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Honeywell - Delaware Plant

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Facility #1 : Honeywell - Delaware Plant


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000088166
Deregistered (Yes/No)No
Facility NameHoneywell - Delaware Plant
Street Address Line 16100 Philadelphia Pike
CityClaymont
StateDE
Zip Code19703
CountyNew Castle County
113th Congressional DistrictDE00: Delaware At Large
Owner or Operator NameHoneywell International Inc.
Parent CompanyHoneywell International Inc.
Latitude39.811616
Longitude-75.434743
Number of RMP Submissions7
Map this facilitylink to map

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000034997
Submission Typerevised submission for facility
Submission Date06/19/2013
Reason For SubmissionProcess no longer covered (source has other processes that remain covered) (40 CFR 68.190(b)(7))
Process Toxic Amount Total (lbs)1,430,000
Process Flammable Amount Total (lbs)15,000
Process Amount Total (lbs)1,445,000
Number of Potential Offsite Consequence Processes3
Potential Offsite Consequence Toxic Amount Total (lbs)1,430,000
Potential Offsite Consequence Flammable Amount Total (lbs)15,000
Potential Offsite Consequence Amount Total (lbs)1,445,000
All Process NAICS32518 32519
Exec Summary Submission Date06/19/2013

Executive Summary facility_Executive_Summary help link help link (Facility #1 : Honeywell - Delaware Plant, executive summary: all)

Executive Summary
RMP*eSubmit Executive Summary

Honeywell Delaware



About Honeywell Delaware



The Honeywell International Inc. Delaware plant (Honeywell Delaware) is a manufacturing facility located in Claymont, Delaware. It is part of the Specialty Materials business group of Honeywell International Inc.



Honeywell International Inc. (Honeywell.com) is a Fortune 100 diversified technology and manufacturing leader, serving customers worldwide with aerospace products and services; control technologies for buildings, homes and industry; automotive products; turbochargers; and specialty materials. Based in Morristown, New Jersey, Honeywell's shares are traded on the New York, London and, Chicago Stock Exchanges. For more news and information on Honeywell, please visit www.honeywellnow.com.



Honeywell Specialty Materials, also based in Morristown, N.J., is a global leader in providing customers with high-performance specialty materials, including fluorine products, specialty films and additives, advanced fibers and composites, intermediates, specialty chemicals, electronic materials and chemicals, and technologies and materials for petroleum refining.



Health, Safety and Environment/Responsible Care®



Honeywell Delaware is committed to managing health, safety and the environment as a core business value to ensure compliance with all applicable government standards and regulations. Honeywell Delaware also integrates health, safety and environmental management into our business as a way of achieving profitable growth and accelerated productivity.



Honeywell Specialty Materials participates in the Responsible Care® program of the American Chemistry Council, and has achieved and maintained certification to the standard since 2005. Responsible Care® is a chemical industry program focused on achieving improvements in environmental, health and safety performance beyond levels required by the U.S. government



The Responsible Care® program directs its compani
es to adopt practices for the safe use of materials, to perform regular audits, and to reach out and communicate with the communities in which the companies operate.



Additionally, the Honeywell Delaware plant holds and maintains ISO-9000 and RC-14001 management system certifications



Honeywell Delaware



Honeywell Delaware is a specialty chemical manufacturing facility that has approximately 29 employees. The plant's products are used to make adhesives, synthetic lubricants and flavor/fragrances.

The material(s) used by the facility include boron trifluoride, hydrogen fluoride, sulfur trioxide and ethyl ether which are on the RMP Rule's list of regulated substances. The Honeywell Delaware plant stores and uses these materials in quantities than exceed the specified threshold(s) of quantity as defined by the EPA's RMP Rule.



In accordance with the requirements of the RMP Rule, a description of the following six elements is provided for Honeywell Delaware:



1) Accidental Release Prevention and Emergency Response Policies:



It is the policy of Honeywell Delaware to operate a safe and environmentally sound facility by identifying and controlling health, safety, or environmental risks related to its operations; by designing its processes to protect people, property and the environment; by conducting and continually reviewing and improving programs for safety, health and environmental excellence; and by establishing processes to assure that all laws and regulations applicable to its operations and products are known and observed. The accidental release prevention and emergency response policy associated specifically with the plant's use of boron trifluoride, hydrogen fluoride, sulfur trioxide and ethyl ether involves the integration of safety devices and technologies inherent in the design of the processes, safe operational procedures and management practices, operator training, emergency response plans, maintenance of emergency response equipment, coord
ination with local emergency response services, and communicating with the community.



