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Home My WebLink AboutHAZARDOUS WASTE HAZARD ANALYSIS JULY '1993 REVISION' CRYSTAL GEYSER WATER COMPANY WZl .Inc.. 4700 Stockdale .Hwy, Suite 120 Bakersfield, California 93309 CRYSTAL G EYS E R WATER COMPANY BAKERSFIELD, CALIFORNIA RISK MANAGEMENT AND PREVENTION PROGRAM OCTOBER, 1 990 REVISED FEBRUARY, 1991 REVISED APRIL, 1991 SUBMI']q'ED TO CITY OF BAKERSFIELD FIRE DEPARTMENT HAZARDOUS MATERIALS DIVISION BY WZl INC. 4800 Easton Drive, Suite 114 Ba. kersfield, California 93309 805 / 326-1112 4800 Easton Drive, Suite 114 Bakersfield, California 93309 Post Office Box 9217 Bakersfield, California 93389 805/326-1112 805/326-0191 FAX Crystal Geyser Water Company Bakersfield, California Risk Management and Prevention Program October, 1990 Revised February, 1991. Revised April, 1991 Submitted to the City of Bakersfield Fire Department Hazardous Materials Division by WZI Inc. 4800 Easton Drive, Suite 114 Bakersfield, California 93309 0332.0010A Table of Contents Page I. Purpose ' 1 II. Introduction 1 III. Certification 1 IV. Revision Record 3 1.0 Background 4 1.1 'General Business Information 4 1.2 Description of Acutely Hazardous Materials (AHM) Used 4 1.3 General Ammonia Refrigeration Processes 5 1.4 Operation of the Ammonia System 5 2.0 Description of AHM Accidents 6 2.1 Accidents at this Location 6 2.2 Underlying Causes 6 2.3 Measures Taken to Prevent Recurrence 6 2.4 Accident Investigatipn Procedures 6 2.5 Release Reporting Procedures 7 3.0 Equipment Report 8 3.1 Nature, Age and Condition 8 3.2 Testing Schedules 12 3.3 Maintenance Schedules 12 4.0 Procedures Report 13 , 4.1 Daily Operating Procedures 13 4.2 Maintenance Procedures 14 5.0 Design, Operating and MaintenanCe Control Systems 16 5.1 Design Control Systems 16 5.2 Operating Control Systems .16 5.3 Maintenance Control Systems 16 6.0 Detection, Monitoring or Automatic Cc;ntrol Systems 17 6.1 Detection Systems 17 6.2 Monitoring Systems 17 6.3 Automatic Control Systems !7 page 7.0 Proposed Risk Reduction Measures 18 7.1 Written Operating Procedures 18 7.2 Written Maintenance Procedures 18 7.3 Increased Ihspections 18 7.4 Better Labeling 18 7.5 Safety and Training Program 18 7.6 Fire Prevention 18 7.7 Physical Plant Changes 19 7.8 Reduction of Risk to Neighboring Homes or Businesses 19 8.0 Emergency Contingency Plans 20 8.1 General Evacuation 20 8.2 Fire 20 8.3 Earthquake 20 8.4 Significant Leak from the Ammonia System 20 8.5 Emergency Responders 21 9.0 Auditing Program 22 10.0 Inspection Program 23 11.0 Risk Management and Prevention Program (RMPP) 24 Implementation 11.1 Personnel Responsible for RMPP Implementation 24 11.2 Implementation Schedule 25 11.3 Training Program for RMPP Implementation 26 12.0 RMPP Record Keeping 28 12.1 Accident Records 28 12.2 Ammonia Charge Records 28 12.3 Training Records 28 12.,4 Audit Records 28 13.0 Qualifications of Certifiers 29 13.1 Q0alified Person 29 13.2 Facility Operator 29 References 30 .Exhibits Exhibit 1 Location Map Exhibit 2 Facility Diagram Exhibit 3 Surrounding Area Exhibit 4 Schematic of the Ammonia Refrigeration System Exhibit 5 Ammonia Incident Report Exhibit 6 Operator's Log Exhibit 7 Maintenance Record Exhibit 8 Evacuation Routes EXhibit 9 Ammonia Charge Record Exhibit 10 Training Required/Completed Record Appendices Appendix A Business Plan Appendix B Hazards Analysis Introduction Summary Hazards Identification Hazard and Operability Study Results Vulnerability Analysis Risk Analysis Appendix: C Ammonia Safety Audit Appendix: D Ammonia Material Safety Data Sheets !_. PurPose This Risk Management and Prevention Program (RMPP) has been developed tO minimize the potential for release of Acutely Hazardous Materials (AHM) from the Crystal Geyser Water Company, Bakersfield, California bottling facility. !1. Introduction This RMPP has been requested pursuant to Section 25534 of Chapter 6.95, Article 2 of the California Health and Safety Code (CHSC) by the City of Bakersfield Fire Department tO reduce the risk of and prevent accidents involving AHM. A risk management .and prevention program is defined in Section 25532 as: "all of the administrative and operational programs of a business which are designed to prevent acutely hazardous materials accident risks, including, but not limited to, programs which include design Safety of new and existing equipment, standard operating procedures, preventive maintenar~ce programs, operator training and accident investigation procedures, risk assessment for unit operations, or operating alternatives, emergency .response planning, and internal or external audit procedures to ensure that these programs are being executed as planned." This RMPP is based upon an assessment of processes, operations, and procedures of this facility and considers results of the hazard and operability study that has identified hazards associated with handling of anhydrous ammonia, an AHM. Ammonia system operators and other employees will use procedures detailed in this plan to improve facility safety. As specified in Section' 25534 (f)., Chapter 6.95, Article 2, CHSC, all records involving the RMPP shall be kept for a minimum of five years. Section 25534 (h). requires that the RMPP shall be reviewed and revised, if necessary, at least once every three years. If a modification is made to the facility that affects AHM handling, a revision of the RMPP must be made within 60 days of-the modification. II!. Certification Section 25534 (j)'of the CHSC requires that the RMPP and any revisions be certified as complete by a qualified person and the faCility operator. Section 25532 of the CHSC defines a qualified person as "a person who is qualified to attest at a minimum, to the validity of the hazard and operability studies performed pursuant to Section 25534, and the relationship between the corrective steps taken by the handler following the hazard and Operability studies and those hazards which were identified in the studies". Qualifications of the certified person, Mary Jane Wilson, and the facility operator, Alex Manns, are.contained in Section 13.0 of this RMPP. Page 1 I hereby certify that this RMPP is complete, that the hazard'and operability studies pedormed on the behalf of Crystal Geyser, Bakersfield are valid and that programs included in this RMPP will mitigate potential hazards determined through the hazard and operability study. , /, /, Reg~stere~ny~ronmental Assessor ~t¢of California s,-ooo o . Expiration Date: June 30, 1991 I hereby certify, as facility operator, that this RMPP is complete. / Alex Manns Plant Manager Crystal Geyser, Bakersfield Page 2 IV... Revision Record All records concerning this Risk Management and Prevention Program shall be kept for . at least five years (Section 25534 (f)). Necessary revisions to the RMPP will be made at least every three years. The RMPP must be modified within 60 days of a modification that materially affects'the handling of an AHM (Section 25534 (h.)). All revisions to this RMPP are to be recorded here. Revision Pages Date of Signature of Number Affected Revision Person Making the Revision 1. 2. 3. 4. 5. 6, 7. 8. 9. 10. Page 3 ---,,- I .0 Background 1.1 General Business Information Name and Location Crystal GeYser Water Company 1 233 East California Avenue Bakersfield, California 93307 Exhibit 1 is a location 'map. Exhibit 2 is a facility diagram. The area immediately surrounding the plant is used for commercial, industrial, and residential purposes, as shown in Exhibit 3, a diagram of the surrOunding area. Business Telephone Number (805) 323-6296 Nature of Business The. Crystal Geyser Water Company Bakersfield plant formulates and bottles Crystal Geyser Brand juice drinks and flavored waters. For process cooling, an ammonia refrigeration system is used. 1.2. Description of AHM Used ., Amount Used The ammonia system holds approximately 300 pounds of liquid and vapor ammonia. One or two 150 pound cylinders are stored outside of the plant. Hazardous Properties Because of its physical properties, a release of liquid ammonia' has a greater potential to cause serious injury to receptors than gaseous ammonia. Liquid ammonia'released at a high rate can form a dense, ground hugging cloud of small liquid particles dispersed in air. A dense gas dispersion has the potential to move through surrounding areas, endangering neighboring rece¢ors. Ammonia vapors, lighter than . air, rise quickly in the atmosphere and are less likely to cause serious injury to. receptors. Ammonia vapors released into an unventilated area could reach high concentrations that present a risk to employees who enter the area unprotected. Page 4 1~! Street --NUE Lake 'CRYSTAL GEYSER l ~'~--'-~, ~ BAKERSFIELD ~- *' .< Potomac ':HE L TE~' ~ McNew {-:t. ~'~y,j"~- - - C~nnon Ave. '$CN. - E. Belle' WZI INC. Scale BAKERSFIELD, CALIFORNIA ?~,e, , 2~' , ~07' ' ' T CRYSTAL GEYSER 0 Mi',$ ~mi, )tmi. %~1~i, 'mi, N BAKERSFIELD / OKilometert .50kin lkm ~ ~ Location'Map DAT~_- 5/1/90 DN 2099 F_XHIBIT 17.33 £. ~-'~d ~ c~ ~,,,~;,,,,~,~,~, I-~-.._._.~~ : ~ ~ ~-.. "' I -. ( ?~. ~[,~J ,. · . ~ , ~ I ; } I . . · -~ ~- A ..~_ x ~ /.. ] ,, . ,'~u ,,,,, '~[ I I~,~ I ,~,:,,,. ,, ~,,,,,,I - ~,1 ' ~ ' ~'~ ~1 Y~ I ~1-'-' ~ ~*1 .- -, ~ ~,,, -I~ .... I ~I .... ' .... ~1' ~'~"~ ';~ ~,~ ' I Is t.~l~l I.~ ,, - · 111~,~,,~/ ' ""' / ~ I~ ........ ~ -~, ,~,J '1~'1-/-_ .... , I~ I~1.~ ..11 ,, !11 /...:-,~,,~ .......... :l ..,. .. FL) ' ' I ~ ~, * / pH~Z~ I I'" .......... ' I / ~ /'~,,."~'": ':'-',": ~'?-'~o~n - WZl INC. ; BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Ammonia Equipment is Highlighted N Facility Diagram c East California Avenue O .c: Vintage Job Crystal Crystal Cryst.a ~o Air Shack Geyser Geyser Geyser I m Storage Bottling Parking I Lot' Facility Lot / '~ Housing Complex Alley 'Housing Complex ~onterey FORNIA ~r, ~treet L~ Henley S ~treet Lucl Potomac WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Surrounding Area DATE ! !EXHIBIT 5/1/90 3 Ammonia, a colorless gas with an extremely pungent odor, can be detected by smell at concentrations at 3.5 to 37 mg/m3 (5 to 53 ppm). Ammonia is corrosive and irritating to the skin. High concentrations can cause dermal' burns, inflammation and swelling of the eyes and is potentially blinding to exposed i'eceptors. Levels of 500 mg/m3 (700 ppm) can cause eye irritation. Coughing occurs at a level of 1200 mg/m3 (1700 ppm). Exposure to higher concentrations can result in debilitating injury and death through pulmonary edema. Ammonia is not recognized as a carcinogen, and it does not cause adverse environmental impacts. 1.3 General Ammonia Refrigeration Processes Mechanical refrigeration is the process of lowering the temperature of a substance to below that of its surroundings. The cooled substance, ammonia, removes heat from process materials. In a single stage refrigeration process two pressures, high and Iow, are used to enable a continuous cooling process. Low pressure vapor is compressed, raising temperatures and pressure levels. DUring compression, heat of compression is added to the vapor as the pressure is raised. At the condenser the high pressure vapor is liquefied by cooling. The liquid refrigerant flows from the condenser to an expansion valve where its pressure is reduced and temperature is further reduced. The liquid ammonia then moves to the evaporator where it absorbs heat from a fluid being cooled and revaporizes. Vaporized ammonia then flows to the compressor suction for recompression to liquid to complete the refrigeration cycle. 1.4 Operation of the Ammonia System 'Exhibit 4 is a schematic diagram of the ammonia system. The system is designed to ' operate ,,,,,hen 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 cools the hot gas into a liquid. The liquid ammonia flows to and is contained in the outdoor receiver. A level control, controlled by a solenoid valve, allows ammonia to · flow from the outdoor receiver into the indoor receiver. Ammonia is charged into the indoor receiver from a 150 pound cylinder. The cap is kept on the cylinder while it 'is transferred through the building. For charging, the cap is removed. The indoor receiver sight glass is watched during delivery to ensure that the proper amount of ammonia is transferred into the system. From the indoor 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 countercurrently, 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. P~ge 5 liquids and vapors Carbo Solenoid Coolers Valve Ammonia controlling Receiver Flow to Level (Inside) Carbo Control Solenoid Coolers Vessel Valve liquids ~ SV SV SV SV Ammonia Added to pry The System from 150 lb Cylinder vapors to compressor suction Ammonia Receiver (Outdoor) Compressor discharge Evaporative Condenser Compressor Evaporative Condenser WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER pry: pressure relief valve BAKERSFIELD sv: shutoff valve Ammonia Schematic Diagram DATE I IEXHIBIT 4 5/15/90 2.0 Description of AHM Accidents 2.1 Accidents at this Location On March 23, 1989 a release involving the ammonia system caused neighbors to complain of an ammonia smell. A power failure caused the system to shut down. When power was returned, the initial startup blew three-thirty amp fuses in the condenser panel, shutting down both compressors. The operator did not know that the condenser were not operating and turned on the ammonia compressors. Pressure in the system quickly rose, forcing ammonia through the high pressure relief valve. 2.2 Underlying Causes The release was caused by the operator who turned on the compressors although the condensers were not working. 2.3' Measures Taken to Prevent Recurrence The operator is now required to check the condensers everY time he turns on the compressors. He has received substantial training to ensure that this type of release does not recur. Only trained personnel are allowed to operate the ammonia system. 