United States
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Research Triangle Park NC 27711
Research and Development
EPA-600/S2-81-003 May t981
Project Summary
Frequency of Leak Occurrence
For Fittings in Synthetic
Organic Chemical Plant
Process Units
J. R. Blacksmith, G. E. Harris, and G. J. Langley
This report summarizes the results
of a study of the frequency of leak
occurrence in the synthetic organic
chemical manufacturing industry
(SOCMI). The work was funded by the
Environmental Protection Agency and
carried out by four contractors: Acurex
Corp.; PEDCo Environmental, Inc.;
Radian Corp.; and TRW, Inc.
The frequency of occurrence of
fugitive emissions was determined by
instrumental screening. The screening
process is defined as the measurement
of the volatile organic compounds
(VOC) concentration as close as possi-
ble to the point of suspected leakage,
such as at the valve stem, pump seal,
etc. The screening value is the maxi-
mum repeatable VOC concentration
detected for any given source, ex-
pressed in parts per million by volume
(ppmv).
A total of 24 process units in the
SOCMI were tested by the four con-
tractors. The frequency of fugitive
emission sources with screening values
equal to or greater than 10,000 ppmv
was tabulated for all units combined,
for each type of chemical process, and
for each process unit.
This Project Summary was devel-
oped by EPA's Industrial Environmental
Research Laboratory In Research Tri-
angle Park. N.C.. to announce key
findings of the research project that is
fully documented in a separate report
of the same title (see Project Report
ordering information at back).
Introduction
The U.S. EPA Industrial Environmental
Research Laboratory (IERL), Research
Triangle Park, N.C., has coordinated a
study to develop information about
fugitive emissions; i.e., unintentional
discharges or leaks, of volatile organic
compounds from equipment sources in
the synthetic organic chemical manu-
facturing industry. The results of this
study will be used by EPA in the evalua-
tion of regulatory strategies for the
control of fugitive emissions from SOCMI
process units (the SOCMI is defined as
those process units which produce, as
intermediate or final products, any of
the chemicals listed in the draft Back-
ground Information Document (BID) for
fugitive emission control standards).
Fugitive emission sources studied in-
clude process valves, pump seals, com-
pressor seals, flanges, relief valves,
open-ended lines, process drains, and
agitator seals.
The objective of the program was to
develop data on the frequency of oc-
currence of fugitive emissions from
various sources in the SOCMI. This
objective was met by a two-fold
approach:
The acquisition of fugitive emis-
sion data by the four participating
contractors listed here with re-
-------
spective EPA contract numbers:
Acurex Corporation (68-02-3176-
01,06)PEDCo Environmental,
Inc. (68-02-3173-02, 11)Radian
Corporation (68-02-3171 -01 )
TRW, Inc., Energy Systems Group
(68-02-3174-04)
Coordination of the program, ad-
ministration of quality control checks,
data processing, and preparation of
the final report by Radian Corpora-
tion.
For this program, "screening" refers
either to the measurement of fugitive
emissions at a single source or to the
overall sampling of a process unit.
"Screening value" refers to the maxi-
mum repeatable concentration of total
hydrocarbons detected at a source with a
portable hydrocarbon detector, ex-
pressed in parts per million by volume.
"Screening data" refers to the informa-
tion recorded for each screened source,
including the type of source, the screen-
ing value, line temperature and pres-
sure, ambient conditions, etc.
The frequency of occurrence of com-
ponent leaks was investigated for 14
types of chemical process units. A total
of 24 process units were screened by
four contractors. The screening took
place over a six-month period (1/22/80
to 8/1/80); an average of about one
week was spent in each process unit.
Table 1 presents the process unit identi-
fication (ID) number, the type of process,
and the contractor for each of the 24
process units.
The screening procedures began with
the definition of the process unit boun-
daries. All feed streams, reaction/sep-
aration facilities, and product and by-
product delivery lines were identified on
process flow diagrams and in the process
unit. Process data, including stream
composition, line temperature, and line
pressure, were obtained for all flow
streams.
Each process stream was then traced
in the field. In most cases, plant person-
nel assisted the screening team in
obtaining process data and identifying
sources to be screened. Accessible
sources were screened by a two-person
team (one person operating the VOC
detector and one person recording data)
as the sources were encountered along
the stream. Tags or markings were
placed on screened sources to prevent
inadvertent rescreening.
