OSHA Inspection: POLYCARBON INDUSTRIES, INC. DBA PCI SYNTHESIS

Issued

Dec 3, 2010

Abate by

Feb 4, 2011

Penalty

Initial $2,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.119(d)(1)(v):   Process safety information pertaining to the
hazards of the highly
hazardous chemicals in the process did not contain the corrosivity data
information:
(a) Location - Manufacturing Area:
On or about 9/17/10, the employer's process safety information did not
include
corrosivity data with respect to chemicals used in the process and it's
interaction with the
materials of construction for the equipment used in the process.

Issued

Dec 3, 2010

Abate by

Jan 19, 2011

Penalty

Initial $2,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(ii):  The employer did not document that the
equipment in the process
complied with recognized and generally accepted good engineering practices:
(a) Location - Establishment:
On or about 9/17/10, the employer did not document that equipment used in
the covered
process (glass lined pressure vessels, piping, rupture discs, chemical
hoses and pumps
etc.) that was constructed in accordance with codes or standards was
complying with
recognized and generally accepted good engineering practices.

Issued

Dec 3, 2010

Abate by

Feb 9, 2011

Penalty

Initial $2,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.119(e)(1):  The employer did not perform an initial process
hazard analysis
(hazard evaluation) on processes covered by 29 CFR 1910.119:
(a) Location - Warehouse and Manufacturing Area:
On or about 9/17/10, the hazard of toxic vapors from accumulating in pits
present to
contain thionyl chloride needs to be identified, evaluated and controlled
should this
condition exist.
(b) Location - Warehouse and Manufacturing Area:
On or about 9/17/10 the employer did not address or prevent the covered
process
or the
storage of thionyl chloride from being struck by forklifts.
(c) Location - Establishment:
On or about 9/17/10, the employer did not address human factors such as
breaks, similar
control panels, alarms and fatigue.
(d) Location - Establishment:
On or about 9/17/10, the employer did not identify appropriate safeguards
to control high
consequence hazards such as fire, explosion and toxic release.

Issued

Dec 3, 2010

Abate by

Jan 19, 2011

Penalty

Initial $2,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(A):  The employer's written operating procedures
covering the
operating limits did not address consequences of deviation beyond such
operating limits:
(a) Location - Establishment:
On or about 9/17/10, operating procedures were not written to address when
and if
operators of the covered process are allowed to override operating
parameters or bypass
equipment.

Issued

Dec 3, 2010

Abate by

Jan 19, 2011

Penalty

Initial $2,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(i):  Inspections and tests were not performed on
process
equipment to
maintain its mechanical integrity:
(a) Location - Manufacturing Area:
On or about 9/17/10, the employer was not conducting mechanical integrity
inspections
of their covered process equipment that was manufactured to specific
engineering
standards.

Issued

Dec 3, 2010

Abate by

Jan 19, 2011

Penalty

Initial $2,500

General-duty citation text

29 CFR 1910.119(l)(1):  The employer did not establish and implement
written procedures to
manage changes to process chemicals, technology, equipment, and
procedures; and, changes to
facilities that affect a covered process:
(a) Location - Establishment:
On or about 9/17/10, the employer never developed a written program to
manage
changes to their covered process.