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Tyson Foods Sherman, TX Case Ready Plant

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Facility #1 : Tyson Foods Sherman, TX Case R


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000194112
Deregistered (Yes/No)No
Facility NameTyson Foods Sherman, TX Case Ready Plant
Street Address Line 14700 Hwy 75 S
CitySherman
StateTX
Zip Code75092
CountyGrayson County
113th Congressional DistrictTX04: Texas 4
Owner or Operator NameTyson Foods, Inc.
Parent CompanyTyson Foods, Inc.
Latitude33.580320
Longitude-96.606189
Number of RMP Submissions2

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000019678
Submission Typerevised submission for facility
Submission Date01/06/2011
Reason For Submission5-year update (40 CFR 68.190(b)(1))
Process Toxic Amount Total (lbs)116,000
Process Flammable Amount Total (lbs)0
Process Amount Total (lbs)116,000
Number of Potential Offsite Consequence Processes1
Potential Offsite Consequence Toxic Amount Total (lbs)116,000
Potential Offsite Consequence Flammable Amount Total (lbs)0
Potential Offsite Consequence Amount Total (lbs)116,000
All Process NAICS311612
Exec Summary Submission Date01/06/2011

Executive Summary facility_Executive_Summary help link help link (Facility #1 : Tyson Foods Sherman, TX Case R, executive summary: all)

Executive Summary
1. Accidental Release Prevention and Emergency Response Polices:
To insure safe operation and to prevent releases at Tyson Foods' Sherman, TX facility, the plant has implemented Occupational Safety and Health Administration's (OSHA) Chemical Process Safety Management Program 29 CFR 1910.119 (PSM). All operators of the ammonia refrigeration system are trained on the PSM program and receive operator training specific to the facility's refrigeration system.

To insure proper and effective responses to emergency situations this facility has implemented emergency action plans as required by OSHA's PSM rule.

2. Stationary Source and Regulated Substances Handled:
Pork and Beef further processing facility
Regulated Substance(s): Anhydrous Ammonia, i.e. NH3

3. General Accidental Release Prevention Program:
This facility complies with OSHA's PSM program and with Environmental Protection Agency's (EPA) Risk Management Program 40 CFR Part 68 (RMP). Tyson Foods also has adopted recommended installation, system operation and maintenance guidelines published by the International Institute of Ammonia Refrigeration (IIAR) for our facility refrigeration systems.

4. Five-year Accident History:
One incident involving the overpressurazation of the Chester Jensen water Chiller. Process controls and training were change to prevent reoccurance.

5. Emergency Response Program:
A fully trained and equipped Emergency Response Team is on site. This team is trained to the level of a Hazardous Materials Responder-Technician in accordance with OSHA 29 CFR 1910.120(q). The team is capable of affecting all control measures (both confinement and containment operations) required to remediate an incident.

A written Emergency Response Plan has been developed and is on record at the facility. This plan includes Pre-Emergency Planning with outside agencies, personnel roles and lines of incident command authority, facility hazard analysis and emergency prevention, safe distances and places of re
fuge, site security and control, evacuation routes and procedures, chemical response procedures, post incident critique and personal protective clothing and emergency equipment.

All HAZMAT (hazardous materials) courses at Tyson Foods, Inc. are designed to meet training requirements of the OSHA 29 CFR 1910.120(q)(7) and (8). All Sherman, TX HAZMAT team members are initially trained 24 hours to the Technician level and to be followed by eight to 24 hours of refresher training per year under the direction of the on-site HAZMAT Instructor at the facility. Each HAZMAT Instructor receives an initial 40 hours of training and then eight to hours per year of re-certification training that takes the instructor to the Incident Commander (I.C.) level of HAZMAT training.

The training is designed to teach both theory and hands-on training, thus giving the person an overall understanding of the nature of hazardous materials and the ability to assess and safely respond to the incidents in the Incident Command structure. Technician level training includes but is not limited to the following:
*Knowledge of basic hazards and risk assessment techniques
*Proper selection and use of appropriate and required PPE for the chemical hazard
*Terminology associated with HAZMAT
*Advanced site control/security procedures
*Advanced Containment/Control/Decontamination procedures
*Use of atmospheric monitoring equipment and containment test procedures
*Incident Command Structure Roles and Line of Authority
*Interaction with local and state officials
*Standard operating procedures for clean-up and termination
*Critique

All training materials, hands-on drills and response procedures have been developed under the direction of Tyson's corporate Environmental Health and Safety department.

