Top of Iowa Coop - Joice Ammonia Facility - Executive Summary
Risk Management Plan (RMP) - Ammonia |
Top of Iowa Coop
Joice Ammonia Facility
1. Accidental Release Prevention and Emergency Response Policies
We at Top of Iowa Coop - Joice Ammonia Facility in Joice, IA 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 Joice Fire
Department, which provides additional 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 two 30,000-, one 12,000-, and one 18,000-gallon interconnected tanks at our
facility in Joice (Figure 1). The maximum amount stored is 76,500 gallons (393,669 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
interconnected anhydrous ammonia storage tanks (393,669 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 8.7 miles (Figure 2). The estimated
population within a 8.7-mile radius of this facility is 3,800.
The alternative release scenario involves a release from an anhydrous ammonia product line. The
scenario involves the release of 7,616.42 pounds of ammonia in a gaseous form over a period of 30
minutes. Under neutral weather conditions, the maximum distance to the 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
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
Top of Iowa Coop - Joice Ammonia Facility maintains a detailed r
ecord of safety information that
describes the chemical hazards, operating parameters, and equipment designs associated 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
Top of Iowa Coop - Joice Ammonia Facility 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 (Appendix B).
Top of Iowa Coop - Joice Ammonia Facility 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.
Top of Iow
a Coop - Joice Ammonia Facility conducts documented maintenance checks on process
equipment to ensure proper operation. Maintenance checks are conducted by qualified personnel
with previous training in 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 Top of Iowa Coop - Joice Ammonia Facility 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.
Top of Iowa Coop - Joice Ammonia Facility
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.
Top of Iowa Coop - Joice Ammonia Facility 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.
Top of Iowa Coop - Joice Ammonia Facility 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,
larly information resulting from process hazard analyses.
5. Five-year Accident History
Top of Iowa Coop - Joice Ammonia Facility has had an excellent record of preventing accidental
releases over the last 5 years. Due to our stringent release prevention policies, no accidental release
has occurred during this period.
6. Emergency Response Plan
Top of Iowa Coop - Joice Ammonia Facility 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 (Appendix A).