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Terra Mississippi Nitrogen, Inc.

Parent Companies:
Terra Industries, Inc.
EPA Facility ID:
100000065911
Other ID:
Facility DUNS:
8161432
Parent Company DUNS:
101123578

Location:

Address:
39041 Highway 18 West
Donaldsonville, LA 70346
County:
ASCENSION
Lat / Long:
30.061, -90.632 (Get map)
Method:
GPS Code Measurements (Psuedo Range) Standard Positioning Service SA ON
Description:
Facility Centroid
Horizonal accuracy:
10 m
Horizontal reference datum:
World Geodetic System of 1984
Source map scale:

Owner/Operator:

Name:
Terra Mississippi Nitrogen, Inc.
Phone:
(225) 473-9231
Address:
P. O. Box 310
Donaldsonville, LA 70346
Foreign Address:

Person responsible for RMP implementation:

Name:
Richard Bartley
Title:
Plant Manager

Emergency contact:

Name:
Joshua Truxillo
Title:
Safety/PSM Coordinator
Phone:
(225) 474-4640
24-hour phone:
(225) 474-4660
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Ascension Parish LEPC
Full-Time Equivalent Employees:
34
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
01800000901
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Oct. 30, 2008
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Ammonia Handling/Storage
RMP ID:
78796
CBI claimed:
No
Program Level:
3
NAICS:
Nitrogenous Fertilizer Manufacturing (325311)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
120,000,000
No
Chlorine
7782-50-5
14,000
No
Ammonia (conc 20% or greater)
7664-41-7
290,000
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:
March 31, 2009
Type:
Resubmission
Reason:
Voluntary update (not described by any of the above reasons)
Registered:
No
RMP ID:
54025

Deregistration:

Date:
Effective Date:
Reason:
Other
Other Reason:
Facility now merged into 100000126446. No longer a separate stationary source

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 Handling/Storage)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by refrigeration
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
2400.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • Dikes
  • Drains
  • Sumps
not considered:
  • Enclosures
  • Berms

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 Handling/Storage)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
HGSYSTEM Model
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • Drains
  • Sumps
not considered:
  • Dikes
  • Enclosures
  • Berms
Active mitigation
considered:
  • Deluge systems
not considered:
  • Sprinkler systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Ammonia Handling/Storage)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
HGSYSTEM Model
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • Drains
  • Sumps
not considered:
  • Dikes
  • Enclosures
  • Berms
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Ammonia Handling/Storage)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's OCA Guidance Reference Tables or Equations
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • Drains
  • Sumps
not considered:
  • Dikes
  • Enclosures
  • Berms
Active mitigation
considered:
  • Deluge systems
not considered:
  • Sprinkler 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

Ammonia Handling/Storage, Nitrogenous Fertilizer Manufacturing (325311)
Prevention Program ID:
46460
Safety Review Date
Jan. 24, 2009, since latest RMP submission
PHA Update Date
Nov. 13, 2008, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Polymerization
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Fire Walls
  • Deluge System
  • Enclosure
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Process Parameters
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
April 1, 2008, since latest RMP submission
Training Review Date
April 1, 2008, since latest RMP submission
Maintenance Review Date
Jan. 27, 2009, since latest RMP submission
Maintenance Inspection Date
Jan. 14, 2009, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 20, 2009
Management of Change Review Date
Jan. 26, 2009
Pre-startup Review Date
Aug. 18, 2008
Compliance Audit Date
Feb. 7, 2006
Compliance Audit Change Completion Date
Nov. 19, 2008
Incident Investigation Date
June 19, 2008
Incident Invest. Change Completion Date
Nov. 20, 2008
Participation Plan Review Date
Jan. 24, 2009
Hot Work Review Date
Jan. 24, 2009
Contractor Safety Review Date
Jan. 9, 2009, since latest RMP submission
Contractor Safety Eval. Date
Jan. 9, 2009, 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:
Jan. 24, 2009
Local Response Agency:
Local Response Agency Phone:
(225) 925-6595
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

RMP EXECUTIVE SUMMARY - Louisiana Facility ID: 2245

Terra Mississippi Nitrogen, Inc. (Terra) Donaldsonville Plant manufactures, stores, and distributes ammonia.

Terra and its employees have an enduring commitment to protecting health, safety, and the environment. In order to document that commitment, Terra's Management has authorized a Health, Safety and Environmental Statement of Policy. This policy is summarized below.

Laws, rules and regulations in the area of health, safety, and the environment impose responsibilities on the Company and its employees. An additional purpose of this policy is to set forth the principles under which those responsibilities are to be fulfilled, thereby providing appropriate protection for employees, as well as the Company.

Employee Health and Safety
Workplace health and safety are paramount concern. The Company and its employees are expected to be aware of and adhere to laws, regulations, Company policy and procedures designed to ensure safe and healthy workplace conditions and practices.

Contractors and Visitor Health and Safety
All contractors working in the Company's facilities or visitors to Company's facilities are expected to be aware of and adhere to all Company health, safety, and environmental policies and procedures. The Company must conduct, or require proof of, appropriate training.

Environment
In all its activities, the Company will remain sensitive to environmental concerns and the need for sound environmental practices. The Company and its employees are expected to be aware of and adhere to laws, regulations, Company policy, and Company procedures designed to ensure that the Company's activities are in compliance with all federal, state, and local environmental laws and regulations.

