McCain Foods USA, Inc., Burley - 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 handle anhydrous ammonia and chlorine in a liquid and vapor state which is considered hazardous by the EPA. Due to the hazardous properties of ammonia and chlorine it is necessary to observe certain safety precautions during their 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 that were are governed by. Safety depends directly on our proper handling of these chemicals coupled with the safety devices, control measures and safe handling procedures that our personnel are trained in. 2. Stationary source and regulated substance handled. McCain Foods USA, Inc., 218 West Highway 30, approximately two miles west of Burley, Idaho, is responsible for the manufacturing of frozen potato products. The plant manufactures product around the clock, (7) seven days a week. There are 900 full time employees at this facility which includes hourly and salary personnel. The potentially hazardous chemicals used at the McCain Foods facility are anhydrous ammonia and chlorine. 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 length 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 sourc e. Chlorine gas is primarily a respiratory irritant. It is so irritating that low concentrations in the air are readily detectable. In high concentrations the irritating effect of the gas will force an individual from a contaminated space unless trapped or unconscious. Liquid chlorine will cause skin and eye burns upon contact. When liquid is exposed to atmospheric pressure and temperature the liquid will vaporize to chlorine gas. The normal operating level of ammonia that is used/stored at the McCain Foods facility is 90,000 pounds. The anhydrous ammonia is used as the refrigerant chemical during the manufacturing and cold storage process. The normal operating level of chlorine that is used/stored at the McCain Foods USA facility is 14,500 pounds. The chlorine is used in the faciltity for water treatment and sanitation. The possible hazards that could lead to an accidental release of either chemical include, but are not limited to, equipment failure, damage to piping, damage to eq uipment and human error. 3. Worst case release scenarios and alternate release scenarios including administrative and engineering controls to limit/prevent the release of ammonia and chlorine. Ammonia worst case release scenario criteria for McCain Foods USA facility: Worst case scenario depicts continuous source leak from the High Pressure Receiver (HPR) located outside the McCain Foods #1 machine room. This vessels normal operating level is 8,500 pounds of liquid ammonia, approximately 50% of it's total capacity. Although it's maximum capacity is 17,000 pounds, this exceeds company policy and written operating procedures that only allows an 80% level at any time. Ammonia Quantity: 8,500 pounds Rate of Release: 850 lbs / min. (10 min. release) LOC (Level of Concern): 200 ppm (EPA ERPG-2) Physical State: Gas Type of Area: Rural Wind Speed: 1.5 m/sec Distance to Endpoint 3.1 miles Ammonia 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 horizontal vessel located within the McCain Foods facility machine room. The SRV would be performing exactly as it is designed to do. Actual venting would take place on the facility roof where the relief vent piping exits to the atmosphere. . Ammonia Quantity: 165 pounds Rate of Release: 23 pounds/min. (14 min. release) Distance to Endpoint: 212 yards (.15 miles) The following administrative and engineering controls are in place at the McCain Foods USA facility to eliminate or control the release of ammonia. * Electronic ammonia detection in machine room. Alarms tie into a local audible alarm. * High and low level switches are configured to pressure vessels to alert refrigeration personnel of potential abnormal operating levels within the associated vessel or the refrigeration system. * Safety relief valves are installed on all condensers, compressor oil separators and pressure vessels to eliminate the possibility of over-pressurization conditions within the particular piece of equipment. * Operators make scheduled rounds, every 2 hours, 24 hours a day and make appropriate log entries to monitor equipment status. * Periodic Maintenance Program is in place within the maintenance department to ensure all refrigeration components are kept in optimum operational and mechanical condition. Chlorine worst case release scenario criteria for McCain Foods USA facility: Worst case scenario depicts continuous source leak from a 1 (one) ton chlorine cylinder located outside McCain Foods USA water treatment room. This vessels normal operating level is 1,600 pounds of liquid chlorine, approximately 80% of it's total capacity. Chlorine Quantity: 1,600 pounds Rate of Release: 160 lbs / min. (10 min. release) LOC (Level of Concern): 10 ppm Physical State: Gas Type of Area: Rural Wind Speed: 1.5 m/sec Distance to Endpoint 1.6 miles Chlorine alternate case release scenario criteria for McCain Foods USA facility: Alternate release scenario is represented by an accidental release of chlorine vapor from a control valve on a 150 pound vertical vessel located outside on a McCain Foods facility local sanitation system. Chlorine Quantity: 150 pounds Rate of Release: 700 pounds/min. (1 min. release) Wind Speed 3.0 m/sec D istance to Endpoint: 1314 yards (.75 miles) The following administrative and engineering controls are in place at the McCain Foods USA facility to eliminate, or control the release of chlorine. * Periodic Maintenance Program is in place within the maintenance department to ensure all chlorine system components are kept in optimum operational and mechanical condition. * Operators make scheduled rounds, every 2 hours, 24 hours a day to monitor equipment status. 4. Five-year accident history. McCain Foods has conducted internal incident investigations for three separate ammonia incidents over the last five years, none of which required medical attention, outside assistance or plant evacuation. There have been no accidents or investigations involving the chlorine system. 5. Emergency Response Program The purpose of the McCain Foods Emergency Response Program is to: 1. Minimize exposure to our employees and the su rrounding 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 has utilized inputs from 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 Mini-Cassia Local Emergency Planning Committee (LEPC) to ensure compliance in the emergency response areas. |