implementation and management of leak detection and repair programs – new rules and other...
TRANSCRIPT
Implementation and Management of Leak Detection and Repair Programs – New Rules and Other Considerations
Nebraska Ethanol Safety & Environmental Coalition (NESEC)
March 4, 2010
Agenda
About Us Why LDAR? Considerations for
Implementation and Management of an LDAR Program
New Rules and Challenges Questions
Why LDAR? Control leaks of Volatile Organic
Compounds (VOC) – precursors to Ozone - and Hazardous Air Pollutants (HAPs)
Is part of the New Source Performance Standards (NSPS)
VOCs are a primary source of fugitive emissions from refineries and chemical plants.
Economics Safety
Chemical Plants Concern is leaks from valves, flanges, connectors,
open-ended lines and other equipment Primary regulation is NSPS Subpart VV and VVa Number of ways to identify leaks
Inventory control Audio, Visual, Olfactory Instrument Detection Smart LDAR (Infrared Camera)
Controlling leaks Process design Equipment selection (“leakless” components and “seal-less”
pumps) Monitoring
What do we mean when we say LDAR? For Chemical Plants
LDAR is a work practice Involves the identification of
regulated components and equipment
Monitoring at specified intervals by prescribed methods
Repair within specified time frames
Recordkeeping and reporting
Elements of LDAR
Identification of Components
Leak Definition
Monitoring
Repair
Recordkeeping & Reporting
Model LDAR Program
Written LDAR program Training Accountability Audits Electronic monitoring and
storage of data QA/QC of LDAR data Records maintenance
Elements of a Written LDAR Program
Method for identifying equipment subject to LDAR
Procedures for identifying leaking equipment
Procedures for repairing and keeping track of leaking equipment
Process for evaluating new and replacement equipment
Elements of an LDAR Program A detailed description of
the facility’s LDAR organization
Procedures for inventory modifications
Procedures associated with specific aspects of the site’s LDAR program
Training expectations and requirements
Overall leak rate goals to be obtained on a unit by unit basis
Roles & Responsibilities Roles
LDAR Coordinator Data Base Manager Monitoring Personnel
Responsibilities that need to be assigned. Monitoring Data Collection and
Validation Scheduling Repair and Re-monitoring
Monitoring
Audible, Visual, Olfactory (AVO)
Method 21 Smart LDAR
Method 21
EPA method of detecting VOC leaks from equipment sources
Instrument requirements Calibration requirements Monitoring techniques for individual equipment
types Safety requirements
Recordkeeping
Information must be kept in a “readily accessible location” for 2 years List of equipment ID numbers subject to the rule
(component inventory) Monitoring information Calibration records Leaking equipment information Delayed repair information Unsafe to Monitor (UTM) Difficult to Monitor (DTM)
Reporting
Initial report due within 180 days of startup Semiannual report due every 6 months thereafter Must Report:
Process unit identification Number of valves, pumps, PRVs, and compressors for
which leaks were detected, and those not repaired within 15 days
Facts explaining each delay of repair Dates of process unit shutdowns >24 hours Revisions made to the inventory
Data Accuracy
Daily QA/QC Periodic Monthly Quarterly
Other Program Considerations
DTMs UTMs OELs Reporting Training
Inventory & Inventory Control
Date:
Technician:
Component ID DescriptionTo Be Added
To Be Removed
Change NotesBackgroud
ReadingReading
Field Documentation
Repair
First Attempt Repair Timing Delay of Repair Chronic Leakers
Delay of Repair
Delay of repair of leaking equipment is allowed if repair within 15 days is technically infeasible without a process unit shutdown
Repairs must occur during the next scheduled shutdown
Delay of repair can not be used as a convenience tool, and records must be authorized and signed by the facility owner/operator
Common Compliance Issues
Not identifying all regulated components Improper classification of components (unsafe or
difficult to monitor) Missed monitoring events Improper monitoring of components Failing to maintain monitoring equipment Improper use of delay of repair Recordkeeping and Reporting Issues Open Ended Lines
Subpart VV and VVa
The primary regulation and the basis for many LDAR regulations – federal and state
VV was amended on Nov. 16, 2007 A stay was imposed (until August 1, 2008) but
only affects The definition of process unit and the storage
vessels associated with the process unit Connectors (60.482-11a)
Amendments to VV
New Definitions Clarification of Process Unit Requirements for New Equipment Requirements for Containers in Closed-Purge
Sampling Systems Monitoring Requirements for Pumps on Delay
of Repair Examples of First Attempts
Other Key Definitions First Attempt at Repair
means each valve, pump, pressure relief device, sampling connection system, open-ended valve or line, and flange or other connector in VOC service.