The Century Systems Models OVA-
108 and OVA-128 VOC detectors were
used for screening. The HNU Systems,
Inc., Model PI 101 Photoionization
Analyzer was also used to screen sources
at the formaldehyde process unit. The
detector probe of the instrument was
placed directly on those areas of the
sources where leakage would typically
occur. For example, gate valves were
Table 1. Chemical Process Units Screened for Fugitive Emissions
Unit No. Unit Type Contractor
1
2
3
4
5
6
11
12
20
21
22
28
29
31
32
33
34
35
60
61
62
64
65
66
Vinyl Acetate
Ethylene
Vinyl Acetate
Ethylene
Cumene
Cumene
Ethylene
Acetone/ Phenol
Ethylene Dichloride
Vinyl Chloride Monomer
Formaldehyde
Ethylene Dichloride
Vinyl Chloride Monomer
Methyl Ethyl Ketone
Methyl Ethyl Ketone
Acetaldehyde
Methyl Methacrylate
Adi pic Acid
Trichloroethylene/Perchloroethylene
1, 1, 1 -Trichloroethane
Ethylene Dichloride
Adipic Acid
Acrylonitrile
Acrylonitrile
Radian
Radian
Radian
Radian
Radian
Radian
TRW
TRW
PEDCo
PEDCo
PEDCo
PEDCo
PEDCo
Acurex
Acurex
Acurex
Acurex
Acurex
PEDCo
PEDCo
PEDCo
PEDCo
PEDCo
PEDCo
screened along the circumference 01
the annular area around the valve sterr
where the stem exits the packing glanc
and at the packing gland/valve bonnet
interface.
The maximum concentration reading
(in ppmv) on the instrument was re
corded for each source. For some sources
the reading fluctuated considerably. In
these cases, the maximum reading
repeated at least once was recorded as
the screening value.
All accessible sources of the following
source types were screened:
process valves
pump seals
compressor seals
agitator seals
relief valves
process drains
open-ended lines.
Also, a randomly selected subset of
flanges was screened. Originally, only
five percent of all flanges were screened
The subset was increased to 20 percent
of all flanges when initial results indi-
cated a higher frequency of measurable
emissions than had been encountered
in previous programs. For the purposes
of this program, "flange" referred to any
pipe-to-pipe or tubing-to-tubing con-
nection, excluding welded joints.
The following data were recorded for
each identified source:
source ID number
source type
screening value (ppmv) if the source
was accessible
type of service (gas, light liquid, or
heavy liquid)
composition of material in the line
(identities and mole fractions of the
two major organic components)
line temperature (°F)
line pressure (psig)
ambient air temperature (°F)
source elevation (number of land-
ings above ground level)
Only those sources containing at
least one weight percent VOC were
screened or identified as inaccessible.
Fittings in steam and cooling water
service were thus eliminated from
consideration. Wastewater and process
water fittings were screened if they
contained at least one weight percent
VOC.
The sources in this study were
screened at an average rate of 1.7
minutes per source for a two-person
team (or 3.4 person-minutes per source).
This average screening rate includes
-------
time spent for instrument calibration
and repair.
A three-part quality control strategy
was used to ensure experimental con-
sistency within the acquired fugitive
emission data base. These three proce-
dures were as follows:
daily instrument calibrations.
determinations of screening re-
peatability.
replicate screening by Radian qual-
ity control personnel.
Conclusions
The overall fugitive emission frequen-
cies for fittings in the 24 process units
are summarized in Table 2. The follow-
ing information is shown for the total
population of each source type:
The number of sources screened
(Column 1)
the percentage of the total identi-
fied sources that were not screened
(Column 2)
the percentage of screened sources
with screening values greater than
or equal to 10,000 ppmv (Column
3)
the 95 percent confidence interval
for the percentage of screened
sources with screening values
greater than or equal to 10,000
ppmv (Column 4)
The 95 percent confidence interval,
denoted by the upper and lower limits in
Column 4, is the interval of percentage
values that can be said, with 95 percent
certainty, to include the true percentage
value.
The sources are further categorized
by phase of the material contained by
the source. For this program, "gas"
refers to gas phase at process condi-
tions. Liquids were classified based on
their most volatile component present
at 20 weight percent or more. If that
component had a vapor pressure equal
to or greater than 0.04 psi (0.3 kPa) at
20°C, the material was classified as a
"light liquid" if not, the material was
classified as a "heavy liquid" (1 kPa =
0.145 psi = 7.50 mmHg).
The detailed results of the screening
program are presented in Fugitive Emis-
sion Profile tables. Each of these tables
presents overall data on a type of chemi-
cal process, as well as the individual
units of that type tested.
An example of a Fugitive Emission
Profile table is Table 3, which presents
data for adipic acid process units 35 and
64. Three data entries, comprising a
"cell," are presented for various source/
service combinations. The first cell in
Table 3 is 0.0%/(0.0, 7.2)/49. The first
data entry in the cell, 0.0%, represents
the combined percentage of flanges in
gas service in units 35 and 64 that had
measured screening values of greater
than or equal to 10,000 ppmv. The
second data entry in the cell, (0.0, 7.2),
is the 95 percent confidence interval.
