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HomeMy WebLinkAboutHAZARDOUS WASTE (2) HAZARD ANALYSIS JULY '1993 REVISION CRYSTAL GEYSER WATER COMPANY WZl .Inc. 4700 Stockdale Hwy, Suite 120 Bakersfield, California 93309 AMMONIA SAFETY ·AUDIT FACILITY: ADDRESS: TELEPHONE: DATE OF AUDIT: CRYSTAL GEYSER, BAKERSFIELD 1233 E. CALIFORNIA AVENUE (805) 323-6296 KEY FACILITY PERSONNEL PLANT MANAGER: · QUALITY CONTROL MANAGER: MAINTENANCE MANAGER: ALEXANDER MANNS GERHARD GAUGEL NORMAN AMBROSE AMMONIA SAFETY AUDIT TEAM PLANT MANAGER: QUALITY CONTROL MANAGER: MAINTENANCE MANAGER: ALEXANDER MANNS GERHARD GAUGEL NORMAN AMBROSE Appendix C Page 1 AmmQni~ ~.afety Audit Continued This safety audit is a review of the ammonia system equipment and operation. Do employees responsible for the ammonia system have a thorough understanding in the following areas? Basic refrigeration fundamentals Compressor functions and limitations ~ Operation, set point and purpose of safety controls Location,Operation and normal position of isolation valves .. Relief valve location, purpose, setting and proper operator response if activated Recognition and response to abnormal conditions Correct procedures for system charging and oil drainage Emergency planning: is there a written emergency plan? ~ System design: the attached forms should be filled out for each piece of ammonia containment vessel. The ammonia incident report should be filled out after an ammonia incident has occurred. Appendix C Page 2 · ~APPENDIX C '- AMMONIA VESSEL SAFETY INSPECTION DATA (COMPLETE ONE FORM FQR EACH VESSEL) VESSEL NAME OR OSE, LOCATION (BLDG.): '~ : ......... LOCATION OF. VESSEL IN BUILDING:; DESCRIPTION OF VESSELS USE: o o NORM_AL PRESSUILE IN VESSEL WHF_N THE REFRI'GEILITI~Y SYSTEM IS IN OPEP. ATI.ON: PSIG'... VESSEL MANUFACTURM-R DESIGN WORKING PP~ESSbqLE: PSIG '7. ES VESSEL ASME (OR EQUIVALENT AIrI14ORITY)' STAMPED: 8' VESSEL REGISTRATION NO.: 9. VESSEL LENGTH: 10. VESSEL DIAMETE!t: 11. YEAR OF MAtCJFACTI/REIt: "'feet inches 12. DOES VESSEL HAV~ A ~LELIEF VALVE?. 13..iS RELIEF VALVE SINGLE OR DUAL?:i f' ... 14. ~HAT IS .VqqE RELIEF VALVE PRESSUILE sETTING? 15. WHAT IS THE RELIEF VALVE .RATING? PSIG lbs. air per minute 16. WHAT IS RELIEF VALVE 117. W%I~T. IS THE. SIZE OF THE RELIEF VALVE OUTLET7 AMD. OUTLET PIPE ,. 18. IS THE~RELIEF VALVE PROPEPdLY PIPED TO THE ATMOSPHEILE? 19. TO YOUR KNOWLEDGE HAS THIS VESSEL ~q BEEN ALTEPdSD OR MODIFiSD? 20. DO YOU. HAVE ANY ASME CERTIFIED PRI~TS OR U-1 'CERTIFICATE (OR LOCAL EQUIVALE2q~) AT'THE ~ACZORY S~TZ? ,.:. ~" ' .".. ? i." (Y/N) PAGE· 3 AMMONIA VESSEL SAFETY INSPECTION DATA {COMPLETE ONE FORM FOR EACH VESSEL) VESSEL MA/CE OR USE 1. LOCATION (BLDG.}: -Plant '? 2. 'LOCATION OF. VESSEL IN BUILDING: 3. DESCRIPTION OF VESSELS USE: 4. NORMAL PRESSURE IN VZSSEL WHEN THE REFRI'GERATI? SYSTEM IS IN OPERATION: pSIG' ... 5. VESSEL MANUFAC~ i:'" 6.. DESIGN WORKING PRESSURF-: PSIG 7. IS VEssE~ ASME (OR EQUIVALENT AUTHORITY)' STAMPED: B · VESSEL REGISTRATION NO.: 9. VESSEL LEI~GTH: 10. VESSEL DIAMETER: ·"feet 'inches 11. YEAR OF MANUFACTITRER: 12. DOES VESSEL HAXrE A RELIEF VALVE? ~ 13. IS RELIEF VALVE SINGLE OR DUAL?: 14. WHAT.IS THE RELIEF VALVE PRESSURE S~TTING? 15. WHAT IS THE·RELIEF VALVE RATING? lbs. air per minute 16. WHAT IS RELIEF VALVE YEAR OF MANUFAC~? .. 17. WHAT .IS THE. SIZE OF THE RELIEF VALVE OUTLET? '. AND:OUTLET PIPE 18.. IS THE RELIEF VALVE PROPEP~LY PIPE~ TO THE ATMOS?HEP~E? ~ 19. TO YOUR KNOWLEDGE HAS THIS VESSEL EVER .BEEN ALTERED OR MODIFIED? ~ ~ PSIG 20. DO YOU HAVE ANY ASME CERTIFIED PRINTS OR U-1 CERTIFICATE (OR LOCAL EQUIVALENT) AT THE FACTORY SITE? (Y/N) 21. IF ALTEP~ED, WAS VESSEL RECERTIFIED' · 22. WHAT CONTROLS ARE FITTED TO THIS. VESSEL A. NONE .. CONDITION x. SE~fING OPERATES.r ..... · ,. (G,...F,:]~):.';.,. % .- Level (Y/N) ' B. HI LIQUID LEVEL CUTOUT C. LIQUID LEVEL CON- 'T~OL · D. LOW LIQUID LEVEL' CUTOUT FAIR BAD D~TE OF LAST TEST: 23. ASSESS CONTROL COLUM/~ DESIGN: h ' {SCREWED JOINTS, STOP VALVE LOCATIONS, CONDITION) GOOD FAIR POOK '~' 24. DOES RELIEF VALVE LOOK: IE/G/F/B) E~CELLENT (CLEAN WITH NO VISIBLE RUST OR CORROSION) ~ d.:~<jD (LOOKS OK BUT SOME CORROSION VISIBLE/LESS THA~ 25 % SURFACE ONLY) · (CONSIDERABLE SURFACE CO~OSION BUT NONE VISI- BLE INTER/qALLY ) (SURFACE AND INTEP/qAL~CORROSION VISIBLE) 25. IS THIS VESSEL COVERED WITH INSULATION7 · CONDITION OF INSULATION: (G/F/B) " GOOD ' ! FAIR (SLIGHT SIGNS OF VAPOR BARRIER LEAKS) BAD (Y/N) (EXTENSIVE SIGNS OF VkPOR BARRIER LEAK~) 26. ANY. ABNORPL~L ICE FORMATIONS ON VESSEL? 27. ANY SIGNS OF RUST/COP~ROSION ON VESSEL? A. NONE B. SLIGHT OR TRACE C. MODERATE BUT APPEARS TO BE SURFACE ONLY D. APPEARS TO BE EXTENSIVE, SHOULD BE EX3~MINED BY CONSULTING E/~GIhrEER E.- CA/~NOT TELL DUE TO INSULATION GIVE DATE ~- !. '.-~-':"-'"'~'- 28 HAS THIS VESSEL BEEN INSPECTED BY oUTsIDE I~SPEC~R w~THI~ WE LAST S u .... BY ~E ME.ODS? .......... 30. '~ES ~E VESSEL.~VE.~ OIL POT? ... .31. ~ES OIL P~ ~VE RELIEF VALVE? ::_:'~"..' 32.. IS OIL POT RELIEF VAL~ CO~CTLY "~".. PIPED? 33. SPECIAL REMARKS ON VESSEL CONDITION OR USAGE: 34. SPECIFY OVERALL RATING (S.I.'R.} -..Compressor'- Room oil accumulator (Y/N) APPENDIX C AMMONIA CO?VPRESSOR SAFETY INSPECTION DATA (COMPLETE ONE FOP_M FOR EACH COMPRESSOR) .1.. COMPRESSOR DUTY : HIGH STAGE BOOSTER SWING 2. COMPRESSOR ~fPE : RECIP VERTICAL ROTARY VANE RECIP V ROTARY SCREW COMPRESSOR lflAbIUFAC~R : 4 MODEL NO. YEAR BUILT CAPACITY DRIVE .:. DIRECT (TOMS) BELT 7 8 COMPRESSOR P~M RELIEF VALVE ?fi?~E : INTERNAL NAM~EPLATE Y~. RPM ~XT E PJ~ AL · · iS A CHECK VALVE PROVIDED AT ~HE DISCE~RGE OF EACH COMPRESSOR? (¥1~)' !0. NOP~LAL COM?RESSOR.PRESSURES (PSI): SUCTION :' ' DISCHARGE MA/{UFACTI/RER RECOFLU~--2fDED MAX, DiSCH3~RGE PRZESSURE 11. LOW PRESSUTt~ CUTOO~ SE%TING (PSi DESIGN ACTUAL CHECKED "' (Y/N) OPERATES PROPL~Y 12. HIGH PAESSb~P~E CIFSOUT SETTING (PSI) DESIGN AC~AL CHECK_ED (Y/N) OP~ATES PROPL~ULY 13. iS HIGH PR, ESSUR_E SWITCH ~A3%D WIRZ/D: a) TO MOTOR'STA~,TER b) TrLVOUGH PLC 14. HIGH DISCHARGE T~M_PEP~kTUR_E CLYi'OLr'k SEI~flNG DESIGN ACTUAL CHECKED. [Y/N) OPEP~A~ES PROPERLY 15. OIL PRESSURE SAFETY SWITCH SETTING (PSI) CHECK-ED (Y/N) OPEP~ATES PROPEJ~LY oc) ...... (Y/N PAGE 6 APPENDIX C 16. IS COMPRESSOR .CO~ECTED ~O A ELOODED VESSEL? IF YES, DOES HIGH LE-V-EL SWITCH STOP COMPRESSOR HiGH LEV-EL SW. CHKII. __[Y/N) OPERATES OK 17. DOES COMPKESSOR START AUTOMATICALLY?. :rF.YES, IS THu_P~E ~2~ "AUTO STAP, T'I.NOT!CE POSTED? ' ' ' (Y/N) 18. COMPRESSOR DR!V-E IS ELECTRIC MOTOR __, sTEM4 TIIP3!ME , GAS ENGINE AT RPM AND C~ PRIME MOVER OVERSPEED? 19. AbNf'ABNORMAL VIBRATIONS PREs~? 20. DRIVE GUARDS: ADEQUATE CO~RAGE AN~ SECIPRIL? 21. ~ ABNORPLIL NOISES? 22. ELECTZRICAL COVERS IN PLACE? 23. ~ry ViSiBLE LEAKS? 24. IS ~HERE A SA_rE MET~HOD FOR ELEC~RICAL ~ SYSTEM ISOLATION? BELTS (Y/N) (Y/N) [Y/N) 25. GENE.PAL ASSESS~ OF COMP}LESSOR e24. Brakers can be locked out, but comulete section of old brakers must be. paddle-locked. '!6. No Hig~ level cut out control. PAGE 7 OPERATORS LOG (typical) TIME PRESSURE TEMPERATURE OIL ADDED? coMMENTS EXHIBIT 6 CRYSTAL GEYSER WATER TRAINING REQUIRED / DATE COMPANY COMPLETED EMPLOYEE AMMONIA AMMONIA SCBA FIRE EMERGENCY EVACUATION SPILLS AND NAME 4ANDLING DIFFUSION SAFETY NOTIFICATION PROCEDURES DILUTION EXHIBIT 10 CRYSTAL GEYSER MAINTENANCE RECORD EQUIPMENT: DATE: WORK PERFORMED: CAUSE: COMMENTS: EQUIPMENT: DATE: WORK PERFORMED: CAUSE: COMMENTS: EXHIBIT 7 CRYSTAL GEYSER AMMONIA CHARGE RECORD Date Ammonia in Plant Amt. Added Initial (Pounds) (Pounds) L EXHIBIT 9 CRYSTAL G EYS E R WATER COMPANY BAKERSFIELD, CALIFORNIA AND RISK MANAGEMENT PREVENTION PROGRAM OCTOBER, 1 990 REVISED FEBRUARY, 1991 REVISED APRIL, 1991 SUBMI'FI'ED TO CITY OF BAKERSFIELD FIRE DEPARTMENT HAZARDOUS MATERIALS DIVISION BY WZl INC. 4800 Easton Drive, Suite 114 Ba. kersfield, California 93309 805 / 326-1112 4800 Easton Drive, Suite 114 Bakersfield, California 93309 Post Office Box 9217 Bakersfield, California 93389 805/326-1112 805/326-0191 FAX CryStal Geyser Water Company Bakersfield, California Risk Management and Prevention Program October, 1990 Revised February, 1991 Revised April, 1991 Submitted to the City of Bakersfield Fire Department Hazardous Materials Division by WZI Inc. 4800 Easton Drive, Suite 114 Bakersfield, California 93309 0332.0010A Table of Contents 1.0 2.0 3.0 4.0 5.0 6.0 Purpose Introduction Certification Revision Record Background 1.1 'General Business Information 1.2 Description of Acutely Hazardous Materials 1.3 General Ammonia Refrigeration Processes 1.4 Operation of the Ammonia System AHM) Used Description of AHM Accidents 2.1 Accidents at this Location 2.2 Underlying Causes 2.3 Measures Taken to Prevent Recurrence 2.4 Accident Investigati.on Procedures 2.5 Release Reporting Procedures Equipment Report 3.1 Nature, Age and Condition 3.2 Testing Schedules 3.3 Maintenance Schedules Procedures Report 4.1 Daily Operating Procedures 4.2 Maintenance Procedures Design, Operating and Maintenance Control Systems 5.1 Design Control Systems 5.2 Operating Control Systems 5.3 . Maintenance Control Systems Detection, Monitoring or Automatic C(~ntrol Systems 6.1 Detection Systems 6.2 Monitoring Systems 6.3 Automatic Control Systems Page 1 1 1 3 4 4 4 5 5 6 6 6 6 6 7 8 8 12 12 13 13 14 16 16 .16 16 17 17 17 !7' 7.0 8.0 9.0 10.0 11.0 12.0 13.0 Proposed Risk Reduction Measures 7.1 Written Operating Procedures 7.2 Written Maintenance Procedures 7.3 increased Ihspections 7.4 Better Labeling 7.5 Safety and Training Program 7.6 Fire Prevention 7.7 Physical Plant Changes 7.8 Reduction of Risk to Neighboring Homes or Businesses Emergency Contingency Plans 8.1 General Evacuation 8.2 Fire 8.3 Earthquake 8.4 Significant Leak from the Ammonia System 8.5 Emergency Responders Auditing Program Inspection Program Risk Management and Prevention Program (RMPP) Implementation 11.1 Personnel Responsible for RMPP Implementation 11.2 Implementation Schedule 11.3 Training Program for RMPP Implementation RMPP Record Keeping 12.1 Accident Records · 12.2 Ammonia Charge Records 12.3 Training Records 12.4 Audit Records Qualifications of Certifiers 13.1 Qualified Person 13.2 Facility Operator References Page 18 18 18 18 18 18 18 19 19 2O 2O 2O 2O 2O 21 22 23 24 24 25 26 28 28 28 28 28 29 29 29 3O Exhibit 1 Exhibit 2 Exhibit 3 Exhibit 4 Exhibit 5 Exhibit 6 Exhibit 7 Exhibit 8 EXhibit 9 Exhibit 10 'Exhibits Location Map Facility Diagram Surrounding Area Schematic of the Ammonia Refrigeration System Ammonia Incident Report Operator's Log Maintenance Record Evacuation Routes Ammonia Charge Record Training Required/Completed Record Appendix A Appendix B Appendix C Appendix D Appendices Business Plan Hazards Analysis Introduction Summary Hazards Identification Hazard and Operability Study Results Vulnerability Analysis Risk Analysis Ammonia Safety Audit Ammonia Material Safety Data Sheets 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, Bakersfield, California bottling facility. I1_~. Introduction This RMPP has been requested pursuant to Section 25534 of Chapter 6.95, Article 2 of the California Health and Safety Code (CHSC) by the City of Bakersfield Fire Department to reduce the risk of and prevent accidents involving AHM. A risk management and prevention program is defined in Section 25532 as: "all of.the administrative and operational programs of a business which are designed to prevent acutely hazardous materials accident risks, including, but not limited to, programs which include design Safety of new and existing equipment, standard operating procedures, preventive maintena.nce programs, operator training and accident investigation procedures, risk assessment for unit operations, or Operating alternatives, emergency .response planning, and internal or external audit procedures to ensure that these programs are being executed as planned." This RMPP is based upon an assessment of processes, operations, and procedures of this facility and considers results of the hazard and operability study that has identified hazards associated with handling of anhydrous ammonia, an AHM. Ammonia system operators and other employees will use procedures detailed in this plan to improve facility safety. As specified in Section 25534 (f)., Chapter 6.95, Article 2, CHSC, all records involving the RMPP shall be kept for a minimum of five years. Section 25534 (h). requires that the RMPP shall be reviewed and revised, if necessary, at least once every three years. If a modification is made to the facility that affects AHM handling, a revision of the RMPP must be made within 60 days of-the modification. I!!. Certification Section 25534 (j)'of the CHSC requires that the RMPP and any revisions be certified as complete by a qualified person and the faCility operator. Section 25532 of the CHSC defines a qualified person as "a person who is qualified to attest at a minimum, to the validity of the hazard and operability studies performed pursuant to Section 25534, and the relationship between the corrective steps taken by the handler following the hazard and Operability studies and those hazards which were identified in the studies". Qualifications of the certified person, Mary Jane Wilson, and the facility operator, Alex Manns, are contained in Section 13.0 of this RMPP. Page 1 I hereby certify that this RMPP is complete, that the hazard;and operability studies 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. / ' ~q ~ane Wilson ' /'' /' sor Reg,stere~'~ny,ronmental Asses ~t¢of California N~. REA-00050 Expiration Date: June 30, 1991 E~~I I hereby certify, as. facility operator, that this RMPP is complete. / AlexManns Plant Manager Crystal Geyser, Bakersfield Page 2 IV. Revision Record All records concerning this Risk Management and Prevention Program shall be kept for at least five years (Section 25534 (f)). NecesSary revisions to the RMPP will be made at least every three years. The RMPP must be modified within 60 days of a modification that materially affects'the handling of an AHM (Section 25534 (h.)). All revisions to this RMPP are to be recorded here. Revision Number 1. 2. 3. 4. 5. 6. 7. 8. '9. 10. Pages Date of Affected Revision Signature of Person Making the Revision Page 3 1.0 1.1 Background General Business Information Name and Location Crystal GeYser Water Company 1233 East California Avenue Bakersfield, California 93307 Exhibit 1 is a location 'map. Exhibit 2 is a facility diagram. The area immediately surrounding the plant is used for commercial, industrial, and residential purposes, as shown in Exhibit 3, a diagram of the surrounding area. Business Telephone Number (805) 323-6296 Nature of Business The. Crystal Geyser Water Company Bakersfield plant formulates and bottles Crystal Geyser Brand juice drinks and flavored waters. For process cooling, an ammonia refrigeration system is used. 1.2. Description of AHM Used Amount Used The ammonia system holds approximately 300 pounds of liquid and vapor ammonia. One or two 150 pound cylinders are stored outside of the plant. Hazardous Properties Because of its physical properties, a release of liquid ammonia has a greater potential to cause serious injury to receptors than gaseous ammonia. Liquid ammonia'released at a high rate can form a dense, ground hugging cloud of small liquid particles dispersed in air. A dense gas dispersion has the potential to move through surrounding areas, endangering neighboring recetdtors. Ammonia vapors, lighter than air, rise quickly in the atmosphere and are less likely to cause serious injury to. receptors. Ammonia vapors released into an unventilated area could reach high concentrations that present a risk to employees who enter the area unprotected. Page 4 1St Street . e ~C~' " :.