| ||||||
Basic Facility Info
 |
| Facility ID | 100000085123 |
| Facility Name | Bayer CropScience - Institute Plant |
| Street Address Line 1 | Route 25 @ I-64 |
| City | Institute |
| State | WV |
| Zip Code | 25112 |
| County FIPS Code | 54039 |
| County | Kanawha County |
| Owner or Operator Name | Bayer CropScience L.P. |
| Parent Company | Bayer CropScience AG (Germany) |
| Second Parent Company | Bayer CropScience L.P. (United States) |
| Latitude | 38.387020 |
| Longitude | -081.774300 |
| Number of RMP Submissions | 3 |
| Most Recent Submission Info
|
| RMP ID | 49132 |
| Submission Type | revised submission for facility |
| Submission Date | 07/30/2007 |
| Reason For Submission | Newly regulated substance above TQ in already covered process (40 CFR 68.190(b)(3)) |
| Process Toxic Amount Total (lbs) | 3,910,700 |
| Process Flammable Amount Total (lbs) | 312,000 |
| Process Amount Total (lbs) | 4,222,700 |
| Number of Potential Offsite Consequence Processes | 5 |
| Potential Offsite Consequence Toxic Amount Total (lbs) | 3,910,700 |
| Potential Offsite Consequence Flammable Amount Total (lbs) | 312,000 |
| Potential Offsite Consequence Amount Total (lbs) | 4,222,700 |
| All Process NAICS | 325199 32532 |
| Exec Summary Submission Date | 07/30/2007 |
| Submission Info
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30) |
| RMP ID | 49132 |
| Submission Type | revised submission for facility |
| Receipt Date | 07/30/2007 |
| Reason For Submission | Newly regulated substance above TQ in already covered process (40 CFR 68.190(b)(3)) |
| Process Toxic Amount Total (lbs) | 3,910,700 |
| Process Flammable Amount Total (lbs) | 312,000 |
| Process Amount Total (lbs) | 4,222,700 |
| Number of Potential Offsite Consequence Processes | 5 |
| Potential Offsite Consequence Toxic Amount Total (lbs) | 3,910,700 |
| Potential Offsite Consequence Flammable Amount Total (lbs) | 312,000 |
| Potential Offsite Consequence Amount Total (lbs) | 4,222,700 |
| Submission - Basic Facility Info
|
| Facility Name | Bayer CropScience - Institute Plant |
| Street Address Line 1 | Route 25 @ I-64 |
| City | Institute |
| State | WV |
| Zip Code | 25112 |
| County FIPS Code | 54039 |
| County | Kanawha County |
| Parent Company | Bayer CropScience AG (Germany) |
| Second Parent Company | Bayer CropScience L.P. (United States) |
| Executive Summary
|
(Facility #1 : Bayer CropScience - Institute , executive summary: all) |
| Executive Summary | ||
| ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES The Institute Site has release prevention and emergency response policies and procedures in place in order to prevent and reduce the potential for releases from the Institute facility. Written procedures are maintained and are followed by Institute personnel. Release-reporting procedures are contained in Institute's manufacturing process units which prescribe immediate and follow-up reporting to federal, state, and local authorities, including the United States Environmental Protection Agency (USEPA), the U.S. Coast Guard, the West Virginia Division of Environmental Protection (WVDEP), the state and local emergency planning centers (EPC's), local fire and police departments, water departments, local residents, schools, hospitals and other interested parties. The plant maintains an emergency response team with appropriate training and equipment to respond to releases of toxic or flammable materials inside the plant. The plant also has mutual-aid agreements with local fire departments for response to various emergencies including chemical releases. FACILITY DESCRIPTION AND REGULATED SUBSTANCES HANDLED The Institute Plant is located eight miles west of Charleston, WV on the north bank of the Kanawha River. The site has a total area of 460 acres, which is owned by Bayer CropScience. Portions of the site are leased to Union Carbide (Dow), Praxair, and Reagent Chemical Company. Bayer CropScience, an agricultural chemical based company, operators a multi-product, multi-process chemical plant. The plant has five basic manufacturing units along with several other production facilities primarily responsible for producing raw materials used in the manufacture of agricultural chemicals. The principal prodcuts produced at the Institute site are SEVIN brand Carbaryl, TEMIK brand Aldicarb, LARVIN brand thiodicarb, methomyl, RHODIMET AT-88, Carbofuran and Carbosulfan. Bayer CropScience also provides person nel to operate and maintain the Dow chemical facilities. Praxair and Reagent Chemical operate their own facilities inside the site. Bayer CropScience has five production processes at this site that are covered by the RMP rule. Four of those processes, Methyl Isocyanate, Phosgene/Chlorine, Methomyl, and Aldicarb support the Bayer CropScience (agricultural chemicals) business. The fifth process, RHODIMETT, supports the Adisseo Animal Nutrition business, which is operated for Adisseo by Bayer CropScience. The Phosgene/Chlorine process receives and converts chlorine into phosgene. Chloroform is used in the Phosgene process to provide cooling. The phosgene is then reacted with monomethylamine in the manufacture of methyl isocyanate in the Methyl Isocyanate (MIC) process. Ammonia is stored onsite to be used in case of a phosgene release in an ammonia steam curtain mitigation system. Chloroform is used in the MIC process to provide cooling. The Methomyl process produces a crystalline material that is used as a raw material for the Larvin process and is also sold as a product. The Methomyl process uses methyl isocyanate, produced by the MIC Unit, and methyl mercaptan as raw materials. The Aldicarb process produces a crystalline material kept in a liquid solution that is further processed off-site before it is used as an insect control agent. The Aldicarb process uses methyl isocyanate, produced by the MIC Unit, and trimethylamine as raw materials. The RHODIMETT AT-88 facility produces methionine hydroxy analog that is used in poultry feed supplies. Ammonia is used as a raw material for this process. GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS Managing Process Safety at the Institute Site requires proactive identification, evaluation, and mitigation or prevention of chemical releases that could occur as a result of failures in processes, procedures, or equipment. We endorse and maintain an effective process safety management program that requires a systematic approach to evaluating the whole process. Using this approach, the process design, process technology, operational and maintenance activities and procedures, non-routine activities and procedures, emergency preparedness plans and procedures, training programs, and other elements which impact the process are all considered in the evaluation. The various lines of defense that have been incorporated into the design and operation of the unit process to prevent or mitigate the release of hazardous chemicals are evaluated and strengthened as needed to assure their effectiveness at each level. Ultimately, the major objective of process safety management of hazardous chemicals is to prevent unwanted releases of hazardous chemicals which could expose our employees and others to serious hazards. In regard to specific chemicals and processes regulated under RMP, the processes subject to the RMP regulation are also subject to OSHA process safety management (PSM) regulation. OSHA's PSM regulation is intended to prevent potential releases inside the plant and the RMP program is meant to help control or prevent releases which may affect off-site human health or the environment. Accidental releases from these processes are prevented by studying the hazards of the processes to identify potential hazards and implementing procedures, installing control devices and systems, and providing training to control those hazards. The processes are periodically evaluated to assess the risk of the operations by current standards and to make improvements where necessary. For methyl isocyanate and phosgene in particular, on-site inventories have been minimized as far as practicable in order to minimize the potential impact in the event of a release. In 1992 and 1993, the Phosgene process was rebuilt and the MIC process was modified to achieve these improvements following a thorough study of potential release scenarios. In addition to skilled o perators, all of the processes are controlled by computerized control systems which monitor and record conditions within the processes and make adjustments accordingly. In addition to the control systems, several of the processes are equipped with redundant computer safety systems which act to correct or shutdown the processes if certain parameters are exceeded and other process are equipped with direct shutdown controls to achieve similar protection. All of the processes covered by RMP utilize scrubbers and flares to destroy emissions from the process to minimize releases to the atmosphere. Maintenance of equipment containing hazardous substances is also a key element in preventing accidental releases. In addition, any changes made to the processes are carefully reviewed prior to implementation to ensure that safety and environmental risks are recognized and addressed. Finally, while many steps have been taken to prevent accidental releases, in the event that an accidental release does occur, it investigated to determine the root causes and to prescribe corrective actions to prevent the release from recurring in the future. FIVE-YEAR ACCIDENT HISTORY The Institute Site has had three accidental releases from RMP-covered processes that meet the RMP reporting criteria during the last five years. The first incident occurred on October 15, 1999 when a pinhole developed on a Reactor in the Methyl Isocyanate process due to corrosion/erosion. As a result, approximately 15 pounds of phosgene was released resulting in one on-site exposure and an off-site shelter-in-place. The second incident occurred on May 22, 2000 when a small amount of chlorine (less than one pound) leaked from a valve inside of the chlorine unloading building leading to an employee exposure. There were no off-site impacts. The third incident occurred on August 13, 2001 when an error during maintenance resulted in a spill of liquid chloroform. Approximately 3000 pounds of the chloroform t hat was spilled evaporated resulting in multiple exposures on-site. There were no off-site impacts. EMERGENCY RESPONSE PROGRAM The Institute Plant maintains a highly trained emergency response team to handle fires, explosions, toxic vapor releases, medical, chemical spills, and natural disasters and rescue emergencies. It also participates in local fire and industrial mutual aid systems. The Institute Plant has a dedicated in-plant Emergency Operations Center, trained incident commanders, and trained and state-certified emergency squad on site at all times. Additionally, a plant-wide notification system is in place in the event of an emergency. The plant has an on site dispensary and medical professional as well as full-coverage with Emergency Medical Technicians (EMTs). CHANGES TO IMPROVE SAFETY There are many operating and mechanical changes that continuously occur to improve the safe operation of the Bayer CropScience facilities. These occur as a result of the periodic risk-based process hazard assessment review process, which is described above. |
| Submission - Other Facility Info
|
| Owner or Operator Name | Bayer CropScience L.P. |
| Owner or Operator Address Line 1 | P.O. Box 1005 |
| Owner or Operator City | Institute |
| Owner or Operator State | WV |
| Owner or Operator Zip | 25112 |
| Parent Dun and Bradstreet Number | 327664793 |
| Second Parent Dun and Bradstreet Number | 1350263 |
| Number of Full Time Employees | 499 |
| Number of FTE CBI Flag | No |
| Other Facility ID | 25112RHNPLROUTE |
| Covered by OSHA PSM Standard | Yes |
| Covered by EPCRA Section 302 | Yes |
| Covered by CAA Title V | Yes |
| CAA Title V Air Operating Permit ID | R30-03900007 |
| Last Safety Inspection Date | 07/02/2006 |
| Last Safety Inspection By | EPA |
| OSHA Star or Merit Ranking | No |
| LEPC Name | Kanawha Putnam LEPC |
| Submission - Contact Info
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30) |
| Owner or Operator Phone | 3047676000 |
| Facility URL | http://www.bayercropscienceus.com/ |
| Facility Phone | 3047676101 |
| Facility Dun and Bradstreet Number | 157627886 |
| RMP Contact | J. M. Wey |
| RMP Contact Title | QHSE Manager |
| RMP Contact Email | Mike.Wey@BayerCropScience.com |
| Submission - Additional Info
|
| RMP Complete Flag | Yes |
| Predictive Filing | No |
| No RMP Accidents Last 5 Years | No |
| Complete Check Date | 07/30/2007 |
| Graphics Indicator | No |
| Attachment Indicator | No |
| Certification Received Flag | Yes |
| Submission Method | RMP*Submit |
| CBI Substantiation Flag | No |
| Electronic Waiver Flag | No |
| Postmark Date | 07/25/2007 |
| Anniversary Date | 07/25/2012 |
| Confidential Business Information | No |
| Unsanitized Version Provided | No |
| Software Version Number | 3.8 |
| Submission - Lat/Long Info
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30) |
| Latitude | 38.387020 |
| Longitude | -081.774300 |
| Valid Lat/Long | Yes |
| Lat/Long Method | Interpolation - Digital map source (TIGER) |
| Lat/Long Location Type | Plant Entrance (General) |
| Lat/Long Horizontal Accuracy | 60 |
| Lat/Long Horizontal Reference | 002 |
| FRS Latitude | 38.38 |
| FRS Longitude | -81.79 |
| FRS Lat/Long Description | FACILITY CENTROID |
| FRS Lat/Long Method | INTERPOLATION-MAP |
| Submission - Counts and Totals
|
| Number of RMP Accidents | 3 |
| Number of Processes | 5 |
| Number of Process Chemicals | 12 |
| Number of Toxic Worst-case Scenarios | 1 |
| Number of Toxic Alternate Case Scenarios | 6 |
| Number of Flammable Worst-case Scenarios | 1 |
| Number of Flammable Alternate Case Scenarios | 1 |
| RMP Accident Flammable Total (lbs) | 0 |
| RMP Accident Toxic Total (lbs) | 2,123 |
| RMP Accident Amount Total (lbs) | 2,123 |
| Total RMP Accident Deaths | 0 |
| Total RMP Accident Injuries | 0 |
| Total RMP Accident Evacuated/Sheltering In Place | 0 |
| Total RMP Accident Property Damage | $250,000 |
| Processes
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #1 : Methyl isocyanate) |
| Process ID | 71238 |
| Process Description | Methyl isocyanate |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 683,000 |
