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Westover Dairy

Parent Companies:
Kroger Company
EPA Facility ID:
100000171921
Other ID:
Facility DUNS:
6999528
Parent Company DUNS:
6999528

Location:

Address:
2801 Fort Avenue
Lynchburg, VA 24501
County:
LYNCHBURG (CITY)
Lat / Long:
37.398, -79.165 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Air Release Vent
Horizonal accuracy:
60 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Kroger Company
Phone:
(434) 528-2560
Address:
2801 Fort Avenue
Lynchburg, VA 24501
Foreign Address:

Person responsible for RMP implementation:

Name:
Robert Bailey
Title:
Site Leader

Emergency contact:

Name:
Badri Shonia
Title:
Plant Engineer
Phone:
(434) 528-2563
24-hour phone:
(770) 289-7474
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(434) 528-2560
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Lynchburg LEPC
Full-Time Equivalent Employees:
85
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:
June 19, 2012
Inspecting Agency:
EPA
Using Predictive Filing:
No

Processes:

Ammonia Refrigeration
RMP ID:
1000045162
CBI claimed:
No
Program Level:
3
NAICS:
Fluid Milk Manufacturing (311511)
Dairy Product (except Frozen) Manufacturing (31151)
Bottled Water Manufacturing (312112)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
12,981
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
Oct. 17, 2013
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000036867

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:
99.8
Physical state:
Liquid
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:
99.8
Physical state:
Liquid
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
1.80
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • Emergency shutdown
not considered:
  • Sprinkler systems
  • 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 4, 2008 at 10:30
ID:
1000030501
NAICS:
Fluid Milk Manufacturing (311511)
Duration:
1 hours and 14 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Weather conditions at time of event
Wind speed:
5.5 miles/h NE
Temperature:
83.00 ℉
Atmospheric stability:
C
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:
$500
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
280
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, Dairy Product (except Frozen) Manufacturing (31151)
Prevention Program ID:
1000039341
Safety Review Date
Aug. 15, 2013
PHA Update Date
Oct. 13, 2010
PHA Techniques
  • What if
  • HAZOP
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Corrosion
  • Equipment failure
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Alarms
  • Backup Pump
  • Purge System
Mitigation Systems
  • Sprinkler System
Monitoring Systems
  • Process Area
Changes since PHA
  • Increased Inventory
  • Process Controls
  • Process Detection
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Observation
Procedure Review Date
July 12, 2013
Training Review Date
Jan. 30, 2013
Maintenance Review Date
Oct. 11, 2013
Maintenance Inspection Date
Oct. 11, 2013
Equipment Tested
Yes
Management of Change Most Recent Date
Feb. 23, 2013
Management of Change Review Date
Feb. 2, 2013
Pre-startup Review Date
Feb. 23, 2013
Compliance Audit Date
June 13, 2011
Compliance Audit Change Completion Date
Dec. 31, 2012
Incident Investigation Date
Oct. 3, 2013
Incident Invest. Change Completion Date
Feb. 1, 2014
Participation Plan Review Date
Oct. 7, 2013
Hot Work Review Date
Nov. 14, 2011
Contractor Safety Review Date
Aug. 1, 2011
Contractor Safety Eval. Date
Sept. 26, 2013

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:
Jan. 30, 2013
Local Response Agency:
Local Response Agency Phone:
(434) 847-1601
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

RMP Executive Summary

Accidental Release Prevention and Emergency Response Policies

The Westover Dairy, Lynchburg, VA complies with the guidelines published by the International Institute of Ammonia Refrigeration (IIAR) for equipment specification and operating procedures, and the American Industrial Hygiene Association (AIHA) for emergency response. Westover Dairy also complies with the OSHA Process Safety Management (PSM) standard for ammonia. If an emergency were to occur, it is our policy to notify the Lynchburg City Fire Department and request that they respond.

Stationary Source and Regulated Substances

Westover Dairy receives, stores, and processes milk products. Many of the products must be stored at temperatures near or below freezing and, therefore, ammonia refrigeration systems are needed to cool and/or freeze different areas throughout the process.

Accidental Release Prevention Program and Chemical Specific Prevention Steps

Westover Dairy complies with the EPA's accident prevention rule and all applicable state and local codes and regulations. First, and most important, this facility is designed to promote prevention, both in the building itself and the equipment used as part of the refrigeration process. Written procedures are in place to manage changes in process chemicals, technology, equipment, and procedures. Audits are regularly conducted to determine if all safety provisions are being properly implemented. We have a preventive maintenance program and maintenance schedule which includes regular maintenance of compressors, pumps, evaporators, condensers, control valves, ammonia detectors, scrubbers, and emergency response equipment. Westover Dairy promptly investigates any incident that has resulted in, or could reasonably result in, a catastrophic release of ammonia with prevention as our goal. Westover Dairy employees are encouraged to voice their views on accident prevention issues and to recommend possible changes because we bel
ieve that safety management and accident prevention require a team effort.

Westover Dairy also is regulated by the OSHA Process Safety Management Rule (PSM). This regulation requires many of the same regulations as the RMP requirements for Program 3 such as; Process Safety Information, Process Hazard Analysis, Operating Procedures, Training, Mechanical Integrity and others. The PSM rule also includes Employee Participation, Pre-Startup Safety Reviews and Trade Secrets.

Emergency Response Program

Westover Dairy has a written emergency response plan that is filed with the Lynchburg City LEPC. The Westover Dairy emergency response team receives training on fire fighting, hazardous materials, and emergency medicine. The emergency response equipment is regularly inspected and serviced. Westover Dairy closely communicates with local and county response teams.

Planned Changes to Improve Safety

Based on this review of the ammonia refrigeration system there are no planned changes to improve safety at this time, however Westover Dairy is dedicated to continuously strive to achieve safety levels that equal or surpass the best in the industry.