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George's, Inc. Further Processing Plant

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Facility #1 : George's, Inc. Further Process


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000175758
Deregistered (Yes/No)No
Facility NameGeorge's, Inc. Further Processing Plant
Street Address Line 1701 Porter St.
CitySpringdale
StateAR
Zip Code72764
CountyWashington County
113th Congressional DistrictAR03: Arkansas 3
Owner or Operator NameGary George
Latitude36.170833
Longitude-094.137778
Number of RMP Submissions7

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000028356
Submission Typerevised submission for facility
Submission Date05/10/2012
Reason For SubmissionVoluntary update (not described by any of the above reasons)
Process Toxic Amount Total (lbs)49,017
Process Flammable Amount Total (lbs)0
Process Amount Total (lbs)49,017
Number of Potential Offsite Consequence Processes1
Potential Offsite Consequence Toxic Amount Total (lbs)49,017
Potential Offsite Consequence Flammable Amount Total (lbs)0
Potential Offsite Consequence Amount Total (lbs)49,017
All Process NAICS11232
Exec Summary Submission Date05/10/2012

Executive Summary facility_Executive_Summary help link help link (Facility #1 : George's, Inc. Further Process, executive summary: all)

Executive Summary
General Executive Summary

For

George's, Inc. Further Processing Facility



1. Accidental Release Prevention and Emergency Response Policies

We at George's, Inc. Further Processing Plant are strongly committed to employee, public and environmental safety. This commitment is demonstrated by our comprehensive accidental release prevention program that covers areas such as design, installation, operating procedures, maintenance, and employee training associated with the processes at our facility. It is our policy to implement appropriate controls to prevent possible releases of regulated substances.





2. The Stationary Source and the Regulated Substances Handled

Our facility's primary activities encompass Poultry further processing. We have 1 regulated substance present at our facility. This substance is Ammonia (anhydrous). Ammonia (anhydrous) is used for our refrigeration process.



The maximum inventory of Ammonia (anhydrous) at our facility is approximately 49017 lb.



3. The Worst Case Release Scenario(s) and the Alternative Release Scenario(s), including administrative controls and mitigation measures to limit the distances for each reported scenario

To perform the required offsite consequence analysis for our facility, we have used RMP Comp. The following paragraphs provide details of the chosen scenarios.



The worst-case release scenario submitted for Program 2 and 3 toxic substances as a class involves a catastrophic release from our Further Processing Plant. In this scenario 49017 lb. of Ammonia (anhydrous) is released from the main receiver. The toxic liquid released is assumed to form a 1 cm deep pool from which evaporation takes place. The entire pool is estimated to evaporate in 10 minutes. The maximum distance of 1.2 miles indicates that as many as9893 people could be affected.



Several alternative releases were also examined and are documented in the plan.



4. The General Accidental Release Prevention Program and the Chemical
-Specific Prevention Steps

Our facility has taken all the necessary steps to comply with the accidental release prevention requirements set out under 40 CFR part 68 of the EPA. This facility was designed and constructed in accordance with NFPA-58 Standard, 1998 Edition. The following sections briefly describe the elements of the release prevention program that is in place at our stationary source.



Process Safety Information

George's, Inc. Further Processing Plant maintains a detailed record of safety information that describes the chemical hazards, operating parameters, and equipment designs associated with all processes.



Process Hazard Analysis

Our facility conducts comprehensive studies to ensure that hazards associated with our processes are identified and controlled efficiently. The methodology used to carry out these analyses is a "What If" scenario. The studies are undertaken by a team of qualified personnel with expertise in engineering and process operations. The program is examined and chaged as necessary at least one a year.



Operating Procedures

For the purposes of safely conducting activities within our covered processes, George's, Inc. Further Processing Plant maintains written operating procedures. These procedures address various modes of operation such as initial startup, normal operations, temporary operations, emergency shutdown, emergency operations, normal shutdown and startup after a turnaround. The information is regularly reviewed and is readily accessible to operators involved in the processes.



Training

George's, Inc. Further Processing Plant has a comprehensive training program in place to ensure that employees who are operating processes are competent in the operating procedures associated with these processes. Refresher training is provided as needed.



Mechanical Integrity

Maintenance checks on process equipment to ensure proper operations are documented. Process equipment examined by these checks includes amon
g others; pressure vessels, storage tanks, piping systems, relief and vent systems, emergency shutdown systems, controls and pumps. Qualified personnel carry out maintenance operations with previous training in maintenance practices. Furthermore, these personnel are offered specialized training as needed. Any equipment deficiencies identified by the maintenance checks are corrected in a safe and timely manner.



