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Home My WebLink AboutRISK MANAGEMENT (5)CRYSTAL GEYSER WATER COMPANY' BAKERSFIELD, CAEIFORNIA RISK MANAGEMENT~AND PREVENTION PROGRAM DECEMBER 1993 WZl Inc. 4700 Stockdale Hwy., Suite.120 Bakersfield,I California 93309 m X SECTION 1.1 FACILITY INFORMATION This seCti0n'6f the .~i~ shall prOvide '~ brief ~i~i~W '°f fa6iiit~?~b~ati°~:"in61uding facility nan~ei' locat~n,' °wnership,':facility emergency c°ntaCtsl''chemical inventories,' content, and regulatOry applicabilitY of the oVerall. FaCility ComPiiance"plan,'i :.'.i~ .' II Unified Program Consolidated Forms: (attached, as ~/Pplicable) I~ Facility Infonnation- business owner / operator identification 1~1 Facility Information - business activities I~ Facility Information - consolidated pennit activities addendum [~1 Hazardous materials inventory I~ Underground storage tank (UST)facility information I~ UST - tank & piping information I~ UST - installation certificate ofcompli~ce ~ Hazardous waste reeyclable materials [~ Onsite hazardous waste treatment notification - facility I~ Onsite hazardous waste treatment notification - unit I~1 Remote waste consolidation site notification Additional Information: (CalARP Risk Management Plan) Igl Latitude & longitude (2740.1 (d)(I)) ~ Dun & Bradstreet number of parent corporation (if different) (2740. I (d)(3)) I~ Number of full time ¢lnpIoyees (2740. I (d)(9)) I~ Subject to Section 5189 of Title 8 CCR (2740.1 (d)(l 0)) , I~1 Subject to Part 355 of Title 40 of CFR (2740.1(d)(11)) l~ Subject to Title V of CAA (2740. l(d)(12)) I~ Date & governmental agency providing last safety inspection (2740. l.(d)(13)) I]3 Executive summary (2745.3) CONSOLIDATED, FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES Section 2740.1 (d)(l) Crystal Geyser.Wate~Company 1233 E. California Avenue Bakersfield, California County of Kern-.93307" 110 degrees West 33 degrees 22 minutes 30 seconds North 39 Full Time Employees I. PURPOSE This Risk Management and Prevention Program (RMPP) has been developed to minimize the potential for release of Acutely Hazardous Materials (AHM) from the Crystal Geyser Water Company bottling facility, Bakersfield, California. Page I II. INTRODUCTION This RMPP has been requested pursuant to Section 25534 of Chapter 6.95, Article 2 of the California Health and Safety Code (CHSC) by the City of Bakersfield Fire Department to reduce the risk of and prevent a~cidents involving AHM. A RMPP is defined in Section 25532 (g) as: "all of the administrative and operational programs of a business which are designed to prevent AHM accident risks, including, but not limited to, programs which include design safety of new and existing equipment, standard operating procedures, preventive maintenance programs, operator training and accident investigation procedures, risk assessment for unit operations,' 'or operating alternatives, emergency response planning, and internal or external audit procedures to ensure that these programs are being executed as planned." This RMPP is based upon an assessment of processes, operations, and procedures of this facility and considers results of the hazards and operability study that has identified hazards associated with handling of anhydrous ammonia, an AHM. The Hazards and Operability Study is included in the Hazards Analysis (Appendix A). The term "ammonia" as used throughout this RMPP refers to its merchant name "anhydrous ammonia". Employees will use procedures detailed in this plan to improve facility safety. As specified in Section 25534 (f), Chapter 6.95, Article 2, CHSC, all records involving the RMPP shall be kept for a minimum of five years. Section 25534 (h) requires that the RMPP shall be reviewed and revised, if necessary, at least once every three years. If a modification is made to the facility that affects AHM handling, a revision of the RMPP must be made within 60 days of the modification. In 1993, Crystal Geyser Water Company modified their existing ammonia refrigeration system. This modification included the installation of new condensers, evaporative condensers, a glycol chiller, master accumulator, accumulator, and high pressure receiver. In addition, a high pressure relief sparge system with diffusion tank was Page 2 installed to reduce the risk of ammonia release in the case of a high pressure release from the pressure relief vents. This new system utilizes the rebuilt carbo coolers. Crystal Geyser is updating the RMPP to reflect these AHM handling system changes. Page 3 1.0 BACKGROUND 1.1 General Business Information Name and Location Crystal Geyser Water Company 1233 East California Avenue Bakersfield, California 93307 Exhibit 1 is a location map. The area immediately surrounding the Crystal Geyser Water Company plant is used for commercial, industrial and residential purposes, as shown in Exhibit 2, surrounding area. Business Telephone (805) 323-6296 Nature of Business The Crystal Geyser Water Company, Bakersfield plant formulates and bottles Crystal Geyser Brand juice drinks and flavored waters. For process cooling, an ammonia refrigeration system is used. Crystal Geyser Water Company's Business Plan is located in Appendix B. Page 6 1.2 Description of Acutely Hazardous Materials Used 1.2.1 Amount Ammonia Used The ammonia used at the Crystal Geyser Water Company facility is contained in the ammonia refrigeration system and holds approximately 4900 pounds of ammonia. A plot plan of the refrigeration and water treatment facility is labeled Exhibit 3. 1.2.2 Hazardous Properties of Ammonia Because of its physical properties, a release of liquid ammonia has a greater potential to cause serious injury to receptors than gaseous ammonia. Liquid ammonia released at a high rate can form a dense, ground hugging cloud of small liquid particles dispersed in air. A dense gas dispersion has the potential to move through surrounding areas, endangering neighboring receptors. Ammonia vapors, lighter than air, rise quickly in the atmosphere and are less likely to cause serious injury to receptors. Ammonia vapors released,into an unventilated area could reach high concentrations that present a risk to employees who enter the area unprotected. Ammonia, a colorless gas with an extremely pungent odor, can be detected by smell at concentrations of 3.5 to 37 mg/m3 (5 to 53 parts per million). Ammonia is corrosive and irritating to the skin. High concentrations can cause dermal burns, inflammation and swelling of the eyes and is potentially blinding to exposed receptors. Levels of 500 mg/m3 (700 parts per million) can cause eye irritation. Coughing occurs at a level of 1,200 mg/m3 (1,700 parts per million). Exposure to higher concentrations can result in debilitating injury and death through pulmonary edema. Ammonia is not recognized as a carcinogen nor does it present a threat to the environment. If involved in a fire, a 16 percent to 25 percent ammonia mixture with air may explode. Table 1 lists the physical properties of ammonia. Page 7 1.3 General Ammonia Refri.qeration Processes Mechanical refrigeration is the process of lowering the temperature of a substance to below that of its surroundings. The cooled substance, ammonia, removes heat from process materials. In a single stage refrigeration process two pressures, high and Iow, are used to enable a continuous cooling process. Low pressure vapor is compressed, raising temperatures and pressure levels. During compression, heat of compression is added to the vapor as the pressure is raised. At the condenser the high pressure vapor is liquefied by cooling. The liquid ammonia flows from the condenser to an expansion valve or injector, where its pressure and temperature are reduced. The ammonia moves to the evaporator where it absorbs heat from a fluid being cooled. Vaporized ammonia then flows to the compressor suction to complete the refrigeration cycle. 1.4 Operation of the Ammonia Systems Exhibit 4 is a flow schematic diagram of the new ammonia system. Piping and equipment layout plans are located in Appendix C. The new ammonia system has been designed to operate continuously 24 hours per day, 7 days per week. From the receiver vessel, liquid ammonia flows through a King solenoid valve to the master accumulator. In the master accumulator, any excess ammonia is boiled off before the liquid ammonia flows to the glycol chiller and the carbo coolers. In these flooded systems, liquid ammonia flows through exchanger plates while the material to be cooled, flowing counter currently, is cooled by the phase change of the boiling ammonia. The carbo coolers and the glycol chiller control the ammonia using a series of float switches. Each unit has an operating float switch and a solenoid valve. When the correct level is reached, the floTM of ammonia is turned off. If the level gets too high it will be caught in the master accumulator. A master high level float switch will shut down the entire refrigeration system. Page 8 Gaseous ammonia enters the screw compressors and is compressed to a higher pressure and temperature. After exiting the screw compressors, the hot gaseous ammonia enters the evaporative condensers. Water running over the condenser coils cools the hot gaseous ammonia into liquid ammonia. The liquid ammonia then returns to the high pressure receiver located inside the compressor building. For the carbo coolers, the liquid ammonia flows through the injectors pulling liquid ammonia from the surge vessel into the coils of the carbo cooler and pre-chiller deaerator and flows to the ammonia surge vessel as a liquid/gaseous phase. Gaseous ammonia from the ammonia surge vessel flows to the ammonia suction trap. The suction trap prevents liquids from returning to the compressors. The gaseous ammonia is then pulled into the compressor suction. Page 9 ;6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page Overall Site with ~ Fac. Unit General Information Location: 1233 E CALIFORNIA AV Community: BAKERSFIELD STATION 02 Map: 103 Hazard: High Grid: 32C F/U: 1AOV: 0.0 ... Contact Name ... Title . Business Phone [ 24-Hour Phone- .~i~k~,~ ODe~ ~,~ ~,~ (~&l-) 323-6296 x GERHARD GAUGEL ~ ~~' (&&~) 323-6296 x I{&~ ) 392-8747 Administrative Data Mail Addrs: 1233 E CALIFORNIA D&B Number: · City: BAKERSFIELD State: CA Zip: 93307- Comm Code: 215-002 BAKERSFIELD STATION 02 SIC Code: 5149 Owner: PETER GORDON / LEO SOONG Phone: (~) 9~1 -O$'60 Address: 501 WASHINGTON ST State: CA City: CALISTOGA Zip: 94515-O30'q :' ' /TZ. '. .... " V.P.MF.O. t{{CI~e~R%22 V~RKLY~H { ~LANT MANAGER. ,::~I,~,RD WEKLYCN t Form IIPP.I WRITTEN INJURY ANU ILLNE99 PrlEVENTIOH PROGnAM Completion of lids form Indlenlei Ihal II I.~ lite policy of lite etdl.loyer lo fully comply with I..nbor Code §6401.? (SB 198) and Oenernl Induslty Safety O~ler ~3201. InJmy a,d III,ess I~evefltimt PmBtam. O~pni~timl~,tlly: .... C R Y P_ AT~6_IL~ .G~.Y ~F~,JR _~LA:f~ULC OJ~lP_Atl X Add~fl: 1233 ~T CALIFORNLA AVEHUE City: ' BAKERSFIELD. ' 81Me: CA Tde~e Num~t: 805/323-6296__ Zip Cable: Type of Busl.ess: HANUFACTURBR Main Activities:. BOTTLING WATER AHU BEVERAGE8 Name/llUo Robert Descdptimsof Autimdty n,d Req~.sil)illty IHPLETION INSFECTtON5 AND INJURY & ILLNESS PEOURAH. Namefritie Richard.Wekl¥ch .. - Vice Pres_i_c!ent Q[ MaP_u_fAcLL. I[jDg ~esctlption uf ^ulhodly a,d fleSlX:~l~ihlllly CEHF.,KAL, AUTIIORIT¥ OF SUF'F_,RVISI. ON OF ,ALLOCATE NE~E. SSAR¥. R_ESOUR__CE$, AS $ UEANCE i. t E'P_. OR' ABAT_E~~Ui[.tJ,-T'X--'t~ A , OR m Review of apIdlcable Oe,etal Imlustry Safely Onlels n,(I ,tiler Safety Orders that apply lo tim opel'allon. Review of Indu,~lfy ami general I,fotmnlioll (lltcludi,l~ Material Rafety Data Sheets for chemicals [Jsed) mi IX)lerlllal occupallo,nl safety and heallh hazards. Investlgfltloh ~f all a¢chlc,l~. I,JuHes. III,eases. m~d mmsuM eve,ts that have occut~cd al fids IocnllOll (sca IV PeR,die mid scheduled |,.~pecthmR O! 8e,eral wink areas n,d .q~ecilic work stalhms (see IV below). Evnluntio, o[ b~h~m~atio, provided by employees (~ee VI beiow). An effective alternative Ineth(xl as described below or attached Io thi,q program liN,, I DeS,:dl~lefl DAVID WRIGHT ~.ND JOSE MENDOZAo GERItARD GAUGEL j~b .~fel~ CI~I .OItCE A lION[II & rALLET '(ARtLq. lIlT-t) which me ,nnltdnl.cd ,l Ihe fi,Ih)wI.R I~tMh,l !233 E. CALIFORNIA BAKERSFZELD U OR I~ C~he, d~mt,,i.d,~, nor~vi6o~6 taV~StlOAttOtl Mnh,l~.ed Il lie f~llowl. R h.:allon~n) I:r(mt t)[ I Ice 12~:E~ C~L~O}{.NIA AVENUE, BAKERSFIELD Form Irreqttett~.~ Ired IRetp~tt,qlt~lllf! Ilrlr ht.,tpe~:fh.t.~t (2) Ate~lvbgefely Clan~ IIACIIIIIE ur~IURS/eRUOUgtLVII & (5) A~e~J.bSsl~ly CIn~s CKIIEEAI, I. AIIOREflB AND SANITATION red~xllc I~cl.cdulcd hl.q~clhm~ ate. d(~m,c,led (.,i l:,mt lilT-4 whlcll I,ch,le.q t, elhml.q. co[Itclluln ul h.,,l~.nhl.~ Ide,,llll.I. ,' .8I~RVJ. I;.(JR~I_CllECIL_I,J.,%T,_LIII~UELM,_rI, Att. IJ~IUfl . .. Acddenl n.d hll.r~llll,e.~l I,~emllllnltell LI hiSl~t:llmt$ (hlvesltgglhm,t) ale c,f~lur, led e su.ll a~ I~-Ible after afl accidctd, UR ILl '1 he~e ru.~l! llt~ m.ltll.hed nt the lull.whig I,)cJ, ilull t)thef fun,n gl dUcqlnlemnth,! {(les¢:,lbe) ..CiRII_II.I~AJ~_U_E_¥.~.~_.R_W_P.R..K__O..R. pI~R FORIIS Iteheshcl,lfnlldni~ I~.llmvlHcd nt the fitlhlwlng h~il~tency UflCE ~..~.~A~ ................. KI f:tnnmtmlcnthm t)f slre l~,tm IIPP- I U 'l;lle I)nle flespo,nlbll~ I'erso,(.~)'. $1R,alufn hltlicnl~.n tirol It c,I)y of the I)tt,fitn,i hn.~ ~e, pmvhlcd .,id ~)1 ~ I t:mllfumhl U,tml~.l of ~.etee l}nlo BAKERSFIELD CI.T?f FIRE DEPARTMENT · . HAZARDOUS MATERIALS INVENTORY PagoJL. of J_ 9usine~sName ~. 5~/_ r~.~¢/',. ~) 7 /L C_O.~.' Address CHEMICAL DESCRIPTION INVENTORY STATUS: New[ ] Addition[ i Revision [)(~ Deletion( ] Check if chemical is a NON TRADE SECRET ,DQ TRADE SECRET [ j Common Name: :3) DOT ¢ (optional) 4) PHYSICAL & H~L~H PHYSICAL H~L~ H~RO CA~GORIES ~re [ ] Reac~e J ~ Sua~en Reie~e of Pressure ~} Imme~i~e He~h (Ac~e) ~ Delayed He~h (Chronic) 5) WAS~ C~SSI~CA~ON (~ig~ ~de ~om'OHS Fo~.80~)- - USE COOE. /O 6) PH~SIC~STA~ Solid [ ~ ~uid [ ] G~ ~ Pure ~ M~ure [ ] Wute [ ] R~ioa~ive [ ] 7) AMOUNT AND TIME AT FACILITY Ma~mum OaJt¥ Amount.: Average Oa~iy Amount: Annual Amount: La~ges~ S~.e Container. # g~ On Site UNITS OF MEASURE 8) STOl{AGE COOES curies [ ] b) Pressure: ~ c) Tem~rature: ~ Circle.~i~ Mom~:. O 9) MIX3~RF' List COMPONENT CAS chemi~ cam~nen~ at JJ ~yAHM com~nen~ ' 1 0 ~mn 3) ' %WT IY1. [] [1 CHEMICAL DESCRIPTION INVENTORY STATUS: New ~ Add~on.[ ] Revision [ ] Deletion [ ] ' Check if chemical is a NON 'TRADE SECRET TRADE SECRET' PHYSICAL & H~L~ PHYSICAL H~O CA~GORIES F~re ~ Ree~Ne [ ] Sudden Rele~e of Pressure 3) DOT # (optional) ~M ( t CAS ,~ ;5-?- HEALTH Immediate HeaJth (Acme) [ ] C~tayed HeaJth (Chronic) WASTE CLASSIFICATION .(3-digit code ~rom DHS Form 80221 6) PHYSICAL STATE SoLid [l Lkluid J~ Ga~ [] AMOUNT AND TIME AT FACit ITY U~mum o~y Amount: Average Dally Amount. Annual Amount: . .~_~..~ La.rcflest Size Contmnen ~ 0~ On S~e _3~ Pure [ Mi:rture'~)t~ Waste [ i Ra(li°ac~lVe [ ]- UNITS OF M~SURE 8) STOOGE CODES curies [ ] b) Pressure: J Ckc~e Which Months: c) Temperate: ~, ~ j, F, M. A. M, J, J. A, S, O, N, O 9) MIX'FURl=' Ust . COMPONENT CAS # % WT AHk4 chemicaJ cammonent~ or ., · ny AHM comCx3nenLs 21 " [ ! 3) " [' ~0) L,~.~,,, EN(C//,]~.e/'Zl/j~ ~.64 //¢ .~a'/'/~i:itsT 0.~ CF Z,;~'.~T ~/~ /A~ cerm'y under penaJ~ or law, mat t nave pe~on~ly ex~tn~ ~o ~ t~tl~ wl~ me intomaDon ,uDmt~ on mrs ~ mJ a~ aoc~en~ I Deu~ Signature ;6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215.000-001418 Page 2 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order 02-014 ANHYDROUS AMMONIA Gas 6720 Extreme · ~~e, Immed Hlth FT3 . ~ CAS #: 7664-4~~Trade Secret: No ~~--~ .__L// ~, Form: Gas :N~65 Use: STORAGE/IN - Con3~ /~~0% Ammonia, Anhydrous Gas . IExtreme ~ 02-030 Anhydrous ammonia Gas 6720 Extreme ~ Pressure, Immed Hlth FT3 CAS #: 7664-41-7 Trade Secret: No Form:· Gas Type: Pure Days: 365 Use: COOLING Daily Max~y Average FT3 ---q--~ual Amount FT3 -- -- Storage IN MACHINE/EQUIP -- Conc ' Components ~P _---/Guide 100.0% IANHYDR~ONIA IUnrat~d~ 0 02-010 ACETYLENE ~ Fire, Pressure, Immed Hlth Gas 130 High FT3 CAS #: 74-86-2 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: WELDING SOLDERING -- Daily Max FT3 130 Daily Average FT3 I Annual·Amount FT3 100.00 230.00 Storage PORT. PRESS. CYLINDER -- Conc 100.0% .IAcetylene Press I Temp Location labors ~Ambient ISOUTHWEST CORNER SHOP STORAGE MCP .~Guide Components IHigh I 17 36/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order Page 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 1Ambient ISOUTH~ PARKING LOT A~A - C0~6& omponen~s MCP ---FGuide 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 AmbientJAmbientlINSIDE WESTSIDE BUILDING -- Conc 50.0% IMuriatic Acid Components MCP iGuide JHigh J 15 02-024 SODIUM HYPOCHLORITE · Reactive, Immed Hlth Liquid 104 High GAL CAS #: 7681-52-9 Trade Secret: No Form: Liquid Type: Pure Days: 365 Use: CLEANING Daily Max GAL 104 I Daily Average GAL 52.00 Annual Amount GAL 1,250.00 Storage PLASTIC CONTAINER Press T Temp Location Ambient~AmbientlWESTSIDE OUTSIDE BUILDING -- Conc 12.5% ISodium Hypochlorite 1.0% Sodium Hydroxide Components MCP ---TGuide High } 45 ModerateI 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 GAL25 I Daily Average20.00GAL Annual Amount GAL 80.00 Storage DRUM/BARREL-NONMETAL press T Temp Ambient~AmbientlBOILER ROOM Location -- Conc 4.0% 8.0% 3.0% Components Isodium Hydroxide Potassium Hydroxide beta-Diethylaminoethanol MCP --l~uide Moderate 60 Moderate 60 High , 29 02-017 GUARD 203 ~ Reactive, Immed Hlth, Delay Hlth Liquid 110 Moderate GAL CAS #: Form: Liquid Daily Max GAL 110 Storage DRUM/BARREL-NONMETAL -- Conc Components 35.0% IPhosphoric Acid Trade Secret: No Type: Mixture Days: 365 Use: NEUTRALIZER Daily Average GAL Annual Amount GAL -- I 55.00 I 1,000.00 Press T Temp Location IAmbient/AmbientlINSIDE WEST BUILDING MCP --~Guide IModerateI 60 02-018 GUARD 219 CHLORINATED FOAMER ~ Reactive, Immed Hlth, Delay Hlth Liquid 110 Moderate GAL CAS #: Form: Liquid Trade Secret: No Type: Mixture DayS: ·365 Use: CLEANING Daily Max GAL 110 Daily Average GAL 55.00 Annual Amount GAL 1,300.00 Storage DRUM/BARREL-NONMETAL Press I Temp Location IAmbient]Ambientl'INSIDE WEST BUILDING -- Conc 25.0% IPotassium Hydroxide Components MCP Guide IModerate 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 Use: CLEANING Daily Max LBS Daily Average LBS 900 I 550.00 T Annual Amount LBS 5,800.00 Storage DRUM/BARREL-NONMETAL Press T Temp Location Iambient~AmbientlINSXDE WEST BUILDING -- Conc 0.0% ISodium Hydroxide Components MCP Guide ModerateI 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 Daily Average GAL 20.00 Storage IN MACHINE/EQUIP Press T Temp I Ambi ent~Ambi ent I SHOP -- Conc ! 89.0% IMineral Spirits Components Use: WASHING Annual Amount GAL 100.00 Location iMCP Guide ModerateI 27 02-008 MALEIC ACID Solid '300 Low LBS CAS #: 6915-15-7 Trade Secret: No Form: Solid Type: Pure Days: 365 Use: FORMULATION/MANUFACTURING Daily'Max LBS 300 I Daily Average LBS 150.00 T Annual Amount LBS 1,200.00 BAG Storage Press T Temp Location Iambient~AmbientlNOmTHWEST BATCH AREA -- Conc 100.0% IMaleic Acid Components MCP ---~Guide 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 Low FT3 CAS #: 7782-44-7 Trade Secret: No Form: Gas Type: Pure Days: 365 Use: WELDING SOLDERING Daily Max FT3 251 Daily Average FT3 251.00 Annual Amount FT3 -- 753.00 Storage PORT. PRESS. CYLINDER Press T Temp Location I Above ~Ambient I SHOP 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 IAmbient~Ambient IOUTSIDE EAST YARD IN DOCK -- Conc ! 100.0% IDiesel Fuel No.2 Components iMCP fGuide Moderate~ 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 I Daily Average GAL I Annual Amount GAL 55 ~ 35.00 55.00 Storage DRUM/BARREL-METALLIC Press T Temp Location IAmbient~AmbientlOUTSIDE WEST BUILDING -- Conci Components 43.0% ISolvent Dewaxed Distillate, Heavy Paraffin MCP Guide ILow 127 ]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 Daily Average FT3 Annual Amount FT3 155.00 Storage Press T Temp Location PORT. PRESS. CYLINDER Above ~AmbientlSHOP STORAGE AREA -- Conc 100.0% IArgon Components MCP Guide IMinimal I 12 02-003 CARBON DIOXIDE ~· Fire, Pressure, Immed Hlth Gas 420333 Minimal FT3 CAS #: 124-38-9 Trade Secret: No. Form: Gas Type: Pure Days: 365 Use: FORMULATION/MANUFACTURING Daily Max FT3 420,333 Daily Average FT3 242,500.00 Annual Amount FT3 -- 2,932,920.00 Storage FIXED PRESS. CYLINDER Press T Temp 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 Form: Solid Type: Pure Daily Max LBS 2,400 I Storage Trade Secret: No Days: 365 Use: FORMULATION/MANUFACTURING Daily Average LBS 7 Annual Amount LBS 1,000.00 ~ 24,000.00 Press T Temp Location Iambient~ambientINORTHWEST BATCH AREA Components MCP ---/Guide IMinimal I 1 BAG -- Conc 100.0% ICitric Acid 36/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 02 - Fixed Containers on Site Hazmat Inventory Detail in MCP Order Page 8 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 4OO.00 Annual Amount LBS -- 3,000.00 BOX Storage Press T Temp Location IAmbient~Ambient IPACKING AREA SOUTH BLDG -- Conc 100.0% IPPO Components MCP ---TGuide IMinimal 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 ---7-- Annual Amount FT3 70.00~ 142.00 Storage PORT. PRESS. CYLINDER Press I Temp Location Above ~AmbientlOUTSIDE BLDG SOUTHWEST CORNER -- Conc 100.0% INitrogen Components . MCP ---IGuide Low ! 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 GALl10 I Daily Average30.00GAL Annual Amount GAL -- 600.00 Storage DRUM/BARREL-NONMETAL Press 7 Temp Location IAmbient~AmbientlINSIDE WEST BUILDING -- Conc, Components 10.0% ID/methyl Benzyl Ammonium Chloride Minimal ~6/03/93 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 m 100.0% IHeavy Machine Oil Trade Secret: No Days: 365 Use: LUBRICANT Daily Average GAL I Annual Amount GAL 35.00 55.00 Press T Temp Location [Ambient[Ambient[OUTSIDE WEST BUILDING Components MCP ---TGuide Minimal [ 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/MANUFACTURING Daily Max LBS Daily Average LBS 200 [ 100.00 I Annual Amount LBS 1,700.00 Storage Press T Temp Location DRUM/BARREL-NONMETAL' Ambient[Ambient{WESTSIDE OF BUILDING -- Conc 100.0% IAscorbic Acid Components MCP ---FGuide IMinimal 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 [Ambient[AmbientlOUTSIDE WEST BUILDING -- Conc~ Components 100.0% ILubriCating Oil (Petroleum-Based) MCP ---TGuide IMinimal I 27 J6/03/93 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 Form: Solid BAG Trade Secret: No Type: Mixture Days: 365 Daily Max LBS 2,000 I Storage Use: FORMULATION/MANUFACTURING Daily Average LBS 7O0.0O Annual Amount LBS -- 20,000.00 Press T Temp Location I AmbientJAmbientlNORTHWEST BATCH AREA -- Conc~ Components 100.0% ITartaric Acid', Diammonium Salt MCP ---TGuide IMinimal I 31 02-022 CHEVRON HANDY OIL 15 · Fire, Immed Hlth, Delay Hlth Liquid 110 Unrated GAL CAS #: Trade Secret: No Form: Liquid Type: Mixture Days: 365 Use: LUBRICANT Daily Max GAL I Daily Average GAL I Annual Amount GAL 110 i 55.00 700.00 Storage I)Press T Temp Location DRUM/BARREL-METALLIC IAmbient~AmbientlOUTSXDE WEST BUILDING -- Conc Components MCP Guide 95.0% ILight Petroleum Distillate IModeratel 27 PAGEI INCIDENT COMMAND SYSTEM {ORGANIZATION } INCIDENT COMMANDER - GERHARD GAUGEL COMMAND STAFF: INFORMATION OFiFICER- ROBERT HOFFERD {ORGANIZATION & ASSISTANT DEE SECARA MEDIA CONTACT } SAFETY OFFICER - - - DAVID WRIGHT ASSISTANTS .... PAUL OCAMPO - - JUANPINON .... JOSE MENDOZA { MONITOR SAFETY OF ALL ASSIGNED PERSONNEL} .... Q.C. TECH { ON DUTY } .... MAINT. TECH { ON DUTY } .... JESSIE MOYA LIAISON OFFICER- - - ASSISTANT - ROBERT HOFFERD DEE SECARA { ON SITE CONTACT FOR OUTSIDE AGENCY, O.E.S. FIRE DEPT. HAZ- MAT TEAM, ETC. } PAGE 2 GENERAL STAFF OPERATIONS SECTION' CHIEF · DEPUTYS · DAVID WRIGHT PAUL OCAMPO JUAN PINON JOSE MENDOZA Q.C. TECH { ON Du~rY } MAINT. TECH { ON DUTY } JESSIE MOYA DEVELOP AND MANAGE THE OPERATIONS SECTIONS TO TO ACCOMPLISH THE INCIDENT OBJECTIVESi PLANNING / INTELLIGENCE & LOGISTICS · CHIEF · ROBERT HOFFERD ASSISTANT: DEE SECARA 1. COLLECT, EVALUATE & DISPLAY INFORMATION ABOUT THE INCIDENT. 2. DEVELOP INCIDENT ACTION PLANS FOR EACH SHIFT 3. MAINTAIN RESOURCE STATUS INFO ON ALL EQUIPMENT & PERSONNEL ASSIGNED. 4. MAINTAIN INCIDENT DOCUMENTATION FINANCE & ADMINSTRATION CHIEF · GERItARD GAUGEL ASSISTANT · DEE SECARA 1. TIME UNIT 2. PROCUREMENT UNIT 3. COMPENSATION / CLAIMS UNIT 4. COST UNIT PAGE 3 INCIDENT ACTION PLAN IN CASE OF AN EMERGENCY PLANT EVACUATION, THE FOLLOWING STEPS HAVE BEEN SET UP FOR EVERYONES SAFETY. 1. AN ANNOUCEMENT OVER THE PAGING SYSTEM TO EVACUATE THE PLANT. 2. ALL PERSONNEL WILL REPORT TO THE STAGGING AREA, LOCATED AT TIlE EAST END OF TIlE PROPERTY. o ON THE WAY OUT OF THE PLANT, CERTIFIED S.C.B.A. PERSONNEL WILL BRING S.C.B.A. UNITS TO THE STAGGING AREA, { ALL THREE UNITS }. ATTENDANCE ROLL COUNT WILL BE TAKEN BY THE OPERATIONS CHIEF { DAVID WRIGHT, OR DUPUTY ON SHIFT. o THE INCIDENT COMMANDER / AND OR, THE COMMAND STAFF WILL MAKE AN OVERALL ASSESSMENT OF THE INCIDENT WHILE IN PROGRESS. IF NECESSARY THE FIRE DEPT, HAZMAT TEAM, MEDICAL UNITS, AND O.E.S. WILL BE NOTIFIED IMMEDIATELY, BY THE LIAISON OFFICER, ROBERT HOFFERD OR ASSISTANT, DEE SECARA. IF THE INCIDENT OCCURS DURING TIlE NIGHT SHIFT, LEAD PERSON JOSE MENDOZA AND GENERAL STAFF MEMBERS ON DUTY WILL EVALUATE THE INCIDENT. IF NEEDED 911 WILL BE CALLED, AND TItEN COMMAND STAFF MEMBERS. IF ALL PERSONNEL ARE NOT ACCOUNTED FOR, A SEARCH AUTHORIZED .BY THE COMMANDER / AND OR, COMMAND STAFF, WILL GET UNDER WAY. THE OFF SITE RESCUE TEAM WHO RESPONDS FIRST WILL BE ASSISISTED BY TWO CERTIFIED S.C.B.A. PERSONNEL FROM OUR GENERAL STAFF IF NEEDED. A MAP OF THE PLANT WILL BE AVAILABLE WITH THE S.C.B.A UNITS, TO ASSIST RESCUE TEAMS IF NEEDED. o THE SAFETY OFFICER, DAVID WRIGHT, AND OR ASSISTANTS ON SHIFT WILL CONTINUE TO MONITOR ALL PERSONNEL SAFETY. INCIDENT OBJECTIVES PRIORITY ONE - INSURE THE SAFETY OF ALL PERSONNEL INVOLVED, INCLUDING THE SURROUNDING AREAS. SECURE THE PREMISES, AND TAKE CONTROl, OF THE SITUATION AS EFFICIENTLY AS POSSIBLE, USING ALL THE RESOURCES AVAILABLE, OR AS NEEDED. 3. GENERATE AND MAINTAIN RECORDS OF ALI_, INFORMATION REGARDING THE INCIDENT. INCIDENT COMMAND STAFF PHONE NUMBERS GERHARD GAUGEL · 392-8747 ROBERT HOFFERD · 832-0453 DAVID WRIGHT · 836- ! 382 DEE SECARA : 832-3322 GI:,NI.,RAL STAFF PHONE NUMBERS ARMANDO RAYO ' 334- I 156 JOHN WILLIAMSON · 587-1786 MARK WOOTEN · 325-4803 RICHARD PITCltFORD ' 634-9159 DARRYL DELATTRE : 392-9325 HARRY BARBA · 823-1708 JOSE MENDOZA · 631-8348 JESSIE MOYA · 396-9822 JUAN PINON · 322-3821 PAUL OCAMPO · 397-7686 INITIATION OF MANAGEMENT OF CHANGE FORM FORM MOC-IB ~( MOC NUMBER SECTION 1: INITIATION OF MANAGEMENT OF CHARGE FORM Section ! is to be completed by individual originating the MOC and forward to the Maintenance ~upervisor. ORIGINATED BY: DATE: NAME OF PROJECT: PRlORrrY OF, P~, qUEST:, {CHECK 0~) . ,, ,,, { } ~RIT[CAL, Affected ~ion ofsy~em should by I~k out ~d ~ed to prevent oper~on u~il ~y i~u~s) resolvM. ~GE~, ~ed potion ofsy~em should be ~ ~d oper~ shoR t~ with ~tion until saf~y issues) resolve. ~ORT~. ~~ ~nion of system should be ta~ed ~d operg~ ~th ~ution umil s~y issues) re~lved. RO~. ~ted ~ion of sy~em should be not~ ~d ( -- } .... ,,,,0~k to r~,~ve mi.or ~re~ !~(9 gheduled. REA.SOS ~O~ REq~S~': . {C~.CK 9~? { } {__} { .,,} {, } {_-} { } Incident Investigation Recommendation (ReE No. ) Mechanical Integrity Audit Recommendation (Re£ No. ) Pre-start Safety Review Recommendation (Re£ No..) Process Hazard Analysis (Ref. No._) Change in Refrigeration ReqUirements Expansion or Renovation of Facility or Systems Other (Explain)Re-location due to Production demands. 'ogscmP-no~ 0~- T~Ca~CAL'hAStS ~'OR CaAr~C;r. 0,tau,0sr., ' ..,ALTrm~A. Tn,'~St RE~r~C~: SKETCa~S OR VgAWm<;S):. ., FORM MOC= 1 C MOC NUMBER SECTION 2: SCREEN OF MANAGEMENT OF CHANGE FORM Section 2 is to be completed by the Utility Team Coordinator, and then a copy of the MOC is to be forwarded to the Group Leader. lftbe requested modification constitutes a change, Sections 2-6 must be completed. Reviewed by: ..... Date: ASSESS TECHNICAL BASIS OF CHANGE The modification as described in Section 1 is classified ns (please check appropriate Technical Basi~ Is the ctmnge a mplncement in kind? Is the modiflmfion a mlgor o~ Is ~e c~n~ ~t or temporary? and an ~-_--_-~f_~nble course of action? Assessment { ~. } Chngeis not a r~hcem..ent in kind { } Modificatio~ is a minor c .h~nRe { ~} Modlfl~mion is a major change, { } ~ is i~man~at {_} Change is temporary { }Yes {_} No ,NO~A~ion Chan~ is not pan of MOC MOC ~ must be followecL FRI in section on MOC ~oncol'lfing duration of chanb, e. Clmnge should be forwarded for ~)mliminnry e. flginceztag. Change should not be implemented. , 2 FORM MOC-I D MOC NUMBER OURATION OF CHANGE If the chanse is temporary, note duration here: No temporary change should be granted more than five one=week extensions or be allowed to extend beyond six weeks, including any extensions. The table below should be used to track temporary changes. SCHEDULE FOR. TEMPORARY CHANGES Initiation D, ,nt~ Exoiration Date Authorization Initial request. Extension #1 Extension #2 Extension #~ Extension ~4 Extension #~ UPDATING PROCESS SAFETY INFORMATION, PROCEDURES, AND DOCUMENTATION Identify the process safety information which needs to be t~wtsed ns a result of this change. Referenc~ # Process flow diagrams Elem-ical one-line dmwiflgs Sun Ammonia equipment lists Cfiterh for d~ign and opero~on Accident investigations procedur~ Audit program Reference # Piping and instrumentation diagrams Fire, water & sewer system drawings Anunonia instrument lists Stnndm'd operating procedures Operator training procedures Otber (describe): BEFORE FREEZER START-UP MAKE SURE u2qrr IS ANCOKED TO TIlE FLOOR, ALL WELI~ FROM 2 ½" AND ~ WILL lqRE~ TO BE BUTT V~[.DS AND A X-RAy PERFORM~ , SECTION 3: PRELIMINARY ENGINEERING PRELIMINARY DESIGN REVIEWED BY: , .Date: / .. UTILITY TEAM COORDINATOR: Date / / REFRIGERATION GROUP LEADER: DATE / / FORM MOC- 1E SECTION 4: Date Completed: / Safety review checklist reviewed by:, SAFETY REVIEW CHECKLIST / MOC NUMBER # Date: SECTION 5: PROCESS HAZARD ANALYSIS (If analysis is performed) Date Hazard Analysis Completed Does the process hazard analysis address the impact of change on safety and health? (Checkone) {_ _ } y~ { } no Hazard analysis report reviewed by: Date SECTION 6: STARTUP AUTHORIZATION Have all applicable drawings, procedures, and documentation noted in Section 2 been revised accordingly (Check one) { } Yes {.} no Have all appropriate operators, maintenance personnel, been informed of and trained in the change? (Chock one) { __ } Yes {, } no Have all, if any, recommendations from the preliminary engineering, safety and health review and the process hazards analysis been Itddre~ed? (Check one) { } Yes { } no Authorization should be given to accept this change and proceed with start-up of the modification if and only if the answers to all of the above questions are "Yes". Authorization for change and start-up is given by: PHA Team Leader: Date:__ Utility Team Coordinator: ,Date: __ Group Leader: .Date: __ Plant / / / / / / Date: / / 4 MOC NO 95-,007 SAFETY REVIEW CHECklIST QUESTION A REMARKS'" REC0~ATIO~S BY COIVIIVIEN'TS ulvcs, m ~-~ s/md lropedy. ~. l'hve the sundm'd operm~ procatmu (SOPs) System? S. Do tl~ t:rcvcntivc ~ ~ MOC NO SAFETY REVIEW CHECKLIST ? 6 MOC 98007 SAFETY REVIEW CHECKLIST QUESTION A REMARKS RECOMMENDATIONS BY COMMENTS I~ tl~ appmpri~ Utiliti~ Tcchnicimu~ MANA~ OF CHAN~-'E FROM OVlOC) LO0 INITIA~n OF REVIEW ENO~ REVIEW ANALYSIS AUTttORlZAI'ION DATE COMPIgrED CltF, ClO~T COMPLRTED OF ~ PRE-START AND/OR PRE-SHUT SAFETY REVIEW DOCUMENTS AMMONIA SYSTEM MOC NUMBER PRE-STARTUP AND/OR PRE-SHUTDOWN SAFETY REVIEW DOCUMENTS Plant: Crystal Geyser Water Company Date: Job tiltle: Project supervisor' Description of change { attach additional sheets if needed }: Reason for the change { attach additional sheets if needed } Management of change documentation must be completed prior to continuing with the pre-startup safety checklist. APPROVAL Project supervisor Team coordinator Operations Manager Data Date Date Page2'~ ~. CRYSTAL GEYSER WATER CO. PRE-,STARTUP SAFETY REVIEW DOCUMENTATION MOC Project Title: ......... ITBII RESPONSIBLE PRE-SHUT PRE-START COMMENTS BY PERSON DOWN UP Have MI control verified? Are all operatinO manu~l, revbed and dlstrib,__,t~__~ Is all training =om~emd and documen__te~_~ ... Has the emergency real, once team been notified of this ~tar~__'m~? .......... Has the emergency re~l~nSe team conducted · drill In_~rel~mtion tr ~mergency equipment on Have two util~ie~ Have been taken to insure that no cutting, into pipe~ Will utilities ~ign-off .nd pre_~? ................ I; .11 PSM file? ' ' '.' Page 3 , '. MOC# ITEM ~r~ISlBLE ' PRE-S~IUT "' I~- COMMENTS BY ~ on hand at the ~e ~ere the w~ will ~o~ed? .... Have confin~ space ~en c~let~ and are ~ey on hand? Have all ~ckout I ....... ~goUt ~ocedu~ ~mple~? Have all ~nesl ~peHy ~m~d t~hn~an? Have .11 valves .......... ~n v~d to a ~e~ test~ Has equipmem .............. rpro~ set has all co~ls that am in conta~ ~ nh3 (pre~ ~t- out, e~.) ~n ve~fi~ ~ ~ey are rat~ ~r n~ has ell ~ hanoer, be~ installed per ilar standards Has ,11 ~pe hangem b~n re~gh~ ~er ~e Insula~on w~k web standarda' C :~AIcEI'y~,RItR3'~TY .DO C Haa the PM planner (PeuM) the~:e- b~n relocated. , ....... Need to irmt~ll Ballard'l to prOteCt NH3 piping horn motor c'herging IIM)t with NH3'. ,; ' ,, IT In the 'tee-b~r III .top Valve" to the relocat.(I (cup- Iinel MM ~oc.~on ~he ~ree~e~ M ~olng. 1~11o~6! w~ll need to be Iocked-ou~ at ~he ~ job ..... Make aure .11 .'top valve, fitting, ind piping meet ne~fel · tandlr.dR. ,.. ,, r... ........................ ~&¼'. angle IrKI plug. Installed 0!!~ ... all .ttachlng to Need to check motor/motorl rotation .top vilv~ with bon~ from UN- .crewing, · r .,,, Ha. contrict~ reMved for piping( i~v. un. 24..!"."e) .... PRE-START UP/PRE-SHUT DOWN CHECK OFF LIST GENERATED BY: ~ ~' COMPLATION DATE: . Page Hee the PM .......... planner (Paule) _been informed j et the lee- earn freeze~ has been relocated. Need to install Ballerd's to protect NH3 piping from motor traffic, Before charging lines with NH3 In the tee-bar all stop valves to the ~'eezer being relocated {cup- line) and the location the freezer is going (roilo#5) will need to ba locked-out at the start, of job. Make sure all stop valves, fittings and piping meet nestles standards nnrse ¼ ° angle Ives and plugs tailed on all strainers attaching to freezer. Need to check motor/motors rotation Need to install stop valves with ' setscrew8 on the bonnet to keep bonnet from UN- scrowJflg. Has corvtractor received 8tandords for plpino( rev. june 24, 1,998) , etON: .... · PRE-START UP/PRE-SHUT DOWN CHECK OFF LIST GENERATED BY: COMPLATION DATE: PROCESS HAZARD ANALYSIS SPECIFIC PHA FOR MOCk_ Item F. qulpmen~/Acti~,.fl.es ,, .(~*stJons Scenarios Consequenc~flmzsmds F.,/A C. ontrob$ L R R ..ec~, ~ Stm'u~ ttt pmcalurcs, p~ clteck off COMPANY: FACILITY: MOC# PROJECT: PHA DATE: PHA TEAM LEADER: TEAM MEMBERS: CONSEQUENCES/HAZARDS ( 1 ) NH3 VAPOR POSING INHALATION HAZARD TO PERSONAL. ( 2 ) NH3 LIQUID CHElVlICAL HAZARD FROM LIQUID. CONTACACT. ( 3 ) .NH3 INGESTION, INTERNAL CHEMICAL. ( 4 ) ~ Wa'OR COMSUSmmITY TH~~ BU~ ~aU). ( 5 ) NIB VAPOR EXPLOSIVE OVER-PRESSURE HAZARD. ( ~ ) _.MECHANICAL OVER-PRESSURE IMPACT HAZARD. ( ? ) NO HAZARDOUS .CONSEQUENCES IDENTIFIED. ( 8 ) ~CENARIO NOT APPLICABLE TO THIS SYSTEM. SEWm~Y ) LIKELIHOOD ) ~USK ~ra~ ) AN EVALUATION OF THE SEVERITY OF THE. HAZARD, AN EVALUATION OF THE LIKELIHOOD OF THE HAZARD. AN ESTIMATE OF THE .RISK OF THE HAZARD SCENARIO. ,,LIKELIHOOD 2) MODERATE 3) MEDn~ 4) LOW 5) VERY LOW L I I # E z L I H 4 0 0 D SEVERnY I 2 3 4 S SEVERITY i) CATASTROPI-~[¢ 2) HIOH 4) LOW s) NONE SECTION II.1 DISCOVERY I · ~Th~s section,i>f~¢:g!~ S~I d~c~be ~e pro~e~::a~nd~¢q~pment,used to~ I Release detection equipment: (check all that apply) ~ liquid leak monitoring device ~ automatic tank level gauge [21 flow totalizers [21 system / flow shut-off devices [] toxic gas / air emissions monitoring [21 high / low pressure sensors ~ temperature sensors / recording charts [] high / low liquid level sensors [] groundwater / vadose zone monitoring [] diesel fuel sulfur content verification Periodic monitoring procedures: (check all that apply) [] daily inspection [] weekly inspection [] continuous leak monitoring [] storm water sampling [] containers dated as received [] adequate facility lighting to detect spills [] statistical inventory reconciliation [] automatic tank gauging & tank testing [] containers inspected before being accepted [] waste effluent discharge point sampling [] raw materials checked before being accepted [] air district witnessed source testing CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICE~; SECTION II.2.a NOTIFICATIONS Facility emergency communication will occur through: (check all that apply) [21 verbal warning [] intercom system [21 telephone (including cellular) [] pagers [] alarm system [] portable radios Report all significant releases or potential unauthorized releases of regulated substances: Emergency notification phone list: * Local emergency response agency .................................... 9-1-1 Local Unified Program Agency .............................. (805) 326-3979 California Office of Emergency Services ..................... 1-800-852-7550 National Response Center ................................. 1-800-424-8802 * Refer to Section II.2.b and/or Annex Ili.2 to provide additional phone listings of facility response team members, contractors, or other necessary environmental response resources. Checklist of information to be provided during notification: Your name and the telephone number where you are calling from. Exact location (address) of the release or threatened release. Date, time, cause, and type of incident (e.g., fire, release, unauthorized discharge, etc.) Material and quantity, to the extent known (size and appearance or opacity). Weather conditions, if applicable. Current condition of the facility Extent of injuries, if any; and, Possible hazards to human health, or the environment, outside the facility. CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION ll.2.b ENVIRONMENTAL MANAGEMENT II The following personnel are responsible for: Responsibilities Emergency Environmental Other Contact(s) Coordinator (specify) Accountability for pollution prevention [ ] [ ] Protection from environmental contamination [ ] [ ] Posting of"no smoking" & warning signs [ ] [ ] Familiarity with chemicals and processes [ ] [ ] Preliminary assessment of the situation [ ] [ ] Initiating alarms [ ] [ ] Notifying response agencies [ ] [ ] Contacting facility responders [ ] [ ] __ Notifying contract service providers [ ] [ ] Authorizing any corrective action work [ ] [ ] Organizing environmental response activities [ ] [ ] Interfacing with public agency responders [ ] [ ] Emergency service arrangements have been made with: (check all that apply) [] locai police [] fire department [] closest hospital [] contractors [] State and local emergency response teams Additional phone list of qualified response personnel and emergency service providers: Name I Phone [ Response times ] Duties or responsibilities Additional notification lists provided as Annex III.2 Additional environmental management procedures provided in Annex III.3 [~l Yes [] No [] Yes [] No CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION II.2.c PRELIMINARY ASSESSMENT Identify areas of the facility and mechanical systems where releases could occur or would require immediate inspection or isolation because of the vulnerability to earthquake related ground motion. (Check all that apply) [] Storage areas [] Bench / Lab [] Tanks [] Piping [] Other: [] Production floor [] Utilities [] Cabinets [] Valves [] Process lines [] Sprinkler systems [~l Shelves [] Racks [] Waste treatment plant Accidental toxic gas or petroleum releases determined to impact areas outside of the facility? [] Yes [] No If "yes," indicate the results below from the risk analysis included in Annex HI.3.d."Planning" Scenario: [] Oil spill (worst case) [] Oil spill (most credible) [] Toxic gas release (worst case) [21 Toxic gas release (alternative) [] Flammable gas release (worst case) [] Flammable gas release (alternative) Release quantity Distance to endpoint (miles): Indicate if any of the following are within 1000 feet or within any distances specified above: [] Schools [] Residences [] Hospitals [] Prisons [] Public recreational areas [] Commercial, office or industrial areas [] National or state parks [] Federal wilderness area [] Wildlife sanctuaries, preserves, or refuges CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION ll.2.d RESOURCES / MITIGATION Emergency medical assistance (check all that apply) [] First aid kit(s) available [21 Eye wash station(s) [] Nearest medical facility location: [~ Emergency shower(s) [] Ambulance phone #: Evacuation (Please also indicate evacuation routes on appropriate map(s) in Annex III. 1) Signal: [] Verbal Primary evacuation route: Alternate evacuation route: [] Phone [~l Alarm [] Public address system Emergency response procedures (typical)* Assess the situation Isolate and deny entry to affected area, evacuate or shelter-in place Provide emergency medical assistance, if necessary Notify response agencies and facility response personnel, as appropriate Control the release, if possible to be done safely or remotely Actively mitigate the release, if properly trained and equipped Provide assistance to public agency responders, as necessary Terminate the response with proper clean-up and disposal Follow-up reporting, evaluation, and critique, as required * Additional facility specific response procedures included as Annex IH.3.c "Operations" [] Yes [] No CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES Emergency Equipment List (typical) * Equipment Category Equipment Type Location* Description** Personal Protective {~ Chemical protective clothing Equipment, Safety D Face shields and First Aid: [3 Hard hats [3 First aid kits / Stations {~l Eye wash stations [3 Safety showers [~[ Respirators / SCBAs Fire Extinguishing [3 Automatic fire sprinkler system Systems: D Fire alarm boxes / Stations O Fire extinguisher systems Spill Control and D Absorbants Decontamination [3 Secondary containment Equipment: ~ Decontamination equipment [3 Exhaust hoods [~ Gas cylinder leak repair kits [~ Neutralizers Additional ~l Equipment: [3 * If appropriate, use the location code(s) from the Map / Grid description on the Site or Facility Diagrams ** Describe the equipment and its capabilities. If applicable, specify any testing or maintenance procedures and intervals. Attach additional pages, or include additional information in the appropriate Annex, if needed. * Additional response resources and support equipment, contract capabilities, etc., included as Annex III.3.f "Finance / Procurement / Administration" [~l Yes ~ No CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION 11.3CONTINUOUS IMPROVEMENTS Measures to be taken during nonconformance conditions or prolonged incidents (typical) * Stopping processes and operations Collecting and containing released waste Removing or isolating containers Monitoring for leaks, pressure build-up, gas generation, ruptures, etc. Sufficient temporary storage of generated wastes Rehabilitation of oiled wildlife (if spill affects marine environments) * Additional continuous facility support procedures included as Annex IH.3.e "Logistics" [21 Yes [] No Planned changes to continuously improve safety / environmental impacts * Improvement: [21 Upgraded equipment [] Revised maintenance [] Revised training [] Revised operating procedures [] New process controls [] New mitigation systems [] Revised emergency response plan [] Changed process [] Reduced inventory [] Other: [] None Expected completion date: * Additional protection and mitigation procedures included in Annex IH.3.d "Planning" * Additional prevention measures included as Annex III.7 "Pollution Prevention" [] Yes [] No [] Yes [] No CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES SECTION 11.4 RETURN TO COMPLIANCE II I Restoration actions:* Waste materials transferred, treated, stored or disposed of Emergency equipment decontaminated Equipment repaired or replaced, if necessary Additional measures taken to prevent reoccurrence * Additional procedures listed in Annex HI.3.d "Planning" (Part 4. Waste Management) [21 Yes [] No Follow-up (typical) * Follow-up reports submitted as soon as practicable to regulatory agency Incident details noted in operating record Facility compliance plan reviewed and amended if necessary * Additional follow-up procedures included in Annex III.4 "Emissions Documentation" * Additional follow-up procedures included in Annex III.6 "Plan Audit & Modification" [] Yes [] No [] Yes [] No CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES CRYSTAL GEYSER ~W~T E R COMPANY ~Co'rporate Office P.O. Box 304 501 Washington Street Calistoga, CA 94515-0304 (707) 942-0500 Fax (707) 942-0647 Dee Secara BUSINESS OFFICE MANAGER 1233 E. California Avenue Bakersfield, CA 93307 Phone: (805) 323-6296 Fax: (805) 323-7264 WZlinc 8.0 EMERGENCY CONTINGENCY PLANS 8.1 General Ewtcuation Employees are verbally notified of emergencies by the Plant Manager or his designee. Ail employees are to leave the facility immediately through the parking lot at East Califbrnia and Lakeview. Exhibit 8 shows emergency evacuation routes and designated ~neeting places. These routes have been planned to bypass ammonia systems that may be leaking. Emergency responders will be notified through 911. Ill tile event of an emergency after normal operating hours, after notit~,ing 911, tile following individuals should be notified in the order given: Bob Hofferd - 805-832-0453 If he cannot be reached, call David Wright - 805-836-1382 If lie calmot be reached, call Norman Ambrose - 805-393-4176 If he cannot be reached, call Gerhard Gaugel - 805-392-8747. 