~- ~ . ~"- ~ I ' ' ~ ~ <l=;~. 6 c ~ ~ ~ ' ~ ~ Sr~r~ .~. ce~[~ ~o[ i' 'SCH. c --0 Terr.ce t. 8e}i~,, 'e~~~lle Terrace Scale BAKERSFIELD, CALIFORNIA 0 Kilometert .50kin lkm ~ ~ Loc~tion -Map 5/1/90 DN 2099 Ammonia Equipment is Highlighted IN BAKWZl INC. ERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Facility Di.agram 5/90 2101 Street Vintage Air East California Avenue Jobl Crystal Shack Geyser Storage ILot' Crystal Geyser Bottling Facility Alley 'Housing Complex Cryst.al~ Geyser I ParkingI ....I , I Housing Complex BET~ Henley S Lucl IN WZI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Surrounding Area DATE I [EXHIBIT 5/1/90 Ammonia, a colorless gas with an extremely pungent odor, can be detected by smell at concentrations at 3.5 to 37 mg/m3 (5 to 53 ppm). Ammonia is corrosive and irritating to the skin. High concentrations can cause dermal' burns, inflammation and swelling of the eyes and is potentially blinding to exposed receptors. Levels of 500 mg/m3 (700 ppm) can cause eye irritation. Coughing occurs at a level of 1200 mg/m3 (1700 ppm). Exposure to higher concentrations can result in debilitating injury and death through pulmonary edema. Ammonia is not recognized as a carcinogen, and it does not cause adverse environmental impacts. 1.3 General Ammonia Refrigeration Processes Mechanical refrigeration is the process of lowering the temperature of a substance to below that of its surroundings. The cooled substance, ammonia, removes heat from process materials. In a single stage refrigeration process two pressures, high and Iow, are used to enable a continuous cooling process. Low pressure vapor is compressed, raising temperatures and pressure levels. DUring compression, heat of compression is added to the vapor as the pressure is raised. At the condenser the high pressure vapor is liquefied by cooling. The liquid refrigerant flows from the condenser to an expansion valve where its pressure is reduced and temperature is further reduced. The liquid ammonia then moves to the evaporator where it absorbs heat from a fluid being cooled and revaporizes. Vaporized ammonia then flows to the compressor suction for recompression to liquid to complete the refrigeration cycle. 1.4 Operation of the Ammonia System · Exhibit 4 is a schematic diagram of the ammonia system. 'The system is designed to . operate when cooling is needed. Gaseous ammonia enters the compressors and is compressed to a higher pressure and temperature. After exiting the compressors, the hot gas enters the evaporative condensers. Water running through the condensers cools the hot gas into a liquid. The liquid ammonia flows to and is contained in the outdoor receiver. A level control, controlled by a solenoid valve, allows ammonia to · flow from the outdoor receiver into the indoor receiver. Ammonia is charged into the indoor receiver from a 150 pound cylinderl The cap is kept on the cylinder while it is transferred through the building. For charging, the cap is rer,~oved. The indoor receiver sight glass is watched during delivery to ensure that the proper amount of ammonia is transferred into the system. From the incloor receiver, liquid ammonia flows through the lines to the cooling. equipment, the carbo coolers. In this flooded system, liquid ammonia flows through exchanger plates while the material to be cooled, flowing countercurrently, is cooled by the phase change of the boiling ammonia. From the carbo coolers, vapor and liquid ammonia travels back to the indoor receiver from'which vapors are pulledby the compressors. Liquids are recycled from the receiver back to the coolers while vapors travel through insulated lines to be compressed to high pressure and then cooled into a liquid, completing the cycle. Page 5 liquids and vapors SV Carbo Coolers Solenoid Valve controlling Flow to Carbo Coolers liquids prv vapors to compressor suction Compressor Compressor SV discharge pry: pressure relief valve sv: shutoff valve Ammonia Receiver Level (Inside) Control Solenoid Vessel Valve SV SV SV Ammonia Added to The System from 150 lb Cylinder Ammonia Receiver (Outdoor) Evaporative Condenser Evaporative Condenser WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Ammonia Schematic Diagram DATE I IEXHIBIT 5/15/90 2.0 Description of AHM Accidents 2.1 Accidents at this Location On March 23, 1989 a release involving the ammonia system caused neighbors to complain of an ammonia smell. A power failure caused the system to shut down. When power was returned, the initial startup blew three-thirty amp fuses in the condenser panel, shutting down both compressors. The operator did not know that the condenser were not operating and turned on the ammonia compressors. Pressure in the system quickly rose, forcing ammonia through the high pressure relief valve. 2.2 Underlying Causes The release was caused by the operator who turned on the compressors although the condensers were not working. 2.3 Measures Taken to Prevent Recurrence The operator is now required to check the condensers every time he turns on the compressors. He has received substantial training to ensure that this type of release does not recur. Only trained personnel are allowed to operate the ammonia system. 2.4 Accident Investigation Procedures After an accident has occurred, an ammonia incident report (Exhibit 5) shall be filled out. A post accident review shall be held in which potential causes of the accident are discussed. Whed the cause of the accident has been determined, a method shall be developed to ensure that the accident will not recur. System design, operating and maintenance procedures that need updating or alteration shall be noted, and a time schedule set for implementation of improvements. Responsibilities: The Plant Manager: o ensures that accident report is complete. o conducts the accident investigation. o guides accident response. The Maintenance Manager: o provides technical details of reports. o assists with the accident investigation. o directs physical plant changes. o' makes changes to the training program, if changes are necessary. All employees: o assist with the accident investigation. Page 6 AMMONIA INCIDENT REPORT FACILITY: DATE OF INCIDENT: TIME OF INCIDENT: SEVERITY OF INCIDENT: VERY SERIOUS SERIOUS LOW THREAT Caused evacuation of the plant or neighbors, or serious injury, and required the use of SCBA (self contained b~eathing apparatusi to contain. Caused injury and or damage to property and required the use of SCBA (self contained breathing apparatus) to contain. Required breathing equipment but caused no injury or damage. LOCATION IN FACTORY: SOURCE OF DISCHARGE (TYPE OF EQUIPMENT) COMPONENT OR ITEM DISCHARGING (SUCH AS SEAL, VALVE, WELD...) CAUSE OF DISCHARGE: AMMONIA INCIDENT REPORT PAGE 1 EXHIBIT 5 ACTIVITY AT TIME OF DISCHARGE: DETAILS OF EMERGENCY RESPONSE: DEGREE OF CONTROL LOW MODERATE EFFECTIVENESS OF EMERGENCY PLAN LOTM DEFICIENCIES IN TI-IE EMERGENCY PLAN: HIGH MODERATE HIGH CONSEQUENCES OF DISCHARGE: NUMBER OF PEOPLE HURT NUMBER HOSPITALIZED EVACUATION: IMMEDIATE DISCHARGE AREA ENTIRE FACILITY ~ (Y/N) NEIGHBORS __ (Y/N) ESTIMATED COST OF INCIDENT: EMPLOYEES OTHERS · EMPLOYEES OTHERS ~ (Y/N) 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 DIREC'I~Y TO THE INCIDENT; WHAT ACTIONS WERE TAKEN TO CONTROL TIlE INCIDENT,; WHAT REMEDIAL ACTION HAS BEEN TAKEN TO PREVENT.A RECURRENCE. AMMONIA INCIDENT REPORT PAGE 2 EXHIBIT 5 2.5 Release' Reporting Procedures Releases of acutely hazardous materials that threaten human health and safety or the environment must be reported. The Plant Manager is responsible for determining the significa0ce and reportability of a release. If an ammonia release exceeds 200 cubic feet during a 24-hour period or constitutes a threat to life, health or the environment, the event is reportable and the following agency must be notified immediately. City of Bakersfield Fire Department Hazardous Materials Division Telephone: (805) '326-3979 California Office of Emergency Services Telephone' 1-800-852-7550 The Plant Manager is responsible for reporting a release. Page 7 3.0 Equipment Report 3.1 Nature, Age and Condition The following equipment makes up the ammoni~ refrigeration system at Crysta! Geyser Bakersfield. Each piece of equipment will be listed along with its nature, age and condition. Equipment: Nature: Age' Condition: _Equipment: Nature: Age: .Condition: Eq_d.pment: Nature: Age: Condition: Equipment: Iq at u re: Age: Condition' Ammonia Compress_or This 75 hp compressor is used to compress arnmonia vapors. Model Number: Vilter ¢446 Built in 1964 Well maintained, good condition Ammonia Compressor #2 This 75 hp compressor is used to compress ammonia vapors. Model Number: Vilter #446 Built in 1964 Well maintained, good condition Oil Separator # 1 This oil separator removes oil from 'the high pressure ammonia vapor d!scharging.from the #1 compressor. Oil is drained from the separator for reuse in the compressor.. Brand: Mojannier, Maximum pressure: 250 psia @ 650 o F Built in 1964 Well maintained, good condition Oil Separator ;l 2 This oil sepa. rator removes oil from the high pressure arnmonia vapor discharging from the #2 compressor. Oil is drained from the separator for reuse in the compressor. Brand: Mojannier, Maximum pressure: 250 psia ~ 650 ~ F Built in 1964 Well maintained, good condition Page 8 _.E_quipment: Nature' Age' Condition: _,Equipment: Nature: Age: Condition: Equipment: Nature: Age' Condition: Evaporative Condenser #1 This Baltimore AirCoil condenser cools the high pressure vapor ammonia to a liquid. 'Air flows up through the condenser, blown by fans. Water flows down through the condenser, evaporating and 'cooling ammonia flowing' .through small lines. Model Number: VNC-110-A, Baltimore AirCoil, Serial No. 77-0531 Built in 1977 Good Evaporative Condenser #2 This Baltimore AirCoil condenser cools the high pressure vapor ammonia to a liquid. Air flows up through the condenser, blown by fans. Water flows down through the condenser, evaporating and cooling ammonia flowing through small lines. Model Number: VNC-110-A, Baltimore AirCoil, Serial No. 77-0532 Built in 1977 Good Outdoor Ammonia Receiver .THis ammonia storage vessel, 56 inches by 19 inches in diameter, is located outside of the building and holds high pressure liquid ammonia from the evaporative condensers. Ammonia is added to the system at this receiver. The receiver has two pressure relief valves. Built in 1964. Good Page 9 Eauioment: Nature: Age: Condition: Equipment: Nature: Age: Condition' Equipment: Nature' Age: Condition: Equipment: Nature: Age' Condition: Jpdoor Ammonia Receiver This ammonia storage vessel is located in the carbo cooler room and holds high pressure liquid ammonia from the outdoor receiver. Ammonia is added to the system at this receiver. A Pressure relief valve is located on a line from the receiver. The pressure relief valve is vented in the room. Liquids flow from this vessel to the carbo coolers, while vapors are suctioned by the compressors. HSB No. 6074, Serial No. 2999 Built in 1956 Good Solenoid Valve Controlling Level in the Indoor Ammonia Receiver This solenoid valve controls liquid flow from the indoor receiver into the carbo cooler plates. Rebuilt in 1990 Good Carbo Cooler #1 Liquid ammonia flows through tubes in the carbo cooler. Heat is absorbed from liquids being cooled by the evaporating ammonia. HSB No.' 1533, Serial No. 2999 Built in: 1.955 Good Carbo CoOler #2 Liquid ammonia flows through tubes in the carbo cooler. Heat is absorbed from liquids being cooled by the evaporating ammonia. HSB No. 1535, Serial No. 2999 Built in: 1955 Good Page 1 0 Equipment: Nature: Age: Condition' Ammonia Lines The ammonia lines carry the ammonia through the system. The lines have been in place in this system for about 6 years. Good, suction lines are insulated · Page 1 1 3.2 Testing Schedules Testing of control equipment is necessary to ensure that the equipment will work when it is needed. High Pressure Cutouts Test Schedule Tested during compressor maintenance Pressure Relief Valves ' Tested when the vessel being protected undergoes maintenance 3.3 Maintenance Schedules The compressors require more maintenance than any other part of the ammonia system. The compressors are given a detailed inspection each month. Every day, operators monitor the equipment and log normal operating variables in addition to unusual'conditions. Exhibit 6 is a copy of a log typical of the operator's log used at Crystal Geyser. Conditions that may require maintenance include: o High temperatures o High or Iow pressures o High oil consumption o Unusual noises o Excessive vibration o Unbalanced operation When problems or potential problems are detected, the equipment is scheduled for maintenance. Equioment Compressors Maintenance schedules for regularly maintained equipment follows: Maintenance Schedule Monthly Inspection Page 1 2 4.0 Procedures Report 4.1 Daily Operating Procedures Operating procedures include' Daily Operatinq Duties 1. Inspect work area and overall system operation 2. Check suction temperatures and pressures constantly. to 40°F and average pressure 28 to 60 psig. 3. Check discharge temperature and pressure constandy. to 85°F and average pressure 60 to 140 psig. 4. 5. Average temperature 15°F Average temperature 40°F. Log in data once per day Check oil levels in compressors. Normal level is mid-point to one-third of sight glass. 6. Check oil pressure in compressors. Average pressure 30 to 60 psig. 7. Investigate abnormal conditions Addition of Oil to the Compressors 1. Open crankcase valve, making sure that the check valve is in place 2. Oil is pumped into crankcase with a high pressure pump 3. When finished, the crankcase valve is closed 4. Compressor is in continuous operation Page 1 3 4.2 Maintenance Procedures Maintenance procedures include: Ammonia System Shutdown 1. Shut suction valves on compressors 2. Shut king valve on receiver to pump all ammonia into the receiver' 3. Turn compressor motor off 4. Shut compressor discharge valves 5. Lock out electrical panel 6. Tag warning on the electrical panel 7. Open discharge valves before starting Isolating a Compressor for Maintenance · 1. Shut suction valve, allow compressor to pump down (remove ammonia 2. Turn compressor motor off 3. Close discharge valve 4. Lock out electrical panel 5. 