OSHA Inspection: HUDSON VALLEY CREAMERY, LLC

Issued

2014-09-24 00:00:00

Abate by

2014-12-30 00:00:00

Penalty

Initial $2800.00 · Current $2425.00 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1): The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees, in that employees were exposed to inhalation and burn hazards resulting from an uncontrolled release of anhydrous ammonia.    (a) Anhydrous ammonia refrigeration system, on or prior to 4/3/2013:  Refrigeration system was not adequately designed, installed, and maintained to protect employees from an uncontrolled release of anhydrous ammonia vapor in that:    ·         Quantity of ammonia in the refrigeration system was not known.  A sign was not posted in the machine room, displaying the following information:  name, address and phone number of servicing contractor; approximate quantity of ammonia; lubricant identity and amount; field test pressure.  (See for example: IIAR Bulletin 109; ASHRAE 15 2010, section 11.2.1).  ·         Emergency shutdown procedures were not established.  Emergency shutdown procedures, including precautions to be observed in the event of a leak, were not displayed on a sign or card located as near as possible to the refrigerant compressors (See for example: ASHRAE 15 2010, Section 11.7)  ·         Labeling of ammonia service piping was not consistent throughout the facility. All piping mains, headers and branches were not identified as to the physical state of the refrigerant (gas or liquid), the relative pressure level of the refrigerant, and the direction of flow (See for example: IIAR-2 Section 10.5).  ·         Labeling of pipes, valves, and equipment in the compressor room was inconsistent.   Some valves, pipes, and equipment were not labeled (See for example: IIAR Bulletin 109). Valves and controls in compressor room were not identified with durable signs having letters more than 0.5 inch in height designating: valves or switches for controlling refrigerant flow, ventilation, and compressor(s) (See for example: ASHRAE 15 2010, section 11.2.2).  ·         Pressure relief valve (PRV) replacement tags did not indicate the installation date.  As a result, the service life of many PRVs could not be determined.  (See for example: IIAR Bulletin109)     ·         Where PRVs were piped to a common manifold relief header, termination of the relief header outside of the compressor room (on the E side of the facility) did not extend 15 feet above ground level (See for example: ASHRAE 15 2010, section 9.7.8).       ·         There was no remote means of controlling the king valve.  The only way plant personnel could close the king valve was via a manual gate valve installed approximately 12 feet above the floor level along the east wall of the compressor room.   Closing the valve required use of a step ladder which might be difficult in an emergency situation.  A remote-controlled solenoid valve which can be closed from outside of the compressor room was not installed.  (See for example: IIAR Bulletin 109)  ·         Corrosion protection was not uniform on all piping in anhydrous ammonia service.  Some pipe runs were painted while others showed significant corrosion.  Inspections for corrosion or insulation damage were not performed on uninsulated and insulated piping (See for example: IIAR Bulletin 109 Sections 4.7.4 and 4.7.5).  ·         The compressor room was not completely sealed and segregated from the rest of the plant.  Multiple penetrations were observed in the west wall of the room, which could allow ammonia vapor to migrate into the main plant in the event of a release. (See for example: ASHRAE 15 2010, section 8.11.2).  ·         The facility did not maintain complete maintenance or inspection records.  Other than work orders maintained by the servicing contractor, there were no records of additional maintenance, such as vibration testing on compressors or inspection of safety cutout switches (See for example: IIAR Bulletin 109).

Issued

2014-09-24 00:00:00

Abate by

2014-10-30 00:00:00

Penalty

Initial $2800.00 · Current $2425.00 Reduced

General-duty citation text

29 CFR 1910.120(q)(1): The employer did not develop and implement an emergency response plan to handle anticipated emergencies prior to commencement of emergency response operations:      (a) Main plant, all work areas:  On or prior to 3/27/14, the employer did not develop and implement an emergency response plan to handle anticipated emergencies associated with an anhydrous ammonia release.