| Flammable Amount Total (lbs) | 280,000 |
| Process Amount Total (lbs) | 963,000 |
| Number of Process Chemicals | 4 |
| Number of Toxic Worst-Case Scenarios | 1 |
| Number of Toxic Alternate Scenarios | 2 |
| Number of Flammable Worst-Case Scenarios | 1 |
| Number of Flammable Alternate Scenarios | 1 |
| Process Chemicals
|
| Process Chemical Record ID | 94604 |
| Process Chemical ID | Methyl isocyanate [Methane, isocyanato-] |
| CAS number | 000624839 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 200,000 |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #1 : Methyl isocyanate, process chemical #2) |
| Process Chemical Record ID | 94605 |
| Process Chemical ID | Phosgene [Carbonic dichloride] |
| CAS number | 000075445 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 13,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 94606 |
| Process Chemical ID | Chloroform [Methane, trichloro-] |
| CAS number | 000067663 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 470,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 94607 |
| Process Chemical ID | Methylamine [Methanamine] |
| CAS number | 000074895 |
| Chemical Type | Flammable |
| Process Chemical Amount (lbs) | 280,000 |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #1 : Methyl isocyanate, process chemical #5) |
| Process Chemical Record ID | 594604 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Worst-Case Toxic Scenarios
|
| Toxic Scenario ID | 46664 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Liquid |
| Model Used | EPA's RMP*Comp(TM) |
| Release Duration (minutes) | 17.4 |
| Wind Speed (meters/sec) | 1.5 |
| Atmospheric Stability Class | F |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #1 : Methyl isocyanate, process chemical #5, alternate toxic scenario #1) |
| Toxic Scenario ID | 55122 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #1 : Methyl isocyanate, process chemical #6) |
| Process Chemical Record ID | 594605 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 594606 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 55123 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Liquid |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #1 : Methyl isocyanate, process chemical #8) |
| Process Chemical Record ID | 594607 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Worst-Case Flammable Scenarios
|
| Flammable Scenario ID | 12149 |
| Model Used | EPA's RMP*Comp(TM) |
| Passive Mitigation - Blast Walls | No |
| Confidential Business Information | No |
| Alternate Case Flammable Scenarios
|
| Flammable Scenario ID | 9281 |
| Model Used | EPA's RMP*Comp(TM) |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Fire Walls | No |
| Passive Mitigation - Blast Walls | No |
| Passive Mitigation - Enclosures | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Excess Flow Valves | No |
| Confidential Business Information | No |
| Process NAICS
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #1 : Methyl isocyanate, process NAICS code #1 : 325199) |
| Process NAICS ID | 72944 |
| NAICS Code | 325199: All Other Basic Organic Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
| Prevention Program ID | 41798 |
| Safety Info Review Date | 05/30/2007 |
| PHA Update Date | 03/24/2004 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | LOPA-type risk assessment |
| PHA Change Completion Date | 03/31/2008 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | Yes |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | No |
| Hazard Identified - Flood | No |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | Yes |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | Yes |
| Mitigation Systems - Neutralization | Yes |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) |
| Procedure Review Date | 07/17/2007 |
| Training Review Date | 07/18/2006 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Type of Training - Other | Computer-based |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | Yes |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 12/20/2006 |
| Maintenance Inspection Date | 05/02/2007 |
| Equipment Tested | Phosgene Flare KO Pot |
| Management of Change Most Recent Date | 02/22/2007 |
| Management of Change Review Date | 11/14/2005 |
| Pre-startup Review Date | 02/22/2007 |
| Compliance Audit Date | 12/17/2004 |
| Compliance Audit Change Completion Date | 11/30/2007 |
| Incident Investigation Date | 02/23/2007 |
| Incident Invest. Change Completion Date | 04/30/2007 |
| Participation Plan Review Date | 10/20/2006 |
| Hot Work Review Date | 06/23/2007 |
| Contractor Safety Review Date | 06/21/2007 |
| Contractor Safety Eval. Date | 05/07/2007 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #1 : Methyl isocyanate, process NAICS code #1 : 325199, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 94604 |
| 94605 |
| 94606 |
| 94607 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 71239 |
| Process Description | Phosgene/Chlorine |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 1,497,700 |
| Flammable Amount Total (lbs) | 0 |
| Process Amount Total (lbs) | 1,497,700 |
| Number of Process Chemicals | 4 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 2 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #2 : Phosgene/Chlorine, process chemical #1) |
| Process Chemical Record ID | 94608 |
| Process Chemical ID | Chlorine |
| CAS number | 007782505 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 1,400,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 94609 |
| Process Chemical ID | Phosgene [Carbonic dichloride] |
| CAS number | 000075445 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 6,200 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 94610 |
| Process Chemical ID | Chloroform [Methane, trichloro-] |
| CAS number | 000067663 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 71,000 |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #2 : Phosgene/Chlorine, process chemical #4) |
| Process Chemical Record ID | 94611 |
| Process Chemical ID | Ammonia (anhydrous) |
| CAS number | 007664417 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 20,500 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 594608 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 55124 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | Yes |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #2 : Phosgene/Chlorine, process chemical #6) |
| Process Chemical Record ID | 594609 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 55125 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #2 : Phosgene/Chlorine, process chemical #7) |
| Process Chemical Record ID | 594610 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 594611 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Process NAICS
|
| Process NAICS ID | 72945 |
| NAICS Code | 325199: All Other Basic Organic Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #2 : Phosgene/Chlorine, process NAICS code #1 : 325199, prev. program 3 #1) |
| Prevention Program ID | 41799 |
| Safety Info Review Date | 06/07/2007 |
| PHA Update Date | 03/05/2003 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | LOPA-type risk assessment |
| PHA Change Completion Date | 09/05/2004 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | Yes |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | No |
| Hazard Identified - Flood | No |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | Yes |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | Yes |
| Mitigation Systems - Neutralization | Yes |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) |
| Procedure Review Date | 07/17/2007 |
| Training Review Date | 07/17/2006 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Type of Training - Other | Computer-based |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 12/20/2006 |
| Maintenance Inspection Date | 08/27/2006 |
| Equipment Tested | Phosgene Converter |
| Management of Change Most Recent Date | 03/22/2007 |
| Management of Change Review Date | 11/14/2005 |
| Pre-startup Review Date | 03/22/2007 |
| Compliance Audit Date | 12/17/2004 |
| Compliance Audit Change Completion Date | 11/30/2007 |
| Incident Investigation Date | 10/06/2006 |
| Incident Invest. Change Completion Date | 01/31/2007 |
| Participation Plan Review Date | 10/20/2006 |
| Hot Work Review Date | 06/23/2007 |
| Contractor Safety Review Date | 06/21/2007 |
| Contractor Safety Eval. Date | 05/07/2007 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #2 : Phosgene/Chlorine, process NAICS code #1 : 325199, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 94608 |
| 94609 |
| 94610 |
| 94611 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 71240 |
| Process Description | Methomyl |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 330,000 |
| Flammable Amount Total (lbs) | 0 |
| Process Amount Total (lbs) | 330,000 |
| Number of Process Chemicals | 2 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 1 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #3 : Methomyl, process chemical #1) |
| Process Chemical Record ID | 94612 |
| Process Chemical ID | Methyl isocyanate [Methane, isocyanato-] |
| CAS number | 000624839 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 40,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 94613 |
| Process Chemical ID | Methyl mercaptan [Methanethiol] |
| CAS number | 000074931 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 290,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 594612 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #3 : Methomyl, process chemical #4) |
| Process Chemical Record ID | 594613 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 55126 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process NAICS
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #3 : Methomyl, process NAICS code #1 : 32532) |
| Process NAICS ID | 72946 |
| NAICS Code | 32532: Pesticide and Other Agricultural Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
| Prevention Program ID | 41800 |
| Safety Info Review Date | 01/10/2007 |
| PHA Update Date | 10/20/2004 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | LOPA-type risk assessment |
| PHA Change Completion Date | 06/30/2008 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | No |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | No |
| Hazard Identified - Flood | No |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | Yes |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | No |
| Mitigation Systems - Neutralization | No |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) |
| Procedure Review Date | 07/17/2007 |
| Training Review Date | 06/20/2007 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Type of Training - Other | Computer-based |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 12/20/2006 |
| Maintenance Inspection Date | 06/12/2007 |
| Equipment Tested | Methomyl Dryer Vac Pump Cooler |
| Management of Change Most Recent Date | 05/23/2007 |
| Management of Change Review Date | 11/14/2005 |
| Pre-startup Review Date | 01/11/2007 |
| Compliance Audit Date | 11/29/2004 |
| Compliance Audit Change Completion Date | 12/31/2007 |
| Incident Investigation Date | 01/06/2007 |
| Incident Invest. Change Completion Date | 02/28/2007 |
| Participation Plan Review Date | 10/20/2006 |
| Hot Work Review Date | 06/23/2007 |
| Contractor Safety Review Date | 06/21/2007 |
| Contractor Safety Eval. Date | 07/28/2006 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #3 : Methomyl, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 94612 |
| 94613 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 71241 |
| Process Description | Rhodimet AT-88 |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 1,400,000 |
| Flammable Amount Total (lbs) | 0 |
| Process Amount Total (lbs) | 1,400,000 |
| Number of Process Chemicals | 1 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 1 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #4 : Rhodimet AT-88, process chemical #1) |
| Process Chemical Record ID | 94614 |
| Process Chemical ID | Ammonia (anhydrous) |
| CAS number | 007664417 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 1,400,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 594614 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 55127 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process NAICS
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #4 : Rhodimet AT-88, process NAICS code #1 : 32532) |
| Process NAICS ID | 72947 |
| NAICS Code | 32532: Pesticide and Other Agricultural Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
| Prevention Program ID | 41801 |
| Safety Info Review Date | 06/12/2007 |
| PHA Update Date | 04/30/2007 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | LOPA-type risk assessment |
| PHA Change Completion Date | 09/30/2008 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | Yes |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | No |
| Hazard Identified - Flood | No |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | No |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | No |
| Mitigation Systems - Neutralization | No |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) |
| Procedure Review Date | 09/30/2005 |
| Training Review Date | 12/20/2006 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Type of Training - Other | Computer-based |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 12/20/2006 |
| Maintenance Inspection Date | 10/26/2006 |
| Equipment Tested | HCN Absorber column |
| Management of Change Most Recent Date | 06/08/2007 |
| Management of Change Review Date | 11/14/2005 |
| Pre-startup Review Date | 06/08/2007 |
| Compliance Audit Date | 12/08/2005 |
| Compliance Audit Change Completion Date | 03/01/2007 |
| Incident Investigation Date | 11/01/2006 |
| Incident Invest. Change Completion Date | 01/01/2007 |
| Participation Plan Review Date | 10/20/2006 |
| Hot Work Review Date | 06/23/2007 |
| Contractor Safety Review Date | 06/21/2007 |
| Contractor Safety Eval. Date | 04/19/2007 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #4 : Rhodimet AT-88, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 94614 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 71242 |
| Process Description | Aldicarb |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 0 |
| Flammable Amount Total (lbs) | 32,000 |
| Process Amount Total (lbs) | 32,000 |
