FORT WORTH, TX —
OSHA Inspection: FIVE STAR CUSTOM FOODS, LTD
Planned inspection · Safety discipline
At a glance
On , OSHA opened a planned safety inspection of FIVE STAR CUSTOM FOODS, LTD in 3709 E. 1ST STREET, FORT WORTH, TX 76111 (NAICS 311991). OSHA activity number 334879780.
OSHA opens inspections for many reasons — routine scheduling under a national or local emphasis program, an employee complaint or referral, or a follow-up after a reported injury. Opening or conducting an inspection is not itself an allegation or a finding that this employer broke any rule; any findings appear as the citations listed below, and citations can be contested, reduced, or withdrawn.
Where did this inspection happen?
- Establishment
- FIVE STAR CUSTOM FOODS, LTD
- Site address
- 3709 E. 1ST STREET
- City
- FORT WORTH
- State
- TX
- ZIP
- 76111
- Mailing
- 3709 E. 1ST STREET, FORT WORTH, TX 76111
What kind of inspection was it?
- Inspection type
- Planned (H)
- Scope
- Partial (B)
- Discipline
- Safety
- Advance notice
- No
- Union status
- B
When did the case open and close?
- Opened
- Closing conference
- Case closed
- Last modified
- Data loaded
Establishment context
- NAICS code
- 311991
- Employees
- 200
- Ownership type
- A
Citations
29 citations on file for this inspection.
1910.22 B01
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $3,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.22(b)(1): Aisles and passageways were not kept clear and in good repair, with no obstruction across or in aisles that could create a hazard. In the kettle area, the employer does not ensure that the path from the freezer room to the kettle area has a minimum clearance of 36 inches.
Recent events (3)
- — F (S) $0
- — C (S) $3000
- — Z (S) $3000
1910.22 D01
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $3,000 · Current $2,000 Reduced
General-duty citation text
29 CFR 1910.22(d)(1): In every building or other structure, or part thereof, used for mercantile, business, industrial, or storage purposes, the loads approved by the building official were not marked in a conspicuous place in each space to which they related. In the shipping and receiving area, the employer is storing material on a storage rack without a load rating sign above a frequently used table and battery charging station, exposing employees to struck-by hazards.
Recent events (3)
- — F (O) $2000
- — C (S) $3000
- — Z (S) $3000
1910.23 A09
- Issued
- Dec 12, 2012
- Abate by
- Dec 17, 2012
- Penalty
- Initial $3,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.23(a)(9): Every floor hole into which persons cannot accidentally walk (on account of fixed machinery, equipment, or walls) were not protected by a cover that leaves no openings more than one inch wide. In the combo wash area, the employer does not ensure the drain hole is covered exposing employees to trip and slip hazards.
Recent events (3)
- — F (S) $0
- — C (S) $3000
- — Z (S) $3000
1910.23 E01
- Issued
- Dec 12, 2012
- Abate by
- Dec 17, 2012
- Penalty
- Initial $3,000 · Current $3,000
General-duty citation text
29 CFR 1910.23(e)(1): Standard railing(s) did not consist of top rail, intermediate rail and/or posts and/or did not have a vertical height of 42 inches (106.7 cm) nominal from upper surface of top rail to floor, platform runway, or ramp level. The employer does not provide a standard guard railing system. Employees utilize working platforms consisting of a top rail and toe board without a mid-rail, exposing employees to a fall hazard of approximately 4 foot to the floor below, at the following locations: a) in the Kettle cook area, and b) in the Grinding room.
Recent events (3)
- — F (S) $3000
- — C (S) $3000
- — Z (S) $3000
1910.37 A03
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $3,000 · Current $3,000
General-duty citation text
29 CFR 1910.37(a)(3): Exit route(s) were not kept free and unobstructed. In the combo wash area, the employer does not ensure employees have a clear and unobstructed exit pathway to the emergency exit door. The exit door is obstructed by a 60" x 69" fan, where employees were exposed to fire and entrapment hazards.
