MORRIS, IL —
OSHA Inspection: AKZO NOBEL SURFACE CHEMISTRY, LLC
Referral inspection · Health discipline
At a glance
On , OSHA opened a referral health inspection of AKZO NOBEL SURFACE CHEMISTRY, LLC in 8005 NORTH TABLER ROAD, MORRIS, IL 60450 (NAICS 325199). OSHA activity number 315239087.
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employer broke any rule; any findings appear as the citations listed below, and citations can be contested, reduced, or withdrawn.
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Where did this inspection happen?
- Establishment
- AKZO NOBEL SURFACE CHEMISTRY, LLC
- Site address
- 8005 NORTH TABLER ROAD
- City
- MORRIS
- State
- IL
- ZIP
- 60450
What kind of inspection was it?
- Inspection type
- Referral (C)
- Scope
- Partial (B)
- Discipline
- Health
- Advance notice
- No
- Union status
- Y
When did the case open and close?
- Opened
- Closing conference
- Case closed
- Last modified
- Data loaded
Establishment context
- NAICS code
- 325199
- SIC code (legacy)
- 2869
- Employees
- 100
- Ownership type
- A
Citations
13 citations on file for this inspection.
1910.119 D03 ID
- Issued
- Nov 1, 2011
- Abate by
- Nov 4, 2011
- Penalty
- Initial $7,000 · Current $4,900 Reduced
General-duty citation text
29 CFR 1910.119(d)(3)(i)(D): Process safety information pertaining to the equipment in the process did not include the relief system design and design basis: Akzo Nobel Surface Chemistry, LLC., did not include the design basis for the following safety valves in the process safety information for the Arquad Unit Reactor #1: a. PSV 309-310 b. PSV 309-401 c. PSV 309-410 d. PSV 309-411 e. PSV 309-413 f. PSV 309-425 g. PSV 309-426 THIS ITEM CORRECTED DURING INSPECTION
Recent events (2)
- — I (S) $4900.00
- — Z (S) $7000.00
1910.119 E01
- Issued
- Nov 1, 2011
- Abate by
- Apr 1, 2012
- Penalty
- Initial $7,000 · Current $4,900 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: In May, 2010, a hydrogen storage tank, with a capacity of 10,000 pounds, was installed at the Akzo Nobel Surface Chemistry, LLC, Morris, Illinois plant. The employer did not perform an initial process hazard analysis on the Hydrogen Storage and Transfer Unit. DOCUMENTATION AND CERTIFICATION IS REQUIRED FOR THIS ITEM.
Recent events (2)
- — I (S) $4900.00
- — Z (S) $7000.00
1910.119 F01 IIB
- Issued
- Nov 1, 2011
- Abate by
- Nov 4, 2011
- Penalty
- Initial $7,000 · Current $4,900 Reduced
General-duty citation text
29 CFR 1910.119(f)(1)(ii)(B): The employer's written operating procedures covering the operating limits did not address the steps required to correct or avoid deviation beyond such operating limits: The operating procedures for the Arquad Unit Reactor #1, at the Akzo Nobel Surface Chemistry, LLC plant in Morris, Illinois, did not address the steps required to correct or avoid deviations from the normal operating limits such as over-pressurization or over- charging of the reactor. THIS ITEM WAS CORRECTED DURING THE INSPECTION
Recent events (2)
- — I (S) $4900.00
- — Z (S) $7000.00
1910.119 J04 I
- Issued
- Nov 1, 2011
- Abate by
- Feb 1, 2012
- Penalty
- Initial $7,000
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: The following equipment, at Akzo Nobel Surface Chemistry, LLC, in Morris, Illinois, has not been inspected or tested in order to maintain its mechanical integrity: a. East Batch Hydro Ammonia Feed Pump (389-125.1) b. West Batch Hydro Ammonia Feed Pump (389-126.1) c. Wash Tank Scrubber Pump (309-171) d. Continuous Hydro Ammonia Feed Pump (303-014.2) e. Ammonia Unloading Pump (389-632) f. The gaskets on the baffle flanges on the Arquad Reactor #2. DOCUMENTATION AND CERTIFICATION IS REQUIRED FOR THIS ITEM.
Recent events (2)
- — I (S)
- — Z (S) $7000.00
1910.119 J04 II
- Issued
- Nov 1, 2011
- Abate by
- Feb 1, 2012
- Penalty
- Initial $7,000
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: Inspections on the following equipment, at Akzo Nobel Surface Chemistry, LLC, in Morris, Illinois, did not follow recognized and generally accepted good engineering practices: a.The results of the piping inspections for Arquad Unit Reactor #1 and the Ammonia Storage and Transfer Unit are not reviewed by an Authorized Piping Inspector who has received certification in accordance with API 570 Piping Inspections Code: In-Service Inspection, Rating, Repair, and Alteration of Piping Systems, November, 2009. b.The results of the pressure vessel inspections for Arquad Unit Reactor #1 and the Ammonia Storage and Transfer Unit are not reviewed by a Certified Inspector in accordance with API 510 Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair and Alteration, June, 2006. c.Arquad Unit Reactor #1: The corrosion rates have not been identified or calculated for this vessel in accordance with API 510 Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair and Alteration, June, 2006. DOCUMENTATION AND CERTIFICATION IS REQUIRED FOR THIS ITEM.