This means that it can be stated with 95
percent certainty that the true percent-
age of sources with screening values
greater than or equal to 10,000 ppmv in
this population of screened flanges lies
within the interval of 0.0 percent and
7.2 percent. The uncertainty in the
estimated percentage of sources with
screening values greater than or equal
to 10,000 ppmv, reflected by the conf i-
dence interval, stems from random
fluctuations in source emission rates,
instrument operation, weather condi-
tions, and other factors. The third data
entry in the cell, 49, is the number of
flanges in gas service screened at units
35 and 64. As indicated in Table 3, the
confidence interval narrows with in-
creasing number of screened sources.
Table 2. Summary of SOCMI Process Unit Emissions
Source Type
Flanges
Process Drains
Open Ended Lines
Agitator Seals
Relief Valves
Valves
Pumps
Compressors
Other'
Service
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Light Liquid
Heavy Liquid
Gas
Gas
Light Liquid
Heavy Liquid
(D
Number
Screened
1,443
2.897
607
83
527
28
923
3,603
477
7
8
1
85
69
3
9.668
18,294
3,632
647
97
29
19
33
2
(2)
%Not
Screened
4.6
2.6
2.4
23.1
1.9
0.0
17.5
10.4
21.5
46.1
11.1
66.7
72.7
40.5
66.7
17.5
12.2
9.9
4.3
40.5
9.4
9.5
19.5
33.3
(3)
% of Screened Sources
with Screening Values
> 10.000 ppmv
4.6
1.2
0.0
2.4
3.8
7.1
5.8
3.9
1.3
14.3
0.0
0.0
3.5
2.9
ao
11.4
6.4
0.4
8.8
2.1
6.9
21.0
6.1
0.0
(4)
95% Confidence Interval
for Percentage of Sources
> 10,000 ppmv
(3.6, 5.8)
(0.9, 1.8)
(0.0, 0.6)
(0.3. 8.4)
(2.3, 5.8)
(0.9, 23.5)
(4.4, 7.5)
(3.3, 4.6)
(0.5. 2.8)
(0.4, 57.9)
(0.0, 36.9)
(0.0, 97.5)
(0.7, 10.0)
(0.3, 10.1)
(0.0, 70.8)
(10.8, 12.1)
(6.1, 6.8)
(0.2, 0.7)
(6.6, 11.1)
(0.3, 7.3)
(0.9. 22.8)
(6.0, 45.6)
(0.7, 20.2)
(0.0, 84.2)
'Includes filters, vacuum breakers, expansion joints, rupture disks, sight glass seals, etc.
-------
Table 3. Fugitive Emission Profile With Confidence Intervals - Adipic Acid
Source
Flanges
Process
Drains
Open Ended
Lines
Relief Valves
Valves
Pumps
Compressors
Other'
Service
Gas
Light Liquid
Heavy Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Gas
Gas
Light Liquid
Heavy Liquid
Heavy Liquid
Gas
Gas
Heavy Liquid
Weighted A verage
0.0%/fO.O, 7.2)/49
0.0%/fO.O, 84.2J/2
0.0%/(0.0, 1.2)/320
0.0%/(0.0. 30.8J/10
O.O%/(0.0, 17.6J/19
0.0%/(0.0, 97.5)/1
0.0%/fO.O, 1.8J/214
0.0%/(0.0, 84.2)/2
0.0%/(0.0, 3.8) / 95
0.0%/(0.0, 19.5J/17
0.0%/(0.0, 0.3)/1478
0.0%/(0.0, 11.6J/30
0.0%/fO.O, 97.5J/1
O.O%/(0.0, 84.2J/2
0.0%/(0.0, 97.5)/1
Unit #35
0.0%/(0.0, 21.8)/15
O.O%/(0.0, 84.2} / 2
0.0%/(0.0, 1.7)/218
0.0%/fO.O, 30.8)/10
0.0%/(0.0, 97.5J/1
O.O%/fO.O, 97.5)/1
0.0%/(0.0, 3.6)/102
0.0%/{0.0. 84.2) / 2
0.0%/(0.0, 7.9)/45
0.0%/fO.O. 19.5)/17
0.0%/<0.0,0.3)/1163
0.0%/(0.0, 97.5)/1
Unit #64
0.0%/fO.O, 10.3)/34
0.0%/(0.0, 3.6)/102
0.0%/fO.O, 18.5)/18
0.0%/fO.O, 3.2)/112
0.0%/fO.O, 7.1)/50
0.0%/fO.O, 1.2)/315
0.0%/(0.0, J1.9J/29
0.0%/(0.0, 97.5)/1
0.0%/(0.0. 84.2) / 2
0.0%/(0.0, 97.5)/1
Each cell contains: Percent > 10,000 ppmv/95% confidence interval/number screened.
