OSHA Inspection: OILFIELD SOLUTIONS, INC.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $2,000 · Current $600 Reduced

General-duty citation text

29 CFR 1910.22(b)(1): Aisles and passageways were not kept clear and in good repair, with no obstruction across or in aisles that could create a hazard.    On or about March 21, 2013, in the Reactor and blending Buildings, pallets, totes and drums near Reactors #2 and #4 blocked the aisles and passageways. Elevated piping, pumps and hoses (used to transfer) were strung across the aisle ways in both the Reactor and Blending building. This condition exposed employees to a trip and slip hazards.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.23(c)(1): Open-sided floors and/or platforms four feet or more above adjacent floor or ground level were not guarded with standard railings, or equivalent, and toeboards:  On or about March 21, 2013, in the Reactor Building; two work platforms had no guardrails, exposing employees to falls of greater than four feet to the concrete floor below:     a)  The work platform leading up to the top of Reactor No.4 was missing guardrails at the end of the platform.       b)  The work platform next to Reactor No. 3 was not guarded with standard guardrails, or equivalent.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $1,600 · Current $1,600

General-duty citation text

29 CFR 1910.23(d)(1)(iii): Flight(s) of stairs with 4 or more risers, less than 44 inches wide and having both sides open were not equipped with one standard stair railing on each side:  On or about March 21, 2013, in the Reactor Building, the five-step stairway leading up to the working platform next to Reactor No. 3 did not have stair railing on the left side, exposing employees to a fall hazard.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.23(e)(1): Standard railing(s) did not consist of top rail, intermediate rail and/or posts and/or did not have a vertical height of 42 inches (106.7 cm) nominal from upper surface of top rail to floor, platform runway, or ramp level:  On or about March 21, 2013, in the Reactor Building, the five-step stairway handrail leading up to the working platform next to Reactor No. 3 did not have a mid-rail on the right side, exposing employees to fall hazards.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $2,800 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.37(a)(3): Exit routes were not free and/or unobstructed. Exit access was through a room that could be locked:    On or about March 21, 2013, exit routes were blocked and exit access went through a room that could be locked. This condition exposed employees to fire hazards:      a)  On the north side of the Main Storage Building, the exit door next to the first bay door was blocked with 5 gallon buckets of chemicals (Bio-Clear 1000), 5-gallon water jugs, boxes stacked on top of each other and equipment such as an unused electrical pump and tubular fixture lights stored in a box,    b)  On the north side of the Blending Building, the exit door adjacent to the first bay door was blocked with Company Trade Mark Blended Chemicals and equipment.    c)  On the east side and to the middle of the Blending Building, the exit door adjacent to the first bay door was blocked with Company Trade Mark Blended Chemicals and equipment. The exit door led to the main entry door which could be locked.    d)  On the eastside of the Reactor Building, the exit door was blocked with material and equipment.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $0 · Current $1,000

General-duty citation text

29 CFR 1910.157(c)(1): Portable fire extinguishers were not mounted, located and identified so that they were readily accessible without subjecting the employees to injuries:     On or about March 21, 2013, In the Reactor Building:      a)   A fire extinguisher was positioned directly below the controls of the overhead crane, between two 55-gallon chemical drums and hidden behind a box of material;    b)  A fire extinguisher was positioned near Reactor No. 5, obscured by the employee's lunch bag and full-faced respirator hanging from it. The fire extinguisher was behind a pallet with a protruding nail which was placed on top of 55-gallon chemical drums.

Issued

Jul 15, 2013

Abate by

Aug 29, 2013

Penalty

Initial $2,800 · Current $2,800

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 that consisted of at least the information specified in sections (d)(1)(i) through (d)(3)(i)(H):  On March 21, 2013, at and times theretofore, at the Oilfield Solutions facility, the employer did not complete a compilation of written process safety information, including but not limited to material of construction, material and energy balances, technology, P&ID's, design codes and operational limits for processes that contained highly hazardous chemicals.

