OSHA Inspection: ADAIR GRAIN, INC.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $7,000 · Current $6,700 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1): The employer did not furnish employment and a place of employment which was free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to the hazards of chemical burns and inhalation of anhydrous ammonia.    On or about April 17, 2013 and at times prior thereto, at the south end of the fertilizer plant employees working with or in proximity to two large 12,000 gallon liquid anhydrous ammonia storage/service tanks were exposed to the hazards of contact with liquid ammonia and inhalation of ammonia vapor from leaking or failed ammonia systems.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $3,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.111(b)(9)(iii): Safety relief devices used in systems covered by paragraphs (c), (f), (g), and (h) of this section were not constructed to discharge at not less than the rates required in paragraph (b)(9)(i) of this section before the pressure is in excess of 120 percent (not including the 10 percent tolerance referred to in paragraph (b)(9)(ii) of this section) of the maximum permitted start-to-discharge pressure setting of the device.    On or about April 17, 2013 and at times prior thereto, the employer did not ensure the safety relief devices for the main storage/service tanks were rated at not less than the tanks minimum rate of discharge in cubic feet per minute.       a)    On the north main stationary storage/service tank  b)    On the south main stationary storage/service tank

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $7,000 · Current $6,700 Reduced

General-duty citation text

29 CFR 1910.109(i)(2)(iii)(b): Storage buildings did not have adequate ventilation or were not constructed to be self-ventilating in the event of fire.       On or about April 17, 2013, and times prior thereto, the employer did not provide suitable ventilation or self-ventilation in the fertilizer plant where ammonium nitrate was stored and handled in case of a fire.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $7,000 · Current $6,700 Reduced

General-duty citation text

29 CFR 1910.109(i)(2)(iii)(c): Walls on exposed sides of storage buildings within 50 feet of combustible buildings, forests, piles of combustible materials and similar exposure hazards were not of fire-resistive construction:    On or about April 17, 2013 and at times prior thereto, the employer did not ensure that the east wall of the fertilizer building and seed room were fire resistant rated and was not located within 50 feet of the office/maintenance shop building.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $7,000 · Current $6,700 Reduced

General-duty citation text

29 CFR 1910.109(i)(2)(iii)(d): Flooring in storage and handling areas was not without open drains, traps, tunnels, pits, or pockets into which molten ammonium nitrate could flow and be confined in the event of fire:     On or about April 17, 2013 and at times prior thereto, the employer did not ensure that the flooring on the west side of the large ammonium nitrate bin did not contain a pit for the bucket conveyor leg into which molten ammonium nitrate could flow.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $7,000 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.109(i)(4)(i)(b): Bulk storage structures exceeded a height of 40 feet where storage facilities were not constructed of noncombustible materials or adequate facilities for fighting a roof fire were not available:        On or about April 17, 2013, and times prior thereto, the employer did not ensure that the ammonium nitrate storage structure that exceeded 40 feet was made of noncombustible material or that facilities for fighting a roof fire were made available.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $7,000 · Current $6,700 Reduced

General-duty citation text

29 CFR 1910.109(i)(4)(ii)(b): Wooden bins were not protected against impregnation by ammonium nitrate:    On or about April 17, 2013, and times prior thereto, the employer did not ensure the wooden bins used for storing ammonia nitrate were treated to prevent impregnation.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $7,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.109(i)(5)(i)(a): Ammonium nitrate was not in a separate building or was not separated by approved type firewalls of not less than 1 hour fire-resistance rating from storage of flammable and combustible materials or other contaminating materials:    On or about April 17, 2013 and times prior thereto, the employer did not ensure that flammable and combustible materials such as but not limited to seed, paper seed bags, wood pallets, and baling twine, were not stored in the same building with ammonium nitrate.  The bin wall separating the ammonium nitrate from the seed room was not fire rated.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $7,000 · Current $6,700 Reduced

General-duty citation text

29 CFR 1910.109(i)(7)(ii)(b): Water supplies and fire hydrants were not available in accordance with recognized good practice:     On or about April 17, 2013, and times prior thereto, the employer did not ensure that suitable water supplies and fire hydrants were available in accordance with recognized good practice at the fertilizer plant where ammonium nitrate was stored in the event of a fire.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $3,500 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.111(b)(3)(i): System nameplates, when required, were not permanently attached to the system so as to be readily accessible for inspection and did not include markings as prescribed in subdivision (ii) of this subparagraph:     On or about April 17, 2013, and at times prior thereto, the employer did not ensure that the south main anhydrous ammonia storage/service tank had a system nameplate.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $2,100 · Current $6,700

General-duty citation text

29 CFR 1910.111(b)(3)(ii)(a): Each container or system covered in paragraphs (c), (f), (g), and (h) of this section were not marked with a notation "Anhydrous Ammonia".    On or about April 17, 2013 and at times prior thereto, the employer did not ensure that the main anhydrous ammonia storage/service tanks were labeled, with the visible words "Anhydrous Ammonia".      a)    On the north stationary main storage/service tank  b)    On the south stationary main storage/service tank

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $3,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.1200(e)(1): The employer did not develop, implement, and/or maintain at the workplace a written hazard communication program which describes how the criteria specified in 29 CFR 1910.1200(f), (g), and (h) will be met:    On or about April 17, 2013, and at time prior to, the employer did not develop or implement a hazard communication program for employees working with chemicals, such as but not limited to, anhydrous ammonia and ammonium nitrate.  The employer did not inform the employees of the potential hazards of these chemicals which include, chemical burns, respiratory illness, fire and explosion.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $4,900 · Current $6,700