Management of Change

Written procedures are in place at George's, Inc. Further Processing Plant to manage changes in process chemicals, technology, equipment and procedures. Process operators, maintenance personnel or any other employee whose job tasks are affected by a modification in process conditions are promptly made aware of and offered training to deal with the modification.



Pre-startup Reviews

Pre-start up safety reviews related to new processes and to modifications in established processes are conducted as a regular practice at George's, Inc. Further Processing Plant. These reviews are conducted to confirm that construction, equipment, operating and maintenance procedures are suitable for safe startup prior to placing equipment into operation.



Compliance Audits

George's, Inc. Further Processing Plant conducts audits on a regular basis to determine whether the provisions set out under the RMP rule are being implemented. These audits are carried out at least once every three years and any corrective actions required as a result of the audits are undertaken in a safe and prompt manner.



Incident Investigation

George's, Inc. Further Processing Plant promptly investigates any incident that has resulted in, or could reasonably result in a catastrophic release of a regulated substance. These investigations are undertaken to identify the situation leading to the incident as well as any corrective actions to prevent the release from reoccurring. All reports are retained for a minimum of 5 years.



Employee Participation

George's, Inc.
Further Processing Plant truly believes that process safety management and accident prevention is a team effort. Company employees are strongly encouraged to express their views concerning accident prevention issues and to recommend improvements. In addition, our employees have access to all information created as part of the facility's implementation of the RMP rule, including information resulting from process hazard analyses in particular.



Contractors

On occasion, our company hires contractors to conduct specialized maintenance and construction activities. Prior to selecting a contractor, a thorough evaluation of safety performance of the contractor is carried out. George's, Inc. Further Processing Plant has a strict policy of informing the contractors of known potential hazards related the contractor's work and the processes. Contractors are also informed of all the procedures for emergency response should an accidental release of a regulated substance occur.



5. Five-year Accident History

There have been two reportable releases in the last five years. One occurred on 5/23/2007. If was caused by an outside contractor installing an improper relief valve. The other occurred on 6/15/2007 after a faulty pop-off valve was installed.



6. Emergency Response Plan

George's, Inc. Further Processing Plant carries a written emergency response plan to deal with accidental releases of hazardous materials. The plan includes all aspects of emergency response including adequate first aid and medical treatment, evacuations, notification of local emergency response agencies and the public, as well as post-incident decontamination of affected areas.



To ensure proper functioning, our emergency response equipment is regularly inspected and serviced. In addition, the plan is promptly updated to reflect any pertinent changes taking place within our processes that would require a modified emergency response.



Washington Co. is the Local Emergency Planning Comm
ittee (LEPC) with which our emergency plan has been coordinated and verified.



7. Planned Changes to Improve Safety

Our company has state of the art equipment to prevent the accidental release of any toxic substance. We feel confident that there is no need to change anything at this time.
Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees975
Owner or Operator NameGary George
Owner or Operator Address Line 1701 Porter St.
Owner or Operator CitySpringdale
Owner or Operator StateAR
Owner or Operator Zip72764
Parent Dun and Bradstreet Number0
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees975
Number of FTE CBI FlagNo
Other Facility ID72764GRGSNMAINO
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VNo
Last Safety Inspection Date04/18/2007
Last Safety Inspection ByEPA
OSHA Star or Merit RankingNo
LEPC NameWashington LEPC

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : George's, Inc. Further Process, RMP submission #1 : 2012-05-10)
Owner or Operator Phone4799277000
Facility URLwww.georgesinc.com
Facility Phone4799277000
Facility Dun and Bradstreet Number0
RMP ContactDon Carter
RMP Contact TitleMaintenance Manager
RMP Contact Emaildon.carter@georgesinc.com

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsNo
Complete Check Date05/10/2012
Postmark Date05/10/2012
Anniversary Date05/10/2017
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link  
Latitude36.170833
Longitude-094.137778
Valid Lat/LongYes
Lat/Long MethodGPS - Unspecified
Lat/Long Location TypePlant Entrance (General)
FRS Latitude36.17
FRS Longitude-94.14
FRS Lat/Long DescriptionPLANT ENTRANCE (GENERAL)
FRS Lat/Long MethodADDRESS MATCHING-HOUSE NUMBER

