Alliant Foodservice-Topeka - Executive Summary |
|
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, 4725 NW U.S. Highway 24, Topeka, Kansas 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 design ed 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: Five screw compressors, one evaporative condensers, one high pressure receiver, two recirculators, one surge drum, twenty six cooler/freezer evaporators, a floor warming heat exchanger and a system purger. The refrigeration system contains 23,000 pounds of aggregate ammonia. There are approximately 100 employees at this facility which includes hourly and salary person nel. 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 concentration level when accompanied w ith 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 machine room. This vessels normal operating level is 6,500 pounds of liquid ammonia, approximately 60% of it's total capacity. Although the high pressure receiver is capable of holding 10,000 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: 6,500 pounds Rate of Release: 65 0 lbs / min. (10 min. release) LOC (Level of Concern): 200 ppm (EPA ERPG-2) Physical State: Gas Type of Area: Rural Wind Speed: 1.5 m/sec Distance to Endpoint 2.7 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 high temperature recirculator vessel located within the Alliant Foodservice facility machine 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: 360 pounds Rate of Release: 35 pounds/min. (20 min. release) Wind Speed: 3.0 m/sec. Distance to Endpoint: .2 miles 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 room and distribution areas. Alarms tie in to Security system. Computer system activates a local audible alarm indicating an ammonia leak in the monitored areas. Security company notifies designated emergency personnel of the potential problem detected by the system. * High level switches are configured to high and low temp recirculators which shut down compressor operation during a high level condition. * 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. * 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 Topeka 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. |