OSHA Inspection: FARMLAND FOODS, INC

Issued

Jun 22, 2012

Abate by

Jul 23, 2012

Penalty

Initial $5,500 · Current $5,500

General-duty citation text

29 CFR 1910.119(d)(3)(ii):     The employer failed to document that equipment complies with recognized and generally accepted good engineering practices.    There are two instances of failing to meet the engineering practices outlined for ammonia refrigeration systems at this location:      a)  Rooftop of the facility, Production Refrigeration System:  The ammonia relief system header discharge piping is located within 15.5 to 19 feet of a ventilation point. ASHRAE 15-2007, Section 9.7.8 states that pressure relief discharges are to be directed 15 feet above the ground, 20 feet from a window, ventilation or building entry.      b)  Engine Room:  The ventilation system was identified in 2009 as being inadequate based upon the area of the room, ammonia capacity of the system, and the existing air exchange rates.  ASHRAE 15-2007, Section 8.11.5 outlines the exchange rates as well as IIAR Bulletin 111.  Farmland Foods Inc. ordered and received a ventilation report and quote for repairs in September of 2011.  As of the date of the inspection the engine room ventilation system had not been brought into compliance with ASHRAE and IIAR.      Abatement certification is required for this violation.  The abatement certification sheet is enclosed with the citations.

Issued

Jun 22, 2012

Abate by

Jul 23, 2012

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(e)(5):     The employer failed to establish a system to promptly address the team's findings and recommendations; assure that the recommendations are resolved in a timely manner and that the resolution is documented; document what actions are to be taken; complete actions as soon as possible; develop a written schedule of when these actions are to be completed; communicate the actions to operating, maintenance and other employees whose work assignments are in the process and who may be affected by the recommendations or actions.    Jobsite located at 200 South 2nd Street, Lincoln, NE and throughout the company:  The employer has not established a system and taken steps to ensure that items found during a Process Hazard Analysis are addressed in a timely manner.  Items found during the 2009 PHA were still open at the time that this inspection was initiated on January 19, 2012.      Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citations.

Issued

Jun 22, 2012

Abate by

Sep 28, 2012

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(f)(1)(i)(D):     The employer has failed to develop and implement an operating procedure that addresses emergency shutdown which includes the condition under which the shutdown is required, and the assignment of shut down responsibility.      Throughout the Facility located at 200 South 2nd Street, Lincoln, NE: The employer did not develop an emergency shutdown procedure that covers the situations in which an emergency shutdown would be required and assigns responsibility for initiating a shut down or emergency actions.  The procedure should clearly state the responsible party for following the procedure.      Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citations.

Issued

Jun 22, 2012

Abate by

Sep 28, 2012

Penalty

Initial $7,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(f)(1)(iii)(C):     The employer has failed to develop and implement an operating procedure discussing the control measures to be taken if physical contact or airborne exposure occurs.      Job site located at 200 N. 2nd Street, Lincoln, NE and Throughout the Facility: The employer did not develop an operating procedure that discusses what actions will be taken in the event of an exposure to anhydrous ammonia.  The employer has failed to develop a procedure for response actions for employee exposure that would include but is not limited to event escalation, emergency response, or containment.     Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citations.

Issued

Jun 22, 2012

Abate by

Sep 28, 2012

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(j)(2):     The employer failed to establish and implement written procedures to maintain the on-going integrity of process equipment.    Throughout the Facility:  The employer has not developed procedures for ensuring the mechanical integrity of the some of the components of the system.  This would include a program outlining preventative maintenance, component replacement, and/or repair.  Examples would include a procedure for valve replacement and a procedure for facility piping inspections.  These procedures should include any manufactures data or recognized engineering practices.      Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citations.

Issued

Jun 22, 2012

Abate by

Jul 23, 2012

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(j)(4)(ii):     The employer failed to ensure Inspection and testing procedures followed recognized and generally accepted good engineering practices.    Throughout the Production area, Ammonia transfer components and vessels:  The piping and vessels for the system were not inspected every 5 years as outlined in any applicable recognized and generally accepted good engineering practices.  The last thickness testing was accomplished in 2004; based upon the dates of inspection places the facility 1.5 years out of compliance.      Abatement certification and abatement documentation is required for this violation.  The documentation should include written verification of abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful.  The abatement certification sheet is enclosed with the citations.

Issued

Jun 22, 2012

Abate by

Sep 28, 2012

Penalty

Initial $3,300 · Current $2,300 Reduced

General-duty citation text

29 CFR 1910.332(b)(2):  Unqualified employees were not adequately trained to be familiar with safe electrical conditions and practices.     Jobsite located at 200 South 2nd Street, Lincoln, NE.  Production floor:  A section of water tight flexible conduct that is supposed to be connected to a control unit on the 5 Saw, Line 2, is broken and exposed the conductors within. Operators and other unqualified employees did not identify and report this condition.    Abatement certification is required for this violation.  The abatement certification sheet is enclosed with the citations.