HomeMy WebLinkAboutRISK MANAGEMENT NESTLI~
ICE CREAM COMPANY
BAICERSFIELD, CALIFORNIA
RISK MANAGEMENT
AND
PREVENTION PROGRAM
AUGUST 1995
RISK MANAGEMENT and PREVENTION PROGRAM
Addendum
RECEIVED
/~U~ 2. t3 1995.
HAZ. MAT, DIV.
Prepared For:
NESTLl~ ICE CREAM COMPANY
BAKERSFIELD, CALIFORNIA
Revised and Updated
August 1995
Prepared By: ~
QUAD ENGINEERING, INC.
5500 Ming Avenue, Suite 410
Bakersfield, California 93309
805/835-8300
TABLE OF CONTENTS
1.0
2.0
3.0
4.0
5.0
6.0
Purpose ................................................. 1
Ammonia Refrigeration Process Equipment ........................... 2
Accident History ............................................ 4
Offsite Consequences Analysis ................................... 7
Recommended Additional Steps .................................. 8
Status of 1994 RMPP Implementation .............................. 9
Appendix A
Appendix B
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1.0 INTRODUCTION
1.01 Purpose
The purpose of this addendum is to revise and update the Nestl6 Ice Cream Company (Nestl6),
Bakersfield, California Risk Management Prevention Program (RMPP) dated April 1994. A
revised RMPP is required whenever a modification is made to the facility which would materially
affect the handling of an acutely hazardous material. Nestl6 uses anhydrous ammonia in a closed
cycle refrigeration system for the manufacture of ice cream and frozen novelties. Anhydrous
ammonia is classified as an acutely hazardous material (AHM).
This addendum is intended to be a supplement to the RMPP dated April 1994. Please refer to the
April 1994 RMPP for complete details.
Changes and facility modifications made and not previously addressed in the RMPP include the
following:
The total quantity of anhydrous ammonia is now estimated to be approximately
100,000 pounds. The 1994 RMPP update identified a total of 82,500 pounds. The
original RMPP dated 1989 identified a total of 120,000 pounds of anhydrous
ammonia.
2. Nestl6 has added the following process equipment to the main production floor:
2 Drum Stick freezer tunnels
1 Frigo-Scandia freezer tunnel with backup ammonia pump
8 ice cream freezers
Nestl6 has added 3 new 8,000 gallon refrigerated mix tanks (MT 30, 31, 32) for
storage of ice cream mix prior to freezing. The mix tanks are located outside the
building in an enclosed space.
In addition to the above changes, Nestl6 has recently reported two accidents which involved the
release of anhydrous ammonia. This addendum will address those accidents, their underlying
cause and measures to avoid recurrence of the accidents.
Finally, the revised RMPP will address any changes required on the offsite consequences analysis
as a result of changes made in the process equipment.
Section 6.0 indicated the status of the 1994 RMPP Implementation.
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2.0 AMMONIA REFRIGERATION PROCESS EQUIPMENT
2.01 Ammonia Inventory
The best estimate of the total quantity of anhydrous ammonia contained within the closed loop
vapor compression refrigeration system is approximately 100,000 pounds. This amount is based
on a June 23, 1995 audit which indicated a total inventory of 99,811 pounds. New process
equipment recently added required the addition of 4,125 pounds (750 gallons) of ammonia
refrigerant. Additional ammonia was added to the system to bring up the level in receivers to
optimize performance during startup.
2.02 Process Equipment Changes
Nestl6 has added the following process equipment to the main production floor:
Drum Stick Freezer (2)
Suction Connection
Liquid Connection
Hot Gas Connection
Location
6" (-55*)
1-1/4" Liquid
1-1/4" Hot Gas
Main Production Floor
Frigo Scandia Freezer
Suction Connection
Liquid Connection
Hot Gas Connection
Location
4" (-55*)
1-1/4" Liquid Ammonia
1-1/2" Hot Gas
Main Production Floor
Ice (2regm Freezers (8 total)
Suction Connection:
Liquid Connection
Hot Gas Connection
Defrost Relief
Pressure relief
Location
2" ¢38°)
3/4" HP Liquid Ammonia
1" Hot Gas
3/4"
to main header
Main Production Floor
Schematic drawings for the new process equipment are included in Appendix A.
