Agrilink Foods - Waseca Plant - Executive Summary |
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This is to inform all interested persons, including employees that Agrilink Foods is complying with OSHA's Process Safety Management Standard (called Process Safety Management or PSM), Title 29 Code of Federal Regulations (CFR) 1910.119, and EPA's Risk Management Program regulations (called RM Program), Title 40 CFR Part 68, to deal with the risks involved with the storage, handling, and processing of hazardous chemicals. In this way we promote overall plant, worker, and public safety. These programs enable our facility to prevent the occurrence, and minimize the consequences, of significant releases of toxic substances as well as fires, explosions, and other types of catastrophic accidents. Overall, these programs prevent accidental fatalities, injuries and illnesses, and avoid physical property damage. Our safety programs are applied to any activity involving hazardous chemicals including any use, storage, manufacturing, handling, or the on-site movement of such chemicals, or com bination of these activities. Any group of vessels which are interconnected and separate vessels which are located such that a hazardous chemical could be involved in a potential release shall be considered a single process. Our safety programs prevent accidents because they focus on the rules, procedures, and practices that govern individual processes, activities, or pieces of equipment. These rules are detailed and improved as necessary. They are also communicated to and accepted by all employees at the facility. DESCRIPTION The ammonia refrigeration process at the facility consists of various pumps, compressors, and condensers that are used to change the state of NH3 from a gas to a liquid and is an open system. This means that the motor and compressor are separate entities, and can be worked on should repairs be needed. The total ammonia inventory on site includes 40,000 pounds. The ammonia is used in freezing of corn, cob corn, peas, and pasta. WORST-CASE SCENARIO Fail ure of the high-pressure receiver containing 40,000 pounds of ammonia would result in a ten-minute release. Under worst-case weather conditions, ammonia could travel 2.3 miles before dispersing enough to no longer pose a hazard to the public or the environment. This scenario is unlikely for the following resons: worst-case weather conditions are uncommon; the vessel is enclosed in a building that would help to contain such a release; industry standards for the manufacture and quality control of pressure vessles; ammonia is not corrosive in this service; pressure safety valves limit operating pressure in this vessel; the accident prevention program in place at the facility including the mechanical integrity program for regular maintenance; inspection and testing, and replacement of equipment, if necessary; installed ammonia sensors in the system to warn of leaks; alarms and a monitoring board in place to warn operating personnel of process upsets; and the emergency response plan and equipment (including a King valve/main shut-off) in place at the facility. ALTERNATIVE RELEASE SCENARIO(S) Failure of a 1/4 inch diameter pipe would result in the release of approximately 6,000 pounds of ammonia over a time period of 60 minutes. Under common weather conditions, ammonia could travel 0.1 mile before dispersing enough to no longer pose a hazard to the public or environment. The 1/4 inch pipe was chosen because it is used to temporarily bleed off a pump so that maintenance activities can be conducted. This scenario is unlikely to occur due to the following reasons: the pump is isolated with valves in the closed position so that only a few pounds of ammonia would be released; the valves in the pump would have to fail completely; the facility has an accident prevention program in place during operational procedures that includes having personnel present at all times during maintenance of the pumps; mechanical integrity program for regular maintenance of the pump at the facility; routine inspections and testing of valves; replacement of defective equipment; and the facility emergency response plan and equipment in place at the facility. PREVENTION PROGRAM The general accident prevention program and ammonia-specific prevention steps were developed as required and complyt with OSHA PSM Standard 29 CFR 1910.119 and EPA RM Program regulations in 40 CFR Part 68. The key prevention steps at the facility consist of the following: Employee Participation Process Safety INformation Process Hazard Analysis Operating Procedures Training Contractor Requirements Pre-startup Safety Review Mechanical Integrity Audits Hot Work Permits Management of Change Incident Investigation Emergency Planning and Response Compliance Audits FIVE YEAR ACCIDENT HISTORY There have been no reportable accidents in the last 5 years. EMERGENCY RESPONSE PROGRAM The Waseca facility's emergency response program is based on the OSHA requirements for Emergency Action Palns (29 CFR 1910 .38). We have trained employees for emergency response and maintain a written emergency response plan. This plan is coordinated with the Waseca Fire Department. We conduct annual drills for implementation of the emergency response plan at the facility. |