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Earthbound Farm

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Facility #1 : Earthbound Farm


Basic Facility Info facility_Basic_Facility_Info help link help link  
Facility ID100000187861
Deregistered (Yes/No)No
Facility NameEarthbound Farm
Street Address Line 11721 San Juan Highway
CitySan Juan Bautista
StateCA
Zip Code95045
CountySan Benito County
113th Congressional DistrictCA20: California 20
Owner or Operator NameEarthbound Farm
Parent CompanyEarthbound Farm
Latitude36.873056
Longitude-121.553333
Number of RMP Submissions3

Most Recent Submission Info facility_Most_Recent_Submission_Info help link help link  
RMP ID1000011882
Submission Typerevised submission for facility
Submission Date12/28/2009
Reason For Submission5-year update (40 CFR 68.190(b)(1))
Process Toxic Amount Total (lbs)44,000
Process Flammable Amount Total (lbs)0
Process Amount Total (lbs)44,000
Number of Potential Offsite Consequence Processes1
Potential Offsite Consequence Toxic Amount Total (lbs)44,000
Potential Offsite Consequence Flammable Amount Total (lbs)0
Potential Offsite Consequence Amount Total (lbs)44,000
All Process NAICS49312 115114
Exec Summary Submission Date12/28/2009

Executive Summary facility_Executive_Summary help link help link (Facility #1 : Earthbound Farm, executive summary: all)

Executive Summary
RELEASE PREVENTION AND EMERGENCY RESPONSE POLICY
Earthbound Farm operates a processing, shipping and cooling facility in San Juan Bautista, CA. Risk prevention and emergency response procedures are in place at this facility. The Emergency Response Plan lists the responsible personnel and the policies for responding to an accident involving the regulated substance.

Earthbound Farm facility has both fixed and portable refrigeration systems onsite composed of compressors with common thermosyphon receiver , evaporative condensers, vacuum tubes, evaporative cooling coils, pressure vessels, ammonia pumps, water chillers, ice generators and diffusion tanks. All compressors have safety switches that would shut down the compressors upon detection of unsafe operating conditions. All the pressure vessels and the compressors are protected by safety relief valves against high pressure situations. There are ammonia detectors in the cold rooms and in the mechanical room for alarming. There is a list of responders experienced with ammonia refrigeration that would respond and determine specific responses for any incident. Safeties and detection equipment are tested and maintained by experienced maintenance personnel as spelled out in the SOPs (Standard Operating Procedures) and testing and inspection program.

Emergency response training will be conducted yearly for current employees and as required for new employees. Records will be kept of all training performed at the site for a minimum of five (5) years.


DESCRIPTION OF SOURCE AND SUBSTANCE HANDLED
Ammonia refrigeration systems are used for cold storage, water chilling, produce precooling and ice generation. A fixed system is attached to the main storage and processing building and is used for cold storage, water chilling, ice generation. Portable units support three vacuum cooling tubes. The total charge for the all the refrigeration systems is approximately 44,400 LBS.

The Earthbound Farm facility is located at 1721
San Juan Highway in San Juan Bautista, California. This facility utilizes anhydrous ammonia as a refrigerant in their precooling, cold rooms and process water chilling operations. Fresh produce is brought from the fields and cooled to remove field heat. The produce is then packaged and stored in a cold storage warehouse prior to shipment from refrigerated docks.
Ammonia refrigeration system equipment at the facility consists of portable and permanently installed equipment. The main refrigeration system configuration includes: Low Pressure Re-circulating units with ammonia pumps, cold room evaporators, various safety equipment including refrigerant discharge diffusion tanks, compressors with a common thermosyphon receiver, evaporative cooling condensers, a high-pressure receiver and a plate and frame make-up water chiller, along with nine falling film water chillers in the processing rooms

Anhydrous ammonia (NH3) is a gas in its natural state and is extremely irritating to mucous membranes and lung tissue. The gas is pungent and may be suffocating as shortness of breath and labored breathing can develop if inhaled. Prolonged inhalation of high concentrations may cause bronchitis and/ or pneumonia, with some residual reduction in pulmonary functions. Repeated or prolonged contact of high concentrations of ammonia to the skin can cause frostbite, redness, pain and serious skin burn.