All Tyson team members are taught in Hazard Communication to report any observed chemical leaks/spills and odors to their supervisor or lead-person immediately. Supervisors and Leads are taught to report these s
ituations to the Safety or Process Manager immediately for further investigation and action to be taken by the HAZMAT team. Material Safety Data Sheet (MSDS) information is available to all Tyson team members for review.

6. Planned Changes To Improve Safety:
There will be continued inspections of equipment with repair or replacement as needed.
Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees1,500
Owner or Operator NameTyson Foods, Inc.
Owner or Operator Address Line 14700 Hwy 75 S
Owner or Operator CitySherman
Owner or Operator StateTX
Owner or Operator Zip75092
Parent Dun and Bradstreet Number6903702
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees1,500
Number of FTE CBI FlagNo
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VNo
Last Safety Inspection Date01/15/2010
Last Safety Inspection ByFire Department
OSHA Star or Merit RankingNo
LEPC NameGrayson County LEPC

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : Tyson Foods Sherman, TX Case R, RMP submission #1 : 2011-01-06)
Owner or Operator Phone9038916000
Facility Phone9038916000
Facility Dun and Bradstreet Number0
RMP ContactJoseph Gerleman
RMP Contact TitleComplex Manager
RMP Preparer NameJessie L. Liles Sr.
RMP Preparer Address Line 14700 Hwy 75 South
RMP Preparer CitySherman
RMP Preparer StateTX
RMP Preparer Zip75090
RMP Preparer Phone9038916013

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsNo
Complete Check Date01/06/2011
Postmark Date01/06/2011
Anniversary Date01/06/2016
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link (Facility #1 : Tyson Foods Sherman, TX Case R, RMP submission #1 : 2011-01-06)
Latitude33.580320
Longitude-96.606189
Valid Lat/LongYes
Lat/Long MethodInterpolation - Digital map source (TIGER)
Lat/Long Location TypeOther

Submission - Counts and Totals facility_Submission_-_Counts_and_Totals help link help link  
Number of RMP Accidents1
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)371
RMP Accident Amount Total (lbs)371
Number of RMP Accidents1
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)371
RMP Accident Amount Total (lbs)371
Total RMP Accident Deaths0
Total RMP Accident Injuries0
Total RMP Accident Evacuated/Sheltering In Place202
Total RMP Accident Property Damage$0

Processes facility_Processes help link help link (Facility #1 : Tyson Foods Sherman, TX Case R, RMP submission #1 : 2011-01-06, process #1 : Ammonia Refrigeration)
Process DescriptionAmmonia Refrigeration
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)116,000
Flammable Amount Total (lbs)0
Process Amount Total (lbs)116,000
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)116,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Tyson Foods Sherman, TX Case R, RMP submission #1 : 2011-01-06, process #1 : Ammonia Refrigeration, 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  
Physical StateGas liquified by pressure
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 : Tyson Foods Sherman, TX Case R, RMP submission #1 : 2011-01-06, process #1 : Ammonia Refrigeration, process chemical #2, alternate toxic scenario #1)
Physical StateGas
Model UsedEPA's RMP*Comp(TM)
Wind Speed3
Atmospheric Stability ClassD
TopographyUrban
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 : Tyson Foods Sherman, TX Case R, RMP submission #1 : 2011-01-06, process #1 : Ammonia Refrigeration, process NAICS code #1 : 311612)
NAICS Code311612: Meat Processed from Carcasses

