OSHA Inspection: UNICOLD CORPORATION

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.22(b)(2):   Permanent aisles and passageways were not appropriately marked:  (a) On or about February 13, 2013, throughout the warehouse facility where powered industrial trucks were operated, there were no marked and identified paths of travel.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.23(a)(2):   Ladderway floor opening(s) or platform(s) were not guarded by a standard railing with standard toeboard(s) on all exposed sides (except at the entrance to opening) with passage through the railing either provided with a swinging gate or so offset that a person could walk directly into the opening:  (a) An opening on the deck of the roof for engine room #1 where a ladderway was present was not guarded by a standard railing on all exposed sides and the opening was not provided with a swinging gate or with an offset railing.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.23(c)(1): Open-sided floors and/or platforms four feet or more above adjacent floor or ground level were not guarded with standard railings (or equivalent) and toeboards. Note: Toeboards are only required when persons can pass, there is moving equipment or there is equipment with which falling materials could create a hazard:  (a) On or about February 13, 2013 an area 16 feet in length beside the intersection of two walkways and at the end of a third walkway above the roof of Engine Room #1 was not guarded.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.23(a)(8)(ii): Every floor hole into which persons could accidently walk was not guarded by a floor hole cover of standard strength and construction:  (a) On or about February 13, 2013; where a hole in the walkway on the deck on above the roof of Engine Room #1  was 4 1/2 inches wide and 9 5/8 inches long was not guarded.   (b) On or about February 13, 2013 a hole in the walkway on the deck above the roof of Engine Room #1 was 10 inches wide and 11 inches long was covered by a scrap of plywood not fastened down and not marked with a warning to indicate the presence of the hole.  (c) On or about February 13, 2013 a hole along the edge of a walkway above the roof of Engine Room #1 that a person could step into measured 10 1/4 inches by 14 feet and was not guarded.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.24(e):   Fixed stairs were not installed at angles to the horizontal of between 30 degrees and 50 degrees:  (a) On or about February 13, 2013 the stairs leading from the roof above Engine Room #1 to the ammonia system service deck was installed at 57 degrees to the horizontal.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.24(h):   Standard railings were not provided on the open sides of all exposed stairways and stair platforms:  (a) On or about February 13, 2013; where fixed industrial stairs leading from the roof above Engine Room #1 to the deck above did not have a midrail on the right side of the steps as viewed while standing at the bottom of the steps.  (b) On or about February 13, 2013; where fixed industrial stairs leading from the roof above Engine Room #1 to the deck above did not have a stair rail on the left side of the steps as viewed while standing at the bottom of the steps.  (c) On or about February 13, 2013; where fixed industrial stairs located between docks 8 & 9 leading from the truck yard to the loading dock did not have a midrail on either side of the steps.   (d) On or about February 27, 2013 stairs leading to the backup generator door at the left end front side of the building did not have a stair rail.  (e) On or about February 27, 2013 the stair platform to the backup generator door at the right end front side of the building did not have a handrail.  (f) On or about February 27, 2013 the stair platform to the backup generator door at the right end front side of the building did not have a handrail.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.36(e)(1):   A side-hinged door was not used to connect any room to an exit route.  (a) On or about February 13, 2013 an overhead door was used to connect areas in the warehouses  to the exit route.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.36(g)(1): Ceiling of an exit route was not at least seven feet six inches.  Any projection from the ceiling must not reach a point less than six feet eight inches from the floor:   (a) The entrance steps coming from the front door had a point where the headroom clearance was 5'-5 29/32 inches from the front edge of the tread to the overhead obstruction.

