An infrared camera for detecting emissions

The U.S. Environmental Protection Agency (EPA) has approved the use of optical gas imaging technology, such as infrared cameras, as a voluntary alternative work practice for leak detection and repair at chemical manufacturing plants.

 Final approval of the new regulation, having been pending since 2006, took effect in December and allows owners or operators to use infrared technology instead of the less efficient Method 21 manual inspection process to detect certain compounds. The infrared inspection is many times faster than the older Method 21 manual inspection system, although EPA will still require manual inspections to be performed at least once a year.

 

In helping set the stage for the new alternative, TCC partnered with EPA in an IR Camera Study to test various infrared camera technologies.  The study, which began last year and is still ongoing, involves extensive third party lab testing at an Iowa facility and field testing at two TCC member sites. In addition to providing facilities for EPA to conduct its testing, TCC and EPA matched contributions to fund the study.  TCC’s active participation in testing the infrared camera technology helped make it possible for EPA to gain final approval for the new regulation.  

 

“The committed support of TCC members has made this regulatory alternative possible,” said Hector Rivero, TCC President. “This is another example of how the chemical industry is voluntarily embracing the best available control technology to reduce emissions, improve efficiency, and protect the health and safety of our employees and the communities where we operate.”

 

Fugitive gas emissions occur in valves, piping connections, pump and compressor seals, and other hard-to-find places as part of the normal wear-and-tear of manufacturing equipment. These emissions account for about half of all plant emissions which have previously been found only by labor intensive Method 21 inspections, which are required under state and federal law. By contrast, an infrared camera can scan large areas and miles of pipeline to deliver thermal images and can pinpoint the smallest of gas leaks in real time. The emissions look like black smoke on the camera’s screen for easy detection, allowing for quick repairs and significant emissions reductions.

 

Some member companies are voluntarily using infrared scanning on a broad scale. “We are using IR cameras in all of our facilities in the Gulf Coast and across the United States,” said one member spokesperson. “The greatest benefit is that it allows us to pinpoint fugitive emissions much sooner than using other technologies.”

 

The EPA-led study will continue final field testing in 2009 and issue its final report later this year.  The study is due to be completed by December 31, 2009.

Speaker Joe Straus State Rep. Joe Straus (R-San Antonio), a pro-business leader with a reputation for fiscal conservatism, was elected Speaker of the Texas House of Representatives during the opening ceremonies of the 81st Legislature on January 13th. Representative Straus was elected to the House of Representatives in 2005 in a special election to replace Elizabeth Ames Jones in House District 121, which includes the communities of Alamo Heights, Olmos Park, Terrell Hills, Windcrest, and northeast San Antonio.  Straus previously served  as Vice-Chairman of the Committee on Economic Development and as a member of the Regulated Industries Committee, chairing its Subcommittee on Energy Conservation and Efficiency. He also served on the Local and Consent Calendars Committee. “We look forward to working with Speaker Straus during the 81st Legislature,” said TCC President Hector Rivero.  “Representative Straus has been a strong leader on energy policy and economic development issues, and has worked closely with our industry in previous sessions.” A lifelong San Antonio resident, Straus is a principal in the insurance and executive benefits firm of Watson, Mazur, Bennett & Straus, L.L.C. He also is affiliated with National Financial Partners, a leading financial services company in the insurance, investments, and benefits industry. In addition, Straus serves on the Board of Governors of the Cancer Therapy and Research Center and the Texas Cord Blood Bank. Straus is a cool-headed businessman with few political debts, adept at building coalitions and shunning ideological politics. His priorities include education, economic development and addressing issues in health and human services, medical insurance, water/infrastructure, and transportation. Straus also has vowed a bipartisan approach in appointing both Republicans and Democrats to House committees. Straus holds a bachelor’s degree in political science from Vanderbilt University and is an avid breeder and owner of thoroughbred horses. He and his wife, Julie Brink Straus, have two daughters, Sara and Robyn. The Texas Legislature convenes every odd-numbered year for 140 days to pass new laws for the state.  During the  Legislative Session, thousands of bills will be introduced, many of them affecting the chemical industry in Texas. TCC actively monitors all legislation impacting industry and is a strong advocate in the legislative process.

