# OAR Box 1168 Prepped by Ollie Stewart



# Document

Number: 

# 68 ) lll-B- 3 Docket Number: 

# A-89-1 0

Printed 4/29/2008 11:23:18 AM Sheet 68 of 131 p. 1

## P. 2

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# CORPORATIO N

MEMORANDU

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# A-89-1 0 II-B- 3 

# FE B |/ f 09 1 TO : Bo bAjax , EPA/SD B j FROM : E dMoretti , Radian/RT P j EP A AI RDOCKE T j DATE : Octobe r 12 , 198 9 SUBJECT : Qualitativ e Analysi s o f Equipmen t Desig nSpecification s an dWor k Practice s fo r Butadiene , Ethylen e Oxide , an dPhosgen e Facilitie s

Th e purpos e o f thi s memorandu m i s t o summariz e th e result s o f a qualitativ e analysi s o f th e equipmen t desig nspecification s an dwor k practice s fo r butadien e (BD) , ethylen e oxid e (EO) , an dphosgen e facilities . Fro m Figur e 1 , th e B Dan dEO facilitie s havin g th e highes t an dlowes t lea kfrequencie s fo r ga s valve s wer e identified . On e EO an dthre e BD facilitie s wer e groupe da s high-leakin g facilitie s an don e B Dan

dthre e E O facilitie s wer e groupe da s low-leakin g facilities . Thre e phosgen e facilitie s als o wer e selecte dfo r compariso nt o th e B Dan dE O facilities . Th e followin g equipmen t desig nspecification s an dwor kpractice s wer e analyzed : • ga s valv e bod

y material ; • ga s valv e packin g materia l an dshape ; • ga s valv e manufacturer ; • ga s valv e type ; • ga s valv e age ; • ga s valv e maintenanc e frequency ; • plan t are a monitorin g systems ; • non-specifi c equipmen t monitorin g (e.g. , plan t walkthrough s wit ha portabl e organic s detector , visua l inspection s o f equipment) ; • component-specifi c lea kdetectio nan drepair ; • exten t o f on-lin e repair ; • recours e fo r unsuccessfu l on-lin e repair ; • miscellaneou s equipmen t desig nspecification s an demissio nreductio n strategies ; • minimizatio no f leak s a s a facto r i nplan t construction ; t lea ktestin g o f pre-installe dequipment ; • QA/Q C step s fo r reducin g leak s durin g plan t construction ; an d • equipmen t change s mad e t o reduc e equipmen t leaks . Progres s Center/320 0 E
. Chape l Hil l Rd./Nelso n Hwy./P.O
. Bo x13000/Researc h Triangl e Park , N.C
. 27709/(919)541-910 0



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# Thes e parameter s wer e requeste db y th e EPA ina lette r sen t t o BD , EO , an d phosgen e producers . Tabl e 1 provide s a qualitativ e analysi s o f th e ga s valv e informatio n liste dabove . Few

difference s ca nb e observe damon g th e facilities . Preliminar y

observatio no f th e informatio nyield s th e following : o mos t low-lea kan

dphosgen e facilitie s appea r t o us e highe r percentage s o f stainles s stee l ga s valve s tha nhigh-lea kfacilities ; an d o low-lea kan

dphosgen e facilitie s appea r t o us e highe r percentage s o f plu g ga s valve s tha nhigh-lea kfacilities . I nth e phosgen e facilities , plu g valve s accoun t fo r mor e tha nhal f o f al l ga s valv e types . Tabl e 2 summarize s th e remainin g wor kpractice s andequipmen t desig n specification s informatio nliste dabove . Thes e parameter s encompas s al l equipmen t types , no t ga s valve s only . Again , few difference s ca nbe observe damon g th e plants . Preliminar y observatio no f th e informatio n yield s th e following : o low-lea kfacilitie s appea r t o b e slightl y mor e conscientiou s in thei r non-specifi c equipmen t monitoring . Two low-lea kfacilitie s perform periodi c plan t walkthrough s wit ha portabl e organic s detecto r (one high-lea kfacilit y als o perform s thi s activity) , an d visua l inspection s appea r t o b e slightl y mor e frequen t a t low-lea k andphosgen e facilities ; o E Ofacilitie s tendt o shu t dow nleakin gequipmen t immediately afte r a nunsuccessfu l on-lin e repai r attempt , whil e B Dfacilitie s d o no t remov e th e equipmen t fro m servic e bu t includ e th e leakin gequipmen t ona shutdow

nwor klist ; an

d o low-lea kandphosgen e facilitie s provide dmor e thoughtfu l response s t o th e question s regarding : 1) . QA/Q C step s fo r reducin gleak s durin g plan t constructio nan d2 ) equipmen t change s t o reduc e equipmen t leaks . Low-lea kan dphosgen e facilitie s appea r mor e conscientiou s abou t reducin g equipmen t lea kemission s b y providin g operato r trainin gonprope r operatio npractice s andb y experimentin g wit hdifferen t equipmen t design s andconstructio nmaterials .

