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RISK MANAGEMENT (3)
CRYSTAL GEYSER WATER COMPANY FACILITY COMPLIANCE PLAN INCLUDING REQUIRED RISK MANAGEMENT PLAN ELEMENTS May 1999 WZl INC. 4700 STOCKDALE HIGHWAY BAKERSFIELD, CALIFORNIA compressor and pump the discharge oil separator down, then pump oil in. Because of the large volume of gas that is contained In these vessels, it would be best to draw the To acoomplish gas back into the system rather than drain it into a container of water. this: 1. Stop oompressor, 2. Close discharge valve. 3. On second stage compressors close suction valve. 4, On second stage compressors open pump out line. 4. On Iow stage compressors open 3/8" bypass line around suction check valle. 4. After oil separator vessel pressure drops to suction pressure, around 2 psig, close the suction valve. 5. Close the bypass valve. 6. Pump in oil as needed. NOTE: If you are going to replace the oil, it is easier and takes less time if you drain the oil before you reduce the vessel pressure. AMMONIA OFF-LOADING PROCEDUR_ES Note: Following our (~ff-loading procedures are copies of Off-Loading Procedures for driver/operators of Ammonia delivery trucks from the two suppliers we usually use. Coordinate our procedures with the driver/operators procedures. Note: For emergency purposes have at hand and ready to use: Gloves, goggles, faceshield, a full face gas mask with industrial size ammonia canister, and a self contained, breathing apparatus..' ~ ..... 1.Locate amrnoni'a'{~U;6~ near ammonia charging stati6n east of the engine room. 2.Make sure wheels are chocked. 3.Put barrier et the valve loading stallon.with, a sign reading "DANGERI_ Stand clear, ammonia loading in progress. 4.Driver will connect hose to receiver fill line. $.Note Ilqutd level of receiver In the engine room, 6.After hose is connected and the bleeder valves are closed, make sure fill line valve is open on the receiver in the engine tooth. '/.Make sure receiver line pump out valve is closed. 8.Slowly open flit line valve,~ . r~-,.when driver/operator is ready. Note: Note: Coordinate with steps 2 through 5 of Hill Brothers procedures or steps 11 through 18 of LaRoche procedures. Read pressures at cargo tank and engine room receiver. If the differential pressure between the truck tank pressure and engine room receiver exceeds the limit of the pumping system, the engine mom operator must reduce the receiver tank pressure to a suitable level. Maximum differential pressure should not excccd 125 PSIG. Operating Instructions - Page 6 ~VZI ,~c 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. Restarting a Compressor 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. Preventative Maintenance Checklist 3. 4. 5. 03320012.001 While the system is in operation, check the refrigerant sight glass: Clear - OK Bubbles - Low on refrigerant Foam - Very Iow Oil sight glass level should be in center of glass. O~, Operate thermostat at the set point. - ~j~)~ e,~( Maintain proper glycol level and concentration. ~,:~,~. Evaporative condenser. Bleed off- clean sump and spray nozzles, chemicals, fans and pump. ~'~)~ -~/',~ ~"~o~ ~ ~.~,. ~__.~..~ 5~~ '~ 63 7. 8. 9. 10. 11. 12. 13. 14. Check suction and discharge pressures. ~_~.i y Listen for strange noises, bad bearings compressor knock. Check all breakers and overloads. Clean pump strainer. Check by-pass and flow switch by turning off glycol pumps, system should pump down and turn off. Tum off refrigerant solenoid and see if system will pump down and shut off at about 10-20 psig. Check for vibration, loose clamps, cap tubes vibrating and/or rubbing. Log compressor hours. During times of light load, time. turn off the lead compressor and let #2 get more run Weekly 2. 3. 4. 5. Log the compressor operating hours. Check the oil level in the compressors. Check the frigerant sight glasses for bubbles. Check fans and pump in evaporative condenser for proper operation. Check tower chemicals. 0,..-~ ,-J// % ~, ~'~ k,~..~ o~ Monthly Shut down the system, drain the condenser sump and clean sump and pump strainer in the condenser. Check for scale. (~'"7' - Check the strength of the glycol solution. Strength should be 30-40%. 1.034 to 1.049 specific gravity. 03320012.001 64 Turn off the glycol pumps and check to see if the flow switch turns off the refrigerant solenoids. Check for loose pipe clamps. 2. 3. 4. 5. 6. 7. 8. 9. 10. Yearly Descale the condenser if necessary. Replace refrigerant driers. More often if necessary. Check the condenser fan belts. -- %.~./v,o,..., Check all safety controls. -.-' ~,~- Check the gauges for proper calibra.~.....~ ~. Check the compressors per. Car~C'recommendations. Change the oil in the compressors and clean the crank cases. Check thermometer and thermostat calibration. Flush the cooling coil drain pans, if any, with fresh' water to clean and check for proper drainage. Turn off power and tighten all electrical connections in the control panel. 03320012.001 65 CRYSTAL GEYSER WATER COMPANY FACILITY COMPLIANCE PLAN INCLUDING REQUIRED RISK MANAGEMENT PLAN ELEMENTS May 1999 Submitted to: City of Bakersfield Office of Environmental Services 1715 Chester Avenue Bakersfield, California 93301 Submitted by: Crystal Geyser Water Company 1233 East California Avenue Bakersfield, California 93307 Prepared by: WZI Inc. 4700 Stockdale Highway, Suite 120 Bakersfield, California 93389 03320012.001 I 4700 STOCKDALE HIGHWAY, SUITE 120 BAKERSFIELD, CALIFORNIA 93309 (805) 326-1112 FAX: (805) 326-0191 SECTION I 1.1 Purpose and Scope of Plan Coverage The Crystal Geyser Water Company, Bakersfield plant, formulates and bottles Crystal Geyser brand juice drinks and flavored waters. For process cooling, an anhydrous ammonia refrigeration system is used. The California Accidental Release Prevention (CalARP) Program merged the existing state Risk Management and Prevention Plan (RMPP) and the new federal Risk Management Plan (RMP) promulgated pursuant to Section 112(r) of the 1990 Clean Air Act Amendments. The California Office of Emergency Services (OES) oversees the CalARP regulations. The U.S. Environmental Protection Agency (USEPA) has delegated implementation authority for the federal program to OES. At the local level, the program is implemented by the Certified Unified Permitting Agency (CUPA). For facilities operating within the City of Bakersfield, the CUPA is the City of Bakersfield Office of Environmental Services. Because the CalARP program is a combination of the federal and state requirements, the program includes two lists of regulated toxic and flammable substances. While many of the chemicals are present on both lists, the state applicability thresholds are generally lower. The RMP must be developed from a comprehensive assessment of the processes, operations, and procedures at the facility, and includes four main elements: A Management System that specifies qualified and responsible persons; A Hazard Assessment that analyzes and documents potential environmental and population receptors due to an accidental release; 03320012.001 2 A Prevention Program that compiles operations procedures, safety information, and specific hazard information into a program that minimizes the threat of an accidental release; and An Emergency Response Program that establishes procedures to deal with the results of an accidental release. Also addressed in this document are requirements of Title 40, Code of Federal Regulations, Part 355. The requirements of this section apply to any facility at which an extremely hazardous chemical is present at or above the threshold planning quantity. These facilities are required to notify the local emergency planning committee or emergency response personnel of the chemicals present, to provide a facility emergency response coordinator and to notify the committee of any changes that occur. Any facility that produces, uses or stores hazardous chemicals above the threshold planning quantity is required to notify specific agencies in the event of a release. Ammonia, the only hazardous chemical of any quantity located at Kern Ice and Cold Storage's facility, has a threshold planning quantity of 500 pounds. The reportable quantity for ammonia is 100 pounds. This plan conforms to the City of Bakersfield's Guidance for the Preparation of a Facility Compliance Plan. The City of Bakersfield's Guidance is taken from the Draft Guidance Document for the California Consolidated Contingency Plan published by the Governor's Office of Emergency Services and is modeled after the National Response Team's Integrated Plan, the "One Plan." 03320012.001 3 1.2 TABLE OF CONTENTS SECTION I .......................................................... 2 1.1 1.2 1.3 1.4 Purpose and Scope of Plan Coverage .......................... 2 TABLE OF CONTENTS ..................................... 4 Current Revision Date ....................................... 9 Facility General Information ................................. 10 SECTION II ......................................................... 1 I1.1 Discovery ............................................... 11 Detection and Monitoring Systems ............................ 11 Odor .............................................. 11 Sight .............................................. 11 Ammonia Gas Sensors ................................ 11 Alarm Indicators ..................................... 12 Operating Thermostat ................................ 12 Control Systems .......................................... 12 System Restart ...................................... 12 Manual Isolation Valves ............................... 13 Machine Room Exhaust System ......................... 13 Machine Room Vent System ........................... 13 Emergency Stop Switch ............................... 14 King Solenoid ....................................... 14 Master High Level Switch .............................. 14 Chiller High Level Switch .............................. 14 Cooler Tower pH Alarm ............................... 15 Sparge Tank pH Alarm ................................ 15 03320012.001 4 VV~l INC 11.2 11.3 11.4 Environmental Response Actions ............................. 16 a. Internal and External Notification Procedures .............. 16 b. Environmental Management System ..................... 18 c. Preliminary Assessment ............................... 19 Worst Case Scenario ................................. 20 Off-Site Receptors for Worst Case Scenario ..........21 Alternate Release Scenario ............................ 22 Off-Site Receptors for Alternate Release Scenario ..... 23 d. Mitigation ..................... : .................... 24 Incident Action Plan .................................. 24 Continuous Improvements .................................. 26 Return to Compliance ...................................... 27 SECTION III ........................................................ 28 II1.1 Maps and Drawings ....................................... 28 a. Maps .............................................. 28 b. Drawings .......................................... 31 c. Areas of Vulnerability ................................. 32 111.2 Notifications ............................................. 38 a. Internal Notifications .................................. 38 b. Local Agency Notifications ............................. 39 c. Regional and State Agency Notifications .................. 40 111.3 Environmental Management System ........................... 41 a. General ............................................ 41 Organizational Chart ................................. 41 03320012.001 5 Co Emergency Response Procedures ....................... 41 General Evacuation ............................. 42 Fire ......................................... 42 Earthquake ................................... 42 Significant Leak from the Ammonia System .......... 43 Command .......................................... 44 Accidental Releases .................................. 44 Management of Change ............................... 44 Operations ......................................... 46 Daily Operating Procedures ............................ 46 Daily Operating Duties ........................... 46 Addition of Oil to the Compressors ................. 46 Detection and Monitoring Systems..: .................... 46 Odor ......................................... 46 Sight ........................................ 47 Ammonia Gas Sensors .......................... 47 Alarm Indicators ................................ 47 Operating Thermostat ........................... 47 Control Systems ..................................... 48 System Restart ................................ 48 Manual Isolation Valves .......................... 48 Machine Room Exhaust System ................... 48 Machine Room Vent System ...................... 49 Emergency Stop Switch .......................... 49 King Solenoid ................................. 49 Master High Level Switch ........................ 49 Chiller High Level Switch ......................... 50 Cooler Tower pH Alarm .......................... 50 Sparge Tank pH Alarm .......................... 50 03320012.001 6 Incident Action Plan .................................. 51 Utility Shut-Offs ..................................... 52 Gas/Propane Tank .............................. 52 Electrical ..................................... 52 Water ........................................ 52 Ammonia ..................................... 52 Gas Meter .................................... 53 Lock Box ..................................... 53 Available Water Supply ............................... 53 Planning ........................................... 54 Worst-Case Scenario ................................. 54 Residential Population Calculations ...................... 57 Worst Case Scenario Area of Vulnerability ................ 57 Alternate Release Scenario ............................ 58 Residential Population Calculations ...................... 61 Alternate Scenario Area of Vulnerability ..................61 Logistics ........................................... 62 Emergency Medical Plan .............................. 62 Maintenance Procedures .............................. 62 Ammonia System Shutdown ...................... 62 Isolating a Compressor for Maintenance ............. 62 Restarting a Compressor ......................... 63 Preventative Maintenance Checklist ................ 63 Weekly ....................................... 64 Monthly ...................................... 64 Yearly ....................................... 65 03320012.001 7 111.5 111.6 111.7 111.8 Emissions Documentation ................................... 66 Documentation ........................................... 66 Incident Investigation ...................................... 66 Five-Year Accident History .................................. 67 Requirements ....................................... 67 Accidental Release ................................... 67 Training ................................................. 68 Plan Review and Modification ........... .. .................... 69 Prevention Program ....................................... 70 NAICS Code ............................................. 70 Name of Chemical Covered ................................. 70 Safety Information ................. ........................ 70 Hazard Review ........................................... 71 Operating Procedures ...................................... 71 Training Programs ......................................... 72 Maintenance Procedures ................................... 72 Compliance Audits ........................................ 72 Certification .............................................. 74 03320012.001 8 1.3 Current Revision Date This document, including a review of the facility, the facility hazards, the off-site area of vulnerability, and the off-site receptors, was completed in May 1999. 03320012.001 9 Alternate Release Scenario An alternative release scenario is also required. This alternative release scenario is determined by either past facility or industry experience to be a more likely credible release scenario. The hazard and operability study determined the alternate release scenario to be the release of the liquid contents of the ammonia receiver into outside air. The potential release scenario judged to be dangerous to offsite receptors is a release of ammonia during an earthquake. Lines from and to the ammonia receiver contain liquid ammonia. A break in this liquid ammonia line could release all of the ammonia in the receiver to outside air. In this potential worst case scenario, the rapid release of liquid ammonia could form an air/ammonia dispersion that would act as a cloud of dense gas. The release rate for the alternative release scenario can be found by using the following equation from USEPA guidance: QR = HA x (203)(Pg)'~' where QR = HA = Pg = Release Rate (lbs per minute) Hole Area (square inches) Gauge Pressure (psig) Using the RMP Comp software provided by the EPA, the distance to the toxic endpoint is estimated to be 0.2 miles. There are no off-site environmental receptors for the alternate release scenario. Residential population calculations are given in Section 111.3.d. Public receptors include commercial, industrial, and residential receptors. 03320012.001 22 A more detailed explanation of the alternate release scenario is given in Section 111.3.d, Planning, and a map of the vulnerable area is provided in Section II1.1, Maps and Drawings. 03320012.001 23 II II 0.2 MILE RADIUS CRYSTAL GEYSER BAKERSFIELD TERRACE AVE FiRE STA. RADIO TOWER SCALE IN MILES 0 0.5 I" [ I [ I "1 WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER Bakersfield, CA ALTERNATE RELEASE SCENARIO d. Mitigation General emergency response procedures are: Assess the situation. Isolate and deny entry to the affected area, and evacuate or shelter-in-place. Provide emergency medical assistance, if necessary. Notify response agencies and facility response personnel, as appropriate. Control the release, if possible. Actively mitigate the release, if properly trained and equipped. Provide assistance to public agency responders, as necessary. Terminate the response with proper clean-up and disposal. Follow-up reporting, evaluation, and critique, as required= Incident Action Plan The incident action plan will be implemented in the case of an emergency plant evacuation. The following steps will be taken in emergency situations: An announcement will be made over the paging system notifying employees of facility evacuation. All employees will report to the staging area on the east end of the property. Employees certified on self-contained breathing apparatus (SCB^) will bring SCBA equipment to the staging area. Attendance will be taken by the Incident Commander or designee to account for employees. The Incident Commander or designee will make an overall assessment of the incident. 