problem in the panel board. 

Ditto 

Primary incinerator down. Experienced difficulty keeping all 

vents in the secondary incinerator due to an electrical 

problem with the flame sensor. 

Ditto 

Ditto 

Ditto 

Occurred during problems with liquid carryover into the vent 

header. 

Ditto 

Ditto 

Secondary incinerator low temperature. 

Ditto 

Secondary incinerator, low temperature. 

Ditto 

Secondary incinerator tripped due to flame sensor problem. 

Ditto 
P.15 

5-27-84 

0335 

0500 

0625 

1250 

0735 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

DATE 

5-18-84 

5-19-84 

5-20-84 

5-23-84 

5-26-84 

TIME 

START 

0320 

1335 

0450 

0550 

0650 

0835 

0320 

0420 

0710 

1015 

1150 

1605 

1705 

1805 

1625 

0235 

CAUSE 

Secondary incinerator tripped due to flame sensor problem 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Secondary'incinerator, low temperature. 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Low air to secondary incinerator, air flow was increased. 

Primary incinerator tripped due to low quench water flow. 

Steam stripper down for maintenance. 

Ditto 

Ditto 

Ditto 

Primary incinerator tripped due to low quench water flow. 

Primary incinerator tripped, cause unknown. 
P.16 

LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

DATE 

TIME 

START END CAUSE 

LBS. VCM 

EMITTED 

3-20-84 

3-22-84 

3-23-84 

3-24-84 

3-26-84 

3-27-84 

4-04-84 

4-06-84 

4-09-84 

4-10-84 

4-12-84 

4-17-84 

4-18-84 

1550 

2040 

0400 

0411 

0430 

1325 

2230 

0500 

0500 

0940 

1210 

1335 

1405 

1450 

0505 

1945 

2010 

0655 

2335 

0150 

1005 

1140 

1645 

1555 

2105 

0405 

0425 

0435 

1335 

2300 

0530 

0540 

1000 

1235 

1350 

1420 

1505 

0515 

1955 

2020 

0700 

2345 

0205 

1015 

1150 

1650 

Low water flow to quench column 

High level in knock-out drum 

High temperature 

High temperature 

High temperature 

Liquid in vent line 

Flame sensor problem 

Control valve on boiler water level malfunction 

Low boiler water level 

Vent flow valve malfunction 

Vent flow valve malfunction 

Incinerator tripped while changing source of 

quench water flow 

Low boiler water level 

Low boiler water level 

High temperature 

Flame sensor problem 

Flame sensor problem 

Unknown 

Unknown 

Low boiler water level 

Low boiler water level 

Boiler water level controller 

Switched vents to secondary - shutdown primary 

to change out boiler water level controller 

30 

150 

30 

84 

30 

60 

180 

180 

240 

120 

150 

90 

90 

90 

60 

60 

60 

30 

60 

90 

60 

60 

30 
P.17 

DATE 

4-20-84 

4-21-84 

4-24-84 

4-29-84 

S-02-84 

5-05-84 

5-06-84 

5-09-84 

5-13-84 

LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

TIME 

START 

0635 

1025 

1435 

1630 

1045 

1120 

1707 

2030 

1845 

1010 

1020 

1033 

1143 

1500 

1500 

1500 

0950 

1015 

1455 

1510 

END 

0725 

1045 

1510 

1645 

1105 

1210 

1716 

2040 

1910 

1015 

1023 

1037 

1150 

1505 

1510 

1510 

1045 

1045 

1510 

1545 

CAUSE 

Flame sensor problem 

Low boiler water level 

Low water flow to quench column 

-Flame sensor problem 

Unknown 

Unknown 

Flame sensor problem 

Low boiler water level 

Boiler water level transmitter 

Switching vents from primary to secondary 

High temperature on secondary. Switched back 

to primary. 

Switching vents from primary to secondary 

Low temperature 

Switched vents from secondary to primary 

High temperature (Oxy vent only) 

High temperature 

Oxy vent only - Oxy unit start-up 

Variation in vent flow 

Blown fuse in panel board - all vents except 

Oxy and PVC put to VCR at 1510 

Primary incinerator back on at 1545. All vents 

put back to primary 

LBS. VCM 

EMITTED 

300 

120 

210 

90 

120 

300 

54 

60 

150 

30 

18 

24 

42 

30 

1.5 

60 

8 

180 

90 

11.9 
P.18 

LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

TIME 

DATE START 

5-14-84 

5-15-84 

5-16-84 

5-17-84 

5-18-84 

0145 

0840 

0930 

1330 

0900 

0920 

1015 

1120 

1420 

1800 

1930 

1940 

1955 

0000 

0315 

0740 

1142 

1202 

1335 

END 

0200 

0915 

1010 

1345 

0905 

0930 

1100 

1140 

1430 

1810 

1935 

1945 

2000 

0005 

0325 

0800 

1153 

1220 

1350 

CAUSE 

High temperature (Oxy vent only) 

Blown fuse in panel board. All vents except 

Oxy and PVC switched to VCR. 