Issued

2014-09-24 00:00:00

Abate by

2014-12-30 00:00:00

Penalty

Initial $2000.00 · Current $1625.00 Reduced

General-duty citation text

29 CFR 1910.132(d)(1): The employer did not assess the workplace to determine if hazards are present, or are likely to be present, which necessitate the use of personal protective equipment (PPE):      (a) Production operations (all, including shipping and receiving):  On or prior to 3/27/14, the employer did not conduct an assessment to determine personal protective equipment needed for production operations, including but not limited to:  use of caustic and/or corrosive cleaners and sanitizers and material handling.    (b) Maintenance operations (all):  On or prior to 3/27/14, the employer did not conduct an assessment to determine personal protective equipment needed for maintenance work, including but not limited to general maintenance , electrical work (including arc flash hazard protection), air handling system maintenance, and anhydrous ammonia refrigeration maintenance (including oil draining).

Issued

2014-09-24 00:00:00

Abate by

2014-10-10 00:00:00

Penalty

Initial $2000.00 · Current $1625.00 Reduced

General-duty citation text

29 CFR 1910.146(c)(1): The employer did not evaluate the workplace to determine if any spaces were permit-required confined spaces:    (a)  Throughout the plant:  On or prior to 3/27/14, the employer did not evaluate the workplace to determine the presence of permit-required confined spaces, including but not limited to the in-ground waste-water pit, waste water storage tank, and air handling/refrigeration system equipment, which could be entered by employees during maintenance work.

Issued

2014-09-24 00:00:00

Abate by

2014-10-10 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.146(c)(2): The employer did not inform exposed employees, by posting danger signs or by any other equally effective means, of the existence and location of and the danger posed by the permit spaces:  (a) Throughout the plant:  On or prior to 3/27/14, the employer did not evaluate the workplace to determine the presence of permit-required confined spaces, including but not limited to the in-ground waste-water pit, waste water storage tank, and air handling equipment which could be entered by employees during maintenance work.

Issued

2014-09-24 00:00:00

Abate by

2014-12-30 00:00:00

Penalty

Initial $2000.00 · Current $1625.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(1):  The employer did not establish a program consisting of energy control procedures, employee training and periodic inspections to ensure that before any employee performs any servicing or maintenance on a machine or equipment where the unexpected energizing, startup or release of stored energy could occur and cause injury, the machine or equipment was isolated from the energy source and rendered inoperative.    (a) Throughout the plant:  On or prior to 3/27/14, the employer did not establish energy control procedures (Lockout/Tagout procedures) for maintenance and servicing operations on equipment, including but not limited to:  production/processing equipment, ammonia refrigeration equipment, and electrical equipment, where employees were potentially exposed to electrical, pnuematic, mechanical, and chemical hazards during maintenance and servicing.

Issued

2014-09-24 00:00:00

Abate by

2014-10-10 00:00:00

Penalty

Initial $1600.00 · Current $1225.00 Reduced

General-duty citation text

29 CFR 1910.151(c): Where the eyes or body of any person may be exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body were not provided within the work area for immediate emergency use.    (a) Compressor room:  On or prior to 3/27/14, an emergency eyewash unit and shower was not located inside the compressor room, where employees could be exposed to skin and eye contact with anhydrous ammonia liquid or vapor.    (b) Main plant:  On or prior to 3/27/14, emergency eyewash unit(s) were not functional in all areas of the plant where they might be needed if employees were exposed to anhydrous ammonia or corrosive materials (i.e. cleaners and sanitizers, battery charging station, etc.).

Issued

2014-09-24 00:00:00

Abate by

2014-11-30 00:00:00

Penalty

Initial $1600.00 · Current $1225.00 Reduced

General-duty citation text

29 CFR 1910.157(g)(1): An educational program was not provided for all employees to familiarize them with the general principles of fire extinguisher use and the hazards involved with incipient stage fire fighting:    (a)  Throughout the plant:  On or prior to 3/27/14, the employer did not ensure that all employees expected or required to fight incipient stage fires were trained in use of portable fire extinguishers.

Issued

2014-09-24 00:00:00

Abate by

2014-11-30 00:00:00

Penalty

Initial $1200.00 · Current $825.00 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): Machine guarding was not provided to protect operator(s) and other employees from hazard(s) created by moving part(s):    (a) Molding room:  On or prior to 4/3/14, the locking handle of a hand cart used for transport of cheese racks exposed employees to pinch-point hazards during operation of the handle, in that employees' fingers could be pinched/caught between the handle and the frame of the cart.

