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ExxonMobil Chemical Co. Baton Rouge Plastics Plant

Parent Companies:
Exxon Mobil Corporation
EPA Facility ID:
100000112433
Other ID:
Facility DUNS:
37966090
Parent Company DUNS:
1213214

Location:

Address:
11675 Scotland-Zachary Hwy
Baton Rouge, LA 70807
County:
EAST BATON ROUGE
Lat / Long:
30.550, -91.186 (Get map)
Method:
Interpolation - Map
Description:
Center of Facility
Horizonal accuracy:
1 m
Horizontal reference datum:
North American Datum of 1927
Source map scale:
1

Owner/Operator:

Name:
ExxonMobil Chemical Company
Phone:
(225) 977-6211
Address:
Post Office Box 1607
Baton Rouge, LA 70821
Foreign Address:

Person responsible for RMP implementation:

Name:
Jacob L. Talbot
Title:
Environmental Coordinator

Emergency contact:

Name:
A-41
Title:
Shift Supervisor
Phone:
(225) 977-6248
24-hour phone:
(225) 977-6248
Ext or PIN:
Email:
N/A

Other contacts:

Facility (or company) email:
Facility phone:
(225) 977-6200
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
East Baton Rouge LEPC
Full-Time Equivalent Employees:
348
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
0840-00018-V6
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Nov. 30, 2006
Inspecting Agency:
OSHA/VPP
Using Predictive Filing:
No

Processes:

V-261 Acetaldehyde
RMP ID:
1000048929
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Acetaldehyde
75-07-0
100,000
No
Public OCA Chemical
0
No
V-266 Butane
RMP ID:
1000048930
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Butane
106-97-8
240,000
No
Public OCA Chemical
0
No
Railcars Butane
RMP ID:
1000048931
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Butane
106-97-8
140,000
No
Public OCA Chemical
0
No
V-263/V-262 1-Butene
RMP ID:
1000048932
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
1-Butene
106-98-9
360,000
No
Public OCA Chemical
0
No
Railcars 1-Butene
RMP ID:
1000048933
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
1-Butene
106-98-9
140,000
No
Public OCA Chemical
0
No
Base Plant Ethylene
RMP ID:
1000048934
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ethylene [Ethene]
74-85-1
44,000
No
Public OCA Chemical
0
No
E-line Ethylene
RMP ID:
1000048935
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ethylene [Ethene]
74-85-1
26,000
No
Public OCA Chemical
0
No
PGPU Ethylene
RMP ID:
1000048936
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ethylene [Ethene]
74-85-1
95,000
No
Public OCA Chemical
0
No
TK-932 Vinyl Acetate
RMP ID:
1000048937
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Vinyl acetate monomer [Acetic acid ethenyl ester]
108-05-4
990,000
No
Public OCA Chemical
0
No
TK-282 Vinyl Acetate
RMP ID:
1000048938
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Vinyl acetate monomer [Acetic acid ethenyl ester]
108-05-4
430,000
No
Public OCA Chemical
0
No
V-966E Recovered V.A.
RMP ID:
1000048939
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Vinyl acetate monomer [Acetic acid ethenyl ester]
108-05-4
60,000
No
Public OCA Chemical
0
No
V-980 Vinyl Acetate
RMP ID:
1000048940
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Vinyl acetate monomer [Acetic acid ethenyl ester]
108-05-4
89,000
No
Public OCA Chemical
0
No
G-Line
RMP ID:
1000048941
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ethylene [Ethene]
74-85-1
63,042
No
Propylene [1-Propene]
115-07-1
63,042
No
1-Butene
106-98-9
63,042
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Eagle Environmental Services, Inc.
Address:
18369 Petroleum Drive
Baton Rouge, LA 70809
Foreign Address:

Phone:
(225) 757-0870

Latest RMP Submission:

