McCain Foods USA, Rice Lake - Executive Summary
McCAIN FOODS USA, INC. |
RISK MANAGEMENT PROGRAM
1. General accidental release and prevention policy of McCain Foods USA, Inc.
In this food product manufacturing facility we handle anhydrous ammonia in a liquid and vapor
state 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 it's 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 US
A, 100 West Coleman Street, Rice Lake, Wisconsin is responsible for the
manufacturing of frozen onion rings. There are approximately 175 employees at this facility
which includes hourly and salary personnel. The plant manufactures product around the clock,
(7) seven days a week. McCain Foods is located in an industrial park on the south west side of
Rice Lake, 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. The dominant characteristic of ammonia vapor is it's 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 exposure to ammonia in a vapor state are irritations to the eyes, nose and
throat. The extent of irritation depends on the exposure amount and le
ngth of exposure.
Ammonia is classified non-flammable by the Department of Transportation. It will burn, but only
in a very narrow, high concentration level with a constant ignition source.
The normal operating level of ammonia that is used/stored at the McCain Foods USA facility is
27,810 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
3. Worst case release scenario and alternate release scenarios including administrative and
engineering controls to limit/prevent the release.
Worst case release scenario criteria for McCain Foods USA facility:
Worst case scenario depicts continuous source leak from the High Pressure Receiver (HPR)
located inside the McCain Foods machine room. This vessels normal operating level is 5,4
pounds of liquid ammonia, approximately 50% of it's total capacity. Although it's maximum
capacity is 10,960 pounds, this exceeds engineering controls and company policy of only allowing
an 80% level at any time.
Ammonia Quantity: 5,480 pounds
Rate of Release: 548 lbs / min. (10 min. release)
LOC (Level of Concern): 200 ppm (EPA ERPG-2)
Physical State: Gas and/or Liquid
Type of Area: Urban
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 pressurization 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. (11 min. release)
Distance to Endpoint: 195 yards
The following administrative and engineering controls are in place at the McCain
Foods USA facility to limit the distance for the reported scenarios.
* Electronic ammonia detection in machine room. Alarms tie into maintenance office
system control PC and also to a local audible alarm.
* Control system is alarmed through ADT Security during off-shift hours and holidays.
ADT alerts 24 hour emergency personnel.
* Operators make scheduled rounds and log entries each shift to monitor equipment
* Periodic Maintenance Program is in place within the maintenance department to ensure
all refrigeration components are kept in optimum operating status.
* Emergency shut down procedures are posted on each machine room doo
r and periodic
training is held to activate the emergency shut down during an actual emergency.
4. Five-year accident history.
McCain Foods USA has reported accidental releases on the following dates:
1/23/96 Pre-Cooler safety relief valve located on the roof opened and released 1,552
pounds of ammonia into the atmosphere. There were no damages on, or off site.
6/15/96 During a defrost cycle a freezer safety relief valve opened due to improper
positioning of shutoff valve and released 178 pounds of ammonia. With no wind
present the resultant ammonia cloud suspended over the building. Ore-Ida Foods
employees as well as Wright Products (adjacent facility) employees were
evacuated. No serious injuries were reported although approximately 22 Ore-Ida
employees were seen at the hospital with minor eye and throat irritations.
5/12/98 Safety relief valve on machine room Intercooler opened at
prescribed 150 psi
rating. Vented through relief piping to the roof and into the atmosphere. McCain
Foods employees were evacuated because of 25 ppm rating inside facility. No
injuries or damages were reported on or off site.
5. Emergency Response Program
The purpose of the McCain Foods USA 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 f
rom the International Institute of Ammonia Refrigeration
in compiling the Emergency Response Program. This ERP currently meets requirements as set
forth in OSHA 29 CFR 1910.38 Employee Emergency Action Plans. Additionally, McCain Foods
has received inputs from and coordinated with the Barron County Local Emergency Planning
Committees (LEPC) and state organizations to ensure compliance in the emergency response