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BASF-Zachary

Parent Companies:
BASF Americas Corporation
EPA Facility ID:
100000130137
Other ID:
Facility DUNS:
828787437
Parent Company DUNS:
555429393

Location:

Address:
111 West Irene Road
Zachary, LA 70791
County:
EAST BATON ROUGE
Lat / Long:
30.612, -91.233 (Get map)
Method:
Interpolation - Map
Description:
Center of Facility
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
56320

Owner/Operator:

Name:
BASF Corporation
Phone:
(225) 654-6801
Address:
111 West Irene Road
Zachary, LA 70791
Foreign Address:

Person responsible for RMP implementation:

Name:
Laurie Stumpe
Title:
Site Director

Emergency contact:

Name:
Travis Schexnaydre
Title:
EHS Specialist Sr I
Phone:
(225) 218-5006
24-hour phone:
(225) 654-6801
Ext or PIN:
4200

Other contacts:

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

Safety:

Local Emergency Planning Committee:
East Baton Rouge LEPC
Full-Time Equivalent Employees:
61
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:
Jan. 24, 2012
Inspecting Agency:
EPA
Using Predictive Filing:
No

Processes:

Glymes Unit
RMP ID:
1000060658
CBI claimed:
No
Program Level:
3
NAICS:
Other Basic Organic Chemical Manufacturing (32519)
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Methyl chloride [Methane, chloro-]
74-87-3
270,000
No
Ethyl chloride [Ethane, chloro-]
75-00-3
93,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Dioxane/Dioxolane Unit
RMP ID:
1000060659
CBI claimed:
No
Program Level:
3
NAICS:
Other Basic Organic Chemical Manufacturing (32519)
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Formaldehyde (solution)
50-00-0
160,000
No
Flammable Mixture
00-11-11
64,000
No
Ethylamine [Ethanamine]
75-04-7
120,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Multi Purpose Unit
RMP ID:
1000060661
CBI claimed:
No
Program Level:
3
NAICS:
Other Basic Organic Chemical Manufacturing (32519)
Chemical name
CAS#
Quantity (lbs.)
CBI
2-Methylpropene [1-Propene, 2-methyl-]
115-11-7
40,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 22, 2015
Type:
Resubmission
Reason:
Process no longer covered (source has other processes that remain covered) (40 CFR 68.190(b)(7))
Registered:
Yes
RMP ID:
1000048451

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 Glymes Unit)
CBI claimed:
No
Percent weight:
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:
Rural
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 Glymes Unit)
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:
  • Water curtain
not considered:
  • Sprinkler systems
  • Deluge systems
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Dioxane/Dioxolane Unit)
CBI claimed:
No
Percent weight:
37.0
Physical state:
Liquid
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:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown

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 Dioxane/Dioxolane Unit)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
Passive mitigation
considered:
  • None
not considered:
  • Blast walls
Public OCA Chemical (in Multi Purpose Unit)
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 Multi Purpose Unit)
CBI claimed:
No
Model used:
EPA's RMP*Comp(TM)
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