OFFSITE CONSEQUENCE ANALYSIS
An offsite consequence analysis for an ammonia release was performed to determine impacts to neighboring schools, businesses, residences, recreation areas, and historical and environmentally sensitive sites.

ACCIDENTAL RELEASE PREVENTION PROGRAM
Earthbound Farm maintains a release prevention program to eliminate or minimize releases. The program includes regular inspections, monitoring equipment and logging conditions, scheduled maintenance, and operator training. Incident Investigation Program is in place to analyze releases for ways to prevent a simila
r future release. A Risk Management Program, which includes accident prevention procedures for the ammonia refrigeration system, is maintained on-site as well.

The ammonia refrigeration system has specific safety procedures to prevent a release. Operators and mechanics are trained for safe operation and maintenance of the refrigeration system. They are also trained in emergency response procedures in the event of an ammonia release. There are emergency shut off switches outside the mechanical room for shutting down the system. Ammonia detectors are installed in all refrigerated rooms and the mechanical room. Personnel will automatically be notified if any detector exceeds set point. Monitoring is 24 hours per day. An emergency control box and diffusion tank allows system pressure to be relieved manually. All relief valves at the facility are tied into ammonia diffusion tank to prevent high pressure releases to ambient


FIVE-YEAR ACCIDENT HISTORY
According to Earthbound Farm Personnel, since startup there have been no releases of anhydrous ammonia resulting in reportable quantities or injuries

EMERGENCY RESPONSE PROGRAM
In event of a release, certain personnel are designated to determine the potential hazard and coordinate response procedures. The Hazmat Team Chief is responsible in coordinating emergency response and will be contacting emergency response agencies, schools, daycare centers, and acute care facilities that may be affected by the release. The Hazmat Team Chief will also be responsible for evacuation of employees if necessary and for coordination with community emergency responders if off-site evacuations are required. A description of the Emergency Response Program is included in Emergency Response Program.

PLANNED SAFETY IMPROVEMENTS
Specific recommendations resulting from the PHA and safety inspection are listed in Process Hazard Analysis as Hazard Mitigation Recommendations. All refrigeration equipment is well maintained and operated
in a safe manner by trained personnel. Operating, maintenance, training, and safety procedures will be formalized with improved written documentation
Submission - Other Facility Info facility_Submission_-_Other_Facility_Info help link help link  
Number of Full Time Employees900
Owner or Operator NameEarthbound Farm
Owner or Operator Address Line 11721 San Juan Highway
Owner or Operator CitySan Juan Bautista
Owner or Operator StateCA
Owner or Operator Zip95045
Parent Dun and Bradstreet Number0
Second Parent Dun and Bradstreet Number0
Number of Full Time Employees900
Number of FTE CBI FlagNo
Covered by OSHA PSM StandardYes
Covered by EPCRA Section 302Yes
Covered by CAA Title VNo
Last Safety Inspection Date07/29/2009
Last Safety Inspection ByKIE Consultants
OSHA Star or Merit RankingNo
LEPC NameRegion II LEPC

Submission - Contact Info facility_Submission_-_Contact_Info help link help link (Facility #1 : Earthbound Farm, RMP submission #1 : 2009-12-28)
Owner or Operator Phone8316237880
Facility URLhttp://www.ebfarm.com
Facility Dun and Bradstreet Number858556517
RMP ContactRichard Paulus
RMP Contact TitleFacility Engineer
RMP Contact EmailRPaulus@ebfarm.com
RMP Preparer NameKIE Consultants
RMP Preparer Address Line 1250 W. 24th Street
RMP Preparer Address Line 2Suite - O
RMP Preparer CityYuma
RMP Preparer StateAZ
RMP Preparer Zip85364
RMP Preparer Zip Extension0000
RMP Preparer Phone9287828095

Submission - Additional Info facility_Submission_-_Additional_Info help link help link  
RMP Complete FlagYes
Predictive FilingNo
No RMP Accidents Last 5 YearsNo
Complete Check Date12/28/2009
Postmark Date12/28/2009
Anniversary Date12/28/2014
Confidential Business InformationNo

