Multi-Media Inspection
Union Carbide Corporation,
Institues, WV
EPA Region III
Environmetnal Services
Division
January 4, 1985
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M u! * i - M 9 d i a Compliance Inspection
O i i i
on Carbide Corporation.lnstitute, WVA
EPA, REGION III
Environmental Services Division
January 4th, 1985
WV 00002
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TABlE of contents
Section
I
II
III
IV
V
VI
VII
Title
Executive Summary
MIC Product ion/Storage
Safety Systems
Compliance Inspection -
Clean Air Act
Compliance Inspection -
CERCLA
Compliance Inspection -
Clean Water Act and SPCC
Compliance Inspection -
RCRA
Compliance Inspection -
TSCA
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Section I - Executive Summary
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1. Purpose of Inspection
The purpose of Che inspection is co determine if this facility is operating
in compliance with the following laws:
° Clean Air Act
° Clean Water Act
° Toxic Substance Control Act
0 Resource Conservation and Recovery Act
° Comprehensive Environmental Response, Compensation,
and Liability Act of 1980
2. General Information
A) Name/Location of the facility:
Union Carbide Corporation
Institute, West Virginia
B) Dates of Inspection
December 7, 8, 10, and 11, 1984
C) Participants
1) EPA
Gary Bryant - (TEAM LEADER) - EPA Region III
Scott McPhilliaoy - EPA Region III
Jack Downie - EPA Region III
William Klettner - EPA Region III
Richard Eaton - EPA Region III
Thomas Fielding - EPA - Chemical Industry Branch, Headquarters
2) Union Carbide Corporation
Nate Martin - Environmental Protection Dept.
L.A. Davis - Shift Supervisor
Mr. Mike Miller - Production Engineer
Ross Rankman - Engineer
Mike Villers - Engineer
Bob Ketcham - Engineer
Mark Trivison - Dept. Head-Energy Systems
Lee Pattan - Engineer
Frank Hardin - Training- Coordinator
E.D. Hunter - Operator
Richard Runyan - Engineer
3) State of West Virginia
Mark Casdroph
> ~ >
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2
3. General Findings
The following findings are based on the Environmental Services
Division's observations during the inspection. The Regional Office
is gathering additional information to supplement the inspection
findings.
Thomas E. Fielding, Industrial Technology Division, Office of
Water, at the request of the Regional Office, participated in the
inspection on December 11th for the purpose of providing technical
assistance. His report describes the various safety systems to
prevent catasprophic releases of MIC at this plant. The systems
include automatic with manual back-up process controls; various air
pollution control devices including scrubbers arid flares; temperature
and pressure automated shut down controls; back-up storage capacity;
and special start-up procedures. All units appear to be well maintained
but a more detailed inspection would be required to determine the
integrity of the systems.
A. Air
The Institute, WV Plant has two (2) steam plants providing
steam for the total facility. Steam plant #1 has six (6) usable boilers
and steam plant #2 has three usable boilers. The fuels used include
pulverized coal, fuel oil, ethane, hydrogen, and by-product residues.
Both sceam plants use electo-static precipitators to control particulate
air pollution. Low sulfur coal (0.61Z Co 0.84%) Is used to control S02
emissions. Our observations at the time of inspection Indicated the
following:
- In compliance with State Implementation Plans (SIP) for SO2,
particulate, and visible emission at the time of inspection.
- The boilers are also used to dispose of sludge wastes. Tests
show 99% efficiency.
- VOC regulations are not part of the SIP and were not evaluated
during this inspection.
Even though the air compliance Inspection was limited to the boilers
units since the emissions from these units are regulated by the State
Implementation Plan, the Regional Office was able to obtain a copy of
the volatile organic carbon emission inventory. It is titled, "Summary
of UCC's, Institute, 1981 Emission Inventory Listed by Pollutant" and
has been included in the inspection report.
/- s-
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3
B. Water
There are two separate sewer systems at this facility. One system
is for the cooling water and has three outfalls that go directly into
the Kanawha River. The second system is for process water and flows to
a waste water treatment unit located about a half mile downsteam from
the main plant. The facility has a comprehensive monitoring system,
however, in the course of the inspection it was discovered that the TOC
monitoring system and TOC permit limits may not be adequate to prevent a
significant toluene release from one of the cooling water outfalls into
the Kanawha River. The results of the inspection indicate the following:
- The TOC permit limits may be too high to detect "spills"
of specific organic compounds
- Compliance with NPDES permit with the exception of the
December 5th and 7th toluene spills
C. RCRA
The facility has filed a Part B permit application with the Regional
Office. It appears that one hazardous waste storage hopper was found
to have the date last emptied as July 8, 1984, and this was interpreted
to possibly indicate storage for a period longer than 90 days. In
addition, it appears that small quantities of MIC used to test for
purity were being treated at the facility laboratory. Based on this
Inspection the potential compliance problems are as follows:
- Minor violations of interim 90 storage status requirements.
- Very small quantities of MIC treated within plant, without
a permit.
D. CERCLA
While reviewing safety records maintained by Union Carbide, OSHA
discovered several instances where MIC had been released from the MIC
production unit. Review of records kept from 1980 thru 1984 indicated
a total of 28 releases. Further information must be gathered to
determine if the releases were entirely contained in the facility or
reached the environment. The quantities released ranged from less than
one pound to greater than ten pounds. Determining the actual quantity
released would be very difficult. These releases occured because of
equipment failure, residual quantities of MIC in lines released during^
human errors, sample collection, etc. Our~inspection results also
indicate a delay in reporting the toluene release to EPA. The results
of our inspection indicate the following:
- There were some unreported MIC releases that possible-should
have been reported to EPA.
- Failure to promptly notify EPA during the December 5th toluene
spill.
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E. Toxic Substance Control Act
There appear to be uo major compliance problems with the PCB
regulations. Additional information will be needed to deternine
compliance with Section 8c and 8e.
F. Spill Prevention Control and Countermeasure Plans
There is a minor violation since the facility didn't incorporate
three underground gasoline storage tanks into the plan. The company
is correcting this oversight.
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Section II - MIC Production/Storage
Safety Systems
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UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON. D.C. 20460
DEC I 3 SSA
OFFICE OF
WAT6H
SUBJECT:
PROM:
TO:
THRU:
Technical Assistance to Region III
and Inspection of the MIC Production
Unit at Union Carbide, Institute, WV
•
Thomas E. Fielding, Chemist
Chemicals Industry Branch
Industrial Technology Division (WH-552)
Jack McGraw, Deputy Assistant Administrator
for Solid Waste and Emergency Response (WH-562A)
ilU \
-?A
Jeffery D. Denit, Director ^ ..
Industrial Technology Divis^nMWn-552)
At the request of Stanley Laskowski, Deputy Regional
Administrator, EPA Region III, I visited the Union Carbide,
Institute, West Virginia Chemicals Manufacturing Plant on
December 11, 1984 to provide technical assistance to the
Region III and Occupational Safety and Heal^ Administration
(OSHAV inspection teams at the plant, who v:?re conducting
compliance monitoring inspections of the plant in general,
and tkH methyl isocyanate (MIC) production unit in particular.
In party the provision of the requested technical assistance
include^ conducting an inspection of the MIC production unit
at Unioiv, Carbide's Institute, West Virginia, plant. I was
accompanied by Mr. L.A. Davis, shift supervisor for the MIC
unit, Mr.\Nate Martin, Institute plant Environmental Protection
Department, and Messers. Gary Bryant, Scott McPhilliaray, and
Jack Downi«, EPA Region III Environmental Services Division.
The MIC unit was not in operation at the time of the inspection.
MIC i£\produced by the gas phase reaction of mononethyl
amine (MMA) \and phosgene. The product and any unreacted MMA
and phosgeneiare condensed, separated, &md the MIC is purified
and stored fir later in-plant use or sale. The process is
controlled^ automatically with manual controls as back-up.
All vents on V:he production unit are connected to a "normal"
scrubber (UniAn Carbide's term), and the unit is designed so
that any releases of MIC or other gases in excess of scrubber
2-
< 1 / i r> 1 ,1 • .1 £ 2. ^ 7 O ft O 7 Q ttf)?
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capacity trigger automatic shutdown of the production unit.
Any changes in control pressures or temperatures also are
supposed to trigger automatic"\shutdown cT the unit. Shift
operators are to monitor the nnnual controls and activate
them if any automatic controls fail to operate. Safety
equipment, including fresh air. self-contained air packs, and
safety showers are located in t.\e unit to allow operators to evacuate
safely and to safely shutdown th>:. unit. The production unit
is designed to shutdown if any M.\£, phosgene, or mma release
occurs or might occur.
The purified MIC from the production unit feeds first to
one of three "make" tanks. These i\hree tanks are protected
from external damage by armor chair' since they are above
ground, and are kept cold (about -ll)°C (14°F)) when MIC is in
the tanks. Two of the tanks were empty at the time of the
inspection. The make tanks operate \at up to 80% capacity; if
the MIC level in the tank rises to 8y% of capacity, the MIC
production unit automatically shuts Aown. In addition to the
three make tanks, there is also an at.">ve ground dump tank which
is twice the size of any of the make VaPks. The dump tank is
to take any liquid or vapor MIC over ^uad.
•
The MIC from the make tanks is fee to any of three
underground storage tanks. These threA tanks are horizontal
and completely buried and are about twii
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There were some short lengths of pipe and valve handles
with exterior rust, but the vast majority of the production
and storage units looked clean and neat* A more detailed
investigation would be required to determine the integrity of
the equipment and overall safety of the operation. The brief
inspection of the production unit conducted as part of the
technical assistance provided to Region III and OSHA was not
sufficiently detailed to allow assessment of the safety of
the unit.
2-3
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Section III - Compliance Inspection
Clean Air Act
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U.S. ENVIRONMENTAL PROTECTION AGENCY
REGION III
WHEELING FIELD SECTION
303 METHODIST BLDG., 11th & CHAPLINE STREETS
WHEELING, WV. 26003
DATE: December 26, 1984
U3JECT-. Air Compliance Incpecuicn Report
FROM: Air Investigation Unit (3ES13.)
Wheeling Field Section, Region III
TO: Robert Kramer, Chief (3ES12)
Air Monitoring and EIS Preparatio-
Attached is a copy of the Air Compliance Inspection report on
Union Carbide Corporation - Institute, WV.
If you have any questions, .please call.
Attachments: Process Residues A1-A2
Boiler-Major Emission Points B1-B39
Visible Emission Report C1-C4
THRU: Gary V. Bryant, Chief
Wheeling Field Section (3ES13)
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REGION III, U.S. ENVIRONMENTAL PROTECTION AGENCY
Wheeling ,Field Section, Wheeling, WV.
Air Compliance Inspection Report
General Information
Company Name: Union Carbide Corporation
Address: Institute, '.west Virginia"
(City): Institute (County) Kanawha (State) WV.
Form of Ownership Same CDS?
Date(s) of Inspection December 10-11 , 1984
Arrival Time: 1: 31PM/7:45AM Departure Time: 4:00PM/1:40PM
Company Personnel: Nate Martin, Senior Staff Engineer; Ross Rankman, Lead
Engineer #1 Steam Plant; Mike Villers, Lead Engineer #2 Steam Plant; Bob Ketch
Control Systems Engineer; Mark Trivison, Dept. Head Energy Systems; Lee Pattari
Staff Engineer.
State Personnel:
EPA Personnel* William Klettner (Report Writer) & Dick Eaton, Wheeling EPA
Office
Type of Inspection: Boiler Plant inspection in conjunction with EPA total in-
spection at the subject facility.
A. Type of Facility (Including production rates, employees, etc):
At the ieiuest of Regional Headquarters an Air Compliance Inspection of the
Union Carbide Corporation steam plants located at Institute, WV., was con-
ducted on 12/10-11/84. This inspection was part of a multi EPA team inspectio
conducted at this facility in response to the MIC disaster which .occurred in
Bhopa.l.,-.
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2
3. Specific Observations & Boiler Plant Operating Data
The Institute, WV., plant has two (2) steam plants providing process steam for the
total facility. Information and data for these steam plants is as follows:
1.
Steam plant ID
No. 1 Steam Plant
No. 2 Steam P.lant
2.
No. boilers
8
3
3.
Boilers IO's
#1 ,2,3,4,5,6,7 & 8
#10,11 and 12
4.
Boilers no longer used
#8 and 7
None
5.
Boiler in Temporary storage #1 and 6
None
6.
Boiler in operation
#2,4 & 5 on 12/10/84
#10 & 11 on 12/10/84
#2,3,4 on 12/11/34
#10 & 11 on 12/11/84
7.
Boiler Type
/\11 boilers at both plants
are pulverized coal fired
balanced draft units
8.
Boiler manufacturer
All units - Reilly Stoker
Combustion Engineering
9.
Year installed
1940 thru 1946
1957 thru 1964
10.
Boiler bottom type
Dry
Dry
11 .
MAX design output of steam
lb/i.f.
175,000 each
270,000 each
12.
Continuous steam pressure
lb/hr.
400 lbs.
1000 lbs.
13.
Max. design heat input
10^ Btu/hr.
236 each
380 each
14.
Max. fuel burn rate lb/hr
20,000 each
32,200 each
15.
Boiler Efficiency
#1,2,5 & 6 = 80%
#10,11 « 12 = 87%
#3 & 4 = 85%
16.
Fuel; burned
Pulverized coal
Pulverized coal
fuel oil
fuel gas
ethane
oil in an emergency
hydrogen
(no by-product residues
by-product residues
are burned at this static
17.
Number of stacks
8 (1 stack per boiler)
1 common stack
18,
Stacu diameter
Rectangular 6 1/2 X 10 1/2'
25'
19.
Stack height
125' from ground level
200'
#1,2,5 & 6
132' from ground level
#3 and 4
20.
Ash retained in furnace
40%
40%
21.
Fly ash handling
Pumped to pond at Dunbar,WV
Bottom ash is taken out
by a contractor and sold for fill. -
22.
% excess air/boiler
3% to 3 1/2 %
10% to 1 5%
23.
Emission controls
Research Cottrell ESP's
Buell ESP's
24.
No. "oal pulverizers
Two (2) per boiler
Two (2) per boiler
For more detailed boiler information refer to Attachments B1 thru B39 provided by
the company. This data is process inventory information prepared at the request of
WVAPCC.
Boilei plant number 2 also procudes electricity via two turbine generators
(12 megawatts) for plant use.
3-3
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3
Both steam plants operate 24 hours per day, 7 days par week.
In s^eam plant ?1 , the following burning conditions exist. In boilers £1
through £6 pulverized coal is burned at two burners at the upper level of these
units. Boilers #1 and #6 are equipped with oil fire igniters to fire fuel oil or
by product liquid feed on the 2 lower elevation burners. Boilers #2,3,4 and 5 have
gas fired igniters rated for continuous service. Boilers #3,4 and 5 are equipped
to burn hydrogen gas on their upper elevation burners, and boilers #3 and #5 are
also being equipped to burn hydrogen or ethane gases on their lower elevation
burners.
For a detailed listing of by-product gases burned in the steam plants refer to
corrpany furnished Attachments A1 and A2 Process Residues and PPM Metals by Catalyst.
Ccal burned at the steam plants is normally purchased from 6 or 7 suppliers, however
only two comoanys are supplying the steam plants atthe present time. Normally a 60
to 90 day supply of coal is maintained, however, due to the anticipated coa.l strikes
during the summer of 1934 the company built up their stockpile. As the strike did n<
occur both steam plants are working off this active storage pile. There is approx-
imately 49,000 tons of coal in this active pile. Grab samples are collected on a
weekly or biweekly basis and analyzed by an outside laboratory Technical Testing
Laboratory, Charleston, WV.
A ci.?c:< of several months of coal analysis reports indicated that the company is
purchasing low sulfur coal which has a sulfur content that averages .61% to .84%
aL ? Btu value of 12,-000 to 13,000 Btu's. The company maintains they are meeting
the SO2 requirements by using this low sulfur coal.
The last analysis on record was for November 21, 1984, with the following results:
The company at present does no backup analysis on the coal, but is anticipating
starting such a program in the future.
Coal coming into the plant is delivered by truck, is sent to the stockpile or direct"
to one of two double roll crushers prior to being conveyed to the steam plants. 0nl\
the £1 crusher was operating at the time of the inspection visit. The #2 crusher
was down for repair of a sheared pin. Both^crushers are located- within a building.
The only emission controls for dust created byvthe crushing process is a Johnson
Marsh dust suppressant system, whereby dust suppressant is sprayed on the coal on
the onveyor to the crushers. According to company officials this suppressant is
seldom needed as the coal received by truck or off the storage pile is usually wet
and no dust is created. Each crusher handles approximately 500 tons of coal per
day.
As Received
Dry Basis
% Ash
% Moisture
5 Sulfur
Btu/lb.
15.78
9.41
.61
11,013
.68
12,157
17.41
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No accurate amount of coal being burnt in the two steam plants could be obtained
.at ,th.a_.tA;7ie_af--ttie-inspect.!on as-the-amount-burned-is dependent on the av-ai 1 abi 1 ity
of by-product fuel and hydrogen gas. The company representatives estimated roughly
iOCQ tons of coal per month is burned. Cn a daily basis depending on operating con-
ditions 100 to 200 tons can be burned.
The following boiler room operating data was obtained:
12/10/84 - Boiler No. 2 4 5 10 11
Drum Pressure 403 395 369 993 992
Super Heater Temp. 623°F 599°F 639°F 773°F 753°F
Stack gas leaving preheater outlet - flue gas temperature
Boiler No. 2 4 5 10 11
TTTT 527JF 426°F 680°F 629°F
Economizer inlet 457°F
Economizer outlet 339°F
12/11/84 - Boiler No. 2 3 4 10 11
Drum Pressure 412 404 404 995 996
Super Heater Temp. 640°F 618°F 609°F 755°F 753°F
Stack gas leaving preheater outlet - flue gas temperature
Boiler No. 2 3 4 10 11
TOT SETT "5T7T WF 348°F'
Economizer inlet 4268F
Economizer outlet 340°F
No breakdown of fuels burned in the #1 steam plant was available for 12/10/84,
however, the different fuels being burned on 12/11/84 was as follows:
Boiler No. 2 3 4
Coal/day 50,000 lb. 50,000 lb. 50,000 lb.
Gas ignition/day 17,000 ft3
Hydrogen/day 15,000 ft3 15,000 ft3
Ethane/day 5,000 ft3 5,000 ft3
3y-product liquid/day 13,000 gal. 7,000 gal. 7,000 gal.
C. Electrostatic Precipitators (ESP's) and Opacity Monitors
Data regarding the ESP's located at both steam plants is as follows:
No. 1 Steam Plant - Each of the No. 1 steam plants 8 boilers has a Research
Cottrell ESP preceded by a "Cyclo-Trel 1" mechanical collector. The mechanical
collectors each are rated at 100,000 cfm, at a dust load of 4.6 grains per cubic
feet, at 450°F. These collectors have a design efficiency of 85%.
The R.C. ESP's have a rated gas volume of 120,000 cfm. Each ESP has two sections/
fields with 30 plates per section. Each section is 24 feet high by 12 feet long.
3-
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5
There are two R.C. TR sets per ESP. Each energized field is approximately 12 feet
long. Each section is fitted with bottle-weightpd wires. The-plates are wrapped at
variable sequential rates. Each unit has a pneumatic ash transport system. Readinqs
are taken on the TR sets once every shift in order to monitor the ESP's operation.
These ESP's are located on the cold side of the boilers after the 10 fans.
2. No. 2 Steam Plant - Each of the No. 2 steam plants 3 boilers has a Buell ESP
associated with it. The Buell ESP's are located on the hot side of the boilers.
