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Honeywell International Inc., Geismar Plant

Parent Companies:
Honeywell International Inc.
EPA Facility ID:
100000085061
Other ID:
70734LLDSGHWY31
Facility DUNS:
41519067
Parent Company DUNS:
41519067

Location:

Address:
P.O. Box 226
Geismar, LA 70734
County:
ASCENSION
Lat / Long:
30.228, -91.054 (Get map)
Method:
GPS - Unspecified
Description:
Plant Entrance (General)
Horizonal accuracy:
10 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Honeywell International Inc.
Phone:
(973) 455-2000
Address:
P.O. Box 226
5525 Highway 3115
Geismar, LA 70734
Foreign Address:

Person responsible for RMP implementation:

Name:
Ronald Snell
Title:
Chemical Plant Manager

Emergency contact:

Name:
Jason Ayres
Title:
HSE Manager
Phone:
(225) 642-3570
24-hour phone:
(225) 907-4522
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(225) 642-8311
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Ascension Parish LEPC
Full-Time Equivalent Employees:
430
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
0180-00003-V1,
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Dec. 9, 2016
Inspecting Agency:
State Environmental Agency
Using Predictive Filing:
No

Processes:

Aclon (TM) Resin Plant
RMP ID:
1000075486
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Trifluorochloroethylene [Ethene, chlorotrifluoro-]
79-38-9
164,000
No
Vinylidene fluoride [Ethene, 1,1-difluoro-]
75-38-7
24,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Hydrogen Fluoride Plant
RMP ID:
1000075487
CBI claimed:
No
Program Level:
3
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Chemical name
CAS#
Quantity (lbs.)
CBI
Oleum (Fuming Sulfuric acid) [Sulfuric acid, mixture with sulfur trioxide]
8014-95-7
2,000,000
No
Boron trifluoride [Borane, trifluoro-]
7637-07-2
120,000
No
Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
7664-39-3
17,000,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
125 Plant
RMP ID:
1000075488
CBI claimed:
No
Program Level:
3
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
7664-39-3
125,000
No
Public OCA Chemical
0
No
245fa Plant
RMP ID:
1000075489
CBI claimed:
No
Program Level:
3
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
7664-39-3
125,000
No
Chlorine
7782-50-5
430,000
No
Chloroform [Methane, trichloro-]
67-66-3
60,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
1234yf Plant
RMP ID:
1000075490
CBI claimed:
No
Program Level:
3
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Chlorine
7782-50-5
4,800
No
Hydrochloric acid (conc 37% or greater)
7647-01-0
13,000,000
No
Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
7664-39-3
100,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Stuart Boone
Address:
5525 Highway 3115
P.O. Box 226
Geismar, LA 70764 -0226
Foreign Address:

Phone:
(225) 642-3550

Latest RMP Submission:

Date:
Feb. 13, 2017
Type:
Resubmission
Reason:
Voluntary update (not described by any of the above reasons)
Registered:
Yes
RMP ID:
1000060458

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 Hydrogen Fluoride Plant)
CBI claimed:
No
Percent weight:
100.0
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:
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 Hydrogen Fluoride Plant)
CBI claimed:
No
Percent weight:
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • Dikes
not considered:
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Hydrogen Fluoride Plant)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
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 Hydrogen Fluoride Plant)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
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:
  • Deluge systems
not considered:
  • Sprinkler systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in 245fa Plant)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
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 245fa Plant)
CBI claimed:
No
Percent weight:
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • Berms
not considered:
  • Dikes
  • Enclosures
  • 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 1234yf Plant)
CBI claimed:
No
Percent weight:
38.0
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
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

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 Aclon (TM) Resin Plant)
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 Aclon (TM) Resin Plant)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve
Public OCA Chemical (in Aclon (TM) Resin Plant)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

