| Inspection Type |
Prog Related
|
| Scope |
Partial
|
| Safety/Health |
Safety
|
| Close Conference |
2016-06-29
|
| Emphasis |
N: CHEMNEP, P: CHEMNEP
|
| Case Closed |
2017-06-01
|
Violation Items
| Citation ID |
01001 |
| Citaton Type |
Serious |
| Standard Cited |
19100119 D03 II |
| Issuance Date |
2016-12-16 |
| Abatement Due Date |
2017-07-01 |
| Current Penalty |
6000.0 |
| Initial Penalty |
7572.0 |
| Final Order |
2017-01-13 |
| Nr Instances |
3 |
| Nr Exposed |
385 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(d)(3)(ii): The employer did not document that equipment complies with recognized and generally accepted good engineering practices. (a) Anhydrous ammonia refrigeration process, North Engine room -- On or prior to 6/23/16, the Suction Accumulator SA-2 was operated at -35F which is below the MDMT for the vessel (-20F) stamped on the ASME data plate. The employer did not document that the vessel was designed for this service. (b) Anhydrous ammonia refrigeration process, North Engine room: The Transfer Assembly and Teikoku pump, was in operation with a 3/8" nipple on the relief line for the Teikoku pump; the nipple was not protected from physical damage from struck-by hazards. (c) Anhydrous ammonia refrigeration process (various locations): On or prior 6/23/16, Process equipment was in operation with 1/2" diameter HPL lines which were not adequately supported, including but not limited to: PT silos, Raw silos, Hansen Auto Purger AP-1, Transfer Assembly with Teikoku pump TA2, Ice Cream Freezer APV-WS-308, Coolmatic AH-1, and New King Unit KU-1. |
|
| Citation ID |
01002 |
| Citaton Type |
Serious |
| Standard Cited |
19100119 E03 I |
| Issuance Date |
2016-12-16 |
| Abatement Due Date |
2017-01-20 |
| Current Penalty |
6000.0 |
| Initial Penalty |
7572.0 |
| Final Order |
2017-01-13 |
| Nr Instances |
5 |
| Nr Exposed |
20 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(e)(3)(i): The process hazard analysis did not address the hazards of the process. (a) Anhydrous ammonia refrigeration process (various locations): On or prior 6/23/16, The process hazard analysis did not address hazards associated with support and protection of 1/2" diameter HPL lines for process equipment including but not limited to: PT silos, Raw silos, Hansen Auto Purger AP-1, Transfer Assembly with Teikoku pump TA2, Ice Cream Freezer APV-WS-308, Coolmatic AH-1, and New King Unit KU-1. (b) Anhydrous ammonia refrigeration process, North Engine room: On or prior to 6/23/16, the process hazard analysis did not address hazards associated with operation of the Suction Accumulator SA2 at a temperature of -35F, which is below the MDMT for the vessel. |
|
| Citation ID |
01003 |
| Citaton Type |
Serious |
| Standard Cited |
19100119 F01 |
| Issuance Date |
2016-12-16 |
| Abatement Due Date |
2017-01-20 |
| Current Penalty |
6000.0 |
| Initial Penalty |
7572.0 |
| Final Order |
2017-01-13 |
| Nr Instances |
1 |
| Nr Exposed |
385 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(f)(1): The employer did not develop and implement written operating procedures that provided clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and addressing at least steps for each operating phase, safe operating limits, safety and health considerations, and safety systems and their functions as outlined by this paragraph: (a) Anhydrous ammonia refrigeration process, engine room(s): On or prior to 6/23/16, written operating procedures were not developed and implemented which include procedures for conducting daily rounds and recording of system operating conditions. The engine room log book noted periodic maintenance activities and unusual conditions, but did not include a daily record of system operations. |
|
| Citation ID |
01004 |
| Citaton Type |
Serious |
| Standard Cited |
19100119 J02 |
| Issuance Date |
2016-12-16 |
| Abatement Due Date |
2017-07-01 |
| Current Penalty |
6000.0 |
| Initial Penalty |
7572.0 |
| Final Order |
2017-01-13 |
| Nr Instances |
1 |
| Nr Exposed |
