OSHA Inspection: TESORO REFINING & MARKETING CO

Issued

Feb 25, 2010

Abate by

Mar 30, 2010

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D)
Information pertaining to the equipment in the process shall include
relief system design and
design basis;
(a)  At the time of the inspection, Thursday, October 22, 2009 through
Monday, February 22,
2010, of Tesoro Refining and Marketing Co. 474 W. 900 N. Salt Lake City,
UT, Compliance
Officers reviewed written process safety information (psi) for the crude
unit pressure relieving
system.  The psi did not include the design information for operating
pressures of steam
powering P-112, which is a piece of equipment used in the system.
Tesoro's written response
to a data request dated February 22, 2010 states "Tesoro has not
established maximum or
minimum operating pressures for the steam system..".  Serious injury or
death could occur due
to not using proper design or design basis for relief systems.

Issued

Feb 25, 2010

Abate by

Mar 2, 2010

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.119(f)(1)(i)(A)
The employer shall develop and implement written operating procedures that
provide clear
instructions for safely conducting activities involved in each covered
process consistent with the
process safety information and shall address initial startup in the steps
for each operating phase:
(a) At the time of inspection, 10/22/09 to 2/22/09, of Tesoro Refinery and
Marketing Co., 474
W 900 N, Salt Lake City, Compliance Officers reviewed Standard Operating
Procedures for the
refinery's crude unit operations.  The Crude unit hot startup procedure
dated 8/27/2008 did not
include steps for the Board Operator to ensure vessels were at normal
operating levels, the Off
Test line was not being used for other purposes, the Knock Out drum was at
low level, and the
pump to the Knock Out durm was operating properly prior to commencing the
Crude Unit Hot
Startup procedure. Serious injury could occur when from overpressuration
of the unit if proper
levels were not maintained during the unit's startup.ed

Issued

Feb 25, 2010

Abate by

Mar 10, 2010

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.119(j)(5)
The employer shall correct deficiencies in equipment that were outside
acceptable limits (as
defined by process information in 29 CFR 1910.119(d)) before further use
or in a safe and
timely manner when necessary means are taken to assure safe operation:
(a) At the time of inspection, 10/22/09 to 2/22/10, at Tesoro Refinery and
Marketing Co., 474
W 900 N, Salt Lake City, the employer did not correct the deficiency of
the calibration test done
on Knockout Drum's, V-107, critical high level alarm, LAH 040363.
Compliance Officer's
review of the quarterly calibration tests done in 2009 were noted to be
from 37 percent to 53
percent and were marked as 'OK' by the inspectors. During the interviews
with employees and
supervisors, the critical high level alarm was set to signal when the
liquid level in the knockout
drum reached 62.7 percent. On the night of 10/21/09, the supervisor
observed from the outside
level gauge that the drum was full but the board was indicating that the
drum was about 49
percent full.  On 10/22/09, a quarterly calibration inspection was done on
the critical high level
alarm on the knockdown drum and the inspector recorded that the critical
high level alarm was
reading about 53 percent full. The inspector wrote in his report as 'OK'
indicating that the level
alarm was functioning properly. No further work was done on the level
alarm system to correct
the deficiency to ensure the correct level in the drum was being reported
to the Board Operator.
Serious injury or death may occur if proper levels in vessels are not
known by employees.

Issued

Feb 25, 2010

Abate by

Mar 30, 2010

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.119(l)(1)
The employer shall establish and implement written procedures to manage
changes (except
for "replacements in kind") to process chemicals, technology, equipment,
and procedures;
and, changes to facilities that affect a covered process.
(a)  At the time of the inspection, Thursday, October 22, 2009 through
Monday, February
22, 2010, of Tesoro Refining and Marketing Co. 474 W. 900 N. Salt Lake
City, UT,
Compliance Officers reviewed a written response to a UOSH data request
dated February 22,
2010.  The response stated that MOC (Management of Change) was not
conducted on the
changes made to the steam header pressure to Pump 112 (P-112) in the Crude
unit. During
interviews, employees stated the changes were made to lower the Pump's
steam header
pressure from 120 psig to approximately 85 psig. Tesoro's written incident
investigation
report confirms this.  By not implementing written procedures to manage
changes, critical
considerations may not be addressed.  This can lead to serious injury or
death to employees.

Issued

Feb 25, 2010

Abate by

Mar 30, 2010

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.119(m)(5)
The employer shall establish a system to promptly address and resolve the
incident report
findings and recommendations. Resolutions and corrective actions shall be
documented.
(a) At the time of the inspection, Thursday, October 22, 2009 through
Monday, February 22,
2010, of Tesoro Refining and Marketing Co. 474 W. 900 N. Salt Lake City,
UT,
Compliance Officers reviewed a written report of an incident which
occurred June 13th,
2006 at the Refinery's crude unit.  Resolutions and corrective actions
were not documented
as part of the incident investigation.  Serious injury or death could
occur due to not
addressing findings from incident reports.