United States Off ice of Air Quality EMB Report No. 80-OSP-1
Environmental Protection Planning and Standards June 1981
Agency Research Triangle Park NC 27711
6EPA
On-Shore Production of
Crude Oil and Natural Gas
Fugitive Volatile Organic
Compound Emission Sources
Emission Test Report
Houston Oil and Minerals Co.
Smith Point Plant
Chambers County, Texas
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DGN 81-222-018-04-39 EMB Report No. 80-OSP-l
EMISSION TEST REPORT
FUGITIVE VOC TESTING
AT
HOUSTON OIL AND MINERALS
SMITH POINT PLANT
Prepared by:
G. E. Harris
Radian Corporation
8501 Mo-Pac Boulevard
Austin, Texas 78759
Prepared for:
Winton Kelly
U. S. Environmental Protection Agency
ESED/EMB (MD-13)
Research Triangle Park, North Carolina 27711
EPA Contract No. 68-02-3542
Work Assignment No. 4
17 October 1981
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CONTENTS
Section Page
1 Introduction 1
2 Summary of Results 3
3 Process Description 9
4 Testing Methodology 13
APPENDIX A 17
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FIGURES
Number Page
3-1 Simplified flow diagram for adsorption Unit A 11
11
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TABLES
Number Page
2-1 Summary of Results: VOC Concentration Occurrence
Distribution Houston Oil and Minerals Smith Point
Gas Plant
2-2 Summary of Results: Soap Scoring Occurrence
Distribution Houston Oil and Minerals Smith Point
Gas Plant
2-3 Summary of Results: VOC Concentration Occurrence
Distribution Houston Oil and Minerals Smith Point
Tank Battery
2-4 Summary of Results: Soap Scoring Occurrence
Distribution Houston Oil and Minerals Smith Point
Tank Battery
2-5 Summary of Results: Component Inventory Houston Oil
and Minerals Smith- Point Tank Battery
4-1 Calibration Error Determination 14
4-2 Response Time Determination ,..,.., 15
1.11
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SECTION 1
INTRODUCTION
This report presents the results of testing for fugitive VOC (Volatile
Organic Compounds) emissions at the Houston"Oil and Minerals gas plant
near Smith Point, Texas. The testing was - performed by Radian Corporation
on October 6 through October 8, 1980. This work was funded and administered
by the Emission Measurement Branch, of the U.S. Environmental Protection
Agency. The purpose of this testing was to develop data to be used in support
of New Source Performance Standards for onshore production facilities.
The testing described in this report consisted of a screening survey
using two fugitive emission detection methods, EPA Method 21 using portable
analyzers and soap scoring. The objectives: of this testing were to:
1). Determine leak frequency by each, method, and
21 Collect comparative data on each, method so that emission
data from other sources could be used to support New
Source Performance Standards-.
The following sections present a summary of results, a description of
the process configuration, and the testing methodology. A full listing of
the data and other supplemental information are included in the appendices,
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SECTION 2
SUMMARY OF RESULTS
This section presents a summary of the screening data. A full
data listing is included as Appendix A.
The gas plant screening results are summarized in Tables 2-1 and 2-2.
Table 2-1 presents the distribution of VOC concentration readings for each
source type, while Table 2-2 presents similar data on soap scores.
The screening results for the production tank battery are presented
separately, since this facility is not part of the gas plant. The limited
screening data obtained for the tank battery are presented in Table 2-3 and
2-4 for VOC concentrations and soap scores, respectively. Table 2-5 presents
a complete inventory of fittings on the tank battery.
It should be noted that the source type called flanges actually includes
a variety of pipe-to-pipe connections including threaded fittings, unions,
and compression-type tubing fittings. Welded joints were not included in this.
survey. The "other" category represents a group of sources that were too few
in number to warrant separate listing. Included in the "other" category
were sight glasses, vacuum breakers, meters, pig traps, control valve
diaphragm vents, and thermowells.
