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Monsanto Co. Crop Protection - Fayetteville, NC.

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Facility #1 : Monsanto Co. Crop Protection -


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000124448
Deregistered (Yes/No)Yes
Facility NameMonsanto Co. Crop Protection - Fayetteville, NC.
Street Address Line 1Hwy 53E & 210S, Cedar Creek Rd
CityFayetteville
StateNC
Zip Code28301
CountyCumberland County
113th Congressional DistrictNC04: North Carolina 4
Owner or Operator NameMonsanto Co.
Parent CompanyMonsanto Co.
Latitude34.985389
Longitude78.781639
Number of RMP Submissions1

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID11754
Submission Typefirst submission for facility
Submission Date06/22/1999
Deregistration Date03/13/2002
Deregistration Effective Date12/31/2001
Process Toxic Amount Total (lbs)100,080
Process Flammable Amount Total (lbs)162,000
Process Amount Total (lbs)262,080
Number of Potential Offsite Consequence Processes2
Potential Offsite Consequence Toxic Amount Total (lbs)100,080
Potential Offsite Consequence Flammable Amount Total (lbs)162,000
Potential Offsite Consequence Amount Total (lbs)262,080
All Process NAICS32532
Exec Summary Submission Date06/22/1999

Executive Summary facility_Executive_Summary help link help link (Facility #1 : Monsanto Co. Crop Protection -, executive summary: all)

Executive Summary
RMP Executive Summary
Monsanto - Fayetteville, NC

Monsanto is a life science company committed to finding solutions to the growing global needs for food and health by sharing common forms of science and technology among agriculture, nutrition and health. The companys 30,000 employees worldwide make and market high-value agricultural products, pharmaceuticals and food ingredients. We are committed to pursuing these goals in sustainable ways that meet peoples needs without compromising future generations ability to meet their needs.

One of the locations contributing to this vision is Monsanto's Fayetteville facility, located at Hwy. 53E & 210S, Cedar Creek Road, Fayetteville, North Carolina. We are manufacturing facility that employees 130 people. The facility has been located in the community since May 1967, initially built by Rohm and Haas Corporation, until acquired by Monsanto in January of 1978.

As part of our operations, we handle quantities of both Isopropylamine and Aqua Ammonia (concentration >20%) in sufficient quantities to require compliance with the EPAs RMP regulation. The major elements of the RMP rule are very similar to OSHAs PSM regulation. In other words, managing risk on a daily basis is nothing new at Monsantos Fayetteville facility .

North Carolinas, state OSHA program, conducted an audit of our facility under their Voluntary Protection Program (VPP) and, in 1994, we were awarded their highest rating - STAR. We were the first manufacturing facility in North Carolina to receive this accreditation. In 1997, NC-OSHA re-certified the facility as a STAR site. Receipt of this award demonstrates our commitment to the safety and health of employees and the surrounding community as well as protection of the environment.

Our location has a documented Emergency Response plan which includes defined responsibilities and actions to be implemented for a number of events, including inclement weather, fire and toxic chemical releases. The
re are personnel responsible for implementation of this procedure on site at all times. In general, the plan describes actions which result in a safe response for company employees as well as prompt notification of community organizations. The plan has been integrated with the Cumberland County Local Emergency Planning Committee (LEPC) and the Vander Volunteer Fire Department. Should an incident occur which could jeopardize the safety and health of personnel in the area surrounding Monsantos Fayetteville facility, the following events would occur:

-Monsanto's emergency response team would respond to the incident,
-the Vander Volunteer Fire Department and Cumberland County LEPC would be notified, and
-the facilitys notification system would be utilized to notify community members of a plant upset.

During the past 5 years, ZERO RMP events have occurred.

Our location handles two chemicals regulated by the RMP, Isopropylamine and Aqua Ammonia (concentration >20%). The consequences of two release scenarios for each chemical has been calculated using methods provided by the EPA. The worst case scenario for each chemical requires that the entire contents of the storage vessel be discharged to the atmosphere in a 10 minute period. The "worst case scenario" is a very unlikely event, and in some cases could not occur as assumed, for example complete release to air in 10 minutes, according to the laws of physics.

Our toxic worst case scenario is failure of an aqueous ammonia storage tank containing 100,080 pounds of 30 weight percent of aqueous ammonia. The aqueous ammonia is into a 2020 square foot dike which mitigates the release. A toxic cloud is formed by the evaporating ammonia which would reach off-site endpoints.

Our flammable worst case scenario is failure of an Isopropylamine storage tank containing 162,000 pounds at 99.5 percent pure. The event is a vapor cloud explosion of Isopropylamine which would reach off-site endpoints.

The regulation al
so requires an analysis of alternate release scenarios. For both Isopropylamine and Aqua Ammonia (concentration >20%) scenarios, Monsanto has selected failure of a unloading hose during the unload process of these chemicals. We estimated that these incidents would be controlled in 5 minutes. The details for each of these four incidents have been shared with the Cumberland County LEPC for integration into the community emergency response plan.