03320012.001 24 o Emergency response personnel such as the fire department, hazardous materials team, medical units, and Office of Environmental Services will be notified immediately by the Safety Coordinator or designee. o o 10. 11. Incidents occurring during the night shift will be evaluated by lead persons and general staff members. If necessary, emergency response personnel will be notified followed by the Safety Coordinator and the Incident Commander. The Incident Commander will initiate a search for employees not accounted for in the attendance count. Emergency response personnel will be assisted by SCBA-trained Crystal Geyser personnel if needed. A map of the plant will be maintained in SCBA storage units to assist emergency response personnel. The Safety Coordinator will continue to monitor personnel safety. Additional protection and mitigation procedures are included in Section 111.3.d, Planning. 03320o12.001 25 11.3 Continuous Improvements Measures to be taken during nonconformance conditions or prolonged incidents include: Stopping processes and operations. Collecting and containing released waste. Removing or isolating containers. Monitoring for leaks, pressure build-up, ruptures, etc. Arranging for repair or replacement of affected system areas. This facility is closely monitored by the facility supervisors and other personnel. Crystal Geyser Water Company is committed to providing a safe environment for its employees and the surrounding area. Improvements are implemented when possible to support this commitment. These improvements may include upgrading equipment maintenance procedures, training requirements, operating procedures or system controls. 03320012.001 26 11.4 Return to Compliance A written follow-up report is required to be completed as soon as practicable, but no later than 30 days following a release. The completed report is to be sent to the Office of Emergency Services. After an accident has occurred, an incident investigation will be initiated as soon as possible but no later than 48 hours after the incident. An incident investigation team consisting of at least one person knowledgeable in the process and any other persons with appropriate knowledge and experience will analyze and investigate the incident. The ammonia incident report on the following page will be completed. A post-accident review will be held in which potential causes of the accident will be discussed. VVhen the cause of the accident has been determined, measures will be implemented to minimize the possibility of recurrence. System design, operating and maintenance procedures that need updating or alteration will be noted, and a time schedule set for implementation of improvements. The Safety Coordinator will be responsible for ensuring the completion of the above activities. All incident investigation reports will be retained for 5 years. Training practices will be adjusted to ensure correct implementation of improvements. New training practices will include refresher training to existing employees to ensure that the employee understands and adheres to current operating procedures of the process. New employees will be trained in general operating practices and job-specific practices prior to operating the process. 03320012.001 27 SECTION III II1.1 Maps and Drawings a. Maps Site maps, including facility evacuation routes, off-site consequence endpoints for worst- case and alternate release scenarios, and sensitive receptors within endpoints, are included on the following pages. 03320012.001 28 0332.0012 4/cj9 U. BRAJ~Y 1500 0.5 SCALE IN MILES CRYSTAL GEYSER Bakersfield, CA LOCATION MAP Industrial Industrial Parking Job Crystal . Cry Vintage [ ~ed~,..k. m'n~ Geyser Geyser Air I - Bottlin~ Parking Alley TIIUXTUN w z WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER Bakersfield, CA SURROUNDING AREA 0332.0012 4/99 1233 EAST CALIFORNIA MIX I I HALLWAY I 1233 EAST CALIFORNIA ROOM BO'I-I'LE · '~ FILLER ERS.[ _A ROOM . ! PACKAGING T AREA OFFICE SHOP PROCESSING AND STORAGE AREA t OFFICE NCH ROOM ALLEY WAREHOUSE' AREA I I RESTROOM I I I I I I I I ~ I I I I__l WZI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER Bakersfield, CA BOTTLING FACILITY EVACUATION POINTS ~ ' ~, /~"-J*" P~.-..Z -.. ~ : *--. ' .... ; .. :/~'---L._$r .' ~,, HALL .' ~ ' ' / ~ ' / - ' -' >- ~r 8 - T ; ' ~ a ~ -' -,' ' ' , [ , ~-~/ ,"~ "--' "~"Y~ RUX~ ~ '~' z - T T _: , ~ ~.~ ,. ' .'~ ~ ~ : -, :~ .' '-..~ } I II ~~~ ~ ~i ~l ~i ~'i~ ~ ~ ~ ~ '1 ;u~! ~ ~ [ · I:' ' : ~ / ~ -- , : ~ ~ ~ , x ' - ; ~; ~i~ t: i-' ~:,., ;y ~ ~ : i i ~ L. O' ~ ~l ~ >. ~: z' iVI~INIA AVE Z; ~ i rt tl~ ~ ~[ ~ ~ J~ ~ ~ ~ ~! ~! ~ ~ ~ . [ ~.~ f ~ J ~ ~t :. ~ ' t ' ' ~- ~ " ~ ' ~ ~l.i ~ ' ~ ' , I - ~ ~ ._...~qL.' :. ~' ' ~ 1~ ~~'/ ~: ~ R~oro rOWER SCALE IN MILES CRYSTAL GEYSER 0 0.5 1 ~kersfield, CA WORST CASE REL~SE ~.~2 SCENARIO ~ · .~.~ ~ · .. ~ ' ~ · ~R~ST~L O~8~R ~ SCALE IN MILES ~k~fl~d, CA ALTERNATE REL~SE ~.~2 SCENARIO Off-Site Receptors for Worst Case Scenario Receptor Approximate Distance (Miles) Direction Southern Pacific Depot State Building Fire Station #2 Vista East High School Martin Luther King Jr. Park Union Cemetary Owens School Virginia Avenue County Park 4/5 9/10 2/3 1/2 1/3 3/10 2/5 2/3 NW NW NW NW W SW SW SE 03320012.001 29 Off-Site Receptors for Alternate Release Scenario There are no off-site environmental receptors for the alternate release scenario. 03320012.001 30 b. Drawings Process flow diagrams for the Crystal Geyser Water Company facility follow. 03320012.001 31 0332.0012 4~99 PRV ACCUMULATOR PRV ACCUMULATOR CHILLER PRV PRY PRY PRV I FILTERS .._~..EVAPORATIVE~. CONDENSER ~_~IEVAPORATIVEI ~ CONDENSER ""- __~EVAPORATIVE~ CONDENSER KING LSV PRV HIGH PRESSURE RECEIVER WZl INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER Bakersfield, CA AMMONIA SCHEMATIC DIAGRAM DETAIL · oO o~ ~.'CHILLER ELEVATION n-iv HO..LVO. ~ ONIdld HNVi ~3AI3OqW EVAPORATIVE CONDENSOR WATER PIPING LEGEND B= 2' OVERFLOW C= 2' FPT OR.MN w/BRASS B.V, D" WATER TREATMENT METER E= CONDUCTMTY PROBE F= CHEMICAL PUMP G= .30 GAL. MIX TANK Z b,J Z 0 X bJ R-9 ONIdld qODAq9 '~31V~ S3MOi ~ ISOiV3 INVq8 ~ L O '1 i , , O h--;-- I I J II I II ~ II I II Il I I II I I '.' : I JI ONIdld H3.£V~ S3A~Oi ~ i~OAVq iNV3d --I II II II II II I I II I J W399~HD > 1¥' ONIdld "! Ill ONIdld N~FI.L3~J ~ A-lddFl$' kI3/~.O/ ~? 1.4 Facility General Information Business Name: Address: Phone: Crystal Geyser Water Company 1233 East California Avenue Bakersfield, CA 93307 (661) 323-6296 NAICS Code: 312112 Latitude: 35°22'04'' Longitude: 118°59'00" Environmental Contact: Bob Hofferd, Safety Coordinator Primary Emergency Contact: Gerhard Gaugel, Quality Control Manager Secondary Emergency Contact: Bob Hofferd, Safety Coordinator Number of Full-Time Employees: 39 Chemicals On-site: Maximum Amount of Chemical: Storage Container: Date of Last Inspection: Inspection Performed By: Inspection Agency: Anhydrous Ammonia 4500 pounds Aboveground Tank (Receiver) March 1999 Howard Wines City of Bakersfield Office of Environmental Services 03320012.001 10 SECTION II I1.1 Discovery Detection and Monitoring Systems Odor The nature of ammonia is such that the presence of ammonia vapors would be detected by smell at very Iow concentrations. Sight Potential ammonia release points can be detected by visual inspection of equipment to identify discolorations, rust, holes or worn spots. Ammonia Gas Sensors Ammonia gas leaks are detected by Manning Systems Model 4485 Ammonia Gas Cell/Transmitters located in the machine room, at the carbo cooler and in the ammonia vent lines. These sensor units consist of an electrochemical sensor and an electronic transmitter and have a detection range of 0-100 ppm ammonia. 03320012.001 11 Alarm Indicators The alarm module is the top of three computer modules located in the computer control panel. The top row of lights are inputs to the computer. The bottom row of lights represent the outputs. The computer inputs must be "ON" (LED light ON). If the light goes out, it signals an alarm condition. Operating Thermostat Operating thermostats are used in the glycol system and the tower water system. The operating thermostat has four stages. Three stages are used to control the temperature. Should the glycol or tower water temperature continue to increase beyond the third stage of cooling by five degrees, the high temperature alarm signal will be sent to the computer alarm module signaling a general refrigeration alarm. Control Systems System Restart If there is a power failure, the system will not restart automatically. A trained operator must restart the system. When the power is restarted, the alarm system will check all of the alarm points. If there are any failures, the alarm horn and light will activate. The operator can silence the alarm horn, but he cannot reset the alarm system until the cause of the alarm is found and corrected. Once all of the alarms are cleared, the compressor can be placed into operation. 03320012.001 12 Manual Isolation Valves In the case of an earthquake there is a possibility that ammonia lines will break. Power will likely be out which will close all automatic valves. Each vessel that contains ammonia has manual isolation valves that can be turned off. Machine Room Exhaust System The machine room has a large two speed fan located on the roof. The fan is used to cool the machine room in the summer and to vent the ammonia out of the machine room in the event of a leak. The fan has a set of automatic dampers. If the fan is being used for ammonia removal, the dampers direct the exhaust air into the cooling tower. This tower acts as a scrubber, removing the ammonia from the air. This will happen under the following conditions: There are two machine room emergency vent switches on the system. One in the dump panel and one on the wall outside the machine room. Either switch will start the fan and the damper, and sound an alarm. If the machine room ammonia sensors detect a leak, it will start the vent system and sound the alarm. Machine Room Vent System The machine room vent system will still function if the emergency stop switch has been used. The control panel is built in two sections. Each section has its own power supply. 03320012.001 13 Emergency Stop Switch There are two emergency stop switches. One is located in the ammonia dump panel and one is' on the wall outside the machine room. The switches are wired in series. If there is an accident, fire, earthquake, or ammonia spill the refrigeration system can be turned off from either remote location. This will sound an alarm at the main computer panel. King Solenoid The system has two King solenoid valves located on the main ammonia line as it leaves the receiver to supply the system. One valve is manual, the other is electric. The electric valve must be energized to open. The valve will close during a power failure, if the emergency stop switch is turned off, or if the King solenoid valve switch is turned off at the contr°l panel. Master High Level Switch The master high level switch is located on the master accumulator. If liquid ammonia floods back to the master accumulator, the master high level switch will shut down the complete refrigeration system. In order to restart the system, an operator must be present to reset the alarm system and place the refrigeration system back in operation. Chiller High Level Switch The glycol chiller has an accumulator that discharges to the master accumulator. The high level float switch is located on the glycol chiller and it will give an alarm signal indicating that the ammonia level is too high. This will not, however, shut the system down. It will let the operator know that an alarm condition is present. 03320012.001 14 Cooler Tower pH Alarm The cooling tower will be used as an ammonia scrubber for the machine room ventilation system. In the event of an emergency, ammonia will be scrubbed out of the air by the cooling tower. This will in turn change the pH of the water in the cooling tower sump. A pH alarm will detect any changes in the sump water and send a signal to the computer alarm module, sounding a general computer alarm. At the same time, it will open a dump solenoid allowing water to drain from the cooling tower to the sparge tank and freSh water will be automatically added to the cooling tower. This will continue until the pH of the tower water is back within predescribed limits. Sparge Tank pH Alarm In the event a relief valve is discharging ammonia into the sparge tank and there is a failure of the ammonia vent alarm and the pH changes substantially in the sparge tank, a signal is sent from the remote pH alarm module located at the tank to the computer alarm module sounding a general alarm. 03320012.001 15 11.2 Environmental Response Actions a. Internal and External Notification Procedures Supervisors, upon notification of a hazardous condition, will use the paging system to notify all employees to evacuate the facility. Each supervisor is to direct the employees in his ama to the safest exit and to ensure that area has been vacated by all personnel. All employees will report to the designated evacuation area. A map of evacuation mutes is shown on the following page. Pursuant to Section 25507 of Chapter 6.95, Article 1 of the H&SC, releases of hazardous materials that may threaten human life, health and safety or the environment must be reported. If an ammonia release exceeds 200 cubic feet during a 24-hour period, the event is reportable and the following agencies must be notified immediately. Local emergency response agency Telephone: 911 City of Bakersfield Fire Department Office of Emergency Services Telephone: (661) 326-3979 California Office of Emergency Services Telephone: (800) 852-7550 National Response Center Telephone: (800) 424-8802 03320012.001 16 I I I < I I I I V"~¥ NOOO ~NIO¥0'I I I i I I LU I' m I 0 I I I I I I ¥::::II::IV ~DNI I~PI ~ I i=o 0 The following information will be provided during notification: · Name and telephone number of person reporting release. · Exact location (address) of the release or threatened release. · Date, time, cause and type of incident (e.g., fire, release, unauthorized discharge, etc.) · Material and quantity, to the extent known (size and appearance or opacity). · Weather conditions, if applicable. · Current condition of the facility. · Extent of injuries, if any; and · Possible hazards to human health, or the environment, outside the facility. 03320012.001 17 b. Environmental Management System The Plant Manager, Richard Weklych, is responsible for the Bakersfield facility. Issues must go through the Plant Manager for final approval before implementation. At the Crystal Geyser Bakersfield location, the Safety Coordinator, Robert Hofferd, will be the qualified individual and Environmental Coordinator. The Environmental Coordinator is responsible for all safety training of employees. The Emergency Contact will be the Quality Assurance Supervisor, Gerhard Gaugel. Any emergency incidents that occur at the facility will be the Emergency Contact's responsibility. All supervisors will be responsible for the safety of the employees in their section. 03320012.001 18 c. Preliminary Assessment The ammonia system is designed to operate when cooling is needed. Gaseous ammonia enters the compressors and is compressed to a higher pressure and temperature. After exiting the compressors, the hot gas enters the evaporative condensers. Water running · through the condensers cool the hot gas into a liquid. The liquid ammonia flows to and is contained in the receiver. A level control, controlled by a solenoid valve, allows ammonia to flow from the receiver to the chiller and carbo cooler. From the receiver, liquid ammonia flows through the lines to the cooling equipment, the carbo coolers. In this flooded system, liquid ammonia flows through exchanger plates while the material to be cooled, flowing counter currently, is cooled by the phase change of the boiling ammonia. From the carbo coolers, vapor and liquid ammonia travels back to the indoor receiver from which vapors are pulled by the compressors. Liquids are recycled from the receiver back to the coolers while vapors travel through insulated lines to be compressed to high pressure and then cooled into a liquid, completing the cycle. A walk-through of the facility and a failure mode and effect analysis were performed to determine potential weaknesses in the facility systems. The most likely event causing a release would be a pipe or valve rupture. The immediate area surrounding the Crystal Geyser plant is both residential and industrial and must be considered in hazard analyses, operating and response procedures. Additional hazard analysis information is included in Section 111.3.d. 03320012.001 19 Worst Case Scenario The worst case scenario is given by USEPA guidance. The maximum amount of anhydrous ammonia is assumed to be released in ten minutes. No mitigation measures are considered to be in effect to slow or prevent the release of the entire amount of ammonia in the system. The rapid release of liquid ammonia could form an air/ammonia dispersion that would act as a cloud of dense gas. The distance to the toxic endpoint is the distance this potential ammonia vapor cloud could travel before dissipating to a point that serious injuries from short-term exposure will no longer occur. Crystal Geyser Water Company systems have a maximum capacity of 4500 pounds of anhydrous ammonia. The USEPA has published Risk Management Program Guidance for Ammonia Refrigeration to assist facilities in RMP preparation. This guidance manual has a standard table to be used for worst case scenarios and is based on the maximum amount of anhydrous ammonia used in the process. Based on this USEPA-supplied table for worst case scenarios, the worst case distance to the toxic endpoint is 0.9 miles. A more detailed explanation of the worst case scenario is given in Section 111.3.d, Planning, and a map of the vulnerable area is provided in Section II1.1, Maps and Drawings. 03320012.001 20 r~ ~.-~=--~-~~ ~/w"f.-M.._! .~ ..... 4.j~,' £~-~-..4 ~~ ~~i~~'~ ~1 ~e',-~ ,',~'~ .... ._ .. ..... ~ ~~? ~' T~X I '":": '-'~'F? ~ =' ~~~~~Z /~/ CRYSTAL ~SER ' ,~ ',~'~i I ~' ?~~_ ~/ F~~ L/ ,~ } i , . ! . . ' I ~ ~ ' I ~ ....~ ~ ' '"i~~~: -- AVE ~ ~ '~~ , , Z ~. ,,,.,-: k~R~l~ ~ , ST : Z ~-'" .;":. - .... .' . ' --, ' ~ ~ ~ ' ' :' ": ~ z' ~0~ - >,' ~ z Ir ' ~ ~ ~ , '."'.. '.': (~r ,~ ,~ : ~: ~; z, ~~ ..... ~-, SCALE IN MILES CRYSTAL G~SER 0 0.5 1 ~kersfield, I I I i I I WORST CASE ~.~ 2 SCENARIO Off-Site Receptors for Worst Case Scenario Receptor Approximate Distance (Miles) Direction Southern Pacific Depot State Building Fire Station #2 Vista East High School Martin Luther King Jr. Park Union Cemetery Owens School Virginia Avenue County Park 4/5 9/10 2/3 1/2 1/3 3/10 2/5 2/3 NW NW NW NW W SW SW SE 03320012.001 21 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 PraxairTM Material Safety Data Sheet I 1. Chemical Product and Company Identification I I Product Name: Ammonia, Anhydrous (MSDS No. P-4562-E) Trade Name: Ammonia, Anhydrous Chemical Name: Ammonia Synonyms: Ammonia Gas, Spirit of Hartshorn Formula: NH3 Chemical Family: Alkaline Gas Telephone: Company Name: 1-800-645-4633' 1-800-424-9300' 1-800-PRAXAIR Emergencies: CHE~C Routine: Praxair, Inc. 39 Old Ridgebury Road Danbury CT 06810-5113 *Call emergency numbers 24 hours a day only for spills, leaks, fire, exposure, or accidents involving this product. For routine information contact your supplier, Praxair sales representative, or call 1-800-PRAXAIR (I-800-772-9247). 