Date:
April 17, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000039760

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 TK-932 Vinyl Acetate)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Liquid
Model used:
EPA's OCA Guidance Reference Tables or Equations
Release duration (mins):
4202.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • Dikes
not considered:
  • 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 TK-932 Vinyl Acetate)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Liquid
Model used:
EPA's OCA Guidance Reference Tables or Equations
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • Dikes
not considered:
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • Emergency shutdown
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers

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 V-263/V-262 1-Butene)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
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 Base Plant Ethylene)
CBI claimed:
No
Model used:
EPA Study 752 & CMA's Management of Hazards Associated with Location of Plant Process Buildings
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

July 15, 2010 at 20:44
ID:
1000032696
NAICS:
Plastics Material and Resin Manufacturing (325211)
Duration:
11 minutes
Chemicals involved:
  • Ethylene [Ethene]
Release events:
Gas release
Weather conditions at time of event
Wind speed:
4.5999999 miles/h WSW
Temperature:
85.00 ℉
Atmospheric stability:
F
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:
$1500000
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:
  • Equipment failure
Off-site responders notified:
Notified Only
Changes introduced as a result of the accident:
  • Revised maintenance

7. Prevention: Program level 3

V-261 Acetaldehyde, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042319
Safety Review Date
Oct. 1, 2013, since latest RMP submission
PHA Update Date
July 23, 2009, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
Process Controls
  • Relief Valves
  • Flares
  • Manual Shutoffs
  • Alarms
  • Grounding Equipment
Mitigation Systems
  • Dikes
Monitoring Systems
  • Perimeter Monitors
Changes since PHA
  • Mitigation Systems
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
Procedure Review Date
Sept. 9, 2013, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
Dec. 29, 2008, since latest RMP submission
Maintenance Inspection Date
Aug. 16, 2012, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Aug. 31, 2011
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
Sept. 13, 2012
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
V-266 Butane, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042320
Safety Review Date
June 3, 2013, since latest RMP submission
PHA Update Date
July 23, 2009, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
Process Controls
  • Relief Valves
  • Flares
  • Manual Shutoffs
  • Alarms
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • Dikes
Monitoring Systems
  • Perimeter Monitors
Changes since PHA
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
Procedure Review Date
Sept. 9, 2013, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
April 1, 2013, since latest RMP submission
Maintenance Inspection Date
June 21, 2012, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 10, 2006
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
April 16, 2005
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
Railcars Butane, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042321
Safety Review Date
Dec. 2, 2013, since latest RMP submission
PHA Update Date
July 23, 2009, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Equipment failure
Process Controls
  • None
Mitigation Systems
  • Deluge System
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
Procedure Review Date
Nov. 10, 2013, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
April 1, 2013, since latest RMP submission
Maintenance Inspection Date
April 23, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
July 22, 2010
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
Dec. 8, 2010
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
V-263/V-262 1-Butene, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042322
Safety Review Date
Oct. 1, 2013, since latest RMP submission
PHA Update Date
July 23, 2009, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
Process Controls
  • Relief Valves
  • Flares
  • Manual Shutoffs
  • Alarms
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • Dikes
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Process Controls
  • None Recommended
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
Procedure Review Date
Sept. 9, 2013, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
Jan. 1, 2013, since latest RMP submission
Maintenance Inspection Date
Dec. 15, 2011, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 23, 2007
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
May 27, 2009
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
Railcars 1-Butene, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042323
Safety Review Date
Dec. 2, 2013, since latest RMP submission
PHA Update Date
July 23, 2009, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Equipment failure
Process Controls
  • None
Mitigation Systems
  • Deluge System
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
Procedure Review Date
Nov. 10, 2013, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
Jan. 1, 2013, since latest RMP submission
Maintenance Inspection Date
July 14, 2011, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Oct. 3, 2012
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
Nov. 15, 2013
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
Base Plant Ethylene, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042324
Safety Review Date
Aug. 3, 2012, since latest RMP submission
PHA Update Date
Aug. 3, 2012, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
  • FMEA
  • FTA
Hazards Identified
  • Fire
  • Explosion
  • Runaway reaction
  • Polymerization
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Inhibitor Addition
  • Rupture Disks
  • Excess Flow Device
Mitigation Systems
  • Blast Walls
  • Deluge System
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Process Detection
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Oct. 21, 2013, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
Jan. 1, 2014, since latest RMP submission
Maintenance Inspection Date
July 25, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 18, 2014
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
March 18, 2014
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
Dec. 19, 2013
Incident Invest. Change Completion Date
March 15, 2014
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
