OSHA Inspection: HYDRITE CHEMICAL CO.

Issued

Jun 25, 2014

Abate by

Jul 17, 2014

Penalty

Initial $4,250 · Current $2,975 Reduced

General-duty citation text

29 CFR 1910.119(e)(3)(v): The process hazard analysis did not address facility siting.  On or about January 16, 2014, the employer did not ensure that the process hazard analysis addressed facility siting, including, but not limited to, the occupied control room locations in relation to the hazardous process, for the following processes:  a) Epichlorohydrin - R12 APC Intermediate 6020 Production.  b) Epichlorohydrin - R13 APC 6020 Purification.  c) Dimethylamine - CR4 Stepan Hallcomid M-8-10 Production.  d) Formaldehyde - R15 Hallstar TP-90B Production.  e) Anhydrous Ammonia - R6 Dorf Ketal n-Propyl Zirconate (NPZ) Slurry Production.  f) Anhydrous Ammonia - R6 Dorf Ketal n-Butyl Zirconate (NBZ) Slurry Production.

Issued

Jun 25, 2014

Abate by

Jul 17, 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:  On or about January 16, 2014, the employer did not promptly determine and document an appropriate response to the compliance audit findings, including but not limited to, not addressing facility siting on the PHAs, and did not document that deficiencies had been corrected:  a) 2012 Epichlorohydrin processing PSM Compliance Audit.  b) 2012 Flammable Liquids processing PSM Compliance Audit.  c) 2012 Formaldehyde Processing PSM Compliance Audit.  d) 2012 Anhydrous Ammonia PSM Compliance Audit.

Issued

Jun 25, 2014

Abate by

Jul 17, 2014

Penalty

Initial $7,000 · Current $4,900 Reduced

General-duty citation text

29 CFR 1910.132(a): Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers was not provided, used, and/or maintained.   On or about January 16, 2014, the employer did not provide personal protective equipment, including but not limited to, personal fall protection, for employees required to climb on top of tanker trucks in the epoxy truck dock for "clean-empty" loading.

Issued

Jun 25, 2014

Abate by

Jul 17, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): Information pertaining to the equipment in the process did not include piping and instrument diagrams (P&ID's):  On or about January 16, 2014, the employer did not ensure that the piping and instrument diagrams were correct to the as-built condition of the covered processes, including but not limited to, the following:  a) The P&ID for the ammonia feed line from T801 (ammonia storage tank 801) indicates a ball valve #816 (BV-816) is present, but no ball valve is present on the line (R6 NPZ Slurry Production Process).  b) The P&ID for valves to the R6 Reactor indicates a valve is labeled "RCV-110" but the valve is actually labeled "BV-RD-817".  c) The P&ID for the ammonia in feed lines from the outside Ammonia storage tank indicate a ball valve #144 (BV-144) is present, but upon inspection BV-144 is missing along with the associated piping.  d) The P&ID for the ammonia in feed lines from the outside Ammonia storage tank indicate a ball valve #145 (BV-145) is present, but upon inspection BV-145 is missing along with associated piping.  e) The P&ID for the ammonia in feed lines from the outside Ammonia storage tank indicate a pressure relief valve #335 (PRV-335) is present, but upon inspection it is missing.  f) The P&ID for the CR04 Receiver is labeled "CR04-RCR-400+S", but on the tank it is labeled "CR04-RCR-470".

Issued

Jun 25, 2014

Abate by

Jul 17, 2014

Penalty

Initial $0 · Current $0

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:  On or about January 16, 2014, the employer did not establish written procedures to test the alarm or interlocks on the process equipment for the following processes:  a) Epichlorohydrin - R12 APC Intermediate 6020 Production.  b) Epichlorohydrin - R13 APC 6020 Purification.  c) Dimethylamine - CR4 Stepan Hallcomid M-8-10 Production.  d) Formaldehyde - R15 Hallstar TP-90B Production.  e) Anhydrous Ammonia - R6 Dorf Ketal n-Propyl Zirconate (NPZ) Slurry Production.  f) Anhydrous Ammonia - R6 Dorf Ketal n-Butyl Zirconate (NBZ) Slurry Production.