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GreenGate Fresh Salinas

Parent Companies:
GreenGate Fresh, LLLP
EPA Facility ID:
100000221459
Other ID:
Facility DUNS:
0
Parent Company DUNS:
0

Location:

Address:
1222 Merrill Street
Salinas, CA 93901
County:
MONTEREY
Lat / Long:
36.646, -121.634 (Get map)
Method:
Interpolation - Digital map source (TIGER)
Description:
Center of Facility
Horizonal accuracy:
5 m
Horizontal reference datum:
World Geodetic System of 1984
Source map scale:

Owner/Operator:

Name:
GreenGate Fresh, LLLP
Phone:
(831) 783-1601
Address:
1222 Merrill Street
Salinas, CA 93901
Foreign Address:

Person responsible for RMP implementation:

Name:
Robert Gleim
Title:
Sr. Maintenance/Facilities Manager

Emergency contact:

Name:
Robert Gleim
Title:
Sr. Maintenance/Facilities Manager
Phone:
(928) 446-1198
24-hour phone:
(928) 446-1198
Ext or PIN:

Other contacts:

Facility (or company) email:
Facility phone:
Facility (or company) URL:

Safety:

Local Emergency Planning Committee:
Region II LEPC
Full-Time Equivalent Employees:
278
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
No
CAA Permit ID#:
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
June 5, 2017
Inspecting Agency:
Monterey County CUPA
Using Predictive Filing:
No

Processes:

Ammonia Refrigeration
RMP ID:
1000086533
CBI claimed:
No
Program Level:
3
NAICS:
Postharvest Crop Activities (except Cotton Ginning) (115114)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
16,900
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
KIE Consulting, LLC
Address:
8 Harris Rd.
Ste. A-8
Monterey, CA 93940
Foreign Address:

Phone:
(831) 218-1802

Latest RMP Submission:

Date:
April 5, 2018
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000069037

Deregistration:

Date:
Effective Date:
Reason:
Other Reason:

2. Toxics: Worst-case

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Ammonia Refrigeration)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
Areal Locations of Hazardous Atmospheres [ALOHA(R)]
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps

3. Toxics: Alternative release

Some Risk Management Plan information is not provided in the available RMP data. You need to make an appointment at an EPA Reading Room In order to get access to details from the Off-Site Consequence Analysis (OCA) such as:

Instructions on how to make an EPA appointment can be found here.

Public OCA Chemical (in Ammonia Refrigeration)
CBI claimed:
No
Percent weight:
100.0
Physical state:
Gas liquified by pressure
Model used:
Areal Locations of Hazardous Atmospheres [ALOHA(R)]
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Urban
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • None
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers
  • Emergency shutdown

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

Oct. 23, 2017 at 18:30
ID:
1000053737
NAICS:
Postharvest Crop Activities (except Cotton Ginning) (115114)
Duration:
1 hours and 30 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Weather conditions at time of event
Wind speed:
8.0 miles/h E
Temperature:
75.00 ℉
Atmospheric stability:
E
Precipitation present:
No
Unknown weather conditions:
No
On-site impacts
Deaths of employees or contractors:
0
Deaths of public responders:
0
Deaths of public:
0
Injuries of employees or contractors:
4
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
300
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Equipment failure
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Revised maintenance

7. Prevention: Program level 3

Ammonia Refrigeration, Postharvest Crop Activities (except Cotton Ginning) (115114)
Prevention Program ID:
1000073111
Safety Review Date
Feb. 7, 2018
PHA Update Date
March 21, 2018
PHA Techniques
  • What if/Checklist
  • HAZOP
Hazards Identified
  • None
Process Controls
  • Vents
  • Relief Valves
  • Check Valves
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
Mitigation Systems
  • None
Monitoring Systems
  • Process Area
Changes since PHA
  • None
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Demonstration
  • Observation
Procedure Review Date
Sept. 7, 2017
Training Review Date
March 22, 2018
Maintenance Review Date
March 22, 2018
Maintenance Inspection Date
Feb. 7, 2018
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 29, 2016
Management of Change Review Date
March 22, 2018
Pre-startup Review Date
Dec. 15, 2016
Compliance Audit Date
Oct. 31, 2016
Compliance Audit Change Completion Date
Oct. 31, 2019
Incident Investigation Date
Oct. 23, 2017
Incident Invest. Change Completion Date
Oct. 24, 2017
Participation Plan Review Date
March 22, 2018
Hot Work Review Date
March 22, 2018
Contractor Safety Review Date
March 22, 2018
Contractor Safety Eval. Date
July 14, 2017