Blown fuse in panel board. All vents except 

Oxy and PVC switched to VCR 

Excess vent flow. All vents except Oxy and 

PVC switched to VCR. 

High temperature - (Oxy vent only) - Oxy unit 

shutdown at 0905 

Oxy unit start-up (Oxy vent only) 

Liquid in vent line - (Oxy vent only) 

Liquid in vent line - (Oxy vent only) 

Low temperature (Oxy vent only) 

Low temperature (Oxy vent only) 

Flame sensor problem - (Oxy vent only) 

Flame sensor problem - (Oxy vent only) 

Flame sensor problem - (Oxy vent only) 

Flame sensor problem - (Oxy vent only) 

Flame sensor problem - (Oxy vent only) 

Low temperature 

Low temperature - (Oxy vent only) 

Low temperature - (Oxy vent only) 

Flame sensor problem - (Oxy vent only) 

NOTE: Primary Incinerator down for 

repairs 5-14-84 thru 5-20-84. 

LBS. VCM 

EMITTED 

2.2 

11.9 

13.5 

5.1 

0.75 

1.5 

6.7 

1.5 

1.5 

1.5 

0.75 

0.75 

0.75 

0.75 

1.5 

120 

1.6 

2.7 

2.2 
P.19 

TIME 

DATE START 

5-19-84 

5-20-84 

5-21-84 

5-23-84 

5-25-84 

5-26-84 

0450 

0515 

0530 

0730 

0825 

0315 

0335 

0420 

0706 

0730 

0905 

1420 

END 

5-27-84 

2204 

0735 

0500 

0525 

0610 

0740 

0855 

0320 

0345 

0440 

0730 

0745 

0910 

1430 

1545 

1700 

0830 

1025 

1620 

0725 

0435 

0525 

0612 

1220 

1550 

1705 

0840 

1035 

1630 

0740 

0515 

0535 

0625 

1225 

2214 

0810 

LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

CAUSE 

Flame sensor problem - (Oxy vent only) 

Flame sensor problem - (Oxy vent only) 

Excess vent flow 

Flame sensor problem 

Flame sensor problem 

Low temperature - (Oxy vent only) 

Low temperature - (Oxy vent only) 

Low temperature - (Oxy vent only) 

Low temperature and flame sensor (Oxy vent only) 

Low temperature and flame sensor (Oxy vent only) 

Low temperature 

Switching vents from primary to secondary to 

repair low level boiler trip on primary. 

Low temperature 

Switching vents from secondary to primary 

Low boiler water level 

Low boiler water level 

Low quench water flow 

Low boiler water level 

Low quench water flow 

Low boiler water level 

Low boiler water level 

Shutdown primary incinerator to repair boiler 

water level trip. Switched vents to secondary. 

Power failure on control panel 

Unknown 

LBS. VCM 

EMITTED 

1.5 

1.5 

25.5 

3.8 

19.2 

0.75 

1.5 

1.5 

3.5 

2.2 

4.2 

8.4 

4.2 

4.2 

60 

60 

60 

90 

240 

60 

78 

30 

60 

210 
P.20 

BORDEN CHEMICAL 

DIVISION OF BORDEN INC BORDEN] 

September 14, 1984 

CERTIFIED MAIL 

Return Receipt Requested 

Mr. William H. Davis 

Chief, NESHAP Unit 

Department of Environmental Quality 

P. 0. Box 44066 

Baton Rouge, Louisiana 70804 

Dear Mr. Davis: 

In accordance with Louisiana Air Quality Regulations, Section 77.11, 

Borden herewith submits its quarterly report for the quarter ending 

August 31, 1984. 

Should you have any questions concerning this report, please contact 

David T. McLemore or me. 

