Ala. Admin. Code r. 335-3-6-.47

Current through Register Vol. 43, No. 1, October 31, 2024

Section 335-3-6-.47 - Leaks From Coke By-Product Recovery Plant Equipment

(1) Except as otherwise required by the context, terms used in this Rule are defined in Rule 335-3-1-.02 or in this paragraph as follows:

(a) "Closed Vent System" means a system that is not open to the atmosphere and that is composed of piping, connections, and, if necessary, flow indicating devices that transport gas or vapor from a piece or pieces of equipment to a control device.

(b) "Coke By-Product Recovery Plant" means any facility engaged in the separation and recovery of various fractions from coke oven gas, including tar, pitch, ammonium sulfate, naphthalene, and light oil.

(c) "Connector" means flanged, screwed, welded, or other joined fittings used to connect two pipe lines or a pipe line and a piece of process equipment.

(d) "Conservation Vent" means a pressure-vacuum valve installed on a napthalene separation unit cover that prevents the release of vapors during small changes in temperatures, barometric pressure, or liquid level.

(e) "Control Device" means an enclosed combustion device, vapor recovery system or flare.

(f) "Equipment" means each pump, valve, pressure relief valve, sampling connection, open-ended valve, and flange or connector in VOC service.

(g) "First Attempt at Repair" means taking rapid action for the purpose of stopping or reducing leakage of organic material to atmosphere using best practices.

(h) "In Gas Service" means that the piece of equipment contains process fluid that is in the gaseous state at operating conditions.

(i) "In Light Liquid Service" means that the piece of equipment contains or contacts a process fluid that is a liquid at operating conditions, one or more components having a vapor pressure greater than 0.3 kPa at 20° C (0.04 psia at 68° F), and the total concentration of the pure components, having a vapor pressure greater than 0.3 kPa at 20° C, is equal to or greater than 20 percent by weight.

(j) "In Vacuum Service" means that equipment is operating at an internal pressure which is at least 5 kPa (0.73 psia) below ambient pressure.

(k) "In VOC Service" means that the piece of equipment contains or contacts VOC.

(1) "Naphthalene Separation Unit" means the settling tank and associated equipment used in the recovery of naphthalene from the final cooler aqueous effluent.

(m) "Open-Ended Valve" means any valve, except pressure relief devices, having one side of the valve in contact with process fluid and one side open to the atmosphere, either directly or through open piping.

(n) "Pressure Release" means the emission of materials resulting from system pressure being greater than set pressure of the pressure relief device.

(o) "Quarter" means the following three-month periods: January through March, April through June, July through September, and October through December.

(p) "Reference Method 21" means Reference Method 21 of Appendix A of 40 CFR 60.

(q) "Repaired" means that equipment is adjusted, or otherwise altered, in order to eliminate a leak as indicated by one of the following: an instrument reading of 10,000 ppm or greater, indication of liquids dripping, or indication by a sensor that a seal or barrier fluid system has failed.

(2) The provisions of this Rule shall apply to all equipment in VOC service in a Coke By-Product Recovery Plant.

(3)General Requirements.

(a) Owners or operators of coke by-product recovery plants shall demonstrate compliance with the requirements of paragraphs (4) through (7) of this Rule. Compliance will be determined by review of records and reports, and inspection using the methods and procedures specified in Reference Method 21.

(b) Equipment that is in vacuum service shall be controlled by means of a closed vent system, or determined to achieve emission limitation at least equivalent to the requirements of paragraphs (4) through (7) of this Rule.

(c) Each component subject to the requirements of this paragraph shall be marked with weatherproof tags that will be readily obvious to both plant personnel and the Director, and have an identification number.

(d) Any component in VOC service that appears to be leaking on the basis of sight, smell, or sound, shall be repaired with an initial attempt as soon as possible and final repair within 15 calendar days.

(4)Pumps in Light Liquid Service.

(a) Each pump in light liquid service shall be monitored each calendar quarter to detect leaks by the methods specified in Reference Method 21.

(b) Each pump in light liquid shall be checked by visual inspection each calendar week for indications of liquids dripping from the pump seal.

(c) If an instrument reading of 10,000 ppm or greater is measured, or if there are indications of liquids dripping from the pump seal, a leak is detected.

(d) When a leak is detected, it shall be repaired as soon as practicable, but no later than 15 calendar days after it is detected, except as provided in paragraph (8) of this Rule.

