houstonlogo rjilogo

The Right-to-Know Network

Back to search

Axiall Corporation, Natrium

Parent Companies:
Axiall Corporation
EPA Facility ID:
100000073868
Other ID:
26155PPGNDSTATE
Facility DUNS:
4336343
Parent Company DUNS:
120957840

Location:

Address:
15696 Energy Road
Proctor, WV 26055
County:
MARSHALL
Lat / Long:
39.748, -80.849 (Get map)
Method:
Interpolation - Photo
Description:
Plant Entrance (General)
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Axiall Corporation
Phone:
(304) 455-2200
Address:
P.O. Box 191
New Martinsville, WV 26155
Foreign Address:

Person responsible for RMP implementation:

Name:
Jerry L. Mullens
Title:
Works Manager

Emergency contact:

Name:
John M. Hirschfield
Title:
Manager EHS&S
Phone:
(304) 455-2200
24-hour phone:
(304) 455-2200
Ext or PIN:
ext. 3361

Other contacts:

Facility (or company) email:
Facility phone:
(304) 455-2200
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Marshall/Wetzel County LEPC
Full-Time Equivalent Employees:
500
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
R30-05100002-20
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Nov. 20, 2014
Inspecting Agency:
EPA
Using Predictive Filing:
No

Processes:

Chlorine Production
RMP ID:
1000065447
CBI claimed:
No
Program Level:
3
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Chemical name
CAS#
Quantity (lbs.)
CBI
Chlorine
7782-50-5
27,000,000
No
Public OCA Chemical
0
No
Sulfur Dioxide Treatment
RMP ID:
1000065448
CBI claimed:
No
Program Level:
3
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Chemical name
CAS#
Quantity (lbs.)
CBI
Sulfur dioxide (anhydrous)
7446-09-5
32,000
No
Public OCA Chemical
0
No
Caustic DH Process
RMP ID:
1000065449
CBI claimed:
No
Program Level:
3
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
85,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Stephen Gaudet
Address:
15696 Energy Road
Proctor, WV 26155
Foreign Address:

Phone:
(304) 455-2200

Latest RMP Submission:

Date:
Nov. 6, 2015
Type:
Resubmission
Reason:
Voluntary update (not described by any of the above reasons)
Registered:
Yes
RMP ID:
1000051838

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 Chlorine Production)
CBI claimed:
No
Percent weight:
Physical state:
Liquid
Model used:
PHAST Version 5.11
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 Chlorine Production)
CBI claimed:
No
Percent weight:
Physical state:
Gas
Model used:
PHAST Version 5.11
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
Public OCA Chemical (in Sulfur Dioxide Treatment)
CBI claimed:
No
Percent weight:
Physical state:
Gas
Model used:
PHAST Version 5.11
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
Public OCA Chemical (in Caustic DH Process)
CBI claimed:
No
Percent weight:
Physical state:
Gas
Model used:
PHAST Version 5.11
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. 27, 2016 at 08:25
ID:
1000047761
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
2 hours
Chemicals involved:
  • Chlorine
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
2.0 miles/h ESE
Temperature:
73.00 ℉
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:
5
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
700
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
  • Tree, lawn, shrub, or crop damage
Initiating event:
Equipment Failure
Contributing factors:
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Revised training
  • Revised emergency response plan
April 24, 2015 at 18:45
ID:
1000040241
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
5 minutes
Chemicals involved:
  • Chlorine
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
0.800000012 miles/h WNW
Temperature:
53.00 ℉
Atmospheric stability:
E
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:
3
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:
Initiating event:
Equipment Failure
Contributing factors:
  • Equipment failure
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
Dec. 11, 2013 at 13:00
ID:
1000040240
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
2 minutes
Chemicals involved:
  • Chlorine
Release events:
Gas release
Weather conditions at time of event
Wind speed:
0.300000012 miles/h NNE
Temperature:
31.00 ℉
Atmospheric stability:
E
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:
1
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:
Initiating event:
Human Error
Contributing factors:
  • Improper procedure
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Revised training
  • Revised operating procedures
July 2, 2013 at 08:30
ID:
1000040239
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
10 minutes
Chemicals involved:
  • Chlorine
Release events:
Gas release
Weather conditions at time of event
Wind speed:
0.100000001 miles/h NW
Temperature:
75.00 ℉
Atmospheric stability:
E
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:
1
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:
Initiating event:
Equipment Failure
Contributing factors:
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
May 13, 2013 at 14:00
ID:
1000040238
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
5 minutes
Chemicals involved:
  • Chlorine
Release events:
Gas release
Weather conditions at time of event
Wind speed:
5.0 miles/h E
Temperature:
50.00 ℉
Atmospheric stability:
E
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:
4
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:
Initiating event:
Human Error
Contributing factors:
  • Improper procedure
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Revised training
April 30, 2013 at 19:20
ID:
1000040237
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
5 minutes
Chemicals involved:
  • Chlorine
Release events:
Gas release
Weather conditions at time of event
Wind speed:
2.29999995 miles/h W
Temperature:
75.00 ℉
Atmospheric stability:
E
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:
1
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:
Initiating event:
Equipment Failure
Contributing factors:
  • Human error
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Revised training