Issued

Aug 9, 2013

Abate by

Aug 15, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.36(g)(2):   Exit access(es) were not at least 28 inches (71.1 cm) wide at all points:  (a) On or about February 13, 2013; where the exit from warehouse on the west side was blocked by truck trailers leaving an egress pathway of only 17 1/2 inches.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.37(a)(2):    Exit routes were not arranged so that employees did not have to travel toward a high hazard area:  (a) On or about February 13, 2013; where the meeting area in the parking lot next to office front door on Ualena Street for employees was between Engine Room #1 and Engine Room #2 where the two highest concentration areas of ammonia were stored and used.  (b) On or about February 13, 2013; where the meeting area in the parking lot next to office front door on Ualena Street for employees was downwind from the prevailing wind direction and the most anticipated area where smoke, fumes, and gases would migrate in the event of an emergency within the warehouse area.  (c) On or about February 13, 2013; where emergencies in warehouses with exits only on the dock side in Warehouses #1, 2 and 3 would force workers to come both past Engine Room #2 and past the ammonia lines within their own warehouse area to reach the parking lot meeting area next to Ualena Street.

Issued

Aug 9, 2013

Abate by

Aug 21, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.37(a)(3):    Stairs or a ramp were not provided where the exit route was not substantially level:  (a) The exit route out of Emergency Exit #1 was not substantially level and stairs or a suitable ramp were not provided.  (b) The exit route out of Emergency Exit #2 was not substantially level and stairs or a suitable ramp were not provided.  (c) The exit route out of Emergency Exit #3 was not substantially level and stairs or a suitable ramp were not provided.  (d) The exit route out of Emergency Exit #4 was not substantially level and stairs or a suitable ramp were not provided.  (e) The exit route out of Emergency Exit #5 was not substantially level and stairs or a suitable ramp were not provided.  (f) The exit route out of Emergency Exit #12 was not substantially level and stairs or a suitable ramp were not provided.  (g) The exit route out of Emergency Exit #13 was not substantially level and stairs or a suitable ramp were not provided.  (h) The exit route out of Emergency Exit #14 was not substantially level and stairs or a suitable ramp were not provided.  (i) The exit route out of Emergency Exit #16 was not substantially level and stairs or a suitable ramp were not provided.  (j) The exit route out of Emergency Exit #17 was not substantially level and stairs or a suitable ramp were not provided.  (k) The exit route out of Emergency Exit #18 was not substantially level and stairs or a suitable ramp were not provided.

Issued

Aug 9, 2013

Abate by

Aug 21, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.37(b)(2):   Each exit was not clearly visible and marked by a sign reading "Exit":  (a) Exit door #12 could not be seen as product was placed in front of the exit and the sign marking it as an exit was covered by stored product as well.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.37(b)(6):   Each exit sign was not illuminated to a surface value of at least five foot-candles (54 lux) by a reliable light source and be distinctive in color:  (a) On or about February 13, 2013 exit signs were not illuminated to a surface value of at least five foot-candles by a reliable light source.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.95(d)(1):   When information indicated that any employee's exposure equaled or exceed the 8-hour time-weighted average of 85 decibels, the employer did not develop and implement a monitoring program:    (a) On or about February 13, 2013; where the employer had not developed and implemented a hearing monitoring program for employees working in the engine rooms where noise levels exceeded 95 dBA.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.119(d)(3)(i):   The employer did not compile information pertaining to the equipment in the process:  (a) On or about February 13, 2013; where  the employer did not compile complete and up-to-date piping and instrumentation diagrams as required by 29 CFR 1910.119(d)(3)(i)(B).  (b) On or about February 13, 2013; where  the employer did not compile complete and up-to-date information pertaining to the electrical classification diagrams as required by 29 CFR 1910.119(d)(3)(i)(C).  (c) On or about February 13, 2013; where  the employer did not compile complete and up-to-date information pertaining to the relief system design and design basis as required by 29 CFR 1910.119(d)(3)(i)(D).  (d) On or about February 13, 2013; where  the employer did not compile complete and up-to-date information pertaining to the ventilation system design and design codes as required by 29 CFR 1910.119(d)(3)(i)(E) and (F).

