OSHA Inspection: STEPAN COMPANY

Issued

2014-02-03 00:00:00

Abate by

2014-03-21 00:00:00

Penalty

Initial $5000.00 · Current $2500.00 Reduced

General-duty citation text

29 CFR 1910.134(d)(1)(i): The employer shall select and provide an appropriate respirator based on the respiratory hazard(s) to which the worker is exposed and workplace and user factors that affect respirator performance and reliability:    On or about November 7, 2013, an employee required to perform Operator duties entered the Sulfur Trioxide (SO3) Hot Room to investigate the cause/source of a leak.  The employee entered the room wearing a full-face air-purifying cartridge respirator (APF 50) that was provided in the work area by the employer.  The employer did not select and provide an appropriate respirator based on the unknown respiratory hazard(s) to which the worker was exposed.

Issued

2014-02-03 00:00:00

Abate by

2014-03-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.134(d)(1)(iii): The employer shall identify and evaluate the respiratory hazard(s) in the workplace; this evaluation shall include a reasonable estimate of employee exposures to respiratory hazard(s) and an identification of the contaminant's chemical state and physical form. Where the employer cannot identify or reasonably estimate the employee exposure, the employer shall consider the atmosphere to be IDLH:  On or about November 7, 2014, in the facility, an employee required to perform Operator duties entered the Sulfur Trioxide (SO3) Hot Room to investigate the cause/source of a leak.  The employee entered the room wearing a during a full-facepiece air-purifying cartridge respirator (APF 50) provided in the work area by the employer.  Where the employer could not identify or reasonably estimate the employee exposure, the employer did not consider the atmosphere to be IDLH.

Issued

2014-02-03 00:00:00

Abate by

2014-03-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.134(k)(1)(ii): The employer shall provide effective training to employees who are required to use respirators, including, but not limited to, ensuring that each employee can demonstrate knowledge of what the limitations and capabilities of the respirator are:  On or about November 7, 2013, in the facility, an employee required to perform Operator duties entered the Sulfur Trioxide (SO3) Hot Room to investigate the cause/source of a leak.  The employee entered the room wearing a full-face air-purifying cartridge respirator (APF 50) provided in the work area by the employer.  The employer did not provide effective training of what the limitations and capabilities of the respirator were.

Issued

2014-02-03 00:00:00

Abate by

2014-03-21 00:00:00

Penalty

Initial $5000.00 · Current $2500.00 Reduced

General-duty citation text

29 CFR 1910.165(b)(1): The employee alarm system shall provide warning for necessary emergency action as called for in the emergency action plan, or for reaction time for safe escape of employees from the workplace or the immediate work area, or both:    On or about November 5 & 7, 2013, in the facility, contract employees were exposed to contact with airborne releases/leaks of hazardous materials from process equipment and/or buildings:    a) On or about November 5, 2013, twenty-one (21) contract employees required to work in the vicinity of the Dowtherm system were exposed to Therminol VP-1 vapor/mist from an overpressure event in process equipment.    b) On or about November 7, 2013, four (4) contract employees required to work in the vicinity of the Sulfur Trioxide (SO3) Hot Room, were exposed to Sulfur Trioxide and/or Sulfuric Acid vapor/mist from a leak in process equipment and room.    The employee alarm system did not provide warning for necessary emergency action as called for in the emergency action plan, or for reaction time for safe escape of the contract employees from the workplace or the immediate work area, or both.  As such, contract employees continued working until exposed to the vapor/mist release.

Issued

2014-02-03 00:00:00

Abate by

2014-03-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.165(d)(1): The employer shall assure that all employee alarm systems are maintained in operating condition except when undergoing repairs or maintenance:  On or about November 7, 2013, four (4) contract employees required to work in the vicinity of the Sulfur Trioxide (SO3) Hot Room were exposed to Sulfur Trioxide and/or Sulfuric Acid vapor/mist from a leak release in process equipment and room.  The audible horn alarm system did not activate due to blown fuses.  As such, contract employees continued working until exposed to the vapor/mist release.

Issued

2014-02-03 00:00:00

Abate by

2014-03-21 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.165(d)(2): The employer shall assure that a test of the reliability and adequacy of non-supervised employee alarm systems is made every two months. A different actuation device shall be used in each test of a multi-actuation device system so that no individual device is used for two consecutive tests:  On or about November 7, 2013, four (4) contract employees required to work in the vicinity of the Sulfur Trioxide (SO3) Hot Room were exposed to Sulfur Trioxide and/or Sulfuric Acid vapor/mist from a leak release in process equipment and room.  The audible horn alarm system did not activate due to blown fuses. As such, contract employees continued working until exposed to the vapor/mist release.  The employer did not assure that a test of the reliability and adequacy of non-supervised employee alarm systems was made every two months.