| Number of Process Chemicals | 1 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 0 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #5 : Aldicarb, process chemical #1) |
| Process Chemical Record ID | 94615 |
| Process Chemical ID | Trimethylamine [Methanamine, N,N-dimethyl-] |
| CAS number | 000075503 |
| Chemical Type | Flammable |
| Process Chemical Amount (lbs) | 32,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 594615 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Process NAICS
|
| Process NAICS ID | 72948 |
| NAICS Code | 32532: Pesticide and Other Agricultural Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #5 : Aldicarb, process NAICS code #1 : 32532, prev. program 3 #1) |
| Prevention Program ID | 41802 |
| Safety Info Review Date | 06/08/2007 |
| PHA Update Date | 04/10/2003 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | LOPA-type risk assessment |
| PHA Change Completion Date | 03/31/2008 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | No |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | No |
| Hazard Identified - Flood | No |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | No |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | No |
| Mitigation Systems - Neutralization | No |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | No |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | Yes |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) |
| Procedure Review Date | 04/30/2007 |
| Training Review Date | 01/06/2006 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Type of Training - Other | Computer-based |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 12/20/2006 |
| Maintenance Inspection Date | 06/12/2007 |
| Equipment Tested | Aldicarb vent Condenser |
| Management of Change Most Recent Date | 07/20/2006 |
| Management of Change Review Date | 11/14/2005 |
| Pre-startup Review Date | 07/20/2006 |
| Compliance Audit Date | 11/09/2004 |
| Compliance Audit Change Completion Date | 06/05/2007 |
| Incident Investigation Date | 08/23/2005 |
| Incident Invest. Change Completion Date | 02/01/2006 |
| Participation Plan Review Date | 10/20/2006 |
| Hot Work Review Date | 06/23/2007 |
| Contractor Safety Review Date | 06/21/2007 |
| Contractor Safety Eval. Date | 07/14/2006 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, process #5 : Aldicarb, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 94615 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Accidents
|
| Accident ID | 7867 |
| Accident Date | 10/06/2006 |
| Accident Time | 0900 |
| Number of Chemicals | 1 |
| Flammable Amount Total (lbs) | 0 |
| Toxic Amount Total (lbs) | 200 |
| Released Amount Total (lbs) | 200 |
| Number of Deaths | 0 |
| Number of Injuries | 0 |
| Number Evacuated / Sheltered | 0 |
| Total Property Damage | $250,000 |
| Environmental Damage | Yes |
| NAICS of Process Involved | 325199: All Other Basic Organic Chemical Manufacturing |
| Release Duration (HHHMM) | 02400 |
| Release Event - Gas Release | No |
| Release Event - Spill | Yes |
| Release Event - Fire | No |
| Release Event - Explosion | No |
| Release Event - Reaction | No |
| Release Source - Storage Vessel | No |
| Release Source - Piping | No |
| Release Source - Process Vessel | Yes |
| Release Source - Transfer Hose | No |
| Release Source - Valve | No |
| Release Source - Pump | No |
| Release Source - Joint | No |
| Wind Speed | 6 |
| Wind Speed Units | miles/h |
| Wind Direction | SW |
| Temperature | 60 |
| Atmospheric Stability Class | B |
| Precipitation | No |
| Unknown Weather | No |
| Workers Killed | 0 |
| Responders Killed | 0 |
| Public Killed (on-site) | 0 |
| Workers Injured | 0 |
| Responders Injured | 0 |
| Public Injured (on-site) | 0 |
| Property Damage (on-site) | $250,000 |
| Off-site Deaths | 0 |
| Hospitalizations | 0 |
| Number Requiring Medical Treatment | 0 |
| Number Evacuated | 0 |
| Number Sheltered In Place | 0 |
| Property damage (off-site) | $0 |
| Environmental Damage - Fish/Animal Kills | No |
| Environmental Damage - Defoliation | No |
| Environmental Damage - Water Contamination | Yes |
| Environmental Damage - Soil Contamination | No |
| Initiating Event | Equipment Failure |
| Contributing Factor - Equipment Failure | No |
| Contributing Factor - Human Error | No |
| Contributing Factor - Improper Procedure | No |
| Contributing Factor - Overpressurization | No |
| Contributing Factor - Upset Condition | Yes |
| Contributing Factor - By-pass Condition | No |
| Contributing Factor - Maintenance | No |
| Contributing Factor - Process Design | No |
| Contributing Factor - Unsuitable Equipment | No |
| Contributing Factor - Unusual Weather | No |
| Contributing Factor - Management Error | No |
| Off-site Responders Notified | No, not notified |
| Changes Introduced - Improved Equipment | No |
| Changes Introduced - Revised Maintenance | No |
| Changes Introduced - Revised Training | No |
| Changes Introduced - Operating Procedures | Yes |
| Changes Introduced - Process Control | Yes |
| Changes Introduced - Mitigation Systems | No |
| Changes Introduced - Response Plan | No |
| Changes Introduced - Changed Process | No |
| Changes Introduced - Reduced Inventory | No |
| Changes Introduced - None | No |
| Confidential Business Information | No |
| Accident Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, accident #1, accident chemical #1) |
| Accident Chemical Record ID | 8641 |
| Chemical ID | Chloroform [Methane, trichloro-] |
| CAS number | 000067663 |
| Chemical Type | Toxic |
| Amount Released (lbs) | 200 |
| Percent Weight (Within Mixture) | 100 |
| Number of Flammable Components | 0 |
| Accidents
|
| Accident ID | 7868 |
| Accident Date | 11/02/2006 |
| Accident Time | 1400 |
| Number of Chemicals | 1 |
| Flammable Amount Total (lbs) | 0 |
| Toxic Amount Total (lbs) | 1,500 |
| Released Amount Total (lbs) | 1,500 |
| Number of Deaths | 0 |
| Number of Injuries | 0 |
| Number Evacuated / Sheltered | 0 |
| Total Property Damage | $0 |
| Environmental Damage | Yes |
| NAICS of Process Involved | 325199: All Other Basic Organic Chemical Manufacturing |
| Release Duration (HHHMM) | 00010 |
| Release Event - Gas Release | No |
| Release Event - Spill | Yes |
| Release Event - Fire | No |
| Release Event - Explosion | No |
| Release Event - Reaction | No |
| Release Source - Storage Vessel | No |
| Release Source - Piping | Yes |
| Release Source - Process Vessel | No |
| Release Source - Transfer Hose | No |
| Release Source - Valve | No |
| Release Source - Pump | No |
| Release Source - Joint | No |
| Wind Speed | 0 |
| Wind Speed Units | meters/second |
| Temperature | 0 |
| Precipitation | No |
| Unknown Weather | Yes |
| Workers Killed | 0 |
| Responders Killed | 0 |
| Public Killed (on-site) | 0 |
| Workers Injured | 0 |
| Responders Injured | 0 |
| Public Injured (on-site) | 0 |
| Property Damage (on-site) | $0 |
| Off-site Deaths | 0 |
| Hospitalizations | 0 |
| Number Requiring Medical Treatment | 0 |
| Number Evacuated | 0 |
| Number Sheltered In Place | 0 |
| Property damage (off-site) | $0 |
| Environmental Damage - Fish/Animal Kills | No |
| Environmental Damage - Defoliation | No |
| Environmental Damage - Water Contamination | No |
| Environmental Damage - Soil Contamination | Yes |
| Initiating Event | Equipment Failure |
| Contributing Factor - Equipment Failure | Yes |
| Contributing Factor - Human Error | No |
| Contributing Factor - Improper Procedure | No |
| Contributing Factor - Overpressurization | No |
| Contributing Factor - Upset Condition | No |
| Contributing Factor - By-pass Condition | No |
| Contributing Factor - Maintenance | Yes |
| Contributing Factor - Process Design | No |
| Contributing Factor - Unsuitable Equipment | No |
| Contributing Factor - Unusual Weather | No |
| Contributing Factor - Management Error | No |
| Off-site Responders Notified | No, not notified |
| Changes Introduced - Improved Equipment | No |
| Changes Introduced - Revised Maintenance | Yes |
| Changes Introduced - Revised Training | No |
| Changes Introduced - Operating Procedures | Yes |
| Changes Introduced - Process Control | No |
| Changes Introduced - Mitigation Systems | No |
| Changes Introduced - Response Plan | No |
| Changes Introduced - Changed Process | No |
| Changes Introduced - Reduced Inventory | No |
| Changes Introduced - None | No |
| Confidential Business Information | No |
| Accident Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, accident #2, accident chemical #1) |
| Accident Chemical Record ID | 8642 |
| Chemical ID | Chloroform [Methane, trichloro-] |
| CAS number | 000067663 |
| Chemical Type | Toxic |
| Amount Released (lbs) | 1,500 |
| Percent Weight (Within Mixture) | 100 |
| Number of Flammable Components | 0 |
| Accidents
|
| Accident ID | 7869 |
| Accident Date | 06/27/2007 |
| Accident Time | 0130 |
| Number of Chemicals | 1 |
| Flammable Amount Total (lbs) | 0 |
| Toxic Amount Total (lbs) | 423 |
| Released Amount Total (lbs) | 423 |
| Number of Deaths | 0 |
| Number of Injuries | 0 |
| Number Evacuated / Sheltered | 0 |
| Total Property Damage | $0 |
| Environmental Damage | Yes |
| NAICS of Process Involved | 325199: All Other Basic Organic Chemical Manufacturing |
| Release Duration (HHHMM) | 01900 |
| Release Event - Gas Release | No |
| Release Event - Spill | Yes |
| Release Event - Fire | No |
| Release Event - Explosion | No |
| Release Event - Reaction | No |
| Release Source - Storage Vessel | No |
| Release Source - Piping | No |
| Release Source - Process Vessel | Yes |
| Release Source - Transfer Hose | No |
| Release Source - Valve | No |
| Release Source - Pump | No |
| Release Source - Joint | No |
| Wind Speed | 0 |
| Wind Speed Units | meters/second |
| Temperature | 0 |
| Precipitation | No |
| Unknown Weather | Yes |
| Workers Killed | 0 |
| Responders Killed | 0 |
| Public Killed (on-site) | 0 |
| Workers Injured | 0 |
| Responders Injured | 0 |
| Public Injured (on-site) | 0 |
| Property Damage (on-site) | $0 |
| Off-site Deaths | 0 |
| Hospitalizations | 0 |
| Number Requiring Medical Treatment | 0 |
| Number Evacuated | 0 |
| Number Sheltered In Place | 0 |
| Property damage (off-site) | $0 |
| Environmental Damage - Fish/Animal Kills | No |
| Environmental Damage - Defoliation | No |
| Environmental Damage - Water Contamination | Yes |
| Environmental Damage - Soil Contamination | No |
| Initiating Event | Equipment Failure |
| Contributing Factor - Equipment Failure | Yes |
| Contributing Factor - Human Error | No |
| Contributing Factor - Improper Procedure | No |
| Contributing Factor - Overpressurization | No |
| Contributing Factor - Upset Condition | No |
| Contributing Factor - By-pass Condition | No |
| Contributing Factor - Maintenance | No |
| Contributing Factor - Process Design | No |
| Contributing Factor - Unsuitable Equipment | No |
| Contributing Factor - Unusual Weather | No |
| Contributing Factor - Management Error | No |
| Off-site Responders Notified | No, not notified |
| Changes Introduced - Improved Equipment | No |
| Changes Introduced - Revised Maintenance | No |
| Changes Introduced - Revised Training | No |
| Changes Introduced - Operating Procedures | Yes |
| Changes Introduced - Process Control | No |
| Changes Introduced - Mitigation Systems | No |
| Changes Introduced - Response Plan | No |
| Changes Introduced - Changed Process | No |
| Changes Introduced - Reduced Inventory | No |
| Changes Introduced - None | No |
| Confidential Business Information | No |
| Accident Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #1 : 2007-07-30, accident #3, accident chemical #1) |
| Accident Chemical Record ID | 8643 |
| Chemical ID | Chloroform [Methane, trichloro-] |
| CAS number | 000067663 |
| Chemical Type | Toxic |
| Amount Released (lbs) | 423 |
| Percent Weight (Within Mixture) | 100 |
| Number of Flammable Components | 0 |
| Emergency Response Plan Info
|
| Facility In Community Plan | Yes |
| Facility Own Response Plan | Yes |
| Specific Facility Response Plan | Yes |
| Inform. Procedures in Response Plan | Yes |
| Emergency Care in Response Plan | Yes |
| Plan Review Date | 04/04/2007 |
| Response Training Date | 07/05/2007 |
| Local Response Agency | Kanawha Putnam LEPC |
| Local Response Agency Phone | 3047441838 |
| Subject To - OSHA EAP | Yes |
| Subject To - OSHA HAZWOPER | Yes |
| Subject To - CWA | Yes |
| Subject To - RCRA | Yes |
| Subject To - OPA | Yes |
| Subject To - State EPCRA | No |
| Submission Info
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21) |
| RMP ID | 34163 |
| Submission Type | revised submission for facility |
| Receipt Date | 06/21/2004 |
| Reason For Submission | 5-year update (40 CFR 68.190(b)(1)) |
| Process Toxic Amount Total (lbs) | 3,890,200 |
| Process Flammable Amount Total (lbs) | 312,000 |
| Process Amount Total (lbs) | 4,202,200 |
| Number of Potential Offsite Consequence Processes | 5 |
| Potential Offsite Consequence Toxic Amount Total (lbs) | 3,890,200 |
| Potential Offsite Consequence Flammable Amount Total (lbs) | 312,000 |
| Potential Offsite Consequence Amount Total (lbs) | 4,202,200 |
| Submission - Basic Facility Info
|
| Facility Name | Bayer CropScience - Institute Plant |
| Street Address Line 1 | Route 25 @ I-64 |
| City | Institute |
| State | WV |
| Zip Code | 25112 |
| County FIPS Code | 54039 |
| County | Kanawha County |
| Parent Company | Bayer CropScience AG (Germany) |
| Second Parent Company | Bayer CropScience L.P. (United States) |
| Executive Summary
|
(Facility #1 : Bayer CropScience - Institute , executive summary: all) |
| Executive Summary | ||
| ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES The Institute Site has release prevention and emergency response policies and procedures in place in order to prevent and reduce the potential for releases from the Institute facility. Written procedures are maintained and are followed by Institute personnel. Release-reporting procedures are contained in Institute's manufacturing process units which prescribe immediate and follow-up reporting to federal, state, and local authorities, including the United States Environmental Protection Agency (USEPA), the U.S. Coast Guard, the West Virginia Division of Environmental Protection (WVDEP), the state and local emergency planning centers (EPC's), local fire and police departments, water departments, local residents, schools, hospitals and other interested parties. The plant maintains an emergency response team with appropriate training and equipment to respond to releases of toxic or flammable materials inside the plant. The plant also has mutual-aid agreements with local fire departments for response to various emergencies including chemical releases. FACILITY DESCRIPTION AND REGULATED SUBSTANCES HANDLED The Institute Plant is located eight miles west of Charleston, WV on the north bank of the Kanawha River. The site has a total area of 460 acres, which is owned by Bayer CropScience. Portions of the site are leased to Union Carbide (Dow), Praxair, and Reagent Chemical Company. Bayer CropScience operates two business entities at the site. They are Bayer CropScience (agricultural chemicals) and Adisseo Animal Nutrition (RHODIMET AT-88). Bayer CropScience also provides personnel to operate and maintain the Dow chemical facilities. Praxair and Reagent Chemical operate their own facilities inside the site. Bayer CropScience has five production processes at this site that are covered by the RMP rule. Four of those processes, Methyl Isocyanate, Phosgene/Chlorine, Methomyl, and Aldicarb support the Bay er CropScience (agricultural chemicals) business. The fifth process, RHODIMETT, supports the Adisseo Animal Nutrition business, which is operated for Adisseo by Bayer CropScience. The Phosgene/Chlorine process receives and converts chlorine into phosgene. Chloroform is used in the Phosgene process to provide cooling. The phosgene is then reacted with monomethylamine in the manufacture of methyl isocyanate in the Methyl Isocyanate (MIC) process. Chloroform is also used in the MIC process to provide cooling. The Methomyl process produces a crystalline material that is used as a raw material for the Larvin process and is also sold as a product. The Methomyl process uses methyl isocyanate, produced by the MIC Unit, and methyl mercaptan as raw materials. The Aldicarb process produces a crystalline material kept in a liquid solution that is further processed off-site before it is used as an insect control agent. The Aldicarb process uses methyl isocyanate, produced by the MIC Unit, and trimethylamine as raw materials. The RHODIMETT AT-88 facility produces methionine hydroxy analog that is used in poultry feed supplies. Ammonia is used as a raw material for this process. GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS Managing Process Safety at the Institute Site requires proactive identification, evaluation, and mitigation or prevention of chemical releases that could occur as a result of failures in processes, procedures, or equipment. We endorse and maintain an effective process safety management program that requires a systematic approach to evaluating the whole process. Using this approach, the process design, process technology, operational and maintenance activities and procedures, non-routine activities and procedures, emergency preparedness plans and procedures, training programs, and other elements which impact the process are all considered in the evaluation. The various lines of defense that have been incorp orated into the design and operation of the unit process to prevent or mitigate the release of hazardous chemicals are evaluated and strengthened as needed to assure their effectiveness at each level. Ultimately, the major objective of process safety management of hazardous chemicals is to prevent unwanted releases of hazardous chemicals which could expose our employees and others to serious hazards. In regard to specific chemicals and processes regulated under RMP, the processes subject to the RMP regulation are also subject to OSHA process safety management (PSM) regulation. OSHA's PSM regulation is intended to prevent potential releases inside the plant and the RMP program is meant to help control or prevent releases which may affect off-site human health or the environment. Accidental releases from these processes are prevented by studying the hazards of the processes to identify potential hazards and implementing procedures, installing control devices and systems, and providing training to control those hazards. The processes are periodically evaluated to assess the risk of the operations by current standards and to make improvements where necessary. For methyl isocyanate and phosgene in particular, on-site inventories have been minimized as far as practicable in order to minimize the potential impact in the event of a release. In 1992 and 1993, the Phosgene process was rebuilt and the MIC process was modified to achieve these improvements following a thorough study of potential release scenarios. In addition to skilled operators, all of the processes are controlled by computerized control systems which monitor and record conditions within the processes and make adjustments accordingly. In addition to the control systems, several of the processes are equipped with redundant computer safety systems which act to correct or shutdown the processes if certain parameters are exceeded and other process are equipped with direct shutdown controls to achieve sim ilar protection. All of the processes covered by RMP utilize scrubbers and flares to destroy emissions from the process to minimize releases to the atmosphere. Maintenance of equipment containing hazardous substances is also a key element in preventing accidental releases. In addition, any changes made to the processes are carefully reviewed prior to implementation to ensure that safety and environmental risks are recognized and addressed. Finally, while many steps have been taken to prevent accidental releases, in the event that an accidental release does occur, it investigated to determine the root causes and to prescribe corrective actions to prevent the release from recurring in the future. FIVE-YEAR ACCIDENT HISTORY The Institute Site has had three accidental releases from RMP-covered processes that meet the RMP reporting criteria during the last five years. The first incident occurred on October 15, 1999 when a pinhole developed on a Reactor in the Methyl Isocyanate process due to corrosion/erosion. As a result, approximately 15 pounds of phosgene was released resulting in one on-site exposure and an off-site shelter-in-place. The second incident occurred on May 22, 2000 when a small amount of chlorine (less than one pound) leaked from a valve inside of the chlorine unloading building leading to an employee exposure. There were no off-site impacts. The third incident occurred on August 13, 2001 when an error during maintenance resulted in a spill of liquid chloroform. Approximately 3000 pounds of the chloroform that was spilled evaporated resulting in multiple exposures on-site. There were no off-site impacts. EMERGENCY RESPONSE PROGRAM The Institute Plant maintains a highly trained emergency response team to handle fires, explosions, toxic vapor releases, medical, chemical spills, and natural disasters and rescue emergencies. It also participates in local fire and industrial mutual aid systems. The Institute Plant has a dedicated in-plan t Emergency Operations Center, trained incident commanders, and trained and state-certified emergency squad on site at all times. Additionally, a plant-wide notification system is in place in the event of an emergency. The plant has an on site dispensary and medical professional as well as full-coverage with Emergency Medical Technicians (EMTs) and paramedics. CHANGES TO IMPROVE SAFETY There are many operating and mechanical changes that continuously occur to improve the safe operation of the Bayer CropScience facilities. These occur as a result of the periodic risk-based process hazard assessment review process, which is described above. |
| Submission - Other Facility Info
|
| Owner or Operator Name | Bayer CropScience L.P. |
| Owner or Operator Address Line 1 | P.O. Box 1005 |
| Owner or Operator City | Institute |
| Owner or Operator State | WV |
| Owner or Operator Zip | 25112 |
| Parent Dun and Bradstreet Number | 327664793 |
| Second Parent Dun and Bradstreet Number | 1350263 |
| Number of Full Time Employees | 743 |
| Number of FTE CBI Flag | No |
| Other Facility ID | 25112RHNPLROUTE |
| Covered by OSHA PSM Standard | Yes |
| Covered by EPCRA Section 302 | Yes |
| Covered by CAA Title V | Yes |
| CAA Title V Air Operating Permit ID | Pending from WV |
| Last Safety Inspection Date | 05/13/2004 |
| Last Safety Inspection By | Other - Fed. Railroad Admin. |
| OSHA Star or Merit Ranking | No |
| LEPC Name | Kanawha Putnam LEPC |
| Submission - Contact Info
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21) |
| Owner or Operator Phone | 3047676000 |
| Facility URL | http://www.bayercropscienceus.com/ |
| Facility Phone | 3047676202 |
| Facility Dun and Bradstreet Number | 157627886 |
| RMP Contact | J. M. Wey |
| RMP Contact Title | QHSE Manager |
| Submission - Additional Info
|
| RMP Complete Flag | Yes |
| Predictive Filing | No |
| No RMP Accidents Last 5 Years | No |
| Complete Check Date | 07/23/2004 |
| Graphics Indicator | No |
| Attachment Indicator | No |
| Certification Received Flag | Yes |
| Submission Method | RMP*Submit |
| CBI Substantiation Flag | No |
| Electronic Waiver Flag | No |
| Postmark Date | 06/17/2004 |
| Anniversary Date | 06/17/2009 |
| Confidential Business Information | No |
| Unsanitized Version Provided | No |
| Software Version Number | 3.1 |
| Submission - Lat/Long Info
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21) |
| Latitude | 38.387020 |
| Longitude | -081.774300 |
| Valid Lat/Long | Yes |
| Lat/Long Method | Interpolation - Digital map source (TIGER) |
| Lat/Long Location Type | Plant Entrance (General) |
| Lat/Long Horizontal Accuracy | 60 |
| Lat/Long Horizontal Reference | 002 |
| FRS Latitude | 38.38 |
| FRS Longitude | -81.79 |
| FRS Lat/Long Description | FACILITY CENTROID |
| FRS Lat/Long Method | INTERPOLATION-MAP |
| Submission - Counts and Totals
|
| Number of RMP Accidents | 3 |
| Number of Processes | 5 |
| Number of Process Chemicals | 11 |
| Number of Toxic Worst-case Scenarios | 1 |
| Number of Toxic Alternate Case Scenarios | 6 |
| Number of Flammable Worst-case Scenarios | 1 |
| Number of Flammable Alternate Case Scenarios | 1 |
| RMP Accident Flammable Total (lbs) | 0 |
| RMP Accident Toxic Total (lbs) | 3,016 |
| RMP Accident Amount Total (lbs) | 3,016 |
| Total RMP Accident Deaths | 0 |
| Total RMP Accident Injuries | 10 |
| Total RMP Accident Evacuated/Sheltering In Place | 11,000 |
| Total RMP Accident Property Damage | $0 |
| Processes
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #1 : Methyl isocyanate) |
| Process ID | 49267 |
| Process Description | Methyl isocyanate |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 683,000 |
| Flammable Amount Total (lbs) | 280,000 |
| Process Amount Total (lbs) | 963,000 |
| Number of Process Chemicals | 4 |
| Number of Toxic Worst-Case Scenarios | 1 |
| Number of Toxic Alternate Scenarios | 2 |
| Number of Flammable Worst-Case Scenarios | 1 |
| Number of Flammable Alternate Scenarios | 1 |
| Process Chemicals
|
| Process Chemical Record ID | 64929 |
| Process Chemical ID | Methyl isocyanate [Methane, isocyanato-] |
| CAS number | 000624839 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 200,000 |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #1 : Methyl isocyanate, process chemical #2) |
| Process Chemical Record ID | 64930 |
| Process Chemical ID | Phosgene [Carbonic dichloride] |
| CAS number | 000075445 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 13,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 64931 |
| Process Chemical ID | Chloroform [Methane, trichloro-] |
| CAS number | 000067663 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 470,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 64932 |
| Process Chemical ID | Methylamine [Methanamine] |
| CAS number | 000074895 |
| Chemical Type | Flammable |
| Process Chemical Amount (lbs) | 280,000 |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #1 : Methyl isocyanate, process chemical #5) |
| Process Chemical Record ID | 564929 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Worst-Case Toxic Scenarios
|
| Toxic Scenario ID | 32236 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Liquid |
| Model Used | EPA's RMP*Comp(TM) |
| Release Duration (minutes) | 17.4 |
| Wind Speed (meters/sec) | 1.5 |
| Atmospheric Stability Class | F |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #1 : Methyl isocyanate, process chemical #5, alternate toxic scenario #1) |
| Toxic Scenario ID | 38088 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #1 : Methyl isocyanate, process chemical #6) |
| Process Chemical Record ID | 564930 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 564931 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 38089 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Liquid |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #1 : Methyl isocyanate, process chemical #8) |
| Process Chemical Record ID | 564932 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Worst-Case Flammable Scenarios
|
| Flammable Scenario ID | 8706 |
| Model Used | EPA's RMP*Comp(TM) |
| Passive Mitigation - Blast Walls | No |
| Confidential Business Information | No |
| Alternate Case Flammable Scenarios
|
| Flammable Scenario ID | 6856 |
| Model Used | EPA's RMP*Comp(TM) |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Fire Walls | No |
| Passive Mitigation - Blast Walls | No |
| Passive Mitigation - Enclosures | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Excess Flow Valves | No |
| Confidential Business Information | No |
| Process NAICS
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #1 : Methyl isocyanate, process NAICS code #1 : 325199) |
| Process NAICS ID | 50393 |
| NAICS Code | 325199: All Other Basic Organic Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
| Prevention Program ID | 28239 |
| Safety Info Review Date | 03/26/2004 |
| PHA Update Date | 03/26/2004 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | LOPA-type risk assessment |
| PHA Change Completion Date | 09/26/2005 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | Yes |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | No |
| Hazard Identified - Flood | No |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | Yes |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | Yes |
| Mitigation Systems - Neutralization | Yes |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) |
| Procedure Review Date | 05/28/2004 |
