Agrilink Foods, Inc. - Watsonville - Executive Summary |
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This is to inform all interested personnel, including employees, that Agrilink Foods, Inc., Watsonville is complying to the OSHA Process Safety Management Standard (PSM) 29 CFR 1910.119 and the EPA Risk Management Program (RMP), 40 CFR Part 68,CAL/OSHA Title 8 Section 3220, to manage the risks involved with the storage, handling, and processing of hazardous chemicals. These programs enable our facility to prevent the occurence and minimize the consequences of significant releases as well as fires, explosions, and other types of accidents. Overall, these programs prevent accidental fatalities, injuries, and illnesses and can also avoid physical property damage. Our safety programs are applied to any activity involving hazardous chemicals including use, storage, handling, or on-site movement. Any group of vessels which are interconnected and separate vessels which are located such that a hazardous chemical could be involved in a potential release shall be considered a single proces s The safety programs are implemented in order to reduce both the number and severity of accidents. Our focus is on the policy, procedures, and safe practices that govern individual processes and acitivities on specific equipment. These programs are communicated and accepted by every employee at this facility. Description: The ammonia refrigeration process at the facility consists of various pumps, compressors, and condensers that are used to change the state of ammonia from a gas to a liquid. It is classified as a closed system process. The total ammonia inventory on site includes 37,000 pounds. The ammonia is used in the freezing of broccoli, cauliflower, spinach, beans, pasta, asparagus, and for cold storage. Worst Case Scenario: Failure of the high-pressure reciever containing 37,000 pounds of ammonia with the receiver quantity limited to 37,000 pounds of the vessel capacity by facility procedures resulting in a ten-minute release. Under worst-case weather conditions, amm onia could travel 2.3 miles before dispersing enough to no longer pose a hazard to the public or the environment. This scenario is unlikely to occur for the following reasons: a. worst-case weather conditions are uncommon b. industry standards for the manufacturer and quality control pf pressure vessels c. ammonia is not corrosive in this service d. pressure safety valves limit operating pressure in this vessel e. accident prevention program in place at the facility to include the mechanical integrity program for regular maintenace and preventive maintenance f. installed ammonia sensors in the system to warn of leaks g. alarms are in place to warn of process upsets h. emergency response plan and equipment at the facility Alternative Case Scenario Failure of 1/4 inch diameter pipe would result in the release of approximately 100 pounds of ammonia per minute for a sixty-minute duration. Under common weather conditions, ammonia could travel 0.1 mile before dispersing enough to no longer pose a hazard to the public and environment. The 1/4 pipe was chosen because it is used to temporaily bleed off a pump so that maintenance activites can be conducted. This scenario is unlikely to occur due to the following reasons: a. the pump is isolated with valves in the closed position so that only a few pounds of ammonia would be released b. the valves of the pump would have to completely fail c. the facility has an accident prevention program in place that establishes operational procedures that include a requirement that personnel be present at all times during maintenance of the pumps d. mechanical integrity program for regular maintenance of the pump at the facility e. routine inspections and testing of valves f. replacement of defective equipment g. facility emergency response plan at the facility Prevention Program The general accident prevention program and ammonia specific prevention steps was developed as a requirement and is in compl iance with OSHA PSM Standard 29 CFR 1910.119 and the EPA RMP Program found in 40 CFR Part 68. The key prevention steps at the facility consists of the following: - Process Safety Information - Process Hazard Analysis - Standard Operating Procedures - Training - Mechanical Integrity Program - Management of Change - Pre-Start Up Review - Compliance Audits - Incident Investigations - Employee Participation - Hot Work Permit - Contractor Qualifications Five Year Accident History Agrilink Foods, Inc., Watsonville has had no reportable releaseduring the five-year period specified Emergency Response Program The Watsonville Facility Emergency Repsonse Program is based on OSHA requirements for the Emergency Action Plan (29 CFR 1910.38 and 1910.119) and HAZWOPER (29 CFR 1910.120) and Cal OSHA requirements in Title 8 Section 3220. The facility has trained employees for emergency response and has maintained an emergency response plan. This plan is coordinated with the Watsonville Haz-Mat T eam and Watsonville Local Emergency Response Planning Committee (LEPC). We conduct annual drills with the local fire department and the LEPC for the implementation and training in the emergency response plan for the facility. |