OSHA Inspection: ABBYLAND FOODS, INC.

Issued

Mar 28, 2014

Abate by

Jul 3, 2014

Penalty

Initial $3,000 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.119(d)(2)(i)(A): The employer's block flow diagrams or simplified process flow diagrams were not accurate and did not represent equipment that was existing and was part of the process:    a) The ARS-1 Process Flow Diagram indicated a 6 inch HTS X-Conn pipe line to the new ammonia refrigeration. The 6 inch HTS X-Conn pipe line was removed in 2010.

Issued

Mar 28, 2014

Abate by

Jul 3, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(2)(i)(C): Process safety information pertaining to the technology of the process did not include the maximum intended quantity:  a) The employer had not calculated and documented the maximum intended quantity of ammonia for ARS-1.

Issued

Mar 28, 2014

Abate by

Jul 3, 2014

Penalty

Initial $5,000 · Current $3,500 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): The employer's piping and instrument diagrams were not accurate and did not represent equipment that was existing and was part of the process:     a) Valves associated with the North Phoenix connecting piping tagged with numbers 1971, 1972, 1973, 1974, 1975, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988 and 1989 were correctly indicated, but the valve numbers were not notated on P&ID page 4 of 4.     b) The red line drawing for the Ice Flaker on P&ID page 4 of 4 was missing the associated valves, pressure relief device and strainer installed on its connecting piping.    c) Valve number 1571 associated with the connecting piping for Evaporator UC24 was missing its identification tag.    d) Valve numbers 1353, 1354 and 1356 associated with the connecting piping for Condenser CN02 were missing their identification tags.    e) Valve tagged with number 0735 associated with Screw Compressor #4 connecting piping was correctly indicated on P&ID 2 of 4, but the valve number was not notated on P&ID 2 of 4.    f) P&ID 2 of 4 indicates a 1 inch RV pipe section from valve number 0699 to the T-junction with a 2 inch RV pipe line. However, the 1 inch RV pipe section from valve number 0699 to the T-junction with a 2 inch RV pipe line is not physically there.    g) P&ID 2 of 4 does not indicate a valve identified as number 0689 on a 2.5 inch LTRL pipe section being present between the T-junction with the LTRL piping connecting Pump #1 and Pump #2 for Vessel VS05 and valve 0753.    h) The Vessel VS05 oil pot, along with its associated piping and other components, is not indicated on P&ID 2 of 4.

Issued

Mar 28, 2014

Abate by

Jul 3, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(G): The employer did not develop energy balances for the equipment that was part of the process:  a) The employer had not developed the energy balance information for ARS-1.

Issued

Mar 28, 2014

Abate by

Dec 31, 2014

Penalty

Initial $5,000 · Current $3,500 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D): The employer did not develop relief system design and design basis for the equipment that was part of the process:    a) The employer did not verify the existing relief system met any recognized and generally accepted good engineering practices for ARS-1.

Issued

Mar 28, 2014

Abate by

Dec 31, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(iii): For existing equipment designed and constructed in accordance with codes, standards, or practices no longer in general use, the employer did not determine and document that the equipment in the process was designed, maintained, inspected, tested, and operating in a safe manner:  a) The employer was not able to verify the ARS-1 relief system met the existing Wisconsin Building Codes when the ammonia refrigeration was built and continued to do so nor determine if the ARS-1 relief system currently met any recognized and generally accepted good engineering practices.

Issued

Mar 28, 2014

Abate by

Oct 17, 2014

Penalty

Initial $5,000 · Current $3,500 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(E): The employer did not develop and/or maintain ventilation system design for the equipment that was part of the process:     a) The employer did not verify the existing ventilation system for the ARS-1 engine room met the company selected design basis.

Issued

Mar 28, 2014

Abate by

Oct 17, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.307(f)(10): The employer did not utilize protection techniques that met the requirements of paragraph (c) of 29 CFR 1910.307:  a) The employer did not install electrical components meeting Class 1, division 2 specifications nor ensure the emergency ventilation system exceeded the requirement for reclassifying an ammonia engine room for ARS-1 engine room.

Issued

Mar 28, 2014

Abate by

Dec 31, 2014

Penalty

Initial $5,000 · Current $3,500 Reduced

General-duty citation text

29 CFR 1910.119(e)(5): The employer did not assure that Process Hazard Analysis (PHA) recommendations were resolved in a timely manner:    a) A PHA finding from before 2005 indicated the employer did not have calculations showing the ARS-1 pressure relief discharges into a common header met codes. The employer had not completed the required calculations by November 13, 2013.    b) A PHA finding from before 2005 indicated the employer did not have design calculations showing the pressure relief valves for ARS-1 were correctly sized. The employer had not completed the required design review and calculations by November 13, 2013.

Issued

Mar 28, 2014

Abate by

Dec 31, 2014

Penalty

Initial $0 · Current $0

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 further use or in a safe and timely manner when necessary means were taken to assure safe operation:   a)  The employer had not evaluated and ensured the appropriate sized pressure relief valves were installed when a Process Hazard Analysis from before 2005 indicated the employer was unable to verify the ARS-1 pressure relief valves were properly sized and complied with recognized and generally accepted good engineering practices before November 13, 2013.  b)  The employer had not evaluated and ensured the appropriate sized and arranged pressure relief discharge piping was installed when a Process Hazard Analysis from before 2005 indicated the employer was unable to verify the ARS-1 pressure-relief discharge piping complied with recognized and generally accepted good engineering practices before November 13, 2013.  c)  The employer had not evaluated and ensured the appropriate sized and designed ventilation system was installed when a March 17, 18, 19 and 24th 2010 Process Safety Compliance Audit finding indicated the employer was unable to determine the south engine room ventilation system physical layout and cfm exchange exceeded the requirements needed for the south engine room to be exempted from Class 1, division 2 electrical requirements.

Issued

Mar 28, 2014

Abate by

Dec 31, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(o)(4): The employer did not promptly determine and document an appropriate response to each of the findings of the compliance audit, and document that deficiencies have been corrected:  a)  The employer's March 17, 18, 19 and 24th, 2010 Process Safety Compliance Audit findings reference number 39: "There is no maximum load calculation on file for the south system." had not been corrected by November 13, 2013.  b) The employer's March 17, 18, 19 and 24th, 2010 Process Safety Compliance Audit findings reference number 45: "No design calculation for the south engine room is specified. Physical layout and cfm exchange needs to be determined to be exempted from Class 1 division 2 requirements." had not been corrected by November 13, 2013.  c)  The employer's March 17, 18, 19 and 24th Process Safety Compliance Audit findings reference number 46: "Page 12 of the PSI Element and additional system specific information for the north system found in the PSI binder under relief valve calculation. South system has no design specification information." had not been corrected by November 13, 2013.  d)  The employer's March 17, 18, 19 and 24th, 2010 Process Safety Compliance Audit findings reference number 48: "A material and energy balance calculation has not been performed for the south system." had not been corrected by November 13, 2013.

Issued

Mar 28, 2014

Abate by

Aug 12, 2014

Penalty

Initial $4,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.132(d)(1)(i): The employer did not select and have each affected employee use the types of personal protective equipment that would protect the affected employee(s) from the hazards identified in the hazard assessment:    a) The employer did not provide footwear or attachments to minimize the slipperiness of the tarmac roof surface, when wet or covered with snow or ice, around the north roof hatch ladder access points and the Freezer #5 north edge roof area to employees accessing the roof area and/or performing maintenance/inspection activities around the Freezer #5 north edge.