Lender's Bagel Bakery - Mattoon Plant - Source

| Source | Accident History | Registration | Executive Summary | Chemicals | Emergency Response |

***** Risk Management Plan *****  
 
***** Section 1. Registration Information *****  
* Source Identification  
Facility Name:             Lender's Bagel Bakery - Mattoon Plant  
Parent Company #1 Name:    Kellogg Company  
Parent Company #2 Name:      
 
* Submission and Acceptance  
Submission Type:           First-time submission  
Description:               Mattoon Plant  
Receipt Date:              21-JUN-1999  
Postmark Date:             18-JUN-1999  
Next Due Date:             18-JUN-2004  
Completeness Check Date:   06-JUL-1999  
Complete RMP:              YES  
De-Registered Date:          
De-Registered Effective  
Date:                        
Certification Received:    YES  
 
* Facility Identification  
EPA Facility Identifier:   1000 0008 9959  
Other EPA Systems  
Facility ID:               61938KRFTNWESTS  
 
* Dun and Bradstreet Numbers (DUNS)  
Facility DUNS:             005356209  
Parent Company #1 DUNS:    005356209  
Parent Company #2 DUNS:      
 
* Facility Location Address  
Street 1:                  3801 DeWitt Ave  
Street 2:                    
City:                      Mattoon  
State:                     ILLINOIS  
ZIP:                       61938  
ZIP4:                        
County:                    COLES  
 
Facility Latitude and Longitude  
Lat. (dd mm ss.s):         39 29 25.0  
Long. (ddd mm ss.s):       -088 24 21.0  
Latitude (decimal):        39.490278  
Longitude (decimal):       -88.405833  
Lat/Long Method:           GPS - Unspecified  
Lat/Long Description:      Plant Entrance (General)  
 
* EPA Default Map Value Latitude/Longitude  
EPA Default Map Value  
Latitude (decimal):        39.490507  
EPA Default Map Value  
Longitude (decimal):       -88.40568  
EPA Default Map Value  
Lat/Long Method:           ADDRESS MATCHING-HOUSE NUMBER  
EPA Default Map Value  
Lat/Long Description:      PLANT ENTRANCE (GENERAL)  
 
* Owner or Operator  
Operator Name:             Kellogg Company  
Operator Phone:            (616) 961-2000  
 
Mailing Address  
Operator Street 1:         One Kellogg Square  
Operator Street 2:          
Operator City:             Battle Creek  
Operator State:            MICHIGAN  
Operator ZIP:              49016  
Operator ZIP4:              
Operator Foreign State  
or Province:                
Operator Foreign ZIP:        
Operator Foreign Country:    
 
* Name and title of person or position responsible for part 68 (RMP) implementation  
RMP name of person:        Gary J. Webster  
RMP Title of person or  
position:                  Technical Manager  
 
* Emergency Contact  
Emergency contact name:    Gary J. Webster  
Emergency contact title:   Technical Manager  
Emergency contact phone:   (217) 258-3210  
Emergency contact  
24-hour phone:             (217) 246-7494  
Emergency contact ext.  
or PIN:                      
 
* Other Points of Contact  
Facility or Parent  
Company E-mail Address:      
Facility Public Contact  
Phone:                     (800) 962-1413  
Facility or Parent  
Company WWW Homepage  
Address:                   www.kelloggs.com  
 
* Local Emergency Planning Committee  
LEPC:                      Coles County Sheriff's Depart.  
 
* Full Time Equivalent Employees  
Number of full time  
employees (FTE) on site:   294  
FTE Claimed as CBI:          
 
* Covered by  
OSHA PSM :                 YES  
EPCRA 302 :                YES  
CAA Title V:                  
Air Operating Permit ID:    
 
* OSHA Ranking  
OSHA Star or Merit  
Ranking:                      
 
* Last Safety Inspection  
Last Safety Inspection  
(by an External Agency)  
Date:                      08-APR-1999  
Last Safety Inspection  
Peformed by an External  
Agency:                    Fire Department  
 
* Predictive Filing  
Did this RMP involve  
predictive filing?:          
 
* Confidential Business Information (CBI)  
CBI Claimed:                  
Substantiation Provided:      
Unsanitized RMP Provided:    
 
* Reportable Accidents  
Reportable Accidents:      See Section 6. Accident History below to determine if there were any accidents reported for this RMP.  
 
