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Geismar Ethylene Plant

Parent Companies:
NOVA Chemicals Inc.
NOVA Chemicals Olefins LLC
EPA Facility ID:
100000098119
Other ID:
70734NNTXSLAHWY
Facility DUNS:
0
Parent Company #1 DUNS:
0
Parent Company #2 DUNS:
68101286

Location:

Address:
5205 Highway 3115
Geismar, LA 70734
County:
IBERVILLE
Lat / Long:
30.236, -91.051 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Center of Facility
Horizonal accuracy:
50 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
NOVA Chemicals Olefins LLC
Phone:
(225) 642-2100
Address:
P.O. Box 470
5205 Hwy 3115
Geismar, LA 70734
Foreign Address:

Person responsible for RMP implementation:

Name:
L.G. Bayer
Title:
Director, Ops and Technical Svcs.

Emergency contact:

Name:
J.G. Berret
Title:
EHS Manager
Phone:
(225) 642-2169
24-hour phone:
(225) 642-2132
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Iberville Parish LEPC
Full-Time Equivalent Employees:
130
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
0180-00029V8
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
June 25, 2013
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

Olefins Manufacturing
RMP ID:
1000052689
CBI claimed:
No
Program Level:
3
NAICS:
Petrochemical Manufacturing (32511)
Chemical name
CAS#
Quantity (lbs.)
CBI
1,3-Butadiene
106-99-0
3,200,000
No
Propane
74-98-6
200,000
No
Propylene [1-Propene]
115-07-1
890,000
No
Ethane
74-84-0
130,000
No
Ethylene [Ethene]
74-85-1
170,000
No
Chlorine
7782-50-5
12,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Peter R. Jordan
Address:
225 Pine Glen Road
Langhorne, PA 19047
Foreign Address:

Phone:
(215) 504-5729

Latest RMP Submission:

Date:
June 13, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000042719

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 Olefins Manufacturing)
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 Olefins Manufacturing)
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

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 Olefins Manufacturing)
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 Olefins Manufacturing)
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

June 13, 2013 at 08:37
ID:
1000033822
NAICS:
Petrochemical Manufacturing (32511)
Duration:
3 hours and 23 minutes
Chemicals involved:
  • Propylene [1-Propene]
  • Flammable Mixture
  • 1,3-Butadiene
  • Nitric oxide [Nitrogen oxide (NO)]
Release events:
Fire
Weather conditions at time of event
Wind speed:
7.30000019 miles/h WNW
Temperature:
89.00 ℉
Atmospheric stability:
C
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
2
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
48
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$113300000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
410
Property damage:
$0
Environmental damage:
Initiating event:
Human Error
Contributing factors:
  • Human error
  • Overpressurization
  • Upset condition
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised training
  • Revised operating procedures
Sept. 5, 2012 at 14:01
ID:
1000033821
NAICS:
Petrochemical Manufacturing (32511)
Duration:
1 minutes
Chemicals involved:
  • Flammable Mixture
Release events:
Explosion
Weather conditions at time of event
Wind speed:
3.0 miles/h W
Temperature:
87.00 ℉
Atmospheric stability:
B
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:
$9000000
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:
  • Improved/upgraded equipment
  • Revised training
  • Revised operating procedures
  • New process controls

7. Prevention: Program level 3

Olefins Manufacturing, Petrochemical Manufacturing (32511)
Prevention Program ID:
1000044375
Safety Review Date
May 19, 2014
PHA Update Date
May 12, 2014
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Polymerization
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Floods
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Rupture Disks
  • Excess Flow Device
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Deluge System
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Increased Inventory
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Feb. 25, 2014
Training Review Date
April 23, 2013
Maintenance Review Date
Jan. 21, 2014
Maintenance Inspection Date
May 6, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
May 19, 2014
Management of Change Review Date
April 23, 2013
Pre-startup Review Date
May 14, 2014
Compliance Audit Date
June 25, 2013
Compliance Audit Change Completion Date
June 25, 2013
Incident Investigation Date
May 17, 2014
Incident Invest. Change Completion Date
May 17, 2014
Participation Plan Review Date
April 23, 2013
Hot Work Review Date
April 23, 2013
Contractor Safety Review Date
April 23, 2013
Contractor Safety Eval. Date
May 15, 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:
Jan. 20, 2014
Local Response Agency:
Local Response Agency Phone:
(225) 621-8300
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

17854 LDEQ Facility ID Number





Executive Summary

NOVA Chemicals Inc.

NOVA Chemicals Olefins LLC

Geismar, Louisiana



An incident occurred in June 2013 that resulted in significant on-site consequences. Although there were no off-site impacts, at approximately 9:10 AM, approximately 410 households received a recorded message from Ascension Parish asking residents to "please shelter-in-place." At approximately 1:25 PM an "all-clear" notice was sent. At the time of the prior 5-year incident update, the facility was not aware of the notice. The June 13, 2013 incident is still under investigation; all information contained in this 5-Year Incident Report is preliminary. This includes the initiating event, the contributing causes, and the quantity of chemicals released. The 5-Year Incident Report input fields (drop down menu) have limited options and no opportunity to provide further explanation. In order to provide a more complete response, the Geismar Ethylene Plant has preliminary concluded that the incident was caused by:



- the unexpected presence of liquid hydrocarbons in the reboiler in standby mode;



- the introduction of heat into this standby reboiler; and



- the pressure relief system was isolated from the reboiler which was in standby mode.