Submission - Lat/Long Info facility_Submission_-_Lat_Long_Info help link help link (Facility #1 : Earthbound Farm, RMP submission #1 : 2009-12-28)
Latitude36.873056
Longitude-121.553333
Valid Lat/LongYes
Lat/Long MethodInterpolation - Digital map source (TIGER)
Lat/Long Location TypeCenter of Facility

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 : Earthbound Farm, RMP submission #1 : 2009-12-28, process #1 : AMMONIA REFRIGERATION)
Process DescriptionAMMONIA REFRIGERATION
Program Level3
Confidential Business InformationNo
Toxic Amount Total (lbs)44,000
Flammable Amount Total (lbs)0
Process Amount Total (lbs)44,000
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)44,000
Confidential Business InformationNo

Process Chemicals facility_Process_Chemicals help link help link (Facility #1 : Earthbound Farm, RMP submission #1 : 2009-12-28, 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 UsedAreal Locations of Hazardous Atmospheres [ALOHA(R)]
Release Duration (minutes)10
Wind Speed (meters/sec)1.5
Atmospheric Stability ClassF
TopographyRural
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 : Earthbound Farm, RMP submission #1 : 2009-12-28, process #1 : AMMONIA REFRIGERATION, process chemical #2, alternate toxic scenario #1)
Percent Weight (Within Mixture)100
Physical StateGas liquified by pressure
Model UsedAreal Locations of Hazardous Atmospheres [ALOHA(R)]
Wind Speed3.4
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 ShutdownNo
Active Mitigation - OtherEmergency Response - Diffusion Tank
Confidential Business InformationNo

Process NAICS facility_Process_NAICS help link help link (Facility #1 : Earthbound Farm, RMP submission #1 : 2009-12-28, process #1 : AMMONIA REFRIGERATION, process NAICS code #1 : 49312)
NAICS Code49312: Refrigerated Warehousing and Storage

Prevention Program 3 facility_Prevention_Program_3 help link help link  
Safety Info Review Date10/20/2009
PHA Update Date10/20/2009
PHA Technique - What IfYes
PHA Technique - ChecklistNo
PHA Technique - What If/ChecklistNo
PHA Technique - HAZOPNo
PHA Technique - FMEANo
PHA Technique - FTANo
PHA Change Completion Date04/01/2010
Hazard Identified - Toxic ReleaseYes
Hazard Identified - FireYes
Hazard Identified - ExplosionNo
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
Hazard Identified - OtherOperator Error
Process Controls - VentsYes
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 PowerYes
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 SystemYes
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 - NeutralizationYes
Mitigation Systems - NoneNo
Monitoring Systems - Process AreaYes
Monitoring Systems - PerimeterNo
Monitoring Systems - NoneNo
Monitoring Systems - OtherMechanical Room Detectors
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 Date09/15/2009
Training Review Date05/18/2009
Type of Training - ClassroomYes
Type of Training - On the JobYes
Type of Training - OtherTail Gates
Competency Testing - Written TestsYes
Competency Testing - Oral TestsNo
Competency Testing - DemonstrationYes
Competency Testing - ObservationYes
Maintenance Review Date09/21/2009
Maintenance Inspection Date07/29/2009
Equipment TestedAll Refrigeration Equipment
Management of Change Review Date09/21/2009
Pre-startup Review Date09/21/2009
Compliance Audit Date09/21/2009
Compliance Audit Change Completion Date04/01/2010
Participation Plan Review Date09/22/2009
Hot Work Review Date09/22/2009
Contractor Safety Review Date09/22/2009
Contractor Safety Eval. Date09/22/2009
Confidential Business InformationNo

Prevention Program 3 Chemicals facility_Prevention_Program_3_Chemicals help link help link (Facility #1 : Earthbound Farm, RMP submission #1 : 2009-12-28, process #1 : AMMONIA REFRIGERATION, process NAICS code #1 : 49312, prev. program 3 #1, prev. program 3 chemical: all)
Process Chemical Record ID
1000017086

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


Process NAICS facility_Process_NAICS help link help link  
NAICS Code115114: Postharvest Crop Activities (except Cotton Ginning)

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 Date09/23/2009
Response Training Date10/12/2009
Local Response AgencySan Benito County Health Department
Local Response Agency Phone8316364035
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 ID100000187861

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