Alliant Foodservice - Phoenix - Executive Summary |
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ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES The Alliant Foodservice facility has an emergency response plan in effect. 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. Alliant 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 chang es. STATIONARY SOURCE AND REGULATED SUBSTANCE The Alliant Foodservice ammonia refrigeration system has been in operation since 1989. Changes/modifications have taken place since the completion of the facility with the most recent change occurring on November 22, 1999. This change included the addition of evaporators for cold storage and processing areas. The ammonia refrigeration process was designed and constructed in accordance with all applicable federal, state, and local regulations. The facility is located at 4650 W. Buckeye Road, Phoenix, Arizona 85043. The ammonia refrigeration system uses 17,132 pounds of ammonia for dock operations, warehouse cold storage, and freezer storage. The majority of the system is located in the machine room including vessels and compressors. The condensers are mounted at ground level outside the machine room as well as the water tank, and all of the evaporators are located in their respective cold storage rooms/areas. HAZARD ASSESSMENT SUMM ARY Worst Case Release Result Summary Scenario Description: Release of the maximum quantity of chlorine that can be stored in a vessel - 12,000 pounds in 10 minutes. The most pessimistic meteorological conditions were used: 1.5 meters/second wind speed, rural topography, and F stability. The SLAB modeling program was used to calculate the downwind distance. This release reaches off-site and could impact population receptors. No environmental receptors are affected by this potential release. Alternative Release Result Summary Scenario Description: A release of ammonia gas from a 1/4 inch diameter leak. The release rate of ammonia due to the pressure of the tank is 100 pounds per minute. The meteorological conditions used were 3 meters per second wind speed, rural topography, and D stability. The SLAB modeling program was used to calculate the downwind distance. This release reaches off-site, but is not likely to impact population receptors. No environmental receptors are aff ected by this potential release. ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS The Alliant Foodservice facility was designed and constructed in accordance with the Uniform Mechanical Code which specifically outlines requirements for the safe operation of ammonia refrigeration systems. 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 machine room or outside of the machine room (condensers). 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 has been in operation since 1989 with the most recent change/mo dification taking place in November 1999. There is no accident history at this facility. EMERGENCY RESPONSE PROGRAM The Alliant 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. Alliant 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 due to the renovation of the facility. PLANNED CHANGES TO IMPROVE SAFETY A Process Hazard Analysis was performed on July 21, 1998 along with a walthrough of the facility occurring in October 8, 1998. This study provided the mitigation measures outlined below to improve safety at the Alliant Foodservice facility located at 4650 W. Buckeye Road, Phoenix, Arizona. Recommendations R01 through R31 have been complete as of June 30, 1999. R01 Determine the concentration level at which ammonia sensors will activate the audible alarm. A different alarm (buzzer) is activated for a compressor shut down. R02 Ensure that the emergency kill switch is adequately located outside of the engine room from the exit doors. Include the procedures for activating the kill switch and personnel responsible in the emergency response plan. R03 Establish a workable emergency response plan that includes an emergency coordinator, evacua tion procedures, notification of employees, and evacuation drills that are possible for all shifts at the facility. R04 Coordinate with the local fire department to verify that they will be emergency responders in the event of an ammonia leak. R05 Ensure that at least one Alliant Foodservice employee is knowledgeable in the shut down procedures of the refrigeration system. R06 Develop and implement a contractor safety program to ensure that contractors are qualified and have received appropriate ammonia operating and emergency response procedures. R07 Include in the Mechanical Integrity program a procedure to replace or recertify relief valves every five years or if one unseats. R08 Include daily, weekly, monthly, etc. inspection criteria in the maintenance program. R09 Include in the Training program that all personnel at the facility are informed that ammonia is present, the smell associated with it, and what to do if they smell ammonia. Those employees who work on the s ystem should know the hazards. Precautions should be taken such as wearing eye protection when working on the system. R10 Include in the Mechanical Integrity program to annually test high shut down on compressors by manually tripping float. R11 Include in the Operating Procedures program an oil draining procedure. Ensure free access to an exit in case of an emergency. R12 Obtain a written schedule from Industrial Refrigeration and include it in the Mechanical Integrity program. R13 Plan emergency evacuation assembly area away from manholes since ammonia will be present in the sewer system. R14 Include in the Mechanical Integrity program to annually check alarm and compressor/pump shut down. R15 Ensure that at least two people are present for maintenance/repairs performed on the refrigeration system on the facility roof. Periodic pipe walks on the roof need only be completed by one person with a radio. R16 Include in the Mechanical Integrity program that evaporators sho uld be kept clean and drains maintained in working order. R17 Include in the Training program to inform all employees at the facility that ammonia is present, the smell associated with it, and what to do if they smell ammonia. R18 Determine a method to account for all truck drivers on site. Ensure that they are all made aware of the presence of ammonia at the facility. R19 Include a regular maintenance program to check compressors of all cut-outs and safeties. Follow manufacturers maintenance procedures. R20 Include in the Mechanical Integrity a daily log sheet of all the compressors temperatures and pressure. R21 Establish a lockout - tagout program and/or confined space entry as necessary when performing maintenance on the condenser. R22 Include in Mechanical Integrity to periodically check condenser fans. R23 Include in the maintenance program to take water samples of the Water Diffusion Tank regularly and to treat water to regulate bacterial growth. R24 Include in the Mechanical Integrity program to maintain and calibrate ammonia sensors on a regular basis. R25 Consider installing an additional emergency shut off button inside the dry warehouse. If not, determine an additional method of shutting down the system in an emergency (i.e. MCC). R26 Ensure that a lockout/tagout program is followed by whoever performs maintenance/ cleaning on the condensers. R27 Place wind socks (or other wind direction indicators) in locations that can be seen from all potential emergency exits (i.e. engine room roof, receiving roof, shipping roof). R28 Ensure that ammonia safety placards are installed on all doors to the ammonia engine room. R29 Establish a procedure to periodically check the pH of the water in the diffusion tank. Also ensure that the water is treated to prevent undesired growth. R30 Consider installing an additional eye wash/safety shower station outside the ammonia engine room near the condensers. R31 Consider installing strobe ligh ts outside the engine room doors that are activated when ammonia is sensed in the engine room to alert people of an ammonia leak. The following recommendations (MOC1 through MOC4) were created due to the change that occurred on November 22, 1999. These were completed as of December 4, 1999: MOC1:Ensure that evaporators and associated piping are located high enough such that they will not be accidentally hit by forklifts. Notify, forklift operators of the location of the additional and relocated evaporators and associated piping. MOC2:Review the need/location for eyewash/safety showers in the new building. MOC3:Ensure that safe access to the evaporators and associated piping is proivided (i.e. roof access or man-lifts.) MOC4:Complete the Safety Review checklist included in the Management of Change Forms. |