'Tag warning on the electrical panel 6. Open discharge valves before starting the compressor 7. Hook bleed off hose to the crankcase to bleed off excess ammonia into a bucket of water Page 1 4 Re$1;arting a Com0ressor 1. Disconnect bleed off hose 2. Open discharge valve at compressor 3. Check oil level in crankcase 4. Remove lockout 'on the electrical panel 5. Turn on compressor motor 6. Check oil pressure 7. Open suction valve at the compressor Page 1 5 5.0 Design, Operating and Maintenance Control Systems Design COntrol Systems Design control sys. tems include proper design of piping to minimize slug formation, automatic control devices (for a listing, see Appendix B-IV of the Hazards Analysis, included in this document as Appendix B), and proper sizing of process equipment. 5.2 Operating Control Systems The operator's log (Exhibit 6) is an effective control of the operating system. Process variables are noted and action is taken if required. Other operatin(g control systems. include labeling to ensure that proper actions are taken, and safe operating procedures training. Inexperienced workers 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. 5.3 Maintenance Control Systems The Maintenance Manager is responsible for controlling maintenance of the system. Maintenance is recorded On the daily operators log, Exhibit 7. The daily operators log is reviewed by the Maintenance Manager and retained on file for future reference. .Maintenance records are a control method. Purchase orders are issued for.maintenance work requiring contractors. Completed -purchase orders are retained by the Plant-Manager. Page 1 6 6.0 Detection, Monitoring or Automatic Control Systems 6.1 Detection Systems Abnormal or hazardous conditions are detected by: Automatic controls (see Appendix B-IV of the Hazards Analysis, Appendix B of this report) Sight: Vibration, discolorations, rust, holes, worn spots Smell: Ammonia leaks, hot oil Hearing: Unusual sounds, lack of usual sounds Experience: A knowledge of what can go wrong with the system detection of hazardous conditions. 6.2 Monitoring Systems The are continuously monitored by automatic following variables equipment: Ammonia pressure- Ammonia liquid flow- will help in controlling Monitored by pressure cutouts, pressure relief valves Monitored by solenoid valves The following'variables are monitored by the operator: Ammonia pressure- Checked by operator Temperature- Checked by operator Oil levels- Checked by operator Ammonia Level- Low levels are deteCted by a rise in the temperature of the process materials. 6.3 Automatic Control Systems Automatic control systems act as a backup to operator detection and actions. A listing of automatic controls on the refrigeration system is included as Appendix B-IV of the Hazards Analysis, Appendix B of this report. Page 1 7 I 7.0 Proposed Risk Reduction Measures. 7.1 Written Operating Procedures Writt'en operating procedures (Section 4.1 of this RMPP) ensure that operators are well trained for their positions. Written procedures ensure that safe practices are continued despite turnover in personnel. These procedures will be kept in the maintenance manager's office and in this RMPP document, easily accessed by operating personnel. 7.2 Written Maintenance Procedures Training using the maintenance procedures (Section 4.2 of this RMPP) as a guide, ensure that workers are well trained to perform maintenance on ammonia refrigeration equipment. Written procedures ensure that safety is continuous despite turnover in personnel. If contract help is required, ,written maintenance procedures may prevent' accidents caused by contractor unfamiliarity with the .ammonia system. These procedures will be kept in the maintenance manager's office and in this RMPP document, easily accessed by maintenance personnel. 7.3 increased Inspections Increased. emphasis on inspections will ensure that deficiencies or problems are detected before they result in a release of ammonia. The inspection program is described in Section 10.0 of this RMPP. 7.4 Better Labeling Labeling and warning signs are an effective means of communicating hazards to new employees and/or visitors to the .plant. Emergency responders may need to know the contents of lines or types of materials in use. Improved labeling of lines or specific hazards will help to reduce the risk. of release of AHM. Ammonia lines will be labeled. 7.5 Safety and Training Program Employees will receive training under Crystal Geyser Bakersfield's safety program. The training program is described in Section 11.3, Training Program for RMPP Implementation. Release prevention and emergency response training will reduce the risk of releases and minimize consequences of releases. 7.6 Fire Prevention Plan The fire prevention plan at Crystal Geyser. Bakersfield relies upon employee safety training, and good housekeeping practices. A sprinkler system protects the building from fires. Page 1 8 7.7 Physical Plant Changes A pressure relief valve (PRV) has been added to the inner receiver. The storage location of the ammonia cylinders will be moved to the totally enclosed canopied and sprinklered compressor area in 1991. 7.8 Reduction of Risk to Neighboring Homes or Businesses The ammonia system is turned off during times when the plant is unoccupied. Maintenance practi'ces coupled with operations training reduce the risk of ammonia releasing accidents. Proposed changes to the physical plant further reduce risk to neighboring facilities. An ammonia diffusion system to be added will absorb the ammonia before it can present a risk to receptors. The plant engineer (maintenance manager) is responsible for operation of the diffusion system. He .will designate a trained employee to operate the ammonia system during his absence. Page 1 9 8.0 Emergency Contingency Plans 8;1 General Evacuation Employees are verbally notified of emergencies by t.he plant manager or his designee. All employees are to leave immediately through the nearest exit and regroup at the parking lot at East California and Lakeview. Emergency responders will be notified through 911. Exhibit 8 is a map showing emergency evacuation routes. This route has been planned to bypass ammonia systems that may be leaking. 8.2 Fire The sprinkler system will engage when it has detected a fire. All employees are to leave immediately through the nearest exit and regroup at the parking lot at East California and Lakeview. Emergency responders will be notified through 911. The sprinklers will extinguish fires in the plant. 8.3 Earthquake Employees should remain in safel stable locations (in. doorways, under st0rdy desks) until earth movement .has ceased. After the earthquake, all employees are to leave immediately through the nearest exit and regroup at the parking lot at East California and Lakeview, far enough from the building to avoid falling masonry. 8.4 Significant Leak from the Ammonia System · Employees are verbally notified of the leak. Notify the Bakersfield City Fire Department through 911. Ammonia operators will work to isolate the leak, if possible. All non essential employees are to leave immediately and regroup at the parking lot at East California and .Lakeview. Clean up procedures for an ammonia release will mitigate the effects of (he release: o Ventilation will reduce concentrations of ammonia in enclosed areas o If liquid ammonia is on the floor, spray it with large quantities of cold water 0 Water will absorb ammonia: high concentrations of ammOnia vapor or dispersed ammonia can be diluted with water spray, During a release, the plant engineer (maintenance manager) will: o Stop leaks o Supervise the use of self contained breathing apparatus. The plant engineer has an in-depth knowledge of the ammonia system. years of experience with refrigeration systems. He has many. Page 2 0 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 P~e 21 9.0 Auditing Program A copy of the audit used at Crystal Geyser Bakersfield is included as Appendix C. The purpose c' the ammonia safety audit is to ensure that the ammonia system is operated and maintS'ined in a manner that ensures the minimum possible risk to personnel, the general public, environment and product safety. Other goals to be achieved by the ammonia safety audit are: o To pinpoint actual and potential safety hazards due to design, location, operation and maintenance of the ammonia system. o To provide a means of objectively assessing and documenting plant safety. o To provide a means of objectively defining . needs for upgrading and modification. o To provide feedback on safe. ty issues. The ammonia safety audit will be conducted on a yearly basis. Page 22 10.0 Inspection Program An inspection program is necessary for the assessment of hazards present in the work place. The person responsible for inspection must be familiar 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 the inspection will be assessed and assigned priorities for correction. Action will be taken to reducb the risk presented by identified hazards. The maintenance manager is responsible for inspecting the work area at the beginning of the shift. Any notes resulting from the inspection will be noted in the log. In addition to daily inspections by the quality control manager and the maintenance manager, the ammonia safety audit includes an intensive inspection of the ammonia refrigeration system. Inspections of the system may be scheduled after process changes, upsets, or accidents. Page 2 3 11.0 RMPP Implementation "Implementation of'the RMPP shall include carrying out all operating, maintenance, monitoring, inventory control, equipment inspection, auditing, record keeping, and training programs as required by the RMPP." 1 1.1 Personnel Responsible for RMPP Implementation The title of each person charged with RMPP implementation du.t. ies are listed below, · along with their respective responsibilities. Title, Plant Manager Maintenance Manager Quality Control Manager All Employees RMPP Implementation Responsibilities Supervise audits, inspection and record keeping, responsible for RMPP implementation Supervise equipment inspection, emergency response training, operating and maintenance training, inventory control and labeling Coordinate emergency response training Undergo emergency response and evacuation training Page 2 4 11.2 implementation Schedule The following schedule will be followed for RMPP Implementation. Proqram. inspection Program Ammonia Safety Audit RMPP Record keeping Safe Operating Procedures Training Maintenance Procedures Training Evacuation Training Emergency Respbnse Training Labeling Airpack Respirator Training Move Cylinder. Storage to Canopied and Sprinklered Area Ammonia Diffusion System Date of Full Implementation Ongoing July, 1991 August, 1991 March, 1991 June, 1991 June, 1991 June, 1991 May, 1991 December, 1991 June, 1991' December, 1991 Page 2 5 1 1.3 Training Program for RMPP Implementation The RMPP training program must ensure that standard operating procedures are easily understood by operators. Training should be able to provide a continuity of safety despite employee turnover or changes in personnel. Training ensures that plans and programs such as emergency evacuation plans will work as designed when they are needed. During training sessions, employees speaking both Spanish and English serve as translators for employees that speak only Spanish. The following subjects will be covered by the training program' Use of Safety Equipment o When to wear a respirator o What type of respirator is appropriate; limitations o How' often must the respirator be replaced o Respirator maintenance During 1991, an airpack respirator will be obtained for. use during emergencies. Ammonia First Aid Procedures o Keep a rope available to retrieve overcome employees o If an employee is overcome by ammonia: 1. Move victim to an area clear of ammonia 2. Call a doctor 2. Remove contaminated clothing 3. Keep the patient still and covered with blankets o For skin burns, wash immediately with water Review of Material Safety Data Sheets, Chemical Hazards Fire Prevention and Response Release Reporting (Section 2.5) Evacuation Procedures (Section 8.1) Earthquake Procedures (Section 8.3) large quantities of Page 2 6 SPill Containment and Dilution Procedures (Section 8.4) Daily Operating Procedures (Section 4.1) Maintenance Procedures (Section 4.2) P~e 27 WZl 12.0 RMPP Record Keeping Record 'keeping, required by RMPP legislation, ensures that RMPP programs are implemented and maintained. · 1 2.1 Accident Records Documentation of accidents is necessary to prevent recurrence. Section 2.0 of this report is a description of accidents involving ammonia, including accident investigation procedures and measures taken to avoid a repetition of the accident or release. 12.2 Ammonia Charge Records Ammonia charge records (Exhibit 9) will document amounts and dates of ammonia deliveries. Inventory control is a significant aspect of RMPP implementation. 1 2.3 Training Records Training records will be kept to ensure that each employee receives required tra. ining~ All employees must be .trained in emergency evacuation procedures. Certain employees need training in specific procedures related to the handling of acutely hazardous materials. Exhibit 10 is the format for the record of training Required/Completed Record. 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 2 8 13.0 Qualifications of Certifiers 13.1 Qualified PerSon Mary_ Jane Wilson, President, .WZl In(;:. Ms. Wilson received a Bachelor of Science Degree in Petroleum Engineering from Stanford University in 1972. She is registered as an Environmental Assessor in California. Ms. Wilson is the President and Corporate Executive Officer of WZI Inc. She monitors WZI Inc. projects to maintain technical standards. She has extensive experience (17 years total).in the petroleum and environmental consulting, industries. She has participated in the design of numerous compliance programs related to the environmental safety of operating facilities. 13.2 Facility Operator Alex Mann.s, Plant Manager Mr. Manns, Plant Manager of Crystal Geyser, has worked as plant manager for Crystal .Geyser for one and 1/2.years. Previous'duties included'a combined 19 i/2 years as plant manager for the Coca Cola and the Pepsi Companies. Page 2 9 References 1. o The Center for Chemical Process Safety, Guidelines for Hazard Procedures, '1985, American Institute of Chemical Engineers. Evalua'(ion Office of Emergency Services, HazardOus Materials Division, Risk Manaqemen'( and Prevention Program Guidancs, 1989, State of California. U.S. Environmental Protection Agency, Federal Emergency Man'agement Agency- and the U.S. Department of Transportation, Technical Guidance for Hazards Analysis: Emergency Planning for Extremely Hazardous S.~.~bstances, 1987. 