***** Executive Summary *****  
 
Lender's Bagel Bakery manufactures a variety of bagels at our bakery in Mattoon.  We have produced bagels in Mattoon since 1986.  We have a strong commitment to operate our facility in a safe and responsible manner.    
 
Ammonia is used at our facility as the cooling medium in our refrigeration systems.  Similar to the function Freon plays in a home or car air conditioning system, ammonia is used to cool the air in our industrial freezers and product coolers.  The ammonia is contained in a closed loop system; it is designed to remain inside the piping and vessels in our facility.  We believe that ammonia provides the safest and most efficient cooling choice for our operation.  
 
 
A. Describe the Accident Release Prevention and Emergency Policies  
 
Lender's takes many precautions to prevent or minimize accidental releases of ammonia from the refrigeration systems.  These precautions include safety controls (alarms and automatic shutdown devices) which are designed to identify and prevent p  
otentially unsafe conditions like pressure increases that could cause a system failure.  We also have a preventive maintenance program designed to maintain the on-going integrity of the systems, a training program designed to ensure that the systems are operated by qualified personnel, and emergency response procedures which enable trained personnel to respond quickly to system upsets.  
 
The Technical Manager is responsible for the management of these ammonia safety programs.  
 
 
B.   Stationary Source and Regulated Substances Handled  
 
Lender's Bagel Bakery produces frozen bagels for sale to the public.  The facility operates two ammonia refrigeration systems, the north system and the south system.  The combined ammonia inventory for both systems is approximately 80,000 pounds.  Ammonia is the only substance covered by the Accidental Release Prevention Regulations handled at the Mattoon Plant.  
 
 
C.   Summary of Worst-Case and Alternative Release Scenarios  
 
EPA requires us to define the wo  
rst case release scenario from the Mattoon plant as the release of 20,000 pounds of ammonia aver a 10 minute period due to the failure of the high pressure receiver in the north refrigeration system. The 20,000 pounds represents the maximum amount of ammonia that would be contained in the receiver at any time.  We have written procedures in place to assure that this is so.  EPA also requires us to assume that the weather conditions are such that there is almost no wind and no mixing in the atmosphere.  
 
The alternative release scenario at the Mattoon Plant would involve the release of 13,500 pounds of ammonia over a 30-minute period due to the rupture of a 1/2" high pressure liquid line in the north refrigeration system.  The duration of the release was estimated for the alternative release scenario by estimating the amount of time required to stop the leak.  Again, EPA required us to estimate the impacts of this release under low wind and stable weather conditions.  
 
Both of these rele  
ases are unlikely for many reasons.  Our equipment and system were designed using industry standards for ammonia refrigeration.   We have taken precautions to protect our equipment from obvious threats, like vehicular traffic.   We have a preventive maintenance program to maintain the on-going integrity of the refrigeration equipment.  Training programs are in place to ensure that qualified personnel operate the systems, and our emergency response procedures allow us to respond quickly in the event of an accident.  
 
D.   Description of the Accidental Release Prevention Program  
 
The facility has an accident release prevention program that complies with Occupational Safety and Health Act's Process Safety Management Standard and EPA's Risk Management Program Regulation.  The prevention program consists of the following elements:  
 
- Employee Participation Program  
- Process Safety Information  
- Process Hazard Analysis  
-  Operating Procedures  
-  Training Program  
- Contractor Safety Progra  
m  
-  Pre-Startup Safety Review Procedures  
- Mechanical Integrity Program  
-  Hot Work Permit Procedures  
- Management of Change Procedures  
- Incident Investigation Procedures  
- Compliance Audit Procedures  
 
 
E.   Five-Year Accident History  
 
Three ammonia-related incidents have occurred at the Mattoon Plant during the past five years.  Two of these incidents resulted in on-site injuries.   The third incident resulted in the discharge of ammonia to the local wastewater treatment plant.  Changes have been made at the plant to prevent the reoccurrence of these incidents.  
 
