DEQ-CFW_00065834

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
MP Report for DuPont - Fayetteville Works
Section 3, Registration Information
1.1 Source Identification: Facility ID: 1 There were no reportable accidents in the last 5 years.
a. Facility Name: DuPont - Fayetteville Works
b. Parent Company #1 Name: E.I. DuPont de Nemours & Company, Inc.
c. Parent Company #2 Name:
1.2 EPA Facility Identifier: 1000 0002 8178
1.3 Other EPA Systems Facility ID: NCD047368642
1.4 Dun and Bradstreet Numbers (DUNS):
a. Facility DUNS: 363650193
b. Parent Company #1 DUNS: 001315704
c. Parent Company #2 DUNS:
1.5 Facility Location Address:
a. Street 1: 22828 NC Highway 87 V�
b. Street 2:
C. City: Fayetteville
f. County: Bladen
Facility Latitude and Longitude:
g. Lat. (dd.dddddd): 34.845000
Lat/Long Method: 14
j. Lat/Long Description: PC
k. Horizontal accuracy measure (n ):
I. Horizontal Reference Datum Code:
m. Source Map Scale Number:
1.6 Owner or Operator.
d. State: NC e. Zip: 28306 - 7332
h. Long. (ddd.dddddd):-078.811667
Interpolation - Digital map source (TICEI)
Process Unit Area Centroid
100
002 North American Datum of 1983
a. Name: E.I. DuPont De Nemours & Co., Inc
b. Phone: [phone]
Mailing address:
c. Street 1: 22828 NC Highway 87 W d. Sheet 2:
e, City: Fayetteville f. 'State: NC g. Zip: 28306 - 7'332
12:54:1.. IM
Page 1 of 22
DEQ-CFW 00065834

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
1.7 Name and title of person or position responsible for part 68 (RMP) implementation:
a. Name of person: Joel C. Blake
b. Title of person or position: SHE Superintendent
c. Email address: [e-mail]
1.8 Emergency contact:
a. Name:
b. Title:
c. Phone:
d. 24-hour phone:
e. Ext. or PIN:
f. Email address:
Joel C. Blake
SHE Superintendent
[phone]
[phone]
Joel. C.Blake @ usa.dupont.com
1.9 Other points of contact:
a. Facility or Parent Company E-Mail Address:
b. Facility Public Contact Phone:
c. Facility or Parent Company WWW Homepage Address:
1.10 LEPC: Cumberland and Bladen County
1.11 Number of full time employees on site: 465
1.12 Covered by:
a. OSHA PSM: Yes
b. EPCRA 302: Yes
c. CAA Title V: Yes Air operating permit ID: 03735
1.13 OSHA Star or Merit Ranking: No
1.14 Last Safety Inspection (by an External Agency) Date:
1.15 Last Safety Inspection Performed by an External Agency:
1.16 Will this RMP involve predictive filing?: No
wwxv.dupont.com
11/20/2003
State environmental agency
1.18 RMP Preparer Information:
a. Name:
b. Telephone:
c. Streetl:
06/02/2004 12:54:15 PM Page 2 of 22
DEQ-CFW 00065835

Facility Name: DuPont -Fayetteville Works
EPA ID: 1000 0002 8178
d. Street2:
e. City.,
f. State: g. ZIP: -
Section 1.17 Process(es)
a. Process ID: 1 Program Level 3 Nafion Manufacturing
b. NAICS Code
32519 Other Basic Organic Chemical Manufacturing
c. Process Chemicals
c.1 Process Chemical (ID / Name)
c.2 CAS Nr.
c.3 Qty (Ibs.)
1 Hydrogen chloride (anhydrous) [Hydrochloric acid]
7647-01-0
24,000
2 Tetrafluoroethylene [Ethene, tetrafluoro-]
116-14-3
31,000
3 Sulfur trioxide
7446-11-9
22,000
a. Process ID: 2 Program Level 3 APFO Manufacturing
b. NAICS Code
32519 Other Basic Organic Chemical Manufacturing
c. Process Chemicals
c.1 Process Chemical (ID / Name)
c.2 CAS Nr.
c.3 Qty (Ibs.)
4 Oleum (Fuming Sulfuric acid) [Sulfuric acid, mixture with sulfur
8014-95-7
50,000
trioxide]
Section 2. Toxics: Worst Case
Toxics: Worst Case ID
2
2.1 a. Chemical Name:
Hydrogen chloride (anhydrous) [Hydrochloric acid]
b. Percent Weight of Chemical (if in a mixture): 44.0
2.2 Physical State:
Gas Liquified by Pressure
2.3 Model used:
EPA`s RMP`Comp(TM)
2.4 Scenario:
Liquid spill & Vaporization
2.5 Quantity released:
24,000 Ibs
2.6 Release rate:
2,400.0 Ibs/min
2.7 Release duration:
10.0 mins
2.8 Wind speed:
1.5 m/sec
2.9 Atmospheric Stability
Class: F
06/02/2004 12:54:15 PM Page 3 of 22
DEQ-CFW 00065836

