OSHA Inspection: REDDY ICE

Issued

Sep 12, 2014

Abate by

Oct 1, 2014

Penalty

Initial $3,000 · Current $7,000

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.       The employer does not ensure piping and instrument diagrams are accurate and represent equipment that exists and part of the process.       A.    The violation occurred in the Ice and Machine/Engine rooms on or about April 15, 2014 and at times prior thereto where the employer exposed employees to fire, explosion, and/or ammonia inhalation hazards when it failed to ensure piping and instrument diagrams were accurate and reflected the existing ammonia refrigeration process including relief system headers and water dispersion tank.      Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure piping and instrument diagrams are accurate and represent equipment that is existing and part of the process.

Issued

Sep 12, 2014

Abate by

Oct 1, 2014

Penalty

Initial $7,000 · Current $0 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D): Process safety information did not include the pressure relief design and design basis:       The employer does not ensure that process safety information includes the pressure relief design and design basis.       A.    This violation occurred in the Ice Making and Machine Rooms on or about April 15, 2014 and at times prior thereto and after where the employer failed to maintain accurate design and design basis information for the pressure relief water dispersion system and relief headers for the entire ammonia refrigeration process.       Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure it documented that equipment in the process complies with recognized and generally accepted good engineering practices.

Issued

Sep 12, 2014

Abate by

Oct 1, 2014

Penalty

Initial $7,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(ii):  The employer did not document that the equipment in the process complied with recognized and generally accepted good engineering practices:      The employer does not ensure it documented that equipment in the process complied with recognized and generally accepted good engineering practices (RAGAGEP).       A.    The violation occurred in the Ice and Machine/Engine rooms on or about April 15, 2014 and at times prior thereto where the employer exposed employees to fire, explosion, and/or ammonia inhalation hazards when it failed to ensure an ammonia detector was installed in the engine room in accordance with RAGAGEP such as ASHRAE 15 and IIAR 2.       B.    The violation occurred in the Ice and Machine/Engine rooms on or about April 15, 2014 and at times prior thereto where the employer exposed employees to fire, explosion, and/or ammonia inhalation hazards when it failed to ensure remote emergency shutdown of equipment was installed outside the entrance to the machinery room in accordance with RAGAGEP such as ANSI/ASHRAE 15 and ANSI/IIAR 2.       C.    The violation occurred in the Ice and Machine/Engine rooms on or about April 15, 2014 and at times prior thereto where the employer exposed employees to fire, explosion, and/or ammonia inhalation hazards when it failed to ensure emergency mechanical ventilation system(s) was activated by an ammonia detector; OR ran continuously and provided with a supervisory alarm to detect failure or shutdown of system in accordance with RAGAGEP such as ANSI/ASHRAE-15 and ANSI/IIAR 2.       D.    The violation occurred in the Ice and Machine/Engine rooms on or about April 15, 2014 and at times prior thereto where the employer exposed employees to fire, explosion, and/or ammonia inhalation hazards when it failed to ensure emergency mechanical ventilation was provided at the capacities required in accordance with RAGAGEP such as ANSI/ASHRAE-15 and ANSI/IIAR 2.       E.    The violation occurred in the Ice and Machine/Engine rooms on or about April 15, 2014 and at times prior thereto where the employer exposed employees to fire, explosion, and/or ammonia inhalation hazards when it failed to ensure the pressure relief device discharge piping was designed and installed in accordance with RAGAGEP such as ANSI/ASHRAE-15 and ANSI/IIAR 2.      Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure it documented that equipment in the process complies with recognized and generally accepted good engineering practices.

Issued

Sep 12, 2014

Abate by

Oct 1, 2014

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(j)(2):  The employer did not establish and implement written procedures to maintain the on-going mechanical integrity of process equipment.      The employer does not ensure written procedures are established and implemented to maintain the on-going mechanical integrity of process equipment.      A.    The violation occurred in the Ice and Machine/Engine rooms on or about April 15, 2014 and at times prior thereto where the employer exposed employees to fire, explosion, and/or ammonia inhalation hazards when it failed to ensure detailed written procedures were established and implemented for testing of process equipment. Identified ammonia refrigeration process equipment include but not limited to:      a.     External visual inspections of insulated and un-insulated vessels   b.     External visual inspection of insulated and un-insulated piping   c.     External visual inspection of relief system.      Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure written procedures are established and implemented to maintain the on-going mechanical integrity of process equipment.

Issued

Sep 12, 2014

Abate by

Oct 1, 2014

Penalty

Initial $7,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(ii):  Inspections and testing procedures performed on process equipment to maintain its mechanical integrity, did not follow recognized and generally accepted good engineering practices.       The employer does not ensure inspections and tests performed on process equipment to maintain its on-going mechanical integrity followed recognized and generally accepted good engineering practices (RAGAGEP).       A.    The violation occurred in the Ice and Machine/Engine rooms on or about April 15, 2014 and at times prior thereto where the employer exposed employees to fire, explosion, and/or ammonia inhalation hazards when it failed to ensure the 5-year major independent inspection and tests of pressure vessels followed RAGAGEP such as IIAR Bulletin 110. Identified vessels include but not limited to:   a.     HPR-1 (Engine Room 1)   b.     HPR-2 (Engine Room 2/4)   c.     Accumulator (Engine Room 1)   d.     Accumulator #3 (Engine Room 2/4)   e.     HRP-1 (Engine Room 2/4)   f.      Accumulator #2 (Engine Room 2/4)       B.    The violation occurred in the Ice and Machine/Engine rooms on or about April 15, 2014 and at times prior thereto where the employer exposed employees to fire, explosion, and/or ammonia inhalation hazards when it failed to ensure annual visual inspections of ammonia refrigeration process equipment were conducted in accordance with RAGAGEP such as IIAR Bulletin 110.      Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure inspections and tests performed on process equipment to maintain its on-going mechanical integrity followed recognized and generally accepted good engineering practices.

Issued

Sep 12, 2014

Abate by

Oct 1, 2014

Penalty

Initial $5,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(iv): The documentation of the inspection or test that been performed on process equipment to maintain its mechanical integrity did not identify the date of the inspection or test, the serial number or other identifier of the equipment on which the inspection or test was performed, a description of the inspection or test, and the results of the inspection or test.       The employer does not ensure inspections and tests performed on process equipment are documented with the date, serial number or equipment identifier, a description, and the result(s) of the inspection or test.       A.    The violation occurred in the Ice and Machine/Engine rooms on or about April 15, 2014 and at times prior thereto where the employer exposed employees to fire, explosion, and/or ammonia inhalation hazards when it failed to ensure results from inspections and tests performed on ammonia refrigeration system cutouts, vessels, and piping were documented with the date, serial number or equipment identifier, a description of the test/inspection performed. Identified cutouts include but are not limited to:   a.     Compressor Discharge High/Low Pressure   b.     Compressor High/Low Oil Pressure Differential   c.     Compressor High Discharge Temperature   d.     High/Low Vessel Levels   e.     External visual inspections of insulated and un-insulated vessels   f.      External visual inspection of insulated and un-insulated piping   g.     External visual inspection of relief systems      Pursuant to 29 C.F.R. 1903.19, within ten (10) calendar days of the abatement date the employer must submit documentation showing it is in compliance with the standard, including describing the steps it is taking to ensure inspections and tests performed on process equipment are documented with the date, serial number or equipment identifier, a description, and the result(s) of the inspection or test.