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HomeMy WebLinkAbout4801_RoseAcCompost_renewapplic_20200714V.O. &m 1250 Seymour, IN 47274 tel.812,A97.31497.557 ROSE AqRE fax: ax* B 123311 W W1V.s-clegg'(W L THE GOOD EGG PEOPLE 6/11 /20 NC DEQ Division of Waste Management Solid Waste Section 1646 Mail Service Center Raleigh, NC 27699-1646 To whom it may concern, Please find enclosed the required documents for renewal for Permit No. 4801 Doc. fD 18895 located at the Hyde County Egg Farm, 1560 Hyde Park Canal, Pantego, NC 27860, There are no proposed design or operational changes at this time. If you have any questions please feel free to contact me. Thank you, Wes Spray Environmental Affairs Rose Acre Farms, Inc. wspray@roseacre.com 812-525-8805 Table of Contents Section 1- General Infonnation..........................................................:............3 Section 3 & 4 — Design and Operation Plan..................................................4 Section 5- Odor Control Plan .............................. , ................... 2 General Information Large Type 3 Rose Acre Farms, Inc. -Hyde County Egg Fann 1560 Hyde Park Canal Pantego, NC 27860 Applicant: Tony Wesner Rose Acre Farms, Inc. C.O.O. 1657 W. Tipton St. Seymour, IN 47274 Contact Persona: Wes Spray Rose Acre Farms, Inc. Envronmental Quality Control 1657 W. Tipton St. Seymour, IN 47274 Invoice and Permit Fee Contact Person: Wes Spray Rose Acre Farms, Inc. Envronmental Quality Control 1657 W. Tipton St. Seymour, IN 47274 3 Section 3 &4 - Design and Operation Plan See inserted design and operation plan, from 2010 application Onsite person responsible for operation of the facility: Jim Hall Complex Manager 252-935-5800 Training Requirements: We currently plan to send at least 2 employees to training prior to the Nov. 1, 2022 Deadline. 4 Section S: Odor Control plan Odor control will be accomplished by maintaining condition which do not lead to odor formation. Daily processing of mortalities will serve to minimize odor because well - operated composting facilities have minimal odor. In addition, the remote location and large size of the site will serve to minimize any impact from odors on adjacent property owners even with prevailing winds and seasonal variations. See attached Google Earth image. Source 1,2, and 3 are all potential sources of odor. These are our 3 composting buildings where manure and mortalities are unloaded and mixed_ Active compost rows are contained in these buildings along with finished product. As discussed above, this facility is on the same property as our layer farm on a very remote and rural site. Since operation began in 2005, to our knowledge there has been no odor complaints. In the event of an odor complaint, all required date will be documented including date, time, site conditions, weather conditions, wind direction, and characteristics and intensity of odor. The complaint will be investigated onsite and offsite and action will be taken depending on the findings. The complex, manager will be contacted along with Wes Spray. Documentation will be sent to both. Odor complaint records will be kept for 3 years. Operators and technicians will be trained on how to properly layer mortality composting bins to achieve the correct C:N ratio and moisture levels_ Incoming feedstock will be layered or Windrow as soon as possible to prevent odor.. Windrows and buns will be turned as prescribed in the operation plan- 5 Signature page of applicant — p d��gqr�t Name of facility �js�rlAr��. Fa+tS �r1C• t ��t EUL1 I certify under penalty of law that this document and all attachments were prepared under my direction or supervision and that the information provided in this application is true, accurate, and complete to the best of my knowledge. I understand that North Carolina General Statute 130A-22 provides for administrative penalties of up to fifteen thousand dollars ($15,000.40) per day per each violation of the Solid Waste Management Rules. I further understand that the Solid Waste Management Rules may be revised or amended in the future and that the facility siting and operations of this solid waste management facility will be required to comply with all such revisions or amendments. i 5� Signature Tint Name Dar (2. D . C) . Title Business or organization name I. Godgle Earth RST ENGINEERING PLLC 5416 ORCHARD ORIOLE TRAIL WAKE FOREST NC 27587-6770 November 30, 2015 Mr. Tony Gallagher, Branch Head Composting and Land Application Branch NC ❑ivision of Solid'Waste 1646 Mail Service Center Raleigh, NC 27699-1646 Subject: Application for Renewal Permit SWC-48-01 Rose Acre Farms, Hyde County Dear Mr. Gallagher: Please find enclosed a notebook which contains a copy of the Application for Renewal and Modification for a permit number SWC-48-01 that was originally submitted November 2, 2010 and a copy of my letter dated July 15, 2011 to Michael Scott that transmitted as -built drawings of the composting facility, sealed by a North Carolina registered professional engineer, and certified that butidings as constructed , meet the functions and intent spelled out the permit application, and relying upon the information provided by another registered professional engineer, will function as intended. The application for renewal and supporting information provided included a revised operating plan reflecting the ❑peration of the facility at that time, and photographs showing details of the construction and of the site. I inspected the site and met with the operator on October 15, 2015 and verified that there have been no substantive changes in the operation of the facility and thus the application and operating plan submitted in 2010 accurately reflects the current operation. Thank you for your assistance in this process. If you have any questions, reed any additional information, or would like to have additional copies, please give me a calf. Sincerely, Ray S. (Stan) Taylor, PE RST Engineering, PLLC p° CC John Brinn, Rose Acre Farms Wes Spray, Rose Acre Farms RST ENGINEERING PLLC 5416 ORCHARD ORIOLE TRAIL WAKE FOREST" NC 27587-6770 November 2, 2010 Mr. Michael Scott, Supervisor Composting and Land Application Branch NC Division of Solid Waste 1646 Mail Service Center Raleigh, NC 27699-1646 subject: Application for Renewal Permit SWC-48-01 Rose Acre Farms, Hyde County Dear Mr. Scott: Please find enclosed an application for the renewal of the subject permit and a revised operating plan that reflect the current operating methods and facilities at the Hyde County Egg Farm. The drawings included were provided electronically and show the design details for the new composting buildings. A set of the drawings, sealed by a North Carolina Registered Professional Engineer, will be delivered to you as soon as they are received. The detailed site drawings, geotechnicai reports, and aerial photos that were provided with the original application have not been re -submitted, but are included by reference. Thank you for your assistance in this process. If you have any questions, need any additional information, or would like to have additional copies, please give me a call. Sincerely, f , Ray S. (Start') Taylor, PE FIST Engineering, PLLC CC John Brinn, Hose Acre Farms Chips Everhart, Rose Acre Farms Application for Permit Renewal and Modification for a Large Type Ili Solid Waste Compost Facility Permit Number SWC-48-01 Prepared for ROSE ACRE FARMS HYDE COUNTY EGG FARM RST Engineering PLLC October 2010 introduction: Rose Acres Farms is requesting renewal and modification of Permit Number 48- 01 which was issued for the composting facility to serve their Hyde County Egg Farm. The requested modification is the covering of two of the concrete pads that have been installed for layer houses, Pad #1 and Pad #14 with "hoop barns" so that they may be used for manure management. No request for increasing the flock size is being made. This modification was approved by letter dated September 23, 2010, and this application will provide drawings and documentation for the planned construction, The proposed layer farm will ultimately include fourteen poultry houses, manure composting/storage houses, grain and meal storage silos, a maintenance shop, a truck and car parking area, and an egg -processing house. A feed mill has been placed on the site. The nominal maximum capacity of the poultry houses is 4,000,000 layers. The actual number on site will be less due to United Egg Producers flock reduction policies. The proposed pullet farm will ultimately include 3 pullet houses with a planned nominal capacity of 710,000 birds and a covered manure storage house. Permit Application A copy of the aerial photograph showing the required information was attached to the original application and is included by reference. A fetter from Hyde County addressing local Zoning was attached to the original application and is included by reference- SITING/DESIGN REQUIREMENTS FOR SOLID WASTE COMPOST FACILITIES (see15A NCAC 13B ,1404) Rose Acres Farms proposes to build a composting facility to serve the Hyde County Egg Farm. Waste to be composted will consist primarily of the manure generated at the layer farm and pullet farm that will comprise the total Egg Farm operation. Title 1 aA Subchapter 13B of the North Carolina Administrative Code Section .1402 (f) (3) describes the material being composted at Rose Acres, indicating that the proposed facility is a Type 3 facility. The site is owned by Rose Acre Farms and will meet, at the time of permitting and continuously thereafter the following conditions (see section (a): V (1) The site is not located within a 100-year floodplain. See the site maps provided with this application. (2) A 100 foot buffer will be maintained between all property lines and all compost areas as shown on the site plans. The nearest property line is approximately 400 feet. (3) A minimum buffer of greater than 500 feet will be maintained between all compost areas and residences or dwellings not owned by Rose Acres Farms. See the site plans provided with this application. The nearest residence is approximately 2,500 yards from the property. (4) A 100-foot minimurn buffer will be maintained between all wells and compost areas, The closest existing well is over 500 feet away. If additional wells are constructed, the 100-foot minimum buffer will be maintained. (5) A 50-foot minimum buffer will be maintained between perennial streams/rivers and compost areas. See the site plans provided with this application for location of the nearest perennial stream or canal. (6) The compost facility will meet the requirements of 15 NCAC 26.0200. A storm water permit has been obtained for the facility and a copy of the approval fetter is attached. (7) None of the facility will be located over a closed out disposal area. See the soil evaluation provided with this application- (8) A 25-foot minimum distance will be maintained between compost areas and swales or berms to allow for adequate access of fire fighting equipment. See site plans. (9) Ail composting will be, done in enclosed buildings and compost or feedstock spills will be cleaned as indicated elsewhere in the application so that there will be no discharge of fill materials into the waters or wetlands of the state, no violation of the requirements of the N P D E S permit for the facility, and there will be no non -point source discharges which violate any assigned water quality standard. (10) Groundwater Requirements will be met by providing anclosed buildings with concrete floors upon which all composting and storage will be done. The floor elevation will be located at least 24 inches above the seasonal high water table. (c) The site meets the following design requirements: (1) Public access to the site is limited by Rose Acres in that the layer farm has limited access to insure control of poultry diseases. The compost facility itself will be in closed buildings, further limiting public access. (2) A sedimentation and erosion control permit application has been fled and a Letter of Approval received, indicating compliance with the requirements of the Sedimentation Pollution Control Law (15A NCAC 4). 3 (3) A site meets the requirements of the Air Pollution Control Requirements (15A NCAC 2D) to minimize fugitive emissions and odors. (4) The site layout and the operation plan that was submitted and approved specify activities to minimize odors at the property boundary. The following items are attached to the application in order to satisfy the requirements of paragraph (b) of Part .1405- Waste to be composted will consist primarily of manure generated at the layer farm, manure generated at the pullet farm, and bird mortality from both farms. Small quantities of eggshells, egg packing waste, or spoiled feed may also be managed at the facility and added to the compost. Solids from the lagoon handling egg wash water will be added to the compost if it becomes necessary to remove them from the lagoon. Sawdust, wood chips, peanut hulls, wheat straw, or other suitable bulking agents approved by the Division of Waste Management will be utilized. The site plan is attached. The initial contact information for this composting facility is: Tony Wesner Rose Acre Farms PO Box 1250 6874 North Base Road Seymour, IN 27274 Phone 812-497-2557 Complex Manager Name Jehfi li;Am" % , Address 1560 Hyde Park Canal Road Phone 252-935-5800 The personnei required to operate the facility will have other responsibilities on the egg farm as well. We anticipate approximately 2 to 3 man -days per week being needed to operate the facility. Tasks which will be specifically done for the composting operation and which require technician level employees include the following: Sampling and Analysis Technician -- daily temperature measurements and inspection of the composting operation, including all record keeping required by the operation plan Equipment operator(s) — movement of manure into the facility, movement of compost within the facility, and movement of finished composted manure from the facility 4 Maintenance mechanics) -- maintenance of the mechanical equipment and processes in the facility Mortalities will be collected from cages daily by the farm staff. Mortalities are identified by a person walking by each cage each day during the daily walk-through inspection that takes place at ail Rose Acres facilities. There will be no regular operating hours when the facility is open to the public. The facility will be open to receive manure or mortalities from the layer farm and pullet farm on a daily basis. Details of daily operations including facility start up and shut down are provided in the O&M manual included with the application for a permit to operate the facility. Neither mixed waste nor household hazardous waste will be received on the site_ This facility is enclosed so adverse weather will have minimum impact on operation. All weather surfaces will be constructed around the facility to avoid problems with periods of high rain. In the event of ice, snow, a hurricane or hurricane like conditions, activity, including waste receipt, can be suspended until the weather abates. The windrows will be large enough to self insulate during periods of extreme cold. General Operation Plan More details are provided in the O&M manual that was submitted with the application for a permit to operate.) Manure from the pullet houses will be stored on the pullet farm site on a concrete floor and under a roof until it is transferred to the composting facility. Initially, manure from the layer houses was allowed to accumulate under the cages in the houses for an estimated 14 months. With the additional manure handling space, the manure will be removed from the houses much more frequently. The reason for this is to reduce the amount that accumulates and to accomplish better vector control Temperatures in the manure piles may exceed 150 degrees F during storage, but the piles will not be turned and the dried manure will not be completely composted. The houses will be cleaned by removing the dried manure with a front-end loader and transporting it to the composting facility, where it will be placed into windrows for composting. 5 Dried manure from the layer houses will be composted in windrows that will be formed as described under the design capacity discussion below. Each windrow will be made up primarily of manure with finished compost and/or moisture added as required to achieve active heating. No bulking agent addition is planned for the manure composting process. Temperature measurements in the windrows will be made in accordance with the Sampling and Analysis procedures and the results recorded, Those procedures will be outlined in the ❑&M Manual that is included with the application for a permit to operate. After the temperature near the center of a windrow exceeds 131 degrees F the windrow will be turned with a self-propelled compost turner. Mortality composting will take place in bins. The design of the bins will be further discussed below. Mortalities from the layer houses and the pullet farm will be collected daily and delivered to the composting facility in closed containers. At the facility, the mortalities will be layered into the composting bins. The mortality will be layered with manure, finished compost, straw, or sawdust/wood chips. Details of the layering process will be provided in the O&M Manual. The schedule of turning of the bins and windrows will be adjusted to meet the Process to Further Reduce Pathogens standards. All parts of the: windrow must be at 131 degrees F or higher for a minimum of 15 days. In the bins, the temperature of 131 degrees F must be maintained in all parts of the bin_ Ventilation pipes may be added with each layer of bulking agent in the mortality composting bins to reduce or eliminate the need for physically turning the bins. The anticipated residence time in the bins is about two to three weeks with additional time in the windrows. The compost will then be moved to the storage portion of the facility where it will continue to cure until it is sold or is used in further composting operations within the facility. Material Transfer Management Moving manure into the composting facility and moving finished compost out creates the potential for spills of materials onto the ground or roadways. As a standard operating procedure, any material spilled outside the walls of the composting facility shall be immediately recovered. Spill management procedures are outlined in the O&M Manual. Finished: Compost Use Finished compost from the facility will be sold to one or more third parties for use as a soil amendment. The primary use of the material is, at this time, expected to be as a soil amendment. Most sales are anticipated to be to hulk purchasers. The name and address of each person receiving the finished compost will be recorded along with the quantity of compost delivered and the date that the delivery takes place. Each person purchasing compost will be given a copy of ET the most recent waste analysis, but will not be given any guarantee of the actual nutrient content of the material they purchase. Handling Off -Specification Material In the event that testing shows that a batch of composted material does not meet, the required quality standards, that material will be run through another composting cycle by being set aside for use as an additive in composting fresh mortalities_ It is anticipated that any off' -specification material that is reprocessed in this manner will meet the desired specifications upon reprocessing. Material that consistently fails to meet specs can be landfilled at a permitted municipal solid waste landfill facility. Handling Emergency Events In the unlikely event of a spill of a significant quantity of compost or manure, the spilled material will be immediately recovered by shoveling and sweeping the material into containers to be delivered to the composting facility for processing. To prevent rainfall from washing any spilled materials to the storm drainage system far the site, no transfers will be allowed during rainfall events. If there is a much higher than anticipated mortality rate, the safety factor in the design of the composting facility may well allow the increased numbers of dead birds to be handled in a normal manner. Based on the experience at other Rose Acres facilities, it is anticipated that the composting facility could handle 45,000 mortalities per month on a short-term basis. If, in the event of some catastrophic event at the facility, the number of mortalities overwhelms the capacity of the compost facility, the mortalities may be shipped off site to a rendering facility or to an approved landfill for burial. Disposal will be in compliance with the requirements of NCGS 106-403. Management of Vectors and Odors Vector control will be achieved by maintaining the composting facility to prevent creation of conditions which attract vectors. The manure brought into the facility will be dry and reasonably stable because of the time it was retained in the layer or pullet houses. Dry, partially stabilized material will not attract flies and other insects readily. The internal temperatures in the piles will be high enough to prevent insect infestation. Mortalities will be delivered daily to the facility in closed containers, which limit access to vectors. Since all handling will be in an enclosed building, vector attraction will be minimized. The end use of the finished Class A compost will not create nuisance conditions or vector attraction problems because of the stable nature of the material. Odor control will be accomplished by maintaining conditions which do not lead to odor formation. Daily processing of mortalities will serve to minimize odor 7 because well -operated composting facilities have minimal odor problems, in addition, the remote location and large size of the site will serve to minimize any impact from odors on adjacent {property owners, No mechanical ventilation is planned for the composting facility, so any emissions which do occur will be fugitive in nature and will not require any permit There will be no point source of emissions and any air quality impacts from particulate matter emissions is expected to be negligible. Design Capacity The Department of Poultry Science at NCSU has published a guidance document entitled "Composting Poultry Mortality', Table 2 of this document is entitled "Estimated Primary & Secondary Bin Capacity for Mortality Composting per 1,000 Birds and Standard Size Units for Various Types of Poultry"_ This table recommends 2.54 cubic feet of bin space per 1000 birds in the flock for layers and 1.96 cubic feet of bin space per 1000 birds in the flock for pullets. Using these recommendations and the design population of 4,000,000 layers and 710,000 pullets, the required bin space is 11,552 cubic feet. It is important to note that the bird populations chosen for estimating the space requirement are greater than will ever be on the site, creating a built in safety factor in the system design. The same publication gives the typical weight of a typical layer at maturity of 4 pounds. The HY-Line W-36 variety used at Rose Acre Farms has a typical weight of 3.48 pounds at maturity, giving an additional safety factor of 15% in the estimated bin volume required. The composting bins at Hyde County are located in Building 1 and Building 2. The total bin volume in Building 1is 5,376 cubic feet and in Building 2 is 9,216 cubic feet. A Spreadsheet is attached which gives the calculations discussed above, Historical information taken from the period of July 1, 2009 through June 30, 2010 was used to estimate the total manure production, based on the original population estimates of 4 million layers and 710 thousand pallets. Note again that the assumed populations for the layer and pullet operations are greater than will ever be experienced, providing a built-in safety factor in sizing the composting facility. A spreadsheet is attached giving the calculations used to estimate the space in the composting facility that is needed to compost the manure. The amount of material composted per length of windrow was calculated from operating data, and that factor is used in showing the capability of the facility with the two new buildings in service. Note that while there is more capacity for managing the manure produced, there is no request to expand flock size. In the event that additional space ,is needed, an additional composting/storage building can be constructed south of the shop building. The location far this building, if it is needed, is shown by dashed lines on the attached 0 plans. Note that minor rerouting of the site drainage system will be required if the building is ever constructed. The composting facility will have three buildings. The original building is Building 1, the building to be constructed on Layer Pad 14 is Building 2, and the building to be constructed on Layer Pad 1 is Building 3. This will increase the floor area of the composting facility by 131,000 square feet. The additional space will be used to store finished compost as needed to satisfy the local demand patterns, and to allow more rapid removal and composting of manure from the layer houses. The additional space will give the operator added flexibility in operation, and the portions of each building used for composting and for storage will be adjusted as necessary to optimize the operation of the facility, The Process block flow diagram was attached to the original application and is included by reference. Storage of Bulking Agents for Composting A bulking agent will be required for use in composting mortalities. The bulking agent of choice will be sawdust or wood chips_ If an adequate supply of sawdust is not available, wheat straw, peanut hulls, or locally available materials, approved by the Division of Waste Management, will be used, Storage space for 20 cubic yards of material is available in composting Buildings 1 & 2. This will provide a 1-month supply of bulking agent at normal use rates. Finished compost may be used to mix with .bulking agent and dead birds and will come from the storage piles in the composting building. Actual movement in and out of the facility will be based on demand for the finished compost. The historical demand