Building B — Polyjuice Base storage and transfer

Risk Management Program

Program 2 risk management program for 25% aqueous ammonia (T-2): hazard assessment, prevention program and emergency response.

Regulation40 CFR Part 68
Program levelProgram 2
DocumentRMP-PJB-001
RevisionRev. 3 · Oct 9, 2026
Program managerDana Scully, EHS Manager
Jump to a section
  1. 1. Purpose and Scope
    1. 1.1 Covered process
    2. 1.2 Stationary source
  2. 2. Applicability and Threshold Determination
    1. 2.1 Listed substance - 68.130
    2. 2.2 What counts toward the threshold
    3. 2.3 Inventory calculation
    4. 2.4 Mixture provisions in 68.115(b)(1)
    5. 2.5 Other Part 68 substances at the source
  3. 3. Program Level Determination - 68.10
    1. 3.1 OSHA PSM status and process boundary determination
  4. 4. Management System - 68.15
  5. 5. Hazard Assessment - Subpart B
    1. 5.1 Offsite Consequence Analysis Parameters - 68.22
    2. 5.2 Worst-Case Release Scenario - 68.25
    3. 5.3 Alternative Release Scenario - 68.28
    4. 5.4 Offsite Impacts - 68.30 and 68.33
    5. 5.5 Review, Update and Documentation - 68.36 and 68.39
    6. 5.6 Five-Year Accident History - 68.42
  6. 6. Program 2 Prevention Program - Subpart C
    1. 6.1 Safety Information - 68.48
    2. 6.2 Hazard Review - 68.50
    3. 6.3 Operating Procedures - 68.52
    4. 6.4 Training - 68.54
    5. 6.5 Maintenance - 68.56
    6. 6.6 Compliance Audits - 68.58 and 68.59
    7. 6.7 Incident Investigation - 68.60
    8. 6.8 Employee Participation - 68.62
  7. 7. Emergency Response - Subpart E
    1. 7.1 Responding stationary source - 68.90(a)
    2. 7.2 Emergency response program - 68.95
    3. 7.3 Coordination with local responders - 68.93
    4. 7.4 Exercises - 68.96
  8. 8. Risk Management Plan Submission and Updates - Subpart G
    1. 8.1 Registration - 68.160(b)
    2. 8.2 Program 2 prevention program data - 68.170
    3. 8.3 Emergency response data - 68.180
    4. 8.4 Updates and corrections - 68.190 and 68.195
  9. 9. Recordkeeping - 68.200
  10. Appendix A - Compliance Dates for the 2024 Amendments
  11. Appendix B - References
Document controlApprovals, revision record, distribution
DocumentRMP-PJB-001
RevisionRev. 3 - October 9, 2026
Last RMP submission / updateJune 12, 2024 (RMP*eSubmit). Next five-year update due June 12, 2029 (68.190(b)(1)).
RMP program manager (68.15(b))Dana Scully, EHS Manager, Building B, (555) 555-0104
Local approvalHari Seldon, Plant Manager, Building B, (555) 555-0107
Management approvalMike Perry, Founder & Chief Awesomeness Officer, (440) 336-0262

Approval

This program has been reviewed and is approved for use. Management commits the resources needed to carry it out.

Name and titleSignatureDateRole
Mike Perry, Founder & Chief Awesomeness OfficerManagement approval
Hari Seldon, Plant Manager, Building BLocal approval
Dana Scully, EHS Manager, Building BRMP program manager
Steve Resko, ERT Leader, Building BEmergency response

Revision History

Rev.DateDescription of changeBy
0June 2014Initial program and RMP submission when T-2 was placed in service above the threshold quantity.D. Scully
1June 2019Five-year RMP update.D. Scully
2June 2024Five-year RMP resubmission (RMP*eSubmit June 12, 2024). Hazard review completed April 2024.D. Scully
3October 9, 2026Annual review. Emergency response coordination update.D. Scully

Distribution

Controlled copies: Building B control room; EHS office; ERT room. Electronic copy on the plant document system. A copy of the emergency response plan and this program's emergency contacts is provided to New Mos Eisley Fire Department and the New Mos Eisley LEPC each year under 68.93.

SECTION 1Purpose and Scope

This document is the risk management program for the Polyjuice Base storage and transfer process at Perry's Awesomeness Factory (Building B). It records how Perry Industries meets 40 CFR Part 68 for this process: applicability, program level, management system, hazard assessment, the Program 2 prevention program, emergency response, the risk management plan (RMP) submitted to EPA, and recordkeeping. The RMP itself is the electronic submission made through EPA's RMP*eSubmit; this document is the supporting program file the rule requires the facility to keep.

1.1 Covered process

Polyjuice Base is 25% aqueous ammonia (ammonium hydroxide solution, CAS 1336-21-6; ammonia CAS 7664-41-7) bought from Tyrell Chemical Distributors and used on the Brilliance line. The covered process is:

  • T-2, 15,000-gallon vertical carbon steel atmospheric tank, 12 ft diameter, in its own reinforced concrete ammonia dike (40 ft x 40 ft x 3.5 ft walls, drain valve DV-2) in the ammonia storage area east of Building B, with pressure-vacuum vent PVRV-201 and level transmitter LT-201;
  • the ammonia unloading pad (curbed, 20 ft x 30 ft = 600 sq ft, 3,500-gal sump), unloading connection and fill line with valve XV-200, including a tank truck while it is connected for unloading;
  • tank outlet valve XV-201, transfer pump P-201 and the piping to the inlet valves of Brilliance blend tanks BR-1, BR-2 and BR-3;
  • ammonia detectors AD-1 to AD-4 around T-2 (alarm 25 ppm, high alarm 50 ppm); safety shower/eyewash SS-4; water-fog monitor WM-1 fed from hydrant FH-2; spill kit SK-10.
Figure 1-1. Polyjuice Base storage and transfer, simplified process diagram.Select to enlarge

1.2 Stationary source

The stationary source is Perry's Awesomeness Factory (Building B), Perry Industries, Inc., 1 Perry Parkway, New Mos Eisley, NAICS 325998. Building A (SYNTO Group, research and development) and Building C (Honey Badger Logistics, warehousing and trucking) are on the same campus but are in different industrial groups and hold no regulated substance above a threshold quantity.

PI-B-101 — Building B — Perry's Awesomeness Factory SPCC Facility DiagramPI-B-101 · Select to enlarge

Figure 1-2. Building B facility diagram, drawing PI-B-101 (drawn at 1 in = 80 ft; reduced here, use the graphic scale). Ammonia storage area (T-2, ammonia dike, NH3 pad) east of Building B, about 170 ft south of the flammable tank farm dike across the access road.

