| Inspection Type |
Complaint
|
| Scope |
Partial
|
| Safety/Health |
Safety
|
| Close Conference |
2011-03-08
|
| Emphasis |
N: CHEMNEP
|
| Case Closed |
2011-08-29
|
Related Activity
| Type |
Complaint |
| Activity Nr |
1475 |
| Safety |
Yes |
|
Violation Items
| Citation ID |
01001A |
| Citaton Type |
Serious |
| Standard Cited |
19100119 D02 I A |
| Issuance Date |
2011-04-15 |
| Current Penalty |
4200.0 |
| Initial Penalty |
7000.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(d)(2)(i)[A]: Process safety information pertaining to the technology of the process did not include a block flow diagram: a) At the whey facility: On or about March 1, 2011, and at times prior thereto, the employer did not have a block flow diagram for the whey plant. Note: Abatement certification and documentation are NOT required for this item. |
|
| Citation ID |
01001B |
| Citaton Type |
Serious |
| Standard Cited |
19100119 D03 I C |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-04-22 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(d)(3)(i)[C]: Process safety information pertaining to the equipment in the process did not include the electrical classification: a) At the facility: On or about March 1, 2011, and at times prior thereto, the employers process safety information did not include details on why the machine rooms were classified NEMA 1. Note: Abatement certification AND documentation is required for this item. |
|
| Citation ID |
01001C |
| Citaton Type |
Serious |
| Standard Cited |
19100119 D03 I E |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-04-22 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
2 |
| Nr Exposed |
1 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(d)(3)(i)[E]: Process safety information pertaining to the equipment in the process did not include the ventilation system design: a) At the cheese plant: On or about March 1, 2011, and at times prior thereto, the employers ventilation system design was based on old inventory values and did not reflect current inventory. b) At the whey plant: On or about March 1, 2011, and at times prior thereto, the employers ventilation system design was based on old inventory values and did not reflect current inventory. Note: Abatement certification AND documentation is required for this item. |
|
| Citation ID |
01002 |
| Citaton Type |
Serious |
| Standard Cited |
19100119 D03 I B |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-06-30 |
| Current Penalty |
4300.0 |
| Initial Penalty |
7000.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
9 |
| Nr Exposed |
1 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(d)(3)(i)[B]: Process safety information pertaining to the equipment in the process did not include the piping and instrument diagrams (P&IDS): a) In the cheese plant machine room: On or about March 1, 2011, and at times prior thereto, the P&ID for the facility did not accurately reflect the equipment and piping configuration in that the thermosiphon lines for Compressor #3 were drawn in reverse of their actual position on the equipment. b) In the cheese plant machine room: On or about March 1, 2011, and at times prior thereto, the P&ID for the facility did not accurately reflect the equipment and piping configuration in that the valve grouping of AV4, ST1, and CK1 coming off Compressor #3 had actually been removed from the equipment. c) In the cheese plant machine room: On or about March 1, 2011, and at times prior thereto, the P&ID for the facility did not accurately reflect the equipment and piping configuration in that the relief valve piping and configuration on the oil cooler for Compressor #3 did not match the actual configuration. d) In the cheese plant machine room: On or about March 1, 2011, and at times prior thereto, the P&ID for the facility did not accurately reflect the equipment and piping configuration in that the drawing for the piping from the high pressure receiver to the purger did not match that of the actual piping configuration. e) In the cheese plant machine room: On or about March 1, 2011, and at times prior thereto, the P&ID for the facility did not accurately reflect the equipment and piping configuration in that the drawing for RCV-1 was missing a quick-release valve off the oil pot. f) In the cheese plant machine room: On or about March 1, 2011, and at times prior thereto, the P&ID for the facility did not accurately reflect the equipment and piping configuration in that two purger valves, GV1 and GV2, were drawn in reverse of their actual position on the equipment. g) In the whey plant: On or about March 1, 2011, and at times prior thereto, the P&ID for the facility did not accurately reflect the equipment and piping configuration in that condensers NE 9 and SE 11 were drawn in reverse of their actual position. h) In the whey plant: On or about March 1, 2011, and at times prior thereto, the P&ID for the facility did not accurately reflect the equipment and piping configuration in that a valve assembly on the east side of each compressor was not included on the drawing. i) In the whey plant: On or about March 1, 2011, and at times prior thereto, the P&ID for the facility did not accurately reflect the equipment and piping configuration in that valve WGV49 is not part of the actual piping configuration. Note: Abatement certification AND documentation is required for this item. |
