OSHA Inspection: COOPER NATURAL RESOURCES

Issued

Aug 19, 2013

Abate by

Aug 26, 2013

Penalty

Initial $2,100 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.22(a)(2): Floor(s) of workroom(s) were not maintained in a clean and, so far as possible, a dry condition.     On or about March 29 2013 employees of were exposed to trip, slip, and fall hazards while working on top of the product tanks due to uneven flooring on top of tanks.

Issued

Aug 19, 2013

Abate by

Oct 4, 2013

Penalty

Initial $2,800 · Current $1,680 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(A): Information pertaining to the process did not include (A)-(H).     This violation was observed on or about April 16, 2013 when the employer did not complete a compilation of written process safety information pertaining to process equipment; in that materials of construction, including but not limited to the original design construction specifications for pressure vessel T-103 (Manufacturer's Data Report for Pressure Vessels, Form U-1 or U-1A), were not included in process safety information.

Issued

Aug 19, 2013

Abate by

Oct 4, 2013

Penalty

Initial $4,900 · Current $2,940 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(ii): The employer did not document that equipment complied with recognized and generally accepted good engineering practices.     This violation was observed on or about April 16, 2013 at Cooper Natural Resources when the employer did not document that the compressors pressure relief discharge complied with ANSI/ASHRAE Standard 15, Safety Standard for Refrigeration System - 2010, Section 9.7.8; when the discharge piping was not terminated in a manner that would prevent the refrigerant from being sprayed in areas occupied by personnel.

Issued

Aug 19, 2013

Abate by

Oct 4, 2013

Penalty

Initial $4,900 · Current $2,940 Reduced

General-duty citation text

29 CFR 1910.119(e)(1): The employer did not perform a process hazard analysis on processes covered by this standard.     This violation was observed on or about April 18, 2013 at the Cooper Natural Resources, when the employer did not perform the process hazard analysis (PHA) revalidations for changes that affect the Ammonia Refrigeration System; including but not limited to the addition of the screw compressors (C-10, C-11), the BAC evaporative condensers (EC-1/EC-4) in 2010 and the High Pressure Receiver (HPR) in 2011.

Issued

Aug 19, 2013

Abate by

Oct 4, 2013

Penalty

Initial $4,900 · Current $2,940 Reduced

General-duty citation text

29 CFR 1910.119(e)(5): The employer did not 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.    This violation was observed on or about April 16, 2013 at Cooper Natural Resources when the employer did not develop a written schedule and document what actions were to be taken to assure that the 2010 PHA team's findings and recommendations; such as but not limited to the potential personnel exposure due to pressure relief valve discharge on T-100, T-102, and T-103; were resolved in a timely manner and that the resolution was documented and communicated to affected employees.

Issued

Aug 19, 2013

Abate by

Oct 4, 2013

Penalty

Initial $4,900 · Current $2,940 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(ii): Inspection and testing procedures did not follow recognized and generally accepted good engineering practices.    a)  This violation was observed on or about April 18, 2013 in the chilling room when the employer did not ensure the insulation on the 6" HSS piping was inspected and sealed per IIAR Bulletin No. 109 section 4.7.5 (Minimum Safety Criteria for a Safe Ammonia Refrigeration System) and IIAR Bulletin No. 110 1993 (Guidelines for: Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems) section 6.7.2 to prevent condensation and corrosion.        b)  This violation was observed on or about April 18, 2013 when the employer did not ensure the compressors C-6 and C-10 were inspected and tested per IIAR Bulletin No. 110 1993 (Guidelines for: Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems) section 6.3.1 for vibration analysis; and section 6.8 for oil maintenance.     c)  This violation was observed in the Ammonia Refrigeration Process at Cooper Natural Resources, Loop, Texas, when the employer did not ensure the pressure relief valves (PSV) discharging to the atmosphere were changed or recertified at least every 5 years per the IIAR Bulletin 109 section 4.9.7. The PSV's include but not limited to HPR(PSV1/PSV2), KO-1(PSV1/PSV2), KO-2(PSV1/PSV2),  RD-2(PSV1/PSV2),  C10-C11(PSV1/PSV2),  and chillers A-E(PSV1)

