OSHA Inspection: GREEN BAY DRESSED BEEF, LLC

Issued

May 17, 2013

Abate by

Jul 5, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): The employer's piping and instrument diagrams were not accurate and did not represent equipment that was existing and was part of the process:    a) Drawing number R-9, Vessels V-3 and VV-3 section,  indicated there is not a butterfly valve present on the B leg. An unidentified butterfly valve was present on the B leg below Recirculator Vessel V-3.    b) Valve number 6A06J094 on Drawing number R-9, Pumps number 1, 2, 3 and 4 section, was missing its identification tag.    c) Drawing number R-9, Pumps number 1, 2, 3 and 4 section, indicated Valve number 2A41J094 was present between Valve number 2A05J091 and Valve number 2A39J094. Valve number 2A41J094 was not physically present.    d) Drawing number R-9, Pumps number 1, 2, 3 and 4 section, indicated a relief valve was identified as 2A30J094 and 2A30J090. The relief valve was tagged 2A30J094. It is standard protocol for each component on a piping and instrumentation diagram to be uniquely identified with a single identifier.     e) Drawing number R-1 indicated there is not a valve present between Valve number 1B34J011 and Valve number 1B33J011 on the 3/4 inch HSS line. An unidentified valve was present between Valve number 1B34J011 and Valve number 1B33J011 on the 3/4 inch HSS line.    f) Drawing number R-1 indicated a valve was identified as 2B03J012. The valve was tagged as 2B03J013. The last digit of the identifying number indicates the type of valve. A 2 indicates a control valve and A 3 indicates a check valve.     g) Valve number 4038J011 on Drawing number R-1 was missing its identification tag.    h) Valve number 2072J014 on Drawing number R-1 was missing its identification tag.    i) Drawing Valve Group VG-07 #1 Cooler indicated there was not a valve between Valve number 2C21R124 and Valve number 2C20R122 on the 1 1/4 inch HTRL line. Valve number 2C20R123 was present between Valve number 2C21R124 and Valve number 2C20R122 on the 1-1/4 inch HTRL line.    j) Valve number 4C17R111 on Drawing Valve Group VG-12 #1 Cooler was missing its identification tag.    k) Valve number 3C03R112 and Valve number 3C04R110 on Drawing Valve Group VG-12 #1 Cooler were missing their identification tags.    l) Drawing Valve Group VG-07E-07W #4 Cooler indicated a valve without a number connected to Valve number 3C14R162. The connected valve was tagged as number 3C15R160.    m) Valve number 1C15R151 on Drawing Valve Group VG-04E-04W #4 Cooler was incorrectly tagged as 3C26R151.    n) Valve number 3C21R154 on Drawing Valve Group VG-03E #4 Cooler was incorrectly tagged as 3C21R151.    o) Drawing Valve Group VG-03E #4 Cooler indicated 1 inch HGD when the pipe diameter was actually 1-1/2 inch.           Abatement Documentation and Abatement Certification required.

Issued

May 17, 2013

Abate by

Jul 5, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.119(e)(5): The employer did not assure that process hazard analysis recommendations were resolved in a timely manner and resolutions were documented:    a)  The employer was not able to provide documentation describing the actions taken to resolve the findings and recommendations of the Process Hazard Analysis Revalidation completed on 02/22/09, nor the dates those actions were taken.         Abatement Documentation and Abatement Certification required.

Issued

May 17, 2013

Abate by

Jul 5, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.119(g)(3): The employer shall ascertain that each employee involved in operating a process has received and understood the training required by this paragraph. The employer shall prepare a record which contains the identity of the employee, the date of training, and the means used to verify that the employee understood the training:    a)  The employer's written process safety management program does not describe the required initial and refresher training required for each employee maintaining and/or monitoring the ammonia refrigeration system.    b)  The employer has not documented initial and refresher in-house training for employees maintaining and/or monitoring the ammonia refrigeration system.         Abatement Documentation and Abatement Certification required.

Issued

May 17, 2013

Abate by

Jun 21, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish or implement written procedures to maintain the ongoing integrity of process equipment:    a) The employer had not incorporated the insulated and uninsulated piping inspections of the written American Foods Group Process Safety Management Program into the computerized maintenance work order system.    b) The employer had not incorporated the control and shut-off valve inspections of the written American Foods Group Process Safety Management Program into the computerized maintenance work order system.         Abatement Documentation and Abatement Certification required.

Issued

May 17, 2013

Abate by

Jul 5, 2013

Penalty

Initial $5,500 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(iv): The employer did not document the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other identifier of the equipment on which the inspection or test was performed, a description of the inspection or test performed, and the results of the inspection or test performed on process equipment:    a)  The employer's computerized maintenance work order system does not record what preventative maintenance was conducted to the specific piece of equipment or the results of the inspection or test performed on process equipment.         Abatement Documentation and Abatement Certification required.

Issued

May 17, 2013

Abate by

Jun 21, 2013

Penalty

Initial $5,500 · Current $3,300 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/or document that deficiencies have been corrected:    a) The employer was not able to provide documentation of what the employer determined the appropriate response was for each finding of the 01/04-07/2010 Ammonia PSM Audit and when the appropriate response was completed.         Abatement Documentation and Abatement Certification required.

Issued

May 17, 2013

Abate by

Jun 21, 2013

Penalty

Initial $4,400 · Current $3,300 Reduced

General-duty citation text

29 CFR 1910.120(q)(9)(i): Members of an organized and designated HAZMAT team and hazardous materials specialist did not receive a baseline physical examination and/or was not provided with medical surveillance as required in 29 CFR 1910.120(f):    a) Seven of the eight members of the HAZMAT team have not received a medical examination and consultations since or before April 24, 2008. 29 CFR 1910.120(f)(3)(i)(B) requires a medical examination every twelve months for each employee covered unless the attending physician believes a longer interval (not greater than biennially) is appropriate.         Abatement Documentation and Abatement Certification required.