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Dover Chemical Corporation

Parent Companies:
ICC Industries Inc.
EPA Facility ID:
100000119686
Other ID:
44622DVRCHWESTF
Facility DUNS:
4210563
Parent Company DUNS:
46177341

Location:

Address:
3676 DAVIS RD. N.W.
Dover, OH 44622
County:
TUSCARAWAS
Lat / Long:
40.533, -81.495 (Get map)
Method:
Interpolation - Photo
Description:
Water Release Pipe
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Dover Chemical Corporation
Phone:
(330) 343-7711
Address:
3676 Davis Road. N.W.
Dover, OH 44622
Foreign Address:

Person responsible for RMP implementation:

Name:
Bridget May
Title:
Environmental Manager

Emergency contact:

Name:
Bridget May
Title:
Environmental Manager
Phone:
(330) 365-3671
24-hour phone:
(330) 365-3651
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(330) 365-3732
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Tuscarawas County LEPC
Full-Time Equivalent Employees:
200
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:
July 10, 2013
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Chlorination/Bromination
RMP ID:
1000044684
CBI claimed:
No
Program Level:
3
NAICS:
All Other Chemical Product and Preparation Manufacturing (32599)
Chemical name
CAS#
Quantity (lbs.)
CBI
Chlorine
7782-50-5
540,000
No
Bromine
7726-95-6
52,000
No
Chloroform [Methane, trichloro-]
67-66-3
50,000
No
Hydrochloric acid (conc 37% or greater)
7647-01-0
1,200,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Phosphite Manufacturing
RMP ID:
1000044685
CBI claimed:
No
Program Level:
3
NAICS:
All Other Miscellaneous Chemical Product and Preparation Manufacturing (325998)
Chemical name
CAS#
Quantity (lbs.)
CBI
Phosphorus trichloride [Phosphorous trichloride]
7719-12-2
310,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
Sept. 25, 2013
Type:
Resubmission
Reason:
Revised OCA due to change (40 CFR 68.190(b)(6))
Registered:
Yes
RMP ID:
1000036456

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 Chlorination/Bromination)
CBI claimed:
No
Percent weight:
100.0
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 Chlorination/Bromination)
CBI claimed:
No
Percent weight:
100.0
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:
  • Emergency shutdown
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
Public OCA Chemical (in Chlorination/Bromination)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Liquid
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:
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Chlorination/Bromination)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Liquid
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:
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Chlorination/Bromination)
CBI claimed:
No
Percent weight:
38.0
Physical state:
Liquid
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:
  • Emergency shutdown
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
Public OCA Chemical (in Phosphite Manufacturing)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Liquid
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:
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

Nov. 4, 2011 at 18:35
ID:
1000030118
NAICS:
All Other Chemical Product and Preparation Manufacturing (32599)
Duration:
13 minutes
Chemicals involved:
  • Chlorine
  • Hydrogen chloride (anhydrous) [Hydrochloric acid]
  • Chloroform [Methane, trichloro-]
Release events:
Gas release
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
None
Temperature:
None ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
Yes
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
3
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$1000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
2
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Improper procedure
  • Maintenance activity/inactivity
  • Management error
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised operating procedures
  • New process controls
  • Revised emergency response plan
April 18, 2009 at 00:30
ID:
1000030116
NAICS:
All Other Chemical Product and Preparation Manufacturing (32599)
Duration:
4 hours
Chemicals involved:
  • Hydrochloric acid (conc 37% or greater)
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
0.100000001 miles/h N
Temperature:
45.00 ℉
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:
$250000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
1000
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Equipment failure
  • Process design failure
  • Engineering specifications inadequately covered storage tank procurement and installation
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised emergency response plan
  • Engineering specifications will be modified and/or created

7. Prevention: Program level 3

Chlorination/Bromination, All Other Chemical Product and Preparation Manufacturing (32599)
Prevention Program ID:
1000038876
Safety Review Date
Oct. 30, 2012, since latest RMP submission
PHA Update Date
Oct. 30, 2012, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Enclosure
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Increased Inventory
  • Process Controls
  • Mitigation Systems
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
Aug. 1, 2013, since latest RMP submission
Training Review Date
Aug. 31, 2012, since latest RMP submission
Maintenance Review Date
Sept. 20, 2013, since latest RMP submission
Maintenance Inspection Date
Aug. 30, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Sept. 3, 2013
Management of Change Review Date
Jan. 31, 2013
Pre-startup Review Date
Sept. 3, 2013
Compliance Audit Date
Aug. 1, 2012
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
Sept. 8, 2013
Incident Invest. Change Completion Date
Sept. 13, 2013
Participation Plan Review Date
July 8, 2013
Hot Work Review Date
Feb. 20, 2012
Contractor Safety Review Date
July 8, 2013, since latest RMP submission
Contractor Safety Eval. Date
July 3, 2013, since latest RMP submission
Phosphite Manufacturing, All Other Miscellaneous Chemical Product and Preparation Manufacturing (325998)
Prevention Program ID:
1000038877
Safety Review Date
Aug. 15, 2013, since latest RMP submission
PHA Update Date
April 15, 2013, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Enclosure
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Process Parameters
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
Sept. 13, 2013, since latest RMP submission
Training Review Date
Aug. 20, 2012, since latest RMP submission
Maintenance Review Date
June 23, 2009, since latest RMP submission
Maintenance Inspection Date
May 20, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Sept. 16, 2013
Management of Change Review Date
Jan. 31, 2013
Pre-startup Review Date
Sept. 16, 2013
Compliance Audit Date
Aug. 13, 2012
Compliance Audit Change Completion Date
June 30, 2014
Incident Investigation Date
Sept. 12, 2013
Incident Invest. Change Completion Date
Oct. 31, 2013
Participation Plan Review Date
July 8, 2013
Hot Work Review Date
Feb. 20, 2012
Contractor Safety Review Date
July 8, 2013, since latest RMP submission
Contractor Safety Eval. Date
July 15, 2013, 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:
July 15, 2013
Local Response Agency:
Local Response Agency Phone:
(330) 343-5552
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