Recent events (3)
- — F (O) $3000
- — C (S) $3000
- — Z (S) $3000
1910.119 D03 II
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $7,000
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 (RAGAGEP). The employer does not ensure that the ammonia refrigeration system complies with recognized and general accepted good engineering practices such as but not limited to the following: a) in the engine room, the employer did not immediately repair the vapor seal to prevent intrusion of water or water vapor which will lead to breakdown of insulation, damaged pipe insulation and corrosion of the pipework; in accordance with IIAR, Bulletin No. 110, Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems, Section 6.7.2 Insulated piping. The vapor seal and pipe insulation were damaged near the L12-02 strainer, in the Engine Room. b) the employer did not immediately repair the vapor seal to prevent intrusion of water or water vapor which will lead to breakdown of insulation, damaged pipe insulation and corrosion of the pipework; in accordance with IIAR, Bulletin No. 110, Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems, Section 6.7.2 Insulated piping. The vapor seal and pipe insulation were damaged in the vicinity of the High Temperature Recirculator (HTR-1/IC-1), outside the Engine Room. c) piping did not identify the refrigerant (i.e. ammonia), the physical state of the refrigerant, the relative pressure level of the refrigerant and the direction of flow; in accordance with IIAR, Bulletin No. 114, Identification of Ammonia Refrigeration Piping and System Components, Section 4.1, Piping Markers. The pipes were not marked in the vicinity of the High Temperature Recirculator (HTR-1/IC-1), outside the Engine Room. f) Ammonia containing piping, such as but not limited to, the purger suction line in the engine room and piping located below HTR-1 connected to the isolation pump and to the oil pot valve, were not correctly labeled in accordance with IIAR Bulletin 114.
Recent events (3)
- — F (S) $7000
- — C (S) $7000
- — Z (S) $7000
1910.119 E05
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $7,000
General-duty citation text
29 CFR 1910.119(e)(5): The employer did not document the resolution of PHA recommendations. The employer does not document that the recommendations of the Process Hazard Analysis were resolved and that the resolution were documented such as but not limited to: a) in the 2002, the Process Hazard Analysis' were resolved and that the resolution were not documented, such as item 7.9 (Piping is mislabeled) -Ammonia containing piping, such as but not limited to, the purger suction line in the engine room and piping located below HTR-1 connected to the isolation pump and to the oil pot valve, were not labeled and item 12.6 (The employee emergency notification system is inoperable during an emergency). The employer has not installed an emergency alarm system, and b) in the 2007 the Process Hazard Analysis' were resolved and the resolution were not documented such as item 1.2 (The PRV is inadequately maintained). The employer has not developed a system to accurately track the replacement dates of Pressure Relief Valves and 5.11 (Valves are not accessible). The employer has not stationed a permanent ladder in the engine room/compressor room.
Recent events (3)
- — F (O) $7000
- — C (S) $7000
- — Z (S) $7000
1910.119 F01
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(f)(1): The employer did not implement written operation procedures that provided clear instructions for safely conducting activities. The employer does not ensure that the standard operating procedures are implemented as written. The written operating procedures (Pump Out Procedure- Evaporative Condenser (SOP EC-1)), were not being used by the mechanic while changing out the evaporator coils on the Compressor-AU2 Evaporator, exposing employees to potential ammonia release.
Recent events (3)
- — F (S) $0
- — C (S) $7000
- — Z (S) $7000
1910.119 F03
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $5,000 · Current $5,000
General-duty citation text
29 CFR 1910.119(f)(3): The employer did not certified annually that the operating procedures are current and accurate. The employer does not ensure that standard operating procedures for Initial Start-up, Normal operation, Normal shutdown, Temporary operation, Emergency shutdown and Emergency operation are certified annually; such as, but not limited to the following equipment: a) low temperature recirculator (SOP LTR-1) b) dual high stage compressor (SOP H-1 &2) c) air cooling evaporator (SOP AU-37) d) evaporator condenser (SOP EC-1)
Recent events (3)
- — F (O) $5000
- — C (S) $5000
- — Z (S) $5000
1910.119 F04
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $7,000
General-duty citation text
29 CFR 1910.119(f)(4): The employer shall develop and implement safe work practices to provide for the control of hazards during operations such as lockout tagout. The employer does not ensure that safe work practices, which include specific lockout/tagout procedures, are established and implemented for all equipment such as, but not limited to, the Low Temperature Recirculator 1 (LTR-1).
Recent events (3)
- — F (O) $7000
- — C (S) $7000
- — Z (S) $7000
1910.147 C04 I
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $0 · Current $0
General-duty citation text
29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section. The employer does not develop specific lockout/tagout procedures for all equipment such as, but not limited to, the Low Temperature Recirculator 1 (LTR-1).
Recent events (3)
- — F (O) $0
- — C (S) $0
- — Z (S) $0
1910.147 C07 I
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $0 · Current $0
General-duty citation text
29 CFR 1910.147(c)(7)(i): The employer did not provide adequate training to ensure that the purpose and function of the energy control program was understood by employees. The employer does not provide adequate training which includes specific lockout/tagout procedures for all equipment such as, but not limited to, the Low Temperature Recirculator 1 (LTR-1).
Recent events (3)
- — F (O) $0
- — C (S) $0
- — Z (S) $0
1910.119 G03
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $3,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(g)(3): The employer did not prepare a record which contains the identity of the employee, the date of training, and the means used to verify that the employee understood the training. The employer does not ensure that any training received by operators of the ammonia refrigeration system is documented in a record which contains the identity of the employee, the date of training, and the means used to verify that the employee understood the training. The employer does not have records documenting the training of each employee involved in changing out the evaporator coils on the Compressor-AU-2 Evaporator, on the safety and health hazards, emergency shutdown operations and safe work practices.
