OSHA Inspection: JEWEL FOOD STORES, INC.

Issued

Jul 8, 2011

Abate by

Oct 5, 2011

Penalty

Current $3,600

General-duty citation text

29 CFR 1910.119(d)(2)(i)(E):  Process safety information pertaining to the
technology of the
process did not include an evaluation of the consequence of deviations,
including those
affecting the safety and health of employees:
a) Jewel Food Stores Inc. - The employer did not evaluate and document the
consequences of
deviations from its ammonia refrigeration process technology ("North" and
"South") for such
operating parameters as, but not limited to:
A. Temperatures, pressures and levels in the high, low and constant
pressure ammonia
receivers.
B. Ammonia compressor suction and discharge pressures and temperatures,
and oil
pressures.
C. Evaporative condenser temperatures and pressures.
In accordance with 29 CFR 1903.19(c), abatement certification is required
for this
violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 8, 2011

Abate by

Oct 5, 2011

Penalty

Initial $5,000 · Current $6,500

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B):  Process safety information pertaining to the
equipment in the
process did not include the piping and instrumentation diagrams (P&IDs):
a) Jewel Food Stores Inc. - The employer's schematics of its ammonia
refrigeration
processes did not include information required for a Piping and
Instrumentation  Diagram
(P&ID), as per recognized and generally accepted good engineering
practice, as well as, the
American National Standard Institude (ANSI), Instrument Society of America
(ISA)
ANSI/ISA S5.1 Code.
Examples of information that was not included are, but are not limited to:
A.Flow directions;
B.Pump capacities and head pressures;
C.Pressure vessel ratings, sizes, nozzle data and materials of
construction;
D.Computer control(s) and system input loops;
E.Pipe sizes and materials of construction;
F.Identification of and numbers for all valves.
In accordance with 29 CFR 1903.19(c), abatement certification is required
for this
violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 8, 2011

Abate by

Oct 5, 2011

Penalty

Initial $5,000 · Current $3,600 Reduced

General-duty citation text

29 CFR 1910.119(e)(3)(i):  The process hazard analysis did not address the
hazards of the
process:
a) Jewel Food Stores Inc. - The employer's process hazard analyses
("North" and "South")
did not address hazards of its ammonia refrigeration processes that were
not controlled as
prescribed by the ANSI/ASHRAE (American Society of heating, Refrigerating
and Air
Conditioning Engineers) Standard 15  "Safety Standard for Refrigeration
Systems", or an
equivalent.  Such hazards included, but are not limited to:
In the "North" and "South" refrigeration processes:
A) The absence of visible and audible ammonia alarms inside the engine
rooms, and outside
each entrance to the engine rooms, with manual resets located inside the
engine rooms and
with the meaning of each alarm clearly marked by signage near the
annunciators.
B) The absence of legible permanent signs, securely attached and easily
accessible, reading
"Engine Room - Authorized Personnel Only" and further communicating that
entry is
forbidden except by those personnel trained in emergency procedures when
the ammonia
alarm has been activated.
C) Door(s) communicating with the engine rooms were not tight fitting,
permitting passage
of escaping ammonia to other work areas of the building.
D) Piping piercing the interior walls of the engine were not tightly
sealed to the walls though
which a passes permitting passage of escaping ammonia to other work areas.
E) Emergency shutdown procedures including precautions to be observed in
case of a
breakdown or leak, not posted outside each engine room, immediately
adjacent to each door.
F) The absence of relieving devices to relieve hydrostatic pressure on
portion(s) of liquid
containing parts of the anhydrous ammonia system capable of being isolated
from the system
during operation, or service, that will be subjected to overpressure from
hydrostatic
expansion of the contained anhydrous ammonia liquid due to temperature
rise.
In addition, other hazards were not addressed, such as but not limited to:
G) Engine room windows to the inside of other work areas were not blast
resistant.
I) Ammonia sensors, were mounted on high ceilings of both engine rooms
("North" and
"South") that may not be able to detect releases of ammonia that form
dense mixtures of
ammonium hydroxide which tend to travel along the ground rather than rise
rapidly.
J) The inability to identify specifically which pressure relief valves(s)
may have lifted during
process operation.
K) Emergency response drills not conducted.
L) Emergency response spill exercises with the local Fire Department not
conducted.
In accordance with 29 CFR 1903.19(d), abatement certification is required
for this
violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET),
and in addition, documentation demonstration that abatement is complete
must be
included with you certification. This documentation may include, but is
not limited to,
evidence of the purchase or repair of the equipment, photographic or video
evidence of
abatement, or other written records.

