Farmers Co-op Elevator, Main Ammonia Plant, Everly - Executive Summary |
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An Emergency Action Plan (EAP) describes policies and procedures necessary to minimize hazards to human safety and health and to the environment from fires, explosions, releases of chemicals, severe weather or other accidents. A written plan is necessary to keep track of all emergency procedures and provisions. It is also easier to ensure training is completed and is consistent for all employees when an Emergency Action Plan is in writing. An Emergency Action Plan must contain emergency escape procedures and emergency escape route assignments; procedures to be followed by employees who remain to operate critical plant operations before they evacuate; procedures to account for all employees after emergency evacuation has been completed; description of rescue and medical duties for those employees who are to preform them; the prefered means of reporting fires and other emergencies; names or regular job titles of persons or departments who can be contacted for further information or explanation of duties under the plan. The written plan also includes all the MSDS sheets for the products that we carry. The purpose of this business is to buy and sell grain, and to retail other farm related supplies and services, including bulk fuels and anhydrous ammonia. This is the plan for the FARMERS COOPERATIVE ELEVATOR COMPANY, Everly, Iowa. 68.185 Our work is year round. Normal operations, (January through December) are Monday through Saturday noon. Working hours are 7:30 a.m. to 5:00 p.m. SPRING SEASON (April through July) workdays are Monday through Sunday. Work hours are from 5:00 a.m. to 10:00 p.m. FALL SEASON (September through November) workdays are Monday through Sunday. Working hours are 7:00 a.m. to 6:00 p.m.(1st shift) and 6:00 p.m. to 7:00 a.m. (2nd shift) There are twentynine full time employees at this facility. The Emergency Coordinator (EC) is Doug Jones. In the event of an emergency, when calling emergency personnel it is necessa ry to give the facility name; give the facility location; give your name; explain the type of emergency; are there any explosions or is the emergency out of control; are there people hurt or injured or is there trapped personnel; also convey any known special needs like equipment, respirators, oxygen, and life support systems. A sign in log is located in the main office and all visitors must sign in the log book. This would include contractors, grain inspecors, state inspectors and others doing work at the facility. The vistors log would help the EC in locating these personnel in the event of an emergency. In the event of an emergency the EC would be ale to assemble his employees to the rendezvous point which is north of the scale, and between the office and the feedmill. At this time a head count would be taken; this would help the EC in locating personnel still missing and also locating personnel signed in the log book if any. At this time the EC would be able to secure the area and asign duties, making sure curious onlookers, the press, and unauthorized employees do not enter the dangerous area. The EC would coordinate outside response assembling the appropriate personnel to take care of the situation. Once the situation is under control it is imparative that the same accident does not happen again. Steps must be taken to correct the problem. Any emergency equipment used, should be be replaced, or cleaned and repaired and returned to its proper position. If replacement is not practical make other arrngements before resuming operations, and advise all personnel of the change. APP.A In a worst case scenario, the release of 110,000 pounds of anhydrous ammonia in a 10 minute time period, would release 11,000 pounds per minute. A wind speed of 1.5 m/sec would be ale to move this material to a 2 mile radius. Offsite receptors include livestock and other animals; crops and green vegitation; businesses and schools; and a population of 700 people . 68.165 (Prepared for Demonstration) OPERATING PROCEDURES (68.52) LOADING A NURSE TANK 1. Safety Comes first. A. An adequate and accessible water supply, such as an eye wash+deluge shower or an open container with at least 150 gallons of CLEAN water is required. B. Gloves and goggles must be worn when handling anhydrous ammonia. Never wear contact lenses when working with anhydrous ammonia. C. Detach the nurse tank from towing vehicle and chock the wheels. Always work upwind when handling or transfering anhydrous ammonia. 2. Make sure main liquid, liquid return, and vapor valves on the storage tank are open. 3. Connect all liquid and vapor hoses fron the riser to the nurse tank valves. Handle valves by the BODY, NOT by the valve HANDLES. Tighten all fittings by hand and close bleeder valves. 4. Open valves on the nurse tank and then open valves on the riser. Open valves slowly. 5. Start the pump to fill the tank. 6. Once liquid BEGINS coming through the 85% FIXED liquid level gauge, the tank is at its maximum RECOMMENDED filling level. Shut pump off. Close liquid and vapor valves starting at the riser first, and the the hose ends, and finally the tank itself. Open bleeder valves to bleed off the liquid and vapor between hose ends and the tank. 7. Once product is bleed off, disconnect hose end valves from nurse tank valves. Return hose ends to there secure holding compartment. Replace the cover caps and remove the wheel chocks. An alternate case scenario, could possibly be a hose rupture of a transfer semi deliverinjg a load to our storage tank. The release of 500 pound in 10 minutes could present immediate danger to the operator. A wind speed of 3 m/s would move a little over 300 feet. Safety valves and shutoffs would more than likely limit the release to less than scenario amounts. There would be no offsite damages. A short term vapor smell would ex ist. To prevent a release of this type transfer hoses need to be inspected daily to ensure there are no cracks, break, or out dated hoses being used. OCA Guidance and tables were used to prepare the worst case scenario and the alternate case scenario. (Scenario did not happen and is prepared for demonstration only) 68.165(b) ANHYDROUS AMMONIA EMERGENCIES Any accidential or unintentional release of ammonia to the atmosphere is an emergency. The seriousness depends on the amount released and the number of persons, animals or crops in the danger zone. Most common accidents happen for the following reasons: 1. Broken riser pipes caused by driving off without disconnecting hoses. 