W. P. Leonard 

Complex II Manager 

WPL:dl 

cc: 0. A. Sandberg 

J. C. Lunn 

Mj, W. Dietzel 

JQ. T. McLemore 

L. L. Bird 

W. B. Barton 

H. A. Rosenzweig 

Director, Enforcement Division 

EPA, Region VI 

1201 Elm Street 

Dallas, Texas 75270 

POST OFFICE BOX 427 • GEISMAR, LOUISIANA • TELEPHONES: (504) 673-6121 (504) 387-5101 
P.21 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

DATE 

6-2-84 

6-7-84 

6-24-84 

6-26-84 

6-28-84 

6-30-84 

7-2-84 

7-4-84 

* 

TIME 

START 

1800 

0240 

2030 

0935 

1035 

1135 

1635 

1735 

1835 

1935 

2035 

2135 

1420 

1630 

0940 

1040 

1320 

0000 

0100 

0200 

0300 

0400 

0500 

0600 

CAUSE 

Primary incinerator tripped due to low boiler water level. 

Occurred while burning waste liquid in the secondary incinerator. 

Primary incinerator tripped due to excess venting. 

VCM in absorber water 

Ditto 

Ditto 

Primary incinerator tripped due to excess venting. 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

VCM in absorber water 

Primary incinerator tripped due to high temperature. 

Primary incinerator tripped due to low quench water flow. 

Ditto 

Primary incinerator tripped due to low combustion air. 

Heavy vent load on incinerator. 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 
P.22 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

DATE 

7-5-84 

7-6-84 

7-7-84 

7-8-84 

•• 

* 

7-9-84 

TIME 

START 

2300 

0255 

0435 

0535 

1105 

1205 

1305 

0330 

0845 

0945 

1045 

1145 

1245 

1345 

1445 

1545 

1645 

1745 

1845 

2035 

2200 

2300 

0000 

0100 

CAUSE 

Primary incinerator tripped due to low quench water flow. 

Occurred while burning waste liquids in the secondary incinerator. 

Primary and secondary incinerators tripped due to low quench 

water flow. 

Ditto 

Ditto 

Ditto 

Ditto 

Low temperature on the incinerator. 

Plant start-up 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Plant tripped out due to problems with refrigeration machine. 

Plant start-up 

Ditto 

Ditto 

Ditto 
P.23 

DATE 

TIME 

START 

7-9-84 

7-11-84 

7-12-84 

7-14-84 

7-17-84 

7-25-84 

0200 

0300 

0400 

0500 

0600 

0700 

0800 

1745 

1845 

1945 

2045 

1150 

2230 

2330 

0030 

0935 

1045 

0045 

0145 

0245 

0345 

0550 

0400 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

CAUSE 

Plant start-up 

Ditto 

Ditto 

Ditto 

Ditto 

» 

Ditto 

Ditto 

Primary incinerator tripped due to low quench water flow. 

Ditto 

Ditto 

Ditto 

Occurred while burning VCM-A waste liquid in the secondary 

incinerator. 

Ditto 

Ditto 

Ditto 

Low temperature on the incinerator. 

Ditto 

Excess venting 

Ditto 

Ditto 

Ditto 

Primary incinerator tripped due to a power dip. 

plant shut down, clearing for turnaround. 
P.24 

DATE 

7-25-84 

TIME 

START 

7-26-84 

0840 

0940 

1040 

1140 

1240 

1340 

1440 

1540 

1640 

1740 

1840 

1940 

2040 

0630 

0730 

0830 

0930 

1030 

1130 

1230 

1330 

1430 

1530 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

CAUSE 

Plant shut down, clearing for turnaround. 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 
P.25 

\ 

niTp 

UAl L. 

7-26-84 

7-27-84 

• 

7-28-84 

* 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

TIME 

START 

1630 

0020 

0800 

1000 

1100 

1200 

1300 

1400 

1500 

1600 

1700 

1800 

1900 

2000 

2100 

2200 

2300 

0000 

0100 

0200 

0300 

0400 

0500 

FOR EMISSION CONTROL DEVICE VENT 

CAUSE 

Plant shut down, clearing for turnaround 

• 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Plant start-up 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 
P.26 

DATE 

TIME 

START 

7-28-84 

7-29-84 

7-30-84 

0600 

0700 

0800 

0900 

1000 

1430 

1530 

1630 

1730 

1830 

1930 

2130 

2330 

0000 

0100 

0200 

0900 

1000 

1330 

1645 

OOOO 

LESHAP SECTION 77.11 c(i) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

CAUSE 

Plant start-up 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 
P.27 

8-6-84 

8-8-84 

8-13-84 

8-14-84 

1200 

2215 

0100 

0200 

0300 

0400 

0500 

0600 

1645 

2020 

2120 

2220 

2320 

0020 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

DATE 

7-31-84 

8-1-84 

8-5-84 

TIME 

START 

1315 

1415 

1515 

1625 

1735 

1835 

1000 

1100 

CAUSE 

Primary incinerator tripped due to excess venting. 