Each unit has a rated collection efficiency of 94.7%. Each ESP has 5 fields arranged
in the direction of the gas flow. Each has a total surface collection area of
66,000 square feet and is fitted with the conventional wieghted wires. The flue
gases flow over the top of the ESP's back through the ESP's and preheaters out to the
stack. All 3 ESP units are common manifolded into one 200 foot stack.
Fly ash collected from the ESP hoppers and boilers (same for the No. 1 steam plant)
are pumped to an ash storage pond. Bottom ash is water ejected from the boilers
into a dewatering bin for removal by contract trucking. The bottom ash is collected
manually.
The total particulate emission rates when firing coal atthe No. 2 steam plant based
on source tests was 42 pounds per hour. The allowaLTlT~is 95 lbs/hr. The steam plant
operation with fuel oil contaminant emission reate of 917 pounds per hour made up
of the following: 1. 77 lbs/hr particulater
2. 240 lbs/hr S02
3. 24 lbs/hr CO2
4. 26 lbs/hr HC
5. 550 lbs/hr N0X
The above rates were obtained from source test results from tests conducted by
Entropy Environmental at the No. 2 steam plant in 1979. Additional test results
is as follows:
Date - 1/13-2/1/79
Boiler No. - 12
Test Results - 0.0080 gr/ACF
Caution Efficiency - 99.59% (average for 3 test runs)
Date - 2/28/79
Boiler No. - 11
Test Results - 0.0071 gr/ACF
Collection Efficiency - 99.70% (average for 3 test runs)
Date - 3/31/79
JJoiler No. - 10
test Results - 0.0062 gr/ACF
Collection Efficiency - 99.72% (average for 3 test, runs)
The only source test that was available for the No. 1 steam plant at the-time of
the inspection visit was one conducted in October 1980, for the "burning of Pesticide
B insecticide by-product residues. According to the test report Pesticide B in-
secticide produces large quantities of residues high in sulfur and nitrogen. The
source test was conducted to check on potential cyanide, hydrogen sulfide and hy-
3 -I
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6
drogen chloride emission problems. It appears that heavy hydrocarbons (polynuclear
aromatic hydrocarbons) many of which are chlorinated are resultant in the Pesticide
3 process.
The test results showed that most of all the chlorine feed was converted to HCL,
and all the sulfur feed was converted to SO2/SO3 and was discharged from the stack.
Methomyl residue, a by-product of the MIC process, was the residue burned during
the test.
The company representatives feel that they are meeting the SO2 standards even
though SO2/SO3 is discharged out the stack when burning by-product residues,
because of the low sulfur coal which makes up nearly 60% of the fuel feed to the
boilers.
Although SO2 monitors (Lier Siegler manufacturer) were installed at both steam
plants. None of the units appeared to be operating at the time of the inspection.
One of the company representatives stated that SO2 is not being monitored.
Visible emissions are monitored at both steam plants via Lier Siegler Opacity monitors
Maintenance on the opacity monitoring system is questionable as no regular maintenance
program appears to be in effect. When asked about their program the company rep-
resentative replied they follow the manufactures recommendations on maintenance,
but did not know what the recommendations were. The equipment appears easily^
accessable for maintenance. At the #1 steam plant the monitors are located at
each stack outlet for boilers 1,2,4, 5 and 6, and in between the economizers and
"ESP's on boiler 3 & 4. At the #2 steam plant the monitors are located after
the ESP at each boiler with a fourth monitor located two-thirds of the way up the
common manifolded stack.
The opacity monitors at both steam plants are Lier Siegler RM-41 double pass monitors
with Lier Siegler Recorders and Honeywell strip charts. Readings recorded during
the inspection visit are as follows:
Date: 12/10/84
Time: 3:12PM
No. 1 steam plant
Boiler No. 2
*3
30%
4
TO
20%
5
21%
Opacity Monitor 10%
Opacity Recorder 10%
~The number 3 boiler was being brought on line.
Date: 12/10/84
Time: 3:31PM
No. 2 steam plant
3oiler No. 10
11
TM
7%
Opacity Monitor 6.9%
Opacity Recorder 7% 7%
Opacity Monitor common stack = 16% opacity (3:32PM)
3- 7
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7
Date: 12/11/84
Time: 10:51AM
No. 1 steam plant
3oiler Mo.
Opacity Monitor
Opacity Recorder
2'
TnT"
10%
9%
9%
9%
9%
Date: 12/11/84
Time: 9:54AM
No. 2 steam plant
Boiler No.
Opacity Monitor
Opacity Recorder
10
TTT
21%
11
6.2%
7%
Opacity Monitor Common Stack = 10%
ESP Readings taken at the time of the inspection are was follows:
1. Mo. 1 Stean PI ant
Date Time Unit No.
TZ/TO TTOTPM '
12/11 1 0: 54?M
T
4
5
2
3
4
2. No. 2 Steam Plant
Date Time Unit No.
12/10 -3:33PM
10
3:37PM
11
12/11 9:55AM
10
10:00AM
11
Outlet
A. C
Inlet
D.C.
Outlet
D.C.
Inlet
Amps
"Z5S
200
Lot voltage
250
250
270
Primary Primary Secondary Secondary
Section Amps Volts Mi 1i amps Volts
230
.3
.2
180
.1 7
.2
300
.32
.29
235
.3
.22
230
.4
.28
180
.24
.2
10A
140
260
.1
28
108
95
210
.1
20
IOC
150
210
1.1
22
100
130
210
.92
20
1OE
140
200
.1
20
11A
25
250
.2
28
118
70
200
.4
14
11C
60
190
.4
15
11D
150
210
1.1
19
HE
150
200
1.1
18
10A
140
260
1.0
28
10B
95
210
1
21
IOC
145
220
1.05
22
10D
130
210
.92
20
10E
140
210
.1
20
11A
20
200
.1
28
118
70
200
.4
14
11C
60
200
.36
18
110
150
220
1.18
20
he
150
200
1 .14
18
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8
On 12/10/84, no visible emissions opacity observations were conducted due to a
dense fog that was covering the entire area thus making Method 9 observations
i-possible. However, brief glimpses of the steam plant stacks indicated no
visible emissions. On 12/11/84, visible emission observation and documentation
was conducted on the stacks of both steam plants. As no emissions were observed
during the entire time of the inspection visit, only 15 minute observations were
conducted. See Attachments CI thru C4.
3-5
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COMPLIANCE STATUS
UNION CARBIDE CORPORATION
INSTITUTE STEAM PLANTS #1 & £2
INSTITUTE, WV.
12/10-11/84
COMPLIANCE STATUS
Based on the fact that no visible emissions were observed or documented, the fact
that low sulfur coal is being burned in conjunction with fuel oils or by-product
liquids of high Btu value, it is highly unlikely that non-compl ianc
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RECOMMENDATIONS
UNION CARBIDE
INSTITUTE STEAM PLANTS #1 and #2
INSTITUTE, WV.
1 2/10-11/84
RECOMMENDATIONS
1. Due to all the confusion at che time of the inspection visU in an attempt
to provide all the inspectors information they were requesting source, test results
for tests conducted at both steam plants was not available for all the boilers. A
114 request should be made requesting this information to better determine' compliance
with applicable hazardous emission standards as the boilers are in essence incin-
erators for by-product liquids resulting from the manufacture of pesticides.
2. Sena a copy of this report to Robert Kramer, Chief of the Air Monitoring Section
(3E312). Mr. Kramer should send a copy of this report to the appropriate personnel
in AEB.
3 -//
-------
5
WEST VIRGINIA AIR POLLUTION CONTROL COMMISSION ACTIONS
"WVAPCC "staff were Che first government agency Co begir. ^ollectina data at Che
Institute Plant. chey will be monitoring all MIC at thir plant until ic is all
consumed. Currently chey
9 monitor all tanks including tank cars, trucks,
and drums of MIC every two hours.
° monitor the temperature, pressure and liquid level
of MIC plus temperature of Che nitrogen blanket at
all stationary tanks.
0 monitor all caustic scrubbir systems which serve
MIC storage.
3 monitor transfer of MIC within the plant. No MIC
being shipped otit of the p^.nt. Only LARVIN Pro-
duction Unit presently consuming MIC - rate 1 ton/hr.
Plan to bring up SEVIN Production Unit by Thursday
December 13 - will consume 3 ton/hr.
0 Reported volume MIC on hand Thursday December 6, 1984.
384 Tons abo"e ground
309 Tons below ground
693 Tons Total
1 - /a.
-------
HP ACT 1V11V Willi:
tiie
0,1?
0.50
17.2*9
10 Pen. F.
AccAone.
014010
Aceltoiie
1 J3i
4-02-14
iio temp
tiie
2 Peg. temp
xi&e-laueAed
no temp >Uie
lane teil
4 Peg. temp
liic-taucmd
96,3
I10H4
gt. titan
150 Pe.i. F.
Actole-in
|35l?0
mdp!
LhiIl£i
N74
1-26-84
t Dep.
tiie
1 Peg. temp
iU&e.-no fai/eA
3 Peg', temp
xiie-no I an vi
10 Peg. temp
1 i it'
64.4
none
none
lea than
20 Pea. F.
Acioiicu
135120
TUBA and
S-l?
1] ST
fciULA
3-19-84
iio temp
tlie
no temp Jiltt
no teap tise
lat/Med
mo temp -tiie
tai/Med
0.13
i
tAace 14. HI
g tCie
no temp i~Lie
2.32
tAace
14.525
tea tha»i
30 Peq. F.'
Actofeoi
J 35120
HPP.aiirf /
S-lf
77 ST
Ta.LtA
5-I7-I4
t Peg.
tiie.
4 Peg. Uie
9 Peg. tejup '
tae
2 Peg. temp
\iie-laiit\ed
1 Peg. tewp
¦rLie
1
0.12
tAace 12.405
gt. {hail
150 Peq. F.
I'otyox
161200
Pofiox
Rei^dues
im
3-29-84
iio temp
ute
4 Pea. C.
1 Peg. f.
Ian tied
3 Pen. C.
44. 7
i
Viacc ! 5.76t
gt. than
150 Peq. F-
M-t-ic Opet
0S6600
CPR|Ug/i£J
andjHvifi
1916
1717
3-19-84
no temp
xlie
no -temp tue
no temp A.i.ic
no temp xu>e
layened
22.61
Viace j 9,553
75 Peg. F.
Rigid Pcly
16512
P/ieiio£,Anti
Wale-t
5003
3-19-14
no teup
lite.
13 Peg. C. Xeirp
xlit
no teap rise
4 Peg. C. temp
liie
91.2t
tAace *417
gt. than
ISO Peg. F.
Kigid Pchj
16515
Cap4
-------
PPM MCTAIS B^ CATAiySl' UBOKATOlil'
YA
.VI
OPUCTIO.v
iir
PROCESS
aeswies
1AHK.
DATE
At
CA
CM
CK
cu
Ft
M
fit
;ig
.'IV
58
Si
Tl
zv
1
tc-toiie
1-10)0
Naphthtit
Rejiiliic
IJ37
J-I2-I4
12
109
344
:e tone
14010
Ac&luua
Res iitai
IJ5S
4-02-14
13
t
10
2
1
304
moLeMi
15120
m
Liakt*
1 174
7-2&-S4
tAace
3.4
Trac
lAotein
iSI?0
TII8A and
S-12
sr
1 ¦! (Y-i
3-19-84
Lett
l
3
314
1
Ttace
"yaot
>4600
Tei QUoi
Rain Watei
*3
10.2
12.7
9.1
1.9
305
11200
lie Opei
8 6SOO
Potijox
ReiuWi
-m
3-29-J4
2
33
Less
0.05
79
V
-
CPR Ug/iXi
and llviji
i) 16
:?i;
3-l9-«4
•t/uice
Ciace
24
Vwee
2^7
cgtrf Poly
5512
P/ieiic£,Aiu
Watet
5 JO 3
3-19-44
i'.r. ce
trace
igiil Pofi/
'.515
Capirt^actn
StKpptlljS
;J22
3-fO-M
144
tnacc
Ota ce
:cli Cent:
JO m
ciolein
35)20
Poltjute >1*
Head Wste
O.t
2«
2.9
V'ch. TUBA,
Cyclo, It. r
56 OH
Ls.
3-28-84
¦
Trac
$^8ln
MC? hvy. Res
Taifl
7-19-84
M
<
Trace
11
554
Tr-.ce
10
4 j
Trace
lycol
L'210— _
tide Dei.
61600
Glycol Res.
Ri5. Tk
10-18-84
2
1.75%
93
^ —
Meoh. from
Glutavaldehy
1 BS.
e
S-13-84
3.3
1.2
1.1
f
0.3
5.4
&j2o
Dec. bottom
layer
4555
10-17-8^
90
7
1.17%
75
'ifeVio j
- . > J
Evaporator
10-17-84
61 j 6
!
4
0.79%
Uj
A.
-------
MAJOR EHISSIPN POINTS (seo Section III.l Instructions)
1
jProcess/Activity Area
or
Equipment Name
H .
Process/Activityi
Area or
Equipment ID
Emission
Point ID
Coordinates:
UTH Easting/Northing
or Latitude/Longitude
Ground Level Elev
above mean sea lo
(ft)
at ion
vel
Boiler
11 Steam Plant
11 Stack
4 317 50E/4 248080N
0
595
^2 Boiler
M
12 Stack
II y II .
II
4) Boiler
II
13 Stack
ii i M
II
III Boiler
II
#4 Stack
h y ii
H
13 Boiler
II
#5 Stack
i« i i*
II
it Boiler
II
16 Stack
ii y ii
II
#10 Boiler
12 Steam Plant
X Stack
432500E/4248150N
II
01 . Bol lc|r
it
II
i
" / "
II
112 Bol le|r
H
•»
II II
II
Splitter j^olumn
EHB
020B
4317
ENB
0200
" / "
II
Dryer Vcn^
POLYOX
2 SOB
432160E/4248150N
II
. /
Dryq'r
1 .
Polymer JR
231D
ii n
II
Page of
-------
STATE OE' WEST VIRGINIA
'AIR POLLUTION CONTROL COMMISSION
Air Pollutar.t Emissions Repor
mtion
orr.a
s emLSSi"-.
'--3- oi •?
-aui ;o
e 3osc caiapranensi.. ^ information possuis.
:-lS (Type or Print) :
GNED: •
.A.NT MANAGER:
Muss be certified zy Plane ."--anager
There are pages ir. this report
S
-------
li :
- Tablo
14 3
\
V.1. 1A nEL USE DATA. Part A
Boll-
ruui
Source3
ruol Quality1*
Jan-Harch
April-June
July-Sept
Oct-fee
year
C rons
ioS scr,
1300 fa-4
Kin
Avg
Max
Avg
Hax
Avj;
1
bit
IS Block
11,911
12,014
12.2
11. S
i.04
.To
15 751'
12,9.7
5, .61
B34
0
i
19,632
2
BIT
15 Block
11,911
12,034
12.2
11.S
1.04
.96
15,750
16.171
' ,900
B34
0
24,9 J5
3
BIT
IS Block
11,911
12,034
12.2
11.5
1.04
.96
15,750
15,632
7,136
7,843
16,012
47,253
4
HIT
»S Block
11,911
12,034
12.2
11.S
1.04
.96
15,750
1,617
3,823
4,672
7,027
17,139
S
BJT
* 5 BLock
11,911
12,034
12.2
11.5
1.04
.96
IS,750
7,547
0
0
8,506
16,053
6
1
BIT
IS Block
11,911
12,034
12.2
11.S
1.04
.96
15,750
0
510
2,503
1
1
1
4
4,608
7,821
re vv 3
tV:SOri fc>. r
in d&tail, hew fus
'Is are
Sled
CJote Bamplin? frei
uency as appropri
f.ta
) Use additional sh^st if
ii'V .
1. Coal: Daily samples taken as loaded for a weekly composite (Blue Cicck coal, Sanderson)
5> w'.iom were analyses ctada: Lab at UCC Mine
2. Othai' /uals (including rcsiduesTI
By -vhom were enal/3n«: r.&de:
-------
* -I -.
Table V.
J
J!
Doll-
ar
ioi.
1. 1A1 Ti
Tuol,
Typo5
1
2
3
4
5
6
OIF
OIF
OTF
OTF
OTF
OTF
KL USE DATA, Part A
SourceJ
j
See 2 Below
Sec 2 Below
See 2 Below
See 2 Below
See 2 Below
See 2 Below
Tuol Quality1* (as racoivad)
BTU per lb
ifocQEal
JpODQfidS
Kin
5,000
5,000
5,000
5,000
5,000
S.000
Ave
11,670
11,670
11,670
11,670
11,670
11,670
Ash(%)
M.ix
Avg
0.1
0.1
0.1
0.1
0.1
0.1
0.01
0.01
0.01
0.01
0.01
0.01
Sulf'ir^
(%/
Ha.
Ave
Max per
hour
Clb.SSF
pa4v)
Fuul turiiucl'' during 19111
(year)
Jan-Hiircli
Actual/quarter
(tons. LK&SKryUSQQcxfliri)
9,400
9,400
9,400
9,400
9,400
9,400
3,103
3,878
3,749
388
1,810
0
April-Jt-ne
2,903
3,913
3,535
1,894
0
' 252
July-Sept
Oct-Cac
Total
for
year
C TOlif
105 "iCi",
IJ0U J'dl)
274
274
2,573
1,533
0
821
I 1.
0
0
3,857
264
1', 530
865
6,280
8,065
13,714
5,079
3,340
1,9.<8
B D.-scribo, In detail, hew fuels ara sampled (Hate sa.T.plir.g f ra—j-sr.cy as appropriate) Use a^dirional shaat if n =>.
^ i- . i z. r
5>- whom were analyses made:
2. Othir fuels (including residues):
Process Unit By-Product Liquid Fuels - Generated by Process Units at UCC Institute Plant
T~"
By whom were analyse1! made: Institute UCC Lab
"7"
-------
Table V.1.1A ' fUi:L USE DATA. Part A
1 Boil-
1 er
1 ID1
Fuel
Type'
Source3
Fuel Quality1* (as received)
BTU per lb
per gal
per SCF
Ash(
t)
S'.lfur®
m
Min
Avg
Max
Avg
Hax
Avg
1
02
Exxon
137,000
144,000
ini
.01
0.6
0.6
2
02
Exxon
137,000
144,000
.01
.01
0,6
0.6
3
02
Exxon
137,000
144,000
.or
;01
0.6
0.6
4
02
Exxon
137,000
144,000
.01
.01
0.6
0.6
S
02
Exxon
137,000
144,000
.01
.01
0.6
0.6
6
02
Exxon
137,000
144,000
.01
.01
0.6
0.6
1
0TF
51,000
54,000
0
0
0
0
2
0TF
51,000
54,000
0
0
0
0
3
01V
51,000
54,000
0
0
0
0
4
orf
51,000
54,000
o
0
0
, 0
S
or-T
51,000
54,000
0
0
0
0
6
OFT
51,000
54,000
0
0
0
0
Max per
hoir
Ub,fCF
gal)
Fuel burned6 during J'JBl
(year)
280 Gal/I
280
280
280
280
280
0
0
BSOlb/hr
850
8 SO
0
Jan-Har cli
'1 Actual/quarter
* tons. 10f-SCF. 1000 gal)
28 M Gal
3S
54
3
16
0
0
0
285
27
149
0
Tons
April- June
23
< 31 Vi
28 i-
15
0
2
0
0
300
161
0
0
July-Septl Oct-Ccc
I
7
7
61
36
0
20
0
0
363
213
0
0
0
' 0
27
12
14
8
0
0
172
f 91
116
0
Total
for
year
(ro;.s
lo5 scr,
1300 val)
58 M Gal
I »
150
66
30
JO
0 Tons
0
1,120
492
265
0
I
'fcrv 5 C.:scriba, in detail, hew fuels are seaplad (Hate sampling frequency as appropriate) I':a ai£ltl>-.al sn^et if :esis:~y.
