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DPC INDUSTRIES, INC.

Parent Companies:
DX HOLDING COMPANY
EPA Facility ID:
100000084892
Other ID:
Facility DUNS:
103980645
Parent Company DUNS:
798366763

Location:

Address:
355 HARMON McDONALD ROAD
MONROE, LA 71202
County:
OUACHITA
Lat / Long:
32.405, -92.114 (Get map)
Method:
GPS - Unspecified
Description:
Center of Facility
Horizonal accuracy:
100 m
Horizontal reference datum:
World Geodetic System of 1984
Source map scale:

Owner/Operator:

Name:
DPC INDUSTRIES, INC.
Phone:
(281) 457-4835
Address:
P.O. BOX 24600
HOUSTON, TX 77229 -4600
Foreign Address:

Person responsible for RMP implementation:

Name:
JOY MONTANIO
Title:
REGULATORY AFFAIRS MGR

Emergency contact:

Name:
GARY LITTLE
Title:
REGIONAL OPERATIONS MANAGER
Phone:
(817) 641-4712
24-hour phone:
(281) 457-4888
Ext or PIN:
Email:
N/A

Other contacts:

Facility (or company) email:
Facility phone:
(281) 457-4835
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
OUACHITA COUNTY LEPC
Full-Time Equivalent Employees:
1
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:
July 18, 2012
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

COMPRESSED GAS STORAGE
RMP ID:
1000080277
CBI claimed:
No
Program Level:
3
NAICS:
Other Chemical and Allied Products Merchant Wholesalers (42469)
Chemical name
CAS#
Quantity (lbs.)
CBI
Chlorine
7782-50-5
77,500
No
Sulfur dioxide (anhydrous)
7446-09-5
15,300
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 12, 2017
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000063980

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 COMPRESSED GAS STORAGE)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
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 COMPRESSED GAS STORAGE)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
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
Public OCA Chemical (in COMPRESSED GAS STORAGE)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
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

None

5. Flammables: Alternative release

None

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

COMPRESSED GAS STORAGE, Other Chemical and Allied Products Merchant Wholesalers (42469)
Prevention Program ID:
1000067514
Safety Review Date
Sept. 3, 2015, since latest RMP submission
PHA Update Date
Jan. 15, 2013, since latest RMP submission
PHA Techniques
  • Checklist
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Contamination
  • Equipment failure
  • Earthquake
  • Tornado
  • Hurricanes
Process Controls
  • Alarms
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • None
Procedure Review Date
Feb. 28, 2017, since latest RMP submission
Training Review Date
Nov. 21, 2014, since latest RMP submission
Maintenance Review Date
Jan. 6, 2016, since latest RMP submission
Maintenance Inspection Date
Feb. 6, 2017, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 17, 2015
Management of Change Review Date
Nov. 1, 2016
Pre-startup Review Date
None
Compliance Audit Date
May 7, 2015
Compliance Audit Change Completion Date
None
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Sept. 3, 2015
Hot Work Review Date
Nov. 20, 2014
Contractor Safety Review Date
March 21, 2016, since latest RMP submission
Contractor Safety Eval. Date
March 1, 2016, 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. 18, 2017
Local Response Agency:
Local Response Agency Phone:
(318) 343-1122
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:
No
Subject To - Other:

Executive Summary

LDEQ FACILITY NUMBER: 23665



EXECUTIVE SUMMARY



Accidental Release Prevention and Emergency Response Policies

The Company is strongly committed to employee, public and environmental safety. This commitment is demonstrated by our comprehensive accidental release prevention program that covers areas such as design, installation, operating procedures, maintenance, and employee training associated with the processes at our facility. It is company policy to comply with all applicable federal, state, and local regulations as well as implement appropriate controls to prevent possible releases of regulated substances.



The facility's emergency response program includes procedures for notification of the local fire department; notification of any potentially affected neighbors; and notification of local, state and federal agencies. Safety is an essential part of facility operations as evidenced by the safety devices built-in to the design of this facility, the safe handling procedures that we use, and the extensive training of our personnel.



The Stationary Source

The facility's primary activities include distributing and repackaging inorganic chemicals including compressed gases for use in water and wastewater treatment.



The Process Safety Management Program

The Company has taken all the necessary steps to comply with the accidental release prevention requirements set out under 40 CFR Part 68 of the EPA. A number of processes at this facility are subject to the OSHA PSM standard under 29 CFR 1910.119. The following sections briefly describe the elements of the release prevention program that is in place at this stationary source.





Process Safety Information

The facility maintains a detailed record of safety information that describes the chemical hazards, operating parameters and equipment designs associated with all processes.



