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The Procter & Gamble Mfg. Company-Alexandria Plant

Parent Companies:
The Procter & Gamble Company
EPA Facility ID:
100000154352
Other ID:
71360THPRC3701
Facility DUNS:
4238200
Parent Company DUNS:
1316827

Location:

Address:
3701 Monroe Hwy
Pineville, LA 71360
County:
RAPIDES
Lat / Long:
31.369, -92.412 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Storage Tank
Horizonal accuracy:
m
Horizontal reference datum:
Source map scale:

Owner/Operator:

Name:
The Procter & Gamble Mfg. Company
Phone:
(318) 640-2800
Address:
P.O. Box 328
Alexandria, LA 71309
Foreign Address:

Person responsible for RMP implementation:

Name:
Todd Hoffman
Title:
Plant Manager
Email:

Emergency contact:

Name:
Jason Covarrubias
Title:
Environmental Manager
Phone:
(318) 640-2800
24-hour phone:
(318) 640-2800
Ext or PIN:
Email:

Other contacts:

Facility (or company) email:
Facility phone:
(318) 640-2800
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Rapides Parish LEPC
Full-Time Equivalent Employees:
272
Covered by OSHA PSM:
No
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
2360-00051-V2
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Nov. 14, 2001
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Soap and other detergent
RMP ID:
35441
CBI claimed:
No
Program Level:
2
NAICS:
Soap and Other Detergent Manufacturing (325611)
Chemical name
CAS#
Quantity (lbs.)
CBI
Oleum (Fuming Sulfuric acid) [Sulfuric acid, mixture with sulfur trioxide]
8014-95-7
380,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
Dec. 26, 2001
Type:
Correction of existing RMP
Reason:
Registered:
Yes
RMP ID:
24767

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 Soap and other detergent)
CBI claimed:
No
Percent weight:
Physical state:
Liquid
Model used:
PHAST (Process Hazard Analysis Software Tools v 5.0)
Release duration (mins):
60.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Rural
Passive mitigation
considered:
  • Dikes
not considered:
  • 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 Soap and other detergent)
CBI claimed:
No
Percent weight:
Physical state:
Liquid
Model used:
PHAST
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

None

5. Flammables: Alternative release

None

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

No Prevention Program level 3

8. Prevention Program level 2

Soap and other detergent, Soap and Other Detergent Manufacturing (325611)
Prevention Program ID:
13627
Safety Review Date
June 8, 2001, since latest RMP submission
PHA Update Date
, since latest RMP submission
Safety Regulations
  • None
Hazards Identified
  • Toxic Release
  • Equipment failure
Process Controls
  • Relief Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Grounding Equipment
  • Rupture Disks
Mitigation Systems
  • Dikes
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classroom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
June 8, 2001, since latest RMP submission
Training Review Date
June 8, 2001, since latest RMP submission
Maintenance Review Date
June 8, 2001, since latest RMP submission
Maintenance Inspection Date
Oct. 1, 2001, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Management of Change Review Date
Pre-startup Review Date
Compliance Audit Date
June 22, 2001
Compliance Audit Change Completion Date
June 22, 2001
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Hot Work Review Date
Contractor Safety Review Date
, since latest RMP submission
Contractor Safety Eval. Date
, since latest RMP submission

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. 4, 2001
Local Response Agency:
Local Response Agency Phone:
(318) 487-5787
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:
No
Subject To - Other:

Executive Summary




PREVENTION IS OUR FIRST PRIORITY - POLICY COMMITMENT TO SAFETY AND ENVIRONMENTAL STEWARDSHIP



Procter & Gamble (P&G) has a long-standing commitment to maintaining a safe work environment

for our employees and minimizing the impact of our operations on the environment. Our safety

and environmental programs are managed by highly skilled employees, and are actively supported

by the participation of all employees and all management, and a strong corporate staff. The

goal of both the safety and environmental programs is prevention. Safety teams which focus on

training and special projects have been formed in every department across this site. Although

P&G's safety record is already among the best in the business, we are constantly striving for

improvement.



P&G is very committed to the safety and protection of the local residents. P&G employees are

active members of several of the local fire departments, response groups and other community,

including Rotary and Keep CENLA Beautiful. P&G has also supported the community in areas

such as supplying mitigation materials to aid the city with a transportation incident.



