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Gaylord Chemical Co., LLC, Bogalusa Plant

Parent Companies:
Gaylord Chemical Co., LLC
EPA Facility ID:
100000034367
Other ID:
70427GYLRD42WIL
Facility DUNS:
609954052
Parent Company DUNS:
186353157

Location:

Address:
420 Willis Ave.
Bogalusa, LA 70427
County:
WASHINGTON
Lat / Long:
30.781, -89.858 (Get map)
Method:
Interpolation - Map
Description:
Process Unit Area Centroid
Horizonal accuracy:
100 m
Horizontal reference datum:
North American Datum of 1927
Source map scale:
24000

Owner/Operator:

Name:
Gaylord Chemical Co.,LLC
Phone:
(985) 732-6300
Address:
420 Willis Ave.
Bogalusa, LA 70427 -3148
Foreign Address:

Person responsible for RMP implementation:

Name:
Claude A. Bloom, Jr.
Title:
Executive V.P., Manufacturing

Emergency contact:

Name:
John L Ferguson
Title:
Director of Environmental Affairs
Phone:
(985) 732-6310
24-hour phone:
(985) 732-8662
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Washington Parish OHLS-EP
Full-Time Equivalent Employees:
25
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
No
CAA Permit ID#:
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Sept. 13, 2006
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

DMSO Reaction
RMP ID:
80659
CBI claimed:
No
Program Level:
3
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Nitrogen Tetroxide
10544-72-6
131,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 25, 2009
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
No
RMP ID:
55396

Deregistration:

Date:
Effective Date:
Reason:
Source terminated operations
Other Reason:

2. Toxics: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in DMSO Reaction)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's OCA Guidance Reference Tables or Equations
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps

3. Toxics: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in DMSO Reaction)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's OCA Guidance Reference Tables or Equations
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • Dikes
  • Enclosures
  • Sumps
not considered:
  • Berms
  • Drains
Active mitigation
considered:
  • Flares
  • Scrubbers
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Emergency shutdown

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

DMSO Reaction, All Other Basic Organic Chemical Manufacturing (325199)
Prevention Program ID:
47437
Safety Review Date
May 12, 2009, since latest RMP submission
PHA Update Date
July 24, 2007, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Sept. 18, 2006, since latest RMP submission
Training Review Date
June 18, 2009, since latest RMP submission
Maintenance Review Date
Dec. 3, 2008, since latest RMP submission
Maintenance Inspection Date
Jan. 1, 2009, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Aug. 2, 2005
Management of Change Review Date
Aug. 20, 2007
Pre-startup Review Date
June 9, 2004
Compliance Audit Date
Feb. 26, 2007
Compliance Audit Change Completion Date
Aug. 31, 2009
Incident Investigation Date
Dec. 23, 2007
Incident Invest. Change Completion Date
Jan. 11, 2008
Participation Plan Review Date
Feb. 1, 2009
Hot Work Review Date
April 14, 2009
Contractor Safety Review Date
April 28, 2009, since latest RMP submission
Contractor Safety Eval. Date
June 10, 2004, since latest RMP submission

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
Yes
Facility Own Response Plan:
No
Specific Facility Response Plan:
Yes
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
Yes
Plan Review Date:
Response Training Date:
May 3, 2007
Local Response Agency:
Local Response Agency Phone:
(985) 732-5200
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
No
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

EXECUTIVE SUMMARY OF
GAYLORD CHEMICAL CO., LLC
RISK MANAGEMENT PLAN

Gaylord Chemical Company, LLC has prepared a Risk Management Plan, in compliance with Louisiana Department of Environmental Quality (LDEQ) requirements, for its Bogalusa, Louisiana plant, which is registered with the LDEQ under Agency Interest # 7365.

? Accidental release prevention and emergency response policies at facility.

Gaylord Chemical?s accidental release prevention program is based on the OSHA Process Safety Management system, and includes regularly scheduled process hazards analyses. Its emergency response program includes a written response plan with specific actions to be taken by Gaylord Chemical personnel and information to be provided to responders in the event of an incident. Gaylord Chemical also works with local emergency response agencies and members of the community to review and improve its emergency response program.

? Facility and regulated substances handled.

At its Bogalusa plant, Gaylord Chemical makes two products?DMS (dimethyl sulfide) and DMSO (dimethyl sulfoxide)?and sells and ships them to customers in countries around the world. Gaylord Chemical makes DMS by combining sulfur with organic wood by-products obtained from a near-by paper mill. DMS is used for a variety of purposes, including as a safety odorant in natural gas. Gaylord Chemical sells some of the DMS it manufactures and combines the remainder with oxygen and nitrogen tetroxide (N2O4), to make DMSO. DMSO is used in the manufacture of pharmaceuticals and agricultural chemicals. N2O4 is a regulated substance under Louisiana regulations. N2O4 exists only under pressure and when released a portion immediately becomes nitrogen dioxide (NO2) gas, a common combustion product. N2O4 is transported, stored, and used directly from one-ton steel cylinders. While connected to the process, the cylinders are contained within a building equipped with an emergency scrubber to mitigate a release.



? General accidental release prevention program and chemical-specific prevention steps.

Gaylord Chemical already complies with the LDEQ?s Risk Management Plan rules and with the accidental release protection steps required under the OSHA Process Safety Management (PSM) program intended to protect workers from accidental releases. The PSM program includes process hazards analyses, operating procedures, training, preventive maintenance, incident investigations, pre-startup reviews, and management of change. Periodic audits assure compliance.

? Five year accident history.

Gaylord Chemical?s past five year accident history includes no accidents covered by these regulations.

? Emergency response program.

Gaylord Chemical?s emergency response program is set forth in its written Emergency Plan and includes actions to be taken by Gaylord Chemical personnel in the event of many types of emergencies. Gaylord Chemical coordinates emergency preparedness measures with local emergency response agencies including the Bogalusa Police Department, Bogalusa Fire Department, and the Washington Parish Office of Homeland Security and Emergency Preparedness (the designated LEPC).
Emergency preparedness training for plant employees includes first aid, CPR, hazardous materials awareness and emergency notification procedures, and fire safety training. Gaylord Chemical maintains a list of qualified emergency hazardous materials contractors available to assist in emergencies requiring specialized expertise. Finally, Gaylord Chemical has chemical monitoring instruments to warn of leaks and an emergency alarm system, which is tested weekly.
In addition to Gaylord Chemical?s internal Emergency Plan, Gaylord Chemical works with the City of Bogalusa and Washington Parish under its emergency preparedness plan that includes coordinated public safety and emergency response measures for Bogalusa and the surrounding area, including the following: a city-wide siren system; a
traffic alert system for Willis Avenue, the street adjacent to the plant; an emergency alert system for local radio stations and cable TV override; coordination with police, sheriff, fire, local hospitals, and doctors; and a planned telephone ring-down notification system. Gaylord Chemical was a principal party in organizing and funding a local HazMat mutual aid emergency response organization ?ERMAS? available to the entire community.


? Planned changes to improve safety.

Gaylord Chemical has already made many improvements to its plant over the years. These improvements, some of which make use of previously unavailable technology, have made the plant safer and have reduced the potential for accidental chemical releases. Gaylord Chemical will continue to evaluate and improve plant safety and its emergency response abilities.