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AES Hawaii, Inc.


Facility #1 : AES Hawaii, Inc.

Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000108787
Deregistered (Yes/No)No
Facility NameAES Hawaii, Inc.
Street Address Line 191-086 Kaomi Loop
Zip Code96707
Zip Code Extension1710
CountyHonolulu County
113th Congressional DistrictHI01: Hawaii 1
Owner or Operator NameAES Hawaii Inc.
Parent CompanyAES Corporation
Number of RMP Submissions4

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000039906
Submission Typerevised submission for facility
Submission Date03/29/2014
Reason For Submission5-year update (40 CFR 68.190(b)(1))
Process Toxic Amount Total (lbs)109,012
Process Flammable Amount Total (lbs)0
Process Amount Total (lbs)109,012
Number of Potential Offsite Consequence Processes1
Potential Offsite Consequence Toxic Amount Total (lbs)109,012
Potential Offsite Consequence Flammable Amount Total (lbs)0
Potential Offsite Consequence Amount Total (lbs)109,012
All Process NAICS221112
Exec Summary Submission Date03/29/2014

Executive Summary facility_Executive_Summary help link help link (Facility #1 : AES Hawaii, Inc., executive summary: all)

Executive Summary

EPA's Accidental Release Prevention Rule, which is authorized

under 112(R) of the Clean Air Act (CAA), requires that

facilities that have covered processes establish Risk

Management Programs to reduce the risks of accidental release

of toxic or flammable materials and establish emergency

response procedures in the event of an accident. This Risk

Management Plan summarizes the efforts that this company has

undertaken to establish a Risk Management Program.

Anhydrous ammonia is the only chemical used at the AES Hawaii

facility that is above the RMP threshold amount. The onsite

maximum storage quantity of the liquid anhydrous ammonia tank

at the AES Hawaii plant is 109,000 pounds, which is above the

10,000 pound RMP applicability threshold. The AES Hawaii plant

does not use any other chemicals or flammable materials in

excess of threshold quantities covered by RMP requirements.

A management system will be in place at the facility to

oversee implementation of the facility's Risk Management

Program. This management system is considered one of the most

important elements of this facility's Risk Management Program,

as its goal is to ensure that lines of authority and

responsibility are clearly defined, helping to ensure that all

elements of the Risk Management Program are implemented. At

the AES Hawaii Facility, the person who has the overall

responsibility for the Risk Management Program is the

environmental coordinator.

The facility also participates in emergency response

activities with the Campbell Local Emergency Action Network

(CLEAN). CLEAN has developed an Emergency Management Plan that

provides supplemental guidance and information to emergency

response personnel, local residents, and business based on the

specific operations in and around Campbell Industrial Park

(CIP). The plan addresses emergency
planning, public health,

and safety.

The AES Hawaii facility generates steam and electricity at 91-

086 Kaomi Loop, Hawaii 96707. The Plant is located near

Barber's Point, within the area known as Campbell Industrial

Park, which is on the Island of Oahu about 30 miles west of

Honolulu. Electricity generated by the facility is supplied to

Hawaiian Electric Company, and steam is sold to the nearby

Chevron USA oil refinery. The plant has two Circulating Fluid

Bed (CFB) coal-fired boilers and one steam turbine. The CFB

boilers use a clean coal technology that minimizes emissions

of sulfur dioxide, nitrogen oxides. The boilers use limestone

that reacts with the sulfur in the coal to reduce sulfur

dioxide emissions. The nitrogen oxides emissions are reduced

by two factors: the relatively low boiler operating

temperatures and the addition of anhydrous ammonia to the

boiler flue gas that reacts with the nitrogen oxides to

produce harmless nitrogen gas and water vapor.