2.03 Mix Tanks
Nestl6 has added 3 new mix tanks (MT 30, 31 and 32), each with 8,000 gallon capacity. The mix
tanks hold ice cream mix prior to freezing. The tanks are ammonia refrigerant cooled via direct
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expansion. A Mueller Temp-Plate Cooling Wall with a volume capacity of 0.22 cu. ft. is used
for heat transfer. The mix tanks are similar to mix tanks used for storage of milk in the receiving
area and for ice cream mix inside the building. The tanks are located outside the main building,
in line with the interior mix tanks. The tanks are protected by a concrete wall. The mix tank
specifications are:
Tag No.
Suction Connection:
Liquid Connection
Hot Gas Connection
Pressure relief
.Location
Temp Plate Oper. Pres.
MT30, MT31, MT32
1-1/4" (20 °)
1/2" HP Liquid Ammonia
None
1-1/4" to 6" main header
Building exterior
33-35 psig (150 psig max.)
A schematic drawing and Standard Operating Procedure (SOP) for the mix tanks are included in
Appendix B.
Nestl~ 3 ~
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3.0 ACCIDENT HISTORY
3.01 Description of AHM Accidents
Nestl6 has had two reportable AHM accidents since the last RMPP revision.
March 18. 1995.8:45 p.m.
A Utilities Technician performing routine maintenance on Chiller No. 4 discharged approximately
11 pounds of ammonia into a bucket while attempting to drain oil from the chiller. The technician
was wearing shoulder length neoprene gloves and a full face cartridge respirator. While draining
the oil, something momentarily stuck in the valve and then suddenly blew out discharging oil and
ammonia. After discharging the ammonia, the technician left the engine room, removed the
gloves and waited until breathing was easier. The technician attempted to re-enter the room to
shut off the valve. The ammonia monitor indicated 85 ppm so the technician left the engine room
and hit the "all call" to evacuate the plant. Two technicians then donned SCBA and re-entered
the engine room to re-check to ensure the valve was closed. The ammonia dissipated within the
room and the residual was removed with large quantities of waster. The Bakersfield City Hazmat
Team responded to the spill. Re-entry to the plant occurred following clearance by the Hazmat
Team.
One OSHA reportable injury occurred. The utility technician received burns on this arms as a
result of ammonia spilling.
Underlying Cause of the Accident:
The accident occurred while a technician was performing the routine maintenance of draining oil
from the chiller accumulator. The accumulator is a pressure tank containing liquid ammonia at
-38'F in the bottom of the tank and gaseous ammonia at the top of the tank. Oil from the
ammonia compressors gradually accumulates at the bottom of the tank and requires periodic
removal.
The accident is believed to have been caused by either hardened or very viscous oil and/or debris
lodging in the accumulator drain valve. The oil becomes very hard at the cold temperatures (-38*)
inside the accumulator. The blockage in the valve was suddenly dislodged when the valve was
further opened resulting in oil and ammonia blowing out. Normally, a blockage does not occur
and technicians are able to bleed off the oil in a controlled flow, thus minimizing the discharge
of ammonia.
One technician was working alone, draining the oil. When the sudden discharge occurred, he was
splashed with oil and ammonia on his protective clothing. His mask became saturated and he
could not breathe. He therefore left to obtain a new mask and gloves, leaving the valve unattended
until he could return.
Nestl~ 4 ~
Measures to avoid recurrence of accident:
Nestl6 has implemented the following procedures to avoid the recurrence of the accident:
1. Utility technicians will work in pairs when draining oil from accumulators.
Nestl~ will provide additional training to technicians on the hazards of draining oil from
accumulators.
o
Refrigeration technicians will be trained to use extreme caution when opening valves to
drain oil.
In addition to the above, Nestl6 is evaluating the cost-effectiveness of installing a hard piped oil
drain system. In this system, oil will be drained and isolated from the accumulators to a pressure
vessel. The pressure vessel is then heated with ammonia hot gas through a heat exchanger. The
liquid ammonia in the vessel would be driven off as a gas to the ammonia system suction piping.
The heated oil can then be drained from the vessel to a waste oil container without danger of
ammonia discharge.
