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Waco Thermal Manufacturing Plant

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Facility #1 : Waco Thermal Manufacturing Pla


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000155333
Deregistered (Yes/No)No
Facility NameWaco Thermal Manufacturing Plant
Street Address Line 18400 Imperial Drive
CityWaco
StateTX
Zip Code76712
CountyMcLennan County
113th Congressional DistrictTX17: Texas 17
Owner or Operator NameCoca-Cola North America
Parent CompanyCoca-Cola North America
Latitude31.488417
Longitude-097.208806
Number of RMP Submissions4

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000023763
Submission Typerevised submission for facility
Submission Date10/24/2011
Reason For Submission5-year update (40 CFR 68.190(b)(1))
Process Toxic Amount Total (lbs)39,099
Process Flammable Amount Total (lbs)0
Process Amount Total (lbs)39,099
Number of Potential Offsite Consequence Processes1
Potential Offsite Consequence Toxic Amount Total (lbs)39,099
Potential Offsite Consequence Flammable Amount Total (lbs)0
Potential Offsite Consequence Amount Total (lbs)39,099
All Process NAICS312111
Exec Summary Submission Date10/24/2011

Executive Summary facility_Executive_Summary help link help link (Facility #1 : Waco Thermal Manufacturing Pla, executive summary: all)

Executive Summary
Coca-Cola North America Waco Thermal Manufacturing Plant

Risk Management Plan for Ammonia



Executive Summary



1. Accidental Release Prevention and Emergency Response Policies



Coca-Cola North America is strongly committed to employee, public, and environmental safety. This commitment is inherent to our comprehensive accidental release prevention program that covers areas such as design, installation, operating procedures, maintenance, and employee training associated with our regulated processes. It is our policy to implement appropriate controls to prevent possible accidental releases of regulated substances. However, if such an accidental release does occur, we are coordinated with the City of Waco Fire Department and the McLennan County LEPC for emergency response support.



2. The Stationary Source and the Regulated Substances Handled



This facility is used for the production of Powerade®, vitaminwater® and FUZE® sports beverages as well as Minute Maid® fruit juices and juice drinks. Ammonia is the only RMP regulated substance present at this facility in a threshold quantity. It is utilized as the primary cooling media in our closed-loop refrigeration system. The ammonia refrigeration system has been operational since December of 1998. The system's purpose is to provide cold storage capabilities for certain products. Due to the characteristics of our ammonia refrigeration system, as well as Process Safety Management (PSM) applicability, this facility is covered under Program 3 of the RMP regulations.



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 evaluate the worst case and alternative release scenarios, the DEGADIS model, Version 2.1, was used. DEGADIS is designed to model the atmospheric dispersion of ground-level area source dense gas clouds released with zero momentum into a
n atmospheric boundary layer over flat, level terrain. The inputs for the DEGADIS model were determined using the assumptions and equations provided in EPA's General Guidance on Risk Management Programs for Chemical Accident Prevention (March 2009) and Risk Management Program Guidance for Offsite Consequence Analysis (March 2009) documents.



The worst case scenario would involve the catastrophic failure of the low-pressure receiver. The low-pressure receiver has a capacity of 48,874 pounds; however, the maximum quantity stored in the receiver at any one time is administratively limited to 80% of the capacity (39,099 pounds). Based on this information a release quantity of the entire vessel (39,099 pounds) is assumed. As specified in the RMP Guidance for Ammonia Refrigeration, the worst case scenario assumes the release occurs over a period of 10 minutes, yielding a release rate of 3,910 pounds per minute. The vessel is located inside the facility engine room, which has an overhead door; however, the release rate is considered unmitigated since the proximity of the storage vessel to the door prevents the use of the door as passive mitigation. Under worst case weather conditions (Class F atmospheric stability and 1.5 m/s wind speed) as required by the RMP rule, DEGADIS yielded a distance of 1.21 miles to the toxic endpoint of 0.14 mg/L (200 ppm) ("zone of influence"). The estimated residential population for the zone of influence is approximately 5,980 based on US Census Bureau Quickfacts for 2006 and the 2005-2009 American Community Survey 5-Year Estimates. Other public receptors identified within the zone of influence include schools, churches, recreation areas, and commercial/industrial areas. No environmental receptors are known to be located within the zone of influence.



Several alternative release scenarios were evaluated; however, when they were modeled none of them reached a toxic endpoint offsite. For the purpose of this RMP submission, the fo
llowing alternative release scenario was chosen because it is the most likely to occur that would potentially release a significant amount of ammonia. The scenario chosen involves the failure of a 0.25 inch safety relief valve in the high pressure part of the ammonia system. This scenario could also be representative of multiple situations such as a small hole in a vessel or pipe, a pinpoint hole in a condenser coil, or a packing leak around a valve stem. Due to the presence of an alarm system and isolation valves and based on a recent release event, the release would occur over a 15 minute timeframe. Under average weather conditions taken from meteorological data from the Waco Regional Airport, DEGADIS yielded a distance to the toxic endpoint of 429 feet. No offsite receptors will be affected by the alternate release.



