US Foodservice - Las Vegas - Executive Summary |
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ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES The US Foodservice facility has an emergency response plan in effect. The Emergency Response Plan (Plan) is detailed in the Emergency Planning and Response section of the PSM/RMP document, which is maintained at the facility and updated as necessary. This Plan was designed to meet the following objectives: 1.) To save lives. 2.) To minimize and avoid injuries. 3.) To protect the environment. 4.) To minimize property damage. US Foodservice maintains a safety committee whose members are the designated emergency coordinators for the facility. The Plan provides the response organization and notification procedures, evacuation routes, ammonia health hazards, and mitigation procedures which will be implemented to respond effectively to emergency situations that may arise at the facility. This Plan is reviewed and updated at least once per year. This Plan will be reviewed and updated to ensure compliance with th e PSM and RMP regulations, as well as to incorporate facility changes. US Foodservice has coordinated emergency response efforts with the local fire department and with the contracted refrigeration operation and maintenance firm. In the case of an ammonia-related emergency, it is the policy of US Foodservice to evacuate and to allow the fire department and the refrigeration contractors to respond to the emergency. STATIONARY SOURCE AND REGULATED SUBSTANCE Construction of the ammonia refrigeration system at US Foodservice was completed in 1998. The facility is located at 1685 W. Cheyenne Avenue in North Las Vegas, Nevada 89030. The system was constructed in accordance with all applicable federal, state, and local regulations including the Uniform Fire and Mechanical Codes. The US Foodservice facility receives and distributes food and food products to local vendors. The ammonia refrigeration system uses 24,000 pounds of ammonia for dock operations, warehouse cold storage, and fr eezer storage. The majority of the system is located in the ammonia engine room including vessels and compressors. The condensers are mounted on the engine room roof, and all of the evaporators are located in their respective cold storage rooms/areas. HAZARD ASSESSMENT SUMMARY * Worst Case Release Result Summary Scenario Description: Release of the maximum quantity of ammonia that can be stored in a vessel (Controlled Pressure Receiver) - 21,600 pounds in 10 minutes. The most pessimistic meteorological conditions were used: 1.5 meters per second wind speed, and F stability. The Risk Management Program Guidance for Ammonia Refrigeration reference tables were used to determine the maximum distance to the toxic endpoint of 200 ppm. This release reaches off site and may impact population receptors. No environmental receptors were affected by this potential release. * Alternative Release Result Summary Scenario Description: A release of ammonia from resulting fro m a 1/4 inch diameter hole in a pipe. The release rate of ammonia due to the pressure of the tank is 134 pounds per minute. The meteorological conditions used were 3 meters per second wind speed, and D stability. The Risk Management Program Guidance for Ammonia Refrigeration reference tables were used to determine the maximum distance to the toxic endpoint of 200 ppm. This release reaches off site and may impact population receptors. No environmental receptors were affected by this potential release. ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS The US Foodservice ammonia refrigeration system has many safety features. Much of the safety of the system is inherent in the policies and procedures that govern the operation of the system. For example, the US Foodservice facility operates in accordance with OSHA's Process Safety Management regulation. The US Foodservice facility including the ammonia system was designed and constructed in accordance with the Uniform Mechanical Code which specifically outlines requirements for the safe operation of the ammonia refrigeration system. These safety features include a water diffusion tank, ammonia sensors in the machine room as well as sensors in selected cold storage areas, and automatic shut down systems. In addition, the majority of the ammonia is maintained inside the engine room and just outside of the machine room (condensers). All pressure vessels are equipped with pressure relief valves that are commonly piped to the water diffusion tank. In addition to the Uniform Mechanical Code, the facility will operate in accordance with the International Institute of Ammonia Refrigeration (IIAR) guidelines. In particular, the IIAR Bulletin 110, "Startup, Inspection, and Maintenance of Ammonia Refrigeration Systems." FIVE YEAR ACCIDENT HISTORY This facility including the ammonia refrigeration system has been in operation since early 1998. There have been no ammonia accidents at th e facility. EMERGENCY RESPONSE PROGRAM The US Foodservice has an emergency response plan in effect at the facility. The Emergency Response Plan (Plan) is detailed in the Emergency Planning and Response section of this PSM/RMP document. This Plan was designed to meet the following objectives: 1.) To save lives. 