OSHA Inspection: FARMLAND DAIRIES, LLC.

Issued

Dec 18, 2012

Abate by

Feb 6, 2013

Penalty

Initial $4,500 · Current $3,150 Reduced

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:      a) Engine room: The ammonia machinery room ventilation inlet air intake is provided through a roll-up door that was not guarded to prevent inadvertent closure thus exposing employees to a potential overexposure to ammonia, on or about 06/20/12.    b) Engine room; No audible or visual alarms in refrigerating machinery room thus delaying employees response during a potential ammonia release and exposing themselves to a hazardous atmosphere, on or about 06/20/12.      c) Production building: The pressure relief valve Cyrus Shank 803 of the main suction accumulator T-102 did not have discharge pipes installed thus exposing employees to a potential ammoniaon splash hazard, or about 06/20/12.

Issued

Dec 18, 2012

Abate by

Feb 6, 2013

Penalty

Initial $4,500 · Current $3,150 Reduced

General-duty citation text

29 CFR 1910.119(e)(3)(i):     The process hazard analysis shall address the hazards of the process;      a) Plant: The process hazard analysis does not fully address the hazards of loss of electricity and its effect on the King valve thus exposing employees to a potential ammonia release, on or about 06/20/12.

Issued

Dec 18, 2012

Abate by

Feb 6, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(5):     The employer did not assure that PHA recommendations were resolved in a timely manner:    a) Plant: Process hazard analysis findings and recommendations were not resolved in a timely manner such as, but not limited to, recommendation for level transmitter for high pressure receiver that prevent ammonia release and the potential employees exposure, on or about 06/20/12.

Issued

Dec 18, 2012

Abate by

Feb 6, 2013

Penalty

Initial $4,500 · Current $3,150 Reduced

General-duty citation text

29 CFR 1910.119(j)(2):     The employer did not establish or implement written procedures to maintain the on-going integrity of process equipment:      a) Plant: The employer did not establish and implement written procedures for inspection, testing, evaluation, and repair of insulated process piping and equipment thus exposing employees to a potential ammonia release, on or about 06/20/12.

Issued

Dec 18, 2012

Abate by

Nov 22, 2013

Penalty

Initial $4,500 · Current $3,150 Reduced

General-duty citation text

29 CFR 1910.119(j)(5):     The employer did not correct deficiencies in equipment that were outside acceptable limits (defined by the process safety information on paragraph (d) of this section) in a safe and timely manner when necessary means where taken to assure safe operation.      a) Plant: The employer did not take remedial action to correct heavily corroded system component such as, but not limited to, main suction accumulator and suction accumulator 1 and 2 piping thus exposing employees to ammonia release, on or about 06/20/12.    b) Engine room: The pressure relief valve, Hanson 5602, of the Frick compressor unit#4 was installed Dec., 2005, which surpassed its 5-year removal from service interval as per IIAR Bulletin No.110, section 6.6.3 thus exposing employees to ammonia release, on or about 06/20/12.    c) Engine room: The pressure relief valve, Henry 5340, of the suction accumulator#1, T-103 was installed Dec., 2005, which surpassed its 5-year removal from service interval as per IIAR Bulletin No.110, section 6.6.3 thus exposing employees to ammonia release, on or about 06/20/12.    d) Engine room: The pressure relief valve, Hanson 5604 of the suction accumulator#2, T-104 was installed Dec. 2005, which surpassed its 5-year removal from service interval as per IIAR Bulletin No.110, section 6.6.3 thus exposing employees to ammonia release, on or about 06/20/12.

Issued

Dec 18, 2012

Abate by

Feb 6, 2013

Penalty

Initial $4,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(o)(4):     The employer shall promptly determine and document an appropriate response to each of the findings of the compliance audit, and document that deficiencies have been corrected:    a) Plant: The employer did not take corrective action to address the findings of the compliance audits such as, but not limited to, the replacement of ammonia pipes identified in 2010 report thus exposing employees to ammonia release, on or about 06/20/12.

Issued

Dec 18, 2012

Abate by

Feb 6, 2013

Penalty

Initial $4,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(l)(1):     The employer did not establish or implement written procedures to manage changes to process chemicals, technology, equipment, and procedures, and changes to facilities that affect a covered process:      a) Plant: The employer did not establish and implement written procedures to manage a reduction in system operators, on or about 06/20/12.

Issued

Dec 18, 2012

Penalty

Initial $4,500 · Current $3,150 Reduced

General-duty citation text

29 CFR 1910.151(c):     Where employees were exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body were not provided within the work area for immediate emergency use:    a) Engine room: The plumbed eyewash/drenching station was not operational thus exposing employees to the corrosive nature of ammonia, on or about 06/20/12.                 Note: The eyewash unit must meet the requirement of American National Standard (ANSI Z358.1-1998)

Issued

Dec 18, 2012

Abate by

Jan 3, 2013

Penalty

Initial $2,700 · Current $1,890 Reduced

General-duty citation text

29 CFR 1910.303(f)(2):     Each service, feeder, and branch circuit, at its disconnecting means or overcurrent device, was not legibly marked to indicate its purpose, nor located and arranged so the purpose was evident:      a) Engine room: The labeling on the circuit breaker#3 for #7 high level ammonia was illegible, on or about 06/20/12.