E-line Ethylene, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042325
Safety Review Date
Nov. 1, 2012, since latest RMP submission
PHA Update Date
Nov. 1, 2012, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
  • FMEA
  • FTA
Hazards Identified
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Grounding Equipment
  • Rupture Disks
  • Quench System
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Blast Walls
  • Deluge System
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Process Parameters
  • Process Controls
  • Mitigation Systems
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
Procedure Review Date
March 4, 2014, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
Jan. 1, 2014, since latest RMP submission
Maintenance Inspection Date
July 26, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 25, 2014
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
Feb. 11, 2014
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
Jan. 14, 2013
Incident Invest. Change Completion Date
May 3, 2013
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
PGPU Ethylene, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042326
Safety Review Date
Jan. 1, 2010, since latest RMP submission
PHA Update Date
Aug. 27, 2010, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
  • FMEA
  • FTA
Hazards Identified
  • Fire
  • Explosion
  • Polymerization
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Grounding Equipment
Mitigation Systems
  • Sprinkler System
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
Procedure Review Date
Feb. 20, 2014, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
Jan. 1, 2014, since latest RMP submission
Maintenance Inspection Date
July 25, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 19, 2013
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
March 10, 2014
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
Dec. 31, 2013
Incident Invest. Change Completion Date
March 17, 2014
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
TK-932 Vinyl Acetate, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042327
Safety Review Date
Sept. 2, 2013, since latest RMP submission
PHA Update Date
July 23, 2009, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Overpressurization
  • Overfilling
  • Equipment failure
Process Controls
  • Relief Valves
  • Manual Shutoffs
  • Alarms
  • Grounding Equipment
Mitigation Systems
  • Dikes
Monitoring Systems
  • Perimeter Monitors
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
Procedure Review Date
Nov. 10, 2013, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
Jan. 1, 2014, since latest RMP submission
Maintenance Inspection Date
Nov. 26, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 4, 2008
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
Jan. 25, 2008
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
TK-282 Vinyl Acetate, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042328
Safety Review Date
Sept. 2, 2013, since latest RMP submission
PHA Update Date
July 23, 2009, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Corrosion
  • Overfilling
  • Equipment failure
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Alarms
  • Grounding Equipment
Mitigation Systems
  • Dikes
Monitoring Systems
  • None
Changes since PHA
  • None Recommended
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
Procedure Review Date
Sept. 9, 2013, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
April 1, 2013, since latest RMP submission
Maintenance Inspection Date
Nov. 26, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
April 8, 2013
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
April 8, 2013
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
V-966E Recovered V.A., Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042329
Safety Review Date
Aug. 1, 2012, since latest RMP submission
PHA Update Date
Aug. 3, 2012, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
Process Controls
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Alarms
  • Grounding Equipment
Mitigation Systems
  • Dikes
Monitoring Systems
  • Process Area
Changes since PHA
  • Mitigation Systems
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 14, 2011, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
Oct. 1, 2012, since latest RMP submission
Maintenance Inspection Date
April 26, 2010, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 23, 2006
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
June 28, 2006
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
V-980 Vinyl Acetate, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042330
Safety Review Date
July 1, 2013, since latest RMP submission
PHA Update Date
Aug. 27, 2010, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Corrosion
  • Overfilling
  • Equipment failure
Process Controls
  • Relief Valves
  • Manual Shutoffs
  • Alarms
  • Grounding Equipment
Mitigation Systems
  • Dikes
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Perimeter Monitoring
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
June 9, 2012, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
Oct. 1, 2013, since latest RMP submission
Maintenance Inspection Date
May 20, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
May 21, 2013
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
May 23, 2013
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, since latest RMP submission
G-Line, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
1000042331
Safety Review Date
Sept. 30, 2011, since latest RMP submission
PHA Update Date
Sept. 30, 2011, since latest RMP submission
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Runaway reaction
  • Polymerization
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Flares
  • 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
  • Sprinkler System
  • Dikes
  • Blast Walls
  • Deluge System
  • Neutralization
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
March 24, 2014, since latest RMP submission
Training Review Date
Oct. 2, 2013, since latest RMP submission
Maintenance Review Date
Jan. 1, 2014, since latest RMP submission
Maintenance Inspection Date
July 2, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 18, 2014
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
Feb. 5, 2014
Compliance Audit Date
July 26, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
Nov. 17, 2013
Incident Invest. Change Completion Date
Nov. 18, 2013
Participation Plan Review Date
July 26, 2013
Hot Work Review Date
March 20, 2014
Contractor Safety Review Date
Feb. 21, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 15, 2014, 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 21, 2014
Local Response Agency:
Local Response Agency Phone:
0000000911
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 EXECUTIVE SUMMARY