Ammonia safety considerations have been incorporated into the

construction of the ammonia system. The ammonia tank is

secured to the ground and has cathodic protection. The tank

has relief valves at the top of the tank. Thus,

overpressurization of the tank would primarily involve the

venting of gas in the upper part of the tank. The vapor lines

from the tank to the boiler area are buried to reduce

potential releases from this piping. Loading and unloading

valves, the tank, and tanker truck are equipped with automatic

shut-off valves in the event that flow through the valves

exceeds design criteria. Therefore, in the event of a loading

hose failure, the flow of ammonia would be automatically

terminated. The facility also has monitors located in the

ammonia system process area that detect leaks and triggers an


This facility maintains a Prevention Progr
am at the facility

that minimizes the possibility of any accidental release from

the ammonia system. The prevention program incorporates a

mechanical integrity program, regularly scheduled maintenance,

daily visual operational checks of equipment, and employee

training in proper operating procedures and emergency


AES Hawaii has designed a Mechanical Integrity Program for

ammonia in accordance with 29 CFR 1910.119(j). The purpose is

to verify that critical process equipment is designed,

installed, maintained properly, and operates correctly. In

accordance with this program, the ammonia processes and

equipment must be constructed, installed, and maintained in

order to minimize the risk of releases of the highly hazardous

chemicals. The mechanical integrity program at AES Hawaii

includes identifying and categorizing equipment. Inspecting

and testing of instrumentation and documenting maintenance

procedures; training of maintenance personnel; establishing

criteria for acceptable test results; documenting test and

inspection results; and documenting manufacturer information

for equipment and instrumentation.

The facility performs a system integrity check every five

years for the ammonia storage tank and all associated

hoses/lines. The most recent vessel inspection was completed

in 2009. In addition, all emergency relief and excess flow

valves, storage tank isolation valves, flexible connections,

and hoses are scheduled for replacement in 2014. The equipment

is maintained in accordance with manufacturer specifications,

and applicable ANSI, and ASME engineering codes. A

computer database generates work orders to identify when such

maintenance needs to be implemented. Once, each 6-hour

period, operators visually observe the equipment for signs

of potential malfunction. Alarms and interlocks are checked

on a
monthly basis.

All new employees, regardless of position, are given a safety

walk of all areas of AES Hawaii. This walk through includes

the ammonia system. Special emphasis is placed on the nature

of the anhydrous ammonia and actions of all personnel in case

of an ammonia problem (i.e. leak). All persons hired who are

responsible for operations of the ammonia system are given

full classroom training before they are allowed to work on,

operate, or otherwise manipulate or affect the ammonia system.

The classroom course includes detailed instruction on the

ammonia system, including the physical aspects of ammonia,

operating the ammonia system, and casualties involving the

ammonia system. They are trained regarding the hazards and

safety precautions to be observed for the ammonia system. In

addition, annual refresher training is required.

The plant has a current ""Disaster and Emergency Plan"". All

employees have been trained in the plan, and the plan is

reviewed frequently to verify that it is current with plant

operating practice. The plan contains emergency response

procedures (ERP) which include actions for evaluating the

severity and controlling releases of hazardous materials

including ammonia. A list of the agencies that must be

notified is included in the plan to assure that the public is

properly notified in the event of an emergency.

AES Hawaii has performed a Hazard and Operability (HAZOP)

Analysis that evaluated all potential hazards for the

facility. The HAZOP study was performed according to the

procedures described in ""Guidelines for Hazard Evaluation

Procedures; Center for Chemical Process Safety"" published by

the American Institute of Chemical Engineers, New York. The

HAZOP was performed by a team of technical experts in the

system's process, engineering, design, operations maintenance,

and safety. The amm
onia system was divided into sections or

segments and assigned a node number. Each node was evaluated

for deviations using guide words such as ""no flow"", ""high

pressure"", etc. The cause and consequence of a guide word

applied to a node were evaluated to determine and identify

deviations and/or hazards that can result from application of

a guide word to the node. Each identified consequence was

assigned a relative risk rank based on the severity of the

consequence and anticipated frequency. The team then discussed

corrective actions which were recorded and implemented or are

in the process of being implemented.