2.4 Accident Investigation Procedures After an accident has occurred, an ammonia incident report (Exhibit 5) shal~ be filled out. A post accident review shall be held in which potential causes of the accident are discussed. Whefi the cause of the accident has been determined, a method shall be developed to ensure that the accident will not recur. System design, operating and maintenance procedures'that need updating or alteration shall be noted, and a time schedule set for implementation of improvements. Responsibilities: The Plant Manager' o ensures that accident report is complete. o conducts the accident investigation. o guides accident response. The Maintenance Manager: o provides technical details of reports. o assists with the accident investigation. ., o directs physical plant changes. '- o makes changes to the training program, if changes are necessary.. All employees' o assist with the accident investigation. Page 6 -AMMONIA INCIDENT REPORT FACILITY: DATE OF INCIDENT: TIME OF INCIDENT: SEVERITY OF INCIDENT: __ VERY SERIOUS Caused evacuation of the plant or neighbors, or serious injury, and required the use of SCBA (self contained bi'eathing apparatusi to contain. __ SERIOUS Caused injury and or damage to property and required the use of SCBA (self contained breathing apparatus) to contain. __ LOW THREAT Required breathing equipment but caused no injury or damage. LOCATION IN FACTORY: , SOURCE .OF DISCHARGE (TYPE OF EQUIPMENT) COMPONENT OR ITEM DISCHARGING (SUCH AS SEAL, VALVE, WELD...) CAUSE OF DISCHARGE: AMMONIA INCIDENT REPORT PAGE 1 EXHIBIT 5 ACTIVITY AT TIME OF DISCHARGE: DETAILS OF EMERGENCY RESPONSE: DEGREE OF CONTROL LOW MODERATE HIGH EFFECTIVENESS OF EMERGENCY PLAN LOW MODERATE HIGH DEFICIENCIES IN THE EMERGENCY PLAN: CONSEQUENCES OF DISCHARGE: NUMBER OF PEOPLE HURT EMPLOYEES OTHERS NUMBER HOSPITALIZRD 'EMPLOYEES OTHERS , EVACUATION: IMMEDIATE DISCHARGE AREA __ (Y/N) ENTIRE FACr[.I'I~ ~ (Y/N) NEIGHBORS __ (Y/N) ESTIMATED COST OF INCIDENT: PROBABLE RECURRENCE OF INCIDENrr: LOW MODERATE HIGH FULL DESCRIPTION OF INCIDENT (INCLUDING RELEVANT EVENTS LEADING TO THE INCDENT; ACTS, FAILLrRES TO ACT AND/OR CONDITIONS THAT CONTRIBUTED DIRECTLY TO THE INCII)ENT; WHAT ACTIONS WERE TAKEN TO CONTROL THE ]2qCIDENT.; WHAT REMEDIAL ACTION HAS BEEN.TAKEN TO PREVENT A RECURRENCE. AMMONIA INCIDENT REPORT PAGE 2 EXHIBIT 5 2.5 Release' Reporting Procedures Releases of acutelY hazardous materials that threaten human health and safety or the environment must be reported. The Plant Manager is responsible for determining the significance and reportability of a release. If an ammonia release exceeds 200 cubic feet during a 24-hour period or constitutes a threat to life, health or the environment, the event is reportable and the following agency must be notified immediately. City of Bakersfield Fire Department Hazardous Materials Division Telephone: (805)'326-3979 California Office of Emergency Services Telephone: 1-800-852:7550 The Plant Manager is responsible for reporting a release. Page 7 3.0 Equipment Report 3.1 Nature, Age and Condition The following equipment makes Lip the ammoni~ refrigeration system at Crystal Geyser Bakersfield. Each piece of equipment will be listed along with its nature, age and condition. Equipment: Ammonia Compress_or #1 Nature: This 75 hp compressor is used to compress ammonia vapors. Model Number: Vilter ¢446 Age' Built in 1964 Condition: Well maintained, good condition _Equipment' Ammonia Compressor ¢2 Nature: This 75 hp compressor is used to compress ammonia vapors. Model Number: Vilter #446 Age' Built in 1964 Condition:: Well maintained, good condition E~_D_ment: Oil Separator # 1 Nature: This oil separator removes oil from 'the higi~ pressure ammonia vapor d!scharging.from the #1 compressor. Oil is drained from tile separator for reuse in the compressor.. Brand: Mojannier, Maximum pressure' 250 psia @ 650 o F Age: Built in 1964 Condition' Well maintained, good condition .Eauipment: Oil Separator # 2 Nature' This oil sepa. rator removes oil from the high pressure ammonia vapor discharging from the #2 compressor. Oil is drained from the separator for reuse in the compressor. Brand: Mojannier, Maximum pressure: 250 psia (Lb 650 -" F Age: Built in 1964 Condition: .Well maintained, good condition Page 8 Equipment: Evaporative Condenser #1 Nature: This Baltimore AirCoil condenser cools the high pressure vapor ammonia to a liquid. 'Air flows up through the condenser, blown by fans. Water flows down through the condenser, evaporating and .cooling ammonia flowing' .through small lines. Model Number: VNC-110-'A, Baltimore AirCoil, Serial No. 77-0531 Age: Built in 1977 Condition: Good Equipment: Evaporative Condenser #2 Nature: This Baltimore AirCoil condenser cools the high pressure vapor ammonia tO a liquid. Air flows up throu9h the condenser, blown by fans. Water flows down through the condenser, evaporating and cooling ammonia flowing through small lines. Model Number: VNC-110-A, Baltimore AirCoil, Serial No. 77-0532 Age: Built in 1977 Condition: Good Equip .ment.; Outdoor Ammonia Receiver Nature: -THis ammonia storage vessel, 56 inches by 19 inches in diameter, is located outside of the building and holds high pressure liquid ammonia from the evaporative c°ndensers. Ammonia is added to the system at this receiver. The receiver has two pressure relief valves. Age: Built in 1964. Condition': Good Page 9 Equioment; Indoor Ammonia' Receiver Nature: This. ammonia storage vessel is located in the carbo cooler room and holds high pressure liquid ammonia from the outdoor receiver. Ammonia is added to the system at this receiver. A Pressure relief valve is located on a line from the receiver. The pressure relief valve is vented in the room. Liquids flow from this vessel to the carbo coolers, while vapors are suctioned by the compressors. HSB No. 6074, Serial No. 2999 Age: Built in 1956 Condition: Good Equipment: Solenoid Valve Controlling Level in the Indoor Ammonia Receiver, Nature: This solenoid valve controls liquid flow from the indoor receiver into the carbo cooler plates. Age: Rebuilt in 1990 Condition: Good Equipment: ' Carbo Cooler#1 Nature' Liquid ammonia flows through tubes in the carbo cooler. Heat is absorbed from liquids being cooled by the evaporating ammonia. HSB No.: 1533, Serial No. 2999 Age: Built in: 1955 Condition: Good Equipment: Carbo Cooler #2 Nature: Liquid ammonia flows through tubes in the carbo cooler. Heat is absorbed from liquids being cooled by the evaporating ammonia. HSB No. 1535, Serial No. 2999 Age: Built in' 1955 Condition: Good Page 1 0 -"~- Equipment: Ammonia Lines Nature' The ammonia lines carry the ammonia through the system. Age: The lines have been in place in this system for about 6 years. Condition' Good, suction lines are insulated Page 1 1 3.2 Testing Schedules Testing of control equipment is necessary to ensure that the equipment will work when · it is needed. ~ Test Schedule High Pressure Cutouts Tested during compressor maintenance pressure Relief Valves '- Tested when the vessel being protected undergoes maintenance 3.3 Maintenance Schedules The compressors require more maintenance than any 'other part of the ammonia system. The compressors are given a detailed inspection each month. Every day, operators monitor the equipment and log normal operating variables in addition to unusual'conditions. Exhibit 6 is a copy of a log typical of the operator's log used at Crystal Geyser. Conditions that may require maintenance include: o High temperatures o High or Iow pressures o High oil consumption o Unusual noises o Excessive vibration o Unbalanced operation When problems or potential problems are detected, the equipment is scheduled for maintenance. Maintenance schedules for regularly maintained equipment follows: Equioment Maintenance Schedule Compressors Monthly Inspection Page 1 2 4.0 Procedures Report 4.1 Daily Operating Procedures Operating procedures include' Daily Operatinq Duties 1. Inspect work area and overall system operation 2. Check suction temperatures and pressures constantly. Average temperature 15°F to 40°F and average pressure 28 to 60 psig. 3. Check discharge temperature and presSure constantly.' Average temperature 40°F · to 85°F and average pressure 60 to 140 psig. 4. Log in data once per day 5. Check oil levels in compressors. Normal level is mid-point to one-third of sight glass. 6. Check oil pressure in compressors. Average pressure 30 to 60 psig. 7. 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 Page I 3 4.2 Maintenance Procedures Maintenance procedures include' Ammonia System Shutdown 1. Shut suction valves on compressors 2. Shut king valve on receiver to pump all ammonia into the receiver' 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 corr~pressor motor off 3. Close discharge valve 4. Lock out electrical panel 5. 'Tag warning on the electrical panel 6. Open discharge valves before starting the compressor 7. Hook bleed off hose to the crankcase to bleed off excess ammonia into a bucket of water page 1 4 Restartinq a C0moressor 1. Disconnect bleed off hose 2. Open discharge valve at 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 Page 1 5 5.0' Design, Operating and Maintenance Control Systems 5.1 Design Control Systems Design control sys. tems include proper design of piping to minimize slug formation, automatic control devices (for a listing, see Appendix B-IV of the Hazards Analysis, included in this document as Appendix B), and proper sizing of process equipment. 5.2 Operating Control Systems The operator's log (Exhibit 6) is an effective control of the operating system. Process variables are noted and action is taken if required. Other operatin~ control systems. include labeling to ensure that proper actions are taken, and safe operating procedures training. Inexperienced workers are not allowed to operate the ammohia system or to perform work on the system. Any new employees must be trained thoroughly before they are allowed to operate the system. 5.3 rvlaintenance Control Systems The Maintenance Manager is responsible for controlling maintenance' of the system. Maintenance is recorded on the daily operators log, Exhibit 7. The daily operators log is reviewed by the Maintenance Manager and retained on file for future reference. Maintenance records are a control method. .Purchase orders are issued for.maintenance work requiring contractors. Completed · purchase orders are retained by the Plant .Manager. Page 1 6 ..- 6.0 Detection, Monitoring or Automatic Control Systems 6.1 Detection Systems Abnormal or hazardous conditions are detected by: Automatic controls (see Appendix B-IV of the Hazards Analysis, Appendix B of this report) Sight: Vibration, discolorations, rust, holes, worn spots Smell: Ammonia leaks, hot oil Hearing: Unusual sounds, lack of usual sounds Experience: A knowledge of what can go wrong with the system will help in detection of hazardous conditions. 6.2 Monitoring Systems The following variables are continuously monitored by automatic controlling equipment: Ammonia pressure- Monitored by pressure cutouts, pressure relief valves Ammonia liquid flow- Monitored 'by solenoid valves The following 'variables are mOnitored by the operator: Ammonia pressure- Checked by operator Temperature- Checked by operator Oil levels- Checked by operator Ammonia Level- Low levels are detected by a rise in the temperature of the process materials. 6.3 Automatic Control Systems Automatic control systems act as a backup to operator detection and actions..A listing of automatic controls on the refrigeration system is included as Appendix B-IV of the Hazards Analysis, Appendix B of this report. Page 1 7 ---..- 7.0 Proposed Risk Reduction Measures, 7.1 Written Operating Procedures Writt'en operating procedures (Section 4.1 of this RMPP) ensure that operators are well trained for their positions. Written procedures ensure that safe practices are continued despite turnover in personnel. These procedures will be kept in the maintenance manager's office and in this RMPP document, easily accessed by operating personnel. 7.2 Written Maintenance Procedures . Training using the maintenance procedures (Section 4.2 of this RMPP) as a guide, ensure that workers are well trained to perform maintenance on ammonia refrigeration equipment. Written procedures ensure that safety is continuous despite turnover in personnel. If contract help is required, .written maintenance procedures may prevent accidents caused 'by contractor unfamiliarity with the ammonia system. These procedures will be kept in the maintenance manager's office and in this RMPP document, easily accessed by maintenance personnel. 7.3 Increased Inspections Increased.. emphasis on inspections will ensure that deficiencies or problems are detected before they result in a release of ammonia. The inspection program is described in Section 10.0 of this RMPP. 7.4 Better Labeling Labeling and warning signs are an effective means of communicating hazards to new employees and/or visitors to the .plant. Emergency responders may need to know the contents of lines or types of materials in use. Improved labeling of lines or specific hazards will help to reduce the riskof release of AHM. Ammonia lines will be labeled. 7.5 Safety and Training Program Employees will receive training under Crystal Geyser Bakersfield's safety program. The training program is described in Section 11.3, Training Program for RMPP Implementation. Release prevention and emergency response training will reduce the risk of releases and minimize consequences of releases. 7.6 Fire Prevention Plan The fire prevention plan at Crystal Geyser. Bakersfield relies upon employee safety .·, training, and good housekeeping practices. A sprinkler system protects the building from fires. Page 1 8 7.7 Physical Plant Changes A pressure relief valve (PRV) has been added to the inner receiver. The storage location of the ammonia cylinders will be moved to the totally enclosed canopied and sprinklered compressor area in 1991. 7.8 Reduction of Risk to Neighboring Homes or Businesses The ammonia system is turned off during times when the plant is unoccupied. Maintenance practices coupled with operations training reduce the risk of ammonia releasing accidents. Proposed changes to the physical plant further reduce risk to neighboring facilities. An ammonia diffusion system to be added will absorb the ammonia before it can present a risk to receptors. The plant engineer (maintenance manager) is responsible for operation of the diffusion system. He.will designate a trained employee to operate the ammonia system during his absence. Page 1 9 8.0 Emergency Contingency Plans 811 General Evacuation Employees are verbally notified of emergencies by the plant manager or his designee. 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. Exhibit 8 is a map showing emergency evacuation routes. This route has been planned to bypass ammonia systems that may be leaking. 8.2 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. The sprinklers will extinguish fires in the plant. 8.3 Earthquake Employees should remain in safel stable locations (in doorways, under stordy desks) until earth movement has ceased. After the earthquake, all employees are to leave immediately through the nearest exit and regroup at the parking lot at East California and Lakeview, far enough from the building to avoid falling masonry. 