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DSM Copolymer Inc., Addis Plant

Parent Companies:
DSM Copolymer Inc.
EPA Facility ID:
100000064271
Other ID:
70710CPLYMLOUIS
Facility DUNS:
0
Parent Company DUNS:
8182990

Location:

Address:
9263 Hwy 1 South
Addis, LA 70710
County:
WEST BATON ROUGE
Lat / Long:
30.340, -91.252 (Get map)
Method:
Interpolation - Map
Description:
Center of Facility
Horizonal accuracy:
m
Horizontal reference datum:
Source map scale:

Owner/Operator:

Name:
DSM Copolymer, Inc.
Phone:
(225) 267-3400
Address:
P.O. Box 2591
Baton Rouge, LA 70821 -2591
Foreign Address:

Person responsible for RMP implementation:

Name:
Henry R. McKenney
Title:
Site Manager
Email:

Emergency contact:

Name:
Bart Wesley
Title:
Site SHE Manager
Phone:
(225) 267-3161
24-hour phone:
(225) 267-3400
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(225) 267-3400
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
West Baton Rouge Parish LEPC
Full-Time Equivalent Employees:
196
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
3120-0004
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Nov. 1, 2000
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Synthetic Rubber Manufact
RMP ID:
38884
CBI claimed:
No
Program Level:
3
NAICS:
Synthetic Rubber Manufacturing (325212)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
20,000
No
Propylene [1-Propene]
115-07-1
650,000
No
Propane
74-98-6
110,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
Nov. 27, 2002
Type:
Resubmission
Reason:
Registered:
No
RMP ID:
27112

