OSHA Inspection: STANDARD-HAYES BOILER AND TANK, LLC

Issued

Apr 22, 1999

Abate by

Jun 8, 1999

Penalty

Initial $4,200 · Current $2,520 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 the hazards of tank rupture, explosion or
release of highly pressurized water.
North bay, West end of building at 1000 West 142nd Street,
Riverdale, IL.; on or about 10/23/98, employees using uncalibrated
impact wrenches to tighten 24 12-inch studs on both the M-1 and M-2
flange joints of the Vacuum Fat Splitter could not determine the
bolt load placed on the studs.
A feasible and useful means of abatement includes, but is not
limited to the following actions:
1) Establish bolting procedures, train employees to utilize those
procedures, including ensure their understanding of the advantages
and limitations of using torque wrenches, bolt tensioners, bolt
heaters and impact wrenches to tighten studs and bolts, and use
torque wrenches that have been calibrated.
2) Determine the torque load prior to torquing in accordance with
the gasket manufacturer's recommendations, as found in the Torgue
Table for Spiral Wound Gaskets used with the American National
Standard Institute's (ANSI) 16.5 Flanges standard.

Issued

Apr 22, 1999

Abate by

Apr 27, 1999

Penalty

Initial $49,000 · Current $29,400 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 the hazard of tank rupture, explosion or
release of highly pressurized water.
North bay/West end of shop/1000 West 142nd Street, Riverdale, IL.;
prior to the accident on or about 10/23/98 the Flexseal Flurocarbon
spiral-wound gaskets (Stamped 20 150 API-601304 L-VC) were not
dimensionally suitable for use with the blind and bottom flanges
(stamped 20-600 B16.5 SA 182 F 304/304I Y 3670 7/98) during a
hydrostatic test to the Vacuum Fat Splitter pressure vessel.
Employees were exposed to a potential catastrophic gasket failure.
A feasible and useful means of abatement includes, but is not
limited to, the following:
1) Ensure that supervisory personnel and other employees are
trained in and familiar with the standard found in the American
Society of Mechanical Engineers (ASME) B16.20b-1997 Addenda to ASME
B16.20-1993 METALLIC GASKETS FOR PIPE FLANGES-RING JOINT, SPIRAL
WOUND, AND JACKETED, which says in part:
a) The standard covers the gaskets listed above and the gaskets are
dimensionally suitable for use with flanges described in the
reference flange standards ASME B16.5, ASME B16.47, and API-6A.
b) Dimensions and tolerances for spiral-wound gaskets, centering
and inner rings, shall be in accordance with Tables 9, 10, and 11
and as specified in this section.
c) Gaskets suitable for more than one pressure class shall be
marked with all applicable classes.
2) Follow the guidelines and specifications of the gasket
manufacturer.
3) Match the gaskets with the rated flanges as outlined in the
employer's detail drawings specifications.

Issued

Apr 22, 1999

Abate by

Apr 27, 1999

Penalty

Initial $49,000 · Current $29,400 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 the hazards of tank rupture, explosion or
release of highly-pressurized water.
Shop area, North Bay, West end of building; on or about 10/23/98,
employees were working on or near the M-1 and M-2 flange joints of
the Vacuum Fat Splitter pressurized vessel (under 1275 psig) during
hydrostatic testing in an attempt to contain leaks and while arc
welding on Davit brackets. The employees were exposed to hazards of
working on or near fully-pressurized vessel.
A feasible and useful means of abatement includes, but is not
limited to the following actions:
1) Conduct hydrostatic test on vessels in accordance with the
standard hydrostatic test requirements of Subsection UG-99(a)&(g)
of Section VIII-Division I, American Society of Mechanical
Engineers (ASME), which states in part:
a) Hydrostatic test shall be conducted on all vessels after all
fabrication has been conducted.
b) Following the application of the hydrostatic test pressure, an
inspection shall be made at a pressure not less than two-thirds of
the test pressure.
2) Similarly, Section 6-95 of the Chemical Engineers' Handbook,
Fifth Edition, states, in part, that until pressure is lowered to
not less than two-thirds of the maximum test pressure personnel
must be kept at a safe distance.