R 336.1628 Emission of volatile organic compounds from components of existing process equipment used in manufacturing synthetic organic chemicals and polymers; monitoring program.

Rule 628. (1) A person shall not cause or allow the emission of a volatile organic compound from a component of existing manufacturing process equipment at a synthetic organic chemical and polymer manufacturing plant located in any of the following counties, unless the provisions of subrules (2) to (16) of this rule are met or unless an equivalent control method, as approved by the department under R 336.1602(2), including the control method described in “Standards of Performance for Equipment Leaks of VOC in the Synthetic Organic Chemicals Manufacturing Industry for which Construction, Reconstruction, or Modification Commenced After January 5, 1981, and on or Before November 7, 2006,” 40 CFR part 60, subpart VV adopted by reference in R 336.1902, is implemented: (a) Western portion of Allegan. (b) Berrien. (c) Kent. (d) Livingston. (e) Macomb. (f) Monroe. (g) Muskegon. (h) Oakland. (i) Ottawa. (j) St. Clair. (k) Washtenaw. (l) Wayne. (2) A person shall not operate existing manufacturing process equipment at a synthetic organic chemical and polymer manufacturing plant unless a monitoring program is implemented. The monitoring program must provide for all of the following: (a) A quarterly inspection of all components in light liquid or gaseous volatile organic compound service that are not designated as difficult-to-monitor components. (b) An annual inspection of all difficult-to-monitor components in light liquid or gaseous volatile organic compound service. Annual inspections must take place during the period of April 1 to June 30. (c) A weekly visual inspection of all seals of pumps in light liquid service. (d) An immediate inspection of all components from which a liquid, including a volatile organic compound, is observed dripping or from which a gaseous volatile organic compound is observed venting to the atmosphere. (e) Within 2 normal business days after it begins venting to the atmosphere, an inspection of each relief valve from which a volatile organic compound could discharge. (f) An inspection, as soon as is practical, but not later than 5 calendar days, after the repair of a component that was found leaking. (3) Except for the visual inspections required by the provisions of subrule (2)(c) of this rule, all inspections must be performed using equipment and procedures as specified in 40 CFR part 60, appendix A, method 21, adopted by reference in R 336.1902. A component is leaking when a concentration of more than 10,000 ppm, by volume, as methane or hexane, is measured by method 21. (4) If implementation of the quarterly leak detection program as specified in subrule (2)(a) of this rule shows that 2% or less of the process valves in a given process unit are leaking for 2 consecutive quarters, then the inspections of process valves in that unit are not required for 1 quarter. If 2% or less of the process valves in a given process unit are leaking for 5 consecutive quarters, then the inspections may be performed annually. If a subsequent inspection shows that more than 2% of the process valves are leaking, then quarterly inspections of valves shall again be required. (5) The percentage of valves leaking on a process unit, as referenced in subrule (4) of this rule, must be determined by dividing the total number of valves found to be leaking on the process unit during the specified monitoring period by the total number of valves on the process unit that are required to be monitored by this rule. (6) The provisions of subrule (2) of this rule do not apply to either of the following: (a) A component that is equipped with a closed vent system that is capable of capturing and transporting a leakage from the component to a control device that is designed and operated to reduce the volatile organic compound emissions vented to it by 95% or more. (b) An unsafe-to-monitor component, until conditions would no longer expose monitoring personnel to immediate danger. (7) The provisions of this rule do not apply to any of the following: (a) A component that contains or contacts a gaseous stream with a volatile organic compound concentration of less than 10% by weight. Procedures that conform to the general methods in the following ASTM standards, adopted by reference in R 336.1902, must be used to determine the percentage of volatile organic compound contents in the process fluid that is contained in or contacts a piece of equipment: (i) Standard Practice for General Techniques of Infrared Quantitative Analysis, ASTM E168. (ii) Standard Practices for General Techniques of Ultraviolet-Visible Quantitative Analysis, ASTM E169. (iii) Standard Practice for Packed Column Gas Chromatography, ASTM E260. (b) A component that operates under a vacuum. (c) Components of synthetic organic chemical and polymer manufacturing process units that produce 1,100 tons per calendar year or less of light liquid or gaseous volatile organic compounds. (d) A relief valve that has an upstream rupture disc. (8) A person shall seal open-ended lines with a second valve, a blind flange, a cap, or a plug, except when the open end is in use, as with relief valves, double block and bleed valves, and composite samplers. In the case of a second valve, the upstream valve must be closed first after each use. (9) A component that is found to be leaking pursuant to the monitoring program provisions of subrule (2) of this rule or for another reason must be repaired. Except as