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Reddy Ice-Bogalusa (328)

Parent Companies:
Reddy Ice Corporation
EPA Facility ID:
100000188192
Other ID:
Facility DUNS:
0
Parent Company DUNS:
364514133

Location:

Address:
2032 Columbia Street
Bogalusa, LA 70427
County:
WASHINGTON
Lat / Long:
30.752, -89.849 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Process Unit
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
Reddy Ice Corporation
Phone:
(214) 526-6740
Address:
5720 LBJ Freeway
Suite 200
Dallas, TX 75240
Foreign Address:

Person responsible for RMP implementation:

Name:
Windell Keating
Title:
Plant Manager

Emergency contact:

Name:
Windell Keating
Title:
Plant Manager
Phone:
(985) 732-3831
24-hour phone:
(985) 516-0578
Ext or PIN:
32881

Other contacts:

Facility (or company) email:
Facility phone:
(800) 628-4423
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Washington Parish LEPC
Full-Time Equivalent Employees:
9
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:
April 15, 2014
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

Ammonia Refrigeration
RMP ID:
1000053266
CBI claimed:
No
Program Level:
3
NAICS:
Ice Manufacturing (312113)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
21,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
May 29, 2014
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
No
RMP ID:
1000043198

Deregistration:

Date:
Effective Date:
Reason:
Source no longer uses any regulated substance
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:
  • Enclosures
not considered:
  • Dikes
  • 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
not considered:
  • Dikes
  • 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

No Registered Accidents

7. Prevention: Program level 3

Ammonia Refrigeration, Ice Manufacturing (312113)
Prevention Program ID:
1000044778
Safety Review Date
Dec. 22, 2013, since latest RMP submission
PHA Update Date
Dec. 22, 2013, since latest RMP submission
PHA Techniques
  • Checklist
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Equipment failure
  • Hurricanes
Process Controls
  • None
Mitigation Systems
  • Enclosure
  • Neutralization
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
Feb. 22, 2014, since latest RMP submission
Training Review Date
Sept. 25, 2012, since latest RMP submission
Maintenance Review Date
Sept. 25, 2012, since latest RMP submission
Maintenance Inspection Date
May 28, 2014, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
None
Management of Change Review Date
Dec. 22, 2013
Pre-startup Review Date
None
Compliance Audit Date
Sept. 25, 2012
Compliance Audit Change Completion Date
Sept. 25, 2013
Incident Investigation Date
Aug. 21, 2012
Incident Invest. Change Completion Date
Sept. 21, 2012
Participation Plan Review Date
Sept. 25, 2012
Hot Work Review Date
Sept. 25, 2012
Contractor Safety Review Date
Sept. 25, 2012, since latest RMP submission
Contractor Safety Eval. Date
None, 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:
No
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
No
Plan Review Date:
Response Training Date:
None
Local Response Agency:
Local Response Agency Phone:
(504) 732-5200
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

PROCESS SUMMARY

Reddy Ice-Bogalusa (328), located at 2032 Columbia Street, Bogalusa, Louisiana, is a manufacturer of ice for wholesale and retail distribution. The facility has a potential production capacity of 250 to 300 tons of ice per day and utilizes of anhydrous ammonia as the refrigerant for ice manufacturing and storage.



The refrigeration operation makes use of standard design ammonia systems. There are eight distinct refrigeration systems in the plant with numerous protective controls including motor overload, high discharge temperature, high discharge pressure, low suction pressure, low oil differential on all compressors, high level cutouts on all vessel and approved pressure relief valves on all applicable equipment. Each system is comprised of one or more compressor packages, evaporative or shell and tube condensers, high-pressure and/or low-pressure ammonia vessels, and either tube icemakers or air-cooling evaporators.