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $4,900 · Current $4,900

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 February 13, 2013; where  the emergency vent pipe exiting from Engine Room #1 that did not comply with recognized and generally accepted good engineering practices.  The vent piping did not discharge 15 feet above ground or 20 feet above a building entry.  The emergency vent piping did not conform to ANSI/ASHRAE 15-2004 Section 9.7.8.  Additionally, the discharge did not terminate such that ammonia would not spray directly on personnel and debris could not enter the piping.   (b) On or about February 13, 2013; where engine Room #3 did not have continuous venting and did not comply with the International Institute of Ammonia Refrigeration (IIAR) Bulletin No. 111 06/02 3.2.1 Emergency Ventilation Rate minimum ventilation of 12 air changes per hour for the quantity of refrigerant in the largest system.  (c) On or about February 13, 2013; where runs of piping in Engine Room #1 were not labeled as to the content, whether it was high pressure or low pressure, and did not indicate the direction of flow.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.119(e)(5):   The employer did not establish a system to promptly address the PHA team's findings and recommendations, assure that the recommendations are resolved in a timely manner and that the resolution was documented:  The employer did not address recommendations made from the Process Hazard Analysis (PHA) audit teams as soon as possible where:    (a) Recommendation 09PHA-01 from the 2009 PHA states, "Update the refrigeration piping and instrumentation diagrams to show all pressure relief valve assemblies on engine room vessels." Target completion date of 2010 passed and on or about February 20, 2013, this condition was observed.   (b) Recommendation R23 from the 2004 PHA states, "Place wind socks (or other wind direction indicators) in locations that can be seen from all potential emergency exits." Target completion date was verified on March 25, 2004, on or about February 20, 2013, there were no windsocks that could be seen when exiting the North facing emergency exits fronting Koapaka Street.   (c) Recommendation R12 from the 2004 PHA states, "Perform and document an annual test of all high level switches in the system that shut down compressors. Status, Complete. Unicold will perform a test on an annual basis on each of 5 suction vessels. Target completion was verified on 3/25/04. Unicold Corporation Annual Compressor and Receiver Safety Test revealed testing on the high level switch for the Low Pressure Receiver and Intercooler for engine room 1 and Low Pressure Receiver for engine room 3." On or about February 20, 2013, there were no documents to show that the Inter-Pressure Receiver (150 lb ammonia capacity, 1963) and the Low Pressure Receiver (150 lb ammonia capacity, 1963) in engine room two had the annual test as indicated by the employer.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $0 · Current $0

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 document that deficiencies have been corrected:  (a)  Where the 2009 PHA-03 found that piping needed to be labeled, and on or about February 13, 2013 piping runs in the Engine Room #1 still needed to be labeled.  (b)  Where the 2009 PHA-01 was to update the refrigeration piping and instrumentation diagrams to show all pressure relief valve assemblies on engine room vessels.  The completion date was 2010. The drawings needed to be updated to cover several changes as noted during the OSHA inspection, but the P&ID drawings had not been updated and employees were using drawings dated before the 2009 PHA was done.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.119(j)(4)(iii): The frequency of inspections and tests of process equipment was not consistent with applicable manufacturers' recommendations and good engineering practices, or more frequently if determined to be necessary by prior operating experience:  The employer did not inspect and/or test process equipment with applicable manufacturers' recommendations and good engineering practices to include but not limited to:  (a) The High Pressure Receivers (McCulloch & Sons, SN 16551 1963).  (b) The Low Pressure Receivers (UNK, 1963).  (c) Intercoolers (UNK, 1963).

