OSHA Inspection: SINTON DAIRY FOODS COMPANY, LLC.

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $4,950 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.23(c)(1):  Open-sided floor(s) or platform(s) 4 feet or more above the adjacent floor or ground level were not guarded by standard railings (or the equivalent as specified in 29 CFR 1910.23(e)(3)(i) through (v)), on all open sides:    a)  On or about November 5, 2012 and times prior, employees were exposed to injuries due to falls from the roof to the lower surface when accessing equipment including but not limited to the cream tank.    Abatement Note:  Abatement certification is required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $4,950 · Current $3,000 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): Information pertaining to the equipment in the process did not include accurate piping and instrument diagrams (P&ID's):    a)  On or about November 5, 2012 and times prior, the employer's piping and instrument diagrams (P&ID's) were not accurate and did not reflect equipment that was existing in the actual process including, but not limited to, the following:    1.  P&ID SC-507 showed three PSV's, 9321, 9311, and 9351 where there were no actual PSV's in the process.     2.  P&ID SC-526 showed the vessel as AV-313 when actually the vessel was AV-307.    3.  P&ID SC-525 labeled two (2) AC units as 509 and 510. The actual AC units were 801 and 802.    4.  P&ID SC-524 showed one PSV 9091 when actually there were two PSV's, the additional one was PSV 08766.    5.  P&ID SC-513 showed silo 1 and silo 2 in service when actually both units were not in service. Also silo (0) and its PSV's were not on the P&ID.     6.  P&ID SC-514 showed silo 6 and silo 7 with four PSV's installed. There were actually only two installed, PSV 9521 and PSV 9531 were not installed.    11. P&ID SC-501 identified the motor as BM-209 but the motor was actually BO-109.    12. P&ID SC-501 showed EX-609 (oil cooler) PSV as being PSV 9861 but the PSV installed was PSV 3041.    Abatement Note:  Abatement certification and documentation are required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $4,950 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D):  Information pertaining to the equipment in the process did not include accurate relief system design and design basis:    a) On or about November 5, 2012 and times prior the employer did not maintain an accurate listing of the location, and inspection information for all Relief Valves (RV) within a covered process on the following RV's:    1) PSV #08766 was not included in the 2010 safety relief vent design analysis and the unit was installed.    2) PSV # 9321 and #9311 were not included in the 2010 safety relief vent design analysis. PSV # 9321 and #9311 were not removed from service until June 2011.    3) The PSV list used to perform PSV checks was not accurate.    Abatement Note:  Abatement certification is required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $4,950 · Current $3,000 Reduced

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) On or about November 5, 2012 and times prior, the high pressure liquid lines from tanks number six and seven were not appropriately marked per IIAR Bulletin #114-1991 which the employer uses as recognized and generally accepted good engineering practices (ragagep).    Abatement Note:  Abatement certification is required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $6,300 · Current $4,000 Reduced

