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Borden Dairy Company of Texas, LLC

Parent Companies:
EPA Facility ID:
100000211861
Other ID:
70506BRDNN1308B
Facility DUNS:
0

Location:

Address:
1308 Bertrand Dr.
Lafayette, LA 70506
County:
LAFAYETTE
Lat / Long:
30.222, -92.052 (Get map)
Method:
Interpolation - Photo
Description:
Plant Entrance (General)
Horizonal accuracy:
25 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:
24000

Owner/Operator:

Name:
Borden Dairy Company
Phone:
(337) 232-5172
Address:
1308 Bertrand Dr.
Lafayette, LA 70506
Foreign Address:

Person responsible for RMP implementation:

Name:
David Woolverton
Title:
Plant Manager

Emergency contact:

Name:
David Woolverton
Title:
Plant Manager
Phone:
(337) 735-1865
24-hour phone:
(337) 501-1304
Ext or PIN:

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Lafayette Parish LEPC
Full-Time Equivalent Employees:
165
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:
Aug. 13, 2013
Inspecting Agency:
State environmental agency
Using Predictive Filing:
No

Processes:

Ammonia Refrigeration
RMP ID:
1000085877
CBI claimed:
No
Program Level:
3
NAICS:
Fluid Milk Manufacturing (311511)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
18,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Compliance Partners, Inc.
Address:
402 E. Avenue G
Midlothian, TX 76065
Foreign Address:

Phone:
(972) 723-9509

Latest RMP Submission:

Date:
March 8, 2018
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000068459

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:
99.9
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:
99.9
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:
  • 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

No Registered Accidents

7. Prevention: Program level 3

Ammonia Refrigeration, Fluid Milk Manufacturing (311511)
Prevention Program ID:
1000072535
Safety Review Date
Dec. 21, 2017, since latest RMP submission
PHA Update Date
May 29, 2015, since latest RMP submission
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Toxic release
  • Fire
  • Explosion
  • Overpressurization
  • Corrosion
  • Overfilling
  • Contamination
  • Equipment failure
  • Cooling loss
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Grounding Equipment
Mitigation Systems
  • Enclosure
Monitoring Systems
  • None
Changes since PHA
  • None
Training Type
  • On the Job
Competency Testing
  • Observation
Procedure Review Date
Dec. 13, 2017, since latest RMP submission
Training Review Date
Dec. 21, 2017, since latest RMP submission
Maintenance Review Date
Oct. 10, 2017, since latest RMP submission
Maintenance Inspection Date
Dec. 21, 2017, since latest RMP submission
Equipment Tested
Yes
Management of Change Most Recent Date
Feb. 20, 2018
Management of Change Review Date
Dec. 21, 2017
Pre-startup Review Date
None
Compliance Audit Date
May 2, 2016
Compliance Audit Change Completion Date
June 30, 2017
Incident Investigation Date
None
Incident Invest. Change Completion Date
None
Participation Plan Review Date
Dec. 21, 2017
Hot Work Review Date
Dec. 21, 2017
Contractor Safety Review Date
Dec. 21, 2017, since latest RMP submission
Contractor Safety Eval. Date
Dec. 18, 2017, since latest RMP submission

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
No
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. 18, 2017
Local Response Agency:
Local Response Agency Phone:
(337) 291-8701
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

EXECUTIVE SUMMARY



Process Description and Regulated Substances



Borden Dairy Company (Borden) primary business is milk, flavored milk, and beverage processing, packaging, and distribution. The facility is located at 1308 Bertrand Drive, Lafayette, Louisiana 70506. The SIC code for the operation is 2026; the NAICS code is 311511. The facility has approximately 165 full time employees and operates 24 hours/day, 7 days/week, 52 weeks/year.



The facility operates an ammonia refrigeration system as part of the process to keep products and raw materials fresh. 40 CFR 68.130 lists anhydrous ammonia as a hazardous chemical subject to RMP regulation with a threshold quantity of 10,000 lbs. The refrigeration system inventory exceeds the 10,000 lb. threshold.



The facility has not experienced a significant release incident as defined by 40 CFR 68.28. Ammonia is recirculated in the system as a liquid and gas depending on system operating pressures and temperatures. The refrigeration system is designed, installed and operated in accordance with the applicable guidelines and standards of the American Society of Mechanical Engineers (ASME), the American National Standards Institute (ANSI), the International Institute of Ammonia Refrigeration (IIAR), the American Society of Heating, Refrigerating, and Air-conditioning Engineers, Inc. (ASHRAE).



Five Year Accident History



The facility has not experienced an accidental release of ammonia during the previous five years that resulted in deaths, injuries, evacuations, sheltering in place, property damage or environmental damage.



Release Prevention and Emergency Response Policies



The facility has evaluated and reported one worst case scenario and has evaluated alternate scenarios and reported one which will result in an offsite impact that is more likely to occur than the worst case scenario.



The system is monitored and inspected by technicians that are trained, qualified, and experienced in ammonia refrig
eration in accordance with the facility's PSM program. The system is inspected periodically for proper operation 24 hours per day. Walking inspections are conducted on intervals not longer than 8 hours during business/production hours. System parameters are logged in a permanent record, as are routine maintenance activities.



The system is equipped with a series of redundant failsafe devices, sensors, and overrides. In the event a malfunction occurs that could result in an ammonia release, these protective devices shut the system down. The system can't be restarted until the cause of the shutdown is identified and corrected. The system is equipped with a shutdown system that is triggered by the presence of ammonia in the engine room. The system shutdown can be manually operated using a kill switch located outside the engine room.



General Accidental Release Prevention Program and Chemical-Specific Prevention Steps



The facility has developed and implemented a Process Safety Management Program (PSM) in accordance with the Occupational Safety and Health Administration (OSHA) Standard, 29 CFR 1910.119. This serves as the prevention plan required by RMP. Qualified outside contractors are used for construction and major repairs or modifications to the system. The facility's PSM program includes provisions for process hazard analyses, management of change, pre-start up safety reviews, safe work practices, inspections, testing, maintenance, compliance audits, and contractor qualifications. The PSM program is reviewed annually and updated as necessary. All significant changes to the system are reviewed in accordance with the PSM / RMP management of change provisions in the facility's plan.



Emergency Response Program



The facility has made arrangements with the local fire department and outside contractors to respond to emergencies involving ammonia. The facility conducts periodic incident response drills. The facility has never experienced an ammoni
a release that resulted in employee, contractor or off-site injuries, or offsite evacuation or sheltering in place. Facility personnel are trained to safely control small, incidental releases of ammonia, in the event they should occur.



The facility has complied with the requirements of section 302 and 303 of the Emergency Planning and Community Right to Know Act (EPCRA) by notifying the State Emergency Response Commission (SERC), the Local Emergency Planning Committee (LEPC), and the Fire Department of the presence of ammonia at the site. The facility files a Tier 2 Chemical Inventory each year with the SERC, LEPC and the Fire Department as required by sections 311 and 312 of EPCRA. The facility's Emergency Action Plan includes procedures for notifying the proper agencies in the event of a reportable release of ammonia. A release of 100 pounds or more must be reported to the National Response Center, the SERC, and LEPC, in accordance with section 304 of EPCRA. The Fire Department will be provided with a copy of the facility's Emergency Action Plan upon request.



Planned Changes to Improve Safety



The prevention plan includes routine and periodic inspections and audits of the process and prevention programs to identify potential deficiencies. The Process Hazard Analyses are conducted initially, as part of major additions or modifications and every five years to identify potential hazards in the process and provide recommendations to eliminate or reduce hazards and improve process safety and efficiency.