# FROM: Cindy Hancy, RTI International

TO: Jodi Howard, EPA/OAQPS

FOR: EPA Docket No. EPA-HQ-OAR-2010-0869

DATE: December 21, 2011

SUBJECT: Analysis of Emissions Reduction Techniques for Equipment Leaks

1. Purpose

This memorandum documents a general review a nd analysis of emissions reduction techniques

for equipment leaks. It reviews control alterna tives and estimates the costs and environmental

impacts for the alternatives identified.

2. Legislative Background

The Clean Air Act (CAA) requires the U.S. Envi ronmental Protection Agency (EPA) to review

promulgated standards periodically to ensure new source performance standards (NSPS) and

national emissions standards for hazardous ai r pollutants (NESHAP) reflect advances in

emissions reduction technology. Sp ecifically, Section 112(d)(6) of the Clean Air Act (CAA)

states that “[t]he Administrato r shall review, and revise as necessary (taking into account

developments in practices, processes, and cont rol technologies), emissi on standards promulgated

under this section no less often than every 8 years.” Sim ilarly, Section 111 (b)(1)(B) requires

EPA to review NSPS for a given source category every 8 years, a nd, if appropriate, revise such

standards. To facilitate these required reviews, EPA is evaluating key em ission sources that exist

across several source categories to provide a cons istent framework for regulating emissions from

these sources. This memorandum provides informati on that may be considered in the course of

conducting a technology review for equipment leak emissions from a specific source category in

the future.

3. Introduction

Equipment leak standards are designed to redu ce or eliminate emissions of volatile organic

compounds (VOCs), volatile haza rdous air pollutants (VHAPs), and organic hazardous air

pollutants (HAPs) from piping and equipment f ound in various manufacturing processes. Many

federal regulations have been written to minimi ze air emissions from equipment leaks. Currently,

most equipment leaks are defined within regul ations primarily on the basis of a detection

instrument that reads the airborne concentration of volatile organic carbons at a potential leak

point on a parts per million (ppm) ba sis or on the basis of visual observation of certain types of

equipment. Generally, if the leak exceeds the th reshold, or leak definition, of the applicable

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

2 regulation, repair of the leaki ng equipment is required. This memorandum considers methods to

reduce emissions from equipment leaks and analy zes the impacts associat ed with these methods

(EPA, 1998).

4. Description of Emission Releases

Emissions from equipment leaks occur in the fo rm of gases or liquids that escape to the

atmosphere through many types of connection points ( e.g. , flanges, threaded fittings) or through

the moving parts of valves, pumps, compressors, pr essure relief devices, and certain types of

process equipment (EPA, 1998).

Pumps

Pumps are used extensively in chemical manufac turing facilities for moving fluids. The most

widely used pump is the centrifugal pump. Othe r types of pumps include positive-displacement,

reciprocating and rotary acti on, and special canned-motor and diaphragm pumps. Chemicals

transferred by pumps can leak at the point of contact between the moving shaft and stationary

casing. To isolate the pump’s interior from th e atmosphere, all pumps, except the sealless type

(canned-motor and diaphragm), require a seal at the point where the shaf t penetrates the housing.

The most commonly used seals in these pumps are packed and mechanical. However, no seal

system is perfect, and many pumps are equipped with a closed-vent system.

Compressors

Centrifugal, reciprocating, and ro tary compressors are used in ch emical manufacturing facilities.

The centrifugal compressor uses a rotating elemen t or series of elements containing curved

blades to increase the pressu re of a gas by centrifugal for ce. Reciprocating and rotary

compressors increase pressure by confining the gas in a cavity and progr essively decreasing the

volume of the cavity. Reciprocating compressors usually use a piston a nd cylinder arrangement,

while rotary compressors use rotating elements such as lobed impellers or sliding vanes.

As with pumps, seals are required to prevent le akage from compressors. Rotary shaft seals for

compressors may be labyrinth, rest rictive carbon rings, mechanical c ontact, or liquid film. All of

these seals are leak restriction devices, but none of them completely eliminate leakage. To

respond to leakage, many compressors are equipped with ports in the se al area that evacuate

collected gases to a control device.

Pressure Relief Devices

Engineering codes require the use of pressure-rel ieving devices or systems in applications where

the process pressure may exceed the maximum allowable working pressure of the vessel. The

pressure relief valve is the most common type of pressure-relieving device used. Typically, relief

valves are spring-loaded and designed to open wh en the system pressure exceeds a set pressure,

allowing the release of vapors or liquids until the system pressu re is reduced to its normal

operating level. When the normal pressure is re-a ttained, the valve reseats and a seal is again

formed. The seal is a disc on a seat, and a leak through this seal is a potential source of fugitive

VOC and HAP emissions. The potential causes of leakage from relief valves are improper

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

3 reseating of the valve after a re lieving operation (which occurs when the system pressure comes

close to the set pressure of th e valve); and corrosion or degrad ation of the valve seat. Some

pressure relief devices can be vented to a closed vent system fo r emissions control.

Rupture discs also may be used to relieve pressu re in process units. Thes e discs are made of a

material that ruptures when a set pressure is exceeded, thus allowing the system to depressurize.

The advantage of a ruptured disc is that the disc seals tightly a nd does not allow any emissions to

escape from the system during normal operations. When the disc ruptures, however, the system

will depressurize until atmospheric conditions are obtained (and then remain open to the

atmosphere until the disk is replaced), unless the disc is used with a pressure relief valve.

Sampling Connections

Process unit operations are checked periodically by routine analys is of feedstocks and products.

To obtain representative samples for these analyses, sampling lines first must be purged. If the

flushed fluid is a liquid, it could be drained onto the ground or into a process drain where it

would evaporate and release emi ssions to the atmosphere. Gas streams could be purged directly

to the atmosphere. Closed-loop sampling systems c ontrol the purged process fluid by returning it

directly to the process line, co llecting and recycling the fluid, or transporting the fluid to a

control device.

Open-ended Lines

Some valves are installed in a system to functi on with downstream lines open to the atmosphere.

Open-ended lines, which are used mainly in intermittent service for sampling and venting,

include purge, drain, and sampling lines. Some open-ended lines are need ed to preserve product

purity. Normally, these are installed between multi -use product lines to prevent products from

collecting in cross-tie lines during valveseat leakag e. A faulty valve seat or incompletely closed

valve would result in leakage through the valv e, releasing emissions to the atmosphere. As

described in section 5, a cap, plug, blind flange, or secondary valv e is used at the end of the

open-ended line to prevent those emi ssions from reaching the atmosphere.

Process Valves

One of the most common types of equipment include d in an equipment leak detection and repair

program is the process valve. Commonly used ty pes are control, globe, gate, plug, ball, relief,

and check valves. All except the relief valve and check valve ar e activated through a valve stem,

which may have either a rota tional or linear motion, depending on the design. The valve stem

requires a seal to isolate the pr ocess fluid inside the valve from the atmosphere. The possibility

of a leak through this seal makes it a potential source of fugitive emissions. A check valve

typically is not a potential source of fugitive em issions because it has no stem or packing gland;

however, some check valves have a hinge that pe netrates the valve housi ng, which is a potential

source of fugitive emissions.

The stem can be sealed to prevent leakage by usi ng a packing gland or O-ring seals. Valves that

require the stem to move in and out with or without rotation must use a packing gland.

Conventional packing glands are suited for a wide variety of packing material. Packing materials

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

4 include graphite, graphite-impregnated fibers, and tetrafluorethylene polymer. The packing

material used depends on the valve applicati on and configuration. Thes e conventional packing

glands can be used over a range of operating te mperatures, but at high pressures, these glands

must be tight to obtain a good seal.

Elastomeric O-rings also are used for seali ng process valves. These O-rings provide good

sealing, but are not suitable if sliding motion occurs through th e packing gland. These seals are

used rarely in high pressure service, and opera ting temperatures are limited by the seal material.

Bellows seals are generally thought to be more effective for prev enting process fluid leaks than

the conventional packing gland or other gland-seal arrangement. This type of seal incorporates

formed metal bellows that makes a barrier be tween the disc and body bonne t joint. The bellows

are the weak point of th is type of system, and service life can be quite variable. Consequently,

this type of seal normally is backed up with a conventional packing gland and often is fitted with

a leak detector in case of failure.

A diaphragm may be used to isolate the working parts of the valve and the environment from the

process liquid. The diaphragm also may be used to control the flow of the process fluid. In this

design, a compressor pushes the diaphragm toward the valve bottom, throttling the flow. The

diaphragm and compressor are connected in a ma nner so that separating them is impossible

under normal working conditions. When the diaphrag m reaches the valve bottom, it seats firmly

against the bottom, forming a leak-proof seal. This configuration is recommended for fluids

containing solid particles and for medium-pressure service. Depending on the diaphragm

material, this type of valve can be used at te mperatures up to 205°C and in severe acid solutions.

If the seal fails, however, a valve using a di aphragm seal can become a source of leaks.

Flanges and Other Connectors

Flanges are bolted, gasket-sealed junctions us ed wherever pipes or other components or

equipment (such as vessels, pumps, valves, a nd heat exchangers) may require isolation or

removal. Connectors are all other nonwelded fittings that serve a similar purpose to flanges,

which also allow bends in pipes (elbows), joining two pi pes (couplings), or jo ining three or four

pipes (tees or crosses). Connectors typically are threaded.

Flanges may become fugitive emissions sources when leakage occurs because of improperly

chosen gaskets or poorly assembled flanges. Th e primary cause of flange leakage is thermal

stress, which causes deformation of the seal be tween the flange faces. Threaded connectors may

leak if the threads become damaged or corroded or if tightened without sufficient lubrication or

torque (EPA Office of Compliance Chemical, Commercial Services, and Municipal Division,

1998).

Agitators

Agitators are used to stir or blend chemicals. Like pumps and compressors, agitators may leak

organic chemicals at the point where the shaft penetrates the casing. C onsequently, seals are

required to minimize fugitive emissions. Four seal arrangements commonly are used with

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

5 agitators: compression pack ing (packed seal), mech anical seals, hydraulic seals, and lip seals.

Packed seals for agitators are very similar in de sign and application to packed seals for pumps.

Although mechanical seals are more co stly than the other three types of seals, they offer a greatly

reduced leakage rate to offset their higher co st. Furthermore, the maintenance frequency of

mechanical seals is one-half to one-fourth that of packed seals. At pr essures greater than 1,140

kPa (150 psig), the leakage rate and maintenance fr equency are so superior that the use of packed

seals on agitators is rare. As with packed seals, the mechanical seals for agitators are similar in

design and application to the mechanical seals for pumps.

Instrumentation Systems

Instrumentation systems consist of smaller pipes and tubing that carry samples of process fluids

to be analyzed to determine process operating conditions or to systems for measurement of

process operating conditions ( e.g. , composition, pressure, flow, etc. ). Valves and connectors are

the predominant type of equipment used in in strumentation systems; however, other types of

equipment may also be included in these systems. These components are ge nerally the source of

leaks from instrumentation systems as well as fl uid that is vented or discharged from the

analyzer or bypass lines.

Closed-Vent Systems

A closed-vent system can be used to collect and convey gaseous emissions from seal oil

degassing vents, pump and compressor seal leakag e, relief valve leakage, and relief valve

discharges because of over-pressure operation. A process or portion of a process also can be

enclosed, and the enclosure can be vented through a closed vent system. A closed-vent system

consists of piping; equipment su ch as connectors, open-ended lines , and valves; flame arrestors,

and, if necessary, flow-inducing devices. Closed-vent systems are designed and operated to

convey emissions to a control device. However, just like in process lines, equipment in a closed

vent system is a potential sour ce of emissions due to leaks.

5. Identification of Control Options for Equipment Leaks

There are two primary techniques for reducing equipment leak emissions: (1) modifying or

replacing existing equipment, and (2) implem enting a leak detection and repair (LDAR)

program. Modifying or replacing existing eq uipment is referred to as an “equipment

modification.” Controlling emissions by equipment modification is achieved by either installing

additional equipment that eliminates or reduces emissions, or replacing existing equipment with

sealless types. An LDAR program is a structured program to detect and repair equipment that is

identified as leaking (U.S. EPA Office of Air Quaility Planning and Standards, 1995).

Equipment Modification Control Alternatives

For each equipment type there are one or more e quipment modifications th at can be implemented

for emissions control. This sec tion reviews the modifi cation alternatives for different equipment

leak types.

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

6 Pumps

Equipment modifications for pump s include routing leaking vapors through a closed -vent system

to control or replacing the existing pump with a new pump that is designed with dual mechanical

seals or is a sealless type.

A pump with dual mechanical seals contains two seals betw een which a barrier fluid is

circulated. Depending on the design of the dual mechanical seal s, the barrier fluid can be

maintained at a pressure that is higher than the pumped fluid or at a pressure that is lower than

the pumped fluid. If the barrier flui d is maintained at a higher pressure than the pumped fluid, the

pumped fluid will not leak to the atmosphere. Th e control efficiency of dual mechanical seals

with a barrier fluid at a highe r pressure than the pumped fl uid is essentially 100 percent,

assuming both the inner and out er seal do not fail simultaneous ly. If the barrier fluid is

maintained at a lower pressure than the pumped fl uid, a leak in the inner seal would result in the

pumped fluid entering the barrier fluid. To pr event emissions of the pumped fluid to the

atmosphere, a barrier fluid reservoir system shoul d be used. At the reservoir, the pumped fluid

can vaporize ( i.e. , de-gas) and then be collected by a closed-vent system.

The actual emissions reduction achievable through use of dual mechanical seals depends on the

frequency of seal failure. Failure of both the inner and outer seal s could result in relatively large

releases of the process fluid. Pressure monitori ng of the barrier fluid may be used to detect

failure of the seals, allowing fo r a quick response to a failure.

Sealless pumps, when operating properly, will no t leak because the process fluid cannot escape

to the atmosphere. Sealless pumps are used primarily in processes where the pumped fluid is

hazardous, highly toxic, or very expensive, and wh ere every effort must be made to prevent all

possible leakage of the fluid. Under proper operating conditions, the control efficiency of

sealless pumps is essentially 100 percent; however , if a catastrophic failure of a sealless pump

occurs, there is a potential fo r a large quantity of emissions.

Compressors

Emissions from compressors may be reduced by collecting and controlling the emissions from

the seal or by improving seal performance. Shaf t seals for compressors are of several different

types--all of which restrict but do not eliminat e leakage. In some cases, compressors can be

equipped with ports in the seal area to evacuat e collected gases using a closed-vent system.

Additionally, for some compressor seal types, em issions can be controlled by using a barrier

fluid in a similar manner as described for pumps.

Pressure Relief Valves

Equipment leaks from pressure relief valves (PRV s) occur as a result of improper reseating of

the valve after a release, or if the process is op erating too close to the set pressure of the PRV

and the PRV does not maintain its seal. Emissi ons occurring from PRVs as a result of an

overpressure discharge are not considered to be equipment leak emissions. There are two

primary alternatives for contro lling equipment leaks from pressu re relief devices: use of a

rupture disk (RD) in conjuncti on with the PRV, or use of a closed-vent system. The control

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

7 efficiency of the RD/PRV combination is assumed to be 100 percent when operated and

maintained properly.

A closed-vent system can be used to transport equipment leaks from a PRV to a control device.

However, the equipment leak control efficiency for a closed-vent system installed on a PRV may

not be as high as the control efficiency that ca n be achieved by installi ng a closed-vent system on

other equipment types. This is due to the difficu lty of designing an effi cient control device that

can handle both high and low flow emissions since emissions from pressure relief devices can be

either high during an overpressure incident or low when associated with equipment leaks.

Valves

Emissions from process valves can be eliminated if the valve stem can be isolated from the

process fluid. Two types of sealless valves are available: diaphragm valves and sealed bellows

valves. The control efficiency of both diaphrag m and sealed bellows va lves is virtually 100

percent. However, a failure of these types of valves has the potential to cause temporary

emissions much larger than thos e from other types of valves.

Connectors

In cases where connectors are not required for safety, maintenance, process modification, or

periodic equipment removal, emissions can be eliminated by welding the connectors together.

Open-Ended Lines

Emissions from open-ended lines can be contro lled by properly installing a cap, plug, or second

valve to the open end. If a second valve is insta lled, the upstream valve should always be closed

first after use of the valves to prevent the tra pping of fluids between the valves. Capping an

open-ended line has the potential to achieve nearly 100 percent control. However, monitoring

has shown that capped open-ended lines of ten leak due to improper installation.

Sampling Connections

Emissions from sampling connections occur as a result of purging the sampling line to obtain a

representative sample of the pr ocess fluid. Emissions from sampling connections can be reduced

by using a closed-loop sampling system or by collec ting the purged process fluid and transferring

it to a control device, back to the process, or for liquids, to a hazardous waste or other type of

treatment unit. The closed-loop sampling system is designed to return the purged fluid to the

process at a point of lower pres sure. A throttle valve or othe r device is used to induce the

pressure drop across the sample loop. The efficiency of a closed-loop system is assumed to be

100 percent. Alternatively, in some cases, sampling connections can be designed to collect

samples without purging the line. If such a samp ling connection is insta lled and no emissions to

the atmosphere occur when a sample is collected, then the control efficiency can be assumed to

be 100 percent (U.S. EPA Office of Air Quaility Planning and Standards, 1995).

Instrumentation Systems

Emissions from the connectors, valves, and othe r equipment in instrumentation systems can be

controlled using the same tech niques described above for such equipment in process lines.

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

8 Emissions of material that is pu rged from the system can be cont rolled using the same types of

techniques as described a bove for sampling connections.

Agitators

Agitators are used to stir or blend chemicals. Like pumps and compressors, agitators may leak

organic chemicals at the point where the shaft penetrates the casing. C onsequently, seals are

required to minimize fugitive emissions. Four seal arrangements commonly are used with

agitators: compression pack ing (packed seal), mech anical seals, hydraulic seals, and lip seals.

Packed seals for agitators are very similar in de sign and application to packed seals for pumps.

Leak Detection and Repair Program

An LDAR program is designed to identify piece s of equipment that are emitting sufficient

amounts of material to warrant reduction of the emissions through repair. Leak detection

methods can include sensory inspections ( i.e. , indications of leaks based on sight, sound, or

smell) or monitoring with portable organic vapor analyzers in accordance with Method 21.

Typically, Method 21 has been used to monitor e quipment in gas/vapor service and equipment in

contact with relatively volatile liquids. Sensory inspections are generally used for equipment in

contact with less volatile liquids ( i.e. , “heavy” liquid service). Thes e programs are best applied to

equipment types that can be repaired on-line, resulting in immediate emissions reduction, and/or

to equipment types for which equipment modifica tions are not feasible. An LDAR program is

best suited to valves and pumps, and can also be implemented for agitators and connectors.

For other equipment types, an LDAR program is not as applicable. Compressors are repaired in a

manner similar to pumps; however, because compressors ordinarily do not have a spare for

bypass, a process unit shutdown may be required for repair. Compre ssors are typically controlled

by seal systems that include a barrier fluid sy stem. Historically, open-ended lines have been

controlled solely by equipment modifications (be cause the modification is expected to achieve

100 percent emissions reduction). Emissions from sampling connections can only be reduced by

changing the method of collecting the sample (sin ce, by definition, equipment leak emissions are

the material purged from the line), and cannot be reduced by an LDAR program. Safety

considerations may preclude th e use of an LDAR program on pressure relief valves.

Many studies have been performed to estimate the control effectiven ess of a given LDAR

program for light liquid pumps, gas valves, light liquid valves , and connectors. The control

effectiveness is based on the re lationship between the percentage of equipment pieces that are

leaking and the corresponding average leak emissi on rate for all of the equipment. The main

factors in determining the control effectiveness are: (1) how a “leak” is defined, (2) the leak

frequency before the LDAR program is implemen ted, and (3) the final leak frequency after the

LDAR program is implemented. The leak definition (or action level) for a piece of equipment is

the screening value at which a “leak” is indicated if the instrument reading is equal to or greater

than that value. The leak frequency is the fractio n of equipment with screen ing values equal to or

greater than the leak definition (EPA, 1995).

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

9 New Control Technologies

No entirely new developments in methods for co ntrolling equipment leak emissions were found.

However, variations and advancements in exis ting technologies and pr actices that are not

currently required in existing EPA rules have been identified and are listed as follows.

• Optical gas imaging – Optical gas imaging devi ces offer the ability to monitor equipment

from a distance and identify leaks (of a suffici ent mass) from equipment within the line

of sight of the optical imager (Envi ron International Corporation, 2003).

• “Low leak” packings – Packing combinations for valves and gaskets for flanges that

significantly reduce emissions are in place in some facilities, particularly refineries.

Facilities and packing manufacturers have crea ted emission testing protocols for packings

in order to study and test their effectivene ss. One of these studies, performed by two

packing manufacturers, revealed that “[s]ev eral aspects of valv e design; including

tolerances, surface finish, stem straightness and the overall alignment of the stem, stem

nut and stuffing box were found to be contribut ing factors to either the failure and/or

success of a particular stem packing to meet the emission requirements.” These studies

have lead to advancements such as pack ing consisting of braided carbon filament end

rings that encapsulate an Inc onel wire mesh with three molded flexible graphite center

rings (Cornelsen, 2006).

Some packing manufacturers have begun marke ting packings as “low-leak” packing and

providing performance guarantees. Companies have also develope d in-house testing

programs to ensure that packings are suitable fo r site-specific applications and to evaluate

the performance of different materials (Reeves, 2011).

• Monitoring of new equipment – Some local governments require monitoring on types

equipment that have not been monitored in th e past. In some cases, this is based on data

collected since LDAR programs where first designed and implemented. For example,

inspection agencies have conducted monitoring of open ended valves and lines (OELs) at

numerous facilities and found OELs that are leaking due to improper installation of the

plugs and other control equipment (W ilwerding 2007, Loukeris 2006). Monitoring on

atmospheric PRVs for releases and leaks is also required by some local governments

(Douglas, 2005).

The South Coast Air Management Quality District (SCAQMD) requires continuous

monitoring of a percentage of atmospheric PR Ds at refineries by installing a monitoring

device capable of recording the duration of each release and quantifying emissions.

Wireless technology allows continuous m onitoring of PRDs and makes it easy for

operators to identify releases and leaks. Th ere are several monitoring devices that can be

used, including acoustic sensors and pressure/di fferential pressure sensors. These sensor

units communicate with a base radio that in terfaces with the existing control system

(Ellis, 2007).

