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Baker Petrlolite Corporation - Rayne Blend Plant

Parent Companies:
EPA Facility ID:
100000100446
Other ID:
70578BKRPT135in
Facility DUNS:
88918305

Location:

Address:
135 Industrial Drive
Rayne, LA 70578
County:
ACADIA
Lat / Long:
30.231, -92.307 (Get map)
Method:
Interpolation - Photo
Description:
Process Unit Area Centroid
Horizonal accuracy:
3 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Baker Petrolite Corporation
Phone:
(800) 321-5977
Address:
135 Industrial Drive
Rayne, LA 70578 -4020
Foreign Address:

Person responsible for RMP implementation:

Name:
Dodi Y Ryder
Title:
Plant Manager

Emergency contact:

Name:
Dodi Y Ryder
Title:
Plant Manager
Phone:
(337) 334-6017
24-hour phone:
(337) 322-5264
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Acadia Parish LEPC
Full-Time Equivalent Employees:
28
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:
Feb. 14, 2013
Inspecting Agency:
EPA
Using Predictive Filing:
No

Processes:

Acrolein Storage
RMP ID:
1000053187
CBI claimed:
No
Program Level:
3
NAICS:
Support Activities for Oil and Gas Operations (213112)
All Other Miscellaneous Chemical Product and Preparation Manufacturing (325998)
Chemical name
CAS#
Quantity (lbs.)
CBI
Acrolein [2-Propenal]
107-02-8
50,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Jadwin V Mayeaux
Address:
135 Industrial Drive
Rayne, LA 70578
Foreign Address:

Phone:
(337) 334-9633

Latest RMP Submission:

Date:
May 28, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000043135

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 Acrolein Storage)
CBI claimed:
No
Percent weight:
95.0
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
15.40
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Rural
Passive mitigation
considered:
  • Dikes
  • Sumps
not considered:
  • Enclosures
  • Berms
  • Drains

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 Acrolein Storage)
CBI claimed:
No
Percent weight:
95.0
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:
  • Dikes
  • Sumps
not considered:
  • Enclosures
  • Berms
  • Drains
Active mitigation
considered:
  • Sprinkler systems
  • Neutralization
not considered:
  • Deluge systems
  • Water curtain
  • 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

Acrolein Storage, Support Activities for Oil and Gas Operations (213112)
Prevention Program ID:
1000044706
Safety Review Date
May 20, 2014, since latest RMP submission
PHA Update Date
April 1, 2014, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Polymerization
  • Overpressurization
  • Corrosion
  • Equipment failure
  • Cooling loss
  • Floods
  • Tornado
  • Hurricanes
Process Controls
  • Relief Valves
  • Check Valves
  • Alarms
  • Inhibitor Addition
  • Rupture Disks
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • Perimeter Monitors
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
May 20, 2014, since latest RMP submission
Training Review Date
April 22, 2014, since latest RMP submission
Maintenance Review Date
April 1, 2014, since latest RMP submission
Maintenance Inspection Date
May 28, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
June 13, 2013
Management of Change Review Date
Dec. 23, 2013
Pre-startup Review Date
April 1, 2014
Compliance Audit Date
July 19, 2012
Compliance Audit Change Completion Date
Sept. 30, 2013
Incident Investigation Date
Dec. 9, 2005
Incident Invest. Change Completion Date
Jan. 10, 2006
Participation Plan Review Date
April 1, 2014
Hot Work Review Date
April 1, 2014
Contractor Safety Review Date
April 1, 2014, since latest RMP submission
Contractor Safety Eval. Date
April 1, 2014, since latest RMP submission

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
No
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:
April 7, 2014
Local Response Agency:
Local Response Agency Phone:
(337) 334-2345
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

General Executive Summary for Baker Petrolite Corporation Rayne, Louisiana

27833 LAOEQ Facility ID Number



1. Accidental Release Prevention and Emergency Response Policies

As employees of Baker Petrolite Corporation, we are strongly committed to safety, for ourselves, our neighbors, and the environment. We strive daily to operate our facility and handle our products in the safest manner possible, consistent with prudent environmental, health, and safety practices. It is our policy to implement appropriate controls wherever possible in order to prevent the unwanted release of any regulated substance. We have a comprehensive accidental release prevention program in place that covers the key elements of design, installation, operating procedures, maintenance, and employee training associated with the processes at our facility. In the unlikely event that a release ever does occur our trained employees shall work under the Incident Command System structure with the Rayne fire department and other emergency response personnel to control and minimize the effects of any release. As members of CMA and SOCMA, we believe in Responsible Care, which includes the CAER code, Community Awareness and Emergency Response. So, even though not required by any regulation, we installed a state of the art emergency response system (monitoring & mitigation)to protect our community in the event of a release. This emergency response system safeguards the acrolein storage area, and includes a containment wall, chemical detectors, a deluge system, plus foam and neutralizer which would deactivate or minimize any release.



