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Burlington Industries - Clarksville Facility

Parent Companies:
Burlington Industries
EPA Facility ID:
100000051999
Other ID:
VAD000814822
Facility DUNS:
3112232
Parent Company DUNS:
1317833

Location:

Address:
899 Burlington Drive
Clarksville, VA 23927
County:
MECKLENBURG
Lat / Long:
36.606, -78.578 (Get map)
Method:
Interpolation - Map
Description:
Center of Facility
Horizonal accuracy:
m
Horizontal reference datum:
Source map scale:

Owner/Operator:

Name:
Burlington Industries
Phone:
(910) 379-2000
Address:
3330 Friendly Avenue
Greensboro, NC 27420
Foreign Address:

Person responsible for RMP implementation:

Name:
Bill Hill
Title:
Plant Manager
Email:

Emergency contact:

Name:
Kenneth French
Title:
Plant Engineer
Phone:
(804) 374-3434
24-hour phone:
(804) 374-8111
Ext or PIN:
Email:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Mecklenburg County LEPC
Full-Time Equivalent Employees:
1,300
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
Reg. No. 30401
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
April 28, 1999
Inspecting Agency:
PENTA Engineering
Using Predictive Filing:
No

Processes:

Propane System
RMP ID:
17423
CBI claimed:
No
Program Level:
2
NAICS:
All Other Miscellaneous Textile Product Mills (314999)
Chemical name
CAS#
Quantity (lbs.)
CBI
Propane
74-98-6
527,717
No
Public OCA Chemical
0
No
Waste Water Treatment Plt
RMP ID:
17424
CBI claimed:
No
Program Level:
3
NAICS:
Sewage Treatment Facilities (22132)
Chemical name
CAS#
Quantity (lbs.)
CBI
Chlorine
7782-50-5
2,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 18, 1999
Type:
First-time submission
Reason:
Registered:
Yes
RMP ID:
12966

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 Waste Water Treatment Plt)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP Guidance for Waste Water Treatment Plants Reference Tables or Equations
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 Waste Water Treatment Plt)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP Guidance for Waste Water Treatment Plants Reference Tables or Equations
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

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 Propane System)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • none
not considered:
  • Blast walls

5. Flammables: 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 Propane System)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • none
not considered:
  • Dikes
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

Oct. 8, 1994 at 13:35
ID:
1591
NAICS:
Sewage Treatment Facilities (22132)
Duration:
4 hours and 40 minutes
Chemicals involved:
  • Chlorine
Release events:
Gas release
Weather conditions at time of event
Wind speed:
3.5 meters/second W
Temperature:
70.00 ℉
Atmospheric stability:
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:
350
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Unknown
Contributing factors:
  • Maintenance activity/inactivity
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised maintenance
  • Revised training
  • Revised operating procedures
  • Improved Detection System

7. Prevention: Program level 3

Waste Water Treatment Plt, Sewage Treatment Facilities (22132)
Prevention Program ID:
9179
Safety Review Date
May 24, 1999
PHA Update Date
Oct. 4, 1995
PHA Techniques
  • What if
Hazards Identified
  • Toxic release
Process Controls
  • None
Mitigation Systems
  • Enclosure
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
Procedure Review Date
May 24, 1999
Training Review Date
Feb. 25, 1997
Maintenance Review Date
April 1, 1999
Maintenance Inspection Date
April 1, 1999
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 8, 1994
Management of Change Review Date
Dec. 8, 1994
Pre-startup Review Date
Dec. 8, 1994
Compliance Audit Date
April 28, 1999
Compliance Audit Change Completion Date
May 15, 2000
Incident Investigation Date
Oct. 8, 1994
Incident Invest. Change Completion Date
April 28, 1995
Participation Plan Review Date
June 15, 1999
Hot Work Review Date
May 15, 1996
Contractor Safety Review Date
Jan. 29, 1996
Contractor Safety Eval. Date
June 11, 1999

8. Prevention Program level 2

Propane System, All Other Miscellaneous Textile Product Mills (314999)
Prevention Program ID:
7248
Safety Review Date
April 28, 1999
PHA Update Date
Safety Regulations
  • None
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Overfilling
  • Equipment failure
Process Controls
  • Relief Valves
  • Excess Flow Device
Mitigation Systems
  • Deluge System
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classroom
  • On the Job
Competency Testing
  • Observation
Procedure Review Date
April 28, 1999
Training Review Date
April 28, 1999
Maintenance Review Date
April 28, 1999
Maintenance Inspection Date
Jan. 13, 1998
Equipment Tested
Yes
Management of Change Most Recent Date
Management of Change Review Date
Pre-startup Review Date
Compliance Audit Date
April 28, 1999
Compliance Audit Change Completion Date
June 15, 2000
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Hot Work Review Date
Contractor Safety Review Date
Contractor Safety Eval. Date