May 22, 2017 at 20:31
ID:
1000051579
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Duration:
12 minutes
Chemicals involved:
  • Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
24.0 miles/h S
Temperature:
68.00 ℉
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:
2
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:
Notified Only
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised training
  • Revised operating procedures
May 15, 2017 at 20:00
ID:
1000051578
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
1 minutes
Chemicals involved:
  • Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
27.0 miles/h ENE
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:
Human Error
Contributing factors:
  • Upset condition
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Revised training
  • New process controls
April 11, 2017 at 22:30
ID:
1000051577
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
1 minutes
Chemicals involved:
  • Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
30.0 miles/h WSW
Temperature:
62.00 ℉
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:
  • Maintenance activity/inactivity
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Revised training
Dec. 10, 2016 at 16:30
ID:
1000047691
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
4 minutes
Chemicals involved:
  • Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
Release events:
Gas release
Weather conditions at time of event
Wind speed:
4.30000019 miles/h SE
Temperature:
49.00 ℉
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:
0
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:
137
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
Off-site responders notified:
Notified Only
Changes introduced as a result of the accident:
  • None
Nov. 2, 2016 at 20:04
ID:
1000047689
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
1 minutes
Chemicals involved:
  • Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
None
Temperature:
None ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
Yes
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:
  • Upset condition
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Revised training
  • Revised operating procedures
Aug. 27, 2016 at 11:45
ID:
1000047688
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
1 minutes
Chemicals involved:
  • Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
None
Temperature:
None ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
Yes
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:
  • Unsuitable equipment
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised training
  • Revised operating procedures
Aug. 13, 2016 at 17:00
ID:
1000047957
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
5 hours and 30 minutes
Chemicals involved:
  • Oleum (Fuming Sulfuric acid) [Sulfuric acid, mixture with sulfur trioxide]
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
7.0 miles/h S
Temperature:
77.00 ℉
Atmospheric stability:
Precipitation present:
Yes
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:
0
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$298096
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
896
Property damage:
$70000
Environmental damage:
  • Fish or animal kills
  • Tree, lawn, shrub, or crop damage
  • Water contamination
  • Soil Contamination
Initiating event:
Equipment Failure
Contributing factors:
  • Equipment failure
  • Unsuitable equipment
  • Unusual weather conditions
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised maintenance
  • Revised training
  • Revised operating procedures
  • New process controls
  • New mitigation systems
  • Changed process
March 2, 2016 at 13:15
ID:
1000046625
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Duration:
1 minutes
Chemicals involved:
  • Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
4.5999999 miles/h NW
Temperature:
75.00 ℉
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:
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:
  • Human error
  • Improper procedure
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Revised maintenance
  • Revised training
  • Revised operating procedures
Dec. 18, 2014 at 07:28
ID:
1000046621
NAICS:
Other Basic Inorganic Chemical Manufacturing (32518)
Duration:
1 hours
Chemicals involved:
  • Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
7.0 miles/h E
Temperature:
58.00 ℉
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:
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:
  • Maintenance activity/inactivity
Off-site responders notified:
Notified Only
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised maintenance
  • Revised operating procedures
Aug. 7, 2013 at 19:30
ID:
1000046619
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Duration:
5 minutes
Chemicals involved:
  • Chlorine
Release events:
Gas release
Weather conditions at time of event
Wind speed:
2.0 miles/h NW
Temperature:
91.00 ℉
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:
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:
  • Equipment failure
  • Human error
  • Improper procedure
  • By-pass condition
  • Maintenance activity/inactivity
Off-site responders notified:
Notified Only
Changes introduced as a result of the accident:
  • Revised maintenance
  • Revised training
  • Revised operating procedures
May 15, 2012 at 00:45
ID:
1000046618
NAICS:
All Other Chemical Product and Preparation Manufacturing (32599)
Duration:
1 minutes
Chemicals involved:
  • Hydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
None
Temperature:
None ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
Yes
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:
  • Human error
  • Improper procedure
  • Maintenance activity/inactivity
  • Unsuitable equipment
Off-site responders notified:
No, not notified
Changes introduced as a result of the accident:
  • Revised maintenance
  • Revised training

