OSHA Inspection: VALERO REFINERY

Issued

Jun 2, 2010

Abate by

Dec 31, 2010

Penalty

Initial $4,500 · Current $4,500

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
employer did not furnish
employment and a place of employment which were free from recognized
hazards that were
causing or likely to cause death or serious physical harm to employees in
that employees were
exposed to fire and explosion hazards.  1) The employer fails to ensure
that the burner
management system on boilers located within the facility are in compliance
with NFPA 85 Boiler
and Combustion Systems Hazards Code 5.3.7.1 and 5.7.2, as well as
manufacturer's and design
specifications.  2) Perform a risk assessment to identify, evaluate and
control the hazards
involved with the process in accordance with ANSI/ISA S.84.001 and
IEC-61511.  3) Ensure
that the boiler maintenance training program for the facility is in
compliance with NFPA 85
Boiler and Combustion Systems Hazards Code 4.4.2.2.1 and 4.4.2.2.2:
1)a)This violation most recently occurred at the Valero Refining facility
in
Texas
City, Texas on or about December 4, 2009, and times thereto, when the
employer
failed to ensure that the response time from flame failure to
de-enerigization or
closure of the safety shutoff valve did not exceed four seconds on B-28
Boiler.
ABATEMENT NOTES: Among other methods, one feasible method of abatement
to reduce this hazard is to:  Follow the requirements of the National Fire
Protection Agency Code 85 Boiler and Combustion Systems Hazards Code
(NFPA 85) Section 5.3.7.1, which states that the response time from flame
failure to de-energization of the safety shutoff valves shall not exceed
four
seconds.  Note:  In addition to abatement certification, the employer is
required
to submit within 10 calendar days after abatement date, documentation for
this
item in accordance with 29 CFR 1903.19.
b)This violation most recently occurred at the Valero Refining facility in
Texas
City, Texas on or about December 4, 2009, and times thereto, when the
employer
failed to ensure that the fuel flow control valve on Boiler B-28 was
equipped with
an interlock action that would trip fuel flow when the flow control valve
left a
predetermined setting during the light off sequence.
ABATEMENT NOTES: Among other methods, one feasible method of abatement
to reduce this hazard is to:  Follow the requirements of the National Fire
Protection Agency Code 85 Boiler and Combustion Systems Hazards Code
(NFPA 85) Section 5.7.2 The following equipment shall be required:  A
safety
interlock system with the capability to provide interlock action that will
trip fuel
should its flow control valve leave a predetermined setting during fuel
transfer.
Note:  In addition to abatement certification, the employer is required to
submit
within 10 calendar days after abatement date, documentation for this item
in
accordance with 29 CFR 1903.19.
c)This violation most recently occurred at the Valero Refining facility in
Texas
City, Texas on or about December 4, 2009, and times thereto, when the
employer
failed to ensure that the solenoid installed on the main fuel gas control
valve798A was appropriate and that the equipment was installed properly and
consistent with design specifications and the manufacturer's instructions.
ABATEMENT NOTES:  Among other methods, one feasible method of
abatement to reduce this hazard is to:  Follow the requirements of the
design
specifications and the manufacturer's instructions, which states that
Solenoid
valves shall be 24 VDC low power type.  Note:  In addition to abatement
certification, the employer is required to submit within 10 calendar days
after
abatement date, documentation for this item in accordance with 29 CFR
1903.19.
2)a)The employer failed to ensure that the process hazard analysis
performed was appropriate to the complexity of the process and did not
identify, evaluate and
control the hazards involved in the process. This violation most recently
occurred
at the Valero Refining facility in Texas City, Texas, on or about December
04,
2009, and times thereto, when the employer failed to identify, evaluate and
control the hazard of the main fuel gas flow control valve failure on the
B28
Boiler.
ABATEMENT NOTES:  Among other methods, one feasible method of
abatement to reduce this hazard is to:  Follow the requirements of the
IEC-61511
and ANSI/ISA 84.001 which requires the employer to perform a risk
assessment
to identify and address the hazards and hazardous events that could occur
under
all reasonably foreseeable circumstances.  Note: In addition to abatement
certification, the employer is required to submit within 10 calendar days
after
abatement date, documentation for this item in accordance with 29 CFR
1903.19.
3)a)The employer did not establish a formal training program that was
consistent
with
the equipment and hazards involved, before allowing maintenance personnel
to
perform all required maintenance task.  This violation most recently
occurred at
the Valero Refining facility in Texas City, Texas on or about December 4,
2009,
and times thereto, when the employer failed to establish a program that
would
train maintenance personnel on, the maintenance of and the hazards
associated
with working on B26, B27 & B28 Boilers.
ABATEMENT NOTES:  Among other methods, one feasible method of
abatement to reduce this hazard is to:  Follow the requirements of the
National
Fire Protection Agency Code 85 Boiler and Combustion Systems Hazards Code
(NFPA 85) Section 4.4.2.2.1, which states the owner or owner's
representative
shall be responsible for establishing a formal and ongoing program that is
consistent with the equipment and hazards involved, for training
maintenance
personnel to perform all required tasks.  Note: In addition to abatement
certification, the employer is required to submit within 10 calendar days
after
abatement date, documentation for this item in accordance with 29 CFR
1903.19.
b)The employer did not ensure that Maintenance procedures and their
associated
training programs were established to cover routine and special
techniques.  This
violation most recently occurred at the Valero Refining facility in Texas
City,
Texas on or about December 4, 2009, and times thereto, when the employer
failed to develop a procedure and provide training for the winterization
process
on B26, B27 & B28 Boilers.
ABATEMENT NOTES:  Among other methods, one feasible method of
abatement to reduce this hazard is to:  Follow the requirements of the
National
Fire Protection Agency Code 85 Boiler and Combustion Systems Hazards Code
(NFPA 85) Section 4.4.2.2.2 which states that maintenance procedures and
their
associated training programs shall be established to cover routine and
special
techniques.  Note: In addition to abatement certification, the employer is
required
to submit within 10 calendar days after abatement date, documentation for
this
item in accordance with 29 CFR 1903.19.