OSHA Inspection: WORTHEN INDUSTRIES, INC.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $1,600 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.23(a)(7):  Temporary floor opening(s) were not guarded by
standard railings or
constantly attended by someone:
a.Mezzanine Behind P-35 - A floor opening created by the removal of
equipment
was not protected as required.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $5,600 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.23(c)(1):  Open sided floor(s) or platform(s) 4 feet or more
above the adjacent
floor or ground level were not guarded by standard railings (or the
equivalent as specified in 29
CFR 1910.23(e)(3)(i) through (v)), on all open sides:
a.Mezzanine - While performing an accident investigation after an explosion
occurred and four workers fell from the unprotected Mezzanine, three
additional
workers were not protected from falls from the Mezzanine Level to the
concrete
floor below.

Issued

Jul 21, 2010

Abate by

Jul 27, 2010

Penalty

Initial $5,600 · Current $2,800 Reduced

General-duty citation text

29 CFR 1926.501(b)(1):  Each employee on a walking/working surface
(horizontal and vertical
surface) with an unprotected side or edge which is 6 feet (1.8m) or more
above a lower level
was not protected from falling by the use of guardrail system(s), safety
net
system(s), or
personal fall arrest system(s):
a.Mezzanine - The worker assisting the construction crew was not protected
from
falls.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $2,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.36(h)(2):  Outdoor exit route subject to ice and snow
accumulation was not
covered:
a.Exterior Stairway from the Polymer Dept. Mezzanine - The exterior exit
stairway
was not covered.  Also, it was not kept free of ice accumulation.

Issued

Jul 21, 2010

Abate by

Aug 23, 2010

Penalty

Initial $2,000 · Current $3,500

General-duty citation text

29 CFR 1910.119(d)(3)(ii):  The employer did not document that the
equipment in the process
complied with recognized and generally accepted good engineering practices:
a.Site - Flammable liquid lines were not labeled outside of the building
nor inside
of the building.
AMONG OTHER METHODS, ONE FEASIBLE AND ACCEPTABLE MEANS OF
ABATEMENT WOULD BE TO FOLLOW THE REQUIREMENTS OF AMERICAN
NATIONAL STANDARDS INSTITUTE (ANSI) 13.1-2007, ENTITLED "SCHEME FOR THE
IDENTIFICATION OF PIPING SYSTEMS".
b.Site - Valves were not singularly identified.
AMONG OTHER METHODS, ONE FEASIBLE AND ACCEPTABLE MEANS OF
ABATEMENT WOULD BE TO FOLLOW THE REQUIREMENTS OF AMERICAN
NATIONAL STANDARDS INSTITUTE (ANSI) 13.1-2007, ENTITLED "SCHEME FOR THE
IDENTIFICATION OF PIPING SYSTEMS".
c.Site - Flammable liquid lines located outside of the facility were not
protected
against corrosion.
AMONG OTHER METHODS, ONE FEASIBLE AND ACCEPTABLE MEANS OF
ABATEMENT WOULD BE TO FOLLOW THE REQUIREMENTS OF THE NATIONAL
FIRE PROTECTION ASSOCIATION (NFPA) 30-2008, ENTITLED "FLAMMABLE AND
COMBUSTIBLE LIQUIDS CODE".
d.Site - Flammable liquid lines located outside of the facility were not
protected
against physical damage.
AMONG OTHER METHODS, ONE FEASIBLE AND ACCEPTABLE MEANS OF
ABATEMENT WOULD BE TO FOLLOW THE REQUIREMENTS OF THE NATIONAL
FIRE PROTECTION ASSOCIATION (NFPA) 30-2008, ENTITLED "FLAMMABLE AND
COMBUSTIBLE LIQUIDS CODE".
e.Site - Quarter-turn ball valves were used control flow from the bottoms
of process
vessels into drums for shipping, instead of self-closing valves, which
would
minimize the quantities of flammables escaping in the event of a release.
AMONG OTHER METHODS, ONE FEASIBLE AND ACCEPTABLE MEANS OF
ABATEMENT WOULD BE TO FOLLOW THE REQUIREMENTS OF THE NATIONAL
FIRE PROTECTION ASSOCIATION (NFPA) 30-2008, ENTITLED "FLAMMABLE
ANDCOMBUSTIBLE LIQUIDS CODE".
f.Churn Room - When pouring a Class I flammable from an upper level
mezzanine
into a process vessel, the pail from which the material was being poured
was
neither bonded nor grounded.
AMONG OTHER METHODS, ONE FEASIBLE AND ACCEPTABLE MEANS OF
ABATEMENT WOULD BE TO FOLLOW THE REQUIREMENTS OF THE NATIONAL
FIRE PROTECTION ASSOCIATION (NFPA) 30-2008, ENTITLED "FLAMMABLE AND
COMBUSTIBLE LIQUIDS CODE".
g.Polymer Dept. - A Hot Work permit was not completed prior to welding
operations.
AMONG OTHER METHODS, ONE FEASIBLE AND ACCEPTABLE MEANS OF
ABATEMENT WOULD BE TO FOLLOW THE REQUIREMENTS OF THE NATIONAL
FIRE PROTECTION ASSOCIATION (NFPA) 30-2008, ENTITLED "FLAMMABLE AND
COMBUSTIBLE LIQUIDS CODE".
h.Churn Room - Combustible and flammable waste material were not disposed
of
daily.
AMONG OTHER METHODS, ONE FEASIBLE AND ACCEPTABLE MEANS OF
ABATEMENT WOULD BE TO FOLLOW THE REQUIREMENTS OF THE NATIONAL
FIRE PROTECTION ASSOCIATION (NFPA) 30-2008, ENTITLED "FLAMMABLE AND
COMBUSTIBLE LIQUIDS CODE".