Ditto 

Ditto 

Primary incinerator tripped due to excess venting. 

Ditto 

Ditto 

Had to take utility vent out of incinerator to repair leak. 

Ditto 

Ditto 

Primary incinerator tripped due to low level in absorber pond. 

Low combustion air flow. 

Ditto 

Ditto 

Ditto 

Ditto 

Primary incinerator tripped due to excess venting. 

Clearing HCl column for maintenance repair 

Ditto 

Ditto 

Ditto 

Ditto 
P.28 

DATE 

TIME 

START 

8-16-84 

8-17-84 

2020 

2120 

2220 

2320 

0020 

0120 

0220 

0320 

0420 

0520 

0620 

0720 

0820 

0920 

1020 

1120 

1220 

1320 

1420 

1520 

1620 

1720 

1820 

1920 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

CAUSE 

Primary incinerator tripped due to high temperature. 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Primary incinerator tripped due to flame sensor problem. 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Primary incinerator tripped due to excess venting. 

Ditto 

Ditto 

Ditto 

Ditto 

V 
P.29 

DATE 

8-17-84 

TIME 

START 

8-23-84 

8-26-84 

8-27-84 

8-29-84 

2020 

2120 

2220 

2320 

0030 

0900 

0730 

1205 

LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

CAUSE 

Primary incinerator tripped due to excess venting. 

Ditto 

Ditto 

Ditto 

Excess venting, clearing equipment for maintenance. 

Primary incinerator tripped due to low boiler water level, 

Primary incinerator tripped due to low boiler water level, 

All incinerators tritroed due to a total nlant power din. 
LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

DATE 

6-2-84 

6-2-84 

6-26-84 

6-26-84 

6-27-84 

6-27-84 

6-28-84 

6-30-84 

6-30-84 

6-30-84 

7-2-84 

7-2-84 

7-2-84 

7-3-84 

7-5-84 

7-6-84 

7-7-84 

7-7-84 

7-7-84 

7-9-84 

7-9-84 

7-9-84 

TIME 

START 

1800 

2330 

1325 

1625 

0930 

1110 

1615 

1120 

1305 

1745 

0750 

1300 

1320 

1050 

2245 

0427 

0835 

1345 

1640 

0850 

0900 

0910 

END 

1805 

2335 

1340 

1715 

0950 

1130 

1625 

1125 

1312 

1800 

0800 

1310 

1330 

1055 

2309 

0438 

0930 

1400 

1650 

0855 

0905 

0915 

CAUSE 

Faulty thermocouple indicated high temperature 

Switched vents back to pri. inc. after thermocouple replaced 

Air line to ethylene FCV was crimped by 

insulator tripping oxy (oxy only) 

High temperature 

High temperature 

Low boiler water level 

High temperature 

Unknown 

Unknown 

Low quench water flow 

Low quench water flow 

Low combystion air 

Low combustion air 

Low quench water flow 

Low quench water flow 

Low quench water flow 

Lost quench feed water 

Lost quench feed water 

Lost quench feed water 

Low quench water flow 

Low quench water flow (oxy only) 

Unknown 

LBS. VCM 

EMITTED 

30 

30 

2.2 

300 

120 

120 

60 

30 

42 

90 

60 

60 

60 

30 

138 

66 

330 

90 

60 

30 

0.75 

30 
P.31 

DATE 

7-9-84 

7-9-84 

7-10-84 

7-10-84 

7-14-84 

7-16-84 

7-17-84 

7-23-84 

7-23-84 

TIME 

START 

1730 

1910 

0820 

1350 

0200 

0505 

0550 

1010 

1118 

END 

1800 

1930 

0825 

1355 

0205 

0545 

0600 

1020 

1136 

7-23-84 

7-25-84 

7-27-84 

7-27-84 

7-29-84 

7-29-84 

7-29-84 

7-29-84 

7-29-84 

7-29-84* 

7-30-84 

7-31-84 

8-1-84 

8-S-84 

1300 

0954 

0900 

1955 

0840 

0850 

0930 

0940 

1630 

1645 

0900 

1400 

1615 

0810 

1320 

1045 

0905 

2050 

0842 

0852 

0932 

0942 

1632 

1648 

0915 

1405 

1625 

0830 

LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

CAUSE 

Plugged quench water flow transmitter 

(oxy only) 

