EMB Report 78-OCM-12F
December 1979
CD
POLLUTION
EMISSION TEST
O
m
PETROLEUM REFINERY
FUGITIVE EMISSIONS
Refinery "E"
Gulf-Coast U.S.
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Emission Measurement Branch
Research Triangle Park. North Carolina
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EMB Project No. 78-OCM-12F
Emission Test Report
Miscellaneous Refinery Equipment VOC Sources
at
Refinery "E", Gulf Coast U.S.
Winton Kelly
K. C. Hustvedt
ESED, OAQPS, EPA
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Table of Contents
I. Introduction 1
II. Summary of Results 2
III. Process Description 6
IV. Sampling and Analysis Procedures 7
Appendix
Field Data Sheets
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I. Introduction
The Environmental Protection Agency is preparing a series of documents
to .describe reasonable available control technology (RACT) for use by the
States in developing implementation plans for control of volatile organic
compound (VOC) emissions. Leaks from refinery.equipment (pumps, valves,
drains, etc.) are a potentially significant source of VOC emissions and
therefore a study was begun to determine reasonable control techniques for
this type source.
Testing was conducted by Emission Standards and Engineering Division,
OAQPS, EPA personnel at a Gulf Coast U.S. refinery (designated as
"Refinery E" in a study conducted by Radian Corporation for the Environmental
Protection Agency ^ ;) during November.28-30, 1977. . The purpose of this
test was to collect emission data for use in formulating the recommended
level of control.
A portable hydrocarbon analyzer was used to determine the localized VOC
concentration near individual sources and the ambient VOC levels in the
unit processing areas. In.addition to the survey work performed in close
proximity to individual sources, the ambient VOC concentrations along the
refinery perimeter were measured and recorded.
(1) "Emission Factors and Frequency of Leak Occurrence for Fittings in
Refinery Process Units", EPA Report No. EPA-600/2-79-044, February 1979.
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II. Summary of.Results
The refinery fenceline. surveys were used to generally establish a
background anbient hydrocarbon concentration. The records of these
surveys are included in the Appendix. During the surveys, several
elevated VOC concentrations were observed, however, no attempt was made
to locate the specific location and cause for the indicated increases.
Walkthrough surveys were conducted in the aromatic extraction unit
and the saturated gas plant. The results from the aromatics extraction
unit survey cannot be easily evaluated since these are numerous elevated
ambient concentrations, generally up to 60-70 ppm.
The saturated gas plant results-generally show increased ambient
concentrations in the area where a number of individual components were
found to be leaking. Also, in those sections where no leaks were found,
generally no ambient increases were observed.
The results of individual component surveys at 5. cm from.the.potential
leak source are summarized for all units.tested in Table II-l. Summaries for
each individual unit are presented in Tables II-2 to II-3: In each of the
summaries, the number of components that had localized VOC concentration
readings in each of the ranges indicated is given for types of equipment
and all equipment combined. The number of readings in each range is
divided by the total number of measurements to determine an occurrence
frequency distribution.
- The field data sheets are included in the Appendix.
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Table II-1 - Summary: Numbers on Components in All Units Tested vs. Volatile
Organic Compound Emission-Concentration Ranges (Refinery E)
VOC Emission
Concentration
(ppm)
0 - 100
101 - 1000
1001 - 10,000
Over 10,000
Total
% of components
Emitting VOC Greater
than 100 ppm
% of Components
Emitting VOC Greater
than 1000 ppm
Number
Pump
Seals
30
6
2
5
of Components
Compressor
Seals
1
0
0
0
Emitting
Drains
8
10
1
5
VOC at Designated Concentrations
mock
Valves
80
30
13
19
L'ontro 1
Valves
54
5
1
1
block & control
Valves
134
35
14
20
Open-Ended
Valves
1
0
0
2
Pump
Seals
Offa 7:'0nb
17
3
0
2
13
3
2
3
43
30
16
0
24
67
25
142
44
23
61
11
203
34
17
67
67
22
21
23 38
24
0 - 100
101 - 1000
1001 - 10,000
Over 10,000
Total
% of Components
with VOC Greater
than 100 ppm
% of Components
with VOC Greater
than 1000 ppm
Total Components
174
51
17
32
274
36
18
Footnotes:
a Pumps not operating
Pumps operating
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Table II-2 - Numbers of Components in Saturated Gas Plant vs. Volatile
Urganic Compound Emission-Concentration Ranges (Refinery E)
Seals
8
4
1
4
Valves
30
19
9
18
Control
Valves-
27
3
1
1
Drains
4
8
1
5
Bleed
Valves
0
0
0
2
Compressor
Seals
1
0
0
0
Seals
Off5 / Or£
4 4
2 2
0 1
2 2
VOC Emission Number of Components Emitting VOC at Designated Concentrations
Concentration
(ppm)
0-100
101 - 1000
1001 - 10,000
Over 10,000
Total 17 76 32 18 2 1 89
% of components
Emitting.VOC Greater
than 100 ppm 52 61 16 78 100 0 50 56
% of Components
Emitting VOC Greater
than 1000 ppm 29 36 6 33 100 0 25 33
Total Components
0 - 100 70
101 - 1000 34
1001 - 10,000 12
Over 10,000 30
Total 146
% of Components
with VOC Greater
than 100 ppm 52
% of Components Footnotes-
with VOC Greater footnotes.