We employ a comprehensive collection of safety systems to maintain the equipment and work practices utilized in our operation. Some examples include:

7 A Process Hazard Analysis (PHA) is conducted every 5 years or more frequently. This involves a team of experts who review the hazards posed by the chemical, best industry practices for handling the material and a defined system to identify hazards. Recommendations for improvement are made and priority placed on implementing them in an prompt manner.
7 Our mechanical integrity system requires regular inspection of the equipment, relief devices and other systems utilized in handling the material.
7 Procedures have been developed to provide detailed actions for employees operating the equipment. They are reviewed annually with active involvement from operating personnel.
7 A management of change system is utilized for modifications to equipment and operating parameters. Each change is appropriately reviewed by a team of personnel to determine if there is any impact to system safety.
7 The site utilizes a number of contract personnel for a variety of services. Our Contractor/Guest program requires that contractors be selected using their actual safety performance as a criteria and open communication must exist between Monsanto and contract employees to identify and control hazards.

In addition, we utilize a number of systems for specific chemicals. Examples include:

7 Isopropylamine and Ammonia area monitors to quickly detect leaks,
7 Water sprinkler and deluge system
s to extinguish fires, and
7 Excess flow indicators which will stop flow under undesired conditions.

Both the general and chemical specific systems work together to minimize the frequency and consequences of chemical releases.

Maintaining and improving the safety of our operations is a core value at Monsanto and this location. In the immediate future:
7 OSHA will reassess our status as a VPP Star location in 2000, a rating we are committed to maintaining,
7 We look forward to working with the LEPC in updating the community emergency response plan over the next 1-2 years. This effort will review the existing plan and make appropriate changes based on the RMP information.

This brief summary provides some insight into the extensive system Monsanto utilizes to maintain safe operations. If you would like additional information about Monsanto, please visit our Internet home page at www.monsanto.com. If you have questions about this RMP, please contact us at (910) 323-3300.
Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees131
Owner or Operator NameMonsanto Co.
Owner or Operator Address Line 1800 N Lindberg Blvd
Owner or Operator CitySt. Louis
Owner or Operator StateMO
Owner or Operator Zip63167
Parent Dun and Bradstreet Number42625988
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees131
Number of FTE CBI FlagNo
Other Facility IDNCDO88563242
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VYes
CAA Title V Air Operating Permit ID04319R14
Last Safety Inspection Date09/25/1998
Last Safety Inspection ByOSHA
OSHA Star or Merit RankingYes
LEPC NameCumberland County LEPC

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : Monsanto Co. Crop Protection -, RMP submission #1 : 1999-06-22)
Owner or Operator Phone3146941000
Facility URLWWW.Monsanto.com
Facility EmailWWW.monsanto.com
Facility Dun and Bradstreet Number42625988
RMP ContactP. Jason Quevedo
RMP Contact TitleSafety Specialist

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsYes
Complete Check Date07/13/1999
Postmark Date06/18/1999
Anniversary Date06/18/2004
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link  
Latitude34.985389
Longitude78.781639
Valid Lat/LongNo
Lat/Long MethodGPS Code Measurements (Psuedo Range) Differential (DGPS)
Lat/Long Location TypePlant Entrance (General)
FRS Latitude34.97
FRS Longitude-78.78
FRS Lat/Long DescriptionFACILITY CENTROID
FRS Lat/Long MethodINTERPOLATION-MAP

Submission - Counts and Totals facility_Submission_-_Counts_and_Totals help link help link (Facility #1 : Monsanto Co. Crop Protection -, RMP submission #1 : 1999-06-22)
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 Processes2
Number of Process Chemicals2
Number of Toxic Worst-case Scenarios1
Number of Toxic Alternate Case Scenarios1
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 : Monsanto Co. Crop Protection -, RMP submission #1 : 1999-06-22, process #1 : Amination)
Process DescriptionAmination
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)0
Flammable Amount Total (lbs)162,000
Process Amount Total (lbs)162,000
Number of Process Chemicals1
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  
Process Chemical IDIsopropylamine [2-Propanamine]
CAS number000075310
Chemical TypeFlammable
Process Chemical Amount (lbs)162,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Monsanto Co. Crop Protection -, RMP submission #1 : 1999-06-22, process #1 : Amination, process chemical #2)
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 ValvesYes
Active Mitigation - OtherInterlocks initiated by flow, air monitors & emergency stops
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : Monsanto Co. Crop Protection -, RMP submission #1 : 1999-06-22, process #1 : Amination, process NAICS code #1 : 32532)
NAICS Code32532: Pesticide and Other Agricultural Chemical Manufacturing

