South Ice Cream Plant, Le Mars - Executive Summary |
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A Risk Management Program (RMP) has been developed and prepared for use and storage of anhydrous ammonia for the refrigeration system at the Wells Dairy South Ice Cream Plant in Le Mars Iowa. The Risk Management Program (RMP) meets and addresses the requirements of Title 40 Code of Federal Regulations Part 68. This Executive Summary briefly describes the following elements: The accidental release prevention and emergency response policies at the stationary source. The stationary source and regulated substances handled. The worst-case release scenario(s) and the alternative release scenario(s), including administrative controls and mitigation measures to limit the distances for each reported scenario. The general accidental release prevention program and chemical-specific prevention steps. The five-year accident history. The emergency response program. Planned changes to improve safety. The accidental release prevention and emergency response policies at the stationary source To address concerns of an accidental release prevention and emergency response all plant and field personnel are trained in ammonia emergency response procedures and use of appropriate protective equipment. Refresher training and emergency response drills are conducted on a periodic basis to ensure personnel are equipped, trained, prepared, and practiced in responding to ammonia emergencies. As a result of information gathered during preparation of this Risk Management Program, Wells Dairy, Inc. (WDI) is committing additional resources to further increase employee awareness and equipment reliability and to establish operator training and preventive maintenance programs. As a demonstration of the WDI's high degree of commitment to public safety and service, WDI is taking action to decrease the risk of ammonia exposure to the public by implementing recommendations made during the Process Hazards Analysis and Off-site Consequence Analysis. The stationary source and regulated subst ances handled. Anhydrous ammonia is used as a refrigerant in the WDI Le Mars facility refrigeration system. The liquid is circulated as needed to the air units and shell and tube chillers where heat is absorbed and removed from the medium. The anhydrous ammonia refrigeration system is a closed loop industrial refrigeration system. The ammonia is not used or mixed in any manner with other chemical processes. The worst-case release scenario(s) and the alternative release scenario(s), including administrative controls and mitigation measures to limit the distances for each reported scenario. A "Worst-Case Scenario Offsite Consequence Analysis" and an "Alternative Scenario Offsite Consequence Analysis" were performed identifying the public and environmental receptors within the toxic endpoint concentration radius of 200 ppm. The results are mitigated by the fact that all the vessels and majority of the piping are inside the Le Mars facility's building. A variety of administrative c ontrols and computerized controls are in place to shut the system down when operating parameters and limits are exceeded. The general accidental release prevention program and chemical-specific prevention steps. The basic elements of the Program 3 Prevention program have been developed and are now in place. These include: Process Safety Information Process Hazard Analysis Standard Operating Procedures Safework Practices Employee and Operator Training Programs Mechanical Integrity Program Management of Change Procedures PSM Compliance Audit Procedures Incident Investigation Procedures Employee Participation Program Hot Work Permit Procedures Contractor Safety Program Emergency Response Program Ammonia specific prevention steps include: Administrative controls Operator Training Computerized controls The Preventative Program 3 provides an extensive maintenance and operator/mechanic training to ensure the system's mechanical integrity is maintained for the life of the covered process . Program 3 also incorporates administrative controls when modifications are made to the covered process (ammonia refrigeration system), so the training and preventative programs are updated as the system expands and changes. The five-year accident history. A five-year accident history has been prepared and included in the RMP since there has been two reportable incidents within the last 5 years. One could be classified |