Document ZkbRD5DeXj4KNkZoKVzgKNK7
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 5
77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604
SUBJECT: FROM: THRU: TO:
CLEAN AIR ACT INSPECTION REPORT Green Plains Madison LLC
Natalia Vazquez, Environmental Engineer AECAB (MI/WI)
Sarah Marshall, Section Supervisor AECAB (MI/WI)
File
BASIC INFORMATION
Facility Name: Green Plains Madison LLC
Facility Location: 395 Bissell Street, Madison, Illinois 62060
Date of Inspection: September 13, 2022
EPA Inspector(s): 1. Natalia Vazquez, Environmental Engineer 2. Charles Hall, Environmental Engineer
Other Attendees: 1. Jason Doyle, Operational Manager, Green Plains Madison 2. Sioux Agnew EHSS Manager, Green Plains Madison 3. Ricky Hulse, PSM Engineer, Green Plains 4. Jonal Broekemier, PSM Program Manager, Green Plains
Contact Email Address: Jason.doyle@gpreinc.com
Purpose of Inspection: Compliance with 112r(7) Clean Air Act
Facility Type: Dry mill ethanol manufacturer
Regulations Central to Inspection: 40 C.F.R. Part 68 Chemical Accident Prevention Provisions
Contains Items Claimed as CBI - Non-Releasable
Arrival Time: 8:00 a.m. Departure Time: 11:00 a.m.
Inspection Type: Unannounced Inspection Announced Inspection
OPENING CONFERENCE
Presented Credentials Stated authority and purpose of inspection Provided Small Business Resource Information Sheet Provided CBI warning to facility
Green Plains Madison (GPM or "Facility") claimed all of its records, photographs and any verbal information as Confidential Business Information. The following information was obtained verbally from Jason Doyle, Sioux Agnew, Jonal Broekemier, and Ricky Hulse unless otherwise noted.
Company Ownership: Green Plains purchased the Madison Facility from Abengoa Energy in September 2016.
Process Description: GPM is an ethanol manufacturing facility that uses the dry mill process. The covered process under 40 C.F.R. Part 68 is the sections that have "denaturant". Denaturant is a flammable blend that includes the following regulated substances: butane, isobutane, and pentane. The Risk Management Plan and the Facility's inventory (in the Risk Management Program Manual) states that the Facility has 900,000 lbs of denaturant in its covered process. The covered process includes the truck unloading of the denaturant, the blending of ethanol and denaturant, and loading of ethanol finished product. After the denaturant is unloaded from a truck, its routed to a storage vessel with a 128,000-gallon capacity (Tank 2104). The denaturant is blended with the ethanol in a specific section of the pipe that routs finished product to a truck loading station.
Staff Interview: The Facility has approximately 52 employees and 20 employees have work responsibilities related to the covered process. There has been no incidents or releases of the regulated substance in the past five years. There has been no near misses in the past five years related to the regulated substances. The Facility has not made any changes to the covered process that would require a Management of Change or a Pre-startup Safety Review. GPM has only done replacements in kind to the process. The Facility does not have a union.
Page 2 of 5
Contains Items Claimed as CBI - Non-Releasable
The Facility used to store and handle anhydrous ammonia, but it recently replaced the ammonia for urea. GPM emptied the anhydrous ammonia storage vessel.
When GPM bought the facility, it came with railroad loading stations. The Facility provided the railroad loading station's pipe and instrumentation diagrams (P&ID), but informed EPA that it has never received denaturant by rail, due to the high cost.
The truck unloading is managed by the truck driver, but the hook up process is managed by GPM's employees. The Facility provided an Operational Procedure for this operation.
The blending operation is automated and therefore the Facility does not have any Operational Procedures for it.
The pressure relief valve (PRV) is a F7800 2"-12" 316 Stainless Steel in 12 inches. The PRV is only on top of Tank 2104, within the covered process.
GPM's employees have access to Part 68 records through "LOOP System, this is a community based internal website to share records with employees. The Facility also uses emails and provides access to monthly Process Safety Management (PSM) meetings. PSM is the Occupational Safety and Health Administration's (OSHA) regulatory program that was used by EPA to develop the Chemical Accident Prevention Provisions.
No hot work has been done near the truck loading stations and the denaturant storage tank.
The Facility uses two contractors PROtech LLC and John Zink Company LLC. PROtech is the contractor that handles leak detection and repair, and inspections of the floating roof on Tank 2104. Facility's representatives mentioned that the leak detection and repair requirement is due to a PSM requirement. John Zink handles inspections of the vapor recovery unit in the ethanol manufacturing process.
PROtech performs annual visual inspection of the internal and external floating roof on Tank 2104. The last two were on 8/25/2022 and 5/27/2021.
Internal inspections of Tank 2104 are every 10 years in accordance with API 653 and it's completed by PROtech.
Piping inspections are completed by PROtech every five years in accordance with API 570. The corrosion rate is reported in mils per year. The Facility doesn't have an internal standard for the corrosion rate or pipe thickness for pipe replacement. The Facility follows PROtech's guidance on deciding if a section of the pipe needs to be replaced. It has not replaced any piping section since it purchased the facility.
