LINDEN, NJ — 2009-04-23 00:00:00

OSHA Inspection: CONOCOPHILLIPS BAYWAY REFINERY

Complaint inspection · Safety discipline

At a glance

On 2009-04-23 00:00:00, OSHA opened a complaint safety inspection of CONOCOPHILLIPS BAYWAY REFINERY in 1400 PARK AVE., LINDEN, NJ 07036 (NAICS 324110). OSHA activity number 311919492.

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employer broke any rule; any findings appear as the citations listed below, and citations can be contested, reduced, or withdrawn.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: Safety
Advance notice: No
Union status: Y

When did the case open and close?

Opened: 2009-04-23 00:00:00
Closing conference: 2009-10-01 00:00:00
Case closed: 2011-06-27 00:00:00
Last modified: 2011-06-28 00:00:00
Data loaded: 2011-10-14 16:38:47

Establishment context

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

Citations

7 citations on file for this inspection.

1910.27 C04

Serious Gravity 02 1 instance 10 exposed

Issued: Oct 1, 2009
Abate by: Nov 19, 2009
Penalty: Initial $2,000 · Current $2,000

General-duty citation text

29 CFR 1910.27(c)(4):  The distance from the centerline of rungs, cleats,
or steps to the
nearest permanent object in back of the ladder was less than 7 inches:
a- ConocoPhillips Bayway Refinery, Poly Splitter - Employees were exposed
to fall
hazards while using a fixed ladder to access the T-104 Poly MEA Treater in
which an
electrical conduit was located within 4-6 inches behind ladder rungs.
Condition noted
on or about 08/20/09.

Recent events (3)

2010-06-28 00:00:00 — R (S) $2000.00
2009-10-27 00:00:00 — J (S) $2000.00
2009-10-01 00:00:00 — Z (S) $2000.00

1910.119 E03 IV

Deleted Serious Gravity 10 1 instance 10 exposed

Issued: Oct 1, 2009
Abate by: Oct 6, 2009
Penalty: Initial $5,000

General-duty citation text

29 CFR 1910.119(e)(3)(iv):  The process hazard analysis did not address
the consequences of
failure of engineering and administrative controls:
a- ConocoPhillips Bayway Refinery, Poly Splitter - The 2004 PHA did not
address
the consequence of sending hydrocarbon to the E-108 A/B/C Regen-Feed
Bottoms and
T-105 MEA Regenerator if the manual valve on D-118 MEA Settler was open.
Condition noted on or about 08/19/09.

Recent events (3)

2010-06-28 00:00:00 — R (S)
2009-10-27 00:00:00 — J (S)
2009-10-01 00:00:00 — Z (S) $5000.00

1910.119 F01 II

Deleted Serious Gravity 10 1 instance 10 exposed

Issued: Oct 1, 2009
Abate by: Nov 19, 2009
Penalty: Initial $5,000

General-duty citation text

29 CFR 1910.119(f)(1)(ii):  The employer's written operating procedures
did not address the
requirements for the operating limits listed in 29 CFR
1910.119(f)(1)(ii)(A) and (B):
a- ConocoPhillips Bayway Refinery, LORU - FGBW-FGBW 2.2.1 General Operating
Information-Normal Start Up-LORU Fractionation Section Start Up Procedure
along
with FGBW-LORU 3.8.01 Safe Operating Limits Critical Operating Parameters
Consequences of Deviation did not contain safe operating limits,
consequences of
deviation and necessary corrective actions with regard to but not limited
to
temperature on the R-20 Hydrogenation Bed.  Condition noted on or about
09/29/09.

Recent events (3)

2010-06-28 00:00:00 — R (S)
2009-10-27 00:00:00 — J (S)
2009-10-01 00:00:00 — Z (S) $5000.00

1910.119 L02 II

Serious Gravity 10 1 instance 2 exposed

Issued: Oct 1, 2009
Abate by: Nov 19, 2009
Penalty: Initial $5,000 · Current $5,000

General-duty citation text

29 CFR 1910.119(l)(2)(ii):  The written procedures to manage changes did
not assure that
the impact of the change on safety and health was addressed prior to any
change:
a- ConocoPhillips Bayway Refinery, Poly Treat - MOC 20060229 Mitigation
Steps To
Avoid H/C Carry Over From The Poly MEA Treater (T-104) To The MEA
Regenerator (T-105) did not consider the safety and health consequences of
piping
vent/drain lines containing liquid propane to the D-119 MEA Storage Tank.
On
04/01/09 liquid propane was sent to D-119, overpressuring the tank and
splitting its
roof.  This resulted in the release of propane vapor and upset conditions
downstream
requiring emergency shutdown of the unit.  Condition noted on or about
04/23/09.

