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Smithfield Fresh Meats Corp. - Tar Heel, NC

Parent Companies:
Smithfield Fresh Meats Corp.
EPA Facility ID:
100000022619
Other ID:
28392CRLNFHWY
Facility DUNS:
3110913
Parent Company DUNS:
0

Location:

Address:
15855 NC HWY 87 W.
Tar Heel, NC 28392
County:
BLADEN
Lat / Long:
34.746, -78.806 (Get map)
Method:
Interpolation - Photo
Description:
Water Monitoring Station
Horizonal accuracy:
51 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
4128

Owner/Operator:

Name:
Smithfield Fresh Meats Corp.
Phone:
(910) 862-7675
Address:
15855 NC HWY 87 W.
Tar Heel, NC 28392
Foreign Address:

Person responsible for RMP implementation:

Name:
Donovan Owens
Title:
Complex Manager

Emergency contact:

Name:
Robert Harris
Title:
Environmental Manager
Phone:
(910) 862-5248
24-hour phone:
(910) 862-7675
Ext or PIN:
248

Other contacts:

Facility (or company) email:
Facility phone:
(910) 862-7675
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Bladen County LEPC
Full-Time Equivalent Employees:
4,600
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
07221T21
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Nov. 29, 2016
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

Animal Slaughtering
RMP ID:
1000081990
CBI claimed:
No
Program Level:
3
NAICS:
Animal (except Poultry) Slaughtering (311611)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
338,603
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Maria Butkovich
Address:
11500 NW Ambassador Dr., Suite 500
Kansas City, MO 64153
Foreign Address:

Phone:
(816) 243-2731

Latest RMP Submission:

Date:
Aug. 22, 2017
Type:
Resubmission
Reason:
Voluntary update (not described by any of the above reasons)
Registered:
Yes
RMP ID:
1000065427

Deregistration:

Date:
Effective Date:
Reason:
Other Reason:

2. Toxics: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Animal Slaughtering)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Rural
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Public OCA Chemical (in Animal Slaughtering)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Rural
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps

3. Toxics: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Animal Slaughtering)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • Released in enclosed space
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Animal Slaughtering)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • Released in enclosed space
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Animal Slaughtering)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Animal Slaughtering)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • Released in enclosed space
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Animal Slaughtering)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Animal Slaughtering)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • Released in enclosed space
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown
Public OCA Chemical (in Animal Slaughtering)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • Released in enclosed space
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

June 17, 2014 at 10:45
ID:
1000050744
NAICS:
Animal (except Poultry) Slaughtering (311611)
Duration:
2 hours and 45 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Weather conditions at time of event
Wind speed:
8.10000038 miles/h NE
Temperature:
88.00 ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
10
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$1700000
Known off-site impacts
Deaths:
0
Hospitalizations:
2
Medicals treatments:
8
Evacuated:
2500
Sheltered-in-place:
0
Property damage:
$1700000
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Equipment failure
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • New process controls
Jan. 29, 2013 at 14:40
ID:
1000050741
NAICS:
Animal (except Poultry) Slaughtering (311611)
Duration:
1 hours and 13 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Weather conditions at time of event
Wind speed:
None
Temperature:
None ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
Yes
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
0
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Equipment failure
  • corrosion
Off-site responders notified:
Notified Only
Changes introduced as a result of the accident:
  • Installed a new valve - even though factory tests found valve to be within tolerance

7. Prevention: Program level 3

Animal Slaughtering, Animal (except Poultry) Slaughtering (311611)
Prevention Program ID:
1000069040
Safety Review Date
March 7, 2017
PHA Update Date
April 9, 2014
PHA Techniques
  • What if
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Earthquake
  • Floods
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Fire Walls
  • Neutralization
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
March 7, 2017
Training Review Date
March 7, 2017
Maintenance Review Date
March 6, 2017
Maintenance Inspection Date
March 7, 2017
Equipment Tested
Yes
Management of Change Most Recent Date
Feb. 28, 2017
Management of Change Review Date
Feb. 28, 2017
Pre-startup Review Date
March 3, 2017
Compliance Audit Date
Feb. 24, 2016
Compliance Audit Change Completion Date
Oct. 30, 2017
Incident Investigation Date
March 4, 2017
Incident Invest. Change Completion Date
Oct. 30, 2017
Participation Plan Review Date
May 26, 2016
Hot Work Review Date
Dec. 19, 2016
Contractor Safety Review Date
Oct. 18, 2016
Contractor Safety Eval. Date
March 7, 2017