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

10 6. Summary of Control Options Analyzed

For the purposes of this memorandum, the baselin e control option is a combination of leak

detection and repair (LDAR) program elements , equipment design standards, and performance

standards which were based on a review of th e requirements and appl icability of existing

regulations, including federal, st ate, and local rules. The base line leak detection and repair

program is equivalent to the requirements in the National Emission Standards for Equipment

Leaks--Control Level 1 (40 CFR part 63, subpa rt TT) and Standards of Performance for

Equipment Leaks of VOC in the Synthetic Organic Compound Manufacturing Industry for

which Construction, Reconstruc tion, or Modification Commenced After January 5, 1981 but

Before November 7, 2006 (40 CFR part 60, subpart VV) and represents the least stringent set of

requirements that apply to faciliti es that are currently subject to equipment leaks standards. Thus,

it is also considered to be the least stringent al ternative for a process unit or facility that is

currently not subject to standards. Table 1 summ arizes the requirements of the baseline for all

equipment.

Table 1. Baseline Requirements for all Equipment Types

Equipment Baseline Requirements

Pumps in light liquid service (Pumps LL) Monthly Method 21 monitoring

Leak definition of 10,000 ppm

Pumps in heavy liquid service (Pumps HL) Sensory Monitoring

Valves in gas and vapor service and Valves in light

liquid service (Valves G/LL) Monthly Method 21 monitoring (or less frequent

depending on leaks found)

Leak definition of 10,000 ppm

Valves in heavy liquid service (Pumps HL) Sensory Monitoring

Connectors in gas and vapor service and

Connectors in light liquid service (Connectors G/LL) Sensory Monitoring

Connectors in heavy liquid service (Connectors HL) Sensory Monitoring

Agitators in gas and vapor service and Agitators in

light liquid service (Agitators G/LL) Monthly Method 21 monitoring

Leak definition of 10,000 ppm

Agitators in heavy liquid service (Agitators HL) Sensory Monitoring

Compressors Barrier fluid options

Open Ended Lines Cap or comparable

Sampling Connection Systems (all types of service) All must be closed purge, closed loop, or have a

closed vent system (CVS)

Pressure relief devices in gas and vapor service

(PRV Gas) No detectable emissions (or rupture disk CVS/air

pollution control device (APCD))

Pressure relief devices in liquid service (PRV

Liquid) Sensory Monitoring

Instrumentation Systems For large valves: Comply with applicable

requirements above

For all other equipment: Sensory monitoring

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

11 In addition, this memorandum also analyzes seve ral alternative means of compliance. From the

baseline, independent alternatives for each comp onent type were developed and are summarized

in Table 2. This approach provides the abilit y to analyze the incremental costs and cost

effectiveness of each alternative individually, while still distributing cost s of certain activities

(such as the use of a monitoring instrument or a da tabase) that apply to, or can be used for, more

than one type of equipment. Furthermore, many of these alternatives match current regulatory

requirements for facilities subject to certain existi ng rules; these alternatives thus can also serve

as the baseline in analyses of nationwide impact s of regulatory alternatives for source-category

specific rules that referen ce the Uniform Standards.

Table 2. Summary of Equipment Leak Requirement Options

Alternative Options Additional Requirements

Valve Option 1 Lowers leak definition of Valves G/LL to 500 ppm

Valve Option 2 Lowers leak definition of Valves G/LL to 100 ppm

Pumps Option 1 Lowers leak definition of Pumps LL to 2,000 ppm 1



# Pumps Option 2 Lowers leak definition of Pumps LL to 500 ppm

Connectors Option 1 Adds instrument monitoring for Connectors G/LL at 500 ppm

1 

# Note that the regulatory leak definit ion for pumps is 2,000 ppm; however, data collected at a leak definition of 1,000

ppm were often used in this analysis to represent pumps with a leak definition of 2,000 ppm.



# Additional Requirements for Open Ende d Lines and Pressure Relief Devices

In addition to the requirements in Table 2, this memorandum also analyses the incremental cost

of conducting annual instrument monitoring to demonstrate that the open-ended valve or line

operates with an instrument reading of less than 500 ppm above background ( i.e. , that the cap,

blind flange, plug, or second valve seals the ope n-ended valve or line at all times). It was

assumed that the annual monitoring would not pr ovide any additional emissions reductions since

the baseline requires OELs to be capped, but w ould result in additional monitoring and repair

costs. The costs of annual monitoring, includ ing repair of any leak s found, are included in

Section 8.

The impacts associated with wireless monitoring for PRDs were also analyzed in this

memorandum. It was assumed that no additional emissions reductions would occur from this

requirement, but it would result in additional capital costs. Wireless monitoring costs are

included in Section 8.

7. Impact Analysis

Model Facilities

To calculate cost estimates and emissions reduc tions for potential equipment leak requirements,

model plants were developed to represent equipm ent counts found at different types of chemical

and refining facilities. Six models were creat ed, three to represent chemical manufacturing

process units and three to re present petroleum refineries. These models allowed for the

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

12 consideration of the costs and emissions reducti on impacts for processes of various sizes in

multiple industries. The six mode ls are summarized in Table 3.

Table 3. Model Plants

Type of Equipment Number of Pieces of Equipment

Model 1 Model 2 Model 3 Model 4 Model 5 Model 6

Simple

Chemical Medium

Chemical Complex

Chemical Topping

Refinery Small

Refinery Large

Refinery

Pump Seals

* Light-liquid service 15 40 56 8 69 176

* Heavy-liquid service 0 5 36 8 61 246

Valves

* Gas/vapor service 77 414 1,379 75 1,178 3,263

* Light-liquid service 380 1,179 1,980 251 2,428 5,857

* Heavy-liquid service 0 71 1,272 216 1,719 3,163

Connectors

* Flanges - gas/vapor 164 2,333 7,641

* Flanges - G/LL 731 2,662 7,410 555 4,644 13,379

* Flanges - HL 454 4,186 7,725

Agitators

* Light-liquid service 0 3 0 0 0 0

* Heavy-liquid service 0 3 0 0 0 0

Compressor Vent 0 2 8 2 19 31

Open-ended Valves 33 141 424 39 238 902

Sampling Connections 8 35 106 10 70 159

Pressure Relief Devices 2 45 76 9 79 119

Total Equipment Counts 1,246 4,600 12,747 1,791 17,024 42,661



# Models 1-3 represent a range of chemical ma nufacturing process units and are based on the

models used in the Final Impacts Analysis for Regulatory Options for Equipment Leaks of VOC

in the SOCMI (Parrish, 2007). These equipment counts en compassed a large ra nge of individual

process units at chemical manufacturing facilities . However, a facility with numerous process

units could have many times more pieces of equi pment than Model 3. Focus was placed on small

facilities since that size range is where the impact s are most likely to be more burdensome. When

impacts for Model 3 are reasonable, we can be certai n that they will also be reasonable for larger

facilities.

Models 4-6 represent different size refineries, from a simple topping refinery to a complex

refinery. The equipment counts presente d for small and large refineries in Locating and

Estimating Air Emissions from Sources of Benzene (EPA, 1998) were used to estimate the

number of pieces of equipment in each type of refinery process un it. Model 4, the topping

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

13 refinery, was assumed to consist of one crude distillation unit. Except for PRV, the equipment

counts for that model are equal to the counts for a crude distillation unit at a small refinery in

Locating and Estimating Air Emissions from Sources of Benzene (EPA, 1998). The PRV counts

were estimated based on a summary of data collected through EPA’s Petroleum Refinery

Information Collection Request (ICR) (EPA, 2011).

Models 5 and 6 were developed using info rmation from the U.S. Energy Information

Administration (EIA) on the number of refineries in the U.S., thei r capacities, and the types of

processes at each (U.S. DOE, 2011). The EIA report includes production capaci ty of facilities in

barrels per day (bbl/d) and the downstream charge capacity of each plant divided into process

type (vacuum distillation, dela yed coking, fluid coking, visbreaki ng, and other processes). Since

Locating and Estimating Air Emissions from Sources of Benzene defines the “large model

refinery” as a refinery with a crude charge capacity greater than 50,000 barrels per stream day,

refineries were classified as “large” or “small” based on the capacity in the EIA report. The

number of each type of process at an average “small” refinery and an average “large” refinery

was estimated based on the data in the EIA re port. For example, the EIA report included 40

“small” refineries, 24 of which reported vacuum di stillation capacity. Ther efore, it was assumed

for purposes of developing a small refinery model that an average small refinery has 0.6 vacuum

distillation units. Finally, the number of each type of process was multiplied by the appropriate

equipment counts in Locating and Estimating Air Emissi ons from Sources of Benzene , and the

results were summed for each type of equi pment except for PRV. The PRV counts were

estimated based on a summary of data from the Petroleum Refinery ICR. References for model

facilities are included in attachment 1.

The goal was to develop models as representative of the potential affected sources as possible so

that the model plants can be used in the futu re to develop source cate gory-specific nationwide

impact estimates in an efficient manner. There are process units and facilities larger than the

largest model; however, these models are intende d to cover a range of sizes representing a

majority of the potential affect ed facilities. In addition, the opt ions considered for the Uniform

Standards that are affected by economies of scale will have a greater impact on smaller processes

than larger processes. These models can be ad justed as needed based on data for a specific

source category or industry to represent that source category or indus try more accurately.

Leak Frequencies

Leak frequency refers to the estimated percenta ge of equipment that will be found leaking at a

given leak definition. Leak frequencies were used to calculate both cost and emission estimates

and are included in Table 4 and 5. Leak freque ncies were estimated using several sources

including the Protocol for Equipment Leak Emissi ons Estimates and industry data. Attachment 2

includes the basis for the leak frequencies in Ta bles 4 and 5. Detailed information on how leak

frequencies were used in cost and emission estim ates is included in the following sections.

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

14 Table 4. Summary of Equipment Leak Frequency % for Model 1-3

Equipment Leak Frequencies % (Initial/Subsequent)

Pump Seals

LL Valves GV Valves LL Agitators

LL Connectors

G/V and LL OELs

Baseline 2.42 / 0.23 0.33 / 0.33 0.33 / 0.33 2.42 / 0.23 NA NA

Valves

Option 1 NA 7.24 / 0.51 4.84 / 0.51 NA NA NA

Valves

Option 2 NA 12.24 / 0.61 8.07 / 0.61 NA NA NA

Pumps

Option 1 13.48 / 0.26 NA NA NA NA NA

Pumps

Option 2 18.43 / 0.33 NA NA NA NA NA

Connectors

Option 1 NA NA NA NA 0.36 / 0.36 NA

OELs Annual

Monitoring NA NA NA NA NA 0.90 / 0.45



# Table 5. Summary of Equipment Leak Frequency % for Model 4-6 1



# Equipment Leak Frequencies % (Initial/Subsequent)

Pump

Seals LL Valves GV Valves LL Agitators

LL Connectors

G/V Connectors

LL OELs

Baseline 0.88 / 0.88 1.18 / 1.18 1.38 / 1.38 0.88 / 0.88 NA NA NA

Valves

Option 1 NA 5.95 / 1.91 6.30 / 1.97 NA NA NA NA

Valves

Option 2 NA 14.73 /

1.28 15.14 /

1.17 NA NA NA NA

Pumps

Option 1 3.31 / 0.98 NA NA NA NA NA NA

Pumps

Option 2 4.57 / 1.26 NA NA NA NA NA NA

Connectors

Option 1 NA NA NA NA 1.70 / 0.81 1.70 / 0.81 NA

OELs

Annual

Monitoring NA NA NA NA NA NA 2.30 /

1.15

1 

# U.S. EPA National Enforcement Inve stigations Center (NEIC) data on leak frequencies for valves at refineries

suggest the actual percentage leaking may be higher. In orde r to account for this, it was estimated that the actual

percentage leaking is 1.7 times higher than typically m easured leak frequencies. This factor represents the 10th

percentile of the data set ( i.e. , 90 percent of the NEIC leak frequencies were at least 1.7 times higher than the leak

frequencies reported by the refineries) and was used determining leak frequencies (Parrish et al. , 2007).

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

15 Emission Reductions

In order to calculate the emissi ons reductions that result from th e baseline requirements, we first

had to estimate uncontrolled em issions. Once the emissions reductions of the baseline were

found, the incremental emissions reductions of each control alternative we re also calculated. The

incremental emissions reductions of each option is incremental w ith respect to the previous

option for a given equipment type. For example, the emissions reduction for pumps Option 1 is

based on the additional emissions reductions of Option 1 with respect to the baseline pump

emissions; similarly, the emissions reduction of pumps Option 2 is based on the additional

emission reduction of Option 2 with respect to Option 1. The following sections describe how

these emissions were calculated.

The first step in calculating emissions was to es tablish emission factors for each equipment type.

Emission factors are the estimated leak rates of an equipment type at a given leak definition and

are normally given in kg/hr/piece of equipment. Tables 6 and 7 summarize the leak emission

factors used for Models 1-3 and 4-6, respectively. Attachment 3 includes detailed information on

the basis for these emission factors.Technical Memorandum – Analysis of Emissions Reduction Techniques for Equipment LeaksDecember 21, 201116Table 6. Emission Factors for Chemical Manufacturing Plant ModelsEmission Factors for Chemical Manufacturing Plant Models 1-3 (kg/hr/piece of equipment)1UncontrolledBaselineValve Option1Valve Option2PumpsOption 1PumpsOption 2ConnectorsOption 1Pump SealsLL1.23E-02 2.51E-03 NA NA 6.95E-04 5.31E-04 NAValvesG/V5.22E-04 3.52E-04 2.03E-04 1.82E-04 NA NA NAValvesLL5.86E-04 3.90E-04 2.32E-04 2.05E-04 NA NA NAConnectors–Flanges G/V3.07E-043.07E-04NA NA NA NA NAConnectors–Flanges G/LL3.07E-04 3.07E-04NA NA NA NA 1.62E-04AgitatorsLL1.23E-02 2.51E-03 NA NA NA NA NACompressor Vent2.28E-01 2.28E-02 NA NA NA NA NAOpen-ended Valves1.70E-03 3.33E-05 NA NA NA NA NASamplingConnections1.50E-02 NA NA NA NA NA NAPRV– Disks1.04E-01 NA NA NA NA NA NA1Equipment in HL service was not included in this analysis because we are unable to quantify thereductions that are achieved using sensory monitoring.Technical Memorandum – Analysis of Emissions Reduction Techniques for Equipment LeaksDecember 21, 201117Table 7. Emission Factors for Refinery ModelsEmission Factors for Refinery Plant Models 4-6 (kg/hr/piece of equipment)1UncontrolledBaselineValve Option1Valve Option2PumpsOption 1PumpsOption 2ConnectorsOption 1Pump SealsLL1.05E-03 7.11E-04 NA NA 3.26E-04 3.22E-04 NAValvesG/V3.71E-04 2.24E-04 8.85E-05 2.10E-05 NA NA NAValvesLL3.75E-04 2.23E-04 8.88E-05 2.02E-05 NA NA NAConnectors– Flanges G/V1.04E-04 1.04E-04 NA NA NA NA 3.95E-05Connectors– Flanges G/LL8.46E-05 8.46E-05 NA NA NA NA 2.77E-05AgitatorsLL1.05E-03 NA NA NA NA NA NACompressor Vent6.36E-01 3.18E-02 NA NA NA NA NAOpen-ended Valves2.30E-03 7.34E-05 NA NA NA NA NASampling Connections1.50E-02 NA NA NA NA NA NAPRV– Disks1.60E-01 NA NA NA NA NA NA1Equipment in HL service was not included in this analysis because we are unable to quantify thereductions that are achieved using sensory monitoring.

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

18 Uncontrolled emissions were calculated by multiplying the emission factors in Tables 6 and 7,

the equipment counts of each model, and the ope rating hours (which were assumed to be 8,760

hours/yr). Uncontrolled emissions for each mode l are summarized in Table 8. Attachment 4

provides detailed calculations.

Table 8. Uncontrolled Emissions for Each Model

Model Total Uncontrolled

Emissions (lb/yr) Total Uncontrolled

Emissions (tpy)

Model 1 20,400 10.2

Model 2 157,000 78.7

Model 3 326,000 163

Model 4 61,000 30.4

Model 5 548,000 274

Model 6 941,000 471



# Once uncontrolled baseline emissions were estab lished, emission estimates were calculated for

the baseline. The leak definitions under the ba seline are 10,000 ppm for pumps LL, valves G/LL,

and agitators in G/LL. Therefore, the leak emission factors for the baseline (summarized in Table

6 and 7) for these equipment types are based on a leak definition of 10,000 ppm. These leak

emission factors were multiplied by the equipment counts for each model and 8,760 hours to get

annual emissions. As stated in Section 5, the efficiency of the control methodologies for

sampling connections and PRVs in gas service is expected to be 100 percent; therefore,

implementing the requirements of the baseline for these types of equipment results in essentially

zero emissions for those equipment types. Emi ssion reductions from sensory requirements were

assumed to be zero because we are unable to quantify emissions reductions associated with

sensory requirements. Baseline compressor vent emissions estimates are based on emission

factors used in the HON analysis (Whitt, 1991), assuming the seal system barrier fluid would be

routed to a reservoir where the fluid could degas and the vapors routed to a control device. For

OELs, we used the emissions factors documented in previous analyses (Parrish and Randall,

2007; Parrish et al. , 2007) at the leak frequencies descri bed earlier in this section. Table 9

summarizes baseline emissi ons for all model plants.

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

19 Table 9. Baseline Emissions Summary

Option 1 Emissions (lb/yr)

Equipment Type Model 1 Model 2 Model 3 Model 4 Model 5 Model 6

Pump Seals

Light-liquid service 728 1,940 2,717 110 948 2,418

Valves

Gas/vapor service 523 2,814 9,374 324 5,092 14,106

Light-liquid service 2,863 8,884 14,920 1,082 10,471 25,259

Connectors

Flanges - gas/vapor 0 0 0 330 4,693 15,371

Flanges - G/LL 4,334 15,782 43,932 906 7,584 21,849

Agitators

Light-liquid service 0 146 0 -- -- --

Compressor Vent 0 881 3,523 1,228 11,669 19,038

Open-ended Valves 21 91 273 55 337 1,278

TOTAL (lb/yr) 8,470 31,538 74,737 4,036 40,795 99,319

TOTAL (tpy) 4.23 15.27 37.37 2.02 20.40 49.66



# The emission reductions for the baseline were calcu lated by subtracting tota l baseline emissions

from total uncontrolled emissions. The alterna tive options for each equipment type provide

additional reductions by increasing the baseline requirements of that equipment type. Table 10

summarizes emissions reductions of the baseline , as well as the additional reductions of each

subsequent option. Detailed calculati ons are included in Attachment 4.

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

20 Table 10. Emissions Summary

Emissions Reductions Summary (tpy)

Model 1 Model 2 Model 3 Model 4 Model 5 Model 6

Uncontrolled Emissions 10.2 78.7 163 30.4 274 471

Baseline Emissions 4.23 15.3 37.4 2.02 20.4 49.7

Baseline Emissions

Reductions 5.96 63.5 126 28.4 254 421

Additional Incremental Reductions:

Valves Option 1 (wrt to

Baseline valve

emissions) 0.69 2.40 5.02 0.42 4.69 11.87

Valves Option 2 (wrt to

Valves Option 1) 0.12 0.43 0.92 0.24 2.55 6.65

Pumps Option 1 (wrt to

Baseline pump

emissions) 0.26 0.70 0.98 0.03 0.26 0.65

Pumps Option 2 (wrt to

Pumps Option 1) 0.02 0.06 0.09 0.0003 0.003 0.007

Connectors Option 1

(wrt to Baseline

connector emissions) 1.02 3.7 10.4 0.41 4.0 12.1



# 8. Control Costs

The cost analysis uses a methodology that was originally presented in Impacts from the Control

of VHAP Emissions from Equipment Leaks in Non-SOCMI Process Units for HON (Whitt,

1991). The methodology has been tailored specifically for this analysis. Seve ral constant values

used in this analysis were developed for previ ous analyses and are deta iled in this section.

Cost calculations can fall into three categories:

1. Monitoring and Equipment Costs

2. Leak Repair Costs

3. Planning and training Costs

The first step was to estimate the costs of implementing the baseline. Once this was completed,

the incremental cost of each alternative was ca lculated. This section will analyze each cost

estimates and summarize the costs for each option.

Labor Hour Rates

Wage rate estimates used to calculate costs we re based on data from the U.S. Department of

Labor, Bureau of Labor Statistics for genera l manufacturing sectors (Sectors 31, 32, and 33)

(BLS, 2010). Overhead factors and fringe benefits were added to labor rates when necessary.

Table 11 summarizes the wage rates and overhead fact ors used to estimate costs for each option.

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

21 Table 11. Summary of 2009 Hourly Labor Rates

Activity $/hr Basis for Estimate

General manufacturing -

Installation, maintenance, repair

occupations 22.08 Mean hourly wage for Installation, Maintenance, and Repair

Occupations

(Standard Occupational Classification (SOC) Code 49-0000)

(BLS, 2010)

Plant and system operators 22.72 Mean hourly wage for Plant and System Operators, All Other

(SOC Code: 51-8099) (BLS, 2010)

Environmental engineering 39.53 Mean hourly wage for Environmental Engineers

(SOC Code: 17-2081) (BLS, 2010)

General and operations

managers 57.80 Mean hourly wage for Engineering Managers

(SOC Code: 11-9041) (BLS, 2010)

General office and admin support 17.31 Mean hourly wage for Office and Administrative Support

Occupations

(SOC Code: 43-0000) (BLS, 2010)

Planning and training labor

charge 1 

# 92.72 Weighted average for technical (39.53), management (57.80),

and clerical labor (17.31). The weighted average assumes

5 hours of management time and 10 hours of clerical effort per

100 hours of technical labor. Includes overhead factor for

planning and training.

Leak Repair Labor Charge 2 

# 66.24 The general manufacturing sector - Installation, Maintenance,

and Repair Occupations labor rate with the overhead factor

applied was used for all repairs

1 

# A planning and training overhead factor of 2.1 was used based on Technology Review for Heat Exchange Systems

(Coburn, 2011).

2 

# A maintenance and repair overhead factor of 3 was used bas ed on a 200 percent overhead factor (which -correlates

to a factor of 3) based on the overhead factor used for performance testing contractor s in the CEMS Cost Model

(EPA, 2002).



# Monitoring and Equipment Modification Costs

Initial monitoring costs are considered capital costs and are higher than annual monitoring costs

in order to account for implementation. They are incurred once at the st art of the program and

were calculated by multiplying the equipment count s in a given model by an estimated initial

monitoring fee. Table 12 summarizes the monitoring fees for each equipment type and the basis

for each.