| Training Review Date | 04/10/2003 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Type of Training - Other | Computer-based |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | Yes |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 12/22/2003 |
| Maintenance Inspection Date | 05/03/2004 |
| Equipment Tested | MIC Vent Separator |
| Management of Change Most Recent Date | 05/26/2004 |
| Management of Change Review Date | 09/10/2002 |
| Pre-startup Review Date | 06/09/2004 |
| Compliance Audit Date | 06/14/2001 |
| Compliance Audit Change Completion Date | 12/31/2004 |
| Incident Investigation Date | 09/23/2003 |
| Incident Invest. Change Completion Date | 02/01/2004 |
| Participation Plan Review Date | 06/05/1996 |
| Hot Work Review Date | 08/27/2003 |
| Contractor Safety Review Date | 10/31/2003 |
| Contractor Safety Eval. Date | 04/10/2004 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #1 : Methyl isocyanate, process NAICS code #1 : 325199, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 64929 |
| 64930 |
| 64931 |
| 64932 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 49268 |
| Process Description | Phosgene/Chlorine |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 1,477,200 |
| Flammable Amount Total (lbs) | 0 |
| Process Amount Total (lbs) | 1,477,200 |
| Number of Process Chemicals | 3 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 2 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #2 : Phosgene/Chlorine, process chemical #1) |
| Process Chemical Record ID | 64933 |
| Process Chemical ID | Chlorine |
| CAS number | 007782505 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 1,400,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 64934 |
| Process Chemical ID | Phosgene [Carbonic dichloride] |
| CAS number | 000075445 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 6,200 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 64935 |
| Process Chemical ID | Chloroform [Methane, trichloro-] |
| CAS number | 000067663 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 71,000 |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #2 : Phosgene/Chlorine, process chemical #4) |
| Process Chemical Record ID | 564933 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 38090 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | Yes |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #2 : Phosgene/Chlorine, process chemical #5) |
| Process Chemical Record ID | 564934 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 38091 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #2 : Phosgene/Chlorine, process chemical #6) |
| Process Chemical Record ID | 564935 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Process NAICS
|
| Process NAICS ID | 50394 |
| NAICS Code | 325199: All Other Basic Organic Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
| Prevention Program ID | 28240 |
| Safety Info Review Date | 03/05/2003 |
| PHA Update Date | 03/05/2003 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | LOPA-type risk assessment |
| PHA Change Completion Date | 09/05/2004 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | Yes |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | No |
| Hazard Identified - Flood | No |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | Yes |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | Yes |
| Mitigation Systems - Neutralization | Yes |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) |
| Procedure Review Date | 11/11/2003 |
| Training Review Date | 05/01/2004 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Type of Training - Other | Computer-based |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 12/22/2003 |
| Maintenance Inspection Date | 03/02/2004 |
| Equipment Tested | Chlorine Superheater |
| Management of Change Most Recent Date | 05/26/2004 |
| Management of Change Review Date | 09/10/2002 |
| Pre-startup Review Date | 04/06/2004 |
| Compliance Audit Date | 06/14/2001 |
| Compliance Audit Change Completion Date | 12/31/2004 |
| Incident Investigation Date | 05/09/2003 |
| Incident Invest. Change Completion Date | 12/01/2003 |
| Participation Plan Review Date | 06/05/1996 |
| Hot Work Review Date | 08/27/2003 |
| Contractor Safety Review Date | 10/31/2003 |
| Contractor Safety Eval. Date | 04/10/2004 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #2 : Phosgene/Chlorine, process NAICS code #1 : 325199, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 64933 |
| 64934 |
| 64935 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 49269 |
| Process Description | Methomyl |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 330,000 |
| Flammable Amount Total (lbs) | 0 |
| Process Amount Total (lbs) | 330,000 |
| Number of Process Chemicals | 2 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 1 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #3 : Methomyl, process chemical #1) |
| Process Chemical Record ID | 64936 |
| Process Chemical ID | Methyl isocyanate [Methane, isocyanato-] |
| CAS number | 000624839 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 40,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 64937 |
| Process Chemical ID | Methyl mercaptan [Methanethiol] |
| CAS number | 000074931 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 290,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 564936 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #3 : Methomyl, process chemical #4) |
| Process Chemical Record ID | 564937 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 38092 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process NAICS
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #3 : Methomyl, process NAICS code #1 : 32532) |
| Process NAICS ID | 50395 |
| NAICS Code | 32532: Pesticide and Other Agricultural Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
| Prevention Program ID | 28241 |
| Safety Info Review Date | 06/14/2001 |
| PHA Update Date | 12/08/1999 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | LOPA-type risk assessment |
| PHA Change Completion Date | 12/31/2001 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | No |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | No |
| Hazard Identified - Flood | No |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | Yes |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | No |
| Mitigation Systems - Neutralization | No |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) |
| Procedure Review Date | 09/11/2003 |
| Training Review Date | 05/03/2004 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Type of Training - Other | Computer-based |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 12/22/2003 |
| Maintenance Inspection Date | 05/24/2004 |
| Equipment Tested | MSS Vent Condenser |
| Management of Change Most Recent Date | 06/10/2004 |
| Management of Change Review Date | 09/10/2002 |
| Pre-startup Review Date | 06/10/2004 |
| Compliance Audit Date | 06/14/2001 |
| Compliance Audit Change Completion Date | 12/31/2004 |
| Incident Investigation Date | 02/05/2003 |
| Incident Invest. Change Completion Date | 02/28/2003 |
| Participation Plan Review Date | 06/05/1996 |
| Hot Work Review Date | 08/27/2003 |
| Contractor Safety Review Date | 10/31/2003 |
| Contractor Safety Eval. Date | 10/03/2003 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #3 : Methomyl, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 64936 |
| 64937 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 49270 |
| Process Description | Rhodimet AT-88 |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 1,400,000 |
| Flammable Amount Total (lbs) | 0 |
| Process Amount Total (lbs) | 1,400,000 |
| Number of Process Chemicals | 1 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 1 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #4 : Rhodimet AT-88, process chemical #1) |
| Process Chemical Record ID | 64938 |
| Process Chemical ID | Ammonia (anhydrous) |
| CAS number | 007664417 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 1,400,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 564938 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 38093 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process NAICS
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #4 : Rhodimet AT-88, process NAICS code #1 : 32532) |
| Process NAICS ID | 50396 |
| NAICS Code | 32532: Pesticide and Other Agricultural Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
| Prevention Program ID | 28242 |
| Safety Info Review Date | 01/28/2004 |
| PHA Update Date | 01/28/2004 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | LOPA-type risk assessment |
| PHA Change Completion Date | 07/28/2005 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | Yes |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | No |
| Hazard Identified - Flood | No |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | No |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | No |
| Mitigation Systems - Neutralization | No |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) |
| Procedure Review Date | 06/11/2004 |
| Training Review Date | 08/01/1999 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Type of Training - Other | Computer-based |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 12/22/2003 |
| Maintenance Inspection Date | 06/08/2004 |
| Equipment Tested | 1210 Acid Tank |
| Management of Change Most Recent Date | 04/19/2004 |
| Management of Change Review Date | 09/10/2002 |
| Pre-startup Review Date | 06/14/2004 |
| Compliance Audit Date | 12/17/2002 |
| Compliance Audit Change Completion Date | 12/31/2004 |
| Incident Investigation Date | 03/27/2003 |
| Incident Invest. Change Completion Date | 07/01/2003 |
| Participation Plan Review Date | 06/05/1996 |
| Hot Work Review Date | 08/27/2003 |
| Contractor Safety Review Date | 10/31/2003 |
| Contractor Safety Eval. Date | 03/26/2004 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #4 : Rhodimet AT-88, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 64938 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 49271 |
| Process Description | Aldicarb |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 0 |
| Flammable Amount Total (lbs) | 32,000 |
| Process Amount Total (lbs) | 32,000 |
| Number of Process Chemicals | 1 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 0 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #5 : Aldicarb, process chemical #1) |
| Process Chemical Record ID | 64939 |
| Process Chemical ID | Trimethylamine [Methanamine, N,N-dimethyl-] |
| CAS number | 000075503 |
| Chemical Type | Flammable |
| Process Chemical Amount (lbs) | 32,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 564939 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Process NAICS
|
| Process NAICS ID | 50397 |
| NAICS Code | 32532: Pesticide and Other Agricultural Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #5 : Aldicarb, process NAICS code #1 : 32532, prev. program 3 #1) |
| Prevention Program ID | 28243 |
| Safety Info Review Date | 04/10/2003 |
| PHA Update Date | 04/10/2003 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | LOPA-type risk assessment |
| PHA Change Completion Date | 10/10/2004 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | No |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | No |
| Hazard Identified - Flood | No |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | No |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | No |
| Mitigation Systems - Neutralization | No |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | No |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | Yes |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) |
| Procedure Review Date | 06/09/2004 |
| Training Review Date | 10/06/2003 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Type of Training - Other | Computer-based |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 12/22/2003 |
| Maintenance Inspection Date | 02/16/2004 |
| Equipment Tested | Tempered Water Tank |
| Management of Change Most Recent Date | 02/21/2004 |
| Management of Change Review Date | 09/10/2002 |
| Pre-startup Review Date | 02/17/2004 |
| Compliance Audit Date | 06/14/2001 |
| Compliance Audit Change Completion Date | 12/31/2004 |
| Participation Plan Review Date | 06/05/1996 |
| Hot Work Review Date | 08/27/2003 |
| Contractor Safety Review Date | 10/31/2003 |
| Contractor Safety Eval. Date | 03/29/2004 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, process #5 : Aldicarb, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 64939 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Accidents
|
| Accident ID | 5525 |
| Accident Date | 10/15/1999 |
| Accident Time | 2050 |
| Number of Chemicals | 1 |
| Flammable Amount Total (lbs) | 0 |
| Toxic Amount Total (lbs) | 15 |
| Released Amount Total (lbs) | 15 |
| Number of Deaths | 0 |
| Number of Injuries | 1 |
| Number Evacuated / Sheltered | 11,000 |
| Total Property Damage | $0 |
| Environmental Damage | No |
| NAICS of Process Involved | 325199: All Other Basic Organic Chemical Manufacturing |
| Release Duration (HHHMM) | 00008 |
| Release Event - Gas Release | Yes |
| Release Event - Spill | No |
| Release Event - Fire | No |
| Release Event - Explosion | No |
| Release Event - Reaction | No |
| Release Source - Storage Vessel | No |
| Release Source - Piping | No |
| Release Source - Process Vessel | Yes |
| Release Source - Transfer Hose | No |
| Release Source - Valve | No |
| Release Source - Pump | No |
| Release Source - Joint | No |
| Wind Speed | 0 |
| Wind Speed Units | miles/h |
| Temperature | 61 |
| Atmospheric Stability Class | F |
| Precipitation | No |
| Unknown Weather | No |
| Workers Killed | 0 |
| Responders Killed | 0 |
| Public Killed (on-site) | 0 |
| Workers Injured | 1 |
| Responders Injured | 0 |
| Public Injured (on-site) | 0 |
| Property Damage (on-site) | $0 |
| Off-site Deaths | 0 |
| Hospitalizations | 0 |
| Number Requiring Medical Treatment | 0 |
| Number Evacuated | 0 |
| Number Sheltered In Place | 11,000 |
| Property damage (off-site) | $0 |
| Environmental Damage - Fish/Animal Kills | No |
| Environmental Damage - Defoliation | No |
| Environmental Damage - Water Contamination | No |
| Environmental Damage - Soil Contamination | No |
| Initiating Event | Equipment Failure |
| Contributing Factor - Equipment Failure | No |
| Contributing Factor - Human Error | No |
| Contributing Factor - Improper Procedure | Yes |
