OSHA Inspection: CRANE ARMY AMMUNITION ACTIVITY

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(c)(1): Employee Participation. Employers shall develop a written plan of action regarding the implementation of the employee participation required by this paragraph.    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not implemented an employee participation plan for process safety management required activities, such as participation and availability of process hazard analysis, their related recommendations, availability of process safety information and process hazard analysis recommendation resolution(s).

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d): Process safety information. In accordance with the schedule set forth in paragraph (e)(1) of this section, the employer shall complete a compilation of written process safety information before conducting any process hazard analysis required by the standard. The compilation of written process safety information is to enable the employer and the employees involved in operating the process to identify and understand the hazards posed by those processes involving highly hazardous chemicals. This process safety information shall include information pertaining to the hazards of the highly hazardous chemicals used or produced by the process, information pertaining to the technology of the process, and information pertaining to the equipment in the process.  a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer failed to compile process safety information (PSI) to enable managers, engineers, engineering technicians, supervisors, explosives technicians and maintenance employees involved in operating and maintaining covered processes to utilize information pertaining to the hazards of the covered processes, the technology of the covered processes and equipment in the covered processes. The employer had not compiled and managed PSI for covered equipment used in covered processes; prepared files for each piece of equipment or for each covered process; organized existing information in a manner that was useable for obtaining PSI; and then populated those files with process safety information (PSI) required by 1910.119(d)(1)-(3), with information utilized to document RAGAGEP compliance required by 1910.119(d)(3)(ii) and with other process information, such as records of equipment use and previous operating conditions.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(2)(i)(A): Process safety information. In accordance with the schedule set forth in paragraph (e)(1) of this section, the employer shall complete a compilation of written process safety information before conducting any process hazard analysis required by the standard. Information concerning the technology of the process shall include at least the following: A block flow diagram or simplified process flow diagram (see Appendix B to this section);     a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not completed, compiled, updated and maintained technology information for covered processes to include block flow or simplified process flow diagrams for manufacturing and demilitarization activities and processes covered by this part.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(2)(i)(B): Process safety information. In accordance with the schedule set forth in paragraph (e)(1) of this section, the employer shall complete a compilation of written process safety information before conducting any process hazard analysis required by the standard. Information concerning the technology of the process shall include at least the following: Process chemistry;    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not compiled process chemistry information for use in conducting process hazard analysis for covered manufacturing and demilitarization operations and activities, including, but not limited to, those in Plants 3, 5, 8A and 8B.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(2)(i)(D): Process safety information. In accordance with the schedule set forth in paragraph (e)(1) of this section, the employer shall complete a compilation of written process safety information before conducting any process hazard analysis required by the standard. Information concerning the technology of the process shall include at least the following: Safe upper and lower limits for such items as temperatures, pressures, flows or compositions;     a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not developed, maintained, updated and compiled process safety information regarding safe upper and lower limits for covered processes in manufacturing and demilitarization operations and their related activities.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(2)(i)(E): Process safety information. In accordance with the schedule set forth in paragraph (e)(1) of this section, the employer shall complete a compilation of written process safety information before conducting any process hazard analysis required by the standard. Information concerning the technology of the process shall include at least the following: An evaluation of the consequences of deviations, including those affecting the safety and health of employees.    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not developed, maintained, updated and compiled process safety information regarding consequences of deviation for covered process operations and related activities as relating to employee safety and health impact rather than the impact on the product or downstream use.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(A): Information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:    Materials of construction;    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not maintained materials of construction information for the following equipment:    a. Personnel shielding, such as those located at/in Plant 8A foil removal and three "Operation 12" workstations, Plant 3 room A-10 reaming drill workstation and the Plant 8B weigh station;    b. Ductwork for dust collection and vacuum systems, such as the ductwork for the Plant 3 Press room, knockout room and slurry room;      c. Hobart mixer, materials used for conversion from electric to pneumatic, Plant  3 Mix Wing,       d. Filters for ventilation systems, such as the "NAPA" filters used in the Simpson Mix Wing ventilation systems.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): Process safety information. Information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:    Piping and instrument diagrams (P&ID's);     Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not develop P&IDs that contain all the equipment involved in covered processes including but not limited to:      a. Plant 3 Pulverizing Room operations,    b. Plant 3 pyrotechnics press room production process,       c. The deactivation furnace system including all the air pollution control equipment;      d. Plant 11 weapon demilitarization operations;      e. Plant 5 P&ID's are not complete to reflect all the equipment in the kettle process and are inaccurate in that the number of existing kettles are two; while the P&ID's reflect five.      f. Plant 8B extrusion room, engineering drawing number 9843 is not accurate. The drawing does not reflect PLC replacement of previous equipment.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(C): Information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:    Electrical classification;     Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not developed, maintained, updated and compiled electrical classification information for the following equipment:      a. Plant 3, Room A-22 Hobart mixer;  b. Plant 3, Room B-15 Globe mixer;  c. Plant 3, Room B-13 Ro_Tap sieve shaker;  d. Plant 3, Room B-9 electric dryer;  e. Plant 8A, Oven (asset# 28456);

