New Horizons Supply Cooperative, Gays Mills - Executive Summary
Risk Management Plan (RMP) - Propane |
New Horizons Supply Cooperative
Gays Mills, Wisconsin
1. Accidental Release Prevention and Emergency Response Policies
We at New Horizons Supply Cooperative in Gays Mills are strongly committed to employee, public,
and environmental safety. This commitment is an inherent part of our comprehensive accidental
release prevention program that covers areas such as design, installation, operating procedures,
maintenance, and employee training associated with the processes at our facility. It is our policy to
implement appropriate controls to prevent possible releases of regulated substances. If such a release
does occur, our trained emergency response personnel are at hand to control and mitigate the effects
of the release. We also coordinate our response effort
s with the Gays Mills Fire Department, which
provides additional emergency response expertise.
2. Stationary Source and Regulated Substances Handled
Our facility's primary activities include propane retail distribution and support services for crop
production. We have propane stored in a 30,000-gallon tank located at our facility in Gays Mills
(Figure 1). The maximum amount stored is 25,500 gallons (107,686.5 pounds) at the maximum fill
capacity of 85%.
3. Worst Case Release and Alternative Release Scenarios
We utilized RMP PRO for the worst case and alternate case scenarios of the required offsite
consequence analysis for our facility. The following details these scenarios.
The worst case release scenario involves a catastrophic release of the entire contents of the propane
storage tank (107,686.5 pounds) in gaseous form over a 10-minute period. At Class F atmospheric
stability and 1.5 m/s wind speed, the maximum distance to an endpoint of 1 psi overpressure is 0.38
(Figure 2). This amount of overpressure can cause partial demolition of houses and can result
in serious injury to people within this distance. The estimated population within a 0.38-mile radius
of this facility is 100.
The alternative release scenario involves a 30-minute release of propane from a product line that
contacts an ignition source and detonates, resulting in a vapor cloud explosion. Under neutral
weather conditions, the maximum distance to an endpoint of 1 psi overpressure is 0.12 mile (Figure
3). The estimated population within a 0.12-mile radius of this facility is 30.
4. General Accidental Release Prevention Program
Our facility has taken all the necessary steps to comply with the EPA's accidental release prevention
requirements as set forth in 40 CFR part 68. The following sections briefly describe the elements
of the release prevention program that is in place at our stationary source.
Process Safety Information
New Horizons Supply Cooperative maintai
ns a detailed record of safety information that describes
the chemical hazards, operating parameters, and equipment designs associated with all processes
Process Hazard Analysis
Our facility conducts comprehensive studies to ensure that hazards associated with our processes are
identified and controlled effectively. Any findings from the hazard analysis are addressed in a
New Horizons Supply Cooperative maintains written operating procedures to ensure that activities
within our covered processes are conducted safely. These procedures address various modes of
operation; the information is regularly reviewed and is readily accessible to operators involved in
the processes (Appendix B).
New Horizons Supply Cooperative has a comprehensive training program in place to ensure that
employees who are operating processes are competent in the operating procedures associated with
New Horizons Su
pply Cooperative conducts documented maintenance checks on process equipment
to ensure proper operation. Maintenance checks are performed by qualified personnel with previous
training in maintenance practices. Examples of process equipment that would receive maintenance
checks include: pressure vessels, storage tanks, piping systems, relief and vent systems, emergency
shutdown systems, controls, and pumps. Any equipment deficiencies identified by the maintenance
checks are corrected in a safe and timely manner (Appendix C).
Management of Change
Written procedures are in place at New Horizons Supply Cooperative to manage changes in process
chemicals, technology, equipment, and procedures. Process operators, maintenance personnel or
other employees whose job tasks are affected by a modification in process conditions are promptly
notified of the modification and offered training to deal with it.
New Horizons Supply Cooperative routinely conducts pre-startup safe
ty reviews related to new
processes and modifications in established processes. These reviews are conducted to confirm that
construction, equipment, and operating and maintenance procedures are suitable for safe startup prior
to placing equipment into operation.
New Horizons Supply Cooperative conducts compliance audits on a regular basis to determine
whether the provisions of the plan, as set out under 40 CFR part 68, are being implemented. Any
non-compliance issue discovered during the audit is promptly corrected.
New Horizons Supply Cooperative truly believes that process safety management and accident
prevention is a team effort. Company employees are strongly encouraged to express their views
concerning accident prevention issues and to recommend improvements. In addition, our employees
have access to all information created as part of the facility's implementation of the RMP
particularly information resulting from process hazard anal
5. Five-year Accident History
New Horizons Supply Cooperative has had an excellent record of preventing accidental releases over
the last 5 years. Due to our stringent release prevention policies, no accidental release has occurred
during this period.
6. Emergency Response Plan
New Horizons Supply Cooperative maintains a written emergency response plan to deal with
accidental releases of hazardous materials. The plan addresses all aspects of emergency response
including first aid and medical treatment, evacuations, and notification of local emergency response
agencies and the public (Appendix A).