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date01/27/1996
PHA Update Date03/16/1995
PHA Technique - What IfNo
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date12/31/1995
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 - EarthquakeNo
Hazard Identified - FloodNo
Hazard Identified - TornadoNo
Hazard Identified - HurricaneNo
Process Controls - VentsNo
Process Controls - Relief ValvesYes
Process Controls - Check ValvesYes
Process Controls - ScrubbersNo
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 PumpYes
Process Controls - GroundingYes
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksNo
Process Controls - Excess Flow DevicesYes
Process Controls - Quench SystemNo
Process Controls - Purge SystemYes
Process Controls - NoneNo
Process Controls - OtherEmergency Stop & antisiphon Valves
Mitigation Systems - SprinklersYes
Mitigation Systems - DikesNo
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 - OtherOverflow Pit
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterNo
Monitoring Systems - NoneNo
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 Date05/31/1999
Training Review Date06/01/1999
Type of Training - ClassroomYes
Type of Training - On the JobYes
Competency Testing - Written TestsYes
Competency Testing - Oral TestsNo
Competency Testing - DemonstrationYes
Competency Testing - ObservationNo
Maintenance Review Date01/01/1996
Maintenance Inspection Date05/17/1999
Equipment TestedIPA Storage Tank
Management of Change Most Recent Date04/28/1997
Management of Change Review Date06/30/1995
Pre-startup Review Date01/27/1996
Compliance Audit Date02/28/1997
Compliance Audit Change Completion Date09/30/1998
Incident Investigation Date05/24/1999
Incident Invest. Change Completion Date07/31/1999
Participation Plan Review Date06/01/1999
Hot Work Review Date04/30/1999
Contractor Safety Review Date06/16/1999
Contractor Safety Eval. Date04/26/1999
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Monsanto Co. Crop Protection -, RMP submission #1 : 1999-06-22, process #1 : Amination, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
19594

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
The process is for the formulation of Roundup Herbacide. The reaction is a neutrilization of an organic acid with an organic base.

Processes facility_Processes help link help link  
Process DescriptionAmmonium Glyphosate
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)100,080
Flammable Amount Total (lbs)0
Process Amount Total (lbs)100,080
Number of Process Chemicals1
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 (Facility #1 : Monsanto Co. Crop Protection -, RMP submission #1 : 1999-06-22, process #2 : Ammonium Glyphosate, process chemical #1)
Process Chemical IDAmmonia (conc 20% or greater)
CAS number007664417
Chemical TypeToxic
Process Chemical Amount (lbs)100,080
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  
Percent Weight (Within Mixture)30
Physical StateLiquid
Model UsedEPA's OCA Guidance Reference Tables or Equations
Release Duration (minutes)10
Wind Speed (meters/sec)1.5
Atmospheric Stability ClassF
TopographyRural
Passive Mitigation - DikesYes
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 : Monsanto Co. Crop Protection -, RMP submission #1 : 1999-06-22, process #2 : Ammonium Glyphosate, process chemical #2, alternate toxic scenario #1)
Percent Weight (Within Mixture)30
Physical StateLiquid
Model UsedEPA's OCA Guidance Reference Tables or Equations
Wind Speed3
Atmospheric Stability ClassD
TopographyRural
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsYes
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 - OtherInterlocks initiated by flow & air monitors
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : Monsanto Co. Crop Protection -, RMP submission #1 : 1999-06-22, process #2 : Ammonium Glyphosate, process NAICS code #1 : 32532)
NAICS Code32532: Pesticide and Other Agricultural Chemical Manufacturing

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date12/02/1998
PHA Update Date04/17/1998
PHA Technique - What IfNo
PHA Technique - ChecklistYes
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPNo
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Technique - OtherLP&EC reviews
PHA Change Completion Date05/01/1998
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireNo
Hazard Identified - ExplosionNo
Hazard Identified - Runaway ReactionNo
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionNo
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationNo
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 - 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 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
Mitigation Systems - SprinklersNo
Mitigation Systems - DikesYes
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
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterNo
Monitoring Systems - NoneNo
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 Date02/28/1999
Training Review Date02/23/1998
Type of Training - ClassroomYes
Type of Training - On the JobYes
Competency Testing - Written TestsYes
Competency Testing - Oral TestsNo
Competency Testing - DemonstrationYes
Competency Testing - ObservationNo
Maintenance Review Date01/01/1996
Maintenance Inspection Date04/12/1999
Equipment TestedAmmonia Sensors
Management of Change Most Recent Date05/11/1999
Management of Change Review Date06/30/1995
Pre-startup Review Date04/27/1998
Incident Investigation Date05/24/1999
Incident Invest. Change Completion Date07/31/1999
Participation Plan Review Date06/01/1999
Hot Work Review Date04/30/1999
Contractor Safety Review Date06/16/1999
Contractor Safety Eval. Date04/26/1999
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Monsanto Co. Crop Protection -, RMP submission #1 : 1999-06-22, process #2 : Ammonium Glyphosate, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
19595

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
An organic acid is reacted with ammonia in an aqueous solution.

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 Date08/31/1998
Response Training Date02/25/1999
Local Response AgencyVander Fire Departmant
Local Response Agency Phone9104835042
Subject To - OSHA EAPYes
Subject To - OSHA HAZWOPERYes
Subject To - CWANo
Subject To - RCRANo
Subject To - OPANo
Subject To - State EPCRANo


Search Criteria Used
RMP Facility ID100000124448

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