Anhydrous ammonia, when properly used, has proven to be a safe and reliable refrigerant. The sharp odor of ammonia provides its own warning agent. Practically all accidents involving anhydrous ammonia can be avoided through the facility's program of proper training; knowledge of the equipment and procedures; and conducting preventive maintenance on all ammonia equipment. Reddy Ice has instituted administrative and engineering controls as well as training programs on the corporate level to prevent such accidents.



The facility has multiple safeguards pertinent to the anhydrous ammonia process. These include machinery room ventilation systems, controls which shut down the compressors if operating limits are exceeded, computerized PLC controls on the icemaker system in Machinery Room 2, pressure relief valves on all vessels, and the capability of shutting down the entire system if required.



The company has developed an emergency action plan that includes procedures for notification of emergency authorities/agencies and the publi
c, evacuation of personnel, and first responder duties by trained refrigeration personnel.



RISK MANAGEMENT PREVENTION PROGRAM 3

Based on the Reddy Ice-Bogalusa facility's ammonia inventory, location, and requirement to meet OSHA PSM standards, it has been determined the facility is subject to the Prevention Program 3 requirements. This accident prevention program is a way to make safe operations and accident prevention systematic throughout the facility. Reddy Ice corporate management and Reddy Ice-Bogalusa management are committed to operating a safe and compliant facility for the protection of its employees, the public, and the environment. A Combined Process Safety Management/Risk Management (PSM/RMP) Program has been developed to meet the accidental release prevention requirements of both EPA's Risk Management Program (40 CFR Part 68) and OSHA's Process Safety Management Standard (29 CFR 1910.119) under the Clean Air Act. The Combined PSM/RMP Program contains thirteen elements, establishing requirements for employee participation, process safety information, hazard analysis, pre-startup safety review, operating procedures, employee training, management of change, mechanical integrity, hot work permits, contractor qualifications, incident investigation, compliance audits, and trade secrets. These elements are tied together by a management system to ensure plant-wide development, implementation and integration of all the program requirements.



MANAGEMENT SYSTEM

A management system has been developed to oversee the implementation of the PSM/RMP Program elements. The plant manager has been identified as PSM/RMP Program Coordinator, with overall responsibility for developing, implementing and integrating the program requirements. Under the PSM/RMP Program, various responsibilities have been assigned to other individuals. The maintenance lead is responsible for portions of the program closely tied to the refrigeration equipment and operation. Each department ma
y conduct monthly safety meetings covering topics pertinent to the job hazards in that area.



HAZARD ASSESSMENT

As required by the Risk Management Program regulations, the Reddy Ice-Bogalusa facility has conducted a hazard assessment including offsite consequence analyses (OCAs) for potential accidental releases of anhydrous ammonia. The OCAs describe the potential offsite exposure to surrounding areas from an accidental release. A worst-case release scenario and alternative release scenarios were developed and calculated using the EPA RMP*Comp modeling program, and the potentially affected offsite population and facilities were identified.



FIVE-YEAR ACCIDENT HISTORY

The Reddy Ice-Bogalusa facility has not had a release within the last five years that would require reporting as part of a five-year accident history.



EMERGENCY PLANNING AND RESPONSE

The Reddy Ice-Bogalusa facility operates under an Emergency Action Plan ("EAP") that includes procedures for: notifying plant personnel, the public, and local emergency responders; emergency evacuation/response procedures; use of emergency alarms and equipment; employee training in evacuation and response procedures; first aid for ammonia exposure; and periodic review and updating of the emergency action plan. The plan is reviewed regularly for verification of data, and revised and updated as necessary to reflect changes in facility operations and personnel.



As required, the facility has coordinated emergency response activities with the Washington Parish Office of Emergency Preparedness and the Bogalusa Fire Department, and has appropriate mechanisms in place to notify emergency responders if needed. The ammonia inventory is verified and reported annually to the state and local authorities, and the plant is incorporated into the community emergency response plan developed under 42 USC.



PLANNED CHANGES

The Reddy Ice-Bogalusa facility operates an ongoing program for continuous improvement to identify and i
mplement changes that may result in risk reduction and operational excellence.