2. Description of the Facility and Regulated Substances Handled



Honeywell Delaware is located on 50 acres. Part of the site is located in Claymont, Delaware and part of the site is located in Marcus Hook, Pennsylvania. The site includes several office buildings, manufacturing buildings, storage buildings, a maintenance shop, and a laboratory building. There are approximately 29 Honeywell employees at the site.



Honeywell Delaware operates 24 hours per day and manufactures fluosulfonic acid, boron trifluoride (BF3) and BF3 complexes. Each of these processes is described in more detail below.



Boron trifluoride is regulated by the RMP rule. It is manufactured in the BF3 process on the Pennsylvania side of the plant, and used as a raw material in the BF3 Complexes process on the Delaware side of the plant. It is a non-flammable, corrosive, compressed gas. If released to the atmosphere, it forms a dense white vapor cloud. It is packaged and shipped in cylinders and tube trailers under high pressure. The boron trifluoride process areas are equipped with water spray systems and remote operated valves designed for emergency use. Boron trifluoride is used to make adhesives, pharmaceuticals, synthetic lubricants, and flavors/fragrances. The raw materials used to produce boron trifluoride are boric acid and fluosulfonic acid. Boric acid is a solid white powder that is received in truck trailers. Fluosulfonic acid is a colorless, corrosive liquid with a pungent odor and is stored on site in bulk tanks.



BF3 complexes are manufactured on the Delaware side of the plant. BF3 complexes are used to make adhesives, pharmaceuticals, synthetic lubricants, and flavors/fragrances. Boron trifluoride is used as a raw material to make BF3 complexes and as mentioned above (BF3 process) is regulated by the RMP rule. One of the complexes, BF3 etherate, is a clear, colorless, flamm
able and corrosive liquid with a sharp pungent odor. BF3 etherate is packaged and shipped in pails, drums, and tank trucks. One of the raw materials used to produce BF3 etherate is ethyl ether. Ethyl ether is regulated by the RMP rule. It is a flammable, liquid and is stored on site in a bulk tank under its own vapor pressure. The BF3 complexes process area is equipped with a water spray system and remote operated valves designed for emergency use.



Fluosulfonic acid (FSA) is manufactured on the Pennsylvania side of the plant. It will be stored as a feedstock for the existing boron trifluoride process. Fluosulfonic acid is produced using the chemicals anhydrous hydrofluoric acid (HF) and sulfur trioxide (SO3), both, regulated by the RMP rule. Anhydrous HF is a clear, colorless fuming liquid with an extremely acrid odor. SO3 is a clear, colorless, and corrosive oily liquid that will rapidly react with water to form sulfuric acid. HF and SO3 are stored onsite in separate bulk tanks, supported by mitigation system and secondary containment.



3. General Accidental Release Prevention Program and Chemical-Specific Prevention Steps



The general accidental release prevention program at Honeywell Delaware consists of 12 elements. Each of these elements is described below. Also described within each of these elements are associated chemical-specific prevention steps, where applicable.



3a. Process Safety Information



Written process safety information is compiled before conducting process hazard analyses for processes involving boron trifluoride, hydrofluoric acid, sulfur trioxide and ethyl ether. This enables the employees involved in operating these processes to identify and understand the potential hazards associated with the processes. The information compiled includes data on the safe use and handling of the regulated chemicals (e.g., material safety data sheets), data on the process technology (e.g., process flow diagrams, process chemistry, flow
rates and storage capacities, operating limits and evaluation of exceedances), and data on the equipment used in the process (e.g., piping & instrument diagrams, materials compatibility, energy ratings and classification, control devices and emergency systems, ventilation systems, design basis including conformance to applicable codes and standards). The process safety information is adequate to show compliance of the process design with generally accepted good engineering practices.



3b. Process Hazard Analyses



Process hazard analyses for the processes involving boron trifluoride, hydrofluoric acid, sulfur trioxide and ethyl ether have been completed in accordance with 29 CFR 1910.119(e) (OSHA Process Safety Management). These process hazard analyses are updated and revalidated in accordance with 29 CFR 1910.119(e), and are retained on site for the life of the process.