7. Prevention: Program level 3

Aclon (TM) Resin Plant, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000063452
Safety Review Date
May 17, 2016, since latest RMP submission
PHA Update Date
Feb. 26, 2015, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Polymerization
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Rupture Disks
  • Excess Flow Device
  • Purge System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
April 26, 2016, since latest RMP submission
Training Review Date
April 28, 2016, since latest RMP submission
Maintenance Review Date
April 26, 2016, since latest RMP submission
Maintenance Inspection Date
April 20, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 21, 2016
Management of Change Review Date
March 14, 2016
Pre-startup Review Date
Feb. 4, 2016
Compliance Audit Date
Dec. 9, 2015
Compliance Audit Change Completion Date
Nov. 30, 2019
Incident Investigation Date
April 11, 2016
Incident Invest. Change Completion Date
Dec. 31, 2016
Participation Plan Review Date
June 30, 2015
Hot Work Review Date
July 20, 2015
Contractor Safety Review Date
Oct. 30, 2015, since latest RMP submission
Contractor Safety Eval. Date
March 26, 2016, since latest RMP submission
Hydrogen Fluoride Plant, Other Basic Inorganic Chemical Manufacturing (32518)
Prevention Program ID:
1000063451
Safety Review Date
March 14, 2016, since latest RMP submission
PHA Update Date
Feb. 22, 2016, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Grounding Equipment
  • Rupture Disks
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
April 28, 2016, since latest RMP submission
Training Review Date
April 28, 2016, since latest RMP submission
Maintenance Review Date
April 26, 2016, since latest RMP submission
Maintenance Inspection Date
April 22, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 12, 2016
Management of Change Review Date
March 14, 2016
Pre-startup Review Date
April 1, 2016
Compliance Audit Date
Dec. 9, 2015
Compliance Audit Change Completion Date
Nov. 30, 2019
Incident Investigation Date
April 11, 2016
Incident Invest. Change Completion Date
Dec. 31, 2016
Participation Plan Review Date
June 30, 2015
Hot Work Review Date
July 20, 2015
Contractor Safety Review Date
Oct. 30, 2015, since latest RMP submission
Contractor Safety Eval. Date
March 26, 2016, since latest RMP submission
125 Plant, All Other Basic Organic Chemical Manufacturing (325199)
Prevention Program ID:
1000063453
Safety Review Date
May 12, 2016, since latest RMP submission
PHA Update Date
Jan. 21, 2014, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • 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
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
April 25, 2016, since latest RMP submission
Training Review Date
April 28, 2016, since latest RMP submission
Maintenance Review Date
April 26, 2016, since latest RMP submission
Maintenance Inspection Date
April 11, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 20, 2016
Management of Change Review Date
Feb. 14, 2016
Pre-startup Review Date
April 13, 2016
Compliance Audit Date
Dec. 9, 2015
Compliance Audit Change Completion Date
Nov. 30, 2019
Incident Investigation Date
April 11, 2016
Incident Invest. Change Completion Date
Dec. 31, 2016
Participation Plan Review Date
June 30, 2015
Hot Work Review Date
July 20, 2015
Contractor Safety Review Date
Oct. 30, 2015, since latest RMP submission
Contractor Safety Eval. Date
March 26, 2016, since latest RMP submission
245fa Plant, All Other Basic Organic Chemical Manufacturing (325199)
Prevention Program ID:
1000063454
Safety Review Date
May 17, 2016, since latest RMP submission
PHA Update Date
May 17, 2016, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • 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
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
April 15, 2016, since latest RMP submission
Training Review Date
April 28, 2016, since latest RMP submission
Maintenance Review Date
April 26, 2016, since latest RMP submission
Maintenance Inspection Date
April 20, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 30, 2016
Management of Change Review Date
March 14, 2016
Pre-startup Review Date
March 16, 2016
Compliance Audit Date
Dec. 9, 2015
Compliance Audit Change Completion Date
Nov. 30, 2019
Incident Investigation Date
April 11, 2016
Incident Invest. Change Completion Date
Dec. 31, 2016
Participation Plan Review Date
June 30, 2015
Hot Work Review Date
July 20, 2015
Contractor Safety Review Date
Oct. 30, 2015, since latest RMP submission
Contractor Safety Eval. Date
March 26, 2016, since latest RMP submission
1234yf Plant, All Other Basic Organic Chemical Manufacturing (325199)
Prevention Program ID:
1000063455
Safety Review Date
March 21, 2016, since latest RMP submission
PHA Update Date
March 1, 2016, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • None
Procedure Review Date
March 1, 2016, since latest RMP submission
Training Review Date
April 28, 2016, since latest RMP submission
Maintenance Review Date
April 26, 2016, since latest RMP submission
Maintenance Inspection Date
April 22, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 13, 2016
Management of Change Review Date
March 14, 2016
Pre-startup Review Date
April 20, 2016
Compliance Audit Date
Dec. 9, 2015
Compliance Audit Change Completion Date
Nov. 30, 2019
Incident Investigation Date
March 3, 2016
Incident Invest. Change Completion Date
April 15, 2016
Participation Plan Review Date
June 30, 2015
Hot Work Review Date
July 20, 2015
Contractor Safety Review Date
Oct. 30, 2015, since latest RMP submission
Contractor Safety Eval. Date
March 26, 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:
May 3, 2016
Local Response Agency:
Local Response Agency Phone:
(225) 621-8360
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*Submit: Executive Summary

