OSHA Inspection: PSC INDUSTRIAL OUTSOURCING INC.

Issued

Aug 29, 2007

Abate by

Oct 3, 2007

Penalty

Initial $5,000 · Current $5,000

Hazardous substances 06401430

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
Commodity Storage Area (Warehouse) - The employer did not take steps to
assure that
incompatible chemicals were not stored together such as to create a
potential hazard.
On 5/7/07 the employer identified two muriatic acid totes that were being
stored
immediately adjacent to bleach (Sodium Hypochlorite) totes creating a
potential mixing
hazard. The employer had identified two missing acid totes that had been
mistakenly
stored among the bleach totes; the employer had identified that the acid
totes had been
mistaken for bleach totes and that the acid totes looked identical to the
bleach totes and
could be mistaken for bleach totes.  The employer did not assure that the
acid totes were
moved to a location separate from the stored bleach totes.
On 5/17/07, 10 days after the acid-bleach hazard was identified, an
incident in which
acid was accidentally added to the bleach holding tank caused an
exothermic reaction that
released chlorine gas and hydrochloric acid vapors.  The acid, muriatic
acid (31
hydrochloric acid), was added to bleach (12.5Sodium Hypochlorite).  The
release
would have been prevented, if the acid totes that were identified as
having been stored
with bleach totes had been promptly removed from the site or to a separate
storage area.
On 5/17/05 PSC contacted Harcross Chemical to remove the acid totes just
prior to the
toxic gas and vapor release.
Muriatic acid and bleach are incomparable.  Incompatible chemicals are
chemicals that
if accidentally mixed could react and cause toxic vapor release or fire.
Among the feasible controls for this hazard were:
1.Assure that the acid totes were moved to a location separate from the
stored
bleach totes.
2.Place large danger signs on the acid totes explaining the potential
reactive mixing
hazard.
3.Inform mill management in the Commodity Storage Area of the acid-bleach
storage hazard.
4.Assure that an adequate management system was in place with a chain of
custody
system to prevent the unsafe storage of incompatible chemicals, including
acid
and bleach.
5.Have PSC employees take direct possession of the delivery of small
quantity
containers (totes and drums) of acid.  Continue to take direct control of
the 5,000
gallon bulk tanker truck.
6.Have a bulk tanker deliver all the acid required for the shutdown and
have
a
larger on-site tanker to accommodate all the acid required for the job.
7.Request that the chemical supplier ship totes that are color coded for
specific
chemicals and not ship incompatible chemicals in totes that are identical
in shape,
size, and color.