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Faustina Plant

Parent Companies:
Mosaic Fertilizer, LLC
Tampa Port Services, LLC (TPS)
EPA Facility ID:
100000117651
Other ID:
Facility DUNS:
807195722
Parent Company #1 DUNS:
807195722
Parent Company #2 DUNS:
79263913

Location:

Address:
9959 Hwy 18
St. James, LA 70086
County:
ST. JAMES
Lat / Long:
30.085, -90.915 (Get map)
Method:
Interpolation - Photo
Description:
Storage Tank
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Mosaic Fertilizer, LLC and TPS
Phone:
(225) 562-3501
Address:
9959 Hwy 18
St. James, LA 70086 -9000
Foreign Address:

Person responsible for RMP implementation:

Name:
Steven P. Chatelain
Title:
Environmental Superintendent-LA Ops

Emergency contact:

Name:
Steven P. Chatelain
Title:
Environmental Superintendent-LA Ops
Phone:
(225) 474-4098
24-hour phone:
(225) 614-2008
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
St. James Parish LEPC
Full-Time Equivalent Employees:
290
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
2560-00021-V6
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
May 15, 2013
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Ammonia Plant
RMP ID:
1000081557
CBI claimed:
No
Program Level:
3
NAICS:
Phosphatic Fertilizer Manufacturing (325312)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
44,235,504
No
Flammable Mixture
00-11-11
48,843
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Ramboll Environ US Corporation
Address:
8235 YMCA Plaza Drive
Suite 300
Baton Rouge, LA 70810
Foreign Address:

Phone:
(225) 408-2696

Latest RMP Submission:

Date:
Aug. 15, 2017
Type:
Resubmission
Reason:
Revised PHA / Hazard Review due to process change (40 CFR 68.190(b)(5))
Registered:
Yes
RMP ID:
1000065021

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 Ammonia Plant)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by refrigeration
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:
  • 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 Ammonia Plant)
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:
Rural
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • 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 Ammonia 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 Ammonia Plant)
CBI claimed:
No
Model used:
TRACE
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

No Registered Accidents

7. Prevention: Program level 3

Ammonia Plant, Phosphatic Fertilizer Manufacturing (325312)
Prevention Program ID:
1000068651
Safety Review Date
Feb. 11, 2016, since latest RMP submission
PHA Update Date
Aug. 12, 2016, since latest RMP submission
PHA Techniques
  • Checklist
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Deluge System
  • Neutralization
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
March 15, 2017, since latest RMP submission
Training Review Date
June 27, 2017, since latest RMP submission
Maintenance Review Date
Feb. 26, 2016, since latest RMP submission
Maintenance Inspection Date
May 7, 2017, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
July 5, 2017
Management of Change Review Date
March 12, 2014
Pre-startup Review Date
June 6, 2017
Compliance Audit Date
Feb. 22, 2016
Compliance Audit Change Completion Date
Feb. 22, 2018
Incident Investigation Date
July 24, 2017
Incident Invest. Change Completion Date
Aug. 1, 2018
Participation Plan Review Date
July 1, 2016
Hot Work Review Date
Feb. 26, 2016
Contractor Safety Review Date
Feb. 26, 2016, since latest RMP submission
Contractor Safety Eval. Date
Feb. 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:
June 27, 2017
Local Response Agency:
Local Response Agency Phone:
(225) 562-2265
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

EXECUTIVE SUMMARY - Mosaic Fertilizer, LLC, Faustina Facility



2425 LDEQ Facility ID Number



Mosaic Fertilizer, LLC, ("Mosaic") owns and operates the Faustina Facility located in St. James, Louisiana. Assets for the ammonia plant are owned and operated by Tampa Port Services (TPS), which is wholly owned by Mosaic. All TPS employees are Mosaic employees. Additionally, Grammar Industries, Inc. is a tenant on Mosaic property operating an ammonia truck loading facility that is covered under this plan.

Mosaic constructed the ammonia truck loading facility in 2016 and early 2017, and Grammar Industries, Inc. began operation of the facility on February 15, 2017. Since the ammonia truck loading facility qualified as a significant change and required the performance of a Process Hazards Analysis (PHA), Mosaic must update the RMP within six months of startup of the loading facility.

The Mosaic Fertilizer, LLC, Faustina Facility has a long standing commitment to our workers, community and the environment. This commitment is demonstrated by our establishment of management systems and resources invested in accident prevention, such as personnel training, emergency equipment, participation in St. James Parish emergency drills, meetings with other companies, and the St. James Parish emergency operations center, and meetings with the Ascension Parish emergency response organizations. This commitment is also consistent with the corporation's environmental, health and safety policy which provides that:

1. All facilities will be designed, safely operated, and managed to protect the health and safety of our employees, the community and the environment;

2. All employees are educated on the applicable environmental, health and safety standards, and procedures to manage the hazards associated with the regulated substance; and

3. Audits will be conducted regularly to verify compliance with management systems as described in the Environmental Protection Agency's (EPA's) re
gulation 40 CFR 68.