Honeywell Geismar Plant



1000 0008 5061 EPA RMP Facility Identifier

2082 LDEQ Facility ID Number



About Honeywell

The Geismar plant is a manufacturing facility located in Geismar, Louisiana. It is part of the Performance Materials and Technology business group of Honeywell International Inc.



Honeywell (NYSE: HON) is a Fortune 100 company that invents and manufactures technologies to address tough challenges linked to global megatrends such as safety, security, and energy. With approximately 130,000 employees worldwide, including 19,000 engineers and scientists, we have an unrelenting focus on quality, delivery, value, and technology in everything we make and do.



Honeywell is a diversified technology and manufacturing leader, serving customers worldwide with aerospace products and services; control technologies for buildings, homes and industry; automotive products; turbochargers; and specialty materials. Headquartered in Morris Township, N.J., Honeywell's shares are traded on the New York, London, Chicago and Pacific Stock Exchanges.



Honeywell Specialty Materials, also based in Morris Township, N.J., is a Honeywell business group and a global leader in providing high-performance specialty materials such as fluorocarbons, specialty films, advanced fibers, customized research chemicals and intermediates.



Health, Safety and Environment/Responsible Care



Honeywell is committed to managing health, safety and the environment as a core business value. The company also integrates health, safety and environmental management into all aspects of our businesses as a competitive advantage in achieving profitable growth and accelerated productivity.



Honeywell participates in the Responsible Care program of the American Chemistry Council. Established in 1988, Responsible Care is a voluntary program focused on achieving improvements in environmental, health and safety performance beyond levels required by the U.S. government




In addition to detailing practices for the safe use of materials and requiring audits, the Responsible Care initiative requires its member and partner companies to develop mechanisms for outreach with the communities in which they operate. Community Advisory Panels (CAP) serve as important links between chemical facilities and their neighboring communities.



Honeywell Geismar Plant

The Honeywell Geismar Plant is an inorganic acid, refrigerant and fluoropolymer resin manufacturing facility that has approximately 280 employees. The plant's products are used to make refrigerants, fluorocarbons, high octane gasoline, pharmaceutical films, foam insulation, and other chemical derivatives.



Some of the materials stored and used by the facility are hydrogen fluoride, oleum, chlorine, hydrogen chloride, trifluorochloroethylene, boron trifluoride, vinylidene fluoride, chloroform and other chemicals which are on the RMP Rule's list of regulated substances. The Honeywell Geismar Plant's storage and use of these substances exceeds the specified threshold quantities as defined by the EPA's RMP Rule.