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

22 Table 12. Initial monitoring Fees

Monitoring Fee ($/

equipment piece) Basis

Pumps LL 23.80 Includes field identification of subject equipment; creating and

issuing drawings; creating data forms and tags; tagging of the

pumps and valves; and populating the software. The value also

assumes that contractors are performing this work. (Updated from

Eastman Chemical Co, 1999.) Valves G/LL

Agitators LL

OELs

Pumps HL 1.10 Based on an estimate of 3 minutes to monitor each piece of

equipment at a “general manufacturing sector - installation,

maintenance, and repair occupations” wage rate. (Update from

Eastman Chemical Co, 1999.) Valves HL

Agitators HL

Connectors



# Annual monitoring costs vary by the number of tim es the equipment type has to be monitored

per year. Table 13 summarizes the annual mon itoring fees by equipment type. The annual

monitoring costs are calculated by multiplying the equipment counts by the monitoring fee and

the monitoring frequency.

Table 13. Annual monitoring/maintenance Fees

Subsequent Monitoring

Fee ($/equipment piece) Basis

Pumps LL 1.50 Based on information provided by a monitoring and

repair contractor (Parrish, 2006) Valves G/LL

Agitators LL

OELs

Connectors GV/LL 2.50



# Equipment modification costs are considered to be capital costs and were calculated for the

baseline requirements to equip open-ended valves with caps or other comp arable seals, install

rupture discs on pressure relief devices in gas service, to equip compressor vents with a seal

system, and to retrofit sample connection system s to be closed purge, closed loop, or have a

closed vent system. Table 14 summarizes the initia l cost for these requirements and the basis for

each cost estimate.

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

23 Table 14. Equipment Modification Costs for PRVs, OEVs, Sampling Connections, and

Compressor vents

Equipment/

Device Type Initial

Cost

($2010) Unit Basis Reference

Pressure Relief

Devices

* Disks 122.11 $/ equipment Cost of one rupture disk. Escalated vendor quote

(Hausle & Whitt, 1992)

* Disk holders,

valves, etc. 6,374.29 $/ equipment Equipment cost of 1 gate

valve, tee, elbow, rupture

disk holder, pressure

gauge, bleed valve, steel

body/trim and labor costs

(36 labor hours). Escalated labor and

equipment cost (Hausle &

Whitt, 1992)

Open-ended

Valves 140.92 $/ equipment Cost for one 2.5 cm gate

valve for open ended

lines and 1.4 labor hours Escalated from costs provided

in Hausle & Whitt, 1992

Sampling

Connections 687.86 $/ equipment Equipment cost for 6

meter pipe, 3 ball valves

and 2.4 labor hours. Escalated from costs provided

in Hausle & Whitt, 1992

Compressor

Vent Seal 10,526.21 $/ equipment Equipment cost of 122

meter pipe, 3 steel

valves, 1 flame arrestor,

and 78 labor hours. Escalated from costs provided

in Hausle & Whitt, 1992



# Monitoring instrumentation is also necessary for Method 21 monitoring, as well as a data

collection system to store mon itoring records. Instrumentation and data collection systems are

capital costs that were estimated at $10,800 a nd $14,500, respectively, per f acility. The estimated

instrumentation costs are roughly equal to the cost to purchase a st andard TVA1000B flame

ionization detector (FID)-only monitor with prob e from Thermo Fisher Scientific (2011). The

data collection system cost was based on Revised MACT Floor, Regulatory Alternatives, and

Nationwide Impacts for Equipment Leaks at Chemical Manufacturing Facilities (Shine et al.

, 2003).

Initial costs for PRD wireless monitoring device capable of identifying and recording the time

and duration of each pressure release and calculati ng the quantity of regulated material released

were also analyzed in addition to the baseline PRD requirements. There are several types of

wireless monitoring systems and costs vary de pending on the number of PRDs at a facility.

Based on cost studies from the BAAQMD staff re port, the estimated cost of wireless monitoring

was assumed to be 7,500 dollars per PRD (the midpoint of the range provided by Douglas

(2005), which includes device parts, installation, maintenance, and data retrieval system. Annual

operating costs were not included in this analys is because they are assumed to be minimal.

Because the cost of electronic monitoring is not li near and facilities requ iring a large number of

monitors will benefit from economies of scale, the sixth-tenths rule was applied to calculate

initial costs which are pr ovided below (Douglas, 2005).

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

24 Leak Frequency and Repair Costs

The control options summarized in Tables 1 a nd 2 require Method 21 mon itoring and repair of

leaks for certain equipment types. Repair costs are a function of the leak frequency of a given

equipment type. An initial leak frequency repres ents the equipment found to be leaking the first

time the monitoring is conducted usi ng a particular leak definition. Th e cost to repair these initial

leaks is considered as initial LDAR costs (along with initial monitoring fees). The subsequent

leak frequency represents the equipment found to be leaking after a few monitoring cycles have

been completed and the program reaches “steady st ate” the cost to repair subsequent leaks are

considered annual repair costs. Generally, the subsequent leak fr equency is estimated to be less

than the initial leak frequency, but in some cases they are assumed to be the same. For example,

the initial leak frequencies for the baseline are the estimated percen tages of uncontrolled

equipment leaking above the 10,000 ppm leak defin ition, and the subsequent leak frequencies are

the estimated percentage of “leakers” once the ini tial leaks are repaired and the requirements are

in place. If initial or subseque nt leak frequencies increase for a control alternative, the initial

LDAR costs or the annual repair costs can increas e because there are more leaks to repair; these

additional repair costs are considered increm ental costs for each alternative option. Leak

frequencies were estimated using several source s including the Protocol for Equipment Leak

Emissions Estimates and industry data. As previous ly stated, attachment 2 includes the basis for

the leak frequencies in Tables 4 and 5.

The cost to repair initial and subsequent leak s is also based on whether the repair can be

performed online and the number of hours required to repair the leak. The general manufacturing

sector - Installation, Maintenance, and Repair Occupations labor rate with the overhead factor

applied ($66.24/hr) was used for all repairs. Tabl e 15 includes the assumptions used to estimate

the cost of repairing leaks and attachment 5 provides detailed cost calculations.

Table 15. Summary of Leak Repair Assumptions

Equipment Type Percent Repaired

Online Hours Required

to repair online

Leak Percent Repaired

Offline Hours Required

to repair Offline

Leak

Pumps LL 100% 16.00 0 NA

Agitators 100% 16.00 0 NA

Valves LL/G 75% 0.17 25% 4.00

Connectors 1 

# 75% 0.17 25% 2.00

OELs 2 

# 75% 0.17 25% 4.00

1 

# Not applicable to Option 1-3 since connectors are not re quired to perform Method 21 monitoring and leak repair.

2 

# Only applicable to annual monitoring requirement (not used in baseline calculations of OELs).



# As part of the initial (LDAR) repa ir cost for pumps we assumed th at the seals would need to be

replaced. The cost to purchas e replacement pump seals was estimated to be $282.71/leaking

pump (updated from Hausle, 1992); therefore, initia l LDAR cost for pumps also includes the cost

of replacement pumps seals multiplied by the number of initial leaks (in addition to the initial

monitoring and repair costs). The annual cost of pump replacements is included as an annual

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

25 maintenance cost. Leak repair costs also include additional monitoring of the repaired leaks in

order to verify the equipment was completely fi xed. These costs are considered annual costs and

were calculated using the subsequent monitoring fee for the equipment type and the subsequent

number of equipment leaking.

Baseline cost estimates for OELs only include the costs related to in stalling caps and annual

maintenance and do not include any OEL repair co sts. OEL repair costs were only used when

calculating incremental cost of annual monitoring on OELs (see Table 17).

Maintenance and Miscellaneous Costs

For pumps and agitators, annual maintenance co sts were included and are based on the annual

number of leaks multiplied by the updated co st of a replacement seal, $282.71 (Hausle, 1992).

Annual maintenance costs were also include d for PRVs, OELs, sampling connections, and

compressor vents as a percentage of initial monitoring fees. For PRV disk holders, OELs,

sampling connections, and compressor vents, annua l maintenance costs were based on 5 percent

of initial monitoring costs and 2 percent of initial monitoring costs for PRV disks.

Annual miscellaneous costs were also included in this analysis fo r pumps, PRDs, OELs,

sampling connections, and compressor vents. For pumps and agitators, th e miscellaneous costs

are based on 80 percent of the annual maintenance costs. For PRDs, OELs, sampling connections

and compressor vents, the annual miscellaneous charges are estimated using 4 percent of initial

monitoring costs (Hausle, 1992).

Administrative, Reporting, Planning, and Training Labor Costs

Planning and training costs are initial costs asso ciated with the implem entation of an LDAR

program. These costs include initial review of requirements and training of facility personnel.

We estimated initial planning and training costs based on an estimate of 320 labor hours and a

labor rate of $92.72/hr. The value of 320 hours per process unit is based on an estimate of initial

administration, planning, and training to implement a SOCMI-based LDAR program (Meardon,

1998). Planning and training costs we re included in baseline estimates, and it was assumed that

no additional planning and training costs would be incurred with any of the alternative options

for pumps and valves ( i.e. , incremental costs of planning and tr aining was assumed to be 0 for all

alternative options). For connectors, it was assumed that an additional 20 hours would be

required for activities such as adding connectors to the LDAR database for instrument

monitoring.

Annual reporting and administra tive costs were estimated usi ng 250 hours at a labor rate of

$92.72/hr to account for preparation of annual repor ts and recordkeeping. The 250 hour estimate

was based on the ratio of the amount of hours required for LDAR programs with and without

connectors which is estimated at 8 people at 32 hours each in Equipment Leak Analysis for

Amino and Phenolic Resins NESHAP (Meardon, 1998). Development of the labor rate is

discussed in Table 11. Annual repo rting costs were included in baseline estimates and it was

assumed that no additional annual reporting costs w ould be incurred with a ny of the alternative

options for pumps and valves ( i.e. , incremental costs of planning and training was assumed to be

$0 for all alternative options). For connectors, it was assumed that an additional 50 hours would

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

26 be required for preparation of annual reports and recordkeeping on ce the LDAR program

included instrument monitoring for connectors.

Annualized Initial Costs

Initial capital costs and labor expenditures were annualized using capital recovery factors. The

following equation was used to calculat e capital recovery factors (EPA, 2002):

CRF = [i * (1+i) n 

# )] / [(1+i) n 

# – 1],

Where, i is the interest rate and n is the life span in years.

For pump seals and rupture disks, the capital re covery factor is 0.244, as suming a life span of 5

years. For all other equipment types, the capital recovery factors is 0.142 based on a life span of

10 years. We also annualized initial repair la bor and planning and traini ng costs over 10 years.

For both factors, an interest ra te of 7 percent was used. The impacts analysis also includes a

recovery credit for the material that is not lost as emissions from equipment leaks. As in the

Technology Review for Heat Exchange Systems (Coburn, 2011), these cred its are $500/ton VOC.

Incremental Costs

Once the total initial and annual costs for th e implementation of baseline requirements was

determined, the incremental annual cost of each alternative option was estimated. Similar to

incremental emissions reductions, incremental cost s are the additional costs of the option with

respect to the preceding option. The incremental co sts were based on the additional repair costs

(initial and subsequent) of the lower leak definition of a given alternative option and any

additional costs that are calcu lated as a function of leak s (maintenance costs, annual

miscellaneous charges, and monitoring costs to veri fy off line repairs). It was assumed that there

are no incremental costs associated with monito ring fees, administrative costs, and planning and

training (except as described for connectors) si nce these are constant and should not increase

with a lower leak frequency. Detailed incremental cost calculations are included in attachment 5.

Cost Summary

Cost estimates are summarized in Table 16 and Ta ble 17. Detailed cost calculations are included

in attachment 5

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

27 Table 16. Baseline Detail Cost Summary

Baseline

Model Capital Cost

($) Annualized Costs

Without Recovery

Credits ($/yr) VOC Recovery

Credit ($/yr) Total Annualized

Cost ($/yr)

Model 1 90,763 41,009 (2,980) 38,029

Model 2 455,982 129,599 (31,731) 97,867

Model 3 859,162 226,203 (62,822) 163,381

Model 4 156,783 57,067 (14,180) 42,887

Model 5 956,067 263,308 (126,809) 136,499

Model 6 1,658,781 461,483 (210,466) 251,017



# Table 17. Summary of Incremental Annualized Cost Estimates for all Control Alternatives

(Including Recovery Credits)

Baseline Valve

Option 1 Valve

Option 2 Pumps

Option 1 Pumps

Option 2 Connectors

Option 1

Model Total Cost ($/yr) Incremental Cost ($/yr)

Model 1 38,029 15 901 312 354 7,360

Model 2 97,867 97 3,223 831 944 13,861

Model 3 163,381 358 7,076 1,163 1,322 29,846

Model 4 42,887 268 2,815 189 437 7,714

Model 5 136,499 3,033 27,993 1,628 3,772 32,188

Model 6 251,017 7,725 79,562 4,152 9,622 87,089



# The cost for the additional requirements for PRDs and OELs are summarized in Table 18.

Incremental costs for each of these opti ons are with respect to the baseline.

Table 18. Additional Costs of Wireless Monitoring for PRDs and Annual OEL Monitoring

(Incremental to Baseline)

Type of

Facility Facility Initial Cost

PRD Wireless

Electronic

Monitoring ($) 1 

# Annualized

Incremental PRD

Wireless Electronic

Monitoring ($/yr) Capital Cost of

Annual OEL

Monitoring ($) Annualized

Incremental Cost

of Annual OEL

Monitoring ($/yr)

Model 1 11,368 1,619 808 176

Model 2 73,619 10,482 3,453 750

Model 3 100,821 14,355 10,383 2,256

Model 4 28,029 3,991 997 234

Model 5 103,190 14,692 6,082 1,429

Model 6 131,944 18,786 23,049 5,415

1 

# Costs calculated using six-tenths rule.

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

28 9. Cost Effectiveness

The cost effectiveness of base line is calculated by dividing th e total annual costs (including

recovery credits) by the total emissions reduction of the baseline. Similarly, incremental cost

effectiveness was calculated by dividing the increm ental cost of each option (including recovery

credits) by the incremental emissions reductions. Tables 19-22 summarize the cost effectiveness

of each control alternative an alyzed in this memorandum.

Additional requirements for wireless monitoring for PRDs and annual monitoring of OELs were

not included in the cost effectiveness summary since no emissions reductions from these

activities is expected.

Table 19. Baseline Cost Effectiveness Summary

Model Emission

Reductions

(tpy) Total Annual

Cost ($/yr) Cost

Effectiveness

($/ton VOC)

Model 1 5.96 38,029 6,380

Model 2 63.46 97,867 1,542

Model 3 125.64 163,381 1,300

Model 4 28.36 42,887 1,512

Model 5 253.62 136,499 538

Model 6 420.93 251,017 596



# Table 20. Valve Options Cost Effectiveness Summary

Valves Option 1 Valves Option 2

Model Incremental

Annualized

Cost ($) Incremental

Emissions

Reduction

(tpy) Overall Cost

Effectiveness

($/ton) Incremental

Annualized

Cost ($) Incremental

Emissions

Reduction

(tpy) Overall Cost

Effectiveness

($/ton)

Model 1 15 0.69 22 901 0.12 7,323

Model 2 97 2.40 40 3,223 0.43 7,506

Model 3 358 5.02 71 7,076 0.92 7,701

Model 4 268 0.42 633 2,815 0.24 11,588

Model 5 3,033 4.69 646 27,993 2.55 10,994

Model 6 7,725 11.87 651 79,562 6.65 11,966

# Technical Memorandum – Analysis of Emissi ons Reduction Techniques for Equipment Leaks

December 21, 2011

29 Table 21. Pump Options Cost Effectiveness Summary

Pumps Option 1 Pumps Option 2

Model Incremental

Annualized

Cost ($) Incremental

Emissions

Reduction

(tpy) Overall Cost

Effectiveness

($/ton) Incremental

Annualized

Cost ($) Incremental

Emissions

Reduction

(tpy) Overall Cost

Effectiveness

($/ton)

Model 1 312 0.26 1,184 354 0.024 14,977

Model 2 831 0.70 1,184 944 0.063 14,977

Model 3 1,163 0.98 1,184 1,322 0.088 14,977

Model 4 189 0.030 6,339 437 0.00031 1,429,098

Model 5 1,628 0.26 6,339 3,772 0.0026 1,429,098

Model 6 4,152 0.65 6,339 9,622 0.0067 1,429,098



# Table 22. Connector Option 1 Cost Effectiveness Summary (Incremental to Baseline)

Connectors Option 1 (Incremental to Baseline)

Model Incremental

Annualized

Cost ($) Incremental

Emissions

Reduction (tpy) Overall Cost

Effectiveness

($/ton)

Model 1 7,360 1.02 7,192

Model 2 13,861 3.73 3,719

Model 3 29,846 10.37 2,877

Model 4 7,714 0.41 18,957

Model 5 32,188 4.00 8,038

Model 6 87,089 12.11 7,191



# 9. References

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Facilities Subject to the Group IV Polymers and Resins NESHAP . Docket A-92-45,

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Shine, EPA/OAQPS. July 12, 2011. Docket Item No. EPA-HQ-OAR-2011-0002-0008.

Cornelsen, Dave. (2006). The development of eff ective fugitive emissions control for valves.

Valve World , February 2006, pp 49-52.

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30 Douglas, Victor. (2005). BAAQMD Staff Report: Proposed Ame ndments to Regulation 8, Rule

28: Episodic Release from Pressure Relief D evices at Petroleum Refineries and Chemical

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Denial of Petition for Reconsideration - Gr oup IV Polymers and Resins Equipment Leak

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Ellis, Kennard. (2007). Final Staff Report for Propose Amended Rule 1173. South Coast Air

Quality Management District (SCAQMD). May 15, 2007.

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Detecting Fugitive Emissions in Ethylene Facilities . Retrieved September 2011, from

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.

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Radian Corporation. February 28, 1992. Docket A-90-20, Document No. II-B-6.

Loukeris, Constantinos. (2006). Cap/Plug Monitoring Data from U.S. EPA Region 5.

Transmitted via e-mail to Karen Rackley. N ovember 28, 2006. Docket Item No. EPA-HQOAR-2006-0699-0073.

Meardon, Kenneth R. (1998). Memorandum from K. Meardon, Pac ific Environmental Services

Inc. to J Schaefer. EPA/OGC. May, 1998. “Attach ment 7: Leak Detection and Repair Cost

Derivatives” In Equipment Leak Analysis for Amino and Phenolic Resins NESHAP . May

1998. Docket No. A-92-19, Document No. II-B-11.

Parrish, Kristin, David Randall, and Je ff Coburn, RTI International. (2007). Final Impacts

Analysis for Regulatory Options for Equi pment Leaks of VOC Petroleum Refineries

. Memorandum to Karen Rackley, EPA/SPPD. Oc tober 30, 2007. Docket Item No. EPA-HQOAR-2006-0699-0089.

Parrish, Kristin; Randa ll, David. (2007). Final Impacts Analysis fo r Regulatory Options for

Equipment Leaks of VOC in the SOCMI . Memorandum to Karen Rackley, EPA/SPPD.

October 30, 2007. Docket Item No. EPA-HQ-OAR-2006-0699-0090.

Parrish, Kristin. (2006). Me morandum to Docket File. Telephone Conference between Kristin

Parrish (RTI International) and Timothy Smith (TEAM Industrial Services, Inc.) regarding

procedure and cost of the dril l and tap method of valve repair . March 27, 2006. Docket Item

No. EPA-HQ-OAR-2006-0699-0012.

Reeves, David. (2011). Designing for Leak Free Operation: The secret to reducing LDAR costs!

Presented at the ISA 11 th 

# LDAR Symposium, May 18-19, 2011, New Orleans, LA.

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December 21, 2011

31 Shine, Brenda, Melissa Icenhour, an d David Randall. (2003) Memorandum: Revised MACT

Floor, Regulatory Alternatives, and Nationwide Impacts for Equipment Leaks at Chemical

Manufacturing Facilities . May 5, 2003. Docket Item No. EPA-HQ-OAR-2003-0121-0004.

Thermo Fisher Scientific. (2011). Thermo Scientific TVA1000B Toxic Vapor Analyzer.

Retrieved December 2011 from

http://www.fishersci.com/ecomm/servlet/fsproductdetail_10652_6471343_29104_-1_0

.

U.S. Department of Energy (U.S. DOE). (2011). Refinery Capacity 2011 . Energy Information

Administration, June 24, 2011. Available at http ://www.eia.gov/petroleum/refinerycapacity/

.

U.S. Department of Labor, Bureau of Labor Statistics (BLS). (2010). May 2009 National

Industry-Specific Occupational Employment and Wage Estimates: Sectors 31, 32, and 33 -

Manufacturing . May 14, 2010. Available at http:/ /www.bls.gov/oes/2009/may/naics2_31-

33.htm

.

U.S. Environmental Protection Agency (EPA). (1995). Protocol for Equipment Leak Emission

Estimates . Office of Air Quaility Planni ng and Standards. November 1995.

U.S. Environmental Protection Agency (EPA). (1998). Locating and Estimating Air Emissions

from Sources of Benzene . Office of Air Quality Planni ng and Standards. EPA-454/R-98-011.

June 1998.

U.S. Environmental Protection Agency (EPA). (2002). EPA Air Pollution Control Cost Manual

Section 1 Chapter 2. Sixth Edition . Office of Air Quality Planning and Standards.

EPA/452/B-02-001. January 2002.

U.S. Environmental Protection Agency (EPA). (2011). Petroleum Refinery Database, based on

Refinery Information Collection Request (ICR) for Calendar Year 2010. March 31, 2011.

Docket ID No. EPA-HQ-OAR-2010-0682.

Whitt, Daryl J. (1991). Impacts From the Control of VHAP Em issions from Equipment Leaks in

non-SOCMI Process Units for the HON . Radian Corporation. Docket No. A-90-20,

Document No. II-B-7.