# Tabl e 1
. QUALITATIVE ANALYSI S OF F0LLO--U . 11 4 LETTE R

Ga s Valve s

Bod yllateria l

Packin g llateria l an d Shap e

Manufacture r

Valv e Typ

e



### Ag e

Maintenanc e Frequenc

y BD-1 0

20 1 S S 80 1 C S

33 1 eac h Asbestos , Graphite , an d Teflo n

1 4 diff . oaouf .

98 1 6at e 2 1 Contro l

11-1 5 y r

Oirected A s neede d Hig h B D BD-l l
20 1 S S 80 1 C S

100 1 Asbesto s 100 1 Square

Majorit ySaith , Henr yVogt

30 1 Gat e 60 1 61ob

e 5 1 Bal l S I Contro l

90 1 16-2 0 y r 10 1 > 2 0 y r

Oirected A s needed 60-1 2

20 1 S S 80 1 C S

U l Teflo n 88 1 Graphite Asbesto s 1 1 Plasti c

1 8 diff . aanuf . Majorit yVogt , Sait h

64 1 Gat e 5 1 Globe 20 1 Bal l 11 1 Contro l

12 1 11-1 5 y r 88 1 > 2 0 y r

Directed A s needed Hig h E 0

. EO- 9
30 1 S S 70 1 C S

100 1 teflo n 100 1 Square

90 1 Slith-Vog t 10 1 Assorte d

80 1 Gat e 10 1 Bal l 10 1 Contro l

40 1 6-1 0 y r 60 1 16-2 0 y r

Directed A s needed Lou B D BD- 7
2 1 S S 98 1 C S

95 1 Asbestos 5 1 Asbestos

/ Graphit e

1 5 diff . unuf .

97 1 Gat e 3 1 Bal l

10 1 0- 5 y r 17 1 6-1 0 y r. 73 1 16-2 0 y r
Directed A s neede d ED- 1

100 1 S S

87 1 Graphit e 7 1 Teflo n 6 1 Unknou n

17 1 Saith , 13 1 Ladish , U l Kit. , 10 1 Bonney , 9 other s
76 1 Gate , 7 1 Needle , 4 1 Plug , 2 1 Check , 2 1 Ball , 8 1 Contro l

14 X0- 5 y r 6 1 6-1 0 y r 80 1 16-2 0 y r
Oirected A s neede d LO R E 0 EB-2
57 1 S S 43 1 C S

56 1 Teflo n 44 1 Graphit e 54 1 Square 34 1 O-Rin g
Unknow n

50 1 Sat e 28 1 Bal l 17 1 Needl e 4 1 Glob e

61 1 0- 5 y r 4 1 6-1 0 y r 34 1 11-1 5 **r
Oirected Buarterl y EO- 4
2 1 S S 98 1 Forge d Stee l

100 1 Teflo n

20 1 eac h Vogt , Saith , Crane , Poeell , Nalaort h

100 1 Gate

100 1 11-1 5 y r

Directed A s neede d Phosgen e

P- 3
9 1 S S 91 1 C S

84 1 Teflo n 16 1 TF E 87 1 Vee 13 1 Brai d
44 1 Tuflin e U I Jaae-bur y 10 1 Durc o 1 0 othe rlanuf . 52 1 Plug , 20 1 Bal l U I Bate , B l Needl e 4 1 BellOHS , 2 1 6lob e 1 1 Contro l

16 1 0- 5 y r 10 1 11-1 5 y r 74 1 16-2 0 y r
Unknon n Phosgene P- 5
40 1 S S 60 1 C S

100 1 Teflo n 100 1 Squar

e

Ourco , Hill s NcCanna , Tuflin e

80 1 Plu g 15 1 Bal l 5 1 Contro l

100 1 < 5 y r

Annuall y Phosgen e P-1 0
92 1 S S B I Forge d Stee l

100 1 Teflo n

62 1 Ourc o 8 1 Vog t 30 1 tlnknou n

62 1 Plu g 8 1 Gat e 30 1 Angl e

Uoknoa n

Unknon n

# Tabl e 2
. QUALITATIV E ANALYSIS O F FOLLON-U P 11 4 LETTER Ga s Valve s

Are a Monitorin g Syste a Non-specifi c Equipaen t Monitorin g

Component

specifi c LDA

R

Exten t a l on-lin e repai r

Recourse fo r unsuccessfu l on-lin e repai r BD-1 0

8 0 Ga s detector s a t 8 0 location s throughou t plan t Taic e dail y visua l inspectio n o foperatin g equipaen t Weekl yvisua l inspectio n of puaps
6 V - Monitore d once pe rqtr . pe r stat e re g L V - Monitore d once pe ry rpe r stat e re g Puaps - Monthl y TL V aonitorin g Coapooents unde r B z NESHA P ar e aonitore d pe r tha t re g Valve s - Tighte n packin g bolt s Flange s - Tighte n flang e bolt s

