OSHA Inspection: WYNNEWOOD REFINING COMPANY, LLC

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(d)(3)(i)(F):  Process safety information pertaining to the equipment did not include the design codes and standards employed:    The employer does not ensure process safety information pertaining to the equipment includes the design codes and standards employed.  In the Zone 2/CAT Wickes Boiler Area the employer does not ensure process safety information pertaining to the equipment included the design codes and standards employed such as National Fire Protection Association (NFPA) Standard 85, Boiler and Combustion Systems Hazard Code, and ASME CSD-1, sections CF-310 & CF-330, and ASME Section VI for the Wickes boiler burner and gas train exposing employees to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing that it is in compliance with the standard, including describing the steps it is taking to ensure that process safety information pertaining to the that equipment included the design codes and standards employed for the Wickes Boiler burner ad gas train.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(e)(3)(i):  The process hazard analysis did not address the hazards of the process:    The employer does not ensure the process hazard analysis addresses the hazards of the process.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure the 1992 and 2008 Process Hazard Analyses addressed the hazards of the process where employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses for hazards of the process such as but not limited to:    a)  Failure to purge or adequately purge the boiler firebox prior to lighting the burner pilot.  b)  Loss of burner pilot during the initial start-up of the boiler burner.  c)  Loss of burner flame.  d)  High or prolonged fuel gas flow to the burner without a pilot or flame present.  e)  Failure of the burner to light.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure the process hazard analysis addresses the hazards of the process.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(3)(iii):  The process hazard analysis did not address the engineering and administrative controls applicable to the hazards and their interrelationship, such as, appropriate detection methodologies to provide early warning of releases:    The employer does not ensure the process hazard analysis addresses the engineering and administrative controls applicable to the hazards and their interrelationship, such as, appropriate detection methodologies to provide early warning of releases.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure the 1992 and 2008 Process Hazard Analyses addressed the engineering and administrative controls applicable to the hazards and their interrelationships such as the appropriate methodologies to provide early warning where employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses for occurrences such as but not limited to:    a)   Loss of burner pilot during the initial start-up of the boiler burner.  b)   Loss of burner flame.  c)   High or prolonged fuel gas flow to the burner without a pilot or flame present.  d)   Failure of the burner to light.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing that it is in compliance with the standard, including describing the steps it is taking to ensure the process hazard analysis addressed the engineering and administrative controls applicable to the hazards and their interrelationships such as the appropriate methodologies to provide early warning.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(3)(iv):  The process hazard analysis did not address the consequences of failure of engineering and administrative controls.    The employer does not ensure the process hazard analysis addresses the consequences of failure of engineering and administrative controls.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure the 1992 and 2008 Process Hazard Analyses addressed the consequences of failure of engineering and administrative controls where employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses for occurrences such as but not limited to:    a)   Loss of burner pilot during the initial start-up of the boiler burner.  b)   Loss of burner flame.  c)   High or prolonged fuel gas flow to the burner without a pilot or flame present.  d)   Failure of the burner to light.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure the process hazard analysis addressed the engineering and administrative controls applicable to the hazards and their interrelationships such as the appropriate methodologies to provide early warning.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(f)(1)(i)(A):  The employer's written operating procedures covering the steps for each operating phase did not address initial startup.    The employer's written operating procedures covering the steps for each operating phase do not address initial startup.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure the written operating procedures covered steps for each operating phase including initial startup such as but not limited to:     a)  The length of time in which the gas can flow to the boiler burner without the burner lighting.  b)  A description of how much the main gas valve can be opened or what the maximum pressure should/can be at the inlet to the burner.  c)  The length of time the firebox is to be purged of gas prior to or after a failed burner lighting attempt.  d)  The maximum gas pressure at the inlet to the gas train on the boiler burner.  e)  The use of natural/purchased gas versus refinery gas.    Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure the written operating procedures covered steps for each operating phase including initial startup.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(3):  The operating procedures were not reviewed as often as necessary to assure that they reflect current operating practice, including changes that result from changes in process chemicals, technology, and equipment, or changes to facilities:    The employer does not ensure operating procedures are reviewed as often as necessary to assure that they reflect current operating practice, including changes that result from changes in process chemicals, technology, and equipment, or changes to facilities.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure written operating procedures for the Wickes Boiler Burner System were reviewed as often as necessary to assure that they reflected current operating practice. Identified errors include but not limited to:    a)  The amount of time the firebox is purged prior to attempting to light the pilot or after a failed burner lighting attempt.  b)  The level the gas control valve bypass valve is to be opened.  c)  The time the gas control valve bypass valve is allowed open before the burner lights.    Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure that written operating procedures are reviewed as often as necessary to assure they reflect current operating practice, including changes that result from changes in process chemicals, technology, and equipment, or changes to facilities for the Wickes Boiler.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(l)(3):  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 employees involved in operating a process and maintenance and contract employees whose job tasks will be affected by a change in the process are informed of, and trained in, the change prior to start-up of the process or affected part of the process.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure employees whose job tasks were affected by a change in the process were informed of and trained on the change prior to startup of the process. Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses for process changes such as, but not limited to:   a)   Standard Operating Procedures covering the start-up of the Wickes Boiler burner after        the 2008 Wickes Boiler Explosion.  (Allegation (a) is removed )  b)   Use of temporary power to power the Wickes boiler during the shutdown/turnaround.  Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure employees involved in operating a process whose job tasks will be affected by a the change are informed of, trained in, the change prior to start-up of the process or affected part of the process.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(B): The energy control procedures did not clearly and specifically outline the steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy:    The employer does not ensure the energy control procedures clearly and specifically outline the steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure the energy control procedures for the lockout/tagout of the fuel gas and purchased gas supply lines to the Wickes Boiler burner clearly and specifically outlined the steps for shutting down, isolating, blocking, and securing equipment to control hazardous energy.  Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure the energy control procedures clearly and specifically outline the steps for shutting down, isolating, blocking, and securing equipment to control hazardous energy.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(4)(ii) (D): The energy control procedures did not clearly and specifically outline the requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures:    The employer does not ensure the energy control procedures clearly and specifically outline the requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure that the energy control procedures for the lockout/tagout of the fuel gas and purchased gas supply lines to the Wickes Boiler clearly and specifically outlined the requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices. Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure the energy control procedures clearly and specifically outline the requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.147(d)(3):  All energy isolating devices that were needed to control the energy to the machine or equipment were not physically located and operated in such a manner as to isolate the machine or equipment from the energy source:    The employer does not ensure all energy isolating devices that are needed to control the energy to the machine or equipment are physically located and operated in such a manner as to isolate the machine or equipment from the energy source.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure all energy isolating devices for the lockout/tagout of the fuel gas and purchased gas supply lines such as, but not limited to, the control valves (FC 702 & FC 704) and bleed valves to the Wickes Boiler were physically located and operated in such a manner as to isolate the machine or equipment from the energy source.  Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure all energy isolating devices that are needed to control the energy to the machine or equipment are physically located and operated in such a manner as to isolate the machine or equipment from the energy source.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(5)(i):  All potentially hazardous stored or residual energy was not relieved, disconnected, restrained or otherwise rendered safe after the application of lockout or tagout devices to energy isolating devices:    The employer does not ensure all potentially hazardous stored or residual energy is relieved, disconnected, restrained or otherwise rendered safe after the application of lockout or tagout devices to energy isolating devices.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure all potentially hazardous stored or residual energy was relieved after the application of lockout or tagout devices such as between the two control valves (FC 702 and FC 704) on the fuel gas and purchased gas supply lines to the Wickes Boiler.  Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure all potentially hazardous stored or residual energy is relieved, disconnected, restrained or otherwise rendered safe after the application of lockout or tagout devices to energy isolating devices.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $38,500 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.119(f)(1)(ii):  The employer did not implement written operating procedures that addressed operating limits; including at least the following elements: consequences of deviation and the steps required to correct or avoid deviation:    The employer does not implement written operating procedures that address operating limits; including at least the following elements: consequences of deviation and the steps required to correct or avoid deviation:    a)  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure the written operating procedures addressed the operating limits of the process such as, but not limited to:    1.  Minimum/Maximum gas pressure to the boiler burner gas train.  2.  Minimum and maximum pressure (PI 721 & PI 711) at the fuel gas inlet to the Wickes.  3.  Minimum and maximum fuel gas flow to the Wickes boiler burner (FI 702).  4.  Minimum and maximum combustion air flow to the Wickes boiler burner (FI-706).  5.  Composition of the gas flow streams to the Wickes boiler burner (fuel gas and purchased gas) including BTU content, lower explosive limits etc.     b)  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure the written operating procedures addressed the consequence of deviation from the safe upper and lower limits of the process such as, but not limited to:    1.  Minimum/Maximum gas pressure to the boiler burner gas train.  2.  Minimum and maximum pressure (PI 721 & PI 711) at the fuel gas inlet to the Wickes.  3.  Minimum and maximum fuel gas flow to the Wickes boiler burner (FI 702).  4.  Minimum and maximum combustion air flow to the Wickes boiler burner (FI-706).  5.  Composition of the gas flow streams to the Wickes boiler burner (fuel gas and purchased gas) including BTU content, lower explosive limits etc.     c)  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure the written operating procedures addressed the steps to correct or avoid deviation from the safe upper and lower limits of the process such as but not limited to:     1.  Minimum/Maximum gas pressure to the boiler burner gas train.  2.  Minimum and maximum pressure (PI 721 & PI 711) at the fuel gas inlet to the Wickes.  3.  Minimum and maximum fuel gas flow to the Wickes boiler burner (FI 702).  4.  Minimum and maximum combustion air flow to the Wickes boiler burner (FI-706).  5.  Composition of the gas flow streams to the Wickes boiler burner (fuel gas and purchased gas) including BTU  content, lower explosive limits, etc.     Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    WYNNEWOOD REFINING WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIPVALENT STANDARD, 29 CFR 1910.119(f)(1)(ii), WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER #309785459, CITATION NUMBER #1, Item# 8b AND WAS AFFIRMED AS FINAL ORDER ON AUGUST 4, 2008, WITH RESPECT TO A WORKPLACE LOCATED AT 906 S. POWELL, WYNNEWOOD OK 73098.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure the written operating procedures address the consequence of deviation and steps required to correct or avoid deviation from the safe upper and lower limits of the process.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $38,500 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.119(g)(2):  The employer did not provide refresher training at least every three years to 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 provide refresher training at least every three years to each employee involved in operating a process to assure that the employee understands and adheres to the current operating procedures of the process.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure refresher training was provided at least every three years to each employee involved in operating the Wickes Boiler to assure that the employee understood and adhered to the current operating procedures.  Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    WYNNEWOOD REFINING WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIPVALENT STANDARD, 29 CFR 1910.119(g)(2), WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER #311001234, CITATION NUMBER #1, Item# 12b AND WAS AFFIRMED AS FINAL ORDER ON SEPTEMBER 8, 2008, WITH RESPECT TO A WORKPLACE LOCATED AT 906 S. POWELL, WYNNEWOOD OK 73098.     Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure refresher training is provided at least every three years to the each employee involved in operating a process to assure the employee understands and adheres to the current operating procedures.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $38,500 · Current $7,000 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 establish and implement written procedures to maintain the on-going mechanical integrity of process equipment.  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure written procedures were established and implemented for the testing and inspection of the Low Combustion Air Flow Fuel Gas Shut-off system safeguard.  Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    WYNNEWOOD REFINING WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIPVALENT STANDARD, 29 CFR 1910.119(j)(2), WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER #309785459, CITATION NUMBER #1, Item# 10 AND WAS AFFIRMED AS FINAL ORDER ON AUGUST 4, 2008, WITH RESPECT TO A WORKPLACE LOCATED AT 906 S. POWELL, WYNNEWOOD OK 73098.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure written procedures are established and implemented to maintain the on-going mechanical integrity of the process equipment.