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D): Information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:    Relief system design and design basis;    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not maintained, developed, compiled and updated process safety information related to relief system design and design basis for the following equipment and structures:    a. the blast walls and blast protection systems associated with roof structures for buildings that house explosives manufacturing and/or demilitarization operations, such as but not limited to Plants 3 and 8B.    b. the explosion vents for the Plant 3 press room explosive material collection system dust collectors.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(E): Information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:    Ventilation system design;    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not developed, maintained, updated and compiled process safety information for ventilation system design for the following locations and systems:      a. Plant 3 press room production operation.  The employer did not compile information for the local exhaust ventilation and dust collection systems and their design.         b. For the following Plant 3 ventilation systems, process safety information for the ventilation system design did not include information regarding design for the materials/chemicals involved in the operations including physical state, chemical properties, quantities and any critical explosive material properties for inclusion in the design basis of the system:      Room B-15, Room B-13, Room B-9, Room A-15, Room A-19, Room A-20, Room A-21, Room A-22, Room A-23, and Room A-24;      c. For the following Building 126 ventilation systems, the employer did not compile information for the local exhaust ventilation system and its design: Room A-10, Room B-12, Room B-14, Room B-2, and Distribution Room B.      d. For Plant 3 Pulverizing room, the process safety information available does not describe the complete dust collection system to include the Donaldson Torit dust collector, associated ductwork and the connection to dust generating equipment (the pulverizers) from this operation.      e. For Plant 8B, the employer did not compile information for the "Air Dry" room ventilation system.      f.  For Plant 8B, the employer did not compile information for the "Oven" room ventilation system.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(F): Information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:    Design codes and standards employed;    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not maintain design codes and standards employed for designing systems, installing systems and equipment, operating them and maintaining them for all covered process equipment, for equipment such as but not limited to, dust collection systems and associated equipment, ventilation systems and equipment used as interlocks.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(G): Information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:    Material and energy balances for processes built after May 26, 1992;      a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not developed, maintained, updated and compiled material and energy balances for all covered processes.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(H): Process Safety Information. Information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:     Safety systems (e.g. interlocks, detection or suppression systems).      Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not developed, maintained, updated and compiled process safety information (PSI) for safety systems such as but not limited to:      a. The Plant 8B extruder room "interlocks" (limit switches) for the extruder, post press, V-blender, the cell door, vent closure and the associated extruder room controls. The PSI provided for this equipment did not include information regarding the limit switches and safety devices used, such as type, ratings, model, serial number, dates of purchase and installation or technical data sheet(s) from the manufacturer.      b. Plant 8A portable deluge systems used for personnel protection, such as the systems at the 3 "assemble igniters" workstations, the 2 located at the "remove foil" workstations, the "remove igniter & cut foil" workstation, the "push out" station, the "load case & foil wrap" workstations and the "crimp" workstation.        c. Plant 3 press room production operation safety systems including, but not limited to, interlocks on moveable guards, fire detection and suppression systems, deluge suppression systems, pressure sensors, and proximity sensors.       d. Safety shielding: The employer does not have process safety information for the design, assembly, fabrication and manufacture for safety shielding components and final shielding product that is made in-house. This shielding is used throughout operations, that include, but are not limited to Plant 126 A-10 the "reaming drill" operation, 3 Plant 8B "igniter assembly" workstations, Plant 8A"foil removal,"Plant 8A "igniter removal" and the Plant 8B "weigh station."    e. Air ionizers: The employer does not have process safety information for air ionizers used to reduce static charge in environmental conditions. Air ionizers are utilized throughout explosives manufacturing operations, including but not limited to Plant 8A "igniter assembly" workstations.      f. Plant 8A saw enclosure: The employer did not provide process safety information for the multiple interlocked doors, the enclosure structure itself and access window, specific to the design of the shields and the material used in fabrication of the components.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(ii): Information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:    The employer shall document that equipment complies with recognized and generally accepted good engineering practices (RAGAGEP).    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not document RAGAGEP compliance for equipment and equipment systems, including but not limited to:    a. The employer did not ensure that the Plant 7 dust collector connected to the projectile maintenance production line complied and documented compliance with RAGAGEP.  The collector, which contained steel dust from an abrasive blast cleaning machine and which was located outdoors, lacked adequate means of (1) fire suppression, (2) explosion protection, and (3) deflagration isolation from upstream process equipment. Employees were exposed to fire and explosion hazards while operating the production equipment associated with this covered process.    b. The employer did not ensure that dust collectors connected to the press room production line in Plant 3 complied with and documented compliance with RAGAGEP.  The collectors did not collect the explosives composition in a safe manner, there was no protection for upstream processes, and safety systems did not safely handle the explosions and fire.      c. The employer did not ensure that the Plant 5 "kettle" process complied with and was documented for compliance with RAGAGEP. Requested hydrostatic testing was not performed, the vessel does not have a U-1 birth certificate regarding the original materials of construction, and there is no mechanical integrity testing and inspection for the associated piping, valves and the associated scrubber systems.      d. The employer did not ensure that the Plant 3 pulverizing room Donaldson Torit dust collector complied with and was documented for compliance with RAGAGEP. The collector does not have a documented design basis, an associated risk analysis or a documented relief design for venting potential collector deflagration to a safe location.    e. The employer did not ensure that safety interlocks used to provide and assure remote operations as a form of personnel protection had not been evaluated with a risk assessment to assure that the level of protection is adequate for the level of risk. Safety interlocks are not comprised of components with ratings for safety applications of SIL 3 category 3 or 4 for explosive material mixing and other dangerous production operations. Basic limit switches intended as positioning devices are the standard component of CAAA interlocked safety systems.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.109(b)(1): "General hazard." No person shall store, handle, or transport explosives or blasting agents when such storage, handling, and transportation of explosives or blasting agents constitutes an undue hazard to life.    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not store, handle and transport explosives in a manner to prevent undue hazard to employees, including but not limited to:    a. The employer did not ensure that the Plant 7 dust collector connected to the projectile maintenance production line handled explosives in a manner to prevent undue hazards to employees.  The collector, which contained steel dust from an abrasive blast cleaning machine and which was located outdoors, lacked adequate means of (1) fire suppression, (2) explosion protection, and (3) deflagration isolation from upstream process equipment. Employees were exposed to fire and explosion hazards while operating the production equipment associated with this covered process.    b. The employer did not ensure that dust collectors connected to the press room production line in Plant 3 handled and stored explosives in a manner to prevent undue hazards to employees. The collectors did not collect the explosives composition in a safe manner, there was no protection for upstream processes, were not "wet" collectors and safety systems did not safely handle the explosions and fire.      c. The employer did not ensure that the Plant 5 kettle process handled explosives in a manner to prevent undue hazards to employees. Requested hydrostatic testing was not performed, the vessel does not have a U-1 birth certificate regarding the original materials of construction, and there is no mechanical integrity testing and inspection for the associated piping, valves and the associated scrubber systems.      d. The employer did not ensure that the Plant 3 pulverizing room Donaldson Torit dust collector handled and stored explosives in a manner to prevent undue hazards to employees. The collector does not have a documented design basis, an associated risk analysis or a documented relief design for venting potential collector deflagration to a safe location.    e. The employer did not ensure that safety interlocks used to provide and assure remote operations as a form of personnel protection had not been evaluated with a risk assessment to assure that explosives handled, stored and transported in a manner to prevent undue hazards to employees. Safety interlocks are not comprised of components with ratings for safety applications of SIL 3 category 3 or 4 for explosive material mixing and other dangerous production operations. Basic limit switches intended as positioning devices are the standard component of CAAA interlocked safety systems.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(2): The employer shall use one or more of the methodologies designated by 29 CFR 1910.119(e)(2)(i) - (vii) that are appropriate to determine and evaluate the hazards of the process being analyzed:    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not designated a methodology for use in the performance of preliminary hazard analysis in the standing operating procedures development process, or for the performance of hazard analysis by hazard analysis working groups. The employer does utilize a defined hazard matrix for risk ranking but does not use a defined methodology for process hazard analysis.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(3)(i): Process hazard analysis: The process hazard analysis shall address the hazards of the process:    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not perform process hazard analysis that addressed the hazards of covered processes. As part of SOP development, the employer completed preliminary hazard analysis for the following covered processes but did not address the following hazards of the process:      a. For the Plant 3 press room manufacturing and related operations, the preliminary hazard analysis did not address all the hazards of the process, including but not limited to the hazards associated with cleaning the press room production equipment, operation of the dust collection system and performing maintenance of the dust collection system.      b. For the Plant 11 "powder room" operations, the preliminary hazard analysis did not address all the hazards of the process, including but  not limited to the hazards associated with collecting explosive material in a cyclone separator, associated maintenance activities for the collection system components and health hazards associated with cleaning the water-based scrubbers containing explosive material.      c. For deactivation furnace operations, the preliminary hazard analysis did not address all the hazards of the process, including but not limited to the hazards associated with maintaining the air pollution control system connected to the deactivation furnace which contained toxic metals.      d. For all covered processes, equipment failure as an ignition source is not addressed. Ovens, such as those in Plant 8A and Plant 8B  can have motor failures, Mixers, such as Plant 3 Simpson, Hobart and Globe mixers can have bearing failures, and pumps can fail; all with potential heat impact as ignition sources.      e. For all covered processes, explosive material equipment temporarily not in use, or that has been retired in place is not addressed. Equipment that goes without decontamination is subject to explosion and increased risk.      f. Plant 8A storage of magnesium is unaddressed by process hazard analysis.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(3)(ii): The process hazard analysis shall address: The identification of any previous incident which had a likely potential for catastrophic consequences in the workplace;    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not identify previous incidents and near misses with potential for catastrophic consequences in any of the process hazard analyses of demilitarization operations, explosive and pyrotechnic manufacturing operation covered processes. The employer performs preliminary hazard analysis as part of each standing operating procedure resulting in a job hazard analysis. These do not include previous incidents and process safety management incident investigation information is not collected for engineering technician use in developing each preliminary hazard analysis.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(3)(iii): The process hazard analsysis shall address; Engineering and administrative controls applicable to the hazards and their interrelationships such as appropriate application of detection methodologies to provide early warning of releases. (Acceptable detection methods might include process monitoring and control instrumentation with alarms, and detection hardware such as hydrocarbon sensors.):     Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not address the interrelationships of engineering (and administrative) controls in preliminary hazard analyses performed in association with and contained in standing operating procedures, such as but not limited to:       a. Valve failure and inability to cool temperature critical operations (SOP CN-ML00-N-284 operation 3),       b. Filter media (failure) used for ventilation systems and administrative procedures to assure the media is appropriate and properly assembled (multiple operations in nearly all covered processes),      c. Conductive flooring and cleaning procedures (nearly all covered processes),      d. Limit switch failure and multiple cell use in mixing operations (SOP CN-0000-M-086),      e. Grounding failure and natural fiber clothing (nearly all covered processes),       f.  Instrumentation and procedural temperature control of an upper or lower safe limit (nearly all covered processes),       g. The multiple engineering and administrative controls for the "openings" in, and the process equipment involved with the saw enclosure (SOP CN-0000-M-018 Operation 4), and      h. The operation and/or shutdown of critical equipment and "immediate evacuation" instructions in SOPs (such as SOP CN-0000-M-018 Operation 2).