'Includes rotary drum seal and tank hatch.
Recommendations
This study developed a significantly
larger data base on the occurrence of
fugitive emissions in the SOCMI than
was previously available. It also pro-
vided valuable information about the
effort required for complete monitoring
of a process unit. When combined with
the results of a closely related study of
the effectiveness of maintenance on
fugitive emissions from valves and
pumps in SOCMI process units, these
data will provide a sound basis for
structuring regulatory requirements
and for assessing the net cost of a
monitoring and maintenance program.
Table 4. Fugitive Emission Profile With Confidence Intervals -
Acetaldehyde
Source
Flanges
Process Drains
Open Ended Lines
Relief Valves
Valves
Pumps
Service
Gas
Light Liquid
Light Liquid
Gas
Light Liquid
Gas
Light Liquid
Gas
Light Liquid
Light Liquid
Unit#33
0.0%/fO.O, 10.91/32
0.0%/(0.0, 2.5/144
41.7%/(15.2, 72.3)/12
8.8%/fJ. 9. 23.7J/34
5.1%/(2.2. 9.8)/158
0.0%/(0.0, 60.2)/4
0.0%/fO.O, 70.8J/3
4.5%/<1. 9. 8.7)/178
0.5%/fO.I, 1.6)/551
9.4%/(2.0. 25.01/32
Each cell contains: Percent > 10.OOO ppmv/95% confidence interval/number screened.
Table 5. Fugitive Emission Profile With Confidence Intervals -
A cet one/Phenol
Source
Flanges
Process Drains
Open Ended Lines
Relief Valves
Valves
Pumps
Service
Light Liquid
Heavy Liquid
Light Liquid
Gas
Light Liquid
Heavy Liquid
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Light Liquid
Heavy Liquid
Unit #12
0.0%/fO.O, 4.4) / 82
0.0%/(0.0, 11.6)/30
20.0%/(2.5, 55.6)/10
0.0%/(0.0. 84.2)/2
1.5%/(0.7, 3.0)/518
0.0%/fO.O, 3.4)/107
0.0%/fO.O, 17.71/19
0.0%/(0.0. 70.8)/3
0.0%/fO.O. 36.9)/8
0.3%/fO.I, 0.7)/1818
0.0%/(0.0, 0.8J/488
2.3%/(0.3, 8.2)/86
0.0%/(0.0. 9.7)/36
Each cell contains: Percent >10. OOO ppmv/95% confidence interval/number screened.
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Table 6. Fugitive Emission Profile With Confidence Intervals - Acyrlonitrile
Source Service Weighted Average Unit #65
Unit #66
Flanges
Process Drains
Open Ended Lines
Valves
Pumps
Compressors
Other1
Gas
Light Liquid
Heavy Liquid
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Light Liquid
Heavy Liquid
Gas
Gas
Light Liquid
Heavy Liquid
2, 5.0)/142
O.O%/(0.0, 1.0)/382
0.0%/(0.0. 12.3J/28
12.5%/(0.3. 52.7)/8
100.0%/(2.5, 100.0)/1
0.9%/I0.0.4.7)/116
2.5%/(1.3, 4.3) /486
10.5%/(2.9, 24.8)/38
2.4%/fJ.O, 4.31/396
1.9%/(1.2. 2.7)/1494
0.0%/(0.0, 3.8)/95
8.2%/(2.7, 18.D/61
25.0%/(3.2,65.1)/8
O.O%/(0.0, 84.2)/2
12.5%/(0.3, 52.7)/8
0.0%/(0.0, 60.2J/4
0.0%/(0.0. 97.5)/1
1.3%/(0.0, 7.2J/75
0.0%/(0.0. 12.31/28
100.0%/(2.5, 100.0)/1
100.O%/(2.5. 100.01/1
0.0%/(0.0, 6.3) / 57
3.7%/f1.3, 8.0)/160
W.5%/(2.9, 24.8) / 38
4.4%/(2.0. 8.3)/203
2.5%/(1.4, 4.1J/591
0.0%/(0.0, 3.8) / 95
5.3%/(0.1,26.0)/19
25.0%/(3.2, 65. 1)/8
0.0%/(0.0, 84.2)/2
12.5%/(0.3,52.7)/8
0.0%/(0.0, 84.21/2
0.0%/(Q.O, 97.5)/1
J.5%/(0.0. 8.0)/67
0.0%/fO.O, 1.4)/265
0.0%/(0.0, 41.0)/7
1.7%/(0.0, 9.D/59
.7, 4.1)/326
0.0%/fO.O, 1.9)/193
1.4%/f0.8, 2.4) / 903
9.5%/(2.7, 22. 6) / 42
0.0%/(0.0, 84.21/2
Each cell contains: Percent > 10,000 ppmv/95% confidence interval/number screened.