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 Synthetic Rubber Manufact)
CBI claimed:
No
Percent weight:
Physical state:
Gas
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 Synthetic Rubber Manufact)
CBI claimed:
No
Percent weight:
Physical state:
Gas
Model used:
EPA's RMP Guidance for Chemical Distributors Reference Tables or Equations
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
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 Synthetic Rubber Manufact)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
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 Synthetic Rubber Manufact)
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:
  • Deluge systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21806
Safety Review Date
April 17, 2000, since latest RMP submission
PHA Update Date
April 17, 2000, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • None
Mitigation Systems
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 5, 2000, since latest RMP submission
Training Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Inspection Date
Nov. 9, 2000, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Sept. 19, 2000
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
Oct. 17, 2000
Compliance Audit Date
Nov. 1, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21807
Safety Review Date
May 27, 1997, since latest RMP submission
PHA Update Date
May 27, 1997, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Jan. 26, 1999, since latest RMP submission
Training Review Date
March 31, 1999, since latest RMP submission
Maintenance Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Inspection Date
Sept. 14, 2000, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
June 21, 2000
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
Oct. 17, 2000
Compliance Audit Date
Nov. 1, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21808
Safety Review Date
April 17, 2000, since latest RMP submission
PHA Update Date
April 17, 2000, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Polymerization
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • None
Mitigation Systems
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 5, 2000, since latest RMP submission
Training Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Inspection Date
Sept. 29, 2000, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Oct. 25, 2000
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
Oct. 17, 2000
Compliance Audit Date
Nov. 1, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21809
Safety Review Date
May 27, 1997, since latest RMP submission
PHA Update Date
May 27, 1997, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 5, 2000, since latest RMP submission
Training Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Inspection Date
Oct. 23, 2000, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Oct. 2, 2000
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
Oct. 17, 2000
Compliance Audit Date
Nov. 1, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21810
Safety Review Date
April 17, 2000, since latest RMP submission
PHA Update Date
April 17, 2000, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Polymerization
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 5, 2000, since latest RMP submission
Training Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Inspection Date
June 21, 2000, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
May 22, 2000
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
Oct. 17, 2000
Compliance Audit Date
Oct. 31, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21811
Safety Review Date
May 27, 1997, since latest RMP submission
PHA Update Date
May 27, 1997, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 5, 2000, since latest RMP submission
Training Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Inspection Date
Sept. 14, 2000, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Oct. 11, 2000
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
Oct. 17, 2000
Compliance Audit Date
Nov. 1, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21812
Safety Review Date
April 17, 2000, since latest RMP submission
PHA Update Date
July 8, 1997, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
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
Dec. 5, 2000, since latest RMP submission
Training Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Inspection Date
Oct. 18, 2000, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Oct. 9, 2000
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
Oct. 17, 2000
Compliance Audit Date
Nov. 1, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21813
Safety Review Date
Dec. 5, 1996, since latest RMP submission
PHA Update Date
Nov. 5, 1996, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
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
Dec. 5, 2000, since latest RMP submission
Training Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Inspection Date
Feb. 21, 2000, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 31, 1999
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
Oct. 17, 2000
Compliance Audit Date
Nov. 1, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21814
Safety Review Date
Jan. 29, 1999, since latest RMP submission
PHA Update Date
Jan. 12, 1999, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
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
Jan. 26, 1999, since latest RMP submission
Training Review Date
March 31, 1999, since latest RMP submission
Maintenance Review Date
June 10, 1999, since latest RMP submission
Maintenance Inspection Date
Jan. 2, 1998, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 18, 2000
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
Oct. 17, 2000
Compliance Audit Date
Oct. 31, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21815
Safety Review Date
Jan. 20, 2000, since latest RMP submission
PHA Update Date
Jan. 20, 2000, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Purge System
Mitigation Systems
  • Deluge System
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
Dec. 5, 2000, since latest RMP submission
Training Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Inspection Date
Nov. 4, 1998, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 30, 1999
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
April 28, 1999
Compliance Audit Date
Nov. 1, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21816
Safety Review Date
Jan. 29, 1999, since latest RMP submission
PHA Update Date
Jan. 12, 1999, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 5, 2000, since latest RMP submission
Training Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Review Date
June 10, 1999, since latest RMP submission
Maintenance Inspection Date
July 15, 1999, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 31, 1999
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
April 28, 1999
Compliance Audit Date
Oct. 31, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
April 13, 1998
Incident Invest. Change Completion Date
Jan. 6, 1999
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21817
Safety Review Date
Jan. 20, 2000, since latest RMP submission
PHA Update Date
Jan. 20, 2000, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Quench System
  • Purge System
Mitigation Systems
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 5, 2000, since latest RMP submission
Training Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Review Date
Dec. 5, 2000, since latest RMP submission
Maintenance Inspection Date
Nov. 13, 2000, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
May 18, 2000
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
Oct. 17, 2000
Compliance Audit Date
Nov. 1, 2000
Compliance Audit Change Completion Date
June 30, 2001
Incident Investigation Date
Nov. 3, 2000
Incident Invest. Change Completion Date
Jan. 15, 2001
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, since latest RMP submission
Synthetic Rubber Manufact, Synthetic Rubber Manufacturing (325212)
Prevention Program ID:
21818
Safety Review Date
Jan. 29, 1999, since latest RMP submission
PHA Update Date
July 8, 1997, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Purge System
Mitigation Systems
  • Deluge System
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
May 6, 1999, since latest RMP submission
Training Review Date
March 31, 1999, since latest RMP submission
Maintenance Review Date
June 10, 1999, since latest RMP submission
Maintenance Inspection Date
Sept. 7, 2000, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 15, 1999
Management of Change Review Date
March 15, 1999
Pre-startup Review Date
May 1, 1999
Compliance Audit Date
Sept. 30, 1998
Compliance Audit Change Completion Date
Dec. 31, 1999
Incident Investigation Date
Jan. 6, 1998
Incident Invest. Change Completion Date
Feb. 4, 1999
Participation Plan Review Date
Aug. 28, 1998
Hot Work Review Date
Aug. 28, 1998
Contractor Safety Review Date
Aug. 28, 1998, since latest RMP submission
Contractor Safety Eval. Date
April 19, 1999, 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:
Dec. 6, 2000
Local Response Agency:
Local Response Agency Phone:
(225) 346-1584
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