Additionally, corporate policies include compliance with OSHA's regulation 29 CFR 119.1910 Process Safety Management standard to ensure that multiple levels of safeguards are established against the catastrophic release of highly hazardous chemicals from potential fire, explosion and /or accidental release of toxic hazards.



2.1 Accidental Release Prevention and Response Policies



The Mosaic Fertilizer, LLC, Faustina Facility implements reasonable controls to prevent accidental releases of regulated and hazardous substances by considering less hazardous alternatives. When using a regulated substance, equipment is designed, built, maintained and operated to reduce the likelihood of an accidental release consistent with industry and government standards. If an accidental release does occur, Mosaic Fertilizer, LLC's emergency response policy includes trained personnel to recognize an accidental release, quickly assess the severity of the release and involve personnel who are trained to control and contain the release in a safe manner. As mentioned above, Mosaic also participates with organizations within St. James Parish and Ascension Parish to ensure plans are in place to minimize the impact to the community and environment.



2.2 Stationary Sources and Regulated Substances



The Mosaic Fertilizer, LLC, Faustina Facility produces granular monoammonium phosphate (GMAP), and diammonium phosphate (DAP) products. The raw materials used in this process include molten sulfur, phosphate rock, anhydrous ammonia, air and steam. Natural gas mixtures are used as a fuel source for some equipment within the granulation facilities. Additionally, the Faustina Facility manufactures anhydrous ammonia in the ammonia plant through a catalytic reaction involving natural gas, steam and air; the ammonia is used within the granulation facilities, stored and shipped off site. The manufacturing process for anhydrous ammonia also includes carbon dioxide as a
byproduct.



The regulated substances involved in these processes at the Faustina Facility that exceed the threshold quantities as described by the RMP rule include anhydrous ammonia and a flammable gas mixture generated in the ammonia plant.



Anhydrous ammonia is stored in a large refrigerated storage tank surrounded by a dike. In addition to the anhydrous ammonia manufactured in the facility's ammonia plant, the Faustina Facility also receives anhydrous ammonia via an underground commercial pipeline, as well as by ship and barge at the facility's river dock on occasion. Mosaic recently completed construction on truck loading racks to allow the loading of ammonia into tanker trucks for transport. Natural gas is received at the facility by an underground commercial pipeline that is connected by piping to the ammonia plant.



2.3 General Accidental Release Prevention Program and Chemical Specific Prevention Steps



Anhydrous ammonia and flammable mixtures are regulated as highly hazardous chemicals under OSHA's Process Safety Management (PSM) standard. Based on the quantities of these substances present at the Faustina Facility, it is subject to OSHA's PSM requirements, and therefore, the Faustina Facility satisfies the eligibility requirements for a Program 3 Prevention Program under EPA's RMP. The Faustina Facility has fully implemented OSHA's PSM standard requirements and is using this program as its RMP Prevention Program. A brief summary of the facility's PSM program is as follows:

Mosaic Fertilizer, LLC, Faustina Facility encourages all employees to participate in all facets of process safety and accident prevention and has an employee participation plan that documents the many ways employees are involved in these processes.



Mosaic Fertilizer, LLC, Faustina Facility has technical documents which describe the process safety information associated with the regulated substance. These documents, which are available to all of our employees, describe (1
) physical properties of the hazardous substances, (2) operating parameters for our equipment and (3) design basis and configuration of our equipment. These documents are for reference and updated if there are changes within the facility through our management of change process.



Mosaic Fertilizer, LLC, Faustina Facility also has a comprehensive program to help ensure that hazards associated with various processes are identified and controlled. Within this program, each process is systematically examined to identify hazards and ensure that adequate controls are in place to manage these hazards through the use of process hazard analysis techniques.



Mosaic Fertilizer, LLC, Faustina Facility periodically revalidates its process hazard analyses to incorporate regulatory changes, new developments (such as lower toxicity standards and technology improvements), and offsite consequences. These revalidations occur every five years and the findings along with their resolutions are kept for the life of the process.



Mosaic Fertilizer, LLC, Faustina Facility has established practices and procedures to operate equipment safely through defined operating procedures which include steps for safely conducting activities, appropriate inclusion of applicable process safety information and safety and health considerations such as personnel protective equipment and actions to be taken if exposed to a hazardous substance. Additionally, we train our workers to safely perform assigned tasks through both initial and refresher training programs.



Mosaic Fertilizer, LLC, Faustina Facility has well-established mechanical integrity practices and procedures to maintain pressure vessels, piping systems, relief and vent systems, controls, pumps and compressors, and emergency shutdown systems in a safe operating condition. The basic aspects of this program include: (1) Conducting training; (2) Developing written procedures; (3) Performing inspections and tests in accordance with recogniz
ed standards; and (4) Correcting identified deficiencies and applying quality assurance measures. For example, the facility performs nondestructive testing on a scheduled basis on the anhydrous ammonia storage vessel to verify mechanical soundness from potential cracks and other sources of corrosion.



