Firestone Synthetic Rubber & Latex Co.-Orange, TX - Executive Summary |
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The Firestone Synthetic Rubber and Latex Company facility located in Orange, Texas is committed to meeting all safety, health and environmental regulations. This is demonstrated by our facility's commitment to the practices of OSHA Process Safety Management Standard (PSM), other OSHA standards, and established environmental practices. Our facility is operated in strict accordance with written operating and maintenance procedures. The operations are ISO 9002 certified, which results in a continual improvement of the plant safety program. The application of the ISO program and PSM ensures rigorous training for operations employees, numerous management checks and balances, and strict attention to changes in the operations with a thorough review and examination of potential incidents that could lead to accidental releases. This facility has emergency medical treatment information readily available for use in an emergency. The Orange facility receives and stores chemicals used primar ily for the manufacture of synthetic rubber, which are used to make many consumer goods, such as: y Tires; y Adhesives for diapers; y Hot melt adhesives; y Food containers; y TV and VCR cabinets; y Toys; y Automobile components; and, y Medical equipment and supplies. Our facility handles only flammable materials that are regulated under the USEPA RMP rule. These flammable materials are 1,3 Butadiene and mixed butenes. The worst case flammable release scenario is a technical evaluation of a hypothetical, accidental release of a flammable material due to a complete failure of the largest storage vessel. According to EPA requirements, this analysis assumes that all safety systems at the Orange Plant on this vessel fail simultaneously, and the weather conditions at the time of the release are the most favorable to maximize the potential consequences of the EPA defined worst case flammable release. This event is highly unlikely and has never occurred at our facility. Based on our analysis using EPA-approved methods, the worst-case release scenario could potentially affect offsite receptors, but would not have any impact on residential receptors. The alternative flammable release scenario is a technical evaluation of an hypothetical, accidental release of a listed flammable material which by EPA regulations should be assumed to ignite and cause an off-site impact. Safety control systems are allowed to operate as designed and the weather conditions are more representative of the area. The alternative release scenario for the Orange Facility assumes a four inch hole develops in the 1,3 butadiene storage tank, or related piping, which causes a 19,345 pounds per minute leak that lasts 60 minutes. There is a subsequent explosion. This scenario has off-site consequences, but does not have any impact on residential receptors. This event is highly unlikely and has never occurred at our facility. This scenario is useful for developing Emergency Response Plans with our local Emergency Planning Committee. Our Safety Programs Include: Designing for Safety y A documented process technology system covers hazards of materials, equipment design basis, and process design basis. y Applicable codes and standards are met. y Materials of construction are chosen to provide mechanical integrity. y Quality Assurance ensures equipment is suitable for its application. y Design changes are documented and reviewed Operating Safely y Operators are trained y Technical resources are available as required y Operators follow approved procedures Maintaining Our Plant y Maintenance personnel are trained and experienced y Contractors are trained and qualified y Mechanics follow approved maintenance procedures y A work permit system controls hazardous work Auditing Our Operations y Routine safety inspections are conducted y Audits and reviews are conducted. y Process Hazard Analyses are performed y Safety critical equipment is periodically inspected to ensure ongoing mechanical integrity. y Incidents are investigated and action taken to prevent recurrence y Pre-startup inspections are conducted prior to starting any new or modified equipment Emergency Preparedness & Response:. Training & Preparation y Plant personnel receive emergency response training y Plant emergency responders are trained y Emergency response plans are in place y Plant participates in emergency drills y Critiques are held on drills and actual events. y Community responders are trained If a Major Release Occurs y Emergency alarm is sounded y Plant emergency Operating Center is activated y Plant Emergency Director and Squad respond y Community emergency responders are notified as appropriate Firestone Synthetic Rubber & Latex Company relies on numerous programs to ensure early identification of and proper response to potential emergencies, including: y training and drills in emergency preparedness, disaster response and control, first-aid, and fire-and-rescu e techniques; y frequent auditing of all preparedness programs; safety training and education; and, y regular review, follow-up, and maintenance of all company operations and equipment. We regularly invite local fire departments and emergency responders to tour our plant and gain familiarity with our operations. The plant is a member of the Local Emergency Planning Committee and the Sabine Neches River Chiefs. Our facility has written emergency response plans that are updated regularly. There have been no RMP defined incidents that have caused deaths, injuries, property or environmental damage, evacuation, or sheltering in place within the past five years. All information supplied under data element 7 are based upon references to the plant's Process Safety Mangement Program. |