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Hanover Foods Corporation - Clayton, DE Plant

Parent Companies:
Hanover Foods Corporation
EPA Facility ID:
100000171725
Other ID:
19901HNVRFRTE
Facility DUNS:
0
Parent Company DUNS:
3004439

Location:

Address:
Route Six and Duck Creek Rd.
Clayton, DE 19938
County:
KENT
Lat / Long:
39.289, -75.641 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Facility Centroid
Horizonal accuracy:
12.2 m
Horizontal reference datum:
World Geodetic System of 1984
Source map scale:

Owner/Operator:

Name:
Hanover Foods Coporation
Phone:
(302) 653-9281
Address:
P.O. Box 1150
Clayton, DE 19938 -1010
Foreign Address:

Person responsible for RMP implementation:

Name:
Terry Johnson
Title:
Maintenance Manager

Emergency contact:

Name:
Alvin Constantine
Title:
Plant Manager
Phone:
(302) 653-9281
24-hour phone:
(443) 988-1439
Ext or PIN:
125

Other contacts:

Facility (or company) email:
Facility phone:
(800) 888-4646
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Kent County LEPC
Full-Time Equivalent Employees:
150
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
AQM-00100024R1
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Oct. 1, 2014
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

Ammonia Refrigeration
RMP ID:
1000060656
CBI claimed:
No
Program Level:
3
NAICS:
Frozen Fruit, Juice, and Vegetable Manufacturing (311411)
Frozen Specialty Food Manufacturing (311412)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
93,585
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
EA Engineering, Science, and Technology, Inc., PBC
Address:
225 Schilling Circle
Hunt Valley, MD 21031
Foreign Address:

Phone:
(410) 584-7000

Latest RMP Submission:

Date:
July 28, 2015
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000048450

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:
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:
  • Enclosures
  • Drains
not considered:
  • Dikes
  • Berms
  • Sumps
Active mitigation
considered:
  • Sprinkler systems
not considered:
  • 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

Feb. 12, 2013 at 11:50
ID:
1000037703
NAICS:
Frozen Fruit, Juice, and Vegetable Manufacturing (311411)
Duration:
15 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Weather conditions at time of event
Wind speed:
10.0 miles/h SE
Temperature:
53.00 ℉
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:
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:
570
Sheltered-in-place:
570
Property damage:
$0
Environmental damage:
Initiating event:
Human Error
Contributing factors:
  • Human error
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Revised training

7. Prevention: Program level 3

Ammonia Refrigeration, Frozen Fruit, Juice, and Vegetable Manufacturing (311411)
Prevention Program ID:
1000050461
Safety Review Date
Jan. 27, 2015
PHA Update Date
July 31, 2012
PHA Techniques
  • What if
  • Checklist
  • What if/Checklist
Hazards Identified
  • Toxic release
  • Overpressurization
  • Corrosion
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Sprinkler System
  • Enclosure
Monitoring Systems
  • Process Area
Changes since PHA
  • Increased Inventory
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Jan. 17, 2015
Training Review Date
Feb. 15, 2010
Maintenance Review Date
Jan. 27, 2015
Maintenance Inspection Date
Dec. 11, 2008
Equipment Tested
Yes
Management of Change Most Recent Date
June 1, 2014
Management of Change Review Date
Jan. 27, 2015
Pre-startup Review Date
June 15, 2014
Compliance Audit Date
Oct. 15, 2014
Compliance Audit Change Completion Date
Aug. 31, 2015
Incident Investigation Date
Feb. 12, 2013
Incident Invest. Change Completion Date
Feb. 18, 2013
Participation Plan Review Date
Jan. 4, 2010
Hot Work Review Date
Jan. 4, 2010
Contractor Safety Review Date
Jan. 4, 2010
Contractor Safety Eval. Date
June 1, 2010

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 9, 2015
Local Response Agency:
Local Response Agency Phone:
(302) 653-7317
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:
No
Subject To - Other:

Executive Summary

Accidental Release Prevention and Emergency Response Policies



Hanover Foods Corporation (Hanover) is committed to the safe operation of the Clayton, Delaware facility. This commitment is demonstrated by the significant use of resources expended in process control equipment, employee training, and management oversight. Hanover uses a written safety policy that outlines its concern and commitment to safety.



Facility Description and Regulated Substance Handled



Hanover is a diverse processor of fresh, frozen, and canned food product. The Clayton, Delaware facility, the subject of this RMP, processes frozen foods. The plant uses anhydrous ammonia as a refrigerant due to its unique properties. The ammonia refrigeration system consists of a main receiver, three additional receivers, seven freezers, three cold storage units, two chiller rooms, and associated piping and process control equipment. The refrigeration system also includes two flume chillers and a spinach chiller system. The maximum amount of ammonia in the system at any time is 93,585 pounds. Ammonia is the only EPA RMP regulated substance exceeding the threshold quantity at the site. The ammonia refrigeration system falls under Prevention Program 3 of the RMP.



Worst Case and Alternate Release Scenarios



The worst-case scenario is the catastrophic release of 18,000 pounds of ammonia from the high pressure receiver on the Frigo-pak, which is the largest vessel in the system. In accordance with the RMP regulation, the release was modeled over a 10 minute period with no mitigating factors. The distance to the toxic endpoint would reach off-site receptors. EPA's model, RMP*Comp, was used in calculating the extent of the release.



Because of the probability of the worst-case scenario is minute, EPA allows calculation of an alternative release scenario. Hanover alternate release scenario has a greater chance of occurring than the worst-case scenario. Hanover's alternative release scenario
is a relief valve lifting on the Frigo-pak pump package receiver. Ammonia would be released at an estimated 42.8 pounds per minute for 60 minutes. The distance to the toxic endpoint would not reach off-site receptors. RMP*Comp was used in calculating the distance to the toxic endpoint.



General Accidental Release Prevention Program and Chemical-Specific Prevention Steps



Hanover understands the risks of using ammonia, and has several active programs in place to mitigate any potential problems. Hanover is subject to OSHA Process Safety Management, and utilizes the 12 elements, including process hazard analysis, standard operating procedures, and employee training, to manage our system. All changes are reviewed by the management of change system, and process hazard reviews are conducted before being placed into operation. A computerized preventive maintenance program is also in place. This facility is staffed by qualified refrigeration personnel 24 hours a day, 365 days a year.



Hanover utilizes a Manning Systems ammonia detection/ventilation control system consisting of four sensors in the main engine room and one in the Frigo-pak compressor room. Hanover also has ammonia detectors in each of the three cold storage freezers, and one in the Wet Pack production room.



Five-Year Accident History



The Hanover Clayton, DE facility had an accident involving anhydrous ammonia in the last five years. As described in Section 6, the facility released a small amount of ammonia while performing a maintenance activity. The wind blew the gas towards a local elementary school, which was eventually evacuated as a result.



Emergency Response Program



Hanover maintains a written emergency response plan that includes evacuation procedures, emergency coordinator responsibilities, notification procedures, and emergency medical procedures. The facility has a fully staffed and trained emergency response team that would respond to an ammonia emergency at the site.
The team receives annual training on emergency response.



Planned Changes to Improve Safety



Hanover provides ongoing training to its employees, and is a member of the Refrigeration Engineers and Technicians Association (RETA) and the International Institute of Ammonia Refrigeration (IIAR). Hanover will continue to use these guidelines in the management of the refrigeration system.