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Home My WebLink AboutRISK MANAGEMENTCRYSTAL GEYSER WATER COMPANY BAKERSFIELD, CALIFORNIA RISK MANAGEMENT AND PREVENTION PROGRAM DECEMBER 1993 WZI Inc. 4700 Stockdale Hwy., Suite 120 Bakersfield, Oalifornia 93309 SECTION 1.1 FACILITY INFORMATION ,i '., This secti°n. 6f the .~.i~ shall pr°~;ide :~ brief 6(,~r~i'~w of fa~iiit~,:6~ratio~'in~luding fac,My name, loeat~",' ownersh,p, fac,hty emergeilcy ~contacts, chenuCal !nventor,es, ~ .content, and regulatory applicability of the overall FaCilitY .ComPliance PIan. :.'..i. I Unified Program Consolidated Forms: (attached, as applicable) {~ Facility Information - business owner / operator identification [~ Facility Information - business activities [~ Facility Information - consolidated permit activities addendum [~ Hazardous materials inventory [~ Underground storage tank (UST) facility information [~ UST - tank & piping information [~ UST - installation certificate of compliance I~ Hazardous waste reeyclable materials [~ Onsite hazardous waste treatment notification - facility [~ Onsite hazardous waste treatment notification - unit [~ Remote waste consolidation site notification Additional information: (CalARP Risk Management Plan) ~ Latitude & longitude (2740.1 (d)(I)) 1~ DUn & Bradstreet number of parent corporation (if di fl~rcnt) (2740. i (d)(3)) [~ Number of full time employees (2740.1 (d)(9)) [~ Subject to Section 5189 of Title 8 CCR (2740. l(d)(10)) , ~ Subject to Part 355 of Title 40 of CFR (2740.1(d)(11)) [~ Subject to Title V of CAA (2740. l(d)(12)) [~ Date & governmental agency providing last safety inspection (2740. l.(d)(13)) [~ Executive sumlnary (2745.3) CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD . ENVIRONMENTAL SERVICES Section 2740.1 (d)(l) Crystal Geyser,Watel~Company 1233 E. Cnlifornin Avenue Bakersfield, California County of Kern93307~ 110 degrees West 33 degrees 22 minutes 30 seconds North 39 Full Time Employees I. 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 bottling facility, Bakersfield, California. Page I II. 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 a~;cidents involving AHM. A RMPP is defined in Section 25532 (g) as: "all of the administrative and operational programs of a business which are designed to prevent AHM accident risks, including, but not limited to, programs which include design safety of'new and existing equipment, standard operating procedures, preventive maintenance 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 hazards and operability study that has identified hazards associated with handling of anhydrous ammonia, an AHM. The Hazards and Operability Study is included in the Hazards Analysis (Appendix A). The term "ammonia" as used throughout this RMPP refers to its merchant name "anhydrous ammonia". 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. In 1993, Crystal Geyser Water Company modified their existing ammonia refrigeration system. This modification included the installation of new condensers, evaporative condensers, a glycol chiller, master accumulator, accumulator, and high pressure receiver. In addition, a high pressure relief sparge system with diffusion tank was Page 2 installed to reduce the risk of ammonia release in the case of a high pressure release from the pressure relief vents. This new system utilizes the rebuilt carbo coolers. Crystal Geyser is updating the RMPP to reflect these AHM handling system changes. Page 3 1.0 BACKGROUND 1.1 General Business Information Name and Location Crystal Geyser Water Company 1233 East California Avenue Bakersfield, California 93307 Exhibit 1 is a location map. The area immediately surrounding the Crystal Geyser Water Company plant is used for commercial, industrial and residential purposes, as shown in Exhibit 2, surrounding area. Business Telephone (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. Crystal Geyser Water Company's Business Plan is located in Appendix B. Page 6 1.2 Description of Acutely Hazardous Materials Used 1.2.1 Amount Ammonia Used The ammonia used at the Crystal Geyser Water Company facility is contained in the ammonia refrigeration system and holds approximately 4900 pounds of ammonia. A plot plan of the refrigeration and water treatment facility is labeled Exhibit 3. 1.2.2 Hazardous Properties of Ammonia 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 receptors. 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. Ammonia, a colorless gas with an extremely pungent odor, can be detected by smell at concentrations of 3.5 to 37 mg/m3 (5 to 53 parts per million). 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 parts per million) can cause eye irritation. Coughing occurs at a level of 1,200 mg/m3 (1,700 parts per million). 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. If involved in a fire, a 16 percent to 25 percent ammonia mixture with air may explode. Table 1 lists the physical properties of ammonia. , Page 7 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 ammonia flows from the condenser to an expansion valve or injector, where its pressure and temperature are reduced. The ammonia moves to the evaporator where it absorbs heat from a fluid being cooled. Vaporized ammonia then flows to the compressor suction to complete the refrigeration cycle. 1.4 Operation of the Ammonia Systems Exhibit 4 is a flow schematic diagram of the new ammonia system. Piping and equipment layout plans are located in Appendix C. The new ammonia system has been designed to operate continuously 24 hours per day, 7 days per week. From the receiver vessel, liquid ammonia flows through a King solenoid valve to the master accumulator. In the master accumulator, any excess ammonia is boiled off before the liquid ammonia flows to the glycol chiller and the carbo coolers. In these flooded systems, liquid ammonia flows through exchanger plates while the material to be cooled, flowing counter currently, is cooled by the phase change of the boiling ammonia. The carbo coolers and the glycol chiller control the ammonia using a series of float switches. Each unit has an operating float switch and a solenoid valve. When the correct level is reached, the flow of ammonia is turned off. If the level gets too high it will be caught in the master accumulator. A master high level float switch will shut down the entire refrigeration system. Page 8 Gaseous ammonia enters the screw compressors and is compressed to a higher pressure and temperature. After exiting the screw compressors, the hot gaseous ammonia enters the evaporative condensers. Water running over the condenser coils cools the hot gaseous ammonia into liquid ammonia. The liquid ammonia then returns to the high pressure receiver located inside the compressor building. For the carbo coolers, the liquid ammonia flows through the injectors pulling liquid ammonia from the surge vessel into the coils of the carbo cooler and pre-chiller deaerator and flows to the ammonia surge vessel as a liquid/gaseous phase. Gaseous ammonia from the ammonia surge vessel flows to the ammonia suction trap. The suction trap prevents liquids from returning to the compressors. The gaseous ammonia is then pulled into the compressor suction. Page 9 ~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 Community: BAKERSFIELD STATION 02 Grid: 32C F/U: 1AOV: 0.0 Contact Name .... Title Business Phone .~ 24-Hour Phone] .~i~k~,~ 03~3~e~ ~A,~ ~,~ (~6t') 323-6296 x GERHARD GAUGEL ~ ~;~a~ (&&~) 323-6296 x (&~,) 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: (~?) 9~1 -05'60 Address: 501 WASHINGTON ST State: CA City: CALISTOGA Zip: 94515-O30'~ Summary THIS FACILITY HAS ;~ INDIVIDUALS TRAINED IN S.C.B.A. WRIH'EN INJURY ANU ILLNEgO PREVENTION PROGRAM Completlml of IMI fo~ IndlealeJ IhM Il Ig tho ~llc~ of the employer I~ fully comply with I..n~r Addle.: lZ)] EAST CALIFORNIA AVENUE City: ' BAKERSFIELD, "' Slate: CA ZIp Ct~le: Tdeplmne Number: 805132]-6296 __ Type of Business: HANUFACTUEER Main Acdvldu: BOTTLING ~4ATER AflU BEVEEAGEI~ ' Name/llde,, Robe r .t Ilo [ Dencdpflmt of AulJmtltly attd Reqw~.slhillly tHFLE'I'IOH t IFFj EHFLOYEEg ~_, T~&.HG. . tPSrECTtOnS ~U INJURY & tt, i,HESS PROGR~. ',,' Ham~de,,, Ri~hard.We~l~h, , - Vi~e, ~lCdplloll Of Aulhodly ami Renl~tSil)lllly GEHE~L AUTIlORII'Y OF SUFERVISION OF ALLOCATE HECESS~Y,RESOURCESt A3SU~HCE_&XFP O~' ABATED Review of applicable Oc.etM Imluntry Safely Onlel. ami i)thet Safely Orders that c~mlcals 9sad) m~ pdentl;l ~cupllo. M sarcly and he.llh h;~mds. ~ Investlgnlloh of nil accl(le,t~, hqudes, III.asses, n.cl mmsunl eve,ds that have ~cuucd . mt this I~ntiml (see IV PetiOle mid scheduled If~s~clhmn of 8e.etfll wink n~M n.d q~cilic wink stations (see IV I~low). · Evnluatio. of bffomtatio, provided by employees (see VI I~ow}. OR ~ An effective alternative metlrxl as descdl~d ~luw or attached to this program . ') " ~1991 California Chsm~l of Commerce (J) Hmne R~T UOrr~nO ' Job ~nfzly CInM OII,~E A (~) Nmm, _D_~Y!D=_W~IGIIT ,~_~9~E_~.E~DQ~A~ GERIIARD GAUGEL lirl,-7) whkh Rte ttmhdnltt~tl pt Ihe fqdlt)~vI,p, I~n(i,, r.l..~ E. CALZFORNZA B~KERSI"'I~T.D F, lalulllfled it tim ~.llowl.K I~nlloll .~.[iIILtJ.tlLL.C~._} 2__3--3 E, CAL~IFORNIA 8_AKERSFIELD ~ ' " From IIPP- I mid Itt, tlmtt.qlldllf FJcquel~y of~clle(lu[ed IIl~l~clhms (WCE EVERY G tlOIl[ll~ . htvestliutlmts Blt d~umc.lc(I mt I:ulm II1'1'-~. 'lhcse IOnn~ ntt mai.tM.ed fll the 1he tiflpluyct u~es mi nliet.flllve mttlK~ t)l hQmyfllllmel lll~111silml (dtsctl~.)',. Fom~ lift-| I.m~ectl~ e.l, lg,m:ttt IR ht~lmlcd tn hdtlnI ~ .l'mt:lo~¢el have b¢~, ad~l~ed h~ the li:lhiwllt[ in~lh:~l _l_~t~O~_..[ BAKERSFIELD Cl.-flY FIRE DEPARTMENT .. HAZARDOUS MATERIALS INVENTORY Page/...L. of l.j... CHEMICAL DESCRIF'FION INVENTORY STATUS: New [ I Addition [ I Revision [)~ Oeteti~n [ ] Check if chemice/is ,~ NON TRADE SECRET ,[~ TRAOE SECRET [ Common Nm'ne:. /~,,~),,4/,/,J/~d :3) DOT # PHYSICAL & HEALTH PHYSICAL HEALTH HAZARO CATEGORIES F~re [ ] Reactive [ ] Suctden Rele~e of Pressure ])() Immedia/e He~d~ (Acute) (~ Oelayed Hea.~h (Chronic) [ ] WASTE CLASSIFiCATiON ~(3-dicjit code (Tom' OHS Fo~m.8022) .... USE COOE 6) PHYSICAL STATE Solid [ ) ~quid [ ] G~s Dk~ Pure ~1~ Mixture [ ) W~te [ I Radio-ctive 7} AMOUNT AN[::) T~4E AT FACILITY UNITS OF MEASURE 8) STORAGE COOES Average 0~Jiy Amount. //~, ~ 5' O ~'i'.~ canes [ ] b} Pressure: Annue/Amount: ///,3 5' ~ c) Temperature: La. rgest Size Container:. ~:/q~g~ # O~ys On Site 3 ~ ~ Circle.Which Mond'ts'... ~ J, F. M~ A. M. J, J, A. S. 0. N, 9) MIXTURF* Ust COMPONENT CAS # % WT AHM. chemicaJ components or a~y AHM com~onems 2} [ ] CHEMICAL DESC~IP'I'ION 1 ) INVENTORY STATUS: New ~ Addition [ ] Revision ( ] Deletion [ ] ' Check if chemic~J is :~ NON T~ADE SECRET 4) PHYSICAL & HEALTH PHYSICAL ,- HEALTH HAZA,c[o CATEGORIE~ Rte ~ ReactrVe [ I Sudden Release of Pressure [ 1 tmmedia~e HeaJth (Acute) [ ] Delayed HeaJth (Chronic) 5') WASTE CLASSIFICATiON (3-die]it cocle from OHS Form 80221 USE COOE O q 6) PHYSICAL STATE Solid [ 1 ~quid ~ Gas [ I Pure [ Mi'cure ~)~ Waste [ [ Rac~io,c~'e 7') AMOUNT AND TIME AT FACILITY UNITS OF' MEASURE 8) STORAGE MS.~mum 0oily Amount: ~.~'~"f-~ tbs [I ga.I [~ ~,3 [ 1 a) Contanen 0~.. A~-'~ /~ Average OaJly Amount· ¢ ~'-,~..~ curies [ I b) Pressure: Annu~t Amount: .~?g)iD c) Tempera~re: L.azgest Size Container:. ~.~'~ # Ds,¥s On Site _~,-~,.~,~' CircteWhic~Months: ~ J. F. M, A. M. J. J. A. 9) MDCFURE: List . COMPONF_NT CAS # % WT AHI~ chemicaJ components or ~'~y A~IM c~mcx3nenm 3) '' cern/unoer pened~ or law, r~a~ I i~ave persona~ly exm'n~neo e. no ~rn te~'nma~ wJ~ ~e ~nromaDon suorntr~eo on mrs m'~ aui ~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 · ~re, Immed Hlth FT3 ~ CAS #: 76~Trade Secret: No ~, Form: Gas Type: .5 Use: STORA PORT. PRESS.-CYLINders IAmbi~nt tCU~..~L~ ~ CORNER -- Con_~I Components ..... 'i MCP~Guiae ~0% ,Ammonia, Anhydrous Gas IExtreme 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 Max FT3 ~ ~~Average-F~~~~nual Amount FT3 -- Daily Storage press I ~ _~ ~ Location IN ~CHINE/EQUIP ~Abo~~e~~er~n~ ~system 02-010 ACETYLENE Gas 130 High · Fire, Pressure, Immed 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 ~Amount FT3 -- 130 ~ 100.00 230 00 Storage ~ Press T Temp~ Location PORT. PRESS. CYLINDER {Above ~AmbientISOUTHWEST CORNER SHOP STORAGE -- Conc Components MCP Guide 100.0% IAcetylene IHigh I 17 )6/03/93 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 ~ Annual Amount FT3 -- 18,158 I 1,455.00 218,340.00 Storage Press T Temp Location FIXED PRESS. CYLINDER Above [Ambient I SOUTHWA~J~ PARKING LOT R~A - C0~H6& - Conc Components MCP Guide 100.0% IPropane IExtreme 1 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 [ Annual Amount GAL 55 I 30.00 55.00 Storage Press I TempI Location DRUM/BARREL-NONMETAL Ambient|AmbientlINSIDE WESTSIDE BUILDING -- Conc Components MCP iGuide 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 I Daily AVerage GAL I Annual Amount GAL 104 I 52.00 1,250.00 Storage IIPress T Temp Location PLASTIC CONTAINER I Ambient~AmbientlWESTSIDE OUTSIDE BUILDING -- ConcI Components I MCP ---TGuide 12.5% {Sodium Hypochlorite High ~ 45 1.0%IS°dium Hydroxide IM°derateI 60 )6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 4 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 GALI Daily Average GAL ] Annual Amount GAL 25 ~ 20.00 80.00 Storage Press T Temp Location DRUM/BARREL-NONMETAL IAmbient~AmbientlBoILER ROOM -- Conc ~ Components { MCP ---TGuide 4.0%IS°dium Hydroxide IModeratel 60 8.0% Potassium Hydroxide IModeratel 60 · 3.0% beta-Diethylaminoethanol IHigh ! 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 GALI Daily Average GAL I Annual Amount GAL 110 ~ 55.00 1,000.00 StorageI~Press T Temp Location DRUM/BARREL-NONMETAL IAmbient[AmbientlINSIDE WEST BUILDING -- ConcI Components I 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 I Temp Location DRUM/BARREL-NONMETAL Ambient[Ambient ·INSIDE WEST BUILDING -- Conc Components MCP Guide 25.0% IPotassium Hydroxide IModeratel 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 LBS900I~ Daily Average 550.00 LBS [ Annual Amount 5,800.00 LBS -- StorageIIPress T Temp Location DRUM/BARREL-NONMETAL IAmbient{AmbientlINSIDE WEST BUILDING -- Conc Components MCP --TGuide 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 I Annual Amount GAL -- 20 { 20.00 100.00 Storage Press 7 Temp Location IN MACHINE/EQUIP {AmbientlAmbientlSHOP -- Conc Components MCP ---~Guide 89.0% {Mineral 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 LBS I Daily Average LBS ~ Annual Amount LBS .... 300 I 150.00 1,200.00 Storage ~lPress T Temp Location BAG IAmbient{AmbientlNORTHWEST BATCH AREA -- Conc Components MCP -~Guide 100.0% IMaleic Acid IL°w ~ 60 76/03/93 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 IAbove ~AmbientISHOP STORAGE AREA -- Conc Components MCP ---TGuide 100.0% IOxygen, Compressed ILow ! 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 I Daily Average GAL I Annual Amount GAL 330 I 110.00 2,500.00 Storage ~lPress T Temp Location DRUM/BARREL-METALLIC IAmbient~Ambient{OUTSIDE EAST YARD IN DOCK -- Conc Components ~ MCP gGuide 100.0% Diesel Fuel No.2 IModerate! 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 llPress l Temp Location DRUM/BARREL-METALLIC IAmbient~ambientlOUTSIDE WEST BUILDING -- Conc Components MCP .Guide 43.0% ISolvent Dewaxed Distillate, Heavy Paraffin ILow I 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 FT3I Daily Average FT3 I Annual Amount FT3 -- 155 ~ 75.00 155.00 Storage Press T Temp Location PORT. PRESS. CYLINDER Iabove 1AmbientlSHOP STORAGE AREA -- Conc Components MCP Guide 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/MANUFACTURING Daily Max FT3 Daily Average FT3 Annual Amount FT3 -- 420,333 I 242,500.00 I 2,932,920.00 Storage~ Press T TempI Location FIXED PRESS. CYLINDER IAbove ~Below INORTHWEST PARKING LOT AREA -- Conc Components MCP ---~uide 100.0% ICarbon Dioxide IMinimal 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 ~ 1,000.00 24,000.00 Storage ~~Press T Temp Location BAG IAmbient~AmbientlNORTHWEST BATCH AREA -- Conc Components MCP ---~uide 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 LBSI Daily Average LBS I Annual Amount LBS 800 I 400.00 3,000.00 Storage Press T TempI Location BOX Ambient/AmbientlPACKING AREA SOUTH BLDG -- Conct Components ~ MCP --TGuide 100.0% IPPO IMinimal 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 ~ Daily Average FT3 Annual Amount FT3 142 I 70.00 142.00 Storage I Press T TempI Location PORT. PRESS. CYLINDER IAbove /AmbientlOUTSIDE BLDG SOUTHWEST CORNER - Conc Components MCP ---[Guide 100.0% INitrogen ILow ~ 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 I Annual Amount GAL 110 I 30.00 _ 600.00 Storage ~ ~Press T Temp Location DRUM/BARREL-NONMETAL t Ambient~AmbientlINSIDE WEST BUILDING - Conc~ Components ~ MCP| Guide 10.0% IDimethyl Benzyl Ammonium Chloride IMinimal ~ 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 ~ 35.00 55.00 Storage Press I TempI Location DRUM/BARREL-METALLIC Ambient~AmbientlOUTSIDE WEST BUILDING -- Conc Components MCP Guide 100.0% IHeavy Machine Oil 1Minimal 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/MANUFACTURING Daily Max LBS I Daily Average LBS I Annual Amount LBS -- 200 I 100.00 1,700.00 Storage IIPress T Temp Location DRUM/BARREL-NONMETAL. IAmbient~AmbientlWESTSIDE OF BUILDING -- Conc Components MCP Guide 100.0% IAscorbic Acid IMinimal I 7 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 GAL55I~ Daily Average'GAL35.00 [ AnnualAmount55.00GAL -- Storage llPress T Temp Location DRUM/BARREL-METALLIC IAmbient~AmbientlOUTSIDE WEST BUILDING -- Conc Components MCP --,/Guide 100.0% ILubriCating Oil (Petroleum-Based) IMinimall 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 LBS Daily Average LBS Annual Amount LBS .. 2,000 I 700.00 I 20,000.00 · - Storage Press T Temp Location BAG IAmbiont~AmbiontlNORTHWESTBATCH AREA -- Conc~ Components ~ MCP ---/Guide 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 GAL I Daily Average GAL I Annual Amount GAL 110 ~ 55.00 700.00 Storage ~lPress T Temp Location DRUM/BARREL-METALLIC IAmbient~ambientlOUTSIDE WEST BUILDING -- Conc Components MCP ---~Guide 95.0% ILight Petroleum Distillate [ModerateI 27 INCIDENT COMMAND SYSTEM PAGE I {ORGANIZATION } INCIDENT COMMANDER - GERHARD GAUGEL COMMAND STAFF' INFORMATION OFFICER- ROBERT HOFFERD {ORGANIZATION & ASSISTANT DEE SECARA MEDIA CONTACT } SAFETY OFFICER - - DAVID WRIGHT {MONITOR SAFETY ,ASSISTANTS - PAUL OCAMPO OF ALL ASSIGNED - - - JUAN PINON PERSONNEL} - - JOSE MENDOZA - - - Q.C. TECH { ON DUTY } - - - MAINT. TECH { ON DUTY } -. - JESSIEMOYA LIAISON OFFICER - ROBERT HOFFER.D { ON SITE CONTACT ASSISTANT .... DEE SECARA FOR ou'rS1DE AGENCY, O.E.S. FIRE DEPT. HAZ- MAT TEAM, ETC.} PAGE 2 GENERAL STAFF OPERATIONS SECTION' CHIEF: DAVID WRIGHT DEPUTYS: PAUL OCAMPO JUAN PINON JOSE MENDOZA Q.C. TECH { ON DUTY } MAINT. TECH { ON DUTY } JESSIE MOYA 1. DEVELOP AND MANAGE THE OPERATIONS SECTIONS TO TO ACCOMPLISH THE INCIDENT OBJECTIVES: PLANNING / INTELLIGENCE & LOGISTICS · CHIEF · ROBERT HOFFERD ASSISTANT: DEE SECARA I. COLLECT, EVALUATE & DISPLAY INFORMATION ABOUT 'THE INCIDENT. 2. DEVELOP INCIDENT ACTION PLANS FOR EACH SHIFT 3. MAINTAIN RESOURCE STATUS INFO ON ALL EQUIPMENT & PERSONNEL ASSIGNED. 4. MAINTAIN INCIDENT DOCUMENTATION FINANCE & ADMINSTRATION CHIEF · GERtlARD GAUGEL .ASSISTANT · DEE SECARA 1. TIME UNIT 2. PROCUREMENT UNIT 3. COMPENSATION / CLAIMS UNIT 4. COST UNIT PAGE 3 INCIDENT ACTION PLAN IN CASE OF AN EMERGENCY PLANT EVACUATION , THE FOLLOWING STEPS HAVE BEEN SET UP FOR EVERYONES SAFETY. 1. AN ANNOUCEMENT OVER THE PAGING SYSTEM TO EVACUATE THE PLANT. 2. ALL PERSONNEL WILL REPORT TO THE STAGGING AREA, LOCATED AT THE EAST END OF THE PROPERTY. 3. ON THE WAY OUT OF THE PLANT, CERTIFIED S.C.B.A. PERSONNEL WILL BRING S.C.B.A. UNITS TO THE STAGGING AREA, { ALL THREE UNITS}. 4. ATTENDANCE ROLL COUNT WILL BE TAKEN BY THE OPERATIONS CHIEF { DAVID WRIGHT, OR DUPUTY ON' SHIFT. 5. THE INCIDENT COMMANDER / AND OR., THE COMMAND STAFF WILL MAKE AN OVERALL ASSESSMENT OF THE INCIDENT WHILE IN PROGRESS. IF NECESSARY THE FIRE DEPT, HAZMAT TEAM, MEDICAL UNITS, AND O.E.S. WILL BE NOTIFIED IMMEDIATELY, BY TIlE LIAISON OFFICER, ROBERT HOFFERD OR ASSISTANT, DEE SECARA. IF THE INCIDENT OCCURS DURING THE NIGHT SHIFT, LEAD PERSON JOSE MENDOZA AND GENERAL STAFF MEMBERS ON DUTY WILL EVALUATE THE INCIDENT. IF NEEDED 911 WILL BE CALLED,' AND THEN COMMAND STAFF MEMBERS. 6. IF ALL PERSONNEL ARE NOT ACCOUNTED FOR, A SEARCH AUTHORIZED BY THE COMMANDER / AND OR, COMMAND STAFF, WILL GET UNDER WAY. THE OFF SITE RESCUE TEAM WHO RESPONDS FIRST W[[,L BE ASSISIfiTED BY TWO CERTIFIED S.C.B.A. PERSONNEL FROM OUR GENERAL STAFF IF NEEDED. A MAP OF THE PLANT WILL BE AVAILABLE WITH THE S.C.B.A UNITS, TO ASSIST RESCUE TEAMS IF NEEDED. 7. THE SAFETY OFFICER, DAVID WRIGHT, AND OR ASSISTANTS ON SHIFT WILL CONTINUE TO MONITOR ALL PERSONNEL SAFETY. INCIDENT OBJECTIVES 1. PRIORITY ONE - INSURE THE SAFETY OF ALL PERSONNEL INVOI,VED, INCLUDING THE SURROUND.lNG AREAS. 2. SECURE THE PREMISES, AND TAKE CONTROL OF THE SITUATION AS EFFICIENTLY AS POSSIBLE, USING ALL THE RESOURCES AVAILABLE, OR AS NEEDED. 3. GENERATE AND MAINTAIN RECORDS OF ALl_, INFORMATION REGARDING THE INCIDENT. INCIDENT COMMAND STAFF PI'lONE NUMBERS GERHARD GAUGEL · 392-8747 ROBERT HOFFERD · 832-0453 DAV1D WRIGHT · 836-1382 DEE SECARA : 832-3322 GENI, ~AL STAFF PHONE NUMBERS ARMANDO RAYO · 334- I 156 JOHN WILL1AMSON · 587-1786 MARK WOOTEN · 325-4803 RICHARD PITCItFORD · 634-9159 DARRYL DELATTRE : 392-9325 HARRY BARBA · 823-1708 JOSE MENDOZA · 631-8348 JESSIE MOYA · 396-9822 JUAN PINON · 322-3821 PAUL OCAMPO · 397-7686 INITIATION OF MANAGEMENT OF CHANGE FORM ~ FORM MOC-IB 2~' MOC NUMBER SECTION l' INITIATION OF MANAGEMENT OF CHARGE FORM Section I is to be completed by |ndividual originating the MOC and forward to the Maintenance supervisor, ORIGlbIATED BY: DATE: NAME OF PRO~ECT: ..... l,~ozrr¥ ,O~ ~qu~s'r: ,, (c~cz O~ , .... {~} CRITICAL. Affected portion ofsystem should by lock out and tagged to prevent operation until safety issue(s) resolved. (,~} URGENT. Affected portion of system should be tagged and operated short term with caution until safety issue(s) resolved. {__} IMPORTANT. Affected portion of system should be tagged and operated with caution until safety issue(s) resolved. { _ _ ~ , ROUTINE. Affected portion of system should be noted and work to resolve minor safety !ssue(s) scheduled. Rr_~SON FOR I~:qUgST: , ICHECK 01~) , {.__} Incident Investigation Recommendation (Ref. No. ) {,__} Mechanical Integrity Audit Recommendation (Ref. No. } {,__} Pro-start Safety Review Recommendation (Ref. No..) {,__} Process Hazard Analysis (Ref. No..) {,~ } Change in Refrigeration ReqUirements { __ '} Expansion or Renovation of Facility or Systems { } Other (Explain) R0-1ocation duo to Pr0~luction demands. ozsou io: 6F ' TECm~ICAL BASlS FOR ~GE O'UR~OSZ, rr Arr s RZSZaZNCZ S ZTC .S OR O WmUS}.' FORM MOC= I C MOC NUMBER SECTION 2: SCREEN OF MANAGEMENT OF CHANGE FORM Section 9_ is to be completed by the Utility Team Coordinator, and then a copy of the MOC is to be forwarded to the Group Leader. If'the requested modification constitutes change, Sections 2-6 must be completed. Reviewed by: .... Date: ASSESS TECttlqlCAL BASIS OF CHANGE The modification as described in Section 1 is classified as (please check appropriate space): .... Technical Basis,, Assessment ..... ~t,~ Action Is the change n replacement in {_} Replacement in kind Change is not pnrt of MOC kind? )rocedur~. { -- } ch~-5~isnota MOC IxocO___ure must be replacement in kind followed. Is thz modification a major or { } Modification is a minor Proce~ h~rd analysts is not { } Modification is a nmjor Process hn~n~d analysis is chan~e required. Is ~te change pemmnent or { } Change is permanent {_} Chan~ is temporary Fill in section on MOC concernin~ duration of chan~e. Is ~hz c~%,z n~y, {__} Yes Chanl~ should be forwardzd for action? {_} No Change should not be , implemented. 2 FORM MOCo 1D MOC NUMBER ~URATION OF CHANGE If the chanse is temporary, note duration here: No temporary change should be l~anted more than five one-week extensions or he allowed to extend beyond six weeks, includin8 any extensions. The table below should be used to track temporary chanses. SCHEDULE FOR TEMPORARY CHANGES ~itiation ,D, ~tq Ex?raft,On Date Authorization Initial request. , ........ F. xtension # 1 t i0n #2 ....... Extension #3 Extension #4 Extension #5 UPDATING PROCESS SAFETY INFORMATION, PROCEDURES, AND DOCUMENTATION Identify the process safety information which needs to be ~zvised as a ri:suit of this change. Reference # Reference # Process flow diagrams Piping and insirumcn~tion diagrnm.~ .Elemical one4ine drawings S~m Fire, wate~ & sewer system drawings Ammonia equipment lis~s Ammonia instnuuent lists Criteria for design and operation Standard operating procedures .Preven~ -~i,,tennnce procedures Operator training procedures Accident inve~igntions procedures Emergency n~sponse procedures Audit program Other (describe): nm~QRE FI~'~.R START-UP MAKE SURE UNIT IS ANCOI~-_r) TO THE FLOOR. ~,T.l. W~..r)s mOM 2 ½" Atto W Wn~ l~nvm TO BE BUCr W~-IOS At4O A X-~Ot. Y PmU~O ~W~. SECTION 3: PRELIMINARY ENGINEERING PRELIM[NARY DESIGN REVIEWED BY' Date: ! [ UTILITY TEAM COORDINATOR: Date / /__ REFRIGERATION GROUP LEADER: DATE / / FORM MOC-1E MOC NUMBER # SECTION 4: SAFETY REVIEW CHECKLIST Date Completed: Safety review checklist reviewed by:. .Date: SECTION 5: PROCESS HAZARD ANALYSIS (If analysis is performed) Date Hazard Analysis Completed Does the process hazard analysis address the impact of change on safety and health? (Check one) (_ _ ) yes ( ) no Hazard analysis report reviewed by:. Date SECTION 6: 5TARTUP AUTHORIZATION Have all applicable drawings, procedures, and d°cmnentation noted in Section :2 been revised accordingly (Check one) ( ) Yes (.) no Have all appropriate operators, maintenance personnel, been informed of and trained in the change? (Check one) (___) Yes (,, ) no Have all, if any, recommendations fi.om the preliminarYengineering, safety and health review and the process hazards analysis been addressed? (Check one) (m) Yes ( ) no Authorization should be given to accept this change and proceed with start-up of the modification ifand only ifthe answers to all of the above questions are "Yes". Authorization for change and start-up is given by: PI-IA Team Leader: Date: / /__ Utility Team Coordinator:. Date: / /__ Group Leader: Date: /. / Plant Manal~er: Date: / /__ 4 lViOC biO 98-007 SAFETY REVIEW CHEC~ST QUESTION A REMARKS ..... ' RE~6~IMENDA~I0i~IS ,.. BY COMMENTS l~mmtm column). Docs 01~ modificatim meet valv~ ~ tl~ sized l~q~dy. ~. Have ~ mmdm'd ~ ~ (SOPs) MOC NO SAFETY REVIEW CHECKLIST QUF~TiON A ' REMARKS RECO~ATIONS BY COMIV~NTS 9. E~s ~ mm~3ca~ b~m my ~ing I0. I~m tl~ mo~a mtu~ tlat anmmia 11. A~e the indicsm~ ~ ~ h ti~ ex/st/n~ MOC 98-O07 SAFETY REVIEW CHEMIST QUESTION A ~ RECOMMENDATIONS BY COMMENTS ! 3. l'hv~ tl~ modifiaaiam ~_~_~ my additia~ 14. la d~cUical pov~ ~ ot~ servi~ (i.e. by th~ ~ Ut~ios Tcchnici~t MANAGEMENT OF CHANGE FROM (MOC) LOG INITL~! ~n OF REVIEW ENOINEERING REVIEW ANALYSIS AUTHORIZAIION DATE -~ COMPLErED CHF. CKI~T COMPLETED OF CtLa. NOE 'PRE-START AND/OR PRE-SHUT SAFETY REVIEW DOCUMENTS AMMONIA SYSTEM MOC NUMBER PRE-STARTUP AND/OR PRE-SHUTDOWN SAFETY REVIEW DOCUMENTS Plant: Crystal Geyser Water Company Date: Job tiltle: Project supervisor: Description of change { attach additional sheets if needed }: Reason for the change { attach additional sheets if needed Management of change documentation must be completed prior to continuing with the pre-startup safety checklist. APPROVAL Project supervisor Data Team coordinator Date Operations Manager Date Page 2":, ' (" CRYSTAL GEYSER WATER CO. PRE-STARTUP SAFEI'Y REVIEW DOCUMENTATION ITBII RF3K)N$1BLE PRE-,~IUT I~E..,~rA~IT COMMENTS BY PEI~ON DOWN UP Have ~11 control verified7 "Are .11 ooerstJng ......... '" manu.l~ revi~d and dJsu'Jbuted? Is all training coml~tad -,nd docunu~tod? ..... HBo the emecgeflay been ncdfled of ~hm ~r~up? Has the response team conducted · drill Irtmergency equjpmeflt off stsnd*by?: · , ............. Hove two utilitlea technicilnl test? Have been taken to insure that no cutdng, into pipea W411 udlitiei and I)relenceT ................. Is all file? :',,',~. :. '. Page 3 -~ " MOC# ITEM RF.~PON$1BLE PRE-,~IUT PRE- COMMENTS BY PEI~a~N DOWN 8TART UP permita on hand at the site where the work will be performed? ...... Have confined space perm~ta been completed and are they on hand? Have all lockout ! ragout procedur~ and permit~ been properly . completed? ,.. equipment been properly pumped out by a utilities technician? Have all valves been verified prior to a pressure teat? Has equlRment tpn properly set up Der sop's? ..... has all controls that are in contact with nh3 (pressure cut- out, etc.) been verified that they are rated for ,n,h3 .......... has all pipe hangers been installed per liar standards Has all pipe hangers been retighten after the Insulation work was co.mpletad. , .... has insulation been installed per standards' C:~.-qAFETY~Rg~I'~f .DOC Page 4:..: .,~.~ (" , : i' " ~' , ' ,~ ~, ,, ~ H.. the PM b~n ml~. . ........ Ne~ ~ i~ll ~na~'s m ~M NH3 ~o~ing I~ ~ NH3 ~' In ~ ~r 811 line) ~ ~, ~ad~ ~e frm~ ~ ~. ~mllo~) ~1 n~d at ~ ~ of job. , . .... m~t ~ ~,. Ing~ .......... ~i~ ::". N~ m ~k m~orl~ m~ N~ m ~1 at~ vd~ ~ ~ ~ UN- Haa ~~ for ~( ~v. ju~ 24,. i998) PRE-~A~-, UP/PRE-SH~ DOWN CHECK OFF LIST GENERATED ..... COMPLA~ON DATE: : . Page 5 ,~ ( !' Has th"~ PM " ' .....' .... planner (Paula) .been Informed let the le~- earn freezer has been r. alocated. ,, Need to install " "· Belisrd's ~o protect NH3 piping from motor traffic, Before charging lines with NH3 In the tee-bar all stop valves to ',he freezer being relocated {cup- line) and the location the freezer ts gMng (rollolS) will need to be locked-out at the start, of job. . .......... Make sure all ............. stop valves, fittings and piping meet neatlee standards ~klvas end plugs hstalled on strainers attaching to freezer Need to check motor/motors rotation Need to inst~ll s~op valvea with setscrow8 on the bonnet to keep bonnet from UN- screwlng, flee contractor received standards for plpin0( rev. june 24. 1,,908) ,meN: , , PRE-START UP/PRE-SHUT DOWN CHECK OFF LIST GENERATED BY: COMPLATION DATE: PROCESS HAZARD ANALYSIS SPECIFIC PHA FOR MOCk_ Item Item Equipment/Activities (~uestions Scena.r~s. . Con~q.o*~_m~s ~..,A, Co-trob S L R Itm~mc.~l.~___ St~tm Pre-stm Add to Pse. smrt COMPANY: FACILITY: MOC# PROJECT: PHA DATE: PHA TEAM LEADER: TEAM MEMBERS: CONSEQUENCES/HAZARDS ( 1 ) H3 VAPOR POSING INHALATION HAZARD TO PERSONAL. ( ~ ) ,NIB LIQUID CHEMICAL HAZARD FROM LIOUID CONTACACT. ( 3 ) .NIB INGES.TION, INTERNAL CHEMICAL. ( 4 ) _NIB VAPOR COMBUSTIBILITY THERMAL BURN HAZARD. ( ~ ) ,NIB VAPOR EXPLOSIVE OVER-PRESSLrRE HAZARD. ( 6 ) MECHAN CAL OV -P. REssuRE nv[PACr ( 7 ) NO HAZARDOUS CONSEQUENCES IDENTIFIED. ( 8 ) SCENARIO NOT APPLICABLE TO THIS SYSTEM. S ( SEVERITY ) AN EVALUATION OF THE SEVERITY OF THE HAZARD, L ( LIKELIHOOD ) AN EVALUATION OF THE LIKELIHOOD OF THE HAZARD. R ( RISK RANKING ) AN ESTIMATE OF THE RISK OF THE HA7__~dtD SCENARIO. ! I ~ 4 5 L - LIKELIHOOD ~ ~ SEVERITY I)-HIGH # 1) CATASTROPI~[C E z 2) mC, ti 2) MODEI~TE L 3) MEDIUM I s 3) MED~ 4)LOW H 4 4)LOW ~) VEinY LOW O ~ ~O~ D SECTION II.1 DISCOVERY ! I:i~ioleas~'~i~'i!~t~fi~::i~!~'~h~'~, i61f~i~~ !.' ~ub~hhe~llht~6~the)env ~o~eiit::~i~i:~ii!~i ~ ~;~ '~:~ :~ ~' ~' 1 I'":" ' < '"'. .......~ ......~.,. >....,...:.,...,.~........~.~e ............. .,.:*,..~. ~.-.¢~...,:..,. ..... . ...... ..................... . ..... ...... ... ..... · .- I Release detection equipment: (check all that apply) ~ liquid leak monitoring device ~ high / low pressure sensors [21 automatic tank level gauge [] temperature sensors / recording charts ~ flow totalizers ~ high / Iow liquid level sensors [] system / flow shut-off devices [] groundwater / vadose zone monitoring [] toxic gas / air emissions monitoring [] diesel fuel sulfur content verification Periodic monitoring procedures: (check all that apply) [] daily inspection [] statistical inventory reconciliation [] weekly inspection [] automatic tank gauging & tank testing [] continuous leak monitoring [] containers inspected before being accepted [21 storm water sampling ~ waste effluent discharge point sampling [] containers dated as received [] raw materials checked before being accepted [] adequate facility lighting to detect spills [] air district witnessed source testing CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION II.2.a NOTIFICATIONS Facility emergency communication will occur through: (check all that apply) [] verbal warning [] intercom system [21 alarm system [] telephone (including cellular) [] pagers [21 portable radios Report all significant releases or potential unauthorized releases of regulated substances: Emergency notification phone list: * Local emergency response agency .................................... 9-1-1 Local Unified Program Agency .............................. (805) 326-3979 California Office of Emergency Services ..................... 1-800-852-7550 National Response Center ................................. 1-800-424-8802 · Refer to Section II.2.b and/or Annex 111.2 to provide additional phone listings of facility response team members, contractors, or other necessary environmental response resources. Checklist of information to be provided during notification: Your name and the telephone number where you are calling from. Exact location (address) of the release or threatened release. Date, time, cause, and type of incident (e.g., fire, release, unauthorized discharge, etc.) Material and quantity, to the extent known (size and appearance or opacity). Weather conditions, if applicable. Current condition of the facility Extent of injuries, if any; and, Possible hazards to human health, or the environment, outside the facility. CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION ll.2.b ENVIRONMENTAL MANAGEMENT The following personnel are responsible for: Responsibilities Emergency Environmental other Contact(s) Coordinator (specify) Accountability for pollution prevention [ ] [ ] Protection fi.om environmental contamination [ ] [ ] Posting of"no smoking" & warning signs [ ] [ ] Familiarity with chemicals and processes [ ] [ ] Preliminary assessment of the situation [ ] [ ] Initiating alarms [ ] [ ] Notifying response agencies [ ] [ ] Contacting facility responders [ ] [ ] Notifying contract service providers [ ] [ ] Authorizing any corrective action work [ ] [ ] Organizing environmental response activities [ ] [ ] Interfacing with public agency responders [ ] [ ] Emergency service arrangements have been made with: (check all that apply) [] local police [] fire department [] closest hospital [] contractors [] State and local emergency response teams Additional phone list of qualified response personnel and emergency service providers: Name Phone I Duties or responsibilities Additional notification lists provided as Annex III.2 [] Yes [] No Additional environmental management procedures provided in Annex III.3 [] Yes [] No CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION II.2.c PRELIMINARY ASSESSMENT Identify areas of the facility and mechanical systems where releases could occur or would require immediate inspection or isolation because of the vulnerability to earthquake related ground motion. (Check all that apply) [] Storage areas [] Production floor [] Process lines [] Bench / Lab [] Utilities [] Sprinkler systems [] Tanks [] Cabinets [] Shelves [] Racks [] Piping [] Valves [] Waste treatment plant [] Other: Accidental toxic gas or petroleum releases determined to impact areas outside of the facility? [] Yes [] No If "yes," indicate the results below from the risk analysis included in Annex HI.3.d."Planning" Scenario: Release quantity Distance to endpoint (miles): [] Oil spill (worst case) [] Oil spill (most credible) [21 Toxic gas release (worst case) [] Toxic gas release (alternative) [] Flammable gas release (worst case) [] Flammable gas release (alternative) Indicate if any of the following are within 1000 feet or within any distances specified above: [] Schools [] Residences [] Hospitals [] Prisons [] Public recreational areas [] Commercial, office or industrial areas [] National or state parks [] Federal wilderness area [] Wildlife sanctuaries, preserves, or refuges CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION ll.2.d RESOURCES / MITIGATION Emergency medical assistance (check all that apply) [] First aid kit(s) available [] Emergency shower(s) [] Eye wash station(s) [] Ambulance phone #: [] Nearest medical facility location: Evacuation (Please also indicate evacuation routes on appropriate map(s) in Annex III. 1) Signal: [] Verbal [] Phone [] Alarm [] Public address system Primary evacuation route: Alternate evacuation route: Emergency response procedures (typical)* Assess the situation Isolate and deny entry to affected area, evacuate or shelter-in place Provide emergency medical assistance, if necessary Notify response agencies and facility response personnel, as appropriate Control the release, if possible to be done safely or remotely Actively mitigate the release, if properly trained and equipped Provide assistance to public agency responders, as necessary Terminate the response with proper clean-up and disposal Follow-up reporting, evaluation, and critique, as required * Additional facility specific response procedures included as Annex III.3.c "Operations" [] Yes [] No CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES Emergency Equipment List (typical) * Equipment Category Equipment Type Location* Description** Personal Protective ~ Chemical protective clothing Equipment, Safety 13 Face shields and First Aid: ~ Hard hats ~l First aid kits / Stations {~ Eye wash stations ~[ Safety showers [~ Respirators / SCBAs Fire Extinguishing ~ Automatic fire sprinkler system Systems: D Fire alarm boxes / Stations [~ Fire extinguisher systems Spill Control and ~ Absorbants Decontamination ~} Secondary containment Equipment: ~l Decontamination equipment {~l Exhaust hoods {~ Gas cylinder leak repair kits {~ Neutralizers Additional ~ Equipment: ~ · If appropriate, use the location code(s) from the Map / Grid description on the Site or Facility Diagrams · * Describe the equipment and its capabilities. If applicable, specify any testing or maintenance procedures and intervals. Attach additional pages, or include additional information in the appropriate Annex, if needed. * Additional response resources and support equipment, contract capabilities, etc., included as Annex III.3.f "Finance / Procurement / Administration" [~l Yes [~ No CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION 11.3CONTINUOUS IMPROVEMENTS Measures to be taken during nonconformance conditions or prolonged incidents (typical) * Stopping processes and operations Collecting and containing released waste Removing or isolating containers Monitoring for leaks, pressure build-up, gas generation, ruptures, etc. Sufficient temporary storage of generated wastes Rehabilitation of oiled wildlife (if spill affects marine environments) * Additional continuous facility support procedures included as Annex III.3.e "Logistics" [] Yes [] No Planned changes to continuously improve safety / environmental impacts * Improvement: Expected completion date: [] Upgraded equipment [] Revised maintenance [] Revised training [] Revised operating procedures [] New process controls [] New mitigation systems [] Revised emergency response plan [] Changed process [] Reduced inventory [] Other: [] None * Additional protection and mitigation procedures included in Annex IH.3.d "Planning"[] Yes [] No * Additional prevention measures included as Annex III.7 "Pollution Prevention" [] Yes [] No CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION II.4RETURN TO COMPLIANCE Restoration actions:* pt Waste materials transferred, treated, stored or disposed of pt Emergency equipment decontaminated Equipment repaired or replaced, if necessary Additional measures taken to prevent reoccurrence * Additional procedures listed in Annex HI.3.d "Planning" (Part 4. Waste Management) [221 Yes [] No Follow-up (typical) * Follow-up reports submitted as soon as practicable to regulatory agency Incident details noted in operating record Facility compliance plan reviewed and amended if necessary * Additional follow-up procedures included in Annex IH.4 "Emissions Documentation" [] Yes [21 No * Additional follow-up procedures included in Annex III.6 "Plan Audit & Modification" [] Yes [] No CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES "1~-, ~ ~1~~.,* Dee Secara BUSINESS OFFICE MANAGER ~ 1233 E. California Avenue ........ Bakersfield, CA 93307 ~ Phone: (805) 323-6296 ............. ................. 'CRYSTAL GEYSER Fax: (805) 323-7264 '-- ', -~ .WATER COMPANY ............ ? '-'CoYporate office P.O, Box 304 501 Washington Street .................. Calistoga, CA 94515-0304 (707) 942-0500 Fax (707) 942-0647 WZlinc 8.0 EMERGENCY CONTINGENCY PLANS 8.1 General.Evacuation Employees are verbally notilied of emergencies by the Plant Manager or his designee. All einployees are to leave the facility immediately through the parking lot at East California and Lakeview. F, xhibit 8 shows emergency evacuation routes arid designated lneeting places. These routes have been planned to bypass ammonia systeins that ~nay be leaking. Emergency responders will be notified through 9 l 1. In tire event of an emergency after normal operating hours, after notifying 911, the following individuals should be notified in the order given: Bob l:lofferd - 805-832-0453 if lie cannot be reached, call David Wright - 805-836-1382 1£ lie cannot be reached, call Norman Ambrose - 805-393-4176 if lie cannot be reached, call Gerhard Gaugel - 8{)5-392-8747. 