SFE Citrus Processors LP, Ltd. - Executive Summary |
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FLorida Global Executive Summary FLORIDA GLOBAL CITRUS RISK MANAGEMENT PROGRAM EXECUTIVE SUMMARY 1. General accidental release and prevention policy of Florida Global Citrus. In this frozen citrus juice processing facility we utilize anhydrous ammonia as a refrigerant. Anhydrous ammonia is considered hazardous by the Environmental Protection Agency. The same properties that make ammonia a valuable refrigerant also makes it necessary to observe certain safety precautions during it's use to prevent exposure to our workers, the surrounding community and the environment. It is our policy at Florida Global to implement the requirements of the Risk Management Program by managing and operating this facility in full compliance with all applicable federal and state regulations that we are governed by. The objective is to minimiz e the risk of an accidental release of hazardous materials. Safety depends directly on our proper handling of ammonia. Our plant personnel have been trained on the equipment operating procedures and the various safety devices that are incorporated in our facility to prevent the possibility of accidental releases. 2. Stationary source and regulated substance handled. Florida Global Citrus, 625 Bridgers Ave., Auburndale, Florida operates four (4) independent refrigeration systems utilizing anhydrous ammonia as the primary refrigerant. Mechanical refrigeration is a thermodynamic process where the refrigerant, ammonia, is used as a heat exchanging fluid to maintain a desired temperature in an enclosed environment. The refrigeration cycle consists of evaporation, compression, condensation and expansion. Evaporation and condensation are designed to alter the quantity of energy associated with the refrigerant. Compression and expansion are designed to change the availability of the assoc iated energy. The refrigeration cycle is a closed loop process. The ammonia cycle utilizes fluid temperature, pressure and latent heat of vaporization for cooling. The refrigeration system uses this phenomenon to remove heat from a desired space, and then to discard that heat through condensation, to an area where it is of no consequence. The Florida Global facility uses ammonia refrigeration to maintain storage room, freezers and processing area temperatures for the citrus products they produce. The refrigeration systems contain the following equipment: Seventeen compressors, seven evaporative condensers, thirty eight vessels, thirty cooler/freezer evaporators, five chillers and a system purger. The refrigeration systems contain the following amounts of ammonia: Machine Room #1, 4,300 pounds, Machine Room #2, 21,800 pounds, Machine Room #3, 14,000 pounds and Machine Room #4, 5,000 pounds of aggregate ammonia. There are approximately 150 employees at this facility during peak season, t his includes hourly and salary personnel. This facility processes frozen citrus products approximately 24 hours a day, five days a week. The potential hazards that could lead to an accidental release of the ammonia include, but are not limited to, equipment failure, damage to piping, damage to equipment, human error, etc. Although ammonia is a colorless, tasteless liquid, it's dominant characteristic is it's pungent, distinct odor. Persons exposed to ammonia will not voluntarily stay in areas of even small concentrations, although these levels would not normally result in any health risks. Risks from accidental exposure to ammonia in a vapor state are irritations to the eyes, nose and throat. The extent of irritation depends on the exposure amount and length of time exposed. Ammonia is classified non-flammable by the Department of Transportation. Ammonia will burn, but only in a very narrow concentration level when accompanied with a constant ignition source. 3. Worst case and alternate case release scenarios including administrative and engineering controls to limit/ prevent accidental release. Worst case scenario depicts continuous source leak from the High Pressure Receiver located just outside machine room #2. This vessels normal operating level is 9,000 pounds of liquid ammonia, approximately 50% of it's total capacity. Although the receiver is capable of holding 18,000 pounds of liquid ammonia, this far exceeds company policy and engineering controls which limits the liquid level within the receiver. Considering the "catastrophic" possibility does exist for this vessel to release it's entire contents, engineering controls incorporated into the system would normally prevent such a release. Worst case release scenario criteria for the Florida Global Citrus facility: Ammonia Quantity: 9,000 pounds Rate of Release: 900 lbs / min. (10 min. release) LOC (Level of Concern): 200 ppm (EPA ERPG-2) Physical State: Gas Type of Area: Urban Wind Speed: 1.5 m/sec Distance to Endpoint 1.7 miles Alternate release scenario is represented by the release of ammonia vapor from a safety relief valve (SRV) due to an overpressurization condition on the controlled pressure receiver vessel located outside machine room #2. The indicated relief valve would be performing exactly as it is designed to do during an overpressurization condition. Valve would open to relieve the over- pressure and vent immediatley into the atmosphere. Alternate case release scenario criteria for Florida Global Citrus facility: Ammonia Quantity: 366 pounds Rate of Release: 32 pounds/min. (22 min. release) Wind Speed: 3.0 m/sec. Distance to Endpoint: .1 miles The f ollowing administrative and engineering controls are in place at Florida Global Citrus. These controls are designed to eliminate, or reduce the possibilities of an accidental release from the refrigeration system. * High level alarms are installed on all pressure vessels that are configured directly to a compressor. Associated compressor will shut down if a high level condition is sensed by the level alarm. All four (4) machine rooms are configured with this shut-down system. * All compressors are configured with critical safety controls (high pressure, low pressure, high oil temp cut-outs, etc.) to shut down the respective compressor in the event of an abnormal operating condition. * Safety Relief Valves are configured to all pressure vessels, condensers and compressor oil separators to eliminate over pressurization conditions in those associated pieces of equipment. * System wide shut-down is installed in all machine rooms. If system head pressure rises above a pre-determined set point the refrigeration equipment will shut down automatically. * Periodic Maintenance Program is incorporated into the maintenance department to ensure the refrigeration system and it's components are kept in optimum mechanical and operating status. * Refrigeration personnel on site twenty four (24) hours a day, five days a week. Security monitors equipment head pressure every hour during weekends. If an abnormal condition is present, security notifies refrigeration personnel via pager. 4. Five-year accident history. Florida Global Citrus has had zero accidental releases to report during the last five (5) years. 5. Emergency Response Program The purpose of the Florida Global Emergency Action Plan is to: 1. Minimize exposure to our employees and the surrounding community in the event of a hazardous material release or spill. 2. Assure the safe emergency evacuation of the plant in the instance that it is required. 3. Provide for prompt medical attention to any employees who become seriously injured or ill at work. 4. Facility management has developed an Emergency Response Plan to ensure a fast and efficient response in the event of an accidental release of hazardous materials. Our Emergency Action Plan currently meets requirements as set forth in OSHA 29 CFR 1910.38, Employee Emergency and Fire Prevention Plans. |