Ice Cream - Executive Summary |
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Smith Dairy Products Company 230 North Vine Street Orrville, OH. 44667 NAICS #: 31152 Process: This facility is a food processing plant that runs a continuous operation. The regulated substance under the RMP Rule is Anhydrous Ammonia' which is used in the refrigeration system. The is a closed loop system to maintain temperature in the facility production and storage areas. Quantity: The facility maintains 23,000 lbs of Anhydrous Ammonia on site as an operating level for the ammonia refrigeration system. Chemical Hazards for: Anhydrous Ammonia Permissible Exposure Limit--25 PPM for 8 hours Short Term Exposure Limit--35 PPM for 15 minutes Imediately Dangerous to Life or Health--300 PPM Inhalation Hazard--1,000 PPM Skin Aborsption Hazard--10,000 PPM Lower Exsplosive Limit--16% Upper Exsplosive Limit--25% EPA Toxic Endpoint--200 PPM DOT Classification:--Non-flammable gas United Nations Number:--UN 1005 Worst-case Scenario for a toxic substance: The worst-case release tox ic endpoint was determined using EPA's "RMP Guidance for Ammonia Refrigeration' reference tables and equations. This scenario was based on the following criteria: Vessel: High Pressure Receiver (HPR) 54" x 18' 0" Amount Released: 10,000 lbs. Duration of Release: 10 minutes Release Rate: 1000 lbs/min Wind Speed: 1.5 meter/sec Atmospheric Stability: F Topography: Urban Passive Mitigation: Building Enclosure The toxic endpoint was calculated taking into consideration building enclosure as passive mitigation. The enclosure measures 38' x 38' x 18' and has one exhaust fan rated at 3,000 cfm producing approximately 7 room air exchanges per hour. Referencing the tables in Chapter Four of the "RMP Guidance for Ammonia Refrigeration", the toxic endpoint would be a radius of 0.6 miles. Affected within this radius is a population of 788, four schools (Orville High School, Orville Junior High School, Oak St reet Elementary School, and Saint Agnes School), a city park, residential, retail, and industrial areas. Alternative release scenario for a toxic substance: The alternative release toxic endpoint was also determined using the EPA's "RMP Guidance for Ammonia Refrigeration" reference tables and equations. The scenario was based on the following criteria: Scenario: Vessel Leak Orifice Size: 1/4" Release Rate: 100 lb/min Duration of Release: 10 min Amount Released: 1000 lbs Wind Speed: 3 meter/sec Atmospheric Stability: D Topgraphy: Urban Using the same passive mitigation formulas as for the worst-case scenario, the release rate, from the building, was calculated at 10 lbs/min with a toxic endpoint of 0.10 miles. Affected within this area is 97 people. Also affected are several businesses and residences. Accidental Release and Emergency Response Policies : Smith Dairy has established an in-house emergency response team to quickly respond to and handle releases of Anhydrous Ammonia. The established steps include initial training under the OSHA regulation 29 CFR 1910.120 HAZWOPER'. The facility has also established annual retraining for all personnel that are on the HAZMAT Team as well as periodic spill drills and plant wide evacuation drills to assure all employees are prepared in the event of an emergency. Smith Dairy has also established training with the Fire Department personnel and community Local Emergency Planning Committee. These established plans and procedures shall be periodically reviewed to assure that they are current and up to date. Emergency Response Program: Smith Dairy has trained the refrigeration operators and selected production and office personnel in Hazardous Waste Operation and Emergency Response 29 CFR 1910.120. The trained personnel will access each release situation and determine the appropriate emergenc y response to initiate. This could be by simply tightening a packing nut or flange bolt or initiating a system shut down. Smith Dairy has established written operating procedures for the ammonia refrigeration system and has included in those procedures the Emergency Shutdown and isolation in the event of a release. Smith Dairy has purchased Level B Chemical Suites, Self Contained Breathing Apparatus and other appropriate equipment to support the in-house HAZMAT team. This team will coordinate their efforts with the outside emergency services to assure the safety of all. Five Year Accident History: Ammonia Release @ Smith Dairy August 11, 1995 @ 11:30AM approximately 30 # of ammonia was purged into a 55 gallon drum and spilled behind the ice cream building. The ammonia had been released in a storm sewer and in the process a frog might have been killed. The whole process started when maintenance was purging a malfunctioning air purging device in ice cream and then spilled the purged water in the ditch. EPA, LEPC and the fire department were notified. After this event all purged ammonia water has been sent to our waste treatment facility. Ammonia Release @ Smith Dairy September 23, 1997 around 4:30 PM a contractor inadvertently released approximately 50 pounds of ammonia. The contractors who had been installing an addition to our ammonia system left a 6 inch valve open which had been "chained" closed and thus the ammonia escaped. It ran down the building through our down spouts and into the storm drainage ditch. The ditch was blocked off effectively so that it did not get into the storm sewer or beyond. Agencies contacted were National Response Center, EPA , LEPC & Orrville Fire Department. After this incident occurred the contractor was required to use a valve lockout device not just a chain as had previously been used. General Accidental Release Prevention Program and Chemical Specific Prevention Steps: Smith Dairy has not only complied with the EPA Ris k Management Program but also the OSHA Process Safety Management regulation to assure that the Ammonia Refrigeration System is well maintained and employees are properly trained and periodically retrained to assure they are kept up to date on any changes and new operations that may effect them. In addition, to maintain the mechanical integrity and safety of this process, this facility practices the following industry codes and standards: ASME Boiler & Pressure Valve Codes ANSI B31.3 Piping Code IIAR industry guideline for safety and good engineering practices NFPA guidelines for fire protection equipment Through regular audits, training, maintenance, testing and inspection programs Smith Dairy has established a history of safe operation and that community emergency action plans are current and training with community services is done for a safe response in the event of an accidental release. |