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Zero Mountain, Inc. Lowell

Parent Companies:
EPA Facility ID:
100000141839
Other ID:
Facility DUNS:
181055658

Location:

Address:
515 North Bloomington
Lowell, AR 72745
County:
BENTON
Lat / Long:
36.263, -94.135 (Get map)
Method:
Interpolation - Photo
Description:
Center of Facility
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
2400

Owner/Operator:

Name:
Joseph F. Rumsey
Phone:
(479) 646-7757
Address:
8425 Hwy 45 South
P.O. Box 6209
Fort Smith, AR 72916
Foreign Address:

Person responsible for RMP implementation:

Name:
Joel Neisler
Title:
Safety/Environmental Manager

Emergency contact:

Name:
Kadin Fancher
Title:
Maintenance Manager
Phone:
(479) 659-3000
24-hour phone:
(479) 957-3556
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(479) 651-1208
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Benton LEPC
Full-Time Equivalent Employees:
35
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 23, 2013
Inspecting Agency:
State occupational safety agency
Using Predictive Filing:
No

Processes:

Ammonia Refrigeration
RMP ID:
1000053994
CBI claimed:
No
Program Level:
3
NAICS:
Refrigerated Warehousing and Storage (49312)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
44,737
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 9, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000043717

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 Guidance for Ammonia Refrigeration Reference Tables or Equations
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
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

Sept. 14, 2010 at 12:35
ID:
1000034197
NAICS:
Refrigerated Warehousing and Storage (49312)
Duration:
11 hours and 30 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
5.0 miles/h SW
Temperature:
92.00 ℉
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:
1
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$56087
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
185
Sheltered-in-place:
568
Property damage:
$0
Environmental damage:
Initiating event:
Human Error
Contributing factors:
  • Equipment failure
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Revised training
  • Changed storage location, Removed piping, Require spotters in the engine room

7. Prevention: Program level 3

Ammonia Refrigeration, Refrigerated Warehousing and Storage (49312)
Prevention Program ID:
1000045319
Safety Review Date
May 13, 2014
PHA Update Date
May 13, 2014
PHA Techniques
  • What if
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
  • Earthquake
  • Floods
  • Tornado
Process Controls
  • None
Mitigation Systems
  • None
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Demonstration
  • Observation
Procedure Review Date
Jan. 6, 2014
Training Review Date
May 24, 2012
Maintenance Review Date
May 24, 2012
Maintenance Inspection Date
June 5, 2014
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 10, 2013
Management of Change Review Date
Jan. 2, 2014
Pre-startup Review Date
Jan. 2, 2014
Compliance Audit Date
Sept. 6, 2012
Compliance Audit Change Completion Date
Sept. 6, 2012
Incident Investigation Date
Sept. 14, 2010
Incident Invest. Change Completion Date
May 31, 2011
Participation Plan Review Date
Jan. 2, 2014
Hot Work Review Date
Jan. 2, 2014
Contractor Safety Review Date
Jan. 2, 2014
Contractor Safety Eval. Date
Nov. 29, 2012

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:
May 8, 2014
Local Response Agency:
Local Response Agency Phone:
(479) 770-0166
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

Executive Summary

Zero Mountain, Inc., Lowell



Accidental Release Prevention and Emergency Response Policies

We at Zero Mountain, Inc. are strongly committed to employee, public and environmental safety. This commitment is demonstrated by our excellent safety record. Programs in place cover areas such as design, installation, operating procedures, maintenance, and employee training associated with the process at our facility. It is our policy to implement appropriate controls to prevent possible releases of regulated substances. Trained response personnel are on staff and ready to respond in the event of an incident.



The Stationary Source and the Regulated Substances Handled

Our facilityA?s primary activity is storage and handling of low temperature food products. We have 1 regulated substance present at our facility. This substance is Anhydrous Ammonia. Ammonia (anhydrous) is used as a refrigerant to maintain the temperature of our warehouse.



The General Accidental Release Prevention Program and the Chemical Specific Prevention Steps

Maintaining the refrigeration system properly and ensuring that maintenance is performed in a safe and professional manner is the most critical part of preventing accidental releases. Operating and maintenance procedures have been implemented to help ensure this is done.



International Institute of Ammonia Refrigeration (IIAR) standards are also very important in preventing releases. IIAR standards are reviewed to help identify potential problem areas, develop good management practices, and maintain our system in a manner that will provide the safest and most efficient operation.



