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Land O'Frost, Inc.

Parent Companies:
Land O'Frost, Inc.
EPA Facility ID:
100000118963
Other ID:
Facility DUNS:
47031190
Parent Company DUNS:
47031190

Location:

Address:
911 Hastings Avenue
Searcy, AR 72143
County:
WHITE
Lat / Long:
35.238, -91.727 (Get map)
Method:
GPS Code Measurements (Psuedo Range) Differential (DGPS)
Description:
Process Unit Area Centroid
Horizonal accuracy:
10 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Land O'Frost, Inc.
Phone:
(800) 323-3308
Address:
16825 Chicago Avenue
Lansing, IL 60438 -0670
Foreign Address:

Person responsible for RMP implementation:

Name:
Teddy Townsend
Title:
EHS Manager

Emergency contact:

Name:
Teddy Townsend
Title:
EHS Manager
Phone:
(501) 268-2473
24-hour phone:
(501) 388-1555
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(800) 323-3308
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
White County LEPC
Full-Time Equivalent Employees:
530
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:
Jan. 16, 2012
Inspecting Agency:
3rd Party Mechanical Integrity Audit
Using Predictive Filing:
No

Processes:

Ammonia Refrigeration
RMP ID:
1000050347
CBI claimed:
No
Program Level:
3
NAICS:
Meat Processed from Carcasses (311612)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
53,448
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Donald Kite / ECCI
Address:
13000 Cantrell Road
Little Rock, AR 72223
Foreign Address:

Phone:
(501) 975-8100

Latest RMP Submission:

Date:
June 19, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000040868

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 Ammonia Refrigeration)
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:
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 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):
3.00
Stability class:
D
Topography:
Urban
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

Aug. 6, 2010 at 09:45
ID:
1000034568
NAICS:
Meat Processed from Carcasses (311612)
Duration:
2 hours and 45 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Weather conditions at time of event
Wind speed:
3.0 miles/h NE
Temperature:
85.00 ℉
Atmospheric stability:
B
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:
0
Medicals treatments:
0
Evacuated:
295
Sheltered-in-place:
0
Property damage:
$0
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:
  • Improved/upgraded equipment

7. Prevention: Program level 3

Ammonia Refrigeration, Meat Processed from Carcasses (311612)
Prevention Program ID:
1000043021
Safety Review Date
June 11, 2012
PHA Update Date
June 11, 2012
PHA Techniques
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
  • Earthquake
  • Tornado
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Sprinkler System
Monitoring Systems
  • Process Area
  • Perimeter Monitors
Changes since PHA
  • None Recommended
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
March 17, 2014
Training Review Date
March 17, 2014
Maintenance Review Date
March 17, 2014
Maintenance Inspection Date
Jan. 16, 2012
Equipment Tested
Yes
Management of Change Most Recent Date
April 11, 2014
Management of Change Review Date
April 11, 2014
Pre-startup Review Date
Feb. 28, 2014
Compliance Audit Date
Jan. 17, 2013
Compliance Audit Change Completion Date
Jan. 17, 2013
Incident Investigation Date
Aug. 6, 2010
Incident Invest. Change Completion Date
Aug. 13, 2010
Participation Plan Review Date
March 17, 2014
Hot Work Review Date
Nov. 12, 2012
Contractor Safety Review Date
March 10, 2014
Contractor Safety Eval. Date
May 16, 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:
April 14, 2014
Local Response Agency:
Local Response Agency Phone:
(501) 268-4810
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
No
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

LAND O'FROST, INC., SEARCY, ARKANSAS 72143

EPA ID #: 1000-0011-8963



FACILITY DESCRIPTION, REGULATED SUBSTANCE, ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES:



The Land O'Frost facility in Searcy manufactures luncheon meat under one large conglomerate of buildings. The manufacturing processes consist of thawing, mixing, cooking, packaging, maintenance, and shipping activities. The regulated stationary source at this facility is the ammonia refrigeration system, which contains anhydrous ammonia. It is utilized at the facility as a refrigerant to cool the buildings and freezers. This substance is listed as a Regulated Toxic Substance under 40 CFR Part 68 and is present in quantities that exceed the threshold for Accidental Release Prevention.