patterns for the Finished compost demonstrated the need for the additional storage and management space in Buildings 2 & 3. No additional facilities will need to be constructed for handling mortalities. Operating experience has shown that shredding is not necessary. Measuring mixing and proportioning will primarily be done with a front-end loader or a bobcat. The composting process duration may be different for processing the mortalities and processing the manure. The mortality process is anticipated to last no more than 20 days in the composting bins. Past experience at other Rose Acre facilities indicates that this time will allow complete composting of the mortalities and will allow for 15 days at temperatures greater than 1310 F, needed for compliance with the requirements for "Further Reduction of Pathogens". After removal from the bins, the mortality compost will be then be added to the manure windrows where it will continue to compost for another approximately 30 days, The compost will then be moved to the storage portion of the facility where it will continue to cure Until it is sold or is used in further composting operations within the facility. The composting process for manure in windrows is anticipated to last for approximately 30 days. The compost will be mixed and turned at least 5 times during this period to achieve 15 days where the temperature of the windrows exceeds 1310 F in order to attempt to meet the requirements for "Further Reduction of Pathogens". Finished compost from the storage areas of the facility will be used to insulate the windrows as necessary. When it is removed from the windrows, the compost will be moved to the storage area of the facility where it will remain until it is sold. Any non-compostable materials found, such as drink bottles, will be managed through the farm solid waste management activities. Each mortality bin and each windrow will be sampled at multiple locations and at a frequency of at least 3 to 5 days per week to demonstrate that the PFRP time and temperature requirements are met. Specific spatial and frequency details are included in the facility O&M manual. A three or four foot compost thermometer will be used to monitor temperatures. Temperature monitoring and record keeping will demonstrate that the temperatures in the bins and the windrows are maintained above 131 degrees F for a period of at least 15 days and that the compost is turned at least five times while the temperatures are above 131 degrees. If timeltemperaturelturning requirements are not met pathogen sampling in accordance with EPAt6251R- 021013, Revised July 2003, will be used to demonstrate pathogen reduction. Aeration for the windrows will be provided through mechanical turning using a self-propelled compost turner, a front-end loader or a bobcat. Turning frequency will be frequent enough to maintain adequate oxygen levels to sustain aerobic biologic activity to maintain temperatures at appropriate levels. Aeration for the bins will be through use of ventilation pipes inserted in each straw layer in the bin if necessary, or through turning with a front-end loader or bobcat. The typical layering in a mortality -composting bin is to place 6 inches of sawdust or finished compost on the concrete floor. This is covered with 6 inches of straw with ventilation tubes. This is covered by a layer of mortalities (about 136 birds or about 473 pounds, about 550 pounds of finished compost or dried manure, and water, if needed to reach desired moisture levels. The bin is then filled with alternating layers of straw (with ventilation tubes if needed) and the mortality "recipe" until full. It is capped with a six-inch layer of sawdust or 10 finished compost. If ventilation pipes are not used, the compost must be turned regularly. Rose Acres has found at Lincoln County that turning is not necessary if the ventilation tubes are used. The need for air emission control technologies is not anticipated. Maintaining proper carbon to nitrogen ratios and proper oxygen levels should control odors. Finished compost will be used to cover windrows if needed to control odors early in the compost process when most of the volatile compounds are released. Since the composting areas are covered there should be no problems maintaining proper moisture levels in the compost. Maintaining proper moisture levels will, in turn, prevent leachate production. The waste storage, composting and curing areas are located on a concrete pad, which will eliminate vertical movement of liquids to the soil or groundwater under the facility. Runoff from around the buildings is controlled through a permitted storm water control system. Runoff control structures are located as shown on the site plan. There will not be any recycling facilities specific to the compost operation. An information sheet will be used to provide information to agricultural users about the quality of the compost. The information sheet will indicate classification grade, recommended uses, adequate nutrient levels to enable users to properly use the compost as a nutrient source. Any restrictions on use will also be provided. The original composting building, Building 1, is a "Hoop Barn" designed and built by Coverall Building Systems, Inc. of Saskatoon, SK, Canada. This is the type building being used at other Rose Acres Farms installations. The attached drawings by RST Engineering, PLLC show the basic lay out and size of the building, and the structural details are shown on the details provided by Dudek Consulting and sealed by Robert Dudek, a North Carolina Professional Engineer, Buildings 2 and 3 will be designed by Evergreen Engineering, based in Eugene, Oregon and will be constructed by Eco-Builders, LLC. The plans For these buildings are attached. 11 OPERATING PLAN ROSE ACRE FARMS HYDE COUNTY EGG FARM COMPOST 1 STORAGE BUILDINGS COMPOSTING OPERATION OVERVIEW The purpose of the Rose Acre Compost Facility in Hyde County is to manage poultry manure and mortality in a responsible manner that will minimize the possibility of any adverse effects to the environment. Manure from the pullet houses will be stored under roof on the pullet farm site until it is transferred to the composting facility. Manure from the layer houses will be allowed to accumulate under the cages in the laying houses, protected from the weather. Typically. the manure will accumulate for approximately 3 to 6 months, but under some circumstances could accumulate for up to 121-18 months as the system was originally designed. The plies will not be turned and the dried manure will not be completely composted while in the houses. Mortalities from the layer mouses and the pullet farm will be collected daily and delivered to the composting facility in closed containers. At the facility, the mortalities will be layered into the composting buts as described in this text_ All mortalities and manure will be composted to meet the EPA Process to Further Reduce Pathogens and Vector Attraction Reduction standards to minimize the possibility of the spread of disease on or off the Hyde County Egg Farm. RESPONSIBLE EMPLOYEES The employees that will be responsible for and execute the handling of the manure, compost, litter, the acquiring of necessary samples, maintaining sufficient inventory- of sampling materials, maintaining all sampling equipment in proper working order, finished compost, and mortalities are as follows: Complex Manager Environmental Services Manager Environmental Services Employees Any other employee designated by the complex manager to assist in the process. It should be noted that only the complex manager, environmental services manager or environmental services employees shall be responsible for the record keeping associated with the composting process. Complex Manager and Compost Facility Contact Name -;Yx x "O\ Address 1560 Hyde Park Canal Road Phone 252-935-5800 1) DEFINITIONS For the purpose of this operating manual litter shall be defined as manure from the pullet or laying houses. Bulking agent shall be defined as any material used as a carbon source for the mixture of the compost, composting process, or hulk storage of raw materials. Finished compost shall mean material that is ready to be delivered for use as an agricultural supplement for the growing of a crop; garden, general horticultural, or other public uses suitable for Grade A compost. COLLECTION OF MATERIAL FOR COMPOSTING As the manure drops from the bird it accumulates in the lower portion of the house. This area, which is on a concrete floor above natural grade, is called the pit. Periodically the manure must be removed from the pit, as it becomes full. In order to accomplish removal activities, a small front end loader or a similar device will enter the pit through a door between the pit level and the outside, and begin to scoop up manure. The manure accumulates as cone -shaped rows under each row of hens. facilitating systematic removal. The manure is removed mid placed directly into the bed of a dump truck. Prior to being loaded in the truck, the manure will be visually inspected for the presence of foreign materials, i.e_, materials that are not either manure or feathers. Should foreign materials be found, they will be removed prior to placing the manure in the bed of the dump track. Any manure that falls to the ground outside the house or the pullet farm storage building during manure removal and transfer shall be swept up either with a broom and dustpan or with a shovel by the end of each work day or prior to significant rainfall. Manure will not be transferred during periods of high rain or high wind. The dump trucks, when full, will move the manure to one of the coznpostinglstorage buildings. During transfer activities, three trucks will be weighed to determine the average weight of manure comprising a load. This average weight will be multiplied by the number of trucks loaded in a given day, and that figure will be recorded in the appropriate column on the RAF Manure and Mortalities Transfer log. During transport from the loading area to the composting building, the roadway will be visually inspected for manure that came out of the truck during transport, Any manure noted will be cleaned up by the end of that work day. The manure collected shall be brought to the compost building and placed with the other manure transferred that day. The manure shall be offloaded in the compost building to form windrows. 3 Manure transfers from the poultry houses shall be documented in the section under the heading "Manure'. The date the transfer took place shall be indicated in the column marked "Date". If the manure was transferred from the layer farm, an "L" shall be placed in the column marked "Farm". If the manure comes from the pullet farm, a "P" shalt be placed in the column marked "Farm"_ The numerical designation of the house the manure was removed from shall be identified in the column marked "House". The weight of manure in tons shah be recorded in the column marked "tons". The employee making the transfer shall write their initials in the column marked "Empl. Initials" to verify the transfer. Mortality transfers shall be documented in the section under the heading "Mortalities". The date the transfer took place shall be indicated in the column marked "Date". if the mortalities were transferred from the pullet farm, then a "P" shall be placed in the column marked "Farm'. If the mortalities were transferred from the layer farm, then an "L" shall be placed in the column marked "Farm". The numerical designation of the house the mortalities were transferred from shall be recorded in the column marked "House". The number of mortalities and combined weight of the mortalities shall be recorded in the columns marked V Birds" and "Weight". The combined weight of the mortalities is critical in determining the proper amount of carbon to be mixed with the mortalities to facilitate composting. The employee will place their initials in the column marked "Emlil. Initials" to verify the transfer. Completion of these forms creates a record of when manure or mortality are removed from the individual houses and placed in the compost building and the quantity that is moved. MORTALITY COMPOSTING When daily mortalities are transferrers from either the pullet farm or the layer farm the pertinent information shall be recorded on the Mortalities Transfer Log as indicated in this document. The composting of mortalities shall follow the set of guidelines outlined below. The mortality composting bins measure eight feet wide by twelve feet deep and are either six or seven feet high. The bins in the original composting house are seven feet high and the bins in the new composting houses are six feet high. At the entrance to each bin is a small channel where 2" thick boards can be stacked edgewise, in order to contain the amount of composted mortalities placed in the bin. Each bin is assigned a number. Each bin is anticipated to be of more than adequate size to contain all the mortalities that would be generated each day_ If space permits it is permissible to place at least a portion of one day's mortalities on top the mortalities in another bin to finish fitting that bin before moving on to the next bin. 4 In order to achieve complete composting of mortalities, the mortalities will have to be mixed with some manure and bulking agent. Typically, bulking agent mixed with mortalities will be comprised of manure and sawdust or straw. Bulking agent may also include wood chips, yard waste, peanut hulls, cotton gin trash or other materials approved by the Solid Waste Section. Finished or partially composted manure from the manure windrows may be also be added to the bins, The ratio of the weights of each ingredient will be adjusted to achieve complete composting of the mortalities. The ideal composition is a C:N ratio of 25:I with a 45% moisture content, A typical recipe, by weight, is one part dead poultry, 1.5 to 2.0 parts manure from the layer or pullet houses and 111 D part straw or sawdust_ The mortalities to be composted each day will be weighed to determine the basis for the day's mix of ingredients_ Alternatively, the mortalities may be counted and a known average weight used to calculate the basis for the day's mix of ingredients. Water will be added only if necessary to achieve composting. The typical layering in a mortality -composting bin is to place 6 inches of finished compost on the concrete floor. This is covered with 6 inches of straw. Ventilation tubes are placed in the straw layers if ventilation tubes are needed. Operating experience over the past five years has shown that ventilation tubes are not normally needed. This is covered by a layer of mortalities (about 136 birds or about 473 pounds). Next, about 6(six) inches of manure is used to cover the mortalities. Water, if needed, is then added to reach desired moisture levels. The bin is then filled with alternating layers of straw and the mortality "recipe" until full. It is capped with a six-inch layer of sawdust or finished compost. Aeration for the bins will be through the use of ventilation pipes inserted into each straw layer in the bin as necessary. Two one inch pipes with holes that are at least (1 J4 ) inch in diameter and spaced every (1-2)inches will be placed in each straw layer in each bin. In the event additional aeration is necessary a front-end loader or bobcat will be used to turn the bins. Composted mortality will normally be transferred to manure windrows after they have been in the bins at least long enough to achieve a minimum temperature of at least 131 degrees F for at least three consecutive days. Re -composting this material will further reduce the possibility of any pathogens in the mortality surviving. The composted mortality material will be layered into the manure windrow most recently placed in the compost building. Finished mortality compost material may also be added to the windrows and then turned in with the turner far incorporation into the windrow. After initial heating, this windrow will be monitored and turned in keeping with normal manure windrow practices. If composted mortalities are to be sold, rather than added to the manure windrows, the temperature and residence time in the bins will also meet the requirements of Compost Rule _1406(11). Specifically, the bin temperatures will remain above 104 degrees F for a total of at Ieast 14 days and the average temperature for that time shall remain above 113 degrees for that 14 day period. The three days at 131 degrees F is included in the 14 day average. Temperature monitoring and record keeping will be continued during this period to demonstrate that this standard has been met. During the three day period when cornposi bin temperatures are to be above 131 degrees F temperatures will be rnosutored in at least three locations and at two depths, in each bin. Each temperature will be recorded. Temperatures may be monitored after three days above 131 degrees to be sure the compost process is proceeding. If the mortality compost is to be distributed directly to the public the bin temperatures will continue to be monitored as noted above to demonstrate that the vector attraction reduction time and elevated temperature requirements are net. The RAF Hen Mortalities Composting Log shall be completed. The finished mortality compost product will be sampled and analyzed_as required in 15 NCAC 13B.1408(a) before the compost is removed from the bin for distribution to the public. Sampling will be done for pathogens, regulated metals, foreign matter and nutrient levels. Samples collected from the bin in question will be assigned a specific sample number in order to accurately track the analytical information pertinent to the compost contained therein.. The sample number will be recorded in the columns marked "Sample 4". The date the sample was collected and sent to the lab will be recorded in the column marked "Date Sent to Lab". Samples are to be sent to the lab on the date they are collected. MORTALITY COMPOSUNG LOG Composting of mortalities shall be verified by completion of the Mortality Composting Log. The date that mortatities are placed in the bin sisalI be recorded in the col umn marked "Date". In the column marked "Farm/House", the farm the mortalities were transferred from shall be designated by placing an "L" for mortalities transferred from the layer farm, or a "P" for mortalities transferred from the pullet farm. Additionally, the numerical designation of the Douse the mortalities were removed from shall be placed in the same column. The number of birds brought to the composting area shall be recorded in the column marked "# of Birds". The numerical designation of the bin the mortalities are placed in shall be recorded in the column marked "Bin #". The depth, in inches, to which the bin is filled shall be recorded in the column marked "Depth in Bin". The date the temperature of the compost in that specific bin initially rises to 131 degrees F shall be recorded in the "131 Deg. Date" column. After reaching this temperature, the compost shall be monitored for the following 3 days, and the temperature on each date shall be recorded in the "24 Hour 'Temp.", "48 Hour Temp.", and "72 Hour Temp" columns. Should the temperature fall below 131 degrees F, then the 3-day recording period will start over after the bin temperature once again reaches 131 degrees F. The date the composted mortalities are removed shall be recorded in the column mar-ked "Date Removed" Manure composting The manure shall be offloaded in the compost building to form windrows. Each windrow begins just beyond the mortality compost bins. Each windrow NO] be a maximum of 535 feet long in the original composting building (Building 1), 526 feet long in Building 2, and 676 feet long in Building 3. The interior walls will have markings painted on therm delineating the starting and ending point for the windrows, and shall also have markings at various distances to enable the individual in control of manure placement to determine the length of the windrow. As the composting process is completed, the finished compost will be stored in one or more of the composting houses. In any given building, as the area occupied by finished compost increases, the available area for constructing windrows decreases. A miai murn separation of 30 feet will be maintained between any finished compost storage and the active windrows to avoid potential cross -contamination with pathogens. This will not create any operating or capacity problem as the area available for composting and storage has increased by a factor of three, and there is no projected increase in the number of chickens on site, so there will be no increase in overall throughput of the composting facilities. Generally, windrows will be formed by positioning the dump trucks where the windrow is to begin or be continued, oponing the tailgate, lifting the bed, and driving down the length of the building, dispensing manure as it proceeds, The individual in control of manure placement shall indicate to the driver of the truck whether to speed up or slow down in order to evenly dispense the manure along the windrow being formed. Windrows will be formed that are approximately fourteen (1 4) feet wide at the base and 9 feet high measured fronn the Boor to the top of the windrow. Operating experience has shown that each foot of windrow will contain about 1.21 tons of compost. As the windrow portion of the building fills up it may be necessary to drop the manure in the open area and use a front end loader to place the manure in the windrow. A small pile of manure will be maintained in the vicinity of the compost bins for daily use in composting mortality. Alter reaching a temperature of 131 degrees F and maintaining it for 3 days, the wind row will be turned. Each windrow will he maintained at temperatures at or above 131 degrees F for at least 15 days and during the period the windrows are above 131 degrees each windrow will be turned five times. Each time the windrow is turned the date and tinge will be recorded in the manure compost log. After the fifth turning, the compost will be sampled and samples will be sent to the lab for analysis. if the analysis shows the compost meets the requirements for a Grade A compost, the compost will be considered ready for further distribution. 7 Compost temperatures will be monitored at least every three days during the 14 day period the temperatures are at or above 131 degrees F for pathogen redaction. Prior to turning the compost, the person in charge of that duty will check the internal pile temperature to determine whether it is at or above 131 degrees F. Temperature testing will be performed at approximately 25 foot intervals along the length of the windrow. Sample points should be approximately one third of the height of the pile from the top. The temperature will be measured 6-12 inches into the pile, and again 3-4 feet into the pile. Each temperature and the depth to which the thermometer was inserted will be recorded in the appropriate location in the manure compost log. Aeration for the windrows will normally be provided through mechanical turning using a self-propelled compost turner. A front-end loader or a bobcat will also be available for turxung if necessary. If areas are noted that are not at the minimum temperature of 131 degrees F, that windrow will not be turned. Staff will then try to determine the reason the temperature is low. If lack of oxygen is determined to be the problem the windrow may be turned more often to keep oxygen levels up. If it is determined that a lack of moisture is the problem, water may be added as necessary to maintain optimum moisture content in the compost in order to sustain appropriate levels of aerobic biological activity. If water is needed it is added through a pipe attached to the compost turning machine and is blended in as the compost is turned_ If at any time during the turning process the temperature drops below the 131 degrees F required the composting process shall begin again_ After a windrow has met the required 131 degrees F for 15 days turning frequency will be only what is necessary to maintain adequate oxygen levels, sustaining aerobic biological activity to maintain temperatures at appropriate levels. MANURE COMPOSTING RECORD The date each load is received shall be recorded on the line provided. The numerical designation of the rove the manure is placed in is to be recorded in the space provided, The person responsible shall record the numbers, in the space provided, to the nearest foot marker, from the beginning and the end of the row created during that day's manure placement activities. Manure from the pullet farms will follow the same process as above except manure will be delivered via a large dumpster. The pullet manure will generally be placed into the next available open row for composting. Pullet manure may have a higher moisture content than the layer manure. If higher moisture content is needed in the layer manure windrow to sustain appropriate levels of aerobic biological activity, the pullet manure may be incorporated into the layer manure. 