Issued

Jul 15, 2013

Abate by

Aug 29, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.119(e)(1): The employer did not perform an initial process hazard analysis (hazard evaluation) on processes covered by 29 CFR 1910.119:    On or about March 21, 2013, the employer had not performed an initial process hazard analysis (hazard evaluation) on processes including but not limited to processes involving formaldehyde. The employer did not identify, evaluate, and control the hazards involved in the processes, exposing employees to explosion hazards and the release of highly hazardous chemicals.

Issued

Jul 15, 2013

Abate by

Aug 29, 2013

Penalty

Initial $2,800 · Current $2,800

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 consistent with the process safety information and that addressed at least the elements outlined in (f)(1)(i) through (f)(4) of this section:  On March 21, 2013 and times theretofore, the employer did not develop and implement written operating procedures when employees were operating the reactors and mixing stations using only a mixing sheet.  Employees had not been provided written process instructions and procedures that addressed all precautions and phases of operations.

Issued

Jul 15, 2013

Abate by

Aug 29, 2013

Penalty

Initial $2,000 · Current $2,000

General-duty citation text

29 CFR 1910.119(g)(1): 29 CFR 1910.119(g)(1):  The employer did not provide initial training on operating procedures for employees required to work on or near a covered process.  On or about March 21, 2013 and times theretofore, at the Oilfield Solutions facility, in Midland, TX, the employer did not ensure that employees were trained on operating procedures for all phases of operation and did not develop a process to assure employees understood and adhere to the procedures.

Issued

Jul 15, 2013

Abate by

Aug 29, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish written procedures to maintain the on-going integrity of process equipment:   At the Oilfield Solutions facility, in Midland, TX, on or about March 21, 2013 and times theretofore, the employer did not develop and implement written maintenance procedures to maintain the on-going of process equipment, including but not limited to reactors RX-1, RX-2, RX-3, RX-4, RX-5, process hoses and piping, process heat exchangers and coolers, exposing employees to explosion and fire hazards, and the release of highly hazardous chemicals.

Issued

Jul 15, 2013

Abate by

Aug 29, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.119(j)(4)(i): The employer did not perform inspection and tests on process equipment that followed the requirements set forth in (j)(4)(ii) through (j)(4)(iv):    At the Oilfield Solutions facility, in Midland, TX, on or about March 21, 2013 and times theretofore, the employer did not  perform inspections and testing of process equipment including but not limited to reactors, blenders, hoses, process heat exchangers and coolers to ensure its fitness for continued service.

Issued

Jul 15, 2013

Abate by

Aug 29, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

1910.119(j)(5): The employer did not correct deficiencies in equipment that were 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:  On or about April 18, 2013, at the Oilfield Solutions facility, in Midland, TX, in the reactor area of Reactor/production building #2, the employer did not ensure that RX-1, RX-2, RX-3, RX-4 and RX-5 had relief devices installed to facilitate relief in the event of an emergency. (ASME Section VIII requires all vessels and tanks operating above 15 psi to have pressure relief devices installed).

Issued

Jul 15, 2013

Abate by

Aug 29, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

1910.119(d)(3)(ii): The employer did not document that equipment complied with recognized and generally accepted good engineering practices.  At the Oilfield Solutions facility, in Midland, TX the employer failed to ensure that RX-1, RX-2, RX-3, RX-4 and RX-5 were constructed and installed in accordance with Recognized and Generally Accepted Good Engineering Practices. The employer did not ensure that the aforementioned reactors had relief devices installed on them to assist in providing pressure relief in the event there was an over pressure situation.  Examples of such (RAGAGEP) include but are not limited to ASME Section VIII - Division 1 and ANSI/API Standard 521.