1 Coal;
3y whom were analyses madet
2. Othar fuel* (including residues): ||ydrogen . ^ ^L~ —
Acetone Units
I
By whom were enalysf* aadet None' '¦>
-------
Table V.l.V 11011.Lit DATA
''Dollar
ID*
>
Dula
Dunaii
Operj-
t ion
(itioAia/yr )
Normal
Status
(Operat-
ine or
Standby)
Maximum
Doslen
lioat
Input
/10®BTU\
Maximum
Duslflli
Output
(lbs stcai
hi
*/
•>
Gross2
Genera-
tion
(MM)
I'uel Uurn
Rata
(lb/hr)
£iiV / fcu,
taUiaoi)
Type'1
1'irinn
Lt|iii p-
IllO (11
Uoilar
Effic-
iency
(\)
Aoh
UolaJfl-
ed in
furnace
(%)
Carbon
in
Flya6h
(1)
Type® fltid Efficiency of
Particulate Control
Cnuipmunt
Type
[ Efficicucv' (I)
\ hr /
Jeslgn
Actual Averapo®
1
1^42
Operating
236
.1 ¦ -
175,000
NAP
20,000
03
80
40
12
08
99
99E
2
1942
Operating
236
175,000
HAP
20,000
03
B0
40
12
f
08 =
99
4
19 2
Operating
236
17S.000
NAP
20,000
Oi
85
40
12
OS •
99
/ JUE
1942
Operating
236
175,000
NAP
20.CJ0
03 ) 65
AC
12
08
99
> 9i)E
&
1941
Operating
236
175.000 .
NAP
20.000
03
80
40 ;
1)1
08
99
9 rntovred in Teble V.l.l) Standard Conditions; 6F°f 29.92
inclw.i Hf;.
4 .
3.
Type of Jirin£ Equipment - Code as follows:
01. Pulveri zed Coal, General 07. Other 6toker (specify)
02. Pulverized Coal, Wet Bottom 08. Oil Burner
03. Pulverized Coal, Dry bottom 09, Gas Burner
04. Cyclone 10. liand-fired
05. Chain Grate Stoker 11. Fluidized Bed
06. Spreader Stoker 12. Other (specify)
Type cf control equior^ent - Code as follows;
01. lione °7- Electrostatic
02. Settling Chamber 1 Precipitator, hot si
-------
n /
Table V.1.3 STACK/HOHITOR DATA
Stack
IDl
Boiler
Ip(s)2
Stack Parameters
i
Continuous Honltoring Equipment
Height
above
ground
(ft)
Inside
Diameter
at top
(ft)
Gas Exit
Velocity'
(ft/sec)
Gas
Temper-
ature3
(°F)
Gas Volume^
(ACFH)
Percent
Excess
Air^
<»>
Manufacturer
Model No.
Data
Recorded1*
Monitor Location5
1
1
)2S
5 X 10
27
580
80,000
25
Lear/Sieglcr/
Dailev
RM41/0J11
01/04
121/10
. 2
1
125
5 X 10
27
S80
80,000
25
•
I*
01/04
121/10
3
3
132
5 X 10
21
380
64,000
25
II
II
01/04
B/10
4
1
1
llV
S X 10
21
380
64,000
25
II
II
01/04
B/10
5
S
12S
S X 10
27
580
80,000
25
II
II
01/04
/ lr/in
6
\
%6
12S
& X 10
27
5t 0
80,OP J
25
• •
U
01/04
/ 121/10
7
7
12S
S X 10
29
700
88,000
60
• 1
II
01
1^1/10
a
8
125
S X 10
29
700
>8,000
60
• »
«l
01 <
121/10
1.
2.
3.
4 .
Use assigned Identification Numbers as outlined in Section I and used in other sections of form.
List all boilers discharging through each stack.
Should be given for maximum load condition.
Data recorded - Code aa follows:
01. Opacity
02. S02
03. H0X
04. o2
05. CO
0C. C<>2
07. Other (spec'^v)
If monitor is located in,stack, report location
relative to base of 6tack/diameter of stack at
monitor location (e.g. 350 ft/10 ft). If monitor
is located in breachln^(B), pleaae so indicate.
Page B of
-------
"^Stflok
< II)
No
boiler
QrO)
It
¦porting Porioil
lor l.'inititiioii!)
i:ml salons Durtnp, i«
"Ty
b i6
Particulate
Hatter
so2
N0X
CO
Hydrocarbons
Lead
uviiux':
1
1
Max
mum hourly (lb) :
9
287
142
8
19
NEG
N1.0
"~JTG ¦ "
Jan
-March (tons) :
8
236
157
9
19
-
Apr
1-Juhe (tona) i
3
107
72
4
11
NRG
NIG
Jul'
(-Sept (tons) <
0
IS
li
1
NEG
NIG
ffl.G
Oct'
Dec (tons) i
0
1
0
0
0
MET
Tot^
il during year (tons):
12
358
239
13
31
NT J
ui:g
2
2
Max:
mum hourly (lb) ;
9.
287
142
8
19
NEG
NI.G
J art'
Harch (tons) :
9
295
197
11
24
NEG
NIG
Apri
1-June (tons) :
S
144
96
S
14
NEG
N1:G y
Julji
-Sept (tons) i
0
IS
11
1
1
NEG
NIC <
Oct-
Dec (tons) :
0
0
0
0
0
KEG
nj:G \
Toti
I during year (tons)i
i/ 15
454
303
17 \
40
NEG
NEC |
3
tVixi
mum l~ourly (lb) :
i 9
287
142
8 -
19
KEG
NEC 1
J an-
March (tons) t
J
285
191
11
1 23 /
KEG
nig /
Apri
1-Jtne (tons) i
4
no
P j
s
/
NEG
NEG
July
" Oct-
-Seot (tons) :
5
143 5
36
5
n
NEG
M!G
Dec (tons) :f
10
;304 (
2f>3 ,
11
25
NEG
n:c
Total during year (tons)^
1 28
/ B6 Z
574 '
32
sg 7^
t NEG \
NIC
4
4
Maximum hourly (lb) :
9
' it 7 / ¦
1 142
S
I 19 '
1 NEC
NIG
Jan-Harch (tons) i
1
' 29
zo ,
/ / J
2
NEG
. Nl'fi
April-June (tons) }
2
70 /.
46 /
1 7
NEG
Nl'.G . ....
July-Sept (tons) :
S
,8» /;
' -67 / !
3
7
KT.G
. NFrG
Oct-Dec (tons)> :
4
in i
85 ' •/
5
. . 10
NEG
Ni:r,
Total during year (tons):
10
/£u /
208 //
12
' 1 "
NEG 1
NEC
5
Maximum hourly (lb) i
9
287
142
8
19
KEG
NEG !
Jan-March (tona) / :
4
13B
Si
5
11
NEG
ni:c
April-June (tons) :
1 0
0
0
0
o-
NEC
ni:g
July-Sept (tone) 1
0
0
0
0
I "
NEG
ni:c
Cct-Dec (tons) :
\ 5
155
104
6
J u
KEG
nec
» S
Total during year (tons)i
9
293
19S
11
23
NEG
NEC
1. If t
hour
shou
spa o
ly and t
Id also
f the design heat inputs fo
atal annual emission rates
report quarterly emissions.
r all boilers operated at the plant
need be reported. Facilities with
t is less tt
greater tha
tan 2S0 MM Btu/hr only the I
n 250 HM Btu/hr design hea
Page <
axiinum
input
f
-------
Table V
StacW!
ID '
No
A_JI
Uoilor
I»(s)
JII.HK HUSSIONS DATA1, I'.n-t
cporting Pariod
for Croisuions
A
L'micsioits Jilfl)
fyuar)
Particulate
Matter
so2
NOx
CO
Hydrocarbons
Lead
Iji lie r:
6
6
Maximum hourly (lb) i
0
20/
112
B
19
NliG
NI.G
Jan-Harch (tons) ;
0
U
0
U
o -
'' Hid
NI:C
iAprll-Juito (tons) s
u
U
1
u
1
Nl.fi
NIC
'July-Sept (tons) :
2
46
31
i
j
Kir.
NIC.
Oct-Dec (tons) :
.>
KB
SB
3
5
MEG
ni:g
Total during year (tons):
S
143
95
S
12
NEG
NIG
Maximum hourly (lb) j
i
/in-Harch (tonst :
April-June (tos) t
July-Sept (ton3) i
.
bct-Dec (tons) :
Total during year (tons)t
Maximum hourly (lb) :
Jan-Harch (tons)
April-June (tons)
\
July-Sept (tons)
Oct-Dec (tons)
Total during year (tons)
\
1
Maximum hourly (lb)
i
- /
1
/
Jan-March (tons)
/
April-June (tons)
July-Sept (tons)
,
bct-Dec (tons)
1
Total during year (tons)
|
1
Maximum hourly (lb)
1
1
/
1
Jan-March (tons)
¦ f T
' >
I
April-June (tons)
Jl
1 1
July-Sept (tons)
/
/
t i
Oct-Dec (tons)
/
1
I
1 1
\
Total during year (tons):
/I
1 t
/I
1
!• If the sum of the design heat inputs for all boilers operated at the plant i6 leas than 250 MH Btu/hr only the maximum
hourly and total annual emission rates need be reported. Facilities with greater than 2S0 HM Btu/hr design heat input
should al60 report quarterly emissions. Page JjO of
-------
ft '<->
T\,hio' v.ll i DDIl.i:R 1:HISSI0NS DATA. Part D
Explain inethojl(s) of determining emissions given in Part A. If by stack test, indicate by "T" followed by month and ye.u> of
test. If by Emission factor, indicate by "EF" followed by a reference citation. If by other method indicate bv "0" and
e )4in. CXAfli'LtS; Particulate Matter - T 10/00} CO - ErC~APJ«T^ Table 1.1-2 (12/77). *
Siac*
ID
f.'o
Uoilec
i r (s ij
Particulate
Matter
MP Table
1.1-2
1.3-1
1.4-1
iOi
OF Table 1.1-2
1.3-1
1.4-1
EF Table 1.1-2
1.3-1
1.4-1
I L
EF Table 1.1-2
1.3-1
1.4-1
'•lydr jcarbom
Iil; Table 1.1-2
1.3-1
1.4-1
Lead
Other
During the ye
.na I function ?
-------
7.1.7 TV'ASu muQ !lGlTO:! ASil :} £ Si'CS Af,
:;u.rioer of :sns o: rIy25p. co'-"J-:" '..z.\
.'rja : -o.»'.c:.on j
-------
Section . 1.0 SOGV
1. Soot Dlowinr in cono•
rr
~ continuously
2. Soot blowing is normally clone by:
0 manual operation
~ automatically
3. If schedule is intermittent:
a. Done 1 Q 2 D 3 Ql i [j 5 O or Q( indicate number)
times per day
b. Duration of soot blowing:
iTi 0-1G minutes
D 1 j-20 minutes
Q 20-30 minutes
Q longer (Indicate ti.tie: )
c. Ncrr-.al beginning ti.~e(s) (e.e. 3:00 Ail, 1:00 PM,
and 5:00 ?M; etc.):
a a ot done on regular schedule
At what intarvals ara air heater surfaces blown? Not 31ow.i
/L ^
>2,
Page t b oS
3-Jfc
-------
Uoilur ID
1
2
3
4
5
6
7
'8
Continuous1
Tull-ycar
Operation?
Normal Shut-
down Time?
(yes/no; dates)
No
No
No
No
No
No
No
No
Actu .1 Operating T.me for
1081
1 year)
Jan-Mar
hr/day
24
24
24
24
24
0
0
0
day/wk
7
7
7
7
7
0
0
0
wk6
8
10
10
1
S
0
0
0
hr/day
24
24
24
24
0
24
0
0
7
7
7
7
0
7
0
0
Apr-June.
day/wk,
wks
8
12
11
6
0
1
0
0
day/wk
hr/day
July-Sept
24
24
24
24
0
24
0
0
7
7
7
7
0
7
0
0
hr/day
day/wk
1
1
11
8
0
J
0
0
Oct-Dec
0
0
24
24
24
24
0
0
0
0
7
7
7
7
0
0
0
0
8
3
'4
2
0
0
To ^ a 1
Ac I ii.. I
I'oijrs
1 or
y-.i.'
2976
3810
66%
28(18
15.V>
1128
,0
0
6 I 'J
To ^a I
Max' niun'
ilotir-J
ii-j r
yu.-.r
806-1
B064
8061
8061
8061
806-1
8064
8064
1. If boiler operated continuously ^'
which the process or equipment was shutdown fornct continuous throughout the year then report "No" end supp.>
quarterly schedule need not be "tToperaK hours for the year of record.
quarterly schedule. In either case, report total operayng ^ , ooerated.
»V. v Ik. nraeess. unit or equipment would ever be operateo.
2. Report maximum number of hours per year that the proce S P P6gt! 0*__
-------
(W
T5 Block
11,911
12,034
12.3
11.5
1.04
.96
32,200
16,604
11,353
2,722
13,963
'
14,642
11
BIT
IS Block
11,911
12,034
12.2
11.5
1.04
.96
32,200
17,675
5,915
7,826
11,391
42,827
12
HIT
«S Block
11,911
12,034
12.2
11.5
1.04
.96
32,200
19,282
8,515
6,465
11,391
ii.652
10
OIF
Sep 2 Below
22,300
22.SOO
0 i
0
0
0
16,800
2,238
6,330
2,081
4,669
IS,318
11
an:
See 2 Below
22,300
22,500
0
0
0
0
16,800
2,382
3,309
5,984
3,809
15,484
12
cnr
See 2 Below
22,300
22,500
0
0
0
0
16,800
2,598
4,747
4,943
3.JI09
!
i
i
16,097
¦
-------
a? 15
W
\
V)
v/>
Boi lei'
IDl
U'.tc
Began
Opt. ra-
ti on
(iiio/cJci/yr)
Normal
Status
(Operat-
ing or
Standby)
Maximum
Design
lloat
Input
/106UXU\
Haxindn
Design
Output
(lbs 6toam/
hr)
J
Grooa'
Genera-
tion
HaximumS
I'ucl Ruri
It.ile
Ob/hr)
OUKXli1X|[
lymoQUixx
Typo1'
Tirinp
Equip-
ment
Boiler
Effic-
i enry
(i)
Al.1i
Uu I >i in-
cil in
I'u ni. ice
m
Ccirbuii
in
lly.iwli
(I)
I'yue^
' Par
Typo
and Efficiency o?
ticulale Control
E(|ui puiunl
l.'t'f ic i u-iicy (t>
I hr )
Jesif.n
Actual Avera^e^
10
Oct. 19S7
Operating
3B0
270,000 <
12
32,200
03
87
40
8
07
99.7
99.7 E
11
July, 1960
pperating
380
270,000
1?
32,200
03
87
40
8
07
99.7
99. 71.
12
Aug. 1964
.i
Operative
380
270,000
1
12
32,200
03
87
40
8
U7
99.7
iJ'J.Vl.
.
1.
?.
3.
lisi 11) assigned as outlined in Section
Tor boilers^ueneratine electricity. If not applicable, put HAp.
fuul consumed at rated Rapacity ^(use average fuel heatinf value reported in
1 - Instructions for Preparation and Submittal, I ten _J-
.1) Siarulisril Conditions: 6il'r, 7^.92
inciu i, lif
Typo of firinc Equipment - Code as
01. Pulverized Coal, General
C2. Pulverized Coal, Wet Bottom
01. Pulverized Coal, Dry Dottom
OM. Cyclone
05. Chain Grate Stoker
0u. Spreader Stoker
Indicate if determined by Stack Test(T)
tost date (e.g. 93tT 10/78).
follows:
07. Other stoker (specify)
Oil burner
Gas Burner
Hand-fired
t'luidized Bed
Other (specify)
08.
09.
10.
11.
12.
lype
01.
02.
03.
04 .
05.
0C.
by Material Balance Estimated.'), or
Table V.l
cf contr
K'one
Set 11 i tif
V.'et Scru
Siini>le (
Kulti-ey
Other N;r
ol ciuii m'pL-iii
07
Clumber
08
bber
yclone 09
clone
tliod (Sr.ecif
Code as
Electros
Precipit
Electros
Precipi t
Other (:;
f o 1 ! i.
r .'
dlO!' ,
l j t i
a cor ,
pcc i '
V )
If by sr = :'
Page
i'. :
liot
si tic
*}
tost, fij:
-------
rw(.
TjW V.1.3 STACK/HONITOR DATA
Stack
IDl
Boiler
ID(6)2
10,11,12
Stack Paramotaru
Height
above
ground
(ft)
200
Inside
Diameter
at top
(ft)
9.S
Gas Exit
Velocity3
(ft/sec)
65
Gas
Temper-
ature3
(°r)
320
Gas Volume^
(ACfH)
275,000
jLA
Percent
Excess
Ail'3
(t)
20
/ /
Continuous Monitoring l-Q" ipmont
Manufacturer
I.ear Sicglar/
l.car SicHlar
Model No.
RM41/
(>IS0
Data
Recorded1'
01/
0-1
Monitor Location^
12-'/17.5
122/17.S
1
Use assigned Identification Numbers outlined }n Section I and used in other sections of form
List all boilers discharging through each 6tack.
Should be given for maximum load condition.
Data recorded - Code as follows:
01. Opacity
5. If monitor is located in,stack, rep
relative to base of 6tack/diameter
monitor location (e.g. 350 ft/10 ft
is located in breaching(B), please
orl location
of stack at
) . T f inoni tor
so indicate.
02.
03.
: on.
05.
oc.
07.
S0j
M0X
°ci
CO 2
Other (spec*'v)
Pcjge _J~] of_
-------
Stac'
• IV
^Boiler
1D(S)
Reporting Period
for Emissions
Emissions During
, -4...
„ ear)
1 ' i
ft o
Particulate
Hatter
SO 2
| N0X
CO
Hydrocarbons
Lead
(J Cher:
Maximum hourly (lb)
t
6
5B7
483
16
5
UBi
KEG
\
Jan-March (tons)
3
303
¦ 24a —
B
T
KEG
KEG
April-June (tons)
2
207
170
6
2
' KEG
KEG
July-Sept (tons)
t
0
SO
4l
1
0
¦ ' tad
KEG
Oct-Dec (tone)
>
2
ZbS
209
7
i
KEG
Nl-G
X
1(1
Total during year (tone)]
6
814
670
22
i.
KEG
NEC
Maximum hourly (lb) ;
:
6
/ 587
483
16
5
KEG
KEG
Jan-Harch (tons)—
t
3
322
26s
n
J
Ktli
KEG
April-June (tons)
:
1
108
B4 '
J
j
HEQ
NF.G
July-Sept Itons)
:
1
14 J
ll>
4
1
Kfed
KEG
Oct-bec (tons)
:
2
208
m
6
2
KEG
M-:<5
_ . * ..
. 11. -
Total during year (tons!
