OSHA Inspection: HUNTER PANELS L.L.C.

Issued

2013-01-25 00:00:00

Abate by

2013-02-28 00:00:00

Penalty

Initial $4000.00 · Current $2800.00 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1):     Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which was free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to fall hazards.    a) Railroad Tanker Cars - On or prior to August 20, 2012, an employee connects and disconnects hoses to the top of the railcar containing Mondur 489 without adequate fall protection.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.22(a)(1): All places of employment, passageways, storerooms or service rooms were not kept clean and orderly or in a sanitary condition.    a)  Production Area - On or prior to August 1, 2012, structural supports, pipes, ductwork, roofing and equipment were not kept free of hazardous accumulation of explosive combustible dust.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.119(d)(1)(v): Process safety information pertaining to the hazards of the highly hazardous chemicals in the process did not contain the corrosivity data information:      a)  Pentane Tank Transfer Pump Area - On or prior to July 27, 2012, process safety information did not include corrosivity data for the resistance of of Type 321 Stainless Steel (material of construction for five metallic hoses) to n-Pentane.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.119(e)(3)(i):  The process hazard analysis did not address the hazards of the process:    a) Production Area - On or prior to July 27, 2012, the process hazard analysis did not address the hazard of a combustible dust deflagration on the pentane process from the accumulation of combustible dust on structural supports, pipes, ductwork, roofing and equipment.    b) Pentane Tank Transfer Pump Area - On or prior to July 27, 2012, the process hazard analysis did not address the hazard of the release of n-pentane near the storage tank, due to the failure of one of the five stainless steel flexible metallic hoses.    c) Pentane Tank Transfer Pump Area - On or prior to July 27, 2012, the process hazard analysis did not address the hazards of plugging of the cartridge in the CUNO Auto-Klean Model EG Filter at the Pentane transfer pump.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.119(e)(5): The employer did not establish a system to promptly address the team's findings and recommendations; did not assure that the recommendations were resolved in a timely manner and that the resolution was documented; did not document what actions were to be taken; did not complete actions as soon as possible; did not develop a written schedule of when these actions were to be completed; did not communicate the actions to operating, maintenance and other employees whose work assignments were in the process and who may have been affected by the recommendations or actions:    a)  Hunter Panels, LLC - On or prior to August 10, 2012, the employer did not document the resolution of action items from the 2012 Process Hazard Analysis.  A system was not created to promptly address the findings and there is still one open item (provide spill kit for small releases to pentane tank area).    b)  Hunter Panels, LLC - On or prior to August 10, 2012, the employer did not document the resolution of action items from the 2007 Process Hazard Analysis.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

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) Pentane Tank Transfer Pump Area - On or prior to August 7, 2012, the employer did not have a line break procedure for opening process equipment and piping including but not limited to: Type 321 Stainless Steel Flexible Metallic Hose.    b) Production Area - On or prior to September 30, 2012, neither Control of Hazardous Energy nor Permit Required Confined Space Entry procedures had been developed or implemented to address the isolation of n-pentane lines during the lubrication of the Hennecke Laminator.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

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) Hunter Panels Facility - On or prior to July 27, 2012, there were no written maintenance procedures for the inspection of pentane piping systems, including but not limited to corrosion under insulation inspection procedures.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

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:    a) Pentane Tank Transfer Pump Area - On or prior to July 27, 2012, the frequency of inspections and tests of the Type 321 Stainless Steel Flexible Metallic Hose was not determined.

Issued

2013-01-25 00:00:00

Abate by

2013-02-06 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 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) Pentane Tank Transfer Pump Area - On or prior to July 27, 2012, the steel piping to and from the Cuno pentane filter was not painted in accordance with the design specification, NFPA-30 or other methods to provide similar protection from corrosion.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 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)  Pentane Tank Transfer Pump Area - On or prior to July 27, 2012, hazards were not evaluated through management of change procedures for the addition of the CUNO Auto-Klean Model EG Filter at the Pentane transfer pump.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.119(o)(4): The employer did not promptly determine and document an appropriate response to each of the findings of the compliance audit, and document that deficiencies have been corrected:    a)  Hunter Panels, LLC - On or prior to August 10, 2012, the employer did not document the corrected deficiencies from the 2007 compliance audit.  The audit has an uncompleted finding (repairs needed in Pentane tank containment area).    b)  Hunter Panels, LLC - On or prior to August 10, 2012, the employer did not document the corrected deficiencies from the 2009 compliance audit.  The audit has uncompleted findings including management of change for the Pentane filter addition and repairs in Pentane tank containment area.

Issued

2013-01-25 00:00:00

Abate by

2013-03-16 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.120(q)(2)(iii): The emergency response plan did not address, to the extent not addressed elsewhere, emergency recognition and prevention:      a)  Hunter Panels Facility -  On or prior to August 1, 2012, the employer's Integrated Spill/Emergency/Fire Prevention and Response Plan dated June 22, 2012, did not define the types of releases or emergencies that could potentially require an emergency response versus the releases that would be incidental releases.