In general, one or more of the following methodologies are used to complete each process hazard analysis: (a) what-if evaluation; (b) checklist; (c) hazard and operability study (HAZOP); (d) failure mode and effects analysis (FMEA); (e) fault tree; (f) process mapping; and (g) cause and effect matrix. Each process hazard analysis addresses the process hazards, process incident history, process control devices and detection systems, evaluation of failure of process control devices, equipment location, and human factors. Each process hazard analysis is performed by a team of employees having experience and knowledge of the process design and operation, and knowledge of how to complete a process hazard analysis. The Management of Change process (described below) is used to track and document process changes which occur as a result of recommendations from process hazard analyses.



3c. Operating Procedures



Written operating procedures are prepared for each of the processes involving boron trifluoride, sulfur trioxide, hydrofluoric acid, and ethyl ether. The operating procedures are avai
lable electronically to all plant employees via a computer document control program. The document control program is used to meet the requirements of ISO 9000 certification for the site. The operating procedures provide clear instructions for safely conducting activities in each of the four regulated areas of the plant. The procedures are maintained up to date to reflect current operating practices, and are certified annually for accuracy.



Specific information and instructions covered by the operating procedures includes startup, normal operation, emergency operation, shutdown, operating limits, operating controls, chemical-specific health and safety information, required personal protective equipment, and use of safety systems. Written procedures are also provided for specific operations such as lockout/tagout, confined space entry, and line breaking.



3d. Training



Employees currently engaged in operating processes involving boron trifluoride, hydrofluoric acid, sulfur trioxide and ethyl ether have received training to ensure they have the required knowledge, skills, and abilities to safely carry out the requirements specified in the written operating procedures. Refresher training is provided every three years at a minimum, or sooner if warranted by changes to operating conditions, equipment, or procedures. If refresher training is required more frequently than every three years, it is triggered through the Management of Change process (described below). Training records are maintained for each employee to show the date training was conducted and the material covered by the training.



3e. Mechanical Integrity



Honeywell Delaware maintains the mechanical integrity of equipment used to process and handle boron trifluoride, hydrofluoric acid, sulfur trioxide, and ethyl ether. Such equipment includes pressurized vessels, storage tanks, piping systems, pressure relief and vent systems, emergency control devices, pumps, and valves. Written procedure
s are established to define the scope and requirements of the mechanical integrity program. Maintenance employees engaged in carrying out the mechanical integrity program are trained to complete the required tasks in a safe manner.



One component of the mechanical integrity program includes inspection and testing of covered equipment. Equipment inspection and testing is conducted in accordance with manufacturer's recommendations and generally accepted good engineering practices. Records of inspections and testing are maintained to show the date, equipment identification, inspector, type of test or inspection performed, and test results or observations. If deficiencies are noted during equipment inspection and testing, corrective actions are taken in a timely manner to assure safe operation of the process. In some cases, equipment inspections are driven by permit requirements as well as the mechanical integrity program.



3f. Management of Change



One component of the site's ISO 9000 certification program is a written procedure for the Management of Change. Except for "replacements in kind", any change to a process involving boron trifluoride, hydrofluoric acid, sulfur trioxide, or ethyl ether requires completion and approval of a Management of Change prior to making the change. Such changes include new process chemicals, new technologies, new or modified equipment, new or modified operating conditions, and new or modified procedures. The Management of Change must be reviewed and approved by a team of employees having experience and knowledge of the process, knowledge of the proposed changes, and knowledge of applicable regulatory requirements. The Management of Change must describe the proposed change and its impact on employee health and safety, the purposes and benefits of the change, the target date for the change to take effect, and whether the change is temporary or permanent. The Management of Change must also indicate whether any of the followi
ng items are required as a result of the change, and if so, who is responsible for completing these items and when they must be completed: (a) process hazard analysis; (b) new product review; (c) Piping & Instrument Diagram update; (d) operating procedure update; (e) employee training, and; (f) process safety information. Records of Requests For Change are maintained to track the status and progress of planned changes.



3g. Pre-startup Review



Prior to startup of a new process involving boron trifluoride, hydrofluoric acid, sulfur trioxide, or ethyl ether, a pre-startup safety review is conducted to ensure that the equipment and installation meets design specifications, a process hazard analysis has been completed, employee training has been completed, and safety, operating, maintenance, and emergency procedures are in place. A pre-startup safety review is also conducted for process changes where the approved Management of Change indicates a change in the process safety information is required. The pre-startup safety review is conducted by a team of employees having knowledge of the process, equipment, operating conditions, procedures, and safety requirements. All items on the pre-startup review checklist must be satisfied prior to commencing startup.



