OSHA Inspection: D & D FOODS, INC

Issued

Jun 26, 2013

Abate by

Jan 10, 2014

Penalty

Initial $4,500 · Current $3,150 Reduced

General-duty citation text

29 CFR 1910.38(d):   The employer faiiled to have and maintain an employee alarm system. The employee alarm system must use a distinctive signal for each purpose and comply with the requirements in 29 CFR 1910.165.    Throughout the Facility:  The employer has not installed any form of alarm system which would notify the employees of an ammonia release.  The reactor area does have an ammonia detector with a local alarm, but that does not provide for notification to the rest of the facility.      Abatement certification is required for this violation. The abatement certification sheet is enclosed for the citations.

Issued

Jun 26, 2013

Abate by

Jul 30, 2013

Penalty

Initial $4,500 · Current $3,150 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.   Rooftop of the facility, Production Refrigeration System at the Hot Room:  The ammonia relief system header discharge piping is located 93 above the roof surface. ASHRAE 15-2004, Section 9.7.8 states that pressure relief discharges are to be directed 15 feet above the ground, 20 feet from a window, ventilation or building entry.  In this instance, due to the fact that maintenance personnel work on the roof that is considered the working surface and the relief discharge should be 15 feet above the roof.       Abatement certification is required for this violation. The abatement certification sheet is enclosed for the citations.

Issued

Jun 26, 2013

Abate by

Jul 30, 2013

Penalty

Initial $4,500 · Current $3,150 Reduced

General-duty citation text

29 CFR 1910.119(e)(7):   The Employer failed to retain process hazards analyses and updates or revalidations for each process covered by this section, as well as the documented resolution of recommendations described in paragraph (e)(5) of this section for the life of the process.    Worksite located at 9425 N. 48th Street, Omaha, NE; Throughout the facility:  The employer failed to maintain the original Process Hazard Analysis for the facility.  It was conducted in late 2008 and carried over to 2009.  This would include the findings, recommendations, and resolutions.      Abatement certification is required for this violation. The abatement certification sheet is enclosed for the citations.

Issued

Jun 26, 2013

Abate by

Jul 30, 2013

Penalty

Initial $3,600 · Current $2,520 Reduced

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, and changes to facilities.  The employer failed to certify annually that these operating procedures are current and accurate.    Worksite located at 9425 N. 48th Street, Omaha, NE; Throughout the facility:  The operating procedures for the ammonia refrigeration system were developed in January of 2012 and have not been reviewed since that time.  There was not an annual certification of any type of review of the procedures.      Abatement certification is required for this violation. The abatement certification sheet is enclosed for the citations.

Issued

Jun 26, 2013

Abate by

Jul 30, 2013

Penalty

Initial $6,300 · Current $4,410 Reduced

General-duty citation text

29 CFR 1910.119(g)(1)(i):    Each employee presently involved in operating a process, and each employee before being involved in operating a newly assigned process, was not trained in an overview of the process and in the operating procedures as specified in paragraph (f) of this section. The training shall include emphasis on the specific safety and health hazards, emergency operations including shutdown, and safe work practices applicable to the employee's job tasks.    Throughout the Facility:  The employer failed to train any employees on the operating procedures for the ammonia refrigeration system.  The procedures were developed in January of 2012 and the employer failed to train the covered employees as to the contents to include emergency procedures and safe work practices.      Abatement certification and abatement documentation is required for this violation. The documentation should include written verification of the abatement, applicable measurements or monitoring results, and photographs or videos which you believe will be helpful. The abatement certification sheet is enclosed with the citations.

Issued

Jun 26, 2013

Abate by

Dec 6, 2013

Penalty

Initial $6,300 · Current $4,410 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.    Throughout the Facility:  The employer has not developed any procedures for ensuring the mechanical integrity of the system.  This would include a program outlining preventative maintenance, component replacement, and/or repair.  One such example would be a valve replacement procedure to include a change out schedule for safety relieve valves.  During the inspection it was also found that the company did not have a piping inspection procedure.  Rusted piping was found in a number of locations that had not been mitigated.      Abatement certification is required for this violation. The abatement certification sheet is enclosed for the citations.

Issued

Jun 26, 2013

Abate by

Jul 30, 2013

Penalty

Initial $4,500 · Current $3,150 Reduced

General-duty citation text

29 CFR 1910.119(k)(1):   The employer failed to issue a hot work permit for hot work operations conducted on or near a covered process.    Worksite located at 9425 N. 48th Street, Omaha, NE; Throughout the facility:  The employer failed to utilize a hot work permitting program for the facility. This would include the implementation of permits to ensure that an adequate number of personnel area available to perform firewatch activities; the proper equipment is available and utilized; and that management is aware of any hot work operation.    Abatement certification is required for this violation. The abatement certification sheet is enclosed for the citations.

Issued

Jun 26, 2013

Abate by

Jul 30, 2013

Penalty

Initial $3,600 · Current $2,520 Reduced

General-duty citation text

29 CFR 1910.119(m)(4):    The employer failed to prepare an incident investigation report at the conclusion of the investigation which included the items outlined in 1910.119(m)(4)(i) - (v) of this paragraph.  This includes the date of incident; date investigation began; a description of the incident; the factors that contributed to the incident; and any recommendations resulting from the investigation.    Worksite located at 9425 N. 48th Street, Omaha, NE; Throughout the facility:  The employer does not include all of the information outlined in the standard in incident investigation reports.  Some examples include the lack of factors that led to the incident and recommendations from the incident investigation.      Abatement certification is required for this violation. The abatement certification sheet is enclosed for the citations.