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Air Products, Luling H2

Parent Companies:
Air Products and Chemicals, Inc
EPA Facility ID:
100000216857
Other ID:
Facility DUNS:
0
Parent Company DUNS:
3001070

Location:

Address:
12501B River Road
Luling, LA 70070
County:
ST. CHARLES
Lat / Long:
29.922, -90.351 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Process Unit
Horizonal accuracy:
10 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Air Products
Phone:
(985) 331-0353
Address:
12501B River Road
Luling, LA 70070
Foreign Address:

Person responsible for RMP implementation:

Name:
Jeff Bellelo
Title:
Area Manager

Emergency contact:

Name:
Wally West
Title:
Site Supervisor
Phone:
(985) 331-0353
24-hour phone:
(225) 202-4576
Ext or PIN:
12

Other contacts:

Facility (or company) email:
Facility phone:
(985) 331-0353
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
St. Charles Parish LEPC
Full-Time Equivalent Employees:
10
Covered by OSHA PSM:
Yes
EPCRA section 302:
No
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
2520-00160-00
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Dec. 17, 2014
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Hydrogen Production Unit
RMP ID:
1000078150
CBI claimed:
No
Program Level:
3
NAICS:
Industrial Gas Manufacturing (32512)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
100,500
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:
Feb. 24, 2017
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000062321

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 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 Hydrogen Production Unit)
CBI claimed:
No
Model used:
EPA's OCA Guidance Reference Tables or Equations
Passive mitigation
considered:
  • Manually-activated or automatic plant shutdown
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

March 26, 2012 at 11:45
ID:
1000048118
NAICS:
Industrial Gas Manufacturing (32512)
Duration:
3 hours
Chemicals involved:
  • Hydrogen
Release events:
Gas release
Fire
Explosion
Weather conditions at time of event
Wind speed:
5.80000019 miles/h NNE
Temperature:
80.00 ℉
Atmospheric stability:
B
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
2
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$95000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Unsuitable equipment
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Replaced improper gasket with one specified per design

7. Prevention: Program level 3

Hydrogen Production Unit, Industrial Gas Manufacturing (32512)
Prevention Program ID:
1000065656
Safety Review Date
Feb. 16, 2017, since latest RMP submission
PHA Update Date
Feb. 16, 2017, since latest RMP submission
PHA Techniques
  • Checklist
  • HAZOP
Hazards Identified
  • Fire
  • Explosion
  • Runaway reaction
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Flares
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Keyed Bypass
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Rupture Disks
  • Excess Flow Device
  • 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 17, 2016, since latest RMP submission
Training Review Date
Feb. 7, 2017, since latest RMP submission
Maintenance Review Date
Dec. 14, 2016, since latest RMP submission
Maintenance Inspection Date
Oct. 8, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
None
Management of Change Review Date
Nov. 26, 2012
Pre-startup Review Date
Feb. 24, 2012
Compliance Audit Date
Feb. 5, 2015
Compliance Audit Change Completion Date
Aug. 5, 2015
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Jan. 7, 2015
Hot Work Review Date
Dec. 1, 2014
Contractor Safety Review Date
Dec. 14, 2015, since latest RMP submission
Contractor Safety Eval. Date
None, 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:
(985) 783-5050
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

Air Products and Chemicals, Inc.

Luling, Louisiana Hydrogen Facility

1. Accidental release prevention and emergency response policies:

At this facility, we manufacture gaseous hydrogen. Hydrogen and methane, 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 Monsanto Fire Brigade and other appropriate local responders so that appropriate measures can be taken 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 (approximately 1,600 degrees F.) 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 Pressure Swing Adsorp
tion (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:

The facility has had one RMP Reportable incident that occurred 3/26/2012 which was a hydrogen release of 290 lbs. and resulted in a fire/explosion.



5. The emergency response program:

The facility's emergency response program is based upon OSHA'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 will receive annual refresher training in their role in the emergency plan. Emergency response activities will be coordinated with Monsanto's Fire Brigade.



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.