OSHA Inspection: DELEK REFINING, LTD

Issued

Nov 21, 2013

Abate by

Dec 11, 2013

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(f)(1)(ii): Operating procedures did not contain written operating limits:        The employer does not ensure that the operating procedures for the Naphtha Hydrotreater Unit, #30.6.1, Consequences of Deviation, contain the alarm values.  The alarm values were not present for the following equipment:      gg. Deviation of a make up compressor 30-C-2A/B 2nd  stage discharge pressure high, which is associated with high high temperature switches (30-TSHH-3033/3037), written operating limits for high alarm, normal value and low alarm are not listed (Bates #00346).

Issued

Nov 21, 2013

Abate by

Dec 11, 2013

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(A): Written operating procedures did not contain consequences of deviations:      The employer does not ensure that operating procedures contain consequences of deviations.      This violation occurred on or about May 23, 2013 and at times prior thereto in the Saturated Gas (Sat-Gas) unit where employees were exposed to inhalation, fire, and explosion hazards from potential releases of hazardous materials without ensure operating procedures contain consequences of deviations.

Issued

Nov 21, 2013

Abate by

Dec 11, 2013

Penalty

Initial $38,500 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): The employer's piping and instrument diagrams were not accurate and did not include process safety information that provided specific identification of equipment that is part of the process:      The employer does not ensure that piping and instrument diagrams (P&IDs) were accurate and include process safety information pertaining to equipment.       This violation occurred on or about May 23, 2013 and at times prior thereto in the Naphtha Hydrotreater (unit 30), Saturated Gas (unit 60), and Storage and Blending(unit 01) units where employees were exposed to inhalation, fire, and explosion hazards from potential releases of hazardous materials without ensure P&IDs were accurate and included process safety information (PSI) for the following instances.    c. P&ID (DK-60-0-0002L, Rev. 16), Sponge Oil Absorber, by pass line for a lean oil air cooler (60-E-30) from the control valve (FV-002) to a lean oil water cooler (60-E-5)  does not exist in the field.

Issued

Nov 21, 2013

Abate by

Dec 11, 2013

Penalty

Initial $70,000 · Current $35,000 Reduced

General-duty citation text

29 CFR 1910.119(f)(3): The operating procedures were not reviewed as often as necessary to assure that they reflect current operating practice, including changes that result from changes in process chemicals, technology, and equipment, and changes to facilities. The employer did not annually certify that operating procedures were current and accurate:      The employer does not ensure that operating procedures are current and accurate.      This violation occurred on or about May 23, 2013 and at times prior thereto in the Naphtha Hydrotreater (NHT) and Saturated Gas (Sat-Gas) where employees were exposed to inhalation, fire, and explosion hazards from potential releases of hazardous materials without ensure operating procedures were current and accurate for the following instances.       a. In the Naphtha Hydrotreater/Saturated Gas/ Unit Operating Limit List of Equipment, Procedure number 30.8.1    Bates: #00376:         . The "Sat Gas Vessel List" is incorrect. It should  be listed as Naphtha Hydrotreater Vessel List.         . The high temperature separator is listed as 30-V-2 that is incorrect. It should be listed as 30-V-1.         . Temperature is controlled with TIC-3002& is incorrect. It should be listed as temperature is controlled with TC-021.         . The low temperature separator is listed as 30-V-3 that is incorrect. It should be listed as 30-V-2.       Bates #00378: The "Naphtha Hydrotreater Vessel List" is incorrect. It should be listed as Saturated Gas Vessel List.       Bates #00379:  In the Debutanizer, 60-V-3A, it states "Bottom product from the Debutanizer is charge to the Splitter Tower (60-V-6)". This is incorrect. The Splitter Tower (60-V-6) was out of service.      Bates #00380: Splitter Tower (60-V-6) and its process safety information (PSI) are listed in the Sat-Gas Vessel list. This tower should be removed because it was out of the service. The new splitter (60-20-V) and its PSI should be added into this procedure.       b. In the "Emergency Procedure /Loss of Utilities", Procedure Number 30.2.7, Bates #00120.  In Step #5, it states"The 300-psig steam to the Splitter reboiler, 60-E-18, will stop". This is incorrect because the reboiler, 60-E-18, was out of service.      c. In the "Normal Start-Up Procedure/Naphtha Hydrotreater/Establishing Naphtha Circulation", Procedure Number 30.3.4, Bates #00155, in the step #7, it states"If Naphtha from the Crude Unit is not available, the Contact Accumulator (60-V-11) and the Stripper (60-V-10) can be established by lining Naphtha to the Splitter Bottoms Pumps (60-P-8A/B)."This is incorrect because Splitter Bottom Pumps (60-P-8A/B) were out of service.      d. The "Special Procedures/Naphtha Hydrotreater Chloride Scrubber (30-V-8) Adsorbent Change out Shutdown Procedure", Procedure Number 30.5.10, Bates #00211-#00217 was listed in the operating procedures. This procedure should be removed because the Booster Gas Chloride Scrubber (30-V-8) was out of service.      e. In the "Start-Up Procedures/Naphtha Hydrotreater /Isolation-Purging-Evacuation in Preparation for Start-Up", Procedure Number 30.3.1, Bates #00165, in step #18, it states "Line up chloride scrubber (30-V-8) for service". This step should be removed because the Booster Gas Chloride Scrubber (30-V-8) was out of service.