'Includes rupture disk, head gasket, mixer, and atmospheric vent.
Table 7. Fugitive Emission Profile With Confidence Intervals - Chlorinated Ethanes
Unit #60
Trichloroethylene/
Source Service Perchloroethylene
Flanges Gas 0.0%/fO.O, 28.5J/1 1
Light Liquid 0.0%/(0.0, 0. 7)/525
Heavy Liquid 0. 0%/(0. 0. 84. 2)/2
Process Drains Light Liquid 0.0%/fO.O, 33.6)/9
Open Ended Lines Gas 0.0%/fO.O, 30.8)/10
Light Liquid 1.5%/(0.5, 3.2J/412
Heavy Liquid 0. 0%/fO. 0, 60. 2)/4
Agitator Seals Light Liquid
Relief Valves Light Liquid 0.0%/(0.0. 70.8)/3
Valves Gas 0.0%/(0.0, 12.3J/28
Light Liquid 0. 1%/(0.0. 0.3J/1620
Heavy Liquid 0.0%/fO.O, 26.5J/12
Pumps Light Liquid 8.3%/(2.8, 18.4)/60
Other' Gas 33.3%/(0.0, 90.6J/3
Light Liquid 9.5%/(1 .2, 30.4)/21
Unit #61
1, 1, 1 -Trichloroethane
0.0%/(0.0, 4.9) /7 3
1.8%/(0.2, 6.4J/111
0.0%/(0.0, 97.5)/1
1.1%/(0.3, 2.8J/373
10.0%/(0.2, 44.5J/10
O.O%/fO.O, 84.2) / 2
Unit #62
Ethylene Dichloride
0.0%/(0.0, 52.2)/5
0.0%/(0.0, 19.5)/17
0.0%/fO.O, 16. Si/20
Each cell contains: Percent > 10,000 ppmv/95% confidence interval/ number screened.
'Includes expansion joint, rupture disk, and sight glass seal.
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Table 8. Fugitive Emission Profile With Confidence Intervals - Cumene
Source Service Weighted Average Unit #5
Unit #6
Flanges
Process Drains
Open Ended Lines
Relief Valves
Valves
Pumps
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Gas
Light Liquid
Heavy Liquid
Gas
Gas
Light Liquid
Heavy Liquid
Light Liquid
Heavy Liquid
5.2%/(3.2,8.1)/367
1.6%/(0.7. 3.01/568
0.0%/fO.O, 2.8)/130
0.0%/fO.O, 45.91/6
3.2%/fO.J, 16.71/31
0.0%/(0.0, 45.9)/6
13.3%/(1.7,40.5)/15
0.0%/(0.0, 97.5)/1
100%/(2.5, 100)/1
14.1%/(11.1, 17.8)/448
10.5%/(8.5. 12.81/799
0.0%/(0.0, 1.81/198
16.0%/(4.5, 36.1 )/25
0.0%/(0.0, 70.8)/3
1.0%/(0.0, 5.5J/100
0.3%/(0.0, 1.8)/317
0.0%/fO. 0,6.2)/58
. 16.7)/31
0.0%/fO.O, 84.2) / 2
0.0%/(0.0. 45.9) / 6
100%/(2.5,
4.6%/f1.5, 10.7)/108
11.0%/(7.9, 15.1)/328
0.0%/(0.0, 5.7)/63
30.0%/(6.7, 65.21/10
0.0%/(0.0, 97.5J/1
. 10.5)/267
3.2%/(1.4, 6.21/251
0.0%/fO.O, 5.0)/72
0.0%/(0.0, 45.9)/6
0.0%/fO.O, 60.2)/4
22.2%/(2.8, 60.0)/9
0.0%/(0.0, 97.5)/1
17.1%/(13.5, 21.91/340
10.2%/(7.7, 13.4)/471
0.0%/(0.0.2.7)/135
6.7%/(0.2. 32.01/15
0.0%/(0.0, 84.2)/2
Each cell contains: Percent > 10,000 ppmv/95% confidence interval/number screened.