 
F.   Description of the Emergency Response Program  
 
An emergency response program has been implemented at the Mattoon Plant.  This program contains procedures describing how the facility will respond to ammonia spills and other emergencies, including evacuation procedures.    
 
The plant has an on-site employee response team, trained to enter and stop an accidental ammonia release.   This team meets monthly for training and  
practice drills.  We conducted an emergency drill with the Mattoon fire department and other local response agencies in October of 1997.  
 
 
G. Planned Changes to Improve Safey  
 
Lender's Bagel Bakery is committed to operating our ammonia refrigeration system in a safe and responsible manner.   We are continually evaluating our equipment and procedures to meet this objective.  Planned improvements include revisions to our preventive maintenance program and a modified operator training program.  
 
 
* Process Chemicals  
Process ID:                8236  
Description:               North Ammonia System  
Process Chemical ID:       9060  
Program Level:             Program Level 3 process  
Chemical Name:             Ammonia (anhydrous)  
CAS Number:                7664-41-7  
Quantity (lbs):            46000  
CBI claimed:                  
Flammable/Toxic:           TOXIC  
 
Process ID:                8237  
Description:               South Ammonia System  
Process Chemical ID:       9061  
Program Level:             Program Level 3 process  
Chemical Name:             Ammonia (anhydrous)  
CAS Number:                7664-41-7  
Quantity (lbs):            34200  
CBI claimed:                  
Flammable/Toxic:           TOXIC  
 
* Process NAICS              
Process ID:                8236  
Process NAICS ID:          8427  
Program Level:             Program Level 3 process  
NAICS Code:                311813  
NAICS Description:         Frozen Bakery Product Manufacturing  
 
Process ID:                8237  
Process NAICS ID:          8428  
Program Level:             Program Level 3 process  
NAICS Code:                311813  
NAICS Description:         Frozen Bakery Product Manufacturing  
 
***** Section 2. Toxic: Worst Case *****  
Toxic Worst ID:            6960  
Percent Weight:              
Physical State:            Gas liquified by pressure  
Model Used:                EPA's RMP Guidance for Ammonia Refrigeration  Reference Tables or Equations  
Release Duration (min):    10  
Wind Speed (m/sec):        1.5  
Atmosphere Stability  
Class:                     F  
Topography:                Rural  
 
Passive Mitigation considered  
Dike:                        
Enclosures:                  
Berms:                        
Drains:                      
Sumps:                        
Other Type:                  
 
***** Section 3. Toxic: Alternative Release *****  
Toxic Alter ID:            7794  
Percent Weight:            100  
Physical State:            Gas liquified by pressure  
Model Used:                EPA's RMP Guidance for Ammonia Refrigeration  Reference Tables or Equations  
Wind Speed (m/sec):        3  
Atmosphere Stability  
Class:                     D  
Topography:                Rural  
 
Passive Mitigation considered  
Dike:                        
Enclosures:                  
Berms:                        
Drains:                      
Sumps:                        
Other Type:                  
 
Active Mitigation considered  
Sprinkler System:            
Deluge System:                
Water Curtain:                
Neutralization:              
Excess Flow Valve:            
Flares:                      
Scrubbers:                    
Emergency Shutdown:          
Other Type:                  
 
***** Section 4. Flammables: Worst Case *****  
***** Section 5. Flammable: Alternative Release *****  
***** Section 6. Accident History *****  
 
** Accident History ID:    665  
Date of accident:          17-NOV-1994  
Time accident began  
(HHMM):                    1630  
NAICS code of process  
involved:                  311813  
NAICS description:         Frozen Bakery Product Manufacturing  
Release duration:          000 Hours 01 Minutes  
 
* Release Event  
Gas release:               YES  
Liquid spill/evaporation:    
Fire:                        
Explosion:                    
 
* Release Source  
Storage vessel:              
Piping:                      
Process vessel:              
Transfer hose:                
Valve:                     YES  
Pump:                        
Joint:                     YES  
Other release source:        
 