:
8
781
642
21
6
KEG
NEG
Maximum hourly (lb)
•
6
587
433
16
S
KEG
Nf.G
Jan-March (tons)
•
j
35Z
289
11)
i
MEG
NEG
yprilrJune (tons) :
2
1«
128
4
1
MFC
NIG
July-Sept (tons) :
1
118
97
3
i
KEG
KEG
Oct-Dec (tons) :
2
208
171
6
¦)
KEG
NEG
X
12 '
Total during year (tons)
s
Maximum hourly (lb) /
Jan-Harch (tons) f
t
f
April-June (tons) ' -
•
July-Sept (tons)
1
1
Oct-Dec (tons)
;
Total during year (tans)
:
ti&ximura hourly (lb)
•
Jan-Harch (tons)
•
•
April-June (tons)
t
July-Sept (ions)
•
Oct-Dec (tons)
:
Total during year (tons):
1 • If 1 lie r.uia of tlia design heat inputs for all boilers operated «t the plant Is lees than 2SQ HH Dtu/hr only the maximum
) hourly .md totnl annual emission ratnc need bo reported. Facilities with greater than 2S0 HH Btu/hr design hc.it input
choulit »ilao report <]uartorly emissions. P«PO IB of
-------
P n
¦ 1 'fable V. .'IP HOIMIK LHISSIONS DATA. Part D ___
Explain mo thoil(s) of determining qmissionu civcn Part A. If by ulack tent, indicate by "V followed by month and yc.ip of
loot. If by cmluoion factor, indicate by "EF" followed by a reference citation. If by other method indicatu by "o" ami
>plaln. EXAMPLES; Particulate Mattor - T 10/00} CO - F.F, AP-'i? Table 1.1-2 (.17/11).
Stack
ID
No
Boiler
ID(s)
Particulate
Matter
S02
NOx
CO
Hydrocarbons
Lead
Other:
X
JO, 11, 12
EF Table 1.1-2
EF Table 1.1-2 .
EF Table 1.1.-2
EF Table 1.1-2
F.F Table 1.1-2
«u
i
%
u
p
During the year of repord, was any boile^ operated with it6 air pollution control devices out of service or experiencing major
malfunction? [if] Yes [J No If yerf, note boiler ID and total number of hours operated in thiS manner. Intermit ten!
prohK'ins cause loss of some portion of F.SP's. Times are not on record but ;are estimated to be less than O.lt of the time. ESP's are off during
start-up and cool down periods for protection of equipment and for safety.
Page |1 of
-------
Section 7.1.0 .SO01' i'.LST;;<"
Soo". -\o r r: .
I XI i n ^utKiv. i. luri u Ly
Q continuously
2. Soot blowing is normally tioue 'oy:
~ manual operation
~ -jii i.oiiiu C ically
3. If schedule is intermittent:
a. Done 1 022 3 QtQ 5 I I cp I i( indicate number)
times per day
b. Duration of soot blowing:
Q 0-10 minutas
E2 1U-20 minutes
O 20-30 mini.res
D longer (Indicate time: )
c. Normal becinniii^ time(s) (e.e. 3:00 AM, 1:00 ?M,
and 5:00 ?M; etc.;.
0 Not dona or regular schedule
<~. At what intervals are air heater surfaces blown? 91 own
3" 3 3
Page
ox
-------
0/
.or. v.i.7 Fr,YA.iii i a¦: j:"ip'"v.x ^
or .j." "o. ^.av: -3 c/'ia1'f
•'i'/C»-;' Crom n.i l' '. .i "e 'jaL.^'.ioa '.qiu c (,caec.< ai> saay
apply):
~ conveyed dry to: Qash storaqc silo
Opermanent disposal sice
D(spcciCy)
0 conveyed wet to: Qmter:r\ediace aend
\
Epermenent disposal sits
~ (specify)
If Slyasn storage silos are used, what, method a; control is
utilized to control silo omissions?
O multiciones Qwet scrubber
~ baghouse Qothcsr (describe)
Flyash from intermediate pond is Q piped D trucked to
permanent disposal site. If other method employed, describe:
Flyash from the silo is O piped Otrucked eo permanent flyash
disposal site.
Wbaw fugitive dust control systam is employed during silo loadout
operations. if removed by truck or railcar?
QFlywetting*^ such as rotating mixing drum,
using — percent moisture mix
OWater spray only (ct<.itainmant and surface watting)
DEnclosure O Closed loop system
Qotfaer (describe} •
Ip trucked, what methods are employed to control fugitive dust
/eais8ions from trucks?
Cltarps. O truck wash systems
Hnone _ Oother
Trucking) of flyash is u.:r«* by:
Q company owned trucks
Qcontract haulers
Qt«rth
2-3H
Pai»e
•of
-------
"iable V.1.1A Tl
Ul
I
u*
u
I
Hot I-
wi-
ll)1
120-2
I'uul
Typo^
Ethane
Cchane
t-'crt s teosaribj( in detail, hsw fuels are se.Tplad (Hote ean.;>linft fr^m^r.cy as ar?ayopri--.Te) l^s atii.'] tiar.al si.?.-; i :
EL|USE DATA, fart A
a >
Source*
Hjipe F.thane
Hb|>e Ethane
Tuel Qu.ility'1 (ao t>accivj. 10£scr. 1000 pal)
17)2
175i
1/
1560
1560
"April-Ju/iu July-Sept
'Oil
iOil
1238
L288
Oci -
I
1 i'.h
I Ufi
l.\ Ceil:
Total
for
vu'ir^
luS'sor,
i3uo j
502.'
'¦>/ whoa were analyses c.arta:
1. Other fuels (itvciuiinjj residues);
Ho eamplea are taken at iltc AB Unit.
~V
l>y i/tiorj wen: analyses r.adc:
/
+-
-------
; v ~
boiler
ID
10
11
12
Continuous*
Tull-ycar
Operation?
Normal Shut-
down Tine?
(yoa/noj dares)
/
Yes-July
res-Mar 27
fes-Kay 31
9-Sept 24
Hay li
July 23
1. If boiler
which tlx process or
^qu.irterly schedule
quarterly schedule
?. Report maximum n
Actual Operating Time for jpni
(year)
Jan-Mar
hr/dayl <* ay/uk
24
24
24
-.7
7
7
w> o
I
l*\
l}'
1?
24
-I
' ' \ r
24
24
7
7
7
Apr-June
In/day | Jay/wiT^ t icj
July-Sep;
l-r/djy
.1
6
9
24
24
24
d-.y/wk
wks
4
11
9
Oct-Dcc
Iir/liciy
24
24
24
iJ^iy/wk
wks
13
11
11
To t-al
Act u.. 1
llOUl'o
lOi'
yja:'
i > s 7-
tH't
C7/e
-t?44-
t Hi
operated co».l»«ou.l, Mta
wMta {r.ss!Lrii!i2rLiii^i ;*«>,*>»«« <» y»=» «.
,umber of hour* per yaar that th. process, unit or equipment would ever he operate . ^
To Til
fl-xiinin
iloisi-a
l"-r "
y«s-s'
—¦H"
,2
00
uo
00
, .! i • -¦i ii^
¦. , li l.i
11, J 1 V*
'U
-------
Tiil.lu V.1.7 1.01 I.I It DATA
v> d-
IDl
120-1
120-2
began
Oj.era-
t ion
wno/d
gal/i.r)
Type'1
Firinii
Ei|uip-
nunt
Uoiler
E f f i c -
icncy
U)
/
I
Aah
Retain-
ed in
' iin ace
(i-x
Carbop
in
Tlyash
(i)
Type® and Efficiency
Particulate Centre
Equipment
Typo
T r f i c i j i
\ hr )
Jesign
Actual A
9/63
Op
39.25
-
NAp
1752
09
-
-
_
9/63
Op
39.25
-
NAp
1752
09
-
-
-
-
/
i
/
I1 '
I I )
1 .
? .
Litiv. II) assi£ncd as outlined in Section I - Instructions for Preparation and Submittal, I ten 2-
Tor boilers generating electricity. If not applicable, put t.'Ap.
Iu.. 1 consumed at rat^d capacity (u6e average fuel heatinf value reported in Table V.l.l) St^nJ
incju s l;£ .
Tyjro of Firing Equipment - Code as follows: f. Type
01. Pulverized Co.;l, General 07. Other 6tcker (specify) 01.
C 2. Pulverized Co.l, Wet Bottom 08. Oil Burner 02.
' ~ gd6 gurner 03.
10. Hand-fired 04.
11. riuidized Bed OS
12. Ott/er (specify) 0C
:rd Conditions: 6S°F, .''J .9?
0 3 .
(I1;.
US.
U6.
cf control ecuinuuiii
07.
l'ulverized Coil, Cry Bottom
Cyclone
Chain Grate Sioker
C.
Spreader Stoki
InnicaLu if determine
tojt date (e.g. 93iT
:.one
Settlinf Chamber
Eaphousi:
l.'et Scrubber
Simple Cyclone
Kulti-cyclone
0b .
00.
Code as
L'lectro
Preci pi
I! lec t ro
Precipi
Other (
fol low:; :
static
tator , )u¦ i
s t a i i i-
taior, 1
spec i fy)
1 ill.'
4 by Stack Test(T), by Material Balance Estirate(E), or Other Method (Specify).
10/78).
If by stack te-.. i , j*iv
Page of
-------
itiblo v. l_. I imidXta
. * A-
boiler
IDl
>
|Catu
Began
Ojiera-
t iun
(wo/da/yr)
Hurwal
Status
(Operat-
ing or
Standby)
Maximum
Design
Meat
Input
/10l»BTU\
¦#
Haxinun^
Design
Output
(lbs steam/
hr)
'
Gross'
Genera-
tion
(KM)
¦ f
HaxintumS
Fuel Burn
SW7KF,
gal/hr)
Typo"'
Firinn
equip-
ment
Doiler
Effic-
iency
m
Ash
Retain-
ed in |
Furnace
(i) 1
Carbon
in
Tlyash
1%)
Type® and Efficiency uf
Particulate Control
Equipment
Type
Er f ic ieni- j* (t)
hr )
Jesign
Actual ,\v
120-1
9/ti
0p
39.25
-
HAp
1752
09
-
-
-
_
_
_
120-2
9/S3
Op '
39.25
-
MAp
1752
U9
-
-
-
-
_
i
i
,
c.f control
1. bs,: ID assigned as outlined in Section I - Instructions for Preparation and Submittal, 1 ten
?. Tor boilers generating electricity. If not applicable, put MAp.
3. Tui-1 coatun.od at rated capacity (use average fuel heating value reported in Table V.l.l) Standard Conditions:
inclu s li£.
¦». Tyiro of liring Equipment - Code as follows t f. Type
07. Other stoker (specify) 01.
08. Oil Burner 02.
09. Gas Burner 03.
10. lland-fired On.
11. riuidized Bed 05.
13. Other (specify) 0G .
01.
Q2.
Q3.
IK .
US.
00.
Pulverized Coal, General
Pulverized Coal, Wet Bottom
Pulverized Coal, Pry Dottoin
Cyclone \
Chain Grate Stoker
Spreader Stoker-,
Indicate if determined L>y Stack Test(T),
t o j c date (e.g. 931T 10^70).
I.one
Settlinp. Chamber
Z-af house
l.'et Scrubber
Sin.ple Cyclone
I'ulti -cyclone
ecui rip.ent -
07.
08 .
00.
6SOF, .o.qv
Code as follows:
Llectrostsric
Precipitator, hoi t, n\a
Electrostjtic
Precipitator, co'.; ii
-------
Stack
' ID*
Boiler
ID(s)2
Stack Parametcr6|
Continuous Monitoring Equipment
lleignt
ab ive
grcund
(ft)
Inside Ifas Exit
l„
Gas
Temper-
ature3
(or)
Gas Volume3
(ACFM)
0 I am
800° F
Percent
Excess
A'.r^
(1)
Diameter
at top
(ft)
velocity3
(ft/sec)
Manufacturer
Model No.
Data
Recorded1*
to;.i tor l,ocatioiA
1
120-1
50*
A*
28.2
800
21285
20
Petro Chcra
63-F-30A6
OA, X cuinb
1 fc/3'9"
2
120-1
50'
28.2
BOO
21285
20
Petro Cliem
63-F-30A6
OA t X corob
/
¦
1.
2.
3.
M .
Use assigned Identification Numbers as outlined in Section I and used in other sections of form.
List ail boilers discharging through each Ltack.
/
Should be given for maximum load condition.
Data recorded - Code as follows:
01. Opacity
02. S02
03. N0X
04. 02
os. cfl
06. C02
07. Other (specify)
S. If monitor is located in*.6tack, report location
relative *.o base O' 6tack/diametei of stack at
monitor 1 ication (j.g. 350 ft/10 ft). If monit>r
is located in breachingtB), please 60 indicate.
Page
(f of
-------
Stack Ljlgilcr
i- D Ml)(s)
|jcp'>rting Period
/ for Emissions
emission:; Durini'
"Tv
iy,
Ho
120-1
f^irticulntc
Matter
1 S<2 N0<
CO
0.4
11} droccirbons
I.CJlJ
i "UIIi.m-:
1 1
i
Maximum hourly (lb)
0.2
O.dlJ
3.8
0.07
NA|>
Jan-March (tons)
0.2
0.012
3.4
0.30
0.06
April-June (tons)
0.12
0.008
2.24
0.24
0.04
i
July-Sept (tons) :
0.1S
0.01
2.80
0.3
0.05
1
Oct-Dec (tons) >
0.13
0.009
2.3
0.26
0.046
Total during year (tons)i
0.6
0.039
10.94
1.16
0.2
1
J
2
i
i
i
i
120-2
Maximum hourly (lb) ;
0.2
0.01)
3.8
0.4
0.0?
NAp
j -J
Jan-March (ton&) :
0.2
0.012
3.4
0.36
0.06
i I
April-June (tons) :
0.12
0.0DB
2.74
0.24
0 04
'LL '. " I
July-Sept (tons) s
0.15
0.01
2.80
0.3
o.os
¦ 1
Oct-Cec (tons)
0.1)
0.009
2.5
0.26
0.046
I
Total during year (tons)
0.6
0.039
10.94
1.16
0.2
:
Maximum hourly (lb)
:
Jan-March (tons) :
I
April-June (ton6) >
July-Sept (tons)
Oct-Dec (tons)
Total during year (tons)
1 /
,
1
Maximum hourly (lb) :
i
Jan-March (tons) :
April-June (tons)
July-Sept (tons)
Oct-Dec (tons)
¦
Total during year (tons)
Maximum hourly (lb)
1
Jan-March (tons)
April-June (tons)
July-Sept (tons)
0«:t-Dec (tons)
'
lotal during year (tons)
1- If the sum of the design heat inputs for all boilers operated at the plant is less than 250 MM Btu/hr only the maximum
hourly and total annual emission rates need be reported. Facilities with greater than 250 MM Btu/hr design hoat input
should also report quarterly emissions. Page x of
-------
•*lc.l/lu Wl.iil) U011.KR FHISSIONS DATA. Part 41
l:K|iluin uiutliocKii) of Outorininlng ciniuuionu tfivon in Part A. If )>v iit.uk tout, iii.llrito |.y "j" folloucil liy month .mil yr.ir o(
. ti.:.t. li l>y fin I titii on fm-tor, indicate l»y "I.T" followed l.y a lvli-ivnro oil.-it Ion. If I>y other mot hod indicate by "u" an.I
a|>1 ain. I.XAHI'l.i::;: Particulate Matter - T 10/(10; CO - l.l", T.il-li: 1.1-? (1 illl). '
Stack
ID
No
Boiler
I D(s )
/
Part iculate
Ma ttar
SO 2
no;
CO
Hydrocarbons
Lead
1
120-1
EF
EF
EF
EF
EF
2
120-2
EF
EF
EF
EF
EF
<4
t
<
All pollutants del
AF-42 Page 1.'
ermtned using
-2 5/74
Other
During the year of record, was any boiler operated with its air pollution control devices out of service or experiencing major
malfunction? Q Yes [3 No If yes, note boiler ID and total number of hours operated in this manner.
Pagr il o^f
-------
-4-
12C-1
120-2
¦ «.«««•- •• rtri v *
i icjr uoi liU iu
boiler ID
Actual OporaiinF, Time for 1001
(year)
Continuous1
Full-year
Operation?
Normal Shut-
down Time?
(yt:6/no; dates)
yes; 5-1/5-22
ye:;; 5-1/5-22
1
an-Mar
hr/day
^ay/wk
wks
Apr-June
hr/day
day/wk
July-Sept
hr/day
day/wk
wks
Oct-Dec
hr/day
day/wk
wks
To t a I
Actual
Hours
tor
year
t>> XI
Total
Maxiniuir'?
Hours
pe r
yerti-
8212
8212
8/60
8/CO
! If boiler operated continuously during the year of record :Jy"*' f°}1~^aS0Sh°arcon1ti,n«ou8 ."the^th,
which the or equipment was shutdown for normals-tenancyi.e.^yesreport an<1 6upply
"«• ^ '¦»*> .p.r.«i»« >.».= ,h. „<
. . ^ i.nit- nr oniii nmpil t would CVC
2.
r'terly schedule. in eii.iie»- • -r~- •
-v..* »ko nmrcas unit or equipment would ever be operated.
Report maximum number of hours per year th P »
Tage
-------
laulo V.1.1A FULL USE DATA, Part A
I1, Of
Uoil-
or
ID1
Fuel
Typo^
Source ®
Fuol Quality'1 (as rocuivod)
Tuol burnoil6 durin
g
(yoiir)
UTU j).<^xxibt
Rifc5c*S**
per SCF
Sulfur5
Hax per
hour
Aotual/q
{tons. lOtsC'F
uarter
, 1000 imI)
Ash(l)
)
fcUt.SCr'
Jgcsi)
Jan-Hiircli
Apri1-June
July-Sonl
Oct- i
rtin
Av«
Max
Max
Ave
250-1
hg
HOPE
1750
0
0
0
0
26,000
(AO,000
capacity)
57.6
52.4
% 3.7
33.6
250-2
re
HOPE
1750
P
0
0
0
24,700
(38,000
capacity)
43.A
39.6
2.8
1
1
25.4
'loi.i'
for
ycdv
!
>¦ who.-n were analyses made:
2. Other fuols (including residues)! ~ ~ " ~
° ' Not sampled by this department
By whom were enalyses ir.ado:<
' ' ' P,"'.' of
-------
i.il.lt V . > la) 11.1.K ItAIA
Do i1er
11)1
l.j le
Derail
Opera-
tion
(mo/il.i/yr)
Normal
Status
(Oporat-
ing or
Standby)
Maximuir.
Dccif.n
lioa I
Input
Maximut.i
Dcsijjn
Output
(lbs stoum/
hr)
Gross'
Genera-
tion
(KIJ)
Max i niuii|3
I'uel Buri
l(.it o
(1b/hr,
SCF/hr,
gal/hr)
Typo1'
I'irinR
l.<|iii(>-
meiil
llo Ller
r.f fic-
iency
(I)
Ash
Kolnin-
ed in
furnace
(»)
Cui-bon
in
llyash
(%)
Type 5
P
I i c i c ncy f
II • C on 1vo1
jlit
i:r r icieiu.y (t)
Actual Ave rap c1,
NAp
250-1
1978
Op
46
35
NAp
26.000
NAp
75
NAj>
NAp
NAp
250-2
1962
Op
AO
30
NAp
2/..700
NAp
75
NAp
NAp
NAp
NAp
NAp
1
1. Use II) assipned as outlined in Section I - Instructions for ['reparation and Submittal, Item 3.
?. Tor boilers generating electricity. If not applicable, put UAi>.
3. Tucl consumed at rated capacity (use average fuel heating value reported in Table V.l.l) Standard Conditions:
inclws li|-.
Code as follows; !
07. Other stoker (specify)
08. Oil Burner
Gas Burner
lland-fired
Tluidized Eed
Other (specify)
Inuicate if determined by Stack Test(T), by Material Balance Estimate(E), or Other Method (Specify)
test date (e.g. 93%T 10/78).