Table 9. Fugitive Emission Profile With Confidence Intervals - Ethylene
Source Service Weighted Average Unit #2
Unit #4
Unit
Flanges Gas 6.2%/(4.5, 8.5)/627
Light Liquid 6.1%/(4.0, 8.9)/407
Heavy Liquid 0.0%/fO.O, 4.1)/89
Process Gas 12.5%/(0.3,52.61/8
Drains Light Liquid 1.0%/fO.3, 2.51/407
Heavy Liquid 7.1%/(0.2, 33.9J/14
Open Ended Gas 12.1%/(8.7. 16.41/305
Lines Light Liquid 19.2%/fll.e. 21.1)/214
Heavy Liquid 0.0%/(0.0, 4.01/91
Relief Valves Gas 3.9%/f0.5. 13.5)/SI
Light Liquid 9.1 %/(0.2, 41.3)/11
Valves Gas 14.8%/(13.9, 15.8)/6294
Light Liquid 23.2%/(21.8. 24.7)/4176
Heavy Liquid 1.1%/(0.6. 1.8)/1237
Pumps Light Liquid 25.6%/(16.4, 36.8J/78
Heavy Liquid 0.0%/(0.0, 21.8)/15
Compressors Gas 5.9%/(0.2, 28.7)/17
3.5%/(1.1. 8. If/142
2.0%/(0.1. 10.51/51
0.0%/tO.O. 4.9)/73
50.O%/(1.3. 98.71/2
0.0%/(0.0. 3.8)/94
7.1%/(0.2. 33.91/14
22.0%/(11.5, 36.0)/50
31.6%/(17.5.48.6)/38
0.0%/(0.0. 4.11/88
6.7%/(4.6, 9.5)/448
6.9%/<4.5. 10.31/335
0.0%/(0.0. 21.81/15
0.0%/(0.0. 1.2)/300
18.3%/(10.1. 29.3)/71
16.7%/f7.9. 29.31/54
0.0%/(0.0. 70.8)/3
16.5)/2153
25.9%/(23. 1. 29.0)/1 191
37.5%/f15.2. 64.61/16
O.O%/(0.0. 21.81/15
14.3%/(0.4. 57.9)/7
20.1%/(18.1, 22.11/1970
24.2%/(22.1, 26.51/1990
3.7%/f0.5. 12,81/54
28.6%/(14.6. 46.31/35
0.0%/fO.O, 70.81/3
10.8%/(3.0. 25.41/37
4.8%/<0.1.23.8)/21
0.0%/(0.0. 97.5)/1
0.0%/(0.0, 45.9)/6
30.8%/(9.1. 61.4//13
7.1%/(3.8, 11.81/184
16.4%/f10.3. 24.21/122
3.9%/(0.5, 13.5J/51
9.1%/(0.2, 41.31/11
10.2%/(8.9. 11.61/2171
17.9%/(15.6, 20.41/995
0.0%/(0.0. 9.01/39
14.8%/(14.Z 33.71/27
0.0%/fO.O, 41.01/7
Each cell contains: Percent > 1O.OOO ppmv/95% confidence interval/number screened.
Table 10. Fugitive Emission Profile With Confidence Intervals - Methyl Ethyl Ketone
Source Service Weighted Average Unit #31
Unit #32
Flanges
Process Drains
Open Ended Lines
Agitator Seals
Relief Valves
Valves
Pumps
Compressors
Gas
Light Liquid
Gas
Light Liquid
Gas
Light Liquid
Gas
Gas
Gas
Light Liquid
Light Liquid
Gas
0.0%/(0.0, 15.4)/22
0.0%/(0.0, 4.71/76
16.7%/(0.4, 64.1J/6
21.7%/(7.5, 43.7)/23
8.1%/f1.7, 21.91/37
10.2%/(6.3, 15.51/186
0.0%/(0.0, 97.51/1
0.0%/(0.0, 70.81/3
9.2%/(5.7. 14.1)/207
5.1%/(3.6, 7.11/671
3.2%/(0.1, 16.71/31
100%/(2.5, 1001/1
0.0%/fO.O, 45.91/6
0.0%/(0.0, 10.01/35
16.7%/(0.4, 64.11/6
21.4%/(4.7, 50.81/14
8.3%/l0.2, 38.51/12
8.6%/(3.8, 16.2)/93
0.0%/fO.O, 97.51/1
0.0%/fO.O, 97.51/1
18.5%/(10.7. 28.71/81
5.3%/(3.2, 8.51/321
0.0%/fO.O, 21.81/15
0.0%/fO.O, 20.6J/16
0.0%/(0.0, 8.6)/41
22.2%/<2.8, 60.0)/9
8.0%/(1.0, 26.01/25
11.8%/(6.1, 20.21/93
0.0%/(0.0. 84.2)/2
3.2%/(0.9, 7.9)/126
4.9%/(2.9. 7.81/350
6.2%/(0.2, 30.21/16
100%/(2.5,
Each cell contains: Percent > 10,000 ppmv/95% confidence interval/number screened.