Process Hazard Analysis

The facility conducts comprehensive studies to ensure that hazards associated with our processes
are identified and controlled efficiently. Through implementation of PSM/RMP program, DPC has utilized several different methodologies over the years to complete these analyses including the What-if, Hazop (Hazard and Operability Study), Checklist as well as a Hazop/Checklist (combined) approach. The studies were undertaken by a team of qualified personnel with expertise in engineering and process operations and are revalidated every five years as required or as necessary. Findings and recommendations assigned from the hazard analysis are documented within the electronic management system and completed in a timely manner.



Operating Procedures

For the purposes of safely conducting activities within the covered processes, the facility maintains written operating procedures. These procedures address various modes of operation such as initial startup, normal operations, temporary operations, emergency shutdown, emergency operations, and normal shutdown. The information is regularly reviewed and is readily accessible to operators involved in the processes.



Training

The facility has a comprehensive training program in place to ensure that all Company employees and any contractor employees, if appropriate, involved in production for covered processes are subject to the Company training program. All maintenance training for these covered processes is addressed in the Mechanical Integrity Policy. Refresher training is provided at least every three years and more frequently as needed.



Mechanical Integrity

The facility carries out highly documented maintenance checks on process equipment to ensure proper operations. A maintenance procedure and associated checklist(s) are attached to work orders that are printed out of the electronic management system. A documented review of the procedure is required prior to the start of each job. This review is to ensure the employee has the knowledge and skills necessary to complete the task and that he/she understands
the requirements. Process equipment examined by these checks includes among others; pressure vessels, storage tanks, piping systems, relief and vent systems, emergency shutdown systems, controls and pumps. Any equipment deficiencies identified by the maintenance checks are documented and completed work orders are uploaded into the electronic management system.



Management of Change

Written procedures are in place at the facility to manage changes in process chemicals, technology, equipment and procedures. MOC will address both permanent and temporary changes. Temporary changes will be considered in the same manner as permanent changes. To ensure affected personnel are aware of changes made to the facility, MOC(s) will be reviewed and documented through the training roster. MOCs will be initiated and completed through an electronic management system.



Pre-startup Reviews

A Pre-Startup Safety Review (PSSR) will be performed for significant MOCs, for new processes regulated under OSHA's PSM standard (29 CFR 1910.119) and processes covered under EPA's RMP Program under 40 CFR 68 as well as modified existing covered processes when the modification is significant enough to require a change in the process safety information. These reviews are conducted to confirm that construction, equipment, operating and maintenance procedures are suitable for safe startup prior to placing equipment into operation. Records of the PSSR shall be maintained in the electronic management system.



Compliance Audits

The Company conducts an audit at the facility using an audit template which serves as the verification sheet providing the auditors with the necessary information to expedite the review of the program and ensure all requirements of the standards are met. The audit is completed every 3-years and is certified as required. All deficiencies and recommendations will be completed and tracked within the electronic management system.



Incident Investigation

The Company
shall investigate each incident which results in, or might possibly result in a catastrophic release of a regulated chemical in the workplace. These investigations are undertaken to identify the situation leading to the incident as well as any corrective actions to prevent the release from reoccurring. An incident investigation shall be initiated as promptly as possible, but no later than 48 hours following the incident. The incident investigation and report will be processed through the electronic management system.



Employee Participation

The Company believes that process safety management and accident prevention is a team effort. Facility employees are encouraged to express their views concerning accident prevention issues and to recommend improvements. In addition, our employees have access to all information created as part of the facility's implementation of the RMP rule, including information resulting from process hazard analyses in particular.



Contractors

On occasion, the company hires contractors to conduct specialized maintenance and construction activities. Prior to selecting a contractor, a thorough evaluation of safety performance of the contractor is carried out. The company has a strict policy of informing the contractors of known potential hazards related the contractor's work and the processes. Contractors are also informed of all the procedures for emergency response should an accidental release of a regulated substance occur.



Five-year Accident History

There have been no reportable releases of a regulated substance from this facility this period.



Emergency Response Plan

The facility maintains a written emergency response plan to deal with accidental releases of hazardous materials. The plan includes all aspects of emergency response including first aid and medical treatment, evacuations, notification of local emergency response agencies and the public, as well as post-incident decontamination of affected areas. To ensure
proper functioning, emergency response equipment is regularly inspected and serviced. In addition, the plan is promptly updated to reflect any pertinent changes taking place within our processes that would require a modified emergency response.



Local responders are invited to tour the facility and meet facility personnel on a regular basis. In addition, it is Company policy for site personnel to participate in the Local Emergency Planning Committee (LEPC). A copy of the emergency response plan is offered to the fire department and LEPC.



Planned Changes to Improve Safety

Through our ongoing implementation of the PSM/RMP program, the Company looks continuously for possible system changes to improve our operations. This is demonstrated in our active participation in Chlorine Institute programs which many regulators consider Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) for our operations.