THE ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES AT THE STATIONARY SOURCE

The accidental release prevention and emergency response policies can best be summarized by ExxonMobil Operations Integrity Management Systems (OIMS). This is a structured approach to managing the safety, health, and environmental risks, which are inherent in our business. While OIMS was not designed to meet a specific regulation, each section of the Process Safety Management (PSM)/Risk Management Program (RMP) standard can be mapped directly to an OIMS system. The OIMS system is the overall guidance, while specific operating, mechanical, technical and / or SHE procedures support the system by providing more detailed information.





THE STATIONARY SOURCE AND REGULATED SUBSTANCES HANDLED

BRPP was constructed in 1968 and manufactures low-density polyethylene (LDPE) via a high-pressure process using six production lines (A-F-Lines). Products produced from the LDPE include plastic films, molding, adhesives, compounding and oil additives. Ethylene, propylene, and vinyl acetate are received by pipeline while other raw materials are received by truck or railcar. BRPP has several small storage tanks for raw materials. All power is generated offsite and supplied through ENTERGY. Four small package boilers provide for the site steam needs. Two flares are used to control continuous and intermittent vent streams from the units. The site utilizes three cooling towers and refrigeration units to supply cooling/chilled water throughout the site. BRPP's Purge Gas Purification Unit is used to recycle ethylene from offgases of the units.



BRPP uses six regulated substances above threshold quantity in 13 separate processes. These substances are acetaldehyde, n-butane, 1-butene, ethylene, propylene, and vinyl acetate.





THE GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS

The following is a gen
eral overview of the OIMS elements supporting the PSM/RMP program at BRFP.



PSM/RMP Element - Employee Participation [29 CFR 1910.119(c), 40 CFR 68.83]

-- OIMS 1.1 - Management, Leadership, Commitment, and Accountability: This system provides the framework for management to set expectations, establish standards and goals, provide resources, and ensure that performance is measured, communicated, and continuously improved. Assurance of operations integrity requires management leadership and commitment visible to the organization and accountability at all levels. Operations Integrity addresses all aspects of operations that can impact safety, security, health and environmental performance (SSH&E).

-- OIMS 5.1 - Personnel Safety: This system is in place to ensure that safety is a core value and will be considered in every decision that is made. No business objective is so important that it will be pursued at the sacrifice of safety. Each employee has a personal responsibility for our safety and the safety of others. Accidents, injuries, and occupational illnesses are preventable through the application of effective systems, procedures, and practices to ensure the safety of personnel.



PSM/RMP Element - Process Safety Information [29 CFR 1910.119(d), 40 CFR 68.65]

-- OIMS 2.1 - Risk Analysis, Assessment, and Management: This system is in place to ensure that risk assessments reduce risks to safety, security, health and the environment and mitigate the consequences of incidents by providing essential information for decision-making. This process involves hazard identification, assessment of probabilities and consequences, and evaluation of risk prevention and mitigation measures. The process applies to ongoing operations, projects, and products.

