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Home My WebLink AboutBUSINESS PLAN CRYSTAL GEYSER WATER COMPANY FACILITY COMPLIANCE PLAN INCLUDING REQUIRED RISK MANAGEMENT PLAN ELEMENTS May 1999 WZI INC. 4700 STOCKDALE HIGHWAY BAKERSFIELD, CALIFORNIA compressor and pump the discharge oil separator down, then pump oil in. Because of the large volume of gas that is e, ontalned In these vessels, it would be bas! to draw the gas back into the system rather than drain it into a container of water. To accomplish this: 1. Stop compressor. 2. Close discharge valve. 3. On second stage compressors close suction valve. 4, On second stage compressors open pump out line. 4. On Iow stage compressors open 3/8" bypass line around suction check valve. 4. After oil separator vessel pressure drops to suction pressure, around 2 psig, close the auction valve. 5. Close the bypass valve. - 6. Pump in oil as needed. NOTE: If you are going to replace the oil, it is easier and takes less time if you drain the oil before you reduce the vessel pressure. AMMONIA OFF-LOADING PROCEDUR~ Note: Following our (;fi-loading procedures 'are copies of Off-Loading Procedures for driver'/operators of Ammonia delivery trucks from the two suppliers we usually use. Coordinate our procedures with the driver/operators procedures. Note: For emergency purposes have at hand and ready to use: Gloves, goggles, faceshield, a full face gas mask with industrial size ammonia canister, and a self containe~.breathing apparatus..' . ..... ~,.,. " l.Locate ammonia'i~:U~ near ammonia charging stati<~n east. of the engine room. 2.Make sure wheels are chocked. 3.Put barrier at the valve loading station.wtth,a sign reading "DANGERI--Stand clear, ammonia loading in progress. .. 4.Driver will connect hose to receiver fill line. $.Note Ilqutd level of receiver In the engine room. 6.After hose is connected end the blccder valves are closed, make sure fill line valve is open on the receiver in the engine tooth. 7.Make sure receiver line pump out valve is dosed. 8.Slowly open flit line valve,~ . ,-,-,.when driver/operator is ready. Note: Coordinate with steps 2 through 5 of Hill Brothers procedures or steps 11 through 18 of LaRoche procedures, Note: Read pressures at cargo tank and engine mom receiver. If the differential pressure between the truck tank pressure and engine room receiver exceeds the limit of the pumping system, the engine room operator must reduce the receiver tank pressure to a suitable level. Maximum differential pressure should not exceed 125 PSIG. Operating Instructions o Page 6 4. Lock out electrical panel. 5. Tag warning on the electrical panel. 6. Attach bleed off hose to the compressor to bleed off excess ammonia into a bucket of water. 7. Open discharge valves before starting the compressor. Restarting a Compressor 1. Disconnect bleed off hose. 2. Open discharge valve at the compressor. 3. Check oil level in crankcase. 4. Remove lockout on the electrical panel. 5. Turn on compressor motor. 6. Check oil pressure. 7. Open suction valve at the compressor. Preventative Maintenance Checklist 1. While the system is in operation, check the refrigerant sight glass: Clear - OK Bubbles - Low on refrigerant Foam - Very Iow 2. Oil sight glass level should be in center of glass. 3. Operate thermostat at the set point. - ~[)~ o~I 4. Maintain proper glycol level and concentration. ~,~.. 5. Evaporative condenser. Bleed off- clean sump and spray nozzles, chemicals, fans and pump. ~)~ _ ~'x/',~ ~'--~c~ 03320012.001 ,~ ua~.,.~ .~u,.~ 63 6. Check suction and discharge pressures. ~l y -~;(~ /o~ 1~ 7. Listen for strange noises, bad bearings compressor knock. ~',~,.~.. ~.,...~, 8. Check all breakers and overloads, oJ,~,-,-~ 9. Clean pump strainer. ,~,~,,/j ~,1 10. Check by-pass and flow switch by turning off glycol pumps, system should pump down and turn off. ~" "~'~' 11. Turn off refrigerant solenoid and see if system will pump down and shut off at about 10-20 psig. 12. Check for vibration, loose clamps, cap tubes vibrating and/or rubbing. 13. Log compressor hours. 14. During times of light load, turn off the lead compressor and let #2 get more run time. {,-.¢4r~ I¢.~. ~ ~a/ Weekly 1. Log the compressor operating hours. 2. Check the oil level in the compressors. 3. Check the frigerant sight glasses for bubbles. 4. Check fans and pump in evaporative condenser for proper operation. 5. Check tower chemicals, o.-.-~ ~// % 3, ~,,""~ k,~,.~ o~.,~ Monthly 1. Shut down the system, drain the condenser sump and clean sump and pump strainer in the condenser. Check for scale. (:~'~"7' - 2. Check the strength of the glycol solution. Strength should be 30-40%. 1.034 to 1.049 specific gravity. 03320012.001 64 3. Tum off the glycol pumps and check to see if the flow switch turns off the refrigerant solenoids. 4. Check for loose pipe clamps. Yearly 1. Descale the condenser if necessary. 2. Replace refrigerant driers. More often if necessary. 3. Check the condenser fan belts. -- ~.r,~,~ 4. Check all safety controls. --.-' ~,,,~. 5. Check the gauges for proper calibra_~:...~_ 6. Check the compressors per. Cartier'recommendations. 7. Change the oil in the compressors and clean the crank cases. 8. Check thermometer and thermostat calibration. 9. Flush the cooling coil drain pans, if any, with fresh' water to clean and check for proper drai'-nage. ~-~ ~- 10. Turn off power and tighten all electrical connections in the control panel. CRYSTAL GEYSER WATER COMPANY FACILITY COMPLIANCE PLAN INCLUDING REQUIRED RISK MANAGEMENT PLAN ELEMENTS May 1999 Submitted to: City of Bakersfield Office of Environmental Services 1715 Chester Avenue Bakersfield, California 93301 Submitted by: Crystal Geyser Water Company 1233 East California Avenue Bakersfield, California 93307 Prepared by: WZI Inc. 4700 Stockdale Highway, Suite 120 Bakersfield, California 93389 03320012.001 I 4700 STOCKDALE HIGHWAY, SUITE 120 BAKERSFIELD, CALIFORNIA 93309 (805) 326-1112 FAX: (805) 326-0191 SECTION I 1.1 Purpose and Scope of Plan Coverage The Crystal Geyser Water Company, Bakersfield plant, formulates and bottles Crystal Geyser brand juice drinks and flavored waters. For process cooling, an anhydrous ammonia refrigeration system is used. The Califomia Accidental Release Prevention (CalARP) Program merged the existing state Risk Management and Prevention Plan (RMPP) and the new federal Risk Management Plan (RMP) promulgated pursuant to Section 112(r) of the 1990 Clean Air Act Amendments. The California Office of Emergency Services (OES) oversees the CalARP regulations. The U.S. Environmental Protection Agency (USEPA) has delegated implementation authority for the federal program to OES. At the local level, the program is implemented by the Certified Unified Permitting Agency (CUPA). For facilities operating within the City of Bakersfield, the CUPA is the City of Bakersfield Office of Environmental Services. Because the CalARP program is a combination of the federal and state requirements, the program includes two lists of regulated toxic and flammable substances. While many of the chemicals are present on both lists, the state applicability thresholds are generally lower. The RMP must be developed from a comprehensive assessment of the processes, operations, and procedures at the facility, and includes four main elements: · A Management System that specifies qualified and responsible persons; · A Hazard Assessment that analyzes and documents potential environmental and population receptors due to an accidental release; 03320012.001 2 · A Prevention Program that compiles operations procedures, safety information, and specific hazard information into a program that minimizes the threat of an accidental release; and · An Emergency Response Program that establishes procedures to deal with the results of an accidental release. Also addressed in this document are requirements of Title 40, Code of Federal Regulations, Part 355. The requirements of this section apply to any facility at which an extremely hazardous chemical is present at or above the threshold planning quantity. These facilities are required to notify the local emergency planning committee or emergency response personnel of the chemicals present, to provide a facility emergency response coordinator and to notify the committee of any changes that occur. Any facility that produces, uses or stores hazardous chemicals above the threshold planning quantity is required to notify specific agencies in the event of a release. Ammonia, the only hazardous chemical of any quantity located at Kern Ice and Cold Storage's facility, has a threshold planning quantity of 500 pounds. The reportable quantity for ammonia is 100 pounds. This plan conforms to the City of Bakersfield's Guidance for the Preparation of a Facility Compliance Plan. The City of Bakersfield's Guidance is taken from the Draft Guidance Document for the California Consolidated Contingency Plan published by the Governor's Office of Emergency Services and is modeled after the National Response Team's Integrated Plan, the "One Plan." 03320012.001 3 1.2 TABLE OF CONTENTS SECTION I .......................................................... 2 1.1 Purpose and Scope of Plan Coverage .......................... 2 1.2 TABLE OF CONTENTS ...................................... 4 1.3 Current Revision Date ....................................... 9 1.4 Facility General Information ................................. 10 SECTION II ......................................................... 11 I1.1 Discovery ............................................... 11 Detection and Monitoring Systems ............................ 11 Odor .............................................. 11 Sight .............................................. 11 Ammonia Gas Sensors ................................ 11 Alarm Indicators ..................................... 12 Operating Thermostat ................................ 12 Control Systems .......................................... 12 System Restart ...................................... 12 Manual Isolation Valves ............................... 13 Machine Room Exhaust System ......................... 13 Machine Room Vent System ........................... 13 Emergency Stop ,Switch ............................... 14 King Solenoid ....................................... 14 Master High Level Switch .............................. 14 Chiller High Level Switch .............................. 14 Cooler Tower pH Alarm ............................... 15 Sparge Tank pH Alarm ................................ 15 03320012.001 4 11.2 Environmental Response Actions ............................. 16 a. Internal and External Notification Procedures .............. 16 b. Environmental Management System ..................... 18 c. Preliminary Assessment ............................... 19 Worst Case Scenario ................................. 20 Off-Site Receptors for Worst Case Scenario ..........21 Alternate Release Scenario ............................ 22 Off-Site Receptors for Alternate Release Scenario ..... 23 d. Mitigation ..................... ; .................... 24 Incident Action Plan .................................. 24 11.3 Continuous Improvements .................................. 26 11.4 Return to Compliance ...................................... 27 SECTION III ........................................................ 28 II1.1 Maps and Drawings ....................................... 28 a. Maps .............................................. 28 b. Drawings .......................................... 31 c. Areas of Vulnerability ................................. 32 111.2 Notifications ............................................. 38 a. Internal Notifications .................................. 38 b. Local Agency Notifications ............................. 39 c. Regional and State Agency Notifications .................. 40 111.3 Environmental Management System ........................... 41 a. General ............................................ 41 Organizational Chart ................................. 41 03320012.001 5 Emergency Response Procedures ....................... 41 General Evacuation ............................. 42 Fire ......................................... 42 Earthquake ................................... 42 Significant Leak from the Ammonia System .......... 43 b. Command .......................................... 44 Accidental Releases .................................. 44 Management of Change ............................... 44 c. Operations ......................................... 46 Daily Operating Procedures ............................ 46 Daily Operating Duties ........................... 46 Addition of Oil to the Compressors ................. 46 Detection and Monitoring Systems..: .................... 46 Odor ......................................... 46 Sight ........................................ 47 Ammonia Gas Sensors .......................... 47 Alarm Indicators ................................ 47 Operating Thermostat ........................... 47 Control Systems ..................................... 48 System Restart ................................ 48 Manual Isolation Valves .......................... 48 Machine Room Exhaust System ................... 48 Machine Room Vent System ...................... 49 Emergency Stop Switch .......................... 49 King Solenoid ................................. 49 Master High Level Switch ........................ 49 Chiller High Level Switch ......................... 50 Cooler Tower pH Alarm .......................... 50 Sparge Tank pH Alarm ............... . ...........50 03320012.001 6 Incident Action Plan .................................. 51 Utility Shut-Offs ..................................... 52 ' Gas/Propane Tank .............................. 52 Electrical ..................................... 52 Water ........................................ 52 Ammonia ..................................... 52 Gas Meter .................................... 53 Lock Box ..................................... 53 Available Water Supply ............................... 53 d. Planning ........................................... 54 Worst-Case Scenario ................................. 54 Residential Population Calculations ...................... 57 Worst Case Scenario Area of Vulnerability ................ 57 Alternate Release Scenario ............................ 58 Residential Population Calculations ...................... 61 Alternate Scenario Area of Vulnerability ..................61 e. Logistics ........................................... 62 Emergency Medical Plan .............................. 62 Maintenance Procedures .............................. 62 Ammonia System Shutdown ...................... 62 Isolating a Compressor for Maintenance ............. 62 Restarting a Compressor ......................... 63 Preventative Maintenance Checklist ................ 63 Weekly ....................................... 64 Monthly ...................................... 64 Yearly ....................................... 65 03320012.001 7 111.4 Emissions Documentation ................................... 66 Documentation ........................................... 66 Incident Investigation ...................................... 66 Five-Year Accident History .................................. 67 Requirements ....................................... 67 Accidental Release ................................... 67 111.5 Training ................................................. 68 111.6 Plan Review and Modification ........... .. .................... 69 111.7 Prevention Program ....................................... 70 NAICS Code ............................................. 70 Name of Chemical Covered ................................. 70 Safety Information ......................................... 70 Hazard Review ........................................... 71 Operating Procedures ...................................... 71 Training Programs ......................................... 72 Maintenance Procedures ................................... 72 Compliance Audits ........................................ 72 111.8 Certification .............................................. 74 03320o12.001 8 1.3 Current Revision Date This document, including a review of the facility, the facility hazards, the off-site area of vulnerability, and the off-site receptors, was completed in May 1999. 03320012.001 9 1.4 Facility General Information Business Name: Crystal Geyser Water Company Address: 1233 East California Avenue Bakersfield, CA 93307 Phone: (661) 323-6296 NAICS Code: 312112 Latitude: 35°22'04'' Longitude: 118°59'00" Environmental Contact: Bob Hofferd, Safety Coordinator Primary Emergency Contact: Gerhard Gaugel, Quality Control Manager Secondary Emergency Contact: Bob Hofferd, Safety Coordinator Number of Full-Time Employees: 39 Chemicals On-site: Anhydrous Ammonia Maximum Amount of Chemical: 4500 pounds Storage Container: Aboveground Tank (Receiver) Date of Last Inspection: March 1999 Inspection Performed By: Howard Wines Inspection Agency: City of Bakersfield Office of Environmental Services 03320012.001 10 SECTION II I1.1 Discovery Detection and Monitorinq Systems Odor The nature of ammonia is such that the presence of ammonia vapors would be detected by smell at very Iow concentrations. Sight Potential ammonia release points can be detected by visual inspection of equipment to identify discolorations, rust, holes or worn spots. Ammonia Gas Sensors Ammonia gas leaks are detected by Manning Systems Model 4485 Ammonia Gas Cell/Transmitters located in the machine room, at the carbo cooler and in the ammonia vent lines. These sensor units consist of an electrochemical sensor and an electronic transmitter and have a detection range of 0-100 ppm ammonia. 03320012.001 11 I Alarm Indicators The alarm module is the top of three computer modules located in the computer control panel. The top row of lights are inputs to the computer. The bottom row of lights represent the outputs. The computer inputs must be "ON" (LED light ON). If the light goes out, it signals an alarm condition. Operating Thermostat Operating thermostats are used in the glycol system and the tower water system. The operating thermostat has four stages. Three stages are used to control the temperature. Should the glycol or tower water temperature continue to increase beyond the third stage of cooling by five degrees, the high temperature alarm signal will be sent to the computer alarm module signaling a general refrigeration alarm. Control Systems System Restart If there is a power failure, the system will not restart automatically. A trained operator must restart the system. When the power is restarted, the alarm system will check all of the alarm points. If there are any failures, the alarm horn and light will activate. The operator can silence the alarm horn, but he cannot reset the alarm system until the cause of the alarm is found and corrected. Once all of the alarms are cleared, the compressor can be placed into operation. 