Type of Ijrinc Equipment
CI. Pulverized Coal, General
C2. Pulverized Coal, Wet Bottom
03. Pulverized Coal, Dry Bottom
Of. Cyclone
OS. Chain Grate Stoker
OG. Spreader Stoker
09,
10,
11,
11,
Type cf control equipment - Code f
01. I.'one 07 • Electro;.!
02. Settling Chair,ber Precipua
03. ca£hou6e 08
0M. l.'et Scrubber
OS. Simple Cyclone 09
0G. I'ult i-cyclone
LlectrosI
Precinila
Other (sp
If bv s
Page__2
6?or, ? ?.9 ?
o]lows :
l: t i c
i cr, hot side
^ t i c
;c:', cold side
c i f y )
l test, f i vo
O of
-------
,\ -:u
TabloT. 1,3 STACK/MONITOR DATA
Stack
ID*
250A
25011
Boiler
10(6)2
21>0-1
250-2
Stack I'aramatero
Height
above
ground
(ft)
85
05
Inside
Diamoter
at top
(ft)
5.5
5.5
Gas Exit
Velocity^
(ft/ccc)
Gas
Temper-
atureS
(oj) I
1000
1000
Gas Volume 3
(ACFM)
12.800
12,800
rorcr.nt
Cxccsc
Ail-3
(%)
Continuous Monitoring rquipinciit
Manufacturer
Nihil'
None
Model No.
Data
Recorded*1
Monitor Location^
7
Use assigned Identification Numbers as outlined in Section I and used in other sections of form.
2. List all boilers discharging through each stack. 5. if monitor is located in ^tack, report 1oca t ion
relative to base of 6tack/diameter of stack at
3. Should be given for maximum load condition. monitor location (e.g. 350 ft/10 ft). If monitor
is located in breaching(B), please so indicate.
4. Data recorded - Code a6 follows:
01. Opacity
02. S02 Page ll of
03. N0X
01. o2
05. CO
06. C02
07. Other (specify)
-------
V*
V
Stack
Ko
l< "Ice
»s)
Reporting Poi'ioil
for Emissions
1 J'mi sbionu I'urinf, _
(yc.rW
'¦CI 1
Particulate
Hatter
S'<2
N0X
CO
llydro-.-arhons
f
Lec-d
j IH IiJ'i :
25QA
250-1
Miximum hourly (lb)
0.5
C.01
3
0.01
-
.
v'an-karcK (tons)
1
April-June (tons)
i
July-Sept (tons)
1
Oct-Dec (tons) »
_...J
Total during year (tons)
1.4
0.03
8.5
0.03
-
-
250B
250-2
Maxiniuin hourly (lb)
0.47
0.01
2.9
0.01
-
_
|
Jan-March (tons)
1
April-June (tons)
1
July-Sept (tons)
1
Oct-Cac (tons)
1
Total during year (tons)
1.1
0.02
6.4
0.02
-
-
Maxiir.uir. hourly (lb)
Jan-March (tons) :
April-June (tons) >
1
July-Sept (tons) :
Oct-Dcc (tons) :
Total during year (tons):
Maximum hourly (lb) :
Jan-March (tons) :
April-June (tons) :
July-Sept (tons) i
Oct-Dec (tons) :
Total during year (tons):
i
Maximum hourly (lb)
Jan-March (tons)
,
I...- ... . -
April-June (tons)
•
July-Sept (ton6)
1
Oct-Dec (tons)
^Total during year (tons)
1
If the jun
t hourly and
6hould also
of the design heat inputs for all boilers operated at the plant i6 less than 250 MM Btu/hr only the maximum
total annual emission rates need be reported. Facilities with greater than 250 MM Btu/hr design heat input
repoijt quarterly emissions. Page £
-------
Tal'lc V.l.MB BOILER EMISSIONS DATA. Part B ' "
i:K|ily " J" foin.uod by month .iml y •>»'• of
11 l>y c-mlkoion fnclor# indicate by "tl" fol lowed by o r^frrt'iico dilation. If Ity other muiliud. iiulicalu bv "o" .tu\\
Yi'l.iln. i.XAHJ'l.lIS! Particulate fuller - T 10/UP; CO - 111', Al'-N? T.ilMc 1.1-/ (l?//7).
Si.-.ck
) n
Ko
lloi ler
IlHs)
Particulate
Matter
S0f
WOx
CO
Hydrocarbons
Lead
Oilier:
L»
t
M
2'.(IA
2 MllJ
250-1
250-2
E.F. AIR poLunia
Henry C. Perkins
1974, p. 54
table 3.10
1
Du.int the year of record, was any boiler operated with its air pollution control devices out of service or expericiu- i up, major
mil I function ? Q Yes No If yes, note boiler ID and total number of hour s operated in ihie manner.
tJAp
All emissions determined by facr.»ca AIR iOl-UmCU II nr> C. ''eikins 19*/4 pJ)'.e 5'i tabic 3 10
Page 1 ^ _of
-------
Lioiloi' 11*
L 101"
f '
2bO-l
250-2
f
Actual Ojior.il ii»f. rimu I I'jyi
Continuous'
Fuil-ycar
Operation!
h'oraal Shut-
down Time?
(yae/no; dates)
Dguj
YES
- 7-1 to 10-27
YES
Down 7-1 to B-12
r 9- '4 to 10-27
Oct-Dec
July-bent
Apr-Juno
^ Jftn-Kar
day/wx
tir/ddy
cUy/wk
hr/duy
hr/day
day/wk
day/wk
WA it
hr/day
tfAjS..
To 1.11
"total
Ao Ui-'.l
{Uixlniuw**
Ho-.irs
iiOUl'Ii
1 K.*
jjor
y *-^
V li i' I1
U)-V1
8760
i.'/uti
8760
1 'if boiler operated continuously during tl.e year of record, rej.~. •. j--
whiuli tlie p^s or .juip-.S ^ for nor«
•cms sbss.-s :&s -«-- —»• b ,otii
»_ - •.*.*» nmrPRs liitir or €;auiprccnt would eve** be opcraica.
2. ho port :ndxiromn number of hours per yea** that P *
iiori
foUo'rfod by tha ar.ui.t
If operation wtit* con t
ysar then report
^ s ;.!5 (iiiring
ll-.iM'.li, IllsJIl
-------
<4
i
i. //
Tafrfre V.1.1A rilEL USE PATAy Part A
Bail-
ed
11)1
A2'J2
112 b 2
Fuel
Type'
Source-
OTF
(ethane)
99.6%
OTF
(ethaoe)
09. G%
tlope
Hope
' -¦¦•t S Ciscriij.
Cc.il:
Fuel^Qualityl ( as received)
3TU per lb
per gal
¦1' per SCf
Kin
Avg
1750
1750
Afih(t)
Max
0,0
0.0
Avg
0.0
0.0
Sulfur^
U)
Max
0.0
0.0
Av t;
0.0
0.0
Fuel burned^ during Hi
(year)
Max per
hour
(lb,SCF
Col)
13 x 10J
43 x 10
Jan-Hiiro^
s—\ Actual/quarter ' /
[tons,. leaser. (10(10 e*l)'
^ A»)'il-JuncJvYy-Scut Cet-Du
10 x 10^
5] x 1Ou
10 x 10u
41 x 10
10 x 10
12 x 10
('•
a
lotal
for
year
(Tons -
L l) " S - I
1000 ;•.
Ill X 10
:ir. \ in
•10 x 10
Hi£) x 10
! I
in • :£tail, hsu fu'la gra s~t;?lad (Hott sa^.pliiK-; f r a n^ncv as a'I ill'2 LiJ- Ji £- 'lLc:'l".r ?_
3
T
!»y whoa were analyses ciada:
2. 0;)
-------
u
I
"I
© 1
?
3
Hoilcr
ID*
^ ¦1.1 1
L> i le
Kc^an
Cpera-
tion
(mo/da/yr)
unAi/>
Nprir.il
Status
(Pperat-
ing or J
Standby|
Maximum
Desipn
llqat
Input
/io6BTU\
Maximum
Design
Output
(lbs 6tean>/
0 hr)
10° DTU/IIR
Cros.*;?
Genera-
tion
(MW)
Ma
-------
9>3L
!
Stack
0 >ilur
IH(&)2
Stack Paramotcr6
Contin>iouB Monitoring Equipment
Height
above
ground
(ft)
Inside
Diameter
at top
(ft)
'
Gas Exit
Velocity-*
(ft/sec)
Cus I G.is Vcluinc->
'orocnt
t'xeess
Air3
m
IDl
Temper-
ature j
(?r)
LACFi)
Manufacturer
Model No.
Dat i
Recorded11
Monitor Location^
252A
A252
54
4.5
8.2 est.
i
770
7867 est.
NAv
25213
D252
63
6.0
15.3
770
26021
30
Lear Slegler,
CM50
°2
25* El.. lfl' Din.
Ul
«
1.
2.
3.
H.
Use assigned Identification Numbers as outlined in Section I and used in other sections of form.
List all boilers discharging through each stack.
Should be given for maximum load condition.
Data recorded - Code as follows:
01. Opacity
02. SOj
03. N0X
O'l. 0,
05. CO
06. C02
07. Other (specify)
If monitor is located in.stack, report location
relative to base of 6tack/diameter of stack at
monitor location (e.g. 350 ft/10 ft). If monitor
is located in breaching(B), please so indicate.
Page 3") of
-------
'•tack
..ID
Ho
A2.V2
l.oportinc Period
for Emissions
l.rni^sioiis Durini;
(yoaPi
f, yi
Particulate
Matter
SO 2
~ 0
0
N0X
'2
.117!)
CO
Hydrocarbons
7031)
Leail
NAv
Hi hi; i';
252A
Maximum hourly (lb) t
. 13
•> •»
Jan-liarcli (tons)
.05
.ortS "
.015
NAv
April-Juno (tone)
.05
0
.875
.085
.015
HAv
JJAv
July-Sept (tons)
.05
0
. 1175
. 0R5
.015
Ocl-Dec (tens)
.05
0
. H75
.085
.015
NAv
Total during year (tone)
.20
0
:i. 60
. 34
. 0G0
NAv
N i\ \f
2520
B252
(I ixicium hourly (lb)
.43
O
/. s:i
. 7.)
i;<>
Jan-March (tons)
.255
0
-1 .40
. 43
.077
NA-
April-June (tons)
.205
r
3.i 9
. 35
. ?o2
NA V
July-Sept (tons)
.210
J
3.68
.30
. Jf.3
N.'.v
Oct-Dec (tons)
. 175
0
3. 00
. 30
.053
N \ v
Total during year (tons)
.845
0
14.79
1 .44
.255
NAv
Maxin-.urc hourly (lb)
Jan-!1arch (tons)
1
April-June (tons)
1
July-Sept (tons)
1
Oct-Dec (tons) :
1
Total during year (tons)
*
Maximum hourly (lb)
Jan-Harch (tons)
1
April-June (tons)
i
\
1
July-Sept (tons)
1
I
Uct-Dec (tons)
1
Total during year (tons)
|
Maximum hourly (lb)
Jan-Harch (tons)
April-June (tons)
July-Sept (ton6)
Oct-Dcc (tons)
Total during year (tons)
1- If the cum of the design heat inputs for all boilers operated at the plant is less than 2S0 MM Btu/hr only the ir.iximur-.
hourly and total annual emission rates need be reported. Facilities with greater than 250 MM Btu/hr design heat input
should also report quarterly emissions. Page 1 of
-------
'laVlt: V.y.U I10II.EK EMISSIONS DATA. I'art D
Explain mcthocKs) of determining emissions j-.iven in Part A. If by utnek test, indicate by "J" followed by month .m ->ns
EF, AP-42
DTuble 1.4-1
(5-74)
L :ad
NAp
U t ho I
During the year of record, was any boiler operated with its air pollution control devices out of service or experiencing major
malfunction? Q Yes Qj Mo If yes, note boiler ID and total number of hours operated in this manner. ;
Page j (1 of
-------
f*,
Uoilur
A252
112 5 a
--¦/
Actual Opuruliin' 'I'iinu foi' 'U_
Cye.nT
Continuous^
rul*.-year
Operation?
lio 'mal Shut-
down Time?
(yes/no; dates)
yes
yes
Jan-Mar
hr/day
day/wit
wks
A >r-Juin:
July-Se'^t
T
Oct-Dec
hr/day
day/wk
hr/day
tlaj /wk
vks
lir/day
day/vk
wV:s
(
i ft
'local
|-!ix ini
I'inu-J
JV. L.ii
Act u.'il
I'C ,ll"i
I Ol'
yv>
KYlie
H7 '.1G
local
i.o i'
,-a r
87(jO
H7150
1.
If boiler opfl™ted.^"tl--U?-!1LiS|r^lStciI"ee0(i"?^e.rt/l-6/15>. H^tion waB contuuous, tlwn th
which the process or equipment was ®Ju^°un VpewItioirHas"not"conlinwus throv,Ehout the year thea report
'5SSS; lT,%[t:rn either t total operating .»«« for the yaar of record.
' 2. Keport Mxi.u^ number of hours per year that the process, unit or equl,,me«t would ever be opera
"lio" anil supply
*jd of
-------
SurjMPVfr of UCC'», Institute, 1981 Emission
Inventory Listed by Pollutant
Process Vents
Pollutant Ib/hr TPY
Acetic Acid 28.54 1.50
Acetone 344.94 142.44
Acetonitrile ^ 1.0 0.004
Acrolein / 0.92 0.56
v/Xcrylonitrile > 39.15 3.36
Ammonia" 0.20 0.64
Aniline 1.15 0.018
v/kenzene 72.07 10- 09^
vl,J-Butadiene 127.27 U45.79 '
Butanol 13.34 0.59
Butyraidehyd* 11.27 3.67
Carbon Monoxide 5.24 13.36
Cellosolve Solvent 35.98 23.84
Chlorine 1.89 0.19
^bhloroforra 22.0 50.12
Crotonaldehyde 0.12 0.011
Cyclohexane 9.16 0.11
Dichloro Methane 20.28 1.24
Dicylononadiene 1.72 1.72
1,3-Dicyclopentadiene 98.83 185.09
Diethyl Ethanolaaine 1.50 0.10
2,6-Dimethyl-4~Heptanol. 0.032 0.01
2,6-OimethyM-Heptanone 0.65 0.28
Ethanol 11.82 1.01
Ethyl Acetate 1.90 0.02
Ethyl Benzane " 2.79 5.70
2-Ethyl Butyraldehyde 6.10 2.43
t-Ethyl Crotonaldehyde 0.71 0.31
/Ethylene Diamine 1.80 0.036
v Ethylene Oxide 443.34 110.58
Ethylidene Norbornene 2.5 '5.34
t-Ethyl-3-propyl Acrolein 0.38 0.17
^Formaldehyde 86.57 1.46
Olutaraldehyda 4.77 0.58
Heptane 2.34 0.14
Hexaldehyde 0.88 0.54
Hexanol 0.021 0.01
Hydrocarbons 0.80 1.92^
Hydrogen Chloride 0.65 1.48
Hydroxy Ethyl Cellulose 68.75 3.30
laophoronfr 1.74 5.23
Uopropanol 584.62 485.14
Page 1 of
3 ~ & ^
-------
UCC, !wtltut«?*Cont'd
Particulate
lb/hr
TPY
lsopropyl Carbitol
4.43
0.2S
Kerosene ¦*
38.58
7.65
Mesitylene oiide
0.34
1.25
Mesityl Oxide
4.70
12.90
Methanol
133,14
48.58
2-M ethyl Butane
351.00
437.94
Methyl Chloride
2.92
8.96
2-Methyl-5-Ethyl Pyridine
0.21
0.16
-/Methyl Isocysnau^
•^8:33
0.14 <
' 4-Methyl-2-Pentanol
2.58
4-Methy!-2-:Pentanone
75.72
90.44
Methoxy Dihydropyrar.
0.20
0.43
Naphthalene
9.64
7.13
Nitric Acid
0.10
0.01
Nitrogen Dioxide
11.59
25.60
n-Honane
1.33
0.96
n-P are fins
4.3a
14.70
PhenoJ_ ___
nZPhos^ene}
0.016
4.03
POLYOX
2.7
0.99
Propylene Oxide
.252.00-
17.46
Sulfur Dioxide
0.29
0.70
Styrene
10.86
0.27
1,2.3,6-Tetrahydroxy Benzaldehyde 0.81
0.017
Tetralin
22.40
39.17
Toluene f"'
4.2S1
23.94
Vinyl Chtorohexane
10.0*
39.10
Vinyl Methyl Ether
i.7r
1.21
Vinyl Norbornene
9.0
-3.18
Total Emissions Prom the Process Vents =' 1999.5 TPY
Combustion Products
1 _
Pollutant
lb/hr
TPY
Carbon Monoxide
103.77
181.90
Hydrocarbons
137.55
250.49
Hydrogen Chloride
135.0
0.80
Nitrogen Oxides
2446.4
3679.7
Methane
2.0
7.40
Particulate Matter
73.93
103.7
Sulfur Dioxide
3650.1
4853.1
TottJ~£gilMio«u Proa ComSustion 'Source* * 9077.1
Total Emission* From This Facility = 11,078.6
1r £•(.
Page 2 c
-------
7iSE3LZ SJUSSION REPORT IMiTHCO 3)
/A'/rtjr / '.Wia/O
Ccooan^ Hajre ^
Coaa-snj Locacioo I*/'/
Source I.D. #a,JC -/?Q.J f£Z(
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DATE: /£////^/
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Cccpany Na=- ' J a; rw pAnlhnh ,
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Source I.D. if2. ZiP/So-l'*, S"^fc
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COMPANY REPRESENTATIVE:
INSPECTOR (Print Name): , W]y\ (j,
Isignacure): ^-/^.
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Co=?»aj 7U=s //*/)„
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rS3?ICTC^ (Print Hme): 6 0 DATE: /3.////<&
j UigpatgT»>: %/ COMPANY REPRESENTATIVE:
-------
Section IV - Compliance Inspection
CERCLA
-------
MIC RELEASE INCIDENTS
UNION CARBIDE
INSTITUTE, WV.
V- I
-------
3
the release was lost to the process sewer this event was interpreted as
a reportable quantity (tost to the ground). However, standard operating
procedures require any leak or air release be sprayed with water to
"knoc'< down" MIC fumes and to hydralyze any actual MTC. This water
then enters the process sewer. The spray w-itsr itsel f was nr. 2 factor
;>n determining the repartab? 1 ity of MIC- Sines any release to the air or
ground is followed by such spray application, the reportability requirement
is based solely on the quantity of MIC lost to the air on the ground.
CONCLUSION
A rsrn'uation of the data indicates eignt {3} occasions w^ere, fret*
a review of company records, it apoears that MIC reportable rsl&sses of
greiter than one (3) pound occurred. Seven of the releases war? determined
as air releases which resulted in only negligible quantities of VIC having
been lost to the process sewer and the WWTP. One MIC release occurred within
a building and, according to the criteria utilized, not subject to the reporting
requi reme.it.
Tha two most significant releases were those which occurred on
January 1 , 1 934 and August 25, 1981. Although LiC personnel rapo-ted the
majority of the rHC/CHCl 3 mixture lost on Jan-uary 1 , 1 984 was recovered,
tha spill fixture contained approximately 840 pounds of MIC. 1>? August 26,"*
1931 event resulted in the loss of MIC (>10 lbs) through the flara tower
in such a manner that the flare was extinguished and had to be reVit.
RECORDATIONS
When MIC releases have occurred, the Environmental Protection Department
has not been routinely informed. [*]
.his failure to inrorm tne tv department nas been
previously documented in the facility contingency plan by the plant manager
in 1981. As a result of the MIC release incidents, EPA made two suggestions
to t!C personnel,
They were: (1) [The sentence or sentences delated contain a predecisional
staff opinion on a legal enforcement Issue.]
(2) As a result of the HQ requirements, the MIC unit
personnel need to be aware that, in addition to
correcting the MIC release problem, they need to make
better estimates on the volume of MIC release in
order that the £P Department can comply with the
CERCLA reporting reqoirements.
* The setite-nce or sentences deleted contain a predecisional staff
opinion on a legal enforcement issue.
