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Rayonier Performance Fibers, LLC, Jesup Mill

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Facility #1 : Rayonier Performance Fibers, L


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000066518
Deregistered (Yes/No)No
Facility NameRayonier Performance Fibers, LLC, Jesup Mill
Street Address Line 14470 Savannah Highway
CityJesup
StateGA
Zip Code31545
CountyWayne County
113th Congressional DistrictGA01: Georgia 1
Owner or Operator NameRayonier
Parent CompanyRayonier Inc.
Latitude31.661111
Longitude-81.843889
Number of RMP Submissions5

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000024259
Submission Typerevised submission for facility
Submission Date10/17/2011
Reason For SubmissionRevised PHA / Hazard Review due to process change (40 CFR 68.190(b)(5))
Process Toxic Amount Total (lbs)2,284,082
Process Flammable Amount Total (lbs)0
Process Amount Total (lbs)2,284,082
Number of Potential Offsite Consequence Processes3
Potential Offsite Consequence Toxic Amount Total (lbs)2,284,082
Potential Offsite Consequence Flammable Amount Total (lbs)0
Potential Offsite Consequence Amount Total (lbs)2,284,082
All Process NAICS32211
Exec Summary Submission Date10/17/2011

Executive Summary facility_Executive_Summary help link help link (Facility #1 : Rayonier Performance Fibers, L, executive summary: all)

Executive Summary
SUMMARY
The Rayonier Jesup Pulp Mill is committed to promoting and protecting the health and safety of their employees, the environment, and the community in which they operate. As part of this commitment, the Jesup mill has established and maintained health, environmental protection, and safety systems to help ensure safe operation of their processes. One component of these systems is a Risk Management Program (RMP). This RMP complies with the requirements of the Environmental Protection Agency's (EPA's) regulation 40 CFR part 68, Accidental release Prevention Requirements: Risk Management programs (the RMP rule). The RMP rule requires regulated facilities to submit a risk management plan describing their risk management program. This document provides a brief overview of the comprehensive risk management activities that the Jesup pulp mill has developed and implemented.

STATIONARY SOURCE AND REGULATED SUBSTANCES
The Rayonier Jesup Pulp Mill is a three-mill, Kraft pulping complex involved in the manufacture of bleached dissolving, paper and fluff pulps. As part of this manufacturing process, we handle several regulated substances in sufficient quantities to be covered by the RMP rule. The RMP-covered processes at our facility are all Program Level 3 processes and are listed below:
1) Chlorine Process
2) Chlorine Dioxide Process
3) Sulfur Dioxide Process
Chlorine and Chlorine Dioxide are used as pulp bleaching chemicals in our process. They are added directly to the pulp as dilute water solutions in carefully controlled bleach stages. Chlorine is used in two of our three mills while Chlorine Dioxide is used in all three mills. Sulfur Dioxide is added directly to the pulp as a dilute water solution and is used to control or stop chlorine reactions in pulp. It is used in all three mills.


ACCIDENTAL RELEASE PREVENTION PROGRAM
The Rayonier Performance Fibers Jesup Mill has developed an accidental release prevention program for all process chemicals covered by the
respective OSHA PSM and EPA RMP regulations. These programs are modeled after, and comply with, the requisite elements of the OSHA PSM and EPA RMP release prevention programs. The EPA RMP rule established that for Program Level 3 processes, OSHA's PSM prevention program could be used to satisfy RMP prevention requirements provided that it was updated to reflect accidental releases with potential off-site impact. This update was accomplished for our three RMP covered processes, and the following is a brief description of the key elements of our OSHA PSM prevention program.

PROCESS SAFETY INFORMATION. A variety of technical documents are maintained and used to help ensure safe operation of the Jesup mill processes. Material safety data sheets (MSDS) document the physical properties of hazardous substances handled at the Jesup mill. Engineering design documents include the operating parameters and the design basis and configuration for the equipment in each covered process. The Jesup mill ensures that this process safety information is up to date and available to all mill employees.