3h. Compliance Audits



Self-assessed compliance audits for processes involving boron trifluoride, hydrofluoric acid, sulfur trioxide, and ethyl ether are conducted every three years at a minimum to ensure that the elements of the general accidental release prevention program are up to date and are being implemented. The compliance audits are conducted by a team of employees having experience and knowledge of the covered processes, and knowledge of the program requirements. Records of the compliance audit reports are maintained to document the results of the audits and corrective actions taken, if necessary.



3i. Incident Investigation



All incidents which resulted in, or could have resulted in, a rel
ease of boron trifluoride, hydrofluoric acid, sulfur trioxide, or ethyl ether are investigated promptly. The incident investigation starts with the completion of an Incident Investigation Report prepared by the supervisor on duty at the time of the incident, and is distributed to the incident investigation team. The incident investigation team is made up of employees having experience and knowledge of the processes affected by the incident, and knowledge of completing incident investigations. Following the incident investigation, a report is prepared to include the following information: (a) date, time, and location of the incident; (b) employees involved in the incident, and their roles; (c) date of the incident investigation; (d) names of employees on the incident investigation team; (e) description of the incident, including a chronology of events; (f) root causes and contributing causes, including conditions at the time of the incident, and; (g) recommendations to prevent a recurrence. Follow-up actions which are taken as a result of the recommendations in the incident investigation report are documented, and records of the reports and follow-up actions are maintained for a minimum of 5 years for future reference.



3j. Employee Participation



All employees at Honeywell Delaware have opportunities to access and participate in the sharing of information related to process safety for the processes involving boron trifluoride, hydrofluoric acid, sulfur trioxide, and ethyl ether. Each employee has computer access to operating procedures located in the document control program (see Operating Procedures above), including a procedure for suggesting changes. A safety audit program is established to allow any employee to note observations, either positive or negative, and submit them to the health, safety and environmental department to reinforce positive observations or to require corrective actions to mitigate negative observations. All employees attend month
ly safety meetings to review incidents, learn about new or modified processes, and discuss specific safety awareness topics. A special committee named the Delaware Safety Council, made up of employees from each of the functional areas of the plant, meets monthly to review the status of in-progress safety action items, review safety policies and procedures for the plant, and recommend changes if necessary. Employees routinely have opportunities to participate in other safety processes under the prevention program such as process hazard analyses, management of change, employee training, and incident investigations.



3k. Hot Work Permits



Honeywell Delaware has established a hot work permit system. The hot work permit system applies to processes involving boron trifluoride, hydrofluoric acid, sulfur trioxide, and ethyl ether. Under the system, a hot work permit must be issued prior to commencing hot work operations. Hot work operations may include burning, welding, or torch cutting. The hot work permit indicates the type and method of hot work to be conducted, the equipment the hot work will be performed on, the date, time, and location authorized for the hot work, the presence of fire prevention and protection systems meeting the requirements of 29 CFR 1910.252(a), and signatures of the supervisory employees authorizing the hot work. A separate hot work permit must be issued for each hot work operation, and a separate hot work permit must be issued for each day. A copy of the hot work permit must be displayed at the job location while hot work is in progress, and the permit is maintained on file after the completion of the hot work.



3l. Contractors



Prior to retaining contractor services for work in the process areas involving boron trifluoride, hydrofluoric acid, sulfur trioxide, or ethyl ether, the contractor's safety performance and program is evaluated. This includes a 3 year review of the contractor's total case incident rate (TCIR), review of O
SHA recordable injuries and illnesses and corrective actions, review of lost work day cases away (LWDCA) and corrective actions, review of the contractor's safety program including safety policies, training, and medical monitoring, and review of any applicable site-specific health and safety plan (HASP) prepared by the contractor. The information supplied by the contractor is retained while the contractor is engaged in work activities.



Prior to commencing work on site, each contractor employee receives a safety orientation provided by Honeywell. The safety orientation covers information on the hazards associated with the process areas where the work will be performed, safety procedures and systems to be used, overview of the site emergency response program including specific procedures to be followed in case of emergency, and a review of site safety rules and applicable operating procedures. A record of each contractor employee's sign-off on the safety orientation is maintained on file at the site, including the date the training was completed. Once the safety orientation is complete, the contractor is responsible for ensuring that each contractor employee performs the assigned work in a manner consistent with the information provided during the safety orientation. If the contractor assigns new employees to the job after work has commenced, the contractor must also ensure that each new employee receives a safety orientation prior to starting work on site. Failure of the contractor or any contractor employee to abide by these requirements is grounds for immediate dismissal from the site.