March 24. 1995.9:15 a.m.
A contractor, Valley Sun Mechanical, was installing piping for the new mix tanks (MT 30, 31,
and 32). As a large pipe, approximately 14 feet long, was lowered through the roof over MT01,
it slipped out of its rigging. The pipe dropped into the enclosure striking and bending the
ammonia suction line near the top of the tank and the flange on the suction line. The break in the
line resulted in a release of approximately 80 pounds of ammonia. The tanks were immediately
isolated and the exhaust system activated to begin ventilation of the room. The EPA and National
Response Center were notified as a precaution.
No injuries occurred as a result of this release.
Underlying Cause of the Accident:
The accident occurred as a result of careless construction practices of a contractor working for
Nestl6. The pipe being lowered through the roof was not adequately and safely rigged, thus
allowing the pipe to slip and fall.
Measures to avoid recurrence of the accident:
Nestl6 has implemented the following procedures to avoid recurrence of the accident:
Contractors working for Nestl6 in and around ammonia piping systems will be provided
instructions in the hazards of ammonia and the potential impact on an ammonia related
accident on Nestl6's operation. Contractors will be warned to use extreme caution around
ammonia systems.
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Nestl6 personnel will closely supervise and inspect all contractors working in and around
the ammonia systems. '
When contractors are working on or around ammonia systems, they will be required to
submit proposed safety procedures for approval by Nestl6.
When pipe is to be rigged and lowered, the contractors will be instructed to weld clips to
the pipe to ensure that the rigging will not slip.
Nestl~ 6 ~
4.0 OFFSITE CONSEQUENCES ANALYSIS
4.01 Release Scenarios
The new equipment and larger ammonia inventory was determined to have no impact on the
offsite consequences analysis previously prepared. The worst case release scenarios do not
change with the new equipment. Possible releases from the new equipment have already been
evaluated in release scenarios 1, 2 and 5.
Nestle 7 ~
5.0 RECOMMENDED ADDITIONAL STEPS
The following items are recommended to be completed to reduce the risk of an accident
associated with the new facility modifications. These are in addition to the risk prevention
programs already in place and recommended in the April 1994 RMPP update.
Install ammonia detector in the enclosure for new 8,000 gallon mix tanks (MT 30,31,32).
The ammonia detector should be integrated into the existing plant alarm system. This
ammonia detector has been installed.
Immediately implement the procedures described in Section 3.01 anytime oil is to be
drained from an accumulator, receiver or other ammonia pressure vessel. These
procedures are necessary to reduce the risk of an accident similar to that described in
Section 3.01.
Review and evaluate the cost-effectiveness of a hard piped system, as described in Section
3.01, for draining oil from receivers, accumulators and other ammonia pressure vessels.
If the system is cost-effective, implement the system first on those vessels which require
frequent oil draining and which have the greatest potential for an accident. Second,
implement the system on the remainder of the pressure vessels where it is cost-effective.
Immediately implement the procedures described in Section 3.01 any time a contractor is
working for Nestl6 in and around the ammonia refrigeration system.
Nestl~ 8 ~
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6.0 STATUS OF 1994 RMPP IMPLEMENTATION
The current status of the 1994 RMPP implementation is as described below:
Install ammonia detector in guard shack. The ammonia monitoring system alarms have
been installed.
Review ammonia piping runs and install shields and guards where impacts are likely. The
review has been completed. Nestl6 will evaluate and prioritize the list by October 1, 1995
for implementation.
3. Complete ammonia safety audit. The audit was completed and current as of April 1994.
Develop comprehensive ammonia refrigeration process flow diagrams. A refrigeration
flow diagram, for the engine room was completed and included as a part of the 1994
RMPP update. Additional flow schematics are now complete and will be posted at key
locations.
o
Develop a written ammonia safety awareness program. The plants Hazardous
Communication Program provides training in ammonia safety.
Develop a written ammonia emergency plan. The plan is complete. Site plans are being
developed for posting.
o
Fully implement the preventative maintenance program. The preventative maintenance
program has been implemented using the plant's ELKE system. This computerized
program automatically writes works orders for preventative maintenance items.