In accordance with the requirements of the RMP Rule, a description of the following six elements is provided for the Honeywell Geismar Plant:



1) Accidental Release Prevention and Emergency Response Policies:



It is the policy of the Honeywell Geismar Plant to operate a safe and environmentally sound facility by identifying and controlling health, safety, and environmental risks related to its operations; by designing its processes to protect people, property and the environment; by conducting and continually reviewing and improving programs for safety, health and environmental excellence; and by establishing processes to assure that all laws and regulations applicable to its operations and products are known and observed. The accidental release prevention and emergency response policy associated specifically with the plant's use of hydrogen fluoride, oleum, chlorine, hydr
ogen chloride, trifluorochloroethylene, boron trifluoride, vinylidene fluoride, and chloroform involves the integration of safety devices and technologies inherent in the design of the process, safe operational procedures and management practices, operator training, the preparation and testing of site

emergency response plans, the maintenance of onsite emergency response equipment and a professionally trained Safety Brigade, coordinating our efforts and resources with local emergency response services, and communicating with the community.



2) Description of the Facility and the Regulated Substance Handled:



The Honeywell Geismar Plant is located primarily in Ascension Parish on the Mississippi River at Mile 187.0 and is bounded by highways 75, 3115 and 30. Honeywell shares the site with three other chemical manufacturing facilities. The area is predominately rural with adjacent and nearby chemical manufacturing facilities. There are no immediate residential neighbors. The plant employs approximately 180 company and about 90 contract workers.



The Honeywell Geismar Plant's five covered processes manufacture new generation ozone friendly refrigerants, inorganic acids and fluoropolymer resin. The Hydrogen Fluoride Plant manufactures hydrogen fluoride. The Multiproducts Plant was converted to a 1234yf manfucaturing plant in 2016 The 1234yf manufacturing plant will produce 1,1,1,2-tetrafluoroproene (HFO-1234yf). The Aclon Resin Plant manufactures fluoropolymer resin. The 125 Plant manufactures pentafluroethane (HFC 125). The 245fa Plant manufactures 1,1,1,3,3-pentafluoropropane (HFC 245fa).



Anhydrous hydrogen fluoride is used as a raw material in the manufacture of refrigerants, fluorocarbons, gasoline, as well as other chemical derivatives. Aqueous solutions of hydrogen fluoride are used in the manufacture of electronic components, circuit boards, steel, high-purity quartz, light bulbs televisions, and computer monitors.



HFC 125 is used as a refrigerant in
residential air conditioners and commercial refrigeration units such as supermarket freezers, display cases and ice machines. HCFC 124 is used in medical sterilants, rigid foam insulation manufacturing and in medium temperature refrigeration blends.HFO-1234yf is used as a refrigerant in automobile applications and is a direct replacement for HFC-134a.



Aclon Resin is used in the manufacture of film used in medicinal and food bubble packaging.



HFC 245fa is used as a foam blowing agent in the manufacture of rigid foam insulation. Because the Geismar site stores and uses hydrogen fluoride, oleum, chlorine, trifluorochloroethylene, boron trifluoride, vinylidene fluoride, and chloroform in more than the threshold quantities specified in the EPA Risk Management Program (RMP) regulation the site is covered by the regulation.



3) The General Accidental Release Prevention Program and Chemical-Specific Prevention Steps:



The general accidental release prevention program at the Honeywell Geismar Site for the affected stationary sources includes the following elements:



a) established process safety management system for oversight and control of the manufacturing processes,

b) process design review to minimize hazard potentials,

c) computer controlled processes with sophisticated interlock and shutdown protocols,

d) development and implementation of accurate procedures for safe operation and maintenance of the process,

e) documented process safety information describing operating limits, control points and consequences of deviations,

f) a system to review and manage changes to the processes and process safety information,

g) an on-going mechanical integrity program that ensures critical process equipment is designed, constructed, and installed in accordance to codes and standards,

h) formalized, documented inspection protocols integrated with preventive and predictive maintenance programs such as vessel thickness testing and non destructive testing to ensure
the reliability of equipment,

i) performance of process hazards analyses with prompt resolution of any recommendations,

j) use of safety shutdown, relief and vent systems, interlocks, dikes and other secondary containment installations, control instrumentation, and process monitoring for early warning and detection,

k) performance of incidence investigations to establish root causes and identify corrective actions,

l) process safety compliance audits,

m) safety reviews of new or modified processes prior to activation,

n) involvement of employees in development of operating procedures, process audits, incident investigations,

o) contractor qualification programs which evaluate long term contractor safety performance and work qualifications,

p) contractor work requirements which include pre-service orientation of supervisors and employees, regular self-audits and incident investigation and correction,

q) comprehensive general and process-specific training programs for process operators and maintenance personnel, and

r) Provision of safe havens for critical control functions to allow for orderly shutdown of processes should an incident occur.