provided in subrule (11) of this rule, the leak must be repaired as soon as possible, but not more than 15 days after the leak is detected. Until the leak is repaired and retested verifying a successful repair, the component that is causing the leak must bear a weather-resistant, numbered identifying tag that indicates the date the leak was discovered. (10) A log of all leaks that are detected under subrule (2) of this rule must be maintained by the person who operates the synthetic organic chemical and polymer manufacturing plant. The log must list all of the following information: (a) The leaking component and synthetic organic chemical and polymer manufacturing process unit. (b) The number of the identifying tag. (c) The date the leak was discovered. (d) The date the leak was repaired. (e) The date the component was retested after the repair, with an indication of the testing results. (f) The person or persons who performed the inspections. (11) All of the following provisions apply to delays in the repair of leaking components: (a) If a leak cannot be repaired within 15 calendar days because the leaking component cannot be repaired unless the synthetic organic chemical and polymer manufacturing process unit is shut down, then the person who operates the synthetic organic chemical and polymer manufacturing plant shall maintain a log of the non-repair and the leak must be repaired at the next unit turnaround. (b) If a leak cannot be repaired within 15 calendar days due to circumstances beyond the control of the person who operates the synthetic organic chemical and polymer manufacturing plant, then the person shall notify the department of the circumstances causing the delay in repair before the end of the fifteenth day and maintain a log of the non-repair. The leak must be repaired in an expeditious manner, which must be within 6 months after the date the leak was detected. (c) The log specified in subdivisions (a) and (b) of this subrule must list all of the following information: (i) The leaking component and synthetic organic chemical and polymer manufacturing process unit. (ii) The date the leak was discovered. (iii) The reason why the leak cannot be repaired within 15 days. (iv) The estimated date of repair. (v) The number of the identifying tag. (12) A log of all unsafe-to-monitor components that are not part of the written program as required by subrule (14) of this rule must be maintained by the person that operates the synthetic organic chemical and polymer manufacturing plant. This log must list all of the following information: (a) The unsafe-to-monitor component and synthetic organic chemical and polymer manufacturing process unit. (b) The number of the identifying tag. (c) The reason why the component was unsafe to monitor. (d) The date or dates the component was unsafe to monitor. (13) Not later than 25 calendar days after the end of the previous quarter, the person that operates the synthetic organic chemical and polymer manufacturing plant shall submit, to the department, a report that contains all of the following information for that quarter: (a) The total number of components tested, by type. (b) The total number of components which are found leaking and which are repaired, by type. (c) The total number of components, by synthetic organic chemical and polymer manufacturing process unit and type, which are found to be leaking and are not repaired within the required time period and the reason for non-repair. (d) The type or types of monitoring equipment utilized during the quarter. (e) The total number of unsafe-to-monitor components that are logged as required by subrule (12) of this rule. The report required by this subrule must be made on a form that is provided by the department. (14) A person that is subject to the provisions of this rule shall develop a written program detailing how the provisions of this rule will be implemented. The program must include listings, by type and synthetic organic chemical and polymer manufacturing process unit, of all of the following: (a) All components that are regularly inspected as required in subrule (2) of this rule. (b) All components that are equipped with a closed vent system subject to the provisions of subrule (6)(a) of this rule. (c) All components that are exempted from the provisions of this rule pursuant to the provisions of subrule (7)(b), (c), and (d) of this rule. (d) All difficult-to-monitor components in light liquid or gaseous volatile organic compound service. (e) All components that are located outside a building, which can only be monitored by elevating the monitoring personnel more than 6 feet above ground level, and are unsafe to monitor during the period of November 1 to March 31. (15) The written program required by the provisions of subrule (14) of this rule and the logs required by the provisions of subrules (10), (11), and (12) of this rule must be made available, to any representative of the department, on Monday through Friday between 9 a.m. and 5 p.m., at the synthetic organic chemical and polymer manufacturing plant. The logs must be maintained for a minimum of 2 years. (16) If a synthetic organic chemical and polymer manufacturing process unit that was previously exempt pursuant to the provisions of subrule (7)(c) of this rule produces light liquid or gaseous volatile organic compounds in excess of 1,100 tons in a calendar year, then the provisions of this rule apply. Inspections begin no later than 6 months after the end of that calendar year and are maintained for as long as the applicable equipment is in operation.