PROCESS HAZARD ANALYSIS. The Jesup mill performs and periodically updates process hazard analyses (PHA's) for each covered process. A team composed of personnel with engineering and process operating experience and a leader with process hazard analyses experience is assembled to perform these PHA's. PHA teams at the Jesup mill use the hazard and operability (HAZOP) technique, supplemented by checklists, to perform the hazard analyses. A written summary report that contains recommendations for mill management review is prepared by the team. Mill management assigns responsibility for resolution of each recommendation. Where appropriate, changes to improve the safety of the process are implemented. PHA's are performed on each covered process at least once every five years.

OPERATING PROCEDURES. Jesup mill operators and supervisors work together to develop and maintain operating procedur
es for all covered processes. These procedures describe how operations should be safely performed under conditions of initial start-up, normal operations, temporary operations, emergency shutdown, emergency operations, normal shutdown, and startup following a turnaround or emergency shutdown. Operating procedures are used both as operating guidelines and training tools. They are annually certified to be current and accurate by mill Management. All operating procedures for covered systems reside on a computer based training network (SkillsNow) and are accessible 24/7 by all employees via the mill's intranet.

TRAINING. Jesup mill training focuses on general process descriptions, a review of the properties and hazards of the process chemicals and detailed process operating procedures and safe work practices. This is accomplished using computer based training tool (SkillsNow) for all covered processes. Modules have been developed for each covered process and include skills testing and testing record keeping. CBT is augmented with classroom and on-the--job training. Refresher training is conducted at least once every three years. All Training modules for covered systems residing in SkillsNow are accessible 24/7 by all employees via the mill's intranet.

MECHANICAL INTEGRITY. The Jesup mill employs a mechanical integrity program to help prevent equipment failures that could endanger workers, the public or the environment. The program applies to all covered processes and includes equipment inspection and testing specifications, replacement parts and equipment specifications, procedures for inspection, testing and maintaining equipment, training of maintenance personnel, and documentation of maintenance activities. The mill currently utilizes an electronic management system to schedule and notify maintenance supervision of equipment tests and inspections as well as maintain an equipment history.

MANAGEMENT OF CHANGE. The Jesup mill management of change procedure r
equires evaluation and approval of all changes to chemicals, equipment, and procedures for covered processes. These procedures help ensure that the change does not impact the safe operation of the process. Central to this process is the updating of process information relating to the change and communication of the change to employees involved in the covered process. The Jesup MOC system utilizes an electronic issuance and tracking system which includes notifications for approvers and MOC coordinators of required review and action items to be addressed. Our computer based training system is also equipped with an MOC function to notify affected employees of all changes to operating procedures resulting from a PSM MOC.

PRE-STARTUP REVIEW. The Jesup mill performs a pre-startup safety review on all covered process changes significant enough to require updating of the process safety information. A pre-startup review team completes a checklist to document the review and to ensure that identified safety issues have been addressed.

COMPLIANCE AUDITS. Process safety compliance audits are an integral part of the Jesup mill prevention program. Audits are performed by an audit team knowledgeable in the process and process safety management. The audit team evaluates whether the prevention program satisfies the requirements of the PSM/RMP rule and is sufficient to help ensure the safe operation of the process. Audit results are documented, recommendations resolved and appropriate improvements to the prevention program are implemented. Audit findings are included in the mill's Consolidated Action Plan, which receives corporate executive review. The Jesup mill audits the prevention program using either an internal or external audit at least once every three years.

INCIDENT INVESTIGATION. The Jesup mill investigates all incidents that result or could potentially result in injury to mill personnel or the public, or could harm the environment. A mill team performs this inves
tigation and documents recommendations aimed at preventing similar incidents from occurring in the future. All recommendations are resolved and appropriate corrective actions are implemented. As with other PSM elements, this too utilizes an electronic issuance and tracking system. Those responsible for conducting the investigation as well as those assigned corrective actions from the investigation are notified via internal e-mail of required completion activities.

EMPLOYEE PARTICIPATION. Employee participation is a key element of the Jesup mill prevention program. This participation ensures that employee concerns relative to the safety of the covered processes are fully addressed. Employees participate in PHA's, incident investigations, procedures development and compliance audits.

HOT WORK PERMITS. The Jesup mill has developed hot work procedures to control spark or flame-producing activities that could result in fires or explosions in the mill covered processes. The mill's Hot Work Permitting process is part of an overarching Safe Work Permitting program including other Safe Work Practices such as Lockout/Tagout, Confined Space Entry, and Line Breaking. Training on hot work permitting and other Safe Work Practices is conducted annually.