Chemical specific prevention steps include:

a) designing the process technology and process equipment based on a thorough understanding of the hazardous properties of all hazardous chemicals,

b) developing an understanding among the operators for the hazardous properties of all hazardous chemicals, the process chemistry and safe operational process limits such as temperatures, pressures, and flows,

c) understanding the consequences of unsafe chemical handling, process deviations and inadvertent mixing of incompatible chemicals,

d) continuous review of process, response and mitigation technologies,

e) designing and installing active and passive mitigation facilities such as vapor absorbing water spray systems, rapid inventory transfer systems, liquid containment dikes and closed circuit monitoring systems

f) clea
r labeling of all vessels and containers to ensure contents are known,

g) having knowledge of the requirements, capabilities and limitations of both personal protective and emergency response equipment and maintaining easily accessible inventories of each hazardous chemical, and

h) maintaining a response team trained to a high level of readiness.



4) The Five Year Accident History:



A review of the facility's incident records for significant events involving chemicals covered by the RMP rule was conducted. Consideration was given to the amount of material released, injuries which may have occurred, and actual or potential impact both on and off the facility. There were eleven accidents which involved an affected chemical at the Honeywell Geismar Site in the past five years. The 5 year accident history event on 08-13-2016 includes off-site impact of 298 persons sheltered-in-place at an industrial neighbor of 298 which encompasses their entire employee headcount. Since the event occurred on a Saturday and they have shift personnel there is a low probability that all 298 were on site and sheltered-in-place during the event.



5) The Emergency Response Plan:



The Honeywell Geismar site has an emergency preparedness planning and response program designed to deal with accidental releases and other unplanned events associated with the facility's use of hazardous chemicals. The site has a written Emergency Response Plan that addresses various types of contingencies including specific actions for responding to accidental releases. The Plan provides for both internal site and external community emergency alerting and notification using established protocols. The plant has multiple means of communication established to alert public safety agencies. The plan addresses emergency health care, sheltering in place, evacuation, emergency responsibilities, response, control procedures, and emergency equipment. The Plan provides for the implementation of an Incident Command
System to direct and coordinate the Site's response activities. The Plan has been coordinated with the local emergency

planning committee and with the local sheriff's agencies that would direct all offsite community response activities. The Honeywell Geismar site maintains its own professionally trained Emergency Response Team (ERT) which is knowledgeable and prepared to respond to incidents involving accidental releases. The ERT holds annual site emergency response drills and other exercises that have been conducted jointly with the local public safety response groups.



The Geismar site utilizes audible warning systems for both onsite and offsite notification. The onsite notification system can be activated at several locations including control rooms and the plant security gate. This system has siren and voice capability that can use prerecorded or live announcements. The system is tested weekly and during routine drills by Honeywell and other companies which share the site.



Notification of persons off the site property is accomplished in conjunction with the local public safety agencies by activation of a regional audible warning system. This system also has siren and voice capabilities. Annually, calendars are hand delivered to residents in the audible warning region. These calendars provide residents instructions and recommendations in response to audible warnings. The system is tested weekly.



In addition to the audible warning system, community alert networks exist to alert near neighbors. These computer-assisted systems are capable of automatically alerting residents, industries, businesses, and others in the covered area by telephone.



6) Planned Changes to Improve Safety:



Honeywell pursues a philosophy of continuous improvement in all aspects of its operations. Improvements are identified and implemented throughout the facility's planning and operating cycles.



The plant's systematic safety review program identifies action items that improv
e upon the existing safeguards at the Geismar site and further reduce the potential for accidental release. The process hazard analyses for the Geismar manufacturing processes are reviewed and revalidated every five years. Continuous improvement of the plant's processes and systems provides the highest level of protection from chemical incidents.