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Koch Fertilizer, LLC- Sterlington Ammonia Terminal

Parent Companies:
Koch Fertilizer Holding Company, LLC
EPA Facility ID:
100000046684
Other ID:
71280MCFRTLOUIS
Facility DUNS:
0
Parent Company DUNS:
0

Location:

Address:
520 Solvent Avenue
Sterlington, LA 71280
County:
OUACHITA
Lat / Long:
32.686, -92.084 (Get map)
Method:
Interpolation - Photo
Description:
Other
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Koch Fertilizer, LLC
Phone:
(316) 828-8705
Address:
4111 E. 37th Street North
Wichita, KS 67220
Foreign Address:

Person responsible for RMP implementation:

Name:
Tommy Andrews
Title:
Terminal Leader

Emergency contact:

Name:
Tommy Andrews
Title:
Terminal Leader
Phone:
(318) 665-4320
24-hour phone:
(318) 307-9830
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Ouachita Parish EOC
Full-Time Equivalent Employees:
4
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:
June 16, 2015
Inspecting Agency:
U.S. Coast Guard
Using Predictive Filing:
No

Processes:

Ammonia Storage & Loading
RMP ID:
1000062764
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
400,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 26, 2015
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000049916

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 & Loading)
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 & Loading)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
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:
  • Excess flow valve
  • Emergency shutdown
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Flares
  • Scrubbers

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

Aug. 21, 2013 at 10:54
ID:
1000038540
NAICS:
Other Chemical and Allied Products Merchant Wholesalers (42469)
Duration:
2 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
1.0 miles/h S
Temperature:
86.00 ℉
Atmospheric stability:
A
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:
0
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:
  • brief road closure
Initiating event:
Equipment Failure
Contributing factors:
  • Equipment failure
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment

7. Prevention: Program level 3

Ammonia Storage & Loading, Other Chemical and Allied Products Merchant Wholesalers (42469)
Prevention Program ID:
1000052136
Safety Review Date
May 5, 2015, since latest RMP submission
PHA Update Date
May 5, 2015, since latest RMP submission
PHA Techniques
  • None
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Purge System
Mitigation Systems
  • Dikes
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Process Controls
  • Process Detection
  • Mitigation Systems
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
April 29, 2015, since latest RMP submission
Training Review Date
March 31, 2015, since latest RMP submission
Maintenance Review Date
June 9, 2015, since latest RMP submission
Maintenance Inspection Date
June 3, 2015, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
June 5, 2015
Management of Change Review Date
Nov. 17, 2014
Pre-startup Review Date
June 8, 2015
Compliance Audit Date
Jan. 21, 2014
Compliance Audit Change Completion Date
Aug. 30, 2015
Incident Investigation Date
May 27, 2015
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Aug. 22, 2014
Hot Work Review Date
Dec. 30, 2014
Contractor Safety Review Date
June 16, 2015, since latest RMP submission
Contractor Safety Eval. Date
June 13, 2015, since latest RMP submission

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
No
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 1, 2015
Local Response Agency:
Local Response Agency Phone:
(318) 322-2641
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



Introduction and Policies



Koch Fertilizer, LLC (KF) is committed to managing all operations in a manner that protects the environment and the 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 the Ouachita Parish Emergency Operations Center or the Louisiana State Police.



Stationary Source and Regulated Substance



The Sterlington Terminal stores anhydrous ammonia in one 200 ton bullet tank. The total storage capacity of anhydrous ammonia at the facility is 400,000 pounds.

Anhydrous ammonia is the only toxic substance regulated under the Risk Management Program (RMP) that is present at the Sterlington Terminal in amounts above threshold quantity. The terminal is subject to the Prevention Program/Program 3 requirements.



Potential Release Scenarios



The facility evaluated both worst-case release scenarios and alternative release scenarios. KF's evaluation took into account process knowledge, hazard review, mitigation
measures and safe-guards (i.e. dike, emergency shut-downs, etc.) in place.



General Accidental Release Prevention Program and Chemical Specific Prevention



The facility complies with EPA's chemical accident prevention rule (40 CFR 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.



Five-Year Accident History



On August 21, 2013, an equipment failure at the Sterlington Terminal resulted in a release of anhydrous ammonia. Based on engineering estimates, approximately 365 pounds of ammonia were released. There were no onsite or offsite deaths, injuries or property damage. However, traffic on Solvent Avenue, south of the Terminal, was briefly diverted as a precautionary measure. The cause of the release was an unpredictable mechanical failure of a pump seal. The seal has since been upgraded to a tandem (double) pump seal, which will decrease the likelihood of such an event recurring. This event 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 Ouachita Parish Emergency Operations Center and request response to the emergency. The facility has discussed this policy with the EOC.



Planned Changes to Improve Safety



Compliance audits will ensure that the level of safety protection at the terminal is periodically evaluated for improvements.

An ongoing dialogue with the Ouachita Parish LEPC 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.