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Koch Fertilizer Beatrice, LLC

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Facility #1 : Koch Fertilizer Beatrice, LLC


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000036999
Deregistered (Yes/No)No
Facility NameKoch Fertilizer Beatrice, LLC
Street Address Line 121178 Southwest 89th Rd.
CityBeatrice
StateNE
Zip Code68310
Zip Code Extension9424
CountyGage County
Owner or Operator NameKoch Fertilizer Beatrice, LLC
Parent CompanyKoch Fertilizer Holding Company, LLC
Latitude40.32
Longitude-96.839167
Number of RMP Submissions10

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000053617
Submission Typerevised submission for facility
Submission Date12/11/2015
Reason For SubmissionRevised PHA / Hazard Review due to process change (40 CFR 68.190(b)(5))
Process Toxic Amount Total (lbs)140,026,000
Process Flammable Amount Total (lbs)20,000
Process Amount Total (lbs)140,046,000
Number of Potential Offsite Consequence Processes1
Potential Offsite Consequence Toxic Amount Total (lbs)140,026,000
Potential Offsite Consequence Flammable Amount Total (lbs)20,000
Potential Offsite Consequence Amount Total (lbs)140,046,000
All Process NAICS32512 325311
Exec Summary Submission Date12/11/2015

Executive Summary facility_Executive_Summary help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, executive summary: all)

Executive Summary
KOCH FERTILIZER BEATRICE, LLC



Beatrice, Nebraska



EXECUTIVE SUMMARY

FOR

THE RISK MANAGEMENT PROGRAM





Introduction and Policies



Koch Fertilizer Beatrice, LLC (KFB) is committed to managing all operations in a manner that protects the environment and the health and safety of employees, customers, contractors and the public while fully complying with applicable laws and regulations. KFB's management philosophy goals are achieved through the implementation of the EHS&T Management System, by the personal commitments of employees and contractors, and by open communication with employees, customers, neighbors, and regulators.



The purpose of this Risk Management Plan is to provide information about operations at the facility, programs to prevent accidental chemical releases, emergency response plans in the event of an accidental release, the five-year accident history of the facility, and planned changes to improve safety at the plant.





Stationary Source and Regulated Substances



KFB produces anhydrous ammonia and urea-ammonium nitrate (UAN), which are loaded on truck and railcar for distribution. Ammonia is also injected into an ammonia pipeline.



The manufacturing portion of the facility consists of an ammonia unit and a UAN unit. The ammonia unit uses natural gas, air, and water to produce ammonia. UAN solution is produced by manufacturing urea in liquid form and combining it with liquid ammonium nitrate, which is made by neutralizing nitric acid with ammonia. Carbon dioxide, a by-product of the ammonia manufacturing process, is sold to third party entities, liquefied in the facility's CO2 plant and sold, used in the UAN plant, or vented to the atmosphere.



Anhydrous ammonia and an aqueous ammonia solution are the only toxic substances regulated under the Risk Management Program (RMP) that are present at KFB in amounts above threshold quantity. Chlorine was reported in previous RMPs, but has been removed as the facility no longer uses
it for water treatment in the cooling water system. All chlorine cylinders have been removed from the facility and replaced with sodium hypochlorite (bleach), which is not an RMP substance, for use in the cooling tower. An RMP-regulated flammable mixture consisting of methane and hydrogen is found in the ammonia production process in amounts greater than threshold quantity. The facility is regulated under the Program Level 3 Prevention Program requirements.



This RMP update is required under the RMP rule due to changes in the ammonia unit, which resulted in a hazard and operability study on the primary reformer. Included in this update is the addition of an aqueous ammonia solution as an RMP toxic substance. This solution is periodically stored at a concentration greater than 20% ammonia and may, depending on operational needs, exceed 20,000 pounds of ammonia in the solution. To be conservative, the quantity of solution stored on-site is being reported as the greatest quantity that may be held in the system.



Accidental Release Prevention and Emergency Response Policies



The accidental release prevention and emergency response programs in place at the facility are part of the protective performance standards adopted by KFB. These high standards include:



- Operating in compliance with required environmental permits and regulations.