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(iv):   The employer did not document each inspection and test that has been performed on process equipment. The documentation did not identify 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.  (a) On or about February 13, 2013; where records for the inspections of the High Pressure Receiver, Low Pressure Receiver and Intercoolers for engine rooms 1,2 and 3did not contain the name of the person who performed the inspection or test and the serial number or other identifier of the equipment.   (b) On or about February 13, 2013; where piping inspections performed on March 2, 2010 did not contain the signature of the person who performed the inspection.      (c) On or about February 13, 2013; where evaporator and Receiver monthly tests only contained columns for a checkmark. There was no indication in the MI Program or Preventative maintenance for the type of inspection or tests to be performed on either the receivers or the evaporators.   (d) On or about February 13, 2013; where there was no information on tests for the exhaust fans in engine room 2 and 3.  (e) On or about February 13, 2013; where there was no information on tests for controls, interlocks or solenoids involved with shutdown of the system.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $4,900 · Current $4,900

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) before further use or in a safe and timely manner when necessary means were taken to assure safe operation:   (a) This violation was observed on or about February 20, 2013 on compressor number #5 in Engine Room #1; where one of the second stage compressors in series was observed to be without a pressure relief valve venting to a safe location. Observations made revealed that compressor #4, Vilter VSR 301 was protected via PRV H5601. Per the employer process safety information, compressor #5, Vilter 458 should have been protected with PRV R/S  H2.   (b) This violation was observed on or about February 13, 2013; where the employer did not address and correct corrosion to electrical boxes in Engine Room #1.  Significant corrosion had occurred on two junction boxes which could allow moisture to get to wiring and it had not been repaired or scheduled for repair.   (c) This violation was observed on or about February 13, 2013; where the employer did not address and correct corrosion to piping in Engine Room #1 or take steps such as painting the pipe to reduce and or prevent further corrosion.   (d) This violation was observed on or about February 13, 2013; where the employer did not seal the cover on an electrical box at one of the screw compressors in Engine Room #1. The cover was left hanging open and water was dripping on the box.   (e) This violation was discovered on or about February 13, 2013; where the ammonia detectors tested on or about 12/28/12, 12/29/12 and 1/9/12 failed and the employer did not address the hazard.   (f) This violation was discovered on or about February 13, 2013; where the Alley strobe and alarm for engine room 1 did not activate during the 2012 tests and the employer did not address the hazard.

Issued

Aug 9, 2013

Abate by

Aug 21, 2013

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.119(n):   The employer did not implement an emergency plan for the entire plant in accordance with the provisions of the hazardous waste and emergency response provisions contained in 29 CFR 1910.120 (a), (p) and (q):  (a) This violation was observed on or about February 13, 2013; where the employer did not develop and implement emergency action plan procedures for an emergency evacuation of the facility that could be followed in the event of an emergency.

Issued

Aug 9, 2013

Abate by

Aug 21, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.120(q)(2):   The employer did not develop an emergency response plan for emergencies which addressed the following minimum requirements of this standard:   (a) On or about February 13, 2013; it was discovered that the employer had provided an emergency response plan which included drawings showing routes to be used for emergency evacuation and the routes for emergency evacuation either did not exist or were blocked.  Coordination and communication of the actual emergency plan is required by 29 CFR 1910.120(q)(2)(i).   (b) On or about February 13, 2013; it was discovered that the employers emergency response plan did not outline the minimum training as required by 29 CFR 1910.120(q)(2)(ii), nor were emergency responders trained.   (c) On or about February 13, 2013; it was discovered that the employers emergency response plan did not consider safe distances and places of refuge for an emergency that included the release of large amounts of ammonia as required by 29 CFR 1910.120(q)(2)(iv).  (d) On or about February 13, 2013; it was discovered that evacuation routes would not be available for the safe evacuation of employees during an emergency such as a fire or ammonia release as required by 29 CFR 1910.120(q)(2)(vi).  (e) On or about February 13, 2013; it was discovered that the employer had not developed and implemented an emergency alerting and response procedure that would recognize the difference between an ammonia release and other types of emergencies as required by 29 CFR 1910.120(q)(2)(ix).