|
| Citation ID |
01003A |
| Citaton Type |
Serious |
| Standard Cited |
19100119 D03 II |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-06-30 |
| Current Penalty |
3500.0 |
| Initial Penalty |
7000.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
5 |
| Nr Exposed |
1 |
| Related Event Code (REC) |
Complaint |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(d)(3)(ii): The employer did not document that the equipment in the process complied with recognized and generally accepted good engineering practices (RAGAGEP): a) At the whey plant: On or about March 1, 2011, and at times prior thereto, the employer did not document that they complied with RAGAGEP in that the system valves were not labeled. Note: Abatement certification AND documentation is required for this item. Abatement note for instance "a": One acceptable means of abatement, among others, would be to comply with the requirements in ASHRAE 15 - 2007, 11.2.2 |
|
| Citation ID |
01003B |
| Citaton Type |
Serious |
| Standard Cited |
19100119 D03 III |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-05-13 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
2 |
| Nr Exposed |
1 |
| Related Event Code (REC) |
Complaint |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(d)(3)(iii): For existing equipment designed and constructed in accordance with codes, standards, or practices no longer in general use, the employer did not determine and document that the equipment in the process was designed, maintained, inspected, tested, and operated in a safe manner: a) In the cheese plant: On or about March 1, 2011, and at times prior thereto, the employer did not document that the relief piping for the oil pot on RCV-3 was safe as it was approximately 12.2 ft above the adjacent working surface. b) In the cheese plant: On or about March 1, 2011, and at times prior thereto, the employer did not document that the system valves were safe as many were mislabeled or not labeled. Note: abatement certification AND documentation are required for this item. Abatement note for instance "a": One acceptable means of abatement, among others, would be to comply with the requirements in ASHRAE 15 - 2007, 9.7.8. Abatement note for instance "b": One acceptable means of abatement, among others, would be to comply with the requirements in ASHRAE 15 - 2007, 11.2.2. |
|
| Citation ID |
01004A |
| Citaton Type |
Serious |
| Standard Cited |
19100119 E01 |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-07-30 |
| Current Penalty |
4200.0 |
| Initial Penalty |
7000.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(e)(1): The employer did not perform an initial process hazard analysis (hazard evaluation) on processes covered by 29 CFR 1910.119: a) At the whey plant: On or about March 1, 2011, and at times prior thereto, the employer did not perform a PHA for the whey plant. Note: Abatement certification AND documentation are required for this item. |
|
| Citation ID |
01004B |
| Citaton Type |
Serious |
| Standard Cited |
19100119 E06 |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-05-13 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(e)(6): The process hazard analysis was not revalidated by a team meeting the requirements in paragraph (e)(4) of this section: a) At the cheese plant: On or about March 1, 2011, and at times prior thereto, the cheese plant PHA was revalidated in 2009 by the Safety Manager and not a team. Abatement certification AND documentation is required for this item. |
|
| Citation ID |
01004C |
| Citaton Type |
Serious |
| Standard Cited |
19100119 I02 III |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-05-13 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(i)(2)(iii): The pre-startup safety review (PSSR) did not confirm that prior to the introduction of highly hazardous chemicals to a process a process hazard analysis had been performed and recommendations had been resolved or implemented before startup: a) At the whey plant: On or about March 1, 2011, and at times prior thereto, the PSSR conducted on the whey plant prior to start-up did not address PHAs. Note: Abatement certification AND documentation are required for this item. |
|
| Citation ID |
01005 |
| Citaton Type |
Serious |
| Standard Cited |
19100119 F01 I B |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-06-30 |
| Current Penalty |
2125.0 |
| Initial Penalty |
4250.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(f)(1)(i)[B]: Written operating procedures for normal operations had not been developed and implemented: a) At the facility: On or about March 1, 2011, and at times prior thereto, detailed operating procedures for each oil draining point were not developed. Note: Abatement certification is required for this item. |
|
| Citation ID |
01006A |
| Citaton Type |
Serious |
| Standard Cited |
19100119 J02 |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-06-30 |
| Current Penalty |
4300.0 |
| Initial Penalty |
7000.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
2 |
| Nr Exposed |
