McCain Foods USA, Inc., Grand Island - Executive Summary
McCAIN FOODS USA, INC. |
RISK MANAGEMENT PROGRAM
1. General accidental release and prevention policy of McCain Foods USA, Inc.
In this food product manufacturing facility we handle anhydrous ammonia in a liquid and vapor
state which is considered hazardous by the EPA. The same properties that make ammonia a
valuable refrigerant also makes it necessary to observe certain safety precautions during it's use to
prevent human exposure, reduce the threat to our workers personal health, the surrounding
community and the environment. It is our policy to adhere to all applicable federal and state
regulations. Safety depends directly on our proper handling of ammonia combined with the safety
devices that are incorporated in our facility and the safe handling procedures that our personnel
are trained in.
2. Stationary source and regulated substance handled.
McCain Foods US
A, 204 East Roberts Street, Grand Island, Nebraska is responsible for the
manufacturing of frozen appetizers. There are approximately 450 employees at this facility which
includes hourly and salary personnel. The plant manufactures product around the clock, (7) seven
days a week. McCain Foods is located in an industrial park on the north side of Grand Islands,
Nebraska. In addition to our manufacturing facility the industrial park also houses other
manufacturing or business facilities.
The potentially hazardous chemical used at the McCain Foods facility is ANHYDROUS
AMMONIA. The dominant characteristic of ammonia vapor is it's pungent, distinct odor.
Persons exposed to ammonia will not voluntarily stay in areas of even small concentrations,
although these levels would not result in any health risks.
Risks from accidental exposure to ammonia in a vapor state are irritations to the eyes, nose and
throat. The extent of irritation depends on the exposure amount and len
gth of exposure.
Ammonia is classified non-flammable by the Department of Transportation. It will burn, but only
in a very narrow, high concentration level with a constant ignition source.
The normal operating level of ammonia that is used/stored at the McCain Foods facility is 24,000
pounds. The anhydrous ammonia is used as the refrigerant chemical in the manufacturing/storage
process. The possible hazards that could lead to an accidental release include, but are not limited
to, equipment failure, damage to piping, damage to equipment, human error, etc.
3. Worst case release scenario and alternate release scenarios including administrative and
engineering controls to limit/prevent the release.
Worst case release scenario criteria for McCain Foods USA facility:
Worst case scenario depicts continuous source leak from the High Pressure Receiver (HPR)
located inside the McCain Foods machine room. This vessels normal operating level is 5,482
unds of liquid ammonia, approximately 50% of it's total capacity. Although it's maximum
capacity is 10,964 pounds, this exceeds company policy of only allowing an 80% level at any
Ammonia Quantity: 5,480 pounds
Rate of Release: 548 lbs / min. (10 min. release)
LOC (Level of Concern): 200 ppm (EPA ERPG-2)
Physical State: Gas and/or Liquid
Type of Area: Urban
Wind Speed: 1.5 m/sec
Distance to Endpoint 2.5 miles
Alternate case release scenario criteria for McCain Foods USA facility:
Alternate release scenario is represented by the release of ammonia vapor from a safety relief
valve (SRV) due to an over pressurization condition on a vertical vessel located within the
McCain Foods facility machine room. SRV would be performing exactly as it is designed to do.
Rate of Release: 36 pounds/min. (17 min. release)
Distance to Endpoint: 264 yards
The following administrative and engineering controls are in place at the McCain
Foods facility to limit the distance for the reported scenarios.
* Electronic ammonia detection in machine room sounds a local alarm and activates an
outside flashing light to alert maintenance personnel of a potential hazard. Detection system also
engages machine room ventilation and shuts off gas heaters.
* Safety Relief valves are installed on pressure vessels, condensers and compressor oil
separators to eliminate over-pressure conditions in those associated pieces of equipment.
* High liquid level alarms are configured to all pressure vessels, except the high pressure
receiver, to indicate high levels and prevent overfilling of vessels.
* Periodic Maintenance Program is in place within the
maintenance department to ensure
all refrigeration components are kept in optimum operational and mechanical condition.
4. Five-year accident history.
McCain Foods USA has had zero reportable accidental releases in the last five years.
5. Emergency Response Program
The purpose of the McCain Foods Emergency Response Program is to:
1. Minimize exposure to our employees and the surrounding community in the event of a
hazardous material release or spill.
2. Assure the safe emergency evacuation of the plant in the instance that it is required.
3. Provide for prompt medical attention to any employees who become seriously injured
or ill at work.
4. Manage an emergency response system and coordinate response of the internal and
external resources required to provide efficient and effective response to any type of
emergency that may occur at McCain Foods.
McCain Foods has utilized inputs from the International
Institute of Ammonia Refrigeration in
compiling the Emergency Response Program. This ERP currently meets requirements as set forth
in OSHA 29 CFR 1910.120 (HAZWOPER) Emergency Response Regulations. Additionally,
McCain Foods has received inputs from and coordinated with the Hall County Fire Department
and state organizations to ensure compliance in the emergency response areas.