8. Prevention Program level 2

No Prevention Program level 2

9. Emergency response

Facility In Community Plan:
Yes
Facility Own Response Plan:
No
Specific Facility Response Plan:
Yes
Inform. Procedures in Response Plan:
No
Emergency Care in Response Plan:
Yes
Plan Review Date:
Response Training Date:
Oct. 23, 2017
Local Response Agency:
Local Response Agency Phone:
(831) 755-4511
Subject To - OSHA EAP:
No
Subject To - OSHA HAZWOPER:
Yes
Subject To - CWA:
No
Subject To - RCRA:
No
Subject To - OPA:
No
Subject To - State EPCRA:
Yes
Subject To - Other:

Executive Summary

A. RMP EXECUTIVE SUMMARY COMPONENT

[40 CFR 68.155]

1. Accidental Release Prevention and Emergency Response Policies

GreenGate Fresh, LLLP conducts inspection procedures to review refrigeration equipment prior to startup and during operations. These procedures identify potential sources of release and equipment corrections required to prevent these releases. On-site personnel and certified refrigeration contractors review the equipment as required.

On-site personnel provide initial emergency response. On-site personnel will make a preliminary assessment in the event of a release and will provide first response. First response may include emergency equipment shutdown, system isolation, or controlled operation such as pump down to prevent or reduce an off-site release. No emergency operations will be performed that are beyond the capabilities of the operators or other on-site personnel. Local fire and police departments with mutual aid response will provide emergency response for a major release event. The refrigeration contractors would also be on-call to provide emergency response.

Emergency response training will be conducted yearly for current employees and as required to for new employees. Records will be kept of all training performed at the site for a minimum of five (5) years.

2. Stationary Source and Regulated Substances Handled

The GreenGate Fresh, LLLP facility acts as a stationary source for regulated substance anhydrous ammonia. The ammonia system is used for cold storage and produce pre-cooling, water chilling and vacuum cooling operations. The facility operates seasonally April through October as produce precooling, processing, cold storage and shipping. To see a location map and site plan of the stationary source, refer to facility drawings in Appendix A.2.

The ammonia refrigeration system was constructed as per applicable codes and industry standards in 2013 as part of the newly constructed GreenGate Fresh, LLLP facility. Refrigeration system i
s composed of both fixed and portable equipment. The fixed equipment includes, pressure vessels ammonia pumps, evaporative condenser, room evaporators, diffusion tank, ammonia sensors, control system and related piping. Portable equipment includes three refrigeration high side trailers, two half car vacuum tubes and a compressor skid. High side trailers have evaporative condenser, screw compressor(s) and high pressure receiver. Portable equipment stays onsite seasonally between April through October. The main high pressure receiver, low pressure receiver three chillers, and evaporators stay on site all the time. All refrigeration equipment, except room evaporators, are located outdoors. At the end of the operating season, all ammonia charge is pumped down to high pressure receiver and low pressure receiver and stays on site.

All compressors have safety switches that would shut down the compressors upon detection of unsafe operating conditions. Cold room evaporators are controlled by the Refrigeration Control Panel located in electrical room. There are ammonia detectors in the cold rooms for alarming and notifying fire alarm company which notifies the facility manager if the ammonia vapor detected in the cold room. Ammonia detection controller is located in fire alarm panel room. All pressure vessels and compressors are protected against high-pressure situations by safety relief valves. Low pressure receiver triggers a local audio visual alarm if the high liquid level is reached in the vessel. There are assigned responders (refrigeration contractors) experienced with ammonia refrigeration that would respond to and determine specific actions for any incident.

The ammonia refrigeration system is a single-stage vapor compression cycle. In general, the process chemistry from this system is shown in Section V.A.2. The total ammonia charge of approximately 16,900 lb is completely sealed and pressurized within the system.

