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Air Products, Geismar 2 SSU Plant

Parent Companies:
Air Products and Chemicals, Inc.
EPA Facility ID:
100000161996
Other ID:
LAR000030247
Facility DUNS:
0
Parent Company DUNS:
3001070

Location:

Address:
36637 LA. Highway 30
Geismar, LA 70734
County:
ASCENSION
Lat / Long:
30.204, -90.992 (Get map)
Method:
Interpolation - Photo
Description:
Center of Facility
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Air Products and Chemicals, Inc.
Phone:
(225) 677-5664
Address:
36637 LA Highway 30
Geismar, LA 70734
Foreign Address:

Person responsible for RMP implementation:

Name:
Darrell Serrett
Title:
Area Manager

Emergency contact:

Name:
Michael Hoormann
Title:
Site Supervisor
Phone:
(225) 677-5682
24-hour phone:
(225) 323-1055
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(225) 677-5664
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Ascension Parish LEPC
Full-Time Equivalent Employees:
55
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
3) 0180-00071V0
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Dec. 11, 2013
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Syngas Separation Unit
RMP ID:
1000059956
CBI claimed:
No
Program Level:
3
NAICS:
Industrial Gas Manufacturing (32512)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
57,038
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Matt Hornyak
Address:
1423 Pasadena Freeway
Pasadena, TX 77506
Foreign Address:

Phone:
(713) 920-7250

Latest RMP Submission:

Date:
Dec. 15, 2014
Type:
Resubmission
Reason:
Voluntary update (not described by any of the above reasons)
Registered:
Yes
RMP ID:
1000048001

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 Syngas Separation 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 Syngas Separation Unit)
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
  • Excess flow valve

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

Syngas Separation Unit, Industrial Gas Manufacturing (32512)
Prevention Program ID:
1000049969
Safety Review Date
Oct. 30, 2014, since latest RMP submission
PHA Update Date
Oct. 30, 2014, since latest RMP submission
PHA Techniques
  • Checklist
  • HAZOP
  • FTA
Hazards Identified
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • Purge System
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Sept. 12, 2014, since latest RMP submission
Training Review Date
Oct. 31, 2014, since latest RMP submission
Maintenance Review Date
April 11, 2014, since latest RMP submission
Maintenance Inspection Date
April 11, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Sept. 15, 2014
Management of Change Review Date
May 1, 2009
Pre-startup Review Date
June 2, 2014
Compliance Audit Date
Feb. 5, 2014
Compliance Audit Change Completion Date
Aug. 5, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Oct. 31, 2013
Hot Work Review Date
Jan. 31, 2012
Contractor Safety Review Date
April 16, 2010, since latest RMP submission
Contractor Safety Eval. Date
Aug. 5, 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:
No
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
No
Plan Review Date:
Response Training Date:
None
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:
Yes
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

Executive Summary





Air Products and Chemicals, Inc.

Geismar, Louisiana Syngas Separation Unit

Louisiana Department of Environmental Quality Agency Interest Number 30073



1. Accidental release prevention and emergency response policies:



At the Syngas Separation Unit facility, gaseous hydrogen and carbon monoxide are produced. Flammable gases containing hydrogen, methane, and ethane are present in the process in concentrations and amounts that cause the process to be covered by the EPA RMP regulation. Other chemicals are produced in processes that are not covered by the RMP regulation.



It is company policy to adhere to all applicable Federal and State rules and regulations. Air Products manages the safety of the regulated processes through the use of operating procedures, equipment testing and inspections, safety devices (e.g.

alarms, shutdowns, instrumentation, relief devices) inherent in the design of the facility and with other controls and systems designed to prevent accidental releases of hazardous chemicals. Safe work practices and training of plant personnel act as a supplement to the inherent safe design of the plant.



Our emergency response program is based on OSHA's HAZWOPER regulation. The emergency response plan includes procedures for the notification of the local fire department and State Police Hazardous Materials unit so that appropriate measures can be taken by local emergency responders to control accidental releases. The facility communicates regularly and works closely with the LEPC (emergency planning committee), the Ascension Parish Office of Homeland Security and Emergency Preparedness (OEP), and other community responders.



This document has been prepared in accordance with EPA's Risk Management Plan regulation (40 CFR, Part 68). The substances and processes considered during the update of this RMP and in the scenarios described were selected based on criteria established in the regulation.



2. The stationary sour
ce and regulated substances handled:



The primary purpose of the covered process located at this facility is the production and purification of gaseous hydrogen and gaseous carbon monoxide. These gases are used by customers to manufacture other chemicals.



A gaseous mixture is received by the plant via pipeline. This gas contains hydrogen and carbon monoxide, but the hydrogen and carbon monoxide are mixed with methane, ethane, and other impurities. The gas is subjected to a series of steps to remove some of the impurities. The hydrogen and carbon monoxide are then separated from each other and from the remaining impurities in a "cold box", which purifies the products by cryogenic distillation. The product gases are compressed and delivered to customers via the pipeline network. A portion of the product gases are also shipped in over-the-road vehicles.



3. The general accidental release prevention program and specific prevention steps:



The Syngas Separation Unit facility developed prevention program elements based on the EPA's Accidental Release Prevention Plan and OSHA's Process Safety Management (PSM) regulation. The facility was designed and constructed to comply with applicable state and industry codes.



4. Five year accident history:



There have been no reportable accidents within the past five years that resulted in any deaths, injuries, or significant property damage on site nor have there been any off-site deaths, injuries, evacuations, sheltering in place, property damage, or environmental damage.



5. The emergency response program:



The facility's emergency response program is based on OSHA's HAZWOPER standard. At the site employees are trained to recognize emergencies and initiate emergency response from outside agencies. They have been trained to OSHA's First Responder - Awareness Level. The employees receive annual refresher training concerning their role in the emergency plan. An alarm system is used for notification of f
ires or spills. In the event of an emergency, Air Products is a member of the Geismar Area Mutual Aid (GAMA) organization and cooperates with local industrial neighbors and emergency response agencies to provide assistance when needed. The facility communicates regularly and works closely with the LEPC (local emergency planning committee), the Ascension Parish Office of Homeland Security and Emergency Preparedness (OEP), and other community responders. Detailed emergency response plans incorporating OEP, local police and fire departments and GAMA are in place at the facility. The OEP maintains a manned, 24-hour, 911 emergency center, and the parish emergency siren systems.



6. Planned changes to improve safety:



Changes to improve safety will be based on revalidated hazard reviews and incident investigations which provide recommendations that may result in modifications to the plant design and/or operating procedures in order to assure safe operation of the facility.