0 Composting Other Materials Any solids that must be removed from the lagoon handling egg wash water may be composted at this facility. These solids will be added to new layer manure windrows when they are created. Broken eggs, egg shells, or eggs which do not meet company standards may also be managed at this compost facility. These materials would also be added to new layer manure windrows when they are created. This material may also be added to the mortality bins for composting with the mortalities. SAMPUNG PLAN The purpose is to establish procedures for the collection of representative samples of composted manure in a manlier that will not result in the contamination of the sample and will allow accurate analysis of the sample for, pathogens, regulated metals, foreign matter, and nutrient content. Foreign matter would be materials made of plastic metal, or glass. Compost sampling and analysis will be performed according to the guidelines outlined in 15 NCAC 138.1408(a)(1), NCAC 13B.1408(a)(2), and NCAC 13B.1408(a)(5). Samples shall be collected for pathogens, regulated metals and foreign matter, at approximately every 6,000 tons of compost produced, or each 6 month period, whichever comes first. The equipment utilized for this shall be a 48 inch or a 40 inch dial head, probe type thermometer, pre -sterilized plastic bags, a stainless steel sampler (a hand auger or tube type sampler) that is a minimum of five feet in length, a staniless steel bowl, a stainless steel trowel, and disposable rubber or latex gloves. Disposable rubber or latex gloves will be worn while sampling or handling manure or compost for analysis. The manure/compost pile will be sampled on a regular basis to document the conditions of the compost and verify that the pathogen levels for the composted material meet 15 NCAC 13B.1408(a) requirements. Material from the bins shall only be tested if the compost is to be distributed and not re -composted with the ntailure. Prior to pathogen sample collection, all sampling tools will be cleaned with water and a detergent by scrubbing with a brush and rinsing with clean fresh water. The sampling tools will be cleaned between each sample and new disposable gloves will be used to collect each sample. Z5 Pathogen samples should be grab samples or a composite sample taken from no more than I bin or windrow. This will make it easier to locate the source of contamination in the event of a bad sample. Samples will be collected using a clean stainless steel auger. The sample will be collected from a point 6 inches into the pile to the depth of the auger. The entire sample shall be placed into the clean stainless steel bowl and mixed thoroughly with the stainless steel trowel. A representative quantity of the mixed sample will be transferred to a plastic bag provided by the analytical laboratory. The bag will be immediately sealed and marked with a sample identification number, the date and time of the sample, and the sampler's name. Pathogen samples will be cooled to approximately 40 degrees F until delivered to the lab. All samples collected will be transferred using standard chain -of - custody procedures to the analytical laboratory for analysis. The detection limit for the fecal coliform analysis should be less than one thousand nrpn per grain and the detection lintit for salmonella must be less than 3 rnpn per 4 grarns. Composite samples will be taken to be analyzed for regulated metals and foreign matter. At least 1 sample will be taken from each manure windrow. The samples will be maintained at approximately 40 degrees F until the 6 month or approximately 6,000 ton period has been reached. At that time the samples will be mixed together and a representative sample taken and sent for analysis, Copper, cadmium, lead, nickel and zinc are the regulated metals to be tested for. The total metal level (mg/kg) of each metal is to be determined by a Waste Analysis from the NCDA Plant Waste Solution Section Lab or Other approved lab. The foreign matter is determined by passing a dried weighed quantity through. a 114 inch screen. Any foreign matter remaining on the screen shall be removed and weighed to determine the percent by weight. A composite sample shall be taken from each batch of compost to determine the nutrient content. A batch is considered to be approximately 6,000 tons. Upon the designation of a halch the required number ofsarnples ,+011 be taken, a composite sample formed 017d this composite sample delivered to a laboratory for analysis. The size of each nutrient sample should be the same. Nutrients to be sampled for include at least nitrogen, phosphorus, potassium, calcium, iron, magnesium, and sulfur. The nutrient levels will he determined by a Waste Analysis from the NCDA Plant Waste Solution Section Lab or other approved lab. All composite samples shall be combined in the stainless steel bowl and thoroughly mixed with the stainless steel trowel. A sample of at least I kg shall be transferred to a container- provided by the analytical. Iaboratory for analysis using standard chain -of - custody procedures. The container will be sealed and marked with a sample identification number, the date and time of sample, and the sampler's name. The 10 analytical laboratory shall test the sample using methods accepted by the North Carolina State University Extension Service. Prior to release of any composted mortalities for distribution other than to be re -composted with the manure composting, a series of samples shall be collected from each bin to determine that the compost meets the pathogen levels defined for CIass A compost. Samples will be collected to reflect the total volume of the pile being sampled. A sample shall be collected and analyzed for fecal caliform or salmonella organisms as required to demonstrate compliance with the pathogen reduction standards outlined in 15 NCAC 13B.1448. Additionally, these samples will be analyzed. to determine the amount of metallic contaminants [cadmium, copper, lead., nickel, and zinc_] and foreign matter present per 15 NCAC 13B. 1408. MARKETING AND DISTRIBUTION PLAN Rose Acre Farms will create a Grade A compost. According to North Carolina Solid Waste rule 15 NCAC l 3B.1497(d)(1), "Grade A compost shall have unlimited, unrestricted distribution. This product may be distributed directly to the public". It is the intent of Rose Acre Farms to work with the farmers and other users in the region to properly use and distribute the compost that is generated from the farm in Hyde County North Carolina. The sale and distribution to local users shall take place only after the compost has completed its processing in the compost and storage facility at the Rose Acre Farms site. In order to assure that the best information is made available to those using the compost for the many and varied uses of this Grade A compost each "batch' shall have an NCDA Waste Analysis, or an analysis from a private vendor providing similar information, performed on it within 90 days of its use. Rose Acre Farms will request a nutrient management plan from any individual which receives more than ten ( 1 d) tons per visit of finished compost. It is also permitted to work with any local, county, state or federal government agencies that may need a nutrient base for any projects they may be required to perform. For any agency that would use the product, nutrient planning would be performed before delivery or application. CONTINGENCY PLANS EQUIPMENT BREAKDOWN Preventive maintenance will be performed on all equipment on a regular basis to lessen the opportunity for an equipment breakdown. if however the equipment does break down the required pate would be immediately ordered after determining the proper parts required to make the necessary repairs. If a technician would need to be brought in then that would be arranged. If the turner is unable to be used due to equipment failure, and manure is scheduled to be turned, then a small bobcat type loader or other suitable piece of equipment would be used_ Turning of mortalities composted in a bin may be accomplished by hand, should no suitable piece of equipment be available to turn it mechanically. Odor- control will be accomplished by maintaining aerobic conditions and proper carbon nitrogen -ratios in the compost bins and windrows. Mortalities and manure will be processed daily. This will avoid putrefication of mortality. If odor does become a problem ON can be adjusted with bulking agent, of finished compost can be placed aver bins and windrows when formed to adsorb odors._ In addition, the remote location and large size of the site will serve to minimize any impact from odors on adjacentproperty owners. HIGH WINDS/TORRENTIAL RAIN In the event of high winds or torrential rains the main doors to the compost building would be closed. Any transfer of manure would be lialted with the exception of manure transferred from the pullet farm, which is transported in a closed container. Compost will not be shipped off site if weather conditions would lead to the loss of material from trucks. VECTORS Vector control will be achieved by maintaining the composting facility to prevent creation of conditions which attract vectors. The manure brought into the facility will be dry and reasonably stable because of the time it was retained in the layer or pullet houses. Dry, partially stabilized material will not readily attract flies and other insects. Internal temperatures in the piles will be high enough to prevent insect infestation. Mortalities will be delivered daily to the facility in closed containers and promptly placed in bins, which limits access to vectors. Since all handling will be in an enclosed 12 building, vector attraction will be minimized. The end use of the finished. Class A compost will not create nuisance conditions or vector attraction problems because of the stable nature of the material. Surface water will not be allowed to stand in or immediately around the compost building to reduce breeding areas. If vectors become a problem standard, commercially available, control methods will be used. FIRE In the unUely event of a fire the Environmental Services Manager, Environmental Services Employees, or other employee of Rose Acre Farms shall immediately attempt to contact the complex manager. Every attempt will be made to extinguish the fire before it spreads into the rest of the building or damages the building. This would be accomplished by using a water hose to extinguish any open flames. For small fires, a fire e x--tinguisher will be on hand. After any open flames are controlled, smoldering areas or other "hot spots" will be controlled by using a small front-end loader to open up the storage area, wind row or composting bin so that the trot area can be further controlled. A decision will be made early in the response to a fire of whether the local fire department should respond. A placard at the entrance to the building shall have local emergency phone numbers on it. After firefighting efforts are finished, finished product will be retumed to its storage area. If the fire was in a wind row or composting bin, the material which had been disturbed would be replaced, and the composting process for the disturbed material re- started from the beginning. A notation of this product would be made on any associated orrequired forms. UNUSUAL MORTALITY If due to unforeseen circumstances a higher than normal death rate would occur that could not be handled by the compost facility, several options would be pursued. One would be to deliver the mortalities to a rendering operation_ A second option would be to deliver the mortalities to an approved landfill. Any option pursued, for unexplainable or disease related increased mortality, would first be approved by the North Carolina State Veterinarian or his/her appropriate staff. COMPOST TEMPERATURES If at any time the temperature of any compost is not meeting the required level as established by the North Carolina Solid Waste Rules governing Class A compost then 13 one of two courses of action will be pursued. One action would be to insert pipes into the compost stacks which will increase aerobic activity, resulting in increased compost temperatures. Another option would be to add some water to the compost, which would also increase the temperature. Particulates Dust should not be an issue since most of the operation is inside. On site road ways will be sprayed with water if dust becomes an off site problem. Noise and Traffic Due to the rural nature of this site, the fact that the operation is inside, and the minimal amount of equipment use noise is not anticipated to be a problem. Off site traffic will only be an issue when compost is distributed to the public. The rural nature of the area and the fact that most of the compost will be transported in large trucks should avoid traffic problems. Record Keeping and Reporting Daily operational records will include compost temperature and turning data, the quantity, type and source of waste received and processed into compost, and the analytical results from the testing done oil the compost. The quantity and classification of compost removed from the facility and the market or disposal facility the compost was distributed to will also be maintained. The following logs will be used to record and maintain this information. MANURE AND MORTALITIES TRANSFER LOG Manure and mortality maintained separately HEN MORTALITIES COMPOSTING LOG MANURE COMPOSTING RECORD P,ecords shall be kept for a period of at least five years and will be made avdilable for inspection by personnel from the Division of Solid Waste Management for the North Carolina Department of Environment and Natural Resources or will be sent to them upon their request. An annual report covering the time frame from July I through June 3 Q will be sent to the Division of Solid Waste Management for the North Carolina Department of Environment and Natural Resources by August 1 of that same year containing the information required in 15 NCAC 13.51408(c). The annual report will fallow the following outline: 14 (l) The facility name, address, and permit number; (2) The total quantity in tags and type of waste received at the facility during the year covered by the report, including tons of waste received from local governments of origin; (3) The total quantity in tons and type of waste processed into compost during the year covered by the report; (4) The total quantity in tons and type of compost produced at the facility, by product classification, during the year covered by the report; (5) The total quantity in tons and type of compost removed for use or disposal from the facility, by product classification, along with a general description of the market if for use during the year covered by the report; (6) Monthly temperature monitoring to support Rule .l 406 of this Section; and (7) Results of analysis for pathogens, regulated metals, foreign matter, and nutrients. The Rose Acre Farms Safety and Personnel Training is Attached hereto and made a part of this Operating permit_ l5 BLOCK FLOW DIAGRAM FOR HYPE COUNTY EGG FARM COMPOSTING FACILITY ___7 Manure from Layer Houses and Pullet Houses Mortalitites from Layer Houses and Pullet Houses Primary Composting Bins Bulking Agent (sawdust, wheat straw, peanut hulls) i. - -41 Windrows for further Shipment to secondary composting, testing and end user for Composting storage. beneficial use Bins Testing will verity Class as soil - A status of finished amendment compost l i [z Calculation of Requirements for Mortality Composting at Hyde County Egg Farm The Department of Poultry Science at NCSU has published a guidance document entitled Given "Composting Poultry Mortality", From: Table 2 - "Estimated Primary & Secondary Bin Information Capacity for Mortality Composting per 1,000 Birds and Standard Size Units for Various Types of Poultry" Use 2.54 cubic feet of bin space per 1000 birds in the flock for layers and 1.96 cubic feet of bin space per 1000 birds in the flock for pullets. Design number of Layers on Site Design number of Pullets on Site Bin Space Required Layers Bin Space Required Pullets Total Bin Space Required height of bin = depth of bin = width (front) of bin = Total area of one bin = 4,000, 000 710,000 10,160 cubic feet 1,392 cubic feet 11,552 cubic feet Building 1 7 ft 12 ft 8 ft 672 cubic feet Buildings 2 6 ft 12 ft 8 ft 576 cubic feet Number of bins provided 8 16 Volume of bins provided 5376 cubic feet 9216 cubic feet Safety Factor 1.3 Number of Bins Proposed = 24 With 24 bins provided, the total area available is 14,592 cu ft The storage space for amendments (sawdust, straw, peanut hulls, or other approved materials) is based on using 0.1 pound per pound of Amendment Storage mortality composted. The average daily mortality for the Hy -Line W-36 Requirements, variety layer used by Rose Acre Farms is calculated below. Data for the calculations is taken from the "Hy -Line W-36 Commercial Management Guide, 2003-2005" Layer Flock Size 4,000,000 Pullet Flock Size 710,000 Layer Flock cycle length 441 days Pullet Flock cycle length 119 days Average layer mortality rate/cycle 0.04 Average pullet mortality ratelcycle 0.03 Layer weight at cycle end 3.48 1b Pullet weight at cycle end 2.8 1b Calculation: average daily ivt of mortality = (bird wt) x (flock size x mortality rateylcycle length Average daily layer mortality in lb 1263 lb Average daily pullet mortality in lb 501 lb Total daily average mortality in Ib 1764 Ib Amendment required = 176 pounds per day(0.1 lb per lb mortality) Storage required (30 days)= 5,291 pounds or 19 cubic yards (Sawdust wt. is 170 kglm'3 or 10.59 lblcuft) Calculation of Manure Production and Composting Required at Hyde County Egg Farm Historical Record (711109 to 6/30/10) Average Flock 2,800.000 birds - Manure Composted (includes Pullet Farm) 45,413,600 pounds Average density of manure in layer houses is Average density of manure in pullet houses is Average density of combined manure is 31.81 lblcuft (from Rase Acres) 25.00 lb/cuft (from Rase Acres) 31.41 Ib/cuft--Use this in calculations Total manure produced @ 4 MM birds= 64,876,571 lb/year 2,065,475 cubic feet Cycles per year to assume 8 composting cycles in windrow area per year Data from Current Operation Shows that Windrow width at base = Windrow height to top = Weight per foot of length Required Length of rows = tons are 2,500 composted in 14 feet 9 feet 1 A 36 tons or 28,546 row-feet/yr or 4 windrows@ 2,273 pounds 3,568 row-feet/cycle Example Operaing Scenario 1--Composting 12 windrows--4 in each mouse Assume all windrows are same length which 297 feet Building Conditions (example Windrow length Storage Lengtl Storage lbs % of annual Production cu ft@31.41 Ib/cuft 550 feet each Length of building 600 ft Manure Density Width of Building 100 ft 31.41 lblcuft Area of Floor 60,000 ft Bins and turning 40 ft Separation 50 ft Building Cross Secti, 2,700 sgft estimated Storage vollfoot 2,160 estimated at 80% of maximum available Individual Total Storage- Storage Windrow Windrow length in Storage vol in Weight in Length (ft) Length (ft) feet tuft pounds Available Length 510 2,040 0 0 0 Assumed Lengths 450 1,800 60 129,600 4,071,255 400 1,600 110 237,600 7,463,968 350 1,400 160 345,600 10,856.680 300 1,200 210 453,600 14,249,393 100 400 410 885,600 27,820,243 0 0 510 1,101,600 34,605,668 Length of building Width of Building Area of door Bins and turning Separation Building Cross Sectit Storage vol/foot Available Length Assumed Lengths Operating Scenario 1 Operating Scenario 1 676 ft Manure Density 97 ft 31.41 lblcuft 65,572 ft 80 ft 50 fit 1,958 sgft estimated 1,370 estimated at 70% of maximum available Total Individual Windrow Storage Windrow Length Storage- Storage vol in Weight in Length (ft) (ft) length in feet cuff pounds 546 2,184 0 0 0 450 1,800 96 131,544 4,132,324 400 1,600 146 200,057 6,284,576 350 1,400 196 268,569 8,436,828 300 1,200 246 337,082 10,589,080 100 400 446 611,132 19,198,088 0 0 546 748,157 23,502,592 297 1,189 249 340,711 10,703,108 446 1,784 100 136,989 4,303,366 Length of building 676 ft Manure Density Width of Building 97 ft 31.41 lb/cuft Area of Floor 65,572 ft Bins and turning 40 ft Separation 0 ft Building Cross Sectic 1,958 sq€t estimated Storage voltfoot 1,370 estimated at 70% of maximurn avaiiablE Total Windro Individual w Storage - Windrow Length length in Storage voi in Length (ft) (ft) feet cult Availabie Length 636 2,544 0 0 Assumed Lengths 450 1,800 186 254,867 400 1,600 236 323,379 350 1,400 286 391,892 300 1,200 336 460,404 100 400 536 734,454 0 0 636 871,479 Operating Scenario ' 297 1,189 339 454,034 Operating Scenario 0 0 636 871,479 BLOCK FLOW DIAGRAM FOR HYDE COUNTY EGG FARM COMPOSTING FACILITY Manure from Layer Houses and Pullet Houses Mortalitites from Layer Houses and Pullet Houses Bulking Agent (sawdust, wheat straw, peanut hulls) Windrows for further Primary Secondary composting, testing Composting Composting and storage. Bins Bins Testing will verify Class A status of finished compost (Composting Buildings 1, 2, and 3) Shipment to end user for beneficial us as soil amendment i T H E C. n Cl TI F C. C. P F Cl P f 9:0 �9 I REVISED 10/13/10 '1�I1 Table of Contents I. Safety Policy Statement IL Lockout/Tagout Program. III. Hazard Communication Program IV. Emcrgency Evacuation Procedures V. Powered industrial Truck Program VI. Confined. Space Entry Program VII. Respiratory Protection Program VIII. Fall Protection Program IX. Fire Extin&sher Program X. Hot Work Permit Program X1. Hearing Conservation Program XII. Personal Protective Equipment Program MI. Btoodhorne Pathogen Program XIV, Safety Committees XV. Safety Compliance Checklist XVI. First Report of Accident/Illness Procedure REVISED I0/13/10 Rose Acre Farms Safety Policy The safety and health of each employee is a primary consideration of the operation of Rose Acre Fauns. Safety must be apart of every operation, and without question, will be the responsibility of each employee; regardless of his/her title, position, or seniority. The, intent of the Rose Acre Farms safety program is io comply with all laws and relating standards as set by the "Occupational Safety and Health Act (OSHA) of 1970." Rose Acre Farms will provide employees with employment free from recognized hazards that cause or are likely to cause death or serious physical injury to employees. Employees are required by law to comply with all standards of QSKA and guidelines of Rose Acre Farms as applicable to the employees own actions and conduct. Rose Acre Farms will maintain a safety and health program conforming to the best practices of organizations of this type. To be successful, the program must include the proper attitude toward injury and illness prevention on the part of managers and employees. Only through such cooperative effort can a safely program be established to reduce accidental injuries and property damage. Ultimately, everybody benefits! fuelusions of the Rose Acre safety program will be: - Periodic inspections to identify unsafe conditions or practices at each facility. - Periodic discussions (safety meetings), by employees and management at each fac.ii4 to discuss areas that are unsafe and methods to correct the situation. Periodic audits to examine the accuracy and completeness of safety programs and training Safety training to employees encompassing safety programs that are specific to each employees work area. Provide mechanical and physical safeguards to the maximum exterit as possible, even if not provided by the manufacturer. REVISED 10/13/10 Lockout/Tag60 Program _y^ Pu r ose This policy establishes the minimum requirements for safely isolating potentially hazardous energy sources. It shall be followed to ensure machines and/or equipment is isolated from all potentially hazardous energy before employees perform service or maintenance activities where there may be an unexpected energization, start-up, or release of stored energy. II. scope The provisions set forth in this policy apply to all equipment and machinery where potentially hazardous energy exists. All employees who maintain or service such equipment and machinery are subject to the procedures outlined in the policy without exception. Failure to follow these procedures will result in disciplinary actions. M. General Re uirements All equipment shall be locked out and tagged out to protect against accidental or inadvertent operation when such operation could cause injury to personneL Authorized employees will be issued locks/tags and equipment necessary to perfom lockout/tagout procedures. Each authorized employee will be held accountable for the equipment and its appropriate usage. Lockout is always the preferred method of isa]ating machines or equipment from energy sources. However, when the equipment is not capable of being locked out, tags must be used. IV. Rest,onsibilities A. Safety DepartmentlHR Department: 1. Conduct training for new hires 2. Dffer departments consultation on safe procedures and policy requirements. 3. Develop, raintain, and review the L ockoutlTagout Policy and provide facilities with updated copies. 4. Review specific lockout/tagout procedures for equipment and machinery that have been developed and submitted by each facility. B. Supervisors Contact Safety Department when consultation is needed Appoint the authorized employees who are allowed to perform service or maintenance on equipment or machinery Ensure that their authorized employees follow lockout/tagoui procedures Identify employees who need additional training Develop and maintain safe shutdown procedures on each piece of equipment or machine that their employees are expected to service or maintain Conduct annual reviews of their department's c*mpliance with this policy. Take disciplinary action on employees who ate observed in non — compliance activities Hold authorized employees accountable for lockout devices REVISED I0/13/10 C. Authorized Employees I . Attend training which. is designed to instruct them on safe lockout/tagout procedures 2. Comply with this policy and the specific shut down procedures which, are outlined by the employee's supervisor 3. Notify their supervisor's when they have any questions about isolating energy sources safely 4. Notify supervisor at any point in time when new or additional lockout devices are needed C. Contractors 1. Comply with Rose Acre Farms LockoutEtagout Policy. Copies of this policy will be provided to there capon request. 2. Ensure that Ws/her employees are appropriately trained and authorized. 3. Comply with iockout/tagoui procedures that have been developed by the facility for each machine or piece of equipment that the contractor must service or maintain- V. General Guidelines Energy control procedures shall be established by each department who has employees that perform lockout/tagout duties, The procedures shall be written for all applicable machines -and/or pieces of equipment. The procedures shall be consistent with the following Criteria: Proper Sequence of Lockout: To protect personnel during equipment maintenance, the following procedures roust be performed in the order presented: l . Notify "affected employees" that a lockout will be performed on the equipment. 2. Shut equipment down. 4, isolates the equipments energy sources 5. Apply lock(s) and tag to energy isolation devices. 