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Westlake, Louisiana Hydrogen Facility

Parent Companies:
Air Products and Chemicals, Inc.
EPA Facility ID:
100000185827
Other ID:
Facility DUNS:
0
Parent Company DUNS:
3001070

Location:

Address:
102 Trousdale Road
Westlake, LA 70669
County:
CALCASIEU
Lat / Long:
30.239, -93.282 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Center of Facility
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Air Products and Chemicals, Inc.
Phone:
(337) 882-2812
Address:
P.O. Box 1060
Westlake, LA 70669
Foreign Address:

Person responsible for RMP implementation:

Name:
Gary Senior
Title:
Area Manager

Emergency contact:

Name:
James Laird
Title:
Site Supervisor
Phone:
(337) 882-2812
24-hour phone:
(337) 529-5025
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(337) 882-2812
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Calcasieu Parish LEPC
Full-Time Equivalent Employees:
9
Covered by OSHA PSM:
Yes
EPCRA section 302:
No
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
0520-00301-04
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Jan. 29, 2009
Inspecting Agency:
EPA
Using Predictive Filing:
No

Processes:

Hydrogen Production
RMP ID:
1000048947
CBI claimed:
No
Program Level:
3
NAICS:
Industrial Gas Manufacturing (32512)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
56,834
No
Public OCA Chemical
0
No

RMP Preparer:

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

Phone:
(713) 920-7250

Latest RMP Submission:

Date:
April 2, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000039765

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 Hydrogen 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 Hydrogen Production)
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

Hydrogen Production, Industrial Gas Manufacturing (32512)
Prevention Program ID:
1000042335
Safety Review Date
Feb. 19, 2014, since latest RMP submission
PHA Update Date
Feb. 19, 2014, since latest RMP submission
PHA Techniques
  • HAZOP
  • FTA
Hazards Identified
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • None
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
July 15, 2013, since latest RMP submission
Training Review Date
Oct. 31, 2013, since latest RMP submission
Maintenance Review Date
July 17, 2013, since latest RMP submission
Maintenance Inspection Date
March 22, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Feb. 11, 2014
Management of Change Review Date
May 1, 2009
Pre-startup Review Date
March 3, 2014
Compliance Audit Date
Oct. 2, 2012
Compliance Audit Change Completion Date
May 1, 2013
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
March 31, 2010
Hot Work Review Date
Jan. 31, 2012
Contractor Safety Review Date
April 16, 2010, since latest RMP submission
Contractor Safety Eval. Date
April 17, 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:
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:
(337) 491-5301
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

Federal RMP Executive Summary





Air Products and Chemicals, Inc.

Westlake, LA Hydrogen Facility



1. Accidental release prevention and emergency response policies:



At this facility, we manufacture gaseous hydrogen. Hydrogen, in the amounts handled by our facility, is considered hazardous by the EPA. It is our policy to adhere to all applicable Federal and state rules and regulations. Air Products manages the safety of the regulated processes by means of operating procedures, equipment testing and inspections, safety devices (e.g., alarms, shutdowns, instrumentation, relief devices) inherent in the design of this facility and other controls and systems designed to prevent accidental releases of hazardous chemicals. Safe work practices and training of our personnel supplement the inherent safe design of the plant.



Our emergency response program is based upon OSHA's HAZWOPER regulation. The emergency response plan includes procedures for the notification of the Conoco Phillips Emergency Response Team so that appropriate measures can be taken by local emergency responders to control accidental releases.



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



2. The stationary source and regulated substances handled:



The primary purpose of this facility is the manufacturing of gaseous hydrogen. Our refinery customer uses the hydrogen. Natural gas is received by our plant via pipeline and used as feedstock. The feedstock is reacted in the reformer furnace. By exposing the feedstock to a catalyst in the presence of heat and steam, a chemical reaction takes place that converts the feedstock into hydrogen, carbon monoxide and carbon dioxide. The carbon monoxide and carbon dioxide are then separated from the hydrogen in a Pres
sure-Swing Adsorption (PSA) system.



The regulated substance handled at this facility is the flammable gas mixture containing hydrogen and methane.



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



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



4. Five-year accident history:



There have been no accidents involving or accidental releases of flammable gas that resulted in any deaths, injuries, or significant property damage on site; or known 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 upon OSHAA?s HAZWOPER standard. At this 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 in their role in the emergency plan. Emergency response activities are coordinated through the Conoco Phillips Emergency Response Team.



6. Planned changes to improve safety:



The facility resolves recommendations from PHAs and Incident Investigations, some of which may result in modifications to the plant design and operating procedures.