OSHA Inspection: SMITHFIELD FARMLAND CORPORATION

Issued

Dec 3, 2014

Abate by

Jan 20, 2015

Penalty

Initial $5,500 · Current $4,000 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:     Employees performing maintenance and operating the ammonia refrigeration system were exposed to hazards associated with exposures of ammonia.  In the event of an emergency such as an ammonia release or for lockout/tagout purposes the piping and instrumentation diagrams would not show possible places where ammonia could escape the system.  The Piping and Instrumentation Diagrams did not show temperature and pressure instruments for the following locations:    A) 27 degree Accumulator Pump #1 Pressure Gauge  B) 27 degree Accumulator Pump #2 Pressure Gauge  C) 27 degree Accumulator Low Pressure Liquid pipe Temperature Indicator (at elbow above Pump #1)  D) 15 degree Accumulator Pump #1 Pressure Gauge  E) 15 degree Accumulator  Pump #2 Pressure Gauge  F) Compressor #1 Pressure Gauge on discharge  G) Compressor #1 Temperature indicator  on suction for control panel  H) Compressor #2 Pressure Gauge on discharge  I)  Compressor #2 Temperature indicator  on suction for control panel  J)  Compressor #3 Pressure Gauge on discharge  K) Compressor #3 Temperature indicator  on suction for control panel  L) Compressor #4, 3 Pressure Gauges on discharge(s)  M) Compressor #4 Temperature indicator  on suction for control panel    N) Compressor #5 Pressure Gauge on discharge  O) Compressor #5 Temperature indicator  on suction for control panel  P) Compressor #6 Pressure Gauge on discharge  Q) Compressor #6 Temperature indicator  on suction for control panel   R) Compressor #7 Pressure Gauge on discharge  S) Compressor #7 Temperature indicator  on suction for control panel  T) Compressor #8 Temperature Gauge on discharge  U) Compressor #8 Temperature Gauge on discharge  V)  Compressor #8 Pressure Gauge on compressor  W) Compressor #8 Temperature indicator  on suction for control panel  X) Compressor #9 Pressure Gauge on the Oil Separator vessel  Y) Compressor #10 Pressure Gauge on the Oil Separator vessel  Z) Compressor #11 Pressure Gauge on the Oil Separator vessel  AA) Compressor #12 Pressure Gauge on the Oil Separator vessel  BB) Compressor #13 Pressure Gauge on the Oil Separator vessel  CC) Compressor #14 Pressure Gauge on the Oil Separator vessel  DD) Evaporators Loaf Cooler/Hot Dog Pressure gauges on Evaporator Control Banks for 1056-1 and 1056-2  EE) Test Kitchen Pressure gauge on Evaporator Control Banks for 1051-2 and 1051-3  FF) Research & Development Pressure gauge on Evaporator Control Bank for 1052-1  GG) Ice Machine Pressure gauge on Ice Machine Control Bank for Control Station 166

Issued

Dec 3, 2014

Abate by

Apr 1, 2015

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(f)(1)(i)(D): The employer did not develop and implement written operating procedures that provide clear instructions for emergency shutdown, including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner:  On or about June 7th, 2014 employees responding to a reported leak of ammonia were exposed to inhalation hazards in that the employer did not have an emergency shut down procedure to address shut down from a major release.  The employer relied on outside contractors not familiar with the plant to enter and shut down the refrigeration plant.

Issued

Dec 3, 2014

Abate by

Jan 20, 2015

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.119(f)(1)(iii)(B): 29 CFR 1910.119 (f)(1)(iii)(B) The employer did not develop and implement written operating procedures that provided clear instructions for safely conducting activities involved in each covered process consistent with the process safety information that addressed health and safety considerations, such as precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment:  On or about June 7th, 2014, employees responding to an ammonia leak were exposed to inhalation hazards in that the "odor" procedure did not address engineering controls and personal protective clothing and respiratory protection needed when ammonia levels are approaching the IDLH levels.

Issued

Dec 3, 2014

Penalty

Initial $7,000 · Current $7,000

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:     On or about June 7th, 2014 employees responding to an ammonia leak were exposed to inhalation hazards from a failed strainer for Evaporator Control Banks 1058-1 and 1058-2.  The employer did not have mechanical integrity procedures for the inspection of valves and strainers.

Issued

Dec 3, 2014

Abate by

Jan 20, 2015

Penalty

Initial $7,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(iii): The frequency of inspections and tests of process equipment shall be consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience:    On or about June 7th, 2014 employees responding to an ammonia leak were exposed inhalation hazards from a failed strainer for Evaporator Control Banks 1058-1 and 1058-2.  The employer had not developed a schedule of inspections for strainers and valves.

Issued

Dec 3, 2014

Abate by

Jan 20, 2015

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

29 CFR 1910.120(q)(6)(iii): Employees who participated as hazardous materials technicians, or were expected to participate as hazardous materials technicians, had not received at least 24 hours of training equal to the first responder operations level, and in addition have competency in the areas outlined in 29 CFR 1910.120(q)(6)(iii)(A) through (q)(6)(iii)(I) and/or the employer did not so certify:  On or about June 7th, 2014 employees responding to an ammonia leak were exposed to inhalation hazards and skin exposures in that the employees tasked with isolating the release were not HAZWOPER trained.