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(3)(iv): The process hazard analysis shall address: Consequences of failure of engineering and administrative controls;      Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not address consequences for the failure of engineering controls in preliminary hazard analyses performed in association with and contained in standing operating procedures, such as but not limited to:        a. Explosive and energetic material collection system failure and explosion/fire (SOP CN-0000-N-086, operations 16, 18 and 37),       b. Limit switch failure in remotely performed operations and explosion/fire (nearly all covered processes),       c. Shielding used for personnel protection failure and explosion/shrapnel (nearly all covered processes),       d. Deluge system and associated detection equipment used for personnel protection and fire/explosion (nearly all covered processes),       e. Ventilation system/local exhaust  filtration failure and ductwork explosion/fire (nearly all covered processes),        f. Vacuum system valve failure and excess explosive material to scrubber (SOP CN-ML00-N-284), and      g. Air ionizer failure and increased risk of static ignition (nearly all covered processes with static ignition risk)

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(3)(v): The process hazard analysis shall address: Facility siting;    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not addressed facility siting during covered process hazard analyses. As part of SOP development, the employer completed preliminary hazard analyses for the following covered processes without adequately evaluating and documenting the evaluation of hazards of facility siting of the process and for process equipment:      a. Plant 5 "kettle" manufacturing processes which are located inside the building;      b. Plant 3, Pulverizing room cyclone separator equipment which is located inside the building;      c. Plant 3, press room dust collection system dust collectors which were located side by side and adjacent to the manufacturing and office buildings.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(3)(vi): The process hazard analysis shall address: Human factors;    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not address human factors in preliminary hazard analyses performed in association with and contained in standing operating procedures, which include but are not limited to:      a. improper sequence of or failure to perform operational steps, i.e wrong action,   b. incorrect amount of explosive or flammable material,  c. subjective application of visual standards of material inspection,  d. lack of experience,  e. lack of or ineffective training,  f. mishandling or damaging equipment and/or tooling,  g. fatigue/stamina,  h. environmental issues impact on employees (lighting, temperature, humidity, light, noise, distractions)  i. inadequate supervision,   j. human/equipment interaction,  k. high/low workload,    l. lack of/quality of procedures,  m. operational displays and controls accessibility, confusing, ease of use, and  n. repetitious tasks/operations.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(3)(vii): The process hazard analysis shall address: A qualitative evaluation of a range of the possible safety and health effects of failure of controls on employees in the workplace.    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not perform process hazard analysis that includes a range of the possible safety and health effects of failure of controls on employees in the workplace. Standard operating procedures including preliminary hazard analysis or job hazard analysis content that do not address complete range of possible effects include:      a. CN-0000-M-015, operation 5 step 2, which involves opening a magnesium dust container, does not address injury impact involved with explosion or deflagration of magnesium dust and describes the effect as a "flammable liquid" fire,      b. CN-0000-M-015, operation 5 step 11, which involves a container to container transfer of magnesium dust/powder, only addresses the dust hazard as a nuisance dust with possible respiratory irritation and does not addresses the potential effects of fire and explosion,      c. CN-0000-M-015, operation 1 which involves receiving materials, does not address any safety and health effects for acetone, magnesium dust and hexane, when discussing a material spill the only effect listed is "environmental spill.      d. CN-ML00-N-284, operation 11 which involves cleaning an explosives containing vessel, does not address the toxic properties for the chemical components of the explosive material and the only effect listed is "burns to the body."      e. CN-0000-N-086, operation 36 step 2 which involves pass explosive composition through a "window," does not address injury impact involved with ignition and explosion of the material. For the description of material dropped/spilled, the listed effect is environmental spill.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(4): Process hazard analysis. The process hazard analysis shall be performed by a team with expertise in engineering and process operations, and the team shall include at least one employee who has experience and knowledge specific to the process being evaluated. Also, one member of the team must be knowledgeable in the specific process hazard analysis methodology being used.    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not a team based approach for use in the performance of preliminary hazard analysis in the standing operating procedures development process, or for the performance of hazard analysis by hazard analysis working groups. The employer had not utilized hazard analysis working groups for any of the covered processes operating at the time of inspection.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(5): The employer shall establish a system to promptly address the team's findings and recommendations; assure that the recommendations are resolved in a timely manner and that the resolution is documented; document what actions are to be taken; complete actions as soon as possible; develop a written schedule of when these actions are to be completed; communicate the actions to operating, maintenance and other employees whose work assignments are in the process and who may be affected by the recommendations or actions.     Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not established a system to promptly address process hazard analysis findings and recommendations to include documentation of the resolution of findings. Process hazard analysis findings resolutions that had not been documented include, but are not limited to:       a. Project S/A 3-00, building change in use preliminary hazard analysis. There were 34 recommendations for resolution from the analysis that included radiation hazards, fire hazards, ordnance electrical safety hazards, high explosive hazards, low explosive hazards and lightning hazards, such as building protection and 7 "planned modifications" associated with the operational narrative including an external blowout relief point for powder transfer piping. The employer did not provide documentation for the resolution of these analysis recommendations and findings.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(1)(i)(B): The employer shall 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 and shall address at least the following elements; Steps for each operating phase: Normal operations;    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not established a safe operating procedure (SOP) for the following operations:      a. The employer had not developed and implemented written operating procedures to perform cleanup of explosive composition from production equipment in the Plant 3 press room.  Improper cleaning techniques exposed employees to fire and explosion hazards.      b. The employer had not developed and implemented written operating procedures to operate and maintain the Donaldson Torit dust collectors for the Plant 3 explosive material collection system.  Performing maintenance on the collectors exposed the employees to fire and explosion hazards associated with the explosive composition which had collected in the units.      c. The employer had not developed and implemented written operating procedures to operate and maintain the wet scrubber system associated with the 30mm shell demilitarization process.      d. The employer had not developed and implemented written procedures to operate and maintain the air pollution control system associated with the deactivation furnace process.  Employees were at risk of barium and cadmium exposure.      e. SOP CN-ML00-N-084 lacked specificity regarding the magnet test in Operation 2 Step 3. This test is performed to minimize the risk of ignition for explosive material used in Plant 5 production processes.      f. SOP CN-ML00-N-084, Operation 3 Step 8 lacked specificity regarding taking temperature manually for Plant 5 "kettle" melting process.      g. SOP CN-ML00-N-084, Operation 3 lacks specificity regarding the application of vacuum (in Step 1) and does not address the required steps for the removal of vacuum for Plant 5 "kettle" process operations.      h. SOP CN-ML00-N-084, Operation 3 Step 10 lacks specificity regarding visual inspection of the production material for the Plant 5 "kettle" process.      