8.2 Fire The sprinkler system will engage when it has detected a fire. All employees are to leave immediately through the nearest exit and regroup at the parking lot at East Calilbrnia and Lakeview. Emergency responders will be notified through 91 l. In the event of an emergency after normal operating hours, after notifying 911, the following individuals should be notified in the order given: Bob Hofferd - 805-832-0453 If he cannot be reached, call David Wright - 805-836-1382 If tie cannot be reached, call Gerhard Gaugel - 805-392-8747 lfhe cannot be reached, call Norman Ambrose - 805-393-4176. 8.3 Earthquake Einployees should remain in safe, stable locations (in doorways, under sturdy desks) until earth movement has ceased. Alter the earthquake, all employees are to leave immediately through the nearest exit and regroup at the parking lot at East California and Lakeview, far enough fi'om the building to avoid falling masonry. 8.4 Significant Leak fi'om the Ammonia Systems Notify tile Bakersfield City Fire Department. Employees are verbally notified of the leak. Mechanics will work to isolate the ammonia leak, if possible. If Norman Ambrose is not in the p/ant, tie should be called immediately after 91 I at 805-393-4176. All nonessential employees are to leave immediately and regroup at the parking lot at East California and Lakeview. Page 32 The following individuals should be called if' Norman Ambrose is not available: Gerhard Gaugel - 805-392-8747 Bob Hoflbrd - 805-832-0453 David Wright - 805-836-1382 Cleanup procedures for an ammonia release will mitigate the effects of the release: * ' Ventilation will reduce concentrations of atmnonia in enclosed areas. If liquid anunonia is on the floor, spray with large quantities of cold water. Water will absorb ammonia: high concentrations of ammonia vapor or dispersed ammonia can be diluted with water spray. During a release, the Plant Engineer (Maintenance Manager) will: Slop leaks, il' possible. Supervise the use of self contained breathing apparatus (SCBA). WZlinc The Plant Engineer has a thorough knowledge of the ammonia system. He has many years of experience with refi'igeration systems. iPage 3 3 8.0 EMERGENCY CONTINGENCY PLANS 8.1 General Evacuation Employees are verbally notified of emergencies by the Plant Manager or his designee. All employees are to leave the facility immediately through the parking lot at East California and Lakeview. Exhibit 8 shows emergency evacuation routes and designated meeting places. These routes have been planned to bypass ammonia systems that may be leaking. Emergency responders will be notified through 911. 8.2 Fire The sprinkler system will engage when it has detected a fire. All employees are to leave immediately through the nearest exit and regroup at the parking lot at East California and Lakeview. Emergency responders will be notified through 911. 8.3 Earthquake Employees should remain in safe, stable locations (in doorways, under sturdy desks) until earth movement has ceased. After the earthquake, all employees are to leave immediately through the nearest exit and regroup at the parking lot at East California and Lakeview, far enough from the building to avoid falling masonry. 8.4 Significant Leak from the Ammonia Systems Employees are verbally notified of the leak. Notify the Bakersfield City Fire Department through 911. Mechanics will work to isolate the ammonia leak, if possible. All nonessential employees are to leave immediately and regroup at the parking lot at East California and Lakeview. Cleanup procedures for an ammonia release will mitigate the effects of the release: Page 32 Ventilation will reduce concentrations of ammonia in enclosed areas. If liquid ammonia is on the floor, spray with large quantities of cold water. Water will absorb ammonia: high concentrations of ammonia vapor or dispersed ammonia can be diluted with water spray. During a release, the Plant Engineer (Maintenance Manager) will: Stop leaks, if possible Supervise the use of self contained breathing apparatus (SCBA). The Plant Engineer has a thorough knowledge of the ammonia system. He has many years of experience with refrigeration systems. Page33 8.5 Emergency Responders In an emergency, the following agencies may be needed: Hospital Memorial Hospital 420 34th Street Bakersfield, California (805)327-1792 Fire Department Call 911 Page34 ~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 MANAGER UPON NOTIFICATION WILL USE THE PAGING SYSTEM TO NOTIFY ALL EMPLOYEES TO EVACUATE THE FACILITY. EACH SUPERVISOR IS TO.DIRECT THE EMPLOYEES IN HIS AREA TO THE SAFEST EXIT AND MAKE SURE THAT HIS AREA HAS BEEN VACATED BY ALL PERSONNEL. ALL EMPLOYEES EVACUATED WILL REPORT TO A DESIGNATED AREA OUTSIDE THE FACILITY. ~3> Public Notif./Evacuation <4> Emergency Medical Plan EACH SUPERVISOR WILL BE TRAINED IN CPR AND FIRST AID. FOR MINOR INJURIES BAKERSFIELD OCCUPATIONAL MEDICAL GROUP WILL BE USED. FOR SERIOUS INJURY OR INJURY DUE TO A HAZARDOUS MATERIAL, SAN JOAQUIN HOSPITAL WILL BE USED. MEMORIAL OR KERN MEDICAL CENTER WILL BE GIVEN SECOND CONSIDERATION. ANY SUPERVISOR HAS THE AUTHORITY TO DIAL 911 FOR MEDICAL EMERGENCIES. ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 00 - Overall Site <E> Mitigation/Prevent/Abatemt 12 ~1> Release Prevention TO PREVENT THE RELEASE OR SPILL OF HAZARDOUS MATERIAL AT THIS FACILITY, ONLY INDIVIDUALS REQUIRED TO USE HAZARDOUS MATERIALS IN THE COURSE OF THEIR WORK WILL BE ALLOWED TO HANDLE THEM. EACH OF THESE INDIVIDUALS WILL BE TRAINED IN THE SAFE HANDLING AND USE PROCEDURES FOR EACH PRODUCT <2> Release Containment PROCEDURES FOR CONTAINMENT WILL BE THOSE RECOMMENDED BY THE MANUFACTURER OF THE PRODUCT AS DESCRIBED IN THE MATERIAL SAFETY DATA SHEET AMMONIA DIFFUSION SYSTEM LOCATED OUTSIDE OF BUILDING, NORTHWEST CORNER. <3> Clean Up PROCEDURES FOR CLEAN-UP WILL BE THOSE RECOMMEDED BY THE MANUFACTURER OF THE PRODUCT AS DESCRIBED IN THE MATEIAL SAFETY DATA SHEET. <4> Other Resource Activation 36/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 00 - Overall Site <F> Site Emergency Factors 13 ~1> Special Hazards <2> Utility Shut-Offs A) GAS/PROPANE TANK: MIDDLE OF WEST SIDE OF BUILDING, 55 FEET NORTH OF ALLEY FENCE - INSIDE FENCE NEXT TO SOUTHWEST CORNER OF BUILDING B) ELECTICAL - INSIDE SOUTHWEST CORNER OF BUILDING ON BOTH SIDE OF EXIT DOOR. C) WATER - IN ALLEY NEXT TO FENCE AND SOUTHWEST CORNER OF BUILDING 330 FEET WEST OF LAKEVIEW 'SPECIAL - AMMONIA SHUT OFF 'IN NORTHWEST CORNER OF BUILDING IN FENCED OFF AREA E) LOCK BOX - NO <3> Fire Protec./Avail. Water PRIVATE FIRE PROTECTION - THIS FACILITY IS EQUIPED WITH AUTOMATICE OVERHEAD SPRINKLERS IN ALL AREAS. THE SPRINKLER SYSTEM IS MONITORED SECURITY SYSTEMS. WE HAVE FIRE EXTINGUISHERS IN ALL AREAS OF THE FACILITY FOR EMERGENCY USE. FIRE HYDRANT - ON THE NORTH SIDE OF EAST CALIFORNIA AVE., 120 FEET WEST OF THE NORTHWEST CORNER OF THE FACILITY A FIRE DEPARTMENT HOOK- UP TO OUR MAIN SPRINKLER SYSTEM RISE~EXISTS. IT IS IN THE ALLEY, 220 FEET WEST OF LAKEVIEW AVE. <4> Building Occupancy Level CRYSTAl. GEYSER WATER COMPANY 215-000-001418 OO - OVERALL SITE SITE EI4ERGENCY FACTORS AMENDMENTS TO <2> UTILITY SIIUT-OFFS: Gas Meter: Propane Tank: C) Water: D) Electrical: Inside fence between buildings next to alley southwest corner of East facility/south of Ammonia tank containment. Special: Southeast corner of East parking lot next to alley and Lakeview Avenue. In alley next to fence and soUthwest corner of East building, 330 feet west of Lakeview Avenue. F) Lock Box: West Processing Facility --Outside on southeast corner of building under stairway. East Processing Facility - Inside building on southwest corner on both sides of exit door next to alley. 1. Ammonia shut-offs inside southeast corner of West building next to alley/ Engineering Support area. 2. Diffusion system box next to roll up door of West building - southside next to alley. Yes (keys only), above north entrance door of west building. II. AMENDMENTS TO: <3> FIRE PROTECTION/AYAILABLE WATER Private Fire Protection - This facility is equipped with automatic overhead sprinklers in all building areas. The sprinkler system is monitored by Tet-Tec Security Systems. Fire extinguishers are in all areas of the facility for emergency use. Fire Hydrant - On th'e"north side of East California Ave., direc~l~ across from the West facili* - building. Sprinkler System Riser llookups - Fire Department hook-up exists in alley ~°0~ ~e=~ west of Lakeview Avenue for East building hook up. West building Riser hook up is inside fence on south side of building 400 feet west of Lakeview Avenue. III. AMENDMENTS TO: <4> BUILDING OCCUPANCY LEVEL 1. East Processing/Warehouse facility - 35 2. West Processing/Engineering Support facility - 4 C:kwpfilesks'~-=^-~ 1 ANNEX III. 1 MAPS & DRAWINGS Items to be addressed in this Annex: Site maps (~ Facility evacuation routes CD Off-site consequence endpoints CD Sensitive receptors within cndpoint distaaccs Facility diagrams showing: (D Utility connection locations ~ Hazardous material storage locations ~ Waste water discharge sampling points OUST monitoring locations ~ Piping and instrumentation design ~ Process flow diagrams Construction details or equipment specifications CONSOLIDATED FACILITY COMPLIANCI~ PLAN CITY OF BAKERSFIELD. ENVIRONMENTAl.. S~RVICE,q Wy. -=NUt: CRYSTAL GEYSER BAKERSFIELD '.CALIFOR~-I~ Henley St.- St. L&ke *' Ave. Ave. Prosl Citrus PoSomac Ave. Fig St. STATE ~'Z '$CH, O -E. Belle' .I --BRUNDA, · Vlrainie Texas St, 0 k~les %mi. %mi. %mi. 1mt. 0 Kilometers .50kin lkm WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. LOCATION MAP DATE 12/93 0332.001 lA I EXHIBIT Vintage Air IndustrialI [ East California Avenue ~L - REFRIGERATION Geyser snack AND WATER I ! TREATMENT ( Bottling . I FAC'L"rY I Facility Alley Housing Complex Industrial Geyser i Parking J / Street IFORNIA EET, Lucl Vir~nia WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELO, CA. SURROUNDING AREA DATE12/93 10332.0011A IExHleIT 2 PRV PRV ACCUMULATOR CHILLER ACCUMULATOR PRV COMPRESSOR PRV COMPRESSOR PRV COMPRESSOR PRV: PRESSURE REUEF VALVE LSV: LIQUID SOLENOID VALVE NOTE: ALL PRV VENT TO DIFFUSION TANK PRV I I FILTERS ~.{ EVAPORATIVE CONDENSER KING LSV PRV RECEIVER EVAPORATIVE CONDENSER __~ EVAPORATIVE CONDENSER WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. AMMONIA SCHEMATIC DIAGRAM DATE 12/93 I0332'0Olla JEXHIBIT 4 II II I II I II 1233 EAST'CALIFORNIA J' MIX HALLWAY I l-- -- -~ BOTTLE ~ I ~_~CYLINDERS~ _A T ' "' I. TB FILLER ROOM I ~ III 0 0 0 ~ cC n-' I'- ~ I~ OFFICE SHOP ^ND PROCESSING AND PACKAGING I AREA I I I I I I I I STORAGE AREA OFFICE NCH [lOOM ALLEY 1233 EAST CALl FORNIA I WAREHOUSE AREA I· I I ' RESTROOM I I I I I I I I ~-I I I I I I Jl DAIE WZl INC. BAKERSFIELD, CALFORNIA CRYSTAL GEYSER BOTTLING FACILITY EVACUATION POINTS I1' ! CALIFORNIA AVENUE TO MEETING AREA © ALLEY I ' I / TO MEETING AREA WZI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER REFRIGERATION AND WATER TREATMENT FACILITY EVACUATION POINTS DATE 12/93 II °332'°°llAInl IEXHIBIT 8-2 HMMP PLAN MAP SITE DIAGRAM FACILITY DIAGRAM I----~_ Business Name: Business Address: /,2..¢~ EA~' E..,4z.,tFo,4/¢/~ AYE~z~ ,,,:, · For Office Use Only .Z First In Station: Inspection Station: Area Map # of NORTH If-/ .. /' A Pr. S. HMMP PLAN MAP SITE DIAGRAM [----] FACILITY DIAGRAM Business Name: Business Address: For Office Use Only First In Station: Inspection Station: Area Map # of NORTH ~ ~~ O. O© ,,, -I I L ~ HMMP PLAN MAP SiTE DIAGRAM Busine~ Nome: Busine~ Adaress: FACILITY DIAGRAM For Office Use Only First In Station: inspection Station: Area Map # of NORTH _1 OFF'/CC ,;o HMMP PLAN MAP SITE DIAGRAM Business Name: ~./Zys~-,~z.- Business Address: /.25~ For Office Use Only FACILITY DIAGRAM ~ 3 0F 3 First In Station: inspection Station: Area Map # of NORTH .~ High Pressure Receiver EXHIBIT 7 0332.00'1 lA Glycol Chiller EXHIBIT 8 0332.001 lA i Avenul HAGOERTY NORTH LOC Lane OLD RIVER !0 11 I2 Leke~i~ Bear Mountain 'PANAMA ~ Phillips Rd." 34!35 I~Mi es 2mi : 4mi. 6mi. 0 Kilometers 5kin 10kin 34 2 SHL $ 39 Round KERN RIVER ~ 29 . ;Z~ -.27 : HART IDLH KERN RIVER GOLpe COUF 3reckenridge IEEDPAT~H7 GIORGIO DATE WZI INC, BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. CASE #1 CLASS F CONDITIONS 4900 lb: RELEASE 7/93 [ 0332.0011A I EXHIBIT 9 VILLJ~GE JAMES C;% i l ~ l* NAGGERTY 4~ ,~3 ! KERN GOLF COURSE MEADOW: ,tt KrRN RIVER SHL $ 39 ...... {~ ....... Round Mtn. ' 25 HART Discovery WeB. GraOe ROUND MTN.I ~'IKLD ,.~) . ~i KERN RIVER. ' STATE~ ~REC. ARE I KERN ooLF~,c0u~ 4900 lb. IDLH Breckenridge, , '~T.~OS. ~.26,.E. Lane ~3 Id 27 OLD RIVER 15 j 23 ! 24 Bear Mountain 2t~. J 27 B~B F'I ELD 33 i 34 ; D t lO J 11 'PANAMA -- ,Phillips Rd~ { 36 9 J lo ,~ Miles 2mi . 4mi. 6mi. ~ m I I ! 0 Kilometer~ 5km 10km Road 35 10 AMON DI · - REC.i DATE Herring WZI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. CASE #1 CLASS F CONDITIONS 4900 lb. RELEASE 7~931 0332.0011A IEXHIBIT 10 · MINTER Avenul ~ KERN GOLF COURSE 2000 lb. LOC ,~ M EADOW~< 2000 lb. IDLH ,i5 Pokey 5HL$39 ~ KERN RIVER .t Round Mtn. 285. ~'L28E. 1616' · 26 25 ,: HART Discovery Well. Grade PIPE IDLH r~,' . p~l .~ PIPE LOC 33I ;DUND MTN IrI£LD RlVEI~ J(ERN RIVER GOLF~C ,OUF 1 Lane :~4 OLD RIVER ~ '13 15 ~ 14 T '" · ~ /,~eJide t. .ol~. h.Z~. m. Rd~" Beer Mountain ~illux PANAMI 0 Kilometers 5kin 10kin 3~* 35~. GREENFIELD Rd.~ 3 2 4 DiGio~ SI-IL . $88~' i Weedpatch L6~)p RECJ WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA, CASE #2 AND #3 CLASS F CONDITIONS 2000 lb. AND PIPE RELEASE DATE 7/93 I 0332.00~A I EXHIBIT 11 I I ~L-'TROPOLITAN '~ I~ECREATION LOC IDLH Uni. n BRUNDAGE 0 Fee~ 2000' CASA DATE Depl. of Waler R ..... ces iiI WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. CASE #4 CLASS B CONDITIONS 4900 lb. RELEASE 7/93 I 0332.0011A IEx"~E~IT ~2 ~. - ~ ' ~regun · ~ 2 0 ~ ' ~ , ~~ l1 ~,~1 ~ e~'. ~~ /I ~1 I _ ~"1 .~1 ~' I ~1 ~E~RA~' - , . / : I ~. ,, ~, ~ t ~ · , ~~ I PIPE IDLH I . e ~ ' I~' .... · 'mg".'~ ~ "- , , I . . Strem ' '..-~ ~ St t .E ~ = -= < Potomac II ' St ~ .... ~ ..... I E 6th I Unmn Cemetery ' ~ ...... H )user ~1 m .~ c bt ~ ~ : ~: ' ~ ~[ -- ~ ( ~ . ..... ; o ~ ~ = o.- c' ~ '; Y ~ I <0~ ~ s" st ~ '-'- '---', , ~ g' ~ ~"~-- lsd = = ! ' ] ~ ~' , . ,,,, ,~ ~' ~_ ~'~ ~- , Ferry m t. Ch r hill ~ O ~Crn~ ~ · ~ ~ ' ~ -- ANIMAL ~ ~ ~ ~/errace X ~J -~ 0 ' ~ '. 0:'::"0 .- --~ -- ~ ~ % ~l~.~' ~ : ~-.A-. ~ ~ . ' '-' ie~S Ln '- - Cannon Ave ' · ;OLDEN STATE '~ c ~ I ~ ~ / >J .... ,' -'. '~ :~¢~""~ "~ ~I An ~NT~ ~Hnnt R. HIGHSC . 0 Terrace ~ ~// ~/ '.~J ~ ~ o-tie Terr ~ .... "~" ~ ~;~"~ '?~'~ '(KERNHSDISTRICT =,(J, < I ' , ~ '-'~ · ~ . I~' :':" 0 ~i ~II o ~Z~s' ~ kC ~ I III ~ ~ ~/'~- ~. ~ , ~.../'~-- .... T ' BAKERSFIELD, CA. CASE ~5 AND ~6 CLASS B CONDITIONS 0 Feet 2000' 2000 lb. AND PIPE RELEASE I I , 0 Miles Ami. ~. ~ATE EXHIBIT 22nd Special Services Our Lady of Guadalupe Sch. OWens School ,.~ St. -"Terrace Way FdiZ ..~ McCaw L;t, ',4TE Smith St. Terrace Williams School 2506 Lake Center IFORNIA Bethel Christian School Potomac I , I --BRUNDAGE __ Mt. Vernon School 2OO0 · --.N-- Feet 2000' 4000' Miles "Ami. · ½mi. ~'n Imi. Kilometers .50kin 1 km WZl INC, BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER BAKERSFIELD, CA. NEIGHBORING RECEPTORS DATE 7/93 10332'O011AIEXHIBIT 15 REFRIGERATION TECHNOLOGY ]NC. CRYSTAL GEYSER o :~:[] ._~[_~L ~Y~STE____~ ALARMS , ~,rc 1 CONTROL PANEL R1 22 NOTE: COMPRESSOR 2 NOTE: Z ~· ~ i""~' F ('F -~-'-N=;-~ _..!.Jl.l_l I,..iL ..... WlI.Jr,.I,L; ............................... REFRIgeRATION TECHNOLOGY INC. ~--*1-~t-''! ...... CRYSTAL GEYSER R-2 SiARi! 1 XTO CONTROL PANEL R2 --D 0.%0 R-1 (rvp.) R-2 , [ '2J -' ~ STAFT-~ R2 CONTROL PANEL II( PI~C[SS ~ HIGH i · REFRIGERATION TECHNOLOGY INC. ',1,' / ...... ~ ,¢,.-~. CRYSTAL ' GEYSER (r~.u~[) R2 , E}..t .......................... ,,odD- ..................... -"'~- ~ ,,,,:,, D..I. ..................... ~.~- ~ ,,o~E3.~ ..................... -~-~ .ID- ..................... C~',~ FIELD CONTROL WIRINC; SEE PLAN E-9 FOR LOCATION OF FIELD PARTS I ; I ~' .~.~ ~ ~ , , , ,,~ '~ ~ : ~.,, i -~;REFRIGERATION TECHNOLOGY INC..j. -IELI) CONT~QL UIRING ._ , .,,, o .I COMPUTER C.ONTROL PANEL CONDENCER PUMPS J]i~ SEAL CONDUIT CONDUIT~ ~ TO PREVENT TO RI ~---AMMONIA FROM ENTERING MAIN PANEL T1 ALARM EXPANDER EXPANDER T2 T5 l! AMMONIA ALARM MACHINE ROOM AMMONIA ALARM VENT AMMONIA ALARM CARBO COOLER GLYCOL PUMPS TOWER PUMPS DOWNI _ 1 0 3~OWd -f P °dAl W3MO! HOV3 31¥'009 ~3ISAS iN3Hi¥381 W31VAA F FI [ SN¥8i 09-k I 1 I 0 Z r-a r--i '.- I I I I~1 I'~ I I I ! L.rJ L..t ©' © © I III ill II I'L -- -'lJJ I I 0 -f MACHINE ROOM LAYOUT ,m CONDENSOR PIPING Z EVAPORATIVE CONOENSOR - NH3 PIPING CHILLER ELEVATION l ;a CATCH ALL '~1 RECEIVER TANK PIPING EVAPORATIVE CONDENSOR - WATER PIPING 0 III ~, , PLANT LAYOUT ~ TOWER WATER, GLYCOL PIPING I ' I01II / ~ I { ) '1' ~ .... I' 0 I r~ ~1-111' ' ' : ~ ~ ~-~ I~'~1 I ~ I1~1 1~ I I' ~- '~1 ~ I I I s ~ II ~ OI I ~ II I II II ~ II I II II II Ii I II .I Il II '1 [ II I II v II I II , II I II I i II I J II I II _~ ~, ~ /~ J · --LU' J I ~1 ~ 0 I ~ I 1 / I I I ~?~ i ~-~' I PLANT LAYOUT X GLYCOL PIPING II · ii I " ' I PLANT LAYOUT X~ TOWER WATER PIPING '-'F T PIPING .AT CHILLER TOWER .SUPPLY &:: RETURN PIPING TOWER .WATER PIPII",IO ANNEX III.2 NOTIFICATIONS Items addressed in this Annex: Immediate verbal notification of CUPA for any release or threatened release Immediate verbal notification of OES for any release or threatened release Immediate verbal notification of NRC for any release or threatened release Immediate verbal notification of POTW for exceeding discharge levels As soon as practicable, written follow-up Section 304 After Action report to OES 24 hour verbal notification to POTW for any operating upsets 24 hour verbal notification to CUPA for UST monitoring alarms Written notice within 5 days to POTW describing any unauthorized discharge 10 day prior written notice to POTW of any anticipated bypass of treatment system Submission of re-analysis to POTW within 30 days of discharge violation Source testing conducted with 30 days notice using District approved methods and procedures Source test results submitted to air District within 60 days 90 days prior notice to POTW for any planned changes to facility's waste water system List of internal corporation notification contacts and reporting forms (attached) List of external resources or contract service providers (attached) Terms: CUPA = Certified Unified Program Agency (City of Bakersfield - Environmental Services) District = San Joaquin Valley Unified Air Pollution Control District NRC --- National Response Center OES = Office of Emergency Services POTW = Publically Owned Treatment Works (City of Bakersfield - Waste Water Division) CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES developed to ensure that the accident will not recur. System design, operating and maintenance procedures that need updating or alteration shall be noted, and a time schedule set for implementation of improvements. Responsibilities: The Plant Manager: Ensures that accident report Is complete. Conducts the accident Investigation. Guides accident response. The Maintenance Supervisor: Provides technical details of reports. Assists with the accident Investigation. Directs physical plant changes. Makes changes to the training program, If changes are necessary. All Employees: Assist with the accident Investigation. 2.5 Release Reporting Procedures Pursuant to Section 25507 of Chapter 6.95, Article 1 of the CHSC, releases of AHM that may threaten human life, health and safety or the environment or exceed the reportable quantity must be reported. The Plant Manager is responsible for determining the significance and reportability of a release. If an ammonia release equals or exceeds 200 cubic feet of gas during a 24-hour period or constitutes a threat to life, health or the environment, the event is reportable and the following agencies must be notified immediately. Bakersfield City Fire Department Hazardous Materials Division Telephone: ' (805) 326-3979 Page 11 California Office of Emergency Services Telephone: (800) 852-7550 The Plant Manager is responsible for reporting a release. Page 12 ANNEX 111.3 ENVIRONMENTAL MANAGEMENT SYSTEM- General Overview ahd Management Level Commitment ::~Thi~ ~:~h6~Id:i66ntain a detailed' de~6Hpti~iii6fth~ 'fa~ili~ ,, S'.:~ii~ii6~atal rnanagemenf ~ I m~agem~nt,~.~a~mitment tow~d~?~ :h~h~~ble en~i~6~e~tatP~?~ce.: · :' ,'/, Items to be addressed in this Annex: I~l Environmental management system used (e.g.: ISO 1400 I), i f applicable 1~ Emergency response managemeut utilizing the Incident Conm~aud System I~ Regulatory compliance assurance through tile environmental m,'magcmcut system [21 Management level commitment toward improvements in environmental performance 1~ Environmental policy for the facility / corporation O Formal policy commitment to haz. ardous waste source reduction gl Accidental release preveution and emergency response policies O Organization chart O Specific job descriptions for each position involved with regulated substances O Detailed description of information flow 121 Safety information related to the regulated substances, processes, and equipment O Material safety data sheets (MSDS) O Safe upper and lower limits for temperatures, pressures, flows, or compositions 0 Codes and standards used O Equipment and safety system design specifications CONgOLIDATItD FACILITY COMPLIANCE PLAN CITY OF IIAKERSFIELD· ENVIRONMENTAL SERVICES 11.0 RISK MANAGEMENT AND PREVENTION PROGRAM IMPLEMENTATION "Implementation of the RMPP shall include carrying out all operating, maintenance, monitoring, inventory control, equipment inspection, auditing, record keeping, and training programs as required by the RMPP." 11.1 Personnel Responsible for RMPP Implementation The title of each person charged with RMPP implementation duties are listed below, along with their respective responsibilities. Title RMPP Implementation Responsibilities Plant Manager Supervise audits, inspection and record keeping, responsible for RMPP implementation Maintenance Manager Supervise ammonia equipment inspection, emergency response training, operating and maintenance training, inventory control and labeling Quality Control Manager Supervise emergency response training, operating and maintenance training, inventory control and labeling. All Employees Undergo emergency response and evacuation training Page 37 11.2 Implementation Schedule The following schedule will be followed for RMPP implementation. Program Date of Full Implementation Inspection Program Ammonia Safety Audit RMPP Record Keeping Safe Operating Procedures Training Maintenance Procedures Training Evacuation Training Emergency Response Training SCBA Labeling Canopied and Sprinklered Area Ammonia Diffusion System Ongoing January 7, 1992 January 1, 1991 July 3, 1991 January 1, 1991 July 3, 1991 July 3, 1991 June 6, 1992 January 1991 January 1, 1991 December 13, 1991 11.3 Training Program for RMPP Implementation The RMPP training program must ensure that standard operating procedures are easily understood by mechanics, Training should be able to provide a continuity of safety despite employee turnover or changes in personnel. Training ensures that plans and programs such as emergency evacuation plans will work as designed when they are needed. During training sessions, employees speaking both Spanish and English serve as translators for employees that speak only Spanish. Page 38 10.0 INSPECTION PROGRAM 10.1 Ammonia Systems An inspection program is necessary for the assessment of hazards present in the work place. The person responsible for inspection must be familiar with the process and system being inSpected. Hazards, deficiencies, out-of-normal variables or unusual observations or occurrences must be recognized and recorded during the inspection. Potential hazards identified through inspection will be assessed and assigned priorities for correction. Action will be taken to reduce the risk presented by identified hazards. The maintenance manager is responsible for inspecting the work area at the beginning of the shift. Any notes resulting from the inspection will be noted in the operator's log. In addition to daily inspections by the maintenance supervisor, the ammonia safety audit includes an intensive inspection of the ammonia refrigeration systems. Inspection of the systems may 'be scheduled after the process changes, upsets, or accidents. Page 36 APPENDIX F AMMONIA VESSEL SAFETY INSPECTION DATA (Complete one form for each vessel) Vessel Name or Use: 1. Location (Building): 2. Location of Vessel in Building: 3. Description of Vessel Use: 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Normal Pressure in Vessel When the Refrigeration System is in Operation: (psig). Vessel Manufacturer: Design Working Pressure: Is Vessel ASME (or Equivalent Authority) Stamped: Vessel Registration No,: Vessel Length: Vessel Diameter: Year of Manufacturer: Does Vessel Have a Relief Valve: Is Relief Valve Single or Dual: What is the Relief Valve Pressure Setting: What is the Relief Valve Rating: What is Relief Valve Year of Manufacture: What is the Size of the Relief Valve Outlet: And Outlet Pipe: (psig) (feet) (inches) .(psig) pounds of air per minute Appendix F Page 6 18. 19. 20. 21. 22. Is the Relief Valve Properly Piped to the Atmosphere: (Y/N) To Your Knowledge Has This Vessel Ever Been'Altered or Modified: (Y/N) Do You Have Any ASME Certified Prints or U-1 Certificate (or Local Equivalent) at the Factory Site: If Altered, Was Vessel Recertified: What Controls are Fitted to this Vessel: Y/N (Y/N) .(Y/N) Condition Settin~ Operates (G, F, P) % Level (Y/N) None Hi Liquid Level Cutout Liquid Level -Control Low Liquid Level Cutout 23. Assess Control Column Design: (Screwed Joints, Stop Valve Locations, Condition) Good Fair Poor 24. Does Relief Valve Look: (E/G/F/B) Excellent (Clean with no visible rust or corrosion) Good (Looks okay but some corrosion visible/less than 25% surface only) Fair (Considerable surface corrosion but none visible internally) Bad (Surface and Internal Corrosion Visible) Date of Last Test: Appendix F Page 7 25. Is This Vessel Covered With Insulation: Condition of Insulation: (G/F/B) Good Fair (Slight signs of vapor barrier leaks) Bad (Extensive signs of vapor barrier leaks) ,(Y/N) 26. An Abnormal Ice Formations on Vessel: .(Y/N) 27. Any Signs of Rust/Corrosion on Vessel: A. None B. Slight or Trace C. Moderate But Appears to be Surface Only D. Appears to be Extensive, Should be Examined .... by Consulting Engineer E. Cannot Tell Due to Insulation Give Date: 28. Has This Vessel Been Inspected by Outside Inspector Within the Last Five Years: (Y/N) Give Date: 29. How Long Since Last Inspection by Non-Destructive Examination (NDE) Methods: 30. 31. 32. Does the Vessel Have an Oil Pot: Compressor Room: Oil Accumulator: Does Oil Pot Have Relief Valve: Is Oil Pot Relief Valve Correctly Piped: (Y/N) (Y/N) (Y/N) (Y/N) Append~ F Page 8 33. Special Remarks on Vessel Condition or Usage: 34. Specify Overall Rating (S.I.R.): Appendix F Page 9 APPENDIX F AMMONIA COMPRESSOR SAFETY INSPECTION DATA (Complete one form for each compressor) 1. Compressor Duty: High Stage Booster Swing 2. Compressor Type: Recip Vertical Recip V or VW Rotary Vane Rotary Screw 3. Compressor Manufacturer: 4. Model No. Year Built 5.' Capacity (Tons) Motor Power 6. Drive: Direct Belt 7. COmpressor RPM Nameplate Max. RPM 8. Relief Valve Type: Internal External 9. Is a check valve provided at the discharge of each compressor? 10. Normal Compressor Pressures (PSI): Suction Discharge Manufacturer Recommended Maximum Discharge Pressure 11. Low Pressure Cutout Setting (PSI) Design Actual Checked (Y/N) Operates Properly 12. High Pressure Cutout Setting (PSI) Design Actual Checked (Y/N) Operates Properly ,(Y/N) (Y/N) (HP) ,(Y/N) Appendix F Page 10 13. Is high pressure switch hard wired? a) To motor starter b) Through PLC 14. High Discharge Temperature Cutout Setting (°F) Design Actual Checked (Y/N) Operates Properly 15. Oil Pressure Safety Switch Setting (PSI) Checked (Y/N) Operates Properly 16. Is compressor connected to a flooded vessel? If yes, does high level switch stop compressor? High Level Sw. Chkd. (Y/N) Operates okay? 17. Does compressor start automatically? If yes, is there an "Auto Start" notice posted? 18~ - Compressor drive is electric motor , Steam Turbine , Gas Engine at RPM and Can prime motor overspeed? 19. Any abnormal vibrations present? 20. Drive Guards: Adequate coverage and secure? 21. Any abnormal noises? 22. Electrical covers in place? 23. Any visible leaks? 24. Is there a safe method for electrical and system isolation? 25. General assessment of compressor unit (S. I. R.) (Y/N) ,(Y/N) .(Y/N) (Y/N) (No.) V Belts VVZl INC. (Y/N) (Y/N) (Y/N) (Y/N) (Y/N) (Y/N) (Y/N) (Y/N) (Y/N) (Y/N) (Y/N) (Y/N) Appendix F Page 11 ~! NC TABLE 1 pHysICAL PROPERTIES OF ANHYDROUS AMMONIA (NH~) Molecular Weight 17.03 Latent Heat 327 Boiling Point -27.4 Solubility 89.9 Specific'Gravity (Liquid) 0.682 Vapor Density 0.59 Autoignition Temperature 651 Explosive Limits 16 to 25 Critical Temperature 651 Critical Pressure 11.5 IDLH 350 LOC 35 STEL 25 Ratio of Specific Heats 1.31 1 ppm Lbm/Lbmole Calorie/Gram °F (-77.7 °C) G/100 mi AT 0 °C (-33.35 °C/4 °C)' (AIR=l) @ 25 °C, 760 mm Hg °C (1,204 °F) % by Volume in Air oC ATM mg/m3 (500 ppm) mg/m3 (50 ppm) mg/m3 (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 (H) atoms. The molecular weight of ammonia, 17 Ibm/Ibmole, is significantly less than that of air which is approximately 29 Ibm/Ibmole. As a result, ammonia in the vapor phase is much lighter than air and rapidly rises when released. MATERIAL SAF TY DATA SHEET MSD$ CODE NO. 5B8~-83 ORIGINAL ISSUE DATE: 8/85 REVISED: 8/91 24 HOUR EMERGENCY TELEPHONE NUMBER CHEMTREC 800-424-9300 :RODUC::T NAME: Anhydrous Ammonia ~.OMMON NAME: Ammonia ~HIPPING NAME: Amrnonia, Anhydrous. Liquefied, 2.2. (Nonilamn',able Gas) JN 1005, RO, Inhalation Hazard. MANUFACTURER AND/OR DISTRIBUTOR: LaRoche IncluSmeS inC. 1100 Johnson Ferry Road. N.E. Atlanla. GA 30342 (404) 851-0300; (404) 491.7987 ah. er hours Prepared By: R. C. Cannon OSHA-PEL ACGIH ~,mmonia NHa 7664-41.7 ~ 99.5 99.99,5 35 pDm 25 ppm 35 ppm ,'~'ater H20 7732-18-5 ~ 0.4 33 ppm None Established ' None Established Oil .... 0.1 2 ppm 5rhg/M3 5re.o/M3 -- ~,OILING POINT (°F) --28.1 ~ I SPECIFIC GRAVITY (H20= 1) 0.62 ~ 60°F POINT(OF) --107,9° J PERCENT VOLATILE BY VOLUME (%) 100 OR PRESSURE (mm Hg.) 4802,9 (94 psi)~60°FI pH Approx. ll.EforlN$oln, inwaler VAPOR DENSITY (AIR- 1) 0.60 ~ 32°F SOLUBILITY IN WATER 33% ~t.) 68~F APPEARANCE AND ODOR: Colorless gas or liquid with extremely pungent odor. .--LASH POINT(method us~,d) NotApptlcable NFPA HEALTH 3 (High) .--LAMMABLE LIMITS 16-25o7o in air HAZARD RATING FIRE 1 (Slight) REACTIVITY 0 (Least) EXTINGUISHING MEDIA: With a source ol ignition, ammonia will burn in the range ot 16 - 2£°/o in air. Use water tog or spray lo extinguish flames. SPECIAL FIRE FIGHTING PROCEDURES: Stop flow of gas; move containers trom fire zone if possible. Stay clear of tank heads. Use water to cool fire-exposed containers and protect personnel. Use water spray to control vapors. Personnel must be equipped with appropr[a[e pro. ~ective c. lothing ~nd respiratory equipment. Do not put water on liquid ammonia. STABILITY I Unstable I [ CONDITIONS TOAVOIO: N°t Applicatsle'Stable X NCOMPATIBILI]'Y: Ammonia can react vid ently with strong acids. Under certain co,'].ditions, ammonia reacts with bromine, chlorine. fluorine or iodine to form compounds which explode spontaneously. Reactions ol ammonia with gold. silver or mercury to lorm explosive fulminate- ke compounds have been reported. HAZARDOUS DECOMPOSITION PRODUCTS: Hydrogen on healing to over 850~F. The decomposition temperature may be lowered to 575 °F ~y contact with certain metals such as nickel. POLYMERIZATION Wilt Not Occur NOTE: Anhydrous Ammonia is subject Io the report,nS requirements of SARA (1986. section 313 pi Title III) and 40 CFR Part 372. L RocHE INDUSTRIES INC. TRANSI~ORTATION EME:RGENCIES C~ll CHEMI'REC B00.-42¢-9300 · f. PS TO BE TAKEN IN CASt. MA'I'ERIAL IS RELEASED. Slop teak il leasable Avoid b~cafl'.ng amn',on~a. Evacuale r.,er.sonr,¢l r,o1 eQuipPed O otective clothes and eClulpmenl. Use copious amounts bi water spray or log to absorb ammonia vapor. DO NO'I' put wateT on I~Clu~d ~. Contain run-0fl Io pruvenl ammonia hon~ enterlng'a mfeam, take. sewer or d~tch ?lOeS~ OI 100 lbs. of mOr¢~ of umrnonir~ wdhin 24 hOUrS must be re,dried id the EPA National ResDor~se Cenler at 800.424-8~02. ~STE DISPOSAL MEIHOD: ~ ~_ No, Applicable '. J / .~over ammoma il leas,hie. Olherwise. lei ammonia eva~r~t~ il apropnale. Only personnel uxperic,ccd ,, ammonia spills should , .Od water lo liquid ammonia. D,s~se bi diluted ameba.:3 as a lerfilizer or ,n ar, ~r,dusmal process. ~[ hazardous waste regulations, celt mc RCRA Ho;bne a~ 8~.424-9346. : FFECTS OF OVEREXPOSURE: )LH Level = 500 pprn · rnmonia is a strong alkali and rea(lily (lamaDes all body hssues. IvlAJOR EXPOSURE HAZARD ~---~INHALATION ,~ SKIN ~ EYE ~ CONTACT)/X,I CONTACTI I INGESTION ,, ,'nmonia is not a cumulative metabolic poison, nor is ~t a listed 3rcinogen by IARC, NPT or OSHA. Inhalation: Depending on exposure concenlralion and (luralion, effects car~ vary Irom none or on!y milc~ ntalion, to obstruction of breathing from laryngeal and bronchial spasn't, to edema and severe d~.mage of the mucous membranes ol the respiratory 'act with possible latal results. Latent edema and residual reduction in pulmonary function may occur, Skin Contact: Prolonged contact with ,~ah concentrations car, cause painful tissue damage, frostbite and serious chemical burns. Eve Contact: Exposure to liquid or h~gh concert- 'S. lions of vapor can cause painful, instant arid possibly irreversible damage to tissues such as the conjunctive, cor nee arid lens. Glaucoma and ;~acities may occur. Ingestion: Tissue damage, chemical burns, nausea and vomiting can occur. Ammonia is a gas under normal almosDheric :onclitions and ingestion is unlikely. --MERGENCY AND FIRST AID PROCEDURES: =-ye Contact: Flush with large amount bi water for at least '15 minutes then immediately seek medical aid. Inhalation: Remove Irom exposure. : ~reathir~ has stopped ~r is difficult administer artificial reslairation or oxygen as needed. Seekimmeciia~e me0ical a~d. Skin Contact: lmmea~ately = ush with targa quantities of water tot at least '15 minutes while removng clothing. Clothing frozen to the Skin ShOuld be thawed with water before - _~'novaL Seek immediate medical aid. Ingestion: DO not induce vomiting. Have the victim drink large quantifies of water it conscious. Immediately medical aid. Never give anything by mouth to an unconscious person. R,,SPIRATORY: R~_spiratory protection approved by NIOSH/MSHA for ammonia must, be used when exposure limits a:e~excee~Oed. Whemer a chemical canri0ge respirator or a self-contained breathing apparatus is sufficient for efiecJve respiratory protection cJepend., on m. type and magnitude of exposure. SKIN: Robber gloves and rubber or other types of approved pro'{ective clothing should be used to prevent skin comact A lace snietd should be used :or ~ncrea, sed protection from contact with liquid. EYE: .~_.hemicaJ splash 'goggles. approved lot use with ammonia, must be worn to prevent eye contact with liqulc or vapor. A lace shield shoulC be used for increased protection from contact with liquicl. ' VENTILATION AND ABSORPTION: Local positive pressure and/or exhaust ventilation should be used to reduce vapor concentrations in confined spaces. Ammonia vapor, being ;:~hter than air, cnn be expecled to dissipate Io the upper almosphere. Ammonia c~nceniralions may also be reduced by ~he use bt an appropriate a~sorbent or reactant material. OTHER PROTECTIVE EQUIPMENT'AND MEASURES: -- mergency eyewash ~ations and deluge showers must be available in the work area. Post a list o~ emergency response contacts and telephone ~umbers. PRECAUTIONS TO BE TAKEN IN HANDLING AN[:) STORAGE: ~efer to the ANSI K61.1 s',andard for storage an(l handling information. Protecl containers from physical damage and teml:~ratures exceeding : 20oF. Use only approved morage system~e, cad~'um and sheir ~loys m,ust..not be used ~n am?..oma s ste_~s si.nc~e.~tn.~e_y :~n be ~~ it. Avoid nydrosta'tiE-D'Fes~ure wh,ch c~'En-C'"a'o~e'EQl:~Dment'ruDtUr eoy adnen~lung Droceaures-an'c tr~u ~roslalJc pressure relief valves where appropriate. OHER COMMENTS: .'~ontact lenses must not be worn wl~en working with ammonia. TrNa inlormation is taken Irom sources or based upon deja believed to be r~-lJeble: however, LaF~oche Induslries Inc. makes no warranty as to '.he absolute correctness or sufficiency of any of the foregoing or that addiuonal ~r othC..[ measures may not be required under particular conditions. MATERIAL SAFETY DATA SHEET PRODUCT NAME' PROPYLENE GLYCOL CAS NUMBER: 57-55-6 HBCC MSDS NO. CP21000 HILL BROTHERS CHEMICAL CO. '1675 No. Main Street Orange, Cali'lornia 92667 Telephone No: Outside CalH: CHEMTREC: 714-998-8800 800-821-7234 800-424-9300 Revision issued: 7/25/91 Supercedes: 7/31/89 First issued: 4/10/89 [M.~.OJ~T.J~.NT! Rea, d this ~/~..JZ:,_e._.or_ disoosa! el this oroducL_ _P_~.~_s_~..o.D..g 1he inlormation to emDiovee~; and aq¥_..oJbeJ_j~.~P~ who could ~ oxoosed to_Lh~_~Lu, gL_t.9_~ufe lhal they are aware o! the jr]~LOr_mabon__O_e?t~ZLc._~.s.e or olher exoosure, This MSDS has b4~en prepared according to the OSHA Hazard Communication Slandard [29 CFR 1910.1200]. The MSDS information is be, seal on sources believed Io be reliable. However, since data, saiety standards, and governmenl regulations are subject to change and lhe c~ndilions of handling and use, or misuse are beyond our control, HiLL BROTNERS CHEMICAL COMPANY makes no warranty, eilher expressed or implied, with respect lo 1he compleleness or cominuing accuracy ot :he inlormalion contained herein and disclaims ali liability ~'or reliance thereon. Also. addilional informalion may be necessary, or helpful tot specific conditions and circumstances o: use. Il is the user's responsibility to determine 1he suitability of this product and to evaluate risks prior to use, and then to exercise appropriate precautions for protection of employees and olhers. [SECTION I- PRODUCT IDENTIFICATION SYNONYMS / COMMON NAMES: PROPYLENE GLYCOL; C3HaO2 CHEMICAL FAMILY ITYPE: OXYGENATED HYDROCARBON DOT PROPER SHIPPING NAME: DOT HAZARD CLASS / I.D. NO.: REPORTABLE QUANTITY: N/A NFPA RATING: HEALTH - 0; 0=lnsignificanl 1 =Slighl 2=Moderate NIA N/A FIRE - 1; REACTIVITY - 0 3:High 4,.Exlr~me ISECTION II - HAZARDOUS INGREDIENTS CAS Chemlcol Na~e Numbor Exposure Llmlls (TWAs) In Air ACGIH TLV OSHA PEL STEL' PROPYLENE GLYCOL 5 7.5 5- 6 'ACGIH short term exposure limit (STEL) 100 N/A N/A N/A ISECTION 111 PHYSICAL AND CHEMICAL PROPERTIES LIQUID AppearancelColorlOdor: COLORLESS; ODORLESS Product/Trade Name : PROPLYLENE GLYCOL [SECTION III - PHYSICAL AND CHEMICAL PROPERTIES CONTINUED pH: N/A Melting Polnt/R~nge: Boiling Point/Range: 369.1° F Solubility in Water: Vapor Pressure(mmHg): NEGLIGIBLE Specific Gravity(Water Molecular Weight: 76.10 Vapor Density(Air = % V01atllos: NEGLIGIBLE How to delect this compound : N/A N/A 100% = 1): 1): 2.G 1 .038 JSECTION IV - FIRE AND EXPLOSION Flesh Point: 214°F - 225°F Autolgnltlon Tomper-ture: 790°F Lower Explonlve Limit: 2.6 Upper E. xploslve Limit: 12.5 Unusual Fire and Explosion Hazards: This material may burn, bul w{ll no~, ignite readily, if c-~n',ainer is not properly cooled, it may explode in the heat el a fire. Vapors are heavier than air and may accumulale in Iow areas. Extinguishing Media: Carbon dioxide, Helen, Polar or Alcohol- ty~'"~ foam, or water spray is recommended. Water may be inefleclive. Special Fireilgh!ing Prccecures: Wear appropriate protective equipmen~ including respiratory protection as conditions warrant. Stop spill/release It it can be done without risk. Move undamaged containers Ir~m fire area if it can be done withou'i risk. Water spray may be useful in minimizing or dk;persing and cooling equipment exposed lo heat and flame. Avoid spreading burning liquid with waler used for cooling purposes. I~;'t~i'CT_ION V - REACTIVITY Stablllty: Stable Hazardous Polymerization: Will Not Occur Condltlon.~ to Avoid: N/A Motorlal~ to Avoid: NIA Hazardous Docompo.