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Hexion Inc.

Parent Companies:
Hexion Inc.
EPA Facility ID:
100000059688
Other ID:
Facility DUNS:
102428430
Parent Company DUNS:
166495924

Location:

Address:
3901 Sugar House Road
Alexandria, LA 71302
County:
RAPIDES
Lat / Long:
31.254, -92.436 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Center of Facility
Horizonal accuracy:
15 m
Horizontal reference datum:
World Geodetic System of 1984
Source map scale:

Owner/Operator:

Name:
Hexion Inc.
Phone:
(318) 445-6115
Address:
3901 Sugar House Rd
Alexandria, LA 71307
Foreign Address:

Person responsible for RMP implementation:

Name:
Brandon Beck
Title:
Site Leader

Emergency contact:

Name:
Brandon Beck
Title:
Site Leader
Phone:
(318) 445-6115
24-hour phone:
(318) 308-7087
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Rapides Parish LEPC
Full-Time Equivalent Employees:
14
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:
March 6, 2013
Inspecting Agency:
EPA
Using Predictive Filing:
No

Processes:

Phenol-formaldehyde resin
RMP ID:
1000055581
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Formaldehyde (solution)
50-00-0
399,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 20, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000044906

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 Phenol-formaldehyde resin)
CBI claimed:
No
Percent weight:
50.0
Physical state:
Gas
Model used:
Trinity Consultants
Release duration (mins):
0.90
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 Phenol-formaldehyde resin)
CBI claimed:
No
Percent weight:
52.0
Physical state:
Liquid
Model used:
Trinity Consultants Formaldehyde/Methaform Release Model
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • Dikes
  • Sumps
not considered:
  • Enclosures
  • Berms
  • Drains
Active mitigation
considered:
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

No Registered Accidents

7. Prevention: Program level 3

Phenol-formaldehyde resin, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000046480
Safety Review Date
Feb. 21, 2013, since latest RMP submission
PHA Update Date
March 16, 2010, since latest RMP submission
PHA Techniques
  • Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Runaway reaction
  • Polymerization
  • Overpressurization
  • Overfilling
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Quench System
Mitigation Systems
  • Dikes
  • Deluge System
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Feb. 15, 2014, since latest RMP submission
Training Review Date
June 29, 2010, since latest RMP submission
Maintenance Review Date
April 15, 2011, since latest RMP submission
Maintenance Inspection Date
April 24, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 15, 2014
Management of Change Review Date
April 1, 2011
Pre-startup Review Date
April 7, 2014
Compliance Audit Date
April 8, 2013
Compliance Audit Change Completion Date
Sept. 30, 2013
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
April 1, 2011
Hot Work Review Date
July 19, 2012
Contractor Safety Review Date
Feb. 26, 2013, since latest RMP submission
Contractor Safety Eval. Date
April 8, 2014, 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:
April 24, 2013
Local Response Agency:
Local Response Agency Phone:
(318) 487-5857
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
Yes
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

Executive Summary



1.Accidental release prevention and emergency response policies



As stated in our Corporate Health, Safety, and Environmental Policy and Principles, the facility is committed to health, safety, and environmental excellence. To accomplish this we integrate health, safety, and environmental planning into all business activities. This includes complying with applicable laws, responsibly managing risks, and working collaboratively with others in addressing health, safety, and environmental issues.



In the Corporate Safety Manual, the Safety Policy Statement clearly states that safety will not be compromised to achieve any other operational or business objective. This manual defines requirements and guidelines developed to prevent injuries and accidental releases.



Included in the Safety Manual are Emergency Response Policies that state that safety is the top priority in all emergency response situations. This policy refers to the plant Emergency Response Plan for specific procedures for handling releases of hazardous materials.



2.Stationary source and regulated substances handled



This plant primarily makes phenol-formaldehyde resins. The site has two (2) Phenol-Formaldehyde Resin reactors.



The regulated substances used in the plant and the maximum quantity stored is formaldehyde.

.

3.Accidental release prevention program and chemical-specific prevention steps



This plant has a comprehensive process safety management program that is in compliance with the EPA Accidental Release Prevention Rule, the OSHA Process Safety Management Standard, and all applicable state codes and regulations. A safety management system is in place to assure on-going compliance. This management system includes the Safety Manual, a list of site safety responsibilities, a file system to maintain records of compl
iance, and a monthly Safety Committee meeting, where a management control checksheet is used to verify that tasks were completed on schedule. The Site Leader has overall responsibility for this program.



Designated personnel are assigned to maintain and improve the safety of their units. Their duties include keeping operating procedures up-to-date, training operators so they can safely carry out these procedures, assuring that the plant is run safely on a daily basis, and when necessary, investigating incidents in their unit. All employees participate in the safety program to improve safety and plant operation.



Designated personnel maintain an Operating Guide that includes process safety information, operating procedures, and a training certification program. Operators use this Operating Guide as a training tool and for reference. By applying the information it contains their actions will prevent accidental releases.



Process hazard analyses are conducted on an on-going basis to identify hazards and recommend safeguards that will prevent an accidental release. As a result of initial process hazard reviews, a significant investment was made in process control systems. Recommendations resulting from the process hazard analyses are entered into an action items database to track the items to completion.



A Management of Change (MOC) system is used to assure that changes to plant equipment, procedures, or processed do not cause accidents. For equipment, procedure, and process changes, a MOC initiates a safety review. This review may include a process hazard analysis. Changes to product formulations initiate a review by technical and plant personnel.



A preventive maintenance program maintains the mechanical integrity of process equipment. A computer database is used to manage the preventive maintenance schedule and other corrective or improvement repairs necessary to maintain the ongoing integrity and reliability of the facility equipment. Each month
scheduled equipment inspections, tests, or servicing are performed. The schedule is based on plant experience to reduce the likelihood of an accidental release caused by equipment failure



The requirements in the Safety Manual include safe work practices which prevent accidental releases. One important section describes safety measures for welding or other "hot" work, which includes a permit system to reduce the risk of fire. The Safety Manual also includes requirements for locking out equipment for maintenance. These procedures reduce the likelihood that a valving error will lead to a release.



Contractors, who periodically perform work in the plant, are given safety orientations to brief them on plant hazards and safety practices. Contractor safety programs and performance are evaluated prior to their selection for jobs that impact process safety.



Incidents that cause or could have caused a release are investigated and recommendations are made to prevent recurrence. These recommendations may lead to improvements in equipment, procedures, operating conditions, or training.



Internal Corporate Health, Safety and Environmental Audits are conducted periodically to maintain compliance with local, state and federal regulations. Regional Safety and Environmental professionals periodically review the health, safety, and environmental programs. Addressing recommendations from these audits and reviews keeps the Facility's Safety and Environmental programs effective.



4.Five-year accident history



In the five year period from June 2009 to June 2014 there were no reportable incidents of a regulated substance from our processes.



5.Emergency response program



The plant Emergency Response Plan describes procedures for actual and threatened releases, including coordination with fire department responders. An emergency response drill is conducted annually to test the Emergency Response Plan and reinforce training that plant responders receive.



6. Plan
ned changes to improve safety



No significant changes are planned.