CONTRACTORS. Contractor safety is included in the Jesup mill prevention program. The Jesup mill reviews the safety records of all contractors to help ensure that they can safely perform the desired job tasks. As with mill employees, contractors are informed of the hazards of the processes they will work on, the Jesup mill emergency response procedures and the mill safe work practices. Contractors are required to provide the Jesup mill with training records and work performance is periodically reviewed to ensure that safe work practices are being followed.

FIVE-YEAR ACCIDENT HISTORY
We keep records for all accidental chemical releases that occur at our facility. The mill has no reportable accidents under the RMP rule/gu
idance.

EMERGENCY RESPONSE PROGRAM
The Jesup mill has a written emergency response plan for the facility to aid in safely responding to accidental releases of hazardous chemicals. This emergency response plan includes:

AA Procedures for how employees will respond to emergency situations.
AA Procedures for specific departmental emergency and evacuation plans.
AA Procedures covering evacuation routes and safe places of refuge.
AA A description and explanation of the emergency alarm system.
AA Procedures for activation of the emergency response team.
AA A description of the incident command system.
AA Training of employees in their responsibilities during an emergency.
AA Procedures for providing proper first aid and emergency medical treatment to treat accidental human exposure to hazardous substances.
AA Procedures for controlling and containing accidental releases of hazardous substances, including the use of emergency response equipment.
AA Procedures for informing County emergency response officials of releases which could reasonably result in off-site consequences.
AA Procedures for informing the public when necessary.
AA Procedures for inspecting and maintaining emergency response equipment.
AA Procedures for reviewing and updating the emergency response plan.

The Rayonier Jesup Mill maintains a twenty-four hour emergency response team trained in emergency response and HazMat procedures. All mill personnel are trained in evacuation procedures. Rayonier periodically conducts emergency response drills. The written emergency response plan has been communicated to the local emergency response officials.


PLANNED CHANGES TO IMPROVE SAFETY
The Jesup Mill strives to continuously improve the safety of our workers and the safety of our processes. There are many systems in place to achieve this goal. Some examples include:

1. The mill has recently revised and updated most of its major safety programs, including Lockout/Tagout, Confined Space Entr
y, Hot Work, Line Braking, and Fall Protection.
2. Recent organizational changed have been focused on heightening awareness and ensuring compliance in safety related areas (such as PSM).
3. AARisk based and data drivenAA accident reduction programs are in place to target those areas where the majority of mill accidents occur. Current focus areas include eye injuries and hand injuries.
4. Documented incident investigations are performed to improve safety. These investigations are conducted whenever an incident has the potential to affect the safety of workers. The mill is in the process of adopting a new Root Cause Analysis model to ensure we truly identify and correct root cause issues for accidents/incidents.
5. Concerning Chlorine, Chlorine Dioxide, and Sulfur Dioxide, the mill has greatly updated and improved its gas monitoring capabilities including upgrading/improving gas sensor technology, installing additional gas sensors, and implementing gas cloud dispersion indicating capability into the DCS.
6. Major efforts to improve our safety continued with Jesup's SkillsNOW computer based training program. This computer-based operating procedure/training system has been in place for several years for the Chlorine, Chlorine Dioxide and Sulfur Dioxide systems, which facilitates procedure changes and provides operators easier access to process information.
7. Mill-wide goals are established each year and each mill department is charged with developing an improvement plan that contributes to each element of the mill plan.
8. Our Central Safety and Health Committee continue to provide the Jesup Mill with tangible safety improvements primarily based on active participation and suggestions from employees.
9. Several hourly workers have recently assumed the role of Departmental Safety Coordinators. This allows the worker's safety concerns to be effectively communicated and addressed via direct interface with department Management.

Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees820
Owner or Operator NameRayonier
Owner or Operator Address Line 14470 Savannah Highway
Owner or Operator CityJesup
Owner or Operator StateGA
Owner or Operator Zip31545
Parent Dun and Bradstreet Number1265263
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees820
Number of FTE CBI FlagNo
Other Facility ID31545TTRYNSAVAN
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VYes
CAA Title V Air Operating Permit ID26313050001V01
Last Safety Inspection Date10/11/2007
Last Safety Inspection ByOSHA
OSHA Star or Merit RankingNo
LEPC NameGeorgia Emergency Mgmt Agency

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17)
Owner or Operator Phone9124275225
Facility URLwww.Rayonier.com
Facility Phone9125888216
Facility EmailMike.Bell@Rayonier.com
Facility Dun and Bradstreet Number75854349
RMP ContactFrederick M. Kershner
RMP Contact TitleDirector, Safety
RMP Contact Emailfred.kershner@rayonier.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 Date09/21/2012
Postmark Date10/17/2011
Anniversary Date10/17/2016
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17)
Latitude31.661111
Longitude-81.843889
Valid Lat/LongYes
Lat/Long MethodInterpolation - Photo
Lat/Long Location TypePlant Entrance (General)
FRS Latitude31.66
FRS Longitude-81.84
FRS Lat/Long DescriptionPLANT ENTRANCE (GENERAL)
FRS Lat/Long MethodCLASSICAL SURVEYING TECHNIQUES

Submission - Counts and Totals facility_Submission_-_Counts_and_Totals help link help link  
Number of RMP Accidents1
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)390
RMP Accident Amount Total (lbs)390
Number of RMP Accidents1
Number of Processes3
Number of Process Chemicals0
Number of Toxic Worst-case Scenarios1
Number of Toxic Alternate Case Scenarios3
Number of Flammable Worst-case Scenarios0
Number of Flammable Alternate Case Scenarios0
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)390
RMP Accident Amount Total (lbs)390
Total RMP Accident Deaths0
Total RMP Accident Injuries4
Total RMP Accident Evacuated/Sheltering In Place0
Total RMP Accident Property Damage$0

Processes facility_Processes help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #1 : Chlorine Process)
Process DescriptionChlorine Process
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)2,160,000
Flammable Amount Total (lbs)0
Process Amount Total (lbs)2,160,000
Number of Process Chemicals0
Number of Toxic Worst-Case Scenarios1
Number of Toxic Alternate Scenarios1
Number of Flammable Worst-Case Scenarios0
Number of Flammable Alternate Scenarios0

Process Chemicals facility_Process_Chemicals help link help link  
Process Chemical IDChlorine
CAS number007782505
Chemical TypeToxic
Process Chemical Amount (lbs)2,160,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #1 : Chlorine Process, process chemical #2)
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 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #1 : Chlorine Process, process chemical #2, alternate toxic scenario #1)
Percent Weight (Within Mixture)100
Physical StateGas liquified by pressure
Model UsedEPA's RMP*Comp(TM)
Wind Speed3
Atmospheric Stability ClassF
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 ValvesYes
Active Mitigation - FlaresNo
Active Mitigation - ScrubbersNo
Active Mitigation - Emergency ShutdownYes
Active Mitigation - OtherDOT header block valves and Unipro valves on Chlorine car angle valves (gas and liquid)
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #1 : Chlorine Process, process NAICS code #1 : 32211)
NAICS Code32211: Pulp Mills