Submission - Counts and Totals facility_Submission_-_Counts_and_Totals help link help link (Facility #1 : George's, Inc. Further Process, RMP submission #1 : 2012-05-10)
Number of RMP Accidents2
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)5,550
RMP Accident Amount Total (lbs)5,550
Number of RMP Accidents2
Number of Processes1
Number of Process Chemicals0
Number of Toxic Worst-case Scenarios1
Number of Toxic Alternate Case Scenarios1
Number of Flammable Worst-case Scenarios0
Number of Flammable Alternate Case Scenarios0
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)5,550
RMP Accident Amount Total (lbs)5,550
Total RMP Accident Deaths0
Total RMP Accident Injuries0
Total RMP Accident Evacuated/Sheltering In Place0
Total RMP Accident Property Damage$0

Processes facility_Processes help link help link (Facility #1 : George's, Inc. Further Process, RMP submission #1 : 2012-05-10, process #1 : Poultry Processing)
Process DescriptionPoultry Processing
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)49,017
Flammable Amount Total (lbs)0
Process Amount Total (lbs)49,017
Number of Process Chemicals0
Number of Toxic Worst-Case Scenarios1
Number of Toxic Alternate Scenarios1
Number of Flammable Worst-Case Scenarios0
Number of Flammable Alternate Scenarios0

Process Chemicals facility_Process_Chemicals help link help link  
Process Chemical IDAmmonia (anhydrous)
CAS number007664417
Chemical TypeToxic
Process Chemical Amount (lbs)49,017
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : George's, Inc. Further Process, RMP submission #1 : 2012-05-10, process #1 : Poultry Processing, process chemical #2)
Process Chemical IDPublic OCA Chemical
CAS number000000000
Process Chemical Amount (lbs)0
Confidential Business InformationNo

Worst-Case Toxic Scenarios facility_Worst-Case_Toxic_Scenarios help link help link  
Percent Weight (Within Mixture)100
Physical StateGas liquified by refrigeration
Model UsedEPA's RMP*Comp(TM)
Release Duration (minutes)10
Wind Speed (meters/sec)1.5
Atmospheric Stability ClassF
TopographyUrban
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsNo
Confidential Business InformationNo

Alternate Case Toxic Scenarios facility_Alternate_Case_Toxic_Scenarios help link help link (Facility #1 : George's, Inc. Further Process, RMP submission #1 : 2012-05-10, process #1 : Poultry Processing, process chemical #2, alternate toxic scenario #1)
Percent Weight (Within Mixture)100
Physical StateGas liquified by pressure
Model UsedEPA's RMP*Comp(TM)
Wind Speed3
Atmospheric Stability ClassD
TopographyRural
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsNo
Active Mitigation - SprinklersNo
Active Mitigation - Deluge SystemsNo
Active Mitigation - Water CurtainNo
Active Mitigation - NeutralizationNo
Active Mitigation - Excess Flow ValvesNo
Active Mitigation - FlaresNo
Active Mitigation - ScrubbersNo
Active Mitigation - Emergency ShutdownYes
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : George's, Inc. Further Process, RMP submission #1 : 2012-05-10, process #1 : Poultry Processing, process NAICS code #1 : 11232)
NAICS Code11232: Broilers and Other Meat Type Chicken Production