SECTION 2Applicability and Threshold Determination

2.1 Listed substance - 68.130

Table 1 to 68.130 lists "Ammonia (conc 20% or greater)", CAS 7664-41-7, with a threshold quantity of 20,000 pounds, basis for listing "a, b" (mandated by Congress; on the EHS list with vapor pressure of 10 mm Hg or greater). Polyjuice Base at 25% ammonia by weight is at or above the 20% concentration, so it is subject to the threshold determination. EPA has stated that ammonium hydroxide must be treated as a solution of ammonia and water for Part 68, regardless of its separate CAS number.

2.2 What counts toward the threshold

  • For a regulated toxic substance in solution, only the weight of the regulated substance counts toward the threshold quantity, not the weight of the whole solution (EPA RMP guidance, Calculating thresholds for toxic substances with concentration qualifiers).
  • Solutions below the listed concentration are not counted. Polyjuice Base is diluted to about 8% in Brilliance blend tanks BR-1 to BR-3, and finished Brilliance contains about 2% ammonia. Neither is counted.
  • 68.115(a): the threshold is present if the total quantity in a process exceeds it.

2.3 Inventory calculation

ItemValueBasis
T-2 maximum intended inventory15,000 galFull tank (no administrative limit is applied)
Density of Polyjuice Base7.57 lb/gal0.907 g/mL, supplier SDS
Solution in T-2113,550 lb15,000 x 7.57
Ammonia in T-2 (25% by weight)28,388 lb113,550 x 0.25
Threshold quantity20,000 lb68.130, Table 1
ResultExceeds by about 8,400 lbProcess is a covered process
Solution volume at which 20,000 lb of ammonia is reachedabout 10,570 gal20,000 / 0.25 = 80,000 lb; 80,000 / 7.57
P-201 and piping, fill lineabout 50 gal (95 lb ammonia)Small; does not change the result

Table 2-1. Threshold determination. Reported to two significant digits in the RMP: 28,000 lb ammonia (in 110,000 lb of 25% solution).

A tank truck connected for unloading is part of the stationary source. Unloading procedure PJB-OP-02 requires the T-2 level plus the delivery to be no more than 15,000 gallons before the hose is connected, so the 15,000-gallon figure is the process maximum during unloading too.

2.4 Mixture provisions in 68.115(b)(1)

  • One-percent rule: Polyjuice Base is 25% ammonia, well above 1%, so the rule's one-percent cutoff does not apply.
  • Partial pressure demonstration: 68.115(b)(1) allows ammonia in a mixture to be left out only if the owner or operator can demonstrate that the partial pressure of ammonia over the solution is less than 10 mm Hg under handling or storage conditions in that portion of the process. That demonstration cannot be made for Polyjuice Base. EPA's Offsite Consequence Analysis Guidance, Appendix B, Exhibit B-3, lists the 10-minute average ammonia vapor pressure from a 24% solution at 25 °C as 241 mm Hg, more than 20 times the 10 mm Hg cutoff; a 25% solution is higher. The full ammonia content is counted.
  • No other exemption in 68.115(b)(3)-(5) (articles, listed uses, laboratory activities) applies. The 68.125 agricultural nutrient exemption does not apply.

2.5 Other Part 68 substances at the source

Thunderbolt (isopropyl alcohol) is not listed in Table 3 or Table 4 of 68.130 and is not a regulated flammable substance. No other regulated toxic or flammable substance is held above its threshold. A flammable worst-case scenario under 68.25(a)(2)(ii) is therefore not required.

SECTION 3Program Level Determination - 68.10

ProgramCriteriaResult for Polyjuice Base
Program 1 - 68.10(j)(1) No accidental release with offsite death, injury or environmental response in 5 years; (2) worst-case endpoint distance less than the distance to any public receptor; (3) response coordinated with local responders.Not eligible. The worst-case endpoint distance (2.7 miles at the site maximum temperature; 0.4 mile at 25 °C; Section 5.2) is greater than the distance to the nearest public receptor (residences about 600 ft north of the ammonia dike, drawing PI-C-001).
Program 3 - 68.10(l)Not Program 1, and either (1) process in NAICS 32211, 32411, 32511, 325181, 325188, 325192, 325199, 325211, 325311 or 32532; or (2) process subject to OSHA PSM, 29 CFR 1910.119.Not met. NAICS 325998 is not on the list. See 3.1 for PSM.
Program 2 - 68.10(k)Not eligible for Program 1 and not subject to Program 3.Program 2 applies.

3.1 OSHA PSM status and process boundary determination

The Polyjuice Base storage and transfer system is not subject to 29 CFR 1910.119. Appendix A to 1910.119 lists ammonia solutions only above 44% ammonia by weight (threshold 15,000 lb); Polyjuice Base is 25%. Aqueous ammonia is not a flammable liquid with a flash point below 100 °F, so 1910.119(a)(1)(ii) does not apply. The PSM-covered Thunderbolt Solvent System (T-1, P-101, XV-101, R-101, E-101, V-102, BT-1 to BT-3) is a separate process. Under 40 CFR 68.3, separate vessels are one process when they are located so that a regulated substance could be involved in a potential release; EPA treats co-located vessels as one process when a single event, such as a fire or explosion, could involve both or interfere with mitigation (EPA RMP guidance, applicability of program levels for co-located vessels).

T-2 is alone in the ammonia dike (40 ft x 40 ft x 3.5 ft, DV-2), about 170 ft from the flammable tank farm dike across the Building B access road, with no shared piping, its own unloading pad (600 sq ft), and its own spill kit SK-10, safety shower SS-4 and water-fog monitor WM-1 (drawing PI-B-101). A release or fire at one area does not involve the other, so the process is not Program 3 under 68.10(l)(2). The hazard review (Section 6.2) carries a flammable tank farm fire as a siting hazard, and any change that reduces the separation is reviewed before it is made; if that review finds one event could involve both, the process becomes Program 3 and the RMP is updated within six months (68.190(b)(7), 68.10(m)).

SECTION 4Management System - 68.15

Perry Industries manages the risk management program through the assignments below (68.15). Dana Scully, EHS Manager, has overall responsibility for development, implementation and integration of the program elements; the people responsible for individual elements and the lines of authority are listed in Table 4-1. The assignments are reviewed at each annual program review; last reviewed October 2026.

  • Overall responsibility (68.15(b)): Dana Scully, EHS Manager, Building B. Qualifications: 12 years in process safety and environmental compliance; trained in Part 68, hazard review methods and OCA.
  • Lines of authority: the EHS Manager reports to Hari Seldon, Plant Manager, who reports to Mike Perry, Founder & Chief Awesomeness Officer. Mike Perry has authority to commit resources.
ElementAssigned toPosition
Overall program; hazard assessment; RMP submission and correctionsDana ScullyEHS Manager
Safety information (68.48); management of major changesDoug HeasleyProcess Controls Engineer
Hazard review (68.50)Dana Scully (lead), Doug HeasleyEHS Manager; Process Controls Engineer
Operating procedures (68.52); operator training (68.54)Jenn ReskoProduction Supervisor, Brilliance Line (days)
Night shift procedures and trainingMarty McFlyNight Shift Supervisor
Maintenance and inspection (68.56)Montgomery ScottMaintenance Manager
Compliance audits (68.58)Dana Scully (coordinates); audit lead from outside Building BEHS Manager
Incident investigation (68.60)Dana ScullyEHS Manager
Employee participation (68.62)Dana Scully; Wendy Weaver (records and access)EHS Manager; Director of Human Resources
Emergency response program, coordination and exercises (68.90-68.96)Steve ReskoERT Leader
Public and media communicationsBrian PhillipsVP Sales & Marketing
Approval of program, RMP certification (68.185)Hari Seldon; Mike PerryPlant Manager; Founder

Table 4-1. Assignment of RMP responsibilities (68.15(c)).