The Dover Chemical Corporation plant manufactures a variety of fire retardant and surfactant chemicals for customers who make consumer and commercial products. Certain raw materials and by-products are toxic chemicals that are regulated under EPA Risk Management Programs regulations that can be hazardous if released to the air in large quantities.



Dover Chemical Corporation is committed to protecting its employees, the public, and the environment from any accidental releases of hazardous materials used at its facilities. We have implemented safety, environmental protection, and risk management programs to prevent hazardous materials releases. If there is an emergency, we will immediately mobilize our emergency response team to contain and minimize the effect of the release and notify the public of any actions necessary to ensure public protection, through local emergency management agencies.



Accidental Release Prevention Steps



To minimize the potential for a chemical release , our facility maintains a release prevention program with the primary focus of protecting plant employees and the public from the hazards associated with an accident or release involving a hazardous chemical. The prevention program has twelve elements designed to meet both EPA and OSHA Process Safety Management requirements.



Our facility is committed to personnel safety, public safety, continued reliable operation and regulatory compliance. Based on this commitment, the EHS Manager and the PSM/RMP Leader have assumed responsibility for the development and implementation of the Risk Management Program. We have also clearly defined accountability and responsibility for each of the twelve prevention program elements.



Our prevention measures include, but are not limited to, the use of:



- Chlorine and hydrochloric acid process area detectors and alarms to rapidly alert operators to any problems;

- Fence line chlorine and hydrochloric acid detectors to assist in emergency resp
onse;

- Operator attended truck loading and unloading operations;

- Automatic shutoff systems for chlorine unloading operations;

- Video camera on the rail car operation to assist the operator in making a rapid decision on whether to shut the automatic valve.

- Secondary containment around tanks;

- An emergency scrubber for bromine and chlorine vents that will effectively capture vapors in the event of a spill or leak;

- Process safety information to document the safe process design;

- Process hazards analyses to evaluate the chemical and process hazards;

- Operating procedures to ensure that the system is operated safely;

- Maintenance, inspection and testing to ensure that the system is maintained according to applicable standards and manufacturer's recommendations;

- Training, hot work permits, contractor safety and employee participation programs to ensure that all employees and contractors working on and around the processes are aware of the hazards, can perform their job duties safely and know the actions to be taken in an emergency;

- management of change and pre-startup safety reviews to ensure that changes are documented, analyzed and kept within the design basis;

- incident investigation procedure to investigate each incident and "near misses" to determine root causes and make needed safety improvements; and

- periodic compliance audits to ensure that our programs are working as they should to protect both employees and the public.



Five-Year Accident History



Dover Chemical Corporation has stringent release prevention policies and emergency preparedness designed to reduce the number and consequences of accidental releases to a minimum.



There have been 2 accidental releases of regulated substances that met EPA regulatory criteria (i.e., an accident that resulted in injuries, property damage or any offsite impacts), from our facility within the last 5 years. The first release took place on April 18, 2009 a hydrochloric acid spill of 27
,000 gallons occurred but all liquid was contained in the secondary containment structure. The release to air was 2706 lbs. No deaths or injuries occurred offsite as a result of this accident and a portion of the surrounding community was sheltered-in-place as a precaution. Onsite, there were no deaths or injuries. There was some onsite property damage.



On November 04, 2011 a release of Chlorine of 82 lbs, hydrochloric acid of 71 lbs, chloroform of 6487 lbs occurred. The release was to air. There were three on-site personnel injuries. There was some minor onsite property damage. No deaths or injuries occurred offsie as a result of this accident. Davis road was shutdown as a precaution.



In each scenario, the incident was reviewed and corrective actions were generated to prevent recurrence.





Emergency Response



In the event that a chemical release does occur, Dover Chemical has an emergency response program that includes trained onsite emergency responders and coordination with the City of Dover Fire Department and the Local Emergency Planning Committee. If an emergency did occur, plant personnel will immediately activate our emergency response team to contain and minimize the effect of the release and notify the public of any actions necessary to ensure public protection, through local emergency management agencies.



Planning to Maintain a Safe Operation



Dover Chemical continually works to safely manage the hazards of chemicals to protect employees and the community we serve. The Risk Management Program will be maintained to reduce the risk of accidental releases and each year we will conduct training, review procedures, maintain the equipment and follow safe work practices. Periodically, we will audit our program, review our Process Hazard Analyses and coordinate with the community emergency response organizations.