Issued

Jul 21, 2010

Abate by

Aug 3, 2010

Penalty

Initial $5,600

General-duty citation text

29 CFR 1910.119(d)(1)(iv):   Process safety information pertaining to the
hazards of the highly
hazardous chemicals in the process did not contain the reactivity data
information:
a.Site - The employer had not assembled process safety information related
to
reactivity data.

Issued

Jul 21, 2010

Abate by

Aug 3, 2010

General-duty citation text

29 CFR 1910.119(d)(2)(i):   Process safety information pertaining to the
technology of the
process did not include the elements specified in 29 CFR
1910.119(d)(2)(i)(A) through (E):
a.Site - The employer had not assembled process safety information related
to
the
technology of the process as required.y

Issued

Jul 21, 2010

Abate by

Aug 3, 2010

General-duty citation text

29 CFR 1910.119(d)(3)(i):  Process safety information pertaining to the
equipment in the process
did not include the elements specified in 29 CFR 1910.119(d)(3)(i)(A)
through (H):
a.Site - The employer had not assembled process safety information related
to the
equipment in the process as required.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $5,600 · Current $2,800 Reduced

General-duty citation text

29 CFR 1910.119(e)(1):  The employer did not perform an initial process
hazard analysis
(hazard evaluation) on processes covered by 29 CFR 1910.119:
a.Site - An initial process hazard analysis had not been developed as
required.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $5,600 · Current $3,500 Reduced

General-duty citation text

29 CFR 1910.119(f)(1):  The employer did not develop and implement written
operating
procedures that provided clear instructions for safety conducting
activities in each covered
process consistent with the process safety information and which addressed
the elements listed
in 29 CFR 1910.119(f)(1)(i) through (f)(1)(v):
a.Site - Written operating instructions for the procedure entitled "Wash
Procedures
for All Polymer Vessels" were not clear.   Also, the procedure was
incomplete.
b.Site - Written operating procedures did not include the necessary
information
specified in (i) through (iv).
ABATEMENT NOTE: Procedures shall address at least the following elements:
1910.119(f)(1)(i) Steps for each operating phase:
(A)  Initial startup;
(B)  Normal operations;
(C)  Temporary operations;
(D)  Emergency shutdown including the conditions under which emergency
shutdown is
required, and the assignment of shutdown responsibility to qualified
operators to ensure
that emergency shutdown is executed in a safe and timely manner.
(E)  Emergency Operations;
(F)  Normal shutdown; and,
(G)  Startup following a turnaround, or after an emergency shutdown.
1910.119(f)(1)(ii) Operating limits:
(A)  Consequences of deviation; and
(B)  Steps required to correct or avoid deviation.
1910.119(f)(1)(iii) Safety and health considerations:
(A)  Properties of, and hazards presented by, the chemicals used in the
process;
(B)  Precautions necessary to prevent exposure, including engineering
controls,
administrative controls, and personal protective equipment;
(C)  Control measures to be taken if physical contact or airborne exposure
occurs;(D)
Quality control for raw materials and control of hazardous chemical
inventory
levels; and,
(E)  Any special or unique hazards.
1910.119(f)(1)(iv) Safety systems and their functions.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $5,600

General-duty citation text

29 CFR 1910.119(f)(4):  The employer did not develop and implement safe
work practices for
employees and contractor employees to provide for the control of hazards
during operations such
as lockout/tagout; confined space entry; opening process equipment or
piping; and control over
entrance into a facility by maintenance, contractor, laboratory, or other
support personnel:
a.Site - Safe work practices were not implemented for employees and
contractor
employees to control of hazards during lockout/tagout operations nor
controlling
entrance into a facility by contractor personnel.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $5,600

General-duty citation text

29 CFR 1910.119(g)(1)(i):  The employer did initially train each employee,
presently involved
in operating process, in a overview of the process and in the operating
procedures
as specified
in 29 CFR 1910.119(f).
a.Site - Workers had not been trained as required.