Glymes Unit, All Other Basic Organic Chemical Manufacturing (325199)
Prevention Program ID:
1000050465
Safety Review Date
Nov. 19, 2014, since latest RMP submission
PHA Update Date
Nov. 19, 2014, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Interlocks
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Fire Walls
  • Deluge System
  • Enclosure
  • Neutralization
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Demonstration
  • Observation
Procedure Review Date
Jan. 27, 2015, since latest RMP submission
Training Review Date
March 24, 2015, since latest RMP submission
Maintenance Review Date
Feb. 5, 2015, since latest RMP submission
Maintenance Inspection Date
May 23, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 19, 2015
Management of Change Review Date
Aug. 26, 2013
Pre-startup Review Date
Nov. 20, 2014
Compliance Audit Date
Dec. 13, 2012
Compliance Audit Change Completion Date
Nov. 14, 2015
Incident Investigation Date
Feb. 17, 2009
Incident Invest. Change Completion Date
July 1, 2009
Participation Plan Review Date
Sept. 26, 2014
Hot Work Review Date
Sept. 28, 2014
Contractor Safety Review Date
April 15, 2015, since latest RMP submission
Contractor Safety Eval. Date
March 18, 2014, since latest RMP submission
Dioxane/Dioxolane Unit, Other Basic Organic Chemical Manufacturing (32519)
Prevention Program ID:
1000050462
Safety Review Date
April 17, 2015, since latest RMP submission
PHA Update Date
April 24, 2015, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Overfilling
  • Equipment failure
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Flares
  • Interlocks
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Deluge System
  • Neutralization
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Demonstration
  • Observation
Procedure Review Date
Jan. 27, 2015, since latest RMP submission
Training Review Date
March 24, 2015, since latest RMP submission
Maintenance Review Date
Feb. 5, 2015, since latest RMP submission
Maintenance Inspection Date
April 24, 2015, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 14, 2014
Management of Change Review Date
Aug. 26, 2013
Pre-startup Review Date
Dec. 17, 2014
Compliance Audit Date
Dec. 13, 2012
Compliance Audit Change Completion Date
Nov. 15, 2015
Incident Investigation Date
June 27, 2011
Incident Invest. Change Completion Date
June 27, 2011
Participation Plan Review Date
Sept. 26, 2014
Hot Work Review Date
Sept. 28, 2014
Contractor Safety Review Date
April 15, 2015, since latest RMP submission
Contractor Safety Eval. Date
March 18, 2014, since latest RMP submission
Multi Purpose Unit, Other Basic Organic Chemical Manufacturing (32519)
Prevention Program ID:
1000050464
Safety Review Date
April 28, 2015, since latest RMP submission
PHA Update Date
April 28, 2015, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Interlocks
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Deluge System
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Demonstration
  • Observation
Procedure Review Date
Jan. 27, 2015, since latest RMP submission
Training Review Date
March 24, 2015, since latest RMP submission
Maintenance Review Date
Feb. 5, 2015, since latest RMP submission
Maintenance Inspection Date
April 29, 2015, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Oct. 9, 2014
Management of Change Review Date
Aug. 26, 2013
Pre-startup Review Date
Oct. 10, 2014
Compliance Audit Date
Dec. 13, 2012
Compliance Audit Change Completion Date
Nov. 14, 2015
Incident Investigation Date
March 24, 2009
Incident Invest. Change Completion Date
March 31, 2009
Participation Plan Review Date
Sept. 26, 2014
Hot Work Review Date
Sept. 28, 2014
Contractor Safety Review Date
April 15, 2015, since latest RMP submission
Contractor Safety Eval. Date
March 18, 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:
April 23, 2015
Local Response Agency:
Local Response Agency Phone:
(225) 654-0026
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

3387 LDEQ Facility Agency Interest Number



Accidental Release Prevention and Emergency Response Policies

With the volumes and kinds of chemicals manufactured and stored at BASF - Zachary, the types of release hazard emergencies possible are spills, toxic releases, fires or explosions.

< The BASF Corporation (BASF-Zachary) has a long-standing commitment to worker and public safety. This commitment is demonstrated by the resources invested in accident prevention, such as the training of personnel and consideration of safety in the design, installation, operation, and maintenance of our processes. Our policy is to implement reasonable controls to prevent foreseeable spills or releases of substances. If, in spite of all precautions, should a release or spill occur, BASF-Zachary's trained personnel will respond to control and contain the release. In addition to trained personnel, berms and containment walls are utilized throughout the facility.

< Chemical burns caused by corrosives and solvents can occur when personnel come into direct contact with the material. Prevention of skin and eye contact with any material will prevent these types of injuries. Training and use of the proper personal protective equipment is emphasized to prevent skin and eye contact. A safety shower and eye-wash stations are provided in all work areas for the safety of workers in the event skin or eye contact should occur. A current eyewash inspection program is in place to ensure the integrity of each eyewash station.

< Burns resulting from fires or explosion would be similar to any high temperature burns. Smoke inhalation is also a possibility in a fire. Fire monitors and sprinkler systems are located throughout the plant. A significant number of employees are members of the plant's Fire Brigade and are trained to fight incipient fires

< Storage and handling of flammable liquids pose the greatest potential for causing an emergency. Every effort is made to ensure that all
chemicals are handled in the safest methods possible to minimize the possibilities of fire or explosion. Smoking is prohibited in the hazardous material storage areas and access is restricted to authorized personnel. Other combustible materials are stored at a safe distance from flammable liquids. Drums are kept securely closed unless it becomes necessary to sample or transfer the chemical. Potential sources of ignition are avoided when chemicals are being handled. Flammable liquids are only handled where ventilation is adequate to avoid amassing a concentration of explosive vapors. Hot Work procedures are in place and permits must be issued before Hot Work must be conducted.