- Operating and maintaining assets in such a manner that unintentional releases are minimized.

- Operating and maintaining assets in such a manner that the small releases associated with normal operation and maintenance will be minimized to the extent possible.

- Correcting non-compliance found by regular audits of the facility.





Prevention Program



KFB is operating under the guidelines of the Occupational Safety and Health Administration (OSHA) Process Safety Management (PSM) Program. Ongoing analysis of the potential hazards of the process, detailed training of employees, and emphasis on safety have helped
minimize the potential for chemical release incidents and the severity of the few incidents that have occurred over the last 5 years. A few examples of accident prevention features implemented at this facility include:



- Removing chlorine in the cooling towers and replacing it with sodium hypochlorite thereby reducing the risk of a toxic release from the facility.

- Minimizing the possibility that combustion of ammonia vapors would be interrupted by having a continuous pilot in the flare.

- Minimizing the possibility of an interruption in power supply to the process control system by having a backup Uninterruptible Power Source (UPS) in place.

- Providing a low-amp trip system to shut down ammonia loading pumps during product movement, in order to prevent a release of ammonia.

- Installing ammonia detectors to help ensure that an ammonia release is detected and terminated as soon as possible.

- Installing low-pressure trip switches on ammonia loading hoses to stop product transfer in the event of a hose rupture.

- Requiring personnel protective equipment at all loading areas and emergency equipment in control rooms and throughout the plant.

- Providing emergency shutdown buttons at the truck loading area that can be activated in case of an ammonia release.

- Equipping the rail loading scale with an automatic shutdown that will prohibit further product movement upon reaching the weight of a full railcar.

- Requiring a brake lock system that prevents truck drivers from driving away before the loading hose is properly disconnected.

- Providing level indications on storage tanks and bullets to help prevent overfilling.

- Providing a fire water system to help with vapor control in the event of an ammonia release.

- Installing cameras at the gate and process areas for early detection of upsets.





Five-Year Accident History



Within the last five years, KFB has experienced one incident reportable in the five-year accident history of the RMP regu
lation. This incident occurred on October 7, 2013 and resulted in the evacuation of county road workers at a nearby building and road project as a precautionary measure. No injuries, deaths or environmental damage occurred during this October 2013 incident.





Emergency Response Program



The facility will continue to conduct emergency response preparedness activities and coordinate any necessary emergency response actions with the Beatrice Rural Fire Department and the Gage County Sheriff Department. As appropriate, also involved in emergency response for the facility would be the Beatrice Hazardous Materials Team, Beatrice Community Hospital, the Nebraska State Patrol, Norris Public Power, and Trailblazer (Tall Grass Energy) Gas Pipeline (natural gas supplier). The KFB Plant Manager is responsible for coordinating the emergency actions. A specific Emergency Response Plan for the facility is in place and that plan has been coordinated with local officials, along with evacuation procedures, regular drilling, and training. The Emergency Response Program provides the essential planning and training for effectively protecting workers, the public, and the environment during emergency situations.





Planned Changes to Improve Safety



Compliance with the RMP Prevention Program forms the framework for continuous safety improvement. Some of the key components of the safety program are:



- The Management of Change provisions ensure that the potential safety and health impacts of any change made to process chemicals, technology, equipment or procedures are considered.

- The Process Hazard Analysis (PHA) provisions serve as a tool to ensure timely evaluation of potential hazards, thereby leading to continual improvements in safety standards.

- The Mechanical Integrity provisions ensure that process equipment and instrumentation are designed, constructed, installed and maintained to minimize the risk of hazardous releases, thereby serving as an int
egral part of the safety program.



Specific actions that will be taken in the future to improve the level of safety at the facility include:



- Internal and third party compliance audits will ensure that the level of safety protection at the facility is periodically evaluated for improvements.

- An ongoing dialogue with the Gage County Emergency Management Director or his designate will ensure a constant state of readiness to respond to any potential emergencies, as well as a means to implement improvements as the need develops.



All interested citizens or community organizations are encouraged to contact the Gage County Emergency Management Director for the latest information on emergency response for the county. The facility coordinates its response capabilities and personnel with those of the county on an ongoing basis.








Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees86
Owner or Operator NameKoch Fertilizer Beatrice, LLC
Owner or Operator Address Line 121178 Southwest 89th Road
Owner or Operator CityBeatrice
Owner or Operator StateNE
Owner or Operator Zip68310
Owner or Operator Zip Extension9424
Parent Dun and Bradstreet Number0
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees86
Number of FTE CBI FlagNo
Other Facility ID68310FRMLN4MIWE
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VYes
CAA Title V Air Operating Permit IDOPSPR1-0036
Last Safety Inspection Date20150616
Last Safety Inspection ByState environmental agency
OSHA Star or Merit RankingNo
LEPC NameHomestead LEPC

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211)
Owner or Operator Phone4022233577
Facility Dun and Bradstreet Number0
RMP ContactPhillip Joyner
RMP Contact TitlePlant Manager
RMP Contact EmailPhil.Joyner@kochind.com
RMP Preparer NameOne World Resource LLC/Ann Slater
RMP Preparer Address Line 1P.O. Box 2339
RMP Preparer CitySt. Francisville
RMP Preparer StateLA
RMP Preparer Zip70775
RMP Preparer Phone2257213019

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsNo
Complete Check Date20151211
Error Report Datenull
Postmark Date20151211
Anniversary Date20201211
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211)
Latitude40.32
Longitude-96.839167
Valid Lat/LongYes
Lat/Long MethodGPS - Unspecified
Lat/Long Location TypeCenter of Facility
FRS Latitude40.3191
FRS Longitude-96.8413
FRS Lat/Long DescriptionPLANT ENTRANCE (GENERAL)
FRS Lat/Long MethodGPS CODE (PSEUDO RANGE) DIFFERENTIAL

Submission - Counts and Totals facility_Submission_-_Counts_and_Totals help link help link  
Number of RMP Accidents1
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)3,923
RMP Accident Amount Total (lbs)3,923
Number of RMP Accidents1
Number of Processes1
Number of Process Chemicals0
Number of Toxic Worst-case Scenarios1
Number of Toxic Alternate Case Scenarios2
Number of Flammable Worst-case Scenarios1
Number of Flammable Alternate Case Scenarios1
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)3,923
RMP Accident Amount Total (lbs)3,923
Total RMP Accident Deaths0
Total RMP Accident Injuries0
Total RMP Accident Evacuated/Sheltering In Place5
Total RMP Accident Property Damage$0

Processes facility_Processes help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg)
Process DescriptionNitrogen Fertilizer Mfg
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)140,026,000
Flammable Amount Total (lbs)20,000
Process Amount Total (lbs)140,046,000
Number of Process Chemicals0
Number of Toxic Worst-Case Scenarios1
Number of Toxic Alternate Scenarios2
Number of Flammable Worst-Case Scenarios1
Number of Flammable Alternate Scenarios1

Process Chemicals facility_Process_Chemicals help link help link  
Process Chemical IDAmmonia (anhydrous)
CAS number007664417
Chemical TypeToxic
Process Chemical Amount (lbs)140,000,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg, process chemical #2)
Process Chemical IDFlammable Mixture
CAS number000001111
Chemical TypeFlammable
Process Chemical Amount (lbs)20,000
Confidential Business InformationNo

Process Flammable Mixture Chemicals facility_Process_Flammable_Mixture_Chemicals help link help link  
Chemical ID
Hydrogen
Methane

Process Chemicals facility_Process_Chemicals help link help link  
Process Chemical IDAmmonia (conc 20% or greater)
CAS number007664417
Chemical TypeToxic
Process Chemical Amount (lbs)26,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg, process chemical #4)
Process Chemical IDPublic OCA Chemical
CAS number000000000
Process Chemical Amount (lbs)0
Confidential Business InformationNo

Worst-Case Toxic Scenarios facility_Worst-Case_Toxic_Scenarios help link help link  
Physical StateGas liquified by pressure
Model UsedEPA's RMP*Comp(TM)
Release Duration (minutes)10
Wind Speed (meters/sec)1.5
Atmospheric Stability ClassF
TopographyRural
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsNo
Confidential Business InformationNo