Issued

Jul 21, 2010

Abate by

Jul 27, 2010

Penalty

Initial $2,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.119(h)(2)(i):  The employer, when selecting a contractor, did
not obtain and
evaluate information regarding the contract employer's safety performance
and programs:
a.Site - Worthen Industries did not obtain and evaluate information
regarding the
contract employer's safety performance and programs.

Issued

Jul 21, 2010

Abate by

Aug 3, 2010

Penalty

Initial $2,000 · Current $2,000

General-duty citation text

29 CFR 1910.119(j)(2):  The employer did not establish and implement
written procedures to
maintain the on-going mechanical integrity of process equipment:
a.Site - Written procedures to maintain the on-going mechanical integrity
of process
equipment had not been developed.

Issued

Jul 21, 2010

Abate by

Aug 3, 2010

Penalty

Initial $2,000

General-duty citation text

29 CFR 1910.119(j)(3):  The employer did not train each employee involved
in maintaining the
on-going mechanical integrity of process equipment in an overview of that
process and its
hazards and in the procedures applicable to the employee's job tasks to
assure that the employee
can perform the job tasks in a safe manner:
a.Site - Workers engaged in maintaining the on-going mechanical integrity
of
process equipment had not been trained in the procedures applicable to the
employee's job tasks to assure that the employee can perform the job tasks
in a
safe manner.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $5,600 · Current $2,800 Reduced

General-duty citation text

29 CFR 1910.119(k)(1):  The employer did not issue a hot work permit for
work operations
conducted on or near a covered process:
a.Site - A hot work permit was not used when conducting welding and cutting
operations on and near covered processes.

Issued

Jul 21, 2010

Abate by

Aug 3, 2010

Penalty

Initial $2,000

General-duty citation text

29 CFR 1910.119(l)(1):  The employer did not establish and implement
written procedures to
manage changes to process chemicals, technology, equipment, and
procedures;
and, changes to
facilities that affect a covered process:
a.Site - The employer had not developed nor implemented written procedures
to
manage changes to process chemicals, technology, equipment, and procedures.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $2,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.151(c):  Where employees were exposed to injurious corrosive
materials, suitable
facilities for quick drenching or flushing of the eyes and body were not
provided
within the work
area for immediate emergency use:
a.Acid Storage Area - Access to the eyewash and shower was blocked by
drums,
pails and other materials in storage.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $2,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.176(b):  Storage of material was allowed to create a hazard:
a.Acid Storage Area - Incompatible materials were stored together,
including but
not limited to fluorotitanic acid, 25sodium hypochlorite and sulfoethyl
methacrylate.
b.Storage Area, Rack Designation 2-F-54 - Rack legs and braces were bent
and out
of plumb.
c.Storage Area, Rack Designation 2-E-22 - Rack legs did not meet the floor
properly.on

Issued

Jul 21, 2010

Abate by

Jul 26, 2010

Penalty

Initial $2,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.304(g)(5):  The path to ground from circuits, equipment, and
enclosures was not
permanent and continuous:
a.Electrical Room - A pedestal fan was found to be missing a ground pin.nd

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $2,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.307(c):  Equipment, wiring methods, and installations of
equipment in
hazardous (classified) locations were not intrinsically safe, approved for
the hazardous
(classified) location, nor safe for the hazardous (classified) location:
a.Mezzanine Level Behind P-40 - The cover to the exhaust fan junction box
in
the classified location was not properly installed nor sealed.

Issued

Jul 21, 2010

Abate by

Aug 3, 2010

Penalty

Initial $5,600 · Current $2,800 Reduced

General-duty citation text

29 CFR 1910.332(b)(1):  Employees were not trained in and familiar with
the safety-related
work practices required by 29 CFR 1910.331 through 29 CFR 1910.335 that
pertained to their
respective job assignments:
a.Site - Workers had not been trained as required.

