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Lamb Weston Delhi Plant

Parent Companies:
Lamb Weston, Inc.
EPA Facility ID:
100000210041
Other ID:
7123WDLHCN77HWY
Facility DUNS:
23099728
Parent Company DUNS:
801242202

Location:

Address:
77 Hwy 609
Delhi, LA 71232
County:
RICHLAND
Lat / Long:
32.459, -91.574 (Get map)
Method:
Interpolation - Photo
Description:
Administrative Building
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Lamb Weston, Inc.
Phone:
(318) 878-3420
Address:
77 Hwy 609
P.O. Box 668
Delhi, LA 71232
Foreign Address:

Person responsible for RMP implementation:

Name:
Thomas Proger
Title:
Plant Manager

Emergency contact:

Name:
Randall Veasey
Title:
Engineering Manager
Phone:
(318) 878-3420
24-hour phone:
(318) 331-3974
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Richland Parish LEPC
Full-Time Equivalent Employees:
275
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:
March 21, 2017
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Unspecified process
RMP ID:
1000062862
CBI claimed:
No
Program Level:
3
NAICS:
Frozen Fruit, Juice, and Vegetable Manufacturing (311411)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
28,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Address:

,
Foreign Address:

Phone:

Latest RMP Submission:

Date:
June 4, 2015
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000050009

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 Unspecified process)
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:
Rural
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 Unspecified process)
CBI claimed:
No
Percent weight:
Physical state:
Gas
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
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

July 2, 2011 at 02:20
ID:
1000038622
NAICS:
Frozen Fruit, Juice, and Vegetable Manufacturing (311411)
Duration:
20 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
0.100000001 miles/h
Temperature:
80.00 ℉
Atmospheric stability:
F
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:
1
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Human Error
Contributing factors:
  • Human error
  • Improper procedure
  • Overpressurization
  • Upset condition
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised training
  • Revised operating procedures
  • New process controls
  • Revised emergency response plan
  • Changed process

7. Prevention: Program level 3

, Frozen Fruit, Juice, and Vegetable Manufacturing (311411)
Prevention Program ID:
1000052232
Safety Review Date
March 30, 2015, since latest RMP submission
PHA Update Date
Oct. 6, 2011, since latest RMP submission
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
  • Hurricanes
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Power
  • Backup Pump
  • Excess Flow Device
Mitigation Systems
  • Fire Walls
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Written Test
  • Oral Test
  • Demonstration
  • Observation
Procedure Review Date
March 6, 2015, since latest RMP submission
Training Review Date
Feb. 2, 2015, since latest RMP submission
Maintenance Review Date
May 8, 2015, since latest RMP submission
Maintenance Inspection Date
May 14, 2015, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
March 6, 2013
Management of Change Review Date
May 18, 2015
Pre-startup Review Date
Sept. 5, 2013
Compliance Audit Date
March 6, 2015
Compliance Audit Change Completion Date
Dec. 31, 2015
Incident Investigation Date
July 2, 2011
Incident Invest. Change Completion Date
May 17, 2012
Participation Plan Review Date
March 13, 2014
Hot Work Review Date
May 21, 2012
Contractor Safety Review Date
July 13, 2012, since latest RMP submission
Contractor Safety Eval. Date
April 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:
Feb. 16, 2015
Local Response Agency:
Local Response Agency Phone:
(318) 728-2071
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

CORPORATE SAFETY COMMITMENTS



ConAgra Foods Lamb Weston has potato processing plants located in Washington, Oregon, Idaho, Minnesota, and Louisiana. ConAgra Foods Lamb Weston is committed to providing its employees and the surrounding community with a safe and healthy environment. The Risk Management Program is an integral part of our strong commitment to "sustainable development," which means development that meets the needs of the present without compromising the ability of future generations to meet their own needs. Sustainable Development requires reductions in the generation of wastes and pollutants, protection of clean air and clean water, sustainable protection of the land, and the wise use of energy. It requires employee commitment, strategic thinking, and innovation, the involvement of our suppliers, new technology and enhanced production processes.



DESCRIPTION OF FACILITY AND REGULATED SUBSTANCES



The Lamb Weston processing facility in Delhi, Louisiana processes raw sweet potatoes into finished consumer frozen potato products. The plant site consists of a main processing plant, primary water treatment facility, and refrigerated cold storage. Activities are conducted at this site during all months of the year.



The potato processing cycle includes a wide array of steps. The plant purchases the majority of its potatoes from local growers. Since potatoes have a single growing season, they must be held under controlled storage conditions. Prior to processing, the potatoes are separated by size and processing specifications. The inspected, washed, peeled, and hand-trimmed potatoes are cut, blanched and fried. The final products are frozen, packaged and prepared for shipping.



