Hi-Temp, Incorporated - Executive Summary |
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Hi-Temp, Inc. Executive Summary 1. Accidental Release Prevention and Emergency Response Policies Hi-Temp, Inc. is committed to employee, public, and environmental safety. We have a comprehensive accidental release prevention program in place. This program covers areas such as design, installation, operating procedures, maintenance, and employee training associated with the processes at our facility. It is our policy to implement appropriate controls to prevent possible releases of regulated substances. In the unlikely event that a release should occur, our emergency response personnel are trained to control and mitigate the effects of such a release. 2. Description of the Facility and the Regulated Substances Handled Hi-Temp, Inc. is a commercial heat treating service utilizing continuous electric and gas heated furnaces to perform multiple manufacturing processes on customers parts. Manufacturing processes include hardening of 410 stainless steel; annealing of all types of steel and cast iron; tempering & stress relieving; copper, silver & nickel brazing; passivating of stainless steel; copper stripping and aqueous washing. In addition zinc electroplating and zinc phosphating processes are also performed. Hi-Temp, Inc. consists of three plants located on one contiguous piece of property. The plants house offices, manufacturing operations and storage. Plant #1 is located at 310 S. Wolf Road, Northlake, IL. Plant #2 is located at 75 E. Lake Street, Northlake. Plant #3 is located at 5400 W. Lake Street, Melrose Park, IL. The mailing address of the facility is 75 E. Lake Street, Northlake, IL 60164. Process 1 - Plant #1: Air Permit Operating 73070248 The property of Plant #1 is bounded by Bristol Hose & Fittings, located at 311 W. Lake Street Lake Street to the North, the Union Pacific Railroad to the South, M. Holland Company, 21 W. Lake Street to the West, and a vacant building to the East. There is an office building and gas station across the bou ndary street to the north. The south boundary is the Union Pacific Railroad, which consists of both freight and passenger lines. The freight lines run on the northern tracks and the passenger trains use the southernmost tracks. The properties that border to the east and west are industrial facilities and offices. A site map of the facility is included as page 8. Plant #1 handles and stores Anhydrous Ammonia (CAS# 7664-41-7). This material is regulated under 40 CFR Part 68 as a toxic gas. It is a gas that is liquefied under pressure. It is delivered, installed by transfer hose, and stored on site in steel tanks in this liquid form. There are two (2) tanks. One 13,000 gallon tank, and one 1,000 gallon tank. The tanks are constructed of steel and are approximately 1.5" thick. These tanks are stored outside of Plant #1 on the south side of the building approximately 100 feet north of the Union Pacific Railroad Line (the south property boundary). The tanks are stored on the ground and a re enclosed in a locked chain link cage. See page 8 for a diagram. Nitrogen and dissociated ammonia are used at Plant #1 in continuous furnaces as the protective atmosphere. Process 2 - Plant #2: Air Permit Operating #73070244 The property of Plant #2 is bounded by Lake Street to the North, the Union Pacific Railroad to the South, Dyna-Burr Chicago, Inc., located at 65 E. Lake Street to the West, and by Hi Speed Race Karts, to the East. There are multiple unit apartment buildings, a motel and an oil-lube change shop across the boundary street to the north. The Union Pacific Railway lines that border to the South run both freight and passenger lines. The passenger trains run on the southernmost tracks. The properties that border to the east and west are industrial facilities and offices. A site map of the facility appears on page 8. Plant #2 handles and stores Anhydrous Ammonia (CAS# 7664-41-7). This material is regulated under 40 CFR Part 68 as a toxic gas. It is a gas tha t is liquefied under pressure. It is delivered, installed by transfer hose and stored in steel tanks in this liquid form. There are two (2) tanks. One 10,000 gallon tank, and one 