* Weather Conditions at the Time of Event  
Wind speed:                  
Units:                     meters/second  
Direction:                  
Temperature:                Degrees Fahrenheit  
Atmospheric Stability  
class:                      
Precipitation present:        
Unknown weather  
conditions:                YES  
 
* On-Site Impacts  
Employee or contractor  
deaths:                    0  
Public responder deaths:   0  
Public deaths:             0  
Employee or contractor  
injuries:                  1  
Public responder  
injuries:                  0  
Public injuries:           0  
On-site property damage  
($):                       0  
 
* Known Off-Site Impacts  
Deaths:                    0  
Hospitalization:           0  
Other medical treatments:  0  
Evacuated:                 0  
Sheltered-in-place:        0  
Off-site property damage  
($):                       0  
 
Environmental Damage  
Fish or Animal Kills:        
Tree, lawn, shrub, or  
crop damage:                  
Water contamination:          
Soil contamination:          
Other environmental  
damage:                      
 
* Initiating Event  
Initiating Event:          Equipment Failure  
 
* Contributing Factors  
Equipment failure:         YES  
Human error:                  
Improper procedures:          
Overpressurization:        YES  
Upset condition:              
By-pass condition:            
Maintenance  
activity/inactivity:          
Process design failure:      
Unsuitable equipment:        
Unusual weather  
condition:                    
Managment error:              
Other contributing  
factor:                      
 
* Off-site Responders Notified  
Off-site responders  
notified:                  No, not notified  
 
* Changes Introduced as a Result of the Accident  
Improved or upgraded  
equipment:                    
Revised maintenance:          
Revised training:          YES  
Revised operating  
procedures:                  
New process controls:        
New mitigation systems:      
Revised emergency  
response plan:                
Changed process:              
Reduced inventory:            
None:                        
Other changes introduced:    
 
* Confidention Business Information  
CBI claimed:                  
 
* Chemicals in Accident History  
Accident Chemical ID:      671  
Quantity Released (lbs):   1  
Percent Weight:            100  
Chemical Name:             Ammonia (anhydrous)  
CAS Number:                7664-41-7  
Flammable/Toxic:           TOXIC  
 
 
** Accident History ID:    666  
Date of accident:          23-JAN-1997  
Time accident began  
(HHMM):                    0910  
NAICS code of process  
involved:                  311813  
NAICS description:         Frozen Bakery Product Manufacturing  
Release duration:          000 Hours 01 Minutes  
 
* Release Event  
Gas release:               YES  
Liquid spill/evaporation:    
Fire:                        
Explosion:                    
 
* Release Source  
Storage vessel:              
Piping:                      
Process vessel:              
Transfer hose:                
Valve:                        
Pump:                        
Joint:                     YES  
Other release source:        
 
* Weather Conditions at the Time of Event  
Wind speed:                  
Units:                     meters/second  
Direction:                  
Temperature:                Degrees Fahrenheit  
Atmospheric Stability  
class:                      
Precipitation present:        
Unknown weather  
conditions:                YES  
 
* On-Site Impacts  
Employee or contractor  
deaths:                    0  
Public responder deaths:   0  
Public deaths:             0  
Employee or contractor  
injuries:                  1  
Public responder  
injuries:                  0  
Public injuries:           0  
On-site property damage  
($):                       0  
 
* Known Off-Site Impacts  
Deaths:                    0  
Hospitalization:           0  
Other medical treatments:  0  
Evacuated:                 0  
Sheltered-in-place:        0  
Off-site property damage  
($):                       0  
 
Environmental Damage  
Fish or Animal Kills:        
Tree, lawn, shrub, or  
crop damage:                  
Water contamination:          
Soil contamination:          
Other environmental  
damage:                      
 
* Initiating Event  
Initiating Event:          Human Error  
 
* Contributing Factors  
Equipment failure:            
Human error:               YES  
Improper procedures:          
Overpressurization:          
Upset condition:              
By-pass condition:            
Maintenance  
activity/inactivity:       YES  
Process design failure:      
Unsuitable equipment:        
Unusual weather  
condition:                    
Managment error:              
Other contributing  
factor:                      
 