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Table 1 1. Fugitive Emission Profile With Confidence Intervals -
Formaldehyde
Source Service Unit #22
Flanges
Open Ended Lines
Valves
Pumps
Gas
Light Liquid
Gas
Light Liquid
Gas
Light Liquid
Light Liquid
0.0%/fO.O, 84.2) /2
12.5%/(0.3, 52.6)/8
0.0%/(0.0, 23.2J/J4
0.0%/fO.O. 9.7J/36
2.4%/(0.1. 12.9)/41
0.0%/(0.0, 3.0)/121
0.0%/(0.0. 36.9) / 8
Each cell contains: Percent > 10,000 ppmv/95% confidence interval/number
screened.
Table 12. Fugitive Emission Profile With Confidence Intervals -
Methyl Methacrylate
Source
Flanges
Process Drains
Open Ended Lines
Agitator Seals
Relief Valves
Valves
Pumps
Service
Gas
Light Liquid
Light Liquid
Gas
Light Liquid
Gas
Light Liquid
Gas
Light Liquid
Gas
Light Liquid
Light Liquid
Unit #34
0.0%/(0.0, 9.2)/38
0.0%/fO.O, 1.5)/247
0.0%/(0.0. 16.1)/21
0.0%/(0.0, 5.7)/63
0.3%/(0.0. 1.7J/335
33.3%/fO.O, 90.6) / 3
0.0%/(0.0, 70.8) /3
0.0%/(0.0, 60.2)/4
8.3%/(0.2, 38.5)/12
0.0%/fO.O, 1.9)/190
0. 1%/(0.0, 0.5)/1058
4.4%/(0.5. 15.1)/45
Each cell contains: Percent > 10,000 ppmv/95% confidence interval/number
screened.
Table 13. Fugitive Emission Profile With Confidence Intervals - Vinyl Acetate
Source
Flanges
Process Drains
Open Ended Lines
Agitator Seals
Relief Valves
Valves
Pumps
Compressors
Other1
Service
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Heavy Liquid
Gas
Light Liquid
Gas
Light Liquid
Heavy Liquid
Light Liquid
Heavy Liquid
Gas
Gas
Light Liquid
Weighted Average
2.8%/(0.6, 8.0J/107
0.0%/(0.0,2.1)/173
0.0%/fO.O, 36.9)/8
0.0%/fO.O, 5.7)/63
0.0%/(0.0, 97.5)/1
0.0%/(0.0, 70.8)/3
5.5%/(2.4. 10.6)/145
2.5%/(1.1, 5.0)/318
9.1%/(1.1, 29.2)/22
0.0%/fO.O, 97.5)/1
0.0%/fO.O, 70.8)/3
0.0%/fO.O, 97.5)/1
O.O%/(0.0, 97.5)/1
0.0%/fO.O, 84.2)/2
3.7%/(2.6, 5.1 )/949
0.4%/(0.2. 0.7)/2136
0.0%/(0.0, 2.9)/124
4.5%/(1.2, 11.1)/89
0.0%/iO.O, 52.2)/5
0.0%/fO.O, 36.9J/8
16.7%/f0.4, 64.1)/6
0.0%/fO.O, 45.9)/6
Unitttl
2.6%/<0.1, 13.8J/38
0.0%/fO.O, 6.4J/56
0.0%/fO.O, 70.81/3
2.7%/(0.1. 14.2)/37
0.0%/(0.0, 7.7)/46
0.0%/(0.0, 36.9)/8
0.0%/{0.0, 70.8)/3
0.0%/(0.0, 97.5)/1
0.0%/(0.0, 84.2) / 2
3.6%/(1.9, 6.4J/329
0.1%/(0.0, 0.8J/736
0.0%/(0.0. 5.4)/67
6.8%/(1.4, 18.7)/44
0.0%/(0.0. 52.2) / 5
0.0%/fO.O, 60.2)/4
16.7%/l0.4,64.1)/6
0.0%/fO.O, 45.9)/6
Unit #3
2.9%/(0.4. 10. 1)/2
0.0%/ (0.0. 3.21/1 17
0.0%/fO.O, 52.2J/5
0.0%/(0.0, 5.7J/63
0.0%/fO.O, 97.5J/1
0.0%/fO.O, 70.8)/3
6.5%/(2.6. 13.0)/108
2.9%/(1.3. 5.8)/272
14.3%/(1.8. 42.8)/14
0.0%/(0.0. 97.5J/1
0.0%/fO.O, 97.5J/1
3.7%/(2.4. 5.5J/620
0.5%/(0.2, 1.0)/1400
0.0%/(0.0, 6.3)/57
2.2%/fO.I, 11.8)/45
0.0%/(0.0, 60.2)/4
Each cell contains: Percent > 10,000 ppmv/95% confidence interval/number screened.
