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Foster Farms Cherry Plant (4/15 Rev.)

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Facility #1 : Foster Farms Cherry Plant (4/1


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000127356
Deregistered (Yes/No)No
Facility NameFoster Farms Cherry Plant (4/15 Rev.)
Street Address Line 12960 Cherry Ave.
CityFresno
StateCA
Zip Code93706
CountyFresno County
113th Congressional DistrictCA16: California 16
Owner or Operator NameFoster Poultry Farms
Parent CompanyFoster Poultry Farms
Latitude36.693000
Longitude-119.783000
Number of RMP Submissions5

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000049717
Submission Typerevised submission for facility
Submission Date04/30/2015
Reason For Submission5-year update (40 CFR 68.190(b)(1))
Process Toxic Amount Total (lbs)37,309
Process Flammable Amount Total (lbs)0
Process Amount Total (lbs)37,309
Number of Potential Offsite Consequence Processes1
Potential Offsite Consequence Toxic Amount Total (lbs)37,309
Potential Offsite Consequence Flammable Amount Total (lbs)0
Potential Offsite Consequence Amount Total (lbs)37,309
All Process NAICS311615
Exec Summary Submission Date04/30/2015

Executive Summary facility_Executive_Summary help link help link (Facility #1 : Foster Farms Cherry Plant (4/1, executive summary: all)

Executive Summary
FOSTER FARMS

FRESNO POULTRY PLANT

RISK MANAGEMENT PROGRAM (CALARP) AND

PROCESS SAFETY MANAGEMENT PROGRAM



Anhydrous Ammonia Refrigeration System





EXECUTIVE SUMMARY

Revised April 2015







Foster Farms Fresno Poultry Plant (referred to hereafter as ""Fresno Poultry"" or ""Foster Farms"") revised this document, previously submitted in April 2010, due to a revalidated Process Hazard Analysis and regulatory requirements requiring re-submittal.



Foster Farms prepared a Chemical Risk Management Program and Process Safety Management Program (RMP/PSM) in general accordance with state and federal regulations. The state risk management regulations, also referred to as the California Accidental Release Prevention (CalARP) program, are codified in California Code of Regulations (CCR), Title 19, Section 2735.1, et. seq. The Environmental Protection Agency (EPA) also regulates facilities with certain toxic and flammable substances. The federal regulations are codified in Title 40 of the Code of Federal Regulations (CFR), Part 68. Finally, both the Occupational Safety and Health Administration (OSHA) and the California Occupational Safety and Health Administration (CalOSHA) regulate facilities with certain acutely hazardous materials under the PSM regulations, as defined in CCR Title 8 Section 5189 and CFR Title 29 Part 1910 Section 119, respectively.



ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES



Foster Farms prepared the RMP/PSM to satisfy regulatory requirements and to demonstrate a commitment to evaluate and improve anhydrous ammonia handling systems and practices at the facility. Many state-of-the-art safety features were i
ncorporated into the ammonia refrigeration system at the facility as part of the original system construction and system modifications. In the unlikely event that a chemical release does occur at the facility, Foster Farms personnel are trained in the appropriate response measures, relying on backup support services provided by the local fire department and/or hazardous materials response team. Foster Farms will continue to improve ammonia-handling safety through the implementation of the prevention program elements of the RMP/PSM.



STATIONARY SOURCE AND REGULATED COMPOUNDS HANDLED



Fresno Poultry is located at 2960 South Cherry Avenue in Fresno, California. The surrounding area consists of industrial and commercial businesses. The facility is approximately 1.5 miles west of Highway 99. The site is bordered by North Avenue to the south, a scrap metal/salvage yard to the north, Highway 41 to the west, and Cherry Avenue to the east.



The facility was constructed in 1986/1987 for Rockford Turkey Processing. Foster Farms purchased the plant in 1990. Operations at the facility consist of the slaughter, processing, storage, and packaging of poultry products. The facility is surrounded by chain-link fencing and has a secured entrance that is staffed by security personnel 24 hours per day, 365 days per year.



Anhydrous ammonia is used in a refrigeration system at the facility. The system provides cooling for production areas, product, water chilling, and ice making. A central computer system monitors and controls the refrigeration system. The desired temperatures are maintained by controlling the flow of ammonia with manually and electrically operated valves, float switches, transfer pumps, and compressor controls.

GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS



The RMP/PSM regulations require a review of the accidental release prevention program and chemical specific prevention steps used by the facility. Foster Farms has i
ncorporated many safety features in the ammonia refrigeration system to prevent system failures and to mitigate potential releases. The predominant safety concern with closed-loop ammonia systems is an inadvertent buildup of pressure exceeding pressure ratings or capacities of equipment due to ammonia expansion. The Fresno Poultry ammonia system is continuously monitored by automated control systems that shut down components if deviations from normal operating conditions occur. The major pressure vessels in the system are connected to a diffusion panel. Ammonia from the vessels can be mixed with water (neutralized) and discharged to the sewer system to prevent over-pressurization of the vessels. Additionally, all pressure vessels in the system are equipped with pressure relief valves.