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.165(b)(3):   The employee alarm was not distinctive and recognizable as a signal to evacuate the work area or to perform action designated under the emergency action plan:  (a)This violation was observed on or about February 13, 2013; where the alarm system was not distinctive and did not provide information such that employees could take the appropriate action for the emergency.

Issued

Aug 9, 2013

Abate by

Aug 21, 2013

Penalty

Initial $3,500 · Current $3,500

General-duty citation text

29 CFR 1910.146(c)(1):   The employer did not evaluate the workplace to determine if any spaces were permit-required confined spaces:    (a)This violation was discovered on or about February 13, 2013; where the employer had not evaluated the workplace to determine if any confined space were permit-required confined spaces and a list of permit-required confined spaces had not been developed.

Issued

Aug 9, 2013

Abate by

Aug 21, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.303(g)(1):   Sufficient access and working space was not provided and maintained about all electric equipment (operating at 600 volts, nominal, or less to ground) to permit ready and safe operation and maintenance of such equipment:   (a) This violation was observed on or about February 13, 2013; where the area in front of electrical panels and the pathway leading to the electrical panels was used for storage which blocked egress to the panels and preventing them from being readily accessible.

Issued

Aug 9, 2013

Abate by

Aug 21, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.305(b)(2)(i):   Each outlet box in completed installations did not have a cover, faceplate, or fixture canopy:  (a) This violation was observed on or about February 13, 2013; where the outlet mounted in a handy box used to plug in the air conditioner in the Facility Manager's office did not have a cover on the outlet.

Issued

Aug 9, 2013

Abate by

Aug 15, 2013

Penalty

Initial $56,000 · Current $56,000

General-duty citation text

29 CFR 1910.36(d)(1):   Employee(s) were not able to open an exit route door from the inside at all times without keys, tools, or special knowledge:  (a) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#1 could not be opened from the inside.  (b) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#2 could not be opened from the inside.  (c) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#3 could not be opened from the inside.  (d) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#4 could not be opened from the inside.  (e) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#5 could not be opened from the inside.  (f) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#6 could not be opened from the inside.  (g) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#12 could not be opened from the inside.  (h) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#13 could not be opened from the inside.  (i) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#14 could not be opened from the inside.  (j) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#15 could not be opened from the inside.  (k) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#16 could not be opened from the inside.  (l) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#17 could not be opened from the inside.  (m) This violation was observed on February 20, 2013 and times prior thereto where emergency exit door#18 could not be opened from the inside.

Issued

Aug 9, 2013

Abate by

Sep 13, 2013

Penalty

Initial $56,000 · Current $56,000

General-duty citation text

29 CFR 1910.37(a)(3): Exit routes were not free and unobstructed; materials or equipment were placed, either permanently or temporarily, within the exit route:   This violation was discovered on or about February 13, 2013; and times thereafter where:  (a) The exit route to Emergency Exit #12 was blocked by boxes and other materials.  (b) The exit routes through the storage racks in the C&S Wholesale Grocers area had been closed off with boxes stored on pallets.  (c) The exit routes through the storage area of Eight Points Distributors had been blocked with boxes stored on pallets.  (d) The exit route out of the center of Warehouse #1 to the emergency exit doors #2, #3 and #4 had been blocked.

Issued

Aug 9, 2013

Abate by

Aug 21, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.37(b)(4):   Signs were not posted along the exit access indicating the direction of travel to the nearest exit and exit discharge when the direction of travel to the exit or exit discharge was not immediately apparent:  (a) On or about February 13, 2013 routes to exits were not labeled or signs posted to clearly indicate the route to the nearest exit.

Issued

Aug 9, 2013

Abate by

Aug 15, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.157(c)(1):   Portable fire extinguishers were not mounted, located and identified so that they were readily accessible without subjecting the employees to injuries:  (a)  On or about February 13, 2013; where a fire extinguisher was located behind a metal storage rack frame requiring a user to reach either through or around the rack to retrieve the extinguisher.