~ltlon Products: Combustion may yield carbon monoxide an/or carbon dioxide. Do no1 breathe smoke or fumes. Wear appropriate prolective equipmenl, ISECTION VI - HEALTH HAZARDS ~ Routes of Exposure: Summary of Acule Health Hazordu: (Statement) INGESTION: While this malarial has a iow degree of toxicitT, ingestion of excessive quamities may cause signs of nervous system depression (e.g.. headache, drowsiness, loss et coordination and N/A Not Applicable PAGE 2 OF 4 Product/Trade Name : PROPLYLENE GLYCOL [SECTION VI - HEALTH HAZARDS CONTINUED INHALATION: While this malarial h;t:; a Iow vo~alility, nxpor, ur(: lo v~pors is unlikely, howevnr, vapom or mists produced under certain conditiorm el u~,~ may cause ,mgns of n(~rvous system depression ((~.g., headache, drowsiness, loss el coordination and ~'atigue). SKIN:- May cause mils skin irritation. Prolonged or repealed conl;~ct m;~y cause redness, burning and drying and cracking el tho skin. Persons wilh pro-oxisling skin disorders ma), be more susceptible ~o effects of this material. EYES: This malarial may cause mild eye ~rrilalion. or misls may cause stinging, tearing and redness. Carclnogeniclty Ll~t s: NO IARC Monograph: NO Summary of Chronic Hearth Hazards: Effects of Overexposure: N/A Emergency and FIr=t Aid Procedur-n: INGESTION: No first aid is normally required: medical attemion. DirRc~ contacl w~th the liquid or RxpostJre Jo VaPOrS NTP: NO OSHA Regulnted: NO however, if swallowed, and symptoms develop, seek INHALATION: If respiratory symptoms develop, move victim away trr)m source cf exposure and into fresh air. I~ symptoms persist, seek medical a~em~on. If victim is no[ breathing, {mmedh~tely begin artificial respiration. If brea~hing difficulties develop oxygen should be ;~dmirdslered by qualified F,~rsonnel. Seek immediate medical a,qention. SKIN: Wash with soap and water, EYES; Flush with plen;y of water. Medical Conditions Generally Aggravated by Exposure: N/A Note to Physlclnns: N/A [SECTION Vll - PRECAUTIONS FOR SAFE HANDLING AND USE Stops To Be T~ken In Case Material Is Released Or Spilled: Small spills: Soa, k up will~ absorbenl material. Large spillS: Dike and pump into suitable containers lor disposal. Handling and Storing Precautions: Normal precautions common to good manulacturlng practice should be lollowed in handling and slorage. Waste Disposal Methods: Dispose ol In accordance with applicable local, county, state and federal regulations. Other Precautions: N/A N/A Not Applicable PAGE 3 OF 4 Product/Trade Name : PROPLYLENE GLYCOL ISECTION VIII - CONTROL MEASURES Respiratory Protection: r:J~.~spiralory prol,~clion may bo necu~L;;Jry lo mimmi2, e e×I'>osur~. [)~p~n(ling Off tho nature ;lad concentration nj the airborm3 m,atori;ll, u'.;o a lespiralor or gas mask wilh approprinln carlridges and cannisters (NIOSH ~.pproved) or supplir~d ;lir equipment. Ventilation: General room ,,,entilat~on is s;Hi.';f;]clory. Addition&l ventii;~tion or exhausl .~ysloms ma), be required, wher6 explosive mixluret; may b(. present. Electrical sysl~lm5 :;afc Jor such Iocalion5 musl ~ used. Protective Clolhing: Rubber gloves are recommoncJed. Eye Protection: Salary glasses and or face shield is recommended. Other Prolecllve Clothing or Equipment: Il is recommended thai a source of clean water be available in the work area for flushing eyes ;~nd skin. Impervious clolhing should be worn. Work/Hygienic Practices: All employees who handle lids producl should wash their hands before eating, smoking, or using teilel facililies. N/A Not Applicable PAGE 4 OF 4 ANNEX III.3.c OPERATIONS Items to be addressed in this Annex: (1) (2) (3) (4) (5) (6) Objectives and targets [~l~ Written operating procedures (2755.3 or 2760.3) ~l Emergency response objectives (2745.8(a)(2)) Discharge or release control [~l Engineering and administrative controls (2760.2(c)(3)) Assessment and monitoring [~l Monitoring and detection systems in use (2755.2(a)(4)) [~l Any other steps used or needed to detect or monitor releases (2760.2(c)(3)) Containment [~ Mitigation systems in use (2745.6(e)(4)) (see also Annex III.7 "prevention") [~l safeguards to prevent equipment malfunction or human error (2755.2(a)(3)) Recovery Decontamination CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSF/ELD - ENVIRONMENTAL SERVICE.~ 4.0 PROCEDURES REPORT Operating procedures comply with manufacturers' recommended procedures. 4.1 Ammonia Systems 4.1.1 Daily Operatin.q Procedures Operating procedures include: Daily Operating Duties 1. Inspect work area and overall operation of systems. Check compressor suction and discharge temperature and pressure twice per day. Check compressor oil levels twice per day. Normal level is mid-point of sight glass. 4. Check compressor oil pressure twice per day. 5. Investigate abnormal conditions. Page 23 Addition of Oil to the Compressors 2. 3. 4. Open crankcase valve, making sure that the check valve is in place. Oil is pumped into crankcase with a high pressure pump When finished, the crankcase valve is closed Compressor is in continuous operation 4.1.2 Maintenance Procedures Maintenance procedures include: Ammonia System Shutdown 2. 3. 4. 5. 6. 7. Shut king valve on receiver to pump all ammonia into the receiver Shut suction valves on compressors Turn compressor motor off Shut compressor discharge valves Lock out electrical panel Tag warning on the electrical panel Open discharge valves before starting Isolating a Compressor for Maintenance 2. 3. 4. 5. 6. Shut suction valve, allow compressor to pump down (remove ammonia) Turn compressor motor off Close discharge valve Lock out electrical panel Tag warning on the electrical panel Attach bleed off hose to the compressor to bleed off excess ammonia into a bucket of water Open discharge valves before starting the compressor Page 24 Restartin,q a Compressor VVZl INC 2. 3. 4. 5. 6. 7. Disconnect bleed off hose Open discharge valve at the compressor Check oil level in crankcase Remove lockout on the electrical panel Turn on compressor motor Check oil pressure Open suction valve at the compressor Page 25 5.0 DESIGN, OPERATING AND MAINTENANCE CONTROL SYSTEMS 5.1 Ammonia 5.1.1 Desi.qn Control Systems Properly designed control systems include design of piping to minimize slug formation, automatic control devices (for a listing, see Appendix IV of the Hazard Analysis, which was submitted as a separate document) and correct sizing of process equipment. The ammonia safety audit requires an extensive review of system design. If ammonia system modifications are necessary, the process equipment revisions shall be performed in accordance with manufacturers' recommendations. The ammonia system modifications shall be documented and process system drawings shall be updated. 5.1.2 Operating Control Systems The operator's Icg, Exhibit 6, is an effective control of the operating system. Process variables are noted and action is taken if required. The operator's Icg is reviewed by the Maintenance Supervisor and retained on file for future reference. Other operating control systems include labeling to ensure that proper actions are taken, and safe operating procedures training is conducted. Inexperienced personnel are not allowed to operate the ammonia system or to perform work on the system. Any new employees must be trained thoroughly before they are allowed to operate the system. Page 26 6.0 DETECTION, MONITORING OR AUTOMATIC CONTROL SYSTEMS 6.1 Ammonia 6.1.1 Detection Systems Abnormal or hazardous conditions are detected by: Automatic controls: Ammonia gas leaks are detected by Manning Systems Model 4485 Ammonia Gas Cell/Transmitters. These units consist of an electrochemical sensor and an electronic transmitter, and have a detection range of 0-100 ppm ammonia. The Instruction and Installation Manual is provided in Appendix E. Sight: Vibration, discolorations, rust, holes, worn spots Smell: Ammonia leaks, hot oil Hearing: Unusual sounds, lack of usual sounds Experience: A knowledge of what can go wrong with the system will help in detection of hazardous conditions. 6.1.2 Monitoring Systems The following variables are continuously monitored by automatic controlling equipment: Ammonia Pressure: Monitored by pressure cutouts, and pressure relief valves. Ammonia liquid flow: Monitored by Solenoid valves. Page 28 5.1.3 Maintenance Control Systems The Maintenance Supervisor is responsible for controlling maintenance on the system. Maintenance performed is recorded on the maintenance record form, Exhibit 7. The maintenance record form is reviewed by the Maintenance Supervisor and retained on file for future reference. Maintenance records are a control method. Purchase orders are issued for maintenance work requiring contractors. Completed purchase orders are retained by the Plant Manager. Page 27 OCT 17 '96 03:llPH CRYSTAL GEYSER N~TER P.2/3 WZh~¢ The following variables are monitored by the operator: Ammonia pressure: Oil Levels: Ammonia level: Temperature: Running lights: Suction and discharge presmre gauges on compressor Systems are checked twice daily and recorded, Checked twice daily and recorded. Low levels are detected by a rise in the temperature of' tl~e cooled product or process materials. Checked twice daily and recorded, Checked during production mn and checked before cip start up and during cip run. (Lights inounted on carbo cooler panel) 6.1.3 Automatic ¢:m!t,,!?l S~ts~ems Automatic control systems act as a backup to mechanic detection and actions. A listing oil automatic controls on the refi'igeration system is included as Appendix I V of' the Hazards Analysis. The compressor High Ammonia Pressure Shutdown device is an automatic shutdown control with manual reset by the pla!~t operator. If this device actuates, the plant operator shall review the system before restarting the compressor, Page 29 The following variables are monitored by the operator: Ammonia Pressure: Suction and discharge pressure gauges on compressor systems are checked twice daily and recorded. Oil Levels: Checked twice daily and recorded. Ammonia Level: Low levels are detected by a rise in the temperature of the cooled product or process materials. Temperature: Checked twice daily and recorded. 6.1.3 Automatic Control Systems Automatic control systems act as a backup to mechanic detection and actions. A listing of automatic controls on the refrigeration system is included as Appendix IV of the Hazards Analysis. The compressor High Ammonia Pressure Shutdown device is an automatic shutdown control with manual reset by the plant operator: If this device actuates, the plant operator shall review the system before restarting the compressor. Page 29 7.0 PROPOSED RISK REDUCTION MEASURES 7.1 Written Operating Procedures Written operating procedures (Section 4.1 of this RMPP) ensure that mechanics are well trained for' their positionS. Written procedures ensure that safe practices are continued despite turnover in personnel. These procedures will be kept in the maintenance manager's office and in this RMPP document, easily accessed by operating personnel. 7.2 Written Maintenance Procedures Training, using the maintenance procedures (Section 4.2 of this RMPP) as a guide, ensures that personnel are well trained to perform maintenance on the ammonia refrigeration equipment. Written procedures ensure that safety is continuous despite turnover in personnel. If contract help is required, written maintenance procedures may prevent accidents caused by contractor unfamiliarity with the ammonia system. These procedures will be kept in the maintenance manager's office and in this RMPP document, easily accessed by maintenance personnel. 7.3 Increased Inspections Increased emphasis on inspections will ensure that deficiencies or problems are detected before they result in a release of ammonia. The inspection program is described in Section 10.0 of this RMPP. 7.4 Better Labeling Labeling and warning signs are an effective means of communicating hazards to new employees and/or visitors to the plant. Emergency responders may need to know the contents of lines or types of materials in use. Improved labeling of lines or specific hazards will help to reduce the risk of release of AHM. Ammonia lines will be labeled, Page 30 7.5 Safety and Training Program Employees will receive training under the safety program. The training program is described in Section 11.3, Training Program for RMPP Implementation. Release prevention and emergency response training will reduce the risk of releases and minimize consequences of releases. 7.6 Fire Prevention Plan The fire prevention plan relies upon: employee safety training housekeeping practices to remove combustible materials fire extinguishes no smoking signs are posted where appropriate Fire extinguishes are strategically located throughout the facility with each location labeled and serviced on a regular basis. 7.7 Physical Plant Changes All previously proposed physical plant changes have been performed, including installation of the ammonia diffUsion system for the high pressure relief valves. With the installation of the glycol chiller system, the amount of ammonia piping has been reduced and the need for 150 lb ammonia cylinders has been eliminated. 7.8 Reduction of Consequence to Neighboring Homes or Businesses The 'ammonia system is turned off during times when the plant is unoccupied. Maintenance practices coupled with operations training reduce the risk of ammonia releasing accidents. Page 31 *17Q?792i417 REFRIGERA~IO~4-TECH 905 CRYSTAL GEYSE~ ~EFRIGERATION SYSTEM CRITICAL TEMPERATURES & PRESSURES OPERATING CONDITIONS Design Suction Temp Design Suction Pressure Design Condensing Temperature Design Condensing Pressure Design Oil Temperature Design Oil Pressure Design Glycol Temperature 27°F 42~ 88°F i60# 120°F 60# 33°F CUT OUT SETTINGS Low Pressure High Pressure High Discharge Temperature Low Oil Pressure Low Oil Temperature High Oil Temperature 3o# 196# 212°F 10# 49°F 167OF SYSTE~TEST PRESSURES High Side LOw Side 249# 149# NEFR1GENA~IOIq-TECN TO START THE SYSTEM 1. Turn on the KING solenoid valve at the refr. igeration control panel R-1. 2. Turn on the glycol chiller. (switch at R-l) 3. Set the glycol operating thermostat to 33°F. 4. Set the glycol safety the~ostat to 27°F. Turn on the glycol pumps to AUTO. 6. Turn on the screw compressor (at R-l). 7. Set each screw compressor to the automatic mode at the control panel on each A computer program inside the compressor Will cycle the compressor ON and OFF as required to meet the refrigeration load. CONTROL PANELS Location: Back wall of machine PANEL R-k is the main refrigeration control panel. It is fed by a 250 amp, 460 volt service. This panel supplies power to the (3) evaporative condensers and the (4) glycol pumps. coNTrOL PANEL R-2.is the control panel for the cooling tower, tower pumps and the machine room exhaust system. This panel is fed by a separate 100amp, 460 volt service. This panel also supplies all of the control power for panel R-1 and the computer control panel. ~ CONTROL PANEL The.computer control panel is a large fiberglass enclosure located on ~he wall to the left of the R-1 and R-2 control panels. This panel contains the following: Main com~uter Module. diagnostics. This is used for the system alarm and Computer Expander I. R-1. This is used to control the equipment in aEFR i GEkal I Ot~- 1E,2H G'~5, F'02 Computer Expander II. This is used to control the equipment in 4. Machine room ammonia detector. 5. Carbo cooler ammonia detector. 6. Vent line a~onia detector. 8. 9. 10. Glycol chiller operating thermostat. Glycol chiller safety thermostat. Glycol chiller EPR thermostat. Machine room thermostat. 11. 12. Glycol pump pressure controls. Tower pump pressure controls. POWER FAII/IRE If there is a power failure, the system will not start automatically. A trained operator must restart the system. When the power is ~started the alarm system will check all of the alarm point~. If ~ere are any failures the alarm horn and light will activate. The ~sperator can silence the alarm horn, but he cannot reset the alarm- system until the cause of the alarm is found and corrected. Once all of the alarms are O.K. the compressor can be placed into operation again. If there was an earthquake there is a possibility that ammonia lines will break. Pow=r will probably be off, ~d ull uu=omati¢ valves will close. Each vessel tha~ contains ammonia has manual isolation valves that can be turned off. AM~0NIA T.~-AF,~ IN G~TERAL The most common ammonia leak is usually found around valve stems and flanges. These are very easy to find and correct. There is the possibility of an a~onia leak if a compressor seal is leaking. This is usually proceeded by excess oil leaks at the seal. If this happens the compressor can be isolated. A spare seal for each compressor should be on hand. A faulty relief valve can open prematurely. If this happens, the ~onia vent lines are piped to the sparge tank. ; To detect ammonia leaks we have installed (3) ammonia detectors in the machine room. One at the carbo cooler and (2) in the vent lines. These sensors will send a'signal to our alarm system. MN'~'niB ]~Z)<~M EXHAUST SYSTEM The machine room has a large two speed fan located on the roof. The fan is used to cool the machine room in the summer ~nd to vent the ammonia out of the machine room in the event of a leak. The fan' has a set of automatic dampers. If the fan is being used for ammonia removal, the dampers direct the exhaust air into the cooling tower. This tower acts as a scrubber, removing the ammonia from the air. This will happen under the following conditions. There are (2) machine room emergency vent switches on thc system. One in the dump panel and one on the wall outside the machine room. Either switch will start the fan and the damper and sound an alarm. If the machine room ammonia sensors detect a leak it will start the vent system and sound the alarm. NOTE: The machine room vent system will still function if the emergency stop switch has been used. The control panel is built in two sections. Each section has its own power supply. All of the control power for both sections comes from section R-2. All of the refrigeration is powered from R-1. The emergency stop switch will shut down section R-1 only. R-2 will continue to operate the machine room vent, cooling tower fans and the'alarm system. computer control panel. The top row of lights are inputs to the computer. The bottom row of lights represent the outputs. The inputs send the computer a message, the outputs do the work. The computer inputs must be "ON" (LED light ON) when O.K. If the light goes out it signals an alarm condition. ii:Z6 0 1 2 4 5 6 7 10 11 12 13 14 15 INPUTS Emergency Stop Switch ,. King Solenoid Master High Level Switch Chiller High Level Switch Ammonia Alarm Machine R~om Ammonia Alarm Carbo Cooler Ammonia Alarm Vent System Cooling Tower Sump PH Alarm Sparge Tank PH Alarm High Glycol Temperature High Tower Water Temperature Voltage or Power Alarm OL Alarm '1 EMT~RGENCY STOP SWI~XH There are two emergency stop switches. One is located in the ammonia dump panel and one is on the wall outside the machine room. The switches are wired in series. If there is an accident, fire, earthquake, or a~on~a spill the refrigeration system can be turned off from either remote location. This will sound an alarm at the ~ain computer panel. 2 KING SOT.~NOID The system has (2) KING solenoid valves located on the ma~n ammonia line as it leaves the receiver to supply the system. One valve is ma/%ual the other is electric. The electric valve must be energized to open. The valve will close during a power failure, if the emergency stop switch is turned off, or if the KING solenoid valve switch is turned off at control panel R-1. 3 MASTER HIGH LEVEL SWIT~/~ The~,~master high level switch is located on the master accumulator. If-iiquid ammonia floods bac~ to the master accumulator the master high level switch will shut down the complete refrigeration system. In order to restart the system an operator must be present to reset the alarm system and place the refrigeration system back in operation. 4 CitI~ ~T~ LEVEL SWITCH This switch is located on the glycol chiller and it will give an alarm signal indicating that the ammonia level is too high. This will no~howeve~ shut the system down, it will let the operator know that an%larm c6ndition is presen~ but~because we have an accumulator it is not necessary to shu~ the system down at this time. 5 AMMONIA ALARM IN THE ~ ROOM We. will have (2) ammonia detectors located in the machine room. Each one.will send a signal back to the ammonia alarm'.module located in the computer control panel. An alarm will send a signal to the computer alarm module and this will sound the general refrigeration alarm. 6 AMMONIA ~ AT T~E CARBO COOLER An ammonia sensor has been located near the ceiling over the carbo cooler in the process area. This unit is extremely sensitive and will also send an alarm signal back to r--he alarm module in the computer control panel. This module will in turn send a signal to the computer alarm module which will sound a general refrigeration alarm. 7 AMMONIA AI~I%RI~IIN ,rills.vizier SYSTEM ~wo ammonia mensorm have been located in ~e mm~onia vent piping. One is between the sparge tank ~d machine room)~e second is between the sparge tank and the carbo cooler. In the egent either system senses ammonia in ~e vent line a sisal will be sent to the a~onia' vent line detector which in turn will send a sisal to the computer ala~ module and so~d a general ala~. All of these al~m will be noted and locked in at ~e ala~ panel so ~e operator c~ easily distin~ish where the ala~ occurred. ~e cooling tower will be used an as a~onia scriber for ~e machine room ventilation system. In ~e ev~= of an e~rgency, a~onia will be sc~bed out of ~e air by ~e cooling tower. This will in tu~ change ~e PH of the wa~er in the cooling tower s~P. A PH ala~ ~ill detec~ any changes in ~he ~p ~a=er and ~end a sisal =o =he co~puter ala~module, so~ding a general computer ala~. A~ ~e same time i= will open a dump ~olenoid allowing water to drain from ~e cooing tower ~o ~e s~arge ~ank ~d at ~e same time fresh water will be automatically aaaed to the cooling tower. This will continue ~til ~e PH o~ ~e ~ower water is back wi~in our predescribed li~ts. 11 SP~GE TAt~K PH ~ In the event a relief valve is discharging ammonia into the sparge tank ~nd there is a failure of the ammonia vent alarm and the PH changes substantially in the sparge tank)we will send a signal from the remote PH alarm module located at the tank to the computer alarm module sounding a general alarm. 12 ]/IGH GLYCOL The operating thermostat for the glycol system has (4) stages. Three stages are used to control the glycol temperature. Should the glycol tsmperature continue to increase beyond the third stage of cooling by 5 : the high glycol temperature alarm signal will be sent to the computer alarm module signalling a general refrigeration alarm. 13 HIGH TOWER WATER TEMPERATUI~E This system will be identical to the high glycol temperature alarm described above. 14 VOLTAGE OR POWER We have installed a voltage monitor inside panel R-1 and R-2. Either module will send a signal to the computer alarm module sounding a general refrigeration alarm. Note: Any of the alarm functions listed above will lock in a signal at the comDuter alarm module which will stay lit even if the alarm condition is corrected. This alarm signal cannot be cleared until the alarm condition has been corrected and the alarm reset button has been pushed. Multiple alarm outputs will lock in at any time. OPERATORS LOG (typical) TIME PRESSURE TEMPERATURE OIL ADDED? COMMENTS EXHIBIT 6 1~-08--1993 13:38 CRYSTAL GEYSER AMMONIA CHARGE RECORD Date Ammonia In Plant Amt. Added Initial (Pounds) (Pound~) EXHIBIT 9 CRYSTAL GEYSER AMMONIA CHARGE RECORD P. O3 Date Ammonia in Plant Amt. Added initial (Pounds) (Pounds) ,,~-/.- ? ,~ ~oo -/-- EXHIBIT 9 CRYSTAL GEYSER AMMONIA CHARGE RECORD Date Ammonia in Plant Amt. Added Inltlal (Pounds) (Pounds). EXHIBIT 9 CRYSTAL GEYSER Fsnergency Stop Switch King Solenoid Master High Level Float Switch Ofiller High Level Float Switch Tower Sump PH Alarm Sparge Tank PH Alarm High Glycol Temp High Water Temp Voltage Alarm SYgrEM ALARMS AND CONTROLS DESCRIFHON/FUNCTION .To completely shut down all equipment m an amergency. To stop the flow of refrigerant after the receiver. Monitors liquid in Master Accumulator. Shuts down the ammonia system. Monitors liquid in the glycol chiller accumulator. Monitors PH level in tower water. Monitors PH level in sparge tank Monitors high glycol temperatures. .Monitors high water temperatures. Monitors high and low voltage at alarm panel IX)CATION Sce drawing. At the outlet of the receiver main liquid line. At Master Accumulator. At Chiller. At tower. At SParge tank. 4th Stage of Glycol Thermostat. 4th Stage of Water ThermostaL At alarm paneL Ammonia Alarm Machine Room Ammonia Alarm Vent Ammonia Alarm Carbo Cooler AMMONIA ALARMS AND CONTROLS DESCRIFI1ON/FUNCTION Monitors Ammonia in machine room. Located in the ammonia vent line going to the sparge tank. Monitors Ammonia at the Carbo Cooler. LOCATION (h~aSensors in chine room located above equip. (l~l)a Sensor in chine mom vent line. (1) Sensor in the carbo cooler vent line. Near ceiling over carbo cooler CRYSTAL GEYSER AMMONIA DUMP CONTROL PANH..: On the back wall of the machine room, outside the building is the ammonia dump panel In the event of an emergency, such as a fire in the machine room, the ammonia pressure can build up. To relieve the pressure, valves were installed ia the dump panel If the pressure exceeds the red line on the face of the gauge the valve is opened allowing ammonia vapor to enter the sparge tank_ (see below) SPARGE TANK: (F..xisting) 12,000 gallon tank. The sparge tank is used to absorb any ammonia vapor discharge as a result of a relief valve popping off or the pump system being used. The emergency stop switch will shut down the power to all of the equipment in the machine room, with the. exception of the ventilation system. . One switch is located in the ammonia dump panel and one in the control box located ' just outside the machine room. MACHINE ROOM VENTILA~ON SYSTEM: The machine room ha a (2) speed fan on the roof, controlled by a two stage thermostat. The fan is also used to vent any ammonia vapor from the room. To prevent ammonia discharge into the ak the fan discharges the machine room air into the cooling tower. This tower scrubs the ammonia out of the air. If this happens, the PH of the tower water will increase. A PH alarm will signal this condition and an alarm will sound. SYSWEM ALARMS: Location: Controls and alarms are located in the computer panel on the back wall of the machine room. Description of Operation: '0 Z CI ANNEX III.3.d PLANNING Items to be addressed in this Annex: (1) (2) (3) (4) Hazard assessment [] Worst-case release scenario analysis (2750.3) [] Alternative release scenario analysis (2750.4) [] Defining off`site impacts to the population (2750.5) [] Defining off`site impacts to the environment (2750.6) [] Off`site consequence analysis documentation (2750.8) Program 3: [~1 Process hazard analysis (2760.2) [] Employee participation (2760.10) Program 2: [] Hazards associated with the process and regulated substances (2755.2(a)(1)) [] Opportunities for equipment malfunction or human error (2755.2(a)(2)) Protection [] Safeguards to prevent equipment malfunction or human error (2755.2(a)(3)) Coordination with natural resources trustees & NGO's [] Community communication outreach (2775.5) Waste management CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES II1. IV. TABLE OF CONTENTS Introduction Hazards Identification A. Identification of AHM B. Quantity of AHM C. Location of AHM D. Potential Hazards of an AHM Release 1. Primary Hazards 2. Other Hazards E. Hazards and operability Study 1. Study Guideline 2. Study Results F. Transportation Methods Vulnerability Analysis A. Summary of Modeling Results B. Receptor Locations C. Essential Service Facilities Risk Analysis A. Summary of On-site and Offsite Consequences Page 1 4 4 4 4 5 5 7 8 8 14 16 16 19 2O 21 22 22 EXHIBITS Exhibit 1 Exhibit 2 Exhibit 3 Exhibit 4 Exhibit 5 Exhibit 6 Exhibit 7 Exhibit 8 Location Map Risk Analysis Matrix Plan Drawing R2329 R1 Plan Drawing R2329 R3 Piping Schematic R2329 R2 Piping Isometric R2329 R4 Pictures of High Pressure Receiver and Piping Pictures of Glycol Chiller and Piping Exhibit 9 Exhibit 10 Exhibit 11 Exhibit 12 Exhibit 13 Exhib~ 14 Exhibit 15. Case 1 - Map of Exposure Zone (IDLH and LOC) Case 1 - Map of Exposure Zone (IDLH only). Case 2 and 3 - Map of Exposure Zone (IDLH and LOC) Case 4 - Map of Exposure Zone (IDLH and LOC) Case 5 and 6 - Map of Exposure Zone (IDLH and LOC) Map of Surrounding Area Map of Receptor Locations TABLES Table 1 Table 2 Physical properties of Anhydrous Ammonia Bakersfield Area Mean Wind Speed and Direction APPENDICES Appendix I Business Plan Appendix II Ammonia MSDS Appendix III Equipment Specifications Appendix IV Ammonia Systems Controls and Alarms Appendix V HazOp Study Node Forms I. INTRODUCTION The Crystal Geyser Water Company (Crystal Geyser) bottling facility, located at the corner of East California Avenue and Lakeview Avenue, Kern County, California (Exhibit 1) formulate, produce, package and ship various brands of Crystal Geyser beverages. The process of manufacturing beverages in the Crystal Geyser plant requires refrigeration. The refrigeration is used to cool tanks of water and juice beverages during their manufacture plus the bottled product after pasteurization and prior to 'carbonation. Crystal Geyser is proposing to install a new higher capacity ammonia refrigerant system that will supply ammonia to their carbo coolers (existing) and the glycol chiller (new). The engineered features that are designed into the new refrigerant system such as the glycol chiller system (keeps ammonia piping to a minimum), high pressure relief sparge system and advanced sensors interlocked with alarming devices have been incorporated to reduce the risk of an ammonia release. This new refrigeration system and building was built in accordance with: 1) 2) 3) 4) 5) 1991 Uniform Building Code 1991 Uniform Fire Code 1991 Uniform Mechanical Code 1991 Uniform Plumbing Code 1990 National Electrical Code A Hazard Analysis of the use of Acutely Hazardous Materials (AHM) for the Crystal Geyser Bakersfield bottling facility, used for their Risk Management and Prevention Program (RMPP), was approved by the Bakersfield Fire Department, Hazardous Materials Division on April 10, 1991. This update of the Hazard Analysis is a revision of the April, 1991 edition to reflect the addition of the new ammonia refrigeration system scheduled for installation and start-up at the Bakersfield facility in July, 1993. This Page 1 Hazard Analysis has been prepared in accordance with EPA/FEMA/USDOT document "Technical Guidance for Hazards Analysis: Emergency Planning for Extremely Hazardous Substance, 1987" and the Bakersfield Fire Department, Hazard Material Division's Risk Management and Prevention Program Preparation Guidelines, Form FD1593. The RMPP has also been updated with the results of this Hazard Analysis and is provided under separate cover. This Hazard Analysis has been prepared as a necessary step in comprehensive emergency planning for Crystal Geyser, its employees and the surrounding community. Comprehensive planning depends upon a clear understanding of what hazards exist and what risk they pose for employees and various members of the community. The analysis represents a means of evaluating potential hazards resulting from the accidental release of an AHM. The three basic components in the Hazard Analysis are (1) hazard identification, (2) vulnerability-analysis, and (3) risk analysis. The hazard identification process, the first step in hazard analysis, focuses on collecting information on: Type and quantity of hazardous materials used and stored at the facility; Physical location of hazardous materials used and stored within the facility; · Potential hazards associated with hazardous material releases; Conditions of operation, storage, loading, processing and using hazardous materials (Hazard and Operability Study); and Transportation routes and methods used for transporting hazardous materials. Page 2 The vulnerability analysis provides information helpful in planning requirements that include: An estimation of the vulnerable zone with air dispersion modeling using AHM concentrations that represent the Immediate Danger to Ufe and Health (IDLH) and the EPA Level of Concern (LOC) along with the conditions and assumptions that were used to estimate each vulnerable zone; The population, in terms of numbers and types (e.g., neighborhood residents, high density transient populations such as stadiums or auditoriums; sensitive populations in hospitals, schools, nursing homes and day care centers) that could be expected to be within the vulnerable zones; and Essential service facilities such as hospitals, police and fire stations, emergency response centers, and communication facilities. Risk analysis is the third part of the hazard analysis process. This risk analysis provides a relative measure of the likelihood and severity of various possible hazardous events. A risk analysis matrix (Exhibit 2) is used as guidance for putting each potential situation into perspective (in terms of the probability that it will occur and the resulting effects it will have) and addresses the most likely and most severe potential hazards. Page 3 II. HAZARDS IDENTIFICATION Ao Identification of AHM Ammonia, as shown in Crystal Geyser's Business Plan (Appendix I), is stored and used in reportable quantities to the Bakersfield Fire Department, Hazardous Material, Division. Quantity of AHM The new ammonia system has been designed to be charged with and operate on a maximum 4900 pounds of ammonia. C. Location of AHM The overall refrigeration plans show the location of all the ammonia equipment, vessels and piping, both in plan and elevation view of the facility in drawing Numbers 92329 R1 and 92329 R3 (Exhibits 3 and 4, respectively). The ammonia compressors, high pressure receiver and glycol chiller, ail new equipment, are located inside the newly constructed compressor room. The only remaining equipment from the old refrigeration system, the carbo coolers, remain in the existing indoor receiver room. The evaporative coolers are located outside on top of the compressor room. The only other equipment located outside is the supply and return lines of the ammonia system between the compressor room and the carbo coolers in the receiver room and the Fire Department Emergency Refrigerant Control Box with associated vent lines to the emergency ammonia diffusion tank. Only during initial filling or refilling of the system or rare times where all the ammonia must be isolated back to the high pressure receiver shall the high pressure receiver retain all 4900 pounds of ammonia. Under normal operating Page 4 INC. conditions, a minimum quantity of liquid ammonia is retained in the high pressure receiver with the bulk of liquid ammonia being spread out to the other components of the system such as the condensers, compressors, glycol chiller and pipelines. D. Potential Hazards of an AHM Release The term "anhydrous ammonia" refers to the compound having the formula NH3, formed by the chemical combination of nitrogen and hydrogen. Appendix II contains a copy of a Material Safety Data Sheet (MSDS) for anhydrous ammonia. Whenever the term "ammonia" appears in this Hazard Analysis it should be understood as meaning anhydrous ammonia and not aqua ammonia, aqueous ammonia or ammonium hydroxide which are solutions of ammonia in water. Ammonium hydroxide solutions generally range in concentrations of ammonia from about 30% down to the 2 to 4% found in the Well known household ammonia. These solutions are all commonly known as ammonia, but should not be confused with liquid anhydrous ammonia which has a much greater hazard potential. "Anhydrous" means "free from water". The physical properties of ammonia are provided in Table 1. At room temperature and atmospheric pressure, ammonia is a pungent, colorless gas approximately 40% lighter than air. Compressed and cooled, ammonia gas condenses to a colorless liquid about 68% as heavy as water. At atmospheric pressure, the liquid boils at -28F. 1) Primary Hazards Ammonia acts as an irritant to human tissue in varying degrees depending upon concentration and exposure. Page 5 The pungent and distinctive odor of the vapor, even at Iow concentrations, provides adequate warning so that no person will voluntarily remain in concentrations which are hazardous. Ammonia is NOT a cumulative metabolic poison; ammonium ions are actually important constituents of living systems. Depending upon concentration and time, the effects of exposure to ammonia vapor vary from none or only mild irritation, to obstruction of breathing from laryngeal and bronchial spasm, to edema and severe damage of the mucous membranes of the respiratory tract with possible fatal results. Exposure levels of ammonia vapor which are tolerated by some persons may produce adverse reactions in others. The following table, Physiological Effects of Ammonia Vapor, indicates human physiological response to various concentrations, in parts per million (ppm), of ammonia in air upon inhalation. PHYSIOLOGICAL EFFECTS OF AMMONIA VAPOR PPM Ammonia in Effect Air by Volume Lease perceptible odor .................................................................................................... 5 ppm Readily detectable odor ........................................................................................... 20-50 ppm No discomfort or impairment of health for prolonged exposure ........................... 50-100 ppm General discomfort ahd eye tearing no lasting effect on short exposure ....... 150-200 ppm Severe irritation of eyes, ears, nose and throat; no lasting effect on short exposure .................................................... [ .............................. 400-700 ppm Coughing, bronchial spasms .................................................................................. 1,700 ppm Dangerous, less than 1/2 hour exposure may be fatal .............................. 2,000-3,000 ppm Serious edema, strangulation, asphyxia, rapidly fatal ............................... 5,000-10,000 ppm Immediately fatal ............................................................................................ over 10,000 ppm (From 'Anhydrous Association, Inc.) Ammonia', Pamphlet G-2 Seventh Edition, Compressed Gas Page 6 For use in this Hazard Analysis, the following concentrations will be used for: LOC (level of concern) IDLH (immediate danger to life and health) = 50 ppm = 500 ppm 2) Other Hazards a) Liquid ammonia boils at -28F under atmospheric conditions, acting as a refrigerant to remove heat form any warmer object it may be contacting. Accordingly, liquid ammonia in contact with the skin can cause frostbite. b) Liquid ammonia exhibits a high coefficient of cubical expansion. A given quantity of liquid ammonia therefore expands considerably in volume with a rise in temperature, as shown in the following table: VAPOR PRESSURE AND VOLUME OF LIQUID AMMONIA AT VARIOUS TEMPERATURES Temperature Degrees F Vapor Pressure psig Volume Gal/CWT -28 0.0 17.57 0 15.7 18.10 30 45.0 18.72 60 92.9 19.43 90 165.9 20.25 115 251.5 21.04 130 315.6 21.58 (Data derived from U.S. Bureau of Standards Circular No. 142) Page 7 For this reason, appropriate measures must be taken to avoid hydrostatic rupture of containers, piping or other equipment as could be caused by such expansion. Eo c). Ammonia vapor, although classified by the U.S. Department of Transportation as a NONFLAMMABLE GAS, in the presence of a flame or spark will ignite, but only within the limited range of 16-25% of ammonia in air by volume. The heat generated by combustion is insufficient to maintain a flame which therefore will extinguish upon ignition source removal. Hazard and Operability (HazOp) Study 1) Study Guideline A HazOp study was performed on the new ammonia system including the carbo coolers to identify hazards and operability problems encountered in the operation, maintenance, filling and replenishing of the system. The concept involved investigating how the plant might deviate from the design intent. A HazOp team was assembled to review, in a series of meetings, the ammonia system design and operation using a structure provided by "guide words" and the team's experience. The HazOp team was made up of the following four people with their respective areas of experience: Team Leader: Gary Fuller, Mechanical Engineer, has over fifteen years of experience in managing large manufacturing facilities. · His expertise includes operations management, process development control, environmental control, quality assurance and Page 8 engineering. Mr. Fuller has performed hazard analyses, consequence analyses and implemented hazard communications programs at manufacturing facilities in both Kern County and the San Francisco Bay Area. Team Member: Alex Manns, Plant Manager, was on the original hazard analysis team at Crystal Geyser which was previously acceptable to the City of Bakersfield. He has been at Crystal Geyser for 4 years and is knowledgeable in the operation and maintenance of ammonia systems. At Crystal Geyser, this includes piping layout, liquid ammonia shut off valves, ammonia safe handling practices and has been trained in the use of Crystal Geyser's ammonia diffusion system. Mr. Manns has been properly trained in the use of self contained breathing apparatus units at the facility and can initiate an emergency response to an incident. Previous to Crystal Geyser, Mr. Manns was Plant Manager at Calvin Coolers for 5 years. Team Member: Dave Butt, Process and Hazard Evaluation, has prior experience on ammonia hazards and operability teams, including Pepsi and Kern Ice and Cold Storage in the City of Bakersfield and Dairyman's Cooperative Creamery in the City of Tulare. In addition, his 29 years of experience is in the design and construction of process equipment such as compressors, high pressure systems, valves, and chemical storage tanks. Page 9 Team Member: Norman Ambrose, Maintenance Supervisor at Crystal Geyser for 4 years, was on the original RMPP team and participated on the team in a similar manner. He has 27.5 years of maintenance experience in the bottling and winery business. The team focused on specific points of the design (called "Study nodes") one at a time. At each of these study nodes, deviations in the process parameters are examined using the guide words. The intention of how the ammonia system is expected to operate in the absence of deviations at the study nodes is shown in the process flow depicted on the Ammonia Piping Schematic Drawing No. 92329 R1 (Exhibit 5) and Piping Isomeric Drawing No. 92329 R4 (Exhibit 6). The individual study nodes have been blocked out and highlighted on the Piping Schematic, shown in Exhibit 5. These Study Nodes included: 1) 2) 3) 4) 5) 7) 8) 9) High Pressure Receiver. Compressor packages (3). In Une Filters (2). Evaporative Condensers (3). Glycol Chiller, including Glycol Chiller Suction Trap and Master Accumulator. Carbo Coolers. Ammonia Receiving. Ammonia Lines. Fire Department Emergency Refrigerant Control Box with Sparge System and Diffusion Tank. In addition, the hazards of potential ammonia releases associated with the process of draining oil from the ammonia refrigerant system has been analyzed. The findings have been documented and supplied in Appendix Page 10 V, study node number 10. The potential hazards associated with the operation of the computer control system, including potential failures and manual overrides has also been analyzed with the finding documented in Appendix V, study node number 11. Specification of this equipment, including make, model, manufacturer, and data. certification sheets, are provided in Appendix III. The new refrigeration system has many features such as the ammonia dump, system, emergency stop switches, vent and room ammonia sensors, systems alarms, etc., that are the intended design for normal operation. A description of the intended operation and functions of these ammonia alarm and controls are provided in Appendix IV. The new ammonia system has been designed to operate continuously 24 hours per day 7 days per week. The intent is that under normal operation, the liquid ammonia boils in the glycol chiller and the carbo cooler. It is this boiling action that supplies the required refrigeration. In order to keep the cycle going, the ammonia vapor must be compressed by the screw compressor and cooled by the evaporative condenser in order to condense it back to a liquid. The liquid now drains back to the receiver where it is stored until it is needed. This process continues as long as there is a need for refrigeration. The process flow'0f .ammonia, shown in Exhibits 5 and 6, start with liquid ammonia that is stored in the receiver. As it leaves the receiver it passes through a KING solenoid valve. The liquid ammonia is piped to the master accumulator where it is used to boil off any excess ammonia. Next, it leaves the master accumulator and-goes to the glycol chiller and the carbo coolers. Each of these units control the.ammonia using a series of float sWitches. Each Unit has an operating float switch and a solenoid valve. Page 11 VVZI INC. When the correct level is reached the flow of ammonia is turned off. If the level gets too high it will be caught in the master accumulator. A master high level float switch will shut down the entire refrigeration system. Gaseous ammonia enters the compressors and is compressed to a higher pressure and temperature. After exiting the compressors, the hot gaseous ammonia enters the evaporative condenser. Water running over the condenser coils cool the hot gaseous ammonia into liquid ammonia. The liquid ammonia then returns to the high pressure receiver located inside the compressor building. For the carbo coolers, the liquid ammonia flows through the injectors pulling liquid ammonia from the surge vessel into the coils of the carbo cooler and pre-chiller deaerator. The liquid ammonia absorbs heat from the carbo cooler and pre-chiller deaerator and flows to the ammonia surge vessel as a liquid/gaseous phase. Gaseous ammonia from the ammonia surge vessel flows to the ammonia suction trap. The suction trap prevents liquids from returning to the compressors. The gaseous ammonia is then pulled into the compressor suction. Deviations or departures from the intention of the normal or expected operation were reviewed in the study nodes by systematically applying the guide words (e.g. "no pressure, "high pressure", etc.) to the process and design parameters. Also investigated in the study nodes were the causes or reasons why these deviations might occur and ff they were meaningful. These causes would be hardware failures, human errors, external disruptions (e.g. 