SECTION 5Hazard Assessment - Subpart B

68.20 requires a Program 2 process to comply with all sections of Subpart B. The offsite consequence analysis (OCA) below uses EPA's Risk Management Program Guidance for Offsite Consequence Analysis (EPA 550-B-99-009, April 1999, revised March 2009), its Appendix B data and its reference tables of distances. The rule allows this method: 68.25(d)(3), 68.25(g) and 68.28(c).

5.1 Offsite Consequence Analysis Parameters - 68.22

ParameterWorst caseAlternative scenario
Toxic endpoint (68.22(a)(1), Appendix A to Part 68)0.14 mg/L (200 ppm, ERPG-2)0.14 mg/L
Wind speed / stability (68.22(b))1.5 m/s, F stability3.0 m/s, D stability (OCA Guidance reference tables)
Ambient temperature / humidity (68.22(c))25 °C, 50% (allowed by 68.22(c) when the OCA Guidance is used)25 °C, 50%
Release height (68.22(d))Ground levelGround level
Surface roughness (68.22(e))Rural (see note)Rural
Dense or neutrally buoyant (68.22(f))Neutrally buoyant - OCA Guidance Exhibit B-3 lists aqueous ammonia as buoyantNeutrally buoyant
Temperature of released liquid (68.22(g))34 °C (94 °F), the highest daily maximum temperature at the site in the previous three years; T-2 is not heated25 °C (68.22(g) allows ambient for alternative scenarios)

Note on topography: the campus and the neighborhood to the north have buildings and trees, which would support urban. Lake Tiberius, an open water surface, lies directly south. Because the worst case must be the greatest distance in any direction, the rural column of the reference tables is used. The urban value is shown for information.

5.2 Worst-Case Release Scenario - 68.25

Scenario

Catastrophic failure of T-2 at maximum intended inventory. The full 15,000 gallons (113,550 lb of 25% aqueous ammonia; 28,388 lb ammonia) spills instantly into the ammonia dike. 68.25(b)(1): greatest amount in a single vessel; no administrative control is used to reduce it. 68.25(d)(1): ammonia solution is normally a liquid at ambient temperature, so it is treated as an instantaneous spill forming a pool.

Passive mitigation - 68.25(h)

The ammonia dike is reinforced concrete, 40 ft x 40 ft with 3.5 ft walls, and holds T-2 only. It is a passive mitigation system that is not damaged by a T-2 shell failure and would still contain the liquid. Check that the dike holds the spill (OCA Guidance Section 3.2.3):

StepResult
Maximum pool area if unconfined, A = QS x DF (Eq. 3-6), DF = 0.55113,550 x 0.55 = 62,453 sq ft
Diked area, 40 ft x 40 ft1,600 sq ft (gross diked area; the T-2 footprint is not deducted)
Area used for evaporation1,600 sq ft (smaller of the two)
Volume spilled, QS x DF x 0.033113,550 x 0.55 x 0.033 = 2,061 cu ft
Dike volume, gross 40 x 40 x 3.55,600 cu ft (no other vessel in the dike)
Liquid depth in dike, 2,061 / 1,6001.3 ft, below the 3.5 ft wall
ResultContained; no overflow

Release rate and distance, 25 °C basis - OCA Guidance Section 3.3, Equation 3-7, Reference Table 10

For a water solution at ambient temperature with passive mitigation, the Guidance uses the Liquid Factor Ambient (LFA) at 1.5 m/s from Exhibit B-3 and Equation 3-7, and the 10-minute reference table, because only the first 10 minutes of evaporation from a solution are considered. Exhibit B-3 lists aqueous ammonia at 30%, 24% and 20%; the 30% factors, the next listed concentration above 25%, are used: LFA (1.5 m/s) = 0.026; DF = 0.55; endpoint 0.14 mg/L; reference table: buoyant.

  • QR = 1.4 x LFA x A = 1.4 x 0.026 x 1,600 = 58.2 lb/min, reported as 58 lb/min. Ammonia volatilized in 10 minutes: about 580 lb.
  • Reference Table 10 (F stability, 1.5 m/s) has entries at 50 and 60 lb/min; the closest to 58 lb/min is 60 lb/min: 0.4 mile rural (about 2,100 ft); 0.2 mile urban.
  • The 24% row (LFA 0.019) gives 43 lb/min; closest entry 40 lb/min, 0.4 mile rural. The result does not change.

Release rate and distance at the site maximum temperature, 34 °C - OCA Guidance Section 3.3, Elevated Temperature

The highest daily maximum temperature at the site in the past three years is 94 °F (34 °C); 68.22(g) requires the release temperature to be that value or the process temperature, whichever is higher. The OCA Guidance (Section 3.3, Releases of Solutions, Elevated Temperature) gives two methods for a solution of ammonia above 25 °C: compute the release rate from the partial vapor pressure of ammonia at that temperature (Appendix D, D.2.1 to D.2.2), or "assume the quantity of the pure substance in the solution is released as a gas over 10 minutes." Perry Industries uses the second method as the conservative worst case.

  • 15,000 gal x 7.57 lb/gal x 0.25 = 28,388 lb ammonia, released over 10 minutes = 2,839 lb/min.
  • Reference Table 10 (aqueous ammonia, rural) has entries at 2,500 lb/min (2.5 miles) and 3,000 lb/min (2.7 miles); the closest to 2,839 lb/min is 3,000 lb/min: 2.7 miles rural (about 14,000 ft); 1.0 mile urban.

The 25 °C diked-pool result above (Exhibit B-3, 0.4 mile) is reported for comparison and is not the reported worst case. The Polyjuice Base SDS vapor pressure, 48 kPa (about 360 mm Hg) at 20 °C, is the initial total vapor pressure of the solution; the Exhibit B-3 value of 241 mm Hg for the 24% row is the 10-minute average ammonia partial pressure over an evaporating pool at 1.5 m/s, which is why the two figures differ.

