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Methanex USA, LLC

Parent Companies:
Methanex Fortier, Inc.
Methanex Corporation
EPA Facility ID:
100000227667
Other ID:
Facility DUNS:
0
Parent Company #1 DUNS:
198092308
Parent Company #2 DUNS:
206354367

Location:

Address:
4171 Hwy 73
Geismar, LA 70734
County:
ASCENSION
Lat / Long:
30.207, -91.021 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Plant Entrance (General)
Horizonal accuracy:
0.1 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Methanex Services USA, LLC
Phone:
(225) 402-0300
Address:
4171 HWY 73
PO Box 118
Geismar, LA 70734 -3533
Foreign Address:

Person responsible for RMP implementation:

Name:
Ryan P. Edwards
Title:
PSM Engineer

Emergency contact:

Name:
Chris Browning
Title:
Emergency Response Specialist
Phone:
(225) 402-0300
24-hour phone:
(225) 402-0300
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(855) 704-2503
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Ascension Parish LEPC
Full-Time Equivalent Employees:
160
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
0180-00210-V2
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Inspecting Agency:
Never had one
Using Predictive Filing:
No

Processes:

Geismar 1 Methanol Plant
RMP ID:
1000072587
CBI claimed:
No
Program Level:
3
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
13,000
No
Ammonia (conc 20% or greater)
7664-41-7
240,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No
Geismar 2 Methanol Plant
RMP ID:
1000072588
CBI claimed:
No
Program Level:
3
NAICS:
All Other Basic Organic Chemical Manufacturing (325199)
Chemical name
CAS#
Quantity (lbs.)
CBI
Flammable Mixture
00-11-11
13,000
No
Ammonia (conc 20% or greater)
7664-41-7
240,000
No
Public OCA Chemical
0
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Rasheed Reynolds
Address:
775 North University Blvd.
Suite 280
Mobile, AL 36608
Foreign Address:

Phone:
(251) 706-8600

Latest RMP Submission:

Date:
July 8, 2016
Type:
Resubmission
Reason:
Newly regulated substance listed by EPA (40 CFR 68.190(b)(2))
Registered:
Yes
RMP ID:
1000058075

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 Geismar 1 Methanol Plant)
CBI claimed:
No
Percent weight:
30.0
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Rural
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 Geismar 1 Methanol Plant)
CBI claimed:
No
Percent weight:
30.0
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
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

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 Geismar 2 Methanol Plant)
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 Geismar 2 Methanol Plant)
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:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Excess flow valve

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

Geismar 1 Methanol Plant, All Other Basic Organic Chemical Manufacturing (325199)
Prevention Program ID:
1000060799
Safety Review Date
May 18, 2016, since latest RMP submission
PHA Update Date
Oct. 24, 2012, since latest RMP submission
PHA Techniques
  • Checklist
  • HAZOP
Hazards Identified
  • None
Process Controls
  • None
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
April 19, 2016, since latest RMP submission
Training Review Date
May 19, 2016, since latest RMP submission
Maintenance Review Date
May 2, 2016, since latest RMP submission
Maintenance Inspection Date
May 16, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
May 12, 2016
Management of Change Review Date
Sept. 14, 2015
Pre-startup Review Date
May 18, 2016
Compliance Audit Date
Jan. 14, 2016
Compliance Audit Change Completion Date
None
Incident Investigation Date
May 10, 2016
Incident Invest. Change Completion Date
June 30, 2016
Participation Plan Review Date
April 21, 2016
Hot Work Review Date
May 17, 2015
Contractor Safety Review Date
Dec. 29, 2014, since latest RMP submission
Contractor Safety Eval. Date
May 21, 2016, since latest RMP submission
Geismar 2 Methanol Plant, All Other Basic Organic Chemical Manufacturing (325199)
Prevention Program ID:
1000060800
Safety Review Date
May 18, 2016, since latest RMP submission
PHA Update Date
Aug. 12, 2013, since latest RMP submission
PHA Techniques
  • Checklist
  • HAZOP
Hazards Identified
  • None
Process Controls
  • None
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
April 19, 2016, since latest RMP submission
Training Review Date
May 19, 2016, since latest RMP submission
Maintenance Review Date
May 2, 2016, since latest RMP submission
Maintenance Inspection Date
May 16, 2016, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
May 12, 2016
Management of Change Review Date
Sept. 14, 2015
Pre-startup Review Date
May 18, 2016
Compliance Audit Date
Jan. 14, 2016
Compliance Audit Change Completion Date
None
Incident Investigation Date
May 10, 2016
Incident Invest. Change Completion Date
June 30, 2016
Participation Plan Review Date
April 21, 2016
Hot Work Review Date
May 17, 2015
Contractor Safety Review Date
Dec. 29, 2014, since latest RMP submission
Contractor Safety Eval. Date
May 21, 2016, 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 26, 2016
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



