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West Liberty Foods L.L.C.

Parent Companies:
Iowa Turkey Growers Cooperative
EPA Facility ID:
100000116769
Other ID:
52776LSRCH207WE
Facility DUNS:
0
Parent Company DUNS:
965099559

Location:

Address:
207 West 2nd Street
West Liberty, IA 52776
County:
MUSCATINE
Lat / Long:
41.569, -91.266 (Get map)
Method:
Interpolation - Other
Description:
Center of Facility
Horizonal accuracy:
50 m
Horizontal reference datum:
North American Datum of 1983
Source map scale:

Owner/Operator:

Name:
West Liberty Foods, L.L.C.
Phone:
(319) 627-6000
Address:
207 West 2nd Street
P.O. Box 318
West Liberty, IA 52776
Foreign Address:

Person responsible for RMP implementation:

Name:
Tom Alberti
Title:
Plant Manager

Emergency contact:

Name:
Michele Boney
Title:
Director of Env. , Health & Safety
Phone:
(319) 627-6000
24-hour phone:
(319) 627-6000
Ext or PIN:
6144

Other contacts:

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

Safety:

Local Emergency Planning Committee:
Muscatine County LEPC
Full-Time Equivalent Employees:
925
Covered by OSHA PSM:
Yes
EPCRA section 302:
Yes
CAA Title Air Operating Permit:
Yes
CAA Permit ID#:
70-02-004
OSHA Star/Merit Ranking
No
Last Safety Inspection Date:
Jan. 8, 2014
Inspecting Agency:
OSHA
Using Predictive Filing:
No

Processes:

Ammonia Refrigeration
RMP ID:
1000065668
CBI claimed:
No
Program Level:
3
NAICS:
Poultry Processing (311615)
Chemical name
CAS#
Quantity (lbs.)
CBI
Ammonia (anhydrous)
7664-41-7
98,000
No
Public OCA Chemical
0
No

RMP Preparer:

Name:
Ramiro Ramos
Address:
207 West 2nd Street
P.O. Box 318
West Liberty, IA 52776
Foreign Address:

Phone:
(319) 627-6059

Latest RMP Submission:

Date:
Sept. 24, 2015
Type:
Resubmission
Reason:
5-year update (40 CFR 68.190(b)(1))
Registered:
Yes
RMP ID:
1000052039

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:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Release duration (mins):
10.00
Wind speed (meters per sec):
1.5
Stability class:
F
Topography:
Rural
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:
Physical state:
Gas liquified by pressure
Model used:
EPA's RMP*Comp(TM)
Wind speed (meters per sec):
3.00
Stability class:
D
Topography:
Rural
Passive mitigation
considered:
  • None
not considered:
  • Dikes
  • Enclosures
  • Berms
  • Drains
  • Sumps
Active mitigation
considered:
  • Emergency shutdown
not considered:
  • Sprinkler systems
  • Deluge systems
  • Water curtain
  • Neutralization
  • Excess flow valve
  • Flares
  • Scrubbers

4. Flammables: Worst-case

None

5. Flammables: Alternative release

None

6. Five-year accident history

Sept. 20, 2015 at 16:30
ID:
1000040379
NAICS:
Poultry Processing (311615)
Duration:
2 hours and 30 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Gas release
Weather conditions at time of event
Wind speed:
3.0999999 miles/h S
Temperature:
74.00 ℉
Atmospheric stability:
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:
0
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
0
Medicals treatments:
0
Evacuated:
0
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
Initiating event:
Equipment Failure
Contributing factors:
  • Designed short comings
Off-site responders notified:
Notified Only
Changes introduced as a result of the accident:
  • Revised training
March 26, 2010 at 11:00
ID:
1000040378
NAICS:
Poultry Processing (311615)
Duration:
24 minutes
Chemicals involved:
  • Ammonia (anhydrous)
Release events:
Liquid spills/evaporation
Weather conditions at time of event
Wind speed:
15.0 miles/h E
Temperature:
43.00 ℉
Atmospheric stability:
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:
16
Injuries of public responders:
0
Injuries of public:
0
Property damage:
$0
Known off-site impacts
Deaths:
0
Hospitalizations:
16
Medicals treatments:
0
Evacuated:
423
Sheltered-in-place:
0
Property damage:
$0
Environmental damage:
  • Water contamination
Initiating event:
Equipment Failure
Contributing factors:
  • By-pass condition
Off-site responders notified:
Notified and Responded
Changes introduced as a result of the accident:
  • Improved/upgraded equipment
  • Revised maintenance
  • Revised operating procedures
  • Changed process

7. Prevention: Program level 3

Ammonia Refrigeration, Poultry Processing (311615)
Prevention Program ID:
1000054586
Safety Review Date
Aug. 3, 2015
PHA Update Date
April 9, 2015
PHA Techniques
  • What if/Checklist
Hazards Identified
  • Fire
  • Explosion
  • Corrosion
  • Contamination
  • Equipment failure
Process Controls
  • Relief Valves
  • Check Valves
  • Scrubbers
  • Manual Shutoffs
  • Automatic Shutoffs
  • Interlocks
  • Alarms
  • Emergency Air Supply
  • Backup Pump
  • Grounding Equipment
  • Purge System
Mitigation Systems
  • Fire Walls
  • Blast Walls
Monitoring Systems
  • Perimeter Monitors
Changes since PHA
  • Increased Inventory
  • Process Parameters
  • Process Controls
Training Type
  • Classrom
  • On the Job
Competency Testing
  • Observation
Procedure Review Date
Aug. 20, 2015
Training Review Date
Aug. 18, 2015
Maintenance Review Date
Dec. 4, 2014
Maintenance Inspection Date
April 30, 2015
Equipment Tested
Yes
Management of Change Most Recent Date
Jan. 30, 2015
Management of Change Review Date
Aug. 3, 2015
Pre-startup Review Date
Jan. 18, 2013
Compliance Audit Date
April 20, 2015
Compliance Audit Change Completion Date
Dec. 31, 2015
Incident Investigation Date
Sept. 21, 2015
Incident Invest. Change Completion Date
Nov. 26, 2015
Participation Plan Review Date
Aug. 3, 2015
Hot Work Review Date
Aug. 22, 2015
Contractor Safety Review Date
Oct. 23, 2013
Contractor Safety Eval. Date
April 30, 2015

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:
April 18, 2015
Local Response Agency:
Local Response Agency Phone:
(563) 288-2526
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

The West Liberty Foods facility (the Facility) produces food products, including primarily poultry. West Liberty Foods, LLC owns and operates the Facility. Iowa Turkey Growers Cooperative owns West Liberty Foods, LLC. We use anhydrous ammonia in our mechanical refrigeration system. We have safety and maintenance programs to prevent accidental anhydrous ammonia releases. We coordinate our emergency plans with Muscatine County Emergency Management, the West Liberty Fire Department, and local police through the County offsite emergency plan, discussions, onsite tours, and drills. Alternative and worse-case release scenarios. One accident was reportable under the EPA's Risk Management regulation (40 CFR 68.42)in the last five years: a suction regulator valve on the roof leaked liquid causing an offsite evacuation. Some employees were treated and released at a hospital. We are continuously reviewing and upgrading our safety, health, and environmental programs.