Compliance with PSM and RMP regulations is another important step in preventing releases. Zero Mountain, Inc. strives to meet or exceed all PSM an RMP requirements. The following sections briefly describe the elements of these programs:



Process Safety Information

Zero Mountain, Inc. maintains a detailed record of safety information t
hat describes the chemical hazards, operating parameters and equipment designs associated with all process.



Process Hazard Analysis

Our facility conducts comprehensive studies to ensure that hazards associated with our process are identified and controlled efficiently. The methodology used to carry out these analyses is the A?What ifA?A? methodology. The studies are undertaken by a team of qualified personnel with expertise in engineering and process operations and are revalidated at a regular interval of at least every five years. Any findings related to the hazard analysis are addressed in a timely manner.



Operating Procedures

For the purposes of safely conducting activities within our covered processes, Zero Mountain, Inc. maintains written operating procedures. These procedures address various modes of operation such as initial startup, normal operations, temporary operations, emergency shutdown, emergency operations, normal shutdown and startup after a turnaround. The information is regularly reviewed and is readily accessible to operators involved in the process. SOP checklists are used to ensure all steps are completed properly, using all safety precautions and PPE.



Training

Zero Mountain, Inc. has a comprehensive training program in place to ensure that employees who are operating the process are competent in the operating procedures associated with this process. Refresher training is provided at least every three years and more frequently as needed.



Mechanical Integrity

Zero Mountain, Inc. carries out highly documented maintenance checks on process equipment to ensure proper operations. Process equipment examined by these checks includes among others; compressors, pressure vessels, storage tanks, piping systems, relief vent systems, emergency shutdown systems, controls and pumps. Qualified personnel carry out maintenance operations with previous training in maintenance practices. Furthermore, these personnel are offered specialized
training as needed. Any equipment deficiencies identified by the maintenance checks are corrected in a safe and timely manner.



Management of Change

Written procedures are in place at Zero Mountain, Inc. to manage changes in our process chemical, technology, equipment and procedures. Process operators, maintenance personnel or any other employee whose job tasks are affected by a modification in process conditions are promptly trained to deal with the modification.



Pre-startup Reviews

Pre-starts up safety reviews related to modifications in our established process are conducted as needed at Zero Mountain, Inc. These reviews are conducted to confirm that construction, equipment, operating and maintenance procedures are suitable for safe startup prior to placing equipment into operation.



Compliance Audits

Zero Mountain, Inc. conducts audits on a regular basis to determine whether the provisions set out under the RMP rule are being implemented. These audits are carried out at least every 3 years and any corrective actions required as a result of the audits are undertaken in a safe and prompt manner.



Incident Investigation

Zero Mountain, Inc. promptly investigates any incident that has resulted in, or could reasonably result in a catastrophic release of a regulated substance. These investigations are undertaken to identify the situation leading to the incident as well as any corrective actions to prevent the release from reoccurring. All reports are retained for a minimum of 5 years.



Employee Participation

Zero Mountain, Inc. truly believes that process safety management and accident prevention is a team effort. Company employees are strongly encouraged to express their views concerning accident prevention issues and to recommend improvements. In addition, our employees have access to all information created as part of the facilityA?s implementation of the RMP rule, including information resulting from process hazard analyses in particular.



C
ontractors

On occasion, our company hires contractors to conduct specialized maintenance and construction activities. Prior to selecting a contractor, a thorough evaluation of safety performance of the contractor is carried out. Zero Mountain, Inc. has a strict policy of informing the contractors of known potential hazards related the contractorA?s work and the process. Contractors are also informed of all the procedures for emergency response should an accidental release of our regulated substance occur.





Five year Accident History

Zero Mountain, Inc. has had an excellent record of preventing accidental releases. Zero Mountain, Inc. Lowell had a reportable accidental release of anhydrous ammonia on 9/14/2010.



Emergency Response Program

Zero MountainA?s emergency response plan to deals with accidental releases of hazardous materials. The plan includes all aspects of emergency response including adequate first aid and medical treatment, evacuations, notification of local emergency response agencies and the public, as well as post-incident decontamination of affected areas.



To ensure proper functioning, our emergency response equipment is regularly inspected and serviced. In addition, the plan is promptly updated to reflect any pertinent changes taking place within our processes that would require a modified emergency response.



Changes to Improve Safety

Zero Mountain has implemented a program that will stop the flow of liquid ammonia to an area if the sensor in that area detects a release. This system is currently in place at all four of our locations and is tested regularly with the Nh3 sensors.



Planned Changes to Improve Safety

Nh3 sensors in the blast freezers to protect customer product and employees. These Nh3 sensors are in place at the Fort Smith facility and will be installed in the future at the other three ZMI locations.