AGA Gas, Inc. - Executive Summary
1. The accidental release prevention and emergency response policies at the facility: |
The AGA Gas, Inc. (AGA) facility located in Maumee, Ohio complies with NFPA requirements for LP-Gas storage and applicable requirements for toxic substances, and it is our policy to adhere to all applicable federal, state, and local laws. If an emergency accidental release were to occur involving our propane, butane, isobutane/propane mixture, ammonia, chlorine, hydrogen chloride, hydrogen fluoride, hydrogen sulfide, sulfur dixode, and methly choride storage/handling systems, it is our policy to immediately notify the Monclova Fire Department and the AGA emergency response team, who would respond to the emergency.
2. A description of the facility and the regulated substances handled:
The AGA facility stores propane, butane and an isobutane/propane mixture in above ground storage tanks (ASTs). All three liquified gases are put into storage cylinders of various sizes before they are sold and shipped
from the facility. The propane, butane, and isobutane/propane storage/handling processes consist of one 14,400-gallon propane AST, two 1,482-gallon butane ASTs, one 4,800-gallon isobutane/propane AST, cylinder filling equipment, filled cylinders of various sizes, and associated piping, valves, and other miscellaneous equipment. Ammonia, Chlorine, Hydrogen chloride, Hydrogen fluoride, Hydrogen sulfide, Methyl chloride, and Sulfur dioxide are stored at the AGA facility in cylinders only. The cylinders are transported to the facility, stored for a period of time, and then shipped from the facility.
3. The worst-case release scenario:
The flammable worst-case release scenario for the AGA facility considers the potential failure of the 14,400-gallon propane storage tank filled to 80% of it's holding capacity (administrative controls limit each storage tank to 80% of capacity at 600F), resulting in a vapor cloud explosion. Utilizing a computer-based version (RMP*Comp) of the metho
dology presented in USEPA's "RMP Offsite Consequence Analysis Guidance", USEPA, May 24, 1996, the distance to the flammable endpoint (1 psi overpressure) was determined to be 0.3 miles. The public receptors affected under this worst-case release scenario include: commercial, office, and/or industrial facilities, residential property, and agricultural land. The residential population within this 0.3-mile radius is approximately 78 persons, which was estimated using an Environmental Data Resources - Offsite Receptor Report.
The toxic worst-case release scenario for the AGA facility considers the potential failure of one 1,000-pound sulfur dioxide cylinder. The 1,000-pound sulfur dioxide cylinders are rarely present at the facility (approximately one month per year). Utilizing RMP*Comp, the distance to the toxic endpoint (0.0078 mg/L) was determined to be 2.1 miles. The public receptors affected under this worst-case release scenario include: commercial, office, and/or industrial
facilities, agricultural land, residential property, hospitals, nursing homes, and schools. The residential population within this 2.1-mile radius is approximately 8900 persons, which was estimated using an Environmental Data Resources - Offsite Receptor Report.
4. The alternative release scenario:
The flammable alternative release scenario for the AGA facility considers the potential release of propane from a 100-pound capacity storage cylinder (i.e., caused by a cylinder being knocked over, resulting in the cylinder valve being broken off), resulting in a vapor cloud explosion. The release rate of propane from the cylinder was estimated to be 1.67 pounds per minute. It was assumed that the release occurred for a duration of 60 minutes. Therefore, the alternative release scenario modeled a release of a total of 100 pounds of propane. Utilizing RMP*Comp, the distance to the flammable endpoint was determined to be 0.02 miles. The only affected public receptors under this alterna
tive release scenario are two railroad tracks and right of ways. There is no residential population within this 0.02-mile radius.
The toxic alternative release scenarios for the AGA facility consider the potential release of each toxic chemical from the most common size of storage cylinder for each chemical (i.e., caused by a cylinder being knocked over, resulting in the cylinder valve being broken off). It was assumed that each release occurred for a duration of 60 minutes. Each release scenario was modeled using RMP*Comp. The distance to each toxic endpoint (listed with the amount released and the toxic endpoint) was determined to be: ammonia (150 pounds, 0.14 mg/L)-0.1 miles, chlorine (150 pounds, 0.0087 mg/L)-0.1 miles, hydrogen chloride (60 pounds, 0.030 mg/L)-0.1 miles, hydrogen fluoride (100 pounds, 0.016 mg/L)-0.2 miles, hydrogen sulfide (60 pounds, 0.042 mg/L)-0.1 miles, methyl chloride (100 pounds, 0.82 mg/L)-0.1 miles, and sulfur dioxide (150 pounds, 0.0078 mg/L)-0.1 mi
les. The only affected public receptors under these alternative release scenarios are commercial facilities and agricultural land. There is no residential population within these 0.2 or 0.1-mile radii.
5. The general accidental release prevention program and chemical-specific prevention steps:
The AGA facility complies with USEPA's accident prevention rule and all applicable federal, state and local codes and regulations. The propane, butane, and isobutane/propane systems are designed, installed, and maintained in accordance with NFPA and state law at the AGA facility in Maumee, Ohio.
6. Five-year accident history:
The AGA facility has never had an accident involving its propane, butane or isobutane/propane storage/handling, and other toxics processes. One accident involving the chlorine process has occurred in the last five years. This accident was release of chlorine gas from a cylinder that resulted from the mechanical failure of the valve on the cylinder. This accident h
ad no events resulting in deaths, injuries, environmental damage, off-site property damage, evacuations, or shelterings in place. Only on-site property damage to the cylinder was sustained.
7. The emergency response program:
In the event of an emergency accidental release involving our covered processes, it is AGA's policy to immediately notify the Monclova Fire Department and AGA Emergency Response Team, who would respond to the emergency. We have communicated this policy with the Hammond Fire Department. All members of the AGA Emergency Response Team are properly trained to respond to emergencies at the facility. All employees have access to AGA's emergency action plan, and emergency response training is conducted annually.
8. Planned changes to improve safety: NONE