General-duty citation text

29 CFR 1910.111(b)(8)(ii): Hose assemblies, when made up, were not capable of withstanding a test pressure of 500 p.s.i.g.    On or about April 17, 2013 and at times prior thereto, the employer did not ensure that when new Parker 7261 anhydrous ammonia system hoses were installed or replaced that they were tested to withstand a test pressure of at least 500 p.s.i.g.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $4,900 · Current $6,700

General-duty citation text

29 CFR 1910.111(c)(2)(i): Each filling connection was not provided with combination back-pressure check valve and excess-flow valve; one double or two single back-pressure check valves; or a positive shutoff valve in conjunction with either an internal back-pressure check valve or an internal excess flow valve.    On or about April 17, 2013 and at times prior thereto, the employer did not ensure that anhydrous ammonia compressors and liquid and vapor filling/service lines had back pressure check valves and/or excess flow valves installed.       a)    At the north tank filling/servicing pump house  b)    At the north tank rail side filling/servicing lines  c)    At the south tank filling/servicing bonnet  d)    At the south filling/servicing island

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $3,500 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.111(c)(7): Precautions were not taken against damage to ammonia systems from vehicles.    On or about April 17, 2013 and at times prior thereto, on the rail side of the main anhydrous ammonia storage/service tanks, the employer did not ensure that the main piping and valves were protected from being struck-by vehicles and other equipment loading, unloading and working in the area.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $3,500 · Current $6,700

General-duty citation text

29 CFR 1910.120(q)(2): The employer did not develop an emergency response plan for emergencies which addressed the following minimum requirements of this standard: 1910.120(q)(2)(i) through 1910.120(q)(2)(xii):    On or about April 17, 2013 and at times prior thereto, the employer received, stored and handled hazardous chemicals such as anhydrous ammonia and did not implement an emergency response plan or procedures to handle anticipated emergencies.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $3,500 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.134(c)(1): A written respiratory protection program that included the provisions in 29 CFR 1910.134(c)(1)(i) - (ix) with worksite specific procedures was not established and implemented for required respirator use:    On or about April 17, 2013, and times prior thereto, the employer did not implement a written respiratory protection program for employees required to wear half-face and full-face respirators during exposure to inhalation hazards, while servicing anhydrous ammonia storage/service tanks, nurse tanks and performing other tasks.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator before the employee was fit tested or required to use the respirator in the workplace:    On or about April 17, 2013, and times prior thereto, the employer did not provide a medical evaluation for employees required to wear half-face and full-face respirators during an unexpected leak/exposure when servicing Anhydrous Ammonia service/storage tanks, nurse tanks and maintenance on the anhydrous ammonia systems.

Issued

Oct 9, 2013

Abate by

Nov 1, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(f)(2): Employee(s) using tight-fitting face-piece respirators were not fit tested prior to initial use of the respirator:    On or about April 17, 2013, and times prior thereto, the employer did not provide fit tests for employees required to wear half-face and full-face respirators during an unexpected leak/release when servicing Anhydrous Ammonia service/storage tanks, nurse tanks and maintenance on Anhydrous Ammonia systems.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $3,500 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.146(c)(1): The employer did not evaluate the workplace to determine if any spaces were permit-required confined spaces:    On or about April 17, 2013, and at times prior thereto, the employer did not evaluate or determine if any spaces were permit required spaces prior to allowing employees to enter for cleaning.      a) Grain silos  b) 32-0-0 liquid fertilizer tanks

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $4,900 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.147(c)(1): The employer did not establish a program consisting of an energy control procedure, employee training and periodic inspections to ensure that before any employee performed any servicing or maintenance on a machine or equipment where the unexpected energizing, startup or release of stored energy could occur and cause injury, the machine or equipment would be isolated from the energy source and rendered inoperative:     On or about April 17, 2013 and at times prior thereto, the employer did not develop or implement an energy control program or procedures for equipment such as but not limited to, grain augers, sweepers and conveyers, rail car wenches, and dry fertilizer bucket and belt conveyors where the employees performed routine and periodic servicing and maintenance.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $2,100 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.157(d)(1): Portable fire extinguishers were not selected based on the classes of anticipated workplace fires and on the size and degree of hazard which would affect their use:    On or about April 17, 2013, and at times prior thereto, the employer did not select and provide the type of fire extinguishers for materials such as but not limited to oxidizers stored in the fertilizer plant.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $3,500 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.178(l)(6): The employer did not certify that each operator has been trained and evaluated as required by this paragraph (l):    On or about April 17, 2013 and at times prior thereto, the employer did not certify that each operator was provided training consisting of a combination of formal instruction, practical training and an evaluation of their performance prior to operating fork lift trucks.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $3,500 · Current $0 Reduced

General-duty citation text

29 CFR 1910.178(q)(7): Industrial trucks were not examined before being placed in service:    On or about April 17, 2013 and at times prior thereto, the employer did not ensure that forklift trucks were inspected prior to use by employees.

Issued

Oct 9, 2013

Abate by

Nov 7, 2013

Penalty

Initial $4,900 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.303(b)(1): Electrical equipment was not free from recognized hazards that were likely to cause death or serious physical harm to employees, in that the employer did not ensure the safety of the equipment pursuant to the considerations in sections (i) through (viii) of 29 CR 1910.303(b)(1):    On or about April 17, 2013 and at times prior thereto, the employer installed spliced two-wire unprotected light bulb sockets hanging freely above each dry fertilizer bin.