* Off-site Responders Notified  
Off-site responders  
notified:                  No, not notified  
 
* Changes Introduced as a Result of the Accident  
Improved or upgraded  
equipment:                 YES  
Revised maintenance:       YES  
Revised training:          YES  
Revised operating  
procedures:                  
New process controls:        
New mitigation systems:      
Revised emergency  
response plan:                
Changed process:              
Reduced inventory:            
None:                        
Other changes introduced:    
 
* Confidention Business Information  
CBI claimed:                  
 
* Chemicals in Accident History  
Accident Chemical ID:      672  
Quantity Released (lbs):   1  
Percent Weight:            100  
Chemical Name:             Ammonia (anhydrous)  
CAS Number:                7664-41-7  
Flammable/Toxic:           TOXIC  
 
 
** Accident History ID:    667  
Date of accident:          22-NOV-1997  
Time accident began  
(HHMM):                    0930  
NAICS code of process  
involved:                  311813  
NAICS description:         Frozen Bakery Product Manufacturing  
Release duration:          048 Hours 00 Minutes  
 
* Release Event  
Gas release:               YES  
Liquid spill/evaporation:    
Fire:                        
Explosion:                    
 
* Release Source  
Storage vessel:              
Piping:                      
Process vessel:            YES  
Transfer hose:                
Valve:                        
Pump:                        
Joint:                        
Other release source:        
 
* Weather Conditions at the Time of Event  
Wind speed:                  
Units:                     meters/second  
Direction:                  
Temperature:                Degrees Fahrenheit  
Atmospheric Stability  
class:                      
Precipitation present:        
Unknown weather  
conditions:                YES  
 
* On-Site Impacts  
Employee or contractor  
deaths:                    0  
Public responder deaths:   0  
Public deaths:             0  
Employee or contractor  
injuries:                  0  
Public responder  
injuries:                  0  
Public injuries:           0  
On-site property damage  
($):                       0  
 
* Known Off-Site Impacts  
Deaths:                    0  
Hospitalization:           0  
Other medical treatments:  0  
Evacuated:                 0  
Sheltered-in-place:        0  
Off-site property damage  
($):                       0  
 
Environmental Damage  
Fish or Animal Kills:        
Tree, lawn, shrub, or  
crop damage:                  
Water contamination:       YES  
Soil contamination:          
Other environmental  
damage:                      
 
* Initiating Event  
Initiating Event:          Human Error  
 
* Contributing Factors  
Equipment failure:            
Human error:               YES  
Improper procedures:          
Overpressurization:          
Upset condition:              
By-pass condition:            
Maintenance  
activity/inactivity:       YES  
Process design failure:      
Unsuitable equipment:        
Unusual weather  
condition:                    
Managment error:              
Other contributing  
factor:                      
 
* Off-site Responders Notified  
Off-site responders  
notified:                  Notified Only  
 
* Changes Introduced as a Result of the Accident  
Improved or upgraded  
equipment:                    
Revised maintenance:       YES  
Revised training:          YES  
Revised operating  
procedures:                YES  
New process controls:        
New mitigation systems:      
Revised emergency  
response plan:                
Changed process:              
Reduced inventory:            
None:                        
Other changes introduced:    
 
* Confidention Business Information  
CBI claimed:                  
 
* Chemicals in Accident History  
Accident Chemical ID:      673  
Quantity Released (lbs):   286  
Percent Weight:            100  
Chemical Name:             Ammonia (anhydrous)  
CAS Number:                7664-41-7  
Flammable/Toxic:           TOXIC  
 
 
***** Section 7. Program Level 3 *****  
 
** Description:  
This section applies to the North Refrigeration System  
 
 
 
 
Program Level 3 Prevention Program Chemicals  
Prevention Program  
Chemical ID:               4119  
Chemical Name:             Ammonia (anhydrous)  
Flammable/Toxic:           TOXIC  
CAS Number:                7664-41-7  
 
