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FAR Research, Inc. (dba FAR Chemical, Inc.)

Parent Companies:
EPA Facility ID:
100000123804
Other ID:
32905FFRSR2210W
Facility DUNS:
108940198

Location:

Address:
2210 Wilhelmina Court, NE
Palm Bay, FL 32905
County:
BREVARD
Lat / Long:
28.055, -80.593 (Get map)
Method:
Interpolation - Photo
Description:
Plant Entrance (General)
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
FAR Research, Inc.
Phone:
(321) 723-6160
Address:
2210 Wilhelmina Ct., NE
Palm Bay, FL 32905 -2548
Foreign Address:

Person responsible for RMP implementation:

Name:
Alfred A. Nuttall
Title:
President/CEO

Emergency contact:

Name:
Alfred A. Nuttall
Title:
President/CEO
Phone:
(321) 723-6160
24-hour phone:
(321) 759-5395
Ext or PIN:
17

Other contacts:

Facility (or company) email:
Facility phone:
(321) 723-6160
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
District 6 LEPC
Full-Time Equivalent Employees:
21
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
0090103-005-AF
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Jan. 14, 2014
Inspecting Agency:
Fire Department
Using Predictive Filing:
No

Processes:

Bromine
RMP ID:
1000057824
CBI claimed:
No
Program Level:
3
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Bromine
7726-95-6
56,000
No
Public OCA Chemical
0
No
Trimethylchlorosilane
RMP ID:
1000057825
CBI claimed:
No
Program Level:
3
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Trimethylchlorosilane [Silane, chlorotrimethyl-]
75-77-4
35,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
Oct. 29, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000046434

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 Bromine)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
2200.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • Dikes
  • Enclosures
not considered:
  • Berms
  • Drains
  • Sumps
Public OCA Chemical (in Trimethylchlorosilane)
CBI claimed:
No
Percent weight:
99.0
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
1050.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • Dikes
  • Enclosures
not considered:
  • 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 Bromine)
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:
  • Dikes
  • Enclosures
not considered:
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • Neutralization
  • Scrubbers
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve
  • Flares
  • Emergency shutdown
Public OCA Chemical (in Trimethylchlorosilane)
CBI claimed:
No
Percent weight:
99.0
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:
  • Neutralization
  • Scrubbers
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve
  • Flares
  • Emergency shutdown

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

Bromine, All Other Basic Organic Chemical Manufacturing (325199)
Prevention Program ID:
1000048141
Safety Review Date
March 18, 2014, since latest RMP submission
PHA Update Date
June 30, 2013, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Overfilling
  • Tornado
  • Hurricanes
Process Controls
  • Relief Valves
  • Scrubbers
  • Manual Shutoffs
  • Grounding Equipment
  • Rupture Disks
Mitigation Systems
  • Dikes
  • Neutralization
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • Process Detection
  • Perimeter Monitoring
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
March 18, 2014, since latest RMP submission
Training Review Date
May 29, 2013, since latest RMP submission
Maintenance Review Date
Feb. 10, 2014, since latest RMP submission
Maintenance Inspection Date
Oct. 3, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
June 4, 2012
Management of Change Review Date
June 4, 2012
Pre-startup Review Date
March 9, 2010
Compliance Audit Date
Sept. 25, 2012
Compliance Audit Change Completion Date
Oct. 16, 2012
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Oct. 6, 2014
Hot Work Review Date
Oct. 6, 2014
Contractor Safety Review Date
Sept. 1, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 24, 2013, since latest RMP submission
Trimethylchlorosilane, All Other Basic Organic Chemical Manufacturing (325199)
Prevention Program ID:
1000048142
Safety Review Date
March 18, 2014, since latest RMP submission
PHA Update Date
June 30, 2013, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Overpressurization
  • Corrosion
  • Overfilling
  • Tornado
  • Hurricanes
Process Controls
  • Relief Valves
  • Scrubbers
  • Manual Shutoffs
  • Grounding Equipment
  • Rupture Disks
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
March 18, 2014, since latest RMP submission
Training Review Date
Oct. 21, 2013, since latest RMP submission
Maintenance Review Date
Feb. 10, 2014, since latest RMP submission
Maintenance Inspection Date
Sept. 19, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
May 9, 2014
Management of Change Review Date
Oct. 6, 2014
Pre-startup Review Date
March 18, 2014
Compliance Audit Date
Sept. 25, 2012
Compliance Audit Change Completion Date
Oct. 16, 2012
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Oct. 6, 2014
Hot Work Review Date
Oct. 6, 2014
Contractor Safety Review Date
Sept. 1, 2012, since latest RMP submission
Contractor Safety Eval. Date
Jan. 24, 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:
Jan. 6, 2009
Local Response Agency:
Local Response Agency Phone:
(407) 623-1075
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