Minimization of Risks and Releases to the Environment and Conservation of Natural Resources
It is the policy of the Company to minimize the environment, health and safety risks to its employees and the communities in which it
operates, to minimize releases to the environment, to conserve natural resources through efficient use and careful planning, to recycle materials whenever technically and economically feasible, and to dispose of wastes in a manner determined to be environmentally sound.

Compliance With Laws
The activities of the Company and its employees are expected to be in full compliance with all applicable laws, rules, and regulations relating to health, safety and the environment.

Assistance to Government
It is the policy of the Company to participate with all levels of government in the development of equitable and effective health, safety and environmental laws, rules and regulations.

Employee Training
It is the Company's continuing policy to inform and educate each employee regarding health, safety and environmental laws and regulations applicable to his or her job. Through such training, the employee is responsible for learning and maintaining knowledge of the health, safety and environmental duties of his or her job.

Internal Reporting by Employees
Employees must be alert to the presence of unsafe conditions or violations of environmental law and shall report these to designated managers. It is the policy of the Company that no retaliatory action will be taken against any employee for good faith reporting consistent with this policy.

Compliance
Compliance with this policy is an ongoing duty of each employee and compliance will be monitored. Each employee is obligated to report immediately to designated managers any failure to comply with this policy.

Employees who violate this policy are subject to disciplinary action, up to and including discharge.

Full compliance with the intent and purpose of this policy requires that employees be diligent within the scope of their responsibilities. Employees will be evaluated and compensation will be based, in part, on their effectiveness in implementation of this policy.

The Company will defend and indemnify any employee
charged with health, safety or environmental offenses when the Company determines that the employee has acted in good faith to comply with this policy.

Disclosure
It is the policy of the Company to make relevant disclosure, consistent with all laws, regulations and this policy, to its employees, and to the public, of incidents relating to its operations that cause environmental harm or pose health or safety hazards.

Commitment of Resources
The Company will commit resources to implement this policy and to monitor and sustain a process to ensure that Terra Management is kept informed of all health, safety and environmental matters.

Terra is capable of producing approximately 550,000 tons of ammonia. In the production of ammonia, Terra uses natural gas, air and water as feedstocks. The feedstocks are heated to a point that they are broken down into nitrogen, hydrogen, and carbon dioxide. This is in the gas state. The carbon dioxide is then removed from the gas stream as a by-product, and only nitrogen and hydrogen remain in the gas stream. The hydrogen and nitrogen is then bonded together to form ammonia (NH3). The ammonia is then cooled to form a liquid at -28 degrees F. The ammonia is sent to two 30,000 ton storage tanks. The process of making ammonia requires the use of cooling water that uses chlorine for purification purposes. Terra stores approximately 14,000 pounds of chlorine within the covered process.

As previously discussed, Terra's commitment to safety and the environment takes priority. Terra's safety and environmental record reflects this commitment. The following is a summary of the multiple layers of safety and environmental protection that Terra has in place at our plants to protect our employees and the community.

*Managing risks is something we do on a daily basis.

*We have worked for many years to reduce risks to our site and to be prepared for emergencies.

*Our employees are highly skilled and well trained.

*Our equipment is rou
tinely inspected and tested to make sure it is safe.

*We have computer monitors and controls throughout our plants to detect potential leaks or releases before they occur.

*Hazard reviews are done for all changes. They involve "what if" scenarios where employee teams investigate every possible scenario of a new project and resolve it as part of the design phase of the project.

*Emergency response includes employee responders as well as off-site responders like LEPC, State Police and HAZMAT.

*We work closely with the police and fire departments and we conduct routine drills.

*In the event of an emergency, we are prepared to respond.

Terra has not had any accidental releases, as defined by the Risk Management Program regulations, for the last five years. The releases that Terra has had in the past five years are typically very small in nature to the air and do not meet the criteria that is stipulated in the regulations.

Terra has an extensive emergency response program both within the facility and within the community. Within the facility there is a written Emergency Response Plan (ERP). The ERP is designed as a guide to help in determining the magnitude of an incident, the steps needed to bring the incident under control and the requirements to ensure that all the federal, state, and local laws are complied with. The ERP is a definitive plan that assigns responsibilities, procedures, and coordinates with outside assistance. The plan has detailed action plans that specifically address incidents concerning chemical spills, fire, acts of nature, civil strife, area risks from outside the facility, personnel injury or fatality, and equipment failures. The plan also designates the type and frequency of training that each person is required to have depending on their responsibilities. Furthermore, the plan commits the management team to devote the necessary resources to prepare, implement and audit the ERP.

Although Terra's ERP is specifically written for th
e Terra facility, the plan is also part of the parish wide emergency response plan organized with the local LEPC. All these plans are reviewed with representatives of the LEPC, State Police, Sheriff's Department, Fire Departments, regulatory agencies and industry.

Terra is striving on a daily basis to try and make the facility as safe as possible for the employees, contractors and the community. Terra literally has safety and/or environmental training going on almost daily; every employee and contractor will attend several safety and/or environmental training meetings annually. Terra and its employees have an enduring commitment to protecting health, safety, and the environmental, and our success is accomplished by research, innovation and the use of good common sense.