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International Paper Red River Mill

Parent Companies:
International Paper
EPA Facility ID:
100000085294
Other ID:
Facility DUNS:
0
Parent Company DUNS:
1316561

Location:

Address:
4537 Highway 480
Campti, LA 71411
County:
NATCHITOCHES
Lat / Long:
31.909, -93.175 (Get map)
Method:
Interpolation - Photo
Description:
Center of Facility
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
International Paper
Phone:
(318) 476-3392
Address:
4537 Highway 480
Campti, LA 71411
Foreign Address:

Person responsible for RMP implementation:

Name:
Carl Gunter
Title:
Mill Manager

Emergency contact:

Name:
Larry Morgan
Title:
Environmental Manager
Phone:
(318) 476-3392
24-hour phone:
(318) 476-3392
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Natchitoches LEPC
Full-Time Equivalent Employees:
358
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
1980-00004-V2
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
March 19, 2009
Inspecting Agency:
EPA
Using Predictive Filing:
No

Processes:

Unspecified process
RMP ID:
80158
CBI claimed:
No
Program Level:
3
NAICS:
Paperboard Mills (32213)
Chemical name
CAS#
Quantity (lbs.)
CBI
Chlorine
7782-50-5
26,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 23, 2009
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
No
RMP ID:
54949

Deregistration:

Date:
Effective Date:
Reason:
Source reduced inventory of all regulated substances below TQs
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 Unspecified process)
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:
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 Unspecified process)
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:
F
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

None

5. Flammables: Alternative release

None

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

, Paperboard Mills (32213)
Prevention Program ID:
47319
Safety Review Date
Aug. 27, 2007, since latest RMP submission
PHA Update Date
Aug. 7, 2006, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
Process Controls
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Emergency Air Supply
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Reduced Inventory
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
Feb. 28, 2008, since latest RMP submission
Training Review Date
March 28, 2009, since latest RMP submission
Maintenance Review Date
Feb. 28, 2008, since latest RMP submission
Maintenance Inspection Date
March 25, 2009, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 30, 2007
Management of Change Review Date
Aug. 27, 2007
Pre-startup Review Date
March 30, 2007
Compliance Audit Date
Aug. 27, 2007
Compliance Audit Change Completion Date
April 28, 2008
Incident Investigation Date
June 5, 2008
Incident Invest. Change Completion Date
June 27, 2008
Participation Plan Review Date
May 27, 2009
Hot Work Review Date
May 31, 2009
Contractor Safety Review Date
June 17, 2009, since latest RMP submission
Contractor Safety Eval. Date
June 17, 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:
March 28, 2009
Local Response Agency:
Local Response Agency Phone:
(318) 352-6432
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
No
Subject To - CWA:
No
Subject To - RCRA:
Yes
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

INTERNATIONAL PAPER RED RIVER MILL RISK MANAGEMENT PLAN: EXECUTIVE SUMMARY
EPA ID 1000 0008 5294

ACCIDENTAL RELEASE PREVENTION AND RESPONSE POLICIES
The Red River Mill has a long-standing commitment to worker and public safety. This commitment is demonstrated by the resources invested in accident prevention, such as training personnel, and safety considerations in the design, installation, operation, and maintenance of the facility's processes. International Paper's policy is to implement reasonable controls to prevent foreseeable releases of substances. However, if a release does occur, trained personnel will respond to, control, and contain the release.

DESCRIPTION OF THE STATIONARY SOURCE AND REGULATED SUBSTANCES
The Red River Mill is an integrated pulp and paper mill that utilizes the standard kraft process for the manufacture of unbleached pulp from wood chips and recycled corrugated containers into linerboard. Chlorine, a regulated toxic substance, is used in the treatment of incoming water for mill processes. It is the only listed substance present in quantities that exceed the Risk Management Planning (RMP) threshold. In addition, the facility is subject to the OSHA Process Management Standard (PSM). The use of chlorine at Red River Mill is classified as a Program 3 process under the Accidental Release Prevention Program.

GENERAL ACCIDENT RELEASE PREVENTION PROGRAM
The following is a summary of the accident prevention program in place at the Red River Mill. Because the RMP regulated process is also subject to OSHA's PSM standard, this summary addresses PSM elements and describes the management system in place to implement the accident prevention program.

EMPLOYEE PARTICIPATION
Active employee participation in the development and implementation of the PSM program is an important step toward the prevention or minimization of consequences of catastrophic releases of chemicals. Employee involvement helps to insure that all perspectives regarding PSM are cons
idered, and that the best ideas are implemented.

Employee involvement in safety issues is promoted through existing safety programs, including the Central Safety Team, regularly scheduled safety meetings, Hazard Communication, and other special training programs such as emergency response training and first aid. In addition, employees participate in operational checks and in developing and reviewing operating and maintenance procedures that ensure that processes remain in control.

PROCESS SAFETY INFORMATION
Written process safety information is readily available to all employees. Material Safety Data Sheets include information on chemical properties and hazards and emergency response/exposure treatment. Other technical documents contain information on equipment design, operating temperature and pressure limts, and materials of construction. The information, in combination with written operating procedures and trained personnel, provides a basis for establishing inspection and maintenance activities, as well as for evaluating proposed process changes from the safety point of view.