The Methanex USA, LLC - Geismar Site (the "facility") is located at 4171 Highway 73; Geismar, Ascension Parish, Louisiana 70734-3533. The facility produces methanol from natural gas by reforming the gas with steam and then converting and distilling the resulting synthesized gas mixture to produce pure methanol. The facility contains the following RMP-regulated substances: methane, hydrogen and ammonia. The final product, pure methanol, is stored in dedicated tanks before being transferred to loading facilities.



The facility's risk management program and maximum chemical inventory were evaluated and it was determined that the facility's processes render the facility subject to 40 CFR 68 requirements. The facility has two (2) identical RMP covered processes and both processes, Geismar 1 and Geismar 2, each contain approximately 13,000 pounds of an NFPA-4 flammable mixture. Additionally, each process contains approximately 240,000 pounds of a 29.4 percent ammonia solution which is used for purposes of flue gas NOx reduction by means of selective catalytic reduction. Moreover, the processes render the facility subject to the United States Occupational Safety and Health Administration (OSHA) - Process Safety Management (PSM) of Highly Hazardous Chemicals, codified in 29 CFR 1910.119. As such, given that the facility has to comply with OSHA PSM standards and the fact that RMP offsite consequence analysis worst-case modeling yields the potential for offsite impacts, the facility is subject to RMP Prevention Program 3 Requirements.



The facility maintains a management system and associated policies, procedures, standing instructions, programs, and work practices that are related to RMP Prevention Program elements. These policies, procedures, standing instructions, programs and work practices are measures that are designed to help the site identify planned changes, which vary at any given time, and are designed to further enhance the facili
ty's existing safety programs and procedures.



GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM



Methanex views the health and safety of its employees and the community in which it operates as its top priority. The facility has implemented a robust OSHA Process Safety Management (PSM) program to protect its people, the local community, and the integrity of process equipment.



RMP FIVE YEAR ACCIDENT HISTORY



No accidents have resulted from the existing Geismar 1 or Geismar 2 processes.



EMERGENCY RESPONSE PROGRAM INFORMATION



The facility maintains a written Emergency Response Plan (ERP), which is in place to protect worker and public safety as well as the environment. The program consists of procedures for responding to a release of a regulated substance, including the possibility of a fire and/or explosion if a flammable substance is accidentally released. The procedures address all aspects of emergency response, including proper first aid and medical treatment for exposures, evacuation plans and accounting for personnel after an evacuation, notification of local emergency response agencies and the public if a release occurs. In addition, the plant has procedures that address maintenance, inspection, and testing of emergency response equipment, as well as instructions that address the use of emergency response equipment. Employees receive training in these procedures as necessary to perform their specific emergency response duties. The emergency response program is updated when necessary based on modifications made to plant processes. The ERP changes are administered through the MOC process, which include informing and/or training affected personnel in the changes.



The overall ERP is coordinated with the Ascension Parish Local Emergency Planning Committee (LEPC). This coordination includes periodic meetings of the committee with local emergency response officials, local government officials, and industry representatives. The facility has ar
ound-the-clock communication capabilities with appropriate LEPC officials and emergency response organizations (e.g., sheriff's department) to facilitate notification of the public and receive a quick response.



Types of RMP site-specific prevention steps include the following:

-Release detection (e.g., process alarms, process area detectors);

-Release containment and control (e.g., pressure relief valves, check valves, automatic shutoff systems, redundant instrumentation, dikes); and

-Release mitigation (e.g., fire extinguishing systems, emergency shutdown devices, and trained operations/emergency response personnel).



PLANNED CHANGES TO IMPROVE SAFETY



The facility resolves all findings from PHAs, some of which result in modifications to the process to improve safety.