SolarWorld

Client: SolarWorld

Location: Ventura, California

Summary:

Semiconductor Manufacturing Plant Expansion New Source Review

Cardno ENTRIX prepared and submitted several authority-to-construct (ATC) permit applications over a number of years for a plant expansion and subsequent process modifications for a major manufacturer of photovoltaic cells and modules. Various process analyses were performed in order to determine the availability of internal VOC offsets and thus minimize the need for purchasing external VOC offsets. Also prepared and submitted Annual Emissions Reports (AERs).

Title V Recordkeeping and Reporting Programs for Manufacturing Industries

Cardno ENTRIX developed regulatory compliance tools which conformed to APCD requirements for maintaining Title V compliance at several manufacturing facilities, including semiconductors. Created compliance manuals, facility-specific recordkeeping forms, recordkeeping and reporting spreadsheet templates, and conducted employee training on how to use the forms and templates.

Manufacturing Facilities Risk Management Plans for Accidental Release Prevention

Cardno ENTRIX prepared and submitted Cal/ARP documents for semiconductor manufacturing facilities utilizing Program 3 processes which use toxic and pyrophoric gases under federal or state OSHA programs. Performed PHA/HAZOPS, hazard assessments, offsite consequence analyses for worst-case and alternate-case release scenarios, external events analyses, reviewed seismic analyses, compiled accident histories, and documented management systems, prevention programs, and emergency response programs.

Manufacturing Facilities Process Safety Management Programs

Cardno ENTRIX developed and documented complete Process Safety Management (PSM) programs for semiconductor manufacturing facilities which use toxic and pyrophoric gases under federal or state OSHA programs. The document was prepared in compliance with Title 29 CFR Part 1910.119, Title 40 CFR Part 68, Title 8 CCR 5189, and Title 19 CCR Division 2 Chapter 4.5, Subchapter 1.

Toxic and Pyrophoric Gases Process Hazard Analysis

Cardno ENTRIX conducted PHAs (HAZOPS) for semiconductor manufacturing facilities which use toxic and pyrophoric gases. Using the what-if / checklist methodology pursuant to Title 19 CCR Section 2760.2, assessed and documented the significance of potential hazards and checked for compliance with applicable codes and standards. The HAZOP identified hazards associated with the processes and regulated substances; opportunities for equipment malfunction or human error that could cause an accidental release; safeguards used or needed to control the hazards or prevent equipment malfunction or human error; any steps used or needed to detect or monitor releases; and effects of external events including seismic events.