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Shell Chemical Company Inc. Taft Plant

Parent Companies:
Shell Oil Company Inc.
EPA Facility ID:
100000123403
Other ID:
70057SHLLCLA18A
Facility DUNS:
184957348
Parent Company DUNS:
8090938

Location:

Address:
473 HWY 3142
Taft, LA 70057
County:
ST. CHARLES
Lat / Long:
29.979, -90.455 (Get map)
Method:
GPS - Unspecified
Description:
Center of Facility
Horizonal accuracy:
m
Horizontal reference datum:
Source map scale:

Owner/Operator:

Name:
Shell Chemical Company Inc.
Phone:
(504) 465-5200
Address:
473 HWY 3142
Taft, LA 70057
Foreign Address:

Person responsible for RMP implementation:

Name:
L.R. Palme
Title:
Plant Manager
Email:

Emergency contact:

Name:
HS&E Star Point
Title:
Process Technician
Phone:
(504) 465-5249
24-hour phone:
(504) 465-5249
Ext or PIN:
Email:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
St. Charles Parish LEPC
Full-Time Equivalent Employees:
49
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:
June 16, 1999
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Polybutylene Process
RMP ID:
15697
CBI claimed:
No
Program Level:
3
NAICS:
Plastics Material and Resin Manufacturing (325211)
Chemical name
CAS#
Quantity (lbs.)
CBI
1-Butene
106-98-9
1,400,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 22, 1999
Type:
First-time submission
Reason:
Registered:
Yes
RMP ID:
11736

Deregistration:

Date:
Effective Date:
Reason:
Other Reason:

2. Toxics: Worst-case

None

3. Toxics: Alternative release

None

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 Polybutylene Process)
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 Polybutylene Process)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Fire wall
  • Blast walls
  • Enclosures
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

Polybutylene Process, Plastics Material and Resin Manufacturing (325211)
Prevention Program ID:
8085
Safety Review Date
May 11, 1998, since latest RMP submission
PHA Update Date
May 11, 1998, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Air Supply
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Quench System
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Deluge System
  • Neutralization
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
Competency Testing
  • Written Test
Procedure Review Date
April 15, 1999, since latest RMP submission
Training Review Date
June 8, 1999, since latest RMP submission
Maintenance Review Date
June 15, 1998, since latest RMP submission
Maintenance Inspection Date
May 19, 1999, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
May 26, 1999
Management of Change Review Date
June 1, 1999
Pre-startup Review Date
June 10, 1999
Compliance Audit Date
April 13, 1998
Compliance Audit Change Completion Date
Dec. 31, 1998
Incident Investigation Date
June 5, 1999
Incident Invest. Change Completion Date
July 30, 1999
Participation Plan Review Date
May 4, 1998
Hot Work Review Date
April 11, 1997
Contractor Safety Review Date
March 5, 1998, since latest RMP submission
Contractor Safety Eval. Date
June 3, 1999, 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:
Dec. 2, 1998
Local Response Agency:
Local Response Agency Phone:
(504) 783-5050
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

Shell Chemical Taft Plant Risk Management Program
LDEQ Facility ID 583


SOURCE AND PROCESS DESCRIPTION

The Shell Chemical Taft facility has one Program 3 covered process described as follows:

Polybutylene is a thermoplastic polymer produced via solution polymerization of 1-butene monomer. The process contains a storage vessel with the maximum capacity of 1,400,000 lbs. of 1-butene.

SUMMARY OF MAJOR HAZARDS

The worse case flammable scenario would be the release of the entire contents of the 1-butene storage vessel with the potential subsequent vapor cloud explosion of 1 psi endpoint that would not reach a residential area. The flammable alternate case scenario is a two inch butene -1 transfer hose at the truck unloading facility fails releasing butene - 1 with a potential subsequent vapor cloud explosion of 1 psi endpoint that would reach an industrial neighbor, but not a residential community.

ACCIDENT PREVENTION

The polybutylene process at the Shell Taft Plant is covered by 29 CFR 1910.119, the OSHA Process Safety Management (PSM) Standard that requires Process Hazards Analysis (PHA). A PHA has been completed for the polybutylene process and safety improvements have been implemented. Any changes to processes (procedures, raw materials, process conditions, etc.) or plant equipment following the PHA must follow the Management of Change (MOC) procedure whereby a team, selected on the basis of expertise and experience, reviews the change to determine if there is any impact on safety, health or environment as well as the technical feasibility. MOC's are tracked and documented as required. All PHA's are revalidated at least every five years and documentation is retained for the life of the process.

The PSM Standard requires that each employee presently involved in operating a process, and each employee before operating a newly assigned process, be trained in an overview of the process and operating procedures. This includes safety, health, emergency oper
ations, shutdown and safe work practices. At the Taft Plant both classroom and field training accomplish this. Written tests and field observation verify understanding of the training. Maintenance and contract maintenance employees are trained, not only in the craft skills and repair procedures, but also in the safety and environmental aspects of their job. Refresher training for operators and maintenance personnel is conducted at least every three years and more often if necessary. Training on certain safe work practices ( hot work, confined space entry, etc. ) is conducted annually.