Develop a response plan for an ammonia emergency that will result in downwind
exposure. The response plan has been developed in cooperation with the Bakersfield Fire
Department. The Fire Department has conducted on-site ammonia safety meetings and has
toured the facility. No table top exercise or simulated drills have been conducted.
Develop a written training program for refrigeration technicians for ammonia safety.
Ammonia safety training has been included in safety training for the last three years.
Nestl6 uses a contractor, Westech, for training.
10.
Develop written work procedures for operation and repairs on the refrigeration system.
Nestl6 is in the process of developing standard operating procedures (SOPs). SOPs have
been written for the new mix tanks (MT 30,31, 32) and are included in this RMPP update.
Nestl6 is currently reviewing SOP procedures for other similar plants and will utilize those
procedures to facilitate the writing of SOPs for the Bakersfield plant. Procedures for
operations and repairs are currently based on the knowledge, experience and training of
the refrigeration technicians. Nestl6's goal is to have written SOPs by January 1, 1996.
Nestl6 9 ~
11.
Construct a 2 foot high containment wall surrounding the pump down receiver.
containment wall was completed in April of 1994.
The
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Appendix A
ILl
LINE 12 TUNNEL REFRIGERATION
LINE 16 TUNNEL REFRIGERATION
LINE ~ TUNNEL REFRIGERATION
Appendix B
Page I of 7
STANDARD OPERATING PROCEDURE
MIX TANll:~ 30, al, 82
Objective:
This procedure is established t~ describe the Technical Operating Specifications (TOS) and to set forth
Standard Operating Procedures (SOP) for the operalion of the arnmoni~ cooling on Mix Tanks 30, 31, 32.
The purpose of the TOS is to provide a description of the tanks defining their function, operating conditions
and limits, consequences of deviations from operating limits, description of controls, instrumentation and
safety systems and setting the operating conditions. The purpose of the SOP is to set forth the proper steps
for starting, monitoring normal operation, stopping and re-starting the ammonia cooling on the tanks.
Careful attention to valve positions is important to this procedure as it is the ammonia cooling that maintains
mix temperature withi~ legal'limits. Among the incidents we are trying to prevent are:
Injury to facilities technics.
Warm Mix
Over pressurization of the tanks resulting in operation of pressure ~,elief valves or failure or rupture of
components and consequent release of ammonia_ to atmosphere.
Dep artment:Facilities
Operator:
Equipment:
Related
Documents:
Facilities T~hniclan
Mix Tanks 30, 31, 32
Paul Mueller Company Drawing # FP08129
Nestle Drawing # P&ID-MT30-32
'4/8/95
Page 2 of 7
STANDARD OPERATING PROCEDURE
MIX TANKS 30, 31, 3g
TECHNICAL OPERATING SPECIFICATION (TOS)
Function: Provide ammonia cooling via direct exp~n~on to mointain mix temperature in 80~ gallon tank.
DESCRIPTION
CAPACITY/SIZI~
OPERATING LIMITS
DEVIATIONS/CONSEQUENCES
MU~.I ,L~,R
TEMP-PLATE
COOLING WA~,~,
VOLUME; .22 CU.FT
Pressure: 33-35 psig
150 psig maximum pressure
Over pressurization may result in
operation of pressure relief valves
DESCRIPTION
ITEM NUMBER
FUNCTION
POSITION/SETPOINT
Col~tro!s and
instrumentation
Level Sensor
Level Sensor
Level Sensor
LS-32
Measure mix level in MT-30
and turn on REF-30
Measure mix level in MT-31
and turn on REF-31
Measure ,nix level in MT-32
and turn on REF-32
ON above 200 gallons
