Samuel Adams Brewery Company, Ltd. - Executive Summary

| Accident History | Chemicals | Emergency Response | Registration | Source | Executive Summary |

ANHYDROUS AMMONIA REFRIGERATION SYSTEM 
SAMUEL ADAMS BREWERY COMPANY, LTD. 
CINCINNATI, OHIO 
 
 
ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES 
 
We at Samuel Adams Brewery Co. are strongly committed to employee, public and environmental safety.  This commitment is inherent to a comprehensive Accidental Release Prevention Program in place that covers areas such as design, installation, operating procedures, maintenance, and employee training associated with the Anydrous Ammonia Refrigeration System process at our facility. 
 
It is our policy to implement appropriate controls to prevent possible releases of regulated substances.  Unforeseeably, if such a release does occur, we have coordinated Emergency Response procedures with the Cincinnati Fire Department which provides highly trained emergency response personnel to control and mitigate the effects of the release of ammonia. 
 
 
OUR FACILITY AND THE REGULATED SUBSTANCE HANDLED 
 
Samuel Adams Brewery Company uses Anhydrous Ammon 
ia as a refrigerant for cooling storage rooms, water, and beer in its operation at 1625 Central Parkway.  The Ammonia Refrigeration System consists of a main ammonia receiver tank, seven shell and tube heat exchangers, twenty-five evaporators, an ammonia vapor accumulator, eight compressors and three evaporative condensers. 
 
We only have one (1) regulated substance [Ammonia] present at our facility.  The maximum inventory of Ammonia at our facility is 13,200 lbs. recirculated through the various equipment pieces mentioned above. 
 
 
GENERAL ACCIDENTAL RELEASE PREVENTION PROGRAM AND THE CHEMICAL-SPECIFIC PREVENTION STEPS 
 
Our facility has taken all the necessary steps to comply with the Accidental Release Prevention requirements set out under 40 CFR Part 68 of the EPA regulations.  This facility was designed and constructed in accordance with both IIAR and ASHRAE Ammonia Refrigeration Standards. 
 
The following sections briefly describe the elements of our Accidental Release Prevention Pr 
ogram that are in place at our stationary source. 
 
Process Safety Information: 
 
Samuel Adams Brewery Co. maintains a detailed record of written safety information that describes the chemical hazards for ammonia, operating parameters and equipment designs associated with the ammonia refrigeration process. 
 
Process Hazard Review: 
 
Our facility has conducted a comprehensive study to ensure that hazards associated with the refrigeration process are identified and controlled efficiently.  The methodology used to carry out these hazard reviews is the HAZOP Methodology.  The studies are undertaken by a team of qualified personnel with expertise in refrigeration engineering and process operations and are re-validated at regular intervals of every four to five years.  Any findings related to the hazard reviews are addressed in a timely manner. 
 
Operating Procedures: 
 
For the purposes of safely conducting activities within our covered process, Samuel Adams Brewery Co. has written operating proce 
dures.  These procedures address various modes of operation such as normal operation, emergency shutdown, normal shutdown and normal startup after a maintenance activity.  The information is regularly reviewed by key personnel and is readily accessible to all operators involved with operating the ammonia refrigeration process. 
 
Training: 
 
Samuel Adams Brewery Co. has a training program in place to ensure that employees that are operating processes are completely competent in the operating procedures associated with these processes.  New employees receive basic training in process operations followed by on-the-job supervision until they are deemed competent to work independently.  Refresher training is provided at least every three years and more frequently as needed. 
 
Mechanical Integrity: 
 
Samuel Adams Brewery Co. carries out documented maintenance checks on process equipment daily to ensure proper functions.  Process equipment examined by these checks includes among others:  receiver 
tanks, piping systems, relief and vent systems, emergency shutdown systems, controls and pumps.  Maintenance operations are carried out by qualified personnel with previous training in maintenance practices.  Furthermore, these personnel are offered specialized training as needed.  Any equipment deficiencies identified by the maintenance checks are corrected in a safe and timely manner. 
 
Management of Change: 
 
Written procedures are in place at Samuel Adams Brewery Co. to manage changes in the process,  technology, equipment and procedures.  Operating Engineers, Maintenance Engineers or any other employee whose job tasks are affected by a modification in process conditions are involved with the Managment of Change Reviews and other employees are promptly made aware of and training is given to deal with the modification(s). 
 
Pre-Startup Safety Reviews: 
 
Pre-Startup Safety Reviews related to new processes and to modifications in established processes are conducted as a regular practice  
at Samuel Adams Brewery Co..  These reviews are conducted to confirm that construction, equipment, operating and maintenance procedures are suitable for safe startup prior to placing new or modified equipment into operation. 
 
Compliance Audits: 
 
Samuel Adams Brewery Co. conducts audits on a regular basis to determine whether the provisions set out under the RMP rule are being implemented.  These audits are carried out at least every 3 years and any corrective actions required as a result of the audits are undertaken in a safe and prompt manner. 
 
Incident Investigation: 
 
Samuel Adams Brewery Co. promptly investigates any incident that has resulted in, or could reasonably result in, a catastrophic release of a regulated substance.  These investigations are undertaken to identify the situation leading to the incident as well as any corrective actions to prevent the release from re-occurring.  All reports are retained for a minimum of 8 years. 
 
Employee Participation: 
 
Samuel Adams Brewery 
Co. truly believes that Process Safety Management and Accident Prevention is a team effort.  Company employees are strongly encouraged to express their views concerning accident prevention issues and to recommend improvements.  Our employees are involved with the Process Hazard Analysis, developing maintenance procedures, reviewing operating procedures, and lead the the Management of Change Process.  Our employees have access to all information created as part of the facility's implementation to the RMP rule. 
 
Contractors: 
 
On occasion, Samuel Adams Brewery Co. hires contractors to conduct specialized maintenance and construction activities.  Prior to selecting a contractor, an evaluation of safety performance of the contractor is carried out.  Samuel Adams Brewery Co. has a strict policy of informing the contractors of known potential hazards related to the contractor's work and the processes.  Contractors are also informed of all the procedures for emergency response should an accid 
ental release of regulated substances occur. 
 
 
FIVE-YEAR ACCIDENT HISTORY 
 
Samuel Adams Brewery Co. has had an excellent record of preventing accidental releases over the last 25 years.  Due to our preventative maintenance programs, daily refrigeration system checks, etc., the number of accidental releases has been reduced to a minimum. 
 
There have been no accidental releases of regulated substances from our facility within the last 5 years.   
 
 
EMERGENCY RESPONSE PLAN 
 
Samuel Adams Brewery Co. has written emergency response procedures to deal with any accidental releases of Ammonia.  The plans and procedures includes all aspects of emergency response including, evacuation, notification of local emergency response agencies, and adequate first aid and medical treatment. 
 
To ensure proper functioning, on-site emergency response equipment is regularly inspected and serviced.   
 
Should outside assistance be required, Cincinnati Fire Department is the primary response organization.  Hamilt 
on County LEPC is the Local Emergency Planning Committee with which Samuel Adams Brewery Co. interacts with to conduct joint drills, tests and the filing of Form R inventory reports. 
 
PLANNED CHANGES TO IMPROVE SAFETY 
 
Several developments and findings have resulted from the implementation of the various elements of our Accidental Release Prevention Program.  Below are some of the major steps we want to take to improve safety at our facility.  These changes are expected to be implemented by November 30, 1999. 
 
A.  Install new remote actuator on king valve. 
B.  Replace all relief valves in the refrigeration system. 
C.  Install high pressure trip switches on the hot gas line to the evaporative condensers.
Click to return to beginning