Costco Wholesale - Tracy - Executive Summary

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

ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES 
 
The Costco Wholesale 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. 
 
Costco Wholesale 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 well as to incorporate facility 
changes. 
 
STATIONARY SOURCE AND REGULATED SUBSTANCE 
 
Two distinct ammonia refrigeration systems are in operation at the facility: the Chill Plant and the Meat Plant.  They are situated in different buildings on the same property. 
 
Construction of the Chill Plant ammonia refrigeration system at Costco Wholesale was recently completed.  Startup of the ammonia refrigeration system occurred on September 9, 1998 with Costco Wholesale personnel taking full responsibility for operating the entire facility in late September 1998.  The Meat Plant has been in operation since 1993.  The facility is located at 25862 S. Schulte Court, Tracy, California 95376.  Each system was constructed in accordance with all applicable federal, state, and local regulations including the Uniform Fire and Mechanical Codes. 
 
The Chill Plant ammonia refrigeration system uses 14,000 pounds of ammonia for cross dock operations, warehouse cold storage, and freezer storage.  The majority of the system is located in the  
Chill Plant machine room including vessels and compressors.  The condensers are mounted on the engine room roof, and all of the evaporators are located in their respective cold storage rooms/areas. 
 
The Meat Plant ammonia refrigeration system also uses 14,000 pounds of ammonia for meat processing equipment, warehouse cold storage, and freezer storage.  The majority of the system is located in the Meat Plant machine room including vessels and compressors.  The condensers are mounted on the machine room roof and all of the evaporators and process freezers are located in their respective cold storage rooms/areas. 
 
HAZARD ASSESSMENT SUMMARY 
 
*  Worst Case Release Result Summary 
 
   Scenario Description: Chill Plant - Release of the maximum quantity of ammonia that can be stored in a vessel - 14,000 pounds in 10 minutes.  The most pessimistic meteorological conditions were used: 1.5 meters per second wind speed, and F stability.  The SLAB modeling program was 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 is 100 pounds per minute.  The meteorological conditions used were 3 meters per second wind speed, and D stability.  The SLAB modeling program was used to determine the maximum downwind 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.  This scenario could occur at either plant.  Due to the location of the processes, the consequences of the release are the same. 
 
ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS 
 
The Costco Wholesale facility including ea 
ch ammonia system 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 container, ammonia sensors in the machine rooms 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 and just outside of the machine room (condensers).  All pressure vessels are equipped with pressure relief valves. 
 
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 1993 (the inception of the Meat Plant).  The Chill Plant was started up in 1998.  There 
have been no ammonia accidents at the facility. 
 
EMERGENCY RESPONSE PROGRAM 
 
The Costco Wholesale 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. 
 
Costco Wholesale 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 well as t 
o incorporate facility changes due to the renovation of the facility. 
 
Costco Wholesale has coordinated emergency response efforts with the local fire department.  Costco Wholesale holds evacuation drills to ensure all employees are aware of the expected evacuation response during an emergency. 
 
PLANNED CHANGES TO IMPROVE SAFETY 
 
The Process Hazard Analysis and provided mitigation measures to improve safety at the Costco Wholesale facility located at 25862 S. Schulte Court in Tracy, California.  All recommendations are scheduled to be complete by June 1999. 
 
Session 1 - Chill Plant HAZOP 
 
R01    Ensure that the ammonia sensors are interlocked to activate visual and audible alarms (at the alarm level) at various locations in the facility including at the engine room doors. 
 
R02    Ensure that the engine room has overhead water sprinkler capabilities. 
 
R03    Establish a procedure to replace relief valves every five years or any time one unseats. 
 
R04    Ensure that the bladder unit is p 
rotected from external corrosion and is periodically inspected. 
 
R05    Consider supplying ammonia sensors with emergency power. 
 
R06    Follow manufacturer's maintenance recommendations regarding all ammonia equipment including compressors, condensers, evaporators, pumps, and sensors. 
 
R07    Establish a procedure to ensure that all employees are aware of the presence of and the hazards associated with ammonia. 
 
R08    Ensure that eye wash/safety shower stations are accessible to all normal maintenance locations.  This could include portable stations for roof activities. 
 
R09    Ensure that operators are properly trained for use of all appropriate personal protective/safety equipment. 
 
R10    Develop an emergency response plan including evacuation procedures and assembly locations.  Include a method to account for all individuals on site. 
 
R11    Establish a procedure to manually test and document operation of high level shut down switches on the accumulator vessels at least annually. 
 
 
R12    Ensure that proper access is available for maintenance/repairs of evaporators and valve assemblies. 
 
R13    Establish programs for routine condenser maintenance and water treatment.  Consider contracting the water treatment service. 
 
R14    Ensure that operators alert somebody when performing maintenance/repairs on the roof. 
 
R15    Investigate necessity for Emergency Refrigerant Control Box.  Consider redesigning system to exclude component. 
 
Session 2 - Meat Plant HAZOP & Walkthrough 
 
R16    Establish and document a procedure to deal with a potential emergency situation when Bay Alarm Company contacts Costco Wholesale. 
 
R17    Consider installing additional emergency kill switches outside the internal engine room door and at some other location in the plant (i.e. administrative offices). 
 
R18    Establish and document a procedure to define when the system should be shut down during emergency situations and how to do it. 
 
R19    Establish and document an emergency response pl 
an to deal with a significant ammonia release. 
 
R20    Coordinate emergency response efforts with local emergency responders (fire department) and with the Chill Plant. 
 
R21    Ensure that operators walk through the engine room at least daily to audibly and visually observe the system. 
 
R22    Follow manufacturer's maintenance recommendations regarding all ammonia equipment including compressors, condensers, evaporators, pumps, and sensors. 
 
R23    Establish a procedure to exercise the king valve (and other key valves in the system) at least annually and document doing so. 
 
R24    Consider installing the capability to shut down all electrical equipment in the area of the engine room during an ammonia release. 
 
R25    Establish a program to ensure that all employees are aware of the presence of and the hazards associated with ammonia. 
 
R26    Ensure that operators are properly trained for the use of all appropriate emergency response/personal protective/safety equipment (i.e. SCBAs). 
 

27    Ensure that the electronic level indicator/controller is tested and calibrated periodically. 
 
R28    Consider the feasibility of installing redundant mechanical float switches on the recirculator vessels that would shut down the appropriate compressors in the event of a failure of the Hansen level controller. 
 
R29    Ensure that oil draining procedures are established (and documented) and performed by trained personnel. 
 
R30    Establish programs for routine condenser maintenance and water treatment.  Consider contracting the water treatment service. 
 
R31    Ensure that an operator alerts somebody when maintenance/repairs are performed on the roof. 
 
R32    Ensure that a portable eye wash station or other water source is available for maintenance/repairs on the roof. 
 
R33    Place placards warning of the presence of ammonia on each engine room man door. 
 
R34    Ensure that the bladder unit is protected from external corrosion and is periodically inspected. 
 
Session 3 - Chill Plant 
Walkthrough 
 
R35    Install eye wash/safety shower stations so that they are easily accessible in and outside the engine room.  Ensure that outside piping is insulated from ambient heat. 
 
R36    Ensure that all piping is labeled as to the contents and the flow direction. 
 
R37    Place wind socks in locations that can be seen from all potential emergency exits (i.e. engine room roof, receiving roof, shipping roof). 
 
R38    Install ammonia safety placards on all doors to the ammonia engine room.
Click to return to beginning