Safety Incidents OSHA Severe Injury Reports · 2015–2025
5,189,992Inspections Most recent open 2026-07-18 Last loaded 2026-07-22

LINDEN, NJ —

OSHA Inspection: CONOCOPHILLIPS BAYWAY REFINERY

Complaint inspection · Health discipline

At a glance

On , OSHA opened a complaint health inspection of CONOCOPHILLIPS BAYWAY REFINERY in 1400 PARK AVE., LINDEN, NJ 07036 (NAICS 324110). OSHA activity number 311913552.

What this inspection record means

OSHA opens inspections for many reasons — routine scheduling under a national or local emphasis program, an employee complaint or referral, or a follow-up after a reported injury. Opening or conducting an inspection is not itself an allegation or a finding that this employer broke any rule; any findings appear as the citations listed below, and citations can be contested, reduced, or withdrawn.

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Where did this inspection happen?

Establishment
CONOCOPHILLIPS BAYWAY REFINERY
Site address
1400 PARK AVE.
City
LINDEN
State
NJ
ZIP
07036
Mailing
1400 PARK AVE, LINDEN, NJ 07036

What kind of inspection was it?

Inspection type
Complaint (B)
Scope
Partial (B)
Discipline
Health
Advance notice
No
Union status
Y

When did the case open and close?

Opened
Closing conference
Case closed
Last modified
Data loaded

Establishment context

NAICS code
324110
SIC code (legacy)
2911
Employees
830
Ownership type
A

Citations

6 citations on file for this inspection.

1910.119 F01

Other-than-serious Gravity 10 1 instance 2 exposed
Issued
Oct 9, 2008
Abate by
Jan 31, 2009
Penalty
Initial $5,000

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 safely 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)(iv):
a) FCAT, Old Compressor Building - On or about 07/23/08 the FCCU
experienced
an upset condition requiring the use of the number 6 blower.  Workers
turned on the
blower and were required to bring it into the unit after approximately 30
minutes of
operation.  This violated the employer's written procedure FCAT FCBW-Turbo
Machinery Equipment Manual 02.02.02-1 Startup Procedure B-6 Discharge to
B-4
Suction Jump over Open which required that the blower be vented to
atmosphere
for
60 minutes prior to opening the discharge to the unit.
Recent events (3)
  • — R (O)
  • — J (O)
  • — Z (S) $5000.00

1910.119 J02

Deleted Serious Gravity 10 1 instance 3 exposed
Issued
Oct 9, 2008
Abate by
Nov 21, 2008
Penalty
Initial $5,000

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) ABW -   The employer did not implement written procedures for the
installation of
epoxy coatings to the interior surfaces of piping.  Such procedures shall
include
proper surface preparation, adequate number of coats and cure times between
coatings, thickness measurement of coatings and necessary
verification/documentation.
On 04/09/08 approximately 2500 lbs. of butane was released from a hole in
the E-
17C exchanger outlet piping.  The epoxy lining on the interior of the pipe
spool had
failed allowing corrosion of the carbon steel pipe.
Recent events (3)
  • — R (S)
  • — J (S)
  • — Z (S) $5000.00

1910.119 J04 II

Deleted Serious Gravity 10 1 instance 3 exposed
Issued
Oct 9, 2008
Abate by
Nov 21, 2008
Penalty
Initial $5,000

General-duty citation text

29 CFR 1910.119(j)(4)(ii):  Inspections and testing procedures performed
on process
equipment to maintain its mechanical integrity, did not follow recognized
and generally
accepted good engineering practices:
a) ABW - On 04/09/08 approximately 2500 lbs. of butane leaked from a hole
in
the
E-17C exchanger outlet piping.  The epoxy lining on the interior of the
pipe spool
had failed allowing corrosion of the carbon steel.  The employer failed to
comply
with API 574 Sections 6.3.6 and 6.3.8 in that effective NDE inspection
methods to
include but not limited to radiographic profile were not used and
appropriate
inspections were not performed of the corrosion-resistant lining.
Recent events (3)
  • — R (S)
  • — J (S)
  • — Z (S) $5000.00