'loss of power, earthquake), etc. Plus the consequences of the deviations should they occur, were reviewed. Trivial consequences, relative to the study objective, were dropped. Page 12 The "guide words" used in the study nodes are simple words used to identify, qualify or quantify possible deviations. The following guide words will be used in the HAZOP study: Guide WOrd Example Meanin,q No Less More 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 Negation of Design Intent Quantitative Decrease Quantitative Decrease Qualitative Decrease Qualitative Increase Logical Opposite of the Intent Substitution from Design Human error analysis was also included in the HazOp study and applied to the study nodes. The purpose of the human error analysis is to identify potential human errors and their effects. Causes of human errors that have occurred in the past may also be identified. Potential areas for operator/human error included: · inadvertent closing or opening any valve · improper or neglected maintenance · accidental damage caUsed by fOrklift operator · improper operation of control system Page 13 The HazOp forms used in the study nodes are provided in Appendix V. Shown on these forms were the guide words used with the possible deviations, including human errors, along with the causes and consequences of such deviations. 2) Study Results Each study node was reviewed for possible deviations from normal operation, and potential consequences resulting from the deviations were recorded. The severity and probability of consequences were then rated. The results of these ratings for each possible deviation considered in the study nodes are recorded on the HazOp Forms provided in Appendix V. In summary, the worst case AHM release event was that due to a significant seismic event. This case involves the release of liquid ammonia from a broken line connected to the high pressure receiver (Study node number 1) when filled with 4900 pounds of ammonia. Pictures showing the high pressure receiver and the associated piping are shown in Exhibit 7. The probability of. occurrence was defined as Iow or considered unlikely during the lifetime of the facility assuming normal operation and maintenance. The severity of the exposure to people was defined as high or the release of ammonia is expected to move into the surrounding environment in concentrations sufficient to cause serious inquiries and/or deaths upon exposure. The main reason the probability was considered Iow was the fact that the high pressure receiver would rarely ever be filled with the entire 4900 pounds of ammonia. The second worst case AHM release event was basically the same as the high pressure receiver but was due to an earthquake causing a liquid ammonia line break on the glycol chiller (Study node number 5), releasing 2000 pounds of ammonia. The chiller will contain the greatest amount of Page 14 liquid ammonia of the entire refrigeration system under normal operation. The glycol chiller and associated piping are shown in the pictures in Exhibit 8. Again the possibility was considered Iow and the severity was rated high. The third worst case AHM release event was considered a liquid ammonia line break in the liquid ammonia supply line from the compressor room to the carbo coolers located in the receiving room. It is a 1" diameter special ammonia schedule 80 pipe approximately 150 feet long, with a potential to release 26 pounds of liquid ammonia. Other items to note from the HazOp study are as follows: Location of equipment in compressor room is such, that it was recommended that a guard rail be installed on the west side of the equipment between the north and south walls of the compressor room. Sparge tank be equipped with automatic level control or checked on a regular basis to ensure water is maintained at the required level. Fire Department Emergency Refrigerant Control Box be equipped with a lock to prevent tampering or inadvertent opening of dump valve(s). Level indicators on high pressure receiver, due to location of receiver, are inconvenient to read. Propose to install remote electric eye to sense level in receiver. Page 15 Recommended to hook-up to Monitoring Company Such as Tel Tec, for 24 hour surveillance on Ammonia Alarm system, with qualified Ammonia systems operator on call. F. Transportation Methods Ammonia will be tranSported to the facility by highway in pressure containers as a liquified compressed gas at ambient temperatures. The initial filling of the refrigeration system will require 4900 pounds of ammonia. It is not anticipated the system will need replenishing very often and therefore no extra ammonia will be stored on site as was done previously. Ammonia will be delivered on an as needed basis. III. VULNERABILITY ANALYSIS An estimation of vulnerable zones with air dispersion modeling using AHM concentrations that represent the IDLH and LOC was performed for three different AHM release scenarios. These ammonia release events represent the three "most likely hazards" as defined in the Bakersfield Fire Department's Hazardous Materials Division Risk Management and Prevention Program Preparation Guidelines. Although all three cases have a Iow probability of release, each event poses a high off-site consequence. These three AHM releases are as discussed previously in the HazOp study results. The worst case release, as determined through the Hazard and Operability Study, was found to be a potential release of the liquid contents of an inside ammonia storage vessel into the atmosphere. The potential release scenario determined to be dangerous to off-site receptors is a release of ammonia during an earthquake. Lines from the ammonia receivers located inside the building (Exhibit 7) contain liquid ammonia. A break in the liquid Page16 ammonia lines could release all the ammonia in a storage vessel to the atmosphere. In this potential worst case scenario, the rapid release of liquid ammonia could form an air/ammonia dispersion that would act as a cloud of dense gas. The Automated Resource for Chemical Hazard Incident Evaluation · (ARCHIE) computer program was used to model the theorized worst case or releases. The Handbook of Chemical Hazard Analysis Procedures (FEMA, U.S. DOT and U.S. EPA, 1989) was also used as a guideline for modeling. The ARCHIE computer program offers a selection of hazard assessment modeling options. Option a, "Estimate Discharge Rate of Liquid or Gas", was used to model the release of ammonia into the atmosphere. This model was chosen because the potential worst case scenario involves the emptying of a storage vessel through open lines. Option d, "Evaluate Toxic Vapor Dispersion Hazards", was used to model the dispersion hazard of the potential release of ammonia into the atmosphere. The ARCHIE computer program recommends that hazard evaluations for emergency planning purposes should strive to assume the worst reasonable and credible conditions. Thus, the following, most pessimistic atmospheric conditions were chosen for modeling purposes for case number 1, 2 and 3. Atmospheric Stability Class F Generally considered the most hazardous atmospheric condition for toxic gas releases, the stability of Class F results in minimal dispersion of the potential ammonia release and will only occur at night. Page 17 * Windspeed = 4.5 mph Low windspeed results in longer fumigation times and further downwind distances. Windspeed for Class F conditions ranges from 4.5 - 6.7 mph. * Ambient Temperature = 70°F Class F conditions occur at nighttime. The warmest ambient nighttime temperature for Bakersfield is 70°F (July). In addition, the following, more likely atmospheric conditions were also chosen for modeling purposes for cases 4, 5 and 6. Table 2 contains mean wind speeds and prevailing Wind directions for the Bakersfield area. Climatological data was gathered at Meadows Field Airport and compiled by the National Climatic Data Center. * Atmospheric Stability Class B The most probable daytime atmospheric condition given the average ambient temperature and average windspeed for Bakersfield. * Windspeed = 6.4 The annual average windspeed for Bakersfield. * Ambient Temperature -- 77.7°F The annual average ambient daytime temperature for Bakersfield. Page 18 A. Summary of Modeling Results A summary of the modeling results are tabulated below followed by a brief synopsis of each case. A computer generated hard copy of the model input and output data files for all six cases are attached in Appendix VI. I Amount of Arrival time Case Ammonia Radius of to IDU-I Radius of Arrival time Number released IDLH Radius LOC to LOC (Pounds) (Miles) (Minutes) (Miles) (Minutes) Case 1' Represents discharge from a broken, 2.5" ID liquid ammonia line off the high pressure receiver (4900 lb liquid ammonia release) with worst case atmospheric conditions. Scenario results have been plotted in Exhibits 9 and 10. Case 2: Represents discharge from a broken, 1 1/4" I.D. liquid ammonia line off the ammonia chiller (2000 lb liquid ammonia release) with worst case atmospheric conditions (Exhibit 11). Case 3: Represents discharge from broken, 1" I.D. liquid ammonia line (26 .~% - lb liquid amr~onia release), approximately 150" long, between carbo coolers and compressor room with worst case atmospheric conditions (Exhibit 11). Page 19 Case 4: Same as Case 1 except with the most likely atmospheric conditions (Exhibit 12). Case 5: Same as Case 2 except with most likely atmospheric conditions (Exhibit 13). Case 6: Same as Case'3 except with most likely atmospheric conditions (Exhibit 13). Bo Receptor Locations The community surrounding the Crystal GeYSer 'facility is shown in Exhibit 14; immediately surrounding the facility to the South is a residential apartment complex. Sensitive receptors located near the facility include: Approximate Distance Receptor (miles) Direction Owens School 0.38 Special Services School 0.44 Our Lady of Guadalupe School 0.69 Williams School 0.69 Mt. Vernon School 0.94 Bethel Christian School 1 SW ENE W NE ESE E These school locations are shown on Exhibit 15. Page 20 C. Essential Service Facilities The essential service facilities located near Crystal Geyser are: Kern Medical Center 1830 Flower Bakersfield, California Telephone: (805) 326-2000 Bakersfield City Fire Department, Station #2 716 East 21st Bakersfield, California Telephone: 911 Page 21 IV. RISK ANALYSIS A. Summary of On-site and Offsite Consequences A summary of the on-site and off site consequence analysis are as follows: Failure On-site Offslte Event/Hazard Probability Consequence 'Consequence 1) Earthquake 4900 (lb) Iow high high NH3 release 2) Earthquake 2000 (lb) Iow high high NH3 release 3) Earthquake 26 (lb) Iow high high NH3 release 4) Improper oil drain from glycol chiller NH3 release. Iow high high 5) Compressor Worn Seals NHa Vapor release medium Iow Iow 6) Power Failure release of NH.~ to diffusion tank medium Iow Iow Use of the definitions of High, Medium, or Low were from Bakersfield Fire Department's Hazardous Material Division Risk Management and Prevention Program Preparation Guidelines and are shown in Exhibit 2. From the HazOp study, the only probability of an AHM release considered greater than a Iow probability was an AHM release resulting from worn seals on the compressor or operator error on the restarting system after a power failure. Page22 Although the probability of occurrence of these releases is possible during the expected lifetime of the facility, the expected release of ammonia is expected to move, if at all, onto the surrounding environment in negligible concentrations. Based upon the RMPP guidelines definition of the "most likely hazards, AHM release or accidents which poses a danger to persons off site", the most likely hazard was determined to be the complete release of 4900 pounds of liquid ammonia due to a significant seismic event. Since the Iow consequence events are not a source of danger, the Iow probability releases with a high off site consequence will be considered the most likely hazard. These are combinations of concern (a Iow probability with a high consequence) which may require planning for credible events as shown in the Risk Analysis Matrix (Exhibit 2))i Page 23 TABLE 2 BAKERSFIELD AREA MEAN WIND SPEED AND DIRECTION Month Wind Speed (mph) Wind Direction January 5.2 NW February 5.8 ENE March 6.5 NW April 7.1 NW May 7.9 NW June 7.9 NW July 7.2 NW August 6.8 NW September 6.2 WNW October 5.5 NW November 5.1 ENE December 5.0 ENE The yearly average mean wind speed is 6.4 mph, originating from the Northwest. RISK ANALYSIS MATRIX LOW MEDIUM HIGH Combinations of Conclusions From Risk Analysis that Identify SituAtions ol Major Concern Combinations that Identity Sil. uations ot Considerable Concern Combina, ti'ons ol Concern Which.may Require Planning lot Credible Events Severity of Consequences Due to AHM Release (From RMPP Guidance for the Preoaration of a Risk Management and Prevent{on Pro,am, November, 1989, California Office of Emergency Services.) LOW: lvEEDIUM: HIGH: LOW: M]EDILr/vi: HIGH: QUALITATIVE DEFINITIONS'OF PROBABILITY OF OCCURRENCE Probability. of occurrence considered unlikely during the expected lifetime of the facility assuming normal operation and maintenance.. Probability of occurrence considered possible during the expected lifetime of the facility. Probability. of occurrence considered sufficiently high to assume event will occur during the expected lifetime of the facility DEFINITIONS OF SEVERITY OF CONSEQUENCES TO PEOPLE Chemical is expected to move into the surround~g e'nv'i.ronment in negligible concentrations. Injuries expected q.nly for exposure over emended periods or when individual personal health conditions create complications. Chemical is expected io move into the surrounding environment in concentrations sufficient to cause serious injuries and/or deaths unless prompt and effective corrective action is taken. Death.· and/or injuries expected only for ~'xpbsure over emended periods or when indMdual per~onal health conditions created complicatibns. Chemical ks expected to move into the surrounding environment in concentrations sufficient to cause serious injuries and/or deaths upon exposure. Large numbers o[ people expected m be affected. · (From thc EPA Technical Guidance for Hazard Analysis, 1987) Form FD 1593 EXHIBIT 2 - -- O.q3~ 0011A HAZOP FORM: CRYSTAL GEYSER J~,_,~. Iqq'5 Slud¥ Node Number: I Equipmenl: I-t~ ~,"~.~-~'-~ (~'~ ~ Guide Consequences ilesulllng Irorn a Causes ol lhe * Prob- Proposed Word Devlallon Devlallon from Normal Operallon Devlallon Severlly ablllly** Conlrols In Place MIIIgallon Descdplion of Equipmenl Operation ~ '?_.~o(~.t~'') ~ ~,,~2.. - ~"/,%'" 'tO ,< IqA"o. ~ , '...~::,d.3~'~ ~ _~O~,., 15~'5 · Severily: Low (injuries unlikely), Medium (may cause injuries or dealh unless corrective measures are taken), ttigh (expecled Io cause injury or dealh to receplors) "Probabilily: High, medium or /ow HAZOP FORM: CRYSTAL GEYSER Ou~- Ftg~ Slud¥ Node Number: ¢3. Equipment: ~ ~ (.~ Guide Consequences'Resulltrtg Item a Causes o! the * Prob- Proposed' Word Devlallon Devlallon from Normal Operation Deviation Severity ablllly** Conlrols In Place M!!lgallon Description o! Equipment Operation ( ! 'Severily: Low (injuries unlikely), Medium (may cause injuries or dealh unless corrective measures are laken), High (expecled Io cause injury or dealh Io receplors) "Probabilily: High, medium or Iow HAZOP FORM: CRYSTAL GEYSER Consequences Resulllng Irom a Deviation Devlallon from Normal O Sludy Node Number: ~, Equipmenl: ~ j~ F'~ Causes of the · Prob- Deviation Controls In Place Proposed Descriplion o~erati°n ' ~'~ ' ' ' - ' ' ' Low (~nju ' ' ' ' · Severily: ~ . ~ 19~ ]' '*Probabilily: High, medium or Iow HAZOP FORM: CRYSTAL GEYSER J,,.,.~ \q~ Slud¥ Node Number: 4/ Equipmenl: ~ ('.~) Guide Consequences Resulling from a Causes of Ihe * Pro'b- Proposed ..Word Devlallon Devlallon from Normal Operation Devlallon Severity ablllly** Conlrols In Place Mitigation Mo~e F~ P~ . ~IF Description ol Equipmenl Operation 'Severily: Low (injuries unlikely). Medium (may cause injuries or dealh unless corrective measures are laken), High (expecled Io cause injury or dealh Io receplorsJ °'Probabilily: High, medium or Iow HAZOP FORM: CRYSTAL GEYSER Consequences Resulllng from a Devlallon Devlallon from Normal C] Sludy Node Number: ~" Causes of the Deviation Equipmenl: '~ ~ Prob- Conlrols In Place Proposed 'Severily: Low (injuries unlikely), Medium (may cause injuries or death unless correclive measures are laken), High (expecled Io cause injury or dealh !o ~eceplors) °'Probabilily: High, medium or Iow HAZOP FORM: Deviation CRYSTAL GEYSER~u,,~ i,t~t~ Sludy Node Number: Cor~sequences Resullir~g lrom a Deviation Irom Normal O[r)eratlo!].. p,,,,,~ Causes ol tile Devlallon Equipment: Prob- ) blllty'~* Severity Controls In Place Proposed Mlllgatlon 'Severity: Low (injuries unlikely), Medium (may cause injuries or death unless correcti, ve measures are taken), Itigh (expec!ed to cause injury or death Io ~eceptors) "Probability: tligh, medium ot Iow H Node Number: 1 Equipment: ~ulde -Consequences Resulllng from a Causes o[ Ihe ~ Prob- Proposed Word Devlallon Devlallon from Normal OEerallon Deviation Severlly ability** Conlr~ls In Place MIIIgallon ~SS ~~ o~e ~ ' ' '~ ~ Ihor _z~.zz_~..~o'~-~ c~ ~ ~' .... - i ........... ~ecfive m,' res are laken R-ti h (expecled Io cause injury or dealh Io ~'eceplors)~ -.~' ' 'Severity: Low (injuries unlikely), Medium (may cause injuries or oeam u.,u:, ......... .- ~as.u ), g HAZOP FORM: CRYSTAL GEYSERt)o~,, I'~ S~.dy Node Number: ~ Equipmenl: ~ ~ Guide Consequences Flesulllng Irom a Causes of Ilie * Prob- Proposed" Word Devlallon Deviation from Normal Operallon Devlallon Severity. .ab!..!lly** Controls In Place Mlll(:jallon Uore ~0~,.o .... Description ol Equipment Operalion ./~ ~, ~ ~'/'z. ;,,eool.,.~-.~& f:tO ,..,.,,..V~ ~ ~ ~~ . ,~~ ~~ 'Severily: Low (injuries unlikely), Medium (may cause injuries or dealh unless correclive measures are laken), tligh (expecled Io cause injury or dealh Io receplors) '"Probabilily: tligh, medium or Iow HAZOP FORM: CRYSTAL GEYSERuI~,.,- I'I~5 Consequences Resulllng from a Deviation i Deviation from Normal 0 Sludy Node Number: Causes el Ihe Devlallon -"-"- ........ ~" "'--- --'=' Proposed * Prob- ~ ~ Controls In Place MIll all_,q_~ Description o~erati°n ' 'Sevedly: °'P¢obabilily: High. medium or Iow HazOp - Crystal Geyser Study Node Number 10 August 1993 Equipment/Process Description - Oil Drainage from Ammonia System There are two places which to check and remove oil form the ammonia refrigerant system. The most common place from which to remove oil is from the oil separators located next to the ammonia compressors in the compressor room. If oil gets past the oil separators it will accumulate and can be removed from the bottom of the glycol chiller, also located in the compressor room. Normal operating procedures require that only qualified personnel, properly trained, are allowed to remove oil from the system. The system has been designed to normally capture and remove oil from the ammonia in the oil separators. The oil separators are equipped with isolation valves that will allow for the safe removal of oil from the separators. When trained personnel are performing this task, normal operating procedures call for the compressor room to be put into the emergency ventilation mode. Normal operating procedures also require that all oil during be done into a 5 gallon bucket of water, which will absorb ammonia that is released with the oil. Though it is not expected, if oil gets past the separators it will accumulate in the bottom of the glycol chiller. The same normal operating procedures apply for removing oil from the glycol chiller as they do for the oil separator. The following deviations from normal operation of draining oil, along with the possible causes of the deviations, resulting consequences, severity, probability and controls in place have been identified on the following page. Haz Op - Crystal Geyser Study Node 10 DEVIATION CONSEQUENCES. CAUSES SEVERITY PROBABILITy, CONTROLS IN PLACE Isolation Release of ammonia Untrained personnel High Low Training personnel/ valves not performing work emergency ventilator closed No water used Release of ammonia Untrained personnel Low Low Training procedures to drain oil into performing work No emergency Uncontrolled ammonia Human error Low Low Training procedures vent mode emissions 03320011.010 HazOp - Crystal Geyser Study Node Number 11 August 1993 Equipment/Process Description - Operation of Control Systems Operating Procedures and a description of the computer control panel and systems is provided in the Hazard Analysis, Appendix III. The system basically consists of Control panel R-l, Control panel R-2 and the computer control panel. R-l, the main refrigeration control panel, supplies power to the compressors, evaporative condenses and glycol pumps. The power to this panel may be turned off while still maintaining power to the R-2 and Computer control panel. This feature allows the ammonia system to be shut-down while still keeping emergency ammonia sensing devices along with room exhaust and scrubbing control systems still active. All equipment switches, with the exception of the emergency stop switch, can only be set in either a manual or automatic mode. This design feature along with installed interlocking mechanisms will always start the evaporative coolers if the compressors are running. For these reasons, potential failures or manual overrides of the computer control system have been assigned a Iow probability with a Iow severity rating. O332OO11.012 HAZARDOUS MATERIAL ADDRESS ~ LOCATION DATE OF ASSESSMENT NAME O~~ DISK FILE = ANHYDROUS AMMONIA = CRYSTAL GEYSER = JULY 1, 1993 = CRYSTAL2.ASF *** SCENARIO DESCRIPTION DISCHARGE OF 4900 LB PRESSURIZED AMMONIA VESSEL TO THE ATMOSPHERE ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate Duration of discharge Amount discharged State of material = 8103.4 lbs/min = .605 minutes = 4900 lbs = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 16873 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 1000000 1000000 73. 1299 .25 131256 131256 950 2497 .48 37538 37538 1820 3695 .7 16078 16078 2690 4893 ..93 8523 8523 3570 6091 1.16 5157 5157 4440 7289 1.39 3409 3409 5310 8487 1.61 2400 2400 6180 9685 1.84 1771 1771 7050' ~3 10883 2.07 1355 1355 7930 12081 2.29 1067 1067 8800 13279 2.52- 861 861 9670 14477 2.75 707 707 10540 15675 2.97f 591 591 11420~. 16873 3.2 . 500 ~500 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts may require a larger width or different direction for.the evacuation zone. See Chapters 3 and 12 · of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .3 1.2 1299 .25 3.3 7.2 2497 .48 6.4 13.3 3695 .7 9.4 19.3 4893 .93 12.4 25.4 6091 1.16 15.4 31.4 7289 1.39 18.5 37.5 8487 1.61 21.5 43.5 9685 1.84 24.5 49.6 10883 2.07 27.5 55.6 12081 2.29 30.6 61.7 13279 2.52 33.6 67.7 14477. 2.75 36.6 73.8 15675 2.97 39.6 79.8 16873 3.2 42.7 85.9 CAUTION: See guide for assumptions used in estimating these times. iNPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES'AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 degrees F = 17 = .52 = 150 psia = 7761 mm Hg = 500 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE TOTAL WEIGHT OF CONTENTS WEIGHT OF LIQUID LIQUID HEIGHT IN CONTAINER WEIGHT OF GAS UNDER PRESSURE TOTAL CONTAINER VOLUME LIQUID VOLUME IN CONTAINER VAPOR/GAS VOLUME IN CONTAINER = DISCHARGE HOLE DIAMETER = DISCHARGE COEFFICIENT OF HOLE = TEMP OF CONTAINER CONTENTS = = Horizontal cylinder = 4900 lbs = 2000 lbs = 2.8 feet = 67 lbs = 201.1 ft3 = 1504 gals = 61.7 ft3 = ~461.6 gals 139.5 ft3 2.5 inch(es) .62 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 WIND VELOCITY = 4.5 ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL ADDRESS \ LOCATION DATE OF ASSESSMENT NAME OF DISK FILE = ANHYDROUS AMMONIA = CRYSTAL GEYSER = JULY 1, 1993 = CRYSTAL2.ASF *** SCENARIO DESCRIPTION DISCHARGE OF 4900 LB PRESSURIZED AMMONIA VESSEL TO THE ATMOSPHERE ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate Duration of discharge Amount discharged State of material = 8103.4 lbs/min = .605 minutes = 4900 lbs = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALysIs RESULTS Downwind distance to concentration of 50 ppm -- at groundlevel = 48275 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 1000000 1000000 73 3542 .68 17664 17664 2580 6983 1.33 3764 3764 5090 10424 1.98 1496 1496 7590 13865 2.63 780 780 10100 17306 3.28 473 473 12600 20747 3.93 315 315 15110 24188 4.59 224 224 17610 27629 5.24 167 167 20120 31070 5.89 130 130 22620 34511 6.54 103 103 25130 37952 7.19 83.7 83.7 27630 41393 7.84 69.5 69.5 30140 44834 8.5 58.6 58.6 32640 48275 9.15 50 50 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .3 1.2 3542 .68 9 18.5 6983 1.33 17.7 35.9 10424 1.98 26.4 53.3 13865 2.63 35.1 70.7 17306 3.28 43.8 88.1 20747 3.93 52.4 . 105.4 24188 4.59 61.1 122.8 27629 5.24 69.8 140.2 31070 5.89 78.5 157.6 34511 6.54 87.2 175 37952 7.19 95~9 192.3 41393 7.84 104.6 209.7 44834 8.5 113.3 227.1 48275 9.15 122 244.5 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 = 17 = .52 = 150 = 7761 = 50 degrees F psia mm Hg ppm CONTAINER CHARACTERISTICS CONTAINER TYPE TOTAL WEIGHT OF CONTENTS WEIGHT OF LIQUID LIQUID HEIGHT IN CONTAINER WEIGHT OF GAS UNDER PRESSURE TOTAL CONTAINER VOLUME LIQUID VOLUME IN CONTAINER VAPOR/GAS VOLUME IN CONTAINER = DISCHARGE HOLE DIAMETER = DISCHARGE COEFFICIENT OF HOLE = TEMP OF CONTAINER CONTENTS = = Horizontal cylinder = 4900 lbs = 2000 lbs = 2.8 feet = 67 lbs = 201.1 ft3 = 1504 gals = 61.7 ft3 = 461.6 gals 139.5 ft3 2.5 inch(es) .62 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 WIND VELOCITY = 4.5 ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL ADDRESS \ LOCATION DATE OF ASSESSMENT NAME OF DISK FILE = ANHYDROUS AMMONIA = CRYSTAL GEYSER , BAKERSFIELD = JULY 1, 1993 = CRYSTAL3.ASF *** SCENARIO DESCRIPTION DISCHARGE OF 2000 LB PRESSURIZED AMMONIA VESSEL TO THE ATMOSPHERE ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate Duration of discharge Amount discharged State of material = 2024.6 lbs/min = 1.02 minutes = 2049 lbs = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 11353 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 . .02 1000000 1000000 73 904 .18 61634 61634 660 1708 .33 20971 20971 1250 2512 .48 10952 10952 1830 3315 .63 6659 6659 2420 4119 .79 4390 4390 3000 4923 .94 3064 3064 3590 5727 1.09 2235 2235 4170 6530 1.24 1689 1689 4760 7334 1.39 1313 1313 5340 8138 1.55 1046 1046 5930 8942 1.7 850 850 6510 9745 1.'85 703 703 ~ 7100 10549 2 589 589 7680 11353 2.16 500 500 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source'~height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .3 1.6 904 .18 2.3 5.6 1708 .33 4.4 9.7 2512 .48 6.4 13.8 3315 .63 8.4 17.8 4119 .79 10.5 21.9 4923 .94 12.5 25.9 5727 1.09 14.5 30 6530 1.24 16.5 34 7334 1.39 18.6 38.1 8138 1.55 20.6 42.2 8942 1.7 22.6 46.2 9745 1.85 24.7 50.3 10549 2 26.7 54.3 11353 2.16 28.7 58.4 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 degrees F = 17 = .52 = 150 psia = 7761· mm Hg = 500 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = TANK DIAMETER = 3.08 TANK LENGTH = 22 TOTAL WEIGHT OF CONTENTS = 2049 WEIGHT OF LIQUID = 2000 LIQUID HEIGHT IN CONTAINER = 1.3 WEIGHT OF GAS UNDER PRESSURE = 49.2 TOTAL CONTAINER VOLUME = 164 = 1226 LIQUID VOLUME IN CONTAINER = 61.7 = 461.6 VAPOR/GAS VOLUME IN CONTAINER = 102.3 DISCHARGE HOLE DIAMETER = 1.25 DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 Horizontal cylinder feet feet lbs lbs feet lbs ft3 gals ft3 gals ft3 inch(es) degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 WIND VELOCITY = 4.5 ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL ADDRESS \ LOCATION DATE OF ASSESSMENT NAME OF DISK FILE = ANHYDROUS AMMONIA = CRYSTAL GEYSER , BAKERSFIELD = JULY 1, 1993 = CRYSTAL3.ASF *** SCENARIO DESCRIPTION DISCHARGE.OF 2000 LB PRESSURIZED AMMONIA VESSEL TO THE ATMOSPHERE ******* DIscHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate Duration of discharge Amount discharged State of material = 2024.6 lbs/min = 1.02 minutes = 2049 lbs = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 50 ppm -- at groundlevel = 32208 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 1000000 1000000 73 2394. .46 11896 11896 1750 4687 .89 3388 3388 3420 6981 1.33 1462 1462 5090 9274 1.76 784 784 6760 11568 2.2 480 480 8430 13861 2.63 321 321 10090 16154 3.06 228 228 ~ 11760 18448 3.5 170 170 13430 20741 3.93 131 131 15100 23035 4.37 104 104 16770 25328 4.8 84.5 84.5 18440 27621 5.24 69.9 - 69.9 20110' 29915 5.67 58.7 58.7 21780 32208 6.1 50 50 1 *Usually safe for <.1 hour release. Longer releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .3 1.6 2394 .46 6.1 13.2 4687 .89 11.9 24.7 6981 1.33 17.7 36.3 9274 1.76 23.5 47.9 11568 2.2 29.3 59.5 13861 2.63 35.1 71.1 16154 3.06 40.8 82.7 18448 3.5 46.6 94.2 20741 3.93 52.4 105.8 23035 4.37 58.2 117.4 25328 4.8 64 129 27621 5.24 69.8 140.6 29915 5.67 75.6 152.2 32208 6.1 81.4 163.7 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 degrees F = 17 = .52 = 150 psia = 7761 mm Hg = 50 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = TANK DIAMETER = 3.08 TANK LENGTH = 22 TOTAL WEIGHT OF CONTENTS = 2049 WEIGHT OF LIQUID = 2000 LIQUID HEIGHT IN CONTAINER = 1.3 WEIGHT OF GAS UNDER PRESSURE = 49.2 TOTAL CONTAINER VOLUME = 164 = 1226 LIQUID VOLUME IN CONTAINER = 61.7 = 461.6 VAPOR/GAS VOLUME IN CONTAINER = 102.3 DISCHARGE HOLE DIAMETER = 1.25 DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 Horizontal cylinder feet feet lbs lbs feet lbs ft3 gals ft3 gals ft3 inch(es) degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 WIND VELOCITY = 4.5 ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODs NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL ADDRESS \ LOCATION DATE OF ASSESSMENT NAME OF DISK FILE = ANHYDROUS AMMONIA = CRYSTAL GEYSER , BAKERSFIELD = JULY 1, 1993 = CRYSTAL1.ASF *** SCENARIO DESCRIPTION DISCHARGE OF AMMONIA FROM A BROKEN HIGH PRESSURE LINE. ******* DISCHARGE RATE/DURATION ESTIMATES Discharge from long distance liquid pipeline Average discharge rate Duration of discharge Amount discharged State of material = 2598.9 lbs/min = .011 minutes = -500 lbs = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 2012 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 1000000 1000000 73 237 .05 161976 161976 180 374 .08 45057 45057 280 510 .1 19043 19043 380 647 .13 9969 9969 480 783 .15 5943 5943 570 920 .18 3866 3866 670 1056 .2 2677 2677 770 1193 .23 1942 1942 870 1329 .26 1462 1462 970 1466 .28 1133 1133 1070 1602 .31 899 899 1170 1739 .33 728 728- 1270 1875 .36 599 599 1370 2012 .39 500 500 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .3 .6 237 .05 .6 1.3 374 .08 1 1.9 510 .1 1.3 2.6 647 .13 1.7 3.3 783 .15 2 4 920 .18 2.4 4.7 1056 .2 2.7 5.4 1193 .23 3.1 6.1 1329 .26 3.4 6.8 1466 .28 3.8 7.5 1602 .31 .' 4.1 8.2 1739 .33 4.4 8.8 1875 .36 4.8 9.5 2012 .39 5.1 10.2 CAUTION: See guide for assumptions used in estimating these times. INPUT~PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 = 17 = .52 = 150 = 7761 = 500 degrees F psia mm Hg ppm CONTAINER CHARACTERISTICS CONTAINER TYPE PIPELINE DIAMETER PIPELINE LENGTH INTERNAL PIPELINE PRESSURE LIQ HEIGHT IN PIPELINE NO. PIPELINE DISCHARGE POINTS = TOTAL WEIGHT OF CONTENTS = WEIGHT OF LIQUID LIQUID HEIGHT IN CONTAINER WEIGHT OF GAS UNDER PRESSURE TOTAL CONTAINER VOLUME LIQUID VOLUME IN CONTAINER DISCHARGE HOLE DIAMETER DISCHARGE COEFFICIENT OF HOLE = TEMP OF CONTAINER CONTENTS = Pipeline 1 150 .03 150 10 2 26.6 26.6 0 0 .9 6.8 .9 6.8 1 .62 35 inches feet miles psia feet lbs lbs feet lbs ft3 gals ft3 gals inch(es) degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 WIND VELOCITY = 4.5 ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL ADDRESS \ LOCATION DATE OF ASSESSMENT NAME OF DISK FILE = ANHYDROUS AMMONIA = CRYSTAL GEYSER , BAKERSFIELD = JULY 1, 1993 = CRYSTAL1.ASF *** SCENARIO DESCRIPTION DISCHARGE OF AMMONIA FROM A BROKEN HIGH PRESSURE LINE. ******* DISCHARGE RATE/DURATION ESTIMATES Discharge from long distance liquid pipeline Average discharge rate Duration of discharge Amount discharged State of material = 2598.9 lbs/min = .011 minutes = -500 lbs = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 50 ppm -- at groundlevel = 5060 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 1000000 1000000 73 455 .09 26115 26115 340 809 .16 5446 5446 590 1163 .23 2074 2074 850 1517 .29 1035 1035 1110 1872 .36 602 602 1370 2226 .43 387 387 1630 2580 .49 266 266 1880 2934 .56 193 193 2140 3289 .63 145 145 2400 3643 .69 113 113 2660 3997 .76 89.1 89.1 2910 · 4351 .83 · · 72.3 72.3 3170 4706 .9 59.7 59.7 3430 5060 .96 50 50 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .3 .6 455 .09 1.2 2.4 809 .16 2.1 4.1 1163 .23 3 5.9 1517 .29 3.9 7.7 1872 .36 4.8 9.5 2226 .43 5.7 11.3 2580 .49 6.6 13.1 2934 .56 7.5 14.9 3289 .63 8.4 16.7 3643 .69 9.2 18.5 3997 .76 10.i 20.2 4351 .83 11 22 4706 .9 11.9 23.8 5060 .96 12.8 25.6 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 = 17 = .52 = 150 = 7761 = 50 degrees F psia mm Hg ppm CONTAINER CHARACTERISTICS CONTAINER TYPE PIPELINE DIAMETER PIPELINE LENGTH INTERNAL PIPELINE PRESSURE LIQ HEIGHT IN PIPELINE NO. PIPELINE DISCHARGE POINTS = TOTAL WEIGHT OF CONTENTS = WEIGHT OF LIQUID LIQUID HEIGHT IN CONTAINER WEIGHT OF GAS UNDER PRESSURE TOTAL CONTAINER VOLUME LIQUID VOLUME IN CONTAINER DISCHARGE HOLE DIAMETER DISCHARGE COEFFICIENT OF HOLE = TEMP OF CONTAINER CONTENTS = Pipeline 1 150 .03 150 10 2 26.6 26.6 0 0 .9 6.8 .9 6.8 1 .62 35 ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 70 WIND VELOCITY = 4.5 ATMOSPHERIC STABILITY CLASS = F VAPOR/GAS DISCHARGE HEIGHT = 0 inches feet miles psia feet lbs lbs feet lbs ft3 gals ft3 gals inch(es) degrees F degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS ~ LOCATION = CRYSTAL GEYSER DATE OF ASSESSMENT = JULY 1, 1993 NAME OF DISK FILE = CRYSTAL2.ASF *** SCENARIO DESCRIPTION' DISCHARGE OF 4900 LB PRESSURIZED AMMONIA VESSEL TO ATMOSPHERE UNDER MOST PROBABLE DAYTIME CONDITIONS ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate Duration of discharge Amount discharged State of material = 8103.4 lbs/min = .605 minutes = 4900 lbs = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 2131 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 518607 518607 350 246 .05 91083 91083 850 391 .08 36182 36182 1360 536 .11 18310 18310 1860 681 .13 10446 10446 2360 826 .16' 6472 6472 2860 971 .19 4268 4268 3370 1116 .22 2956 2956 3640 1261 .24 2130 2130 3440 1406 .27 1584 1584 3210 1551 .3 1210 1210 2930 1696 .33 946 946 2590 · 1841 .35 753 753 2150 1986 .38 610 610 1550 '2131 .41 500 500 1 *Usually safe for < 1 hour release. Longer releases or sudden~wind shifts, may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario.was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .2 1 246 .05 .5 1.5 391 .08 .7 2 536 .11 1 2.6 681 .13 1.3 3.1 826 .16 1.5 3.6 971 .19 1.8 4.1 1116 .22 2 4.6 1261 .24 2.3 5.1 1406 .27 2.5 5.6 1551 .3 2.8 6.2 1696 .33 3.1 6.7 1841 .35 3.3 7.2 1986 .38 3.6 7.7 2131 .41 3.8 8.2 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT. CONTAINER CHARACTERISTICS CONTAINER TYPE TOTAL WEIGHT OF CONTENTS WEIGHT OF LIQUID LIQUID HEIGHT IN CONTAINER WEIGHT OF GAS UNDER PRESSURE TOTAL CONTAINER VOLUME = -27.4 degrees F = '17 = .52 = 150 psia = 7761' mm Hg = 500 ppm LIQUID VOLUME IN CONTAINER VAPOR/GAS VOLUME IN CONTAINER = DISCHARGE HOLE DIAMETER = DISCHARGE COEFFICIENT OF HOLE = TEMP OF CONTAINER CONTENTS = Horizontal cylinder 4900 lbs 2000 lbs 2.8 feet 67 lbs 201.1 ft3 1504 gals 61.7 ft3 461.6 gals 139.5 ft3 2.5 inch(es) .62 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 WIND VELOCITY = 6.4 ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL ADDRESS \ LOCATION DATE OF ASSESSMENT NAME OF DISK FILE = ANHYDROUS AMMONIA = CRYSTAL GEYSER = JULY 1, 1993 = CRYSTAL2.ASF *** SCENARIO DESCRIPTION DISCHARGE OF 4900 LB PRESSURIZED AMMONIA VESSEL TO ATMOSPHERE UNDER MOST PROBABLE DAYTIME CONDITIONS ******* .DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate Duration of discharge Amount discharged State of material = 8103.4 lbs/min = .605 minutes = 4900 lbs = Mix of gas/aerosol .******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 50 ppm -- at groundlevel = 4807 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less~ See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 518607 518607 350 437 .09 28647 28647 1520 773 .15 7643 7643 2680 1109 .21 3004 3004 3840 1445 .28 1469 1469 5010 1781 .34 825 825 6170 2117 .41 510 510 7340 2454 .47 337 337 8270 2790 .53 235 235 7830 3126 .6 170 170 7310 3462 .66 128 128 6670 3798 .72 97.7 97.7 5900 4134 .79· · 76.8 76.8 .~ 4910 4470 .85 61.5 61.5 3540 4807 .92 50 50 1 *Usually safe for < 1 hour~release. Longer releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source height specified .by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTs Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 437 .09 773 .15 1109 .21 1445 .28 1781 .34 2117 .41 2454 .47 2790 .53 3126 .6 3462 .66 3798 .72 4134 .79 4470 .85 4807 .92 .2 1 .8 2.2 1.4 3.4 2 4.6 2.6 5.8 3.2 7 3.8 8.2 4.4 9.4 5 10.6 5.6 11.8 6.2 12.9 6.8 14.1 7.4 15.3 8 16.5 8~.6 17.7 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 degrees F = 17 = .52 = 150 psia = 7761 mm Hg = 50 'ppm CONTAINER CHARACTERISTICS CONTAINER TYPE TOTAL WEIGHT OF CONTENTS WEIGHT OF LIQUID LIQUID HEIGHT IN CONTAINER WEIGHT OF GAS UNDER PRESSURE TOTAL CONTAINER VOLUME LIQUID VOLUME IN CONTAINER = VAPOR/GAS VOLUME IN CONTAINER = DISCHARGE HOLE DIAMETER = DISCHARGE COEFFICIENT OF HOLE = TEMP OF CONTAINER CONTENTS = Horizontal cylinder 4900 lbs 2000 lbs 2.8 feet 67 lbs 201.1 ft3 1504 gals 61.7 ft3 461.6 gals 139.5 ft3 2.5 inch(es) .62 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 WIND VELOCITY = 6.4 ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL ADDRESS \ LOCATION DATE OF ASSESSMENT NAME OF DISK FILE = ANHYDROUS AMMONIA = CRYSTAL GEYSER , BAKERSFIELD = JULY 2, 1993 = CRYSTAL3.ASF *** SCENARIO DESCRIPTION DISCHARGE OF 2000 LB PRESSURIZED AMMONIA VESSEL TO ATMOSPHERE UNDER MOST PROBABLE DAYTIME CONDITIONS ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate Duration of discharge Amount discharged State of material = 2024.6 lbs/min = 1.02 minutes = 2049 lbs = Mix of gas/aerosol ***.****TOXIC VAPORDISPERSION ANALYSIS RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 1492 feet Note:. Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 129572 129572 350 200 .04 33968 33968 700 299 .06 15473 ~15473 1040 399 .08 8845 8845 1380 498 .1 5721 5721 1730 598 .12 3986 3986 2070 697 .14 2911 2911 2420 796 .16 2196 2196 2530 896 .17 1697 1697 2390 995 .19 1338 1338 2230 1095 .21 1071 1071 2030 1194 .23 870 870 1790 1293 .25 716 716 1490 1393 .27 596 596 1080 1492 .29 500 500 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .2 1.4 200 .04 .4 1.8 299 .06 .6 2.1 399 .08 .8 2.5 498 .1 .9 2.8 598 .12 1.1 3.2 697 .14 1.3 3.5 796 .16 1.5 3.9 896 .17 1.6 4.3 995 .19 1.8 4.6 1095 .21 2 5 1194 .23 2.2 5.3 1293 .25 2.3 5.7 1393 .27 2.5 6 1492 .29 2.7 6.4 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 degrees F = 17 = .52 = 150 psia = 7761 mm Hg = 500 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = TANK DIAMETER = TANK LENGTH = TOTAL WEIGHT OF CONTENTS = WEIGHT OF LIQUID = LIQUID HEIGHT IN CONTAINER WEIGHT OF GAS UNDER PRESSURE TOTAL CONTAINER VOLUME LIQUID VOLUME IN CONTAINER VAPOR/GAS VOLUME IN CONTAINER = DISCHARGE HOLE DIAMETER = DISCHARGE COEFFICIENT OF HOLE = TEMP OF CONTAINER CONTENTS = Horizontal cylinder 3.0~ feet 22 feet 2049 lbs 2000 lbs 1.3 feet 49.2 lbs 164 ft3 1226 gals 61.7 ft3 461.6 gals 102.3 ft3 1.25 inch(es) .62 35 degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 WIND VELOCITY = 6.4 ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL ADDRESS ~ LOCATION DATE OF ASSESSMENT NAME OF DISK FILE = ANHYDROUS AMMONIA = CRYSTAL GEYSER , BAKERSFIELD = JULY 2, 1993 = CRYSTAL3.ASF *** SCENARIO DESCRIPTION DISCHARGE OF 2000 LB PRESSURIZED AMMONIA VESSEL TO ATMOSPHERE UNDER MOST PROBABLE DAYTIME CONDITIONS ******* DISCHARGE RATE/DURATION ESTIMATES Liquefied gas discharge from outlet <= 4 in. from tank Average discharge rate Duration of discharge Amount discharged State of material = 2024.6 lbs/min = 1.02 minutes = 2049 lbs = Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 50 ppm -- at groundlevel = 3510 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC' VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 129572 129572 350 344 .07 11795 11795 1200~ 588 .12 4122 4122 2040 831 .16 2002 2002 2880 1075 .21 1119 1119 3730 1318 .25 683 683 4570 1562 .3 446 446 5410 1805 .35 306 306 6030 2049 .39 219 219 5700 2292 .44 162 162 5320 2536 .49 123 123 4860 2780 .53 95.5 95.5 4290 ~3023 .58 75.8 75.8 3570, 3267 .62 61.1 61.1 2570 3510 .67 50 50 1 *Usually safe for < 1 hOur release. LOnger releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .2 1.4 344 .07 .7 2.3 588 , .12 1.1 3.2 831 .16 1.5 4 1075 .21 2 4.9 1318 .25 2.4 5.8 1562 .3 2.8 6.6 1805 .35 3.3 7.5 2049 .39 3.7 8.3 2292 .44 4.1 9.2 2536 .49 4.6 10.1 2780 .53 5 10.9 3023 .58 5.4 11.8 3267 .62 5.9 12.7 3510 .67 6.3 13.5 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 degrees F = 17 = .52 = 150 psia = 7761 mm Hg = 50 ppm CONTAINER CHARACTERISTICS CONTAINER TYPE = TANK DIAMETER = 3.08 TANK LENGTH = 22 TOTAL WEIGHT OF CONTENTS = 2049 WEIGHT OF LIQUID = 2000 LIQUID HEIGHT IN CONTAINER = 1.3 WEIGHT OF GAS UNDER PRESSURE = 49.2 TOTAL CONTAINER VOLUME = 164 = 1226 LIQUID VOLUME IN CONTAINER = 61.7 = 461.6 VAPOR/GAS VOLUME IN CONTAINER = 102.3 DISCHARGE HOLE DIAMETER = 1.25 DISCHARGE COEFFICIENT OF HOLE = .62 TEMP OF CONTAINER CONTENTS = 35 Horizontal cylinder feet feet lbs lbs feet lbs ft3 ,gals ft3 gals ft3 inch(es) degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 WIND VELOCITY = 6.4 ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED HAZARDOUS MATERIAL = ANHYDROUS AMMONIA ADDRESS \ LOCATION = CRYSTAL GEYSER , BAKERSFIELD DATE OF ASSESSMENT = JULY 2, 1993 NAME OF DISK FILE = CRYSTAL1.ASF *** SCENARIO DESCRIPTION DISCHARGE OF AMMONIA FROM PRESSURIZED LINE DURING MOST PROBABLE DAYTIME CONDITIONS ******* DISCHARGE RATE/DURATION ESTIMATES Discharge from long distance liquid pipeline Average discharge rate Duration of discharge Amount discharged State of material 2598.9 lbs/min .011 minutes 28.6 lbs Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYsIs RESULTS Downwind distance to concentration of 500 ppm -- at groundlevel = 363 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 20784 20784 350 119 .03 12636 12636 420 138 .03 8265 8265 480 157 .03 5708 5708 550 175 .04 4111 4111 610 194 .04 3062 3062 620 213 .05 2344 2344 590 232 .05 1835 1835 560 250 .05 1465 1465 530 269 .06 1188 1188 490 288 .06 978 978 450 307 .06 815 815 390 325 .07 .. 