Prevention Program Level  
3 ID:                      3611  
NAICS Code:                311813  
 
* Saftey Information        
Safety review date (The  
date on which the safety  
information was last  
reviewed or revised):      28-JAN-1999  
 
* Process Hazard Analysis (PHA)  
PHA completion date  
(date of last PHA or PHA  
update:                    16-DEC-1997  
 
The Technique Used  
What IF:                      
Checklist:                    
What If/Checklist:         YES  
HAZOP:                        
Failure Mode and Effects  
Analysis:                    
Fault Tree Analysis:          
Other technique used:        
PHA change completion  
date (The expected or  
actual date of  
completion of all  
changes resulting from  
last PHA or PHA update):   01-DEC-1999  
 
Major Hazards Identified  
Toxic release:             YES  
Fire:                        
Explosion:                    
Runaway reaction:            
Polymerization:              
Overpressurization:        YES  
Corrosion:                 YES  
Overfilling:                  
Contamination:                
Equipment failure:         YES  
Loss of cooling,  
heating, electricity,  
instrument air:            YES  
Earthquake:                  
Floods (flood plain):        
Tornado:                      
Hurricanes:                  
Other major hazard  
identified:                  
 
Process Controls In Use  
Vents:                        
Relief valves:             YES  
Check valves:              YES  
Scrubbers:                    
Flares:                      
Manual shutoffs:           YES  
Automatic shutoffs:        YES  
Interlocks:                YES  
Alarms and procedures:     YES  
Keyed bypass:                
Emergency air supply:        
Emergency power:              
Backup pump:               YES  
Grounding equipment:          
Inhibitor addition:          
Rupture disks:                
Excess flow device:          
Quench system:                
Purge system:                
None:                        
Other process control in  
use:                        
 
Mitigation Systems In Use  
Sprinkler system:          YES  
Dikes:                        
Fire walls:                  
Blast walls:                  
Deluge system:                
Water curtain:                
Enclosure:                 YES  
Neutralization:              
None:                        
Other mitigation system  
in use:                      
 
Monitoring/Detection Systems In Use  
Process area detectors:    YES  
Perimeter monitors:          
None:                        
Other  
monitoring/detection  
system in use:              
 
Changes Since Last PHA Update  
Reduction in chemical  
inventory:                    
Increase in chemical  
inventory:                    
Change process  
parameters:                  
Installation of process  
controls:                  YES  
Installation of process  
detection systems:            
Installation of  
perimeter monitoring  
systems:                      
Installation of  
mitigation systems:          
None recommended:            
None:                        
Other change since last  
PHA or PHA update:          
 
Review of Operating Procedures  
Operating procedures  
revision date (The date  
of the most recent  
review or revision of  
operating procedures):     28-APR-1999  
 
* Training                  
Training revision date  
(The date of the most  
recent review or  
revision of training  
programs):                 22-DEC-1998  
 
The Type of Training Provided  
Classroom:                    
On the job:                YES  
Other type of training  
provided:                    
 
The Type of Competency Testing Used  
Written test:                
Oral test:                    
Demonstration:             YES  
Observation:               YES  
Other type of competency  
testing used:                
 
* Maintenance  
Maintenance procedures  
revision date (The date  
of the most recent  
review or revision of  
maintenance procedures):   29-DEC-1998  
Equipment inspection  
date (The date of the  
most recent equipment  
inspection or test):       10-MAY-1999  
Equipment tested:  
(Equipment most recently  
inspected or tested)       Compressor  
 
* Management of Change  
Change management date  
(The date of the most  
recent change that  
triggered management of  
change procedures):        21-DEC-1998  
Change management  
revision date (The date  
of the most recent  
review or revision of  
management of change  
procedures):               29-DEC-1998  
 
* Pre-Startup Review  
Pre-startup review date  
(The date of the most  
recent pre-startup  
review):                   18-JUN-1998  
 
* Compliance Audits  
Compliance audit date  
(The date of the most  
recent compliance audit):  18-OCT-1998  
Compliance audit change  
completion date  
(Expected or actual date  
of completion of all  
changes resulting from  
the compliance audit):     01-DEC-1999  
 