Refrigeration system drawings are located in App
endix A.2. A list of refrigeration equipment used at this facility can be found in the schedules located on sheet R0.0. International Institute of Ammonia Refrigeration (IIAR) "Ammonia Refrigeration Safety Inspection Checklists", located in Appendix A.1, describe equipment details. Sheets 2.0 and 2.1 in Appendix A.2 show the refrigeration equipment layout.

Anhydrous ammonia (NH3) is a gas in its natural state and is extremely irritating to mucous membranes and lung tissue. The gas is pungent and may be suffocating as shortness of breath and labored breathing can develop if inhaled. Prolonged inhalation of high concentrations may cause bronchitis and/ or pneumonia, with some residual reduction in pulmonary functions. Repeated or prolonged contact of high concentrations of ammonia to the skin can cause frostbite, redness, pain and serious skin burn. See Appendix A.4 Safety Data Sheets (SDS) for anhydrous ammonia.

3. General Accidental Release Prevention Program

GreenGate Fresh, LLLP maintains a release prevention program to eliminate or minimize releases. The program includes regular inspections, monitoring equipment and logging conditions, scheduled maintenance, and operator training. There is a program to analyze releases for ways to prevent a similar future release, see Appendix J-Incident Investigation.

GreenGate Fresh, LLLP is a "Non-Responding facility". Facility is only respond to situations that are within their capabilities. These may include, emergency shutdown, equipment isolation and pumping down the system. No emergency response actions or site clean-up that are beyond the capabilities of the refrigeration personnel will be performed. In case of an emergency, incident will be reported immediately to Facility Managers, RMP administrator and designated Emergency Responders as outlined in Section VI.

The ammonia refrigeration system has specific safety procedures to prevent a release. Refrigeration contractors and facility technicians are trained for sa
fe operation and maintenance of the refrigeration system. All the compressors are controlled by local microprocessors which shuts down the compressors if the operating conditions exceeds the normal operating limits. The facility has ammonia detectors in the cold rooms that triggers audio visual alarm inside the cold room notifying the employee of an ammonia leak. Monitoring is 24 hours per day during the operating season. The relief valves in the system are all tied into the diffusion tank.

4. Five-Year Accident History

GreenGate Fresh, LLLP was constructed and started operation in 2013. On October 23, 2017 a release occurred causing onsite evacuation of personnel and offsite consequences. The release emanated from screw compressor #1 on the GGF-RT 12/14 high side trailer. The oil separator man-way gasket failed releasing approximately 1,871 lb of anhydrous ammonia. The equipment failed on the manway cover gasket as it was pushed out between the cover and the separator. Neighboring businesses also evacuated due to the release. The Salinas Fire Dept. was contacted upon discovery. The release was mitigated within an hour by the facility refrigeration contractor and the Fire Dept. allowed resumption of operation thereafter. There were four GreenGate employees who received medical attention at a nearby hospital, complaining of respiratory issues. All four were released following medical examination and went to work the following day. An Incident Investigation was initiated by a team of qualified personnel. A copy of the detailed Incident Investigation is maintained onsite and readily available upon request.

5. Emergency Response Program

In event of a release, certain personnel are designated to determine the potential hazard and coordinate response procedures. The Safety Coordinator is responsible in coordinating emergency action plan and will be contacting emergency response agencies, schools, daycare centers, and acute care facilities that may be affected by the
release. The Safety Coordinator will also be responsible for evacuation of employees if necessary and for coordination with community emergency responders if off-site evacuations are required. Description of the emergency action plan is included in Appendix N.

6. Planned Changes to Improve Safety

Recommended corrective actions to mitigate the potential for an accidental ammonia release are proposed on the tables located in Section VIII. The table items are a result from recommendations made during the Process Hazard Analysis, a Code Compliance Review, and a Safety Inspection performed by a qualified person. Some corrective items in the recommendation table originate from multiple codes but are listed only once. Based on the severity of the hazards identified, implementation deadlines are also recommended.

All refrigeration equipment is well maintained and operated in a safe manner by trained personnel. Operating, maintenance, training, and safety procedures will be formalized with improved written documentation.



Note: All references above may be found within the onsite facility RMP.