7. Prevention: Program level 3

Chlorine Production, Other Basic Inorganic Chemical Manufacturing (32518)
Prevention Program ID:
1000054413
Safety Review Date
Jan. 21, 2015
PHA Update Date
Jan. 21, 2015
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Overpressurization
  • Corrosion
  • Equipment failure
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Grounding Equipment
  • Rupture Disks
Mitigation Systems
  • Enclosure
  • Neutralization
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Process Parameters
  • Process Controls
  • Perimeter Monitoring
Training Type
  • None
Competency Testing
  • None
Procedure Review Date
Sept. 16, 2015
Training Review Date
Aug. 26, 2015
Maintenance Review Date
July 6, 2015
Maintenance Inspection Date
July 16, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Sept. 14, 2015
Management of Change Review Date
Nov. 6, 2014
Pre-startup Review Date
Sept. 8, 2015
Compliance Audit Date
Aug. 31, 2015
Compliance Audit Change Completion Date
Sept. 30, 2016
Incident Investigation Date
Sept. 14, 2015
Incident Invest. Change Completion Date
Oct. 31, 2015
Participation Plan Review Date
Feb. 22, 2013
Hot Work Review Date
Feb. 26, 2013
Contractor Safety Review Date
Aug. 14, 2014
Contractor Safety Eval. Date
March 31, 2014
Sulfur Dioxide Treatment, Other Basic Inorganic Chemical Manufacturing (32518)
Prevention Program ID:
1000054414
Safety Review Date
Dec. 12, 2013
PHA Update Date
Oct. 18, 2011
PHA Techniques
  • HAZOP
Hazards Identified
  • Overpressurization
  • Corrosion
  • Equipment failure
  • Cooling loss
Process Controls
  • Scrubbers
  • Manual Shutoffs
  • Alarms
  • Emergency Air Supply
  • Rupture Disks
Mitigation Systems
  • Neutralization
Monitoring Systems
  • Perimeter Monitors
Changes since PHA
  • Reduced Inventory
  • Perimeter Monitoring
Training Type
  • None
Competency Testing
  • None
Procedure Review Date
June 25, 2015
Training Review Date
Dec. 10, 2014
Maintenance Review Date
July 6, 2015
Maintenance Inspection Date
Dec. 27, 2011
Equipment Tested
Yes
Management of Change Most Recent Date
June 5, 2015
Management of Change Review Date
June 13, 2013
Pre-startup Review Date
June 10, 2015
Compliance Audit Date
Aug. 31, 2015
Compliance Audit Change Completion Date
Sept. 30, 2016
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Feb. 22, 2013
Hot Work Review Date
Feb. 26, 2013
Contractor Safety Review Date
Aug. 4, 2014
Contractor Safety Eval. Date
March 31, 2014
Caustic DH Process, Other Basic Inorganic Chemical Manufacturing (32518)
Prevention Program ID:
1000054415
Safety Review Date
June 10, 2013
PHA Update Date
April 29, 2011
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
Mitigation Systems
  • Sprinkler System
Monitoring Systems
  • Perimeter Monitors
Changes since PHA
  • Process Detection
  • Perimeter Monitoring
Training Type
  • None
Competency Testing
  • None
Procedure Review Date
Sept. 1, 2015
Training Review Date
Jan. 16, 2015
Maintenance Review Date
July 6, 2015
Maintenance Inspection Date
July 7, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Aug. 27, 2015
Management of Change Review Date
Nov. 6, 2014
Pre-startup Review Date
Aug. 27, 2015
Compliance Audit Date
Aug. 31, 2015
Compliance Audit Change Completion Date
Sept. 30, 2016
Incident Investigation Date
May 4, 2015
Incident Invest. Change Completion Date
July 13, 2015
Participation Plan Review Date
Feb. 22, 2013
Hot Work Review Date
Feb. 26, 2013
Contractor Safety Review Date
Aug. 14, 2014
Contractor Safety Eval. Date
March 31, 2014