686 686 330 344 .07 583 583 230 363 .07 500 500 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts ~may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .2 .4 119 .03 .3 .5 138 .03 .3 .6 157 .03 .3 .6 175 .04 .4 .7 194 .04 .4 .7 213 .05 .4 .8 232 .05 .5 .9 250 .O5 .5 .9 269 .06 .5 1 288 .06 .6 1.1 307 .06 .6 1.2 325 .07 .6 1.2 344 .07 .7 1.3 363 .07 .7 1.4 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 = 17 = .52 = 150 = 7761 = 500 degrees F psia mm Hg ppm CONTAINER CHARACTERISTICS CONTAINER TYPE PIPELINE DIAMETER PIPELINE LENGTH INTERNAL PIPELINE PRESSURE LIQ HEIGHT IN PIPELINE NO. PIPELINE DISCHARGE POINTS = TOTAL WEIGHT OF CONTENTS = WEIGHT OF LIQUID LIQUID HEIGHT IN CONTAINER WEIGHT OF GAS UNDER PRESSURE TOTAL CONTAINER VOLUME .. LIQUID VOLUME IN CONTAINER DISCHARGE HOLE DIAMETER DISCHARGE COEFFICIENT OF HOLE = TEMP OF CONTAINER CONTENTS = Pipeline 1 150 .03 150 10 2 26.6 26.6 0 0 .9 6.8 .9 6.8 1 .62 35 inches feet miles psia feet lbs lbs feet lbs ft3 gals ft3 gals inch(es) degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 WIND VELOCITY = 6.4 ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED ~%ZARDOUS MATERIAL ADDRESS ~ LOCATION DATE OF ASSESSMENT NAME OF DISK FILE =ANHYDROUS AMMONIA = CRYSTAL GEYSER , BAKERSFIELD = JULY 2, 1993 = CRYSTAL1.ASF *** SCENARIO DESCRIPTION DISCHARGE OF AMMONIA FROM PRESSURIZED LINE DURING MOST PROBABLE DAYTIME CONDITIONS ******* DISCHARGE RATE/DURATION ESTIMATES Discharge from long distance liquid pipeline Average discharge rate = Duration of discharge = Amount discharged = State of material = 2598.9 lbs/min .011 minutes 28.6 lbs Mix of gas/aerosol ******* TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind distance to concentration of 50 ppm -- at groundlevel = 805 feet Note: Minimum computable answer is 33 feet! Actual hazard distance may be less. See attached table(s) for further details. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Groundlevel Concentration (ppm) Source Height Concentration (ppm) Initial Evacuation Zone Width* (feet) 100 .02 20784 20784 350 151 .03 6381 6381 530 201 .04' 2765 2765 700 251 .05 1447 1447 870 302 .06 853 853 1050 352 .07 546 546 1220 402 .08 371 371 1400 453 .09 264 264 1340 503 .1 195 195 1260 553 .11 148 148 1170 604 .12 115 115 1070 654 .13 91.1 91.1 940 704 .~ .14 73.6' 73.6 780 754 .15 60.3 60.3 560 805 .16 50 50 1 *Usually safe for < 1 hour release. Longer releases or sudden wind shifts may require a larger width or different direction for the evacuation zone. See Chapters 3 and 12 of the guide for details. Source height specified by the user for this scenario was 0 feet. TOXIC VAPOR DISPERSION ANALYSIS RESULTS Downwind Distance (feet) (miles) Contaminant Arrival Time at Downwind Location (minutes) Contaminant Departure Time at Downwind Location (minutes) 100 .02 .2 .4 151 .03 .3 .6 201 .04 .4 .8 251 .05 .5 1 302 .06 .6 1.1 352 .07 .7 1.3 402 .08 . .8 1.5 453 .09 .9 1.7 503 .1 .9 1.8 553 .11 1 2 604 .12 1.1 2.2 654 .13 1.2 2.4 704 .14 1.3 2.6 754 .15 1.4 2.7 805 .16 1.5 2.9 CAUTION: See guide for assumptions used in estimating these times. INPUT PARAMETER SUMMARY PHYSIOCHEMICAL PROPERTIES OF MATERIAL NORMAL BOILING POINT MOLECULAR WEIGHT LIQUID SPECIFIC GRAVITY VAPOR PRES AT CONTAINER TEMP TOXIC VAPOR LIMIT = -27.4 = 17 = .52 = 150 = 7761 = 50 degrees F psia mm Hg ppm CONTAINER CHARACTERISTICS CONTAINER TYPE PIPELINE DIAMETER PIPELINE LENGTH INTERNAL PIPELINE PRESSURE LIQ HEIGHT IN PIPELINE NO. PIPELINE DISCHARGE POINTS = TOTAL WEIGHT OF CONTENTS = WEIGHT OF LIQUID = LIQUID HEIGHT IN CONTAINER WEIGHT OF GAS UNDER PRESSURE TOTAL CONTAINER VOLUME LIQUID VOLUME IN CONTAINER DISCHARGE HOLE DIAMETER DISCHARGE COEFFICIENT OF HOLE = TEMP OF CONTAINER CONTENTS = Pipeline 1 150 .03. 150 10 2 26.6 26.6 0 0 .9 .9 6.8 1 .62 35 inches feet miles psia feet lbs lbs .' feet lbs ft3 gals ft3 gals inch(es) degrees F ENVIRONMENTAL/LOCATION CHARACTERISTICS AMBIENT TEMPERATURE = 77.7 WIND VELOCITY = 6.4 ATMOSPHERIC STABILITY CLASS = B VAPOR/GAS DISCHARGE HEIGHT = 0 degrees F mph feet KEY RESULTS PROVIDED BY USER INSTEAD OF BY EVALUATION METHODS NONE OBSERVED KEY RESULTS OVERRIDDEN BY USER AT SOME POINT AFTER COMPUTATION NONE OBSERVED ITl X m ANNEX III.3.e LOGISTICS Items to be addressed in this Annex: (1) (2) O) (4) ($) (6) Medical needs [] Information on emergency health care (2745.8(a)(4)) [21 Proper first-aid and emergency medical treatment procedures (2765.2(a)(1)(B)) Site security Communications Transportation Personnel support Equipment maintenance and support [] Maintenance procedures (Program 2)(2755.5) [] Mechanical integrity of the system (Program 3)(2760.5) CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES PREVENTATIVE MAINTENANCE CHECK LIST While the system is in operation check the fol. lowing: Refrigerant sight glass: Clear - OK Bubbles - Low on refrigerant - Foam - Very low 2. Oil sight glass level should be in center of glass. 3. Operating thermostat set point. 4. Safety thermostat set point. 5. Glycol level and concentration. 6. Evap condenser: Bleed off - Clean sump and spray nozzles, chemicals, fans & pump. 7. Suction and discharge pressures. Listen 'for strange noises, bad bearings compressor knock. -Check all breakers and overloads. Clean pump strainer. -check.~by-pass & flow switch by turning off glycol pumps, :.S~st'em should pump down and turn off. solenoid and see if system will pump about 10-20 PSIG. loose clamps, cap tubes vibrating and/or turn off the lead compressor and MAINTENANCE SCHEDULE WEEKi. Y 1. 2. 3. 4. LOg the compressor operating hours. Check the oil level in the compressors. Check the refrigerant sight glasses for bubbles. Check fans & pump in evap condenser for proper.operation. Check tower chemicals. MONTHLY 1..: Sh~t dow~ the system, drain the condenser sump and clean sump-& 'pump strainer in the condenser. Check for scale. 2. Check the strength of the glycol solution. 30% to 40%, 1.034 to 1.049 SPECIFIC GRAVITY. Turn off the glycol pumps & check to see if the flow switch turns off the refrigerant solenoids. 4. Check for loose.pipe clamps. ' 'YEA~hY 1. Descale 'the condenser if necessary. -. 2. Replace refrigerant driers. (More often if necessary) 3. Check the condenser fan belts. ':'~!:i.'~<':i?~/.-4' ' Check all safety controls. ' ".' C'-."3~:.' :~'::.- . "=.'-<~':<!-:.'..'.5.Check the gauges for proper calibration. :..:.:·....-..:.-<-: ":".:~.'.'~i}:i?i}:'~:ii:('~'6".: Check the compressors per Carrier recommendations. · .. ' .'"'-.:1 .>- 3.... ?-~..' .... -,:::,_.~::.~:...:.........Change the oil in the compessors and clean the crank cases. ' .. ;.<~f.'-.'::;'8:'~'>.~"Check thermometer and thermostat cal ibration. - . .:: ·:.-r::::i%~<:-..-; ...- ... .::.:}.':"?~:~';§>.. 'Flush the cooling coil drain pans, if any, with fresh water .".~'.:i.'1~:i>7~:<· ">:: ~o''Clean and-"cheek for proper drainage. ; .::.. 10. Turn .off power and tighten ali electrical connections in the control panel. Parts Needed: URGENT NEXT CALL, GENERAL INSPECTION CUSTOMER SYSTEM DATE JOB TYPE OF SERVICE CHKD ( ) CHECK REFRIGERANT LEVEL & RECORD COMPLETE FOLLOW-U] ( ) IF LOW, ADD GAS AND LEAK CHECK ( ) CHECK FOR LOOSE CLAMPS ( ) CHECK FOR VIBRATION, CAP TUBES, ETC. (' ) LOOK FOR OIL LEAKS · .. (..)' "cLEAN :UP THE EQUIPMENT '..' '"">.i'") .RZPLACE DRIER CORES ( ) PRIME RUSTY 2~dqEAS W/RED OXIDE ( ) CHECK. OIL RETURN SYSTEM MECHANIC: COMPRESSOR CHKD () () () () () () () () () CHECK OIL LEVEL cHECK UNLOADER SETTINGS cHECK COMPRESSOR PULL'DOWN & Vi~LVES TEST OIL FAILURE SWITCH, CK SETTINGS TEST-HIGH pRESSURE SWITCH, CK SETTINGS TEST LOW PRESSURE swiTcH, CK SETTINGS GREASE MOTOR CHECK ALL CLA~PS CHECK COUPLINGS CHECK CRANK CASE HEATER CHECK OIL PRESSURE AND RECORD COMPLETE EOLLOW-UP CONDENSER ( ) CHECK FAN ( ) CHECK PUMP '.'(.;..>)'CHECK BELTS ".(~ i CHECK .TOWER CONDITION · ~ ':.':".':'!~(!~)'/'"C~'ECK WATER TREATMENT SYSTEM 'A~D/o CLEAN INC. TOWER STRAINER ....... · .('.~).' CHECK. NOZZLES ( . )'~.' 'GREASE BEARI'NGS --- ( ) ACID CLEAN IF NECESSARY COMPLETE FOLLOW-UP COOLING COILS CHKD ( ) ,C'HECK FANS ( ) CHECK DRAINS ( ) CLEAN COILS ( ) CHECK DEFROST COMPLETE FOLLOW-UP GLYCOL SYSTEM ( ) CHECK FOR GLYCOL LEAKS ( ) CHECK FOR BAD INSULATION (')' CHECK GLYCOL'SPECIFIC GRAVITY % ( ) CHECK GLYCOL LEVEL, LOW OK HIGH__ ( ) CHECK PUMPS 3' ~ ,."<.'::.~::( )' CHECK'_T~K THERMOSTATS cHECK TANK THERMOMETERS ( ) CHECK CHILLER GLYCOL THERMOMETERS CHECK GLYCOL FLOW,SWITCH ELECTRICAL CONTROL PANEL CHKD ( ) CH~CK CONTACTS IN STARTERS & CONTACTORS COMPLETE FOLLOW-UP ( )' TIGHTEN ALL CONNECTIONS ( ).: CHECK FOR 'LOOSE WIRES, SIGNS OF EXCESS HEAT ( ) REPLACE ANY BULBS NOT WORKING ( ) CLEAN UP WIRING ~AFETY. CONTROLS ( ) CHECK ALL SETTINGS CHECK FOR PROPER OPERATION ( ) HIGH PRESSURE SWITCH ( ) LOW PRESSURE SWITCH ( ) ~ OIL FAILURE SWITCH '-:(") ~!".FAN CYCLE SWITCH i'. · (..':~)" OPERATING THERMOSTAT ( ) MA~T~R LOW PRSSBURE SWITCH HUMIDIFIERS CHKD ( 'i' ".CLEAN-UP EXTERIOR ( ) ~CLEAN AND DRAIN SUMP ( ) CLEAN AND CHECK FLOAT VALVE ( ) CLEAN AND CHECK METERING VALVE ( ) CHECK TIMER AND CONTROL FOR PROPER OPPERATION ( ) CHECK MOTOR AND BEARINGS ( ) INSTALH ANTI SLIME TABS R COOLED CONDENSER ( ) FAN OPERATION ( ) MOTOR BEARINGS (' ) DRIVE BELTS · .-( -: ) FAN -BEARINGS · ·',.i )<::,[:~;dH~CK CONDENSER COIL & CLEAN FINS .~ %"2'..:~ :?'... 'i-.~::~: ".'¥; .:. ':% · ." 5'.::. '.'-' '. :' ;~.'~'172;?..{::':."?. ' ', ~''' . -~.- .. ~:.?- ;- COMPLETE FOLLOW-UP 5 CRYSTAL GEYSER MAINTENANCE RECORD EQUIPMENT: DATE: WORK_PERFORMED: CAUSE: COMMENTS: EQUIPMENT: DATE: WORK PERFORMED: CAUSE: COMMENTS: EXHIBIT 7 ~l~l~ I INC. APPENDIX E MANNING SYSTEMS GAS CELLFI'RANSMI~ER INSTRUCTION AND INSTALLATION MANUAL INSTRUCTION AND INSTALLATION MANUAL MODEL 4485 AMMONIA GAS CRLL/TRANSMITTER Manning Systems, Inc. 11511 West 83 Terrace Lenexa, Kansas 66214 Tel- 913-894-1185 Fax~.913-894-1296 INDEX Introduction ...... ~ ............. 3 System Description and Specifications ....... 3 Specifications .................. 4 Dimensions ..................... 4 Gas Sensor Assembly ............... 5 Rain Shield / Calibration Adapter ........ 6 Electrical Wiring ............... 7 Sensor Performance ................. 8 Accuracy ............. 8 Response ~i~e' ~ ~ ~ ~ ~ 8 Humidity ..................... 8 Sensor Life ................... 9 Interferences .................. 9 Installation ....... 10 · ...... Radio Frequency I t rfere c Protection .... 11 Start-up / Operation ................ 12 Calibration ................... 13 Routine Maintenance ................ 14 Quick System Check .............. 14 Troubleshooting .................. 15 Sensor Replacement ................ 15 Typical Signal Voltages ............. 15 Spare Parts List .................. 17 Warranty ...... ................ 18 INTRODUCTION This manual has been prepared to help the buyers and installers of the Model 4485 Gas Transmitter to understand the operating principles of the system, initial start-up and routine maintenance procedures. Please call Manning Systems, Inc. (913-894-1185) for advice of help with any questions that may arise during installation, start-up or future maintenance. SYSTEM DESCRIPTION AND SPECIFICATIONS The Model 4485 is a two-wire transmitter designed for monitoring ammonia gas concentrations in areas where it might accumulate or leak from refrigeration or process equipment. It consists of two components: an electrochemical sensor and an electronic transmitter. The transmitter module is enclosed in anexplosion-proof enclosure. The sensor is screwed into one hub of the enclosure. The standard Model 4485 has a detecting range of 0-100 ppm ammonia. Other ranges are available up to a maximum of 0-500 ppm. The range of each Model 4485 is marked on the serial number tag attached to the transmitter module. Contact Manning Systems for information on ranges other than the standard. The 4485 'systems are normally located at the point of measurement with the sensor simply exposed to ambient air. For outdoor applications, an accessory rain shield/calibration adapter is available. An accessory flow cell is also available for applications requiring a sampling system. For applications where temperatares may be at or below -40°F, heat tracing on the sensor and transmitter will allow reliable operations. Such appli- cations should be discussed with Manning Systems, Inc. applications engineers before purchase and installation of equipment. sPECIFICATIONS: Range: 0-100 ppm ammonia Standard O- 50 ppm ammonia Minimum 0-500 ppm ammonia Maximum .Linearity: ±2% of Full Scale Repeatability: ±2% of Full Scale Lower Detectable Limit: .5 ppm Output: Isolated 4-20 mA DC, 125 ohms maximum at 12 VDC 700 ohms maximum at 24 VDC Power: 12-40 VDC, 33 mA maximum Temperature Limits: -40°F to +120°F Humidity: 10 to 99% RH non-condensing Sensor Pressure Limits: O-10 psig Enclosure: Explosion-proof, Class 1, Group B,C,D Class 2, Group E,F Class 3, Nema 4 Weight: 3 pounds DIMENSIONS 118 mm 114 mm (2) ~/~ o~- _~ 3.~t (2) 1/~ ~ FIGURE 1 - TRANSMI3-rER DIMENSIONS t/2' Nlq' FIGURE 2 - PLUG-IN SENSOR DIMENSIONS GAS SENSOR ASSEMBLY: Series 4485 transmitters utilize a modular electrochemical sensor that requires no regular maintenance. The plug-in design allows simple and quick field replacement without special tools. The sensing element plugs into the stainless steel h~using, and is held in place either with an end cap as shown below, or a combination rain shield and cali- bration adapter as shown on the following page. Plug-in sensing elements will normally provide up to 18 months or more Of operating service. They carrya full 12 month warranty, and are stable if. stored in a cool location (40°/80°F) in the sealed container in which they are shipped. I I I fPLUG-IN SENSOR RAIN SHIELD / CALIBRATION ADAPTER: The electrochemical sensor used to detect ammonia is designed for use either indoors or outdoors. However, it is important to avoid water droplets adhering to the outside surface of the protective membrane on the front of the sensor. The water will not harm the sensor but it will form a barrier to ammonia diffusion into the sensor. Do not hose down 'the sensor directly. If this cannot be avoided, dry the tip of the sen- sor with a soft tissue. The rain shield is recommended for outdoor in- stallations. The rain shield also contains an integral calibration fitting which allows calibration gas to flow past the sensor at a controlled rate. A hose barb is provided for connection of the calibration gas. See the following drawing for dimensions of the Rain Shield/Calibration Adapter. 6 © © CAUTION: When calibrating outdoors on a windy day, it will be necessary th temporarily block off the holes around the circumference of the rain shield. Otherwise, rapid air flow caused by wind will dilute the gas standard as it enters the sensor area. The holes need not be tightly sealed, but simply covered to prevent direct entry of high wind velocities. ELECTRICAL WIRING: The signal output of the Model 4485 Transmitter is monitored by one or two channels of the Model 21 Indicator and Alarm System (see the Model 21 Installation and Instruction Manual). Follow the wiring diagram below. All penetrations into a refrigerated room should be sealed with a silicone-type sealant, i.e., be sure to seal the inside of a conduit that is carryinK sensor cables. ~: We s~ly recc~mer~having a drip loop c~ these el~~cml sensors. & Ob"T ~ VC~ MODEL 21 INDICATOR AND ALARM SYSTEM 0 L )~ 0 C ~C .C NO _. I 2 (~. I~ORTANT: Use two-conductor shielded #13 for wiring distances up to 1000'. We recommend Bel- den #8760. For distances greater than 1000',we recom-' mend #16 two-conductor shielded (Belden #8719). The interface board has been pre-wired to the main terminal strip at the factory. 'DO NOT make any changes in these wires. If panel meters are used, those have also been pre-wired to the interface board.. NOTE: The Model E/C is in a Nema 4 enclosure. DONoTMOONTE/C~ MIT~INAMAZARDO3S LOCATION. Contact Manning Systems for special explosion-proof design. SENSOR PERFORMANCE -ACCURACY: The accuracy of a toxic gas sensing system is basically limited by the accuracy of the standard used to calibrate the system~ For many toxic gases, obtaining a high accuracy Standard that is suit- able for field calibration use is quite difficult. For this reason, no fixed accuracy statement is possible. The accuracy of a 4485 system' will generally be equal to the accuracy of the calibration gas source. The best accuracy to be expected, assuming a perfect standard, is limi- ted by the repeatability which is ±2% of span. About the best accuracy achievable is 5%, using a permeation'system (where appropriate) for calibration. Bottled gas standards are general- ly ±10%. RESPONSE TIME: These electrochemical gas sensors are optimized to give the fastest possible response time while maintaining excellent zero sta- bility and minimum drift. The sensor output vs. time characteristic, for a given concentration, approximates to a logarithmic curve. An am- monia sensor will generally read 90% of actual concentration within 360 seconds. Often, a far more useful response time measurement is the time it takes for an alarm to be actuated at the TLV (Threshold Limit Value) when the sensor is exposed to either two times or five times the TLV concentra- tion. This giy~s a more realistic picture of the alarm time a user can expect in a real leak condition of two different magnitudes. The current TLV for ammonia is 25 PPM. For the ammonia gas sensor, the alarm times are: 2 times TLV exposure - 45 seconds to TLV alarm 5 times TLV exposure - 9 seconds to TLV alarm HUMIDITY: Gas sensors are designed to provide stabl~ output over a range of humidity conditions. Typical relative humidity conditions from 25% to 95% RH will not effect operation of the Series 4485 sensors. However, the user should be aware of two humidity conditions which can adversely effect sensor performance. The first potential problem is extremely dry air or sample streams. At relative humidities continuously below 20%, sensors can exhibit a loss of sensitivity after a few days to a week of operation. This is caused by a slow loss of water in the internal sensor electrolyte. SuSpending the sensor over a jar of water for 24 hours will usually restore sensi- tivity~ The second potential problem is extremely wet conditions. Diffusion sen- sors rely on a relatively unobstructed gas diffusion path into the sensor. If the gas stream or ambient air is condensing on the sensor, the water droplets on the membrane will cause loss of sensitivity, or slow response, or both. Once the sensor has had a chance to dry out, normal operation should be restored. SENSOR LIFE: Series 4485 sensors will generally provide a minimum of 12 months of service in ambient air leak detection applications. Ammonia sensors are capable of operation continuously for one year in the pre- sence of 5 PPM ammonia gas. In applications where only trace levels of ammonia exist, except under leak conditions, sensor life will most likely be over 18 months. While sensors may have some, or even substantial life remaining, the factory recommendation is that sensors be replaced at a convenient interval between 12 and 18 months. Experience in'a given application or plant condition will determine the best replacement fre- quency. High ammonia gas concentrations and high temperatures can reduce the life of a sensor. Continuous sensor operation at 120°F will most likely result in a maximum of 12 months sensor life. Exposure of an ammonia sensor-to percent levels of ammonia gas for more than a few hours can completely-exhaust a sensor. If this occurs, allow the sensor to recover to zero and. then carefully test with calibration gas. If the sensor responds sluggishly, replace the sensor. IN~~CES: Series 4485 sensors are designed to provide maximum sensitivity with a minimum of interference from other gases. However, there are certain gases.which .can present an interference problem, and the user should be aware of the possibility of responses from these gases. In the case of th~ ammonia sensor, the potential interferences are listed below. The table shows the relative response of an ammonia sensor to 1PPM of the interfering gas. If these gases are present in the area where ammonia is to be sensed, the system will measure all of the inter- fering gases present at any given time. GAS RESPONSE (PPM) -'CO 0.03 H2S 0.50 NO2 -0.23 HCN 0.05 .O3/F2 ;1.0 GAS RESPONSE (PPM) NO 0.03 PH3 0,42 Cl2/Br2 -0.5 H2 0,13 CH3SH 0,17 10 INSTALLATION Installation of a Model 4485 ammonia transmitter simply requires physical mounting and connection of the power/output lines. For mounting, the .transmitter enclosure is provided with bolt holes in the mounting flange. A wall mounting spacer plate is supplied with the unit and should be used as shown in the following drawing. The spacer is required in order to provide clearance for the calibration adapter to be screwed onto the sensor. The transmitter can also be supported directly from the electrical con- duit as shown. If this method is to be used, clearance must still be allowed from any surfaces so that the calibration adapter can be screwed onto the sensor. I~gM ~du~t ~amp WALL MOUNT CONDUIT MOUNT NOTE: In ~igh moisture areas, to minimize the possibility of water con- densing in the conduit feeding the electrochemical cell, we stronEly recommend to put a drip loop utilizinE flexible conduit. BE SURE TO SEAL ALL CONDUIT CONNECTIONS. 11 RADIO FREQUENCY INTERFERENCE PROTECTION: The Model 4485 is designed to eliminate spurious signals caused by radio frequency noise encountered in some plant environments. However, under extremely severe conditions where high-powered radio transmitters are nearby, or where high-powered hand-held radios are in use, some noise pickup can occur directly through the sensor. Installing output wiring in metallic conduit helps to in- sure that pickup does not occur through wiring. 12 START-UP / OPERATION When all installation work has been completed, the transmitter is ready for operation. Prior to applying power, re-check electrical connections ~o be certain that the wiring is correct. The transmitter must be allowed to operate at least 2-4 hours to stabilize in preparation for zeroing and calibration. Both of these procedures are performed at the factory prior to shipment but should be re-checked on start-up. ZEROING: The transmitter zero is set by adjusting the output of the trans- mitter to 4mA while the sensor is exposed to air with no ammonia present. If the ambient air is known to be free of ammonia, zero grade'air is not required. If zero grade air is to be used, connect the cylinder as shown in the following drawing. NOTE: As a convenience during zeroing and calibration, a TEST terminal is provided on the transmitter terminal block. This test point provides a voltage signal proportional to ammonia concentrations which track the output signal. It is not necessary to break the power/output loop. The voltage signal at the test point is 0.04 - 0.2V (40-200 mV). 13 Remove the transmitter cover to allow access to the zero potentio- meter. Connect a digital voltmeter to transmitter terminals "TEST" and "( )" If zero air is to be used, screw the calibration adapter onto the end of the sensor and conhect a cylinder of zero grade air as shown on the previous page. "Crack" the cylinder valve and allow the zero air to flow gently through the sensor adapter for 3-5 minutes. 3. Adjust the zero potentiometer, if necessary, until the digital voltmeter reads 0.04 VDC. The transmitter is now zeroed and ready for a calibration check. CALIBRATION: Transmitter calibration requires passing an air flow con- taining a known ammonia concentration past the sensor. Best results are obtained with an ammonia concentration of 70-100% of transmitter range (minimum - 50% of transmitter range). Calibrating gas can be obtained through Manning Systems, Inc. Connect the calibrating gas cylinder as shown in the diagram on the previous page. Screw the calibration adapter onto the end of the sensor and assemble the rest of the calibration system as shown. Attach a digital volt- meter to the "TEST" and "(-)" terminals. 2. "Crack" the valve on the standard gas cylinder and allow the standard gas to flow gently through the sensor adapter for 3-5 minutes.~ NOTE: The concentration of ammonia in ppm is marked on each standard gas cylinder.. ~his is the value to be used in adjusting the transmitter. Do not use a standard gas cylinder that is over one year old. Store cylinders in a cool place to prolong their useful life. Use the calibration potentiometer on the front of the transmitter to adjust the voltage on the digital voltmeter to the voltage cal- culated from the following formula: V = 0.040 + (0.160 x PPM OUTPUT/FULL SCALE PPM) For example, if the cylinder is labeled 80 ppm and the transmitter full scale range is 100 ppm, the digital voltmeter voltage should be 0.168 VDC. After calibration is complete, disconnect the calibration system and replace t-he transmitter cover. The unit should now be operating properly and transmitting the current ammonia concentration. 14 ROUTINE MAINTENANCE The system requires no regular maintenance except that the transmitter Must be zeroed and calibrated at regular intervals. It is recommended that the zero be checked monthly and the calibration checked every two or'three months. Ammonia gas sensors will usually gSve two or more years of service at low ammonia exposure levels. Should the protective membrane on the tip of the sensor become dirty or wet, it should be cleaned with a soft tissue and distilled water. .DO NOT USE DETERGENTS OR SOLVENTS OF ANY KIND. QUICK SYSTEM CH~CK: The system can be checked periodically (at least monthly) by exposing the sensor to ammonia fumes from a bottle of house- hold cleaner containing ammonia. Open the bottle and hold it no closer than one inch from the sensor'tip. DO NOT leave the ammonia bottle under the sensor for too long or it will take a long time for the sensor to recover to zero. Do not splash liquid ammonia on the membrane. The transmitter should cause the Model 20 iow and high level alarm LED's to light within a few seconds. The channel and master relays will switch over after a ten second delay. When connected to the Analygas Model 21, the transmitter will activate the audible and light alarms and switch the relay upon reaching the alarm setpoint. IMPORTANT: These electrochemical sensors are extremely reliable, but over a period of time and exposure to varying concentrations of gases, the c911 chemicals can become depleted. If this occurs, the unit can go "asI~f' with no outward indication of failur9 other than the sensor will not respond.' IT IS ABSOLUTELY ESSENTIAL THAT THESE UNITS BE EXERCISED WITH AN AMMONIA SAMPLE ON A TIMEI,Y BASIS at least every two to four weeks when new and at least on a 1-2 week basis after the unit is more than a year old or with exposure to large concentrations of ammonia. Output signals must be verified and loRRed. 15 TROUBLESHOOTING The Model 4485 has only two components: a sensor and an electronic cir- -cuit. Failure of the sensor will result in a lack of response to ammonia gas. Failure of the electronic circuit will cause a complete loss of out- put, an output which is saturated at 33 mA or instability. To isolate a problem, connect a sensor simulator to the transmitter module. A sensor simulator consists of a 100K resistor and a voltage source. Shown below is the proper connection of the sensor simulator and the input voltages required to simulate various ammonia concentrations. 123 ¢56 T+- ~ E 4-20 S mA Go T - 100K · '~- ADJUSTA PPM VOLTAGE R (OHMS) 0 0 100K 50 -0.250 100K 100 -0.500- 100K 500 -2.500 lOOK VOLTAGE SOURCE SENSOR REPLACEMENT: Simply unscrew the sensor end cap from the hub of the transmitter enclosure, unplug the old sensor, plug in a replacement and screw back on the end cap. Replacement sensors are available through Manning Systems, Inc. Be sure to allow a new sensor a few hours to stabi- lize before zeroing and calibration. The Model 4485 gas sensors will nor- mally give two or more years of service at iow exposure levels. Frequent or prolonged exposure to very high concentrations of ammonia can result in reduced sensor life. TYPICAL SIGNAL VOLTAGES: The standard Model 4485 has a detecting range of 0-100 ppm of ammonia. Other models are available up to a detecting range of 0-500 ppm of ammonia. The isolated 4-20 mA output of the standard Model 4485, when the unit is properly zeroed and calibrated, should be 4~mA when the sensor is exposed to ammonia-free air and 20 mA when the sensor is exposed to air containing 100 ppm of ammonia. Likewise, the 0-500 Model should read out 4 mA in zero ammonia air and 20 mA when ex- posed to 500 ppm ammonia in air. The Model 4485, when monitored by a Model 20, 20-B, or Model 21, will also produce a signal ~oltage at the signal test point of the unit. The signal will be in VDC and will activate the LED's, audible alarm and switch over the relays whenever the alarm trip level is exceeded. The following chart illustrates typical signal voltages which may be expected when the Model 4485 is monitored by a Model 20, 20-B or a Model 21: (readings may vary ± 2%) PPM NH3 Model 4485 mA Model 20 Model 20-B Model 21 SIG VDC SIG VDC SIG VDC 100 20 2.05 2.05 1.60 88 18 1.85 1.85 1.40 75 16 1.65 1.65 1.20 63 14 1.45 1.45 1.00 50 12 1.25 1.25 .80 38 10 1.05 1.05 .65 25 8 .85 .85 .45 13 6 .65 .65 .30 0 4 .45 .45 .15 PPM NH3 Model 4485 mA Model 20 Model 20-B Model 21 SIG VDC SIG VDC SIG VDC 500 20 2.05 2.05 1.60 437 18 1.85 1.85 1.40 375 16 1.65 1.65 1.20 312 14 1.45 1.45 1.00 250 12 1.25 1.25 .80 187 10 1.05 1.05 .65 125 8 .85 .85 .45 62 6 .65 .65 .30 0 4 .45 .45 .15 16 17 Part No. 096-1024 096-1023 096-0534 096-0878 073-0082 096-0876 096-0935 SPARE PARTS LIST MODEL 4485 NH3 TRANSMITTER Descriptfon Transmitter module Ammonia amplifier board Driver board Ammonia sensor, plug-in (specify ppm range) Transmitter enclosure Sensor housing assembly, with 1' cable End cap and gasket assembly WARRANTY - MODEL 4485 ~.LECTROCHEMICAL CELl. AND TRANSMITI~ER Manning Systems, Inc. warrants to the original purchaser and/or ultimate customer of the manufacturer's products, that if any part(s) thereof (except gas sensors) proves to be defective in material or workmanship within 18 months from the date of shipment or 12 months from the date of start-up, whichever comes first, such defective part(s), will be repaired or replaced free of charge if shipped prepaid to Manning Systems, Inc., 11511 West 83 Terrace, Lenexa, Kansas 66214, in a pack- age equ~ to (or) original container, the product will be returned freight pre- paid and repaired or replaced if it is determined by the manufacturer that the part(s) failed due to defective materials or workmanship. The repair or replace- ment of any such defective part(s) shall be Manning Systems, Inc.'s sole responsi- bility and liability under this limited warranty. Gas sensors (which are part of certain products) are covered by a 12 month war- ranty of the manufacturer. The Buyer shall be limited to the warranty of the manu- facturer of the gas sensor which is should there be a failure of the gas sensor within 12 months of shipment, the sensor will be replaced at no charge. This warranty is in lieu of all other warranties (including without limiting the generality of the foregoing, warranties of merchantability and fitness for a parti- cular purpose), guarantees, obligations or liabilities expressed or implied by the seller or its representatives and by any statute or rule of law, all of which are disclaimed by Manning Systems, Inc. Manning Systems, Inc. assumes no liability for consequential damages of any kind, and the buyer by acceptance of the equipment will assume all liability for the consequences of its use or misuse by the buyer, his employees or others. A defect within the meaning of this warranty in any part of any piece of equipment shall not, when such part is capable of being renewed, repaired or replaced, operate to condemn such piece of equipment. This warranty does not cover consumable items, batteries, or wear items subject to periodic replacement including lamps and fuses. This warranty is void if the instrument has been subject to misuse or abuse, or has not been oPerated in accordance with instructions, or if the serial number has been removed. The warranty printed above is the only warranty applicable to this purchase. Ail other warranties, express or implied, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose are disclaimed. It is understood and agreed that Manning Systems, In~'s liability, whether in contract, in tort, under any warranty, in negligence or otherwise, shall not exceed the return of the amount of the purchase price paid by the buyer and under no cir- cumstances shall Manning Systems, Inc. be liable for special, indirect or conse- quential damages. The price stated for the equipment is a consideration in limiting Manning Systems, In~'s liability. No action, regardless of form, arising out of the transactions under this agreement may be brought by buyer more than one year after the cause of action has accrued. INSTRUCTION AND INSTALTATION MANUAL Manr~ng S~stems, Inc'. 11511 West 83 Terrace Lenexa, Kansas 66214 913-894-1185 Section 6 7 CONTENTS Title Introduction WaTranty System Specifications Control Unit Sensors. Remote Sensor Enclosures Drawing - Outdoor Mounting Enclosure Indoor Mounting Enclosure System Description Electrical Power Indicator Panel Sensors Single Sensor Units Relays Alarm Trip Levels - illustration Time Delays Typical Time Delay Relay Wiring Installation Unpacking Control Unit Location Sensor Locations Sensor Wiring External Wiring for Model 21 Electrical Power Wiring Relay Wiring Start-up Initial Testing Routine Maintenance How to Take Voltage Readings Trouble Shooting' -' Nuisance Gases Adjusting Sensitivity Fault Light Page 3 3 4 4 4 4 5 5 6 6 6 6 6 7 7 7 8 9 9 9 9 10 11 11 11 12 12 13 13 14 14 14 14 SECTION 1 INTRODUCTION This manual has been prepared to help the buyers and installers of the Mpdel 21 Gas Monitoring Alarm System to understand the operating principles of the system, initial start-up and routine maintenance pro- cedures. This manual should be studied in detail by the people who will install and maintain the equipment with careful attention given to sensor locations. Please call Manning Systems, Inc. (913-894-1185) for advice or help with any questions that may arise during installation, start-up or future maintenance. WARRANTY Analygas Systems Ltd., warrants gas sensing equipment manufactured and sold by us to be free from defects in materials, workmanship and performance for a per~od of one year from date of shipment. Any parts found defective within that period will be repaired or replaced, at our option, free of charge, FOB factpry. This warranty does not apply to those items which by their nature are subject to deterioration or consumption in normal ser- vice, and which must be cleaned, repaired or replaced on a routine basis. Warranty is Voided by abuse including rough handling, mechanical damage, alteration or repair procedures not in accordance with instruction manual. This warranty indicates the full extent of liability, and Analygas is not responsible for removal or replacement costs, local repair costs, trans- portation costs or contingent expenses incurred without our prior approval. This warranty shall not apply to any Analygas products which have been al- tered in any way outside Analygas' manufacturing facilities so as to, in Analygas' judgement, affect its use, function or reliability or which shall have been subject to misuse, alteration, improper installation, painting, misapplication, negligence or accident. Analygas' obligation und~r this warranty shall be limited to repairing or rePlacing, and returning any product which has been returned to Analygas at its manufacturing facilities, with transportation charges prepaid; and which Analygas' examination shall disclose to its satisfaction to have been defective. This warranty is expressly in lieu of any and all other warranties and re- presentations, expressed or implied, and all other obligations or liabili- tie~ on the part of Analygas'inc~udi-~g,--but not limited--Go, the warranty of~fitness-for a particular purpose..In no event shall Analygas be liable for direct, incidental or consequential loss' or damage of any kind'con- nected with the use of its products or failure of its product to function or operate properly. SECTION 2 SYSTEM SPECIFICATIONS THE CONTROL UNIT is manufactured of 16 gauge steel. Dimensions are 11~5/8" x 8-5/8" x 4-3/4". Shipping weight is 11 pounds. The unit is painted a dark green pebble finish enamel. It is designed to be wall- mounted in a non-hazardous atmosphere. The door is hinged and gasketed to minimize entry of dust, insects, etc. The audible alarm and four lamps (two are also switches) are mounted on the door. The lamps are visual indication of the system status. Alarm horn on the control unit provides a sound pressure level of 73 dB at 10 feet. The control unit houses the power supply, relay, electric and electronic elements and switches which power the sensors, monitor their voltages and react to the pre-set alarm trip level. SENSORS are solid state metallic oxide and are shipped mounted on the main control unit, unless the customer purchases remote sensor housings and, in that case, the sensors are shipped already mounted in the housings. REMOTE SENSOR ENCLOSURES: Sensors can be installed up to 1,000' from the main--control unit in an-enclosure especially designed for this purpose. INDOOR SENSOR ENCLOSURES are manufactured of 16 gauge steel. Dimensions are 4-1/2" x 4-1/2" x 2-1/2". Shipping weight is 2 pounds. The e,cio- sure has two 7/8" holes to accept 1/2" conduit and a sensor socket. The door is hinged and gasketed to minimize entry of dust and insects. It is painted a dark green pebble finish enamel and contains a four-point terminal strip. It is designed to be mounted through four flange holes in a non-hazardous atmosphere. (See next page for drawing.) WEATHERPROOF ENCLOSURES are manufactured of 16 gauge steel. Dimensions are 6" x 4-1/2" x 3-1/2". Shipping weight is 3-1/2 pounds. The enclo- sure has two 7/8" holes to accept 1/2" conduit and a sensor socket. The door is gasketed and held in place by four clamps and screws-to make a weather-tight seal. It is painted a dark green pebble finish enamel and contaiJs a four-point terminal strip. It is designed to be mounted through four flange holes in a non-hazardous atmosphere. (See next page.) Manning Systems, Inc. 11511 West 63 Terrace I Lenexa. KS 66214 i 913-.894-1185 FAX 913-894-17<:J6 Manning Systems, · 11l~11 We~l ~3 Terr&ce Lenexa, K8 66214 913-694,! 1~,~ P^X913-894.t296 7 ZOO 4 t/4' (4 P~J.c~s) ~s S~j4~ OUTDOOR MOUNT I NC ENCLOSURE P~OT~C~V~ D, rCLOS~K(/ CAS PART ~Z~-8-1 $20 I 1 I/4° INDOOR MOUNTING ENCLOSURE SECTION 3 SYSTEM DESCRIPTION The Model 21 Gas Alarm System is a broad spectrum detector uti- lizing a simple on-off alarm ci~rcuitry, which responds to the presence of r~ducing gases such as ammonia, freon, carbon monoxide, smoke, etc. ELECTRICAL POWER is conventional ll5.VAC, 60 Hz at 0.1 amp. The transformer output is 25 VDC at .5 amp. INDICATOR PANEL: The front panel of the control unit contains the audible alarm and four indicating lamps. Two of the lamps are also switches. Their functions are: ~. Green, when lighted indicates POWER on. " White TEST/FAULT lamp and momentary switch. When lighted, this lamp indicates a sensor wiring fault or failed sensor. When used as a switch (depressed), it~ turns on the other three lamps and sounds the audible alarm. The alarm relay, however, will not switch over. Amber WARN, ~hen lighted, indicates that the audible alarm has been silenced. Red ALARM, when lighted, indicates that an alarm condition exists. · When ~used as a switch (push on-push off),.it will silence the audible alarm and will cause the amber "WARN" lamp to be lighted. SENSORS utilizea heated resistive metallic oxide element which undergoes a drastic reduction in electrical resistance in the presence of a reducing atmosphere such as ammonia vapor. Each sensor has four active electrical leads: Two red wires carry approxi- mately 5 VDC from the main control unit to the sensor's heater coil. Two orange wires "report" back to the main control unit any change in the re- sistance of the sensor's element. The presence of a reducing gas Will lower the element's resistance allowing a higher voltage through the orange wires.-(See ALARM TRIP LEVELS, Section 3.) Theoretically a sensor exposed to completely pure dry air at 60°F would have an orange wire voltage of zero. This is known as the "resting volt- age". .This condition, however, can only be achieved in the laboratory so a sensor's resting voltage under ordinary ambient conditions can be ex- pected'to range from .2 to 1.2 VDC. SINGLE SENSOR UNITS:..While most Model 21 Gas Monitor Systems are installed to monitor two sensors, there may be a need to use only a single sensor. In these instances a 30 ohm 1 watt ballast resistor must be connected to the red wire terminals for sensor #2 to complete the circuit left open if sensor #2 is not used. RELAYS: Each.Model 21 unit is equipped with one output relay. The relay is energized during normal (no alarm) operating conditions and will de- energize to the alarm condition should a gas concentration exceed the pre- set alarm trip level, or in the event of a power faildze. Model 21 users may want to consider use of a 10-15 second time delay device in conjunction with the relay to minimize nuisance alarms. Silencing the audible alarm will not cause the relay to switch back to a no-alarm position. The cause of the alarm condition must be found and corrected. A~,M TRIP LEVELS are determined at the time a customer orders a Model 21 Gas Detecting System, according to the customer's heeds and desires. The alarm trip levels are factory set but can be field adjusted as conditions change. (See NUISANCE GASES, Section 7.) The following diagram illus- trates what happens when an alarm is tripped,' why it is tripped and how alarm signals are activated. Alarm3T~~ Level Sensor orange wire voltage under normal operating conditions. Sensor orange wire voltage exceeds 3 VDC which, in this example, is the pre-set alarm trip level. The door panel red ALARM lamp is lighted, the audible alarm sounds and the relay switches over to operate any connected equipment. The audible alarm may be silenced by pressing the red lamp switch and the amber WARN lamp.then will be lighted. The ~ondition causing the alarm (high gas concentration or power fail- uce) has been corrected.