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date05/02/2009
PHA Update Date11/06/2007
PHA Technique - What IfNo
PHA Technique - ChecklistYes
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Technique - OtherBrainstorming
PHA Change Completion Date12/31/2009
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireNo
Hazard Identified - ExplosionNo
Hazard Identified - Runaway ReactionNo
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureNo
Hazard Identified - CorrosionYes
Hazard Identified - OverfillingNo
Hazard Identified - ContaminationNo
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossNo
Hazard Identified - EarthquakeNo
Hazard Identified - FloodNo
Hazard Identified - TornadoNo
Hazard Identified - HurricaneNo
Process Controls - VentsNo
Process Controls - Relief ValvesYes
Process Controls - Check ValvesYes
Process Controls - ScrubbersYes
Process Controls - FlaresNo
Process Controls - Manual ShutoffsYes
Process Controls - Auto ShutoffsYes
Process Controls - InterlocksYes
Process Controls - AlarmsYes
Process Controls - Keyed BypassNo
Process Controls - Emergency AirNo
Process Controls - Emergency PowerNo
Process Controls - Backup PumpNo
Process Controls - GroundingNo
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksYes
Process Controls - Excess Flow DevicesYes
Process Controls - Quench SystemNo
Process Controls - Purge SystemNo
Process Controls - NoneNo
Mitigation Systems - SprinklersNo
Mitigation Systems - DikesNo
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsNo
Mitigation Systems - Water CurtainsNo
Mitigation Systems - EnclosureNo
Mitigation Systems - NeutralizationYes
Mitigation Systems - NoneNo
Mitigation Systems - OtherAutomatic shut-off valves
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterYes
Monitoring Systems - NoneNo
Monitoring Systems - OtherVideo Cameras
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryNo
Changes Since PHA - Process ParametersNo
Changes Since PHA - Process ControlsYes
Changes Since PHA - Process DetectionNo
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsYes
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Procedure Review Date05/11/2011
Training Review Date05/11/2011
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherComputer-based training
Competency Testing - Written TestsYes
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Competency Testing - OtherComputer-based testing
Maintenance Review Date07/19/2011
Maintenance Inspection Date10/03/2011
Equipment TestedThird party Chlorine System Piping inspection
Management of Change Most Recent Date05/03/2011
Management of Change Review Date03/03/2011
Pre-startup Review Date05/03/2011
Compliance Audit Date03/03/2011
Compliance Audit Change Completion Date10/31/2011
Incident Investigation Date08/30/2010
Incident Invest. Change Completion Date11/29/2010
Participation Plan Review Date03/03/2011
Hot Work Review Date10/01/2011
Contractor Safety Review Date05/05/2011
Contractor Safety Eval. Date05/05/2011
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #1 : Chlorine Process, process NAICS code #1 : 32211, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000035619

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
Chlorine Process for the 'A' and 'B' Pulp Mills. Two identical and parallel Chlorine systems feed the 'A' and 'B' mills. The prevention programs for the Chlorine Systems are the same for 'A' and 'B' pulp mills.

Processes facility_Processes help link help link  
Process DescriptionSulfur Dioxide Process
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)66,700
Flammable Amount Total (lbs)0
Process Amount Total (lbs)66,700
Number of Process Chemicals0
Number of Toxic Worst-Case Scenarios0
Number of Toxic Alternate Scenarios1
Number of Flammable Worst-Case Scenarios0
Number of Flammable Alternate Scenarios0

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #2 : Sulfur Dioxide Process, process chemical #1)
Process Chemical IDSulfur dioxide (anhydrous)
CAS number007446095
Chemical TypeToxic
Process Chemical Amount (lbs)66,700
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link  
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)100
Physical StateGas liquified by pressure
Model UsedEPA's RMP*Comp(TM)
Wind Speed3
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 ValvesYes
Active Mitigation - FlaresNo
Active Mitigation - ScrubbersNo
Active Mitigation - Emergency ShutdownNo
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #2 : Sulfur Dioxide Process, process NAICS code #1 : 32211)
NAICS Code32211: Pulp Mills