2519 LDEQ Facility ID Number

DSM COPOLYMER, INC., ADDIS, LA -- EXECUTIVE SUMMARY

ACCIDENTAL RELEASE PREVENTION AND RESPONSE POLICIES

DSM Copolymer's Addis plant has a Iong-standing commitment to protection of the health and safety of its employees and the public. This commitment is demonstrated by the resources invested in accident prevention, such as training personnel and emphasizing safety in the design, installation, operation, and maintenance of our processes. Our policy is to implement reasonable controls to prevent foreseeable releases of regulated substances. However, if a release does occur, our trained personnel will respond to control and contain the release.

DESCRIPTION OF THE STATIONARY SOURCE AND REGULATED SUBSTANCES

The Addis plant is located one mile south of Addis, LA in West Baton Rouge parish. The plant produces synthetic rubber and liquid oil additives. The plant uses or produces relatively few regulated substances: ethylene, propylene, propane and hydrogen (flammables); and ammonia, and hydrochloric acid (toxic substances). Of these, ethylene, hydrogen and hydrochloric acid are present only in amounts or concentrations below the EPA RMP threshold quantities, and are therefore exempted.

HAZARD ASSESSMENT RESULTS

NOTE: Although we have numerous controls to prevent unplanned releases and to manage their consequences, no credit for administrative controls or passive mitigation measures was taken into account in evaluating worst-case scenarios for toxic or flammable substances.

The worst case scenario (WCS) associated with toxic substances at the plant is a catastrophic failure of a anhydrous ammonia storage tank, resulting in a release of 4,300 lb of ammonia over a 10-minute period. The maximum distance to a toxic endpoint of 0.14 milligram per literfor this WCS is 0.80 miles.

The alternative release scenario (ARS) for ammonia is a 1-inch pipe break in the vapor piping, resulting in a release of 2,800 lb. of ammonia over a 30-m
inute period. The maximum distance to the toxic endpoint of 0.14 milligram per liter for this ARS is 0.1 mile.

The WCS associated with a release of flammable substances at the plant is a vapor cloud explosion (VCE) involving the full inventory of the largest storage tank containing propylene. No administrative controls are in place to limit the storage inventory in the tank; therefore, the full tank inventory of approximately 650,000 lb. is assumed to release, completely vaporize, and ignite, resulting in a VCE. The maximum distance to the 1-psi endpoint for this WCS is 0.7 mile.

The ARS for flammable substances at the plant is a VCE resulting from release of approximately 2,500 lb. of propylene from a ?" hole in a transfer line over a period of 30 minutes. The release is expected to be detected and isolated by the operators within a maximum of 30 minutes (active mitigation). The maximum distance to the 1-psi endpoint for this event is 0.11 mile.

GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM STEPS

The following is a summary of the general accident prevention program in place at the Addis plant. Because processes at the plant that are regulated by the EPA RMP regulation are also subject to the OSHA PSM standard, this summary addresses each of the OSHA PSM elements and describes the management system in place to implement the accident prevention program.

Employee Participation

The Addis plant encourages employees' participation in all facets of process safety management and accident prevention. Examples of employee participation range from updating and compiling technical documents and chemical information to participating as a member of a process hazard analysis (PHA) team. Employees have access to all information created as part of the plant accident prevention program. Specific ways that employees can be involved in the accident prevention program are documented in an employee participation plan that is maintained at the plant. In addition, the plan
t has a number of intitiatives under way that address process safety and employee safety issues. These initiatives include forming employee process-improvement teams to promote both process and personal safety. The teams typically have members from various areas of the plant, including operations, maintenance, engineering and plant management.

