Part 236: Synthetic Organic Chemical Manufacturing Facility Component Leaks

(1) CAS number. Chemical Abstracts Service registration number as signed to specific chemicals, isomers, or mixtures of chemicals.

(2) Component. Any piece of process unit equipment which has the potential to leak a chemical listed in section 236.8, table 1, of this Part when monitored as prescribed by section 236.7 of this Part. These include, but are not limited to: pumps, compressors, valves, open-ended pipes, and pressure relief devices. Excluded from these are valves which are not externally operated.

(3) Department. The New York State Department of Environmental Conservation.

(4) Double block-and-bleed system. Two block valves connected in series with a bleed valve or line that can vent the line between the two block valves.

(5) Initial attempt to repair. To take rapid action to repair leaks. These include, but are not limited to: tightening or replacing bonnet bolts, tightening packing bolts or glands, or injecting lubricant into lubricated packing.

(6) In gas/vapor service. Any equipment which processes, transfers, or contains a chemical or mixture of chemicals in the gaseous phase having a concentration greater than 10 percent by weight of the chemicals listed in section 236.8, table 1, of this Part.

(7) In heavy liquid service. Any equipment which processes, transfers, or contains a fluid and is not in gas/vapor or light liquid service.

(8) In light liquid service. Any equipment which processes, transfers, or contains a fluid having a vapor pressure greater than 0.3 kilopascals at 20°C (0.0427 psia at 68°F) and having a concentration greater than 10 percent by weight of the chemicals listed in section 236.8, table 1, of this Part.

(9) In vacuum service. Equipment operating at an internal pressure at least 5 kilopascals (0.712 psia) below ambient pressure.

(10) Leak. The emission of a chemical listed in section 236.8, table 1, of this Part at a concentration greater than or equal to 10,000 parts per million by volume (ppmv) as shown by monitoring. An indication of liquids dripping shall also be considered a leak.

(11) Liquids dripping. Any visible leakage from a seal or opening including, but not limited to: dripping, spraying, misting, clouding, or ice formation.

(12) Open-ended valve or line. Any valve having one side of the valve seat in contact with the process fluid and one side open to the atmosphere either directly or through open piping. Pressure relief valves are an exception to this definition.

(13) Process unit. Components assembled to produce, as an intermediate or final product, one or more of the chemicals listed in section 236.8, table 1, of this Part.

(14) Process unit shutdown. A scheduled work practice or operational procedure that stops production from all or part of a process unit. Process unit shutdowns do not include unscheduled work practice or operational procedures that stop production from all or part of a process unit for less than 24 hours, or the use of spare equipment or a technically feasible bypass without stopping production.

(15) Repair. To adjust or otherwise alter a component to eliminate a leak.

(16) Synthetic organic chemical manufacturing facility. A facility which manufactures, as an intermediate or final product, one or more of the synthetic organic chemicals, polymers and resins listed in section 236.8, table 1, of this Part.

(1) prepare a leak detection and repair plan in accordance with section 236.5 of this Part; and

(2) be in compliance with the provisions of this Part within 180 days of the effective date of this Part.

(1) each pump in light liquid service;

(2) each compressor in gas/vapor service;

(3) each pressure relief valve in gas/vapor service;

(4) each valve in light liquid service; and

(5) each valve in gas/vapor service.

(b) Leaks detected in any of the monitored components must be repaired in accordance with the provisions set forth in section 236.4 of this Part.

(c) Any owner or operator of a synthetic organic chemical manufacturing facility must also comply with the following component standards:

(1) Pumps in light liquid service must be visually inspected each calendar week for evidence of liquids dripping. Any leaks detected during visual inspection must be repaired in accordance with section 236.4 of this Part.

(2) Pressure relief devices in gas/vapor service must be monitored for leaks within five days of an over-pressure release. Any leaks detected during monitoring must be repaired in accordance with section 236.4 of this Part.

(3) Open-ended valves or lines in gas/vapor or light liquid service must be sealed with either a second valve, blind flange, cap, or plug. The sealing device may only be removed while a sample is being taken or during maintenance operations.

(1) affix a weatherproof and readily visible tag to the leaking component bearing an identification number and the date the leak was detected. This tag must not be removed until the component is repaired and passes reinspection;

(2) make an initial attempt to repair the leaking component within five days;

(3) repair the leaking component as soon as practicable, but not later than 15 calendar days after the leak is detected; and

(4) remonitor all leaking components within 48 hours after repairs have been completed.

(1) A request for reconsideration must be filed in writing with the department within 20 days of the receipt of the department's directed rescheduling, and must be signed by a duly authorized representative of the facility.

(2) Such request must include a statement supporting the source owner's claims of misapplication of laws or regulations in the department's directive, and a statement specifying the relief sought by the source owner.

(1) name of process unit where the component is located;

(2) tag identification number;

(3) type of component;

(4) date on which the leak was detected for the component;

(5) date on which the component was repaired;

(6) identification of those components which cannot be repaired until process unit shutdown, the reason repair must be delayed, and the signature of a duly authorized representative of the facility whose decision was that the leaking component could not be repaired without a process unit shutdown;

(7) the date of each calibration of the monitoring instrument;

(8) date and monitor instrument reading detected after the component is repaired; and

(9) total number of components monitored and the total number of components found leaking;

(1) number and type of leaking components located, but not repaired within 15 days;

(2) number and type of leaking components awaiting process unit shutdown for repair;

(3) number and type of components inspected;

(4) number and type of components repaired;

(5) elapsed time to repair each leaking component; and

(6) a signed statement by a duly authorized representative of the facility attesting to the fact that, with the exception of those components listed in paragraphs 236.6 (e)(1) and (2) of this Part, all inspections and repairs were performed in accordance with the leak detection and repair plan.

(1) Components that are unsafe to monitor because of extreme temperatures, extreme pressures, location more than two meters (6.6 feet) above a permanent support structure, or for other reasons may be exempt from quarterly monitoring provided that the owner or operator requests a waiver from the department which includes a plan to monitor these components at least once per year.

(2) Components constructed to vent the emissions of chemicals regulated in this Part to an air cleaning installation may be exempt from quarterly monitoring provided that the owner or operator requests a waiver from the department which includes a plan to monitor these components at least once per year. The waiver application must also show that the air cleaning installation provides on overall capture and removal efficiency of at least 81 percent.

(3) An alternative method of compliance with the provisions of this Part may be acceptable if the owner or operator can demonstrate to the department that the methods utilized constitute reasonably available control technology.