OSHA Inspection: A C & S, INCORPORATED

Issued

Dec 20, 2012

Penalty

Initial $2,100 · Current $2,100

General-duty citation text

29 CFR 1910.23(d)(1)(iv):     The employer did not ensure that stairs with four or more risers that were more than 44 inches wide but less than 88 inches wide had a stair railing on each open side and a handrail on each enclosed side.     (a)  Main Office:  A stairway going between the first and second floor was measured at 54 1/2 inches wide and it only had one handrail that was located on the left side descending as determined on July 18, 2012.    ABATEMENT CERTIFICATION REQUIRED.

Issued

Dec 20, 2012

Abate by

Jan 3, 2013

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.119(d)(3)(i)(C):     Process safety information pertaining to the equipment in the process did not include the electrical classification:    (a)  Dye Production Area:  The employer had not developed process safety information that included the electrical classification of the process areas where greater than 10,000 pounds of flammable liquids are processed.  The employer had not determined and documented that only electrical equipment approved for a Class I Division 2 area could be used in the Dye Production Area as determined on July 18, 2012.    (b) Dye Distillation Area:  The employer had not developed process safety information that included the electrical classification of the process areas where greater than 10,000 pounds of flammable liquids are processed.  The employer had not determined and documented that only electrical equipment approved for a Class I Division 2 area could be used in the Dye Distillation Area as determined on July 18, 2012.      ABATEMENT CERTIFICATION REQUIRED.

Issued

Dec 20, 2012

Abate by

Jan 3, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.307(c):     Equipment, wiring methods, and installations of equipment in hazardous (classified) locations were not intrinsically safe, approved for the hazardous (classified) location, or safe for the hazardous (classified) location:    (a)  Dye Production and Distillation Areas:  Dayton Electric Chain Hoists were used at the process reactors to lift containers of flammable liquids onto the work deck and they were not electrically approved for a Class I Division 2 area where large quantities of flammable liquids were present in process reactors as determined on July 18, 2012.    ABATEMENT CERTIFICATION IS REQUIRED.

Issued

Dec 20, 2012

Abate by

Jan 3, 2013

Penalty

Initial $0 · Current $0

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:      (a)  Dye Production Area:  The employer had not documented that process equipment was designed, operated, and maintained according to Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) in processes that use greater than 10,000 pounds of flammable liquids as determined July 18, 2012.    (b)  Dye Distillation Area:  The employer had not documented that process equipment was designed, operated, and maintained according to Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) in processes that use greater than 10,000 pounds of flammable liquids as determined July 18, 2012.      ABATEMENT CERTIFICATION IS REQUIRED.

Issued

Dec 20, 2012

Abate by

Jan 10, 2013

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.119(e)(3)(vii):     The process hazard analysis did not address a qualitative evaluation of a range of the possible safety and health effects of failure of controls on employees in the workplace.      (a)  The Process Hazard Analysis (PHA) for Blue A conducted in June 2011 did not include a qualitative evaluation of the range of safety and health effects associated with the hazards identified in the PHA involving greater than 10,000 pounds of the flammable liquids that are processed as determined on July 18, 2012.    (b)  The Process Hazard Analysis (PHA) for HBN Coupler Step 1 conducted in October 2011 did not include a qualitative evaluation of the range of safety and health effects associated with the hazards identified in the PHA involving greater than 10,000 pounds of the flammable liquids that are processed as determined on July 18, 2012.    ABATEMENT CERTIFICATION REQUIRED.

Issued

Dec 20, 2012

Abate by

Jan 10, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.119(e)(5):     The employer did not complete actions to resolve PHA recommendations as soon as possible:    (a)  Unisol Liquid Blue A & AHF Process:  An action item from the June 2011 Process Hazard Analysis was not completed in that the employer did not verify that a Nitrogen purge at four cubic feet per minute would inert the reactor with an oxygen level of less than six percent to prevent a fire potential as determined on July 18, 2012.    (b)  Unisol Liquid Red B Step 1 Coupler HBN Process:  An action item from the June 2011 Process Hazard Analysis was not completed in that the employer did not verify that breaking vacuum on the reactor with a Nitrogen purge at four cubic feet per minute would inert the reactor with an oxygen level of less than six percent to prevent a fire potential as determined on July 18, 2012.      ABATEMENT CERTIFICATION AND DOCUMENTATION IS REQUIRED.

Issued

Dec 20, 2012

Abate by

Jan 10, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.119(f)(1)(i)(D):     The employer did not develop and implement written operating procedures that provide clear instructions for emergency shutdown, including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner.    (a)  The written operating procedures (Process Batch Sheets) for the processes containing greater than 10,000 pounds of flammable liquids including, but not limited to, the Unisol Liquid Red B Step 1 Coupler HBN process did not contain an emergency shutdown procedure and the conditions that would require an emergency shutdown as determined on July 18, 2012.    ABATEMENT CERTIFICATION IS REQUIRED.