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
2.10 Topography: Rural
2.11 Distance to Endpoint: 9.3
2.12 Estimated Residential population within distance to endpoint: 24,000
2.13 Public receptors within distance to endpoint:
a. Schools: Yes d. Prisons/Correction facilities: No
b. Residences: Yes e. Recreation areas: Yes
c. Hospitals: No f. Major commercial, office or, industrial areas: Yes
g. Other (Specify):
2.14 Environmental receptors within distance to endpoint:
a. National or state parks, forests, or monuments: No
b. Officially designated wildlife sanctuaries, preserves, or refuges: No
c. Federal wilderness areas: No
d. Other (Specify):
2.15 Passive mitigation considered:
a. Dikes: No d. Drains: No
b. Enclosures: No e. Sumps: No
c. Berms: No f. Other (Specify):
2.16 Graphic file name:
&oxics: Worst Case ID 1
2.1 a. Chemical Name: Sulfur trioxide
b. Percent Weight of Chemical (if in a mixture):
2.2 Physical State: Liquid
2.3 Model used: EPA's RMP'Comp(TM)
2.4 Scenario: Liquid spill & Vaporization
2.5 Quantity released: 22,000 Ibs
2.6 Release rate: 2,200.0 ibs/min
2.7 Release duration: 10.0 mins
2.8 Wind speed: 1.5 m/sec
2.9 Atmospheric Stability Class: F
2.10 Topography: Rural
2.11 Distance to Endpoint: 2.20 mi
2.12 Estimated Residential population within distance to endpoint: 500
2.13 Public receptors within distance to endpoint:
06/02/2004 12:54:15 PM Page 4 of 22
DEQ-CFW 00065837

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
a. Schools: No d. Prisons/Correction facilities: No
b. Residences: Yes e. Recreation areas: Yes
c. Hospitals: No f. Major commercial, office or, industrial areas: No
g. Other (Specify):
2.14 Environmental receptors within distance to endpoint:
a. National or state parks, forests, or monuments: No
b. Officially designated wildlife sanctuaries, preserves, or refuges: No
c. Federal wilderness areas: No
d. Other (Specify):
2.15 Passive mitigation considered:
a. Dikes: Yes d. Drains: Yes
b. Enclosures: Yes e. Sumps: Yes
c. Berms: No f. Other (Specify):
2.16 Graphic file name:
Toxics: Worst Case ID 3
2.1 a. Chemical Name: Oleum (Fuming Sulfuric acid) [Sulfuric acid, mixture with s
b. Percent Weight of Chemical (if in a mixture):
2.2 Physical State: Liquid
2.3 Model used: EPA's RMP`Comp(TM)
2.4 Scenarlo: Liquid spill & Vaporization
2.5 Quantity released: 50,000 Ibs
2.6 Release rate: 5,000.0 Ibs/min
2.7 Release duration: 10.0 mins
2.8 Wind speed: 1.5 m/sec
2.9 Atmospheric Stability Class: F
2.10 Topography: Rural
2.11 Distance to Endpoint: 3.00 ml
2.12 Estimated Residential population within distance to endpoint: 1,500
2.13 Public receptors within distance to endpoint:
a. Schools: No d. Prisons/Correction facilities: No
b. Residences: Yes e. Recreation areas: Yes
c. Hospitals: No f. Major commercial, office or, industrial areas: No .
g. Other (Specify):
06/02/2004 12:54:15 PM Page 5 of 22
DEQ-CFW 00065838