Issued

Jul 8, 2011

Abate by

Oct 5, 2011

Penalty

Initial $5,000 · Current $3,600 Reduced

General-duty citation text

29 CFR 1910.119(e)(5):  The employer did not establish a system to
promptly address the
team's findings and recommendation; assure that the team's recommendations
were resolved
in a timely manner and that the resolution was documented; and actions
were completed as
soon as possible:
a) Jewel Food Stores Inc. -  The employer did not resolve and document in
a timely manner
its process hazard analysis (PHA) team's safety recommendations made in
the 2/1999 process
hazard analyses (PHA) recommendations made in the 2/1999 "South" process
PHA as
follows:
A) "Consider installing an ammonia sensor in the RV discharge header with
the alarm to the
control room to alert engineers of the relief situation."
B) "Consider coordinating emergency team's activities with all outside
involved emergency
response teams."
C) "Verify the vessel's design can accommodate operating temperatures as
low as negative
20 degrees Fahrenheit."
b) Jewel Food Stores Inc. - The employer did not establish a system to
complete actions
recommended by the process hazard analysis (PHA) team as soon as possible.
The employer
approved, but did not complete, as soon as possible, actions recommended
by its process
hazard Analysis (PHA) team in the May, 2009, revalidations of the 1999 and
2003 PHAs of
the "North" and "South" refrigeration processes, specifically:
D)"The addition of chains or scaffolding to access valves located on top
of tanks."
("North" process revalidation, May 2009)
E)"The onsite haz mat refresher with the Franklin Park Fire Department."
("South"
process revalidation, May 2009)
In accordance with 29 CFR 1903.19(d), abatement certification is required
for this
violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET),
and in addition, documentation demonstration that abatement is complete
must be
included with you certification. This documentation may include, but is
not limited to,
evidence of the purchase or repair of the equipment, photographic or video
evidence of
abatement, or other written records.

Issued

Jul 8, 2011

Abate by

Oct 5, 2011

Penalty

Initial $5,000 · Current $3,600 Reduced

General-duty citation text

29 CFR 1910.119(f)(1)(i)(B):  The employer's written operating procedures
covering the
steps for each operating phase did not address normal operations:
a) Jewel Food Stores Inc. - The employer's written "Normal Startup and
Operating
Procedures" (SOPs) for its refrigeration process compressors, including
CPR-07 and CPR-
10, did not include the limits of operation for operating parameters, such
as pressures
(including oil pressures), temperatures, vessel levels and motor amps
(under different
seasonal designs).
In accordance with 29 CFR 1903.19(c), abatement certification is required
for this
violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 8, 2011

Abate by

Oct 5, 2011

Penalty

Current $6,500

General-duty citation text

29 CFR 1910.119(f)(1)(iii)(B):  The employer's written operating
procedures covering safety
and health considerations did not address the precautions necessary to
prevent exposure,
including engineering controls, administrative controls, and personal
protective equipment:
a) Jewel Food Stores Inc. - The employer's written "Line Break Procedure"
(SOP #794-26)
did not address the purging and evacuation of anhydrous ammonia as part of
that procedure,
including the precautions necessary to prevent exposure, including
engineering controls,
administrative controls, and personal protective equipment.
In accordance with 29 CFR 1903.19(c), abatement certification is required
for this
violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 8, 2011