AES Hawaii performs on site Ammonia Release Scenario Drills at

least once per year. Response team members who are qualified

to respond to Anhydrous Ammonia releases, walk through a

potential uncontrolled release scenario to determine potential

gaps in emergency preparedness. These gaps are then

incorporated into future emergency preparedness training


AES has implemented these various analyses and training

programs to prevent and prepare for an emergency release. To

date, this facility's Five Year History (and entire history of

the plant) includes only one accidental releases from the

ammonia system which resulted in an injury to an employee. The

release was quickly isolated, and can be attributed to

the inexperience of an operator trainee. There have been no

other accidental releases which resulted in deaths, injuries,

or significant property damage onsite, or known offsite deaths,

injuries, evacuations, sheltering in-place, property damage,

or environmental damage.

Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees47
Owner or Operator NameAES Hawaii Inc.
Owner or Operator Address Line 191-086 Kaomi Loop
Owner or Operator CityKapolei
Owner or Operator StateHI
Owner or Operator Zip96707
Owner or Operator Zip Extension1710
Parent Dun and Bradstreet Number43857812
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees47
Number of FTE CBI FlagNo
Other Facility ID96707SHWNC91086
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VYes
CAA Title V Air Operating Permit ID0087-02-C
Last Safety Inspection Date20130814
Last Safety Inspection ByOSHA
OSHA Star or Merit RankingNo

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : AES Hawaii, Inc., RMP submission #1 : 20140329)
Owner or Operator Phone8086823414
Facility Dun and Bradstreet Number606534931
RMP ContactPaul Karaffa
RMP Contact TitleEnvironmental Coordinator
RMP Contact

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsNo
Complete Check Date20140329
Error Report Datenull
Postmark Date20140329
Anniversary Date20190329
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link  
Valid Lat/LongYes
Lat/Long MethodInterpolation - Photo
Lat/Long Location TypeCenter of Facility
FRS Latitude21.3103
FRS Longitude-158.117

Submission - Counts and Totals facility_Submission_-_Counts_and_Totals help link help link (Facility #1 : AES Hawaii, Inc., RMP submission #1 : 20140329)
Number of RMP Accidents1
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)5
RMP Accident Amount Total (lbs)5
Number of RMP Accidents1
Number of Processes1
Number of Process Chemicals0
Number of Toxic Worst-case Scenarios1
Number of Toxic Alternate Case Scenarios1
Number of Flammable Worst-case Scenarios0
Number of Flammable Alternate Case Scenarios0
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)5
RMP Accident Amount Total (lbs)5
Total RMP Accident Deaths0
Total RMP Accident Injuries1
Total RMP Accident Evacuated/Sheltering In Place0
Total RMP Accident Property Damage$0

Processes facility_Processes help link help link (Facility #1 : AES Hawaii, Inc., RMP submission #1 : 20140329, process #1 : SNCR Ammonia System)
Process DescriptionSNCR Ammonia System
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)109,012
Flammable Amount Total (lbs)0
Process Amount Total (lbs)109,012
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 IDAmmonia (anhydrous)
CAS number007664417
Chemical TypeToxic
Process Chemical Amount (lbs)109,012
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : AES Hawaii, Inc., RMP submission #1 : 20140329, process #1 : SNCR Ammonia System, 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)99.7
Physical StateGas liquified by pressure
Model UsedEPA's RMP*Comp(TM)
Release Duration (minutes)10
Wind Speed (meters/sec)1.5
Atmospheric Stability ClassF
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 : AES Hawaii, Inc., RMP submission #1 : 20140329, process #1 : SNCR Ammonia System, process chemical #2, alternate toxic scenario #1)
Percent Weight (Within Mixture)99.7
Physical StateGas liquified by pressure
Model UsedEPA's RMP*Comp(TM)
Wind Speed3
Atmospheric Stability ClassD
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 CurtainYes
Active Mitigation - NeutralizationNo
Active Mitigation - Excess Flow ValvesYes
Active Mitigation - FlaresNo
Active Mitigation - ScrubbersNo
Active Mitigation - Emergency ShutdownYes
Active Mitigation - Otheroperator attended
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : AES Hawaii, Inc., RMP submission #1 : 20140329, process #1 : SNCR Ammonia System, process NAICS code #1 : 221112)
NAICS Code221112: Fossil Fuel Electric Power Generation

