OSHA Inspection: MFG CHEMICAL, INC.

Issued

Aug 8, 2005

Abate by

Mar 31, 2006

Penalty

Initial $3,000 · Current $2,000 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
employer did not furnish to each of his employees
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:
(a) Plant #2, reactor area - Relief device discharge piping (blow-down
lines) for reactors D1, D2, R2, R4, and the
reactor condenser receivers, were all located approximately 2 feet above
the reactor lower floor within the containment
zone. An over pressure situation could cause the release of volatile
chemicals underneath the reactor's first floor.  The
location of these vents represent a health hazard from the release of
flammable
chemicals, due the possibility of a toxic
substance release or a fire and explosion hazard to employees working in
the reactor area.
Among other methods, feasible and acceptable abatement methods to correct
this hazard are:
(1) Re-configure blow down to a closed system by adding the necessary
piping and blow down drum that
will retain expelled liquid and safely vent gases.
ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED

Issued

Aug 8, 2005

Abate by

Mar 31, 2006

Penalty

Initial $3,000 · Current $2,000 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
employer did not furnish to each of his employees
employment and a place of employment that was free from recognized hazards
that were causing, or likely to cause, death or
serious physical harm to employees, in that employees were exposed to
struck by hazards:
(a) Plant #2 - The employer did not have relief device size justification
(calculations) for rupture disks located on
reactors D1,D2,R2, and R4.
Among other methods, feasible and acceptable abatement methods to correct
this hazard are:
(1) Perform necessary calculations to determine appropriate size for
relief devices and install relief devices
that prevent internal pressure from exceeding 10of vessel's MAWP during
actual relief.
ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED

Issued

Aug 8, 2005

Abate by

Nov 16, 2005

Penalty

Initial $3,000 · Current $2,000 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
employer did not furnish to each of his employees
employment and a place of employment that was free from recognized hazards
that were causing, or likely to cause, death or
serious physical harm to employees, in that employees were exposed to fire
and/or explosion hazards:
(a) Plant #2 - The employer did not have documentation that showed the
wall thickness or other inspection data for
reactors located on reactors D1,D2,R2, and R4.
Among other methods, feasible and acceptable abatement methods to correct
these hazards include, but are not limited
to the following:
(1) Establish an effective program of pressure vessel inspections that
ensure the determination of probable
corrosion rate and specification of maximum period between inspections
performed in accordance with
ASME Boiler & Pressure Vessel Code and ANSI/National Board Inspection Code
and API 510 Pressure
Vessel Inspection Code.
(2) Determine and use of inspection points for non-destructive testing.
(3) Ensure that each pressure vessel is provided with an original U1
report and readable nameplate in
accordance with ASME Boiler & Pressure Vessel Code.
ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED

Issued

Aug 8, 2005

Abate by

Sep 23, 2005

Penalty

Initial $1,200 · Current $800 Reduced

Issued

Aug 8, 2005

Abate by

Sep 23, 2005

Issued

Aug 8, 2005

Abate by

Oct 30, 2005

Penalty

Initial $1,500 · Current $800 Reduced

Issued

Aug 8, 2005

Abate by

Sep 23, 2005

Penalty

Initial $900 · Current $450 Reduced

Issued

Aug 8, 2005

Abate by

Sep 23, 2005

Penalty

Initial $900 · Current $450 Reduced

Issued

Aug 8, 2005

Abate by

Sep 23, 2005

Penalty

Initial $3,000 · Current $1,500 Reduced

Issued

Aug 8, 2005

Abate by

Sep 23, 2005

Issued

Aug 8, 2005

Abate by

Sep 23, 2005

Issued

Aug 8, 2005

Abate by

Oct 30, 2005

Issued

Aug 8, 2005

Abate by

Oct 30, 2005

Issued

Aug 8, 2005

Abate by

Oct 30, 2005