Issued

2013-01-25 00:00:00

Abate by

2013-03-31 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.120(q)(2)(iv): The emergency response plan did not address, to the extent not addressed elsewhere, safe distances and places of refuge:     a) Hunter Panels Facility - On or prior to August 1, 2012, the Integrated Spill/Emergency/Fire Prevention and Response Plan identified only one location for the meeting place after an evacuation. Alternate meeting locations were not considered, taking into account the location of the release, and the direction of the wind on the release date.

Issued

2013-01-25 00:00:00

Abate by

2013-03-01 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.120(q)(8)(i):Employees who were trained in accordance with 29 CFR 1910.120(q)(6) did not receive annual refresher training of sufficient content and duration to maintain their competencies or did not demonstrate competency in those areas at least yearly:    a)  Hunter Panels Facility - On or prior to August 1, 2012, the Safety Manager acting as a Emergency Coordinator under the Integrated Response Plan dated June 22, 2012, is expected to take all reasonable actions to stop the spread of a chemical release.  The Safety Manager did not have annual refresher training.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $3000.00 · Current $2000.00 Reduced

General-duty citation text

29 CFR 1910.133(a)(1):  The employer did not ensure that each affected employee uses appropriate eye or face protection when exposed to eye or face hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors, or potentially injurious light radiation:    a) Hennecke Laminator - On or about September 30, 2012, the three employees, who were lubricating the Laminator, were not wearing safety goggles to protect against dripping grease and dust.

Issued

2013-01-25 00:00:00

Abate by

2013-03-14 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.134(c)(1): A written respiratory protection program that included the provisions in 29 CFR 1910.134(c)(1)(i) - (ix) with worksite specific procedures was not established and implemented for required respirator use:    a) Dust Collector in Facility Yard - On or prior to October 6, 2012, an employee standing on the lower platform of the dust collector that was required to wear a 3M 8210 disposable N95 respirator while retrieving the socks from the collector.      b) Laminator in the Facility-On or prior to September 30, 2012, employees inside the laminator oiling the greasing fittings were required to wear 3M 8210 disposable N95 respirators.

Issued

2013-01-25 00:00:00

Abate by

2013-03-01 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace:    a) Dust Collector in Facility Yard - On or prior to October 6, 2012, an employee standing on the lower platform of the dust collector that was required to wear a 3M 8210 disposable N95 respirator while retrieving the socks from the collector.      b) Laminator in the Facility-On or prior to September 30, 2012, employees inside the laminator oiling the greasing fittings were required to wear 3M 8210 disposable N95 respirators.

Issued

2013-01-25 00:00:00

Abate by

2013-03-01 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.134(k)(3): Training was not provided prior to requiring employees to use a respirator in the workplace:      a) Dust Collector in Facility Yard - On or prior to October 6, 2012, an employee standing on the lower platform of the dust collector that was required to wear a 3M 8210 disposable N95 respirator while retrieving the socks from the collector.      b) Laminator in the Facility-On or prior to September 30, 2012, employees inside the laminator oiling the greasing fittings were required to wear 3M 8210 disposable N95 respirators.

Issued

2013-01-25 00:00:00

Abate by

2013-02-14 00:00:00

Penalty

Initial $6000.00 · Current $4200.00 Reduced

General-duty citation text

29 CFR 1910.138(b): The employer did not base selection of appropriate hand protection on an evaluation of the performance characteristics of the hand protection relative to the tasks to be performed, conditions present, duration of use, and the hazards and potential hazards identified:      a) Production Area - On or about August 2012, for employees opening the Mondur 489 chemical pumps to remove and clean out the filter, while wearing TNT Blue Nitrile 92-675 disposable gloves.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.146(d)(3)(i):  Under the permit-required confined space program required by 29 CFR 1910.146(c)(4), the employer did not develop and implement the means, procedures, and practices necessary for safe permit space entry operations, including specifying acceptable entry conditions.    a) Hennecke Laminator  - On or about September 30, 2012, procedures had not been developed and implemented for the lubrication of the Laminator specifying the acceptable entry conditions, such as but not limited to: the speed of the conveyor, the temperature in the Laminator, and the level of atmospheric chemicals (e.g. pentane).

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.146(d)(5)(i): The employer did not test conditions in the permit space to determine if acceptable entry conditions existed before entry was authorized:    a)  Hennecke Laminator - On or about September 30, 2012, for the operators who made entry into the Hennecke Laminator that under normal operations contains chemicals, including but not limited to, Pentane (flammable), Mondur 489 (sensitizer), and Polycat 36 (corrosive).

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.146(f)(9):  The entry permit that documented compliance and authorized entry to a permit space did not identify the acceptable entry conditions:    a) Hennecke Laminator  - On or about September 30, 2012, the entry permit for the lubrication of the Laminator did not specify the acceptable entry conditions, such as but not limited to: the speed of the conveyor, the temperature in the Laminator, and the level of atmospheric chemicals (e.g. pentane).

