Search Criteria Used (More)

PCS Nitrogen Fertilizer, L.P. Augusta Georgia

Searching...


Facility #1 : PCS Nitrogen Fertilizer, L.P.


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000076142
Deregistered (Yes/No)No
Facility NamePCS Nitrogen Fertilizer, L.P. Augusta Georgia
Street Address Line 11460 Columbia Nitrogen Road
CityAugusta
StateGA
Zip Code30901
CountyRichmond County
113th Congressional DistrictGA12: Georgia 12
Owner or Operator NamePCS Nitrogen Fertilizer, L.P.
Parent CompanyPotash Corporation of Saskatchewan
Latitude33.442222
Longitude-081.930556
Number of RMP Submissions4

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000022420
Submission Typerevised submission for facility
Submission Date05/31/2011
Reason For SubmissionProcess no longer covered (source has other processes that remain covered) (40 CFR 68.190(b)(7))
Process Toxic Amount Total (lbs)72,270,000
Process Flammable Amount Total (lbs)30,000
Process Amount Total (lbs)72,300,000
Number of Potential Offsite Consequence Processes1
Potential Offsite Consequence Toxic Amount Total (lbs)72,270,000
Potential Offsite Consequence Flammable Amount Total (lbs)30,000
Potential Offsite Consequence Amount Total (lbs)72,300,000
All Process NAICS325311
Exec Summary Submission Date05/31/2011

Executive Summary facility_Executive_Summary help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , executive summary: all)

Executive Summary
RMP Executive Summary 11/29/2012



Accidental Release Prevention and Emergency Response Policies.



Below is our Safety, Heath, and Environmental Policy.



As employees of PCS Nitrogen, we have the responsibility to manage our operations to protect human health and the environment. Sound health, safety and environmental policies are an integral part of our everyday job requirements.



In recognition of this responsibility, we will correct any unsound health, safety, and environmental practices or conditions, or call them to the attention of those who will do so, as soon as they are identified. Specifically we will:



Conduct our operations in compliance with any applicable health, safety and environmental laws and regulations.



Continue to improve our safety, health, and environmental performance through the Augusta Does Accident Prevention Together (ADAPT) Process.



Conduct periodic assessments of our operations to ensure and reduce risks.



Implement progressive health, safety, and environmental practices that apply risk management and loss control principles to our operations.



Establish safety, health, and environmental performance goals and assign responsibilities for developing and implementing related measurement systems.



Provide educational and training regarding applicable laws, regulations, policies, and procedures to protect human health and the environment.



Cooperate with our neighbors, industry trade groups, government agencies, and others to develop effective, reasonable rules and regulations to protect human health and the environment.



PCS Nitrogen's success depends on our positive health, safety, and environmental attitude and actions to achieve continuous improvement.



The worst case release scenario are for a regulated toxic substance from PCS Nitrogen facility would be the failure of a pressurized ammonia storage tank, and the sudden release of it's contents. The distance to the toxic endpoint (200ppm) as determined by RM
PComp version would impact public receptors. By implementing administrative controls in the form of written operation procedures. We have administratively reduced the tank's design capacity by 314,000 lbs.



The alternative release scenario (ARS) for ammonia would be the failure of a pipeline during the unloading of a railcar. This release would last for 25 minutes. The distance to the toxic endpoint (200 ppm) as determined by RMPComp version 1.06 would impact receptors.



The alternative release scenario (ARS) for ammonia (conc. 20% or greater) involves the overflow of a product tank. This release would last for a five minute period. The distance to the toxic endpoint (200 ppm) as determined by RMPComp version 1.06 would impact public receptors.



The worst case scenario for a regulated flammable substance from the PCS Nitrogen facility would be the release of a flammable gas mixture from the CO2 absorber column and a subsequent vapor cloud explosion. The distance to the endpoint (overpressure of 1PSI) as determined by equations found in EPA's OCA Guidance document would impact public receptors.



The alternative release scenario (ARS) for a flammable substance would be the same scenario as for worst case using the equations found in the OCA guidance document. This scenario would also impact public receptors.



The PCS Nitrogen facility has experienced six accidental releases of anhydrous ammonia in the past five years. The largest release was 2,243 pounds. This release occurred on June 18, 2009 and lasted a duration of eighty minutes. This release had no off site impact on public receptors.



The PCS Nitrogen facility has not had any reportable accidental releases of flammable gas mixtures in the last five years.