i. SOP CN-ML00-N-084, Operation 5 Step 1 lacks specificity regarding trace line use and operation and controlling material temperature during activities associated with removing manufactured material from thePlant 5 "kettle" process.      j. SOP CN-ML00-N-084, Operation 11 does not address disposal of contaminated "dump valve" water associated with cleaning of Plant 5 "kettles."     k. SOP CN-0000-M-015, Operation 8 lacks specificity regarding ensuring combustible vapor sensor function for Plant 8B mixing operations.      l. SOP CN-0000-M-015, Operation 8 Step 15 lacks specificity regarding visual inspection of composition during Plant 8B mixing operations.      m. SOP CN-0000-M-015, Operation 8 Step 16 lacks specificity for, and Operation 6 does not address, V-Shell blender use with magnesium powder during Plant 8B mixing operations.      n. SOP CN-0000-M-015, Operation 8 Step 20 is lacks specificity and details. Numbered operational steps are missing and the total length of mixing time in Step 20 and Step 20 (6) are unclear for Plant 8B mixing operations.      o. SOP CN-0000-M-015, Operation 8 Step 25 lacks specificity regarding mixer activation and operation for Plant 8B mixing operations.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(1)(i)(D): The employer shall 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 and shall address at least the following elements. Emergency shutdown including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner.     Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not developed operating procedures to address emergency shutdown, the conditions for which shutdown is required and operational shutdown responsibilities for the following operations:       a. SOP CN-ML00-N-084 does not address operational conditions for which emergency shutdown is required such as loss of agitation or loss of temperature control (cooling abilities) for the Plant 5 "kettles" manufacturing process.      b. The employers standing operating procedures, including but not limited to SOP CN-0000-M-015, the hazard control briefing section regarding RED ALERT lacks specificity in assigning the shutdown of manufacturing operations in a safe condition.        c. SOP CN-0000-M-015 Operation 2 Steps 1-3 lacks specificity in that conditions for shutdown are not designated in the event of a "major acetone spill" and the operators are instructed to evacuate the area for Plant 8B mix and extrude operations.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(A): The employer shall 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 and shall address at least the following elements:  Consequences of deviation:    Crane Army Ammunition Activity, Crane, Indiana: as of and prior to March 29, 2013, the employer did not develop standing operating procedures (SOP) that address the consequences of deviation and incorporate them into OSHA process safety management compliant standard operating procedures for the following covered process activities:      a. SOP CN-ML00-N-284, Operation 3, the procedure does not address the consequences of deviation for the batch temperature exceeding 205 degrees during Plant 5 "kettle" melting process operations.      b. SOP CN-0000-N-114, Operation 25, the procedure does not address the consequences of  deviation of the press force over 7000 lbs. when pressing the smoke candle during Plant 3 manufacturing operations.      c. SOP CN-0000-N-086, Operation 37, the procedure does not address the consequences of deviation of the press force of 63,000 lbs. +- 3,000 lbs. on the dead load during Plant 3 manufacturing operations.      d. SOP CN-0000-M-015, Operation 10, the procedure does not address the consequences of deviation of the oven temperature exceeding 180 degrees during Plant 8B oven drying activities.      e. SOP  CN-0000-M-015, Operation 15, the procedure does not address the consequences of deviation of the press force exceeding 8400 lbs. of force during Plant 8A manufacturing operations.      f. SOP CN-ML00-N-284, Operation 2, Step 3, there is no consequence for deviation listed or included for the wet scrubber not being turned on, available or operating effectively/efficiently during Plant 5 material inspection activities. This equipment collects explosive material.       g. SOP CN-ML00-N-284 Operation 3 Step 3, there is no consequence for deviation listed for ineffective or loss of agitation during Plant 5 "kettle" melting process operations.       h. SOP CN-ML00-N-284 Operation 3 Step 8, there is no consequence for deviation listed that addresses glass thermometer use for manual temperature readings during Plant 5 "kettle" melting process operations.      i. SOP CN-0000-M-015 Operations 5 and 6 there are no consequences of deviation listed for Plant 8B magnesium powder processing operations.      j. SOP CN-0000-M-015 Operation 8 Step 52, there are no consequences of deviation listed regarding use of a scraping method for dry composition during Plant 8B mixer cleaning operations.       k. SOP CN-0000-M-015 Operation 9 does not list consequences of deviation for spraying Nitrile gloves with anti-static spray related to drying and weighing operations in Plant 8B.      l. SOP CN-0000-M-015 Operation 9 Step 4 does not list consequences of deviation for drying times that exceed one hour for Plant 8B composition drying operations.       m. SOP CN-0000-M-015 Operation 9 Step 7 does not list consequences of deviation for hand carrying composition related to Plant 8B composition weighing operations.      n. SOP CN-0000-M-015 Operation 12 Step 13 does not list consequences of deviation if ram tip is not cleaned related to Plant 8B extrusion manufacturing operations.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(B): The employer shall 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 and shall address at least the following elements:  Steps required to correct or avoid deviation.    Crane Army Ammunition Activity, Crane, Indiana; As of and prior to March 29, 2013, the employer did not develop standing operating procedures (SOP) that address the operational steps to avoid and/or correct deviation and incorporate them into OSHA process safety management compliant standard operating procedures for the following covered process activities:      a. SOP CN-ML00-N-284, Operation 3 procedural steps were not included to avoid  deviation when a batch size requires manual temperature measurement, such as how often to check the temperature inside the kettle and what adjustments must be made to the temperature controls to the process within the dictated operating temperature range.      b. SOP CN-0000-N-114, Operation 25, the procedure lacked specificity in the steps to correct or avoid the deviation of the press force exceeding 7000 lbs. when pressing the smoke candle during Plant 3 manufacturing operations.      c. SOP CN-0000-N-086, M853A1 Operation 37 did not include steps to correct or avoid the deviation of the press force to bring the press force within the acceptable range during Plant 3 press room manufacturing operations.        d. SOP CN-0000-M-015, Operation 10, the procedure lacked specificity in the steps to correct or avoid the deviation of the oven temperature exceeding 180 degrees during Plant 8B oven drying activities.      e. SOP CN-0000-M-015, Operation 15 did not include steps to correct the deviation of the press force exceeding 8400 lbs. of force lacked the specificity to bring the press force back within the acceptable range during Plant 8A manufacturing operations.      f. SOP CN-ML00-N-284 Operation 3 does not include corrective steps to address temperature increase above 205 degrees Fahrenheit or prevent temperature increase after agitator functional loss for Plant 5 "kettle" process operations.      g. SOP CN-0000-M-015 Operation 7 Step 1 does not address corrective steps for unscreened material for Plant 8B production operations.      h. SOP CN-0000-M-015 Operation 9 Step 4 does not address corrective steps for exceeding dry time of one hour for Plant 8B composition drying operations.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(1)(iii)(B): The employer shall 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 and shall address at least the following elements; Safety and health considerations: Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment;      Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not established safe operating procedures to address engineering controls and administrative controls for the following covered processes:      a. SOP CN-0000-N-086, Operation 37 does not address the use of the local exhaust ventilation in the Plant 3 Press Room during pressing operations.      b. SOP CN-ML00-N-284, Operation 2 Step 2 lacks specificity regarding the use of an exhaust during material inspection in Plant 5.      c. SOP CN-ML00-N-284 Operation 13 Step 4 lacks specificity regarding exhaust use for Naphtha cleaning of stenciling equipment in Plant 5.      d. SOP CN-0000-M-015, Operation 16 lacks specificity regarding the use of a vent hood during Plant 8A mixing operations.      e. SOP CN-0000-M-015, Operation 3 Steps 3-6 do not address and the hazard control briefing section lacks specificity regarding hexane weighing and local exhaust use during Plant 8B production operations.      f. SOP CN-0000-M-017, Operation 2 the Operational Safety instruction lacks specificity regarding saw blade setup checks for Plant 8A saw cutting operations.      g. SOP CN-0000-M-015, Operation 6 lacks specificity regarding use of exhaust/ventilation system for Plant 8B magnesium powder weighing activities.      