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Foster Farms Farmerville (2-14 Update)

Parent Companies:
Foster Farms
EPA Facility ID:
100000061005
Other ID:
71241CNGRBHWY15
Facility DUNS:
0
Parent Company DUNS:
9178856

Location:

Address:
6648 Highway 15 North
Farmerville, LA 71241
County:
UNION
Lat / Long:
32.833, -92.432 (Get map)
Method:
Interpolation - Satellite
Description:
Center of Facility
Horizonal accuracy:
10 m
Horizontal reference datum:
World Geodetic System of 1984
Source map scale:

Owner/Operator:

Name:
Foster Farms
Phone:
(318) 368-4200
Address:
6648 Highway 15 North
P.O. Box 726
Farmerville, LA 71241
Foreign Address:

Person responsible for RMP implementation:

Name:
Tim Biron
Title:
Operations Manager

Emergency contact:

Name:
Scott Barton
Title:
Safety Manager
Phone:
(318) 368-4339
24-hour phone:
(318) 436-1239
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Union Parish Police Jury LEPC
Full-Time Equivalent Employees:
1,200
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
No
CAA Permit ID#:
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
July 27, 2009
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Fresh Plant
RMP ID:
1000047069
CBI claimed:
No
Program Level:
3
NAICS:
Poultry Processing (311615)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
64,000
No
Public OCA Chemical
0
No
Cook Plant
RMP ID:
1000047070
CBI claimed:
No
Program Level:
3
NAICS:
Poultry Processing (311615)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
50,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
Feb. 4, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000038340

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 Fresh Plant)
CBI claimed:
No
Percent weight:
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 Fresh Plant)
CBI claimed:
No
Percent weight:
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

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

No Registered Accidents

7. Prevention: Program level 3

Fresh Plant, Poultry Processing (311615)
Prevention Program ID:
1000040941
Safety Review Date
Jan. 15, 2014, since latest RMP submission
PHA Update Date
Jan. 15, 2014, since latest RMP submission
PHA Techniques
  • What if/Checklist
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
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • Process Detection
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Jan. 20, 2014, since latest RMP submission
Training Review Date
Jan. 2, 2014, since latest RMP submission
Maintenance Review Date
Dec. 6, 2013, since latest RMP submission
Maintenance Inspection Date
Jan. 31, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Dec. 3, 2013
Management of Change Review Date
Jan. 2, 2014
Pre-startup Review Date
Dec. 5, 2013
Compliance Audit Date
Jan. 14, 2013
Compliance Audit Change Completion Date
Jan. 30, 2015
Incident Investigation Date
June 28, 2012
Incident Invest. Change Completion Date
June 28, 2012
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Jan. 2, 2014
Contractor Safety Review Date
Jan. 2, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 6, 2013, since latest RMP submission
Cook Plant, Poultry Processing (311615)
Prevention Program ID:
1000040942
Safety Review Date
Jan. 15, 2014, since latest RMP submission
PHA Update Date
Jan. 15, 2014, since latest RMP submission
PHA Techniques
  • What if/Checklist
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
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Jan. 20, 2014, since latest RMP submission
Training Review Date
Jan. 2, 2014, since latest RMP submission
Maintenance Review Date
April 24, 2013, since latest RMP submission
Maintenance Inspection Date
Jan. 31, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 9, 2012
Management of Change Review Date
Jan. 2, 2014
Pre-startup Review Date
Nov. 9, 2012
Compliance Audit Date
Jan. 14, 2013
Compliance Audit Change Completion Date
Jan. 30, 2015
Incident Investigation Date
Feb. 1, 2011
Incident Invest. Change Completion Date
May 20, 2013
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Jan. 2, 2014
Contractor Safety Review Date
Jan. 2, 2014, since latest RMP submission
Contractor Safety Eval. Date
Nov. 6, 2013, since latest RMP submission

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
No
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:
May 9, 2013
Local Response Agency:
Local Response Agency Phone:
(318) 368-7159
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

FOSTER FARMS

FARMERVILLE COMPLEX

RISK MANAGEMENT PROGRAM AND

PROCESS SAFETY MANAGEMENT PROGRAM



Anhydrous Ammonia Refrigeration Systems



Revised January 2014



EXECUTIVE SUMMARY



This Risk Management Plan (RMP) covers Foster Farms Farmerville Poultry Processing Facility. Foster Farms revised this document, previously submitted in November 2009 update, due to the required 5-year revalidation of their process hazard analysis and regulatory requirements requiring re-submittal within six months of a change that resulted in a revised process hazard analysis and also the EPA RMP 5-year re-submittal requirements.



The amount of anhydrous ammonia contained in these systems exceeds the US Occupational Safety and Health Administration (OSHA) Process Safety Management (PSM) and the US Environmental Protection Agency (EPA) Risk Management Program (RMP) threshold reporting quantities.



Many state-of-the-art safety features were incorporated into the ammonia refrigeration systems at the facility as part of the original system construction and system modifications. Foster Farms will continue to improve ammonia handling safety through the implementation of the prevention program elements of the RMP/PSM programs. In the unlikely event that a ammonia release does occur at the facility, Foster Farms personnel are trained in the appropriate response measures and do not rely on support services provided by the local fire department and/or hazardous materials response team to end the release.