Other safety features at the facility include:

Ammonia Detection System:

Ammonia detection sensors are installed in all production areas that have ammonia equipment.

Production area sensors shut off liquid ammonia to equipment upon activation.

Ammonia detection sensors are installed in engine rooms.

Ammonia detection sensors in engine rooms activate emergency ventilation system.

Ammonia detection system provides audible and visual alarm signals.

Emergency shutdown systems

Component specific safety shutdowns

Safeties are tested annually

Pressure relief valves on all vessels, compressors, and several other areas in the system where trapped ammonia could build pressure

All major vessels are connected to a fire diffusion panel

Many of the ammonia pipes, valves and components are labeled

Pressure relief valves are replaced at least every 5 years

A fire sprinkler system is installed in the plant

A central computer system monitors the refrigeration system and alarms when safety set-points are exceeded

Operators receive ongoing training in operations, maintenance and emergency response



In addition to the physical features of the ammonia r
efrigeration system at the facility, Foster Farms has extensive administrative controls in place to maintain safe operation of the system. Administrative controls include, but are not limited to, formal training programs for system operators and mechanics, emergency training, a hot work permit program, a lockout/tagout program, a contractor safety program, incident investigation program, mechanical integrity program, management of change program, pre start-up safety review program, and a RMP/PSM auditing and inspection program. Written standard operating procedures (SOPs) have been prepared for the ammonia system at the facility. The SOPs provide a basis for site specific operator training and a ready reference for operating and trouble-shooting the systems.



Foster Farms is committed to maintaining the mechanical integrity of the ammonia refrigeration system. A preventive maintenance system is utilized to manage the maintenance of the refrigeration system. Preventive maintenance at the facility includes shift, daily, weekly, and periodic inspection; calibration; testing; and overhaul of ammonia system equipment. The system is used to track equipment performance and to create reports that are used by maintenance personnel to monitor the frequency of repairs and deviations from normal operating parameters.



FIVE-YEAR ACCIDENT HISTORY



The RMP/PSM regulations require a discussion of accidents involving a release of a reportable quantity (RQ) of ammonia that have occurred at the facility within 5 years prior to the request for submitting the RMP or that resulted in deaths, injuries, or significant property damage onsite or known offsite deaths, injuries, evacuations, sheltering in place, property damage, or environmental damage within 5 years of the request for submitting the RMP. Foster Farms knows of no reportable releases at the facility within the required reporting period.





EMERGENCY RESPONSE PROGRAM

Foster Farms has developed a written Emergency Respo
nse Plan (ERP) that identifies emergency personnel responsibilities, procedures, evacuation measures and reporting requirements. The Foster Farms ERP is based on an emergency operations organization in which the Incident Commander serves as the chief officer in emergency situations. The Incident Commander will take charge of the emergency response and response team and direct all operations when an emergency is declared and will remain in charge until the emergency is ended. The ERP addresses ammonia specific issues as required by the RMP/PSM standards, including a determination of incidents that constitute an emergency.



Foster Farms has developed the ERP to assure compliance with RMP/PSM requirements. The Plant Manager or designee will maintain the ERP. Additionally, a copy of the ERP will be kept with the RMP/PSM documentation and at other appropriate locations. Refer to the ERP, for further information regarding emergency planning and response.



PLANNED CHANGES TO IMPROVE SAFETY



Changes to improve safety at the facility have been ongoing. Many of the mitigation measures suggested by the recent process hazard analysis revalidation team have already been implemented. Others will be implemented during the next eighteen months.



Foster Farms will respond to all suggested mitigation measures promptly. Foster Farms is scheduling completion of proposed actions. Management responses and support will be consistent with Foster Farms' commitment to safe and environmentally responsible operations.



Foster Farms recognizes that the RMP/PSM is a continuous process for evaluating, monitoring, and improving anhydrous ammonia handling operations at its facility. As such, this document and related attachments and program elements will evolve as Foster Farm continues their ongoing focus and dedication of risk minimization and safety improvement for their employees and surrounding community. Foster Farms will submit revised information if a change occurs that is con
sidered significant and requires resubmission under the regulations. However, minor improvements/modifications to the RMP/PSM and related attachments and program elements will be incorporated consistent with Foster Farms' internal review practices; Foster Farms will maintain the most current versions on site. Thus, the most current version RMP/PSM and related documents and elements maintained on site may vary slightly from the information submitted to the EPA and other regulatory agencies.




Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees1,700
Owner or Operator NameFoster Poultry Farms
Owner or Operator Address Line 12960 Cherry Ave.
Owner or Operator CityFresno
Owner or Operator StateCA
Owner or Operator Zip93706
Parent Dun and Bradstreet Number0
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees1,700
Number of FTE CBI FlagNo
Other Facility IDCA0002419331
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VNo
Last Safety Inspection Date20140815
Last Safety Inspection ByCounty Environmental Agency
OSHA Star or Merit RankingNo
LEPC NameRegion 5 LEPC Inland South

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : Foster Farms Cherry Plant (4/1, RMP submission #1 : 20150430)
Owner or Operator Phone2093946914
Facility Dun and Bradstreet Number38121828
RMP ContactScott Swows
RMP Contact TitlePlant Manager
RMP Contact Emailshowss@fosterfarms.com
RMP Preparer NameCondor Earth Technologies, Inc.
RMP Preparer Address Line 121663 Brian Lane
RMP Preparer CitySonora
RMP Preparer StateCA
RMP Preparer Zip95370
RMP Preparer Phone2095320361

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsNo
Complete Check Date20150430
Error Report Datenull
Postmark Date20150430
Anniversary Date20200430
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link (Facility #1 : Foster Farms Cherry Plant (4/1, RMP submission #1 : 20150430)
Latitude36.693000
Longitude-119.783000
Valid Lat/LongYes
Lat/Long MethodInterpolation - Digital map source (TIGER)
Lat/Long Location TypeCenter of Facility
FRS Latitude36.6942
FRS Longitude-119.782
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  
Number of RMP Accidents0
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)0
RMP Accident Amount Total (lbs)0
Number of RMP Accidents0
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)0
RMP Accident Amount Total (lbs)0
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 : Foster Farms Cherry Plant (4/1, RMP submission #1 : 20150430, process #1 : Foster Farms Fresno Poul)
Process DescriptionFoster Farms Fresno Poul
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)37,309
Flammable Amount Total (lbs)0
Process Amount Total (lbs)37,309
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)37,309
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Foster Farms Cherry Plant (4/1, RMP submission #1 : 20150430, process #1 : Foster Farms Fresno Poul, 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 UsedSLAB
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 : Foster Farms Cherry Plant (4/1, RMP submission #1 : 20150430, process #1 : Foster Farms Fresno Poul, process chemical #2, alternate toxic scenario #1)
Physical StateGas liquified by pressure
Model UsedSlab
Wind Speed2.1
Atmospheric Stability ClassD
TopographyUrban
Passive Mitigation - DikesNo
Passive Mitigation - EnclosuresNo
Passive Mitigation - BermsNo
Passive Mitigation - DrainsNo
Passive Mitigation - SumpsNo
Active Mitigation - SprinklersYes
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
Active Mitigation - OtherFire Diffusion System
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : Foster Farms Cherry Plant (4/1, RMP submission #1 : 20150430, process #1 : Foster Farms Fresno Poul, process NAICS code #1 : 311615)
NAICS Code311615: Poultry Processing

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date20150120
PHA Update Date20150303
PHA Technique - What IfNo
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPYes
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date20170303
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 - ContaminationNo
Hazard Identified - Equipment FailureYes
Hazard Identified - Cooling LossYes
Hazard Identified - EarthquakeYes
Hazard Identified - FloodNo
Hazard Identified - TornadoNo
Hazard Identified - HurricaneNo
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 - 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
Process Controls - OtherDiffusion System and Ammonia Detection System with Liquid Shut Off
Mitigation Systems - SprinklersNo
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
Mitigation Systems - OtherDiffusion System and Ammonia Detection System with Liquid Shut Off
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 DetectionYes
Changes Since PHA - Perimeter MonitoringNo
Changes Since PHA - Mitigation SystemsNo
Changes Since PHA - None RecommendedNo
Changes Since PHA - NoneNo
Procedure Review Date20150102
Training Review Date20150102
Type of Training - ClassroomYes
Type of Training - On the JobYes
Competency Testing - Written TestsNo
Competency Testing - Oral TestsYes
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Maintenance Review Date20150102
Maintenance Inspection Date20150430
Equipment TestedCompressors
Management of Change Most Recent Date20150228
Management of Change Review Date20150102
Pre-startup Review Date20150228
Compliance Audit Date20120510
Compliance Audit Change Completion Date20140510
Incident Investigation Date20141107
Incident Invest. Change Completion Date20141120
Participation Plan Review Date20150102
Hot Work Review Date20150102
Contractor Safety Review Date20150102
Contractor Safety Eval. Date20150109
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Foster Farms Cherry Plant (4/1, RMP submission #1 : 20150430, process #1 : Foster Farms Fresno Poul, process NAICS code #1 : 311615, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000076986

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


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 Date20140701
Response Training Date20150219
Local Response AgencyFresno Fire Department
Local Response Agency Phone5592911515
Subject To - OSHA EAPYes
Subject To - OSHA HAZWOPERYes
Subject To - CWANo
Subject To - RCRANo
Subject To - OPANo
Subject To - State EPCRAYes


Search Criteria Used
RMP Facility ID100000127356

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