The Polybutlene process Safety Design Criteria is based on Industry Recognized and Generally Accepted Good Engineering Practices. Pre-startup Safety Reviews (PSSR) are conducted to verify compliance prior to startup. PSSR is also conducted as a step in the MOC process when there is an equipment change or modification.

The Taft Plant has a formal Mechanical Integrity Management System that defines the frequency and protocol of preventive maintenance which sustains the mechanical integrity of critical process equipment such as pressure vessels, storage tanks, piping systems, pressure relief valves, pumps, emergency shutdown systems and control systems.


EMERGENCY PREPADREDNESS

The Shell Chemical Taft Plant has a written Emergency Response Plan which details the responsibilities of employees during emergency situations including fire, explosion, chemical release and process deviations. Each shift has Health and Safety Star Points that are trained in the Incident Command System and receive annual Industrial Fire Training at Delgado Fire School. All operations and maintenance personnel attend the Industrial Fire Training at Delgado Fire School.

The plant has an emergency alarm system that is sounded in emergencies, followed by the activation of the plants emergency action plan. Emergency drills are conducted periodically to test the response to emergencies and drills are
critiqued in order to improve response capabilities.

Operations and maintenance personnel receive Hazardous Waste and Emergency Response (HAZWOPER) training as required by OSHA. Employees involved in the transport of hazardous materials receive DOT training.

The Taft Plant has written procedures on emergency preparedness for other unusual situations such as hurricanes and bomb threats. The process has a backup system to the instrument air system. This allows a safe shutdown in the event of an electrical power failure.

Shell is an active participant in the St. Charles Industrial Mutual Aid Organization which supports members with equipment in case of emergency situations.

COMMUNITY SAFETY

Through active participation in the St. Charles Parish Industrial Mutual Aid organization and close work with the St.Charles Parish Emergency Preparedness Department, Shell is involved in developing and maintaining the system designed to protect the community in the event of a chemical emergency. A network of sirens is in place to immediately alert the community of an emergency and the need to monitor radio and TV for instructions from the Department of Emergency Preparedness.

INCIDENT HISTORY

40 CFR 68.42, the US Environmental Protection Agency (EPA) requires covered industries to report a five-year accident history in the Risk Management Plan based on the following guidelines: "all accidental releases from covered processes that resulted in deaths, injuries or significant property damage on site, or known off-site deaths, injuries, evacuations, sheltering in place, property damage or environmental damage." The Shell Taft Plant has had no incidents in the past five years which meet these criteria.

COMMUNITY OUTREACH

The CMA requirements for achieving "Practice In Place" for the Responsible Care codes of management practice (which Shell Taft Plant has achieved) involves a lot of interaction with the community. Although Responsible Care has certainly increased th
ese activities, Shell Taft has always sought to be a good corporate Neighbor. Examples of this are participation in the Lulling Elementary School Partners in Education Program, building a wheel chair ramp for a handicapped person in the community, painting the St. Charles Parish senior citizen hall, cleaning-up and painting the St. Charles Association for handicapped & retarded citizens, recognizing Jr. Fire-fighters, judging science fairs for the schools, having blood drives, and participating in the United Way Program, etc.

Shell Taft has given educational seminars and tours to the St. Charles Parish Advisory Panel (CAP) and its partners in education teachers. The plant has also hosted a teacher from another parish to follow employees for several days in order to gain a better understanding of what chemical plant workers do and what the academic requirements needede to obtain jobs in the chemical industry.

Shell Plant management is an active participant with the St. Charles Parish Community Advisory Panel (CAP). Typical topics of discussion at CAP meetings are emergency preparedness, environmental concerns, community health concerns and transportation safety, etc.. In addition to scheduled presentations by plant representatives and technical experts (environmental, etc.) the CAP meetings provide an open forum for community members to question plant management about their concerns relative to plant operations and to provide feedback from the community at large.

PLANT HISTORY

The Taft Plant was owned and operated by Witco Chemical Company Inc. beginning production in 1974. December of 1977 Shell Chemical Company Inc. purchased the plant.

The Taft Plant is Shell's only Polybutylene plant in the world. It occupies 6.5 acres of land at 473 Hwy 3142, Taft, La., 70057. The Taft Facility employs fourty-nine full time employees and approximately eleven contract employees.

PRODUCT INFORMATION

At Taft, we manufacture polybutene resins (PB). There is a
wide range of polybutene grades that supply material for a wide range of uses.

Some of these uses are: pipe products for plumbing (hot and cold water) and under-floor heating, water heater liners, industrial strength films, peel-seal applications, autoclavable films and industrial adhesives.

Since PB is very strong, it is often added to other plastics to increase their strength, such as in baby diapers and diaper liners. Since PB is FDA approved for food contact and serum uses, it is found in medical applications such as blood and plasma bags. PB can also be used to make packaaging such as cereal bags and pudding containers easier to open.