Abate by

Oct 5, 2011

Penalty

Initial $5,000 · Current $3,600 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(ii):  Inspections and testing procedures performed
on process
equipment to maintain its mechanical integrity, did not follow recognized
and generally
accepted good engineering practices:
a) Jewel Food Stores Inc. - The employer did not ensure that an
independent inspection of
ammonia vessels and heat exchangers, "North" and "South" processes, was
carried
out by a
competent person independent of immediate commercial and production
pressures for the
installation; and, using whatever testing methods and extent that they
would consider as
necessary, to assure the on-going integrity of the equipment, as per the
International Institute
of Ammonia Refrigeration (IIAR) 110, or equivalent.
A.) The employer replaced pressure relief valves associated with work
orders (WO).  WO
3471098 on 7/12/2008 and WO 3498359 on 7/25/2008 and did not document the
conditions
of the valves that were replaced, as per recognized and generally accepted
good engineering
practice.
B.) The employer did not test the high and low pressure cutouts on the
compressors in the
"North" and "South" engine rooms, at the required setting(s), as
prescribed by IIAR 110, or
equivalent.
In accordance with 29 CFR 1903.19(c), abatement certification is required
for this
violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 8, 2011

Abate by

Oct 5, 2011

General-duty citation text

29 CFR 1910.119(j)(4)(iii):  The frequency of inspections and tests of
process equipment to
maintain its mechanical integrity was not consistent with applicable
manufacturers'
recommendations and good engineering practices, or more frequently if
determined to be
necessary by prior operating experience:
a) Jewel Food Stores Inc. - The employer's inspections and tests of
critical  equipment in its
ammonia refrigeration processes ("North" and "South") were not conducted
at a frequencies
consistent with applicable manufacturers' recommendations and good
engineering practices,
equipment included, but was not limited to:
A.) Ammonia compressors  CPR-007, CPR-008 and CPR-009 for which vibration
analyses
have not been conducted since 2006.
B.) Compressor safety cutouts associated with the ammonia compressors
CPR-03, CPR-04
and CPR-05 were not function tested annually.
In accordance with 29 CFR 1903.19(c), abatement certification is required
for this
violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 8, 2011

Abate by

Oct 5, 2011

Penalty

Initial $5,000 · Current $6,500

General-duty citation text

29 CFR 1910.119(o)(4):  The employer did not determine and document an
appropriate
response to each of the findings of the compliance audit required by 29
CFR 1910.119(o)(1),
and document that the deficiencies had been corrected:
a) Jewel Food Stores Inc. - The employer did not respond to the findings
of the Process
Safety Management program compliance audits of its ammonia refrigeration
processes, and
did not take and document corrective actions and their completion
including the following:
11/2007 Audit:
A) "Modify the Piping and Instrumentation Diagram (P&ID) to show the
safety system
interlocks, cutouts, detection and/or suppression systems."
B) "Add controls loops to the P&ID.
C) "Modify the written (Operating Procedure) program to describe the logic
of the software
and the relationship between the equipment and control system."
D) "Create a standard operating procedure for evacuation and purging of
the system (as part
of the line breaking procedures.)"
10/2010 Audit:
E) "Perform nondestructive testing for the vessels."
F) "Develop written procedures to maintain the on-going integrity of a
pressure vessels,
storage tanks and piping systems."
G) "Obtain all mill specifications sheets for process piping."
In accordance with 29 CFR 1903.19(d), abatement certification is required
for this
violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Jul 8, 2011

Abate by

Oct 5, 2011

General-duty citation text

29 CFR 1910.119(h)(2)(vi): The employer did not maintain a contract
employee
injury and
illness log related to the contractor's work in the process areas.
a) Jewel Food Stores Inc. - The employer did not maintain a contract
employee injury and
illness log related to the work of outside contractors, such as DualTemp
and Spur Electric, in
its covered processes.
In accordance with 29 CFR 1903.19(c), abatement certification is required
for this
violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).