OSHA Inspection: FOX VALLEY SYSTEMS, INC.

Issued

2013-09-05 00:00:00

Abate by

2013-10-10 00:00:00

Penalty

Initial $2000.00 · Current $2000.00

General-duty citation text

29 CFR 1910.106(b)(2)(vii)(a): Area(s) surrounding tank(s) containing flammable or combustible liquids were not provided with adequate drainage or dikes:   On or about March 6, 2013, Fox Valley Systems Inc., did not provide adequate drainage or dikes for the outside atmospheric tanks for Toluene, Acetone and Lactol spirits to prevent accidental discharge of liquid.  The tanks are located adjacent to the employee parking lot.    DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-09-25 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.106(d)(3)(ii)(a): The door of the metal storage cabinet(s) for flammable and combustible liquids was not provided with a three point lock:   On or about March 6, 2013, flammable liquids were stored in a metal storage cabinet in the laboratory at Fox Valley Systems, Inc., located in Cary, Illinois.  The lock on the metal cabinet was broken and did not provide a lock at three points.   DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $0.00 · Current $2800.00

General-duty citation text

29 CFR 1910.307(c): Equipment, wiring methods, and installations of equipment in hazardous (classified) locations were not intrinsically safe, approved for the hazardous (classified) location, or safe for the hazardous (classified) location:     On or about March 6, 2013, the following equipment at Fox Valley Systems, Inc., was identified as not intrinsically safe, approved for the hazardous (classified) location or safe for the hazardous (classified) location:       a. An alarm panel located west of alarm panel box and VFD control panel along north wall of the raw material storage warehouse. This area is classified as a Class I, Division 2 Hazardous Location.     b. Control panels and circuit boxes for the thermal oxidizer along the north wall of the raw material storage warehouse. This area is classified as a Class I, Division 2 Hazardous Location.     c. Outlet boxes and other electrical equipment such as circuit boxes located along the west wall of the raw material storage warehouse. This area is classified as a Class I, Division 2 Hazardous Location.     d. Fan and heaters mounted on the ceiling of the raw material storage warehouse. This area is classified as a Class I, Division 2 Hazardous Location.     e. Lighting fixtures mounted on the ceiling of the raw material storage warehouse. This area is classified as a Class I, Division 2 Hazardous Location.       f.  A portable heater was utilized in the laboratory where propellants were quality tested.  This area is classified, at a minimum, as a Class I, Division 2 Hazardous Location.       DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-10-10 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.106(e)(2)(ii)(b)(2): The quantity of Category 2, 3 or 4 flammable liquid located outside of an inside storage room or storage cabinet in a building or in any one fire area of a building exceeded 120 gallons:   On or about March 6, 2013, in the general warehouse area at Fox Valley Systems, Inc., approximately 8300 gallons of wash solvent was stored.  The wash solvent used by the company is toluene, which is a Category 2 flammable liquid.   DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.106(e)(3)(v)(a): Areas as defined in paragraph (e)(3)(i) of this section using Category 1 or 2 flammable liquids, or Category 3 flammable liquids with a flashpoint below 100 degrees F (37.8 degrees C), were not ventilated at a rate of not less than 1 cubic foot per minute per square foot of solid floor area. This shall be accomplished by natural or mechanical ventilation with discharge or exhaust to a safe location outside of the building. Provision shall be made for introduction of makeup air in such a manner as not to short circuit the ventilation. Ventilation shall be arranged to include all floor areas or pits where flammable vapors may collect.   On or about March 6, 2013, Fox Valley Systems, Inc., operated a paint mixing operation and a paint can filling operation in the production area of the facility.  These operations included the use of Category 2 flammable liquids and/or Category 3 flammable liquids with a flashpoint below 100 degrees Fahrenheit.  This area was not ventilated at a rate of not less than 1 cubic foot per minute per square foot of solid floor area.  The floor area is 9,472 square feet, and a provision was not made for introduction of makeup air in such a manner as to not short circuit the ventilation.  According to the ventilation drawing dated 1982, in Mode 1, normal day operation, the total ventilation is 0.844 cubic feet per minute per square foot of solid floor area.    DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-09-25 00:00:00

