RCS-Smithfield - Executive Summary
RCS-SMITHFIELD ( RCSS ) |
Risk Management Program
Accidental Release Prevention and Emergency Response Policy
RCSS has established a Process Safety Management Program (PSM ) to identify, evaluate, and prevent chemical releases that could occur due to a failure in process, procedures, or equipment.
The PSM is designed to provide reasonable assurance that operational hazards are identified, that significant operational safety incidents are avoided, that operational safety requirements are considered in evaluating decisions and that risks to persons, property, products, and the environment are minimized or avoided.
The PSM program includes all phases of plant operations including conceptualization, design, construction, operation, maintenance, and decommissioning. The program in place covers all aspects of OSHA's CFR 1910.
RCSS has a program for employees covering lock-out tag-out and Personnel Protective Clothing (PPE), PPE testing emergency response training, and co
nfined space training. Yearly inspections are performed on all aspects of the process along with outside inspectors in the evaluation of the process.
Facility Description and Regulated Substance
RCSS is a refrigerated warehouse that uses anhydrous ammonia for the refrigerant. It is located on Highway 10 North, 10070 Old Stage Highway, Smithfield, VA 23430. The warehouse, which was completed in 1988, is a 124,000 square feet facility designed to freeze and store frozen commodities.
The ammonia refrigeration system is a two stage recirculated system. It utilizes a roof top evaporative condenser.
Worst Case and Alternative Release Scenarios
The worst case scenario is the high-pressure receiver, which can hold up to 3393 pounds of anhydrous ammonia. If this vessel was damaged and all 3393 pounds released over a 10 minute period (the required assumption by the Risk Management Program parameters), 200 ppm could reach 0.80 miles from the release point as calculated by the OCA Guidance A
nalysis. The liquid is contained in the Machine Room. There is no passive mitigation system to mitigate the release of gas.
An Alternate Release Scenario, which is more likely, would be a pipe leak that could leak approximately 150 pounds of anhydrous ammonia within a 10 minute period. A toxic endpoint level of 200 ppm is 0.2 miles from the release point as calculated by the OCA Guideance Analysis.
The facility was designed so that material handling equipment would not accidentally damage ammonia piping. The facility is controlled by a computer system that can assist in reducing the quantity of ammonia released. The computer system can be controlled from off-site.
Accidental Release Prevention Program
The engineers have been trained to follow the PSM program guidelines established for this facility. Employees participate in regular safety meetings, safety inspections, and annual training classes on ammonia safety.
A preventative maintenance program and facility check lists provide
routine inspection of the refrigeration system. An annual inspection following the International Association of Refrigerated Warehouses (IIAR) guidelines is performed on the equipment. The facility design incorporated good safety practices for ammonia refrigeration.
5 Year Accident History
This facility was completed and started operation in September 1988. There have been no accidental releases at this facility.
Emergency Response Program
The Emergency Response Program includes coordination with the local LEPC and the Smithfield Fire Department.
The facility engineers have received the 24 hour Emergency Responder Training and receive an annual 8 hour Responder Refresher Course.
Planned Changes to Improve Safety
RCSS plans to improve it's safety program in 1999 in several ways. The engineers will attend a demonstration put on by the local LEPC and HAZMAT teams. A program has been put into place to evaluate the Process Safety Management Program annually. A training program has
been put in place to inform and provide additional information to employees about company safety programs. Our insurance company provides regular inspections of our equipment. This includes infrared scans of all electrical switch gear and fire protection systems.
The facility has been designed and constructed in accordance with current good safety practices and procedures. There are no facility modifications pending.