~ The relay switches back to the no-alarm position. If the red lamp switch has not been depressed, the red lamp will turn off and the audible alarm will be silenced. TIM~ DELAYS: The previous diagram illustrates the series of events occur- ing when'the signal voltage exceeds the alarm trip voltage. In some in- stances, this condition may exist for a few seconds, then correct itself. A p~er failure may occur for a few secon-dS-and result in an--~nnecessary alarm. Some Model 21 .users have installed-an inexpensive time delay-on and/or del~y-off relay at the output end of the internal relay to filter out unnecessary alarms. (See typical layout on next page.) TYPICAL TIME DELAY RELAY WIRING O 1 2 · III lC 0 -. 4 OUT TP VCC 5 6 ~GC .5 AMP~ + L N G G NC Connect LtoC ALARM ADJ. C NO TP REF O O TP SIG OR OR R R Sensor i Sensor 2 8 To'connect a Time Delay Relay ON DELAY as shown on the diagram below. Relays are avail- able through Manning Systems or your local electrical supply house. Normally Open' Time Delay Contact Push Button Normally Closed Normally Open Time Delay Contact To ADT or · other remote alarm system 8-A The relay is positioned as shown in the drawing below when all of the following conditions are met: - Power is applied to the monitoring unit - There are no wiring or sensor faults - The ambient gas level is below the alarm trip level ~en any of the following happens, · - The unit goes into alarm - AC power is lost to the unit - There is a fault alarm condition (white light on) the relay will trip causing the "C" and "NO" terminals to close, thus providing a completed'circuit to trip a remote alarm or start a vent fan. The relay is NOT INTERNALLY FUSED so donnected equipment must be pro- tected by the user. Maximum relay load rating is 3 amps. 9 SECTION 4 INSTALLATION This part of the manual has been prepared especially for the people who are to install the Model 21 Gas Monitoring Alarm System. For trouble- fr~e'start-up and operation, it is important that the instructions given here be followed carefully and completely. Direct qt~estions to Manning Sys- tems, Inc. (913-894-1185) in Kansas City. UNPACKING: Inspect all boxes'and contents for shipping damage. If any screws or other metal parts are missing, they must be found to ensure that the printed circuits will not be damaged when power is applied. IMPORTANT - The installer should identify on a plant floor plan where each sensor is located, whether it is sensor #1 or #2 and the control unit to which each sensor reports. CONTROL UNIT LOCATION: The control unit is designed to be mounted on a wall fhrough holes in the four mounting flanges. While the physical loca- tion must be determined in part by local conditions, it is important to remember the following: Protect the main control unit from rain, snow, water sprays from clean- ing crews and physical damage~ Mount the unit on a wall at eye level for convenience in taking read- ings, servicing, etc. The Model 21 is not eXplosion proof. Do not mount in a hazardous atmosphere. Operating temperature range for the control unit is 0° to 120°F. Should it be necessary to drill holes in the main unit box, be sure to remove all metal filings. These could short out the main unit printed circuits. SENSOR LOCATIONS: The sensors utilize a heated resistive metal- lic oxide element which undergoes a drastic reduction in electrical re- sistance when exposed to ~ reducing atmosphere, such as ammonia vapor. This resistance change., is used to trigger an electronic switching circuit which in turn actuates an alarm circuit. Because each sensor can only "report" what it is "smelling" at the moment, it is very important that the sensors be located where leaks may most likely occur. Ammonia vapor iS"~'b~ut~n~half the ~eight°~f a~§ient air. Locate sen- sors'near the ceilings of equipment rooms, blast freezers, cold rooms, etc. Contact Manning Systems for information concerning other gases. Locate sensors near the control/piping ends of evaporators and valve complexes. 10 Take air movement and ventilation patterns into account when locating sensors. When installing sensors near evaporators in refrigerated' }paces, ..keep sensors out of direct air flow from and to the evaporator and away from any moisture created during defrost. The best location usually is on the piping/control side three to four feet from the evaporator and within eighteen to twenty-four inches of the room ceiling. Blast freezer applications can be very difficult. Please contact Mannin~ Systems to discuss. Both Sensors for one Model 21 MUST be in similar, atmospheres. EXAMPLE: Do not locate Sensor #1 in a blast freezer and Sensor #2 in an equipment room. Install sensors pointing downwards. Conduit must. enter sensor enclo- sures from the bottom of the enclosure (or from the side if~ the bottom cannot be used) to minimize the opportunity for condensation (i.e., water from wash-down procedures) to enter the enclosure. NEVER ENTER TRE ENCLOSURE FROM THE TOP. Ail penetrations into a refrigerated room should be sealed with a silicone-type sealant. BE SURE TO SEAL THE INSIDE OF A CONDUIT THAT IS CARRYING SENSOR CABLES. Protect sensbrs from water and excessive humidity~. Protect.'sensors from hose-down by clean-up crews. Mount sensor enclosures through the flange holes. Sensors may be installed up to 1000' from the control unit. (See SENSOR WIRING.) Operating temperature range for the sensors is -40°F to 120°F. Below -15°F requires heated enclosures (contact Manning Systems). SENSOR WIRING: Power is supplied to the sensors from the control unit. Each sensor on the Model 21 requires four conductors. Use #16 AWG conductor for runs up to 300'. Use #14 AWG conductor for runs from 300' to 600'. Use #12 AWG conductor for runs from 600' to 1000'. Run wiring in steel conduit to provide the necessary electrical shield- ing or use shielded four-conductor cable, such as Belden 16/4 #9954. Non-shielded wire can be used but care must be taken to keep away from .j~long AC lines. Keep run lengths as short.as·~possible. Care must be taken..~o norcross orange and red conductors between sensor ~nclosure and control unit terminal strips. 11 EXTERNAL WIRING FOR MODEL 21 Remote Sensor #2 - up to 1000' Four Conductors - in conduit or shielded ELECTRICAL POWER WIRING: Power requirements are 115 VAC, 60 HZ at 0.1 amps. Maximum relay rating is 115 VAC, 3 amps resistive, unpowered contacts, Form C. The instrument MUST be correctly grounded. RELAY WIRING: Wire the relay(s) to the required equipment. The relays have Form C contacts and are unpowered so that any required power source (pro- vided that it is'within the relay's rating of up to 3 amps) may be used. The relay contacts are not interdally protected. The installer must ensure that the external circuits are properly fused. Relay wiring must be run in conduit separate from sensor wiring if the r~lay circuit is AC. .. . .... 12 SECTION 5 START-UP Before Applying power~ make a final check ~of all wiring for co~ltinuity~ sbortp~grounds, etc. It is usually best that external alarms and other equipment powered by the relays be disconnected from the relays until the initial start-up is completed. Be sure tha( the sensors are in gas-free air. When power is applied, the following events should occur: IMMEDIATELY: The green POWER lamp.will be lighted. If this does not occur, check the power wiring to the unit. TEN SECONDS: The audible alarm will sound after about 10 seconds and the relay will switch over. The audible alarm may be silenced by de- pressing the ALARM switch. The WARN lamp will be lighted~ TEN MINUTES: The system will stabilize to the extent that the relay will switch back and the audible alarm may be reset by again depressing the ALARM switch. Sensor elements require up to 24 hours to stabilize prior to checking calibration. If the white TEST/FAULT light turns on, check~ sensor wiring and connec- tions. See Section 7 - TROUBLE SHOOTING. Check sensors for physical damage, evidence 6f water or other liquid contamination. INITIAL TESTING: Allow 24 hours for the system tO stabilize before test- ing the sensors. Because sensors may be located at a distance from the main control unit, the testing time required and accuracy will be improved if two People use radio contact. Use a digital voltmeter to take a set of readings as described in Routine Maintenance, Section 6. Record these on the Reference Data Sheet shipped with the unit. Using the installer's floor plan referenced in Section 4, have one person expose each sensor to a small amount of a ho'usehold cleaning product con- taining ammonia. The second person will stay at the control unit to determine: That each sensor, when exposed to ammonia fumes, does trip the alarm. That, referring to the f!o0~ p~n, the proper sensor, is responding to - the ammonia gas. '~rhat"~he out'~ut relay does switch over (us'e a test light). When these tests are completed the system is now in proper operation and should continue to operate without further adjustments. 13 SECTION 6 ROUTINE MAINTENANCE Very little routine maintenance is required due to the design and construc- tion of the main control unit and sensors, providing that the guidelines ~d instructions given in Section 4 have been followed. Keep the main unit enclosure clean. A cloth damp with soapy water gives good results. Never use any chemical cleaning agent. Keep the door closed, except when entry is necessarl. DAILY: Visual inspection of the door panel lamps to check system status. The green POWER lamp must be lighted. Depress the TEST/FAULT lamp/switch to check the other lamps and the audible alarm. WEEKLY: Use a digital multimeter (Radio Shack Cat. No. 22-188 does well) to take periodic readings at the main test points. Record this data for future reference. Connect multimeter black (ground) lead to the main control unit TP GND (test point ground), and the red lead to TP VCC (source). This voltage should be 12 VDC (±.2 volt). Move the red lead to TP REF (test point reference). This is the. alarm trip'level at which the unit has been calibrated. This reading will vary from 1.2 VDC to'6 VDC depending on the ppm level at which the alarm is set' to trip. Move the red lead to TP SIG (test point signal). This voltage will normally be from one-fourth to one-third of the reading noted at TP REF (previous paragraph) but will vary with changes in ambient tempera- ture, humidity and airborne contaminants at the sensors. (See also the diagram at ALARM TRIP LEVELS, Section 3.) Move the red lead to the bottom of the diode labeled #1. This is the orange wire "reporting" voltage from sensor #1. This voltage will continually vary a few hundredths of a volt. Move the red lead to the bottom of the diode labeled #2. This voltage is the orange wire "reporting" voltage from sensor #2 and will vary as does sensor #1. MONTHLY: ~Expos~ each sensor to ammonia vapors. This will verify that each SenSor has a normal response and will also check alarm light and audible signals, as well as relay action. IMPORTANT: It is essential that the enclosed log sheets be utilized with signal voltages being taken and logged on a consistent basis. Periodically sensors should be exposed to an ammonia sample and the results logged. 14 These tests should be done on a daily basis right after start-up. De- pending on environment and experience, these times can be usually ex- tended to once a month after a first few weeks of successful operation. These sensors are mechanical devices and along with all the associated wiring, relays, etc. are subject to day-to-day exposure to physical damage requiring that the complete system be tested and wiring integrity .werified regularly. SECTION 7 TROUBLE SHOOTING Refer to the diagram at ALARM TRIP LEVELS, Section 3. The most usual reaction to a nuisance alarm is to raise the alarm trip level. Many nui- sance alarms can be traced to an unknown or unexpected source of a gas or vapor and serious efforts should be made to check these out and eliminate the source before raising the alarm trip level. NUISANCE GASES include (but are not limited to) solvents, paints, alcohols, exhaust gases from fork lifts and trucks, and even certain odorless com- pounds, such as carbon monoxide. ADJUSTING SENSITIVITYi If the interferences from nuisance gases cannot be eliminated, it may be necessary to reduce the sensitivity of the unit by raising thealarm trip level. To raise the alarm trip level: Connect the multimeter black lead to TP GND and the red lead to TP REF in the main unit. Observe the reading. Directly above the relay is a small blue box with a small screw in the top. Raise the alarm trip level by turning the screw counter-clockwise. To lower the trip level, turn clockwise. The rate and amount of change will be noted as changes in. voltage on the voltmeter. FAULT LIGHT: Sensors are normally long-lived unless physically damaged or soaked with water (or any other liquid). When wiring has passed the initial start-up phase, ther~ is little probability of wiring problems unless physically damaged by storm or accident.~ Sensors which do not have a resting voltage or are constantly showing an alarm trip voltage shoutd~be'-~replaced. . .. ~_ -' Ca'~ii Manning Systems, Inc. at '913-894-118'5 for help as necessary. 22-8-1001 22-8-1002 22-8-1003 22-8-1004 22-8-1008 22-8-1009 22-8-1010 22-8-1011 22-8-1012 22-8-1013 22-8-1014 22-8~1015 22-8-1016 22-8-1017 22-8-1018 SPARE PARTS - MODEL 21 Momentary Action Switch Alternate Action Switch Indicator Lamp Bulb Indicator Lamp ImnsCap:- Red, Amber, White or Green Audible Alarm c/w Mounting Ring Fuse, AGC 1/2 amp Relay Front Plate Escutcheon "Gas Alarm" Door Board c/w Lamps, sWithhes and Connector · Printed Circuit Card Complete Calibration Gas Kit (includes valve, hose and fittings and two disposable cylinders containing 300 ppm ammonia) Spare Calibration Cylinder containing 300 ppm ammonia Spare Operating Manual C~libration Gas Kit (includes valve, hose and fittings and two disposable cylinders containing 500 ppm freon) Spare Calibration Cylinder containing 500 ppm freon SENSORS WITH HOUSINGS: 22-8-1005 Ammonia type (solid-state) 22-8-1007 Freon type (solid-state) 3.0 EQUIPMENT REPORT 3.1 Ammonia Equipment The following equipment makes up the ammonia refrigeration system at Crystal Geyser Bakersfield. Each piece of equipment will be listed along with its nature, age and condition. 3.1.1 Nature, A.qe and Condition Equipment: Compressor #1 Reserved for future installation. Equipment: Compressor #2 Nature: This is a high pressure screw-type compressor package driven by a 100 horsepower, 460 VAC electric motor. It receives Iow pressure ammonia vapors and compresses them to high pressure. Manufacturer Model Serial Number Frick York International RXB 39 S0421LFMNTHAA3 Age: Built in 1993 Condition: New Page 13 Equipment: Compressor #3 Nature: This is a high pressure screw-type compressor package driven by a 150 horsepower, 460 VAC electric motor. It receives Iow pressure ammonia vapors and compresses them to high pressure. Manufacturer - Model - Serial Number - Frick York International RWB II 76 S0348LFMPTHAA3 Age: Built in 1993 Condition: New Equipment: Compressor #4 Nature: This is a high pressure screw-type compressor package driven by a 150 horsepower, 460 VAC electric motor. It receives Iow pressure ammonia vapors and compresses them to high pressure. Manufacturer Model Serial Number Frick York International RWB II 76 S0347LFMPTHAA3 Age: Built in 1993 Condition: New Equipment: Oil Separator #1 Reserved for future installation. Page 14 Equipment: Oil Separator #2 Nature: This horizontal oil separator removes oil from the high pressure ammonia vapor discharging from the #2 compressor. Oil is drained from the separator into the compressor. Manufacturer Size Serial Number Frick York International 16 inch O.D. by 6 feet 3'inch NB105300 Age: Built in 1993 Condition: New Equipment: Oil Separator #3 Nature: This horizontal oil separator removes oil from the high pressure ammonia vapor discharging from the #3 compressor. Oil is drained from the separator into the compressor. Manufacturer Size Serial Number Frick York International 20 inch O.D. by 11 feet 4 inch NB109133 Age: Built in 1993 Condition: New Page 15 Equipment: Oil Separator #4 Nature: This horizontal oil separator removes oil from the high pressure ammonia vapor discharging from the #4 compressor. Oil is drained from the separator into the compressor. Manufacturer - Size - Serial Number - Frick York International 20 inch O.D. by 11 feet 4 inch NB109132 Age: Built in 1993 Condition: New Equipment: Evaporative Condenser #1 Nature: This condenser cools the high pressure ammonia vapor to a liquid. Water running over the condenser coils cools the hot ammonia vapors flowing through the condenser coil bundle. Air is blown through the water spray to cool the water. Manufacturer IMECO Model XLP-ML 380 Age: Built in 1993 Condition: New Page 16 Equipment: Evaporative Condenser #2 Nature: This condenser cools the high pressure ammonia vapor to a liquid. Water running over the condenser coils cools the hot ammonia vapors flowing through the condenser coil bundle. Air is blown through the water spray to cool the water. Manufacturer IMECO Model XLP-ML 425 Age: Built in 1993 Condition: New Equipment: Evaporative Condenser #3 Nature: This condenser cools the high pressure ammonia vapor to a liquid. Water running over the condenser coils cools the hot ammonia vapors flowing through the condenser coil bundle. Air is blown through the water spray to cool the water. Manufacturer - IMECO Model - XLP-ML 425 Age: Built in 1993 Condition: New Equipment: Evaporative Condenser #4 Reserved for future installation. Page 17 Equipment: Liquid Ammonia Receiver Nature: This horizontal receiver accepts high pressure liquid ammonia from the evaporative condenser. Manufacturer - Size - Serial Number - Roy E. Hanson Jr. Mfg. 47.4 inches O.D. by 192 inches 338125 Age: Build in 1993 Condition: New Equipment: King Valve Nature: This solenoid valve controls liquid flow from the receiver to the master accumulator. Age: Manufacturer - Parker Model - S5A Built in 1993 Condition: New Equipment: Carbo Cooler #1 Nature: Uquid ammonia flows through tubes in the carbo cooler. Heat is adsorbed from liquids being cooled by the evaporating ammonia. Manufacturer Mojonnier Bros. Page 18 Model . Serial Number 3140 6745 Age: Built in 1957 Condition: Good Equipment: Carbo Cooler #2 Nature: Liquid ammonia flows through tubes in the carbo cooler, heat is adsorbed from liquids being cooled by the evaporating ammonia. Manufacturer - Mojonnier Bros. Model - 3140 Serial Number - 6595 Age: Built in 1957 Condition: Good Equipment: Glycol Chiller Nature: In this horizontal refrigerant chiller, liquid ammonia adsorbs heat from liquids. The liquid is cooled by the evaporation of ammonia. Manufacturer - Size - Serial Number - E.L. Nickel Co., Inc. 37 inch ID by 22 feet 42878 Age: Built in 1993 Page 19 Condition: New Equipment: Master Accumulator Nature: Excess liquid ammonia boils off in the master accumulator before ammonia flows to glycol chiller and carbo coolers. Manufacturer Size Serial Number Roy E. Hanson Jr. Manufacturing 24 inches O.D. by 120 inches 338126 Age: Built in 1993 Condition: New Equipment: Accumulator Nature: This horizontal-type accumulator stores excess liquid ammonia. Manufacturer - Size - Serial Number - E.L. Nickel Co., Inc. 18 inches O.D. by 18 feet 42879 Age: Built in 1993 Condition: New Equipment: Ammonia Lines Nature: The ammonia lines carry the ammonia through the system. Page 20 Age: Installed in 1993 Condition: Good 3.1.2 Testin,q Schedules Testing of control equipment is necessary to ensure that the equipment will work when it is needed. Equipment Test Schedule High Pressure Cutouts Tested during compressor maintenance Pressure Relief Valves Tested when the vessel being protected undergoes maintenance. 3.1.3 Maintenance Schedules The compressors require more maintenance than any other part of the ammonia system. The compressors are given a detailed inspection each month. Every day, mechanics monitor the equipment and log normal operating variables in addition to unusual conditions. Exhibit 6 is a copy .of a typical operators log used at Crystal Geyser Water Company. Conditions that may require compressor maintenance include: High temperatures High or Iow pressures High oll consumption Unusual noises Excessive vibration Unbalanced operation Page 21 When problems or potential problems are detected, the equipment is scheduled for maintenance. Maintenance schedules comply with manufacturers' recommended maintenance schedules. Manufacturers' equipment manuals are retained and are available for review in the Plant Manager's office. Maintenance schedules for regularly maintained equipment are found in Crystal Geyser's Preventative Maintenance Check Ust (Appendix D). Page22 COMPRESSOR #1 OOMP~R 4/2 CRYSTAL GEYSER MODEL: Frick York International RXB 39 Screw Compressor Package With Microprocessor 100H?, 230/460 Volts, Serialg X~SI70L0637F Serialg S0421LFMNTHA~ 6-5/8"od X 5'0" Sealed for life Model# RWB 1176 Serial# NB10844 OIL SEPERATOR: 16"od X 6'3" Horizontal ........................... Serial//NB105300 OIL FILTER: Seriai~ MC92755 c~rDmo~: New 1993 COMPRESSOR ~3 MFG. MODEL: MOTOR: COMPRESSOR: OIL COOI.FR: OIL SEPERATOR: OIL FILTI~ CoNDmON: Frick York International RWB 1I 76 Screw Compressor Package 150HP, 230/460 Volts, Serial//TDSH163L1609B 6-5/8"od X 5'0" Sealed for life Model# RWB 1I 76 20"od X 1174" Horizontal Serial//NB109133 Serial# MCX)2906 New 1993 COMPRESSOR 0:4 MFG. MOD1;I: MOTOR: COMPRESSOR: OIL COOIFR: OIL FILTER: CONDITION: Frick York International RWB II 76 Screw Compressor Package 150HP, 230/460 Volts, Serial# TDSH163L1610B SeriaW so347 m rH 3 6-5/8"od X 5'0" Sealed for life Model//RWB II 76 Seria~ NBltB92.2 20"od X 11'4" Horizontal Serialg NB109132 Serial# MC92904. New 1993 CRYSTAL GEYSER EVAPORATIVE CONDENSER #1 MFG. MODEL: PUMP:. FAN MOTORS: CONDITION: (1) 5HP, 184T, 460-3-60, ODP High efficiency (1) 3HP, 182T, 4604--60, ODP High efficiency New 1993 EVAPORATIVE CONDENSER ~g2 ... MFG... MODI~: PUMP:. FAN MOTORS: CONDITION: (1) 7.5HP, 213T, 460-3-60, ODP High efficiency (1) 5HP, 184T, 460-3-60, ODP High efficiency New 1993 EVAPORATIVE CONDENSER #3 MFG. MOD~.: PUMP:.. FAN Mo'roRs: CONDITION: IMF_IX) XLP-ML 425 5HP, 4604-60 0) 7.5I-m, 213T, 4604-60, OD? High efficiency 0) 5I-U', l T, ODe High efficiency New 1993 EVAPORAITCE CONDENSER - C RYST A L GEYSER GLYCOL CHu J I~R MFG. EL Nickell Co., Inc. TYPE: 37~ ID X 22'0~ TF-TF Horizontal Refrigerant Chiller SER]A].~. 428?8 CONDITION: New 1993 ACCUMULATOR MFG. g-!- Nickell Co., Inc. TYPE: 18~ OD X 18'0~ O.A.L. Horizontal Refrigerant Accumulator SERIALS. 42879 ODND1TION: New 1993 SERIA.L~. CONDITION: Roy E Hanson Jr. Mfg. 24" OD X 120" O.AL Horizontal Refrigerant Accumulator with Boil out loop 338126 New 1993 MFG. TYPE: CONDITION: Roy E. Hanson Jr. Mfg. 47.4" ID X 192" O.A. Horizontal Refrigerant Receiver 338125 New 1993 KING VALVE MFG. Parker MODb7 ~. S5A PORT SITF: 32-75mm (1 1/4-3") (Drawings and instructions to follow) ...~.`.~:.~:~`-~`~.~.~?~x.~...`~.`.:.~..~..~..x~.~.:~`.~........;.`~.~...~.~.~ '"~ ...... ' ....'" ...... "'"'" '~"'~:~" ::~":~ ~'-','-::"~-"",'~."~'"~":'r'~?"~",'i, ...:.._..,?,, ~ .. ':,~ .~.,- .~... ~,~.,:..,~?.',....-~..,.,..~,-.o.~-. o~. ~¢'.-,~ , ,': '.,~ ..'.~. , ~ .;.- .. . , .... , ' "t"d"" :'"'~' '"";"' '":" '~=~ "~1 "" '"':'&'"" .... ;'" " '"'-' .... Type S5A · ., ~i-...,Type SSA (SSAE)' ' '. ' Port"Size: 32-75mm (1V.-3") For Ammonia, R-12, R-22, R,502, and other common Refrigerants. 'Features ..... , .Standard Coil Housing Meets ..:i~;..':~:-)::~.-~N~MA3R and NEMA 4,Rain Tight · . . ~., '3~:.:~:~.',';,~:'?.',~. ;;~.,,'--,,',..,..,-..:. ?.. ;.:.. ~ · .. . . · ;'-~:'~;-':~;~,, · ~: Coil. Housing Surpasses N EMA Salt Spray Test 7.~;-:.'~.~:'~":*.:;Plunger-Needle Assembly Same For..' (,.;.'.,;~i.}i.x~!,;S~';:.sg'A'i"S6N s6A" :':'..' .". "' . . ..;~ ..;:~;.¢~',.,.,,.~-.:~,~._. ',':L',"-; ..... :.. :' ' ' - ~i~'.;:':~i: Re~51~ii::eable Piston Plug Assembly'.' ..... -, :' .~-,),.:....- . Molded Glass 13 . Co~l ConstruGbon -~,!,~;~!?:ir'.;:':JPii~3i' i"'igh't A~ilable";;::" ,-:".. '.-" · -" :' :"' -. '. :'~.::~}.:.:i~;}}?~:'.:;~,h:~'al"Ol~ening Stem :'. ;-.. · ~:,~:!ThiS' J'{~/dut~'solen0id valve i~'Suitable for Ammonia, R-12, R-22, ~.:~,i:~'~I ~502;"~th(~r ~efrig'erants; 'certain oils and other fluids approved -- 2~.ii2: f0i'"U$~'ih reiii'g~rati0n. The S§/~ iS'~ piiot 0'p~'rated semi-steel bed-' ~::~?'~i[[.:i'i~_d~l'v.~.?h. e-valve-maybe °p~n'ed by.. means of the manual open-. '.:'":'i~!¢!.'~',.!:iing"$t~'m'f0~'$ervicing or in case of electrical power failure. :!~5::'.";:.:::i-i!];Th'e'~y~l~i:s~i~ SolenOid valve is furnished With FPT: internal NPT -.:'-.i;?,~)'(U.S.'..Standard.Taper Pipe ·Thread), Socket Weld, Weld Neck or ~i!??.:'.~::i ODS' (s0!de'rs"~ver' copper tubing of given diameter)·connections. -.i:!.?,v.;!;~:Th'e'valve"may. be easily removed from between the flanges for' .x¢-i;::i~!!;~i, ~v'ici'n~.'.',...:ii:f,i~':q::~..~:, :-...,: :~.., .:... ,:'..:. =, .~ . .-,~: :.... .. "+":;:-;:: '...'%,q:.-.'.".", :.' '-, =' ';'" "':.', :. '; '. '', :i' · '.. ': ' : .. ' :.;;!~'!.::.::~: !"1 '. ~'~ ';?';..'? :';:.~'. ;!.'L.~';' -.':" .' .' ...;-...- i" '. '~"~'""':'~':~'"'1 :";"":'"';"}~ '' ~"~:'"':"" '" "' ' ' '"''~'' ' ' :.~:~"~:L~.'~ !:;.{,;',=?::'.&.x~?.;".":'.,:;'r~:'. :::-v.'!} ...:.....~-.;..:; ~ · ' .: · .: '{-;.:i~"~:?-I::.~':t^SSE~SLY'. ::....:u" ~..: .,~<.,,:...........! ~1~ I " · .::::'?.i:,:.:-:.:-I '..';~.:.:';~:':'.;'.:';' ::..":-" ":'.:.: .;" . \'--." ~ 'h,JL",~: ..... ~..;.,-.::.;:.;~..;~:. ;:.,;:..;.,::.x..:::.....~..!. v: ::',..--,.':~.' ... :..' .-...'. . · ' . ' .?: ~ .~;~:{.,'::!';~ ¢~T'ExTE RN A'L i~O u~~ ' ~ -'..~{~.".'~i~;;..".,'.~. ;~;-.~\pORm PLUG. '~ .1."-~ ..":. ~"*'~r--~ It~.,~ : ;?~.."-;'i'~'~:'; .'.~,'¢:~1~:~ 7'~'~.': ';;~.~ %'.." ,' ':::. ""i:",, .-':': · ~'=-,J?: ,;~{~.r ~,:~k~¢~.~' -,;=~ ,. ~.. ... ., ?...: ....... .. · _': ,"-'-~:'~'.?- ~; ;,','~,:-;;4:-~..5~,': ~'.,.-::',,F' ':.' :' . ' . -~,~o...;..;'=.:.~. '. ;..'.;,......;.:~;,:;;,' ,.;.-'~.: ,.'..., . .. . '. . :~:!;{'),:;;~i.:"- .':.;.'?.~';!'.~i:?., :,:!;';~':"z..: '.,... ~.. :-- ...... · - -.:--~..-','?'4' ',-i.'.:'!ii,"{?{'.::;i-.::;!.::':~.'. ' ... ~ .;.;.;:!.t_L. ' ~ '. .. ::'.:; .. .?~p~.'L~;--.- .:. ~ .~ .'.-... . ~' . .... ·. . .- ' , ' , 'i' ·'.'"'~ · " -'~..' '~; :,' = ' ',' ·'. ' '" ......':'" ~ ..... ::'" '" ' ':::~ i;-::':'...' ' "' ' ::,,.' ...... ':'-:i:---',",:..'... '.'.' :.":.;' '.:: ' :~:.'~:: ':} :. '""".. ..... "'":":" '" '"' ' I ,11 I April, 1986 Installation, Sendce and Pads Inlormallon It is advisable to install a strainer upstream of each valve to prevent entrance of foreign material into the valves and the rest of the sys- tem. Refrigerating Specialties strainers are available to close- couple to valve inlets. Purpose Type S5A is recommended for use in.refrigerant liquid or suction lines. It is not recommended for hot gas lines and other applications where high pressure drops will-exist when the valve is open,. Principles of Operation The TyPe S5A is a Pilot .operated solenoid.. Operation is as follows: The Val~e, in'its closed position, with the solenoid coil de-energized and the plunger-needle in its seated position, is shown in Figure 1. · Before the valve is opened, the pressure above the piston-main valve assembly is equalized through the bleed hole and is the same as the inlet pressure. Electrical energization of the solenoid coil forms a magnetic field, pulling up the plunger which strikes the nee- dle, lifting it off its seat. This permits the refrigerant trapped above the piston-main valve ' assembly to flow through the pilot and through Port N to the downstream side of the valve. The pressure above the piston-main valve is reduced and the higher inlet pres- sure against the underside of the piston-main valve assembly forces it upward. This puts the valve in the open position permitting flow of the refrigerant. The minimum pressure drop to hold the valve wide open is 0.07 Bar (1.0 PSI~ De-energization of the solenoid'coil permits the spring-assisted needle to drop back into its seat, stopping the flow through the pilot port, and the pressure above and below the piston-main valve is equalized. The weight of the piston-main valve then causes it to drop tO its s~at, Stopping the flow Of the refrigerant. The Fressure difference across the valve, acting upon the area of the valve seat, holds the piston-main valve in a tightly closed position. ·. Manual Opening' Stem (See' Fig. 1) -' - The manual opening stem on the Type S5A is for the purpose of opening the valve without energizing the solenoid coil. For access . to the stem the seal cap on the bottom of the valve must be re- moved. This must be done with caution as refrigerant may have · been trapped inside the seal cap. Manual opening is accomplished by turning the stem clockwise until only the flats on the end of the stem protrude from the packing nut. To reset for automatic opera- . · tion turn the stem counterclockwise as far as it goes.'...- · . I I II 6 Housing Asm, . 1 13 Bushing, Seal 1 1,3,5, Housing Kit 201629 6,13 7A Sol. Tube Nut 1 7B Sol. Tubp Asm. 1 8 Gasket· 1 7A,7B,8 Sol. Tu~ Kit 201036 ..... g. Plunger/Needle Asm. ~ I I I .:.:22,23,24." Stem Packing Kit 202100 202101 ~(-'28.;'.:;~: :.;' ..Flange Gasket Pkg ....... . 12 . ~ 202080 202081 202082 202083 .'L~ii?'::-'.:i;'.~'¥.:':?gi':';,~:;.':DIMENSlONAL TALE ;~- DIMEXSION ;~ : 32mm (1V4) .' 40mm & 58mm (lV/, & 2) i ' 65mm ~'~/'z)75mm (3) ~;"-'. : MM .:'.'.'. 3,48 :.'. '" · ' · 411 437 511 :.:.~ ,A.~.~.. '."- .... · ~',::';'." :' INCa -':' ';':.':'.', '13.7 .......... .: "16.2 17.2 20.1 :~!'B.".,/..:: .MU ?:-~ ........ '..117"';.':. ' ...... .' 127 :" ' ' 137 198 ~'~;;:: :INCa ;':'-'~':~,*':~4.6';-.';-'. : ":..- '-'::.- '5.0 .':;.'L- .'. '5.4 7.8 '~;C:~.'~'MM ~C,- ,:~'.':~;; 203 -T~'..~ ..";:: :. :.::' 251 '~'-".:. '":.' 251 311 ' INCH :' ' ".; ,..~. 8.0 .. 9.9 . · g.9 12.2 ' INCa ';" "":.':' "10.1 ' '. . 12.1 . ' 13.0 15.3 ~.'.~'E:'-,~,;. MM;?~7.!"/1V~'' .l'h '.. '.'":'-'1¥~. 1 ' 2 401 478 r,,.~!.~ ....[ ~ ?,:" 364 .... '"1 ' ' ' 371'"' - ' : ':(WN'I':.: ' '~ '"'~' ';~300 :-[ 304. '.: ' I.~11.a.b12.0 ..... · 14.3 -...i..-,. 14.6 - . lS.S 16.s "('~:. !~'::;~';:2~.f.2~9.1304 ..... 3~ '~l.-:-~: I': '~:· 3~ 3~ 4~. 432 ...~,A~ .... '~NC~;: 10.$.~11.0 ~ 120 ;:.-1¢.1 ~..:~ :; 13.3,. ~ .14.1 -.. 13.7 .15.3 15.3 17.0 ":..'G'~.{..,,: 'MM'.=... .17~ .'.~:-',q .- 251 314 314 ;:.~-~.',?: INCa~:~" -"~-~:.7.0 '::: .... ,:~'!'~.;-.* .~,~ 9.9'" . ~: · 12.4 - 12.4 ~:'H~:~ la~'.,~."I:.. ":. t~7-'-.'...'"'. ' 140 159 ?..:'.'"~;, "INCa 7'~ 'Z.-=. ' 4.$ ?" :-2. :.L . .- '. '$:5 ' ' '. --6.2 ' - 7.0 :'~j':~. .laM..- ...... !:. ~', -".'. ........... 284 ' 300 · 312 -".'.'!:.: INCH'.:'.' ~'i . 11.2 · · ." 11.8 12.3 ¢o~) ....... ~ I ~ I 33 28 . .' 3~ ' 3~ 4143 43 I 4s aCH .~ ! ,e .e .6 ~.o 1.~ (MAX.) BETWEEN TUBE STOPS "~[ O.O.S. SOLDER -.' E FLANGES ~'" B iWELD NECK II I I I I I I II I MENT (FPT, SW) FLANGES ALLOW 100 Ma (4') ABOVE VALVE FOR REMOVAL ' OF COIL HOUSING ASSEMBLY ALLOW 25 MM (~')BELOW VALVE TO'OPERATE MANUAL OPENING STEM ;,;-...In~tAIIAtlnn'~. "~:'p ....... , ..' ' ' ~. '. ' ~." ': ";'' - ' . hold Coil remove//7 Tube Assembly, lift out #9 Plunger Assemb y, then re..,. ':.' '... ' ~.. ~...-...? ~::..:, . , .; . .. , ... .~ . .. ..... ,-..,.. , ~,;~-:....-.,:T...'.~.~-..-?~ .,.~. 2 ...'; ........:', '~ '; '. ~. , .... :... ".- .., move//11 Adapter Assemb y and #31 p slon pug Remove every trace of dirt'.;. .... :. ,-.': ~"~'l.'l'oteCf'lnlloe o~ ValVe from did, 'Chips aha moisture outing instehatlon ............ . ' '-- - r ' ' "':':" ' ',-, :,.' . · , . ~ .... ' .......... ~ from the piston ana cy,,noer usm0 line emery ClOtn to remove Du rs I nec'es*.... ..v ~ount only in rtorlzon~al p~pe line with solenolo coil at the top' this vmve wm .... I n II - n ~ r m' le usl a Ii ht film of raid r ' ':'" ' ~rk properly'only In this po,ilion. Ina liquid line the Solenoid Valve should :~lorY~,o~l~oOrno~hgen~isC;~na a partes a ea,,e o .ne g ge- · -:.... ~'~ near the expansion valve Inlet. t Is edv sable to install the S5A close ' i ' ..~":'~, ~ ~.lp ed companion strainer ahead of the valve lot protection against dirt end 2.. Fa, llura to Close: (a! Electrical contro. I circuit, Is not op..e..ni.ng., pppe.?y. '. ~ f · 'hl"'S ' CnecK wiring and controls. (b) There are chips or airt on the ~'i~ot '" ~' ' Main Valve Seat, praventingproperseating'.DisassembleandcleanValveas ": The S5A solenoid valve must be installed with the arrow on the valve body in the direction of flow Ihrough the valve. II the valve is backwards, the flow will not be stopped when the valve is electrically de-energized, Like all Solenoid Valves, the S5A can stop flow only in the direction lrom normal inlet to normal outlet (as shown by the arrow on the body). If reversal of pressure occurs in .:.. the system so the culler pressure exceeds the inlet pressure the piston will .',,.. be blown away from its seat and reverse flow will occur· If a system has this ':;;=:i' type of pressure reversal (as encountered during hot gas delrost with liquid ~!~e~ii~[Jlation syste.~s), a Check valve such as Refrigerating Specialties Divi- ~. :~.-~j~':Ty~-C'K4A i~-S~rie~"With the'solenoid valve will prevent flow revemal. ~C~r4'~ ~St '~'i~tai~a d~nstraam to avoid trapping liquid.) ' . . ~, , .... ~ .... ~ .~'"~.:...'-.~ . .... ~;Electrlcal ~;.,:.~',:.~;::.~,..,:..,~.. ,..-. '...... '~ . · " ' ~' ~;~.~-~..~;~.~,'...,:.,..'. :..:' , . ..'.'. . .: . . -, . . -- . ~,~he Refngemt~ng S~cialt~es D~wsmn molded water resistant Class ~ s~ ~ ~id'~il.i~' ~Sig'~ed.fo~ ~ong lileand powedul opening Iorce. The standard :~[~'~asin'g'~ee~.NEMA 3R and 4 requirements. This sealed construction ;~'~l{~tan~"di~e~ d~tact with'moisture and ice. The coil housing far ex- · ~'~S t~e 'require'~nts' ~f NEMA'Standard ICS, 1-110.57 salt spray test :-~,.~'-~-.':-~:?:.~',~...=.~. ~......'.-. . . . . . . ~By def, mtmn,.Class'"B ,'co~l construction w~ll permit co~l temperatures as ~6~s'br~d b~' 'reSistance' method, as high as 130'C (266=~. Final coil tem- '~:~'~r~'"e ~ctio~"Of both fluid a~d ambient temperatures, The higher '.'?~fi'~'~d ~m~r~tu~es requi/e lower ambient temperatures so the maximum coil ::7=~;te'~perature is no{ exceeded. Convemely Iow fluid temperatures permit ~:~hgherambenttempemtures . · '. . ' ,..-?.,...,..~.:= . .. ..... · ;. _.... · '.~-T~e' ~eidea C ~ss "B":~oi s ~va ab e from st~k with most standard vo t- · ~ ~ges.'Howeve[' coils are ava able for other voltages and frequencies, as well ~:~;;:,~.~[,~[?~t c~rren~. ~ls are also available as tra.nsformer type w~th a 6 volt ~sec0nd~'windidg fo~u~e With ~he Refrigerating S~ciatties Division Pilot ~g~e~Jy (se~ ~'~rent copy.of Bu!l~tin 60-10,."P~lot Light Assembly' ~d Sole~eid.~ransformer Coil")." ". '. :'?:~:- '....' . . . :.:~The"~&l';~0i~ c~ii ~'aSi'~e c~n~ected to el&ctrica~ lines with volts and He.z "~:~?'~me ~s stained on ~0il.'The supply circuits musi-be ~r~;ly sized to give . .~'~..adequate. voltage at the coil leads even when other electrical equipment is ':c-. o~rating. The coil is designed to operate with line voltage from 85% to ?~' 110~'of rated Coil ~oltage: Operating with ~ line voltage above or below these ,.:limits may result in coil burn~ut. Also, operating with line voltage below the ::limit will'definitely result in lowering the valve opening pressure differential. P~f ~nsdmption during n0rm'al 0perati0n'will be 33 watts or less. ~::~.~;:~'=:~.~..~:.~.~:~.:~:.~.~';?~:'"/.".. '.~".'.~-" .=': '~" :' ~"rush' Running Fuse · S{~d~ ~i177:.::: .';:?.;'::'. '.'Pa~ : .."' Currant' Currant Size '. ,~H~::~??:::?~?.:.~:::... :::..; Number':~:.(Amps) (Amps) (Amps) ;~ 2b~ (Blue iead~)' .;~???:;' ,;': :.201401. ;':::~ '1.60 0.52 1 ;20U6P:.(Bl~'.&:.Red.l~s) :: ='-/'..'201405 ":' 0.88 . 0.28 1 ?~7240160 (Red ~eeds):-:=.~:'.' .'.' . 201402 .:. 0.86 .0.26 1 : ~;~;:~:~1~ ~el!~:& R~d !e~ds~'- :'201.411 . '. 0.39 0.13 1 '-:~'~-~'~5150 ~e 6w & B ue cads) ~: 201409 :' 1.50 0.46 1 ':."~;~/~0 ~eil~"?~ds~ ~:~;t:..~::.' :':-;'.2q{406 [:~{ :'0.92 ': '. 0.26. 1 .-;~'~her'::::?[~T~};'?.q,'~L~;~,;:~':,-'~,:':~-~,.~...'".:..~.~..;'. (ContactFactow) , ::~'~O~'{~io~'~'~'~II ~'~'V01{' I~A~ are alWays biac~. ' .' - · .~ · . . ;..~, .....? ;'-.:..: , ~ ~ '~' ,. .,.,. , · :~ ..,Se~me. Polntem~..~... :~ :~:..? ..,:....,...: . . · · :~.~he SSA Solenoid Valve and Strainer are easily removable for cleaning or re- .' :~:'~.'~-Ai~:~:.T~ 'r~M'~v~ 9alva' and stmlne~, merely Unscrew the flange bolts and "':?~s~re~d~e IIA~llghtly apeA.:: ~- - ?~:';. ,':.".:~' .': ': ' '~.~:~:: i:-FalJ'~m"{0': o~en:" (a) Coil is ~f 'in~o~eCt'l~ h'lgh'vol{~ge. See "Electrical:' .?::~ Check'veita'ge':printed 'on the coil (b) Li~e voltage Is abnormally Iow. See ::'.]~{:.."Electrlcal~' Check line ·voltage at coil leads with a voltmeter. (c) Failure to ::'.'electrically energize. Check control circuit. (d) Pressure difference across . valve Is I~ high. Th~ 85A will open against a maximum pressure difference '~)cross the vaive el 20,7 Bar (300 pslg). (e) Solenoid Coil Is burned~ut. See ~:-'Electrlcal;' and replace with proper coll. (f) Plunger/Needle Assembly Is .'..;. stlcklng,.To·disassemble the valve for inspection of internal parts (attar · ~':;~'~:pumplng ou't the s~tem as r~qulred); disconnect p~er source to ~4 Sole- .~:. ;~- -?,..' ,.,.......-;...,]~:,...., ,-.,,., ~. . · .,- . -. ,. ., , · . ...... ... '..: ,. - .: ~:.?.~.;,~..~.,~. ;=:. :~ ;~. ]- ,.....:.::~: ... ~ /..... ..... -.:. :......' . . '.', ,"~ · ; ~ I I outlined in (lt) above· (c) Main Valve Seat, Pilot Seat, or Valve Needle may be worn or damaged and therefore leaking. Disassemble and clean Valve as outlined in (lf) above. If any of these parts need replacing, it is advisable to replace using the proper replacement kit. (d) #31 Piston is sticking. See (lf) , above. (e) #32 Manual Opening Stem is turned all or partly in holding//31 Pi- son Plug Assembly open and permitting flow through the valve. (f) #5 Coil Housing Screw (made of non-magnetic stainless steel) has been replaced with a screw made of magnetic material and residual.magnetism is holding //9 Plunger Needle Assembly in the open position.. Consequently, the Main Valve is not closing. Replace with screw el correct material. 3. Leakage Through Valve: See (2) above. 4. Overheating: The Solenoid Coil is designed to operate hot and is con- structed of high temperature materials accordingly. Unless troubled with ac- .tual Coil burn-outs, high coil tei'nperature should be ignored. Persistent burn-outs indicate improper line or coil voltage. See (le) above. Warranty .. All Refrigerating Specialties Products are warranted against defeci in work- manship and materials for a period of one year from date Of shipment Item factory; This warranty is in force only when products are properly installed, field assembled, maintained and operated in use and service as specifically stated in Refrigerating Specialties Catalogs or Bulletins for normal refrigera- tion applications, unless otherwise approved in writing by Refrigerating Spe-. cialties division. Defective products, or parts thereof, returned to the factory with transportation charges prepaid and found to be defective by factory in- spection will ~)e replaced or repaired at Refrigerating Specialties option, free of charge, F.O.B. factory. Warranty does not cover products which have been altered or repaired in the field, damaged in transit, or have suffered acci- dents, misuse, or abuse. Products disabled by dirt, or other foreign sub- stances will not be considered detective. -THE EXPRESS WARRANTY SET FORTH ABOVE CONSTITUTES THE- ONLY WARRANTY APPLICABLE TO REFRIGERATING SPECIALTIES PRODUCTS, AND IS IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR IMPLIED, WRI'~'EN OR ORAL, INCLUDING ANY WARRANTY OF · MERCHANTABILITY, OR FITNESS FOR A PARTICULAR PURPOSE. No employee, agent, dealer or other person is authorized to give any warranties on behalf of Refrigerating Specialties, nor to assume, for Refrigerating Spe- cialties, any other liability in connection with any of its products. Safe Operation (see also Bulletin RSB) People doing any work on a refrigeration system must be qualified and com- pletely familiar with the system and the Refrigerating Specialties Division valves involved, or all other precautions will be meaningless. This includes reading and understanding pertinent Relrigerating Specialties Division prod- uct Bulletins, and Safety Bulletin RSB prior to installation or servicing work. Where cold refrigerant liquid lines are used, it is necessary that certain pre- cautions be taken ,to avoid damage which could result from liquid expansion. TemPerature increase in a piping section full of solid liquid will cause high pressure due to the expanding liquid which can possibly rupture a gasket, pipe or valve. All hand valves isolating such sections should be marked, warning against acciden:al closing, and must not be closed until the liquid is removed. Che~.k valves must never be installed upstream of solenoid valves, or regulators with.e_l~ctric shut-off, nor should hand valves upstream of sole: .... . ..... noid valve~ 0r'downst'ream of check valves be closedCu'ntil ihe'iiquid has been removed, t s adv sable to'properly.install relief devices in any section where liquid expansion could take place. Avoid all piping or control arrangements which, might produce thermal or pressure shock. For the protection of people and p~oducts, all refrigerant must be removed from the section to be worked on belora a valve, strainer, or other device is opened or remove=d.. ~. Flanges with ODS connections are ~ot suitable lor ammonia service. ':?:' .' Refrigerating' ~peo s riel DIv sion '. ~' T~lsx 72-8482 '.:...'-:" · FORM U-1 MANUFACTURER°S DATA REPORT FOR PRESSURE VESSELS As Required by the Provisions of the ASME Code Rules, Section VIII, Division I Manulaclured and certified by E..L. Nickell Company, Inc., 635 Franklin Street, (Name and address o! Manufa<:~rer) nu~acturedfor Refrigeration TechnologY_, I~¢.. 595 Po~J~al St.~. Cotat~.. CA q&q~1 (Name and address of Purchaser) 3. LocatlonofinsiallatJon Crystal Gey,%~[', 123~_alif. Ave.: Bmkermfimld._ (Name and address) ~V, 0 Type: Ho._rizontal S & T _Cj~l].e~r 42B78 N/A C-i0533-A 40153 1993 (Hor~Z, vert., or sphere) (Tank, se ,l~a~alor, jkL vessel, heat exh.. etc.) (Mfg's serial No.) (CRN) (Drawing No.) (Natl. Bd. No.) (Year ~ ASMECode. SecuonVfll. Oiv. t 1989, 12-31-91 N/A Edition and Addenda (date) Code Case No. Speci~ Service per UG-120(d) ~lems 6- I !inct. to be completed for ~'~"~'~ _~a~;~ei~cjactu~r,.