Bobby Laughlin

TCC Chairman Greg Kraft (Alcoa) has announced the appointment of John R. “Bobby” Laughlin of DuPont to succeed Steve Wood (LyondellBasell) as Chairman of the TCC Occupational Safety Committee.  Laughlin has served on the TCC Board of Directors since 2007 and will join the Executive Committee as Chair of the Occupational Safety Committee.

Steve Wood serves as Vice Chairman of TCC and will continue to serve as an officer on the TCC Executive Committee.

Laughlin is the Plant Manager at DuPont’s LaPorte, TX site. He began his career in 1978 with DuPont at their Victoria, TX site, holding various roles in operations management, including Production Supervisor, Supply Chain Manager, HR Manager, and Corporate Operations Consultant.  Laughlin also served as Plant Manager at DuPont’s Yerkes site in Buffalo, NY  before becoming Plant Manager at DuPont’s La Porte site in 2007. 

Laughlin is Sponsor for the DuPont Corporate Electrical Safety Team, a member of the LaPorte Plant Managers Group, and serves on the University of Texas Chemical Engineering Advisory Board. He holds a bachelor’s degree in chemical engineering from the University of Texas

“I am very pleased to appoint Bobby as Chair of the TCC Occupational Safety Committee,” said Kraft.  “DuPont is an industry leader in occupational safety, and Bobby brings many years of industry experience to an already robust committee of safety professionals.  I look forward to working with Bobby in this important role within TCC.  I would also like to thank the outgoing Chair, Steve Wood, for his leadership of the Committee.”

The TCC Occupational Safety Committee manages all issues relating to occupational safety within the chemical industry.  The Committee provides a forum for the free exchange of best practices and stays abreast of the latest trends in safety technology and regulations.  The Committee also promotes educational opportunities within the industry, including the Annual TCC/ACIT Environmental Health & Safety (EHS) Seminar – one of the nation’s best educational seminars for chemical industry professionals. 

The Occupational Safety Committee also administers the Distinguished Service and Best in Texas awards, which recognize TCC member facilities that have achieved exemplary results and demonstrated commitment to safe operations through implementation of TCC safety-related programs.

“It has been an honor to serve as Chairman of the TCC Occupational Safety Committee,” stated Steve Wood.  “This committee performs a very important role to ensure that safety remains at the forefront of everything we do in the chemical industry.  I am confident that Bobby Laughlin will proudly carry the torch and provide great leadership for the committee.”

Third Annual Maintenance & Reliability Symposium Set for August 2009

The Houston Chapter of the Society for Maintenance and Reliability Professionals (SMRP) will present the 3rd Annual Maintenance and Reliability Symposium (MaRS) Aug. 27-28, 2009. The 1½-day program will be held at Moody Gardens in Galveston, TX.

Panel discussions and technical presentations -- dealing the real-time issues on Business Management, Process Reliability, Equipment Reliability, People Skills, and Work Management -- will give attendees practical solutions to the maintenance and reliability issues encountered in their daily work activities. Exhibitors will show the latest in tools, techniques and services for maintenance & reliability.

The Texas Chemical Council (TCC) and Association of Chemical Industry of Texas (ACIT) have endorsed the MaRS 2009 program. This is an unprecedented value for Gulf Coast maintenance & reliability workers to learn, increase their abilities, and network with their peers. They will return to work with new knowledge, prepared to increase the productivity of their facilities as a result of participating in MaRS 2009.

Presentations will be given by maintenance & reliability professionals from companies such as LyondellBasell, DuPont, Air Liquide, BP, and others. For more information on the symposium or the organization, please e-mail Ed Foster of The Mundy Companies or call him at 281-530-8711, ext. 350.

SMRP today is an international organization with 6000 members; the Houston Chapter has 115 affiliated members. SMRP has become the premier global source for education and knowledge transfer for maintenance & reliability professionals.