BasisRelease rateDistance to 0.14 mg/L (rural)
25 °C, pool evaporation (Exhibit B-3, Eq. 3-7)58 lb/min0.4 mile
34 °C site maximum, gas release over 10 min (Section 3.3)2,839 lb/min2.7 miles

Worst-case result reported in the RMP: 2.7 miles to the ammonia toxic endpoint of 0.14 mg/L. The 34 °C result governs because 68.22(g) sets the release temperature at the site maximum. Method: EPA Risk Management Program Guidance for Offsite Consequence Analysis, Section 3.3 and Reference Table 10.

68.25(i) check of other scenarios

Smaller quantities at higher temperature or pressure, or closer to the boundary, were considered. No part of the process is heated or pressurized. A full 3,000-gallon tank truck compartment (22,710 lb) released on the ammonia unloading pad, which is closer to the north property line than T-2, is held by the pad curb and 3,500-gallon sump; the pad area (600 sq ft) is smaller than the unconfined pool (12,490 sq ft), so at 25 °C QR = 1.4 x 0.026 x 600 = 22 lb/min (Reference Table 10, closest entry 20 lb/min: 0.3 mile rural). At the site maximum temperature the compartment's ammonia content, 5,678 lb, released over 10 minutes gives 568 lb/min (closest entry 600 lb/min: 1.3 miles rural). Both are less than T-2. T-2 remains the worst case.

5.3 Alternative Release Scenario - 68.28

Scenario selection

68.28(b)(2)(i) lists transfer hose releases due to splits or sudden uncoupling. The April 2024 hazard review identified unloading hose failure as the most likely release from this process; there have been no releases in the five-year history (68.28(e)). The scenario is more likely than the worst case and reaches an endpoint offsite (68.28(b)(1)).

Scenario: the 3-inch unloading hose splits during delivery. The truck pump delivers about 150 gal/min. The attending driver stops the truck pump with the emergency stop and the Perry operator closes XV-200 from the pad or the control room within 5 minutes. Quantity released: 150 x 5 = 750 gal = 5,678 lb of 25% solution (1,420 lb ammonia), onto the curbed ammonia unloading pad.

StepResult
Maximum pool area if unconfined, QS x DF = 5,678 x 0.553,123 sq ft
Ammonia unloading pad area (passive mitigation, 68.28(d))600 sq ft (20 ft x 30 ft); used, since smaller. Spill volume 103 cu ft (770 gal) is held by the 3,500-gal sump
LFA at 3.0 m/s, 30% row of Exhibit B-30.019
QR = 2.4 x LFA x A (Eq. 7-10)2.4 x 0.019 x 600 = 27.4 lb/min, reported as 27 lb/min
Liquid release rate for comparison (150 gal/min x 7.57)1,136 lb/min; evaporation rate is lower, so it is used
Active mitigation creditedDriver emergency stop and XV-200 closure (limits quantity). ERT water fog not credited
Reference Table 23 (D stability, 3.0 m/s); entries at 20 and 30 lb/min, closest 30 lb/minRural 0.1 mile (about 530 ft); urban less than 0.1 mile (table note: report as 0.1 mile)

Alternative scenario result: 0.1 mile (about 530 ft) to 0.14 mg/L (rural). Measured on drawing PI-C-001 (1 in = 150 ft), the ammonia pad is about 400 ft from the north property line and about 500 ft from the nearest homes. The endpoint reaches offsite onto Perry Parkway and reaches about as far as the first homes north of the Parkway.

5.4 Offsite Impacts - 68.30 and 68.33

ItemWorst case (2.7 miles)Alternative (0.1 mile)
Residential population (68.30(a), two significant digits; most recent Census data, 68.30(c))1,10040
Public receptors noted (68.30(b))Residences and commercial buildings north of Perry Parkway; Perry Parkway; Lake Tiberius shoreline (about 350 ft south of the ammonia dike; recreational use); institutions within 2.7 miles listed in the RMPPerry Parkway; first row of homes north of Perry Parkway
Institutions (schools, hospitals, prisons)None identifiedNone
Environmental receptors (68.33, USGS maps)None identifiedNone

5.5 Review, Update and Documentation - 68.36 and 68.39

  • 68.36(a): the OCA is reviewed and updated at least once every five years; last reviewed for the June 2024 resubmission and at this annual review.
  • 68.36(b): if a change could increase or decrease the endpoint distance by a factor of two or more (for example a larger tank, removal of the dike, a higher concentration), a revised analysis is completed within six months and the RMP is updated under 68.190.
  • 68.39: the OCA file kept at the source contains: the vessel and substance selected and the rationale; the assumptions and parameters, including the dike as passive mitigation and its effect on release rate; the quantity released, release rate and duration; the method (EPA OCA Guidance, Exhibit B-3, Reference Tables 10 and 23); and the data used for population and receptors. Section 5 of this document is that record.

5.6 Five-Year Accident History - 68.42

No accidental release from the Polyjuice Base process in the past five years resulted in deaths, injuries or significant property damage on site, or known offsite deaths, injuries, evacuations, sheltering in place, property damage or environmental damage. The five-year accident history reported in the RMP is: none. If an accident meeting 68.42(a) occurs, the data in 68.42(b)(1)-(11) are submitted within six months under 68.195(a).

SECTION 6Program 2 Prevention Program - Subpart C

Provisions of the 2024 amendments to Part 68 that carry a later compliance date are identified where they occur and are scheduled in Appendix A.

6.1 Safety Information - 68.48

(a)(1) Safety Data Sheet

The current SDS for Polyjuice Base (Tyrell Chemical Distributors, emergency phone (555) 555-0189) meets 29 CFR 1910.1200(g) and is kept in the control room, at the unloading pad station and in the ERT room. Key hazard data:

ItemPolyjuice Base, 25% aqueous ammonia
IdentityAmmonia, aqueous solution (ammonium hydroxide), CAS 1336-21-6; ammonia CAS 7664-41-7. UN2672, Ammonia solution, 10-35% ammonia (ERG Guide 154)
GHS classification (SDS PB-394)Acute toxicity, oral, Category 4 - H302 Harmful if swallowed. Skin corrosion Category 1B - H314 Causes severe skin burns and eye damage. Serious eye damage Category 1 - H318 Causes serious eye damage. Corrosive to the respiratory tract (Appendix C to 1910.1200, note to C.4.4). Signal word: Danger
Exposure limits (ammonia)OSHA PEL 50 ppm TWA; NIOSH REL 25 ppm TWA, 35 ppm STEL; IDLH 300 ppm
Health effectsIrritation of eyes, nose and throat; difficulty breathing, wheezing, chest pain; pulmonary edema; skin and eye burns (NIOSH)
PhysicalClear, colorless liquid, strong pungent odor. Density 0.907 g/mL (7.57 lb/gal). Releases ammonia gas, which is lighter than air (vapor density 0.60). Ammonia gas LEL 15%, UEL 28%
IncompatibilitiesStrong oxidizers, acids, halogens, salts of silver and zinc. Corrosive to copper and galvanized surfaces (NIOSH)
Endpoint for OCA0.14 mg/L (200 ppm), Appendix A to Part 68