Mosaic Fertilizer, LLC, Faustina Facility also has procedures in place to ensure continuation of the entire PSM program, including: writing and periodically updating operating procedures; training operators and maintenance personnel; management of change programs; incident investigation; safe work and hot work practices; contractor safety programs; plus maintaining an audit schedule that meets EPA's RMP and OSHA's PSM requirements.



Mosaic Fertilizer, LLC, Faustina Facility has incorporated a number of redundant safety features to prevent and/or minimize releases of regulated substances:



The large refrigerated anhydrous ammonia storage vessel is double-walled. The storage vessel is monitored by operators for ammonia leaks and has continuous monitoring electronic leak detection equipment with control room alarm monitoring the annular space between the double wall for ammonia leaks. Typically, the vessel operates significantly below maximum capacity. In the event of a long-term compressor outage, the anhydrous ammonia could be flared; sent to another ammonia producer in nearby Ascension Parish; or consumed in the granulation plants. In the event of a vessel rupture, there is a dike completely surrounding the vessel sufficiently high to contain its entire contents with a margin of safety. There is also an internal dike within the main dike that would keep smaller spills from spreading out to the maximum area of the dike thus reducing spill evaporation. A series of relief valves connected to a flare also protect the tank from overpressure.



Other smaller pressurized anhydrous ammonia storage vessels in the ammonia plant have relief valves that are piped directly t
o a flare system or vented to atmosphere. Other ammonia relief valves are placed such that a discharge is elevated and would be significantly diluted before reaching areas affecting people. There are also automated shutdown systems for the anhydrous ammonia manufacturing plant at the site. The Ammonia Truck Loading Facility is equipped with a manual emergency shutdown and deluge system in the event of an emergency. Measures to prevent the accidental release of the flammable gases in the ammonia plant and to minimize the effects of any accidental releases include: redundant instruments, backup systems, and water deluge systems.



2.4 Five-Year Accident History



The five-year accident history includes a review of all accidental releases of regulated substances held above threshold quantities in covered processes that resulted in on-site deaths, injuries, or significant property damage, or known off-site deaths, injuries, evacuations, sheltering-in-place, property damage, or environmental damage. For the five-year period prior to August 2017, there have been no accidental releases that have resulted in any of the listed potential consequences.



2.5 Emergency Response Program



Mosaic Fertilizer, LLC, Faustina facility maintains a written emergency response program that is in place to protect worker and public safety as well as the environment. The program consists of procedures for responding to releases of regulated and other substances, including the possibility of ammonia releases and fire or explosion. There are established processes to review and update the emergency response program appropriately, and it complies with federal contingency regulations [e.g., OSHA regulation 29 CFR 1910.38(a)]. A copy of the plan has been provided to the fire department and the Local Emergency Planning Committee].



Mosaic Fertilizer, LLC, Faustina Facility is located in St. James Parish Louisiana and is also in close proximity to Ascension Parish. When an emergency situa
tion arises requiring outside assistance, the Faustina Facility's overall emergency response program is coordinated with the St. James Parish Emergency Operations Center (St. James EOC). Via this organization, Faustina works closely with other emergency response organizations including the sheriffs of both parishes, St. James and Ascension Parish emergency response personnel, Louisiana State Police and Prevost Memorial Hospital in Donaldsonville. Faustina has 24-hour capability to communicate with these organizations. Faustina uses an Incident Command System for emergency response.



Mosaic Fertilizer, LLC, Faustina Facility is an active member of the St. James Parish mutual aid, Geismar Area Mutual Aid group of Ascension Parish and the Baton Rouge Mutual Aid Organization. These groups include parish government and major area industries.



Mosaic Fertilizer, LLC, Faustina Facility has an emergency equipment maintenance, inspection, and testing program. In addition, Faustina employees receive training for the use of emergency response equipment, emergency response, medical assistance, and the Incident Command System. There is a significant number of appropriately trained personnel on each shift, and all employees receive a periodic training update. The emergency response program is periodically audited. Appropriate changes are made in response to audit recommendations and operating experience.



Mosaic Fertilizer, LLC, Faustina Facility periodically tests its emergency response program. The testing consists of onsite testing of emergency response equipment, in plant drills, and periodic mock emergency response scenarios coordinated by the St. James EOC. The Faustina facility also includes TV and radio station telephone numbers in its emergency response plan.



2.6 Planned Changes to Improve Safety



Mosaic Fertilizer, LLC, Faustina Facility has action items assigned and scheduled to be completed as a result of soliciting safety suggestions from our employees, i
nternal audits, equipment inspections and process hazard analyses.



2.7 RMP Update and Resubmittal



The August 2017 update and resubmittal incorporated changes due to the construction of the ammonia truck loading facility, as well as providing updated prevention program and general facility information as required for a 5-year resubmittal.