-------
MIC RELEASE INCIDENTS - UNION CARBIDE, INSTITUTE, WV
BACKGROUND (December 10-1 2, 1984)
After leaving the Union Carbide Institute facility on December 10,
1934, EPA personnel were notified by the Union Carbide (UC) Environmental
Protection (EP) Department that OSHA inspectors had discovered several
instances where methyl isocyanate (MIC) had been released from the MIC
production unit. This information was located by OSHA personnel while
reviewing UC Safety Department records in an attempt to obtain information
relative to worker exposure associated with MIC production/usage.
Cn December 11, 1934, the E? representative provided EPA personnel
with documentation of the MIC releases. This documentation is prepared
by the JC Safety Department and is not generally forwarded to the EP
Department.
OSHA personnel had conducted a review of such records for the period
1933-1984. EPA then requested such information for the period 1980-1932.
UC maintains such records for a five year period (1980-1984).
h review of the 1980-1984 data indicated a total of 28 MIC releases.
UC^Safcty and UC MIC production unit personnel reviewed each of the
23 MIC releases and made estimates of the volume of MIC released. EPA
was^aiio provided a copy of the incident reports covering the 28 MIC
releases
Cr. December 12, 1984, the Wheeling EPA Office compared the MIC
eases to the "Reportable Quantities" requirement of Section 103(a)
otLCEfcQLA'. The RQ value of MIC is one (1) pound. The proposed, revision
to the 'JF.RCLA reportable quantity will raise the MIC release/spill
level to TOO pounds. The release data, as summarized by UC, was as follows:
No. of Releases
I. Less than erne (1) pound 12
II. One to 10 pounds 7
III-. Greater than 10 pounds 7
IV._ Undetermined due to limited data, 2
but probably greater than one pound.
[The sentence or sentences deleted contain a predeicisional staff
opinion on a legal enforcement issue.1 fnese re teases
occurred because of equipment railure, residual quantities of MIC in lines
re1eased during equipment repair or replacement, human error, sample
colleci-ion, etc. In general, the majority of these MIC releases are
_attribut-at>-Ve-to the-types of product releases inherent to the large scale
production of any chemical product.
-------
2
The MIC releases which have occurred were complicated by the
difficulty in measuring the volume of release. This is of particular note
with small quantity (a few pounds) iosses which are vented to the air
"P3n release. Spills that actually reach the floor of the MIC unit are
hy-jrolyzed and sent to the process sewer.
On each occasion that a spill occurred, the appropriate alarms
were sounded and MIC unit personnel implemented the necessary contingency
and clean up procedures.
UPDATE (Dec. 19-21 , 1934)
After preparation of the initial report detailing the MIC releases
and the applicability to the CERCLA reporting requirements, the Wheeling
EPA Office was informed that all sixteen incidents may not have been
subject to the reporting requirement. During a 12/19/34 phone conversation
with Bruce Smith, Chief, Hazardous Waste Enforcement Branch, he indicated
that criteria, other than the volume of release, can be utilized when
evaluating a spill release incident.
These criteria include items (a) to (d) as listed below:
(a) Any MIC release to the ground (essentially any liquid MIC
release) exceeding one pound should be considered as a
reportable quantity. However, if any MIC release occurred
within a building (totally enclosed) then the release
was exempted from the reporting requirement.
(b) Any MIC release described 1n item (a) was applicable
irregardless of whether it occurred within or outside the
actual production or utilization areas.
(c) Any MIC release as described in item (a) was a reportable
quantity-i-rregardless of whether the MIC was contained
(in whole or part) and eventually placed back into use.
(d) At the present time the RO has not formulated an opinion
on whether or not an MIC release to the air (irregardless
of quantity) is'subject to the CERCLA reporting requirements.
Reportedly, discussions are ongoing within the RO which
L ' 1 - ces are necessary before
Utilizing the above information, the Wheeling EPA Office reevaluated
the 16 MIC releases. Those instances which appear solely as air release
incidents are so noted 1n Table 1. At this time they are not considered
as events"applicable to the CERCLA reporting requirements.
The "Toxic Substance Release" reports prepared by the Union Carbide
Safety Department were utilized to evaluate the type of release (air/
ground). In some instances the information was somewhat conflicting
ind it became difficult to make a definitive decision as to the route
of the MIC release. In addition, a number of the reports note that MIC
was lost to both the process sewer and the air. When a major portion of
reporting requirements
V- 3
-------
MIC Ht LIIASES, UNION CAKIlIDi; - 1NS F1 i IJIL!. NY.
Page 1
Date of Hoi oases
9/28/84
\
\
6/7/84
2/8/84
1/1/84
12/28/83
9/22/83
8/27/81
8/26/81
Release
2/ Release
Quantity 1/
>10 lbs.
1 to 10 lbs
1 to 10 lbs.
14,000 lbs.
1 to 10 lbs.
1 to 10 lbs.
Undetermined,
>10 lbs.
Majori-,' ueleasos
to: Air/Ground
Ground
A1r
Air
Ground
A1r
Ground
Air
Ground/Air 2/
Cu'imon t s
Report documents release- lo air arwl
process sewer. There appears little
douhL the liquid MIC was lost to the
ij round.
irs majority of release to air
duo to defective equipment. General
clean-up included wash down of leaking
pump.
Release to air followed by wash down
of leaking flange
See attached explanation for this
re 1 ease event.
Appears majority of release was to air
wiion piping separated without prior
evacuation of MIC
Leak from MIC line. Incident report
states loss to air, but it appears MIC
was probably also lost to ground
MIC released from knock-out pot
associated with flare tower
MIC released through flare tower
due to procedural error. i'lare
was extinguished and had to t>e relit.
volumes estimated by MIC unit and Safety Department personnel.
incident with significant quantity of MIC lost to air and process sewer
i,». Ul. LA
!'( porI1 o
[The sentence or
sentences deleted
contain a prede-
cisional staff
opinion on a legal
enforcement issue.1
-------
TAolE I
)ate of Releases ¦
6/ 5/81
4/2/81
7/7/80
^ 4/24/80
I
„ 3/14/80
2/7/30
Quanti ty
I
MIC RELEASES, UNION CARBIDE - INSTITUTE, WV.
/
ConiriiC-nls
Majority of Releases
to: Air/Ground •
ndetermlned, Ground, but
ut assumed inside building
>1 lb.
>10 lbs.
•10 lbs.
>10 lbs.
>10 lbs.
Ground
Air
1 to 10 lbs. Air
Air/Ground
Ground
CERCLA
Reportable
Release from a piece of equipment re-
moved fro.n service for repair. How-
ever, it appears contamination occurred
inside a shop building.
Procedj,^1 problem resulted in MIC re-
lease to ground
Failure of valve
Weld failure allowed release of MIC
primarily to ai r
Weld failure allowed release of MIC/
CHC13 mixture, incident reports re-
lease to air. However, it appears
likely that some portion of mixture
v
-------
ADDITIONAL INFORMATION PERTAINING TO JANUARY 1, 1984 NIC RELEASE
According to 1-1-84 incident report a total of 14,000 lbs. of a
MIC/CHCI3 mixture was- lost due-to-a- break in 2 feed line. "J-C personnel
reported to EPA that this mixture consisted of 94" CMC 13 and £'¦= MIC.
Tnis would correspond to a loss of 13,160 lbs. of CHCI3 and 2-0 lbs. of
MIC.
EP personnel reported ( as does incident report) that this mixture
was collected in the MIC unit sump, picked up and returned to scrubbers
for clean up, and returned to production. None of this material was
sent to WWTP. Actual MIC losses cannot be estimated. However, winter
temperatures would have minimized MIC volatility.
-y- 7
-------
MIC.
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Deportment Report No.
Oeoortment: /^* "?6 f Ffl OS 4*/U A* » C
Shift: g£
g Q^flSe^t Reported:
.acation: ^XflS'-O^ f>
Data al _
Oeurrenee: Y-2-? ''Y
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0 Impr
Pert ornionce error
0 Kno>»J*dg« Delienney
MCulion Ovlicitncy
•fective
fteswlt: Choch Applicable Squflft*
Q Injury
~ Fire
Q Equipment Qamag*
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O Mi*w9 jf Product
Q No Laii-Na injwry incident (Near Mitt;
O 0»Sjr (Including Security Losses)
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<
a
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Jg
ly O
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tnelwdo both immediate and lowf render plana, stud lea, assignments.
Responsibilities? Completion dates? Attaah additional shoot if neoaosary. h
•verity Potential
io»
_ Serious
~ Minor "
tokeblo Reewrronao Rate
Frequent
|OeeaelonoJly
Rarely
Torgtt
Oofa for
Camolation
A«eeuntability
^ &LJh
~ CSoek iquora if report thould b«
comwunictftod to rfie plant
Form S12-2437-H (1-83)
Dat»
ASSIST
y- ?
"ANT PUfh
Ignature
Z20
NT MANAGER
SEE OTHER SIOE FOR DEFINITIONS,
V I Vl#« »
-------
'lQXJC KZLtHSt. Inititute Plant
(See Plant Safety Procedure IL-3)
./57
Dept. No. Submitting Report
Department Report No.
tfr SE
| 0«»«rtmant-.
Shift:
Pan RapoMad: 9 — ? ¦*
.^cation:
dS*- /^/6. -TT5 ACs**"
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f(JXK (~>AS Ad£L £/)$£ AWWUCmziiKiucwi r\ur uft i
Institute Plant
(Se* Plant Safety'Procedure 11-8)
l£L
Dept. No. Submitting Report
0«parlm«nt Report Mo.
Shift:
M
§ Oaf Rt>«(nd:
Local ion:
Sate at .
Ocgrrence: Time: y^j'*
Ootcrlptlon of Accident/tncldanr:
^2.
Signotgr*
^T_
Banc Caute: Check Applicable Square «i
Performance Error
Q Knowledge Oeficiency
~ Elocution Deficiency
Procedures
~ Lack of
D Inadequate
£ qui pment/Material/Facility
O Improper
^JSL^efecr i»e
Result: Chock Applicable Square*
~ Injwy
Q Pire
0 Equipment Damage
od uction Lost (Buti.'ett Interruption) Q Mixup a I Product
0 Lot * of Product (Spi ll/Releate) J3i No Lou-No in|w1
Ui>
i*
jwfgo*tlon><3)l Prtven^Reeurronqtj
/
- Materiel Laos Occurred, Check Appropriate Sleek* Below)
*• 1 i. Ma tor la I La** Lb*. La it tei Q Pteao** Sewer Q Air
B. $ Product Mlsua (Rerun, Devaluation, Ete.) 5 Ground D Plre
~ Cooling Weter ~ Plere
ft^erlt^Petenrl^
Major
w.
c. s
~o. s
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.Equipment Domoge (J to Reploee/Rapair)
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O Sertewe
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rrekeble Recurrence I
Stfroeuent ®
TJ3 Occasionally
Q Rerely
AddltJonel Agtlen: What additional octien it plennod to avoid this typa incident in tho future?
Include bath immediate and long rongo plant, itgd'ot, atiignmontt, etc.
Reipantibilitiot? Completion dotet? Attach additional the*-' if necetsary,
Accountability
Targe
Oote Ic
Comolef I
a
1
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L
Date: ~Lu>~e£- jL C£)//>
~ Check square if report ihouid be
communicated to the plant
V-V/
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54. 12/12 15:13 ?04 *£PH WHttLlNL,
/ OX./C #£.C£Ai£ I Pl<""
.'lant Safety Procsdure 11-3)
Z£ZLo.pt. No- Submitting Rtpar?
r i ~ ^ .i- luau
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fliffin tam ' Uh
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O No Laaa-Ma Injury inciJ«nt (Naar Ml**)
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coamunicatad la tha piont 0«m^fcy g ,rL
Actountabilify
Tafflot
Data (or
Gsmoltfion
•^oy|
S<4«t«tvfa
Form 512-2437'H (1-33)
.y ASSISTANT PLANT MANAGER
SEE OTHeR SIDE POR DEFINITIOMS,
-------
3 4. iC/i* iC-iJ WIEfcU'"" ^ ^ iu^u
6NT/INC10ENT REPORT
f^O'&lC. P\E.L+&A $ £. In»»itu»* Plant
'lant Scfaty Procedure II—-8)
/ rurt Ho. Submiilinf Rtpo/1 Department R«port No..
0«partm«n>: /O 5^. -
Slilff: -"S^
D O'^foata R*9Mta4:
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juacBt.a*.: //j f <5"
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J-°.ITICAL ACCICS'iT/'JiCIucwi wtnjKi_ jNT/|NCIDENT REPORT RECEIVED
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~ O.foet ivt
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3u.« of Product WjjnT7R«Ua»a) 0 N« La»»-No injury meidant (Noor Mi»•)
Quantity? ¦X/'V / O Othar
Immadiata Action TaWon & Suggoinont to * .:»•«» R»cu'r«nc«
r
^ /oc,*/ a/*r~t *"
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Q Ground O Ftro-
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Ity Potential
A. S
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Product Ml»up (Rofwn, Oeveluetlen, Etc.)
2 qui prnom Damage (J to Replace/Repair)
Bw$ 0^ /y^Z&2J/ XL
r—i Cliack iQuora if rap art ihould ba ^ ^ jL -,
Accountability
O^ajlZ^Z,
u,^e
Targrt
Oafa for
Coton
~ Uiack iquora it rap art
communieotad to tha plant
-------
CRITICAL OCCIOEHr/INCICeNT REPORT :NT/INCIDEHT REPORT
r«/t £/}$ /2£L£yfSE 1 p'«" RECEIVEu
. %... -iont Safety Proc^duf* 11-8) HCwClVCU
L£JLd*9*- No. Submitting R«poct i' ,(r)y ^Qgg^nonf Report No..
- /T7
Shift:
Location :^2^T
Ccuftw. Jt-S- £?"? i Tl
Qeicriotlon of Accident/Incident:
J&f ZT& -/» Lo»»-No I njufy incident (N«ar Mit
Quantity? O Other
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. Material Lee* _^______ Lfce> Leaf to: Q Proeee* Sewer Q Air
~ Gre*md Q Fire
•a O Ceollnf Wete* Q Plere
Potential
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_^To«al Valg» of Lom. -
Sewe
Soriow*
Miner
•.ofceble Recurrence 9a
Preewent
Oceoslonaily
Rarely
-Addltloiral Action:
'What additional action It planned to avoid thit type incidenr In ihe future?
Include both immediate and lonf range olant, ttudlea, attignmentt, etc.
Reepontibilitie*? Campletion date*? Attacfuadditianal iheet if neceeiory.
£l/s<7/? ^t>jj Ast^, £- rxa* /
Accountability
Tgrgof
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Cimelotu
r
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communicated to rfto plant
- i
-------
84.12/12 18:13 Pn.c «EPfl HI H F £ L 1 N C FTS 923- 1050
_ „ . /I,- / JCNI/INUUCNJ KCHJKI
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_ w«w Plant Safety Procedure 11-3)
/ / rU|»t No. Submitting Report
JUL 2 11983
SAf£Tyj?£.SJ-N...
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w
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/*JCC.is The Js'/FF/72 3?£7£cX,
E Clock iquaro if report should bo
to
-------
Toxic, gas
112. D«p1. No. Submitting Report
- ^pent/incident report
Institute Plant
Plant Safety Procedure 11-3)
0« part man t Report No.
Sk.lt:
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3 ~
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Performance Error
O Knowledge Deficiency
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Procedure*
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C Improper
(2 Defective
Result; Chock Applicable jquJ'ei
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asica.ce AtaOtHr/INCIBfiHr REPORT
T&XIC GAS gELS-ASE- pi™,
—j . (See Plant Safety Procedure 11-3)
-L±_Zo«pt. No. Submitting Report
^ * 1 *»* " '•* *
Department Report No._
w
Shift:
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TU P-.yi ^ ^
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L>*» Anatym | g}7ihATSO S LOSS (II Material La** Oeewrrod, Cfceali Appropriate 3lock* 9a law)
''Mill Sewer^S*Air
A. $
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a. s
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P 1 /&& +
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~ p
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Q
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0 Minor
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~ Pra^uonl
.~ Oecotlonally
*S Roroly
Arfditionoi Action:
j£l-£L
What additional action ii piannod la avoid tht¦ typo incident m iha futuro?
Includo both imritodlaia and lan| ranfa plan*, (tvdiat, «»»ignmanti, «ie.
Ra«pon«ibilitia*' Complation datat' Attach additional thaal if naroiiary
-j "P- >£-&-* ty- ' fa t
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Date for
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t
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~ Chock i ff If ({_t^\
** - ~ •* '
-------
TOXIC /?£LE4S£
ACCIDENT/INCIDENT RfcPUKl
Initituta Plant
(S«« Plant Safety Procedure 11-8)
, (j.
No. Submitting Report
Department Report No.
Shift:
Location. MJ.
STr'iS.-
w *1
Date o< - j
Ocurrane*; v5 Minur
Oaacrlptian of Accidant/lncidant:
J'
/
Signotura:
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Performance Error
~ Knowladga Oaficiancy
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Procedure*
O Lack at
CJ '^adequate
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n i
w Improper
yJ^Oefeciiv*
"« j 11' Chaclt Appticabla Squaxt
~ Production Lo»» (Bgtin«s« lnf«ffyptl on I Cj Mixus o' Product
^j3>Uoss of Product (Spi ll/Pal«a*«) 0 No Lot i-No ;n|gry incident (N«or Mn:
Quantify' 0 Cth«f
QInjury
Q Fira
QEquipmant Oemaga
lm<.i«diot« Aciioi. Tuk«n i 5gcjg«»nani la fiavanl Hacurranca
/, ss- / A^>
t
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ly C
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B. S Product Miiup (Rerun, Oevoluetion, Ete.) — ®,ou,,^ ^ ^,r• 0 Minor
Severity .°a»entiol
c. 7 7-~
. t • ' ( I I t ' I <' ' ' •'*
Accountability
Target
Dote for
Comoleiian
M-J..
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communicated to tlie plant
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.. ^ w«o ^lant Safety Procedure II*8)
J• 0*p»- No.'SubmiMing Rtport
D«porlm«nf Rtport Ho..
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S*lif«; aE
eg
/ 3 ~ 0«t» Rapanad:
t/y/s?
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o
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^ Q Improper
« Q^O»f«Ctiy«
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~ No La*i«No in|ury incident (Maar Mi(t)
~ Othar (Including Security Losses)
Immodiof Action Tokft & Suggtifiom to Prt»oa> 3tcurr«nj
*— •
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^ITI 20 L&t. Loaf toi 3 Pr»«a*a Sawar(2 Air
Product Mteuo (Rtnjfl. Oovduation. Etc| Q Gr«*«d Q p,„
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84. 12/12 16:13 ?i<5 WhtM I N'i ¦ agJ tu3u
THTTIflU. ACC1C£NT/INCI0£NT REPORT
ToxTZ GAS #EL£A$£ ^
^£12-0: /
SJifft-
Location; ^2. /H7~ g. Ac/ <
Joia ai
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/•?V v" S<*J~ erf dtxr^
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Came let ion
395=r
iwai
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¦CRITICAL ACCIDENT/INCIDCNT REPORT
rox/c <545 rt£L£AS£
£Zo* . No. Submifting R«pofl
JSNT/lNCiOENT REPORTRt0t,vcu
Imtitut* Plant
.. .'iant Saftty Procedur* 11-8) qqJ
D< pa ft went Report No,.
jpartment:
/s?
Shift:
8L
Date #
_Oeurren««r_
Dale Kaaornd:
locatiQH- sprTC. jT/g/
••S---_i-..i-1 .>«—iJ * wf.
Description o> Accident/lncldent: 7a^Ji-^
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.Equipment Oamefle ($ to Raplaea/Rap«ir)
J. J fty«!».««. Interrupt Ian (J 0roa« Margin Las*)
ity Potential
rloit«
Last
enable Reewrrenee Rata
Fraquanl
Oeeaaienaily
Rarefy
* Additional Aetion:
Z
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What additional action It planned to ovoid (hit type incident in the future?