2. Ruptured hoses caused by using faulty or damaged hoses. 3. Ruptured hoses caused by hydrostatic valves not operating properly. 4. Defective valves or inoperative excess flow valves. 5. Collision or upset truck or nuses tank. (APP C) HISTORY Within the last five y ears, our facility has not had a release of anhydrous ammonia. We have not had any offsite injuries. This period covers May 1, 1994 through May 1, 1999. (68.168) We have traing meeting to inform employees of the proper procedures of handling anhydrous ammonia. We also have meetings informing employees of the hazards associated with handling anhydrous ammonia. Our most recent training session on anhydrous ammonia for this year was March 23, 1999. (68.170) ANHYDROUS AMMONIA STORAGE TANK CHECKLIST (yes is in compliance) YES: Area around storage tank, risers, and parking area free of trash, weeds, and other debris. YES: White or light-colored reflecting paint on tank is in good shape,with no scratches or rust. YES: Tank has appropriate decals and labeling. YES: Piping and connections free of rust and signs of leakage. YES: Ground wire is in place on stationary tank. YES: Valves are color coded to indicate which are liquid and vapor. (liquid=orange & vapor=yel low) YES: All valves are in good working order and sized for piping used. YES: Pump is in good working order. YES: Hoses free of wear, bulges, blistering, soft spots, cuts or tears, leakage and within "expiration date. YES: Supply of clean water is available for employees to rinse off in case of emergencies. YES: Supply of clean water is available for bleeding off. YES: Safety equipment is available, in good repair and easily accessable: approved gas mask with current ammonia caniaster, ammonia resistent gloves and boots, rainsuit, and splash proof goggles. (INSPECTION COMPLETED) 04-12-1999 (INSPECTOR) Larry J. Back (68.56 & 68.58) (RCI) Regulatory Consultants Incorporated submit our Tier II reports to the state and federal agencies. They mail us TierII reports for the county and local fire department. We in turn check them over, sign them and mail them to the Clay County LEPC, in Spencer, Iowa. The other Tier II report we signed and mailed to the Everly Fire Department, Everly, Iowa. (APP D) The company has a RIGHT TO KNOW meeting each and every year. This is to inform all employees of the hazards that are present in the work place. This meeting informs everyone of the Emergency Action Plan, in the event of a disaster or an emergency situation. We comply with OSHA 29 CFR 1910.38 by having an emergency action plan. We comply with the state EPCRA Rules and Laws, as we mail Tier II reports to the city fire department and county emergency agency. Class Date (02-18-1999) The company also puts on a training class for all personnel handling anhydrous ammonia. The class covers the safe handling of anhydrous ammonia and concludes with a written test on the material covered. All questions are answered and the test is gone over during the class to assure all personel are instucted on the proper procedures. Test Date (03-23-1999) ANHYDROUS AMMONIA STORAGE FACILITY MAINTENCE RECORD FIRM: Farmer Coop Elevator CITY: Everly, Iowa 51338 STORAGE TANK IDENTIFICATION: SN. 307785 DATE PERFORMED: (08-13-1997) WORK PERFORMED: (Relief valves replaced) DATE EXPIRES: (08-13-2002) PERFORMED BY: (Jeff Stone) ANHYDROUS AMMONIA HEALTH HAZARD INFORMATION EYES: Amonia vaporis an irritant at 100-125 ppmand at 700 ppm can cause serious and permanent injury with extreme rapidity. Exposure to high gas concentrations may lead to temporary blindness and severe tissue damage. Contact with the liquid can produce severe frostbite or freezing, chemical burns and blindness. Exposure to ammonia may exacerbate symptoms in persons with eye disease. SKIN: Liquid solutions and high concentrations of gaseous ammonia can cause blistering or first- and second- degree burns. Rapid evaporation of the liquid and chemical reaction with the skin's moisture will cause freezing of the tissue follo wed by caistic burn. Severe injuries can be fatal. INHALATION: The odor of ammonia, which can be detected at 1-50 ppm, serves as an excellent warning. Accidental exposure to high concentrations (i.e., 400 ppm and above) can cause severe irritation of the respiratory system such as coughing, difficulty in breathing, chest pain, bronchopneumonia and pulmonary edema. Breathing concentrations of 5,000 ppm has been reported to cause lung inflamationand death by asphyxiation. Continued exposure to lower concentrations of the gas cause irritation to mucous membranes and upper respiratory tractand possible damage to the lungs. Exposure to ammonia may exacerbate symptoms in persons with impared kidney, liver, or pulmonary function. INGESTATION: Can produce corrosion and inflamation of the esophagus, gastritis, abdominal spasms, nausea, faintness, and bluish skin. Other possible effects are esopheal ulcers that can result in strictures and in gastric, duodenal and stenosis. TOXICTY VA LUES: LCLO: 5,000 ppm for humans exposed for 5 minutes by inhalation. LC50: 2,000 ppm for rats exposed for 4-hours by inhalation. LD50: 350 mg/kg for ratsexposed orally. EMERGENCY & FIRST AID PROCEDURES EYES: Hold eye lids open and flush eyes immediately with plenty of water. Seek medical attention. SKIN: Flush with plenty of water; do not remove contaminated clothing until flushing has begun. INHALATION: Move exposed person to fresh air immediately. If not breathing, give artificial resporation INGESTATION: If person is conscious, give large quanities of water and demulcents (e.g.., olive oil, milk or eggwhites or a mixture of both) to dilute substances. DO NOT INDUCE VOMITING. NOTE TO PHYSICIAN: Watch for delayed symptoms of pulmonary edema. Treat symptomatically, administering analgesics and corticosteriods as necessary. Surgical intervention (tracheostomy) may be needed to maintain an airway. Watch fo r chemical pneumonitis after ingestion or inhalation of fumes. All information submitted in this report is true, accurate and complete to the best of my knowledge. The worst case scenario and alternate release scenario were writtenn for demonstration purposes ONLY.. DOUG JONES Doug Jones MANAGER 05/25/1999 |