Issued

Jul 15, 2013

Abate by

Aug 1, 2013

Penalty

Initial $2,800 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.147(c)(1): The employer did not establish a program consisting of energy control procedures, 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 shall be isolated from the energy source and rendered inoperative:      On or about March 21, 2013, the employer did not develop and implement a program for the control of hazardous energy which included energy control procedures, employee training, and periodic inspection. Employees performing maintenance on five reactors, blenders, motors and other equipment were exposed to the unexpected startup and release of hazardous energy.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

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

General-duty citation text

29 CFR 1910.151(c): Where employees were exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body were not provided within the work area for immediate emergency use:    On or about March 21, 2013, three instances where the employer did not provide employees with sufficient facilities for quick drenching or flushing of the eyes and body for emergency use in the event of contact with chemicals such as but not limited to Benzyl Chloride and Formaldehyde. This condition exposed employees to eye, skin and inhalation chemical hazards.       a)  In the Reactor Building, eyewash station was inoperative.     b)  In the blending Building, eyewash station was inoperative.     c)  In the blending Building, immediate access to the drench/shower station was restricted because chemical containers blocked access and the door to the room containing the emergency shower was closed.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $1,600 · Current $800 Reduced

General-duty citation text

29 CFR 1910.253(b)(2)(ii): Assigned storage spaces for cylinders was not located away from elevators, stairs, or gangways where cylinders could not be knocked over or damaged by passing or falling objects, or subject to tampering by unauthorized persons:     On or about March 21, 2013, an oxygen cylinder and acetylene cylinder were unsecured next to the north-side bay door entry of the Reactor Building. The acetylene cylinder was leaning against a structural beam, exposing employees to struck-by hazards.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.253(b)(2)(iv): Valve protection caps, where cylinders were designed to accept caps, were not always in place, hand-tight, except when cylinders were in use or connected for use:    On or about March 21, 2013, an oxygen cylinder and acetylene cylinder were unsecured next to the north-side bay door entry of the Reactor Building. Welding attachments were left on and valve protection caps were not utilized, exposing employees to struck-by hazards.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $1,600 · Current $1,000 Reduced

General-duty citation text

1910.303(b)(7)(iii): Internal parts of electrical equipment, including busbars, wiring terminals, insulators, and other surfaces, were damaged or contaminated by foreign materials such as paint, plaster, cleaners, abrasives, or corrosive residues:    On or about March 21, 2013, foreign materials such as abrasives or corrosive residues contaminated the control box providing various electrical outputs within the Blending Building. This condition exposed employees to fire and electrical hazards.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

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

General-duty citation text

29 CFR 1910.305(b)(1)(i): Conductors entering cutout boxes, cabinets, or fittings were not protected from abrasions:    On or about March 21, 2013, conductors were not protected from abrasions, exposing employees to electrical hazards      a)  At the Toshiba Control Box located in the Blending Building near on the south end near the bay door. Individual live conductors exited the conduit and entered the control box, with no abrasion protection.     b)  At the electrical distribution box in the Blending Building near the south end adjacent to the bay door.  A flexible cord ran through a hole cut out of the back right corner of the box, without a bushing. The hole did not have smooth, well-rounded surfaces on which the cord could bear.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $2,800 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.305(d)(2): Panelboards were not mounted in cabinets, cutout boxes, or enclosures designed for the purpose and were not dead front:      On or about March 21, 2013, in the Blending Building near on the south end near the bay door the electrical distribution box providing various electrical outputs throughout the building was missing a dead front, exposing employees to electrical hazards.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(f)(2): Each service, feeder, and branch circuit, at its disconnecting means or overcurrent device, was not legibly marked to indicate its purpose, nor located and arranged so the purpose was evident:  On or about March 21, 2013, electrical panels were not legibly marked to indicate their purpose, exposing employees to electrical hazards:    a)  A panel in the Blending Building at the south end near the bay door the electrical panel was not legibly marked to indicate the circuits it controlled.   b)  A panel on the south side and outside of the Blending Building was not marked to indicate its purpose.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $2,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in boxes, cabinets, or fittings were not effectively closed:    On or about March 21, 2013, the electrical control box used to monitor the amount of chemical added into Reactor No.1 had an unused opening, exposing employees to electrical and fire hazards.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