4. National Response Team, Hazardous Materials Emerqency Planning Guide, 1987. Page 3 0. HAZARDS ANALYSIS CryStal Geyser Water Company Bakersfield, California Appendix B Submitted to the Hazardous Materials Division of the Bakersfield City Fire Department August, 1990 Revised October 1, .1990 Revised April, 1991 TABLE OF CONTENTS Section 1.0 2.0 3.0 3.1 3.2 3:3 3.4 Introduction Summary Hazards Identification Chemical identity of Acutely Hazardous Materials Location of Acutely Hazardous Materials Quantity Nature of Hazard 4.0 Hazard and Operability 5.0 6.0 Study Results 4.1 Summary 4.'2 Release Scenarios 4.3 Offsite Consequences 4.4 Onsite Consequences 4.5 Human Error Analysis Vulnerability Analysis 5.1 Vulnerable Zone 5.2 Human Populations 5.3 Critical Facilities Risk Analysis 6.1 · Release Probability 6.2 Severity of Consequences Page 1 2 3 3 3 3 ,3 6 6 6 9 10 10 13 13 14 i5 16 16 16 Exhibit B-1 Exhibit B-2 Exhibit B-3 Exhibit B-4 Exhibit B-5 Exhibit B-6 Exhibit B-7 Exhibit B-8 Exhibit B-9 EXHIBITS Location Map Hazards Analysis Flowchart Facility Diagram Ammonia Schematic Diagram Map of Surrounding Area Factors Affecting Vulnerable Zone Estimations Neighboring Receptors Worst Case Vulnerable Zone Map Worst Case IDLFI Exposure Map Table 1 TABLES Physical Properties of Ammonia Appendix B-I Appendix B-Il Appendix B-Ill Appendix B-IV APPENDICES Hazard and Operability Study Guideline Hazard and Operability Study Forms Modeling Results Alarms and Control Devices 1.0 INTRODUCTION This hazards analysis of the use of Acutely Hazardous Materials (AHM) has been prepared for the Crystal Geyser Bakersfield bottling facility, located at the corner of East California Avenue and Lakeview Avenue, Kern County, California (Exhibit B-l). This analysis has been prepared in accordance with the EPA/FEMA/USDOT document "Technical Guidance for Hazards Analysis: Emergency Planning for Extremely Hazardous Substances, 1987." There are three, basic components in hazards analysis (Exhibit B-2) which provide the outline of this report: o Hazards Identification o Vulnerability Analysis o Risk Analysis Page 1 H{:~ITAL mil.. BERNARD, ~W~, et,--, ~.~'ZStreet ENUE ,.7,1 · CRYSTAL GEYSER BAKERSFIELD 7 "4. iF .CALIFORNIA Henley St.. Lak~ C~nttr ~ Potorm~¢ .I, Ac. Ki~IL E E . St., · ,STATE "Z .__:~... [ ~: 'r~r~c~ Murdb~r. 5L --BRUNDAGE Scale D Fee~ 2'000' 4090' 0 Kilometers .50km lkm I IN WZI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Location Map 5/1/90 D.N 2099 EXHIBIT B-1 HAZARDS ANALYSIS FLOWCHART HAZARDS IDENTIFICATION CHEMICAL IDENTITY NATURE OF THE VULNERABILITY ENVIRONMENTAL RISK A N A L Y S i S LIKELIHOOD OF A RELEASE OCCURING SEVERITY OF THE CONSEQUENCES REFERENCE: EPA/FEMA 1987 EXHIBIT B-2 2.0 ~ The potential for offsite and onsite consequences is presented by the ammonia refrigeration system in operation at the Crystal Geyser Bakersfield beverage formulation and bottling facility. Ammonia releases could occur leading to possible exposure of workers and receptors above the Level 'of Concern (LC)C), 50 ppm, and the Immediately Dangerous to Life and Health Level (IDLH), 500 ppm. The worst case credible scenario, determined through the hazard and operability study, was determined to be the formation of dispersion cloud of ammonia released by the rupture of a liquid ammonia line outdoors. Liquid ammonia released at high rate could form a liquid/air dispersion cloud that could migrate to neighboring residential areas. The immediate area surrounding the Crystal Geyser plant is both residential and industrial. Apartment buildings are immediately adjacent to the Crystal Geyser plant. Worst case credible onsite consequences may be experienced with the rupture of a line at the indoor receiver, releasing the liquid contents in a liquid/air dispersion, followed by the subsequent release of liquids and vapors remaining in the system into the building. The extent of the vulnerable zone for a worst case credible release of the contents of the ammonia receiver, 216 pounds of ammonia, determined through modeling, is approximately'2.3 miles (3.7 km) at 30 minutes after release. LOC eXposure at 2.3 miles from point of release is expected to last approximately 30 minutes. The IDLH level, 500 ppm, may be reached at UP to 0.8 miles (1.3 km) away 11 minutes after release. The IDLH exposure is expected to last approximately 12 minutes at 0.8 miles from the point of release. This Hazards Analysis showed the Crystal Geyser ammonia refrigeration system to be' highly automated. The design of the system is such that.employees need only to switch on the system in the morning and periodically add oil. Less frequently, make-up ammonia is added to the system. The system design needs to be better documented: no drawings of the system were located. Only two employees, the Maintenance Manager and the Mechanic and Production Supervisor, are authorized to perform mainten~.nce on the ammonia system. As part of the RMPP, Crystal Geyser will implement a safety audit of. the refrigeration system. The RMPP should focus on minimizing risk and on emergency response. Employee training and training documentation will be supplemented; as will inventory and procedural record keeping. Page 2 3.0 HAZARDS IDENTIFICATION 3,1 Chemical Identity of Acutely Hazardous Materials Anhydrous ammonia is stored and used in reportable quantities at the Crystal Geyser Bakersfield facility. 3.2 Location of AHM at Facility The ammonia in use at the Crystal Geyser facility is Contained in the ammonia refrigeration system. Exhibit B-3 is a facility diagram. Exhibit B-4 is a schematic diagram of the ammonia system. Liquid anhydrous ammonia is stored in the two receivers, one outdoors and one indoors. An ammonia cylinder is chained outside of the building at the southwest corner. When ammonia is needed, the cylinder is unchained from its outdoor storage location and wheeled into the room containing the indoor receiver and carbo coolers. The ammonia system is recharged from the cylinder into a line connected to the inside receiver. 3.3 Quantity The ammonia system holds up to 300 pounds of ammonia. A 150 pound cylinder is stored outside and. is used to replace ammonia lost as fugitive emissions from the system. 3.4 Nature of Hazard Ammonia presents the risk of death or debilitating injury to humans exposed to high concentrations. Major releases from the ammonia system may cause high concentrations of ammbnia to reach receptors, either in the plant or in surrounding areas. Page 3 1.233 ~ ~ ~ ~X I~ . ~ ~..,~ ..... ~ ~. t~ 'h" ' '" 1' . ~,~ ...... ~ .... ~. =~ , · ~ ~ I ~ ~'L~ [~1 I --~ ....... '-~ . . ~,~?~l~l ;1~.,. ~~ I //IF~~ ......... ~..~.__,.. ...... ,~...., ~ '1;~ I ~~:,~f//ILI, I~ :} __~L ........ · ,, ..... .. ., ~ ~ ,, U ............. , I ' · ' .. '. I ~U~ .' ............................... .~ r~, ,~ ' ~ ~1"" , .... / I · ......................... I ~ ~ : ,,,,,~,,,,~,, - ......__ . ~ or~r~rj "i'! '~'" ............. ,~ ~1 ~'"'/~ s,~ ~ , ....... . . :?,.) ~ '~..:~.-."; , ...... ...... ' .... ...... 1l :' ~1,/~.,~ ~' :' I dr,~,l~l ., ' '" ......... .~, ~ . I so M~'I-.I , ,- I., ~'~, . . ~_._~_2 l.t~,.. I I I ,. .'~'~ ~, ,,.~ ~.,._,, ..,,,~,, ............. .,., I ...... ~'J"] ........ i,~'. ~ ~ _~"~:. :- ~ ~. Ammonia Equipment is Highlighted IN DATE I.)I ~.)' I wzI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Facility Diagram §/90 I DN 2~o,IF"XHLBJrB-3 Because of its physical properties, a release of liquid ammonia is most likely to cause serious injury to receptors. Liquid ammonia released at a high rate can form a dense, slow moving cloud of liquid ammonia dispersed in air. Ammonia vapors, lighter than air, rise quickly in the atmosphere and are less likely to cause serio(Js injury to receptors. Ammonia vapors released into an unventilated area can present high concentrations to receptors entering the area. Ammonia, a colorless gas with an extremely pungent odor, can be detected by smell at concentrations at 3.5' to 37 mg/m3 (5 to 53 ppm). Ammonia is corrosive and irritating to the skin~ High concentratio&s can cause dermal burns, inflammation and swelling of the eyes and is potentially blinding to exposed receptors. Levels of 500 mg/m3 (700 ppm) can cause eye irritation. Coughing occurs at a level of 1200 mg/m3 (1700 ppm). Exposure to higher concentrations can result in debilitating injury and death through pulmonary edema. Ammonia is not recognized as a carcinogen nor does it present a threat to the environment. Table 1 lists physical properties of ammonia. Page 4 Table 1. Physical Properties of Anhydrous Ammonia (NH3) . MOLECULAR WEIGHT LATE NTH EAT BOLLING POINT SOLUBILITY SPECIFIC GRAVITY (LIQUID) ' VAPOR DENSITY AUTOIGNITION TEMPERATURE EXPLOSIVE LIMITS CRITICAL TEMPERATURE CRITICAL PRESSURE IDLH LOC STEL RATIO OF SPECIFIC HEATS 1 PPM 17.03 327 -27.4 89.9 0.682 0.59 651 16 TO 25' 132.9 11.5 35O 35 25 1.31 LBM/LBMOLE CALORIE/GRAM oF G/100 mi AT 0 oC (-33.35 oC/4 oC) (AIR=l) @25 oC, 760 mm HG oC (1204 oF) % BY VOLUME IN AIR oC ATM mg/m3 mg/m3 mg/m3 (-77.7 °C) (500 ppm) (50 ppm) (35 ppm) 0.7 mg/m3 @ 25 oC AND 760 mm HG The molecular structure of ammonia is composed of one Nitrogen (N) and three Hydrogen atomS (H). The molecular weight of ammonia, 17 Ibm/Ibmole, is significantly less than that of air whi~:h is approximately 29 Ibm/Ibmole. As a result, ammonia in the vapor phase is much lighter than air and rapidly rises when released. Page 5 4.0 Hazard and Operability Study Results Appendix B-I is a copy of the guideline used for the Hazard and Operability Study. Forms uSed during the Hazard and Operability Study are included as Appendix B-II. Appendix B-Ill contains modeling results, and Appendix B-IV lists alarms and control devices in the ammonia system. 4,1 Summary_ Each study node was reviewed for possible deviations from normal operation, and potential consequences resulting from the deviations were recorded. The severity and probability of consequences were rated. It was determined that the greatest risk is presented by release of liquid ammonia, which can form a dense ammonia/air dispersion. A dense dispersion can hug the ground, potentially inflicting injury upon receptors. In summary, the most likely worst case release at the Crystal Geyser Bakersfield plant is a release of the contents of the outdoor ammonia receiver through a line broken during a severe earthquake. Appendix B-Ill contains results of modeling the worst case credible release. 4.2 Release Scenarios Accidents such as fires or hazardous material releases are often not caused by a single factor but are the result of a chain of circumstances. A scenario is an abbreviated description of a specific chain Of events that causes a particular outcome such as an AHM release related death, injury, property loss, or other incident. Release scenario characteristics include: O O O O O O 'O O Condition: Temperature, pressure of the material released Equipment at Which the release originates Time of inCident: Day, night, morning, afternoon Cause of release: Over pressurization, ruptured lines, operator error Direct cause of loss: Exposure to high levels of amrn'~nia Type of loss: Death, injury and/or property loss Receptors: Employees, sensitive receptors Magnitude of loss: Number of people affected, property lost Page 6 Release scenarios at the Crystal Geyser Bakersfield plant are based upon the most likely .hazards that were developed through the hazard and operability study. Probabilities of accidents can be determined' through a study of reliability data. Two main types of reliability data are required' O O Equipment and instrument failure rate and repair rate data Human error probabilities and recovery probabilities The following causes of accidents that can occur in processing plants were reviewed in preparation for the hazard and operability study: o Improper maintenance methods o Modifications to equipment o Human error o Improper labeling o Improper operating methods 'o Wrong materials used. in construction o Faulty Equipment o Fire o Earthquake Deviations that result in situations that could severely affect onsite or offsite receptors were denoted by a high-medium designation on the HAZOP form. Potentially severe consequences determined through the hazard and operability study included those due to the following deviations: o Major leak.in system. 1. Pooled liquid ammonia outdoors (Presents.a high concentration of ammonia in a localized area) Dispersed liquid ammonia outdoors (greatest potential to affect large numbers of offsite receptors) Pooled liquid ammonia indoors (presents a high risk to employees in an unventilated buildings) '~ Page 7 Dispersed liquid ammonia indoors (presents a severe. ~lsk to employees in the building, ventilated or unventilated) Release of vapor ammonia outdoors (presents a localized risk due to high concentrations in the immediate area: ammonia will likely rise before it' reaches great distances; dispersion is affected by temperature and wind speed) Release of vapor ammonia indoors (presents a high risk to employees in an unventilated building, lesser risk in a ventilated building; risk is dependent upon amount, rate of release) O Earthquake (pipes may be ruptured in a severe earthquake, quickly releasing large quantities of ammonia within or outside the building. O High pressure shutdown failure (high pressure may lead to an ammonia releaSe through pressure relief valves) o Pressure relief valve (prv) failure (high. pressure may lead to a rupture in a line or vessel) o Exit valve to compressor closed (high pressure may lead to pry release) o Exit valve to receiver closed (high pressure may lead to pry release)' O Fire (high temperatures may result in high system pressures, causing ammonia release) o Release during ammonia loading (human error, equipment failure) Deviations that result in scenarios that are likely to occur were listed with a medium to a high probability. Situations of concern that were determined to be likely to occur were results of the following deviations. o Valve closed incompletely (human error) o Power failure (compressor seals fail) o Minor leak in system (fittings, corrosion) o Earthquake Page 8 One deviation from normal operation was found to have a medium to high probability combined with a medium to high severity; an earthquake. The possibility of a release .due to an earthquake is mitigated by the design and anchoring of the system. The greatest potential for major release from the Crystal Geyser Bakersfield bottling facility was found to be Circumstances over which the operators have no control, such as earthquake or fire conditions. Human errors were determined to be likely to result in lesser, non-reportable releases. 4~3 gLo. site Conseg.