~:~;R~'1~x-~lx, shell of heat exchangers, Shell (al No. o! course(s): 5 (b) Overall length (~t & in.): 2 2 1-0" TF-'~ Course(s) Material Thickness Long Joint (Cat. A) ' Circum, Joint (Cat. A, B & C) Heat Trea~-nent No. Diameter, in. Lengl/~ (ti & in.) SpecJGrade ~Type ' Nom. Corn Type Full, Spot, None Elf.. ; Type Full, Spot, None Elf. Temp. Tree 1,2 37" 96" SA-516-70 5/1 ," 0 2 None ,65 2 None .65~ 3,4 " 6" " " " " " " " " ·" " " 5 " 57" " " " " " " " " " " " 7. Heads: (al (b) (Marl Spec. No., Grade o~ Type) H.T. - Time & Tamp ~, .. (Marl Spec. No., Grade or Type) H.T. - Time & Tamp Location (Top, Thickness Radius ~ EllipUcal Conical Hemisl:~ric~ Flat Side to Pressu~'e Catego~' A Bottom, Ends) Min. Corr. Cnmm Knu<:~le Ralio .' Apex Angle Radius Diametei' Convex Concave Type Full, Spot, None Ett. (a) ............................... it remov'4bte, bolts used (des~ibe o~ fa~te~ng) (Marl Spec. No., Grade, size, No.) Jacket closure ....... (l:::)es~ibe as ogee & weld, bar: etc:) If bolted, desc~be or 9. MAWP ' 150 ' "°F (intemaJ) (externaJ) -: . ~O. Imp~c~test Impacts exempt per: UCS-66(a) .... ~ (Indicate yes or no and ~ component(s) impact tested) 11. ~.. pneu., o~. test ~ess. ' .... 1 8 8 ........ Proof test N/A .terns 12 and 13 to be completed for aJbe .~c~ons.' ........... '" ........... i 2. TubesheeC 1 ~./2" psi at max. temp. -I-225 '-' .......... . .. (imem .aQ '.i. '.,: (external) Min. design metal temp. ' .--~ °F at I ~{') SA-516-70 ': '~:':' '~'~''' 37" " '"~' '0 '" Stationary (Marl Spe~c. No:)' '..:::. ' Di,~,.~.in: (subj'' ~ ~'~ ;' m N~'' ~k.. in. ..... Corr. Allo~v:, in. .... 'WeldeE Floating (Matq Spec. No.) ., - Dia., in. Nom. lhk., in. Cor'r. Allow., in: ' 13. Tubes: SA-214 ' ' : ...... 1 1/4" ": '"' '13 GA " :' 442 Mat1 Spec. No., Grade 0~ Type .. O.D., in. Nom. Ihk., in. or gauge Number Items 14 · 18 incl. to be completed for i~;~,~~,~Te,' channels 6f heat exc. hange~s. 14. Shell (al No. of course(s): (b) Overall length (h & in.): ·. A.)mchmem Straight Type (S~ralght m U) :::+::::,: :: ::::: ::: :::: :::: :::: ::: :::: ::::::::: :::: :::::::::_ Heads'(a)- *"1/4 ' SA-516-70 " (b) SAME ' .' (Ma¢l Spec. No., Grade or Type) H.T. - Time & Tamp (Mat'l Spec. No., Grade or Type) H.T. - Time & Tamp Loca~on (Top, 'Min:'" I Radius I EllipUcal ConicaJ Hemispheric~ Fiat Bo.om. End,)/ ICo..,Crow.~,.uckle, Ratio ~.pe.~.ngle Radius marne,er co~ve, lco~ca~, T,~eF~".SPO,.-- End 1.237l 0 l----q- ..... I 2:1 ' - ..... None .239 " ,, ,, ,, ,, ,, .: ,, 7, I" / 7, I " if removable, tx:~ltsuw, ed(des~ibeom~r!astomrr, g) 80 -- 3/4" SA-193-B7 Studs with 160 - 3/4" SA-194-2H Nuts. (Mat'l Spec. No., Grade, Size, No.) This torm may be obtained Irom The National Board of Boiler and Pressure Ve',se{ Inspeclora, 1055 Crupper Ave., Columbus., OH 43229 FORM U-lA MANUFACTURERS' DATA REPORT FOR PRESSURE VESSELS (Alternate Form for Single Chamber, Completely Shop-Fabricated Vessels Only)". ,. , es required by the provisions of the ASME Code rules, Section VIII, Division 1 .. 1. Manufactured and certified by_ E. L. Nickell Company, Inc., 635 Franklin St., Constantine. MI 49042 theme ae,~ a~dtess o! manufmCtu~'o~ 2. Manufactur~lor Ee[~e~atton ~echno[oAY (nc. 595 ~o'[ta[ SC Co~att CA 9493[ Po#3755-9 3. Location of Installation C~stal Ceyse~ 1233 g Ca11~ Ave ~a~ersfteld CA 93307 Hor iz. {n~e ~d 4. Type: Accumulator 42879 N/A C-10533-B 40154 1993 ~V. 0 5. The chemical and physical prope~ies of all parts meet the requirements of material specifications of the ASME BOILER AND PRE~URE VESSEL CODE. The design, construction and workmanship conform to ASME Code, Section VIII, Division 1: 1989 , le(~clend& (date)) (Co(~? Case no.) 6. Shell: SA-53-B 1/4" 0 (mat't. ($p~:. ~.. g~ (n~. thickne~ (In.)) (corr. ~low. (in.)) 7. Seams: ~PE E None 85% N/A (lang. ~ei~. e~l., sngl. la~. ~tt)) IRT (a~t ~ full) (eH. (%)) IHT temp. ['~) 8. Heads: la) 1/4" NOM. SA-516-70 lb) tspeclel se, mice per 1 Ft 5 1/2 In. 16 ~t 10 1/2 In. (dia. ID (lt. & in.)) (length (oversll) (It. & in.)) N/A' TYPE 2 None l {time (hr.)) (girth (welded, dOt., (RT (spot. partial. (no. O! courses) sngl., lap, butt)) o~ tull)) Same matt (spec. no.. grade)) {mat's. (spec. no.. grade)) Louation (top, Minimum Co~roslon Crown Knuckle Elliptical Conical Hemispherical Flat Side to Pressure bottom, ends) Thickness Allowance Radius Radius Ratio Apex Angle Radius Oiameler (convex o~ concave} la) End .237 0 2:1 Concave lb) " . 239 " " " " ,.,:" " " " If removable, bolts used (describe o'ther fastenings): N/A (mat'L, spec. no.. gr.. size. no.) 9. MAWP: 150 at max. temp. '.,+225 . Men design metal temp. -~2(5 at ] 5(5 . t-Jc~a~., pneu:.~:'ql~, test pressure ] FiR . tps,] {. F) {' F) (p si). (psi) 3. Nozzles, inspection and safety valve openings.~...~ Purpose . Dis. Nom. Reinlorcement How (inlet. outlet. Drain. etc.} NO. or Size Ty~,e Mat'l. Thickness Mat'S. Attsciqed LocatiOn Risers 3 8" P~pe SAiO6B S/40 W~l d~d N/A Suction 2 6" · " " " " " " Column 1 1 1/2" CplE gal05 q(5(50 " " " Relief, Vent 1,1 3/4"3/4" Pine SAl(56B ~/gO " ,. " " 11. Supports: Skirt No Lugs 0 Legs 0 Other q Ri,~'~ Attached~e~ (yes or no) (no.I (no.) (describe) (where & row) i2. Remarks: Manufacturers' Partial Data Reports properly identified and signed by Commissioned Inspectors have been furnished for the ' N/^ following items of the report: (name of peq. item number, raft's, name and iOentit¥ing ~ - CERTIF CATE OF SHOP COMPLIANCE / ~ Date / /~- ~ Name ~ .... ' - Ire~,esentalive) ' -- CERTIFICATE OF SHOP INSPECTION Vessel constructed by E_ Z._ Ntctce'l '! (':.nmr~anv- In~. at ~n~Rn~tnP = HT ,.-i I, the undersigned, holding a valid commission issued by The National Board of Boiler and Pressure vessel Inspectors and the state or prov- inceof MI - and employedby~emPer National In~urmn~e C~mp~n~e~ .~ ol Lmn~ Grove .' IL have inspected the component described in this Manufacturers' Data Report on ~ ~ . 19~ and~ ~state that, to the best el my knowledge and belief, the manufacturer has constructed this pressure vessel in accordance with the ASM~ Code Section VIII, Division 1. By signing this certificate neither the inspector nor his employer makes any warranty, expressed or implied, concern~ lng the pressure vessel described in the Manufacturers' Data Report. Furthermore, neither the inspector nor his employer shall be lied e in any or ropert~a~r a loss o~ny ~i~ arising~om or connected.with this inspection. This to~m may be obtained from The National Board of Boiler and Pressure Vessel rnspecto~s, 1055 Crupper Ave., Columbus, OH 43229 FORM U-la M,e'" tFACTUF{ER'S DATA REPORT FOR PRFqSURE VESSELS (Alternativo Form ,.. 'Single Chamber, Completely Shop-Fa, '.'atod Vessels Only) As Required by the Provisions of the ASME Code Rules, Section VIII, Division I Manufactured end cortlfiec~ by (Name and add, ese el mAnldAclL..,) ROY [. IIANSON Jl{. ~tf'G.~ I 924 Coral)loft ~'~r~e, I.os Aft~(~l~r Cnlilorllia Manufacturedlor(Namoa~lAdd,o,~ofpurchasoO. REF"RIO[~F~A'rION 'I'ECHHOI_OGY~ Il,lC. COTATI~ CA ~,~8 .I....,, HA '- 729-D 122568 1993 Type HOR ~ Z. "~ _ ....... Tho chemical And physical i)ropo,tios ul ~11 perth moot the re(1,~iron~o.t5 el material spucilicalion$ of tho ASMI.'~ t3OILER AND PF;ESSURE VESSEL CODE. Tho design, construct[on, et~d workmanship conlorm to A~,,ME f:~LJles. :3DC,iOn VIII, Oivic. ionf 19{]~:1 ID Sh-~12 .3,t5" 6. ~hell: ' SPOT ~5 SPOT 7. Seams: Welded - Dbl. Bull Welded - Sngl. to ~U L~O. ~e~ed, ~., R,T. (S~ ~ Full) Ell. (%) H.T. To~. ('Fl 8. Heads: (al MeM. ~ (b) Mall. (spd~, No.. ~,}zlm~) (~. No., Grade) LOCATION MIN. CORR. CROWN KNUCKLE El.l. IP.~E CONICAL HEMISPH. FLAT SIDE TO PRESSURE (Top. BetiDe, Ends) THK. ALLOW. RAOIUS RADIUS RA1 lO APEX ANGLE RADIUS DIAM. (Co.vex et' Conc. ava} BOTH .387" 0 38" 6-3/4" (al ' CONCAyE lb) II removable, bolts used (describe other fastenings) ~. MAWP 250 Min. design metal lamp. -~0 'F al t0. Nozzles, inspection and safely valve openings,: (Mitt., Sl~¢. NO. Qt., SIze. NO.) psi al max. temp.. 600 ,'F ~,~0 psi Hydro., pneu,, or comb. tesl pressure 375 psi. Purpose Di~m. Ty~e Idall. Nom. Re;nlo~comenl How Location (Inlet, Ot~le~, Drain) NO,. er Size. Thk. Mall. Allached ROTEST .1. 3/~" FNPT SA-:I. 05 3000ti WELl)ED SHELL ACCESS 2 '~" F'IF'I=' SA-iOG-B ,?CH. 80 WEI. DED SHEI_L/F'IPE SUMP 1 8" PIPE SA-'I. 06-E~ SCH. 40 SA-612 WELDED SHELL ACCESS I 3" PIPE SA-106-[{ SCH.80 WEI_DED PIPE ACCESS 2 4" F'IPE SA-1OG-B SCH. 80 WELDED SHELL ACCESS 2 3/4" PIPE SA-10G-B SCH. 80 WELDED SHEI_L/PIF'E ACCESS 2 1" FIqF'T SA--105 300011 WELDED SHELL/PIPE 11. Supports: Skirt N0 Lugs .Legs Other 3 SUF'F'01;;TS .Allached SHELL WELDED (Yes or No) (No.) Ir,iD.) (Oer, c~ibe) (Where end how) 12. Remarks: Manulacturer's Partial DaLe Reports properly identified and signed by CommissiPned Inspectors have been lurnished for tl~e Iollowing ilems of the fsgsr~; UOL~O(f) UCS-GG(a) FOR NONCORROSIVE SEP':ICE. HEADS ARE STRESS RELIEVED 16511 Shell sLress (psi), 17353 Head Si,ess (psi) Type el Sen'ice AMMONIA CERTIFICATE OF SHOP COMPLIANC VVe certify thai the alatemenfs made In this rePorl are cDr,ecl and Ihal all details el design, maleri, i~o~nsl~Jclion, an~v..,,~(nm, anship o, this vessel ~nform to the ASME Code for Pressure Vessels, Sec[ion Viii. Division 1. 'U' CeMilicale el Aulhorization No. / I rue / expires~ UECE&{~ER 31 ,19 9~. Dam 3/3/93 co. n~me ROY E. tlANSON JR. MFG. ' Signed [ /~ ~ ' . · CERTIFICATE OF SHOP INSPECTION .vessel const~uclod by - ROY E. IIAN~uN glO, MI'U. ,al 1924 COMi'TON AVENUE, LOS ANGELES, CALIFORNIA I. the undersigned, holding a valid commission issued by 1130 National Ooard of Boiler and Pressure Vessel Inspectors an~or tho Slalo or Province of ~LIFORNIA Rnd employoO bye. , Tile CI~ OF LOS ANGELES kinspected G~ent this Manulacluror's Data Roport on tho described In nowledge and belie~, the Manulaclufor has construclod thi5 p~essuro vessel In accordance wllh ASME Code, Section VIII, Division 1. By signing this codificute neither the Inspector nor his employu~ makes any warranty, expressed or implied, concor~ng tho prossu[o vessel described in this Manufacturer's Dale ~epo~. Fudhermore, neither the InapeGIor nor Ilia employer shall be liable in any manner for any personal Inju~ FORM U-lA MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS (Alternative Form... . Single Chamber, Completely Shop-Fa' 'sled Vessels Only) As Required by the Provisions o! tho ASME Code Rules, S~c[ion VIII, Division 1 Mnn~lfachJred nnd ce,lilied by (N.n,e and .dd,o.o al rnanulaclu,u,) ItOY [. IIANSON ,IlL MI'G.~ 1D24 Coral)lo. Avenuc, LbS Ang~:~ California ;~nufaclurod lot (Name a~ a~ro,~ of pu,ch~,o,) RI.:]:R.[ GERAT .[ ON 'I'I~X;HNOI.OGY ~ fi'lC. COTAT [ ~ CA 3. L~IIo~ of Installallon (Name and .~reem) ,. ~-,',,'nq 1993 4. Type HOR[Z. 338126 NA-728-B .~u~. (tluit. ~ v.tl. te,~) I~l~.'...,~1 Nh,) (C~N)-- (Drnwln0 ~,) (N~I1. ~. NO.) {Yemf B~ll) 5. The chemical and physical p~opo~llu~ uf ~11 pa[ts meal Iho roquiromu~ds ~1 malarial spocilicnfions el Iho ASME BOILER AND PflESSUI~E VESSEL CODE. The design, ~nslruclion, and workmanship carlotta to ASME Rules, 5action VIII, Division 1 19~]9 1991 tO 7, Seams; Welded. DbL ~ull SPOT 85 Welded - Sngl. Io BU SPOT 8n~.. ~p. au,) S~L. ~p. Bull) PI~II, Full) Heads: (a) Matt. SA-~55 (b) ~att,. SAME LOCATION MtN. CORR. CROWN KNI ICKI. E EI.LIP~E CONICAL HEMI~PH. F~T SIDE lO PRESSURE (Top. Ooll~. E~s) THK. ALLOW. RAOIUS RAOILJS RATIO APEX ANGLE RADIU~ elAM. (~ox ~ ~ve) (a) BOTH . ~875" 0 ~: 1 ' C0N~VE It removable, bolls used (describe other lastenings) 600 'F 9~ MAWP .1.50 .psi at max, temp. Min. design metal temp. -20 'F at 150 psi Hydro., pneu., or comb. lest pressure "~-'J psi. 10. Nozzles, inspect;on and solely valve openings: NO*, Or,. $,zo. No,) ~ Puli)asa No. Diam, Typo Mall. Localt~ /(InlOII OuUets Drain) 9r ~iiq, Thk, MRS, AllflG~d ~~ ~. F~II F'~P[: s O':.igj~- ~' SCH. 40 UELr, Er, __ SHELl. A~C~SS 1 1" F'I F'E SA-IO6-B SCH. 80 WELDI:D SHEI. L ACCESS 2 3/4" PIPE SA-106-B SCH. 80 WELDEI) SHELL ACCESS 1 2" F'IPE SA,- 106'-B SCH. 40 WEI_[tE[~ · SHEI_L AC.C.E$_S ,.. 2. ~"~ PIPE oA---.LOu-'B SCH.40 WELDED HEArt A C.C.I~SS 2 6" F.' I F'E SA-106'-B SCH. 40 HELDED HEAD '~ SHELL WEI..DED 11. Supports: Skirt NO Lugs ,Legs~ Other ~. SUPP0[;,"]'S Attached (Yll or No) (No.) tNo) 12. Ro~rks: Manulaoture~8 Pa~ial Data ~epo~ properly idenfiHod and signed UG-20(f), UCS-66(a) FOR I',IONCOF(F~OSIVI:" SISF~VICI':, H'IZ. ADS AP,.Ig STRIgSS I{.I~LIEVED Shell slress (psi) 9540 Head Stress (psi) 9465 Type al Sen/ice AMMONIA CERTIFICATE OF $1~IOP COMPLIAN.~'--~ We certify that the statements made in this report are correct and thai all de,ails of design, mate '~,,~co~nslj~bclion. andp~{nn anship of this vessel conform tO ,he ~ME Code I~?essure Vessels, Soclion VIII. Division 1. 'U' Codillcato of Aulhorization No. /. iu:~ / expires //. DECEMBEIt 31 ., 19 94 . Date 3/~J Co. name ROY [. HANSON ~l~. ~FG. Signed ~ ~ ~ ' ' , iM~l~o~e,) ...; .... C~RTIFICATE OF SHOP INSPECTION Vessel oons[ructod by I{0Y E. IIANSON Jif. MFG. al 1924 COMI)'[ON AVENU[, LOS ANGELES, ~LIFORNIA I. the undersigned, holding a valid commi~s~n Issued by I~o N~tional Board al Boiler and Prosst.o Vessel Inspoclors an~or ~LIFORNIA and employed by. ~llE CI~' OF LOS ANGELES Ihs component described In this M~nulactu[er's Data Repo~ on and belie/, the Manufacturer ha~ conslruclod this pressure vo~ol i~ accordance with AS~E Code, SocUon VIII, Division 1. Dy signing this ce~ilicale nailher Ihe Inspector nor his employe~ rn~k~ any warranty, expressed or implied, concerning the pressure vessel described in this Manufacturer's Data I~epo~. Fu~hermore. neither Ihe Inspector nor his employer shall be Itztbla In any manner lot any personal inju~ or p~ope~y damage or ~ loss al any kind arising Oalu~ '' ?' -- ~ Signed C Commission; ¢~ ''5-~ OHiO CO~a FRICK ORDER 208847 CUST. ORDER 3753r95 - FORM U-3 MANUFACTURER'S CERTIFICATE OF COMPLIANCE COVERING PRESSURE VESSELS TO BE STAMPED WITH THE UM SYMBOL. SEE U-1 (j) As Required by the Provisions of the ASME Code Rules. Section VIII, Division 1 Menuf.ct.r.de-dc.~,i.dbv *FRICK COMPANY, 100 C.V. AVE. WAYNESBORO: PA T).qA 17268-~1997 ~. M.,u~,,,.d~o, ~EFRIGERATION TECHNOLOGY INC. COTATI, CA 3. u~.~o, of ,,,~,t,.~m, X~X~X~X CRYSTAL GEYSER. B~ERSFIELD. CA ~.Typ. Vert .66 cu.ft. 5B5D017B"G" MC ~%~ ... .... iW92' {HQf,Z. or Veft. I [C~acily} ICRN) {O,ew,~ No.) (MISts. Sir. NO.) IYear Built) 5. The chemical and physical prope~ies of alt pa~s moot the r~lrements of material s~eclfication~ of the ASME BOILER 'AND PRESSURE VESSEL CODE. The design, construction, and workmanship confo~ to ASME Rul~, S~tlon VIII, Divition I 1989 (year) and Addenda to 'A~i ..... ' '...,o,,.) ..d cod. c.- .o,. 2131 & 1518-2 ~mnufec~re~' Pm~al Da%a R~o~t~ proper~ }dent}~ied smd l]gned b~ Comm}~}oned ~m~ec%Dr~ h~e been furni~h~ for ~he following ~tem~ of ~he ~epor~: N/A S. Sh.ih SA-414-G .1~4 0 0'-8 ~/8" I'-10 1/16" Matt. (~e~. NO., Grail Nom. Thk. {in.) ~.. Allow. (m.I Diam. {fi & in.J 7. s,ams: WSB nOD~ 7,0 no L~g, IWtd.. O~l., ~gl., LaD. ButtJ R.T. (~t ~ Ful[I Elf. (%j H.T. Temp. ~ F ) 0 none none . T,~ (hr} Girth ~ld.. O~l.. ~1.. L~D. Gull) R.T. (~t, Partial, s. H.~,: (.) M.~. SA-5~6-70 m) ~,,,. R~-5~ 6-70 . (~c. No., GrUel · · Tpp : '.937. 0 _ _ ) - - - 8 3/8 - . . Bottom 1;000 0 - -I - I - - " I - ... Ifrem~weble. bolts used {describa other fastenings) SA-325, 120~000, ~/8, 8 (t~4atl,. Spec. NO.. Grade, Size. tqo,) Type of Jacket Proof Test Jacket Closure -- If bar, give dimensions (Des~'iDe a~ OOee& v,~J~', l~lr. 11. Const. for max. allow, work~ng press. 350 psi at max, temp. +200 ~., pneu., ~ test pres. 438 12. ~fety Valve Outlets: No. i Size 1/2 °F. Min. design metal temp. ~op-I-lead If bolte<~, describe or sketch. -20 oFa~ !0.2 p~. 13. Nozzles and Inspection Openings: i P~rpose J D;,wn. Nom. ReinlorCzm~nt How (inlet, Outlet. Drain) Ne. or ~ize Typ~ ~etl. Thk. ~lll. AtTI~ Lo~tion Oil Out ~ 1 1 1/4 Fit $AL105 - nnn~ u~a~a Inspect{ 1 8 ~/8 " $A-516-70 1.187 " . . " ...... Inspect 1 8 3/8 F'I~ ,, .9~ , " . .bnlt~d ~mp . - -- Bracket( ] ) Attached side-welded 14. Supports: Skirt no Lugs Legs .Other (Yes, o~' no) INc.) (No.I (Oeso'ib~l (Wh~e ,Inc} howl 3/8 OD x 24" oil filter. For non-lethal/non-corrosive service "Charpy 'impact testing is exempted per UG-20F' · CERTIFICATE OF COMPLIANCE form to the ASME Code for Pressure Vessels. Section VIII, Division 1. o,t. ]~9-2-"'q~Z- s~g,.d Frick Company by_ . _ ,__ _ _ ' "UM" C.~,f,c.,e of ^u~o,a.t,o..o. 2676 .~ire, May 28' ~ 93 FRICK ORDER 20U847 CUST. ORDER 3753-95 FORM U-3 MANUFACTURER°S CERTIFICATE OF COMPLIANCE COVERING PRESSURE VESSELS TO BE STAMPED WITH THE UM SYMBOL. SEE U-1 (j) As Required by the Provisions of the ASME Code Rules. Section VIII, Division 1 Menulecturedendc.r~lfiedby FRICK COMPANY. 100 C.V. AVE. WAYNESBORO. PA USA 17268-0997 .. M.,u,.c,ured fo, REFRIGERATION TECHNOLOGY INC, COTATI, CA 3. Loce,~o, o, In,ten.t~o. XY~)~(~W~X CRYSTAL GEYSER, BAKERSFIELD, CA ~.~~ ~. ~,. VE~T .66 CU.FT. 5~5D0276 . . MC..q~qO~_ ..... ~ ~ .... 5. The chemical en~ physical p~ope~les of ell parts meet the requirement~ of materiel specifications of the ASME 8OILE R AND PRESSURE VESSEL cODE. Ag] ,~.,,, and Code Case Not. 1518--~ & 21ql Manufacturers~ Partial Date Repo~s properly Identified amd slg~sd Dy Commissioned I~ectors h~e bee~ ~urmlsh~ for the foliowlmg ite~s of the report: s. Shell: SA-4]~-G Mall. ISOee. No.. Gra~e) Nee: Thk, (in.) ?. S.ems: L~. ~ld.. Dbl.. ~gl.. Lap. Butt) 0 1,~ 8. ,,ed,: (,) u,,~. SA-516-70 0 0'va ~/8" 1'-!0 1/16" Allow. lin.) Diam. Itt & in.) Length itt & in.) NONE 70 NO R.T. (mt ~ Full) Elf. (%) H.T. ~emp. ~ F) NONE NONE 1 Girth {WICI.. DbL, Sn91.. Lap, Butt) (b) Mall. R.T. (SLot, Partial, or Full) SA-516-70 {S~ec. No., Gr~ee) No. of Courses I Location (Top. Mm,mum Corrosion Crown Knuckle Elli~cal Conical Hem,sPherical. I Flat S~e to Pfesture q~op .9~7 o ..... I ~ ~/8 - [ RnmmnM 1.000 0 ..... I ,, _ If removable, bolts us;d (describe other fastenings) SA-193-B7, 5/8., 8 9.Type of Jacket -- Proof Test 0. Jacket Closure -- If bar; give dimenslons ID~iae a~ oge~ & weld, bar. etc}. Cons,. for max. allow, working press. ~50 ~=i ~ max. temp. +200 12. ~f~y VelveOu~leu: No. 1 Size 1/~ ~ Location 13. Nozzles and Ins )~tlon Openings: ' ' (Mall., Spec. No., Oracle, Size. NO.) °F. Min. design metal temp. SHELL SIDE If bolted, describe or sketch. -20 °~at10-2 p~. O_~L OUT ~ I! 1/~ FiT SA-lO5 - / NONE .I wELDED TW.~P~C.T 1 i8 .~/8 " SA-516-70 I1.250~ " " INSPECT I $8 3/8 FLG ,, .937 ,, BOLTED ~ TOP SAFETY i ~ 1/2 FIT SA-105 .'161 " WELDED I ~. S~ppons: Skirt NO Lugs - Legs - Other BRACKET ( 1 ) Attached SIDE-WELDED IY~ o~ no) (No.) INo. I. {D~saib~} (Whet'e aha how) 15. P, emerks: 8 3/8 OD X 24" OIL FILTER. FOR NON-LETHAL/NON CORROSIVE SERVICE. "CHARPY IMPACT TESTING IS EXEMPTED PER UG-2OF" CERTIFICATE OF sHOP COMPLIANCE V,*e cenih/ that the statements made in this report are correct and that all details of design, material, construction, and workmanship of this vessel conform to the A,SME Code for Pressure Vessels, Section VIII, Division 1. 9 3 '"J,M" Certificate of Authorization No. 2676 expires MAY 28 19 - D,:-'--~'7--q-~ Companynam~ FRICK COMPANY Signed /~/~J~ · This Form (EO011 I) may be obtained from the ASME Order Dept[, 22 Law Drive. Box 2300, Fairfield, NJ 07007-230~ FRICK ORDER 208847 CUST .ORDER 3753-95 FORM U-3 MANUFACTURER'S CERTIFICATE OF COMPLIANCE COVERING PRESSURE VESSELS TO BE STAMPED WITH THE UM SYMBOL. SEE U-1 (j) As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 Me,~f,ctur,oe,dc*rtm*dby F~ICK COMPANY, 100 C.V..~VE. WAYNESBORO. PA USA 17268-0997 ~Menufectured for_ ~EFRIGERATION TECHNOLOGY INC ~ COTATI, CA Location oi In,tellatlon ~X~XX CRYSTAL GEYSER, BAKERSFIELD, CA Typ. VERT .66 CU.FT. 535D0276 MC q~O~ ' (Hm~z. o~ Ve~L) (C.p~c,t~) ~CHNI IO,*w,~ No.) (Mlgr~. Sar. NO.) (Year Built) 5. The chemical and physical properties of all parts meet the requlroments of meter(al specifications of the ASME BOILER AND PRESSURE VESSEL CODE. The design, construction, and workmanship conform to ASME Rule~. Section VIii, Division 1 !989 (Y,,,) and Addenda to Ag1 )D,,,, .nd Code Ce,. No,. 1518--3 & 2131 Manufacturers' Part(el Data Reports properly identified and signed by Commi'ssioned Inspectors have been furnished for the following items of the report: ~Aatt. f~mr. No.. G~a~e) NDe: ~hk. 7. S*,m,: WSB 0 NONE s. H~,d,: (,) M,U. SA-5~6-70 lsat. NO.. 0 0'-8 ~/8" 1'-10 1/16" C4:~. A~ow. ti~.l ~).am. Itt & in.) Length lit & in.) NONE 70 NO R.T. (S~ot o~ Full) Elf. (%) H.T. Temp. NONE 1 R.T. (Soot, Partial, or Fu$1) No. of Cc~J..e~ SA-5!6-70 (Spec. No.. Gra~e) Gfflh (Wld.. Dbl.. $~gL. Lap. Butt) (b) Marl. I l(a) o ..... 8 - I(~) RClmmrlM I .000 [ 0 ..... " - If removable, bolts used (descrlbe other fastenings) SA-193-B7, 5/8, 8 (Marl.. S~ec. No.. Gracle, Size, NO.) 9.Type of Jacket -- , Jacket Closure IOesc~ibe l$ o~ee & w~la, bar. etcJ, i..,~.o~. Const.. for max. allow, working press. ~ 50 12. Safe~y Valve Outlets: No. 1 Size 13. Nozzles and Insp~tion Openings: Proof Test, If bar, give dimensions -- psi at max. temp. +200 °F. Min. design metal teeD. !/2 NPT Location SHELL SIDE If bolted, describe or sketch. --20 eFat ].0.2 psi. Purpose Di~. Nom. [ Reihlorce~n! How I OIL OUT 1 1 1/~ FIT SA-105 - t NONE WELDED. 7N~wECT 1 8 ~/8 " SA-516-70 1.250 I " " t INSPECT 1 8 3/8 FLG ,I .937i ,, BOLTED I TOP SAFETY 1 1/2 FIT SA-105 .1611 " WELDED 14. Supports: Skirt NO L~gs -- .Leg, - Other BRACKET(1 ) (Ya~ m nol (ND.l/ {No.) (Describe) ~s. n.m.~,: 8 3/8 OD X 24,,"/'0IL FILTER. At~eched SIDE-WELDE__~D FOR NON-LETHaL/NON CORROSIVE SERVICE.. "CHARPY IMPA~T TESTING IS EXEMPTED PER UG-20F" CERTIFICATE OF SHOP COMPLIANCE ;';e certify that the statements made in this report ere correct and that all details of design, material, construction, and workmanship of this vessel conform to the ASME Code for Pressure Vessels, Sectlo. VIII, Division 1. ~- 'qJM" Certificate of Authorization No. 267~ 0 expires MAY 28 19 Data J-t~--q .~ Company name FRICK COMPANY Signed ./2/,~_~.,~.d/~_ (12/~8) This Form(EO0111) may be obtained from the ASMEOrder Dept., 22 Law Drive, Box 2300, Fairfield. NJ 07007-2300 'RICK ORDER 208847 :UST.ORDER 3753-95 FORM U-lA MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS {Alternative Form for Single Chamber, Completely Shop-Fabricated Vessels Only) -As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 Sht lof2 Manufactured and certified by Manufactured for . Location of installation Type Horiz The chemical and Physical · F~TCW COMPANY: lO0 C.~'. AVE: W~YNRgR~RO, REFRIGERATION TECHNOLOGY INC, COTATI, CA ~y~X~y~Y~XX CRYSTAL GEYSER, BAKERSFIELD, CA PA ll~A 17268-0gg7 5. properties 'of all parts meet the requirement~ of material SDeclficatlons of the ASME BOILER AND PRESSURE VESSEL CODE'. The design, construction, and workmanship conform to ASME Rules, Section VIII, Division 1 1989 A-gL...!;, 1518-3 /.2131 N/A tO s. Sh.,I: SA-414-G .187 0 1'-3 5/8" 5'-8 3/4" ~. s.am,: WSB none 70 no 0 none none 1 Leeg. {Wekled, Did.. R.T. toper m' Full} EH. I%) H.T. temp. (~Fi Tie~e Ihf) Oirt~ IWe~ded. Did.. R.T. (S~L Pemid. No. o! 0 8. Heads: ia) Marl. SA-414-G (b) Mat~. L~atlon ~op. Minimum Corrosion Crown Knuckle EIliglicel Can;cai Hemispherical Flat Side to Pressure Bottom. Ends) . Thickness Allowance Radius Radius Ratio Apex Angle Radius Diameler (Convex er Concave) ~'~1 End .157 0 - - 2:1 - - - concave miI End 1.12~ " ,, .... ._ 16 - Ifromovable. boltsusad(descrlbootherfastan'ngs) SA-19~-B7, 125,000, 5/8, 12 +200 o~ 9. MAWP 300 psi at max. 'camp. Min. design metal temp. --20 OF at 10 · 2 psi."-~, ,1~3~, pneu.,~, test pressure 3 7~ psi. Nozzles, inspection end safety valve openings: Nom. Reiniorcemen, How t,ocation Purpose Diam. Type Marl. (ln~,.L Outlet. Drain) No. or Size Thk. Mall. Attached Safety 1 1/2 Fit SA-!05 .161 none welded I Drain 2 I 3/4 PIPE 'SA-iO6-B .154 " " I I Charge 1 i 1/2 FIT SA-lO5 .161 " " t OilRetur~ i t 3/4 ,, " .!70 " _ " I 11. Suppor13: Skirt no Lugs -- Legs -- Other Bracket (2) Attached Bottom-welded 12. Remarks: Manufacturer's Partial Data Reports properly identified end signed by Commissioned Inspectors have boon furnished for the following items of the report: N/A 16" OD x 75" oil separator for refrigerants.For non-l~ch~l~ o~Tco_r?_osz~ve service. Refer attached U-4 form."Charpy impact testing is exempted~r~ UG-2OF". CERTIFICATE OF SHOP COMPLIANCE / We certify that t'he statements mede In this report are correct and that all details of design, material, construction, ej~ workmanship of this vessel con- / focm,o 1~e ASNiF_J~ode for Pressure Vessels. Sec~on.V~l,. ~lvlslon 1. "U" Certificate of Authorization No. 14 ~/~~~~~ O,~, /"/~'V.'~ co. name ~'r~cK uompany Sign,~ Frick Company CERTIFICATE OF SHOP INSPECTION Waynesboro Vessel constructed by .at '1. the undebs~necl. holding a valid commlsslonand employedlssued by theby NotlonaJKEMPERBOard NATIONAL'Df Boiler. and PressureiNS. v e. ss.elCOMPANiES .I nt4:)ector!,LONG~n~or theGROVE,Stat, o( ILLPr°~ce of h~e Inspired the component described In this Manufacturer's Data Repo~ on . 19 ~ , and state that, to %he best of y knowledge and belief, the Manufac~rer has constructed this pressure vessel in accordance with ASME C~e, S~tion VIIS, Division 1. By ~Thh certlflca[e neither the Inspector nor his employer ma~es en~ty,~ess~ or Implied, concerning the pressure vessel described in ~isManu- ~t~rer', Oa,a Report. Furth.rmora, neither ,he InspeCt nFh~l~er~all bo liable In any m[nner for any personal injury or proper~ damage /O'' loss Of any kind ,~lngfrom or connectedwl~i/insP~,I/~ [ / ....... ~ - {12187) ~ ~s Form lEO0117~ybeobrained from the ASME Orde~ Dept.. 22 Law Drive. Box 2300, Fairfield. NJ 07007-2300 FRICK ORDER CUST.ORDER 208847 3753-95 FORM U~ MANUFACTURER'S DATA REPORT SUPPLEMENTARY SHEET As Required by the Provisions of the ASME Code Rules, Se~ion VIII, Division 1 SHT 2 OF 2 end certified by, FRICK COMPANY~ 100 C.V. AVE, WAYNESBORO,.PA uSA 17268-0997 9. Manufactured for REFRIGERATION TECHNOLOGY INC, COTATI, CA 3. Locetlon of ln,t~llatlon )~Y~r~k~XX CRYSTAL GEYSER~ BAKERSFIELD, CA . l 06'300 ,'G,, 4. Type 105300 Data Report Item Number BULBWELL 4 3/4 FIT SA-105 .170 NONE WELDED (ITEM 10 IN U-lA) L.L.FLOAT 1 1 " " .196 II II (ITEM 10 IN U-lA) SIGHT GLASS (ITEM 10 IN U-lA) I1 II OIL OUTLET 1 (ITEM 10-IN U-lA) 1 1/4 " " .208 II II HTR CARRIER 1 (ITEM 10 IN U-lA) 1 1/2 PIPE SA-106-B .400 II I1 GAS INLET 2 (ITEM 10 IN U-lA) 3 " " .216 " " GAS OUTLET 1 (ITEM 10 IN U-lA) 3 PIPE SA-106-B .216 NONE WELDED GAS INLET 1 $ FIT ITEM 10 IN U-lA) SA-234 WPB " " " INSPECTION 1 (ITEM 10 IN U-iA) 16 HD RING' SA-5!6-70 1.437 MIN " " Dete [12/~2) ~form (E0011~ ~allable ~rom ~e Order Oept., ASME. 345 E. 47 St., N~ York, N.Y. 10017 :RICK ORDER lUST. ORDER 208847 FORM U-lA MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS 3753-95 (Alternative Form for Single Chamber, Completely Shop-Fabricated Vessels Only) As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 Sht I of 2 Menufocturedand.certfledby~ FRICK COMPANY. !OO C.V. AVE_ WAYNF. gRNRN: for REFRIGERATION TECttNOLOGY INC, COTATI, CA p~ H~G ]7?RR-nqg7 3. Loc.tlo, of~n,talla,~on ".IX~Y. XK)~'6~i~XXX CRYSTAL GEYSER~ BAKERSFIELD, CA ,. ,,p. .oriz I Oql 3 2_ '548D0611 ,u,,IOqlS 5o The chemical end physical propertle~ of all parts meet the requlrement~ of material specifications of VESSEL CODE. The design, construction, and workmanship conform to ASME Rules. Section VIII, Division 1 to A91 1518-~ e. She,. SA-106-B · 375 0 7. Seems: none none . 85 no B. Heeds: (,) Marl. the A. SME BOILER AND PRESSURE 1989 & 2131 · Yw N/A 1'-7 1/4" 10 '-0" 0 no~e none l (b) Marl. -- Location (Top, Minimum Corrosion Crown Knuckle Elliptical Conical Hemispherical Flal Bide 1o Pressure Bottom. Ends) Thickness Allowance Radius ' Radius Ratio Apex Angle Radius Diameter (Convex or Concave) (') Ends .!98 0 - - 2 :! - - - If removable, bolts used (describe other fastenings) Gr., Size. Ne.) 9. MAWP 500 · psi at max. temp. +200 OF , in. design metal temp. --2 0 °F et 10.2 psi.~l~.OCO., pneu., oJ(c~j0b, test pressure ~ 7 ~ psi. ozzlas, Inspection and safety valve openings: ql~. ~ Nom. Reinforcement I How Diam. Type ' Marl Location '"~'ihlet, Outlet, Df~i~) I. Ho. - or Size Tnk. Mad. Attached 1 ,'ia [ Safety 1 1 Fit SA-105 . ,6 none Vent i ~/8 " " . l 38 " " DischGas ! q/8 " " " " " PurKe 1 1/2 ,, ,, .161 ~ ,, ,, supports: Skim no LGO, -- Legs -- ......Other BEllyband (2) A, ached bottom-welded 12. Remarks: Manufacturer's Partial Data Reports properly identified and signed by Commie)aBed Inspectors have been furnished for the following items of the report: N/A 20" OD X 11'-2 5/8" oil separator for refriKerant$, For non-lethal/non-corrosive service.Refer attached U-4 form. "Charpy impact testing is exempted per UG-2OF". ...... ' ' ' ' CERTIFICATE OF SHOP CCh'VIPLIANCE I We cer~fy that ~h. statemen~ made In this repdrt are correct and that all details of d.lgn, material, construction, a~o~anshlp of ~I, v.,.I con- form ,o ~. ASME Code for Pressure V.s.l,. Se=Ion yIII, Dlvlllon 1. "U' Ce~lflcata of Authorize,Ion No.~.~. CERTIFICATE OF SHOP INSPECTION Frick Company Waynesboro ' Vessel constructed by at I, the undar~ned., holding a valid commission Issued by me National Board of Boiler and Prel~r' Vessel In~,or, end/or me State or Province of and employ~ by ~RHPER NA~TONAL INS. COMPANIES.LONG GROVE. TT,L h.v. Inlp~ted the comDonen, de.rib. In ,hi, Manuf~tur/,', Data Repo~ on JAN 2 8 ~3__. ,.. ,ts,, ,.,,. ,o m. b.. o, my knowledge mad belief, The Menufac~rer hal con~ruct~ %h[~ prellu~vellel~ccordlnce with ASME Code, S~tion VIII, Divllion 1. By signing o,.Ioaaofanvkindarlslngfromorconn~ted~lnsp~ // ~ kl~ ~ lA/ PAPPgA Da,d~ 9~ ~3 Signed / ~" ~l ~~XCommlsllon,..... 37~ ,, ,,....... ' ~l Form (EgO 1171 ma/~obtainod from the ASME Order Dept.. 22 Law Drive, Box 23~. Fairfield. NJ 07007-2300 2187l FRICK ORDER CUST.ORDER 20884? 3753-95 FORM U-4 MANUFACTURER'S DATA REPORT SUPPLEMENTARY SHEET, SHT 2 OF 2 As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 FRICK COMPANY, 100 C.V. AVE, WAYNESBORO, PA USA 17268-0997 1, Menufectur®d er~d certified by REFRIGERATION TECHNOLOGY INC, COTATI, CA ~u fecturecl for CRYSTAL GEYSER, BAKERSFIELD, CA Data ReDOtX Item Number Rem,~s OIL CHARGING 1 1/2 FIT 'SA-iO~ .161 NONE WELDED (TmE~ ~0 ~N U-lA) ~IT~ P[TNP 1 1/2 " " " " " (Imam lO TN H-lA} BULB WELL 3 3/4 " (ITEM 10 IN U.1A) II II OIL RELIEF . 1 1 1/4 " " .208 " " (ITEM 10 IN U-i~) L.L.FLOAT 1 2 " " .28] (ITEM 10'tN U-iA) STGHT GLASS ~ 2 " " .281 DRAIN ~ fTTEM 10 TN H-lA) II I 3/4 PIPE SA-iO6-B .154 " " 1/2 " " .147 " " 1/2 PIPE SA-106-B .400 " " .200 " " .203 " " .2lb " " (ITEM lO IN U-lA) OUTLET 2 (ITEM 10 IN U-lA) (ITEM 10 IN U-iA) INLET 1 ELBOW SA-23.4WPB " " " FLANGE SA-lO5 1.125 " " (ITEM 10 IN U-lA), MANVAY (TTEM 10 IN U-lA) ltX15 FIT SA-106-C .75 " " HEAD JAN 86 19~J3 / .... .., ORDER 20B847 FORM U-lA MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS Sht 1 of 2 ORDER 3753-95 (Alternative Form for Single Chamber. Completely Shop-Fabricated Vessels Only) As Required by the Provisions of the ASME Code Rules. Section VIII, Division I M...f.c,,r.~ .,d c.,,,fled by F~ICK ,n,fect,,ed fo,.. REFRIGER^TION COMPANY. ]00 C.V. AVE. WAYNRSRORO: TECHNOLOGY INC, COTATI, CA P/~ USA ] 7PgR-~lQQ7 3. toc,tlo, o,~n,t.,,.t,on N%~X~X C~YST^L GEYSEr, BAKERSFIELD, CA. ,. )oq SD061 '!U" I o.q 155 5, The chemical and physical properties of mil part~ meet the requiremenm of material specifications of The D. SME BOILER AND PRESSURE i989 VESSEL CODE. The design, construction, end workmanship conform lo ASME Rulel, Section VIII, D}vision I s. Sh.,,: SA-106-B .375 0 1'-7 1/4" lO'-f~" 7. sa.m,: none none ., 8~ no 0 nQD~ , none ] ..... s. Head,: (e) Me,I. SA-plb-'(O (b) Matt Location (Top. Minimum Corrosion Crowg. Knuckle Elliptical Conical Hemisphe¢icel Flat"" ' Side to Pressure Bottom. Ends) Thickness Allowance Radius Radius Ratio Apex Angle Radius Diameter (Convex or ~ncave) Ends /198 0 - - 2: 1 - .- r~nc~v~ If removable, bolts used (describe other fastenings) -- I~tl. ~ ~.. Gr., ~,. ~o.! M^wP ~O0 .~,i,t m,. t,mp~ +200 o~ Min. design metal temp. --20 OF at lO . 2 . psi.~o., pneu,, o~W~b, test p~essure ~75 ~si. Iozzles, inspection and safe'cy valve openings: ~ ?utr~eTD Nom. Reinlorcement How Location Diam. - Type Matt. et. rain) NO. or Size Th~ Marl. A.oched Safety 1 i Fit sA-z05 , !Q6 none w~] d~d .Vent i 3/~, " " -1~ " " Di$chGas 1 ~/8 " " " " " Purge 1 1/2 " " .161 " " - - Oth.r BEllyband (2) A~,ch~ bottom-welded 11. Suppor~s: Skl~ no Lugs Legs 12. Remarks: Manufa~refJ Pa~Ial Data Repo~s properly identified end signed by Comml~loned Inspectors have been furnished for the following items of ~h~ r~o~: N/A 20" OD x 11'-2 5/8" oil separator for refrigerants, For 'non-lethal/non-corrosive service,~efer ~ttached U-U form. '_'Charpy impact testing is exemoted per UG-2OF". --. " - - ' CERTIFICATE OF SHOP COMPLIANCE I Wa certify that the Itetement~ m~de in this repor~ are correct an(~ that all details of design, materiel, conrcructlon, and/(vor~.manshlp of this vessel con- .I CERTIFICATE OF SHOP iNSPECTiON Frick Company . .at Waynesboro Vessel conItrUcted by I, the undersigned, holding a Valid commission Issued by the Natiof~'~l Board ~f Boiler and Pressure Vessel In~oectorl end/or The State or Province of PA ,n~.mploy~by K~MPF. R N.a.q~TONAL INR. COMPANIES..LONG GROVE. ILL ... ,.,~,ed ,h. ~o~.o..-, *-~,,~ ,. ,",, M..u~.~,.'. O.,. R.~o~ o. JAN ~ 8 '1~ - ...~ ,,',. ,.',. ,o ,.. ~ o, my knowledge end belief, the Manuflc~ror has conltructed thll presture ve,,el In accordance with ASME Code. S~tion VIII, Divitlon 1. 8y signing lli certificate neither the Jnlp~tor nor his employer makes on~y, e~ or implied, concerning ~e pres~re v~sel d~rlbed In ~it Menu- ,c~rer'l Date Repo~. Furthermore, neither the Inl~tor norris em~loyer(Iha~ be liable in any manner for any personll injury or properw damage '" 12187} ts For~ {EeO 1173 , be obtained from the ASME Order Dept.. 22 Law Drive, Box 2300. FairfielD; NJ 07007-2300 FRICK ORDER LUST.ORDER 2088~? 3753-95 FORM U-4 MANUFACTURER'S DATA REPORT SUPPLEMENTARY SHEET SHT 2 OF 2 As Required by the Provisions of the ASME Code Rules, Section VIII, Division 1 FRICK COMPANY, 100 C.V. AVE, WAYNESBORO, PA USA 17268-0997 1. ManufeCtured and certl¢l,d by REFRIGERATION TECHNOLOGY INC, COTATI, CA 3. Locado, o! I,,~lladon ~[(~)~ff~[~X CRYSTAL GEYSER. BAKERSFIELD~ CA 4. -ryp, . HORIZ 548D0611 IIUl! Item Number Remarks OTL CHARGING 1 ~/2 FIT SA-105 .161 NONE WELDED (TTRM 10 TN U-lA) ~)TT, PU~ 1, ]/2 " " " " " (T~F~ 18 TN U-lA} BULB WELL ~ 3/4 " " " " " (ITEM 10 IN U-iA) OIL RELIEF 1 1 1/4 ,' " .208 " " 1993 (ITEM 10 IN U-iA) L.L.FLOAT (ITEM 10 IN UrlA)- ST~HT ~LASS (TTRM ~0 IN H-lA) ' DRAIN CO T.==C R '"~JF H~R A~RRTRR ~"i'....(T~ ~ TN Ii-iAI OIL OUTGB~ fIT~M ]0 TN U-1A~ ... ST~T fT~M ID TN INLET (ITEM 10 IN U-IA) OUTLET (ITEM 10 IN 0-lA) ~ 2 " " .281. " ' ~" 3/4 PIPE SA-106-B .154 " " 1 ~/2 " " .147 " " 2 ] 1/2 PIPE SA-106-B .400 " " 1 1/2 " " .200 " " 1 3 " " .21 b " " ELBOW SA-254 WPB " " " OUTT,R~ (ITEM io ZN U-iA) INLET 1 3 FLANGE SA-105 1.125 " '| (ITEM lO IN U-iA) MANWAY 1 (ITEM 10 IN U-lA) llXi~ FIT SA'-106-C .75 " " HEAD JAN 8 8 1993 ~.,. J A.N 8 8 1993 (12/82) FRICK ORDER 208847 CUST.ORDEP~ 3753-95 FORM U-1 MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS A~ Required by the Provisions of the ASME Code Rules, Section VIii, Division 1 FRICK COMPANY, lO0 C.V. AVE, WAYNESBORO, FA USA 172bU-O997 Manufactured end ce~lflad by REFRIGERATION TECHNOLOGY INC, COTATI, CA 3. 4. 5. Manufactured for Location of installation ND%X~Z~XXX CRYSTAL GEYSER,.BAKERSFIELD, CA The chemlcll end physical properties of ell parts meet the requirements of material specifications of the ASME Boiler and Pressure Vessel Code. The design, ~o~struction,' end 'workmanship conform to ASME Rules, Section V II I, Division 1 1989 A91 1518-3 & 2131 N/A Items G- l ?/nc/. to be completed/or single well vessel=, jackets o/jacketed vessels, or sheJl$ o/heat exchangers 6. She,,: SA-106-B .280 0 0'-6.065" Seams: none none 100 0 none none 4' -11 7/8" 1 -- (b) Matt.. -- 8. He, ds: (a) MatI.~ tSpec. No.. Gradel (Spec, No.. Grade) Locetlon ~'op, Minimum Corrosion. Crown Knuckle Elliptical Conlcat Hern~spherlcal Flat I S~de to Pressure BoUom. Ends1 Thickness Allowance Rad4us Radius Ratio Apex Angle Radius D~ametet (Convex Or ConcaveT If removable, bolts used (describe other fastenings) · ~.Type of Jacket -- Proof Tc'-t 10. Jacket Closure -- If bar. 91ye dlmenslons - - (Describe aS ogee & weld, bar, etc.) I 1.tv~AWP - _~00 psi at max. temp. ~., pneu.. ~,est press. 3 7 5 . Ife~ 12 and 13 fo be completed for tube ~ect/on~ ~2. ~b.he~: SA-516-70 6 5/8 .50 0 . . Stationary Mid. (Spec. No.. GrJ Diam. (in.) (Subject to pressure) Nom. ThE. (in.) Corr. Aflow. (~n.} ....... ~et~hg MItt. (Spec.,No.. Gr.) .' '~c': ~ ~ Diam. {~n.) Nom. Thk. {tn.} Corr. Allow. lin.) ~3. T~.: SA-214 5/8" .049 mtn 36 Matt. [Spec~ NO., Gr,) O.D (in ~ NOm. Thk. ([~. Of Gaugel Number (Marl.. Spec, No.. Gr,. Size. No.I " ," 200 ' "F. Min' design metal tamp. psi. Iten'.,$ 1.4-17 incl, to be completed for inner chambers of jacketed vessel= or channels of heat exchangers Shell: 15. Seems: ... SA'-234 -WPB (b) Marl. If bolted, describe or sketch. o F at ~ psi. 16. Heeds: (e) welded Attach. (Welded. Bolted~ straight Type (Straight Or 'U") (Spec. NO. Grade) (Spec. No., Grade) ENDS Knuckle Elhp6cel Ratio Con,cai Apex Angle Hem[sphericll Radius Flat Diameter (Convex Of Concave) I .280 0 - - 2: ! - - - CONCAVE If removable, bolts used (describe other fastenings) (Mad.. Spec. No.. Gr.. $ile. No.) 17. MAWP ~00' psialmex, temp. 200 oF. Min. designmetaltemp._ -20 oFa~ 10.2 psi. ~. PNEUx~,,,, ,,,,,. 375 . ~,'- . " . ....... Form U-1 {Back) Nozzles, Inspection and Safety Valve Openings: Safety I 1~2 ~it sALi05 .l~l' ' none welded Vent 1 1/2 ,, ,, ,i , ,, Drain i 1/2 ', " " " " Oil In 1 1 1/4 Pipe SA-iO6-B .19i " " Oil Out 1' 1 1/4 '" " " " " RefrIn 1 2 1/2 ,, " .203 " " RefrOut ' 1 2 1/2 " " " " " LOll Drai~ 1 1/2 Pipe SA-10'6-B ' ',~'~'? " ..... " .... I 19. Supports: Skirt no Lugs -- . Legs -- Other -- A~tached : {Yes O~ no) (No.) (No.) {Describe) {Where and how) 20. Remarks: Manufacturer's Partial Data Reports properly identified and signed by Commissioned Inspectors have been furnished for the following items of the report: 6 5/8" OD x 2'-0" SFL-Thermo$.yphon Oil Cooler w/re£rigerant in tube chamber. Yet non-lethal/non-corrosive service, "Charpy'impact l~esting 'is exempted per UG-20F", CERTIFICATE OF SHOP COMPLIANCE We certify that the statements made in this report are correct and that all details of design, material, construction, and workmanship of this vessel con- ~rm,o the ASME Code for Pressure Vesse)s0 Section V),,. Division .1. - . /~j~) ~ .-. / _/ U" Ce~ificaxe of Authorization NO. 142 expires May 28 ' . / CERTIFICATE OF SHOP INSPECTION ve-,e, con,truct~ ~v, 'Frick Company . at_ Waynesboro I, ~he undersigned, holding a valid commission issued by .the National Board of Boiler and Pressure Vessel Ins~3ectors and/or the State or Province of PA . and emp,ove~ by_ KEMPER NATIONAL INS. COMP',~.~IES of , ,Long Grove, ILL have inspected xhe pressure vessel de,crlbed in ~hi, Manuf,c~rer's Data R~orzon JAN ! ~ ~3 ,, and state that. to the bestof my knowleUge and belief, the Manufac~rer has constructed this pressure v,sel iff accordance with ASME Code. Sect~'Vl,I. D~ S~ng this certificate neither the Inspirer nor his employer makes any war- ran~, expr~sed or implied, concerning ~e Pressu~ ~sel desk, ed [~ ~e M~nufac~urer's Data Report. Furthermore. neither the Inspector nor his em- .......... / We ce~ify that the field assembly ~ctlon of ell parts o~thisvess~l conforms with ~he reQuirements of Section VIII, Division 1 of the AS~E Boiler and Pressure Vessel Code. 'U' Certificate of Authorlzat~on No. ex~ires 19 ,, . ~ate Co. name , Signed CERTIFICATE OF FIELD ASSEMBLY INSPECTION .I, the ungersigned, hold[rig a valid co_mmlsslon issued b~ the National Board of Boiler end Pressure Vessel Inspectors and/or the State or Province of and employed by , of .... have compared the statements in this Manufacturer's Data Report wi~h the described pressure vessel and state that parts re~erred to as ~ata items not included in the ca~lflclte of shop Inspection, have been insOected by me and t~at, to the best of my knowledge and belief, the Manu~acture/ has constructed and assem- Xhil prellure vessel in accordance ~.JTh ASME Code. ~ectlon VIII. Division 1. The described vessel was inspected and Sub~ected to a hydrostatiC test psi. By signing this certificate neither the Inspector nor his employer makes any warranty, expressed Or implied, concerning the pressur~ v~lel de*crlDed in shit ~anufacturer'l Data Repo~. Furthermore, neither the Inspector nor his employer shall be liable in any manner for any persona. InjuW or property damage or e lost of Any kind arising from or connected with this $nsp~tion. Daze Signed Commissions FRICK ORDER CUST.OBDER 2088~7 3753-95 FORM U-1 MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS As Required by the Provisions of the ASME Code Rules, Section VIII, Division I FRICK COMPANY, i00 C.V. AVE, WAYNESBORO, PA USA 17268-0997 end certified by . =. M...fac,ur.d'or REFRIGERATION TECHNOLOGY INC, COTATI, CA --/ (Name end address ol pu,chaterl ~/~ 3. Loeatlo. of I.sta,latlon ×~X~X CRYSTAL GEYSER, BAKERSFIELD, CA [,~ The chemical and physical properties of ell parts meet the requirements of materiel sDeciflcations of the ASME Boiler and Pressure Vessel Code. The design. construction, end workmanship conform to AiM E Rules, Section V ll I, Division 1 19 8 9 A91 1518-3 & 213i N/A Items 6-I I incl. to be completed for single wail vessels./acRet$ o/jacketed vessels, or z/tells o! heat exchangers e. s~,,,: SA-106-B .280 0 0'-6.065" none none 100 Seams: 0 none none ISpec. No., GraOe) 8, Heads: la) Mad. -- (b) Mall. (Spec. No.. Grade) 9 '-iD 7/8" no 1 Location (Top. Minimum Corrosion Crown Knuckle Elliptical Conical Hemispherical Flat Side lo Pressure Bottom, Ends] Thickness Allowance Radius Radius Relic Apex Angle Radius Diameter {Convex or Concave) If removable, bolts used (describe. other fastenings) (Mad.. Spec. No.. Gr.. Size. NO.} 9. Type· of Jacket ' -- 10. Jacket Closure -- (Des~'ibe Is o~ee & weld. bar, etC. I 11. MAWP ~00 psi at max. temp. ~{,~cOG.. pneu.. ~2~R3~ test press. 3 7 5 /:ems 12 and 13 Io be compleled for tube sectiens ~=. Tube~hee,,: SA-~lb-70 StatiOnary Mall. (Spec. No.. Gr.{ Diam. (in.) (Sub/ecl lo pressure) If bar, give dimensions Proof Tc~t -- 200 °F. Min. design metal temp. --20 psi. ,50 0 Nom. Thk. lin.) Corr. Allow. lin.) If bolted, describe or sketch. °F ~t ~ psi. ,- '_-.. Fleeting M iU. (Spec. No.. Gr.) Diem. (in.) Nora, Thio (in.) Corr. Allow. (in,I ~3. Tub.: SA-2~4 5/8" .0~9 m~n ~6 Mall. {Spec. No.. Gr.) , .. O.D. (in.) Nora, Thk. fin. or Gauge) Number Items 14-17/nC/. IO be, completed for inner chambers of iacketed vessels or, channels of heal exchangers welded Attach· (Welded. ~oltedl straight lyl3e IStr&ight or ':U") Heeds: {e) Marl. SA234 W P B (b) ma,,. - (Spec. NO.. Or.cia) ISpec. NO.. Grade) ENDS .280 ~ - - 2:i - - I - - CONCAYE I! removable, bolts used (describe other tat'tonings) N/A 17. MAWP 300 psi;, ma,:,e,,p. 200 X~X.,'PNEU'~. ,.,, p,.,,. 375 (Mall., Spec. NO., Gr.. S,ze. No.) OF. Min. des~gnm~teltemp. --20 OF et 10.2. psi. , psi. Form U-1 {Back) Nozzles, inspection and Safety Valve Openings; Safety ' 1 1/2 Fit SA-105 .161 none wel dP_d Vent , ~k 1/2 " " " " " Drain i 1/2 " " " " " ~_Oil In 1 1 1/2 Pioe EA-lO6.B .200 ,, t, ~_Oil Out , 1 1 l/2 " " " " " Reft Tn ] 2 1 /2 " " ?fl3 " " _]~efrOut ] ?_ ]/? " " " " " Drain- ~ 1/2. Pipe SA-106-B .]47 " "' 19, Supports: Skirt no . Lugs -- Legs -- . Other__ -- Attached lyes or ne) INa.) INa.) (Describe) (Where end howl Remarks: Manufacturer's Partial Data Reports properly identified end signed by Commissioned Inspectors have been furnished for the following items of the report:, ,, ' N/A 6 5/8" OD x i0'-0" SFL'Thermosypbon Oil Cooler w/r~fri~erant For non-lethal/nOn-corrosive service. '"Charpy impact testing is exempted per UG-2OF". in tube chamber. CERTIFICATE OF SHOP COMPLIANCE Be certify that the statements made in this reDort are correct end that all details of design, meterlal, construction, and workmanship of this vessel con- ~lbrm tO the ASME Code for Pressure Vessels, Section VIII, Division 1. ' //~~ "U" Certificate of Authorization 1%1o. , 1~2 expires May 2~ oat~N ~ ~ 1~qt co. name Pr~ r.k ~nmn~nv .... signe~, CERTIFICATE OF SHOP INSPECTION Vessel constructed by Pl*~ ak P, omp~ny .at Wayne_~bor~- I, the undersigned, holding a valid commission issued by the National Board of Boiler end Pressure Vessel Ins~tor$ and/or the Sta~e or Province Of 8fld employ~ by ;KEMPER .NATIONAL" ~S'.COMP~NIES.LONG GROVE. ILL of Long ~ov~_ TT,T, . have ins0~ted the pressure v~sel described in this Manufac~rer's Data ~*~o,~o. ' JAN 2 2 1~9] . and state that. to ~t of my knowledge and belief, the Ma.ufec~rer has constructed this ran.. exDressed or im~lied, Concerning .e pressure~.se, d.