Unicold Corporation - Executive Summary |
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ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES The Unicold Corporation 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 document maintained at the facility. 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. Unicold Corporation 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 was reviewed and updated to ensure compliance with the PSM and RMP regulations, as wel l as to incorporate facility changes. STATIONARY SOURCE AND REGULATED SUBSTANCE The ammonia refrigeration system at Unicold Corporation was built in 1965. The facility is located at 3140 Ualena Street, Honolulu, Hawaii 96819. The system was constructed in accordance with all applicable federal, state, and local regulations. The ammonia refrigeration system uses approximately 11,000 pounds of ammonia for dock operations, warehouse cold storage, freezer storage, and food processing equipment. The majority of the system including vessels and compressors is located in two engine rooms plus a small additional room. The condensers are mounted on the main 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 - 6,000 pounds in 10 minutes. The most pessimistic meteorolog ical 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 from a 1/4 inch diameter hole in a pipe. The release rate of ammonia due to the pressure of the tank and the area of the hole is 134 pounds per minute. The meteorological conditions used were 3 meters per second wind speed, and D class 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 th is potential release. ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS The Unicold Corporation facility including the ammonia system was designed and constructed in 1965 in accordance with the appropriate building and fire codes. The Unicold Corporation 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 Unicold Corporation operates in accordance with OSHA's Process Safety Management regulation. Other safety features of the ammonia refrigeration system include: an ammonia sensor that sounds a facility-wide alarm, an emergency shut down button that kills power to the engine room equipment, relief valves on all pressure vessels, continuous ventilation in the main engine room to prevent ammonia explosions. In addition to the Uniform Mechanical Code, the facility will operate in accordance with the industry standard: the International Institute of Ammonia Refrigeration (IIAR) guidelines. In particular, the IIAR Bulletin 110, "Startup, Inspection, and Maintenance of Ammonia Refrigeration Systems" is used at the facility. FIVE YEAR ACCIDENT HISTORY There have been no ammonia accidents at the Unicold Corporation facility since June 1994. EMERGENCY RESPONSE PROGRAM The Unicold Corporation 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 the PSM/RMP document, which is maintained at the facility. 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. Unicold Corporation maintains a safety committee whose members are the designated emergency coordinators for the facility. The Plan provides the response organization and notification procedures, evacuation rou tes, 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 was reviewed and updated to ensure compliance with the PSM and RMP regulations, as well as to incorporate facility changes due to the renovation of the facility. PLANNED CHANGES TO IMPROVE SAFETY The Process Hazard Analysis generated mitigation measures (Recommendations) to improve safety at the Unicold Corporation facility located at 3140 Ualena Street, Honolulu, Hawaii 96819. Unicold Corporation would like to note that the following recommendations are complete: R02 through R16, R18, and R20. All other recommendations from the technical studies are scheduled to be complete by January 1, 2000. * HAZOP Study R01 Investigate and document the setpoint(s) and associated action(s) of the ammonia sensor currently in use in the main engine room. R02 E stablish and document a procedure to shut down the system in case of a major ammonia leak. R03 Consider installing a new ammonia detector that could automatically shut down the system and/or activate engine room exhaust fans. R04 Coordinate emergency response efforts with the local professional emergency responders (i.e. fire department). R05 Establish a policy to replace/recertify all pressure relief valves every five years or when used. R06 Establish a procedure to perform and document an annual visual inspection on the vessels in the system. R07 Verify that the liquid supply solenoid valve downstream of the High Pressure Receiver is interlocked to restart upon restoration of electrical services. R08 Ensure that outside contractors and Unicold employees are aware of the presence of and the hazards associated with ammonia. R09 Ensure that employees who are expected to perform emergency response actions are properly trained. R10 Establish a method to acc ount for all employees and contractors on site during an emergency evacuation situation. R11 Establish a procedure to alert the waste water treatment plant if liquid ammonia drains into sewer system. R12 Perform and document an annual test of all high level switches in the system that shut down compressors. R13 Establish a procedure to use an absorbent material to help dispose of pooled liquid ammonia. R14 Consider installing a spring-loaded valve on the liquid drain line on the oil pot at the high pressure receiver. R15 Ensure that operators (especially new hires) are properly trained for draining oil. R16 Determine if the drain in Engine Room 2 goes to the sewer system. R17 Follow maintenance/calibration recommendations on ammonia equipment including sensors, compressors, condensers, pumps. R18 Consider installing an emergency kill switch outside to shut down Engine Room 3, or provide training to use the power breaker for emergency shut down. R19 E nsure that a maintenance program is established for the condensers including water treatment and general maintenance. R20 Ensure that operators who are to perform maintenance on the condensers (facility roof) alert somebody of expected return time. * What-If Walkthrough R21 Consider installing audible and visual alarms outside the main engine room in the alley. R22 Update ammonia warning placards on the doors of Engine Rooms 2 & 3. R23 Place wind socks (or other wind direction indicators) in locations that can be seen from all potential emergency exits. R24 Investigate and document whether the ammonia detectors in the cold rooms activate visual alarms on the dock areas. |