Recent events (3)
- — 3 (S) $0
- — C (S) $3000
- — Z (S) $3000
1910.119 J02
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $7,000
General-duty citation text
29 CFR 1910.119(j)(2): The employer did not establish and implement written procedures to maintain the on-going integrity of process equipment. The employer does not ensure the mechanical integrity procedures are written for inspecting vessels, compressors, evaporators, insulation and piping; in accordance with consensus documents, such as but not limited to: a) External visual inspection of compressor H-1 and H-2; in accordance with IIAR, Bulletin No. 110 "Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems, Section 6.3. b) External visual inspection of insulated piping segments AU 2-7; in accordance with IIAR, Bulletin No. 110 "Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems, Section 6.7.2. c) External visual inspection of un-insulated vessels L-11 and L-12; in accordance with IIAR, Bulletin No. 110 "Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems, Section 6.4. d) External visual inspection of un-insulated piping of the AU 2-7; in accordance with IIAR, Bulletin No. 110 "Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems, Section 6.7.1. e) Inspection, testing, and preventive maintenance of the compressors outside the engine room, H-1 and H-2; in accordance with IIAR, Bulletin No. 110 "Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems, Section 6.3.
Recent events (3)
- — F (S) $7000
- — C (S) $7000
- — Z (S) $7000
1910.119 J04 III
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(j)(4)(iii): The frequency of inspections and tests of process equipment shall be consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience. a) The employer does not ensure that inspections and tests are conducted at a frequency consistent with recognized and generally accepted good engineering practice such as, IIAR Bulletin 110, for specific safety systems identified as safeguards in the 2007 process hazard analysis (PHA). Annual visual inspections of un-insulated piping, insulated piping, vessels and heat exchangers were not performed in 2010 and 2011 in accordance with IIAR Bulletin 110, Section 6.
Recent events (3)
- — F (S) $0
- — C (S) $7000
- — Z (S) $7000
1910.119 J04 IV
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $5,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(j)(4)(iv): The employer did not document the date of inspection, the name of the person performing the inspection, the serial number or other identifier of the equipment on which the inspection or test was performed, a description of the inspection, and the results of the inspection for each piece of process equipment. The employer does not ensure that inspections of process equipment are properly documented. The inspection records does not include the description of the inspection and the results of the inspection for each piece of process equipment, such as but not limited to the following: a) Evaporator: AU-9, AU-10, AU-11, AU-12, AU-13, AU-14, AU-15, AU-16, AU-17, AU-18, AU-19, AU-20, AU-21, AU-22, AU-23, AU-24, AU-25, AU-26, AU-27 AND AU-28. b) Recirculator HTR-1/IC-1: Piping and valves, ammonia liquid pump, piping and valves, Cornell pump and ammonia pressure vessel-oil pot. c) Intercooler Vessel Package (IC-2): Pressure relief valves and piping, piping and valves, and ammonia pressure vessel-oil pot. d) Pressure Vessel (HPR-1): piping and valves, and ammonia pressure vessel.
Recent events (3)
- — F (S) $0
- — C (S) $5000
- — Z (S) $5000
1910.119 K01
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(k)(1): The employer did not issue a hot work permit for hot work operations conducted on or near a covered process. The employer does not ensure that hot work permits are issued in accordance with their program, during welding operations on the high pressure liquid line (HPL) and while adding coils to the AU-2 and AU-4 in the blast freezer.
Recent events (3)
- — F (S) $0
- — C (S) $7000
- — Z (S) $7000
1910.119 L01
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $7,000
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. The employer does not ensure that written procedures for management of change are established for modifications to equipment, such as but not limited to; a) the installation of the new HTR-2.
Recent events (3)
- — F (S) $7000
- — C (S) $7000
- — Z (S) $7000
1910.119 L02 III
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $0 · Current $0
General-duty citation text
29 CFR 1910.119(l)(2)(iii): The employer did not ensure that the operating procedures were addressed and modified prior to any change. The employer does not ensure that the operating procedures are modified prior to placing equipment into service, such as but not limited to the following: a) installing a new HTR-2.
Recent events (3)
- — F (S) $0
- — C (S) $0
- — Z (S) $0
1910.119 L03
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $0 · Current $0
General-duty citation text
29 CFR 1910.119(l)(3): The employees involved in operating a process and maintenance and contract employees whose job tasks will be affected by a change in the process were not informed of, and trained in, the change prior to start-up of the process or affected part of the process. The employer does not ensure that operations, maintenance, and contract employees involved in operating a process were trained in the change, prior to the start-up of the process, for the following pieces of equipment: a) installing a new HTR-2.