Reaov e equipaen t fro a service , i f possible ; i fnot , add t o shutdoa n aor k lis t Hig h B D BD- U B O Ba s detector s a t 8 0 location s throughou t plan t Dail yvisua l inspectio n o f coaponent s

Coaponents unde r B i NESHA

P ar e aonitore d pe r tha t re g

Valve s - Tighte n packin g bolts ; injec t sealan t Flange s - Tighte n flang e bolt s
Includ e on a shutdoa n aor k 

### lis t BD-1 2 8 0 Ga s detector s a t B O location s throughou t plan t Taic a dail y visua l inspectio n ofcoaponents

Coaponent

s unde r B z NESHA P ar e aonitore d pe r tha t re g

Valve s - Tighte n packin g bolt s

Includ e on a shutdoa n aor k lis t Hig h E O £0- 9

Visua l inspectio n ofal l puaps severa l tiae s pe rshif t Nalkthroug h ait h portabl e detecto r onc e pe rshif t
6 V >10 1 E

O - Monitore d once pe rqtr . pe r stat e re g L V >10 I E

O - Monitore d once pe ryr . pe r stat e re g

Flange s - Tighte n flang e bolt s

Uni t o rpar t o f uni t i s shu t doan ieaediatel y an d equipaen t i s repaire d Loa B D BD- 7 45 Ga s detector s a t 45 location s throughou t plan t Visua l inspectio n o fcoaponent s taic e pe rshif t

Coaponents unde r B z NESHA P ar e aonitore d pe r tha t re g

Valve s - Tighte n packin g

Reaov e equipaen t fro a servic e pe r standard safet y procedures ; repaire d by traine d craftsae n EO- 1 37 6a s detector s a t 37 location s throughou t plan t Dail yaalkthroug h ait h IM u t o ensur e aabien t reading s < 5 0 ppa

v G C fo rcontinuou s aonitorin g o f contro l roo a an d analyze rbuildin g Valve s - Monitore d eonthly/quarterl y ait h TL V Puap s - Monitore d aeekl yait h TL

V

Consultan t retaine d t o claa p leakin g equip , t o sto p lea k unti l shutdoa n

Reaov e equipaen t fro a servic e t o repai rlea k Loa E0 EO-2 6a s detector s throughou t plan t Meekl yvisua l inspectio n o f puaps

Valves , Puaps - Monitore d quarterl yb

y contracto r Periodi c aonitorin g of flange s b

y operatin g cre a

Puaps - Saitc h t o spar e

Shu t doa n affecte d portion s o fplan t an d repai rlea k Phosg e E0- 1 P- 3

Halkthroug h ait h TL V once pe rshif t



# •

Valve s - Tighte n packin g bolt s Flange s - Tighte n flang e gaske t Puaps - Saitc h t o spar e Plan t i s shu t doa n i fsever e leak s cannot b

e repaire d e Phosgen e P- 5 Phosgen e P-1 0

Visual , olfactor y inspectio n of plan t once ever yta o hour s Phosgen e badges aor n b yal l eaployee s

Flange s - Tighte n flang e bolt s Puaps an d Agitator s - Adjus t seal s

Uni t i s shu t doa n coapletely , leakin g coaponen t i s evacuated ; aashed , dried , the n repaire d

•a le n

# Tabl e 2 (Continued)
. QUALITATIVE ANALYSIS O F FOLLON-U P 11 4 LETTE R (continued l Ga s Valve s 

# _____=__=_!____

_
Equipaen t desig n specification s (o reaissio n reductio n and aiscellaneou s eaissio n reductio n strategie s 

# ==__=________==_==

_ BD-1 0 None give n 

# _=______;___________- _ Hig h B D BD- U None give n __-=_=________._________s________ = : Hig h E O BD-1 2 E0- 9 None give n Puaps -.Dua l

seal s ait h barrie rfluid ; pressur e alar a i n contro l roo a i f inne rsea l leak s Valve s - Al l ar e disasseable d prio rt o installatio n t o verif yvalv e ste a packin g an d t o ensur e tba t a 