Nitric Oxide ("NO") is an RMP chemical; NOx is a product of combustion produced from combustion of released flammable materials. Available factors were used to estimate the amount of NOx produced. NO is a component of NOx.



If necessary, the Geismar Ethylene Plant will update the 5-Year report after the investigation is completed.





Accidental Release Prevention and Response Policies



The Geismar Ethylene Plant has a long-standing commitment to protect employees, the community and the environment. This commitment is demonstrated by the resources invested in accident prevention, such as training personnel and considering safety and environmental consequences in the design, installation, o
peration, and maintenance of our processes. Our policy is to implement reasonable controls to prevent foreseeable releases of hazardous materials. However, if a release does occur, our trained emergency response personnel will respond to control, contain and mitigate the release.





Description of the Stationary Source and Regulated Substances



The Geismar Ethylene Plant, located in Geismar, Louisiana, operates an olefins facility to produce ethylene, propylene, crude butadiene and debutanized aromatic concentrate from ethane and propane feedstocks. The Geismar Ethylene Plant is subject to the requirements of 40 CFR Part 68, Chemical Accident Prevention Provisions. The Geismar Ethylene Plant has regulated flammable substances including, propane, 1,3-butadiene, propylene, ethylene and ethane. Additionally, the plant uses chlorine, which is also a regulated toxic substance.





Other Five-Year Accident History



The Geismar Ethylene Plant has had an excellent record of accident prevention over the past 5 years. Every incident is investigated very carefully to determine ways to prevent the incident or similar incidents from recurring.



Less than 1 pounds of a flammable mixture was released in 2012 when improper procedures were followed on a furnace. The resulting explosion caused property damage. The flammable mixture was consumed during the explosion. New process controls are being added, operating procedures are being revised, and additional training will be conducted as a result of this accident.





General Accidental Release/Chemical-Specific Prevention Programs Steps



An accident prevention program is in place at the Geismar Ethylene Plant. Because the process at the Geismar Ethylene Plant is regulated by the EPA Risk Management Program (RMP) regulation and is also subject to the OSHA Process Safety Management (PSM) standard, the elements of these programs are listed below. Collectively, these prevention program activities help minimize potentia
l accident scenarios that could be caused by (1) equipment failures and (2) human errors.



Employee Participation

Process Safety Information

Process Hazard Analysis (PHA)

Operating Procedures

Training

Contractors

Pre-startup Safety Reviews

Mechanical Integrity

Safe Work Practices

Management of Change

Incident Investigation

Compliance Audits



The Geismar Ethylene Plant also has a security plan in place designed to comply with the Maritime Transportation Security Act (MTSA). The MTSA is a federal law designed to protect U.S. ports and waterways from a terrorist attack. It requires measures to control access to facilities and vessels that might be vulnerable to an incident resulting in a significant loss of life, environmental damage, transportation system disruption, or economic disruption.





Emergency Response Program Information



The Geismar Ethylene Plant maintains a written emergency control program, which is in place to protect worker and public safety as well as the environment. The program consists of procedures for responding to a release of a regulated substance, including the possibility of a fire or explosion if a flammable substance is accidentally released. The procedures address all aspects of emergency response, including proper first-aid and medical treatment for exposures, evacuation plans and accounting for personnel after evacuation, notification of local emergency response agencies and the public if a release occurs, and post incident cleanup and decontamination requirements. In addition, the Geismar Ethylene Plant has procedures that address maintenance, inspection, and testing of emergency response equipment, as well as instructions that address the use of emergency response equipment. Employees receive training in these procedures as necessary to perform their specific emergency response duties. The emergency control program is updated when necessary based on modifications made to Geismar Ethylene Plant processes or o
ther Geismar Ethylene Plant facilities.



The overall emergency control program for the Geismar Ethylene Plant is coordinated with the Ascension and Iberville Parishes Local Emergency Planning Committees (LEPC). This coordination includes periodic meetings of the committees, which include local emergency state officials, local government officials, and industry representatives. The Geismar Ethylene Plant has communications capability with appropriate officials and emergency response organizations (e.g., sheriff's office, Geismar Area Mutual Aid, complex emergency brigade, etc.). This provides a means of notifying the public of an incident, if necessary, as well as facilitating quick response to an incident. In addition to periodic LEPC meetings, the Geismar Ethylene Plant conducts periodic emergency drills.





Planned Changes to Improve Safety



The Geismar Ethylene Plant is committed to operating our facility in a safe and responsible manner. We are continually evaluating our equipment and procedures to meet this objective and have identified recommendations during past studies. These recommendations are currently being implemented where appropriate.