P&G is also very committed to the safety and protection of the natural environment. P&G

Alexandria site employees have participated in the local Earth Day celebrations, have provided

environmental training in schools, and is active in the Partners in Education program with

Northwood High School.





SOURCE + SUBSTANCES: PREVENTION, CONTROLS + MITIGATION



The P&G Alexandria site manufactures laundry detergent. Oleum is one of the key raw materials

used to make the detergent. Oleum is delivered to the site by specially designed railcars, and

is unloaded into a storage tank. While not required by any regulation, our storage tank is made

of extra-thick stainless steel and designed to meet Pressure Vessel code details. Additionally,

they are located in a diked area and enclosed in a metal building. The tanks
are routinely

visually inspected and the metal walls are tested for integrity. The unloading area is also

spill protected. The storage and unloading areas are monitored by continuous video cameras

placed in critical areas. The storage tanks are heated to the minimum level in order to keep

the oleum in a liquid state for use in our process. Slight wisps or vapors which may occur when

opening the railcar for unloading and during maintenance are collected in a mist vacuum and

scrubber system. Oleum is completely consumed in the reactions in the processes.





RELEASE SCENARIOS: Minimizing the potential for accidental releases



A "Worst Case Release" is defined by EPA as an instantaneous release of the single largest

vessel (the storage tank), outdoors, during a time of light winds and stable weather conditions.

An instantaneous release of this kind could be caused by, for example, an earthquake or by an

airplane hitting the tank. The worst case release assumes that no emergency response would occur,

even though both site personnel and the local Haz Mat team are trained to respond to this type

of spill. The spilled liquid contents of an entire storage tank would be confined to an existing

diked area.





The Alternative Release Scenario is defined by the EPA as a 15 minute release from a leaking

unloading line at more normal weather conditions. If necessary, the foam suppression systems

and/or shutting valves to shut down the operation could be activated within 15 minutes.

The facility has also modeled its Alternative Release Scenario. This scenario can also be

located in the RMPlan.



SAFETY, RELEASE PREVENTION, AND EMERGENCY RESPONSE



The first line of defense at our plant is accident prevention. A detailed hazard study was

conducted to identify potential points from which oleum may be spilled or leaked from the

process. These points have received special consideration during the process design, the

training of oper
ators and maintenance personnel, and in the development of our accident

prevention and response systems. The studies are updated routinely by a team of specially

trained employees and engineers. Training, maintenance, controls, operating practices, and

purchasing requirements are updated based on the results of these hazard studies.



The entire oleum system has numerous and redundant process controls, detection and alarm

systems, and an emergency shut-down system. When operating, highly skilled operators monitor

the process from the control rooms equipped with cameras and computers that monitor important

data on the liquid levels in the tanks, the temperature and pressure of the tank contents,

and the tank's volume. Oleum is only unloaded into a tank when there is enough space to

allow unloading all the contents of the railcar. This procedure of hookup-unload- disconnect

only once per railcar minimizes the risk of accidental spills.



In the event of an accident, the site has systems to react to the spill or leak quickly.

Spills or leaks of oleum can be quickly communicated by personnel on the scene from phones

located in the control rooms. The Police and Fire departments have procedures to manage

communications and instructions to the public by means of TV and radio broadcasts, and by

direct communications in the streets of affected neighborhoods.







HISTORY OF SAFE OPERATIONS



The P&G Alexandria site has an excellent history of oleum system safety. We have had zero

RMP 68 incidents within the past five years.





EMERGENCY RESPONSE PROGRAM



Technicians handling oleum have been qualified in all of our standard operating procedures.

The operating procedures include both routine and non-routine operations. Thirty employees

are trained as part of an onsite Team to handle emergencies; with each shift having trained

members. All employees participate in annual Emergency Response drills. The results of both

hazard as
sessments and the emergency response drills are communicated to the operating and

unloading teams.





An Emergency Response Plan has been developed and coordinated with the LEPC, including the

fire department, hospitals, and police. The drills allow the opportunity to train new

responders, to refresh the skills of the experienced responders, and to improve the

communications and response systems. Equipment that may be used to respond during a real

emergency, such as a foam system, may be activated during these drills. The local Fire

department(s) and police agencies are toured through the site on a regular basis to reinforce

their awareness of what is on site and where critical materials are stored.









Execsum2.doc