Fair Oaks Farms, LLC - Executive Summary

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ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES 
 
The Fair Oaks Farms facility has an emergency response plan in effect. The Emergency Response Plan (Plan) is detailed in the Emergency Planning and Response section of this PSM/RMP document.  This Plan was designed to meet the following objectives: 
 
1.  To save lives. 
2.  To minimize and avoid injuries. 
3.  To protect the environment. 
4.  To minimize property damage. 
 
Fair Oaks Farms maintains a safety committee whose members are the designated emergency coordinators for the facility.  The Plan provides the response organization and notification procedures, evacuation routes, ammonia health hazards, and mitigation procedures which will be implemented to 
respond effectively to emergency situations that may arise at the facility.  This Plan is reviewed and updated at least once per year. This Plan was reviewed and updated to ensure compliance with the PSM and RMP regulations, as well as to incorporate facility changes. 
 
STATI 
ONARY SOURCE AND REGULATED SUBSTANCE 
 
The Fair Oaks Farms ammonia refrigeration system has been in operation since 1992. The ammonia refrigeration process was designed and constructed in accordance with all applicable federal, state, and local regulations.  The facility is located at 7600 95th St. in Pleasant Prairie, WI 53158. 
 
The ammonia refrigeration system uses approximately 12,500 pounds of ammonia for the processing and cold storage of meat products..  The majority of the system is located in the engine room including vessels and compressors.  The condensers and high pressure receiver are mounted on the engine room roof, and all of the evaporators are located in their respective cold process/storage rooms/areas. 
 
ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION 
STEPS 
 
The Fair Oaks Farms facility was designed and constructed in accordance with ammonia refrigeration industry safety and design standards (Uniform Mechanical Code). In addition, the majority of  
the ammonia is maintained inside the engine room or on the engine room roof.   The engine room is provided with continuous ventilation and all equipment are monitored for temperature and pressure 24 hours a day.  The facility is secured and guarded at all times. 
 
In addition to the Uniform Mechanical Code, the facility will operate in accordance with the International Institute of Ammonia Refrigeration (IIAR) guidelines.  In particular, the IIAR Bulletin 110, "Startup, Inspection, and Maintenance of Ammonia Refrigeration Systems." 
 
HAZARD ASSESSMENT SUMMARY 
 
Worst Case Release Result Summary 
 
Scenario Description: Release of the maximum quantity of ammonia that can be stored in the high pressure receiver - 12,500 pounds - in 10 minutes.  No passive mitigation measures were used.  The most pessimistic meteorological conditions were used: 1.5 m/s and F stability.  The EPA's RMP Guidance for Ammonia Refrigeration  Reference Tables were used to determine the distance to the toxic endpoint  
of 200 ppm.  This release reaches offsite and may affect public receptors.  No environmental receptors were affected by this potential release. 
 
Alternative Release Result Summary 
 
Scenario Description: A 0.25 inch diameter leak of high pressure liquid ammonia for one hour.  The quantity of ammonia released in one hour at this rate is 7600 pounds.  The meteorological conditions used were 3 m/s and D stability.  The EPA's RMP Guidance for Ammonia Refrigeration  Reference Tables were used to determine the distance to the toxic endpoint of 200 ppm.  This release reaches offsite and may affect public receptors.  No environmental receptors were affected by this potential release. 
 
FIVE YEAR ACCIDENT HISTORY 
 
This facility has been in operation since 1992 and changes/modifications have taken place since the completion.  There is no accident history at this facility from June 1994 through June 1999. 
 
EMERGENCY RESPONSE PROGRAM 
 
Fair Oaks Farms maintains a safety committee whose members are th 
e designated emergency coordinators for the facility.  The Plan provides the response organization and notification procedures, evacuation routes, ammonia health hazards, and mitigation procedures which will be implemented to respond effectively to emergency situations that may arise at the facility.  This Plan is reviewed and updated at least once per year. This Plan was reviewed and updated to ensure compliance with the PSM and RMP regulations.  In the event that an ammonia leak is discovered, the person nearest to the leak will alert any personnel in the immediate area who are unaware of the danger, and the Fair Oaks Farms Maintenance Supervisor (if he is present).  He will then use a portable radio to inform the other managers and contractors of the situation. The Fair Oaks Farms Maintenance Supervisor will determine what procedures and personnel are necessary to remedy the problem.  Emergency agencies will also be notified as neccessary as outlined in the Emergency Repsonse Plan. 
 
 
PLANNED CHANGES TO IMPROVE SAFETY 
 
The Process Hazard Analysis provided the mitigation measures outlined below to improve safety at the Fair Oaks Farms facility located at 7600 95th St. in Pleasant Prairie, WI 53158.  The recommendations will be implemented by June 1, 2000. 
 
R01:  Replace relief valves every five years. 
 
R02:  Install an ammonia release detection system, with remote alarms (Security Office and ADS). Release detection should also tie in to automatic ventilation system, per IIAR Bulletin #111. 
 
R03:  Alarm system should be upgraded to provide visual and audible alarm and a remote signal. 
 
R04:  Preventative Maintenance shall include replacing critical solenoid valves every five years. 
 
R05:  Consider installation of ammonia sensors in each room with an evaporator.  Sensors should have audible and visual alarms, as well as remote signals at Engine Room Office, Maintenance Shop, Security Office, and/or ADS.  Sensors should also be tied in with the solenoid valves so they  
will close automatically. 
 
R06:  Drain oil on regular weekly or monthly schedule. 
 
R07:  Install emergency quick drench shower in the Engine Room. 
 
R08:  Install self-closing valves on intercooler oil pots. 
 
R09:  Assure ATMP have proper training and understand the consequences of unattended open valves. 
 
R10:  Install rupture disk on relief valves without a common header; 6 on evaporative condensers, 13 total on system. 
 
R11:  Install ammonia sensor in common header on rooftop.
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