8.4 Significant Leak from the Ammonia System Employees are verbally notified of the leak. Notify the Bakersfield City Fire Department through 911. Ammonia operators will work to isolate the leak, if possible. All non essential employees are to leave immediately and regroup at the parking lot at East California and.Lakeview. Clean up procedures for an ammonia release will mitigate the effects of {he release: o Ventilation will reduce concentrations of ammonia in enclosed areas o If liquid ammonia is on the floor, spray it with large quantities of cold water o Water will absorb ammonia: high concentrations of ammOnia vapor or dispersed ammonia can be diluted with water spray, During a release, the plant engineer (maintenance manager) will: o Stop leaks o Supervise the use of self contained breathing apparatus, The plant engineer has an in-depth knowledge of the ammonia system. He has many years of experience with refrigeration systems. Page 2 0 8.5 Emergency Responders In an emergency, the following agencies may be ne'eded: Hospita! Memorial Hospital 420 34th Street Bakersfield, California (805) 327-1792 Fire De0artment Call 91 '1 P~e 21 ""-~ .9.0 Auditing Program A copy of the audit used at Crystal Geyser Bakersfield is inctuded as Appendix C. The purpose c' the ammonia safety audit is to ensure that the ammonia system is operated and maintained in a manner that ensures the minimum possible risk to personnel, the general public, environment and product safety. Other goals to be achieved by the ammonia safety audit are: o To pinpoint actual and potential safety hazards due to design, location, operation and maintenance of the ammonia system. o To provide a means of objectively assessing and documenting plant safety. o To provide a means of objectively defining . needs for upgrading and modification. o To provide feedback on safe. ty issues. The ammonia safety audit will be conducted on a yearly basis. Page 22 · '--- 10.0 Inspection Program An inspection program is necessary for the assessment of hazards present in the work place. The person responsible for inspection must be familiar wiLh the process and system being inspected. Hazards, deficiencies, out-of-normal variables or unusual observations or occurrences must be recognized and recorded during the inspection. Potential hazards identified through the inspection will bi~ assessed and assigned priorities for correction. Action will be taken to reducb the risk presented by identified hazards. The maintenance manager is responsible for inspecting the work area at the beginning of the shift. Any notes resulting from the inspection will be noted in the log. In addition to daily inspections by the quality control manager and the maintenance 'manager, the ammonia safety audit includes an intensive inspection of the ammonia refrigeration system. Inspections of the System may be scheduled after process changes, upsets, or accidents. Page 2 3 11.0 RMPP Implementation "Implementation of the RMPP shall include carrying out all operating, maintenance, monitoring, inventory control, equipment inspection, auditing, record keeping, and training programs as required by the RMPP." 1 1.1 Personnel Responsible for RMPP Implementation The title of each person charged with RMPP implementation dut. ies are listed below, along with their respective responsibilities. Tit. l~ RMPP Implementation Responsibilities Plant Manager Supervise a0dits, inspection and record keeping,' responsible for RMPP implementation Maintenance Manager Supervise equipment inspection, emergency ' response training, operating and maintenance training, inventory control and labeling Quality Control Manager Coordinate emergency response training All Employees Undergo emergency response and evacuation training Page 2 4 -,.- 11.2 Implementation Schedule The following schedule will be followed for RMPP Implementation. Program Date of Full Implementation Inspection Program Ongoing Ammonia Safety Audit July, 1991 RMPP Record keeping August,' 1991 Safe Operating Procedures Training March, 1991 Maintenance Procedures Training June, 1991 Evacuation Training June, 1991 Emergency Respbnse Training June, 1991 Labeling May, 1991 Airpack Respirator Training December, 1991 Move Cylinder. Storage to Canopied June, 1991' and Sprinklered Area Ammonia Diffusion System December, 1991 Page 2 5 11.3 Training Program for RMPP Implementabon The RMPP training program must ensure that standard operating procedures are easily understood by operators. Training should be able to provide a continuity of safety despite employee turnover or changes in personnel. Training ensures that plans and programs such as emergency evacuation plans will work as designed when they are needed. During training sessions, employees speaking both Spanish and English serve as translators for employees that speak only Spanish. The following subjects'will be covered by the training program: Use of Safety Equipment o When to wear a respirator o What type of respirator is appropriate; limitations o How often must the respirator be replaced o Respirator maintenance During 1991, an airpack respirator will be obtained for. use during emergencies. Ammonia First Aid Procedures o Keep a rope available to retrieve overcome employees o if an employee is overcome by ammonia: 1. Move victim to an area clear of ammonia 2. Call a doctor 2. Remove contaminated clothing 3. Keep the patient still and covered with blankets o For skin burns, wash immediately with large quant'ities of water Review of Material Safety Data Sheets, Chemical Hazards Fire Prevention and Response Release Reporting (Section 2.5) ~ Evacuation Procedures (Section 8.1) Earthquake Procedures (Section 8.3) Page 2 6 SPill Containment and Dilution Procedures (Section 8.4) Daily Operating Procedures (Section 4.1) Maintenance Procedures (Section 4.2) Page 2 7 12.0 RMPP Record Keeping Record keeping, required by RMPP legislation, ensures that RMPP programs are implemented and maintained. 1 2.1 Accident Records Documentation of accidents is necessary to prevent recurrence. Section 2.0 of this report is a description of accidents involving ammonia, including accident investigation procedures and measures taken to avoid a repetition of the accident or release. 1 2.2 Ammonia Charge Records Ammonia charge records (Exhibit 9) will document amounts and dates of ammonia deliveries. Inventory control is a significant aspect of RMPP implementation. 1 2.3 Training Records Training records will be kept to ensure that each employee receives required tra. ining~ All employees must be .trained in emergency evacuation procedures. Certain employees need training in specific procedures related to the handling of acutely hazardous materials. Exhibit 10 is the format for the record of training Required/Completed Record. 1 2.4 Audit Records Results of the ammonia safety audit are kept for future reference. Documentation ensures that hazards identified through the safety audit are addressed in a timely manner. A copy of the ammonia safety audit is.contained as Appendix C. Page 2 8 13.0 Qualifications of Certifiers 13.1 Qualified PerSon Mary Jane Wilson, President, WZI Inc. Ms. Wilson received a Bachelor of Science Degree in Petroleum Engineering from Stanford University in 1972. She is registered as an Environmental Assessor in California. Ms. Wilson is the President and Corporate Executive Officer of WZI Inc. She monitors WZl Inc. projects to maintain technical standards. She has extensive experience (17 years total).in the petroleum and environmental consulting, industries. She has participated in the design of numerous compliance programs related to the environmental safety of operating facilities. 13.2 Facility Operator ,. A/ex..M..a.nns, Plant Man. M.8.0..8.g~ Mr. Manns, Plant Manager of Crystal Geyser, has worked as plant manager for Crystal .Geyser for one and 1/2.years. Previous.duties included a'combif~ed 19 i/2 years as plant manager for the Coca Cola and the Pepsi Companies. Page 2 9 References 1. The Center for Chemical Process Safety, Guidelines for .Hazard Evaluation Procedures, '1985, American Institute of Chemical Engineers. 2. Office of Emergency Services, HazardOus Materials Division, Risk Management and Prevention Program Guidance, 1989, State of California. 3. U.S.-Environmental Protection Agency, Federal Emergency Man'agement Agency- and the U.S. Department of Transportation, Technical Guidance for Hazards Analysis: Emergen..cy Planning for Extremely Hazardous Substances, 1987. 4. National Response Team, Hazardous Materials Emergency Plannina_ Guide, 1987. Page 30. HAZARDS ANALYSIS CryStal Geyser Water Company Bakersfield, California Appendix B Submitted to the Hazardous Materials Division of the Bakersfield City Fire Department August, 1990 Revised October 1, ,1990 Revised April, 1991 TABLE OF CONTENTS Section Page 1.0 Introduction 1 2.0 Summary 2 3.0 Hazards Identification 3 3.1 Chemical Identity of Acutely Hazardous Materials 3 3.2 Location of Acutely Hazardous Materials 3 3:3 Quantity 3 3.4 Nature of Hazard .3 4.0 Hazard and Operability Study Results 6 4.1 Summary 6 4.'2Release Scenarios 6 4.3 Offsite Consequences · 9 4.4 Onsite Consequences 10 4.5 Human Error Analysis 10 5.0 Vulnerability Analysis I 3 5.1 Vulnerable Zone 13 5.2 Human Populations 1 4 5.3 Critica! Facilities i 5 6.0 Risk Analysis 1 6 6.1 · Release Probability 16 6.2 Severity of Consequences 1 6 EXHIBITS Exhibit B-1 Location Map Exhibit B-2 Hazards Analysis Flowchart Exhibit B-3 Facility Diagram Exhibit B-4 Ammonia Schematic Diagram Exhibit B-5 Map of Surrounding Area Exhibit B-6 Factors Affecting Vulnerable Zone Estimations Exhibit B-7 Neighboring Receptors Exhibit B-8 Worst Case Vulnerable Zone Map Exhibit B-9 Worst Case IDLH Exposure Map TABLES 'Table 1 Physical Properties of Ammonia APPENDICES Appendix B-I Hazard and Operability Study Guideline Appendix B-II Hazard and Operability Study Forms Appendix B-III Modeling Results Appendix B-IV Alarms and Control Devices 1.0 INTRODUCTION This hazards analysis of the use of Acutely Hazardous Materials (AHM) has been prepared for the Crystal. Geyser Bakemfield bottling facility, located at the corner of East California Avenue and Lakeview Avenue, Kern County, California (Exhibit B-l). This analysis has been prepared in accordance with the EPA/FEMA/USDOT document "Technical Guidance for Hazards Analysis: Emergency Planning for .Extremely Hazardous Substances, 1987." There are three, basic components in hazards analysis (Exhibit B-2) which provide the outline of this report: o Hazards Identification o Vulnerability Analysis o Risk Analysis Page 1 ~~ CRYSTAL GEYSER ,~=.~~ ~~~~ BAKERSFIELD a. ~ ~ ~ WZI INO. Sca I ~ BAKERSFIELD, CALIFORNIA A }k CRYSTAL GEYSER Feet ~' 40~' 0 Kilo~eZer% .SOkm lkm , ', ~ Location Map ~:~:~il ~::i::HAZARDS !i IDENTIFIOATION ANALYSIS :'?iiiiLOCATION ilii HUMAN POPULATIONS CRITICAL FACILITIES NATURE OF THE ~ HAZARDS ~,,~ .ENVIRONMENTAL .Be ~ REFERENCE: EPA/FEMA 1987 EXHIBIT B-2 2.0 ~ The potential for offsite and onsite consequences is presented by the ammonia refrigeration system in operation at the Crystal Geyser Bakersfield beverage formulation and bottling facility. Ammonia releases could occur leading to possible exposure of workers and receptors above the Level of Concern (LOC), 50 ppm, and the Immediately Dangerous to Life and Health Level (IDLH), 500 ppm. The worst case credible scenario, determined through the hazard and operability study, was determined to be the formation of dispersion cloud of ammonia released by the rupture of a liquid ammonia line outdoors. Liquid ammonia released at high rate Could form a liquid/air dispersion cloud that could migrate to neighboring residential areas. The immediate area surrounding the Crystal Geyser plant is both residential and industrial. Apartment buildings are immediately adjacent to the Crystal Geyser plant. Worst case credible onsite consequences may be experienced with the rupture of a line at the indoor receiver, releasing the liquid contents in a liquid/air dispersion, followed by the subsequent release of liquids and vapors remaining in the system into the building. The extent of the vulnerable zone for a worst case credible release of the contents of the ammonia receiver, 216 pounds of ammonia, determined through modeling, is approximately' 2.3 miles (3.7 km) at 30 minutes after release. LOC eXposure at 2.3 miles from point of release is expected to last approximately 30 minutes. The IDLH level, 500 ppm, may be reached at UP to 0.8 miles (1.3 km) away 11 minutes after release. The IDLH exposure is expected to last approximately 12 minutes at 0.8 miles from the point of release. This Hazards Analysis showed the Crystal Geyser ammonia refrigeration system to be' highly automated'. The design of the system is such that .employees need only to switch on the system in the morning and periodically add oil. Less frequently, make-up ammonia is added to the system. The system design needs to be better documented: no drawings of the system were located. Only two employees, the Maintenance Manager and the Mechanic and Production Supervisor, are authorized to perform mainten~tnce on the ammonia system. As part of the RMPP, Crystal Geyser will implement a safety audit of the refrigeration system. The RMPP should focus on minimizing risk and on emergency response. Employee training and training documentation will be supplemented; as will inventory and procedural record keeping. Page 2 3.0 HAZARDS IDENTIFICATION 3,1 Chemical Identity of Acutely Hazardous Materials Anhydrous ammonia is stored and used in reportable quantities at the Crystal Geyser Bakersfield facility. 3.2 Location of AHM at Facility The ammonia in use at the Crystal Geyser facility is Contained in the ammonia refrigeration system. Exhibit B-3 is a facility diagram. Exhibit B-4 is a schematic diagram of the ammonia system. Liquid anhydrous ammonia is stored in the two receivers, one outdoors and one indoors. An ammonia cylinder is chained outside of the building at the southWest corner. When ammonia is. needed, the cylinder is unchained from its outdoor storage location and wheeled into the room containing the indoor receiver and carbo coolers. The ammonia system is recharged from the cylinder into a line connected to the inside receiver. 3.3 Quantity The ammonia system holds up to 300 pounds of ammonia. A 150 pound cylinder is stored outside andr is used to replace ammonia lost as fugitive emissions from the system. 3,4 Nature of Hazard Ammonia presents the risk of death or debilitating injury to humans exposed to high concentrations. Major releases from the ammonia system may cause high concentrations of ammbnia to reach receptors, either in the plant or in surrounding areas. Page 3 ,.~_ ._ ~l;.~, "1~ ;. ~ ~ , ~ · -"" ~1~~ ~1 ~N //ll,t" "l ~' ~" .....~ "'~1 ~" ( [EIII ~[," ......... //I[~:::~: .:-- I, I ...................................... '~ .~ ~ ....... ~ ~-I ' '~,L l_¢''~ ' - ............... '"'" ·' .... p./ ..... ~ ,'"'"'" .:::"" '""-"~"- r~ ~ tT~"~ I o n~,, :~¥:~ l.