2. Composition / Information on Ingredients For custom mixtures of this product request a Material Safety Data Sheet for each component. See Section 16 for important information about mixtures. PERCENTAGE INGREDIENT NAME CAS NUMBER Ammonia, Anhydrous 7664-41-7 *The symbol ">" means "greater than." I >99%* lOSHA PEL 50 ppm ACGIH TLV 25 ppm (TLV-STEL, 15 min = 35 ppm) Hazards Identification EMERGENCY OVERVIEW DANGER! Corrosive liquid and gas under pressure. Harmful if inhaled. Causes eye, skin, and respiratory tract bums. May cause kidney and respiratory system damage, Can catch fire. Self-contained breathing apparatus must be worn by rescue workers. Odor: Pungent, irritating THRESHOLD LEVIIT VALUE: TLV-TWA = 25 ppm, TLV-STEL (15 min) = 35 ppm (ACGIH 1997). TLV-TWAs should be used as a guide in the control of health hazards and not as fine lines between safe and dangerous concentrations. Copyright 1979, 1985, 1989, 1992-1993, 1997 Praxair Technology, Inc. All rights reserved. Page 1 of 8 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 EFFECTS OF A SINGLE (ACUTE) OVEREXPOSURE: INHALATION-Overexposure to concentrations moderately above the Threshold Limit Value (TLV) of 25 ppm may irritate the eyes, nose, and throat. Higher concentrations may cause breathing difficulty, chest pain, bronchospasm, pink frothy sputum, and pulmonary edema. Overexposure may predispose to acute bronchitis and pneumonia. SKIN CONTACT-Liquid may cause moderate to severe redness, swelling, and ulceration of the skin, depending on the degree and duration of contact. At high concentrations, gas may cause chemical burns. Prolonged or widespread skin contact may result in the absorption of potentially harmful amounts of material. SWALLOWING-An unlikely route of exposure; this product is a gas at normal temperature and pressure. But exposure, should it occur, may cause chemical burns of the mouth, throat, esophagus, and stomach. EYE CONTACT-Liquid may cause pain, severe redness, and swelling of the conjunctiva, damage to the iris, corneal opacification, glaucoma, and cataracts. Gas may cause pain and excessive tearing with acute corneal injury at high concentrations. EFFECTS OF REPEATED (CHRONIC) OVEREXPOSURE: Chronic exposure may cause chemical pneumonitis and kidney damage. OTHER EFFECTS OF OVEREXPOSURE: None known. MEDICAL CONDITIONS AGGRAVATED BY OVEREXPOSURE: Inhalation may aggravate asthma and inflammatory or fibrotic pulmonary disease. Skin irritation may aggravate an existing dermatitis. SIGNIFICANT LABORATORY DATA WITH POSSIBLE RELEVANCE TO HUMAN H~'.ALTH HAZARD EVALUATION: None known. CARCINOGENICITY: Ammonia, Anhydrous is not listed by NTP, OSHA, and IARC. ] 4. First Aid Measures, , [ INHALATION: Remove to fresh air. If not breathing, give artificial respiration. WARNING: Rescuer may receive chemical burns from giving mouth-to-mouth resuscitation. If breathing is difficult, qualified personnel may give oxygen. Keep patient warm. Call a physician. SKIN CONTACT: Immediately flush skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Discard clothing and shoes. Call a physician. SWALLOWING: An unlikely route of exposure; this product is a gas at normal temperature and pressure. Give at least two glasses of water or milk at once, Do not induce vomiting. Call a physician. EYE CONTACT: Immediately flush eyes thoroughly with water for at least 15 minutes. Hold the eyelids open and away from the eyeballs to ensure that all surfaces are flushed thoroughly. See a physician, preferably an ophthalmologist, immediately. NOTES TO PHYSICIAN: Victims of overexposure should be observed for at least 72 hours for delayed edema. The hazards of this material are mainly due to its severe irritant and corrosive properties on the skin and mucosal surfaces. There is no specific antidote, and treatment should be directed at the control of symptoms and clinical condition. Page 2 of 8 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 5. Fire Fighting Measures FLASH POINT Flammable Gas AUTOIGNITION 1204°F (651°C) (test method) TEMPERATURE FLAMMABLE LIMITS LOWER 15% UPPER 28% IN AIR, % by volume EXTINGUISHING MEDIA: CO2, dry chemical, water spray, or fog. SPECIAL FIRE FIGItTING PROCEDURES: DANGER! Toxic, corrosive, flammable liquefied gas under pressure (see section 3). Evacuate all personnel from danger area. Do not approach area without self-contained breathing apparatus and protective clothing. Immediately cool cylinders with water spray from maximum distance, taking Care not to extinguish flames. Remove sources of ignition if without risk. If flames are accidentally extinguished, explosive reignition may occur. Reduce corrosive vapbrs with water spray or fog~ Stop flow of gas if. without risk, while continuing cOoling water spray~' Remove a!1 containers ifrom..area of ftre iflWith0ut-risk. '~' ¥": .'! Allow fire to burn out. On-site fire brigades'must c?mPly with 0SHA'29 CFR 191-0.1561 :' ' ' .. UNUSUAL FIRE AND EXPLOSION HAZARDS: Forms explosive mixtures with air and oxidizing agents. Heat of fire can build pressure in cylinder and cause it to rupture; no part of cylinder should be subjected to a temperature higher than 125°F (52°C). Ammonia cYlinders are equipped with a pressure relief device. (Exceptions may exist where authorized by DOT--in this case, where the cylinders contain less that 165 pounds of product.) If leaking or spilled product catches fire, do nOt extinguish flames. Flammable and toxic vapors may spread from leak and could explode if reignited by sparks or flames. Explosive atmospheres may linger. Before entering area, especially a confined area, check atmosphere with an appropriate device. Reverse flow into cylinder may cause it to ruptUre. To protect persons from cylinder fragments and toxic fumes 'should a rupture occur, evacuate the area if the fire cannot be brought under immediate control. HAZARDOUS COMBUSTION PRODUCTS: See section 10. I 6. Accidental Release Measures I STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED: DANGER! Toxic, corrosive, flammable liquefied gas under pressure (see section 3). Forms explosive mixtures with air (see section 5). Keep personnel away. Before entering area, especially a confined area, check atmosphere with an appropriate device. Use self-contained breathing apparatus and protective clothing where needed. Remove all sources of ignition if without risk. Reduce vapors with fog or f'me water spray. Shut off flow if without risk. Ventilate area or move cylinder to a well-ventilated area. Contain spills in protected areas; prevent runoff from exposing personnel to liquid and vapors and contaminating the. surrounding environment. WASTE DISPOSAL METHOD: Prevent waste from contaminating the surrounding environment. Keep personnel away. Discard any product, residue, disposable container or liner in an environmentally acceptable manner, in full compliance with federal, state, and local regulations. If necessary, call your local supplier for assistance. I 7. Handling and Storage PRECAUTIONS TO BE TAKEN IN STORAGE: Store and use with adequate ventilation. Firmly secure cylinders upright to keep them from falling or being knocked over. Screw valve protection cap firmly in place by hand. Store only where temperature will not exceed 125°F (52°C). Store full and empty Page 3 of 8 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 cylinders separately. Use a first-in, first-out inventory system to prevent storing full cylinders for long periods. PRECAUTIONS TO BE TAKEN IN HANDLING: Protect cylinders from damage. Use a suitable hand truck to move cylinders; do not drag, roll, slide, or drop. Never attempt to lift a cylinder by its cap; the cap is intended solely to protect the valve. Never insert an object (e.g., wrench, screwdriver, pry bar) into cap openings; doing so may damage the valve and cause a leak. Use an adjustable strap wrench to remove over-tight or rusted caps. Open valve slowly. If valve is hard to open, discontinue use and contact your supplier. For other precautions in using ammonia, anhydrous, see section 16. For additional information on storage and handling, refer to Compressed Gas Association (CGA) pamphlet P-l, "Safe Handling of Compressed Gases in Containers," available from the CGA. Refer to section 16 for the address and phone number along with a list of other available publications. 8. Exposure Controls/Personal Protection VENTILATION/ENGINEERING CONTROLS: ...' '..' ~. LOCAL EXHAUST-Use a local exhaust ventilation System with sUfficient air'floW velocity to - maintain concentration below the TLV in the worker's breathing zone. MECHANICAL (general) Not recommended as a primary ventilation system to control worker's exposure. SPECIAI_MJse only in a closed system. An explosion-proof, corrosion-resistant, forced-draft fum~ hood is preferred. OTI-W~R-None. RESPIRATORY PROTECTION: Use air-supplied respirators for concentrations up to 10 times the applicable permissible exposure limit. For higher concentrations, a full-face, self-contained breathing apparatus operated in the pressure demand mode is required. Respiratory protection must conform to OSHA rules as specified in 29 CFR 1910.134. PROTECTIVE GLOVES: Neoprene. EYE PROTECTION: EYE PROTECTION: Wear safety glasses when handling cylinders; vapor-proof goggles and a face shield during cylinder changeout or wherever contact with product is possible. Wear safety glasses when handling cylinders; vapor-proof goggles where needed. Select per OSHA 29 CFR 1910.133. OTHER PROTECTIVE EQUIPMENT: Metatarsal shoes for cylinder handling. Protective clothing where needed. Select per OSHA 29 CFR 1910.132 and 1910.133. 'Regardless of protective equipment, never touch live electrical parts..... 9, Physical and Chemical Properties MOLECULAR WEIGHT: 17.031 EXPANSION RATIO: Not applicable I SOLUBILITY IN WATER: Appreciable SPECIFIC GRAVITY (air=l): At 32°F (0°C) and I atm: .5970 GAS DENSITY: At 32°F (0°C) and I atm: .0481 Ib/ft3 (.771 kg/m3) PERCENT VOLATILES BY VOLUME: 100 BOLLING POINT (1 atto): -28°F (33.3°C) ~VAPOR PRESSURE: AT 70°F (21.1°C): 114.1 psig (786.7 kPa) EVAPORATION RATE (Butyl Acetate=l ): I High pH: Not applicable Page 4.of 8 Product: Ammonia,,Anhydrous Form No.: P-4562-E Date: October 1997 FREEZING POINT (1 arm): -107.9°F (-77.7°C). APPEARANCE, ODOR, AND STATE: Colorless gas at normal temperature and pressure; pungent, irritating odor. I lO. Stability and Reactivity [ STABILITY: UnstableI [ Stable I X INCOMPATIBILITY (materials to avoid): Gold, silver, mercury, oxidizing agents, halogens, halogenated compounds, acids, copper, copper-zinc alloys (brass), aluminum, chlorates, zinc HAZARDOUS DECOMPOSITION PRODUCTS: The normal products 'of combustion are nitrogen and water. Hydrogen may be formed at temperatures above 1,544°F (840°C). CONDITIONS TO AVOID: None known. · :': -. . ... - - 11. Toxicological Information LCd0 = 7338 ppm, 1 hr, rat. 12. Ecological Information Ammonia, Anhydrous does not contain any Class I or Class II ozone-depleting chemicals. Ammonia, Anhydrous is not listed as a marine pollutant by DOT. 13. Disposal Considerations WASTE DISPOSAL METHOD: Keep waste from contaminating surrounding environment. KeeP personnel away. Do not dispose of unused quantities. Return cylinder to supplier. I 14. Transport Information I DOT/IMO SHIPPING NAME: Ammonia, anhydrous, liquefied IDENTIFICATION NUMBER: LIN 1005 SHIPPING LABEL(s): NONFLAMMABLE GAS (domestic); TOXIC GAS, coRRosIVE (international) HAZARD CLASS: 2.2 (domestic shipment) 2.3 (international shipment) PRODUCT RQ: 100 lbs (4.'54 kg) PLACARD (When required): NONFLAMMABLE:. GAS (domestic); TOXIC GAS~ CORROSIVE. international) SPECIAL SHIPPING INFORMATION: Cylinders should be transported in a seeure position, in a well-ventilated vehicle. Cylinders transported in an enclosed, nonventilated comparitnent of a vehicle can present serious safety hazards. Additional Marking Requirement: Inhalation Hazard (for international shipment) Shipment of compressed gas cylinders that have been filled without the owner's consent is a violation of federal law [49 CFR 173.301(b)]. Page 5 of 8 Product: Ammonia, Anhydrous Form No.: P-4562-E 15. Regulatory Information The following selected regulatory requirements may apply to this product. Date: October 1997 I Not all such requirements are identified. Users of this product are solely responsible for compliance with all applicable federal, state, and local regulations. U.S. FEDERAL REGULATIONS: EPA (Environmental Protection Agency) CERCLA: Comprehensive Environmental Response, Compensation, and Liability Act of 1980 (40 CFR Parts 117 and 302): Reportable Quantity (RQ): 100 lbs (45.4 kg) SARA: Superfund Amendment and Reauthorization Act: SECTIONS 3021304: Require emergency planning based on Threshold Planning Quantity (TPQ) and release reporting based on Reportable Quantities (RQ) of extremely hazardous substances (40 CFR Part 355): Threshold Planning Quantity (TPQ): 500 lbs (226.8 kg) Extremely Hazardous Substances (40 CFR 355): None e SECTIONS 311/312: Require submission &Material Safety Data Sheets (MSDSs) and chemical inventory reporting with identification of EPA hazard categories. The hazard categories for this products are as follows: IMMEDIATE: Yes PRESSURE: Yes DELAYED: Yes REACTIVITY: Yes FIRE: Yes · SECTION 313: Requires submission of annual reports &release of toxic chemicals that appear in 40 CFR Part 372. · Ammonia, Anhydrous requires reporting under Section 313. 40 CFR 68: Risk Management Program for Chemical Accidental Release Prevention: Requires development and implementation of risk management programs at facilities that manufacture, use, store, or otherwise handle regulated substances in quamities that exceed specified thresholds. Ammonia, Anhydrous is listed as a regulated substance in quantities of 10,000 lbs (4536 kg) or greater. TSCA: Toxic Substances Control Act: Ammonia, Anhydrous is listed on the TSCA inventory. ' OSHA (OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION): 29 CFR 1910.119: Process Safety Management of Highly Hazardous Chemicals: Requires facilities to develop a process safety management program based on Threshold Quantities (TQ) of highly hazardous chemicals. Ammonia, Anhydrous is listed in Appendix A as a highly hazardous chemical in quantities of 10,000 pounds (4536 kg) or greater. Page 6 of 8 Product: Ammonia, Anhydrous STATE REGULATIONS: Form No.: P-4562-E Date: October 1997 CALIFORNIA: This product is not listed by California under the Safe Drinking Water Toxic Enforcement Act of 1986 (Proposition 65). PENNSYLVANIA: This product is subject to the Pennsylvania Worker and Community Right-To-Know Act (35 P.S. Sections 7301-7320). 16. Other Information I Be sure to read and understand all labels and instructions supplied with all containers of this product. OTm~R ILnZARDOUS CoNDmoNs o1~ HANDLING, STORAGE, AND USE: Toxic, corrosive, flammable, liquefied gas underpressur~ Do not breathe gas. Do not get vapor or liquid in eyes, on skin, or on clothing. (See section 3.) Have safety showers and eyewash fountains immediately available. Use piping and equipment adequately designed to withstan, d pressures to be encountered. Store and use with adequate ventilation at all times. Prevent reverse flow. Reverse flow into cylinder may cause rupture. Use a check valve or other protective device in any line or piping from the cylinder. May form explosive · mixtures with tdr. Keep away from heat, sparks or open flame. Ground all equipment. Use only spark-proof tools and explosion-proof equipment. Store and use with adequate ventilation at all times. Use only in a closed system. Close valve after each use; keep closed even when empty. Keep away from oxidizing agents and from other flammables. Never work on a pressurized systena If there is a leak, close the cylinder valve. Blow the system down in an environmentally safe manner in compliance with all federal, state, and local laws, then repair the leak. Never ground a compressed gas cylinder or allow it to become part of an electrical circuit. NOTE: Prior to using any plastics, confirm their compatibility with ammonia, anhydrous. MIXTURES: When you mix two or more gases or liquefied gases, you can create additional, unexpected hazards. Obtain and evaluate the safety information for each component before you produce the mixture. Consult an industrial hygienist, or other trained person when you evaluate the end product. Remember, gases and liquids have properties that can cause serious injury or death. HAZARD RATING SYSTEMS: NFPA RATINGS: HEALTH FLAMMABILITY REACTIVITY SPECIAL = 2 (gas) 3 (liquid) = 1 (gas) 1 (liquid) = 0 (gas) 0 (liquid) None HIVIIS RATINGS: HEALTH = 3 FLAMMABILITY = 1 REACTIVITY = 0 STANDARD VALVE CONNECTIONS FOR U.S. AND CANADA: THREADED: PIN-INDEXED YOKE: ULTRA-HIGH-INTEGRITY CONNECTION: CGA-705, CGA-240 Standard, CGA-660 Limited Standard Not applicable CGA-720 Use the proper CGA connections. DO NOT USE ADAPTERS. Additional limited-standard connections may apply. See CGA Pamphlet V-1 listed below. Page 7 of 8 Product: Ammonia, Anhydrous Form No.: P-4562-E Date: October 1997 Ask your supplier about free Praxair safety literature as referenced on the label for this product; you may also obtain copies by calling 1-800-PRAXAIR. Further information about ammonia, anhydrous, can be found in the following pamphlets published by the Compressed Gas Association, Inc. (CGA), 1725 Jefferson Davis Highway, Arlington, VA 22202-4102, Telephone (703) 412-0900. P-1 Safe Handling of Compressed Gases in Containers V-1 Compressed Gas Cylinder Valve Inlet and Outlet Connections Handbook of Compressed Gases, Third Edition Praxair asks users of this product to study this Material Safety Data Sheet (MSDS) and become aware of product hazards and safety information. To promote safe use of this product, a user should (1) notify employees, agents and contractors of the information on this MSDS and of any other known product hazards and safety information, (2) furnish this information to each purchaser of the product, and (3) ask each purchaser to notify its employees and customers of the product hazards and safety information. The opinions expressed herein are those of qualified experts within Praxair, Inc. We believe that the information contained herein is current as of the date of this Matedal Safety Data Sheet. Since the use of this information and the conditions of use of the product are not within the control of Pmxair, Inc., it is the user's obligation to determine the conditions of safe use of the product. I Praxair MSDSs are fumished on sale or delivery by Praxair or the independent distributors and suppliers who package and sell our products. To obtain current Praxair MSDSs for these products, contact your Praxair sales representative or local distributor or supplier. If you havequestions regarding Praxair MSDSs, would like the form number and date of the latest MSD$, or would like the names o-f the Praxair suppliers in your area, phone or write the Praxair Call Center (Phone: 1-800-PRAXAIR; Address: Praxair Call Center, Praxair, Inc., PO Box 44, Tonawanda, NY 14150-7891). Praxair is a trademark of Praxair Technology, Inc. / PRAXAIR Praxair, Inc. 39 Old Ridgebury Road Danbury CT 06810-5113 Printed in USA Page 8 of 8 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, California 92667 Telephone No: Outside Calif: CHEMTREC: 714-998-8800 800-821-7234 800-424-9300 Revision issued: 7/25/91 Supercedes: 7/31/89 First issued: 4/10/89 JJtt~_0~T! R,~ad 1his I~Lc.