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date05/09/2012
PHA Update Date05/09/2012
PHA Technique - What IfYes
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPNo
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date05/09/2012
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireNo
Hazard Identified - ExplosionNo
Hazard Identified - Runaway ReactionNo
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionNo
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationNo
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossNo
Hazard Identified - EarthquakeYes
Hazard Identified - FloodNo
Hazard Identified - TornadoYes
Hazard Identified - HurricaneNo
Process Controls - VentsYes
Process Controls - Relief ValvesYes
Process Controls - Check ValvesNo
Process Controls - ScrubbersNo
Process Controls - FlaresNo
Process Controls - Manual ShutoffsNo
Process Controls - Auto ShutoffsNo
Process Controls - InterlocksNo
Process Controls - AlarmsYes
Process Controls - Keyed BypassNo
Process Controls - Emergency AirNo
Process Controls - Emergency PowerNo
Process Controls - Backup PumpNo
Process Controls - GroundingNo
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksNo
Process Controls - Excess Flow DevicesNo
Process Controls - Quench SystemNo
Process Controls - Purge SystemNo
Process Controls - NoneNo
Mitigation Systems - SprinklersYes
Mitigation Systems - DikesNo
Mitigation Systems - Fire WallsNo
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsNo
Mitigation Systems - Water CurtainsNo
Mitigation Systems - EnclosureNo
Mitigation Systems - NeutralizationNo
Mitigation Systems - NoneNo
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterNo
Monitoring Systems - NoneNo
Changes Since PHA - Reduced InventoryNo
Changes Since PHA - Increased InventoryNo
Changes Since PHA - Process ParametersNo
Changes Since PHA - Process ControlsNo
Changes Since PHA - Process DetectionNo
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneYes
Procedure Review Date02/13/2012
Training Review Date01/07/2012
Type of Training - ClassroomYes
Type of Training - On the JobYes
Competency Testing - Written TestsYes
Competency Testing - Oral TestsNo
Competency Testing - DemonstrationNo
Competency Testing - ObservationYes
Maintenance Review Date01/07/2012
Maintenance Inspection Date01/31/2012
Equipment TestedCompressor inspection and vibration review by GEA Refrigeration.
Management of Change Most Recent Date01/07/2012
Management of Change Review Date01/07/2012
Pre-startup Review Date01/07/2012
Compliance Audit Date03/11/2010
Compliance Audit Change Completion Date06/15/2010
Incident Investigation Date06/06/2007
Incident Invest. Change Completion Date06/06/2007
Participation Plan Review Date05/01/2012
Hot Work Review Date11/15/2007
Contractor Safety Review Date01/20/2012
Contractor Safety Eval. Date03/01/2012
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : George's, Inc. Further Process, RMP submission #1 : 2012-05-10, process #1 : Poultry Processing, process NAICS code #1 : 11232, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000041828

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description


Accidents facility_Accidents help link help link  
Accident Date05/23/2007
Accident Time0037
Number of Chemicals1
Flammable Amount Total (lbs)0
Toxic Amount Total (lbs)2,870
Released Amount Total (lbs)2,870
Number of Deaths0
Number of Injuries0
Number Evacuated / Sheltered0
Total Property Damage$0
Environmental DamageNo
NAICS of Process Involved11232: Broilers and Other Meat Type Chicken Production
Release Duration (HHHMM)00207
Release Event - Gas ReleaseNo
Release Event - SpillYes
Release Event - FireNo
Release Event - ExplosionNo
Release Event - ReactionNo
Release Source - Storage VesselNo
Release Source - PipingNo
Release Source - Process VesselNo
Release Source - Transfer HoseNo
Release Source - ValveYes
Release Source - PumpNo
Release Source - JointNo
Wind Speed1.5
Wind Speed Unitsmiles/h
Wind DirectionSW
Temperature68
Atmospheric Stability ClassD
PrecipitationNo
Unknown WeatherNo
Workers Killed0
Responders Killed0
Public Killed (on-site)0
Workers Injured0
Responders Injured0
Public Injured (on-site)0
Property Damage (on-site)$0
Off-site Deaths0
Hospitalizations0
Number Requiring Medical Treatment0
Number Evacuated0
Number Sheltered In Place0
Property damage (off-site)$0
Environmental Damage - Fish/Animal KillsNo
Environmental Damage - DefoliationNo
Environmental Damage - Water ContaminationNo
Environmental Damage - Soil ContaminationNo
Initiating EventEquipment Failure
Contributing Factor - Equipment FailureNo
Contributing Factor - Human ErrorYes
Contributing Factor - Improper ProcedureNo
Contributing Factor - OverpressurizationNo
Contributing Factor - Upset ConditionNo
Contributing Factor - By-pass ConditionNo
Contributing Factor - MaintenanceNo
Contributing Factor - Process DesignNo
Contributing Factor - Unsuitable EquipmentNo
Contributing Factor - Unusual WeatherNo
Contributing Factor - Management ErrorNo
Contributing Factor - OtherWrong Relief Valve Installed by Contractor
Off-site Responders NotifiedNo, not notified
Changes Introduced - Improved EquipmentYes
Changes Introduced - Revised MaintenanceYes
Changes Introduced - Revised TrainingNo
Changes Introduced - Operating ProceduresYes
Changes Introduced - Process ControlNo
Changes Introduced - Mitigation SystemsNo
Changes Introduced - Response PlanNo
Changes Introduced - Changed ProcessNo
Changes Introduced - Reduced InventoryNo
Changes Introduced - NoneNo
Total RMP Accident Deaths0
Total RMP Accident Injuries0
Total RMP Accident Evacuated/Sheltering In Place0
Total RMP Accident Property Damage$0

