OSHA Inspection: BAYER MATERIAL SCIENCE LLC

Issued

2013-03-15 00:00:00

Abate by

2013-04-08 00:00:00

Penalty

Initial $6000.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.119(i)(2)(ii):  The employer did not ensure that safety, operating, maintenance, and emergency procedures are in place and are adequate;      On or around September 27, 2012, in the MR-1 Unit of the Bayer Material Science chemical manufacturing facility in Baytown, TX, In its pre-start safety review of the temporary hose installation in the MR-1 Unit, the employer did not ensure prior to introducing chemicals and placing the hose in service that procedures for clearing the hose after use were in place and adequate.

Issued

2013-03-15 00:00:00

Abate by

2013-04-08 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(l)(2)(ii): The employer did not consider the impact that changes to the process would have on safety and health;    This was most recently occurred when the employer did not to consider the impact that installing temporary hose to supplement MCB flow to the vacuum pumps would have on the health and safety of workers in and around     a) In the the MR-1 unit of the Bayer MaterialScience facility in Baytown, TX, the employer failed to  identify, evaluate and correct the hazard of reverse flow when employees were allowed to purge a temporary flex line to the surge tank.     b) In the the MR-1 unit of the Bayer MaterialScience facility in Baytown, TX, the employer failed to consider that phosgene was being processed and could be present and released from the temporary hose used.

Issued

2013-03-15 00:00:00

Abate by

2013-04-08 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(l)(2)(iii):  The employer did not assure that modifications to operating procedures were addressed prior to any change:      On or around September 27, 2012 the employer failed to modify operating procedures of the MR-1 Unit in the Bayer MaterialScience chemical manufacturing facility to include instruction and guidance to workers for clearing the temporary hose installed under MOC BTN-PUR-MR1-2012-033 with nitrogen prior to removing the hose from service and un-installing the supplemental cooling to the vacuum ring header pumps.

Issued

2013-03-15 00:00:00

Abate by

2013-04-08 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(l)(5): When a change covered by this paragraph resulted in a change in the operating procedures or practices required by paragraph (f) of this section, such procedures or practices were not updated accordingly.      On or around September 27, 2012  operating procedures were not updated in the MR-1 Unit at the Bayer Material Science Baytown chemical manufacturing facility to reflect required steps for clearing the temporary hose that was installed under MOC BTN-PUR-MR1-2012-033 to supply supplemental cooling to the vacuum ring pumps prior to removing the hose from service in the unit.

Issued

2013-03-15 00:00:00

Abate by

2013-04-08 00:00:00

Penalty

Initial $6000.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not implement written procedures to maintain the on-going integrity of process equipment.       a) This violation was observed in the MR-1 Unit at the Bayer Material Science facility in Baytown, Texas, when the employer did not ensure that procedures such as, but not limited to Bayer's flanged joint torqueing procedure were utilized in the assembly of the hose connections.      b) This violation was observed in the MR-1 Unit at the Bayer Material Science facility in Baytown, Texas, when the employer did not ensure that the leak test conducted on the assembled hose flange joints were tested at or above the pressure at which the hose would experience during its service cycle.