~ences The compressors, the most probable origin of ammonia release are located outside of the plant, protecting the rest of the plant from high levels of ammonia due to a release from the compressors. A release of ammonia vapor from the compressors is likely to occur a.t a slcw rate. The outdoor location prevents the slow concentration of high levels in the immediate area. A release of ammonia in the vapor form will rapidly rise in the atmosphere, out of 'the range of receptors. Past ammonia releases from the compressors (due to human error and described in the RMPP) annoyed neighbors but did not cause injury to offsite receptors or employees. An indoor release could affect Crystal Geyser's 1'7 pen,'nanent employees and an undetermined number of temporary workers (the number varies from day to day). Any indoor release is dangerous, large or small, because of the potential for a high concentration to build in areas that are not well ventilated. Evacuation and emergency response training help to mitigate the potential for onsite consequences. Doors at either side of the building can be opened for ventilation if ammonia concentrations in side 'the building. The room in which the indoor ammonia equipment is held is somewhat isolated from 'the rest of the building. The indoor receiver is connected to a relief valve that vents above the roof line. Page 9 4..4 ©ffsite Conseauences The outdoor ammonia receiver contains the largest amount of liquid ammonia located where a dispersion cloud could be released towards offsite receptors. The most likely potential release of the contents of the receiver to the outdoors was determined to be through a break in the liquid ammonia line leading from the evaporative condensers to the receiver or lines from the outdoor receiver to the indoor receiver. A cloud of dispersed ammonia from a rapid, large release presents the greatest danger to offsite receptors. 4,5 Human Error .Analysis The purpose of a human error analysis is to identify potential human errors and their effects. :Causes of human errors that have occurred in the past may also be identified. Human Error: Normal O0eration During normal operation the highly automated ammonia system requires little operator action. The maintenance manager, the main ammonia system operator, will, in the future, record information regarding system variables onto a log. Oil is regularly 'drained manually from the oil receivers. Potential areas for operator error during normal operation include: Areas for Proposed Ooerator error Consequence8 SeveritY/Likelihood Improper logging Poor records' Low/Low Valve not shut off Potential for Low/Med after oil drain sm, ammonia release Open wrong Damage to compressor compressor valve Low/Low · Forget to Damage to Low/Low add oil compressor Neglect Relief valve Med/Low high pressures release Mitigation Employee training EmploYee training Employee training Log, Employee Training Auto controls, relief valves, employee training Page 1 0 Human Error: Ammonia Addition When necessary, ammonia is added at the indoor receiver. The maintenance manager supervises ammonia addition. An ammonia canister is carried from outside the building to inside the carbo cooler room. A hose is attached from the canister to the connection below the indoor receiver. -The sight glass on the indoor receiver is watched while the ammonia is added. After a sufficient amount of ammonia is added, the hose is disconnected and the cylinder removed. The following errors are possible during ammonia addition: Areas for Proposed Ooerator erro[ (;;~pseouences SeYeritv/Likelihood Mitiaation Sight glass Too much ammonia Low/Meal Employee not read properly in system; Relief Training · valves may relieve Valve not shut Ammonia leak Low/Low Employee off properly Training Worn hose not Ammonia leak Med/Low Replace hose noticed possible when worn Hose not disconnected Ammonia release Med/Low Inspect hose possible Human Error: Emerqency Situations Emergency situations include fires, earthquakes. Areas for Operator error 0onsequences Improper use of breathing equipment Improper fire fighting procedures Employee injury equipment difficulties, Earthquake response: Improper evacuation procedures Earthquake response: Improper shutdown procedures Severity/Likelihood Med/Low Employee injury, Med/Low ammonia release Increased risk of Low/Low employee injury Possible increased ammonia release Low (relative to severity of earthquake)/ ~w Page 1 1 ammonia leaks, and Proposed Mitigation Employee ' training Employee training Employee training Employee training Human Error: Maintenance Procedures Areas for Proposed O~erator error ~.,onseouences Severity/Likelihood [~itigation Compressor SmalVmedium Med/Low Employee not pumped down ammonia release; training/ for maintenance possible emp. injury supervision In summary, AHM releases due to human error were found to be likely to be smaller in magnitude than potential releases from events such as an earthquake or fire. The automation of the ammonia system reduces the risk of human error. 'Increased training of'workers will further reduce the risk of human errors in normal, maintenance and emergency operations at the Crystal Geyser Bakersfield plant. Page 1 2 Vulnerability Analysis 5.1 Vulnerable Zone The worst case vulnerable zone radius is the maximum distance from the release to the point at which the airborne chemical concentration equals or exceeds the L.O.C. Exhibit B-5 is a map of the area' surrounding the Crystal Geyser plant. Factors affecting vulnerable zone estimations are summarized in Exhibit B-6. Neighboring receptors are shown in Exhibit B-7, and the Worst Case Vulnerable Zone is shown as Exhibit B-8. Exhibit B-9 shows the area which could be exposed to ammonia concentrations above the IDLH in a worst case release. .EPA/FEMA/DOT guidelines (1987) indicate that decisions about evacuation are incident specific and are to be made at the time of actual release. An estimated vulnerable zone should not automatically be used as the basis for evacuation during emergency response. In this study, the vulnerable zone radius is estimated using assumptions for a credible worst case scenario. Quantity and Rate of Release to Air The vulnerable zone is proportional to the quantity and rate of release. In this study of credible worst base scenarios, a break in an outdoor liquid ammonia line was determined to present the greatest risk to offsite receptors, in the worst case release 216 pounds of ammonia would be released from the outdoor ammonia receiver. Computer modeling determined that release could Occur i'n as little as 1/2 minute. Meteorological Conditions Wind speed and atmospheric stability have a significant effect on the size of estimated vulnerable zones. Increased wind speed and the accompanying atmospheric stability will result in' greater airborne dispersion an~i a decrease in the size of the estimated vulnerable zone. Low wind speeds are used in worst case scenarios. Page 1 3 ~tree! Strut Vintage Air East California Avenue Jobl Crystal Shack Geyser Storage Lot Crystal Geyser Bottling Facility Alley Housing Complex Housing Complex Crystal'~ Geyser[ ParkingI Poton~ec FORNIA ,~rendon St i I*~onterey BET~ Henley Lucl Holly Ave. WZI INC. BAKERSF ELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Surrounding Area DATEs/1/90 ! !EXHIBIT B'5 Exhibit B-6 Fector8 Affecting Vulnerable Zone Estimations Quantity of Release Physical State (solid, liquid, gas) of Material Temperature of Stored Material Pressure of Stored Material Physical Characteristics of Material (Molecular weight, Pressure, etc.) Surface Area of Spill, if Liquid Type of Release .(Leak, Explosion, etc.) .Rate of Release Meteorological Conditions (W. ind Speed, Cloud Cover, Temperature) Surrounding Topography Level of Concern of Material Vapor 22nd Sorter ;Special Services 3ol Williams School Monterey ~12500 'Our Lady !of Guadalupe Sch. Owens Scho'ol ,g St. -'Terrace Way Feliz ...~.. Cannon Ave. FORNIA hel Christian School' I __ Mt. Vernon School $~EL TE~q CENTER SCHOOL ' · 0 Miles '/,mi .... Y, .m.i. )~ni. ~) Kilometers .50km l~m WZI INO. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Neighboring Receptors DATE 5/1/90' B-7 WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Worst Case Vulnerable Zone Map 5/1/90 ~,alTAL _Shad~ In. ~LEy 'ace WBV BERNARD~ - E. Belle' Terrace CRYSTAL GEYSER BAKERSFIELD · ! Fetiz Cannon Ave. Smith St. Terrece .50km 1 km Kilometers I [ Bernard Lake Henley St., Potomac , Virc~nia TeL · ..:REGIONAL occU~ATIONAq: ',,~. CENTER SCI, COOl ' ' WZI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD Worst Case IDLH Exposure Map DATE5/1/9 0! !~xH'~'T B-9 Surrounding Topography The Crystal Geyser plant is surrounded by residential apartments, open areas and industrial offices and warehouses. Levels of Concern (L.O.C.) The L.O.C. for anhydrous ammonia is 50 ppm (0.035 g/m3)· H~jman Populations The community surrounding the Crystal Geyser Bakersfield facility is shown in Exhibit B-5. Immediately surrounding the facility to the South is a residential apartment complex, currently uninhabited and undergoing renovation. Sensitive receptors located near the facility include' Receptor ,Approxi mate Distance (miles) Di recti o n Owens School 3/8 SW Special Services School 7/16 ENE Our Lady of Guadalupe Sch. 11/16 W Williams School 11/16 NE Mt. Vernon School 15/16 ESE Bethel Christian School Prevailing wind direction is from the Northwest. A worst case release (Exhibits B-8 and B-9) of dispersed ammonia could reach and affect receptors at these locations. Page 1 4 WZi ~ ~ 5.3 Critical Facilities Critical facilities near Crystal Geyser Bakersfield are: Kern Medical Center 1830 Flower Bakersfield, California Telephone: (805) 326-2000 Bakersfield City Fire Department, Station #2 716 East 21st Bakersfield, California Telephone' 911 Page 5 6.0. RISK ANALYSIS 6.1- Release Probability The ammonia system at the Crystal Geyser plant has been in operatior~ for approximately five years. The hazard and operability study determined that the probabil.ity of minor releases of ammonia through fugitive emission points or through compressor shaft seals during system shutdown was fairly high.. The risk of a major release due to human error or system malfunction is much lower, but can be further reduced through procedural changes and an improved training and record keepir~g program. A release resulting from a major earthquake is likely to be large. 6.2 Seyerlty of Consequences The severity of consequences from an ammonia release is moderate because: 1. The quantity of ammonia in the ammonia system is sufficient to cause injury to neighboring receptors in a worst case release. · 2. It meets the criteria provided by the EPA/FEMA (1987) of "high" severity of consequences to people. Those criteria are: Low: Chemical is expected to move into the surrounding environment in negligible concentrations. Injuries expected only for exposure over extended periods or when individual personal health conditions create complications. II. Medium' Chemical is expected to move into the surrounding environment in concentrations sufficient to cause serious injuries and/or deaths unless prompt and effective corrective action is taken. Death and/or injuries are expected only for exposure over extended periods or when individual personal health conditions create complications. Page 1 6 Ill. High' Chemical is expected to move into the surrounding environment in concentrations sufficient to cause serious injuries and/or deaths upon exposure. Large numbers of people would 'be expected to be affected. Psge 1 7 APPENDIX B-I HAZARD AND OPERABILITY STUDY GUIDELINE Appendix B-I Hazard and Operability Study Guideline' Contents 1. Introduction 2. Hazard and Operability Study Team Members and Qualifications 3. Study Nodes 4. Intention: Normal Operation of the Ammonia System 5. Deviations 6. Causes of Deviations 7. Consequences 8.' Guide Words 9. .Focus of Study 1_. Inl;roduction A HAZOP study is used to identify hazards and operability problems. The primary objective of the HAZOP study is identification of problems. Possible solutions to problems may be discussed and recorded during the study. This HAZOP study will focus on the .ammonia refrigeration system. 2._,. Hazard and Operability Study Team Members a~d Qualifications · The Crystal Geyser HAZOP team is made up of the following individuals: Alex Manns: Plant Manager, Crystal Geyser Bakersfield Mr. Manns has worked 'as plant manager for Crystal Geyser for one and 1/2 years.' Previous to his employment with Crystal Geyser, he worked five years as plant manager for Calvin Coolers which operated at this location. Mr. Manns previously worked as plant manager for the Coca Cola and Pepsi Cola Companies. Norm Ambrose: Plant Engineer, Crystal Geyser Bakersfield Mr. Ambrose has Worked in maintenance departments for bottlers and wineries for 25 years. He has been at Crystal Geyser for one and 1/2 years. He will perform quality control for this study. Gerhard Gaugel' Crystal Geyser Bakersfield Mr. Gaugel has worked as assistant plant manager for Crystal Geyser for one year. He was quality control manager at Pepsi for six years. Appendix B~l.Page 1 Linda Knowles, Staff Chemical Engineer, WZI Inc. Linda Knowles is a degreed chemical engineer (Texas A&M University, 1980). She has two years of experience in the chemical process industries and two years of experience in the environmental consulting industry, focusing on safety and risk 'assessment. She will lead the HAZOP team, conduct the consequence analysis and pedorm a human error'analySis as described in the Guidelines for Hazard Evaluation Procedures, AICHE, 1985. Normar~ Ambrose and Linda Knowles will walk through the facility; Gerhard Gaugel and Alex Manns are on site and available for consultation. Study Nodes ' The-study nodes (locations at which the process parameters are to be investigated for deviations) in the Crystal Geyser plant are listed below: 1. Compressor#1 and #2 2. Evaporative Condensers #1 and #2 3. Outdoor Ammonia Receiver 4. Indoor Ammonia Receiver 5. Carbo Coolers (2) 6. Ammonia Receiving 7. Ammonia Lines 8. Outdoor Ammonia Storage 4~ Intention: Normal Operation of the Ammonia System The plant is designed to-operate continuously. Gaseous ammonia enters the compressors and is compressed to a higher pressure and temperature. After exiting the compressors, the hot gas enters the evaporative condensers. Water running through the condensers cools the hot gas into a liquid. The liquid ammonia enters the outdoor receiver. From the receiver, liquid ammonia flows through the lines to the indoor ammonia receiver. Ammonia is. charged from 150 lb. (3000'cubic feet) ammonia storage canisters (supplied by Hopper) i!nto the indoor receiver. The ammonia flows from the receiver into the carbo cooler level control vessel, and then into the carbo cooler. The carbo cooler has an expansion valve that allows the liquid ammonia to expand, into a gas. The phase change of the ammonia takes in heat, cooling the carbo coolers. The expanded, now gaseous ammonia is then cycled, back to the indoor receiver, where vapors are pulled by the compressor suction and liquids go to the carbo coolers. Appendix B-I Page 2 5, Deviations Deviations are potential departures from the intention of the plant, Possible deviations are discovered by systematically applying HAZOP guide words (no, more) to process parameters such as pressure and temperature. 