Costco Wholesale - Mira Loma - Executive Summary |
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ACCIDENTAL RELEASE PREVENTION AND EMERGENCY RESPONSE POLICIES The Costco Wholesale facility has an emergency action plan in effect. The Emergency Action 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. 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 Construction of the ammonia refrigeration system at Costco Wholesale was completed in 1997. The facility is located at 11600 Building B Riverside Drive, Mira Loma, California 91752. The system was constructed in accordance with all applicable federal, state, and local regulations including the Uniform Fire and Mechanical Codes. The 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 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. HAZARD ASSESSMENT SUMMARY * Worst Case Release Result Summary Scenario Description: Release of the maximum quantity of ammonia that can be stored in a vessel - 14,000 pounds in 10 minutes. The most pe ssimistic meteorological 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 in rural conditions. 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 33 pounds per minute. The meteorological conditions used were 3 meters per second wind speed, and D stability. A modeling program, Degadis, was used to determine the maximum downwind distance to the toxic endpoint of 200 ppm in rural conditions. This release reaches off site and may impact population receptors. No environmental receptors were affected by this potential re lease. ACCIDENTAL RELEASE PREVENTION PROGRAM AND CHEMICAL-SPECIFIC PREVENTION STEPS The Costco Wholesale 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 Costco Wholesale facility operates in accordance with OSHA's Process Safety Management regulation. Refrigeration contractors, experts in the ammonia refrigeration industry, are contracted at the facility to maintain the system. The Costco Wholesale facility including each ammonia system was designed and constructed in accordance with the Uniform Mechanical Code which specifically outlines requirements for the safe operation of the ammonia refrigeration system. These safety features include a water diffusion tank, ammonia sensors in the machine room as well as sensors in selected cold storage areas, and automatic shut down systems. In addition, the majority of the ammonia is maintained ins ide the machine room and just outside of the machine room (condensers). All pressure vessels are equipped with pressure relief valves that are commonly piped to the water diffusion tank. 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 including the ammonia refrigeration system has been in operation since late 1997. There have been no ammonia accidents at the facility. EMERGENCY RESPONSE PROGRAM The Costco Wholesale has an emergency action plan in effect at the facility. The Emergency Action 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 p rotect 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 due to the renovation of the facility. In case of an ammonia emergency, Costco Wholesale plans to evacuate all employees stationed in the cold storage warehouse and alert the local emergency responders (fire department). Costco Wholesale plans to coordinate emergency response efforts with the fire department on a periodic and ongoing basis. PLANNED CHANGES TO IMPROVE SAFE TY The Process Hazard Analysis and Hazard Assessment (Off-Site Consequence Analysis) provided mitigation measures to improve safety at the Costco Wholesale facility located at 11600 Building B Riverside Drive in Mira Loma, California. All recommendations from the technical studies are implemented and deemed complete. The facility has worked to address safety issues as they arise in a continued effort to ensure a safe work environment. The management at Costco Wholesale is planning to continue with this program as follows: 1. Follow manufacturer's maintenance recommendations regarding all ammonia equipment including sensors, compressors, and evaporators. 2. Continue to inspect the vessels and other equipment on a regular basis to ensure the ongoing integrity of the equipment. 3. Do not store drained waste oil or other flammables in engine room. 4. Perform and document periodic test of mechanical float control on each accumulator to ensure proper functionality. 5. Perform regular maintenance activities on condensers including testing the pH of the water. (Higher than normal pH indicates an ammonia leak.) 6. Invite the fire department (or appropriate emergency responders) to participate in ammonia emergency drills. Explain the purpose and the design of the control box to them. |