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date11/11/2008
PHA Update Date11/18/2008
PHA Technique - What IfNo
PHA Technique - ChecklistYes
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPNo
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Technique - OtherBrainstorming
PHA Change Completion Date12/31/2009
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireNo
Hazard Identified - ExplosionNo
Hazard Identified - Runaway ReactionNo
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionYes
Hazard Identified - OverfillingNo
Hazard Identified - ContaminationNo
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossNo
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 - FlaresNo
Process Controls - Manual ShutoffsYes
Process Controls - Auto ShutoffsYes
Process Controls - InterlocksYes
Process Controls - AlarmsYes
Process Controls - Keyed BypassNo
Process Controls - Emergency AirNo
Process Controls - Emergency PowerNo
Process Controls - Backup PumpNo
Process Controls - GroundingNo
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksYes
Process Controls - Excess Flow DevicesYes
Process Controls - Quench SystemNo
Process Controls - Purge SystemNo
Process Controls - NoneNo
Process Controls - OtherBack flow regulator
Mitigation Systems - SprinklersNo
Mitigation Systems - DikesNo
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsNo
Mitigation Systems - Water CurtainsNo
Mitigation Systems - EnclosureNo
Mitigation Systems - NeutralizationNo
Mitigation Systems - NoneNo
Mitigation Systems - OtherAutomatic shut-off valves
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterYes
Monitoring Systems - NoneNo
Monitoring Systems - OtherVideo Cameras
Changes Since PHA - Reduced InventoryYes
Changes Since PHA - Increased InventoryNo
Changes Since PHA - Process ParametersNo
Changes Since PHA - Process ControlsYes
Changes Since PHA - Process DetectionNo
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsYes
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Procedure Review Date05/11/2011
Training Review Date05/11/2011
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherComputer-based training
Competency Testing - Written TestsYes
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Competency Testing - OtherComputer-based testing
Maintenance Review Date07/19/2010
Maintenance Inspection Date10/03/2011
Equipment TestedThird party Sulfur Dioxide piping inspection
Management of Change Most Recent Date05/16/2011
Management of Change Review Date03/03/2011
Pre-startup Review Date04/08/2011
Compliance Audit Date03/03/2011
Compliance Audit Change Completion Date10/31/2011
Incident Investigation Date04/27/2011
Incident Invest. Change Completion Date06/09/2011
Participation Plan Review Date03/03/2011
Hot Work Review Date10/01/2011
Contractor Safety Review Date03/01/2011
Contractor Safety Eval. Date05/05/2011
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #2 : Sulfur Dioxide Process, process NAICS code #1 : 32211, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000035620

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
Sulfur Dioxide Process for the 'A','B' and 'C' pulp mills. A single process feeds all three mills.

Processes facility_Processes help link help link  
Process DescriptionChlorine Dioxide Process
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)57,382
Flammable Amount Total (lbs)0
Process Amount Total (lbs)57,382
Number of Process Chemicals0
Number of Toxic Worst-Case Scenarios0
Number of Toxic Alternate Scenarios1
Number of Flammable Worst-Case Scenarios0
Number of Flammable Alternate Scenarios0

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #3 : Chlorine Dioxide Process, process chemical #1)
Process Chemical IDChlorine dioxide [Chlorine oxide (ClO2)]
CAS number010049044
Chemical TypeToxic
Process Chemical Amount (lbs)57,382
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link  
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)1.1
Physical StateGas liquified by refrigeration
Model UsedEPA's RMP*Comp(TM)
Wind Speed3
Atmospheric Stability ClassD
TopographyUrban
Passive Mitigation - DikesYes
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsYes
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 ShutdownYes
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #3 : Chlorine Dioxide Process, process NAICS code #1 : 32211)
NAICS Code32211: Pulp Mills

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date06/13/2009
PHA Update Date03/21/2011
PHA Technique - What IfNo
PHA Technique - ChecklistYes
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Technique - OtherBrainstorming
PHA Change Completion Date06/01/2011
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionNo
Hazard Identified - Runaway ReactionYes
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionNo
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationYes
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossNo
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 - FlaresNo
Process Controls - Manual ShutoffsYes
Process Controls - Auto ShutoffsYes
Process Controls - InterlocksYes
Process Controls - AlarmsYes
Process Controls - Keyed BypassNo
Process Controls - Emergency AirNo
Process Controls - Emergency PowerNo
Process Controls - Backup PumpNo
Process Controls - GroundingNo
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksYes
Process Controls - Excess Flow DevicesNo
Process Controls - Quench SystemYes
Process Controls - Purge SystemNo
Process Controls - NoneNo
Process Controls - OtherBack flow regulators, emergency shutdown system
Mitigation Systems - SprinklersYes
Mitigation Systems - DikesYes
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsYes
Mitigation Systems - Water CurtainsNo
Mitigation Systems - EnclosureNo
Mitigation Systems - NeutralizationNo
Mitigation Systems - NoneNo
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterYes
Monitoring Systems - NoneNo
Monitoring Systems - OtherVideo Cameras
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryNo
Changes Since PHA - Process ParametersNo
Changes Since PHA - Process ControlsNo
Changes Since PHA - Process DetectionYes
Changes Since PHA - Perimeter MonitoringYes
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Procedure Review Date05/11/2011
Training Review Date05/11/2011
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherComputer-based training
Competency Testing - Written TestsYes
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Competency Testing - OtherComputer-based testing
Maintenance Review Date07/19/2011
Maintenance Inspection Date10/03/2011
Equipment TestedThird party ClO2 system piping inspection
Management of Change Most Recent Date07/19/2011
Management of Change Review Date03/03/2011
Pre-startup Review Date02/28/2011
Compliance Audit Date03/03/2011
Compliance Audit Change Completion Date10/31/2011
Incident Investigation Date04/10/2011
Incident Invest. Change Completion Date08/23/3011
Participation Plan Review Date03/03/2011
Hot Work Review Date10/01/2011
Contractor Safety Review Date10/01/2011
Contractor Safety Eval. Date05/05/2011
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, process #3 : Chlorine Dioxide Process, process NAICS code #1 : 32211, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000035621