Process Safety Information

The Addis plant has a variety of technical documents that are used to help maintain safe operation of the processes. These documents address chemical properties and associated hazards, limits for key process parameters and specific chemical inventories, and equipment design basis/configuration information. Specific departments within the plant are assigned responsibility for maintaining up-to-date process safety information. Employees have access to any necessary process safety information.

Chemical-specific information, including exposure hazards and emergency response/exposure treatment considerations, is provided in material safety data sheets (MSDSs). This information is supplemented by documents that specifically address known hazards such as those associated with the inadvertent mixing of chemicals. For specific process areas, the plant has documented safety-related limits for applicable process parameters (e.g., temperature, level, composition). The plant ensures that the process is maintained within these limits using process controls and monitoring instruments, highly trained personnel, and protective instrument systems.

The plant also maintains numerous technical documents that provide information about the design and construction of process equipment to include materials of construction, design pressure and temperature ratings, electrical rating of equipment, etc. This information, in combination with written procedures and trained personnel, provides a basis for establishing inspection and maintenance activities, as well as for evaluating proposed process and facility changes
to ensure that safety features in the process are not compromised.

Process Hazard Analysis (PHA)

The Addis plant has a comprehensive program to help ensure that hazards are identified and controlled. Within this program, each process is systematically examined to identify hazards and ensure that adequate controls are in place to manage these hazards. The plant primarily uses the hazard and operability (HAZOP) analysis technique to perform these evaluations. HAZOP analysis is recognized as one of the most systematic and thorough hazard evaluation techniques. The analyses are conducted by a team of people who have operating and maintenance experience as well as engineering expertise. This team identifies and evaluates hazards of the process as well as accident prevention and mitigation measures, and makes suggestions for additional prevention and/or mitigation measures when the team believes such measures are necessary.

The PHA team findings are forwarded to local and corporate management for resolution. Implementation of mitigation options in response to PHA findings is based on a relative risk ranking assigned by the PHA team. This ranking helps ensure that potential accident scenarios assigned the highest risk receive prompt attention. All approved mitigation options being implemented in response to PHA team findings are tracked until they are complete. The final resolution of each finding is documented and retained for the life of the process.

To help ensure that the process controls and/or process hazards do not eventually deviate significantly from the original design safety features, the Addis plant will update and revalidate the hazard analysis results at least once every 5 years for the life of the process. The results and findings from these updates are documented and reviewed with management, and the final resolution is documented and retained.

Operating Procedures

The Addis plant maintains written procedures that address various modes of proce
ss operations, such as startup, normal and emergency operations, temporary operations, normal and emergency shutdown, and initial startup of a new process. These procedures can be used as a reference by experienced operators and provide a basis for consistent training of new operators. Procedures are maintained current and accurate by revising them as necessary to reflect changes made through the management of change process. Procedures are periodically reviewed and annually certified as current and accurate.

Training

The Addis plant has implemented a comprehensive training program for all employees involved in operating a process. New employees receive basic training both in safety issues and in plant operations. After successfully completing this training, a new operator will work with a senior operator to learn process-specific duties and tasks. After new operators demonstrate (e.g., through tests, skills demonstration) having adequate knowledge to perform the duties and tasks in a safe manner on their own, they can work independently. Operators receive refresher training on the operating procedures at least every 3 years to ensure that their skills and knowledge are maintained at an acceptable level. Training is documented for each operator, including the means used to verify that the operator understood the training.

Contractors

The Addis plant routinely employs contractors to work on or near process equipment. Additional contractor work force is present during periods of increased maintenance or construction activities. Procedures are in place to ensure that contractors perform their work in a safe manner, have the appropriate knowledge and skills, are aware of the hazards in their workplace, understand what they should do in the event of an emergency, understand and follow site safety rules, and inform plant personnel of any hazards that they find during their work. Each contractor employee is provided with a process overview and information abo
ut safety and health hazards, emergency response plan requirements, and safe work practices prior to beginning work. Contractor safety programs and performance are evaluated during the selection of a contractor. Plant personnel periodically monitor contractor performance to ensure that contractors are fulfilling their safety obligations.

