OSHA Inspection: AKZO NOBEL FUNCTIONAL CHEMICALS LLC

Issued

Oct 12, 2000

Abate by

Oct 18, 2000

Penalty

Initial $2,250

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
by exposing them
to the fire and/or explosion hazards due to the release of carbon
disulfide.
a)On or about May 8, 2000, a weld failed on an 8 inch high pressure pipe
located between
the B-line Reactor and the carbon disulfide process unit condenser,
allowing carbon
disulfide to be released into the atmosphere and ignite. The welds in this
piping system
were not examined by random ultrasonic or radiography testing in order to
check the
welding product of the welder or welding operators doing the work.  Among
others, a
feasible and acceptable method to correct this hazard is to perform
examination of welds
prior to the initial operation of each piping installation, including its
components and
workmanship, as defined and in accordance the American Society of
Mechanical
Engineers, B31.3 Process Piping Code, 1993, Paragraph 341.4.1(b)(1), which
states:
"Not less than 5of circumferential butt and miter grove welds shall be
examined
fully
by random radiography in accordance with paragraph 344.5 or by random
ultrasonic
examination in accordance with paragraph 344.6.  The welds to be examined
shall be
selected to ensure that the work product of each welder or welding
operator doing the
production weld is included."

Issued

Oct 12, 2000

Abate by

Oct 18, 2000

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 by exposing them
to the fire and/or explosion hazards due to the release of carbon
disulfide.
a)On or about May 8, 2000, a weld failed on an 8 inch high pressure pipe
located between
the B-line Reactor and the carbon disulfide process unit condenser,
allowing carbon
disulfide to be released into the atmosphere and ignite.  There were no
certifications,
records or other evidence to verify that the materials and components of
the welds were
of the specified grades and that they had received the required heat
treatment,
examination and testing.  Among others, a feasible and acceptable method
to correct this
hazard is to maintain written certification, records or other evidence in
accordance with
the American Society of Mechanical Engineers, B31.3 Process Piping Code,
1993,
Paragraph 341.4.1 (c), which states: "The examiner shall be assured, by
examination of
certifications, records and other evidence, that the materials and
components are of the
specified grades and they have received the required heat treatment,
examination, and
testing."

Issued

Oct 12, 2000

Abate by

Oct 17, 2000

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 by exposing them
to the fire and explosion hazards due to the release of carbon disulfide.
a)On or about May 8, 2000, a weld failed on an 8 inch high pressure pipe
located between
the B-line Reactor and the carbon disulfide process unit condenser,
allowing carbon
disulfide to be released into the atmosphere and ignite.  The employer did
not have
records for the welding qualifications of the welding procedures and the
performance of
welders and welding operators for the welds used to install this piping
system in 1995.
Among others, one feasible and acceptable method to correct this hazard is
to establish
and to maintain records of welding qualifications of the welding
procedures to be used
and for the performance of welders and welding operators in accordance
with the
American Society of Mechanical Engineers, B31.3 - 1993, Paragraph
328.2.1(a), which
states: "Qualification of welding procedures to be used and of the
performance
of welders
and welding operators shall conform to the requirements of the Boiler and
Pressure
Code, Section IX, except as modified herein;" and also Paragraph 328.2.4
which states:
"The employer shall maintain a self-certified record, available to the
owner (and owner's
agent) and the Inspector, of the procedures used and the welders and
welding operators
employed, showing the date and results of the procedure and performance
qualifications,
and the identification symbol assigned to each welder and welding
operator."