6. Causes of Deviations Causes of deviations may be human error, equipment failure, etc. causes will be listed dudng the HAZOP study. Deviations and 7_. Conseqt~ence$ Consequences are results of deviations from normal process operation. Consequences which could negatively impact process safety will be discussed and recorded. Deviations which have no effect on process safety will be dropped from the HAZOP study. 8~ GUide Word.~ Guide words are simple words used to identify, qualify or quantify possible deviations. The following guide words will be used in the HAZOP study: Guide Word Example Meaning No Less More Other Part of As Well As Reverse Other Than Power Shutoff Low FIowrate High temperature Partial Power Shutoff Water added to NH3 Flow in Wrong Direction Earthquake Conditions Conditions Negation of' Design Intent Quantitative Decrease Quantitative Increase Qualitative Decrease Qualitative Increase Logical Opposite of the Intent Substitution. from Design Each guide word will be applied to process variables at each study node. This purpose of this study is to determine the most likely point of release and most damaging release of ammonia to the atmosphere.. 9. Focus of Study The following specific consequences will be considered in this study: O O Threats to Employee Safety Threats to Safety of Offsite Receptors Appendix B-I Page 3 APPENDIX B-Ii HAZARD AND OPERABILITY STUDY FORMS Crystal Geyser Bakersfield Study Node Number: I Equipment: -- 't r- r"'.7 Mitigation Guide Word Deviation Consequences Causes Risk . No Flow (14~:~~) ~o~c le~ me_.(~' ~ su~n ~e~r~ ~b~&~¢~ ....... Power ¢0 ~;n~ I~ ~6~w~ ' 'lo~ no~.-r~u~¢~ ...' J As Well As ..90 ?¢(gp 3rystal Geyser Bakersfield Study Node Number: '~, Equipment: Guide Word Deviation Consequences Causes Co ,"' F' a o,>'"' Risk Oil 'art of ~an$ nd · ,j ~everse ~ther Than ~,,f44,,-a~q *k,e~ .Crystal Geyser Bakersfield Study Node Number: ~ Equipment: Guide Word Deviation Conse.quences Causes Risk Mitigation 0 ~- ~'~ ~' , Power Oil qo .ess ~ ~s WeJl As teverse Crystal Geyser Bakersfield Study NodeNumber:.,~- Equipment: Guide Word Deviation ConsecL?_ences Causes Risk Power ~ ~ ' Oil _ess ~ ~s Well As ~everse Dther Than ~f~L.~- Crystal Geyser Bakersfield ,Study NodeNumber: Guide Word Deviation Consequences Causes Risk Mitigation ~ Flow .<;~ro.~,l~ C~¢~,or-e_£s.o¢ ,b\~,c.P~ l, ;,~ orle..¢.)c~ f~e_d !0,¢J cr, e£cu,r~,. ~k~~ Power ~o~ ¢¢~tc~t~ ~ Oil ~ ~ ~ ~e, ~ _ess ~ore ~1o~r~°r~ ~r~l~ ~%~',~ Coo~~ ~h ~ ~ ~*~ ~ ~<ao~ ~. ~ .'~f~ .~~. c~ c~r~ ~art of ~s Well As qeverSe APPENDIX B-ill MODELING RESULTS Appendix B-III Modeling Results Summary. The Automated Resource for Chemical Hazard Incident Evaluation (ARCHIE) computer program was used to-model theorized worst case credible releases. The Handbook of Chemical Hazard Analysis Procedures (F.E.M.A., U.S.D.O.T., and U.S.E.P.A., 1989) was used as a guideline for modeling. Modeling results indicated that a worst case credible release could pose a significant risk to offsite receptors. Crystal Geyser, Bakersfield is c~mmitted to making changes that minimize releases. Worst Case Credible Scenario The worst, case credible release, as determined through the hazard and operability study, was found to be a potential release of the liquid contents of the outdoor ammonia receiver into outside air. The potential release scenario judged to be dangerous to offsite receptors is a release of ammonia during an earthquake. Lines from and to the outdoor ammonia receiver contain liquid ammonia. A break in this liquid ammonia line could release all of the ammonia in the receiver to outside air. In this potential worst case scenario,, the rapid release of liquid ammonia could form a air/ammonia dispersion that would act as a cloud of dense gas. Choice of Modeling Options Option a, Estimate discharge rate of liquid or gas, was chosen to model the release of liquid ammonia into the atmosphere.. This model was chosen because the potential worst case scenario involves the emptying of the receiver through open lines. Option b, Estimate area of liquid pool, and Option c, Estimate of vaporization rate of liquid pool, are not valid for the ammonia release because the release would be made up .of both liquid and gas. Option d, Evaluate toxic vapor dispersion hazards, was used to model the following releases: Scenario: Release from broken lines during an earthquake Appendix B-Ill Page I Modeling Results A discharge from a broken liquid line may release 216 pounds of ammonia in 30 seconds. Scenario results have been plotted in Exhibit B-8, Vulnerable Zone, and Exhibit B-9, Extent of 500 PPM Concentration. Modeling printouts are attached. The following table contains mean wind speeds and prevailing wind directions for the Bakersfield area. Climatological data was gathered at Meadows Field Airport and compiled by the National Climatic Data center. 1989 Mean Wind Speed and Direction, Bakersfield Area Month Wind Speed (mph) Wind Direction January February March April May June July August September October November December 5.2 NW 5.8 ENE 6.5 NW 7.1 NW 7.9 NW 7.9 NW 7.2 NW 6.8 NW 6.2 WNW 5.5 NW 5.1 ENE ,, 5.0 ENE The yearly average mean wind speed for 1989 is 6.4 mph, originating from the Northwest. Appendix B-Ill Page 2 CURRENT PARAMETER VALUES FOR DISCHARGE RATE ESTIMATION METHODS 4 DISCHARGE HOLE DIAMETER = 5 DISCHARGE COEFFICIENT = 6 LIQUID HEIGHT IN CONTAINER = 7 WEIGHT OF CONTAINER CONTENTS = 8 TEMPERATURE OF TANK CONTENTS = 9 AMBIENT TEMPERATURE 10 CHEM VAP PRES IN CONTAINER 12 NORMAL BOILING POINT 13 LIQUID SPECIFIC GRAVITY 15 LIQUID SPECIFIC HEAT MODEL RESULTS: Peak discharge rate Duration of discharge Amount discharged State of material 1 inch(es) .62 .9 ' feet 215.72 lbs 60 deg F .= 90 deg F = 104.7 psia = -27.4 deg F = .682 '= 1.31 BTU/lb-F = 454 lbs/min = .476 minutes = 215.72 lbs = Mix of gas and aerosols CURRENT PARAMETER VALUES FOR TOXIC GAS OR VAPOR HAZARD EVALUATION 1 MOLECULAR WEIGHT = 17 2 TOXIC VAPOR LIMIT = 500 3 VAPOR/GAS DISCHARGE HEIGHT = 10 4 ATMOSPHERIC STABILITY CLASS = F 5 WIND VELOCITY AT SURFACE = 4.5 6 AMBIENT AIR TEMPERATURE = 90 7 VAPOR/GAS EMISSION RATE = 454 8 DURATION OF EMISSION = .476 MODEL RESULTS: Downwind toxic hazard distance at groundlevel at exit height = 4429 = 4398 Peak cOncentration on ground is 36358.7 at a downwind distance of 312 ft ppm feet mph deg F lb/min minutes feet feet ppm Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 410 .08 719 .14 1028 .2 1337 .26 1646 .32 1956 .38 .2265 .43 2574 .49 2883 .55 3192 .61 35'01 .67 3811 .73 4120 .79 4429 .84 .3 1 1.1 2.6 1.9 4.2 2.6 5.7 3.4 7.3 4.2 8.8 5 10.4 5.8 12 6.5 13.5 7.3 15.1 8.1 16.6 8.9 18.2 9.7 19.8 10.5 21.3 11.2 22.9 CAUTION: See guide for assumptions used in estimating these times! Want 'to rerun the model with different input values (Y/N or <cr>)? Downwind Distance Groundlevel Concentration (feet) (miles) (ppm) source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02' 113 436074 73 410 .08 32150 32019 300 719 .14 16978 14939 530 1028 .2 9950 9032 750 1337 .26 6372 5929 980 1646 .32 4322 4087 l 1200 1956 .38 .. 3064 2929 1430 2265 .43 2254 .2171 1650 2574. .49 1709 1656 1880 2883 .'55 1331 1294 2100 3192 .61 1059 1034 2330 3501 .67 859 840 2550 3811 .73 708 694 2780 4120 .79 5'91 581 3000 4429 .84 500 492 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. ****** Press ENTER to Continue ****** CURRENT PARAMETER VAL~ES FOR TOXIC GAS OR VAPOR HAZARD EVALUATION 1 MOLECULAR WEIGHT = 17 2 TOXIC VAPOR LIMIT = ~0 3 VAPOR/GAS DISCHARGE HEIGHT = 10 4 ATMOSPHERIC STABILITY CLASS = F 5 WIND VELOCITY AT SURFACE = 4.5 6 AMBIENT AIR TEMPERATURE = 90 7 VAPOR/GAS EMISSION RATE = 454 8 DURATION OF EMISSION = .476 ppm feet mph deg F lb/min minutes MODEL RESULTS: Downwind toxic hazard distance at groundlevel at exit height = 11961 feet = 11933 feet Peak concentration on ground is 36380.7 ppm at a downwind distance of 304 ft *** Press ENTER to View Various Tables *** ~Downwind Distance Groundlevel Concentration (feet) (miles) (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 113 436074 73 948 .18 11312 10185 690 1795 .34 3645 3467 1310 2642 .51 1614 1565 1930 3489 .67 865 847 2540 4336 .83 525 517 3160 5184 .99 348 343 3780 6031 1.15 245 242 4390 6878 1.31 180 178 5010 7725 1.47 138 137 5630 8572 1.63 108 107 6240 9420 1.79 86.7 86.1 6860 10267 1.95 71.1 70.6 7480 11114 2.11 59.2 58.9 8090 11961 2.27 50 50 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts.may require a larqer Width or different direction fOr the evacuation zone. ****** Press ENTER to Continue ****** Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at'Downwind Location (minutes) 100 .02 .3 1 948 .18 2.4 5.3 1795 .34 4.6 9.6 2642 .51 6.7 13.9 3489 .67 8.9 18.1 4336 .83 11 22.4 5184 .99 13.1 26.7 6031 1.15 15.3 31 6878 1.31 1714 35.3 7725 1.47 19.6 39.5 8572 1.63 21.7 43.8 9420 1.79 23.8 .48.1 10267 1.95 26 52.4 11114 2.11 28.1 56.7 11961 2.27 30.3 60.9 CAUTION: See guide for assumptions used in estimating these times! Want to rerun the model with different in~ut values (Y/N or <ct>)? APPENDIX B-IV ALARMS AND CONTROL DEVICES EauiDment Solenoid High Pressure/ Temperature Cutoff: Compressors Smoke alarms Sprinklers Pressure .Relief Valves Outdoor Receiver Pressure Relief Valve Connected to Indoor Receiver Appendix B-IV Alarms and Control Devices Type Automatic Details Rebuilt in 1990, Operates control valve for indoor receiver Automatic Manual reset level Automatic Automatic Automatic Proposed to alert employees case of fire Throughout building Two valves, 8' high, 3/4" pipe in Automatic One valve vented indoors, plans are to extend prv to above. level roof ~"i '~ LIQUID AIR CORPORATION ALPHAGAZ DIVISION ..... Material Safety Data Sheet ALPHAGAZ Specialty Gas LIQUIO AIR CORPORATION One California Plaza, Suite 350 2121 N. California Blvd. Walnut Creek, California 94596 ISSUE DATE OCTOBER 1, 1985 AND REVISIONS CORPORATE SAFETY DEPT. I~ODUCT 'NAME Ammonia TELEPHONE (415) 977-6500 EMERGENCY RESPONSE INFORMATION ON PAGE 2 TRADE NAME AND SYNONYMS Ammoni a, Anhydrous Ammonia CHEMICAL NAME AND SYNONYMS Ammoni a, Anhydrous Ammonia FORMULA MOLECULAR WEIGHT 'NH3 17.0 CAS NUMBER 7564-41-7 CHEMICAL FAMILY Nitrogen hydride HEALTH HAZARD DATA TIME WEIGHTED AVERAGE EXPOSURE LIMIT 25 Molar PPM; STEL = 35 Molar PPM (ACGIH, 1984-85) ; 50 Molar PPM (OSHA, 1985) SYMPTOMS OF EXPOSURE Corrosive andirritating to the skin, eyes, upper respiratory system and all mucosal tissue. Depending. on the concentration inhaled, it may cause burning sensations, ~oughing, wheezing, shortness of breath, headache, nausea, with eventual collapse. ',4ild concentrations of vapor will cause dermatitis or conjunctivitis. Higher concentrations of vapor or liquid contact wilt cause caustic-like dermal burns a'nd .inflammation and swelling of the eyes with possible loss of vision. Rapidly evaporating liquid contacting dermal tissue or the eyes will cause cryogenic "burns." TOXICOLOGICAL PROPERTIES Inhalation; Affects the-upper airway (larynx and bronchi) by causing caustic-like burning resulting in edema and chemical pneumonitis. If it enters the deep lung, pulmonary edema will result. Toxic level exposure to dermal tissue causes caustic-like burns and skin lesions resulting in e3rly necrosis and scarring. Bums to the eye result in lesions and possible loss of vision. Cryogenic "burns" are like frostbite with a change in skin color to gray or white possibly followe, d by blistering. Listed as Carcinogen National Toxicology Yes [] I.A.R.C. Yes [] OSHA Yes or Potential Carcinogen Program No ~ Monographs No ~x'-i No .x--. ~ECOMMENDED FIRST AID TREATMENT · '" 'tD-- ~"~'P, TC'r~l A ,~MA'~T ~ P~C,',, ~,',_~,~_ ATTENTION IS MANDATORY !H ALL * ~ OF ~:ouv ~ C.sS~S 0 / ...... POSUP,~ TO =.',,.,~'~,.~. p¢~r,~p PERSOHNEL SHOULD BE EQUIPPED WI IH SELF-CONTAIr, ED ~R=A~HING APPARATUS AND COG;'tiZANT 0F EXTREHE FIRE AND EXPLOS!0;'.i HAZARD. inhalation: Conscious persons should be assisted to an uncontaminated area and inhale fresh air. Undcnscious persons should be'moved to an uncontaminated area and given ...... ~.. ~o-mou~,, resusci~-~ion and Su~pl ..... n~_t oxygen Keep ~ne victi~ ¥,,a;-2 and - ;~ssure that n~ucvs or vomited material does not obstruct the airway by ocsitionai (Continued on last page.) :: ....'l H~Z~OOUS MIXTURES OF OTHEI~ LIQUIDS. $OLIoS, On GA~E~ .... . "r ~-' . · :.-..,.::.- :.... -', ....... . ........ , "; ';'.T '~' ':~'":'::.'.' '~;~;I,,~:'~onia is fla~able over a relatively "'arrow rang;'in air. It reacts vigO'~ously 'fi~l'" with fluorine, chl0rifie, hydrogen chloride, hydrogen bromide, nitrosyl chlOride, ' ':' {~_~.~. chromyl chlo~ide,"trioxygen diflu0ride, nitrogen dioxide and nitrogen trichloride. ~?}'~. PHYSICAL DATA 8OILING POINT -28.14°F (-33.41°C) VAPOR PRESSURE La 70°F (21.1°C) : 128 psia (883 kPa) SOLUBILITY IN WATER Very soluble, liberating heat APPEARANCE AND ODOR Colorless gas with a pgupgent odor. LIQUID DENSITY AT BOILING POINT 42.6 lb/ft3 (682.'kg/m3) GAS DENSI~ AT 70'F 1 aim .0442 lb/ft3 (.708 kq/m3) FREEING POINT -107.9°F (-77.74°C) Specific gravity ¢70°F (Air = 1,0) is ,59, FIRE AND EXPLOSION HAZARD DATA FLASH POINT (METHOD USED) AUTO IGNITION TEMPERATURE FLAMMABLE LIMITS % BY VOLUME Gas 1274°F (690°C) ' LEL : 15 UEL = 27 Ex'rINGUISHING MED,A { ELECTRICAL CLASSIFICATION Water I Cla~q i: GrOup D SPECIAL FIRE FIGHTING PROCEDURES If possible, stop the flow of gas. Since ammonia is soluble in water, it is the best extinguishing media -- not only extinguishing the fire, but also absorbing (£~ntinued on last UNUSUAL FIRE AND EXPLOSION HAZARDS The minimum ignition energy for amaonia is very high. It is approximately 500 ..... · ->)times greater than the energy required for igniting hydrocarbons and 1000 to · !0,000 times greater than that reeuired fnr hydrogen, ~EACTIVITY DATA STABILI'~'Y CONDITIONS TO AVOID Un~tabie X Stable INCOMPAT]BILITY (Malerials lo avoid) -See Hazardous Mixtures of Other Liquids, Solids or Gases. HA~kRDous DECOMPOSITION PRODUCTS Hydro~e.n at-.very high temperatures (1544°F; 840°C) ..... HAZARDOUS POLYMERIZATION I CONDITIONS TO AVOID May Occur Will Not Occur X SPILL OR L.--Ai< =ROCEDURES STEPS TO 5E TAKEN tN CASE MATERIAL ~S RELEASED OR SPILLED . Evacuate all ,personnel from affected area. Use appropriate Protective eoui?ment. Tf leak is in 'J~= ' , .... ._r s equipment be certain to ource 'oiping with an inert oas prior to attempting.repairs, if leak is in container or container valve, contac~ the closest Liquid Air Corporation location. WAST= DISPOSAL :,tETHCD Cisoosai, con:act the c~osest LiQuid ~ , . .~,r Corporation location. ~'-': ,-'.,' :,;~:-~:-- -SPECIAL PROTECTION INFORMATION r~ES~IRATORYPR(~TECTION(Sp~cif)'t)~P")Positive pressure ~lr line w11:/~ mask'or seif-cb-nCained ]:UCP~athiog apparatus should be available for emergency"use. VEN~I~ON · . , :.:; .. '. :,j::. LOCAL :,AUS~ T6 prevent, aCcumu..la~.