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date20140121
PHA Update Date20131127
PHA Technique - What IfYes
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date20140601
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 - OverfillingYes
Hazard Identified - ContaminationNo
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossNo
Hazard Identified - EarthquakeYes
Hazard Identified - FloodYes
Hazard Identified - TornadoNo
Hazard Identified - HurricaneYes
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 PumpNo
Process Controls - GroundingYes
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksNo
Process Controls - Excess Flow DevicesYes
Process Controls - Quench SystemNo
Process Controls - Purge SystemNo
Process Controls - NoneNo
Mitigation Systems - SprinklersNo
Mitigation Systems - DikesNo
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsNo
Mitigation Systems - Water CurtainsYes
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 ControlsNo
Changes Since PHA - Process DetectionNo
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Changes Since PHA - OtherAddition of administrative controls & procedures
Procedure Review Date20131230
Training Review Date20131030
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 Date20131120
Maintenance Inspection Date20131127
Equipment Testedammonia vessel( API-510 report and UTT survey) ammonia piping ( API-570 report and UTT survey)
Management of Change Most Recent Date20140301
Management of Change Review Date20131127
Pre-startup Review Date20131127
Compliance Audit Date20120423
Compliance Audit Change Completion Date20120727
Incident Investigation Date20100410
Incident Invest. Change Completion Date20100930
Participation Plan Review Date20131127
Hot Work Review Date20131127
Contractor Safety Review Date20131127
Contractor Safety Eval. Date20110614
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : AES Hawaii, Inc., RMP submission #1 : 20140329, process #1 : SNCR Ammonia System, process NAICS code #1 : 221112, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID

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

Accidents facility_Accidents help link help link  
Accident Date20100410
Accident Time2100
Number of Chemicals1
Flammable Amount Total (lbs)0
Toxic Amount Total (lbs)5
Released Amount Total (lbs)5
Number of Deaths0
Number of Injuries1
Number Evacuated / Sheltered0
Total Property Damage$0
Environmental DamageNo
NAICS of Process Involved221112: Fossil Fuel Electric Power Generation
Release Duration (HHHMM)1
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 VesselNo
Release Source - Transfer HoseNo
Release Source - ValveYes
Release Source - PumpNo
Release Source - JointNo
Wind Speed5
Wind Speed Unitsmiles/h
Wind DirectionSSW
Atmospheric Stability ClassE
Unknown WeatherNo
Workers Killed0
Responders Killed0
Public Killed (on-site)0
Workers Injured1
Responders Injured0
Public Injured (on-site)0
Property Damage (on-site)$0
Off-site Deaths0
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 FailureNo
Contributing Factor - Human ErrorYes
Contributing Factor - Improper ProcedureNo
Contributing Factor - OverpressurizationNo
Contributing Factor - Upset ConditionNo
Contributing Factor - By-pass ConditionNo
Contributing Factor - MaintenanceNo
Contributing Factor - Process DesignNo
Contributing Factor - Unsuitable EquipmentYes
Contributing Factor - Unusual WeatherNo
Contributing Factor - Management ErrorNo
Off-site Responders NotifiedNo, not notified
Changes Introduced - Improved EquipmentYes
Changes Introduced - Revised MaintenanceNo
Changes Introduced - Revised TrainingYes
Changes Introduced - Operating ProceduresNo
Changes Introduced - Process ControlYes
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 Injuries1
Total RMP Accident Evacuated/Sheltering In Place0
Total RMP Accident Property Damage$0

Accident Chemicals facility_Accident_Chemicals help link help link (Facility #1 : AES Hawaii, Inc., RMP submission #1 : 20140329, accident #1, accident chemical #1)
Chemical IDAmmonia (anhydrous)
CAS number007664417
Chemical TypeToxic
Amount Released (lbs)5
Percent Weight (Within Mixture)99.7

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 Date20131118
Response Training Date20130926
Local Response AgencyCLEAN
Local Response Agency Phone8086743388
Subject To - OSHA EAPYes
Subject To - CWAYes
Subject To - RCRAYes
Subject To - OPAYes
Subject To - State EPCRAYes

Search Criteria Used
RMP Facility ID100000108787