Alliant Foodservice- Cincinnati - Executive Summary

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                        ALLIANT FOODSERVICE, INC. 
                         RISK MANAGEMENT PROGRAM 
                                                     EXECUTIVE SUMMARY 
1.  General accidental release and prevention policy of Alliant Foodservice. 
In this frozen food distribution center 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 Alliant Foodservice 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 minimize the 
risk of an accidental release of hazardous materials. Safety depends di 
rectly 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. 
Alliant Foodservice, 5445 Spellmire Drive, Cincinnati, Ohio operates a refrigeration system 
utilizing anhydrous ammonia as the primary refrigerant. The refrigeration system is located on the 
north side of the facility in an enclosed two story section of the main building.  
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 designe 
d to change the availability of the associated 
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 Alliant Foodservice facility uses ammonia refrigeration to maintain storage room 
temperatures for various types of fresh and frozen food distributed to their customers. The 
refrigeration system contains the following equipment: Four screw compressors, two evaporative 
condensers, two controlled pressure receivers, two accumulators, four transfer drums, six loading 
dock evaporators, thirteen cooler evaporators, a floor warming heat exchanger and a system 
purger. The refrigeration system contains 10,500 pounds of aggregate ammonia. 
There are approximately 100 employees at this facility which inc 
ludes hourly and salary personnel.  
This distribution facility receives and prepares shipment of frozen and refrigerated food products 
via tractor trailers approximately 24 hours a day, six 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 concentr 
ation 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 (HPR) 
located inside the plant vessel room.  This vessels normal operating level is 1,400 pounds of liquid 
ammonia,  approximately 50% of it's total capacity. Although the high pressure receiver is capable 
of holding 2,800 pounds, this far exceeds company policy  and engineering controls which limits 
the liquid level to a maximum of 80% at any time.  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 Alliant Foodservice facility: 
    Ammonia Quantity:                  1,400 pounds 
    Rate of Rele 
ase:                   140 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                    .75 miles 
Alternate release scenario is represented by the release of ammonia vapor from a safety relief 
valve (SRV) due to an overpressurization condition on a vertical vessel located within the Alliant 
Foodservice facility vessel room. 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 into the atmosphere via the roof vent pipe. 
    Alternate case release scenario criteria for Alliant Foodservice facility: 
    Ammonia Quantity:                  100 pounds 
    Rate of Release:                         20 pounds/min. (11 min. release) 
  Wind Speed:                        3.0 m/sec. 
    Distance to Endpoint:                   140 yards 
    The following administrative and engineering controls are in place at Alliant 
Foodservice. These controls are designed to eliminate, or reduce the possibilities of an 
accidental release from the refrigeration system. 
    *  Electronic ammonia detection in compressor, vessel and distribution areas.  Alarms tie 
in to ADT Security system.  Computer system activates a local audible alarm indicating an 
ammonia leak in the monitored areas. ADT notifies designated emergency personnel of the 
potential problem detected by the system. 
    *  High level switches are configured to high and low temp accumulators which shut down 
compressor operation and close liquid make-up feed solenoid valves during a high level condition. 
    * All compressors are configured with critical safety controls (high pressure, low pressure, 
high oil temp cut-outs, etc.) to sh 
ut 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. 
    *  Periodic Maintenance Program is contracted through a reputable refrigeration company 
to ensure the refrigeration system and it's components are kept in optimum mechanical and 
operating status. 
4.  Five-year accident history. 
The Alliant Foodservice, Inc. facility at Cincinnati has had zero accidental releases to report.  
5.   Emergency Response Program 
The purpose of the Alliant Foodservice 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.  
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