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
2.14 Environmental receptors within distance to endpoint:
a. National or state parks, forests, or monuments: No
b. Officially designated wildlife sanctuaries, preserves, or refuges: No
c. Federal wilderness areas: No
d. Other (Specify):
2.15 Passive mitigation considered:
a. Dikes: Yes d. Drains: Yes
b. Enclosures: Yes e. Sumps: Yes
c. Berms: No f. Other (Specify):
2.16 Graphic file name:
Section 3. Toxics: Alternative Release
Toxics: Alternative Release ID: 1
3.1 a. Chemical Name: Hydrogen chloride (anhydrous) [Hydrochloric acid]
b. Percent Weight of Chemical (if in a mixture): 44.0
3.2 Physical State: Gas Liquified by Refrigeration
3.3 Model- EPA's RMP" Comp(TM)
3.4 Scenario: Transfer hose failure
3.5 Quantity released: 24,000 Ibs
3.6 Release rate: 3570.0 Ibs/min
3.7 Release duration: 7.0 mins
3.8 Wind speed: 3.0 m/sec
3.9 Atmospheric Stability Class: D
3.10 Topography: Rural
3.11 Distance to Endpoint: 3.80 mi
3.12 Estimated Residential population within distance to endpoint: 2,600
3.13 Public receptors within distance to endpoint:
a. Schools: Yes d. Prisons/Correction facilities: No
b. Residences: Yes e. Recreation areas: Yes
c. Hospitals: No f. Major commercial, office, or industrial areas: No
g. Other (Specify):
3.14 Environmental receptors within distance to endpoint:
a. National or state parks, forests, or monuments: No
b. Officially designated wildlife sanctuaries, preserves, or refuges: No
c. Federal wilderness areas: No
d. Other (Specify):
06102/200412:54:16 PM Page 6 of 22
DEQ-CFW 00065839

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
3.15 Passive mitigation considered:
a. Dikes: No
b. Enclosures: No
c. Berms: No
3.16 Active mitigation considered:
a. Sprinkler, systems:
b. Deluge system:
c. Water curtain:
d. Neutralization:
e. Excess flow valve:
3.17 Graphic file name:
d. Drains: No
e. Sumps: No
f. Other (Specify):
No f. Flares:
No g. Scrubbers:
No h. Emergency shutdown systems:
No i. Other (Specify):
Yes
06/02/2004 12:54:16 PM
No
No
Yes
Paae 7 of 22
DEQ-CFW 00065840

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
�'oxics: Alternative Release ID: 2
3.1 a. Chemical Name: Sulfur trioxide
b. Percent Weight of Chemical (if in a mixture):
3.2 Physical State: Liquid
3.3 Model: EPA's RMP`Comp(TM)
3.4 Scenario: Transfer hose failure
3.5 Quantity released: 21,800 Ibs
3.6 Release rate: 182.0 Ibs/min
3.7 Release duration: 120.0 mins
3.8 Wind speed: 3.0 m/sec
3.9 Atmospheric Stability Class: D
3.10 Topography: Rural
3.11 Distance to Endpoint: 1.60 mi
3.12 Estimated Residential population within distance to endpoint: 170
3.13 Public receptors within distance to endpoint:
a. Schools: No d. Prisons/Correction facilities:
No
b. Residences: Yes e. Recreation areas:
Yes
c. Hospitals: No f. Major commercial, office, or industrial areas:
No
g. Other (Specify):
3.14 Environmental receptors within distance to endpoint:
a. National or state parks, forests, or monuments:
No
b. Officially designated wildlife sanctuaries, preserves, or refuges:
No
c. Federal wilderness areas:
No
d. Other (Specify):
3.15 Passive mitigation considered:
a. Dikes: Yes d. Drains: Yes
b. Enclosures: No e. Sumps: Yes
c. Berms: No f. Other (Specify):
3.16 Active mitigation considered:
a. Sprinkler systems: No f. Flares:
No
b. Deluge system: No g. Scrubbers:
No
c. Water curtain: No h. Emergency shutdown systems:
Yes
d. Neutralization: No i. Other (Specify): A foam application
system is available 24
hours oer day for use in the event of a leak.
e. Excess flow valve: No
3.17 Graphic file name.
06/02/2004 12:54:16 PM Page 8 of 22
DEQ-CFW 00065841

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
06/02/2004 12:54:16 PM Page 9 of 22
DEQ-CFW 00065842

