McCain Foods USA, Inc. Fort Atkinson - Executive Summary |
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McCAIN FOODS USA, INC. RISK MANAGEMENT PROGRAM EXECUTIVE SUMMARY 1. General accidental release and prevention policy of McCain Foods USA, Inc. In this food product manufacturing facility we use/store anhydrous ammonia which is considered hazardous by the EPA. The same properties that make ammonia a valuable refrigerant also makes it necessary to observe certain safety precautions during ammonia use to prevent human exposure, reduce the threat to our workers' personal health, the surrounding community and the environment. It is our policy to adhere to all applicable federal and state regulations. Safety depends directly on our proper handling of ammonia combined with the safety devices that are incorporated in our facility and the safe handling procedures that our personnel are trained in. 2. Stationary source and regulated substance handled. McCain Foods USA, 801 Rockwell Avenue, Fort Atkinson, Wisconsin is responsible for the manufacturing of frozen vegetables, assorted cheese products and appetizers. There are approximately 300 employees at this facility which includes hourly and salaried personnel. The plant manufactures product around the clock, (5) five days a week. McCain Foods is located in an industrial park on the south west side of Fort Atkinson, Wisconsin. In addition to our manufacturing facility the industrial park also houses other manufacturing or business facilities. The potentially hazardous chemical used at the McCain Foods facility is ANHYDROUS AMMONIA. Anhydrous ammonia is classified as a Group 2 Refrigerant per ASHRAE Standard 34-1989. The dominant characteristic of ammonia vapor is the pungent, distinct odor. Persons exposed to ammonia will not voluntarily stay in areas of even small concentrations, although these levels would not result in any health risks. Risks from accidental exposu re to ammonia in a vapor state are irritations to the eyes, nose and throat. The extent of irritation depends on the exposure amount and length of time exposed. Ammonia is classified non-flammable by the Department of Transportation. Ammonia will burn, but only in a very narrow, high concentration level when accompanied with a constant ignition source. The normal operating level of ammonia that is used/stored at the McCain Foods facility is 17,000 pounds. The anhydrous ammonia is used as the refrigerant chemical in the manufacturing/storage process. The possible hazards that could lead to an accidental release include, but are not limited to, equipment failure, damage to piping, damage to equipment, human error, etc. 3. Worst case release scenario and alternate release scenarios including administrative and engineering controls to prevent, or limit the amount of release. Worst case release scenario criteria for McCain Foods USA facility: Worst c ase scenario depicts continuous source leak from the High Pressure Receiver (HPR) located inside the McCain Foods machine room. This vessels' normal operating level is 5,380 pounds of liquid ammonia, approximately 50% of it's total capacity. Although the receivers maximum capacity is 10,760 pounds, this exceeds company policy of only allowing an 80% level at any time. Ammonia Quantity: 5,300 pounds Rate of Release: 530lbs / min. (10 min. release) LOC (Level of Concern): 200 ppm (EPA ERPG-2) Physical State: Gas and/or Liquid Type of Area: Rural Wind Speed: 1.5 m/sec Distance to Endpoint 2.5 miles Alternate case release scenario criteria for McCain Foods USA facility: Alternate release scenario is represented by the release of ammonia vapor from a safety relief valve (SRV) due to an over-pr essurization condition on a vertical vessel located within the McCain Foods facility machine room. SRV would be performing exactly as it is designed to do. . Ammonia Quantity: 195 pounds Max. Rate of Release: 36 pounds/min. (10 min. release) Distance to Endpoint: 270 yards The following administrative and engineering controls are in place at the McCain Foods facility to limit the distance for the reported scenarios. * Electronic ammonia detection in machine room and on roof by safety relief discharge vent. Audible and flashing alarms are located in both the maintenance and production areas. * High level liquid switches are configured to all pressure vessels which will shut down compressor operation during an abnormal level condition. * Safety relief valves are installed on all pressure vessels, condensers and compressor oil separators to eliminate ov er pressurization conditions in those associated pieces of equipment. * Periodic Maintenance Program is in place within the maintenance department to ensure all refrigeration components are kept in optimum operating status. 4. Five-year accident history. McCain Foods has had zero accidental releases to report over the last 5 years. 5. Emergency Response Program The purpose of the McCain Foods Emergency Response Program is to: 1. Minimize exposure to our employees and the surrounding community in the event of a hazardous material release or spill. 2. Assure the safe emergency evacuation of the plant in the instance that it is required. 3. Provide for prompt medical attention to any employees who become seriously injured or ill at work. 4. Manage an emergency response system and coordinate response of the internal and external resources required to provide efficient and effective response to any type of emergency that may occur at McCain Foods. McCain Foods USA has utilized inputs from the International Institute of Ammonia Refrigeration in compiling the Emergency Response Program. This EAP currently meets requirements as set forth in OSHA 29 CFR 1910.38, Emergency Evacuation and Alarms. McCain Foods has received inputs and worked with the Fort Atkinson Fire Department, Jefferson County Local Emergency Planning Committees (LEPC) and State of Wisconsin HAZMAT organizations to ensure compliance in the emergency response areas. |