1,000 gallon tank. The tanks are constructed of steel and are 1.5" thick. The tanks are stored outside of Plant #2 on the east side of the building approximately 125 feet south of Lake Street (the north property boundary). The tanks are stored on the ground and are enclosed in a locked chain link cage. See page 8 for a diagram. Plant #2 uses two systems for providing the protective atmosphere in continuous furnaces. The first system combines both nitrogen and dissociated ammonia. The second system uses only disassociated ammonia. in continuous furnaces as the protective atmosphere. Plant #3 Plant 3 does not store or use any chemicals in quantities that would trigger a Risk Management Plan. 3. Worst-Case Release Scenarios Process 1 - Plant #1: Ammonia, anhydrous Failure of a High-Pressure Steel tank t hrough a puncture or failure at the valve will have no effect on an adjacent ammonia tank. However, in the worst case scenario, the maximum combined quantity of ammonia stored in the 13,000 gallon and 1,000 gallon tank equal 12,180 gallons as they are kept only 87% full. This amounts to 68,208 lbs of ammonia. If this maximum quantity of ammonia (68,208 lbs.) was simultaneously released from both tanks, the resulting denser-than-air vapor would release at ground level with a toxic endpoint distance of 3.1 miles. This distance extends past the property boundaries and would affect the surrounding population of 104,807. The toxic concentration endpoint for anhydrous ammonia is 0.14 mg/l (200 ppm). Assumptions and Calculations follow (OCA Guidance): RMP*Comp Ver. 1.06 Results of Consequence Analysis Chemical: Ammonia, anhydrous CAS #: 7664-41-7 Category: Toxic Gas Scenario: Worst-case Liquefied under pressure Quantity Released: 68,208 pounds Release Type: Ground Level Release E stimated Distance to toxic endpoint: 3.1 miles (5.0 kilometers) --------Assumptions About This Scenario--------- Wind Speed: 1.5 meters/second (3.4 miles/hour) Stability Class: F Air Temperature: 77? F (25? C) ---------------------------------------------------------- Process 2 - Plant #2: Ammonia, anhydrous Failure of a High-Pressure Steel tank through a puncture or failure at the valve will have no effect on the adjacent ammonia tank. However, in the worse case scenario the maximum combined quantity of ammonia stored in the 10,000 gallon and 1,000 gallon tank equal 9,650 gallons as they are kept only 87% full. This amounts to 54,040 lbs of ammonia. If this maximum quantity of ammonia (54,040 lbs) was simultaneously released from both tanks, the resulting denser-than-air vapor would release at ground level with a toxic endpoint distance of 2.6 miles. This distance extends past the property boundaries and would affect the surrounding population of 65,735. The toxic concentratio n endpoint for anhydrous ammonia is 0.14 mg/l. (200 ppm). Assumptions and Calculations follow (OCA Guidance): RMP*Comp Ver. 1.06 Results of Consequence Analysis Chemical: Ammonia, anhydrous CAS #: 7664-41-7 Category: Toxic Gas Scenario: Worst-case Liquefied under pressure Quantity Released: 54,040 pounds Release Type: Ground Level Release Estimated Distance to toxic endpoint: 2.6 miles (4.2 kilometers) --------Assumptions About This Scenario--------- Wind Speed: 1.5 meters/second (3.4 miles/hour) Stability Class: F Air Temperature: 77? F (25? C) ---------------------------------------------------------- 4. Alternative Case Release Scenario Process 1 - Plant #1: Ammonia, anhydrous Process 2 - Plant #2: Ammonia, anhydrous An accidental release of ammonia for both processes would more likely occur as a result of a transfer hose failure. This type of release would occur at the time of receiving new quantities of ammonia and having the facility's ammonia tanks refilled. Th e transfer hose is 2" in diameter and is 22' long. If there were a failure in this hose, the resulting ammonia release would only involve the quantity of ammonia that existed within the transfer hose. This quantity is 22 pounds of ammonia. With this size of an ammonia release, the resulting toxic distance endpoint is <0.1 miles. This would not extend past the property boundaries, therefore, this type of ammonia release would not generate a public health