__~.."..C._~.L di~Dosal el this orodu_ct. .P_c..~_s_~9.e9 1he information e~ngloYe~ and ~Y~JE¢~~ who cgu!d ~ ox~sed to~~_~ufe 1hal they are ~,w~re i~orma~io~ be¢or¢ use or olher exBosure. This MSDS has ~Jen prepared ~ccording lo the OSHA H~ard Communicalion Sl~ndard [29 CFR 1910.1200]. The MSDS information is bs~d on sources ~lieved Jo be reliable. However, since d~t~, sate~y s~andards, and governmenl regulalions ~re subjec: ~o change and lhe condilions of handling Bnd use, or'misuse are ~yond our conlrol, HILL BROTHERS CHEMICAL COMPANY m~kes no warranty, eiJher expressed or impli¢, wi~h respecl lo 1he complelenoss or continuing accuracy ol ~he information comained herein and disclaims all lisbiliW for reliance lhereon. Also. addilional information may be necess~w or helpful tot s~cific conditions and circumstances o~ use. I~ is the user's responslbili~ ~o demrmine 1he suitability o~ this pr~uct 2nd ~o evaluate risks prior lo use, and exercise ~ropria~e precautions lot pro~ecfion of employees and olhers. [SECTION I - PRODUCT IDENTIFICATION ,, I SYNONYMS / COMMON NAMES: PROPYLENE GLYCOL; C3H802 CHEMICAL FAMILY / TYPE: OXYGENATED HYDROCARBON DOT PROPER SHIPPING NAME: N/A DOT HAZARD CLASS / I.D. NO.: N/A REPORTABLE QUANTITY: N/A NFPA RATING: HEALTH. 0; O=lnsignificanl l=Slighl 2=Moderale ¢ ISE~DTION II - HAZARDOUS INGREDIENTS FIRE - 1; REACTIVITY - 0 3=High 4-Exlrbme CAS Exposurb Chemical Na~ne Number % ACGIH TLV PROPYLENE GLYCOL 5 7- 5 5- 6 'ACGIH short term exposure limit (STEL) 100 N/A Limits (TWAs) In Air OSHA PEL STEL' N/A N/A ISECTION III - PHYSICAL AND CHEMICAL PROPERTIES Physical State: LIOUID Appearance/Color/Odor: COLORLESS; ODORLESS Product/Trade JSECTION III- N~rne : PROPLYLENE GLYCOL PHYSICAL AND CHEMICAL PROPERTIES CONTINUED pH: N/A Bolling Point/Range: 369.1° F Vapor Pr~,ssure(mmHg): NEGLIGIBLE Molecular Weight: 76,10 % V°latllos: NEGLIGIBLE How lo delect this compound : N/A Molting Point/Range:' N/A Solubility in Water: 100% Specific Gravity(Water = 1): 1.038 Vapor Density(Air = 1): 2.G JSECTION IV - FIRE AND EXPLOSION J Flash Point: 2t4°F - 225°F Autoignitlon Tomporelure: 790°F Lower Explonlve Limit: .2.6 Upper Explosive Limit: 12.5 Unusual Fire and Explosion Hszards: This m~,terial may burn. bul will not ignite readily, if con',airier is not propgrly cooled, it may explode in the heat o! a 'fire. Vapors are heavier than air ~nd may accumulate in low areas. Extinguishing Media: C~,rbon dioxide. Halon, Polar or Alcohol- lyp~ team, or wntc~r sprny is recommended. Ware[ may be ineffective. ,.~p(~cinl Firailgh!ing Prececures: Wear appropriale protective equipmen~ including res~ir,'3, tory proleclion ss conditions warrant. Slop splli/rele;zse I! i~ can be done withou; risk. Move undamaged containers Item fire area if it can be done wilhoul risk. WAter spray m3y be useful in minimizing or dicpersin9 and cooling equipment exposed Io heat and llama. Avoid spreading burning liquid wilh water used for cooling purposes. JSECTION V - REACTIVITY Stability: Stable Hazardous Polymerization: Will Not Occur Conditions to Avoid: N/A Matorlnl~ to Avoid: N/A Hazardous Decomposition Products: Combustion may yield carbon monoxide an/or carbon dioxide. Do no1 breathe smoke or fumes. Wear appropriate protective equipment. JSECTION VI- HEALTH HAZARDS Routes of Exposure: Summary of Acute Health Hazard=: (Statement) INGESTION: While ~his malarial has a Iow degree of toxicity, ingestion of excessive qu,3nd~ies may cause signs et nervous syslem depression (e.g.. headache, drowsiness, loss et coordination and laligue). N/A Not Applicable PAGE 2 OF 4 Product/Trade PROPLYLENE GLYCOL ISECTION Vt - HEALTH HAZARDS CONTINUED INHALATION: While this material ha,'; a Iow vo!atility. ¢~xpo.-,ure to vapors iS unlikely, however, vapors or mists produced under cenasn condilionr, el uc,,e may cause sign.", of nc~rvous system deprnssion (e.g.. headache, drowsiness, loss el coordination arid latigue). SKIN:- May cause mild skin irraation. Prolonged or repealed cent;icl m;iy cause redness, burning nnd drying and cracking of tho skin. Persons with pre-existing skin disorders may be more suscepHble to the effecls of lhis malonal. EYES: TI-ds material may cause mild eye ~rritalion. or mists may cause slinging, leering and redness. Carclnogenlclty Ll~t~: NO IARC Monograph: NO Summary of Chronic Health Hazards: Effects of Overexposure: N/A Emergency and Fir.~t Aid Procedures: INGESTION: No fhst aid is normally required: medical a~,ention. Direc: con:ac1 w~th tne liquid or exposure id vapors NTP: N O OSHA Regulated: NO however, if s¥,,nllowed, and symptoms develop, seek INHALATION: If respiratory symptoms develop, move victim away lrom source 'cf exposure and into lresh air. h' symploms persist, seek medical anonlion. If victim is no~ breathin9. immed~a~,ely begin arlificial respiration. If brealhing difficulties develop oxygen should be admir, istered by qualified F.,omonnel. Seek immediate medical anention. SKIN: Wash with soap and water. EYES: Flush with plen".y of water. Medical Conditions Generally Aggravated by Exposure: N/A Note to Physlclana: N/A ]SECTION VII - PRECAUTIONS FOR SAFE HANDLING AND USE ,} Stops To Be Taken In Ca.~e Material is Released Or Spilled: Small spills: Soak up with absorbent malarial Large spills: Dike and pump into ~uimble containers for disposal. Handling and Storing Precaution=: Normal precautions common to good manufacturing practice should be Iollowed in handling and slorage. Waste DIspos-~,l Mothod.~: Dispose of In accordance wilh applicable local, county, s'mte and federal regulations. Other Precaution:~: N/A NIA Not Applicable PAGE 3 OF 4 Product/Trade Name : PROPLYLENE GLYCOL ISECTION VIII - CONTROL MEASURES ReRplratory Pro~octlon: R¢~spiralory protection may be rlocus,.;ary Io minimize ezposur~ D~p~nding on tho naluro and concentration ol the airborne mnlori;d, u=;u a ~espiralor or gas mask wilh npproprime cartridges and cannisler= (NIOSH ~pproved) or suppli~ air equipment. Vonlllaiion: General room ventJlal~on i~ s;lli~;f;~clory. Additional VOnlilation or exhaust sysloms may ~ required, wher~ explosive mixluro~ may ~- present. [l~trical sysl~ms ~;afe Ior such Iocalion5 musl ~ Protective Clothing: Rubber gloves are recommended. Eye Protection: Sale~ glasses and or face shield is recommendS. Other Prolocllve Clothing or Equipment: I1 is recommended thai a source el clean waler ~ available in ~h~ work area for flushing eyes and skin. Im~wious clothing should bo worn. WorWHyglonic Practices: All employees who handle Ibis ptoducl should wash their hands bolero eating, smoking, or using loilel facilities. N/A Not Applicable PAGE 4 OF zl FORM MOC-IB -~( MOC NUMBER SECTION 1: INITIATION OF MANAGEMENT OF CHA/~E FORM Section I is to be completed by individual originating the MOC and forward to the Maintenance supervisor. ORIGINATED BY: DATE: NAME OF PROJECT: ..... ~PRIORITY OF REQUEST: R~SON FOR REQUEST: (CHECK 0~) ,. CRITICAL, Affected portion of system should by lock out and tagged to prevent operation until safety issue(s) resolved. ~URGENT. Affected portion of system should be tagged and operated short term with caution until safety issue(s) resolved. .IMPORTANT. Affected portion ofsystem should be tagged and operated with caution until safety issue(s) resolved. ROUT[NE, Affected portion of system should be noted and work to resolve minor safety issue(s) scheduled. ,,~cm~cK Or~) ' { } { } { {~} (_ } { } Incident Investigation Recommendation (Ret'. No. ) Mechanical Integrity Audit Recommendation (Ret'. No. Pre-start Safety Review Recommendation (Ret'. No..) Process Hazard Analysis (Reft No._) Change in Refrigeration ReqUirements Expansion or Renovation of Facility or Systems Other (Explain) Re-location due to Production d~mands. DESCRIPTION OF TECHNICAL BASIS FOR CI~HGE (PURPOSE, ALTERNATIVES! REFERENCE SKETCHES OR DRAWINGS)'... .... FORIVl 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 Lend~. If the requested modification constitutes a change, Sections 2-6 mu~ be completed. Reviewed by:. ~ Date: ASSESS TECHNICAL BASIS OF CHANGE The modification ss described in Section 1 is.classified as (please check appropriate sp ,, Technical Basis, , Assessment I. the change a rcph~cement in kind7 Is the modific~ion a ~ or minor _e~qnge? {__} Replacement in kind { -- } Change is not a replacement in kind { } Modification is a minor change { . } Modification is n major change { ,. } Change is permanent Is the clum~ pcrmnncnt or temporary? {_} Change is temporary Is the ek..~ necesmuy. {~} Yes nmi nn acceptable course of action? {_} No ,.Next ,Action C~nge is not part of MOC procedure. MOC procedure mu~ be followed. Pro~css ~d nnei~sls is not Fill in section on MOC concerning durafl~ of change. Change rd~tld be forwarded for prelimlnnty engineering. Clumgo ~hould not be implemented. ~OKIVI MOC-1D MOC NUMB~-R DURATION OF CHANGE tithe chanl~c 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 ]nitiation Date Expiration.Date , Authorization lniti_a! reg. uest. .,,, Extension #1 Ext_~_~ion #2 Extension//3 Extension//4 Extension//5 UPDATING PROCESS SAFEFY INFORMATION, PROCEDURES, AND DOCUMENTATION Identify the proc~___$ safety informn*ion which needs to be revised as aresult of this chnnge. Reference # Process flow diagrams .Electrical oneqine drawings Stan Ammonia equipment lists Criteria for d~ign and operation ProvenCe maintenance pm~___urcs Accident investigations procedur~ Reference # Piping and instrumcntation diagrnm-~ Fire, water & sewer system drawings Ammonia instrument lists S~ndard operaUns proccdm~ O~rator ~aining ~ FROM2 ½" AND UP W~.I. ~ TO BE BUTT W~-~23S AND A X-RAYPHRFO~ SECTION 3: PRELIMINARY ENGINEERING PRELIMINARY DESIGN REVI~.WED BY' UTILITY TEAM COORDINATOR:. REFRIGERATION GROUP I,EADER:, Date DATE ,Date: / / / FORM MC)C- IE SECTION 4: Date Completed: /.__ __ Safety review checklist reviewed by:. SAFETY REVIEW CHECKLIST / MOC NUMBER # Date: SECTION PROCESS HAZARD ANALYSIS (If analysis is performed) Date Hazard Analysis Completed Does the process b-s_ 7~_ rd analysis address the impact of change on safety and health? (Check one) {_ _ } yes { } 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? (Check one) { __ } Yes {~} no Have all, if any, recommendations from the preliminary engineering safety and health review and the process hazards analysis been addressed? (Check one) { } Yes { } no Authorization should be given to accept this change and proceed with start-up of the modification if and only if the answers to all of the above questions are "Yes". Authorization for change and start-up is given by: PI-IA Team Leader:,,, Date:__ Utility Team Coordinator: Date: __ __ Group Leader: Date: __ __ Plant Manager: / / / / / / Date: / / M0C NO SAFETY REVIEW CHECKLIST qUESTION A RECOMMENDA'~IO~S BY COMMENTS Sy~n? r~ct ~~ often a~l ~oc ~o i SAFETM KEVIEW CHECKLIST QUESTION A KEMAgKS KECOMMENDATIONS BY '" COMMENTS ~. D~ tl~ n~r/~:m~ b,/jxm ny exis~na f~ ~,w b~n provi~l~ im:$~rw tl~ ~ lO.~m~~~ ~~~~.,. ,. , ,, MOC 98-007 SAFETY REVIEW CI-~.IST UESTION A REMARKS RECOMMENDATIONS BY COMMENTS 7 MANAGEMENT OF CHANGE FROM (MOC) LO0 ]NITLa! l~n OF REVIEW ENOINEERINO REVIEW ANALYSIS AIfIHORI~TION DATE COMPLEIIE) ~-!,~T COMI'LEI3~ OF CIL~E3E ITEM #4 13.0 ~ o'i6- C G B ~ BRUNDAGE WHSE ~001 Preliminary determinations "Cleaning in Place". This system program is working properly and does not require modification. A study of the system did yield an improvement to prevent over pressurerizing during hot C.I.P. operator error and or system failure has resulted in a blown pressure relief valve. The suction line attached the surge drum above the em'bo-cooler has a back pressure ,~ _, ,,~.A_ in line at 30 psi. We are going to install'a by-pass back pressure regulator, which we will set mechanically around 75 to 100 psi. This will compensate for an increase of pressure from C.I.P. functions and allow the vapor to flow back to master accumulator without blowing the pressure relief valve. Areas of Vulnerability Equipment specifications and the current condition of the 'equipment is presented on the following pages. The process was inspected and the hazards associated with the process were identified. These hazards are included in the hazard and operability study forms which follow the equipment specifications. 03320012.001 32 1 CR¥ST A L (~EYSER OIL ttlL~ Sedal~ MC~Z755 ~X~NDI~ON: New 19~ VVZI NC OILFILTR~ (X)ND1TION: OIL OIL FILTI~:. 'O3ND1TION: 150HP, ~l~Vo~ Sexial$'~165L160~ 6-5/Ir~.D. X 5'fi' Smlexl forIife Modd~RWB II 76 2ffO. D. X lr4"Horizontal Setia~MC92906 New 1993 . . RWB 1I 76 Screw O~npn~sor Package MOde~ RWB l176 New 1993 I CRYSTAL OEYS__ER CONDITION: CONDITION: CONDITION: (1) 7.SHP, 21.%T, 460-3--60, ODP New 1.995 (1).7....~-IP_, 2.~3T, 460-3-f~ ODP (1~~460~3~0' ODP New 1~6 The.above condense~ were sclcc~ to meet thc condition of thc ln?_ _~a~'igexation Wazchou~ tchatc ptogra~ 2 CRYSTAL GEYSER ~:_l _ Nickcll Go., Inc. 37'ID X 22'g'.'IF='IFHorizontel 'I:EMP IN: 41F 'I~MP OW~. 33F SUC-~ON: 26F 425 Tons ~TRFACE: 3142 sq ft 42878 CONDITION: New 1.993 Nick. ell Co.~ ~ 18~ OD X 18'0' LHorizontal 42879 C]ONI}I'ITON:' 24"OD X 120,' LHorizontal ~ 338~6 03NDmON: New CONDITION: Roy'F-. ~n;lr. Mi'g, 47.4" ID X 192~ L Horizontal · New ].993 ,..~2--7Smm (] 1/4.3") 3 _CRY.ST A L GEY'-~ER SIZE: 012=2 3100 g~llon,.7'7' Dia x 10' H Pmpoly~n¢ glycol 25% wi~ ru~ ~hibitozs. Gould · (2) 10~41~11135 21/2 x 3, 245 GPM (2) 1.5tff411e11635 2 1/2 X 3, 370GPM '4 CRYST A L GEYSER AMMONIA~GI~IATION SYSTEM SYSI'EM DI~211XFIION This sys~m used ammonia to cool prod~ ~ thc Carbo cooler and m~l ~lgt~ ~c~. ~~l~p~ ~u~ ~P~ %c system was ~ for (4) _CVal~ _mtivc condenser. Three wac installed now. and th~ is space for on~ in thc futurc. Thc condensers wcn~ seicct~ to meet Icquittctn _c~ts for ]:'G&Ecncrgy rcbates. They ]Lave a very low hn I-~ vs. capacit~ ratio. Thc t?~_~cr was.dcsi~n~__ to hold 12~ ofth~ total ammonia charge. In provide off coolin~ . c yc. otctu'n iS t to i tonsotca acit , xtis . .d~dgncd to-opaatc at 27oF st~ion tanpeattum and si~Pply t3oF glycol switch on the glyc~ chiller and ~ will sound a pmdann wieh if, the high Icvd amd~ion Rnk. i~ the ma-q~ high levd float on the ' ln88tcr ~'~in~.: ~ oil or nmmogllia get into thc IIIRM~ ~CIllllnlatol thc~isa drainvalvcconne~tr, dtotheglc~o.l, cht~. Tosubcoolthe · ammonia end also boil-off any excess liquid in thc mawr accumulator a pump_r. (~):for thc tower water system and (_4) f~r. tbe ~col_ systan. The ~lycol'pumps a,-c _c _yf. lcd on and off a~ a ~mctton ot' ~ prcssurc. Pmss6rc ~scnd _Si_gnalstoacomputcrwhichin turnm ~ thc pumps, Thc glycol tenk is located on a platform over the glycoI pumps. __CRYSTAL G.EYSER AMMONIA DUMP CON'IROL PANI~-- 'panrl./ntl~cvcatofancanczgcncT, such as a ~m in the machine toom, the ammonia · pressttrecan buildup. To xdi~-vctl~premue, valveswcr~instalkdintbe dump · .paneL If thc pressu~ ~ the redline on tl~ face of the gauge the valve is opened anowing.anunonia vapor to enter the spa~ tanlc (~ i~ow) . . · ' intoacoiunonvcnt _system. The vent line mns to ti~ spal'ge tank. _Any ammonia ~ Wal gO_m the sparg~ tank where a sp_arger bubbks the nmmotiiab~lot, b~wat~'. Thewaterwfilabsod~~~ .' Thc cm~rg.eacy.stop switch will shut down thc powe~ to'nil of th~ equipment in ~he machine room, with the e~Pfion of the ventihtion~usys'stem. · · One swiW. h is lOCated in thc ammonia dump panel and on~ in.the contwl box located j.st ont~ld~t~ ~ room. · .. MACHINB ROOM VENIII~TION ~ This tower scrubs the ammonia out of the air. If this happ~=, the PH of the tower wa/er w/Il incr~a~. A PH alarm will ~ml tl~ cond/fi~n and an ahrm w/il mnnd. and alarms am located in the compul~ panel on the back wan o£the machine room. 6 CRYSTAL GEYSER PANEL~ condenser f~_-_; condcnsc~' pm. ps and gl _y~_l pumps. The compressors havc their own stair panels l~co on tl~ ~ i~hind each comp~sor. All of the ovcr load switches are wired inpamllel. Ifany oveload failsit will soundthc alann and lig~_ on t~pancL You msut open the door and inspect each overload to find thc one tlmt ~ed.. PANEL R-2 1~..el R--2is the ri~ht lmlf of the main power panel for tl~ refrigct~on system. It contains all of the ~ breakers, motor starters and owr loads exhaust fan and the (~P exhaust f3n. This panel 1~ its own pwoer andR-2 ca~ supp~_so R--1 can I~ shut down during an emergency aaa ~ tbc kept of thc machtni exhaust air. 3. F:=pandcr ~- This unit controls thc cooli~ tower system and exhaust fan~ 4. ThcrmOStat ~ Consols thc ~lycol tf~nt)cratu~c and high ~mp alarm. Cbatrols the ~lYcol ~ ~ motor. Cbntrols the machine room ~kaust sys~m. 8. (2) Glycol pump load up/load down swishes, 9. (2) Cl~iiI~ waU~r load up/load down swi~he~ 7 CRYSTAL GEYSER co~fl~rfE~ D~ON The ~_ Mer consi~ of~) modules (thc main _compu~r and two _expand~s), ,N~,.. modulelia~a.rowofli~J~_ at_~etop andthc ix)ttom. xnns, pumps nd.alto provide, vismd alarm indication. mcreisandmputZ(~D'). ArcdLEDlightatX~willindicat~ffthc. · inp_ut_~ qN orOFE :A ~t U~ atY~ ~ indi~te if~ o,,q~ut is ON ~...~_. ~'~s a 7 year .huuy whtc~ ~ ~ p..m .yam... in mmqr~. tnttery, wcalsolo~p acopyofthcprogramonfilemottrofficc. · ALARM MODULE Thc nlm'm moduk is the ~p module in tl~ compute- panel. 'For easy v/sual feed hack thc top mw of alarm _in, uts wcrc ~ to be ON LIT if the ~h_rm d~vise WaS ~ In flfi~ way aH of the lights Whould be IR f3omXl~o Xl6. Any lig~ out in this sequence will show up as a turn on agabr tf~ h~,-pcns thc ahrm condition' will turn on and be ~ by pre~,~ g thc alarm reset Im¢on on ti~ door of RL For example, ff thc~ is ammonh in thc n~chinc momX~ will go out. 'l'nis w~ l-cck in ou~_ ut Yl(t Y10 w~l stay on even ifX~ corm~ itscif and ..g~c~ bacl[ on. To rcsct Y10, XSmust bc fixed and thc light back on, 8 CRYSTAL .GEYSER GLYCI~ ~ ] ~ OPI~A~ON PRIOH.I~ OF OPI~A'IION The chilk~ con~i**t of a larg~ out~- dgll that surrounds several handed sinai/tuigg Anm~ floods th~ ouu~ shvli nntil it i~ about CRYSTAl. GEYSER GLYOOL ~ OPERATION 3. Open tl~ liquid li~ valve at the chiller. 