Issued

Mar 27, 2013

Abate by

Apr 10, 2013

Penalty

Initial $38,500 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.119(l)(1):  The employer did not establish and 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 establish and implement written procedures to manage changes to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process.       a)  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure management of change procedures were implemented to manage changes to the process operating procedures such as, but not limited to:       1.  The amount of time the firebox is purged prior to attempting to light the pilot or after a failed burner lighting attempt.     2.  The amount that the gas control valve bypass valve is to be opened.     3.  The time that the gas control valve bypass valve is allowed open before the burner lights.     b)  In the Zone 2/CAT Wickes Boiler Area the employer did not ensure management of change procedures were implemented to manage changes to the process equipment, such as the addition of temporary power to operate the Wickes Boiler.    Employees were exposed to fire and explosion hazards from potential releases of fuel gas and other flammable liquids or gasses.    WYNNEWOOD REFINING WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIPVALENT STANDARD, 29 CFR 1910.119(l)(1), WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER #309785459, CITATION NUMBER #1, Item# 12 AND WAS AFFIRMED AS FINAL ORDER ON AUGUST 4, 2008, WITH RESPECT TO A WORKPLACE LOCATED AT 906 S. POWELL, WYNNEWOOD OK 73098.    Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure the written operating procedures were established and implemented to manage changes to the process operating procedures.