-- OIMS 3.1 - Facility Design and Construction: This system ensures that inherent safety and security can be enhanced and risk to health and the environment minimized by using sound standards, procedures, and mana
gement systems for facility design, construction, and start-up.

-- OIMS 4.1 - Documentation / Information: This system ensures accurate information on the configuration and capabilities of processes and facilities, properties of products and materials handled, potential safety, security, health, and environmental hazards, and regulatory requirements is essential to assess and manage risk.

-- OIMS 5.2 - Occupational Health: The purpose of this system is to protect the health of employees, contractors, and the community from adverse effects that may result from operations.

-- OIMS 6.1 - Operating and Maintenance Procedures: This system ensures that operation of our facilities within established operating and regulatory parameters. Operations and maintenance procedures provide guidance for plant personnel for work activities which are complex, critical, or infrequent and thus should be formalized to ensure consistent and effective execution.



PSM/RMP Element - Process Hazard Analysis [29 CFR 1910.119(e), 40 CFR 68.67]

-- OIMS 2.1 - Risk Analysis, Assessment, and Management: This system is in place to ensure that risk assessments reduce risks to safety, security, health and the environment and mitigate the consequences of incidents by providing essential information for decision-making. This process involves hazard identification, assessment of probabilities and consequences, and evaluation of risk prevention and mitigation measures. The process applies to ongoing operations, projects, and products.



PSM/RMP Element - Operating Procedures [29 CFR 1910.119(f), 40 CFR 68.69]

-- OIMS 6.1 - Operating and Maintenance Procedures: This system ensures that operation of our facilities within established operating and regulatory parameters. Operations and maintenance procedures provide guidance for plant personnel for work activities which are complex, critical, or infrequent and thus should be formalized to ensure consistent and effective execution.



PSM/RMP
Element - Training [29 CFR 1910.119(g), 40 CFR 68.71]

-- OIMS 5.4 - Training: This system ensures that personnel whose work could affect the operations integrity of the site have, and maintain, the necessary knowledge and skills to execute their job in a manner consistent with the safe and environmentally sound operation of the site.



PSM/RMP Element - Contractors [29 CFR 1910.119(h), 40 CFR 68.87]

-- OIMS 8.1 - Third Party Services: This system ensures that third parties doing work on ExxonMobil's behalf perform in a manner consistent and compatible with ExxonMobil's policies and business objectives.



PSM/RMP Element - Pre-Startup Safety Review [29 CFR 1910.119(i), 40 CFR 68.77]

-- OIMS 3.1 - Facility Design and Construction: This system ensures that inherent safety and security can be enhanced and risk to health and the environment minimized by using sound standards, procedures, and management systems for facility design, construction, and start-up.

-- OIMS 7.1 - Management of Change: This system ensures that changes in operations, procedures, applicable standards, facilities, and personnel are evaluated and managed to ensure that safety, security, health, and environmental risks arising from these changes remain at an acceptable level.



PSM/RMP Element - Mechanical Integrity [29 CFR 1910.119(j), 40 CFR 68.73]

-- OIMS 5.4 - Training: - This system ensures that personnel whose work could affect the operations integrity of the site have, and maintain, the necessary knowledge and skills to execute their job in a manner consistent with the safe and environmentally sound operation of the site.

-- OIMS 6.1 - Operating and Maintenance Procedures: This system ensures that operation of our facilities within established operating and regulatory parameters. Operations and maintenance procedures provide guidance for plant personnel for work activities which are complex, critical, or infrequent and thus should be formalized to ensure consistent and effective
execution.

-- OIMS 6.3 - Safety Critical Equipment: This system is in place to ensure that critical equipment is designed to prevent, mitigate, detect, or respond to process incidents that could result in loss of containment of flammable or toxic materials, potential severe injuries or deaths, or a release of materials that could have a serious environmental impact. Critical equipment also includes devices which protect against breaches of security access that have the potential for serious consequences. This system is intended to help ensure this equipment operates when called upon.