Low quench water flow (oxy only) 

Unknown 

Low quench water flow 

Unknown (oxy vent only) 

Low quench water flow 

Power dip 

Took oxy vent out of incinerator to stabilize 

variable vent flow (oxy only) 

Supply air to natural gas valve failed 

(oxy only) 

Low temperature 

Low quench water flow 

Switched vents from sec. to pri. 

High temperature 

Flame sensor problem 

Switched vents back to pri. 

Flame sensor problem 

Switched vents back to pri. 

Flame failure 

Switched vents back to pri. 

Excess venting 

Excess venting 

Excess venting 

Took utility vent out of inc. to repair leak 

LBS. VCM 

EMITTED 

4.5 

3.0 

30 

30 

0.75 

240 

60 

1.5 

2.7 

120 

306 

30 

330 

12 

12 

12 

12 

12 

12 

90 

30 

60 

10 
P.32 

LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

DATE 

8-6-84 

8-6-84 

8-7-84 

8-7-84 

8-8-84 

8-8-84 

8-8-84 

8-8-84 

8-9-84 

8-9-84 

8-10-84 

8-10-84 

8-10-84 

8-10-84 

8-11-84 

8-11-84 

8-11-84 

8-11-84 

8-11-84 

8-11-84 

8-11-84 

TIME 

START 

2225 

2236 

0800 

1310 

1635 

1643 

1652 

1700 

1440 

1452 

0806 

0820 

0824 

0837 

0015 

0045 

0225 

0258 

0615 

0625 

0745 

END 

2235 

2245 

0810 

1320 

1637 

1645 

1654 

1702 

1442 

1454 

0808 

0821 

0825 

0838 

0017 

0047 

0227 

0300 

0618 

0627 

0747 

CAUSE 

Lost water level in absorber pond 

Flame failure 

Planned shutdown of pri. for maintenance 

Switched vents back to pri. after repairs 

Excess venting 

Switched vents back to pri. 

Thermocouple failure 

Switched vents back to pri. after thermocouple 

repairs. 

Excess venting 

Switched vents back to the pri. 

Unknown (partial bypass only) 

Switched vents back to the pri. (partial bypass 

only) 

High temperature (partial bypass only) 

Switched vents back to the pri. (partial bypass 

only) 

Low quench water flow (partial bypass only) 

Switched vents back to the pri. (partial 

byr>ass only) 

Low quench water flow (partial bypass only) 

Switched vents back to the pri. (partial bypass 

only) 

Low quench water flow (partial bypass only) 

Switched vents back to the pri. (partial 

bypass only) 

Unknown 

LBS. VCM 

EMITTED 

60 

54 

60 

60 

12 

12 

12 

12 

12 

12 

1.3 

0.65 

0.65 

0.65 

1.3 

1.3 

1.3 

1.3 

1.9 

1.3 

1.3 
. *•• -

P.33 

LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

DATE 

8-11-84 

8-11-84 

8-11-84 

8-11-84 

8-11-84 

8-12-84 

8-12-84 

8-13-84 

8-13-84 

8-16-84 

8-17-84 

8-17-84 

8-17-84 

• 8-18-84 

8-18-84 

8-19-84 

8-19-84 

» 

8-19-84 

8-19-84 

8-19-84 

TIME 

START 

0755 

1201 

1208 

2055 

2128 

0840 

1305 

1720 

1740 

1750 

0810 

0820 

1520 

2220 

2245 

0130 

0200 

1110 

1125 

1320 

END 

0757 

1204 

1210 

2110 

2130 

0855 

1308 

1724 

1744 

1752 

0815 

0825 

1525 

2222 

2247 

0133 

0201 

1113 

1148 

1322 

CAUSE 

Switched vents back to the pri. (partial 

bypass only) 

Unknown (partial bypass only) 

Switched vents back to the pri. (partial 

bypass only) 

Unknown (oxy vent only) 

Switched vents back to the pri. (partial 

bypass only) 

Low quench water flow (oxy vent only) 

High temperature (oxy vent only) 

Low boiler water level (partial bypass only) 

Switched vents back to pri. (partial bypass 

only) 

High temperature (utility vent only) 

Flame sensor problem (partial bypass only) 

Switched vents back to the pri. (partial 

bypass only) 

Excess venting 

Low boiler water level (utility vent only) 

Switched vents back to the pri. 

