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Praxair - Geismar, LA

Parent Companies:
Praxair, Inc.
EPA Facility ID:
100000144426
Other ID:
70734LQDCRPOBOX
Facility DUNS:
168569788
Parent Company DUNS:
197154586

Location:

Address:
Highway 75 Avenue E
Geismar, LA 70734
County:
ASCENSION
Lat / Long:
30.199, -91.013 (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:
Praxair, Inc.
Phone:
(225) 673-8831
Address:
P.O. Box 230
Geismar, LA 70734
Foreign Address:

Person responsible for RMP implementation:

Name:
Craig Robnik
Title:
Manufacturing Director

Emergency contact:

Name:
Craig Robnik
Title:
Manufacturing Director
Phone:
(225) 673-5135
24-hour phone:
(225) 290-0547
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(800) 772-9247
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Ascension Parish LEPC
Full-Time Equivalent Employees:
52
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
0180-00031-V6
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
April 17, 2014
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

Formaldehyde Production
RMP ID:
1000054602
CBI claimed:
No
Program Level:
3
NAICS:
Industrial Gas Manufacturing (32512)
Chemical name
CAS#
Quantity (lbs.)
CBI
Formaldehyde (solution)
50-00-0
2,300,000
No
Public OCA Chemical
0
No
Emission Control
RMP ID:
1000054603
CBI claimed:
No
Program Level:
3
NAICS:
Industrial Gas Manufacturing (32512)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
58,000
No
Public OCA Chemical
0
No
Syngas Production
RMP ID:
1000054604
CBI claimed:
No
Program Level:
3
NAICS:
Industrial Gas Manufacturing (32512)
Chemical name
CAS#
Quantity (lbs.)
CBI
Methane
74-82-8
38,000
No
Hydrogen
1333-74-0
20,000
No
Flammable Mixture
00-11-11
380,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 13, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000044209

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 Emission Control)
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:
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 Formaldehyde Production)
CBI claimed:
No
Percent weight:
50.0
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:
  • Sumps
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
Active mitigation
considered:
  • Emergency shutdown
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
Public OCA Chemical (in Emission Control)
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:
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

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 Syngas Production)
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 Syngas Production)
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:
  • Deluge systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

Formaldehyde Production, Industrial Gas Manufacturing (32512)
Prevention Program ID:
1000045707
Safety Review Date
Feb. 19, 2014, since latest RMP submission
PHA Update Date
Nov. 29, 2011, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
Mitigation Systems
  • Dikes
Monitoring Systems
  • None
Changes since PHA
  • None Recommended
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Jan. 14, 2014, since latest RMP submission
Training Review Date
Jan. 31, 2014, since latest RMP submission
Maintenance Review Date
March 20, 2014, since latest RMP submission
Maintenance Inspection Date
May 16, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Feb. 11, 2014
Management of Change Review Date
Dec. 31, 2012
Pre-startup Review Date
Nov. 15, 2013
Compliance Audit Date
April 17, 2014
Compliance Audit Change Completion Date
Dec. 1, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
April 8, 2014
Hot Work Review Date
Dec. 18, 2013
Contractor Safety Review Date
Dec. 15, 2013, since latest RMP submission
Contractor Safety Eval. Date
May 16, 2014, since latest RMP submission
Emission Control, Industrial Gas Manufacturing (32512)
Prevention Program ID:
1000045708
Safety Review Date
Feb. 19, 2014, since latest RMP submission
PHA Update Date
July 11, 2011, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Grounding Equipment
  • Excess Flow Device
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Jan. 14, 2014, since latest RMP submission
Training Review Date
Jan. 31, 2014, since latest RMP submission
Maintenance Review Date
March 20, 2014, since latest RMP submission
Maintenance Inspection Date
Oct. 9, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
July 3, 2013
Management of Change Review Date
Dec. 31, 2012
Pre-startup Review Date
Feb. 19, 2014
Compliance Audit Date
April 17, 2014
Compliance Audit Change Completion Date
Dec. 1, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
April 8, 2014
Hot Work Review Date
Dec. 18, 2013
Contractor Safety Review Date
Dec. 15, 2013, since latest RMP submission
Contractor Safety Eval. Date
May 16, 2014, since latest RMP submission
Syngas Production, Industrial Gas Manufacturing (32512)
Prevention Program ID:
1000045709
Safety Review Date
Feb. 19, 2014, since latest RMP submission
PHA Update Date
March 25, 2013, since latest RMP submission
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Grounding Equipment
  • Rupture Disks
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None Recommended
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Jan. 14, 2014, since latest RMP submission
Training Review Date
Jan. 31, 2014, since latest RMP submission
Maintenance Review Date
March 20, 2014, since latest RMP submission
Maintenance Inspection Date
May 21, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
May 6, 2014
Management of Change Review Date
Dec. 31, 2012
Pre-startup Review Date
April 26, 2014
Compliance Audit Date
April 17, 2014
Compliance Audit Change Completion Date
Dec. 1, 2015
Incident Investigation Date
Dec. 8, 2013
Incident Invest. Change Completion Date
June 1, 2016
Participation Plan Review Date
April 8, 2014
Hot Work Review Date
Dec. 18, 2013
Contractor Safety Review Date
Dec. 15, 2013, since latest RMP submission
Contractor Safety Eval. Date
May 16, 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 10, 2014
Local Response Agency:
Local Response Agency Phone:
(225) 621-8360
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