2. The Stationary Source and the Regulated Substances Handled

Our facility is a small blend plant, which produces and distributes oilfield production chemicals. We store one (1) regulated substance at our facility. This substance is Acrolein [2-Propenal], which is used as a biocide, or as a hydrogen sulfide scavenger/antifoulant in the treatment of produced oil field wa
ter.





3. General Accidental Release Prevention Program and the Chemical-Specific Prevention Steps

Our facility has taken all the necessary steps to comply with the accidental release prevention requirements set out under 40 CFR part 68 of the EPA. Our facility is subject to the OSHA PSM standard under 29 CFR 1910.119. Our facility is also subject to EPCRA Section 302 notification requirements. The following sections briefly describe the elements of the release prevention program that is in place at our stationary source.



Process Safety Information

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



Process Hazard Analysis

Our facility conducts comprehensive studies to ensure that hazards associated with our processes are identified and controlled efficiently. The primary methodology used to carry out these analyses is HAZOP. The studies are undertaken by a team of qualified personnel with expertise in engineering and process operations and are revalidated at least every five years. Any findings related to the hazard analysis are addressed in a timely manner.



Operating Procedures

For the purposes of safely conducting activities within our covered processes, we maintain written operating procedures. These procedures address unloading, transport, storage, and loading of acrolein cylinders and skids. The information is reviewed regularly and is readily accessible to operators involved in the processes.



Training

Baker Petrolite Corporation has a comprehensive training program in place to ensure that employees are competent in the operating procedures associated with various plant processes. Refresher training is provided at least every year and more frequently as needed. Training provided to employees at the Rayne facility includes required core safety training as defined by OSHA, plus additional training su
ch as Environmental Awareness. Plant assigned drivers also attend defensive driving classes taught by a certified instructor through Smith Driving Systems, plus small vehicle Driving Safety. First Aid/CPR training is provided bi-annually by qualified First Aid Instructors.



Mechanical Integrity

Baker Petrolite's employees perform documented maintenance checks on process equipment to ensure proper operations. Process equipment examined by these checks includes among others; pressure vessels, piping systems, relief and vent systems, excess flow valves and lifting devices. Maintenance operations are conducted by qualified personnel who have received previous training in safe and effective maintenance practices. Furthermore, these personnel are offered specialized training as needed. Any equipment deficiencies identified by the maintenance checks are corrected in a safe and timely manner





Management of Change

Written procedures are in place at our facility to manage changes in process chemicals, technology, equipment and procedures. Process operators, maintenance personnel or any other employee whose job tasks are affected by a modification in process conditions are promptly made aware of and offered training to deal with the modification.



Pre-startup Reviews

Pre-start up safety reviews related to new processes and to modifications in established processes are conducted as a regular practice at all Baker Petrolite locations. These reviews are conducted at each site to confirm that construction, equipment, operating and maintenance procedures are suitable for safe startup prior to placing equipment into operation.



Compliance Audits

Baker Petrolite's corporate EHS/Q&RA Department conducts audits on a regular basis to determine whether the provisions set out under the PSM and RMP rule are being implemented. These audits are carried out at least every 3 years and any corrective actions required as a result of the audits are addressed in a safe and prompt m
anner.



Incident Investigation

Qualified Baker Petrolite employees promptly investigate any incident that has resulted in, or could reasonably result in a catastrophic release of a regulated substance. These investigations are conducted by teams at several levels of the organization as directed by the Vice President of Oilfield operations. The investigations are designed to identify the root causes of incidents, and identify corrective actions to prevent the release from reoccurring. All reports are retained for a minimum of 5 years.



Employee Participation

Baker Petrolite Corporation truly believes that process safety management and accident prevention is a team effort. Company employees are strongly 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

If necessary, our company hires contractors to conduct specialized maintenance and construction activities. Prior to selecting a contractor, we conduct a thorough evaluation of their safety performance. Only those who meet strict acceptance criteria are authorized to enter the facility. The Rayne facility routinely informs the contractors of known potential hazards related the contractor's work and plant processes. Contractors are also informed of the procedures for emergency response should an accidental release of a regulated substance occur.



4. Five-year Accident History

The Rayne blending facility has an excellent safety record over the last 5 years, with no reportable quantity accidental releases occurring during this period. It is our policy to strive for continuous improvement in our operations, and this has led to more stringent release prevention policies, and more elaborate emergency response plans. Because of this, we strive to prevent
a releases from ever occurring. However, we are realistic enough to plan our emergency response for even the most unexpected release scenario. Therefore, we expect to be able to control and minimize a release, should one ever occur.



5. Emergency Response Plan

Baker Petrolite's Rayne facility has a written emergency response plan to deal with accidental releases of hazardous materials. The plan includes all aspects of emergency response including adequate 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, our 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.



6. Planned Changes to Improve Safety

Our systems are focused on continual improvement in the prevention of accidents and pollution, effective communications and training, and accountability throughout the organization. In line with our goal of continuous improvement, we plan to build on our existing good relationships with our close industrial neighbors, and the community.