The BASF - Zachary site is also manned by a 24/7 Guard Service to prevent any incidents involving unauthorized persons who may accidently or intentionally cause damage to our site, our neighbors, or the environment. BASF - Zachary also abides by all DHS Security regulations and has a DOT Security Plan in place.



Description of the Facility and Regulated Substances Handled



BASF-Zachary manufactures, processes, and stores specialty chemicals in Zachary, East Baton Rouge Parish, Louisiana, and evaluated the facility to determine if any regulated flammable or toxic substances exceeded threshold quantities. Based on process knowledge, BASF-Zachary identified the regulated substances and quantities kept on site. See the Registration Information in Section I of this RMP Plan for details on chemicals and processes.

In addition, BASF-Zachary is subject to Occupational Safety & Health Administration (OSHA) Process Safety Management (PSM) and is classified under a listed SIC Code (2869). Therefore, the four BASF-Zachary processes are classified as Program 3 processes under the Accidental Release Prevention (ARP) Program.



Worst-Case Scenarios



Flammable Substances: The endpoint for the worst-case release of flammable substances is 1 pound per square inch (psi) over pressure
(i.e., 15.7 psia) for vapor cloud explosions. The ARP Program requirement for flammables assumes an instantaneous release and vapor cloud explosion. BASF-Zachary has 2 worst case scenarios for flammables because the scenarios go off-site and affect different off-site receptors. The distance to the endpoint of 1 psi over pressure for the worst-case release of 2-methylpropene using RMP Comp is 0.3 miles and for the flammable mixture (with acetaldehyde) using RMP Comp is also 0.3 miles.



Toxic Substances: Toxic endpoints are listed in Appendix A to 40 CFR Part 68 (Table of Toxic Endpoints). Each of the three regulated toxic substances at BASF-Zachary was reviewed to determine the substance with the greatest distance to endpoint. The RMP Comp results indicate that a worst-case release of methyl chloride results in a distance to the toxic endpoint of approximately 3.7 miles.



Alternative Release Scenarios



Alternative release scenarios are those that are more likely to occur than the worst-case release scenario. Alternative release scenarios for toxic substances should be those that lead to concentrations above the endpoint beyond the facility's fence line. Conditions considered for alternative release scenarios are: a release rate dependent upon scenario; use of typical meteorological conditions at the stationary source; the actual release height; and consideration of active and passive mitigation systems.



Flammable Substances: A single alternative release scenario for all flammable substances is required under the ARP Program. BASF-Zachary considered several alternative release scenarios. Using RMP Comp, it was determined that a hypothetical release of 2-Methyl Propene would result in the greatest off-site impact, having a distance to endpoint of 0.1 miles.



Toxic Substances: One alternative release scenario for each toxic substance is required under the ARP program. Release scenarios have been evaluated for the regulated toxic substa
nces at BASF-Zachary. Based on the RMP Comp results, the substances and the distances selected for the toxic endpoints are: formaldehyde (0.1 miles) and methyl chloride (0.4 miles).

General Accidental Release and Chemical Specific Prevention Program



At BASF-Zachary, processes regulated by the EPA's risk management program (RMP) regulation are also subject to the OSHA's PSM standard, and a brief summary of each OSHA PSM/EPA RMP element is provided.



Employee Participation: BASF-Zachary encourages employees to participate in all facets of process safety management and accident prevention. Examples of employee participation range from updating and compiling technical documents and chemical information to participating as members of process hazard analysis (PHA) teams. In addition, BASF-Zachary has a number of initiatives under way that address process safety and employee safety issues. The teams typically have members from various areas of the plant, including operations, maintenance, engineering, and plant management.



The BASF-Zachary site has also implemented a Behavior Based Safety Program. This program enables employees to observe work being performed and determine if any unsafe behaviors occur.



Process Safety Information: BASF-Zachary keeps a variety of technical documents that are used to help maintain safe operation of the processes. Specific departments within the plant are assigned responsibility for maintaining up-to-date process safety information.



Chemical-specific information, including exposure hazards and emergency response/ exposure treatment considerations, is provided in material safety data sheets (MSDSs)/safety data sheets (SDSs). This information is supplemented by documents that specifically address known corrosion concerns and any known hazards associated with the inadvertent mixing of chemicals.