Prevention Program



We prevent accidents by adhering to the OSHA PSM and EPA's RMP Standard and by:



Designing for safety:



Process equipment designed per industry codes.

Automatic and manual shutoff devices are provided at critic
al locations.

Process areas are routinely monitored by operations staff members for leaks and spills

System designs incorporate multiple layers of protection/redundant safeguards



Maintaining our plant:



Maintenance personnel are trained, skilled, and certified craftsmen

Critical equipment including tanks, relief devices, hoses, piping, instrumentation, and shutdown systems are routinely inspected and tested to assure proper operation.

Preventative Maintenance (PM) Program conducted by qualified instrumentation, electrical and mechanical technicians.

Equipment is tested and rechecked by operations staff members after it is worked on by maintenance to assure proper operation.



Operating Safety:



Operators are trained and certified to operate the plant safely

Continuous computer, operator monitoring and surveillance

Written operating procedures and operational standards based on process risk analysis

Controlled entry to process and work permit system to control hazardous work in areas



Auditing our Operation:



Operator and Management safety inspections

Pre-startup safety reviews prior to startup of new or modified equipment in the area

Process Hazardous Analysis conducted on all equipment and processes

Design changes are reviewed for proper design and complete documentation

Routine audits are conducted to assure safe practices

Investigation of all accidents to determine the Root Cause

Failure mode and Effects Analysis are performed on all pieces of equipment in the plant



Emergency Response Program



Training and preparation:



Plant Emergency Management Plan

Simulated drills are conducted on a regular basis

Critiques of drills and actual events are conducted. The ERT participates in the annual ERT competition rodeo.

The Emergency Response Team is on site 24 hrs per day. The ERT trains a minimum of 8 hours each month.

The Emergency Response Team is trained in Hazardous Materials, Fire fighting, and Confined Space/High angle Rescue


Certified Emergency Medical personnel are on the Emergency Response Team

Participate in simulation drills with the community responders

Off-Site Emergency Response Team for Transportation Emergencies



If a release occurs:



Fire monitors provide a water spray to cool tanks and suppress vapors

Fence line monitoring and computer modeling

Emergency Response Team can be activated instantly via All-Call pager system

Computer system provides real time weather conditions

Preplanned release scenarios available to provide quick preliminary evaluation of impact

Emergency Response equipment located throughout the facility





Planned Changes to Improve Safety:



Hazardous materials team training for the Emergency Response Team is scheduled annually to maintain certifications of team members. We have constructed a fire training facility and two training railcars in order to provide additional training for the Response Teams.



A 7,500 square foot ERT Training Facility was constructed on site to enable and enhance the quality of training.
Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees135
Owner or Operator NamePCS Nitrogen Fertilizer, L.P.
Owner or Operator Address Line 1Post Office Box 1483
Owner or Operator CityAugusta
Owner or Operator StateGA
Owner or Operator Zip30903
Parent Dun and Bradstreet Number248190209
Second Parent Dun and Bradstreet Number248190209
Number of Full Time Employees135
Number of FTE CBI FlagNo
Other Facility ID30903CLMBN23C
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VYes
CAA Title V Air Operating Permit ID2873-245-0002
Last Safety Inspection Date04/25/2007
Last Safety Inspection ByState environmental agency
OSHA Star or Merit RankingNo
LEPC NameRichmond County LEPC

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , RMP submission #1 : 2011-05-31)
Owner or Operator Phone7064691200
Facility URLPotashCorp.com
Facility Phone7064691200
Facility Dun and Bradstreet Number610041386
RMP ContactJohn McKinnon
RMP Contact TitleEnvironmental Manager
RMP Contact Emailjohn.mckinnon@potashcorp.com

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsNo
Complete Check Date11/30/2012
Postmark Date05/31/2011
Anniversary Date05/31/2016
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link  
Latitude33.442222
Longitude-081.930556
Valid Lat/LongYes
Lat/Long MethodLoran C
Lat/Long Location TypeAdministrative Building
FRS Latitude33.44
FRS Longitude-81.93
FRS Lat/Long DescriptionFACILITY CENTROID
FRS Lat/Long MethodGPS - UNSPECIFIED