4. Five-Year Accident History



In the past 5 years, there have been no accidental releases of boron trifluoride, hydrofluoric acid, sulfur trioxide, or ethyl ether from Honeywell Delaware which met the reporting requirements described in the RMP rule.



5. Emergency Response Program



Honeywell Delaware has an emergency response program for the purpose of protecting p
ublic health and the environment. The program includes a written Emergency Response Plan, employee training in emergency response procedures, procedures to review and update the plan, and procedures for the use, inspection, testing, and maintenance of emergency response equipment.



The Emergency Response Plan includes procedures for emergency response after an accidental release of boron trifluoride, hydrofluoric acid, sulfur trioxide, or ethyl ether at the site. The Emergency Response Plan also includes procedures for administering first aid and emergency medical care as required in case of exposure following a release. The Emergency Response Plan includes notification procedures for informing the public and outside agencies in case an accidental release occurs. Outside agencies such as fire departments, local emergency planning committees, and state environmental agencies are notified according to regulatory reporting requirements at a minimum, and as necessary to provide or assist with emergency response. In addition, representatives of Honeywell Delaware meet regularly with an established local Community Advisory Panel to inform the public about relevant activities at the plant, including accidental releases.



The Emergency Response Plan is coordinated with the local emergency planning committees, and information in the plan is readily available to the local emergency response officials for the purpose of developing and implementing the community emergency response plans. Offsite community response activities are implemented in accordance with the community emergency response plans as developed by the local emergency planning committees. Representatives from Honeywell Delaware meet regularly with the local emergency planning committees to review procedures, training requirements, equipment needs, and to conduct emergency response exercises.



As part of the site emergency response program, Honeywell Delaware maintains a professionally trained Emergen
Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees29
Owner or Operator NameHoneywell International Inc.
Owner or Operator Address Line 1101 Columbia Road
Owner or Operator CityMorristown
Owner or Operator StateNJ
Owner or Operator Zip7962
Parent Dun and Bradstreet Number139691877
Second Parent Dun and Bradstreet Number139691877
Number of Full Time Employees29
Number of FTE CBI FlagNo
Other Facility ID19703LLDSG6100P
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VNo
Last Safety Inspection Date11/16/2012
Last Safety Inspection ByState environmental agency
OSHA Star or Merit RankingNo
LEPC NameNew Castle LEPC

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19)
Owner or Operator Phone9734552000
Facility URLwww.honeywell.com
Facility Phone3027916701
Facility EmailKeith.Shuler@Honeywell.com
Facility Dun and Bradstreet Number54717939
RMP ContactKeith Shuler
RMP Contact TitlePlant Manager
RMP Contact EmailKeith.shuler@Honeywell.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 Date04/10/2014
Postmark Date06/19/2013
Anniversary Date06/19/2018
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19)
Latitude39.811616
Longitude-75.434743
Valid Lat/LongYes
Lat/Long MethodGPS - Unspecified
Lat/Long Location TypeAdministrative Building
FRS Latitude39.8105
FRS Longitude-75.4386
FRS Lat/Long DescriptionPLANT ENTRANCE (GENERAL)
FRS Lat/Long MethodADDRESS MATCHING-HOUSE NUMBER

Submission - Counts and Totals facility_Submission_-_Counts_and_Totals help link help link  
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 Processes3
Number of Process Chemicals0
Number of Toxic Worst-case Scenarios1
Number of Toxic Alternate Case Scenarios3
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 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #1 : Boron Trifluoride)
Process DescriptionBoron Trifluoride
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)430,000
Flammable Amount Total (lbs)0
Process Amount Total (lbs)430,000
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  
Process Chemical IDBoron trifluoride [Borane, trifluoro-]
CAS number007637072
Chemical TypeToxic
Process Chemical Amount (lbs)430,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #1 : Boron Trifluoride, process chemical #2)
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
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 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 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #1 : Boron Trifluoride, process NAICS code #1 : 32518)
NAICS Code32518: Other Basic Inorganic Chemical Manufacturing