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
Chlorine Dioxide Process for the 'A','B' and 'C' pulp mills. A single process feeds all three mills.

Accidents facility_Accidents help link help link  
Accident Date03/23/2012
Accident Time1947
Number of Chemicals1
Flammable Amount Total (lbs)0
Toxic Amount Total (lbs)390
Released Amount Total (lbs)390
Number of Deaths0
Number of Injuries4
Number Evacuated / Sheltered0
Total Property Damage$0
Environmental DamageNo
NAICS of Process Involved32211: Pulp Mills
Release Duration (HHHMM)00053
Release Event - Gas ReleaseYes
Release Event - SpillNo
Release Event - FireNo
Release Event - ExplosionNo
Release Event - ReactionNo
Release Source - Storage VesselNo
Release Source - PipingNo
Release Source - Process VesselYes
Release Source - Transfer HoseNo
Release Source - ValveNo
Release Source - PumpNo
Release Source - JointNo
Wind Speed0.5
Wind Speed Unitsmiles/h
Wind DirectionSSW
Temperature66
Atmospheric Stability ClassF
PrecipitationNo
Unknown WeatherNo
Workers Killed0
Responders Killed0
Public Killed (on-site)0
Workers Injured4
Responders Injured0
Public Injured (on-site)0
Property Damage (on-site)$0
Off-site Deaths0
Hospitalizations0
Number Requiring Medical Treatment0
Number Evacuated0
Number Sheltered In Place0
Property damage (off-site)$0
Environmental Damage - Fish/Animal KillsNo
Environmental Damage - DefoliationNo
Environmental Damage - Water ContaminationNo
Environmental Damage - Soil ContaminationNo
Initiating EventHuman Error
Contributing Factor - Equipment FailureYes
Contributing Factor - Human ErrorNo
Contributing Factor - Improper ProcedureYes
Contributing Factor - OverpressurizationNo
Contributing Factor - Upset ConditionNo
Contributing Factor - By-pass ConditionNo
Contributing Factor - MaintenanceYes
Contributing Factor - Process DesignNo
Contributing Factor - Unsuitable EquipmentNo
Contributing Factor - Unusual WeatherNo
Contributing Factor - Management ErrorNo
Off-site Responders NotifiedNo, not notified
Changes Introduced - Improved EquipmentYes
Changes Introduced - Revised MaintenanceYes
Changes Introduced - Revised TrainingYes
Changes Introduced - Operating ProceduresYes
Changes Introduced - Process ControlNo
Changes Introduced - Mitigation SystemsNo
Changes Introduced - Response PlanNo
Changes Introduced - Changed ProcessNo
Changes Introduced - Reduced InventoryNo
Changes Introduced - NoneNo
Total RMP Accident Deaths0
Total RMP Accident Injuries4
Total RMP Accident Evacuated/Sheltering In Place0
Total RMP Accident Property Damage$0

Accident Chemicals facility_Accident_Chemicals help link help link (Facility #1 : Rayonier Performance Fibers, L, RMP submission #1 : 2011-10-17, accident #1, accident chemical #1)
Chemical IDSulfur dioxide (anhydrous)
CAS number007446095
Chemical TypeToxic
Amount Released (lbs)390
Percent Weight (Within Mixture)100

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 Date07/22/2008
Response Training Date06/15/2009
Local Response AgencyWayne County Emergency Mgmt. Agency
Local Response Agency Phone9124275979
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 ID100000066518

*END OF REPORT*