To assist a manufacturer of polyisocyanurate foam insulation for the commercial and residential markets, HRP prepared a construction air permit application for the use of isopentane/cyclopentane blowing agent in the production of foam board. As leaders of this commercial market sector, the client gained a distinctive quality and cost advantage by obtaining this air permit and thus market share of the revenue for their products. In addition, HRP prepared a combination Risk Management / Process Safety Management Plan that satisfied the requirements of 40 CFR 68 (EPA’s Chemical Accident Prevention Provisions) and 29 CFR 1910.119 (OSHA’s Process Safety Management of Highly Hazardous Chemicals).
HRP performed off-site impact analyses for both worst case (rupture of 12,000 gallon storage tank containing cyclopentane) and alternative chemical release scenarios (rupture piping, hoses, or pump release of cyclopentane) using EPA approved software. HRP compiled written chemical and process safety information including pure chemical states and blended mixtures. Equipment analyzed included bulk storage tanks, pumps and piping, heat exchangers, pressurized foam equipment, day tanks, hydrocarbon detection systems, and NFPA/NEC Class I Division 1/2 electrically XP rated controls and equipment.
HRP provided the project management and leadership of 10 Rmax employees for the Process Hazard Analysis (PHA) using a What-If? Methodology via a software program. HRP also prepared the necessary RMP Submit (EPA software) information for electronic submittal to EPA.
To date, the client has retained HRP for two (2) iterations of PSM Program Audits and two (2) 5-year PHA update reviews pre OSHA regulations.