| Contributing Factor - Overpressurization | No |
| Contributing Factor - Upset Condition | Yes |
| Contributing Factor - By-pass Condition | No |
| Contributing Factor - Maintenance | No |
| Contributing Factor - Process Design | No |
| Contributing Factor - Unsuitable Equipment | No |
| Contributing Factor - Unusual Weather | No |
| Contributing Factor - Management Error | No |
| Off-site Responders Notified | Notified Only |
| Changes Introduced - Improved Equipment | Yes |
| Changes Introduced - Revised Maintenance | Yes |
| Changes Introduced - Revised Training | Yes |
| Changes Introduced - Operating Procedures | Yes |
| Changes Introduced - Process Control | Yes |
| Changes Introduced - Mitigation Systems | Yes |
| Changes Introduced - Response Plan | No |
| Changes Introduced - Changed Process | No |
| Changes Introduced - Reduced Inventory | No |
| Changes Introduced - None | No |
| Confidential Business Information | No |
| Accident Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, accident #1, accident chemical #1) |
| Accident Chemical Record ID | 5957 |
| Chemical ID | Phosgene [Carbonic dichloride] |
| CAS number | 000075445 |
| Chemical Type | Toxic |
| Amount Released (lbs) | 15 |
| Percent Weight (Within Mixture) | 100 |
| Number of Flammable Components | 0 |
| Accidents
|
| Accident ID | 5526 |
| Accident Date | 05/22/2000 |
| Accident Time | 0800 |
| Number of Chemicals | 1 |
| Flammable Amount Total (lbs) | 0 |
| Toxic Amount Total (lbs) | 1 |
| Released Amount Total (lbs) | 1 |
| Number of Deaths | 0 |
| Number of Injuries | 1 |
| Number Evacuated / Sheltered | 0 |
| Total Property Damage | $0 |
| Environmental Damage | No |
| NAICS of Process Involved | 325199: All Other Basic Organic Chemical Manufacturing |
| Release Duration (HHHMM) | 00020 |
| Release Event - Gas Release | Yes |
| Release Event - Spill | No |
| Release Event - Fire | No |
| Release Event - Explosion | No |
| Release Event - Reaction | No |
| Release Source - Storage Vessel | No |
| Release Source - Piping | No |
| Release Source - Process Vessel | No |
| Release Source - Transfer Hose | No |
| Release Source - Valve | Yes |
| Release Source - Pump | No |
| Release Source - Joint | No |
| Wind Speed | 6 |
| Wind Speed Units | miles/h |
| Temperature | 63 |
| Atmospheric Stability Class | B |
| Precipitation | No |
| Unknown Weather | No |
| Workers Killed | 0 |
| Responders Killed | 0 |
| Public Killed (on-site) | 0 |
| Workers Injured | 1 |
| Responders Injured | 0 |
| Public Injured (on-site) | 0 |
| Property Damage (on-site) | $0 |
| Off-site Deaths | 0 |
| Hospitalizations | 0 |
| Number Requiring Medical Treatment | 0 |
| Number Evacuated | 0 |
| Number Sheltered In Place | 0 |
| Property damage (off-site) | $0 |
| Environmental Damage - Fish/Animal Kills | No |
| Environmental Damage - Defoliation | No |
| Environmental Damage - Water Contamination | No |
| Environmental Damage - Soil Contamination | No |
| Initiating Event | Equipment Failure |
| Contributing Factor - Equipment Failure | No |
| Contributing Factor - Human Error | No |
| Contributing Factor - Improper Procedure | Yes |
| Contributing Factor - Overpressurization | No |
| Contributing Factor - Upset Condition | No |
| Contributing Factor - By-pass Condition | No |
| Contributing Factor - Maintenance | No |
| Contributing Factor - Process Design | No |
| Contributing Factor - Unsuitable Equipment | No |
| Contributing Factor - Unusual Weather | No |
| Contributing Factor - Management Error | No |
| Off-site Responders Notified | No, not notified |
| Changes Introduced - Improved Equipment | Yes |
| Changes Introduced - Revised Maintenance | Yes |
| Changes Introduced - Revised Training | Yes |
| Changes Introduced - Operating Procedures | Yes |
| Changes Introduced - Process Control | No |
| Changes Introduced - Mitigation Systems | No |
| Changes Introduced - Response Plan | No |
| Changes Introduced - Changed Process | No |
| Changes Introduced - Reduced Inventory | No |
| Changes Introduced - None | No |
| Confidential Business Information | No |
| Accident Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, accident #2, accident chemical #1) |
| Accident Chemical Record ID | 5958 |
| Chemical ID | Chlorine |
| CAS number | 007782505 |
| Chemical Type | Toxic |
| Amount Released (lbs) | 1 |
| Percent Weight (Within Mixture) | 100 |
| Number of Flammable Components | 0 |
| Accidents
|
| Accident ID | 5527 |
| Accident Date | 08/13/2001 |
| Accident Time | 0843 |
| Number of Chemicals | 1 |
| Flammable Amount Total (lbs) | 0 |
| Toxic Amount Total (lbs) | 3,000 |
| Released Amount Total (lbs) | 3,000 |
| Number of Deaths | 0 |
| Number of Injuries | 8 |
| Number Evacuated / Sheltered | 0 |
| Total Property Damage | $0 |
| Environmental Damage | No |
| NAICS of Process Involved | 325199: All Other Basic Organic Chemical Manufacturing |
| Release Duration (HHHMM) | 00026 |
| Release Event - Gas Release | No |
| Release Event - Spill | Yes |
| Release Event - Fire | No |
| Release Event - Explosion | No |
| Release Event - Reaction | No |
| Release Source - Storage Vessel | No |
| Release Source - Piping | No |
| Release Source - Process Vessel | No |
| Release Source - Transfer Hose | No |
| Release Source - Valve | No |
| Release Source - Pump | No |
| Release Source - Joint | Yes |
| Wind Speed | 3 |
| Wind Speed Units | miles/h |
| Temperature | 73 |
| Atmospheric Stability Class | B |
| Precipitation | Yes |
| Unknown Weather | No |
| Workers Killed | 0 |
| Responders Killed | 0 |
| Public Killed (on-site) | 0 |
| Workers Injured | 8 |
| Responders Injured | 0 |
| Public Injured (on-site) | 0 |
| Property Damage (on-site) | $0 |
| Off-site Deaths | 0 |
| Hospitalizations | 0 |
| Number Requiring Medical Treatment | 0 |
| Number Evacuated | 0 |
| Number Sheltered In Place | 0 |
| Property damage (off-site) | $0 |
| Environmental Damage - Fish/Animal Kills | No |
| Environmental Damage - Defoliation | No |
| Environmental Damage - Water Contamination | No |
| Environmental Damage - Soil Contamination | No |
| Initiating Event | Human Error |
| Contributing Factor - Equipment Failure | No |
| Contributing Factor - Human Error | Yes |
| Contributing Factor - Improper Procedure | No |
| Contributing Factor - Overpressurization | No |
| Contributing Factor - Upset Condition | No |
| Contributing Factor - By-pass Condition | No |
| Contributing Factor - Maintenance | No |
| Contributing Factor - Process Design | No |
| Contributing Factor - Unsuitable Equipment | No |
| Contributing Factor - Unusual Weather | No |
| Contributing Factor - Management Error | No |
| Off-site Responders Notified | Notified Only |
| Changes Introduced - Improved Equipment | No |
| Changes Introduced - Revised Maintenance | No |
| Changes Introduced - Revised Training | Yes |
| Changes Introduced - Operating Procedures | Yes |
| Changes Introduced - Process Control | No |
| Changes Introduced - Mitigation Systems | No |
| Changes Introduced - Response Plan | No |
| Changes Introduced - Changed Process | No |
| Changes Introduced - Reduced Inventory | No |
| Changes Introduced - None | No |
| Confidential Business Information | No |
| Accident Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #2 : 2004-06-21, accident #3, accident chemical #1) |
| Accident Chemical Record ID | 5959 |
| Chemical ID | Chloroform [Methane, trichloro-] |
| CAS number | 000067663 |
| Chemical Type | Toxic |
| Amount Released (lbs) | 3,000 |
| Percent Weight (Within Mixture) | 100 |
| Number of Flammable Components | 0 |
| Emergency Response Plan Info
|
| Facility In Community Plan | Yes |
| Facility Own Response Plan | Yes |
| Specific Facility Response Plan | Yes |
| Inform. Procedures in Response Plan | Yes |
| Emergency Care in Response Plan | Yes |
| Plan Review Date | 04/29/2004 |
| Response Training Date | 03/26/2004 |
| Local Response Agency | Kanawha Putnam LEPC |
| Local Response Agency Phone | 3047441838 |
| Subject To - OSHA EAP | Yes |
| Subject To - OSHA HAZWOPER | Yes |
| Subject To - CWA | Yes |
| Subject To - RCRA | Yes |
| Subject To - OPA | Yes |
| Subject To - State EPCRA | No |
| Submission Info
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21) |
| RMP ID | 18892 |
| Submission Type | first submission for facility |
| Receipt Date | 06/21/1999 |
| Process Toxic Amount Total (lbs) | 2,143,000 |
| Process Flammable Amount Total (lbs) | 318,000 |
| Process Amount Total (lbs) | 2,461,000 |
| Number of Potential Offsite Consequence Processes | 4 |
| Potential Offsite Consequence Toxic Amount Total (lbs) | 2,143,000 |
| Potential Offsite Consequence Flammable Amount Total (lbs) | 318,000 |
| Potential Offsite Consequence Amount Total (lbs) | 2,461,000 |
| Submission - Basic Facility Info
|
| Facility Name | Rhone Poulenc Institute Plant |
| Street Address Line 1 | Route 25 at I-64 |
| City | Institute |
| State | WV |
| Zip Code | 25112 |
| County FIPS Code | 54039 |
| County | Kanawha County |
| Parent Company | Rhone Poulenc Ag Company Inc. |
| Executive Summary
|
(Facility #1 : Bayer CropScience - Institute , executive summary: all) |
| Executive Summary | ||
ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES The Institute Plant has release prevention and emergency response policies and procedures in place in order to prevent and reduce the potential for releases from the Institute facility. Written procedures are maintained and are followed by Institute personnel. Release-reporting procedures are contained in Institutes manufacturing process units which prescribe immediate and follow-up reporting to federal, state, and local authorities, including the United States Environmental Protection Agency (USEPA), the U.S. Coast Guard, the West Virginia Division of Environmental Protection (WVDEP), the state and local emergency planning centers (EPCs), local fire and police departments, water departments, local residents, schools, hospitals and other interested parties. The plant maintains an emergency response team with appropriate training and equipment to respond to releases of toxic or flammable materials inside the plant. The plant also has mutual-aid agreements with local fire departments for response to various emergencies including chemical releases. Finally, the plant is subject to OSHA process safety management regulations to prevent potential releases inside the plant and the RMP program to help control or prevent releases which may affect off-site human health or the environment. FACILITY DESCRIPTION AND REGULATED SUBSTANCES HANDLED The Institute Plant is located eight miles west of Charleston, WV on the north bank of the Kanawha River. The site has a total area of 460 acres, which is owned by Rhone-Poulenc. Portions of the site are leased to Union Carbide, Lyondell, and Reagent Chemical Company. Rhone-Poulenc has two business entities that are supported by this plant. They are Rhone Poulenc Ag Company (agricultural chemicals) and RP Animal Nutrition (RHODIMET AT-88). Rhone-Poulenc also provides personnel to operate and maintain the Union Carbide and Lyondell chemical facilities. Reagent o perates their own facility inside the plant. Rhone-Poulenc has four production process at this site that are covered by the RMP rule. Three of those process, methyl isocyanate, methomyl, and aldicarb support the Rhone-Poulenc (agricultural chemicals) business. The forth one, RHODIMET, supports the RP Animal Nutrition business. The methomyl and aldicarb facilities both produce a solid crystalline material that is used as an insect control agent. Both of these facilities use methyl isocyanate, produced by the Methyl Isocyanate Unit, as one of the principle raw materials. In addition to methyl isocyanate, the methomyl facility uses acetaldoxime, chlorine and methyl mercaptan as raw materials. The aldicarb facility also uses aldicarb oxime and trimethylamine as raw materials. The methyl isocyanate is produced from natural gas and chlorine with phosgene being produced as an intermediate. The RHODIMET AT-88 facility produces methionine hydroxy analog that is used in poultry feed supplies. Raw materials for this process include ammonia, sulfuric acid, natural gas, and methylthiopropionaldehyde. WORST-CASE TOXIC RELEASE SCENARIO The worst-case toxic release scenario involves methyl isocyanate and presumes the sudden loss of the entire contents of the double-walled stainless steel underground storage tank to the surface of the ground, when completely full, releasing 200,000 lbs. over a 10-minute period. The release duration is reported as 17.4 minutes since that is the time required for the liquid pool that is formed to evaporate and release the material to the air. No credit was taken for the passive mitigation that would occur, even with complete failure of both walls of the tank, by the earth that surrounds the tank. This scenario will have an off-site impact. There are many factors that make this scenario very unlikely. Some of the more significant are: 1) an emergency dump tank that is available for the safe transfer and containment of material from a leaking tank, 2) a process scrubber and a flare which are both capable of safely destroying all the methyl isocyanate from any storage tank, 3) in addition to containing the contents of the tank, the tank is also protected from external forces by the surrounding earth, and 4) the tank is monitored by redundant devices that continuously measure the tank pressure, temperature, and level. WORST-CASE FLAMMABLE RELEASE SCENARIO The worst-case flammable release scenario involves monomethylamine and presumes the sudden loss and ignition of the entire contents of a rail car (160,000 lbs.) over a 10-minute period. This scenario will have an off-site impact. There are many factors that make this scenario very unlikely. The most significant is that rail cars are designed and manufactured according to DOT standards (impact resistant and bullet proof) that meet or exceed American Society of Mechanical Engineering (ASME) standards. ALTERNATE TOXIC METHYL MERCAPTAN RELEASE SCENARIO The alternate toxic release scenario for methyl mercaptan presumes the loss of 151,000 lbs. over a 45-minute period through a failed unloading hose while transferring from the rail car to the storage tanks. No credit was taken for active or passive mitigation measures that include: 1) operation of the tank car excess flow shut-off valve, 2) at least one trained employee is present