OSHA Inspection: CORN PRODUCTS - A UNIT OF CPC NORTH AMERICA

Issued

Apr 6, 1993

Abate by

May 10, 1993

Penalty

Initial $7,000 · Current $5,000 Reduced

General-duty citation text

Section 5(a)(1):  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 the hazards of oxygen deficiency, flammable
and/or toxic atmospheres inside vessels such as but not limited to
rotorells.
a.  On or about November 18, 1992, and at times prior thereto, employees
were exposed to the hazards associated with improper confined space entry
while cleaning, servicing and/or inspecting the interior of rotocell
extractor #2 in building 26 of the Crude Oil Unit.
Prior to entry, a confined space program had been developed, however
procedures for confined space entry were not fully implemented or enforced
and the confined space program was inadequate.  ie:  appropriate
atmospheric testing and monitoring equipment had not been provided nor
had employees been provided training in the irritations and proper use
of such equipment, an effective method to summon rescuers was not
accessible to the attendants proper atmospheric testing procedures were
not followed when re-entering a previously vacated confined space,
confined
space entry permits were not adequately completed and adequate respiratory
protection was not available to all employees participating in confined
space entry.
Among other methods, one feasible and acceptable abatement method to
correct these hazards is to implement and enforce an adequate plant
confined space entry program such as that stipulated by ANSI Z117.1-1989
American National Standard Institute Safety Requirements for Confined
Spaces.  Such a program shall include, as a minimum, the following
elements:
1).  Written procedures covering a permit system, ventilation, atmospheric
testing, rescue procedures and employee training.
2).  The completion and posting of a confined space entry permit which
requires authorization and approval in writing that specifies the location
and type of work to be done and certifies that all existing and potential
hazards have been evaluated by a qualified person and that necessary
measures have been taken to ensure the safety of each worker.
3).  Blinding, blocking, bleeding, purging, lockout or any other steps
necessary to reduce and to ensure zero mechanical and thermal state of
all mechanical, electrical, hydraulic, pneumatic liquid and gas systems
relating to the confined space that may create a hazard to employees
during
entry or while working in the confined space should any of these systems
be put in motion or otherwise activated.  A worker individual lock is to
be applied and in unique situation tag shall be attached to the lock and
energizing or activating controls or devices.
4).  Mechanical ventilation of the confined space prior to entry and
continued ventilation to provide a safe atmosphere, when determined
neccessary as described in (2) above.
5).  Testing the atmosphere of the confined space prior to entry and on
a regular basis for presence of sufficient oxygen (19.5) and absence of
hazardous levels of toxic or combustible gases or vapors, when determined
necessary as described in (2) above.
6).  Emergency rescue procedures with requirement that trained personnel
are available and are stationed outside the confined space with proper
equipment to provide for the rescue of persons entering the space as
determined necessary and as described in (2) above.  Such equipment must
include safety harness and life lines with provisions for hoisting
employees from the confined space.  If entry is required for a rescue,
the rescuing employee must be equipped with approved air supplied
respiratory equipment and other appropriate personal protective equipment.
7).  Training of any and all employees required to enter the confined
spaces and all employees required to standby for rescue.  This training
shall include procedures required prior to entry, during occupation of
the confined space, procedures for safe rescue of employees in the
confined space and the hazards associated with work in confined spaces.