(a)(2)-(a)(3) Maximum intended inventory and safe limits

ParameterNormalSafe lowerSafe upperAlarm / control
T-2 inventory3,000-13,500 gal750 gal (5%, P-201 suction)15,000 gal (maximum intended)LT-201; LAH-201 at 14,250 gal (95%); unloading ullage check
T-2 temperatureAmbient32 °F (freeze protection of instrument lines)100 °FTI-201; vapor release through PVRV-201 increases with temperature
T-2 pressureAtmospheric-0.5 oz/in2 (vacuum setting)+0.5 oz/in2 (pressure setting)PVRV-201; emergency vent
P-201 flow20-30 gpm-35 gpmFQ-201 batch totalizer stops P-201
Unloading flow100-150 gpm-150 gpmTruck pump; attended unloading
Composition25% NH3 (24.5-25.5%)24.5%25.5%Certificate of analysis checked before unloading
Air at T-2 and pad0 ppm-25 ppmAD-1 to AD-4: 25 ppm alarm, 50 ppm high alarm

Table 6-1. Maximum intended inventory and safe upper and lower limits (Perry design basis).

(a)(4) Equipment specifications and (a)(5) codes and standards

EquipmentSpecificationIndustry standard used
T-215,000 gal vertical, 12 ft dia., carbon steel, atmospheric, shop-fabricated (2014)UL 142; API Standard 2000 (venting)
Piping and valvesCarbon steel and 316 SS; no copper, brass or galvanized partsASME B31.3
Unloading hose3-inch, rated for aqueous ammonia, dry-break couplingHose manufacturer's specification
P-201Centrifugal, 316 SS wetted parts, double mechanical sealManufacturer
Ammonia detectorsElectrochemical, 0-100 ppmManufacturer
ElectricalGeneral purpose (the process is not a classified location)NFPA 70

68.48(b): EHS Consulting Services (Sarah B. Wood, PE) documented in 2014, and again in the April 2024 hazard review, that the process is designed in compliance with recognized and generally accepted good engineering practices (letter ECS-2024-021). 68.48(c): the safety information is updated whenever a major change makes it inaccurate.

6.2 Hazard Review - 68.50

Last hazard review: April 2024, What-If/Checklist method, led by Sarah B. Wood, PE, with Dana Scully, Doug Heasley, Jenn Resko, an experienced Brilliance-line operator, Montgomery Scott and Steve Resko. The equipment was inspected to confirm it is built and operated to the standards in Section 6.1 (68.50(b)). Next update due: July 2029, or sooner for a major change (68.50(d)).

68.50(a) itemFindings, April 2024
(1) Hazards of the process and substanceToxic and corrosive liquid; ammonia vapor release from spills; skin and eye burns; vapor toward the residential area north of Perry Parkway.
(2) Equipment malfunctions or human errorsUnloading hose split or uncoupling; T-2 overfill during delivery; P-201 seal leak; wrong product unloaded into T-2 (acid); valve left open after sampling.
(3) Safeguards used or neededDike; curbed pad and sump; LAH-201; ullage check; dry-break coupling; dedicated, labeled fill connection; AD-1 to AD-4; XV-200 and XV-201 remote closure; ERT; safety shower SS-4; water-fog monitor WM-1. Standby or backup power for monitoring equipment: see Appendix A (compliance date May 10, 2027).
(4) Steps to detect or monitor releasesAD-1 to AD-4 annunciate in the control room; operator rounds each shift; attended unloading.
(5) Natural hazardsLightning; high wind; freezing weather (instrument lines heat-traced); flooding from Lake Tiberius (ammonia storage area grade above the 100-year flood elevation).
(6) SitingResidences about 600 ft north of the ammonia dike and 500 ft north of the ammonia pad; flammable tank farm (T-1, T-3) about 170 ft north across the access road, in a separate dike with no shared piping (fire and smoke exposure considered; see Section 3.1); ammonia pad near SI-1 storm inlet (drain cover at SK-10).

Recommendations from the April 2024 review: (1) add ammonia detector AD-4 at the unloading pad side - done 2024; (2) add remote closure of XV-200 from the control room - done March 2025. Problems identified are resolved in a timely manner and documented (68.50(c)).

6.3 Operating Procedures - 68.52

NumberProcedure68.52(b) item
PJB-OP-01Initial startup of T-2 and transfer system(1)
PJB-OP-02Receiving Polyjuice Base by tank truck (certificate check, ullage check, bonding, attended unloading)(2)
PJB-OP-03Transfer to Brilliance blend tanks BR-1 to BR-3 with P-201(2)
PJB-OP-04Temporary operations: transfer with one detector out of service; temporary hose(3)
PJB-OP-05Emergency shutdown and emergency operations: close XV-200 and XV-201, stop P-201, shelter-in-place alarm(4)
PJB-OP-06Normal shutdown and isolation(5)
PJB-OP-07Startup after normal or emergency shutdown or a major change(6)
Each procedureOperating limits from Table 6-1, consequences of deviation, and steps to correct or avoid deviation(7)
PJB-OP-08Operator equipment inspections: daily tank and dike check, weekly detector check(8)
PJB-OP-09Documentation when monitoring equipment is removed due to safety concerns from imminent natural hazards(9)

Procedures are consistent with the safety information. They are updated, if necessary, whenever a major change occurs and before startup of the changed process (68.52(c)). Procedures are kept in the control room and at the unloading pad station.

6.4 Training - 68.54

  • (a) Each employee operating the process, and each employee newly assigned, is trained or tested competent in the operating procedures that pertain to their duties. Training: classroom (2 hours) plus on-the-job (minimum 3 supervised deliveries and 3 transfers). Competency: written test and supervisor observation.
  • (b) Refresher training at least every three years, and more often if necessary. Frequency set in consultation with the operators (Building B Safety Committee, March 2024): every three years, plus an annual review of PJB-OP-02 and PJB-OP-05.
  • (c) Hazard communication and HAZWOPER training are used to the extent they meet this section.
  • (d) Operators are trained in any new or updated procedure before startup after a major change.

Records: employee name, date, procedures covered, test result or observation. Kept by Human Resources (Wendy Weaver).

