Johns Manville Corporation, Willows, CA - Executive Summary

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Johns Manville International, Inc. 
Willows, California 
1)  Brief Description of the Willows, California Facility:                                               
   The Johns Manville (JM) Plant in Willows, California was constructed in 1973.  The                 
   facility manufactures fiberglass building insulation which is sold in the commercial,                
   residential, and retail markets.  The facility currently encompasses approximately                   
   701,250 square feet under roof and is set in 478 acres of rural area.  There are presently           
   about 375 full time employees who operate the Plant 24 hours a day, 365 days a year.                 
   Johns Manville places a strong emphasis on safety and environmental leadersh 
ip.  The                 
   Company fosters a proactive philosophy to ensure that employees work in a safe                       
   environment and that each facility remains in full compliance with all applicable federal,           
   state, county and local regulations.  JM is also committed to environmental leadership               
   within the community served.  This commitment is exemplified in the Willows Facilitys               
   strong recycling and waste minimization program development.  The Companys long                     
   term goal is to have zero process wastes taken to disposal facilities, with all residual             
   materials either recycled or used for beneficial purposes.                                           
   The facility maintains a good working relationship with all federal, state, county and               
   local agencies.            
2)  Brief Description of the Accidental Release Prevention and Emergency Response                        
    Policies at the Johns Manville Facility in Willows, California:                                      
   The Johns Manville fiberglass manufacturing plant in Willows, California qualifies for               
   the USEPA 112R (40 CFR 68) requirements due to the use of formaldehyde.  The facility                
   exceeds the qualifying threshold of 15,000 pounds of this material onsite for a single               
   Liquid resin solution containing formaldehyde (above 1% mixture) is delivered to the                 
   facility via truck transport.  Resin solution is stored in cold storage until it is mixed with       
   water and other materials to make a binder solution (less than 1% formaldehyde) which is             
   applied to fiberglass.  This binder solution is applied in the fiberglass manufacturing              
   process as a low VOC binder which acts to bind glass fibers.  The formaldehyde                       
   containing resin solution is stored as a liquid in numerous storage tanks (ranging in size           
   from 4,500 to 6,000 gallon maximum capacity) located inside the facility.  The storage               
   vessels are constructed and operated in accordance with ASME specifications.  The resin              
   storage process is designed to 
minimize spills in the event of an accidental release.  The           
   resin storage room is equipped with trenches that minimize the surface area of a spill.  In          
   addition, the resin storage room is maintained at 50 degrees F to reduce the volatility of           
   the material.  Although not a qualifying mitigation measure for the 112R program, low                
   storage temperatures give plant personnel adequate time to react to the situation by                 
   reducing the volatilization rate of the resin material.  As a result of these factors, Johns         
   Manville has not experienced an accidental release of formaldehyde over the entire life of           
   the facility.  Modeling impacts indicate that a worst-case release of formaldehyde from              
   the resin storage tanks would not impact the public beyond the Facilitys property line              
   and therefore is qualified as a Program 1 facility.                                   
   With the exception of minor incidents, it is the Facilitys policy to immediately contact            
   and rely on outside emergency responders in the event of a significant unforeseen or                 
   accidental release of formaldehyde-containing liquid resin.  Outside responders would                
   include the community fire department and other community or contractor services as                  
3)  Brief Description of the Worst Case Scenario, including Administrative Controls and                  
    Mitigation Measures to Limit the D 
istances for each Reported Scenario:                               
   According to 40 CFR 68, the worst-case scenario is to be based on the release of the                 
   greatest amount held in a single vessel, taking into account administrative controls that            
   limit the maximum quantity.  Under a worst-case scenario, a single vessel containing                 
   6,000 gallons of liquid resin, which includes about 12.0% formaldehyde, is assumed to                
   spill with complete indoor containment in the resin room and adjacent water room.                    
   Distance to the toxic endpoint of 12.0 mg/m3 is calculated for Willows using AFTOX, a                
   dispersion model that will determine toxic chemical concentrations at hazard distances.              
   According to AFTOX, a worst-case resin spill and subsequent formaldehyde vaporization     
   onsite at Willows will result in a distance of 0.06 miles to the toxic endpoint.  A plant and        
   topographic map analysis indicates that 0.06 miles from the location of the resin tank is            
   completely onsite.  Therefore, the formaldehyde-containing liquid resin process at                   
   Willows does not qualify for Program 2 of 112R.                                                      
4)  Brief Description of the Five Year Accident History (68.42):                                         
   The Willows facility has never had an accident involving formaldehyde-containing liquid              
   resin that caused deaths, injuries, pro 
perty or environmental damage, evacuations, or                
   sheltering in place.                                                                                 
5)  Brief Description of the Emergency Response Program (68.90  68.95):                                 
   In the event of an emergency involving the Facilitys formaldehyde-containing liquid                 
   resin system, it is the Facilitys policy to notify the local fire department and other              
   emergency responders and request that they respond to the emergency.  Plant personnel                
   have discussed this policy with the fire department; members of the fire department have       
   inspected the facility.                                                                              
   In addition to the emergency action and notification procedures described earlier in this            
   document, Johns Manville complies with and maintains numerous other operational                      
   programs for the purpose of promoting employee safety and minimizing potential hazards               
   to the surrounding community.  These include, but are not limited to:                                
       a. Emergency Hotline notifications                                                                   
       b. Spill, Prevention, Control and Countermeasure Plan and equipment.                             
       c.  RCRA Contingency Plan                                                                        
       d.  Hot Work Permit Program          
       e.  Safety Lockout-Tagout Program                                                                
       f.  Extensive safety programs throughout the location                                            
       g.  Fire Prevention Plan                                                                         
       h.  Bomb Threat Plan                                                                             
       i.  Agency, insurance and physicians inspections                                                 
       j.  Job Safety Analyses                                                                          
       k.  Confined Space Entry procedures                                                              
       l.  Injury Investigation Procedure and Root Cause Analysis                                       
       m.  New and Altered Equipment Inspection (Management of Change)                             
       n. Outside Contractor Review Policy                                                              
       o. Community Emergency Response Coordination Policy                                              
       p.  Various emergency communication systems throughout the facility                              
                 such as audible alarms, paging systems, hand-held radios, phones,                      
                 visual alarms.                                                                         
       q.  Right-To-Know Notification Programs issued to State and local                                
                 agencies (Emission Release Reports, SARA Title III, etc)                               
       r.  Extensive and detailed employee training in all phases of job related                        
                 safety, chemical awareness, handling potential spills, HAZCOM,                         
                 RTK, emergency procedures, noti 
fication and numerous other programs
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