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.146(d)(9): The employer did not develop and implement procedures for summoning rescue and emergency services, for rescuing entrants from permit spaces, for providing necessary emergency services to rescued employees, and for preventing unauthorized personnel from attempting a rescue:    a)  Production Area - On or prior to September 30, 2012, entry was made into the laminator, a permit required confined space, for greasing by employees without the availability of a rescue team.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.146(j)(4):  The employer did not ensure that each entry supervisor verified that rescue services were available and that the means for summoning them were operable:    a) Hennecke Laminator - On or about September 30, 2012, the entry supervisor did not verify that rescue services were available while employees were lubricating the Laminator, a permit required confined space.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.146(k)(1)(i):  The employer did not evaluate a prospective rescuer's ability to respond to a rescue summons in a timely manner, considering the hazard(s) identified:      a)  Hennecke Laminator - On or prior to September 30, 2012, employees entered the Laminator, a permit required confined space, for greasing without the employer having evaluated the designated rescue service's ("911") ability to rescue entrants from the permit required confined space in a timely manner.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.146(k)(1)(ii):  The employer did not evaluate a prospective rescue service's ability, in terms of proficiency with rescue-related tasks and equipment, to function appropriately while rescuing entrants from the particular permit space or types of permit spaces identified:    a)  Hennecke Laminator - On or prior to September 30, 2012, employees entered the Laminator, a permit required confined space, for greasing without the employer having evaluated the designated rescue service's ("911") ability to rescue entrants from the permit required confined space.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.146(d)(3)(iii): Under the permit-required confined space program required by 29 CFR 1910.146(c)(4), the employer did not develop and implement the means, procedures, and practices necessary for safe permit space entry operations, including isolating the permit space:      a) Hennecke Laminator  - On or about September 30, 2012, the entry permit for the lubrication of the Laminator did not identify measures used to eliminate or control permit space hazards, such as but not limited to: the speed of the conveyor, the temperature in the Laminator, and the flow of hazardous chemicals (e.g. pentane).

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.146(f)(7):  The entry permit that documented compliance and authorized entry to a permit space did not identify the hazards of the permit space to be entered:    a) Hennecke Laminator - On or about September 30, 2012, the entry permit for the lubrication of the Laminator did not identify the potential of a chemical hazards being present in the Laminator.  Chemicals that could be present include but are not limited to n-Pentane (flammable) and Mondur 489 (containing isocyanate, sensitizer).

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.146(g)(1): The employer did not provide training so that all employees whose work was regulated by 29 CFR 1910.146 (permit required confined spaces) acquired the understanding, knowledge, and skills necessary for the safe performance of the duties assigned under 29 CFR 1910.146:    a) Hennecke Laminator  - On or about September 30, 2012, for the entry supervisor that was not provided confined space training prior to supervising the greasing operation entry into the laminator.  Entrants did not receive adequate training about the control of hazards due to the employer having an inadequate procedure for entry.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

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:    a)  Production Area - On or about September 30, 2012, for failure to develop, document and utilize procedures to control thermal, chemical, and pinch point hazards for the operator entry into the Hennecke Laminator for the greasing operation.    b)  Piping Systems and Equipment in Facility - On or about August 7, 2012, for failure to develop, document and utilize line break procedures for opening pipes and equipment containing hazardous chemicals.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i)(A): Each authorized employee did not receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control:    a)  Hunter Panels Facility - On or about September 30, 2012, for operators that were not trained conducting maintenance on, including but not limited to, the Hennecke Laminator.    b)  Hunter Panels Facility - On or about August 7, 2012, for maintenance employees that were not trained on safe procedures for opening piping and equipment containing hazardous chemicals.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $3000.00 · Current $2100.00 Reduced

General-duty citation text

29 CFR 1910.303(b)(2):  Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling:    a)  Hennecke Laminator - On or about September 30, 2012, a two-receptacle 120 V metallic outlet box was used on the end of a flexible cord to provide electricity to a fluorescent lamp during the permit required confined space entry.  This box is designed to be wall-mounted instead of being placed on the floor.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $3000.00 · Current $2100.00 Reduced

General-duty citation text

29 CFR 1910.305(g)(2)(iii):  Flexible cords were not connected to devices and fittings so that tension would not be transmitted to joints or terminal screws:    a) Hennecke Laminator  - On or about September 30, 2012, a flexible cord attached to a fluorescent light was not provided with strain relief in that the outer shielding had separated from the light.

Issued

2013-01-25 00:00:00

Abate by

2013-04-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

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) Dust Collector in Facility Yard - On or prior to October 6, 2012, an employee was required to wear a disposable 3M 8210 N95 respirator while retrieving socks from the dust collector.

Issued

2013-01-25 00:00:00

Abate by

2013-02-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.146(f)(3): The entry permit that documented compliance and authorized entry to a permit space did not identify the date and the authorized duration of the entry permit:    a)  Hennecke Laminator - On or about September 30, 2012, for the operators who made entry into the Hennecke Laminator for a greasing operation the permit had the incorrect date of entry.