4. NH3 Should fill the chilL-r until the operating float swilch is ~d~L ~.nn~...l, on~ls3 andon~is4. The3 valveisa dial EPR valve. ' 'l~4'tsa duaiEPRwithaSTOPf~atm~, ~ag~(l) onon the thc, nnostat Th~ second stage Wl~Open the stop valve on tl~.4 l~Rand on thc 4" EPR valvc. When the sYstem is under load,, adjust the band expnn~on valve rune. ,by cycle time we mcen thc. lcn~hth of time bctwccn a ~ for mole- ammonia and the time to mt~y thc flopat ann wl~.n it calls again isa fm~tion of tl~ load and can not -~L GEY*~ER AMMONIA ~~TION SUCI'ION TEMPERATURI~: 26 F NOTE: This tempo-ature should not be lower than Thc condensers wcrc selected to proviod~ 88 F condensing at 78F Wet Bulb. ThC fans arc contmlk:d by · ~mputcr and ~c designed to that controls thc condensers nrc loc~tcd in a tcni~c cnclosu~ to 'i'nc oth~ ~w~'-h is to load down th ~ This switch closes on CRYSTAL GEYSER F:mc~&cn~-y Stop'Switch D t~?~I~,IFIION/H, rNCTION m an cmct'gcncy. m lmll ontsi~ie At th~ outlet of. the receiver main liquid line.. Hoar Switch Tower S~np PH Alarm High Glycol Tcmp I-Ii~ Water Tcmp Volta~ Alarm OvedoadAlarm . ', Monitors PH level in sparse ~ank. high and low volU~ at alarm pan¢~ 4th Stage of(31~ol Th~mo~t 4~hS~age o~ :hilled Water · Mec~c Room ~mm~Alann 11 CRYSTAL GEYSER AMMONIA SYSIE~ MA~ORH3~ O3~ START-UP Thc compressor ope. ration is discussed in great ~ in the factory video. All .opexatg. ts should be ~ to view this video befo~ Tn~ compre.~o~ Me d..~gned to turn ON and O~ automatically. ~_h · compressor must I~ ~t on ~ ~ l~zmot~ slid~ valve and Auto vi. . To ovcn. ide the timer it is ncccs,q~ to advancc thc s:~cn and advance thc curccr to thc reset t~cr. Tl~n pu& ~ Fl, then pUsh Start. 85/28/1999 16:88 8053210251 ROBERT PAGE 02 0~/o5/99 16:~4 Business In~l~C4Jon Questionnaire r-! YuffoMqofstton3) ~ No (go to qucstion 2) .~. U'not, whit percennge oFtbe'eMgm(hl bush, ess ~slgms age Y2~ compliant? Am all em(ms~ bl~iness syalmus that hay. e ~oinputer oloments which oouM iflfhmnge chemical loss Y2K c~plbmt? ~ Lqsthan$% 0 Sq4fo10% CI I1%to25% 0 26%1o~0~ 0 SI%to?S% ~ Ovu,?$% ri' 100% .~. Has the i~b,~ ~bli~M ~ Y2K aetkm plan? ~ Yes- O. No At whst projected date will ill btiSbleSS ~ ~ ¥2K compliant? (~ J~msa..~l, 1999 f"l ]ulyl, 1999 ~ laaua~y l, ?,000 D Aft~Jaaum. yl, 2000 $. 14m dM I~sim~ Meatified all 'mart imm'emeats" c~Main{ng cmbcdd~ chip systems? ,1~ Yes ~ ~o 6. lbs the bminesa r~eived mmu'anmf ii'om ~:ematial suf~lim that e~ndaf compulwr elements are Y2K ~mptiant? 0 yes 0 b d~e business emmn~ assistteg, or phnnkg to assist, essential supplic~ wilh Y2K c, ompli~t pr~paratiot4'? r't yes ~ No Has dm imeinf~ douloped a Y2X, ~ r, oudn~fl~y plan` ks enmu~ the pMvaf~on eftccident~l 0 Yet !~ ~o ' FLu the busfmus prepmed a Y2K conthgency plan h any of tiM ~ollowMg utegod0s? 1 i. CouM clf~n4c powor lass cans~ · I'ml, oplosi0n, a' unphnnexi rete. n~ of chemical7 Would elagb, le, pow~, or tel~emummikltJm loss ~t the Isusing~s ftum contacting emergon~, rgspon~s? HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY System: AMMONIA REFRIGERATION SYSTEM Equ pment: COMPRESSORS Drawing References: Guide Deviation Cause of the Consequences Resulting from a Severity Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No Power Power Outage None Low Medium Automatic system shutdown None Ammonia Flow Closed discharge valve Open relief valve Low Low Employee training, high pressure shut down switch, spa~ge system None Oil Oil leak None Low Low Routine maintenance, Iow pressure shut down switch None Less Power Worn motor None Ammon a gas leak Work seals Ammonia flow More Ammonia flow Pressure Temperature Temperature Temperature System overfill Closed discharge valve Low water No water C osed discharge valve Activate high level shutdown switch Open relief valve Compressor shutdown Compressor shutdown Compressor shutdown Low Low Routine maintenance None Low Med um Emp oyee training, ammonia mom monitors, gradual release None Low Low Employee training, qualified fillers None Low Low Employee training, high pressure shutdown switch, sparge system None Low Low Employee training, high pressure shutdown switch, sparge system None Low Low Employee training, high pressure shutdown switch, sparge system None Low Low Emp oyee training, high pressure shutdown switch, sparge system None Other Earth movement Earthquake Fracture ammonia gas lines High Low Schedule 80 pipe with welded fittings None Earth movement Earlhquake Power outage Low Low Automatic system shutdown None None High Low Emp oyee training, schedule 80 pipe Fracture ammonia gas lines Ammon a ne hit by fork iff Operator error April 1999 clients~ccyshazo.wb2 HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY ISystem: .... AMMONIA RI~?-RtGERATION SYSTEM Equipmen!: AMMONIA RECEIVER Drawing References: Guide Deviation Cause ofthe Consequ'e'nces Resulting from a Severity Probability Controls in Place PropOsed Mitigation Word Deviation Deviation from Normal Operatlor~ Measures No Ammonia flow Closed valve to vessel N(~e (compressors down) Low Low None None Ammonia flow Closed valve from vessel High pressure (compressors on) Mad Low Employee training None Ammonia flow Minor leak in system Release to ambient air (liquid ammonia) Low Med Regular maintenance None Ammonia flow System shutdown for maintenance None Low Mad None None Pressure Compressor shutdown (valve closed) None Low Low None None ILess IAmmonia flow I Pressure ITemperature I More IAmmonia flow I Pressure · Temperature Other Earth movement Fire I Receiver PRV failure Location Compressor/condenser malfunction None Compressor/condenser malfunction None Less demand None Peak demand Valve closed Condenser fa ute Earthquake Fire Defective PRV H t by forklift None Open relief valve Open relief valve Broken liquid ammonia line Ammonia line failure Possible line/vessel rupture Broken liquid ammonia line Low Low I None Low Low None Low Low System designed for minimum load Low Low System designed for peak demand Low Low High pressure shutdown switch, employee ffaining, sparge system Low Low High temperature shutdown switch, employee training, High I Low Structural integrity, schedule 80 pipe with welded fittings High Low I Employee ffaining, sprinklers, extinguishers, alarms Low Low Regular maintenance/testing H gh Low Employee training, guardreils, schedule 80 pipe with welded fittings None None None None None None None None None None Apd11999 client~cryshazo.wb2 HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY System: AMMONIA REFRIGERATION SYSTEM Equ pment: LOADING OF AMMONIA RECEIVER Drawing References: Guide D~vlation Cause of the Consequences Resulting from a Severity Probability Controls in Place '"Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No Ammonia flow into tank Inlet valve closed Overpressudze line. hose rapture High Low PRVs, operator present dudng filling, wdffen procedures None Ammonia vapor retums Return line valve closed Overpressudze line, hose rupture High Low PRVs, operator present dudng tilling, wdtten procedures None Ammonia flow from truck Check valve on liquid till None Low Low None None Power Power failure None Low Low None None Less Ammonia flow into tank Ammonia vapor returns IAmm°nia vapor returns Ammonia flow from truck IAmmonia flow into tank Pressure in tank Temperature Inlet valve closed Return line valve closed High pressure in storage tank Check valve on liquid till Overpressudze line. hose rupture Overpressudze line, hose rupture PRV opens None N/A Higher ambient temperature Higher ambient temperature N/A Limit tiOw during tilling ncreaee pressure, flow potential Earthquake Hit by forklift Rupture ammonia lines Rupture ammonia !nes High I Low PRVs, operator present during filling, written procedures None High Low PRVs, operator present dudng filling, written procedures None Low Low Sparge system for PRV None None Low Low None N/A N/A N/A Low Low Training, vapor return line, PRVs Low Low Train ng, written procedures None None None None None None Apdl 1999 clients\cryshazo.wb I HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY System: AMMONIA REFRIGERATION SYSTEM Equ pment: In Line Filters Drawing References: · 'uide Deviation Cause of the Consequences Resulting from a Severity Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No Ammonia flow Filters plugged Bubbling in sight glass Low Low Employee training None Ammonia flow Valve closed Bubbling in sight glass Low Low Employee training None Pressure System shutdown None Low Low None None Power Power failure None Low Low None None ILess Ammonia flow More Ammonia flow Pressure IOther IEarth movement I Fire Location Compressor malfunction Less efficient operations Low Low Routine maintenance and inspections None Peak demand None Low Low None None Plugged filters Bubb ing in sight glass Low Low Emp oyee training, qualified personnel change filters None Earthquake Fire Hit by forklift Broken liquid ammonia line High Low Schedule 80 pipe with welded fittings None Broken liquid ammonia line High Low Fire protection installed None i Broken liquid ammonia line None H gh Low Guard ra April 1999 clients\cr~shazo.wbl HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY Syster~n: AMMONIA REFRIGERATION SYSTEM Equ pment: EVAPORATIVE CONDENSERS Drawing References: Guide Deviation Causeofthe Consequences Resulting froma iSeverity Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No Ammonia flow Valve closed None Low Low None None Flow Compressor shutdown None Low Low None None Power Power outage Relief valve open-ammonia pressure & temp increases Low Low High temperature & pressure shutdown switch, microprocessor control of system, employee training None Water flow Closed water valve, pump failure Relief valve open-ammonia pressure & tamp increases Low Low High temperature shutdown and alarm, employee training, sparge None system Air flow Motor or fan failure Relief valve open-ammonia pressure & tamp increases Low Low High temperature & pressure shutdown, routine maintenance, None sparse system Less Air flow Water flow IMore Pressure IOther FE~rerlh movement Motor or fan failure malfunction Relief valve open-ammonia pressure & temp increases Par~al valve closing or blockage Relief valve open-ammonia pressure & temp increases Relief valve open Valve closed, no air or water Earthquake Broken liquid ammonia line F re Broken liquid ammonia line Low Low High temperature & pressure shutdown, routine maintenance, sparge system Low Low High temperature & pressure shutdown, routine maintenance, sparge system Low Low I Employee training, high pressure shutdown, spa~ge system I High Low IStructurallY approved by registered engineer, schedule 80 pipe H gh Low F re system nsta ed None None None None None Apd11999 clients\cryshazo.wb 1 HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY ISystem: Equipment: Drawing References: AMMONIA 'REFRIGERATION SYSTEM GLYCOL CHILLER Guide Deviation Iw°rd I I No [Ammonia flow I (Power I IPressure, ILess Ammonia flow More [Ammonia flow IPressure Other FE~rer~h movement Cause of theNone Consequences Resulting from a Deviation Deviation from Normal Operation Compressor shutdown/valve closed Power outage None Compressor shutdown/valve closed None Valve partially stuck I None Peak demand None Valve closed/malfunction level switch Open relief valve Fracture lines, ammonia leak Fracture lines, ammonia leak Earthquake Fire S~verity Probability Low Low Employee training Low Low None Low Low Employee training Controls in Place Proposed Mitigation Measures None None None Low Low System designed for peak demand Low Low High level and pressure shutdown switch, employee training, sparge system INone None None INone None Apd11999 clien~\kemhazo.wbl HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY ISystem: AMMONIA REFRIGERATION SYSTEM Equipment :,.. CARBO COOLERS Drawing References: ILess IAmmonia flow I Ammonia flow IMore None Other Earth movement Fire Guide D'eviation cause of the Consequences Resulting fr~m a Severity i Probability Controls in Place Proposed Mitigation Word Deviation Deviation from Normal Operation Measures No Ammoniafl(~v Closed valve None Low ' Low None None Compressor malfunction Loss of cooling Low Low ee training, Low ammonia supply Loss of cooling Low Low Employee training, murine maintenance JNone ] Broken liquid ammonia lines I { Low Employee training, schedule 80 pipe with welded fittings None Earthquake Broken liquid ammonia lines ) High Fire HighI Low None F re system installed Apd11999 clients\cryshazo.wb 1 HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY System! ' AMMONIA REFRIGERATI'0N SYSTEM | Equ, pment: AMMONIA LINES I Drawing References: Guide (~eviation Cause ofthe Consequences Resulting froma Se'verity Probability Controls in Piace Propo'sed Mitigation Word Deviation Deviation from Normal Operation Measures No None None None Low Low None None ILess None None None Low I Low None None isolated line Ruptured line or open pressure relief valve Broken liquid ammonia lines Broken liquid ammonia lines Broken liquid ammonia lines IMore Pressure IOther JEarth movement I Fire Location Earthquake Fire Line hit by forklift High Low I Employee training, schedule 80 pipe with welded fittings None High I Low I Schedule 80 pipe with welded fittings None None High Low [ Fire system installed None H gh Low Emp oyee tm n ng, schedu e 80 p pe and we ded fittings, guard rails Apdl ~999 clients\cryshazo.wb 1 HAZARDS AND OPERABILITY (HAZOP) STUDY FORM COMPANY: CRYSTAL GEYSER WATER COMPANY ISystern! Equipment: AC/IMONIA REFRIGERATION SYSTEM EMERGENCY REFRIGERANT CONTROL BOX WITH SPARGE SYSTEM AND DIFFUSION TANK Drawing References: ~uide Deviation Causeofthe Consequences Resulting from a Severity Probability Controls in Place Proposed Mitigation" Word Deviation Deviation from Normal Operation Measures No Water L~aking diffusion tank/PRV open Release of ammonia vapors High Low Closed top'tank, regular level Che~ks, employee training None ILess Water IMore {Water Other Open dump valve Leaking diffusion tank/PRY open Release of ammonia vapors None None Inadvertant opening/tampering of valve Release ammonia to diffusion tank , ' None i None None None Apd11999 clients~cryshazo.wbl 111.2 Notifications a. Internal Notifications Facility personnel will report an accidental release or any other emergency condition to their supervisor. Supervisors will notify office personnel who will use the paging system to notify all employees to evacuate the facility. If emergency situation occurs after work hours, supervisor will use paging system to notify employees of evacuation. 03320012.001 38 be Local Agency Notifications Pursuant to the Emergency Planning and Community Right-to-Know Act (EPCRA) and Section 112(r) of the Clean Air Act, releases of listed regulated chemicals must be reported. The Plant Manager is responsible for determining the significance and reportability of a release. The Plant Manager is also responsible for reporting a release. If .an ammonia release exceeds 100 cubic feet during a 24-hour period, the event is reportable and the following agencies must be notified immediately. 911 City of Bakersfield Fire Department Hazardous Materials Division Telephone: (805) 326-3979 03320012.001 39 c. Regional and State Agency Notifications In addition to local notifications, the following regional and state agency notifications will be made: California Office of Emergency Services Telephone: (800) 852-7550 National Response Center Telephone: (800) 424-8802 In addition to the verbal notification, a written follow-up report is required to be completed as soon as practicable, but no later than 30 days following a release. The completed report is to be sent to the Office of Emergency Services. A form, approved by the Office of Emergency Services, is included on the following page. This form, when filled out, reports follow-up information required by Section 25507 of Chapter 6.95, Article 1 of the H&SC and Title 42 United States Code, Section 11004. Instructions for filling out and mailing the form when complete are also provided. 03320012.001 40 EMERGENCY RELEASE FOLLOW-UP NOTICE REPORTING FORM A B Ii]BUSINESS NAME DATE OES CONTROL II I D [~ P~SIC~ $TA~ ~~D ~ P~SIC~ STA~ ~ED QU~ ~LE~ED ::::::::i::ii:::: ACTIONS TAKEN I]KNOWN OR ANTICIPATED HEALTH EFFECTS (Us~ the comments section for additional information) [] ACUTE OR IMMEDIATE (explain) [] CHRONIC OR DELAYED (explain) [] ~OT KNOWN (ex~lain) ADVICE REGARDING MEDICAL ATTENTION NECESSARY FOR EXPOSED INDIVIDUALS COMMENTS INDICATE SECTION (AG AND ITEM WITH COMMENTS OR ADDITIONAL INFORMATION H CERTIFICATION: I hereby certify under penalty of law that I have personally easement and I am familiar with t he information submitted and believe the submit~d/nformation/s true, accurate, and complete. REPORTING FACILITY REPRESENTATIVE (print or typ~). SIGNATURE OF REPORTING FACILITY REPRESENTATIVE DATE EMERGENCY RELEASE FOLLOW-UP NOTICE REPORTING FORM INSTRUCTIONS GENERAL INFORMATION: Chapter 6.95 of Division 20 of the California Health and Safety Code requires that written emergency release follow-up notices prepared pursuant to 42 U.S.C. § 11004, be submitted using this reporting form. Non-permitted releases of reportable quantities of Extremely Hazardous Substances (listed in 40 CFR 355, appendix A) or of chemicals that require release reporting under section 103(a) of the Comprehensive Environmental Response, Compensation, and Liability Act of 1980 [42 U.S.C. § 9603(a)] must be reported on the form, as soon as practicable, but no later than 30 days, following a release. The written follow-up report is required in addition to the verbal notification. BASIC INSTRUCTIONS: · The form, when filled out, reports follow-up information required by 42 U.S.C. § 11004. Ensure that all information requested by the form is provided as completely as possible. · If the incident involves reportable releases of more than one chemical, prepare one report form for each chemical release. · If the incident involves a series of separate releases of chemical(s) at different times, the releases should be reported on separate reporting forms. SPECIFIC INSTRUCTIONS: Block A: Block B: Block C: Block D: Block E: Block F: Block G: Block H: Block I: Enter the name of the business and the name and phone number of a contact person who can provide detailed facility information concerning the release. Enter the date of the incident and the time that verbal notification was made to OES. The OES control number is provided to the caller by OES at the time verbal notification is made. Enter this control number in the space provided. Provide information pertaining to the location where the release occurred. Include the street address, the city or community, the county and the zip code. Provide information concerning the specific chemical that was released. Include the chemical or trade name and the Chemical Abstract Service (CAS) number. Check all categories that apply. Provide best available information on quantity, time and duration of the release. Indicate all actions taken to respond to and contain the release as specified in 42 U.S.C. § 11004(c). Check the categories that apply to the health effects that occurred or could result from the release. Provide an explanation or description of the effects in the space provided. Use Block H for additional comments/information if necessary to meet requirements specified in 42 U.S.C. § 11004(c). Include information on the type of medical attention required for exposure to the chemical released. Indicate when and how this information was made available to individuals exposed and to medical personnel, if appropriate for the incident, as specified in 42 U.S.C. § 11004(c). List any additional pertinent information. Print or type the name of the facility representative submitting the report. Include the official signature and the date that the form was prepared. MAIL THE COMPLETED REPORT TO: Chemical Emergency Planning and Response Commission (CEPRC) Local Emergency Planning Committee (LEPC) Attn: Section 304 Reports 2800 Meadowview Road Sacramento, CA 95832 111.3 Environmental Management System a. General Or.qanizational Chad Shown on the following page is an organizational chart for Crystal Geyser Water Company. At the Crystal Geyser Bakersfield location, the Safety Coordinator, Robert Hofferd, will be the Qualified Individual and Safety Coordinator. The Safety Coordinator is responsible for all safety training of employees. The Emergency Contact will be the Quality Assurance Supervisor, Gerhard Gaugel. Any emergency incidents that occur at the facility will be the Emergency Contact's responsibility. Emergency Response Procedures General emergency response procedures are: · Assess the situation. · Isolate and deny entry to the affected area, and evacuate or shelter-in-place. · Provide emergency medical assistance, if necessary. · Notify response agencies and facility response personnel, as appropriate. · Control the release, if possible. · Actively mitigate the release, if properly trained and equipped. · Provide assistance to public agency responders, as necessary. · Terminate the response with proper clean-up and disposal. · Follow-up reporting, evaluation, and critique, as required. 