Pre-startup Safety Reviews (PSSR's)

The Addis plant conducts a PSSR for any new facility or facility modification that requires a change in the process safety information. The purpose of the PSSR is to ensure that safety features, procedures, personnel, and the equipment are appropriately prepared for startup prior to placing the equipment into service. This review provides one additional check to make sure construction is in accordance with the design specifications and that all supporting systems are operationally ready. The PSSR review team uses checklists to verify all aspects of readiness. A PSSR involves field verification of the construction and serves a quality assurance function by requiring verification that accident prevention program requirements are properly implemented.

Mechanical Integrity

The Addis plant has well-established practices and procedures to maintain pressure vessels, piping systems, relief and vent systems, controls, pumps and compressors, and emergency shutdown systems in a safe operating condition. The basic aspects of this program include: (1) conducting training, (2) developing written procedures, (3) performing inspections and tests, (4) correcting identified deficiencies, and (5) applying quality assurance measures. In combination, these activities form a system that maintains the mechanical integrity of the process equipment.

Maintenance personnel receive training on (1) an overview of the process, (2) safety and health hazards, (3) applicable maintenance procedures, (4) emergency response plans, and (5) applicable safe work practices to help ensure that they can perform their job in a
safe manner. Written procedures help ensure that work is performed in a consistent manner and provide a basis for training. Inspections and tests are performed to help ensure that equipment functions as intended, and to verify that equipment is within acceptable limits (e.g., adequate wall thickness for pressure vessels). If a deficiency is identified, employees will correct the deficiency before placing the equipment back into service (if possible), or Management will review the use of the equipment and determine what actions are necessary to ensure the safe operation of the equipment.

Another integral part of the mechanical integrity program is quality assurance. The Addis plant incorporates quality assurance measures (e.g., purchasing specifications and inspection procedures) into equipment purchases and repairs. This helps ensure that new equipment is suitable for its intended use and that proper materials and spare parts are used when repairs are made.

Safe Work Practices

The Addis plant has long-standing safe work practices in place to help ensure worker and process safety. Examples of these include (1) control of the entry/presence/exit of support personnel, (2) a lockout/tagout procedure to ensure isolation of energy sources for equipment undergoing maintenance, (3) a procedure for safe removal of hazardous materials before process piping or equipment is opened, (4) a permit and procedure to control spark-producing activities (i.e., hot work), and (5) a permit and procedure to ensure that adequate precautions are in place before entry into a confined space. These procedures (and others), along with training of affected personnel, form a system to help ensure that operations and maintenance activities are performed safely.

Management of Change

The Addis plant has a comprehensive system to manage changes to processes. This system requires that changes to items such as process equipment, chemicals, technology (including process operating conditions), pr
ocedures, and other facility changes be properly reviewed and authorized before being implemented. Changes are reviewed to (1) ensure that adequate controls are in place to manage any new hazards and (2) verify that existing controls have not been compromised by the change. Affected chemical hazard information, process operating limits, and equipment information, as well as procedures, are updated to incorporate these changes. In addition, operating and maintenance personnel are provided any necessary training on the change.

Incident Investigation

The Addis plant promptly investigates all incidents that resulted in, or reasonably could have resulted in, a fire/explosion, toxic gas release, major property damage, environmental loss, or personal injury. The goal of each investigation is to determine the facts and develop corrective actions to prevent a recurrence of the incident or a similar incident. The investigation team documents its findings, develops recommendations to prevent a recurrence, and forwards these results to plant management for resolution. Corrective actions taken in response to the investigation team's findings and recommendations are tracked until they are complete. The final resolution of each finding or recommendation is documented, and the investigation results are reviewed with all employees (including contractors) who could be affected by the findings. Incident investigation reports are retained on file as supplements to the hazard analysis records for the affected areas, and are reviewed during PHA's and PHA revalidations.

