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Diversified Foods & Seasonings, L.L.C. -Madisonvil

Parent Companies:
Al Copeland Investments
EPA Facility ID:
100000185694
Other ID:
Facility DUNS:
0
Parent Company DUNS:
0

Location:

Address:
109 Highway 1085
Madisonville, LA 70447
County:
ST. TAMMANY
Lat / Long:
30.462, -90.188 (Get map)
Method:
GPS - Unspecified
Description:
Process Unit
Horizonal accuracy:
15 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Diversified Foods & Seasonings,LLC
Phone:
(985) 809-3626
Address:
1404 Greengate Drive
Suite 300
Covington, LA 70433
Foreign Address:

Person responsible for RMP implementation:

Name:
Daryl Hagen
Title:
Plant Manager

Emergency contact:

Name:
Daryl Hagen
Title:
Plant Manager
Phone:
(985) 809-3660
24-hour phone:
(985) 214-6446
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
(504) 615-4746
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
St. Tammany Parish LEPC
Full-Time Equivalent Employees:
75
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:
Oct. 22, 2015
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

Refrigeration System
RMP ID:
1000062750
CBI claimed:
No
Program Level:
3
NAICS:
Refrigerated Warehousing and Storage (49312)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
35,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
UF Ammonia Services, Inc.
Address:
2679 Bonaire Terrace
Marietta, GA 30066
Foreign Address:

Phone:
(770) 509-0779

Latest RMP Submission:

Date:
May 8, 2015
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000049901

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 Refrigeration System)
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 Refrigeration System)
CBI claimed:
No
Percent weight:
Physical state:
Gas
Model used:
Areal Locations of Hazardous Atmospheres [ALOHA(R)]
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

Dec. 3, 2015 at 07:23
ID:
1000042357
NAICS:
Perishable Prepared Food Manufacturing (311991)
Duration:
27 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Weather conditions at time of event
Wind speed:
None miles/h
Temperature:
None ℉
Atmospheric stability:
Precipitation present:
No
Unknown weather conditions:
Yes
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:
$165000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
  • waste water contaminated, contained
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
Oct. 16, 2015 at 08:25
ID:
1000041237
NAICS:
Frozen Specialty Food Manufacturing (311412)
Duration:
2 hours and 49 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Weather conditions at time of event
Wind speed:
5.0 miles/h S
Temperature:
70.00 ℉
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:
$650000
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
3
Evacuated:
78
Sheltered-in-place:
78
Property damage:
$650000
Environmental damage:
  • Fish or animal kills
  • Tree, lawn, shrub, or crop damage
  • Water contamination
  • Soil Contamination
Initiating event:
Equipment Failure
Contributing factors:
  • Equipment failure
  • Overpressurization
  • Process design failure
  • hydrolic shock
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised maintenance
  • Revised operating procedures
  • New process controls
  • Changed process

7. Prevention: Program level 3

Refrigeration System, Refrigerated Warehousing and Storage (49312)
Prevention Program ID:
1000052126
Safety Review Date
Oct. 30, 2015, since latest RMP submission
PHA Update Date
June 22, 2012, since latest RMP submission
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Cooling loss
  • Tornado
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Purge System
Mitigation Systems
  • Fire Walls
  • Enclosure
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Dec. 13, 2016, since latest RMP submission
Training Review Date
April 14, 2016, since latest RMP submission
Maintenance Review Date
May 8, 2015, since latest RMP submission
Maintenance Inspection Date
Aug. 19, 2013, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Nov. 17, 2016
Management of Change Review Date
Feb. 1, 2016
Pre-startup Review Date
Nov. 17, 2016
Compliance Audit Date
May 8, 2015
Compliance Audit Change Completion Date
May 6, 2016
Incident Investigation Date
Oct. 16, 2015
Incident Invest. Change Completion Date
Oct. 29, 2016
Participation Plan Review Date
Oct. 9, 2015
Hot Work Review Date
May 8, 2015
Contractor Safety Review Date
May 8, 2015, since latest RMP submission
Contractor Safety Eval. Date
Oct. 30, 2015, since latest RMP submission

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:
Oct. 8, 2015
Local Response Agency:
Local Response Agency Phone:
(985) 898-4913
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



ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES



This facility follows a rigorous thirteen volume Process Safety Management Program to prevent the accidental release of ammonia. The PSM program is in compliance with Occupational Safety and Health Administration (OSHA), Process Safety Management (PSM) of 29 CFR 1910.119. Employees and management participate and cooperate in the PSM program to maintain a work environment that is safe to employees, the community, and the environment.



The facility has developed an Emergency Action Plan with the responsibility to notify the Goodbe and Mandeville Fire Departments of an incident for a timely response. Trained Diversified Foods and Seasonings personnel will initiate safety systems as they evacuate to minimize the impact of the emergency. Once the Fire Department arrive on-scene they will assume the role of Incident Commander and have control the incident.



STATIONARY SOURCE AND REGULATED SUBSTANCES



This food processing facility operates a two-stage, anhydrous ammonia (R-717) refrigeration system. Anhydrous ammonia (R-717) refrigerant is a Group II refrigerant.



Engine room electrical classification is NEMA-1.



There are some mitigating measures in place. Although there are doors and windows, the overall enclosure acts as a dike creating liquid pooling and limiting the liquid run-off. Ammonia leak detection is installed in this area that sounds alarms and starts emergency ventilation. The emergency ventilation is automatically controlled and discharges the engine room air through the roof which creates a lower level of concentration in the engine room for responders. It also starts air dispersion at lower concentration levels and disperses the ammonia with greater air turbulence.



GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM CHEMICAL-SPECIFIC PREVENTION STEPS



This facility follows the OSHA Process Safety Management Program. Various special elements have been
incorporated into this program to meet the additional EPA requirements for the RMP. Following is an overview.