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 Calitbmia and Lakeview. Emergency responders will be notified through 91l. In the event of an emergency after normal operating hours, after notifying 911, tile following individuals should be notified in the order given: Bob Hofferd - 805-832-0453 If lie caimot be reached, call David Wright - 805-836-1382 If ire cannot be reached, call Gerhard Gaugel - 805-392-8747 If he cannot be reached, call Norman Ambrose - 805-393-4176. 8.3 Earthquake Employees should remain in safe, stable locations (in doorways, under sturdy desks) until earth movement has ceased. Alter the earthquake, all employees are to leave immediately through the nearest exit and regroup at the parking lot at East Calil~ornia and Lakeview, far enough fi'om the building to avoid falling masonry. 8.4 Significant Leak fi'om the Ammolfia Systems Notify tile Bakersfield City Fire Department. EInployees are verbally notified of the leak. Mechanics will work to isolate the ammonia leak, if possible. If Norman Ambrose is not in the plant, he should be called immediately after 911 at 805-393-4176. All nonessential employees are to leave immediately and regroup at the parking lot at East California and .Lakeview. Page 32 WZlinc The following individuals should be called if Norman Ambrose is not available: Gerhard Gaugel - 805-392-8747 Bob Hofferd - 805-832-0453 David Wright - 805-836-1382 Cleanup procedures for an ammonia release will mitigate the effects of the release: · Ventilatiou will reduce concentrations of ammonia in euclosed areas. · If liquid ammonia is on the floor, spray with large quantities of cold water. · Water will absurb ammonia: high concentrations of alllmO!llia vallor or dispersed ammonia can be diluted with ~wder spray. During a release, the Plant Engineer (Maintenance Manager) will: SIoI) leaks, il' possible. Supervise the use of self contained brealhing apparatus (SCBA). The Plant Engineer has a thorough knowledge of the ammonia system. He has many years of experience with refi'igeration systems. Page 33 8.0 EMERGENCY CONTINGENCY PLANS 8.1 General Evacuation Employees are verbally notified of emergencies by the Plant Manager or his designee. All .employees are to leave the facility immediately through the parking lot at East California and Lakeview. Exhibit 8 shows emergency evacuation routes and designated meeting places. These routes have been planned to bypass ammonia systems that may be leaking. Emergency responders will be notified through 911. 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. 8.3 Earthquake Employees should remain in safe, stable locations (in doorways, under sturdy desks) until earth movement has ceased. After the earthquake, all employees are to leave 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 Systems Employees are verbally notified of the leak. Notify the Bakersfield City Fire Department through 911. Mechanics will work to isolate the ammonia leak, if possible. All nonessential employees are to leave immediately and regroup at the parking lot at East California and Lakeview. Cleanup procedures for an ammonia release will mitigate the effects of the release: Page 32 · Ventilation will reduce concentrations of ammonia In enclosed areas. · If liquid ammonia Is on the floor, spray with large quantities of cold water. · 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: · Stop leaks, if possible · Supervise the use of self contained breathing apparatus (SCBA). The Plant Engineer has a thorough knowledge of the ammonia system. He has many years of experience with refrigeration systems. Page33 8.5 Emergency Responders In an emergency, the following agencies may be needed: Hospital Memorial Hospital 420 34th Street Bakersfield, California (805)327-1792 Fire Department Call 911 Page 34 ~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 IN CASE OF A HAZARDOUS MATERIAL SPILL, THE PLANT MANAGER 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 THAT 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 ~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 - AMMONIA 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 BY-A~)5~7~-L-~L 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 CRYSTAL GEYSER WATER COPIPANY 215-000-001418 OO - OVERALL SITE (Fy SITE EME RGENCY FACTORS I. AMENDMENTS TO <2> UTILITY SHUT-OFFS: A) Gas Meter: Inside fence between buildings next to alley southwest corner of East facility/south of Ammonia tank containment. B) Propane Tank: Southeast corner of East parking lot next to alley and Lakeview Avenue. C) Water: In alley next to fence and soUthwest corner of East building, 330 feet west of Lakeview Avenue. D) Electrical: West Processing Facility -'Outside on southeast corner of building under stairway. East Processing Facility - Inside building on southwest corner on both sides of exit door next to alley. E) Special: 1. Ammonia shut-offs inside southeast corner of West building next to alley/ Engineering Support area. 2. Diffusion system box next to roll up door of West building - southside next to alley. F) Lock Box: Yes (keys only), above north entrance door of west building. II. AMENDMENTS TO: <3> FIRE PROTECTION/AVAILABLE WATER Private Fire Protection- This facil~-'x~, is equipped with automatic overhead sprinklers in all building areas. The sprinkler system is monitored by Tet-Tec Security Systems. Fire extinguishers are in all areas of the facility for emergency use. Fire Hydrant - On the'~north side of East California Ave., directly across from the West facility building. Sprinklero~.=~ '-tem Riser Hookups - Fire Department hook-up exist's in alley 220 feet west of Lakeview Avenue for East building hook up. West building Riser 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:kwpfilesksi~-= -~ ..~ rn Z ANNEX III. 1 MAPS & DRAWINGS .ThiS:'~b~' ~ii0iild P~Vide'det~iled'inf.,0~ifib'fffii th~'tfi~[',0fih~ facilitYand the ~'i ."' :~'~ ]1 I ..:,.~,.: .... :,:,,~..,., :~,?.??..:, :~:~,.,. ,,:,:. · .~.~:.: .~,,.',.:~::..,:. /.x~.~:...e ,r,i. :~.'~.,,.?.~:.,.,, !/.!:~ 3!~;Vi:~!~/.,~,~ii':',:.~., :, ,. · .' , ', surro,tding eny!ronment~ ine.l~ding pl~.dra~mgs necess.~..~to'demonstrate comphance ';.".: I W~th Constroq,°n sP~6,~cahon~'0~' p~pi~'~di~s~m~fitati~n~de~.' :~'.." .' ~ "~ '..: 1 :'iii": :'~:' '"¥':~ ...... "":": ":'i':~:"Sr':l :'l "'~":~::'""'"::~'7':"V :~;':~::"~'~:~"':"?::"~':'~[::~;:'~*~' ~:~ ~:i?~"W:i'~''''::''''' '~''' :': ~ ~' .... m Items to be addressed in this Annex: I~ Site maps ~ Facility evacuation routes ® Off-site consequence endpoints g) Sensitive receptors within cndpoint dismccs . {~ Facility diagrams showing: ~ Utility connection locations ~ Hazardous material storage locations '.. ~ Waste water discharge sampling points . '~',~.. 0 UST monitoring locations ~ Piping and instrumentation design ~ Process flow diagrams I~1 Construction details or equipment specifications .i . t.I COH$OLIDATED I~ACILITY COMPUAFICII Pt,AFl CITY OF BAKERSFIELD. EFIVIRONMENTAL, SERVICF,~ HO$~ITAL t $CHOOI. SIT; ~.R'4~-~tree t ST, ENUE " CRYSTAL GEYSER =" -- Center BAKERSFIELD '- -- ^-. COtton Ave. · CA~.IFORI~I~, I P'°" U Henley St.. · Viro;nia --BRUNDA( ' . ...... I St. 2t)()() : . '..' · '$CH. 0 Terrace Sew BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSF!ELD, CA. O Feet 2000' o ~.,, ~mi. ~mi. ~,,i. ~a,;. LOCATION MAP 0 Kilometers .SOkm 1kin , , DATE 12/93 East California Avenue F"~I Jobl C~WSE. I Crystal Crysta Vintage ~. '.REFRIGERATION Geyser GeyserI ec Air ~nacK AND WATER I ! TREATMENT I Bottling ParkingI '~ I FACILITYI Facility Lot / ,~ Housing Complex Alley ' ~ Housing Complex Monterey IFORNIA ~tree! ~ Henley Street '~treet Lucl · ~ Vir~nia BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. SURROUNDING AREA DATE12/93 I 0332.0011A IEXHIBIT 2 III PRV PRV ~ ACCUMULATOR PRV f ACCUMULATOR CHILLER ~1 HIGH PRESSURE I) '~ RECEIVER PRV KING LSV -~1 c so. I~ __~W.O.^*,V~cONDENSERI PRV -i wz,,,c. BAKERSFIELD, CALIFORNIA COMPRESSOR I~ EVAPORATIVE CONDENSER CRYSTAL GEYSER BAKERSFIELD, CA. AMMONIA SCHEMATIC DIAGRAM PRY: PRESSURE REMEF VALVE LSV: LIQUID SOLENOID VALVE DATE 12/931 o332.oo~1A IExH'B'T 4 I I NOTE: ALL PRV VENT TO DIFFUSION TANK 1233 EAST'CALIFORNIA 1233 EAST CALIFORNIA J' MIX HALLWAY I I I I ---~I ! _.~_ ~ ROOM t I BOTTLE · I ~ I L~CYL1NDERS.[ _A ROOM t AREA I I ;'I'l TS III I < I z I I I ~ o o .I 0 0 0 I STORAGE AREA I OFF~CE SHOP/ ~ I AND ~ I ' I I FREEZER REA I I LUNCH I < ROOM RESTROOM T T ALLEY WZI INC. BAKERSFIELD, CALFO~IA CRYSTAL GEYSER BO~LING FAClLI~ EVACUATION POINTS DAIE 1~93 J 0332.~11A EXHIBIt 8-1 I CALIFORNIA AVENUE TO MEETING AREA . - .....-.--.,. ,, :,-..;: ~j. :-o.. o:...;... ~,.~....% , ;....,...,o ,.'., .' '-- ....',,; ::..;..2. -'i ..... .,'".';- ! · " , ;:.. ..i;. ?, ----'---", -.--" ' ,.' . 'T-~;r--- I · I rT R-- ,. I TO MEETING ALLEY AREA BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER REFRIGERATION AND ' WATER TREATMENT FACILI~ EVACUATION POINTS DATE 1~3 I ~3~.~,,A IEXHIBITS-2 HMMP PLAN MAP SITE DIAGRAM Business Name' Business Aaare~: For Office Use Only First In Station: Area Map # of Inspecl'ion StQtion: NORTH ~"'~ I - Y/NrA ~ ~ HMMP PI,AN MAP SITE DIAGRAM FACILITY DIAGRAM ~ / or 3 Busine~ Name: Busine~ Aaaress: /2-~-3 £,~s:r' 0~4~-/~,~,o..~4 ,~v~'_,uur For Office Use Only First In Station: Area Map # of Inspeolion Slalion: NORTH HMMP PLAN MAP SITE DIAGRAM FACILITY DIAGRAM Business Name: C,¢.,/.~'~-' ~,~y.~,~4 t.,.,.~-e,~ Ca/,,.,~,u~ Business Aaaress: For Office Use Only First In Station: Area Map # of Inspection Station: NORTH ~,,,x~ HMMP PLAN MAP SITE DIAGRAM [ I FACILITY DIAGRAM Business Name: F_Aysr,~/.. G¢¥s~:~ ~,~-r¢~t c~'~,~? Business Adc:ires.s: /,~ $~, E~T (..,~.l~'~x,uz,~ A~¢ For Office Use Only First In Station: Area Map # of Inspection Station: NORTH ~'"'~ High Pressure Receiver EXHIBIT 7 0332.001 lA Glycol Chiller EXHIBIT 8 0332.001 lA HAGGERTY LOC ~ ;. SHL539 , ~0 t /' ~-"'~I 11 '~N~ ROUND ~4TNJ ~5 ~ ~RoundM KERN RIVER ~. 2~ 2~ ~ ~ 2~ - 2~ ..27 : HART IDLH KERN ;R GOL~. COU; ROSEDALE '~ : ~: ~. ,, < IBreckenridge Lane t:.305. R.28E PANAMA GREENFIELD OLD RIVER Rd/ = i~ GIORGIO 2. ~ ' 4 DiGior~ We~patch ; ~ /EED~T~H7 Bear Mountain Mountain BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. CASE ~1 Mles 2mi : 4mi. ' 6mi. CLASS F CONDITIONS ' ' ' ' ' I ' ' 4900lb;RELEASE 0,,,o~,,.r,, .. ~,~. . ,0~. ~*~ 7~3 I 0~.~,,* I~x''~'~ g I I KERN GOLF COURSE 6 5 · SHL T.2~S. : , HART KERN RIVER STATE~' Discovery ~in~ Gr~e 7 KERN RIVER 4900 lb. IDLH 8reckenrid~e Lane La,nview ' ~ 'PANAMA -- GREENFIELD OLD RIVER Rd.: SHL W~patch 17 ~ '~ent 23 ~ 24 Benr Mountain WZI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. CLASS F CONDITIONS '. . . I , , 4900 lb. RELEASE Kilometers 5km 10kin DATE 7~93 0332.~11A EXHIBIT 1 $HL$39 -- ROUND MTN, · MINTER , ,~' VILLAGE ~s ~ ~ '[ ~ ~' __~_~_ ~iI..~ .28S.~.28E. 1616'~ r,z~o __ ov ~ 2~ · 2~ 26 25 ~ HART KERN STATE% Disc~ery I ~ ~Hlct'' S~w 2000 lb. LOC KERN RIVER GOL~COU ROSEDAL N PIPE IDLH 2O00 lb. IDLH PIPE LOC 35 3~ Lane .... ;rd= l~ PANAMA- GREENFIELD OLD RIVER Rd.' ~ ~ GIORGIO 2 1 . 4 DiGi~ S88~~ We~patch Lbbp 15 ~ ~4 13 ~..Z~. tn. Rd[" Bear Mountain Mountain ~ 33 ~ ~ .. AR~ 32 illux . ' I BAKERSFIELD, CALIFORNIA CRYSlAL GEYSER BAKERSFIELD, CA. CASE ~2 AND ~3 CLASS F CONDITIONS Miles 2mi. , 4mi. 6mi. ' ' ' ~ I ~ , 2000 lb. AND PIPE RELEASE 0Kilometers, ~. 5km, . . ,0km, DATE 7/93 [ 0332.~11A IExH~BIT 11 ',,'~:..,,o,,,,...j,~ ..... ~ ~,r .,,,,,_. ,,,~ ~ ~; _.. i ...... ,,:.. 1 .~.,,, ~,~ ,.., .1'1 ' St ~ ~ O~ ~1 ~'~ 0 I~.',~ '/ O~ ': R~nS~ ; 1~/' ~lCo~ . ~ = ~ '~'4 ~ ~,~ Bud V ~ ~ ~ , ,h S, ~'~-~ .'" ' ~"'~ ~i~ '~'.~T ~ ~1~ ~ ~:~ ~1~¢~' " ~ : · ~ · · ~1 ....... '----r ~ / , I i ..... ~ I LI~ i~ { = ~ Z .. / ~ ' I -- ' _': O ~ 8~UN~ .. ~----~--~ I1~ '~ ~ ~ ' ' ~'' ~ST BRdNDAGE .LAN~~ O '~ g ~ ~ ~ ~ v ~ ~. ~d ~,',~,. ~ ' - ..... .,,.','~,,,,.~,.,. , ' ~.,'~ ol ~ ~Y/'~l .~,. ,~-;. = = ~ Dr. _ - -'- I'~ · ~'~'~'~.L:/ ~ gs~:~'~:~,,"..,,.~.,,.~ = g ,s'l ~. ~,,.~:~. .'.. '~""~""~-~rrI ~:- - , _ _ ,...~.... ~ ~ ~ffm,oo~ I~ ~ ~Adam~St. · ~ ~ ~ ~ i~ ................ -.-..~~ CASA ~ LOM~ DRIVEo ~ ,u,=,~ .- .C~ - D,.~{ '-'1~- ~-~,.~-"~.=~:~=,,,~o,,' .... '-~ ~' '~'~~ .... ~ ............... =':':"':'"'~ ~l WZl INC. CRYSTAL GEYSER BAKERSFI ELD, CA. CASE ~4 CLASS B CONDITIONS o,,., ~ooo' 4900 lb. RELEASE ~Ki, ...... 50kin 7~93 0332.~11A EXHIBIT 12 m e'~Z _------~-(----. E-oc'""'.,~c;L ;I I ""~c',~'~.i~"~./ I, ~'~15~, I ~ IAIAme~iaP~. St. ~ ~=~ Ou,nc¥/~. ~ _.-'L '~/-' ~ / I ~ r~,m,'f~'~. ~el/~:r<.._~ G,,c__~F .~..~.Z',~'~"~ EGei~.._[AvI j -.wOE~[. O~ I["'-._~ ~'"'C~ 5er,,. ~ _....,~ r ~ ~_~/ /-'""-J~-~/J :~'; J '~/ ~'/ ~ L ISC~. I' J ' ~'Central Parh ' ~'"~Ee.,,/ ~ S ~ ~/11[......~ ~ .~ J"~,~,.~ /~ I/ ~ ~ -~ 1 [ ~:j'~ ~'/ ~_ '~'~3, .. · ' ~ ' , = -- Ct' - BiM ' :~treet "~ ~= · c · ' ' C I/AVENUE ~ q T-RUXTUN '~::::~4~ ~X~"O~I"~'"',-.. ~ ...~.~_~/74....~ ~---~'ld%,~,! ~1 PIPELOO I-J-.~.~J~,~'r~'.~''; ~' ~ ,~._A/:.... =-.L 'l~.'~-'-.~ Cente~ ;dM' I--'T'~ Ln !. ~L", ~.~m~m~.~.. '~-p~' i I ~. ,~ .,.~ ~ C .~,~ ~ ~ · . u~ , l_ ~t ..... ~11:~~~r. /I J Larcu~l ~ ~ ~v - · ,~~~o~ :""' I 2ooo~.LOC I,~,~'"~'~ ..~.~t ti/ ,u~.'~;~j~ ~ · L btreel ~ ~ :'-' "~" H ' 'c .c .- '!~- ~treet I i E 8th .'7-~. -: · . "'' ~ '"""~ _"~""r I'~ "~ V£R/VON ,~ - ' " "- N;~ '' '.' Gorr St '. ! '-; ' w ,.'~ :(;;;"t~ 'f,'!:~ O ! ...... :j GUADALUPESCH. ~'" Ralr, tonS! [ t J ~"~.~/'~-Icoe >- ~ ' -I .... ~"., ~, _ ,'~ ~ Buddy ~ s~..,~ ..,.,~ .... :- i E. ~h './ u,,,,, C,me~.,7 · ~,,d,,ok S~ ! H,u.,e~-I~t..~_--° ~ ~,. ? ' -: '.~. 't'!l: .' " ~ · ,: ' ' ~ ' ~ c : ~ ~.. CD m ~, '-! ;.~ .-;- . '.:-~'~. ",., ~, ~1 J... ~fl -- ~ .. ",,,.,,n~0 ~ ~...,~.'--/X'~- ~,e = ~1~ V,,o-~ .-~ -' ~v~ ::c~ ,.~. ~. o ,~ = oI = '- ~ ,~ -= " 2 ~-. "r ~j ~ -'~ .~1 ~ " ' ~ ~ '~ i ~ .' ..J - Texas S! VISTA '~ · '-' ~ .0 - -- ~ ,.~~~'/~%1> ~^~ w,,~,., ~:..! st.l~ = -- ~ ~. I / z . ' ,cuq - ~' '= ~- I ~,, s, ~ :_oyd · I' : ~, . o ... '-~ --r'-"'J"-'' IP ,: ' ·" EAST BR;!NDAGE --~ .L~NE,r~ / ,,,., '"' . __~v ~.~-"J'errace Way Ch~ o Jgros, S,I '~l~ ./,, Feliz J'~:-SJ Dr ~--J' ! · ndnrl~.. I m ~, .L'" bE ~.l ~.z/-< ~cmewL;t i,5 2 .... ,- ..... ~- .Gateway Dr. · ~'~ ".1 .~ ~ ,e,ace \ £1 .... / o ' u. ' · o;';:::: O....- ,, , · ' "~,~' - (~-~--~ · :..~ : ~:.?-- ~ ~1o m wn~. < '~ ~exs L~ x ? .~-~' -' Cannon Ave '-': .'= ":::"~ '?~ ~, - ~ .~ ~ '/ LOI "~ c. mi~,l~ ~;1 · ,':, · '.;-o~ VCL';~.¢'~TM ~" ~ FIEGIOIV.~L OCCUP,~TIONAI ;O£OENST~T£ - ''Z -E Belie % -- '%-I >1 . ~ ........ ,':F"::,.'.-. '-": .-~'.~.~;~:(?.~ ::-~.:.,~& ~(; CE/VTERSC~OOL 3eUul'errace':.:J ~ ~': fac <' --' - ;'" -- :? ,'~ .... ""' :OU~T,'::~ ~' ~'~/ zs'~" ~"':',:~.~",~:'~I '~ I ! ..'."~= ~ve T: = ./ \ I'..~':yJ. Ix: m I ~----J~madm I~ 'om /~"'AdamsSt. '~ · ~ l: :I~j .'" '~.~ --I /.~'.%. ~-,'~. ' ~ ~-~Cheath8m ~AiRGUOUND$t- /"',, c ' , ,,,'\Re*seo A,,e . I lira. 14 (/3 , - ~, -- ,--,.o -- ...... CRYSTAL GEYSER BAKERSFIELD, CA. CASE #5 AND #6 CLASS B CONDITIONS Feet 2000' 0Mi~e~ Y;mi. ~. 2000 lb. AND PIPE RELEASE .5o~ D^TE 7/93 I oa,zoo~^ I~x"~Bn' ~3 I0 Kilometers Stl~l Williams School Special Services School IFORNIA ,Our Lady Bethel Christian School~ ~ of Guadalupe Sch. Po,om.~ I, t D · ,.. OWens School -- __Mt. Vernon School I I ,~ St. -- 2000' _t. P~dre ~efrace Way Feliz . C~nnon ' - Smith '. TE "~' CE~E~ SC~OL ' :H. 0 ~-E. Belle' ~ - WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFI ELD, CA. ~ Feet 2000' 4000' ., , ,, , l~mi. 0 Mile, V. mi. ½.m.i. f~mi. NEIGHBORING RECEPTORS 0 Kilometers .50kin lkm l I DATE EXHIBIT 7~93 0332.001 lA 1 5 SYSTEM ALARMS ... TTTTTTTTTTTTTTTTTTTTTTTT. .-,' Ac .,.,/ ... , ,¢, .,,. ,.~ ...,~/' EXPANDER //1 ,.b~. ,r .,.....,~. ..,- TTTTTTTTTTTTTTTTTTT; ~ e' ~ e' g' ~ e'~ ~ :,~ :~' :,~' :,:r :,~ ~ :~ ~ ~' :~' :~' :,~' :,,: :~' :~ :~ :~ ~' :~ :" ~ :*' :~.-:~ / ¢ ¢ ¢ ¢ COOLING TOWER/MACH. AND C.l.P. ROOM FANS //////~" .212' CONTROL PANEL R1 . ffi ~ ~ ~. L~ .,* ,',~ '" · ~ ~ ' ~" ~ "~ Y~6 ~ .cso NOTE: '0' ~ NOTE; , ~--- ~- __ ~. ~..,,~, .~. --~::::::~ ~;~.~'~':: .. . .... :....: ,.~ ~..,z~t; ~,.: ..' . ... . . ~-. CONTROL PANEL R1 , .., ~ CO~DENSOR CONTROL PANEL CONTROL PANEL R1 ~_o.o ~ .... ~ ..... ~ ..... ~.~ D D D m c~[~ ~ ~ o ....... I-~ o ......... ~ ~ .... (~p.) .... '~-" CONTROL PANEL R2 - ~ ................ CONTROL PANEL R2 :(:g,' N ! · I · L N ".5 : ..... I-~ ..... I'"~]'a'""'[] ~~--~-~ '0 '~ '*' ~1~ 0 ~ '"~ ~ ~.~,:;~,~.,..:.. ..... . ~ ' ' ~: -,~. c,.* ..... o MCC R1 MCC R2 I iii ::: , ~ ~ E - 7 ........................... ~, , ......................... [-~ .......... 2Z222Z ~" .,~.~ ...................... ~_. , ~ r ..................... ~ ~o*~ ....................... ~-a ~.,~. ~-~-'-~ .... iZZZZii~" '~ ........................... ~ ~ ~ ~ .......................... ...................... r- ~ ....................... ~ ~ ~ ~ .......................... ~ ~ ~- ~ ....................... ~-, ........................... ~ ................. ~.-, ~_~ ................. ~ ~, FIELD CONTROL ............................ ~ WlRIh. I'~' I C ........................ ,,~ .......... r ............ ~ SEE P~N E-9 FO~ - ...................... '~ LOCATION OF FIELD PARTS C,l,P. RODM ,-- , c~,~ ,o~c, CONTROL .... ~ ,~ .. _~, [ PUMP (~) ,,~ . ~,,' BASE ~uuu ~.~ :~;~ ' ' 6LYCOL TANK /, A~ ~ ~ 0 ........... '"~ .... ~m I · COMPRESSOR I " i I ' I '1 ' '1- I. ~- ~ ..... .}., COMPUTER CONTROL PANEL I ALARM T1 T,3 I EXPANDER 1 , T2 I EXPANDER 2 IT4 AMMONIA AMMONIA AMMONIA CONDENOER PUMPS ALARM ALARM ALARM 17"'~ r~ MACHINE VENT CARBO ROOM COOLER GLYCOL PUMPS TOWER PUMPS CONDUIT~/'z~ ~ TO PREVENT I DOWNI _ TO R1 '---AMMONIA FROM I ENTERING MAIN : PANEL i ) ....................................'~ --t-7' I--:' IJ M pX,) ... "- LOCATE AT [] I I TYP. 4- WATER TREATMENT SYSTEM PROBE LIrC~IO · % / %% / ,. , . I I cot I L-_J ~ ~ r ' I 1 tc-~ I I "~ ' CRYSTAL GEYSER BAKERSFIELD PLANT AMMONIA PIPING R.1 ROOF PFNATRATIONS c~ ,~, } . · ........... ~ --& · ........ ~ C.I.P. ROOM ~,..., ~ ..... ,;: : ~-~ '/~ / BASE '" I~ ~ ~1 ....................... / ~ _ ~ ..... ~11 ~11 ............ [ < ~' · l / ' co~sso~ i i i~Y-~ 'Y'~J I1~ ~ ~ I .... I I.~J Iu I.~ ~ 0 ~.'.,-~,.' .... ~ ......... x ~-2 '..;:t~ ~.¢':. . ' "~' ?:"'~" ' '' ' ' ' ' ' ONIdld EIO.SNEtGNOO ? ::i ONldld CHN - ~OColxl~l(1NO0 3AI.LV~OdYA] ~ ~6X4 CHILL[R SUCTION ,-~ (,~ TO ACCUMULATOR *'" ,,*- L~ 5' EPR P~ VIEW A-A ~ SEt 112' ~ ~ II CHILLER H~CH L~EL ACCUMU~TOR J X ~1 I~J t ~. [ BULLS EYE 3/4 ' CK4 FILTER · -- RECEIVER /. , ~,~ ~':v'~'~ DETAIL AA. B= 2" OVERFLOW C= 2" FPT ORA~N W/BRASS B.v. O= WATER TREATMENT MEI'ER Z ~o E= CONDUCTIVITY PROBE 0 GL~ ~ c F= CHEMICAL PUMP ('") G= 50 GAL. MIX TANK O EVAPORATIVE CONDENSOR Ld · .. WATER PIPING :. R-9 .,~,,'..~;t~;~,'..i~;;~,.;',,.,,,.,. i ..; .... ,,,.~,.,.~.,,.o...,'.L.*..,,,;;.;,,,'.',, .,-~.~ ..... '~ .......... ..~, I0" 150~ STL. FLG. ~ 0" p.v.c. AT CHILLER M- '~.~,~, .~.. , . ..... .~. ~ ...... ~..:. , , .~.~. ''4 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: · Ensures that accident report Is complete. · Conducts the accident Investigation. · Guides accident response. The Maintenance Supervisor: · Provides techniCal details of reports. · Assists with the accident Investigation. · Directs physical plant changes. · Makes changes to the training program, If changes are necessary. All Employees: · Assist with the accident Investigation. 2.5 Release Reporting Procedures Pursuant to Section 25507 of Chapter 6.95, Article 1 of the CHSC, releases of AHM that may threaten human life, health and safety or the environment or exceed the reportable quantity must be reported. The Plant Manager is responsible for determining the significance and reportability of a release. If an ammonia release equals or exceeds 200 cubic feet of gas during a 24-hour period or constitutes a threat to life, health or the environment, the event is reportable and the following agencies must be notified immediately. Bakersfield City Fire Department Hazardous Materials Division Telephone: (805) 326-3979 Page 11 California Office of Emergency Services Telephone: (800) 852-7550 The Plant Manager is responsible for reporting a release. Page 12 ANNEX 111.3., ENVIRONMENTAL MANAGEMENT \: SYSTEM - General Overview a~d -: ~ Management Level Cmnmitment '~!S. ~e .X:' shP~!~ contain a detailed descnpt~on,i~fthe facfl!tyYs envtronmental management: I :, :~':':~: ",::,::~.::~::'~-.' :~??::~:~::~:.::::.: ::':~. '"' ..... ,"~ ::' 5:'; :'~ :'~'~ :;c:~~'~ :', ~.':. 5, ~.. ~:~ ;',";,~ ':".,~ ;::'.', :~:.' ~':.:'~,7;: :,' :..~ :..' ., ~: sys em :~ el! ~con?m sp~fic mfO~auon.on cnwmmcnial pohc~es m place ~d top I m~agemin't,s:.'~a~m~tment t°w~d ~im~'a~hi~ablo enVli~'e~ai':p~fo~Ce.' .. :' '. III I I Items to be addressed in this Annex: Environmental management system used (e.g.: ISO 1.4001), if applicable Emergency response management utilizing thc Incident Command System Regulatory compliance assurance through Ihe environmental mmmgcmcnt system Management level commitment toward improvements in environmental performance Environmental policy for the facility / corporation O Formal policy commitment to h~ardous waste source reduction ~ Accidental release prevention and emergency response policies O Organization chart O Specific job descriptions for each position involved with regulated substances O Detailed description of information flow Safety information related to tl.~e regulated substances, processes, and equipment O Material safety data sheets (MSDS) O Safe upper and lower limits for temperatures, pressures, flows, or compositions O Codes and standards used 0 Equipment.and safety system design specifications CON~LIDATED FACILITY COMPLIANCI~ PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICE5 11.0 RISK MANAGEMENT AND PREVENTION PROGRAM 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." 11.1 Personnel Responsible for RMPP Implementation The title of each person charged with RMPP implementation duties are listed below, along with their respective responsibilities. Title RMPP Implementation Responsibilities Plant Manager Supervise audits, inspection and record keeping, responsible for RMPP implementation Maintenance Manager Supervise ammonia equipment inspection, emergency response training, operating and maintenance training, inventory control and labeling Quality Control Manager Supervise emergency response training, operating and maintenance training, inventory control and labeling. All Employees Undergo emergency response and evacuation training Page 37 11.2 Implementation Schedule The following schedule will be followed for RMPP implementation. Pro.qram Date of Full Implementation Inspection Program Ongoing Ammonia Safety Audit January 7, 1992 RMPP Record Keeping January 1, 1991 Safe Operating Procedures Training July 3, 1991 Maintenance Procedures Training January 1, 1991 Evacuation Training July 3, 1991 Emergency Response Training July 3, 1991 SCBA June 6, 1992 Labeling January 1991 Canopied and Sprinklered Area January 1, 1991 Ammonia Diffusion System December 13, 1991 11.3 Training Program for RMPP Implementation The RMPP training program must ensure that standard operating procedures are easily understood by mechanics. 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. Page 38 10.0 INSPECTION PROGRAM 10.1 Ammonia Systems An inspection program is necessary for the assessment of hazards present in the work place. The person responsible for inspection must be familiar with 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 inspection will be assessed and assigned priorities for correction. Action will be taken to reduce 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 operator's log. In addition to daily inspections by the maintenance supervisor, the ammonia safety audit includes an intensive inspection of the ammonia refrigeration systems. Inspection of the systems may be scheduled after the process changes, upsets, or accidents. Page 36 APPENDIX F AMMONIA VESSEL SAFETY INSPECTION DATA (Complete one form for each vessel) Vessel Name or Use: 1. Location (Building)' 2. Location of Vessel in Building: 3. Description of Vessel Use: 4. Normal Pressure in Vessel When the Refrigeration System is in Operation: (psig). 5. - -Vessel Manufacturer: 6. Design Working Pressure: (psig) 7. Is Vessel ASME (or Equivalent Authority) Stamped: 8. Vessel Registration No.: 9. Vessel Length: (feet) 10. Vessel 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: pounds of air per minute 16. What is Relief Valve Year of Manufacture: 17. What is the Size of the Relief Valve Outlet: And Outlet Pipe: Appendix F Page 6 18. Is the Relief Valve Properly Piped to the Atmosphere: (Y/N) 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) 21. If Altered, Was Vessel Recertified: (Y/N) 22. What Controls are Fitted to this Vessel: · Y/N Condition Setting Operates (G, F, P) % Level (Y/N) A. None B. Hi Liquid Level Cutout C. Liquid Level · - 'Control D. Low Liquid Level Cutout 23. Assess Control Column Design: (Screwed Joints, Stop Valve Locations, Condition) Good Fair Poor 24. Does Relief Valve Look: (E/G/F/B) Excellent (Clean with no visible rust or corrosion) Good (Looks okay but some corrosion visible/less than 25% surface only) Fair (Considerable surface corrosion but none visible internally) Bad (Surface and Internal Corrosion Visible) Date of Last Test: Appendix F Page 7 25. Is This Vessel Covered With Insulation: (Y/N) Condition of Insulation: (G/F/B) Good Fair (Slight signs of vapor barrier leaks) Bad (Extensive signs of vapor barrier leaks) 26. An Abnormal Ice Formations on Vessel: .(Y/N) 27. Any Signs of Rust/Corrosion on Vessel: A. None B. Slight or Trace C. Moderate But Appears to be Surface Only D. Appears to be Extensive, Should be Examined by Consulting Engineer E. Cannot Tell Due to Insulation Give Date: 28. Has This Vessel Been Inspected by Outside Inspector Within the Last Five Years: (Y/N) Give Date: 29. How Long Since Last Inspection by Non-Destructive Examination (NDE) Methods: 30. Does the Vessel Have an Oil Pot: Compressor Room: ,(Y/N) Oil Accumulator: .(Y/N) 31. Does Oil Pot Have Relief Valve: .(Y/N) 32. Is Oil Pot Relief Valve Correctly Piped: .(Y/N) Appendix F Page 8 33. Special Remarks on Vessel Condition or Usage: 34. Specify Overall Rating (S.I.R.): Appendix F Page 9 APPENDIX F AMMONIA COMPRESSOR SAFETY INSPECTION DATA (Complete one form for each compressor) 1. Compressor Duty: High Stage Booster Swing 2. Compressor Type: Recip Vertical Recip V or VW Rotary Vane Rotary Screw 3. Compressor Manufacturer: 4. Model No. Year Built 5.' Capacity (Tons) Motor Power (HP) 6. Drive: Direct Belt 7. COmpressor RPM Nameplate Max. RPM 8. Relief Valve Type: Internal External 9. Is a check valve provided at the discharge of each compressor? (Y/N) 10. Normal Compressor Pressures (PSI): Suction Discharge Manufacturer Recommended Maximum Discharge Pressure 11. Low Pressure Cutout Setting (PSI) Design Actual Checked (Y/N) Operates Properly ,(Y/N) 12. High Pressure Cutout Setting (PSI) Design Actual Checked (Y/N) Operates Properly (Y/N) Appendix F Page 10 13. Is high pressure switch hard wired? a) To motor starter (Y/N) b) Through PLC .(Y/N) 14. High Discharge Temperature Cutout Setting (°F) Design Actual Checked ,(Y/N) Operates Properly (Y/N) 15. Oil Pressure Safety Switch Setting (PSI) Checked (Y/N) Operates Properly (Y/N) 16. Is compressor connected to a flooded vessel? .(Y/N) If yes, does high level switch stop compressor? .(Y/N) High Level Sw. Chkd. __(Y/N) Operates okay? ,(Y/N) 17. Does compressor start automatically? (Y/N) If yes, is there an "Auto Start" notice posted? .(Y/N) 18; - Compressor drive is electric motor , Steam Turbine , Gas Engine at RPM and (No.) V Belts Can prime motor overspeed? (Y/N) 19. Any abnormal vibrations present? (Y/N) 20. Drive Guards: Adequate coverage and secure? (Y/N) 21. Any abnormal noises? (Y/N) 22. Electrical covers in place? ,(Y/N) 23. Any visible leaks? ,(Y/N) 24. Is there a safe method for electrical and system isolation? .(Y/N) J 25. General assessment of compressor unit (S. I. R.) Append~ F Page 11 TABLE 1 PHYSICAL PROPERTIES OF ANHYDROUS AMMONIA (NH~) Molecular Weight 17.03 Lbm/Lbmole Latent Heat 327 Calorie/Gram Boiling Point -27.4 °F (-77.7 °C) 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 °C (1,204 °F) Explosive Limits 16 to 25 % by Volume in Air Critical Temperature 651 °C Critical Pressure 11.5 ^TM 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 °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. MATERIAL SAFETY DATA SHEET M.~DS CODE NO. 5BDt-83 ORIGINAL ISSUE DA'fL: B/85 REVISED: 8/91 -- I ~ ~ ' ~ ( ~. '~ ' I ...... '" -- -'--"=' 24 HOUR EMERGENCY TELEPHONE NUMBER CHEMTREC 800-424-9300 ;RODUCT NAME: Anhydrous Ammonia [ MANUFACT,U,~ER AND/OR DISTRIBUTOR: _~OMMON NAME; Ammonia / LaRoche Indu,mes inc. SHIPPING NAME: Arrlrnonia, Anhydrous. Liquefied, 2.2 (Nonilammable Gas) ~ 1100 Johnson Ferry Road. N.E. JN 1005, RO, inhalation Hazard. I Atlanta. GA 30342 ~ (404) 851-0300; (404) .,91-7987 after hours Prepared By: R. C. Cannon MATERIAL FORMULA CAS. NO.: %WT. EXPOSURE LIMITS OSHA-PEL ACGIH p.Gr~de TLV STEL :,mmonia NH,, 7664-41-7 99.5 99.995 35 ppm 25 ppm 35 ppm l,'*.'ater HzO 7732-18-5 0.4 33 ppm None Established None Established ,.~it O. 1 2 ppm 5mg/M3 Smg/M" ~,OILING POINT (°F) '--28.'1 o J SPECIFIC GRAVITY (H20= 1) 0.62 @ 60'~F !LTING POINT (°F) --107.9° I PERCENT VOLATILE BY VOLUME ('Yo) 100 PRESSURE (mm Hg.) 4802.9 (94 psi) ~' 60°F]. pH Approx. ll.6forl NSoln. inwater VAPOR DENSITY (AIR -1) 0.60~,32~F i SOLUBILITY IN WATER 33% (Wt.) ~ 68oF APPS[ARANCE AND ODOR: Colorless gas or liquid with extremely pungent odor. .--LASH POINT (method used) Not Applicable NFPA HEALTH 3 (High) FLAMMABLE LIMITS 16-25% in air HAZARD RATING FIRE 1 (Slight) REACTIVITY 0 (Least) EXTINGUISHING MEDIA: With a source of ignition, ammonia will burn in the range o! 16 - 250/,` in air. Use water tog Or spray IO extinguish flames. SPECIAL FIRE FIGHTING PROCEDURES: Stop flow of gas; move containers from fire zone if possible. Stay clear of tank heads. Use water to cool fire-exposed containers and protect personnel. Use water spray to control vapors. Personnel must be equipped with appropriate pro. ;active c. Iothing and respiralory equipment. Do not put water on liquid ammonia. STABILITY I Unstablestable I X I CONDITIONS TO AVOID: Not ApplicBlsle. INCOMPATIBILITY: Ammonia can react violently with strong ac ds. Under carte n co."Lditions, ammonia reacts with bromine, chlorine, lluorir,e or iodine to form compounds which explode spontaneously· ~eactions ol ammonia with gold. silver or mercury to Iorm explosive lulm:nate-like compounds have been reported. HAZARDOUS DECOMPOSITION PRODUCTS: Hydrogen on heating to ova; 8,50¢F. The decomposition temperature may be lowered to 57-.5 % by contact wilh certain metals such as nickel· t i t CONDITIONS TO AVOID: Not Applicable HAZARDOUS May Occur 'X POLYMERIZATION Will NOt Occur NOTE: Anhydrous, Ammonia is subject Io Ihe reporhng requirements ol SARA (19B6. secfio¢ 313 of Tille III) and 40 CFR Part 372· - l.J ROcuE INDUSTRIES INC. TRANS~ORIATION EM[RGENCI~S Call CHEM~REC B00~24-9300 ' ~PG TO BE TAKEN IN CA~ MATERIAL IS RELEASED. Stop I~ak il leas,hie Avoid b~=atl',ng ammonia. Evacuate Der~nr,¢l r,o1 eOUlD~ Clothing ~n~ equipment. Use cop~ous amounts el w~ter spray or ~og to absorb ammonia vapor. ~O NOT put wale~ on hQu~d 00at,ir, rur~-Ofl Io pruvenl ammonia hem entenng a suede, take. sewer or 0~tch ~STE DISPOSAL METHOD: ~. NOt ~pplicable .~over ammoma i~ lea~ble. Olherwise. lei ammonia eva~r~le il . aDtOpriale. Only per,one,el experienced ,, Demonic spills should 3d water 1o liquid ammonia. D~s~e el deuled demon.:3 as a lerfilizer or ,n ar, ~nduslnal proceSS. ~r hazardous waste rcgulahons, call tnt RCRA Ho;hne al 800.42~-9346. ~FFECTS OF OVEREXPOSURE: MAJOR EXPOSURE HAZARD DLH Level = 500 ppm ~ ~SKIN ~EYE ~ . mmonia is a strong alkali and readily OamaDes all buoy t~ssues. INHALATION OONTACT~ CONTACT~ [ INGESTION ,mmonia is not e cumulative metallic poison, nor is ~l a listed ~r~nogen by IARC, NPT or OSHA. Inhalation: Depending on exposure concentration eno duration, effects c~r, vary tree none or only mil~ ntation, to ob~rucfion el breathing from I~yngeal and bro~hial spasm, to edema and severe d~age of the mucous membranes ol [he respiratory 'act ~ possible fatal results. Latent edema and resiOual reduction in pulmonary function may occur. Skin Contact: Prolonged con;act wil~ .,ah concentrations car, caus~ pair,lul tissue Oamage. frostbite and serious chemical burns. Eve Contact: ~xDosure lo li0uid or h~gh concen- '~tions of vapor ~n cause painful, instem and possibly irreversible damage to tissues such as the conjunctive, cdr nee and lens. Glaucoma and ; ~acities may o~ur. Ingestion: Ti~ue damage, chemi~l burns, nausea and vomiting can ~cur. Ammonia is a gas under normal atmospheric :onditions an~ inge~tion is unlikely. [MERGENCY AND FIRST AID PROCEDURES: ~ye Genteel: Flush with large amount 0t water tor at leas~ 15 mnutes then immediately seek medical aid. Inhalation: Re~ove from exD0su : ~r~thi~ has ~op~ br s ~ifl cut adminimer a~ifici~ respiration or oxygen ns needed. Seek immediate me0ical a~d. Skin ~ontact: Immea~a[e~y : ush ~ targa quantities of water tot at least 15 minutes while reedy nD clothing. Clothing frozen to Ihe sk r, ShOU ~ be thawed with water belore -~ov~. Seek immediate m~ical aid. Ing~tlon: Do not induce vomiting. Have ~e victim drink large quan,Jlies el water ii conscious. Immediate[y mac ~d. Never give an~hing by mo~h to an unconscious person. ~piratoW prolecfion a~proved by NIOSH/MSHA for ammonia mus~ ~ used ~en exposure limits are exceeded. Whether a chemical canri0ge respirator or a self-contained breathing apparatus is sufficient lot effective respiratory protec~on depends on :ne type and magnitude of exposure, SKIN: ~db~r gloves and rubber or other types of approved pro~tive clothing s~ould be used ~o prevent skin comact A ~ace s~ield should ~e used ;or ~ncre~ed protection from contact with liquid. EYE: ~heml~ s~ash'goQgies, aporoved lot use with ammonia, must be worn to prevent eye contact with liqu~c or vapor. A ~aca shie;d shouiC ~s~ for incre~ed protec;ion ires contact with liquid. VENTI~ION ANO ABSORPTION~ Local p~;tiv8 pressure and/or exhaust venti[at;on should be used to reduce vapor concentra[~ons in confined spaces. An',mon~a vapor, ;,.Dhter than m~r. can be ex~ct~ to d~ss~pate to the up~r ~;mosphere. Ammon~B concemra~ons may also be reduced Oy ;he use el an appropna~e 60~r~nt Or reactant material. OTHER PROTECTIVE EOUiPMENTAWD MEASURES: · Emergercy eyewash ~ations and deluge showers must ~ available ;n the work area, Post a list o~ emergency r~sponse contacts and telephone ~um~rs. PRECAUTIONS TO RE TAKEN IN HANDLING AND STORAGE: ~eier to the ANSI K61.1 standard for storage and handling inlormation. Protecl containers from physical damage and temperatures exceeding ; 20°F. Use only approved storage sys~em~l r. caclrn~m and lheir alloys must not be used n~ ammonia ~' s~ems since they :.an be ra idl co d d 13 it. Avoid hydroSl~wh~ch c . u ' ent'rub-Tb-Te by adner~hng ~ro~Eoure?a'nC the ~""o'~'~oslatic pressure relief valves where appropriate. iHER COIvlMENTS: ,ntac[ lenses must not be worn wr~en working with ammonia. This inlormalion is taken lrom source= or based upon da~a believed lo be reliable: however, LaRoche Industrie~ Inc. makes no warranty as to :he absolute correctness or sutficiency of any of tl'~e loregoing or/hat addiUonal or other measures may not be required under particular conditions. MATERIAL SAFETY DATA SHEET PRODUCT NAME' PROPYLENE GLYCOL CAS NUIvIBER: 57-55-6 HBCC MSDS NO. CP21000 ..,,,,,, c~,,.~ HILL BROTHERS CHEMICAL CO. ~"'- - '(' ~ .J,J~1675 No. Main Street Orange. California 92667 Telephone No: 714-998-8800 j Outside Calif: 800-821-7234 ~ ].0.....~ CHEMTREC' 800-424-9300 Revision issued: 7/25/91 Supercedes: 7/31/89 FirsI issued: 4/10/89 JJ~L~.Q..,P'z.,T~ Rea, d this M~DS beloLe_.q.s ,_e.~_~rdisDosa! el this orodu_~t. _P_c..~_s_~d..o2a 1he informaJion to ~,,nDIovee~and ~m¥_..o. tb~,.L.~£~ who c~)u!d ~ oxoosed toth~.eL~Lu.ot t9_1;3.*_~_~.' tha~ they ;zre ~w~re o! the )~°rma~tion 0eJor ,.LC._.~se of'other exD0sure. This MSDS has b<ten prepared according to the OSHA Ha~.ard Communication Standard [29 CFR 19~0.1200]. The MSDS intormation is based on sources believed iD be reliable. However, since data, satety standards, and government regulations are subject to change and the conditions of handling ~nd use, or misuse are beyond our conlrol, HILL BROTHERS CHEMICAL COMPANY makes no warranty, either expressed or implied, with respect ~o the compleleness or continuing accuracy et the information contained herein and disclaims all liability for reliance thereon. Also. addilional informalion may be necessary, or helptul for specific condilions and circumstances o~ use. it is the user's responsibility Io delermine 1he suitability of this product and to evaluate risks prior to use, and then to exercise appropriale precautions Ior protection of employees and olhers. [SECTION I - PRODUCT IDENTIFICATION SYNONYMS / COMMON NAMES: PROPYLENE GLYCOL; C3H802 CHEMICAL FAMILY / TYPE: OXYGENATED HYDROCARBON DOT PROPER SHIPPING NAME: N/A DOT HAZARD CLASS / I.D. NO.: N/A REPORTABLE QUANTITY: N/A NFPA RATING: HEALTH - O; FIRE - 1; REACTIVITY - 0 O=lnsignificam l=Slighl 2=Moderate 3=High 4,.Exlr~me [SECTION II- HAZARDOUS INGREDIENTS CAS Exposure Limits (TWAs) In Air Chemical Na~n'e Number % ACGIH TLV OSHA PEL STEL" PROPYt..ENE GLYCOL 5 7- 5 5- 6 1 O0 N/A N/A N/A 'ACGIH shes term exposure limit (STEL) ISECTION III - PHYSICAL AND CHEMICAL PROPERTIES Phy.~lca! State: LIOUID Appearance/Color/Odor: COLORLESS; ODORLESS Product/Trade Name : PROPLYLENE GLYCOL [SECTION III - PHYSICAL AND CHEMICAL PROPERTIES CONTINUED I pH: N/A M~ltlng Polnt/R~nge: N/A Bolling Point/Range: 369.1° F Solubility In Water: 100% Vapor' Pressure(mmHg): NEGLIGIBI. E Specific Gravity{Water = 1): 1.038 Molecular Weight: 76.10 Vapor Density(Air = 1): 2.6 % Volatllos: NEGLIGIBLE How to delect this compound : N/A [SECTION IV - FIRE AND EXPLOSION Fl~sh Point: 214OF - 225OF Autolgnltlon Tompor-ture: 790°F Lower Explo~lve Limit: 2.6 Upper Explosive Limit: 12.5 Unusual Fire and Explosion Hazards: This material may burn, c~n:ainer is not properly cooled, it may explode in the heat ola fire. Vapors are heavier than air and may accumulate in Iow areas. Extinguishing Media: Carbon dioxide, Helen, Polar or Alcohol- recommended. Water ma}' be ineffective. Special F;reilghting Prccecures: Wear appropriate protective equipmen; including resl3ir,'3.1ory prolection as conditions warrant. Stop spill/release Il it can be done withou; risk. Move undamaged containers from fire area if it can be done without risk. Water spray may be usetul in minimizing or dispersing and cooling equipment exposed to heat and llama. Avoid spreading burning liquid with water used for cooling purposes. ISECTION V - REACTIVITY J Stability: Stable Hazardous Polymerization: Will Not Occur Condltlon.~ to Avoid: N/A Matorlnl~ to Avoid: N/A Hazardous Decomposition Products: Combuslion may yield carbon monoxide an/or carbon dioxide. Do not breathe smoke or fumes, Wear appropriate prolective equipment. [SECTION VI- HEALTH HAZARDS Routes of Exposure: Summary of Acute Health Hazard:~: (Statement) INGESTION: While this malerial has a Iow degree of loxicit7, ingestion of excessive quantities may cause signs o! nervous system depression (e.g., headache, drowsiness, loss el coordination and fatigue). N/A Not Applicable PAGE 2 OF 4 Product/Trade Name : PROPLYLENE GLYCOL [SECTION VI - HEALTH HAZARDS CONTINUED INHALATION: While this malarial h;~.'; ;~ Iow vot;~tility, expor, ure 1o v;zpors is unlikely, however, vapor,~ or mists produced under cea, am conditions al uc, e may cause sign.", of ~(,rvous system depression (r).g., headache, drowsiness, loss al coordination and fatigue). SKIN:- M~y cause mild skin irriJation. Prelongeci or repeamd cenl;~cl m;~y cause re0ness, burning and Orying and cracking o[ lho skin. Persons wilh pro-oxisling skin disorders may be more susceptible to Ihe effects of this maler~al. EYES: This material may cause mild eye ~rritation. Direcl contacl w~th me liquid r)r exposure or misls may cause slinging, tearing and redness;. Carclnogenlclty Lists: NO NTP: NO IARC Monograph: NO OSHA Regulated: NO Summary of Chronic H~alth Hazards: Effects of Overexposure: N/A Emergency and First Aid Procedures: INGESTION: No first aid is normally required: however, if sw~llowedl ;zed symptoms develop, seek medical atl, enlion. INHALATION: If respiralory symptoms develop, move victim away from .~ource cf exposure and into iresh air. I~, symploms pe~rsist, seek medical attention. If victim is not breathing, immedh~lely b~gin artificial respiration. If breathing dilficulties develop oxygen should be ;zdministered by qualified ,c.o~onnel. Seek immediate medical a,qention. SKIN: Wash wilh soap and water. EYES: Flush with plen*,¥ of waler. Medical Conditions Generally Aggravated by Exposure: N/A Note to Physicians: N/A JSECTION VII - PRECAUTIONS FOR SAFE HANDLING AND USE Stops To Be Taken In Ca~o Material ls Released Or Spilled: SrT~all spills: So~k up with absorbent malarial. Large spills: Dike and pump into ~uitable containers for disposal. Handling and Storing Precautions: Normal precaution.