Alternate Case Toxic Scenarios facility_Alternate_Case_Toxic_Scenarios help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg, process chemical #4, alternate toxic scenario #1)
Physical StateGas liquified by pressure
Model UsedEPA's RMP*Comp(TM)
Wind Speed3
Atmospheric Stability ClassD
TopographyRural
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsNo
Active Mitigation - SprinklersNo
Active Mitigation - Deluge SystemsNo
Active Mitigation - Water CurtainNo
Active Mitigation - NeutralizationNo
Active Mitigation - Excess Flow ValvesNo
Active Mitigation - FlaresNo
Active Mitigation - ScrubbersNo
Active Mitigation - Emergency ShutdownYes
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg, process chemical #5)
Process Chemical IDPublic OCA Chemical
CAS number000000000
Process Chemical Amount (lbs)0
Confidential Business InformationNo

Worst-Case Flammable Scenarios facility_Worst-Case_Flammable_Scenarios help link help link  
Model UsedEPA's RMP*Comp(TM)
Passive Mitigation - Blast WallsNo
Confidential Business InformationNo

Alternate Case Flammable Scenarios facility_Alternate_Case_Flammable_Scenarios help link help link  
Model UsedEPA's RMP*Comp(TM)
Passive Mitigation - DikesNo
Passive Mitigation - Fire WallsNo
Passive Mitigation - Blast WallsNo
Passive Mitigation - EnclosuresNo
Active Mitigation - SprinklersNo
Active Mitigation - Deluge SystemsNo
Active Mitigation - Water CurtainNo
Active Mitigation - Excess Flow ValvesNo
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg, process chemical #6)
Process Chemical IDPublic OCA Chemical
CAS number000000000
Process Chemical Amount (lbs)0
Confidential Business InformationNo

Alternate Case Toxic Scenarios facility_Alternate_Case_Toxic_Scenarios help link help link  
Percent Weight (Within Mixture)24
Physical StateLiquid
Model UsedEPA's RMP*Comp(TM)
Wind Speed3
Atmospheric Stability ClassD
TopographyRural
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsNo
Active Mitigation - SprinklersNo
Active Mitigation - Deluge SystemsNo
Active Mitigation - Water CurtainNo
Active Mitigation - NeutralizationNo
Active Mitigation - Excess Flow ValvesNo
Active Mitigation - FlaresNo
Active Mitigation - ScrubbersNo
Active Mitigation - Emergency ShutdownNo
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg, process NAICS code #1 : 32512)
NAICS Code32512: Industrial Gas Manufacturing

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date20150615
PHA Update Date20130510
PHA Technique - What IfNo
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistYes
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date20160530
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionNo
Hazard Identified - Runaway ReactionNo
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionYes
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationNo
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossYes
Hazard Identified - EarthquakeNo
Hazard Identified - FloodNo
Hazard Identified - TornadoNo
Hazard Identified - HurricaneNo
Process Controls - VentsYes
Process Controls - Relief ValvesYes
Process Controls - Check ValvesYes
Process Controls - ScrubbersNo
Process Controls - FlaresNo
Process Controls - Manual ShutoffsYes
Process Controls - Auto ShutoffsYes
Process Controls - InterlocksYes
Process Controls - AlarmsYes
Process Controls - Keyed BypassNo
Process Controls - Emergency AirYes
Process Controls - Emergency PowerNo
Process Controls - Backup PumpYes
Process Controls - GroundingYes
Process Controls - Inhibitor AdditionYes
Process Controls - Rupture DisksYes
Process Controls - Excess Flow DevicesYes
Process Controls - Quench SystemNo
Process Controls - Purge SystemNo
Process Controls - NoneNo
Mitigation Systems - SprinklersNo
Mitigation Systems - DikesNo
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsNo
Mitigation Systems - Water CurtainsNo
Mitigation Systems - EnclosureYes
Mitigation Systems - NeutralizationNo
Mitigation Systems - NoneNo
Mitigation Systems - OtherFire Water System, Building Ventilation
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterYes
Monitoring Systems - NoneNo
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryNo
Changes Since PHA - Process ParametersYes
Changes Since PHA - Process ControlsYes
Changes Since PHA - Process DetectionNo
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Changes Since PHA - OtherEmergency Lighting and Exit Signs
Procedure Review Date20150809
Training Review Date20140401
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherCross-site help from operators familiar with system
Competency Testing - Written TestsYes
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Competency Testing - OtherMultiple layers of sign-off
Maintenance Review Date20150821
Maintenance Inspection Date20150911
Equipment TestedCable DB02B to 70TON 480 After Oil
Management of Change Most Recent Date20150615
Management of Change Review Date20150817
Pre-startup Review Date20151005
Compliance Audit Date20130222
Compliance Audit Change Completion Date20160131
Incident Investigation Date20150710
Incident Invest. Change Completion Date20160601
Participation Plan Review Date20131024
Hot Work Review Date20140220
Contractor Safety Review Date20140326
Contractor Safety Eval. Date20151009
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg, process NAICS code #1 : 32512, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000083152