General-duty citation text

29 CFR 1910.119(e)(6): At least every five (5) years after the completion of the initial process hazard analysis, the process hazard analysis was not updated and revalidated by a team meeting the requirements in paragraph (e)(4) of this section, to assure that the process hazard analysis is consistent with the current process:     a) On or about November 5, 2012 and times prior the 2009 PHA Revalidation did not address inconsistencies in the P&ID's. The 2009 PHA stated that "all available engineering drawing, specifications, and P&ID's relevant to facility expansion and modification since the last PHA" had been reviewed. The recommendation that no action items were noted during this PHA Revalidation was not accurate.     Abatement Note:  Abatement certification and documentation are required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $6,930 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.119(l)(1): The employer did not establish and implement written procedures to manage changes (except for "replacements in kind") to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process:    a) On or about November 5, 2012 and times prior the employer removed from service silo 1 and silo 2. The employer also installed silo (0). The employer did not establish and implement written procedures to manage change prior to performing the job task exposing employees and sub-contractor employees to hazards associated with exposures to ammonia.    Abatement Note:  Abatement certification and documentation are required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $6,930 · Current $5,000 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) On or about November 5, 2012 and times prior, employees were exposed to a potential unintended release of ammonia at the following locations:     1. Unit AV 312, expansion tank valve L 837 missing 1/2" cap.   2. Unit EX 601A, G-100 valve missing end cap.   3. Unit DS 304, valve L 588 missing end cap.     b)  On or about November 5, 2012 and times prior, employees were exposed to a potential unintended release of high pressure liquid from improperly supported lines which resulted in excessive vibration at the following location:     1. AC 508, the high pressure liquid (HPL).  There was excessive vibration in this line due to the line not being effectively supported.     Abatement Note:  Abatement certification and documentation are required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $4,950 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.219(d)(1):  Pulleys, any part of which are seven (7) feet or less from the floor or working platform, were not guarded in accordance with the standards specified in paragraphs (m) and (o) of this section:     b)  On or about November 5, 2012 and times prior, employees were exposed to injuries from an unguarded pulley at the de-stator (0) drive motor.     Abatement Note:  Abatement certification is required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(e)(1)(i):  Horizontal belts which had both runs seven feet or less from the floor level were not guarded with a guard that extended to at least fifteen inches above the belt:    b)  On or about November 5, 2012 and times prior, employees were exposed to injuries from an unguarded belt at the de-stator (0) drive motor.    Abatement Note:  Abatement certification is required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $4,950 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.219(i)(2): Shaft couplings were not so constructed as to present no hazard from bolts, nuts, setscrews, or revolving surfaces. Bolts, nuts, and setscrews will, however, be permitted where they are covered with safety sleeves or where they are used parallel with the shafting and are countersunk or else do not extend beyond the flange of the coupling:    a) On or about November 5, 2012 and times prior, employees were exposed to injury in that, the rotating shaft coupling for the spoiler pack unit was not adequately guarded.    Abatement Note:  Abatement certification is required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $4,950 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.305(e)(2): Switches, circuit breakers, and switchboards. Switches, circuit breakers, and switchboards installed in wet locations were not enclosed in weatherproof enclosures.    a) On or about November 5, 2012 and times prior, employees were exposed to electrical shock injury at the following locations:    1) A 110-volt box (light switch) located in the milk vault on the west wall between uc402 and uc403 was not approved for wet applications. The 110-volt light switch outer protective cover was missing exposing the light switch to moisture.     Abatement Note:  Abatement certification is required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(j)(2)(iv): A receptacle installed in a wet or damp location was not suitable for the location.    a) On or about November 5, 2012 and times prior, employees were exposed to electrical shock injury at the following location:    1) A 220-volt plug receptacle located in the vat room was not adequate for wet applications. The lower protective covers had failed exposing the receptacle to moisture.     Abatement Note:  Abatement certification is required for this item (see enclosed "Certification of Corrective Action Worksheet").

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $9,900 · Current $7,000 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)  On or about November 5, 2012 and times prior, the employer had not developed and implemented effective procedures to address coating of installed piping, valves and other process equipment or an inspection process to identify equipment where a protective coating had not been applied. Two areas of piping observed were the high stage suction line going to AC 506 and the high pressure liquid line. There were additional sections of lines and valves observed during the inspection where piping had been installed and a protective coating had not been applied.  Several of these sections of pipe contained surface corrosion.     Abatement Note:  Abatement certification and documentation are required for this item (see enclosed "Certification of Corrective Action Worksheet").     Sinton Dairy Foods Company, LLC, was previously cited for a violation of this occupational safety and health standard or its equivalent, which was contained in OSHA Inspection Number 312139199, Citation Number 1, Item Number 2, and issued on August 7, 2009, with respect to a workplace located at 3801 N. Sinton Road, Colorado Springs, CO 80907. This citation became final order on August 18, 2009.

Issued

May 1, 2013

Abate by

Jun 18, 2013

Penalty

Initial $9,900 · Current $5,000 Reduced

General-duty citation text

29 CFR 1910.305(b)(2)(i): All pull boxes, junction boxes, and fittings were not provided with covers identified for the purpose:    a) On or about November 5, 2012 and times prior, employees were exposed to injuries from electrical shock in that the 440-volt electrical box was missing a frontal protective cover plate. The electrical box controls the first wash pump located on the north wall of the case raised platform.    Abatement Note:  Abatement certification and documentation are required for this item (see enclosed "Certification of Corrective Action Worksheet").     Sinton Dairy Foods Company, LLC, was previously cited for a violation of this occupational safety and health standard or its equivalent, which was contained in OSHA Inspection Number 312139140, Citation Number 1, Item Number 2, and issued on August 7, 2009, with respect to a workplace located at 3801 N. Sinton Road, Colorado Springs, CO 80907. This citation became final order on August 18, 2009.

Issued

May 1, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(g)(1)(i):  Working space in front of electric equipment rated 600 volts, nominal, or less was used for storage:    a) On or about November 5, 2012 and times prior, the employer had placed ladders along the north wall in front of the electrical panel located in the basse loader room.    Abatement Note:  Abatement certification is required for this item (see enclosed "Certification of Corrective Action Worksheet").