6.5 Maintenance - 68.56

  • (a) Written procedures maintain the on-going mechanical integrity of T-2, piping, valves, P-201, the unloading hose and the detectors. Vendor procedures and industry codes are used as the basis.
  • (b) Each employee maintaining the process is trained in its hazards, how to avoid or correct unsafe conditions, and the procedures for the job. (c) Contract maintenance employers ensure their employees are trained to perform these procedures.
  • (d) Inspections and tests follow recognized and generally accepted good engineering practice, at frequencies consistent with manufacturers' recommendations, industry standards, good engineering practice and operating experience:
EquipmentInspection / testFrequency
T-2Operator visual; formal external inspection; shell thickness (UT)Monthly; 5 years; 10 years (STI SP001, industry standard)
PVRV-201 and emergency ventInspect, clean, verify settingsAnnual
Piping, valves, XV-200, XV-201Visual walk-down; valve stroke testQuarterly
P-201Seal and vibration checkMonthly
Unloading hoseVisual before each use; hydrostatic testEach use; annual (hose manufacturer)
AD-1 to AD-4Bump test; calibrationMonthly; quarterly (manufacturer)
LAH-201Alarm function testQuarterly

6.6 Compliance Audits - 68.58 and 68.59

Perry Industries audits compliance with Subpart C at least every three years and certifies the result. The most recent audit was September 2025, led by Sarah B. Wood, PE (EHS Consulting Services) with Dana Scully and Kara Thrace, combined with the PSM compliance audit; the previous audit was September 2022. The September 2025 report found four items for this process; all four responses are documented and the corrections closed by December 2025. Hari Seldon, Plant Manager, signed the certification. The next audit is due by September 2028. The September 2022 and September 2025 reports are kept in the EHS office.

A third-party audit under 68.59 is required for the next audit if an accidental release meeting 68.42(a) occurs at the source or the implementing agency requires one (68.58(f), compliance date May 10, 2027). Dana Scully keeps the written procedure for selecting an independent auditor (RMP-P-06, issued September 2026).

6.7 Incident Investigation - 68.60

Dana Scully, EHS Manager, leads the investigation of any incident that resulted in, or could reasonably have resulted in, a catastrophic release from the Polyjuice Base process. The investigation starts within 48 hours; the team includes at least one person knowledgeable in the process (normally Jenn Resko or the Brilliance line lead operator) and others as needed. The report uses form PSM-F-03 and records the date of the incident, the date the investigation began, a description, contributing factors and recommendations. Findings are entered in the PSM Action Tracker, resolved and documented, and reviewed with affected personnel at shift meetings. Reports are kept five years. Perry applies a recognized root cause method (5-Whys with a causal factor chart) and completes the report within 12 months for any incident meeting 68.42 (68.60(h), compliance date May 10, 2027).

No incident meeting 68.60(a) has occurred in this process since T-2 was placed in service in 2014.

6.8 Employee Participation - 68.62

68.62 was added by the 2024 amendments. Its compliance date is May 10, 2027 (68.10(g)(5)). Perry will have the following in place by that date and is using parts of it now through the Building B Safety Committee:

  • (a) A written plan of action for employee participation. The PSM employee participation plan (PSM-TSS-001, Section 3) will be extended to cover this process.
  • (a)(1) An annual written or electronic notice to employees and their representatives that the plan is available and how to see it. (a)(2) Training on the plan as often as necessary.
  • (b) A process for employees and their representatives to report, anonymously or with attribution, to Perry and/or EPA: unaddressed hazards that could lead to a catastrophic release; accidents covered by 68.42(a) not reported under 68.195(a); and any other noncompliance with Part 68. Records of reports made to Perry kept three years.
  • (c) Access for employees and their representatives to hazard reviews and all other information developed under Subpart C.

SECTION 7Emergency Response - Subpart E

7.1 Responding stationary source - 68.90(a)

Perry employees on the Building B Emergency Response Team (ERT) will respond to accidental releases of Polyjuice Base. Building B is therefore a responding stationary source and complies with 68.93, 68.95 and 68.96. The ERT has 12 members across both shifts, trained to the hazardous materials technician level under 29 CFR 1910.120(q)(6)(iii), led by Steve Resko, ERT Leader, (555) 555-0101.

7.2 Emergency response program - 68.95

The Building B Emergency Response Plan (maintained by the ERT Leader under 29 CFR 1910.120(q)) is the emergency response plan for this process. Under 68.95(b), a written plan that complies with other Federal contingency plan regulations and includes the 68.95(a) elements satisfies 68.95, provided 68.95(c) is also met. The plan is kept at the source. Its 68.95 elements are:

68.95 elementHow the plan meets it
(a)(1)(i) Informing the public and agenciesControl room calls 911 for NMEFD. NMEFD runs the community notification system (reverse-call and sirens) for the neighborhood north of Perry Parkway; Perry asks NMEFD to activate it for any release that reaches or may reach the fenceline. Agency notifications: a release of 1,000 lb or more of Polyjuice Base solution (about 132 gal) in 24 hours is reported against the ammonium hydroxide RQ (CAS 1336-21-6, RQ 1,000 lb, 40 CFR 302.4); EPA guidance says the CERCLA mixture rule does not need to be applied to the ammonia in the solution. Free ammonia vapor released (for example from the T-2 headspace) is reported separately if it reaches the ammonia RQ of 100 lb. Either one: notify the National Response Center 1-800-424-8802 immediately (40 CFR 302.6), and give EPCRA section 304 notice, immediately by phone and in writing as soon as practicable after, to the State Emergency Response Commission (SERC), (555) 555-0195, and the New Mos Eisley LEPC (555) 555-0185 (40 CFR 355.40 to 355.43). Also call the state spill line (555) 555-0190. This matches Polyjuice Base SDS PB-394, Sections 6 and 15. Partnership with NMEFD on community notification documented under 68.93(c).
(a)(1)(ii) First aid and emergency medical treatmentMove to fresh air; flush skin and eyes with water for at least 15 minutes (safety shower and eyewash SS-4 at the ammonia storage area); remove contaminated clothing; oxygen by trained personnel; transport to Tiberius Regional Medical Center, which has the Polyjuice Base SDS. Kaitlyn Perry, RN, Occupational Health Nurse, (555) 555-0143.
(a)(1)(iii) Response proceduresSound shelter-in-place alarm (alternating high-low tone and voice message) for the campus; control room closes XV-200 and XV-201 and stops P-201; ERT in Level B encapsulating splash suits with SCBA isolates the leak, uses water fog to knock down vapor, and keeps runoff inside the ammonia dike (DV-2 stays locked closed); water-fog monitor WM-1 (from FH-2) for vapor knockdown; drain cover placed at SI-1 from SK-10 for pad releases; Sheaves Environmental Response (555) 555-0177 for cleanup.
(a)(2) EquipmentERT room by the control room: 8 SCBA (30-minute cylinders) with 8 spare cylinders, cascade fill at the Gate 2 house; 6 Level B encapsulating splash suits (no Level A; the NMEFD hazmat team provides Level A); butyl and nitrile gloves, chemical boots; one portable 4-gas meter (O2/LEL/CO/H2S) with PID and one spare 4-gas meter; ammonia colorimetric tubes and pump; pH paper; decon kit; two 95-gal overpack drums; stretcher. Ammonia area: water-fog monitor WM-1, spill kit SK-10 with four ammonia escape respirators, safety shower SS-4; fixed detectors AD-1 to AD-4. ERT inspects monthly and after each use; SCBA serviced per manufacturer; meters calibrated monthly by Montgomery Scott; AD-1 to AD-4 calibrated quarterly.
(a)(3) TrainingAll Building B employees: shelter-in-place signal and actions, annually. ERT: 1910.120(q) technician training and annual refresher; ammonia response drills.
(a)(4) Review and updateERT Leader reviews the plan annually and after any change at the source, coordination meeting, exercise or incident investigation that shows a need. Employees are informed of changes at shift meetings.
(c) Timely data to responders; coordination with community planERT Leader or control room gives NMEFD the best current estimate of the release: material, amount, rate, duration, wind direction (windsock on Building B roof). The plan is coordinated with the community emergency response plan under 42 U.S.C. 11003; information is given to the LEPC or responders on request.