6. Release any residual (stored) energy that may be present (ex. springs, coils, jarnmcd augers, feed chains, rotating flywheels, hydraulic systems, steam lines, and capacitors. 7_ Verify the lockout (attempt to start). This will confirm that all residual energy has been removed and that it will tot start while you are working on it. 8 Perform servicing and/or maintenance. 9. Afier performing work, verify thatall tools have been removed from the area, all guards have been replaced and all employees are clear of equipment. 1 il. Release equipment from the lockout. 11. Advise all "affected employees" that the lockout has been completed. 12. The equipment can now be re -energized REVISED 10113110 ❑ Periodic inspection: A periodic inspection of the company's Energy Control Program will take place at least annually (See Appendix A). The inspection will be used to: Identify any inadequacies and review those with the "authorized" employees in the facility. 1 Review "authorized" personnel responsibilities in this program. Document the following information: a. Equipment serviced during the lockout. 6. Date of inspection. c. Employees included in this inspection. d. Inspector name. e. Inadequacies identified and shared with "authorized personnel,,- E. Hardware Identification: Lockout devices trust indicate the identity of the employee who attaches the device. The safety locks used trust be standardized in a least one of the following criteria: a. color b. size c. shape SAFETY LOCKS MAY NOT BE USED FOR OTHER PURPOSES. F. Training and Communication: 1. Training will be provided to ensure that the purpose and function of the energy control program is understood by employees and that the knowledge and the skills required for the safe application., usage, and removal of energy control are acquired by employees. The training shall include the following; a. Each authorized employee will receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and Control- b. All other employees whose work operations are or maybe in an area where energy control procedures may be utilized, will be instructed about the procedure, and about the prohibition relating to attempts to restart or re -energize machines or equipment which are locked out. F. Retraining shalt be provided for all authorized and affected employees annually, whenever there is a change in their job assignments, a change in maclines, equipment or processes that present a new hazard, or when there is a change in the energy control procedures. REVISED 10/13/10 3. Additional retraining shall also be conducted whenever a periodic inspection reveals that there is deviation from or inadequacies in the employee's knowledge or use of the energy control procedures. G. Special Conditions: Lock Removal - If the ern pIo_yee who placed a lock on the equipment is absent front the site, the lock may be removed provided: a. A supervisor attempts to contact the individual, determine the status of the work:. and the reason the lock was left at the job site. b. If the equipment can be returned to service, the employee needing the lock removed will remove the lock only in the presence of a supervisor. All of the above will sign the "Lock Removal Authority". (See appendix B) c. The supervisor ensures that the employee is notified that his/her lock has been removed before he/she resumes work. a_ Group Lockouts -Group lockouts can be accomplished through a locout box or hasp REVISED 10113/10 Appendix A Energy Control/Lockout Program Periodic Inspection Form Facility: Date: Inspector: Equipment Serviced: Employees Observed. Inadequacies Identified: Other Observations: Signed: REVISED 10/13/10 Appendix B Lock Removal Authority Date 1 1 Time—:— a.m.lp.rn. Lock Identifier. Supervisor; ... Was attempt made to contact employee? Yes No If yes, when? Reason For Removal Location Assigned to: By Whom Prior to the energy control device being removed, employees must contact the VCC Safety Coordinator for Authorization, Authorization: Complex Manager: Employee Thai Removed Lock: REVISED 10/13/10 (Signature) (Signature) Hazard Communication Program- 1 Purpose and Scope The Rose Acre Farms, Inc. Hazard Communication Program is designed to ensure employees are informed about hazardous chemicals in their workplace and how to properly use than to avoid potential accidents and injuries. The program complies with the Federal OSHA Standard. (29CFR 1910.1200). The Occupational Safety and Health Administration's (OSHA) Hazard Communication standard (29 CFR I910.1200) is based an the simple concept that employees have Moth a need and a "right to know" the identities and hazards of any chemicals they work with during the course of their employment - Objectives Container Labeling a) Complex Managers or an employee designated by the Complex Manager will verify that all product containers kept onsite will clearly list the following on the label: • Product Name • Appropriate hazard warnings, and • Manufacturer's name and address. b) It is the policy of Rose Acre Farms, Inc. that no container will be released for use'unless it has a complete label. Complex Managers or an employee designated by the Complex Manager will ensure that secondary- containers, such as spray bottles, have complete labels by one of the following methods: i. A copy of the original manufacturer's label will be made and placed on the secondary container, or ii. The minimal information bulleted above will be places} on the container in permanent ink/marker or a laminated tag. 2. Material Safety Data Sheets (MSDS's) a] Copies of MSDS's for all hazardous chemicals to which employees of RAF, Inc. may be exposed will be kept on -site at each complex is a 3-ring binder. Employees are encouraged to consult the MSDS far the chemical being used. MSDS's will be available to all employees during all shiftsr if an MSDS is missing, or if a new product arrives without an MSDS, the safety department should be notified immediately to request an MSDS from the chemical supplier- 3.) Hazardous Chemicals List a) The Complex Manager or an employee designated by the Complex Manager will compile a list of all the chemicals and products used at each facility. This List will be kept in the front ofthe MSDS book and serve as a Table of Contents. Each chemical entry on the inventory list has a corresponding N48DS available for providing specific hazard information and personal protective treasures. This list will be updated every six (6) months to remove chemicals that are no longer in use and to add new products. REWSED 10/13/10 4.) Personal Protective E-gAip t [PPE a) Supervisors will be responsible for supplying, maintaining, inspecting and replacing all proper personal protective equipment used in the handling of hazardous chemicals. Training 1.) Responsibilities a) Safety Department Prior to beginning work, each new employee will attend ahealth and safety orientation and will receive training and information to accomplish the following: ■ Educate employees on how to read and obtain information from chemical labels. • Educate employees on how to read and obtain information from Material Safety Data Sheets. • Educate employees on the types of health and physical hazards they may face in the workplace caused by hazardous chemicals. ■ Educate the employee on the types of personal protective equipment used to prevent accidents or injuries from hazardous chemicals_ • Educate the employee on proper procedures should there be a chemical spill. • Educate the employee on the proper first aid requirements in the case of a chemical exposure ii. The employee will be required to sign a form to verify that he or she attended the training and understands Rose Acre Farms, Inc.'s policies an hazard communication. b) Supervisors i. Responsible for the job specific hazard training on chemica4s used by their employees and should include the following. Identify the location of the complex's MSDS 3-ring binder. • Identify the location where personal protective equipment used for handling hazardous chemicals is stored. • Educate the employee on the proper use of personal protective equipment. • Instruct employee on procedures to inspect, fit and maintains personal protective equipment. ii_ Notes on training: • Training shall be provided at the time of initial assignmeni to tasks where occupational exposure to a hazardous chemical may take place. ■ Training shall be repeated whenever a new chemical or a new hazard is introduced in the work area, • Refresher training shall be annually iii. Hazardous Non -Routine Tasks ■ Occasionally, Rose Acre Farm employees may be asked to perform a task that is not part of their normal job. Before taking on a new task, REVISED 10/13/10 the affected employee will be given information by their supervisor about any hazardous chemicals that might he used during the activity. + This information will include- L Spe6firc chemical hazards; ii, protective measures employees can take; and iii. The use of proper personal protective equipment. Informing Contractors It is the responsibility of the Complex Manager or their designated employee to provide contractors with the following information: • Hazardous chemicals to which they maybe exposed while working at Rose Acre Farms, Inc. and the procedure for obtaining MSDS's; and • Precautions eontr-acted employees may take to reduce the possibility of exposure by using appropriate protective measures; and • Provide an explanation of the chemical labeling systern. It is also The Complex Manager's responsibility to identify and obtain MSDS's for chemicals the contractor brings to RAF facilities. Conclusion Rose Acre Farms, Inc. is committed to the prevention of hazardous material and chemical incidents that could result in injury and/or illness to any employee. We will Sparc no effort in providing a safe and healthful work environment for employees and ail levels of supervision will be accountable for the safety of those employees under their direction. REVISED 10/13/10 Emergency Action Plan I. PURPOSE a. The purpose of this program is to provide guidelines for personnel in the event of an emergency response. This program applies to all Rose Acre Farms personnel, contractors, and visitors. This program complies with OSIIA 29 CFR 1910.39. 11. SCOPE a. This program applies to Rose Acre Farms facilities. It will be implemented in the event of fire, chemical release such as ammonia, severe weather, serious injury, and any other emergency situations, Ils. EMERGENCY ESCAPE PROCEDURES AND ROUTE ASSIGNMENTS a. Ail areas will have emergency escape procedures and emergency escape mute assignments. b. The evacuation routes for each area will be posted in a conspicuous area. The evacuaticnt routes will be reviewed with each employee upon initial assignment to an area_ Each employee will be retrained on the emergency escape procedures and route assignments annuaLy. C. All persons shall shutdown the equipment they are using at the time d. All persons shall follow exit routes to their designated meeting site for a bead count. e. Complex Manager and supervisors shall make a sweep of their areas (provided this can be done safely) to ensure that all personnel are out of the work area. 1V, uVacuatiion a. The types of evacuation to be used in an emergency include: i. Partial Evacuation- the affected area of concern is evacuated (ex.chemical spiIvleak). ii. Plant wide cvacuad0n- the entire facility is evacuated. TIf s would include the entire facility and outlying areas (ex. Fire, Ammonia Leak). iii. Hazardous Weather Evacuation- all personnel are to report to the nearest weather shelter (See Appendix A). V PROCEDURES FOR CRITICAL PLANT OPERATIONS a. All critical equipment will have an emergency shutdown procedure. Personnel in each area will receive appropriate training on the equipment identified in their area to follow for emergency shutdown procedures. This type of equipment may include, but not limited to, the boiler, ammonia system. generator, pumps, etc. b. The Critical Operations Shutdown procedure to be followed by those employees who have been assigned to care for essential building operations include; Operation 1. r REVISED 10/13/10 Responsibility 3. 4 5 c. Persons involved in the Critical Operations Shutdown listed above shall be notified by management of this responsibility in advance. d. Once safe shutdown is accomplished, the designated operators will evacuate. V1. EVACUATION HEAD COUNT PROCEDURES a. When the employees reach the designated meeting area, the supervisor will be responsible to ensure that all of his/her personnel are accounted for. The supervisor shalt report their findings to the Complex Manager immediately. b. Contractors will be responsible to ensure that all of their personnel are accounted for. They must report their findings to the Complex Manager immediately. c. When a head count shows that a person is missing it shall he reported to the local response authorities (i.e. Fire Chief). The Complex Manager shall coordinate a search and rescue with the emergency response team members. VII. RESCUE AND MEDICAL DUTIES a. The local volunteer fire department will respond to site medical emergencies. They will respond to medical emergencies and administer appropriate first aid care until further medical help arrives. VIII. MEANS OF REPORTING EMERGENCIES a. Phone- The complex manager or immediate supervisor will be contacted for reporting fires, chemical leaks, serious injuries, or other emergencies. b. PA System- The complex manager will call the appropriate ]oval emergency authorities and than report the emergency announcement and instructions. c. Two-way Radios- Aziother method ❑f'reporting plant emergencies are through hand held radios. Ix. RESPONSIBILITY OF PROGRAM IMPLEMENTATION a. It is the responsibility of the. Comptex manager to ensure the program is implemented and updated appropriately. b. It is the responsibility of each manager to ensure that each new hire in their area is trained on the appropriate exit routes and meeting locations for his/her location. REVISED 10/13/10 X. TRAINING a_ Training will be given Io personnel to assist in the safe and orderly emergency evacuation of employees. b. Training shall be conducted with each employee: il. Initially when the plan is developed H. Initially when hired iii. Whenever the employee's responsibilities under the plan change. iv. Annual refresher training c. The type of training shall include: i. Emergency procedures ii. Primary and Secondary means of egress W. Designated meeting points after evacuation iv. Written Emergency Action Plan v. Evacuation drills REVISED 101131I0 Appendix A TORNADO/ SEVERE WEATHER PROCEDURES 1. General Guidelines: A. NOTIFICATION- Should a tornado or severe wind storm become imminent. an announcement will be made over the P.A. system for all employees to leave their stations and take cover. B. TORNADO/SEVERE SHELTER AREAS- The following areas have been designated as tornado shelter areas in the plant. Employees should seek shelter in the area that is nearest their work location_ (Areas are to be listed in facilities evacuation program) C. If time penn its, operators designated to remain for the safe shutdown aFany operating unit should shutdown the specified equipment and immediately seek shelter D. In case a tornado occurs of an intensity to cause s1ructiu-al damage and creates an imminent hazard, the Complex Manager shall direct the employees to secondary shelter. E, During a "weather emergency" it may only be necessary for personnel to get against an interior wall and assume a protective position (scrunch down, tuck head between knees and cover head with hands). F. After the tornado/severe weather has passed, the Complex Manager will assess the immediate needs and appoint persons to assist them. The first priority is to check for personal injury. Request medical assistance if necessary. The person in charge of each area must snake a head count of employees assigned to that area. Once this priority has been achieved, efforts shall be directed to minimize damage to facilities and equipment, and restore operations, REVISE❑ 10/13/10 Appendix B Catastrophic Ammonia Release Critical Shut -Down Guidelines In the event of a major chemical release of anhydrous ammonia, operators will follom, the guidelines provided: 1. When ammonia is detected in the plant area, notify the complex manager. Ali non -essential personnel must evacuate the plant area immediately and follow the Evacuation Plan. The NH3 response team will assess the situation. 2. Appropriate authorities will be contacted_ (Local Fire Department) AMMONIA RELEASE PROCEDURES Minor Release- If a rainor release occurs on the ammonia system, all persons tmist evacuate the immediate area. All other locations shall remain in place until the release is controlled. All minor releases shall be reported and announcements made for persons to stay clear of area, Major/Catastrophic Release- If major/catastrophic release occurs an the ammonia system, all persons must evacuate the immediate area and proceed to the primary evactlalion designated area or the secondary staging area. Caution must be taken to observe the wind direction via the local windsocks or otbcr observations. Never pass through a cloud of aneutsunis. REMISED I0/13/10 Appendix C Fire Response Guidelines Purpose: The purpose of this guideline is to eslahlish a uniform method for reporting a fn•e and coordinating our response efforts, Guideline: In the event of a f re, the following guidelines should be fol lowed: 1. REPORTING- Upon discovery of a fire. the person detecting the fire will report the emergency to the complex manager or His/her supervisor. 2. NOTIFICATION- The emergency will be announced over the PA system. 3. EVACUATION- In the event of an evacuation all personnel not assigned to a specific duty will report to their primary staging area. An evacuation may range from partial for the affected area up to a plant snide evacuation. 1, RESPONSE- The local fire departments shall he contacted (911). S. RESPONSIBILITIES- A person will be sent to the main gate to directthe local fire fighting units and responders to the scene. REVISED 10/13/10 Powered Industrial Trucks Program I -Poliev All powered industrial trucks shall be operated and maintained in accordance with this policy. Scope This policy applies to all powered industrial trucks and provides guidance to employees on the safe operation of propane, gasoline and electric battery powered forklifts and power Iifts. AuthorirN and Resstwnsibilit Safe_iy Department • Reviewing the Powered Industrial Truck policy to assure compliance; ■ Coordinating and providing training of affected employees; • Providing initial audio-visual training and written tests. 5'urlen*ars ■ Ensuring employees attend training and operate powered industrial trucks in a safe manner; ■ Assuring operators perform appropriate pre -operation safety inspections prior to operating equipment- * Ensuring all equipment is in proper working condition; • Inspecting forklift checklist * Scheduling maintenance • Maintaining required documentation. • Maintaining training records of att operators. ■ Schedule and perform refresher training Erngtoyees • Comply with this policy. • Attend all training General Requirements The Occupational Safety and Health Administration (OSHA) per 29 CFR 1910.178 states in part, only trained and authorized operators shall be permitted to operate a powered industrial t-uck; The employee is responsible for ensuring the safe operation of the powered industrial truck; Modifications and additions that affect capacity and the safe operation of the powered industrial truck shall not be performed by the Rose Acre Farms, Inc. without the manufacturer's prior written approval. Capacity, operation, and maintenance instruction plates, tags, or decals shall be modified accordingly; REVISED 10/13/10 • if the powered industrial truck is equipped with front-end attachments other than factory installed attachments, the powered industrial mck shall be marked to identify the attachments and show the approximate weight of the truck and attachment combination at maximum+ elevation with load laterally centered; • Nameplates and markings shall be in place and maintained in a legible condition. Pre -Operation Safety Inspection • Prior to operating a powered industrial truck, the employee small perform a pre -operation safety inspection using the appropriate Inspection Checklist: • When powered industrial trucks are used on a round-the-clock basis, they shall be examined after each shift; • The inspection shall identify any conditions that could affect the safe operation of the powered industrial truck; ■ If any condition(s) exist, the powered industrial truck shall be removed from service and flagged "Out of Servicc" until the proper repairs or concerns are addressed; ■ Upon an operator discovering any concerns, immediately notify your supervisor so he or she can notify tine person responsible for the repairs Fuel Handling and Storage The handling and storage of liquid fuels such as gasoline shall be in accordance with the National Fire Protection Association (NFPA) Flammable and Combustile Liquids Code (NFPA 30). The handling and storage of liquefied petroleum gas fuel shal3 be in accordance with the Storage and Handling of Liquefied Petroleum Gases Code (NFPA 58). The following procedures shall be followed: • When refueling or recharging the batteries of a powered industrial truck, the operator shall ensure that the powered industrial truck is shut-off and the parking brake is engaged; • Refueling and recharging shall be completed in areas that are designated and well ventilated; ■ Personal protective equipment (approved face shield, goggles, gloves" :gall be worn during all refueling and battery recharging operations; • Emergency eyewash/shower station shall be present in the area; • Smoking shall be prohibited in refueling and recharging areas. Fuel vapors and gases, which can escape from the battery and fuel vents, are extremely flammable; * Tools and other metallic objects shall be kept away from the top of uncovered batteries; and • An ABC rated fire extinguisher shall be present in all refueling or recharging areas. Workplace Hazards Hazards may exist in the workplace and are easily detectable if a quick survey of the area is conducted. These hazards include, but are not limited to, the following: ■ Overhead obstructions such as fire protection sprinkler piping, ventilation ducts, fighting fixtures, power lines. If the load you are moving is carried too high or the powered industrial truck mast is raised too high, damage can occur to the overhead obstruction and possibly cause injury to the operator or people in the immediate area; ■ Co-workers or pedestrians traveling to and from certain areas within the facility; ■ Poor housekeeping such as debris left on the floor and wet floors; + Poor condition of the floor surface such as uneven concrete, potholes and cracks; REMED 10/13/10 • Poor visibility around corners. Theoperator's view from a powered industrial truck can be blocked or obstructed by the load, if there is not a clear view, drive in reverse or have a co- worker, "spotter", direct you; • Operating a powered industrial truck in a confined area with pour ventilation can allow the powered industrial truck exhaust gases to accumulate. This creates a hazard not only for the forklift Operator, but also for others within the area or building. The Safety Department shall be contacted if air quality concerns should arise; • For those individuals who wear eyeglasses, this could be a hazard when entering a warm atmosphere from a cold atmosphere (processing to cooler) and having your eyeglasses steam up; and ■ Driving too fa5n for the conditions of the area. When operating a powered industrial truck, always remain alert and cautious. Note the existing and potential hazards and conditions that do or could exist in your work environment. Wht-never a hazard is discovered which requires action such as housekeeping, poor floor condition or poor ventilation, immediately notify ,your supervisor to ensure the proper procedures are followed to address the hazards. Operating Procedures When operating a powered industrial truck, always travel with the forks approximately 2-4 inches from the ground so they clear any uneven surfaces. Always survey the area ahead and to the sides as you travel. Always travel in reverse or use a "spotter" when the load you are carrying obstructs your view. Some factors that could cause the powered industrial truck to tip over: • Overloads; + Unstable loads; + Uad not centered on forks. + Traveling with the load raised; • Sudden stops and starts; ■ Making sharp turns; and ■ Traveling across a ramp or incline. Saletr Fracttces The following safety practices shall be adhered to at all times. • Wear seatbelts whenever the powered industrial truck is equipped with them; ■ Keep all body parts inside the driver's compartment; • Drive at appropriate speeds; ■ Do not carry passengers on the powered industrial truck: No person shall be pennitted to stand or pass under elevated portions of any powered industrial truck, whether loaded or empty; + All powered industrial truck operators working on platforms that are four feet above a lower level shall have adequate fall protection devices such as guardrails etc. • When traveling behind other powered industrial truck or vehicles, always maintain at least three forklift lengths from the vehicle or powered industrial truck ahead, and rnainmin control of the powered industrial truck at all times; ■ Slowly approach ramps and inclines straight, not at an angle; ■ Never turns the powered industrial truck while on a ramp or incline; REVISED 10/13/10 • When parking a powered industrial truck and prior to dismounting or leaving the unit, shut-off the power and engage the parking brake. The operator shall never leave a mnning powered industrial truck unattended; • When the powered industrial truck is left unattended the load shall be fully lowered, controls shall be neutralized power shut off, brakes set and wheels blocked if powered industrial truck is parked on an incline' + Never park a powered industrial truck in front of any fire protection equipment, emergency exits, or in a manner that would obstruct a person from exiting the area; + If at any time during operation a powered industrial truck is found to be in need of repair, defective, or in any way unsafe, it shall be immediately removed from service, The department supervisor shall be notified so he or she can notify the person responsible for the repairs; and + Refueling and recharging areas equipped with emergency eyewash stations shall be inspected on a monthly basis. Training Rose Acre Farms, Inc. employees designated to operate a powered 'industrial truck shall be required to participate in and successfult)r complete a powered industrial truck training progam offered through the Safety Department to ensure the operator is competent to operate a powered industrial truck safely before assuming their responsibilities. Training consists of a combination of formal instruction and practical staining. Formal instruction includes lecture, interactive discussion, video, and written material handouts. Practical training includes demonstrations performed by the trainer, practical exercises performed by the trainee, and evaluation of the operator's performance in the workplace. Trainees may operate a powercd industrial truck only: ■ [Under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence; and • Where such operation does not endanger the trainee or other employees, Carrindum The curriculum of the training program shall, at a minimum, address the following topics: ■ Pre -Operation Safety Inspection; + Workplace Hazards; + Safe Driving and Operating Procedures; • Loading -Carrying -Unloading of Materials; and • Operation and Safety Driving Practical - Retraining Employees shall be required to participate in refresher training at least once every three years_ Retraining may also be deemed necessary when it has been dacumented that the operator has been observed to operate the powered industrial truck in an unsafe and/or inappropriate manner, involved in an accident or near miss incident, is assigned to drive a different type of powered industrial truck, or a condition in the workplace changes in a manner that could affect safe -operation of tla'e powered industrial truck as directed by this policy and according to OSHA regulations. REVISED I0113/10 I Confined Space Entry Program A. PURPOSE Wuries and fatalities may occur if certain essential precautionary measures are not taken when entering confined spaces. This instruction is provided to help Rose Acre Farm, Inc management and employees to be aware of Confmaed Space Entry Requirements. These detailed requirements will be met by ail personnel involved with confined space entry. This procedure covers most Confined Space Entry situations. Those, which present unique conditions, will be addressed by management and safety professionals, as required by this procedure. 