03320012.001 41 Crystal Geyser Water Company May 14, 1999 Peter Gordon oduction Superviso.,~ JuanPinon ~ IJoseMendozal Lead Sanitation V~p,~laichard WeklychX ManufaCturing/I nt Manager IGerhard Gaugel1 QC Supervisor iLeoSoong ~President Office Manager I Armando Rayo Lead General Evacuation Employees are verbally notified of emergencies by the Incident Commander or designee. All employees are to leave the facility immediately through the parking lot at East California and Lakeview. Emergency evacuation routes and designated meeting places are shown on the following page. These routes have been planned to bypass ammonia systems that may be leaking. Emergency responders will be notified through 911. Fire The sprinkler system will engage when it has detected a fire. All employees are to leave immediately through the nearest exit and regroup at the parking lot at East California and Lakeview. Emergency responders will be notified through 911. Earthquake Employees should remain in safe, stable locations (in doorways, under sturdy desks) until earth movement has ceased. After the earthquake, all employees are to leave the building through the nearest exit as soon as it is safe and regroup at the parking lot at East California and Lakeview, far enough from the building to avoid falling masonry. 03320012.001 42 0332.0012 4/99 1233 EAST CALIFORNIA MIX c ROOM D.L F~" vL,.~E.s1 _* . 1' B 't I OFFICE I I HALLWAY I BOTTLE FILLER ROOM I I I I I I PACKAGING I T' AREA I I I I I PROCESSING I AND I STORAGE AREA 1233 EAST CALIFORNIA WAREHOUSE' AREA SHOP AND I I ALLEY 1 OFFICE NCH ROOM RESTROOM I I I I I I I I I I ! I ], ,I WZI INC. BAKERSFIELD, CALIFORNIA CRYSTAL GEYSER Bakersfield, CA BOTTLING FACILITY EVACUATION POINTS Significant Leak from the Ammonia System Notify the Bakersfield City Fire Department. Employees will be notified through the paging system. All nonessential employees will leave the building through the nearest exit and regroup at the parking lot at East California and Lakeview. Supervisors will ensure employees in their area are evacuated. Mechanics will isolate the ammonia leak if possible. 03320012.001 43 b. Command Accidental Releases During an accidental release, the Quality Assurance Supervisor, Gerhard Gaugel, will act as the facility Incident Manager. As the Incident Manager, he will decide if a release is of a reportable quantity and if necessary will report the incident to the appropriate agencies as stated in Section 111.2. The Safety Coordinator, Robert Hofferd, will act as the Qualified Individual. As the Qualified Individual, the Safety Coordinator will maintain up-do-date safety information on regulated substances, processes and equipment. This safety information will include: Material Safety Data Sheets (MSDS) that meet Section 5189 of Title 8 of the California Code of Regulations (included on the following pages); Maximum intended inventory of equipment in which the regulated substances are stored or processed; Safe upper and lower temperatures, pressures, flows and compositions; and Equipment specifications. MSDS forms for ammonia meet safety information requirements and are attached. Management of Change Any process change will initiate the Management of Change process. This will include the reason for the process change, the priority of the change, technical aspects of proposed equipment, a proposed schedule of the modification and a process hazard analysis if necessary. On the following pages are the Management of Change forms 03320012.001 44 needed to perform this process. A log of all process changes requiring Management of Change also follows. 03320012.001 45 OPERATING INSTRUCTIONS BAKERSFIELD, FACILITY NORMAL OPERATING INSTRUCTIONS in this facility the operator is the maintenance man as well as the operator. The refrigeration machinery runs automatically. The normal operating procedure is to check and log process pressures, temperatures liquid levels, lubrication, and pertinent changes and data on all the refrigeration'machinery about two times in each eight hour working day. He will check the items listed in this RMPP Book under Management Programs, Section 3, Operators responsibilities and Section 5, Engineering Logs. He Is tO analyze the machinery and logs. When they differ from design or established limits, he is to determine the cause and make corrections immediately. He will also make the routine checks and complete the required maintenance spelled out in Section 6, PreventaUve Maintenance Procedures under Management Programs. He is to log all inspections, findings, and malntenance performed either in the daily engine room log, or machinery log book as he chooses. __SHUTDOWN.OPERATING INSTRUCTIONS Under normal conditions, it is v~ery safe to shut down the refrigeration machinery by pushing the stop button ~ the ~ beard m the engineers office or fire__m_e_n's eme en._e._e._e._e._e~~x. When it is pushed, all compressors and ammonia pumps stop, and the electric Iiquld ammonia feed king valve is de-energized and closes. All machinery' remains in this state until the,. In this stopped condition, the evaporator solana)ids and fans remain energized and operating. Ammonia cannot feed the evaporators because the king valve Is closed. . fha hinh ,*l;,~nhew-,.-. h,~e,-I ~,,-.-,~,- .... The ammonia compressors and pumps have check .valves In line that don't allow the process fluid 'to flow backwards in the system. The refrigeration process pressures usually equal out to ambient temperature pressures. When you are to be off for an extended period of time a controlled shutdown is best. I~ i~ a_.~a follows: 1. Make a printout 'of all process set points and limit settings. The mi~:roprocessors have a battery backup that lasts from two to four hours. If you are planning to shut off the power for an extended period of time, you could loose these settings..it makes it a Iot easier if you have this record when you start. ~,?, ~,.. k ~.~ 'J . . 2. Shut off manual hot gas king valve 4~m the ~f, and the liquid ammonia krug valve up stream of the electric solenoid king valve in the engine room. Allow time for some ammonia in the evaporators, LP and HP pump receivers, and feed piping to boll off and return to the receiver. Liquid ammonia in the pumped liquid recirculating circuit to the evaporators tends to flow back and fill the Iow pressure receiver after compressors and pump are stopped. This makes start-up difficult if liquid height in the vessel is near the high level float cut out. If possible, let the system run until you see the ammonia in the LP and HP pump receivers drop a few inches below the operating level, Operating Instructions- Page 1 and you see frost forming on the liquid ammonia feed piping..s=~-.,,.-,.,~,'---~---=.~,*.,~-..~__: ..... . ._ ,..-.... ~..~,,, indP~.'~t_~_~ __red,_~_~c__. ....... ,~ ,,n~ ,....~.~ ,,'n,'n_,,~!~ q,,entity ~,~ ~"' ,'qpes. You can let the system run as long as the ammonia pump does not cavitate. 3. Stop the liquid ammonia feed pump. (Remember to taq-out and write down everything you shut off and olose.) 4. Stop ali evapo~'ator fens at each individual electrical cut off. 5. Stop all compressors using the stop button on each compressor microprocessor panel. Stop the booster compressors first, and the second stage compressors last. More than likely, they will be cycling on and off at this point because of the reduced refrigeration load. Make sure yot~ push the stop button, and the monitor reads "stop". 6 Shut off condenser fans, end pumps. Allowing a little time for the condensers to cool and the head pressure to comes down 7. if you are making a complete electrical shutdown: a. Make sure all office computers off. b. Make sure all personnel are out of unlighted areas. c. Shut off each electcical panel individually with circuit breaker on the main electrical panel in the engine room. d. Shut off main power circuit breaker on main electrical panel in the engine room by turning trip lever. START-UP Op,.E, RATING INSTRUCT. IONS 1. Make sure all electrical panel cimuit breakers, and compressor circuit breakers are in the off position so you will not have a large power surge when you close the main power switch. 2. Close the main power switch with hand lever. It is spring loaded and bangs in rather hard. 3. Switch on all electrical panels at their individual circuit breakers on the main electrical panel in the.engif~ room. ~~ ~ 4. Switch on compressor end any remaining circuit breakers. 5. Check compressor microprocessors. Make sure they are in the stop position. Check alt microprocessors to see that they are up and running, and have retained their proper set points. NOTE: Screw. compressors have heaters in the oil sump, and the microprocessors. will not let the compressors start until the oil reaches the oil separator temperature lower ilmit set potnL If the power has been off an extended time, Ihis may take as long as four to six hours. 6. Start condenser fans and pumps. When pumps are stopped, water that has been entrained in the air flow, overflows down the drain. Allow time for water sump to fill before going to the next step. 7. Start high side compressor in the unloaded position. Gradually load the compressor manually, to bring the high side suction pressure down slowly to around 25 to 30 psig. This slow draw-down keeps ammonia, out in the system, from boiling too violently. If draw-down is too fast, liquid ammonia in the HP pump receiver could expand to the high float cutoff. When it reaches its' operating pressure, switch the load control to remote or automatic. Operating Instructions - Page 2 a~vd ~a~oa [s~e~c~s~e es:sT ~ee~/~e/~[ 8. Open slowly the liquid ammonia hand king valve so as no.t to I~ammer the piping with -~lugs of liquid ammonia. Opening this valve, sends liquid ammonia to the HP pump moetver, end the USD^ mom evaporator. 9. Start the HP liquid ammonia fcc-."J pump. This feeds liquid ammonia to the truck and mil dock evaporators and to penthouse evaporators that are valved to the 30 PSIG cooler system. 10. Start the low side compressor in the manually unloaded position. Gradually load the compressor manually, to bang the Iow side suction pressure down slowly to around 2 psig. Watch to make sure that ammonia in the low pressure pump receiver does not reach the high float a's you lower the pressure, and in turn lower its' boiling point. Also keep an eye on the high side compressor, that you don't load it too fast, because the discharge gas from the Iow side compressor is going into the suction of the high side compressor. When the Iow side suction pressure reaches its' operating pressure, switch the load control to remote or automatic. 11. Open slowly the liquid ammonia hand valve feeding the LP pump receiver. Opening this valve, sends liquid ammonia to Ihs LP pump receiver. 12. Start the LP liquid ammonia feed pump. This feeds liquid ammonia to the penthouse evaporators valved to 2 PSIG freezer system. 13. Start the fans on all the room evaporators. Turn them on slowly, one at a time, so as not to add too much refflgeration load to the system ali at once. t4. Open the hot gas defrost king valve. Again, open it slowly. 15. Notify the monitoring alarm company that the system is back on the line. EMERGENCY SHUTDOWN OPERATING INSTRUCT[O...N_.S. NOTE,. First scenarip: By emergency shutdown, we are assuming, the reason to do so would be an ammonia leak somewhere out in the warehouse. Our objective. would be two fold. First, to stop ammonia flowing from the engine room, out into the warehouse. Second, if possible, draw ammonia back into the engine room fi.om the. room evaporators and refrigeration piping. 1. If you can locate and get to the leak, shut the liquid feed and hot gas valves closest to the leak, upstream of the leak, NOTE: If it is a large leak, and you can't get close to it; 2. Close the hand king valve in the engine room. :3. Shu~ off the liquid ammonia feed pumps. 4. Close all four ammonia feed pump discharge valves. NOTE: if you do not close the standby pump discharge, ammonia could continue to feed through the check valve. 5. Close the main hand hot gas valve, NOTE: The HP and LP Pump Receivers have valves on the suction piping coming from the rooms above the roof. Shut them after you pump the system down as much as possible. If you stop the compressors before closing these valves, pressure will build in these vessels, and ammonia will flow backwards into the room piping, toward the leak. It is best to keep the compressors running to draw as much liquid ammonia back Into the system. Lower the suction pressure to around 1 or 2 psig. That should greatly slow the leak. Put on enough compressors to hold the suction at that pressure. Station someone Operating instructions - Page 3 in the engine mom to watch and control this. Do not allow the suction pressure to go into a vacuum. If it does, air could be drawn in through the leak. That air would eventually get Into the condensers and cause high discharge pressure. The compressors would then shut down on high discharge pressure, causing the suction pressures to increase just when you were depending on them to hold the suction down. 6. Locate and isolate the leak NOTE: Second S. cenar, l.o,: We would assume an emergency shut down to be needed because of a leak in the high side discharge piping. That could be from the high side compressors discharge piping, through the oil separators, through the condenser on the roof, through the high pressure receiver, up to the king valve. 1. Push the refrigeration emergency stop button located in the engineers' office or in the fireman's emergency box outside the building on the east wall. NOTE: The compressors are the driving force to increase the pressure in the system described above. Pushing the stop button stops all compressors, closes the liquid ammonia king valve from the receiver, and stops the liquid ammonia feed pumps. Stopping the compressors lowers the discharge pressure. YOU may want to rum condenser fans on manual to lower the head pressure as much as possible. 2. Locate and Isolate the leak. OIL REMO.VA, L -,LP..,~d:HP.. PUMP RECEIVERS NOTE: Under normal operating conditions, the valve on the bottom of the LP pump receiver oil leg to the oil pot, and the oil pot vent valve from the top of the oil pot to the top of the LP pump receiver, should be open. Under some conditions, if the oil pot vent valve is wide open, you will get a circulating effect of the ammonia and oil. It is best to keep this vent valve pinched down, to keep the .movement in the oil pot still and allow the oil to seUle out. To remove oil from the Iow pressure pump receiver oil pot, to the central oil removal pot: 1. Close the valve from the LP or HP pump receiver to the oil pot. NOTE: Allow several hours, or wait over night for ammonia to separate out of the oil through the vent line to the LP pump receiver. 2. Close the vent line valve. 'NOTE: Pressure in the oil pot should build to 'around 60 psig pressure within several hours. You will need pressurize the oil pot in order to have a difference in pressure for oil to move. Then, open the oil drain valve on the oil removal pot, and drain the oil into a bucket for reclamation or disposal. Close the drain valve when all oil is removed, and ammonia vapor comes from drain valve DO NOT LEAVE THE ENGI~..E. OOM UNTIL THE OIL DRAIN VALVE IS CLOSED NOTE: Make sure you have the 10 or 15 pstg pressure on the oil removal pot before you open the oil drain valve, and while your are draining oil. If the oil removal pot were in a vacuum, you would draw air into the system. OIL~ REMOVAL ;. HIGH PRESSURE COOLERS ';. RECEI_¥ER~AND THERMO$_Y_PHON __OIL Operating InstnJctions - Page 4 3~'d .L~I3~O~ [9~01~08 69 :q~ ~00~/~0/~[ 1. Make sure suction valve from central oil removal vessel is open to the LP Pump receiver. 2. Set suction' back pressure valve on oil removal pot to 10 or 15 psig. Make sure it is not hand Jacked open with boffom stem. With this valve in the automatic position, the bottom stem is turned in clockwise all the way with just about 1~4" of stem showing below valve body. 3. Close Inlet valve from oll removal line on top of central oil removal vessel. 4. Make sure ali oil removal valves are closed on each thermosyphon oil cooler and HP receiver. 5. Open the valve in the oil removal line from the vessel you want to drain oil from. 6. Crack open the valve of the oil removal line on top of the oil removal vessel, no more than 1/4 or 1/2 turn. NOTE: If you open this to much, liquid ammonia will blow right through the oil in the bottom of the receiver or thermosyphon vessel. Now and then, oil clogs this valve opening, so you will need to open it a turn or two just long enough to blow. out oil clog, then close it back down to a 1/'4 or 1/2 turn. 7. When all oil is removed from the vessel, close the hand valve on the bottom of the vessel you were draining from.. 8. When line is pumped out, close the hand valve on top of the oil out pot. 9. To remove oil from central oil removal vessel, follow steps laid out in the section called OIL REMOVAL - LP AND HP PUMP RECEIVER. EMER,GENC. y AIR PURGING In an emergency situation, if you had a large volume of air in the condensers, causing the discharge pressure to rise above safe operating limits, you would purge air as follows: 1. Stop all the compressors, leave the condenser water pumps, and fans on. This will cool and condense all the liquid ammonia, and separate the ammonia vapor and air. With the loss of velocity in the piping, due to stopping the compressors, the air will separate and rise to the top of the condensem. 