The plant also maintains numerous technical documents that provide information about the design and construction of pro
cess equipment. This information, in combination with written procedures and trained personnel, provides a basis for establishing inspection and maintenance activities, as well as for evaluating proposed process and facility changes to ensure that safety features in the process are not compromised.



Process Hazard Analysis (PHA): BASF-Zachary has a comprehensive program to help ensure that hazards associated with the various processes are identified and controlled. Within this program, each process is systematically examined to identify hazards and ensure the adequate controls are in place to manage these hazards.



BASF-Zachary primarily uses the hazard and operability (HAZOP) analysis technique to perform these evaluations. HAZOP analysis is recognized as one of the most systematic and thorough hazard evaluation techniques. The PHA team identifies and evaluates hazards of the process as well as accident prevention and mitigation measures, and the team makes suggestions for additional prevention and/or mitigation measures when the team believes such measures are necessary.



The PHA team findings are forwarded to management for resolution. Implementation of mitigation options in response to PHA findings is based on a relative risk ranking assigned by the PHA team. This ranking helps ensure that potential accident/hazard scenarios assigned the highest risk receive immediate attention. To help ensure that the process controls and/or process hazards do not eventually deviate significantly from the original design safety features, BASF periodically updates and revalidates the hazard analysis results.



Operating Procedures: BASF-Zachary maintains written operating procedures that address various modes of process operations. These procedures can be used as a reference by experienced operators and provide a basis for consistent training of new operators.



Training: To complement the written procedures for process operations, BASF-Zachary ha
s implemented a comprehensive training program for all employees involved in operating a process. New employees receive basic training in plant operations if they are not already familiar with such operations. In addition, all operators periodically receive refresher training on the operating procedures to ensure that their skills and knowledge are maintained at an acceptable level.



Contractors: BASF-Zachary uses contractors to supplement its workforce during periods of increased maintenance or construction activities. Because some contractors work on or near process equipment, the plant has procedures in place to ensure that contractors (1) perform their work in a safe manner, (2) have the appropriate knowledge and skills, (3) are aware of the hazards in their workplace, (4) understand what they should do in the event of an emergency, (5) understand and follow site safety rules, and (6) inform plant personnel of any hazards that they find during their work. This is accomplished by providing contractors with (1) a process overview, (2) information about safety and health hazards, (3) emergency response plan requirements, and (4) safe work practices prior to beginning work. In addition, BASF-Zachary evaluates contractor safety programs and performance during the selection of a contractor. Plant personnel periodically monitor contractor performance to ensure that contractors are fulfilling their safety obligations.



Pre-startup Safety Reviews (PSSRs): BASF-Zachary conducts a PSSR for any facility modification that requires a change in the process safety information. The purpose of the PSSR is to ensure that safety features, procedures, personnel, and equipment are appropriately prepared for startup prior to placing the equipment into service. This review provides one additional check to make sure construction is in accordance with the design specifications and that all supporting systems are operationally ready. The PSSR review team uses checkli
sts to verify all aspects of readiness. A PSSR involves field verification of the construction and serves a quality assurance function by requiring verification that accident prevention program requirements are properly implemented.



Mechanical Integrity: BASF-Zachary has well-established mechanical integrity practices and procedures. The basic aspects of this program include: (1) conducting training, (2) developing written procedures, (3) performing inspections and tests, (4) correcting identified deficiencies, and (5) applying quality assurance measures. In combination, these activities form a system that maintains the mechanical integrity of the process.



Maintenance employees receive training as applicable to help ensure that they can perform their jobs in a safe manner. Inspections and tests are performed to help ensure that equipment functions as intended and to verify that equipment is within acceptable limits (e.g., adequate wall thickness for pressure vessels). Another integral part of the mechanical integrity program is quality assurance. BASF-Zachary incorporates quality assurance measures into equipment purchases and repairs. This helps ensure that new equipment is suitable for its intended use and that proper materials and spare parts are used when repairs are made.



Hot Work Permits and Other Safe Work Practices: BASF-Zachary has long-standing safe work practices in place to help ensure worker and process safety. A hot work permit system is used to control potential ignition sources. Other procedures include: confined space entry; lockout/tagout to ensure isolation of energy sources; work permits to assure safe removal of hazardous substances before process piping or equipment is opened; and personal protective equipment to provide employee protection. Training of personnel in safety procedures helps ensure that operations and maintenance activities are performed safely.