Accident Chemicals facility_Accident_Chemicals help link help link (Facility #1 : George's, Inc. Further Process, RMP submission #1 : 2012-05-10, accident #1, accident chemical #1)
Chemical IDAmmonia (anhydrous)
CAS number007664417
Chemical TypeToxic
Amount Released (lbs)2,870
Percent Weight (Within Mixture)99.9

Accidents facility_Accidents help link help link  
Accident Date06/15/2007
Accident Time0400
Number of Chemicals1
Flammable Amount Total (lbs)0
Toxic Amount Total (lbs)2,680
Released Amount Total (lbs)2,680
Number of Deaths0
Number of Injuries0
Number Evacuated / Sheltered0
Total Property Damage$0
Environmental DamageNo
NAICS of Process Involved11232: Broilers and Other Meat Type Chicken Production
Release Duration (HHHMM)00200
Release Event - Gas ReleaseNo
Release Event - SpillYes
Release Event - FireNo
Release Event - ExplosionNo
Release Event - ReactionNo
Release Source - Storage VesselNo
Release Source - PipingNo
Release Source - Process VesselNo
Release Source - Transfer HoseNo
Release Source - ValveYes
Release Source - PumpNo
Release Source - JointNo
Wind Speed1.5
Wind Speed Unitsmiles/h
Wind DirectionSW
Temperature70
Atmospheric Stability ClassD
PrecipitationNo
Unknown WeatherNo
Workers Killed0
Responders Killed0
Public Killed (on-site)0
Workers Injured0
Responders Injured0
Public Injured (on-site)0
Property Damage (on-site)$0
Off-site Deaths0
Hospitalizations0
Number Requiring Medical Treatment0
Number Evacuated0
Number Sheltered In Place0
Property damage (off-site)$0
Environmental Damage - Fish/Animal KillsNo
Environmental Damage - DefoliationNo
Environmental Damage - Water ContaminationNo
Environmental Damage - Soil ContaminationNo
Initiating EventEquipment Failure
Contributing Factor - Equipment FailureYes
Contributing Factor - Human ErrorNo
Contributing Factor - Improper ProcedureNo
Contributing Factor - OverpressurizationNo
Contributing Factor - Upset ConditionNo
Contributing Factor - By-pass ConditionNo
Contributing Factor - MaintenanceNo
Contributing Factor - Process DesignNo
Contributing Factor - Unsuitable EquipmentNo
Contributing Factor - Unusual WeatherNo
Contributing Factor - Management ErrorNo
Off-site Responders NotifiedNo, not notified
Changes Introduced - Improved EquipmentYes
Changes Introduced - Revised MaintenanceNo
Changes Introduced - Revised TrainingNo
Changes Introduced - Operating ProceduresNo
Changes Introduced - Process ControlNo
Changes Introduced - Mitigation SystemsNo
Changes Introduced - Response PlanNo
Changes Introduced - Changed ProcessNo
Changes Introduced - Reduced InventoryNo
Changes Introduced - NoneNo
Total RMP Accident Deaths0
Total RMP Accident Injuries0
Total RMP Accident Evacuated/Sheltering In Place0
Total RMP Accident Property Damage$0

Accident Chemicals facility_Accident_Chemicals help link help link (Facility #1 : George's, Inc. Further Process, RMP submission #1 : 2012-05-10, accident #2, accident chemical #1)
Chemical IDAmmonia (anhydrous)
CAS number007664417
Chemical TypeToxic
Amount Released (lbs)2,680
Percent Weight (Within Mixture)99.9

Emergency Response Plan Info facility_Emergency_Response_Plan_Info help link help link  
Facility In Community PlanYes
Facility Own Response PlanYes
Specific Facility Response PlanYes
Inform. Procedures in Response PlanYes
Emergency Care in Response PlanYes
Plan Review Date02/26/2009
Response Training Date02/26/2009
Local Response AgencySpringdale Fire Department
Local Response Agency Phone4797514510
Subject To - OSHA EAPYes
Subject To - OSHA HAZWOPERYes
Subject To - CWANo
Subject To - RCRANo
Subject To - OPANo
Subject To - State EPCRANo


Search Criteria Used
RMP Facility ID100000175758

*END OF REPORT*