OSHA Inspection: NATIONAL STEAK AND POULTRY

Issued

Oct 2, 2012

Abate by

Oct 17, 2012

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.119(d)(2)(i)(C): Process safety information pertaining to the technology of the process did not include the maximum intended inventory:    The employer does not ensure that process safety information includes the maximum intended inventory exposing employees to the hazards associated with uncontrolled anhydrous ammonia vapor releases into the atmosphere.

Issued

Oct 2, 2012

Abate by

Dec 19, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D): Process safety information pertaining to the equipment in the process did not include the relief system design and design basis:  The employer does not ensure that the process safety information is developed and maintained for the ammonia refrigeration system such as the relief system design and design basis thereby exposing employees to the hazards associated with the release of ammonia liquid and/or vapor into the atmosphere.

Issued

Oct 2, 2012

Abate by

Dec 19, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(E): Process safety information pertaining to the equipment in the process did not include the ventilation system design.        The employer does not ensure that process safety information included ventilation system design exposing employees to the hazards associated with uncontrolled anhydrous ammonia vapor releases into the atmosphere.

Issued

Oct 2, 2012

Abate by

Dec 19, 2012

Penalty

Initial $5,000 · Current $3,000 Reduced

General-duty citation text

29 CFR 1910.119(e)(5): The employer did not develop a written schedule as to when the actions recommended by the process hazard analysis team are to be completed:    The employer does not ensure that a written schedule is completed for action items resulting from the 2000, 2005 and the 2010 ammonia refrigeration process hazard analyses exposing employees to the hazards associated with uncontrolled releases of ammonia liquid and/or vapor into the atmosphere.

Issued

Oct 2, 2012

Abate by

Jan 11, 2013

Penalty

Initial $5,000 · Current $2,400 Reduced

General-duty citation text

29 CFR 1910.119(g)(2): The employer did not provide refresher training at least every three years to the each employee involved in operating a process to assure that the employee understands and adheres to the current operating procedures of the process;    The employer does not ensure that employees involved in the operation of the ammonia refrigeration system are provided refresher training every three years and that employees understand and adhere to the current operating procedures thereby exposing employees to the hazards associated with the release of ammonia liquid and/or vapor into the atmosphere.

Issued

Oct 2, 2012

Abate by

Jan 11, 2013

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish and implement written procedures to maintain the on-going mechanical integrity of process equipment.    The employer does not ensure written procedures are established and implemented for process equipment to maintain its on-going mechanical integrity such as but not limited to:   a.	External visual inspection of insulated and un-insulated vessels  b.	External visual inspection of insulated and un-insulated piping  c.	Establishing thickness measuring locations when/if used as a supplement to the                  external visual inspection  d.	Compressor Pressure Cut Out (High & Low)  e.	Compressor Oil Pressure Differential Cut Out  f.	Compressor High Discharge Temperature Cut Out  g.	Engine Room Emergency Ventilation & Ammonia Detectors  h.	Engine Room Emergency Stop Button  i.	Medium and Low Temperature Accumulator High & Low Level Controls   j.	Intercooler High & Low Level Controls.   These violation instances occurred in the ammonia refrigeration engine room where these conditions exposed employees to the hazards associated with uncontrolled anhydrous ammonia vapor releases into the atmosphere.

Issued

Oct 2, 2012

Abate by

Jul 1, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(ii): Inspections and testing procedures performed on process equipment to maintain its mechanical integrity, did not follow recognized and generally accepted good engineering practices.    The employer does not ensure that inspections and tests are conducted at a frequency consistent with recognized and generally accepted good engineering practice for process equipment in the ammonia refrigeration systems such as but not limited to:   a.          Six (6) month inspection of relief valves for corrosion or the accumulation of scale                and leaks  b.          Six (6) month inspection of vent lines to ensure they are clear and free of moisture  c.          Three (3) month inspection of the compressor motive power system and                compressor alignment  d.          Monthly defrost and external inspection of ammonia pumps  e.          Annual inspection of ammonia centrifugal pumps including but not limited to                opening and inspecting for possible wear or damage.  f.           Five year independent inspection of pressure vessels such as but not limited to:                       1.	High Pressure Receiver                       2.	Intercooler Accumulator                       3.	Medium Temperature Recirculation Unit                       4.	Low Temperature Recirculation Unit                       5.	Glycol Shell & Tube Heat Exchanger                       6.	Chilled Water Heat Exchanger.  These violation instances were occurred in the ammonia refrigeration machine room where these conditions exposed employees to the hazards associated with uncontrolled ammonia liquid/vapor releases into the atmosphere.

Issued

Oct 2, 2012

Abate by

Jan 11, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(iv): The documentation of the inspection or test that been performed on process equipment to maintain its mechanical integrity did not include a description of the inspection or test, and the results of the inspection or test.    The employer does not ensure that documentation of inspection(s) and test(s) performed on process equipment includes a description of the test/inspection for such process equipment as but not limited to:  a.	Compressor Pressure Cut Out (High & Low)  b.	Compressor Oil Pressure Differential Cut Out  c.	Compressor High Discharge Temperature Cut Out  d.	Engine Room Emergency Ventilation & Ammonia Detectors  e.	Engine Room Emergency Stop Button  f.	Medium and Low Temperature Accumulator High & Low Level Controls   g.	Intercooler High & Low Level Controls  These violation instances occurred in the ammonia refrigeration machine room where these conditions exposed employees to the hazards associated with uncontrolled anhydrous ammonia liquid and/or vapor releases into the atmosphere.

Issued

Oct 2, 2012

Abate by

Dec 19, 2012

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.119(o)(1): The employer did not certify that they had evaluated compliance with the provisions of 29 CFR 1910.119 at least every three years to verify that the procedures and practices developed under this standard were adequate and are being followed.    The employer does not ensure that process safety management compliance audits are conducted for the ammonia refrigeration system every three years as required by the standard exposing employees to the hazards associated with uncontrolled releases of ammonia liquid and/or vapors into the atmosphere.

Issued

Oct 2, 2012

Abate by

Oct 17, 2012

Penalty

Initial $5,000 · Current $3,000 Reduced

General-duty citation text

29 CFR 1910.134(c): The employer did not develop and implement a written respiratory protection program with required worksite-specific procedures and elements for required respirator use.    The employer does not implement respiratory protection program with required worksite-specific procedures and elements for required respirator use.  This violation occurred at National Steak and Poultry, where employees that were required to wear a 3M 6000 full face respirator while draining oil in compressors and responding to potential anhydrous ammonia leaks.