Formed in 1992, SMRP charter members include Alumax of South Carolina, Amdahl Corporation, B.F. Goodrich Chemical, E.I. DuPont, Eastman Kodak Company, Elkem Metals Company, Ford Automotive Components Group, Henkel Corporation, Howmet Corporation, Hudson Bay Mining, Lake Superior Paper, Lockheed Aeronautical Systems Company, Logan Aluminum, Ore-Ida Foods, Postal Service, and Uno-Ven Company.

Please mark your calendars and consider attending this important event!

TCC Rolls Out 2009 Science Teachers and Industry Program at Educators’ Conference Dr. Eugene Chiappetta, right, talks with prospective STI participants visiting TCC’s conference booth. Hundreds of Texas school teachers received information about TCC’s Science Teachers and Industry (STI) training program during a recent educators’ conference in Fort Worth. Staffing a colorful booth at the Forth Worth Convention Center, TCC was among high-profile exhibitors at the Conference for the Advancement of Science Teaching (CAST), which drew more than 5,000 instructors from across Texas. Many passing teachers appeared pleasantly surprised to learn of STI, which provides 11 days of accredited instruction at the University of Houston (UH) on the relationship between chemicals and the environment. Now entering its 20th year, STI is taught each summer by veteran UH educator Dr. Eugene Chiappetta. Up to 35 science teachers of grades 5-12 will be accepted into this year’s program. Science teachers visiting the TCC booth appeared very interested in the STI program and were pleased to hear about the free tuition and housing offered to teachers living outside the city. Several STI alumni attending the conference offered on-the spot endorsements to other teachers who expressed interest in the program. More than 600 teachers took away an introductory brochure with an application to sign up for the instruction. STI offers three hours of graduate credit and 40 hours of professional development credit for teaching gifted and talented students. It also includes three field trips to Houston-area chemical facilities. TCC thanks volunteers Michelle Holyfield (Eastman Chemicals), John Koegel (Rohm and Haas Texas), and Dr. Chiappetta for their help in setting up and staffing the TCC display at the CAST Conference.

Governor thanks industry for hurricane response and economic contribution at TCC/ACIT Annual Meeting 

Gov. Perry keynotes at TCC/ACIT luncheon

Governor Rick Perry praised the Texas chemical industry for responding with compassion and generosity to Gulf Coast communities recovering from recent hurricane devastation – and for its leadership in helping give Texas the best economic climate in the nation.

Speaking Oct. 16 to a capacity crowd at TCC/ACIT Annual Meeting Luncheon, Perry thanked the state’s chemical industry for contributing more than $20 million and volunteer assistance to storm-stricken communities.

“I wanted to come here today and say ‘thank you’ to those of you in the chemical industry for what you did,” the governor told a luncheon audience of more than 250 industry representatives. “You have gone beyond the call of duty to help your fellow citizens.”

Perry also praised TCC member companies for their commitment to safely restarting their facilities that had been shut down or damaged by hurricanes Hurricane Ike. “Your industry didn’t wait for the federal government to show up down here to clean everything up,” he said. “You were back doing that when the sun came up [the next] day, helping your neighbors, compassionately working with folks.”

As examples, the governor cited Shell Chemical’s Deer Park facility for donating a large generator to a temporary shelter at the Jimmy Burke Activity Center; Kaneka Texas Corporation in Pasadena for opening its contractor parking lot for FEMA and recovery workers; and Puffer‑Sweiven in La Porte for hosting a blood drive in conjunction with the Gulf Coast Regional Blood Center.

“These are great examples of the humanitarian assistance, the corporate citizenship we have in this state,” Perry said.

The governor also lauded the chemical industry for being an important economic engine for the state.  He stated that the Texas economy has created half of the new U.S. jobs over the past 12 months. “The chemical industry makes an extraordinary contribution to the economic health of our state,” he said. “You provide 70,000 direct jobs to the state, 400,000 indirect jobs, while injecting $35 billion a year to the state economy.”

“Although Texas will not escape the impact of the current international credit crisis,” Perry said, “the state has a fundamentally sound economy and is well positioned to lead an eventual national rebound.” State positives include a well-educated workforce, healthy business climate, low taxes and reasonable regulatory environment, he noted.

 “Our foundation is strong,” Perry said. “When they find the bottom … and the financial markets get turned around, Texas will be the best suited of any state to lead the economic charge to go forward. We can lead America to its greatest days.”
 