Employee Participation -The Employee Participation Program is an asset to both employees at the site and to the community as a whole. As a general rule, employees who are fully involved have a greater sense of responsibility; they are more likely to catch the problems that can cause accidents. Employee awareness is for employees, not directly involved with the process, this includes knowing the hazards, the safety rules, warning signs, and evacuation procedures. All employees have access to the PSM Program. Involved employees participate directly in every phrase of the PSM program, including conducting the PHA, developing or reviewing operating procedures, reviewing incident investigations, and conducting mechanical integrity and compliance audits.



Community involvement is through coordination and cooperation with the local Fire department and LEPC.



Process Safety Information - Process Safety Information includes a wide variety of books, manuals, and process information. These are available to employees that operate, maintain, or repair the process equipment or piping. There are three major categories of information: ammonia data such as MSDS, safety information, first aid, chemical properties, IIAR safety bulletins, etc.; process information such as piping & instrumentation diagrams (P&ID's), block flow diagram, mass flow balance, design codes and standards, pressure safety relief settings, safety system/devices, ventilation system design, operating procedures, safe operating limits, and ramification of process deviation; and process equipment information such as equipment specifications, electrical classifications, materials of construction, installation manuals, operating and maintenance manuals, and manufacturer's manuals.



Process Hazard Analysis -A Process Hazard Analysis (PHA) was completed using the "What-if" technique. This addressed
hazards, engineering and administrative controls, consequences of failure of engineering and administrative controls, facility siting, human factors, and a qualitative evaluation of the possible safety and health impact. The results of the PHA were prioritized and incorporated into a PHA Findings Report for follow-up as a corrective action log.



Standard Operating Procedures - SOPs are provided for each compressor, condenser, ammonia vessel and oil pot, and evaporator. Topics include general information such items as objectives, hazards, location, equipment needed, P&ID's, task flow diagrams, and step-by-step procedures with specific warnings and comments. The SOPs cover different phases of operations such as: initial startup; normal, temporary and emergency operations; emergency shutdowns; and startup following a shutdown.



Training - All employees are who are involved with anhydrous ammonia have been properly trained, at a minimum, in understanding the MSDS, routine refrigeration system operation, emergency refrigeration system operation, emergency and normal refrigeration safety practices, and, if appropriate, the individual's role in the emergency response plan.



Contractors - This site follows strict guidelines for qualifying contractors who directly influence the safety of the process or the system. The contractor qualification procedure ensures that contractors and their employees are fully aware of the potential dangers involved with the ammonia process, that contractors understand their responsibility and train their people, and that a contractor's safety record is considered in reviewing the bids.



Pre-Startup Review - Pre-startup safety reviews are required on all new or modified equipment/systems. This involves process safety information, process hazard analysis, training, safety procedures, operating procedures, and verification that construction and equipment are in accord with the design specifications.



Mechanical Integrity Audits - T
he purpose of the Mechanical Integrity Audit program is to ensure that the equipment is maintained in good working condition. These are performed on all compressors, condensers, evaporators, pressure vessels, piping system, relief and vent systems and devices, emergency shutdown systems, controls, and pumps.



Hot Work Permits - This permit process is to protect against fire, explosion and other dangers resulting from hot work (welding and cutting outside the designated areas). Hot work permits must be obtained before any work is done outside the shop area. The Maintenance Supervisor reviews and issues the permits to insure all fire prevention and protection rules are met. Permits indicate the appropriate dates and the work to be done. The permits are kept on file until workers have completed the hot work operations.



Management of Change - The Management of Change (MOC) procedure requires that all changes (even "replacement in kind") be reviewed to see if there is a possible negative effect. The MOC review addresses the

technical basis for the change, the impact on safety and health, modifications to operating procedures, and authorization requirements for the proposed change. Employees affected by the change are informed of the change before startup and trained in the proper procedures.



Incident Investigation - An incident investigation shall be performed any time there is an incident which resulted in, or which could reasonably have resulted in, a catastrophic release of ammonia. The purpose is to gain information that could prevent further accidents and to identify weaknesses in the emergency response plan that need to be addressed. Investigations are initiated promptly using a trained team. The findings and recommendations will be studied and appropriate corrective action taken.



Emergency Response Plan - This facility has a comprehensive emergency response plan that meets established criteria. This plan will be provided to the local fire departme
nts and the Local Emergency Planning Committee (LEPC).



Compliance Audits and RMP Revisions - To insure that all the other 12 areas of PSM program are followed, the company requires compliance audits. At a minimum, these must be completed every three years.



Resubmission of the RMP shall be done according to RMP Section 6.2 to meet the OCA requirements.



FIVE-YEAR ACCIDENT HISTORY



There was a release in October 2015 involving hydraulic shock on the roof of the building. A release was also recorded in December 2015 involving a limited release of ammonia inside the spiral freezer whereby a motor fell from a conveyor belt onto the evaporator fan shroud which bent and contacted the fan blades shattering them and sending pieces into the coil rupturing it.



EMERGENCY RESPONSE PROGRAM



This facility has an Emergency Response Plan (ERP) in accordance to OSHAA?a HAZWOPER Standard 1910.120(q). The ERP defines the sequence of actions to be taken by facility employees in the event of an accidental release of hazardous materials. This ERP has been communicated to the Goodbe Fire Department, the Mandeville Fire Department, and the Local Emergency Planning Committee (LEPC).



PLANNED CHANGES TO IMPROVE SAFETY



The Diversified Foods and Seasonings, Inc., Madisonville facility is proactive on performing audits and hazard analysis per their Process Safety Management and Risk Management programs. Any areas for improvement during these audits and hazard analysis are identified and corrective actions are recommended.