~ common to good manufacturing practice should I:~ lollowed in handling and slorage. Waste Disposal Mothod.~: Dispose at' in accordance wilh applicable local, county, state and federal regulallons. Other Precautions: N/A NIA - Nol Applicable PAGE 3 OF 4 .-_ ?-.,j .... ~. Product/Trade Name : PROPLYLENE GLYCOL [SECTION VIII - CONTROL MEASURES Respiratory Protection: Respiralory promclion may bo necessary Io minimize expo~r~ I)~p~nding on tho naluro and concentration el the nlrbcrn~ ma~ori;d, ut;u ~ ~espiralor or gas mask wi~h npproprinln cartridges and cannislers (NIOSH ~pproved) or suppli~ air equipment. Ventilation: General room ventilation i5 5;Hi~;f;~clory. Additionsl venlilation or ~ required, where explosive mixlures may ~* present. Electrical u~d. Protective Clothing: Rubber gloves are recommonSed. Eye Protection: S~fe~ glasses and or face shield is recommendS. Other Protecllvo Clothing or Equipment: It available in 1he work area for flushing eyes ~nd skin. Im~ious clothing should be worn. Wet. Hygienic Practices: All employees who handle Ibis product should wash their hands before eating, smoking, or using toilel facilities. N/A - Not Applicable PAGE 4 OF 4 ANNEX III.3.c OPERATIONS Items to be addressed in this Annex: (1) Objectives and targets [~ Written operating procedures (2755.3 or 2760.3) [] Emergency response objectives (2745.8(a)(2)) (2) Discharge or release control [] Engineering and administrative controls (2760.2(c)(3)) (3) Assessment and monitoring [] Monitoring and detection systems in use (2755.2(a)(4)) [] ~my other steps used or needed to detect or monitor releases (2760.2(c)(3)) (4) Containment [] Mitigation systems in use (2745.6(e)(4)) (see also Annex III.7 "Prevention") [] Safeguards to prevent equipment malfunction or human error (2755.2(a)(3)) (5) Recovery (6) Decontamination CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES 4.0 PROCEDURES REPORT Operating procedures comply with manufacturers' recommended procedures. 4.1 Ammonia Systems 4.1.1 Daily Operating Procedures Operating procedures include: Daily Operating Duties 1. Inspect work area and overall operation of systems. 2. Check compressor suction and discharge temperature and pressure twice per day. 3. Check compressor oil levels twice per day. Normal level is mid-point of sight glass. 4. Check compressor oil pressure twice per day. 5. Investigate abnormal conditions. Page 23 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 4.1.2 Maintenance Procedures Maintenance procedures include: Ammonia System Shutdown 1. Shut king valve on receiver to pump all ammonia into the receiver 2. Shut suction valves on compressors 3. Turn compressor motor off 4. Shut compressor discharge valves 5. Lock out electrical panel 6. Tag warning on the electrical panel 7. Open discharge valves before starting Isolatin.q a Compressor for Maintenance 1. Shut suction valve, allow compressor to pump down (remove ammonia) 2. Turn compressor motor off 3. Close discharge valve 4. Lock out electrical panel 5. Tag warning on the electrical panel 6. Attach bleed off hose to the compressor to bleed off excess ammonia into a bucket of water 7. Open discharge valves before starting the compressor Page 24 Restarting a Compressor 1. Disconnect bleed off hose 2. Open discharge valve at the compressor 3. Check oil level in crankcase 4. Remove lockout on the electrical panel 5. Turn on compressor motor 6. Check oil pressure 7. Open suction valve at the compressor Page 25 5.0 DESIGN, OPERATING AND MAINTENANCE CONTROL SYSTEMS 5.1 Ammonia 5.1.1 Design Control Systems Properly designed control systems include design of piping to minimize slug formation, automatic control devices (for a listing, see Appendix IV of the Hazard Analysis, which was submitted as a separate document) and correct sizing of process equipment. The ammonia safety audit requires an extensive review of system design. If ammonia system modifications are necessary, the process equipment revisions shall be performed in accordance with manufacturers' recommendations. The ammonia system modifications shall be documented and process system drawings shall be updated. 5.1.2 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. The operator's log is reviewed by the Maintenance Supervisor and retained on file for future reference. Other operating control systems include labeling to ensure that proper actions are taken, and safe operating procedures training is conducted. Inexperienced personnel are not allowed to operate the ammonia system or to perform work on the system. Any new employees must be trained thoroughly before they are allowed to operate the system. Page 26 6.0 DETECTION, MONITORING OR AUTOMATIC CONTROL SYSTEMS 6.1 Ammonia 6.1.1 Detection Systems Abnormal or hazardous conditions are detected by: Automatic controls: Ammonia gas leaks are detected by Manning Systems Model 4485 Ammonia Gas Cellfl'ransmitters. These units consist of an electrochemical sensor and an electronic transmitter, and have a detection range of 0-100 ppm ammonia. The Instruction and Installation Manual is provided in Appendix E. 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. 6.1.2 Monitorin.q Systems The following variables are continuously monitored by automatic controlling equipment: Ammonia Pressure: Monitored by pressure cutouts, and pressure relief valves. Ammonia liquid flow: Monitored by Solenoid valves. Page 28 5.1.3 Maintenance Control Systems The Maintenance Supervisor is responsible for controlling maintenance on the system. Maintenance performed is recorded on the maintenance record form, Exhibit 7. The maintenance record form is reviewed by the Maintenance Supervisor 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 27 OCT 17 '96 0:3:11PM CRYSTAL GEYSER glgtTER P.2/3 WZhNc The following variables are monitored by the operator: Ammonia pressure: Suction and discharge pressure gauges on compressor Systems are checked twice daily and recorded, Oil Levels: Checked twice daily and recorded. Ammonia levek Low levels are detected by a rise itl tile temperature of'tile cooled product or process materials. Temperature: Checked twice daily and recorded, Running lights: Checked during production mn and checked before cip start up and during cip run. (Lights mounted on carbo cooler panel) 6.1.3 Aulomatic Conlrol Syslems Automatic control systems act as a backup to mechanic detection and actions. A listing olf automatic controls on the refrigeration system is included as Appendix IV of the Hazards Analysis. The compressor High Ammonia Pressure Shutdown device is an automatic shutdown control with manual reset by the plapt operator, If this device actuates, the plant operator shall review the system before restarting the compressor. Page 29 The following variables are monitored by the operator: Ammonia Pressure: Suction and discharge pressure gauges on compressor systems are checked twice daily and recorded. Oil Levels: Checked twice daily and recorded. Ammonia Level: Low levels are detected by a rise in the temperature of the cooled product or process materials. Temperature: Checked twice daily and recorded. 6.1.3 Automatic Control Systems Automatic control systems act as a backup to mechanic detection and actions. A listing of automatic controls on the refrigeration system is included as Appendix IV of the Hazards Analysis. The compressor High Ammonia Pressure Shutdown device is an automatic shutdown control with manual reset by the plant operator; If this device actuates, the plant operator shall review the system before restarting the compressor. Page 29 V~i~Z ~ ~NC 7.0 PROPOSED RISK REDUCTION MEASURES 7.1 Written Operatinq Procedures Written operating procedures (Section 4.1 of this RMPP) ensure that mechanics 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, ensures that personnel are well trained to perform maintenance on the 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 risk of release of AHM. Ammonia lines will be labeled. Page 30 7.5 Safety and Training Program Employees will receive training under the 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 relies upon: · employee safety training · housekeeping practices to remove combustible materials · fire extinguishes · no smoking signs are posted where appropriate Fire extinguishes are strategically located throughout the facility with each location labeled and serviced on a regular basis. 7.7 Physical Plant Changes All previously proposed physical plant changes have been performed, including installation of the ammonia diffUsion system for the high pressure relief valves. With the installation of the glycol chiller system, the amount of ammonia piping has been reduced and the need for 150 lb ammonia cylinders has been eliminated. 7.8 Reduction of Consequence to Neighborinq 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. Page 31 C~¥STAL GEYSE~ ]~.FI{IGERATION SYEg'EM CRITICAL TEMPERATURES & PRESSURES OPERATING CONDITION~ Design Suction Temp 27°F Design Suction' Pressure 42# Design Condensing Temperatttre 88°F Design Condensing Pressure 160# Design Oil Temperature 120°F Design Oil Pressure " .60# Design Glycol Temperature 33°F $Y$~ t'[YI' OU'/' SETTINGS Low Pressure 309 High Pressure 196# High Discharge Temperature 212°F Low Oil Pressure 10% Low Oil Temperature 49°F High Oil Temperature 167°F S¥STEM TEST PRESSIIRES High Side 249% Low Side 149% · ., -17877921~17 ;EEFR1GER;~] iO~4-TECH ~q'5 POi ]U~a 16 '9] 1~:4~ 1. Turn on the KING solenoid .valve at the ref.rigeration control panel R-1. 2. Turn on the glycol chiller. (switch at R-l) 3. Set the glycol operating thermostat to 33°F. 4. Set the glycol safety the~ostat to 27°F. 5. Turn on the glycol pu~ps to AUTO. 6. Turn on the screw compressor (at R-i). 7. Set each screw compressor to the automatic mode at the control panel on each compressor. 8, A computer program inside the compressor Will cycle the compressor ON and OFF as required to meet the refrigeration load. CONTROL PANELS Location: Bac~ wall of machine room PANEL R--1 R-k is the main refrigeration control panel. It is fed by a 250 amp, 460 volt service. This panel supplies power to the (3) evaporative condensers and the (4) glycol pumps. coNTrOL PANEL R--2 R-2 .is the control panel for the cooling tower, tower pumps and the machine room exhaust system. This panel is fed by a separate 100amp, 460 volt service. This panel also supplies all of the control power for panel R-1 and the computer control panel. COMI~TERCON~ROL PANEL The-computer control panel is a large fiberglass enclosure located on the wall to the left of the R-1 and R-2 control panels. This panel contains the following: 1. Main Computer Module. This is used for the system alarm and diagnostics. 2. Computer Expander I. This is used to control the equipment in 3. Computer Expander II. This is used to control the equipment in R-2. 4. Machine room ammonia detector. " 5. Carbo cooler ammonia detector. 6. Vent line ammonia detector. 7° Glycol chiller operating thermostat. 8. Glycol chiller safety thermostat. 9. Glycol chiller EPR thermostat. 10. Machine room thermostat. 11. Glycol pump pressure controls. .. .. 12. Tower pump pressure controls. POWER FAIIZIRE If there is a power fail~re, the system will not start automatically. A trained operator must restart the system. When the power is started the alarm system will check all of the alarm points. If ere are any failures the alarm horn and light will activate The erator can silence the alarm horn, but he cannot reset the alarm- system until the cause of the alarm is found and corrected. Once all of the alarms are O.K. the compressor can be placed into operation again. If there was an earthquake there is a possibility that ammonia lines will break. Power will probably be o££, ~d ~ll ~u~omatic valves will close. Each vessel tha% contains ammonia has manual isolation valves ~ha~ can be t~rned off. A~I~O~T~ IN G~FERAL The most common a~monia leak is usually found around valve stems and flanges. These are very easy to find and correct. There is the possibility of an ammonia leak if a compressor seal is leaking. This is usually proceeded by excess oil leaks at the seal. If this happens the compressor can be isolated. A spare seal for each compressor should be on hand. A faulty relief valve can open prematurely. If this happens, the a~onia vent lines are piped to the sparge tank. TO detect ammonia leaks we have installed (3) ammonia detectors in the machine room. One at the carbo cooler and (2) in ~he vent lines. These sensors will send a signal to our alarm system. The machine room has a large two ~peed fan located on the roof. The f~n is used to cool ~e ~chine room in the s~er ~d to vent ~e ~onia out of the machine room in ~e event of a leak. The fan' has a ~et of auto,tic dam?ers. If ~e fan is being used ~or a~onia r~oval, the dampers dlrec~ the e~aus~ air in~o ~e cooling tower. This to,er acts as a scriber, removing ~e a~onia from the air. ~is will happen ~der ~e following conditions. 1. There are (2) machine room emergency vent switches on th~ . system. One in the d~p panel and one on the wall outside the mac~ine room. Eider switch will start the fan and ~e damper and so~d an ala~. 2. If ~e machine room =~onia sensors detect a leak it will s~t the vent system and so~d ~e ala~. NOTE: The machine room went system will still f~ction if ~e emergency stop switch has ~en used. The control panel is built in two sections. Each section has its o~ power supply. All of the control power for ~th sections comes from section R-2. All of ~e refrigeration is powered from R-1. The emergency stop switch will shut do~ section R-1 only. R-2 will continue to operate the machine room vent, cooling tower fans and the'ala~ system. computer control panel. The top row of lights are inputs to the computer. The bottom row of lights represent the outputs. The inputs send the computer a message, the outputs do the work. The computer inputs must be "ON" (LED light ON) when O.K. If the light goes out it signals an alarm condition. INPUTS 0 i Emergency Stop Switch 2 King Solenoid 3 Master High Level Switch 4 Chiller High Level Switch 5 Ammonia Alarm Machine Room 6 ~monia Alarm Carbo Cooler 7 Ammonia Alarm Vent System 10 Cooling Tower Sump PH Alarm 11 S~arge Tank PH Alarm 12 High Glycol Temperature 13 High Tower Water Temperature 14 Voltage or Power Alarm 15 OL Alarm I ~GENCY STOP SWI'IXIH - There are two emergency stop switches. One is located in the a~onia dump panel and one is on the wall outside the machine room. The switches are wired in series. If there is an accident, fire, earthquake, or ammonia spill the refrigeration system can be turned off from either remote location. This will sound an alarm at the main computer panel. 2 ~ING SOT.~NOID The system has (2) KING solenoid valves located on the ~in ammonia line as it leaves the receiver to supply the system. One valve is manual the other is electric. The electric valve must be energized to open. The valve will close during a power failure, if the emergency stop switch is turned off, or if the KING solenoid valve switch is turned off at control panel R-1. 3 MASTER HIGH LEVEL SWITCH Th~mas=er high level switch is located on the master accumulator. If~iquid ammonia floods back~ =o =he master accumulator the master high level switch will shut down the complete refrigeration system. In order to restart the system an operator must be present to reset the alarm system and place the refrigeration system back in operation. 4 CHI~.~HIGH ~.~L SWITCH This switch is located on the glycol chiller and it will give an alarm signal indicating that the ~onia level is too high. This will no~howeve% shut the system down, it will let the operator know that an~larm condition is pre~en~ but~because we have an accumulator it is not necessary to shd~ the system down at this time. We. will have (2) ammonia detectors located in the machine room. Each one .will send a signal back to the ammonia alarm'.module located in the computer control panel. An alarm will send a signal to the computer alarm module and thim will mound the general refrigeration 6 AMMONIA ALAllM AT THE CARBO COOLER An a~onia sensor has been located near the ceiling over the carbo cooler in the process area. This unit is extremely sensitive and will also send an alarm signal back to the alarm module in the computer control panel. This module will in turn send a signal to the computer alarm module which will sound a general refrigeration alarm. Two ammonia sensors have been located in the ammonia vent piping. One is between the sparge tank and machine room)the second is between the sparge tank and the carbo cooler. In the egent either system senses ammonia in the vent line a signal will be sent to the ammonia vent line detector which in turn will send a signal to the computer alarm module and sound a general alarm. All of these alarms will be noted and locked in at the alarm panel so tthe operator can easily distinguish where the alarm occurred. The cooling tower will be used an as ammonia scrubber for the machine room ventilation system. In the event of an emergency, ammonia will be scrubbed out of the air by the cooling tower. This will in turn change the PH of the water in the cooling tower sump. A PH alarm will detect any changes in the sump water and send a signal to the computer alarm module, sounding a general computer alarm. At the same time it will open a dump solenoid allowing water to drain from the cooing tower to the sparge tank and at the same time fresh water will be automatically added to the cooling tower. This will continue until the PH of the tower water is back within our predescribed limits. 11 SPARGE TANK PH ALARM In the event a relief valve is discharging ammonia into the sparge tank and there is a failure of the ammonia vent alarm and the PH changes substantially in the sparge tank;we will send a signal from ~he remote PH alarm module located at the tank to the computer alarm module sounding a general alarm. 12 ~IGH The operating thermostat for the glycol ~ystem ha= (4) ~tage~. Three ~=ages are used to control the glycol temperaU~r~. Should the ~lycol t~mperature continue to increase beyond the third stage of cOoling by 5-~ the high glycol temperature alarm signal will be sent to the computer alarm module signalling a general refrigeration alarm. 13 HIGH TOW~WATERT~ERATU~E This system ~ill be identical to the high glycol temperature alarm described above. 14 VOLTA~ We have installed a voltage monitor inside panel ~-1 and R-2. Either module will send a signal to the computer alarm module sounding a general refrigeration alarm. Note: Any of the alarm functions listed above will lock in a signal at the computer alarm module which will stay lit even if the alarm condition is corrected. This alarm ~ignal cannot be cleared until the alarm condition has been corrected and the alarm reset button has been pushed. Multiple alarm outputs will lock in at any time. OPERATORS LOG (typical) TIME PRESSURE TEMPERATURE OIL ADDED? COMMENTS EXHIBIT 6. 12-08--~.993 ~.3:38 P. 02 " CRYSTAL GEYSER AMMONIA CHARGE RECORD Date Ammonia In Plant Amt. AddedInitial (Pounds) (Pounds) I-/- ?-/~oo~ ~ /~o_ ~.z ~~ ~_~/- ?/~m~ .~_ /~*~. ,, - ~ ?-1-7/ --~a~.~ />~'~ z zI-I'.P/ 3oo~ ¢~_~Z ..... .~. ,. !7 l-P/ I~ ~ " ' EXHIBIT 9 1~-~8-1993 13:38 P.03 CRYSTAL GEYSER AMMONIA CHARGE RECORD Date Ammonia in Plant Amt. Added Initial (Pounds) (Pounds) EXHIBIT 9 i2-08-1993 i~:38 P.04 CRYSTAL GEYSER AMMONIA CHARGE RECORD Date Ammonia in Plant Amt. Added Initial (Pounds) (Pounds). EXHI~IT 9 CRYSTAL GEYSER ~ ALARMS AND CONTROLS ITEM DESCRIFrlON/FUNCTION LOCATION g~aergency Stop Switch .To completely shut down all equipment See drawing. m an amergency. King Solenoid To stop the flow of refrigerant after the At the outlet of receiver, the receiver main liquid line. Master High Level Monitors liquid in Master Accumulator. At Master Float Switch Shuts down the ammonia system- Accumulator. Chiller High Level Monitors liquid in the glycol chiller At fltiller. Float Switch accumulator. Tower Sump PH Alarm Monitors PH level in tower water. At tower. Sparge Tank PH Alarm Monitors PH level in SParge tank At sParge tank High Glycol Temp Monitors high glycol temperatures. 4th Stage of Glycol Thermostat. High Water Temp .Monitors high water temperatures. 4th Stage of Water Thermostat. Voltage Alarm Monitors high and low voltage at alarm panel At alarm panel AMMONIA ALARMS AND CONTROLS ITEM DES~ON/FUNCTION LOCATION Ammonia Alarm Monitors Ammonia in machine room. (2) Sensors in Machine Room Machine room located above equip. Ammonia Alarm Located in the ammonia vent line going to the (1) Sensor in Vent sparge tank Machine mom vent line. (1) Sensor in the carbo cooler vent line. Ammonia Alarm Monitors Ammonia at the Carbo Cooler. Near ceiling over Carbo Cooler carbo cooler C,RYSTA L GEYSER AMMONIA DUMP CONTROL PANEL: On the hack wall of the machine room, outside the building is the ammonia dump panel In the event of an emergency, such as a fire in the machine room, the ammonia pressure mn build up. To relieve the pressure, valves were installed in the d.ump , panel If the pressure exceeds the red line on the face of the gauge the valve ~s openea allowing ammonia vapor to enter the sparge tank. (see .below) SPARGE TANK: (E. xisting) 12,000 gallon tank. The sparge tank is used to absorb any ammonia vapor discharge as a result ora relief valve popping offor the pump system being used. The emergency stop switch will shut down the power to all of thc equipment in the machine room, with the exception of thc ventilation syste, m. . . One switch is located in the ammonia dump panel and one tn the control box located just outside the machine room. MACHINE ROOM VENTR, A~ON SYSTEM: The machine room ha a (2) speed fan on the roof, controlled by a two stage thermostat. The fan is also used to vent any ammonia vapor fa'om the room. To prevent ammonia discharge into the air the fan discharges the machine room air into the cooling tower. This tower scrubs the ammonia out of the air. If thLs happens, the PH of the tower water will increase. A PH alarm will signal this condition and an alarm win sound. Location: Controls and alarms are located in the computer panel on the hack wall of the machine room. Description of Operation: '0 Z X 0 Items to be addressed in this Annex: (1) Hazard assessment [] Worst-case release scenario analysis (2750.3) [] Alternative release scenario analysis (2750.4) [] Defining offsite impacts to the population (2750.5) [] Defining offsite impacts to the environment (2750.6) [] Offsite consequence analysis documentation (2750.8) Program 3: [] Process hazard analysis (2760.2) [] Employee participation (2760.10) Program 2: [] Hazards associated with the process and regulated substances (2755.2(a)(1)) [] Opportunities for equipment malfunction or human error (2755.2(a)(2)) (2) Protection [21 Safeguards to prevent equipment malfunction or human error (2755.2(a)(3)) (3) Coordination with natural resources trustees & NGO's [] Community communication outreach (2775.5) (4) Waste management CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES TABLE OF CONTENTS Pa.qe I. Introduction 1 II. Hazards Identification 4 A. Identification of AHM 4 B. Quantity of AHM 4 C. Location of AHM 4 D. Potential Hazards of an AHM Release 5 1. Primary Hazards 5 2. Other Hazards 7 E. Hazards and Operability Study 8 1. Study Guideline 8 2. Study Results 14 F. Transportation Methods 16 Iil. Vulnerability Analysis 16 A. Summary of Modeling Results 19 B. Receptor Locations 20 C. Essential Service Facilities 21 IV. Risk Analysis 22 A. Summary of On-site and Offsite Consequences 22 EXHIBITS Exhibit 1 Location Map Exhibit 2 Risk Analysis Matrix Exhibit 3 Plan Drawing R2329 R1 Exhibit 4 Plan Drawing R2329 R3 Exhibit 5 Piping Schematic R2329 R2 Exhibit 6 Piping Isometric R2329 R4 Exhibit 7 Pictures of High Pressure Receiver and Piping Exhibit 8 Pictures of Glycol Chiller and Piping Exhibit 9 Case 1 - Map of Exposure Zone (IDLH and LOC) Exhibit 10Case 1 - Map of Exposure Zone (IDLH only) ~ Exhibit 11Case 2 and 3 - Map of Exposure Zone (IDLH and LOC) Exhibit 12Case 4 - Map of Exposure Zone (IDLH and LOC) Exhibit 13Case 5 and 6 - Map of Exposure Zone (IDLH and LOC) Exhibit 14Map of Surrounding Area Exhibit 15- Map of Receptor Locations TABLES Table 1 Physical properties of. Anhydrous Ammonia Table 2 Bakersfield Area Mean Wind Speed and Direction APPENDICES Appendix I Business Plan Appendix II Ammonia MSDS Appendix III Equipment Specifications Appendix IV Ammonia Systems Controls and Alarms Appendix V HazOp Study Node Forms I. INTRODUCTION The Crystal Geyser Water Company (Crystal Geyser) bottling facility, located at the corner of East California Avenue and Lakeview Avenue, Kern County, California (Exhibit 1) formulate, produce, package and ship various brands of Crystal Geyser beverages. The process of manufacturing beverages in the Crystal Geyser plant requires refrigeration. The refrigeration is used to cool tanks of water and juice beverages during their manufacture plus the bottled product after pasteurization and prior to 'carbonation. Crystal Geyser is proposing to install a new higher capacity ammonia refrigerant system that will supply ammonia to their carb© coolers (existing) and the glycol chiller (new). The engineered features that are designed into the new refrigerant system such as the glycol chiller system (keeps ammonia piping to a minimum), high pressure relief sparge system and advanced sensors interlocked with alarming devices have been incorporated to reduce the risk of an ammonia release. This new refrigeration system and building was built in accordance with: 1) 1991 Uniform Building Code 2) 1991 Uniform Fire Code 3) 1991 Uniform Mechanical Code 4) 1991 Uniform Plumbing Code 5) 1990 National Electrical Code A Hazard Analysis of the use of Acutely Hazardous Materials (AHM) for the Crystal Geyser Bakersfield bottling facility, used for their Risk Management and Prevention Program (RMPP), was approved by the Bakersfield Fire Department, Hazardous Materials Division on April 10, 1991. This update of the Hazard Analysis is a revision of the April, 1991 edition to reflect the addition of the new ammonia refrigeration system scheduled for installation and start-up at the Bakersfield facility in July, 1993. This Page I Hazard Analysis has been prepared in accordance with EPA/FEMNUSDOT document "Technical Guidance for Hazards Analysis: Emergency Planning for Extremely Hazardous Substance, 1987" and the Bakersfield Fire Department, Hazard Material Division's Risk Management and Prevention Program Preparation Guidelines, Form FD1593. The RMPP has also been updated with the results of this Hazard Analysis and is provided under separate cover. This Hazard Analysis has been prepared as a necessary step in comprehensive emergency planning for Crystal Geyser, its employees and the surrounding community. Comprehensive planning depends upon a clear understanding of what hazards exist and what risk they pose for employees and various members of the community. The analysis represents a means of evaluating potential hazards resulting from the accidental release of an AHM. The three basic components in the Hazard Analysis are (1) hazard identification, (2) vulnerability-analysis, and (3) risk analysis. The hazard identification process, the first step in hazard analysis, focuses on collecting information on: · Type and quantity of hazardous materials used and stored at the facility; · Physical location of hazardous materials used and stored within the facility; · Potential hazards associated with hazardous material releases; · · Conditions of operation, storage, loading, processing and using hazardous materials (Hazard and Operability Study); and · Transportation routes and methods used for transporting hazardous materials. Page 2 The vulnerability analysis provides information helpful in planning requirements that include; · An estimation of the vulnerable zone with air dispersion modeling using AHM concentrations that represent the Immediate Danger to Ufe and Health (IDLH) and the EPA Level of Concern (LOC) along with the conditions and assumptions that were used to estimate each vulnerable zone; · The population, in terms of numbers and types (e.g., neighborhood residents, high density transient populations such as stadiums or auditoriums; sensitive populations in hospitals, schools, nursing homes and day care centers) that could be expected to be within the vulnerable zones; and · Essential service facilities such as hospitals, police and fire stations, emergency response centers, and communication facilities. Risk analysis is the third part of the hazard analysis process. This risk analysis provides a relative measure of the likelihood and severity of various possible hazardous events. A risk analysis matrix (Exhibit 2) is used as guidance for putting each potential situation into perspective (in terms of the probability that it will occur and the resulting effects it will have) and addresses the most likely and most severe potential hazards. Page 3 II. HAZARDS IDENTIFICATION A. Identification of AHM Ammonia, as shown in Crystal Geyser's Business Plan (Appendix I), is stored and used in reportable quantities to the Bakersfield Fire Department, Hazardous Material, Division. B. Quantity of AHM The new ammonia system has been designed to be charged with and operate on a maximum 4900 pounds of ammonia. C. Location of AHM The overall refrigeration plans show the location of all the ammonia equipment, vessels and piping, both in plan and elevation view of the facility in drawing Numbers 92329 R1 and 92329 R3 (Exhibits 3 and 4, respectively). The ammonia compressors, high pressure receiver and glycol chiller, all new equipment, are located inside the newly constructed compressor room. The only remaining equipment from the old refrigeration system, the carbo coolers, remain in the existing indoor receiver room. The evaporative coolers are located outside on top of the compressor room. The only other equipment located outside is the supply and return lines of the ammonia system between the compressor room and the carbo coolers in the receiver room and the Fire Department Emergency Refrigerant Control Box with associated vent lines to the emergency ammonia diffusion tank. Only during initial filling or refilling of the system or rare times where all the ammonia must be isolated back to the high pressure receiver shall the high pressure receiver retain all 4900 pounds of ammonia. Under normal operating Page 4 conditions, a minimum quantity of liquid ammonia is retained in the high pressure receiver with the bulk of liquid ammonia being spread out to the other components of the system such as the condensers, compressors, glycol chiller and pipelines. D. Potential Hazards of an AHM Release The term "anhydrous ammonia" refers to the compound having the formula NH3, formed by the chemical combination of nitrogen and hydrogen. Appendix II contains a copy of a Material Safety Data Sheet (MSDS) for anhydrous ammonia. Whenever the term "ammonia" appears in this Hazard Analysis it should be understood as meaning anhydrous ammonia and not aqua ammonia, aqueous ammonia or ammonium hydroxide which are solutions of ammonia in water. Ammonium hydroxide solutions generally range in concentrations of ammonia from about 30% down to the 2 to 4% found in the Well known household ammonia. These solutions are all commonly known as ammonia, but should not be confused with liquid anhydrous ammonia which has a much greater hazard potential. "Anhydrous" means "free from water". The physical properties of ammonia are provided in Table 1. At room temperature and atmospheric pressure, ammonia is a pungent, colorless gas approximately 40% lighter than air. Compressed and cooled, ammonia gas condenses to a colorless liquid about 68% as heavy as water. At atmospheric pressure, the liquid boils at -28F. 1) Primary Hazards Ammonia acts as an irritant to human tissue in varying degrees depending upon concentration and exposure. Page 5 The pungent and distinctive odor of the vapor, even at Iow concentrations, provides adequate warning so that no person will voluntarily remain in .I concentrations which are hazardous. Ammonia is NOT a cumulative metabolic poison; ammonium ions are actually important constituents of living systems. Depending upon concentration and time, the effects of exposure to ammonia vapor vary from none or only mild irritation, to obstruction of breathing from laryngeal and bronchial spasm, to edema and severe damage of the mucous membranes of the respiratory tract with possible fatal results. · Exposure levels of ammonia vapor which are tolerated by some persons may produce adverse reactions in others. The following table, Physiological Effects of Ammonia Vapor, indicates human physiological response to various concentrations, in parts per million (ppm), of ammonia in air upon inhalation. PHYSIOLOGICAL EFFECTS OF AMMONIA VAPOR PPM Ammonia in Effect Air by Volume Lease perceptible odor .................................................................................................... 5 ppm Readily detectable odor ........................................................................................... 20-50 ppm No discomfort or impairment of health for prolonged exposure ........................... 50-100 ppm General discomfort ahd eye tearing no lasting effect on short exposure ....... 150-200 ppm Severe irritation of eyes, ears, nose and throat; no lasting effect onshortexposure .................................................... ; ..... ; ........................ 400-700ppm Coughing, bronchial spasms .................................................................................. 1,700 ppm Dangerous, less than 1/2 hour exposure may be fatal .............................. 2,000-3,000 ppm Serious edema, strangulation, asphyxia, rapidly fatal ............................... 5,000-10,000 ppm Immediately fatal ............................................................................................ over 10,000 ppm (From 'Anhydrous Ammonia', Pamphlet G-2 Seventh Edition, Compressed Gas Association, Inc.) Page 6 For use in this Hazard Analysis, the following concentrations will be used for: LOC (level of concern) = 50 ppm IDLH (immediate danger to life and health) --- 500 ppm 2) Other Hazards a) Liquid ammonia boils at -28F under atmospheric conditions, acting as a refrigerant to remove heat form any warmer object it may be contacting. Accordingly, liquid ammonia in contact with the skin can cause frostbite. b) Liquid ammonia exhibits a high coefficient of cubical expansion. A given quantity of liquid ammonia therefore expands considerably in volume with a rise in temperature, as shown in the following table: VAPOR PRESSURE AND VOLUME OF LIQUID AMMONIA AT VARIOUS TEMPERATURES Vapor Temperature Pressure Volume Degrees F psig Gal/CWT -28 0.0 17.57 · . 0 15.7 18.10 3O 45.0 18.72 60 92.9 19.43 90 165.9 20.25 115 251.5 21.04 130 315.6 21.58 (Data derived from U,S. Bureau of Standards Circular No. 142) Page 7 For this reason, appropriate measures must be taken to avoid hydrostatic rupture of containers, piping or other equipment as could be caused by such expansion. · Ammonia vapor, although classified by the U.S. Department of Transportation as a NONFLAMMABLE GAS, in the presence of a flame or spark will ignite, but only within the limited range of 16-25% of ammonia in air by volume. The heat generated by combustion is insufficient to maintain a flame which therefore will extinguish upon ignition source removal. E. Hazard and Operability (HazOp) Study 1) Study Guideline A HazOp study was performed on the new ammonia system including the carbo coolers to identify hazards and operability problems encountered in the operation, maintenance, filling and replenishing of the system. The concept involved investigating how the plant might deviate from the design intent. A HazOp team was assembled to review, in a series of meetings, the ammonia system design and operation using a structure provided by "guide words" and the team's experience. The HazOp team was made up of the following four people with their reSpective areas of experience: Team Leader: Gary Fuller, Mechanical Engineer, has over fifteen years of experience in managing large manufacturing facilities... His expertise includes operations management, process development control, environmental control, quality assurance and Page 8 engineering. Mr. Fuller has performed hazard analyses, consequence analyses and implemented hazard communications programs at manufacturing facilities in both Kern County and the San Francisco Bay Area. Team Member: Alex Manns, Plant Manager, was on the original hazard analysis team at Crystal Geyser which was previously acceptable to the City of Bakersfield. He has been at Crystal Geyser for 4 years and is knowledgeable in the operation and maintenance of ammonia systems. At Crystal Geyser, this includes piping layout, liquid ammonia shut off valves, ammonia safe handling practices and has been trained in the use of Crystal Geyser's ammonia diffusion system. Mr. Manns has been properly trained in the use of self contained breathing apparatus units at the facility and can initiate an emergency response to an incident. Previous to Crystal Geyser, Mr. Manns was Plant Manager at Calvin Coolers for 5 years. Team Member: Dave Butt, Process and Hazard Evaluation, has prior experience on ammonia hazards and operability teams, including Pepsi and Kern Ice and Cold Storage in the City of Bakersfield and Dairyman's Cooperative Creamery in the City of Tulare. In addition, his 29 years of experience is in the design and construction of process equipment such as compressors, high pressure systems, valves, and chemical storage tanks. Page 9 Team Member: Norman Ambrose, Maintenance Supervisor at Crystal Geyser for 4 years, was on the original RMPP team and participated on the team in a similar manner. He has 27.5 years of maintenance experience in the bottling and winery business. The team focused on specific points of the design (called "Study nodes") one at a time. At each of these study nodes, deviations in the process parameters are examined using the guide words. The intention of how the ammonia system is expected to operate in the absence of deviations at the study nodes is shown in the process flow depicted on the Ammonia Piping Schematic Drawing No. 92329 R1 (Exhibit 5) and Piping Isomeric Drawing No. 92329 R4 (Exhibit 6). The individual study nodes have been blocked out and highlighted on the Piping Schematic, shown in Exhibit 5. These Study Nodes included: 1) High Pressure Receiver. 2) Compressor packages (3). 3) In Line Filters (2). 4) Evaporative Condensers (3). 5) Glycol Chiller, including Glycol Chiller Suction Trap and Master Accumulator. 6) Carbo Coolers. 7) Ammonia Receiving. 8) Ammonia Lines. 9) Fire Department Emergency Refrigerant Control Box with Sparge System and Diffusion Tank. In addition, the hazards of potential ammonia releases associated with the process of draining oil from the ammonia refrigerant system has been analyzed. The findings have been documented and supplied in Appendix Page 10 V, study node number 10. The potential hazards associated with the operation of the computer control system, including potential failures and manual overrides has also been analyzed with the finding documented in Appendix V, study node number 11. Specification of this equipment, including make, model, manufacturer, and data. certification sheets, are provided in Appendix III. The new refrigeration system has many features such as the ammonia dump, system, emergency stop switches, vent and room ammonia sensors, systems alarms, etc., that are the intended design for normal operation. A description of the intended operation and functions of these ammonia alarm and controls are provided in Appendix IV. The new ammonia system has been designed to operate continuously 24 hours per day 7 days per week. The intent is that under normal operation, the liquid ammonia boils in the glycol chiller and the carbo cooler. It is this boiling action that supplies the required refrigeration. In order to keep the cycle going, the ammonia vapor must be compressed by the screw compressor and cooled by the evaporative condenser in order to condense it back to a liquid. The liquid now drains back to the receiver where it is stored until it is needed. This process continues as long as there is a need for refrigeration. The process flow'0f ammonia, shown in Exhibits 5 and 6, start with liquid ammonia that is stored in the receiver. As it leaves the receiver it passes through a KING solenoid valve. The liquid ammonia is piped to the master accumulator where it is used to boil off any excess ammonia. Next, it leaves the master accumulator and-goes to the glycol chiller and the carbo coolers. Each of these units control the ammonia using a series of float switches. Each Unit has an operating float switch and a solenoid valve. Page 11 When the correct level is reached the flow of ammonia is turned off. If the level gets too high it will be caught in the master accumulator. A master high level float switch will shut down the entire refrigeration system. Gaseous ammonia enters the compressors and is compressed to a higher pressure and temperature. After exiting the compressors, the hot gaseous ammonia enters the evaporative condenser. Water running over the condenser coils cool the hot gaseous ammonia into liquid ammonia. The liquid ammonia, then returns to the high pressure receiver located inside the compressor building. For the carbo coolers, the liquid ammonia flows through the injectors pulling liquid ammonia from the surge vessel into the coils of the carbo cooler and pre-chiller deaerator. The liquid ammonia absorbs heat from the carbo cooler and pre-chiller deaerator and flows to the ammonia surge vessel as a liquid/gaseous phase. Gaseous ammonia from the ammonia surge vessel flows to the ammonia suction trap. The suction trap prevents liquids from returning to the compressors. The gaseous ammonia is then pulled into the compressor suction. Deviations or departures from the intention of the normal or expected operation were reviewed in the study nodes by systematically applying the guide words (e.g. "no pressure, "high pressure", etc.) to the process and design parameters. Also investigated in the study nodes were the causes or reasons why these deviations might occur and if they were meaningful. These causes would be hardware failures, human errors, external disruptions (e.g.