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TABLE 2-1
SUMMARY OF RESULTS:
VOC CONCENTRATION OCCURRENCE DISTRIBUTION
HOUSTON OIL AND MINERALS
SMITH POINT GAS PLANT
Source Type
PROCESS
Screening Value FLANGES' DRAINS
(ppmv) it % // %
0 TO 199 180 80.7 0
200 TO 9,999 31 13.9 0
>= 10.000 12 5.4 0
TOTAL SOURCES SCREENED 223 19.8 0
SOURCES NOT SCREENED 902* 80.2 0
TOTAL SOURCES 1125* 0
OPEN RELIEF PUMP
ENDED LINES VALVES VALVES SEALS COMPRESSORS OTHER
It % //%#%#% it 7. it %
,a ,, 0 1 10.0 197 59.5 0 0.0 0 — 18 39.1
£.0 o/ . 2.
10 22.2 0 0.0 56 16.9 1 100.0 0 — 14 30.4
7 15.6 9 90.0 78 23.6 0 0.0 0 — 14 30.4
45 95.7 10 90.9 331 97.1 1 100.0 0 — 46 100.0
2 4.3 1 9.1 10 2.9 0 0.0 0 — 0 0.0
47 11 341 1 0 46
# - NUMBER OF SOURCES
% - PERCENT OF TOTAL SOURCES SCREENED
* ESTIMATED VALUE - EVERY FIFTH FLANGE WAS SURVEYED
-------
TABLE 2-2
SUMMARY OF RESULTS:
SOAP SCORING OCCURRENCE DISTRIBUTION
HOUSTON OIL AND MINERALS
SMITH POINT GAS PLANT
SOURCE TYPE
SOAP SCORE
0
1
2
3
4
TOTAL SOURCES SOAPED
SOURCES NOT SOAPED
TOTAL SOURCES
FLANGES
It %
205
6
2
6
5
224
901*
1125*
91.5
2.7
0.9
2.7
2.2
19.9
80.1
PROCESS
DRAINS
// '/
It /o
0
0
0
0
0
0
0
0
OPEN
ENDED LINES
t %
9 60.0
2 13.3
3 20.0
0 0.0
1 6.7
15 31.9
32 68.1
47
RELIEF
VLAVES
t %
7
1
0
0
1
9
2
11
77.8
11.1
0.0
0.0
11.1
81.8
18.2
PUMP
VALVES SEALS
# % t %
235
10
15
16
55
331
10
341
71.0 1
3.0 0
4.5 0
4.8 0
16.6 0
97.1 1
2.9 0
1
100.0
0.0
0.0
0.0
0.0
100.0
0.0
COMPRESSORS
#. %
0
0
0
0
0
0
0
0
OTHER
# %
20
5
1
0
10
36
10
46
55.6
13.9
2.8
0.0
27.8
78.3
21.7
# - Number of Sources
% - Percent of Total Sources Soaped
* - Estimated Value - Every fifth flange was surveyed
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TABLE 2-3
SUMMARY OF RESULTS:
VOC CONCENTRATION OCCURRENCE DISTRIBUTION
HOUSTON OIL AND MINERALS
SMITH POINT TANK BATTERY
SOURCE TYPE
PROCESS
SCREENING VALUE FLANGES DRAINS
(PPMV) // 7. It 7.
0 TO 199 7 100.0 0
200 TO 9,999 0 0.0 0
>- 10,000 0 0.0 0
TOTAL SOURCES SCREENED 7 100.0 0
SOURCES NOT SCREENED 0* 0.0 0
TOTAL SOURCES 7* 100.0 0
0.0
OPEN RELIEF PUMP
ENDED LINES VALVES VALVES SEALS COMPRESSORS OTHER
» % 6 % # % t % # % // %
5 83.3 2 33.3 41 97.6 0 — 0 — 1 100.0
1 16.7 3 50.0 0 0.0 0 — 0 — 0 0.0
0 0.0 1 16.7 1 2.4 0 — 0 — 0 0.0
6 100.0 6 85.7 42 100.0 0 — 0 — 1 100.0
0 0.0 1 14.3 0 0.0 0 0 — 0 0.0
6 7 42 0 0 1
// - NUMBER OF SOURCES
7. - PERCENT OF TOTAL SOURCES SCREENED
* ESTIMATED VALUE - EVERY FIFTH FLANGE WAS SURVEYED
-------
SOAP SCORE
TOTAL SOURCES SOAPED
SOURCES NOT SOAPED
TOTAL SOURCES
TABLE 2-4
SUMMARY OF RESULTS:
SOAP SCORING OCCURRENCE DISTRIBUTION
HOUSTON OIL AND MINERALS
SMITH POINT TANK BATTERY
FLANGES
II %
7 100.0
Source Type
PROCESS
DRAINS
0.0 0
0.0 0
0
7 100.0 0
0* 0.0 0
7* 0
- NUMBER OF SOURCES
- PERCENT OF TOTAL SOURCES SOAPED
OPEN
ENDED LINES
RELIEF
VALVES
VALVES
PUMP
SEALS
COMPRESSORS
3 100.0
0 0.0
0 0.0
4 100.0 41 97.6 0
0 0.0 0 0.0 0
0 0.0 0 0.0 0
0 0.0 0 0.0 0 0.0 0
0 0.0 0 0.0 1 2. It 0
3 50.0 4 57.1 42 100.0 0
3 50.0 3 42.9 0 0.0 0
6 7 42 0
OTHER
0
0 0.0
0 0.0
1 100.0
* ESTIMATED VALUE - EVERY FIFTH FLANGE WAS SURVEYED
-------
Component Type
Valves - block/gate
- block/plug
- block/ball
- control/globe
- control/plug
