OSHA Inspection: 5ENERAL CHEMICAL LLC

Issued

May 7, 2012

Abate by

May 20, 2012

Penalty

Initial $3,000 · Current $1,500 Reduced

General-duty citation text

29 CFR 1910.23(c)(1):  Open sided floor(s) or platform(s) 4 feet or more
above the adjacent
floor or ground level were not guarded by standard railings (or the
equivalent as specified in 29
CFR 1910.23(e)(3)(i) through (v)), on all open sides and ends:
a)On or about 12/1/2011, Fluid Bed Dryer:  A platform used to access the
dryer was not provided with a completely decked platform or rail system,
employees exposed to falls of six feet.
Abatement certification must be submitted for this item.

Issued

May 7, 2012

Abate by

May 20, 2012

Penalty

Initial $5,000 · Current $2,500 Reduced

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 accurate Piping and Instrument Diagrams (P&ID'S)
and did not represent
equipment that was existing and was part of the process:
a)On or about 11/30/2011, Ammonia Unload Area:  Valve A-V12WA noted on
P&ID sheet 1 of 3 was not present on the system.
b)On or about 11/30/11, Ammonia Unload Area:  Valve A-V2 was chain locked
open, which is not designated on to be chain locked on P&ID sheet 1 of 3.
c)On or about 11/30/11, Ammonia Unload Area:  A plugged 2 inch T located
prior to the bulk storage tanks was removed, but was still present on P&ID
sheet 1 of 3.
Abatement certification must be submitted for this item.

Issued

May 7, 2012

Abate by

May 20, 2012

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)On or about 11/30/2011, Ammonia Unload Area:  An Ammonia absorption
water bucket was in use with a flexible discharge hose.  The discharge hose
was not weighted or secured near the bottom of the bucket to prevent
displacement.  There was no design specifications for the quantity of water
needed to mitigate the potential hazard.  Reference ANSI K61.1, Safety
Requirements for the Storage and Handling of Anhydrous Ammonia, Section
4.4.1.
b)On or about 11/30/11, North and South Trains:  At the Vaporizers, Rupture
Discs were in use in lieu of Pressure Relief Devices that would re seat
themselves after opening.  Reference ANSI K61.1, Safety Requirements for
the Storage and Handling of Anhydrous Ammonia, Section 5.8.1.
Abatement certification must be submitted for this item.

Issued

May 7, 2012

Abate by

Nov 20, 2012

Penalty

Initial $5,000 · Current $2,500 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)On or about 11/30/2011, Ammonia Unload Area:  The Process Hazard
Analysis did not address the failure of utilities such as the water supply
to the
fog nozzles protecting the Ammonia Bulk Storage Tanks.
Abatement certification must be submitted for this item.

Issued

May 7, 2012

Abate by

May 20, 2012

Penalty

Initial $3,000 · Current $1,500 Reduced

General-duty citation text

29 CFR 1910.146(d)(3)(vi):  Under the permit-required confined space
program required by 29
CFR 1910.146(c)(4), the employer did not develop and implement the means,
procedures, and
practices necessary for safe permit entry operations, including verifying
that conditions in the
permit space were acceptable for entry throughout the duration of an
authorized entry:
a)On or about 11/30/2011, Fluid Bed Dryer:  During entry into the Fluid Bed
Dryer, the employees did not lock out energy sources such as steam and
compressed air.
Abatement certification must be submitted for this item.

Issued

May 7, 2012

Abate by

May 20, 2012

Penalty

Initial $3,000 · Current $1,500 Reduced

General-duty citation text

29 CFR 1910.212(a)(1):  One or more methods of machine guarding was not
provided to protect
the operator and other employees in the machine area from hazards such as
those
created by the
point of operation, ingoing nip points, rotating parts, flying chips and
sparks:
a)On or about 12/1/2011, Warehouse:  Employees were exposed to the
unguarded bag clamp and pivoting bag holder on the bag filling machine.
Abatement certification must be submitted for this item.

Issued

May 7, 2012

Abate by

May 20, 2012

Penalty

Initial $4,000 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.215(b)(9):  Guard for abrasive wheel machine where the
operator stands in front
of the machine was not constructed so that the peripheral protecting
member could be adjusted
to the constantly decreasing diameter of the wheel:
a)On or about 12/1/2011, Maintenance Shop:  A grinder was not provided with
an adjustable tongue guard.
Abatement certification must be submitted for this item.

Issued

May 7, 2012

Abate by

May 20, 2012

Penalty

Initial $5,000 · Current $2,500 Reduced

General-duty citation text

29 CFR 1910.303(g)(2)(i):  Live parts of electric equipment operating at
50 volts or more were
not guarded against accidental contact by approved cabinets or other forms
of approved
enclosures, or other means listed under this provision:
a)On or about 12/1/2011, Wet Side Control Room:  A Relay had exposed
energized parts and a two energized cable were exposed and energized.
Abatement certification must be submitted for this item.