(partial bypass only) 

Flame sensor problem (partial bypass only) 

Switched vents back to the pri. 

(partial bypass only) 

Thermocouple failure 

Excess venting 

Switched vents to pri. 

LBS. VCM 

EMITTED 

1.3 

1.9 

1.3 

2.2 

1.3 

2.2 

0.45 

12 

12 

0.98 

15 

15 

30 

0.98 

6 

1.9 

0.65 

18 

138 

12 
P.34 

DATE 

8-19-84 

8-19-84 

8-19-84 

8-19-84 

8-19-84 

8-19-84 

8-19-84 

8-20-84 

8-23-84 

8-24-84 

8-26-84 

8-27-84 

8-27-84 

8-29-84 

8-29-84 

LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

TIME 

START 

1550 

1600 

2206 

2230 

2258 

2335 

2339 

0010 

0735 

0445 

0855 

0645 

0645 

0650 

0740 

0907 

1205 

END 

1552 

1602 

2208 

2231 

2300 

2336 

2340 

0011 

0737 

0446 

0925 

0730 

0650 

0730 

0800 

0912 

1220 

CAUSE 

Low boiler water level (partial bypass only) 

Switched vents back to pri. (partial bypass 

only) 

Flame sensor problem (partial bypass only) 

Switched vents back to pri. (partial bypass 

only) 

Flame sensor problem (partial bypass only) 

Switched vents back to pri. (partial bypass 

only) 

Flame sensor problem (partial bypass only) 

Switched vents back to pri. (partial bypass only' 

Planned shutdown for maintenance (partial 

bypass only) 

Switched vents back to pri. (partial bypass 

Low boiler water level (partial bypass only) 

Low boiler water level (one incident, two 

divisions) 

Total bypass 

Partial bypass only 

Low boiler water level (partial bypass only) 

Maintenance personnel knocked tubing from 

flame sensor (oxy vent only) 

Total plant power dip 

LBS. VCM 

BUTTED 

6 

6 

1.3 

0.65 

1.3 

0.65 

0.65 

0.65 

6 

0.65 

19.5 

30 

120 

60 

0.75 

90 
P.35 

BORDEN CHEMICAL 

DIVISION OF BORDEN INC BORDEN] 

December 13, 1984 

Mr. William H. Davis 

Chief, NESHAP Unit 

Department of Environmental Quality 

P. 0. Box 44066 

Baton Rouge, Louisiana 70804 

Dear Mr. Davis: 

In accordance with Louisiana Air Quality Regulations, Section 77.11, 

Borden herewith submits its quarterly report for the quarter ending 

November 30, 1984. 

Should you have any questions concerning this report, please contact 

David T. McLemore or me. 

17^PC^U? C 

eonard 

II Manager 

CERTIFIED MAIL P 404 220 621 

REGISTERED RECEIPT REQUESTED 

WPL:aly 

CC: 0. A. Sandberg 

J. C. Lunn 

M. W. Dietzel 

D. T. McLemore 

L. L. Bird 

W. B. Barton 

H. A. Rosenzweig 

Director, Enforcement Division 

EPA, Region VI 

1201 Elm Street 

Dallas, Texas 75270 

» " " «ee.r r onv 497 . RPISMAR I OUISIANA • TELEPHONES: (504) 67X12 1 (504) 367-5101 
LESHAP SECTION 77.11 c(l) 