Management of Change: BASF-Zachary has a comprehe
nsive system to manage changes to all covered processes. This system requires that changes to items such as process equipment, chemicals, technology (including process operating conditions), procedures, and other facility changes are properly reviewed and authorized before being implemented. Changes are reviewed to (1) identify hazards, (2) ensure that adequate controls are in place to manage any new hazards, and (3) verify that existing controls have not been compromised by the change. Affected chemical hazard information, process operating limits, and equipment information, as well as procedures, are updated to incorporate these changes.



Incident Investigation: BASF-Zachary promptly investigates all incidents that resulted in, or reasonably could have resulted in, a fire/explosion, toxic gas release, major property damage, environmental loss, or personal injury. The goal of each investigation is to determine the facts and develop corrective actions to prevent a recurrence of the incident or a similar incident.



Compliance Audits: To help ensure that the accident prevention program is functioning properly, BASF-Zachary periodically conducts an audit to determine whether the procedures and practices required by the accident prevention program are being implemented.



Chemical-Specific Prevention Steps



The processes at BASF-Zachary have hazards specific to the individual chemicals that must be managed to ensure continued safe operation. These are addressed through operating procedures for the DXA/DXL (Dioxane/Dioxolane), Glymes, and the Multi-Purpose Units. In addition to other measures, flammable materials (2-Methylpropene and others) are stored and used under nitrogen blanket to prevent mixing with air which could form flammable mixtures. Toxic substances are often stored under pressure (methyl chloride) and/or under nitrogen blanket at lower pressures to prevent atmospheric venting or introduction of air or moisture.

BASF-Zachary h
as safety features on many units to help (1) contain/control a release, (2) quickly detect a release, and (3) reduce the consequences of (mitigate) a release.



Five-Year Accident History



BASF-Zachary has not had any accidental releases during the past five years which meet the criteria for an accidental release per 40 CFR 68.42.



Emergency Response Program Information



BASF-Zachary maintains a written emergency response plan to protect worker and public safety as well as the environment during an emergency. The plan consists of procedures for responding to a release of a regulated substance, including the possibility of a fire or explosion if a flammable substance is accidentally released. The procedures address all aspects of emergency response, including first aid and medical treatment, evacuation and accounting for personnel, notification of local emergency response agencies and the public if a release occurs, incident mitigation and post-incident cleanup and decontamination requirements. The plant routinely performs maintenance on emergency equipment including tests and inspections and provides employee training on equipment use. Employees receive training as necessary to perform their specific emergency response duties. The emergency response plan is updated when necessary based on modifications made to plant processes or for changes in personnel.



The overall emergency response program for BASF-Zachary is coordinated with East Baton Rouge Parish emergency response officials and the Zachary Fire Department. Periodic meetings with response agency personnel are conducted to discuss needs and concerns in the event of an incident at the plant. BASF-Zachary has around-the-clock communications capability with state and federal agencies and with local emergency response agencies through a hotline system to access additional emergency equipment and services (i.e., firefighting equipment, manpower, ambulances, hospitals, law enforcement, and HAZMAT
operations). Notification of the public by local officials can also be accomplished through hotline notifications. BASF-Zachary conducts periodic emergency drills that involve local emergency response organizations.



Planned Changes to Improve Safety



BASF-Zachary has several elements of the management system of the accident prevention program in place to improve safety throughout the facility. These elements are part of an overall ongoing safety improvement process.

BASF-Zachary recently implemented the BASF "Journey to Excellence" program designed to be worked through concerted efforts of all BASF employees. The program is a goal oriented system for continuous improvement of safety performance which not only results in safer workplaces and safer communities where we operate, but it also provides all of our employees an opportunity to participate in noteworthy safety functions which will improve the overall safety culture of our site. Site focus for this program includes: a program launch with 100% employee participation; development of a safety roadmap; reactivating safety committees; upgrading safety systems throughout the site; enhancement of training such as operations, procedures, permit reviews, PSM/RMP analysis/compliance audits, PHA and MOC leadership, and Root Cause Analysis and practices; and conducting EHS assessments.

In addition, the BASF-Zachary site is strongly involved in a Behavior Based Observation Program that heightens the site's ability to recognize hazards and to prevent incidents from happening. Employees do an excellent job of "looking out" for one another.