1910.119 J06 II

Serious Gravity 10 1 instance 3 exposed
Issued
Oct 9, 2008
Abate by
Feb 16, 2009
Penalty
Current $5,000

General-duty citation text

29 CFR 1910.119(j)(6)(ii):  Appropriate checks and inspections were not
performed to assure
that equipment is installed properly and consistent with design
specifications and the
manufacturer's instruction:
a) ABW - The employer failed to perform checks and inspections on an epoxy
coating
applied to the interior of outlet piping for the E-17C exchanger in March
2005.  The
employer did not verify the correct number of coats and proper cure time
between
applications.  In addition, appropriate thickness readings were not taken
of
the epoxy
lining.  On 04/09/08 approximately 2500 lbs. of butane was released from a
hole in
the above noted piping as the epoxy lining had failed allowing corrosion
of the carbon
steel.
Recent events (4)
  • — R (S) $5000.00
  • — P (S) $5000.00
  • — J (S) $5000.00

1910.119 L01

Other-than-serious Gravity 10 1 instance 5 exposed
Issued
Oct 9, 2008
Abate by
Jan 31, 2009
Penalty
Initial $5,000

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) FCAT - An MOC was not performed when workers were required to start the
number 6 blower in response to a unit upset on 07/23/08 and bring it into
the unit
after approximately 30 minutes of operation.  FCAT FCBW-Turbo Machinery
Equipment Manual 02.02.02.1 Startup Procedure B-6 Discharge to B-4 Suction
Jump
over Open requires that the blower be vented to atmosphere for 60 minutes
prior to
opening the discharge to the unit.  Condition noted on or about 07/25/08.
b) ABW - In March 2005 an MOC was not performed when carbon steel outlet
piping
for the E-17C and E-18C exchangers was lined with epoxy.  Piping interior
had been
lined in response to leaks caused by hydrochloric acid pitting on the
carbon steel.
Condition noted on or about 08/01/08.
Recent events (3)
  • — R (O)
  • — J (O)
  • — Z (S) $5000.00

1910.119 M05

Deleted Serious Gravity 10 1 instance 3 exposed
Issued
Oct 9, 2008
Abate by
Nov 21, 2008
Penalty
Initial $5,000

General-duty citation text

29 CFR 1910.119(m)(5):  The employer did not establish a system to
promptly address and
resolve the incident investigation report findings and recommendations:
a) ABW - The employer failed to adequately resolve recommendations found in
incident investigation number 7578 concerning a butane leak at the E-17C
outlet
piping on 01/24/05 and related engineering analysis entitled ABW E-17C and
E-18C
Outlet Chloride Corrosion - Winter 2005 dated 05/25/05.  The findings
directly
related to the butane release on 04/09/08 of the same piping noted above.
The
employer failed to look into the feasibility of the following
recommendations:
1) switch from Univar's diaphragm grade caustic to the low-chloride grade
caustic,
2) install a water purification system which removes chlorides on the BFW
to
D-11, the reactor effluent water wash settler,
3) add a chloride trap to the Vis-J spent feed stream which removes organic
chlorides.
Condition noted on or about 06/12/08.
Recent events (3)
  • — R (S)
  • — J (S)
  • — Z (S) $5000.00

More inspections at Conocophillips Bayway Refinery

Jul 8, 2011 LINDEN, NJ Jun 24, 2011 LINDEN, NJ Jun 2, 2011 LINDEN, NJ Apr 8, 2010 LINDEN, NJ Jun 17, 2009 LINDEN, NJ

View Conocophillips Bayway Refinery's full OSHA safety record →

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Source

This record is reproduced from the U.S. Department of Labor Open Data API (OSHA inspection dataset). The original IMIS detail view is available at OSHA's Establishment Search for activity number 311913552.

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