Wilwerding, Joseph. (2007). Refinery Plug Moni toring Data from the National Enforcement

Investigations Center. Transmitted via email to Karen Rackley. June 14, 2007. Docket Item

No. EPA-HQ-OAR-2006-0699-0072.Attachment 1Based on data inRefinery Capacity 2010(U.S. DOE, 2011) and the analysis of amendments to 40 CFR part 60, subpart GGG:Number of process units in average small refinery: Number of process units in average large refinery:0.9 Crude Distillation 1 Crude Distillation0.1 Alkylation (sulfuric acid) 0.4 Alkylation (sulfuric acid)0.1 Alkylation (HF) 0.4 Alkylation (HF)0.5 Catalytic Reforming 1.1 Catalytic Reforming0.1 Hydrocracking 0.5 Hydrocracking1.5 Hydrotreating/Hydrorefining 3.7 Hydrotreating/Hydrorefining0.3 Catalytic Cracking 0.9 Catalytic Cracking0.03 Thermal Cracking (visbreaking) 0.02 Thermal Cracking (visbreaking)0.1 Thermal Cracking (coking) 0.6 Thermal Cracking (coking)0.2 Hydrogen Plant 0.4 Hydrogen Plant0.7 Asphalt Plant 0.4 Asphalt Plant1 Product Blending 1 Product Blending0.7 Sulfur Plant 1.3 Sulfur Plant0.6 Vacuum Distillation 0.9 Vacuum Distillation2 Full-Range Distillation 3 Full-Range Distillation0.3 Isomerization 0.6 Isomerization0.2 Polymerization 0.2 Polymerization0.05 MEK Dewaxing 0.05 MEK Dewaxing0.2 Other Lube Oil Processes 0.1 Other Lube Oil Processes0.08 Aromatics 0.2 AromaticsChemicalManufacturingLeakFrequencies(UsedtocalculateRepairCosts)Type of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisPump Seals* Light-liquid service 2.42Calculated using table 1 of Revised MACT floor, RegulatoryAlternatives, and Nationwide Impacts for Equipment Leaksat Chemical Manufacturing Facilities MON Memorandum5/5/2003 and TABLE 5-4. EQUATIONS RELATINGAVERAGE LEAK RATE TO FRACTION LEAKING ATSOCMI UNITS of the Protocol for Equipment Leak EmissionEstimates. Calculation of this value shown in thisattachment.0.23Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment EValves* Gas/vapor service 0.33Set equal to the Subsequent Leak Frequency (Calculated aleak frequency of 0.22 using procedure similar to pumpsabove; however, this value was not used because it is lessthan the Subsequent Leak Frequency)0.33Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment E* Light-liquid service 0.33Set equal to the Subsequent Leak Frequency (Calculated aleak frequency of 0.22 using procedure similar to pumpsabove; however, this value was not used because it is lessthan the Subsequent Leak Frequency)0.33Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment EConnectors* Flanges - gas/vapor N/AN/A* Flanges - light liquid N/AN/AAgitators* Light-liquid service 2.42 Same as pump seals0.23 Same as pump sealsOELN/AN/ABaselineAttachment2‐Page1ChemicalManufacturingLeakFrequencies(UsedtocalculateRepairCosts)Type of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisValves* Gas/vapor service 7.24Sum of Initial Leak Frequency at 10,000 ppm (Baseline; seeabove) and Initial Leak Frequency at 500 ppm(Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment E)0.51Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment E* Light-liquid service 4.84Sum of Initial Leak Frequency at 10,000 ppm (Baseline; seeabove) and Initial Leak Frequency at 500 ppm(Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment E)0.51Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment EType of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisPump Seals* Light-liquid service 13.48Sum of Initial Leak Frequency at 10,000 ppm (Baseline; seeabove) and Initial Leak Frequency at 1,000 ppm(Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment E)0.26Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment EType of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisConnectors* Flanges - gas/vapor 0.36Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment E0.36Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment E* Flanges - light liquid 0.36Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment E0.36Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment EOption 1 for PumpsOption 1 for ConnectorsOption 1 for ValvesAttachment2‐Page2ChemicalManufacturingLeakFrequencies(UsedtocalculateRepairCosts)Type of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisValves* Gas/vapor service 12.24Sum of Initial Leak Frequency at 10,000 ppm (Baseline; seeabove), Initial Leak Frequency at 500 ppm (Memorandum:Final Impacts Analysis for Regulatory Options for EquipmentLeaks of VOC in the SOCMI, Attachment E), and Initial LeakFrequency at 100 ppm of 5.00% (Calculation of this valueshown in this attachment)0.61= Subsequent Leak Frequency for Average Refinery Valves,100 ppm (Semiannual monitoring) / Subsequent LeakFrequency for Average Refinery Valves, 500 ppm(Semiannual monitoring) x Subsequent Leak Frequency forChemical Manufacturing Valves, 500 ppm (Semiannualmonitoring)* Light-liquid service 8.07Sum of Initial Leak Frequency at 10,000 ppm (Baseline; seeabove), Initial Leak Frequency at 500 ppm (Memorandum:Final Impacts Analysis for Regulatory Options for EquipmentLeaks of VOC in the SOCMI, Attachment E), and Initial LeakFrequency at 100 ppm of 3.22% (Calculation of this valueshown in this attachment)0.61= Subsequent Leak Frequency for Average Refinery Valves,100 ppm (Semiannual monitoring) / Subsequent LeakFrequency for Average Refinery Valves, 500 ppm(Semiannual monitoring) x Subsequent Leak Frequency forChemical Manufacturing Valves, 500 ppm (Semiannualmonitoring)Type of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisPump Seals* Light-liquid service 18.43Sum of Initial Leak Frequency at 10,000 ppm (Baseline; seeabove), Initial Leak Frequency at 1,000 ppm (Memorandum:Final Impacts Analysis for Regulatory Options for EquipmentLeaks of VOC in the SOCMI, Attachment E), and Initial LeakFrequency at 500 ppm of 4.95% (Calculation of this valueshown in this attachment)0.33= Subsequent Leak Frequency for Chemical ManufacturingPumps, 1,000 ppm (Monthly monitoring) x Subsequent LeakFrequency for Refinery Pumps, 500 ppm (Quarterlymonitoring) / Subsequent Leak Frequency for RefineryPumps, 1,000 ppm (Quarterly monitoring)Option 2 for PumpsOption 2 for ValvesAttachment2‐Page3ChemicalManufacturingLeakFrequencies(UsedtocalculateRepairCosts)Type of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisOEL0.90Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in the SOCMI,Attachment K0.45Assume that since an instrument reading of 500 ppm orgreater means that the OEL is out of compliance,owners/operators will be more diligent about ensuring thatcaps and plugs are replaced properly after being removed tocollect samples. This increased diligence is expected tolead to a reduction in leaks.OEL MonitoringAttachment2‐Page4RefineryLeakFrequencies(UsedtocalculateRepairCosts)Type of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisPump Seals* Light-liquid service 0.88Set equal to the Subsequent Leak Frequency0.88Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in PetroleumRefineries, Attachment DValves* Gas/vapor service 1.18Set equal to the Subsequent Leak Frequency1.18Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in PetroleumRefineries, Attachment D* Light-liquid service 1.38Set equal to the Subsequent Leak Frequency1.38Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in PetroleumRefineries, Attachment DConnectors* Flanges - gas/vapor N/AN/A* Flanges - light liquid N/AN/AAgitators* Light-liquid service 0.88 Same as pump seals0.88 Same as pump sealsOELN/AN/AType of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisValves* Gas/vapor service 5.95Sum of Initial Leak Frequency at 10,000 ppm (see above)and Initial Leak Frequency at 500 ppm (Memorandum: FinalImpacts Analysis for Regulatory Options for EquipmentLeaks of VOC in Petroleum Refineries, Attachment E)1.91Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in PetroleumRefineries, Attachment D* Light-liquid service 6.30Sum of Initial Leak Frequency at 10,000 ppm (see above)and Initial Leak Frequency at 500 ppm (Memorandum: FinalImpacts Analysis for Regulatory Options for EquipmentLeaks of VOC in Petroleum Refineries, Attachment E)1.97Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in PetroleumRefineries, Attachment DBaselineOption 1 for ValvesAttachment2‐Page5RefineryLeakFrequencies(UsedtocalculateRepairCosts)Type of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisPump Seals* Light-liquid service 3.31Sum of Initial Leak Frequency at 10,000 ppm (see above)and Initial Leak Frequency at 1,000 ppm (Memorandum:Final Impacts Analysis for Regulatory Options for EquipmentLeaks of VOC in Petroleum Refineries, Attachment E)0.98Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in PetroleumRefineries, Attachment DType of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisConnectors* Flanges - gas/vapor 1.70Protocol for Equipment Leak Emission Estimates, USEPA,November 1995 (EPA-453/R-95-017), Table G-20.81Average Percent Leaking G and LL Connectors, 500 ppm(API Data, Quarterly Monitoring (Memorandum: FinalImpacts Analysis for Regulatory Options for EquipmentLeaks of VOC in Petroleum Refineries, Attachment C)) x 4quarters/year x 0.9 (10% repeat leakers)* Flanges - light liquid 1.70Protocol for Equipment Leak Emission Estimates, USEPA,November 1995 (EPA-453/R-95-017), Table G-20.81Average Percent Leaking G and LL Connectors, 500 ppm(API Data, Quarterly Monitoring (Memorandum: FinalImpacts Analysis for Regulatory Options for EquipmentLeaks of VOC in Petroleum Refineries, Attachment C)) x 4quarters/year x 0.9 (10% repeat leakers)Option 1 for PumpsOption 1 for ConnectorsAttachment2‐Page6RefineryLeakFrequencies(UsedtocalculateRepairCosts)Type of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisValves* Gas/vapor service 14.73Sum of Initial Leak Frequency at 10,000 ppm (Baseline; seeabove), Initial Leak Frequency at 500 ppm (Memorandum:Final Impacts Analysis for Regulatory Options for EquipmentLeaks of VOC in Petroleum Refineries, Attachment E), andInitial Leak Frequency at 100 ppm of 8.78% (Calculation ofthis value shown in this attachment)1.28Estimated subsequent leak frequency for refinery gas/vaporvalves at 500 ppm to be 2.45% based on curve defined byleak frequencies at other leak definitions (see Memorandum:Final Impacts Analysis for Regulatory Options for EquipmentLeaks of VOC in Petroleum Refineries, Attachment D).Since this value is greater than 2%, quarterly monitoringwould be required.Subsequent Leak Frequency, 100 ppm (QuarterlyMonitoring) = Subsequent Leak Frequency, 500 ppm(Quarterly Monitoring) / Subsequent Leak Frequency, 500ppm (Semiannual Monitoring) x Subsequent LeakFrequency, 100 ppm (Semiannual Monitoring)* Light-liquid service 15.14Sum of Initial Leak Frequency at 10,000 ppm (Baseline; seeabove), Initial Leak Frequency at 500 ppm (Memorandum:Final Impacts Analysis for Regulatory Options for EquipmentLeaks of VOC in Petroleum Refineries, Attachment E), andInitial Leak Frequency at 100 ppm of 8.83% (Calculation ofthis value shown in this attachment)1.17Estimated subsequent leak frequency for refinery light liquidvalves at 500 ppm to be 2.24% based on curve defined byleak frequencies at other leak definitions (see Memorandum:Final Impacts Analysis for Regulatory Options for EquipmentLeaks of VOC in Petroleum Refineries, Attachment D).Since this value is greater than 2%, quarterly monitoringwould be required.Subsequent Leak Frequency, 100 ppm (QuarterlyMonitoring) = Subsequent Leak Frequency, 500 ppm(Quarterly Monitoring) / Subsequent Leak Frequency, 500ppm (Semiannual Monitoring) x Subsequent LeakFrequency, 100 ppm (Semiannual Monitoring)Option 2 for ValvesAttachment2‐Page7RefineryLeakFrequencies(UsedtocalculateRepairCosts)Type of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisPump Seals* Light-liquid service 4.57Sum of Initial Leak Frequency at 10,000 ppm (Baseline; seeabove), Initial Leak Frequency at 1,000 ppm (Memorandum:Final Impacts Analysis for Regulatory Options for EquipmentLeaks of VOC in Petroleum Refineries, Attachment E), andInitial Leak Frequency at 500 ppm of 1.26% (Calculation ofthis value shown in this attachment)1.26= Subsequent Leak Frequency, 1,000 ppm (MonthlyMonitoring) / Subsequent Leak Frequency, 1,000 ppm(Quarterly Monitoring) x Average Percent Leaking Pumps,500 ppm (API Data, Quarterly Monitoring)Type of EquipmentInitial LeakFrequency(%)BasisSubsequentLeakFrequency(%)BasisOEL2.30Memorandum: Final Impacts Analysis for RegulatoryOptions for Equipment Leaks of VOC in PetroleumRefineries, Attachment K1.15Assume that since an instrument reading of 500 ppm orgreater means that the OEL is out of compliance,owners/operators will be more diligent about ensuring thatcaps and plugs are replaced properly after being removed tocollect samples. This increased diligence is expected tolead to a reduction in leaks.OEL MonitoringOption 2 for PumpsAttachment2‐Page8Table 1: Resulting Emission Rates and Program Efficiencies for CMA data.ComponentLeakDefinition(ppmv)No.Monitored No.LeakingInitialLeakRate(%)Pumps500 121 001000 683 13 1.92000 82 00G Valves500 20766 104 0.5 0.505000 374 39 10.435000 161 00 0.0010000 662 13 1.9610000 7062 41 0.58 0.581Valves500 62299 312 0.5LL Valves500 41533 208 0.5 0.505000 483 005000 322 00 0.0010000 21185 123 0.5810000 14123 82 0.58 0.581Source: Memo: Revised MACT floor, Regulatory Alternatives, and Nationwide Impacts for Equipment Leaks at Chemical ManufacturingFacilities MON. From Brenda Shine, Melissa Icenhour, and David Randall 5/5/2003InitialLeakFreq‐10,000ppmAttachment2‐Page9UncontrolledEmissions NEIC Factor1.71ALR @ 500ppm(kg/hr/source)Leakfraction @10,000 ppmLeakfraction @10,000 ppm(%)AverageUncontrolledLeak RateAverageUncontrolledEmissionFactor(kg/hr/source)GasValves0.000394 0.00339 0.339 0.501974818 5.22E-04Light Liquid Va0.000430 0.00292 0.292 0.467353214 5.86E-04Valves (usingL0.0004297642.92E-03 2.92E-010.46735321 0.000585944ALR @ 1,000ppm(kg/hr/source)Leakfraction @10,000 ppmLeakfraction @10,000 ppm(%)ALR @ 5,000ppmLeak fraction@ 10,000 ppmLeakfraction @10,000ppm (%)AverageUncontrolled LeakRateAverageUncontrolledEmission Factor(kg/hr/source)Pumps 0.0040420280.00892512 0.89251157 0.03715172 0.146882176 14.68822 4.3323540.012297649Rate for costsALR @ 500ppm(kg/hr/source)Leakfraction @10,000 ppmLeakfraction @10,000 ppm(%)AverageUncontrolledLeak RateValves0.0002621.03E-03 1.03E-010.22303044ALR @ 1,000ppm(kg/hr/source)Leakfraction @10,000 ppmLeakfraction @10,000 ppm(%)ALR @ 5,000ppm(kg/hr/source)Leak fraction@ 10,000 ppmLeakfraction @10,000ppmAverageUncontrolled LeakRatePumps0.002550.00266393 0.26639344 0.02226 0.084833333 8.483333 2.420517Based on 5-46 of Equipment Leaks Protocol Equations and Revised MACT Floor, reg alternative, and nationwide impacts for equipmentleaks... memo. May 5 2003InitialLeakFreq‐10,000ppmAttachment2‐Page10Chemical Manufacturing Models - Gas Valves - From 500 to 100EPA's SOCMI dataProtocol nocontrol %leakersaleakconcentrationPercentleakers whenmonitoredassumed typicalscreening value in therange to the nextthresholda10 261039.7100 17.51001.05 Option232500 13.65000.87 Baseline6651000 12100013302000 10.5200029905000 8.75000665010000 7.5100002320050000 5.55000066500100000 4.5100000397000397001000000DistributionleakconcentrationPercentleakers whenmonitored5000.7210000.6320000.5250000.45500000.331000000.27Leak Freq calcs100 500Baseline0.51Option 8, Initial5.0Option 8, Subsequent 0.61aFrom figure B-3-3 in the Protocol documentEmissions New CalcsAttachment2- Page 11Chemical Manufacturing Models - Gas ValvesUse correlation equation to estimate emissions for uncontrolled scenario1 - No control2 - Baseline before control 3 - Baseline controlledGV default zero 6.60E-07Average aboveInstantaneous500LeakDefinitionRange ofconcentrationsPercent ofvalues inrangeaAveragescreening valuein rangeEmission rate,kg/hr (per 100valves)Percent ofvalues inrangeaEmission rate,kg/hr (per 100valves)Percent ofvalues inrangeaEmission rate,kg/hr (per 100valves)<1074.00.0000488484.9 0.00005604 85.3 0.0000562810 10 to 100 8.539.7 0.0003959.8 0.000454 9.8 0.000456100 100 to 500 3.9232 0.0008474.5 0.000972 4.5 0.000976500 500 to 1000 1.6665 0.0008720.10 0.000056 0.05 0.0000281000 1000 to 2000 1.5 1330 0.0014960.10 0.000095 0.05 0.0000482000 2000 to 5000 1.8 2990 0.0036420.11 0.000232 0.06 0.0001165000 5000 to 10000 1.2 6650 0.0048790.08 0.000311 0.04 0.00015510000 10000 to 50000 2.0 23200 0.024207 Pegged value 0.13 0.001543 0.06 0.00077150000 50000 to 100000 1.0 66500 0.0303500.11 0.06 0.001935 0.03 0.000967100000 >100000 4.5 310000 0.5236160.495 0.29 0.033375 0.14 0.016688Emission rateper valveEmission rateper valveEmission rateper valve0.00590 0.005620.000390.000203Emission rate estimated using (500 ppm)(10,000 ppm)(10,000 ppm)ALR equation 0.00600.000500.00032Leak Frequency CalculationsBaseline Option<1074.0<10 85.289.110 10 to 100 8.510 to 100 9.810.2100 100 to 500 3.90.61100 to 500 4.50.14500 500 to 1000 1.60.51500 to 1000 0.060.061000 1000 to 2000 1.51000 to 2000 0.060.052000 2000 to 5000 1.82000 to 5000 0.070.065000 5000 to 10000 1.25000 to 10000 0.040.0410000 10000 to 50000 2.010000 to 50000 0.070.0750000 50000 to 100000 1.050000 to 100000 0.040.03100000 >100000 4.5>100000 0.170.16Emissions New CalcsAttachment2- Page 12Chemical Manufacturing Models - Gas ValvesUse correlation equation to estimate controlled emissions (for HON program)4 - Option 8 prior to control5 - Option 1 controlledGV default zero 6.60E-07Average above, assume half repairs are successful b/t 500 and1100LeakDefinitionRange ofconcentrationsPercent ofvalues inrangeAveragescreening valuein rangeEmission rate, kg/hr(per 100 valves) whenmonitoredEmissionrate afterrepair, kg/hrPercent ofvalues inrangeaEmission rate,kg/hr (per 100valves)<10 88.80.0000586 0.000066 89.3 0.000058910 10 to 100 10.239.7 0.00047410.3 0.000477100 100 to 500 0.23232 0.0000510.16 0.000034500 500 to 1000 0.10665 0.0000520.05 0.0000261000 1000 to 2000 0.091330 0.0000900.04 0.0000452000 2000 to 5000 0.112990 0.0002180.05 0.0001095000 5000 to 10000 0.076650 0.0002920.04 0.00014610000 10000 to 50000 0.1223200 0.0014480.06 0.00072450000 50000 to 100000 0.0666500 0.0018160.03 0.000908100000 >100000 0.27310000 0.0313270.13 0.015663Emission rate pervalveEmission rateper valve0.000358 0.000000660.000182Average emission rateduring monitoring period 0.000179Emissions New Calcs Attachment2- Page 13Chemical Manufacturing Models - Light Liquid Valves - from 500 to 100EPA's SOCMI dataProtocol nocontrol %leakersaleakconcentrationPercentleakers whenmonitoredassumed typicalscreening value in therange to the nextthresholda10 181039.7100 111001.05 Option232500 8.55000.87 Baseline66510007100013302000 5.8200029905000 5.15000665010000 4.5100002320050000 2.95000066500100000 2.2100000397000397001000000DistributionleakconcentrationPercentleakers whenmonitored5000.8110000.6720000.5550000.49100000.43500000.281000000.21Leak Freq calcs500 10000Baseline0.27Option, Initial3.2Option, Subsequent 0.61aFrom figure B-3-4 in the Protocol documentEmissions New CalcsAttachment2- Page 14Chemical Manufacturing Models - Light Liquid ValvesUse correlation equation to estimate emissions for uncontrolled scenario1 - No control2 - Baseline before control 3 - Baseline controlledLLV default zero 4.90E-07Average aboveInstantaneous500LeakDefinitionRange ofconcentrationsPercent ofvalues inrangeaAveragescreening valuein rangeEmission rate,kg/hr (per 100valves)Percent ofvalues inrangeaEmission rate,kg/hr (per 100valves)Percent ofvalues inrangeaEmission rate,kg/hr (per 100valves)<1082.00.000040288.8 0.0000435 89.2 0.000043710 10 to 100 7.039.7 0.0008447.6 0.000914 7.6 0.000918100 100 to 500 2.5232 0.0012312.7 0.001333 2.7 0.001339500 500 to 1000 1.5665 0.0017090.2 0.000174 0.1 0.0000871000 1000 to 2000 1.2 1330 0.0023750.1 0.000242 0.1 0.0001212000 2000 to 5000 0.7 2990 0.0026430.1 0.000270 0.0 0.0001355000 5000 to 10000 0.6 6650 0.0042830.1 0.000437 0.0 0.00021810000 10000 to 50000 1.6 23200 0.030922 Pegged value 0.2 0.003154 0.1 0.00157750000 50000 to 100000 0.7 66500 0.0313140.15 0.1 0.003194 0.0 0.001597100000 >100000 2.2 310000 0.3356570.33 0.2 0.034232 0.1 0.017116Emission rateper valveEmission rateper valveEmission rateper valveEmission rate per valve 0.00411 0.004050.000440.000232Emission rate estimated using (500 ppm)(10,000 ppm)(10,000 ppm)ALR equation 0.004020.000580.00037Leak Frequency CalculationsBaseline Option<1082.0<10 89.291.610 10 to 100 7.010 to 100 7.67.8100 100 to 500 2.50.61100 to 500 2.70.14500 500 to 1000 1.50.51500 to 1000 0.10.081000 1000 to 2000 1.21000 to 2000 0.10.072000 2000 to 5000 0.72000 to 5000 0.00.045000 5000 to 10000 0.65000 to 10000 0.00.0310000 10000 to 50000 1.610000 to 50000 0.10.0950000 50000 to 100000 0.750000 to 100000 0.00.04100000 >100000 2.2>100000 0.10.12Emissions New CalcsAttachment2- Page 15Chemical Manufacturing Models - Light Liquid ValvesUse correlation equation to estimate controlled emissions (for HON program)4 - Option 1 prior to control5 - Option 1 controlledLLV default zero 4.90E-07Average above, assume half repairs are successful b/t 500 and1100LeakDefinitionRange ofconcentrationsPercent ofvalues inrangeAveragescreening valuein rangeEmission rate, kg/hr(per 100 valves) whenmonitoredEmissionrate afterrepair, kg/hrPercent ofvalues inrangeaEmission rate,kg/hr (per 100valves)<10 91.20.0000447 0.000049 91.7 0.000044910 10 to 100 7.839.7 0.0009387.8 0.000943100 100 to 500 0.24232 0.0001170.16 0.000078500 500 to 1000 0.14665 0.0001630.07 0.0000811000 1000 to 2000 0.111330 0.0002260.06 0.0001132000 2000 to 5000 0.072990 0.0002520.03 0.0001265000 5000 to 10000 0.066650 0.0004080.03 0.00020410000 10000 to 50000 0.1523200 0.0029430.08 0.00147250000 50000 to 100000 0.0766500 0.0029810.03 0.001490100000 >100000 0.21310000 0.0319480.10 0.015974Emission rate pervalveEmission rateper valveEmission rate per valve 0.000400 0.000000490.0002050.066712Average emission rate0.533356during monitoring period 0.000200-0.86658 -0.86657656vs.Emissions New CalcsAttachment2- Page 16Chemical Manufacturing Models - Pumps - from 1000 to 500EPA's SOCMI dataProtocol nocontrol %leakersaleakconcentrationPercentleakers whenmonitoredassumed typicalscreening value in therange to the nextthresholda10 445000.56 Option665100 3010000.44 Baseline1330500 21200029901000 17.1500066502000 13.210000232005000 9.850000665001000071000003970003970050000 3.510000001000002DistributionleakconcentrationPercentleakers whenmonitored50099.59100099.70200099.79500099.861000099.9650000100.00100000100.05Leak Freq calcs500 1000Baseline0.26Option, Initial (NSPS) 4.9Option, Subsequent 0.33aFrom figure B-3-2 in the Protocol documentEmissions New CalcsAttachment2- Page 17Chemical Manufacturing Models - PumpsUse correlation equation to estimate emissions for uncontrolled scenario1 - No control2 - Baseline before control 3 - Baseline controlledP default zero 7.50E-06Average aboveInstantaneous1000LeakDefinitionRange ofconcentrationsPercent ofvalues inrangeaAveragescreening valuein rangeEmission rate,kg/hr (per 100pumps)Percent ofvalues inrangeaEmission rate,kg/hr (per 100pumps)Percent ofvalues inrangeaEmission rate,kg/hr (per 100pumps)<1056.00.0004267.3 0.000504408 67.4 0.00050551910 10 to 100 14.0 39.7 0.00552416.8 0.006635 16.9 0.006649100 100 to 500 9.0232 0.01521110.8 0.018268 10.8 0.018308500 500 to 1000 3.9665 0.0156974.7 0.018852 4.7 0.0188931000 1000 to 2000 3.9 1330 0.0277890.1 0.000714 0.1 0.0003572000 2000 to 5000 3.4 2990 0.0472260.1 0.001214 0.0 0.0006075000 5000 to 10000 2.8 6650 0.0751480.1 0.001931 0.0 0.00096510000 10000 to 50000 3.5 23200 0.263017 Pegged value 0.1 0.006758 0.0 0.00337950000 50000 to 100000 1.5 66500 0.2684420.62 0.0 0.006898 0.0 0.003449100000 >100000 2.0 310000 1.272523 1.2400 0.1 0.032698 0.0 0.016349Emission rateper pumpEmission rateper pumpEmission rateper pumpEmission rate per valve 0.01991 0.019580.000940.00069Emission rate estimated using (1,000 ppm)(10,000 ppm)(10,000 ppm)ALR equation 0.00000.002330.00212Leak Frequency CalculationsBaseline Option<1056.0<10 67.470.710 10 to 100 14.010 to 100 16.817.7100 100 to 500 9.0100 to 500 10.811.4500 500 to 1000 3.90.33500 to 1000 4.70.061000 1000 to 2000 3.90.261000 to 2000 0.10.062000 2000 to 5000 3.42000 to 5000 0.10.055000 5000 to 10000 2.85000 to 10000 0.00.0410000 10000 to 50000 3.510000 to 50000 0.10.0550000 50000 to 100000 1.550000 to 100000 0.00.02100000 >100000 2.0>100000 0.00.03Emissions New CalcsAttachment2- Page 18Chemical Manufacturing Models - PumpsUse correlation equation to estimate controlled emissions (for HON program)4 - Option 9 prior to control5 - Option 9 controlledP default zero 7.50E-06Average above, assume half repairs are successful b/t 1000 and500LeakDefinitionRange ofconcentrationsPercent ofvalues inrangeAveragescreening valuein rangeEmission rate, kg/hr(per 100 pumps) whenmonitoredEmissionrate afterrepair, kg/hrPercent ofvalues inrangeaEmission rate,kg/hr (per 100pumps)<10 70.50.000528656 0.00075 70.7 0.00053023910 10 to 100 17.639.7 0.00695417.7 0.006974100 100 to 500 11.3232 0.01914611.4 0.019204500 500 to 1000 0.10665 0.0004200.07 0.0002801000 1000 to 2000 0.101330 0.0007440.05 0.0003722000 2000 to 5000 0.092990 0.0012650.05 0.0006325000 5000 to 10000 0.076650 0.0020130.04 0.00100610000 10000 to 50000 0.0923200 0.0070440.05 0.00352250000 50000 to 100000 0.0466500 0.0071890.02 0.003595100000 >100000 0.05310000 0.0340800.03 0.017040Emission rate perpumpEmission rateper pumpEmission rate per valve 0.000794 0.00000750.00053Average emission rateduring monitoring period 0.000401vs.Emission rate estimated usingALR equation 0.0005771(HON avg leak rate, kg/hr)Emissions New CalcsAttachment2- Page 19Refinery Leak FrequenciesPUMPSNew = Monthly 500, baseline = Monthly 1,0001leak range 0 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (500 ppm), % 2.16 <-- (this value for monthly monitoring)percent in range 88.057 9.784 0.472 1.079 0.433 0.061 0.113 100.000representative value default 165 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/pump) 0.000024 1.13E-03 2.65E-03 7.89E-03 2.31E-02 4.40E-02 1.31E-010.000505032Controlled estimate using average leak rate as one-half of reported leak frequency, converted to monthly monitoringleak range 0 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (500 ppm), % 2.16 <-- (this value for monthly monitoring)percent in range 88.958 9.884 0.315 0.540 0.217 0.030 0.057 100.000representative value default 165 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/pump) 0.000024 1.13E-03 2.65E-03 7.89E-03 2.31E-02 4.40E-02 1.31E-010.000321953Then determine the percent leaking at other leak definitions by assuming the same distribution of leaking pumps as reported by API.leak range0 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (1,000 ppm), %1.69 2.16 (at 1,000 ppm)percent in range88.057 9.784 0.472 1.079 0.433 0.061 0.113 100.000representative valuedefault165 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/pump)0.000024 1.13E-03 2.65E-03 7.89E-03 2.31E-02 4.40E-02 1.31E-010.000505034Then determine the percent leaking at other leak definitions by assuming the same distribution of leaking pumps as reported by API.leak range0 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (1,000 ppm), %1.69percent in range88.816 9.868 0.472 0.540 0.217 0.030 0.057 100.000representative valuedefault165 665 3,970 23,200 66,500 397,000average for values above 1,000 zeroemissions (kg/hr/pump)0.000024 1.13E-03 2.65E-03 7.89E-03 2.31E-02 4.40E-02 1.31E-010.000325915Baseline and Initial Leak Freq. Calc.leak range0 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (1,000 ppm), %0.98 1.26 (at 500 ppm)percent in range88.866 9.874 0.276 0.630 0.253 0.036 0.066Controlled, w/ leak frequency as summarized in API report equal to leak frac. (i.e., estimate emission rate when monitored, not avg. over monitoring period) convert to monthly monitoringBaseline estimate - Apply industry-based baseline-to-controlled percent leakers ratio for valves to controlled leak frequency for pumps above 1,000 ppm (adjusted to monthly monitoring).Baseline estimate - Average above 1,000 ppmAttachment2- Page 20Refinery Leak FrequenciesGAS VALVESNew = Quarterly, 100, Baseline = Semiannual, 500 (VVa to Opt7)1Controlled, with leak frequency as summarized in API report equal to leak fraction (i.e., estimate emission rate when monitored, not average over monitoring period)leak range 0 100 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (100 ppm), % 2.19percent in range 88.031 9.781 1.753 0.052 0.275 0.061 0.012 0.035 0.108representative value default 33 232 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/valve) 0.0000078 3.11E-05 1.33E-04 2.92E-04 1.11E-03 4.14E-03 9.07E-03 3.44E-020.000031202Controlled estimate using average leak rate as one-half of reported leak frequencyleak range0 100 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (100 ppm), %2.19percent in range88.752 9.861 1.169 0.026 0.138 0.031 0.006 0.018 100.000representative valuedefault33 232 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/valve)0.0000078 3.11E-05 1.33E-04 2.92E-04 1.11E-03 4.14E-03 9.07E-03 3.44E-020.000021033Baseline estimateleak range0 100 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (500 ppm), %3.28 10.050 (at 100 ppm)percent in range87.049 2.902 6.770 0.391 2.072 0.460 0.089 0.266 100.000representative valuedefault33 232 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/valve)0.0000078 3.11E-05 1.33E-04 2.92E-04 1.11E-03 4.14E-03 9.07E-03 3.44E-020.000159544Baseline estimate - average above 10,000 ppmleak range0 100 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (500 ppm), %3.28 10.050 (at 100 ppm)percent in range88.524 2.951 6.885 0.196 1.036 0.230 0.044 0.133 100.000representative valuedefault33 232 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/valve)0.0000078 3.11E-05 1.33E-04 2.92E-04 1.11E-03 4.14E-03 9.07E-03 3.44E-020.000088415Baseline and Initial Leak Freq. Calc.leak range0 100 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (500 ppm), %1.91 8.779 (at 100 ppm)percent in range88.278 2.943 6.866 0.228 1.209 0.269 0.052 0.155Attachment2- Page 21Refinery Leak FrequenciesLIGHT LIQUID VALVESNew = Quarterly, 100, Baseline = Semiannual, 500 (VVa to Opt7)1Controlled, with leak frequency as summarized in API report equal to leak fraction (i.e., estimate emission rate when monitored, not average over monitoring period)leak range0 100 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (100 ppm), %2.01percent in range88.192 9.799 1.599 0.070 0.226 0.074 0.010 0.031 100.000representative valuedefault33 232 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/valve)0.0000078 3.11E-05 1.33E-04 2.92E-04 1.11E-03 4.14E-03 9.07E-03 3.44E-020.000029522Controlled estimate using average leak rate as one-half of reported leak frequencyleak range0 100 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (100 ppm), %2.01percent in range88.856 9.873 1.066 0.035 0.113 0.037 0.005 0.016 100.000representative valuedefault33 232 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/valve)0.0000078 3.11E-05 1.33E-04 2.92E-04 1.11E-03 4.14E-03 9.07E-03 3.44E-020.000020153Baseline estimateleak range0 100 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (500 ppm), %3.38 3.376 (at 500 ppm)percent in range86.961 2.899 6.764 0.573 1.857 0.609 0.079 0.259 100.000representative valuedefault33 232 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/valve)0.0000078 3.11E-05 1.33E-04 2.92E-04 1.11E-03 4.14E-03 9.07E-03 3.44E-020.000160244Baseline estimate - average above 10,000 ppmleak range0 100 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (500 ppm), %3.38 3.376 (at 500 ppm)percent in range88.481 2.949 6.882 0.287 0.928 0.305 0.039 0.129 100.000representative valuedefault33 232 665 3,970 23,200 66,500 397,000zeroemissions (kg/hr/valve)0.0000078 3.11E-05 1.33E-04 2.92E-04 1.11E-03 4.14E-03 9.07E-03 3.44E-020.000088765Baseline and Initial Leak Freq. Calc.leak range0 100 500 1,000 10,000 50,000 100,000 1,000,000leak frequency (500 ppm), %1.97 8.832 (at 100 ppm)percent in range88.227 2.941 6.862 0.334 1.083 0.355 0.046 0.151Attachment2- Page 22