The 2024 amendments to 68.90(b) and 68.95(a) (the community notification partnership wording) have a compliance date of May 10, 2027 (68.10(g)(6)). The plan already includes the partnership with NMEFD.

7.3 Coordination with local responders - 68.93

  • Coordination with New Mos Eisley Fire Department (NMEFD) Station 7 and the New Mos Eisley LEPC at least annually, and more often when the source, the plan or the community plan changes - 68.93(a).
  • Perry provides: this emergency response plan; the Campus Emergency Action Plan; updated emergency contacts; and other information needed for the local plan. Perry consults with NMEFD to set schedules and plans for field and tabletop exercises, and requests a meeting with the LEPC and NMEFD to review these materials - 68.93(b).
  • Records kept for each coordination activity: names, phone numbers, email addresses and organizations of the people involved; dates; nature of the activity - 68.93(c).
OrganizationContactPhoneEmail
New Mos Eisley Fire Department, Station 7 (hazmat team)Station Captain911 / (555) 555-0180 (non-emergency)station7@nmefd-nme.org
New Mos Eisley LEPCLEPC Chair(555) 555-0185chair@tiberiuslepc.org
State Emergency Response Commission (SERC)Duty officer(555) 555-0195(by phone; SERC does not publish a duty email)
New Mos Eisley Police DepartmentWatch Commander911 / (555) 555-0182(by phone)
Tiberius Regional Medical CenterEmergency Department911 / (555) 555-0183(by phone)

Most recent coordination: March 2026 (NMEFD tour of the ammonia storage area and ammonia unloading pad; plan and contacts provided; exercise schedule agreed).

7.4 Exercises - 68.96

ExerciseLast conductedNext due
Notification exercise - 68.96(a), at least once each calendar yearNovember 18, 2025 (Steve Resko; NMEFD dispatch and LEPC called; record on file)November 2026, combined with the tabletop. Records kept five years.
Tabletop exercise - 68.96(b)(2), at least every three years after the firstNot yet held; frequency set with NMEFD at the March 2026 coordination meetingNovember 2026 with NMEFD and the LEPC (scenario: T-2 failure into the ammonia dike), before the December 21, 2026 date in 68.96(b)(2)(i); then every three years.
Field exercise - 68.96(b)(1), at least every ten years after the firstNot yet held; frequency set with NMEFD at the March 2026 coordination meetingFebruary 2027 with NMEFD (scenario: unloading hose failure, ERT deployment, community notification test), before the March 15, 2027 date in 68.96(b)(1)(i); then every ten years.

68.96(b)(3): an evaluation report is prepared within 90 days of each field and tabletop exercise, with the scenario, names and organizations of participants, evaluation and lessons learned, recommendations, and a schedule to resolve them. 68.96(c): a real response, or an exercise done for another requirement, may count if it includes the required actions; an after-action report is then prepared within 90 days.

SECTION 8Risk Management Plan Submission and Updates - Subpart G

Perry submits a single RMP for the stationary source through EPA's RMP*eSubmit, with an executive summary (68.155), registration (68.160), OCA data (68.165), five-year accident history (68.168), Program 2 prevention data (68.170), emergency response data (68.180) and certification (68.185).

8.1 Registration - 68.160(b)

ItemData elementEntry
(1)Source name, street, city, county, state, zip, latitude/longitude, method and descriptionPerry's Awesomeness Factory, 1 Perry Parkway, New Mos Eisley, Tiberius County, 00042. Latitude 41.0000 N, longitude 81.0000 W (decimal degrees; center of T-2, from drawing PI-C-001 by interpolation)
(2)Source Dun and Bradstreet number04-123-4575
(3)Corporate parent and D&B numberPerry Industries, Inc.; 04-123-4567
(4)Owner or operator name, phone, mailing addressPerry Industries, Inc., Mike Perry, (440) 336-0262, 1 Perry Parkway, New Mos Eisley
(5)Person with overall responsibility for RMPDana Scully, EHS Manager
(6)Emergency contact: name, title, phone, 24-hour phone, emailSteve Resko, ERT Leader, (555) 555-0101; 24-hour: Gate 2 security house (555) 555-0112; email ert@perryindustries-nme.com
(7)Process: substance and CAS above TQ; maximum quantity (two significant digits); NAICS; Program levelAmmonia (conc 20% or greater), 7664-41-7; 28,000 lb ammonia (in 110,000 lb of 25% solution); NAICS 325998; Program 2
(8)EPA facility identifier1000 0042 7731
(9)Number of full-time employees70
(10)Subject to 29 CFR 1910.119?Yes (Thunderbolt Solvent System)
(11)Subject to 40 CFR part 355?Yes (ammonia above its threshold planning quantity of 500 lb)
(12)CAA Title V permit numberNot a Title V source
(13)Last government safety inspection, date and agencyMarch 12, 2025, state air agency
(14)Contractor who prepared the RMPPrepared by Perry staff. OCA reviewed by EHS Consulting Services, (330) 689-9164
(15)-(19)Optional: email, homepage, public inquiry phone, LEPC, VPP statusLEPC: New Mos Eisley LEPC. Public inquiries: Brian Phillips, (555) 555-0144. VPP: none
(20)Type of and reason for changes to a previous RMPJune 12, 2024: five-year update under 68.190(b)(1)
(21)Public meeting held after an RMP reportable accident (68.210(b))?No - no reportable accident
(22)How the public within 6 miles is told chemical hazard information is available (68.210(d))Provision promulgated May 10, 2024; reported in RMPs submitted after May 10, 2028 (68.10(i))

8.2 Program 2 prevention program data - 68.170

Data elementEntry
(b) NAICS / (c) chemical325998 / Ammonia (conc 20% or greater)
(d) Last review of safety information; codes and standardsApril 2024; UL 142, API 2000, ASME B31.3, NFPA 70
(e) Last hazard review; expected completion of changesApril 2024; all changes complete (March 2025)
(f) Last review of operating proceduresJanuary 2026
(g) Last review of training program; type; competency testingMarch 2024; classroom plus on the job; written test and observation
(h) Last review of maintenance procedures; last inspectionJanuary 2026; T-2 external inspection January 12, 2026
(i) Last compliance audit; third-party?September 2025; not a third-party audit
(j) Last incident investigationNone
(k) Last change that triggered a reviewMarch 2025 (XV-200 remote closure)

8.3 Emergency response data - 68.180

(a) Local organizations last coordinated with: NMEFD Station 7 and New Mos Eisley LEPC (names, phones, email); date of last coordination; Federal or state emergency plan requirements the source is subject to: 29 CFR 1910.38, 1910.120(q); 40 CFR 112 (SPCC); 40 CFR 262 Subpart M. (b) Responding stationary source: date of last ERP review, last notification exercise, last field exercise, last tabletop exercise. Under 68.10(f), these items must be included in the next RMP update after December 19, 2024.

