John Morrell & Co. (Sioux City) - Executive Summary

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This submittal informs all interested parties that John Morrell & Company is participating in the OSHA Process Safety Management (PSM) program defined in 29 CFR 1910.119, and the EPA Risk Management Program (RMP) defined in 40 CFR Part 68.  These programs provide for the implementation of detailed prevention and response procedures when storing and handling hazardous chemicals.  The program objectives are to ensure worker and public safety and provide environmental protection. 
 
Our Accidental Release Prevention and Emergency Response Policies 
 
It is the policy of the company to conduct all of its operations in a manner, which is consistent with protecting human health and the environment.  It is our policy to comply with all laws and regulations applicable to our operations, including, but not limited to all permitting, recordekeeping, and reporting requirements.  It is our policy that employees and contractors are properly trained and that they have access to information.  It is our p 
olicy to audit compliance with applicable laws and regulations and to promptly remedy any noncompliance. 
 
Because there is absolutely no envisioned gain worth injury or loss of life, the company is committed to safety.  This commitment is demonstrated through our routine safety training sessions for  employees.  In addition, employees working directly with applicable hazardous chemicals receive annual 8-hour hazardous materials refresher training. 
 
Each year, the written emergency action plan is reviewed and/or updated for the facility.  Each year, the company reports the location and quantity of hazardous chemicals stored at their facility to the local fire department, the local emergency planning committee and the state emergency planning committee.  Each year, the company reports the amount of hazardous chemicals used and/or released to the environment to state and/or federal regulatory agencies. 
 
Our Facility and Regulated Substances Handled 
 
This facility is a meatpacking plant lo 
cated in Sioux City, Iowa.  The facility kills, cuts and packages fresh pork.  The facility utilizes various conveyors and manual and automated processing and packaging equipment.  Various sanitation chemicals are stored and used for cleaning the facility in strict accordance with USDA food safety regulations. 
 
Anhydrous ammonis is the only substance at the facility that is regulated under the PSM and RMP programs.  This is the same type of ammonia commonly sprayed on fields by farmers to fertilize crops. 
 
Anhydrous ammonia is used as a refrigerant throughout the plant to maintain desired meat temperatures in coolers, freezers and working areas.  Expelling heat caused from altering the ammonia between a liquid and a gas state creates refrigeration in the facility.  The refrigeration system consists of a series of compressors, condensers, evaporators, vessels, piping and valves.  About 64,000 pounds of ammonia is in the refrigeration system throughout the plant. 
 
Our Worst-Case and Alte 
rnate Release Scenarios 
 
The distance to the toxic endpoint (0.14 mg/L) of the worst-case release of ammonia extends 1.2 miles offsite.  This scenario assumes that the largest vessel of 11,000 pounds of liquid ammonia is released over 10 minutes with a wind speed of 1.5 m/s and an atmospheric stability class of F.  The EPA Model RMP for Ammonia Refrigeration Guidance, 6/98 was followed and no administrative or passive mitigation factors were assumed. 
 
The distance to the toxic endpoint (0.14 mg/L) of the alternate-case release of ammonia extends 0.10 miles offsite.  This scenario assumes a pump seal leaks under pressure releasing 1,000 pounds of ammonia  over 10 minutes.  This alternative release was chosen because of its higher probability of occurrence compared to the less likely worst-case scenario. 
 
Our General Accidental Release Prevention Program and Chemical-Specific Prevention Steps 
 
The following lists rules, regulations and standards that the company believes are important to 
their prevention program: 
 
  OSHA Process Safety Management Program 29 CFR 1910.119 
  EPA Risk Management Program 40 CFR 68 
  OSHA Emergency Action Plan Program 29 CFR 1910.38 
  ANSI/IIAR2 standards for equipment design, installation and operation 
 
The company also implements a maintenance management system that tracks and schedules work orders for preventive, predictive and corrective maintenance as well as tracks parts inventory.  This system helps provide quality control in making sure the right parts and materials are ordered and that the equipment is serviced in a timely manner. 
 
Our Five Year Accident History 
 
The facility has experienced one accidental release over the past five years.  The accidental release occurred in 1996 and consisted of approximately 2 pounds of ammonia being released from an evaporator coil damaged by a faulty fan blade hub.  The facility was evacuated and the leak was quickly contained.  There were two minor injuries, and 10 people off site were eva 
cuated. 
 
Our Emergency Response Program 
 
The facility implements an emergency action plan that addresses various emergency response scenarios.  These scenarios include response procedures for various types of chemical releases, fires and other system failures and natural disasters.  This plan is reviewed annually and made available to the local fire department and the local emergency planning committee. 
 
Our Planned Changes to Improve Safety 
 
No substantial projects are currently planned.  Our procedures are established to promote continuous improvement in our operations through inspection, training and auditiing.
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