# Attachment 3 - Emission Factors

SOCMI

Uncontrolled Emission Rates

(kg/hr/piece of

e q ui p ment )

Pump Seals LL 1.23E-02

Valves G/V 5.22E-04

Valves LL 5.86E-04

Agitators LL 1.23E-02

Connectors – Flanges G/V 3.07E-04

Connectors – Flanges G/LL 3.07E-04

Compressor Vent 2.28E-01

Open-ended Valves 1.70E-03

Sampling Connections 1.50E-02

PRV – Disks 1.04E-01



# Baseline Emission Rates

(kg/hr/piece of

e q ui p ment )

Pump Seals LL 2.51E-03

Valves G/V 3.52E-04

Valves LL 3.90E-04

Agitators LL 2.51E-03

Connectors – Flanges G/V 3.07E-04

Connectors – Flanges G/LL 3.07E-04

Compressor Vent 2.28E-02

Open-ended Valves 3.33E-05



# Valves Option 1

(kg/hr/piece of

e q ui p ment )

Valves G/V 2.03E-04

Valves LL 2.32E-04



# V l O ti 2 Calculated using initial leak rates of pumps and valves from facility data used in calculating MACT floors for the MON

(Table A1) and the equations in Table 5-4 from the Protocol for Equipment Leak Estimates. See sample calculation for

Model 1 pumps in light liquid service.



# See Uncontrolled basis.

Based on Table 2-1 of Equipment Leaks Protocol. 10 percent of uncontrolled compressor seal value

Based on Memorandum: Analysis of Additional Data on Leaks from Open-Ended Lines



# Basis Based on EPA SOCMI data for Pumps at 10,000 ppm

Based on EPA SOCMI data for Gas Valves at 500 ppm

Based on EPA SOCMI data for LL Valves at 500 ppm Based on on SOCMI average emission factors in Table 2-1 of the Protocol for Equipment Leak Emission Estimates Based on Equipment Leak Protocol Table 5-4 and MON leak rate data for connectors at 500 ppm. NEIC Factor applied.

((0.047*0.360*1.71/100)+1.7E-5)*Equipment Count*8760

Where 1.71 is the NEIC factor, 0.360 is the leak frequency of connectors at 500 ppm from MON data, and 0.047 and

1.7E-5 are Table 5-4 values. 

# Basis

Basis

Based on EPA SOCMI data for Pumps at 10,000 ppm

Based on EPA SOCMI data for Gas Valves at 10,000 ppm

Based on EPA SOCMI data for LL Valves at 10,000 ppm



# Attachment 3

‐ Page 1 V alves Option 2

(kg/hr/piece of

e q ui p ment )

Valves G/V 1.82E-04

Valves LL 2.05E-04



# Pumps Option 1

(kg/hr/piece of

e q ui p ment )

Pump Seals LL 6.95E-04



# Pumps Option 2

(kg/hr/piece of

e q ui p ment )

Pump Seals LL 5.31E-04

Connectors Option 1



# (kg/hr/piece of

e q ui p ment )

Connectors – Flanges G/LL 1.62E-04 Based on EPA SOCMI data for Connectors at 500 ppm 

# Basis

Based on EPA SOCMI data for Gas Valves at 100 ppm

Based on EPA SOCMI data for LL Valves at 100 ppm



# Basis

Based on EPA SOCMI data for Pumps at 500 ppm 

# Basis

Based on EPA SOCMI data for Pumps at 1,000 ppm



# Basis



# Attachment 3

‐ Page 1

# Refinery Models

Uncontrolled Emission Rates

(kg/hr/piece of

e q ui p ment )

Pump Seals LL 

# 1.05E

‐ 03

Valves G/V 

# 3.71E

‐ 04

Valves LL 

# 3.75E

‐ 04

Agitators LL 

# 1.05E

‐ 03

Connectors – Flanges G/V 

# 1.04E

‐ 04

Connectors – Flanges G/LL 

# 8.46E

‐ 05

Compressor Vent 

# 6.36E

‐ 01

Open-ended Valves 

# 2.30E

‐ 03

Sampling Connections 

# 1.50E

‐ 02

PRV – Disks 

# 1.60E

‐ 01

Baseline Emission Rates

(kg/hr/piece of

e q ui p ment )

Pump Seals LL 

# 7.11E

‐ 04

Valves G/V 

# 2.24E

‐ 04

Valves LL 

# 2.23E

‐ 04

Connectors – Flanges G/V 

# 1.04E

‐ 04

Connectors – Flanges G/LL 

# 8.46E

‐ 05

Compressor Vent 

# 3.18E

‐ 02

Open-ended Valves 

# 7.34E

‐ 05

Valves Option 1

(kg/hr/piece of

e q ui p ment )

Valves G/V 8.85E-05

Valves LL 8.88E-05



# Valves Option 2

(kg/hr/piece of

e q ui p ment )

Valves G/V 2.10E-05

Valves LL 2.02E-05



# Pumps Option 1

(k /h / i f Basis

Memorandum: Final Impacts Analysis for Regulatory Options for Equipment Leaks of VOC in Petroleum Refineries Basis

Based on on Refinery average emission factors in Table 2-2 of the Protocol for Equipment Leak Emission Estimates Memorandum: Final Impacts Analysis for Regulatory Options for Equipment Leaks of VOC in Petroleum Refineries

Based on on Refinery average emission factors in Protocol for Equipment Leak Emission Estimates

Memorandum: Final Impacts Analysis for Regulatory Options for Equipment Leaks of VOC in Petroleum Refineries

Basis

Based on on Refinery average emission factors in Protocol for Equipment Leak Emission Estimates

Basis

Based on on Refinery average emission factors in Protocol for Equipment Leak Emission Estimates



# Attachment 3

‐ Page 2 (kg/hr/piece of

e q ui p ment )

Pump Seals LL 

# 3.26E

‐ 04

Pumps Option 2

(kg/hr/piece of

e q ui p ment )

Pump Seals LL 

# 3.22E

‐ 04

Connectors Option 1



# (kg/hr/piece of

e q ui p ment )

Connectors – Flanges G/V 3.95E-05

Connectors – Flanges G/LL 2.77E-05 Basis Based on on Refinery average emission factors in Protocol for Equipment Leak Emission Estimates

Based on on Refinery average emission factors in Protocol for Equipment Leak Emission Estimates

Basis

Based on on Refinery average emission factors in Protocol for Equipment Leak Emission Estimates Basis



# Attachment 3

‐ Page 2

# Table A1. Resulting Emission Rates and Program Efficiencies for CMA Data



# Leak Definition

(ppmv) No. Monitored No. Leaking I n iti a l

Leak

Rate (%)

Pumps 500 121 0 0

1000 683 13 1.9

2000 82 0 0

5000 374 39 10.43

10000 662 13 1.96

Valves 500 62299 312 0.5

5000 483 0 0

10000 21185 123 0.58

Sample calculation for Model 1 pumps in light liquid service is as follows: Reference: Revised MACT Floor, Regulatory Alternatives, and Nationwide Impacts for Equipment Leaks at Chemical Manufacturing Fa cilities

MON memorandum



# Step 1: Calculate the LKFRAC % @ 10,000 ppm using 1,000 leak definition

ALR @ 1,000 ppm (kg/hr/source) = Equation 1

(0.11 × LKFRAC @1,000 ppm) + 4.6E-04 Table 5-4 Equipment Leak Protocol

LKFRAC @ 1,000 ppm = Equation 2

(NEIC Factor x 1.9 % Initial Leak Rate of Pumps LL @ 1,000ppm)/100

Substitute the leak frequency back into Equation 1.

ALR @ 1,000 ppm (kg/hr/source) =

0.11 × (NEIC Factor x 1.9 % Initial Leak Rate of Pumps LL @ 1,000ppm)/100 × 4.6E-04

ALR @ 10,000 ppm (kg/hr/source) = Equation 3

(0.24 × LKFRAC @ 10,000 ppm) + 1.9E-03 Table 5-4 Equipment Leak Protocol

Rearrange Equation 3 and substitute ALR@ 10,000 ppm with ALR at 1,000 ppm

LKFRAC % @ 10,000 ppm =

[(ALR @ 1 000 ppm (kg/hr/source)

- 1 9E

- 03 )/0 24] × 100

Attachment 3

‐ Page 3 

# LKFRAC % @ 10,000 ppm =

[(ALR @ 1,000 ppm (kg/hr/source) - 1.9E-03)/0.24] × 100

Substitute Equation 3 into Equation 4

LKFRAC % @ 10,000 ppm = Equation 4

[(0.11 × (((NEIC Factor x 1.9 % Initial Leak Rate of Pumps LL @ 1,000ppm)/100 × 4.6E-04) - 1.9E-03)/0.24] × 100

