Indiana Packers Corporation - Executive Summary

| Accident History | Chemicals | Emergency Response | Registration | Source | Executive Summary |

It is the policy of Indiana Packers Corporation to conduct business in a manner that is safe to the employees, the community and the environment.  The Company's officers, managers and supervisors are accountable to carry out the policies of the Company relevant to the prevention of accidental releases of hazardous materials.  Indiana Packers has made a determined effort to develop a plan to prevent releases of extremely hazardous substances.  Procedures to assist in the prevention of extremely hazardous material releases are set forth in EPA's Risk Management Program.  In the event of a release, the Emergency Response Plan will be the guidance for responding to, containing and reporting such releases.  The Response Plan includes an incident command system for decision-making authority for each stage of a release situation.  The Company will coordinate with public responders and emergency services in ensuring safety of the pub 
Indiana Packers Corporation is a pork processing facility.  Pigs are trucked in, slaughtered and processed for human consumption.  To preserve the meat and prevent bacteria contamination, two extremely hazardous substances are utilized, ammonia and chlorine.  Ammonia is used as a refrigerant to maintain cool to freezing temperatures in the various stages of the process.  The refrigeration system is a closed loop system, meaning the ammonia is continually reused.  Chlorine is used to treat the water to kill bacteria.  Chlorine is injected into the water via a vacuum system.  When mixed with water, it is diluted to harmless concentrations. 
Indiana Packers Corporation has developed models of the release scenarios at this facility to identify the potential affected areas.  A commercial computer model, Phast Professional, was used to develop the models. This is not an exact prediction of what would in the event of  
a release, but an estimate of the affected area and the resources needed in the event of a release. 
The worst-case release of ammonia involves the sudden failure of the High Stage Recirculator when used as a storage vessel.  The release would also involve the High Pressure Receiver releasing an estimated 31,770 pounds of ammonia.  Depending on wind direction, residences and businesses at a distance of 2.7 miles could be affected.  Approximately 4,200 people live within a 2.7 mile radius of the facility.  This type release is not likely to occur because of the stringent construction codes for pressure vessels and annual inspections of the pressure vessels. 
The alternative release of ammonia involves the failure of a 3/4 inch line on the High Pressure Receiver releasing 3,016 pounds of liquid ammonia over a three minute period.  Residences up to .23 mile from the release would be affected.  This release was selected because appurtenances are more likely to be broken.  Protective device 
s are put in place to protect lines from traffic and accidental breaking. 
The worst-case release of chlorine involves the sudden failure of two 1-ton storage cylinders (side by side), releasing 4,000 pounds of chlorine gas.  Residences would be affected by chlorine gas approximately 5.26 miles from the release.  Approximately 5,737 people live within a 5.26 mile radius of the facility.  This release is unlikely because of the high standards of construction and maintenance applicable to chlorine cylinders. 
An alternative release involves a gasket failure on the vacuum regulator.  Approximately 72 pounds of chlorine is released and could affect residences up to 720 feet from the release.  Approximately 2 people live within a 720 foot radius from the point of release.  This release was selected because a gasket failure on the vacuum regulator could occur.  This type of release is not likely to occur due to maintenance procedures and maintenance personnel training. 
Indiana Packers has set forth in its policies the importance of operating safely.  The Company has aggressively developed programs, policies and materials requirements to minimize the possibility of releases.  These programs include compliance with appropriate OSHA and EPA regulations and sound safety practices.  Stringent material and contractor requirements have been developed to assure that materials and work conform to recognized standards.  Training for employees is conducted to maintain a high level awareness when working with hazardous materials. 
Indiana Packers has had eight ammonia releases and one chlorine release during the last five years.  No offsite injuries were reported and evacuation of nearby residences was not required. 
On-site emergency response teams train to respond to releases to effectively minimize the release.  Joint response training is conducted with local emergency service organizations (i.e. fir 
e police, rescue, etc.)  Drills are conducted quarterly for on-site response teams and bi-annually with outside organizations.  Although William Washburn, Safety Director, is the key 24 hour contact, James Lex will be the contact should Mr. Washburn be unavailable.  The telephone numbers will be the same. 
Future changes to improve release prevention include:  improved maintenance procedures and periodicity; addition of new technology as it becomes available; and continued training of plant and response personnel.
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