Johns Manville Corporation, Richmond, IN - Executive Summary

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Johns Manville International, Inc. 
Richmond, Indiana 
1)  Brief Description of the Richmond, Indiana  Facility:                                           
   Johns Manville International, Inc., (JM) purchased its Richmond, Indiana, facility in          
   1937.  The facility manufactures fiberglass building insulation which is sold in               
   commercial, residential, and retail markets.  There are approximately 750,000 square feet      
   under roof on 43 acres of urban property.  There are presently about 140 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 leadership.  The           
   Company fosters a proactiv 
e 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 Richmond                   
   Facilitys strong recycling and waste minimization programs.  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 Richmond, Indiana:                                  
   The Johns Manville fiberglass insulation manufacturing plant in Richmond, Indiana              
   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 on site for    
   a single process.                                                                              
   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 glass fibers.  This binder solution is applied in the insulation manufacturing      
   process as a low VOC binder which acts to bind glass fibers.  The formaldehyde                 
   containing resin solution is stored as a liquid in several 3,800 gallon storage tanks 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 a dike that           
   minimizes 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 a release 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.  Outs 
ide responders would          
   include the local fire department and other community or contractor services as required.      
3)  Brief Description of the Worst Case Scenario, including Administrative Controls and            
    Mitigation Measures to Limit the Distances 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           
   3,800 gallons of liquid resin, which includes about 12.0% formaldehyde, is 
assumed to          
   spill with partial containment (dike) in the resin room.  Liquid not contained in the resin    
   room is assumed to spill outside and covers an area to a depth of one centimeter.              
   Distance to the toxic endpoint of 12.0 mg/m3 is calculated for Richmond 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 Richmond will result in a distance of 0.04 miles to the toxic endpoint.  A plant     
   and topographic map analysis indicates that 0.04 miles from the location of the resin tank     
   is completely on site.  Therefore, the formaldehyde-containing liquid resin process at         
   Richmond does not qualify for Program 2 of 112R.                                               
4)  Brief Description of the Five Year Accident History (68.42):                                   
   The Richmond facility has never had an accident involving formaldehyde-containing              
   liquid resin that caused deaths, injuries, property 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:                           
. 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.  Con 
fined 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, notification and numerous other programs
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