1. Definitions (General): Confined Space A Confined Space is an enclosure or cornparlment with limited means of exit or entry, ventilation of the space is lacking or inadequate, allowing for potential accumulation of toxic air contaminants, tlarnmable or expl¢sive agents, and/or depletion of oxygen. They include, but are not limited to: Sag Houses Excavations; narr-ow/deep Feed Bins Boilers Pits Dryer Tunnels silos Wood Burner Hag dust collectors Tanks/Tankers Manholes -Non-Permit Required C:oniined Space A confined space that does not contain or with respect to atmospheric hazards., have the potential to contain any hazard capable of causing death or serious physical harm. -Permit Required Confined Space A confined space with one or more of the following hazards: 1. Contains or has the potential to contain a hazardous atmosphere. 2. Contains a material that has the potential for engulfing an entrant. 3. Has an internal configuration such that an entrant could be trapped or asphyxiated by inwardly converging walls, or 4. Corrtaans any other recognized serious safety or health hazard Notes Permit Required Confined Spaces require completion of a Confined Space Permit REVISED 10/13/10 -Attendant Au individual, stationed outside the permit space, who monitors the authorized entrant and performs duties as described in this index- -Authorized Entrant A trained. and authorized employee, who enters permit required confined spaces. -Entry Supervisor The trained individual, who determines if acceptable entry conditions are present at a permit required space, where entry into confined spaces is planned and oversees, authorizes or terminates entry permits. S. Potential Hazards. Hazards which are commonly encountered by personnel working in confined spaces are: 1. Toxic vapors 2. Flammable gases 3. Oxygen deficiency 4. Electric shock from installed and portable electric equipment S. Injury from :mechanical equipment inside of the confined space b. Physica[ hazards such as falling and slipping 7. Hazards resulting from the steam, water, chemical, etc, input lines being opened into the confined Space. 8. Engulfment hazards C. IDENTIFICATIONIW ARMING: Each Confined space will be labeled with a confined space sign- The following warning applies to confuted spaces DANGER- Permit required confined space. DO NOT ENTER. I . Employees shall not enter any confined space until all steps have been completed. If problems are encountered, notify Complex Manager or the Entry Supervisor, 2. Occasionally, work may be required in an area which seems to fit the definition of confined space but is unidentified. The manager/coordinator responsible for the project should contact Safety Director or the Entry Supervisor for a determination. A permanent sign andlor tag./number will then be posted if required. D. DUTIES AND RESPGNSIBLITIES 1. The Complex Manager must instruct personnel entering a confined space to: a. Obtain a Confuted Space Entry Permit (See Attachmcut "A") b. Completely fill out the permit. Sign the permit verifying all precautions have been met. Call the Entry Supervisor for review and sign -off. REVISED 10/13/10 c. Past permit in a conspicuous place near point of entry. d. Be certain that all personnel understand the hazards of a confined space and are instructed about the necessary precautions to be taken. Confused Space traitung will be conducted annually and records of the most recent training program shall be maintained including the date of the program, the names of the instrector(s) and the employce(s) to whore the training was given. Employee signatures are required for attendees. These records will be kept by the Confined Space Entry Supervisor or his/her designated record keeper. only trained and authorized employees shall enter confined spaces and monitor employee entry. e. Ensure that all personnel entering the confined space are physically/mentally capable of worming in a confined space. An observer must be present before any entry into permit confuted spaces. f: Ensure that the number of people inside the confined space is kept to a minimum. 2. Entry Supervisor a. Know the hazards that may be faced during entry including the signs, symptoms and consequences of exposures. b. Verify that all tests specified by the permit have been conducted and that all procedures and equipment specified by the permit are its place before signing the permit and allowing entry. On joint entry involving contractor personnel, the, coordinator will serve entry supervisor and complete requirements of the permit using confined space form. The coordinator is responsible to make sure following conditions are met: 1) Notify the contractor of hazards that the confined space could present ?) Contractor understands that he is to follow all applicable state and federal laws and regulations, such as 0814A and regulations issued thereunder. Contractors shall also meet all requirements by writing and implementing their own Permit Required Corifined Space Program 3) Permit is posted in a conspicuous place near paint of entry. 4) The Contractor is fully responsible for providing all required cquiprnent, such as air testing/monitoring equipment or confined space rescue kit and persona; protective equipment. 5) Ensuring that all instrumentation is serviced, calibrated and accurate.. A log shall be kept of calibration and service. The log shall indicate the nature of the service, repairs made, the date and individual providing the service. c. Terminate entry and cancel The permit upon completion of the entry, or, when a condition that is not allowed under the permit exists. d. Verify rescue services are available & means of summoning them are operational. Remove unauthorized individuals who enter or attempt to enter permit: spaces during entry operations. f. Whenever permit responsibility is transferred to another supervisor ensure that entry operations consistent with terms of the permit. REVISED 10113/10 3. Authorized Entrant a. Know the hazards that you may face during entry ineluding the signs, symptoms and consequences of exposures. b. Know how to properly use the equipment required by this permit c. Communicates with attendant, regularly. d. Alert the attendant and exit the space whenever you recognize any waming sign or symptom of exposure to a hazard, detect a prohibited condition, or an evacuation alarm goes off. e. Exit the space if so directed by the attendant 4. Attendants Routine Duties a. Ensure direct communication (phone, radio, or voice) before entry is trade b. Understand the procedure for use of two-way radios, if verbal communications are unavailable. c. Understand the hazards present in the confuted space. d. Understand the symptoms associated with exposure to toxic agents or oxygen deficiency. e_ Never leave the post for any reason while personnel are inside the confined space. if the observer must leave the post, another trained observer must replace, hbn/her; otherwise, the personnel inside the confined space must come out. f. 'Pass tools into the personnel working in the confined space. g_ Maintain verbal communication and have continuous awareness of the activities of the personnel in the confined space. h_ Have the lifelines anchored and ready for use to ensure they are ready in the event of an emergency. 3. Observer Emergency Duties In the event of an emergency, the observer shall summon aid immediately by: a- Dialing 911 b. Safety Department The safety department is responsible for: a, Training managers. observers, attendants, and employees woo will enter confirmed spaces. b. Conducting a review on the overall confined space program at least annually and revise it as necessary. E. PREPARATION OF A CONFINED SPACE 1. Air Quality Testing a. All confined spaces must be tested for air quality prior to entry. Testing shall be made using instrumentation of sufficient sensitivity to identify and evaluate any hazardous atmosphere that may exist. h. The Complex Manager will initially test the atmasphere for !lose Acre Farms employees using approved and properly calibrated instruments. Entrants are permitted to observe test procedures. REVISED 10/13/10 c, if the Complex Manager suspects that toxic vapors, fume or mist are present then the Safety Director will be consulted to ensure that the atmosphere does not exceed OSHA specified limits for airborne contamination_ d. Testing of confined spaces for contractor envy will be performed by that contractor or their designated Entry Supervisor. Contractor employees shall not enter confined spaces without meeting all requirements found in this procedure. e. If entry is authorized, continuous monitoring is required for the duration of the entry, unless determined otherwise by the Entry Supervisor. The instruments used for continuous monitoring shall be provided witb audible and visual alarms to warn when the permissible amounts of flammable toxic vapors or oxygen deficiency are exceeded. f. If ventilation is required for the area it must be thoroughly ventilated. Special care should be taken to ensure that circulated air will reach isolated pockets and prevent recirculating contaminated air. Provisions sbali be made to provide for adequate fresh air during the entire time personnel are inside a confined space. A system of blowing and exhausting air shall be used under such conditions as a tunnel or large diameter tank are entered.' g. If the integrity of the atmosphere in the confined space cannot be guaranteed and a primary breathing air supply is required "Do Not Enter" h, Monitoring shall be performed in the following order. - oxygen 2. combustible vapors and gases 3. toxic gases and vapors i. Entry shall be denied under the following conditions; 1. Oxygen concentration equal to or less than 19.5% by volume 2, Presence of toxic gases 3. The presence of explosive or flammable gases 2. Purging And Removal of Contents The confined space trust be clean, free of hazardous material and chemicals. Where necessary, remove vapor by purging with water, air or other equivalent means. 3. Isolation Ail input lines which discharge into or out of the confined space shall be physically disconnected, Mocked, blanked, capped or othe ise isolated. The use of in -lire shut off valve as the sole means of isolating the confined space from any inputloutput line is prohibited. Double block and bleed procedures are acceptable. 4. Lockout a. The electrical equipment, excluding lighting, shall be locked out and tagged out in accordance with CFR 1910.147 REVISED 10/13/10 b. The lock key is to be kept by the person performing the job, and only this person is authorized to unlock the apparatus and remove the lock upon completion of the Job. If more than one person is working in the confined space, each must place a Sock on the device and retain his/her own key. 5. Security Of Covers Al! manhole and clean out covers sha11 be openings maintained clear of any obstructions. All access openings must be immediately barricaded by approved railings. When hinged dbpr5 or covers are provided, they shall be secured so they cannot be closed while someone is inside the confined space. All unsecured lids shalt be secured or laid flat on ground level. 6. Welding a• An hot work permit must be obtained before any welding operation begins. b. Personnel welding in a confined space shall be provided with and required to use the proper welding equipment and other required personal protective equipment. Welding and cutting torches must not be taken into confined space until ready to be used and must be removed from the area immediately after use. Cylinders ofoxygen or other gases shall not be taken into confined space. They must be turned offat the cylinder valve when riot use. F. WHILE WORK IS 1N PROGRESS 1. Tools: a. Where a possibility of flammable vapors or gases exists, hand tools are to be an approved spark -proof type. Electrical power tools and equipment roust be explosion proof rated. b. All portable electrical power tools must be grounded or double insulaied..Extensiou cords are to be grounded and in good repair. Ground -fault circuit protection muss be provided in wet areas or outside of the buildings. c. In lieu of ground -fault circuit interrupter protection, battery or transformer equipment operated at 12 volts or less may be used. d. A ladder may be used as a cleans of entering and exiting provided it does not obstruct the opening. e. A hoist or other suitable means may be used with the approval of Entry Supervisor. G. PROTECTIVE EQURNIENT AND DEVICES: Any Rose Acre Farms employee entering a confined space shall use the following protective equipment as prescribed by OSHA and The Entry Supervisor. 1, FulI body harness, unless proven it will create a hazard ?. An approval lifeline shall be attached to the harness. The other end of the lifeline is to be securely anchored outside the confined space, It is required to have a block and tackle positioned on a tripod or fastened by other suitable means above the confined space. 3. All Rose Acre Farms personnel entering a confined space will be required to wear approved footwear and eye protection. Some entries may require hard hats and other protective equipment. If contaminant in the confined space can cause dermatitis or can be absorbed through the skin, those REVISED 10/13110 entering must wear appropriate protective clothing. (Such as: chemical resistant gloves, special clothing, etc_). 4. All of the major areas previously mentioned are covered on the entry permit. If all applicable requirements have been met, The. Entry Supervisor will validate the permit for the job, location, personnel and time specified by signing the permit. A change in personnel or conditions will require revalidation of the permit by the Entry Supervisor, initialing all changes. H. TRAININGICERTIFICATION I. The following employees shall receive formal training in confnned space envy procedures, safe entry and emergency procedures and shall have refresher training annually- a. Those who work in confined spaces b, Those who coordinate confined space entries by other employees c. Those who observe or attend entry of confined spaces d. Other affected employees 2. Tr -dining shall certi N an employee as qualified to work and complete all duties associated with confined space entry and rescue. Certification shall include testing for proficiency, record keeping and signatures of those attending training classes as well as the instructor's signatures. Training shall include the following: a. Duties of the "authorized entrants" b. Duties of the "attendants" Cr Duties of the "Entry Supervisors' d. Duties of the rescue and emergency personnel (local fire department) REVISED 0113110 PART 1: Confined Space Evaluation Permit No. Entry Date: Entry Time. _ Person Completing Evaluation: onfned Space Location/Description: Purpose of Entry and Assigned Work: Potential Physical Hazards o Corrosive a Stearn o Entrapment o Heat or Cold Flammable Materials Materials o Machinery o Water a Engulfment o Slip, Trip, Falls o Hot Work a 0 th er Are all valves, switches, operating mechanisms and energy sources locked and tagged out?.......... Yes No N/A Has Not Work Permit been issued? ....... .......................... ............................................ ........................ Yes No N/A Potential Atmospheric Hazards a Lack of Oxygen 0 Inert Gases ❑ Combustible, Flammabie, or Toxic Gases, Vapors or Dusts o Otte er Pre -Entry Atmospheric Testing Data Date/Time Tested % Oxygen (19.5%-23.5%) eriodic Atmospheric Testing Data % Oxygen Date/Time Tested (19.5%-23.5%) Atmosphere to be tested: Forced Ventilation to be used: Lower Explosive Limit [<10% LEL) Lower Explosive Limit (E10% LEL) a Continuously a Continuously Carbon Monoxide (Under 35 ppm Carbon Monoxide (Under 35 ppm) o Prior to entry a 0 t h e r Hydrogen Sulfide (Under 10ppm) Hydrogen Surf:de (Under 10ppm) Personal Protective EuuipmentlSafety-Equipment Needed o Coveralls 0 Hearing o Fall Protection o Special Rescue Gear Protection a Hard Hat o Lighting o Ventilation o Communication Equipment Equipment o Barricades c Lifting o Fire Extinguishers o Safety Harness/Lifeline Equipment a Gloves a Eye Protection o Safe Footwear o Monitoring Equipment c N95 Dust o Oth Mask er PART 2: Entry Briefing (To be completed prior to entry for all confined spaces) REVISED 20/13/10 Has an attendant been designated? — ............ ..._...,....,..,...._......._........ _.. Yes No NIA Have all employees been adequately trained? ...................................................... Yes No NIA Has means of emergency response/rescue been established?.............. ................. Yes No NIA Describe: Name: Phone: Have the hazards of the work been explained? ... .................. ................-------.__•-•---.......... Yes No NIA Has means of communication been established? ........ — ... .......... ................ Yes into NIA Describe: PART 3: Confined Space Entry Permit (To be completed prior to entering PRCS) This space has been designated a permit required confined space {PROS}. This space may only be entered by personnel who have been specially trained to work in PROS. A specially trained Attendant shall remain outside of the PRCS for the duration of the entry operation and will be designated in the appropriate space below. Each Entrant must sign in and out each time the PRCS is entered and exited in the appropriate space below. This confined space entry permit must be posted at or near the confined space point of entry for the entire duration of the entry operation. Authorized Entrant(s) Name fPrint] Time -in ! Time put N e int Time In 1 TimE out Name (Print Permit Authorization Duration of Permit: Date of Permit: _ Complex Manager (Print): Signature: REVISED 10/13/10 Attendanttsl Name [Printt 1 1 1 1 1 Permit Cancellation Date: Time: Complex Manager (Print): Signature: _ Reason for Cancellation: a Entry Operation Completed c Occurrence of Prohibited Condition -- -- - Respiratory Program General A. Administrative and/or engineering controls shall be used to prevent exposing employees to contaminated air. S. If neither administrative or engineering controls are feasible, then appropriate respirators shall be used as a means of protecting employees from overexposure to contanunated air. Hazard Evaluation A hazard evaluation of each facility shall be conducted by facility management to determine if airborne hazards are present. Hazardous airborne conditions include, but are not limited to, the following: An oxygen level below 19.5%. 2. Atmospheres contaminated with the toxic gases, vapors, mists, and/or particles. Work areas specifically identified for respirator use. C. -Respirators shall be selected on the basis of hazards that are found to be present during the hazard evaluation. Types of Respirators: Air -purifying: These respirators are designed to remove certain gaseous and particulate contaminants from the atmosphere. The purifying elements can be attached to a full or half facepiece and some of the respirators can be disposable. The 3 types of air -purifying respirators are. a. Particulate respirators b. Gas and vapor (chemical cartridge) respirators Gas masks 2. Air -supplying: These respirators provide a supply of breathable air different from the work place air. The two types of air -supplying respirators are: Supplied air respirators (not to be used in IDLH atmospheres) b. Self-contained breathing apparatus (SCSA) Note: IDLH means h=ediately Dangerous to Life or Health D. Training: Employees and the supervisor of the employees who are or may be required to use respirators shall be trained on the following information and procedures: a. The reason for respirators and why other methods of control cannot be rased. REVISED 10/13/10 b. The respirator selection process including the identification and evaluation of the hazards. C. Demonstration of proper fitting, wearing, and removing the respirator. d. The limitations, capabilities, and operation of the respirator. C. The proper maintenance and storage procedures. F. Allow the employee to wear the respirator in a safe atmosphere to permit them to become familiar with its characteristics. g. Correctly fit the respirator using a qualitative fit test. h. How to recognize and cape with emergency situations. i. Special uses of the respirator. j. Regulations regarding the use of respirators. L How to perform positive and negative fit tests before respirator use to ensure a good fit, E. Cleaning and Disinfecting 1. All single use and disposable respirators shall be discarded at the end of their useful life. These respirators shall not be cleaned and reused under any circumstances. 2. Respiratory protection that is .not disposable shall be washed and disinfected by the employee after each day of use. 3. Respirators shall be assigned to individual workers for their exclusive use. 4. Cleaning of routinely -worn respirators (except for non -washable parts of supplied respirator) shall include, a. Removal of any filters or cartridges- b. Wash facepiece by using a cleaning/sanitizing solution that can be purchased from the manufacturer. C. Rinse completely in clean, warm water. d. Air dry in a clean area. F. Respirators shall be stored in a convenient, clean, and sanitary location, and in such a manner that the rubber pieces are not mis-shaped. G. Maintenance and Inspection l . The inspection shall include as a minimum for all respirators: REVISED t0113114 a. The tightness of all connections. l3_ The condition of the facepiece, headbands, valves, connecting tubes. and canisters. C. The close visual inspection of the rubber and fabric for deterioration. 2. The parts used to replace defective respirator components shall be aquired from the same manufacturer as the respirator. This also applies to replacement cartridges and Titers. H. An evaluation of this program shall be conducted on an annual basis or as needed. I_ Fit Testing 1. Each employees who wears a respirator shall be fit tested by a qualified trainer before being allowed to wear a respirator. A fit test record must be maintained (Appendix A). 2. Fit testing shall be repeated each time the user receives a different type of respirator, face piece, or if the wearer undergoes significant changes in racial features, dental configuration, or body weight- J . Respirators shall be. selected from those approved by both the Mine Safety and Health Administration (MSHA) and National Institute for Occupational Safety and Health (NIOSH): K. Special Considerations When the respirator user roust wear corrective spectacles and wear a full face respirator, the lenses shall be compatible with the assigned facepiece. The adapter shall be provided by the facepiece manufacturer. 2, Contact lenses shall not be used inside full facepiece respirators. 3. Such conditions as a beard, sideburns, a skull cap, temple pieces on glasses. and the absence of uzie or both dentures can seriously effect the fit of a facepiece. L , Recordkeeping } . Respirator Fit -Test records shall be maintained by facility management for the duration of employment. (Appendix A) 2. A record of employee training shall be maintained by facdity management for a minirrium of three }rears (Appendix B). Resources 1. 