Issued

Jul 21, 2010

Abate by

Aug 3, 2010

General-duty citation text

29 CFR 1910.332(b)(3): Qualified persons (i.e. those permitted to work on
or near exposed
energized parts) were not, at a minimum, trained:
a.Site - Employees that the employer had designated to work on or near
energized
parts were not trained as required.
ABATEMENT NOTE:  Such employees shall be trained in the following, at a
minimum:
(i)  The skills and techniques necessary to distinguish exposed live parts
from other parts
of electric equipment;
(ii)  The skills and techniques necessary to determine the nominal voltage
of exposed live
parts;
(iii)  The clearance distances specified in 1910.333(c) and the
corresponding voltages to
which the qualified person will be exposed.

Issued

Jul 21, 2010

Abate by

Jul 26, 2010

Penalty

Initial $5,600 · Current $2,800 Reduced

General-duty citation text

29 CFR 1910.335(a)(1)(i):  Employees working in areas where there were
potential
electrical
hazards were not provided with, and/or did not use, electrical protective
equipment that was
appropriate for the specific parts of the body to be protected and for the
work to be performed:
a.Site - Personal protective equipment for the specific parts of the body
were not
provided to workers as required.

Issued

Jul 21, 2010

Abate by

Jul 26, 2010

Penalty

Initial $5,600 · Current $2,800 Reduced

General-duty citation text

29 CFR 1910.335(a)(2)(i):  When working near exposed energized conductors
or circuit parts,
each employee did not use insulated tools or handling equipment when the
tools or handling
equipment might have made contact with such conductors or parts:
a.Site - Insulated tools had not been provided to workers who perform work
on
exposed live parts.

Issued

Jul 21, 2010

Abate by

Aug 3, 2010

Penalty

Initial $4,000 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.1200(e)(2):  The employer produced, used, or stored hazardous
chemicals at the
workplace in such a way that employees of other employer(s) could be
exposed and did not
ensure that the hazard communication program included all of the elements
listed in 29 CFR
1910.1200(e)(2)(i) through (iii):
a.Site - The employer's Hazard Communication Program did not outline and
the
employer did not implement the elements specified in paragraphs (i)
through (iii)
for outside contractors working in the facility.
ABATEMENT NOTE:  The elements specified in paragraphs (i) through (iii)
are:
(i)   The methods the employer will use to provide the other employer(s)
on-site access to
material safety data sheets for each hazardous chemical the other
employer(s)' employees may
be exposed to while working;
(ii)  The methods the employer will use to inform the other employer(s) of
any precautionary
measures that need to be taken to protect employees during the workplace's
normal operating
conditions and in foreseeable emergencies; and,
(iii)  The methods the employer will use to inform the other employer(s)
of the labeling system
used in the workplace.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $2,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.1200(h)(1):  Employees were not provided information and
training as specified
in 29 CFR 1910.1200(h)(1) and (2) on hazardous chemicals in their work
area at the time of
their initial assignment and whenever a new hazard was introduced into
their work area:
a.Site - Workers not regularly assigned to the facility were not trained
as required.

Issued

Jul 21, 2010

Abate by

Jul 26, 2010

Penalty

Initial $63,000 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.252(a)(3)(i):  Welding, cutting, or other hot work was
performed on used
drums, barrels, tanks, or other containers that had not been cleaned so
thoroughly as to make
absolutely certain there were no flammable materials present or any
substances such as
greases, tars, acids, or other materials which where subjected to heat,
might produce
flammable or toxic vapors:
a.Site - Welding was permitted on a Vessel P-35 where the vessel had not
been
cleaned so thoroughly as to make absolutely certain there were no flammable
materials present.

Issued

Jul 21, 2010

Abate by

Jul 26, 2010

Penalty

Current $7,000

General-duty citation text

29 CFR 1910.252(a)(3)(ii):  All hollow spaces, cavities, or containers
were not vented to
permit the escape of air or gases before preheating, cutting, or welding
was performed:
a.Site - Vessel P-35 was not ventilated prior to allowing welding on the
vessel.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $800

General-duty citation text

29 CFR 1904.29(b)(1):  A log of all recordable work-related injuries and
illnesses (OSHA Form
300 or equivalent), was not completed in the detail as required by the
regulation:
a.2008 OSHA 300 Log Column F - Events logged did not fully describe the
injury
or illness, parts of body affected, and object/substance that directly
injured or
made the person ill.

Issued

Jul 21, 2010

Abate by

Jul 25, 2010

Penalty

Initial $800

General-duty citation text

29 CFR 1904.29(b)(1):  A log of all recordable work-related injuries and
illnesses
(OSHA Form
300 or equivalent), was not completed in the detail as required by the
regulation:
a.2009 OSHA 300 Log Column F - Events logged did not fully describe the
injury
or illness, parts of body affected, and object/substance that directly
injured or
made the person ill.