Offbelow 200 gallons
ON above 200 gallons
Off below 200 gallons
ON above 200 gallons
Off below 200 gallons
~8~5
Page 3 of 7
STANDARD OPERATING PROCEDURE
MIX TANKS 30, 31, 32:
DESCRIPTION
ITEM NUMBER
FUNCTION
POS1TION/SETPOINT
Controls and
instrumentation (cont'd)
IAcluid supply
solenoid valve
REF-30
Liquid supply
solenoid valve
REF-31
Liquid supply
solenoid valve
REF-32
Thermal expansion
valve
TEV-30
Thermal exp~n~on
valve
TEV-31
Open and close in response
to LS-30
Open and close in response
to LS-31
Open and close in response
to LS-32
Provides variable orifice
for ammonia expansion into
Mueller Temp-Plate C~liog
Wall. on MT-30
Provides variable orifice
for ammonia expnn~on into
Mueller Temp-PLate Cooling
Wall. on MT-31
Open above 200 gallons of mix in vessel
Close below 200 gallons of mix in vessel
Open above 200 gallons of mix in vessel
Close below 200 gallons of mix in vessel
Open above 200 gallons of mix in vessel
Close below 200 gallons of mix in vessel
Automatic valve set to 8° to 12° superheat
Automatic valve set to 8° to 12° superheat
4/8/95
Pag~ 4 ~f 7
STANDARD OPERATING PROCEDURE
MIX TANKS 30, 31, 3Z
DESCRIPTION
ITEM NUMBER
FUNCTION
POSITION/SETPOINT
Controlz p~nd
instrlunentatlola (cont'd)
Themal expansion
valve
TEV-32
Provides variable orifice
for ammonia expansion into
Mueiler Te_m_p-Plate Cooling
Wall. on MT-32
Automatic valve set to 8° to 12° superheat
Safety systems
Relief valve
Relief valve
Relief valve
RV-30
RV-31
RV-32
Open on rise in Mueller
Temp-Plate Cooling Wall on
MT-30 and relieve to
Common relief header
Open on rise ~n Mueller
Temp-Plate Cooling Wall on
MT-al and relieve to
Common relief header
Open on rise in Mueller
Temp-Plate Cooling Wall on
MT-32 and relieve to
Common re]id header
150 paig
150 psig
150 psig
4/~/95
Page 5 of 7
STANDARD OPERATING PROCEDURE
MIXTANKS 30, 31, 32
STANDARD OPERATING PROCEDURE (SOP)
TASK FLOW DIAGRAM
1. ,.get up tanks for initial oper ,ation
! ...... 2. open Valves
3. Monitor normal operation
,, 4. Close valves
i 5. Restart tanks after ahutdown I
~8/95
Page 6 of 7
STANDARD OPERATING PROCEDURE
MIXTANKS 30, 31, 32
TASK STEP COMMENT
THE FOLLOWING STEPS ARE FOR MT-BO. THE PROCEDURE FOR MT 31 AND 32 IS THE SAME USING
THE APPROPRIATE VALVES FOR MT 31 AND 32. REFER TO P&ID-MT~O-B2.
1. Set up t~n]~ for fnjtial oPeration
1. Close V30-1, V30-2, V30-3, V30-4
TEV30
2. Open TEV30 two full turns
2. Open Valves 1.
Slowly open V30-1 one turn. When flow
noises stop fully open V30-1.
Fully open V30-3
Fully open V30-2
Allows pressure to
equalize with compressor
suction.
Allows liquid to flow
through TEV30 when
REF-30 opens.
Monitor normal operation
1. Monitor REF-30 to ensure the valve
opens and doses at the correct setpoints.
Page 7 of 7
STANDARD OPERATING PROCEDURE
MIX TANKS 30, 31, a2
TASK
STEP COMMENT
3. Monitor normal operation (cont'd)
2. Adjust TEV30 as necessary to maintain
Mix temperature.
<45 degF
4. Close Valves
1. Close V30-2, V30-3
2. Leave V30-1 open to allow for a constant
equalization afpressure within the
Temp-Plate Cooling Wall.
Stops liquid flow
V30-1 is to be abut only
to isolate the tank for
maintenance.
6' COMMON HEADER - VENT UNE
TIEIN TO EXISTING AMMONIA LINES I
,N EA~ ~,x 'r,,,.~< ~ T30 MT51'
· ~ 3/~" HPL
V-2 ~/~R~-30 ~/~REF-3' ~/E-REF-32
) .SOL
~_~ .~o ~o_.~_~o ~L._.
V31-2 V32-2
LEGEND:
V - STOP VALVE
TEN/ - THERMAL EXP, VALVE
S(
H~
R\
)L - SOLENOID VALVE
)L - HIGH PRESSURE LIQUID
- RELIEF VALVE
~llNeI~ Ice Crea~n Coznp~n7
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