Lone Star Bakery - Executive Summary |
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Lone Star Bakery Risk Management Plan EXECUTIVE SUMMARY Section1 This is to inform all interested persons, including employees that Lone Star Bakery is complying with OSHA's Process Safety Management Standard (called Process Safety Management or PSM), Title 29 Code of Federal Regulations (CFR) 1910.119, and EPA's Risk Management Program regulations (called RM Program), Title 40 CFR Part 68, to deal with the risks involved with the storage, handling, and processing of hazardous chemicals. In this way we promote overall plant, worker, and public safety. These programs enable our facility to prevent the occurrence, and minimize the consequences, of significant releases of toxic substances as well as fires, explosions, and other types of catastrophic accidents. Overall, these programs prevent accidental fatalities, injuries and illnesses and avoid physical property damage. Our safe ty programs are applied to any activity involving hazardous chemicals including any use, storage, manufacturing, handling, or the on-site movement of such chemicals, or combination of these activities. Any group of vessels which are interconnected and separate vessels which are located such that a hazardous chemical could be involved in a potential release shall be considered a single process. Our safety programs prevent accidents because they focus on the rules, procedures, and practices which govern individual processes, activities, or pieces of equipment. These rules are detailed and improved as necessary. They are also communicated to and accepted by all employees at the facility. Like all PSM/RM programs, ours contains the following major elements: General Company Policy Employee Participation Process Safety Information Process Hazard Analysis Standard Operating Procedures Training Contractor Qualifications Pre-Startup Safety Review Mechanical Integrity Program Hot Work Permit Ma nagement of Change Incident Investigation Emergency Planning and Response Compliance Audits Trade Secrets Management System Hazard Assessment Five Year Accident History Preparation of a Risk Management Plan (RMP) Damon Smith is the program coordinator with overall responsibility to ensure that program goals and objectives are met and appropriate resources are available. Damon Smith will review and update the program as necessary. Copies of the written program may be reviewed by checking with Damon for access to the appropriate information. We encourage all suggestions because we are committed to the success of our PSM/RM program. We strive for a comprehensive, integrated prevention system which obtains clear understanding, safe behavior, and involvement in the program from every level of the facility and the public. Section 2 Overview of the System Lone Star Bakery prepares bakery items and supplies various retail merchandisers. Some items are frozen on spiral freezers and are held in a freezer until shipped. Packaging and material storage areas are kept at approximately 40 degrees. The ammonia refrigeration system has three suction temperature systems. The packaging and dock system is operated at 20 to 25 PSIG(5 to 10 degrees). The freezer system is operated at 4 to 5 PSIG(-20 to -17 degrees). The spiral or blast system is operated at 2 to 5 InHg(-35 to -30 degrees). Currently six compressors, two for each system are operated as single stage compressors discharging to the common high stage discharge piping that leads to three evaporative condensers. The liquid ammonia from these condensers is piped to a common high pressure receiver. A portion of the liquid leaving the receiver is subcooled through a subcooling vessel before entering the low temperature recirculators. Section 3 Worst Case Scenario Failure of the high pressure receiver containing 7330 pounds of ammonia with the receiver capacity quantity limited to 50% of vessel capacity by facil ity procedures resulting in a ten minute release. Under worst case weather conditions, ammonia could travel 1.6 miles before dispersing enough to no longer pose a hazard to the public. Ths scenario is unlikely for the following reasons: Worst case weather conditions are uncommon. Industry standards for the manufacture and quality control of vessels. Ammonia is not corrosive in this service. Pressure safety valves limit operating pressure in this vessel. The mechanical integrity program in place at this facility for regular maintenance, inspection and replacement of equipment on a timely basis. Distance to endpoint is calculated to be 1.6 miles, using RMP*Comp. Section 4 Alternative Release Scenario Due to an upset in the system, an overpressure occurs in the low temperature recirculator causing a crack in one of the ammonia pumps equivilent to a one-half inch diameter hole. As a result 400 pounds per min are released for a period of ten minutes. Ths scenario is unlikely f or the following reasons: Industry standards for the manufacture and quality control of vessels. Ammonia is not corrosive in this service. Pressure safety valves limit operating pressure in this vessel. The mechanical integrity program in place at this facility for regular maintenance, inspection and replacement of equipment on a timely basis. Failure of several systems would have to occur to allow this scenario to happen. Distance to endpoint is calculated to be 0.3 miles, using RMP*Comp. |