-- OIMS 6.4 - Mechanical Integrity: The mechanical integrity system protects the safety and health of personnel, the environment, equipment, and satisfies applicable laws, regulations, and approved standards. It addresses the mechanical integrity of all equipment that can impact SSH&E with a focus on prevention of loss of containment. It applies to existing facilities, new construction, modifications to existing facilities, and replacements-in-kind.



PSM/RMP Element - Hot Work Permits [29 CFR 1910.119(k), 40 CFR 68.85]

-- OIMS 6.4 - Mechanical Integrity: This system ensures that each site has a work permit system in place to protect personnel (employees and contractors), site facilities, and the surrounding community. The purpose of a work permit system is to ensure that jobs are planned, equipment is prepared, personnel are informed of hazards and procedures, precautions are taken, and work is executed in a manner to protect safety, security, health, and the environment.



PSM/RMP Element - Management of Change [29 CFR 1910.119(l), 40 CFR 68.75]

-- OIMS 7.1 - Management of Change: This system ensures that changes in operations, procedures, applicable standards, facilities, and personnel are evaluated and managed to ensure that safety, security, health, and environmental risks arising from these changes remain at an acceptable level.



PSM/RMP Element - Incident Investi
gation [29 CFR 1910.119(m), 40 CFR 68.81]

-- OIMS 9.1 - Incident Investigation: This system is in place to ensure that effective incident investigation, reporting, analysis and follow-up are undertaken to provide the opportunity to learn from incidents, to use the information to take corrective action, and prevent recurrence.



PSM/RMP Element - Emergency Planning & Response [29 CFR 1910.119(n), 40 CFR 68.95]

-- OIMS 10.1 - Emergency Preparedness: This system is in place to ensure that, in the event of an incident, all necessary actions are taken for the protection of the public, employees, contractors, the environment, and assets.



PSM/RMP Compliance Audits [29 CFR 1910.119(o), 40 CFR 68.79]

-- OIMS 11.1 - Assessment and Improvement: This system is in place to improve Operations Integrity by measuring performance relative to requirements. This is accomplished through a process of internal and external assessments and follow-up.

-- OIMS 6.6 - Regulatory Compliance: This system ensures compliance with safety, security, health, and environmental laws, regulations, permits and other governmental requirements, including Consent Decrees/Agreed Government Orders (CD/AGOs).





THE FIVE-YEAR ACCIDENT HISTORY

One June 15, 2010, mechanical failure in the E-Line unit's C-110 secondary compressor resulted in the release of 788 pounds of ethylene. The release qualifies as reportable under RMP due to "significant property damage on-site." A revision to the site's RMP accident history was completed in October 2010 to incorporate this event.





THE EMERGENCY RESPONSE PROGRAM

As previously stated, OIMS 10.1 (Emergency Preparedness) is in place to ensure that, in the event of an incident, all necessary actions are taken for the protection of the public, employees, contractors, the environment, and assets. This is achieved through comprehensive response procedures that coordinate on-site responders with Local Emergency Planning Committee (LEPC), industry
, and public agencies. Fixed fire protection equipment is maintained on-site with additional capability provided by area ExxonMobil resources.





PLANNED CHANGES TO IMPROVE SAFETY

As previously discussed, OIMS 11.1 (Assessment and Improvement) is in place to improve Operations Integrity by measuring performance relative to requirements. Since OIMS supports PSM / RMP elements as discussed above, the assessment and improvement process under OIMS 11.1, by definition, improves overall process safety at the site. This is accomplished through a process of internal and external OIMS assessments and follow-up. Internal assessments are conducted annually utilizing personnel trained in the expectations OIMS. External assessments are conducted periodically by personnel from outside the affected operation. Team composition and frequency are consistent with the complexity of operations, regulations, and performance history.