Flanges
Open-ended lines
Relief valves
TABLE 2-5
SUMMARY OF RESULTS:
COMPONENT INVENTORY
HOUSTON OIL AND MINERALS
SMITH POINT TANK BATTERY
Service
Population
Gas
Liquid
Gas
Liquid
Gas
Liquid
Gas
Liquid
Gas
Liquid
Gas
Liquid
Gas
68
16
51
15
6
16
5
2
708
263
3
10
9
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SECTION 3
PROCESS DESCRIPTION
The Houston Oil and Minerals Smith Point Plant is located on the upper
Texas Gulf Coast. This gas plant uses the solid bed adsorption principle to
partially remove ethane and heavier hydrocarbons from natural gas before
routing it to a sales gas pipeline.
Natural gas liquids are removed by adsorption onto silica gel in a set
of swing adsorbers. The treated natural gas goes to a pipeline for sale with
custody transfer taking place before the metering station. The natural gas
liquids are stripped from a spent bed with hot regeneration gas and then
condensed. The condensed liquids are routed to on-site tankage, from which
they are periodically off-loaded into tank trucks for sales.
This site had three separate adsorption units (Units A, B, and C).
Adsorption Unit A was the largest of the three with a capacity of 60 MMSCFD
(million standard cubic feet per day). During the testing, the charge rate
to Unit A varied from 55 MMSCFD to 33 MMSCFD. Unit B (capacity 20 MMSCFD) was
shut down and depressured, so no survey was conducted there. Unit C (capacity
of 30 to 60 MMSCFD) was not operating, but it was under pressure with natural
gas. A survey of Unit C was, therefore, performed. There was also an oil
production tank battery at this site, so a limited survey was made of that
area. The results sections are coded as follows to distinguish between sources:
Unit No. Description
Adsorption Unit A and the storage and loading
facilities
2 Adsorption Unit C
3 Tank Battery
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Figure 3-1 presents a simplified schematic diagram of one cycle of opera-
tion of Adsorption Unit A. The inlet gas flows through a liquid knock-out
drum and into a manifold of time-cycled three-way valves. In the cycle shown
in the drawing, the feed gas is routed through adsorbers #1 and #2 and out to
sales. A slipstream of the treated gas is heated and routed to adsorber #3
for regeneration. The rich outlet from adsorber #3 ±s condensed and the liquids
routed to storage. The noncondensibles are used as fuel in the regeneration
gas heater. Adsorber #4 is cooling prior to return to adsorption service.
In the next cycle, adsorbers #1 and #4 would be in adsorption service,
adsorber #2 would be regenerating, and adsorber #3 would be cooling. Four
such consecutive cycles would return the unit to the starting point.
Adsorption Units B and C were quite similar, except that they had only
three adsorbers each. With only one vessel in adsorption service, these units
would finish a complete loop in only three cycles.
10
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HIGH
PRESSURE
SEPARATOR
LOW
PRESSURE
SEPARATOR
TREATED GAS
TO SALES
REGENERATION
GAS HEATER
M NORMALLY CLOSED
[XJ NORMALLY OPEN
Figure 3-1. Simplified flow diagram for adsorption Unit A.