}~..I ,- ...... ,.. ; ~ ~ '~:' / "F~ ' 4 ......... "~ -~ 4':~ .... ~ .............. "" [", t/~ ' " WZI INC. ~AKERSF~ELD, CAUFORN~A ....... ~ ~ CRYSTAL GEYSER BAKERSFIELD Ammonia Equipment is Highlighted N Facility Diagram . ; DA3E 5/90 2101 B-3 Because of its physical properties, a release of liquid ammonia is most likely to cause serious injury to receptors. Liquid ammonia released at a high rate can form a dense, slow moving cloud of liquid ammonia dispersed in air. Ammonia vapors, lighter than air, rise quickly in the atmosphere and are less likely to cause serious injury to receptors. Ammonia vapors released into an unventilated area can present high concentrations to receptors entering the area. Ammonia, a colorless gas with an extremely pungent odor, can be detected by smell at concentrations at 3.5 to 37 mg/m3 (5 to 53 ppm). Ammonia is corrosive and irritating to the skin~ High concentrations can cause dermal burns, inflammation and swelling of the eyes and is potentially blinding to exposed receptors. Levels of 500 mg/m3 (700 ppm) can cause eye irritation. Coughing occurs at a level of 1200 mg/m3 (1700 ppm). Exposure to higher concentrations can result in debilitating injury and death through pulmonary edema. Ammonia is not recognized as a carcinogen nor does it present a threat to the environment. Table 1 lists physical properties of ammonia. Page 4 Table 1. Physical Properties of Anhydrous Ammonia (NH3) · MOLECULAR WEIGHT 17.03 LBM/LBMOLE LATE NTH EAT 327 CA LO RI E/G RAM BOILING POINT -27.4 oF (-77.7 °C) SOLUBILITY 89.9 G/100 mi AT 0 oC SPECIFIC GRAVITY (LIQUID) 0.682 (-33.35 oC/4 oC) VAPOR DENSITY 0.59 (A~R=I) @25 oC, 760 mm HG AUTOIGNITION TEMPERATURE 651 oC (1204 °F) EXPLOSIVE. LIMITS 16 TO 25' % BY VOLUME IN AIR CRITICAL TEMPERATURE 132.9 oC CRITICAL PRESSURE 11.5 ATM IDLH 350 mg/m3 (500 ppm) LOC 35 mg/m3 (50 ppm) STEL 25 mg/m3 (35 ppm) RATIO OF SPECIFIC HEATS 1.31 1 PPM 0.7 mg/m3 @ 25 oC AND 760 mm HG The molecular structure of ammonia is composed of one Nitrogen (N) and three Hyd¢ogen atomS (H). The molecular weight of ammonia, 17 Ibm/Ibmole, is significantly less than that of air which is approximately 29 Ibm/Ibmole. As a result, ammonia in the vapor phase is much lighter than air and rapidly rises when released. Page 5 4.0 Hazard and Operability Study Results Appendix B-I is a copy of the guideline used for the Hazard and Operability Study. Forms used during the Hazard and Operability Study are included as Appendix B-II. Appendix B-Ill contains modeling results, and Appendix B-IV lists alarms and control devices in the ammonia system. 4,1 Summary_ Each study node was reviewed for possible deviations from normal operation, and potential consequences resulting from the deviations were recorded. The severity and probability of consequences were rated. It was determined that the greatest risk is presented by release of liquid ammonia, which can form a dense ammonia/air dispersion. A dense dispersion can hug the ground, potentially inflicting injury upon receptors. In summary, the most likely worst case release at the Crystal Geyser Bakersfield plant is a release of the contents of the outdoor ammonia receiver through a line broken during a severe earthquake. Appendix B-Ill contains results of modeling the worst case credible release. 4.2 Release Scenarios Accidents such as fires or hazardous material releases are often not caused by single factor but are the result of a chain of circumstances.. A scenario is an abbreviated description of a specific chain o'f events that causes a particular outcome such as an AHM release related death, injury, property loss, or other incident. Release scenario characteristics include: o Condition: Temperature, pressure of the material released o Equipment at Which the release originates o Time of incident: Day, night, morning, afternoon o Cause of release: Over pressurization, ruptured lines, operator error o Direct cause of loss: Exposure to high levels of ammonia o Type of loss: Death, injury and/or property loss DO 'o Receptors: Employees, sensitive receptors o Magnitude of loss: Number of people affected, property lost Page 6 Release scenarios at the Crystal Geyser Bakersfield plant are based upon the most likely .hazards that were developed through the hazard and operability study. Probabilities of accidents can be determined' through a study of reliability data. Two main types of reliability data are required: o Equipment and instrument failure rate and repair rate data o Human error probabilities and recovery probabilities The following causes of accidents that can occur in processing plants were reviewed in preparation for the hazard and operability study: o Improper maintenance methods o Modifications to equipment o Human error o Improper labeling o Improper operating methods 'o Wrong materials used in construction o Faulty Equipment o Fire o Earthquake Deviations that result in situations that could severely affect onsite or offsite receptors were denoted by a high-medium designation on the HAZOP form. Potentially severe consequences determined through the hazard and operability study included those due to the following deviations: o Major leak,in system. 1. Pooled liquid ammonia outdoors (Presents.a high concentration of ammonia in a localized area) 2. Dispersed liquid ammonia outdoors (greatest potential to affect large numbers of offsite receptors) 3. Pooled liquid ammonia indoors (presents a high risk to employees in an unventilated buildings) '" Page 7 · 4. Dispersed liquid ammonia indoors (presents a severe* ~'isk to employees in the building, ventilated or unventilated) 5. Release of' vapor ammonia outdoors (presents a localized risk due to high concentrations in the immediate area: ammonia will likely rise before it reaches great distances; dispersion, is affected by temperature and wind speed) 6. Release of' vapor ammonia indoors (presents. a high risk to employees in an unventilated building, lesser risk in a ventilated building; risk is dependent upon amount, rate of release) o Earthquake (pipes may be ruptured in a severe earthquake, quickly releasing large quantities of ammonia within or outside the building. o High pressure shutdown failure (high pressure may lead to an ammonia releaSe through pressure relief valves) o Pressure relief valve (prv) failure (high. pressure may lead to a rupture in a line or vessel) o Exit valve to compressor closed (high pressure may lead to pry release) o Exit valve to receiver closed (high pressure may lead to pry release)' o Fire (high temperatures may result in high system pressures, causing ammonia release) o ReleaSe during ammonia loading (human error, equipment failure) Deviations that result in scenarios that are likely to occur were listed with a medium to a high probability. Situations of concern that were determined to be likely to occur were results of the following deviations. o Valve closed incompletely (human er~°r) o Power failure (compressor seals fail) o Minor leak in system (fittings, corrosion) o Earthquake 8 Page One deviation from normal operation was found to have a medium to high probability combined with a medium to high severity; an earthquake. The possibility of a release · due to an earthquake is mitigated by the design and anchoring of the system. The greatest potential for major release from the Crystal Geyser Bakersfield bot[ling facility was found to be circumstances over which the operators have no control, such as earthquake or fire conditions. Human errors were determined to be likely to result in lesser, non-reportable releases. 4.3 ~62_0.s it e C o n s.~.~.._e nces The compressors, the most probable origin of ammonia release are located outside of the plant, protecting the rest of the plant from high levels of ammonia due to a release from the compressors. A release of ammonia vapor from the compressors is likely to occur a.t a slcw rate. The outdoor location prevents the slow concentration of high levels in the imrnediate area. A release of ammonia in the vapor form will rapidly rise in the atmosphere, out of 'the range ol receptors. Past ammonia releases from the 'compressors (due to human error and described in the RMPP) annoyed neighbors but did not cause injury to offsite receptors or employees. An indoor release could affect Crystal Geyser's. 1'7 permanent employees and an undetermined number of temporary workers (the number varies from day to day). Any indoor release is dangerous, large or small, because of the potential for a high concentration to build in areas that are not well ventilated. Evacuation and emergency response training help to mitigate the potential for onsite consequences. Doors at either side of the building can be opened for ventilation if ammonia concentrations in side 'the building. The room in which the indoor ammonia equipment is held is somewhat isolated from the rest of the building. The indoor receiver is connected to a relief valve that vents above the roof line. Page 9 4.4 Offsite Conseauences The outdoor ammonia receiver contains the largest amount of liquid ammonia located where a dispersion cloud could be released towards offsite receptors. The most likely potential release of the contents of the receiver to the outdoors was determined to be through a break in the liquid ammonia line leading from the evaporative condensers to the receiver or lines from the outdoor receiver to the indoor receiver. A cloud of dispersed ammonia from a rapid, large release presents the greatest, danger to offsite receptors. Human Error .Analysis The purpose of a human error'analysis is to identify potential human errors and their effects. '.Causes of human errors that have occurred in the past may also be identified. Human Error: Normal Operation During normal operation the highly automated ammonia system requires little operator action. The maintenance manager, the main ammonia system operator, will, in the future, record information regarding system variables onto a log. Oil is regularly 'drained manually from the oil receivers. Potential areas for operator error during normal operation include: Areas for Proposed Operator error .Consequence~ SeveritY/Likelihood Mitigation Improper logging Poor records' Low/Low Employee training Valve not shut off Potential for Low/Med EmploYee training after oil drain sm. ammonia release Open wrong Damage to Low/Low Employee training compressor compressor valve · Forget to Damage to Low/Low Log, Employee add oil compressor Training Neglect Relief valve Med/Low Auto controls, high pressures release relief valves, emPloyee training Page 1 0 Human Error: Ammonia Addition When necessary, ammonia is added at the indoor receiver. The maintenance manager supervises ammonia addition. 'An ammonia canister is carried from outside the building to inside the carbo cooler room. A hose is attached from the canister to the connection below the indoor receiver..The sight glass on the indoor receiver is watched while the ammonia is added. After a sufficient amount of ammonia is added, . the hose is disconnected and the cylinder removed. The following errors are possible during ammonia addition: Areas for Proposed Ooerator error Conse(~uences Severity/Likelihood Mitioation Sight glass Too much ammonia Low/Mad Employee not read properly in system; Relief Training · valves may relieve Valve not shut Ammonia leak Low/Low Employee off prope¢ly Training Worn hose not Ammonia leak Mad/Low Replace hose noticed possible when worn Hose not disconnected Ammonia release Mad/Low Inspect hose. possible H~Jman Error: Emerqency Situations Emergency situations include fires, equipment difficulties, ammonia leaks, and earthquakes. Areas for Proposed Operator error Oonseque, nces Severity/Likelihood Mitigation Improper use of Employee injury Med/Low Employee - breathing equipment training Improper fire Employee injury, Med/Low Employee fighting procedures ammonia release training Earthquake response: Increased risk of Low/Low Employee Improper evacuation employee injury training procedures Eadhquake response: Possible increased Low (relative to Employee Improper shutdown ammonia release severity of earthquake)/ training procedures Low Page 1 1 Human Error: Maintenance Procedures Areas for Proposed Operator error Conseauences Severity/Likelihood Mitiaation Compressor SmalVmedium Med/Low Employee not pumped down ' ammonia release; training/ for maintenance possible emp. injury supervision In summary, AHM releases due to human error were found to be likely to be smaller in magnitude than potential releases from events such as an earthquake or fire. The automation of the ammonia system reduces the risk of human error. Increased training of'workers will further reduce the risk of human ei'rors in normal, maintenance and emergency operations at the Crystal Geyser Bakersfield plant. P~e 12 5.0. Vulnerability Analysis 5.1 Vulnerable Zone The worst case vulnerable zone radius is the maximum distance from the release to the point at' which the airborne chemical concentration equals or exceeds the L.O.C. Exhibit B-5 is a map of the area' surrounding the Crystal Geyser plant. Factors affecting vulnerable zone estimations are summarized in Exhibit B-6. Neighboring receptors are shown in Exhibit B-7, and the Worst Case Vulnerable Zone is shown as Exhibit B-8. Exhibit B-9 shows the area which could be exposed to ammonia concentrations above the IDLH in a worst case release. ,EPA/FEMA/DOT guidelines (1987) indicate that decisions about evacuation are incident specific and are to be made at the time of actual release. An estimated vulnerable zone should not automatically be used as the basis for evacuation during emergency response. In this study, the vulnerable zone radius is estimated using assumptions for a credible worst case scenario. A. Quantity and Rate of Release to Air The vulnerable zone is proportional to the quantity and rate of release. In this study of credible worst ~;ase scenarios, a break in an outdoor liquid ammonia line was determined to present the greatest risk to offsite receptors. In the worst case release 216 pounds of ammonia would be released from the outdoor ammonia receiver. Computer modeling determined that release could Occur i'n as little as 1/2 minute. B. MeteQrological Conditions Wind speed and atmospheric stability have a significant effect on the size of estimated vulnerable zones. Increased wind speed and the accompanying atmospheric stability will result in' greater airborne dispersion an~l a decrease in the size of the estimated vulnerable zone. Low wind speeds are used in worst case scenarios. Page 1 3 Industrial · Industrial ~ Parking c East California Avenue 0 '- Vintage Job Crystal Crystal Crysta ~ ~ Air Shack Geyser GeyserI u) Storage Bottling ParkingI ~: Lot Facility Lot / '~ Housing Complex Alley "J ~ Housing Complex [ ~onterey [ -~ WZI INC. I BAKERSFIELD, CALI,FORNIA CRYSTAL GEYSER N BAKERSFIELD Surrounding Area Exhibit 'B-6 F~ctors Affecting Vulnerable Zone Estimations o Quantity of Release o Physical State (solid, liqUid, gas) of Material o Temperature of Stored Material o Pressure of Stored Material o. Physical Characteristics of Material (Molecular weight, Vapor Pressure, etc.) o Surface Area of Spill, if Liquid o Type of Release (Leak, Explosion, etc.) o .Rate of Release o Meteorological Conditions (W. ind Speed, Cloud Cover, Temperature) o Surrounding Topography o Level of Concern of Material 22nd LStt~! Williams School "~' i Special Services IFORNIA ~OurLady ' ' Bethel Christian School' i : arendon St. '~ 0~-'Guadalupe Sch. 61 P~o,,,= 1, ~ ' l' ' Victod~l D Owens Sch6ol __ Mt. Vernon School ~ E.~ S~ ~ I I Tex~ S~. ~ --L~ --BRUNDAGE ~l : o . ,g St. -- 2OD0' .' ~errace Way Feliz ~ 5~EL~E~ · i"'" ,' :~" i, 4o..oo, , ; I wz~ ~NC. r'~ BAKERSFIELD, CALIFORNIA Miles Y, mi. . , .½.m.i. ~'b:ni. · ~ · ?~,o.