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Pilgrim's Pride - Bossier City Further Processing

Parent Companies:
Pilgrim's Pride Corporation
EPA Facility ID:
100000064841
Other ID:
Facility DUNS:
611941308
Parent Company DUNS:
7334170

Location:

Address:
5310 Kennon Lane
Bossier City, LA 71112
County:
BOSSIER
Lat / Long:
32.528, -93.676 (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:
Pilgrim's Pride Corporation
Phone:
(903) 855-1000
Address:
PO Box 1111
110 South Texas Street
Pittsburg, TX 75686
Foreign Address:

Person responsible for RMP implementation:

Name:
Linda J. McDaniel
Title:
Corporate PSM Director

Emergency contact:

Name:
Katherine Smith
Title:
Site Safety Manager
Phone:
(318) 549-4678
24-hour phone:
(318) 549-4666
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(318) 549-1215
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Bossier-Caddo Parish LEPC
Full-Time Equivalent Employees:
300
Covered by OSHA PSM:
Yes
EPCRA section 302:
No
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
0400-00056-01
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
July 9, 2005
Inspecting Agency:
Fire Department
Using Predictive Filing:
No

Processes:

Ammonia Refrigeration
RMP ID:
73312
CBI claimed:
No
Program Level:
3
NAICS:
Poultry Processing (311615)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
19,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
Dec. 27, 2007
Type:
Correction of existing RMP
Reason:
New accident history information
Registered:
No
RMP ID:
50492

Deregistration:

Date:
Effective Date:
Reason:
Other
Other Reason:
Chemical removed from site

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 Ammonia Refrigeration)
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:
Urban
Passive mitigation
considered:
  • Dikes
not considered:
  • 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 Ammonia Refrigeration)
CBI claimed:
No
Percent weight:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
1.50
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

June 23, 2007 at 03:43
ID:
8097
NAICS:
Poultry Processing (311615)
Duration:
5 hours and 17 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
5.0 miles/h SSW
Temperature:
77.00 ℉
Atmospheric stability:
D
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:
0
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
2
Medicals treatments:
0
Evacuated:
60
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Overpressurization
  • Upset condition
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised training
  • Revised emergency response plan

7. Prevention: Program level 3

Ammonia Refrigeration, Poultry Processing (311615)
Prevention Program ID:
43000
Safety Review Date
Nov. 28, 2004, since latest RMP submission
PHA Update Date
Sept. 14, 2004, since latest RMP submission
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Toxic release
  • Fire
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
  • Tornado
Process Controls
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Dikes
  • Fire Walls
  • Enclosure
Monitoring Systems
  • Process Area
Changes since PHA
  • None Recommended
Training Type
  • Classrom
Competency Testing
  • Written Test
Procedure Review Date
April 27, 2005, since latest RMP submission
Training Review Date
Nov. 22, 2005, since latest RMP submission
Maintenance Review Date
April 27, 2005, since latest RMP submission
Maintenance Inspection Date
Nov. 9, 2005, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 31, 2005
Management of Change Review Date
Nov. 23, 2005
Pre-startup Review Date
March 31, 2005
Compliance Audit Date
May 27, 2005
Compliance Audit Change Completion Date
May 31, 2005
Incident Investigation Date
April 20, 2005
Incident Invest. Change Completion Date
June 30, 2006
Participation Plan Review Date
Nov. 23, 2005
Hot Work Review Date
Nov. 23, 2005
Contractor Safety Review Date
Nov. 23, 2005, since latest RMP submission
Contractor Safety Eval. Date
Feb. 15, 2005, 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:
Nov. 29, 2004
Local Response Agency:
Local Response Agency Phone:
(318) 741-8330
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 Risk Management Plan (RMP) covers the Pilgrim?s Pride Bossier City Further Processing facility. The reason for submitting this RMP is to report the change of ownership from Wayne Farms LLC to Pilgrim?s Pride Corporation. This facility has one refrigeration system using anhydrous ammonia as the refrigerant. The amount of anhydrous ammonia contained in the system is above the EPA threshold reporting quantity of 10,000 pounds.

Because anhydrous ammonia is listed by both the US Occupational Safety and Health Administration (OSHA) and the US Environmental Protection Agency (EPA) as a hazardous chemical, our accidental release prevention policy is designed to comply with the Process Safety Management (PSM) and Risk Management Program (RMP) regulations of these two agencies. These regulations are designed to prevent the accidental release of ammonia and minimize negative consequences in the event that a release should occur.

Pilgrim's Pride is committed to continuously improving the safety of its employees and the surrounding community. This commitment includes both human health and the protection of the environment. Safety is ensured through careful preventive measures and emergency planning. The intent of our release prevention policy is to minimize all potential risks that could possibly lead to an accidental ammonia release. The Emergency Response Plan focuses on reducing the potential impact of an accidental release. This is done by coordinating emergency actions with the local Fire Department and ensuring that employees are trained on the proper response to an emergency situation. Drills are conducted and critiques are made to improve the response process. The Emergency Response plan is designed to comply with all government emergency response regulations.

Pilgrims Pride Corporation?s accidental release prevention program is based on the following key elements:

* Hands-on and classroom training of the refrigeration partners
* Written Partner Part
icipation program
* Preventative maintenance program
* Operating procedures, written with the participation of the refrigeration partners
* Performance of a process hazard analysis of the entire system including equipment and piping
* Design and implementation of an auditing and inspection program
* Management of Change Procedures
* Pre-Startup review procedures for significant system modifications
* Up-to-date process safety information
* Procedures for investigating release incidents or near-misses
* Hot-work permits for work on or near the ammonia process.
* Line Break procedures

This program was developed with the participation of Bossier City refrigeration partners and focuses primarily on the safe operation and the mechanical integrity of the ammonia refrigeration process equipment. Our partners were instrumental in developing the Process Safety Information. Anhydrous ammonia pipes and valves are labeled and equipment information has been compiled. Pilgrim?s Pride Corporation follows the International Institute of Ammonia Refrigeration (IIAR) guidelines for safe operations and preventative maintenance of the refrigeration equipment. In addition, the facility has procedures in place for notifying contractors and their employees of the hazards pertaining to the system, as required under the regulations. Chemical-specific exposure prevention steps include availability of self-contained breathing apparatus (SCBA) and air purifying respirators for the refrigeration partners, and awareness of the hazardous and toxic properties of anhydrous ammonia. Refrigeration partners are provided with HAZMAT training on an annual basis.

In accordance with the PSM and RMP regulations, periodical Compliance Audits and Process Hazard Analyses are performed to enhance continued safe performance. Several recommended actions to improve safety were identified during these audits and reviews and are being tracked regularly for timely completion.

An offsite consequence analysis
was performed for this facility, including consideration of ammonia release scenarios as ?worst case release? and ?alternative release scenarios?. We incorporate several management systems to decrease the likelihood of an incident occurring. This site has not experienced any ammonia incidents that have resulted in offsite consequences since the last RMP was submitted.