Chairman Kraft presents Leadership Award to governor

After the speech, TCC Chairman Greg Kraft presented Perry with the 2008 TCC Leadership Award and thanked the governor for his support of the chemical industry and commitment to the state’s economy, environment and disaster responsiveness.

“Throughout your administration, you have been a champion for economic development and job growth,” Kraft told the governor. “You have also led the charge for lawsuit reform and … demonstrated a strong commitment to improving our state’s air quality by signing into law the Texas Emissions Reduction Act. Finally, you have led the development of one of the most sophisticated state emergency management departments in the country.”

“Governor Perry is a proven leader and a friend of business and the chemical manufacturing industry,” stated Hector Rivero, President & CEO of TCC and ACIT.  “We are proud that the governor recognizes our industry’s contribution to Texas.”

Dedicated TCC Committee Members Recognized for Outstanding Service in 2008

Four individual members have won 2008 Outstanding Service Awards in recognition of their dedicated service on TCC committees. The awards were presented by committee chairs during the recent TCC and ACIT Annual Meeting Luncheon in Houston, and include:

Dennis Kos, Sterling Chemicals, Inc. - Outreach Committee.  Dennis has been a long-time member of the Outreach Committee, including serving as vice chair in 2007, contributing significantly to the ongoing success of both the Caring for Texas Awards Program and the Chemicals Day at the Capitol initiative. Dennis has also served as a strong advocate and has helped to  promote the Science Teachers and Industry workshop. During his tenure as vice chair, he provided strong leadership for the Outreach Committee.

Photo: Kos receives award from TCC Outreach Committee Chairman, Rick Roberts.

Nathan Pepper, DuPont - Communications Committee. Nate served as first Vice Chair of the Communications Committee from its formation in 2006 until last summer. In that capacity, he worked resolutely to help raise the bar for external communications at TCC and ACIT, and was a major driver in developing the first effective TCC media plan. Nate continues to serve as an active member of the committee. (Photo not available.)

Thuy Mai, DuPont - Air Conservation Committee. Thuy has been described as “a tireless worker in leading the Permits Subcommittee.” This Subcommittee has tackled several difficult issues, such as permit by rule (PBR); maintenance, startup and shutdown (MSS) permitting; Title V permitting; Title V Deviation Reporting; commenting on fugitive emissions “boilerplate” language; and modeling and effect review applicability (MERA) flowchart revisions.

Photo: Mai receives her award from Zeb Nash, TCC Air Conservation Committee Chairman.

John Terry, Celanese Chemicals - Occupational Safety Committee. As leader of the Lessons Learned Subcommittee, John has organized and provided valuable information about industry learnings that are shared with all TCC members. He has consistently provided valuable lessons at quarterly meetings in 2008, making sure that shared items are meaningfully summarized for Occupational Safety Committee members.

Photo: Terry accepts his award from Steve Wood, TCC Occupational Safety Committee Chairman.


TCC congratulates these hard-working committee members, whose selfless service contributes significantly to our ability to provide leadership for the Texas chemical industry.

Featuring the Keynote Address by Governor Rick Perry


Registation has begun for the 2008 TCC & ACIT Annual Meeting & Luncheon. 

 Keynote Address by Governor Rick Perry.  

Registration Information






Flashback to 2007 Annual Meeting

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Industry Appears Grazed, but not Pummeled, by Hurricane Ike 

In the wake of Hurricane Ike, preliminary assessments are trickling in from our member companies  – and the picture taking shape is that injuries to people and damage to our facilities have been mercifully light.

More than 100 petrochemical plants were affected by the massive storm, which has caused at least 30 deaths in eight states. Nearly two million Texas residents and many chemical plants are without power as of this writing – although more than 7,500 utility employees are working to restore service in an area the size of New York State. TCC offers condolences to those who are suffering from this disaster, while also giving thanks that many other lives, homes and businesses have been spared.