(Shown in one of four possible cycles)
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12
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SECTION 4
TESTING METHODOLOGY
The fugitive emissions testing at this site was limited to "screening."
Screening is a generic term covering any quick, portable method of detecting
fugitive emissions. Two screening methods were used in parallel on this task,
instrumental screening (using the Century Systems OVA-108) and soap scoring.
The instrumental screening was done according to the procedures
specified in EPA Proposed Method 21.! The instrument performance evaluations
are included as Tables 4-1 and 4-2. Method 21 only requires the exact con-
centration to be recorded if it is over the leak definition specified in
the applicable standard, but since this effort was more oriented to
standards support than to regulatory monitoring, the maximum screening
value was recorded for all sources.
The soap scoring method was modeled after a method used in screening fugitive
2
emissions from petroleum production facilities. The soap solution was prepared
from 100 ml. of rug shampoo (HR Professional Formula) mixed with a gallon of
either distilled water or a mixture of distilled water and ethylene glycol.
The solution was applied using a common garden sprayer.
Each source was sprayed with soap solution, being sure to coat all areas
of potential leakage. A careful inspection was then conducted to detect any
bubble formation. A soap score was then assigned based on the estimated bubble
volume generated in a six-second observation:
federal Register, v46 n2 Monday Jan. 5, 1981, pp. 1160.
zEaton, W.S., et al. "Fugitive Hydrocarbon Emissions from Petroleum Production
Operations." API Publication No. 4322, American Petroleum Institute (1980).
13
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TABLE 4-1
CALIBRATION ERROR DETERMINATION
Instrument ID cei
iturv Svqfpms OVA-1 08
Serial Number: 2158
Run
No.
1.
2.
3.
4.
5.
6.
7.
a.
9.
Mean Difference
Calibration Error
^ 'Calibration Gas
Calibration Gas Data i-g-si
Calibration « "990 ppmv
Instrument Meter Di
Reading, ppm
8000
8200
3000
8000
8000
8400
8100
8500
8200
( 2}
- Mean Difference^ ' ,nn
Calibration Gas Concentration A
Concentration - Instrument Reading
fference^ '
ppm
-10
-210
-10
-10
-10
-410
-110
-510
-210
-166
-2.1
14
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TABLE 4-2
RESPONSE TIME DETERMINATION
Instrument ID
Century Systems OVA-108
Serial Number: 2158
Calibration Gas Concentration
7990 ppmv
1-9-81
90% Response Time:
Without Dilution Probe
1. 5.8
2. 7.0
3. 5.5
Response Time
Seconds
Seconds
Seconds
6.1
With Dilution Probe
7.1 Seconds
9.5 Seconds
7.0 Seconds
Seconds
7.8 Seconds
15
-------
Soap Score Estimated Bubble Volume
0 No detectable bubbles
1 0 to 1 cc/6 sec
2 1 to 10 cc/6 sec.
3 10 to 100 cc/6 sec.
4 >100 cc/6 sec.
The screening methods outlined above were used on every accessible
source except for flanges. Approximately 20 percent of the flanges were
screened because of their large population. Sources screened included valves,
flanges, pumps, compressors, open-ended lines, drains, relief valves, and
other miscellaneous sources. The survey was conducted on a line-by-line basis
to minimize the time required to obtain process data, such as the composition
and phase of the material in the line. For those sources that were not screened
due to either physical inaccessibility or safety problems which prevented close
approach, entries were recorded on the data sheets to insure that a complete
source inventory was obtained.
16
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APPENDIX A
TABLE A-l: Full Data Listing
TABLE A-2: Listing of Coding Conventions
TABLE A-3: Material Coding Sheets
TABLE A-4: QA/QC Data
17
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18
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TABLE A-l.
FULL DATA LISTING
19
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Screening Data Sheet
1234 56
PlanI
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11 12 13
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14 15
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-------
Date
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Plant) M
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Screening Data Sheet
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Screening Data Sheet
Date
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14 15
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Screening Data Sheet
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Screening Data Sheet
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-------
Screening Data Sheet
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Date|/4|f £l8 Q|
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Plant
1234 56
7 a
Screening Data Sheet
Process Unit I 1.31
9 10
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11 12 13
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Plant
1234 56
7 8
Screening Data Sheet
Process Unit
9 10
Screening Team I / \2~] 3 I
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-------
TABLE A-2
PROTOCOL FOR CODING
THE
SCREENING DATA SHEET
99
-------
TABLE A-2. DATA CODING CONVENTIONS
Columns Coding
1,2 Month (i.e., May = 05, October = 10)
3,4 Day of the month
5,6 Year (19 8. 0)
7,8 A sequential identification number assigned to each plant.