Step 2: Calculate the LKFRAC % @ 10,000 ppm using 5,000 leak definition

Attachment 3

‐ Page 3Attachment 4UncontrolledType of EquipmentPump Sealskg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr* Light-liquid service 15 1,616 3,562 40 4,309 9,500 56 6,033 13,300 8 74 162 69 635 1,401 176 1,621 3,573* Heavy-liquid service 0 -- -- 5 -- -- 36 -- -- 8 -- -- 61 -- -- 246 -- --Valves* Gas/vapor service 77 352 776 414 1,891 4,170 1,379 6,300 13,890 75 244 538 1,178 3,833 8,450 3,263 10,617 23,406* Light-liquid service 380 1,950 4,300 1,179 6,052 13,342 1,980 10,163 22,406 251 824 1,816 2,428 7,970 17,570 5,857 19,225 42,385* Heavy-liquid service 0 -- -- 71 -- -- 1,272 -- -- 216 -- -- 1,719 -- -- 3,163 -- --Connectors* Flanges - gas/vapor0 0 0 0 0 0 0 0 0 164 150 3302,333 2,129 4,693 7,641 6,972 15,371* Flanges - G/LL 731 1,966 4,334 2,662 7,159 15,782 7,410 19,927 43,932 555 411 906 4,644 3,440 7,584 13,379 9,911 21,849* Flanges - HL0 0 0 0 0 0 0 0 0 454 04,186 0 7,725 0Agitators* Light-liquid service0 0 0 3 323 712 0 0 0 0 0 0 0 0 0 0 0 0* Heavy-liquid service 0 -- -- 3 -- -- 0 -- --000000000Compressor Vent00023,995 8,806 8 15,978 35,226 2 11,143 24,565 19 105,856 233,372 31 172,712 380,765Open-ended Valves33 491 1,083 141 2,100 4,629 424 6,314 13,920 39 786 1,732 238 4,795 10,572 902 18,173 40,066Sampling Connections8 1,051 2,317 35 4,599 10,139 106 13,928 30,707 10 1,314 2,897 70 9,198 20,278 159 20,893 46,060Pressure Relief Devices* Disks2 1,822 4,017 45 40,997 90,382 76 69,239 152,646 9 12,614 27,810 79 110,726 244,110 119 166,790 367,710* Disk holders, valves,etc.2 -- -- 45 -- -- 76 -- -- 90 790 1190TOTAL (lb/yr)20,390157,464326,02760,758548,030941,185TOTAL (tpy)10.1949978.73175163.013330.37886274.0151470.5923CountEmissionsCountEmissionsCountEmissionsCountEmissionsCountEmissionsCountEmissionsModel 1Model 2Model 3Model 4Model 5Model 6Attachment 4 - Page 1BaselineType of EquipmentPump Sealskg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr* Light-liquid service 15 330 728 40 880 1,940 56 1,232 2,717 8 50 110 69 430 948 176 1,097 2,418* Heavy-liquid service 0 -- -- 5 -- -- 36 -- -- 8 -- -- 61 -- -- 246 -- --Valves* Gas/vapor service 77 237 523 414 1,277 2,814 1,379 4,252 9,374 75 147 324 1,178 2,310 5,092 3,263 6,398 14,106* Light-liquid service 380 1,299 2,863 1,179 4,030 8,884 1,980 6,767 14,920 251 491 1,082 2,428 4,750 10,471 5,857 11,457 25,259* Heavy-liquid service 0 -- -- 71 -- -- 1,272 -- -- 216 -- -- 1,719 -- -- 3,163 -- --Connectors* Flanges - gas/vapor0 0 0 0 0 0 0 0 0 164 150 3302,333 2,129 4,693 7,641 6,972 15,371* Flanges - G/LL 731 1,966 4,334 2,662 7,159 15,782 7,410 19,927 43,932 555 411 906 4,644 3,440 7,584 13,379 9,911 21,849* Flanges - HL0 0 0 0 0 0 0 0 0 454 04,186 0 7,725 0Agitators* Light-liquid service0 0 0 3 66 146 0 0 0 0 -- -- 0 -- -- 0 -- --* Heavy-liquid service 0 -- -- 3 -- -- 0 -- -- 0 -- -- 0 -- -- 0 -- --Compressor Vent0 0 0 2 399 881 81,598 3,523 2 557 1,228 19 5,293 11,669 31 8,636 19,038Open-ended Valves33 10 21 141 41 91 424 124 273 39 25 55 238 153 337 902 580 1,278Sampling Connections8 0 0 35 0 0 106 0 0 10 0 0 70 0 0 159 0 0Pressure Relief Devices* Disks 2 0 0 45 0 0 760 0 9 0 0 79 0 0 119 0 0* Disk holders, valves,etc. 2 -- -- 45 -- -- 76 -- -- 9 0 79 0 119 0TOTAL (lb/yr) 8,470 30,538 74,737 4,036 40,795 99,319TOTAL (tpy) 4.234773 15.26886 37.36873 2.018204 20.39728 49.65975TOTAL REDUCTION (lb/yr) 11,920 126,926 251,289 56,721 507,236 841,865TOTAL REDUCTION (tpy) 5.960215 63.46289 125.6445 28.36066 253.6178 420.9325CountEmissionsCountEmissionsCountEmissionsCountEmissionsCountEmissionsCountEmissionsModel 1 Model 2 Model 3 Model 4 Model 5 Model 6Attachment 4 - Page 2Valves Option 1Type of Equipmentkg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yrValves* Gas/vapor service 77 136.67 301 414 734.83 1,620 1,379 2,447.67 5,396 75 58 128 1,178 913 2,013 3,263 2,529 5,576* Light-liquid service 380 770.69 1,699 1,179 2,391.17 5,272 1,980 4,015.70 8,853 251 195 431 2,428 1,889 4,165 5,857 4,558 10,048* Heavy-liquid service 0 -- -- 71 -- -- 1,272 -- -- 216 -- -- 1,719 -- -- 3,163 -- --Other emissions (Opt 2) 2,306 5,083 8,545 18,839 22,881 50,444 1,193 2,630 11,445 25,231 27,195 59,955TOTAL (lb/yr) 7,083 25,731 64,693 3,188 31,409 75,579TOTAL (tpy) 3.541575 12.86557 32.34645 1.594243 15.70471 37.78925TOTAL REDUCTION (lb/yr) 1,386 4,807 10,045 848 9,385 23,741TOTAL REDUCTION (tpy) 0.6932 2.4033 5.0223 0.4240 4.6926 11.8705Pumps Option 1Type of EquipmentPump Sealskg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr* Light-liquid service 15 91.27 201 40 243.40 537 56 340.76 751 8 23 50 69 197 434 176 502 1,108* Heavy-liquid service 0 -- -- 5 -- -- 36 -- -- 8 -- -- 61 -- -- 246 -- --Other emissions (Opt 2) 1,975 4,355 7,665 16,899 21,649 47,727 1,143 2,520 11,015 24,283 26,098 57,537Other emissions (Opt 3) 907 2,000 3,126 6,892 6,463 14,249 253 559 2,802 6,178 7,087 15,624TOTAL (lb/yr) 6,557 24,327 62,728 3,129 30,896 74,269TOTAL (tpy) 3.278368 12.16368 31.36381 1.564474 15.44796 37.13435TOTAL REDUCTION (lb/yr) 526 1,404 1,965 60 513 1,310TOTAL REDUCTION (tpy) 0.263207 0.701884 0.982638 0.029768 0.25675 0.654898Connectors Option 1Type of Equipmentkg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yrConnectors* Flanges - gas/vapor 0 -- -- 0 -- -- 0 -- -- 164 56.8 125 2,333 808.1 1,782 7,641 2,646.7 5,835* Flanges - G/LL 731 1,037.3 2,287 2,662 3,777.6 8,328 7,410 10,515.4 23,182 555 135 297 4,644 1,128 2,487 13,379 3,249 7,164* Flanges - HL 0 -- -- 0 -- -- 0 -- -- 454 -- -- 4,186 -- -- 7,725 -- --Other emissions (Opt 2) 10 21 507 1,117 1,721 3,795 582 1,284 5,446 12,006 9,215 20,317Other emissions (Opt 3, 4) 999 2,202 3,369 7,428 6,804 15,001 276 609 2,999 6,613 7,589 16,732TOTAL (lb/yr) 4,510 16,873 41,978 2,315 22,887 50,047TOTAL (tpy) 2.25489 8.436596 20.98901 1.157537 11.44337 25.02346TOTAL REDUCTION (lb/yr) 2,047 7,454 20,750 814 8,009 24,222TOTAL REDUCTION (tpy) 1.023479 3.727086 10.3748 0.406938 4.004589 12.11089CountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionModel 1 Model 2 Model 3 Model 4 Model 5 Model 6CountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionModel 1 Model 2 Model 3 Model 4 Model 5 Model 6CountEmissionsCountEmissionsCountEmissionsCountEmissionsCountEmissionsCountEmissionsModel 1 Model 2 Model 3 Model 4 Model 5 Model 6Attachment 4 - Page 3Valves Option 2Type of Equipmentkg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yrValves* Gas/vapor service 77 122.61 270 414 659.22 1,453 1,379 2,195.81 4,841 75 13.81 30 1,178 216.98 478 3,263 601.01 1,325* Light-liquid service 380 682.76 1,505 1,179 2,118.35 4,670 1,980 3,557.53 7,843 251 44.31 98 2,428 428.63 945 5,857 1,033.98 2,280* Heavy-liquid service 0 -- -- 71 -- -- 1,272 -- -- 216 -- -- 1,719 -- -- 3,163 -- --Other emissions (Opt 2) 0 0 465 1,026 1,598 3,523 557 1,228 5,293 11,669 8,636 19,038Other emissions (Opt 4, 5, 6) 1,129 2,488 4,021 8,865 10,856 23,934 214 473 2,133 4,702 6,399 14,106TOTAL (lb/yr) 4,264 16,014 40,140 1,829 17,794 36,749TOTAL (tpy) 2.131855 8.007205 20.07009 0.914589 8.897193 18.3746TOTAL REDUCTION (lb/yr) 246 859 1,838 486 5,092 13,298TOTAL REDUCTION (tpy) 0.123035 0.429391 0.918926 0.242948 2.546176 6.648868865.17Pumps Option 2Type of EquipmentPump Sealskg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr kg/yr lb/yr* Light-liquid service 15 69.82 154 40 186.20 410 56 260.67 575 8 22.56 50 69 194.60 429 176 496.37 1,094* Heavy-liquid service 0 -- -- 5 -- -- 36 -- -- 8 -- -- 61 -- -- 246 -- --Other emissions (Opt 2) 0 0 465 1,026 1,598 3,523 557 1,228 5,293 11,669 8,636 19,038Other emissions (Opt 5, 6) 1,037 2,287 3,778 8,328 10,515 23,182 192 422 1,936 4,268 5,896 12,999Other emissions (Opt 8) 805 1,776 2,778 6,123 5,753 12,684 58 128 646 1,423 1,635 3,605TOTAL (lb/yr) 4,216 15,888 39,964 1,829 17,789 36,736TOTAL (tpy) 2.108209 7.944149 19.98181 0.914283 8.894554 18.36787TOTAL REDUCTION (lb/yr) 47 126 177 0.61 5.28 13.47TOTAL REDUCTION (tpy) 0.023646 0.063056 0.088278 0.000306 0.002639 0.006733CountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionModel 1 Model 2 Model 3 Model 4 Model 5 Model 6CountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionCountEmissions ReductionModel 1 Model 2 Model 3 Model 4 Model 5 Model 6Attachment 4 - Page 4Attachment 5: Cost Effectiveness and Cost CalculationsUncontrolledEmissions (tpy) Capital Costs ($)AnnualizedCosts WithoutRecoveryCredits ($/yr)VOC RecoveryCredit ($/yr)Total AnnualizedCost ($/yr)EmissionsReduction (tpy)Model 110.19 90,763 41,009(2,980) 38,0295.96Model 278.73 455,982 129,599 (31,731) 97,86763.46Model 3163.01 859,162 226,203 (62,822) 163,381125.64Model 430.38 156,783 57,067 (14,180) 42,88728.36Model 5274.02 956,067 263,308 (126,809) 136,499253.62Model 6470.59 1,658,781 461,483 (210,466) 251,017420.93VALVESCapital Costs($)AnnualizedCosts WithoutRecoveryCredits ($/yr)VOC RecoveryCredit ($/yr)IncrementalAnnualized Cost($/yr)IncrementalEmissionsReduction (tpy)Overall CostEffectiveness($/ton)IncrementalCapital Costs ($)IncrementalAnnualized Cost($/yr)VOC RecoveryCredit ($/yr)IncrementalAnnualized Cost($/yr)IncrementalEmissionsReduction (tpy)Overall CostEffectiveness($/ton)Model 11,707362(347)150.69223,768963(62)9010.127,323Model 26,2161,299(1,202)972.4040 13,7163,438(215)3,2230.437,506Model 314,0302,869(2,511)3585.0271 30,9447,536(459)7,0760.927,701Model 41,211480(212)2680.426335,2992,937(121)2,8150.24 11,588Model 513,3565,379(2,346)3,0334.69646 58,507 29,266(1,273) 27,9932.55 10,994Model 633,743 13,660(5,935)7,72511.87651 147,886 82,886(3,324) 79,5626.65 11,966PUMPSCapital Costs($)AnnualizedCosts WithoutRecoveryCredits ($/yr)VOC RecoveryCredit ($/yr)IncrementalAnnualized Cost($/yr)IncrementalEmissionsReduction (tpy)Overall CostEffectiveness($/ton)IncrementalCapital Costs ($)IncrementalAnnualized Cost($/yr)VOC RecoveryCredit ($/yr)IncrementalAnnualized Cost($/yr)IncrementalEmissionsReduction (tpy)Overall CostEffectiveness($/ton)Model 12,231443(132)3120.261,184998366(12)3540.02 14,977Model 25,9481,182(351)8310.701,1842,661976(32)9440.06 14,977Model 38,3281,654(491)1,1630.981,1843,7251,366(44)1,3220.09 14,977Model 4262204(15)1890.036,339135437(0)4370.00 1,429,098Model 52,2591,756(128)1,6280.266,3391,1683,773(1)3,7720.00 1,429,098Model 65,7634,479(327)4,1520.656,3392,9809,625(3)9,6220.01 1,429,098OEL Monitoring (Incremental to Baseline)CONNECTORSCapital Costs($)AnnualizedCosts WithoutRecoveryCredits ($/yr)VOC RecoveryCredit ($/yr)IncrementalAnnualized Cost($/yr)IncrementalEmissionsReduction (tpy)Overall CostEffectiveness($/ton)IncrementalCapital Cost ($)IncrementalAnnualized Cost($/yr)Model 119,3687,872(512)7,3601.027,192Model 1808176Model 265,633 15,725(1,864) 13,8613.733,719Model 23,453750Model 3179,391 35,034(5,187) 29,84610.372,877Model 310,3832,256Model 419,4947,918(203)7,7140.41 18,957Model 4997234Model 5173,029 34,190(2,002) 32,1884.008,038Model 56,0821,429Model 6517,562 93,145(6,055) 87,08912.117,191Model 623,0495,415BaselineValves Option 1 (Incremental to Baseline)Valves Option 2 (Incremental to Option 1)Pumps Option 1 (Incremental to Baseline)Pumps Option 2 (Incremental to Option 1)Connectors Option 1 (Incremental to Baseline)Attachment 5 - Page 1Baseline Cost EstimatesType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost ($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksPercentRepairedOnLineModel 1Pump Seals* Light-liquid service15 23.80 742.42121.50 580.13 116.32 2.42 0.36 0.23 0.41 100* Heavy-liquid service01.10 0.00Valves* Gas/vapor service77 23.80 1852.5121.50 231.000.33 0.26 0.33 0.51 75* Light-liquid service380 23.80 9142.2521.50 1140.000.33 1.27 0.33 2.54 75* Heavy-liquid service01.10 0.00Connectors* Flanges - gas/vapor01.10 0.00* Flanges - light liquid731 1.10 807.02* Flanges -heavy liquid01.10 0.00Agitators* Light-liquid service0 23.80 0.00121.50 0.00 0.00 2.42 0.00 0.23 0.00 100.00* Heavy-liquid service01.10 0.00Pressure Relief Devices* Disks2 122.11 244.2102.00 0.00 4.88* Disk holders, valves,etc.2 6,374.29 12748.585.00637.43OEL33 140.92 4650.435.00232.52Sampling Connections8 687.86 5502.865.00275.14Compressor Vent0 10526.21 0.005.000.00Replacement Pump Seals15 282.71 102.65Monitoring Instrument1 10,800 10,800Data Collection System1 14,500 14,500hr/activity $/hrAdministrative and Reports250 92.72Planning and Training320 92.7229670.40TOTALS61092.92 29670.401951.13 1266.30Capital Costs ($) 90,763Annualized Capital ($/yr)12,924Annual Expenses ($/yr) 28,085Annual Fixed Costs ($/yr) 37,123 41,009Annual Variable Costs ($/yr) 3,886BaselineAttachment 5 - Page 2Baseline Cost EstimatesType of ComponentModel 1Pump Seals* Light-liquid service* Heavy-liquid serviceValves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceConnectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAgitators* Light-liquid service* Heavy-liquid servicePressure Relief Devices* Disks* Disk holders, valves,etc.OELSampling ConnectionsCompressor VentReplacement Pump SealsMonitoring InstrumentData Collection SystemAdministrative and ReportsPlanning and TrainingTOTALSRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)16.00 66.24 436.08 0 80.00 66.24 0.00 0.6293.060.17 66.24 4.2725 4.00 66.24 34.08 0.770.17 66.24 21.06 25 4.00 66.24 168.17 3.8116.00 66.24 0.000 80.00 66.24 0.00 0.000.009.77509.94186.02220.110.0023180.00461.41202.25 5.20 23180.00 1018.90BaselineAttachment 5 - Page 3Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost ($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksPercentRepairedOnLineModel 2Pump Seals* Light-liquid service40 23.80 1979.78121.50 1547.01 310.20 2.42 0.97 0.23 1.10 100* Heavy-liquid service51.10 5.52Valves* Gas/vapor service414 23.80 9960.2421.50 1242.000.33 1.38 0.33 2.77 75* Light-liquid service1,179 23.80 28365.0321.50 3537.000.33 3.94 0.33 7.88 75* Heavy-liquid service71 1.10 78.38Connectors* Flanges - gas/vapor01.10 0.00* Flanges - light liquid2,662 1.10 2938.85* Flanges -heavy liquid01.10 0.00Agitators* Light-liquid service3 23.80 71.41121.50 140.11 0.00 2.42 0.07 0.23 0.08 100.00* Heavy-liquid service31.10 3.31Pressure Relief Devices* Disks45 122.11 5494.7802.00 0.00 109.90* Disk holders, valves,etc.45 6,374.29 286842.955.0014342.15OEL141 140.92 19870.035.00993.50Sampling Connections35 687.86 24075.015.001203.75Compressor Vent2 10526.21 21052.425.001052.62Replacement Pump Seals40 282.71 273.72Monitoring Instrument1 10,800 10,800Data Collection System1 14,500 14,500hr/activity $/hrAdministrative and Reports250 92.72Planning and Training320 92.7229670.40TOTALS426311.44 29670.406466.12 18012.11Capital Costs ($) 455,982Annualized Capital ($/yr)65,338Annual Expenses ($/yr) 64,261Annual Fixed Costs ($/yr) 103,059 129,599Annual Variable Costs ($/yr) 26,539BaselineAttachment 5 - Page 4Option 1 Cost EstimatesType of ComponentModel 2Pump Seals* Light-liquid service* Heavy-liquid serviceValves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceConnectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAgitators* Light-liquid service* Heavy-liquid servicePressure Relief Devices* Disks* Disk holders, valves,etc.OELSampling ConnectionsCompressor VentReplacement Pump SealsMonitoring InstrumentData Collection SystemAdministrative and ReportsPlanning and TrainingTOTALSRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)16.00 66.24 1162.87 0 80.00 66.24 0.00 1.65248.160.17 66.24 22.95 25 4.00 66.24 183.22 4.150.17 66.24 65.35 25 4.00 66.24 521.78 11.8216.00 66.24 87.22 0 80.00 66.24 0.00 0.120.00219.7911473.72794.80963.00842.1023180.001338.39705.00 17.73 23180.00 14541.57BaselineAttachment 5 - Page 5Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost ($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksPercentRepairedOnLineModel 3Pump Seals* Light-liquid service56 23.80 2771.69121.50 2165.81 434.27 2.42 1.36 0.23 1.54 100* Heavy-liquid service36 1.10 39.74Valves* Gas/vapor service1,379 23.80 33176.7421.50 4137.000.33 4.61 0.33 9.21 75* Light-liquid service1,980 23.80 47635.9221.50 5940.000.33 6.61 0.33 13.23 75* Heavy-liquid service1,272 1.10 1404.29Connectors* Flanges - gas/vapor01.10 0.00* Flanges - light liquid7,410 1.10 8180.64* Flanges -heavy liquid01.10 0.00Agitators* Light-liquid service0 23.80 0.00121.50 0.00 0.00 2.42 0.00 0.23 0.00 100.00* Heavy-liquid service01.10 0.00Pressure Relief Devices* Disks76 122.11 9280.0702.00 0.00 185.60* Disk holders, valves,etc.76 6,374.29 484445.885.0024222.29OEL424 140.92 59751.025.002987.55Sampling Connections106 687.86 72912.885.003645.64Compressor Vent8 10526.21 84209.705.004210.48Replacement Pump Seals56 282.71 383.21Monitoring Instrument1 10,800 10,800Data Collection System1 14,500 14,500hr/activity $/hrAdministrative and Reports250 92.72Planning and Training320 92.7229670.40TOTALS829491.78 29670.4012242.81 35685.85Capital Costs ($) 859,162Annualized Capital ($/yr)122,987Annual Expenses ($/yr) 103,217Annual Fixed Costs ($/yr) 174,938 226,203Annual Variable Costs ($/yr) 51,265BaselineAttachment 5 - Page 6Option 1 Cost EstimatesType of ComponentModel 3Pump Seals* Light-liquid service* Heavy-liquid serviceValves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceConnectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAgitators* Light-liquid service* Heavy-liquid servicePressure Relief Devices* Disks* Disk holders, valves,etc.OELSampling ConnectionsCompressor VentReplacement Pump SealsMonitoring InstrumentData Collection SystemAdministrative and ReportsPlanning and TrainingTOTALSRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)16.00 66.24 1628.02 0 80.00 66.24 0.00 2.30347.420.17 66.24 76.44 25 4.00 66.24 610.29 13.820.17 66.24 109.75 25 4.00 66.24 876.27 19.8416.00 66.24 0.000 80.00 66.24 0.00 0.000.00371.2019377.842390.042916.523368.3923180.001814.211486.57 35.97 23180.00 28771.40BaselineAttachment 5 - Page 7Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost ($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksPercentRepairedOnLineModel 4Pump Seals* Light-liquid service8 23.80 264.94121.50 309.40 238.15 0.88 0.07 0.88 0.84 100* Heavy-liquid service81.10 8.83Valves* Gas/vapor service75 23.80 1852.8921.50 225.001.18 0.89 1.18 1.78 75* Light-liquid service251 23.80 6238.3621.50 753.001.38 3.46 1.38 6.93 75* Heavy-liquid service216 1.10 238.46Connectors* Flanges - gas/vapor164 1.10 181.06* Flanges - light liquid555 1.10 612.72* Flanges -heavy liquid454 1.10 501.22Agitators* Light-liquid service0 23.80 0.00121.50 0.00 0.00 0.88 0.00 0.88 0.00 100.00* Heavy-liquid service01.10 0.00Pressure Relief Devices* Disks9 122.11 1098.9602.00 0.00 21.98* Disk holders, valves,etc.9 6,374.29 57368.595.002868.43OEL39 140.92 5495.975.00274.80Sampling Connections10 687.86 6878.575.00343.93Compressor Vent2 10526.21 21052.425.001052.62Replacement Pump Seals8 282.71 19.85Monitoring Instrument1 10,800 10,800Data Collection System1 14,500 14,500hr/activity $/hrAdministrative and Reports250 92.720.00Planning and Training320 92.7229670.40TOTALS127112.84 29670.401287.40 4799.91Capital Costs ($) 156,783Annualized Capital ($/yr)22,377Annual Expenses ($/yr) 34,690Annual Fixed Costs ($/yr) 49,424 57,067Annual Variable Costs ($/yr) 7,643BaselineAttachment 5 - Page 8Option 1 Cost EstimatesType of ComponentModel 4Pump Seals* Light-liquid service* Heavy-liquid serviceValves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceConnectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAgitators* Light-liquid service* Heavy-liquid servicePressure Relief Devices* Disks* Disk holders, valves,etc.OELSampling ConnectionsCompressor VentReplacement Pump SealsMonitoring InstrumentData Collection SystemAdministrative and ReportsPlanning and TrainingTOTALSRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)16.00 66.24 892.78 0 80.00 66.24 0.00 1.26190.520.17 66.24 14.74 25 4.00 66.24 117.69 2.670.17 66.24 57.49 25 4.00 66.24 458.97 10.3916.00 66.24 0.000 80.00 66.24 0.00 0.000.0043.962294.74219.84275.14842.1023180.00965.01576.66 14.32 23180.00 3866.30BaselineAttachment 5 - Page 9Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost ($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksPercentRepairedOnLineModel 5Pump Seals* Light-liquid service69 23.80 2285.11121.50 2668.59 2054.04 0.88 0.61 0.88 7.27 100* Heavy-liquid service61 1.10 67.34Valves* Gas/vapor service1,178 23.80 29102.6721.50 3534.001.18 13.95 1.18 27.91 75* Light-liquid service2,428 23.80 60345.6121.50 7284.001.38 33.51 1.38 67.03 75* Heavy-liquid service1,719 1.10 1897.78Connectors* Flanges - gas/vapor2,333 1.10 2575.63* Flanges - light liquid4,644 