News reports and postings to various company websites indicate that more refineries and chemical facilities came through Ike with light or no damage, although some are reporting moderate damage. However, extensive damage to power lines and infrastructure are hampering efforts to restore power to production facilities and residents alike along the Gulf Coast. Details  remain scarce, but a TCC survey of company reports and announcements revealed the following snapshot of industry conditions as of  Friday, Sept. 19:

• Nearly 30 facilities remain shut down, although several are expected to be back on line this week. Others will require a week or more to re-start.

• Several plants are reporting wind damage to cooling towers and other structures, as well as minor flood damage to buildings.

• Nitrogen is flowing again to plants after several days of limited supplies. However, other raw materials remain scarce for a significant number of manufacturers. Some have advised their customers to expect disruptions in chemical shipments.

• Many TCC members are reaching out to hard-hit communities with donations and other assistance. Two companies have announced they will donate a total of $13 million to disaster relief organizations; one plant provided a large electrical generator to a temporary shelter; and another facility has been sending some of its own generator power to local utilities to help residents and businesses recover.

Here at TCC, Regulatory Affairs Director Mike McMullen has been in frequent contact with the State Emergency Operations Center, where Jack Colley, Texas Emergency Management Chief, leads a team of experts from the National Weather Service, Texas Forestry Service, Department of Public Safety (DPS), and various industry and local organizations.  Chief Colley praised the chemical industry for their organized storm preparations and for their communications with state agency’s in advance of the hurricane.

Mike has been sending TCC and ACIT members daily alerts before the storm and in the aftermath as recovery efforts are underway and member sites are dealing with such issues as power, water, fuel, and re-entry for workforce. He and the entire TCC staff stand ready to assist members with re-entry credentialing and other state regulatory assistance.

Also, TCC would like to thank the Texas Commission on Environmental Quality for their tireless effort to assist our members during this trying time. Under the leadership of the Executive Director, Mark Vickery, TCEQ deputies and staff have reached out to the chemical industry to aid in the restoration of our plants. TCC commends them for their professionalism and courtesy

With planning, teamwork, and attention to detail, our state and industry have learned to effectively prepare for  the damage that a hurricane can bring and protect the health and safety of chemical plants, their employees, and those residing in the storm’s path. We thank the dedicated people who are making this system work, and we continue to look for even better practices and technologies that will help us withstand and recover from nature’s ferocity.

PUC Chairman Briefs TCC Board on State’s Energy Outlook

Texas needs all the energy it can muster to handle future growth in both population and demand, Barry Smitherman, chairman of the Texas Public Utility Commission (PUC), told members of the TCC Board of Directors recently. Smitherman appeared at the Summer Board Meeting, where he assessed the State Energy Plan submitted to Gov. Rick Perry by the Governor’s Competitiveness Council.

The population of Texas is expected to soar to 50 million by 2045-2050, engendering an energy demand that will need 50 to 70 gigawatts of generating capacity by 2028, according to Smitherman. Every resource – including natural gas, clean coal, nuclear, wind and solar – should be tapped to meet this projected consumption, he said.

“We need all sources of energy and not take anything off the table,” Smitherman said. “We need to balance the supply and demand equation by working on both ends” to increase the former while moderating consumption, he added.

Smitherman pointed out several encouraging energy developments: five coal-fired plants currently under construction in Texas; the planned addition of two units to the South Texas nuclear facility; and rapid growth in wind energy, which he said could account for as much of 18 percent of future state generating capacity.

“Reliable, competitively priced energy is essential to competing globally,” Smitherman said. “We must aggressively ensure that Texas remains a competitive place to do business.”

Smitherman also cited several activities and trends that could impact the chemical industry:

• Proposed federal climate change bills would have a disproportionately negative impact on states such as Texas, with long driving distances, high demand for heating and cooling, and an established manufacturing and chemical-processing industry. “We’ve got a bull’s eye on our back when it comes to climate change legislation,” he stated.

• The state’s new focus on energy efficiency in homes and small businesses is helping distribute that responsibility beyond the chemical industry and other industrial customers.

• New technologies for capturing and storing carbon are needed to allow coal to be burned more cleanly for energy generation. But coal, including Texas lignite, will remain an indispensible part of the state energy equation for decades to come.

Photo: Barry Smitherman