~......sokm ~m CRYSTAL GEYSER BAKERSFIELD Neighboring 5/1/90' WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Worst Case Vulnerable Zone Map DATE5/1/90 ! IEXHIBIT B'8 ~MORIA{ .,;;. ~Shad Lake Ln, CRYSTAL GEYSER BAKERSFIELD .... Potomac . Viro~nia Te: I Feet ~l~ u. ...... ~000' ..' 4000' : W Z I I N C. OMiles '~mi, ,, BAKERSFIELD, CALIFORNIA · 4% 0K,o.~e,...50k.~ ~km ' CRYSTAL GEYSER BAKERSFIELD Worst Case IDLH Exposure Map I C. Surrounding Topography The Crystal Geyser plant is surrounded by residential apartments, open areas and .~ industrial offices and warehouses. D. Levels of Concern (L.O.C.~) The L.O.C. for anhydrous ammonia is 50 ppm (0.035 g/m3)· 5.2 H~jman Populations The community surrounding the Crystal Geyser Bakersfield facility is shown in Exhibit B-5. Immediately surrounding the facility to the South is a residential apartment complex, currently uninhabited and undergoing renovation. Sensitive receptors located near the facility include: Receptor ,Approximate Distance (miles) Direction Owens School 3/8 SW Special Services School 7/16 ENE Our Lady of Guadalupe Sch. 11/16 W Williams School 11/16 NE Mt. Vernon School 15/16 ESE Bethel Christian School 1 E Prevailing wind direction is from the Northwest. A worst case release (Exhibits B-8 and B-9) of dispersed 'ammonia could reach and affect receptors at these locations. Page 1 4 WZi ,Nc, 5,3 Critical Facilities Critical facilities near Crystal Geyser Bakersfield are: Kern Medical Center 1830 Flower Bakersfield, California Telephone: (805) 326-2000 Bakersfield City Fire Department, Station #2 716 East 21st Bakersfield, California Telephone' 911 Page 1 5 6.q RISK ANALYSIS 6.1. Release Probability The ammonia system at the Crystal Geyser plant has been in operation for approximately five years. The hazard and operability study determined that the probabil.ity of minor releases of ammonia through fugitive emission points or thiough compressor shaft seals during system shutdown was fairly high. The risk of a major release due to human error or system malfunction is much lower, but can be further reduced through procedural changes and an improved training and record keepir~g program. A release resulting from a major earthquake is likely to be large. 6.2. Severity of Consequences The severity of consequences from an ammonia release is moderate because: 1. The quantity of ammonia in the ammonia system is sufficient to cause injury to neighboring receptors in a worst case release. 2. It meets the criteria provided by the EPA/FEMA (1987) of "high" severity of consequences to people. Those criteria are: I. Low: Chemical is expected to move into the surr°unding environment in negligible concentrations. Injuries expected only for exposure over extended periods or when individual personal health conditions create complications. II. Medium: Chemical is expected to move into the surrounding environment in concentrations sufficient to cause serious injuries and/or deaths unless prompt and effective corrective action is taken. Death and/or injuries are expected only for exposure over extended periods or when individual personal health conditions create complications. Page 1 6 III. High' Chemical is expected to move into the surrounding environment in c°ncentrations sufficient to cause serious injuries and/or deathS upon exposure. Large numbers of people would be expected to be affected. Page 1 7 APPENDIX B-I HAZARD AND OPERABILITY STUDY GUIDELINE Appendix B-I Hazard and Operability Study Guideline Contents 1. Introduction 2. Hazard and Operability Study Team Members and Qualifications 3. Study Nodes 4. Intention: Normal Operation of the Ammonia System 5. Deviations 6. Causes of Deviations 7. Consequences 8.' Guide Words 9. .Focus of Study Introduction A HAZOP study is used to identify hazards and operability problems. The primary objective of the HAZOP study is identification of problems. Possible solutions to problems may be discussed and recorded during the study. This HAZOP study will focus on the .ammonia refrigeration system. 2~ Haza, rd and Operability Study Team Members a~d Qualifications. The Crystal Geyser HAZOP team is made up of the following individuals: AleX Manns: Plant Manager, Crystal Geyser Bakersfield Mr. Manns has worked 'as plant manager for Crystal Geyser for one and 1/2 years.' Previous to his employment with Crystal Geyser, he worked five years as plant manager for Calvin Coolers which operated at this location. Mr. Manns previously worked as plant manager for the Coca Cola and Pepsi Cola Companie¢. Norm Ambrose: Plant Engineer, Crystal Geyser Bakersfield Mr. Ambrose has Worked in maintenance departments for bottlers and wineries for 25 years. He has been at Crystal Geyser for one and 1/2 years. He will perform quality control for this study. Gerhard Gaugel: Crystal Geyser Bakersfield Mr. Gaugel has worked as assistant plant manager for Crystal Geyser for one year. He was quality control manager at Pepsi for six years. Appendix B-I.Page 1 Linda Knowles, Staff Chemical Engineer, WZI Inc. Linda Knowles is a degreed chemical engineer (Texas A&M University, 1980). She has two years of experience in the chemical process industries and two years of experience in the environmental consulting industry, focusing on safety and risk 'assessme. nt. She will lead the HAZOP team, conduct the consequence analysis and perform a human error'analySis as described in the Guidelines for Hazard Evaluation Procedures, AICHE, 1985. Norman Ambrose and Linda Knowles will walk through the facility; Gerhard Gaugel and Alex Manns are on site and available for consultation. , Study N0de~, ~ The .study nodes (locations at which the process parameters are to be investigated for deviations) in the Crystal Geyser plant are listed below: 1. Compressor#1 and #2 2. EvapOrative Condensers #1 and #2 3. Outdoor Ammonia Receiver 4. indoor Ammonia Receiver 5. Carbo Coolers (2) 6. Ammonia Receiving 7. Ammonia Lines 8. Outdoor Ammonia Storage 4..~. Intention: Normal Operation of the Ammonia System The plant is designed to .operate continuously. 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 cools the hot gas into a liquid. The liquid ammonia enters the outdoor receiver. From the receiver, liquid a'mmonia flows through the lines to the indoor ammonia receiver. Ammonia is. charged from 150 lb. (3000'cubic feet) ammonia storage canisters (supplied by Hopper) iCto the indoor receiver. The ammonia flows from the receiver into the carbo cooler level control vessel, and then into the carbo cooler. The carbo cooler has an expansion valve that allows the liquid ammonia to expand,into a gas. The phase change of the ammonia takes in heat, cooling the c~trbo coolers. The expanded, now gaseous ammonia is then cycled, back to the indoor receiver, where vapors are pulled by the compressor suction and liquids go to the carbo coolers. Appendix B-I Page 2 5. ..Deviations Deviations are potential departures from the intention of the plant. Possible deviations are discovered by systematically applying HAZOP guide words (no, more) to process parameters such'as pressure and temperature. 6.. Causes of Deviations Causes of deviations may be human error, equipment failure, etc. Deviations and causes Will be listed during the HAZOP study. 7~ Consequences Consequences are results of deviations from normal process operation. Consequences which could negatively impact process safety will be discussed and recorded. Deviations which have no effect on process safety will be dropped from the HAZOP study. 8~GUide Word~; Guide words are simple words used to identify, qualify or quantify possible deviations. The following guide words will be used in the HAZOP study: Guide WQr~I Example Meaning No Power Shutoff Negation of' Design Intent Less Low FIowrate Quantitative Decrease More High temperature Quantitative Increase Other Part of Partial Power Shutoff Qualitative Decrease As Well As Water added to NH3 Qualitative Increase Reverse Flow in Wrong Direction Logical Opposite of the Intent Other Than Earthquake Conditions Substitution.from Design Conditions Each guide word will be applied to process variables at each study node. This purpose of this study is to determine the most likely point of release and most damaging release of ammonia to the atmospl~ere. ~ 9_.,. Focus of Study The following specific consequences will be considered in this study: o Threats to Employee Safety o Threats to Safety of Offsite Receptors Appendix B-I Page 3 APPENDIX B-II HAZARD AND OPERABILITY STUDY FORMS Crystal Geyser Bakersfield Study Node Number: I Equipment: : , , ~ k~ ~ "~UMitigatio Guide Word Deviation Consequences Causes Risk . ' As Well As ~ . , . .. , ~ ~,~' DrysJ~l Geyser B~kersfield study Node Number: ~ Equipment: Guide Word Deviation Consequences Causes Co~p(~J~' Risk leverse ..Crystal Geyser Bakersfield Study Node Number: ..~ Equipment: ~t~w'~o~lo.. '~E-c__~VCt- (~t~mr") '1~(~ ~ Guide'Wgrd Deviation ' Conseguences Causes Risk Mitiga(ion ~s we~ As leverse Crystal Geyser Bakersfield Study Node Number: <- Equipment: Guide Word Deviation Conse~ences Causes Risk Power ~ o~ ~ [( I Oil ~ ~ -- .ess ~o ~ o~ ~ ~s Well As Reverse Jther Than ~.~¢~. ~ c~c~ I~ ~roEe~..~ Crystal Geyser Bakersfield $ludy Node Number: Guide Word Deviation Consequences Causes Risk Miti~tion Power ~ Oil ~ ~art of ~s Well As aev~rse APPENDIX B-Ill MODELING RESULTS -'--* .. .Appendix B-Ill Modeling Results Summary. The Automated Resource for Chemical Hazard Incident Evaluation (ARCHIE). computer program was used to-model theorized worst case credible releases. The Handbook of Chemical Hazard Analysis Procedures (F.E.M.A., U.S.D.O.T., and U.S.E.P.A., 1989) was used as a guideline for modeling. Modeling results indicated that a worst case credible release could pose a significant risk to offsite receptors. Crystal Geyser, Bakersfield is c'ommitted to making changes that minimize releases. Worst Case Credible Scenario The worst, case credible release, as determined through the hazard and operability study, was found to be a potential release of the liquid contents of the outdoor ammonia receiver into outside air. The potential release scenario judged to be dangerous to off$ite receptors is a release of ammonia during an earthquake. Lines from and to'the outdoor 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 a air/ammonia dispersion that would act as a cloud of dense gas. Choice of Modeling Options Option a, Estimate discharge rate of liquid or gas, was chosen to model the release of liquid ammonia into the atmosphere.. This model was chosen because the potential worst case scenario involves the emptying of the receiver through open lines. Option b, Estimate area of liquid pool, and Option c, Estimate of vaporization rate of liquid pool, are not valid for the ammonia release because the release would be made up .of both liquid and gas. Option d, Evaluate toxic vapor dispersion hazards, was used to model the following releases: Scenario' Release from broken lines during an earthquake Appendix B-Ill Page 1 Modeling Results A discharge from a broken liquid line may release 216 pounds of ammonia in 30 seconds. Scenario results have been plotted in Exhibit B-8, Vulnerable Zone, and Exhibit B-9, Extent of 500 PPM Concentration. Modeling printouts are attached. The following table contains mean wind speeds and prevailing wind directions for the Bakersfield area. Climatological data was gathered at Meadows Field Airport and compiled by the National Climatic Data center. 1989 Mean Wind Speed and Direction, Bakersfield Area .Month Wind Speed (m.oh) Wine Direction January 5.2 NW February 5.8 ENE March 6.5 NW April 7.1 NW May 7.9 NW JUne 7.9 NW July 7.2 NW August 6.8 NW September 6.2 WNW October 5.5 NW November 5.1 ENE December 5.0 ENE The yearly average mean wind speed for 1989 is 6.4 mph, originating from the Northwest. Appendix B-III Page 2 CURRENT PARAMETER VALUES FOR DISCHARGE RATE ESTIMATION METHODS 4 DISCHARGE HOLE DIAMETER = 1 inch(es) 5 DISCHARGE COEFFICIENT = .62 6 LIQUID HEIGHT IN CONTAINER = .9 " feet 7 WEIGHT OF CONTAINER CONTENTS = 215.72 lbs 8 TEMPERATURE OF TANK CONTENTS = 60 deg F 9 AMBIENT TEMPERATURE .= 90 deg F 10 CHEM VAP PRES IN CONTAINER = 104.7 psia 12 NORMAL BOILING POINT = -27.4 deg F 13 LIQUID SPECIFIC GRAVITY = .682 15 LIQUID SPECIFIC HEAT '= 1.31 BTU/lb-F MODEL RESULTS: Peak discharge rate = 454 lbs/min Duration of discharge = .476 minutes Amount discharged = 215.72 lbs State of material = Mix of gas and aerosols CURRENT PARAMETER VALUES FOR TOXIC GAS OR VAPOR HAZARD EVALUATION 1 MOLECULAR WEIGHT = 17 2 TOXIC VAPOR LIMIT = 500 ppm 3 VAPOR/GAS DISCHARGE HEIGHT = 10 feet 4 ATMOSPHERIC STABILITY CLASS = F 5 WIND VELOCITY AT SURFACE = 4.5 mph 6 AMBIENT AIR TEMPERATURE = 90 deg F 7 VAPOR/GAS EMISSION RATE = 454 lb/min 8 DURATION OF EMISSION = .476 minutes MODEL RESULTS: Downwind toxic hazard distance at groundlevel = 4429 feet at exit height = 4398 feet Peak concentration on ground is 36358.7 ppm at a downwind distance of 312 ft Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .3 1 410 .08 1.1 2.6 719 .14 1.9 4.2 1028 .2 2.6 5.7 1337 .26 3.4 7.3 1646 .32 4.2 8.8 1956 .38 5 , 10.4 .2265 .43 5.8 12 2574 .49 6.5 13.5 2883 .55 7.3 15.1 3192 .61 8.1 16.6 3501 .67 8.9 18.2 3811 .73 9.7 19.8 4120 .79 10.5 21.3 4429 .84 11.2 22.9 CAUTION: See guide for assumptions used in estimating these times! Want 'to rerun the model with different input values (Y/N or <cr>)? Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 113 436074 73 410 .08 32150 32019 300 719 .14 16978 14939 530 1028 .2 9950 9032 750 1337 .26 6372 5929 980 1646 .32 4322 4087 ~ 1200 1956 .38 ~. 3064 2929 1430 2265 .43 2254 .2171 1650 2574 .49 1709 1656 1880 2883 .'55 1331 1294 2100 3192 .61 1059 1034 2330 3501 .67 859 840 2550 3811 .~73 708 694 2780 4120 .'79 5'91 581 3000 4429 .84 500 492 · 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. ****** Press ENTER to Continue ****** CURRENT PARAMETER VALUES FOR TOXIC GAS OR VAPOR HAZARD EVALUATION 1 MOLECULAR WEIGHT = 17 2 TOXIC VAPOR LIMIT = ~0 ppm 3 VAPOR/GAS DISCHARGE HEIGHT = 10 feet 4 ATMOSPHERIC STABILITY CLASS = F 5 WIND VELOCITY AT SURFACE = 4.5 mph 6 AMBIENT AIR TEMPERATURE = 90 deg F 7 ~VAPOR/GAS EMISSION RATE = 454 lb/min 8 DURATION OF EMISSION = .476 m~nUtes MODEL RESULTS: Downwind toxic hazard distance at groundlevel = 11961 feet at exit height = 11933 feet Peak concentration on ground is 36380.7 ppm at a downwind distance of 304 ft *** Press ENTER to View Various Tables *** Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 113 436074 73 948 .18 11312 10185 690 1795 .34 3645 3467 1310 2642 .51 1614 1565 1930 3489 .67 865 847 2540 4336 .83 525 517 3160 .. 