Submission - Counts and Totals facility_Submission_-_Counts_and_Totals help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , RMP submission #1 : 2011-05-31)
Number of RMP Accidents0
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)0
RMP Accident Amount Total (lbs)0
Number of RMP Accidents0
Number of Processes1
Number of Process Chemicals0
Number of Toxic Worst-case Scenarios1
Number of Toxic Alternate Case Scenarios2
Number of Flammable Worst-case Scenarios1
Number of Flammable Alternate Case Scenarios1
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)0
RMP Accident Amount Total (lbs)0
Total RMP Accident Deaths0
Total RMP Accident Injuries0
Total RMP Accident Evacuated/Sheltering In Place0
Total RMP Accident Property Damage$0

Processes facility_Processes help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , RMP submission #1 : 2011-05-31, process #1 : Ammonia)
Process DescriptionAmmonia
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)72,270,000
Flammable Amount Total (lbs)30,000
Process Amount Total (lbs)72,300,000
Number of Process Chemicals0
Number of Toxic Worst-Case Scenarios1
Number of Toxic Alternate Scenarios2
Number of Flammable Worst-Case Scenarios1
Number of Flammable Alternate Scenarios1

Process Chemicals facility_Process_Chemicals help link help link  
Process Chemical IDAmmonia (anhydrous)
CAS number007664417
Chemical TypeToxic
Process Chemical Amount (lbs)72,000,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , RMP submission #1 : 2011-05-31, process #1 : Ammonia, process chemical #2)
Process Chemical IDFlammable Mixture
CAS number000001111
Chemical TypeFlammable
Process Chemical Amount (lbs)30,000
Confidential Business InformationNo

Process Flammable Mixture Chemicals facility_Process_Flammable_Mixture_Chemicals help link help link  
Chemical ID
Methane
Hydrogen

Process Chemicals facility_Process_Chemicals help link help link  
Process Chemical IDAmmonia (conc 20% or greater)
CAS number007664417
Chemical TypeToxic
Process Chemical Amount (lbs)270,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , RMP submission #1 : 2011-05-31, process #1 : Ammonia, process chemical #4)
Process Chemical IDPublic OCA Chemical
CAS number000000000
Process Chemical Amount (lbs)0
Confidential Business InformationNo

Worst-Case Toxic Scenarios facility_Worst-Case_Toxic_Scenarios help link help link  
Percent Weight (Within Mixture)100
Physical StateGas liquified by pressure
Model UsedEPA's RMP*Comp(TM)
Release Duration (minutes)10
Wind Speed (meters/sec)1.5
Atmospheric Stability ClassF
TopographyUrban
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsNo
Confidential Business InformationNo

Alternate Case Toxic Scenarios facility_Alternate_Case_Toxic_Scenarios help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , RMP submission #1 : 2011-05-31, process #1 : Ammonia, process chemical #4, alternate toxic scenario #1)
Percent Weight (Within Mixture)100
Physical StateGas liquified by pressure
Model UsedEPA's RMP*Comp(TM)
Wind Speed2.9
Atmospheric Stability ClassD
TopographyUrban
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsNo
Active Mitigation - SprinklersNo
Active Mitigation - Deluge SystemsNo
Active Mitigation - Water CurtainNo
Active Mitigation - NeutralizationNo
Active Mitigation - Excess Flow ValvesNo
Active Mitigation - FlaresNo
Active Mitigation - ScrubbersNo
Active Mitigation - Emergency ShutdownNo
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , RMP submission #1 : 2011-05-31, process #1 : Ammonia, process chemical #5)
Process Chemical IDPublic OCA Chemical
CAS number000000000
Process Chemical Amount (lbs)0
Confidential Business InformationNo

Worst-Case Flammable Scenarios facility_Worst-Case_Flammable_Scenarios help link help link  
Model UsedEPA's OCA Guidance Reference Tables or Equations
Passive Mitigation - Blast WallsNo
Confidential Business InformationNo

Alternate Case Flammable Scenarios facility_Alternate_Case_Flammable_Scenarios help link help link  
Model UsedEPA's OCA Guidance Reference Tables or Equations
Passive Mitigation - DikesNo
Passive Mitigation - Fire WallsNo
Passive Mitigation - Blast WallsNo
Passive Mitigation - EnclosuresNo
Active Mitigation - SprinklersNo
Active Mitigation - Deluge SystemsNo
Active Mitigation - Water CurtainNo
Active Mitigation - Excess Flow ValvesNo
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , RMP submission #1 : 2011-05-31, process #1 : Ammonia, process chemical #6)
Process Chemical IDPublic OCA Chemical
CAS number000000000
Process Chemical Amount (lbs)0
Confidential Business InformationNo