03320012.001 12 Manual Isolation Valves In the case of an earthquake there is a possibility that ammonia lines will break. Power will likely be out which will close all automatic valves. Each vessel that contains ammonia has manual isolation valves that can be turned off. Machine Room Exhaust System The machine room has a large two speed fan located on the roof. The fan is used to cool the machine room in the summer and to vent the ammonia out of the machine room in the event of a leak. The fan has a set of automatic dampers. If the fan is being used for ammonia removal, the dampers direct the exhaust air into the cooling tower. This tower acts as a scrubber, removing the ammonia from the air. This will happen under the following conditions: · There are two machine room emergency vent switches on the system. One in the dump panel and one on the wall outside the machine room. Either switch will start the fan and the damper, and sound an alarm. · If the machine room ammonia sensors detect a leak, it will start the vent system and sound the alarm. Machine Room Vent System The machine room vent system will still function if the emergency stop switch has been used. The control panel is built in two sections. Each section has its own power supply. 03320012.001 13 Emergency Stop Switch There are two emergency stop switches. One is located in the ammonia dump panel and one is on the wall outside the machine room. The switches are wired in series. If there is an accident, fire, earthquake, or ammonia spill the refrigeration system can be turned off from either remote location. This will sound an alarm at the main computer panel. King Solenoid The system has two King solenoid valves located on the main ammonia line as it leaves the receiver to supply the system. One valve is manual, the other is electric. The electric valve must be energized to open. The valve will close during a power failure, if the emergency stop switch is turned off, or if the King solenoid valve switch is turned off at the contr°l panel. Master High Level Switch The master high level switch is located on the master accumulator. If liquid ammonia floods back to the master accumulator, the master high level switch will shut down the complete refrigeration system. In order to restart the system, an operator must be present to reset the alarm system and place the refrigeration system back in operation. Chi,er High Level Switch The glycol chiller has an accumulator that discharges to the master accumulator. The high level float switch is located on the glycol chiller and it will give an alarm signal indicating that the ammonia level is too high. This will not, however, shut the system down. It will let the operator know that an alarm condition is present. 03320012.001 14 Cooler Tower pH Alarm The cooling tower will be used as an ammonia scrubber for the machine room ventilation system. In the event of an emergency, ammonia will be scrubbed out of the air by the cooling tower. This will in turn change the pH of the water in the cooling tower sump. A pH alarm will detect any changes in the sump water and send a signal to the computer alarm module, sounding a general computer alarm. At the same time, it will open a dump solenoid allowing water to drain from the cooling tower to the sparge tank and freSh water will be automatically added to the cooling tower. This will continue until the pH of the tower water is back within predescribed limits. Sparge Tank pH Alarm In the event a relief valve is discharging ammonia into the sparge tank and there is a failure of the ammonia vent alarm and the pH changes substantially in the sparge tank, a signal is sent from the remote pH alarm module located at the tank to the computer alarm module sounding a general alarm. 03320012.001 15 WZl ,NC 11.2 Environmental Response Actions a. Internal and External Notification Procedures Supervisors, upon notification of a hazardous condition, will use the paging system to notify all employees to evacuate the facility. Each supervisor is to direct the employees in his area to the safest exit and to ensure that area has been vacated by all personnel. All employees will report to the designated evacuation area. A map of evacuation routes is shown on the following page. Pursuant to Section 25507 of Chapter 6.95, Article 1 of the H&SC, releases of hazardous materials that may threaten human life, health and safety or the environment must be reported. If an ammonia release exceeds 200 cubic feet during a 24-hour period, the event is reportable and the following agencies must be notified immediately. Local emergency response agency Telephone: 911 City of Bakersfield Fire Department Office of Emergency Services Telephone: (661) 326-3979 California Office of Emergency Services Telephone: (800) 852-7550 National Response Center Telephone: (800) 424-8802 03320012.001 16 1233 EAST CALIFORNIA 1233 EAST CALIFORNIA .L MIX HALLWAY I I_-- '-~ I I -- --" BOTTLE I I ,~ , IcvU.DERS] _A ROOM , T AREA I ' "' L__ T a I1~ I I I I I PROGFSSING I WAREHOUSE' · 1~ STOFIAGE AFtF:A OFFICE _L1.. ~._ t T _ ..........__ SHOP I AND -'- I I OFFICE FREEZER REA ~ I ~ ~ ! .,~ -L. LUNCH I I I~'"' T T .oo,,., .EST.OO. ALLEY WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER Bakersfield, CA BOTTLING FACILITY 0332.0012 EVACUATION POINTS 4/99 The following information will be provided during notification: · Name and telephone number of person reporting release. · Exact location (address) of the release or threatened release. · Date, time, cause and type of incident (e.g., fire, release, unauthorized discharge, etc.) · Material and quantity, to the extent known (size and appearance or opacity). · Weather conditions, if applicable. · Current condition of the facility. · Extent of injuries, if any; and · Possible hazards to human health, or the environment, outside the facility. 03320012.001 17 b. Environmental Management System The Plant Manager, Richard Weklych, is responsible for the Bakersfield facility. Issues must go through the Plant Manager for final approval before implementation. At the Crystal Geyser Bakersfield location, the Safety Coordinator, Robert Hofferd, will be the qualified individual and Environmental Coordinator. The Environmental Coordinator is responsible for all safety training of employees. The Emergency Contact will be the Quality Assurance Supervisor, Gerhard Gaugel. Any emergency incidents that occur at the facility will be the Emergency Contact's responsibility. All supervisors will be responsible for the safety of the employees in their section. 03320012.001 18 c. Preliminary Assessment The ammonia system is designed to operate when cooling is needed. Gaseous ammonia enters the compressors and is compressed to a higher pressure and temperature. After exiting the compressors, the hot gas enters the evaporative condensers. Water running through the condensers cool the hot gas into a liquid. The liquid ammonia flows to and is contained in the receiver. A level control, controlled by a solenoid valve, allows ammonia to flow from the receiver to the chiller and carbo cooler. From the receiver, liquid ammonia flows through the lines to the cooling equipment, the carbo coolers. In this flooded system, liquid ammonia flows through exchanger plates while the material to be cooled, flowing counter currently, is cooled by the phase change of the boiling ammonia. From the carbo coolers, vapor and liquid ammonia travels back to the indoor receiver from which vapors are pulled by the compressors. Liquids are recycled from the receiver back to the coolers while vapors travel through insulated lines to be compressed to high pressure and then cooled into a liquid, completing the cycle. A walk-through of the facility and a failure mode and effect analysis were performed to determine potential weaknesses in the facility systems. The most likely event causing a release would be a pipe or valve rupture. The immediate area surrounding the Crystal Geyser plant is both residential and industrial and must be considered in hazard analyses, operating and response procedures. Additional hazard analysis information is included in Section 111.3.d. 03320012.001 19 Worst Case Scenario The worst case scenario is given by USEPA guidance. The maximum amount of anhydrous ammonia is assumed to be released in ten minutes. No mitigation measures are considered to be in effect to slow or prevent the release of the entire amount of ammonia in the system. The rapid release of liquid ammonia could form an air/ammonia dispersion that would act as a cloud of dense gas. The distance to the toxic endpoint is the distance this potential ammonia vapor cloud could travel before dissipating to a point that serious injuries from short-term exposure will no longer occur. Crystal Geyser Water Company systems have a maximum capacity of 4500 pounds of anhydrous ammonia. The USEPA has published Risk Management Program Guidance for Ammonia Refrigeration to assist facilities in RMP preparation. This guidance manual has a standard table to be used for worst case scenarios and is based on the maximum amount of anhydrous ammonia used in the process. Based on this USEPA-supplied table for worst case scenarios, the worst case distance to the toxic endpoint is 0.9 miles. A more detailed explanation of the worst case scenario is given in Section 111.3.d, Planning, and a map of the vulnerable area is provided in Section II1.1, Maps and Drawings. 03320012.001 20 BA~RSFIELD, CALIFORNIA SCALE IN MILES CRYSTAL GEYSER ~kersfield, CA 0 0.5 1 WORST CASE REL~SE ~.~12 SCENARIO Off-Site Receptors for Worst Case Scenario Receptor Approximate Distance (Miles) Direction Southern Pacific Depot 4/5 NVV State Building 9/10 NVV Fire Station #2 2/3 NVV Vista East High School 1/2 NVV Martin Luther King Jr. Park 1/3 W Union Cemetery 3/10 SVV Owens School 2/5 SVV Virginia Avenue County Park 2/3 SE 03320012.001 21 Alternate Release Scenario An alternative release scenario is also required. This alternative release scenario is determined by either past facility or industry experience to be a more likely credible release scenario. The hazard and operability study determined the alternate release scenario to be the release of the liquid contents of the ammonia receiver into outside air. The potential release scenario judged to be dangerous to offsite receptors is a release of ammonia during an earthquake. Lines from and to the ammonia receiver contain liquid ammonia. A break in this liquid ammonia line could release all of the ammonia in the receiver to outside air. In this potential worst case scenario, the rapid release of liquid ammonia could form an air/ammonia dispersion that would act as a cloud of dense gas. The release rate for the alternative release scenario can be found by using the following equation from USEPA guidance: QR = HA x (203)(Pg)~ where QR = Release Rate (lbs per minute) HA = Hole Area (square inches) Pg = Gauge Pressure (psig) Using the RMP Comp software provided by the EPA, the distance to the toxic endpoint is estimated to be 0.2 miles. There are no off-site environmental receptors for the alternate release scenario. Residential population calculations are given in Section 111.3.d. Public receptors include commercial, industrial, and residential receptors. 03320012.001 22 A more detailed explanation of the alternate release scenario is given in Section 111.3.d, Planning, and a map of the vulnerable area is provided in Section II1.1, Maps and Drawings. 03320012.001 23 ~ , ~ ~ ~, ~ ~ ~,, , ~, ~, I ~ ]~ '~v~~~ ~!.~'~t~ :.i .. ~ ~ ~-~ / · >t / ./ Kern M, ,-,, ~ ~: :1' ~r-~~~:.. ~L crvstac O~SE. ~~~ ~ · ..... ~.q~.~ ~ ..... ,,, ,', ~ ...... [ ,~-~ --' ~, ~,~ .... -~ .... ~ · ~' · "' .... ~ · I~' " ~ ~ ~ ~ ~ ? . ~'~l~s .. ~ ~ ~ ~ ~ ~ ~ me~- , ~ : : · · ..': · ~ · · ":::~! ~ [' ' ~ ~ I "" : ~' 1" :'"' '' ~ "~' 7 8 , ~,- · : ,:..~ .~ I. ~'~ :.:: i-...:::.~'., j .,~!....1 :..'1 ~ ~ ~ -' I ' ~ : ' ~ ~' : ' [ ~ ~ ~, ~ ' '1'~1' ~. .". :.] [' '~: ~" ~ ~' : ' : LI~A~Y":~: ''~"~' [ ~ ~[ ' [ Z ~ ' ~ ", '. i ', , , ,.~ - . m~ut ~ , , I .'~ '~ ..JL~'.~: '~.'~:"'.':~'.:..::~2i ~ ~i,,.o. ~ CRYSTAL GEYSER ~ SCALE IN ~ILES ~k~, CA N 0 0.5 1 ALTER~TE REL~SE ~.~ 2 SCENARIO d. Mitigation General emergency response procedures are: · Assess the situation. · Isolate and deny entry to the affected area, and evacuate or shelter-in-place. · Provide emergency medical assistance, if necessary. · Notify response agencies and facility response personnel, as appropriate. · Control the release, if possible. · Actively mitigate the release, if properly trained and equipped. · Provide assistance to public agency responders, as necessary. · Terminate the response with proper clean-up and disposal. · Follow-up reporting, evaluation, and critique, as required~ Incident Action Plan The incident action plan will be implemented in the case of an emergency plant evacuation. The following steps will be taken in emergency situations: 1. An announcement will be made over the paging system notifying employees of facility evacuation. 2. All employees will report to the staging area on the east end of the property. 3. Employees certified on self-contained breathing apparatus (SCBA) will bring SCBA equipment to the staging area. 4. Attendance will be taken by the Incident Commander or designee to account for employees. 5. The Incident Commander or designee will make an overall assessment of the incident. 03320012.001 24 6. Emergency response personnel such as the fire department, hazardous materials team, medical units, and Office of Environmental Services will be notified immediately by the Safety Coordinator or designee. 7. Incidents occurring during the night shift will be evaluated by lead persons and general staff members. If necessary, emergency response personnel will be notified followed by the Safety Coordinator and the Incident Commander. 8. The Incident Commander will initiate a search for employees not accounted for in the attendance count.. 9. Emergency response personnel will be assisted by SCB^-trained Crystal Geyser personnel if needed. 10. A map of the plant will be maintained in SCB^ storage units to assist emergency response personnel. 11. The Safety Coordinator will continue to monitor personnel safety. Additional protection and mitigation procedures are included in Section 111.3.d, Planning. 03320012.001 25 11.3 Continuous Improvements Measures to be taken during nonconformance conditions or prolonged incidents include: · Stopping processes and operations. · Collecting and containing released waste. · Removing or isolating containers. · Monitoring for leaks, pressure build-up, ruptures, etc. · Arranging for repair or replacement of affected system areas. This facility is closely monitored by the facility supervisors and other personnel. Crystal Geyser Water Company is committed to providing a safe environment for its employees and the surrounding area. Improvements are implemented when possible to support this commitment. These improvements may include upgrading equipment maintenance procedures, training requirements, operating procedures or system controls. 03320012.001 26 11.4 Retum to Compliance A written follow-up report is required to be completed as soon as practicable, but no later than 30 days following a release. The completed report is to be sent to the Office of Emergency Services. After an accident has occurred, an incident investigation will be initiated as soon as possible but no later than 48 hours after the incident. An incident investigation team consisting of at least one person knowledgeable in the process and any other persons with appropriate knowledge and experience will analyze and investigate the incident. The ammonia incident report on the following page will be completed. A post-accident review will be held in which potential causes of the accident will be discussed. When the cause of the accident has been determined, measures will be implemented to minimize the possibility of recurrence. System design, operating and maintenance procedures that need updating or alteration will be noted, and a time schedule set for implementation of improvements. The Safety Coordinator will be responsible for ensuring the completion of the above activities. All incident investigation reports will be retained for 5 years. Training practices will be adjusted to ensure correct implementation of improvements. New training practices will include refresher training to existing employees to ensure that the employee understands and adheres to current operating procedures of the process. New employees will be trained in general operating practices and job-specific practices prior to operating the process. 03320012.001 27 SECTION III II1.1 Maps and Drawings a. Maps Site maps, including facility evacuation routes, off-site consequence endpoints for worst- case and alternate release scenarios, and sensitive receptors within endpoints, are included on the following pages. 03320012.001 28 - ~ ~ t '~ r/~ ~; '-~ ~r ~. '-.~ ~. -~ ,' .~ ' t ~ .. · ~ , r- ... -.~ . ; --.~ ~: . ~--~ ~~ ~~~~~,' , ~: ~ ~. ~ ~ ~ ~ "~..~r ~ ~ 8 - ~~~_ -/~~ ~ --.< ~,~-._~- ~.' ~..~ ~x~. ~ .. J~L~ ~.- ~F~ ~ ' '. ~,'~...~, ....,, -/ ~ ~-~. ~ "~ :~ :~ ~ =;~ :~ :/ '".4~ ~: ~1~ : ~:"-'~ ...... · ~'--' ~~, -~ ]~H ' :~ ~ ~ ~ ~t ~ ~~~~~' ~ ~ -. ~Z~ ~ .'--~. .... '6:_:~ ....... :~ ' · · ' m ~ ~ .... ~ .o - ' ~ · :~ 'LUCKY AV~ : ,~ · ~ LUCKY ~= : =, ~~ ~ . ' -~.-~ ....... ~ . = ............ _ ~ ~ D ~ ~ , h~~,'. ~v~ s~'~~ZL. ~ ST: ~: ~ z~wRqJ~v~ ~ ~ , ~ ~ ~, ,-.'_~,:':L'~ -'-': ~ ~ ~..~_..~L~ ........ =: ~ ~~K. , ~ ..... ~_.._~ : - . CRYSTAL GEYSER SCALE IN MILES ~kersfleld, CA N O 0.5 1 ~.~2 tOCATION MAP East California Avenue ~ Vimage I~,:~,~a~aE~Z~4 Geyser Geyser/ ~ Facd~y L~ ~ Ho~ ~m~ L WZI INC. BAKERSFIELD, CALIFORNIA /~ CRYSTAL GEYSER N I~akersfield, CA o332.oo'~ 2 SURROUNDING AREA 1233 EAST CALIFORNIA 1233 EAST CALIFORNIA .L MIX HALLWAY I I I I I ~--.~ ROOM I I BO'I'TLE I I"°x I--;.,. ~ FILLER PACKAGING I Li ! L.JcYLINDERS.[ _A ROOM T AREA '1 "' I , T 8 ~11 { I ,t- --,. 88~o ~ ~ I PROCESSING I WAREHOUSE' ~ I I -- -- -- ..~ AND I AREA o, I ~.. STORAGE AREA I OFFICET -- -- --' - ! I I ! SHOP AND "" I .L Ii I / FREEZER REA I I IIE ' LUNCH I I < .oo I I REST~OO~ ALLEY WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER Bakersfield, CA BOTTLING FACILITY 0332.0012 EVACUATION POINTS 4/99 ~t. ' ' ' '~ P ' .... ': ..... · ~. :~. -...$/' ~ HA/J- ~--------1 ~~ I~/Z ;%- I ~-~ ..... -~-, ,-.;~, ~ .,. ~ ,--.; . ..~ -.. ~ v~ n n mae, t~ ~ / .~--"4L'-.