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



The facility has taken all necessary steps to comply with the accidental release prevention requirements set forth in 40 CFR Part 68. Our facility is also subject to the OSHA PSM standard under 29 CFR 1910.119, as well as the EPCRA Section 302 and 311/312 notification/reporting requirements. The following sections briefly describe the elements of the accidental release prevention program that is in place at our facility.



Process Safety Information



Coca-Cola North America maintains a detailed record of safety information that describes the chemical hazards, operating parameters, and equipment designs associated with the ammonia refrigeration system.



Process Hazard Analysis



As part of the ammonia refrigeration system installation process, and as required under PSM, the facility conducted a comprehensive study to ensure that hazards associated with its ammonia refrigeration system are identified and controlled efficiently. These studies, using "What If" scenarios, will be repeated every 5 years by a team of qualified personnel with
expertise in refrigeration engineering and process operations. Any findings related to the process hazard analysis will be addressed in a timely manner.



Operating Procedures



For the purpose of safely conducting activities related to our ammonia refrigeration system, Coca-Cola North America maintains written operating procedures. These procedures address various modes of operation including startup, normal operations, emergency operations, normal shutdown, and emergency shutdown. The information is regularly reviewed and is readily accessible to all operators and contractors who work with the ammonia refrigeration system.



Training



Coca-Cola North America has a comprehensive training program in place to ensure that employees who are working with the ammonia refrigeration system are competent in all relevant operating procedures. Refresher training is provided at least every three (3) years or more frequently as needed.



Mechanical Integrity



Coca-Cola North America carries out and documents maintenance checks on ammonia refrigeration system equipment to ensure proper operation. Process equipment examined by these checks includes among others: pressure vessels, piping systems, pressure relief valves, emergency shutdown systems, controls and pumps. Maintenance operations are carried out by qualified personnel with previous training in applicable 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 Coca-Cola North America to manage changes in ammonia refrigeration system technology, equipment, and procedures. Process operators, maintenance personnel, or any other employee whose job tasks are affected by an ammonia refrigeration system modification are promptly made aware of, and offered training to deal with, the modification.



Pre-st
artup Reviews



Pre-start up safety reviews are conducted any time the ammonia refrigeration system, or any of its components, is opened for repairs, tie-ins, or modifications. These reviews are conducted to confirm that construction, equipment, operating procedures, and maintenance procedures are suitable for safe startup prior to placing equipment into operation.



Compliance Audits



Coca-Cola North America will conduct audits on a regular basis to ensure that the provisions set out under the RMP rule are being properly implemented. These audits will be carried out at least every three (3) years and any corrective actions required as a result of the audits shall be undertaken in a safe and prompt manner.



Incident Investigation



Coca-Cola North America promptly investigates any incident that has resulted in, or could reasonably result in, an accidental release of ammonia. These investigations are undertaken to identify the situation leading to the incident, as well as any corrective actions implemented to prevent the release from reoccurring. All incident investigation reports will be retained for a minimum of five (5) years.



Employee Participation



Coca-Cola North America truly believes that 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 related to RMP implementation, including Process Hazard Analyses (PHA) information.



Contractors



On occasion, our company hires experienced contractors to conduct specialized maintenance and/or construction activities related to the ammonia refrigeration system. Prior to selecting a contractor, a thorough evaluation is made of the contractor's safety performance. Coca-Cola North America has a strict policy of informing the contractors of known potential hazards related to the contractor's work with the ammonia refrigeration
system. Contractors are also informed of all the procedures for emergency response should an accidental release of ammonia occur.



5. Five-year Accident History



In July 2011, an overpressurized relief valve on the chiller system released approximately 412 pounds. The relief valve was determined to be in compliance.



6. Emergency Response Plan



Coca-Cola North America Emergency Response Policy focuses on evacuation of the facility in the event of an ammonia emergency, with local emergency response agencies performing all rescue, firefighting, first-aid, medical treatment, and other response functions. The facility maintains a written Emergency Response Plan to document specific procedures to be implemented in the event of various emergencies, including an ammonia release. The Emergency Response Plan includes procedures for facility evacuation, as well as for notification of the local emergency response agencies which are responsible for notifying the public. The plan is promptly updated to reflect any pertinent changes taking place within the facility that would require modified procedures.



The McLennan County LEPC is the Local Emergency Planning Committee (LEPC) with which our Emergency Response Plan has been coordinated. The Waco Fire Department is the primary emergency response agency for all facility emergencies, including ammonia releases.



7. Planned Changes to Improve Safety



The facility has no currently planned changes to the ammonia refrigeration system, but will periodically assess opportunities to improve the safety of that system.


Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees326
Owner or Operator NameCoca-Cola North America
Owner or Operator Address Line 1One Coca-Cola Plaza
Owner or Operator CityAltanta
Owner or Operator StateGA
Owner or Operator Zip30301
Parent Dun and Bradstreet Number3296175
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees326
Number of FTE CBI FlagNo
Other Facility IDTXR000056226
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VNo
Last Safety Inspection Date12/06/2006
Last Safety Inspection ByEPA
OSHA Star or Merit RankingNo
LEPC NameMclennan County LEPC

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : Waco Thermal Manufacturing Pla, RMP submission #1 : 2011-10-24)
Owner or Operator Phone4046766426
Facility Dun and Bradstreet Number0
RMP ContactEd Palican
RMP Contact TitleSES Manager
RMP Contact Emailepalican@coca-cola.com
RMP Preparer NameTRC
RMP Preparer Address Line 1505 East Huntland Drive
RMP Preparer Address Line 2Suite 250
RMP Preparer CityAustin
RMP Preparer StateTX
RMP Preparer Zip78752
RMP Preparer Phone5123296080

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsYes
Complete Check Date10/24/2011
Postmark Date10/24/2011
Anniversary Date10/24/2016
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link (Facility #1 : Waco Thermal Manufacturing Pla, RMP submission #1 : 2011-10-24)
Latitude31.488417
Longitude-097.208806
Valid Lat/LongYes
Lat/Long MethodInterpolation - Photo
Lat/Long Location TypeCenter of Facility
FRS Latitude31.49
FRS Longitude-97.21
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 Accidents1
RMP Accident Flammable Total (lbs)0
RMP Accident Toxic Total (lbs)412
RMP Accident Amount Total (lbs)412
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)412
RMP Accident Amount Total (lbs)412
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 : Waco Thermal Manufacturing Pla, RMP submission #1 : 2011-10-24, process #1 : Ammonia Refrigeration)
Process DescriptionAmmonia Refrigeration
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)39,099
Flammable Amount Total (lbs)0
Process Amount Total (lbs)39,099
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)39,099
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Waco Thermal Manufacturing Pla, RMP submission #1 : 2011-10-24, 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  
Percent Weight (Within Mixture)100
Physical StateGas liquified by pressure
Model UsedDEGADIS
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 : Waco Thermal Manufacturing Pla, RMP submission #1 : 2011-10-24, process #1 : Ammonia Refrigeration, process chemical #2, alternate toxic scenario #1)
Percent Weight (Within Mixture)100
Physical StateGas liquified by pressure
Model UsedDEGADIS
Wind Speed4.3
Atmospheric Stability ClassC
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 ShutdownNo
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : Waco Thermal Manufacturing Pla, RMP submission #1 : 2011-10-24, process #1 : Ammonia Refrigeration, process NAICS code #1 : 312111)
NAICS Code312111: Soft Drink Manufacturing

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date06/22/2011
PHA Update Date06/11/2009
PHA Technique - What IfYes
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPNo
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date06/11/2009
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 LossYes
Hazard Identified - EarthquakeNo
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 - InterlocksYes
Process Controls - AlarmsNo
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 WallsYes
Mitigation Systems - Blast WallsNo
Mitigation Systems - Deluge SystemsNo
Mitigation Systems - Water CurtainsNo
Mitigation Systems - EnclosureYes
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 InventoryYes
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 - NoneNo
Procedure Review Date05/06/2011
Training Review Date05/06/2011
Type of Training - ClassroomYes
Type of Training - On the JobYes
Competency Testing - Written TestsYes
Competency Testing - Oral TestsNo
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Maintenance Review Date05/13/2011
Maintenance Inspection Date03/31/2011
Equipment TestedEntire system tested for mechanical integrity
Management of Change Review Date05/13/2011
Pre-startup Review Date06/22/2011
Compliance Audit Date05/13/2011
Incident Investigation Date07/22/2011
Incident Invest. Change Completion Date11/30/2011
Participation Plan Review Date05/13/2011
Hot Work Review Date09/24/2010
Contractor Safety Review Date09/21/2010
Contractor Safety Eval. Date05/02/2011
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Waco Thermal Manufacturing Pla, RMP submission #1 : 2011-10-24, process #1 : Ammonia Refrigeration, process NAICS code #1 : 312111, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000034715

Prevention Program 3 Text facility_Prevention_Program_3_Text help link help link  
Prevention Program Description
OSHA Process Safety Managment (PSM) Program

Accidents facility_Accidents help link help link  
Accident Date07/16/2011
Accident Time0100
Number of Chemicals1
Flammable Amount Total (lbs)0
Toxic Amount Total (lbs)412
Released Amount Total (lbs)412
Number of Deaths0
Number of Injuries0
Number Evacuated / Sheltered0
Total Property Damage$0
Environmental DamageNo
NAICS of Process Involved312111: Soft Drink Manufacturing
Release Duration (HHHMM)00015
Release Event - Gas ReleaseYes
Release Event - SpillNo
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 Speed9
Wind Speed Unitsmiles/h
Wind DirectionSSE
Temperature85
Atmospheric Stability ClassC
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 ErrorNo
Contributing Factor - Improper ProcedureNo
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 NotifiedUnknown
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 : Waco Thermal Manufacturing Pla, RMP submission #1 : 2011-10-24, accident #1, accident chemical #1)
Chemical IDAmmonia (anhydrous)
CAS number007664417
Chemical TypeToxic
Amount Released (lbs)412
Percent Weight (Within Mixture)100

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 Date09/02/2011
Response Training Date09/07/2011
Local Response AgencyCity of Waco Fire Department
Local Response Agency Phone2547501740
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 ID100000155333

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