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
The facility consists of one "covered" process, Nitrogen Fertilizer Mfg., which is separated into units for the purposes of the Prevention Program. Units include: (1) Ammonia production unit, (2) Urea-Ammonium Nitrate (UAN) production unit, (3) Loading and Storage, and (4) CO2 Plant. This record refers to the CO2 Plant. Each unit (and Prevention Program) has elements that are specific to that unit. They are: Process Hazard Analysis, Operating Procedures, Maintenance (Mechanical Integrity), Management of Change, Pre-startup Safety Review, and Incident Investigation. Those elements implemented on a plant-wide basis include: Training, Maintenance program, Management of Change program, Compliance Audits, Employee Participation Plan, Hot Work Permit Program, Contractor Safety Program, and Contractor Safety Evaluation. The information submitted for the latter elements is the same for all units.

Process NAICS facility_Process_NAICS help link help link  
NAICS Code325311: Nitrogenous Fertilizer Manufacturing

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date20150624
PHA Update Date20150624
PHA Technique - What IfYes
PHA Technique - ChecklistYes
PHA Technique - What If/ChecklistYes
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Technique - OtherLayer of Protection Analysis
PHA Change Completion Date20171215
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionYes
Hazard Identified - Runaway ReactionYes
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionYes
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationYes
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossYes
Hazard Identified - EarthquakeNo
Hazard Identified - FloodNo
Hazard Identified - TornadoNo
Hazard Identified - HurricaneNo
Process Controls - VentsYes
Process Controls - Relief ValvesYes
Process Controls - Check ValvesYes
Process Controls - ScrubbersYes
Process Controls - FlaresYes
Process Controls - Manual ShutoffsYes
Process Controls - Auto ShutoffsYes
Process Controls - InterlocksYes
Process Controls - AlarmsYes
Process Controls - Keyed BypassYes
Process Controls - Emergency AirYes
Process Controls - Emergency PowerYes
Process Controls - Backup PumpYes
Process Controls - GroundingYes
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksYes
Process Controls - Excess Flow DevicesYes
Process Controls - Quench SystemYes
Process Controls - Purge SystemYes
Process Controls - NoneNo
Mitigation Systems - SprinklersNo
Mitigation Systems - DikesNo
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsYes
Mitigation Systems - Water CurtainsNo
Mitigation Systems - EnclosureNo
Mitigation Systems - NeutralizationNo
Mitigation Systems - NoneNo
Mitigation Systems - OtherFire Water System
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterYes
Monitoring Systems - NoneNo
Monitoring Systems - OtherCameras
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryNo
Changes Since PHA - Process ParametersYes
Changes Since PHA - Process ControlsYes
Changes Since PHA - Process DetectionYes
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Procedure Review Date20151022
Training Review Date20140401
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherCross-site help from operators familiar with system
Competency Testing - Written TestsYes
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Competency Testing - OtherMultiple layers of sign-off
Maintenance Review Date20150821
Maintenance Inspection Date20150831
Equipment TestedFV-1001
Management of Change Most Recent Date20151016
Management of Change Review Date20150817
Pre-startup Review Date20151006
Compliance Audit Date20130222
Compliance Audit Change Completion Date20160131
Incident Investigation Date20151016
Incident Invest. Change Completion Date20151016
Participation Plan Review Date20131024
Hot Work Review Date20140220
Contractor Safety Review Date20140326
Contractor Safety Eval. Date20151009
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg, process NAICS code #2 : 325311, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000083152
1000083153