9,10 An identification number for each process unit encountered.
For example:
let 01 = Gas Plant - Adsorption
02 = Gas Plant - Cryogenic
etc.
11,12,13 A unique identification number assigned to each screening
team. Each team member is assigned a personal ID number
between 0 and 9. Column 11 will then contain the ID for the
soap score reader, column 12 will be the OVA operator, and
column 13 will be the data recorder.
14,15 A sequential ID number assigned to each instrument used.
Outside documentation should then include:
Instrument 1 = OVA #2158
Instrument 2 = OVA #1575
etc.
16-21 A sequential ID number for each source encountered. Start
back at No. 1 for each new plant.
22 - 28 The instrument screening value in ppmv.
29,30 Source Type Code
Source Code
Flange 1
Process drain 2
Open-end line 3
Agitator seal 4
Relief valve 5
100
-------
TABLE A-2. DATA CODING CONVENTIONS (continued)
Columns
Coding
29,30 (cont'd)
Valves
On-line
Pump
Seals
Source Code
*Block valve - gate type 10
Block valve - globe type 11
Block valve - plug type 12
Block valve - ball type 13
Block valve - butterfly type 14
Block valve - other types 15*
Control valve - gate type 20
Control valve - globe type 21
Control valve - plug type 22
Control valve - ball type 23
Control valve - butterfly type 24
•Control valve - other types 25*
D
Single, mechanical, emission point at seal 30
Single, mechanical, emission point at vent 31
Single, mechanical, other emission point 32*
Double, mechanical, emission point at seal 33
Double, mechanical, emission point at vent 34
Double, mechanical, other emission point 35*
Single, packed, emission point at seal 36
Single, packed, emission point at vent 37
Single, packed, other emission point 38*
Sealless pumps 39*
*Explain in comment field.
101
-------
TABLE A-Z. DATA CODING CONVENTIONS (continued)
Columns
29,30 (cont'd)
Off-line
Pump
Seals
On-line
Compres-
sor
Seals
Source
'Single,
Single,
Single,
Double,
Double,
Double,
Single,
Single,
Single,
Coding
mechanical, emission point at seal
mechanical, emission point at vent
mechanical, other emission point
mechanical, emission point at seal
mechanical, emission point at vent
mechanical, other emission point
packed, emission point at seal
packed, emission point at vent
packed, other emission point
Sealless pumps
'Single,
Single,
Single,
Double,
Double,
Double,
Single,
Single,
Single,
Sealless
mechanical, emission point at seal
mechanical, emission point at vent
mechanical, other emission point
mechanical, emission point at seal
mechanical, emission point at vent
mechanical, other emission point
packed, emission point at seal
packed, emission point at vent
packed, other emission point
compressors
Code
40
41
42*
43
44
45*
46
47
48*
49*
50
51
52*
53
54
55*
56
57
58*
59
^Explain in the comment field.
102
-------
TABLE A-2. DATA CODING CONVENTIONS (continued)
Columns Coding
29,30 (cont'd) Source
Off-line
Compres-
sor
Seals
Single, mechanical, emission point at seal
Single, mechanical, emission point at vent
Single, mechanical, other emission point
Double, mechanical, emission point at seal
Double, mechanical, emission point at vent
Double, mechanical, other emission point
Single, packed, emission point at seal
Single, packed, emission point at vent
Single, packed, other emission point
Sealless compressors
Vacuum Breakers
Expansion Joints
Rupture Disks
Sight Glass Seals
31 Service Code -
Code
60
61
62*
63
64
65*
66
67
68*
69*
70
71
72
73
1 = Gas at Process Conditions
2 = Light Liquids (naphthas and lighter with a vapor
pressure _> 0.04 psi @ 20°C)
3 = Heavy Liquids (kerosene and less volatile liquids
with a vapor pressure < 0.04 psi @ 20°C)
32 - 35 Material Code - a unique sequential identification number
for each new process stream encountered. The code should be
explained on the "Material Coding Sheet" shown as Table A-3
The stream description should include information about
specific components and their concentrations (i.e., de-
propanizer overhead - 80% propane, 11% propylene, 3% ethane,
6% isobutane).