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:
Nov. 5, 1998
Local Response Agency:
Local Response Agency Phone:
(804) 374-8100
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:
No
Subject To - Other:

Executive Summary

Burlington Industries owns and operates a textile manufacturing facility at 899 Burlington Drive in Clarksville, Mecklenburg County, Virginia. This facility is surrounded by local residences, businesses, and the Roanoke River. The Burlington Industries facility employees approximately 1,300 full-time persons from the surrounding community.

It is the policy of Burlington Industries to meet all requirements established by applicable safety, health, and environmental regulations. The Burlington Industries Clarksville facility is subject to 40 CFR 68 for propane and chlorine and subject to General Duty requirements of this regulation for sulfur dioxide and anhydrous ammonia.

The Burlington Industries Clarskville facility stores propane on-site. The facility maintains three (3) 30,000-gallon and two (2) 18,000-gallon above-ground storage tanks. Propane is used at the facility as a fuel source for some production processes. In addition, the facility uses propane to power lift trucks used at the facility.

The Burlington Industries Clarksville facility stores chlorine at its wastewater treatment plant in one ton cylinders. Burlington Industries is required by the DEQ and Health Department to chlorinate (disinfect) all wastewater effluent.

The "worst-case release scenario" for propane is the release of the entire contents of the largest storage tank, a 30,000 gallon (125,647 lbs) tank due to rupture. For flammable substances, such as propane, it is assumed that the maximum amount of the substances vaporizes resulting in a vapor cloud explosion. The analysis incorporates a 10 percent yield factor for TNT-equivalency models. The distance to the endpoint is defined as the distance over which a minimum pressure of one (1) pound per square inch (psi) occurs from the pressure wave formed by detonation. No passive mitigation was considered in determining the worst-case impact. The maximum distance to the endpoint was determined using the EPA's RMP Off-Site Consequen
ce Analysis Guidance (May 1996) and verified by using the RMP CompTM Program.

The "worst-case release scenario" for chlorine is the release of the entire contents of the largest cylinder directly to the atmosphere. For release of 2,000 lbs of chlorine over a 10-minute period, the distance to the toxic endpoint was determined using the EPA's RMP Guidance for Waste Water Treatment Plants (October 1998) and verified by using the RMP CompTM Program.

The "alternative release scenario" for propane is assumed to be a instant rupture of the tank truck at 85% capacity or 9,860 lbs. The maximum distance to the flammable endpoint was determined using the EPA's RMP Off-Site Consequence Analysis Guidance (May 1996) and verified by using the RMP CompTM Program. This scenario is based on an assumed wind speed of 3.0 meters per second (6.7 miles/hr), Class D stability, and an air temperature of 77 degrees Fahrenheit (770F) at 50 percent relative humidity (50% RH).

Several alternative release scenarios were identified for propane. The scenario thought to be the most likely to occur, pressure releif valve lifting due to overpressurization/overfilling, did not result in an off-site impact.

The "alternative release scenario" for chlorine is assumed to be a release at 35 lb/min. This is a conservative estimate based on a previous incident at the facility. The maximum distance to the toxic endpoint was determined using the EPA's RMP Guidance for Waste Water Treatment Plants (October 1998) and verified by using the RMP CompTM Program. This scenario is based on an assumed wind speed of 3.0 meters per second (6.7 miles/hr), Class D stability, and an air temperature of 77 degrees Fahrenheit (770F) at 50 percent relative humidity (50% RH).

The Burlington Industries Clarksville facility has worked to maintain a safe environment for it's employees and the surrounding commuity. There have been no incidents involving propane at the facility. There has been one incident at the fac
ility involving chlorine. Facility personnel and local emergency response agencies took immediate action and the incident resulted in no injuries or fatalities to plant or off-site persons. In response to this incident, Burlington Industries reviewed all procedures, maintenance activities, detection systems, and emergency response actions. The facilty up-graded the detection system. Any release occcurring today, should be detected immediately.

The facility has established an emergency response program detailing specific actions to be taken in the event of a propane incident with and without fire. These actions are outlined in the Burlington Industries Emergency Procedures Manual and Alert Diagrams. The facility has coordinated emergency response plans with the Clarksville Police and Rescue Squad.