5184 .99 348 343 3780 6031 1.15 245 242 4390 6878 1.31 180 178 5010 7725 1.47 138 137 5630 8572 1.63 108 107 6240 9420 1.79 86.7 86.1 6860 10267 1.95 71.1 70.6 7480 11114 2.11 59.2 58.9 8090 11961 2.27 50 50 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts may require a larg.er Width or different direction for the evacuation zone. ****** Press ENTER to Continue ****** Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at, Downwind Location '~'(feet)~ (miles) (minutes) (minutes) 100 .02 .3 1 948 .18 2.4 5.3 1795 .34 4.6 9.6 2642 .51 6.7 13.9 3489 .67 8.9 18.1 · 4336 .83 11 22.4 5184 .99 13.1 26.7 6031 1.15 15.3 31 6878 1.31 17~ 4 ~35.3 7725 1.47 19.6 39.5 8572 1.63 .21.7 43.8 9420 1.79 23.8 .48.1 ~ 10267 1.95 26 52.4 11114 2.11 28.1 56.7 11961 2.27 30.3 60.9 CAUTION: See guide for assumptions used in estimating these times! Want to rerun the model with different in~ut values (Y/N or <ct>)? APPENDIX B-IV ALARMS AND CONTROL DEVICES Appendix B-IV Alarms and Control Devices Eg_uioment ~ D~tails Solenoid Automatic Rebuilt in 1990, Operates level. control valve for indoor receiver High Pressure/ Automatic Manual reset Temperature Cutoff: Compressors Smoke alarms Automatic Proposed' to alert employees in case of fire Sprinklers Automatic Throughout building Pressure Relief Valves Automatic Two valves, 8' high, 3/4" pipe Outdoor Receiver Pressure Relief Valve Automatic One valve vented indoors, plans Connected to Indoor are to extend prv to above, roof Receiver level AMMONIA SAFETY AUDIT FACILITY: CRYSTAL GEYSER, BAKERSFIELD ADDRESS: 1233 E. CALIFORNIA AVENUE TELEPHONE: (805) 323-6296 DATE OF AUDIT: KEY FACILITY PERSONNEL PLANT MANAGER: ALEXANDER MANNS · QUALITY CONTROL MANAGER: GERHARD GAUGEL MAINTENANCE MANAGER: NORMAN AMBROSE AMMONIA SAFETY AUDIT TEAM PLANT MANAGER: ALEXANDER MANNS QUALITY CONTROL MANAGER: GERHARD GAUGEL MAINTENANCE MANAGER: NORMAN AMBROSE Appendix C Page 1 Ammonia Safety Audit Continued This safety audit is a review of the ammonia system equipment and operation. Do employees responsible for the ammonia system have a thorough understanding in the following areas? Basic refrigeration fundamentals Compressor functions and limitations Operation, set point and purpose of safety controls Location, operation and normal position of isolation valves Relief valve location, purpose, setting and proper operator response if activated ... Recognition and response to abnormal conditions Correct procedures for system charging and oil drainage Emergency planning: is there a written emergency plan? __ System design: the attached forms should be filled out for each piece of ammonia containment vessel. The ammonia incident report should be filled out after an ammonia incident has occurred. Appendix C Page 2 ~ .~. .rApPENDIX C . AM2flONIA VESSEL SAFE~"~f INSPECTION DATA .... (COMPLETE ONE FORM FQK EACH VESSEL) VESSEL NAME OR 0SE. '-~ .... ' - "'' 1. LOCATION (BLDG.): '? " : ........ :' ' ' ..... ":"': ....... 2. LOCATION OF-VESSEL IH BUILDING:i: '- ... 3. DESCRIPTION OF VESSELS USE: 4. NORMAL PRESSUTdE IN VESSEL WHEN THE REFRI'GERATI?.W SYSTEM IS IN OPERATION: PSIG',. 5. VESSEL MAlqUFAC~ ; '' 6. DESIGN WORKING PRESSURE: PSIG '7. IS VEssEL ASME (OR EQUIVAL~qT AUTHORITY)' STAMPED: 8.' VESSEL, REGISTRATION NO.: ~ ' · '"feet 9 VESSEl, LENGTH: i0. VESSEL DTA/~ETER: inches 1 1. YEAR OF FLkNUFACTLS~EA: !2. DOES VESSEL HAVE A ~ELIEF VALVEZ 13. IS RELIEF VALVE SINGLE OR DUAL?::, ? -.. t4. %CHAT IS THE RELIEF VALVE PPdESSLrR]5 SET~ING7 ._L_' PSIG 15. %CHAT lIS THE RELIEF VALVE .RATING? ;'.?.; lbs. air per · ! , minute 16. hq~AT IS RELIEF VALVE Y~n3~R OF MAh"JFACTU]%E? _' -' . .- [17. %C~3~T. !.S THE. SiZE OF THE RELIEF VALVE OUTLET7 A.ND. OUTLET PIPE 18. IS THE' RELIEF VALVE PROPERLY PIPKD TO THE ATMOSPHERE? ; ~ (Y/N) 19. TO YOUR KNOWLEDGE HAs THIS VESSEL EV--a3{ BEEN ALTE~25D oR h0DIFISD? , . (Y/N) 20. DO YOU. HAVE ANY ASME CERTIFIED PRINTS OR U-1 'CERTIFICATE (OR LOCAL EQUIVALENT) ' '" -" AT' THE FACTORY SITE? i (Y/N) PAGE. 3 ' ') AMMONIA VESSEL SAFETY INSPECTION DATA '. (COMPLETE ONE FORM FOR EACH VESSEL) VESSEL NAME OR USE "' 1. LOCATION {BLDG.): ~Plant '~ - : ........ 2. LOCATION OF. VESSEL IN BUILDING: : 3. DESCRIPTION OF VESSELs USE: ~'' 4. NORMAL PP~ESSUPdE IN VESSEL WHEN THE REFRIGERATI~ SYSTEM IS IN OPERATION: PSIG'~t' 5. VESSEL'MANUFAC~'~ 6.. DESIGN WORKING PRESSURE: PSIG 7. IS vEsSE~ ASME (OR EQUIVALENT AUTHORITY)' STAMPED: 8.' VESSEL REGISTRATION NO.: -- 9. VESSEL LENGTH: >feet _)~ 10VESSEL DIAMETER: ''inches 11. YEAR OF MANUFACTURER: 12. DOES VESSEL HAVE A RELIEF VALVE? 13. IS RELIEF VALVE SINGLE OR DUAL?: 14. WHAT IS THE RELIEF VALVE PRESSURE SETTING? PSIG 15. WHAT IS THE'RELIEF VALVE RATING? _ lbs. air per minute 16. WHAT IS RELIEF VALVE YEAR OF MA/TUFACTIrR~? .. 17. WHAT IS THE. SIZE OF THE RELIEF VALVE OUTLET? .' AND. OUTLET PIPE 18.. IS THE RELIEF vALVE PROPERLY PIPE6 TO THE ATMOS?HERE? ~ (Y/M) 19. TO' yOuR KNOWLEDGE HAS THIS VESSEL EVER .BEEN ALTERED OR MODIFIED? (Y/N) 20. DO YOU HAVE ANY ASME CERTIFIED PRINTS OR U-1 CERTIFICATE (OR LOCAL EQUIVALENT) AT THE FACTORY SITE? (Y/N) ~ '.' I .... ~.~.~"., '22 ~T COBOLS ~ FI~ TO ~IS1 ~SSEL ... A. NONE ';- B. HI LIQUID LEaL ": C~O~ C. LIQUID L~EL CON- · D. LOW LIQUID L~L '. ::'~ ~, "~ C~O~ ' '" 23. ASSESS COBOL COL~ DESIGN: h ' · · (SC~ED JOINS, S~P VAL~ LOCATIONS, CO~ITION) P~ '~' · 24. ~ES ~ELIEF VAL~ L~K: [E/G/F/B) ~:nELL~ (CL~ WI~ NO VISIBL~~ RUST OR CO~OSION) ~,~ (L~KS OK B~ SO~ CO~OSIOM VISIBLE/LESS '~ ~ 25 % S~ACE ONLY) ; FAIR (CONSIDE~LE S~FACE CO~OSION B~ NONE VISI- BLE I~E~LY) B~ (S~ACE ~ I~,~O~OSIOM VISIBLE) D,~TE OF LAST TEST: 25. IS ~IS ~SSEL CO~K~ WI~ INSU~TION? ~' (Y/N) CO~ITION OF INSU~TION: (G/F/B) FAIR {SLIG~ SIGNS OF VA~R B~I~ L~) B~ (~T~SI~ SIGNS OF V~K B~IER L~) 26. ~' ~NO~ ICE FO~TIOMS ON VESSEL? (Y/N) 27. ~ SIGNS OF RUST/CO~OSION ON ~SSEL? k. NONE ~ B. SLIG~ O~ ~CE C. MODE~TE B~ APP~S ~ BE 5~ACE ONLY · D. APPE~S TO BE ~SI~, SHOU~ BE E~IN~ BY CONSULTING ~GI~ E. C~ TELL DUE ~ INSULATIOM, GIVE DATE ~ ~'::'"'=~£:"- 28. HAS THIS VESSEL BEEN INSPECTED BY oUTsIDE · '::'~::"~".:.'::''"''- 29. HOW LONG SINCE LAST INSPECTION u ...... BY NDE ME.ODS? .......... 30..DOES THE VESSEL PLAVE AN OIL POT? ,: .:.- {Y/N)'..Compresso~-'Room .... :- oil accumulator .' '31. DOES OIL POT HAVE RELIEF VALVE? (Y/N) :.::'r~':...' 32.. IS OIL POT RELIEF VALVE CORRECTLY ":: PIPED? " (Y/N) 33. SPECIAL REMARKS ON VESSEL CONDITION OR USAGE: 34. SPECIFY OVEKALL RATING (S.I.'R.) APPENDIX C '"" AMI4OMiA CO~TPRESSOR SAFETY INSPECTION DATA (COMPLETE ONE FOP_M FOR EACH COMPR_ESSOR) .1.. COMPRESSOR DUTY : HIGH STAGE BOOSTER SWING 2. COMPRESSOR TYPE : RECIP VERTICAL RECIP V OR'V~ ROTARY VANE ROTARY SCR~ 3. COMPRESSOR I43dTUFACII/PdLR : 4 HODEL NO. YEAR BUILT 5 CAPACIT!! TOMS MOl'OR Pe~R. (HP) 6 DRIVE .: . DIRECT BELT ·' 7 COMPRESSOR P~M . NAMEPLATE YD, X. RPM _ _--- 8 RELIEF VALVE %i!~E : INTERNAL F~XTEPS4AL 9 iS A CHECK VALVE PROVIDED AT T'HE DISCHARGE OF EACH COMPRESSOR? (Y/N) !0. MOP'AL C'OM?RESSOR.PRESSURES (PS!): SUCTION : DISCHARGE M3/~UFACTIFRER RECON~ifDED MAX. DISC~D~RGE PR_ESSUP, E 11. LOW PRESSU!tE CUTObll SETTING (PSi) DESIGN ACTUAL CHECKED "' {Y/M) OPERATES p RO P F_~LY ',Y/M) 12 · HIGH PRESSURE CI/TOUT SETTING (PSI) DESIGN ACTIIAL CHECK3~D { Y/N) OPF_RATES PROPLRLY Y/N) 13. iS HIGH P.~LESSURi~ SWITCH PLAAD WlPOLD: a) TO MCYPOR'STAP, TER __(Y'/N) b) ~"r~ROUGH PLC . {Y/N} 14. HIGH DISCHARGE TF--MP~LRATUR-E CUi'OUT SET'ZING ~C) " DESIGN ACTUAL CHECKED [Y/N) OPERATES PROPF-RLY (Y/N) 15. OIL PRESSURE SAFETY SWITCH SETTING (PSI) CHECK-ED (Y/N) OPERATES PROP EILLY PAGE 6 APPENDIX C !6. IS CO?~RESSOR .CONNECTED ~O A TLOOgEg VESSEL7 IF YES, DOES HIGH LEnZEL SWITCH STOP '-~- COMPRESSOR __(Y/M) HiGH LE%-EL SW. CHYG). __(Y/M) OPER~XTES OF. (Y/N) 17. DOES COMPRESSOR START AUiIDMAT!CALLY? (Y/M) :TF YES, IS THE~E ~M "AUTO STAP. T'!.NOT!CE . POSTED? ' { Y/l{) 18. COMPRESSOR DRI~ IS ELECTRIC MOTOR STEAM ~UP~B I N E GAS ENGINE AT RPM AND __[MO. ) V BELTS CAM PRII!E MOVER OVERSPEED7 Y/N) 19. AbFf'ABMOPdiAL VIBRATIONS PRESEI,~f? 20. DRIVE GUAttDS: ADEQUATE CO'~AGE AiCD SECIFRE? 21. A2~-f AENORPL1L NOISES? (Y/N 22. ELECTi&ICAL COV-ERS IN PLACE? (Y/N 23. ANY~ ViSiBLE LEA/iS? (Y/N 24. IS I~HERE A SA-=E METHOD FOR ELEC~iCAL ANID SYSTE~M ISOLATION? .[Y/N 25. GENERAL ASSESS~CE2fT OF COMPFdSSOR .. bn,~IT (S.Z.R.) ': t24. Brakers can be locked out, but comglete section of old brakers 'must be. paddle-locked. '16. No High level cut out.control. PAGE 7 OPERATORS LOG (typical) TIME PRESSURE TEMPERATURE OIL ADDED? COMMENi5 I EXHIBIT 6 CRYSTAL GEYSER WATER cOMPANY TRAINING REQUIRED / DATE COMPLETED EMPLOYEE AMMONIA AMMONIA SCBA FIRE EMERGENCY EVACUATION SPILLS AND NAME HANDLING DIFFUSION SAFETY NOTIFICATION PROCEDURES DILUTION EXHIBIT 10 CRYSTAL GEYSER wz~ ,Nc. MAINTENANCE RECORD EQUIPMENT: DATE: WORK PERFORMED' CAUSE' COMMENTS' EQUIPMENT: DATE: WORK PERFORMED' CAUSE' COMMENTS: EXHIBIT 7 CRYSTAL GEYSER AMMONIA CHARGE RECORD Date Ammonia in Plant Amt. Added Initial (Pounds) (Pounds) EXHIBIT 9 · LIQUID AIR CORPORATION ' ' ALPHAGAZ DIVISION ........ Specialty Gas Material Safety Data Sheet · . P1RODUCT 1,,lAME Ammonia TELEPHONE (415) 977-6500 EMERGENCY RESPONSE INFORMATION ON PAGE 2 LIQUID AIR CORPORATION TRADE NAME AND SYNONYMS Ammoni a, CAS NUMBER One California Plaza, Suite 350 Anhydrous Ammonia 7564-41-7 2121 N. California Blvd. CHEMICAL NAME AND SYNONYMS Ammoni a, Walnut Creek, California 94596 Anh.ydrous Ammonia ISSUE DATE OCTOBER 1, 1985 FORMULA MOLECULAR WEIGHT CHEMICAL FAMILY AND REVISIONS CORPORATE SAFETY DEPT.'NH3 1 7.0 : Hi trogen hydri de HEALTH HAZARD DATA TIME WEIGHTED AVERAGE EXPOSURE LIMIT 25 Molar PPM; STEL = 35 Molar PPM (ACGIH, 1984-85) ; 50 Molar PPM (OSHA, 1985) SYMPTOMS OF EXPOSURE Corrosive and. irritating to the skin, eyes, upper respiratory system and all mucosal tissue. Depending· on the concentration inhaled, it may cause burning sensations, ouohing, wheezing, shortness of breath, headache, nausea, with eventual collapse. il~ concentrations of vapor'will cause den~at'itis or conjunctivitis. Higher - concentrations of vapor or liquid contact wilt cause caustic-like dermal burns a'nd .inflammation and swelling of the eyes with possible loss of vision. Rapidly evaporating liquid contacting dermal tissue or the eyes will cause cryogenic "burns." TOXICOLOGICAL PROPERTIES Inhalation: Affects the ·upper airway (larynx and bronchi) by causing caustic-like burning resulting in edema and chemical pneumonitis. If it enters the deep lung, pulmonary edema will result. Toxic level exposure to dermal tissue causes caustic-like burns and skin lesions resulting in e~rly necrosis and scarring. Burns to the eye result in lesions and possible loss of vision. Cryogenic "burns" are like frostbite with a change in skin color to gray or white possibly followe, d by blistering. Listed as Carcinogen National Toxicology Yes [] A.R.C. Yes [] OSHA Yes L_!._ or Potential Carcinogen Program No x~ Monographs No ~, No .x_: RECOMMENDED FIRST AID TREATMENT PROMPT MED[CAL ATTENTION IS MANDATORY [H ALL C,qS[S 0F 0VEP,[XPOSURE T0 RSSCUE ,:RSONHEL SHOULD BE EQU[PPED WT=u,,,, SELF-CONTA]HED BR:A~H]NG APPARATUS ~.UG, JLL.~NI OF :A R~'IE FTRE AND EXPLOS[O;'.i HAZARD inhalation: Conscious persons should be assisted to an uncontaminated area and inhale ~,-cc ' U~SC,OUS ~ .... ,,._n air. " ~ ~.rsons should be moved to an uncontaminated ~r=a a~d eiv=n :-'south-to-mouth ,"~ '~-~' ~: ~- _ .. . .,~ -'-' .=susc~:~]on and suF. pl: .... n~:l oxygen Keep ~ne victim ,.,~rm and cu~ ~.ssu:-e that mucus or vomited material does not obstruct the airway by gcsitional I (Continued on last page.) ::.._gL::: 2:- ..... · ':'. '" · : "-~.:':' ' ' '"" I HAZARDOUS MIXTURES OF OTHER LIQUIDS. SOLIDS, OR G-~'ES ' ~ '. '' - ~Ir.'.-:..' ::....::.- ::-.. "~ .... ... " . ........ . · ." :~ 'LT:. ':7' · ':",'"". :' L. ...... '=;i~l,:~iVA~onia is flammable over a relatively narrow range in air. It re'acts vig0'rously '-'!~i~]" with fluorine, chi°riMe, hydrogen chloride, hydrogen bromide, nitrosyl chloride, ;i.!..:.~t chromyl chlo~ide,"trioxygen diflu0ride, nitrogen dioxide and nitrogen trichloride. PHYSICAL DATA ~OlUNG POINT UOU~D DENSIT'~ AT ~O~LI~G POI~ _ -28.14°F (-33.41°C) 42.6 lb/ft3 (fi82.'kg/m3) ' ' VAPOR PRESSURE L~ 70°F (21.1°C) = GASDENSll'YAT70'Flatm 128 psia (883 kPa) .0442 lb/ft3 (.708 kq/m3) SOLUBILITY IN WATER FREEZING POINT Very soluble, liberatinq heat -107.9°F (-77.74°C) APPEARANCE AND ODOR Colorless oas with a ptuzgent odor. Specific gravity ¢70°F (Air = 1,0) i$ ,59, FIRE AND EXPLOSION HAZARD DATA FL.ASH POINT (METHOD USED) { AUTO IGNITION TEMPERATURE I FLAMMABLE LIMITS % BY VOLUME Gas 1274°F (690°C) LEL = 15 UEL : 27 EXTINGUISHING MEDIA I ELECTRICAL CLASSIFICATION Water Clas~ .l: Grnu~ D SPECIAL FIRE FIGHTING PROCEDURES If possible, stop the flow of gas. Sinc~ ammonia is soluble in water, it is the best extinguishing media -- not only extinguishing the fire, but also absorbing (Continued ~.n last UNUSUAL FIRE AND EXPLOSION HAZARDS ' The minimum ignition energy for a~nonia is very high. It is approximately 500 ..... "!)times greater than the energy required for igniting hydrocarbons and 1000 to · !0:000 timPs gr~atPr than that rPnuired 'for hydrogen. REACTIVITY DATA STABILITY . CONDITIONS TO AVOID UnItable X Stable INCOMPATIBILITY (Malerials to a,,'oid) · See Hazardous Mixtures of 0~h~r Liquids, Solids or Gases HAZARDOUS DECOMPOSITION PRODUCTS' Hydrogen at. ver.y high temperatures (1544°F; 840°C) HAZARDOUS POLYMERIZATION CONDITIONS TO AVOID Ma), Occur Will Not Occur X SPILL OR L.--Ai< :ROC'EDURES STEPS TO ~E TAXEN IN CASE MATERIAL !S REIJ[ASED OR SPILLED . Evacuate all ,personnel from affected., area. Use appropriate protective :xu~m~n~.~"~ .-'-'-' '- ~f leak is in user's equipment, be certain to purge piping with an inert gas prior to at:erupting repairs if leak is in container or container valve, contact closest Liquid A:r CorFor:~,on location. WASTE DIS,=CSAL METHOD Co not =.t=,,=,~ t.o dj'sc. Dso of '..:as~ or gmused quantiti=~ ....... n -,n ....... ~.rotection ca~ in d~ace to L~quid .~ir ucrpora=.~on for procer disposal, for eme~g.n~y t Cis,sosai, concact ~he c~osest Licuid ~ , , .~,r Corporation location. I ' : .' :'.' :'.?'.:.- ' Page 3 .. ~.': ,--,' ..::_-::- .SPECIAL PROTECTION INfoRMATION ... ~.:~'~.',:" RE$1:~IFUkTORYPROTECTION(SpeclI)'IYPe) Positive pressure ~lr'line with mask' or self-cont~ined -':!~.ibreathinq apparatus should be available for emerge~c~"~s'e. ""': ...... ' ...... "" :~'' ,.-~ V~T{~ON~ :.. '..; ... ~:.. LOCxLEX~AuST ~o preven~ accumulation ~.. S,EC~~'' ..: ~ L H~o~";With '¢Or~d '":'..'-':..' above ~he TUA .... '.'..-':": ' · ' ' .- . .-. 'J. MECHANICAL (Gem) OTHER .~.;~:%... ventilation In accordance with electrical codes. . ,.... PRO~ECTIVE GLOVES '~]:'[r Plastic or rubber EYE PROTECTION '::~" Safety goggles or glasses :~' "t . OT~ ~CTJVE EQUIPMENT ~ ' 5~fe~y shoes, safe~y showe~, eyewash "fountain" SPECIAL PRECAUTIONS* SPECIAL ~BELING INFORMA~ON D0~ 5h~pp~ng Hame: ~mon~a, Anhydrous (R~ [00'/45.