OSHA Inspection: ACCURATE WIRE, INC.

Issued

Feb 18, 2014

Penalty

Initial $1,600 · Current $860 Reduced

General-duty citation text

29 CFR 1910.111(b)(5)(v): Storage areas shall be kept free of readily ignitable materials such as waste, weeds, and long dry grass.    OUTSIDE:  The in and around the fenced storage area for the anhydrous ammonia tank was not kept free from readily ignitable material, such as (but not limited to) dried leaves.      ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $2,000 · Current $1,100 Reduced

General-duty citation text

29 CFR 1910.111(b)(10)(ii): Stationary storage installations must have at least two suitable gas masks in readily-accessible locations. Full-face masks with ammonia canisters that have been approved by NIOSH under 42 CFR part 84 are suitable for emergency action involving most anhydrous ammonia leaks, particularly leaks that occur outdoors. For respiratory protection in concentrated ammonia atmospheres, a self-contained breathing apparatus is required.    WORKSHOP/OUTSIDE:  The employer had not provided the employee with two (2) suitable full face piece respirators with ammonia canister for the employee during anhydrous ammonia releases.     ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.132(d)(1): The employer shall assess the workplace to determine if hazards are present, or are likely to be present, which necessitate the use of personal protective equipment (PPE). If such hazards are present, or likely to be present, the employer shall:  WORKSHOP/OUTSIDE:  The employer had not assessed the workplace to determine the necessitate and appropriate types of personal protective equipment (PPE), such as (but not limited to) full facepiece cartridge respirators for the employees during the ammonia releases.    ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $2,000 · Current $1,100 Reduced

General-duty citation text

29 CFR 1910.119(c)(1): Employers shall develop a written plan of action regarding the implementation of the employee participation required by this paragraph.    WORKSHOP:   A written plan of action for the implementation of the employee participation in the Process Safety Management of Anhydrous Ammonia was not developed and implemented.        ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(g)(1)(i): Each employee presently involved in operating a process, and each employee before being involved in operating a newly assigned process, shall be trained in an overview of the process and in the operating procedures as specified in paragraph (f) of this section. The training shall include emphasis on the specific safety and health hazards, emergency operations including shutdown, and safe work practices applicable to the employee's job tasks.   WORKSHOP:  The employees, involved in operating a process and procedures for the Process Safety management of the Anhydrous Ammonia were not trained at least in the elements specified in paragraphs (f)(1)(i) through (f)(1)(iv) of this section.   ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $2,000 · Current $1,100 Reduced

General-duty citation text

29 CFR 1910.119(d): The employer did not develop a written compilation of process safety information on hazardous chemicals in the process, the technology of the process, and the equipment in the process before conducting the process hazard analysis:    WORKSHOP:  The employer did not compile a written process safety information for the employees involved in the Process Safety Management of the Anhydrous Ammonia prior to conducting any process hazard analysis.    ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(e)(1): The employer shall perform an initial process hazard analysis (hazard evaluation) which is not only appropriate to the complexity of the processes, but also identified, evaluated and controlled the hazards involved in the process:   WORKSHOP:  The employer did not perform an initial process hazard analysis (hazard evaluation) that was not only appropriate to the complexity of, but also identified, evaluated and controlled the hazards where employees were engaged in the Process Safety Management with Anhydrous Ammonia.   ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(1): The employer shall 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 shall address at least the following elements listed in 29 CFR 1910.119(f)(1)(i) through (f)(1)(iv):  WORKSHOP:  The employer did not develop and implement written operating procedures that not only provided clear instructions for employees to safely conduct activities involved in the process safety of Anhydrous Ammonia, but also addressed at least the elements listed above.  ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $2,000 · Current $1,100 Reduced