The Facility pulls annually an individual contractor and performs a safety audit and verifies that it's meeting its requirements. The Facility has a process to correct any identified deficiencies. If the contractor doesn't show improvement, then it's replaced.
GPM recently started using a software to track compliance for different regulations including its latest compliance audit required under 68.79.
GPM participated in Madison County Local Emergency Planning Committee Tabletop Exercise on August 30, 2022. The Facility also did an exercise where it simulated a tank breach and deployed a boom on September 9, 2021.
Page 3 of 5
Contains Items Claimed as CBI - Non-Releasable
TOUR INFORMATION
EPA Tour of the Facility: Yes
Data Collected and Observations: EPA did not observe any liquid staining around the PRV on top of Tank 2104.
Photos and/or Videos: were taken during the inspection. The photographs were claimed as CBI.
Field Measurements: were not taken during this inspection.
RECORDS REVIEW
1. GPM Risk Management Program Manual (8/30/2022) 2. Risk Management Program Management System 3. 2021 Drill and 2022 Tabletop 4. Emergency Response Plan 5. Block flow diagram 6. P&ID 7. Electrical Classification Table 8. Intended inventory for denaturant 9. Material and Energy balance 10. Material of construction 11. Safety Data Sheet of denaturant 12. Upper and lower limit and consequence of deviations 13. Safety system 14. Ventilation design basis 15. 2017 and 2022 Process Hazard Analysis 16. Chemical denaturant truck log and paperwork (Operational Procedure) 17. Tank 2104 floating roof inspection (2022 and 2021) 18. Piping internal inspection (12/11/2019) 19. Pump monthly preventative maintenance tracking list (denaturant pumps and denaturant
off-load pump) 20. Original PSSR checklist (previous owner) 21. PSMP Employee Participation Policy 22. Hot work Policy 23. Contractor list
Page 4 of 5
Contains Items Claimed as CBI - Non-Releasable
CLOSING CONFERENCE
Provided U.S. EPA point of contact to the facility
Requested documents: Appendixes B, C, D, and E from the Risk Management Program Manual - the Facility provided the Risk Management Program Manual version that included all Appendixes during the inspection. Equipment List Mechanical Integrity - Facility resubmitted this record, in pdf format, during the inspection. Prequalification and annual review of PROtech - Facility submitted this record during the inspection. 2021 Annual drill - Facility resubmitted this record during the inspection. Training records for 3 additional employees (covered process) - Facility submitted this record during the inspection. List of the 20 employees that work in the covered process - Facility resubmitted this record during the inspection. Emergency Response Plan for release of a tank above 10,000 lb - Facility submitted this during the inspection. Tracking list of recommendations made during the compliance audit, including who is responsible, due date and completion date.
Compliance Assistance: The Emergency Response Plan mentions anhydrous ammonia, EPA recommended that GPM removes ammonia from this record.
DIGITAL SIGNATURES
NATALIA
Digitally signed by NATALIA
VAZQUEZ RIVERA
Report Author: _V_A_Z_Q__U_E_Z__R_I_V_E_R_A__D_a_te_: 2_02_2._09_.2_0 _12_:1_6:_11_-0_5'_00_'
Section Supervisor:
SARAH
Digitally signed by SARAH
MARSHALL
_M_A__R_S_H__A_L_L________D_ate_: _20_22_.0_9_.20_1_4_:0_9:1_7_-0_5_'00_'
Page 5 of 5
Contains Items Claimed as CBI - Non-Releasable Facility Name: Green Plains Madison LLC Facility Location: 395 Bissell Street, Madison, Illinois 62060 Date of Inspection: September 13, 2022 APPENDICES AND ATTACHMENTS 1. Appendix A: Digital Image Log 2. Appendix B: RMP Program Level 3 Checklist - filled before and during the inspection
CBI Page 1 of 1
Facility Name: Green Plains Madison LLC Facility Location: 395 Bissell Street, Madison, Illinois Date of Inspection: September 13, 2022
APPENDIX A: DIGITAL IMAGE LOG - CONTAINS CBI
1. Inspector Name: Natalia Vazquez
2. Archival Record Location: One Drive
Image Number
1 2 3 4 5
6
7
8 9
File Name
P9130047.JPG P9130048.JPG P9130049.JPG P9130050.JPG P9130051.JPG
P9130052.JPG
P9130053.JPG
P9130054.JPG P9130055.JPG
Date and Time (incl. Time zone
and DST) 2022:09:13 08:44:17 2022:09:13 08:51:28 2022:09:13 08:51:35 2022:09:13 08:51:52 2022:09:13 08:51:56
2022:09:13 09:08:56
2022:09:13 09:09:02
2022:09:13 09:09:44 2022:09:13 10:06:38
Latitude and
Longitude
Description of Image
Railcar unloading Truck unloading Truck unloading and piping to storage tank 2104 truck loading finished product truck loading of finished product Denaturant storage tank 2104 and pump system that routes denaturant towards blending section Pumps system that routes denaturant towards blending section piping section that includes denaturant and ethanol blending (blue pipe section) Green Plains entrance sign
Appendices Page 1 of 1
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