~~ ~f.turer's Data Re.or% Furthermore. neither the Ins,actor .or his We certify ~t the field assembly construction of all parts of this vessel conforms with the requirements of Section VIii, Division 1 of the ASME Boiler and Pr~sure Vessel Code, "U" Cer~iflca~e of Authorization No. expires . 19 Co. name . Signed .... CERTIFICATE OF FIELD ASSEMBLY INSPECTION l, the undersigned, holding a valid commission issued by the-National'Board of Boiler end Pressure Vessel Inspectors a'nd/or the State or Province of and employed by of have compared the statements in this Manufacturer's Data Report with the described pressure vessel and state that Parts referred to As data items not inclucled in the ertlflcate of shop inspection, have been inspected bY me end that, to the best of my knowledge end belief, the Manufacturer has constructed andassem' led this pressure vessel in accordance with ASME Code, Section VIII. Division 1. The described vessel was inspected and subjected to a hydrostatic test of pal By sSgnJng this certificate neither the Inspector nor his employer makes Any warranty, expressed or implied, concerning the pressurr vellel clescribed in thli Manufec, turar's Data Report. Furthermore, neither the Inspector nor his employer shall be liable in any manner for any persona. Injury or property damage or a loss of any kind arising from or connacled with this InspeCtiOno Date ,. Signed Commissions FRICK ORDER 2088~Y :-' .CUST.ORDER 3753-95 ...... FORM U-1 MANUFACTURER'S DATA REPORT FOR PRESSURE VESSELS As Required by the Provisions of the ASME Code Rules, ~ion VIII, Division 1 FRICK COMPANY, lO0 C.V. AVE, WAYNESBORO, PA USA 17268-0997 end certified by ~. =. M..u~ae,.red~o, REFRIGERATION TECHNOLOGY INC, COTATI, CA '. / ,__ 3. Locet~o- of Insta.etlo. N~×KYUOMUOXXX CRYSTAL GEYSER. BAKF, RSCT~,T,D~ ~ I -I ~'~g 5. The chemiCal and ~hys~l properties of ell parts meat the requirements of material specifications of the ~ME Boiler and Pressure Vestal Code. The design, con~ctlon, and workmanship conform to ASME Rules. Se~ion VIII, Division I [~8~ A91 1518-3 & 2131 ,N/A Items 6-I I incl. to be completed for sin£/e wa//vessels, jackets of jacketed vessels, or $h¢115 of heat exchanger= e. She,,: SA-IO6-B .280 0 0'-6.065l' Seams: Heeds: (al Mall. none none 100 0 none none (Spec. No.. Grade) 9'-1!' 7/8" no {Spec. No., Grade) Location ~op. Minimum Co~rosion Crown Knuckle Eltlptical Conical I HemisDhetlcal Flat Side to Pressure Bottom, Ends) Thickness Allowance Radius Radius Ratio Apex Angle) Radius Diameter {Convex or Concave) faznuahl~ hnlf~ If~:~'~ (describe other fastenlnes) (MSt(.. Spec, NO,. Gr.. Site. NO.I. 9. Type of Jacket " -- Proof Tcs: 10. Jacket Closure -- If bar. give dimensions (Describe as ogee & weld, bar, ese,) '~ 1. MAWP ~00 psi at max. temp. 200 OF, Min. design metal tenD, ~:~:~'O.. pneu.. ]~,r:)~T~l(~[ test press. 3~5 .... psi. Items 12 AAd I3 lO be completed for tube $eclions S~alionaty Moll. ~S~e~ No,. Gl.} Diam. lin,) lSub~ect to p~essure~ Nom. Thk. (in.I Corr. Al(ow. ((nj Floating Matt. (Spec. No.. Gr.)Diam. {in.) Nom. Thk. (in.I Corr. Allow, Nom, ThK, (in. or Gau~e~ Numbe~ ~3. T.b~,: SA-214 5/8" .... Marl. ISaac. No.. G~.) O.D. lin.) If bolted, descrlt~e or sketch. °F at ~ psi. w~10ed Auach. (Welded, 8oltedl AtlaCh. · straight Ty~e (Straight or "U") /terns 14-~ 7 /,';/'cZ to be completed fo~ inner chambers o/jacketed.vessels or channels of heal exchangers 14. Shell: -- -- -- 15. Seams: EII.I%I SA23~ W P B 16. Heads:'(a') Marl. (Spec. No.. Grade) Location (Top, jMinimum Corroaion C~'own Knuckle If removable, bolts Used (describe other fastenings) N/A (b| Mall., IS;~ec. No.. Grade) Elhplical Conical Hamisphelical Ratio Ape~ Angle Radius 2:1 Side tO PressureI ' {Convex or Concave). - I - - CONCAVE (Mall.. Spec. No., Gr.. Site, No.I oF, Mia. design metal temp. --20 OF at lO.,2,, psi. ps{. This Fo,m lEO0108) may be obtained ttom the ASME Orde, Deal., 22 Law Drive. Box 2300. Fairfield. NJ 07007-230C Form U-1 (Back) . Inspection end Safety Valve Openings: Nozzles. safe~.Y 1 1/2 Fit SA-105 , . .!61 none w~l dP.d Vent 1 1/2 " " " " " _/Zr_ail]____~'! 1/2 " " " " " Oil In 1 1 ]/2 Pipe SA-]O6-B' Oil Out 1 1 1/2 " " , , " " " Reft Tn I 2 1/2 " " .203 " " _R_efrOut I 2 1 /2 " " " " " Drain ~ 1/2 Pipe · S^'106-B . ] t17 ,' " 19. Supports: Skirt. no, Lugs - Legs -- Other__ -- Attached -- (Yes or noi INo.I (N0.I (Describe) ~VVhere end how) 20. Remarks: Manufacturer's Partial Data Reports properly identified end signed by Commissioned Inspectors have been furnished for the following items of the report:, N/A 6 5/8" OD x 10'-0" SFL-Thermosyphon Oil Cooler w/refrigerant For non-lethal/non-corrosive service. '"Chavpy, imoact testing is exempted per UG-20F". in tube chamber. CERTIFICATE OF SHOP COMPLIANCE certify that the statements made in this report are correct and that ail details of design, material, construction, end workmanship of this vessel con- J" Certificate of Authorization No. ,, 1;42 expires M~.V ?~ Date )-- I~'~(~ Co, name F~C~ ~C~T~T~.r Signed CERTIFICATE OF SHOP INSPECTION Vessel constructed by Fri ~_k P. nmp~n¥ at · I, the undersigned° holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the State or Province of PA and employ~ by ;KEMPEB .NATIONAL' INS'. CO~?AN!ES .LONG GBOVE. TLL have inspected the pressure vessel described in this Manufacturer's Data Repo~ on ~ , ,19 c ~ , and state that, to the best of my knowledge and belief, the Manufac~rer has constructed this pressure v~sel in accordance with ASME Code, Se¢tion VIII, Divi~ By si~ this certificate neither the Inspirer nor his employer makes any war, ~e pressure v~e, desitin' / ,h~Ma~fec,urer's' ' Data Report. Furthermore. neither the Inspector nor his expressed or implied, concerning ployershall b~lia~ei~ any manner for any persona~n~E or~~a~ag~or//~ I /alossof any kind ar[slng~m.or connecte~with,~s I~ectlon. Date~ S~gned ' ' ~' - Commissions '- ~ ' ' ~~T~ A~EMB~ COMPLIANCE' and Pre~su~e Vessel Code. "U" Certificate of Authorization No, expires 19 , . . Date Co. neme Signed. CERTIFICATE OF FIELD ASSEMBLY INSPECTION I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and/or the State or Province of end employed by Of have compared the statements ir~ this Manufacturer's Data Report with the described pressure vessel and state that parts referred to es data items not included in the certificate of shop inspection, have been inspected by me and that, tO the best of my knowledge end belief, the Manufacturer has constructed end eases° this pressure v~ssel in accordance with ASME Coda, Section Viii, Division 1. The described vessel was inspected and subjected to a hydrostatic test psi, By signing this certiliceta neither the Inspector nor his employer makes any warranty, expressed or implied, concerning the pressur' vessel described In thtl Manufacturer's ~ata Ropo~. Furthermore, neither the Inspirer nor his employer shall beliab(e in any manner for any person~ Injury or property damage or a toss of any kind arising from or connected with ~his Inspection. gate ' Signed., , . Commissions ANNEX llI.3.f FINANCE Items to be addressed in this Annex: O) (2) O) (4) (s) (6) (7) Resource list Personnel Response equipment Support equipment Contracting [21 Contractor and facility owner responsibilities (Program 3) (2760.12) [21 Contractor safety procedures review (Program 3) (2745.7(0)) {~1 Contractor safety performance evaluation review (Program 3) (2745.7(p)) Claims procedure Forms which can be included in this annex,: [21 Underground Storage Tank (UST) Certification of Financial Responsibility [~ Letter from Chief Financial Officer in support of UST Cleanup Fund [21UST installation certificate of compliance [21 Hazardous waste certification of financial assurance Cost documentation CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES ANNEX III.4 EMISSIONS DOCUMENTATION Items addressed in this Annex: Date of most recent incident investigation and response thereto (2745.60), 2745.7(1)) Incident investigation procedures (2755.7, 2760.9) Five-year accident history reports (2750.9) All waste water treatment records maintained on file for 3 years Each waste water sampling activity shall record the following information: O O O O O O date, location, time, & sampling method who performed the sampling date of sample analysis who performed the analysis analytical method used results of the analysis CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES OCT 17 'gG O~:llPM CRYSTAL GEYSER N~TER WZi~: 2.0 DESCRIPTION OF AC, UTELy HAZARDOUS MATERIALS ACCIDENTS 2. I Accidents at this location On March 23, 1989 a release involving the ammonia system caused neighbors to complain of an ammonia smell. A power faihu'e caused tile system to shut down. When power was returned, tile initial startup blew three-thirty amp fuses in the condenser panel, shutting down both condensers. The operator did not know that the condensers were inoperative and turned on tile ammonia compressors, Pressure in tile system quickly rose, forcing ammonia through the high pressure relief valve. 2,1,1 On August 14, 1996, asmnonia loss due to power failure (brownout) - the compressors are set up iht a 20 minute delay. Thc operator in the Filling Room did not know of the power failure and he proceeded to heat up Carbo Cooler, The loss of ammonia was released into sparge tank through pressure relief valves on Carbo Cooler. The satEty system worked as it was designed for incidents such as this. 2.2 tlnderl¥ing Causes Tl~e release was caused by thc operator who turned on the compressors although the condensers were not working. 2.3 Measu res Taken !'9~ prevent Recurrc.ce The operates' is now required to check tile condensers every time he turns on tile compressors, The operator has received extensive training to ensure that this type of release does not recur, Only trained personnel are allowed to operate the ammonia system. In 1993, a sparge system with a diflhsion tank was installed to reduce the severity el' ail ammonia release in any future emergency relief'occurrences. 2.3.1 Installed on the Carbo Cooler panel in the filler room are Green Run 'Lights to assure operator that compressors are running and that all operators have been instructed. 2.4 Accident lnvestig, a~i. on Procedures After an accident has occurred, an ammonia incident report (exhibit) shall be filled out. A post accident review shall be held in which polential causes of the accident are discussed. When the cause &the accident has bern determined, a method shall be Page 10 2.0 DESCRIPTION.OF ACUTELY HAZARDOUS MATERIALS ACCIDENTS 2.1 Accidents~at this Location On March 23, 1989 a release involving the ammonia system caused neighbors to complain 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 condensers. The operator did not know that the condensers were inoperative and turned on the ammonia compressors. Pressure in the system quickly rose, forcing ammonia through the high pressure relief valve. 2.2 Underlying Causes The release was caused by the operator who turned on the compressors although the condensers were not working. 2.3 Measures Taken to Prevent Recurrence The operator is now required to check the condensers every time he turns on the compressors. The operator has received extensive training to ensure that this type of release does not recur. Only trained personnel are allowed to operate the ammonia system. In 1993, a sparge system with a diffusion tank was installed to reduce the severity of an ammonia release in any future emergency relief occurrences. 2.4 Accident Investigation Procedures After an accident has occurred, an ammonia incident report (Exhibit 5) shall be filled out. A post accident review shall be held in which potential causes of the accident are discussed. When the cause of the accident has been 'determined, a method shall be Page 10 FACILITY: DATE OF INCIDENT: AMMONIA INCIDENT REPORT TIME OF INCIDENT: SEVERITY OF INCIDENT: VERY SERIOUS SERIOUS LOW THREAT LOCATION IN FACTORY: Caused evacuation of the plant or neighbors, or serious injury, and required the use of SCBA (self contained breathing apparatus) 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. SOURCE OF DISCHARGE (TYPE OF EQUIPMENT) COMPONENT OR ITEM DISCHARGING (SUCH AS SEAL, VALVE, WELD...) CAUSE OF DISCHARGE: AMMONIA INCIDENT REPORT PAGE 1 EXHIBIT 5-1 ACTIVITY AT TIME OF DISCHARGE: DETAILS OF EMERGENCY RESPONSE: DEGREE OF CONTROL LOW MODERATE EFFECTIVENESS OF EMERGENCY PLAN . LOW DEFICIENCIES IN THE EMERGENCY PLAN: HIGH MODERATE HIGH CONSEQUENCES OF DISCHARGE: NUMBER OF PEOPLE HURT NUMBER HOSPITALIZED EVACUATION: IMMEDIATE DISCH.ARGE 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, FA]LURES TO ACT AND/OR CONDITIONS THAT CONTRIBUTED DIRECTLY TO THE INCIDENT; WHAT ACTIONS WERE TAKEN TO CONTROL THE INCIDENT; WHAT REMEDIAL ACTION HAS B~EN TAKEN TO PREVENT A RECURRENCE. AMMONIA INCIDENT REPORT PAGE 2 EXHIBIT 5-2 V~l~Z IINC 12.0 RMPP RECORD KEEPING Record keeping, required by RMPP legislation, ensures that RMPP programs are implemented and maintained. 12.1 Accident Records Documentation of accidents is necessary to prevent recurrence. Section 2.0 of this report is a description of accidents involving ammonia, including accident investigation procedures and measures taken to avoid a repetition of the accident or release. 12.2 Ammonia Charge, Record Ammonia charge records (Exhibit 9) will document amounts and dates of ammonia deliveries. Inventory control is a significant aspect of RMPP implementation. 12.3 Training Records Training records will be kept to ensure that each employee receives required training. All employees must be trained in emergency evacuation procedures. Certain employees need training in specific procedures related to the handling of acutely hazardous materials. Exhibit 10 is the ammonia system Training Required/Date Completed record. 12.4 Audit Records Results of the ammonia safety audit are kept for future reference. Documentation ensures that hazards identified through the safety audit are addressed in a timely manner. A copy of the ammonia safety audit is contained as Appendix C. Page 41 ANNEX III.5 TRAINING Type of Training: Check all that apply classroom on-the-job vendor provided instruction by trained personnel written mining plan (10+ employees) applicable to job duties Frequency of Training: el__/ / Cl. / / initial training: 0 prior to assignment 0 prior to changed process 0 upon modification of response plan annual refresher training ~ / / date of most recent training program revision date of most recent change that triggered a training program revision date of most recent emergency response training for employees Documentation of Training: records kept until facility closure employer certification of employee skills testing or verification of competency former employee records kept 3 years documentation at the facility: 0 employee name & job title 0 written job description 0 description of required training 0 training records Required Training Content: Health and Safety; ~' medical assistance availability ~ methods for safe handling of materials I/fire hazards of materials / processes ~' hazardous characteristics of materials ~' safe food handling procedures ~ emphasis on health and safety t/safe work practices Operations and Maintenance: ~' maintenance and use of equipment ~' operation of UST system ~ operation of UST monitoring equipment I/ maintaining integrity of process equipment t~' operating procedures ~,t overview of the process Risk Manaeement: ~ conditions likely to worsen emergencies I,t appropriate corrective actions Emergency Response: ~t coordinating local emergency response I~' use of emergency response equipment t/communication and alarms ~t response to fires and explosions ~ contaminated groundwater response ~ waste feed cut-off ,t' notification procedures I~' use of fire fighting equipment ~ employee evacuation ~' emergency shut-down ~' site specific response CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICE~ The following subjects will be covered by the training program: Use of Safety Equipment When to wear a Self Contained Breathing Apparatus (SCBA) What type of SCBA is appropriate; limitations How often must the SCBA be replaced SCBA maintenance Ammonia First Aid Procedures Keep a rope available to retrieve overcome employees If an employee Is overcome by ammonia: 2. 3. 4. 5. Move victim to an area clear of ammonia Call a doctor Remove contaminated clothing Keep the patient still and covered with blankets Use cardiopulmonary resuscitation (CPR) If required For liquid splashes in the eyes, irrigate the eyes Immediately with a solution of two and one-half percent boric acid, two and one-half percent borax, and distilled water. For skin burns, wash Immediately with large quantifies of water. Review of Hazardous Business Plan Review of Material Safety Data Sheets, Chemical Hazards Review of Emergency Plan Release Reporting (Section 2.5) Daily Operating Procedures (Section 4.1.1) Maintenance Procedures (Section 4.1.2) Evacuation Procedures (Section 8.1) Page 39 Fire Procedures (Section 8.2) Earthquake Procedures '(Section 8.3) Ammonia Significant Leak (Section 8.4) Page 40 ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 00 - Overall Site <G> Training 14 ~1> Page 1 WE HAVE 35 EMPLOYEES AT THIS FACILITY ,WE HAVE MATERIAL SAFETY DATA SHEETS ON FILE SUMMARY OF TRAINING INCLUDES A LIST OF THOSE QUALIFIED IN S.C.B.A. SUMMARY OF TRAINING: EACH EMPLOYEE INVOLVED IN THE USE OF HAZARDOUS MATERIALS WILL BE GIVEN INSTRUCTION IN THE SAFE HANDLING AND USE OF EACH PRODUCT BEFORE THEY BEGINUSE. EACH EMPLOYEE WILL BE PROVIDED WITH SAFETY EQUIPMENT REQUIRED FOR EACH PRODUCT HANDLED. SAFETY PROCEDURES FOR SPILL CLEAN-UP OF HAZARDOUS MATERIALS WILL BE TAUGHT. NEW HAZARDOUS MATERIALS INTRODUCED INTO INVENTORY WILL BE REVIEWED WITH EACH INDIVIDUAL BEFORE USE. REFRESHER COURSES IN SAFE HANDLING OF HAZARDOUS MATERIAL WILL BE REQUIRED OF EACH EMPLOYEE INVOLVED IN THE USE OR HANDLING DURING THE YEAR. IN ACCORDANCE WITH YOUR REQUEST WE SUBMIT THE FOLLOWING LIST OF INDIVIDUALS WHO HAVE BEEN TRAINED TO INITIATE AN EMERGENCY RESPONSE TO AN UNLIKELY INCIDENT. 1) NORMAN AMBROSE - MAINTENANCE SUPERVISOR ~. o~2~BROSE IS KNOWLEDGEABLE AND HAS EXPERIENCE IN ALL ASPECTS OF OUR ~MONIA SYSTEM: PIPING LAYOUT, LIQUID AMMONIA SHUT OFF VALVES, COMPRESSOR INTENANCE AND RECORDS, AMMONIA SAFE HANDLING PRACTICES AND HAS BEEN TRAINED IN THE USE OF OUR AMMONIA DIFFUSION SYSTEM. aLSO, mR. aMBROSE HAS BEEN TRAINED IN THE PROPER USE OF OUR S.C.B.A. UNITS. HE IS ALSO KNOWLEDGEABLE OF OUR FIRE/EMERGENCY EVACUATION PLANS AND WOULD BE ABLE TO INITIATE AND HANDLE AN EMERGENCY RESPONSE TO ANY INCIDENT. MR. %/-/OF~£hb. IS KNOWLEDGABLE AND HAS BEEN TRAINED IN ALL ASPECTS OF AMMONIA SYSTEMS: PIPING LAYOUT, LIQUID AMMONIA SHUT OFF VALVES, AMMONIA SAFE HANDLING PRACTICES, AND HAS BEEN TRAINED IN THE USE OF OUR AMMONIA DIFFUSION SYSTEM. MR. ~0~ .... HAs BEEN TRAINED IN THE PROPER USE OF S.C.B.A. UNITS AND IS KNOWLEDGEABLE OF OUR FIRE EMERGENCY EVACUATION PLANS AND WOULD BE ABLE TO INITIATE AN EMERGENCY RESPONSE TO AN INCIDENT. 3) ALEX MANNS'- PLANT MANAGER MR. MANNS IS KNOWLEDGEABLE OF OUR AMMONIA SYSTEM: PIPING LAYOUT, LIQUID AMMONIA SHUT OFF VALVES, AMMONIA SAFE HANDLING PRACTICES, AND HAS BEEN TRAINED IN USE OF OUR AMMONIA DIFFUSION SYSTEM. MR. MANNS HAS BEEN PROPERLY TRAINED IN THE USE OF OUR S.C.B.A. UNITS AND CAN INITIATE AN EMERGENCY RESPONSE TO AN INCIDENT. 4) ~b.4~'~mm~M - MECHANIC ~4//~ZY~tmY~n; HAS KNOWLEDGE OF OUR AMMONIA SYSTEM: PIPING LAYOUT, LIQUID AMMONIA SHUT OFF VALVES, AMMONIA SAFE HANDLING PRACTICES, AND HAS BEEN TRAINED IN USE OF OUR AMMONIA DIFFUSION SYSTEM. MR. ~~,.,~cA:.z=. IS KNOWLEDGEABLE OF OUR FIRE/EMERGENCY EVACUATION PLAN AND WOULD BE ABLE TO INITIATE AN EMERGENCY RESPONSE IF AN INCIDENT OCCURRED. ALSO, MR. ~O/YL~ ~6/03/93 CRYSTAL GEYSER OF BAKERSFIELD 215-000-001418 Page 00 - Overall Site <G> Training 15 :1> Page 1 (Continued) HAS BEEN PROPERLY TRAINED IN THE USE OF OUR S.C.B.A. UNITS. 5) GERHARD GAUGEL - QUALITY CONTROL MANAGER MR. GAUGEL HAS KNOWLEDGE OF OUR AMMONIA SYSTEM AND ITS OPERATION: PIPING LAYOUT, ~"~~~ ~ONIA SHUT OFF VALVES, AMMONIA SAFE HANDLING PRACTICES, A~D HAS BEEN TRAINED IN THE USE OF OUR AMMONIA DIFFUSION SYSTEM. MR. GAUGEL HAS BEEN TRAINED IN THE PROPER USE OF OUR SoC.B.A. UNITS AND CAN ALSO INITIATE 'AN EMERGENCY RESPONSE TO AN INCIDENT. ALL PLANT MANAGEMENT, MAINTENANCE PERSONNEL AND OTHER EMPLOYEES WHO WORK WITH LITTLE SUPERVISION WILL BE TRAINED IN FIRST AID AND C.P.R. :2> Page 2 as needed ~3> Held for Future Use ~4> Held for Future Use CRYSTAL GEYSER TRAINING REQUIRED / DATE COMPLETED EMPLOYEE AMMONIA AMMONIA FIRE EMERGENCY EVACUATION SPILLS AND NAME HANDLING DIFFUSION SCBA SAFETY NOTIFICATION PROCEDURES NEUTRALIZATION ..I EXHIBIT 10 TRAINING CRYSTAL REQUIRED GEYSER / DATE COMPLETE;D EMPLOYEE 1 AMMONIA AMMONIA FIRE EMERGENCY EVACUATION SPILLS AND NAME| HANDLING DIFFUSION SCBA SAFETY NOTIFICATION PROCEDURES NEUTRALIZATION EXHIBIT 10 p [ , [[[ ~[ [ ,[ ,[ ......... ] '1 .. !FIRST -~N~ _ ~C:B:'A' ......... HAZARD AMMONIA iCANNERY~ ~OILER"' AID X ~S ~. i ~ LI~NSE ...... ~~, JO~ ~ ~o~7' x. ~ m . ~E~ R~ x ,, 1~1~8 ~VO~ L~Y x 1~21~8 DELEO~ ~IClO ' ~ "1~/9~' ,, x ,,, 12~1~ , . ' ~~ ~SE x ~ 1~1~8 ~~ S~ I x 1~8 ' X MOYAiJ~ ~ 10~9/97- '~ ~ x 1~1~8 X' ~,~,P~L ' 10~9/g7 x ~ x 1~8 X 0~1~ .... X 1~ OEEC, J~ ~_ ' ,, x "1~1/~ .......... DIXON~ ~H IX 12~198 X 1~21~8 DE~ 700 ....... rx x " x C~ILLO, RUDY'X 10129/97 ~x 1~21/98 " CEJ~ MIGUEL ~X 10/29/97 ~x 10/31/97 ,, ~r ~NA ~x 1~21'/98 ' X ~1,~ ' PITCHFO~D EIC~ ~X "'12/21~8 x 1'~ ~x 1~21/9~' ' ~X 1~ GAU~,G~O 'X' x ~a x 12121~8 ~X 0~1~, ' X "1~ ~ON~L~,,~p ...... 1~8 ' ~x ~2~1/g8' ,,, ', "' ~FFERD~ RO~ET X 1~1~8 x ~ ~ ~21~8 LO~NO~AiOA ' X 10~7 ,x '10~1~7 .......... ~N~ J08E X 10/29~7 . ~ x t0/29/97 P~iNP,,~, x ~/98 x o~ ,, NILS~ ~Y x 1~1~ " ~YO~~ x ~ X 12DI~8 " X 1 ~ON,~N ' x ~ x 12D1/98 X 1~ W~T~k X 09~12]~ ' x ~ x t~1~ ....... X .... 1~2~ [~I~T, DAVID . x '~ x 1~1~8 X ~11~3 X 1~ ~P~EE~ ~O~ X ,"~/98 '," , '" x ~8 .... ~V~"~ iX ~O/29~7 ... x 10Gl/97 V~QU~ HECT~ X 0~2~8 ...... x, 12~1/98 ~ ..... ~ ..... CRYSTAL GEYSER TRAINING REQUIRED ;/ DATE COMPLETED EMPLOYEE I AMMONIA AMMONIAri FIRE EMERGENCY EVACUATION SPILLS AND NAME/ HANDLING DIFFUSION SCBAI SAFETY NOTIFICATION PROCEDURES NEUTRALIZATION EXHIBIT 10 ITl Z ANNEX III.6 PLAN REVIEW & MODIFICATION Items addressed in this Annex: Updated within five years and recorded dates of any reviews (2745.10, 2750.7) Compliance audits at least every three years (2755.6, 2760.8) Written procedures to manage changes that affect regulated processes (2760.6) Facility compliance plan review after any incident or nonconformance condition Facility compliance plan review upon any change in the facility potentially affecting plan content (2745.11) Terms and conditions may be subject to modification by the participating permitting agencies at any time Facility compliance plan may be modified to incorporate special conditions resulting from the issuance of a special order or promulgation of new standards Modifications which result in new conditions shall be revised in the facility compliance plan within 60 days Change of facility ownership shall obligate the new owner to seek prior written approval from the City of Bakersfield - Environmental Services for the continuance of the use of the facility compliance plan The facility shall allow any authorized representative of a participating permitting agency, upon the presentation of credentials, to: O Enter the premises where a regulated activity is conducted or where records must be kept O Have access to and copy, at reasonable times, any records that must be kept O Inspect at reasonable times any facilities, equipment (including monitoring and control equipment), practices, or regulated operations O Sample or monitor, for the purposes of assuring compliance, any substances or parameters at any location O Inspect any area where pollutants or other regulated substances could originate, be stored, or be discharged into the environment CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES IV. REVISION RECORD All records concerning this RMPP shall be kept for at least five years (Section 25534 (f)). Necessary revisions to the RMPP will be made at least every three years. The RMPP must be modified within 60 days of a modification that materially affects the handling of an AHM-(Section 25534(h)). All revisions to this RMPP are to be recorded here. Revision Pages Date of Number Affected Revision 2. 3. 4. 5. 6. 7. 8. 9. 10. All 12/93 Signature of Person Making the Revision Page 5 OCT FlEE CHIEF MICHAEL R, KELLY SUPPgE~ION SEitVICE$ 2101 'H" Sites1 Bakersfield, CA 93301 (8O,5) 326-3941 FAX (GO~) 3~5,.1349 PREVENTION SERVICES ! 15 Cheslor Ave, flokordlelrJ, CA 93301 (805] 326-&gill p 326.05~6 ENVIEONMENIAL SERVICES ] 715 Clleslei' Ave. Bokefsfleld, CA 9,3301 (005) 326-3979 Ftg((805) 326.0576 TI~AININ6 DIVISION ~ VicTor Slieel Balce~sfleld, CA 93308 (IL05) 39~-4697 FAX (~0~) 3W-5763 03:i0PM CRYSTRL GEYSER NRTER B A K ER S F I.E L D FIRE DEPARTMENT October 8, 1996 8mtiago Martinez, Plat Manager, C~Tstal C, ey~r Water Co. 1233 East California Avam~ Bnkenflteld, CA 93307 RE: 1LMPP Update Request Dee' htr. Marfin~z'., On August 14, 1996, your facility experienced an activation of the Risk Management and Prevention Program ~viPP) plan implamentation of thc ammonia diffusion system. Tiffs office is very pleased with the feint success of your RMPP in general. ~nd the wrumonia diffusion ~stem in particular. The follow-up relx~l on the incident that was sent to lids office by Non.~ Ambm,,~ sp~ified that indicator lights would be imtslled on tho c~rbo cooler panel to alert lite operator oran ~unmonia compressor failure, Our records also show that a similar ammonia incident occun~ on March 23, 1989, likewise involvh~g a power failure, and the operator's inability to assess the operational condition of the vm-ious ~mponents of the an~monia ~stem. Therefore, this office concurs with the proposal to install thc htdicator lights ss spe~i,fied aud requires limt you update the appropriate s~tions of thc RMPP to document die installation of thc indicator li~ts,, Sp~ciilcally, you should address s~;tion 2.3: Measures Takcn to~revcnt Rccurr~n~ and section 6.0: D_~ectioii. Monitoriue or Automatic Control Systems, In addition, lrsinin8 ~d operating procedures should refer~tc~ the indicator lights as an abnormal condition r~qujring operator attention. Pie&se submit'the modifientions to the RMP? within 30 days of this letter, You may submit only thos~ pages of thc pla that contain revisions, Ir'you have any questions, please f~l free to call me at 326-3979. Thank you for your contlm~cd efforts to help make thc City of Bakersfield a safer piece in which to work and live, FIHW/dlm ~: R. Huey How,,'di l:Iazardo~ Post-It* Fax Note 7671 Date "l"~t of ~. Phone # Phone tt I -- / ' FaX ~ Fa~ ~" 9.0 AUDITING PROGRAMS 9.1 Ammonia Systems A copy of the audit used at Crystal Geyser Bakersfield plant is included as Appendix F. The purpose of the ammonia safety audit is to ensure that the ammonia system is operating and maintained in a manner that ensures the minimum possible risk to employees, the general public, environment and product safety. Other goals to be achieved by the ammonia safety audit are: To pinpoint actual and potential safety hazards due to design, location, operation and maintenance of the ammonia systems. To provide a means of objectively assessing and documenting plant safety. To provide a means of objectively defining needs for upgrading and modification. To provide feedback on safety Issues. The ammonia safety audit will be conducted on a yearly basis. Page 35 APPENDIX F AMMONIA SAFETY AUDIT FACILITY: Crystal Geyser Company ADDRESS: 1233 East California Avenue, Bakersfield, California 93307 TELEPHONE: (805) 323-6296 DATE OF AUDIT: KEY FACILITY PERSONNEL: Plant Manager: Quality Control Manager: Maintenance Manager: AMMONIA SAFETY AUDIT TEAM: Plant Manager: Quality Control Manager: Maintenance Manager: Appendix F Page 4 This safety audit is a review of the ammonia system equipment and operation. Do employees responsible for the ammonia system have a thorough understanding in the following areas? Basic refrigeration fundamentals Compressor functions and limitations Operations, set point and purpose of safety controls Location, operation and normal position of isolation valves Relief valve location, purpose, setting and proper operator response is activated Recognition and response to abnormal conditions Correct procedures for system charging and oil drainage Emergency Planning: Is there a written emergency plan? System Design: The attached forms should be filled out for each piece of ammonia containment vessel. The ammonia incident report should be filled out after an ammonia incident has occurred. Appendix F Page 5 APPENDIX F AMMONIA SAFETY AUDIT Instructions The questions have been designed to assist you in determining what level of safety exists in your plant. Some of the questions are provided to record descriptive information for future reference by your staff, and others who will review the audit results. Most of the questions directly related to an item that impacts system safety, have been formulated to require only a '~'es / No" answer. The sense of these questions is generally such that a "No" answer signals some degree of deficiency for that item. The audits should be carried out annually, by the plant audit group, and every four years by-a full audit group. The timing for the audits should be set by the plant management to suit the availability of staff. The' schedule should allow adequate time for the audit. The date can be scheduled well in advance, allowing sufficient time for the prior collection of some of the basic information by non-key staff. The audit group, for the annual audit, should consist of the: Plant Manager Maintenance Manager Quality Control Manager and for a full audit, by the plant audit team with the addition of an outside refrigeration consultant. Appendix F Page I The audit group will have to judge what classification should be assigned for the Safety Item Rating (S.I.R.) for each item. Usually, although not necessarily in every case, those items give a "No" answer will require some level of remedial action. It is intended that the S.I.R. reflects that level by means of assigning one of the following classifications: "E" (Emergency) Action should be taken immediately to correct a situation that represents an imminent danger. "U" (Urgent) A firm deadline should be set to correct a deficiency that may be a serious hazard, but not immediately dangerous to life or property. "1" (Improvement) Improvement is required, but can be achieved through the regular channels of maintenance activity, capital improvements or assignment to the functional staff (e.g. organizational, training, procedural improvements). No action considered necessary. In case the item is not applicable to your plant situation. When the checklist has been completed, the audit group must review the Safety Item Ratings given to each element. Lists should be made separately for the Emergency and Urgent items, and the audit summary form must be completed. The audit team will be required to arrange the lists in order of priority, and to formulate a practical plan for the execution of the works, including a timetable, allocation of responsibilities for the work, and preliminary budget estimates of the costs involved. Appendix F Page 2 The audit team's findings, lists and recommendations are to be discussed with the plant manager at the conclusion of the audit. Completed copies of the audit forms are to be retained by the plant manager for future reference. Appendix F Page 3 ANNEX 111.7: POLLUTION PREVENTION Structural Control: (check all that apply) Secondary Containment: [] absorbent materials [] berms [] booms [] catchment basin [] collection systems [] containment curbs [] culverting [] dikes [] drainage trench [] drip pans [] gutters [~ holding pond [] oil drainage collection equipment around: 0 pumps 0 valves 0 flanges 0 expansion joints 0 hoses 0 drain lines 0 separators 0 treaters 0 tanks 0 allied equipment [] protection of areas subject to flooding [] retaining walls [] secondary containment for portable tanks [] spill diversion ponds [] wiers Container Management: [] tank & container material compatible with: O substance stored O temperature O pressure [~l hazardous waste containers properly labeled [] incompatible materials physically separated [] materials stored in covered areas or containers [] materials stored in secured storage areas [] equipment positioned to prevent spills [] radioactives stored to prevent release Corrosion Protection: [] metallic tanks and piping protected by: O coatings O cathodic protection O regular pressure testing O protective wrapping O alternative exposed pipe corridors [] partially buried tanks avoided unless coated [] pipe supports minimize abrasion & corrosion and allow for expansion & contraction [] submerged piping protected from stress & fishing operations in offshore waters [] vehicle clearance signs under overhead piping Process Control: (check all that apply) Equipment: [~ vents [] relief valves [] check valves [] scrubbers [] flares [] manual shutoffs [221 automatic shutoffs [] interlock system: O warning light O physical barrier O warning signs [] alarms & procedures [] keyed bypass [] emergency air supply [] emergency power [] backup pump [] grounding equipment [] inhibitor addition [] rupture disks [] excess flow device [] quench system [] purge system Design: [] industry-specific design codes and standards: O NFPA 58 (or state equivalen0 OOSHA 1910.111 O ASTM O ANSI standards O ASME standards O [] internal heating coil leakage controlled by: C) monitoring for contamination O settling tank O skimmer O installation of external heating coil O other separation or retention system [] fail-safe engineered sump and drain systems: O adequate tank capacity O overflow accommodation O adequate vacuum protection O redundant pumps and controls [] special precautions for separators and treaters: O flare within diked area O high liquid level shuts in well O parallel redundant dump valves [] blowout prevention well control measures [] materials stored close to process areas [] material balances performed for critical process [] radioactives not in a respirable size range Emergency Control: (check all that apply) [] fire control equipment: O portable fire extinguishers O fire water hose O automatic sprinklers C) water spray systems O fire extinguishing foam O inert gas O dry chemicals O fire walls O blast walls O deluge system O water curtain O enclosure [~l spill control equipment {21 neutralization [221 decontamination equipment Emissions Control: (check all that apply) Stormwater Run-Off [221 drainage from diked areas restrained by: O valves O manually activated pumps O other drainage spill prevention O design to handle such leakage 1~ diked area drainage valve operations: O use of non-flapper type valves O manual open & close design O storm water inspected before drained [21 undiked drainage flows into: O ponds O lagoons O catchment basins O diversion ditches O treatment unit(s) ~]l diked rainwater drainage protected by: O normally closed bypass valve O inspection before draining O supervised bypass valve operation O records of all such drainage events [21 drainage valves normally closed & sealed [] effluent disposal facilities monitored often Air Pollution: [21 vapor control systems: O submerged fill pipe O pressure tank O vapor recovery system O floating roof tank [21 gasoline pump nozzle hold-open latch Procedural Control: (check all that apply) Maintenance and Operation: [21M&O to minimize possibility of fire or release [21 testing & maintenance of equipment [] preventative maintenance of monitoring equipment in accordance with manufacturers's instructions ) [] required equipment: O location O availability O maintenance schedule [21 visible leaks promptly corrected [] out of service pipes marked, capped, or blank flanged [21 valves & piping regularly examined or tested [21 loading rack in compliance with DOT [21 facility transfer operations: O valves & pipelines inspected O salt water disposal facilities inspected O flowline maintenance program [21 well shut in procedures adequately described [21 submerged pipelines adequately maintained [21 fully fenced and locked when unattended [] valves locked in closed position [] pump controls locked in "off" position [] loading rack connections capped or blanked [] internal / external corrosion detection / repair [] damage criteria for equipment repair / replace [] maintenance & inspection records available [] standard procedures for transfers: O pre-transfer checklist O review of transfer procedures O verification ofoil levels & volumes O inspection of key components: [~J valves ~1 hoses [~ piping [~ pumps O hook-up, start-up, & shut down O reduced loading rates at start & finish O emergency shut down of transfer O wellhead or platform shut down Procedural Control: (continued Inspection and Testing: [] regularly scheduled inspection & testing of: O tanks O pipelines O storage equipment O transfer equipment O production equipment O pumps O valves O flanges O overpressure safety devices [] methods &testing include: O hydrostatic testing O visual inspection [] overfill detection device testing: O prior to each transfer O monthly testing O monthly inspection & annual testing [] clear communications during transfer Source Reduction: [] employee incentives for good housekeeping [] cost accounting for waste generation / disposal {~ first-in / first-out materials usage policy [~ perishable materials used up before outdated [] computer tracking of material inventories [] materials stored in reusable containers ~ materials stored in low traffic areas ~ proper equipment to move drums safely [] waste streams segregated [] materials used only for intended purposes [] pre-weighed materials in soluble bags [~l lab scale tests performed before production [] solvent waste generated from cleaning is: O drummed for disposal O drummed for use in another process O sent to a holding tank [] piping is pigged before flushing [] product storage tanks cleaned by: O manually scraped O high pressure spray system using caustic, then solvent rinsed [] established procedures for cleaning equipment [] communication between cleaning & production crews [] formal policy commitment to source reduction [~[ use of non-hazardous material alternatives: C) non-chlorinated solvent cleaners (2) non-caustic cleaning solutions (2) biodegradable detergents O low VOC paints & coatings (3 reduced cleaning [] counter current rinsing processes installed [] automated raw material feed [] product design modified to reduce waste Procedural Control: (continued) Safety Management: [] / / date of most recent review or revision of safety information [] process safety information: (2) regulated substance hazards (2) process technology O process equipment specifications (2) safe upper / lower temperatures O safe upper / lower pressures (2) codes / standards built by (3 good engineering practices [~1 mechanical integrity: (3 written mech. integrity procedures (32) inspection / testing of equipment (3 correcting equipment deficiencies (2) quality assurance for suitability C) installed properly to specifications (2) suitable spare parts & equipment [] management of change: O technical basis for proposed change O impact of change on health & safety O modifications to operating procedures O necessary time period for change O authorization requirements for change [] employee participation: O written action plan for participation O in development of PHA O employee access to PHA results O source reduction techniques O hazardous materials policies [] hot work permit: O issued for work on or near process O fire prevention per 29 CFR 1910.252 {~l contractors: (3 informed of process hazards (3 informed of emergency action plan (2) trained in safe work practices (3 safety program evaluated C) illness & injury log available [] pre-start up safety review: (3 whenever changes in process safety C) adequate procedures in place C) PHA performed & implemented O employee participation in review [] injury & illness prevention program (3 per requirements of 8 CCR 3203 (2) drug & alcohol testing ANNEX III.8 CERTIFICATIONS Items addressed in this Annex: Regulatory cross-references (attached) Program 1 certification (only if applicable) (2735.4) Certification statement of complete and correct information: "I certify under penalty of law that this document and ail attachments were prepared under my direction or supervision in accordance with a system designed to assure that quaIified personnel properIy gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete." Printed name & title Signature Date CONSOLIDATED FACILITY COMPLIANCE PLAN CITY OF BAKERSFIELD - ENVIRONMENTAL SERVICES III. CERTIFICATION Section 25534 (j) of the CHSC requires that the RMPP and any revisions be certified as complete by a qualified person and the facility operator. Section 25532 (f) of the CHSC defines a qualified person as "a person who is qualified to attest at a minimum, to the validity of the hazard and operability studies performed pursuant to Section 25534, and the relationship between the corrective steps taken by the handler following the hazard and operability studies and those hazards which were identified in the studies". Qualifications of the certified person, Mary Jane Wilson, and Plant Manager, are contained in Section 13.0 of this RMPP. I hereby certify that this RMPP is complete, that the hazard and operability studies performed on the behalf of Crystal Geyser, Bakersfield are valid and that programs included in this RMPP will mitigate potential hazards determined through the hazard and operability study. Registere 'd~nvironmental Assessor State of California No. REA-00050 Exoiration Date~ June 30,.~1,.~~ Santiago Martinez Plant Manager Crystal Geyser Water Company, Bakersfield Page 4 13.0 QUALIFICATIONS OF CERTIFIERS 13.1 Qualified Person .Mary Jane Wilson, President, WZl Inc. Ms. Wilson received a Bachelor of Science Degree in Petroleum Engineering from Stanford University in 1972. She is registered as an Environmental Assessor in California. Ms. Wilson is the President and Chief Executive Officer of WZl Inc. She monitors WZl Inc. projects to maintain technical standards. She has extensive experience (21 years total) in the petroleum and environmental consulting industries. She has Participated in the design of numerous compliance programs related to the environmental safety of operating facilities. 13.2 Facility Operator Santiago Martinez, Plant Manager, Crystal Geyser, Bakersfield. Mr. Martinez, Plant Manager of Crystal Geyser, has 22 years of experience in the beverage bottling industry. He has been involved with the installation, modification and maintenance of numerous bottling and ammonia refrigeration systems during this time. Page 42