OSHA Inspection: PERFORMANCE CHEMICALS AND REAGENTS, INC.

Issued

Sep 19, 1990

Abate by

Oct 18, 1990

Penalty

Initial $200 · Current $120 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
employer did not furnish employment and a place of employment which were
free from recognized hazards that were causing or likely to cause death
or serious physical harm to employees in that employees working in the
Acid Bottling Area were exposed to inhalation and chemical burn hazards
from possible breach of containment of 96.5% sulfuric acid solution.
The following conditions contributed to the existence of these hazards:
a) An operating procedure for the sulfuric acid bottling /drumming
process was not developed and communicated in writing to employee(s),
including shift supervisor directly involved in the unloading and
bottling of sulfuric acid on or about July 13, 1990.
b) There were inadequate methods to detect sulfuric acid and warn
employee of leaks along the piping system, on or about July 13, 1990.
c) Nuts/bolts were either missing or corroded on the exterior flange
located at the tank truck transfer paint, on or about July 13, 1990.
d) The unused end of the sulfuric acid pipe located along the wall at
the point where the pipe enters the building was not blanked off, on
or about July 13, 1990.
e) The Piping system and tank truck were not equipped with automatic
controls that would stop the flow of acid in the event of a rupture
on or about July 13, 1990.
g) A procedure was not set up for purging lines after employees were
done bottling/drumming, on or about July 13, 1990.
h) There were no provisions to contain spills at the tank truck
unloading area and at the bottling area, on or about July 13, 1990.
i) Acid pipe intake was not identified or protected from physical damage
on or about july 13, 1990.
j) Connect/disconnect procedures were not developed to address the
transfer of acid from the tank truck to the bottling/drumming
operation, on or about July 13, 1990.
Feasible and acceptable methods among others include:
1) Written standard operating procedure which include (instance (a)):
a) General description of the process.
b) properties od the materials involved.
c) Description of the equipment including process equipment
instrumentation, and protective equipment.
d) Startup and shutdown procedures.
e) Normal operating procedures.
f) Safety considerations routine to fire, explosion, accidents and
health.
g) Precautions and actions to be avoided.
h) What constitutes and emergency.
i) Emergency procedures.
2) Installation of a monitoring and audible alarm to detect and alert
employees of leaks.  (Instance (b))
3) Replace any missing or corroded hardware and provide for a periodic
inspection program to determine the need for replacement of parts.
(Instance (c))
4) Blank off any unused portions of the sulfuric acid piping system.
(Instance (d))
5) Replace the cock stop valve with a self activating type valve.
(Instance (e))
6) Install and excess flow valve/bypass at the tank truck to
automatically shut off the flow of acid in the event of pressure
changes being detected.  (Instance (f))
7) Implement a procedure to purge lines after bottling/drumming
operations are completed.  (Instance (g))
8) Install diking and/or drains at the tank truck unloading area and
bottling area to contain spills.  (Instance (h))
9) Affix labels to the exterior transfer pipe and install barriers
where necessary to prevent damage to the pipe.  (Instance (i))
10) Develop tank truck connect/disconnect procedures which include
(Instance (j)):
a) Safe operating procedures for loading/unloading.
b) Procedures for depressurizing or venting tank trucks.
c) Assurances that transfer hoses are not compatible.
d) Description of the personal protective equipment provided.
e) Procedure to prevent truck or tank car movement.
f) Provisions for spill cleanup in the immediate area.
g) Describe the location of fire extinguishers.

Issued

Sep 19, 1990

Abate by

Nov 30, 1990

Penalty

Initial $200 · Current $120 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
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employer did not furnish employment and a place of employment which were
free from recognized hazards that were causing or likely to cause death
or serious physical harm to employees in that employees were exposed to
inhalation hazard from discharge of the sodium hydroxide solution which
was directed towards and open drain from a scrubber on or about July 13,
1990.
a) Sodium hydroxide used in the Ceilcate Scrubber to neutralize the acid
mist generated at the bottling/drumming operation was directly
discharged into an open drain.
b) PH meter, flow meter and static pressure gauge were either unoperable
or not calibrated.
Feasible and acceptable abatement methods, among others, include:
1) Install a barrier or other protective devices to prevent employees
from stepping into the sodium hydroxide solution. (Instance (a))
2) Calibrate and test instruments according to manufacturers
specifications at frequent and regular intervals.

Issued

Sep 19, 1990

Abate by

Sep 24, 1990

Issued

Sep 19, 1990

Abate by

Oct 31, 1990

Penalty

Initial $150 · Current $110 Reduced

Issued

Sep 19, 1990

Abate by

Nov 30, 1990

Penalty

Initial $250 · Current $150 Reduced

Issued

Sep 19, 1990

Abate by

Dec 31, 1990

Issued

Sep 19, 1990

Abate by

Sep 29, 1990

Issued

Sep 19, 1990

Abate by

Sep 25, 1990

Penalty

Initial $250 · Current $150 Reduced

Issued

Sep 19, 1990

Abate by

Sep 25, 1990

Issued

Sep 19, 1990

Abate by

Oct 2, 1990