emergency. Assumptions and Calculations follow (OCA Guidance): RMP*Comp Ver. 1.06 Results of Consequence Analysis Chemical: Ammonia, anhydrous CAS #: 7664-41-7 Category: Toxic Gas Scenario: Alternative Case Liquefied under pressure Quantity Released: 22 pounds Release Type: Ground Level Release Estimated Distance to toxic endpoint: <0.1 miles (<0.16 kilometers) --------Assumptions About This Scenario--------- Wind Speed: 3.0 meters/second (6.8 miles/hour) Stability Class: D Air Temperature: 77? F (25? C) ----------------- ---------------------------------------------- 5. Accidental Release Prevention Program and Chemical Specific Prevention Steps Process 1 - Plant #1: Ammonia, anhydrous Ammonia is stored and used at Hi-Temp, Inc., Plant #1 in two (2) tanks of 13,000 and 1,000 gallon capacity. The storage area is protected from vehicular and pedestrian traffic, and un-trained or un-authorized personnel. The anhydrous ammonia at Plant #1 is dissociated into 75% hydrogen and 25% nitrogen and used in continuous furnaces as the protective atmosphere. All personnel who operate this equipment or otherwise handle the ammonia tanks have been properly trained in the risks and precaution associated with this substance. Process 2 - Plant #2: Ammonia, anhydrous Anhydrous ammonia are stored and used at Hi-Temp, Inc., Plant #2, in tanks of 10,000 and 1,000 gallon capacity. The storage area is protected from vehicular and pedestrian traffic, and un-trained or un-authorized personnel. The anhydrous ammonia is used in continuous furnaces . All personnel who operate this equipment or otherwise handle these tanks have been properly trained in the risks and precaution associated with this substance. The rules and regulations with which Hi-Temp, Inc. complies for both plants and processes include: - OSHA PSM Rule - OSHA Regulations at 29 CFR 1910.38 - OSHA Regulations at 29 CFR 1910.120 - Clean Water Act Regulations at 40 CFR 112 - RCRA Regulations at 40 CFR 264,265, and 279.52 - State EPCRA Rules or Laws 6. Five Year Accident History There have been no accidental releases of ammonia in the past five years. 7. Emergency Response Program Hi-Temp, Inc. has an Emergency Action Plan that includes, but is not limited to accidental releases of toxic gases, chemical spills, fires, explosions and personal injury. This plan includes: - Emergency Response Team Coordinator - Emergency Response Team - Chain of Command - Emergency Communication - Emergency Escape Procedure - Emergency Shutdown Procedures - Training programs Emergency Response Team members are trained and evaluated in the following emergency response procedures: - Fire Extinguishers - First Aid - Shut Down Procedures - Evacuation Procedures - Chemical Spill - Breathing Apparatus - Search and Rescue All Hi-Temp, Inc. employees are trained regularly on the following emergency procedures: - Evacuation Plans - Alarm Systems - Reporting Procedures for Personnel - Shutdown Procedures - Types of Potential Emergencies The training program is administered as follows: A. Initially when plan is first developed B. For all new employees C. When new equipment, materials, or processes are introduced D. When procedures are updated or revised E. When exercises show that employee performance needs improvement F. At least annually 8. Safety Program Hi-Temp has a comprehensive Employee Training Program, which includes the following elements: - OSHA Hazard Communication (Right-to-know) Law - 29 CFR 1910.1200 - Location o f safety equipment and usage - Plant / process operations - Lockout / Tagout - Prevention of, and response to, spill discharges 9. Certification Hi-Temp, Inc.'s storage and use of ammonia falls within the limits of a Program Level 3 Process as defined in 40 CFR 68.12(b)(4), specifically: - The quantity of ammonia is greater than the threshold quantity - The process is subject to the OSHA PSM standard The undersigned certifies that, to the best of my knowledge, information and belief, formed after reasonable inquiry, the information submitted is true, accurate, and complete. Signed - __________________________________________________ Title - __________________________________________________ Date - __________________________________________________ |