~!IA. / ,'"*'-~ ~ ; '~- ; ~"~' K~RN CO. ~ ~ / ~ '~ :/ ~'--4 ~UX~ ~ /~ ~ MI BA~RSFIELD, C~IFORNIA SCALE IN MILES CRYSTAL GEYSER 0 0.5 I ~kersfield, CA WORST CA8E REL~SE ~.~ 2 8CENARIO ' HL ~, · ~ ~ ~ · ~ / ~ ' ~ ~ N ~X~N~ ~ ~N ~~~ ~ sF?~ ~ ~ ~ ~' ' ~'~ TI ~ ~ ,~,u~ ~'L ~ / ~ ~ -~ . .~ '~ -~ ~ ,~KEN~( ~ ~~~ E;~ BAKERSFIELD ~=~ ~~ ~ / ~ ~ ~ ~ ' ' i ' 4 -:~. ":.:: ;-: -i ~ '~ [ ~ ~ - .. . ....... ~:, ~:~ ._. ~: ~ ~ : I ~ ~ I I IIll l~J: .j~: ~ f I I / I ~ / ~t. Lf .! .":A ~~ · ~. '~-~.~::. ~.."~ ~ ~ CRYSTAL G~SER ~ SCALE IN MILES CA N 0 0.5 1 I I t I t I i t ALTER~TE REL~SE m.~2 SCENARIO Off-Site Receptors for Worst Case Scenario Receptor Approximate Distance (Miles) Direction Southern Pacific Depot 4/5 NW State Building 9/10 NVV Fire Station #2 2/3 NW Vista East High School 1/2 NW Martin Luther King Jr. Park 1/3 W Union Cemetary 3/10 SW Owens School 2/5 SVV Virginia Avenue County Park 2/3 SE 03320012.001 29 Off-Site Receptors for Alternate Release Scenario There are no off-site environmental receptors for the alternate release scenario. 03320012.001 30 b. Drawings Process flow diagrams for the Crystal Geyser Water Company facility follow. 03320012.001 31 eRV PRV -"' (I MASTER -", ACCUMULATOR I PRV CHILLER FILTERS ~~ PR~ PRY KING LSV Bako~field, AMMONIA SCHEMATIC DIAGRAM 0332.0012 4/99 N O IIYA-:I'-I 3 ~I3qqlHO.'~ [ BULLS £Y( FILTER 3/4° CK4 CULLS [~ · ~ ~ ~ I 9NIdld >INV.L W3AI3:D3kl ~. ONIdld ~3iVM - ~OSN3GNO0 3AI.LV~OdVA3 T o. il, , . · II II II ~J3991H3 IV' C)Nldld ~. Ol',lldld N~JFI.L':i~I ~ A"lddl"l$' klq~Ol ~ O~dld H31Vb6' ~3MOi :~ ! c. Areas of Vulnerability Equipment specifications and the current condition of the 'equipment is presented on the following pages. The process was inspected and the hazards associated with the process were identified. These hazards are included in the hazard and operability study forms which follow the equipment specifications. 03320012.001 32 OOMPRES~OR ~ ]dFC,: Frk:k Yolk ~m~ RWanT~ sc~ c~~~ ~R~H76 CRYSTAL OEYS_ER AMMONIA ~ MAJOR~ FAN MO'IOR~ (1) 5HP, _1_84T__,lf~3-60, ODP · /X)ND1TION: New 1~ MOIIEL: 0)?3HP, . coNDITION:· New 1993 MOn~-' XLF-ML 425 NOTN: Thc above condensers wcrc selected to mat thc condition ofthe PC~,~ l~rigeration Warehouse rctnte prol~am. CRYSTAL. GEYSER GLYO21L ~ · ~ 37' ID X 22'0" 'l~-TFHoriz~nt~l GL¥ODL~ l~Pely~ ~ SUC'IION: ODNDI'TION: New ~ ~ .. JB" OD X 18'0" LHodz~ · ~ 24" OD 'X ~ _CRYSTAL GEYSER GLY(X)L TANK MODEL: 012'~ ~ 3100 gnl~n, ??" Dia x 10' H Gould VV~Zl NC CRYST A L GEYSER AMMONIA REFRIG//RATION ~ · glycol .at.thc ~/col chilcr. Thc ~COl is pumpcd throu~Mu~ the Plant where ~ is used to cool tanks mid hc~t c~:c~.used in thc production process CRYSTAL GEYSER. AMMONIA IXIMP O3N'IROL PANI~_- pr~:ssurecan build rip. To rdi/vc the premue, valv~ wa'~ inslalledin the dump · . panel If thc pxcss~ tnr. ee, ds thc red,thC on thc face of thc gaugc thc valve/s ~ /~owing ammonia vapor to cnta'thc spar~ tank. (s= below) watcr..All., of thc l'clid valve_and the nmmonia ~ system ate piped · .. intoaCO~hmonvcat.sysmn. Ihevcntlincrunstoth/spargetank~ _Any Thc cruet§_ -enC'Ystop swilch will shut down thc power to'all ofthe equipment ' in the ma/.hin¢ room, with the exception of.thc ventilation sYsu~n. ' ' One switch/s located in thc ammonia dump pand and one in.the contwl box.located The machille roo~ ha a (2) speed fall on the roof, controlled by a two slage thermostat. This tower scrubs the ammonia out of thc air. If this happens_ the IT1 of the tower water will increase. A PH alann will signal this condifib/~ and an ahnn will sound. Location: qlontroh and ahnns ate located in thc computer panr. l on thc I~ack wan o£the machine room. CRYSTAL, GEYSER PANEL R--I condcnscr f~; condenser pun}ps and gl ~y~_l pumps. The compressors have their own starter panels located on the ~ bc-hind each comprcssor. All of the ovcr load switciw, sax~whcdinpamlkl. If any oveload . fnit~ it will sound thc alarm and ~ on t~ panel. _You msut open the door and inspect each overload to find the one that fa~cd.. PANtR. R--2 Pa~, .~ R-2isthc right h~ of the main powerp .m~_ for thc ' ~ and over loads for thc coolin~ towc~ system, thc machhtc room · supply so K-1 c~n lx~ shut down during an em~ .and R-2 can be kept of thc mecht~ cr~ust air. NOTE: Power to operate comcs from _l~n~_ R'~ Ifyou turn offpowcr to R-2 you will lose aI~. _computer function for R-lbut you can still operat~ any · R-1 motor in thc manual or'band position. . . · COMPU'II~ Cl)N'IR~ PANI!L ' Thc C°mpUU:r COnlrol'Pan~l consists of thc following dmris~. .L ~ Co ut~r" ' · ' ' ' 5.. Thermostat ~'~- ' ' & C~) <~.o~ pump ~O~d ~/md down 9. '(Z) Otilled wa~ md up/load down swi~:hex 7 CR'Y~TAL OEY~ER CO~ DES(~IPTION The compu~' consi~ of@) modu~ (tl~ nmin .compmm- and two fan~ pumps aud.aldo provid~vinml alarm indication. 'Nor _~amp..?.t we program thecomputer~.tum on_ .omput 1 .0~1_ ). any time.' there is ahd input $ (X~ A r~d LE) Rght at X~ will indka~ ff rite" COMPtrIER ~y ' · . The a]arm module is the top module ~n t]~ computer panel. For ~ ritual f~ trick the top ~ow o~ alarm inputs were ~ to, be _o~ or .. faJ~ue. 5~ould thc alarm conditlon correct it, ll .the alarm light will be conccted by press~ thc a~m reset ~Uon on.t~e door orR1. For example, if there is ammonia in thc machine room~ w~l go out. ~is w~ ~ock in output YIa Y10 w~l stay on ev _en~fX~ corrects itsclf and g0cs ba~on. To tcsct Y10, X5 must bc f~l and thc light back on, CRYSTAL GEYSEK GLYCDL cl-m ~ ~R OPI~ATION PRI~ OF O~'IION · hund~r,d ~ tub~ Ammonh floods tl~ ou~, CRYSTAL GEYSER GLYO3L O-fa ~ ~R OPERATION __CRYSTAL GEYSER AMMONIA RBF~Gtil~tTION ~ IR.ICIION ~TURE: 26 F ' The condm.w.~ we~ sdec~ to proviod~ ~F -c'gnd~ing at ~FWet .p ~ p p~tre ~ . pr~t ammonia from ~mterin~ the computer ~ndostu~. On~ pressure Th~ otl~ switch is to load dov.'n th cfan~ This switch ¢lo~s on CRYSTAL GEYSER c~ Wa~ ' 11 CRYSTAL GEYSER AMMONIA ~ M_AIORH~~ CO~ START-UP The compre~or operation is/im~ in great detail in the/actory video. All operators s~uld ~ te. qutred ~o view this video Iz~om opcret~ thc equipment. ' . 'lilt colnp~--~ts arc ~ to turn ON and OFF automn~, l~ac_h compressor must bc set on Remote Start, l~nnol~ slid~ v~lv¢ end Auto Vl. to sta.,% it is being hcld-Ob-F on its auto recycle ~; It is designed To overrid~ tl~ timer it is ~ to advancc thc s:tcca and advance tl~ cmx=r to tl~ t~.sct timer. Th~a pusk ~.FL rhea pU~ Start. 85/28/1999 1G:88 8853210251 ROBERT PAGE 82 ~;.~S I~PEORON QUES~ON~IRE ~ y~- O. No ~ y~ ~ No 0 Y~ ~ No ' ova HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY System: AMMONIA REFRIGERATION SYSTEM Equ pment: COMPRESSORS Drawing References: Suide Deviation Cause of the Consequences Resulting from a Severity Probabtiity Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No Power Power Outage None Low Medium Automatic system shutdown None Ammonia Flow Closed discharge valve Open relief valve Low Low Employee training, high pressure shut down switch, sparge system None Oil Oil leak None Low Low Routine maintenance, Iow pressure shut down switch None Less Power Worn motor None Low Low Routine maintenance None None flow Low Med um Emp oyee tm n ng, ammonia mom monitors, gradual release Ammonia Work sea s Ammonia gas leak More Ammonia flow System overfill Activate high level shutdown switch Low Low Employee training, qualified fillers None Pressure Closed discharge valve Open relief valve Low Low Employee training, high pressure shutdown switch, sparge system None Temperature Low water Compressor shutdown Low Low Employee training, high pressure shutdown switch, sparge system None Temperature No water Compressor shutdown Low Low Employee training, high pressure shutdown switch, spa~ge system None Temperature C osed d scharge va ve Compressor shutdown Low Low Emp oyee train ng, high pressure shutdown switch, sparge system None Other Earth movement Earthquake Fracture ammonia gas lines High Low Schedule 80 pipe with welded fittings None Earth movement Power outage Low Low Automatic system shutdown None None Ammonia ine hit by fork iff Fracture ammonia gas lines Operator eh'or Earthquake H gh Low Emp oyee training, schedu e 80 p pe Apd11999 clients~cryshazo.wb2 HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY System: AMMONIA REFRIGERATION SYSTEM I Equ pment: AMMONIA RECEIVER I Drawing References: Guide Deviation Cause of the Consequences Resulting from a Severity Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No Ammonia flow Closed valve to vessel None (compressors down) Low Low None None Ammonia flow Closed valve fi.om vessel High pressure (compressors on) Med Low Employee training None Ammonia flow Minor leak in system Release to ambient air (liquid ammonia) Low Med Regular maintenance None Ammonia flow System shutdown for maintenance None Low Med None None Pressure Compressor shutdown (valve closed) None Low Low None None Less Ammonia flow Compressor/condenser malfunction None Low Low None None Pressure TemperatureLessC°mpress°r/c°ndenserdemand malfunction NoneN°neLowL°W LowL°W SystemN°ne des gned for m n mum load NoneN°ne More Ammonia flow Peak demand None Low Low I System designed for peak demand None Pressure Valve closed Open relief valve Low Low I High pressure shutdown switch, employee training, sparge system None Temperature Condenser failure Open tel ef valve Low Low High temperature shutdown switch, employee training, None sparge system Other Earth movement Earthquake Broken liquid ammonia line High I Low I Structural integrity, schedule 80 pipe with welded fittings None Fire Fire Ammonia line failure High Low Employee training, sprinklers, extinguishers, alarms None I Receiver PRV failure Defective PRV Possible line/vessel mpturs Broken liquid ammonia line Location Low Low I Regular maintenance/testing H t by fonkl ft H gh Low Emp oyee tm n ng, guardrails, schedule 80 pipe with welded fittingsNoneN°ne April 1999 client~cryshazo.wb2 HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY System: AMMONIA REFRIGERATION SYSTEM I Equ pment: LOADING OF AMMONIA RECEIVER I Drawing References: Guide Deviation Cause of the Consequences Resulting from a Severity Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No I Ammonia flow into tank Inlet valve closed Overpressudze line, hose rupture High Low PRVs, operator present dudng tilling, wdtten procedures None !Ammonia vapor returns Return line valve closed Overpressudze line, hose rupture High Low PRVs, operator present dudng tilling, wdtten procedures None Ammonia flow from truck Check valve on liquid till None Low Low None None Power Power failure None Low Low None None Less Ammonia flow into tank Inlet valve closed Overpressudze line, hose rupture High Low PRVs, operator present dudng tilling, wdtten procedures None Ammonia vapor returns Return line valve closed Overpressudze line, hose rupture High Low PRVs, operator present dudng tilling, wdtten procedures None Ammonia vapor returns High pressure in storage tank PRV opens Low Low Sparge system for PRV None None Ammonia tiow from truck Low Low None Check va ve on qu d ti None More Ammonia flow into tank N/A N/A N/A N/A N/A None Low Low Training, vapor return line, PRVs None Pressure in tank Limit flow dudng filling Higher ambient temperature None ncrease pressure, flow potential Low Low Tra n ng, written procedures Higher ambient temperature Temperature None IOther LEoartcahtiomnOVement HEi~ brtl~qf~l~lieft RR~t~;; :~l~;r~iaa ,li~;: HHiigg~ ~ ~Emm~,loO~;: ~tl~[~niinn~ NNoO~: April 1999 clients\c~shazo.wbl HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY System: AMMONIA REFRIGERATION SYS"[EM J Equ pment:. In Line Filters I Drawing References: Guide Deviation Cause of the Consequences Resulting from a Severity Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation ,. I Measures No Ammonia flow Filters plugged Bubbling in sight glass Low Low Employee training None Ammonia flow Valve closed Bubbling in sight glass Low Low Employee training None Pressure System shutdown None Low Low None None Power Power failure None Low Low None None ILess Ammonia flow lC°mpress°r malfunction Less efficient operations Low Low Routine maintenance and inspections None IMoreIAmmonia flow None Pressure Peak demand None Pugged fi ters Bubbling in sight glass Low Low None Low Low Emp oyee training, qualified personnel change filters None Other Earth movement Earthquake Broken liquid ammonia line High Low Schedule 80 pipe with welded fittings None Fire Fire Broken liquid ammonia line Broken liquid ammonia line Location High Low Fire protection installed H t by forklift NoneN°ne H gh Low Guard ra April 1999 clients\cr~shazo.wbl HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY System: AMMONIA REFRIGERATION SYSTEM ~ IEquipment :, EVAPORATIVE CONDENSERS I Drawing References: ~uide Deviation Cause of the Consequences Resulting from a Severity Probability Controls in Place Proposed Mitig~,tion Word Deviation Deviation from Normal Operation Measures No Ammonia flow Valve closed None Low Low None None i FIow Compressor shutdown None Low Low None None Power Power outage Relief valve open-ammonia pressure & temp increases Low Low High temperature & pressure shutdown switch, microprocessor control of system, employee training None Water flow Closed water valve, pump failure Relief valve open-ammonia pressure & temp increases Low Low High temperature shutdown and alarm, employee training, sparge None system Air flow Motor or fan failure Relief valve open-ammonia pressure & temp increases Low Low High temperature & pressure shutdown, routine maintenance, None sparge s~stem Less Air flow Motor or fan failure malfunction Relief valve open-ammonia pressure & temp increases Low Low HighspargetemperatUresystem & pressure shutdown, routine maintenance None Water flow Partial valve closing or blockage Relief valve open-ammonia pressure & temp increases Low Low Highspargetemperaturesystem & pressure shutdown, routine maintenance None I More Pressure Valve closed, no air or water Relief valve open Low Low Employee training, high pressure shutdown, spa~ge system None IOther FE~rer~h movement Earthquake Broken liquid :mmmmoOnnii: Ilii~; High Low Structurally approved by registered engineer, schedule 80 pipe NNoO~: F re Broken liquid H gh Low Fire system installed Apdl 1999 clients\c~shazo.wbl HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY ISystem: AMMONIA REFRIGERATION SYSTEM Equipment: GLYCOL CHILLER Drawing References: Guide Deviation Cause of the Consequences Resulting from a Severity Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No Ammonia flow Compressor shutdown/valve closed None Low Low Employee training None Power Power outage None Low Low None None Pressure Compressor shutdown/valve closed None Low Low Employee training None ILess Ammonia flow !Valve partially stuck None Low Low None None More Ammonia flow Peak demand None Low Low System designed for peak demand None Pressure Open rel ef va ye Low Low High level and pressure shutdown switch, employee training, None Valve closed/malfunction level switch sparge system OtherFireEarthm°vement Earthquake Fracture lines, ammonia leak High Low Schedule 80 pipe with welded fittings NNoOnn: F re Fracture lines, ammonia leak High Low F re protect on nstalled Apdl 1999 clients\kemhazo.wbl HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY System: AMMONIA REFRIGERATION SYSTEM ~ Equ pment: CARBO COOLERS I Drawing References: Guide Deviation Cause of the Consequences Resulting from a Severity Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No Ammonia flow Closed valve None Low Low None None Compressor malfunction Loss of cooling I Low I Low Employee training, routine maintenance None I Low t Low training, murine maintenance Less Ammonia flow Low ammonia supply None Emp oyee Loss of coo ing Ammonia flow Other Earth movement Earthquake Broken liquid ammonia lines I High Low Employee training, schedule 80 pipe with welded fittings None I High Low None F re system nstalled F re F re Broken liquid ammonia lines Apd11999 clients\cryshazo.wb 1 HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY I System: AMMONIA REFRIGI:P, ATION SYSTI:M I Equipment: AMMONIA LINES Drawing References: Guide Deviation Cause of the Consequences Resulting from a Severity Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No None None None Low Low None None ILess None None None Low Low None INone ! IMore Pressure Isolated line Ruptured line or open pressure relief valve High Low Employee training, schedule 80 pipe with welded fittings None Other Earth movement Earthquake Broken liquid ammonia lines High Low Schedule 80 pipe with welded fittings None Fire Broken liquid ammonia lines High Low Fire system installed None Fire Broken iquid ammonia lines H gh Low Emp oyee tra n ng, schedule 80 pipe and None Location L ne hit by fork iff welded fittings, guard tells Apd11999 clients\cryshazo.wb I HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY ISystem: AMMONIA REFRIGEI'~ATION SYSTEM Equipment: EMERGENCY REFRIGERANT CONTROL BOX WITH SPARGE SYSTEM AND DIFFUSION TANK Drawing References: Guide Deviation Cause of the Consequences Resulting fror~ a I Severity Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No Water Leatdng diffusion tank/PRY open Release of ammonia vapors High Low Closed top tank, regular level checks, employee training None ILess Water Leaking diffusion tanldPRV open I Release of ammonia vapors · High Low Closed top tank, regular level checks, employee training None IMore Water None None None None IOther IOpen dump valve Inadvertant opening/ta mpedng of valve Release ammonia to diffusion tank Low Low IEmployee training, lock control box INone April 1999 clients\cryshazo.wbl 111.2 Notifications a. Internal Notifications Facility personnel will report an accidental release or any other emergency condition to their supervisor. Supervisors will notify office personnel who will use the paging system to notify all employees to evacuate the facility. If emergency situation occurs after work hours, supervisor will use paging system to notify employees of evacuation. 03320012.001 38 b. Local Agency Notifications Pursuant to the Emergency Planning and Community Right-to-Know Act (EPCRA) and Section 112(r) of the Clean Air Act, releases of listed regulated chemicals must be reported. The Plant Manager is responsible for determining the significance and reportability of a release. The Plant Manager is also responsible for reporting a release. If an ammonia release exceeds 100 cubic feet during a 24-hour period, the event is reportable and the following agencies must be notified immediately. 