Owens Corning Fairburn plant - Executive Summary

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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.  
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  
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. 
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. 
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  
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  
Distance to Endpoint  -    0.22 miles  (ALOHA) 
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  
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  
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  
No mitigation measures were considered in formulating the alternative  
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. 
No documented incidents have occurred for either covered process during  
the preceding five-year period. 
Fairburn maintains an up-to-date Emergency Response Plan and conducts  
mock drills to train personnel on response procedures. 
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.
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