OSHA Inspection: CHEMSTAR PRODUCTS COMPANY

Issued

Jul 14, 2011

Abate by

Aug 16, 2011

Penalty

Initial $4,900 · Current $3,430 Reduced

General-duty citation text

29 CFR 1910.119(e)(3)(i):  The process hazard analysis did not address the
hazards of the
process:
At the establishment, the process hazard analysis for the propylene oxide
system did not
address the hazards of combustible dust thereby exposing employees to a
catastrophic
release of propylene oxide which could result in respiratory hazards
including death,
cancer, fire and explosions leading to injury and death to persons in and
near the facility.
29 CFR 1903.19(d)(1) requires certification and documentation that the
abatement of the
above violation is completed.

Issued

Jul 14, 2011

Abate by

Aug 16, 2011

Penalty

Initial $4,900 · Current $3,430 Reduced

General-duty citation text

29 CFR 1910.119(f)(3):  The employer did not certify annually that the
operating procedures
are current and accurate:
Employees were exposed to a catastrophic release of propylene oxide which
could result
in respiratory hazards including death, cancer, fire and explosions
leading to injury and
death to persons in and near the facility.
29 CFR 1903.19(d)(1) requires certification and documentation that the
abatement of the
above violation is completed.

Issued

Jul 14, 2011

Abate by

Aug 16, 2011

Penalty

Initial $4,900 · Current $3,430 Reduced

General-duty citation text

29 CFR 1910.119(g)(2):  The employer did not provide refresher training at
least every three
years to the each employee involved in operating a process to assure that
the employee
understands and adheres to the current operating procedures of the process:
At the establishment, the employer did not provide refresher training to
employees
operating and maintaining the propylene oxide system thereby exposing
employees to a
catastrophic release of propylene oxide which could result in respiratory
hazards
including death, cancer, fire and explosions.
29 CFR 1903.19(d)(1) requires certification and documentation that the
abatement
of the
above violation is completed.

Issued

Jul 14, 2011

Abate by

Aug 16, 2011

Penalty

Initial $4,900 · Current $3,430 Reduced

General-duty citation text

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:
At the establishment, the employer had not developed and implemented
written
procedures for the repair of process equipment to maintain the ongoing
integrity of
equipment including storage tanks, reactors, piping, valves, and pumps.
These
procedures shall include written mechanical integrity specific task
procedures for the
inspection, testing and preventive maintenance of each process equipment,
material and
spare parts control, outlining responsibilities, authorizations and
approval for repairs,
steps to accomplish for repairing or replacing equipment, frequency of
replacement,
employee training and qualifications, welding and heat treating
requirements, inspection
and testing after repair, and documentation requirements.  Employees were
exposed to
catastrophic releases of propylene oxide which could result in respiratory
hazards
including death, cancer, fire and explosions leading to injury and death
to persons in and
near the facility.
29 CFR 1903.19(d)(1) requires certification and documentation that the
abatement of the
above violation is completed.

Issued

Jul 14, 2011

Abate by

Aug 16, 2011

Penalty

Initial $4,900 · Current $3,430 Reduced

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:
At the establishment, the employer did not perform a management of change
for the
installation of the dose vessel and the scrubber unit.  Employees were
exposed to a
catastrophic release of propylene oxide which could result in respiratory
hazards
including death, cancer, fire and explosions.
29 CFR 1903.19(d)(1) requires certification and documentation that the
abatement
of the
above violation is completed.

Issued

Jul 14, 2011

Abate by

Aug 16, 2011

Penalty

Initial $4,900 · Current $3,430 Reduced

General-duty citation text

29 CFR 1910.119(o)(1):  The employer did not certify that they had
evaluated compliance with
the provisions of 29 CFR 1910.119 at least every three years to verify
that the procedures and
practices developed under this standard were adequate and are being
followed:
At the establishment, the employer did not evaluate the propylene oxide
system
procedures and practices at least every three years to verify compliance
with the
provisions of 29 CFR 1910.119.  Compliance audits were not performed
thereby
exposing employees to a catastrophic release of propylene oxide which
could result in
respiratory hazards including death, cancer, fire and explosions leading
to injury and
death to persons in and near the facility.
29 CFR 1903.19(d)(1) requires certification and documentation that the
abatement of the
above violation is completed.