Anhydrous ammonia is used in closed-loop refrigeration systems at the facility. The systems provide cooling for production areas, storage areas, freezers, product, water
chilling, and ice making. Central computer systems monitor and control the refrigeration systems. The desired temperatures are maintained by controlling the flow of ammonia with manually and electrically operated valves, float switches, transfer pumps, and compressor controls.



The RMP regulations require facilities to identify and evaluate chemical release scenarios resulting from potential failures of the chemical handling systems covered by the RMP. Program 3 requirements of the RMP apply to the Farmerville Complex due to the quantity of ammonia used. Program 3 facilities are required to evaluate one worst-case release scenario (release parameters are defined by the regulations) for a facility and an alternative release scenario for each covered chemical. The regulations define a worst-case release scenario as "...the greatest amount held in a single vessel...released as a gas over 10 minutes." An alternative release scenario is identified as a release that is more likely to occur at the facility. For facilities with multiple processes, the regulations require that the worst case scenario with the greatest distance to the toxic endpoint must be modeled. Additional worst case scenarios are not required if the affected populations from worst case release scenarios from other processes are within the populations affected by the selected scenario.



This facility has prepared worst-case and alternative release scenarios. These are not summarized herein as recommended by EPA, but are presented in the RMP submittal.



In accordance with the PSM and RMP regulations, Foster Farms also performs periodic audits and hazards reviews to enhance continued safe performance. Recommended actions to improve safety are identified during these audits and reviews and are tracked regularly for completion as required.



The RMP/PSM regulations require a review of the five-year accident history at the regulated facility. The facility has experienced no reportab
le ammonia release within the past five years.



Foster Farms is committed to the safety of its employees and the surrounding community. Our accidental release prevention policies are designed to comply with the PSM and RMP regulations. These regulations are designed to prevent the accidental release of ammonia and minimize negative consequences in the event that a release should occur. Our emergency response policies are designed to comply with all governmental emergency response regulations.



Foster Farms accidental release prevention programs are based on the following key elements:

+ Hands-on and classroom training of the refrigeration mechanics and operators

+ Preventive maintenance (Mechanical Integrity) program

+ Operating procedures, written with the participation of the refrigeration mechanics and operators (Employee Participation Program)

+ Performance of a process hazard analysis of the refrigeration systems including equipment and piping

+ Implementation of an auditing and inspection (Compliance Audit) program

+ Procedures for handling all changes to the refrigeration systems (Management of Change)

+ Pre-Startup review procedures for significant refrigeration system modifications

+ Regular reviews and updates of process safety information

+ Procedures for investigating ammonia related release incidents and near-misses (Incident Investigation Program)

+ On site HazMat team

+ Emergency Response and Action Plan

+ Hot-work permit program and procedures

+ Line Break procedures

+ Contractor Safety program



Foster Farms follows the International Institute of Ammonia Refrigeration (IIAR) guidelines for safe operations and preventive maintenance of the refrigeration equipment. In addition, the facility has procedures in place for notifying our employees, contractors and their employees of the hazards pertaining to the ammonia refrigeration systems, as required under the regulations. Chemical-specific exposure prevention steps include the
availability of air purifying respirators, self contained breathing apparatuses, air monitoring (ammonia and oxygen) devices, for the refrigeration mechanics and awareness of the hazardous and toxic properties of anhydrous ammonia.



Foster Farms is committed to maintaining the mechanical integrity of the ammonia refrigeration systems. A preventive maintenance system is utilized to manage the maintenance of the refrigeration systems. Preventive maintenance at the facility includes daily, weekly, and periodic inspection; calibration; testing; and overhaul of equipment in the ammonia systems. The system is used to track equipment performance and to create reports that are used by maintenance personnel to monitor the frequency of repairs and deviations from normal operating parameters.



Changes to improve safety at the facility are ongoing. The mitigation measures suggested by the previous process hazard analysis team have already been implemented. Others resulting from the recent process hazard analysis revalidation will be implemented during the next several months.



Foster Farms will respond to all suggested mitigation measures promptly. Foster Farms is scheduling completion of proposed actions. Management responses and support will be consistent with Foster Farms' commitment to safe and environmentally responsible operations.



Foster Farms recognizes that the RMP/PSM is a continuous process for evaluating, monitoring, and improving anhydrous ammonia handling operations at its facility. As such, this document and related attachments and program elements will evolve as Foster Farm continues their ongoing focus and dedication of risk minimization and safety improvement for their employees and surrounding community. Foster Farms will submit revised information if a change occurs that is considered significant and requires resubmission under the regulations. However, minor improvements or modifications to the RMP/PSM and related attachments and progra
m elements will be incorporated consistent with Foster Farms' internal review practices and Foster Farms will maintain the most current versions on site. Thus, the most current version RMP/PSM, related documents and elements maintained on site may vary slightly from the information submitted to the EPA and other regulatory agencies.