Issued

2014-09-24 00:00:00

Abate by

2014-10-10 00:00:00

Penalty

Initial $1600.00 · Current $1225.00 Reduced

General-duty citation text

29 CFR 1910.303(b)(2): Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling:    (a) Adjacent to packaging area, panelboard PB-PF-1:  On or about 3/27/14, two single pole 20A breakers were joined with a length of wire to create a double-pole breaker.

Issued

2014-09-24 00:00:00

Abate by

2014-10-30 00:00:00

Penalty

Initial $1600.00 · Current $1225.00 Reduced

General-duty citation text

29 CFR 1910.305(b)(2): Pull boxes, junction boxes, and fittings were not provided with covers approved for the purpose:    (a)  Compressor room:  On or prior to 3/27/14, Square D motor controllers and Paragon time controllers (below defrost timer switches)  located along the north wall of the room were missing components and/or not completely covered and enclosed/kept closed.    (b)  Outside boxing room:  On or about 3/27/14, Panel PB-PF-1, circuit breaker position 30 was missing a blank or cover, exposing the bus bar.     (c)  Electrical room:  On or about 3/27/14, Panel UP-1, circuit breakers position 19, 21, and below CB 29 were missing a blank or cover, exposing the bus bar.

Issued

2014-09-24 00:00:00

Abate by

2014-11-30 00:00:00

Penalty

Initial $2000.00 · Current $1625.00 Reduced

General-duty citation text

29 CFR 1910.332(b)(1): Employees were not trained in and familiar with the safety-related work practices required by 1910.331 through 1910.335 that pertained to their respective job assignments:    (a) Maintenance operations (all):  On or prior to 3/27/14, employees performing electrical work (including energizing/de-energizing equipment) were not trained in and familiar with the safety-related work practices required for electrical maintenance work, including use of personal protective equipment for arc flash protection where arc flash hazards were present.

Issued

2014-09-24 00:00:00

Abate by

2014-11-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.335(a)(1): Employees working in areas where there were potential electrical hazards were not provided with, and/or did not use, electrical protective equipment that was appropriate for the specific parts of the body to be protected and for the work to be performed:    (a) Maintenance operations (all):  On or prior to 3/27/14, employees performing electrical work (including energizing/de-energizing equipment) were not provided with and/or did not use personal protective equipment for arc flash protection where arc flash hazards were present.

Issued

2014-09-24 00:00:00

Abate by

2014-10-25 00:00:00

Penalty

Initial $1200.00 · Current $825.00 Reduced

General-duty citation text

29 CFR 1910.1200(e)(1): The employer did not develop, implement, and/or maintain at the workplace a written hazard communication program which describes how the criteria specified in 29 CFR 1910.1200(f), (g), and (h) will be met:    (a) Molding room/production area:  On and prior to 3/27/14, for production employees using or exposed to chemicals including, but not limited to:  AFCO cleaners and sanitizers (containing organic acids, peroxides, caustic, ammonium chloride, sodium metasilicate, and dichloroisocyanurate dihydrate)), Wyandotte sanifect wipes (containing ethanol), and nitrogen gas.    (b) Compressor room:  On and prior to 3/27/14, for maintenance employees using or exposed to chemicals including, but not limited to:  anhydrous ammonia and refrigeration lubricant.

Issued

2014-09-24 00:00:00

Abate by

2014-10-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.1200(h)(1): Employees were not provided effective information and training on hazardous chemicals in their work area at the time of their initial assignment and whenever a new hazard that the employees had not been previously trained about was introduced into their work area:  (a) Molding room/production area:   On and prior to 3/27/14, for production employees using or exposed to chemicals including, but not limited to:  AFCO cleaners and sanitizers (containing organic acids, peroxides, caustic, ammonium chloride, sodium metasilicate, and dichloroisocyanurate dihydrate)), Wyandotte sanifect wipes (containing ethanol), and nitrogen gas; training did not address the transition to GHS.  (b) Compressor room:  On and prior to 3/27/14, for maintenance employees using or exposed to chemicals including, but not limited to:  anhydrous ammonia and refrigeration lubricant; training did not address the transition to GHS.

Issued

2014-09-24 00:00:00

Abate by

2014-10-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.178(l)(6): Certification. The employer shall certify that each operator has been trained and evaluated as required by this paragraph (l). The certification shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation.  (a)  Main plant:  On or prior to 3/27/14, the employer did not maintain certification of training and evaluation for operators of the Yale ERP 040 forklift.