OSHA Inspection: A. E. STALEY MFG. CO.

Issued

Jun 21, 1990

Abate by

Jun 24, 1990

Penalty

Initial $600 · Current $600

Issued

Jun 21, 1990

Abate by

Jul 23, 1990

Penalty

Initial $800 · Current $800

Issued

Jun 21, 1990

Abate by

Aug 23, 1990

Issued

Jun 21, 1990

Abate by

Oct 22, 1990

Penalty

Initial $800 · Current $800

Issued

Jun 21, 1990

Abate by

Jul 23, 1990

Issued

Jun 21, 1990

Abate by

Jul 23, 1990

Issued

Jun 21, 1990

Abate by

Aug 21, 1990

Penalty

Initial $8,000 · Current $4,000 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 were
exposed to:
On May 15, 1990 mechanics entered entered #1 Hamaco Reactor,
a confined space, for the purpose of maintenance and repair and proper
confined space entry procedures, as outlined in the abatement methods
were not followed. Employees entered the reactor located in 118
building (specialty starch) on second shift. Shortly after entering,
the employees were exposed to approximately 10,000 ppm of propylene
oxide.
Among other methods a feasible and acceptable abatement method
to correct the hazards should follow the procedures set forth in the
American National Standards Institute (ANSI) Z117.1-1977, "Safety
Requirements for Working in Tanks and Other Confined Spaces", and
should include the following:
1) Implementation of the formal confined space entry program
currently in existence at the facility. The program should include
the following areas:
a) Establishment of a permit system. Entry into a confined
space shall be by permit ONLY. The supervisor or a qualified person
shall be responsible for securing the permit and both shall sign off
when the area has been reviewed and necessary actions confirmed. The
permit shall include: location and description of work to be done,
hazards that may be encountered, complete isolation of the confined
space (blanking and/or disconnection, electrical and mechanical lockout)
protective equipment and clothing required, atmospheric test readings,
standby person, emergency procedures and the location of first aid
equipment. Their permit shall be dated and carry an expiration time
that will be valid for ONLY ONE SHIFT.
b) Establishment of a training program which includes the following
areas: emergency entry and exit procedures, use of applicable respira-
tors, first aid, lockout procedures, safety equipment use, rescue and
training drills, permit system, and work practices. Training shall not
be considered complete until the employee is judged to have attained an
acceptable degree of proficiency for entering and working in confined
spaces.
c) Mechanical ventilation of the confined space shall be provided
prior to entry and continued to provide a safe atmosphere.
d) Entry into a confined space shall be prohibited until initial
testing of the atmosphere has been done from the outside. The tests
performed shall include those for oxygen content, flammability, and
toxic material. Measurements shall be made with instruments calibrated
daily according to manufacturer's instructions, Instrument operators
shall be trained in the use and care of the instruments.
e) All entrances to any confined space shall be posted.
f) Lockout and tagout procedures shall be used for any electrical
or mechanical equipment to which an employee in a confined space could
be exposed.
g) Personal protective equipment such as respiratory protection
shall chosen and provided on the basis of testing and monitoring. Users
of this equipment shall be trained in its limitations and use. Respira-
tory protection shall be used in accordance with section 1910.134 of 29
CFR 1910 General Industry Standards. Additional personal protective equ-
ipment such as gloves, hard hats, and eye protection shall be chosen
when determined to be necessary by a qualified person.
h) An individual shall be required to standby for rescue outside
the confined space to be in immediate contact with the employee(s) in
the confined space.
i) Emergency rescue procedures shall be established with a
requirement that the standby person is stationed outside of the confined
space with proper equipment to provide for the rescue of the person(s)
in the confined space. Such equipment shall include safety harness and
lifelines with provisions for hoisting the employee(s) from the confined
space. If entry is required for rescue, the rescue employee shall be
equipped with approved air supply respiratory protection and other
appropriate protective equipment. The standby person shall have some
means of alerting others to an emergency situation.
2) Implementation of a training program covering proper confined space
entry and exit procedures, lockout and tagout, emergency procedures,
personal protective equipment available, and work practice. Employees
should not be allowed to enter a confined space until he/she displays
a thorough understanding of the procedures necessary for safe entry and
the associated hazards.
3) The elimination of system cross-ties and/or the addition of a means
of isolation for each system.
4) The elimination of condensate accumulation within the vent lines.
5) Complete isolation of the system involved.
6) Performance of air monitoring surveys for toxic chemicals (such as
propylene oxide). Such surveys would require the ecquisition of monito-
ring equipment specific for the chemicals involved.
7) Ensure the availability of equipment necessary in the event of an
emergency and that it is in proper working order.
DISCLAIMER:
A. The employer is not limited to the abatement methods suggested by
OSHA;
b. The methods explained are general and may not be effective in all
cases;
c. The employer is responsible for selecting and carrying out an effec-
tive abatement method.