EXCEEDANCE OF 10 PPM AVERAGE PER HOUR 

FOR EMISSION CONTROL DEVICE VENT 

DATE 

TIME 

START CAUSE 

9/16/84 

9/17/84 

9/18/84 

9/20/84 

10/25/84 

11/2/84 

11/9/84 

11/11/84 

11/12/84 

11/15/84 

11/17/84 

11/19/84 

1810 

1800 

1900 

2000 

0835 

0945 

1045 

1145 

1245 

1345 

1445 

1545 

1750 

1850 

1950 

0434 

0800 

2115 

0645 

2205 

1735 

1845 

0045 

1130 

0850 

0950 

1050 

1150 

1425 

1945 

1400 

Secondary incinerator tripped due to high temperature 

Secondary incinerator tripped due to low flow on quench water 

Ditto 

Ditto 

Secondary incinerator while an instrument man was adjusting 

an alarm setting 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Ditto 

Secondary incinerator tripped due to high temperature 

Ditto 

Ditto 

Ditto 

Secondary incinerator tripped due to flame sensor problems 

Ditto 

Primary and secondary incinerators tripped due to liquid in the 

vent header 

Heavy vent load on the incinerator 

Primary and secondary incinerators tripped due to liquid in the 

vent line 

Primary incinerator tripped due to a heavy vent load 

Primary incineartor tripped due to an overload on the blower 

Primary and secondary incinerators tripped due to liquid in 

the vent header 

Primary and secondary incinerators tripped due to liquid in 

the vent header 

Primary and secondary incinerators tripped due to liquid in 

the vent header 

Ditto 

Ditto 

Ditto 

Primary incinerator tripped while switching quench water pumps 

Primary and secondary incinerators tripped due to liquid in 

the vent header. 

Primary incinerator tripped due to blower trip-out. 
•v • ' * 

P.37 

A) f -ADATE 

9/5/84 

9/5/84 

9/10/84 

9/10/84 

9/11/84 

9/11/84 

9/16/84 

9/16/84 

9/16/84 

9/16/84 

9/16/84 

9/16/84 

9/17/84 

9/18/84 

9/18/84 

9/19/84 

9/20/84 

9/21/84 

9/24/84 

9/24/84 

9/28/84 

9/28/84 

10/1/84 

10/1/84 

10/1/84 

10/1/84 

10/1/84 

LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

TIME 

START 

2030 

2040 

1245 

1325 

0845 

0908 

1100 

1250 

1455 

1755 

1815 

1935 

1430 

0830 

1550 

0425 

0415 

1600 

1630 

2233 

0834 

0931 

1220 

END 

1245 

1414 

1625 

1958 

10/7/84 

10/7/84 

10/7/84 

10/25/84 

10/25/84 

10/25/84 

10/25/84 

0800 

0805 

0826 

2115 

2131 

2141 

2220 

0802 

0816 

0828 

2120 

2135 

2142 

2221 

2032 

2042 

1250 

1330 

0853 

0910 

1102 

1254 

1500 

1800 

1905 

1945 

1435 

0915 

1600 

0429 

0420 

1605 

1632 

2233 

0836 

0933 

1221 

1247 

1415 

1627 

1959 

CAUSE 

Low quench water flow (partial by-pass only) 6 

Switched vents back to pri. (partial by-pass only) 6 

Planned shutdown to replace thermocouple 

(partial by-pass only) 15 

Switched vents back to pri. 30 

Incinerator tripped on low air flow while 

instrument man was making instrument PM check 48 

Switched vents back to pri. 12 

Shutdown pri. for maintenance 12 

High temperature 24 

High temperature 30 

High temperature 30 

Low quench water flow (partial by-pass only) 150" 

