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Koch Fertilizer, LLC - Taft Terminal

Parent Companies:
Koch Fertilizer Holding Company, LLC
EPA Facility ID:
100000046666
Other ID:
70057KCHNDLAHWY
Facility DUNS:
0
Parent Company DUNS:
0

Location:

Address:
266 LA Hwy 3142
Taft, LA 70057
County:
ST. CHARLES
Lat / Long:
29.985, -90.461 (Get map)
Method:
GPS - Unspecified
Description:
Plant Entrance (General)
Horizonal accuracy:
15 m
Horizontal reference datum:
World Geodetic System of 1984
Source map scale:

Owner/Operator:

Name:
Koch Fertilizer, LLC
Phone:
(316) 828-5521
Address:
4111 E. 37th Street North
Wichita, KS 67220
Foreign Address:

Person responsible for RMP implementation:

Name:
Title:
Terminal Leader
Email:

Emergency contact:

Name:
Eric Lafaucia
Title:
Terminal Leader
Phone:
(985) 783-1441
24-hour phone:
(815) 875-7107
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
St. Charles Parish OEP
Full-Time Equivalent Employees:
17
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:
Oct. 1, 2013
Inspecting Agency:
US Coast Guard
Using Predictive Filing:
No

Processes:

Ammonia Storage
RMP ID:
1000046975
CBI claimed:
No
Program Level:
3
NAICS:
Other Chemical and Allied Products Merchant Wholesalers (42469)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
200,000,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
Jan. 29, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000038285

Deregistration:

Date:
Effective Date:
Reason:
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 Ammonia Storage)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Rural
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 Ammonia Storage)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by refrigeration
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

June 19, 2009 at 09:15
ID:
1000031642
NAICS:
Other Chemical and Allied Products Merchant Wholesalers (42469)
Duration:
5 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
12.6999998 miles/h W
Temperature:
86.00 ℉
Atmospheric stability:
C
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
1
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Human Error
Contributing factors:
  • Human error
  • Improper procedure
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Revised operating procedures

7. Prevention: Program level 3

Ammonia Storage, Other Chemical and Allied Products Merchant Wholesalers (42469)
Prevention Program ID:
1000041177
Safety Review Date
Dec. 20, 2013, since latest RMP submission
PHA Update Date
Oct. 1, 2010, since latest RMP submission
PHA Techniques
  • None
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Deluge System
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • None
Procedure Review Date
Sept. 15, 2013, since latest RMP submission
Training Review Date
Jan. 14, 2014, since latest RMP submission
Maintenance Review Date
Nov. 16, 2013, since latest RMP submission
Maintenance Inspection Date
Jan. 17, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 6, 2014
Management of Change Review Date
Dec. 6, 2013
Pre-startup Review Date
Jan. 10, 2014
Compliance Audit Date
Sept. 12, 2013
Compliance Audit Change Completion Date
Sept. 30, 2014
Incident Investigation Date
Jan. 10, 2014
Incident Invest. Change Completion Date
Dec. 15, 2014
Participation Plan Review Date
April 18, 2013
Hot Work Review Date
Dec. 26, 2013
Contractor Safety Review Date
Oct. 10, 2013, since latest RMP submission
Contractor Safety Eval. Date
Dec. 31, 2013, 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:
Oct. 21, 2013
Local Response Agency:
Local Response Agency Phone:
(985) 783-5050
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

EXECUTIVE SUMMARY FOR THE RISK MANAGEMENT PLAN (RMP)



Koch Fertilizer, LLC (KF) is committed to managing all operations in a manner that protects the environment and health and safety of employees, customers, contractors and the public while fully complying with applicable laws and regulations. The chemical accident prevention provisions require an executive summary in the Risk Management Plan (RMP) submission to EPA. Per 40 CFR 68.155, the owner or operator shall provide in the RMP an executive summary that includes a brief description of the following elements:

(a) The accidental release prevention and emergency response policies at the stationary source;

(b) The stationary source and regulated substances handled;

(c) The general accidental release prevention program and chemical-specific prevention steps;

(d) The five-year accident history;

(e) The emergency response program; and

(f) Planned changes to improve safety.





Accidental Release Prevention and Emergency Response Policies



The facility complies with OSHA's 29 CFR 1910.111 requirements for anhydrous ammonia storage, and it is the facility's policy to adhere to applicable federal, state, and local laws. If an emergency were to occur, it is KF's policy to notify Hahnville Volunteer Fire Department, St. Charles Parish Emergency Operations Center (EOC), St. Charles Parish Sheriff,and Louisiana State Police.





Stationary Source and Regulated Substances



The Taft terminal recieves anhydrous ammonia by ship and barge and stores it in two cryogenic storage tanks (50,000 tons of anhydrous ammonia per tank) and one pressurized bullet tank (156 tons) until it is either (a) loaded onto a ship or barge or (b) injected into a third-party pipeline for further transport or distribution. The total storage capacity of anhydrous ammonia at the facility is 200,312,000 pounds. Anhydrous ammonia is the only regulated substance stored at the Facility in amounts above threshold quantity. The Facility is su
bject to the Program 3 Prevention Program of the chemical accident prevention provisions (40 CFR Part 68).





General Accidental Release Prevention Programs and Chemical-Specific Prevention



The Facility complies with EPA's chemical accident prevention provisions (40 CFR Part 68) and applicable state and local codes and regulations. The anhydrous ammonia system is designed, installed, and maintained in accordance with 29 CFR 1910.111 and relevant American Society of Mechanical Engineers (ASME) standards.



Some release preventive features at the Facility include

- Emergency shutdown buttons at the barge and ship loading area and multiple locations throughout the terminal that can be activated by KF personnel or the ship/barge crew in case of an ammonia release.

- Surge bladders on the ship/barge loading lines to absorb the shock during a sudden closure of the valve due to emergency shutdown.

- A firewater deluge system on top of the cryogenic ammonia tanks.

- Ammonia sensors in the process areas and on the property to detect ammonia.





Five-year Accident History



On June 19, 2009, a KF employee was exposed to an accidental release of anhydrous ammonia on his legs. The employee was taken to a local emergency room, treated for exposure, and released the same day. Approximately 80 pounds of anhydrous ammonia were released from a block valve during a maintenance operation. The cause of the release was human error and improper procedure, and, as a result, KF updated its procedures. This release was reported to regulatory agencies.





Emergency Response Program



In the event of an emergency involving the anhydrous ammonia system, it is the facility's policy to notify the Louisiana State Police and St. Charles Parish EOC and request response. A specific Emergency Response Plan for the terminal is in place and that plan has been coordinated with local officials. The Emergency Response Program provides the essential planning for effectively protect
ing workers, the public, and the environment during emergency situations.





Planned Changes to Improve Safety



Internal and third party compliance audits will ensure that the level of safety protection at the terminal is periodically evaluated for improvements.



An ongoing dialogue with the St. Charles Parish EOC will ensure a constant state of readiness to respond to any potential emergencies, as well as a means to implement improvements as the need develops.