~ on ,.. SPEC~L'" .......':' H~o~':~'ith"forced ..':.. above the TWA ' · ..... venti I ati on "' "- ':. MECHANICAL (Gen.) OTHER In accordance with electrical codes. PROTECTIVE GLOVES Plastic or rubber Page 3 EYE PROTECTION Safety goggles or glasses O T,HE.R P,RO TE. CTJVE EQUIPMENT ~ ' Safety shoes, safety shower, eyewash "fountain" SPECIAL PRECAUTIONS* SPECIAL LABELING INFORMATION DO.T Shipping Name: Ammonia, Anhydrous (RQ 100/45.4) I.D. No.: UN 1005 DOT ShiD~inq ,Label: Nonflammable Gas DOT Hazard Class' Nonflarmable gas SPECIAL HANDLING RECOMMENDATIONS ~ Use only in well-ventilated areas. Valve protection caps must remain in place unless container is secured with valve outlet piped to use point. Do not drag, slide or roll cylinders. Use a 'suitable hand truck for cylinder movement. Use a pressure reducing regulator when connecting cylinder to lower pressure (<500 psig) piping or systems. Do not heat cylinder by any means to increase the discharge rate of product from the cylinder. Use a check valve or trap in the discharge line to prevent hazardous back flow into the cylinder. For additional ha'ndling recommendations consult L'Air Liquide's Encyclopedia de Gaz or Compressed Gas Association Pamphlet P-~. PECIAL STORAGE RECOMMENDATIONS ":-~Protect c~linders from physical damage. Store in coo.l, dry, well-ventilated area of non-combustible construction away from heavily trafficked areas and emergency exits. Do not allow the t~mperature where cylinders are stored to exceed 130F (54C), Cylinders should be stored ~pright and firmly secured to prevent falling or being knocked over. Full and empty cylinders should be segregated. Use a "first in-first out" inventory system to prevent full cylinders being stored for excessive periods of time, Post "No Smoking or Open Flames~' signs in the storage or use area. There should be no sources of ignition in the storage or use area. Fo'r additional storage recommendations consult L'Air Liquide's Encyclopedia de Ga~ or Co. mpressed Gas Association Pamphlet Po1. SPECIAL PACKAGING RECOMMENOATIONS Gaseous or liquid anhydrous ammonia corrodes certain metals at ambie'nt temperatures. Oxygen presence enhances the corrosion of ordinary or semi-alloy steels. The addition of water inhibits this enhancement. Keep anhydrous ammonia systems scrupulously'dry. OT~R RECO;~{MENDAT)CNS CR PRECAUTIONS Ea~'.{h-ground and bond. all lines and equipment associated with the ar,.~onia system. ElEctrical ecuipment should be non-sparking or explosion procf. Co~,~pressed.gas cylinders shc~d not be 're;illed exce.~ by qualified producers of ccm~r~sse~ ~hipment of a comoressed gas cylinder wi3ich has not been '~iiled by the owner or with ~_~is (written) ' ' ' - ~-. ...... c~nsen~. ~s ~, violation cf Federal Law "!'!:"~ k LIOUiD AIR CORPORATION ALPHAGAZ DIVISION ':~i~. .' :~':'. "~ :".':'. '"'. i' "~ ".i?::.'.~ ,~ '?~'i ), ADDITIONAL DATA RECOmmENDED FIRST AID TREATMENT: (Continued) Eye Contact: PERSONS WITH POTENTIAL EXPOSURE TO AMMONIA SHOULD NOT WEAR CONTACT LENSES. Flush contaminated'eye(s) with copious quantities of water. Part eyelids to assure complete flushing, Continue for a minimum of 15 minutes. Skin Contact' Flush affected area with copious quantities of water. Remove affected clothing as rapidly as possible. Dermal Contact or Frostbite: Remove contaminated clothing and flush affected areas with lukewarm water. DO NOT USE HOT WATER. A physician should see the patient promptly if the cryogenic "burn" has resulted in blistering of the dermal surface or deep tissue freezing, SPECIAL FIRE FIGHTING PROCEDURES' (Continued) the escaped ammonia gas. Use water spray to cool surrounding containers. o~s-03 LEGEND DRAWN JURISDICTtON SUBD, KEY DISCLAIMER ----./ PTN. 'TRACT 1301 ........................................................ ~Sf '- -GA~'tFORt~ ......... ~,,. f &: NWl/4 OF SEC.33 T. 29S. R.28E. t / ~ / ~ ........... t .... ~ ....... : ...... i~ ' ~F_AST-LII-TR .... -ST,---i ..... 2 ................... lOTH ST, ASSESSORS MAP NO. 018-0,3 COUNTY OF KERN 018-03.TIF 6600x4200x2 tiff A643 - TAX-ENTITY NEXT-FUNC: KIPS #ROLLINQ ATN F±le APN SITE No 01 018 031 1233 Owner U S Bill 10 TRA-No CHG DT Chg Type Mineral Land/PI Imprvment Other Imp Pers Prop Exmp Amt Net Value NOT ATTACHED TO ANY PARCEL KEY: UNSECURED ROLL INQUIRY 1007926 009 5 Lgnd 08 8 Lgl E CALIFORNIA AV BAKERSFIELD KEY INACTIVE Roll 4 Use AG Presv NO Acres CPest BPSSD 5 FILTER / IONPURE INC Doc TECHNOLOGY DR LOWELL MA 01851 2002 NO ROLL DATA PROMPT P22241 Code 91 O0 UF NT 99-7012130-00-4 001 012 1,296 1,296 PFI:HELP 2:MENU 3:RTRN 4:TOG 5:FUTR 9:BILL IO:UFL' 11=BUS 12=EVTSEL PF13=NEH 14=APN HIST 16=EXEMPT 17=SUPPL 18=ADDR 19=ROLL CORR PF20'PREV YR 21=NEXT YEAR 22=PRT 23=NEXT 24=PREV 07/29/02 10:58 OF PRIOR #ROLLINQ ROLL KEY: B390 - END NEXT- FUNC: KIPS ATN FJ. ie No 01 0085208 015 8 APN 018 031 08 8 Lgl SITE 1233 E CALIFORNIA AV Owner A L A C I NC Bi. ii P 0 BOX 408 NILLIS TRA-No CHG DT Chg Type Mineral Land/PI Imprvment Other Imp Pers Prop Exmp Amt Net Value DATA UNSECURED ROLL Lgnd BAKERSFIELD TX 77378 2002 NO ROLL INQUIRY INACTIVE Acres Doc KEY Roii 4 Use Code AG Presv NO CPest BPS SD 5 UF DATA PROFIPT P22241 9100 NT PFI=HELP 2=FIENU 3=RTRN 4=TOG 5=FUTR 9=BILL I O=UFL 11=BUS 12=EVTSEL PF13:NEN 14:APN HIST 16:EXEFqPT 17:SUPPL 18:ADDR 19:ROLL CORR PF20=PREV YR 21=NEXT YEAR 22=PRT 23=NEXT 24=PREV 07/29/02 11:02 NEXT- FUNC: KIPS #ROLLINQ ATN File No 01 APN 018 031 SITE 1233 Owner AIR Bill P 0 BOX TRA-No CHG DT Chg Type Mineral Land/PI Imprvment Other Imp Pers Prop Exmp Amt Net Value KEY: UNSECURED ROLL 1005717 014 5 Lgnd J 08 8 Lgl E CALIFORNIA AV BAKERSFIELD LIQUIDE AMERICA CORPORATION IN(~UIRY ACTIVE 460149 HOUSTON TX 77056-8149 R.B.P. 03 02-7008870-00-2 001 507 001 507 Acres Doo KEY Roll 4 Use AG Presv NO CPest BPS 0 SD 5 01-7009596-00-1 001 507 25,865 25,865 25,679 DATA PROMPT P22241 Code 91 O0 UF NT 25,865 25,865 25,679 PFI:HELP 2:MENU 3:RTRN 4:TOG 5:FUTR 9:BILL IO:UFL PF13=NEN 14=APN HIST 15=OI~NERS 16=EXEMPT 17=SUPPL PF20=PREV YR 21:NEXT YEAR 22:PRT 23:NEXT 24:PREV 11=BUS 12=EVTSEL 18=ADDR 19=ROLL CORR 07/29/02 11:01 NEXT- FUNC: KIPS #ROLLINQ ATN F±le No 01 APN 997 001 SITE 1233 KEY: 0062259 003 6 03 7 Lgl E CALIFORNIA AV Owner THE MEAD CORP Bill COURTHOUSE PLAZA NE TRA-No CHG'DT Chg Type Mineral Land/PI Imprvment Other Imp Pers Prop Exmp Amt Net Value UNSECURED ROLL Lgnd BAKERSFIELD DAYTON OH 45463 2002 NO ROLL INQUIRY INACTIVE Acres Doo KEY Roll 4 Use AG Presv NO CPest BPS SD DATA PROMPT P22241 Code 91 O0 UF NT 98-7004936-00-6 001 001 135,155 135,155 PFI=HELP 2=MENU 3=RTRN 4=TOG 5=FUTR 9=BILL IO=UFL 11=BUS 12=EVTSEL PF13=NEN 14=APN HIST 16=EXEMPT 17=SUPPL 18=ADDR 19=ROLL CORR PF20=PREV YR 21=NEXT yEAR 22=PRT 23=NEXT 24=PREV 07/29/02 10:53 HMM-P PLA~ MAP SITE DIAGRAM ~ FACILI'FY DIAGRAM Busine~ Nome: C A ysr-,4 t. Busine~ Adclre~: /233 ~',~-~¢' For Otfice Use Only Area Mop # of Firs! In Sladon: Inspection SSalion: NORTH WEsT Vintage Air ~tr~eT ~t'reet I I I Industrial East California Avenue Jobl Crystal Shack Geyser Storage ILot Crystal Geyser Bottling Facility Crystal Geyser Parking Lot Alley Housing Complex Housing Complex I~ Viroini,~ ~onterey SET~ Henley S Lucl Wz INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD sU'rro'undin~g Area ! 'Il Industrial Parking Vintage Air East California Avenue Job c~,~, Shack Crystal Geyser . Bottling Facility Crystah GeyserI ParkingI Lot Alley Housing Complex P~rk ~tre~t Stm~t t Potomac FORNIA arendon ~£T* Henley LucI CALIFORNIA AVENUE COKIR~L ~ ALLEY CRYSTAL GEYSER REFRIGERATION AND WATER TREATMENT FACILITY PLOT PLAN DATE 12/93 I 0332.0011A,, IEXHIBIT 3 Bakersfield 4700 Stockdale Highway, Suite 120 Post Office Box 9217 Bakersfield, California 93389 805/326-1112 805/326-0191 FAX Fresno 470 East Herndon Avenue, Suite 203 Fresno, California 93720 209/261-9160 209/261-9171 FAX WZl ,.c. Crystal Geyser Water Company Bakersfield, California Risk Management and Prevention Program October, 1990 Revised February, 1991 Revised April, 1991 Revised December, 1993 Submitted to: The City of Bakersfield Fire Department Hazardous Materials Division Prepared by: WZI Inc. 4700 Stockdale Highway, Suite 120 Bakersfield, California 03320011.013 TABLE OF CONTENTS Section I. Purpose II. Introduction III. Certification IV. Revision Record 1.0 Background 2.0 3.0 4.0 1.1 General Business Information 1.2 Description of Acutely Hazardous Materials Used 1.2.1 Amount Ammonia Used 1.2.2 Hazardous Properties of Ammonia 1.3 General Ammonia Refrigeration Processes 1.4 Operation of the Ammonia Systems Description of Acutely Hazardous Materials Accidents Accidents at this Location Underlying Causes Measures Taken to Prevent Recurrence Accident Investigation Procedures Release Reporting Procedures Equipment Report 3.1 Ammonia Equipment 3.1.1 Nature, Age and Condition 3.1.2 Testing Schedules 3.1.3 Maintenance Schedules Procedures Report 4.1 Ammonia Systems 4.1.1 Daily Operating Procedures 4.1.2 Maintenance Procedures 2.1 2.2 2.3 2.4 2.5 Page 1 2 4 5 6 6 7 7 7 8 8 10 10 10 10 10 11 13 13 13 21 21 23 23 23 24 TABLE OF CONTENTS Section 5.0 'Design, Operating and Maintenance Control Systems 5,1. Ammonia 5.1.1 5.1.2 5.1.3 Design Control Systems Operating Control Systems Maintenance Control Systems 6.0 Detection, Monitoring or Automatic Control Systems 6.1 Ammonia 6.1.1 6.1.2 6.1.3 Detection Systems Monitoring Systems Automatic Control Systems 7.0 Proposed Risk Reduction Measures 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 Written Operating Procedures Written Maintenance Procedures Increased Inspections Better Labeling Safety and Training Program Fire Prevention Plan Physical Plant Changes Reduction of Consequence to Neighboring Homes or Businesses 8.0 Emergency Contingency Plans 8.1 8.2 8.3 8.4 8.5 General Evacuation Fire Earthquake Significant Leak from the Ammonia Systems Emergency Responders 9.0 Auditing Program ,PaRe 26 26 26 26 27 28 28 28 28 29 30 3O 3O 3O 3O 31 31 31 31 32 32 32 32 32 33 35 9.1 Ammonia Systems 35 Section 10.0 11.0 12.0 Inspection Program TABLE OF CONTENTS 10.1 Ammonia Systems Risk Management and Prevention Program (RMPP) Implementation 11.1 11.2 11.3 Personnel Responsible for RMPP Implementation Implementation Schedule Training Program for RMPP Implementation RMPP Record Keeping 12.1 12.2 12.3 12.4 13.0 13.1 13.2 References Accident Records Ammonia Charge Record Training Records Audit Records Qualifications of Certifiers Qualified Person Facility Operator INC. Pa~e 36 36 37 37 38 38 41 41 41 41 41 42 42 42 43 Exhibit 1 Exhibit 2 Exhibit 3. Exhibit 4 Exhibit 5 Exhibit 6 Exhibit 7 Exhibit 8 Exhibit 9 Exhibit 10 EXHIBITS Location Map Surrounding Area Refrigeration and Water Treatment Facility Plot Plan Schematic of Ammonia Refrigeration System Ammonia Incident Report Compressor Operator's Log Maintenance Record Evacuation Routes Ammonia Charge Record Ammonia System Training Required/Date Completed Record Table 1 TABLES Physical Properties of Anhydrous Ammonia Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F APPENDICES Hazards Analysis (Under Separate Cover) Business Plan Piping and Equipment Layout Plans Preventative Maintenance Check List Manning Systems Gas Cell/Transmitter Instruction and Installation Manual Ammonia Safety Audit REFERENCES The Center for Chemical Process Safety, Guidelines for Hazard Evaluation Procedures, 1985, American Institute of Chemical Engineers. Office of Emergency Services, Hazardous Materials Division, Risk Management and Prevention Proqram Guidance, 1989, State of California. U. S. Environmental Protection Agency, Federal Emergency Management Agency and the U. S. Department of Transportation, Technical Guidance for Hazards Analysis: Emerqency Plannin.q for Extremely Hazardous Substances, 1987. 4. National Response Team, Hazardous Materials Emergency Planninq Guide, 1987. Page43 TABLE 1 PHYSICAL PROPERTIES OF ANHYDROUS AMMONIA (NH~) Molecular Weight 17.03 Lbm/Lbmole Latent Heat 327 Calorie/Gram Boiling Point -28.03 , °F Solubility 89.9 G/100 mi AT 0 °C Specific Gravity (Liquid) 0.682 (-33.35 °C/4 °C) Vapor Density 0.59 (AIR=l) @ 25 °C, 760 mm Hg Autoignition Temperature 651 °C (1,204 °F) Explosive Limits 16 to 25 % by Volume in Air · Critical Temperature 651 °C Critical Pressure 11.5 ATM IDLH 350 mg/m3 (500 ppm) LOC 35 mg/m3 (50 ppm) STEL 25 mg/m3 (35 ppm) Ratio of Specific Heats 1.31 I ppm 0.7 mg/m3 @ 25 oC and 760 mm Hg The .molecular structure of ammonia is composed of one nitrogen (N) and three hydrogen (H) atoms. The molecular weight of ammonia, 17 Ibm/Ibmole, is significantly less than that of air which is approximately 29 Ibm/Ibmole. As a result, ammonia in the vapor phase is much lighter than air and rapidly rises when released. 03320011.014 I~ i- ra ~/~ Bakersfield 4700 Stockdale Highway, Suite 120 Post Office Box 9217 Bakersfield, California 93389 805/326-1112 805/326-0191 FAX Fresno 470 East Herndon Avenue, Suite 203 Fresno, California 93720 209/261-9160 209/261-9171 FAX HAZARD ANALYSIS · AUGUST 1993 REVISION CRYSTAL GEYSER WATER COMPANY BAKERSFIELD, CALIFORNIA August 1993 Submitted to: The City of Bakersfield Fire Department Hazardous Materials Division Prepared by: WZI Inc. 4700 Stockdale Highway, Suite 120 Bakersfield, California 93309 o332.o011.oo7 APPENDIX D PREVENTATIVE MAINTENANCE CHECK LIST $CH. ' Wy. ~nt~l hrk ~.)~ALStree I ENUE ~UXTUN CRYSTAL GEYSER BAKERSFIELD ~Ot ton Wy. ,.CA~-IFORNIA c Henley St.. St, Lake " Avl. Ave, IProwl Potomac Ave. ' D Fee! I 0 I~iiet _o - E. Beite' 'i errlct Smifh St. 4000' f~ni. 0 Kilomelet$ .50km 1 1 km .I --BRUNDAGE DATE '~ exa~ St. ~ E WZI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. LOCATION MAP EXHIBIT 7/93 0332.001 lA I APPENDIX B BUSINESS PLAN' ;6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page Overall Site with ~ Fac. Unit General Information Location: 1233 E CALIFORNIA AV Map: 103 Hazard: High Community: BAKERSFIELD STATION 02 Grid: 32C F/U: 1 AOV: 0.0 1 Contact Name Title Business Phone .! 24-Hour Phoneq ALEX MANNS ~,~ ~,~ (805) 323-6296 x I (805) 589-6906~ GERHARD GAUGEL ~ ~t~A~ · (805) 323-6296 x (805) 392-8747/ Administrative Data Mail Addrs: 1233 E CALIFORNIA D&B Number: 'City: BAKERSFIELD State: CA Zip: 93307- Comm Code: 215-002 BAKERSFIELD STATION 02 SIC Code: 5149 Owner: PETER GORDON / LEO SOONG Phone: (~e~) 9~1 -o$'60 Address: 501 WASHINGTON ST State: CA City: CALISTOGA Zip: 94515-O3O~ Summary THIS FACILITY HAS 5 INDIVIDUALS TRAINED IN S.C.B.A. BAKERSFIELD C1.T7¢ FIRE DEPARTMENT · . RAZARDOUS MATERIALS INVENTORY P~.ae/oil CHEMICAL DESCRIPTION .' 1} INV'"r_NTORY STATUS: New [ I Addition [ I Revision D00elei,~n ( I Check i! chem,c,,~ i.~ & NON TRAOE SECRET ~ TRAOE SECRET 2) Common ~'~e: cas ~ ?&& ,/- ~/- -7 PHYSICAl.. & HE.~LT'H PHYSICAL HEALTH HAT...ARD CATEGORIES ~re [ I ReactNe [ I Suc~0en Release of Pressure ~X~I ImmeOia. ze He,tn (Ac~e) ~ Delsyed Hee. n.h (Chronic) WAS~ C~SSI~CA~ON (~igk ~de from0HS Fo~ 8022) USE COOE. /O 7) AMOUNT AND TiME AT FACILITY UNITS OF MEASURE 8) STORAGE COOE. S ~mumO~Amount: //O~S'O "~ ~t= ti g~' [~ =3 ~0 ,)con~'ne~. Avera. ge Oaily Amount:. //Oj ~L ~ 0 ~'7'.