Issued

Aug 19, 2013

Abate by

Oct 4, 2013

Penalty

Initial $4,900 · Current $2,940 Reduced

General-duty citation text

29 CFR 1910.119(j)(5): The employer did not correct deficiencies in equipment that was outside acceptable limits (defined by the process safety information in paragraph (d) of this section) before further use or in a safe and timely manner when necessary means are taken to assure safe operation.      This violation was observed in the Ammonia Refrigeration Process at Cooper Natural Resources, Loop, Texas, when the employer did not ensure the T-103 (Run Down Receiver for C,D,E chillers) equipment deficiencies were assessed and/or corrected; including but not limited to the vessel wall thickness below the retirement thickness t-min before further use exposing employees to inhalation hazards.

Issued

Aug 19, 2013

Abate by

Oct 4, 2013

Penalty

Initial $4,900 · Current $2,940 Reduced

General-duty citation text

29 CFR 1910.119(l)(1): The employer did not 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 affected a covered process.    a) This violation was observed on or about April 18, 2013 at the Cooper Natural Resource, Cedar Lake plant when the employer did not implement Management Of Change (MOC) procedure to manage changes that affect the Ammonia Refrigeration process; including but not limited to the addition of the screw compressors (C-10, C-11), BAC evaporative condensers (EC-1 -  EC-4) in 2010 and High Pressure Receiver (HPR) in 2011.    b) This violation was observed on or about April 18, 2013 at the Cooper Natural Resource, Cedar Lake plant when the employer did not implement Management Of Change (MOC) procedure for fitness-for-service evaluations to manage changes that affect the process equipment; including but not limited to metal loss resulting in wall thickness below the retirement thickness t-min for T-103.

Issued

Aug 19, 2013

Abate by

Aug 29, 2013

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.219(f)(3):  Sprocket wheels and chains which were seven 7 feet or less above floors or platforms were not enclosed.      On or about  March 29 2013 employees of Cooper Natural Resources were exposed to  of caught-in, crushing, and nip-point hazards while working near unguarded chain and sprockets.      a) on top of tank 5    b) on top of tank 6

Issued

Aug 19, 2013

Penalty

Initial $3,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.219(k)(1):     Clutches, cutoff couplings, or clutch pulleys had projecting parts which were not enclosed by a stationary guard.    On or about March 29 2013 employees of Cooper Natural Resources were exposed to caught-in, crushing, and nip-point hazards while working near unguarded couplings with projecting parts.    a) on top of tank 5  b) on top of tank 6

Issued

Aug 19, 2013

Penalty

Initial $4,900 · Current $2,940 Reduced

General-duty citation text

29 CFR 1910.303(b)(6): 29 CFR 1910.303(b)(6): Equipment located in damp or wet locations and exposed to a corrosive salt atmosphere was not identified for that purpose.     On or about March 29 2013 employees of Cooper Natural Resources were exposed to electrical hazards due to corrosion of:       a)   electrical panels in the chilling room       b)   a corroded outlet in the drying room

Issued

Aug 19, 2013

Abate by

Aug 27, 2013

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.305(g)(2)(iii): Flexible cords and cables were not connected to devices and fittings so that strain relief was provided that would prevent pull from being directly transmitted to joints or terminal screws.    On or about March 29 2013 employees of Cooper Natural Resources were exposed to electrical hazards while working in the chilling room due to a lack of strain relief for flexible cables.

Issued

Aug 19, 2013

Abate by

Feb 28, 2015

Penalty

Initial $8,400 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.22(a)(2):      Floors of workrooms were not maintained in a clean and, so far as possible, a dry condition.     On or about March 29 2013 employees of Cooper Natural Resources were exposed to trip, slip, and fall hazards while working in the chilling department and the drying department due to wet and muddy conditions as a result of drainage not being maintained.    Cooper Natural Resources was previously cited for a violation of this occupational safety and health standard which was contained in OSHA inspection number 313123341, citation number1, item number 1 and was affirmed as a final order on May 19 2010, with respect to a workplace located at FM 166 at Cedar Lake, Loop, Texas 79342.