OSHA Inspection: PPG INDUSTRIES

Issued

2013-12-12 00:00:00

Abate by

2014-02-28 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(d): Process safety information (PSI). In accordance with the schedule set forth in paragraph (e)(1) of this section, the employer shall complete a compilation of written process safety information before conducting any process hazard analysis required by the standard. The compilation of written process safety information is to enable the employer and the employees involved in operating the process to identify and understand the hazards posed by those processes involving highly hazardous chemicals. This process safety information shall include information pertaining to the hazards of the highly hazardous chemicals used or produced by the process, information pertaining to the technology of the process, and information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:    29 CFR 1910.119(d)(3)(i)(E): Ventilation system design;    a. The company did not have complete PSI for the ventilation system in the Paint Plant, Back tank Department. The PSI was inadequate in that the ventilation did not include fundamental design information such as but not limited to intended use, calculations, assumptions, balancing information between inlet dilution ventilation and exhaust ventilation and reasonable worst case scenario information. Without adequate ventilation system PSI, the employer has increased risk for fire and explosion.

Issued

2013-12-12 00:00:00

Abate by

2014-03-28 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(d): Process safety information (PSI). In accordance with the schedule set forth in paragraph (e)(1) of this section, the employer shall complete a compilation of written process safety information before conducting any process hazard analysis required by the standard. The compilation of written process safety information is to enable the employer and the employees involved in operating the process to identify and understand the hazards posed by those processes involving highly hazardous chemicals. This process safety information shall include information pertaining to the hazards of the highly hazardous chemicals used or produced by the process, information pertaining to the technology of the process, and information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include:  29 CFR 1910.119(d)(3)(i)(F): Design codes and standards employed;    a. The PSI for the back tank department did not clearly and specifically identify which design codes and standards were incorporated.

Issued

2013-12-12 00:00:00

Penalty

Initial $6600.00 · Current $6600.00

General-duty citation text

29 CFR 1910.119(j)(4)(i): Mechanical integrity. Inspection and testing. Inspections and tests shall be performed on process equipment.  a. The employer failed to inspect and test emergency stop buttons on the M2, M3, M4, and M5 lines for functionality as part of the emergency shutdown systems. Employees in the back tank department were exposed to a potential release of flammable material, fire, or explosion.    b. The employer failed to perform routine tests and inspection to ensure system operability for ventilation systems in the back tank area; Ventilation systems in the back tank area are used to control flammable vapor emissions.

Issued

2013-12-12 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(j)(4)(iv): The employer shall document each inspection and test that has been performed on process equipment. The documentation shall 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. The employer did not document the testing and inspection of emergency stops on process equipment in the SM Mills area of the back tank department.

Issued

2013-12-12 00:00:00

Abate by

2015-04-27 00:00:00

Penalty

Initial $7000.00 · Current $6000.00 Reduced

General-duty citation text

29 CFR 1910.307(c): Electrical installations. Equipment, wiring methods, and installations of equipment in hazardous (classified) locations shall be intrinsically safe, approved for the hazardous (classified) location, or safe for the hazardous (classified) location.     a. In the back tank department the case packer is not rated for Class 1 hazardous location; thereby due to this potential ignition source exposing employees to an explosion or fire hazard.    b. In the back tank department there was a 480 VAC 3 phase breaker panel box that was not rated for a Class 1 hazardous location; thereby due to this potential ignition source exposing employees to an explosion or fire hazard.    c. In the back tank department the employer had a 480 VAC knife switch that was not rated for a Class 1 hazardous location; thereby due to this potential ignition source exposing employees to an explosion or fire hazard.     d. In the back tank department the employer had a 600 VAC knife switch that were not rated for installation in a Class 1 hazardous location; thereby due to this potential ignition source exposing employees to an explosion or fire hazard.

Issued

2013-12-12 00:00:00

Abate by

2014-02-28 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer shall conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirements of this standard are being followed.    a. The employer did not conduct a periodic inspection of operators performing required duties covered by this part. In the back tank department, operators apply locks during the performance of process equipment cleaning, such as spill cleanup in the casepacker. During these activities, employees have exposure to potential electrocution, shock, fire and explosion related hazards.

Issued

2013-12-12 00:00:00

Abate by

2015-04-15 00:00:00

Penalty

Initial $5500.00 · Current $1000.00 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(C): Information pertaining to the equipment in the process. Information pertaining to the equipment in the process shall include: Electrical classification;    a. The employers Process Safety Information (PSI) was inadequate, in that it identified the back tank area as a Class 1 Division 1 Hazardous location, however 10 feet above the floor level the company installed Class 1 Division 2 rated electrical equipment and the case packer area involves multiple pieces of unclassified electrical equipment. The inconsistency is not properly documented by the PSI and poses a potential hazard for fire or explosion to employees.

Issued

2013-12-12 00:00:00

Abate by

2015-04-27 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(l)(2)(ii): The procedures shall assure that the following considerations are addressed prior to any change: Impact of change on safety and health;    a. The employer failed to address all the impacts on safety and health related to MOC 15750 - an electrical reclassification project for new equipment installation in the back tank area of the Paint plant. The safety and health impact associated with flammable vapor ignition was not adequately addressed.