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  

Prevention Program Description
The facility consists of one "covered" process, Nitrogen Fertilizer Manufacturing, which is separated into units for the purposes of the RMP Prevention Program. Units include: 1) Ammonia production unit, 2) Urea-Ammonium Nitrate (UAN) production unit, 3) Loading and Storage, and 4) CO2 Plant. This record refers to the Ammonia production unit. Each unit (and Prevention Program) has elements that are specific to that unit. They are: Process Safety Information, Process Hazard Analysis, Operating Procedures, Maintenance (Mechanical Integrity), Management of Change, Pre-startup Safety Review, and Incident Investigation. Those elements implemented on a plant-wide basis include: Training, Maintenance program, Management of Change program, Compliance Audits, Employee Participation Plan, Hot Work Permit program, Contractor Safety program, and Contractor Safety Evaluation. The information submitted in this RMP for the latter elements is the same for all units.
Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date20151006
PHA Update Date20110415
PHA Technique - What IfNo
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date20151215
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionYes
Hazard Identified - Runaway ReactionYes
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionYes
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationYes
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossYes
Hazard Identified - EarthquakeNo
Hazard Identified - FloodNo
Hazard Identified - TornadoNo
Hazard Identified - HurricaneNo
Process Controls - VentsYes
Process Controls - Relief ValvesYes
Process Controls - Check ValvesYes
Process Controls - ScrubbersYes
Process Controls - FlaresYes
Process Controls - Manual ShutoffsYes
Process Controls - Auto ShutoffsYes
Process Controls - InterlocksYes
Process Controls - AlarmsYes
Process Controls - Keyed BypassNo
Process Controls - Emergency AirYes
Process Controls - Emergency PowerYes
Process Controls - Backup PumpYes
Process Controls - GroundingYes
Process Controls - Inhibitor AdditionYes
Process Controls - Rupture DisksYes
Process Controls - Excess Flow DevicesYes
Process Controls - Quench SystemNo
Process Controls - Purge SystemNo
Process Controls - NoneNo
Mitigation Systems - SprinklersNo
Mitigation Systems - DikesYes
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsNo
Mitigation Systems - Water CurtainsNo
Mitigation Systems - EnclosureYes
Mitigation Systems - NeutralizationYes
Mitigation Systems - NoneNo
Mitigation Systems - OtherFire Water System, Building Ventilation
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterYes
Monitoring Systems - NoneNo
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryYes
Changes Since PHA - Process ParametersYes
Changes Since PHA - Process ControlsYes
Changes Since PHA - Process DetectionYes
Changes Since PHA - Perimeter MonitoringYes
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Changes Since PHA - OtherInstalled pressure indicator on safety shower skid, replaced safety shower pumps
Procedure Review Date20150930
Training Review Date20140401
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherCross-site help from operators familiar with system
Competency Testing - Written TestsYes
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Competency Testing - OtherMultiple layers of sign-off
Maintenance Review Date20150821
Maintenance Inspection Date20150813
Equipment TestedEast BFW Turbine
Management of Change Most Recent Date20151008
Management of Change Review Date20150817
Pre-startup Review Date20151001
Compliance Audit Date20130222
Compliance Audit Change Completion Date20160131
Incident Investigation Date20150708
Incident Invest. Change Completion Date20160530
Participation Plan Review Date20131024
Hot Work Review Date20140220
Contractor Safety Review Date20140326
Contractor Safety Eval. Date20151009
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg, process NAICS code #2 : 325311, prev. program 3 #2, prev. program 3 chemical: all)
Process Chemical Record ID
1000083152