911 City of Bakersfield Fire Department Hazardous Materials Division Telephone: (805) 326-3979 03320012.001 39 c. Regional and State Agency Notifications In addition to local notifications, the following regional and state agency notifications will be made: California Office of Emergency Services Telephone: (800) 852-7550 National Response Center Telephone: (800) 424-8802 In addition to the verbal notification, a written follow-up report is required to be completed as soon as practicable, but no later than 30 days following a release. The completed report is to be sent to the Office of Emergency Services. A form, approved by the Office of Emergency Services, is included on the following page. This form, when filled out, reports follow-up information required by Section 25507 of Chapter 6.95, Article 1 of the H&SC and Title 42 United States Code, Section 11004. Instructions for filling out and mailing the form when complete are also provided. 03320012.001 40 EMERGENCY RELEASE FOLLOW-UP NOTICE REPORTING FORM B DATE OES CONTROL [ [ I I [ I I I I NOTIF~D I I [ [ I I NO I iiiiii?:i:: CHECK IF CHEMICAL IS LISTED IN iiiiii}ill CHECK IF RELEASE REQUIRES NOTIFICATION !!i!::!::!:::: PI-IYSIC,~d.~ STATE CONTAINED ::!!iiii::::::il PHYSICAL STATE RELEASED i}!}i!i}::!}i QUANTITY RELEP~gED iiiiiii!ii ENVIRONMENTAL CONTAMINATION iiiiii!iiiiiii TIME OF RELEASE !:i:i!i!!!!i DURATION OF P~LEASE [] AIR [] WATER [] GROUND [] OTHER iiiiiii~iii :~!i!i~iiiii DAYS HOURS ~ MINLrrES i ACTIONS TAKEN F [] CHRONIC OR DELAYED (~x~lain) [] NOT KNOWN (explain) CERTIFICATION: I he~oy certify und~ penalty ofhw that I have personally ~ and I am fimailiar with t he information mbmitted and bdicve the submitted information i~ l~ue, accurate, and con~i~. I REPORTING FACILITY REPRESENTATIVE (print or typ~) SIGNATURE OF REPORTING FACILITY REPRESENTATIVE DATE EMERGENCY RELEASE FOLLOW-UP NOTICE REPORTING FORM INSTRUCTIONS GENERAL INFORMATION: Chapter 6.95 of Division 20 of the California Health and Safety Code requires that written emergency release follow-up notices prepared pursuant to 42 U.S.C. § 11004, be submitted using this reporting form. Non-permitted releases of reportable quantities of Extremely Hazardous Substances (listed in 40 CFR 355, appendix A) or of chemicals that require release reporting under section 103(a) of the Comprehensive Environmental Response, Compensation, and Liability Act of 1980 [42 U.S.C. § 9603(a)] must be reported on the form, as soon as practicable, but no later than 30 days, following a release. The written follow-up report is required in addition to the verbal notification. BASIC INSTRUCTIONS: · The form, when filled out, reports follow-up information required by 42 U.S.C. § 11004. Ensure that all information :requested by the form is provided as completely as possible. · If the incident involves reportable releases of more than one chemical, prepare one report form for each · chemical release. · If the incident involves a series of separate releases of chemical(s) at different times, the releases should be reported on separate reporting forms. SPECIFIC INSTRUCTIONS: Block A: Enter the name of the business and the name and phone number of a contact person who can provide detailed facility information concerning the release. Block B: Enter the date of the incident and the time that verbal notification was made to OES. The OES control number is provided to the caller by OES at the time verbal notification is made. Enter this control number in the space provided. Block C: Provide information pertaining to the location where the release occurred. Include the street address, the city or community, the county and the zip code. Block D: Provide information concerning the specific chemical that was released. Include the chemical or trade name and the Chemical Abstract Service (CAS) number. Check all categories that apply. Provide best available information on quantity, time and duration of the release. Block E: Indicate all actions taken to respond to and contain the release as specified in 42 U.S.C. § 11004(c). Block F: Check the categories that apply to the health effects that occurred or could result from the release. Provide an explanation or description of the effects in the space provided. Use Block H for additional comments/information if necessary to meet requirements specified in 42 U.S.C. § 11004(c). Block G: Include information on the type of medical attention required for exposure to the chemical released. Indicate when and how this information was made available to individuals exposed and to medical personnel, if appropriate for the incident, as specified in 42 U.S.C. § 11004(c). Block H: List any additional pertinent information. Block I: Print or type the name of the facility representative submitting the report. Include the official signature and the date that the form was prepared. MAIL THE COMPLETED REPORT TO: Chemical Emergency Planning and Response Commission (CEPRC) Local Emergency Planning Committee (LEPC) Attn: Section 304 Reports 2800 Meadowview Road Sacramento, CA 95832 111.3 Environmental Management System a. General Organizational Chart Shown on the following page is an organizational chart for Crystal Geyser Water Company. At the Crystal Geyser Bakersfield location, the Safety Coordinator, Robert Hofferd, will be the Qualified Individual and Safety Coordinator. The Safety Coordinator is responsible for all safety training of employees. The Emergency Contact will be the Quality Assurance Supervisor, Gerhard Gaugel. Any emergency incidents that occur at the facility will be the Emergency Contact's responsibility. Emergency Response Procedures General emergency response procedures are: · Assess the situation. · Isolate and deny entry to the affected area, and evacuate or shelter-in-place. · Provide emergency medical assistance, if necessary. · Notify response agencies and facility response personnel, as appropriate. · Control the release, if possible. · Actively mitigate the release, if properly trained and equipped. · Provide assistance to public agency responders, as necessary. · Terminate the response with proper clean-up and disposal. · Follow-up reporting, evaluation, and critique, as required. 03320012.001 41 Crystal Geyser Water Company May 14, 1999 Peter Gordon 1~ Leo Soong President ych VP Manufacturin, Plant Manager I David Wri,qht ~ Robert Hofferd -~ Gerhard Gau,qel-~ Dee Secara -'~ reduction Superviso.,~ ~. af-'~ ~o~o,~ I OC Supervisor .,~ Io~er ,,) I Armand° Ray° lLead I JuanPin°n I IJ°seMend°zal Lead Sanitation General Evacuation Employees are verbally notified of emergencies by the Incident Commander or designee. All employees are to leave the facility immediately through the parking lot at East California and Lakeview. Emergency evacuation routes and designated meeting places are shown on the following page. These routes have been planned to bypass ammonia systems that may be leaking. Emergency responders will be notified through 911. Fire The sprinkler system will engage when it has detected a fire. All employees are to leave immediately through the nearest exit and regroup at the parking lot at East California and Lakeview. Emergency responders will be notified through 911. Earthquake Employees should remain in safe, stable locations (in doorways, under sturdy desks) until earth movement has ceased. After the earthquake, all employees are to leave the building through the nearest exit as soon as it is safe and regroup at the parking lot at East California and Lakeview, far enough from the building to avoid falling masonry. 03320012.001 42 1233 EAST CALIFORNIA 1233 EAST CALIFORNIA I .L MIX HALLWAY I iI I I r-~ R°°M I I BOTTLE I aox J D.,. T'~ FILLER PACKAGING L.i I L._JCYLINDER$.L _A ROOM T AREA I I ' "' ],,, Tn I I I ~.. I I I I ~I I ~:I I I ~ I ~ I PROCESSING I _ _ _ _~1 AND I AREA o, I L STORAGE AREAt '~' I ---.- - , · I~] I T SHOP / I I I I AND -'- I _L I ~ I FREEZER REA I ~ I [--, z,,<, < .oou I T T REST.OO,,., ALLEY WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER Bakersfield, CA BOTTLING FACILITY 0332.0012 EVACUATION POINTS 4/99 Significant Leak from the Ammonia System Notify the Bakersfield City Fire Department. Employees will be notified through the paging system. All nonessential employees will leave the building through the nearest exit and regroup at the parking lot at East California and Lakeview. Supervisors will ensure employees in their area are evacuated. Mechanics will isolate the ammonia leak if possible. 03320012.001 43 b. Command Accidental Releases During an accidental release, the Quality Assurance Supervisor, Gerhard Gaugel, will act as the facility Incident Manager. As the Incident Manager, he will decide if a release is of a reportable quantity and if necessary will report the incident to the appropriate agencies as stated in Section 111.2. The Safety Coordinator, Robert Hofferd, will act as the Qualified Individual. As the Qualified Individual, the Safety Coordinator will maintain up-do-date safety information on regulated substances, processes and equipment. This safety information will include: · Material Safety Data Sheets (MSDS) that meet Section 5189 of Title 8 of the California Code of Regulations (included on the following pages); · Maximum intended inventory of equipment in which the regulated substances are stored or processed; · Safe upper and lower temperatures, pressures, flows and compositions; and · Equipment specifications. MSDS forms for ammonia meet safety information requirements and are attached. Mana.qement of Chan.qe Any process change will initiate the Management of Change process. This will include the reason for the process change, the priority of the change, technical aspects of proposed equipment, a proposed schedule of the modification and a process hazard analysis if necessary. On the following pages are the Management of Change forms 03320012.001 44 needed to perform this process. A log of all process changes requiring Management of Change also follows. 03320012.001 45 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 PraxairTM Material Safety Data Sheet 1. Chemical Product and Company Identification Product Name: Ammonia, Anhydrous (MSDS No. Trade Name: Ammonia, Anhydrous P-4562-E) Chemical Name: Ammonia Synonyms: Ammonia Gas, Spirit of Hartshorn Formula: NH3 Chemical Family: Alkaline Gas Telephone: Emergencies: 1-800-645-4633' Company Name: Praxair, Inc. CI-W~C 1-800-424-9300' 39 Old Ridgebury Road Routine: 1-800-PRAXAIR Danbury CT 06810-5113 *Call emergency numbers 24 hours a day only for spills, leaks, fire, exposure, or accidents involving this product. For routine information contact your supplier, Praxair sales representative, or call 1-800-PRAX/IIR (1-800-772-9247). For custom mixtures of this product request a Material Safety Data Sheet for each component. See Section 16 for important information about mixtures. INGREDIENT NAME CAS NUMBER PERCENTAGE OSHA PEL IACGIH TLV ! Ammonia, Anhydrous 7664-41-7 >99%* 50 ppm 125 ppm I(TLV-STEL, 15 rain I= 35 ppm). *The symbol ">" means "greater than." I , 3. Hazards Identification , I EMERGENCY OVERVIEW DANGER! Corrosive liquid and gas under pressure. Harmful if inhaled. Causes eye, skin, and respiratory tract bums. May cause kidney and respiratory system damage, Can catch fire. Self-contained breathing apparatus must be worn by rescue workers. Odor: Pungent, irritating THRESHOLD LIMIT VALUE: TLV-TWA = 25 ppm, TLV-STEL (I5 min) = 35 ppm (ACGIH 1997). TLV-TWAs should be used as a guide in the control of health hazards and not as fine lines between safe and dangerous concentrations. Copyright 1979, 1985, 1989, 1992-1993, 1997 Praxair TechnologY, Inc. Page 1 of 8 All rights reserved. Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 EFFECTS OF A SINGLE (ACUTE) OVEREXPOSURE: INHALATION-Overexposure to concentrations moderately above the Threshold Limit Value (TLV) of 25 ppm may irritate the eyes, nose, and throat. Higher concentrations may cause breathing difficulty, chest pain, bronchospasm, pink frothy sputum, and pulmonary edema. Overexposure may predispose to acute bronchitis and pneumonia. SKIN CONTACT-Liquid may cause moderate to severe redness, swelling, and ulceration &the skin, depending on the degree and duration of contact. At high concentrations, gas may cause chemical burns. Prolonged or widespread skin contact may result in the absorption of potentially harmful amounts of material. SWALLOWING-An unlikely route of exposure; this product is a gas at normal temperature and pressure. But exposure, should it occur, may cause chemical burns of the mouth, throat, esophagus, and stomach. EYE CONTACT-Liquid may cause pain, severe redness, and swelling of the conjunetiva, damage to the iris, corneal opacification, glaucoma, and cataracts. Gas may cause pain and excessive tearing with acute corneal injury at high concentrations. EFFECTS OF REPEATED (CHRONIC) OVEREXPOSURE: Chronic exposure may cause chemical pneumonitis and kidney damage. OTHER EFFECTS OF OVEREXPOSURE: None known. MEDICAL CONDITIONS AGGRAVATED BY OVEREXPOSURE: Inhalation may aggravate asthma and inflammatory or fibrotic pulmonary disease. Skin irritation may aggravate an existing dermatitis. SIGNIFICANT LABORATORY DATA WITH POSSIBLE RELEVANCE TO HUMAN HEALTH HAZARD EVALUATION: None known. CARCINOGENICITY: Ammonia, Anhydrous is not listed by NTP, OSHA, and IARC. I 4. First Aid Meas, ures ,, , [ INHALATION: Remove to fresh air. If not breathing, give artificial respiration. WARNING: Rescuer may receive chemical burns from giving mouth-to-mouth resuscitation. If breathing is difficult, qualified personnel may give oxygen. Keep patient warm. Call a physician. SKIN CONTACT: Immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Discard clothing and shoes. Call a physician. SWALLOWING: An unlikely route of exposure; this product is a gas at normal temperature and pressure. Give a~ least two glasses of water or milk at once, Do no~ induce vomiting. Call a physician. EYE CONTACT: Immediately flush eyes thoroughly with water for at least 15 minutes. Hold the eyelids open and away from the eyeballs to ensure that all surfaces are flushed thoroughly. See a physician, preferably an ophthalmologist, immediately. NOTES TO PHYSICIAN: Victims of overexposure should be observed for at least 72 hours for delayed edema. The hazards of this material are mainly due to its severe irritant and corrosive properties on the skin and mucosal surfaces. There is no specific antidote, and treatment should be directed at the control of symptoms and clinical condition. Page 2 of 8 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 I 5. Fire Fighting Measures FLASH POINT Flammable Gas AUTOIGNITION 1204°F (651°C) (test method) TEMPERATURE FLAMMABLE LIMITS I LOWER 15% IUPPER 28% IN AIR, % by volume ' EXTINGUISHING MEDIA: CO2, dry chemical, water spray, or fog. SPECIAL FIRE FIGHTING PROCEDURES: DANGER! Toxic, corrosive, flammable liquefied gas under pressure (see section 3). Evacuate all personnel from danger area. Do not approach area without self-contained breathing apparatus and protective clothing. Immediately cool cylinders with water spray from maximum distance, taking Care not to extinguish flames. Remove sources of ignition if without risk. If flames are accidentally extinguished, explosive reignition may occur. Reduce corrosive vapbrs with water spray or fog.. Stop flow of gas if. without risk, while continuing cooling water sprayi'Remove all containers.from.area· of fU'e if WithbUt.Hsk. ':' ."': .! Allow fire to burn out. On-site fire brigades must comply with 0SHA29 'CFR 191-0.1561' : ' "" .. ': '. UNUSUAL .FIRE AND EXPLOSION HAZARDS: Forms explosive mixtures with air and oxidizing agents. Heat of fn'e can build pressure in cylinder and cause it to rupture; no part of cylinder should be subjected to a temperature higher than 125°F (52°C). Ammonia cylinders are equipped with a pressure relief device. (Exceptions may exist where authorized by DOT--In this case, where the cylinders contain less that 165 pounds of product.) If leaking or spilled product catches fire, do n°t extinguish flames. Flammable and toxic vapors may spread from leak and could explode if reignited by sparks or flames. Explosive atmospheres may linger. Before entering area, especially a confined area, check atmosphere with an appropriate device. Reverse flow into cylinder may cause it to ruptUre. To protect persons from cylinder fragments and toxic fumes-should a rupture occur, evacuate the area if the fire cannot be brought under immediate control. HAZARDOUS COMBUSTION PRODUCTS: See section 10. ] 6. Accidental Release Measures STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED: DANGER! Toxic, corrosive, flammable liquefied gas under pressure (see section 3). Forms explosive mixtures with air (see section 5). Keep personnel away. Before entering area, especially a confined area, check atmosphere with an appropriate device. Use self-contained breathing apparatus and protective clothing where needed. Remove all sources of ignition if without risk. Reduce vapors with fog or £me water spray. Shut off flow if without risk. Ventilate area or move cylinder to a well-ventilated area. Contain spills in protected areas; prevent runoff from exposing personnel ito liquid and vapors and contaminating the surrounding environment. WASTE DISPOSAL METHOD: Prevent waste from contaminating the surrounding environment. Keep personnel away. Discard any product, residue, disposable container or liner in an environmentally acceptable manner, in full compliance with federal, state, and local regulations. If necessary, call your local supplier for assistance. I 7. Handling and Storage PRECAUTIONS TO BE TAKEN IN STORAGE: Store and use with adequate ventilation. Firmly secure cylinders upright to keep them from falling or being knocked over. Screw valve protection cap firmly in place by hand. Store only where temperature will not exceed 125°F (52°C). Store full and empty Page 3 of 8 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 cylinders separately. Use a first-in, first-out inventory system to prevent storing full cylinders for long periods. PRECAUTIONS TO BE TAKEN IN HANDLING: Protect cylinders from damage. Use a suitable hand truck to move cylinders; do not drag, roll, slide, or drop. Never attempt to lift a cylinder by its cap; the cap is intended solely to protect the valve. Never insert an object (e.g., wrench, screwdriver, pry bar) into cap openings; doing so may damage the valve and cause a leak. Use an adjustable strap wrench to remove over-tight or rusted caps. Open valve slowly. If valve is hard to open, discontinue use and contact your supplier. For other precautions in using ammonia, anhydrous, see section 16. For additional information on storage and handling, refer to Compressed Gas Association (CGA) pamphlet P-l, "Safe Handling of Compressed Gases in Containers," available fi.om the CGA. Refer to section 16 for the address and phone number along with a list of other available publications. 