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
Toxics: Alternative Release ID: 3
3.1 a. Chemical Name: Oleum (Fuming Sulfuric acid) [Sulfuric acid, mixture with s
b. Percent Weight of Chemical (if in a mixture):
3.2 Physical State: Liquid
3.3 Model: EPA's RMP*Comp(TM)
3.4 Scenario: Transfer hose failure
3.5 Quantity released: 40,000 Ibs
3.6 Release rate: 1390.0 Ibs/min
3.7 Release duration: 29.0 mins
3.8 Wind speed: 3.0 m/sec
3.9 Atmospheric Stability Class: D
3.10 Topography: Rural
3.11 Distance to Endpoint: 1.20 mi
3.12 Estimated Residential population within distance to endpoint: 10
3.13 Public receptors within distance to endpoint:
a. Schools: No d. Prisons/Correction facilities:
No
b. Residences: Yes e. Recreation areas:
Yes
c. Hospitals: No f. Major commercial, office, or industrial areas:
No
g. Other (Specify):
3.14 Environmental receptors within distance to endpoint:
a. National or state parks, forests, or monuments:
No
b. Officially designated wildlife sanctuaries, preserves, or refuges:
No
c. Federal wilderness areas:
No
d. Other (Specify):
3.15 Passive mitigation considered:
a. Dikes: Yes d. Drains: Yes
b. Enclosures: Yes e. Sumps: Yes
c. Berms: No f. Other (Specify):
3.16 Active mitigation considered:
a. Sprinkler systems: No f. Flares:
No
b. Deluge system: No g. Scrubbers:
No
c. Water curtain: No h. Emergency shutdown systems:
Yes
d. Neutralization: No i. Other (Specify): Emergency personnel
and foam are
positioned for use anytime a tanker is being
unloaded.
e. Excess flow valve: Yes
06/02/2004 12:54:16 PM Page 10 of 22
DEQ-CFW 00065843

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
3.17 Graphic file name:
Section 4. Flammables: Worst Case
Flammables: Worst Case ID: 1
4.1 Chemical Name: Tetrafluoroethylene [Ethene, tetrafluoro-]
4.2 Model used: EPA's RMP"Comp(TM)
4.3 Scenario: Vapor Cloud Explosion
4.4 Quantity released: 31,000 Ibs
4.5 Endpoint used: 1 PSI
4.6 Distance to Endpoint: 0.10 mi
4.7 Estimated Residential population within distance to endpoint: 0
4.8 Public receptors within distance to endpoint:
a. Schools: No d. Prisons/Correction facilities: No
b. Residences: No e. Recreation areas: No
c. Hospitals: No f. Major commercial, office, or industrial areas: No
g. Other (Specify):
4.9 Environmental receptors within distance to endpoint:
a. National or state parks, forests, or monuments: No
b. Officially designated wildlife sanctuaries, preserves, or refuges: No
c. Federal wilderness areas: No
d. Other (Specify):
4.10 Passive mitigation considered:
a. Blast walls: No
b. Other (Specify): TFE is stored as an azeotrope of TFE/HCl which is not
flammable. TFE is produced as needed to meet
consumption rates.
4.11 Graphic file name:
Section 5. Flammables: Alternative Release
Flammables: Alternative Release ID: 1
5.1 Chemical Name: Tetrafluoroethylene [Ethene, tetrafluoro-]
06/02/2004 12:54:16 PM Page 11 of 22
DEQ-CFW 00065844

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
5.2 Model used: EPA's RMP"Comp(TM)
5.3 Scenario: Vapor Cloud Explosion
5.4 Quantity released: 31,000 Ibs
5.5 Endpoint used: 1 PSI LFL value: % Volume
5.6 Distance to Endpoint: 0.10 mi
5.7 Estimated Residential population within distance to endpoint: 0
5.8 Public receptors within distance to endpoint:
a. Schools: No d. Prisons/Correction facilities: No
b. Residences: No e. Recreation areas: No
C. Hospitals: No f. Major commercial, office, or industrial areas: No
g. Other (Specify):
5.9 Environmental receptors within distance to endpoint:
a. National or state parks, forests, or monuments: No
b. Officially designated wildlife sanctuaries, preserves, or refuges: No
c. Federal wilderness areas: No
d. Other (Specify):
5.10 Passive mitigation considered:
a. Dikes: No
b. Fire walls: No
c. Blast walls: No
d. Enclosures: No
e. Other (Specify): TFE is stored as an azeotrope of TFE/HCI which is not
flammable. TFE is produced to meet consumption rates.
5.11 Active mitigation considered:
a. Sprinkler system: No
b. Deluge systems: No
c. Water curtain: No
d. Excess flow valve: No
e. Other (Specify):
5.12 Graphic file name:
Section 6. Accident History --- No Data To Report
Section 7. Prevention Program 3
Process ID: 1 Nafion Manufacturing
Prevention Program ID: 1
06/02/2004 12:54:16 PM Page 12 of 22
DEQ-CFW 00065845

