OSHA Inspection: GENAGAIN TECHNOLOGIES, LLC

Issued

Sep 19, 2014

Abate by

Oct 16, 2014

Penalty

Initial $4,900 · Current $4,900

General-duty citation text

29 CFR 1910.119(d)(2)(i)(A): Information pertaining to the technology of the process did not have a block flow diagram or simplified process flow diagram that was accurate.    a)  GenAgain: The employer's current PSI (Process Safety Information) contained a block flow diagram that was not current and updated to show an accurate flow of product within all major vessels. Employees were exposed to a fire/explosion hazard that may result from materials such as, but not limited to, naphtha, crude oil and other by products of synthetic oil. The block flow diagram did not show the flow of material from the crude oil tank to the distillation column and its return to the final synthetic oil storage tank.

Issued

Sep 19, 2014

Abate by

Oct 8, 2014

Penalty

Initial $4,900 · Current $4,900

Hazardous substances 2584

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D): Process Safety Information(PSI) pertaining to the equipment in the process did not include relief system design and design basis for all pressure vessels.       a) WFE Distillation Process: The employer failed to maintain process safety information that contained calculations and design for relief devices that were utilized to protect the WFE (White Film Evaporator). Employees were exposed to the hazard of a fire/explosion hazard while performing activities involving the manufacture of naphtha and other hydrocarbons.

Issued

Sep 19, 2014

Abate by

Nov 6, 2014

Penalty

Initial $4,900 · Current $4,900

Hazardous substances 2584

General-duty citation text

29 CFR 1910.119(e)(1): The employer did not perform an initial process hazard analysis (hazard evaluation) on processes covered by 29 CFR 1910.119:         a)WFE Distillation:  The employer failed to conduct an initial process hazard analysis on the distillation process and/or updated its PHA (Process Hazard analysis) (HAZOP study) to include the distillation of raw synthetic crude. Employees were exposed to a fire/explosion hazard involving HHC(highly hazard chemicals) such as, but not limited to, naphtha.

Issued

Sep 19, 2014

Abate by

Oct 16, 2014

Penalty

Initial $4,900 · Current $4,900

Hazardous substances 0320V109

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not implement written procedures to maintain the on-going integrity of process equipment.        a)  GenAgain: The employer failed to develop and implement procedures to maintain the on-going mechanical integrity of process equipment. Employees were exposed to materials such as, but not limited to, benzene, naphtha, synthetic crude and other hazardous materials while performing repairs and maintenance on valves, piping and other process equipment for the manufacture of  synthetic crude oil.

Issued

Sep 19, 2014

Abate by

Oct 16, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 0320V109

General-duty citation text

29 CFR 1910.119(j)(3): The employer did not train each employee involved in maintaining the on-going integrity of process equipment in the procedures applicable to the employee's job tasks to ensure that the employee can perform the job tasks in a safe manner:   a)  GenAgain: The employer failed to provide training on an overview of the processes and hazards associated with the processes to ensure that maintenance personnel performed assigned work activities in a safe manner to maintain the on-going mechanical integrity of process equipment. Employees were exposed to materials such as, but not limited to, benzene, naphtha, synthetic crude and other hazardous materials while performing repairs and maintenance on valves, piping and other process equipment.

Issued

Sep 19, 2014

Abate by

Nov 6, 2014

Penalty

Initial $4,900 · Current $4,900

Hazardous substances 0320V109

General-duty citation text

29 CFR 1910.119(l)(1): The employer did not implement procedures to manage changes to process chemicals, technology, equipment, and procedures, and changes to facilities that affect a covered process      a) GenAgain: The employer failed to develop and implement management of change procedures for each covered process which reflects deviation from normal operating procedures involving chemicals, equipment and other changes that may affect covered processes. Employees were exposed to the hazard of a fire/explosion and other hazardous conditions while performing duties for the manufacture of synthetic crude oil.

Issued

Sep 19, 2014

Abate by

Nov 6, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 0320V109

General-duty citation text

29 CFR 1910.119(l)(3): Employees involved in operating a process and maintenance and contract employees whose job tasks would be affected by a change in the process were not informed of and trained in the change prior to start-up of the process or affected part of the process.   a) GenAgain: The employer failed to provide training on management of change for each covered process which reflects deviation from normal operating procedures involving chemicals, equipment and other changes that may affect covered processes. Employees were exposed to the hazard of a fire/explosion and other hazardous conditions while performing duties for the manufacture of synthetic crude oil.

Issued

Sep 19, 2014

Abate by

Oct 8, 2014

Penalty

Initial $4,900 · Current $4,900

Hazardous substances 0320

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) Production Area: The employer failed to evaluate the workplace and determine if permit required confined spaces were present. Employees and contracted workers were exposed to benzene and other hazards while performing entry into DCC and other spaces to perform duties involving clean-out, repairs/maintenance of various equipment and other activities requiring the entry into confined spaces.

Issued

Sep 19, 2014

Abate by

Sep 29, 2014

Penalty

Initial $4,200 · Current $4,200

Hazardous substances 2260

General-duty citation text

29 CFR 1910.151(c): Where employees were 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) Caustic Tank: Employees were exposed to the hazard of caustic soda while performing activities for the manufacture of synthetic crude. The eyewash/shower station in the caustic area did not maintain water pressure.

Issued

Sep 19, 2014

Abate by

Oct 1, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 0320

General-duty citation text

29 CFR 1910.157(c)(1): Portable fire extinguishers were not mounted, located and identified so that they were readily accessible without subjecting the employees to injuries:    a) GenAgain- DDC: The employer failed to ensure that a fire extinguisher was mounted and located for exposed employees required to utilize the extinguisher in the event of an emergency. Employees were exposed to a fire hazard and were required to utilize the equipment for small incipient stages of a fire. A Badger(ADU-10) extinguisher was located on the floor near PRU 30.

Issued

Sep 19, 2014

Abate by

Oct 1, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 0320

General-duty citation text

29 CFR 1910.157(c)(4): Portable fire extinguishers were not maintained in a fully charged and operable condition.   a) GenAgain- PUC 30: The employer failed to ensure that a Badger (ADU-10) fire extinguish was fully charged. Employees required to utilized fire control devices during incipient stages of a fire were exposed to a fire while performing various activities involving the manufacture of synthetic crude involving materials such as, but not limited to, benzene and naphtha.

Issued

Sep 19, 2014

Abate by

Oct 8, 2014

Penalty

Initial $0 · Current $0

Hazardous substances 0320

General-duty citation text

29 CFR 1910.157(g)(3): Employees who have been designated to use fire fighting equipment as part of the emergency action plan were not provided training in the use of the appropriate equipment:   a) GenAgain: The employer failed to ensure that employees required to utilized fire control devices during incipient stages of a fire were adequately training on the operational use of the equipment. Employees were exposed to a fire while performing various activities involving the manufacture of synthetic crude involving materials such as, but not limited to benzene and naphtha.