-loss of power, earthquake), etc. Plus the consequences of the deviations should they occur, were reviewed. Trivial consequences, relative to the study objective, were dropped. Page 12 The "guide words" used in the study nodes are simple words used to identify, qualify or quantify possible deviations. The following guide words will be used in the HAZOP study: Guide WOrd Example Meaning No Power Shutoff Negation of Design Intent Less Low Flowrate Quantitative Decrease More High Temperature Quantitative Decrease 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 Human error analysis was also included in the HazOp study and applied to the study nodes. The purpose of the 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. Potential areas for operator/human error included: · inadvertent closing or opening any valve · improper or neglected maintenance · accidental damage caUsed by fOrklift operator ° improper operation of control system Page 13 The HazOp forms used in the study nodes are provided in Appendix V. Shown on these forms were the guide words used with the possible deviations, including human errors, along with the causes and consequences of such deviations. 2) Study Results 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 then rated. The results of these ratings for each possible deviation considered in the study nodes are recorded on the HazOp Forms provided in Appendix V. In summary, the worst case AHM release event was that due to a significant seismic event. This case involves the release of liquid ammonia from a broken line connected to the high pressure receiver (Study node number 1) when filled with 4900 pounds of ammonia. Pictures showing the high pressure receiver and the associated piping are shown in Exhibit 7. The probability of. occurrence was defined as Iow or considered unlikely during the' lifetime of the facility assuming normal operation and maintenance. The severity of the exposure to people was defined as high or the release of ammonia is expected to move into the surrounding environment in concentrations sufficient to cause serious inquiries and/or deaths upon exposure. The main reason the probability was considered Iow was the fact that the high pressure receiver would rarely ever be filled with the entire 4900 pounds of ammonia. The second worst case AHM release event was basically the same as the high pressure receiver but was due to an earthquake causing a liquid ammonia line break on the glycol chiller (Study node number 5), releasing 2000 pounds of ammonia. The chiller will cor~tain the greatest amount of Page 14 liquid ammonia of the entire refrigeration system under normal .operation. The glycol chiller and associated piping are shown in the pictures in Exhibit 8. Again the possibility was considered Iow and the severity was rated high. The third worst case AHM release event was considered a liquid ammonia line break in the liquid ammonia supply line from the compressor room to the carbo coolers located in the receiving room. It is a 1" diameter special ammonia schedule 80 pipe approximately 150 feet long, with a potential to release 26 pounds of liquid ammonia. Other items to note from the HazOp study are as follows: · Location of equipment in compressor room is such, that it was recommended that a guard rail be installed on the west side of the equipment between the north and south walls of the compressor room. · Sparge tank be equipped with automatic level control or checked on a regular basis to ensure water is maintained at the required level. · Fire Department Emergency Refrigerant Control Box be equipped with a lock to prevent tampering or inadvertent opening of dump valve(s). · Level indicators on high pressure receiver, due to location of receiver, are inconvenient to read. Propose to install remote electric eye to sense levet in receiver. Page 15 · Recommended to hook-up to Monitoring Company such as Tel Tec, for 24 hour surveillance on Ammonia Alarm system, with qualified Ammonia systems operator on call. F. Transportation Methods Ammonia will be transported to the facility by highway in pressure containers as a liquified compressed gas at ambient temperatures. The initial filling of the refrigeration system will require 4900 pounds of ammonia. It is not anticipated the system will need replenishing very often and therefore no extra ammonia will be stored on site as was done previously. Ammonia will be delivered on an as needed basis. Iii. VULNERABILITY ANALYSIS An estimation of vulnerable zones with air dispersion modeling using AHM concentrations that represent the IDLH and LOC was performed for three different AHM release scenarios. These ammonia release events represent the three "most likely hazards" as defined in the Bakersfield Fire Department's Hazardous Materials Division Risk Management and Prevention Program Preparation Guidelines. Although all three cases have a Iow probability of release, each event poses a high off-site consequence. These three AHM releases are as discussed previously in the HazOp study results. The worst case release, as determined through the Hazard and Operability Study, was found to be a potential release of the liquid contents of an inside ammonia storage vessel into the atmosphere. The potential release scenario determined to be dangerous to off-site receptors is a release of ammonia during an earthquake. Lines from the ammonia receivers located inside the building (Exhibit 7) contain liquid ammonia. A break in the liquid Page 16 ammonia lines could release all the ammonia in a storage vessel to the atmosphere. In this potential worst case scenario, the rapid release of liquid ammonia could form an air/ammonia dispersion that would act as a cloud of dense gas. The Automated Resource for Chemical Hazard Incident Evaluation (ARCHIE) computer program was used to model the theorized worst case or releases. The Handbook of Chemical Hazard Analysis Procedures (FEMA, U.S. DOT and U.S. EPA, 1989) was also used as a guideline for modeling. The ARCHIE computer program offers a selection of hazard assessment modeling options. Option a, "Estimate Discharge Rate of Liquid or Gas", was used to model the release of ammonia into the atmosphere. This model was chosen because the potential worst case scenario involves the emptying of a storage vessel through open lines. Option d, "Evatuate Toxic Vapor Dispersion Hazards", was used to model the dispersion hazard of the potential release of ammonia into the atmosphere. The ARCHIE computer program recommends that hazard evaluations for emergency planning purposes should strive to assume the worst reasonable and credible conditions. Thus, the following, most pessimistic atmospheric conditions were chosen for modeling purposes for case number 1, 2 and 3. * Atmospheric Stability Class F Generally considered the most hazardous atmospheric condition for toxic gas releases, the stability of Class F results in minimal dispersion of the potential ammonia release and will only occur at night. Page 17 * Windspeed = 4.5 mph Low windspeed results in longer fumigation times and further downwind distances. Windspeed for Class F conditions ranges from 4.5 - 6.7 mph. * Ambient Temperature = 70°F Class F conditions occur at nighttime. The warmest ambient nighttime temperature for Bakersfield is 70°F (July). In addition, the following, more likely atmospheric conditions were also chosen for modeling purposes for cases 4, 5 and 6. Tabte 2 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. * Atmospheric Stab!lity Class B The most probable daytime atmospheric condition given the average ambient temperature and average windspeed for Bakersfield. * Windspeed = 6.4 The annual average windspeed for Bakersfield. * Ambient Temperature = 77.7°F The annual average ambient daytime temperature for Bakersfield. Page 18 A. Summary of Modeling Results A summary of the modeling results are tabulated below followed by a brief synopsis of each case. A computer generated hard copy of the model input and output data files for all six cases are attached in Appendix VI. I Amount of Arrival time Case Ammonia Radius of to IDLH Radius of Arrival time Number released IDLH Radius LOC to LOC (Pounds) (Miles) (Minutes) (Miles) (Minutes) Case 1: Represents discharge from a broken, 2.5" ID liquid ammonia tine off the high pressure receiver (4900 lb liquid ammonia release) with worst case atmospheric conditions. Scenario results have been plotted in Exhibits 9 and 10. Case 2: Represents discharge from a broken, 1 1/4" I.D. liquid ammonia line off the ammonia chiller (2000 lb liquid ammonia release) with worst case atmospheric conditions (Exhibit 11). Case 3: Represents discharge from broken, 1" I.D. liquid ammonia line (26 lb liquid amrhonia release), approximately 150" long, between carbo coolers and compressor room with worst case atmospheric conditions (Exhibit 11). Page 19 Case 4: Same as Case I except with the most likely atmospheric conditions (Exhibit 12). Case 5: Same as Case 2 except with most likely atmospheric conditions (Exhibit 13). ' Case 6: Same as Case'3 except with most likely atmospheric conditions (Exhibit 13). B. Receptor Locations The community surrounding the Crystal GeYSer facility is shown in Exhibit 14; immediately surrounding the facility to the South is a residential apartment complex. Sensitive receptors located near the facility include: Approximate Distance Receptor (miles) Direction Owens School 0.38 SW Special Services School 0.44 ENE Our Lady of Guadalupe School 0.69 W Williams School 0.69 NE Mt. Vernon School 0.94 ~ ESE Bethel Christian School 1 E These school locations are shown on Exhibit 15. Page 20 C. Essential Service Facilities The essential service facilities located near Crystal Geyser are: Kern Medical Center 1830 Flower Bakersfield, California Telephone: (805) 326-2000 Bakersfield City Fire Department, Station #2 716 East 21 st Bakersfield, California Telephone: 911 Page 21 IV. RISK ANALYSIS I. A. Summary of On-site and Offsite Consequences A summary of the on-site and off site consequence analysis are as follows: Failure On-site Offsite Event/Hazard Probability Consequence Consequence 1) Earthquake 4900 (lb) Iow high high NH3 release 2) Earthquake 2000 (lb) iow high high NH3 release 3) Earthquake 26 (lb) Iow high high NH.~ release 4) Improper oil drain from glycol chiller NH3 release. Iow high high 5) Compressor Worn Seals NH3 Vapor release medium Iow Iow 6) Power Failure release of NH3 to diffusion tank medium Iow Iow Use of the definitions of High, Medium, or Low were from Bakersfield Fire Department's Hazardous Material Division Risk Management and Prevention Program Preparation Guidelines and are shown in Exhibit 2. From the HazOp study, the only probability of an AHM release considered greater than a Iow probability was an AHM release resulting from worn seals on the compressor or operator error on the restarting system after a power failure. Page 22 Although the probability of occurrence of these releases is possible during the expected lifetime of the facility, the expected release of ammonia is expected to move, if at all, onto the surrounding environment in negligible concentrations. Based upon the RMPP guidelines definition of the "most likely hazards, AHM release or accidents which poses a danger to persons off site", the most likely hazard was determined to be the complete release of 4900 pounds of liquid ammonia due to a significant seismic event. Since the Iow consequence events are not a source of danger, the Iow probability releases with a high off site consequence will be considered the most likely hazard. These are combinations of concern (a Iow probability with a high consequence) which may require planning for credible events as shown in the Risk Analysis Matrix (Exhibit 2)) Page 23 TABLE 2 BAKERSFIELD AREA MEAN WIND SPEED AND DIRECTION Month Wind Speed (mph_) Wind 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 is 6.4 mph, originating from the Northwest. RISK AN~YSIS MATRIX Combinations o$ Conclusions ~k n- From Risk Analysis that c) (O · Identify Siluations of Major ("d 'T' Concern '*~ .~. . . · Situations et Considerable ZD ~ ' Concern · -'- LU m ......... ,,,,,,,,,., Combinat ns oI Concern Which. may Require Planning "" ......... for Cr0dible Events LOW MEDIUM HIGH Severity of Consequences Due to AHM Release (From RMPP Guidance for the Preoaratiou of a Risk Management and Prevention Prot-ram, November, 1989, C.a~omia Office of Emergency Serdces.) QUALITATIVE DEFINITIONS' OF PROBABILITY OF OCCURRENCE LOW: Probability. of occurrence considered unlLkely during the expected lifetime of the facility assuming normal operation and maintenance. MEDIUM: Probability of occurrenCe considered possible during the expected Lifetime of the facility. HIGH: Probability of occurrence considered sufficiently high to assume event·will occur dur/ng the expected Lifetime o£ the facility ... DEFINITIONS OF SEVERITY OF CONSEQUENCES TO PEOPLE LOW: Chemical is expected to move into the surrounding envh'om:nent La negli§ib]e concentrations. Injuries expected c~.rdy for exposure over emended periods Or when individual personal health conditions create complications. MEDILrM: Chemical is expected {o 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 expected only for ~'xpbsure over emended periods or when individual personal health conditions created compLicatibas. HIGH: Chemical is expected to move into the surrounrllng environment in concentrations sufficient to cause serious/njurics and/or deaths upon exposure. Large numbe~ of people expected to be affected. (From the EPA Technical Guidance for Hazard Analvs'i% 1987) Form FD 1593 EXHIBIT 2 HAZOP FORM: CRYSTAL GEYSER J~,~- ~qq 5 Sludy Node Number: I Equipmenl: I-t,~t/~ ~)~ ~""~ ~ '" ~ulde' Consequences Ro~ulllng from a Causes el the' * Prob- Proposed Word Devlatlor Devlallon from Normal Operation Devlallon Severlly ablllly*' Conlrols In Place MIIIgallon, 'Severily: Low (injuries unlikely), Medium (may cause injuries or dealh unless correclive measures are laken). High (expecled Io cause injury or dealh Io ieceplots) *'Pl'obabilJly: High, medium or Iow HAZOP FORM: CRYSTAL GEYSER 0~,,~- ~q~ Slud¥ Node Number: ~. Equipment: Consequences Resulting from a Causes of Ihe · Prob- Proposed Deviation Devlallon from Normal O Deviation Controls In Place Description ol Ecjuipment Operalion (~ ') ~:~lz. ~&~.~;~_t-_-.~-~-..P. L~I' (,-,~.(~) F'~,~- V,!l~ I~) ~p - ~?o-;'~.-~;;,---~ ~ i~r~ ,~ ,~,._.n~,~, .~ ,-,-~Y~/~ · $everily: Low (injuries unlikely), Medium (may cause injuries or dealh unless corrective measu[es are laken), Iligh (expected Io cause injury or dealh Io receplors) "Probabilily: High, medium or Iow HAZOP FORM: CRYSTAL Ul:Y~-r~ o,.~,y Node Number: r-' - pr ob.--~-- Proposed ~'~ulde Consequences Resulting from a Causes o! the Word Devlallon Devlallon from Normal Operallon Deviation Severlly abllll¥** Conlrols In Place MIIIgallon Descriplion o~ali°n ' ~ ' ' ' *Severily: Low (Inju *'Probabilily: High, medium or Iow HAZOP FORM: CRYSTAL GEYSER J,,,,.,_ \':t~ Sludy Node Number: /,/ Equipment: Consequences Resulllng from a Causes of lhe Prob- Proposed Devlallon Devlallon from Normal 0 Devlallon Conlrols In Place Description of Equipmenl Operalion (''5 ~) Z-.-~.e_~r ~ ~. 5~ /~"~ ~ ,4,-.~-~ - ~ ,d~,~ -/~-? *Severily: Low (injuries unlikely). Medium (may cause injuries or dealh unless correclive measures are taken), High (expecled Io cause injury or 'dealh Io receplors) "Probabilily: High, medium or Iow HAZOP FORM: CRYSTAL GEYSER Sludy Node Number: ~" Equipment: ~ / ~ ¢~--~3 Guide Consequences Resulllng from a Causes of Ihe * Prob. ProPosed Word Deviation , Devlallon'lrom Normal Operallon Deviation i Severlly .a_bllll¥** Conlrols In Place MIIIgall9n Less More Other "Severily: Low (injuries unlikely), Medium (may cause injuries or dealh unless correclive measures are laken), High {expecled lo cause injury or dealh Io receplors) ':Probabilily: High. medium or Iow /p,~ ~ /~.~ ,ve~.~,.~.,~ ~,'~~ .-- ~ ,'t.J.~ _/'i HAZOP FORM: CRYSTAL GEYSER0~,~ i~(e~, Study Node Number: ~ Equipmenl: ~ ~ Guide Consequences Resulling Item a Causes el lhe * Pro~- Proposed Word Dovlallon Devlallon from Normal Oporallon Dovlallon Severlly ablllly** Controls In Place Mlllgallon ! Description of_E-quipmenl Operalion /,)~, ,,.~. ,~, ,~,,~.. ~,~,,/"~,o/~r.~l~,~ ¢,..,~P, 'Severily: Low (injuries unlikely), Medium (may cause injuries or death unless correcl[ve measures are laken), Itigh (expecled lo cause injury or dealh Io teceplors) "Probabilily: High, medium or Iow HAZOPFORM: CRYSTAL GEYSER o~,-.- ~5c~ Study Node Number: "/ Equipment: '~ ~ Consequences Resulllng from a Causes o! the ~ Prob- Proposed Deviation Deviation from Normal Deviation Controls In Place ~,,,.~ ~ ..4..~.~-~-~--'~ ~-~'~-~ ~ . ' .. ~' -~,,,,,~ .... t~,~ '~ /'lnh texoecled lo cause injury or dealh lo ~eceplo~s)d"-,- ~ · °Severity: Low (injuries unlikely), Medium (may cause injuries or oealh umess correcT,ye [ne .............. n,, I- = , ~ "Pl'obability: Fligh, medium o~' Iow ~ ~'~'"~ ~ ~ ~'~9 /~l~, · · ' HAZOP FORM: CRYSTAL GEYSER~)~,.~ 1~157 Slud¥ Node Number: ~ Equipmenl: ~ ~ Guide Consequences Resulllng Irom a Causes ol lhe * Prob- Proposed Word Devlallon Devlallon from Normal Operallon Deviation Severlly ~blllly" Conlrols In Place ~]lllgallon More ~ Descriplion ol Equipmenl Operation ~ ~ ~ ~ ~_ ;-5~,u,~b,.~ ~:~ u.,;~l, ~ ~ '8evedly: Low (injuries unlikely), Medium (may cause injuries or dealh unless correclive measures are laken), High (expecled Io ~ause injur~ or dealh Io ""Probabilil~: tligh, medium or Iow HAZOP FORM' CRYSTAL GEYSER ~)u,,~ Viq'5 S~udv Node Numbor: ~1 Equipmenl: ~ Consequences Resulllng from a Causes ol Ihe Prob- P~oposed ~ Deviation Conlrols In Place Devlallon. Devlallon Irom Normal 0 ~~'- ~ ~ ~ ~~--ar; laken' Ili-h ,ex~ec ed Io cause injury~or dealh Io ,eceplors) ~ .. ~. ~ ,.,._,_, ~;,,~ i ay cause Jn'ulies or dealh unless corrocuve measurub , i, s ~ · Sevedly: Low [injuries-un~ ~U~yl, ,~,~u,~,,, ~m ~ J "P~obabilily: tligh, medium or Iow HazOp - Crystal Geyser Study Node Number 10 August 1993 Equipment/Process Description - Oil Drainage from Ammonia System There are two places which to check and remove oil form the ammonia refrigerant system. The most common place from which to remove oil is from the oil separators located next to the ammonia compressors in the compressor room. If oil gets past the oil separators it will accumulate and can be removed from the bottom of the glycol chiller, also located in the compressor room. Normal operating procedures require that only qualified personnel, properly trained, are allowed to remove oil from the system. The system has been designed to normally capture and remove oil from the ammonia in the oil separators. The oil separators are equipped with isolation valves that will allow for the safe removal of oil from the separators. When trained personnel are performing this task, normal operating procedures call for the compressor room to be put into the emergency ventilation mode. Normal operating procedures also require that all oil during be done into a 5 gallon bucket of water, which will absorb ammonia that is released with the oil. Though it is not expected, if oil gets past the separators it will accumulate in the bottom of the glycol chiller. The same normal operating procedures apply for removing oil from the glycol chiller as they do for the oil separator. The following deviations from normal operation of draining oil, along with the possible causes of the deviations, resulting consequences, severity, probability and controls in place have been identified on the following page. Haz Op - Crystal Geyser Study Node 10 DEVIATION CONSEQUENCES CAUSES SEVERITY PROBABILITY CONTROLS IN PLACE Isolation Release of ammonia Untrained personnel High Low Training personnel/ valves not performing work emergency ventilator closed No water used Release of ammonia Untrained personnel Low Low Training procedures to drain oil into performing work No emergency Uncontrolled ammonia Human error Low Low Training procedures vent mode emissions 03320011.010 HazOp - Crystal Geyser Study Node Number 11 August 1993 Equipment/Process Description - Operation of Control Systems Operating Procedures and a description of the computer control panel and systems is provided in the Hazard Analysis, Appendix III. The system basically consists of Control panel R-l, Control panel R-2 and the computer control panel. R-l, the main refrigeration control panel, supplies power to the compressors, evaporative condenses and glycol pumps. The power to this panel may be turned off while still maintaining power to the R-2 and Computer control panel. This feature allows the ammonia system to be shut-down while still keeping emergency ammonia sensing devices along with room exhaust and scrubbing control systems still active. All equipment switches, with the exception of the emergency stop switch, can only be set in either a manual or automatic mode. This design feature along with installed interlocking mechanisms will always start the evaporative coolers if the compressors are running. For these reasons, potential failures or manual overrides of the computer control system have been assigned a Iow probability with a Iow severity rating. 03320011.012 HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER ~L~.~ DATE OF ASSESSMENT = JULY 1, 1993 NAME O~ DISK FILE = CRYSTAL2 ASF ~ ~ ~ ,~,,~ *** SCENARIO DESCRIPTION ~c ~ DISCHARGE OF 4900 LB PRESSURIZED AMMONIA VESSEL TO THE ATMOSPHERE ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate = 8103.4 lbs/min Duration of discharge = .605 minutes Amount discharged = 4900 lbs State of material = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 16873 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 1000000 1000000 73 1299 .25 131256 131256 950 2497 .48 37538 37538 1820 3695 .7 16078 16078 2690 4893 ..93 8523 8523 3570 6091 1.16 5157 5157 4440 7289 1.39 3409 3409 5310 8487 1.61 2400 2400 6180 9685 1.84 1771 1771 7050' ~3 10883 2.07 1355 1355 7930 12081 2.29 1067 1067 8800 13279 2.52- 861 861 9670 14477 2.75 707 707 10540 ~'~ 15675 2.97~ 591 591 11420~.'~ 16873 3.2 500 500 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. See Chapters 3 and 12~ of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .3 1.2 1299 .25 3.3 7.2 2497 .48 6.4 13.3 3695 .7 9.4 19.3 4893 .93 12.4 25.4 6091 1.16 15.4 31.4 7289 1.39 18.5 37.5 8487 1.61 21.5 43.5 9685 1.84 24.5 49.6 10883 2.07 27.5 55.6 12081 2.29 30.6 61.7 13279 2.52 33.6 67.7 14477 ~ 2.75 36.6 73.8 15675 2.97 39.6 79.8 16873 3.2 42.7 85.9 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT = 17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES'AT CONTAINER TEMP = 150 psia = 7761 mm Hg TOXIC VAPOR LIMIT = 500 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = Horizontal cylinder TOTAL WEIGHT OF CONTENTS = 4900 lbs WEIGHT OF LIQUID = 2000 lbs LIQUID HEIGHT IN CONTAINER = 2.8 feet WEIGHT OF GAS UNDER PRESSURE = 67 lbs TOTAL CONTAINER VOLUME = 201.1 ft3 = 1504 gals LIQUID VOLUME IN CONTAINER = 61.7 ft3 '~ =~ ~461.6 gals VAPOR/GAS VOLUME IN CONTAINER = 139.5 ft3 DISCHARGE HOLE DIAMETER = 2.5 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 degrees F WIND VELOCITY = 4.5 mph ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER DATE OF ASSESSMENT = JULY 1, 1993 NAME OF DISK FILE = CRYSTAL2.ASF ~/~ ,~,,?.~ *** SCENARIO DESCRIPTION DISCHARGE OF 4900 LB PRESSURIZED AMMONIA VESSEL TO THE ATMOSPHERE ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate = 8103.4 lbs/min Duration of discharge = .605 minutes Amount discharged = 4900 lbs State of material = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 50 ppm -- at groundlevel = 48275 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 1000000 1000000 73 3542 .68 17664 17664 2580 6983 1.33 3764 3764 5090 10424 1.98 1496 1496 7590 13865 2.63 780 780 10100 17306 3.28 473 473 12600 20747 3.93 315 315 15110 24188 4.59 224 224 17610 27629 5.24 167 167 20120 31070 5.89 130 130 22620 34511 6.54 103 103 25130 37952 7.19 83.7 83.7 27630 41393 7.84 69.5 '69.5 30140 44834 8.5 58.6 58.6 32640 48275 9.15 50 50 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. See Chapters 3 and 12 of the guide for details. Source height specified the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .3 1.2 3542 .68 9 18.5 6983 1.33 17.7 35.9 10424 1.98 26.4 53.3 13865 2.63 35.1 70.7 17306 3.28 43.8 88.1 20747 3.93 52.4 . 105.4 24188 4.59 61.1 122.8 27629 5.24 69.8 140.2 31070 5.89 78.5 157.6 34511 6.54 87.2 175 37952 7.19 95~9 192.3 41393 7.84 104.6 209.7 44834 8.5 113.3 227.1 48275 9.15 122 244.5 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT = 17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia = 7761 mm Hg TOXIC VAPOR LIMIT = 50 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = Horizontal cylinder TOTAL WEIGHT OF CONTENTS = 4900 lbs WEIGHT OF LIQUID = 2000 lbs LIQUID HEIGHT IN CONTAINER = 2.8 feet WEIGHT OF GAS UNDER PRESSURE = 67 lbs TOTAL CONTAINER VOLUME = 201.1 ft3 = 1504 gals LIQUID VOLUME IN CONTAINER = 61.7 ft3 = 461.6 gals VAPOR/GAS VOLUME IN CONTAINER = 139.5 ft3 DISCHARGE HOLE DIAMETER = 2.5 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 degrees F WIND VELOCITY = 4.5 mph ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER , BAKERSFIELD DATE OF ASSESSMENT = JULY 1, 1993 NAME OF DISK FILE = CRYSTAL3.ASF -" *** SCENARIO DESCRIPTION DISCHARGE OF 2000 LB PRESSURIZED AMMONIA VESSEL : TO THE ATMOSPHERE ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate = 2024.6 lbs/min Duration of discharge = 1.02 minutes Amount discharged = 2049 lbs State of material = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 11353 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 i .02 1000000 1000000 73 904 .18 61634 61634 660 1708 .33 20971 20971 1250 2512 .48 10952 10952 1830 3315 .63 6659 6659 2420 4119 .79 4390 4390 3000 4923 .94 3064 3064 3590 5727 1.09 2235 2235 4170 6530 1.24 1689 1689 4760 7334 1.39 1313 1313 5340 8138 1.55 1046 1046 5930 8942 1.7 850 850 6510 9745 1.85 703 703 · 7100 10549 2 589 589 7680 11353 2.16 500 500 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. See Chapters 3 and 12 of the guide for details, source'rheight specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .3 1.6 904 .18 2.3 5.6 1708 .33 4.4 9.7 2512 .48 6.4 13.8 3315 .63 8.4 17.8 4119 .79 10.5 21.9 4923 .94 12.5 25.9 5727 1.09 14.5 30 6530 1.24 16.5 34 7334 1.39 18.6 38.1 8138 1.55 20.6 42.2 8942 1.7 22.6 46.2 9745 1.85 24.7 50.3 10549 2 26.7 54.3 11353 2.16 28.7 58.4 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT ~= 17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia = 7761 mm Hg TOXIC VAPOR LIMIT = 500 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = Horizontal cylinder TANK DIAMETER = 3.08 feet TANK LENGTH = 22 feet TOTAL WEIGHT OF CONTENTS = 2049 lbs WEIGHT OF LIQUID = 2000 lbs LIQUID HEIGHT IN CONTAINER = 1.3 feet WEIGHT OF GAS UNDER PRESSURE = 49.2 lbs TOTAL CONTAINER VOLUME = 164 ft3 = 1226 gals · LIQUID VOLUME IN CONTAINER = 61.7 ft3 = 461.6 gals VAPOR/GAS VOLUME IN CONTAINER = 102.3 ft3 DISCHARGE HOLE DIAMETER = 1.25 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 degrees F WIND VELOCITY = 4.5 mph ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER , BAKERSFIELD DATE OF ASSESSMENT = JULY 1, 1993 NAME OF DISK FILE = CRYSTAL3.ASF ~.! *** SCENARIO DESCRIPTION DISCHARGE OF 2000 LB PRESSURIZED AMMONIA VESSEL TO THE ATMOSPHERE ******* DIscHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate = 2024.6 lbs/min Duration of discharge = 1.02 minutes Amount discharged = 2049 lbs State of material = Mix of gas/aerosol ******* TOxic VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 50 ppm -- at groundlevel = 32208 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 1000000 1000000 73 2394 .46 11896 11896 1750 4687 .89 3388 3388 3420 6981 1.33 1462 1462 5090 9274 1.76 784 784 6760 11568 2.2 480 480 8430 13861 2.63 321 321 10090 16154 3°06 228 228 ~'~ 11760 18448 3°5 170 170 13430 20741 3.93 131 131 15100 23035 4.37 104 104 16770 25328 4.8 84.5 84.5 18440 27621 5.24 69.9 · 69.9 20110. ~ 29915 5.67 58.7 58.7 21780 32208 6.1 50 50 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. See Chapters 13 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .3 1.6 2394 .46 6.1 13.2 4687 .89 11.9 24.7 6981 1.33 17.7 36.3 9274 1.76 23.5 47.9 11568 2.2 29.3 59.5 13861 2.63 35.1 71.1 16154 3.06 40.8 82.7 18448 3.5 46.6 94.2 20741 3.93 52.4 105.8 23035 4.37 58.2 117.4 25328 4.8 64 129 27621 5.24 69.8 140.6 29915 5.67 75.6 152.2 32208 6.1 81.4 163.7 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT = 17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia = 7761 mm Hg TOXIC vAPOR LIMIT = 50 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = Horizontal cylinder TANK DIAMETER = 3.08 feet TANK LENGTH = 22 feet TOTAL WEIGHT OF CONTENTS = 2049 lbs WEIGHT OF LIQUID = 2000 lbs LIQUID HEIGHT IN CONTAINER = 1.3 feet WEIGHT OF GAS UNDER PRESSURE = 49.2 lbs TOTAL CONTAINER VOLUME = 164 ft3 · = 1226 gals LIQUID VOLUME IN CONTAINER = 61.7 ft3 = 461.6 gals VAPOR/GAS VOLUME IN CONTAINER = 102.3 ft3 DISCHARGE HOLE DIAMETER = 1.25 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 degrees F WIND VELOCITY = 4.5 mph ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER , BAKERSFIELD ~ ~ .... -,,, DATE OF ASSESSMENT = JULY 1, 1993 ~ ' .... " "~"'~ NAME OF DISK FILE = CRYSTAL1.ASF DISCHARGE OF AMMONIA FROM A BROKEN HIGH PRESSURE LINE. ******* DISCHARGE RATE/DURATION ESTIMATES Discharge from long distance liquid pipeline Average discharge rate = 2598.9 lbs/min Duration of discharge = .011 minutes Amount discharged = -500 lbs State of material = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 2012 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 1000000 1000000 73 237 .05 161976 161976 180 374 .08 45057 45057 280 510 .1 19043 19043 380 647 .13 9969 9969 480 783 .15 5943 5943 570 920 .18 3866 3866 670 1056 .2 2677 2677 770 1193 .23 1942 1942 870 1329 .26 1462 1462 970 1466 .28 1133 1133 1070 1602 .31 899 899 1170 1739 .33 728 728· 1270 1875 .36 599 599 1370 2012 .39 500 500 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. See Chapters 13 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .3 .6 237 .05 .6 1.3 374 .08 1 1.9 510 .1 1.3 2.6 647 .13 1.7 3.3 783 .15 2 4 920 .18 2.4 4.7 1056 .2 2.7 5.4 1193 .23 3.1 6.1 1329 .26 3.4 6.8 1466 .28 3.8 7.5 1602 .31 ~ 4.1 8.2 1739 .33 4.4 8.8 1875 .36 4.8 9.5 2012 .39 5.1 10.2 CAUTION: See guide for assumptions used in estimating these times. INPUT'PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT = 17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia = 7761 mm Hg TOXIC VAPOR LIMIT = 500 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = Pipeline PIPELINE DIAMETER = 1 inches PIPELINE LENGTH = 150 feet = .03 miles INTERNAL PIPELINE PRESSURE = 150 psia LIQ HEIGHT IN PIPELINE = 10 feet NO. PIPELINE DISCHARGE POINTS = 2 TOTAL WEIGHT OF CONTENTS = 26.6 lbs WEIGHT OF LIQUID = 26.6 lbs LIQUID HEIGHT IN CONTAINER = 0 feet WEIGHT OF GAS UNDER PRESSURE = 0 lbs TOTAL CONTAINER VOLUME = .9 ft3 = 6.8 gals LIQUID VOLUME IN CONTAINER = .9 ft3 = 6.8 gals DISCHARGE HOLE DIAMETER = 1 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 degrees F WIND VELOCITY = 4.5 mph ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER , BAKERSFIELD..~ .... . ~.~.~ DATE OF ASSESSMENT = JULY 1, 1993 NAME OF DISK FILE = CRYSTAL1.ASF ~s~ *** SCENARIO DESCRIPTION DISCHARGE OF AMMONIA FROM A BROKEN HIGH PRESSURE LINE. ******* DISCHARGE RATE/DURATION ESTIMATES Discharge from long distance liquid pipeline Average discharge rate = 2598.9 lbs/min Duration of discharge = .011 minutes Amount discharged = -500 lbs State of material = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 50 ppm -- at groundlevel = 5060 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 1000000 1000000 73 455 .09 26115 26115 340 809 .16 5446 '5446 590 1163 .23 2074 2074 850 1517 .29 1035 1035 1110 1872 .36 602 602 1370 2226 .43 387 387 1630 2580 .49 266 266 1880 2934 .56 193 193 2140 3289 .63 145 145 2400 3643 .69 113 113 2660 3997 .76 89.1 89.1 2910 4351 .83 · 72.3 72.3 3170 4706 .9 59.7 59.7 3430 5060 .96 50 50 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. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .3 .6 455 .09 1.2 2.4 809 .16 2.1 4.1 1163 .23 3 5.9 1517 .29 3.9 7.7 1872 .36 4.8 9.5 2226 .43 5.7 11.3 2580 .49 6.6 13.1 2934 .56 7.5 14.9 3289 .63 8.4 16.7 3643 .69 9.2 18.5 3997 .76 10.1 20.2 4351 .83 11 22 4706 .9 11.9 23.8 5060 .96 12.8 25.6 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT = 17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia = 7761 mm Hg TOXIC VAPOR LIMIT = 50 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = Pipeline PIPELINE DIAMETER = 1 inches PIPELINE LENGTH = 150 feet = .03 miles INTERNAL PIPELINE PRESSURE = 150 psia LIQ HEIGHT IN PIPELINE = 10 feet NO. PIPELINE DISCHARGE POINTS = 2 TOTAL WEIGHT OF CONTENTS = 26.6 lbs WEIGHT OF LIQUID· = 26.6 .lbs LIQUID HEIGHT IN CONTAINER = 0 feet WEIGHT OF GAS UNDER PRESSURE = 0 lbs TOTAL CONTAINER VOLUME = .9 ft3 = 6.8 gals LIQUID VOLUME IN CONTAINER = .9 ft3 = 6.8 gals DISCHARGE HOLE DIAMETER = 1 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 degrees F WIND VELOCITY = 4.5 mph ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER DATE OF ASSESSMENT = JULY 1, 1993 NAME OF DISK FILE = CRYSTAL2.ASF *** SCENARIO DESCRIPTION DISCHARGE OF 4900 LB PRESSURIZED AMMONIA VESSEL TO ATMOSPHERE UNDER MOST PROBABLE DAYTIME CONDITIONS ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate = 8103.4 lbs/min Duration of discharge = .605 minutes Amount discharged = 4900 lbs State of material = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 2131 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 518607 518607 350 246 .05 91083 91083 850 391 .08 36182 36182 1360 536 .11 18310 18310 1860 681 .13 10446 10446 2360 826 .16· 6472 6472 2860 971 .19 4268 4268 3370 1116 .22 2956 2956 3640 1261 .24 2130 2130 3440 1406 .27 1584 1584 3210 1551 .3 1210 1210 2930 1696 .33 946 946 2590 1841 .35 753 · 753 .2150 1986 .38 610 610 1550 2131 .41 500 500 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. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .2 1 246 .05 .5 1.5 391 .08 .7 2 536 .11 1 2.6 681 .13 1.3 3.1 826 .16 1.5 3.6 971 .19 1.8 4.1 1116 .22 2 4.6 1261 .24 2.3 5.1 1406 .27 2.5 5.6 1551 .3 2.8 6.2 1696 .33 3.1 6.7 1841 .35 3.3 7.2 1986 .38 3.6 7.7 2131 .41 3.8 8.2 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT = ~17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia = 7761' mm Hg TOXIC VAPOR LIMIT. = 500 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = Horizontal cylinder TOTAL WEIGHT OF CONTENTS = 4900 lbs WEIGHT OF LIQUID = 2000 lbs LIQUID HEIGHT IN CONTAINER = 2.8 feet WEIGHT OF GAS UNDER PRESSURE = 67 lbs TOTAL CONTAINER VOLUME = 201.1 ft3 = 1504 gals LIQUID VOLUME IN CONTAINER = 61.7 ft3 = 461.6 . gals VAPOR/GAS VOLUME IN CONTAINER = 139.5 ft3 DISCHARGE HOLE DIAMETER = 2.5 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 degrees F WIND VELOCITY = 6.4 mph ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER DATE OF ASSESSMENT = JULY 1, 1993 NAME OF DISK FILE = CRYSTAL2.ASF *** SCENARIO DESCRIPTION' DISCHARGE OF 4900 LB PRESSURIZED AMMONIA VESSEL TO ATMOSPHERE UNDER MOST PROBABLE DAYTIME CONDITIONS ******* .DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate = 8103.4 lbs/min Duration of discharge = .605 minutes Amount discharged = 4900 lbs State of material = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS ~ Downwind distance to concentration of 50 ppm -- at groundlevel = 4807 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less~ See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 518607 518607 350 437 .09 28647 28647 1520 773 .15 7643 7643 2680 1109 .21 3004 3004 3840 1445 .28 1469 1469 5010 1781 .34 825 825 6170 2117 .41 510 510 7340 2454 .47 337 337 8270 2790 .53 235 235 7830 3126 .6 170 170 7310 3462 .66 128 128 6670 3798 .72 97.7 97.7 5900 4134 .79' .. 76.8 76.8 .~ 4910 ~ . 4470 .85 61.5 61.5 3540 4807 .92 50 50 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. See Chapters 3 and 12 of the guide for details. Source height specified .by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTs Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .2 1 437 .09 .8 2.2 773 .15 1.4 3.4 1109 .21 2 4.6 1445 .28 2.6 5.8 1781 .34 3.2 7 2117 .41 3.8 8.2 2454 .47 4.4 9.4 2790 .53 5 10.6 3126 .6 5.6 11.8 3462 .66 6.2 12.9 3798 .72 6.8 14.1 4134 .79 7.4 15.3 4470 .85 8 16.5 4807 .92 8~.6 17.7 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT = 17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia = 7761 mm Hg TOXIC VAPOR LIMIT = 50 .ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = Horizontal cylinder TOTAL WEIGHT OF CONTENTS = 4900 lbs WEIGHT OF LIQUID = 2000 lbs LIQUID HEIGHT IN CONTAINER = 2.8 feet WEIGHT OF GAS UNDER PRESSURE = 67 lbs TOTAL CONTAINER VOLUME = 201.1 ft3 = 1504 gals LIQUID VOLUME IN CONTAINER = 61.7 ft3 ~. = 461.6 gals VAPOR/GAS VOLUME IN CONTAINER = 139.5 ft3 DISCHARGE HOLE DIAMETER = 2.5 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 degrees F WIND VELOCITY = 6.4 mph ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS ~ LOCATION = CRYSTAL GEYSER , BAKERSFIELD DATE OF ASSESSMENT = JULY 2, 1993 NAME OF DISK FILE = CRYSTAL3.ASF *** SCENARIO DESCRIPTION DISCHARGE OF 2000 LB PRESSURIZED AMMONIA VESSEL TO ATMOSPHERE UNDER MOST PROBABLE DAYTIME CONDITIONS ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate = 2024.6 lbs/min Duration of discharge = 1.02 minutes Amount discharged = 2049 lbs State of material = Mix of gas/aerosol ***.****TOXIC VAPORDISPERSION ANALYSIS RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 1492 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 129572 129572 350 200 .04 33968 33968 700 299 .06 15473 ~15473 1040 399 .08 8845 8845 1380 498 .1 5721 5721 1730 598 .12 3986 3986 2070 697 .14 2911 2911 2420 796 .16 2196 2196 2530 896 .17 1697 1697 2390 995 .19 1338 1338 2230 1095 .21 1071 1071 2030 1194 .23 870 870 1790 1293 .25 716 716 1490 1393 .27 596 596 1080 1492 .29 500 500 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. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .2 1.4 200 .04 .4 1.8 299 .06 .6 2.1 399 .08 .8 2.5 498 .1 .9 2.8 598 .12 1.1 3.2 697 .14 1.3 3.5 796 .16 1.5 3.9 896 .17 1.6 4.3 995 .19 1.8 4.6 1095 .21 2 5 1194 .23 2.2 5.3 1293 .25 2.3 5.7 1393 .27 2.5 6 1492 .29 2.7 6.4 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT = 17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia = 7761 mm Hg TOXIC VAPOR LIMIT 500 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE - Horizontal cylinder TANK DIAMETER = 3.08 feet TANK LENGTH = 22 feet TOTAL WEIGHT OF CONTENTS = 2049 lbs WEIGHT OF LIQUID = 2000 lbs LIQUID HEIGHT IN CONTAINER = 1.3 feet WEIGHT OF GAS UNDER PRESSURE = 49.2 lbs TOTAL CONTAINER VOLUME = 164 ft3 = 1226 .. gals. LIQUID VOLUME IN CONTAINER = 61.7 ft3 = 461.6 gals VAPOR/GAS VOLUME IN CONTAINER = 102.3 ft3 DISCHARGE HOLE DIAMETER = 1.25 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 degrees F WIND VELOCITY = 6.4 mph ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER , BAKERSFIELD DATE OF ASSESSMENT = JULY 2, 1993 NAME OF DISK FILE = CRYSTAL3.ASF *** SCENARIO DESCRIPTION DISCHARGE OF 2000 LB PRESSURIZED AMMONIA VESSEL TO ATMOSPHERE UNDER MOST PROBABLE DAYTIME CONDITIONS ******* DISCHARGE RATE/DURATION ESTIMATES' Liquefied gas discharge from outlet <= 4~.in. from tank Average discharge rate = 2024.6 lbs/min Duration of discharge = 1.02 minutes Amount discharged = 2049 lbs State of material = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 50 ppm -- at groundlevel = 3510 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 129572 129572 350 344 .07 11795 11795 1200. 588 .12 4122 4122 2040 831 .16 2002 2002 2880 1075 .21 1119 1119 3730 1318 .25 683 683 4570 1562 .3 446 446 5410 1805 .35 306 306 6030 2049 .39 219 219 5700 2292 .44 162 162 5320 2536 .49 123 123 4860 2780 .53 95.5 95.5 4290 3023. .58 75.8 75.8 3570 . 