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
Prevention Program Description:
This prevention program includes the TFE/HCI Distillate Storage facility
and unloading of TFE/HCI Distillate into the storage facility.
7.1 NAICS Code 32519
7.2 Chemicals Chemical Name
Hydrogen chloride (anhydrous) [Hydrochloric acid]
Tetrafluoroethylene (Ethene, tetrafluoro-]
7.3 Date on which the safety information
was last reviewed or revised: 03/06/2001
7.4 Process Hazard Analysis (PHA):
a. Date of last PHA or PHA update: 03/06/2001
b. The technique used:
What If: Yes
Failure Mode and Effects Analysis: No
Checklist: Yes
Fault Tree Analysis: No
What If/Checklist: Yes
Other (Specify):
HAZOP: No
c. Expected or actual date of completion of all changes from last PHA or PHA update:
01/13/2003
d. Major hazards identified:
Toxic release: Yes
Contamination:
No
Fire: Yes
Equipment failure:
Yes
Explosion: No
Loss of cooling, heating, electricity, instrument air:
Yes
Runaway reaction: No
Earthquake:
No
Polymerization: No
Floods (flood plain):
No
Overpressurization: Yes
Tornado:
No
Corrosion: Yes
Hurricanes:
No
Overfilling: Yes
Other (Specify):
e. Process controls in use:
Vents:
Yes Emergency air supply: No
Relief valves:
Yes Emergency power: No
Check valves:
Yes Backup pump: No
Scrubbers:
No Grounding equipment: Yes
Flares:
No Inhibitor addition: No
Manual shutoffs:
Yes Rupture disks: Yes
Automatic shutoffs:
Yes Excess flow device: Yes
interlocks:
Yes Quench system: No
Alarms and procedures:
Yes Purge system: No
Keyed bypass:
No None: No
06/02/2004 12:54:16 PM Page 13 of 22
DEQ-CFW 00065846

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
Other (Specify):
f. Mitigation systems in use:
Sprinkler system: No Water curtain: No
Dikes: No Enclosure: No
Fire walls: No Neutralization: No
Blast walls: No None: Yes
Deluge system: No Other (Specify):
g. Monitoring/detection systems in use:
Process area detectors: Yes None: No
Perimeter monitors: No Other (Specify):
h. Changes since last PHA or PHA update:
Reduction in chemical inventory: No Installation of perimeter monitoring systems: No
Increase in chemical inventory: No Installation of mitigation systems:
No
Change process parameters: No None recommended:
No
Installation of process controls: No None:
Yes
Installation of process detection systems: No Other (Specify):
7.5 Date of most recent review or revision of operating procedures:
03/15/2004
7.6 Training:
a. The date of the most recent review or revision of training programs:
02/25/2004
b. The type of training provided:
Classroom: Yes On the job: Yes Other (Specify):
c. The type of competency testing used:
Written test: Yes Observation: Yes
Oral test: Yes Other (Specify):
Demonstration: Yes
7.7 Maintenance:
a. The date of the most recent review or revision of maintenance procedures:
04/16/2004
b. The date of the most recent equipment inspection or test:
05/06/2004
c. Equipment most recently inspected or tested : #2 TFE/HCL Storage Tank relief valves
7.8 Management of change:
a. The date of the most recent change that triggered management of
05/12/2004
change procedures:
06/02/2004 12:54:16 PM
Page 14 of 22
DEQ-CFW 00065847

•
•
Facility Name: DuPont- Fayetteville Works
EPA ID: 1000 0002 8178
b. The date of the most recent review or revision of management of
05/07/2004
change procedures: __
7.9 The date of the most recent pre -startup review:
05/05/2004
7.10 Compliance audits:
a. The date of the most recent compliance audit:
02/26/2004
b. Expected date of completion of all changes resulting from the compliance audit:
12/31/2005
7.11 Incident investigation:
a. The date of the most recent incident investigation (if any):
b. Expected or actual date of completion of all changes resulting from the investigation:
7.12 The date of the most recent review or revision of employee participation plans:
08/14/2003
7.13 The date of the most recent review or revision of hot work permit procedures:
11/11/2003
7.14 The date of the most recent review or revision of contractor safety procedures:
09/12/2003
7.15 The date of the most recent evaluation of contractor safety performance:
04/21/2004
Process ID: 1 Nafion Manufacturing
1) Prevention Program ID: 2
Prevention Program Description: This prevention program includes the S03 Storage facility and unloading
of S03 into the storage facility.
7.1 NAICS Code 32519
7.2 Chemicals Chemical Name
Sulfur trioxide
7.3 Date on which the safety information was last reviewed or revised: 12/16/2002
7.4 Process Hazard Analysis (PHA):
a. Date of last PHA or PHA update:
12/16/2002
b. The technique used:
What If: No
Failure Mode and Effects Analysis: No
Checklist: No
Fault Tree Analysis: No
What If/Checklist: No
Other (Specify):
HAZOP: Yes
c. Expected or actual date of completion of all changes from last PHA or PHA update:
d. Major hazards identified:
Toxic release: Yes
Contamination:
Fire: No
Equipment failure:
Explosion: Yes
Loss of cooling, heating, electricity, instrument air:
Runaway reaction: No
Earthquake:
12/31/2004
No
Yes
No
No
06102/200412:54:16 PM Page 15 of 22
DEQ-CFW 00065848

