Owens Corning Fairburn plant - Executive Summary |
EXECUTIVE SUMMARY 1.0 INTRODUCTION Owens Corning is committed to achieving environmental leadership within its industry and beyond. The Insulation Systems Business Unit (ISB), of which the Fairburn Insulation Plant is a key part, demonstrates this pursuit of excellence by proactively managing its operations to reduce environmental impacts while improving the quality of its products and the well-being of its employees and the community. ISB Environmental has implemented a programmatic approach to compliance with the EPA's Risk Management Program (RMP) Rule. All of the business units manufacturing facilities will address process safety and risk management issues for key materials utilized by the plants in manufacturing fiberglass insulation products. The program will fulfill the general duty clause requirement in the RMP rule. Facilities, like Fairburn, with threshold quantities above the RMP triggers, have utilized a management manual system to comply with the require ments of RMP. This submittal only characterizes the subject processes that require a RMP submittal and certification by June 21, 1999. 2.0 ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES Owens Corning is committed to developing and operating its manufacturing facilities in a manner protective of the environment and human health. This priority is expressed through continuing process improvement, risk reduction, and an emphasis on pollution prevention. In order to produce the quality products that Owens Corning is known for, the Fairburn facility uses an aqueous ammonia solution to maintain the pH of the chemical binder that is used at the facility. The facility uses propane as motorized vehicle fuel for forklift trucks, as well as back-up fuel. Because these are toxic chemicals, numerous controls have been implemented to prevent an accidental release of these chemicals. In the event of a release, the Fairburn facility has an emergency response program that will be implemented. This program is made up of employee volunteers that have been properly trained in certain elements of emergency response, as well as communication with the appropriate responder organizations in the community. 3.0 DESCRIPTION OF THE FACILITY AND REGULATED PROCESSES The Fairburn facility, located in Fairburn, Georgia, is a producer of wool glass fibers, which are fabricated into insulation materials. Glass fiber manufacturing involves the high-temperature conversion of various materials into a homogeneous melt, followed by the fabrication of this melt into glass fibers. After the formation of the glass fibers, a thermosetting chemical binder solution is applied to the fibers. The glass fibers and binder solution are then collected on a conveyor belt where they are sent through a large curing oven and then through a cooling section. The result is a mat that is then cut into batts or rolls of the desired dimensions and then packaged. The Fairb urn Insulation plant has two covered processes that are subject to RMP. Both the aqueous ammonia and liquid propane storage tank systems are classified as Program 2 processes. The ammonia process is a binder system ingredient used to manufacture wool fiberglass insulation at the plant. Propane is used as a backup fuel for the process and as a motor vehicle fuel for plant forklifts and service equipment. 4.0 HAZARD ASSESSMENT RESULTS Owens Corning has determined the distance to the toxic endpoints for the regulated substances present at the Fairburn facility. The following release scenarios have been considered: 29.5% Ammonia 29.5% aqueous ammonia is received by bulk tanker truck in approximately 4,700-gallon loads. The bulk liquid is then off loaded from the truck into a 12,000- gallon fiberglass Ammonia storage tank in the Tank Farm. The tank is located in a diked containment area with a surface area of 546.2 square feet. Tanker trucks unload the material throu gh a 2-inch hose. Worst-case release is an instantaneous release of 62,000-gallons of aqueous ammonia, which forms a liquid pool in the dike. The release duration is assumed to be 60-minutes because the concentration of aqueous ammonia in solution after 10-minutes of evaporation is not significantly lower than the initial concentration. Distance to Endpoint - 0.45 miles (ALOHA) The alternative release involves a failure of the unloading line during product delivery resulting in a release of 3,800 pounds over a 5-minute period. The liquid released from the line break is not immediately contained. Distance to Endpoint - 0.22 miles (ALOHA) Propane Propane is stored in six interconnected horizontal storage tanks of 29,835-gallon water capacity. The maximum fill volume of each propane tank is 80% for a capacity of 23,868 gallons. At 4.24 lb/gal, each tank maximum inventory is 101,200 pounds. The tanks operate at ambient temperature and equilibrium pre ssure. Worst-case release is an instantaneous release of maximum inventory and formation of a vapor cloud, which explodes. Ten percent of the vapor participates in the explosion. Endpoint for a flammable is defined as the distance to a 1-psi overpressure. Distance to Endpoint - 0.38 miles (OCAG) Alternative case release is an instantaneous release of maximum inventory and formation of a vapor cloud, which explodes. Three percent of the vapor participates in the explosion. Endpoint for a flammable is defined as the distance to a 1-psi overpressure. Distance to Endpoint - 0.23 miles (OCAG) The release scenarios examined above could result in off-site impact. Both OCA guidance look-up table values and air dispersion modeling results for the toxic compounds via ALOHA were examined and reported as indicated. 5.0 GENERAL ACCIDENTAL RELEASE PREVENTION/CHEMICAL- SPECIFIC PREVENTION STEPS No mitigation measures were considered in formulating the alternative scen arios. The presence of a spill containment system to prevent stormwater contact serves to protect the plant's stormwater retention pond. However, it was not considered in evaluating the impact of the release scenarios. Accidental releases are mitigated by an aggressive spill reporting program and operator training in spill response. 6.0 FIVE-YEAR ACCIDENT HISTORY No documented incidents have occurred for either covered process during the preceding five-year period. 7.0 EMERGENCY RESPONSE PROGRAM Fairburn maintains an up-to-date Emergency Response Plan and conducts mock drills to train personnel on response procedures. 8.0 PLANNED CHANGES TO IMPROVE SAFETY In 1998, a spill containment area and system was installed for $137,000. The purpose of this area is to capture all non-storm water activity prior to reaching the plant's main storm water retention pond, which ultimately discharges off plant property. The containment area addresses all controlled drainage surfaces such as plant roadways, chemical and material handling and storage areas, and the plant roof. The containment area is equipped with sensors, which when activated, control a sluice gate at the inlet of the stormpond. Upon evaluation, captured materials can be removed to storage areas for appropriate disposition. |