OSHA Inspection: VALERO MCKEE REFINERY

Issued

Nov 7, 2012

Abate by

Nov 28, 2012

Penalty

Initial $0 · Current $1,500

General-duty citation text

29 CFR 1910.119(d)(3)(ii): The employer did not document that equipment complies with recognized and generally accepted good engineering practices:      On or about June 1, 2012, and at times prior thereto, two instances where the employer did not document equipment that complied with recognized and generally accepted good engineering practices:      b)  The employer failed to document that process equipment in the Alky/Propane De-asphalter Unit complies with recognized and generally accepted good engineering practices, in that the employer failed to implement the Overpressure Protection Car-Seal       Policy and Procedure to identify, install and properly maintain the secured open position on the 4-inch manual valve on the Low Pressure Asphalt Stripper T-108 overhead stream.

Issued

Nov 7, 2012

Abate by

Nov 28, 2012

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.147(d)(6):  Prior to starting work on equipment that has been locked out, the authorized employee did not verify that isolation and deenergization of the equipment had been accomplished.    On or about June 1, 2012, the employer did not confirm that the employee adequately verified the isolation of the 10 inch settler effluent line to ensure so far as possible that all sulfuric acid had been removed.

Issued

Nov 7, 2012

Abate by

Nov 28, 2012

Penalty

Initial $7,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(iii): The frequency of inspections and tests of process equipment was not consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience:     On or about June 1, 2012, and at times prior thereto, the employer did not perform inspections and tests on process equipment with adequate frequency to assure its mechanical integrity. This was observed when the employer did not ensure that inspections and tests of process equipment occurred with the necessary frequency, such as but not limited to the following:     c)  The employer does not ensure adequate frequency of visual inspection utilized for piping in the PDA Unit, such as but not limited to the piping to the Recovery Light Ends Compressor.  h)  The employer did not conduct visual inspections at adequate frequency to identify and correct damaged and or missing paint (external coatings) on piping in the Crude Unit.     Valero failed to timely conduct a visual inspection of the Recovery Light End Compressor.

Issued

Nov 7, 2012

Abate by

Nov 28, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(i): Inspections and tests were not performed on process equipment:     On or about June 1, 2012, and at times prior thereto, the employer did not perform inspections of process equipment and did not assure its safe operation when:     a)  Valero failed to inspect and correct deficiencies of the Low Pressure Condensate Pot of the Alky/PDA.     Valero failed to timely correct deficiencies of the Low Pressure Condensate Pot of the Alky/PDA.

Issued

Nov 7, 2012

Abate by

Nov 28, 2012

Penalty

Initial $7,000 · Current $5,000 Reduced

General-duty citation text

29 CFR 1910.119(j)(5): The employer did not correct deficiencies in equipment that are outside acceptable limits (defined by the process safety information in paragraph (d) of this section) before further use or in a safe and timely manner when necessary means are taken to assure safe operation:    On or about June 1, 2012, and at times prior thereto, the employer did not correct deficiencies for the following:    a)  The employer operated the pipe to the C101 Recovery Light Ends Compressor of the Propane De-Asphalter Unit without the pipe being properly supported.   b)  The employer operated piping connected to the #1 and #2 Reactors in the Iso-Octene Unit with deficiencies present that allowed loss of primary containment of flammable hydrocarbons.   c)  The employer operated piping in Crude Unit that was improperly supported.   f)  The employer operated the Crude Unit with a deficient pipe support structure (pipe rack) missing several components necessary to ensure the integrity of the structure.

Issued

Nov 7, 2012

Abate by

Nov 28, 2012

Penalty

Initial $7,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.106(c)(4): Piping systems were not substantially supported and protected against physical damage and excessive stresses arising from settlement, vibration, expansion, or contraction:    On or about June 1, 2012, and at times prior thereto, the employer operated deficient process equipment in the Propane De-Asphalting Unit (PDA), where a 6-inch diameter horizontal pipe of approximately 10 feet long had a pipe shoe not contacting its support plate, causing the pipe to vibrate, pulsate and noticeably swinging from side to side.

Issued

Nov 7, 2012

Abate by

Nov 28, 2012

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(l)(5): If a change covered by this paragraph resulted in a change in the operating procedures or practices required by paragraph (f) of this section, such procedures or practices were not be updated accordingly:    On or about June 1, 2012:      (a)  The Fluid Catalytic Cracker Unit (FCCU) operating procedures were not updated.    (b)  The FCCU de-inventory procedures were not implemented.

Issued

Nov 7, 2012

Abate by

Nov 14, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

1910.27(d)(1)(iv): Cage(s) did not extend down the ladder to a point not less than 7 feet nor more than 8 feet above the base of the ladder:    On or about June 1, 2012, and at times prior thereto, the #2 Vacuum Heater Tower Ladder equipped with a cage that did not extend down to a point not less than 7 feet nor more than 8 feet above the base of the ladder. The bottom of the cage ended approximately 9-feet, 5-inches above the base of the ladder.