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
Polymerization: No
Floods (flood plain): No
Overpressurization: Yes
Tornado: No
Corrosion: Yes
Hurricanes: No
Overfilling: No
Other (Specify):
e. Process controls in use:
Vents:
Yes
Emergency air supply: No
Relief valves:
Yes
Emergency power: No
Check valves:
Yes
Backup pump: No
Scrubbers:
No
Grounding equipment: Yes
Flares:
No
Inhibitor addition: No
Manual shutoffs:
Yes
Rupture disks: Yes
Automatic shutoffs:
Yes
Excess flow device: Yes
Interlocks:
Yes
Quench system: No
Alarms and procedures:
Yes
Purge system: No
Keyed bypass:
No
None: No
Other (Specify):
f. Mitigation systems in use:
Sprinkler system: No
Water curtain: No
Dikes: Yes
Enclosure: No
Fire walls: No
Neutralization: No
Blast walls: No
None: No
Deluge system: No
Other (Specify): There is a containment basin
adjacent to the tank and the site
Emergency Response Team
maintains foam for mitigation of a
release.
g. Monitoring/detection systems in use:
Process area detectors: No
Perimeter monitors: No
h. Changes since last PHA or PHA update:
Reduction in chemical inventory:
Increase in chemical inventory:
Change process parameters:
Installation of process controls:
None: No
Other (Specify): Employees are present at all times
when a tanker is being unloaded.
The area is staffed 24 hours per day
and leak patrols are routine.
No Installation of perimeter monitoring systems: No
No Installation of mitigation systems: No
No None recommended: No
No None: Yes
06/02/2004 12:54:16 PM Page 16 of 22
DEQ-CFW 00065849

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
Installation of process detection systems: No Other (Specify):
7.5 Date of most recent review or revision of operating procedures: 09/25/2003
7.6 Training:
a. The date of the most recent review or revision of training programs: 06/03/2003
b. The type of training provided:
Classroom: Yes On the job: Yes Other (Specify):
c. The type of competency testing used:
Written test: Yes Observation: Yes
Oral test: Yes Other (Specify):
Demonstration: Yes
7.7 Maintenance:
a. The date of the most recent review or revision of maintenance procedures:
b. The date of the most recent equipment inspection or test:
c. Equipment most recently inspected or tested : S03 Vaporizer Relief Valve
7.8 Management of change:
a. The date of the most recent change that triggered management of
change procedures:
b. The date of the most recent review or revision of management of
change procedures:
7.9 The date of the most recent pre -startup review:
7.10 Compliance audits:
a. The date of the most recent compliance audit:
b. Expected date of completion of all changes resulting from the compliance audit:
7.11 Incident investigation:
a. The date of the most recent incident investigation (if any):
b. Expected or actual date of completion of all changes resulting from the investigation:
7.12 The date of the most recent review or revision of employee participation plans:
7.13 The date of the most recent review or revision of hot work permit procedures:
7.14 The date of the most recent review or revision of contractor safety procedures:
7.15 The date of the most recent evaluation of contractor safety performance:
Process ID: 2 APFO Manufacturing
Prevention Program ID: 3
04/16/2004
01 /10/2004
03/01 /2004
05/07/2004
05/13/2004
02/26/2004
12/31 /2005
08/14/2003
11/11/2003
09/12/2003
04/21/2004
Prevention Program Description: This prevention program includes the Oleum Storage facility and
unloading of Oleum into the storage facility.
06/02/2004 12:54:16 PM Page 17 of 22
DEQ-CFW 00065850