h. SOP CN-0000-M-015, Operation 9 lacks specificity regarding use of exhaust/ventilation system for Plant 8B composition drying and weighing activities.      i. SOP CN-0000-M-015, Operation 10 Step 4 lacks specificity regarding the visual inspection process for Plant 8B oven drying activities.      j. SOP CN-0000-M-015, Operation14 lacks specificity regarding the oven room exhaust system for Plant 8A composition normalization activities.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(1)(iv): The employer shall 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 and shall address at least the following elements:  Safety systems and their functions.      Crane Army Ammunition Activity, Crane, Indiana; As of and prior to March 29, 2013, the employer did not develop standing operating procedures (SOP) that provide clear instructions regarding safety systems and safety system functions; then incorporate them into OSHA process safety management compliant standard operating procedures for the following covered process activities:      a. SOP CN-0000-N-086, Operations 12, 13, and 23 lacks specificity for safety interlock system use on cell doors for Plant 3 mixing operations.       b. SOP CN-0000-N-123, Operation Steps 14 and 15 do not address the use of and function of the high speed deluge system for Plant 3 mixing operations.      c. SOP CN-ML00-N-084, Operation 3 does not address the wet scrubber(s) and the system(s) associated with their operational use. This equipment collects explosive material.      d. SOP CN-ML00-N-084, Operation 5 Step 1 lacks specificity regarding grounding of conductive matting for transfer operations of manufactured material from the Plant 5 "kettle" process.      e. SOP CN-ML00-N-084, Operation 10 Step 7 lacks specificity regarding grounding of the transportation cart for the Plant 5 pour pellets operation.      f. SOP CN-0000-M-017, Operation 2 lacks specificity regarding the safety interlock checks for the saw enclosure/saw cell for Plant 8A manufacturing operations.      g. SOP CN-0000-M-015, Operation 8 does not address interlocks for the Plant 8B mixing operations.      h. SOP CN-0000-M-015, Operation 11 lacks specificity regarding cell door interlocks and Operation 12 does not address cell door interlocks regarding Plant 8B extrusion operations.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(g)(1)(i): Training. Initial training. Each employee presently involved in operating a process, and each employee before being involved in operating a newly assigned process, shall be 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.    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not ensure that employees performing cleaning activities in the press room and associated equipment were trained to perform these tasks safely.  Employees were tasked with operating and maintaining the dust collection system and were not adequately trained to perform these tasks.  Employees were exposed to fire and explosion hazards while performing this work.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(h)(2)(v): The employer shall periodically evaluate the performance of contract employers in fulfilling their obligations as specified in paragraph (h)(3) of this section.      a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not developed an effective contractor program to address all the elements  of paragraph (h)(3) and mandatory CAAA dictated explosives safety program elements for the contractor that impact covered processes, such as but not limited to injury and illness performance, effect on other PSM required elements (such as mechanical integrity activity documentation and management of change impact) and CAAA required contractor activities, such as the accuracy of the Activity Hazard Analysis.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(i)(1): Pre-startup safety review.  The employer shall perform a pre-startup safety review for new facilities and for modified facilities when the modification is significant enough to require a change in the process safety information:    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer failed to perform a pre-startup safety review including all the required elements for a modified facility for the following operations:      a. The employer failed to perform the required pre-startup safety review when two Donaldson Torit dust collectors, purchased in 2005, were added to the dust collection system(s) for the pyrotechnics production activities in Plant 3. The employer did not ensure that the collectors met design specifications; that safety, operating and maintenance procedures were in place; and that a process hazard analysis was conducted.      b. The employer failed to perform the required pre-startup safety review when two "kettles" were moved into Plant 5 for explosives manufacturing activities. The employer did not ensure the "kettles" were covered by mechanical integrity testing and inspection procedures, that a design basis for the scrubber system was established and that the "kettles" system relief design and a relief system met design specifications for explosion protection.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(2): Written procedures. The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment.       a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer failed to establish, document and implement mechanical integrity procedures to assure safe operation of process equipment, such as but not limited to, accumulators/collectors, local exhaust ventilation systems, general (HVAC) ventilation systems, instrumentation, bearings, safety interlocks, safety switches, electrical equipment, valves, portable deluge systems, mixing equipment, presses, process piping and vacuum systems.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(3): Mechanical integrity. Training for process maintenance activities. The employer shall train each employee involved in maintaining the on-going integrity of process equipment in an overview of that process and its hazards and in the procedures applicable to the employee's job tasks to assure that the employee can perform the job tasks in a safe manner.       a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer failed to establish, document and implement mechanical integrity training to maintenance activities will assure the safe operation of process equipment, such as but not limited to, accumulators/collectors, local exhaust ventilation systems, general (HVAC) ventilation systems, instrumentation, bearings, safety interlocks, safety switches, electrical equipment, valves, portable deluge systems, mixing equipment, presses, process piping and vacuum systems.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(i): Mechanical Integrity. Inspection and testing.  Inspections and tests shall be performed on process equipment.    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not performed inspections and tests on process equipment, including but not limited to:    a. Ventilation systems in Plant 8B, such as the Oven room and Air Dry room local exhaust systems,     b. Ovens in Plant 8B, such as those in the Oven room,     c. The Mikro Pulverizer and electric motor in the Plant 3 Pulverizing room,      d. The Plant 3 Press room, 4 Post Press and associated interlocks,      e. The Plant 3, room B-8 safety system (door interlock),      f.  Plant 3, the general building ventilation system,      g. Plant 3, Ro-Tap sieve shaker and safety system (interlocked door),      h. Plant 8B, Extech Instruments model RH520, humidity and temperature recorder,      i.  Plant 8B, instrumentation for Ovens 7 and 8 (temperature recorder, temperature controller and high limit thermostat),      j.  Plant 8A, Oven (asset #28456),      k. Plant 5, 2 pressure vessels known as "kettles" used to melt explosives, to include associated valves and piping,       l.  Plant 5, utilities piping, such as steam lines, water lines and associated operational valves and pressure relief valves, and      m.  Plant 5, 2 dual throat scrubbers.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(ii): Mechanical integrity. Inspection and testing. Inspection and testing procedures shall follow recognized and generally accepted good engineering practices.    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had performed inspection and testing that followed recognized and generally accepted good engineering practices for the following process equipment:      a. For the Plant 3 Simpson Mix Mullers and the Hobart mixer in the mix wing operations area, vibration, bearing and heat testing/inspections were not included in the "PM" for each of these pieces of equipment, asset #s 000447, 028459, 011381, 000445, 032774, 24487 and 032776. This testing is a method of maintenance involved with preventing failure and potential ignition of explosive material during mixing operations.      b. In general, dust and explosive material collection systems and ventilation systems are not tested for adequate ductwork and capture velocities to assure proper system performance based on the design basis for these systems. This includes, but is not limited to, ventilation systems associated with Plant 3 mixing operations and press room collection systems.      c. For Plant 5 Kettles appropriate pressure vessel hydrostatic testing had not been performed prior to installation.      d. For Plant 3 B-8 rotary screener, bearings were not included in the PM for this piece of equipment (asset #L00798).