Issued

Dec 20, 2012

Abate by

Jan 10, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(4):     The employer did not develop and implement safe work practices to provide for the control of hazards during operations such as lockout/tagout; confined space entry; opening process equipment or piping; and control over entrance into a facility by maintenance, contractor, laboratory, or other support personnel:    (a)  Dye Production and Distillation Areas:  Safe work procedures were not developed for breaking into process lines that are used to transport flammable liquids from one vessel to another as determined on July 18, 2012.    ABATEMENT CERTIFICATION REQUIRED

Issued

Dec 20, 2012

Abate by

Jan 10, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.119(j)(2):     The employer did not establish written procedures to maintain the on-going integrity of process equipment:    (a)  Dye Production and Distillation Areas:  The employer had not developed a mechanical integrity program that included tests and inspections of pumps, piping, and gauges used in process areas that handle greater than 10,000 pouunds of flammable liquids as determined on July 18, 2012.    ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED.

Issued

Dec 20, 2012

Abate by

Dec 27, 2012

Penalty

Initial $7,000 · Current $7,000

Hazardous substances 1900

General-duty citation text

29 CFR 1910.134(i)(8):     Breathing air couplings were not incompatible with other gas systems to prevent inadvertent servicing of air line respirators with non-respirable gases or oxygen:    (a) AC&S Unit 2A-2B: An employee uses a supplied air sandblasting hood while conducting sandblasting operations. The supplied air pipeline did not have couplings that were incompatible with other gas systems, in that the employee's airline was connected to a Nitrogen pipeline which caused an asphyxiation death, as determined on or about 07/01/2012.      ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED

Issued

Dec 20, 2012

Abate by

Dec 27, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.22(d)(1):     On 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 on plates of approved design and securely affixed in a conspicuous place in each space to which they relate.    (a) Maintenance Building: Employee(s) using the roof of a office as a storage area with equipment, storage of parts and pallets, did not have the load rating marked as observed on or about 07/10/2012.    ABATEMENT CERTIFICATION REQUIRED

Issued

Dec 20, 2012

Abate by

Dec 27, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.95(d)(1):     When information indicated that any employee's exposure equaled or exceed the 8-hour time-weighted average of 85 decibels, the employer did not develop and implement a monitoring program:    (a) Railcar Division: Employees conduct sand blasting operations inside of railcars which exposes them to a noise hazard. The employer provides hearing protection and training but did not develop and implement a monitoring program, as determined on or about 07/10/2012.     ABATEMENT CERTIFICATION REQUIRED

Issued

Dec 20, 2012

Abate by

Jan 10, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(c)(1):     The employer did not develop a written plan of action regarding the implementation of employee participation.    (a)  The employer had not developed a written plan on how employees, who work with greater than 10,000 pounds of flammable liquids, would be consulted on the development of the procedures required by this standard as determined on July 18, 2012.    Abatement Certification Required.

Issued

Dec 20, 2012

Abate by

Dec 27, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(d)(1)(iii):     The employer did not identify and evaluate the respiratory hazard(s) in the workplace; including a reasonable estimate of employee exposures to respiratory hazards and identification of the contaminant's chemical state and physical form:    (a) Railcar Division: Employees conduct sand blasting operations inside of railcars which contain creosote and coal tar pitch. The employer did not identify and evaluate the respiratory hazard(s) in the work place before requiring an employee to use a supplied air sandblasting hood, as determined on or about 07/10/2012.     ABATEMENT CERTIFICATION REQUIRED

Issued

Dec 20, 2012

Abate by

Dec 27, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.212(a)(1):     One or more methods of machine guarding was not provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks:    (a) Building 6 Maintenance Building: Employees hands are approximaetly 10 inches from the rotating chuck and bit of a Clausing Drill Press, s/n 518115.  The drill press was not equipped with a chuck guard when employees drilled holes in aluminum plates, as determined on or about 07/10/2012.    ABATEMENT CERTIFICATION REQUIRED

Issued

Dec 20, 2012

Abate by

Dec 27, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.212(b):     Machine(s) designed for fixed location(s) were not securely anchored to prevent walking or moving:    (a) Building 6 Maintenance Shop: An employee used a Clausing Drill Press, s/n 518115, to drill metal parts. The Drill Press was not anchored to prevent walking or moving, as determined on or about 07/10/2012.    ABATEMENT CERTIFICATION REQUIRED