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
7.1 NAICS Code 32519
7.2 Chemicals Chemical Name
Oleum (Fuming Sulfuric acid) (Sulfuric acid, mixture with sulfur trioxi
7.3 Date on which the safety information was last reviewed or revised:
10/24/2002
7.4 Process Hazard Analysis (PHA):
a. Date of last PHA or PHA update: 10/24/2002
b. The technique used:
What If: No
Failure Mode and Effects Analysis:
No
Checklist: No
Fault Tree Analysis:
No
What If/Checklist: Yes
Other (Specify):
HAZOP: Yes
c. Expected or actual date of completion of all changes from last PHA or PHA update:
d. Major hazards identified:
Toxic release: Yes
Contamination:
Fire: No
Equipment failure:
Explosion: No
Loss of cooling, heating, electricity, instrument air;
Runaway reaction: No
Earthquake:
Polymerization: No
Floods (flood plain):
Overpressurization: Yes
Tornado:
Corrosion: Yes
Hurricanes:
Overfilling: No
Other (Specify):
e. Process controls in use:
Vents:
Yes Emergency air supply:
No
Relief valves:
Yes Emergency power:
No
Check valves:
Yes Backup pump:
No
Scrubbers:
Yes Grounding equipment:
Yes
Flares:
No Inhibitor addition:
No
Manual shutoffs:
Yes Rupture disks:
Yes
Automatic shutoffs:
Yes Excess flow device:
Yes
Interlocks:
Yes Quench system:
No
Alarms and procedures:
Yes Purge system:
No
Keyed bypass:
No None:
No
Other (Specify):
I. Mitigation systems in use:
Sprinkler system: No Water curtain: No
06/02/2004 12:54:16 PM
09/18/2002
Yes
Yes
Yes
No
No
No
No
Page 18 of 22
DEQ-CFW 00065851

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
Dikes: Yes
Enclosure: Yes
Fire walls: No
Neutralization: Yes
Blast walls: No
None: No
Deluge system: No
Other (Specify): Air from the enclosure is vented
through a scrubber. When
unloading a tanker, operators are on
the scene with a foam cannon pre -
positioned.
g. Monitoringidetection systems in use:
Process area detectors: Yes
None: No
Perimeter monitors: No
Other (Specify):
h. Changes since last PHA or PHA update:
Reduction in chemical inventory:
No Installation of perimeter monitoring systems: No
Increase in chemical inventory:
No Installation of mitigation systems: No
Change process parameters:
No None recommended: No
Installation of process controls:
No None: Yes
Installation of process detection systems:
No Other (Specify):
7.5 Date of most recent review or revision of operating procedures: 06/20/2003
7.6 Training:
a. The date of the most recent review or revision
of training programs: 04/17/2003
b. The type of training provided:
Classroom: Yes On the job: Yes
Other (Specify):
c. The type of competency testing used:
Written test: Yes Observation: Yes
Oral test: Yes Other (Specify):
Demonstration: Yes
7.7 Maintenance:
a. The date of the most recent review or revision of maintenance procedures, 04/16/2004
b. The date of the most recent equipment inspection or test: 01/10/2004
c. Equipment most recently inspected or tested : Alarm and Interlock Function Checks
7.8 Management of change:
a. The date of the most recent change that triggered management of
change procedures:
b. The date of the most recent review or revision of management of 05/07/2004
change procedures:
06/02/2004 12:54:16 PM Page 19 of 22
DEQ-CFW 00065852

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
7.9 The date of the most, recent pre -startup review:
7.10 Compliance audits:
a. The date of the most recent compliance audit:
b. Expected date of completion of all changes resulting from the compliance audit:
7.11 Incident investigation:
a. The date of the most recent incident investigation (if any):
b. Expected or actual date of completion of all changes resulting from the investigation:
7.12 The date of the most recent review or revision of employee participation plans:
7.13 The date of the most recent review or revision of hot work permit procedures:
7.14 The date of the most recent review or revision of contractor safety procedures:
7.15 The date of the most recent evaluation of contractor safety performance:
Section 9. Prevention Program 2 --- No Data To Report
Section 9. Emergency Response
9.1 Written Emergency Response (ER) Plan:
a. Is facility included in written community emergency response plan? Yes
b. Does facility have its own written emergency response plan? Yes
9.2 Does facility's ER plan include specific actions to be taken in
response to accidental releases of regulated substance(s)? Yes
9.3 Does facility's ER plan include procedures for informing the public
and local agencies responding to accidental releases? Yes
9.4 Does facility's ER plan include information on emergency heath care?
Yes
9.5 Date of most recent review or update of facility's ER plan: 03/24/2004
9.6 Date of most recent ER training for facility's employees: 04/03/2003
9.7 Local agency with which facility's ER plan or response activities are coordinated:
a. Name of agency: Cumberland County LEPC
b. Telephone number: [phone]
9.8 Subject to:
a. OSHA Regulations at 29 CFR 1910.38: Yes
b. OSHA Regulations at 29 CFR 1910.120: Yes
c. Clean Water Act Regulations at 40 CFR 112: Yes
08114/2003
11 /11 /2003
09/12/2003
04/21 /2004
06102/200412:54:17 PM Page 20 of 22
DEQ-CFW 00065853

Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
d. RCRA Regulations at 40 CFR 264, 265, and 279.52: Yes
e. OPA-90 Regulations at 40 CFR 112,33 CFR 154,49 CFR 194, or 30 CFR 254: Yes
f. State EPCRA Rules/Law:
g. Other (Specify):
Executive Summary
Yes
ACCIDENT RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES
At DuPont Fayetteville Works, we are committed to operating and maintaining our processes in a safe and
responsible manner. We use a combination of accidental release prevention programs and emergency
response planning programs to help insure the safety of our employees, the public and the environment. We
follow the DuPont Corporate philosophy that the "goal is zero". This means that we constantly strive for zero
process safety incidents, zero environmental incidents and zero injuries. We have programs, procedures and
management practices in place to support our goal of zero. Our site safety, operating and emergency response
procedures are available to all site employees through hard copies and/or electronic copies on computers
placed throughout the plant.
FACILITY DESCRIPTION
The DuPont Fayetteville Works site consists of approximately 2200 acres located on the Bladen and
Cumberland County line adjacent to N.C. Highway 87. It is approximately 15 miles southeast of Fayetteville,
North Carolina. Approximately 400 acres are currently used for manufacturing, with the remainder set aside for
future manufacturing needs.
The NAFION(TM) and APFO processes at the DuPont Fayetteville Works are Prevention Program 3
processes. The NAFION(TM) process produces a membrane used in fuel cells and the Chloralkali industry. In
the production of that product, the following regulated substances are used as raw materials:
Hydrogen Chloride, anhydrous (received and TFE/HCL Distillate)
Tetrafluoroethylene (received as TFE/HCL Distillate)
Sulfur Trioxide
APFO is a material used in the TEFLON polymer manufacturing process. To produce APFO, the following
regulated substance is used as a raw material:
- Oleum
WORST CASE TOXIC RELEASE SCENARIO 1-1
This information is not to be included in the Executive Summary of the 2004 update of the RMP.
WORST CASE FLAMMABLE RELEASE SCENARIO
This information is not to be included in the Executive Summary of the 2004 update of the RMP.
ALTERNATIVE TOXIC RELEASE SCENARIOS
This information is not to be included in the Executive Summary of the 2004 update of the RMP.
ACCIDENTAL RELEASE PREVENTION PROGRAM
The DuPont Fayetteville Works site is in compliance with the requirements of 29 CFR 1910.119 and 40 CFR
Part 68. Our safety programs include guidelines which include a documented process technology system
covering the hazards of materials, equipment design basis and process design basis. It includes the
requirement to choose materials of construction to provide mechanical integrity and incorporates extensive
safety instrumentation such as alarms, interlocks, and gas detectors. It also includes identifying all process
safety critical equipment and performing routine inspections to insure proper operation and mechanical
integrity. A work order and permit system is used to control maintenance work performed. Our maintenance
and operations personnel are trained, qualified and experienced. The guidelines also include the requirement
for operators and mechanics to follow approved procedures. Processes are continually monitored by computer
control systems and operators. These individual elements of our prevention program work together to prevent
accidental chemical releases.
FIVE YEAR ACCIDENT HISTORY
There have been no on site injuries and no off site injuries, evacuations, sheltering in place, property damage or
environmental damage due to the accidental release of RMP regulated substances from the DuPont
Fayetteville Works in the past 5 years.
06/02/2004 12:54:17 PM Page 21 of 22
DEQ-CFW 00065854

0
•
Facility Name: DuPont - Fayetteville Works
EPA ID: 1000 0002 8178
EMERGENCY RESPONSE PROGRAM
Our program provides planning and training to effectively protect our employees, the public and the environment
during emergency situations. An emergency response plan is in place and updated regularly and all employees
are trained for their role in the emergency response plan. The plant conducts emergency drills, and critiques
are held after drills and actual events. The plant is an actively involved with the Cumberland County LEPC.
IMPROVING SAFETY
We constantly strive to evaluate and improve the safety of our processes. Every person on the site has a
responsibility to improve the safety of our operations. As part of our Process Hazards Analysis process, teams
consisting of operators, mechanics, technical engineers and management thoroughly examine and evaluate our
manufacturing operations on a periodic frequency to identify risk reduction opportunities. Audits, both first party
and second party, are conducted using site based personnel and non -site based personnel to evaluate
compliance with safety, environmental, occupational health and process safety management requirements and
regulations. Findings are documented and tracked to closure.
RMP Validation Errors/Warnings --- No Data To Report
06/02/2004 12:54:17 PM Page 22 of 22
DEQ-CFW 00065855