385 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(j)(2): The employer did not establish or implement written procedures to maintain the on-going integrity of process equipment. (a) Anhydrous ammonia refrigeration system: On or prior to 6/23/16, the employer did not establish written procedures to ensure the mechanical integrity of process equipment, including but not limited to: refrigerant piping and valves (including insulation); pressure vessels and storage tanks, pressure relief system(s); controls (including compressor safety cutouts, high/low level switches and alarms, interlocks, etc.); emergency shut-down systems; and pumps. |
|
| Citation ID |
01005 |
| Citaton Type |
Serious |
| Standard Cited |
19100119 J05 |
| Issuance Date |
2016-12-16 |
| Abatement Due Date |
2017-01-20 |
| Current Penalty |
6000.0 |
| Initial Penalty |
7572.0 |
| Final Order |
2017-01-13 |
| Nr Instances |
7 |
| Nr Exposed |
15 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(j)(5): The employer did not correct deficiencies in equipment that were outside acceptable limits (defined by the process safety information on paragraph (d) of this section) before further use or in a safe and timely manner when necessary means were taken to assure safe operation. (a) PT and Raw Silos -- On or prior to 6/23/16, 1/2" HPL lines and valve groups were in operation with visible external corrosion. 1.5", 2" and 2.5" HSS lines and valve groups were in operation with visible external corrosion and damaged and/or missing insulation. (b) South Engine room -- On or prior to 6/23/16, Frick screw compressor SC-1 was in operation with visible external corrosion at 5" HSS lines and damaged and/or missing insulation at valve HSS-M1. (c) South Engine room -- On or prior to 6/23/16, Vilter reciprocating compressor RC-5 was in operation with missing insulation on 4" HSS lines near valve HSS-M8 (d) South Engine room On or prior to 6/23/16, Hasegawa reciprocating compressor RCB-2 was in operation with missing insulation on an elbow on 4" LSS lines. (e) South Engine room -- On or prior to 6/23/16, Hasegawa reciprocating compressor RCB-3 was in operation with damaged insulation on an elbow on 4" LSS lines near valve LSS-4. (f) North Engine room -- On or prior to 6/23/16, Suction accumulator was in operation at -35F, which is below the specified MDMT of the vessel. (g) North engine room -- On or prior to 6/23/16, 1.5" HPL (sub cool liquid) line was supported by a nylon web strap. (h) North engine room -- On or prior to 6/23/16, 3/8" nipple to relief vent line from Teikaku pump was not protected from physical damage. |
|
| Citation ID |
01006 |
| Citaton Type |
Serious |
| Standard Cited |
19100119 L01 |
| Issuance Date |
2016-12-16 |
| Abatement Due Date |
2017-01-20 |
| Current Penalty |
4000.0 |
| Initial Penalty |
7572.0 |
| Final Order |
2017-01-13 |
| Nr Instances |
1 |
| Nr Exposed |
10 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(l)(1): The employer did not implement procedures to manage changes to process chemicals, technology, equipment, and procedures, and changes to facilities that affect a covered process(a) ( (a) Anhydrous ammonia refrigeration process, North engine room: On or prior to 6/23/16, the employer did not implement management of change procedures to address process changes including but not limited to installation of storage racking along north and east walls and use of the building for storage of vehicles and equipment, such as lawn equipment, forklift, scissor lift, and aerial boom lift. |
|
| Citation ID |
02001 |
| Citaton Type |
Other |
| Standard Cited |
19100119 O01 |
| Issuance Date |
2016-12-16 |
| Abatement Due Date |
2017-01-20 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2017-01-13 |
| Nr Instances |
1 |
| Nr Exposed |
385 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(o)(1): The employer did not certify that they have evaluated compliance with the provisions of this section at least every three years: (a) Anhydrous ammonia refrigeration process: On or prior to 6/23/16, the date of the last certified compliance audit was March 29, 2012. |
|
|