Incident Investigation  
Incident investigation  
date (The date of the  
most recent incident  
investigation (if any)):   05-JAN-1998  
Incident investigation  
change date (The  
expected or actual date  
of completion of all  
changes resulting from  
the investigation):        05-JAN-1998  
 
* Employee Participation Plans  
Participation plan  
revision date (The date  
of the most recent  
review or revision of  
employee participation  
plans):                    13-NOV-1998  
 
* Hot Work Permit Procedures  
Hot Work permit review  
date (The date of the  
most recent review or  
revision of hot work  
permit procedures):        29-DEC-1998  
 
* Contractor Safety Procedures  
Contractor safety  
procedures review date  
(The date of the most  
recent review or  
revision of contractor  
safety procedures):        26-OCT-1998  
Contractor safety  
performance evaluation  
date (The date of the  
most recent review or  
revision of contractor  
safety performance):       30-DEC-1998  
 
* Confidential Business Information  
CBI claimed:                  
 
** Description:  
This section applies to the South Refrigeration System  
 
 
 
 
Program Level 3 Prevention Program Chemicals  
Prevention Program  
Chemical ID:               4120  
Chemical Name:             Ammonia (anhydrous)  
Flammable/Toxic:           TOXIC  
CAS Number:                7664-41-7  
 
Prevention Program Level  
3 ID:                      3612  
NAICS Code:                311813  
 
* Saftey Information        
Safety review date (The  
date on which the safety  
information was last  
reviewed or revised):      28-JAN-1999  
 
* Process Hazard Analysis (PHA)  
PHA completion date  
(date of last PHA or PHA  
update:                    16-MAY-1996  
 
The Technique Used  
What IF:                      
Checklist:                    
What If/Checklist:         YES  
HAZOP:                        
Failure Mode and Effects  
Analysis:                    
Fault Tree Analysis:          
Other technique used:        
PHA change completion  
date (The expected or  
actual date of  
completion of all  
changes resulting from  
last PHA or PHA update):   01-DEC-1999  
 
Major Hazards Identified  
Toxic release:             YES  
Fire:                        
Explosion:                    
Runaway reaction:            
Polymerization:              
Overpressurization:        YES  
Corrosion:                 YES  
Overfilling:                  
Contamination:                
Equipment failure:         YES  
Loss of cooling,  
heating, electricity,  
instrument air:            YES  
Earthquake:                  
Floods (flood plain):        
Tornado:                      
Hurricanes:                  
Other major hazard  
identified:                  
 
Process Controls In Use  
Vents:                        
Relief valves:             YES  
Check valves:              YES  
Scrubbers:                    
Flares:                      
Manual shutoffs:           YES  
Automatic shutoffs:        YES  
Interlocks:                YES  
Alarms and procedures:     YES  
Keyed bypass:                
Emergency air supply:        
Emergency power:              
Backup pump:               YES  
Grounding equipment:          
Inhibitor addition:          
Rupture disks:                
Excess flow device:          
Quench system:                
Purge system:                
None:                        
Other process control in  
use:                        
 
Mitigation Systems In Use  
Sprinkler system:          YES  
Dikes:                        
Fire walls:                  
Blast walls:                  
Deluge system:                
Water curtain:                
Enclosure:                 YES  
Neutralization:              
None:                        
Other mitigation system  
in use:                      
 
Monitoring/Detection Systems In Use  
Process area detectors:    YES  
Perimeter monitors:          
None:                        
Other  
monitoring/detection  
system in use:              
 
Changes Since Last PHA Update  
Reduction in chemical  
inventory:                    
Increase in chemical  
inventory:                    
Change process  
parameters:                  
Installation of process  
controls:                  YES  
Installation of process  
detection systems:            
Installation of  
perimeter monitoring  
systems:                      
Installation of  
mitigation systems:          
None recommended:            
None:                        
Other change since last  
PHA or PHA update:          
 
