OSHA Inspection: SUGAR CREEK PACKING COMPANY, INC.

Issued

Jul 11, 2012

Abate by

Dec 10, 2012

Penalty

Initial $7,000 · Current $4,900 Reduced

General-duty citation text

29 CFR 1910.119(e)(5):  The employer did not establish a system to
communicate the actions
to be taken, as a result of the process hazard analysis team's
recommendations, to operating,
maintenance and other employees whose work assignments are in the process
and who could be
affected by the recommendations actions:
At the establishment, the employer did not communicate all the findings
and recommendations
of the 2002 Process Hazard Analysis (PHA) initial study, and the 2007
Process Hazard Analysis
(PHA) revalidation study to the Ammonia Department employees such as, but
not limited to, all
operators, technicians, maintenance employees, and hazardous chemical
release responders.
Employees were exposed to catastrophic release of ammonia which results in
asphyxiation,
explosion and flash fire leading to death and injury 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 11, 2012

Abate by

Dec 10, 2012

Penalty

Initial $7,000 · Current $4,900 Reduced

General-duty citation text

29 CFR 1910.119(f)(1):  The employer did not develop and implement written
operating
procedures that provided clear instructions for safety conducting
activities in each covered
process consistent with the process safety information and which addressed
the elements listed
in 29 CFR 1910.119(f)(1)(i) through (f)(1)(iv):
At the establishment, the employer did not develop and implement a written
operating procedure
or task procedure with clear instructions related to the emergency
shutdown buttons (ESB)
located on the outside of the engine room.  Employees were exposed to
catastrophic release of
ammonia which results in asphyxiation, explosion and flash fire leading to
death and injury 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 11, 2012

Abate by

Jul 16, 2012

Penalty

Initial $7,000 · Current $4,900 Reduced

General-duty citation text

29 CFR 1910.119(f)(1)(iv):  The employer's written operating procedures
did not address
requirements for the safety systems and their functions:
At the establishment, at the time of inspection, the current written
operating procedures
including but not limited to the SOP BC-16-01-LT Operation of Booster (Low
Stage)
Compressor; SOP PC-16-53-HT  - Primary (High Stage) Compressor; SOP
BC-16-02-LT
Operation of Booster (Low Stage) Compressor; SOP BC-17-06-LT Operation of
Booster (Low
Stage) Compressor; EC-19-01-HT Operation of Evaporative Condenser;
EV-01-10-HT Operation
of Process Temperature Control Evaporator did not address the function of
safety
systems such
as:  emergency stop buttons, isolation devices (King Valves), water spray
systems, and
emergency backup power.  Employees were exposed to catastrophic release of
ammonia which
results in asphyxiation, explosion and flash fire leading to death and
injury to persons in and
near the facility.
29 CFR 1903.19(c)(2) abatement of the above violation was verified at the
time of
inspection.  No certification is required.tion

Issued

Jul 11, 2012

Abate by

Dec 10, 2012

Penalty

Initial $7,000 · Current $4,900 Reduced

General-duty citation text

29 CFR 1910.119(g)(1)(i):  The employer did not train each employee,
before being involved
in operating a newly assigned process, in an overview of the process and
in
the operating
procedures as specified in 29 CFR 1910.119(f):
At the establishment, the employer did not provide training to the Ammonia
Department
employees such as, but not limited to, all operators, technicians,
maintenance employees, and
hazardous chemical release responders regarding specific safety and health
hazards, emergency
operations to include shut down and safe work practices related to their
assigned duties and
responsibilities.  Employees have not received the required knowledge,
skills, and abilities
including but not limited to the training on the facility specific
operating procedures such as but
not limited to the SOP BC-16-01-LT Operation of Booster (Low Stage)
Compressor; SOP PC-
16-53-HT  - Primary (High Stage) Compressor; SOP BC-16-02-LT Operation of
Booster (Low
Stage) Compressor; SOP BC-17-06-LT Operation of Booster (Low Stage)
Compressor; EC-19-
01-HT Operation of Evaporative Condenser; EV-01-10-HT Operation of Process
Temperature
Control Evaporator.  Employees were exposed to catastrophic release of
ammonia which results
in asphyxiation, explosion and flash fire leading to death and injury 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 11, 2012

Abate by

Dec 10, 2012

Penalty

Initial $7,000 · Current $4,900 Reduced

General-duty citation text

29 CFR 1910.119(j)(3):  The employer did not train each employee involve
in maintaining the
on-going mechanical integrity of process equipment in an overview of that
process and its
hazards and in the procedures applicable to the employee's job tasks to
asssure that the employee
can perform the job tasks in a safe manner:
At the establishment, training for process maintenance activities was not
implemented.  The
employer did not provide training for the Ammonia Department employees
such as, but not
limited to, all operators, technicians, maintenance employees, and
hazardous chemical release
responders related to the maintaining of the on-going mechanical integrity
of ammonia
refrigeration system; the ammonia system equipment; the inspection,
testing and preventive
maintenance procedures applicable to the employee's job tasks to assure
that the employees can
perform the job tasks in a safe manner.  Employees were exposed to
catastrophic release of
ammonia which results in asphyxiation, explosion and flash fire leading to
death and injury 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.