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date12/04/2009
PHA Update Date12/04/2009
PHA Technique - What IfNo
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date04/12/2010
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionYes
Hazard Identified - Runaway ReactionNo
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 - EarthquakeYes
Hazard Identified - FloodYes
Hazard Identified - TornadoYes
Hazard Identified - HurricaneYes
Hazard Identified - OtherSecurity Breach
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 AirYes
Process Controls - Emergency PowerYes
Process Controls - Backup PumpYes
Process Controls - GroundingYes
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 - OtherEmergency shutdown
Mitigation Systems - SprinklersNo
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 AreaNo
Monitoring Systems - PerimeterNo
Monitoring Systems - NoneNo
Monitoring Systems - OtherVideo Surveillance
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 SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Procedure Review Date12/31/2013
Training Review Date01/04/2012
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 Date06/11/2013
Maintenance Inspection Date04/24/2013
Equipment TestedPlant air pressure control valve
Management of Change Most Recent Date05/07/2013
Management of Change Review Date10/11/2013
Pre-startup Review Date05/23/2013
Compliance Audit Date02/25/2013
Compliance Audit Change Completion Date08/30/2013
Incident Investigation Date01/22/2013
Incident Invest. Change Completion Date01/22/2013
Participation Plan Review Date01/21/2013
Hot Work Review Date03/13/2013
Contractor Safety Review Date03/14/2013
Contractor Safety Eval. Date05/14/2013
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #1 : Boron Trifluoride, process NAICS code #1 : 32518, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000051389

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
The following information is for the Boron Trifluoride process

Processes facility_Processes help link help link  
Process DescriptionBF3 Complexes
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)0
Flammable Amount Total (lbs)15,000
Process Amount Total (lbs)15,000
Number of Process Chemicals0
Number of Toxic Worst-Case Scenarios0
Number of Toxic Alternate Scenarios0
Number of Flammable Worst-Case Scenarios1
Number of Flammable Alternate Scenarios1

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #2 : BF3 Complexes, process chemical #1)
Process Chemical IDEthyl ether [Ethane, 1,1'-oxybis-]
CAS number000060297
Chemical TypeFlammable
Process Chemical Amount (lbs)15,000
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

Worst-Case Flammable Scenarios facility_Worst-Case_Flammable_Scenarios help link help link  
Model UsedEPA's RMP*Comp(TM)
Passive Mitigation - Blast WallsNo
Confidential Business InformationNo

Alternate Case Flammable Scenarios facility_Alternate_Case_Flammable_Scenarios help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #2 : BF3 Complexes, process chemical #2, alternate flammable scenario #1)
Model UsedEPA's RMP*Comp(TM)
Passive Mitigation - DikesYes
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 NAICS facility_Process_NAICS help link help link  
NAICS Code32519: Other Basic Organic Chemical Manufacturing

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date04/11/2013
PHA Update Date04/11/2013
PHA Technique - What IfNo
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date04/08/2014
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionYes
Hazard Identified - Runaway ReactionNo
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionNo
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationYes
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossYes
Hazard Identified - EarthquakeYes
Hazard Identified - FloodYes
Hazard Identified - TornadoYes
Hazard Identified - HurricaneYes
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 AirYes
Process Controls - Emergency PowerYes
Process Controls - Backup PumpYes
Process Controls - GroundingYes
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksYes
Process Controls - Excess Flow DevicesNo
Process Controls - Quench SystemNo
Process Controls - Purge SystemYes
Process Controls - NoneNo
Process Controls - OtherEmergency Stop
Mitigation Systems - SprinklersNo
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
Mitigation Systems - OtherEmergency Stops
Monitoring Systems - Process AreaNo
Monitoring Systems - PerimeterNo
Monitoring Systems - NoneNo
Monitoring Systems - OtherVideo Surveillance
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryYes
Changes Since PHA - Process ParametersYes
Changes Since PHA - Process ControlsYes
Changes Since PHA - Process DetectionNo
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Procedure Review Date12/31/2013
Training Review Date01/25/2013
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherComputer based
Competency Testing - Written TestsYes
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Maintenance Review Date06/11/2013
Maintenance Inspection Date03/21/2013
Equipment TestedOrganic Trailer Static Ground
Management of Change Most Recent Date05/13/2013
Management of Change Review Date10/11/2012
Pre-startup Review Date02/28/2013
Compliance Audit Date02/25/2013
Compliance Audit Change Completion Date08/30/2013
Incident Investigation Date03/27/2013
Incident Invest. Change Completion Date03/27/2013
Participation Plan Review Date01/21/2013
Hot Work Review Date03/13/2013
Contractor Safety Review Date03/14/2013
Contractor Safety Eval. Date05/14/2013
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #2 : BF3 Complexes, process NAICS code #1 : 32519, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000051391