1 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(j)(2): The employer did not establish and implement written procedures to maintain the on-going integrity of process equipment: a) At the facility: On or about March 1, 2011, and at times prior thereto, the employer did not have a written procedure that addressed inspection and testing of pipes and associated valves. b) At the whey plant: On or about March 1, 2011, and at times prior thereto, the employer did not have a procedure for changing valves that included torque specifications for the bolts. Note: Abatement certification AND documentation is required for this item. |
|
| Citation ID |
01006B |
| Citaton Type |
Serious |
| Standard Cited |
19100119 J04 I |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-05-13 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(j)(4)(i): Inspections and tests were not performed on process equipment: a) At the facility: On or about March 1, 2011, and at times prior thereto, testing was not performed on compressor safety cutout switches. Note: Abatement certification AND documentation are required for this item. |
|
| Citation ID |
01007 |
| Citaton Type |
Serious |
| Standard Cited |
19100119 J05 |
| Issuance Date |
2011-04-15 |
| Current Penalty |
2125.0 |
| Initial Penalty |
4250.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Related Event Code (REC) |
Complaint |
| 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 are outside acceptable limits (defined by the process safety information in 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) At the facility: On or about March1, 2011, and at times prior thereto, the pressure relief valve on the oil pot for RCV-3 was due to be replaced in July of 2010. Note: Abatement certification is NOT required for this item. |
|
| Citation ID |
01008 |
| Citaton Type |
Serious |
| Standard Cited |
19100119 J06 III |
| Issuance Date |
2011-04-15 |
| Current Penalty |
4300.0 |
| Initial Penalty |
7000.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Related Event Code (REC) |
Complaint |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(j)(6)(iii): The employer did not assure that maintenance materials, spare parts and equipment were suitable for the process application for which they were used: a) At the facility: On or about February 8, 2011, a hose that was not rated for use with ammonia was used to pump-down a condenser during which process it ruptured, releasing ammonia, and exposing an employee. Note: Abatement certification and documentation are NOT required for this item. |
|
| Citation ID |
01009 |
| Citaton Type |
Serious |
| Standard Cited |
19100212 A05 |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-04-22 |
| Current Penalty |
1250.0 |
| Initial Penalty |
2550.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Gravity |
1 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.212(a)(5): Fan blade guards, where the periphery of the blades was less than seven feet above the floor or working level, had openings larger than one-half inch: a) At the facility: On or about March 1, 2011, and at times prior thereto, the cover for a condenser was missing a section creating an opening larger than ? inch. Note: Abatement certification is required for this item. |
|
| Citation ID |
01010 |
| Citaton Type |
Serious |
| Standard Cited |
19100253 B04 III |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-04-22 |
| Current Penalty |
1700.0 |
| Initial Penalty |
3400.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.253(b)(4)(iii): Oxygen cylinders in storage were not separated from fuel-gas cylinders or combustible materials (especially oil or grease), a minimum distance of 20 feet (6.1 m) or by a noncombustible barrier at least 5 feet (1.5 m) high having a fire-resistance rating of at least one-half hour: a) In the yard between the cheese and whey plants: On or about March 1, 2011, and at times prior thereto, oxygen, propane, and acetylene cylinders were stored together. Note: Abatement certification is required for this item. |
|
| Citation ID |
02001 |
| Citaton Type |
Other |
| Standard Cited |
19100119 H02 I |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-04-22 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.119(h)(2)(i): The employer did not obtain and evaluate information regarding the contract employer's safety performance and programs: a) At the facility: On or about March 1, 2011, and at times prior thereto, the employer did not obtain information related to the safety programs of the contractor who had worked onsite. Note: Abatement certification is required for this item. |
|
| Citation ID |
02002 |
| Citaton Type |
Other |
| Standard Cited |
19100305 B01 II |
| Issuance Date |
2011-04-15 |
| Abatement Due Date |
2011-04-22 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2011-05-14 |
| Nr Instances |
1 |
| Nr Exposed |
1 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.305(b)(1)(ii): Unused openings in boxes, cabinets, or fittings were not effectively closed: a) In the whey plant: On or about March 1, 2011, and at times prior thereto, an unused opening the in the breaker box being used to supply temporary power to a trailer was not plugged. Note: Abatement certification is required for this item. |
|
|
