OSHA Inspection: SUNOCO PHILADELPHIA REFINERY

Issued

May 14, 2009

Abate by

Jun 8, 2009

Penalty

Initial $2,125 · Current $2,125

General-duty citation text

29 CFR 1910.119(f)(1)(i)(F) or, in the alternative, 1910.147(c)(4)(ii)(B):
The employer's
written operating procedures covering the steps for each operating phase
did not address normal
shutdown:
a. Sunoco Philadelphia Refinery, Light Hydrocarbon Separation Unit # 431 -
Two
employees sustained first and second degree burns that resulted from a
flash fire. The
accident occurred when a large flammable vapor cloud of either butane or
isobutane was
released from a 3 inch drain valve.  The documented energy control
procedure,
"Philadelphia Refinery Operating Procedure HFAU-433 Complex 431 LHSU Maint
Prep
DIB (V-211), Reboiler (E-214F) and Reflux Drum (V-212) for Maint Procedure
Number
VIII-E-1," did not clearly and specifically outline all of the steps to be
followed by
authorized employees to accomplish the lockout/tagout of the E-213 (A
through F)
Deisobutanizer Overhead Condensers and Reflux Pumps (P-214 and P-214A).
It
omitted: the process side product inlet and outlet valves for the E-213 (A
through F)
Deisobutanizer Overhead Condensers; drive steam, exhaust steam, and
suction/discharge
valves for the P-214 pump; and the drive steam and suction/discharge
valves for the P-
214A pump.  On or About 02/03/09.
ABATEMENT NOTE: ABATEMENT DOCUMENTATION IS REQUIRED.TION

Issued

May 14, 2009

Abate by

May 27, 2009

General-duty citation text

29 CFR 1910.147(d)(3): All energy isolating devices that were needed to
control the energy to
the machine or equipment were not physically located and operated in such
a manner as to
isolate the machine or equipment from the energy source(s):
a. Sunoco Philadelphia Refinery, Light Hydrocarbon Separation Unit # 431,
Deisobutanizer - During the evening of February 3, 2009, at approximately
7:00 PM,
two employees sustained first and second degree burns that resulted from a
flash fire.
The accident occurred when a large flammable vapor cloud of either butane
or isobutane
was released from an opened 3 inch drain valve.  The employer failed to
isolate
the
process sides of the Deisobutanizer Reflux Pumps,P-214 and P-214A.  On or
About
02/03/09.
ABATEMENT NOTE: ABATEMENT DOCUMENTATION IS REQUIRED.TION

Issued

May 14, 2009

Abate by

May 27, 2009

General-duty citation text

29 CFR 1910.147(d)(5)(i): Following the application of lockout or tagout
device(s) to energy
isolating device(s), all potentially hazardous stored or residual energy
was not relieved,
disconnected, restrained or otherwise rendered safe:
a. Sunoco Philadelphia Refinery, Light Hydrocarbon Separation Unit # 431 -
During the
evening of February 3, 2009, at approximately 7:00 PM, two employees
sustained first
and second degree burns that resulted from a flash fire. The accident
occurred when a
large flammable vapor cloud of either butane or isobutane was released
from the 3 inch
drain valve. The Deisobutanizer Reflux Drum (V-212) had not been
completely purged
of hydrocarbons.   On or About 02/03/09.
ABATEMENT NOTE: ABATEMENT DOCUMENTATION IS REQUIRED.TION