2.) To minimize and avoid injuries. 3.) To protect the environment. 4.) To minimize property damage. US Foodservice maintains a safety committee whose members are the designated emergency coordinators for the facility. The Plan provides the response organization and notification procedures, evacuation routes, ammonia health hazards, and mitigation procedures which will be implemented to respond effectively to emergency situations that may arise at the facility. This Plan is reviewed and updated at least once per year. This Plan will be reviewed and updated to ensure compliance with the PSM and RMP regulations, as well as to incorporate facility changes due t o the renovation of the facility. PLANNED CHANGES TO IMPROVE SAFETY The Process Hazard Analysis (PHA) provided mitigation measures to improve safety at the US Foodservice facility located at 1685 W. Cheyenne Avenue in North Las Vegas, Nevada 89030. A majority of the recommendations from the PHA were determined to be complete during the PHA Revalidation on March 29, 1999. The remaining recommendations are scheduled to be complete by June 1, 1999. HAZOP Study R01 Investigate and document the number of sensors in the engine room. Also document system actions upon reaching concentrations of the low and the high ammonia sensor setpoints. R02 Establish a procedure to replace/recertify relief valves every time one unseats or every five years, whichever is sooner. R03 Establish and document system maintenance procedures that include following the manufacturer's recommendations on all applicable equipment. R04 Install safety shower/eye wash stations that can be easily rea ched from normal maintenance locations including the roof of the engine room (for condensers). R05 Include checking pressure regulator valves on daily log sheet. R06 Establish a procedure to clean up (with an absorbent material) and properly dispose of spilled liquid ammonia. R07 Inform the fire department or other potential emergency responders of the danger of spraying water on a pool of ammonia. R08 Ensure that the High Stage Accumulator is equipped with a high level alarm, and a high level switch that shuts down compressors. R09 Establish and document a procedure to annually test the high level alarm and the high level switch on the High Stage Accumulator. R10 Ensure that booster compressors shut down as a result of the high stage compressors shutting down (not vice versa). R11 Establish and document a regular procedure for draining oil from the system. R12 Establish a procedure to test the pH of the water in the dilution tank periodically as an indi cation of an ammonia leak. Document normal water pH at the facility and set a limit above which the water will be changed. R13 Determine and document whether the pumps on the Low Stage Accumulator automatically turn on after losing power. R14 Ensure that activating an ammonia sensor in the dock/cold storage areas results in termination of liquid supply to that particular set of evaporators by: - Closing king solenoid valve on CPR, or - Shutting off liquid pumps on LSA. R15 Install audible and visual alarms that are interlocked with the ammonia sensors to alert operators/ employees of an ammonia leak in either the cold storage areas or the engine room. R16 Establish a familiarity program to inform all employees about ammonia and the refrigeration system in place. R17 Inform employees/contractors to alert management if they hear banging in the evaporator pipes. R18 Consider contracting refrigeration operators to perform daily checks of the system on the wee kends. R19 Establish and document a procedure to ensure that the compressor swing valves (on C-2 & C-4) are adjusted correctly and that the control panels are correctly set up for either high stage or booster operation. R20 Alert employees about the danger of the high stage compressor discharge line (contains high pressure vapor) that feeds the condensers. R21 Include regular condenser water treatment in maintenance program. R22 Include a process flow diagram of the ammonia refrigeration system on the inside of the control box. Label all valves in the box and indicate where the lines originate. Procedures Review, What If Walkthrough R23 Determine if the engine room drains go to the sewer system. If yes, ensure that evacuation assembly locations are not near sewer vents. R24 Install a visual alarm that is triggered at the first ammonia detection level outside the ammonia engine room at the man door. R25 Place a system process flow diagram and operating ins tructions on the inside of the control box. R26 During the initial and subsequent fill operations, ensure that the area is isolated from vehicle and foot traffic. R27 Provide an appropriate lift for servicing freezer evaporator valves. This could include an articulating lift. A typical scissor lift would not be sufficient. R28 Establish a primary evacuation location based on the prevailing westerly and southwesterly wind directions. Consider a location at the Northwest side of the property along Cheyenne Avenue. R29 Finalize the emergency response plan. Decide if SCBAs will be on-site and who will be assigned to use them. |