Alternate Case Toxic Scenarios facility_Alternate_Case_Toxic_Scenarios help link help link  
Percent Weight (Within Mixture)30
Physical StateLiquid
Model UsedEPA's RMP*Comp(TM)
Wind Speed2.9
Atmospheric Stability ClassD
TopographyUrban
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsNo
Active Mitigation - SprinklersNo
Active Mitigation - Deluge SystemsYes
Active Mitigation - Water CurtainYes
Active Mitigation - NeutralizationNo
Active Mitigation - Excess Flow ValvesNo
Active Mitigation - FlaresNo
Active Mitigation - ScrubbersNo
Active Mitigation - Emergency ShutdownNo
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , RMP submission #1 : 2011-05-31, process #1 : Ammonia, process NAICS code #1 : 325311)
NAICS Code325311: Nitrogenous Fertilizer Manufacturing

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date06/20/2012
PHA Update Date06/20/2012
PHA Technique - What IfNo
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date11/01/2012
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionYes
Hazard Identified - Runaway ReactionYes
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionYes
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationYes
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossYes
Hazard Identified - EarthquakeNo
Hazard Identified - FloodNo
Hazard Identified - TornadoNo
Hazard Identified - HurricaneNo
Process Controls - VentsYes
Process Controls - Relief ValvesYes
Process Controls - Check ValvesYes
Process Controls - ScrubbersYes
Process Controls - FlaresYes
Process Controls - Manual ShutoffsYes
Process Controls - Auto ShutoffsYes
Process Controls - InterlocksYes
Process Controls - AlarmsYes
Process Controls - Keyed BypassYes
Process Controls - Emergency AirYes
Process Controls - Emergency PowerYes
Process Controls - Backup PumpYes
Process Controls - GroundingYes
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksNo
Process Controls - Excess Flow DevicesYes
Process Controls - Quench SystemNo
Process Controls - Purge SystemNo
Process Controls - NoneNo
Mitigation Systems - SprinklersYes
Mitigation Systems - DikesYes
Mitigation Systems - Fire WallsYes
Mitigation Systems - Blast WallsYes
Mitigation Systems - Deluge SystemsYes
Mitigation Systems - Water CurtainsYes
Mitigation Systems - EnclosureNo
Mitigation Systems - NeutralizationNo
Mitigation Systems - NoneNo
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterYes
Monitoring Systems - NoneNo
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryNo
Changes Since PHA - Process ParametersYes
Changes Since PHA - Process ControlsYes
Changes Since PHA - Process DetectionYes
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsYes
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Procedure Review Date01/05/2012
Training Review Date05/17/2012
Type of Training - ClassroomYes
Type of Training - On the JobYes
Competency Testing - Written TestsYes
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Maintenance Review Date11/01/2012
Maintenance Inspection Date05/13/2011
Equipment TestedTK-607A 7-28-09/ TK607B 8-6-08/ TK607C 5-13-11
Management of Change Most Recent Date11/16/2012
Management of Change Review Date09/20/2011
Pre-startup Review Date11/16/2012
Compliance Audit Date07/15/2011
Compliance Audit Change Completion Date12/31/2013
Incident Investigation Date10/09/2012
Incident Invest. Change Completion Date03/01/2013
Participation Plan Review Date06/17/2009
Hot Work Review Date01/25/2011
Contractor Safety Review Date10/28/2010
Contractor Safety Eval. Date08/31/2012
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : PCS Nitrogen Fertilizer, L.P. , RMP submission #1 : 2011-05-31, process #1 : Ammonia, process NAICS code #1 : 325311, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000032470

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
Ammonia

Emergency Response Plan Info facility_Emergency_Response_Plan_Info help link help link  
Facility In Community PlanYes
Facility Own Response PlanYes
Specific Facility Response PlanYes
Inform. Procedures in Response PlanYes
Emergency Care in Response PlanYes
Plan Review Date11/04/2010
Response Training Date06/25/2012
Local Response AgencyAugusta Richmond County LEPC
Local Response Agency Phone7068211155
Subject To - OSHA EAPYes
Subject To - OSHA HAZWOPERYes
Subject To - CWAYes
Subject To - RCRAYes
Subject To - OPAYes
Subject To - State EPCRAYes


Search Criteria Used
RMP Facility ID100000076142

*END OF REPORT*