Recent events (2)
- — I (S)
- — Z (S) $7000.00
1910.119 J04 III
- Issued
- Nov 1, 2011
- Abate by
- Jun 1, 2012
- Penalty
- Initial $7,000 · Current $4,900 Reduced
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 determined to be necessary by prior operating experience: The frequency of inspections and test for the following equipment at Akzo Nobel Surface Chemistry, LLC, in Morris, Illinois, was not consistent with good engineering practices: a.South Alcohol Recovery Tank (309-314) has not had an internal inspection in accordance with API 510 Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair and Alteration, June, 2006, within the past 10 years. b.Arquad Alcohol Chiller Wash Tank (309-410) has not had an internal inspection in accordance with API 510 within the past 10 years. c.North Alcohol Recovery Tank (309-315) has not had an internal inspection in accordance with API 510 within the past 10 years. DOCUMENTATION AND CERTIFICATION IS REQUIRED FOR THIS ITEM.
Recent events (2)
- — I (S) $4900.00
- — Z (S) $7000.00
1910.119 J05
- Issued
- Nov 1, 2011
- Abate by
- Dec 31, 2012
- Penalty
- Initial $7,000 · Current $4,900 Reduced
General-duty citation text
29 CFR 1910.119(j)(5): The employer did not correct deficiencies in equipment that were outside acceptable limits (as defined by process information in 29 CFR 1910.119(d) before further use or in a safe and timely manner: Akzo Nobel Surface Chemistry, LLC, Morris, Illinois, did not correct the following deficiencies in equipment that were outside acceptable limits before further use or in a safe and timely manner when necessary means are taken to assure safe operation: a.MI-Reactor Vent Chiller (309-409): In 2008, an inspection indicated that the top head thickness was below that which was minimally required. No action has been taken to address or correct this condition. In 2008, an inspection indicated that the shell was too corroded and pitted to take any readings. No action has been taken to address or correct this condition. b.Arquad Drop Tank Reboiler (309-414): In 1998, all head readings were well below the minimum thickness required. No action has been taken to address or correct this condition. c.Alcohol/MeCl Chiller (309-413): In 2003, shell readings were below the minimum thickness required. No action has been taken to address or correct this condition. DOCUMENTATION AND CERTIFICATION IS REQUIRED FOR THIS ITEM.
Recent events (2)
- — I (S) $4900.00
- — Z (S) $7000.00
1910.119 L02
- Issued
- Nov 1, 2011
- Abate by
- Nov 4, 2011
- Penalty
- Initial $7,000
General-duty citation text
29 CFR 1910.119(l)(2): The written procedures did not assure that the considerations in subparagraphs (i) through (v) were addressed prior to any change: Prior to the installation of bracing on spools at Arquad Unit, Reactors #1, 2 and 3, at Akzo Nobel Surface Chemistry, LLC, in Morris, Illinois, the considerations of subparagraphs (i) through (v) were not addressed. The subparagraphs include the technical basis, impact of change on safety and health, modifications to operating procedures, necessary time period for change, and authorization requirements for the change. THIS ITEM WAS CORRECTED DURING THE INSPECTION.
Recent events (2)
- — I (S)
- — Z (S) $7000.00
1910.119 O04
- Issued
- Nov 1, 2011
- Abate by
- Feb 1, 2012
- Penalty
- Initial $7,000
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: In 2008, a psm audit was conducted at Akzo Nobel Surface Chemistry, LLC, in Morris, Illinois. One of the action items, Item PSI-1-R, was closed out prior to the completion of the actual work to correct the deficiency. DOCUMENTATION AND CERTIFICATION IS REQUIRED FOR THIS ITEM.
Recent events (2)
- — I (S)
- — Z (S) $7000.00
1910.119 J04 I
- Issued
- Nov 1, 2011
- Abate by
- Apr 1, 2012
- Penalty
- Current $4,900
Recent events (3)
- — Q $7000.00
- — I (S) $4900.00
- — Z (S) $7000.00
1910.119 J04 II
- Issued
- Nov 1, 2011
- Abate by
- Apr 1, 2012
Recent events (3)
- — Q $7000.00
- — I (S)
- — Z (S) $7000.00
1910.119 L02
- Issued
- Nov 1, 2011
- Abate by
- Nov 4, 2011
- Penalty
- Current $4,900
Recent events (3)
- — Q $7000.00
- — I (S) $4900.00
- — Z (S) $7000.00
1910.119 O04
- Issued
- Nov 1, 2011
- Abate by
- Apr 1, 2012
Recent events (3)
- — Q $7000.00
- — I (S)
- — Z (S) $7000.00
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Source
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 315239087.
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