Repaired means that equipment is
adjusted, or otherwise altered, in order to eliminate a leak as defined in the applicable sections of the subpart and is re-monitored as specified in 60.485 (b) to verify that emissions from the equipment are below the applicable leak definition.
New Equipment Requirements
Pumps 60-482-2 (a)(1) A pump that begins
operation in light liquid service after the initial startup date for the process unit must be monitored for the first time within 30 days after the end of its startup period.
Valves 60.482-7 (a)(2) A valve that begins
operation in gas/vapor service or light liquid service must be monitored for the first time within 30 days after the end of its startup period.
Weekly Visual Inspections
Weekly visual pump inspections are required by Subpart VV and VVa
Repair requirements for visually leaking pumps No reporting requirement for visual inspections,
but must be able to demonstrate compliance
Changes to Visual Inspection Requirements
For Pumps If there are indications of
liquids dripping from the pump seal at the time of the weekly inspection
Monitor the pump within 5 days as to determine if there is a leak of VOC or barrier fluid.
Designate the visual indications of liquids dripping as a leak
Note there was a change in the sensor leak information as well 60.482-2(d)(5)(i)
Other General Changes Added a provision that containers part
of a closed-purge system must be covered or closed when not being filled or emptied.
Added – as an alternative to monitoring all of the valves in the first month of a quarter, an owner may elect to subdivided the process unit into 2 or 3 groups of valves and monitor each subgroup in a different month during the quarter, provided each subgroup is monitored every 3 months. The owner must keep records of the valves assigned to each subgroup.
Explanation for calculating the percent of valves leaking.
Added some provisions for equipment in Batch or in Service less than 300 hours per year.
VVa For affected facilities that commenced
construction, reconstruction, or modification after Nov. 7, 2006.
Demonstrate compliance within 180 days of initial startup.
New leak definitions of 2000 ppm for most pumps, and 500 ppm for valves, connectors, and pressure relief devices
New requirements for Connectors in VVa 60-482-11a
VVa Applicability
Modification means any physical or operational change to an existing facility which results in an increase in the emission rate to the atmosphere of any pollutant to which a standard applies
Routine maintenance, repair, or replacement of equipment does not meet the requirements of a “modification”
VVa Applicability
Reconstruction means the replacement of components of an existing facility where the fixed capital cost of the new components exceeds 50 percent of the fixed capital cost that would be required to construct a comparable entirely new facility
VVa Applicability
A facility must comply with Subpart VVa if it meets the definitions of construction, reconstruction, or modification after November 7, 2006
60.482-11a Connectors in gas/vapor and light liquid service Initially monitor all connectors in the process unit by the
later of either 12 months after the compliance date or 12 months after the initial startup. (If all connectors in the process unit have been monitored for leaks prior to the compliance date, no initial monitoring is required provided not process changes have been made.)
Leak Rate is 500 ppm Perform monitoring subsequent to the initial monitoring:
If %leaking is >0.5 % within 12 months. If %leaking is >0.25% but <0.5% within 4 years. If %leaking is <0.25% there is a specified time table.
Stayed until August 1, 2008
Actions
Need to evaluate your facilities practices to incorporate changes.
Need to self audit to ensure compliance. Need to look carefully at new equipment in
existing units and look at the rule for equipment subject to VVa
Watch the new record keeping requirements.
Questions?