Facility Description



The Geismar, Louisiana facility operates steam-methane reformer (SMR) units, each of which produces a flammable gas mixture called synthesis gas (syngas) . This "syngas" contains primarily hydrogen, carbon monoxide, methane and small amounts of other flammable and inert gases. The syngas from the units is further refined on-site into final products of hydrogen, methane and carbon monoxide. Some of the syngas produced by the reformer units is also used indirectly as a raw material in a formaldehyde production process. Anhydrous ammonia is used to control the air emissions from one of the reformer units. The ammonia is injected into the flue gas and passed over a catalyst to reduce potential air pollutants into harmless substances such as nitrogen and water vapor.





Regulated Substances



This facility uses, manufactures, or stores a chemical listed in part 68 of Title 40 of the Code of Federal Regulations, beyond a threshold quantity, as established by the EPA;



1. Methane: Supplied by a local natural gas utility, is reacted in steam-methane reformer units to produce "syngas", which is a flammable gas mixture containing hydrogen, methane and other non-regulated substances.



2. Hydrogen: Produced on site and supplied to local customer via pipeline.



3. Formaldehyde: Stored in our tank farm, and distributed to a nearby customer via pipeline.



4. Anhydrous ammonia: Used to control the air emissions from one of the reformer units.





Accidental Release Prevention Policy



Praxair is dedicated to being the best performing industrial gas company in all aspects of our business, including safety, health, and environmental affairs. Our safety, health, and environmental policy call for a commitment to protecting the health and safety of our employees, neighbors, and the surrounding environment. This policy is the basis for engineering and construction programs that produce equipment and process systems that minimize the possi
bility of accidental chemical releases and operational safety programs that ensure safe operation of our facilities. Praxair is committed to the continuous improvement of these programs.



Praxair is an active member of the American Chemistry Council and subscribes to the council's program of Responsible CareA® Employee Health and Safety Code of Management Practices.



Prevention Program



In accordance with OSHA's Process Safety Management standard and EPA's Risk Management Program rule, the Geismar, LA facility has a comprehensive accident prevention program in place. This program is built around process safety concepts such as:

- Technical documentation of Process Safety Information, describing the physical properties of the hazardous substances, the safety systems in place to control these substances, and the critical operating parameters of the associated equipment and systems.

- Procedures and programs to develop, maintain, and control key program elements such as process operations, equipment mechanical integrity, employee training, management of change, hot work permits, incident investigation, and contractor activity.

- Initial and periodic review of new or modified processes through application of comprehensive design safety and management of change programs that include Process Hazard Analysis study and pre-startup review.



Praxair has an employee participation program that promotes involvement in the process safety program and helps ensure understanding of facility-specific elements of the safety program.



The prevention program is audited periodically, by our corporate assessment group, to ensure that the process safety concepts and practices are in place and working effectively.



Chemical-specific Prevention Steps



In addition to the required prevention program elements, we have implemented safety features specific to the covered processes at our facility. Following is a description of some of these safety features.



All of the RM
P covered processes have process monitoring by manned control rooms 24 hours a day, 7 days a week. Each unit has secondary containment for regulated substances. There are alarms, procedures and interlocks in place to aid in preventing releases. The Geismar facility has in place both manual and automated shutdowns of the processes.



Five-year Accident History



The Geismar, SMR facility accident history indicates continuous safe operation of our covered chemical processes over the last five years. There were no covered process releases that resulted in an EPA RMP recordable accident.







Emergency Response Programs



Praxair has an emergency response program in place to minimize the effects of accidental release of regulated substances on employees, the public, and the environment. The Geismar location will be a "responding facility" as defined in Chapter 8 of the CEPPO General Guidance for Risk Management Programs (July 1998), i.e. Praxair employees will respond to spills & releases of a covered substanc, and a first responder role.



In addition, Praxair has in place an emergency response plan in coordination with the Ascension Parish CAER (Community Awareness and Emergency Response), GAMA (Geismar Area Mutual Aid).



The plan is communicated and coordinated with community response plans. All training, drills, and plan reviews are documented. Visitors and contractors receive an orientation covering sheltering-in-place, evacuation, security, hazardous work permitting and on site chemicals.





All facility employees are trained in their role in the emergency plan and emergency drills are conducted at least annually.





Planned Changes to Improve Safety



Praxair has a commitment to safety that is expressed in a company-wide goal of "Zero/Zero", which means zero accidents and zero injuries or illnesses at each and every location. We look to constantly improve the safety of our processes using recommendations developed through the prevention prog
ram and a program soliciting safety suggestions from our employees.