1.10 5126.98* Flanges -heavy liquid4,186 1.10 4621.34Agitators* Light-liquid service0 23.80 0.00121.50 0.00 0.00 0.88 0.00 0.88 0.00 100.00* Heavy-liquid service01.10 0.00Pressure Relief Devices* Disks79 122.11 9646.3902.00 0.00 192.93* Disk holders, valves,etc.79 6,374.29 503568.745.0025178.44OEL238 140.92 33539.495.001676.97Sampling Connections70 687.86 48150.025.002407.50Compressor Vent19 10526.21 199998.035.009999.90Replacement Pump Seals69 282.71 171.17Monitoring Instrument1 10,800 10,800Data Collection System1 14,500 14,500hr/activity $/hrAdministrative and Reports250 92.720.00Planning and Training320 92.7229670.40TOTALS926396.30 29670.4013486.59 41509.78Capital Costs ($) 956,067Annualized Capital ($/yr)136,763Annual Expenses ($/yr) 126,545Annual Fixed Costs ($/yr) 193,382 263,308Annual Variable Costs ($/yr) 69,926BaselineAttachment 5 - Page 10Option 1 Cost EstimatesType of ComponentModel 5Pump Seals* Light-liquid service* Heavy-liquid serviceValves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceConnectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAgitators* Light-liquid service* Heavy-liquid servicePressure Relief Devices* Disks* Disk holders, valves,etc.OELSampling ConnectionsCompressor VentReplacement Pump SealsMonitoring InstrumentData Collection SystemAdministrative and ReportsPlanning and TrainingTOTALSRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)16.00 66.24 7700.24 0 80.00 66.24 0.00 10.901643.230.17 66.24 231.52 25 4.00 66.24 1848.46 41.860.17 66.24 556.08 25 4.00 66.24 4439.77 100.5416.00 66.24 0.000 80.00 66.24 0.00 0.000.00385.8620142.751341.581926.007999.9223180.008487.846288.23 153.29 23180.00 33439.34BaselineAttachment 5 - Page 11Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitialMonitoringFee or UnitCost ($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksPercentRepairedOnLineModel 6Pump Seals* Light-liquid service176 23.80 5828.68121.50 6806.84 5239.29 0.88 1.54 0.88 18.53 100* Heavy-liquid service246 1.10 271.58Valves* Gas/vapor service3,263 23.80 80612.9121.50 9789.001.18 38.65 1.18 77.30 75* Light-liquid service5,857 23.80 145570.1321.50 17571.001.38 80.84 1.38 161.68 75* Heavy-liquid service3,163 1.10 3491.95Connectors* Flanges - gas/vapor7,641 1.10 8435.66* Flanges - light liquid13,379 1.10 14770.42* Flanges -heavy liquid7,725 1.10 8528.40Agitators* Light-liquid service0 23.80 0.00121.50 0.00 0.00 0.88 0.00 0.88 0.00 100.00* Heavy-liquid service01.10 0.00Pressure Relief Devices* Disks119 122.11 14530.6402.00 0.00 290.61* Disk holders, valves,etc. 119 6,374.29 758540.265.0037927.01OEL902 140.92 127111.845.006355.59Sampling Connections159 687.86 109369.325.005468.47Compressor Vent31 10526.21 326312.585.0016315.63Replacement Pump Seals176 282.71 436.61Monitoring Instrument1 10,800 10,800Data Collection System1 14,500 14,500hr/activity $/hrAdministrative and Reports250 92.720.00Planning and Training320 92.7229670.40TOTALS1629110.97 29670.4034166.84 71596.60Capital Costs ($) 1,658,781Annualized Capital ($/yr)237,074Annual Expenses ($/yr) 224,410Annual Fixed Costs ($/yr) 317,880 461,483Annual Variable Costs ($/yr) 143,604BaselineAttachment 5 - Page 12Option 1 Cost EstimatesType of ComponentModel 6Pump Seals* Light-liquid service* Heavy-liquid serviceValves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceConnectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAgitators* Light-liquid service* Heavy-liquid servicePressure Relief Devices* Disks* Disk holders, valves,etc.OELSampling ConnectionsCompressor VentReplacement Pump SealsMonitoring InstrumentData Collection SystemAdministrative and ReportsPlanning and TrainingTOTALSRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)16.00 66.24 19641.19 0 80.00 66.24 0.00 27.804191.430.17 66.24 641.30 25 4.00 66.24 5120.15 115.950.17 66.24 1341.42 25 4.00 66.24 10709.93 242.5316.00 66.24 0.000 80.00 66.24 0.00 0.000.00581.2330341.615084.474374.7713052.5023180.0021623.9115830.08 386.27 23180.00 57626.02BaselineAttachment 5 - Page 13Pump Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 1Pump Seals* Light-liquid service150.00 2146.74121.50 580.13 130.46 13.48 2.02 0.26 0.46* Heavy-liquid service00.000.00Replacement Pump Seals15282.71 571.84hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS2718.58 0.00580.13 130.46Capital Costs ($) 2,719Annualized Capital ($/yr)444Annual Expenses ($/yr) 1,305Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 1Pump Seals* Light-liquid service150.00385.35121.50 580.13 116.32 2.42 0.36 0.23 0.41* Heavy-liquid service00.000.00Replacement Pump Seals15282.71 102.65hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS488.00 0.00580.13 116.32Monitoring RepairBaseline Capital Costs ($) 488488.00Baseline Annualized Capital ($/yr)8079.77Baseline Annual Expenses ($/yr) 1,226580.75 552.40INCREMENTAL COSTS OF PUMP OPTION 1Incremental Capital Costs ($) 2,230.58Annualized Capital ($/yr) 364.60Incremental Annual Expenses ($/yr) 78.53Pumps Option 1Attachment 5 - Page 14Pump Option 1 Cost EstimatesType of ComponentModel 1Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 1Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 489.08 0 80.00 66.24 0.00 0.69104.370.00489.080.00 0.69 0.00 104.37PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 436.08 0 80.00 66.24 0.00 0.6293.060.00436.080.00 0.62 0.00 93.06Pumps Option 1Attachment 5 - Page 15Pump Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 2Pump Seals* Light-liquid service400.00 5724.65121.50 1547.01 347.90 13.48 5.39 0.26 1.23* Heavy-liquid service50.000.00Replacement Pump Seals40282.71 1524.89hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS7249.55 0.001547.01 347.90Capital Costs ($) 7,250Annualized Capital ($/yr)1,185Annual Expenses ($/yr) 3,479Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 2Pump Seals* Light-liquid service400.00 1027.60121.50 1547.01 310.20 2.42 0.97 0.23 1.10* Heavy-liquid service50.000.00Replacement Pump Seals40282.71 273.72hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS1301.32 0.001547.01 310.20Monitoring RepairBaseline Capital Costs ($) 1,3011,301.32Baseline Annualized Capital ($/yr)213212.71Baseline Annual Expenses ($/yr) 3,2701,548.65 1,473.07INCREMENTAL COSTS OF PUMP OPTION 1Incremental Capital Costs ($) 5,948.23Annualized Capital ($/yr) 972.27Incremental Annual Expenses ($/yr) 209.41Pumps Option 1Attachment 5 - Page 16Pump Option 1 Cost EstimatesType of ComponentModel 2Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 2Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 1304.22 0 80.00 66.24 0.00 1.85278.320.001304.220.00 1.85 0.00 278.32PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 1162.87 0 80.00 66.24 0.00 1.65248.160.001162.870.00 1.65 0.00 248.16Pumps Option 1Attachment 5 - Page 17Pump Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 3Pump Seals* Light-liquid service560.00 8014.51121.50 2165.81 487.06 13.48 7.55 0.26 1.72* Heavy-liquid service360.000.00Replacement Pump Seals56282.71 2134.85hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS10149.37 0.002165.81 487.06Capital Costs ($) 10,149Annualized Capital ($/yr)1,659Annual Expenses ($/yr) 4,871Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 3Pump Seals* Light-liquid service560.00 1438.64121.50 2165.81 434.27 2.42 1.36 0.23 1.54* Heavy-liquid service360.000.00Replacement Pump Seals56282.71 383.21hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS1821.85 0.002165.81 434.27Monitoring RepairBaseline Capital Costs ($) 1,8221,821.85Baseline Annualized Capital ($/yr)298297.79Baseline Annual Expenses ($/yr) 4,5782,168.12 2,062.30INCREMENTAL COSTS OF PUMP OPTION 1Incremental Capital Costs ($) 8,327.52Annualized Capital ($/yr) 1,361.17Incremental Annual Expenses ($/yr) 293.18Pumps Option 1Attachment 5 - Page 18Pump Option 1 Cost EstimatesType of ComponentModel 3Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 3Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 1825.91 0 80.00 66.24 0.00 2.58389.650.001825.910.00 2.58 0.00 389.65PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 1628.02 0 80.00 66.24 0.00 2.30347.420.001628.020.00 2.30 0.00 347.42Pumps Option 1Attachment 5 - Page 19Pump Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 4Pump Seals* Light-liquid service80.00281.35121.50 309.40 267.10 3.31 0.27 0.98 0.94* Heavy-liquid service80.000.00Replacement Pump Seals8282.71 74.94hr/activity$/hrAdministrative and Reports092.72Planning and Training0 92.72 0.00TOTALS356.29 0.00 309.40 267.10Capital Costs ($) 356Annualized Capital ($/yr)58Annual Expenses ($/yr) 1,793Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 4Pump Seals* Light-liquid service 8 0.00 74.50 12 1.50 309.40 238.15 0.88 0.07 0.88 0.84* Heavy-liquid service 8 0.00 0.00Replacement Pump Seals8282.71 19.85hr/activity$/hrAdministrative and Reports0 92.72Planning and Training0 92.72 0.00TOTALS94.35 0.00309.40 238.15Monitoring RepairBaseline Capital Costs ($) 9494.35Baseline Annualized Capital ($/yr)1515.42Baseline Annual Expenses ($/yr) 1,632310.67 1,130.93INCREMENTAL COSTS OF PUMP OPTION 1Incremental Capital Costs ($) 261.95Annualized Capital ($/yr) 42.82Incremental Annual Expenses ($/yr) 160.77Pumps Option 1Attachment 5 - Page 20Pump Option 1 Cost EstimatesType of ComponentModel 4Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 4Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 1001.30 0 80.00 66.24 0.00 1.42213.680.001001.300.00 1.42 0.00 213.68PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 892.78 0 80.00 66.24 0.00 1.26190.520.00892.780.00 1.26 0.00 190.52Pumps Option 1Attachment 5 - Page 21Pump Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 5Pump Seals* Light-liquid service690.00 2426.65121.50 2668.59 2303.71 3.31 2.29 0.98 8.15* Heavy-liquid service610.000.00Replacement Pump Seals69282.71 646.39hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS3073.04 0.002668.59 2303.71Capital Costs ($) 3,073Annualized Capital ($/yr)502Annual Expenses ($/yr) 15,464Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 5Pump Seals* Light-liquid service690.00642.59121.50 2668.59 2054.04 0.88 0.61 0.88 7.27* Heavy-liquid service610.000.00Replacement Pump Seals69282.71 171.17hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS813.76 0.002668.59 2054.04Monitoring RepairBaseline Capital Costs ($) 814813.76Baseline Annualized Capital ($/yr)133133.01Baseline Annual Expenses ($/yr) 14,0772,679.49 9,754.28INCREMENTAL COSTS OF PUMP OPTION 1Incremental Capital Costs ($) 2,259.28Annualized Capital ($/yr) 369.29Incremental Annual Expenses ($/yr) 1,386.68Pumps Option 1Attachment 5 - Page 22Pump Option 1 Cost EstimatesType of ComponentModel 5Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 5Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 8636.20 0 80.00 66.24 0.00 12.221842.970.008636.200.00 12.22 0.00 1842.97PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 7700.24 0 80.00 66.24 0.00 10.901643.230.007700.240.00 10.90 0.00 1643.23Pumps Option 1Attachment 5 - Page 23Pump Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 6Pump Seals* Light-liquid service1760.00 6189.71121.50 6806.84 5876.12 3.31 5.83 0.98 20.78* Heavy-liquid service2460.000.00Replacement Pump Seals176282.71 1648.77hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS7838.49 0.006806.84 5876.12Capital Costs ($) 7,838Annualized Capital ($/yr)1,281Annual Expenses ($/yr) 39,444Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 6Pump Seals* Light-liquid service1760.00 1639.08121.50 6806.84 5239.29 0.88 1.54 0.88 18.53* Heavy-liquid service2460.000.00Replacement Pump Seals176282.71 436.61hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS2075.69 0.006806.84 5239.29Monitoring RepairBaseline Capital Costs ($) 2,0762,075.69Baseline Annualized Capital ($/yr)339339.28Baseline Annual Expenses ($/yr) 35,9076,834.63 24,880.48INCREMENTAL COSTS OF PUMP OPTION 1Incremental Capital Costs ($) 5,762.80Annualized Capital ($/yr) 941.96Incremental Annual Expenses ($/yr) 3,537.05Pumps Option 1Attachment 5 - Page 24Pump Option 1 Cost EstimatesType of ComponentModel 6Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 6Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 22028.56 0 80.00 66.24 0.00 31.184700.900.0022028.560.00 31.18 0.00 4700.90PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 19641.19 0 80.00 66.24 0.00 27.804191.430.0019641.190.00 27.80 0.00 4191.43Pumps Option 1Attachment 5 - Page 25Pump Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 1Pump Seals* Light-liquid service150.00 2934.59121.50 580.13 166.99 18.43 2.76 0.33 0.59* Heavy-liquid service00.000.00Replacement Pump Seals15282.71 781.70hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS3716.29 0.00580.13 166.99Capital Costs ($) 3,716Annualized Capital ($/yr)607Annual Expenses ($/yr) 1,508INCREMENTAL COSTS OF PUMP OPTION 2Incremental Capital Costs ($) 998Annualized Capital ($/yr) 163Incremental Annual Expenses ($/yr) 203Pumps Option 2Attachment 5 - Page 26Pump Option 2 Cost EstimatesType of ComponentModel 1Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 626.02 0 80.00 66.24 0.00 0.89133.590.00626.020.00 0.89 0.00 133.59Pumps Option 2Attachment 5 - Page 27Pumps Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 2Pump Seals* Light-liquid service400.00 7825.59121.50 1547.01 445.31 18.43 7.37 0.33 1.58* Heavy-liquid service50.000.00Replacement Pump Seals40282.71 2084.53hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS9910.11 0.001547.01 445.31Capital Costs ($) 9,910Annualized Capital ($/yr)1,620Annual Expenses ($/yr) 4,020INCREMENTAL COSTS OF PUMP OPTION 2Incremental Capital Costs ($) 2,661Annualized Capital ($/yr) 435Incremental Annual Expenses ($/yr) 541Pumps Option 2Attachment 5 - Page 28Pumps Option 2 Cost EstimatesType of ComponentModel 2Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 1669.38 0 80.00 66.24 0.00 2.36356.250.001669.380.00 2.36 0.00 356.25Pumps Option 2Attachment 5 - Page 29Pumps Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 3Pump Seals* Light-liquid service560.00 10955.82121.50 2165.81 623.43 18.43 10.32 0.33 2.21* Heavy-liquid service360.000.00Replacement Pump Seals56282.71 2918.34hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS13874.16 0.002165.81 623.43Capital Costs ($) 13,874Annualized Capital ($/yr)2,268Annual Expenses ($/yr) 5,628INCREMENTAL COSTS OF PUMP OPTION 2Incremental Capital Costs ($) 3,725Annualized Capital ($/yr) 609Incremental Annual Expenses ($/yr) 757Pumps Option 2Attachment 5 - Page 30Pumps Option 2 Cost EstimatesType of ComponentModel 3Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 2337.13 0 80.00 66.24 0.00 3.31498.740.002337.130.00 3.31 0.00 498.74Pumps Option 2Attachment 5 - Page 31Pumps Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 4Pump Seals* Light-liquid service80.00388.31121.50 309.40 341.88 4.57 0.37 1.26 1.21* Heavy-liquid service80.000.00Replacement Pump Seals8282.71 103.43hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS491.74 0.00309.40 341.88Capital Costs ($) 492Annualized Capital ($/yr)80Annual Expenses ($/yr) 2,208INCREMENTAL COSTS OF PUMP OPTION 2Incremental Capital Costs ($) 135Annualized Capital ($/yr) 22Incremental Annual Expenses ($/yr) 415Pumps Option 2Attachment 5 - Page 32Pumps Option 2 Cost EstimatesType of ComponentModel 4Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 1281.65 0 80.00 66.24 0.00 1.81273.500.001281.650.00 1.81 0.00 273.50Pumps Option 2Attachment 5 - Page 33Pumps Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 5Pump Seals* Light-liquid service690.00 3349.14121.50 2668.59 2948.71 4.57 3.16 1.26 10.43* Heavy-liquid service610.000.00Replacement Pump Seals69282.71 892.12hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS4241.26 0.002668.59 2948.71Capital Costs ($) 4,241Annualized Capital ($/yr)693Annual Expenses ($/yr) 19,046INCREMENTAL COSTS OF PUMP OPTION 2Incremental Capital Costs ($) 1,168Annualized Capital ($/yr) 191Incremental Annual Expenses ($/yr) 3,582Pumps Option 2Attachment 5 - Page 34Pumps Option 2 Cost EstimatesType of ComponentModel 5Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 11054.21 0 80.00 66.24 0.00 15.652358.970.0011054.210.00 15.65 0.00 2358.97Pumps Option 2Attachment 5 - Page 35Pumps Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 6Pump Seals* Light-liquid service1760.00 8542.73121.50 6806.84 7521.35 4.57 8.05 1.26 26.60* Heavy-liquid service2460.000.00Replacement Pump Seals176282.71 2275.55hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS10818.28 0.00 6806.84 7521.35Capital Costs ($) 10,818Annualized Capital ($/yr)1,768Annual Expenses ($/yr) 48,581INCREMENTAL COSTS OF PUMP OPTION 2Incremental Capital Costs ($) 2,980Annualized Capital ($/yr) 487Incremental Annual Expenses ($/yr) 9,138Pumps Option 2Attachment 5 - Page 36Pumps Option 2 Cost EstimatesType of ComponentModel 6Pump Seals* Light-liquid service* Heavy-liquid serviceReplacement Pump SealsAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)100 16.00 66.24 28196.24 0 80.00 66.24 0.00 39.916017.080.0028196.240.00 39.91 0.00 6017.08Pumps Option 2Attachment 5 - Page 37Valve Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 1Valves* Gas/vapor service770.00423.9321.50 231.007.24 5.58 0.51 0.78* Light-liquid service3800.00 1399.2221.50 1140.004.84 18.40 0.51 3.84* Heavy-liquid service00.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS1823.15 0.001371.00 0.00Capital Costs ($) 1,823.15Annualized Capital ($/yr)259Annual Expenses ($/yr) 1,723Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 1Valves* Gas/vapor service770.0019.5621.50 231.000.33 0.26 0.33 0.51* Light-liquid service3800.0096.5221.50 1140.000.33 1.27 0.33 2.54* Heavy-liquid service00.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS116.080.001371.00 0.00Monitoring RepairBaseline Capital Costs ($) 116.08116.08Baseline Annualized Capital ($/yr)1616.48Baseline Annual Expenses ($/yr) 1,6031,375.58 227.58INCREMENTAL COSTS OF VALVE OPTION 1Incremental Capital Costs ($) 1,707.07Annualized Capital ($/yr) 242.40Incremental Annual Expenses ($/yr) 119.35Valves Option 1Attachment 5 - Page 38Valve Option 1 Cost EstimatesType of ComponentModel 1Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 1Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 6.4625 4.00 66.24 51.60 1.1775 0.17 66.24 31.89 25 4.00 66.24 254.63 5.770.0038.35306.22 6.93 0.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 4.2725 4.00 66.24 34.08 0.7775 0.17 66.24 21.06 25 4.00 66.24 168.17 3.810.0025.33202.25 4.58 0.00 0.00Valves Option 1Attachment 5 - Page 39Valve Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 2Valves* Gas/vapor service4140.00 2279.3121.50 1242.007.24 29.98 0.51 4.19* Light-liquid service1,1790.00 4341.2621.50 3537.004.84 57.09 0.51 11.93* Heavy-liquid service710.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS6620.56 0.004779.00 0.00Capital Costs ($) 6,620.56Annualized Capital ($/yr)940Annual Expenses ($/yr) 6,004Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 2Valves* Gas/vapor service4140.00105.1621.50 1242.000.33 1.38 0.33 2.77* Light-liquid service1,1790.00299.4821.50 3537.000.33 3.94 0.33 7.88* Heavy-liquid service710.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS404.630.004779.00 0.00Monitoring RepairBaseline Capital Costs ($) 404.63404.63Baseline Annualized Capital ($/yr)5757.46Baseline Annual Expenses ($/yr) 5,5884,794.96 793.30INCREMENTAL COSTS OF VALVE OPTION 1Incremental Capital Costs ($) 6,215.93Annualized Capital ($/yr) 882.66Incremental Annual Expenses ($/yr) 416.02Valves Option 1Attachment 5 - Page 40Valve Option 1 Cost EstimatesType of ComponentModel 2Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 2Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 34.75 25 4.00 66.24 277.41 6.2875 0.17 66.24 98.95 25 4.00 66.24 790.01 17.890.00133.69 1067.42 24.17 0.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 22.95 25 4.00 66.24 183.22 4.1575 0.17 66.24 65.35 25 4.00 66.24 521.78 11.820.0088.30705.00 15.96 0.00 0.00Valves Option 1Attachment 5 - Page 41Valve Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 3Valves* Gas/vapor service1,3790.00 7592.1821.50 4137.007.24 99.85 0.51 13.95* Light-liquid service1,9800.00 7290.6621.50 5940.004.84 95.88 0.51 20.03* Heavy-liquid service1,2720.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS14882.84 0.0010077.00 0.00Capital Costs ($) 14,882.84Annualized Capital ($/yr)2,113Annual Expenses ($/yr) 12,661Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 3Valves* Gas/vapor service1,3790.00350.2821.50 4137.000.33 4.61 0.33 9.21* Light-liquid service1,9800.00502.9421.50 5940.000.33 6.61 0.33 13.23* Heavy-liquid service1,2720.