Review of Operating Procedures  
Operating procedures  
revision date (The date  
of the most recent  
review or revision of  
operating procedures):     28-APR-1999  
 
* Training                  
Training revision date  
(The date of the most  
recent review or  
revision of training  
programs):                 22-DEC-1998  
 
The Type of Training Provided  
Classroom:                    
On the job:                YES  
Other type of training  
provided:                    
 
The Type of Competency Testing Used  
Written test:                
Oral test:                    
Demonstration:             YES  
Observation:               YES  
Other type of competency  
testing used:                
 
* Maintenance  
Maintenance procedures  
revision date (The date  
of the most recent  
review or revision of  
maintenance procedures):   29-DEC-1998  
Equipment inspection  
date (The date of the  
most recent equipment  
inspection or test):       26-MAY-1999  
Equipment tested:  
(Equipment most recently  
inspected or tested)       Compressor  
 
* Management of Change  
Change management date  
(The date of the most  
recent change that  
triggered management of  
change procedures):        23-DEC-1998  
Change management  
revision date (The date  
of the most recent  
review or revision of  
management of change  
procedures):               29-DEC-1998  
 
* Pre-Startup Review  
Pre-startup review date  
(The date of the most  
recent pre-startup  
review):                   05-FEB-1999  
 
* Compliance Audits  
Compliance audit date  
(The date of the most  
recent compliance audit):  18-OCT-1998  
Compliance audit change  
completion date  
(Expected or actual date  
of completion of all  
changes resulting from  
the compliance audit):     01-DEC-1999  
 
Incident Investigation  
Incident investigation  
date (The date of the  
most recent incident  
investigation (if any)):   08-OCT-1997  
Incident investigation  
change date (The  
expected or actual date  
of completion of all  
changes resulting from  
the investigation):        15-OCT-1997  
 
* Employee Participation Plans  
Participation plan  
revision date (The date  
of the most recent  
review or revision of  
employee participation  
plans):                    13-NOV-1998  
 
* Hot Work Permit Procedures  
Hot Work permit review  
date (The date of the  
most recent review or  
revision of hot work  
permit procedures):        29-DEC-1998  
 
* Contractor Safety Procedures  
Contractor safety  
procedures review date  
(The date of the most  
recent review or  
revision of contractor  
safety procedures):        26-OCT-1998  
Contractor safety  
performance evaluation  
date (The date of the  
most recent review or  
revision of contractor  
safety performance):       30-DEC-1998  
 
* Confidential Business Information  
CBI claimed:                  
 
 
***** Section 9. Emergency Response *****  
 
* Written Emergency Response (ER) Plan  
Community Plan (Is facility included in  
written community emergency response plan?):   YES  
Facility Plan (Does facility have its own  
written emergency response plan?):             YES  
Response Actions (Does ER plan include  
specific actions to be taken in reponse to  
accidental releases of regulated  
substance(s)?):                                YES  
Public Information (Does ER plan include  
procedures for informing the public and  
local agencies responding to accidental  
release?):                                     YES  
Healthcare (Does facility's ER plan include  
information on emergency health care?):        YES  
 
* Emergency Response Review  
Review Date (Date of most recent review or  
update of facility's ER plan):                 29-OCT-1998  
 
* Emergency Response Training  
Training Date (Date of most recent review or  
update of facility's employees):               08-OCT-1998  
 
* Local Agency  
Agency Name (Name of local agency with which  
the facility ER plan or response activities  
are coordinated):                              Mattoon Fire Department  
Agency Phone Number (Phone number of local  
agency with which the facility ER plan or  
response activities are coordinated):          (217) 234-2442  
 
* Subject to:  
OSHA Regulations at 29 CFR 1910.38:            YES  
OSHA Regulations at 29 CFR 1910.120:           YES  
Clean Water Regulations at 40 CFR 112:         YES  
RCRA Regulations at CFR 264, 265, and 279.52:  YES  
OPA 90 Regulations at 40 CFR 112, 33 CFR  
154, 49 CFR 194, or 30 CFR 254:                  
State EPCRA Rules or Laws:                        
Other (Specify):                                
 
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