# -_____==_==____=_ _ Loa B D BD- 7 Us e ofcoapaoy approve d specs . fo rconstructio n aethod s an d aaterial s Us e o fskille d craftsae n fo r repair s Operato rtrainin g t o detec t an d reac t t o leak s ne a gaske t aeetin g Puaps - Tandra specification s i s installe d Flanges/Conn . - Gasket s hav

e aelde d tab s t o verif yuse o

f prope rgasket ; flange s ar e torque d ait h torqu e arench ; Open-ended Lines Al l ar e plugge d prio rt o placin g i n servic e Relie fValve s - Reaove d fro a uni t seal s ait h

pressur e alaras ; eaission s reliev e t o flar e syste a Relie fValve s - . Reliev e t o flar e syste a Closed-loo p saaplin g systea s

an d teste d annually ; rescreene d afte r releas e t o ensure prope rreseatin g Compressor

s - Nitroge n buffe r t o preven t ataospheri c leakage ; al l ar e overhaule d every fiv e year s ___-=--___3=__---
_ EO- 1 Puaps - Ga

s aonitor s o n seals ; currentl y installin g sealles s puap s Valve s - Tighte n packin g i fscreenin g value s excee d 30 0 ppa ; Grafoi l ribbo n packin g i n al l valve s Flange s - Stainles s steel , Grafoil-fille d gasket s ait h inne ran d oute rring s Open-ende d Lines Doubl e valve s 

# =__=____=__=___=_ _ Loa E O EO- 2 Compressor

s - Barrie rga

s Ta o aechanic s accoapany contracto r durin g screenin g and fi * leak s ieaediately , i fpossibl e ___==_______=__z____= :
E0- 4 Open-ende d Lines Caps o rplug s require d Flange s - Teflon-filled , spiral-mun d gasket s Valve s - Teflo n valv e packing s an d Teflo n valv e bonnet gasket s =S_______=__3=_
_ Phosgen e P- 3 

# ________

________ _ Phosgen e P- 5 

# __=____-=_________=

_ Phosgen e P-1 0 Puaps - Dua l aechanica l seal s ait h pressur e indicator s o n th e inne rsea l Relie fValve s - Sock s place d ove r relie fstac k

t o indicat e i fi t ha s bloa n Agitato rSeal s - Dua l aechanica l seal s ait h barrie rflui d

T J ^ 1

# Tabl e 2 (Continued )
DUALITATIV E ANALYSI

S O F FOUON-U P 11 4 LETTER Ga s Valve s

Miniaizatio n o f. leak s a (acto r i n plan t design? . Leak testin g befor e installation ?

OA/P C step s lo r reducin g leak s durin g plan t constructio n

Equipaen t change s t o •educ e equipaen t leak s BD-1 0 

### N o

Al l coaponent s

None give n

None give n Hig h B D BD-I I 

### N o

Al l coaponent s

Non e give n

Non e give n BD-1 2



### Ye s

Al l coaponent s

None give n

Non e give n Hig h E O EO-9 

### Ye s

Al l coaponent s

Hiniaiz e (lange s

None give n Lo a B D BD- 7 

### Ye s

Al l coaponents

Neld s are : I-raye d an d dye-checked . Hydrostati c testin g Ultrasoni c testin g

Miniaizatio n of fitting s - aor e aelde d connection s Metal , spiral - •oun d gasket s fo rflange s Send relie fvalv e discharge s t o flar e syste a EO- 1 

### Ye s

Al l coaponent s nitroge n pressur e teste d folloae d b ysoa p bubbl e testin g Visua l inspectio n o faor k Spot I-ray s o f aeld s Spot hydrostati c testin g o

fequi p

Replace d ta o puaps ait h sealles s puap s ait h goo

d result s Reduc e nuabe r o fflange s aher e possibl e Reaov e unnecessary blee d valve s Loa E O EO-2 

### Ye s

Al l coaponent s

Neld s ar e I-raye d Al l equip , an d pipin g i s lea k teste d ait h iner t ga s o r hydrostaticall y teste d

Outsid e boltin g service s t o tighte n critical , larg e flange s Screae d connection s ar e backaelde d EO- 4 

### Ye s

Al l coaponents

'Lea k reductio n ove rth e past 10-1 5 year s ha

s bee n drive n b

y OSH A regulation s an d are a aonitoring ' Phosgen e P- 3



# ' Phosgen e P- 5 Phosgen e P-1 0 

### Ye s

Al l coaponents

Trainin g o

f aaintenanc e an d constructio n personne l t o use prope r installatio n procedure s Hydrostati c . testin g o

fal l pipin g systea s Replace d glas s pip e ait h Teflon-line d stee l pip e Installe d Teflon-line d valves , gaskets , puaps Revise d pipin g syste a t o reduc e nuabe rofflange s Installe d dua l aechanica l seal s o n puap s Increase d operato r knoaledg e throug h trainin g on prope roperatio n practice s

0 0