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
Yes
Facility Own Response Plan:
No
Specific Facility Response Plan:
Yes
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
Yes
Plan Review Date:
Response Training Date:
March 7, 2017
Local Response Agency:
Local Response Agency Phone:
(910) 862-6760
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

This is to inform all interested persons, including employees that Smithfield is complying with the Occupational Safety and Health Administrations (OSHA) Process Safety Management (PSM) Regulation, Title 29 Code of Federal Regulations, (CFR) 1910.119, and the Environmental Protection Agency (EPA) Risk Management Program (RMP) Regulations, Title 40 Code of Federal Regulations (CFR) Part 68. These Regulations deal with the risk involved with the storage, handling and processing of hazardous chemicals. In complying, we promote overall facility, employee and public safety. Our program enables 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 are in place to prevent the potential for accidental injury, illness or death and to avoid the potential for property and environmental impact.



Smithfield's safety programs are applied to all activities involving hazardous chemicals including use, storage handling or the on-site movement of chemicals. Any groups of vessels inter connected and separate vessels which are located such that a hazardous chemical could be involved in a potential release shall be considered a single process. Smithfield Packing Company has a commitment to employee safety and it is expressed in all the programs and training.



Smithfield's safety programs prevent accidents because they focus on the rules, procedures, and best practices which govern processes, activities, and/or pieces of equipment. These rules are detailed and revised as necessary; all information is communicated to employees of Smithfield Packing Company through training and documentation. The safety equipment used for HAZ-MAT purposes is inspected monthly and records are maintained by the Maintenance Department.

Smithfield is a pork-harvesting, processing and packaging company which utilizes approximately 338,603 pound
s of Anhydrous Ammonia in its refrigeration system to cool the facility's production and shipping areas.





The Worst Case Scenario (1) is highly unlikely for the following reasons:

The 150,000 gallon storage vessel is not normally in use - but CAN be - so it has been listed. The worst case therefore would be that for some reason we would need to transfer the majority of our ammonia out of the system to perform some major maintenance activity and during that time a hurricane or some other serious disaster were to strike.







The Worst Case Scenario (2) is highly unlikely for the following reasons:

The vessel is in a protected area clear of vehicular traffic and pedestrian traffic

Industrial Safety standards for the construction and quality control of pressure vessels

Safety relief valves preventing over-pressurization of the vessel are in use

Accident prevention programs in place

Mechanical Integrity programs, inspections and testing procedures are in place

Emergency alerting alarms integrated into the process system

Emergency response and action plans in place at the facility





The alternative release scenarios even though potentially possible, are unlikely for the following reasons:

Emergency shut-down procedures

Regular maintenance seal and valve upgrade

Inspections and rounds made daily of the process system to ensure safe operation

Emergency response plan and refrigeration personnel on-site around the clock





Smithfield's accidental release prevention programs are based on safe work practices as referenced by the OSHA, EPA and American National Safety Standards (ANSI), and the International Institute of Ammonia Refrigeration (IIAR) 2-1992 Key element of this prevention program are comprise of:

Equipment Design

Installation and Operation of Ammonia Process Systems (ANSI/IIAR 2)

Emergency Response and Action Plan Program - (ICP) (OSHA 29 CFR 1910.120, 1910.38 and EPA 40 CFR Parts 68)

Mechanical Integrity

Eme
rgency shut down procedures

Inspection program (OSHA 29 CFR 1910.119)



Smithfield has experienced two accidental releases or near misses over the past 5 (five) years.



The facility emergency response program is based on OSHA's Regulation for Emergency Action Plans (1910.38 and 1910.119) and HAZWOPER (29 CFR 1910.120). Smithfield Packing Company has an on-site trained emergency response team (HAZMAT) and maintains a written emergency response plan which is reviewed annually. This plan is coordinated with the Local Emergency Planning Committee (LEPC), the Fire Department, Police and Emergency Medical facilities to ensure communication with all potential or actual involved resources should their involvement be necessitated by a release.



Through Process Hazard Analysis, inspections, annual reviews and audits, Smithfield Packing Company - Tar Heel Division continuously improves its process system, procedures, programs and training to ensure mitigation, control, technology, equipment and organizational changes remain consistent and in force. Through this initiative, Smithfield Packing Company can ensure the utmost safeguards are utilized as it related to its process systems and programs for the overall safety and well being of the employees, facility and the environment.