8. Exposure Controls/Personal Protection 'VENTILATION/ENGINEERING CONTROLS " : ' · i. i' ·' LOCAL EXHAUST-Use a local exhauStl.ventilation System 'with sUfficient aii; flow velocity to' .. maintain concentration below the TLV in the worker's breathing zone. MECHANICAL (general) Not recommended as a primary ventilation system to control worker's exposure. SPECIAI.MJse only in a closed system. An explosion-proof, corrosion-resistant, forced-draft fum~ hood is preferred. OTHER-None. RESPIRATORY PROTECTION: Use air-supplied respirators for concentrations up to 10 times the applicable permissible exposure limit. For higher concentrations, a full-face, self-contained breathing apparatus operated in the pressure demand mode is required. Respiratory protection must conform to OSHA rules as specified in 29 CFR 1910.134. PROTECTIVE GLOVES: Neoprene. EYE PROTECTION: EYE PROTECTION: Wear safety glasses when handling cylinders; vapor-proof goggles and a face shield during cylinder changeout or wherever contact with product is possible. Wear safety glasses when handling cylinders; vapor-proof goggles where needed. Select per OSHA 29 CFR 1910.133. OTHER PROTECTIVE EQUIPMENT: Metatarsal shoes for cylinder handling. Protective clothing where needed. Select per OSHA 29 CFR 1910.132 and 1910.133. Regardless of protective equipment, never touch live electrical parts.. . 9. Physical and Chemical Properties I MOLECULAR WEIGHT: 17.031 EXPANSION RATIO: Not applicable SPECIFIC GRAVITY (air=l): At 32°F (0°C) SOLUBILITY IN WATER: Appreciable and 1 atm: .5970 GAS DENSITY: At 32°F (0°C) and 1 atm: VAPOR PRESSURE: AT 70°F (21.1°C): .0481 Ib/ft3 (.771 kg/m3) 114.1 psig (786.7 kPa) PERCENT VOLATILES BY VOLUME: 100 EVAPORATION RATE (Butyl Acetate=l ): High BOILING POINT (1 arm): -28°F (33.3°C) pH: Not applicable Page 4 of 8 Product: Ammonia,,~Anhydrous Form No.: P-4562-E Date: October 1997 FREEZING POINT (1 atm): -107.9°F (-77.7°C) APPEARANCE, ODOR, AND STATE: Colorless gas at normal temperature and pressure; pungent, irritating odor. I 10. Stability and Reactivity I STABII ~YrY: I Unstable [ ] Stable I X INCOMPATIBIIJTY (materials to avoid): Gold, silver, mercury, oxidizing agents, halogens, halogenated compounds, acids, copper, copper-zinc alloys (brass), aluminum, chlorates, zinc HAZARDOUS DECOMPOSITION PRODUCTS: The normal products of combustion are nitrogen and water. Hydrogen may be formed at temperatures above 1,544°F (840°C). CONDmONS TO AVOID: None known. ':' ' ' '"' :'" ': : . I 11. Toxicological Information [ LCd0 = 7338 ppm, 1 hr, rat. 12. Ecological Information I Ammonia, Anhydrous does not contain any Class I or Class II ozone-depleting chemicals. Ammonia, Anhydrous is not listed as a marine pollutant by DOT. I13. Disposal Considerations ] WASTE DISPOSAL METHOD: Keep waste from contaminating surrounding environment. KeeP personnel away. Do not dispose of unused quantities. Return cylinder to supplier. I 14. Transport Information I DOT/IMO SHIPPING NAME: Ammonia, HAZARD CLASS: 2.2 (domestic shipment) anhydrous, liquefied 2.3 (international shipment) IDENTIFICATION NU1VIBER: LIN 1005 PRODUCT RQ: 100 lbs (4.'54 kg) SHIPPING LABEL(s): NONFLAMMABLE PLACARD (When required): NONFLAMMABLE:. GAS (domestic); TOXIC GAS, coRRosIVE GAS (domestic); TOXIC GAS, CORROSIVE: ': (international) (international) SPECIAL SHIPPING INFORMATION: Cylinders should be transported in a secure position, in a well-ventilated vehicle. Cylinders transported in an enclosed, nonventilated compartment of a vehicle can present serious safety hazards. Additiottal Marking Requirement: Inhalation Hazard (for international shipment) Shipment of compressed gas cylinders that have been filled without the owner's consent is a violation of federal law [49 CFR 173.301(b)]. Page 5 of 8 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 I I Regulatory Information The following selected regulatory requirements may apply to this product. Not all such requirements are identified. Users of this product are solely responsible for compliance with all applicable federal, state, and local regulations. U.S. FEDERAL REGULATIONS: EPA (Environmental Protection Agency) CERCLA: Comprehensive Environmental Response, Compensation, and Liability Act of 1980 (40 CFR Parts 117 and 302): Reportable Quantity 0iQ): 100 lbs (45.4 kg) SARA: Superfund Amendment and Reauthorization Act: · SECTIONS 302/304: Require emergency planning based on Threshold Planning Quantity (TPQ) and release reporting based on Reportable Quantities (RQ) of extremely hazardous substances (40 CFR Part 355): Threshold Planning Quantity (TPQ): 500 lbs (226.8 kg) Extremely Hazardous Substances (40 CFR 355): None · SECTIONS 311/312: Require submission of Material Safety Data Sheets (MSDSs) and chemical inventory reporting with identification of EPA hazard categories. The hazard categories for this products are as follows: IMMEDIATE: Yes PRESSURE: Yes DELAYED: Yes REACTIVITY: Yes FIRE: Yes · SECTION 313: Requires submission of annual reports &release of toxic chemicals that appear in 40 CFR Part 372. · Ammonia, Anhydrous requires reporting under Section 313. 40 CFR 68: Risk Management Program for Chemical Accidental Release Prevention: Requires development and implementation of risk management programs at facilities that manufacture, use, store, or otherwise handle regulated substances in quantities that exceed specified thresholds. Ammonia, Anhydrous is listed as a regulated substance in quantities of 10,000 lbs (4536 kg) or greater. TSCA: Toxic Substances Control Act: Ammonia, Anhydrous is listed on the TSCA inventory. ' OSItA (OCCUPATIONAL SAFETY AND I:[EALTH ADMINISTRATION): 29 CFR 1910.119: Process Safety Management of Highly Hazardous Chemicals: Requires facilities to develop a process saf~y management program based on Threshold Quantities (TQ) of highly hazardous chemicals. Ammonia, Anhydrous is listed in Appendix A as a highly hazardous chemical in quantities of 10,000 pounds (4536 kg) or greater. Page 6 of 8 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 STATE REGULATIONS: CALIFORNIA: This product is not listed by California under the Safe Drinking Water Toxic Enforcement Act of 1986 (Proposition 65). PENNSYLVANIA: This product is subject to the Pennsylvania Worker and Community Right-To-Know Act (35 P.S. Sections 7301-7320). I 16. Other Information,, , [ Be sure to read and understand all labels and instructions supplied with all containers of this product. OTHER HAZARDOUS CONDITIONS OF HANDLING, STORAGE, AND USE: Toxic, corrosive, flammable, liquefied gas under pressur~ Do not breathe gas. Do not get vapor or liquid in eyes, on skin, or on clothing. (See section 3.) Have safety showers and eyewash fountains immediately available. Use piping and equipment adequately designed to withstan~d pressures to be encountered. Store and use with adequate ventilation at all times. Prevent reverse flow. Reverse flow into cylinder may cause rupture. Use a check valve or other protective device in any line or piping from the cylinder. May form explosive mixtures witIt air. Keep away from heat, sparks or open flame. Ground all equipment. Use only spark-proof tools and explosion-proof equipment. Store and use with adequate ventilation at all times. Use only in a closed system. Close valve a~er each use; keep closed even when empty. Keep away from oxidizing agents and from other flammables. Never worl~ on a pressurized systena If there is a leak, close the cylinder valve. Blow the system down in an environmentally safe manner in compliance with all federal, state, and local laws, then repair the leak. Never ground a compressed gas cylinder or allow it to become part of an electrical circuit. NOTE: Prior to using any plastics, confirm their compatibility with ammonia, anhydrous. MIXTURES: When you mix two or more gases or liquefied gases, you can create additional, unexpected hazards. Obtain and evaluate the safety information for each component before you produce the mixture. Consult an industrial hygienist, or other trained person when you evaluate the end product. Remember, gases and' liquids have properties that can cause serious injury or death. HAZARD RATING SYSTEMS: NFPA RATINGS: HMIS RATINGS: HEALTH = 2 (gas) 3 (liquid) HEALTH = 3 FLAMMABILITY = 1 (gas) 1 (liquid) FLAMMABILITY = 1 REACTIVITY = 0 (gas) 0 (liquid) REACTIVITY = 0 SPECIAL None STANDARD VALVE CONNECTIONS FOR U.S. AND CANADA: THREADED: CGA-705, CGA-240 Standard, CGA-660 Limited Standard PIN-INDEXED YOKE: Not applicable ULTRA-HIGH-INTEGRITY CONNECTION: CGA-720 Use the proper CGA connections. DO NOT USE ADAPTERS. Additional limited-standard connections may apply. See CGA Pamphlet V-1 listed below. Page 7 of 8 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 Ask your supplier about free Praxair safety literature as referenced on the label for this product; you may also obtain copies by calling 1-800-PRAXAIR. Further information about ammonia, anhydrous, can be found in the following pamphlets published by the Compressed Gas Association, Inc. (CGA), 1725 Jefferson Davis Highway, Arlington, VA 22202-4102, Telephone (703) 412-0900. P-1 Safe Handling of Compressed Gases in Containers V- 1 Compressed Gas Cylinder Valve Inlet and Outlet Connections Handbook of Compressed Gases, Third Edition Praxair asks users of this product to study this Material Safety Data Sheet (MSDS) and become aware of product hazards and safety information. To promote safe use of this product, a user should (1) notify employees, agents and contractors of the information on this MSDS and of any other known product hazards and safety information, (2) furnish this information to each purchaser of the product, and (3) ask each purchaser to notify its employees and customers of the product hazards and safety information. The opinions expressed herein are those of qualified experts within Praxair, Inc. We believe that the information contained herein is current as of the date of this Material Safety Data Sheet. Since the use of this information and the conditions of use of the product are not within the control of Praxair, Inc., it is the user's obligation to determine the conditions of safe use of the product. I Praxair MSDSs are furnished on sale or delivery by Praxair or the independent distributors and suppliers who package and sell our j3mducts. To obtain current Praxair MSDSs for these products, contact your Praxair sales representative or local distributor or supplier. If you have questions regarding Praxair MSDSs, would like the form number and date of the latest MSDS, or would like the names of the Praxair suppliers in your area, phone or write the Praxair Call Center (Phone: 1-800-PRAXAIR; Address: Praxair Call Center, Praxair, Inc., PO Box 44, Tonawanda, NY 14150-7891 ). Praxair is a trademark of Praxair Technology, Inc. Praxair, Inc. 39 Old Ridgebury Road Danbury CT 06810-5113 : PRAXAIR Printed in USA Page 8 of 8 MATERIAL SAFETY DATA SHEET PRODUCT NAME: PROPYLENEGLYCOL CAS NUMBER: 57-55-6 HBCC MSDS NO. CP21000 ~¢~,~.u '~'~""t, HILL BROTHERS CHEMICAL CO. h lJ ? NO. Main Street .4b.ir,,.~ Orange, Cali'lornia 92667 Telephone No' 714-998-8800 l)_.~,te¢/~' Outside Calif: 800-821-7234 ~ ~ C H EMTR EC: 800-424 o 9300 Revision issued' 7125191 Supercedes: 7/31/89 First issued' 4/10/89 J.l~,t~¢J~T..,~'r! Rea, d lhi$ M~D$ be~OLe__q.s.c:_qr disoosal el lhis orodu~l. E~S~_~9 lhe information to i~0rm~lio~ e~Jore use or olher exBosure. This MSDS has ~en prepared according 1o the OSHA H~ard Communicalion Sl~ndard [29 CFR 1910.1200]. The MSDS information is ba~d on sources ~lieved Io be reliable. However, since data, salely s~andards, and governmenl regulations are subjec: Io change and lhe conditions of handling and use, or misuse are ~yond our control, HILL BROTHERS CHEMICAL COMPANY m~kes no warranty, eilher e~pressed or impli¢, with respecl ~o ~he completeness or continuing accuracy el ~he information comained herein and disclaims all liabili[y for reliance 1hereon. Aisc. additional informalion may be necessaw or helpful tot s~cific condilions and circumstances o~ use. II is th'e user's responslbili~ ~o determine 1he suitability of this pr~uct ~nd 1o evaluate risks prior to use, and 1hen to exercise ~ropri~le precautions lot pro~ecfion of ~mployees and olhers. [SECTION I - PRODUCT IDENTIFICATION ,, ' SYNONYMS / COMMON NAMES: PROPYLENE GLYCOL; C3H802 CHEMICAL FAMILY / TYPE: OXYGENATED HYDROCARBON DOT PROPER SHIPPING NAME: N/A DOT HAZARD CLASS / LD, NO,: N/A REPORTABLE QUANTITY: N/A NFPA RATING: HEALTH - 0; FIRE - 1' REACTIVI~ - 0 0=lnsignificanl 1 =Slighl 2=M~erale 3=High 4-E~r~me [SE"~TION !1- HAZARDOUS INGREDIENTS CAS Exposur~ Llmlls (TWAs) In Air Chemical Na~e Number % ACGIH TLV OSHA PEL STEL' PR~ENE GLY~L 57.55- 6 100 N/A N/A N/A 'ACGIH short 1erm exposure limi~ (STEL) ~SECTION III - PHYSICAL AND CHEMICAL PROPERTIES Phy~lcol Slole: LIOUID Appearance/Color/Odor: COLORLESS; ODORLESS Product/Trade Name : PROPLYLENE GLYCOL [SECTION III - PHYSICAL AND CHEMICAL PROPERTIES CONTINUED pH: N/A M~ltlng Polnt/R~nge: N/A Bolling Point/Ran§o: 369.1° F Solubility in W~ter: 100% Vapor Prossure(mmHg): NEGLIGIBLE Specific Gravity(Water : 1): 1.038 Molecular Weight: 76.10 Vapor Density(Air = 1): 2.6 % Volatllos: NEGLIGIBLE How lo delect this compound : N/A JSECT.ION IV - FIRE AND EXPLOSION J Fl~sh Petal: 214°F - 225°F Autolgnltlon Tomper,,turc: 790°F Lower Exploalve Limit: .2.6 Upper Explosive Limit: 12.5 Unusual Fire and Explosion H~zards: This material may burn. bt~t will not {gnito readily. cea;air,er is not prol:~trly cooled, it may explode in the heat el a 'fire. Vapors are heavier than air and may accumulate in Iow areas. Extinguishing Media: Ca. rbon dioxide. Helen. Polar or Alcohol- ly~'-m loam. or water spray is recommended. Water ma>' be ineffective. ,~pe~ci,-3.1 FiraJlgh!ing Prccecures: Wear appropriale protective equipmen; includin_c resDir,'3, tory proleclion as conditions w~rranL Stop spill/release Il it can be done withou; risk. Move undamaged containers Item fire area if it can be done without risk. Water spray ma)' be usetul in minimizing or dispersing and cooling equipment exposed Io heat and I'lame. Avoid spreading burning liquid wilh water used for cooling [SECTION V - REACTIVITY Stability: Slable Hazardous Polymerization: Will Not Occur Condltlon.~ to Avoid: N/A Matorial~ to Avoid: N/A Hazardous Decomposition Products: Cornbuslion may yield carbon monoxide an/or carbon dioxide. Do not brealhe smoke or fumes. Wear appropriat(~ protective equipment. ISECTION VI- HEALTH HAZARDS Routes of Exposure: Summary of Acute Health Hazard=: (Statement) INGESTION: While ~his malarial has a Iow degree of toxicity, ingestion of excessive quand~ies may cause signs o~ nervous system depression (e.g.. headache, drowsiness, loss el coordinalion and ~a~igue}. N/A Not Applicable PAGE 2 OF 4 Product/Trade Name : PROPLYLENE GLYCOL JSECTION VI- HEALTH HAZARDS CONTINUED INHALATION: While this material h;{.'; a Iow volatility, exper, ute lo v;zpor., is unlikely, however, vapor,~ or mists produced under car',am condifionr, el use may cause .rages of n(¢rvous system depression (e.g., headache, drowsiness, loss el coordination and latigue). SKIN:- May cause mild skin irritation. Prolonged or repealed contact may cause redness, burning r~nd drying and cracking el tho skin. Persons with pro-exisling skin disorders may be more susceplible to efiects of this material. EYES: This malarial may cause mild eye ,rritallon. Direc~ conlacl w~th me liquid or exposure to vapors or misls may cause slinging, tearing and redness. Carclnogenlclty Llsf~: NO l',rTP: NO IARC Monograph: NO OSHA Regulat~l: NO Summary oi Chronic Health Hazards: Effects of Overexposure: N/A Emergency and FIr.~t Aid Procedur~: INGESTION: No first aid is normally required: however, if swallowed, arid symptoms develop, seek medical attention. iNHALATION: If respiratory symptoms develop, move victim away from source 'cf exposure and into fresh air. I; symploms persist, seek medical artonlion. If victim is not breathing, immediately begin artificial respiration. If breafhing difficulties develop oxygen should be adminislered by qualified pemonnel. Seek immediate medical a,'lention. SKIN: Wash wilh soap and water. EYES: Flush with plen:y of waler. Medical Conditions Generally Aggravated by Exposure: NIA Note to Physlclan~: N/A ISECTION VII - PRECAUTIONS FOR SAFE HANDLING AND USE Stops To Be Taken In Ca.~e Material ls Released Or Spilled: Small s'pills: So;:tk up with absorbent malarial Large spillS: Dike and pump into suilabio containers for Handling and Storing Precautions: Normal precautions common to good m~nulacturln9 practice should be lollowed in handling and storage. Waste Disposal Methods: Dispose of tn accordance, wilt) applicable local, county, state and tederal regulations. Other Precaution=: N / A N/A - No! Applicable PAGE 3 OF 4 Product/Trade Name : PROPLYLENE GLYCOL {SECTION VIII - CONTROL MEASURES Respiratory Protection: R(.~spiralory prnlnction may bo r~ecut;sary to n~inimiz, e e×l~os~r~ l.)~pRnding on ~ho nalt~r(~ ;]nd cor~cont~ation el the airborne m,alori;tl, u~;u a ~espira~or or gas mask wi~h approprinle cartridges and carmislefs (NIOSH spproved) or suppli~ air equipment. Vonlllalion: General room ventilation is s;lli~;f;iclory. Additional venliialion or exhatJst syslems ~ require~, wher~ ex[)losive mixlure~ may ~ present. El~tricnl Prol.ctlvo Clolhing: Rubber gloves are recommended. Eye Prolectlon: S~Iew glasses and or face st~iold is recommendS. Other Prolecltve Clothing or Equipment: I1 ~v~ilable in the work area for flushing eyes and skin, Im~wiot;s clolhir~g si)ould be worn. WorWHyglonic Pracllces: All employees who h~ndle this product should wash their hands be[ore eating, smoking, or using loilel facililies. N/A - Not Applicable PAGE 4 OF zi ~ FORM MOC-IB .~ MOC NUMBER SECTION 1: IHITIATION OF MANAGEMENT OF CHARGE FORM Section I is to be completed by individual originating the MOC and forward to the Maintenance supervisor. ORIGINATED BY' DATE: NAME OF PROJECT: PRIORITY OF REQUEST: (CHECK ONE) . ,, {.__} CRITICAL, Affected portion ofsystem shouid by iock out and tagged to prevent operation until safety issue(s) resolved. ( } URGENT, Affected portion of system should be tagged and operated short term with caution until safety issue(s) resolved. {__} IMPORTANT. Affected portion of system should be tagged and operated with caution until safety issue(s) resolved. { __ } ROUTINE, Affected portion of system should be noted and work to resolve minor safety !ssue(s) scheduled. Sr. ASON FOR REq ST:' icm c {.__} Incident Invest/gation Recommendation (Ref. No. ) {__} Mechanical Integrity Audit Recommendation (Ref. No. {.~} Pre-start Safety Review Recommendation (Ref. No..) {__} Process Hazard Analysis (Ref. No..) (.