*Explain in the comment field.
103
-------
TABLE A-2. DATA CODING CONVENTIONS (continued)
Columns Coding
36 Elevation Code -
0 = Below ground level (pits, etc.)
1 = Ground level
2 = 1st Platform above ground
3 = 2nd Platform above ground
etc,
37 Accessibility Code -
Blank = normal (easy) accessibility
1 = accessible with a free standing ladder or a
minor amount of scaffolding
2 = accessible only with a crane, cherry picker,
or major scaffolding
3 = physically accessible, but not safe to
approach
4 = emission point inaccessible because it is hard
piped to a control device
5 = shrouds or other safety devices prevent access
to the seal area
? = Other codes may be assigned and documented in
the field
38 Soap Score Code -
0 = No detectable bubbling during the six second
observation period
1 = Zero to 1 cc total bubble volume in six seconds
2 = 1 cc to 10 cc per six seconds
3 = 10 cc to 100 cc per six seconds
4 = > 100 cc per six seconds, which is characterized
by bubbles popping before the 6 second period is up
and/or the soap solution being blown away from the
seal area
39 Orientation Code -
1 = Horizontal seal interface (vertical-mounted valve)
2 = Vertical seal interface (horizontal-mounted valve)
3 — Diagonal seal interface
4 = Rotating seal, no soap score possible
104
-------
TABLE A-2. DATA CODING CONVENTIONS (continued)
Columns Coding
40 - 79 Comments - Free form alpha-numeric field which can be used
to describe any significant information noted about the
source, such as:
VISIBLE LIQUID EMISSION,
VISIBLE VAPOR EMISSION,
HOT SOURCE, SOAP VAPORIZING,
COLD SOURCE, ICE FORMING,
SEAL AREA VENTED TO FLARE,
SCREENED AT SEAL OIL VENT, etc.
105
-------
106
-------
TABLE A-3
MATERIAL CODING SHEETS
107
-------
TABLE A-3.. MATERIAL CODING SHEET
^/X/f/
,
Plant ID / , Process Unit ID
1-2 34
Stream Description Code
^7//- __
5678
L
1
}
/ 1 , „ ' _ ,i " V 37 38 39 40
}
}
-}
108
t+P Set,. £«.r~ 10+ %
'' > 13 14 15 16
3
21 22 23 24
29 30 31 32
_ ___ £_
45 46 47 48
G?«.s tram Oner- fO-h ~£"&& . £•>- «\- ~7
~n ' > . 53 54 55 56
Sfcrav* Q-P £*\~ > g_
61 62 63 64
69 70 71 72
77 78. 79 80
-------
TABLE A-3. MATERIAL. CODING SHEET
H-^f
Plant ID / , Process Unit ID
I
-}
-y
•y
2
Stream. Description Code
5678
13 -14 15 16
21. 22 23 24
30 31 32
. 37 38 39 40
45 46 47 48
53 54 55 56.
61 6Z 63 64.
69 70. 71 72.
77 78- 79 80
109
-------
TABLE A-3. MATERIAL CODING SHEET
Plant ID / , Process Unit ID /
12 34
Stream DescriDtion Code
^j
5678
/ /> 13 14 15 16
I
}
-}
_ _ - _£.
21 22 23 24
L'l+«°,l-
29 3Q 31 32
' jsr.&jl-. C,6 *. (*7..Cf=+rz) 37 38 39 40
LPG;- Cf» 3.,-rx c, --*.4 c3 -r.5" Jci'- **%
& 70%
"45 46 47 4T
}
3
53 54 55 56
'..... > 61, 62 63 64
7
^l
V
3
69 70 71 72
77 78 79 80
110
-------
TABLE A-4
QA/QC DATA
111
-------
CALIBRATION CHECKING FORM
JC.
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1 1 i 1 1
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Dilution Probe
Calibration
9n
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1 1 III
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1 II I 1
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III!!
Comments:
-------
TABLE 7-2
REPEAT SCREENING FORM
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Comments:
------- |