OSHA Inspection: CALPINE CHANNEL CENTER ENERGY

Issued

Jul 25, 2007

Abate by

Aug 27, 2007

Penalty

Initial $5,000

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 chemical
unloading procedures were inadequate: At 12000 Lawndale, Gate 5, Pasadena,
TX 77017, on
or about April 11, 2007, the operating procedure for the unloading of
hydrochloric acid (HCL)
from delivery truck (tanker) to the facility's HCL's storage was
inadequate in that the procedure
did not contain the following information:
Steps necessary to verify the liquid level in the HCL delivery truck
tanker.
Steps necessary to inform the delivery truck driver/unloader that the HCL
transfer was
complete.  The driver who monitored the HCL transfer operation had no
means of
verifying the HCL quantity that remained in the delivery truck tanker
other
than visually
looking for the hammer effect on the transfer hose.
The allowable flow limits (air pressure) for the HCL transfer operation.
Means such as radio or unit alarm for the delivery truck driver/unloader
to warn the
board operator and other workers nearby of an emergency release such as
the HCL
release that occurred on or about March 28, 2007.
***Certification AND Documentation of Abatement Required***
Among other methods, one feasible and acceptable abatement method is to
install engineering
controls and administrative controls to monitor the liquid level in the
hydrochloric acid storage
tank.  Also, engineering controls to monitor the flow rate for the HCL
transfer operation. The
administrative controls can be in the form of specific written operation
procedures.
DISCLAIMERS:
1) You are not limited to the abatement methods suggested above.
2) The methods explained are general and may not  be effective in all
cases.
3) The employer is responsible for selection and carrying out an
appropriate abatement
method.