FAR Research, Inc. (FAR) is a manufacturer of pharmaceutical intermediates and fine organic chemicals. Bromine and trimethylchlorosilane (TMCS) are two of the chemicals used by FAR that are stored in sufficient quantity to require development and submission of a Risk Management Plan (RMP). This summary describes FAR's activities and safeguards which have been instituted to protect employees, the public, and the environment.

FAR has operated at the Palm Bay, Florida facility since 1983. FAR synthesizes pharmaceutical intermediates and fine organic chemicals. These chemicals are sold to the pharmaceutical, cosmetic, electronics, and general chemical industries. Over the years, FAR's products have been used in compounds designed to fight Aids, Hepatitis B, and other diseases. Other FAR products have been used to facilitate the manufacture of electronic chips; others have been used by the space industry. One FAR product has improved the efficiency of the manufacture of nylon. FAR and its employees are committed to continue to safely manufacture organic compounds that make a positive difference.

FAR consists of employees and the physical facility. The technical, operations, and support groups are committed to the safe development and manufacture of the products synthesized. The typical "path" for a new product at FAR begins with a customer need, followed by a thorough literature search for safety and process information. Upon completion of the background work, a synthesis route is proposed and the laboratory work commences. Chemists and technicians complete process development on a small, glassware scale to ensure that the synthesis can be completed safely. The next step includes the writing of a proposed, detailed procedure to be completed at the pilot scale. A process safety review meeting is then scheduled. The review participants include the process development chemist, the manufacturing manager, the technical director, the safety manager and the general manager. O
ther staff may be involved if warranted. The review includes verification that proper development procedures have been followed and that available safety and health information has been obtained, checked, and included with the batch record. Any recommended changes made by the committee must be completed prior to scale-up of the process. The review committee may also require that special operator training sessions be held prior to running certain compounds or chemistries.

Equipment Summary: Process equipment at FAR is designed for the intended use. Process vessels are glassteel or grade 316 stainless steel. The vessels are ASME Code rated and are protected with rupture discs and/or relief valves. If corrosion is of concern, testing may be completed prior to running in a given vessel. Glassteel vessels may be spark tested to verify integrity. Alloy vessels are tested using ultrasonic wall thickness testing devices. Key vessels and equipment are checked for maintenance annually. Both the TMCS and the bromine tanks are surrounded by a containment dike designed to hold more than the maximum volume of the tank. In addition, the TMCS tank is protected with an AFFF 3% medium expansion foam deluge system.

The materials triggering filing of the RMP are bromine and TMCS. Liquefied bromine is stored in a 2,000-gallon storage tank and a 1,500-gallon receiving vessel/reactor. TMCS is stored in a 5,000-gallon pressure rated carbon steel tank. The maximum quantities of bromine and TMCS inventoried are 56,000 pounds and 35,000 pounds, respectively. FAR's policy is to minimize inventory of all raw materials. The materials are delivered by bulk tank wagon in quantities of approximately 30,000 pounds. Orders are not placed unless inventories are less than 15,000 pounds for bromine and 2,000 pounds for TMCS. Bromine inventory is verified by tank load cells, receiving and usage records. TMCS inventory is verified by level gauge, receiving and usage records.


No accidental releases
of bromine or TMCS have occurred in the past five years.

FAR plans to continue to safely handle bromine and TMCS and will incorporate procedures that will further reduce the possibility of a chemical release.