~ cudes [ I ' b) Pressure: Annu~.l Amount: ///, $ 5' ~"- C) Tempcrsture: L,~/'~esl S~e ConlaJner: ,4)/q,~,.q 9) MI~'TURF' Lis: the ~ree most ha.za, rdous chemic~ componen~ or any AHM components 2) COMPONENT CAS ~I % WT AHM [1 CHEMICAL DESCRIPTION 1) INVENTORY STATUS: New~ Add,on[ ] Revision[ ~J Deletion[ ] ... Check'dchemiC~&NONTRADESECRET 3) C~T # (op~Jon~ HF_ALTH Immedia:, HeaJ~ (Acme) [ ] Oelayed Hea~th (Chronic) WASTE CLASSIFICATiON {3-(Sigit cooe from OHS Form ~C~22) USE CCOE 0 q 6) PMYSICAt. STAI'E Solid AMOUNT AND TiME AT FACIUTY ~=rnum 0~'ly Amount: ~nu~ Amount: . ~gesc Size Commne~ the t.'3r~e most chemical comoonents any AHM components Which Months: c) Temoerazure: ~, J. F. M. A. M. J. J. A. $. O. N. 0 · cat'my uno er pena~ or law, ~ar I nave pe~n~ly examinee ~o ~ /e. rn;,~r w;m me intomaoon suomtl=eo on gll'~ ~ CJI aF2tc~'ieo eecUrllenee- ~ ~; =ubrniC, m~ inforrnadon i~ rue, accurem, e.nd ccmplem. ~RII~T Na~ne & ~tJe of Autllo~ze~ Com/:;~J?y/::Jepreaenradve $ign~.mre b ,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 #: 7664-4 Trade Secret: No G~ ~, Form: Gas 5 Use: STORA '.,~/ ~ Dail ~0~._{~ .~ , ~ ,p , , LocatiOn o ~__ /~/~ e~'~ ~' . St°ragi3~i~~i~~g t~ --Con~-/ ' - Compone~~'~'d>w~:'~'''v¢ ~~uide ~0% A~onia, Anhydrous Gas IExtreme I~ 02-030 Anhydrous ammonia · Pressure, Immed Hlth Gas 6720 Extreme FT3 CAS #: 7664-41-7 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: COOLING Daily Max~y Average FT3 ~/K~ual Amount FT3 -- Storage ___~.~ Press T Te ~ -- Location IN MACHINE/EQUIP IAbove/~A~ientlRefrigera~ system -- Conc / Components ~ ~P .--TGuide 100.0% IANHYDRO~US~A~ONIA IUnra~ 0 02-010 ACETYLENE · Fire, Pressure, Immed Hlth Gas 1'30 High FT3 CAS #: 74-86-2 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: WELDING SOLDERING Daily Max FT3 130 I Daily Average FT3 ----T---- Annual Amount FT3 ~ 100.00~ 230.00 Storage Press T Temp Location PORT. PRESS. CYLINDER Above IAmbientlSOUTHWEST CORNER SHOP STORAGE -- Conc Components '. MCP 100.0% IAcetylene IHigh Guide ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order Page 3 02-004 PROPANE · Fire, Pressure, Immed Hlth Gas 18158 High FT3 CAS #: 74-98-6 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: FUEL Daily Max FT3 18,158 Daily Average FT3 1,455.00 Annual Amount FT3 -- 218,340.00 Storage FIXED PRESS. CYLINDER -- Conc -. 100.0% IPropane Press T Temp Location IAbove /Ambient lSOUTHWL~5~ PARKING LOT ~EA-C0~6& omponents MCP ---[Guide IExtreme I 22 02-020 DESCALE 10-50 · Reactive, Immed Hlth, Delay Hlth Liquid 55 High GAL CAS #: 7647-01-0 Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: OTHER Daily Max GAL Daily Average GAL Annual Amount GAL 55.00 Storage DRUM/BARREL-NONMETAL Press T Temp Location AmbientIAmbientlINSIDE WESTSIDE BUILDING -- Conc - 50.0% IMuriatic Acid Guide Components IHi~~P I 15 02-024 SODIUM HYPOCHLORITE · Reactive, Immed Hlth Liquid 104 High GAL CAS #: 7681-52-9 Trade Secret: No Form: Liquid Type: Pure Daily Max GAL 104 I Days: 365 use: CLEANING Daily Average GAL ¥ Annual Amount GAL 52.00 / 1,250.00 Storage PLASTIC CONTAINER Press T Temp Location IAmbientIAmbientlWESTSIDE OUTSIDE BUILDING -- Conc 12.5% ISodium HypoChlorite 1.0% Sodium Hydroxide Components MCP Guide Moderate 60 ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order Page 4 02-029 COFIDENCE 41C · Immed Hlth, Delay Hlth Liquid 25 High GAL CAS #: Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: WATER TREATMENT Daily Max GAL I Daily Average GAL 25 I 20.00 Annual Amount GAL -- 80.00 Storage DRUM/BARREL-NONMETAL Press T Temp IAmbient~Ambient IBOILER ROOM Location -- Conc 4.0% 8.0% 3.0% Components Isodium Hydroxide Potassium Hydroxide beta-Diethylaminoethanol MCP ----~Guide ModerateI 60 ModerateI 60 High ! 29 02-017 GUARD 203 · Reactive, Immed Hlth, Delay Hlth Liquid 110 Moderate GAL CAS #:' Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: NEUTRALIZER Daily Max GAL Daily Average GAL I Annual Amount GAL 1,000.00 Storage DRUM/BARREL-NONMETAL Press T Temp Location IAmbient~AmbientlINSIDE WEST BUILDING -- Conc 35.0% IPhosphoric Acid Components · MCP ---/Guide IModerateI 60 02-018 GUARD 219 CHLORINATED FOAMER · Reactive, Immed Hlth, Delay Hlth Liquid 110 "Moderate GAL CAS #: Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: CLEANING Daily Max GAL Daily Average GAL 110 I 55.00 Annual Amount GAL 1,300.00 Storage DRUM/BARREL-NONMETAL Press T Temp Location Ambient~AmbientlINSIDE WEST BUILDING -- Conc 25.0% IPotassium Hydroxide Components MCP ---TGuide IModerateI 60 )6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order Page 02-021 CHLOR 231 · Fire, Immed Hlth, Delay Hlth Solid 900 Moderate LBS CAS #: 1310-73-2 Trade Secret: No Form: Solid Type: Mixture Days: 365 Daily Max LBS 900 I Storage DRUM/BARREL-NONMETAL -- Conc Components 0.0% ISodium Hydroxide Use: CLEANING Daily Average LBS 550.00 Annual Amount LBS -- 5,800.00 Press T Temp Location · AmbientJAmbientlINSIDE WEST BUILDING MCP ---TGuide IModerateI 60 02-028 SAFETY KLEEN 105 SOLVENT · Fire Liquid 20 Moderate GAL CAS #: 64742-41-9 Trade Secret: No Form: Liquid Type: Mixture Days: 365 Daily Max GAL 20 I Storage IN MACHINE/EQUIP Daily Average GAL 20.00 Press T Temp I AmbientJAmbi ent I SHOP -- Conc 89.0% IMineral Spirits Components Use: WASHING Annual Amount GAL 100.00 Location MCP ---TGuide IModerateI 27 02-008 MALEIC ACID Solid '300 Low LBS CAS #: 6915-15-7 Form: Solid Type: Pure Daily Max LBS 300 J Storage BAG -- Conc 100.0% JMaleic Acid Trade Secret: No Days: 365 use: FORMULATION/MANUFACTURING Daily Average LBS [ Annual Amount LBS -- 150.00 I 1,200.00 Press T Temp Location IAmbientJAmbientlNORTHWESTBATCH AREA MCP ---TGuide Components ILow ~ 60 )6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order Page 02-005 OXYGEN · Fire, Pressure, Immed Hlth Gas 251 FT3 Low CAS #: 7782-44-7 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: WELDING SOLDERING Daily Max FT3 251 Daily Average FT3 Annual Amount FT3 251.00 I 753.00 Storage PORT. PRESS. CYLINDER Press T Temp Location Above /AmbientlSHOp STORAGE AREA -- Conc 100.0% IOxygen, Compressed Components MCP ---TGuide ILow '~ 14 02-015 CHEVRON DIESEL FUEL #2 · Fire, Immed Hlth, Delay Hlth Liquid 330 Low GAL CAS #:. 68476-34-6 Trade Secret: No Form: Liquid Type: Pure Days: 365 Use: FUEL Daily Max GAL 330 I Daily Average GAL 110.00 Annual Amount GAL 2,500.00 Storage DRUM/BARREL-METALLIC Press T Temp Location Ambient/AmbientlOUTSIDE EAST YARD IN DOCK -- Conc I 100.0% IDiesel Fuel No.2 Components · .. MCP ---TGuide ModerateI 27 02-019 PENNANT NL OIL 150 · Fire, Reactive Liquid 55 Low GAL CAS #: Trade Secret: No Form: Liquid Type: Mixture Days: 365' Use: LUBRICANT Daily Max GAL Daily Average GAL Annual Amount GAL 55.00 Storage DRUM/BARREL-METALLIC Press T Temp Location IambientlAmbientlOUTSIDE WEST BUILDING -- Conci Components 43.0% ISolvent Dewaxed Distillate, Heavy Paraffin MCP ---TGuide ILow ~ 27 ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order Page 7 02-006 ARGON · Fire, Pressure, Immed Hlth Gas 155 FT3 Minimal CAS #: 7440-37-1 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: WELDING SOLDERING Daily Max FT3 155 Daily Average FT3 Annual Amount FT3 75.00 I 155.00 Storage PORT. PRESS. CYLINDER Press T Temp Location lAbors ~AmbientlSHOP STORAGE AREA -- Conc 100.0% IArgon Components MCP ---~Guide Minimal I' 12 02-003 CARBON DIOXIDE · Fire, Pressure, Immed Hlth Gas 420333 Minimal FT3 CAS #: 124-38-9 Form: Gas Type: Pure Daily Max FT3 420,333 I Trade Secret: No Days: 365 Use: FORMULATION/5~NUFACTURING Daily Average FT3 Annual Amount FT3 242,500.00 I 2,932,920.00 Storage Press T Temp FIXED PRESS. CYLINDER IAbove ]Below Location INORTHWEST PARKING LOT AREA -- Conc 100.0% ICarbon Dioxide Components MCP --TGuide 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 2,400 Daily Average LBS 1,000.00 Annual. Amount LBS 24,000.00 BAG Storage Press i' Temp Location IAmbient~Ambient INORTHWEST BATCH AREA - Conc 100.0% ICitric Acid Components MCP ----~uide Minimal I 1 :6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order Page 02-002 HOT MELT ADHESIVE Solid 800 Minimal LBS CAS ~: 92717 Trade Secret: No Form: Solid Type: Pure Days: 365 Use: ADHESIVE Daily Max LBS 800 I Daily Average LBS 400.00 Annual Amount LBS 3,000.00 BOX Storage Press T Temp Location IAmbient~AmbientlPaCKING AREA SOUTH BLDG -- Conc 100.0% Components i.. MCP ---rGuide Minimal I 1 02-013 NITROGEN · Fire, Pressure, Immed Hlth Gas 142 Minimal FT3 CAS #: 7727-37-9 Trade Secret: No Form:' Gas , Type: Pure Days: 365 Use:.EXPERIMENTAL/ANALYTICAL Daily Max FT3 142 Daily Average FT3 ---V-- Annual Amount FT3 70.00~ 142.00 Storage PORT. PRESS. CYLINDER Press T Temp Location IAbove ~AmbientlOUTSIDE BLDG SOUTHWEST CORNER -- Conc 100.0% INitrogen Components MCP ---~Guide ILow ~ 21 02-016 GUARDQUAT 128 · Immed Hlth, Delay Hlth Liquid 110 Minimal GAL CAS #: Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: FUNGICIDE Daily Max GAL Daily Average GAL 110 I 30.00 Annual Amount GAL 600.00 Storage .DRUM/BARREL-NONMETAL Press T Temp Location Ambient~AmbientlINSIDE WEST BUILDING -- Conci Components 10.0% IDimethyl Benzyl Ammonium Chloride MCP iGUidle IMinimal 36/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order Page 02-023 ARCO GEAR OIL SAE (85W-140W) · Fire, Immed Hlth, Delay Hlth Liquid 55 Minimal GAL cas #: 64742-54-7 Form: Liquid Type: Pure Daily Max GAL .55 Storage DRUM/BARREL-METALLIC -- Conc~ Components 100.0% IHeavy Machine Oil Trade Secret: No Days: 365 Use: LUBRICANT i Daily Average GAL Annual Amount GAL 35.00 I 55.00 Press I Temp Location Ambient~AmbientlOUTSIDE WEST BUILDING .. MCP ----[Guide IMinimal I 27 02-025 ASCORBIC ACID Solid · Fire, Reactive, Immed Hlth, Delay Hlth 200 Minimal LBS CAS #: 50-81-7 Trade Secret: No Form: Solid Type: Mixture Days: 365 Use: FORMULATION/F~%NUFACTURING Daily Max LBS 200 Daily Average LBS 100.00 Annual Amount LBS 1,700.00 Storage DRUM/BARREL-NONMETAL Press 7 Temp Location Ambient~AmbientlWESTSIDE OF BUILDING -- Conc 100.0% IAscorbic Acid Components MCP ----~uide Minimal I 7 02-026 ARCO GEAR OIL (90 WT) · Fire, Delay Hlth Liquid 55 Minimal GAL CAS #: 8020835 Trade Secret: No Form: Liquid Type: Pure Days: 365 Use: LUBRICANT Daily Max GAL Daily Average GAL 35.00 Annual Amount GAL 55.00' Storage DRUM/BARREL-METALLIC Press T Temp Location IAmbient~AmbientlOUTSIDE WEST BUILDING -- Concj Components 100.0% ILubricating Oil (Petroleum-Based) MCP ---7Guide Minimal I 27 ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order Page 10 02-027 TARTARIC ACID Solid · Fire, Reactive, Immed Hlth, Delay Hlth 2000 Minimal LBS CAS #:~ 87-69-4 Trade Secret: No Form: sOlid Type: Mixture Days: 365 Use: FORMULATION/MANUFACTURING Daily Max LBS Daily Average LBS I Annual Amount LBS 2,000 J 700.00 20,000.00 Storage BAG Press T Temp Location AmbientJAmbientJNORTHWEST BATCH AREA -- Conc) Components 100.0% JTartaric Acid, Diammonium Salt MCP ---/Guide JMinimal I 31 02-022 CHEVRON HANDY OIL 15 · Fire, Immed Hlth, Delay Hlth Liquid 110 Unrated GAL CAS #: Form: Liquid Daily Max GAL 110 Storage DRUM/BARREL-METALLIC -- Conc t Components 95.0%JLight Petroleum Distillate Trade Secret: No Type: Mixture Days: 365 Use: LUBRICANT - Daily Average GAL j Annual Amount GAL J 55.00 700.00 Press T Temp . Location JAmbientJAmbientlOUTSIDE WEST BUILDING MCP ---iGuide JModerateJ 27 ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 00 - Overall Site <D> Notif./Evacuation/Medical 11 °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 5~NAGER UPON NOTIFICATION WILL USE THE PAGING SYSTEM TO NOTIFY ALL EMPLOYEES TO EVACUATE THE FACILITY. EACH SUPERVISOR IS TO DIRECT THE EMPLOYEES IN HIS AREA TO THE SAFEST EXIT AND MAKE SURE 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 ~ACH 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 00 - Overall Site <E> Mitigation/Prevent/Abatemt 12 il>Release Prevention TO PREVENT THE RELEASE OR SPILL OF HAZARDOUS MATERIAL AT THIS FACILITY, ONLY INDIVIDUALS REQUIRED TO USE HAZARDOUS MATERIALS IN THE COURSE OF THEIR WORK WILL BE ALLOWED TO HANDLE THEM. EACH OF THESE INDIVIDUALS WILL BE TRAINED IN THE SAFE HANDLING AND USE PROCEDURES FOR EACH PRODUCT :2> Release Containment PROCEDURES FOR CONTAINMENT WILL BE THOSE RECOMMENDED BY THE MANUFACTURER OF THE PRODUCT AS DESCRIBED IN THE MATERIAL SAFETY DATA SHEET AMMONIA DIFFUSION SYSTEM LOCATED OUTSIDE OF BUILDING, NORTHWEST CORNER. :3> Clean Up PROCEDURES FOR CLEAN-UP WILL BE THOSE RECOMMEDED BY THE MANUFACTURER OF THE PRODUCT AS DESCRIBED IN THE MATEIAL SAFETY DATA SHEET. ~4> Other Resource Activation CRYSTAL GEYSER WATER COI~ANY 215-000-001418 OO - OVERALL SITE <F> SITE EHERGENCY FACTORS I. AMENDMENTS TO <2> UTILITY SIIUT-OFFS: A) Gas Meter: Inside fence between buildings next to alley southwest corner of ~'~-','.=so facility/south of Ammonia ~ ~' ~an~ 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 ~- ~ ~=eu 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 ~,, sides of exit door next to ~=.. E) Special: · nm,,on~= shut-offs inside southeast corner of '",,e=-~ building,e.,~ to alley/ Engineering Support area. 2. Diffusion system box next to roll up door of West building - southside next to alley. Yes (keys only), above north entrance door of west building. II· ~,'~=,,~,,~,,^um~'n~'~'~e~ ~ TO: <3> FIRE PROTECTION/AVAILABLE WATER Priva~- F:-- Protection ****= faci ~ equipped w~~ automatic overhead - -' "~ . The =p, ln~=ers in all building areas spri-~-~ - ,=_-,=~ . · ,,~,e~ system is monitored by ~-] ~- Security Systems Fire extinguishers are in all areas of the facility for emergency use. Fire "--a-ant,,.~, - On the north side of East California Ave. , a~rectly across from ~ ' u~ ~,~e West facility building. ~_ :_1_1 ~: , -, ..... Department ~--~' up o~r~,,~,~- System set ,Io~up= Fire ,~- · - -~ o20 - '-~- "' East exists ~,, =~-y=, ~ feet west of ~e..xew Avenue for build~ng hook up. "~- ~ · .,=s~ 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 t. East Processing/Warehouse facility - 35 2. .%{est Processing/Engineering Support facility - 4 ,6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 00 - Overall Site <F> Site Emergency Factors 13 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 QFF 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~I=/~£-~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 HMMP MAP SITE DIAGRAM BusJne~ Nome: Busine~ Aaare~: For Office Use Only FACILITY DIAGRAM ~ / or 3 First In Slalion: Inspec',ion Slalion: Area Map # NORTH .of PiPE 5oa. AcC HMMP PLAN MAP SITE DIAGRAM Buslne% Nome: FACILITY DIAGRAM For Office Use Only First In Station: Area Map # of NORTH Inspection Slalion: f_LFk,~'ru~ I _{ ,~o HMMP PLA~ SITE DIAGRAM FACILITY DIAGRAM ~ 3 ¢F 3 Busine~ Name: F.~.vs~-Rt. (~E¥~:4. w~r¢/~ c~/~? For Office Use Only First In Station: Area Map # NORTH of APPENDIX A HAZARDS ANALYSIS (UNDER SEPARATE COVER) APPENDIX C PIPING AND EQUIPMENT LAYOUT PLANS APPENDIX F AMMONIA SAFETY AUDIT