29cfrl910.134 "Respiratory Protectiorf' REVISED 10/13/110 Appendix A Respirator User Fit -Test Record F ' ity #: _ Respirator User: Jab Classification: Work Activities Requiring Respirator Use: w individual Performing The Fit Test: `List the fit -test atmosphere here: Saccharin, Isoamyl Acetate. Irritant Smoke. REVISED 10/13/10 Appendix B Respiratory Protection Training Log P 'ram Administrator: Facility #: REVISED 10/13/10 Date: ATTACH COPY OF RESPIRATOR TRAINING AGENDA Fail Protection Program PurLvse T Rose Acre Farms fdcility or operation shall have a fall protection program with the intent of minimizing the risk of injury as a result of i. ,rout elevated work locations. The practices and procedures to be included in the fall protection program are outlined as follows: A. Identify areas that present fall hazards. B. Establish guidelines for selection, use and care of fall protection equipment and systems. C. Provide education and training on all aspects of fall protection systems. D. incorporate fall prevention when ever possible into project planning and design. Scope This program applies to all Rose Acre Farms facilities and operations. It covers any elevated work location where the feet of an individual are four (4) feet or more above the floor or grade level. General A. Rose Acre Farms shall provide some type of fall prevention for any free fall hazard which may be present within a facility. B. Any employee whose feet are more than four (4) feet above the floor or grade level shall wear fall protection if other means of fall prevention cannot be applied. These work areas may include, but are not limited to unprotected sides and edges of floors, roofs, and other structures. C. Fall prevention measures can be guardrails, scaffolds with proper guardrails, and platform ladders (if performing activities that are not physically demanding). L Fall protection equipment consists of the proper anchorage, full body harnesses, shock absorbing lanyards, self -retracting lifelines, etc. F. All jobs shall be evaluated to determine the need for fall prevention or a fall protection system. The supervisor of the job being evaluated and the employee performing the job shall be responsible for performing the evaluation. Some key points to consider when evaluating the job are: Height of the job. Fall protection/prevention that is heeded. Other hazards that may be present. If work must be performed where fall hazards are present then either the proper fall prevention measures shall be implemented or a fall protection system shall be selected and 'installed. Ali employees, who are required to work at elevated heights, shall thoroughly inspect all components of a fail protection system before it is used. G, Equipment Fall protection equipment shall be worn by any employee who may be exposed to free fall hazard_ Fall protection equipment at Rose Acre Farms includes: a. Full body harnesses Shock absorbing lanyards C. Self -retracting lifelines REVlSED 10/13/10 d. Anchonng devices e. Platforms with railings or cages 2. Body belts are not considered adequate fall protection, and shall not be used. 3. When ascending or descending, ladders are considered fall protection only when two hands of the person are free and on the ladder. 4. Fall protection equipment. shall not be modified without written approval from the manufacturer. 3. DarnagedlDefective equipment shall be tagged out of service until a sufficient replacement is installed. H. Equipment Storage and Inspection I. Fall protection equipment shall be stored in a clean and dry area. 2. Never store fail protective equipment near any solvents, chemicals, oil, grease, etc, 3. Equipment shall be inspected regularly and before each use. Any frayed or damaged equipment shall be removed from service and replaced. J, Training i. Ali employees required to use fall protection equipment shall be trained in the following: a. The identification oftiee fall harards in a work area. b. The proper use and operation of fall protection equipment. c. The proper inspection techniques of fall protection equipment. d. The proper storage and care of fall protection equipment_ 2. All employees must receive refresher training annually REVISED 10/13/10 Fire Eitinguisfie- r Program Classification of Hazards A. Most of RAF facilities are classified as an Ordinary (moderate) Hazard. Il. General Requirements A. Portable extinguishers shall be maintained in a My charged and operable condition, When they are not in use, they should be kept in their designated places at all times. B. Extinguishers shall be conspicuously located where they will be readily accessible in the event of a fire. Preferably, the extinguishers shall be located along the normal paths of travel, including exits. C. Extinguishers shall not be obstructed or obscured from view_ D_ Extinguishers shall be installed on the hangers or in the brackets supplied E. Extinguishers weighing less than 40 lbs. shall be mounted so that the top of the extinguisher is NOT more than 5 feet above the floor, Extinguishers weighing more than 40 lbs. shall be mounted so that the top of the extinguisher is NOT more than 3.5 feet above the floor. in no case shall the clearance between the bottom of the extinguisher and the floor be less than 4 inches. F. The operating instructions of a fire extinguisher shall face out. III. Selection of Extinguisher A. Extinguisher for protecting class A, B, and C fires shall be used, iv, Lnspection A. Frequency- extinguishers shall be inspected monthly and documented on service tag. Annual maintenance shall be performed by trained persons with suitable testing equipment and facilities. B, Procedure for inspection: 1. Located in designated place, 2. No obstruction to access or visibility. 3. Operating instructions on nameplate legible and facing outward. 4. Seals and tamper indicators not broken or missing. 5. Determine fullness by wcigbing or "hefting". 6. Examine for obvious physical damage, corrosion, leakage, or clogged nozzle 7. Pressure gauge reading or indicator in the operable range or position. Corrective Action- when an inspection of any extinguisher reveals a deficiency in any of the conditions listed in the above procedure, immediate corrective action shall be taken. A. Rechargeable Extinguisher- When an inspection reveals a deficiency in any of the conditions listed in (3), (4),(S).(6) of the above procedure, the servicing provider must be called to perform maintenance. B. Non -rechargeable- when an inspection of any non -refillable disposable extinguisher reveals a deficiency in any of the conditions Fisted in (3), (4), (5), (6) of the above procedure, it shall be removed from service. C. Hydrostatic Testing muse be performed by trained persons with suitable testing equipment and facilities. REVISED 10/13/10 V Record keeping A. Each extinguisher shall have a tag or label securely attached that indicates the month, year, and person perforating the maintenance. The same record, tag or label shall indicate whether or not recharging was also performed, Training fit. An educational program will he pro►=idcd to authorized employees to familiarize them thern with the general principles of fire extinguisher use and the hazards itivolved with incipient stage fire fighting. B3 Training will be conducted upon initial assignment to the designated group and annually thereafter. REVISED 10/13/10 Hot Work Permit Program 7 .eduction This proLrarn establishes written procedures to prevent fires resulting from temporary operations involving an open t]ante or spark. This includes, but is not limited to brazing, cutting, grinding, soldering, welding, and other forms of torch operations. This written program requires the issuance of a Hot Work Permit before beginning any hot work. Scope This program applies to Rose Acre Farms employees and contractors who perform or supervise hot work activities in existing buildings, new construction in existing buildings, and new construction attached to existing buildings. This program does not apply to areas that are specifically designed and equipped for such operations, e.g., designated welding areas. Responsibilities Health and 5afet ti Depaztment • Distribute and update Hot Work Permit forms • Provide assistance with program implementation and administration • Provide assistance in training supervisors, employees, and project managers • Update Hot Work Program as needed Stx��ervisor • Establish designated areas for cutting and welding • ire hot work procedures are being implemented and followed in other than designated areas are that all employees and contractors are following hot work procedures • Ensure that a hot work permit is issued prior to the start of work Ensure that all cutting and welding equipment is in satisfactory condition • Ensure that employees are suitably trained in the operation of the equipment and safe use of the process Employee • Follow and use hot work procedures; • Obtain a hot work permit prior to starting work; • Attend and actively participate in training sessions • Protect nearby personnel against heat, sparks, etc. when working in occupied buildings. Procedures Hot work should not be performed if the work can be avoided or performed in a safe manner. When practical, objects to be welded, cut, or heated must be moved to a designated safe location, e,g., a designated welding area, if hot wotk cannot be moved to a safe working area, then cutting and welding may be perfertned, but only alter the following conditions are met: 1) A Hot Work, Permit must be acquired before the hot work begins (Appendix A) 2) The Hot Work Permit will be completed by the person in charge of the work site who is able to ensure that all the requirements of the permit will be met. The permit is valid only for the date(s) and time specified on the permit. A copy of the permit must be delivered to the complex manager. Original permit must be kept at the site, where the hot work is taking place. personnel (employees, contractors, building occupants) must be suitably protected against hazards generated by the work, e.g., heat; sparks. fumes, welding rays, etc, This may include, but is not limited to, the use of personal protective equipment (safety glasses, eye and face shields, gloves with gauntlets, leathers, and footwear), screens, or local exhaust ventilation. REVISED 10/13/110 special Precautions Special precautions shall be taken for buildings, equipment, and processes within 35 it. horizontal radius of the work (welding) area: 1. Move all combustibles to a location outside the 35 ft. radius. If material cannot be removed, it shall be protected with Fire retardant tarps, metal shields, or other noncombustible material. Edges of covers and cover overlaps shall be tight to the floor. 2. Floors shall be cleaned of all combustibles. 3. Combustible floors, walls, and ceilings shall be wet down, covered with damp sand, or protected 4. Wall floor openings, and other openings shall be protected. Where necessary, fire retardant tarps shall be suspended beneath work to collect sparks. 5. When cutting and welding in structures with open grating or expanded metal Moors, care should betaken to control and contain fire/sparks at that level. b. If cutting and welding is done on metal walls, partitions, roof, etc„ precautions shatl be taken to prevent the ignition of combustibles on the opposite side from conduction, direct flame from the torch, or other means. 7_ if cutting and welding is Clone on elevated metal decks, grating, or platforms, the area below the work shall be cleared of all combustible and flammable materials. This area should be blocked off to prevent use until after cutting and welding is completed and verified r hibited Conditions A Not Work Permit will not be issued if ANY of the following conditions exist: • Combustiible or flammable materials are within 35 feet and cannot be moved or protected Floor and wall openings cannot be covered; • Cutting or welding on pipes or other metals can conduct enough heat to ignite nearby combustible materials or • Any condition that could result in 'undue hazards by performing the work_ • In the presence of explosive atmospheres or flammable gases, vapors, liquids, or dusts with air or explosive atmospheres that may develop inside uncleaned or improperly prepared tanks or equipment which have previously contained such materials, or that may develop in areas with an accumulation of combustibles dusts. • Any condition that could result in undue hazards by performing the work. Fire Watch • Ensure proper fire fighting equipment is readily available (i.e. appropriate extinguisher for type of operation and material) • Extinguish a Fire ONLY when it is safe to do so and within trained capabilities. • A fire watch must be maintained at the work site for at least I hour after the work is completed • A method to summon the fire department or other emergency services must be established Contractors �--.,tractors doing work for Rose Acre Farms trust follow the written Clotting and Welding Policy, REVISED 10/13/10 ROSE ACRE FARMS, INC. WORK PERMIT T' Good From Date. - TO Date: Building/Location Time Starred —:-- am pm Describe Work To Be Done: DEPT.; Time:__ (am/pm) Time: (amlpm) Time Completed ant pm NOTE: Answer each question YES or NO. If Question does not apply, check off indicating that it has been given consideration. 1. Can the equipment be removed from the building? 2. Can the work be done other than by the use of flame? 3, Have all process materials (solids, liquids, gases) been removed from the equipment? _ 3. Have connections been blinded of17 5. Have valves been tagged and/or locked close? 6, Have switches and electric disconnects been tagged and/or locked open'? [Safety Socks on push buttons are not sufficient? 7. Has equipment and all attached piping been cleaned? Has equipment been ventilated? Is ventilation to be continued during shutdown or repair procedures? la. Have trenches and sewer openings been covered and steamed to eliminate explosive vapors? IL . Have gas tests been made? 12. Can sparks ignite material in vicinity or on lower floor or levels? 13. Is adjacent equipment safe? _ __ Are there any special precautions to be observed? Supervisor in Charge: Complex Manager: REVISED 10/13/10 Hearing Conservation Program I. PURPOSE This purpose of this hearing conservation program is to prevent occupational hearing loss and comply with the OSHA Standard 29 CFR 1910,95 - Occupational Noise Exposure. II. APPLICATION The Occupational Safety and Health Administration (OSHA) Occupational Noise Exposure standard 29 CFR 1910.95 establishes a permissible exposure limit(PEL) for occupational noise exposure, and requirements for audiometric testing, hearing protection, and employee training if those sound Ievels are exceeded. This regulation defines an "action level" (AL) as a "dose" of 50%, which is equivalent to an ea i-hour time wen kited averai:e of SS dBA. When noise levels exceed this amount, an effective hearing conservation program is required, which includes as a minimum: Reg niregtent Section 1. Noise monitoring 29 CFR 1910.95(d)(e)(0 2. Audiometric testing 29 CFR 1910.95(g)(h) 3. Hearing protectors 29 CFR 1910.95(i)U) 4, Education and training 29 CFR 1910,95(k)(1) 5. P ecordkeeping 29 CFR 1910.95(rn) Note. Re OSHA regulation only indicates a minimum level of hearing protection and focuses on permanent hearing loss. Short durations of noise, especially sharp bursts of noise at these levels can not only induce bearing loss but can also affect an employee's health and safety in other ways (See Table # 1 on page IS). lilt. BACKGROUND Occupational noise can cause hearing loss, and increase the worker's susceptibility to other workplace problems including physical and psychological disorders, interference with speech and communication, and disruption of job performance associated with excessive noise intensities. This exposure to noise produces hearing loss of a neural type involving injury to the inner car hair cells. The loss of heating may be temporary ot permanent. Brief exposure causes a temporary loss. Repeated exposure to (sigh n©ise levels will cause a permanent loss. Permanent healing loss is preventable with the continued use of proper hearing protection and reduction of workplace noise levels to below 85 decibels. This will benefit not only employees who can listen and communicate well throughout there lifetimes, but also helps the employer in terms of reduced exposure to hearing loss compensation claims and a potential for increased general safety and job performance. IV. RESPONSIBILITY FOR COMPLIANCE The administration of this program will be the responsibility of the complex manager. Administrative responsibilities include: 1. Coordination and supervision of noise exposure monitoring. 2. Identification of employees to be included in the Hearing Conservation Program. 3. Coordination and supervision of audiometric testing program_ 4. Supervision of hearing protector selection. 5. development of policies relating to the use of hearing protectors. REVISED 10/13/10 6. Supervision of employee training programs, 7. Coordination and supervision of required recordkeeping. 8. Periodic evaluation of overall program. 9. Coordination of required changes/improvements in the program- V. NOISE MONITORING l . When information indicates that any employee's exposure may equal or exceed an 8-hour time -weighted -average of 85 decibels, the employer shall develop and implernent a monitoring program - ?. Employers shall identify employees for McIusion in the hearing conservation program and to enable the proper selection of bearing protectors. 3. All continuous, intermittent and impulsive sound levels from 80 decibels to 130 decibels shall be integrated into the noise measurmrnents. d. Instruments used to measure employee noise exposure shall be calibrated to ensure measurement accuracy. �. Monitoring shall be repeated whenever a change in pruduction, process, equipment or controls increases noise exposures to the extent that: i. Additional employees may be exposed at or above the action level, or ii. 'The attenuation provided by hearing protectors being used by employees may be rendered inadequate to meet the requirements (explained in section IX). 6. The employer shall notify each employee exposed at or above an 8-hour time -weighted average of 85 decibels of the results of the monitoring. 7. The employer shall provide affected employees or their representatives with an opportunity to observe any noise measurernems conducted. S_ Monitoring will be coordinated by complex manager with assistance from Safety Department. 9. The results of the noise exposure Measurements will be recorded on form # 1, V II. AUDIOMETRIC TESTING The employer shall establish and maintain an audiometric testing by making audiometric testing available to all employees whose exposures equal or exceed an 8-hour time -weighted average of 85 decibels. The program shall be provided at no cost to employees. Audiometric tests shall be performed by a licensed or certified audiologist_ orolaryugologist, or other physician, or by a technician who is certified by the Council of Accreditation in Occupational Hearing Conservation, or wbo has satisfactorily demonstrated competence in administering audioretric examinations, obtaining valid audiograms, and properly using, maintaining and checking calibration and proper functioning of the audiometers being used. A technician who operates microprocessor audiometers does not need to be certified_ A technician who performs audiometric tests must be responsible to arc audiologist, otolaryngologist or physician. Baseline audiogram Within 6 months of an employee's first exposure at or above the action level, the employer shall establish a valid baseline audiograrn against which subsequent audiograms can be compared. Mobile test van exception REVISED 10/13/10 Where mobile test vans are used to meet the audiometric testing obligation, the employer shaI1 Obtain a valid baseline audiogram within I year of an employee's first exposure at or above the action level, Where baseline audiogt-ms are obtained more than 6 months after the employee's first exposure at or above the action level, employees shall wearing hearing protectors for any period exceeding six months after first exposure until the baseline audiograrn is obtained. Testing to establish a baseline audiognum shall be preceded by at least 14 hours without exposure to workplace noise. Hearing protectors may be used as a substitute for the requirement that baseline audiograms be preceded by 14 hours without exposure to workplace noise. The complex manager shall notify employees of the need to avoid high levels of non -occupational noise exposure during the 14-hour period immediately preceding the audiometric ex amination. Annual audiogram Audiograms will be conducted at least annually after obtaining the baseline audiogram for each employee exposed at or above an S- hour time -weighted average of 85 decibels. The complex manager will maintain a record of all employee audiometric test records. This record will include 1. Name and job classification of the employee. 2. Date of the, audiogram. 3. The examiner's name. 4. Dare of the last acoustic or exhaustive calibration of the audiometer. 5. Employee's most recent noise exposure assessment. _ UDIOMETRIC EVALVATI 1 Each employee's annual audiogram will be compared to hisiber baseline audiogram by qualified evaluator to determine if a Standard Threshold SM11(STS) has occurred. 'This comparison may be done by a technician. 2. A Standard Threshold Shift is defined by OSHA as a change in hearing threshold relative to the baseline of an average of IOdB or more at 2000, 3000, and 4000 Hz either ear. 3. In determit&g if a Standard Threshold Shift has occurred, an allowance can be made for the contribution of aging (presbycusis). The age correction vaiues to he used are found in Appendix F of 1910.95. 4. 'The audiologist, otolaryngologist, or physician shall review problem audiograms and shall determine whether there is a need for further evaluation. The employer shall provide to the person performing this evaluation the following information: a. A copy of the requirements for hearing conservation as set forth in the standard. b. The baseline audiogram and most recent audiog7arn of the employee to be evaluated. c. Measurements of background sound pressure levels in the audiometric test room as required in Appendix D: Audiometric Test Rooms. d. Records of audiometer calibrations If the annual audlogra a shows that an employee has suffered a standard threshold shift, the employer may obtain a retest within 30 days and consider the results of the retest as the annual audiograrn. REVISED 10/13/30 6. Unless a physician determines that the standard threshold shift is not work related or aggravated by occupational noise exposure, the employer shall ensure thiat the foIiowing steps are taken when a standard threshold shift occurs: a. Employees not using hearing protectors will be trained, fitted, and required to use hearing protectors if they are ext)osed to an 8 hour TWA average sound level of 85 decibels or greater. b. Employees already using hearing protectors shall be retrained, refitted, and required to use hearing protectors and provided with hearing protectors offering greater attenuation if necessary. c. The complex manager will inform the employee, in writing, within 21 days of this determination, of the existence of a permanent Standard Threshold Shift. (See Form # 2) A copy of the STS letter will also be sent to the employee's supervisor. d. The complex manager will counsel the employee on the importance of using hearing protectors and refer the employee for further Clinical evaluation if necessary. 7. Persistent significant threshold shins roust be entered on the OSHA 300 Log if determined to be work related- S. If subsequent audiometric testing of an employee whose exposure to noise is Jess than an 8-hour TWA of 90 decibels indicates that a Standard Threshold Shift is not persistent, the complex manager: a. Shall inform the employee of the new audiometric interpretation. b. May discontinue the required use of hearing protectors for that employee VZII. PROTECTION EQUIPMENT A. The complex manager shall ensure that hearing protectors are worn: By any employee who is subjected to sound levels eQual to or exceeding art 8-hour TWA of 90 decibels. By any employee who has experienced a persistent Standard Threshold Shift and who is exposed to 8-hour TWA of 85 decibels or greater. By any employee who has not had a initial baseline audiogram and who is exposed to 8-hour TWA of 85 decibels or greater. B. Employees will be given the opportunity to select their hearing protectors from a variety of suitable hearing protectors at no cost to thern. C. The complex manager will provide training in the use and care of all hearing protectors. D. The complex manager will ensure proper initial fitting and supervise the correct use ofali hearing protectors. E_ Employees will be held accountable for not properly using and maintaining the equipment furnished. F. The complex manager will evaluate the attenuation characteristics of the hearing protectors to ensure that a given protector will reduce the individual's exposure to the required decibels. (See Form # 3) Iftbc, 8-hour TWA is over 90 decibels, then the protector mast attenuate the exposure to at least an 8-hour TWA of 90 decibels or below. If the protector is being worn because the employee experienced a Standard "Ihreshold Shift, then the protector must attenuate the exposure to a 8-hour TWA of 85 decibels or below. If employee noise exposures increase to the extent that the hearing protectors provided may no longer provide adequate attenuation. the employee will be provided more effective hearing protectors. REVISED 10/13/10 G, It is the responsibility of the supervisor to ensure that hearing protectors are wom by all e►rrpIoyees who are exposed to noise levels at or above an eight Stour TXVA of 90 decibels or if the employee experienced a permanent STS or has not yet had a baseline audiogram. EMPLOYEE EDUCATIONAL TRAINING An annual training program for each employeeincluded in the hearing conservation program will be conducted by Examfoetics and will include information on: 1. The effects of noise on hearing. 2. The purpose and use of hearing protectors. 3. The advantages, disadvantages, and attenuation of various types of protection. 