3267 .62 61.1 61.1 2570 3510 .67 50 50 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. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .2 1.4 344 .07 .7 2.3 588 .12 1.1 3.2 831 .16 1.5 4 1075 .21 2 4.9 1318 .25 2.4 5.8 1562 .3 2.8 6.6 1805 .35 3.3 7.5 2049 .39 3.7 8.3 2292 .44 4.1 9.2 2536 .49 4.6 10.1 2780 .53 5 10.9 3023 .58 5.4 11.8 3267 .62 5.9 12.7 3510 .67 6.3 13.5 CAUTION: See guide for assumptions used in estimating these times. IN~UT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT I = 17 LIQUID SPECIFIC GR~,VITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia TOXIC VAPOR LIMIT = 7761 mm Hg l = 50 ppm CONTAINER CHARACTERISTI S CONTAINER TYPE I = Horizontal cylinder TANK DIAMETER = 3.08 feet TANK LENGTH I = 22 feet TOTAL WEIGHT OF CONTENTS = 2049 lbs ! = 2000 lbs WEIGHT OF LIQUID LIQUID HEIGHT IN CpNTAINER = 1.3 feet WEIGHT OF GAS UNDER PRESSURE = 49.2 lbs TOTAL CONTAINER voLuME = 164 ft3 · i = 1226 gals LIQUID VOLUME IN CbNTAINER = 61.7 ft3 I = 461 6 gals VAPOR/GAS VOLUME IN CONTAINER = 102.3 ft3 DISCHARGE HOLE DIAMETER = 1.25 inch(es) DISCHARGE COEFFICIiENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION iCHARACTERISTICS AMBIENT TEMPERATURE = 77.7 degrees F WIND VELOCITY I = 6.4 mph ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARdE HEIGHT = 0 feet KEY RESULTS PROVIDED B~ USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT sOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER , BAKERSFIELD DATE OF ASSESSMENT = JULY 2, 1993 NAME OF DISK FILE = CRYSTAL1.ASF *** SCENARIO DESCRIPTION DISCHARGE OF AMMONIA FROM PRESSURIZED LINE DURING MOST PROBABLE DAYTIME CONDITIONS ******* DISCHARGE RATE/DURATION ESTIMATES Discharge from long distance liquid pipeline Average discharge rate = 2598.9 lbs/min Duration of discharge = .011 minutes Amount discharged = 28.6 lbs State of material = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALysIs RESULTS~ Downwind distance to concentration of 500 ppm -- at groundlevel = 363 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 20784 20784 350 119 .03 12636 12636 420 138 .03 8265 8265 480 157 ' ' .03 5708 5708 550 175 .04 4111 4111 610 194 .04 3062 3062 620 213 .05 2344 2344 590 232 .05 ·1835 1835 560 250 .05 1465 1465 530 269 .06 1188 1188 490 288 .06 978 978 450 307 .06 815 815 390 325 .07 686 686 .~ 330 · · 344 .07 583 583 230 363 .07 500 500 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. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .2 .4 119 .03 .3 .5 138 .03 .3 .6 157 .03 .3 .6 175 .04 .4 .7 194 .04 .4 .7 213 .05 .4 .8 232 .05 .5 .9 250 .05 .5 .9 269 .06 .5 1 288 .06 .6 1.1 307 .06 .6 1.2 325 .07 .6 1.2 · 344 .07 .7 1.3 363 .07 .7 1.4 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL· PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT = 17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia = 7761 mm Hg TOXIC VAPOR LIMIT = 500 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = Pipeline PIPELINE DIAMETER = 1 inches PIPELINE LENGTH = 150 feet = .03 miles INTERNAL PIPELINE PRESSURE = 150 psia LIQ HEIGHT IN PIPELINE = 10 feet NO. PIPELINE DISCHARGE POINTS = 2 TOTAL WEIGHT OF CONTENTS = 26.6 lbs WEIGHT OF LIQUID = 26.6 lbs LIQUID HEIGHT IN CONTAINER = 0 feet WEIGHT OF GAS UNDER PRESSURE = 0 lbs TOTAL CONTAINER VOLUME = .9 ft3 = 6.8 gals LIQUID VOLUME IN CONTAINER = .9 ft3 = 6.8 gals DISCHARGE HOLE DIAMETER = 1 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 degrees F WIND VELOCITY = 6.4 mph ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED ~%ZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER , BAKERSFIELD DATE OF ASSESSMENT = JULY 2, 1993 NAME OF DISK FILE = CRYSTAL1.ASF *** SCENARIO DESCRIPTION DISCHARGE OF AMMONIA FROM PRESSURIZED LINE DURING MOST PROBABLE DAYTIME CONDITIONS ******* DISCHARGE RATE/DURATION ESTIMATES Discharge from long distance liquid pipeline Awerage discharge rate = 2598.9 lbs/min Duration of discharge = .011 minutes Amount discharged = 28.6 lbs State of material = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance t° concentration of 50 ppm -- at groundlevel = 805 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Groundlevel Source Height Initial Evacuation Concentration Concentration Zone Width* (feet) (miles) (ppm) (ppm) (feet) 100 .02 20784 20784 350 151 .03 6381 6381 530 201 .04~ 2765 2765 700 251 .05 1447 1447 870 302 .06 853 853 1050 352 .07 546 546 1220 402 .08 371 3.71 1400 453 .09 264 264 1340 503 .1 195 195 1260 553 .11 148 148 1170 604 .12 115 115 1070 654 .13 91.1 91.1 940 704 .. .14 73.6' 7.3.6 780 754 .15 60.3 60.3 560 805 .16 50 50 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. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance Contaminant Arrival Time Contaminant Departure Time at Downwind Location at Downwind Location (feet) (miles) (minutes) (minutes) 100 .02 .2 .4 151 .03 .3 .6 201 .04 .4 .8 251 .05 .5 1 302 .06 .6 1.1 352 .07 .7 1.3 402 .08 .,~ .8 1.5 453 .09 .9 1.7 503 .1 .9 1.8 553 .11 1 2 604 .12 1.1 2.2 654 .13 1.2 2.4 704 .14 1.3 '2.6 754 .15 1.4 2.7 805 .16 1.5 2.9 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT = -27.4 degrees F MOLECULAR WEIGHT = 17 LIQUID SPECIFIC GRAVITY = .52 VAPOR PRES AT CONTAINER TEMP = 150 psia = 7761 mm Hg TOXIC VAPOR LIMIT = 50 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = Pipeline PIPELINE DIAMETER = 1 inches PIPELINE LENGTH = 150 feet = .03. miles INTERNAL PIPELINE PRESSURE = 150 psia LIQ HEIGHT IN PIPELINE = 10 feet NO. PIPELINE DISCHARGE POINTS = 2 TOTAL WEIGHT OF CONTENTS = 26.6 lbs WEIGHT OF LIQUID = 26.6 lbs LIQUID HEIGHT IN CONTAINER = 0 feet WEIGHT OF GAS UNDER PRESSURE = 0 lbs TOTAL CONTAINER VOLUME = .9 ft3 = '"6.8 gals LIQUID VOLUME IN CONTAINER = .9 ft3 = 6.8 gals DISCHARGE HOLE DIAMETER = 1 inch(es) DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 degrees F WIND VELOCITY = 6.4 mph ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED ANNEX lll.3.e LOGISTICS Items to be addressed in this Annex: (1) Medical needs [21 Information on emergency health care (2745.8(a)(4)) [21 Proper first-aid and emergency medical treatment procedures (2765.2(a)(1)(B)) (2) Site security (3) Communications (4) Transportation (5) Personnel support (6) Equipment maintenance and support [21 Maintenance procedures (Program 2)(2755.5) [21 Mechanical integrity of the system (Program 3)(2760.5) CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES PREVENTATIVE MAINTENANCE CHECK LIST 1. While the system is in operation check the roi. lowing: Refrigerant sight glass: Clear - OK Bubbles - Low on refrigerant - Foam - Very low 2. Oil sight glass level should be in center of glass. 3. Operating thermostat set point. 4. Safety thermostat set point. 5. Glycol level and concentration. 6. Evap condenser: Bleed off - Clean sump and spray nozzles, chemicals, fans & pump. 7. Suction and discharge Pressures. 8. Listen 'for strange noises, bad bearings compressor knock. .... ~9", .Check all breakers and overloads, · ~.:~'.!0, Clean pump strainer, ?~?~i..!ilt~.~..~.._... _ . checkjby-pass & ~low switch by turning o~ glycol pumps, /?~?.~7/".~'<~'/Syst'em.. _ _ should pump down and turn off. ~?~i~2'.'J<<TUrn~'6~<re~rigerant--"-- - - solenoid and see If system will pump '%'.i,:.3/~%?~j~.~I~/~ a'~'Qh~.~d'~shut off at about 10-20 PSIG. "~>%~:%n'.~~' ?'i{-.;~:-~.'~ '" ' ""' ".-~.' ' :' ,.' · ' ' ~?~%~:]~!]~?~?~Check~.~.for.'..vibration, loose clamps, cap tubes vibrating and/or ~l~.='~'~'{'~.lL.l'56g compressor hours. .~.'"~1~5''. During.~times o~ llght-load turn o~ the lead compressor and "· ' let"~'~2...get more run time. MAINTENANCE SCHEDULE WEEKLY 1. Log the compressor operating hours. 2. Check the oil level in the compressors. 3. Check the refrigerant sight glasses for bubbles. · 4. Check fans & pump in evap condenser for proper operation. ~' "5. Check tower chemicals. MONTHLY 1.~ Shut doW~ the system, drain the condenser sump and clean sump.'& pump strainer in the condenser. Check for scale. 2. Check the strength of the glycol solution. 30% to 40%, 1.034 to 1.049 SPECIFIC GRAVITY. 3. Turn off the glycol pumps & check to see if the flow switch turns off the refrigerant solenoids. 4. Check for loose.pipe clamps. · 'YEA~R~ Y 1'. Descale 'the condenser if necessary. '..'. :. 2. Replace refrigerant driers. (More often if necessary) ' 3. Check the condenser fan belts. · "~<'-<~:<!<:.',5.Check the gauges for proper calibration. · '..jili?i2,?u6.',Check the compressors per Carrier reco~endations. · 'i:.-?<~[~?f'8~i~:-.i''check thermometer and thermostat cal lbrat ion. - .~]:~.]:'~%~:~ .... -Flush the cooling coil drain pans, if any, with fresh water - .'." '..~}][:'7%~. '.:" tO"Clean an'd-~Check for proper drainage. .. · -.;:..' 10. Turn .off power and tighten all electrical connections in the control panel. Parts Needed: GENERAL INSPECTION URGENT EXT CALL. CUSTOMER SYSTEM DATE JOB TYPE OF SERVICE CHKD COMPLETE FOLLOW-U] ( ) CHECK REFRIGERi~T LEVEL & RECORD ( ) IF LOW, ADD GAS AND LEAK CHECK ( ) CHECK FOR LOOSE CLAMPS · ( ) CHECK FOR VIBRATION, CAP TUBES, ETC. (') LOOK FOR OIL LE~S (.)' 'cLEAN ,UP THE EQUIPMENT ~ ~' ..(') R~PLACE DRIER CORES ( ] PRIME RUSTY AREAS W/RED OXIDE ( ) CHECK OIL RETURN SYSTEM COMPRESSOR h CHKD COMPLETE FOLLOW-UP ( ) CHECK OIL LEVEL ( ) ~ cHEcK UNLOADER SETTINGS ( ) cHECK COMPRESSOR PULL'DOWN & VALVES ( ) TEST OIL FAILURE SWITCH, CK SETTINGS ( ) TEST-HIGH pRESSURE SWITCH, CK SETTINGS (.) TEST LOW PRESSURE swiTcH, CK SETTINGS ( ') GREASE MOTOR ( ) CHECK ALL CLAMPS ( ) CHECK COUPLINGS ( ) CHECK CRANK CASE HEATER ( ) CHECK OIL PRESSURE AND RECORD C'ONDENSER COMPLETE FOLLOW-UP CHECK FAN CHECK PUMP CHECK. BELTS CHECK ,TOWER CONDITION CHECK-NOZZLES · GREASE '~BE~'iNGS iCfU 'CLE~ IF NECESS~Y COOLING COILS CHKD COMPLETE FOLLOW-UP ( ) . C'HECK FANS ( ) CHECK DRAINS ( ) cLEAN COILS ( ) CHECK DEFROST GLYCOL SYSTEM ( ) CHECK FOR GLYCOL LEAKS ( ) CHECK FOR BAD INSULATION ( )' CHECK GLYCOL·SPECIFIC GRAVITY % ( ) CHECK GLYCOL LEVEL, LOW OK__ HIGH__ ~- ( ) CHECK PUMPS ::.) '). CLEAN PUMP STRAINERS ='- ~,.;,.?:.?:(') · CHECK'_T~K THERMOSTATS ._ .(' ) CHECK T~K THERMOMETERS ( ) CHECK CHILLER GLYCOL THERMOMETERS ·..-.-,~..i,~(.'....,.. . ) ... CHECK. . GLYCOL, FLOW-.. SWITCH. ~LECTRICAL CONTROL PANEL CHKD COMPLETE FOLLOW-UP ( ) CH~CK CONTACTS IN STARTERS & CONTACTORS ( )' TIGHTEN ALL CONNECTIONS ( )-: CHECK FOR 'LOOSE WIRES, SIGNS OF EXCESS HEAT ( ) REPLACE ANY BULBS NOT WORKING ( ) CLEAN UP WIRING SAFETY CONTROLS ( ) CHECK ALL SETTINGS CHECK FOR PROPER OPERATION ( ) HIGH PRESSURE SWITCH ( ) LOW pRESSURE SWITCH ( ). OIL FAILURE SWITCH OP]~RATING THERMOSTAT ~::~.~:.>-!:{.?i(.J) :::ii:'iFSOW .' SWITCH ( ) MA~T~R LOW PR~SBUR~ SWITCH HUMIDIFIERS ~ CHKD COMPLETE FOLLOW-UP ( i'"'.CLEJd~I-UP EXTERIOR '( ) 'CLEAN AND DRAIN SUMP ( ) CLEAN AND CHECK FLOAT VALVE ( ) CLEAN AND CHECK METERING VALVE ( ) CHECK TIMER AND CONTROL FOR PROPER OPPERATION ( ) CHECK MOTOR AND BEARINGS ( ) INSTALL' ANTI SLIME TABS COOLED CONDENSER ( ) F~I OPERATION ( ) MOTOR BEARINGS (i) DRIVE BELTS " ~..,(.:) FAN .BEARINGS CRYSTAL GEYSER MAINTENANCE RECORD EQUIPMENT: DATE: WORK_PERFORMED: CAUSE: COMMENTS: EQUIPMENT: DATE: WORK PERFORMED: CAUSE: COMMENTS: EXHIBIT 7 APPENDIX E MANNING SYSTEMS GAS CELL/'I'RANSMI'I'rER INSTRUCTION AND INSTALLATION MANUAL INSTRUCTION AND INSTALLATION MANUAL MODEL 4485 AMMONIA GAS CRT.L/TRANSMITTER Manning Systems, Inc. Serial No.__~- - 11511 West 83 Terrace ~ Lenexa, Kansas 66214 - Tel' 913-894-1185 Fax" 913-894-1296 INDEX Introduction ...... , ............. 3 " System Description and Specifications ....... 3 Specifications .................. 4 Dimensions .................... 4 Gas Sensor Assembly ............... 5 Rain Shield / Calibration Adapter ........ 6 Electrical Wiring ................ 7 Sensor Performance ................ 8 Accuracy ..................... 8 Response Time .............. ~ .... 8 Humidity ..................... 8 Sensor Life ................... 9 Interferences .................. 9 Installation ................. 10 ~ ' . Radio Frequency Interference rotection ..... 11 Start-up / Operation ................ 12 · ' Calibration ................... 13 Routine Maintenance ................ 14 Quick System Check ................ 14 '~ Troubleshooting .................. 15 Sensor Replacement ................ 15 Typical Signal Voltages ............. 15 Spare Parts List .................. 17 Warranty ...... ................ 18 · ' INTRODUCTION This manual has been prepared to help the buyers and installers of the Model 4485 Gas Transmitter to understand the operating principles of the system, initial start-up and routine maintenance procedures. Please call Manning Systems, Inc. (913-894-1185) for advice of help with any questions that may arise during installation, start-up or future maintenance. SYSTEM DESCRIPTION AND SPECIFICATIONS The Model 4485 is a two-wire transmitter designed for monitoring ammonia gas concentrations in areas where it might accumulate or leak from refrigeration or process equipment. It consists of two components: an electrochemical sensor and an electronic transmitter. The transmitter module is enclosed in anexplosion-proof enclosure. The sensor is screwed into one hub of the enclosure. The standard Model 4485 has a detecting range of 0-100 ppm ammonia. Other ranges are available up to a maximum of 0-500 ppm. The range of each Model 4485 is marked on the serial number tag attached to the transmitter module. Contact Manning Systems for information on ranges other than the standard. The 4485 ·systems are normally located at the point of measurement with the sensor simply exposed to ambient air. For outdoor applications, an accessory rain shield/calibration adapter is available. An accessory flow cell is also available for applications requiring a sampling system. For applications where ~emperat.ures may be at or below -40°F, heat tracing on the sensor and transmitter will allow reliable operations. Such appli- cations should be discussed with Manning Systems, Inc. applications engineers before purchase and installation of equipment. spECiFICATiONS: Range: 0-100 ppm ammonia Standard O- 50 ppm ammonia Minimum 0-500 ppm ammonia Maximum .Linearity: ±2% of Full Scale Repeatability: ±2% of Full Scale Lower Detectable Limit: .5 ppm Output: Isolated 4-20 mA DC, 125 ohms maximum at 12 VDC 700 ohms maximum at 24 VDC Power: 12-40 VDC, 33 mA maximum Temperature Limits: -40°F to +120°F Humidity: 10 to 99% RH non-condensing Sensor Pressure Limits: 0-10 psig Enclosure: Explosion-proof, Class 1, Group B,C,D Class 2, Group E,F Class 3, Nema 4 Weight: 3 pounds DIMENSIONS ..... FIGURE 1 - TRANSMITTER DIMENSIONS FIGURE 2 - PLUG-IN SENSOR DIMENSIONS GAS SENSOR ASSEMBLY: Series 4485 transmitters utilize a modular electrochemical sensor that requires no regular maintenance. The plug-in design allows simple and quick field replacement without special tools. The sensing element Plugs into the stainless steel hbusing, and is held in place either with an end cap as shown below, or a combination rain shield and cali- bration adapter as shown on the following page. Plug-in sensing elements will normally provide'up to 18 months or more Of operating service. They carrya full 12 month warranty, and are stable if. stored in a cool location (40°/80°F) in the sealed container in which they are shipped. 6 RAIN SHIE1.D / CALIBRATION ADAPTER: The electrochemical sensor used to detect ammonia is designed for use either indoors or outdoors. However, it is important to avoid water droplets adhering to the outside surface of the protective membrane on the front of the sensor. The water will not harm the sensor but it will form a barrier to ammonia diffusion into the sensor. Do not hose down '~he sensor directly. If this cannot be avoided, dry the tip of the sen- sor with a soft tissue. The rain shield is recommended for outdoor in- stallations. The rain shield also contains an integral calibration fitting which allows calibration gas to flow past the sensor at a controlled rate. A hose barb is provided for connection of the calibration gas. See the following drawing for dimensions of the Rain Shield/Calibration Adapter. 0 0 CAUTION: When calibrating outdoors on a windy day, it will be necessary tO temporarily block off the holes around the circumference of the rain shield. Otherwise, rapid air flow caused by wind will dilute the gas standard as it enters the sensor area. The holes need not be tightly sealed, but simply covered to prevent direct entry of high wind velocities. ELECTRICAL WIRING: The signal output of the Model 4485 Transmitter is monitored by one or two channels of the Model 21 Indicator and Alarm System (see the Model 21 Installation and Instruction Manual). Follow the wiring diagram below. Ail penetrations into a refrigerated room should be sealed with a silicone-type sealant, i.e., be sure to seal the inside of a conduit that is carryinK sensor cables. I~mmm~: We strc~l~ ~ having i~ 1~C 0 3 OUT q [. MODEL AND ALARM SYSTEM ~ ~ G G ~C · C ~0 Use Cvo-conduc~o~ shielde~ - · ~1~ for wiring distances up + - + - to 1000'. W~ recommend Bel- ~~ jo~oiolO~ ~~ den ~8760. For distances ]O~0[O~O~ greater than 1000',we recom-' ' ~ ~ t mend ~16 two-conductor '" shielded (Belden ~8Y19). ~ .3K o~, 1/4w I~RT~T: The interface board has been pre-wired to the main terminal strip at the factory. '~ NOT make any chanEes in these wires. If panel meters are used, those have also been pre-wired to the interface board.· NOTE: The Model E/C is in a Nema 4 enclosure. DONO~DONTE/C~ MITI~INA~2~RD0[~SLOCATION. Contact Manning Systems for special explosion-proof design. 8 SENSOR PERFORMANCE -ACCURACY: The accuracy of a toxic gas sensing system is basically limited by the accuracy of the standard used to calibrate the system~ For many toxic gases, obtaining a high accuracy standard that is suit- able for field calibration use is quite difficult. For this reason, no fixed accuracy statement is possible. The accuracy of a 4485 system will generally be equal to the accuracy of the calibration gas source. The best accuracy to be expected, assuming a perfect standard, is limi- ted by the repeatability which is ±2% of span. About the best accuracy achievable is 5%, using a permeation'System (where appropriate) for calibration. Bottled gas standards are general- ly ±10%. RESPONSE TIME: These electrochemical gas sensors are optimized to give the fastest possible response time while maintaining excellent zero sta- bility and minimum drift. The sensor output vs. time characteristic, for a given concentration, approximates to a logarithmic curve. An am- monia sensor will generally read 90% of actual concentration within 360 seconds. Often, a far more useful response time measurement is the time it takes for an alarm to be actuated at the TLV (Threshold Limit Value) when the sensor is exposed to either two times or five times the TLV concentra- tion. This giwes a more realistic picture of the alarm time a user can expect in a real leak condition of two different magnitudes. The current TLV for ammonia is 25 PPM. For the ammonia gas sensor, the alarm times are: 2 times TLV exposure - 45 seconds to TLV alarm 5 times TLV exposure - 9 seconds to TLV alarm HUMIDITY: Gas sensors are designed to provide stable output over a range of humidity conditions. Typical relative humidity conditions from 25% to 95% RH will not effect operation of the Series 4485 sensors. However, the user should be aware of two humidity conditions which can adversely effect sensor performance. The first potential problem is extremely dry air or sample streams. At relative humidities continuously below 20%, sensors can exhibit a loss of sensitivity after a few days to a week of operation. This is caused by a slow loss of water in the internal sensor electrolyte. Suspending the sensor over a jar of water for 24 hours will usually restore sensi- tivity~ · 9 The second potential problem is extremely wet conditions. Diffusion sen- sors rely on a relatively unobstructed gas diffusion path into the sensor. If the gas stream or ambient air is condensing on the sensor, the water droplets on the membrane will cause loss of sensitivity, or slow response, or both. Once the sensor has had a chance to dry out, normal operation should be restored. SENSOR LIFE: Series 4485 sensors will generally provide a minimum of 12 months of service in ambient air leak detection applications. Ammonia sensors are capable of operation continuously for one year in the pre- sence of 5 PPM ammonia gas. In applications where only trace levels of ammonia exist, except under leak conditions, sensor life will most likely be over 18 months. While sensors may have some, or even substantial life remaining, the factory recommendation is that sensors be replaced at a convenient interval between 12 and 18 months. Experience inca given application or plant condition will determine the best replacement fre- quency. High ammonia gas concentrations and high temperatures can reduce the life of a sensor. Continuous sensor operation at 120°F will most likely result in a maximum of 12 months sensor life. Exposure of an ammonia sensor .to percent levels of ammonia gas for more than a few hours can completely'exhaust a sensor. If this occurs, allow the sensor to recover to zero and. then carefully test with calibration gas. If the sensor responds sluggishly, replace the sensor. IN~~CES: Series 4485 sensors are designed to provide maximum sensitivity with a minimum of interference from other gases. However, there are certain gases.which .can present an interference problem, and the user should be aware of the possibility of responses from these gases. In the case of th~ ammonia sensor, the potential interferences are listed below. The table shows the relative response of an ammonia sensor to 1PPM of the interfering gas.. If these gases are present in the area where ammonia is to be sensed, the system will measure all of the inter- fering gases present at any given time. GAS RESPONSE GAS RESPONSE (PPM) (PPM) ~CO 0.03 NO 0.03 H2S 0.50 PH3 0.42 NO2 -0.23 Cl2/Br2 -0.5 HCN 0.05 H2 0.13 .O,3/F2 ~1.0 CH3SH 0.17 10 .. INSTALLATION Installation of a Model 4485 ammonia transmitter simply requires physical mounting and connection of the power/output lines. For mounting, the .transmitter enclosure is provided with bolt holes in the mounting flange. A wall mounting spacer plate is supplied with the unit and should be used as shown in the following drawing. The spacer is required in order to provide clearance for the calibration adapter to be screwed onto the sensor. The transmitter can also be supported directly from the electrical con- duit as shown. If this method is to be used, clearance must still be allowed from any surfaces so that the calibration adapter can be screwed onto the sensor. j. ~ou~ng Suffa~ ~amp Spacer " / Tm~ WALL MOUNT CONDUIT MOUNT NOTE: In Nigh moisture areas, to minimize the possibility of water con- densing in the conduit feeding the electrochemical cell, we strongly recommend to put a drip loop utilizin~ flexible conduit. BE SURE TO SEAL ALL CONDUIT CONNECTIONS. RADIO FREQUENCY INTERFERENCE PROTECTION: The Model 4485 is designed to eliminate spurious signals caused by radio frequency noise encountered in some plant environments. However, under extremely severe conditions where high-powered radio transmitters are nearby, or where high-powered hand-held radios are in use, some noise pickup can occur directly through the sensor. Installing output wiring in metallic conduit helps to in- pure that pickup does not occur %hrough wiring. 12 START-UP / OPERATION When all installation work has been completed, the transmitter is ready for operation. Prior to applying power, re-check electrical connections lo'be certain that the wiring is correct. The transmitter must be allowed to operate at least 2-4 hours to stabilize in preparation for zeroing and calibration. Both of these procedures are performed at the factory prior to shipment but should be re-checked on start-up. ZEROING: The transmitter zero is set by adjusting the output of the trans- mitter to 4mA while the sensor is exposed to air with no ammonia present. If the ambient air is known to be free of ammonia, zero gradeair is not required. If zero grade air is to be used, connect the cylinder as shown in the following drawing. NOTE: As a convenience during zeroing and calibration, a TEST terminal is provided on the transmitter terminal block. This test point provides a voltage signal proportional to ammonia concentrations which track the output signal. It is not necessary to break the power/output loop. The voltage signal at the test point is 0.04 - 0.2V (40-200 mV). 13 1. Remove the transmitter cover to allow access to the zero potentio- meter. Connect a digital voltmeter to transmitter terminals "TEST" 2. If zero air is to be used, screw the calibration adapter onto the end of the sensor and conhect a cylinder of zero grade air as shown on the previous page. "Crack" the cylinder valve and allow the zero air to flow gently through the sensor adapter for 3-5 minutes. 3. Adjust the zero potentiometer, if necessary, until the digital voltmeter reads 0.04 VDC. The transmitter is now zeroed and ready for a calibration check. CALIBRATION: Transmitter calibration requires passing an air flow con- taining a known ammonia concentration past the sensor. Best results are obtained with an ammonia concentration of 70-100% of transmitter range (minimum - 50% of transmitter range). Calibrating gas can be obtained through Manning Systems, Inc. Connect the calibrating gas cylinder as shown in the diagram on the previous page. .. 1. Screw the calibration adapter onto the end of the sensor and assemble ~ the rest of the calibration system as shown. Attach a digital volt- meter to the "TEST" and "(-)" terminals. 2. "Crack" the valve on the standard gas cylinder and allow the standard gas to flow gently through the sensor adapter for 3-5 minutes.~ NOTE: The concentration of ammonia in ppm is marked on each standard gas cylinder.. ~his is the value to be used in adjusting the transmitter. Do not use a standard gas cylinder that is over one year old. Store cylinders in a cool place to prolong their useful life. 3. Use the calibration potentiometer on the front of the transmitter to adjust the voltage on the digital voltmeter to the voltage cal- culated from the following formula: V = 0.040 + (0.160 x PPM OUTPUT/FULL SCALE PPM) For example, if the cylinder is labeled 80 ppm and the transmitter full scale range is 100 ppm, the digital voltmeter voltage should be 0.168 VDC. After calibration is complete, disconnect the calibration system and replace · t-he transmitter cover. The unit should now be operating properly and transmitting the current ammonia concentration. 14 ROUTINE MAINTENANCE The system requires no regular maintenance except that the transmitter Must be zeroed and calibrated at regular intervals. It is recommended that the.zero be checked monthly and the calibration checked every two or'three months. Ammonia gas sensors will usually gSve two or more years of service at low ammonia exposure levels. Should the protective membrane on the tip of the sensor become dirty or wet, it should be cleaned with a soft tissue and distilled water. .DO NOT USE DETERGENTS OR SOLVENTS OF ANY KIND. QUICK SYSTEM CHECK: The system can be checked periodically (at least monthly) by exposing the sensor to ammonia fumes from a bottle of house- hold cleaner containing ammonia. Open the bottle and hold it no closer than one inch from the sensor'tip. DO NOT leave the ammonia bottle under the sensor for too long or it will take a long time for the sensor to recover to zero. Do not splash liquid ammonia on the membrane. The transmitter should cause the Model 20 low and high level alarm LED's to light within a few seconds. The channel and master relays will switch over after a ten second delay. When connected to the Analygas Model 21, the transmitter will activate the audible and light alarms and switch the relay upon reaching the alarm setpoint. IMPORTANT: These electrochemical sensors are extremely reliable, but over a period of time and exposure to varying concentrations of gases, the c9!1 chemicals can become depleted. If this occurs, the unit can go "asle~f' with no outward indication of failur9 other than the sensor will not respond.' IT IS ABSOLUTELY ESSENTIAL THATTHESE UNITS BE EXERCISED WI/MAN AMMONIA SAMPLE ON A TI~.Y BASIS at least every two to four weeks when new and at least on a 1-2 week basis after the unit is more than a year old or with exposure to large concentrations of ammonia. Output signals must be verified and loRRed. 15 TROUBLESHOOTING The Model 4485 has only two components: a sensor and an electronic cir- -cuit. Fa~ure of the sensor will result in a lack of response to ammonia gas. Failure of the electronic circuit will cause a complete loss of out- put, an output which is saturated at 33 mA or instability. To isolate a problem, connect a sensor simulator to the transmitter module. A sensor simulator consists of a 100K resistor and a voltage source. Shown below is the proper connection of the sensor simulator and the input voltages required to simulate various ammonia concentrations. 16;)(5;)6;)()(5;) PPM VOLTAGE R (OHUS) , ,23 T+- 50 -0.250 OOK ,oo _o. oo. ,oo mA 500 -2.500 100K I ,o T - lOOK -~ADJU~A ~ VOL~GE SOURCE + SENSOR REPLACEMENT: Simply unscrew the sensor end cap from the hub of the transmitter enclosure, unplug the old sensor, plug in a replacement and screw back on the end cap. Replacement sensors are available through Manning Systems, Inc. Be sure to allow a new sensor a few hours to stabi- lize before zeroing and calibration. The Model 4485 gas sensors will nor- mally give two or more years of service at low exposure levels. Frequent or prolonged exposure to very high concentrations of ammonia can result in reduced sensor life. TYPICAL SIGNAL VOLTAGES: The standard Model 4485 has a detecting range of 0-100 ppm of ammonia. Other models are available up to a detecting range of 0-500 ppm of ammonia. The isolated 4-20 mA output of the standard Model 4485, when the unit is properly zeroed and calibrated, should be 4'._mA when the sensor is exposed to ammonia-free air and 20 mA when the sensor is exposed to air containing 100 ppm of ammonia. Likewise, the 0-500 Model should read out 4 mA in zero ammonia air and 20 mA when ex- posed to 500 ppm ammonia in air. 16 The Model 4485, when monitored by a Model 20, 20-B, or Model 21, will also produce a signal ~oltage at the signal test point of the unit. The signal will be in VDC and will activate the LED's, audible alarm and switch over the relays whenever the alarm trip level is exceeded. The following chart illustrates typical signal voltages which may be expected when the Model 4485 is monitored by a Model 20, 20-B or a Model 21: (readings may vary ± 2%) PPM NH3 Model 4485 mA Model 20 Model 20-B Model 21 SIG VDC SIG VDC SIG VDC 100 20 2.05 2.05 1.60 88 18 1.85 1.85 1.40 75 16 1.65 1.65 1.20 63 14 1.45 1.45 1.00 50 12 1.25 1.25 .80 38 10 1.O5 1.05 .65 25 8 .85 .85 .45 13 6 .65 .65 .30 0 4 .45 .45 .15 PPM NH3 Model 4485 mA Model 20 Model 20-B Model 21 SIG VDC SIG VDC SIG VDC 500 20 2.05 2.05 1.60 437 18 1.85 1.85 1.40 375 16 1.65 1.65 1.20 312 14 1.4~ 1.45 1.00 250 12 1.25 1.25 .80 187 10 1.O5 1.05 .65 125 8 .85 .85 .45 62 6 .65 .65 .30 0 4 .45 .45 .15 17 SPARE PARTS LIST MODEL 4485 NH3 TRANSMITTER Part No. Descriptfon 096-1024 Transmitter module 096-1023 Ammonia amplifier board 096-0534 Driver board 096-0878 Ammonia sensor, plug-in (specify ppm range) 073-0082 Transmitter enclosure 096-0876 Sensor housing assembly, with 1' cable 096-0935 End cap and gasket assembly WARRANTY - MODEL 4485 ~.T.F. CTROCHEMICAL C~.T,T. AND TRANSMI~R Manning Systems, Inc. warrants to the original purchaser and/or ultimate customer of the manufacturer's products, that if any part(s) thereof (except gas sensors) proves to be defective in material or workmanship within 18 months from the date of shipment or 12 months from the date of start-up, whichever comes first, such defective part(s), will be repaired or replaced free of charge if shipped prepaid to Manning Systems, Inc., 11511 West 83 Terrace, Lenexa, Kansas 66214, in a pack- age equ~% ~to (or) original container. ~he product will be returned freight pre- paid and repaired or replaced if it is determined by the manufacturer that the part(s) failed due to defective materials or workmanship. The repair or replace- ment of any such defective part(s) shall be Manning Systems, Inc.'s sole responsi- bility and liability under this limited warranty. Gas sensors (which are part of certain products) are covered by a 12 month war- ranty of the manufacturer. The Buyer shall be limited to the warranty of the manu- facturer of the gas sensor which is should there be a failure of the gas sensor within 12 months of shipment, the sensor will be replaced at no charge. This warranty is in lieu of all other warranties (including without limiting the generality of the foregoing, warranties of merchantability and fitness for a parti- cular purpose), guarantees, obligations or liabilities expressed or implied by the seller or its representatives and by any statute or rule of law, all of which are disclaimed by Manning Systems, Inc. Manning Systems, Inc. assumes no liability for consequential damages of any kind, and the buyer by acceptance of the equipment will assume all liability for the consequences of its use or misuse by the buyer, his employees or others. A defect within the meaning of this warranty in any part of any piece of equipment shall not, when such part is capable of being renewed, repaired or replaced, operate to condemn such piece of equipment. This warranty does not cover consumable items, batteries, or wear items subject to periodic replacement including lamps and fuses. This warranty is void if the instrument has been subject to misuse or abuse, or. has not been operated in accordance with instructions, or if the serial number has been removed. The warranty printed above is the only warranty applicable to this purchase. Ail other warranties, express or implied, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose are disclaimed. It is understood and agreed that Manning Systems, In~'s liability, whether in contract, in tort, under any warranty, in negligence or otherwise, shall not exceed the return of the amount of the purchase price paid by the buyer and under no cir- cumstances shall Manning Systems, Inc. be liable for special, indirect or conse- quential damages. The price stated for the equipment is a consideration in limiting Manning Systems, In~'s liability. No action, regardless of form, arising out of the transactions under this agreement may be brought by buyer more than one year after the cause of action has accrued. INSTRUCTION AND INSTALLATION MANUAL MOOEL 21 GAS M~N1TCRING ALARM SYST~ Manr~ng S~stems, Inc'. Serial 11 511 West 83 Terrace ~' Lenexa, Kansas 66214 ' .... ~',~-~.~1'~ CONTENTS Section Title PaRe 1 Introduction 3 Warranty 3 2 System Specifications 4 Control Unit 4 Sensors~ 4 Remote Sensor Enclosures 4 Drawing - Outdoor Mounting Enclosure 5 Indoor Mounting Enclosure 5 3 System Description 6 Electrical Power 6 Indicator Panel 6 Sensors 6 Single Sensor Units 6 Relays 7 AlaPm Trip Levels - illustration 7 Time Delays 7 Typical Time Delay Relay Wiring 8 4 Installation 9 Unpacking 9 Control Unit Location 9 Sensor Locations 9 Sensor Wiring 10 External Wiring for Model 21 11 Electrical Power Wiring 11 Relay Wiring 11 5 ' Start-up 12 ! Initial Testing 12 6 Routine Maintenance 13 How to Take Voltage Readings 13 7 "Trouble Shooting- -' 14 ~ Nuisance Gases 14 Adjusting Sensitivity 14 Fault Light 14 SECTION 1 INTRODUCTION This manual has been prepared to help the buyers and installers of the Mpdel 21 Gas Monitoring Alarm System to understand the operating principles of the system, initial start-up and routine maintenance pro- cedures. This manual should be studied in detail by the people who will install and maintain the equipment with careful attention given to sensor locations. Please call blanning Systems, Inc. (913-894-1185) for advice or help with any questions that may arise during installation, start-up or future maintenance. WARRANTY Analygas Systems Ltd., warrants gas sensing equipment manufactured and sold by us to be free from defects in materials, workmanship and performance for a per~od of one year from date of shipment. Any parts found defective within that period will be repaired or replaced, at our option, free of charge, FOB factgry. This warranty does not apply to those items which by their nature are subject to deterioration or consumption in normal ser- vice, and which must be cleaned, repaired or replaced on a routine basis. Warranty is ~oided by abuse including rough handling, mechanical damage, alteration or repair procedures not in accordance with instruction manual. This warranty indicates the full extent of liability, and Analygas is not responsible for removal or replacement costs, local repair costs, trans- portation costs or contingent expenses incurred without our prior approval. This warranty shall not apply to any Analygas products which have been al- tered in any way outside Analygas' manufacturing facilities so as to, in Analygas' judgement, affect its use, function or reliability or which shall have been subject to misuse, alteration, improper installation, painting, misapplication, negligence or accident. Analygas' obligation und~.r this warranty shall be limited to repairing or rePlacing, and returning any product which has been returned to Analyga$ at its manufacturing facilities, with transportation charges prepaid; and which Analygas' examination shall disclose to its satisfaction to have been defective. This warranty is expressly in lieu of any and all other warranties and re- presentations, expressed or implied, and all other obligations or liabili- ti~ on the part of Analygas'inc~udi~'g,-.but not limited--to, the warranty of~fitness-for a particular purpose. -In no event shall Analygas be liable for direct, incidental or consequential loss or damage of any kind'con- nected with the use of its products or failure of its product to function or operate properly. SECTION 2 SYSTEM SPECIFICATIONS THE CONTROL UNIT is manufactured of 16 gauge steel. Dimensions are i1~5/8" x 8-5/8" x 4-3/4". Shipping weight is 11 pounds. The unit is painted a dark green pebble finish enamel. It is designed to be wall- mounted in a non-hazardous atmosphere. The door is hinged and gasketed to minimize entry of dust, insects, etc. The audible alarm and four lamps (two are also switches) are mounted on the door. The lamps are visual indication of the system status. Alarm horn on the control unit provides a sound pressure level of 73 dB at 10 feet. The control unit houses the power supply, relay, electric and electronic elements and switches which power the sensors, monitor their voltages and react to the pre-set alarm trip level. SENSORS are solid state metallic oxide and are shipped mounted on the main control unit, unless the customer purchases remote sensor housings and, in that case, the sensors are shipped already mounted in the housings. REMOTE SENSOR ENCLOSURES: Sensors can be installed up to 1,000' from the main..control unit in an-enclosure especially designed for this purpose. INDOOR SENSOR ENCLOSURES are manufactured of 16 gauge steel. Dimensions are 4-1/2" x 4-1/2" x 2-1/2". Shipping weight is 2 pounds. The enclo- sure has two 7/8" holes to accept 1/2" conduit and a sensor socket. The door is hinged and gasketed to minimize entry of dust and insects. It is painted a dark green pebble finish enamel and contains a four-point terminal strip. It is designed ~to be mounted through four flange holes in a non-hazardous atmosphere. (See next page for drawing.) WEATHERPROOF ENCLOSURES are manufactured of 16 gauge steel. Dimensions are 6" x 4-1/2" x 3-1/2". Shipping weight is 3-1/2 pounds. The enclo- sure has two 7/8" holes to accept 1/2" conduit and a sensor socket. The door is gasketed and held in place by four clamps and screws'to make a weather-tight seal. It is painted a dark green pebble finish enamel and contaids a four-point terminal strip. It is designed to be mounted through four flange holes in a non-hazardous atmosphere. (See next page.) OUTDOOR HOUNT I HC ENCLOSURE -- P~OTECll~ M, nning Systems, Inc. 11511 West ~ Terrace Lenex~ KS ~214 I Loo oo) [ ~ DO0 ~ HOU~TI ~C .... ~. __ (7/8' ~1 ~anning 5ys[ems, 11¢11 We&! ~ Te~ce SECTION 3 SYSTEM DESCRIPTION The Model 21 Gas Alarm System is a broad spectrum detector uti- lizing a simple on-off alarm ci~rcuitry, which responds to the presence of r~ducing gases such as ammonia, freon, carbon monoxide, smoke, etc. ELECTRICAL POWER is conventional ll5.VAC, 60 Hz at 0.1 amp. The transformer output is 25 VDC at .5 amp. INDICATOR PANEL: The front panel of the control unit contains the audible alarm and four indicating lamps. Two of the lamps are also switches. Their functions are: Green, when lighted indicates POWER on. White ~zEST/FAULT lamp and momentary switch. When lighted, this lamp indicates a sensor wiring fault or failed sensor. When used as a switch (depressed), it~ turns on the other three lamps and sounds the audible alarm. The alarm relay, however, will not switch over. Amber WARN, ~hen lighted, indicates that the audible alarm has been silenced. Red ALARM, when lighted, indicates that an alarm condition exists. -When-used as a switch (push on-push off),.it will silence the audible alarm and will cause the amber "WARN" lamp to be lighted. SENSORS utilize a heated resistive metallic oxide element which undergoes a drastic reduction in electrical resistance in the presence of a reducing atmosphere such as ammonia vapor. Each sensor has four active electrical leads: Two red wires carry approxi- mately 5 VDC from the main control unit to the sensor's heater coil. Two orange wires "report" back to the main control unit any change in the re- sistance of the sensor's element. The presence of a reducing gas Will lower the element's resistance allowing a higher voltage through the orange wires.