General-duty citation text

29 CFR 1910.119(i)(1): The employer shall perform a pre-startup safety review for new facilities and for modified facilities when the modification is significant enough to require a change in the process safety information.    WORKSHOP:  A pre-start up safety review (PSSR) was not performed when the ammonia disassociator was started in the ammonia processing area at the #19 strand annealer.         ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(ii): The employer shall document that equipment complies with recognized and generally accepted good engineering practices.  WORKSHOP:  The employer did not document that the ammonia disassociator and its system at the #19 strand annealer complied with recognized and generally accepted good engineering practices.      ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $2,000 · Current $1,100 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment.    WORKSHOP:  The employer did not establish and implement written procedures to maintain the on-going mechanical integrity for piping, valves and others associated with the process utilizing the ammonia disassociator/process equipment.     ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(3): Training for process maintenance activities. The employer shall train each employee involved in maintaining the on-going integrity of process equipment in an overview of that process and its hazards and in the procedures applicable to the employee's job tasks to assure that the employee can perform the job tasks in a safe manner.  WORKSHOP:  The employees, involved in maintaining the on-going mechanical ntegrity of the ammonia disassociator equipment were not provided with appropriate information and training in an overview and it's hazards and in the procedures applicable to the employee's tasks to ensure for safe operation at all times.   ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $2,000 · Current $1,100 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(ii): Inspection and testing procedures shall follow recognized and generally accepted good engineering practices.    WORKSHOP:  The inspection and testing procedures performed on the ammonia disassociator/process equipment to maintain its mechanical integrity did not follow recognized and generally accepted good engineering practices.      ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(n): Emergency planning and response. The employer's emergency action plan did not include procedures for handling small releases:  WORKSITE: The employer's emergency action plan did not include procedures for handling small releases while performing the Anhydrous Ammonia disassociator process.   ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $2,000 · Current $1,100 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures shall be developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section.     WORKSHOP:  The hazardous energy control lockout/tagout procedures were generic and not written step-by-step, had not included alternative methods, in machine specifics for the employees during servicing and maintenance of equipment, such as (but not limited to) the furnaces, overhead crane, and annealing and shaping machines.    ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(7)(i): The employer shall provide training to ensure that the purpose and function of the energy control program are understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees. The training shall include the following:  WORKSHOP:  The employees, as authorized, affected and other typeswere not provided with training and information in the controlling of potentially hazardous and unexpected releases of energy sources (lockout/tagout) during servicing and maintenance of equipment, such as (but not limited to) the furnaces, overhead crane, and annealing and shaping machines.    ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Abate by

Apr 4, 2014

Penalty

Initial $1,600 · Current $860 Reduced

General-duty citation text

29 CFR 1910.178(l)(4)(ii): Refresher training in relevant topics shall be provided to the operator when a condition in the workplace has changed in a manner that could affect safe operation of the truck:    WORKSHOP:  The employee who had previously been trained on powered industrial truck (PIT) by a former employer was not re-trained and evaluated by the employer.

Issued

Feb 18, 2014

Penalty

Initial $1,600 · Current $860 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): Types of guarding. One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding methods are-barrier guards, two-hand tripping devices,electronic safety devices, etc.    WORKSHOP:      1.  The unused portions of the Wells rotating horizontal metal cutting bandsaw were unguarded.    ABATED DURING THE INSPECTION.       2.  The rotating chuck of the Harrison lathe was unguarded.       ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $1,600 · Current $860 Reduced

General-duty citation text

29 CFR 1910.304(f)(1)(iv): The overcurrent devices sahllbe readily accessible to each employee or authorized building management personnel:     A. WORKSHOP/ANNEALING DEPARTMENT:      The electrical panels/disconnects, having built-in overcurrent protection devices and located behind #20, #21, and #22 shaping machines, unknown identification were blocked with two chairs, red tray, broom, and a drum of dried powder hand soap.      ABATED DURING THE INSPECTION.         B. MAINTENANCE DEPARTMENT:      The electrical panel, having built-in overcurrent protection devices was blocked with a piece of wood and supplies.       ABATED DURING THE INSPECTION.

Issued

Feb 18, 2014

Penalty

Initial $1,200 · Current $860 Reduced

General-duty citation text

29 CFR 1910.305(g)(1)(i): Flexible cords and cables shall be approved for conditions of use and location.    WORKSHOP:  The flexible cord of the #5 wire drawing machine, unknown identification was cut and taped exposing the employees to the hazards of fire/burns and electrical shocks.      ABATED DURING THE INSPECTION.