Penalty

Initial $2000.00 · Current $2000.00

General-duty citation text

29 CFR 1910.106(e)(9)(iv): Ground areas around buildings and unit operating areas were not kept free of weeds, trash, and/or other unnecessary combustible materials:   On or about March 6, 2013, the floor of the production room at the paint can filling unit, at Fox Valley Systems, Inc., was covered unnecessarily with cardboard which is a combustible material.   DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.119(c)(1): The employer did not develop a written plan of action regarding the implementation of the employee participation required by this paragraph:    On or about March 6, 2013, a written plan of action regarding the implementation of the required elements of employee participation was not developed for the covered process (propellant charging process) at Fox Valley Systems Inc.   DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-11-09 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.119(d)(2)(i)(D): The employer did not compile information concerning the technology of the process including safe upper and lower limits for such items as temperatures, pressures, flows or compositions:   On or about March 6, 2013, the employer did not compile information concerning the technology of the covered process (propellant charging) at Fox Valley Systems, Inc., such as, but not limited to, safe upper and lower limits for such items as temperatures, pressures, flows or compositions.   DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-11-09 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(d)(2)(i)(E): The employer did not compile information concerning the technology of the process including an evaluation of the consequences of deviations, including those affecting the safety and health of employees:    On or about March 6, 2013, the employer did not compile information concerning the technology of the covered process (propellant charging) at Fox Valley Systems, Inc., such as, but not limited to, an evaluation of the consequences of deviations, including those affecting the safety and health of employees.    DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.119(e)(1):     The employer shall perform an initial process hazard analysis (hazard evaluation) on processes covered by this standard. The process hazard analysis shall be appropriate to the complexity of the process and shall identify, evaluate, and control the hazards involved in the process. Employers shall determine and document the priority order for conducting process hazard analyses based on a rationale which includes such considerations as extent of the process hazards, number of potentially affected employees, age of the process, and operating history of the process. The process hazard analysis shall be conducted as soon as possible, but not later than the following schedule:

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.119(f)(4): The employer did not develop and implement safe work practices to provide for the control of hazards during operations such as lockout/tagout; confined space entry; opening process equipment or piping; and control over entrance into a facility by maintenance, contractor, laboratory, or other support personnel:    On or about March 6, 2013, the employer did not develop and implement safe work practices to provide for the control of hazards during operations such as lockout/tagout; confined space entry; opening process equipment or piping for the covered process (propellant charging) at Fox Valley Systems, Inc.    DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.119(g)(1)(i): The employer did not train each employee in an overview of the process:    On or about March 6, 2013, the employer did not train each employee in an overview of the covered process (propellant charging) at Fox Valley Systems, Inc., and in safe operating procedures and work practices.    DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.119(j)(3): The employer did not train employees, or contract employees, involved in maintaining the on-going integrity of process equipment in an overview of the inspection process and the procedures required to perform the employee's job tasks.    On or about March 6, 2013, the employer did not train employees, or contract employees, involved in maintaining the on-going integrity of process equipment in an overview of the inspection process and the procedures required to perform the employee's job tasks for the covered process (propellant charging) at Fox Valley Systems, Inc.    DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-10-10 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.119(n): The employer did not establish an emergency plan for the entire plant in accordance with the provisions of 29 CFR 1910.38:  On or about March 6, 2013, Fox Valley Systems owned and operated a covered process (propellant charging).  The employer did not establish an emergency plan for the entire plant in accordance with the provisions of 29 CFR 1910.38.  DOCUMENTATION AND CERTIFICATION IS REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-10-10 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.38(c)(1): Procedures for reporting a fire or other emergency;   On or about March 6, 2013, Fox Valley Systems, Inc., was required, by 29 CFR 1910.119, to develop an emergency action plan.  The plan did not include procedures for reporting a fire or other emergency.   DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.119(o)(1): The employer did not certify that they have evaluated compliance with the provisions of this section at least every three years:  On or about March 6, 2013, for the covered process (propellant charging) at Fox Valley Systems, Inc., the employer did not certify that they had evaluated compliance with this section at least every three years.   DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-09-25 00:00:00