-(See ALARM TRIP LEVELS, Section 3.) Theoretically a sensor exposed to completely pure dry air at 60°F would have an orange wire voltage of zero. This is known as the "resting volt- age". ·This condition, however, can only be achieved in the laboratory so a sensor's resting voltage under ordinary ambient conditions can be ex- pected'to range from .2 to 1.2 VDC. SINGLE SENSOR UNITS:..While most Model 21 Gas Monitor Systems are installed to monitor two sensors, there may be a need to use only a single sensor. In these instances a 30 ohm 1 watt ballast resistor must be connected to the red wire terminals for'sensor #2 to complete the circuit left open sensor #2 is not used. 7 R~LAYS: Each.Model 21 unit is equipped with Qne output relay. The relay is energized during normal (no alarm) operating conditions and will de- energize to the alarm condition should a gas concentration exceed the pre- set alarm trip level, or in the event of a power faildre. Model 21 users may want to consider use of a 10-15 second time delay device in conjunction with the relay to minimize nuisance alarms. Silencing the audible alarm will not cause the relay to switch back to a no-alarm position. The cause of the alarm condition must be found and corrected. A~kRM TRIP LEVELS are determined at the time a customer orders a Model 21 Gas Detecting System, according to the customer's heeds and desires. The alarm trip levels are factory set but can be field adjusted as conditions change. (See NUISANCE GASES, Section 7.) The following diagram illus- trates what happens when an alarm is tripped,' why it is tripped and how alarm signals are activated. Alarm Trip Level Q Sensor orange wire voltage under normal operating conditions. O Sensor orange wire voltage exceeds 3 VDC which, in this example, is the pre-set alarm trip level. The door panel red ALARM lamp is lighted, the audible alarm sounds and the relay switches over to operate any connected equipment. The audible alarm may be silenced by pressing the red lamp switch and the amber WARN lamp'.then will be lighted. Q The condition causing the alarm (high gas concentration or power fail- uce) has been corrected.-The relay switches back to the no-alarm position. If the red lamp switch has not been depressed, the red lamp will turn off and. the audible alarm will be silenced. TIME DELAYS: The previous diagram illustrates the series of events occur- ing when~the signal voltage exceeds the alarm trip voltage. In some in- stances, this condition may exist for a few seconds, then correct itself. '- ........ A pp~er failure may occur for a few seconds-and result in an---dnnec~ssary alarm. Some Model 21-users have installed-an inexpensive time delay-on and/or del~y-off relay at the output end of the internal relay to filter . · out unnecessary alarms. (See typical layout on next page.) TYPICAL TIME DELAY RELAY WIRING 2 To'connect a Time Delay Relay ~ll IC O .. 4 ON DELAY as shown TP VCC 5 on the diagram 6 below. Relays are avail- --~ able through ALARM r---n Manning Systems ADJ. ITl or your local electrical supply I I , TPoREF house. TP SIG 1 2 ~ L N G G NC C NO OR OR R R OR oR· R R Connect L to C .@ . .@. · I Pilot Light _~~VAC Normally 0 h Button Time Delay Contact Normally Closed Normally Open I Time Delay Contact · To ADT or · " other remote · ,~ alarm system The relay is positioned as shown in the drawing below when all of the following conditions are met: - Power is applied to the monitoring unit - There are no wiring or sensor faults - The ambient gas level is below the alarm trip level When any of the following happens, · - The unit goes into alarm - AC power is lost to the unit - There is a fault alarm condition (white light on) the relay will trip causing the "C" and "NO" terminals to close, thus providing a completed'circuit to trip a remote alarm or start a vent fan. The relay is NOT INTERNALLY FUSED so Connected equipment must be pro- tected by the user. Maximum relay load rating is 3 amps. 9 SECTION 4 INSTALLATION This part of the manual has been prepared especially for the people who are to install the Model 21 Gas Monitoring Alarm System. For trouble- fr~e start-up and operation, it is important that the instructions given here be followed care'fully and completely. Direct q~estions to Manning Sys- tems, Inc. (913-894-1185) in Kansas City. UNPACKING: Inspect all boxes'and contents for shipping damage. If any screws or other metal parts are missing, they must be found to ensure that the printed circuits will not be damaged when power is applied. IMPORTANT - The installer should identify on a plant floor plan where each sensor is located~ whether it is sensor #1 or #2 and the control unit to which each sensor reports. CONTROL UNIT LOCATION: The control unit is designed to be mounted on a wall t'hrough holes in the four mounting flanges. While the physical loca- '~ tion must be determined in part by local conditions, it is important to remember the following: Protect the main control unit from rain, snow, water sprays from clean- ing crews and physical damage~ Mount the unit on a wall at eye level for convenience in taking read- ings, servicing, etc. The Model 21 is not eXplosion proof. Do not mount in a hazardous atmosphere. Operating temperature range for the control unit is 0° to 120°F. Should it be necessary to drill holes in the main unit box, be sure to remove all metal filings. These could short out the main unit printed circuits. SENSOR LOCATIONS: The sensors utilize a heated resistive metal- lic oxide element which undergoes a drastic reduction in electrical re- sistance when exposed to a reducing atmosphere, such as ammonia vapor. This resistance change.. ~s used to trigger an electronic switching circuit which in turn actuates an alarm circuit. Because each sensor can only "report" what it is "smelling" at the moment, it is very important that the sensors be located where leaks may most likely occur. '~ - Ammonia vapor iS'~'b~ut~o~half the ~eigh~-°f a~§ient air. Locate sen- ~ors'near the ceilings of equipment rooms~ blast freezers, cold rooms, etc. Contact Manning Systems for information concerning other gases. Locate sensors near the control/piping ends of evaporators and valve complexes. I0 Take air movement and ventilation patterns into account when locating sensors. When installing sensors near evaporators in refrigerated' ~paces, .keep sensors out of direct air flow from and to the evaporator and away from any moisture created during defrost. The best location usually is on the piping/control side three to four feet from the evaporator and within eighteen to twenty-four inches of the room ceiling. Blast freezer applications can be very difficult. Please contact Manning Systems to discuss. Both Sensors for one Model 21M~JST be in similar atmospheres. EXAMPLE: Do not locate Sensor #1 in a blast freezer and Sensor #2 in an equipment room. Install sensors pointing downwards. Conduit must. enter sensor enclo- sures from the bottom of the enclosure (or from the side if. the bottom cannot be used) to minimize t'he opportunity for condensation (i.e., water from wash-down procedures) to enter the enclosure. NEVER ENTER THE ENCLOSURE FROM THB TOP. All penetrations into a refrigerated room should be sealed with a silicone-type sealant. BE SURE TO SEAL THE INSIDE OF A CONDUIT THAT IS CARRYING SENSOR CABLES. Protect sensbrs from water and excessive humidity. Protect.'sensors from hose-down by clean-up crews. Mount sensor enclosures through the flange holes. Sensors may be installed up to 1000' from the control unit. (See SENSOR WIRING.) Operating temperature range for the sensors is -40°F to 120°F. Below -~5°F requires heated enclosures (contact Manning Systems). SENSOR WIRING: Power is supplied to the sensors from the control unit. Each sensor on the Model 21 requires four conductors. Use #16 AWG conductor for runs up to 300' Use #14 AWG conductor for runs from 300' to 600' Use #12 AWG conductor for runs from 600' to 1000' Run wiring in steel conduit to provide the necessary electrical shield- ing or use shielded four-conductor cable, such as Belden 16/4 #9954. -.Non-shielded wire can be used but care must be taken to keep away from ..... i.long AC lines· Keep run lengths as short.as_possible. · Care must be taken.Po notcro~s orange and red conductors between sensor '~ncl°sure and control unit terminal strips. 11 ~oo~D ~ ~ EXTERNAL WIRING FOR MODEL 21 ~'~ic o ~ . Remote Sensor #2 ocr ~,vcc ~ "' - up to 1000' 6 ~ I~ o Four Conductors ~s~o - in conduit ~-~]I I ~ L ~ ~ G NC C NO OR OR R R OR OR R R ~n~or 2 .Sensor ELE~IC~ ~ WIRING: Power requirements are 115 VAC, 60 HZ at 0.1 amps. Maximum relay rating is 115 VAC, 3 amps resistive, unpowered contacts, Form C. The instrument ~ST be correctly grounded. ~LAY ~RING: Wire the relay(s) to the required equipment. The relays have Form C contacts and are unpowered so that any required power source (pro- vided that it is within the relay's rating of up to 3 amps) may be used. The relay contacts are not interfially protected. The installer must ensure that the external circuits are properly fused. Relay wiring must be run in conduit separate from sensor wiring if the .- r~lay circuit is AC. .. . .... SECTION 5 START-UP Before Applying power~ make a final check of all wiring for continuity~ sborts~ grounds~ etc. It is usually best that external alarms and other equipment powered by the relays be disconnected from the relays until the initial start-up is completed. Be sure tha~ the sensors are in gas-free air. When power is applied, the following events should occur: IMMEDIATELY: The green POWER lamp.will be lighted. If this does not occur, check the power wiring to the unit. TEN SECONDS: The audible alarm will sound after about 10 seconds and the relay will switch over. The audible alarm may be silenced by de- pressing the ALARM switch. The WARN lamp will be lighted. TEN MINUTES: The system will stabilize to the extent that the relay will switch back and the audible alarm may be reset by again depressing the ALARM switch. Sensor elements require up to 24 hours to stabilize prior to checking calibration. If the white TEST/FAULT light turns on, check sensor wiring and connec- tions. See Section 7 - TROUBLE SHOOTING. Check sensors for physical damage, evidence 6f water or other liquid contamination. INITIAL TESTING: Allow 24 hours for the system tO stabilize before test- ing the sensors. Because sensors may be located at a distance from the main control unit, the testing time required and accuracy will be improved if two people use radio contact. Use a digital voltmeter to take a set of readings as described in Routine Maintenance, Section 6. Record these on the Reference Data Sheet shipped with the unit. Using the installer's floor plan referenced in Section 4, have one person expose each sensor to 'a small amount of a ho'usehold cleaning product con- taining ammonia. The second person will stay at the control unit to determine: That each sensor, when exposed to ammonia fumes, does trip the alarm. That, referring to the floor p~n, the proper sensor· is responding to - the ammonia gas. ' '~That'~he out'~ut relay does swi·~ch over (us'e a test light). When these tests are completed the syStem is now in proper operation and should continue to operate without further adjustments. SECTION 6 ROUTINE MAINTENANCE Very little routine maintenance is required due to the design and construc- tion of the main control unit and sensors, providing that the guidelines ~d instructions given in Section 4 have been followed. Keep the main unit enclosure clean. A cloth damp with soapy water gives good results. Never use any chemical cleaning agent. Keep the door closed, except when entry is necessarl. DAILY: Visual inspection of the door panel lamps to check system status. The green POWER lamp must be lighted. Depress the TEST/FAULT lamp/switch to check the other lamps and the audible alarm. WEEKLY: Use a digital multimeter (Radio Shack Cat. No. 22-188 does well) to take periodic readings at the main test points. Record this data for future reference. Connect multimeter black (ground) lead to the main control unit TP GND (test point ground), and the red lead to TP VCC (source). This voltage should be 12 VDC (±.2 volt). Move the red lead to TP REF (test point reference). This is the alarm trip'level at which the unit has been calibrated. This reading will vary from 1.2 VDC tO'6 VDC depending on the ppm level at which the alarm is set. to trip. Move the red lead to TP SIG (test point signal). This voltage will normally be from one-fourth to one-third of the reading noted at TP REF (previous paragraph) but will vary with changes in ambient tempera- ture, humidity and airborne contaminants at the sensors. (See also the diagram at ALARM TRIP LEVELS, Section 3.) Move the red lead to the bottom of the diode labeled #1. This is the orange wire "reporting" voltage from sensor #1. This voltage will continually vary a few hundredths of a volt. Move the red lead to the bottom of the diode labeled #2. This voltage is the orange wire "reporting" voltage from sensor #2 and will vary as does sensor #1. MONTHLY: .Expos~ each sensor to ammonia vapors. This will verify that each SenSor has a normal response and will also check alarm light and audible signals, as well as relay action. IMPORTANT: It is essential that the enclosed log sheets be utilized with signal voltages being taken and logged on a consistent basis. Periodically sensors should be exposed to an ammonia sample and the results logged. These tests should be done on a daily basis right after start-up. De- pending on environment and experience, these times can be usually ex- tended to once a month after a first few w~eks of successful operation. These sensors are mechanical devices and along with all the associated wiring, relays, etc. are subject to day-to-day exposure to physical damage requiring that the complete system be tested and wiring integrity .verified regularly. SECTION 7 TROUBLE SHOOTING Refer to the diagram at ALARM TRIP LEVELS, Section 3. The most usual reaction to a nuisance alarm is to raise the alarm trip level. Many nui- sance alarms can be traced to an unknown or unexpected source of a gas or vapor and serious efforts should be made to check these out and eliminate the source before raising the alarm trip level. NUISANCE GASES include (but are not limited to) solvents, paints, alcohols, exhaust gases from fork lifts and trucks, and even certain odorless com- pounds, such as carbon monoxide. ADJUSTING SENSITIVITY: If the interferences from nuisance gases cannot. be eliminated, it may be necessary to reduce the sensitivity of the unit by raising the alarm trip level. To raise the alarm trip level: Connect the multimeter black lead to TP GND and the red lead to TP REF in the main unit. Observe the reading. Directly above the relay is a small blue box with a small screw in the top. Raise the alarm trip level by turning the screw counter-clockwise. To lower the trip level, turn clockwise. The rate and amount of change will be noted as changes in. voltage on the voltmeter. FAULT LIGHT: Sensors are normally long-lived unless physically damaged or soaked with water (or any other liquid). When wiring has passed the initial start-up phase, ther~ is little probability of wiring problems unless physically damaged by storm or accident.. Sensors which do not have a resting voltage or are constantly showing an alarm trip voltage should~be'~replaced. . ~' ~- -' C~ii Manning Systems, Inc. at 913-894-1185 for help as necessary. SPARE PARTS - MODEL 21 22-8-1001 Momentary Action Switch 22-8-1002 Alternate Action Switch 22-8-1003 Indicator Lamp Bulb 22-8-1004 Indicator Lamp I~.nsCap=- Red, Amber, White or Green 22-8-1008 Audible Alarm c/w Mounting Ring 22-8-1009 Fuse, AGC 1/2 amp 22-8-1010 Relay 22-8-1011 Front Plate Escutcheon "Gas Alarm" 22-8-1012 Door Board c/w Lamps, switches and Connector ~- 22-8-1013 Printed Circuit Card Complete 22-8-1014 Calibration Gas Kit (includes valve, hose and fittings and two disposable cylinders containing 300 ppm ammonia) 22-8~1015 Spare Calibration Cylinder containing 300 ppm ammonia 22-8-1016 Spare Operating Manual · 22-8-1017 C~libration Gas Kit (includes valve, hose and fittings and two disposable cylinders containing 500 ppm freon) 22-8-1018 Spare Calibration Cylinder containing 500 ppm freon SENSORS WITH HOUSINGS: 22-8-1005 Ammonia type (solid-state) 22-8-1007 Freon type (solid-state) 3.0 EQUIPMENT REPORT 3.1 Ammonia Equipment The following equipment makes up the ammonia refrigeration system at Crystal Geyser Bakersfield. Each piece of equipment will be listed along with its nature, age and condition. 3.1.1 Nature, A.qe and Condition Equipment: Compressor #1 Reserved for future installation. Equipment: Compressor #2 Nature: This is a high pressure screw-type compressor package driven by a 100 horsepower, 460 VAC electric motor. It receives Iow pressure ammonia vapors and compresses them to high pressure. Manufacturer - Frick York International Model - RXB 39 Serial Number - S0421LFMNTHAA3 Age: Built in 1993 Condition: New Page 13 _ Equipment: Compressor #3 Nature: This is a high pressure screw-type compressor package driven by a 150 horsepower, 460 VAC electric motor. It receives Iow pressure ammonia vapors and compresses them to high pressure. Manufacturer - Frick York International Model - RWB II 76 Serial Number - S0348LFMPTHAA3 Age: Built in 1993 Condition: New Equipment: Compressor #4 Nature: This is a high pressure screw-type compressor package driven by a 150 horsepower, 460 VAC electric motor. It receives Iow pressure ammonia vapors and compresses them to high pressure. Manufacturer - Frick York International Model - RWB II 76 Serial Number - S0347LFMPTHAA3 Age: Built in 1993 Condition: New Equipment: Oil Separator #1 Reserved for future installation. Page 14 Equipment: Oil Separator #2 Nature: This horizontal oil separator removes oil from the high pressure ammonia " vapor discharging from the #2 compressor. Oil is drained from the separator into the compressor. Manufacturer - Frick York International Size - 16 inch O.D. by 6 feet 3inch Serial Number - NB105300 Age: Built in 1993 Condition: New Equipment: Oil Separator #3 Nature: This horizontal oil separator removes oil from the high pressure ammonia vapor discharging from the #3 compressor. Oil is drained from the separator into the compressor. Manufacturer - Frick York International Size - 20 inch O.D. by 11 feet 4 inch Serial Number - NB109133 Age: Built in 1993 Condition: New Page 15 EqUipment: Oil Separator #4 Nature:. This horizontal oil separator removes oil from the high pressure ammonia vapor discharging from the #4 compressor. Oil is drained from the separator into the compressor. Manufacturer - Frick York International Size - 20 inch O.D. by 11 feet 4 inch Serial Number - NB109132 Age: Built in 1993 Condition: New Equipment: Evaporative Condenser #1 Nature: This condenser cools the high pressure ammonia vapor to a liquid. Water running over the condenser coils cools the hot ammonia vapors flowing through the condenser coil bundle. Air is blown through the water spray to cool the water. Manufacturer IMECO Model - XLP-ML 380 Age: Built in 1993 Condition: New Page 16 Equipment: Evaporative Condenser #2 Nature: This condenser cools the high pressure ammonia vapor to a liquid. Water running over the condenser coils cools the hot ammonia vapors flowing through the condenser coil bundle. Air is blown through the water spray to cool the water. Manufacturer - IMECO Model - XLP-ML 425 Age: Built in 1993 Condition: New Equipment: Evaporative Condenser #3 Nature: This condenser cools the high pressure ammonia vapor to a liquid. Water running over the condenser coils cools the hot ammonia vapors flowing through the condenser coil bundle. Air is blown through the water spray to cool the water. Manufacturer - IMECO Model - XLP-ML 425 Age: Built in 1993 Condition: New Equipment: Evaporative Condenser #4 Reserved for future installation. Page 17 Equipment: Liquid Ammonia Receiver Nature: This horizontal receiver accepts high pressure liquid ammonia from the evaporative condenser. Manufacturer Roy E. Hanson Jr. Mfg. Size 47.4 inches O.D. by 192 inches Serial Number 338125 Age: Build in 1993 Condition: New Equipment: Kinq Valve Nature: This solenoid valve controls liquid flow from the receiver to the master accumulator. Manufacturer - Parker Model - S5A Age: Built in 1993 Condition: New Equipment: Carbo Cooler #1 Nature: Liquid ammonia flows through tubes in the carbo cooler. Heat is adsorbed from liquids being cooled by the evaporating ammonia. Manufacturer - Mojonnier Bros. Page 18 Model . - 3140 Serial Number - 6745 Age: Built in 1957 Condition: Good Equipment: Carbo Cooler #2 Nature: Liquid ammonia flows through tubes in the carbo cooler, heat is adsorbed from liquids being cooled by the evaporating ammonia. Manufacturer - Mojonnier Bros. Model - 3140 Serial Number - 6595 Age: Built in 1957 Condition: Good Equipment: Glycol Chiller Nature: In this horizontal refrigerant chiller, liquid ammonia adsorbs heat from liquids. The liquid is cooled by the evaporation of ammonia. Manufacturer - E.L. Nickel Co., Inc. Size - 37 inch ID by 22 feet Serial Number - 42878 Age: Built in 1993 Page 19 Condition: New Equipment: Master Accumulator Nature: Excess liquid ammonia boils off in the master accumulator before ammonia flows to glycol chiller and carbo coolers. Manufacturer - Roy E. Hanson Jr. Manufacturing Size - 24 inches O.D. by 120 inches Serial Number - 338126 Age: Built in 1993 Condition: New Equipment: Accumulator Nature: This horizontal-type accumulator stores excess liquid ammonia. Manufacturer E.L Nickel Co., Inc. Size - 18 inches O.D. by 18 feet Serial Number 42879 Age: Built in 1993 Condition: New Equipment: Ammonia Lines Nature: The ammonia lines carry the ammonia through the system. Page 20 Age: Installed in 1993 Condition: Good 3.1.2 Testing Schedules Testing of control equipment is necessary to ensure that the equipment will work when it is needed. Equipment Test Schedule High Pressure Cutouts Tested during compressor maintenance Pressure Relief Valves Tested when the vessel being protected undergoes maintenance. 3.1.3 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, mechanics monitor the equipment and log normal operating variables in addition to unusual conditions. Exhibit 6 is a copy .of a typical operators log used at Crystal Geyser Water Company. Conditions that may require compressor maintenance include: · High temperatures · High or Iow pressures · High oil consumption · Unusual noises · Excessive vibration · Unbalanced operation Page 21 When problems or potential problems are detected, the equipment is scheduled for maintenance. Maintenance schedules comply with manufacturers' recommended maintenance schedules. Manufacturers' equipment manuals are retained and are available for review in the Plant Manager's office. Maintenance schedules for-regularly maintained equipment are found in Crystal Geyser's Preventative Maintenance Check List (Appendix D). Page 22 CRYSTAL GEYSER COMPREK R #1 OOMPRESSOR//2 MFG. Frick York International MODI~-' RXB 39 Screw Compressor Package With Microprocessor . MOTOR: 100HP, 230/460 Volts, Serialg XIS170L0637F COMPRESSOR: Serialg S0421LP-3,EN~AAA3 OIL COOLER: 6--5/8'od X 5'0" Sealed for life Model//RWB II 76 OIL SEPERATOR: 16'od X 6'3' Horizontal ............................ ,~rial# NB105300 OIL FIL~ Serialg MC92755 CDNDITION: New 1993 COMPRESSOR #3 MFG. Frick York Intemational MODEL: RWB II 76 Screw Compressor Package MOTOR: 150HP, 230/460 Volts, Serialg TDSH163L1609B OIL COOI.FR: 6--5/8'od X 5'0" Sealed forlffe Modelg RWB II 76 OIL SEPERATOR: 20"od X Il!4" Horizontal Serialg NB109133 OIL FILTER: Serialg MC92906 CONDmON: New 1993 COMP~R//4 MFG. Frick York International MODgl-' RWB II 76 Screw Compressor Package MOTOR: 150HP, 230/460 Volts, Serialg TDSH163L1610B COMPRESSOR: Sefialg S034~ OIL COOLER: 6-5/8"od X 5'0" Sealed for life Modelg RWB II 76 Seria 108922 OIL SEPERATOR: 20"od X 11'4" Horizontal Serialg NB109132 OIL FILTER: Serialg MC92904 CONDITION: New 1993 CRYSTAL GEYSER MOD~: XLF-ML PUMP:. FAN MOTORS: (1) 5HP, 184T, 460-3-60, ODP High cfficicncy (1) BFIP, 182T, 450-B-50, ODP High cfBcicncy CONDITION: New 1993 EVAPORATIVE CONDENSER ~ MFG... IMEO0 MODr~: XLP-ML 428 PUM~. FAN MOTORS: (1) 7.SHP, 213T, 450-~, ODP High efficiency (1) 5HP, 184T, 450-B-50, ODP High c~cicncy CONDITION: New MODEL: XLP-ML 425 FAN MOTORS: (1) ?.~-IP, 21~T, 450-B-50, ODP High efficiency (~) ~n~, ~S4T, 450~, OD? High efficiency CONDITION: New EVAPORA~ITVE OONDENSER ~4 CRYSTAL GEYSER GLYCOL CHII] I~R MFG. F_.L. Nickell Co., Inc. TYPE: 37' ID X 22'~ TF-TF Horizontal Refrigerant Oailler ~ 42878 CONDITION: New 1993 ACCUMULATOR MFG. gA. Nickell Co., Inc. TYPE: 18" OD X 18'0" O.A.L. Horizontal Refrigerant Accumulator SERIALg:. 42879 CONDITION: New 1993 MASTER ACCUMULATOR MFG. Roy E. Hanson Jn Mfg. TYPE: 24" OD X 120" O.A.L Horizontal Refrigerant Accumulator with Boil out loop ~ 338126 CONDITION: New 1993 MFG. Roy E. Hanson Jr. Mfg. TYPE: 47.4" ID X 192" O.A. Horizontal Refrigerant Receiver ~ 338125 CONDITION: New 1993 ~" KING VALVE MFG. Parker MODEL~. S5A PORT SIZE: 32-75mm (1 l/4-Y) · . (Drawings and.instructions to follow) .. . . ,.,.~. -,~ ~.~ '~ . .,, ~ ! -,,, ~ ~, ~ ~ ..... , ............. ~ ~ . ~. , ~ .' .., . . .... ~ ....;....,. ~ ,.~ , . ~ .. . . ., .,. . .~ . , .... , ~ ............. . . v' ~ ~ ~-~'.,,~..'..~'. ~;~..,~.'~'.~,.,, · ..... ' ' ~ ~ ¥~,~; ..., ' ~'..,,~.'. ., '..: · . · .. ~ '.'~ . -'.' .' , ' .' ':-'~ '"... . ~. ; '':'. '~ '. '. ,.' Bulletin30-93C ' '. '.' i .' i.~.~ .,~...,,~...-..--~.- :' · ~,-- ,, ~.- 'i?'! ... ' · v... · ' Type S5A ~':., ~:-.,Type SSA (S5AE)' ' .. .., " Port:Size: 32-75mm (11/4:3") For Ammonia, R-12, R-22, R,502, , and other common Refrigerants. '" 'Features' · . .... ,..Standard Coil Housing Meets " .;~?'~;::i.~":~-~ N~MA'3R and NEMA 4,Rain Tight . . ( 'i{ ::,~. ,~ ' .. ...,... ~.,. ~ ., .~,,.~. . , ~-F-,,.::'.".': .- . ~ .:-,,~:: .. ,w, 3,..~.?:,,, . ,~t: ....... , ;.....,.~,.,;-.~.. - -... - ~ - .." ' · · · .:',.~:~5;~;?., fCoiI.Hous ng Surpasses NEMA Salt Spray Test :.:.,,?,.t;*,~.t:.~,::"" ,;'., t.... .. . · · . . · ..:..~,,,.'~_~;t.::.:~;Plunger-Needle Assembly Same For. .. , t,::'~.,,.,,~.,.:,S4A, .S5.A,.S6N, S6A.... ;: . --;-'..;A',~;~:~: ~*'. ..... :~'.'~.',-- ...~., ' t . ' , - ' ' -'-i.~i;~,~:.',.'.. 'Replaceab e P ston Pug Assembly ..... . ..:~: · ~"'~.,z.:.:, .~.'.' ?. · . .. · · · · :',:~,%i......'. '~"e.." ' ' ....... ' ......" " '" ' ' ' .;:~ ...- Molded Class B . Cod Construcbon . AprU. Installation, Service · !~._i.,':..:"~:Pii~'~g ~igh't A~;Ailable ':*~':" ,':'..' '.'" ' '" . :' . '" -. a.d Parts Information .~!t~'.:,..::¢?:~::,."':,~i~i'l~i~Ss S{eel'N'~edler::'-'' .::,; .'. ..... , . ?i~:;"!'7;::':'b~;;~'~'ai'Obeni"-~--.......,..____. _~' Stem :.. "'" , is adv~sab,e ~o ~.sta, a strainer upstream of each va,va to prevent - -SWP 20.7 %r PS,G) entre,ce of foreign materia nto the valves and the rest of the sys- tem. Refrigerating Specialties strainers are available to close- couple to valve inlets. .i!~i ;i::ii:i~i'i:iii!i~:ii. i! i:ii.! ':'.i".::. i':.'i::'i:'-": .."i'.: .i'.' ::.:..i '.'' : ' Purpose : . Type S5A is recommended for use in refrigerant liquid or suction .~i~!~!~!.!J D~i~i'i~ii '.0'n '?. :?L.'' /.'":.'.: :'.: "....'... . ' lines. It is not recommended for hot gas lines and other applications ~:,~..?'.iLT,~.i~'.~:e~;~'i~u.~i'So~en.°.!d Valve.. i~'S~itab~e for ^mmonia, R-~2, R-22, where high pressure drops wi,exist when the valve is open.. ~.?!. arLd ~5~2', 0t.h~r ~'efrigeran.ts; ce_~ta.ir) oils aa.d 0!he.r fluids approved Principles of Operation -- ,,/.;i, for'use' in refrigeration.. The S5A is a pilot operated semi-steel bed- · ~?!;::~,i~;:'i~dii~l'.v.~'.?h.e .valve-may'be Open'ed by.. means of the manual open-. The TyP_e S5A is a Pilot .operated solenoid. Operation is as follows: '.:~i~:!~:.~'.:.'.'.:t:'iing'Stem f0('sen/icing or in case of electrical power failure. The valve, in its closed position, with the solenoid coil de-energized ~:..., :,.;:..-.~ HU :~ypu a~',:~'g"::"";:~:;;;~'L';'~;7~'Z:'S;";' ·SOlenOid val'~,e is furnished With FP"~ Internal NPT and the plunger-needle in its seated position, is shown in Figure 1. · Before the valve is opened, the pressure above the piston-main · :.~:i:..';:,,::~i'i'i(U.S.i.:Standard. Taper. pipe .Thread), Socket Weld, Weld Neck or valve assembly is equalized through the bleed hole and is the same ':~¢.~;~'!~;-:.:.ODS (solders'over' copper tubing of given diameter)'connections. · ii'".:i!i.L:'~'?i-::Th'e'valv'e"may, be easily removed from between the flanges for' as the inlet pressure. Electrical energization of the solenoid coil -."-.'::'"::::/:~-';-';~':=¢:'n:;.:'~:;~:.:'?.:-i::;.::...:~,+;;:...::;.?.,v~ , g- ..,,; · -'.. ~:?... ' :- :..:.:. .. ~'. '~ .-' ,..:,... '.. .- forms a magnetic field, pulling up the plunger which strikes the nee- '-:',:.:~.;':~ :.~.,;,~.'..'.v,..., :.'-'..,. '~..-..':.. :: .- ': "':: . ...... : . . . die, lifting it off its seat. This permits the refrigerant trapped above the piston-main valve·assembly to flow through the pilot and '-'::,'F -:?:.-'. ..... ~-...?.. ',t-'-'~.,' .',.:. ," ". ' · . ' · · through Port N to the downstream side of the valve. The pressure '::.~".'.~,~.:"."- :'.v..t','~,,~-. :,"...:.;,.'. '. .. ' . ..: ' · .. ' ..~.~ ~.,~..~ ~-..:.,,,..:.~,~....:_~. ......... . ........... . .. above the piston-main valve is reduced and'ihe higher inlet pres- '.?:~:e%~.:::::: L::."'i" '".~'"' ..... :'.~'" ' "· :'. .' .~:':~,'.' " ' .. ~:,~.-.~.~.-.,.:....::1~-!:..::~: ~. · .- . sure against the underside of the piston-main valve assembly ~. :,~ .~-. ~:'.~:.:- . ~ :,I&SSE~BL¥ ...... .. ,,. ~ '. · !:~;:~' 'flow of the refrigerant. The minimum pressure drop to hold thevalve ,.:':~.~;,!..-','.?1 ASSEMBL~ - - - -~ wide open is 0.07 Bar (1.0 PSI).. De-energization of the solenoid-coil permits the sprir~g-assisted needle to drop back into its seat, stopping the flow through the pilot port, and the pressure above and below the piston-main valve is HOLE equalized. The weight of the piston-main valve then causes it to : drop tO its s~at, Stopping the flow Of the refrigerant. The F~essure difference across the valve, acting upon the area of the valve seat, · _':~';:?::b~:; ~ holds the piston-main valve in a tightly closed position. '. Manual Opening'Stem (See' Fig. 1) " .:'-.::" :..t -" The manual opening stem on the Type SSA is for the purpose of ' ": opening the valve without energizing the solenoid coil. For access' .-.. -..' .to the stem the seal cap on the bottom of the valve must be re- moved. This must be done with caution as refrigerant may have been trapped inside the seal cap. Manual opening is accomplished -.~.,~... ;','-.~.. '-.' -.' :i. - :...'" · ',,.: '~., .... Fig. 1 by turning the stem clockwise until only the flats on the end of the "'" '"" ~'-.":i?::":." ?!. i:.':i;: :.~i'i. '.:?::'.-Ti:.t:"'.' .{ ".': ". ii:.':' '.': ' : stem protrude from the packing nut. To reset for automatic opera- ....~~.`.:;:~!:...~..~~ ' .':" ... tion'turn the stem counterclockwise as far as it goes.!.. ..... .- ... · .' ~:!i--::,i ;.:.".'..'.:', .? i~/::,.. ';' i i''~ "'!:'..".~' '":!'::" -" ..... · :-:'-;'~::i i "-::." i~':.-,.:: ': "." ' ' : ..... : .... : ,: ....... ' ~:~:.":-; :. . . . . :: . . ...... ..,...:. ... .::."-.~.,:"..-[ I I II I IIII I '1 I -- ' "?":"?: ""' ........ :' ........." '"'"' ..... ' '. ~) 6 HouslngAsm, . 1 -.. 13 Bushing, Seal 1 1,3,5, Housing Kit 201629 6,13 7A Sol, Tubs Nut 1 7B Sol, Tubp Asm. 1 8 GaskeL 1 7A,7B,8 Sol, Tube Kit 201036 .:?/~;'12,31~;?.~';? . Piston Plug Kit 201200 201140. 201139 201117 201121 ::.'.22,23,24.:*'stem Packing Kit 202100 202101 · ~; ~-' 28 ;' '?: :-;' .. Flange Gasket Pkg .... .... .. 12 202080 202081 202082 202083 _ [~-. ,.~. 1.1 ~ 1.5 1.5 1.7 1.7 ALLOW lOO MM (4') ABOVE VALVE FOR RE~OVAL ' ; ~.. ~ ' 1'~ 2 ~.. 25 ~ OF COIL HOUSING ASSEMBLY '.-' . . .15 I 15 15 15 " ALLOW 25 MM (~') BELOW VALVE TO;OPERATE -.'.~; I 3 4 5 6 / . ~. 10 28 23 , : . · 32-75mm (~ ~/4 - 3") ;.~ .M.OUnt only in no.rlz,or~al pipe ,l?e W. lth e.olenol(3 coil at~n,e InO(~;~ Valve should san/, Thorough y clean all pans and reassemble using a light film el relrlger.' ' .' '.; :'' ~il~rk properly only In this position, m a hquld line the ~om o o atlo~ o on the Piston ' ' ' '. ~ near the expansion valve Inlet. It Is advisable to install the SSA c ese ....... ' ....... i . · ' - ' ~,'""~ '~F [.~l~el ~,~..~nanjnn ~tralnar ahead of the u~,lv~, fnr nrotectlon aha nsf din and z.I.-allUm io l~lOSe: {aI ~-~ec~rical contrOl circuit is no[ opemng property. ' --. ~ ........ ~. .............. ~. =, Check wiring and controls. (b) There are chips or din on the Pilot Seat or the ' ~,. . chips. Main Valve Seat, preventing proper seating~Disassemble and clean Valve as '"= The SSA solenoid valve must be installed with the arrow on the valve body in outlined in (11) above. (c) Main Valve Seat, Pilot Seat, or Valve Needle may be the direction of flow through fha valve. II the valve is backwards, the flow will worn or damaged and therefore leaking. Disassemble and clean Valve as not be stopped when the valve is electrically de-energized. Like all Solenoid outlined in (1fl above. If any of these pans need replacing, it is advisable to · Valves, Ihe SSA can slop flow only in Ihe direction Irom normal inlet to normal replace using the proper replacement kit. (d)//31 Piston is slicking. See (1 f) , · outlet (as shown by the arrow on the body). If reversal el pressure occurs in above. (el #32 Manual Opening Stem is turned all or partly in holding #31 Pi- the system so the outlet pressure exceeds the inlet pressure the piston will · ;. son Plug Assembly open and permitting flow through fha valve· (1~ #5 Coil .... be blown away from its seat and reverse flow will occur. If a system has this Housing Screw (made ct non-magnetic stainless steel) has been replaced 'i~i' type o{ pressure reversal (as encountered during hot gas delrost with liquid ~ib~l~!ion s'yste~s),'a Check valve such as ·Refrigerating Specialties Divi- withe screw made of magnetic material and residual.magnetism is holding :~i~'i3'y~C~..4A I~'S~i~'wlth the ·solenoid valve will prevent flow reversal. #9 Plunger Needle Assembly in the open position.. Consequently, the Main ~-~(CK'~A,.~'~S_t 'l;~ilr~aiJ'~i downstream to avoid trapping liquid.),. . . Valve is not closing. Replace with screw el correct material. .~. -- .... .,..~~..~.?;......:'_.~.-~,~.' ....,... : .... · .~ · structed of high temperature materials accordingly. Unless troubled with ac- ~,'. ;-~-. -~ .- --~'?-~'~.Re.~rige.~ti~;S~ci~lties. Divisi°n molded water !esistant Class "B" so- .fuel Coil burn-outs, high coil teh~perature should be ignored. Persistent :2~"'~.-~l~oid'coil is'd.eSig~ed for !cng life·and powerful opening force. The standard burn-outs indicate improper line or coil voltage. See (la) above. ~:'.~I'~(~Si~'g'~.~etSNEMA 3R and 4 requirements. This sealed construction ~.;~.~;ceeds the requirements'~f NEMA Standard ICS, 1-110.57 salt spray test for Warranty · '!~.,~'"~. ~fl~iti0~',..,Cla-~'"B'~ ~oil Construction will permit'coil temperatures, as All Refrigerating Specialties Produ~:ts are warranted against defect in work- .;~,:'~n6~s'~r~d b~' reSistanCe' method as high as 130~C (266°F). Final coil tam- manship and materials for a period of one year from date Of shipment Item .--~.,~.~.'~:... ...... . ......;. .... ... .... , . . . factory; This warranty is in lorce only when products are properly installed, · !~p?.~a!ures.ar~ a .function el both flutd and ambmnt temperatures. The h~gher field assembled, maintained and operated in use and service as specifically · ;=~fl'~id t~mPeratures requi~;e lower ambient temperatures so the maximum coil stated in Refrigerating Specialties Catalogs or Bulletins for normal refrigera. ?~-~'te'mperature is' not exceeded. Conversely Iow fluid temperatures permit ,~ .......... .... ............. . . lion applications, unless otherwise approved in writing by Refrigerating Spa-. ~higher ambient temperatures . : .... ' ' .' cialties division. Defective products, or par~s thereof, returned to the factory ' ~.Th'e~ m'~id~l' Class ;"B~!;'coil is -available from stock with most standard volt- with transportation charges prepaid and found to be defective by factory in- ..~i~':.:~ges.' However; co~ls are available for other voltages and frequencies, as well spection will be replaced or repaired at Refrigerating Specialties option, free .~;~.;,', .as.. f~.r,dL[.e~t cu~'ran.t. Co~ls are also avmlable as tra.nsformer type w~th a 6 volt of charge, F.O.B. tactory. Warranty does not cover products which have been ~$~:0n~'~;-wi~'din'g'fo~;iu~e With ~he Refrigerating Specialties Division Pilot altered or repaired in the field, damaged in transit, or have suffered acci- ~r~'ht' ~e~l~iy (se~.~;r~nt copy of Bultetin 60-10, "Pilot Light Assembly dents, misuse, or abuse. Products disabled by dirt, or other foreign sub- (~' .~'d S(~ieh0id-..Transformer Coil").' '. ' - ~ "::::.- ....:' ..:'- · . stances will not be considered delective. ~.i.'.',~h;"~i';~'~i~ ~ii 'm'U~i'l~e c~n~ected to el~cirical lines with volts and Hertz -THE EXPRESS WARRANTY SET FORTH ABOVE CONSTITUTES THE- "~:!?'~r~e ~s stamped on' ~0il.'The supply cftc'airs musi-be pr~)i~e¥1y sized to give ONLY WARRANTY APPLICABLE TO REFRIGERATING SPECIALTIES ;~¥:.adequate voltage at the coil leads even when other electrical equipment is PRODUCTS, AND IS IN LIEU OF ALL OTHER WARRANTIES. EXPRESS ' ':c-.oPerating. The coil is designed to operate with line voltage from 85% to OR IMPLIED, WRI'I-I'EN OR ORAL, INCLUDING ANY WARRANTY OF '.?~'110o/o'of rated coil voltage; Operating with ~ line voltage above or below these · MERCHANTABILITY, OR FITNESS FOR A.PARTICULAR PURPOSE. No · :i!~ilimits may result in coil burn-out..AIso, operating with line voltage below the employee, agent, dealer or other person is authorized to give any warranties .:i:i~:limit"will'definitely' result in lowering the valve opening pressure differential, on behalf of Refrigerating Specialties, nor to assume, for Refrigerating Spe- ;-'i~'~:p0W~r' ~0nsdmption during n0rm'al 0Perati0n'will be '33 watts or less. cialties, any other liability in connection with any of its products· :..~;~.lnrush and runmng current ,shsted below: ": .~'~ 2676~.(Blue'i~ad~)':.ii!~'~'~'::=::'~: ?!"::.r:201401 '.~':::' '1.60' .' 0.52 1 People doing any work on a refrigeration system must be qualified and com- ;~'208/60 (Blu-~" &' Red ' 1 · le~ds) '. '.~'.'201405 ":" 0.88 ' : 0.28 pletely familiar with the system and the Relrigerating Specialties Division :.'%"'..?240/60 (Red le~ds)i'"'?!:'.' .'-' .. 201402 . :. ' 0.86 .' 0.26 1 valves involved, or all otl~er precautions wil[ be meaningless. This includes ~ ~i~!i'~ '.4~16~ ~'~el!~.'w~.:& R~d'!e~dsi' .' :.-201411 . .. 0.39 0.13 1 reading and understanding pertinent Refrigerating Specialties Division prod- :-.?'[!t~i'15/50 (Yeli0w & Blue leads) ~: 201409 .. '- 1.50 0.46 1 uct Bulletins, and Safety Bulletin RSB prior to installation or servicing work. .:.;i,.;.-,~Oih'er'::.~?i~L?~?..':.-.';~.=.?~?~:,.:!,:.~:~. '~... ' "-: .?! '.. (Contact Factory) Where cold refrigerant liquid lines are used, it is necessary that certain pre- ,'::~O~'{~h~o~.~n~;'~i 'tl~'~ '6'V01~ I~i~ are a~ways black'. ' " - cautions be taken ,to ave d damage which could result Imm liquid expansion. Temperature increase in a piping section full of solid liquid will cause high ..~:.~Servlce.Polnters...~-..-! ,::,. ~., ...,:. · . .~ ~ · · . - pipe or valve. All hand valves isolating such sections should be marked, ' :~..'.'.~.The SSA Solenoid Valve and Strainer are easily removable for cleaning or re- · ~.:;painng~:To remove valve and strainer, merely unscrew the flange bolts and removed. Check valves must never be installed upstream of solenoid valves, noid valve~ 0r'downst'ream of check valves be ciosed~./ntil ihe'iiquid ha~ ?.~.;:.1.. Failure to Open::(a) Coil Is of Incorrectly high vo_lt.a_ge. See "Electrical;' ... been removed. It is advisable to-properly.install relief devices in any section .?:~ Check"v~itageyrinted 'on the coll. (b) Line voltage Is abnormally Iow. See where liquid expansion could take place. ~:.?.!:. Electrical.." Check linc'voltage at coil leads with a voltmeter. (c) Failure to Avoid all piping or control arrangements which, might produce thermal or ::".'electrically energize. Check control circuit. (d) Pressure difference across . valve iS Icc high. The SSA will open against a maximum pressure difference pressure shock. ~ 'i~cross the valve ct 20.7 Bar (300 pslg), (e) Solenoid Coil is burned-out. See For the protection of people and products, all refrigerant must be removed /,. .