OSHA Inspection: WELCO ACETYLENE CORP.

Issued

Nov 27, 2013

Penalty

Initial $2,000 · Current $1,268 Reduced

General-duty citation text

29 CFR 1910.106(b)(2)(vii)(c)(3): Walls of the diked area were not designed to be liquid tight:     a) Establishment - outdoor area - Acetone tank     The containment wall for the 3500 gallon atmospheric storage tank containing acetone, a Category 1 flammable liquid, had an open drain pipe designed into the dike.     violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Feb 13, 2014

Penalty

Initial $2,000 · Current $1,268 Reduced

General-duty citation text

29 CFR 1910.106(e)(2)(iv)(d): Flammable liquids were not drawn from or transferred into vessels, containers, or portable tanks within a building only through a closed piping system, from safety cans, by means of a device drawing through the top, or from a container or portable tanks by gravity through an approved self-closing valve:     a) Establishment - cylinder charging room     Employees dispensed acetone, a Category 1 flammable liquid, into compressed gas cylinders through in-plant piping with manually closing valves.     Violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Penalty

Initial $2,000 · Current $1,268 Reduced

General-duty citation text

29 CFR 1910.106(e)(9)(iii): Combustible waste material and residues in a building or unit operating area were not kept to a minimum, stored in covered metal receptacles and disposed of daily:      a) Establishment - cylinder charging room      Paper towels with acetone were disposed in open plastic trash receptacles.     Violation observed on or about 6/11/2013

Issued

Nov 27, 2013

Abate by

Feb 13, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(d): The employer did not complete a compilation of written process safety information pertaining to the equipment in the process, the technology of the process, and the equipment in the process before conducting the process hazard analysis:    a) Establishment    The employer failed to compile PSI before conducting the PHA to include the required schedule for inspection, testing and servicing of equipment such as but not limited to the compressor oil, belts, and crankcase.    Violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Feb 13, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): Process safety information pertaining to the equipment in the process did not include the piping and instrument diagrams (P&ID's):      a) Establishment - compressor room   The employer did not ensure that the written process safety information included all the necessary information pertaining to the equipment in the process when an existing shutoff valve between Compressors # 1,2,3, & 4 and the high pressure dryer was not represented on P&ID sheet # B09, B11, B13, & B15.     b) Establishment - compressor room    The employer did not ensure that written process safety information including all the necessary information pertaining to the equipment in the process in that the existing pressure gauge and valve at the bottom of the high pressure dryer system's flash arrestor for systems #1,2,3, & 4 were not represented on P&ID sheet # B09, B11, B13 & B15.      c) Establishment - compressor room    The employer did not ensure that written process safety information accurately reflected existing equipment in the process in that valve #X168J in high pressure dryer system #1, valve #X181J in high pressure dryer system #2, valve #X194J in high pressure dryer system #3, however these valves do not exist in the plant process.      d) Establishment - fill room   The employer did not ensure that the written process safety information included all the necessary information pertaining to the equipment in the process when an existing valve installed in Fill Rack #7 was not represented on P&ID sheet # B17.     e) Establishment - trailer manifold   The employer did not ensure that the written process safety information included all the necessary information pertaining to the equipment in the process when the fail safe position of the nitrogen emergency automatic valve was not identified on P&ID sheet # B02.     Violations observed on or about 5/30/2013

Issued

Nov 27, 2013

Abate by

Apr 16, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(e)(3)(v): The process hazard analysis did not address facility siting:      a) Establishment      The 2007 and 2012 PHAs did not address potential acetylene vapor cloud explosion scenarios and the associated over pressure impact on an occupied wooded framed building located 25 feet from the compressor room and approximately 100 feet from acetylene trailers.     Violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Feb 13, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(e)(5): The employer did not establish a system to assure that the recommendations were resolved in a timely manner and that the resolution was documented:    a) Establishment - PHA  A 2007 PHA line 1.24 action item was to update P&IDs with piping specifications. The current P&IDs do not include piping specifications.    b) Establishment - PHA  A 2007 PHA line 1.7 action item was to update P&ID  sheet #B02 to reflect correctly PRV 113 pressure setting of 20 PSIG. The P&ID currently has PRV 113 labeled with a pressure setting of 15 PSIG.    Violation observed on or about 5/30/13.