Penalty

Initial $1200.00 · Current $1200.00

General-duty citation text

29 CFR 1910.303(b)(2): Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling:   On or about March 6, 2013, a relocatable power tap, located in the packaging area of the general warehouse, used to power warming lights, was attached to the equipment in such a way as to violate the Underwriter Laboratories, Inc., standard UL1363; the physical mounting of a relocatable power tap is allowable as long as it shall not require the use of tools to remove it.  The relocatable power tap was attached to the process equipment with zip-ties which would require a knife or scissors to remove.   DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-10-10 00:00:00

Penalty

Initial $2000.00 · Current $2000.00

General-duty citation text

29 CFR 1910.304(g)(5): The path to ground from circuits, equipment, and enclosures was not permanent, continuous, and effective:     On or about March 6, 2013, the following electrical equipment, at Fox Valley Systems, Inc., did not have a continuous path to ground:   a.  The connection from path to ground on the emergency lights located in the shipping area/general warehouse was not continuous.     b.  The connection from path to ground on the heat lamps mounted on the tippers located in the packaging and shipping area was not continuous.     DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-10-10 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

General-duty citation text

29 CFR 1910.305(b)(1)(i): Conductors entering cutout boxes, cabinets, or fittings were not protected from abrasion:   On or about March 6, 2013, the conductor entering the box on the emergency lighting in the general warehouse, at Fox Valley Systems, Inc., was not protected from abrasion.   DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-09-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in boxes, cabinets, or fittings were not effectively closed:   On or about March 6, 2013, the openings through which conductors enter were not effectively closed for the following equipment at Fox Valley Systems, Inc.:   a. The unused opening, on the circuit box located on the wall behind the table saw in the woodworking area of the general warehouse, was not effectively closed.   b. The unused opening on the circuit box, DP2, located in the general warehouse area, was not effectively closed.    c. The unused opening on the control box of the stand mixer in the production room was not effectively closed.  The production room is classified as a hazardous location.   d. The unused opening on the limit switch on the stand mixer in the production room was not effectively closed.  The production room is classified as a hazardous location.   DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-09-25 00:00:00

Penalty

Initial $35000.00 · Current $7000.00 Reduced

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:     On or about March 6, 2013, employees at Fox Valley Systems, Inc. were not able to open the exit door from the conveyor room (conveyor alley) from the inside at all times without keys, tools, or special knowledge.  The door was locked from the outside.     DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-09-25 00:00:00

Penalty

Initial $35000.00 · Current $7000.00 Reduced

General-duty citation text

29 CFR 1910.37(a)(3): Exit route(s) were not kept free and unobstructed:     On or about March 6, 2013, the employer did not maintain the following exits in the conveyor room (conveyor alley) free and unobstructed at Fox Valley Systems, Inc.:     a. The exit route from the conveyor room (conveyor alley) to the exit door was blocked with a pallet and other debris.  The employee had only 10 inches of clear, unobstructed floor space to get to the exit door.     b. The exit door from the conveyor room (conveyor alley) to the parking lot was blocked by snow which had been plowed up against the door.      DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $35000.00 · Current $25000.00 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i): The employer did not compile information pertaining to the equipment in the process:      On or about March 6, 2013, the employer did not compile information pertaining to the equipment in the covered process (propellant charging) at Fox Valley Systems, Inc., such as, but not limited to: materials of construction, piping and instrument diagrams (P&IDs), electrical classification, relief system design and design basis, ventilation system design, design codes and standards employed, material and safety systems (e.g., interlocks, detection or suppression systems).      DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $35000.00 · Current $12000.00 Reduced

