Mt. Airy, NC


HRP was retained for two tasks related to the development of a new chemical blending process at a flexible foam and chemical manufacturer in North Carolina. The first task entailed the review and approval of the structural design of a 12,000 gallon above ground storage tank to be used for the storage of pure cyclopentane. With this review, the design of secondary containment as well as the truck unloading area, and concrete details were verified by HRP’s on staff Professional Engineers.

The second task was for HRP to prepare a Process Safety Management Plan that satisfied the requirements of 40 CFR Part 68 ( EPA’s Risk Management Regulations) 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 also compiled written chemical and process safety information for the process including pure chemical states and blended mixtures, and revised an existing facility Emergency Action Plan to prepare and prevent potential accidents from occurring. Equipment detailed within the plan included bulk storage tanks, pumps and piping, heat exchangers, pressurized foam equipment, day tanks, hydrocarbon detection systems, and XP rated controls and equipment.

HRP provided the project management and leadership of 7 NCFI employees for the Process Hazard Analysis (PHA) using a What-If? Methodology via the Protech software program. In addition, HRP developed required program elements such as a Contractor Safety Program, Incident Investigation Program, Mechanical Integrity Program, Employee Participation Procedures, Management of Change Procedure, and the site specific RMP/PSM Training Program. HRP also prepared the necessary RMP Submit (EPA software) information for electronic submittal to EPA.