Compliance Audits

To help ensure that the accident prevention program is functioning properly, the Addis plant periodically undergoes audits to determine whether the procedures and practices required by the accident prevention program are being implemented. Compliance audits are conducted at least every 3 years. Both hourly and management personnel participate in the audits. The audit team develops findings t
hat are forwarded to the plant management for resolution. Corrective actions taken in response to the audit team's findings are tracked until they are complete. The final resolution of each finding is documented, and the two most recent audit reports are retained on file.

CHEMICAL-SPECIFIC PREVENTION STEPS

The processes at the Addis plant have hazards that must be managed to ensure continued safe operation. The accident prevention program summarized previously is applied to all EPA RMP-covered processes at the Addis plant. Collectively, these prevention program activities help prevent potential accident scenarios that could be caused by equipment failures and/or human errors. In addition to the accident prevention program activities, the Addis plant has safety features on many units to help (1) contain/control a release, (2) quickly detect a release, and (3) reduce the consequences of (mitigate) a release. The following types of safety features are used in various processes:

Release Detection

-- Hydrocarbon detectors with alarms

Release Containment/Control

-- Process relief valves that discharge to a flare to capture and incinerate episodic releases
-- Scrubber to neutralize chemical releases
-- Valves to permit isolation of the process (manual or automated)
-- Automated shutdown systems for specific process parameters (e.g., high level, high temperature)
-- Curbing or diking to contain liquid releases
-- Redundant equipment and instrumentation (e.g., uninterruptible power supply for process control system, backup firewater pump)
-- Atmospheric relief devices

Release Mitigation

-- Fire suppression and extinguishing systems
-- Deluge systems for specific equipment
-- Trained emergency response personnel
-- Personal protective equipment (e.g., protective clothing, self-contained breathing apparatus)

FIVE-YEAR ACCIDENT HISTORY

The Addis plant has an excellent record of accident prevention. During the past 5 years there have been no incidents in covered
processes involving onsite deaths, recordable injuries or significant property damage, or offsite deaths, injuries, evcuations, shelter-in-place, property damage or environmental damage.

EMERGENCY RESPONSE PROGRAM INFORMATION

The Addis plant maintains a written emergency response program to protect worker and public safety as well as the environment. The program consists of procedures for responding to a release of a regulated substance, including the possibility of a fire or explosion if a flammable substance is accidentally released. The procedures address all aspects of emergency response, including proper first-aid and medical treatment for exposures, evacuation plans and accounting for personnel after an evacuation, notification of local emergency response agencies and the public if a release occurs, and post-incident cleanup and decontamination requirements. Plant procedures also address the use, maintenance, inspection, and testing of emergency response equipment. Employees receive training in these procedures as necessary to perform their specific emergency response duties. The emergency response program is reviewed annually and updated when necessary based on modifications made to plant processes or other plant facilities.

The overall emergency response program for the Addis plant is coordinated with the West Baton Rouge Parish Local Emergency Planning Committee (LEPC) and the Baton Rouge Area Mutual Aid System (BRAMAS). The Addis plant has around-the-clock communications capability with appropriate emergency response organizations. This provides a means of notifying the public of an incident, if necessary, as well as facilitating quick response. The Addis plant conducts periodic emergency drills and provides annual refresher training regarding the hazards of regulated substances in the plant.

PLANNED CHANGES TO IMPROVE SAFETY

The Addis plant addresses each recommendation resulting from process hazard analyses. Some recommendations result i
n modifications to the process. The following types of changes are currently under consideration:

Decrease in process chemical inventories;
Revisions to process instrumentation and/or controls;
Design and installation of safety instrumented systems;
Revision and upgrade of personnel training programs;
Revision of written operating and maintenance procedures; and,
Review and upgrade of facility pressure relief system.