Coastal Chem, Inc. - Cheyenne Wyoming - Executive Summary |
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Coastal Chem, Inc., Cheyenne, Wyoming Executive Summary Accidental Release Prevention and Emergency Response Policies The Coastal Chem, Inc., Cheyenne Facility has been in continuous operation since 1965 with a commitment to safe operation and protection of workers and the general public. The facility has actively implemented all of the elements of the OSHA Process Safety Management System to review the safety of processes that could pose a hazard to employees and the public. These PSM policies define the manner in which the processes are maintained and inspected, operated, and modified. The PSM policies also define the manner in which the processes are evaluated for safe operation and the training of the personnel employed to operate and maintain the facility. Safe Work Procedures are in place for hot work, lock-out/tagout, line break, and hot tap work to prevent accidental releases and maintain the integrity of the equipment. In the event that an accidental release were to oc cur, Coastal Chem, Inc. has established an Emergency Response Plan which is used to guide the response. The facility has a well-trained emergency services team comprised of fire fighters, medical personnel, hazardous materials technicians, and rescue personnel. Coastal Chem Inc is a member of the Laramie County Industrial Mutual Aid Organization which may be called upon and provide additional resources to emergencies. Stationary Source and Regulated Substances Handled Coastal Chem, Inc. produces industrial chemicals, fertilizer products, and oxygenates for automotive fuels. Finished products shipped from the facility are Anhydrous Ammonia, Ammonium Nitrate Liquid, Ammonium Nitrate Prills, Urea Prills, Urea Liquid Solution, Urea-Ammonium Nitrate Solution, Carbon Dioxide, Methanol, and Methyl-Tertiary-Butyl-Ether. These products are produced from natural gas, air, water and butane. Coastal Chem, Inc. handles the following regulated substances in quantities greater than the thresho ld amount: Anhydrous Ammonia, Ammonia Solutions (>20%), Chlorine, Mixed Butanes, Pentane, and 2-methyl-propene (isobutylene). Worst-Case and Alternate Case Release Scenarios Toxic Release Scenarios The worst-case scenario for toxic substance in the facility is a catastrophic failure of the refrigerated anhydrous ammonia storage tank in the ammonia storage and refrigeration process. The complete failure of this storage tank was assumed to release 60,000,000 pounds of ammonia vapor over a 10-minute period. No mitigation systems were considered in this release scenario. The distance to an ERPG-2 endpoint (200-PPM) for this WCS is 25 miles. This release scenario was modeled using EPA's RMP*Comp. The alternate case release scenarios for Anhydrous Ammonia is a loading hose failure in the ammonia storage and refrigeration process. This failure results in the release of 24,570 pounds of anhydrous ammonia in 30 minutes. The release was assumed to be isolated by plant personnel within this time. The distance to an ERPG-2 endpoint (200-PPM) for this ARS is 0.43 miles. This release scenario was modeled using EPA's RMP*Comp. The alternate case release scenarios for Ammonia Solution (>20 wt. %) is a failure of an ammonia solutions pump discharge line in the Urea Process. The line failure results in the release of 2,300 pounds of ammonia from a 43 wt% solution in 10 minutes. The plant operators respond and control and contain the vapor cloud with water. The remote pump shutdown and closure of shut-off valves in the process stop the within this time. The distance to an ERPG-2 endpoint (200-PPM) for this ARS is 0.31 miles. This release scenario was modeled using the EPA's OCA Guidance Equations. The alternate case release scenarios for Chlorine is a 1/4 inch hole in the 1-ton storage container in the Ammonia Process. The hole results in the release of 1,500 pounds of chlorine in 10 minutes. The release was assumed to be isolated by plant personnel within this time. T he distance to an ERPG-2 endpoint (3-PPM) for this ARS is 0.22 miles. This release scenario was modeled using the EPA's RMP Guidance for Waste Water Treatment Plants Equations. Flammable Release Scenarios The worst-case scenario for flammable substance in the facility is a catastrophic failure of a butane storage tank in the MTBE process. The complete failure of this storage tank was assumed to release 2,500,000 pounds of butane, complete vaporization, and ignition resulting in a vapor cloud explosion. No mitigation systems were considered in this release scenario. The distance to the 1 psi overpressure endpoint for this WCS is 1.09 miles. This release scenario was modeled using the EPA's OCA Guidance Equations. The alternate case scenario for flammable substance in the facility is a failure of a 6" butane offloading line in the MTBE process. The scenario releases 17,400 pound of butane, complete vaporization, and ignition resulting in a vapor cloud explosion. The failure of thi s piping is assumed to go undetected for 10 minutes before being isolated by plant personnel. The distance to the 1 psi overpressure endpoint for this ARS is 0.21 miles. This release scenario was modeled using the EPA's OCA Guidance Equations. General Accidental Release Prevention Program and Chemical Specific Action Steps A multi-faceted approach is used in the prevention of accidental releases in the facility. Equipment integrity is maintained by following proper design, fabrication, and installation, and maintenance practices and design codes. Solid, well written operating procedures and training programs for personnel in the facility are used to prevent process upsets and equipment damage. Continuous monitoring of the facility's processes is accomplished by both process operators and computer control to operate within equipment and process limitation. Advisory alarms and emergency shutdown systems are designed and tested to automatically limit the potential for a release. I ncident investigations are used to learn the cause of both near misses and incidents so those corrective action steps may be implemented to prevent the future incidents. Following is a partial listing of chemical specific programs in the facility to prevent releases. The use of portable ammonia specific detection equipment to detect and repair minor leaks in the facility. An inspection program for the detection and repair of leaks from hydrocarbon systems. Continuous monitoring of flammable rail car loading and unloading by video camera and personnel. Spare ammonia refrigeration compressors capacity. Remote automated shutdown of ammonia loading pumps and storage tank isolation valves. Chlorinators for delivery of chlorine to cooling water systems, which automatically stop the flow of chlorine in the event of a break in the delivery tubing. Five-year Accident History Coastal Chem, Inc. has not experienced any releases with off-site consequences during the past five years. We have experienced a total of 4 release events during the last five years with on-site effects. 3 of these incidents resulted in only equipment damage onsite. One incident resulted in an employee OSHA Recordable injury. Emergency Response Program Coastal Chem, Inc. maintains a written emergency response program with procedures to address both large and small incidents. The facility maintains a volunteer emergency services team with members trained as fire fighters, medical personnel, hazardous materials technicians, and rescue personnel. Coastal Chem Inc is a member of the Laramie County Industrial Mutual Aid Organization which can provide additional resources to emergencies in the community and member facilities. The facility maintains an array of emergency response equipment and supplies. Routine training for all personnel is held a necessary to perform their assigned response duties. The facility participates in the community Local Emergency Planning Committee. Planned Changes to Improve Safety 1. Additional emergency shutoff valves in the ammonia truck and rail car loading process. 2. Installation of additional fire water pumping capacity. 3. Fixed Ammonia detectors in the ammonia storage and loading areas. |