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

OSHA Inspection: SUNOCO, INC. (R&M) (MARCUS HOOK)

Referral inspection · Safety discipline

On , OSHA opened a referral safety inspection of SUNOCO, INC. (R&M) (MARCUS HOOK) in 100 GREEN ST., MARCUS HOOK, PA 19061 (NAICS 324110). OSHA activity number 312490527.

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employer broke any rule; any findings appear as the citations listed below, and citations can be contested, reduced, or withdrawn.

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Site address
100 GREEN ST.
City
MARCUS HOOK
State
PA
ZIP
19061
Inspection type
Referral (C)
Scope
Partial (B)
Discipline
Safety
Advance notice
No
Union status
Y
Opened
Closing conference
Case closed
Last modified
Data loaded
NAICS code
324110
SIC code (legacy)
2911
Employees
600
Ownership type
A

2 citations on file for this inspection.

1910.119 E03 VI

Serious Gravity 10 2 instances 12 exposed
Issued
Nov 13, 2009
Abate by
Dec 16, 2009
Penalty
Initial $7,000 · Current $7,000
29 CFR 1910.119(e)(3)(vi):  The process hazard analysis did not address
human factors:
a) Sunoco Marcus Hook- Ethylene Complex- The process hazard analysis did
not address human
factors related to the accessibility of manually operated isolation valves
during fire emergencies.
Operators could not gain access to unit boundary isolation valves due to
intense fire.  On or
about May 17, 2009.
b) Sunoco Marcus Hook- Ethylene Complex- The process hazard analysis did
not address the
issue of clearly labeling emergency isolation valves.  Employees had
difficulty identifying
isolation valves to stop the flow of process streams feeding a fire in the
Ethylene Unit.  On or
about May 17, 2009.
NOTE: DOCUMENTATION OF ABATEMENT OF THIS CONDITION IS REQUIREDN
Recent events (2)
  • — F (S) $7000.00
  • — Z (S) $7000.00

1910.119 J02

Serious Gravity 10 1 instance 6 exposed
Issued
Nov 13, 2009
Abate by
Jan 4, 2010
Penalty
Initial $25,000 · Current $7,000 Reduced
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:
Sunoco MH- Ethylene Complex-  Sunoco failed to establish and implement
written procedures
to maintain the on-going mechanical integrity of process piping systems.
A 10" high-pressure
process gas line experienced a 10"x 7" rupture due to heavy corrosion of
the outside diameter
of the pipe, accelerated by the formation of a corrosion cell in a crevice
where it rested on a
carbon steel sleeve on top of a concrete support.  No written procedures
were implemented to
address this recognized point of concern for corrosion.
NOTE:  DOCUMENTATION OF ABATEMENT OF THIS CONDITION IS REQUIRED
Sunoco, Inc. was previously cited for a violation of this Occupational
Safety and Health
Standard or its equivalent standard, which was contained in OSHA
Inspection: #310720263,
Citation 1, Item 1a and affirmed as a final order on 09/15/2008, with
respect to a
workplace located at the Marcus Hook plant.
Recent events (2)
  • — F (S) $7000.00
  • — Z (S) $25000.00

View Sunoco, INC. (R&M) (Marcus Hook)'s full OSHA safety record →

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 312490527.

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