2. After allowing time for cooling, you can {hen purge the air to the atmosphere, or into a container of water, from the purge valves located on top of the condenser coil headers. ADDING._O_IL TO COMP _R__ESSORS - OPERATING INSTRUCTIQN,~ SCREW COMPRESSORS NOTE: A level of oil is maintained in the discharge oil separator that operates at compressor discharge pressure. It can be dangerous to pump oil in the fill valve of this vessel against compressor discharge pressure. I believe it is best to stop the Operating Instructions - Page 5 39~'d compressor and pump the discharge oil separator down, then pump oil in. Because of the large volume of gas that is contained in these vessels, it would be best to draw the gas back into the system rather than drain it into a container of water. To accomplish this: 1. Stop compressor 2. Close discharge valve. 3. On second stage compressors close suction valve. 4. On second stage compressors open, pump out line. 5. On Iow stage compressors, open 3/8", bypass line around suction check valve. 6. After oil separator vessel pressure drops to suction pressure, around 2 psig, close the suction valve. 7. Close the bypass valve. 8. Pump in oil as needed. Note: If you are going to replace the oil, it is easier and takes less time if you drain the oil before you reduce the vessel pressure. AMMONIA OFF-LOADING PROCEDURES Note: Note: Following our off-loading procedures are copies of Off-Loading Procedures for driver/operators of Ammonia delivery trucks t~om the two suppliers we usually use. Coordinate our procedures with the driver/operators procedures. For emergency purposes have at hand and ready to use: Gloves, goggles, faceshield, a full face gas mask with industrial size ammonia canister and a self contained breathing apparatus. 1. Locate ammonia truck near ammonia charging station east of the engine room. 2. Make sure wheels are chocked. 3. Put barrier at the valve loading station with a sign reading "Danger"! "Stand clear, ammonia loading in progress". 4. Driver will connect hose to the high-pressure receiver at the bottom of the oil drain trap. 5. Note liquid level of receiver in the engine room. 6. After hose is connected and the bleeder valves are closed, make sure fill line valve is open on the receiver in the engine room. 7. Make sure receiver line pump out valve is closed. 8. Slowly open fill line valve when driver/operator is ready. Note: Note: Coordinate with steps 2 through 5 of Hill Brothers procedures or steps 11 through 18 of LaRoche procedures. Read pressures at cargo tank and engine room receiver. If the differential pressure between the truck tank pressure and engine room receiver exceeds the limit of the pumping system; the engine room operator must reduce the receiver tank pressure to a suitable level. Maximum differential pressure should not exceed 125 PSIG. Operating Instructions - Page 6 g. Keep constant check on ammonia receiver level. DO NOT OVER FILL sYSTEM. It may be necessary to stop loading procedures for a few minutes to see where system level stands. 10. VVhen the drive~'loperator indicates the desired quantity of ammonia has been received, close fill line valve outside the engine room. 11. Close fill line valve at the receiver. 12. Open pump out valve to the fill line to remove liquid ammonia. (you could pump out truck hose if driver/operator so desired). 13. Close pump out valve. 11. Collect and return ell protective equipment, signs, and barriers used in off-loading procedures LO Operating Instructions- Page 7 39~'d c. Operations Daily Operatin,q Procedures Daily Operating Duties 2. 3. 4. 5. 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. Check compressor oil pressure twice per day. Investigate abnormal conditions. 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. Detection and Monitoring Systems Odor The nature of ammonia is such that the presence of ammonia vapors would be detected by smell at very Iow concentrations. 03320012.001 46 Sight Potential ammonia release points can be detected by visual inspection of equipment to identify discolorations, rust, holes or worn spots. Ammonia Gas Sensors Ammonia gas leaks are detected by Manning Systems Model 4485 Ammonia Gas Cell/Transmitters located in the machine room, at the carbo cooler and in the ammonia vent lines. These sensor units consist of an electrochemical sensor and an electronic transmitter and have a detection range of 0-100 ppm ammonia. Alarm Indicators The alarm module is the top of three computer modules located in 'the computer control panel. The top row of lights are inputs to the computer. The bottom row of lights represent the outputs. The computer inputs must be "ON" (LED light ON). If the light goes out, it signals an alarm condition. Operating Thermostat Operating thermostats are used in the glycol system and the tower water system. The operating thermostat has four stages. Three stages are used to control the temperature. Should the glycol or tower water temperature continue to increase beyond the third stage of cooling by five degrees, the high temperature alarm signal will be sent to the computer alarm module signaling a general refrigeration alarm. 03320012.001 47 Control Systems System Restart If there is a power failure, the system will not restart automatically. A trained operator must restart the system. When the power is restarted, the alarm system will check all of the alarm points. If there are any failures, the alarm horn and light will activate. The operator can silence the alarm horn, but he cannot reset the alarm system until the cause of the alarm is found and corrected. Once all of the alarms are cleared, the compressor can be placed into operation. Manual Isolation Valves In the case of an earthquake, there is a possibility that ammonia lines will break. Power will likely be out which will close all automatic valves. Each vessel that contains ammonia has manual isolation valves that can be turned off. Machine Room Exhaust System The machine room has a large two speed fan located on the roof. The fan is used to cool the machine room in the summer and to vent the ammonia out of the machine room in the event of a leak. The fan has a set of automatic dampers. If the fan is being used for ammonia removal, the dampers direct the exhaust air into the cooling tower. This tower acts as a scrubber, removing the ammonia from the air. This will happen under the following conditions: There are two machine room emergency vent switches on the system. One in the dump panel and one on the wall outside the machine room. Either switch will start the fan and the damper, and sound an alarm. 03320012.001 48 If the machine room ammonia sensors detect a leak, it will start the vent system and sound the alarm. Machine Room Vent System The machine room vent system will still function if the emergency stop switch has been used. The control panel is built in two sections. Each section has its own power supply. Emergency Stop Switch There are two emergency stop switches. One is located in the ammonia dump panel and one is on the wall outside the machine room. The switches are wired in series. If there is an accident, fire, earthquake, or ammonia spill the refrigeration system can be turned off from either remote location. This will sound an alarm at the main computer panel. King Solenoid The system has two King solenoid valves located on the main ammonia line as it leaves the receiver to supply the system. One valve is manual, the other is electric. The electric valve must be energized to open. The valve will close during a power failure, if the emergency stop switch is turned off, or if the King solenoid valve switch is turned off at the control panel. Master High Level Switch The master high level switch is located on the master accumulator. If liquid ammonia floods back to the master accumulator, the master high level switch will shut down the complete refrigeration system. In order to restart the system, an operator must be present to reset the alarm system and place the refrigeration system back in operation. 03320012.001 49 Chiller High Level Switch This switch is located on the glycol chiller and it will give an alarm signal indicating that the ammonia level is too high. This will not, however, shut the system down. It will let the operator know that an alarm condition is present. Since there is an accumulator, it is not necessary to shut the system down at this time. Cooler Tower pH Alarm The cooling tower will be used as an ammonia scrubber for the machine room ventilation system. In the event of an emergency, ammonia will be scrubbed out of the air by the cooling tower. This will in turn change the pH of the water in the cooling tower sump. A pH alarm will detect any changes in the sump water and send a signal to the computer alarm module, sounding a general computer alarm. At the same time, it will open a dump solenoid allowing water to drain from the cooling tower to the sparge tank and fresh water will be automatically added to the cooling tower. This will continue until the pH of the tower water is back within our predescribed limits. Sparge Tank pH Alarm In the event a relief valve is discharging ammonia into the sparge tank and there is a failure of the ammonia vent alarm and the pH changes substantially in the sparge tank, a signal is sent from the remote pH alarm module located at the tank to the computer alarm module sounding a general alarm. 03320012.001 50 Incident Action Plan The Quality Assurance Supervisor, Gerhard Gaugel, is the Emergency Contact and will act as the Incident Commander. The Incident Commander will implement the incident action plan in case of emergency. The incident action plan will be implemented in the case of an emergency plant evacuation. The following steps will be taken in emergency situations: o o An announcement will be made over the paging system notifying employees of facility evacuation. All employees will report to the staging area on the east end of the property. Employees certified on self-contained breathing apparatus will bring the SCBA equipment to the staging area. Attendance will be taken by the Incident Commander to account for employees. The Incident Commander or designee will make an overall assessment of the incident. Emergency response personnel such as the fire department, hazardous materials team, medical units, and Office of Environmental Services will be notified immediately by the Safety Coordinator or designee. Incidents occurring during the night shift will be evaluated by lead persons and general staff members. If necessary, emergency response personnel will be notified followed by the Safety Coordinator and the Incident Commander. The Incident Commander will initiate a search for employees not accounted for in the attendance count. Emergency response personnel will be assisted by SCBA-trained Crystal Geyser personnel if needed. 03320012.001 51 10. 11. A map of the plant will be maintained in SCBA storage units to assist emergency response personnel. The Safety Coordinator will continue to monitor personnel safety. Utility Shut-Offs In emergency situations, utilities for the facility may need to be discontinued. The locations for each utility shut-off follows: Gas/Propane Tank: Southeast corner of each parking lot next to the alley and Lakeview Avenue. Electrical: Western building - Outside of building on the southeast corner of the building under the stairway. Eastern building - Inside building on the southwest corner on both sides of the exit door next to the alley. Water: In the alley next to the fence and the southwest corner of the building 330 feet west of Lakeview Avenue. Ammonia: The ammonia shut-off is in the southeast corner of the west building (engineering support)' next to the alley. The Fire Department hook-up and ammonia dump system valve control is on California Avenue over the main entrance. The diffusion system box is next to the roll-up door of the west building on the southside next to the alley. 03320012.001 52 Gas Meter: Inside the fence between the buildings next to the alley, southwest corner of eastern facility, south of the ammonia tank containment. Lock Box: Keys located above the north entrance door of the west building. Available Water Supply The following water supplies exist near the Crystal Geyser facility: Fire hydrant located on the north side of East California Avenue. A fire department hook-up to Crystal Geyser's main sprinkler system riser for the east building one hundred and twenty (120) feet west of the northwest corner of the facility and two hundred and twenty (220) feet west of Lakeview Avenue. Fire department hook-up to west building in the alley approximately four hundred feet west of Lakeview Avenue. 03320012.001 53 d. Planning Worst-Case Scenario The worst-case scenario is defined as the release of the largest quantity of a regulated substance from a single vessel or process line failure that results in the greatest distance to an endpoint. The distance to the endpoint is the distance an ammonia vapor cloud will travel before dissipating to a point that serious injuries from short-term exposures will no longer occur. The worst-case scenario is assumed to be an unmitigated release occurring over a period of ten minutes. Suggested parameters provided in EPA guidance documents for modeling worst-case releases assumes wind speed to be 1.5 meters per second, a wind stability class of F, and a ground level release. Surface roughness is classified as either urban, obstructed terrain, or rural, fiat terrain. This facility is considered urban due to its location within the City of Bakersfield. The release rate is calculated by dividing the total amount of the hazardous substance by ten minutes. Using the maximum amount of ammonia held on-site and dividing it by an assumed release period of ten minutes results in a release rate of: 4500 lbs / 10 minute release = 450 lbs/minute Using the EPA-supplied table for worst-case scenarios, the toxic endpoint distance is 0.9 miles. To estimate the population present within the endpoint circle, census data for six census tracts was obtained from the Kern Council of Governments. The census data is based on the 1990 census data and has been updated to 1998 using a shared allocation method. 03320012.001 54 The aerial extent of each tract was determined and the population density was calculated. The area of each census tract within the circle defined by the toxic endpoint of the worst case release was measured and the residential population within that area was estimated using the population density within each census tract. The calculations used to determine the residential population are presented on the following pages. 03320012.001 55 ~~~~ ./'~ ~'~ ..' ~-.~: . "L' ', . . . ., . .... · ; I~''~ , , , ~ ~ ~ : . .. ~,_ . ~ ~ ~ , ~ ~. ~.~ ~ , - ~ '~ ~i y'~ ~ ~i . · " >~. l'...':'~ ,~.. . .~N ~: : I ~ ~ ~.---.Z ~: ~ = ~Z .... ~ ~'~'~ .: ~ ~y~ .... ' i ~L 0~ ~/ t >, ~: z iVI~tNIAAVE ~ ~ ~ ,.~-~ .... ~ "~ : ~ ~ ~( f~ ~.~ ~ =, ~i~K.. ~ ~ · ~ ; : ' . ~ ~ ~ · · , ~ ~ .v'//~ ........ ~ ...... ~: // ~..- ~:~~. ~:!... ~:~_.: ...... SCALE IN MILES CRYSTAL GEYSER Bakersfield, CA 0.5 1 WORST CASE REL~SE SCENARIO Off-Site Receptors for Worst Case Scenario Receptor Approximate Distance (Miles) Direction Southern Pacific Depot State Building Fire Station #2 Vista East High School Martin Luther King Jr. Park Union Cemetary Owens School Virginia Avenue County Park 4/5 9/10 2/3 1/3 3/10 2/5 2/3 NW NW NW NW W SW SW SE 03320012.001 56 Residential Population Calculations Census Tract Population Density 12.00 13.00 15.00 21.00 22.00 23.02 9,649 people per square mile 9,473 people per square mile 9,504 people per square mile 6,519 people per square mile 7,831 people per square mile 3,168 people per square mile Worst Case Scenario Area of Vulnerability Census Tract Area of vulnerability (sq. mi.) Population (density x area) 12.00 0.2304 13.00 0.2764 15.00 0.8456 21.00 0.2572 22.00 0.7536 23.02 0.4582 2,224 2,618 2,963 1,677 5,901 1,451 Total estimated population within circle: 16,834 03320012.001 57 Alternate Release Scenario An alternative release scenario analysis is also required. This alternative release scenario is determined by either past facility or industry experience to be a more likely credible scenario. The hazard and operability study determined the alternate release scenario to be the release of the liquid contents of the ammonia receiver into outside air. The potential release scenario judged to be dangerous to offsite receptors is a release of ammonia during an earthquake. Lines from and to the ammonia receiver contain liquid ammonia. A break in this two inch liquid ammonia line could release all of the ammonia in the receiver. In this potential worst case scenario, the rapid release of liquid ammonia could form an air/ammonia dispersion that would act as a cloud of dense gas. The ammonia receiver contains 4500 pounds of ammonia which would release to the compressor room leading to outside air, immediately affecting the surrounding area. The release rate would be 2040 pounds per minute and last 2.21 minutes to release the entire 4500 pounds of ammonia. This scenario satisfies the requirements for the alternative release scenario analysis under Title 19 Section 2750.4. The EPA-released guidance document recommends "average" weather conditions t© be a wind speed of 3 meters per second and stability class D, and an ambient temperature of 25 degrees Celsius. Using the RMP Comp software provided by the EPA, the distance to the toxic endpoint is an estimated 0.2 miles. There are no off-site environmental receptors for the alternate release scenario. Public receptors include commercial, industrial, and residential receptors. 03320012.001 58 To estimate the population present within the endpoint circle, census data for six census tracts were obtained from the Kern Council of Governments. The census data is based on 1990 census data and has been updated to 1998 using a shared allocation method. The aerial extent of each tract was determined and the population density was calculated. The area of each census tract within the cimle defined by the toxic endpoint of the alternate release scenario was measured and the residential population within that area was estimated using the population density within each census tract. The calculations used to determine the residential population are presented on the following pages. 03320012.001 59 , ,~ , ~-, . · ~' ~ ~7 ~/ ~ - , ~' .'~ ~5~'~*- :/~~ ,7 .:'~ ....... ~ ~- ~~~~~C.~/~. '~ I %' ~,. ~ ..~E .. ~UX~N ~ ~~~ '. ~ ~~ .. 