4. Instruction in the selection, fitting, use and care of protectors, s. The purpose of audiometric testing and an explanation of the test procedures. Fonn #4 will be used to record the training dates and the employees in attendance. Infonnation provided in the training program shall be updated to be consistent witb changes in protective equipment and work processes, X. RECORDKEEPING Noise exposure measurement records will be retained far two years. Audiometric test records will be retained for the duration of the affected workers employment plus thirty years. Access to records_ All records required by this section shall be provided upon request to employees, former employees, representatives designated by the individual employee, and the Assistant Secretary. M. PROGRAM EVALUATION At least annually, the Nearing Protection Program will be evaluated by the Safety Department. After the evaluation, the changes/revisions to the program deemed necessary will be made as soon as possible. REVISED 10/13/10 Form # 1 Noise Exposure Measurements Organization Location Process/Operation Noise Exposure Levels in Decibels i REVISED 10/13/10 Form # 2 Sample Standard Threshold Shift (STS) Letter Dear Your most recent audiometric test result vas compared to your baseline audiogram. This comparison indicates that your hearing has deteriorated to the point where your hearing impairment constitutes a "standard threshold shift" This is defined by the Occupational Safety and Health Administration (DSHA) as a relative hearing Ioss of an average of 10 decibels in either ear at the frequencies of 2 00 0. 3046 and 4, 00OHz. An audiogram cannot define why you have a hearing loss, but there are many possible reasons such as infections, wax buildup in your car and noise. By taking the necessary action now, we can try to stop bearing loss from getting worse. Consequently, we want to fit you with hearing protectors. Please call _ to arrange an appointment with Whenevcr you are in a work environment that would result in noise exposure that equals or exceeds an 8 bour Time Weighted Average (TWA) of 85 decibels, bearing protection must be used. Loss of hearing wilt affect you He. Preserve your hearing while you still have a chance. Our Department will attempt to answer any questions you may have. Sincerely, REVISED 10i]MO Farm # 3 Hearing Protection Equipment Summary f -anization: Type �II Name Noise Reduction (muff/cap/plug) (Brand and Model.) - _Rating k DEVISED 10/13/10 Farm # 4 Hearing Conservation Training Record 0-vanization: Name of Employee 11 Job Classification 11 Department Trainer: Date: REVISED IM31I4 Table # 1 Permissible Noise Exposures 29 CFR 1910.95 Table G-16(a) Duration illoursy Sound Level Slow Response 32.0 80 27.9 81 24.3 82 21.1 83 18.4 84 16.0 as 13.9 86 12.1 87 10.6 88 9.2 89 &0 90 7.0 91 6.2 92 5.3 93 4.6 94 4.0 95 3.5 96 3.0 97 2.6 98 2.3 99 2.0 100 1.7 101 1.5 102 1.4 103 1.3 104 1.0 105 0.87 106 0.76 107 0.66 108 0.57 109 0.5 110 0.44 111 0.38 112 0.33 113 0.29 114 0.25 115 0.22 116 0.19 Ii7 0.16 119 0.14 119 0.125 120 0.11 121 0-095 122 0.082 123 0.072 124 0.063 125 0.054 126 0.047 127 0.041 128 0,036 129 0.031 130 REVISED 10/13/10 Personal Protective Equipment Program Purpose and Scope The Rose Acre Farms Personal Protective Equipment Program addresses eye, face, ear, head, hand and foot protection. Empioyees will be provided personal protective equipment (PPE) to reduce the likelihood of an injury and/or illness. PPE is not a substitute for engineering or administrative catirrols, or good work practices, but should be used in conjunction with these controls. 11 Responsibilities III . Training A. Supervisors Supervisors have the primary responsibility for implementation of the PPE Program in their work area. This involves: • Providing appropriate PPE and making it available to employees. + Ensuring employees are trained on the proper use, care; and cleaning of PPE. Supervising staff to ensure that the PPE Program elements are foil owed and that employees properly use and care for PPE. + Seeking assistance from Safety Department to evaluate hazards. • Notifying Safety Department when new hazards are introduced or when processes are added or changed. ■ Ensuring defective or damaged equipment is replaced immediately, B. Employees the PPE user is responsible for following the requirements of the PPE Program + Wearing PPE as required. • Attending required training sessions. • Cleaning, and maintaining PPE as required. + Triforming the supervisor of the need to repair or replace PPF C, Safety Department The Safety Department is responsible for the development, implementation, and administration of the PPE Program. This involves: • Conducting workplace hazard assessments to determine the presence of hazards which necessitate the use of PPE, • Conducting periodic workplace reassessments as requested by supervisors, ■ Providing training and technical assistance to supervisors on the proper use, ewe, and cleaning of approved PPE. Providing guidance to the supervisor for the selection and purchase of approver] PPE. • Reviewing, updating, and evaluating the overall effectiveness of the PPE Program, A. Emptoyees who wear' PPE shall be trained in the following: • Which PPE is necessary ■ When PPE is necessary • How ro properly adjust and wear their PPE • 'The limitations of the PPE REVISED 10113110 • The proper care, decontamination and maintenance of PPE • The proper disposal of the PPE B. Training will be provided prior to the employee. working in an area requiring the use of PPE. Additional training is needed when: • Changes in the employee's lob duties require different PPE. • Changes in the style or type of PPE used, renders the previous training obsolete. • An event has occurred which indicates the affected employee has not retained the training on the proper use of the PPE. • The employee is observed incorrectly using the assigned PPE. C. A training certificate will be kept for each employee. The certificate will contain the name of the employee trained, date of training and identify the PPE covered in the training. These certificates should be kept in the employee's training file. See Appendix "A". W. Protective Devices A. All PPE will be appropriate for the work to be performed and maintained in a clean condition. Equipment must meet American National Standards Institute (ANSI) standards. Gloves must be selected based on style, size and performance characteristics of the glove in relation to the hazards encountered. {Note: currently there is no ANSI standard for hand protection). 1 ] Eye and Face Protection Employees must use appropriate eye or face protection when exposed to hazards frova flying particles, liquid chemicals, acids or caustics, chemical gases or vapors, or injurious light radiation. Eyewear shall comply with ANSI 287.1 as indicated by labels on the PPE. When there is a hazard from flying objects, side protectors meeting ANSI standards must be used. Examples of jobsltasks at RAF where this protection is needed includes: • electrician & Breaker • chemical operators handling ► grinders • construction • welders • Ia gat cleanup . sloop ► sanitizers • laboratcty workers • groutadskeepers • bird movers ■ house managers packers * This list is not meant to be all-inclusive as otherjobs/tasks muy require PPE @ limes* Those employees wearing prescription glasses need to wear approved safety glasses that incorporate the prescription into the glasses o+t wear goggles over the prescription glasses. Visitors, contractors, or others passing through an identified eye hazard area need to wear appropriate eyewear also. An ample supply of visitor safety glasses should be available for use 2) Emergency Eyewash Stations Emergency eyewash facilities will be provided in ail areas where the eyes of any employee may be exposed to corrosive materials. All such emergency facilities will be located where they are easily accessible in an emergency. 3) Foot Protection REVISED 10/13/10 Employees working in areas where there is a danger of foot injuries due to failing or rolling objects, or objects piercing the sole shall wear protective footwear. It is mandatory for employees working in or near breaking facilities to wear anti -slip foomear. Open shoes such as sandals and "flip-flops" are not considered as substantial footwear by the Safety Department. 4) Head Protection All employees must wear a hard hat when there is a danger froin impact and/or penetration from failing objects, or the possibility of striking protruding objects with their head in any work location. S) Hand Protection Employees must use appropriate hand protection when exposed to hazards from skin absorption of harmful substances, severe cuts or lacerations; abrasions, punctures, chemical burns, or temperature extremes. Glove selection will be based on performance characteristics of the gloves. conditions, duration of use, and hazards present_ One type of glove will not work in all situations, When selecting gloves for use against chemicals, the exact chemicals encountered treed to be determined. Labels and MSDSs can provide this information. Recommended glove types are often listed in the section for PPE on the MSDS. All glove materials are eventually permeated by Chemicals. They can be used safely for a limited time. A manufacturer's glove selection guide is the best reference when selecting gloves. The Safety Department can assist in determining the specific type of glove material that should be worn for particular chemicals. 6) Hearing Protection The controlling of existing noise levels by engineering controls is the most preferable course of action. Therefore, the feasibility of such controls should be carefully considered. Due to the complexity of some machinery, and in view of economic limitations, some noise levels cannot be reduced to below acceptable limits. In these cases, the manufacturers of machinery that produces noise levels exceeding the accepted guidelines should be notified of the high noise levels. The suppliers should be requested to redesign machinery where possible to meet the defined regulations. As interim solutions, consideration should be given to the design and construction of partial or total enclosures, and other engineering noise control procedures for reducing the existing noise levels, where such procedures are deemed technologically and economically feasible. Until engineering controls reduce the amount of noise exposure to or below the accepted limits, RAF will make available appropriate personal hearing protection to noise -exposed employees, RAF will also ensure that the hearing protection is worn effectively. It is recognized that the use of these devices is considered a temporary solution to the problem of over -exposure until feasible controls are provided. As with all safety equipment, the wearing of hearing protection in required areas is mandatory. All supervisors roust enforce hearing protection requirements. Individuals responsible for issuing and fitting hearing protection roust be appropriately trained. Fitting and issuing of hearing protective devices be&s when employees are hired. The criteria for the selection of hearing protection should include.: the level of daily worker exposure, the workers' hearing and communication requirements, use of other personal protective equipment, temperature and climate, and physical constraints of the worker or work activity. Where noise levels cannot be. reduce to or below the exposure limits by engineered noise controls, warning signs will be posted stating that a noise hazard exists and that all workers entering the area must wear hearing protection. All workers required ro enter these areas must be supplied hearing protection and the supervisor must ensure that any worker in these areas wears hearing protection. REVISED l to/l 3 /14 V. Cleaning and Maintenance A. It is the employee's responsibility to ensure their PPE is clean and properly maintained, Cleau nng is particularly important for eye and face protection where dirty or fogged lenses could impair vision. PPE should be inspected, cleaned and maintained at regular intervals. B. it is also important to ensure that eontarninatc;d PPE, which cannot be decontaminated, is disposed of in a warmer that protects employees frorn exposure to hazards. REVISED 10/13/10 Appendix A Personal Protective Equipment Training Certification has received and demonstrated Printed name of employee understanding of the PPE training given by Name of instructor Signature of trainer Date The following personal protective equipment has been assigned for use Cbeck applicable boxes ldengt specific assigned PPE } Eve and face Protection Head Protection { Foot protection i Hand Protection { } Respiratory Protection Hearing Protection Other Protection I have received and understand the PPE training given to me by Name of instructor on Date ^ Employee signatm REVISED 10/13/10 Bloodborne Pathogen Program I. PURPOSE The purpose of this exposure control plan (ECP) is to eliminate or minimize occupational exposure to bioodborn e pathogens in accordance with OSHA standard 29 CFR 1910.1 030. The ECP is a key document to assist in implementing and ensuring compliance with the standard, thereby protecting our employees. This ECP includes: Determination of employee exposure ■ Impletnent.ation of various methods of exposure control. including: • Universal precautions • Engineering and work practice controls + Personal protective equipment + Housekeeping • Hepatitis B vaccination • Post -exposure evaluation and follow-up • Communication of hazards to employees and training • Record keeping • Procedures for evaluating circumstances surrounding an exposure incident J. PROGRAM ADMINISTRATION The Safety Department is responsible for the implementation of the ECP. The Safety Department will maintain, review, and update the ECP to include new or modified tasks and procedures, new safety devices, or when an exposure incident indicates the need for a revision in the plan. Those employees who are determined to have occupational exposure to blood or other potentially infectious materials (OPIM) must comply with the procedures and work practices outlined in this ECP. K EMPLOYEE EXPOSURE DETERMfNATiON Tltere are certain job classifications @ Rose Acres that may be considered "at risk" For occupational exposure to blood of other potentially infectious materials. This exposure detcrmination has been made without regard for the use of personal protective equipment or the fxegoency of the exposure. Employees who have not had bloodborne pat.hugen training are not allowed to clean up or handle blood or body fluids. Employees who voluntarily render first aid are not covered under this exposure control plan; they da so as a "Good Samaritan." L. METHODS OF LMPLEMENTATION AND CONTROL Engineering controls and work practice controls will be used to prevent or minimize exposure w bloodborne pathogens. Engineering controls • New procedures and new products will be evaluated on a regular basis. Both front line workers and management officials will be involved in choosing safer products and procedures. Work practice controls • Universal Precautions (Appendix A) - all employees will treat blood and body fluids containing blood as if they are infected and use universal precautions, • Personal Protective Equipment (PPE) is required - it is not optional. Selection and availability of PPE will be discussed in the employee's initial training session. All employees using PPE raust observe the following precautions: ■ Wash hands immediately or as soon as feasible after removing gloves/PPE, • Remove PPE after it becomes contaminated, and before leaving the work area. ■ Contaminated PPE may be disposed of in a properly marked biohazard container. REVISED 10/13/10 • Wear appropriate gloves when it can be reasonably anticipated that there may be hand contact with blood or OPIM. and when handling or touching contaminated items or surfaces; replace gloves if torn. punctured, contaminated, or if their ability to function as a barrier is compromised. • Utility gloves may be decontaminated for reuse if their integrity is not compromised; discard utility gloves if they show signs of cracking, peeling, tearing, puncturing, or deterioration, ■ Never wash or decontaminate disposable gloves for reuse. • Wear appropriate face and eye protection when splashes, sprays. spatters; or droplets of blood or OPIM pose a ha7.ard to the eyes, nose, or MOA. • remove immediately or as soon as feasible any garment contaminated by blood or OPINi, in such a way as to avoid contact with the outer surface, All procedures will be conducted in a manner that will minimize splashing, spraying, splattering, and generation of droplets of blood or other potentially infectious materials. • No eating, drinking, smoking, or application of cosmetics is allowed in work areas where there is potential for contamination with infectious materials. Housekeeping ■ Arcas that are contaminated with blood or other potentially infectious materials will be cleaned with a fresh solution of sodium hypochlorite (household bleach) or an EPA registered germicide. The Centers for Disease Control (CDC) recommends a solution of 5.25 percent bleach diluted with water - 1 part bleach to 10 parts water up to 1 part bleach to 100 parts water (from '/, cup to 1 '/2 cups bleach per gallon of water). This is an effective solution for disinfecting environmental surfaces and for decontamination of sites following initial cleanup (wiping up) of spills of blood or other potentially infectious materials. It can also be used to decontaminate reusable gloves and cleaning equipment, All contaminated work surfaces and equipment will be decontaminated as soon as feasible. • Any sharp object contaminated with blood such as broken glassware or sharp metal should not be picked up by hand. Employees must use tongs, a brush and dustpan, cardboard, or other available material to remove the contaminated glassware. ■ All regulated waste must be clearly marked with the universal biohazard label. Bio-hazw-dous materials for disposal should Fe placed in ieak-proof red bags that bear the biohazard label and are securely sealed ■ Regulated biohazard waste disposal will be performed in accordance with all Federal, State, and local regulations. M. EXPOSURE INCIDENTS An exposure incident is defined by OSHA as "a specific eye, mouth, other mucous membrane, non -intact skin, or parenteral contact with blood or other potentially infectious materials that results from the performance of an employee's duties." Should an exposure incident occur, Hash the affected area with non-abrasive soap and warm P cuter brrmedialely. Following the initial first aid (clean the wound, flush eyes or other mucous membrane, etc_) contact your supervisor immediately? VL PROCEDURES FOR EVALUATING THE CIRCUMSTANCES SURROUNDING AN EXPOSURE INCIDENT The Safety Department and the employee's supervisor will review the circumstances of all exposure incidents to determine; + engineering controls in use at the time • work practices followed • protective equipment or clothing that was used at the tune of the exposure incident • location of the incident • procedure being performed when the incident occurred • employee's training The Safety Department will record all injuries from contaminated sharps in the Sharps Injury i .og, recording the incident but maintaining the employee's confidentiality. Nqi. EMPLOYEE TRAINING All employees who are considered to be at risk for occupational exposure to bloodborne pathogens receive training conducted by a qualified trainer. Training will be given prior to initial assignment to tasks where exposure may occur and a refresher course will be given annually. The training wits cover the ep idemi o iogy, symptoms, and transmission of btoodborne diseases, In addition, the training program covers, at a minimum, the following elements: REVISED 10/13/10 • a copy and explanation of the standard • an explanations of our Exposurc. Control Program and how to obtain a copy an explanation of methods to recognize tasks and other actiAties that may involve exposure to blood and other potentially infectious material, including what constitutes an exposure incident. • an explanation of the use and limitations of engineering controls, work practices, and PPE as explanation of the types, uses, location, removal, handling, decontamination, and disposal of PPE • an explanation of the basis for PPE selection • information on the hepatitis 8 vaccine, including information on its efficacy, safety, method of administration, the benefits of being vaccinated, and that the vaccine will be offered free of charge + information on the appropriate actions to take and persons to vontact in an emergency involving blood or OPIM ■ an explanation of the procedure to follow if an exposure incident occurs, including the method of reporting the incident and the medical follow-up that will be made available • information on the post -exposure evaluation and follow-up that the employer is required to provide for the employee following an exposure incident REVISED 10/13/10 SAFETY COMMITTEES 0t `active To assist management in generating employee involvement and recommendations in establishing, cornmunicating and maintaining a safe, healthy and efficient workplace environment, as well as assist in meeting or exceeding government rules and regulations. Membership Members will be chosen in view of the duties and responsibilities of the comtnitteE.Comniittee members shalt be selected according to their position, knowledge, abilities, and interest in promoting safety. Each department should be represented and are to include management representation (gader, houses; cooler, breaker plant, etc.). The complex manager ar assigned representative is responsible for coordinating all committee activities and for facilitating committee meetings. Scope A welt -run Safety Committee is an iniporrrnt part of the loss control program. It can help reduce the cost of operation and produce many other effects, such as: • Reducing the occurrence, frequency andJor severity of accidents • Increase productivity (quality and quantity) ■ Improve the use of equipment + Reduce material waste Enhance employee satisfaction Facilitate employee cooperation and contributions a Provide analysis and evaluation of inju y and incident data and program per#brmance to management • Develop and reeommend adoption of appropriate safety programs to supplement a general program (a specific housekeeping program, protective clothing program, confined space; etc.) t' -is The Safety Committee shall be responsible for recommending goals concerning hazard control and accident prevention. Once the goals are set and specific objectives formulated, they are to be forwarded to the Safety Director and complex manager. (Goals are to he site specific) Activities and Duties The Safety Committee shall meet no less than a minimum of 1 time per month. The frequency shall be deteimiined by the Safety Director or f y assigned representative at each location to accomplish its goals and objectives. The Safety Committee shall also discuss accidents, near misses, new training requirements, and employee suggestions. Other actions include: • Review of accident investigation reports • Review actions taken to prevent accident recurrences • Establish a system for handling employee safety suggestions ■ Review results ofsafety inspectionlaudit made by Safety Department ■ Review OS14A 300 Log • Provide input toward enhancing safety rules and procedures when applicable Activity and Duties (coat,) • Review and help implement specific accident prevention activities • Review loss control issues and problems REVISED 10/131110 Effective Committee Meetings Good safety meetings require thorough planning and effort. Notices of meetings should be sent to each member of the committee. The meeting place should be comfortable, well lighted, with no distractions. ■ C 1 to Order- The meetings should be called to order promptly at the appointed time. • Roll Call bti the Facilitator- Names of members and others present should be recorded. Absences should be noted. • Minutes- Of the previous meeting should be briefly reviewed. ■ Unfinished Business- A status review of issues or assignments mods during the last meeting should take place. • Review of Accidents- Serious accidents or incidents since the last meeting should the reviewed with an aim towards preventing recurrences_ Plant loss statistics may be reviewed and discussed. Also, employees with restrictions should be discussed. ■ Other Activities- Inspections, ergonomic studies, training programs, safety suggestions, and ether activities from the past month should he reviewed, e.g., reports received from insurance company service representatives or Safety Director. ■ New Business- Any new issues, programs, problems, etc., should be brought up. Appropriate action items should be givers • GeneraI Discussion -tiny relevant comments or suggestions for the good of the company should be discussed. ■ Ad ournmeni- Set time, date, and location of the next meeting, Adjourn on time. Minutes should be taken, prepared, and u.iz-culated by the facilitator. The minutes should acciTately record all decisions made and actions taken since they serve as a means of [seeping management informed of the group's work and as a follow-up. The Safety Department should receive a copy of the minutes. Copies should be maintained for I year. REVISED 10/13/)0 RAF Safety Compliance Checklist Pgte: Yes N 1. Administrative A OSHA poster placed by time clock or within break room w B. 6-year history of OSHA 300 & 300A I s C. Up-to-date RAF Safety Manual r D. All authorized & unauthorized training has been completed E. Safety committee meeting notes & minutes — i F. Emergency contact list posted in conspicuous area 11. Hazard Communication Standard 1910.1200 A. Chemical provider has conducted chemical -specific training B. Material safety data sheets for all chemicals placed within MSDS binder C. Chemical containers are labeled D. PPE assessments performed for all areas _ E. PPE readily available F_ PPE requirements are being enforced G. Emergency eye wash stations located in areas with causticlacid material M. Lockout 1 Tagout Standard 1910.41 A. LOTO procedures written and available for all rnachiriery/equipment P -1nual training conducted for authorized employees uTO accessories provided for all authorized employees 0. LOTo requirements are being enforced IV. Respiratory Protection 1910.134 A. Testing conducted to verify ammonia levels in houses B. Are employees using half or full -face respirators? If so: D_ Medical evaluations conducted and results on hand E. Fit testing conducted for affected employees F. Cleaning & storage procedures in place r G. Signed Appendix D Forms. V. Bloodborne Pathogens (29 CFR 1910.1030) A. BBP clean —ur, kit available B. H EP B declination forms C. First aid and CPR train ing up-to-date ❑. First aid kits available V 1, Powered Industrial Trucks (29 CFR 1910.95) A. Initial training conducted for em to ees operafing powered industrial trucks B. Daily forklift/pallet jack inspections documented and on file C. An out -of -service to in /notification system is in place D. Refresher training conducted every 3 years and documented E. Operators wearing seatbelts F. Homs are being used G. Forklifts have functional back up warning a ui ment '%' Confined Spaces (29 CFR 1910.146) 1- unfined spaces labeled and identified properly B. Atmospheric testing data documented prior to and during entry C. Ventilation and/or rescue methods for confined s ace entries utilized REVISED 10/13/10 D. Harness and lanyard readily available E. Attendant in place during entry F. Contractor notification program of our confined space entry program, G. 4 gas monitor calibrated and in proper working condition H--4nceled permits retained for 1 year. %..a. Personal Protection Equipment (29 CFR 1910.132) A. Anti -slip shoe p9riq enforced B. Hearing protection requirements enforced C. Chemical resistant PPE available and used correctf D. OSHA approved compressed air nozzles being used IX. Egress and Evacuation (29 CFR 1910.33) A. Written emergency action plan updated B. Effective emergency notifications stem in place C. Employees trained on emergency evacuation procedures D. Exits identified with visible signs and lighting E. Month!testing of emerpncy lightln2 conducted and documented F. Exits free of obstructions G. Emergency evacuation ma s posted for all areas H. Written ammonia emergency response Rrocedures atapelicable farms 1. Windsock located in hi hl visible area J. Annual meeting with fire department conducted X. Hearing Conservation Program (29 CFR 1910.95) A. Noise recordings have been conducted and posted in conspicuous area B. Areas exposed to greater than 85 dB for an 8hr TWA but less than gQ dB: hearing conservation program developed C. Earplugs available D. Far lu s being wom in areas above 85 dB f Ming conducted for employees within Hearin2 Conservation program F...,u16 le es of hearin2 protection made available G. Audiometric testng conducted for all employees in the Hearing Conservation Program X1. ,Electrical Safety (29 CFR 1910.301) A. All disconnects and circuit breakers identified and labeled B. All exposed live electrical equipment covered/guarded C. All electrical circuits greater than GOD volts are marked as "High Volta e.