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
The following information is for the BF3 Complexes process

Processes facility_Processes help link help link  
Process DescriptionFluosulfonic Acid
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)1,000,000
Flammable Amount Total (lbs)0
Process Amount Total (lbs)1,000,000
Number of Process Chemicals0
Number of Toxic Worst-Case Scenarios1
Number of Toxic Alternate Scenarios2
Number of Flammable Worst-Case Scenarios0
Number of Flammable Alternate Scenarios0

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #3 : Fluosulfonic Acid, process chemical #1)
Process Chemical IDHydrogen fluoride/Hydrofluoric acid (conc 50% or greater) [Hydrofluoric acid]
CAS number007664393
Chemical TypeToxic
Process Chemical Amount (lbs)460,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link  
Process Chemical IDSulfur trioxide
CAS number007446119
Chemical TypeToxic
Process Chemical Amount (lbs)540,000
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

Worst-Case Toxic Scenarios facility_Worst-Case_Toxic_Scenarios help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #3 : Fluosulfonic Acid, process chemical #3, worst-case toxic scenario #1)
Percent Weight (Within Mixture)100
Physical StateLiquid
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  
Percent Weight (Within Mixture)100
Physical StateLiquid
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 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 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #3 : Fluosulfonic Acid, process chemical #4)
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 StateLiquid
Model UsedEPA's RMP*Comp(TM)
Wind Speed3
Atmospheric Stability ClassD
TopographyUrban
Passive Mitigation - DikesYes
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsYes
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 NAICS facility_Process_NAICS help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #3 : Fluosulfonic Acid, process NAICS code #1 : 32518)
NAICS Code32518: Other Basic Inorganic Chemical Manufacturing

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date10/24/2013
PHA Update Date10/24/2013
PHA Technique - What IfNo
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date08/01/2014
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionNo
Hazard Identified - Runaway ReactionYes
Hazard Identified - PolymerizationYes
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionYes
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationNo
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossYes
Hazard Identified - EarthquakeYes
Hazard Identified - FloodYes
Hazard Identified - TornadoYes
Hazard Identified - HurricaneYes
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 AirYes
Process Controls - Emergency PowerYes
Process Controls - Backup PumpYes
Process Controls - GroundingYes
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 - Othervideo surveillance, Emergency Stop
Mitigation Systems - SprinklersNo
Mitigation Systems - DikesYes
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsYes
Mitigation Systems - Water CurtainsYes
Mitigation Systems - EnclosureNo
Mitigation Systems - NeutralizationNo
Mitigation Systems - NoneNo
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterNo
Monitoring Systems - NoneNo
Monitoring Systems - Othervideo surviellence
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryYes
Changes Since PHA - Process ParametersNo
Changes Since PHA - Process ControlsYes
Changes Since PHA - Process DetectionNo
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Procedure Review Date12/31/2013
Training Review Date02/20/2011
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherComputer Based
Competency Testing - Written TestsYes
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Maintenance Review Date06/11/2013
Maintenance Inspection Date04/17/2013
Equipment TestedControl Valve on line from SO3 vent to Scrubber
Management of Change Most Recent Date05/06/2013
Management of Change Review Date10/11/2012
Pre-startup Review Date05/17/2013
Compliance Audit Date02/25/2012
Compliance Audit Change Completion Date08/30/2013
Incident Investigation Date05/22/2012
Incident Invest. Change Completion Date07/27/2012
Participation Plan Review Date01/21/2013
Hot Work Review Date03/13/2013
Contractor Safety Review Date03/14/2013
Contractor Safety Eval. Date05/14/2013
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Honeywell - Delaware Plant, RMP submission #1 : 2013-06-19, process #3 : Fluosulfonic Acid, process NAICS code #1 : 32518, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000051392
1000051393

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
This following information is for the FSA process

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 Date06/06/2013
Response Training Date06/18/2013
Local Response AgencyClaymont and Marcus Hook Fire Depts
Local Response Agency Phone3027986858
Subject To - OSHA EAPYes
Subject To - OSHA HAZWOPERYes
Subject To - CWAYes
Subject To - RCRAYes
Subject To - OPANo
Subject To - State EPCRAYes


Search Criteria Used
RMP Facility ID100000088166

*END OF REPORT*