Land O'Frost's commitment to providing a safe, healthy work environment for employees as well as providing a safe, healthy environment for the surrounding community is supported by Land O'Frost's installation of the latest technology in process controls and monitoring detection systems. The properties of ammonia that make it valuable as a refrigerant also make it necessary to observe certain safety precautions to prevent unnecessary human exposure, to reduce the threat to our own personal health as well as our co-workers, and to reduce the threat to nearby members of the community.



Land O'Frost's policy in the event of an uncontrolled accidental release of ammonia is to contact local emergency agencies for assistance as well as necessary contractors needed to respond, clean up and restore facility functions to normal. Land O'Frost adheres to all applicable Federal, State and local safety and environmental regulations for the prevention of releases of this chemical.



ACCIDENT RELEASE PREVENTION PROGRAM:



The Searcy facility complies with the Program 3 requirements of EPA's Risk Management Plan (RMP) rule through the implementation of the Process Safety Management rule of OSHA standard 29 CFR 1910
.119 for the prevention of hazardous chemical releases. The Process Safety Management Plan is a comprehensive program with fourteen elements, including process hazard analysis, employee training, operating procedures, mechanical integrity, pre-safety startup, contractor safety, emergency planning and response, compliance auditing, and employee participation.



The Process Safety Management Program ensures that the process and the equipment in the process is designed, constructed, and maintained according to industry codes and standards and that the process is operated according to good engineering practices. The mechanical integrity element of the program includes scheduled inspections and tests of equipment and of monitoring devices in the process to detect any deficiencies or defects in equipment. Preventative maintenance and replacement policies for parts and equipment ensure that deficiencies are addressed and corrected before they could potentially contribute to a release incident. All elements of the Process Safety Management Program help to ensure an uncontrolled release of anhydrous ammonia is prevented.



FIVE YEAR ACCIDENT HISTORY:



A small release happened on August 6, 2010, when a instrumentation fitting failed. The facility was evacuated and the local fire department was notified. The fire department quickly isolated the leak and an Incident Investigation commenced. The findings of the investigation suggested all similar fittings be replaced with a sturdier design, much less susceptible to vibration failure. All similar instruments were replaced by August 13, 2010.



EMERGENCY RESPONSE PROGRAM:



Land O'Frost has developed an emergency response plan (in accordance with 29 CFR 1910.38 and 29 CFR 1910.120) that includes provisions to respond to chemical emergencies on-site with trained Land O'Frost personnel and provisions to evacuate non-responding employees from the facility in the event of an uncontrolled accidental release of a hazardous che
mical. The emergency response program focuses on the following key elements: Emergency Telephone Call Log, Coordination with Local Authorities, Structure of Authority, Emergency Team Role Descriptions, Media Interaction Procedures, Emergency Notification Procedures, Emergency Evacuation Instructions, Personnel Accounting Procedures, Notification Procedures, Severe Weather, Bomb Threat, and Fire and/or Explosion.



It is Land O'Frost's policy to contact the local emergency planning committee, and the local fire department in the event of a hazardous chemical release. Land O'Frost has coordinated with the local emergency planning committee on its emergency response plan, and in the unlikely event of an uncontrolled release, the local authorities will be notified by Land O'Frost and a joint decision will be made on whether local areas will be evacuated. The local authorities will notify any affected neighbors or surrounding properties if an evacuation is necessary.





PLANNED CHANGES TO IMPROVE SAFETY:



Land O'Frost is committed to continuous efforts to improve the safe operation of the anhydrous ammonia process by implementing preventative maintenance programs, inspection programs, and employee training in the safe operation of the equipment and the system. The anhydrous ammonia process is designed in accordance with good engineering practices. Periodic auditing of the Process Safety Management Prevention Program ensures that any system changes or modifications are evaluated and necessary safety precautions and or safety improvements are made before the process is placed into operation.