OSHA Inspection: ARCHER DANIELS MIDLAND CO.

Issued

Jan 16, 2003

Abate by

Feb 5, 2003

Penalty

Initial $2,500 · Current $2,500

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 employement which were free from hazards
that were
causing or likely to cause death or serious physical harm to employees in
that: Alcohol Plant
employees/operators performing steam start-up activities afer Alcohol
Plant shut down were
exposed to the hazard of steam burns due to a "condensation induced water
hammer"
condition resulting from excessive condensate in the 30" steam header
line.  Among other
methods, one feasible and acceptable method to correct this hazard would
be to drain steam
piping of condensate that may have collected in low points behind closed
valves.  To prevent
against condensation induced water hammer at the time of steam start-up
activities, the
following steps must be initiated:
a) Provide operating procedures for employees to follow whenever they are
engaged in a
steam start-up activity after Alcohol Plant shut down.  Such procedures
should include the
following elements:
1.order of valves controlling steam to the main distribution lines to be
turned
off/on;
2.steps to take whenever a valve controlling steam to a main distribution
line is
turned off/on, i.e., open/close bypasses, open/close blow-offs, open/close
steam traps;
3.steps to take whenever a valve controlling steam to a main distribution
line is
found to be in disrepair, especially if it hinders drainage of condensate;
4.emergency response procedures and instructions;
5.persons to notify; and
6.paperwork to be completed.
b) Provide training to employees required to perform steam start-up
activities after Alcohnl
Plant shut down from superintendents down to affected operators.  Such
trainng should
include the fllowing elements:
1.the basics of steam itself;
2.recognition of the hazard of condensate in steam lines;
3.what conditions create this hazard;
4.what steps are requried to assure that main distrubution steam lines are
safely
drained of condensate; and
5.what actions to take when blocked or inoperative valves and other
components
are encountered.