Warrick's Inc. - Executive Summary
Risk Management Plan (RMP) - Ammonia |
1. Accidental Release Prevention and Emergency Response Policies
We at Warrick's, Inc. in Wellington 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 efforts with the Wellington Fire Department, which
ional emergency response expertise.
2. Stationary Source and Regulated Substances Handled
Our facility's primary activities include support services for crop production. We have anhydrous
ammonia stored in a 10,000- and two interconnected 12,000-gallon tanks at our facility in
Wellington (Figure 1). The maximum amount stored is 28,900 gallons (148,719.4 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 two
interconnected anhydrous ammonia storage tanks (104,978.4 pounds) in gaseous form over a 10-
minute period. At Class F atmospheric stability, 1.5 m/s wind speed, and urban topography, the
maximum distance to a toxic endpoint of 0.14 mg/L is 4.6 miles (Figure 2).
population within a 4.6-mile radius of this facility is 3,000.
The alternative release scenario involves a release from an anhydrous ammonia product line. The
scenario involves the release of 7,995.83 pounds of ammonia in a gaseous form over a period of 30
minutes. Under neutral weather conditions, the maximum distance to the toxic endpoint of 0.14
mg/L of ammonia is 0.31 mile (Figure 3). The estimated population within a 0.31-mile radius of the
facility is 1,200.
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
Warrick's, Inc. maintains a detailed record of safety information that describes the chemical hazards,
operating parameters, and equipment designs associat
ed with all processes (Appendix D).
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
Warrick's, Inc. 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
Warrick's, Inc. has a comprehensive training program in place to ensure that employees who are
operating processes are competent in the operating procedures associated with these processes.
Warrick's, Inc. conducts documented maintenance checks on process equipment to ensure proper
operation. Maintenance checks are conducted by qualified personnel with previous trai
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 Warrick's, Inc. 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.
Warrick's, Inc. routinely conducts pre-startup safety 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.
Warrick's, Inc. conducts compliance audits on a regular basis to determine whether the plan's
provisions, set out under the 40 CFR part 68, are being implemented. Any non-compliance issue
discovered during the audit is promptly corrected.
Warrick's, Inc. 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 analyses.
5. Five-year Accident History
Warrick's, Inc. has had a very good record of preventing accidental releases over the last 5 years.
Due to our stringent release prevention policies, only one minor accidental release has occurred
s period. The release, due to human error, resulted in one minor injury to an employee;
the employee has fully recovered. After the release, Warrick's, Inc. conducted a full review of
maintenance and inspection procedures for the facility. All employees completed a safety refresher
6. Emergency Response Plan
Warrick's, Inc. 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