OSHA Inspection: XL FOUR STAR BEEF INC.

Issued

Aug 8, 2011

Penalty

Initial $7,000 · Current $3,000 Reduced

General-duty citation text

29 CFR 1910.23(c)(1):  Open-sided floors and/or platforms four feet or more above adjacent floor or ground level were not guarded with standard railings (or equivalent) and toeboards:    a) At the facility: On or about April 5, 2011, and at times prior thereto, refrigeration technicians reading gages on the cooler roof were exposed to an approximate 20 ft. fall.    Note: Abatement certification and documentation are NOT required for this item.

Issued

Aug 8, 2011

Abate by

Sep 5, 2011

Penalty

Initial $7,000 · Current $4,450 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(H):  Process safety information pertaining to the equipment in the process did not include piping and instrumentation diagrams (P&IDs):    a) In the high side machine room, high pressure receiver: On or about April 5, 2011, and at times prior thereto, P&ID number Nampa 1 did not reflect that valve 30114 was removed.    b) In the high side machine room, between the Hansen Auto Purger and High Temperature Recirculator (V-2): On or about April 5, 2011, and at times prior thereto, a valve on the 1 pipe was not drawn on, and valves, including valve 30231, were improperly labeled on P&ID Nampa 1.    c) In the high side machine room, in the vicinity of V-2: On or about April 5, 2011, and at times prior thereto, valve 30208 was mislabeled on P&ID Nampa 1.    d) In the high side machine room, Frick Compressor: On or about April 5, 2011, and at times prior thereto, valve 10517 was incorrectly drawn on, and two valves in the thermosiphon loop were not drawn on, P&ID Nampa 1.    e) On the roof near the condensers: On or about April 5, 2011, and at times prior thereto, an angle valve between the thermosiphon vessel and the High Side Discharge pipe was not drawn on P&ID Nampa 1.    f) On the roof at 700 condenser: On or about April 5, 2011, and at times prior thereto, ball valves on the south end of the condenser were not drawn on, and components were not correctly identified on, P&ID Nampa 1.    Note: Abatement certification AND documentation are required for this item.

Issued

Aug 8, 2011

Abate by

Sep 6, 2011

Penalty

Initial $0 · Current $0

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:    a) At the facility: On or about April 5, 2011, and at times prior thereto, the employer did not have documentation or calculations related to the relief system and or the design basis for the relief system.    Note: Abatement certification AND documentation are required for this item.\r\n

Issued

Aug 8, 2011

Abate by

Sep 6, 2011

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(E):  Process safety information pertaining to the equipment in the process did not include ventilation system design:\r\n\r\na) In the high side machine room: On or about April 5, 2011, and at times prior thereto, the ventilation calculations were based on individual vessel contents and not on the whole system.\r\n\r\nb) In the high side machine room: On or about April 5, 2011, and at times prior thereto, the employer did not have documentation on the capacity of the ventilation fans.\r\n\r\nNote: Abatement certification AND documentation are required for this item. \r\n

Issued

Aug 8, 2011

Abate by

Sep 5, 2011

Penalty

Initial $7,000 · Current $4,450 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(ii): The employer did not document that equipment complied with recognized and generally accepted good engineering practices:    a) At the facility: On or about April 5, 2011, and at times prior thereto, the employer did not document that they complied with RAGAGEP as the piping inspection program did not adequately addressed the amount of rust observed on piping and vessels.    b) At the facility: On or about April 5, 2011, and at times prior thereto, the employer did not document that they complied with RAGAGEP as they did not have a valve changing procedure that included torque specifications for the bolts.    c) In the high side machine room: On or about April 5, 2011, and at times prior thereto, the employer did not document that they complied with RAGAGEP as the piping for the Mycom compressor was not labeled.    d) On the roof near the condensers: On or about April 5, 2011, and at times prior thereto, the employer did not document that they complied with RAGAGEP as the relief vents for the compressors and vessels in the high side machine room were less than 15 feet above the adjacent roof level.    e) In the high side machine room: On or about April 5, 2011, and at times prior thereto, the employer did not document that they complied with RAGAGEP as the openings where relief venting and piping penetrated the wall were not sealed.    f) Throughout the facility: On or about April 5, 2011, and at times prior thereto, the employer did not document that they complied with RAGAGEP as system valves were incorrectly, or not, labeled.    Note: Abatement certification AND documentation is required for this item.    Abatement note for instance a: One acceptable means of abatement, among others, would be to comply with the requirements in IIAR Bulletin 110, 6.7.1    Abatement note for instance b: One acceptable means of abatement, among others, would be to comply with the requirements in IIAR 2  2008, 10.3.1.2.    Abatement note for instance c: One acceptable means of abatement, among others, would be to comply with the requirements in IIAR 2 - 2008, 10.5, and/or IIAR Bulletin 114.    Abatement note for instance d: One acceptable means of abatement, among others, would be to comply with the requirements in IIAR 2 - 2008, 11.3.6.4    Abatement note for instance e: One acceptable means of abatement, among others, would be to comply with the requirements in IIAR 2 - 2008, 13.3.1.9    Abatement note for instance f: One acceptable means of abatement, among others, would be to comply with the requirements in ASHRAE 15 - 2007, 11.2.2

Issued

Aug 8, 2011

Abate by

Sep 5, 2011

Penalty

Initial $4,675 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(e)(3)(v): The process hazard analysis did not address facility siting:    a) At the facility: On or about April 5, 2011, and at times prior thereto, train derailment and facility impact was not addressed in the PHA.    b) At the facility: On or about April 5, 2011, and at times prior thereto, protection of the low side accumulator from vehicular impact was not addressed in the PHA.    Note: Abatement certification and documentation are required for this item.

Issued

Aug 8, 2011

Abate by

Sep 5, 2011

Penalty

Initial $7,000 · Current $4,450 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(i): Inspections and tests were not performed on process equipment:     a) At the facility: On or about March 1, 2011, and at times prior thereto, testing was not performed on compressor safety cutout switches.    Note: Abatement certification AND documentation are required for this item.

Issued

Aug 8, 2011

Abate by

Aug 15, 2011

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(g)(1)(iv)[A]:  Flexible cords and/or cables were used as a substitute for the fixed wiring of a structure:    a) In the chiller room: On or about April 5, 2011, and at times prior thereto, extension cords were being used to power the overhead lights in the room.    Abatement certification is required for this item.