~) I.D. No.' UN [005 DOT 5h~pp~n~ Lab~3: ~onf3a~ab3e Gas DOT Hazard C~ass: Nonf~a~ab~e SPECIAL HANDLING RECOMMENDATIONS Use on~5 ~n we~-ven~ed a~eas. Valve p~o~ec~on caps mus~ ~em~n ~n p~ace un, ess con~a~ne~ ~s secured w~h w~ve ou[3e~ p~ped ~o use po~n~. Do no~ d~ag, s~de ~o~ c~nde~s. Use ~ su~b~ h~nd ~uck fo~ c~nde~ movement. Use ~educ~ng ~egu~a~o~ when connecting cs~nde~ ~o 3owe~ p~essu~e (4500 ps,g) o~ systems. Do no~ heat cy~nde~ by any means ~o ~nc~ease ~he d~scha~ge p~oduc~ f~om ~he cy3~nde~. Use a checE valve o~ ~ap ~n ~he d~scha~ge ~ne ~o p~even~ hazardous bac~ f~ow ~n~o ~he cy3~nde~. For additional h~ndling recommendations consult L'Air Liquide's Encyclopedia de Gaz or Compressed Gas Association Pamphlet p-1. PECIAL STORAGE RECOMMENDATIONS '- Protect c~linders from physical damage. Store in cOol, dry, well-ventilated area of non-combustible construction away from heavily trafficked areas and emergency exits. Do not allow the temperature where cylinders are stored to exceed 130F (54C). Cylinders should be stored ~pright and firmly secured to prevent falling or being knocked over. Full and empty cylinders should be segregated. Use a "first in-first out" inventory system to prevent full cylinders being stored for excessive periods of time. Post "No Smoking or Open Flames'-' signs in the storage or use area. There should be no sources of ignition in the storage or use area. Fc~r additional storage recommendations consult L'Air Licluide's Encyclopedia de Ga~ or C~mpressed Gas Association Pamphlet P-1. SPECIAL PACKAGING RECOMMENDATIOHS Gaseous or liquid anhydrous ammonia corrodes certain metals at a~,bie'nt temperatures. Oxygen presence enhances the corrosion of ordinary or semi-alloy steels. The addition of water inhibits this enhancement. Keep anhydrous ammonia systems scrupulously' dry. OTHER RECOMMSNDATICNS CR PRECAUTIONS _:r~h-ground and bond. all lines and equipment associated w~n ~ne a,m, monia system Electrical equipment should be non-sparking or explosion ~roof. Co~pressed gas cylinders should not be refilled = ~=~-+ ..... · ..x .... by qua~T~e~ producers of cc~,gress~d ~a~s ] hfpment Of a compressed gas cviinder'which has not been 'Filled by the o~,ner or with ~s (written) consent is a violation cf Federal Law. ,'.~cr=~=~,,.., ADDITIONAL DATA RECOHHENDED FIRST AID TREATHENT: (ContSnued) Eye Contact: PERSONS WITH POTENTIAL EXPOSURE TO'A~MONIA SHOULD ttOT ~4EAR CONTACT LENSES. ~, Flush contaminated'eye(s) with copious quantities of water. Part eyelids to assure complet'e flushing. Continue for a minimum of 15 minutes. Skin Contact: Flush affected area with copious quantities of water. Remove affected clothing as rapidly as possible. Dermal Contact or Frostbite: Remove contaminated clothing and flush affected areas with lukewarm water. DO NOT USE HOT WATER. A physician should see the patient promptly if the cryogenic "burn" has resulted in blistering of the dermal surface or deep tissue freezing. SPECIAL FIRE FIGHTING PROCEDURES: (Continued) the escaped ammonia gas. Use water spray to cool surrounding containers. o~s-03 "--J PTN. TRACT 1301 & NWl/4 OF SEC.33 T.29S. R.28E. 0,8-03 DRAWN / . , ~ ~Sr 10~ S~ ~ ASSESSORS WAP NO. 018-03 COUNTY OF KERN 018-03.TIF 6600x4200x2tiff A643 - TAX-ENTITY NOT ATTACHED TO ANY PARCEL NEXT-FUNC: KEY: KEY DATA PROMPT KIPS #ROLLINQ UNSECURED ROLL INQUIRY P22241 ATN INACTIVE Roll 4 Use Code 9100 File No 01 1007926 009 5 Lgnd AG Presv NO APN 018 031 08 8 Lgl Acres CPest SITE 1233 E CALIFORNIA AV BAKERSFIELD BPS SD 5 UFNT Owner U S FILTER / IONPURE INC Doc Bili 10 TECHNOLOGY DR LONELL MA 01851 2002 NO ROLL gg-7012130-00-4 TRA-No 001 012 CHG DT Chg Type Minerai Land/PI Imprvment Other Imp Pers Prop 1,296 Exmp Amt Net Value 1,296 PFI=HELP 2=MENU 3=RTRN 4=TOG 5=FUTR 9=BILL IO=UFL' 11=BUS 12=EVTSEL PF13=NEN 14=APN HIST 16=EXEMPT 17=SUPPL 18=ADDR 19=ROLL CORR PF20=PREV YR 21=NEXT YEAR 22=PRT 23=NEXT 24=PREV 07/29/02 10:58 B390 - END OF PRIOR ROLL DATA NEXT-FUNC: KEY: KEY DATA PROMPT KIPS #ROLLINQ UNSECURED ROLL INQUIRY P22241 ATN INACTIVE Roll 4 Use Code 9100 File No 01 0085208 015 8 Lgnd AG Presv NO APN 018 031 08 8 Lgl Acres CPest SITE 1233 E CALIFORNIA AV BAKERSFIELD BPS SD 5 UF NT Owner A L A C INC Doc B±ll P 0 BOX 408 NILLIS TX 77378 2002 NO ROLL TRA-No CHG DT Chg Type Mineral Land/PI Imprvment Other Imp Pets Prop Exmp Amt Net Value PFI=HELP 2:MENU 3=RTRN 4:TOG 5:FUTR 9=BTLL 10=UFL 11=BUS 12:EVTSEL PF13=NEN 14=APN HTST 16=EXEMPT 17=SUPPL 18=ADDR 19=ROLL CORR PF20=PREV YR 21=NEXT YEAR 22=PRT 23=NEXT 24=PREV 07/29/02 11:02 NEXT- FUN¢: KEY: KEY DATA PROMPT KIPS #ROLLINQ UNSECURED ROLL INQUIRY P22241 ATN ACTIVERoii 4 Use Code 9.100 File No 01 1005717 014 5 Lgnd J AG Presv NO APN 018 031 08 8 Lgl Acres CPest SITE 1233 E CALIFORNIA AV BAKERSFTELD BPS 0 SD 5 UF NT ONne r AIR L IQU I DE AMERI CA CORPORAT TON Doc B±11 P 0 BOX 460149 HOUSTON TX 77056-8149 R.B.P. 03 02-7008870-00-2 01-7009596-00-1 TRA-No 001 507 001 507 001 507 CHG DT Chg Type Mineral Land/P[ Imprvment Other Imp Pets Prop 25,865 25,865 25,679 Exmp Amt Net Value 25,865 25,865 25,679 PFI=HELP 2=MENU 3=RTRN 4=TOG 5=FUTR 9=BTLL IO=UFL 11=BUS 12=EVTSEL PF13=NEN 14=APN HIST 15=OklNERS 16=EXEMPT 17=SUPPL 18=ADDR 19=ROLL CORR PF20=PREV YR 21=NEXT YEAR 22=PRT 23=NEXT 24=PREV 07/29/02 11:01 NEXT-FUNC: KEY: KEY DATA PROMPT KIPS #ROLLINQ UNSECURED ROLL INQUIRY P22241 ATN INACTIVE Roi1 4 Use Code 9100 F±le No 01 0062259 003 6 Lgnd AG Presv NO APN 997 001 03 7 Lgi Acres CPest SITE 1233 E CALIFORNIA AV BAKERSFIELD BPSSD UF NT Owner THE MEAD CORP Doc B±11 COURTHOUSE PLAZA NE DAYTON OH 45463 2002 NO ROLL 98-7004936-00-6 TRA-No 001 001 CHG DT Chg Type M±neral Land/PI Imprvment Other Imp 135,155 Pers Prop Exmp Amt Net Value 135,155 PFI=HELP 2=MENU 3=RTRN 4=TOG 5=FUTR 9=BILL I O=UFL 11=BUS 12=EVTSEL PF13=NEH 14=APN HIST 16=EXEMPT 17=SUPPL 18=ADDR 19=ROLL CORR ,PF20=PREV YR 21=NEXT YEAR 22=PRT 23=NEXT 24=PREV 07/29/02 10:53 H M M-P PLAN MAP ., SITE DIAGRAM 1~ FACILITY DIAGRAM r----] Fol Office Use Only /J JJ Fils, In Slo,Jon: Alea Mop// of -- rking East California Avenue c~ Crystal Crystal~ Vintage ~ Geyser GeyserI Air ParkingJ i i~'w~or I B°ttling 'Facility Lot '~ Housing Comp Alley Housing Complex · .. Industrial ::: :-' rking - ~ i':'"':-~:.: c East California Avenue O · n.- Crysta .c: Vintage Job Crystal Crystal ~ Air Shack Geyser Geyser GeyserI ~ co Storage Bottling ParkingI ~; Lot Facility Lot / ~'~ Hous~.~omplex · --I Alley . .. Housing Complex r~et I~,onterey IFORNIA BEt, ~treet Henley S' Street .~treet .ucl A ~ BAKERSFIELD, CALIFORNIA N BAKERSFIELD CALIFORNIA AVENUE ALLEY CRYSTAL GEYSER REFRIGERATION AND WATER TREATMENT FACILITY PLOT PLAN DATE 12/93 J O~.O0~a IEXH,~,T 3 Bakersfield Fresno 4700 Stockdale Highway, Suite 120 470 East Herndon Avenue, Suite 203 Post Office Box 9217 Fresno, California 93720 Bakersfield, California 93389 209/261-9160 805/326-1112 805/326-0191 FAX 209/261-9171 FAX Crystal Geyser Water Company Bakersfield, California Risk Management and Prevention Program October, 1990 Revised February, 1991 Revised April, 1991 Revised December, 1993 Submitted to: The City of Bakersfield Fire Department Hazardous Materials Division Prepared by: WZI Inc. 4700 Stockdale Highway, Suite 120 Bakersfield, California 03320011,013 TABLE OF CONTENTS Section Page I. Purpose 1 II. Introduction 2 III. Certification 4 IV. Revision Record 5 1,0 Background 6 1.1 General Business Information 6 1.2 Description of Acutely Hazardous Materials Used 7 1.2.1 Amount Ammonia Used 7 1.2.2 Hazardous Properties of Ammonia 7 1.3 General Ammonia Refrigeration Processes 8 1.4 Operation of the Ammonia Systems 8 2.0 Description of Acutely Hazardous Materials Accidents 10 2.1 Accidents at this Location 10 2.2 Underlying Causes 10 2.3 Measures Taken to Prevent Recurrence 10 2.4 Accident Investigation Procedures 10 2.5 Release Reporting Procedures 11 3.0 Equipment Report 13 3.1 Ammonia Equipment 13 3.1.1 Nature, Age and Condition 13 3.1.2 Testing Schedules 21 3.1.3 Maintenance Schedules 21 4.0 Procedures Report 23 4.1 Ammonia Systems 23 4.1.1 Daily Operating Procedures 23 4.1.2 Maintenance Procedures 24 TABLE OF CONTENTS Section Pa.qe 5.0 Design, Operating and Maintenance Control Systems 26 5:1 · Ammonia 26 5.1.1 Design Control Systems 26 5.1.2 Operating Control Systems 26 5.1.3 Maintenance Control Systems 27 6.0 Detection, Monitoring or Automatic Control Systems 28 6.1 Ammonia 28 6.1.1 Detection Systems 28 6.1.2 Monitoring Systems 28 6.1.3 Automatic Control Systems 29 7.0 Proposed Risk Reduction Measures 30 7.1 Written Operating Procedures 30 7.2 Written Maintenance Procedures 30 7.3 Increased Inspections 30 7.4 Better Labeling 30 7.5 Safety and Training Program 31 7.6 Fire Prevention Plan 31 7.7 Physical Plant Changes 31 7.8 Reduction of Consequence to Neighboring 31 Homes or Businesses 8.0 Emergency Contingency Plans 32 8.1 General Evacuation 32 8.2 Fire 32 8.3 Earthquake 32 8.4 Significant Leak from the Ammonia Systems 32 8.5 Emergency Responders 33 9.0 Auditing Program 35 9.1 Ammonia Systems 35 TABLE OF CONTENTS Section Page 10.0 Inspection Program 36 10.1 Ammonia Systems 36 11.0 Risk Management and Prevention Program (RMPP) 37 Implementation 11.1 Personnel Responsible for RMPP Implementation 37 11.2 Implementation Schedule 38 11.3 Training Program for RMPP Implementation 38 12.0 RMPP Record Keeping 41 12.1 Accident Records 41 12.2 Ammonia Charge Record 41 12.3 Training Records 41 12.4 Audit Records 41 13.0 Qualifications of Certifiers 42 13.1 Qualified Person 42 13.2 Facility Operator 42 References 43 EXHIBITS Exhibit 1 Location Map Exhibit 2 Surrounding Area Exhibit 3 Refrigeration and Water Treatment Facility Plot' Plan Exhibit 4 Schematic of Ammonia Refrigeration System Exhibit 5 Ammonia Incident Report Exhibit 6 Compressor Operator's Log Exhibit 7 Maintenance Record Exhibit 8 Evacuation Routes Exhibit 9 Ammonia Charge Record Exhibit 10 Ammonia System Training Required/Date Completed Record TABLES Table 1 Physical Properties of Anhydrous Ammonia APPENDICES Appendix A Hazards Analysis (Under Separate Cover) Appendix B Business Plan Appendix C Piping and Equipment Layout Plans Appendix D Preventative Maintenance Check List Appendix E Manning Systems Gas Cell/Transmitter Instruction and Installation Manual Appendix F Ammonia Safety Audit REFERENCES 1. The Center for Chemical Process Safety, Guidelines for Hazard Evaluation Procedures, 1985, American Institute of Chemical Engineers. 2. Office of Emergency Services, Hazardous Materials Division, Risk Management and Prevention Program Guidance, 1989, State of California, 3. U.S. Environmental Protection Agency, Federal Emergency Management Agency and the U. S. Department of Transportation, Technical Guidance for Hazards Analysis: Emergency Planning for Extremely Hazardous Substances, 1987. 4. National Response Team, Hazardous Materials Emergency Planning Guide, 1987. Page 43 TABLE 1. PHYSICAL PROPERTIES OF ANHYDROUS AMMONIA (NH3) Molecular Weight 17.03 Lbm/Lbmole Latent Heat 327 Calorie/Gram Boiling Point -28.03 °F Solubility 89.9 G/100 mi AT 0 °C Specific Gravity (Liquid) 0.682 (-33.35 °C/4 °C) Vapor Density 0.59 (AIR=l) @ 25 °C, 760 mm Hg Autoignition Temperature 651 o C (1,204 o F) Explosive Limits 16 to 25 % by Volume in Air ' Critical Temperature 651 °C Critical Pressure 11.5 ATM IDLH 350 mg/m3 (500 ppm) LOC 35 mg/m3 (50 ppm) STEL 25 mg/m~ (35 ppm) Ratio of Specific Heats 1.31 I ppm 0.7 mg/m~ @ 25 °C and 760 mm Hg The'molecular structure of ammonia is composed of one nitrogen (N) and three hydrogen (H) atoms. The molecular weight of ammonia, 17 Ibm/Ibmole, is significantly less than that of air which is approximately 29 Ibm/Ibmole. As a result, ammonia in the vapor phase is much lighter than air and rapidly rises when released. 03320011.014 Bakersfield Fresno 4700 Stockdale Highway, Suite 120 470 East Herndon Avenue, Suite 203 Post Office Box 9217 Fresno, California 93720 Bakersfield, California 93389 209/261-9160 805/326-1112 805/326-0191 FAX 209/261-9171 FAX HAZARD. ANALYSIS AUGUST 1993 REVISION CRYSTAL GEYSER WATER COMPANY BAKERSFIELD, CALIFORNIA August 1993 Submitted to: The City of Bakersfield Fire Department Hazardous Materials Division Prepared by: WZI Inc. 4700 Stockdale Highway, Suite 120 Bakersfield, California 93309 0332.0011.007 APPENDIX D PREVENTATIVE MAINTENANCE CHECK LIST BAKERSFIELD Street ~.a'~&Street St. ;NUE ; L.k, " CRYSTAL GEYSER ~ -- -- Center '~; BAKERSFIELD WV.' Ave. Pr~ .CALIFORhl~ mar~ ~vt. ~ Henley Ave. Un~n Ce ~urdb~ S~ . Vito;ni~ .I · .'~ ~ ~e~ S:. I --BRUNDAGE ...... Feliz ~ ~*t~ ~ . Cannon Ave. · T~ TE Smith ST. ~E~O~4L ~C~a T~ON~. '~cH. ~ ~. Be~le' ~ :~. C[~[~ ~OL · WZI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. Fee! 2000' 4000' ..... ! LOCATION MAP Milei }.mi. ~mi. %zni. 1mi. 0 Kilometers .5Okm 1kin , , DATE 7~93 I 0332.0011A I EXHIBIT I APPENDIX B BUSINESS PLAN' ;6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 1 Overall Site with ~ Fac. Unit General Information Location: 1233 E CALIFORNIA AV Map: 103 Hazard: High I Community: BAKERSFIELD STATION 02 Grid: 32C F/U: 1 AOV: 0.0 Contact Name ~(~.,,~/l~,~,7,'~Title _ Business Phone ~124-Hour Phone~ ALEX MANNS ?.'~,ar ~.~,~-~ (805) 323-6296 x 805) 589-6906! GERHARD GAUGEL (805) 323-6296 x 805) 392-8747/ Administrative Data Mail Addrs: 1233 E CALIFORNIA D&B Number: 'City: BAKERSFIELD State: CA Zip: 93307- Comm Code: 215-002 BAKERSFIELD STATION 02 SIC Code: 5149 Owner: PETER GORDON / LEO SOONG Phone: (~e.~) 9q~ -o$'~0 Address: 501 WASHINGTON ST State: CA City: CALISTOGA Zip: 94515-O30~ Summary THIS FACILITY HAS 5 INDIVIDUALS TRAINED IN S.C.B.A. BAKERSFIELD C1."EY FIRE DEPARTMENT · . I-:IAZARDOUS MATERIALS INVENTORY usine~s Name ,. '5¢'~&. r ~¢'~ '7 /'~ C..O..' Address /2 ~3 c~¢P ~. ~A~¢'~ CHEMICAL DESCRI~ION PHYSICAL & H~LTd PHYSICAL. H~L~ H~RO CA~GORIES ~re [ 1 ReactNe [ ) SuG0en Rele~e of Pressure ~l ImmeOi~e He~h (Ac~e) ~ Delayed He~h (Chronic) WAS~ C~SSI~CA~ON (~i~k ~de ~om' OHS Fo~ 6022) USE CODE. 7) ~OUNT AND ~ME AT FACIU~ UN~S OF M~SURE 8) STOOGE COOES Average O~ly Amount: //0~ ~ E 0 ~ ~de3 [ ~ ' b) Pressure: AnnuN Amount: ///, 3 ~ ~ c) Tem~rstura: 9) MI~R~ Ust COMPONE~ CAS ~ chemi~ com~nen~ or ~y ~M com~nen~ 2~ 3~ CHEMICAL DESCBI~ION 1'} t~ORY STA~S: New ~ Add,on [ ~ Rev~ion [ ~ Oeie~n [ ] . ... C~eck~ chemi~'~ · NON ~E SEC~ 4) PHYSlC~L & H~Ta PHYSICAL H~LTH H~.D CA~GORIE5 Rte ~ Re~~ [ ] Sudden Rele~e of Pressure [ ~ Immedi~a He~ (~cme) [ ] ~l~yed He~h (C~ron~) S~ WASTE C~SSIFICA~ON {~iait co~e from OHS Fo~ 6G~2) USE C~OE 0 ~ ~ ...... ~ -~'~ 'P~pyz4~ ~z~p~ ~ AMOU~ AND ~ME AT FACi~ UNITS OF M~SURE a) STOOGE CODES ~ O~OnSEe .~ C~e~ichMonms: ~ J.. F. M. ~ M. J. J. A. S. O, N. 0 9) MI~R~ ~st · COMPON~ CAS c~e~i~ ¢om~nen~ or ., ~y ~M ~m~nan~ · 3) ce~ u~ er pen~ or law, ~r I ~ve pe~n~ly eX~l~ ~ ~ I~lll~ Wl~ ~e I~[O~OH ~UD~I~ O~ ~ ~ PRI~ N~e & ~e of A~o~z~ Com~epresenm~e 5ig~a~re .6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 2 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order 02-014 ANHYDROUS AMMONIA Gas 6720 Extreme · ~e, I~ed Hlth FT3 CAS #: 7664-4 Trade Secret: No ~, Form: Gas~ G~. ~ ' ' ' 5 Use: STO~ 02-030 Anhydrous a~onia Gas 6720 Extreme · Pressure, I~ed Hlth FT3 CAS #: 7664-41-7 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: COOLING Daily Max FT3 ~Average FT~ --~/K~ual Amount FT3 -- Storage Press T Te_~ ~-~ Location ~ IN MACHINE/EQUIP IAbov~%A~bientlRefriger~system/~$ot~ - Conc / Components ' ~P ---TGuide 100.0% IANHYDRO~~ONIA IUnra~ 0 02-010 ACETYLENE Gas 130 High ~ Fire, Pressure, I~ed Hlth FT3 CAS #: 74-86-2 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: WELDING SOLDERING Daily Max FT3 I Daily Average FT3 I Annual ~ount FT3 130 ~ 100.00 230.00 Storage I Press T Temp~ Location PORT. PRESS. CYLINDER IAbove ~AmbientlSOUTHWEST CORNER SHOP STOOGE - Conc Components MCP -~Guide 100.0% IAcetylene IHigh~ 17 )6/03/~3 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 3 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order 02-004 PROPANE Gas 18158 High · Fire, Pressure, Immed Hlth FT3 CAS #: 74-98-6 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: FUEL Daily Max FT3 I Daily Average FT3 I Annual Amount FT3 -- 18,158 I 1,455.00 218,340.00 Storage Press T Temp ..