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(iii): Inspection and testing. The frequency of inspections and tests of process equipment shall be consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience.    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not performed inspection and testing at the appropriate frequency for the following process equipment:      a. In Plant 3, for the two Donaldson Torit dust collectors inspections and tests were not performed on the established schedule developed by the employer. The annual "PM's" (inspection) had not been performed since August 22, 2011, a semiannual vacuum blower "PM" (inspection) for collector asset number L00825 had not occurred since August 30, 2012 and a semiannual vacuum blower "PM" (inspection) for collector asset number L00825 had not occurred since August 30, 2012.       b. In Plant 3, calibration had not been performed for the Extech humidity instrumentation since 2007. The manufacturer sets calibration frequency as an annual activity.      c. In Plant 3, the dryers and ovens in the Pulverizing room/area (asset numbers 026912, 026913, 026914 and 026916) had not been inspected on the frequency determined by the employer. The semiannual "PM" had not occurred since February 2012 and the quarterly "PM" had not occurred since August 2012.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(iv): Mechanical integrity. Inspection and testing. The employer shall document each inspection and test that has been performed on process equipment. The documentation shall 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.     Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not documented mechanical integrity activities associated with process equipment, such as but not limited to the following:      a. The employer did not document the pre-installation tests and inspections associated with setting up portable deluge systems and their associated components. Navy facility employees are utilized to assure proper equipment set-up. Portable deluge systems use includes Plant 8A operations, such as igniter assembly stations, the igniter removal station and the foil removal station.      b. The employer did not document the inspection and changing of filter for the Plant 3 ventilation systems associated with Mix Wing Simpson mixers.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(6)(i): Mechanical integrity. Quality assurance. In the construction of new plants and equipment, the employer shall assure that equipment as it is fabricated is suitable for the process application for which they will be used.      Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not have a PSM documented quality assurance program to assure process safety management perspective suitability for designing, implementing and assembling new process applications in existing CAAA buildings, or in new construction projects, such as but not limited to:      a. The Plant 5 manufacturing operation known as the "kettle"process The employer did not assure that the kettle process equipment, as it was fabricated, was suitable for the process application. In developing this process application, kettles and scrubbers are interconnected without proper documentation of relief system design, explosion protection equipment design, isolation, explosion venting, protective enclosure, or separation by location from other operations.       b. The Plant 3, press room explosive material collection system. The employer did not assure that the dust collection system dust collectors were suitable for the process application. In developing this process application, the collectors were connected to the ductwork from local exhaust ventilation without the documentation of a design basis, relief system (explosion venting) design basis, isolation, protective enclosure, separation by location from other inhabited areas, and separation from the other dust collector component.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(6)(ii): Mechanical Integrity. Quality assurance. Appropriate checks and inspections shall be performed to assure that equipment is installed properly and consistent with design specifications and the manufacturer's instructions.    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not have a PSM documented quality assurance program to assure the appropriate checks and inspections are performed proper equipment installation, for new equipment, such as but not limited to two Donaldson Torit dust collectors. There were no design specifications or design basis to check installation or inspect against and installation did not occur in a consistent fashion with the instructions regarding design review and approval.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(6)(iii): Mechanical integrity.  Quality Assurance.  The employer shall assure that maintenance materials, spare parts and equipment are suitable for the process application for which they will be used.      Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not have a PSM documented quality assurance program to assure that maintenance materials, spare parts and equipment are process suitable before use, such as but not limited to antistatic cleaning brushes, non-spark tools, filter media for ventilation systems and electrical equipment.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(l)(1): Management of change.  The employer shall 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.    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not implemented and documented management of process and procedures, for the following process changes:    a. Plant 3Tiger Vac vacuum implementation. TigerVacs were introduced to use for cleaning explosive material associated with illuminating candle production operations. The employer did not evaluate the hazards associated with the new equipment and impact on existing collection systems.    b. Plant 3 dust collectors. The new collectors were used to clean up explosive composition from the press room production line. The employer did not evaluate the hazards associated with the new collectors and associated piping.       c. Plant 3 Press room "Press cell" clamping change associated with pressing Yellow Smoke canisters and wiring back or defeating the lower range, eject cylinder limit switch. Other than an inclusion in the SOP for the clamping, there was no management of change for this production change.      d. Plant 3 ventilation systems changes, such as the multiple rooms with blocked off ducts, blinded ducts and taping of slots in slotted hood style local exhaust ventilation systems,      e. Plant 5 heat jacket addition for the metal pouring tube drain on the kettle. There was no management of change.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(m)(1): Incident Investigation. The employer shall investigate each incident which resulted in, or could reasonably have resulted in a catastrophic release of highly hazardous chemical in the workplace.    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not developed an incident investigation program that has incidents with potential for release or detonation of an explosive material. The employer's existing program does not initiate with every near miss having potential for explosive material detonation.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(m)(4): Incident Investigation. A report shall be prepared at the conclusion of the investigation which includes at a minimum the information required by 29 CFR 1910.119(m)(4)(i)-(v):      a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not generated incident investigation reports for the series of incidents involving the Plant 3 "Press Delay" operation. There were a number of near misses and ignition/detonations beginning in late 2011. Investigation actions documented for the existing program did not meet the requirements of this part for each incident or near miss.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(m)(5): Incident Investigation. The employer shall establish a system to promptly address and resolve the incident report findings and recommendations. Resolutions and corrective actions shall be documented.    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not established a system to address, track and resolve incident report findings, such as, but not limited to, the series of incidents involving the Plant 3 Press Delay operation. The employer did not promptly address findings of need to address proper location of parts and tools during assembly process after press activation/initiation.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(o)(1): Compliance Audits.  Employers shall certify that they have evaluated compliance with the provisions of this section at least every three years to verify that the procedures and practices developed under the standard are adequate and are being followed.      a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had never completed an audit to determine compliance with the provisions of this section.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.132(d)(1): Hazard assessment and equipment selection.  The employer shall assess the workplace to determine if hazards are present, or are likely to be present, which necessitate the use of personal protective equipment (PPE). If such hazards are present, or likely to be present, the employer shall:  (i) select, and have each affected employee use, the types of PPE that will protect the affected employee from the hazards identified in the hazard assessment; (ii) communicate selection decisions to each affected employee; and, (iii) select PPE that properly fits each affected employee.    a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not performed and documented a personal protective equipment (PPE) hazard assessment that includes all employee maintenance activities and work performed by production employees that is not covered by SOPs, including but not limited to work activities performed by the Plant 3 press room "cleaning crew" and maintenance personnel performing PMs on dust collector systems.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(4)(ii): Energy control procedure. The procedures shall clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance including, but not limited to, the Items A-D of this section:     Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not developed specific procedures for the following activities:      a. Machine specific procedures were not developed for maintenance department employees performing covered activities, such as but not limited to PMs on dust collectors and other ventilation systems throughout the facility.      b. Machine specific procedures were not developed for Plant 3 press room "cleaning crew" cleaning activities associated with the Donaldson Torit collectors and collection system.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(5)(i): Protective materials and hardware. Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware shall be provided by the employer for isolating, securing or blocking of machines or equipment from energy sources.      a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, in Plant 3, employees cleaning Simpson Mix Muller machines in the Mix wing area have not been provided adequate hardware for use in required covered activities. These cleaning activities occur on a daily basis and explosives handlers performing the tasks have been provided tags for tagout without receiving self-locking fasteners for applying the tag to the disconnect switch for the machine.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(5)(ii)(C)(2):  Protective materials and hardware. Tagout devices, including their means of attachment, shall be substantial enough to prevent the inadvertent or accidental removal.      a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, in Plant 3, employees cleaning Simpson Mix Muller machines in the Mix wing area use a tag and thin metal wire attachment as the energy isolation device during the performance of required duties under this part. The thin metal wire attachment is applied by hand to the electrical disconnect switchbox, is not self-locking and is of inadequate strength to prevent the inadvertent or accidental removal of the tagout device.