° D. All wiring Is permanent. Tem ora vArIng is not acceptable X11. Fire Protection (29 CFR 1019.155) A. Portable fire extinguishers are adequately placed throughout fadlit S. All fire extinguishers are mounted and identified properly. C. Authorized employees trained annually D. Monthly inspections of the fire extinguishers conducted and documented E. Extinguishers are in working order and free of obstruction, rus and/or dust/debris XI11. Walking and Working Surfaces and Fall Protection (29 CFR 1910.2.1 and 1926.50) A. Walking working surfaces greater than A fit. above ground level have fall protection provided -and B. Stair railings have the required railing C. Platform surfaces above the working floor level have a toe rail D. Employees working on surfaces and/or ladder systems_ greater than 6 ft. in height are usin fail protection systems T E. Employees workingabove 6 ft. in height are trained on fall protection requirements. r iployees working in mobile aerial lifts are provided with full body fall _-otection systems G. Adequate lighting provided in all areas XIV. Hazardous Materials (29 CFR 1910.101) REVISED 10/13/10 A. Compressed cylinders secured by chain and capped B. Flammable and combustible liquids are stored proeerly XV. Machine Guarding (29 CFR'19"10.211) A. Guarding in place for all moving equipment 'Inding wheels properly guarded _C i nch grinders and drill presses secured to the floor XVlll. Hot Work A. Completed/canceled Hot Work Permits on file 8_ Appropriate ventilation provided C. Designated hot work area is adequate UVISED 10/13/10 THE GOOD EGG PEOPLE® r First Report of Accident/Illness Procedure I . Employee must report injurylillness to Supervisor by the end of the work shift in which incident occurred_ 2. Supervisor, along with the employee, are to fill out a "First Report of Injury" form. In the event of the Supervisor not being available, the Complex Manager or Safety Department must be contacted to complete the accident form with the injured employee. 3. The Supervisor must then complete the "Accident Investigation" form immediately. 4. If another employee witnesses the accident, the witness must complete the "Witnesses Accident investigation" form 5. Once al! forms are completed, reviewed, and then signed by the Complex Manager all accident reports must be scanned and emailed to the Safety Department, which includes: • Derick Stuckwisch — dst_uckwischin j000detwa.com • Travis Otte—.totte@p-oodep-p-.com • Matt Rotert--mrotertregook.&g.com 6. If medical attention is needed, the HR Manager or Safety Deparnnent will make an appointed with a Physician. 7. Upon return from doctor visit, employee's must provide their Supervisor and Complex Manager with the "Attending Physicians Report," listing all findings and restrictions. 8. This status report will he faxed to the Safety Department immediately. 9. Supervisor should do A I possible to accommodate any restriction(s). if unable to do so, the Safety Department must be contacted. REVISER 10/13/10 i RDLP _Buildinc�Dacumen#s ECKAAL kOtEE Uxµo Wwa�r ::F,-sopm KTN RSfE iPaer4.lenwn NTie�Miylyq I-Em�o a aeuyrr. pr.fp KFt MEX r iw vb. arks TIN YT • v a a<,Ere vqr dw nrv.rwrn -OW-" fl , i .rr."KM m-+rnwwm.w.. xX,pnow rrr,FF•]0n41 Tw C.Q.ae.]nwa E,da�wlw,wnr 1e ou.rt TPt.i]Ir ie,7 rlw EYmt+ ntl prr.e�Yw x9 V Rwna IY • �E W � ... rew h.e.•Nr..ra E•'.w rNY,.we.. 7 7 om A-. M, lG/+., ry • YO W4 ii1t w Hdr.arr..ro rw'r'pf•lah. ep•%AD Eyi EV ON [Wrlw e &4 wm L--j 'y.EL'M ova, l ON1FE I"-4 Ei.f Erc Yhl C,ml N.•r•,e ltuY. 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Rue Acxes Forms IWLPx'672, Manure Sto?ege aI HaWIRR VM ftiWlGs JDV. A MW 1OPWAXAM BIIAs arnV !,'e Kkrli PNOEtlf is Ie cNnry prsrN'we. eta etd" Fw"Pan old pbnvd� 7-1ra 1.1 anNar `� 2579M1.t.� •E. t � •E •� 81Bi.1 {x6y A1`.. l238,.5 TfB7. S Srr31 BRl7.tDIM A5 ' r�Kvs°lptl° W- �/ Canv4e tns,a6aGon Notes A. 1 W012 SUg55ea- Carwas 04-110wrr p0da.4 is 'mm"denmV. a, Vftn PuIIIrm can"S. "mr- S"Dwd xe ffisvery 26, of the In 0 of e,e tuft astem7ly in the conv!!s lhra'a 0vtr �r1dk,¢ and u6e to Pun camr4s over 7uldtn({. C, C.a,vaz vhourd be rabid outt4e length of the twildmg. Mate Ivils,g out the wrrraa erY *. ens+xe V:81 She canvot VMi bB Nang down WhOr, , puling mr the brildlt,g. ,'Ms la dope 4 lGoeng the CMIV65 Togo. D. Dr) no,install vw-var during a day+n which gosi are above 10 MOO E. Pimlyrnn 1ne con—$ Into the m„q"hNp pyll�InC=.T•IV64. F_ Cam s 1s wtnmb,e to OW unel ea mnne liaw hevd heron 41'Wad. G. [�a nut WSW camas If Pea hd'+torm Rd on a,e I top of lha 1Nisms. V,- Canvas anould he 1n7tged by nand Ratafl pwaible, I. At wnner." A55ra1.0 and AI&81.6 .tmdnrd ON-" 11,00W bill, do" To 40401Labs. . 1.1401.1 nr,drar k_+ 8,Ig1.5 MIA 4% A591a5.4 ---~ ,•_ A5rg1,4-�_ - AMA — —dB7t j.fd61.1 and W.t per �4lf3t h L1 �1,7 dnd 4W., ,mm per erd A 1 Tom` A13�B,.4 �1Bi.1 • 3 f 77!®7.7 2301.1 19en-Buildem, I_LC. Rose Acres Farms __ •� I OOLP x 672• Manure Sk"ge I Pan v. Nth C 14,91 1 II- I lILR,1 I IMI 1 4� , R7„t - 2INS 1 emt-, (Al 211BI 11 Al2" L) r t�T'ITTTT�7F� T+T'•' i ♦ t4f ift�♦fY.;. ��F,3 w 2M%, ftd Aft. Si QL 2w r_. %0 1 "N a G-B iffoo-Builders, LLC. Tw Qe Aves Forms I OOLP x 672. Manure Starage _eg2, NC JAW.W. D. M U.1 End Wall Cam panents M LL R4 7 _1 se_a _ I saw I �a — i-- la I ,a•a�. L �r� Rosa Acres Fauns -a 1 OOLP x 672. 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M„ irl A [OYi � ; .:�. � r ra• 3j•'�-3 TbA•eCfiG � ; R � " , f: A T ATE/OPTIONAL SECTION ° �: HAHP� sr: -.•x gip. 64, ISSUED FOR nrnN1CTll11/•rlR►I a.11l RST ENGINEERING PLLC 5416 ORCHARD ORIOLE TRAIL WAKE FOREST NC 27587-6770 .duly 15, 2011 Mr. Michael Scott, Supervisor Composting and Land Application Branch NC Division of Solid Waste 1 646 Mail Service Center Raleigh, NC 27699-1646 Subject: As Built Drawings Permit SWC-48-01 Rose Acre Farms, Hyde County Dear Mr. Scott: By letter dated November 2, 2010 1 transmitted an application for the renewal and modification of the subject permit by Rose Acre Farms. At that time a revised application and operating plan were submitted along with drawings, sealed by a North Carolina Registered Professional Engineer, to show the details of the construction of the new composting and storage buildings that were being erected on existing concrete foundations at the site. The detailed site drawings, geotechnical reports, and aerial photos that were provided with the original application and were not re -submitted, but were included by reference. The construction of the new covers for conversion of the existing building foundations to compost service has now been completed. The buildings as finally constructed differ in some of the structural details from the drawings originally submitted with the application. These changes were made to simplify and reduce the cost of the construction. The structural revisions were designed by a North Carolina Registered Professional Engineer, and a complete set of sealed engineering drawings for the revised structure is attached for your files. The capacity and use of the building modifications did not change with the structural detail changes, and the operation plan submitted with the application has not charged with the structural detail changes. I visited the facility on April 26, 2011 to inspect and photograph the new Composting buildings. While structural analysis is outside my area of practice, i observed that the buildings and covers followed the plans provided. Based on my inspection and review of the previously submitted application documents, I can certify that the modifications to the facilities, as constructed, meet the functions and intent spelled out the permit application, and relying upon the information provided by another registered professional engineer, will function as intended. f am providing my photographs of the site for your records_ Thank you for your assistance in this process. If you have any questions, need any additional information, or would like to have additional copies, please give me a call. 0*21V.&. Sincerely, ;r;p��� CA R401�9',, SEAL 4 7747 i i Ray S. Stan) Taylor, PEryG� E�fr':il'�~ a. RST Engineering, PLLC yatp��N.. ��,•� Attachment_ Site Photographs CC: John Brinn, Rose Acre Farms Chips Everhart, Rose Acre Farms Joe Miller, Rose Acre Farms fill �1 4 1 41d ww- I h4� iu: � im � �1► Am { i 41""ortalityliCom- posting - -�q� � fa WANO IL W� �r�i AL - cr, rr 1 4 =;Ftw r n i +" 1 PW ISS pUpport detail 0 3� V lWX, N1 rl 01 Ln I-GENEltAL SITE .0-11010K 11!AI 1R 143091E i93$S3ih (HJti'9�1y': S2bj 4°.CS PGNT-CC coso er >�scuem+ wn I pnicVm T '1 ROSE aCk`E FARIAT ill UdA`� TE � i ty?AreL; 9lJII..D!?�C '-56„ `(sCC PlR15 CANAL ROP13 m*ANIrW. IS^RM- LROUNA 27fE,7k vuE rout rr mG,.LECr NuvEick; �TidC•S! MUNDF f:024 DRA`HIN^S FCR { i oo'r4ab` `'THAN- TEEM ,LP 'UU4 C:NG 1JI nECEk+arR 6. 2:}10 _7RE 4fiED FOR- HA► 4nYL �-YU PR60VC75, 41C. al(]t Ir3N TVA. IOWA :5 ED rM GONSTRUCTION N:9&Q U L%—N S 1:01%cR- jfiM-1 :-t F4LL POLNDATTV FLAN 5-2 r00P:7APOH PLAN Fl:r'.K SINE 1 70 21 -3 Fr'JNDAMN RLAi'I FRAME LINE 2. 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HOUGHTON, IGVA ISSUED FOR COfNSTRUC-PON IN{)F.x OF DRAMN.G5 [_._ j ' MCOV'ER slur 0 S--I PULL i:OUNDATION PLAN - POUNDATION PLAN FRAME LJN[ 1 TO 29 S-3 FOUNDATION PLAN FRAME UNE 29 TO 57 5-4 ENDWALL ELEVATION I=RAME LINE I & 57 S-S CONCRETE MALL RETAILS &S-6 ANCHOA 801-r & 9A5r_ PLATF LA �eJ7 5-7 SPECIFICATIONS StRVOSKY DMIMU NG PLLC ?a" -' �d Hvyend, 'iJ CvnwYeq 5n.s� CvC+eran�as5] 7 :x4� h"'�7f6VE71 4rA.^,n+h�en4e?e! Pyr 15t L {:.Span-Tecf�F... Z ;-, �3-c5-fn r ass M■me rr sxn "Moo s_ Lwl Po vzx 2m mm KEY 12 C3IAli�1 BEFORE YOU 171E CALL THE NORTH CA9"A ONE -CALL CENTER 1i"2-44949 �•'e:t ��I 6•' � I r rr ��2 r'6 y�.%e '•�� COVERS-H-E-ETT - ROSE ACRE. FARMS - �I PANTEGG, NC-�J DN SCALE °"°, 5wT.?oml ��' Caves SHEET PM 12'-2' {TYPICAL 0 RJD BAYS] 12' (TYPICAL) � Z� 4 5 8' i' 8 9)(1Q ti 1 0. 1� G ] 1 IJ�;21 d 9, 3 -ti 4 � 9,d �(4Z.+ 44",�I. rr w CONCRETE SIDEWALL (TYPICAL) ANCHOR de PLATE 6 24'08' ODOR CENTERED SEE DETAIL 1 k. 2 0H S-5 LAY❑}JT SEEEE DETAIL I ON $ 6 IN ENDWALL (TYP—BOTH FNDHALLS) CONCRETE 'FLOOR THICg x J' TALL EXISTING' CONCR'_TF SIOEWALL (TYPICAO /�-�.� DOLLARD$ OPTIONAL BY tlW+VER—''I r (TYP-4 PLACES) SEE DETAIL 2 OFf S--E 6 al /1 672`-31 C'—G OF AIEYI CONCRETE WALLS a:t I SK 11 FU L FOUNDAT113N PLAN � staur p . n,• � �P •��.5Rr �f � ! i1J�I'�.S f a ynvY i -—pLt+5,6+•+ — SEPYINSKY UIONMING PiLG FULL FOUNDATION PLAN _ ndbnq W �a+i�651a i!' C,nglFp !INeNW >�v3••••'• Ktla6181�7d11-pM, —` � llLSC�PTJpry 4A'[ pan-TechFe.,m: [t7 iSSIIEk.tlR ror.s>r+verwer a-,r-�o ROSE ACRE FARMS ANTS❑ NC I:s.�,. - Mr1o!>cr3 iNL. Fa RIMouWTrH, L1 5rs]ILt[ SCA[E 1" Sa` H0 $PT 1Q.Oi3 I $5 1 `� ?M--2' WT � BASE PLP.1F T#} FRAM Lik£ �g �^ 12`-24 (AL D VIC! BAYS If 7iGAL) •3 L� T2,1,t3 142 -.--- ' -ANCHCR SOLT !k UA�E PLATE f EW C{]NMETc- 5faEWALL rtHCAL') LAYOUT. SEE uVAli i ON S-C 5EE OETAIL I & 2 ON S-5 -8C L RU5 OP71ONAL BY t1MER (TVP-2• 'PLACES) SEE CETAiL 2 CN 5-5 3 44 ! � >< I i ° ��—x4'x18' OODFE CC! TE EO IN ENDWALL ❑ I � I N• � 1 SAWCUT le REMOVE 2'-21' OF WEST END ❑? SIDEWALL (7 MAL 6OT13 SIOLWALLS7 EXISTING CONCRETE FLOOR r� tii �zi r,q- TRCK x 3' Ml EXWING f CONCRETE SIOEI ALL (TYPICAL) I 336'—i C CLlT OF NEY! KIRETE WALL, TO FRAME LINE 28 �2'-21EVS-011, CONCRETTE hALL TO aE RCIs Or.0 338"_; " DJT' Or EXI"NG CONCREIL WALL TO FRAFAC LINE 29 �sf� � F0LINDATION PLAIN C P,AME LINE iTO ?2 SCN,E S• 30' — - -- fir4s9pw5l 4ER4Kt+SKY ENGINE£NFNG pLI.0 01�,�"14-05M F OUNGATfON PLAN FRAME LINE I TO 9 Y• N+w4✓cp Svueprd Frg+,err [6}61 7.76-f�1 W RN OE3cuarirpr+ I OA7C ,sYf+dpvEp me•r,eaiwnw�.q,ram ►a A16 1JE.89ef �• ,� FOPMWSMu Wu ri-„=1a ,�. p R05E ACRE FARMS � P_ — an�Techl=�n��� �,:, ANTEGO. NC „sir sxe. rs mrx`�b a__My_ r,au+u use g SCREE T" a 3Q' °""rb 5PT.IO.[1T 1 ELT 5-2. I r.9r a4G7fw k` S k NG r�d1 YZ 'RCS & ANCHOR EYJS RtOAR NOT SHG*N !N ELEVATION 1 L0r,YhONS ONLY 1 i -10"xa. SPAN -TECH SFDEWALL BAS PLATE 4)�� TIES 0 ANCHOR LOCATIONS ONLY FIELD, SEND 16 PROJECTED BAR TO S"-\ HOCK AS SHOWN 2E` { #3 VEPrCAL BAR a I ox 4 f 1`-lo' E 1—�yk j TREATED2x4 OR 24 APRON BOARD__ 5 EFnR :a• I.G. wf 1 1 . HOOk 'n 3V OZ S -s 8AR. 19" LG. HOCK 9 36" � n {3} ,ys i70'A'r:LS r4" Li,. W/ 12'-�� 1S" � �!S HDPf�CPlTAL { HOOK 0 318' O.0 DRILL A EPDXY EiARS +2" O_C. CROUT WITH s' EMBEDMENT ' •-45 VERTICAL 1 t Bk4 -413" Q.0 EXISTING �I �KI5Tlilo TRICK it35" HIGH • FLOEOfl CONCRETE WA_ll - I j E1fI T lCT�-�xisnNG F00TN O- 13AR V 39" �7.C. - -- ! r �3 0hR 13" LG. 0 39' ox DRILL a OKLT EXISTINO VERTICAL _ GROUT W11 4' EMS !- E REBaR IN E7gSTING WALL - , ---$ , I - { f r v:. z t3} p5 HORIZL�JTAL j11' 1 SAWS CGNTiNUM � SHOWN IN SECTTLW +y , i �' ~f - � ' I i'�.•- TOP & BOTTOM ,�1- ,7 HORirPC}N7AL� USE HILTI kY 150 MAX SO BARS 18" I G. 0 1 241 ..--- t61. GRAVEL 8ASC •y EPDXY OR .APPROVIED EOUAI. 24" O.C.-- FOR EMBEDOM DOWELS r&-5C13NCRE TE 5IIDE'df+t.t-. SECTION r nC.ts s I L y SERVl4%y ENCtNEERIHC WiC Spa n-Tech r,,:,M,: - I — —1�� I' i - d i ---� - ----- N� 4G. WI 12 { (TYP; HOOK 0 36" O.C. DRILL b + EPDXY GROUT I „ WITH t" ! EMBEDMENT NS 13AR ,x,-= Lc, a 36' O.G. DRILL x J EPDXY GROUT ! { r IV HmTZ,. �s�12" -- . r^'Z a �y ---- — -. BARS -, : liQRf�QV�AL -; TOP r..5" GRAVEL'BASE RAPS 1 B' LC. S 5 CQNCRrTF- VULWALL EXTERIOR ELEVATTLlfv �� srau.t art^ _'I• CONCRETE WALL DETAILS ^� ROSE ACRE FARMS PANTEEGO, NC- 0 ' SCALE: 3/4' = I• ;� SPT.111 w g-g - I s" a" a" SPEt•IF1C7Y!•:15ti S-' 1 �" ' i -� �„kx FOR ANL•}IOPi aVAr; , itl T+ f- F j 6C TS REF.. 5 SPar.-TECH i ��^+� = } - � •—_� "_I _l._.! ___�_I j � � �i 1 - ��L'`NTFp BA�� j. � 'i E�j ASSE:'�LY �IQ1wI1^ $.tei -r�1- , .., iJ .t'!^ `�Jam{ .-. �y'�4»"I _. -w.••. � 1 •L A5SFMBLY 412, OFFSET BASE- � 1: - ]I FFS[ BASEfpNN- 6A5E PL. _:J CONN. BASE DL. ASSEMBLY. Y i �•.,---- t?• 'nod .•� if RASE aL ATE ASSyA�yLv YYP,9JV5 to '9?:FRi :lff+1:P:":Jf s•CY• ` 1T_ L, t GOYE lt$: �g"q nrpE 51 H. 40i CONCRETE SAFETY Z'FLLC:Yj I . 5i4T' _GRRWE . PLATE ' - vrr�CEw TO P:PE NC TE. EWLLARD OPlICNAL a,*O*N. ER zA" ..` ` � � SC4LF: !i_•• = 1- -0' +`lam BUTS RUr SCCTIDAI 0 INDTALL-S'RECIFICA7iONS t&'ASE OL ON 5-7 T `�.� r, r � F }• • REFEPENCE SPAN -TECH PRAWNGS FOR OAK PLAT�_ s.e ! . a AR-S, SI=FS. dE CYO ?IStGNS lk j S-6 li l_HD = UwrL i _ BASE PLATE riYi wllE P. SE�'F�st� Cr*'WEMMR bux zao n,,,yo ti,. t"'e"' rain. r' 54+-•;.�[ - r ,._, p /� I 7- Q BASE f'1! V i.f r t.� �1 i_7 LJ'L 1 i�� I_11"I q r , �; •1 r A. y� r a rcls7 -V 1.9 9 rn {6f Eta:;fig l r" `� 1 - i Span-TeG� ROSE .CRC : AW. S . T.-T; : NC ..r-. ,.. 1' ��: [ 8 S�kk i AS NOTEDa.:r�T.T 7.G11 -� �I 1^I ELI M j SITE LOCAMIX BULDDta SIM AND IDOMPAHcr Y... Yra C Rama, 9.vr A- fm PryrfadL 4aial{dif: t_'W Hyde P.hA Cans Rudd. ao'tepc, Ratth Cora tic 278ad Buldpg Srre WWi 67Y. U700 so— Ices Vre 6raefp if-rs)rimilNin jGnstNotkn yips 4F kdn Mwau7e End Un: Eyy K4Rn-•Laygr 9Awoel �1I11GilM1L 11E51ON Ltlt95 n kpTlh CaaWra &e4•Yng CAde:iBC 20M Fiver Saackfre mrd FoWc Cave ir'9 D Pw 9d�t-Tnc:: Buifdingi g fkld11 Er -ed 16n6 5geed 120 �+rph, E•araJre C Rdof Swr Lbod 20 PA! yyv hn.ortanrr Fxthe to +r 0.50 Wnd ImW.n:e Fedor h n 0.11 Toerraar Factor C[ Dead lead - 7, pef sm"'c am B, Slra Lnot7 It Short PD W ipectrol RasaoAee .5ia412g [IZZ9) Dnr Srgond spec[*o1 Rerpanee Seo-tLDEp (632) Fenrne Luadrin-per reveirane grvrFaoJ hrrerr, A, GCriCRAL REMIlEluETt15 1. AA M w shoo no dG pq t%S A etwdardm orld t rse�vloii¢rri. +{ 2- dbwIpn prlar apGru.A hum 04Aa hen ak'"14uLng f makwich, r em.pme.t.. i Worlt shall ranTem, to all gwrn,nq codes. A, EyiaNlefs keatlo.r e1 r dergrarind yIlihtim (pra•odrd by oShera) prfar to Work S. Rorer to wr vv In? aLron Ix Mir vork tpraN(led by 6thmr) . 6• Wanda final ryadin g, Iwen2. leov%4 aOMPMUDI and aara-nq a1 nacdmacry wnhTA nfreNad area a{. 11uRdlr.9 & "RIM tW1plr at DA MIA6E 1, Plnce 5' m. yliveL rkuahrd Stone or C nwl I' amdo[Iga, {AAStf7d H-, i) 2 ikmaoct orb-bdm end grarm per AS74 D-SSST 3, Mvdda rindt ..ado, tw a"- esuy teem f 4LI"., 4 0-w a 9r­Vbre fa•.1 mile W."a. L`. CONCRM _ T. 28 dcy 1hitins P catramulre sualgts+: Gdatrete Ipr frafls At Fa01-5g ',IVDD Per. 2. Cancrate mkt "1 O1 a .rrlAr-ormepl ratio of OAS rnaxheanm. - RLN5Ws j a RW WE Pee 9 j� Issm TVA Q{Nsftc#ON :1.-1T-10 I IYY! { R Y GE?FRAf_ NLH'SIXIS q w-10 3. R.e +LxNaq Skro- Cr lde 5Q ham It. Lirndd�r, euvr for mv;A(* nq p, v ahi! Ab ga fag­Canarafk Wst duns! vmm 3 L1ehPe mifftwm FH .user error- 2 -ulna $. '{)oe C r c a11 aK n'my b'r .rsed ^1 U6 116 mh' U94MIum Xy clan eoatant >fidf he 20 parcent by Wei^hk of tlrmml' 5, Submft Milk celfg, SD £ngn.er W opara 7 Footimge x Stahs stink tre pi" w a Isvdylrematrd camiwdW srb-!foss, h'as of oryvda mefeclgt and IrnaL 6- At- r Irzn#g damtslurC ASW C-M- 3. $apI!1041trGIk" ►ETim CA94 t7Pe p V. V. IO. Wak.• Rezu«n/patufnera c-►ga, ton AA - It. Pred ictloo surd elacsmmS Per A13 W 12. Caw Weather Canceling: Heal. trrei, hd nMkcl ter ma r Whr cmM 01M, Malhada Sn pre-L Arerinq ]hblt be us-d ox rJ 4MR. 13, Wak %hdt 86 frr "and pwi-A G tmucu% YAMcwt cNd 33tn1a. Pfa�o. a 4,rd Fvnr and 6' PVC .nt"kac t1 a cod Pf1ht fa wad. i,a. H nza.t.f ha fn. qh laanf 11,. femme. dnd VOW, for [Iee. 9aTf ecp.eed aarkic" I nWn, D. A17LTSOR 904i5 1. caai-Ai, a +0G+c+e- r+ n5bs ur Aza IV Lang ede[I6hedrasn4 TZ' prajeatlan, +dfh ballam j' pfeY.. woeh er me, nul. 2. Endr+aA past Fo 6* 0,100red to e.fut:aq aancele ,Iat, (2) rs HNU s« @all 3, -IY me,. ea b, 3. Pre.lde deeha at ["01 , lharO M yraeinge. 4[nv anchor kw" IV or ruliMAW hr aporowl by Enn,Ipeer_ E._epLOjDAT10N REACT NS AT TDF W fMALt^ INR1L ShkVE5 PER SpAH -TEC/I 9WLC4lC L'� (Rorer to r.�Oil awl tl�rrn W-Iw um6d) Tha Adlo:r cj bads .ere p•drWrd 4 IMP Sprtl -Tarn OtAding Cdr*b!:&. ♦4amaimer_1 to 14.6 klpe cmt Wcamal ay tdpe In Ha>♦rwte 19.6 lekra a kD I4.Dann ica3g�PA " ]. 5FF.1NFF51C'! EF1C,rHEERN'1G Pl1C 7su Pagfee Arn __._, Hra,.d, fN reua-sg19 �SlJr cwr+nr Yy starewar Fi'pn..rxfetaY 7aa-reel FPRArx'LO 11 !l mvrHo-r.•Wne4y+ng.w�f �a. (am) Tie-931N ee:' an -Tech - —1 .v P FatKli• 9C ldntgs mss.---•-----_..M __ -—„-.._..---- - -- Fa FHD AWSK 'NRPW;oY 'H Wd tqr Ws strKwe k any ueed iur irl:M 009ol mA"I ak tear FoarlC Trr 't-uVeo.. I. -pa;'f-A eduod" a, 1l 10 ProHee a cMtrV*L 2dL a1' 2rtj oprpe "-wd an thh a+tcia 5aayng pr�hrrtier, Olhvr R.4.kd. may br u.0 tiered an the arperisnce of 9w Soon -Tack 6uNdrngn tna.Lbr! L AH klmysr yap11 E•. pratwrf. sealed rlt+ a Wesumt1 r per AMPA Sto.0" u6. WlnMum "a erarn pk ACA. !, miss mVetrMMt ta% �' r � w drnre. 16' a.d. pro-dr:J1 M lYlllhbr cuivu"t .. Orel ackhor Et16 9r_md Rate; C. FDM_ DM6N BEIVeNG CAaAWN N- 3PFW-►EOe 9MLDPNQ t. ' JWIEMg eprrelheekron•i -0 per '3ppR-Teen Duttlmu .vnr Jndr• ea�ar-+5,�a�6mHtd. J. CONCPUZ SLAS I, cwosr Ir raapmso. gar Dap& D" oT 1105 Is net by 5lrrmk4y En9hwrM4 .NRiG. These ]paaiRcaSiWlt dti fpr fAaidp[ktr and !x[n►tl!ir an!µ Tha Cmnlraota 'I ere rnrpoerTle !x propM raatinq, _11m kal, phrnhl ill. A. dFaik", oed deehuml requim- nla sH the build", LAP spurE sCHFS1Ar-TENsWyN BARS SAO 9LLE 9LSIC• (yFSS 6 N3 14 RICHES _� Aa 20 WCHES IFS 24 h+CMEs 0 78 abw Psi c**-p.ES4VE ImE➢ crdL SPECIFICATIONS ROSE ACRE FARMS I PANTEGO, NC si E 1 SCALD AS ND7EDN1SPT,ISPT,10.011�1 T S_Z Galia2her, Tonv 1�)07- 1 rJ From: Timothy Waters Jbmothy_waters@goodegg.cornI Sent: Thursday, May 02, 2013 2:57 PM To: Gallagher, Tony Subject: Re- Hyde permit Hopefully this is what you are needing_ I'm not sure why the otber items showed up on the attachment I sent you earlier, but I crossed referenced, and these book and page numbers were the only ones that pulled up on the Hyde County GIS. Pullet farm (20 acres; book: 209 Page: 287) -- Parcel # E4 50A Main complex including composting (770.9 acres; book: 196 page: 646) -- Parcel # D3 Total acres of facility and pullet farm T 790.9 acres Thanks, Timothy Waters Rose Acres Farms Whatever you are, be a good one.. - Abraham Lincoln From: "Tony Gallagher" <tony.gallagher@ncdenr.gov> To: "Timothy Waters" <timothy_waters@goodegg.com> Sent: Thursday, May 2, 2013 8:13:33 AM Subject: RE: Hyde permit Timothy, Thanks for getting this information so quickly to me, so that I can complete year permit renewal. My apologies, but as it turns out l will need the total acres you provided me to be broken-down by per {parcel of land based on the attached document you sent listing each book and page 10. Thanks M.A. (Tony) Gallagher, Supervisor Composting & Land Application Branch Solid Waste Section phone/fax (919)707-8280 E-mail address - tort -gall a he ncdenr. ov httf': _ uortal.ncdennorg web, wm / sw senta e E-inail correspondence to and from this address may be subject to North Carolina public records law and may be disclosed to third parties. From: Timothy Waters[mailto:timothy_waters@goodegg.00m] Sent: Wednesday, May 01, 2013 12:49 PM To: Gallagher, Tony Subject: Re: Hyde permit I believe I've gat the rest of what you need in the numbers below. As you saw when you visited, our plan is to compost in 2 buildings and use the 3rd for finished storage. Obviously, as we store more compost, then our available space to use for composting is reduced. Please let me know if you need anything else on top of this data. Facifi1y Acres • facility minus composting buildings acres = 20 acres compost buildings acres = 4.389 acres • total facility including composting = 24.388 acres Composting Information • max height of windrows = 9 ft • max width of windrows =14 ft • max height of finished compost storage =35 ft • inax width of finished compost storage = 100 ft • total capacity of in process and finished. compost = 1,101,785 cu ft Thanks, Timothy Waters Rose Acres Farms Whatever you are, be a good one. - Abraham Lincoln From: "Tony Gallagher" <tony.gallagher@a ncdenr.gov> To: "Timothy Waters" <timcthy_waters a@goodegg.com> Sent: Tuesday, April 30, 2013 9:00:54 AM Subject: RE: Hyde permit Timothy, Thanks for the information you sent_ Do all those different parcels in your attachment represent Rose Ares property at one location? if so are all of these different parcels under one ownership row? I still need the total acres of your facility and the nurnbers of acres that your include your composting area (the three barns). Thanks M-A. (Tony) Gallagher, 5upen-isor Composting 8v Land Application Branch 2 Solid Waste Section phone/fax (9I9)707-8280 E-mail address - ton alga he cdenr. ov http: l / Portal.ncdenr.org/webi wm 1 swl septaee E-mail correspondence to and from this address may be subject to Nortb Carolina public records Iaw and may be disclosed to third parties. Frorn: Timothy Waters [rnailto:timothy_watem@goodegg.com] Sent: Monday, April 29, 2013 5:54 PM To: Gallagher, Tony Subject: Hyde permit Tony, I have attached some of the information you need for the permit to this email, and I hope to have the rest for you soon, The attached should answer the questions about who and when land was purchase along with how much land. It has the book and page numbers, too. I'm working on the capacity nuznbers as I want to be stare I get these correct. Please verify you need the following: • max height and width of windrows • max height and width of finished compost storage • total capacity I'd like to ask you to clarify with me agar exactly what needs to be included in the total capacity number. Is that for finished compost storage oxtly? Finished compost plus in process compost? Just trying to get a clear understanding of what you need so I can work it up and get it to you. Thanks, Timothy Waters Rose Acres Farms Whatever you are, he a good one. - ,lbraham Lincoln