Mallard Creek Polymers, Inc. - Executive Summary |
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Risk Management Summary for the Accidental Release of Butadiene Putting it in Perspective Mallard Creek Polymers has been using butadiene (BD) safely for more than 30 years. MCP regularly uses more than 15,000,000 pounds of BD annually. In the past 5 years the only RQ release of BD was 188 pounds on May 5, 1999, due to a pump seal failure. No offsite impacts, onsite injuries nor property damage occurred. MCP has completed 11 years without a lost time incident and 4 years without an OSHA Recordable incident. Butadiene: is a colorless gas with a mild aromatic odor liquefies under pressure, much like propane is extremely flammable and is a suspected human carcinogen is kept inhibited to prevent polymerization is 37th in U.S. chemical production volume is heavier than air and tends to seek low places is used by MCP to produce emulsion SBR polymers for adhesives textiles and coatings is used to produce synthetic rubber for tires and rubber goods Hazard Assessment Worst Case Accidental Release Scenario is total loss of both storage tanks (48,000 gallons) in ten minutes. The overpressurization endpoint would be .5 miles. Strict guidelines are specified, such as no safety nor preventative measures or emergency response means may be considered to mitigate event. Alternate Release Scenario More credible model would be loss of contents of an 8000 gallon tanktruck of BD. Overpressurization endpoint would be .12 miles. Safety and preventative measures can be considered and model must have an off-site impact. We prevent chemical releases at Mallard Creek by... Designing for Safety Taking care of our Equipment Maintaining Safe Operations Operating Safely Maintaining Emergency Response Capability Designing for Safety Backup safety systems and interlocks are part of our design Piping and vessels are designed according to strict engineering standards and codes BD storage tanks are surrounded by a dike which would contain the entire contents of the largest ta nk Continuous computer and operator monitoring of the process systems is maintained All key equipment is periodically inspected. Inspection checklists are computer generated. Process hazard analyses are conducted every 5 years on the entire covered process. Taking care of our Equipment Computerized preventive maintenance programs are in place Contractors are pre-qualified before working in the process area Periodic inspection of critical devices such as relief valves and rupture discs are conducted Maintenance and Operations personnel are highly skilled and trained Maintaining Safe Operations Safety reviews are conducted before critical changes are made Continuous camera surveillance is maintained from the control room Access to the Operating area is restricted Written operating and unloading procedures are used Facility is ISO 9002 certified Operating Safely Operators are trained in accordance with ISO 9002 and OSHA PSM standards MCP has operated more than 11 years without a lo st time accident, and 4 years without an OSHA recordable incident A standby generator is automatically activated for backup power to critical equipment Computers continuously monitor critical operating parameters (flows, levels, pressure, temperature) Maintaining Emergency Response Capability We would utilize our written emergency response plan Involve other response agencies including the Mallard Creek Fire Department and the Charlotte Hazmat Team Utilize contracted emergency responders such as Four Seasons Environmental or Hepaco Environmental Use our own trained workers. Many plant personnel have received Operational and Technician Level Hazmat training as well as incipient stage fire brigade training from Texas A & M University. In plant emergency response drills are performed regularly with modern, up-to-date equipment |