BASF Corporation Washington NJ Site - Executive Summary |
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RISK MANAGEMENT PLAN EXECUTIVE SUMMARY Commitment to the Community BASF Corporation has a long tradition of operating its facilities in the safest possible manner. BASF also believes in being a responsible corporate citizen and maintaining open, constructive dialogue with our neighbors. These principles are an integral part of our corporate vision statement and values. We believe that sharing this information with our neighbors makes good sense. By doing so, we believe the community will better understand how safe and ecologically sound BASF operations are. Policies BASF Corporation has the following Corporate Guidelines related to environmental, health and safety: 7 We produce products that are safe to manufacture, use and dispose of. 7 We assist our customers to use our products safely and in an environmentally sound manner. We provide them with information on correct handling of our products. 7 We minimize the impact on mankind and the environment during production, stor age, transportation, marketing and use of our products. 7 Economic considerations do not take priority over environmental protection, health and safety. 7 An important contribution to "Sustainable Development" is our involvement in the "Responsible Care" initiative worldwide. This applies to our products and services in all our businesses and affiliates. 7 We are committed to making continuous improvements in safety, health and environmental protection. We do this acting on our own initiative and in consultation with recognized regulatory authorities. We take any action judged to be necessary, whether or not dictated by statutory obligation or official regulations. 7 We encourage safety, environmental and health awareness among employees. 7 We regard it as an important corporate duty to advance science and technology in order to improve safety and environmental protection. 7 We carefully weigh the potential benefits and risks of new discoveries and technologies in dialogue with scie ntists and society before deciding on how to proceed. 7 We pursue an open dialogue with all relevant opinion leaders in society. Our goals are to promote and strengthen mutual understanding and deepen trust in what we do. The BASF Corporation Washington, NJ Site implements these policies through site-specific programs and procedures. Facility Description The BASF Corporation Washington, NJ Site uses ethylene oxide (EO), propylene oxide (PO), and ethylenediamine (EDA). These chemicals are used to manufacture products such as toothpaste, mouthwashes, wastewater treatment (defoamers), fuel additives, detergents, and agricultural chemicals. Release Scenarios Worst Case 7 Gas release of ethylene oxide with off-site impact. Alternative 7 Flange gasket leak of ethylene oxide with off-site impacts. 7 Flange gasket leak of propylene oxide with off-site impacts. 7 Flange gasket leak of ethylenediamine with off-site impacts. A dike is taken into consideration as passive mitigati on. Accidental Release Prevention Program To prevent accidental releases, this facility is in compliance with the EPA Risk Management Program, the OSHA Process Safety Management standard, the Chemical Manufacturer Association's Responsible Care Process Safety Code, and the New Jersey Toxic Catastrophe Prevention Act. Significant chemical-specific prevention steps that are found at the facility include: 7 Being prepared to handle unexpected rises in temperature and pressure by using automatic shut-off device and relief valves. 7 Multiple layers of protections such as safety controls, including warning alarms, automatic shutdown systems and leak detectors. 7 Identifying potential problems by continuously monitoring pressure in vessels and piping. 7 Ensuring proper operation by regularly inspecting equipment. 7 Ensuring staff and contractors receive extensive emergency response, health care and safety training following regulatory and corporate guidelines. 7 Training staff in start- up, operation, and maintenance of all equipment. 7 Investigating safety and chemical related incidents and implementing corrective actions to prevent reoccurrence. 7 Obtaining regulatory permits. 7 Performing routine audits (inspections) to ensure correct procedures are followed. 7 Conducting safety analysis of processes and resolving identified hazards. Five Year Accident History Ethylene Oxide: This facility has had 1 accidental release over the past five years which meets the reporting criteria. The release occurred from a pump transferring dilute ethylene oxide. As corrective action, pumps that transfer ethylene oxide no longer use packing glands. Although an evacuation of the surrounding neighbors was taken as precautionary measure, there was no adverse impact to the community or BASF employees. Propylene Oxide: This facility has had no accidental release over the past five years which meets the reporting criteria. Ethylenediamine: This facility has had no accidental rel ease over the past five years which meets the reporting criteria. Emergency Response Program This facility has an emergency response plan that is coordinated with the community plan. Hazmat team members are trained and participate in drills regularly. This facility has an emergency response program which consists of: 7 Establishing a team of emergency responders who have completed required training. 7 Conducting annual emergency exercises for emergency responders. 7 An emergency response plan which is located on-site and copies distributed to local fire and police departments, hospitals, and emergency management centers. 7 Arrangements with local fire department to familiarize themselves with the site. 7 Having stationary emergency response equipment such as emergency shutdown instruments, combustible vapor detectors, adequate fire water and fire sprinklers. 7 Having portable emergency response equipment such as walkie-talkies, personal protective equipments (PPE's), absorbent materials, combustible vapor detectors, and fire extinguishers. 7 Training in proper first aid and medical treatment. Planned Changes to Improve Safety Facility processes are routinely changed to improve safety as a result of employee suggestions, process hazard analyses, incident investigations, and others. Employee's suggestions are encouraged and evaluated for its feasibility. This facility believes that an employee's suggestions should be strongly considered because of their detailed knowledge in the operation of the equipment. Process hazard analyses are conducted prior to commissioning of any equipment after changes are made. This ensures that all potential deviations from normal operating parameters are evaluated and corrective actions taken if necessary. Incident investigations are performed to understand the reasons why, when, how, and what occurred during the incident. From the investigations, long-term corrective actions are implemented to ensure the least chance of reoccurrence. Some past changes that have been implemented to improve safety include: 7 Switching to gaskets that are more resistant to corrosive materials. 7 Pumps which transfer ethylene oxide and propylene oxide no longer use packing glands. 7 Increasing the number of stationary combustible gas detectors. 7 Readiness for the Year 2000 (Y2K) potential computer bug. 7 Connecting all stack emissions for ethylene oxide, propylene oxide, and ethylenediamine to a central control device which decreases the emissions to the atmosphere. |