Grimmway Frozen Foods Inc. - Executive Summary

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1.    Accidental Release Prevention and Emergency Response Policies: 
We at Grimmway Frozen Foods Inc. are strongly committed to employee, public and environmental safety.  This commitment is demonstrated by 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. 
2.    The Stationary Source and the Regulated Substances Handled: 
Our facility's primary activities encompass Carrot freezing.  We have 1 regulated substances present at our facility.  This substance is Ammonia (anhydrous).  Ammonia (anhydrous) is used in our refrigeration system. 
The maximum inventory of Ammonia (anhydrous) at our facility is 52180.80 lbs. 
3.    The Worst Case Release Scenarios and the Alternative Release Scen 
arios, including administrative controls and mitigation measures to limit the distances for each reported scenario: 
To evaluate the worst case scenarios, we have used the EPA's OCA Guidance Reference Tables or Equations and the EPA's RMP Guidance for Ammonia Refrigeration Reference Tables or Equations.  For alternative release scenario analyses we have employed the EPA's OCA Guidance Reference Tables or Equations.  The following paragraphs provide details of the chosen scenarios. 
The worst case release scenario submitted for Program 2 and 3 toxic substances as a class involves a catastrophic release from Building 3.  In this scenario 12700 lbs. of Ammonia (anhydrous) is released.  The toxic liquid released is assumed to form a 1-cm deep pool from which evaporation takes place.  The entire pool is estimated to evaporate over 10 minutes.  At Class F atmospheric stability and 1.5 m/s windspeed, the maximum distance of 2.18 miles is obtained corresponding to a toxic endpoint of 0.14 mg/L 

The alternative release scenario for Ammonia (anhydrous) involves a release from Building 3.  The scenario involves the release of 1016 lbs. of ammonia.  The toxic liquid is assumed to be released to form a 1-cm deep pool from which evaporation takes place.  The entire pool is estimated to have evaporated after 10 minutes.  Passive mitigation controls such as an enclosure are taken into account to calculate the scenario, having the effect of containing the release of the ammonia.  Under neutral weather conditions, the maximum distance to the toxic endpoint of 0.14 mg/L of Ammonia (anhydrous) is 0.19 miles. 
4.    The General Accidental Release Prevention Program and the Chemical-Specific Prevention Steps: 
Our facility has taken all the necessary steps to comply with the accidental release prevention requirements set out under 40 CFR part 68 of the EPA.  This facility was designed and constructed in accordance with NFPA-58 Standard, 1967 Edition.    The following sections briefly descr 
ibe the elements of the release prevention program that is in place at our stationary source. 
Process Safety Information: 
Grimmway Frozen Foods Inc. maintains 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 efficiently.  The methodology used to carry out these analyses is HAZOP.  The studies are undertaken by a team of qualified personnel with expertise in engineering and process operations and are revalidated at a regular interval of every three years.  Any findings related to the hazard analysis are addressed in a timely manner.  The most recent PHA/update was performed on 07/26/1996. 
Operating Procedures: 
For the purposes of safely conducting activities within our covered processes, Grimmway Frozen Foods Inc. maintains written op 
erating procedures.  These procedures address various modes of operation such as initial start-up, normal operations, temporary operations, emergency shutdown, emergency operations, normal shutdown and start-up after a turnaround.  The information is regularly reviewed and is readily accessible to operators involved in the processes. 
Grimmway Frozen Foods 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.  Refresher training is provided at least every yearly and more frequently as needed. 
Mechanical Integrity: 
Grimmway Frozen Foods Inc. carries out highly documented maintenance checks on process equipment to ensure proper operations.  Process equipment examined by these checks includes among others; condensing towers, receiver tanks, compressors, accumulators, inner-coolers, Phillips dump system, IQF tunnel, piping, coils, belts, motors, bearings,  
relief valves, solenoids, and isolation valves.  Maintenance operations are carried out by qualified personnel with previous training in maintenance practices.  Furthermore, these personnel are offered specialized training as needed.  Any equipment deficiencies identified by the maintenance checks are corrected in a safe and timely manner. 
Management of Change: 
Written procedures are in place at Grimmway Frozen Foods Inc. to manage changes in process chemicals, technology, equipment and procedures.  The most recent review/revision of maintenance procedures was performed on 02/18/1999.  Process operators, maintenance personnel or any other employee whose job tasks are affected by a modification in process conditions are promptly made aware of and offered training to deal with the modification. 
Pre-start-up Reviews: 
Pre-start up safety reviews related to new processes and to modifications in established processes are conducted as a regular practice at Grimmway Frozen Foods Inc.  The mo 
st recent review was performed on 02/27/1998.  These reviews are conducted to confirm that construction, equipment, operating and maintenance procedures are suitable for safe start-up prior to placing equipment into operation. 
Compliance Audits: 
Grimmway Frozen Foods Inc. conducts audits on a regular basis to determine whether the provisions set out under the RMP rule are being implemented.  The most recent compliance audit was conducted on 05/14/1999.  These audits are carried out at least every 3 years and any corrective actions required as a result of the audits are undertaken in a safe and prompt manner. 
Incident Investigation: 
Grimmway Frozen Foods Inc. promptly investigates any incident that has resulted in, or could reasonably result in a catastrophic release of a regulated substance.  These investigations are undertaken to identify the situation leading to the incident as well as any corrective actions to prevent the release from reoccurring.  All reports are retained for a m 
inimum of 5 years. 
Employee Participation: 
Grimmway Frozen Foods 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 rule, including information resulting from process hazard analyses in particular. 
On occasion, our company hires contractors to conduct specialized maintenance and construction activities.  Prior to selecting a contractor, a thorough evaluation of safety performance of the contractor is carried out.  Grimmway Frozen Foods Inc. has a strict policy of informing the contractors of known potential hazards related to the contractor's work and the processes.  Contractors are also informed of all the procedures for emergency response should an accidental release of a regula 
ted substance occur. 
5.    Five-year Accident History: 
Grimmway Frozen Foods Inc. has had an excellent record of preventing accidental releases over the last 5 years.  Due to our stringent release prevention policies, there has been no accidental release during this period. 
6.    Emergency Response Plan: 
Grimmway Frozen Foods Inc. carries a written emergency response plan to deal with accidental releases of hazardous materials.  The plan includes all aspects of emergency response including adequate first aid and medical treatment, evacuations, notification of local emergency response agencies and the public, as well as post-incident decontamination of affected areas. 
To ensure proper functioning, our emergency response equipment is regularly inspected and serviced.  In addition, the plan is promptly updated to reflect any pertinent changes taking place within our processes that would require a modified emergency response. 
7.    Planned Changes to Improve Safety: 
Several developments and  
findings have resulted from the implementation of the various elements of our accidental release prevention program.  Continued monthly safety walk through inspections, computerization of refrigeration controls, and renovation of electrical systems are some of the major steps we want to take to improve safety at our facility.  These changes are expected to be implemented by 6/30/2000.
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