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Kraft Heinz Company_Madison WI

Parent Companies:
Kraft Heinz Company
EPA Facility ID:
100000033858
Other ID:
WID006105266
Facility DUNS:
6105266
Parent Company DUNS:
877147228

Location:

Address:
910 Mayer Avenue
Madison, WI 53704
County:
DANE
Lat / Long:
43.111, -89.356 (Get map)
Method:
Interpolation - Satellite
Description:
Plant Entrance (General)
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Jeff Manor
Phone:
(608) 285-3033
Address:
910 Mayer Ave.
Madison, WI 53704
Foreign Address:

Person responsible for RMP implementation:

Name:
Jenny Touchet
Title:
SSE Manager

Emergency contact:

Name:
Jenny Touchet
Title:
SSE Manager
Phone:
(608) 285-3122
24-hour phone:
(608) 609-6421
Ext or PIN:
4-3122

Other contacts:

Facility (or company) email:
Facility phone:
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Dane County LEPC
Full-Time Equivalent Employees:
1,300
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
113004650-P20
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Sept. 26, 2011
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

Refrigeration
RMP ID:
1000054152
CBI claimed:
No
Program Level:
3
NAICS:
Meat Processed from Carcasses (311612)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
250,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Song Yeung
Address:
910 Mayer Ave.
Madison, WI 53704
Foreign Address:

Phone:
(608) 285-3747

Latest RMP Submission:

Date:
June 11, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000043835

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 Refrigeration)
CBI claimed:
No
Percent weight:
Physical state:
Gas
Model used:
SLAB (June 1990 version)
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
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 Refrigeration)
CBI claimed:
No
Percent weight:
Physical state:
Gas
Model used:
EPA's RMP Guidance for Ammonia Refrigeration Reference Tables or Equations
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • Sprinkler systems
  • Emergency shutdown
not considered:
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

Dec. 23, 2001 at 09:35
ID:
1000034224
NAICS:
Meat Processed from Carcasses (311612)
Duration:
1 hours and 35 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
None meters/second
Temperature:
22.00 ℉
Atmospheric stability:
Precipitation present:
Yes
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
1
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
1
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:
Human Error
Contributing factors:
  • Human error
  • Improper procedure
  • Maintenance activity/inactivity
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Revised maintenance
  • Revised training
  • Revised operating procedures
  • Revised emergency response plan

7. Prevention: Program level 3

Refrigeration, Meat Processed from Carcasses (311612)
Prevention Program ID:
1000045421
Safety Review Date
May 5, 2014
PHA Update Date
May 5, 2014
PHA Techniques
  • What if
Hazards Identified
  • None
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Emergency Power
  • Backup Pump
Mitigation Systems
  • Sprinkler System
  • Blast Walls
Monitoring Systems
  • Process Area
Changes since PHA
  • Increased Inventory
  • Process Controls
  • Process Detection
Training Type
  • Classrom
  • On the Job
Competency Testing
  • None
Procedure Review Date
May 1, 2014
Training Review Date
May 4, 2014
Maintenance Review Date
Dec. 1, 2013
Maintenance Inspection Date
Feb. 20, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
April 27, 2014
Management of Change Review Date
Nov. 17, 2013
Pre-startup Review Date
Dec. 1, 2013
Compliance Audit Date
Dec. 10, 2013
Compliance Audit Change Completion Date
Dec. 31, 2014
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
May 7, 2014
Hot Work Review Date
April 17, 2014
Contractor Safety Review Date
May 5, 2014
Contractor Safety Eval. Date
May 5, 2014

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 14, 2014
Local Response Agency:
Local Response Agency Phone:
(608) 266-4420
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
Yes
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

EXECUTIVE SUMMARY:

1.0 Release Prevention and Emergency Response Policies

The Kraft Foods facility in Madison, Wisconsin, has an excellent record in preventing and minimizing releases of anhydrous ammonia (hereafter, anhydrous ammonia will be referred to as ammonia). This facility has implemented an electronic preventive maintenance system. This system uses a real time database to track preventive maintenance, training and inspection dates and issue reminders to responsible groups.

The emergency response procedures at this facility ensure emergency response coverage 24 hours a day, seven days a week. There are also adequate provisions for coordination with outside agencies, such as with the City of Madison Fire Department and Dane County Local Emergency Planning Committee (LEPC), in the event of an emergency.