7 ~, "- ~ ~~'~~¢i~ ./~ ~ BAKERSFIELD ~' ~, 0 -. [ .... - ....... .I.,...: h ' ' ~ ~ ~ =~ ' .... · . · · . -..., .;:,~' . ';~;:'. ...... ;...;:; i ~ r ... ~:...~e' . '. Er::' .I l~ I ~ ~t ~ ~ ~i ~ al.. t.~ ~ . .. i.~ , ,., a~ e~. ~... ~ ~ o .... .... . . / : ,- . m' ~ ' ~.~ )~ - ,- =I" l~:~l:~t Bi.~I:D :'Z~ i , , I '~~ : 'Jk~:~ ~' :'.".'.. //~/~ ~.,.o. ~t ,~ ~~ ....... ~L ~ ~:.,..._~.~_._.~. CRYSTAL G~SER ~ SCALE IN MILES ~k~d, CA N 0 0.5 1 ALTER~TE RE~8E ~.~2 8OE~RIO Off-Site Receptors for Alternate Release Scenario There .are no off-site environmental receptors for the alternate release scenario. 03320012.001 60 Residential Population Calculations Census Tract Population Density 15.00 22.00 9,504 people per square mile 7,831 people per square mile Alternate Scenario Area of Vulnerability Census Tract Area of Vulnerability (sq. mi.) Population (density x area) 15.00 0.0558 22.00 0.0772 55 6O5 Total estimated population within circle: 660 03320012.001 61 e. Logistics 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 Hospital or Kern Medical Center will be given second consideration. Any supervisor has the authority to dial 911 for medical emergencies. Maintenance Procedures Ammonia System Shutdown 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 Shut suction valve, allow compressor to pump down (remove ammonia). Turn compressor motor off. Close discharge valve. 03320012.001 62 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. Restarting a Compressor 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. Preventative maintenance checklist 1/17/03 Daily While the system is in operation, check the refrigerant sight glass: Clear- OK Bubbles-Low on refrigerant Foam - very low 2. Oil sight glass level should be in center of glass. 3. Operate thermostat at the set point. 4 .Check suction and discharge pressures. 5. Listen for strange noises,bad bearings compressor knock. 6. Check all breakers and overloads. 7. Check for vibration,loose clamps,cap tubes vibrating and/or rubbing. 8. Log compressor hours. 9. During times of light load,turn off the lead compressor and let # 2 get more run time. 10. Log the compressor operating hours. 11. Check the oil level in the compressors. 12. Check the frigerant sight glasses for bubbles. Weekly 1. Check fans and pump in evaporrative condenser for proper operation. 2. Check tower chemicals. Quarterly 1. Maintain proper glycol level and concentration - strength should be 30 - 40 % -- 1.034 to 1.049 specific gravity. 2. Evaporative condenser. Bleed off- clean sump and spray nozzles, chemicals, fans and pump. 3. Clean pumP strainer 4. Check by-pass and flow switch by turning off glycol pumps, system should pump down and turn off. ~. Check evaporator condensor fan belts for wear and cracks 6. Check for loose pipe clamps. 7. Descale the condensor if needed. Page 64 Yearly 1. Check all safety controls - ammonia sensors, high level float valves on chiller, and accumulators, Recalibrate if needed. 2. Check all gauges for proper calibratiom Compressors 3. Change the oil and clean the crank cases, - every 30,000 hrs. 4. Check pressure and temperature calibration - every 10,000 hrs. 5. Change filters on compressors every 10,000 hrs. 6. Clean oil strainers on compressors every 10,000 hrs. 7. Clean liquid strainers 10,000 hrs. 8. Clean coalescers every 30,000 hrs: ' 9. Clean suction screen every 10,000 hrs. 10. Check alignment every 10,000 hrs. 11. Check couplings every 10,000 hrs. 12. Due oil analysis every 10,000 hrs. 13. Vibration analysis every 5000 hrs. 14. Replace seal every 30,000 hrs. Page 65 111.4 Emissions Documentation WZl ,NC Documentation Emissions documentation at this facility is limited to an accidental release of anhydrous ammonia from the ammonia refrigeration system. Any sizeable release is reported to the Bakersfield City Fire Department and the required State and Federal agencies. Incident Investi,qation If a release occurs, the following incident investigation procedures will be performed: A release incident report will be completed (included on the following pages); A post accident review will be performed in which potential causes of the accident are discussed; A method shall be developed to ensure that the accident will not recur; Any system design specification, operating procedures or maintenance procedures that need updating or alternation shall be noted; and A time schedule for accomplishing the required changes will be set. An release incident report will be completed in the event of a release and all records concerning the release will be retained on-site for a minimum of five years. A sample of the release incident report follows. 03320012.001 66 RELEASE INCIDENT REPORT Date: Time: Release Duration: Chemical(s) Released Quantity Released Release Event: Gas Release Liquid Spill/Evaporation Fire Explosion Release Source: Storage Vessel Piping Process Vessel Transfer Hose Valve Pump Joint Other (Specify) Weather Conditions: (Use "Unknown" for any missing Wind Speed and Direction Temperature Stability Class Precipitation Present information) On-site Impacts: Deaths Injuries Property Damage Known Off-site Impacts: Deaths Injuries Evacuated Sheltered Environmental Damage Initiating Event: Equipment Failure Human Error Weather Conditions Unknown Contributing Factors: Equipment Failure Human Error Improper Procedu res Overpressurization Upset Condition By-pass Condition Maintenance Activity Process Design Unsuitable Equipment Weather Conditions Management Error Were off-site responders notified? Changes introduced as a result of accident: Improved/Upgraded Equipment Revised Maintenance Revised Training Revised Operating Procedures New Process Controls New Mitigation Systems Revised Response Plan Changed Process Reduced Inventory Other None Five-Year Accident History Requirements A five-year accident history is required for releases from a covered process involving a regulated substance that caused one of the following: · On-site deaths, injuries, or significant property damage. · Known off-site deaths, injuries, property damage, environmental damage, evacuations, or sheltering in place. Accidental Release No accidental releases meeting the above criteria have occurred in the last five years. 03320012.001 67 "AMERICA'S N~ATURAL BEVERAGE COMPAN~ Tim Ryah, Wastewater Inspector City of Bakersfield 8101 Ashe Rd. Bakersfield, Ca 93313 Re: Ammont~ Leak of 4/02/0~ Dear Tim: The source of the ammonia leak on 4/2/02 was determined to have originated from the evaporative cooling tower that was in the process of being serviced to repair a safety r~lief valve. The outside contractor, James Bartell and Associates, was removing ammonia vapor (20 psi) ilom the condensed liquid line when tile gaseous odor was noticed. The liquid ammonia was previously evacuated from the same line back into tho ammonia compressors, but ammonia vapor remained in the isolated evaporative cooling system. The contracting personnel proceeded to vent the 20 psi ammonia vapor into a 55 gallon drum of water and w~ adding additional water with a hose to dilute the ammonia odor, As the drum of water and ammonia vapor o~rflowed the liquid mixture flowed to the roof &sin. The contractor's employee was not aware that the roof drain flowed directly to tho street curb attd down the storm drain, As soon as we were informed by yourself and our office staff, we investigated the situation and asked the contractor to immediately stop the procedure and inform his supervisor of the problem. A decision was made to run an extra hose from vapor line being evacuated to the ammonia compressor room. The hose was attached'to thc suction sidc of the compressor and the linc that contained thc vapor was sucked empty after a few hours. Tim line with ammonia vapor contained approximately 15 psi of vapor when the water and vapor mixing was halted. 5 psi of vapor pressure was dumped to the roof and eventually to the street curb drain. Normally, the water m~d vapor mixing is performed to remove the remaining vapor, It saves time and cost. Unfortunately, the contractor did not take into account the location of our facility and proximity to housing and pedestrians. The ammonia vapor can be very Irritating to all individuals not previously exposed to such an odor. In the future, we will require that the ammonia compressors be totally evacuated ofammmda and vapor; which require a facility shutdown or we must use thc compressors to remove the remaining vapor. The5© will be added to our standard operating procedures. ~0 , CRYSTAL GEYSER WATER COMPS, NY P.O. Box 304, 501 Washington Street, Calistoga, CA 9451 $.0304 (707) 942-0500 FAX (?07) 942-0647 '~AMERICA 'S NATURAL ~£VERAG£ COMPANY~ The release of more than 100 lbs of liquid ammonia constitutes a hazardous release and reporting of the incident to all governmental authorities with hazardous material responsibilities. Our incidental release did not meet that criteria, according to Howard Wines, Ha,'~rdous Material Specialist, City of Bakersfield Fire Department. Mr. Wines appreciated our decision to cease the vapor removal until we devised a plan to eliminate the vapor without releasing into the atmosphere. He stated that we took the correct actions and did not violate a hazardous material ordinance for ammonia release. If you have any questions, plcoze feel free to call David Wright, Production Supervisor, or Robert Hofferd 5af~y Coordinator at 323-6296. Sincerely,' Q.C. Supervisor Crystal Geyser Water Co. £0 · CRYSTAL GEYSER WATER COMPANY P.O. Box 304, 501 Washington Streel, Calistoga, CA 94~15-0304 (707) 942-0500 FAX 0'07) 942-0647 111.5 Training Effective training programs are necessary to ensure that all plant personnel can successfully implement the elements of this RMP. Training will be able to provide a continuity of safety despite employee turnover. Training ensures that plans and programs such as emergency evacuation plans will work as designed when they are needed. The following subjects will be covered by the training program: Use of Safety Equipment Ammonia First Aid Procedures Review of Material Safety Data Sheets, Chemical Hazards Fire Prevention Response Release Reporting Evacuation Procedures Earthquake Procedures Spill Containment and Dilution Procedures Daily Operating Procedures Maintenance Procedures Training is verified by testing employees for comprehension of the training programs developed for the elements of the RMP that need ongoing implementation. On the following page is a training checklist that will track the training received by each employee. Training is dictated by regulatory requirements and by industry standards. The Safety Coordinator will ensure that employees have received a level of training required by industry standards and any regulatory requirements. This may include attendance at industry specific meetings to maintain current knowledge of industry recommended standards. 03320012.001 68 CRYSTAL GEYSER WATER COMPANY TRAINING REQUIRED / DATE COMPLETED EMPLOYEE AMMONIA AMMONIA SCBA FIRE EMRGCY EVAC FORKLIFT SAFETY DIFFUSION SAFETY NOTIF. PROCED. lOSE BALDEMAR // ~ i/ -o ~ LUCY BRAVO OFELIA CANALES //-//-o CHAD CHANTHAPRY STANLEY COOK /o- ~-o-~ VERONICA F~GUEROA - //_//_~,,~ SERGIO MIGUEL GUILLEN JOSE AIDA SEPULVEDA GEORGE MAESE IOSEMENDOZA /~_~.~..~, //_//~,,~. /1_/1_o~ 7/_ /1_~ ,~ _~, _o~. RICHARD ARMANDO RAYO JOSH Ro_gRIQU~Z //~ -~. CRYSTAL GEYSER WATER COMPANY TRAINING REQUIRED /DATE COMPLETED EMPLOYEE AMMONIA AMMONIA SCBA FIRE EMRGCY EVAC FORKLIFT SAFETY DIFFUSION SAFETY NOTIF. PROCED. JASON sMrra //_//_,~. JOSE URRUTIA // JOAQUIN ELI VASQUEZ JOHN DAVIS TED BOB HOFFERD DEE SEC~ TRAINING COMPLETED EMPLOYEE AMMONIA SAFETY FIRE SAFETY EMERGENCY EVACUATION SPILLS AND NEUTRALIZATION NOTIFICATION PROCEDURES TRAINING COMPLETED EMPLOYEE AMMONIA SAFETY FIRE SAFETY EMERGENCY EVACUATION SPILLS AND NEUTRALIZATION NOTIFICATION PROCEDURES TRAINING COMPLETED EMPLOYEE AMMONIA SAFETY FIRE SAFETY EMERGENCY EVACUATION SPILLS AND NEUTRALIZATION NOTIFICATION PROCEDURES TRAINING COMPLETED ..... EMPLOYEE AMMONIA SAFETY FIRE SAFETY EMERGENCY EVACUATION SPILLS AND NEUTRALIZATION NOTIFICATION PROCEDURES TRAINING COMPLETED EMPLOYEE AMMONIA SAFETY FIRE SAFETY EMERGENCY EVACUATION SPILLS AND NEUTRALIZATION NOTIFICATION PROCEDURES 111.6 Plan Review and Modification All records concerning this RMP shall be kept for at least five years (Section 2755.1). Necessary revisions to the RMP will be made at least every five years (Section 2745.10 (a)(1). The RMP must be revised within 60 days of a modification that results in a significant increase in either the amount of regulated substance handled at the facility or in the risk of handling the regulated substance (Section 2745.11 (b)). All revisions to this RMP are to be recorded here. DATE PAGES/ OF CHANGES/INPUTS MADE TO SECTION CHANGE DOCUMENT AFFECTED SIGNATURE/DATE 03320012.001 69 RMP AUDIT CHEC'KLIST VVZI ~,c ' Crystal Geyser.Water Company Date, /'-/..C--o_~ Signature ~.£.~--~ / Has a Facility Modification affecting regulated substance handling been documented in the PJVIP? Yes No If yes, does the Hazard Analysis need to be modified? Yes No * Are all ~ operating procedures up to date? (~Ye_~,P No *' A~er an unannounced spot check, were the standard operati.ng proced..~.es~SOP) performed as written? No Date and time of SOP spot checks If no, has training been scheduled to review written procedures? Yes No * Have in SOP or New SOP been documented in the RMP? ~ No N/A '. Have all~tenance inspections, and PMs been performed? No * Have all safety relief valves been inspected/replaced annually? * Has each regulated substance accident/incident been investigated including method developed to prevent reoccurrence been documept~? * Has a regulated substance~ase been reported as required? Yes No /_N/A~,,~ * Have changes made to regulated substance system, processes and operations been reviewed under management of change procedures prior to imple~a;eat,ation. Yes No * Is all regulated substance safety equipment available and in good . conditi~-~ No * Has list of all current employees been reviewed against master training~c, bec~list provided in of the RMP? (~Yes_~ No * If yes hav~ employees received the training listed on checklist? (~ Ye.s.J No * If no, has training been scheduled to bdng all employees current? Yes No 03320012.001 73 111.7 Prevention Program The following information is required for each RMP facility designated as Program 2: NAICS Code Bottled Water Manufacturing facilities are designated as NAICS Code 312112. Name of Chemical Covered Anhydrous ammonia is listed under CalARP regulations as a state regulated substance with a threshold quantity of 500 pounds. Crystal Geyser Water Company has a maximum amount of 4500 pounds of anhydrous ammonia on-site. Safety Information All safety information was reviewed in March of 1999. This included a review of the process and required inspection and maintenance required by Federal or State regulations or industry-specific design codes and standards. The EPA issued Chemical Safety Alert entitled Hazards of Ammonia Releases at Ammonia Refrigeration Facilities contains steps that ammonia refrigeration facilities could take to prevent or reduce the severity of a release. These suggested steps include establishing training programs for employees, replacing existing valves with spring-loaded valves on 03320012.001 70 oil drain valves, erecting barriers to protect refrigeration equipment and developing a written preventive maintenance program and schedule according to manufacturer's specifications. Hazard Review A hazard analysis was performed at Crystal Geyser Water Company's facility in 1993. A review of this hazard analysis was compared with the requirements of CalARP regulations Section 2760.2(c) and found to cover the following required points: The hazards of the process; The identification of any previous incident which had a likely potential for catastrophic consequences; Engineering and administrative controls applicable to the hazards; Consequences of failure of engineering and administrative controls; Stationary source siting; Human factors; A qualitative evaluation of a range of the possible safety and health effects of failure of controls; and Consideration of external events, including seismic events. Operatin,q Procedures Operating procedures were reviewed in the compilation of this document and were found to be adequate for Crystal Geyser Water Company's needs. Details of the operating procedures in existence at this facility can be found in Section 111.3.c. o3320012.001 71 Training Programs Existing training programs were reviewed and found to be adequate. Details of the training program used can be found in Section 111.5. Maintenance Procedures Maintenance procedures were reviewed and found to be adequate. Details of the maintenance procedures used at this facility can be found in Section 111.3.e. Compliance Audits A compliance audit will be performed at least every 3 years to verify that procedures and practices are adequate and being followed. This compliance audit will be conducted by at least one person knowledgeable in the process. On the following page is the form which will be used to perform the compliance audit. A report of the findings will be developed. Each of the report findings and deficiencies will be addressed. The two most recent compliance audits, reports and responses to the findings will be kept on-site. 03320012.001 72 RMP AUDIT CHECKLIST Crystal Geyser Water Company Date Name Signature * Has a Facility Modification affecting regulated substance handling been documented in the RMP? Yes No N/A If yes, does the Hazard Analysis need to be modified? Yes No * Are all wdtten operating procedures up to date? Yes No * After an unannounced spot check, were the standard operating procedures (SOP) performed as written? Yes No Date and time of SOP spot checks __ If no, has training been scheduled to review written procedures? Yes No * Have changes in SOP or New SOP been documented in the RMP? Yes No N/A * Have all maintenance inspections, and PMs been performed? Yes No * Have all safety relief valves been inspected/replaced annually? Yes No * Has each regulated substance accident/incident been investigated including method developed to prevent reoccurrence been documented? Yes No N/A * Has a regulated substance release been reported as required? Yes No N/A * Have changes made to regulated substance system, processes and operations been reviewed under management of change procedures prior to implementation. Yes No N/A * Is all regulated substance safety equipment available and in good condition? Yes No * Has list of all current employees been reviewed against master training checklist provided in of the RMP? Yes No * If yes have all employees received the training listed on checklist? Yes No * If no, has training been scheduled to bring all employees current? Yes No 03320012.001 73 111.8 Certification "1 certify under penalty of law that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, aCCurate, and complete." Robert Hoffer~' Shipping Supervisor/Safety Coordinator Date 03320012.001 74