Include both immediate and long range plena, itudiet, assignment*, »tc.
Responsibilities? Completion dote*? Attach additional iheot if necsssary.
'I-Z ^CC T?1 MA;s/T. * Q/=E& /ma/t/S^
Account ability
Tor^at
Oato fsr
Comol«ticn
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: — ^CM / trtV.IUCM KCruit I
TOXIC R£LE.Q$£- Initiful. Plant
.'lent Sofaty Procedure 11—8)
SJ.** . No. Submitting Raport
Dapartmant Rapcrt No.
U ifr sfl
T
'"laoortmont:
/S*7
Data R«9ort«»«» Information)
5*lo»»-w Pfo«39t» D>' l>fr^qtsiy
Q.j^«!tr? rlfAJi ,
~ Uixuo of Product
0 H« Laat-No iniury Incidont (Noor Mill)
Cj OlS«f
Immodloro Aarlon Tokori & Swflgoirfan* to ?ro»o ^¦« sSi- -s£~ ~"
. CllA^d^-. ft f f'fn" T rft« iitii^wii 1^1"^
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Ua«« An«ty«(#f ESTIMATED I LOSS ft# M«t*rf«t Lo*< Oesurro^, ChMk Ap^oprlM* 3l««k« So low)
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rueiMA/ ri// OSS j5vziwl Hs-«r at
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Accountabilify
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Date for
Caenalttien
~ iieek j^uaro if r«port thouia
sommuniesta^ to tfca plant
farm SH_5A1T-<*- M_T«M
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.
ASSISTAMT Pt iMT
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Ptrfofrnonc* Error
0 2
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^^0^^!osF7n^«Hifia^l«»»^Seufra37cha J Cooling Woter u Plore
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Bu»inat« Iniarruptlon (S Croat Margin Loi()
Savarity Patannal
M Molar
JS Sarleut
Q Mino«
3ibabla Aacurranea Ra
Pro^uant
S. S .Total Valua «l Loo
^ Occasionally
C Raroly
Additional Aeno«; | WHot additional action it planned to avoid thit typ* incident in the future?
Include bath immediate and leng range plan*, ttudie*, a(«ignmen«>, ate.
Ratpanaibiline*? Completion data*? Attach additienol iheet if neceaaory.
S'J&yl A+rtS-
-------
i. 1 2/ I 2 i 5 ' 13 i a * c f H Wnuc-uin-, ...
/ O 6 A S ££LEA$ £ ACCIDENT/INCIDENT REPORT
~ ln»fifut« Plant
' (S«» Plant Safety Proeadwn 11-3)
jLi_Z.O«pt. No.
(Uport Ms,
ff
'•Oortw^Ai:
/ 5 7
Shift:
j^J-Oata Rapcrtad:
Location;
5et/'<- < 7TZV/f/w - . j»-f V J? ^ 1 Ocurfanca:
0«»}-4/Jsi<~ r-h szjtpnt<7*
Vfthjltf A J PiJ*\ "P 5* - /*>P,»A}5sr l^fA/r&d B ?,)At? hrtfd ft***? h »J h**A
^<*Vt1 a » i } c » * * m » i / ^ J
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.Signature
Efl-Z.
a»» Analy»i>: ItSTlMATSC^t LOSS (I' Maiarlai La»» Oe««r«J, Chaek *ppro»yp* incidam In tha 'gtu>«?
Includa bath immadlata and long ranga plana, ttudiaa, aitlgnnwnta, ate.
Ratpanfibtlitia*? Complatiofl data*? Attach additional ihaat <1 nacanary.
D:
C0/P/?£CT~ Ta'S? Tfzirr *
Aeeounrobilily
1arqtr
Data for
CsmoUtiofi
T^^s^aj. j/^g ~P$A/r Vs/r &/o fo#YAi
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rSs/ou/ Co^aj^cT" 4.v„Lc.jf. hi;777. ,
'** --US3 51OF >'09 OS F INIt I ONS,
-------
3 4. 12/12 • i o : i J trn uncciuiu a ,,. ^ j i. _i 4 , „
LUU\L ALUiJWU/iflHUtiU tltrucu
3%I'C'OAS RELEASE.
!S1
, D«pt. Ho.
ACCIDENT/INCIDENT report
Injfiiu't Plont
(Sm Plant Saf«fy Procedure It—S)
Mm
er
V
Rtpari No..
^ A- ! C /
\ Shiff:
M
ii
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9otie Caul*: CS««W Apgncabi* Squarot
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O D«lici«nCy
Q Exocurion 0«'i
Q lnjuJe"iT Pc'/wjO 1*V" * i/Mc-l; TO — i/^£.
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rtk. >.< W to I < t ! II^IWUI* I l\k-l W<\ I
Institute Plant
(Saa Plant Safety Procedure 11-3)
Dept. No. Submitting Report
Department Report No.
T«oanm«nt: / jf* ^
SH.ft:
Oat* Saoartad' 7-7- VC>
Location:
2- fr*
~ ate at
i Ocurranca
: 7-V-^O iT.m.=
Oascri ption a I Acc idant/lnc .dent: jSqFsTy 1* ~J /J/ *. 7~Q jZ~V,+J Pa s* P
$<.5 c> -ro
H£gglVCD
Signature: /"*"
3atic Came: Chack Appheabia Sauaraij
Parformanca Error
O KnowUdg* Oaflciancy
~ Elocution Oaficiancy
Procedures
O Lack of
JUl 91280
J Inadaauara G.E.LEWIS
C qwipmont/Motvrid I/Fqci It fy
Cj \rrypt*Q*r
«—J Im^r
5r
r?atyi»: Cn»ck AoplicabI« Squares
~ iniury
Q Fir*
Q Equipment Oemage
ImmadiataAcrlanTaljanAiuggai^ion^^a^favant^acuifaneaJ
D Production Lot* Ouiinao Interruption) O Mi*up at Product
ETloss of Product (Spill/Raleaie) G No Less-No iniury incident !Near Mix'.
Quantity? ^ ^ Q Otner
/t-* rr> <* — /u r s=''*- J"
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A. S MoteriaI Let* _____ Lbs. Lost to: Q.*P' 0*J At* _yQ S^CP J dsi
«»«pontibi »»»«••.' LempietioAdOfes f a»?oc n a
Q
Accountability
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P
orm 513-2437-G (4-79^
ASSISTANT_ ^LANX MANAGER
SEE OTHER SIDT 1 OR OL ¦¦'IN>T I0US.
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Ajdmonal Action: 1 tfet'Of il fo av«t4 ihi* »yp« incidtnr m (h« f^iur«?
(nclud* ioiti ano long t«nf« tilani, tiudi*i, oitiqnmanit, «tc.
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m'-zsisf; fdrcstsis^y; />*J*su- jPi''
-------
•k* » iKi.s.iWbtll/ t .KU4"JiNl
TOXIC GAS RELEASE
/S7 tw Mo.
ACCIDENT/INCIDENT REPORT
Institute Plant
(See Plant Safety Procedure 11-8)
Report No.
toarf menf:
r\-T7
SK i ft:
Oof Baportad: JL * jfC
Location:
/ ^c. sJ/y/JZ.
Jateot
Ccurrence:
7- ?c
Tin
Qateription of Ace idant/lnciJanr
" 2 so J' ^*0 * 'T?*#
/A*
dfiav* * /s#sf. -^y/r ^vyg
ca
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S&12-
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Signature
3oi.c Cause: CHick Aapl.cobU Square*
P«r#o"«once Srror
O Knowledge 0#fic:ency
O £*e
X
Ui
a.
3
Iniury
O F ire
~ EquiOment Oomoq#
3 Production Lo«*
IS Lots of Product (Spill/3eleate)
Cj Mi*up o# Product
C No Loti-No injury incident (N«or Milt
C Other
lm«d 22
ui>
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7"
. >/7/ro frUCZb**
Oete
J
.a»» Anolyei*: jESTlMATcP S LOSS (" Meienol Lou Occured, Chech Appropriate Block* Below)
A. $ ^ "Lot* Lb». Lo»t to: J^^reeeit Srww^t*Alr
B. i Pfodmt Mlivip (R*fwn, Devaluation, Set.) 5 ®,auB^ ^ ^>r*
^ t//TO-0e « a , yB . . ~ Coolin9 Water u Pl«»a
C. J / y T"l * Damage (S to Rtelace/Kapair) q ^
0. $ _^__3u»ln«»i Intarwetien (J C>a«i Margin Laii)
£. t/£***-> T...t V«lua a> Latt
L»»«/5r^«rftY Potanrial
.DM
&Z1'
_ 9flOH$
O Miner
Probabla Raeu/ranee Par
LJ fraeuent
Lj Oecanonally
»S Rafaly
Additional Aeiion: j What additional action ii planntd to avoid ihn typa incident m tha future1
Includa oath immadiata and long range plant, itudiat, attignmantt,
-------
Toxic QAs release.
^S£o.(i . No. Submitting R«port
cm/ii^iucm ncrurxt
""" Institute Plant
1ant Safety Procedure l!*8)
s—' 1 1
D#portm«ftt Rtport No^S--££Z^r
Uaoartmont: /.TO / L/LS inilf:
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•— ^ 'v.n is' 1 **^'*¦• "f°l^ ~^r^~ ^('¦• -
hath*. L-)^re. t=i.v»(w -~t: j
P«f/orman<« Error
O Knowledge Deficiency
O Saecufion Oeflcioney
Procedure*
G Lack of
D Inodoauar
Equipment/War erlal/Faci lily
\ST Improper
Q Oaftcrive
*
O
>
X
vu
X
Solvit: Check Applicable Squares
~ injury
~ Fir*
~ Equipment Oamaqa
Q Production La** (Bu»ln««» Interruption) O /ji*u0 of Ptoduci
O Lot* of Product (Spill/Rolao«a)
Quantity?
LJ Mi*up of Ptod
La*i>Mo injury incident (N««r Mi*»'<
Q Other (Including Security Lo*3#J)
du r*>f. A. UJt-'f'k /V^ + Q^ylari- ¦r<.r*(4csj, He J t£u4-6
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Report No._Oj_^ ' " ^
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TOXIC SU&i'lWLZ |M,ifu,# Plant
f'lant Safety Procedure 11-8)
® .Dept. No. Subrniltinj Rapor^
Department Report No..
0«p4rtm«rtf: /JT7<3/ PAcS***je-r«\ e.
Shift:
TEL
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mm«diof« Action Token 4 Suggoiriont ro Pnvmf Recurrence:
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S 1984—'
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ity Lossat
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HCT i
SAFETY DEPT.
*tH4Ho««I Action: ^a« additional actlsn I* planned 10 avoid (hit typa ineidanr In m« futura?
In«lud« both ImrnaWUt* and lonf ranqo plan*, itudla*, dciignmant*, •««.
Ra*p*»«ibilltia*? Complollon data*? Attach additional *h*ot if jia^anary.
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Data for
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Form 512-2437-H (1 -83) ASSISTANT PLANT MANAGER
^ ^ TH6N PORWARO TO
SEE OTHER SI06 POR OEPINITIOnS,
souTinr. and oiSTpibiition
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Toxic. <543
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JfcNI/INUIJtNl KCfUK I
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OX i C ACLt^i'£
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U1 V > I i£ I* I r t l%4 1141 t* I A I I tj|«i
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Department Report No..
T^pOftmtnt: AJ>* 7
Shift:
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Data 9»port«d-
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Additional Action: i W>igi oddiiionol action it slonnod to ovoid this fyp« incident m rnt fu>wr«?
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Section V - Compliance Inspection
Clean Water Act
-------
NPOES COMPLIANCE INSPECTION
UNION CARBIDE INSTITUTE PLANT
DECEMBER 10, 1984
Permit # WV 000086
-------
The tragic accident at a Union Carbide plant in India brought concern for the
status of environmental regulation ccmpl i ance—cfctb-H—Un+oft-Car.h.j de facility
since similar production units are a part'of the Institute Plant. Thus a
team of U.S. EPA and WVDNR personnel conducted an inspection of this facility
on December 10, 1984. The State personnel had conducted a similar inspection
October 18, 1984, and not much had changed at this facility.
There are three cooling water outfalls which flow directly to the Kanawha River:
CG5, called the SubEast Outfall is at the Upstream edge of the plant; 003, called
the Center Cut fall is just downstream of the main river water intake; 002, called
zh= West Outfall is at the downstream edge of the plant. Process wastewater
flows in a reperate sewer system to the Waste Water Treatment Unit (WWTU) located
about a *alf mile downstream from the main Institute Plant (a sketch of the
W*TU is attached). Flow rates are measured monthly at the WWTU with a lithium
dilution test" and the ultrasonic liquid level monitor and electronic flow cal-
culator ^re calibrated. Flow rates in the cooling water sewers are measured
quarterly with the lithium dilution test.
The permit has net permit limits for many parameter so an influent monitoring
point was set up at the No. 2 Pump House. This point is downstream from the
005 outiVl. During this inspection, a toluene spill occurred on outfall 005
violating net permit limits, but the toluene being detected in the intake most
likely came from Outfall 005.
.6 - X
-------
2
MONITORING STAFF
~ne Invironmental Protection Department (EPD) of the Union Carbide Corporation,
Insv'tuta Plant is responsible for iiPDES permit activities at pier'.
piiance with permit requirements is a goal they seek to maintain through a
state-of-the-art monitoring system at outfalls and within process wastewater
severs. Much effort has been expended to establish a dual sewer system - one
for cooling water and one for process wastewater - serving the entire 775 acre
plane site. The EPO has inventoried chemicals and processes within each of the
production areas and they know which sewers could receive spills of these
¦arterial s and what amounts all sewers normally receive. They have set up a
soil: detection system based upon continuous monitoring of Total Organic
carbon (TGC) to alert them to instantaneous changes in water quality. The
c-a --.Tieter TOC was selected after much study as the most applicable to this
*nich handles and produces organic chemicals usually involving organic
orbon compounds in the reactions. They also sample more conventionally
usi?3 grab samples plus commercial composite samples. The composite samples
usually run from midnight to midnight and are analyzed the day they are
r.oncleted. Grab samples are also usually analyzed the same day they are
collected, all in the central plant laboratories. The EPD staff review the
•fata and are able to quickly notify production units of problems, sometimes
even before the production unit staff know they have a problem.
Tfr? permit requires quarterly monitoring for selected organics from the
priority pollutant list. The EPO staff was collecting grab-samples' under
this Tore extensive analytical effort the week of December 3, 1 984. The
data from that weeks monitoring illustrates: (1) how well their EP Department
stiff resgonis-to problems detected by their monitoring efforts (2) how
*-• 3
-------
3
the TOC spill monitoring system on the outfalls does not detect all sig-
nificant spills of organic carbon compounds.
Tne quarterly sailing for some priority pollutants began Wednesday, December 5
at 12:50PM with a grab sample on Outfall 001, the wastewater treatment unit
outfall. .Preliminary sample results were received by the EPO staff the
following morning and they were:
Methylene Chloride 273 ppb No permit limit
Aery Ionitri1e 254 ppb = 7.2 lbs/day Permit limit 10 lbs/day
Benzene <10 ppb
Toluene 333 ppb = 9.4 lbs/day Permit limit 10 lbs/day
Isophorone 1.9 lbs/day Limit 10 lbs/day
The high Acrylonitrile and Toluene concentrations were cause for alarm, even
though permit limits were not violated, so the EPO staff ordered another set of
samples at Outfall 001.
The grab sample at Outfall 005 at 11:15AM had a toluene concentration of 3,444 ppb.
The EPD^staff ordered the analysis of the 24 hour composite sample to determine
if the toluene discharge rate exceeded the reportable quantity (RQ) of 1000 lb/day.
The composite sample had 1,215 ppb Toluene = 709 lb/day.
Thursday December 6, they resampled Outfall 001 and found no high concentrations
of organics. The data is:
Methylene Chloride 215 ppb
Acrylonitrile <100 ppb
Benzene Not Detected
To!uene 10 ppb
Isophorone Not Detected
a-¥
-------
d
They felt the wastewater treatment unit was in compliance and stable. They
asked for toluene analysis of the composite on 005. It. rue! ! 005 ppb
toluene = 533 lbs/day. They now knew there was a toluene problem on 005 even
though the T0C was not excessive.
Friday, December 7, they sampled the 005 outfall to determine permit compliance,
thus they sampled the intake to get net concentrations on a grab sample.
The SEVIN Production Unit confirmed that there was a sp+11 in their area and it
was abated about noon. The EPD staff monitored the outfall to assure the
spill was stopped. Outfall sample data for Friday is:
Toluene Concentration in ppb
CG5 Intake Met Net Permit Limit
>10CO a 10:30 250
395 ? 13:50 199 ® 14:00 196 250
3S3 a 13:00 216 9 18:00 1 72 250
Saturday, December 7, 1984, they felt the toluene excursion was coming under
control. The EPA/State inspection team was notified of the toluene problems
upon arrival at 8:30AM. The intake and outfall were sampled again at 9:00 and
the concentrations of toluene were 445 ppb at 005; 28 ppb at intake; 417 ppb net.
The permit limit of 250 ppb net was exceeded again. Most of the EPO staff were
occupied with supplying data to the EPA/State inspection team the entire day.
Sunday, December 8, the intake and outfall 005 were sampled about 8AM again for
toluene. Results were: 232 ppb 9 005; 31 ppb @ intake; 201 ppb net. They felt
the toluene problem was resolved.
6 - s>
-------
5
Monday, December 9, the EPA/State inspection team arrived for an NPDES inspection.
The TOC graphs from the 001 and 005 outfalls were reviewed and the Tack of TOC
detection of the spill was discussed. A copy of the TCC determinations for the
SubEast Outfall is attached. Copies of the monitoring data from their
PERMIT LOG were provided for the period 12/3-9/84, and these are attached.
This normal daily sample data did not identify any spill at outfalls. The TOC
concentration limit at 005 is 12 ppm net. The net TOC concentration at 005
from the Permit Log data attached is -0.47 mg/1 on Sunday; 1.15 mg/1 on Monday;
0.07 mg/1 on Tuesday; 0.0 mg/1 on Wednesday; 0.4 mg/1 on Thursday.
CONCLUSIONS & RECOMMENDATIONS
1) The TOC limit of 12.0 mg/1 on Outfall 005 may be too liberal and should be
reevaluated in the light of this spill data.
2) The ESD staff responded well to a spill detected through their quarterly
monitoring program.
A-'i
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DATE
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( 1/nio)
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(3/wk)
pll
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( 2 9 6 9 A)
'jI2-2656a
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Ai>n lyat
Dnte
i
-------
PERMIT LOG
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(3/wk)
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.85
\
! 1
\
X
(2969A)
512-2656«
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.UurlU
Ann Iyst
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-------
PERMIT LOC
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( 1/wk)
i
t
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!
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-------
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-------
PERMIT LOG OOb
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-------
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-------
permit log
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y
-------
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-------
DAILY TOC DETERMINATIONS
Subeast Outfall
20 .
1 3 .
16 .
14 .
E
Q
Q
12 .
U
10 .
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4 .
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7 DEC., 19B4
LEGEND
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^ - / C>
-------
8
POLREP in - Toluene Spill
POLREP !H - Toluene Spill to Che Kanawha River
Mile Point 49 to 40 near
Institute, WV
I. Situation ( 12/11/34 - 1700 hours)
A. On Saturday, 12/8/84 0830 hours, Mr. Mace Martin, Senior
Environmental Engineer for the Union Carbide Plant, Institute. WV reported
that the chemical plant was exceeding their permit limit for toluene. EPA
personnel including the OSC were on scene at the chemical plane for Che
purpose of conducCing inspections to determine if the plant was in
compliance with all EPA regulatory programs. The inspections were ordered
due to the fact that the plant produces and stores methyl isocyanate.