2.0 Process Description and Regulated Substances
At this location Kraft Foods processes meats. The North American Industrial Classification System (NAICS) code for the primary process at this facility is 311612. This facility is capable of producing and packaging various meat products including hot dogs, bologna, cold cuts, etc. for consumer intake but the plant is not equipped to slaughter animals. The storage and process areas of the plant are refrigerated by ammonia to keep the products fresh and wholesome. Ammonia has been widely used as a refrigerant in the food industry for decades.

The ammonia threshold for triggering applicability to 40 CFR 68 is 10,000 pounds. The quantity of ammonia stored on-site is approximately 250,000 pounds.

Ammonia is classified as a Group 2 Refrigerant per ASHRAE Standard 34-1989. Its distinctive, pungent odor is very noticeable to most people, even in small quantities. Ammonia is flammable in a very narrow and high range of concentration with a high ignition temperature. It is not poisonous, but it can be corrosive to human tissue. Ammonia is readily absorbed into the moisture of the skin and, at high concentrat
ions, can cause burns. The potential risks to people exposed to an accidental ammonia release include irritation of respiratory tract, burning of skin and other tissue when contacted by ammonia vapor, and freezing of skin and other body tissue when contacted by liquid ammonia.

3.0 Worst Case and Alternative Release Scenarios
Although there are quality and safety systems in place at Kraft's Madison plant, a release from the ammonia refrigeration system could potentially affect employees on-site and the general public offsite. USEPA requires companies to use models for "worst-case" and "alternate" release scenarios for each regulated chemical. Given the safety precautions at the plant, both scenarios are unlikely to occur. If a release occurred, however, the alternative scenario would be more likely.

The ammonia release scenario was modeled using SLAB (June 1990 version) to obtain the distance to the ERPG-2 endpoint. The Emergency Response Planning Guideline, Level 2, ERPG-2, was developed by the American Industrial Hygiene Association. It refers to the level of ammonia that individuals could be exposed to for up to one hour without being subjected to irreversible or other serious health effects that could make it difficult for them to leave the affected area.

4.0 General Accidental Release Prevention Program and Chemical-Specific Prevention Steps
This facility has developed an OSHA PSM program for their ammonia refrigeration system. Ammonia falls under the RMP Program 3 prevention program which is identical to the OSHA PSM program. EPA has said that if the process is in compliance with OSHA PSM, then it is in compliance with RMP Program 3. Thus, Kraft's ammonia PSM has been reviewed and determined to be complete for the RMP document.

There are several aspects of the prevention program that are key:

1. Personnel assigned to the ammonia system are on site 24 hours a day, seven days a week.

2. Major pieces of refrigeration equipment have automatic det
ection, alarm, and shut down controls.

3. The emergency response cart is on the third floor along with the training suits and all the HAZMAT equipment needed to isolate a leak (if one were to happen).

4. Most of the pipe work is out of the way of people and the machinery (on the ceiling), and so there is less of a chance of an ammonia release.

5. The plant maintains good training, certification and employee awareness programs.

5.0 Five-year Accident History

The review of this facility's accident history includes the following range of dates: June 11, 1999 - June 11, 2009 According to 40 CFR Part 68.42(a), there has been one accidental release at this facility. The release occurred on December 23, 2001, during maintenance on some processing equipment. Approxiamtely 395 pounds of liquid and gas anhydrous ammonia, used in the refrigeration system associated with the piece of equipment, was released to atmosphere. There was one fatality and one serious injury as a result of the release. The Madison Fire Dept. was called in due to the injuries. The fire department assisted the Madison Response Team in isolating the leaking ammonia. The National Response Center as well as state and local regulatory agencies were notified. Case Number 589362 was assigned by the National Response Center.

6.0 Emergency Response Program

This facility has developed an emergency response program in which emergency communications, emergency evacuation procedures and an off-site plan in the event of a hazardous substance release are addressed in detail. The three above mentioned documents, combined, form a very comprehensive and thorough Emergency Response Program document for the Madison plant. It includes, but is not limited to, steps to address the following topics:

accidental discharge of hazardous substances and hazardous waste into the environment

the measures to be taken to prevent an accident

countermeasures to be taken in the event of an emergency, and;

procedures
for containing and limiting the duration of the emergency measures to be employed for further protection of employees responding to the emergency, as well as other plant personnel

Our comprehensive emergency response plan is designed to protect our employees, environment and the community and, among other things, requires that:

All nonessential personnel immediately exit the area affected by the release;

Kraft immediately notify local officials, requesting their assistance, if necessary;

For a release which leaves the Kraft site, the company would work with local officials to notify neighbors so that appropriate safety precautions could be taken. If ammonia is in the outside atmosphere, the safest place to be is indoors with windows and doors shut and the ventilation system turned off.