Carolina Culinary Foods, L.P. - Executive Summary |
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Carolina Culinary Foods, L.P. 1964 Old Dunbar Rd. West Columbia, SC 29172 Phone: (803) 739-8920 Fax: (803) 739-8075 Process: Carolina Culinary Foods, L.P. is a further processing poultry facility that is in continuous operation. Carolina Culinary Foods utilizes a refrigeration system that is a closed loop system containing anhydrous ammonia. The entire amount of anhydrous ammonia on site is approximately 22,000 pounds and is entirely contained in one system that is used for plant refrigeration and product freezing. Carolina Culinary Foods is commited to the safety of the ammonia refrigeration system and the implementation of the requirements under the Risk Management Program of 40 CFR Part 68 and the Process Safety Management Program of 29 CFR 1910.119. Accidental Release Prevention and Emergency Response Policy: Carolina Culinary Foods, L.P. is dedicated to the safe operation of its refrigeration system and to the safety of the employees, public, and environment. Carolina Culinary Foods conducts employee training in accordance with the OSHA Hazard Communication Standard 29 CFR 1910.1200. We also perform annual HAZWOPER training and retraining of key employees who will perform entry work during an ammonia release. Carolina Culinary Foods has also invited the Cayce Fire Department and Lexington County HAZMAT members onsite to make them more aware and informed of our plant, process, and system. "Worst Case" Scenario and "Alternative Release" Scenario In following with the requirements of the RMP, Carolina Culinary Foods has determined a "worst case scenario" and an "alternative release scenario" for anhydrous ammonia from our system. The "worst case scenario" involves a rupture of our high pressure receiver. Through review by the manufacturer of the ammonia system it has been determined that the HP Receiver has a maximum inventory of 12,320 lbs. Using RMP Guidance for Ammonia Refrigeration Reference Tables or Equations, a release of 10 minutes woul d mean a loss of 1,230 lbs. per minute and since Carolina Culinary Foods is in an urban area, this would mean a release end point of 1.5 miles. Per the Cayce Department of Public Safety, the approximiate population within a 1.5 mile radius of Carolina Culinary Foods is 4,007. The "alternative release scenario" involves an overpressurization of the condensing tower resulting in a shank relief valve discharge. Through review by the manufacturer and plant maintenance we have come to the conclusion that the relief valve would stay open for approximately 5 minutes and release approximately 21 pounds per minute resulting in a release endpoint of .1 miles. Five Year Accident History: No accidents in past five years. General Accidental Release Prevention Program: Carolina Culinary Foods is subject to OSHA's Process Safety Management Standard and has imlemented a Process Safety Management Program to minimize the exposure of its employees, the public, and the environment from an anhdrous ammonia release. The ammonia system is constantly monitored by computer and employees to ensure that all equipment is operating within expected parameters. Procedures have been written and implemented on how to properly isolate and shutdown the refrigeration system components in the event of an emergency. Multiple safety devices are used on each piece of equipment to protect from an accidental release. Emergency Response Program: Carolina Culinary Foods has developed a plan to provide notification and evacuation of plant employees and the surrounding public. Procedures have been developed to notify the Cayce Fire Department and Lexington County HAZMAT Team to respond to any substantial ammonia release. Procedures have also been developed for the notification of the Lexington County LEPC and the Department of Health and Environmental Control (DHEC). Key employees have been trained in either 24 OR 40 Hour HAZWOPER so that they will able to assist the Cayce Fire Department an d Lexington County HAZMAT with stopping an ammonia release. Members of the Cayce Fire Department and Lexington County HAZMAT have been onsite to keep themselves more familiar with the process and the plant layout. Planned Changes to Improve Safety Carolina Culinary Foods, L.P. performs a complete review of the refrigeration process when there has been changes to its design. Through this review process we identify and implement changes to improve system safety. |