8.4 Updates and corrections - 68.190 and 68.195

TriggerDeadline
Five-year update - 68.190(b)(1)At least every five years from the most recent update. Last: June 12, 2024. Next: by June 12, 2029.
New regulated substance or new process above TQ - (b)(3), (b)(4)By the date the substance is first present above TQ
Change requiring a revised hazard review - (b)(5)Within six months of the change
Change requiring a revised OCA (68.36) - (b)(6)Within six months of the change
Change in Program level - (b)(7)Within six months of the change
New accident history information - 68.195(a)Within six months of the release, or at the next update if earlier
Emergency contact change - 68.195(b)Within one month of the change
No longer subject - 68.190(c)De-registration within six months

SECTION 9Recordkeeping - 68.200

Related public information duties (Subpart H, 68.210): the RMP is available to the public under 42 U.S.C. 7414(c) and 40 CFR part 1400. A public meeting is held within 90 days of any RMP reportable accident with known offsite impacts (68.210(b)). The chemical hazard information request process in 68.210(d)-(h) has a compliance date of May 10, 2027 (Appendix A).

68.200 requires records supporting implementation of Part 68 to be kept at the stationary source for five years, unless Subpart D provides otherwise. Subpart D applies to Program 3 only and does not change this for Program 2.

RecordKept byRetention
OCA documentation (68.39)EHS Manager5 years
Hazard reviews and resolution of findingsEHS Manager5 years (Perry keeps for the life of the process)
Safety information, operating procedures (current and superseded)Process Controls Engineer5 years
Training recordsHuman Resources5 years
Maintenance, inspection and test recordsMaintenance Manager5 years
Compliance audit reportsEHS ManagerTwo most recent (68.58(e)); 5 years
Incident investigation reportsEHS Manager5 years (68.60(g))
Coordination records (68.93(c))ERT Leader5 years
Notification exercise recordsERT Leader5 years (68.96(a))
Field and tabletop evaluation reportsERT Leader5 years
Employee hazard reports (68.62(b)(3), from May 10, 2027)EHS Manager3 years (Perry keeps 5)
RMP submissions and correspondenceEHS Manager5 years

APPENDIX ACompliance Dates for the 2024 Amendments

EPA's 2024 amendments to Part 68 (89 FR 17622, March 11, 2024; effective May 10, 2024) set later compliance dates for some provisions in 68.10(g)-(i). Perry Industries' schedule for this Program 2 process:

ProvisionCompliance datePerry plan / status
68.50(a)(3) standby or backup power for release monitoring equipmentMay 10, 2027AD-1 to AD-4 and the control room annunciator moved to the GEN-1 emergency panel with UPS ride-through. MOC-2026-005. Due March 2027.
68.58(f)-(h), 68.59 third-party auditsMay 10, 2027Applies only if triggered. Procedure for selecting an independent auditor drafted.
68.60(h) root cause analysis; 12-month reportMay 10, 2027Method already in use (Section 6.7).
68.62 employee participationMay 10, 2027Plan extension and reporting process to be issued by April 2027 (Section 6.8).
68.90(b), 68.95(a) emergency response amendmentsMay 10, 2027Community notification partnership with NMEFD documented March 2026.
68.210(d)-(h) availability of information to the publicMay 10, 2027Request process and notice to be posted on the Perry website by April 2027.
Subpart G amendments (for example 68.160(b)(22), 68.170(e)(7), (i))May 10, 2028Included in the next RMP update after that date.
68.96(b)(2) first tabletop exerciseBefore December 21, 2026Scheduled November 2026.
68.96(b)(1) first field exerciseBefore March 15, 2027Scheduled February 2027.
Amendments not listed in 68.10(g)-(i), for example 68.48(b), 68.50(a)(5)-(6), 68.52(b)(9), 68.95(c)In force since May 10, 2024In this program.

EPA proposed further changes to Part 68 on February 24, 2026 (Common Sense Approach to Chemical Accident Prevention). The EHS Manager will revise this appendix when a final rule is published.

APPENDIX BReferences

  • 40 CFR Part 68, Subparts A, B, C, E, F, G and H, eCFR (including amendments at 89 FR 17622, March 11, 2024, and 89 FR 102789, December 18, 2024). Proposed rule, Common Sense Approach to Chemical Accident Prevention, 91 FR 8970, February 24, 2026.
  • U.S. EPA, Risk Management Program Guidance for Offsite Consequence Analysis, EPA 550-B-99-009, April 1999 (revised March 2009), and Appendices (Exhibit B-3; Reference Tables 10 and 23).
  • U.S. EPA RMP guidance: Calculating thresholds for toxic substances with concentration qualifiers; ammonium hydroxide treated as ammonia solution; quantity of a regulated substance in aqueous solution for OCA; applicability of program levels for co-located vessels.
  • 29 CFR 1910.119 Appendix A (ammonia solutions >44%); 29 CFR 1910.120(q); 29 CFR 1910.38.
  • 40 CFR 302.4 and 302.6 (CERCLA reportable quantities: ammonium hydroxide, 1336-21-6, 1,000 lb; ammonia, 7664-41-7, 100 lb); 40 CFR part 355 (EPCRA). U.S. EPA, Determining the Amount Released for Ammonia and Ammonium Hydroxide for Release Notification Requirements under CERCLA Section 103 and EPCRA Section 304 (epa.gov/epcra).
  • NIOSH Pocket Guide to Chemical Hazards, Ammonia. PubChem, Ammonium hydroxide (CID 14923), GHS classification.
  • Industry standards: UL 142; API Standard 2000; ASME B31.3; STI SP001; NFPA 70.
  • Related Perry documents: PSM Program, Thunderbolt Solvent System (PSM-TSS-001); Campus Emergency Action Plan Rev. 4; Building B Emergency Response Plan; Building B SPCC Plan; LQG Contingency Plan Rev. 3 (separate document; cross-references the SPCC Plan); drawings PI-B-101 and PI-C-001.

Perry Industries is a fictitious company created for SYNTO training. Not a real facility. Not for use as a plan, SDS or record for any real facility, and not to be reproduced outside SYNTO training. The chemistry, the hazards and the regulations are real.

© 2026 SYNTO. Provided for SYNTO training. Not for reuse or redistribution.

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