Recent events (3)
- — F (S) $0
- — C (S) $0
- — Z (S) $0
1910.119 M04
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(m)(4): An incident report was not prepared at the conclusion of the investigation that included at a minimum, the date of the incident, date the investigation began, a description of the incident, and any recommendations resulting from the investigation. On or about June 13, 2012 and times prior thereto, at the facility, the employer does not ensure that an incident report is prepared at the conclusion of the investigation which includes at a minimum, the date of the incident, date the investigation began, a description of the incident, and any recommendations resulting from the investigation. On April 22, 2011, in the Engine Room there was an ammonia leak requiring the evacuation of the employees.
Recent events (3)
- — F (S) $0
- — C (S) $7000
- — Z (S) $7000
1910.119 O01
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(o)(1): The employer did not certify that they have evaluated compliance with the provisions of this section at least every three years. The employer does not ensure that process safety management compliance audits are conducted for the ammonia refrigeration system at least every three years as required by the standard. The employer had not conducted an OSHA compliance audit by June 2012, in accordance with the standard.
Recent events (3)
- — 3 (S) $0
- — C (S) $7000
- — Z (S) $7000
1910.151 C
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $4,000 · Current $4,000
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. The employer does not provide an emergency shower or eye wash station in the immediate vicinity where employees are required to charge forklift batteries. The employees are exposed to injuries from where battery acid, including but not limited to the following locations: a) in the shipping dock area b) in the receiving dock area.
Recent events (3)
- — F (S) $4000
- — C (S) $4000
- — Z (S) $4000
1910.119 N
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $7,000
General-duty citation text
29 CFR 1910.119(n): The employer did not establish and implement an emergency plan for the entire plant in accordance with the provisions of 29 CFR 1910.38. The employer does not implement an emergency action plan for the entire plant in accordance with the provisions of 29 CFR 1910.38, such as, reviewing the emergency action plan and emergency evacuation procedures with visitors and non-employees.
Recent events (3)
- — F (S) $7000
- — C (S) $7000
- — Z (S) $7000
1910.165 B02
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $7,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.165(b)(2): The employee alarm could not be perceived above ambient noise or light levels by all employees in the affected portions of the workplace. The employer does not provide and maintain an employee alarm system that has a distinctive sound that can be heard by all employees throughout the facility.
Recent events (3)
- — F (S) $0
- — C (S) $7000
- — Z (S) $7000
1910.303 F02
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $3,000 · Current $3,000
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. The employer does not ensure each electric power switch boxes are legibly marked to indicate its purpose including but not limited to the following locations: a) shipping dock area b) receiving dock area
Recent events (3)
- — F (S) $3000
- — C (S) $3000
- — Z (S) $3000
1910.303 G01 II
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $3,000 · Current $2,000 Reduced
General-duty citation text
29 CFR 1910.303(g)(1)(ii): The required working space about electric equipment rated 600 volts, nominal, or less to ground, was used for storage. The employer does not ensure that the working space around electrical equipment is used for storage. The employer allowed the storage of several ladders adjacent to electrical panels, inside an electrical room.
Recent events (3)
- — F (O) $2000
- — C (S) $3000
- — Z (S) $3000
1910.305 B02 I
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $3,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.305(b)(2)(i): Pull boxes, junction boxes, and fittings were not provided with covers approved for the purpose. The employer does not ensure the electrical junction box with exposed wires located below the HTR-1/IC-1 had a cover plate; exposing employees to electrical shock hazards.
Recent events (3)
- — F (S) $0
- — C (S) $3000
- — Z (S) $3000
1910.305 G02 III
- Issued
- Dec 12, 2012
- Abate by
- Jan 4, 2013
- Penalty
- Initial $3,000 · Current $0 Reduced
General-duty citation text
29 CFR 1910.305(g)(2)(iii): Flexible cords and cables were not connected to devices and fittings so that strain relief was provided that would prevent pull from being directly transmitted to joints or terminal screws. The employer does not ensure that electrical power cords entering electrical junction boxes are fitted with strain relief devices in areas such as but not limited to: a) shipping dock area, the supply cord that energizes the battery charging unit is not connected with a strain relief device. b) south freezer, the supply cord that energizes the freezer motor is not connected with a strain relief device. c) above the compressor pump, the supply cord entering the junction box is not connected with a strain relief device.
Recent events (3)
- — F (S) $0
- — C (S) $3000
- — Z (S) $3000
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Source
This record is reproduced from the U.S. Department of Labor Open Data API (OSHA inspection dataset). The original IMIS detail view is available at OSHA's Establishment Search for activity number 334879780.
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