__} Change in Refrigeration ReqUirements { __ } Expansion or Renovation of Facility or Systems ( __ } Other (Explain) Re-location due to Production d~mands. DESCRIPTION OF TECHNICAL BASIS FOR CHANGE (PURPOSE, ALTERNATIVES~ REFERENCE SKETCHES OR DRAWINGS): ,, FORM MOC- 1C MOC NUMBER. SECTION 2: SCREEN OF MANAGEMENT OF CHANGE FORM Section 2 is to be completed by the Utility Team Coordinator, ~nd then a copy of the MOC is to be forwarded to the Group Leader. If the requested modification constitutes a chanse, Sections 2-6 mu t be completed. Reviewed by: . r Date: ASSESS TECttNICAL BASIS OF CHANGE The modifie~ion as described in Section 1 |s.cl$.aaified ~ (please check appropriate sp ): , Technical Basis Asse$oment Next A~Cion I~ the change a ~-pla~ement in {_} Replacement in kind Change is not pa~ of MOC kind? arocedm~. ( ~- } Change is not a MOC pt'ocedure must be ~pla~ement in kind followed. I~ the modification a m~jor or {... } Modification is a minor Process ~,,xi analysis is not {. ) Modification is a major Proc~ ~ analysis is change r~qulred. Is ~e ctumge per,,~,,ent or { } Change is permanent temporary? {_} Change is temporary Fill in section on MOC concerning duration of change. Is the ctumge necessary, { } Yes Change should be fot~uxled for action7 {_} No Clum$o should not bc ,, , implemented. ~'ORM MOC4D MOC NUMBER DURATION OF CHANGE If the change is temporary, note duration here: No temporary change should be granted more than five one-week extensions or be allowed to extend beyond six wee~ including any extensions. The table below should be used to track temporary change~. $CH~-DULE FOR TEMPORARY CHANGES Jnifiafion Date Expiration.Date Authod~tion Initial request. Ext~sion//1 ~x~en~ion//2 Extension//3 Extension #4 Extension #5 UPDATING PROCESS SAFETY INFO~ON, PROCEDURES, AND DOCUMENTATION Identi~t the po0ce~ safety hlfo _rm.5_ fion which needs to be ~-wi~xl ~s are/mit offlli~ change. Reference # Reference # Process flow diagram~ Piping and instrum~tation di%vr~m_~ Am-m-~. equyme~t ~ Ammonia instrument lists Criteria for design and operation Standard operating procedures Audit l~ogram ]~ROM 2 ½" AND I./P V~.L ~ TO BE BUTT w~-r)s ,AND A X-RAY PERFOR_.MI~ SECTION 3: PRELIMINARY ENGINEERING PRELIMINARY DESIGN REVIEWED BY: Date: UTILITY TEAM COORDINATOR: D~tc / REFRIGERATION GROUP I.F. ADER: DATE /~/ FORM MOC-IE MOC NUMBER # SECTION 4: SAFETY REVIEW CHECKLIST Date Completed: ~/ / Safety review checklist reviewed by: Date: SECTION 5: PROCESS HAZARD ANALYSIS (~ffanalysis is pv"rf0rmed) Date H~rd Analysis Completed Doe~ the process hazard analysis ~cldress the impact of change on safety and health? (Check one) (_ _ }yes ( .}no Hazard mudysis report reviewed by:. Date SECTION 6i STARTUP AUTHORIZATION Have all applicable drawings, procedure~ and documentation noted in Section 2 been revised ~ccordingly (Check one) { } Yes (_} no Have all appropriate operators, maintenance personnel, been informed of and trained in the change? (Check one) { __ } Yes {,~} no Have all, if'any, recommendations from the preliminary engineering, safety and health review and the process ha:,~rds analysis been address~-d? (Check one) { } Yes { } no Authorization should be given to accept this change and proceed with start-up of the modification if and only if the answers to all of the above questions are "Yes". Authorization for change and start-up is given by: PI-lA Team Leader: Date: / / Utility Team Coordinator: Date: / / __ Group Leader: Date: __/ / Plant Manager: Date: / /__ M0C NO 98..007 SAFETY REVIEW CHECKLIST . ~UESTION A REMARKS RECOMMENDATIONS BY COMMENTS 1. Li~ th~ ~ mi mmtmta ~ whic~ tl~ " ' ...... NO, ,L, QUESTION A ~S RECOMMENDATIONS BY COMMENTS MOC 98-007 SAFETY REVIEW CHECKLIST QUESTION A 1~~ RECOMMENDATIONS BY COMMENTS 14. la et~caial lXmer,,~ otl~ smfc~ (~.c. MANAGEMENT OF CHANGE FROM (MOC) LOG MOC NUMBER DATE MO(; DA'I'F, INITIAL DATE'IN1TIAL DATE BAFETY DATg I-IAZ~RD DATE F~R START-UP ~ oF REV~ ENOn~UNO REVIEW ANALYSIS AD"ntOR~TE~ DATE ¢OMF~ C~-~T COMPLETI~ OF (2HANGE /';.!~:33. !3:08 FAX C G B -~ BRUNDAGE WHSE [~001 iTEM ~4 13.0 Prelimin~ dete~imtions "Cle~g in Pl~e". This sy~em pro~ is work~g properly ~d does not require modification. . A study of~e system did yield ~ improvement to prevent over press~efizing d~ing hot ' C.I.P. operator e~or ~d or system failme hm resulted in a blom press~e relief valve. ~e suction line aflach~ the sure ~ above ~e c~-~01er has a back press~e "2" ' ~n line at 30 psi. We ~e going to ~stall a by-pros back press~e re~lator, which we will set mech~c~ly ~o~d 75 m 1~ psi. ~is ~ compensate for ~ increase ofpress~e ~m C.I.P. ~ctions ~d allow the vapor to flow back to master accmulator ~thout blo~ng the press~e relief v~ve. OPERATING INSTRUCTIONS BAKERSFIELD, FACILITY NORMAL OPERA~NG.!NSTRUCTIONS In this facility the operator is the maintenance man as well as the operator. The refrigeration machinery runs automatically. The normal operating procedure is to check and log process pressures, temperatures liquid levels, lubrication, and pertinent changes and data on all the refrigeration'machinery about two times in each eight hour working day. He will check the items listed in this RMPP Book under Management Programs, Section 3, Operators responsibilities and Section 5, Engineering Logs. He Is tO analyze the machinery and logs. When they differ from design or established limits, he is to determine the cause and make corrections immediately. He will also make the routine checks and complete the required maintenance spelled out in Section 6, Preventative Maintenance Procedures under Management Programs. He is to log all inspections, findings, and maintenance performed either in the daily engine room log, or machinery log book as he chooses. ~HUTDQWN OPERATING IN.STRI, ICTIONS Under normal conditions, it is very safe to shut down the refrigeration machinery by · la, pushing the stop button e~ the ~h~'l~ard in the engineers office or fi..,r.e__rn_e~'s emergency .'b~x. When it is pushed, all compressors and ammonia pumps stop, and the '~---~, electric liquid ammonia feed king valve is de-energized and closes. All machinery' remains in this state until the.. C, 6 i rD.. ,~,.¢ g~ In this stopped condition, the evaporator solenoids and fans remain energized and operating. Ammonia cannot feed the evaporators because the king valve Is closed. '-~ . ~h-- hlnh HIe,',ho,',",=_.~____ _ h.-.,~a. ...... ~ ,~. The ammonia compressors and pumps have check .valves In fine that don't allow the process fluid 'to flow backwards in the system. The refrigeration process pressures usually equal out to ambient temperature pressures. When you are to be off for an extended period of time a controlled shutdown is best. !~ La a..~s follows: 1, Make a printout 'of all process set points and limit settings. The mi~::roprocessors have a battery backup that lasts from two to four hours. If you are planning to shut off the power for an extended period of time, you could loose these .settings. Jt makes it a lot easier if you have this record when you start. ~,,~ ~.. ~ ~., ~ . 2. Shut off manual hot gas king valve ~, the re~f, and the liquid ammonia king valve up stream of the electric solenoid king valve in the engine room. Allow time for some ammonia in the evaporators, LP and HP pump receivers, and feed piping to boll off and return to the receiver. Liquid ammonia in the pumped liquid recirculating circuit to the evaporators tends to flow back and fill the Iow pressure receiver after compressors and pump are stopped. This makes start-up difficult if liquid height in the vessel is near the high level float cut out. If possible, let the system run until you see the ammonia in the LP and HP pump receivers drop a few inches below the operating level, Operating instructions- Page I and you see frost forming on lhe liquid ammonia feed piping. i~.-~!_~_~ n~H,l~,.,~_ ...... ,~ ~_~4 a~an!~ q,~a~lif~ 1, i~ ~. You ~n let the s~tem mn as long as the ammonia pump d~s not ~vitate, 3. Stop the liquid ammonia fe~ pump. (Remem~r to taq-out and ~ite down eve~hing you shut off and close.) 4. S~p ali eva~rator fans at each indi~dual ei~t~ml ~ off. 5. Stop all ~mpmssom using the stop button on each ~mpmssor micm~ssor panel. Stop the b~ster ~mpressom tirol and ~e 8e~nd stage ~mpmsom last. Mom ~an lik~y, t~y ~11 ~ ~ding on and off at this point ~use of the indued mffigemtlon load. Make sum yob push the stop b~ton, and the monitor marls "stop". 6 Shut off ~ndenser fans, and pumps. Allowing a little time for the ~ndensers to c~l and the head pressure to ~mes d~n 7. If y~ am making a ~mplete elect~l shutd~n: a. Make sum all offi~ mputem off. b. Make sum all pemon~l am o~ of unlighted areas. c. Sh~ off each el~d~l panel individually ~th dmuit breaker on the main el~fi~! panel in ~e engine d. Shut off main power clmult breaker on main electdml panel in the engine mm by turning t~p lever. START-UP Op,~NG INSTRUCTIONS 1. Make sure all el~tfi~l panel ~muit bmakem, and ~mpressor cir~it bmakem are in ~e off position so you will not have a [a~e p~er surge when you cl~e the main ~er s~tch. 2. Close ~e main ~r swit~ ~th hand lever. It is spring loaded and bangs in rather ha~. 3. S~tch on all electH~l panels a[ their individual dmuit bmakem on the main el~tH~l panel in the~ mom. 4. S~tch on ~mpmssor end any remaining cimuit breakers. 5. Check ~mpmssor m[cmpro~ssom. Make sum they are in the stop position. Che~ ell microp~ssom to see that ~ey am up and running, and have retained their pm~r set point. NOTE: Scmw.~mpmssom have heatem in the oil sump, and the mi~p~ssors. will not let the ~mpmssom stad until the oil ma~es the oil separator temperature lower limit set ~tnL If the ~r has ~en off an e~end~ time, this may ~ke as long as four to six houm. 6. S~ ~ndenser fans and pumps. ~en pumps am stopped, water that has been entrained in the air flow, ove~ d~n the drain. Allow time for water sump to fill before g~ng to the n~ step. 7. Sta~ high side ~m~essor in the unloaded position. Gradually I~d the ~mpressor manually, to bring the high side suction pressure down slo~y to around 25 to 30 psig. This sl~ d~o~ keeps ammonia, out in the s~tem, from ~iling t~ ~olently. If dmw~n is too fas[, liquid ammonia in the HP pump r~iver ~uid expand to the high float ~toff. ~en it roaches its' operating pressure, switch the load ~ntml to remote or automatic. Operating Instructions - Page 2 8. Open slowly the liquid ammonia hand king valve so as not to I~ammer the piping with slugs of liquid ammonia. Opening this valve, sends liquid ammonia to the HP pump rec.,civet, and the USDA room evaporator. 9. Start the HP liquid ammonia feed pump. This feeds liquid ammonia to the truck and rail dock evaporators and to penthouse evaporators that are valved Io the 30 PSIG cooler system. 10. Start the low side compressor in the manually unloaded position. Gradually load the compressor manually, to bring the Iow side suction pressure down slowly to around 2 psig. Watch to make sure that ammonia in the low pressure pump receiver does not reach the high float a's you lower Ihe pressure, and in rum lower its' boiling point. Also keep an eye on the high side compressor, that you don't load it too fast, because the discharge gas from the low side compressor is going into the suction of the high side compressor. When the Iow side suction pressure reaches its' operating pressure, switch the load control to remote or automatic. 11. Open slowly the liquid ammonia hand valve feeding the LP pump receiver. Opening this valve, sands liquid ammonia to the LP pump receiver. 12. Start the LP liquid ammonia feed pump. This feeds liquid ammonia to the penlhouse evaporators valved to 2 PSIG freezer system. ~13. Start the fans on all the room evaporators. Turn them on slowly, one at a time, so as not to add too much refrigeration load to the system all at once. '14. Open the hot gas defrost king valve. Again, open it slowly. 15. Notify the monitoring alarm company that the system is back on the line. .E, ME~ENCY .SHUTDOWN OPERATING IN$,TI~UC,TIONS NOTE,. Fimt scenario: By emergency shutdown, we are assuming, the reason to " do so would be an ammonia leak somewhere out in the warehouse. Our objective. would be two fold. First, to stop ammonia flowing from the engine room, out into the warehouse. Second, if possible, draw ammonia back into the engine room from the. mom evaporators and refrigeration piping. 1. If you can locate and get to the leak, shut the liquid feed and hot gas valves closest to the leak, upstream of the leak, NOTE: If it is a large leak, and you can't get close to it; 2. Close the hand king valve in the engine room, 3. Shut off the liquid ammonia feed pumps. 4. Close all four ammonia feed pump discharge valves. NOTE: if you do not close the standby pump discharge, ammonia could continue to feed through the check valve. 5. Close the main hand hot gas valve, NOTE: The HP and LP Pump Receivers have valves on the suction piping coming from the rooms above the roof. Shut them after you pump the system down as much as possible. If you stop the compressors before closing these valves, pressure will build in these vessels, and ammonia will flow backwards into the room piping, toward the leak. It is best to keep the compressors running to draw as much liquid ammonia back Into the system. Lower the suction pressure to around 1 or 2 psig. That should greatly slow the leak. Put on enough compressors to hold the suction at that pressure. Station someone Operating instructions - Page 3 3E)'o'd /~J3~IO~l ~ci~0'E~£~08 6§ :Cil~ ~00~/;~0/~'E in the engine room to watch and control this. Do not allow the suction pressure to go into a vacuum. If it does, air could be drawn in through the leak. That air would eventually get into the condensers and r.,ause high discharge pressure. The compressors would then shut down on high discharge pressure, causing the suction pressures to increase just when you were depending on them to hold the suction down. 6, Locate and isolate the leak NOTE: Second S, cenar, l,o,: We would assume an emergency shut down tO be needed because of a leak in the high side discharge piping. That could be from the high side compressors discharge piprng, through the oil separators, through the condenser on the roof, through the high pressure receiver, up to the king valve. 1. Push the refrigeration emergency stop button located in the engineers' office or in the fireman's emergency box outside the building on the east wall. NOTE: The compressors are the driving force to Increase the pressure in the system described above. Pushing the stop button stops all compressors, closes the liquid ammonia king valve from the receiver, and stops the liquid ammonia fccd pumps. Stopping the compressors lowers the discharge pressure. You may want to turn condenser fans on manual to lower the head pressure as much as possible. 2. Locate and isolate the leak. OIL REMOyAL - .L .P,.~,Bd_HP PUMP RECEIVERS NOTE: Under normal operating conditions, the valve on the bottom of the LP pump receiver oil leg to the oil pot, and the oil pot vent valve from the top of the oil pot to the top of the LP pump receiver, should be open. Under some conditions, if the oil pot vent valve is wide open, you will get a circulating effect of the ammonia and oil. It is best to keep this vent valve pinched down, to keep the .movement in the oil pot still and allow the oil to settle out. To remove oil from the Iow pressure pump receiver oil pot, to the central oil removal pot: 1. Close the valve from the LP or HP pump receiver to the oil pot. NOTE: Allow several hours, or wait over night for ammonia to separate out of the oil through the vent line to the LP pump receiver. 2. Close the vent line valve. NOTE: Pressure in the oil pot should build to around 60 psig pressure within several hours. You will need pressurize the oil pot in order to have a difference in pressure for o[I to move. Then, open the oil drain valve on the oil removal pot, and drain the oil into a bucket for reclamation or disposal. Close the drain valve when all oil is removed, and ammonia vapor comes from drain valve DO NOT LEAVE THE .E_ _N_GI~.R. OOM UNTIL THE OIL DRAIN VALVE IS CLOSED NOTE: Make sure you have the 10 or 15 pslg pressure on the otl removal pot before you open the oil drain valve, and while your are draining oil. If the oil removal pot were in a vacuum, you would draw air into the system. OI[.~ ,R,EMOVAL -.,.....HIGH PRESSURE RECE!_V. ER._,AND THERMOS~PHON OIL COOLERS Operating Instructions - Page 4 '1. Make sure suction valve from central oil removal vessel is open to the LP Pump receiver. 2. Set suction' back pressure valve on oil removal pot to 10 or 15 psig. Make sure it is not hand jacked open with boffom stem. With this valve in the automatic position, the bottom stem is turned in clockwise all the way with just about t~A" of stem showing below valve body. 3. Close Inlet valve from oll removal line on top of central oil removal vessel. 4. Make sure ali oil removal valves are closed on each thermosyphon oil cooler and HP receiver. 5. Open the valve in the oil removal line from the vessel you want to drain oli from. 6. Crack open the valve of the oil removal line on top of the oil removal vessel, no more than 1/4 or 1/2 turn. NOTE: If you open this to much, liquid ammonia will blow right through the oil in the bottom of the receiver or thermosyphon vessel. Now and then, oil clogs this valve opening, so you will need to open it a turn or two just long enough to blow out oil clog, then close it back down to a 114 or 1/2 turn. 7. When all oil is removed from the vessel, close the hand valve on the bottom of the vessel you were draining from.. 8. When line is pumped out, close the hand valve on top of the oil out pot. 9. To remove oil from central oil removal vessel, follow steps laid out in the section called OIL REMOVAL. - LP AND HP PUMP RECEIVER. EMERGENCY AIR PURGING In an emergency situation, if you had a large volume of air in the condensers, causing the discharge pressure to rise above safe operating limits, you would purge air as follows: 1. Stop all the compressors, leave the condenser water pumps, and fans on. This will cool and condense all the liquid ammonia, and separate the ammonia vapor and air. With the loss of velOcity In the piping, due to stopping the compressors, the ail will separate and rise to the top of the condensers. 2, After allowing time for cooling, you can {hen purge the air to the atmosphere, or into a container of water, from the purge valves located on top of the condenser coil headers. ADDING_QIL TO COMP~ES.SORS - OPERATING INSTRUCTIQNS SCREW COMPRESSORS. NOTE: A level of oil is maintained in the discharge oil separator that operates at compressor discharge pressure. It can be dangerous to pump oil in the fill valve of this vessel against (~ompressor discharge pressure. I believe it is best to stop the Operating Instructions - Page 5 compressor and pump the discharge oil separator down, then pump oil in. Because of the large volume of gas that is contained in these vessels, it would be best to draw the gas back into the system rather than drain it into a container of water. To accomplish this: 1. Stop compressor 2. Close discharge valve. 