General-duty citation text

29 CFR 1910.119(f)(1): The employer did not develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information:      On or about March 6, 2013, the employer did not develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in the covered process (propellant charging), at Fox Valley Systems, Inc.     DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $35000.00 · Current $25000.00 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:       On or about March 6, 2013, the employer did not establish written procedures to maintain the on-going integrity of the process equipment for the covered process (propellant charging) at Fox Valley Systems, Inc.       DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-10-10 00:00:00

Penalty

Initial $35000.00 · Current $12000.00 Reduced

General-duty citation text

29 CFR 1910.178(c)(2)(iv): Power-operated industrial trucks designated as DY, EE, or EX were not used in locations where volatile flammable liquids or flammable gases were  handled, processed or used, but in which the hazardous liquids, vapors or gases will normally be confined within closed containers or closed systems from which they can escape only in case of accidental rupture or breakdown of such containers or systems, or in the case of abnormal operation of equipment:      On or about March 6, 2013, power-industrial trucks designated as DY, EE, or EX were not used in the production room at Fox Valley Systems, Inc.  The propane-powered industrial trucks used in the production room were designated as LP and LPS.  The production room is classified as a Class I, Division 2, hazardous location.     DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $0.00 · Current $25000.00

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:     On or about March 6, 2013, Fox Valley Systems, Inc., did not document that the covered process equipment (propellant charging) complied with recognized and generally accepted good engineering practices such as, but not limited to, NFPA 30 B Code for the Manufacture and Storage of Aerosol Products, NFPA 77 Recommended Practices on Static Electricity, NFPA 91 Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists, and Noncombustible Particulate Solids.  Documented deficiencies include but are not limited to:       a.  Conveyor systems between the production area (filling) and the flammable propellant charging rooms (gas house) included covers that were not open at the bottom and did not prevent flammable vapors from entering the production area through the conveyor enclosure as required by NFPA 30B (2011) Section 5.13.1.3.      b.  The design and construction of conveyor lines in the flammable propellant charging rooms (gas house) did not provide for direct access to the secondary emergency exit route as required by NFPA 30B (2011) Section 4.2.2.2.     c.  The flammable propellant charging rooms (gas house) were not provided with an approved, operational gas detection system that is equipped with interlocks to provide for propellant supply shutdown, aerosol line shutdown, audible and visual alarms, and emergency ventilation rates as required by NFPA 30B (2011) Sections 5.7.1, 5.7.2, and 5.12.      d.  The flammable propellant charging rooms were not provided with a deflagration suppression system as required by NFPA 30B (2011) Section 5.11.1.     e.  Gas detection sensors were not provided with detection heads within conveyor enclosures between the production area (filling) and the flammable propellant charging rooms (gas house) as discussed in NFPA 30B (2011) Section A.5.7.     f.  The exhaust ventilation system for the propellant charging rooms (gas house) were not provided with a make-up air system required by NFPA 30B (2011) Section 5.4.1.1.      g.  The exhaust ventilation system for the propellant charging rooms (gas house) did not minimize the use of non-metallic flexible duct to specific equipment inlets where movability/portability or vibration reduction was necessary as required by NFPA 91 (2010) Sections 4.4.12 and 8.2.1 and NFPA 77 Section 8.4.3.1.     DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.

Issued

2013-09-05 00:00:00

Abate by

2013-12-09 00:00:00

Penalty

Initial $0.00 · Current $11200.00

General-duty citation text

29 CFR 1910.119(j)(4)(i): The employer did not perform inspection and tests on process equipment:       On or about March 6, 2013, the employer did not perform inspections and tests on the equipment within the covered process (propellant charging) at Fox Valley Systems, Inc., such as but not limited to, the propellant pressure vessels, the related pressure relief valves; pumps, piping systems and relief venting; atmospheric solvent tanks, pumps and piping systems; atmospheric resin tanks, pumps and piping systems; emergency ventilation system and controls; and flammable gas detection system and controls, etc.       DOCUMENTATION AND CERTIFICATION ARE REQUIRED FOR THIS ITEM.