The production unit producing this material at Institute, WV is very
similar to the Union Carbide Unit in Bhopal, India that had a catostrophic
release.
B. The Ohio River Valley Sanitation Commission (0RSANC0) had detected
the presence of toluene in the 'Kanawha River at cheir St. Albans, WV
Organic Detection System Station located at Mile Point 40 which is
approximately 9 miles downstream from the Union Carbide Institute, WV
Plant. 0RSANC0 (Linda Shumley) reported the following daca for the St.
Albans Station during the spill episode:
Dec 4 Tue. 77 PP3 Toluene
Dec 5 Wed. 57 PPB Toluene
Dec 6 Thu. 151 PPB Toluene
Dec 7 Fri. 98 PPB Toluene
Dec 8 Sat. 88 PPB Toluene
Dec 9 Sun. No sample
Dec 10 Mon. 9 PPB Toluene
Dec 11 Tue. 7 PPB Toluene
C. The nearest drinking water intake at Huntington, WV was alerted
to the problem. Another organic detection system at this intake on the
Ohio River downstream the mouth of the Kanawha River only detected trace
quantities (less than 5 PPB).
I. Actions Taken
A. On Saturday Evening EPA (Bryant & Dowuie) met with DNR (Xasdorph)
for the purpose of implementing a Kanawha River sampling survey to verify
the ORSANCO monitor results and to determine Che source of the discharge.
sT-n
-------
9
B. WV DNR sampled the Kanawha River from bridges on Sunday and Monday
12/9 and 12/10. We are presently awaiting official sample results.
C. OSC contacted ORSANCO (Linda Shumiey) Monday and Tuesday, 12/10
and 12/11 for the purpose of exchanging information and data. 3y Monday,
12/10 the toluene levels in the River had subsided significantly. Ms.
Shumiey reported that at the River temp of 13°C the toluene would readily
biodegrade. The chemical could also be lost from the river by volitilization.
D. The source of the toluene spill at the Union Carbide Plant was
determined to be from the pesticide "SEVIN" production unit. This unit
was in the process of being started up. This unit uses the highest quantity
of nethvl isocyanate at the Union Carbide Plant.
PAGE 2 - POLREP !H - Toluene Spill near Institute, WV
Plant Officals are anxious to use up the 600 ton inventory of methyl
isocynate that is being stored in above ground and underground tanks.
Presentlythe safest disposition for this chemical is to use It in the
manufacture of pesticides until questions about the storage tank release
in India can be answered. No more methyl isocynate is being produced at
the Institute Plant and it will cake an undetermined period of time to
use up the remaining stockpile.
At about noon Friday, 12/7 the source of the toluene discharge was
traced to a leaking condenser on the toluene stripper still. The unit
was shut down and the toluene levels appeared to begin subsiding in the
river. The condenser is cooled by river water which discharges to the
005 subeast outfall milepoint 49. At 1500 hours, 12/8 the OSC spoke with
Mr. Mike Miller the "SEVTN" Unit Production engineer concerning the
toluene release and the possibility of methyl isocanate being present in
the toluene that was discharged to the river. Mr. Miller reported that:
1) The purpose of the toluene still is to remove water from the toluene
and that methyl isocanate is not present in toluene at this stage of the
process. 2)The SEVEN unit at the time of the toluene discharge was not
ready for production, therfore, the methyl isocynate was not being used
at the SEVIN Production Unit. 3) if methyl isocynate were to enter the
river it would readily hydrolyre to dimethyl urea and carbon dioxide
which are relatively harmless.
E. Gary Bryant (EPA Staff Engineer) was on scene for the purpose of a
joint EPA, WVDNR NPDES inspection of the Institute Plant. High toluene
levels were noted Friday 12/7 in both the cooling water discharge and the
treatment plant discharge. A detailed analysis of the permit violoation
will be made by Bryant and WV DNR representatives. Information concerning
reportable quantity violations will be covered in a separate report
presently being prepared by EPA Wheeling Staff.
VI. Future Plans
\ I ¦ ¦ I -'-I —.1—1 I !¦
A. Awaiting official WV DNR bridge sampling data.
3. Continue to work with 0RSANC0 in monitoring the toluene levels in
the Kanawha River.
Jack L. Downie, OSC
EPA - Region III - Wheeling, WV
a-wr
-------
SPCC PLAN INSPECTION
A. Facility Name
Address
Telephone
Contact
Union Carbide Corporation
1350 1st Avenue, South
Institute, MV 26143
(304) 747-5422
Nats Martin
B. Has an SPCC Plan been prepared?
Has an SPCC Plan been Implemented?
Has it been certified by a Reglste 2d
Professional Engineer?
Title Senior Snv1ronmenta1 Enq
Yes X NO
Yes 1
Yes
NO
NO
E.
Closest water body: Kanawah
River
Oistance: South
Boundary of Plant
Faci1i ty
start-up date 1975
Storage:
Location
Capacity
Tank No.
Servi ce
Buildinq
Gallons
Sewer
Diesel
Deisel Oil
936
S2215
8,250
P.S.
1024
Necton 011
342
5-W
10,000
P.S.
Oil Drum
New ol1 drum
342
330-W
600 Drums
P.S.
1023
HYQ63-AW
342
5-W
10,000
P.S.
308
Fuel Oil
095
S3068
1,200
P.S.
Drums
Sutlalr Oil
042-
S. of 211
50 Drums
P.S.
1246
C9 Fract Fuel
156
¦D" 5 3rd
700,000
P.S.
1232
C9 Frace Fuel
156
"D" 4 3rd
110,000
P.S.
1037
C9 Fract Fuel
044
E MH40
26,000
cw
232
Code 11
044
N Bldg 9
6,000
P.S.
None
Code 4
044
ME Bldg 9
2,000
P.S.
996
#2 Fuel Oil
044
W Bldg 40
10,000.
P.S.
1602
iZ Fuel 011
007
W Field.
2.1 MMGa1
M.CW
-
Gasoline
-
Veh. Garage
2x3,000 gal
-
F. Confronts:
The facility has an approved SPCC plan in effect. No oil spills either major
or minor have been reported reaching navigable waters for at least the past 3 years.
Gasoline storage for 3 underground tanks was not Incorporated Into the plan. The
company 1s correcting this oversight. The company has Immense storage of hazardous
production materials, however, this storage 1s not covered by current EPA SPCC
regulations. The chemical plant personnel are currently trying to comply with the
proposed SPCC Regulations for Hazardous material storage even though these regula-
tions are not yet In effect. Plant management reports that the newer production
units comply with the proposed Hazardous Material SPCC Regulations. Hazardous waste
material 3CRA Contingency plans are in effect as well as NPQES 8est Management Practices.
Inspected 3y:
on tJjJllJJLZL
-------
Section VI - Compliance Inspection
RCR A
-------
U.S. fcnviromnenUI Protection Agency
Region III
Wheeling Office
303 Methodist Bldg., 11th & Chapllne Sts.
Wheeling, WV. 26003
13)
TO: Peter Schaul, Chief
RCRA Enforcement Section (3HW11)
THRU: Len Manglaracina, Deputy Director
Environmental Services Division (3ES00)
The WV DNR and US EPA conducted a RCRA inspection of the Union Carbide
Institute Plant Oecember 8 and 10, 1984, with Mark Casdorph of the State
leading the Inspection. A copy of his trip report on this Inspection is
attached. There were two areas where compliance with RCRA regulations
was questionable.
^ Hazardous waste from the various Production Units at the Institute
Ptant is accumulated 1n bins or hoppers placed at selected sites in
.the Production Unit area. These hoppers are lined with a plastic
sheet which 1s used to cov?r the hazardous waste when the container 1s
full and while it 1s belny transported to Union Carbide's hazardous
waste landfill, Gcff Mountain. Each hopper has a card attached to 1t
to Show accumulation time 1n compliance with 11 262.34. One hopper
-Jjr-the SEVIN Production Unit was found to have the date last emptied
as"July 8, 1984, and thlb was Interpreted to possibly Indicate storage
for a period longer than 90 days. This is described 1n the middle of
Page; 5 of the attached trip report. In addition to this apparent pro-
blem with accumulation time, the containers were not all covered as
required 1n fl 265.173. This technical problem was discussed in an
^earlier Inspection at thia facility and the opinion was that 1f the
~plast1c Uner was folded over the material being accumulated, the
-facility would be 1n compliance with the regulation. The plastic
sheets lining the hoppsrs were usually left draped over the outside
edges of the hoppers, not covering the material being accumulated.
The second area of questionable compliance was 1n the central laboratory
at Institute. Samples of MIC from the MIC Production Unit are sent
to the lab—for quality checks and a portion of these samples are not
used. The leftover samples are normally dumped Into a 5 gallon can
which, when filled, 1s manifested and sent to Carbide's Incinerator at
-thelr-Tecti Center for disposal. The lab staff began to hydrollze the
leftover samples and dispose of this hazardous waste 1n their lab when
the Plant Manager Issued orders that no more MIC would be shipped from
the Institute Plant. Their lab 1s not believed to be a disposal facility
for hazardous waste as specified in 11 265, Subpart Q. This practice 1s
0ATE: January 4, 1985
SUBJECT: RCRA Inspection Report - Union Carbide Institute, WV.
FROM: Gary Bryant, Chief jv
\
6 ' f
-------
2
described in the atta^c-d trip report in Pages 3 and 6 when it is noted that this
disposal practice "prob?bly occurred only on that day" (of tne Inspection).
The State plans to act to assure compliance with RCRA Regulations.
cc: Richard Pastor (3ES10)
(3ES12)
£ - -x
-------
TRIP REPORT
On December 8, 1984 at 8:30 a.m. Gary Bryant, Jack Downie, and
Scott McPhilliamy of the U.S.Environmental Protection Agency (EPA)
ir-.d ¦his inspector—».—Caadoi'pu)—anivgu ai. the Agricultural
Products Division of Union Carbide Corporation located at Institute,
Kansrwha flrumfy tJogr V4 a trsf <¦> ->g c-T-dut tir.g ZT.
inspection. Upon entering the plant, the EPA inspectors produced
credentials identifying their authority and I presented identification
as an authorized representative of the Chief of the Division of Water
Resources pursuant to Chapter 20, Articles 5, 5A, 5B, 5E, and 5F of
*
J. . j? ft . f. r ' 1 ¦ « « • - - - -
«•***•• w*. «A^54>i4i.a. wuwc a u uutS f we GItt L detllOr SCQXI
Engineer Nate Martin and proceeded to his office to review records
and. the day's activities. Mr. Martin had been previously notified" of
our intended arrival.
We explained the purpose of our inspection as being to assess
the facility's compliance with the Toxic Substances Control Act, their
National.Pollutant Discharge Elimination System (NPDES) permit, their
SPCC plan, the Resource Conservation and Recovery Act (RCRA) and with
the State's Hasardyjc Vasts-Management Act, with particular attention
being directed to those production areas using methyl-isocyanate'. "My
role, and the primary subject of this report concerns determining
compliance of the company's hazardous .waste management program.
I obtained, and reviewed a copy of the facility's contingency plan
\
which they are required to maintain on-site. The plan was presented
as part of their Part 3 permit application. The contingency plan
covered both on and off-site emergency response procedures. The
6-3
-------
UC'J Trip Report
December 8, 1984
Page 2
company's off-site response planning centers around their participation
ir» the Ksr.avr.a Valley Industrial Emergency. Fidiuiing Council (.iCvit.i'U) .
This organisation is comprised of manufacturing companies within the
valley which have established a communications and assistance network
for emergency situations. Activation of this system and off-site
notification of State and local authorities, and the news media is
performed by the plant's shift administrators. If the shift admin-
istrator determines that on-site resources are inadequate to control
an abnormal condition or if a situation may impact adjoining communi-
ties, the shift administrator declares an emergency and initiates
off-site notification by telephoning the local State Police detachment
and the National Weather Service (NWS). The NWS in turn notifies
local radio and television stations by broadcasting an emergency
message thrrmjh fha National Oceanic and Atmospheric Administration
Weather Radit/ and via a weather teletype service.
On-site cond-fr-tnn« were determined by - physical inspection of
the plant. Inspectors Byant and McPhilliamy, and I were escorted
by Senior Environmental Engineer Lee Patton through the five units
which genej..
-------
UCC Trip Report
December 8, 1984
Page 3
2. Service Production Unit: 2 abcve-ground tanks, 2 scrubbers,
and 1 dump tank;
3. MCB Production Unit: 1 scrubber
4.' Larvin Production Unit: 1 dump tank, 1 above-ground tank,
and 2 scrubbers
5. Distribution Area: current product stock is in 9
railroad tank cars, and in
approximately 150 fifty-five
gallon drums.
We began our field inspection by touring the MIC production unit.
Mr. Patton explained that the only hazardous waste MIC generated would
be the samples taker to assess product quality. He explained that
once a batch of MiC is made, a sample (usually 1 Co 2 ounces per sample)
is obtained and analyzed by the plant laboratory. If the material is
of sufficient quality, the batch is fed to one of the underground tanks
and from there, d-f srr-f hnt-aH m --it-. Off
fication batches are recycled back through the process. Mr. Patton
said that the MIC remaining in the sample container is accumulated in
a five gallon can. When the can is full, it is transported to the
Union Carbide Corporation's Tech Center in South Charleston for
incineration.
Mr. Patton identified two metal dumpsters (4 cubic yard capacity
each) in the MIC unit as the hazardous waste storage area. The
dumpsters were lined with four milliliter thick plastic. Mr. Patton
stated that when the hoppers are full, the corners of the plastic are
6 -sT
-------
UCQ, Trip Report
December"^, 1984
Page 4
tied together and the bundle is transported via truck to the Goff
Mountain Landfill. Upon inspection, both hoppers were marked as
containing hazardous wastes ana to each a card was attached indi-
cating the dates on which they began filling the emptied hopper<
A review of these dates (most recent were 9/25/84, 10/10/84, 11/8/84,
and 11/28/84) indicates wastes were being shipped off-site within
the required ninety days.
We spoke with unit operator E. D. Hunter. In response to our
questions Mr. Hunter explained that most spills (the unit also
maintains storage tanks of other chemicals related to the process)
drain to a nearby concrete sump where the chemicals are pumped back
into the process. He stated that "pills, mostly caustic, causing
local soil contaminations are shoveled into the storage hoppers.
Our inspection of the hopper contents found mostly chemical contaminated
protective clothing (gloves, Tyvek suits, etc.) and other debris that
Mr. Patton said were not hazardous wastes but which they did not want
to dispose of at a municipal landfill, such as asbestos.
Mr. Hunter explained the unit's emergency procedure. In the
*
event of a release, the local aicrm is activated. The alarm is
centrally located and upon activation, blue flashing lights surrounding
the unit perimeter are turned on. We noted that in addition to having-
manual and electronic~t~emperatuxc and pressure devices, the unit is
also surrounded by high pressure water cannons. Mr. Hunter said the"
cannons are designed to control fires and to knock down a gas release.
-------
ULC Trip Report
December 8, 1984
Page 5
He also pointed out that the unit is situated adjacent to the plant's
emergency Response team unit.
We theii toured the Sevin Production Unit where we met unit
training coordinator Frank Hardin. We inspected the above-ground
MIC storage tank and noted that it is surrounded by a concrete here
which Mr. Hardin said was primarily designed to prevent contact with
leaked materials from adjacent product storage tanks. The floor
drains under the adjacent tanks lead to the waste water treatment
facility. We inspected several hazardous waste dumpsters in the area
and found one which was marked as being last emptied on July 8, 1984.
Mr. Patton stated that the card nay have just not been updated. I
said that we would interpret the situation as storage for a period
exceeding niuety days.
Our Inspection of the Larvin Production Unit revealed properly
labeled dw*'»psters and a fifty-five gallon drum of hazardous waste.
Upon inspection-of the drum's contents, we saw several small vials
and bottles and one % gallon bottle of discarded acetone. Mr. Patton
explained that the. drum had speedy dry at the bottom to reduce free
liquids.
We toured the laboratory to observe their procedures for accumu-
lating wa3te MIC samples. Upon arrival we were informed by the lab
technician that h*e had just hydrolyzed a sample under a vented hood.
We spoke with his supervisor uhr> o-ypl a-ts u'ndnT—
procedure war? to accumulate .waste MIC in a five gallon container,
£ 7
-------
UCC Trip Report
December 8, 1984
Page 6
transport it as a hazardous waste to the Tech Center for incineration
and nanifest the empty can back to the Lab; I obtained copies of
manifests numbers 00212 and 00006 documenting such.
We then concluded the day's inspection.
On December 10, 1984 I returned to the plant to complete the
inspection. Jack Bownie joined me and Lee Patton escorted us to the
MC3 Production Unit. There, we met unit representative Richard Runyan
who showed us to the storage hoppers. Mr. Runyan explained that the
hoppers are primarily used for disposal of Broot contaminated protective
clothing, insulation and other debris. Mr. Patton stated t>at while
3root. tradename for a carbamate pesticide, is net a hazardous waste,
the company prefers to dispose of the incipient wastes at the "-off
Mountain Landfill- Two drums (DOT £-7768-55) of waste pesticide were
also seen.
Mr. Runyan stated that they have both automatic and manual shut-
off controls for the MIC feed lines and that the MIC is fed directly
into the process with no storage. He said that after every batch,
and in the event of an emergency, the MIC lines are cleared using
nitrogen gas blow-back to the MIC production unit.
We then concluded the inspection.
(NOTE: Lee Patton called me on December 11, 19$"4 to say th«i^ the MIC
treatment at the lab probably only occurred on that date. He explained
that the lab personnel .were under orders not to transport the material
and the supervisor did not want to accumulate the waste material in
the lab.>
6 "
-------
SECTION VII
Compliance Inspection - TSCA
-------
TSCA PCB 6(e) INSPECTION:
Union Carbide Institute implemented a PCB Control Program in 1978 in accordance
with the applicable regulations.
At the present time the facility maintains 76 transformers classified as
PCB units. In addition, UC operates 168 large high voltage capacitors
and 37 large low voltage units. Actually UC has taken a very conservative
approach to the classification of their transformers. This approach has
resulted in the inclusion of units into the PCB program which, according to
the regulation, would not be subject to control. According to the 1983
Annual Report the above referenced equipment contains the following quantities
of. PCB:
Transformers: 66926 kg
Large HV Capacitors: 4261 kg
Large LV Capacitors: 880 kg
TOTAL 72,067 kg
However, this total quanity of PCB fluid has been somewhat reduced due to
the removal or classification (by testing) of approximately ten transformers.
This information will be included in the 1984 Annual Document which is due
July 1, 1985.
During this inspection of the facility 12 transformers and four capacitor banks
were inspected. All units displayed the proper PCB Mark (ML) and exhibited
no signs of either present or pasc leakage.
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A transformer inspection was implemented for both capacitors (not required)
and transformers in February 19&Q^ Such a program was not required until
August 1981. These inspections have^ contained at the required interval up
to the time of this inspection.
UC maintains a PCB storage area on the Institute property for their PCB
equipment, etc., removed from service. This facility complies with the
requirements for the construction of such storage areas. In addition, the
monthly Inspections of the items in storage have been conducted.
It does not appear that UC Institute has utilized PCB heat transfer or
hydraulic fluids. A review of the fluids utilized for such purposes was
made with plant personnel. In addition, the facility does not appear on
the "Monsanto List" as a receiver of such material shipments. However, in
order to insure the absence of such fluids at the Institute facility,
arrangements have been made with plant personnel to resolve this issue by
sample analysis of the applicable fluid reservior systems.
7- 2.
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