(5)Valves in Gas and Light Liquid Service.

(a) Each valve in gas and light liquid service shall be monitored each calendar quarter to detect leaks by the methods specified in Reference Method 21, except as provided in subparagraph (d) of this paragraph.

(b) If an instrument reading of 10,000 ppm or greater is measured, a leak is detected.

(c) When a leak is detected, it shall be repaired as soon as practicable, but no later than 15 calendar days after the leak is detected.

(d) Valves in gas and light liquid service may be exempted from this paragraph provided:

1. An owner or operator demonstrates that a valve cannot be monitored without elevating the monitoring personnel more than 2 meters above a support surface.

2. A valve has no external actuating mechanism in contact with the process fluid.

(6)Pressure Relief Valves in Gas Service.

(a) Each pressure relief valve in gas service shall be monitored each calendar quarter to detect leaks by methods specified in Reference Method 21.

(b) If an instrument reading of 10,000 ppm or greater is measured, a leak is detected.

(c) When a leak is detected, excluding over pressure releases, it shall be repaired as soon as practicable, but not later than 15 calendar days after it is detected.

(7)Open Ended Valves.

(a) Each open-ended valve shall be equipped with a cap, blind flange, plug, or a second valve, except during operations requiring fluid flow through the open-ended valve.

(b) Each open-ended valve equipped with a second valve shall be operated in a manner such that the valve on the process fluid end is closed before the second valve is closed.

(c) Open-ended valves which serve as a sampling connection shall be equipped with a closed purge system or closed vent system such that:

1. purged process fluid be returned to the process line with zero VOC emissions to atmosphere, or

2. collect and recycle the purged process fluid with zero VOC emissions to atmosphere.

(8)Delay of Repair.

(a) Delay of repair of equipment for which leaks have been detected will be allowed if repair is technically infeasible without process unit shutdown. Repair of this equipment shall occur before the end of the next process unit shutdown.

(b) Delay of repair of equipment will be allowed for equipment which is isolated from the process and which does not remain in VOC service.

(c) Delay of repair for valves will be allowed if the owner or operator demonstrates that emissions of purged material resulting from immediate repair are greater than the fugitive emissions likely to result from delay of repair, and when repair procedures are effected, the purged material is collected and destroyed or recovered in a control device or collected and recycled with zero emissions to atmosphere.

(9)Naphthalene Separation Unit Emissions.

(a) Each owner or operator of any open settling tank used in the separation of napthalene from final cooler aqueous effluent shall enclose and seal the tank to contain VOC emissions. The cover may include the following items of equipment:

1. a vent equipped with a water leg seal or a conservation vent; and

2. an access hatch which is equipped with a gasket.

(b) The cover may be removed when required by process operations, but must be replaced at the completion of operations.

(10)Recordkeeping Requirements.

(a) Owners or operators of coke by-product recovery plants shall maintain monitoring records for all components subject to the requirements of this Rule. This log shall contain at a minimum the following data:

1. the type of component;

2. the location of the component;

3. the identification number of the component;

4. the date on which a leaking component is discovered, initial repair attempted, and the component is repaired;

5. the date and instrument reading of the recheck monitoring after a leaking component is repaired;

6. a record of the calibration of the monitoring instrument; and

7. the identification of components awaiting repair according to paragraph (8) of this Rule.

(b) Copies of the monitoring log shall be retained by the owner or operator for a minimum of 2 years after the date on which the record was made or the report prepared.

(c) Copies of the monitoring log shall immediately be made available to the Director or his representative upon verbal or written request, at any reasonable time.

(11)Reporting Requirements. Owners or operators of coke by-product recovery plants shall submit reports for each calendar quarter to the Director listing the following data:

(a) the total number of components inspected;

(b) the total number of components found leaking; and

(c) the total number of components awaiting repair per delay of repair provisions of paragraph (8) of this Rule.

(12) The Director, upon written notice, may modify the monitoring, recordkeeping and reporting requirements.

Author:

Ala. Admin. Code r. 335-3-6-.47

Effective Date: June 9, 1987. Amended: Effective Date: July 31, 1991. Amended: Filed October 17, 1996; effective November 21, 1996.

Statutory Authority:Code of Ala. 1975, §§ 22-28-14, 22-22A-5, 22-22A-6, 22-22A-8.