than 1000 ppm 29
Pumps not operating
Pumps operating
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Table II-3 - Numbers of Components in Aromatic Extraction (BTX) Unit vs.
Volatile Organic Compound Emission-Concentration Range?
(Refinery E)
VOC Emission
Concentration
0 - 100
101 - 1000
1001 - 10,000
Over 10,000
Total
% of components
Emitting VOC Greater
than 100 ppm _
% of Components
Emitting VOC Greater
than 1000 ppm _
Number of Components Emitting VOC at Designated Concentrations
Seals
22
2
1
1
.
Valves
50
11
4
1
Control
Valves
22
2
0
0
Seals
Drains
4
2
0
0
Off3 ,
13
1
0
0
f Onb
9
1
1
1
26
15
66
24
24
33
14
12
25
17
0 - 100
101 - 1000
1001 - 10,000
Over 10,000
Total
% of Components
with VOC Greater
than 100 ppm
% of Components
with VOC Greater
than 1000 ppm
Total Components
98
17
5
2
122
20
Footnotes:
Pumps not operating
Pumps operating
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III. Process Description
Refinery E .is a fairly Targe integrated refinery located in the
U.S. Gulf Coast area. . It is a recently.built grass-roots refinery and is
owned by one of the major oil companies.
Two units.were surveyed during the test period; an aromatics recovery
unit and a saturated gas plant. Both units were operating normally during
testing.
-------
IV. Sampling and Analytical Procedures
The analysis instrument used at.these facilities^was a Century
Systems Corporation OVA-108 organic vapor analyzer/ ' The.analyzer
was calibrated with methane by the local instrument distributor immediately
prior to the beginning of the test program.
The refinery fence!ine surveys-vwere conducted.by placing the instrument
probe outside an automobile window and driving around the refinery perimeter
at speeds of 10-15 mph. VOC concentrations and their location were
recorded on a refinery plot plan and a portable strip chart recorder.
Walkthrough surveys.were conducted by first selecting a survey
path through the process unit so that all ground level pumps and
control valves could be surveyed at an upwind and downwind distance
of about 1 meter. Reference points to indicate location were noted
on a unit plot plan.. Then the path was walked slowly. The instrument
meter was observed during the survey, and the VOC concentrations were
recorded onaportable chart recorder. The prevailing.wind direction
was recorded on a unit plot plan for each walkthrough.
The cooling tower was evaluated by recording hydrocarbon concentration
around the base of the tower, around the top railing, and in the fan
exhaust vents.
Wastewater separators were evaluated by walking around the liquid pit
area with the instrument probe positioned about 0.5 meter above ground
level and recording the concentration.
The height above water level at this probe location varied due to the
liquid level and is noted on the respective data sheets. Any pumps and
valves associated with waste water separators were evaluated by the
procedures described below.
Individual component surveys were conducted by placing the probe
inlet at a distance of 5 cm from each potential leak.source and
traversing the periphery. The largest reading observed was recorded.
(1) Mention of a. specific-product or trade name does not constitute
endorsement by the Environmental Protection Agency.
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APPENDIX A
FIELD DATA SHEETS
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