ABITEC Corporation - Executive Summary

| Accident History | Chemicals | Emergency Response | Registration | Source | Executive Summary |

The accidental release and emergency response polices at this facility: 
An emergency situation, by definition, occurs unexpectedly.  Whatever its form, it may present a potentially serious threat to Company operations, and to the health and safety of employees and the community.  Some emergencies - for example, chemical releases - are governed by strict federal, state and local laws.  Therefore, it is essential for all employees to be aware of potential emergency situations, to plan for them, and to take prompt and effective response should an emergency event actually occur. 
The purpose of these procedures are to provide information and to establish guidelines in preparing for and response to emergencies.  The procedures include reporting requirements, emergency communication, evacuation plans, and other vital information needed to put response plans into action. 
The procedures are divided into sections so that quick reference and action are facilitated.  All employees are expected  
to be familiar with these procedures and to review them routinely. {source EMG. PROCED. Section 1, page 1} 
The Janesville plant is committed to safety.  The plant has developed site emergency response procedures and actively participates in the Rock County District Local Emergency Planning Committee.  Site officials work closely with the local fire department and safety and environmental consultants.  Air and water monitoring are performed regularly to ensure compliance with all permits and regulations. {source EMG. PROCED. Section 1, page 2} 
The facility and the regulated substances handled: 
ABITEC Corporation's Janesville production facility is a 7 acre site located at 1530 S. Jackson Street in Janesville, WI.  Chemical operations began at the site in 1962 with a major expansion (doubling capacity) in 1980. 
The facility manufactures surface active agents (surfactants).  The principle products manufactured are food grade, Kosher certified specialty oils; and fabric softener bases  
and other specialty surfactants.  The former are used in foods, cosmetics, pharmaceuticals and personal care products.  The latter are used by formulators of dryer and rinse-cycle fabric softeners, detergents, lubricants and personal care products. 
The Risk Management Program applies to this facility because ethylene oxide and propylene oxide may be on-site in excess of 10,000 pounds at any one time. 
Worst case release scenario(s) alternative release scenario(s): 
The worst case senario is defined by the regulation as "..the release of the largest quantity of a regulated substance from a vessel or process line that results in the greatest distance to endpoint defined in Sec. 68.22(a)." 
Our worst case scenario was determined using EPS's "RMP OFFSITE CONSEQUENCE ANALYSIS GUIDANCE" dated May 24,1996. 
The scenario, as required, describes the release of 180,000 pounds (a full railroad car) of ethylene oxide. 
The radius of the off site consequence, using the above referenced method, is  
9.9 miles.  The center of this circle is our facility at N 42.659 W 89.020 (using MARPLOT map).  The estimated population within this circle is 93,169 (using 1990 census data available at www.census.gov). 
The above mentioned populations includes residential and business areas, schools, hospitals and other healthcare facilities, a correctional institution, and numerous parks, golf courses and other recreational facilities. 
An alternative release of two hundred (200) pounds of ethylene oxide was considered.  Although this is a larger release than anything we have experienced in the last five years, we are aware of such a release at a facility practicing similar operations.  The radius of the off site consequences is sixty (60) yards with the only public receptor being a rail road siding. 
General accidental release prevention program and chemical-specific prevention steps: 
This facility is required to comply with the OHSA PSM rule.  We therefore have written operating procedures, etc. 
which prevent accidental releases.  We also have temperature, pressure and vapor alarms that allow us to react in the incipient stages of any release. 
The five-year accident history: 
In the last five years we have had no releases resulting in off-site consequences. 
Emergency response program: 
Our Safefty & Environmental Manager is a member of the Rock County L.E.P.C.  We have conducted emergency procedures drills which emphasize operation shutdown, personnel accounting, evacuation and reporting to local, state and federal authorities 
For large scale releases we depend upon 911 response from the local fire department (response time estimated as fifteen minutes). 
Planned changes to improve safety: 
Installation of water cannons (3) for fire supression at the rail car siding and the tank farm areas. 
There are plans to install diking for the ethylene oxide railcar. 
A fire surpression sprinkler system is to be installed over the intermediate storage tanks (day tanks). 
Awarning was 
generate after completing this submission regarding 1.12.c Clean Air Act Operating Permit.  We have submitted our application to the Wisconsin DNR (dated 4/3/95) but have not received a newer permit number to replace our previously assigned number of MIA-05-80-54-140. 
Although there is presently a low level shut off for the fluid barrier for the double mechanical seals of the centrifugal EO/PO pumps, we intend to place alarms on these level sensors.
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