Ammonia releases result in upgrade order

South San Francisco, Calif. — Specialty meats producer Columbus Foods is investing $7 million to change over to an ammonia/glycol refrigeration system under an agreement with the U.S. Environmental Protection Agency and the Department of Justice following two releases of anhydrous ammonia in 2009. One release resulted in the evacuation of the plant and several neighboring businesses and sent 17 people to the hospital. The consent decree last Jan. 31 requires Columbus to pay a penalty of $685,446 and convert its refrigeration system to a safer technology, along with improving its alarm and ammonia release notification procedures. Officials with the two agencies stated that the releases were the result of Columbus’ failure of its general duty of care to identify hazards and to maintain a safe facility, and its failure to comply with regulatory requirements for process safety management under the Clean Air Act. The first accidental ammonia release in February 2009 sent 217 pounds of ammonia gases into the atmosphere. Six months later, in August 2009, the plant again released an ammonia cloud – this time approximately 200 pounds – that resulted in one person being hospitalized for four days. In addition, off-ramps from Highway 101 and several local streets were shut down as a result of the release. EPA took action following the August 2009 incident, ordering Columbus to complete initial upgrades to its ammonia refrigeration system, including the replacement of safety relief valves and components with any signs of corrosion, and the proper labeling of all its piping. In 2011, the company paid $850,000 in fines to San Mateo County as a result of the incident. Columbus responded that reconfiguring the ammonia refrigeration system will exceed current EPA Clean Air Act standards and provide increased safety for employees and the community surrounding its plant. The system features state-of-the-art hardware and controls technology, safeguards including secondary containment and an air scrubbing system, and a complex sequence for leak detection, alarm and notification. To further ensure control of the ammonia gases, the refrigeration system and ammonia charge will be fully contained in an enclosed building.