'Includes filter and vacuum breaker.
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Table 14. Fugitive Emission Profile With Confidence Intervals - Vinyl Chloride Mononjer
Source Service Weighted Average Unit #21
Unit #29
Flanges
Open Ended Lines
Relief Valves
Valves
Pumps
Gas 4.0%/(0.1,20.4J/25 0.0%/fO.O, 84.2J/2 4.3%/(0.1.22.0J/23
Light Liquid 0.6%/fO.O, 3.4J/163 0.0%/(0.0, 7.9)/45 0.8%/(0.0, 4.6J/118
Gas 0.0%/fO.O, 3.6)/100 0.0%/fO.O, 60.2)/4 O.O%/fO.0,3.81/96
Light Liquid 3.4%/(2.0, 5.5J/473 4.8%/fO.6, J6.2J/42 3.2%/(1.8. 5.5)/431
Gas 0.0%/fO.O, 41.0J/7 0.0%/fO.O, 45.9J/6 0.0%/fO.O, 97.5)/1
Light Liquid 0.0%/(0.0, 30.8J/10 0.0%/fO.O, 30.8J/10
Gas 1.0%/(0.3, 2.5J/402 0.0%/fO.O, 4.6)/79 1.2%/(0.3. 3.2)/323
Light Liquid 1.1 %/(0.7, 1.6)/2250 0.0%/fO.O, 0.6J/670 1.5%/(1.0, 2.3J/1580
Light Liquid 5.3%/(1.1, 14.6)/57 0.0%/(0.0, 30.8)/10 6.4%/(1.3, 17.5)/47
Each cell contains: Percent > 10,000 ppmv/95% confidence interval/number screened.
Table 15. Fugitive
Source
Flanges
Process Drains
Open Ended Lines
Agitator Seals
Relief Valves
Valves
Pumps
Emission Profile
Service
Gas
Light Liquid
Light Liquid
Gas
Light Liquid
Gas
Light Liquid
Gas
Light Liquid
Gas
Light Liquid
Light Liquid
With Confidence Intervals
Weighted A verage
12.5%/(1.6. 38.4)/16
O.O%/(0.0, 7.61/47
40.0%/(5.3. 85.3J/5
3.6%/f0.4, 12.5J/55
5.3%/(3.2. 8.4)/340
0.0%/fO.O, 84.2)/2
O.O%/(0.0, 97.5J/1
0.0%/fO.O, 26.5J/12
0.0%/fO.O, 33.6J/9
7.3%/(5.0, 10.3J/412
1.0%/f0.5, 1.7J/1210
10.8%/(4.4, 20.9J/65
- Ethylene Dichloride
Unit #20
0.0%/(0.0, 30.8J/10
0.0%/fO.O, 8.8)/40
50.0%/(1.3,98.7)/2
0.0%/fO.O, 11.6)/30
2.3%/f0.8, 5.5J/213
0.0%/(0.0, 84.2) / 2
0.0%/fO.O, 97.5J/1
0.0%/fO.O, 41.0)/7
0.0%/(0.0, 41.01/7
2.2%/(0.8. 4.8)/276
0.5%/(0.1. 1.3)/798
9.1%/(2.5.21.7)/44
Unit #28
33.3%/(4.3, 77. 7)/ 6
0.0%/fO.O, 41.0)/7
33.3%/fO.O, 90.61/3
8.0%/fl.O, 26.0)/25
10.2%/(5.6, 16.91/127
0.0%/fO.O, 52.2)/5
0.0%/(0.0, 84.20/2
17.6%/(11.7,25.2)/136
1.9%/(0.8, 3.8J/412
14.3%/(3.1,36.3)/21
Each cell contains: Percent > 10,000 ppmv/95% confidence interval/number screened.
J. R. Blacksmith, G. E. Harris, and G. J. Langley are with Radian Corporation,
Austin, TX 78759.
Bruce A. Tichenor is the EPA Project Officer (see below).
The complete report, entitled "Frequency of Leak Occurrence for Fittings in
Synthetic Organic Chemical Plant Process Units," (Order No. PB 81-141 566;
Cost: $14.00, subject to change) will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Industrial Environmental Research Laboratory
U. S. Environmental Protection Agency
Research Triangle Park, NC 27711
ft Ua GOVERNMENT PRINTING OFFICE 1S81 -757-012/7116
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