Issued

Sep 27, 2013

Abate by

Dec 1, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(f)(3)(i): Group lockout or tagout.  When servicing and/or maintenance is performed by a crew, craft, department or other group, they shall utilize a procedure which affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device.      a. Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, two Explosive Handlers cleaning the inside of the mixing bowl of the Simpson Mix Muller machine did not utilize a procedure to provide them with a level of protection equivalent to a personal lockout or tagout device.  The group tagout did not involve a self-locking fastener to attach the tag isolation device to the electrical disconnect switch.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(6)(ii): Periodic inspection. The employer shall certify that the periodic inspections have been performed. The certification shall identify the machine or equipment on which the energy control procedure was being utilized, the date of the inspection, the employees included in the inspection, and the person performing the inspection.    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not adequately certified that periodic energy control procedures (lockout/tagout) periodic inspections had been performed for the following activities:    a. For all required duties covered by this part, the employer did not document any machine or equipment in manufacturing or demilitarization operations, as part of the certification of the periodic inspection for maintenance activities covered by the lockout tagout standard; Maintenance does not have any machine specific lockout-tagout procedures.    b. For explosives handlers performing Plant 3cleaning operations, the employer did not document the certification of the periodic inspection for dust collector internal cleaning and the cleaning of the Mix Wing Simpson Mullers. Employees performing dust collector cleaning do not apply lockout devices at the appropriate disconnect switch and self-locking fasteners are not provided for energy isolation in the Mix Wing Simpson cleaning activity.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(7)(i)(A): The employer shall provide training to ensure that the purpose and function of the energy control program are understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees. Each authorized employee shall receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control:    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer did not ensure that employees received training and understood the purpose and function of the lockout/tagout program, recognition of hazardous energy sources, and the methods and means necessary for energy isolation and control for the following required duties:       a. Maintenance employees had not received training in specific requirements for energy control, such as training in machine specific procedures. Maintenance employees perform required duties such as blower motor "PMs," belt changes on power transmission equipment and saw blade changes without benefit of training for machine specific procedures;      b. Plant 3 press room explosives handlers working on the "cleaning crew" had not received training in specific machine specific procedures for the dust collectors during explosives material cleaning of the collectors, filtration equipment servicing and filtration equipment replacement;      c. Plant 3 mix wing explosives handlers had not received training in the means necessary for adequate energy isolation control device application for tagout. Plant 3 mix wing explosives handlers had not received training in applying self-locking devices that meet the 50 pounds strength requirement when utilizing tagout energy isolating devices.