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

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(A): Flexible cords and/or cables were used as a substitute for the fixed wiring of a structure:    On or about March 21, 2013, the Blending Mixing Machine located to the south east of the Blending Building was wired using an extension cord. The extension cord was cut at both ends and wired directly from the Blending Mixing Machine to the Distribution Control Box. This condition exposed employees to electrical shock/electrocution hazards.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $2,000 · Current $1,000 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 21, 2013, in the Blending Building near on the south end near the bay door the electrical distribution box providing various electrical outputs throughout the building had an electrical cord connected to fittings, no strain relief was provided that would prevent pull from being directly transmitted to joints or terminal screws. This condition exposed employees to electrical shock/electrocution hazards.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.334(a)(2)(i): Portable cord and plug connected equipment and flexible cord sets (extension cords) were not visually inspected before use on any shift for external defects (such as loose parts, deformed and missing pins, or damage to outer jacket or insulation) and for evidence of possible internal damage (such as pinched or crushed outer jacket):  On or about March 21, 2013, the orange extension cord connected to the pipe heating cable in front of Reactor No.2 had its outer jacket damaged; a visual observation found the outer jacket was pierced through to the bare conductor. This condition exposed employees to electrical shock/electrocution hazards.

Issued

Jul 15, 2013

Abate by

Aug 1, 2013

Penalty

Initial $2,800 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.1048(d)(1)(i): Employees of a workplace covered by this standard were not monitored to determine their exposure to formaldehyde:     On or about March 21, 2013, Operators working in the Reactor Building were exposed to Formaldehyde and Paraformaldehyde routinely.       a)  When using Formaldehyde, Operators were instructed to disconnect the Formaldehyde hose after each use and have contents drip into a five-gallon barrel.    b)  When using Paraformaldehyde, Operators were instructed to load the Paraformaldehyde onto a hopper platform then reach in and untie the bag so contents can fall into the hopper.

Issued

Jul 15, 2013

Abate by

Aug 1, 2013

Penalty

Initial $2,800 · Current $0 Reduced

General-duty citation text

29 CFR 1910.1048(j): For operations involving formaldehyde liquids or gas, the employer did not conduct a program to detect leaks and spills, including regular visual inspections:    On or about March 21, 2013, the employer did not establish appropriate procedures/program to detect leaks and spills, including regular visual inspections the formaldehyde hose(s) used in the Reactor process.

Issued

Jul 15, 2013

Abate by

Aug 1, 2013

Penalty

Initial $2,800 · Current $0 Reduced

General-duty citation text

29 CFR 1910.1048(k): When there was the possibility of an emergency involving formaldehyde, the employer did not ensure  that appropriate procedures were adopted to minimize injury and loss of life and implemented in the event of an emergency:    On or about March 21, 2013, the employer did not establish appropriate procedures for Operators working in the Reactor Building to minimize injury and loss of life and implemented in the event of emergency involving formaldehyde.

Issued

Jul 15, 2013

Abate by

Aug 1, 2013

Penalty

Initial $2,800 · Current $2,800

General-duty citation text

29 CFR 1910.1200(e)(1): Employer had not developed or implemented a written hazard communication program:     On or about March 21, 2013, the employer did not develop, implement, and/or maintain at the workplace a written hazard communication program that addressed the third element of a written hazard communication program, employee information and training on hazards associated with  chemicals used at Respondent's workplace.

Issued

Jul 15, 2013

Abate by

Jul 25, 2013

Penalty

Initial $0 · Current $0

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 March 21, 2013, the employer did not ensure or could not certify the training and evaluation of operators of the Toyota Forklift, Model #7FDU30.

Issued

Jul 15, 2013

Abate by

Jul 19, 2013

Penalty

Initial $400 · Current $0 Reduced

General-duty citation text

29 CFR 1904.32(b)(6): The Summary of Work-Related Injuries and Illnesses (OSHA Form 300A or equivalent) for the previous year was not posted between February 1st and April 30th.     On or about March 21, 2013, the employer had not post the OSHA Form 300-A Summary of Work-Related Injuries and Illnesses for the year 2012 within the establishment.