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  

Prevention Program Description
The facility consists of one "covered" process, Nitrogen Fertilizer Manufacturing, which is separated into units for the purposes of the Prevention Program. Units include: 1) Ammonia production unit, 2) Urea-Ammonium Nitrate (UAN) production unit, 3) Loading and Storage, and 4) CO2 Plant. This record refers to the UAN production unit. Each unit (and Prevention Program) has elements that are specific to that unit. They are: Process Safety Information, Process Hazard Analysis, Operating Procedures, Maintenance (Mechanical Integrity), Management of Change, Pre-startup Safety Review, and Incident Investigation. Those elements implemented on a plant-wide basis include: Training, Maintenance program, Management of Change program, Compliance Audits, Employee Participation Plan, Hot Work Permit program, Contractor Safety program, and Contractor Safety Evaluation. The information submitted in this RMP for the latter elements is the same for all units.
Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date20151130
PHA Update Date20141031
PHA Technique - What IfYes
PHA Technique - ChecklistYes
PHA Technique - What If/ChecklistYes
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Technique - OtherLayer of Protection Analysis
PHA Change Completion Date20160515
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionYes
Hazard Identified - Runaway ReactionNo
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionYes
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationNo
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossYes
Hazard Identified - EarthquakeNo
Hazard Identified - FloodNo
Hazard Identified - TornadoNo
Hazard Identified - HurricaneNo
Process Controls - VentsYes
Process Controls - Relief ValvesYes
Process Controls - Check ValvesYes
Process Controls - ScrubbersNo
Process Controls - FlaresYes
Process Controls - Manual ShutoffsYes
Process Controls - Auto ShutoffsYes
Process Controls - InterlocksYes
Process Controls - AlarmsYes
Process Controls - Keyed BypassNo
Process Controls - Emergency AirYes
Process Controls - Emergency PowerNo
Process Controls - Backup PumpYes
Process Controls - GroundingYes
Process Controls - Inhibitor AdditionYes
Process Controls - Rupture DisksNo
Process Controls - Excess Flow DevicesYes
Process Controls - Quench SystemNo
Process Controls - Purge SystemNo
Process Controls - NoneNo
Mitigation Systems - SprinklersNo
Mitigation Systems - DikesYes
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsNo
Mitigation Systems - Water CurtainsNo
Mitigation Systems - EnclosureYes
Mitigation Systems - NeutralizationNo
Mitigation Systems - NoneNo
Mitigation Systems - OtherFire Water System
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterYes
Monitoring Systems - NoneNo
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryNo
Changes Since PHA - Process ParametersYes
Changes Since PHA - Process ControlsYes
Changes Since PHA - Process DetectionNo
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Procedure Review Date20150914
Training Review Date20140401
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherCross-site help from operators familiar with system
Competency Testing - Written TestsYes
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Competency Testing - OtherMultiple layers of sign-off
Maintenance Review Date20150821
Maintenance Inspection Date20150911
Equipment TestedCable B02B to 70TON 480 After Oil
Management of Change Most Recent Date20151020
Management of Change Review Date20150817
Pre-startup Review Date20150912
Compliance Audit Date20130222
Compliance Audit Change Completion Date20160131
Incident Investigation Date20150629
Incident Invest. Change Completion Date20151201
Participation Plan Review Date20131024
Hot Work Review Date20140220
Contractor Safety Review Date20140326
Contractor Safety Eval. Date20151009
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, process #1 : Nitrogen Fertilizer Mfg, process NAICS code #2 : 325311, prev. program 3 #3, prev. program 3 chemical: all)
Process Chemical Record ID
1000083152
1000083154

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
The facility consists of one "covered" process, Nitrogen Fertilizer Manufacturing, which is separated into units for the purposes of the Prevention Program. Units include: 1) Ammonia production unit, 2) Urea-Ammonium Nitrate (UAN) production unit, 3) Loading and Storage, and 4) CO2 Plant. This record refers to Loading and Storage. Each unit (and Prevention Program) has elements that are specific to that unit. They are: Process Safety Information, Process Hazard Analysis, Operating Procedures, Maintenance (Mechanical Integrity), Management of Change, Pre-startup Safety Review, and Incident Investigation. Those elements implemented on a plant-wide basis include: Training, Maintenance program, Management of Change program, Compliance Audits, Employee Participation Plan, Hot Work Permit program, Contractor Safety program, and Contractor Safety Evaluation. The information submitted in this RMP for the latter elements is the same for all units.