-~'Elactrlcal,' and replace with proper coll. (fl Plunger/Needle Assembly Is from the section to be worked on belore a valve, strainer, or other device is .-..-.'~.stlcklng,.To disassemble the valve for Inspection of Internal pans (after opened or remove~. . · · ??pumping 'o~! th?-a .ys~,em as required); dlsconnect..power source to #4 Sole- Flanges with ODS connections are ~ot suitable for ammonia service. . ~"*' .... ~ ...... ............ I ....... IIII I II · FORM U-1 MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS o As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 Manulaclu,odandcerllfiedb¥ E..L. Nickell Company, Inc., 635 Franklin Street; Cnn-~nn~n~: NT (Name and address of Manulacturer) :~or Refrigeration Technology, Inc.. 595 Po~._ta! St.: Cotntt: CA 9&931 ~ottR755-9 (Name and address o! Purchaser) 3. Loc~ilonofinslalla~on Crystal Gey. se~, 1233 E. Calif. Ave., Bak~_r.~f~ld._ CA q33C)7 (Name ar~ address) R~V. 0 ., Type: Horizontal 'S & T _CJ~i]_e~r 42878 N/A C-10533-A 40153 1993 (Hof,z,. yeti., or sphere) ('ra~k. se .p.p.p.p?alo¢, jkt vessel, heat exh., elc.) (M~g's serial No.) (CAN) (Drawing No.) (Natl. Bd. No.) (Year 5. ASMECo~e. Sec,onVIII. Div.~ 1989, 12-31-91 N/A EdilJon and Addenda (dale} Code Case No. Special Service per UG-120(d) l[ems 6 - 11. incl. Io be compleled ID, ~n~G;~e~£~C~U3U~,j~As~tX, shell of heat exchangers, 5. Shell {a) No. el course(s): ~ (b) Overall length (h & in.): 2 2 ~ -0" TF-TF Course(s) Material Thickness Long Join~ (Cat. A) ' Circum, Joim (Cat. A, B & C) Heal Tream~en! No. Diameter, in. Length (fl & in.) SpecJGrade ~.Type ] Nom. Corr. Type Full, Spot. None Eft.. : Type Full, SpoL None E,. Temp. Tree '1,2 37" 96" sA-516-70 5/1(," 0 2 N. one .65 2 None 3,4 " 6" " " " " " " " " '" " " 5 " 57" " " " " " " " " " " " 7. Heads: (a) (b) (Mall Spec. No.. Grade o~ Typ~) H.T. - Time &Tem ~. (IV(afl Spec. No., Grade or Type) H.T. - Time & Temp Location (Top, Thickness Radius : Elliptical Conical Hemisl:~ericaJ Flat Side to Pressure ' Catego¢7 A Bottom, Ends) Min. Corr. Crown Knuckle Ralio -' Apex Angle Radius Diameter Convex Concave Type Full, SpoL None Elf. ~ ts) ............................. (b) ....................... I1 removable, bolts used (describe oB3e~ bistening) . · ' (Marl Spec. No.. Grade. size. No.) ~. Type o! jacket ~ Jacket closure . give di ors I~ bolted, close'the or g. MAWP '150 psiatmax, temp. +225 ..... 'F Min, design me~ temp. '-~0 'Fat (internal) · (exteRnal) ......... . .. (intern.al) : (external) -- . - ' lO. Impacitest Impacts exempt per: UCS-66(a) ...... (Indicate yes De no and ~he component(s) impact tested) ~ ~. I~rT~.. pneu., O~X~;~. test press. ' .... 188 ........ Proof test N/A " ;roms 12 and 13 to be completed for ~ube .~c~ons.' ......... ' ....... ~.~ube~hee~ :' SA-516-70 "'~:':' '?'' 37" ' ":" ' 1'~/2" ' ' '0 '"'::' ' ':"Welde'd ...... Stationary (Marl Spe~ Noj)""" .pi";*: inl (subject to press.)' '." ' N°m'. ~hk., in. Corr. Allo~., in. ' ':' At~ch'n~m'~lded Or boa,~ Ftoa6ng (Mat'l Spec. No.) .... Dia., in. Nom. thk., in. Cor'r. Allow., in: ' . . A..ttachment 13. Tubes: SA-214 ' ' : ...... I 1/4" ": '13 GA - :' 442 Straight Mad Spec. No., Grade cx Type · O.D., in. Nom. I~k., in. or gauge Number Type (eL, sigh! ~ U} Items 14- 18 incl. to be completed ~o~ i~Xc~;~~~ channels ~! heat exc. ha~gers. 14. Shell (a) No. ol course(s): (b) Overall leng{h (h & in.): ~5. Heads: (a)- / --5 l -70 " ih) SAME ' .. ' (Mal'l Spec. No., Grade o~ Type) H.T. · Time & Temp (Mad Spec. No., Grade o~ Type) H.T. - Time & Temp 8o,om. EndSl~End 2Rati°: 1 ,~pex Angle Radius ." Disrobe(er ~ Full. Spot. NOneNone Em ,I ,-movable. boll. used(de$cziboo~h'er!aslening) 80 -- 3/4" SA-I93-B7 Studs with 160 - 3/4" SA-I94-2H'Nuts. (Marl Spec. No., Grade, Size, No.) This Iorm may be obtained Item The National Board o! Boiler and Pressure Vessel Inspectors, 1055 Crupper Ave., Columbus., OH 43229 Rev , FORM U-lA MANUFACTURERS' DATA REPORT FOR PRESSURE VESSELS (Alternate Form for Single Chamber, Completely Shop. Fabricated Vessels Only)". ,. as required by the provlelons of the ASME Code rulee, Section VIII, Division 1 .' 1. Manufactured and cerllfled by E. L, Nickell Company, ]:nc., 635 Frankl'ln St., ConstantfLne. MT 490~,2 2. Manufactured for Re[r±~eration TechnoloAY ]:nc. 59.5 ?o'rtal St: Cot:at:i CA 94931 ?0#3755-9 (name and a~:lr~ea of pur¢l~&ser) .. 3. Locatlonoflnstallatlon Crystal Geyser 1233 F Calif Ave Bakersfleld CA 93307 Horiz re,me ,n4 4. Type: Accumulator 42879 N/A C-10533-B 40154 1993 (ho~tz. ~' vet~., tank) ~nl~$. Sedal no.) (CRN) {drawing mo.) (Nat'l. 9d. no.) (yeas I~JIIt) REV. 0 5. The chemical and physical properties of all parts meet the requirements.of material specifications of the ASME BOILER AND PRESSURE VESSEL COOE. The design, construction and workmanship conform to ASME Code, Section VIII, Division 1:1989 , 12-31-91 N/A N/A (e~(lenda (date)) (Coc~. Case mo.) {epeclal sen, ice per UG-t20(~) 6. Shell: SA-53-B 1/4" 0 _1 Ft 5 1/2 In. 16 Et 10 1/2 In. {mat't. (-,Dec. no.. gra~eB (nom. thickness (in.)) (corr. allow. (in. il (dia. lO (ft. & in.)} (length (overall) (tr. A In.)) 7. Seams: TYPE E None 85Z N/A N/A' TYPE 2 None 1 (long. {weldee. dt)l., sngl. lap. butt}) iRT (spot or tull))" (eft. t%)) (HT temp. {'Fl) {time (hr.)} (girlh (welded. dbl.. (RT (spot, partial. (no. OI coumea) sngl., leis. butt)) or lull)) 8. Heads: (al 1/4" NOM. SA-516-70 (b) Same (mat'l. (SPUC. no.. grade)) (mat'1. (al:)ec. no.. graOe)) Location (top, Minimum Corrosion Crown Knuckle Elliptical Conical Hemispherical Flat Sic~e to Pressure bottom, ands) Thickness' AllowanCe RagSius Radius Ratio Apex Angle Radius Diameter (convex or concave) (a) End .237 0 ............ 2:1 Concave [ (b) " .239 " " " " " " " " If removable, bolts used {describe other fastenings): N/A (mar'l_ spec. no.. gr.. size. no.) 9. MAWP: 1..50 atmax, temp. '.,+225 .Mindesignmetalternp. -20 at ]50 .~.,pneuxx:~testpressure 1RR . tps~ {' F) (' F) (psi). (psi) O. Nozzles, inspection and safety valve openings: ' Purpose _ Oia. Nom. Relnlo,cement How (inlet. outlet, drain, etc.) No. or Size Type MaI'I. Thicxness Mat'l. At~sc~e(~ Location Risers 3 8" Pioe SAiO6B S/40 We] d~a N/A Suction 2 6" " " " " " " Colum~ 1 1 1/2" Cp]g SAID5 ~000 " " " ,,- Relief, Vent 1,1 3/4"3/4" P~_ne. SA]O6B g/gO " " " 11: Supports: Skirt ~Q Lugs 0 Legs Other '~ R-{ ~-~ _ (yes or no) (no.I (no.) (describe) (where & how) i2. Remarks: Manufacturers' Partial Data Reports properly identified and signed by Commissioned Inspectors have been furnished for the N/A " following items of the report: (name of peri. item number, mh"s. name and iOentitying stamp) CERTIFICATE OF SHOP COMPLIANCE / ~ ) -. We certify that the statements made in this report are correct and that all details of design mater'~l,~onstruct~d~anship of this ves- sel conform to the ASME Code for Pressure Vessels Section VIII, Division 1. "O" CertifiCate of A'/u~atY/JO/r~.~Ptress-30' 199_.5_.. .... -- -- . CERTIFICATE OF SHOP INSPECTION _ Vesselconstructedby E_ L_ N~cke]] (/.nmr~anv. Trtc'. at C0n~mnt~ne.. MT I, the undersigned, holding a valid commission issued by The National Board of Boiler and Pressure Vessel Inspectors and the state or pr inca of HT . and employed by_Kemper. National Insurance Cnmt~ani. e.~ .---~ ,~'~ 19~'~ and eL Lon~ Grove .' IL have inspected the component described in this Manu{acturers' Data Report on Istate that, to the best el my knowledge and belief, the manufacturer has constructed this pressure vessel in accordance with the ASME Co<~e Section VIII, Division 1. By signing this certificate neither the inspector nor his employer makes any warranty, expressed or imp ed, concern.i ing the pressure vessel described in the Manufacturers' Oats Report. Furthermore, neither the inspector nor his employer shall be liable in manner for any personal inj..ur¥ or propertv..da.,maoJ-qr a loss o~,.-any J~i~n,d arising 'fl'om or connected~with this inspection. This form may be obtained Iron The National Board of Boiler and Pressure Vessel fnspectors, 1055 Crupper Ave., Columbus, OH 43229 ~e.' FORM U-lA M/~''' tFACTURER'S DATA REPORT FOR PRFqSURE VESSELS (Alternative Form ... 'Single Chamber, Completely Shop-Fa, ';atod Vessels Only) As Required by the Provisions of the ASME Code Rules, Section VIII, Division I ManulacluredloriNnmen~lndd, o..olpurchasor) REFRIGEF(A'FIDI'I "I'ECHH01_0GYr :ti,Il:. COTATIt CA 4. Type ItORIZ. ~38:1.'''~ .............. N~,.-729-B 1,.~u68 1993 5. Tho chemical and physical p~ope~tion ut ull parts noel the ~oq[ii~omo,;t~ el n~tori~l 5pocilications el U~o ASME liOILER AND PrIESSURE VESSEL CODE. The design, construclion, and workmanship co~loml Io A~ME i~ul(m, Section VIII, Dive,ion I :[ ~[~9 199 l Sh-G12 .3q5" '" 0 3~ I3.4" 1Dx ~" 6. Shell: ' SPOT 05 SPOT '~ 7. Seems:, Welded - Obi. Bull Welded -SItgl. lo BU L~g. (We~d, ~.. ~T. (S~ ~ Full) Ell. (%) H.T. Tom. ('Fi T,m (hr.) Ol~h (WiI~. O~., R.T. (S~I, ~. ~ 8. Heads: (e) MeII.~_. (b) Mall. [O~TION MIN. ~RR. CROWN KNUCKLE ELLIPSE CONICAl HEMISPH, F~T SIDE TO PRESSURE (Top. B~lom, Ends) THK. ALLOW. RADIUS RADIUS RA1 I0 ~EX ~GLE RADIUS OlAM. (~vex ~ C~ve} ~0TH .387" 0 38" 6-3/~" (a) · - (b) /, II removable, bolts used (describe other lastenlngs) g. MAWP 250 psi al max. lemp. ~00 'F Min. design metal lemp. -~0 'F al ~0 . psi HyOro., pneu,, or ~mb. teal p[essure ~7~ psi. t0. Ne[zles, i~pection a~ ~[e[y valve ~enlngs.: Pu~se Diam. T~e Mall. Nom. Relnlorcomenl H~ ~t~ (In~t, ~et, Oza~] NO. ¢ Size. TI~. Mae. Att~ed tYDROTEST ~ 3/4" F'NF'T 9~-105 3000If ~ELDED SHELL ~CCESS 2 2" F'[ F'E S~- 10~-B SCH. ~0 ~ELDED SHELL/PIPE S~B 1 8" PIPE SA-.].06-B SCH. 40 SA-612 WELDEP SHELL ACCESS I 3" PIPE ~,~- 106-E SCH. 80 t~IEI. DE[~ F'IPE ACCESS 2 4" F'IPE SA-106-B SCH. 80 WELDED SHELL ACCESS 2 9/4" PIPE SA- 106--B SCH. El0 WELDI{D SHEI_L/P IF'E ACCESS 2 1" FNPT SA-105 3OO0~t WELBED SHELL/PIPE 11. Sup~: SkIM N0 Lugs Legs Other 3 SUPPORTS . A,achod SHELL P~ELDED l~. ~emar~: Manulaclurer'~ Pad;al Dala Repeals properly i~ontilied an~ signed by Commissipned Inspectors have been ;urnished for tl~e Ioilowin9 ilem$ UOL20(f) UCS-66(a) FOR NONCORROSIVE SEP'~ICE' HEADS A~ ST~SS 16511 Sn~, ~m~ (p~;).. 17353 Head Simms (ps0 ' Type el Sen'ice AMMONIA CERTIFICATE OF SHOP COMPLIANC~ ' We cedily ,hal ,he slatemenls made In ,his repod are cDr,ecl and ,hal all delails o, design, maler~onsl,~clion, and~manship o, this vessel ~n~orm ,o ,he ASME O~e for Pressure Vessels. $~ctlon VIII Division ~ 'U' Cenilicale el Auihorization No ~093 / expires~ O~M~[R 31 19 94 . Date 3/3/9~.. Ce. name R~E. IIAN~'ONJR. MFG. ' Sgnod' (/~ ~' _ CERTIFICATE OF SHOP INSPECTION .veaset consl~ucled by ROY E. IIANSUN git. MI-U. .al 1924 COMPTON AVENUE, ~OS ANGEL~S~ CALIFORNIA I. the undersigned, holding a vatld commission issued by II~e National Ooard el Boiler and P~ossure Vessel Inspectors an~or Ihe Slate or Province of ~LIFO~NIA and employee Dy ~ TIlE CI~ OF LOS ANGELES kinpecled ~opod on , 19 .. , and slalo Ihal, Io besl 3/3 93 tho d~scrlbod In this Manulacluro~'s Data Ihe ~owledge and bullel, the Manulactu~or h~s construcled thi~ pressure vessel In accordance wilh ASME Code, Seclion VIII, Division t, By signing this co~ilicu{e neither lite Inspoclor nor his employe~ m~kos any w~rraniy, expressed or implied, concor~ng the pressure vessel described i~ this Manulacturer's ~epo~, FuAhermore, nellher the h~spector nor I~le employer shall be lieblo ~n any manner Ior any personal Inju~ o~ properly demago or a loss o~ any kind FORM U-lA MAt~UFACTURER'S DATA REPORT FOR PRESSURE VESSELS (Alternative Form.,. . Single Chamber, Completely Shop-Fa' 'ated Vessols Only) As Requlrod by the Provisions o! tho ASME Code Rules, S~3c[ion VIII, Division 1 dlj.Manulaclurednnd ceHIlied .~ .dd,o.e el manul~clt, o,) I[OY E. IIANRON .IR. ~Ii'G.~ 1924 Comido, Avemm, l.os Angcl~:~ California by 4, Type HORIZ. 338126 NA-728'-B l~u6 J 1993 ". 5. Tho clmmicul and physical propoflio5 of ~11 paris moot lbo roquiromo.[= ol material 5pocilicallon~ el Iho ASME BOILER AND PRESSUI~E VESSEL CODE. The design, ~nslrucllon, mid workmanship conlorm to ASME Rules, Section Viii, Division 1 1 ~ 1991 6. she,': SA-612 .1875" 0 1~ 11.6" B~ 10" 7. Se~m~; Welded- Dbl. fiull SPOT 85 Welded - Sngl. Io BU SPOT 2 · flW.. ~P. Gulf) S~l.. ~p. Guts) Pa~t. 8. Hoaas: (8) Mall. SA-~J5 (b) Mall, L~ATION MIN, ~RR. CROWN KNI.ICK[E EI.[i~SE CONICAL HEMISPH, F~T SIDE ~0 PRE~SURE (Top. Bolla. E~s) THK. ALLOW. RADIUS RA()IU~ RATIO APEX ANGLE RADIUS DIAM. (~ex ~ ~ve) ia) ~0TH .1675" 0 (b) - Il removable, bolls used (describe giber laslenin~s) (Mo,., sp~. ~o., or., s,~o. No.) 9~ MAWP ~.50 .psi at max, leap. 600 'F =-- 225 Min. design metal temp. -~0 .'F at ~ ~L) psi Hydro., pneu., or comb. test pressure ..psi. 10. Nozzie=, insp~tlon and safely valve openings: Nom. Roinlo~e~nl Pu~ Diam. T~a k~ll. L~Ii~ CCE~S 1 6" PiPE S~--106-[~ 5CH. 40 WELDED ~ SHELL A~CESS ~ [" F'[ F'E SA-10~-[{ SCH. 90 ~EI_DED SHELL ACCESS 2 3/4" P[F'E SA-~06-B SCH. 80 ~ELDED SHELL RCCESS [... ~"~ F'[F'E 3~.-[0C.-B SCH. ~0 WELDED · SHELL A~E~ 2, ~°" PIPE SA--106--}~ SCH. 40 WELDED HEAD AC~.~S~ 2 6" F' ~ F'E SA-106.-B SCH. qO ~ELDED HEAD 11. Supers: S~A NO LUgS .Legs Other~ SUPPORTS Attached SHELL WELDED (Yes or NO} (No.) (t~o) I~,~) {~m~e e~ ~) 12. Ro~rks; Manufooture~e 'Pe~ial Dale Repo~ properly identified end s;~ned by Co,¥,,',~;~;ur,ed I,',~Fu~lo,~ 1,6v~ bus,', lu,,',;sl,~d Jo( tim Ivllowh,g ;te,.~ repo~: UG-20(f), UCS-66(a) FOR NONCORROSIVE SI~RVICI[~ I.I~DS A~ ST~SS ~LIEVED Shell atrass (psi) 9540 Head Stress (psi) 9465 Type gl Se~ice AMMONIA ~M~ ~e lot Pressure Vessols, S.Cl;On Viii. OJvislon ~. "~' Cem;I;cato of Aulho~iza[ion No. /~"~/~ u:~ / expires ///~DEC[~B[I; 31 ,,, 19 94 . Dale 3/2/93 .q%.name ROY [. HANSON Jl{. MFG. Siggod ~ ~ ~ ~ CERTIFICATE OF SHOP INSPECTION Vessel oonstructod by lt0Y E. tlANSON Jl[. MFG. al 1924 COMIYrON AV[NUE~ LOS ANGELES,.~LIFORNIA I. the undersigned, holding a valid commission Issued by I~o National ~oa~d el Boiler and Pross[.o Vessel Inspectors an~or Ihs State or Provinc0 el ~LIFORNIA and employed by TIlE CI~ OF LOS ANGELES ~ inspected lbo component described In this M~nulactu~er's Data Rupo~ on ~/~ , 1~ ~ and slate thai, Io the best ~knowl~ge and befiel, the Manutactu~er ha~ conslruclod Ihi~ pressure vessel i~ accordance will~ ASME Code, Section VIii, Division 1. By signing this cabin,cate neilhar lbo Inspec[or nor his en~ploye~ rn~kue ally warranty, expressed or implied, concerning tho pressure vessel described in this Manufacturer's Data I~epo~. Fu~hermo~o. neither the h~spoctor nor his employer shall bu li~blo In any manno~ lot any personal inju~ or p[ope~y damage or ~ loss el any kind Oulu~ '' ~' -- ~1 Signed C Commisslon~ ,¢~ ~6PCNflk-WC-03m FRICK ORDER 208847 CUST.ORDER 3753r95 FORM U-3 MANUFACTURER'S CERTIFICATE OF COMPLIANCE COVERING PRESSURE VESSELS TO BE STAMPED WITH THE UM SYMBOL. SEE U-1 (j) As Required by the Provisions of the ASME Code Rules. Section VIII. Division Menufectur®dandcar~lfladby 'FRICK COMPANY, 100 C.V. AVE, WAYNESBORO~ PA ll.fiA 17P6R-0qq? 2. Menuf~turedfor ttEF~IGERATION TECHNOLOGY INC. COTATI. CA 3. uo~etio, of ~n,tenat~On X~X~}~gN~X CRYSTAL GEYSER. B~KERSFIELD. CA ~.Typ. Vert .66 cu.ft. 5~SDO17~"G" MC )Ho~'I/. Ot Vettl (Capacity) )CRN) {D,~w,n9 No.I (Mlgt~. Sar. No.I (Year Built) I S. The chemical and physical properties of all peres meat the reclulrements of material specifications of the ASME BelLE R 'AND PRESSURE VESSEL CODE. The design, construction, end workmanship conform to ASM'E Rules, Section VIII, Division 11989{Ye,,} and Addenda to 'kgl. m,,.~,,dCo~oCa,~Nos. 2131 & . 1518-~ Manufacturers' Partial Data Reports properly Identified and signed by Commissioned In,petters have been furnished for the following items of the report: N/A S. Sh.,: SA-414-G .134 0 0'-8 ~/8" l"-.10 1/]6" Marl. {S~ec. No.. Gr~pel Nom. ThK. ~in.} C~. Allow. (in.} Di~rn. (ft & in.) Length (I1 & in.} 7. seams: WSB none 70 no Long. (WId.. Dell.. ~gl.. La~). Butt) ~[.T. (SOot 0 none none 1 T,me (hH Girth (Wid.. D~I.. Sngl.. Lap. Butt) R.T. {SOot, Parfiai, or Full) No. of Coteries ~. ~o~,: ~e~ Metg SA-516-70 ~bl ~au. SA-51 6-70 , [SOe¢, No.. Grade) · (Spec. No.. G~de) (a) ToP '.93.7.. 0 - _ I - _ _ 8 3/8' - , (~ . Bottom 1;000 0 - _I - i - _ ,, I - If removable, bolts used (describe other fastenings) SA-325, 120,000, 5/8, 8 (Marl.. Spec. NO., Grade, Size. No.) .Type of Jacket Proof Test, Jacket Closure If bar, give dimensions If bolted, describe or sketch. IDes=ice ~s ogee & w~lcL bar. eec). 11. Const. formax, aliow, working press. 350 psiatmax, temp. +200 eF. Min. design metal temp' -20 CFat !0.2 psi. i 12. ~afety Valve Outlets: No. i . Size1/2 NPTLocationTop-Head 13. Nozzles end Inspection Openings: Pu~'pose I Diam. Nom. I Reintorc~ment How Oil Out j 1 1 1/4 Fit $A-105 - Inspect I 1 8 3/8 " $A-516-70 1.1,87 " " Inspect 1 8 ~/8 F'i~ 14. S4Jpports: Skirt no ,Lug, - Legs ---- Other Bracket( {YI$ m' nol (No.I ~No.I ~S.R,m,~,: 8 3/8 OD x 24" oil filter. ~- ':"'-- For non-letha]-/non-corroslve ~ervice.. ' "Charpy~impact testing is exempted per UG-20F". · CERTIFICATE OF COMPLIANCE ..~W, certify that the statements made In this rep6rl ere c~orrect and that ali details of aesign, material, con t~~con- *~form tO the ASME Code for Pressure Vessels, Section VIII, Division 1. [o,t. IO-?--'~_. Sl~ned Frick Compan~ f , 26?6 /°°UM'' Cartl ices* o Authorization No. expires May 28' 1993 / FRICK ORDER 20~847 CUST. ORDER 3753-95 FORM U-3 MANUFACTURER°S CERTIFICATE OF COMPLIANCE COVERING PRESSURE VESSELS TO BE STAMPED WITH THE UM SYMBOL. SEE U-1 (j) As Required by the Provisions of the ASME Code Rules, Section VIII, Division Manufecturedendc.rtifiedby FBICK COMPANY. 100 C.V. AVE. WAYNESBORO. PA USA 17268-0997 Me,u,.c,u,ed fo, REFRIGERATION TECHNOLOGY INC, COTATI , CA 3. Location o, Installer,on XX~X~(~X CRYSTAL GEYSER, BAKERSFIELD, CA ,. Ty.. VERT .66 CU.FT. 5~5D0276 Mc,.q2..qo~'- 5. The chemical end physical properties of ell parts meet the requirements of materiel specifications of the ASME BOILER AND PRESSURE VESSEL CODE. The design, construction, and workmanship conform to ASME Rules, Section VIII, Division 1 1989 (Yee,) and Addenda to Agl ,D.,,, ,nd Coda c.,. Nos. 1518-2 & 2IR1 Manufacturers' Partial Data Reports properly identified and signed by Commissioned Inspectors have been furnished for the following items of the report: H/^ S. Sho,: SA-4]~-G .lqq O 0'-8 B/8" 1'-!0 1/16" 7. Seams: W$~ NONE 70 NO 0 NONE NONE 1 s. ,ced,: Ia) M.t,. SA-516-70 (bi Met,. 5A-516-70 IS~ec. No,. G~Klel (Spec. No., I(.) q~nl~ . ,937 0 ..... I ~ ~./8 - t~n~mnM 1.000 0 ..... i ,, _ If removable, bolts us;d (closer|be other fastenings) SA-193-B7, ~/8 ~ 8 9.Type of Jacket -- Proof Test 3. Jacket Closure, -- If bar,' give dimenslons. -- If bolted, describe or sketch. ConeS. tor max. allow, working press. :~0 psi at max. temp.. 't'200 °F. Min. design metal tamp. --20 °F at !0.2 _ psi. ~2. s~f.~v Valve Outleu: No. ], size 1/2 NPT Location SHELL SIDE 13. Nozzles and Inspection Openings: ' ' purposeI i o,.. ~o.. FIeint t ..... I How OIL OUT 1 I! 1/4 FIT SA-lO5 - NONE I WELDED TNgPRP. m 1 i8 3/8 " SA-516-70 1.250 " " t INSPECT 1 i8 3/8 FLG " .937 " BOLTED TOP SAFETY t I 1/2 FIT SA-105 .161 " WELDED 14. ~upports: Skirt NO Lugs -- Legs -- .Other BRACKET(l) Arts:chad SIDE-WELDED IYe~ I~' nO) INO.I (No.) (D~eribeI {Where ancl how) ~s. R,~,rk,: 8 3/8 OD X 24" OIL FILTER. FOR NON-LETHAL/NON CORROSIVE SERVICE. "CHARPY IMPACT TESTING IS EXEMPTED PER UG-20F" CERTIFICATE OF sHOP COMPLIANCE V.'e certify thai the s~aternents made in this report are correct and that all details of design, material, construction, and workmanship of this vessel conform to the ,~SME Code for Pressure Vessels, Sectio. Viii, Division 1. '~M" Cenllicate of Authorization No. 2676 expires MAY 28 19 93 Ds:-(--ZT--q-~ Companynsm~ FRICK coMpANY Signed (1~) ' ThisFo~m (E00111) may be obtained tfomtheASMEOrder Oept:. 22 Law Drive. Box 2300, Fairfleld. NJ07007-230~ FRICK ORDER 208847 CUST.ORDER 3753-95 FORM U-3 MANUFACTURER'S CERTIFICATE OF COMPLIANCE COVERING PRESSURE VESSELS TO BE STAMPED WITH THE UM SYMBOL. SEE U-1 (j) As Required by the Provisions of the ASME Code Rules. Section VIII. Division 1 MenufactureOenOcartlfladby F~ICK COMP^NY, 100 C.V. /~VE, WAYNESBORO. PA USA 17268-0997 IManufectured for ~EFRIGERATION TECHNOLOGY INC~ COTATI ~ CA 3. Locetio. o, ~..ta.at~on J~X~XX CRYSTAL GEYSER, BAKERSFIELD, CA 4. Vyp. VERT .66 CU.F.T. 535D0276 MC (H~iz. et Ve, t.I (Capet,tV) ICHN) lO,aw,n9 No.} ~Mfgrl. Sir. NO.) (Year BuiltJ 5. The chemical and physical proper'ties of ell parts meet the requirements of materiel Ipeclflcetions of the ASME BelLE R AND P RESSU RE VESSEL CODE. Thadeslgn, construction, and workmanship conform to ASME Rules. Section VIII, Division 1 1C)8C) IYeaH end Addenda to Aql )o,,.I and Code Cesa NO,. 1518-~ & 2!~! Manufacturers' Partial Data Reports properly identified and signed by Commissioned Inspectors hm, e been furnished for the following Items of the report: S. She,,: SA-414-G ' .1'~ 0 ...0'-8 R/8" 1'-10 1/16" Mill. (.~*¢. NO., Gripe} Nora: Thk. (ifl. I Corr. Allow. )il%J D,am. Ih & in,) Lenglh itt & in.I ~. S,em,: WSB NONE 70 NO L~. {Wld.. Dbl.. ~gl.. Lad. Butt} R.T. ISoot o~ Full) Eft. I%l H.T. Temp. (' FI 0 NONE NONE 1 Time Ih,) G~r~h (Wld., Dbl.. ~ngl., Lip, Butt) R.T. (~)ot, Partial, o~ Full) No. of Courter S. Heads: (a) Mall. SA-516-70 (b) ~,t,. SA-516-70 (Spec. NO.. Grade) (SPec. No.. Grade) (bi IRCI"P'T'nM 1.000 [ 0 ..... " - If removable, bolts used (describe other fastenings) SA-193-B7. 5/8, 8 9.Type of Jacket -- Proof Test -- Jacket Closure -- If bar, give dimensions -- If bolted, describe or sketch. :.~..~. Const..for max. allow, working press. ~0 , . psi at max. temp. +200 °F. Min. design metal temp. -20 OF at 10 . 2 psi. H¥~Y~X pneu.,~×~(~Xtest press. 4 3 ~ ' '~,i. 12. Safety Valve Outlets: No. 3 Size i/2 NPT Location SHELL SIDE 13. Nozzles end Inspection Openings: ' ' (Inlet, Outlet, Drsin] No. or Size TyPe ' Mill. Thk. Mill. Attac:~e<l Location OIL OUT 1 1 1/4 FIT SA-lO5 - I NONE WELDED. TNRP~.Cm 1 8 .~/8 " SA-~16-70 1.250 I " " INSPECT 1 8 3/8 FLG ,, .937i " BOLTED I TOP SAFETY 1 1/2 FIT SA-105 .1611 " WELDED I I ~4. Suppor,,: s~ir~ NO L~gs -- .Legs -- Other BRACKET(i) Attached SIDE-WELDED (Yes m no) (No.)/" [No.) (De$o'iPe) (Where &nO how) ~5. ,.~.~.: 8 3/8 OD X 24/"/'OIL FILTER. FOR NON-LETH~AL/NON CORROSIVE' SERVICE. · "CHARPY IMPA~T TESTING IS EXEMPTED PER UG-20F" CERTIFICATE OF SHOP COMPLIANCE V,'e cartJ(y that the stalcments made In this report are correct and that all details o~' design, material, construction, and workmanship of this vessel conform to the ASME Code for Pressure Vessels, Sectio. VIII. Division 1. 'qJM" Certificate of Authorization No. 2676 ~pi~es MAY 28 ~9 93 Data'-- ~--~ ~ Comp,ny name FRICK COMPANY mgn~d .22~~~ (1~) This Form (EO0111) may be obtained from the ASME Order Dept., 22 Law Drive, Box 2300. Fairfield, NJ 07007-2300 'RICK ORDER 208847 :UST. ORDER 3753-9~ FORM U-lA MANUFACTURER'S DATA REPORT FOR PRESSURE VE~EL$ (Alternative Form for Single Chamber, Completely Shop-Fabricated Vessels Only) -As R~uired by the Provisions of the ASME ~de Rules, Semion VIII, Division 1 M.."'.~,..W,or REFRIGERATION TECHNOLOGY INC, COTATI, CA ~. u~.~o..~...,,.~. ~~X CRYSTAL GEYSER, BAKERSFIELD, CA ~_~ ~_~ 5. The chemical and phylical properties 'of ell pa~s meet the requlremen~ of material sp~ifications of the ASME BOILER AN~ PRESSURE VESSEL CODE~ The design, construction, and workmanship conform to ASME Rules, Section VIII, Division 1 1989 ~-9L..~, [5~8-3 /.213~ N/a s. s,.,,: SA-414-G .187 0 1'-3 5/8" 5'-8 3/4" ~. s..~,: WSB none 70 no 0 none none 1 8. Heads: (a) Marl SA-414-G (b) Marl L~ation ~o~. Minimum Corrosion C~own Knuckle Elliptical ~ Conical Hemispherical Flat Side ~o Pressure Bottom. Ends) . Thickness Allowance Radi~s Radius Retie~ Apex Angle Redlus Diameter {Convex or Concave) (') ~End .157 0 - , - 2:1 ~ - - - concave ~,,~ End 1.12~ ,, ,,~ ....~ 16 - . ,~o~.~,.. ~o,~ .,.~ (~.~. o~,.r ~.~..~.,,) S~-19~-B7 ~ 125 ~000 ~ 5/8 ~ 12 s. MAWP ~00 ' p,i ,~ m.x.~,mp. +200 ~in. design metal temp. --20 °F at 10.2 psi.~, pneu..m~K test pressure Nozzles, inspection and ~feW v~lve o~enlngs: ~ No~ Re,nlorcement How ~ Pur~se Diam. ~ype Marl. Location (In~ O~le~ Dteln) No. or Size Thk. Marl. Attached Drain 2 3/4 PIPE 'SAL!O6-B .154 " " Charge 1 ~ 1/2 FIT ~ SA-iO~ .!61 " " .. OilReturr 1 ~ ~/4 ,,~ " .170 " " ~ ~. sup~om: ski~ no Lu~, -- Legs -- Other Bracket ( 2 ) A~ech~ Bottom-welded ~e repo~: N/A 16" OD x 7~'" oil separator fo~ ~ef~i~e~ants.Fo~ non-l~l/~Tco~os~e service. Befe~ attached U-~ fo~m."Cha~p~ impact testinE is exempted CERTIFICATE OF SHOP COMPLIANCE We ~e~Ify xhaT ~e stateme~ mede In this repo~ are co~re~t a~d That all de~lls of d~gn, m.terlal, cofl~truc~, f~ to ~a A~ode for Pressure Vassals, Se~on V~tt. ~,vlslon 1. "U" Ca,If lc ate of Authorization ~[c~ C0mpen7 CERTIFICATE OF SHOP INSPECTION ~aTnesbo~o V~l constructed by at '1. ~e unde~n~, holding a valid commi~ion Issued by the National Board of Boiler. and Pres~re V~s.el.ln~tor~)n~or the ~tete DC Pro~ce of ..d.~>~oy~y KEMPE~ NATIONAL'INS. COMPANIES,LONG GEOVE, ILL ;y knowl~ge and belief. The Manufec~rer has constructed This pressure vessel In accordance with ASME C~e, S~tion VIII, Division 1. By signing h~ certificate neither The Inspector nor his employer m~ es e~t~ess~ or Implied, concerning the pre .... e vessel descrlbed in this Manu- ~rer'l Data Report. Furthermore, neither The InspeCt nyh~ ~~ell be Ii.bls In any manner for any personal injury or properw damage i (12/871 ~ ~s Form {SO0137~ay be obtained from the ASME Orde~ Dept.. 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300 FRICK ORDER 208847 CUST. ORDER 3753-95 FORM U~ MANUFACTURER'S DATA REPORT SUPPLEMENTARY SHEET ~s Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 SHT 2 OF 2 · -d c.r,,led by FRICK COMPANYI 100 C.V. AVE, WAYNESBORO, .PA USA 17268-0997 2. Menufactur®d for REFRIGERATION TECHNOLOGY INC, COTATI, CA 3. ~.o=e,~o, o~ m,~,,e,lo, )~.Y~0~0XX CRYSTAL GEYSER~ BAKERSFIELD, CA . I l-q3 l, NoRIz )0 300 48D0 6 "G"J05500 4. Type Data Report Item Number Remarks BULBWELL 4 3/4 FIT SA-105 .170 NONE WELDED (ITEM 10 IN U-lA) L. L. FLOAT 1 1 " " .196 " " (ITEM 10 IN U-lA) SIGHT GLASS 3 1 " " " " " (ITEM 10 IN U-lA) OIL OUTLET 1 1 1/4 " " .208 " " (ITEM 10-IN U-lA) HTR CARRIER 1 1 1/2 PIPE SA-106-B .400 " " (ITEM 10 IN U-IA) GAS iNLET '2 .~ " " .216 " " (ITEM 10 IN U-lA) GAS OUTLET 1 3 PIPE SA-106-B .216 NONE WELDED (ITEM 10 IN U-lA) GAS INLET 1 ~ FIT SA-2~4 WPB " " " ITEM lO IN U-lA) INSPECTION 1 16 HD RING' SA-5!6-70 1.437 MIN" " (ITEM 10 IN U-lA) ~.e "~ Co.,em. FRICK COMPANY/'? ._~ , ~,~( ~ Signed · . ,) ([2~2) ~form (E0011~ ~mlleble from ~e Order Dept., ASME, 345 E. 47 St., N~ York. N.Y. 10017 ~RICK ORDER 208847 FORM U-lA MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS Sbt 1 of 2 :UST · ORDER 31' 5 3-9.5 (Alternative Form for Single Chamber, Completely Shop-Fabricated Vessels Only) Al Required by the Provisions of the ASME Code Rules, Section VIII, Division I 1. Manufactured end carttfl~l:l by FRICK COMPANY. !00 C.V. AVE_ WAYN~RRCIRC). P/~ IIR~ 17PgR-~7 ~.~,~,o, REFRIGERATION TECItNOLOGY INC, COTATI, CA 3. Loc.~o. of ~.,~.,.,~on '-.~XK~y~XXX CRYSTAL GEYSER, BAKERSFIELD, CA 5. The chemical end physical propertle~ of all parts meet the requlremant'i of material specifications of tha ,~,SME BOILER AND PRESSURE 1989 VESSEL CODE, The design, construction, and workmanship conform to ASME Rules, Section VIII, Division I A91 1518-R & 2131 N./A to 6. Sh,,: SA-106-B .375 0 1'-7 1/4" lO'-0" ?. s.am,: none none 85 no 0 none none 1 B..e.d,: I.l M.t,. SA-5!6-70 Ibl M.t,.. -- Lot. ilion ('Fop. Minimum Corrosion Crown Knuckle Elliptical Conical Hemispherical Flat Side to Pressure Bottom. Ends) Thickness Allowance Radius ' ' Radius Ratio Apex Angle Radius Diameter (Convex or Concave) (,I Ends .'198 0 - - 2:! - - - ron~w lb) ...... "i -- -- -- -- If removable, bolt~ used (describe other fastenings) I~. ~ Ne~ Gr., S~ze, No.) 9. MAWP 500 psi et max. t.mp. +200 Min. design metal temp. --20 °F at l0.2 psi.l'~z~o., pneu., oJ(~0b, test pressure 375 psi. llN__ozzles,Inspection and ~fe~ valve openings: [~i~le~ Outle~ Or~i~) o. - or Size Type * Mall. T~k. Mall.] A~ached I Safety i i Fit SA-105 .!~6 non~ ~ Vent ! ~/~ " " .1RS " " ~ PischGas ! R/8 " " " " " ~ Purge i 1/2 . ,, .161 ~ ,, ~. s~.,orm: skim. no Ldo, - Ue~, - O~,e~ BEllyband (2) A:.c,~ botto~-we!ded 12. Remarks: Manufecturar'a Partial Data Reports properly identified and signed by Comml~ioned Inspectora have been furnished for the following Items of the report: N/A 20" OD x ll'-2 5/8" oil separator for refrigerants, For non-lethal/non-corrosive service.~efer ~ttached U-~ form. "Charpy impact testing is exempted per UG-2OF". form to ~0 ASME Code for Pressure V,soI,, Se:ion Vlll Division1. "U" Cemif[cate of Authorization N o.~o~-- ~: 1~ CERTIFICATE OF SHOP INSPECTION F~ick Company .~ Waynesboro Vessel construct~ by I, the under~n~, holding i valid comml~lo. I,,u~ by ~e National Board of Boiler and Prelate Vas, el In~tor, and/or me Stele or Province of. my knowledge and belief, the ~anufac~rer hms con~ruc~ this p~essu~ve~el~ccordance with ASME Code, S~tlon VIII, ~ivlmion 1. BV signing ri, certificate neither ,ha Inapactor nor hl, amployareka, any w~ty~ax~.,~ or implied, concerning ~a prater. .... I d~rlbed in thl. Menu- or a IDea of amy kind arlalng from or connoted wi t Intp~tl . -- ....... ' ~a Form (E00117) ma~obtainod Irom the ASME Order Dept., 22 Law Drive, Box 23~, Fairfield. NJ 07007-2300 2/871 FRICK ORDER 208847 CUST.ORDER 3753-95 FORM U-4 MANUFACTURER'S DATA REPORT SUPPLEMENTARY SHEET , SHT 2 OF 2 As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 FRICK COMPANY, lO0 C.V. AVE, WAYNESBORO, PA USA 17268-0997 1. Menufectured encJ certified by ~*.~*~.~ REFRIGERATION TECHNOLOGY INC, COTATI, CA Menufectur,d for 3. Lo,.t~on o~ I,.%.,,.,~o, ~yoY0X~nYoY~XX CRYSTAL GEYSER, BAKERSFIELD, CA " Data Report Item Number Remarks OTL CHARGING 1 1/2 FIT 'SA-IO~ .161 NONE WELDED (TTEM 30 IN U-lA) ~TT. DIIM'P ] ] /? " " " " " (Tq'FN 3 O TN H-lA) BULB WELL ~ 3/4 " " " " " (ITEM 10 IN U-lA) OIL RELIEF 1 1 1/4 " " .208 " " (ITEM 10 IN U-lA) ,, ,, L.L.FLOAT 1 2 " " " .28] ' {ITEM 10'IN U-iA) STGHT O,T,A SS ~ 2 " " .281 " ' (T'PP.M 10 TN II-lA) · DRATN ~ 3/4 PIPE SA-106-B .154 " " {TTIZ, M ~(l TN U-lA1 COA/.R.qCRR BLEED 1 ~/2 " " .147 " " ~ H'T'R P. ARR'FlqR 2 ! I /2 PIPE SA-IO6-B .400 " " '~ (TTP,,M ]~'TN Il-lA') OIL OUTLET ~ 1 1/2 " " .200 " " {ITEM 10 IN U-1A] .~To, Mq~ OJ,A.qS ! 2 1/2 " " .203 " " {Tq'~M '{0 TN Il-la') INLET 1 3 " " .2lb " " (ITEM 10 IN U-lA) OUTLET 2 3 " " " " " (ITEM 10 IN U-lA) OI{~T,RT 1 ~ ELBOW SA-2~4 WPB " " " (ITEM 10 IN U-lA) INLET 1 3 FLANGE SA-105 1.125 " " (ITEM 10 IN U-lA) MAN,AY 1 llXi~ FIT SA-106-C .75 " " HEAD (ITEM 10 IN U-lA) ZK ORDER 20§847 FORM U-lA MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS Sht [ o£ 2 ~.ORDER 3753-95 (Alternative Form for Single Chamber, Completely Shop-Fabricated Vessel, Only) As R~luired by the Provisi~)ns of the ASME Code Rules, Section VIII, Division 1 ~. M..u,.c,ur.,a.do.,ttfl.~bv FRICK COMPANY. 100 C.V. AVE_ WAYNF_SRORO_ P/~ lIRA ~.nuf.ctur-~for REFRIGERATION TECHNOLOGY INC, COTATI, CA 3. Loc.t~o. of~n.ta,.,~o. )~X~X CRYSTAL GEYSER, BAKERSFIELD, CA. 4. Typ. Horiz )O9 I ~B 548D0611 '!U" lOCI 1'~5 ]993 5. The chemical and phFslcal properties of ali pert~ me.t the requiremen~ of material specifications 'of the D. SME BOI~ER ANO ' i989 VESSEL CODE..The design, cons%ruction, and workmanship con~orm ~o ASME Ru{es, Section Viii, ~lv~s{on 1 A91. 1518-~ & 2131 N/A s. sh.,,: SA-106-B .37~ 0 1'-7 1/4" 10'-~" ~. s..~.: none none 85 no 0 none none 1 Bottom. Ends) Thickness Allowance Radius Radius Ratio Apex Angle Radius Diameter (Convex or ~ncave) ["~1 Ends :198 0 - - 2:! - - - ........... _ If removable, bol~ used {de~ribe other fast~nlngs) -- ~. ~w, ~00 p,, ,: ~,~. ,.~p. +200 Min. design metal temp. -20 .F at !0.2 psi.~o., pneu., oK~mb, test pressure ~75 psi. ~ozzle~. In~e~lon and ~f~ valve openings: , Nom. aein,o,c .... , How Diam. - T~e Marl · Location min) . No. or Size Th~ Marl. A~ached 1 ! Fit SA-105 . !96 non~ w~! vent t/B " ,' " " DischG~s 1 q/8 " " " " " Purge 1 1/2 " " .161 " " 11. Suppor~:Skl~ no Lugs - Legs -- Other BEllyband (2) A~h~ bottom-welded 12. Remarks: Manufa~ure~ Pa~lal Data Repo~s ~roperly identified and signed by Commi~loned Inspectors have been furnished for the following Items of 20" OD x 11'-2 5/8" oil sepa~ato~ fo~ ~ef~iKe~ant$, Fo~ non-lethal/non-corrosive service. Beret ~ttached U-~ fo~m. "Champ7 impac~ testin~ is exemoted per UG-20F". · - , · ' . CERTIFICATE OF SHOP COMPLIANCE We codify that ~e statemen~ made In this ~e~o~ are ¢orr~ and that all de~lls of d~lgn, material, conduction, end~or~manshlp of this v~sel con- O.,. 16N 9~ l~q co ..~. Frick Compan~ s,~.~ ~'~~ CERTIFIGATE OF SHOP INSPECTION ~c~ Compan~ ~a~nesbo~o Vessel construct~ by I. the under~n~, holding · ~alld coaTi,Ion Ilsu~ by the Natio~gl eoa.d gf Collar and ere,~'r, Ve,.el Inm~tor, and/or ~e State or ProvinCe of and employ~ by K~P~ NRTTONRT, TNS. COMPANTES:LONG GROVE. h.~.,..~,.~,h.~o~o...,~.~b~,.,~,.~..u,.c~.~'.D.,. R..o~o. JAN 28 '1~ J my kmowJedge and belief, the Manuflcmrer his constructed this pressure vellel in accordance wi[h ASME Coda. S~Jon VIII, Division 1. By signing ~c~re,', Data Repo.. Furthermor .... Ither the lng. tot_/~~n°r/h --~yerf.~[ / be liable in any manner for .ny perlOnll injury or proper~ damage 132/871 / /Thla Fo~ lEO0137I~Y be obtained from the ASME Order Dept,. 22 Law Drive. Box 2300, Fairfield; NJ 07007-23~ FRICK ORDER 208847 CUST.ORDER 3753-95 FORM U-4 MANUFACTURER'S DATA REPORT SUPPLEMENTARY SHEET SHT 2 OF 2 As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 FRICK COMPANY, lO0 C.V. AVE, WAYNESBORO, PA USA 17268-0997' 1. Mmnufactured end certified by Mo,u,.c,,,od So, REFRIGERATION TECItNOLOGY INC, COTATI, CA 3. toca,~o, of ~.,,~HaUon Y~KX~MX CRYSTAL GEYSER, BAKERSFIELD, CA ,. HoRIz Date Report Item Number Remarks OTT, CHARGING ' 1 1/2 FIT SA-105 .161 NONE WELDED . (TT~M ~0 TN U-iA) {'ITT. pIIMP ] ]/2 " " " " " (TTEM lO TN II-lA] BULB WELL ~ 3/4 " " " " " (ITEM 10 IN U-lA) OIL BELIEF 1 1 1/4 " " .208 " " (ITEM 10 IN U-IA) L. L. FLOAT 1 ~ " ' "' ' 281 " "' (ITEM 10 IN U-iA) RT r, MT UT.ASS ~ 2 " " .281. " ' (ITEM ~0 TN U-lA) · DRAIN ~ ' ' 3/4 PIPE SA-106-B .154 " " (TTlqM 10 TN U-lA) CO A T,P-~CR..R ~T,EED I ~/2 " " -]-1)7 " " (~j) m -lA} '~ HTR CARRTW. R 2 I I /2 PTPE SA-iO6-B .400 " " "J'~" (Tm~.M l0 TN I)-iA) OIL OUTLET 1 1 1/2 " " .200 " " (ITEM lO IN U-lA) gTGHT r,T,Agg 1, 2 1/2 " " .203 " " (TTF..M 10 TN U-lA) INLET 1 3 " " .21 b " " (ITEM 10 IN U-lA) OUTLET 2 3 " " (ITEM 10 IN U-IA) OUTLET 1, .~ ELBOW SA-2~4 WPB " " " (ITEM 10 IN U-lA) INLET 1 3 FLANGE SA-105 1.125 " " (ITEM 10 IN U-lA) MANWAY 1 llXI5 FIT SA'-106-C .75 " " HEAD (ITEM !0 TN U-lA) ' --0.,.'JAN ~8 ?9§3 ~,or,.~ ,,'"~' ~ -~"~,//-'/~ Commission, NB6373 (A).P.,.,A~..,~,~_4.,.., (~2/82) ~.Je~form (EOOlla)~/a'vellable from thi Order Dept., ASh~E, 345 E. 47 St.. New York, N.Y. 10017 i FHICK ORDER 208847 CUST. ORDER~ 3753-95 FORM U-1 MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 FRICK COMPANY, 100 C.V. AVE, WAYNESBORO, PA USA 172b~-0997 Menutectured end cat, If led by 2. Menutec~ured for REFRIGERATION TECHNOLOGY INC, COTATI, CA (Name inCl .rid,esi o! purchaier) ~ ~'~ n. toc.t~o-of i,,<eHet~on ND%X]C~Y~X, XX CRYSTAL GEYSER, BAKERSFIELD, CA I-I 5. The chemical end phyaical propertiea of ell parts meet the requirements of materiel specifications of the ASME Boiler end Pressure Vessel Code. The design. ~or~struction,' end Workmanship conform to AS~/IE Rules, Section V II I, Division 1 A91 1518-3 & 2131' N/A Items 6-! 1 incl. to be completed fo~ =ingle well vessels, jackets of jacketed vessels, or shcH$ of heat exchengers ~. She.: SA-106-B .280 0 0'-6.065" 4'-11 7/8" 7. Seems: none none 100 no 0 none none 1 8. Heads: (a) Mall, -- {b) Mall. -- (Spec. No.. Grade) (Spec. No.. Grade} LOCltiOn ~"1'op, Minimum Corrosion Crown Knuckle Elliptical Conical Hem~sphe6cal Flat I S~,~e to Pressure Bonom. Ends} Thicknes~ Allowance Radius Radius Ratio Apex Angle Radius DiameterI (Convex or Concave} ~.~': IMatl.o Spec. ~o.. Gr., $i~e. No.I :. ~' . ' ~. Type of Jecket -- ~roof Test -- 10. Jacket Closure -- If bar, 91va din3ensions -- If bolted, describe or sketch. - - (Describe as ogee & weld. bar. etc.} 11. MAWP ' '~0CI psi at max. temp. ?0~ ' ' eF. Uin;deslgnmetaltemp. '--~0 .... OF at "~0-~ 'psi. ::~X~x~.. p.eu.. DY x~Y=Y:CC, est p,ess. 375 psi. Items 12 and 13 to be completed for tube sections ' 12. Tube~heets: SA-516-70 6 5/8 .50 0 welded · . Stationary Mill. {Spec. No., Gr.) Diam. (in.) (Subject to pressure) Nom. Thk. (in.) Corr. Allow. (in.) Attach. {Welded. Bolted) .........Ff6almg Mall· (Spec. NO., Gr.) ";~"'. ;/~, Diam. (in.) Nom. Thk. (in.) Corr. Allow. lin.) ' ,. -, Attach. 13. Tubes: SA-214 5/8" .049 min 36 straight Matt (Spec~ No.. G,.) O.D. (iq:} ............ N0_m. :rgk. J!n..o.r Oapge). Number Type IStraight or "U") I[en'.~ f 4-! 7 incl. to be completed for inner chambers of jacketed vessels or channels of heat exchangers 14. Shell: 15. Seams: 16. Heeds: (al Matt.' " SA'-234- -WPB (b) Mall. -- (Spec. NO.. Grade) (Spec. No., Gridel I ENDS .280 0 - - 2 :l - - - CONCAVE If removable, bolts used (deacrlba other fastenings) (Mill.. Spec. NO.. Gr.. Size. No.) 17. MAWP ~00' pslatmax, temp. 200 . eF. Min. design metal temp' --20 oFat 10.2 psi. ~Y~... PNEU*:~,~Xte,t ~,ea,. 375 ~,,. . .. _ Form U-1 (Back) B. Nozzles, Inspection end Safety Valve Openings: · Safety 1 1/2 ~it SA-lO5 .161 none welded Vent 1 1/2 " " " ,, " Drain i 1/2 ,, ,, ,i ,, ,i Oil In 1 .1 1/4 Pipe SA-106-B .19i " " Oil Out 1' 1 1/4· " " " " " RefrIn 1 2 1/2 " " .20.3 " " RefrOut ' 1 2 1/2 " " " " " Oil Drai~ i 1/2 Pipe SA-iO6'-B '.14'7 " " t 19. Supports: Skirt no Lugs -- _ Legs -- Other -- Attached lYes or no) IND.) IND.) IDescribe) IWhe~e and how} :20. Remarks: Manufacturer's Partial Data Reports properly identified end signed by Commissioned Inspectors have been furnished for the following · items of the report: 6 5/8" OD x 5'-0" SFL-Thermosyphon OI1 Cooler w/refrigergnt in gube chamber. For non-lethal/non-corrosive service, "Charpy.impact ~esting'is exempted per UG-20F", CERTIFICATE OF SHOP COMPLIANCE Ye certify that the statements made in this report are correct and that ell detalia of design, material, construction, end workmanship of this vessel con- ira '~o the ASME Code for Pressure Vessels, Section VIII, Division U" Cert,f;cete of Authorizat,on No. lq~ e×p,res Ma,~r 28 ' /~_~P,~ Det~.~n~H i ~ ¶~/~'3 Co. name Frick Company ..... signed_. /~--~---~-- ~-~, ~--~-~-~_ ,- CERTIFICATE OF SHOP INSPECTION Frlck ye.e, constr.cted by uompany . at Wayr~esDoro I, the undersigned, holding a valid commission issued by .the National Board of Boiler and Pressure Vessel Inspectors and/or the State or Province of PA and employed by_ KEMPER NATIONAL INS. COMPANIES of-bong Grove, ILL have inspected the pressure vessel described in ~his tvtanufac~urer's Data on .J~.N 1 2 ~3 . and state that. to the best of my knowledge and belief, theManufac~urer has constructed this Re~ort pressure vessel in accordance with ASME Code0 Sect~'VIII. Divi~ By/~ng this cerdficate nekher the Inspector nor his employer makes any war- rantS0 expre~$ed or implied, concerning the pressul~e l~essel des~ibed i~ ~e M~nufacturer's Oa~a Report. Furthermore. neither the Inspector nor his em- ¢>iOyershallbeiiebleinanymannerforanyperso~el/n'jury~1~'~J/eoralossofany kindari$|ngfromorconnectedwith this Inspection. .. ..... . // .... ..... We certify that the field assembly ond~,t~t~uctlon of all parts of~hisvess~l conforms with the requirements of Section VIII, Division 1 of the ASME Boiler and Pressure Vessel Code. "U'* Certificate of Authorization No expires ° 19 Date Co. name Signed CERTIFICATE OF FIELD ASSEMBLY INSPECTION I, the u~ersigned, holding a valid ~:._ommissloq issued b~ the National Board of Boiler and Pressure Vessel Inspectors and/or the State or Province of and employed by of have compared the statements in this Manufacturer's Data Report with the described pressure vessel and state that parts referred to as data items not included in the car~]flclta of shop inspection, have been inspected by me and that. to the best of my knowledge and belief, the Manufacturer has constructed end assam- ed this pressure vessel in accordance wi~h ASME Code. Section VIII. Division 1. The described vessel wes inspected and subjected to a hydrostatic test i psi. By signing this certificate neither the Inspector nor his employer makes any warranty, expressed or implied, concerning the pressure ve~tel described in this {v%anu(ecturer's Data Report. Furthermore, neither the Inspector nor his employer shell be liable in any manner for any persona. injury or property damage or a loss of any kind arising from or connected with this Inspection. Date Signed Commissions I FRICK ORDER 208847 CUST.ORDER 3753-95 FORM U-1 MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 FRICK COMPANY, lO0 C.V. AVE, WAYNESBORO, PA USA 17268-0~J97 ]red end certified by =. M.nufac,urod~or REFRIGERATION TECHNOLOGY INC, COTATI, CA ' (Name end address al ~u,choJe~J ~. ~o~,,~o~ o~--,,,,~o, X~X~X CRYSTAL GEYSER, BAKERSFIELD, CA 5. Th~ chemical ~d phytl~l properties of ~11 p~t meet the requirements of material specification~ of the ASME Boiler and Pressure Vettel Code, The detign, con~tmctlo~, and workmanthlp conform to ASME Rule~, Sexton V I I I, Division 1 [ ~ ~ ~ Agl 1518-3 & 213i N/A Item$ 6-I 1 incl. re be completed for single wall vessels, jackets of jacketed vessels, or $hells of heat exchanger~ s. s~.,,: SA-106-B .280 0 0'-6.065" 9'-1~ 7/8" 7. S,am,: ~o~e ~o~e 100 ~o 0 none none 1 8. Heeds: (a) Marl. (b) Marl. iSpec. No.. Grede) l~e~ No.. If removable, bol~ us~ (describe other fa~enlngs) {MalL. S~ec. No,. Gr.. Size. No.