Recent events (3)

2010-06-28 00:00:00 — R (S) $5000.00
2009-10-27 00:00:00 — J (S) $5000.00
2009-10-01 00:00:00 — Z (S) $5000.00

1910.119 G02

Serious Gravity 10 1 instance 10 exposed

Issued: Oct 1, 2009
Abate by: Nov 19, 2009
Penalty: Initial $25,000 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.119(g)(2):  Refresher training shall be provided at least
every three years, and
more often if necessary, to each employee involved in operating a process
to assure that the
employee understands and adheres to the current operating procedures of
the process:
a- ConocoPhillips Bayway Refinery - On or about 4/23/09, employees
involved
in the
LORU Fractionator Section start up did not adequately communicate to the
on-coming
shift that the automatic shutdown systesm (HIMA) were in the bypass mode.
ConocoPhillips Bayway Refinery was previously cited for a violation of this
Occupational Safety and Health standard or its equivalent standard, 29 CFR
1910.119(f)(1), which was contained in OSHA Inspection number 311913552,
Citation number 1, Item number 1, issued on 10/09/08, with respect to a
workplace located at 1400 Park Ave., Linden, NJ 07036.  The citation
became a
final order on 03/23/09.

Recent events (3)

2010-06-28 00:00:00 — R (S) $7000.00
2009-10-27 00:00:00 — J (S) $7000.00
2009-10-01 00:00:00 — Z (R) $25000.00

1910.119 J04 II

Serious Gravity 10 1 instance 10 exposed

Issued: Oct 1, 2009
Abate by: Nov 19, 2009
Penalty: Initial $25,000 · Current $7,000 Reduced

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 (RAGAGEP):
a- ConocoPhillips Bayway Refinery, No.7 Pipe Still - The employer failed
to follow
Refining Engineering Practice (REP) 5-5-3 Pipe Erection and Testing when
using city
water containing chloride levels in excess of 50 ppm to hydrotest newly
installed
stainless steel piping.  Condition noted on or about 04/05/09.
ConocoPhillips Bayway Refinery was previously cited for a violation of this
Occupational Safety and Health standard or its equivalent standard, 29 CFR
1910.119(j)(4)(ii), which was contained in OSHA Inspection number
310149836,
Citation number 1, Item number 14b, issued on 04/30/08, with respect to a
workplace located at 1400 Park Ave., Linden, NJ 07036.  The citation
became a
final order on 09/29/08.

Recent events (3)

2010-06-28 00:00:00 — R (S) $7000.00
2009-10-27 00:00:00 — J (S) $7000.00
2009-10-01 00:00:00 — Z (R) $25000.00

1910.119 L04

Serious Gravity 10 2 instances 10 exposed

Issued: Oct 1, 2009
Abate by: Oct 6, 2009
Penalty: Initial $25,000 · Current $49,000

General-duty citation text

29 CFR 1910.119(l)(4):  A change covered by 29 CFR 1910.119(l) resulted in
a change in
the process safety information required by 29 CFR 1910.119(d) and process
information was
not updated:
a- ConocoPhillips Bayway Refinery, Poly Treat - P&ID Drawing No. 109-5CA-10
Sheet No. 1A was never updated in response to MOC 20060229 to reflect the
correct
location of valves and piping associated with the installation of TL006
and
TL007 on
the T-104 Poly MEA Treater.  Condition noted on or about 04/23/09.
b- ConocoPhillips Bayway Refinery, LORU - P&ID Drawing No. 032-22GB Sheet
No. 1 was never updated in response to MOC 20040210 to reflect the removal
of
control valve DM-208 and replacement of the valve with a spool piece.
Condition
noted on or about 08/21/09.
ConocoPhillips Bayway Refinery was previously cited for a violation of this
Occupational Safety and Health standard or its equivalent standard, 29 CFR
1910.119(l)(4), which was contained in OSHA Inspection number 311915854,
Citation number 1, Item number 7, issued on 03/05/09, with respect to a
workplace located at 1400 Park Ave., Linden, NJ 07036.  The citation
became a
final order on 04/20/09.

Recent events (3)

2010-09-28 00:00:00 — R (S) $49000.00
2009-10-27 00:00:00 — J (S) $49000.00
2009-10-01 00:00:00 — Z (R) $25000.00

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 311919492.

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