Accidents facility_Accidents help link help link  
Accident Date20131007
Accident Time925
Number of Chemicals1
Flammable Amount Total (lbs)0
Toxic Amount Total (lbs)3,923
Released Amount Total (lbs)3,923
Number of Deaths0
Number of Injuries0
Number Evacuated / Sheltered5
Total Property Damage$0
Environmental DamageNo
NAICS of Process Involved325311: Nitrogenous Fertilizer Manufacturing
Release Duration (HHHMM)4
Release Event - Gas ReleaseYes
Release Event - SpillNo
Release Event - FireNo
Release Event - ExplosionNo
Release Event - ReactionNo
Release Source - Storage VesselNo
Release Source - PipingNo
Release Source - Process VesselYes
Release Source - Transfer HoseNo
Release Source - ValveYes
Release Source - PumpNo
Release Source - JointNo
Wind Speed5
Wind Speed Unitsmiles/h
Wind DirectionSE
Temperature60
Atmospheric Stability ClassB
PrecipitationNo
Unknown WeatherNo
Workers Killed0
Responders Killed0
Public Killed (on-site)0
Workers Injured0
Responders Injured0
Public Injured (on-site)0
Property Damage (on-site)$0
Off-site Deaths0
Hospitalizations0
Number Requiring Medical Treatment0
Number Evacuated5
Number Sheltered In Place0
Property damage (off-site)$0
Environmental Damage - Fish/Animal KillsNo
Environmental Damage - DefoliationNo
Environmental Damage - Water ContaminationNo
Environmental Damage - Soil ContaminationNo
Initiating EventHuman Error
Contributing Factor - Equipment FailureYes
Contributing Factor - Human ErrorYes
Contributing Factor - Improper ProcedureYes
Contributing Factor - OverpressurizationNo
Contributing Factor - Upset ConditionNo
Contributing Factor - By-pass ConditionNo
Contributing Factor - MaintenanceYes
Contributing Factor - Process DesignNo
Contributing Factor - Unsuitable EquipmentNo
Contributing Factor - Unusual WeatherNo
Contributing Factor - Management ErrorNo
Off-site Responders NotifiedNotified Only
Changes Introduced - Improved EquipmentNo
Changes Introduced - Revised MaintenanceYes
Changes Introduced - Revised TrainingYes
Changes Introduced - Operating ProceduresYes
Changes Introduced - Process ControlNo
Changes Introduced - Mitigation SystemsNo
Changes Introduced - Response PlanNo
Changes Introduced - Changed ProcessNo
Changes Introduced - Reduced InventoryNo
Changes Introduced - NoneNo
Changes Introduced - OtherAdded acoustic sensor
Total RMP Accident Deaths0
Total RMP Accident Injuries0
Total RMP Accident Evacuated/Sheltering In Place5
Total RMP Accident Property Damage$0

Accident Chemicals facility_Accident_Chemicals help link help link (Facility #1 : Koch Fertilizer Beatrice, LLC, RMP submission #1 : 20151211, accident #1, accident chemical #1)
Chemical IDAmmonia (anhydrous)
CAS number007664417
Chemical TypeToxic
Amount Released (lbs)3,923
Percent Weight (Within Mixture)100

Emergency Response Plan Info facility_Emergency_Response_Plan_Info help link help link  
Facility In Community PlanYes
Facility Own Response PlanYes
Specific Facility Response PlanYes
Inform. Procedures in Response PlanYes
Emergency Care in Response PlanYes
Plan Review Date20140123
Response Training Date20151001
Local Response AgencyBeatrice Rural Fire Department
Local Response Agency Phone4022234080
Subject To - OSHA EAPYes
Subject To - OSHA HAZWOPERYes
Subject To - CWAYes
Subject To - RCRANo
Subject To - OPANo
Subject To - State EPCRAYes


Search Criteria Used
RMP Facility ID100000036999

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