during the entire unloading process to monitor for leaks and take corrective action, 3) tank car chocks, hand brakes, and derails are set to prevent tank car motion, 4) hoses are fabricated of rugged (braided stainless steel) construction with a burst pressure that is 12 times the normal operating pressure, and 5) new hoses are hydro tested prior to service and replaced annually to guard against catastrophic hose failure. This scenario will have an off-site impact. ALTERNATE TOXIC CHLOROFORM RELEASE SCENARIO The alternate toxic release scenario for chloroform presumes the loss of 180,000 lbs. over a 41-minute peri od through a failed unloading hose while transferring from the rail car to the storage tanks. No credit was taken for active or passive mitigation measures that include: 1) the tank car unloading area has slopped drainage to the process sewer, 2) at least one trained employee is present during the entire unloading process to monitor for leaks and take corrective action, 3) tank car chocks, hand brakes and derails are set to prevent tank car motion, 4) hoses are fabricated of rugged (braided stainless steel) construction with a burst pressure that is 12 times the normal operating pressure, and 5) new hoses are hydro tested prior to service and replaced annually to guard against catastrophic hose failure. This scenario will have an off-site impact. ALTERNATE TOXIC PHOSGENE RELEASE SCENARIO The alternate toxic release scenario for phosgene presumes the loss of 114 lbs. over a 45-minute period through a 0.8 mm hole in a metal gasket. A few of the many design and operating practices that are used to minimize the possibility and extent of leaks are: 1) strictly enforced inventory limits to limit the actual amount of material stored on site, 2) double-walled valves and pipelines for liquid service that are equipped with leak detection to provide secondary containment, 3) automatic isolation valves to prevent and minimize the extent of a leak should one occur, 4) a leak detection and repair (LDAR) program that identifies and repairs leaks while they are very small, and 5) periodic testing and inspections for tanks, columns, heat exchangers, pumps, instruments, and pipes to evaluate their integrity. This scenario will have an off-site impact. ALTERNATE TOXIC METHYL ISOCYANATE RELEASE SCENARIO The alternate toxic release scenario for methyl Isocyanate presumes the loss of 118 lbs. over a 45-minute period through a 0.8 mm hole in a metal gasket. A few of the many design and operating practices used to minimize the possibility and extent of leaks are: 1) double-wall ed pipelines for liquid service that are equipped with leak detection to provide secondary containment on critical transfer lines, 2) extensive use of all welded pipe to minimize the number of flange joints, 3) automatic isolation valves that are strategically installed to prevent and minimize the extent of a leak should one occur, 4) a leak detection and repair (LDAR) program that identifies and repairs leaks while they are very small, and 5) periodic testing and inspections for tanks, columns, heat exchangers, pumps, instruments, and pipes to evaluate their integrity. This scenario will have an off-site impact. ALTERNATE TOXIC AMMONIA RELEASE SCENARIO The alternate toxic release scenario for ammonia presumes the loss of 160,000 lbs. over a 48-minute period through a failed unloading hose while transferring from the rail car to the storage tanks. A pool of liquid on the ground vaporizes and airborne vapors reach an ignition source and explode. No credit was taken for active or passive mitigation measures that include: 1) operation of the tank car excess flow shut-off valve, 2) at least one trained employee is present during the entire unloading process to monitor for leaks and take corrective action, 3) tank car chocks, hand brakes and derails are set to prevent tank car motion, 4) hoses are fabricated of rugged (braided stainless steel) construction with a burst pressure that is 12 times the normal operating pressure, and 5) new hoses are hydro tested prior to service and replaced annually to guard against catastrophic hose failure. This scenario will have an off-site impact. ALTERNATE TOXIC CHLORINE RELEASE SCENARIO The alternate toxic release scenario for chlorine presumes the loss of 164 lbs. over a 45-minute period through a 0.8 mm hole in a metal gasket. A few of the many design and operating practices that are used to minimize the possibility and extent of leaks are: 1) extensive use of all welded pipe to minimize the number of flange joints, 2) a utomatic isolation valves that are strategically installed to prevent and minimize the extent of a leak should one occur, 3) a leak detection and repair (LDAR) program that identifies and repairs leaks while they are very small, and 4) periodic testing and inspections for tanks, columns, heat exchangers, pumps, instruments and pipes to evaluate their integrity. This scenario will not have an off-site impact. ALTERNATE FLAMMABLE MONOMETHYLAMINE RELEASE SCENARIO The alternate flammable release scenario involves monomethylamine and presumes the loss of 160,000 lbs. over a 48-minute period through a failed unloading hose while transferring from the rail car to the storage tanks. A pool of liquid on the ground vaporizes and air-borne vapors reach an ignition source and explode. No credit was taken for active or passive mitigation measures that include: 1) operation of the tank car excess flow shut-off valve, 2) at least one trained employee is present during the entire unloading process to monitor for leaks and take corrective action, 3) tank car chocks, hand brakes and derails are set to prevent tank car motion, 4) hoses are fabricated of rugged (braided stainless steel) construction with a burst pressure that is 12 times the normal operating pressure, and 5) new hoses are hydro tested prior to service and replaced annually to guard against catastrophic hose failure. This scenario will have an off-site impact. FIVE-YEAR ACCIDENT HISTORY There has not been an accident or incident that has met the RMP reporting criteria in any of the Institute Plant Rhone-Poulenc RMP-covered processes during the last five years. EMERGENCY RESPONSE PROGRAM The Institute Plant maintains a highly trained emergency response team to handle fires, explosions, toxic vapor releases, medical, chemical spills, and natural disasters and rescue emergencies. It also participates in local fire and industrial mutual aid systems. The Institute Plant has a dedicated in-plant Emergency Opera tions Center, trained incident commanders, and trained and state-certified emergency squad on site at all times. Additionally, a plant-wide notification system is in place in the event of an emergency. The plant has an on site dispensary and doctor as well as full-coverage with Emergency Medical Technicians (EMTs) and paramedics. CHANGES TO IMPROVE SAFETY There are many operating and mechanical changes that continuously occur to improve the safe operation of the Rhone-Poulenc facilities. These occur as a result of the on going process hazard assessment review Process. |
| Submission - Other Facility Info
|
| Owner or Operator Name | Rhone Poulenc Ag Company Inc. |
| Owner or Operator Address Line 1 | P.O. Box 2831 |
| Owner or Operator City | Charleston |
| Owner or Operator State | WV |
| Owner or Operator Zip | 25330 |
| Parent Dun and Bradstreet Number | 1350263 |
| Second Parent Dun and Bradstreet Number | 0 |
| Number of Full Time Employees | 997 |
| Number of FTE CBI Flag | No |
| Other Facility ID | 25112RHNPLROUTE |
| Covered by OSHA PSM Standard | Yes |
| Covered by EPCRA Section 302 | Yes |
| Covered by CAA Title V | Yes |
| CAA Title V Air Operating Permit ID | Pending from WV |
| Last Safety Inspection Date | 02/01/1995 |
| Last Safety Inspection By | OSHA |
| OSHA Star or Merit Ranking | No |
| LEPC Name | Kanawha Putnam LEPC |
| Submission - Contact Info
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21) |
| Owner or Operator Phone | 3047676000 |
| Facility Phone | 3047676202 |
| Facility Dun and Bradstreet Number | 157627886 |
| RMP Contact | Patrick Ragan |
| RMP Contact Title | HSE Manager |
| Submission - Additional Info
|
| RMP Complete Flag | Yes |
| Predictive Filing | No |
| No RMP Accidents Last 5 Years | Yes |
| Complete Check Date | 11/24/1999 |
| Graphics Indicator | No |
| Attachment Indicator | No |
| Certification Received Flag | Yes |
| Submission Method | RMP*Submit |
| CBI Substantiation Flag | No |
| Electronic Waiver Flag | No |
| Postmark Date | 06/18/1999 |
| Anniversary Date | 06/18/2004 |
| Confidential Business Information | No |
| Unsanitized Version Provided | No |
| Software Version Number | 1.1.7 |
| Submission - Lat/Long Info
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21) |
| Latitude | 38.385 |
| Longitude | -81.776333 |
| Valid Lat/Long | Yes |
| Lat/Long Method | GPS - Unspecified |
| Lat/Long Location Type | Plant Entrance (General) |
| FRS Latitude | 38.38 |
| FRS Longitude | -81.79 |
| FRS Lat/Long Description | FACILITY CENTROID |
| FRS Lat/Long Method | INTERPOLATION-MAP |
| Submission - Counts and Totals
|
| Number of RMP Accidents | 0 |
| Number of Processes | 4 |
| Number of Process Chemicals | 9 |
| Number of Toxic Worst-case Scenarios | 1 |
| Number of Toxic Alternate Case Scenarios | 6 |
| Number of Flammable Worst-case Scenarios | 1 |
| Number of Flammable Alternate Case Scenarios | 1 |
| RMP Accident Flammable Total (lbs) | 0 |
| RMP Accident Toxic Total (lbs) | 0 |
| RMP Accident Amount Total (lbs) | 0 |
| Total RMP Accident Deaths | 0 |
| Total RMP Accident Injuries | 0 |
| Total RMP Accident Evacuated/Sheltering In Place | 0 |
| Total RMP Accident Property Damage | $0 |
| Processes
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #1 : Methyl isocyanate) |
| Process ID | 26593 |
| Process Description | Methyl isocyanate |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 1,143,000 |
| Flammable Amount Total (lbs) | 290,000 |
| Process Amount Total (lbs) | 1,433,000 |
| Number of Process Chemicals | 5 |
| Number of Toxic Worst-Case Scenarios | 1 |
| Number of Toxic Alternate Scenarios | 3 |
| Number of Flammable Worst-Case Scenarios | 1 |
| Number of Flammable Alternate Scenarios | 1 |
| Process Chemicals
|
| Process Chemical Record ID | 34581 |
| Process Chemical ID | Methyl isocyanate [Methane, isocyanato-] |
| CAS number | 000624839 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 200,000 |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #1 : Methyl isocyanate, process chemical #2) |
| Process Chemical Record ID | 34582 |
| Process Chemical ID | Phosgene [Carbonic dichloride] |
| CAS number | 000075445 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 13,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 34583 |
| Process Chemical ID | Chloroform [Methane, trichloro-] |
| CAS number | 000067663 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 460,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 34584 |
| Process Chemical ID | Chlorine |
| CAS number | 007782505 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 470,000 |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #1 : Methyl isocyanate, process chemical #5) |
| Process Chemical Record ID | 34585 |
| Process Chemical ID | Methylamine [Methanamine] |
| CAS number | 000074895 |
| Chemical Type | Flammable |
| Process Chemical Amount (lbs) | 290,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 534581 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Worst-Case Toxic Scenarios
|
| Toxic Scenario ID | 17576 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Liquid |
| Model Used | EPA's RMP*Comp(TM) |
| Release Duration (minutes) | 17.4 |
| Wind Speed (meters/sec) | 1.5 |
| Atmospheric Stability Class | F |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #1 : Methyl isocyanate, process chemical #7) |
| Process Chemical Record ID | 534582 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 20421 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #1 : Methyl isocyanate, process chemical #8) |
| Process Chemical Record ID | 534583 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 20422 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Liquid |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #1 : Methyl isocyanate, process chemical #9) |
| Process Chemical Record ID | 534584 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 20423 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #1 : Methyl isocyanate, process chemical #10) |
| Process Chemical Record ID | 534585 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Worst-Case Flammable Scenarios
|
| Flammable Scenario ID | 4566 |
| Model Used | EPA's RMP*Comp(TM) |
| Passive Mitigation - Blast Walls | No |
| Confidential Business Information | No |
| Alternate Case Flammable Scenarios
|
| Flammable Scenario ID | 3557 |
| Model Used | EPA's RMP*Comp(TM) |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Fire Walls | No |
| Passive Mitigation - Blast Walls | No |
| Passive Mitigation - Enclosures | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Excess Flow Valves | No |
| Confidential Business Information | No |
| Process NAICS
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #1 : Methyl isocyanate, process NAICS code #1 : 32532) |
| Process NAICS ID | 27275 |
| NAICS Code | 32532: Pesticide and Other Agricultural Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
| Prevention Program ID | 14633 |
| Safety Info Review Date | 03/05/1999 |
| PHA Update Date | 03/05/1999 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Change Completion Date | 03/31/2001 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | Yes |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | Yes |
| Hazard Identified - Flood | Yes |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | Yes |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | Yes |
| Mitigation Systems - Neutralization | Yes |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) is in the process of being developed |
| Procedure Review Date | 05/11/1999 |
| Training Review Date | 04/30/1998 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 02/04/1998 |
| Maintenance Inspection Date | 05/10/1999 |
| Equipment Tested | Pumps - Unit Wide Inspection |
| Management of Change Most Recent Date | 05/11/1999 |
| Management of Change Review Date | 12/10/1996 |
| Pre-startup Review Date | 01/20/1999 |