~ Location FIXED PRESS. CYLINDER Above ~AmbientlSOUTH~ PARKING LOT A~EA- Compone3~c~~,~= ~ ~ ....Conc MCP -Guide 100.0% IPropane IExtreme 22 02-020 DESCALE 10-50 Liquid 55 High · Reactive, Immed Hlth, Delay Hlth GAL CAS #: 7647-01-0 Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: OTHER Daily Max GAL I Daily Average GAL I Annual Amount GAL 55 ~ 30.00 55.00 Storage Press T Temp~ Location DRUM/BARREL-NONMETAL Ambient~AmbientlINSIDE WESTSIDE BUILDING -- Conc . Components I MCP' Guide 50.0% IMuriatic Acid IHigh I 15 02-024 SODIUM HYPOCHLORITE Liquid 104 High · Reactive, Immed Hlth GAL CAS #: 7681-52-9 Trade Secret: No Form: Liquid Type: Pure Days: 365 use: CLEANING Daily Max GAL Daily Average GAL Annual Amount GAL -- 104 I 52.00 I 1,250.00 Storage Press T Temp~ Location PLASTIC CONTAINER Ambient~AmbientlWESTSIDE OUTSIDE BUILDING -- Conc . Components I MCP ---/Guide 12.5% ISodium HypoChlorite High ~ 45 1.0%~Sodium Hydroxide IM°derateI 60 ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order 02-029 COFIDENCE 41C Liquid 25 High ~ Immed Hlth, Delay Hlth GAL CAS #: Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: WATER TREATMENT Daily Max GAL25 II Daily Average 20.00 GAL 1 Annual Amount 80.00 GAL Storage Press T Temp Location DRUM/BARREL-NONMETAL Ambient[/unbientlBOILER ROOM -- ConcI Components i MCP ---TGuide 4.0% Sodium Hydroxide ModerateI 60 8.0% Potassium Hydroxide ModerateI 60 3.0% beta-Diethylaminoethanol High ~ 29 02-017 GUARD 203 Liquid 110 Moderate ~ Reactive, Immed Hlth, Delay Hlth GAL CAS #:' Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: NEUTRALIZER Daily Max GAL I Daily Average GAL 1 Annual Amount GAL 1!0 ~ 55.00 1,000.00 Storage ~~Press T Temp Location 'DRUM/BARREL-NONMETAL IAmbient~AmbientlINSIDE WEST BUILDING - Conc Components MCP ---7Guide 35.0% IPhosphoric Acid IModeratel 60 02-018 GUARD 219' CHLORINATED FOAMER Liquid 110-'Moderate ~ Reactive, Immed Hlth, Delay Hlth GAL CAS #: Trade Secret: No Form: Liquid .Type: Mixture Days: 365 Use: CLEANING Daily Max GAL I Daily Average GAL I Annual Amount GAL 110 ~ 55.00 1,300.00 Storage ~~Press T Temp Location DRUM/BARREL-NONMETAL IAmbient~AmbientlINSIDE WEST BUILDING -- Conc~ Components MCP ---~Guide 25.0% IPotassium Hydroxide ModerateI 60 ;6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 5 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order 02-021 CHLOR 231 Solid 900 Moderate · Fire, Immed Hlth, Delay Hlth ~ LBS CAS #: 1310-73-2 Trade Secret: No Form: Solid Type: Mixture Days: 365 Use: CLEANING Daily Max LBSI Daily Average LBS I Annual Amount 5,800.00 LBS 900 ~ 550.00 Storage Press I Temp~ Location DRUM/BARREL-NONMETAL Ambient/AmbientlINSIDE WEST BUILDING -- Conc Components ~ MCP ---/Guide 0.0% ISodium Hydroxide IModeratel 60 02-028 SAFETY KLEEN 105 SOLVENT Liquid 20 Moderate · Fire GAL CAS #: 64742-41-9 Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: WASHING Daily Max GAL I Daily Average GAL ~ Annual Amount 100.00 GAL -- 20 I 20.00 Storage Press T Temp Location IN MACHINE/EQUIP IAmbientlAmbientlSHOP -- Conc Components .. MCP ---/Guide 89.0% IMineral Spirits IModeratel 27 02-008 MALEIC ACID Solid '300 Low · LBS CAS #: 6915-15-7 Trade Secret: No Form: Solid Type: Pure Days: 365 use: FORMULATION/MANUFACTURING Daily Max LBS300 I ... Daily Average 150.00 LBS ----~ Annual Amount 1,200.00 LBS -- Storage } Press I Temp Location BAG iAmbient/AmbientlNORTHWEST BATCH AREA -- Conc Components . .. MCP ----~Guide 100.0% iMaleic Acid ILow ~ 60 ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 6 02 - Fixed Containers on Site Hazmat Inventory Detail in MCp Order 02-005 OXYGEN Gas 251 Low ~ Fire, Pressure, Immed Hlth FT3 CAS #: 7782-44-7 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: WELDING SOLDERING Daily Max FT3I Daily Average FT3 I Annual Amount FT3 251 ~ 251.00 753.00 Storage Press T Temp~ Location PORT. PRESS. CYLINDER Above ~AmbientlSHOp STORAGE AREA -- Conc~ Components MCP ---vGuide 100.0% IOxygen, Compressed Low! 14 02-015 CHEVRON DIESEL FUEL #2 Liquid 330 Low ~ Fire, Immed Hlth, Delay Hlth GAL CAS #:. 68476-34-6 Trade Secret: No Form: Liquid Type: Pure Days: 365 Use: FUEL .... Daily Max GAL Daily Average GAL Annual Amount GAL 330 I 110.00 I 2,500.00 - Storage ~~Press T Temp Location DRUM/BARREL-METALLIC IAmbient~AmbientlOUTSIDE EAST YARD IN DOCK -- Conc ·I Components MCP ---7Guide 100.0% IDiesel Fuel No.2 ModerateI 27 02-019 PENNANT NL OIL 150 Liquid 55 Low · Fire, Reactive GAL CAS #: Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: LUBRICANT Daily Max GAL I Daily Average GAL ~ Annual Amount GAL -- 55 ~ 35.00 55.00 Storage ~~Press T Temp Location DRUM/BARREL-METALLIC Ikmbient~AmbientlOUTSIDE WEST BUILDING -- c°nc 'I Components ~ MCP ---TGuide 43.0% ~Solvent Dewaxed Distillate, Heavy Paraffin ILow ~ 27 ;6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 7 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order 02-006 ARGON Gas 155 Minimal ~ Fire, Pressure, Immed Hlth FT3 CAS #: 7440-37-1 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: WELDING SOLDERING Daily Max FT3 I Daily Average FT3 I Annual Amount FT3 155 ~ 75.00 155.00 Storage .- Press T Temp .I Location PORT. PRESS. CYLINDER Above ~AmbientlSHOP STORAGE AREA -- Conc Components MCP ---~uide 100.0% IArgon IMinimal I' 12 02-003 CARBON DIOXIDE Gas 420333 Minimal ~ Fire, Pressure, Immed Hlth FT3 CAS #: 124-38-9 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: FORMULATION/5~NUFACTURING Daily Max FT3 I Daily Average FT3 I Annual Amount FT3 420,333 I 242,500.00 2,932,920.00 Storage I Press T TempI Location FIXED PRESS. CYLINDER IAbove ~Below INORTHWEST PARKING LOT AREA -- Conc~ Components MCP ----~uide 100.0% ICarbon Dioxide Minimal I 21 02-007 CITRIC ACID ANHYDROUS Solid 2400 Minimal ~ LBS CAS #: 77-92-9 Trade Secret: No Form: Solid Type: PUre Days': 365 Use: FORMULATION/MANUFACTURING Daily Max LBS I Daily Average LBS I Annual· Amount LBS 2,400 I 1,000.00 _ 24,000.00 Press 7·Temp~ Location Storage BAG Ambient~AmbientlNORTHWEST BATCH AREA -- Conc Components MCP Guide 100.0% ICitric Acid IMinimal I 1 ;6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 8 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order 02-002 HOT MELT ADHESIVE Solid 800 Minimal LBS CAS ~: 92717 Trade Secret: No Form: Solid Type: Pure Days: 365 Use: ADHESIVE Daily Max LBS I Daily Average LBS I Annual Amount LBS 800 ~ 400.00 3,090.00 Storage Press · Temp Location BOX IAmbient AmDiontlPACKING AREA SOUTH BLDG -- ConcI Components MCP ---/Guide 100.0% IPPO Minimal I 1 02-013 NITROGEN Gas 142 Minimal · Fire, Pressure, Immed Hlth FT3 CAS #: 7727-37-9 Trade Secret: No Form:' Gas. Type: Pure Days: 365 Use:.EXPERIMENTAL/ANALYTICAL Daily Max FT3 I Daily Average FT3 I Annual Amount FT3 142 I 70.00 142.00 Storage Press T Temp~ Location PORT. PRESS. CYLINDER Above ~AmbientlOUTSIDE BLDG SOUTHWEST CORNER -- Conc Components ---~Guide 100.0% INitrogen ILo~cP ! 21 02-016 GUARDQUAT 128 Liquid 110 Minimal · Immed Hlth, Delay Hlth GAL CAS #: Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: FUNGICIDE Daily Max GAL I Daily Average GAL --,~ Annual Amount GAL 110 ~ 30.00 600.00 Storage Press T Temp~ Location · DRUM/BARREL-NONMETAL Ambient~AmbientlINSIDE WEST BUILDING - Conc~ Components ~- MCP ---[Guide 10.0% IDimethyl Benzyl Ammonium Chloride IMinimal I 1 )6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 9 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order 02-023 ARCO GEAR OIL SAE (85W-140W) Liquid 55 Minimal · Fire, Immed Hlth, Delay Hlth GAL cas #: 64742-54-7 Trade Secret: No Form: Liquid Type: Pure Days: 365 Use: LUBRICANT Daily Max GAL I Daily Average GAL I Annual Amount GAL 55 I 35.00 55.00 Storage ~~Press T Temp Location DRUM/BARREL-METALLIC IAmbient~AmbientlOUTSIDE WEST BUILDING - Conc~ Components MCP ---~uide 100.0% IHeavy Machine Oil Minimal I 27 02-025 ASCORBIC ACID Solid 200 Minimal · Fire, Reactive, Immed Hlth, Delay Hlth LBS CAS #: 50-81-7 Trade Secret: No Form: Solid Type: Mixture Days: 365 Use: FORMULATION/F~NUFACTURING '~ Daily Max LBS I Daily Average LBS I Annual Amount LBS 200 ~ 100.00 1,700.00 Storage Press T Temp~ Location DRUM/BARREL-NONMETAL Ambient~AmbientlWESTSIDE OF BUILDING -- Conc Components MCP ---~uide 100.0% IAscorbic Acid IMinimal I 02-026 ARCO GEAR OIL (90 WT) Liquid 55 Minimal · Fire, Delay Hlth GAL CAS #: 8020835 Trade Secret: No Form: Liquid Type: Pure Days: 365 Use: LUBRICANT Daily Max GAL I Daily Average GAL I Annual Amount GAL ~. 55 I 35.00 55.00 Storage I~Press T Temp Location DRUM/BARREL-METALLIC Iambient~ambientlOUTSIDE WEST BUILDING -- Conc . Components MCP ---~Guide 100.0% ILubricating Oil (Petroleum-Based) Minimal I 27 )6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 10 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order 02-027 TARTARIC ACID Solid 2000 Minimal · Fire, Reactive, Immed Hlth, Delay Hlth LBS CAS #:~ 87-69-4 Trade Secret: No Form: sOlid Type: Mixture Days: 365 Use: FORMULATION/MANUFACTURING Daily Max LBSI Daily Average LBS I Annual Amount LBS 2,000 I 700.00 20,000.00 Storage ~ Press T Temp~ Location BAG IAmbient/AmbientlNORTHWEST BATCH AREA -- Conc. Components~ MCP ~uide 100.0% ITartaric Acid, Diammonium Salt IMinimal I 31 02-022 CHEVRON HANDY OIL 15 Liquid 110 Unrated · Fire, Immed Hlth, Delay Hlth GAL CAS #: Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: LUBRICANT Daily Max GALt Daily Average GAL I Annual Amount GAL 110 ~ 55.00 700°00 Storage Press T Temp~ Location DRUM/BARREL-METALLIC AmbientlAmbientlOUTSIDE WEST BUILDING -- Conc Components MCP Guide 95.0% ILight Petroleum Distillate IModeratel 27 ;6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 11 00 - Overall Site <D> Notif./Evacuation/Medical °1> Agency Notification CALL 911 THE STATE OFFICE OF EMERGENCY SERVICES WILL ALSO BE NOTIFIED AS REQUIRED ~2> Employee Notif./Evacuation ~N CASE OF A HAZARDOUS MATERIAL SPILL, THE PLANT 5~NAGER UPON NOTIFICATION 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 MAKE SURE THA~T HIS AREA HAS BEEN VACATED BY ALL PERSONNEL. ALL EMPLOYEES EVACUATED WILL REPORT TO A DESIGNATED AREA OUTSIDE THE FACILITY. ~3> Public Notif./Evacuation ~4> Emergency 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 OR KERN MEDICAL CENTER WILL BE GIVEN SECOND CONSIDERATION. ANY SUPERVISOR HAS THE AUTHORITY TO DIAL 911 FOR MEDICAL EMERGENCIES. ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 12 00 - Overall Site <E> Mitigation/Prevent/Abatemt ~1> Release Prevention TO PREVENT THE RELEASE OR SPILL OF HAZARDOUS MATERIAL AT THIS FACILITY, ONLY INDIVIDUALS REQUIRED TO USE HAZARDOUS MATERIALS IN THE COURSE OF THEIR WORK WILL BE ALLOWED TO HANDLE THEM. EACH OF THESE INDIVIDUALS WILL BE TRAINED IN THE SAFE HANDLING AND USE PROCEDURES FOR EACH PRODUCT :2> Release Containment PROCEDURES FOR CONTAINMENT WILL BE THOSE RECOMMENDED BY THE MANUFACTURER OF THE PRODUCT AS DESCRIBED IN THE MATERIAL SAFETY DATA SHEET AMMONIA DIFFUSION SYSTEM LOCATED OUTSIDE OF BUILDING, NORTHWEST CORNER. :3> Clean Up PROCEDURES FOR CLEAN-UP WILL BE THOSE RECOMMEDED BY THE MANUFACTURER OF THE PRODUCT AS DESCRIBED IN THE MATEIAL SAFETY DATA SHEET. ~4> Other Resource Activation CRYSTAL GEYSER WATER COMPANY 215-000-001418 O0 - OVERALL SITE <F> SITE EMERGENCY FACTORS I. AMENDMENTS TO <2> UTILITY SIIUT-OFFS: A) Gas bleter: Inside fence between buildings next to alley southwest corner of ~.~-~..==~ facility/south of Ammonia tank containment. D) Propane Tank: Southeast corner of East parking lot next to alley and Lakeview Avenue· C) Water: In allmy~, next to fence and southwest corner of East building, ~o0· =e ~ west of Avenue. D) Electrical: West Processing Facil" ~ ' ~u~ -' Outside on southeast corner of building under stairway. East Processing Facility - Inside building on southwest corner on oo~,, =ides of exit door next to ~ ~ ~ey. Special: I. Ammonia ...... -~,~= inside southeast corner of West building next to alley/ Engineering Support area. 2 Di~ ' · z~uslon system box next to ro~, up door of 'West building - southside next to alley. F) Lock~-":~.~ Yes (keys only), above nor~,~ entrance door of west building. · rm-.,,~.,~,,~o TO: <3> FIRE PRO~E,.TION/,~,~ILABLE WATER Private Fire Protection- ~:~,~=- facil:~-' ~s' =q~p~=u- "~ --~ automatic overhead spring,ers in all building areas. The F ~,,~=~. system is monitored by Te!-Tec Securi~'' Systems. Fire extinguishers are in all areas of the facility for emergency use. F~re ,,.u~,,~ - On the north side of East California Ave., directly across from ~ ' u,,e West facil~ty building. . wr~x=~ System Riser llookupm - Fire Department exists i. ~e~ ~ feet we~t of ' ~'- -"ew Avenue for buildin~ hook up. '~.',=s~ ~ building Eider hook up is inside fence on south side of building 400 feet west of Lakeview Avenue. III. AMENDMENTS TO: <4> BUILDING OCCUPANCY LEVEL 1. East Processing/Warehouse facility - 35 2. ~West Processing/Engineering Support facility - 4 C:~wpfiles~s~ ~act ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 13 00 - Overall Site <F> Site Emergency Factors :1> Special Hazards ~2> Utility Shut-Offs A) GAS/PROPANE TANK: MIDDLE OF WEST SIDE OF BUILDING, 55 FEET NORTH OF ALLEY FENCE - INSIDE FENCE NEXT TO SOUTHWEST CORNER OF BUILDING B) ELECTICAL - INSIDE SOUTHWEST CORNER OF BUILDING ON BOTH SIDE OF EXIT DOOR. C) WATER - IN ALLEY NEXT TO FENCE AND SOUTHWEST CORNER OF BUILDING 330 FEET WEST OF LAKEVIEW SPECIAL - AM~4ONIA SHUT OFF IN NORTHWEST CORNER OF BUILDING IN FENCED OFF AREA E) LOCK BOX - NO :3> Fire Protec./Avail. Water PRIVATE FIRE PROTECTION - THIS FACILITY IS EQUIPED WITH AUTOMATICE OVERHEAD SPRINKLERS IN ALL AREAS. THE SPRINKLER SYSTEM IS MONITORED SECURITY SYSTEMS. WE HAVE FIRE EXTINGUISHERS IN ALL AREAS OF THE FACILITY FOR EMERGENCY USE. FIRE HYDRANT - ON THE NORTH SIDE OF EAST CALIFORNIA AVE., 120 FEET WEST OF THE NORTHWEST CORNER OF THE FACILITY A FIRE DEPARTMENT HOOK- UP TO OUR MAIN SPRINKLER SYSTEM RISE~EXISTS. IT IS IN THE ALLEY, 220 FEET WEST OF LAKEVIEW AVE. :4> Building Occupancy Level HMMP PLAN MAP SITE DIAGRAM I I FACILITY DIAGRAM Busine~ Nome: ¢./~¥.s¢,4L. C;Ey~t~/z /,¢,4¢'~4 ~N~ For O~ice Use Only First In $1ofion: Area Map # ol Inspec:ion S~'alion: NORTH 0. o HMMP PLAN MAP SITE DIAGRAM [ I FACILITY DIAGRAM ~ ~ ¢~- 3 Bus~ne~ Nome: C~y~'~-' 6;¢.y~ u~,~fE~ ~,,',~,-/' Business AChier: /2-33 [,4~r- ,r.,~Z/r~,4/c~A ,4//C,,¢~' For Office Use Only First In Slation: Area Map # of HMMP P~ MAP' SITE DIAGRAM [__1 FACILITY DIAGRAM ~ 3 oF 3 Busine~ Nome' Busine~ Addfe~: /2 35 E,4,1,7" (..~z. IFa~/dl~ For Office Use Only First In Slolion: A~ea Map # of // rn Z APPENDIX A HAZARDS ANALYSIS (UNDER SEPARATE COVER) APPENDIX C PIPING AND EQUIPMENT LAYOUT PLANS APPENDIX F AMMONIA SAFETY AUDIT