The Henkel Corporation, Kankakee, Illinois, facility considers protection of employees, the public and the environment to be its most important responsibility. A key element of its protection program is the developemnt and implementation of plans to prevent accidental chemical releases. In addition, if an accidental release should occur, the facility is prepared to respond in an organized and effective manner.
The Henkel Corporation, Kankakee, Illinois, facility accident prevention and emergency response programs have been developed in accordance with federal and state regulations industry standards, and coordiation from Kankakee County emergency response organizations. Although the facility's programs have been highly successful - the facility has never had a significant chemical release - the facility continually seeks ways to improve its prevention and response programs.
federal regulatory requirements regarding the prevention of accidental chemical releases (40 CFR Part 68 Accidental Release Prevention Requirements). The purpose of the regulation is to reduce the potential for an accidental chemical release and strengthen emergency response planning at the facility and within the community. The RMP describes the incident at the facility which would have the most catastrohpic effects ("the worst case") and several scenarios of lesser magnitude ("alternative cases"). Although it is highly unlikely for the worse case described in the report to occur, worst case information is provided to support conservative emergency response planning. In this way, the community is well prepared to respond to the lesser magnitude scenarios which are more likely to occur.
cial release modeling. Henkel invested in this software to ensure that it had access to the most accurate emergency planning data available.
Henkel Corporation is part of the worldwide Henkel Group, headquartered in Dusseldorf, Germany. Henkel Corporation manufactures products that improve people's lives. Henkel produces chemical ingredients that are used in many industries including personal care (such as soap and shampoo), nutrition, automotive, construction, paint and agriculture. Henkel supplies pretreatment products to help metal and plastic surfaces resist corrosion and remain attractive and serviceable. Henkel Supplies high-tech adhesives to growth sectors, and other adhesives for manufacturing operaitons. And Henkel is a growing provider for adhesives, stationery supplies and home improvement products for retail consumers. The Henkel Group has more than 55,000 employees serving in more than 330 companies in 70 nations.
a central tenet of Henkel. Henkel Corporation was cited by the U.S. Environmental Protection Agency as an Environmental Champion for our performance in the voluntary 33/50 pollution prevention program. Henkel voluntarily participates in the Chemcial Manufacturers' Association Responsible Care initiative and is implementing its environmental, health and safety codes of practice on a worldwide basis.
It is the policy of the Henkel Corporation facility to prevent all releases of potentially harmful substances. Senior management is responsible for release prevention and response programs and the facility has invested extensive time and resources in this effort.
The facility has detailed procedures which ensure that safety is considered in the design, installation, operation and maintenance of each process. Facility personnel receive regular safety training and employee input is solicited on every aspect of safety improvement.
Failure to follow safety policies is grounds for dismissal.
If a release were to occur, trained facility personnel would control and contain the release. The standard procedure is to technically evaluate each situation, identify potential on-site and off-site impacts, evacuate workers as necessary, contain the release and contact the local fire department to control the release and reduce any consequences.
The Henkel Corporation, Kankakee, Illinois, facility is a chemical manufacturing facility located at South Kensington Road. This facility is one of the largest Henkel manufacturing sites in the United States. Orginally constructed in 1948, the facility is situated on 310 acres of area land. Of this, more than 75 acres have been developed. The plant operates 24-hours a day, seven days a week. On average employees have more than 13 years of service with the company.
s, adhesives, shampoos, inks, coatings, food additives, vinyl sidings and plastic pipe.
The Kankakee site serves as an important distribution center. Centrally located in the United States, it is within one day's transportation time of nearly half of the country's industry. The facility also exports products worldwide.
The facility handles three substances regulated by the RMP rule in sufficient quantities to be covered by the RMP rule: anhydrous ammonia, ethylenediamine and hydrogen chloride. The RMP rules classifies these chemicals as toxic substances. No facility chemicals are classified as flammable substances.
Chemical-specific information, including exposure hazards and emergency response/exposure treatment considerations, is provided in material safety data sheets (MSDSs). For specific process areas, the facility has documented safety-related limits for specific process parameters (e.g., temperature, level, composition) within the batch cards and operating proceudres. The facility ensures that the process is maintained within these limits using process controls and monitoring instruments, highly trained personnel, and protective instrument systems (e.g., automated shutdown systems).
information about the design and construction of process equipment. The information includes materials of construction, design pressure and temperature ratings, electrical rating of equipment, etc. This information, in combination with written procedures and trained personnel, provides a basis for establishing inspection and maintenance activities, as well as for evaluating proposed process and facility changes to ensure that safety features in the process are not compromised. Operating personnel have access to the information described above.
To ensure that personnel operate equipment in accordance with all safety precautions, the facility maintains detailed written operating procedures. The procedures describe the safety considerations unique to specific operating modes, e.g.
used as a reference by experienced operators and provide a basis for consistent training for new operators. These procedures are periodically reviewed and annually certified as current and accurate. The procedures are maintained current and accurate by revising them as necessary to reflect changes made through the management of change (MOC) process.
- safe work practices prior to their beginning work.
l periodically monitor contractor performance to ensure that contractors are fulfilling their safety obligations.
The facility conducts a PSSR for any new process or process modification that requires a change in process safety information. The purpose of the PSSR is to ensure that safety features, procedures, personnel, and equipment are prepared before placing the equipment into service. This review provides one additional check to make sure construction is in accordance with design specifications and that all supporting systems are operationally ready. The PSSR review team uses checklists to verify all aspects of readiness. A PSSR involves field verification of the construction and serves a quality assurance function by requireing verification that proces safeyt management and accident prevention program requirements are properly implemented.
In combination, these activities form a system that maintains the mechanical integrity of the process equipment.
Maintenance personnel training includes an overview of the process, safety and health hazards, applicable maintenance procedures, emergency response plans and applicable safe work practices. Written procedures help ensure that work is performed in a consistent manner and provide a basis for training. Inspections and tests are performed to help ensure that equipment functions as intended, and to verify that equipment is within acceptable limits (e.g., adequate wall thickness for pressure vessels).
If a deficiency is identified, employees will correct the deficiency before placing the equipment back into service (if possible), or an MOC team will review the use of the equipment and determine what actions are necessary to ensure the safe operation of the equipment.
Another integral part of the mechanical integrity program is quality assurance. The facility incorporates quality assurance measures into equipment purchases and repairs. This helps ensure that the new equipment is suitable for its intended use and that proper materials and spare parts are used when repairs are made.
These procedures ( and others), along with training of affected personnel, form a system to help ensure that operations and maintenance activities are performed safely.
updated to incorporate these changes. In addition, operating and maintenance personnel are provided any necessary training on the change.
t 5 years so that te reports can be reviewd during future PHAs and PHA revalidations.
To help ensure that the accident prevention program is functioning properly, the Kankakee facility periodically conducts an audit to determine whether the procedures and practices required by the accident prevention program are being implemented. compliance audits are conducted at least every 3 years. Both hourly and management personnel participate as audit team members. The audit team develops findings that are forwarded to the facility manager for resolution. Corrective actions taken in resonse to the audit team's findings are tracked until they are complete. The final resolution of each finding is documented and the two most recent reports are retained.
necessary to perform their specific emergency response duties. The emergency response program is updated when necessary based upon modifications made to the faiclity processes or other faiclity facilities. The emergency response program changes includes informing and/or training affected personnel in the changes.
ency drills that involve emergency response organizations and the facility provides refresher training to local emergency responders regarding the hazards of regulated substances in the facility.