3. On second stage compressors close suction valve. 4. On second stage compressors open, pump out line. 5. On low stage compressors, open 3/8", bypass line mound suction check valve. 6. After oil separator vessel pressure drops to suction pressure, around 2 psig, close the suction valve. 7. Close the bypass valve. 8. Pump in oil as needed. Note: If you are going to replace the oil, it is easier and takes less time if you drain the oil before you reduce the vessel pressure. AMMONIA OFF-LOADING PROCEDURES Note: Following our off-loading procedures are copies of Off-Loading Procedures for driver/operators of Ammonia delivery trucks fi:om the two suppliers we usually use. Coordinate our procedures with the driver/operators procedures. Note: For emergency purposes have at hand and ready to use: Gloves, goggles, faceshield, a full face gas mask with industrial size ammonia canister and a self contained breathing apparatus. 1. Locate ammonia truck near ammonia charging station east of the engine room. 2. Make sure wheels are chocked. 3. Put barrier at the valve loading station with a sign reading "Danger"! "Stand clear, ammonia loading in progress". 4. Driver will connect hose to the high-pressure receiver at the bottom of the oil drain trap. 5. Note liquid level of receiver in the engine room. 6. After hose is connected and the bleeder valves are closed, make sure fill line valve is open on the receiver in the engine room. 7. Make sure receiver line pump out valve is closed. 8. Slowly open fill line valve when driver/operator is ready. Note: Coordinate with steps 2 through 5 of Hill Brothers procedures or steps 11 through 18 of LaRoche procedures. Note: Read pressures at cargo tank and engine room receiver. If the differential pressure between the track tank pressure and engine room receiver exceeds the limit of the pumping system; the engine room operator must reduce the receiver tank pressure to a suitable level. Maximum differential pressure should not exceed 125 PSIG. Operating Instructions - Page 6 9. Keep constant check on ammonia receiver level. DO NOT OVER FILL SYSTEM. It may be necessary to stop loading procedures for a few minutes to see where system level stands. 10. When the ddve~?operator indicates the desired quantity of ammonia has been received, close fill line valve outside the engine room. 11. Close fill line valve at the receiver. 12. Open pump out valve to the fill line to remove liquid ammonia. (you could pump out truck hose if driver/operatOr so desired). 13. Close pump out valve. 11. Collect and return all protective equipment, signs, and barriers used in off-loading procedures Operating Instructions - Page 7 /_8 3~9~d .L;~3~021 ];~0'[~0B S~ :(:J'[ ~00~/~0t2~]; c. Operations Daily Operating Procedures Daily Operating Duties 1. Inspect work area and overall operation of systems. 2. Check compressor suction and discharge temperature and pressure twice per day. 3. Check compressor oil levels twice per day. Normal level is mid-point of sight glass. 4. Check compressor oil pressure twice per day. 5. Investigate abnormal conditions. Addition of Oil to the Compressors 1. Open crankcase valve, making sure that the check valve is in place. 2. Oil is pumped into crankcase with a high pressure pump. 3. When finished, the crankcase valve is closed. 4. Compressor is in continuous operation. Detection and Monitoring Systems Odor The nature of ammonia is such that the presence of ammonia vapors would be detected by smell at very Iow concentrations. 03320012.001 46 W~I ~nC Sight Potential ammonia release points can be detected by visual inspection of equipment to identify discolorations, rust, holes or worn spots, Ammonia Gas Sensors Ammonia gas leaks are detected by Manning Systems Model 4485 Ammonia Gas Cell/Transmitters located in the machine room, at the carbo cooler and in the ammonia vent lines. These sensor units consist of an electrochemical sensor and an electronic transmitter and have a detection range of 0-100 ppm ammonia. Alarm Indicators The alarm module is the top of three computer modules located in 'the computer control panel. The top row of lights are inputs to the computer. The bottom row of lights represent the outputs. The computer inputs must be "ON" (LED light ON). If the light goes out, it signals an alarm condition. Operating Thermostat Operating thermostats are used in the glycol system and the tower water system. The operating thermostat has four stages. Three stages are used to control the temperature. Should the glycol or tower water temperature continue to increase beyond the third stage of cooling by five degrees, the high temperature alarm signal will be sent to the computer alarm module signaling a general refrigeration alarm. 03320012.001 47 Control Systems System Restart If there is a power failure, the system will not restart automatically. A trained operator must restart the system. When the power is restarted, the alarm system will check all of the alarm points. If there are any failures, the alarm horn and light will activate. The operator can silence the alarm horn, but he cannot reset the alarm system until the cause of the alarm is found and corrected. Once all of the alarms are cleared, the compressor can be placed into operation. Manual Isolation Valves In the case of an earthquake, there is a possibility that ammonia lines will break. Power will likely be out which will close all automatic valves. Each vessel that contains ammonia has manual isolation valves that can be turned off. Machine Room Exhaust System The machine room has a large two speed fan located on the roof. The fan is used to cool the machine room in the summer and to vent the ammonia out of the machine room in the event of a leak. The fan has a set of automatic dampers. If the fan is being used for ammonia removal, the dampers direct the exhaust air into the cooling tower. This tower acts as a scrubber, removing the ammonia from the air. This will happen under the following conditions: · There are two machine room emergency vent switches on the system. One in the dump panel and one on the wall outside the machine room. Either switch will start the fan and the damper, and sound an alarm. 0332_0012.001 48 · If the machine room ammonia sensors detect a leak, it will start the vent system and sound the alarm. Machine Room Vent System The machine room vent system will still function if the emergency stop switch has been used. The control panel is built in two sections. Each section has its own power supply. Emergency Stop Switch There are two emergency stop switches. One is located in the ammonia dump panel and one is on the wall outside the machine room. The switches are wired in series. If there is an accident, fire, earthquake, or ammonia spill the refrigeration system can be turned off from either remote location. This will sound an alarm at the main computer panel. King Solenoid The system has two King solenoid valves located on the main ammonia line as it leaves the receiver to supply the system. One valve is manual, the other is electric. The electric valve must be energized to open. The valve will close during a power failure, if the emergency stop switch is turned off, or if the King solenoid valve switch is turned off at the control panel. Master High Level Switch The master high level switch is located on the master accumulator. If liquid ammonia floods back to the master accumulator, the master high level switch will shut down the complete refrigeration system. In order to restart the system, an operator must be present to reset the alarm system and place the refrigeration system back in operation. 03320012.001 49 Chiller High Level Switch This switch is located on the glycol chiller and it will give an alarm signal indicating that the ammonia level is too high. This will not, however, shut the system down. It will let the operator know that an alarm condition is present. Since there is an accumulator, it is not necessary to shut the system down at this time. Cooler Tower pH Alarm The cooling tower will be used as an ammonia scrubber for the machine room ventilation system. In the event of an emergency, ammonia will be scrubbed out of the air by the cooling tower. This will in turn change the pH of the water in the cooling tower sump. A pH alarm will detect any changes in the sump water and send a signal to the computer alarm module, sounding a general computer alarm. At the same time, it will open a dump solenoid allowing water to drain from the cooling tower to the sparge tank and fresh water will be automatically added to the cooling tower. This will continue until the pH of the tower water is back within our predescribed limits. Sparge Tank pH Alarm In the event a relief valve is discharging ammonia into the sparge tank and there is a failure of the ammonia vent alarm and the pH changes substantially in the sparge tank, a signal is sent from the remote pH alarm module located at the tank to the computer alarm module sounding a general alarm. 03320012.001 50 Incident Action Plan The Quality Assurance Supervisor, Gerhard Gaugel, is the Emergency Contact and will act as the Incident Commander. The Incident Commander will implement the incident action plan in case of emergency. The incident action plan will be implemented in the case of an emergency plant evacuation. The following steps will be taken in emergency situations: 1. An announcement will be made over the paging system notifying employees of facility evacuation. 2. All employees will report to the staging area on the east end of the property. 3. Employees certified on self-contained breathing apparatus will bring the SCB^ equipment to the staging area. 4. Attendance will be taken by the Incident Commander to account for employees. 5. The Incident Commander or designee will make an overall assessment of the incident. 6. Emergency response personnel such as the fire department, hazardous materials team, medical units, and Office of Environmental Services will be notified immediately by the Safety Coordinator or designee. 7. Incidents occurring during the night shift will be evaluated by lead persons and · general staff members. If necessary, emergency response personnel will be notified followed by the Safety Coordinator and the Incident Commander. 8. The Incident Commander will initiate a search for employees not accounted for in the attendance count. 9. Emergency response personnel will be assisted by SCBA-trained Crystal Geyser personnel if needed. 03320012.001 51 10. A map of the plant will be maintained in SCBA storage units to assist emergency response personnel. 11. The Safety Coordinator will continue to monitor personnel safety. Utility Shut-Offs In emergency situations, utilities for the facility may need to be discontinued. The locations for each utility shut-off follows: Gas/Propane Tank: Southeast corner of each parking lot next to the alley and Lakeview Avenue. Electrical: Western building - Outside of building on the southeast COrner of the building under the stairway. Eastern building - Inside building on the southwest corner on both sides of the exit door next to the alley. Water: In the alley next to the fence and the southwest corner of the building 330 feet west of Lakeview Avenue. Ammonia: The ammonia shut-off is in the southeast corner of the west building (engineering support)' next to the alley. The Fire Department hook-up and ammonia dump system valve control is on California Avenue over the main entrance. The diffusion system box is next to the roll-up door of the west building on the southside next to the alley. 03320012.001 52 Gas Meter: Inside the fence between the buildings next to the alley, southwest corner of eastern facility, south of the ammonia tank containment. Lock Box: Keys located above the north entrance door of the west building. Available Water Supply The following water supplies exist near the Crystal Geyser facility: · Fire hydrant located on the north side of East California Avenue. · A fire department hook-up to Crystal Geyser's main sprinkler system riser for the east building one hundred and twenty (120) feet west of the northwest corner of the facility and two hundred and twenty (220) feet west of Lakeview Avenue. · Fire department hook-up to west building in the alley approximately four hundred feet west of Lakeview Avenue. 03320012.001 53 d. Planning Worst-Case Scenario The worst-case scenario is defined as the release of the largest quantity of a regulated substance from a single vessel or process line failure that results in the greatest distance to an endpoint. The distance to the endpoint is the distance an ammonia vapor cloud will travel before dissipating to a point that serious injuries from shod-term exposures will no longer occur. The worst-case scenario is assumed to be an unmitigated release occurring over a period' ' of ten minutes. Suggested parameters provided in EPA guidance documents for modeling worst-case releases assumes wind speed to be 1.5 meters per second, a wind stability class of F, and a ground level release. Surface roughness is classified as either urban, obstructed terrain, or rural, fiat terrain. This facility is considered urban due to its location within the City of Bakersfield. The release rate is calculated by dividing the total amount of the hazardous substance by ten minutes. Using the maximum amount of ammonia held on-site and dividing it by an assumed release period of ten minutes results in a release rate of: 4500 lbs / 10 minute release = 450 lbs/minute Using the EPA-supplied table for worst-case scenarios, the toxic endpoint distance is 0.9 miles. To estimate the population present within the endpoint circle, census data for six census tracts was obtained from the Kern Council of Governments. The census data is based on the 1990 census data and has been updated to 1998 using a shared allocation method. 03320012.001 54 The aerial extent of each tract was determined and the population density was calculated. The area of each census tract within the circle defined by the toxic endpoint of the worst case release was measured and the residential population within that area was estimated using the population density within each census tract. The calculations used to determine the residential population are presented on the following pages. 03320012.001 55 SCALE IN MILES CRYSTAL GEYSER 0 0.5 I Bakersfield, CA WORST CASE REL~SE ~-~ SCENARIO Off-Site Receptors for Worst Case Scenario Receptor Approximate Distance (Miles) Direction Southern Pacific Depot 4/5 NW State Building 9/10 NW Fire Station #2 2/3 NW Vista East High School ½ NW Martin Luther King Jr. Park 113 W Union Cemetary 3/10 SW Owens School 2/5 SW Virginia Avenue County Park 2/3 SE 03320012.001 56 Residential Population Calculations Census Tract Population Density 12.00 9,649 people per square mile 13.00 9,473 people per square mile 15.00 9,504 people per square mile 21.00 6,519 people per square mile 22.00 7,831 people per square mile 23.02 3,168 people per square mile Worst Case Scenario Area of Vulnerability Census Tract Area of vulnerability (sq. mi.) Population (density x area) 12.00 0.2304 2,224 13.00 0.2764 2,618 15.00 0.8456 2,963 21.00 0.2572 ... 1,677 22.00 0.7536 5,901 23.02 0.4582 1,451 Total estimated population within circle: 16,834 03320012.001 57 Alternate Release Scenario An alternative release scenario analysis is also required. This alternative release scenario is determined by either past facility or industry experience to be a more likely credible scenario. The hazard and operability study determined the alternate release scenario to be the release of the liquid contents of the ammonia receiver into outside air. The potential release scenario judged to be dangerous to offsite receptors is a release of ammonia during an earthquake. Lines from and to the ammonia receiver contain liquid ammonia. A break in this two inch liquid ammonia line could release all of the ammonia in the receiver. In this potential worst case scenario, the rapid release of liquid ammonia could form an air/ammonia dispersion that would act as a cloud of dense gas. The ammonia receiver contains 4500 pounds of ammonia which would release to the compressor room leading to outside air, immediately affecting the surrounding area. The release rate would be 2040 pounds per minute and last 2.21 minutes to release the entire 4500 pounds of ammonia. This scenario satisfies the requirements for the alternative release scenario analysis under Title 19 Section 2750.4. The EPA-released guidance document recommends "average" weather conditions to be a wind speed of 3 meters per second and stability class D, and an ambient temperature of 25 degrees Celsius. Using the RMP Comp software provided by the EPA, the distance to the toxic endpoint is an estimated 0.2 miles. There are no off-site environmental receptors for the alternate release scenario. Public receptors include commercial, industrial, and residential receptors. 03320012.001 58 To estimate the population present within the endpoint circle, census data for six census tracts were obtained from the Kern Council of Governments. The census data is based on 1990 census data and has been updated to 1998 using a shared allocation method. The aerial extent of each tract was determined and the population density was calculated. The area of each census tract within the circle defined by the toxic endpoint of the alternate release scenario was measured and the residential population within that area was estimated using the population density within each census tract. The calculations used to determine the residential population are presented on the following pages. 03320012.001 59 / PRC~ 0.2 MILE ~UXTUN ! RADIUS CRYSTAL GEYSER BAKERSFIELD HAROLD~'~ I'L ~1 '~ ~ I B~RSFIELD, C~IFORNIA CRYSTAL GEYSER SCALE IN MILES ~ke~d, CA ~1 0 0.5 I' ,'~' I I I ' I ALTER~TE RE~SE ~.~2 SCE~RIO ~1 NC Off-Site Receptors for Alternate Release Scenario There .are no off-site environmental receptors for the alternate release scenario. 03320012.001 60 Residential Population Calculations Census Tract Population Density 15.00 9,504 people per square mile 22.00 7,831 people per square mile Alternate Scenario Area of Vulnerability Census Tract Area of Vulnerability (sq. mi.) Population (density x area) 15.00 0.0558 55 22.00 0.0772 605 Total estimated population within circle: 660 03320012.001 61 e. Logistics Emer,qency Medical Plan Each supervisor will be trained in CPR and first aid. For minor injuries, Bakersfield Occupational Medical Group will be used. For serious injury or injury due to a hazardous material, San Joaquin Hospital will be used. Memorial Hospital or Kern Medical Center will be given second consideration. Any supervisor has the authority to dial 911 for medical emergencies. Maintenance Procedures Ammonia System Shutdown 1. Shut King valve on receiver to pump all ammonia into the receiver. 