Issued

Sep 27, 2013

Abate by

Nov 3, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(d)(1): Guarding. Pulleys, any parts of which are seven (7) feet or less from the floor or working platform, shall be guarded:      As of and prior to March 29, 2013, a belt and pulley were not guarded in the shaker loading area in Plant 7. This condition exposes employees to a caught-in hazard associated with the ingoing nip point.

Issued

Sep 27, 2013

Abate by

Dec 1, 2016

Penalty

Initial $0 · Current $0

Hazardous substances E101

General-duty citation text

29 CFR 1960.8(a): The head of each agency shall furnish to each employee employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to employees in that employees were exposed to fire and explosion hazards.               (a)  On or about April 25, 2013, the employer did not ensure that employees were protected from combustible dust deflagration, explosion, and other fire hazards.  Employees working in the blocking and bracing shop were exposed to hazards from the dust collector which was located outdoors, was connected to powered wood working tools, and which lacked means of explosion protection and deflagration isolation from upstream process equipment.          Among other methods, a feasible abatement method to correct the hazards would be to follow the National Fire Protection Association (NFPA) Standard 664 "Standard for the Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities, 2012 Edition", Sections 8.2.2.5.3 and 8.2.4 and/or to follow the FM Global Property Loss Prevention Data Sheet 7-73 "Dust Collectors and Collection Systems, January 2012", Sections 2.2, and 2.6; and, FM Global Property Loss Prevention Data Sheet 7-76 "Prevention and Mitigation of Combustible Dust Explosion and Fire, April 2013", Sections 2.4  and 2.5.        Specifically, protect the collectors with a method of explosion protection such as, but not limited to, deflagration venting to a safe location in accordance with NFPA 68 and provide a method of flame front propagation isolation protection to connected ducting and equipment through the use of a listed isolation device in accordance with NFPA 69.

Issued

Sep 27, 2013

Abate by

Feb 3, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(m)(6):  The report shall be reviewed with all affected personnel whose job tasks are relevant to the incident findings.      Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the results of an incident investigation involving explosives in the Pyrotechnic Division, (MEP), had not been reviewed with all affected employees whose job tasks are relevant to the incident.

Issued

Sep 27, 2013

Abate by

Feb 3, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(d)(1)(iii): The employer shall identify and evaluate the respiratory hazard(s) in the workplace; this evaluation shall include a reasonable estimate of employee exposures to respiratory hazard(s) and an identification of the contaminant's chemical state and physical form. Where the employer cannot identify or reasonably estimate the employee exposure, the employer shall consider the atmosphere to be IDLH.    Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 29, 2013, the employer had not evaluated all the respiratory hazards associated with demilitarizing ammunition using the deactivation furnace.  Employees operated and maintained the furnace and air pollution control equipment and were exposed to toxic metals. The employer did not evaluate employee exposure to barium.

Issued

Sep 12, 2013

Abate by

Nov 16, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(c)(1): Permit-required confined spaces. General requirements. The employer did not evaluate the workplace to determine if any spaces are permit-required confined spaces.   Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 14, 2013, the employer did not ensure that the workplace was evaluated to determine if any structures or equipment in the facility were permit-required confined spaces.  Employees routinely entered the dust collectors to perform maintenance.  The space was accessed via a ladder and contained explosive composition.  Employees were exposed to explosion and fire hazards.

Issued

Sep 12, 2013

Abate by

Nov 16, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(c)(2): Permit-required confined spaces. General requirements. The employer did not inform exposed employees, by posting danger signs or by any other equally effective means, of the existence and location of and the danger posed by the permit spaces.   Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 14, 2013, the employer did not inform workers of the location and dangers of permit-required confined spaces present in the workplace.  The dust collectors at the pyrotechnics building were not identified by signs and employees were not informed that the collectors were permit-required spaces.  Employees routinely entered the spaces to perform maintenance and were exposed to explosion and fire hazards.

Issued

Sep 12, 2013

Abate by

Nov 16, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(d)(3): Permit-required confined space. Permit-required confined space program. Develop and implement the means, procedures, and practices necessary for safe permit space entry operations, including, but not limited to, the Items (i)-(iv):  Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 14, 2013, the employer did not develop and implement procedures for safe entry into permit-required confined spaces.  Procedures to enter the dust collectors at the pyrotechnics building, which were permit-required spaces, were not developed and implemented.  While performing routine maintenance on the collectors, employees entered the collectors without implementation of safe entry protocols, such as but not limited to, neutralizing the energy sources, presence of attendant, use of entry permit, and verification that no atmospheric hazards existed.

Issued

Sep 12, 2013

Abate by

Nov 16, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(e)(1): Permit-required confined spaces. Permit system. Before entry is authorized, the employer did not document the completion of measures required by paragraph (d)(3) of this section by preparing an entry permit.   Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 14, 2013, the employer did not complete an entry permit before employees entered permit-required spaces to perform work.  Employees routinely entered the dust collectors at the pyrotechnics building in order to perform maintenance on the collectors.  Prior to entry, the employer did not document that conditions were acceptable for safe entry, such as but not limited to, all hazards were effectively neutralized, that appropriate personal protective equipment was available and used, and emergency equipment was available.

Issued

Sep 12, 2013

Abate by

Nov 16, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(g)(1): Permit-required confined spaces. Training. The employer did not provide training so that all employees whose work is regulated by this section acquire the understanding, knowledge, and skills necessary for the safe performance of the duties assigned under this section.  Crane Army Ammunition Activity, Crane, Indiana: As of and prior to March 14, 2013, the employer did not ensure that the employees entering the dust collectors at the pyrotechnics building had the necessary knowledge to safely work in the permit-required confined spaces.  Employees routinely entered the space and were not aware of the hazards present in the space and were knowledgeable in the necessary steps to implement to protect themselves from the fire and explosion hazards.