| Compliance Audit Date | 10/13/1998 |
| Compliance Audit Change Completion Date | 10/13/1998 |
| Incident Investigation Date | 04/27/1999 |
| Incident Invest. Change Completion Date | 07/31/1999 |
| Participation Plan Review Date | 06/05/1996 |
| Hot Work Review Date | 08/28/1997 |
| Contractor Safety Review Date | 08/28/1997 |
| Contractor Safety Eval. Date | 01/21/1999 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #1 : Methyl isocyanate, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 34581 |
| 34582 |
| 34583 |
| 34584 |
| 34585 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 26594 |
| Process Description | Methomyl |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 330,000 |
| Flammable Amount Total (lbs) | 0 |
| Process Amount Total (lbs) | 330,000 |
| Number of Process Chemicals | 2 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 2 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #2 : Methomyl, process chemical #1) |
| Process Chemical Record ID | 34586 |
| Process Chemical ID | Methyl mercaptan [Methanethiol] |
| CAS number | 000074931 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 290,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 34587 |
| Process Chemical ID | Methyl isocyanate [Methane, isocyanato-] |
| CAS number | 000624839 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 40,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 534586 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #2 : Methomyl, process chemical #3, alternate toxic scenario #1) |
| Toxic Scenario ID | 20424 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #2 : Methomyl, process chemical #4) |
| Process Chemical Record ID | 534587 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 20425 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process NAICS
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #2 : Methomyl, process NAICS code #1 : 32532) |
| Process NAICS ID | 27276 |
| NAICS Code | 32532: Pesticide and Other Agricultural Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
| Prevention Program ID | 14634 |
| Safety Info Review Date | 10/02/1998 |
| PHA Update Date | 02/28/1995 |
| PHA Technique - What If | Yes |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Technique - Other | HAZOP was completed on 10/17/94 / Action items complete 12/9/96 |
| PHA Change Completion Date | 06/13/1997 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | Yes |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | Yes |
| Hazard Identified - Flood | Yes |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | Yes |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | Yes |
| Mitigation Systems - Neutralization | Yes |
| Mitigation Systems - None | No |
| Mitigation Systems - Other | Flare |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | Yes |
| Changes Since PHA - Process Controls | Yes |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Update Operating Procedures |
| Procedure Review Date | 04/14/1999 |
| Training Review Date | 11/20/1998 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 02/04/1998 |
| Maintenance Inspection Date | 05/10/1999 |
| Equipment Tested | Brine Stripper Rupture Disk RD 0460 |
| Management of Change Most Recent Date | 06/03/1999 |
| Management of Change Review Date | 12/10/1996 |
| Pre-startup Review Date | 12/18/1998 |
| Compliance Audit Date | 10/02/1998 |
| Compliance Audit Change Completion Date | 10/01/2001 |
| Incident Investigation Date | 03/23/1999 |
| Incident Invest. Change Completion Date | 12/31/1999 |
| Participation Plan Review Date | 06/05/1996 |
| Hot Work Review Date | 08/28/1997 |
| Contractor Safety Review Date | 08/28/1997 |
| Contractor Safety Eval. Date | 01/21/1999 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #2 : Methomyl, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 34586 |
| 34587 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 26595 |
| Process Description | Rhodimet AT-88 |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 670,000 |
| Flammable Amount Total (lbs) | 0 |
| Process Amount Total (lbs) | 670,000 |
| Number of Process Chemicals | 1 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 1 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #3 : Rhodimet AT-88, process chemical #1) |
| Process Chemical Record ID | 34588 |
| Process Chemical ID | Ammonia (anhydrous) |
| CAS number | 007664417 |
| Chemical Type | Toxic |
| Process Chemical Amount (lbs) | 670,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 534588 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Alternate Case Toxic Scenarios
|
| Toxic Scenario ID | 20426 |
| Percent Weight (Within Mixture) | 100 |
| Physical State | Gas liquified by pressure |
| Model Used | EPA's RMP*Comp(TM) |
| Wind Speed | 3 |
| Atmospheric Stability Class | D |
| Topography | Urban |
| Passive Mitigation - Dikes | No |
| Passive Mitigation - Enclosures | No |
| Passive Mitigation - Berms | No |
| Passive Mitigation - Drains | No |
| Passive Mitigation - Sumps | No |
| Active Mitigation - Sprinklers | No |
| Active Mitigation - Deluge Systems | No |
| Active Mitigation - Water Curtain | No |
| Active Mitigation - Neutralization | No |
| Active Mitigation - Excess Flow Valves | No |
| Active Mitigation - Flares | No |
| Active Mitigation - Scrubbers | No |
| Active Mitigation - Emergency Shutdown | No |
| Confidential Business Information | No |
| Process NAICS
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #3 : Rhodimet AT-88, process NAICS code #1 : 32532) |
| Process NAICS ID | 27277 |
| NAICS Code | 32532: Pesticide and Other Agricultural Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
| Prevention Program ID | 14635 |
| Safety Info Review Date | 05/01/1999 |
| PHA Update Date | 08/14/1998 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Change Completion Date | 12/31/2001 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | Yes |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | Yes |
| Hazard Identified - Flood | Yes |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | Yes |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | Yes |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | Yes |
| Mitigation Systems - Enclosure | No |
| Mitigation Systems - Neutralization | No |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | Yes |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | No |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | Yes |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Procedure Review Date | 04/01/1999 |
| Training Review Date | 08/01/1996 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 02/04/1998 |
| Maintenance Inspection Date | 06/03/1999 |
| Equipment Tested | Rotating Equipment Vibration Analysis - Unit wide inspection |
| Management of Change Most Recent Date | 05/26/1999 |
| Management of Change Review Date | 12/10/1996 |
| Pre-startup Review Date | 05/26/1999 |
| Compliance Audit Date | 05/01/1999 |
| Compliance Audit Change Completion Date | 06/01/2001 |
| Incident Investigation Date | 10/06/1998 |
| Incident Invest. Change Completion Date | 12/31/1998 |
| Participation Plan Review Date | 06/05/1996 |
| Hot Work Review Date | 08/28/1997 |
| Contractor Safety Review Date | 08/28/1997 |
| Contractor Safety Eval. Date | 01/21/1999 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #3 : Rhodimet AT-88, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 34588 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Processes
|
| Process ID | 26596 |
| Process Description | Aldicarb |
| Program Level | 3 |
| Confidential Business Information | No |
| Toxic Amount Total (lbs) | 0 |
| Flammable Amount Total (lbs) | 28,000 |
| Process Amount Total (lbs) | 28,000 |
| Number of Process Chemicals | 1 |
| Number of Toxic Worst-Case Scenarios | 0 |
| Number of Toxic Alternate Scenarios | 0 |
| Number of Flammable Worst-Case Scenarios | 0 |
| Number of Flammable Alternate Scenarios | 0 |
| Process Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #4 : Aldicarb, process chemical #1) |
| Process Chemical Record ID | 34589 |
| Process Chemical ID | Trimethylamine [Methanamine, N,N-dimethyl-] |
| CAS number | 000075503 |
| Chemical Type | Flammable |
| Process Chemical Amount (lbs) | 28,000 |
| Confidential Business Information | No |
| Process Chemicals
|
| Process Chemical Record ID | 534589 |
| Process Chemical ID | Public OCA Chemical |
| CAS number | 000000000 |
| Process Chemical Amount (lbs) | 0 |
| Confidential Business Information | No |
| Process NAICS
|
| Process NAICS ID | 27278 |
| NAICS Code | 32532: Pesticide and Other Agricultural Chemical Manufacturing |
| Number of Prevention Program 2 Records | 0 |
| Number of Prevention Program 3 Records | 1 |
| Prevention Program 3
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #4 : Aldicarb, process NAICS code #1 : 32532, prev. program 3 #1) |
| Prevention Program ID | 14636 |
| Safety Info Review Date | 02/12/1999 |
| PHA Update Date | 02/12/1999 |
| PHA Technique - What If | No |
| PHA Technique - Checklist | No |
| PHA Technique - What If/Checklist | No |
| PHA Technique - HAZOP | Yes |
| PHA Technique - FMEA | No |
| PHA Technique - FTA | No |
| PHA Change Completion Date | 02/12/2001 |
| Hazard Identified - Toxic Release | Yes |
| Hazard Identified - Fire | Yes |
| Hazard Identified - Explosion | Yes |
| Hazard Identified - Runaway Reaction | Yes |
| Hazard Identified - Polymerization | No |
| Hazard Identified - Overpressure | Yes |
| Hazard Identified - Corrosion | Yes |
| Hazard Identified - Overfilling | Yes |
| Hazard Identified - Contamination | Yes |
| Hazard Identified - Equipment Failure | Yes |
| Hazard Identified - Cooling Loss | Yes |
| Hazard Identified - Earthquake | Yes |
| Hazard Identified - Flood | Yes |
| Hazard Identified - Tornado | No |
| Hazard Identified - Hurricane | No |
| Process Controls - Vents | Yes |
| Process Controls - Relief Valves | Yes |
| Process Controls - Check Valves | Yes |
| Process Controls - Scrubbers | Yes |
| Process Controls - Flares | Yes |
| Process Controls - Manual Shutoffs | Yes |
| Process Controls - Auto Shutoffs | Yes |
| Process Controls - Interlocks | Yes |
| Process Controls - Alarms | Yes |
| Process Controls - Keyed Bypass | Yes |
| Process Controls - Emergency Air | Yes |
| Process Controls - Emergency Power | Yes |
| Process Controls - Backup Pump | Yes |
| Process Controls - Grounding | Yes |
| Process Controls - Inhibitor Addition | Yes |
| Process Controls - Rupture Disks | Yes |
| Process Controls - Excess Flow Devices | Yes |
| Process Controls - Quench System | Yes |
| Process Controls - Purge System | No |
| Process Controls - None | No |
| Mitigation Systems - Sprinklers | Yes |
| Mitigation Systems - Dikes | Yes |
| Mitigation Systems - Fire Walls | No |
| Mitigation Systems - Blast Walls | No |
| Mitigation Systems - Deluge Systems | Yes |
| Mitigation Systems - Water Curtains | No |
| Mitigation Systems - Enclosure | No |
| Mitigation Systems - Neutralization | Yes |
| Mitigation Systems - None | No |
| Monitoring Systems - Process Area | No |
| Monitoring Systems - Perimeter | No |
| Monitoring Systems - None | Yes |
| Changes Since PHA - Reduced Inventory | No |
| Changes Since PHA - Increased Inventory | No |
| Changes Since PHA - Process Parameters | No |
| Changes Since PHA - Process Controls | No |
| Changes Since PHA - Process Detection | No |
| Changes Since PHA - Perimeter Monitoring | No |
| Changes Since PHA - Mitigation Systems | No |
| Changes Since PHA - None Recommended | No |
| Changes Since PHA - None | No |
| Changes Since PHA - Other | Risk reduction plan (as a result of PHA) is in the process of being developed |
| Procedure Review Date | 02/08/1999 |
| Training Review Date | 01/12/1999 |
| Type of Training - Classroom | Yes |
| Type of Training - On the Job | Yes |
| Competency Testing - Written Tests | Yes |
| Competency Testing - Oral Tests | No |
| Competency Testing - Demonstration | Yes |
| Competency Testing - Observation | Yes |
| Maintenance Review Date | 02/04/1998 |
| Maintenance Inspection Date | 05/10/1999 |
| Equipment Tested | Pumps - Unit Wide Inspection |
| Management of Change Most Recent Date | 05/24/1999 |
| Management of Change Review Date | 12/10/1996 |
| Pre-startup Review Date | 02/11/1999 |
| Compliance Audit Date | 10/13/1998 |
| Compliance Audit Change Completion Date | 10/13/1998 |
| Incident Investigation Date | 04/27/1999 |
| Incident Invest. Change Completion Date | 04/27/1999 |
| Participation Plan Review Date | 06/05/1996 |
| Hot Work Review Date | 08/28/1997 |
| Contractor Safety Review Date | 08/28/1997 |
| Contractor Safety Eval. Date | 01/21/1999 |
| Confidential Business Information | No |
| Prevention Program 3 Chemicals
|
(Facility #1 : Bayer CropScience - Institute , RMP submission #3 : 1999-06-21, process #4 : Aldicarb, process NAICS code #1 : 32532, prev. program 3 #1, prev. program 3 chemical: all) |
| Process Chemical Record ID |
| 34589 |
| Prevention Program 3 Text
|
| Prevention Program Description |
| All elements of the prevention program are applied to the entire process |
| Emergency Response Plan Info
|
| Facility In Community Plan | Yes |
| Facility Own Response Plan | Yes |
| Specific Facility Response Plan | Yes |
| Inform. Procedures in Response Plan | Yes |
| Emergency Care in Response Plan | Yes |
| Plan Review Date | 02/28/1999 |
| Response Training Date | 06/18/1999 |
| Local Response Agency | Kanawha Putnam LEPC |
| Local Response Agency Phone | 3047441838 |
| Subject To - OSHA EAP | Yes |
| Subject To - OSHA HAZWOPER | Yes |
| Subject To - CWA | Yes |
| Subject To - RCRA | Yes |
| Subject To - OPA | Yes |
| Subject To - State EPCRA | Yes |
*END OF REPORT*
Your search failed because the database could not understand a search statement. This might happen because you typed odd characters into a search screen, or it might be a bug. If you want to report it, please send Email to dbadmin@rtknet.org.
/rmp/rmp.php
Error 1062 Line: 37
Duplicate entry '201007-rmp' for key 1
<br>
Query: insert into logs.logs_searches values ("/rmp/rmp.php", "data.rtknet.org", "CCBot/1.0 (+http://www.commoncrawl.org/bot.html)", "38.107.191.89", "reptype=a&database=rmp&facility_name=&operator_name=Bayer+CropScience&parent=&all_naics=32532&execsum=&city=Institute&county=&state=WV&zip=25112&detail=4&datype=T", 201007, 20100731121038, "rmp", "v20092", "5", "T", "4", "a", "1", "1")
--End--