2. Shut suction valves on compressors. 3. Turn compressor motor off. 4. Shut compressor discharge valves. 5. Lock out electrical panel. 6. Tag warning on the electrical panel. 7. Open discharge valves before starting. Isolating a Compressor for Maintenance 1. Shut suction valve, allow compressor to pump down (remove ammonia). 2. Turn compressor motor off. 3. Close discharge valve. 03320012.001 62 4. Lock out electrical panel. 5. Tag warning on the electrical panel. 6. Attach bleed off hose to the compressor to bleed off excess ammonia into a bucket of water. 7. Open discharge valves before starting the compressor. Restarting a Compressor 1. Disconnect bleed off hose. 2. Open discharge valve at the compressor. 3. Check oil level in crankcase. 4. Remove lockout on the electrical panel. 5. Turn on compressor motor. Check oil pressure.. 7. Open suction valve at the compressor. P~ G'S Preventative maintenance checklist 1/17/03 Daily : 1. While the system is in operation, check the refrigerant sight glass: i: Clear- OK Bubbles-Low on refrigerant ~ Foam - very low 2. Oil sight glass level should be in center of glass. 3. Operate thermostat at the set point. 4 .Check suction and discharge pressures. 5. Listen for strange noises,bad bearings compressor knock. 6. Check all breakers and overloads. 7. Check for vibration,loose clamps,cap tubes vibrating and/or rubbing. 8. Log compressor hours. 9. During times of light load,mm offthe lead compressor and let # 2 get more run time. 10. Log the compressor operating hours. 11. Check the oil level in the compressors. 12. Check the frigerant sight glasses for bubbles. Weekly 1. Check fans and pump in evaporrative condenser for proper operation. 2. Check tower chemicals. Quarterly 1. Maintain proper glycol level and concentration - strength should be 30 - 40 % -- 1.034 to 1.049 specific gravity. 2. Evaporative condenser. Bleed off- clean sump and spray nozzles, chemicals, fans and pump. 3. Clean pump strainer 4. Check by-pass and flow switch by turning off glycol pumps, system should pump down and mm off. 5. Check evaporator condensor fan belts for wear and cracks 6. Check for loose pipe clamps. 7. Descale the condensor if needed. Page 64 Yearly 1. Check all safety controls - ammonia sensors, high level float valves on chiller, and accumulators, Recalibrate if needed. 2. Check all gauges for proper calibratiom Compressors 3. Change the oil and clean the crank cases, - every 30,000 hrs. 4. Check pressure and temperature calibration - every 10,000 hrs. 5. Change filters on compressors every 10,000 hrs. 6. Clean oil strainers on compressors every 10,000 hrs. 7. Clean liquid strainers 10,000 hrs. 8. Clean coalescers every 30,000 hrs: ' 9. Clean suction screen every 10,000 hrs. 10. Check alignment every 10,000 hrs. 11. Check couplings every 10,000 hrs. 12. Due oil analysis every 10,000 hrs. 13. Vibration analysis every 5000 hrs. 14. Replace seal every 30,000 hrs. Page 65 111.4 Emissions Documentation Documentation Emissions documentation at this facility is limited to an accidental release of anhydrous ammonia from the ammonia refrigeration system. Any sizeable release is reported to the Bakersfield City Fire Department and the required State and Federal agencies. Incident Investigation If a release occurs, the following incident investigation procedures will be performed: · A release incident report will be completed (included on the following pages); · A post accident review will be performed in which potential causes of the accident are discussed; · A method shall be developed to ensure that the accident will not recur; · Any system design specification, operating procedures or maintenance procedures that need updating or alternation shall be noted; and · A time schedule for accomplishing the required changes will be set. An release incident report will be completed in the event of a release and all records concerning the release will be retained on-site for a minimum of five years. A sample of the release incident report follows. 03320012.001 66 RELEASE INCIDENT REPORT Date: Time: Release Duration: Chemical(s) Released Quantity Released Release Event: Gas Release Liquid Spill/Evaporation Fire Explosion Release Source: Storage Vessel Piping Process Vessel Transfer Hose Valve Pump Joint Other (Specify) Weather Conditions: (Use "Unknown" for any missing information) Wind Speed and Direction Temperature Stability Class Precipitation Present On-site Impacts: Deaths Injuries Property Damage Known Off-site Impacts: Deaths Injuries Evacuated Sheltered Environmental Damage Initiating Event: Equipment Failure Human Error Weather Conditions Unknown Contributing Factors: Equipment Failure Human Error Improper Procedures Overpressu rization Upset Condition By-pass Condition Maintenance Activity Process Design Unsuitable Equipment Weather Conditions Management Error Were off-site responders notified? Changes introduced as a result of accident: Improved/Upgraded Equipment Revised Maintenance Revised Training Revised Operating Procedures New Process Controls New Mitigation Systems Revised Response Plan Changed Process Reduced Inventory Other None Five-Year Accident History Requirements A five-year accident history is required for releases from a covered process involving a regulated substance that caused one of the following: · On-site deaths, injuries, or significant property damage. · Known off-site deaths, injuries, property damage, environmental damage, evacuations, or sheltering in place. Accidental Release No aCCidental releases meeting the above criteria have occurred in the last five years. 03320012.001 67 "AMERICA'S April, 4, 2002 N~TUe, AL BEVERAGE COMPANY" Tim Ryafi, Wastewater Inspector City of Bakersfield 8101 Ashe Rd. Bakersfield, Ca 93313 Re: Ammont~ Leak of 4/02/~2 Dear Tim: The source of the ammonia leak on 4/2/02 was determined to have originated from the evaporative cooling tower that was in the process of being serviced to repair a safety relief valve. The outside contractor, James Bm'tell and Associates, was removing ammonia vapor (20 psi) from the condensed liquid line when the gaseous odor was noticed. The liquid ammonia was previously evacuated from the same line back into tho ammonia compressors, but ammonia vapor remained in file isolated evaporative c.~ling system. The contracting personnel proceeded to vent the 20 psi ammonia vapor into a 55 gallon drum of water and were adding additional water with a hose to dilute the ammonia odor. As the drum of water and ammonia vapor overflowed the liquid mixture flowed to the roof drain. The contractor's employee was not aware that the roof drain flowed directly to the street curb and down the storm drain. As soon as we were informed by yourself and our office staff, we investigated the situation and asked the contractor to immediately stop the procedure and inform his supervisor of the problem. A decision was made to run an extra hose from vapor line being evacuated to the ammonia compressor room, The hose was attached.to the suction side of the compressor and the line tlmt contained the vapor was sucked empty after a few hours. The line with ammonia vapor contained approximalely 1 ~ psi of vapor when the water and vapor mixing was halted, 5 psi of vapor pressure was dumped to the roof and eventually to the street curb drain. Normally, the water mad vapor mixing is performed to remove the remaining vapor. It saves time and cost. Unfortunately, the contractor did not take into account the location of our facility and proximity to housing and pedestrians. The ammonia vapor can be very irritating to all individuals not previously exposed to such an odor. In the future, we will require that the ammonia compressors be totally evacuated of ammmtla and vapor; which require a facility shutdown or we must use the compressors to remove the remaining vapor. These will be added to our standard operating procedures. , CRYSTAl. GEYSER WATER COMP,~NY P.O. Box 304, 501 Washington Street, Calistoga, CA 94515-0304 (707) 942-0500 FAX (?07) 942-0647 ., I "AMERICA 'S NATURAL ~EVERAGE COMPANY~ The release o£more than 100 lbs of liquid ammonia constitutes a hazardous release and reporting of the incident to all governmental authorities with hazardous material responsibilities. Our incidental release did not meet that criteria, according to Howard Wines, Hn,~rdou~ Material Specialist, City of Bakersfield Fire Department. Mr. Wines appreciated our decision to cease the vapor removal until we devised a plan to eliminate the vapor without releasing into the atmosphere. He stated that we took the correct action~ and did not violate a hazardous material ordinm~ce for ammonia rele~ze. If you have any questions, please feel free to call David Wright, Production Supervisor, or Robert Hofferd Safety Coordinator at 323-6296. Sincerely,' Q.C. Supervisor Crystal C, eyser Water Co. · CRYSTAL GEYSER WATER COMPANY P.O. Box 304~ 501 Washington Streel, Calistol~a, CA 94515-0304 (707) 942-0500 FAX (707) 942-0647 111.5 Training Effective training programs are necessary to ensure that all plant personnel can successfully implement the elements of this RMP. Training will be able to provide a continuity of safety despite employee turnover. Training ensures that plans and programs such as emergency evacuation plans will work as designed when they are needed. The following subjects will be covered by the training program: · Use of Safety Equipment · Ammonia First Aid Procedures · Review of Material Safety Data Sheets, Chemical Hazards · Fire Prevention Response · Release Reporting · Evacuation Procedures · Earthquake Procedures · Spill Containment and Dilution Procedures · Daily Operating Procedures · Maintenance Procedures Training is verified by testing employees for comprehension of the training programs developed for the elements of the RMP that need ongoing implementation. On the following page is a training checklist that will track the training received by each employee. Training is dictated by regulatory requirements and by industry standards. The Safety Coordinator will ensure that employees have received a level of training required by industry standards and any regulatory requirements. This may include attendance at industry specific meetings to maintain current knowledge of industry recommended standards. 03320012.001 68 CRYSTAL GEYSER WATER COMPANY TRAINING REQUIRED / DATE COMPLETED EMPLOYEE AMMONIA AMMONIA SCBA FIRE ElVIRGCY EVAC FORKLIFT SAFETY DIFFUSION SAFETY NOTIF. PROCED. JOSE LUCY BRAVO //-/1 - OFELIA CANALES //_//_~, STANLEY COOK /o - ~ -~, VERONICA SERGIO GONZALES //_// -o~. MIGUEL GUILLEN JOSE ROSErOAR~Z //.//-~ //-//- o~. //-d-o~ AIDA SEPULVEDA GEORGE MAESE t/-//- RICHARD ARMANDO JOSH RO__DRIQUEZ CRYSTAL GEYSER WATER COMPANY TRAINING REQUIRED / DATE COMPLETED EMPLOYEE AMMONIA AMMONIA SCBA FIRE EMRGCY EVAC FORKLIFT SAFETY DIFFUSION SAFETY NOTIF. PROCED. JASON SMITH JOSE UrmUT~ // JOAQUIN ELI VASQUEZ JOHNDAVIS /~-/~-o;~. /0-/~-~,~ /l-/I-OD. //-//-o;,~. //-//-oD. TED RODRIQUEZ la ~/6 -o;z /o -/ ~, -o~ //_z/_o~. //_/I _o~. //-//- og~. /2 -~3'--oD_ BOB HOFFERD WRIGHT L l,,l.N TRAINING COMPLETED EMPLOYEE AMMONIA SAFETY FIRE SAFETY EMERGENCY EVACUATION SPILLS AND NEUTRALIZATION NOTIFICATION PROCEDURES TRAINING COMPLETED EMPLOYEE AMMONIA SAFETY FIRE SAFETY EMERGENCY EVACUATION SPILLS AND NEUTRALIZATION NOTIFICATION PROCEDURES TRAINING COMPLETED EMPLOYEE AMMONIA SAFETY FIRE SAFETY EMERGENCY EVACUATION SPILLS AND NEUTRALIZATION NOTIFICATION PROCEDURES TRAINING COMPLETED EMPLO~'EE AMMONIA SAFETY FIRE SAFETY EMERGENCY EVACUATION SPILLS AND NEUTRALIZATION NOTIFICATION PROCEDURES TRAINING COMPLETED EMPLOYEE AMMONIA SAFETY FIRE SAFETY EMERGENCY EVACUATION SPILLS AND NEUTRALIZATION NOTIFICATION PROCEDURES 111.6 Plan Review and Modification All records concerning this RMP shall be kept for at least five years (Section 2755.1). Necessary revisions to the RMP will be made at least every five years (Section 2745.10 (a)(1). The RMP must be revised within 60 days of a modification that results in a significant increase in either the amount of regulated substance handled at the facility or in the risk of handling the regulated substance (Section 2745.11 (b)). All revisions to this RMP are to be recorded here. DATE PAGES/ OF CHANGES/INPUTS MADE TO SECTION CHANGE DOCUMENT AFFECTED SIGNATURE/DATE 03320012.001 69 RMP AUDIT CHECKLIST Crystal Geyser .Water Company * Has a Fa~l~ Mediation affe~ng regulated su~nce handling ~en do~mented in ~e ~P? Yes No ~ If yes. does ~e H~ard ~al~ need to be modifi~? Yes No * ~e all~ operating procedures up to date? ~Ye~ No *' After an unannounced spot check, were ~e ~ndard operating proced~OP) petered as ~en? ~ No Date and time of SOP spot checks ~-/ /~ o~ If no. has ~aining been scheduled to renew w~en procedures? Yes No * Havec~s in SOP or New SOP been documented in ~e RMP? * Have a~tenance inspe~ons, and P~ been pe~o~ed? ~ No * Have all ~e~ relief valves been inspe~replaced annuall~ * Has each regulated sub. nee acdden~ncident been inves~gated including me~ develo~d to prevent reoccuffence been docum~? * Has a regulated su~n~ase been repoKed as required? Yes No [N/A~ * Have changes made to regulated substance s~em, proce~es and operations been renewed under management of ~ange procedures pdor to imp~afion. Yes No ~A~ * Is all regulated su~ance safe~ equipment available and in good . ~nd~ * Has li~ of all cu~ent employees been renewed against ma~er ~ainin~l~t prodded in of ~e RMP? ~Ye~ No * If yes ~ employees receded ~e training listed on chec~lis~ * If no. has ~aining been scheduled to bdng all employees curren~ Yes No 03320012.001 73 111.7 Prevention Program The following information is required for each RMP facility designated as Program 2: NAICS Code Bottled Water Manufacturing facilities are designated as NAICS Code 312112. Name of Chemical Covered Anhydrous ammonia is listed under CalARP regulations as a state regulated substance with a threshold quantity of 500 pounds. Crystal Geyser Water Company has a maximum amount of 4500 pounds of anhydrous ammonia on-site. Safety Information All safety information was reviewed in March of 1999. This included a review of the process and required inspection and maintenance required by Federal or State regulations or industry-specific design codes and standards. The EPA issued Chemical Safety Alert entitled Hazards of Ammonia Releases at Ammonia Refrigeration Facilities contains steps that ammonia refrigeration facilities could take to prevent or reduce the severity of a release. These suggested steps include establishing training programs for employees, replacing existing valves with spring-loaded valves on 03320012.001 70 oil drain valves, erecting barriers to protect refrigeration equipment and developing a written preventive maintenance program and schedule according to manufacturer's specifications. Hazard Review A hazard analysis was performed at Crystal Geyser Water Company's facility in 1993. A review of this hazard analysis was compared with the requirements of CalARP regulations Section 2760.2(c) and found to cover the following required points: · The hazards of the process; · The identification of any previous incident which had a likely potential for catastrophic consequences; · Engineering and administrative controls applicable to the hazards; · Consequences of failure of engineering and administrative controls; · Stationary source siting; · Human factors; · A qualitative evaluation of a range of the possible safety and health effects of failure of controls; and · Consideration of external events, including seismic events. Operating Procedures Operating procedures were reviewed in the compilation of this document and were found to be adequate for Crystal Geyser Water Company's needs. Details of the operating procedures in existence at this facility can be found in Section 111.3.c. 03320012.001 71 Training Programs Existing training programs were reviewed and found to be adequate. Details of the training program used can be found in Section 111.5. Maintenance Procedures Maintenance procedures were reviewed and found to be adequate. Details of the maintenance procedures used at this facility can be found in Section 111.3.e. Compliance Audits A compliance audit will be performed at least every 3 years to verify that procedures and practices are adequate and being followed. This compliance audit will be conducted by at least one person knowledgeable in the process. On the following page is the form which will be used to perform the compliance audit. A report of the findings will be developed. Each of the report findings and deficiencies will be addressed. The two most recent compliance audits, reports and responses to the findings will be kept on-site. 03320012.001 72 RMP AUDIT CHECKLIST VVZ! ,Nc Crystal Geyser Water Company Date Name Signature ............... * Has a Facility Modification affecting regulated substance handling been documented in the RMP? Yes No N/A If yes, does the Hazard Analysis need to be modified? Yes No * Are all written operating procedures up to date? Yes No * Alter an unannounced spot check, were the standard operating procedures (SOP) performed as wdtten? Yes No Date and time of SOP spot checks ~ If no, has training been scheduled to review written procedures? Yes No * Have changes in SOP or New SOP been documented in the RMP? Yes No N/A * Have all maintenance inspections, and PMs been performed? Yes No * Have all safety relief valves been inspected/replaced annually? Yes No * Has each regulated substance accident/incident been investigated including method developed to prevent reoccurrence been documented? Yes No N/A * Has a regulated substance release been reported as required? Yes No N/A * Have changes made to regulated substance system, processes and operations been reviewed under management of change procedures pdor to implementation. Yes No N/A * Is all regulated substance safety equipment available and in good condition? Yes No * Has list of all current employees been reviewed against master training checklist provided in of the RMP? Yes No * If yes have all employees received the training listed on checklist? Yes No * If no, has training been scheduled to bring all employees current?. Yes No 03320012.001 73 111.8 Certification "1 certify under penalty of law that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete." Shipping Supervisor/Safety Coordinator - // - Date 03320012.001 74