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date11/10/2010
PHA Update Date11/09/2010
PHA Technique - What IfYes
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPNo
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date02/20/2011
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionYes
Hazard Identified - Runaway ReactionNo
Hazard Identified - PolymerizationNo
Hazard Identified - OverpressureYes
Hazard Identified - CorrosionYes
Hazard Identified - OverfillingYes
Hazard Identified - ContaminationYes
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossYes
Hazard Identified - EarthquakeYes
Hazard Identified - FloodNo
Hazard Identified - TornadoYes
Hazard Identified - HurricaneNo
Hazard Identified - OtherHuman factors
Process Controls - VentsNo
Process Controls - Relief ValvesYes
Process Controls - Check ValvesYes
Process Controls - ScrubbersNo
Process Controls - FlaresNo
Process Controls - Manual ShutoffsYes
Process Controls - Auto ShutoffsYes
Process Controls - InterlocksYes
Process Controls - AlarmsYes
Process Controls - Keyed BypassNo
Process Controls - Emergency AirNo
Process Controls - Emergency PowerNo
Process Controls - Backup PumpYes
Process Controls - GroundingYes
Process Controls - Inhibitor AdditionNo
Process Controls - Rupture DisksYes
Process Controls - Excess Flow DevicesNo
Process Controls - Quench SystemNo
Process Controls - Purge SystemYes
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 Date11/09/2010
Training Review Date11/09/2010
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherSOP
Competency Testing - Written TestsYes
Competency Testing - Oral TestsNo
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Maintenance Review Date11/09/2010
Maintenance Inspection Date11/09/2010
Equipment TestedRefrigeration units
Management of Change Most Recent Date08/25/2009
Management of Change Review Date11/09/2010
Pre-startup Review Date10/08/2009
Compliance Audit Date11/09/2010
Compliance Audit Change Completion Date06/01/2011
Incident Investigation Date02/21/2006
Incident Invest. Change Completion Date02/21/2006
Participation Plan Review Date11/09/2010
Hot Work Review Date11/09/2010
Contractor Safety Review Date11/09/2010
Contractor Safety Eval. Date11/09/2010
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Tyson Foods Sherman, TX Case R, RMP submission #1 : 2011-01-06, process #1 : Ammonia Refrigeration, process NAICS code #1 : 311612, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000028546

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
This facility uses ammonia in a closed-loop refrigeration system for the purposes of process cooling.

Accidents facility_Accidents help link help link  
Accident Date02/21/2006
Accident Time0525
Number of Chemicals1
Flammable Amount Total (lbs)0
Toxic Amount Total (lbs)371
Released Amount Total (lbs)371
Number of Deaths0
Number of Injuries0
Number Evacuated / Sheltered202
Total Property Damage$0
Environmental DamageNo
NAICS of Process Involved311612: Meat Processed from Carcasses
Release Duration (HHHMM)70000
Release Event - Gas ReleaseYes
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 - ValveNo
Release Source - PumpNo
Release Source - JointNo
Release Source - OtherChester Jensen water chiller
PrecipitationNo
Unknown WeatherYes
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 Evacuated2
Number Sheltered In Place200
Property damage (off-site)$0
Environmental Damage - Fish/Animal KillsNo
Environmental Damage - DefoliationNo
Environmental Damage - Water ContaminationNo
Environmental Damage - Soil ContaminationNo
Initiating EventHuman Error
Contributing Factor - Equipment FailureYes
Contributing Factor - Human ErrorYes
Contributing Factor - Improper ProcedureYes
Contributing Factor - OverpressurizationYes
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 NotifiedNotified Only
Changes Introduced - Improved EquipmentNo
Changes Introduced - Revised MaintenanceNo
Changes Introduced - Revised TrainingYes
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 Place202
Total RMP Accident Property Damage$0

Accident Chemicals facility_Accident_Chemicals help link help link (Facility #1 : Tyson Foods Sherman, TX Case R, RMP submission #1 : 2011-01-06, accident #1, accident chemical #1)
Chemical IDAmmonia (anhydrous)
CAS number007664417
Chemical TypeToxic
Amount Released (lbs)371
Percent Weight (Within Mixture)99.5

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 Date11/09/2010
Response Training Date12/15/2010
Local Response AgencySherman Fire Department
Local Response Agency Phone9038927263
Subject To - OSHA EAPYes
Subject To - OSHA HAZWOPERYes
Subject To - CWAYes
Subject To - RCRAYes
Subject To - OPAYes
Subject To - State EPCRAYes


Search Criteria Used
RMP Facility ID100000194112

*END OF REPORT*