} .. 9. Type of Jacket -- Proof Tc=t -- 10. Jacket Closure -- If bar, give dimensions -- If bolted, describe or sketch. ~.. pneu.. ~ ~est press. ~ 75 psi. hems 12 and 13 re be completed for tube sections Stati0na~ Mall. [~pe~ N0.. Gr.) Diam. (in.) (Subjecl to pressure) Nom. T~k. lin.) Cart. Allow, (in.} A~tach. (Welded. Bohe~l ~- ~. Fleeting Moll. (S~ec. No.. Gr.~ Diam. (in.) Nom. 7h~ {~n.) Corr. Allow. (in.) Attach. Marl. {S~e~. No, Gr.} . .. O.D. lin.) Nom. Th~ (in. at Gaugel Number 7y~e (Straight at 'iU") I~ em~ 14-I Y incl. to be. completed for inner chambers of jacketed vessels o~ channel~ of heal exchang~r~ 14. Shell: ..... 15. S~ms: 16. Ha,dr: (,) M,~I.SA234 W P B (b) u,~,. - (Spec. No.. Grade) (Spec. No.. -- ENDS ,200 ~ - .... CONCAVE Jr removobio, boltt us~ (detcrlbe o~her ~a~enlngJ) N/A 17. MAWP 300 psi ~% max: temp. 200 o F. Min. ~esign m~tal temp' --20 Form U-1 (Back) Nozzles, Inspection and Safety Valve Openings: Safety · 1 1/2 Fit SA-lO5 .161 none Vent 1 1/2 " " " " " ~ __-'l ]/2 ,, ,, ,, ,, ,, Oil In I ] 1/2 P~pe EA-]O6-B .?00 " " Oil Out · ~ 1 1/2 " " " " " Reft Tn ] ? 1 /P " " .Pti3 " " RefrOut 1 2 1 /? " " ,, ,, ,, Drain ~ 1/2. Pioe SA-106-B .147 " " 19. Supports: Skirt no Lugs -- Legs -- Other~ At~ached -- (Yes or no} (No.) (No.) (Describe) IWhere anti how) Remarks: Manufacturer's Partial Data Reports properly identified end signed by Commissioned Inspectors have been furnished for the following items of the report: N/A 6 ~/8" OD x i0'-0" SFL~Thermosyphon Oil Cooler w/refrigerant in tube chamber. For non-letha2/non-corrosive service. '"Charpy impact testing; is exempgeql per UG-20~". CERTIFICATE OF SHOP COMPLIANCE ce~ify that ~he statements made in ~is repor~ are correct and that all de,ails of design, material, construction, and workmanship of ~his vessel con- to the ASME Code for Pressure Vessels, Section VIII, Division 1. CERTIFICATE OF SHOP INSPECTION Vessel constructed by ~ ~k ~m~ny a~ I, ~e undersignS, holding a valid commi~ion issued by the National Board of Boiler and Pressure Vessel Insp~tors and/or the State or Province of PA ,,d ,mploy~ by ,;KEMPER . NATIONAL" INS'.COMPANIES.LONG GROVE. ILL N have inspired the pressure v~sel described in this Manufec~rer's Date o~ Lone Grove, If 2 2 19~ Of my knowledge and belief, the Manufac~rer has constructed this Report on , and state that, t~% ol my / ren~, expressed or implied, concerning ~e pressu ~sel d /I / /CERTIFICATE ~ELD ASSEM~ COMPLIANCE We certify ~t the field assembly construction of all parts of this vessel conforms with the requirements of Section VIII, Division 1 of the ASME Boiler and Pr~sure Vessel Code. . "~*' Certiflcete of Authorization No. expires , 19. Da~e Co. name Signed .-. CERTIFICATE OF FIELD ASSEMBLY INSPECTION I, the undersigned, holding · valid commission issued by th~-Netional'Boerd of Boiler and Pressure Vessel InsD~tors a'nd/or the State or Province of end employed by, ' of have comDared the statements in this Manufacturer's Data Report with the ~e~crJbed pre,sure vet~el and state ~hat parts referred to as date items not incluOed in the ertJflcete of shop inspection, have been inspected by me and that, to the best of my knowledge end belief, the ~anufecturer has constructed and led this preflure vessel in accordance with ASME Code, Section VIII. Division 1. Thedescr bed vesse was ns~ected end subjected to a hydrostatic test of. psi. By signing this certificate neither the Inspector nor his employer makes any warranty, expressed or implied, concerning the pressurr ve~el described tn this Manufacturer's Data Repo~. Furthermore, neither the Insp~tor nor his employer ~all bailable in any manner for any persona. injury or property damage or a loss of any k Ind arising from or connected with this inspection. Date Signed Commissions 'FRICK ORDER 20~847 :=' .CUST, ORDER 3753-95 ...... FORM U-1 MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 FRICK COMPANY, 100 C.V. AVE, WAYNESBORO, PA USA 17268-0(J97 d certified by (Name end address of manutsc~uret} z. Men.fact.rodfor REFRIGERATION TECHNOLOGY INC, COTATI, CA '~ / .... __ 3. Location of~n,,,etlon N~×K~r~xxx CRYSTAL GEYSER. BAKF. RSPTET,~ r.A ~. Type Horiz 547D021 5. The chemical and physical properties of all parts meet the requirements of material specifications of the ASME Boiler and Pressure Vessel Code. The design, conStruction, and workmanship conform to ASME Rules, Section VIII0 Division 1 i989 A91 1518-3 & 2131 Items 6-! ! incl. to be completed for single wall vesselSo /eckets o/jacketed vessels, or shells o! heat e~changers s. She,,: SA-106-B .280 0 0'-6.065" 9'-1~ 7/8" 7. Seams: Fiend no~e 100 ~o · 0 none none 1 8. Heads: (el Marl. -- (b) Marl. (Spec. No., Grade) (Spec. No.. Grade) Location (Top, Minimum Corrosion Crown Knuckle Elliplical Conical J Hemispherical Flat Side to Pressure Bonom. Ends} Thickness Allowance Radius Radius Ratio Apex AngleI Radius Diameler (Convex or Concave) is}....... ) -- -- I{ ral-I~nv~hla h~[l~ usl~ (describe other fastenings) ' IMetl.. Spec. No.. Gr.. Size. No.) 9. Type of Jacket ' -- Proof Test 10. Jacket Closure -- If bar° give dimensions -- If bolted, describe or sketch. (Describe es ogee & wel~. bar. etc.) 11. MAWP ~00 psi at max. temp. 200 OF. Min. design metal temp. --20 K¥~dT~.. pneu., ~7r. Yu~3~: test press. 375 ,, . ~si. Items 72 and I3 lo be completed for tube sections 1:2. Tubeshee~: SA-516-70 6 5/8 .50 0 Slalienary Marl. (Spec. NO, Gr.) Diam. (in.) (Subject to pressure) Nom. Thk. (in.) Corr. Allow. (in.) Attach. (Welded. Bolted) Floating Malt. (Spec. No.. Gr.) Diam. (in.) Nom. Thk. lin.) Corr. Allow. (in.} Attach. ~. T~b~,: SA-2~4 5/8" .049 rain ~6 straight .... Marl. (Spec. No., Gr.} O.D. (in.) Nom. Thk. (in. or Gauge} Number Type (Stra;ghl or "U") hems 14-17 in'c/, to be completed for inner chambers of jacketed,vessels or channels of heat exchangers '-~5:" S.ms: .......... = - - - '16. Haads~'{a) Marl. SA234 W P B (b) Marl. -- (Spec. No.. Grade) (Si)et. No,. Grs0a} Location (Top. Minimum Corrosion Crown Knuckle Elhptlcal / Conical Hemispherical Flal Side tO Pressure Betided Endl} Thickness Allowance Radius Radius Ratio Ape~ Angle Radius Diameter (Conve~ or Concave! . If removable, boltl used (describe other fastenings) N/A {Marl., Spec- No., Gr.. Size. NO.) 17. ~MAWP 300 palatmax, tomp. 200 OF. Min. design metal temp' --20 OFat 10.2 psi. XYJ~..'PNEU'7.Z~7~. t,,t ~ro,,. 3 7 5 ..... ~, This Form (EOO1081 may be obtained from the ASME Order Dept.. 22 Law Ddve. Box :;)300. Fairfield, NJ O7007-23OC. Form U-1 (Back) ~:~. Inspection end Safely Valve Openings: Nozzles. Safety 1 1/2 ~t SA-lO5 .!61 none welded Vent ~ 1/~ " " " " " Drain 'l 1/2 " " " " " Oil In 1 ] ]/2 Pipe SA-IO6-B .P00 " " Oil Out 1 ] ]/P " " " " " Refr Tn ] ? 1/? " " .293 " " __RefrOut 1 2 ~ /P " " " " " Drain 1 1/2 Pi~ · SA-106-B .] 47 " " 19. Supports: Skirt no Lugs -- Legs -- Other -- Attached -- {Yes or no) INo.) INo.) (Describe) {VVhere an{3 how) 20. Remarks: Manufacturer's Partial Data Reports properly identified and signed by Commissioned Inspectors have been furnished for the following ' items of the report: N/A 6 )/8" OD x 10'-0" SFL-Thermosyphon Qil Cooler w/refrigerant in tube chamber For non-lethal/non-corrosive service. '"Charpy imT)ac't testing is exempted per UG-20F". CERTIFICATE OF SHOP COMPLIANCE Ye certify that the statements made in this report are correct and that all details of design, material, construction, and workmanship of this vessel con- 'U" Ce~ificate of Authorization No. !42 ex0ires ~a~ ?~ Date ) -- I ~ --q ~ Co. name ~P~ ~k ~m~R~y Sign~ CERTIFICATE OF SHOP INSPECTION Vessel constructed by ~ nk Cnmpany a: Wayne~bo~ I, the undersignS, holding a valid ¢ommi~slon issued by the National Board of Boiler and Pre~$ure Vessel ln~p~tor$ end/or the S~a~e or ~rovlnCe PA and employ~ by ~KEMPER .~AT!0NAL'INS'.C0~!PANIES.LONG GROVE. ILL of Long ~rove; TT,T, . have inspected the pressure vessel described in this Manufacturer's DaTa Repo. on /-- / ~ .19 ~,~ ,and state that, to thebes, of my knowledge and belief, ,he Manufac~rer has constructed pressure v~sel in accordance with ASME Code, Section VIII. Div~ By si~ this certificate neither the Insp~tor nor his employer makes any war- ranW. expressed or implied, concerning ~e pressure v el d t acturer's Data Report. Furthermore. neither the Inspector nor his em- ELD A~EMBLY COMPLIANCE We certify ~6a~'th~"~eld as$smbl~ construction of all part~ of this vessel conform~with the requirements of Section VIII. Division 1 of xhe ASME Boiler and Pre$lure Vessel Code. "U" Certificate of Authorization No. expires 19 De~e ' Co. name Signed. CERTIFICATE OF FIELD ASSEMBLY INSPECTION _ I. ~he undersigned, holding a valid commi$$ion issued by the National Board of Bo3ler and ~ressure Vessel Insp~tor~ end/or the State or Province and e~ployed by of have compared the ~ta~ement$ in this Manufacturer's Data Repots with the described p~e~ure vessel and irate ~hat pa~s refer~ed to as data i~em~ not included in the ce~tlftc~te of shop inspection, have been inspected by ~e and that. to the ba~ of my knowledge and belief, the Manufacturer has constructed and a~ thll pral$ure v,l~al in accordance with ASME Code. Section VIII. Division 1. The described vessel was inspected and lubjected to a hydroltatic p~l. By lioning thi$ certificate nehher the Inspsc[or nor hl~ employer make$ any warranty, expressed or implied, concerning ~he prelsur' veilal delc~lb*~ In thll Manufac~urer'i Data Repo~. Furthermore. neither the Inlp~tor nor hi$ employer shall bailable in an~ manner lot any Injury o~ property damage or a Io~ of any kind arising from or connected with ~hi~ Inspection. Date ' Slona~ Comml$iion~ rn Z ANNEX lll.3.f FINANCE Items to be addressed in this Annex: (1) Resource list (2) Personnel (3) Response equipment (4) Support equipment (5) Contracting [21 Contractor and facility owner responsibilities (Program 3) (2760.12) [] Contractor safety procedures review (Program 3) (2745.7(0)) [] Contractor safety performance evaluation review (Program 3) (2745.7(p)) (6) Claims procedure Forms which can be included in this annex: [] Underground Storage Tank (UST) Certification of Financial Responsibility [] Letter from Chief Financial Officer in support of UST Cleanup Fund [] UST installation certificate of compliance [] Hazardous waste certification of financial assurance (7) Cost documentation CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES ITl Z C~ ANNEX III.4 EMISSIONS DOCUMENTATION Items addressed in this Annex: Date of most recent incident investigation and response thereto (2745.60), 2745.7(1)) Incident investigation procedures (2755.7, 2760.9) Five-year accident history reports (2750.9) All waste water treatment records maintained on file for 3 years Each waste water sampling activity shall record the following information: O date, location, time, & sampling method O who performed the sampling O date of sample analysis O who performed the analysis O analytical method used O results of the analysis CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICEs OCT 17 ~6 0B:11PM CRYSTAL ~EYSER W~TER P.B×B WZI~Nc 2.0 DESCRIPTION OF ACUTELy HAZARDOUS MATERIALS ACCIDENTS 2.1 Accidents at this location On March 23, 1989 a release involving the ammonia system caused neighbors to complain oran ammonia smell. A power failm'e caused tile system to shut down. When power was returned, thc initial startup blew tlaree-thirty amp fuses in the condenser panel, shutting down both condensers. The operator did not know that the condensers were inoperative and tm'ned on tile ammonia compressors, Pressure iii the system quickly rose, forcing ammonia through tile high pressure relief'valve. 2.1.1 On August 14, 1996, ammonia loss due to power failure (brownout) - the compressors are set up for a 20 minute delay. The operator in tile Filling I~,oom did not know ofthe power failure and he proceeded to heat up Carbo Cooler, Thc loss of ammonia was released into sparge tank through pressure relief valves on Carbo Cooler, The sat~ty system worked as it was designed for incidents such as this. 2.2 Underlying Causes 'rt~e release was caused by thc operator who turned on the compressors although the condensers were not working. 2.3 M easu res Tal<~n ..B~.: Prevent Recurrence The operator is now required to check the condensers every time he turns on the compressors. The operator has received extensive training to ensure that this type of release does not recur. Only trained personnel are allowed to operate the ammonia system. In 1993, a sparge system with a ditl~usion tank was installed to reduce the severity ot'an ammonia release in any future emergency tell& occurrences. 2.3.1 Installed on the Carbo Cooler panel in the filler room are Green Run Lights to assure operator that compressors are running and that all operators have been instructed. 2.4 Accident lnvestigat.[O;~.Procedures After an accident has occurred, an ammonia incident report (exhibit) shall be filled out. A post accident review shall be held in which polential causes of the accident are discussed. When the cause &the accident has beon determined, a method shall be Pagcl0 2.0 DESCRIPTIOi~.~.0F, ACUTELY HAZARDOUS MATEi~IALS ACCIDENTS 2.1 Acmden~t.th~s 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 sta~up blew three-thi~ amp fuses in the condenser panel, shu~ing down both condensers. The operator did not know that the condensers were inoperative 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. The operator has received extensive training to ensure that this type of release does not recur. Only trained personnel are allowed to operate the ammonia system. In 1993, a sparge system with a diffusion tank was installed to reduce the severity of an ammonia release in any future emergency relief occurrences. 2.4 Accident Investigation Procedures After an accident has occurred, an ammonia incident report (Exhibit 5) shall be filled out. A post accident review shall be held in which potential causes of the accident are discussed. When the cause of the accident has been determined, a method shall be Page 10 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 breathing apparatus) 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 5-1 ACTIVITY AT TIME OF DISCHARGE: DETAILS OF EMERGENCY RESPONSE: DEGRRR 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 HOSPITALIZED EMPLOYEES OTHERS EVACUATION: IMMEDIATE DISCHARGE AREA ~ (Y/N) ENTIRE FACILITY ~ (Y/N) NEIGHBORS ~ (Y/N) ESTIMATED COST OF INCIDENT: PROBABLE RECURRENCE OF INCIDENT: LOW MODERATE HIGH FULL DESCRIPTION OF INCIDENT (INCLUDING RELEVANT EVENTS LEADING TO THE INCIDENT; ACTS, FAILURES TO ACT AND/OR CONDITIONS THAT CONTRIBUTED DIRECTLY TO THE INCIDENT; WHAT ACTIONS WERE TAKEN TO CONTROL THE INCIDENT; WHAT REMEDIAL ACTION HAS BEEN TAKEN TO PREVENT A RECURRENCE. AMMONIA INCIDENT REPORT PAGE 2 EXHIBIT 5-2 12.0 RMPP RECORD KEEPING Record keeping, required by RMPP legislation, ensures that RMPP programs are implemented and maintained. 12.1 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. 12.2 Ammonia Charge Record Ammonia charge records (Exhibit 9) will document amounts and dates of ammonia deliveries. Inventory control is a significant aspect of RMPP implementation. 12.3 Traininq Records Training recordS will be kept to ensure that each employee receives required training. 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 ammonia system Training Required/Date Completed record. 12.4 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 41 ANNEX III.5 TRAINING Type of Training: Check all that apply Required Training Content: [~[ classroom [21 on-the-job Health and Safety: [2~ vendor provided pt medical assistance availability [~ instruction by trained personnel pt methods for safe handling of materials [21 written training plan (10+ employees) pt fire hazards of materials / processes [21 applicable to job duties pt hazardous characteristics of materials pt safe food handling procedures pt emphasis on health and safety pt safe work practices Frequency of Training: Operations and Maintenance: pt initial training: pt maintenance and use of equipment O prior to assignment pt operation of UST system O prior to changed process pt operation of UST monitoring equipment O upon modification of response plan pt maintaining integrity of process equipment pt annual refresher mining pt operating procedures ~ ~ / / date of most recent training program pt overview of the process revision [21 / / date of most recent change that Risk Management: triggered a training program revision pt conditions likely to worsen emergencies [2~ / / date of most recent emergency pt appropriate corrective actions response training for employees Emereenc¥ Response: pt coordinating local emergency response pt use of emergency response equipment Documentation of Training: pt communication and alarms pt response to fires and explosions pt records kept until facility closure pt contaminated groundwater response pt employer certification of employee skills pt waste feed cut-off pt testing or verification of competency pt notification procedures t/former employee records kept 3 years pt use of fire fighting equipment ~' documentation at the facility: pt employee evacuation O employee name & job title pt emergency shut-down O written job description pt site specific response O description of required training iD training records CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES The following subjects will be covered by the training program: Use of Safety Equipment · When to wear a Self Contained Breathing Apparatus (SCBA) · What type of SCBA is appropriate; limitations · How often must the SCBA be replaced · SCBA maintenance Ammonia First Aid Procedures · Keep a rope available to retrieve overcome employees · If an employee Is overcome by ammonia: 1. Move victim to an area clear of ammonia 2. Call e doctor 3. Remove contaminated clothing 4. Keep the patient still and covered with blankets 5. Use cardiopulmonary resuscitation (CPR) if required · For liquid splashes in the eyes, irrigate the eyes Immediately with a solution of two and one-half percent boric acid, two and one-half percent borax, and distilled water. · For skin burns, wash Immediately with large quantifies of water. Review of Hazardous Business Plan Review of Material Safety Data Sheets, Chemical Hazards Review of Emergency Plan Release Reporting (Section 2.5) Daily Operating Procedures (Section 4.1.1) Maintenance Procedures (Section 4.1.2) Evacuation Procedures (Section 8.1) Page 39 Fire Procedures (Section 8.2) Earthquake Procedures (Section 8.3) Ammonia Significant Leak (Section 8.4) Page 40 ;6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 14 00 - Overall Site <G> Training '1> Page 1 WE HAVE 35 EMPLOYEEs AT THIS FACILITY .WE HAVE MATERIAL SAFETY DATA SHEETS ON FILE -. SUMMARY OF TRAINING INCLUDES A LIST OF THOSE QUALIFIED IN S.C.B.A. SUMMARY OF TRAINING: EACH EMPLOYEE INVOLVED IN THE USE OF HAZARDOUS MATERI~LS WILL BE GIVEN INSTRUCTION IN THE SAFE HANDLING AND USE OF EACH PRODUCT BEFORE THEY BEGINUSE. EACH EMPLOYEE WILL BE PROVIDED WITH SAFETY EQUIPMENT REQUIRED FOR EACH PRODUCT HANDLED. SAFETY PROCEDURES FOR SPILL CLEAN-UP OF HAZARDOUS MATERIALS WILL BE TAUGHT. NEW HAZARDOUS MATERIALS INTRODUCED INTO INVENTORY WILL BE REVIEWED WITH EACH INDIVIDUAL BEFORE USE. REFRESHER COURSES IN SAFE HANDLING OF HAZARDOUS MATERIAL WILL BE REQUIRED OF EACH EMPLOYEE INVOLVED IN THE USE OR HANDLING DURING THE YEAR. IN ACCORDANCE WITH YOUR REQUEST WE SUBMIT THE FOLLOWING LIST OF INDIVIDUALS WHO HAVE BEEN TRAINED TO INITIATE AN EMERGENCY RESPONSE TO AN UNLIKELY INCIDENT. 1) NORMAN AMBROSE - MAINTENANCE SUPERVISOR ~i~. kMBROSE IS KNOWLEDGEABLE AND HAS EXPERIENCE IN ALL ASPECTS OF OUR '.~MONIA SYSTEM: PIPING LAYOUT, LIQUID AMMONIA SHUT OFF VALVES, COMPRESSOR INTENANCE AND RECORDS, AMMONIA SAFE HANDLING PRACTICES AND HAS BEEN TRAINED IN THE USE OF OUR AMMONIA DIFFUSION SYSTEM. aLSO, mR. aMBROSE HAS BEEN TRAINED IN THE PROPER USE OF OUR S.C.B.A. UNITS. HE IS ALSO KNOWLEDGEABLE OF OUR FIRE/EMERGENCY EVACUATION PLANS AND WOULD BE ABLE TO INITIATE AND HANDLE AN EMERGENCY RESPONSE TO ANY INCIDENT. MR. ~/-[Op~fhb. IS KNOWLEDGABLE AND HAS BEEN TRAINED IN ALL ASPECTS OF AMMONIA SYSTEMS: PIPING LAYOUT, LIQUID AMMONIA SHUT OFF VALVES, AMMONIA SAFE HANDLING PRACTICES, AND HAS BEEN TRAINED IN THE USE OF OUR AMMONIA DIFFUSION SYSTEM. MR. ~O~r~ .... HAS BEEN TRAINED IN THE PROPER USE OF S.C.B.A. UNITS AND IS KNOWLEDGEABLE OF OUR FIRE EMERGENCY EVACUATION PLANS AND WOULD BE ABLE TO INITIATE AN. EMERGENCY RESPONSE TO AN INCIDENT. 3) ALEX MANNS°- PLANT MANAGER MR. MANNS IS KNOWLEDGEABLE OF OUR AMMONIA SYSTEM: PIPING LAYOUT, LIQUID AMMONIA SHUT OFF VALVES, AMMONIA SAFE HANDLING PRACTICES, AND HAS BEEN TRAINED IN USE OF OUR AMMONIA DIFFUSION SYSTEM. MR. MANNS HAS BEEN PROPERLY TRAINED IN THE USE OF OUR S.C.B.A. UNITS AND CAN INITIATE AN EMERGENCY RESPONSE TO AN INCIDENT. 4) ~O~'~mz~ - MECHANIC .~//~Z/~t~f~½ HAS KNOWLEDGE OF OUR AMMONIA SYSTEM: PIPING LAYOUT, LIQUID AMMONIA SHUT OFF VALVES, AMMONIA SAFE HANDLING PRACTICES, AND HAS BEEN TRAINED IN USE OF OUR AMMONIA DIFFUSION SYSTEM. MR. ~~c~C'~z.~-~ IS KNOWLEDGEABLE OF OUR FIRE/EMERGENCY EVACUATION PLAN AND WOULD BE ABLE TO INITIATE AN EMERGENCY RESPONSE IF AN INCIDENT OCCURRED. ALSO, MR. ~3/YL~$~m3 36/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 15 00 - Overall Site <G> Training · 1> Page 1 (Continued) HAS BEEN PROPERLY TRAINED IN THE USE OF OUR S.C.B.A. UNITS. 5) GERHARD GAUGEL - QUALITY CONTROL MANAGER MR. GAUGEL HAS KNOWLEDGE OF OUR AMMONIA SYSTEM AND ITS OPERATION: PIPING LAYOUT, ~~ ~MONIA SHUT OFF VALVES, AMMONIA SAFE HANDLING PRACTICES, AND HAS BEEN TRAINED IN THE USE OF OUR AMMONIA DIFFUSION SYSTEM. MR. GAUGEL HAS BEEN TRAINED IN THE PROPER USE OF OUR S.C.B.A. UNITS AND CAN ALSO INITIATE 'AN EMERGENCY RESPONSE TO AN INCIDENT. ALL PLANT MANAGEMENT, MAINTENANCE PERSONNEL AND OTHER EMPLOYEES WHO WORK WITH LITTLE SUPERVISION WILL BE TRAINED IN FIRST AID AND C.P.R. :2> Page 2 as needed ~3> Held for Future Use -'4> Held for Future Use CRYSTAL GEYSER TRAINING REQUIRED / DATE COMPLETED EMPLOYEE AMMONIA AMMONIA SCBA FIRE EMERGENCY EVACUATION SPILLS AND NAME HANDLING DIFFUSION SAFETY NOTIFICATION PROCEDURES NEUTRALIZATION · 2 -..~-'P/ 2 -- -.~. ,..,,- ~. N-z~-~ 2.2~.~ ¢/-/2-¢~ EXHIBIT 10 ..! CRYSTAL GEYSER TRAINING REQUIRED / DATE COMPLETE;D EMPLOYEE I AMMONIA AMMONIA FIRE EMERGENCY EVACUATION SPILLS AND NAME HANDLING DIFFUSION SCBA SAFETY NOTIFICATION PROCEDURES NEUTRALIZATION I EXHIBIT ~ U~NSE ........ ~E~ R~ ~ 1 ~1 ~8 ....... ~l:~ J~I X - ~1~8 i ii C~ILLO~ RUDY X 10/29/97 Ix 12/2,/~8 .... CE~ Mi~UEL I X 10/29/97 IX 10/31~97 I I i LO~NO~AIDA X 10~7 . . x 10B1~7 , MENDO~ ~OSE X 10~9~7 x 10/29/97 ~YO. ~~ ix .~ x 12~/~.. ,, X :x i i, ~I~T~ DAVID X' x ~ ' x 1~1~8 X ~1~3 , , X 1~ V~U~ HECT~ ; 0~2~8 I i i. i I I X 12~8 iii ' CRYSTAL GEYSER TRAINING REQUIRED ;/ DATE COMPLETED EMPLOYEE AMMONIA AMMONIA FIRE EMERGENCY EVACUATION SPILLS AND NAME HANDLING DIFFUSION SCBA SAFETY NOTIFICATION PROCEDURES NEUTRALIZATION EXHIBIT 10 ANNEX III.6 PLAN REVIEW & MODIFICATION This Items addressed in this Annex: [] Updated within five years and recorded dates of any reviews (2745.10, 2750.7) Compliance audits at least every three years (2755.6, 2760.8) [] Written procedures to manage changes that affect regulated processes (2760.6) Facility compliance plan review after any incident or nonconformance condition Facility compliance plan review upon any change in the facility potentially affecting plan content (2745.11) Terms and conditions may be subject to modification by the participating permitting agencies at any time Facility compliance plan may be modified to incorporate special conditions resulting from the issuance of a special order or promulgation of new standards Modifications which result in new conditions shall be revised in the facility compliance plan within 60 days ~ Change of facility ownership shall obligate the new owner to seek prior written approval from the City of Bakersfield - Environmental Services for the continuance of the use of the facility compliance plan The facility shall allow any authorized representative of a participating permitting agency, upon the presentation of credentials, to: O Enter the premises where a regulated activity is conducted or where records must be kept O Have access to and copy, at reasonable times, any records that must be kept O Inspect at reasonable times any facilities, equipment (including monitoring and control equipment), practices, or regulated operations O Sample or monitor, for the purposes of assuring compliance, any substances or parameters at any location O Inspect any area where pollutants or other regulated substances could originate, be stored, or be discharged into the environment CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICE8 WZ[ IV. REVISION RECORD All records concerning this RMPP 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 Person Number Affected Revision Making the Revision 1. All 12/93 2. 5. 6. 7. 8. 9. 10. Page 5 OCT 17 '96 OB: 10PM CRYSTRL GEYSER WRTER P. B A K E R S F I E L D FIRE DEPARTMENT 2tO1 'H' ~ketSfl~d, ~ 95~1 ~1 ~P Update Rcq~g SOP~E~lOU S~C~$ On Augmt 14, 1996, y~ fgility ~p~Sm~ m activation of~e ~ Mmaa~mt 2101 'H" ~teel ~,e,sfleM, CA%a01 l're~fim~ Pro~ ~P) plm implm~tation of~c ~monia dZ~i~ ~gm. ~fis offi~ is (ms) 32~-~ vc~ pleas~ wi~ ~e r~t ~ss ofyo~ ~PP in g~al, ~d ~ ~o~a ~ion ~slcm in ~ (~5) ~a,.~a4v p~ticular. ~tvmno, s~v~c~s Thc lo,ow-up ~pm~ on ~e incidmt that was ~nt to Uds o~ by N~,,m ~b~ 115 Cheslor Ave, , ' nokorm:irJ, c~ 9a~[ sp~ifi~d that indbator lights would be ~slsll~ on ~ c~bo c~ler panel to sim file o~ator a~s.~ M~ch 23.1989. l~i~ involving a pow~ fail~ md ~e operator's inability to as~ss ~e operational mn~fion o~ fl~e v~om ~mp~mts of ~ ~oNa EflV~ONMENTAL 1715 Cl~esler Ave, (~s) a2t,-awv ~cquir~s flint you u~ate ~c a~a~ ~ti~s of ~e ~P to d~t flze ~t~lafi~ ~d station 6.0: D_~gti~. Moni~nl or Au~atic Con~l Svstms, In ad~fi~, ~aM~g ~A~N~N~ ~V~S~ON opcrating pr~s should ref~ ~c in~caor h~ as ~ abno~al con~tion ~2 V~lo¢ Skeel ~e~t~ld, cA ~aa~ oporator attention. (8~) a~-4697 r~ cms) 3~-s~ PI~ ~b~t'~e m~csfi~ to ~e ~P wi~ 30 days offs Icftu. You m~ ~bmit only ~o~ pages of ~¢ plm ~t ~n~n m~ons. If you haw ~y questions, pieag f~l ~ to call me at 326-3979. Th~ you f~ yo~ cmfim~ed ~s to ~lp ~kc ~c Cit~ of B~sfield a s~ pla~ which to work ~d live, Post-it* Fax Note 7671 Date [~ges H~dol ~ne a ' Phone a 9.0 AUDITING PROGRAMS 9.1 Ammonia Systems A copy of the audit used at Crystal Geyser Bakersfield plant is included as Appendix F. The purpose of the ammonia safety audit is to ensure that the ammonia system is operating and maintained in a manner that ensures the minimum possible risk to employees, the general public, environment and product safety. Other goals to be achieved by the ammonia safety audit are: · To pinpoint actual and potential safety hazards due to design, location, operation and maintenance of the ammonia systems. · To provide a means of objectively assessing and documenting plant safety. · To provide a means of objectively defining needs for upgrading and modification. · To provide feedback on safety Issues. The ammonia safety audit will be conducted on a yearly basis. Page 35 APPENDIX F AMMONIA SAFETY AUDIT FACILITY: Crystal Geyser Company ADDRESS: 1233 East California Avenue, Bakersfield, California 93307 TELEPHONE: (805) 323-6296 DATE OF AUDIT: KEY FACILITY PERSONNEL: Plant Manager: Quality Control Manager: Maintenance Manager: AMMONIA SAFETY AUDIT TEAM: Plant Manager: Quality Control Manager: Maintenance Manager: Appendix F Page 4 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 Operations, set point and purpose of safety controls Location, operation and normal position of isolation valves Relief valve location, purpose, setting and proper operator response is 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 F Page 5 VVZl INC {'"'~' APPENDIX F AMMONIA SAFETY AUDIT Instructions The questions have been designed to assist you in determining what level of safety exists in your plant. Some of the questions are provided to record descriptive information for future reference by your staff, and others who will review the audit results. Most of the questions directly related to an item that impacts system safety, have been formulated to require only a "Yes / No" answer. The sense of these questions is generally such that a "No" answer signals some degree of deficiency for that item. The audits should be carried out annually, by the plant audit group, and every four years by-a full audit group. The timing for the audits should be set by the plant management to suit the availability of staff. The schedule should allow adequate time for the audit. The date can be scheduled well in advance, allowing sufficient time for the prior collection of some of the basic information by non-key staff. The audit group, for the annual audit, should consist of the: Plant Manager Maintenance Manager Quality Control Manager and for a full audit, by the plant audit team with the addition of an outside refrigeration consultant. Appendix F Page I The audit group will have to judge what classification should be assigned for the Safety Item Rating (S.I.R.) for each item. Usually, although not necessarily in every case, those items give a "No" answer will require some level of remedial action. It is intended that the S.I.R. reflects that level by means of assigning one of the following classifications: "E" (Emergency) Action should be taken immediately to correct a situation that represents an imminent danger. "U" (Urgent) - A firm deadline should be set to correct a deficiency that may be a serious hazard, but not immediately dangerous to life or property. "1" (Improvement) Improvement is required, but can be achieved through the ...... regular channels of maintenance activity, capital improvements or assignment to the functional staff (e.g. organizational, training, procedural improvements). "N" - No action considered necessary. "NA" In case the item is not applicable to your plant situation. When the checklist has been completed, the audit group must review the Safety Item Ratings given to each element. Lists should be made separately for the Emergency and Urgent items, and the audit summary form must be completed. The audit team will be required to arrange the lists in order of priority, and to formulate a practical plan for the execution of the works, including a timetable, allocation of responsibilities for the work, and preliminary budget estimates of the costs involved. Appendix F Page 2 The audit team's findings, lists and recommendations are to be discussed with the plant manager at the conclusion of the audit. Completed copies of the audit forms are to be retained by the plant manager for future reference. Append~ F Page 3 ANNEX 111.7: POLLUTION PREVENTION Structural Control: (check ali that apply) Process Control: (check all that apply) Secondary Containment: Equipment: [~ absorbent materials [21 vents [~ berms [] relief valves [21 booms [~ check valves [~ catchment basin [21 scrubbers ~1 collection systems [] flares [21 containment curbs [] manual shutoffs [21 culverting [21 automatic shutoffs [~ dikes [] interlock system: [~l drainage trench O warning light [] drip pans O physical barrier [] gutters O warning signs [] holding pond [] alarms & procedures [21 oil drainage collection equipment around: [] keyed bypass C) pumps [2] emergency air supply O valves [] emergency power 0 flanges [] backup pump 0 expansion joints [] grounding equipment O hoses [] inhibitor addition O drain lines [~ rupture disks O separators [~ excess flow device C) treaters [~ quench system O tanks [~ purge system 0 allied equipment [] [~[ protection of areas subject to flooding [] retaining walls Design: ~l secondary containment for portable tanks I~1 industry-specific design codes and standards: [~1 spill diversion ponds O NFPA 58 (or state equivalent) I~] wiers O OSHA 1910.111 O ASTM Container Management: O ANSI standards [] tank & container material compatible with: O ASME standards 0 substance stored 0 0 temperature [] internal heating coil leakage controlled by: 0 pressure 0 monitoring for contamination [] hazardous waste containers properly labeled 0 settling tank [] incompatible materials physically separated 0 skimmer [] materials stored in covered areas or containers 0 installation of external heating coil [] materials stored in secured storage areas 0 other separation or retention system [21 equipment positioned to prevent spills [] fail-safe engineered sump and drain systems: [~ radioactives stored to prevent release 0 adequate tank capacity 0 overflow accommodation Corrosion Protection: 0 adequate vacuum protection ~l metallic tanks and piping protected by: 0 redundant pumps and controls 0 coatings [] special precautions for separators and treaters: 0 cathodic protection 0 flare within diked area 0 regular pressure testing 0 high liquid level shuts in well 0 protective wrapping 0 parallel redundant dump valves 0 alternative exposed pipe corridors [~l blowout prevention well control measures ~l partially buried tanks avoided unless coated [] materials stored close to process areas [] pipe supports minimize abrasion & corrosion [~l material balances performed for critical process and allow for expansion & contraction [~] radioactives not in a respirable size range [21 submerged piping protected from stress & fishing operations in offshore waters [21 vehicle clearance signs under overhead piping Emergency Control: (check all that apply) [~ fire control equipment: 0 portable fire extinguishers 0 fire water hose 0 automatic sprinklers 0 water spray systems Procedural Control: (check all that apply) 0 fire extinguishing foam 0 inert gas Maintenance and Operation: 0 dry chemicals [~l M&O to minimize possibility of fire or release 0 fire walls [] testing & maintenance of equipment 0 blast walls [] preventative maintenance of monitoring 0 deluge system equipment in accordance with manufacturers's 0 water curtain instructions ) 0 enclosure [~ required equipment: [~ spill control equipment 0 location [] neutralization 0 availability [] decontamination equipment 0 maintenance schedule [] [] visible leaks promptly corrected [~ out of service pipes marked, capped, or blank flanged Emissions Control: (check all that apply) [] valves & piping regularly examined or tested [] loading rack in compliance with DOT Stormwater Run-Off: [] facility transfer operations: [] drainage from diked areas restrained by: 0 valves & pipelines inspected 0 valves 0 salt water disposal facilities inspected 0 manually activated pumps 0 flowline maintenance program 0 other drainage spill prevention [] well shut in procedures adequately described 0 design to handle such leakage [] submerged pipelines adequately maintained [] diked area drainage valve operations: [] fully fenced and locked when unattended 0 use of non-flapper type valves [] valves locked in closed position 0 manual open & close design [] pump controls locked in "off" position 0 storm water inspected before drained ~l loading rack connections capped or blanked [~l undiked drainage flows into: [~ internal / external corrosion detection / repair 0 ponds [] damage criteria for equipment repair / replace 0 lagoons [] maintenance & inspection records available 0 catchment basins [] standard procedures for transfers: 0 diversion ditches 0 pre-transfer checklist 0 treatment unit(s) 0 review of transfer procedures [] diked rainwater drainage protected by: 0 verification of oil levels & volumes 0 normally closed bypass valve 0 inspection of key components: 0 inspection before draining [] valves 0 supervised bypass valve operation [] hoses 0 records of all such drainage events [] piping [~1 drainage valves normally closed & sealed [] pumps [] effluent disposal facilities monitored often 0 hook-up, start-up, & shut down 0 reduced loading rates at start & finish Air Pollution: 0 emergency shut down of transfer [] vapor control systems: 0 wellhead or platform shut down 0 submerged fill pipe 0 pressure tank 0 vapor recovery system 0 floating roof tank /~ gasoline pump nozzle hold-open latch Procedural Control: (continued) Inspection and Testing: [2] regularly scheduled inspection & testing of: O tanks Procedural Control: (continued) O pipelines O storage equipment Safety Management: O transfer equipment [] -- / . / date of most recent review or O production equipment revision of safety information O pumps [~l process safety information: O valves O regulated substance hazards O flanges O process technology O overpressure safety devices O process equipment specifications [~ methods of testing include: O safe upper/lower temperatures O hydrostatic testing O safe upper / lower pressures O visual inspection O codes / standards built by [~l overfill detection device testing: O good engineering practices O prior to each transfer [~ mechanical integrity: O monthly testing O written mech. integrity procedures C) monthly inspection & annual testing O inspection / testing of equipment [~l clear communications during transfer O correcting equipment deficiencies O quality assurance for suitability Source Reduction: O installed properly to specifications [~ employee incentives for good housekeeping O suitable spare parts & equipment I~ cost accounting for waste generation / disposal I~l management of change: ~ first-in / first-out materials usage policy O technical basis for proposed change [] perishable materials used up before outdated O impact of change on health & safety [~l computer tracking of material inventories O modifications to operating procedures [~l materials stored in reusable containers O necessary time period for change [~l materials stored in low traffic areas O authorization requirements for change [] proper equipment to move drums safely [~l employee participation: [21 waste streams segregated O written action plan for participation [] materials used only for intended purposes O in development of PHA O employee access to PI-IA results [~1 pre-weighed materials in soluble bags O source reduction techniques [] lab scale tests performed before production O hazardous materials policies [~ solvent waste generated from cleaning is: [] hot work permit: O drummed for disposal O issued for work on or near process O drummed fo{use in another process O fire prevention per 29 CFR 1910.252 O sent to a holding tank [] piping is pigged before flushing [] contractors: [] product storage tanks cleaned by: O informed of process hazards O informed of emergency action plan O manually scraped O trained in safe work practices O high pressure spray system using caustic, then solvent rinsed O safety program evaluated [~l established procedures for cleaning equipment O illness & injury log available [] communication between cleaning & [~ pre-start up safety review: O whenever changes in process safety production crews ~ formal policy commitment to source reduction O adequate procedures in place I~ use of non-hazardous material alternatives: O PHA performed & implemented O non-chlorinated solvent cleaners O employee participation in review O non-caustic cleaning solutions [] injury & illness prevention program O per requirements of 8 CCR 3203 O biodegradable detergents O low VOC paints & coatings O drug & alcohol testing O reduced cleaning [~ counter current rinsing processes installed [] automated raw material feed [] product design modified to reduce waste ANNEX III.8 CERTIFICATIONS Items addressed in this Annex: Regulatory cross-references (attached) Program 1 certification (only if applicable) (2735.4) Certification statement of complete and correct information: '7 certify under penalty of law that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete." Printed name & title Signature Date CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES III. 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 (f) 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 Plant Manager, are contained in Section 13.0 of this RMPP. I hereby certify that this RMPP is complete, that the hazard and operability studies performed 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. ~Registere~nvironmental Assessor State of California No. REA-00050 E,~piration Datek June 30, 199~- . Santiago Martinez Plant Manager Crystal Geyser Water Company, Bakersfield Page 4 13.0 QUALIFICATIONS OF CERTIFIERS 13.1 Qualified Person Mary Jane Wilson, President, WZl 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 Chief Executive Officer of WZI Inc. She monitors WZI Inc. projects to maintain technical standards. She has extensive experience (21 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 Santiago Martinez, Plant Manager, Crystal Geyser, Bakersfield. Mr. Martinez, Plant Manager of Crystal Geyser, has 22 years of experience in the beverage bottling industry. He has been involved with the installation, modification and maintenance of numerous bottling and ammonia refrigeration systems during this time. Page 42