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS853.210.0010077.00 0.00Monitoring RepairBaseline Capital Costs ($) 853.21 853.21Baseline Annualized Capital ($/yr)121121.16Baseline Annual Expenses ($/yr) 11,783 10,110.66 1,672.76INCREMENTAL COSTS OF VALVE OPTION 1Incremental Capital Costs ($) 14,029.63Annualized Capital ($/yr) 1,992.21Incremental Annual Expenses ($/yr) 877.22Valves Option 1Attachment 5 - Page 42Valve Option 1 Cost EstimatesType of ComponentModel 3Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 3Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 115.73 25 4.00 66.24 924.03 20.9275 0.17 66.24 166.17 25 4.00 66.24 1326.74 30.040.00281.91 2250.77 50.97 0.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 76.44 25 4.00 66.24 610.29 13.8275 0.17 66.24 109.75 25 4.00 66.24 876.27 19.840.00186.191486.57 33.66 0.00 0.00Valves Option 1Attachment 5 - Page 43Valve Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 4Valves* Gas/vapor service750.00339.0921.50 225.005.95 4.46 1.91 2.87* Light-liquid service2510.00 1203.1921.50 753.006.30 15.82 1.97 9.89* Heavy-liquid service2160.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS1542.28 0.00978.00 0.00Capital Costs ($) 1,542.28Annualized Capital ($/yr)219Annual Expenses ($/yr) 1,948Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 4Valves* Gas/vapor service750.0067.5521.50 225.001.18 0.89 1.18 1.78* Light-liquid service2510.00263.4321.50 753.001.38 3.46 1.38 6.93* Heavy-liquid service2160.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS330.970.00978.00 0.00Monitoring RepairBaseline Capital Costs ($) 330.97330.97Baseline Annualized Capital ($/yr)4747.00Baseline Annual Expenses ($/yr) 1,640991.06 648.88INCREMENTAL COSTS OF VALVE OPTION 1Incremental Capital Costs ($) 1,211.31Annualized Capital ($/yr) 172.01Incremental Annual Expenses ($/yr) 308.19Valves Option 1Attachment 5 - Page 44Valve Option 1 Cost EstimatesType of ComponentModel 4Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 4Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 23.81 25 4.00 66.24 190.10 4.3075 0.17 66.24 82.04 25 4.00 66.24 655.04 14.830.00105.85 845.14 19.14 0.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 14.74 25 4.00 66.24 117.69 2.6775 0.17 66.24 57.49 25 4.00 66.24 458.97 10.390.0072.23576.66 13.06 0.00 0.00Valves Option 1Attachment 5 - Page 45Valve Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 5Valves* Gas/vapor service1,1780.00 5325.9921.50 3534.005.95 70.05 1.91 45.08* Light-liquid service2,4280.00 11638.8021.50 7284.006.30 153.07 1.97 95.66* Heavy-liquid service1,7190.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS16964.79 0.0010818.00 0.00Capital Costs ($) 16,964.79Annualized Capital ($/yr)2,409Annual Expenses ($/yr) 21,519Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 5Valves* Gas/vapor service1,1780.00 1060.9221.50 3534.001.18 13.95 1.18 27.91* Light-liquid service2,4280.00 2548.1921.50 7284.001.38 33.51 1.38 67.03* Heavy-liquid service1,7190.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS3609.110.0010818.00 0.00Monitoring RepairBaseline Capital Costs ($) 3,609.113,609.11Baseline Annualized Capital ($/yr)512512.49Baseline Annual Expenses ($/yr) 18,03610,960.40 7,075.83INCREMENTAL COSTS OF VALVE OPTION 1Incremental Capital Costs ($) 13,355.68Annualized Capital ($/yr) 1,896.51Incremental Annual Expenses ($/yr) 3,482.74Valves Option 1Attachment 5 - Page 46Valve Option 1 Cost EstimatesType of ComponentModel 5Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 5Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 373.97 25 4.00 66.24 2985.82 67.6175 0.17 66.24 793.64 25 4.00 66.24 6336.44 143.490.001167.61 9322.26 211.10 0.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 231.52 25 4.00 66.24 1848.46 41.8675 0.17 66.24 556.08 25 4.00 66.24 4439.77 100.540.00787.606288.23 142.40 0.00 0.00Valves Option 1Attachment 5 - Page 47Valve Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 6Valves* Gas/vapor service3,2630.00 14752.7221.50 9789.005.95 194.02 1.91 124.86* Light-liquid service5,8570.00 28075.9821.50 17571.006.30 369.24 1.97 230.76* Heavy-liquid service3,1630.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS42828.70 0.0027360.00 0.00Capital Costs ($) 42,828.70Annualized Capital ($/yr)6,082Annual Expenses ($/yr) 54,400Baseline MonitoringType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 5Valves* Gas/vapor service3,2630.00 2938.6921.50 9789.001.18 38.65 1.18 77.30* Light-liquid service5,8570.00 6146.9421.50 17571.001.38 80.84 1.38 161.68* Heavy-liquid service3,1630.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS9085.630.0027360.00 0.00Monitoring RepairBaseline Capital Costs ($) 9,085.639,085.63Baseline Annualized Capital ($/yr)1,2901,290.16Baseline Annual Expenses ($/yr) 45,53127,718.47 17,812.79INCREMENTAL COSTS OF VALVE OPTION 1Incremental Capital Costs ($) 33,743.07Annualized Capital ($/yr) 4,791.52Incremental Annual Expenses ($/yr) 8,868.30Valves Option 1Attachment 5 - Page 48Valve Option 1 Cost EstimatesType of ComponentModel 6Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSBaseline MonitoringType of ComponentModel 5Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 1035.89 25 4.00 66.24 8270.57 187.2975 0.17 66.24 1914.47 25 4.00 66.24 15285.22 346.130.002950.36 23555.79 533.42 0.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 641.30 25 4.00 66.24 5120.15 115.9575 0.17 66.24 1341.42 25 4.00 66.24 10709.93 242.530.001982.7215830.08 358.47 0.00 0.00Valves Option 1Attachment 5 - Page 49Valve Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsTotal'Frequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 1Valves* Gas/vapor service770.001314.6021.50 231.00 0.00 12.24 9.42 0.61 0.94* Light-liquid service3800.004276.5621.50 1140.00 0.00 8.07 30.65 0.61 4.64* Heavy-liquid service00.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS5591.16 0.001371.00 0.00Capital Costs ($) 5,591Annualized Capital ($/yr)794Annual Expenses ($/yr) 2,150INCREMENTAL COSTS OF VALVE OPTION 2Incremental Capital Costs ($) 3,768Annualized Capital ($/yr)535Incremental Annual Expenses ($/yr) 427Valves Option 2Attachment 5 - Page 50Valve Option 2 Cost EstimatesType of ComponentModel 1Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)50 0.17 66.24 5.2050 4.00 66.24 124.63 1.4150 0.17 66.24 25.68 50 4.00 66.24 615.07 6.960.0030.88739.70 8.38 0.00 0.00Valves Option 2Attachment 5 - Page 51Valve Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsTotal'Frequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 2Valves* Gas/vapor service4140.007068.1021.50 1242.00 0.00 12.24 50.66 0.61 5.06* Light-liquid service1,1790.00 13268.5921.50 3537.00 0.00 8.07 95.11 0.61 14.40* Heavy-liquid service710.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS20336.69 0.004779.00 0.00Capital Costs ($) 20,337Annualized Capital ($/yr)2,888Annual Expenses ($/yr) 7,494INCREMENTAL COSTS OF VALVE OPTION 2Incremental Capital Costs ($) 13,716Annualized Capital ($/yr) 1,948Incremental Annual Expenses ($/yr) 1,490Valves Option 2Attachment 5 - Page 52Valve Option 2 Cost EstimatesType of ComponentModel 2Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)50 0.17 66.24 27.98 50 4.00 66.24 670.10 7.5950 0.17 66.24 79.67 50 4.00 66.24 1908.33 21.610.00107.65 2578.43 29.19 0.00 0.00Valves Option 2Attachment 5 - Page 53Valve Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsTotal'Frequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 3Valves* Gas/vapor service1,3790.00 23543.2721.50 4137.00 0.00 12.24 168.76 0.61 16.85* Light-liquid service1,9800.00 22283.1321.50 5940.00 0.00 8.07 159.72 0.61 24.19* Heavy-liquid service1,2720.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS45826.40 0.0010077.00 0.00Capital Costs ($) 45,826Annualized Capital ($/yr)6,507Annual Expenses ($/yr) 15,802INCREMENTAL COSTS OF VALVE OPTION 2Incremental Capital Costs ($) 30,944Annualized Capital ($/yr) 4,394Incremental Annual Expenses ($/yr) 3,142Valves Option 2Attachment 5 - Page 54Valve Option 2 Cost EstimatesType of ComponentModel 3Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)50 0.17 66.24 93.19 50 4.00 66.24 2232.05 25.2750 0.17 66.24 133.80 50 4.00 66.24 3204.83 36.290.00226.995436.89 61.56 0.00 0.00Valves Option 2Attachment 5 - Page 55Valve Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsTotal'Frequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 4Valves* Gas/vapor service750.001540.7741.50 450.00 0.00 14.73 11.04 1.28 3.83* Light-liquid service2510.005300.3341.50 1506.00 0.00 15.14 37.99 1.17 11.77* Heavy-liquid service2160.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS6841.09 0.001956.00 0.00Capital Costs ($) 6,841Annualized Capital ($/yr)971Annual Expenses ($/yr) 4,132INCREMENTAL COSTS OF VALVE OPTION 2Incremental Capital Costs ($) 5,299Annualized Capital ($/yr) 752Incremental Annual Expenses ($/yr) 2,184Valves Option 2Attachment 5 - Page 56Valve Option 2 Cost EstimatesType of ComponentModel 4Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)50 0.17 66.24 21.18 50 4.00 66.24 507.42 5.7550 0.17 66.24 65.10 50 4.00 66.24 1559.35 17.660.0086.292066.77 23.40 0.00 0.00Valves Option 2Attachment 5 - Page 57Valve Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsTotal'Frequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 5Valves* Gas/vapor service1,1780.00 24200.3341.50 7068.00 0.00 14.73 173.47 1.28 60.16* Light-liquid service2,4280.00 51271.6841.50 14568.00 0.00 15.14 367.51 1.17 113.86* Heavy-liquid service1,7190.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS75472.01 0.0021636.00 0.00Capital Costs ($) 75,472Annualized Capital ($/yr)7,281Annual Expenses ($/yr) 45,913INCREMENTAL COSTS OF VALVE OPTION 2Incremental Capital Costs ($) 58,507Annualized Capital ($/yr) 4,872Incremental Annual Expenses ($/yr) 24,394Valves Option 2Attachment 5 - Page 58Valve Option 2 Cost EstimatesType of ComponentModel 5Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)50 0.17 66.24 332.74 50 4.00 66.24 7969.83 90.2450 0.17 66.24 629.76 50 4.00 66.24 15084.11 170.790.00962.5023053.93 261.03 0.00 0.00Valves Option 2Attachment 5 - Page 59Valve Option 2 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsTotal'Frequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 6Valves* Gas/vapor service3,2630.00 67033.6941.50 19578.00 0.00 14.73 480.49 1.28 166.64* Light-liquid service5,8570.00 123681.3241.50 35142.00 0.00 15.14 886.53 1.17 274.66* Heavy-liquid service3,1630.000.00hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS190715.01 0.0054720.00 0.00Capital Costs ($) 190,715Annualized Capital ($/yr)27,082Annual Expenses ($/yr) 116,286INCREMENTAL COSTS OF VALVE OPTION 2Incremental Capital Costs ($) 147,886Annualized Capital ($/yr) 21,000Incremental Annual Expenses ($/yr) 61,886Valves Option 2Attachment 5 - Page 60Valve Option 2 Cost EstimatesType of ComponentModel 6Valves* Gas/vapor service* Light-liquid service* Heavy-liquid serviceAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)50 0.17 66.24 921.67 50 4.00 66.24 22076.02 249.9550 0.17 66.24 1519.16 50 4.00 66.24 36386.99 411.990.002440.83 58463.01 661.95 0.00 0.00Valves Option 2Attachment 5 - Page 61Connectors Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 1Connectors* Flanges - gas/vapor023.800.000.25 2.50 0.000.36 0.00 0.36 0.00* Flanges - light liquid73123.80 17514.060.25 2.50 456.880.36 2.63 0.36 0.66* Flanges -heavy liquid00.000.00hr/activity$/hrAdministrative and Reports5092.72Planning and Training2092.721854.40TOTALS17514.06 1854.40456.88 0.00INCREMENTAL COSTS OF CONNECTORS OPTION 1Incremental Capital Costs ($) 19,368Annualized Capital ($/yr)2,750Incremental Annual Expenses ($/yr) 5,122Type of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 2Connectors* Flanges - gas/vapor023.800.000.25 2.50 0.000.36 0.00 0.36 0.00* Flanges - light liquid2,66223.80 63778.960.25 2.50 1663.750.36 9.58 0.36 2.40* Flanges -heavy liquid00.000.00hr/activity$/hrAdministrative and Reports5092.72Planning and Training2092.721854.40TOTALS63778.961854.401663.75 0.00INCREMENTAL COSTS OF CONNECTORS OPTION 1Incremental Capital Costs ($) 65,633Annualized Capital ($/yr)9,320Incremental Annual Expenses ($/yr) 6,405Connectors Option 1Attachment 5 - Page 62Connectors Option 1 Cost EstimatesType of ComponentModel 1Connectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAdministrative and ReportsPlanning and TrainingTOTALSType of ComponentModel 2Connectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 0.0025 2.00 66.24 0.00 0.0075 0.17 66.24 5.4625 2.00 66.24 21.79 1.644636.005.4621.79 1.64 4636.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 0.0025 2.00 66.24 0.00 0.0075 0.17 66.24 19.88 25 2.00 66.24 79.35 5.994636.0019.8879.35 5.99 4636.00 0.00Connectors Option 1Attachment 5 - Page 63Connectors Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 3Connectors* Flanges - gas/vapor023.800.000.25 2.50 0.000.36 0.00 0.36 0.00* Flanges - light liquid7,41023.80 177536.480.25 2.50 4631.250.36 26.68 0.36 6.67* Flanges -heavy liquid00.000.00hr/activity$/hrAdministrative and Reports5092.72Planning and Training2092.721854.40TOTALS177536.48 1854.404631.25 0.00INCREMENTAL COSTS OF CONNECTORS OPTION 1Incremental Capital Costs ($) 179,391Annualized Capital ($/yr)25,474Incremental Annual Expenses ($/yr) 9,560Type of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 4Connectors* Flanges - gas/vapor16423.80 4023.600.25 2.50 102.501.70 2.79 0.81 0.33* Flanges - light liquid55523.80 13616.440.25 2.50 346.881.70 9.44 0.81 1.13* Flanges -heavy liquid4540.000.00hr/activity$/hrAdministrative and Reports5092.72Planning and Training2092.721854.40TOTALS17640.031854.40449.38 0.00INCREMENTAL COSTS OF CONNECTORS OPTION 1Incremental Capital Costs ($) 19,494Annualized Capital ($/yr)2,768Incremental Annual Expenses ($/yr) 5,150Connectors Option 1Attachment 5 - Page 64Connectors Option 1 Cost EstimatesType of ComponentModel 3Connectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAdministrative and ReportsPlanning and TrainingTOTALSType of ComponentModel 4Connectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 0.0025 2.00 66.24 0.00 0.0075 0.17 66.24 55.33 25 2.00 66.24 220.88 16.674636.0055.33220.88 16.67 4636.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 2.7725 2.00 66.24 11.05 0.8375 0.17 66.24 9.3725 2.00 66.24 37.39 2.824636.0012.1348.44 3.66 4636.00 0.00Connectors Option 1Attachment 5 - Page 65Connectors Option 1 Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 5Connectors* Flanges - gas/vapor2,33323.80 57238.100.25 2.50 1458.131.70 39.66 0.81 4.75* Flanges - light liquid4,64423.80 113936.460.25 2.50 2902.501.70 78.95 0.81 9.45* Flanges -heavy liquid4,1860.000.00hr/activity$/hrAdministrative and Reports5092.72Planning and Training2092.721854.40TOTALS171174.56 1854.404360.63 0.00INCREMENTAL COSTS OF CONNECTORS OPTION 1Incremental Capital Costs ($) 173,029Annualized Capital ($/yr)24,570Incremental Annual Expenses ($/yr) 9,620Type of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 6Connectors* Flanges - gas/vapor7,64123.80 187465.220.25 2.50 4775.631.70 129.90 0.81 15.54* Flanges - light liquid13,37923.80 328242.000.25 2.50 8361.881.70 227.44 0.81 27.21* Flanges -heavy liquid7,7250.000.00hr/activity$/hrAdministrative and Reports5092.72Planning and Training2092.721854.40TOTALS515707.221854.4013137.50 0.00INCREMENTAL COSTS OF CONNECTORS OPTION 1Incremental Capital Costs ($) 517,562Annualized Capital ($/yr)73,494Incremental Annual Expenses ($/yr) 19,651Connectors Option 1Attachment 5 - Page 66Connectors Option 1 Cost EstimatesType of ComponentModel 5Connectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAdministrative and ReportsPlanning and TrainingTOTALSType of ComponentModel 6Connectors* Flanges - gas/vapor* Flanges - light liquid* Flanges -heavy liquidAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 39.37 25 2.00 66.24 157.17 11.8675 0.17 66.24 78.37 25 2.00 66.24 312.85 23.614636.00117.74 470.01 35.48 4636.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)75 0.17 66.24 128.94 25 2.00 66.24 514.74 38.8575 0.17 66.24 225.77 25 2.00 66.24 901.29 68.034636.00354.72 1416.04 106.89 4636.00 0.00Connectors Option 1Attachment 5 - Page 67OEL Monitoring Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 1OEL140.92 0.005.000.00Annual monitoring3323.80 808.1311.50 49.500.90 0.30 0.45 0.15hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS808.13 0.0049.50 0.00Incremental Capital Costs ($) 808.13Annualized Capital ($/yr)114.75Incremental Annual Expenses ($/yr) 60.79Type of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 2OEL140.92 0.005.000.00Annual monitoring14123.80 3452.9311.50 211.500.90 1.27 0.45 0.63hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS3452.93 0.00211.50 0.00Incremental Capital Costs ($) 3,453Annualized Capital ($/yr) 490Incremental Annual Expenses ($/yr) 260OEL MonitoringAttachment 5 - Page 68OEL Monitoring Cost EstimatesType of ComponentModel 1OELAnnual monitoringAdministrative and ReportsPlanning and TrainingTOTALSType of ComponentModel 2OELAnnual monitoringAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)0.0075 0.17 66.24 1.23 25 4.00 66.24 9.84 0.220.001.239.84 0.22 0.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)0.0075 0.17 66.24 5.26 25 4.00 66.24 42.03 0.950.005.2642.03 0.95 0.00 0.00OEL MonitoringAttachment 5 - Page 69OEL Monitoring Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 3OEL140.92 0.005.000.00Annual monitoring42423.80 10383.2811.50 636.000.90 3.82 0.45 1.91hr/activity$/hrAdministrative and Reports092.72Planning and Training092.720.00TOTALS10383.28 0.00636.00 0.00Incremental Capital Costs ($) 10,383Annualized Capital ($/yr) 1,474Incremental Annual Expenses ($/yr) 781Type of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 4OEL140.92 0.005.000.00Annual monitoring3923.80 996.5811.50 58.502.30 0.90 1.15 0.45hr/activity$/hrAdministrative and Reports092.720.00Planning and Training092.720.00TOTALS996.58 0.0058.50 0.00Incremental Capital Costs ($) 997Annualized Capital ($/yr) 142Incremental Annual Expenses ($/yr) 93OEL MonitoringAttachment 5 - Page 70OEL Monitoring Cost EstimatesType of ComponentModel 3OELAnnual monitoringAdministrative and ReportsPlanning and TrainingTOTALSType of ComponentModel 4OELAnnual monitoringAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)0.0075 0.17 66.24 15.83 25 4.00 66.24 126.39 2.860.0015.83126.39 2.86 0.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)0.0075 0.17 66.24 3.72 25 4.00 66.24 29.71 0.670.003.7229.71 0.67 0.00 0.00OEL MonitoringAttachment 5 - Page 71OEL Monitoring Cost EstimatesType of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 5OEL140.92 0.005.000.0023823.80 6081.7011.50 357.002.30 5.47 1.15 2.74hr/activity$/hrAdministrative and Reports092.720.00Planning and Training092.720.00TOTALS6081.70 0.00357.00 0.00Incremental Capital Costs ($) 6,082Annualized Capital ($/yr) 864Incremental Annual Expenses ($/yr) 565Type of ComponentNumber ofComponentsInitial MonitoringFee or Unit Cost($/comp)Initial LDARCosts ($)(Capital)InitialLDARAdmin.CostsFrequency ofMonitoring(times/yr)SubsequentMonitoringFee ($/comp)or Charge(%)AnnualMonitoringCosts ($/yr)AnnualMaintenanceCosts ($/yr)Initial LeakFrequency(%)InitialNumberof LeaksSubsequentLeakFrequency(%)AnnualNumberof LeaksModel 6OEL140.92 0.005.000.0090223.80 23049.1511.50 1353.002.30 20.75 1.15 10.37hr/activity$/hrAdministrative and Reports092.720.00Planning and Training092.720.00TOTALS23049.15 0.001353.00 0.00Incremental Capital Costs ($) 23,049Annualized Capital ($/yr) 3,273Incremental Annual Expenses ($/yr) 2,142OEL MonitoringAttachment 5 - Page 72OEL Monitoring Cost EstimatesType of ComponentModel 5OELAdministrative and ReportsPlanning and TrainingTOTALSType of ComponentModel 6OELAdministrative and ReportsPlanning and TrainingTOTALSPercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)0.0075 0.17 66.24 22.71 25 4.00 66.24 181.30 4.110.0022.71181.30 4.11 0.00 0.00PercentRepairedOnLineRepairTime(hours)LaborCharge($/hr)AnnualOnLine LeakRepair Cost($/yr)PercentRequiringFurtherRepairRepairTime(hours)LaborCharge($/hr)AnnualOffline LeakRepair Cost($/yr)Monitoringto VerifyRepair ($)AnnualAdmin.Cost($/yr)AnnualMisc.Charges($/yr)0.0075 0.17 66.24 86.06 25 4.00 66.24 687.11 15.560.0086.06687.11 15.56 0.00 0.00OEL MonitoringAttachment 5 - Page 73