Low quench water flow (partial by-pass only) 30 

Quench water pump tripped 30 

Incinerator tripped while an instrument man was 

adjusting alarm settings (partial by-pass only) 135 

High temperature (partial by-pass only) 30 

High temperature (partial by-pass only) 12 

Flame sensor problem (partial by-pass only) 15 

Shut down secondary for maintenance (partial 

by-pass only) 15 

Shut down primary for maintenance (partial by-pass 

only) 6 

Switched vents back to pri. (partial by-pass only) 6 

Flame sensor (partial by-pass only) 6 

Switched vents back to pri. (partial by-pass only) 6 

Switching vents to secondary incinerator, 

experienced flame failure on secondary, 

switched back to primary. Primary was being 

taken out of service for maintenance (partial 

by-pass only) 3 

Switched vents to secondary (partial by-pass only) 6 

Switched vents from secondary to primary 

(partial by-pass only) 3 

Flame failure, flame sensor problem (partial 

by-pass only) 6 

Switched vents from sec. to pri. (partial by-pass 

only) 3 

High temperature (partial by-pass only) 6 

High temperature (partial by-pass only) 33 

Switched vents from sec. to pri. (partial by-pass 

only) 6 

Liquid in the vent header 30 

UNKNOWN (partial by-pass only) 12 

UNKNOWN (partial by-pass only) 3 

Switched vents from sec. to pri. (partial by-pass 

only) 3 

LBS. VCM 

EMITTED 
LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

DATE 

10/29/84 

10/29/84 

10/31/84 

10/31/84 

10/31/84 

10/31/84 

10/31/84 

11/3/84 

11/8/84 

11/9/84 

11/9/84 

11/9/84 

11/9/84 

11/9/84 

11/11/84 

11/11/84 

11/11/84 

11/11/84 

11/11/84 

11/12/84 

11/12/84 

11/12/84 

11/13/84 

11/13/84 

11/13/84 

11/15/84 

11/15/84 

11/15/84 

11/15/84 

11/15/84 

11/17/84 

TIME 

START 

0730 

0910 

0300 

0900 

0905 

1115 

1120 

1445 

0010 

2200 

2203 

2211 

2229 

2356 

1730 

1745 

1830 

1842 

1943 

0035 

0050 

0100 

1007 

1024 

2340 

1040 

1048 

1052 

1735 

1755 

0845 

END 

0732 

0912 

0305 

0902 

0907 

1117 

1122 

1455 

0014 

2202 

2210 

2228 

2240 

2358 

1735 

1750 

1833 

1855 

1945 

0049 

0059 

0125 

1010 

1025 

0030 

1043 

1052 

1135 

1737 

1757 

0846 

CAUSE 

Shut down pri. for maint (partial by-pass only) 

Switched vents from sec. to pri. (partial by-pass 

only) 

NO incinerator outage - utility vent switched 

to vent tank to correct problem in utility 

vent header 

Switched vents from pri. to sec to check vent 

line for pluggage (partial by-pass) 

Switched vents from sec. to pri. (partial bypass only) 

Flame failure flame sensor problem (partial bypass only) 

Switched vents from sec to pri (partial by-pass 

only) 

NO incinerator outage - utility vent switched 

to vent tank because of high vent header 

pressure 

NO incinerator outage - utility vent switched 

to vent tank because of high vent header 

pressure 

Liquid in vent line 

Liquid in vent line 

Liquid in vent line 

Liquid in vent line 

Switched vents from sec. to pri. 

Heavy venting 

Switched vents from sec to pri 

Overload on pri inc. blower 

UNKNOWN 

Switched vents from sec. to pri 

Liquid in vent header 

Liquid in vent header 

Liquid in vent header 

Heavy venting - high temp 

Switched vents from sec to pri 

Oxy vent only - oxy start-up 

Flame sensor 

Heavy venting 

Partial by-pass only 

Low quench water flow (partial by-pass only) 

Switched vents from sec to pri (partial by-pass 

only) 

Unknown (partial by-pass only) 

LBS. VCM 

EMITTED 

6 

6 

2.5 

6 

6 

6 

6 

4.9 

2 

12 

42 

102 

66 

12 

30 

30 

18 

78 

12 

84 

54 

150 

18 

6 

7. 

18 

24 

129 

6 

6 

1.5 
P.39 

LESHAP SECTION 77.11 c(l) 

EMISSION CONTROL DEVICE BY-PASS 

DURATION LESS THAN ONE HOUR 

TIME 

DATE START END CAUSE 

LBS. VCM 

EMITTED 

11/17/84 

11/17/84 

11/17/84 

11/17/84 

11/17/84 

11/17/84 

11/17/84 

11/17/84 

11/17/84 

11/17/84 

11/17/84 

11/19/84 

11/19/84 

11/19/84 

11/27/84 

11/27/84 

0847 

0906 

0942 

1205 

1422 

1445 

1942 

1945 

2025 

2107 

0854 

1009 

1330 

1332 

0435 

0439 

0900 

0937 

1020 

1227 

1425 

1447 

1944 

2010 

2030 

2108 

0857 

1011 

1332 

1413 

0437 

0453 

Faulty thermocouple (partial by-pass only) 

Flame failure (partial by-pass only) 

Liquid in vent header (partial by-pass only) 

Oxy start-up - oxy vent only 

Tripped while switching quench water pumps 

(partial by-pass only) 

Switched vents from sec to pri (partial by-pass 

only) 

High temp, liquid in switching manifold 

High temp liquid in switching manifold 

High temp liquid in switching manifold 

Switched vents from sec to pri 

Unknown (partial by-pass only) 

Switched vents from sec to pri (partial by-pass 

only) 

Blower tripped 

Blower tripped (partial by-pass only) 

High temperature 

High temperature 

39 

93 

114 

3.2 

6 

12 

150 

30 

6 

9 

6 

12 

123 

12 

84