Issued

Nov 27, 2013

Abate by

Feb 13, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(f)(1): The employer did not develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process:       a) Establishment - Rexarc Generator    The employer did not write operating procedure for starting up the Rexarc Generator after a prolonged shutdown or return to service.    Violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Feb 13, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(f)(1)(iv): The employer's written operating procedures did not address requirements for the safety systems and their functions:     a) Establishment   The "Acetylene Operations Critical Operating Parameters" chart did not include the critical operating parameters and safety systems, including but not limited to PRVs and nitrogen emergency shutdown system, for the acetylene trailer operation     b) Establishment   The employer did not specify safety systems, including but not limited to PRVs and mercoid switches, and their function in operating procedures, including but not limited to, "Acetylene Compressor Start-up Procedure," "Rexarc High Pressure Dryer Operating Procedure," "Acetylene Compressor Shut-down Procedure," and/or the "Acetylene Operations Critical Operating Parameters."     Violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Feb 13, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(f)(4): The employer did not develop and implement safe work practices to provide for the control of hazards during operations such as lockout/tagout; confined space entry; opening process equipment or piping; and control over entrance into a facility by maintenance, contractor, laboratory, or other support personnel:      a) Establishment    The employer failed to implement an adequate safe work practice regarding control and accountability of outside contractors entering/exiting the facility.    Violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Apr 16, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(h)(2)(i): The employer, when selecting a contractor , did not obtain and evaluate information regarding the contract employer's safety performance and program:     a) Establishment - contractor safety     The employer did not evaluate the health and safety programs nor the performance of contractors including, but not limited to electrical, fire suppression, and maintenance contractors that worked on the covered process.     Violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Apr 16, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish and implement written procedures to maintain the on-going integrity of process equipment:    a) Establishment    The employer did not establish and implement written procedures for inspecting process piping containing acetylene gas at pressures of 5 to 400 PSI.    b) Establishment    The employer did not establish and implement written procedures for inspecting, testing and changing out flash arrestors in the acetylene filling manifold.      Violations observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Apr 16, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(ii): Inspections and testing procedures performed on process equipment to maintain its mechanical integrity did not follow recognized and generally accepted good engineering practices (RAGAGEP):     a) Establishment - process piping     The employer did not follow RAGAGEP such as, but not limited to, NFPA 51A when they failed to conduct hydrostatic testing inspection as required on process piping containing acetylene at 5 to 400 PSI.     Violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Feb 13, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(iv): The documentation of each inspection and test that was performed on the process did not 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:     a) Establishment    The acetylene filling process has been active since 2002, the employer failed to maintain documentation of data for inspection and testing activities conducted prior to 2012.    Violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Feb 13, 2014

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(j)(5): The employer did not correct deficiencies in equipment that were outside acceptable limits (defined by the process safety information on paragraph (d) of this section) before use:     a) Establishment - compressor room   Mercoid switches in panel were missing cover plates.   Violation observed on or about 5/30/2013     b) Establishment - cylinder charging room   Pigtails for small cylinders (B & MC) were used to fill cylinders with acetylene gas while the reinforcement cover was pinched and frayed.   Violation observed on or about 5/30/2013     c) Establishment - cylinder charging room   Employees charged compressed gas cylinders on line 2 while flash arrestor was labeled "bad".   Violation observed on or about 5/30/2013     d) Establishment - compressor room   Compressor 4 was in use with a vibrating acetylene line due to motor belt deficiency.   Violation observed on or about 5/30/2013

Issued

Nov 27, 2013

Penalty

Initial $2,800 · Current $1,820 Reduced

General-duty citation text

29 CFR 1910.119(l)(5): When a change covered by this paragraph resulted in a change in the operating procedures or practices required by paragraph (f) of this section, such procedures or practices were not updated accordingly:    a) Establishment - compressor room    Operating procedures were not updated after a change to the high pressure dryer manifold affected a change to the dryer condensate draining process.    Violation observed on or about 5/30/2013.

Issued

Nov 27, 2013

Abate by

Mar 14, 2014

Penalty

Initial $2,000 · Current $1,268 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:    a) Establishment    Employees locked out equipment, including but not limited to compressors, to conduct service/repairs without equipment specific procedures.    Violation observed on or about 6/14/2013

Issued

Nov 27, 2013

Penalty

Initial $2,000 · Current $1,268 Reduced

General-duty citation text

29 CFR 1910.178(l)(1)(i): The employer did not ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (l):     a) Establishment     Employees operated fork trucks without completing operator training. Fork trucks were used to move empty and full tanks of acetylene gas.     Violation observed on or about 5/30/2013.