The freezing process where finished products are conveyed through the freezer to be quickly cooled and frozen is made possible by refrigeration systems containing anhydrous ammonia, an EPA-regulated chemical. Virtually all major food processors, including Lamb Weston
, utilize anhydrous ammonia in large refrigeration or freezing plants and the chemical has been used in this capacity since the 1850's.



ACCIDENTAL RELEASE PREVENTION PROGRAM



ConAgra Foods Lamb Weston's accident prevention/loss control systems and policies involve a unified approach that integrates technologies, procedures, and best-management practices. The OSHA-PSM and the EPA-RMP plans work together to assure that potential on-site hazards and off-site consequences are identified and controlled to the best of our ability, and that the processes are meeting health and safety objectives.



The RMP Prevention Program is comprised of the 13 elements of OSHA's PSM program: Employee Participation, Process Safety Information, Process Hazard Analysis, Management of Change, Pre-Startup Safety Review, Operating Procedures, Hot Work Permits, Employee Training, Incident Investigation, Mechanical Integrity, Emergency Planning & Response, Contractor Safety, and Audits.



Employee participation brought together people that knew and understood the system, from practical experience as well as their technical knowledge, to develop the Plan. Process safety information is a collection of data that allows us to identify and understand the hazards posed by our inventory. Representatives from our skilled work force and management, who understood the process being analyzed including the engineering behind the covered process, conducted the process hazard analysis. This analysis identifies potential process failures that could result in an uncontrolled release of ammonia.



In order to safely manage changes that need to be made to the processes containing ammonia, a system of checks and balances has been established. This system will evaluate safety prior to the work being done, and provide a solid review of the system to assure that once started, it will run as designed. Standard operating procedures are in place for each operating phase and are readily accessible t
o those workers who operate or maintain the process. In addition, a policy and procedure are used to assure that proper safety precautions are taken for all personnel performing Hot Work. The integrity of the refrigeration system equipment is maintained according to recognized and generally accepted good engineering practices and according to a well-documented preventive maintenance program.



An extensive training program is in place for those employees and contractors involved in working on or around the process and covers operating procedures, health and safety hazards, emergency operations, and safe work practices. The facility also has a training program for all employees and contractors regarding the hazards of the chemical and safe work practices to be used. Part of this training includes monthly safety meetings as well as drills on spill response and plant evacuation.



Any incidents related to the ammonia refrigeration systems are promptly investigated even though the rule only requires investigation of those incidents, which resulted in, or could reasonably have resulted in, a catastrophic release. All incidents are analyzed, resolved, and findings shared with affected employees. In order to assure compliance with all elements of the prevention program, an audit is conducted every three years including a report of the findings and documentation of any deficiencies corrected.



FIVE-YEAR ACCIDENT HISTORY



The Lamb Weston Delhi facility was newly constructed in 2009-2010. On July 2, 2011 the facility released approximately 6,000 pounds of ammonia when a storage vessel relief valve vent lifted. The release resulted in an off-site evacuation. No other incidents have resulted in deaths, injuries, or significant property damage on site, or known offsite deaths, injuries, evacuations, sheltering in place, property damage, or environmental damage.



EMERGENCY RESPONSE PROGRAM



The Lamb Weston Delhi facility has an emergency action plan which h
as been coordinated (reviewed) with the Delhi Fire Department. Both are members of the Local Emergency Response Planning Committee.



The plan applies to all Lamb Weston Delhi employees, visitors, and support service contractors performing tasks and activities as part of ongoing operations. The purpose of the plan is to establish policies and procedures for protecting the health and safety of employees, contractors, and visitors, and to comply with all applicable federal and state regulations. Training of employees and contractors includes providing a copy of the plan upon initial employment at Lamb Weston Delhi and reviewing it for their specific assignment, annual refresher training for current employees, and review for all whenever the plan is changed. In addition, plant evacuation drills are conducted on a regular basis.



The plan is comprehensive enough to deal with all types of emergencies specific to the Lamb Weston Delhi facility and defines the following:



? How to conduct activities in a manner that protects the safety of employees, the public, and the environment



? Preferred means for reporting fires, hazardous materials incidents, medical, and any other emergencies



? Emergency escape procedures and emergency escape route assignments



? Procedures to account for all employees including contractors and visitors



? Names of agencies and persons to contact for further assistance, information, or explanation of the plan



PLANNED CHANGES TO IMPROVE SAFETY



The Lamb Weston Delhi facility takes seriously its responsibility for the safety of its employees, neighbors, and community. Central to this responsibility are our programs to prevent the release of chemicals to the environment. We will continue to implement these precautions and programs, to act as a responsible neighbor, and to maintain the goodwill of the community.