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:
June 15, 2015
Local Response Agency:
Local Response Agency Phone:
(304) 455-2200
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



Axiall Corporation, Natrium Facility



Accidental release prevention and emergency response policies



The Axiall Natrium facility complies with OSHA's Process Safety Management Rule (29 CFR 1910.119), applicable Federal and State Regulations, and applicable Coast Guard and Department of Transportation requirements. Axiall also follows the Responsible Care® Codes of Management Practice, including the Responsible Care® Community Awareness Code of Management Practice, and Axiall's own Community Awareness and Emergency Response (CAER) Policy to assure emergency preparedness and foster community right-to-know. Axiall's CAER Policy requires each manufacturing plant to have a pro-active community awareness and emergency response program to handle emergencies that might happen in that facility. All of these activities form an integral part of Axiall's overall Environment, Health and Safety Policy, which is to "operate and maintain its facilities according to the Guiding Principles of Responsible Care in compliance with all local, state, provincial, and national laws governing Environmental, Health, Safety and Security (EHS&S). All Company operations shall be managed in a manner that protects employees, surrounding

communities, the environment, and physical assets and strives for continuous improvement in our performance."



Regulated substances handled



The Natrium facility is part of the Chlor-Alkali business group of Axiall Corporation. Natrium is a principle producer of chlorine, sodium hydroxide, hydrochloric acid and calcium hypochlorite. Chlorine and sodium hydroxide are produced concurrently by the electrolysis of salt dissolved in water in either a mercury cell or diaphragm cell. Chlorine is used in the purification of drinking water, wastewater treatment, and several household products and as a powerful disinfectant. Chlorine is widely used in the manufacture of many synthetic chemicals such as chlorinated solvents, refrig
erants, pesticides, synthetic rubber, and household cleaners. The Natrium facility has three applicable RMP toxic chemicals including chlorine, anhydrous ammonia and sulfur dioxide.



Worst-case and alternative case release scenarios



An off-site consequence analysis was performed for the largest quantities of flammable and toxic materials in the facility. The Natrium facility has no RMP applicable flammable chemicals. The guidelines and Off-site Consequence Analysis Guidance as per 40 CFR 68.25 were utilized in this process. Natrium used commercial software titled PHAST Professional, version 5.11, to determine off-site impacts from both the worst-case and alternative release scenarios.



EPA rules require that a worst case scenario be analyzed which would involve the highly unlikely release in ten minutes of the entire contents of the largest storage container. Based on dispersion modeling using PHAST 5.11 software and the EPA specified assumptions, off-site concentrations of chlorine would cause off-site impact.