PROCESS HAZARD ANALYSIS
The Red River Mill primarily uses the HAZOP analysis technique to systematically evaluate process hazards. The analyses are conducted using a team of people who have operating and maintenance experience as well as engineering expertise. This team identifies and evaluates hazards of the process and determines accident prevention and mitigation measures. Implementation of mitigation options in response to process hazards analyses is prioritized based on the relative risk rating assigned by the team.

To help ensure that the process hazards or controls do not eventually deviate from the original design safety features, the mill periodically updates and revalidates the hazard analysis results. Team findings are forwarded to management for consideration, and the final resolution is documented and retained.

OPERATING PROCEDURES
Written procedures are maintained that
address various modes of process operation, such as startup, normal operations, temporary operations, emergency shutdown, normal shutdown, and startup of a new process. The procedures provide guidance for experienced operators and provide the basis for training new operators. Operating procedures are periodically reviewed and certified as current.

TRAINING
The Red River Mill has a comprehensive training program for all employees involved in operating the process. New employees receive basic training in mill operations, and all operators periodically receive refresher training on operating procedures. All training is documented, including the means to verify that the operator understood the training.

CONTRACTORS
Prior to beginnning work, contractors are provided an orientation session that covers process overview, information about safety and health hazards, emergency response plan requirements, and safe work practices. Contractor safety programs and safety performance are evaluated as criteria in the selection of contractors.

PRE-STARTUP SAFETY REVIEWS
Pre startup safety reviews are conducted on any new facility or facility modification that requires a change in process safety information. The review involves field verification of the construction and serves a quality assurance function by requiring verification that accident prevention program requirements are properly implemented.

MECHANICAL INTEGRITY
The basic components of the mechanical integrity program for the process include training, development of written procedures, inspections and tests, correction of equipment deficiencies when identified, and application of quality assurance measures.
Maintenance personnel receive training in safe work practices to enable them to work safely.

SAFE WORK PRACTICES
Safe work practices are in place to help ensure worker and process safety. Examples of these include lockout/tagout isolation of energy sources before beginning work on equipment, hot work permit proce
ss, and confined space entry procedures.

MANAGEMENT OF CHANGE
The Red River Mill has a comprehensive system to manage changes in all covered processes.This system requires that changes to items such as process equipment, technology, procedures, and other facility changes be properly reviewed and authorized before being implemented. Affected chemical hazard information, process operating limits, equipment information, and procedures are updated to incorporate the changes. Operating and maintenance personnel are provided any necessary training on the change.

INCIDENT INVESTIGATION
Incidents that resulted in, or reasonably could have resulted in a fire/explosion, toxic gas release, major property damage, environmental loss, or personal injury are prompyl investigated for root cause and development of corrective actions.

COMPLIANCE AUDITS
To help ensure proper functioning of the accident prevention program, compliance audits are conducted at least every three years by a team of hourly and staff personnel. Corrective actions taken in response to the team's findings are tracked until complete. The final resolution of each finding is documented, and the two most recent audit reports are maintained.

CHEMICAL SPECIFIC PREVENTION STEPS
The following is a description of existing safety features applicable to prevention of accidental releases of regulated substances at the facility.

Universal Prevention Activities
The accident prevention program summarized previously is applied to all RMP-covered processes. Collectively, these prevention program activities help prevent potential accident scenarios that could be caused by equipment failures and human errors.

Specialized Safety Features
Safety features are on many units to help contain/control a release, quickly detect a release, and reduce the consequences of a release. The following types of safety features are used in the covered processes:

Release Detection
Chlorine detectors with alarms, local and transmitted to the o
perating control room

Release Containment/Control
Manual valves to isolate the process
Redundant equipment and instrumentation (e.g., backup firewater pump)

Release Mitigation
Fire extinguishers and extinguishing systems
Personnel trained in emergency procedures
Personal protective equipment (e.g., chemical protective clothing, self contained breathing apparatus)

FIVE YEAR ACCIDENT HISTORY
Over the last five years there have been no accidental releases from RMP covered processes at Red River Mill.

EMERGENCY PROCEDURE INFORMATION
The Red River Mill maintains a written emergency procedure for the possibility of a safety or health hazard if a hazardous substance is accidentally released. The procedures address notification of local emergency response agencies if a release occurs, and post incident cleanup and decontamination requirements. Employees receive training in emergency procedures. The emergency procedure is updated when necessary based on modifications to the mill. The emergency procedures are administered through the Management of Change process, which includes informing and /or training affected personnel in the changes.

The overall emergency procedure program for the Red River Mill is coordinated with the Natchitoches Parish, Louisiana, Local Emergency Planning Committee (LEPC). The Red River mill has around-the-clock communications capability with local LEPC officials and emeergency response organizations (e.g., fire department). This provides a means of notifying the public of an incident, if necessary, as well as facilitating a quick response to an incident. The Red River Mill conducts periodic emergency drills and provides periodic refresher training to mill personnel regarding the hazards of regulated substances in the plant.