Alternative case release scenarios (ACRS) were developed for each of the listed chemicals in the facility. These scenarios followed the guidelines provided by EPA and used PHAST software to perform the end-point calculations. The local emergency planning committee and office of emergency planning will utilize the ACRS information in conjunction with Axiall experts to develop emergency response plans, train responders, perform practice drills and maintain the appropriate equipment.



The ACRS for chlorine evaluated a scenario where a chlorine railcar is moved during loading and a loading line is ruptured. The quantity released of 376 pounds would be limited by check valves and automatic shutoff valves. No off-site impacts result from this scenario.



The ACRS for anhydrous ammonia evaluated a scenario where a liquid ammonia unloading hose ruptures during truck unloading. The amount of ammonia released of 300 pounds would be limited by pro
cess check valves and excess flow valves. No off-site impacts result from this scenario.



The ACRS for sulfur dioxide evaluated a scenario where a sulfur dioxide line develops a leak in a half inch line instrument fitting. The operator would discover the leak on equipment rounds and isolate the leak. The release rate would be 585 pounds over a 30 minute period. No off-site impacts result from this scenario.



General accidental release prevention program and chemical specific prevention steps



Trained personnel and environmental, health and safety measures are included in all phases of the Natrium facility operation. Detailed engineering and design standards are used. These standards may include national codes and standards, quality assurance inspections, over pressure protection systems, flammable and toxic gas detectors, emergency shutdown systems, a fire water system and computer controls for the processes. Employees at the facility receive job-appropriate training. Training is an ongoing process that includes periodic retraining, as appropriate. Safety, environmental, operating and training procedures are subject to periodic reviews and updates. Additionally Management of Change (MOC) procedures assure review of proposed changes and ensure that training needs are met. Operators and foremen actively participate with engineers that lead process hazard analyses to review potential hazards and to recommend additional safeguards if needed.



The Natrium facility has an array of maintenance and inspection programs to minimize equipment or piping failures. Inspections of equipment are scheduled at a frequency related to the equipment condition, the severity of the service environment, the required reliability or the manufacturers recommended schedule. Equipment inspections utilize procedures such as proof testing where safeguard systems are forced to function in a controlled manner. This assures that the safeguards will function as intended if neede
d. Preventive and predictive maintenance programs are utilized and can include vibration monitoring, infrared imaging to detect differences in temperature, inspections by independent experts, inspections by insurance specialists and a root-cause analysis program. Piping systems are inspected and tested with X-rays and/or hydrostatic tests. The piping is monitored by a variety of methods. Training and procedures have been developed for activities that are specific to different types of equipment.



Five-year accident history



The Natrium facility has had ten recordable injuries associated with a release of an RMP applicable chemical in the last five years. The incidents involved the release of chlorine and resulted in only minor inhalation injuries on-site. There were no off-site impacts.



Emergency response program



The Natrium facility maintains an Emergency Response Manual which addresses emergency planning and response. The Natrium facility has a trained on-site Emergency Response Team that is HAZWOPER certified and available for around the clock response to emergency incidents, provide emergency medical attention, fight fires, control chemical releases, and initiate road blocks and/or public emergency procedures. Additionally, Natrium participates in regularly scheduled meetings with a Community Advisory Panel (CAP) and emergency responders regarding emergency response for the community. There are also community emergency alarm systems in place at the facility to alert the public of an evacuation or shelter-in-place activation.



Planned changes to improve safety



Axiall is committed to the process of continuous improvement. This commitment extends beyond production into the environmental and safety aspects of all operations. For further information, contact Mr. Jerry L. Mullens, Works Manager, Natrium Facility at (304) 455-2200.



In addition to the Emergency Contact Person identified in section 1.8, Plant Security may be contacted at the
same number provided at extension 3361.



Additional information about Axiall Corporation can also be obtained at our Axiall website located at www.axiall.com.