OSHA Inspection: SURLEAN FOODS

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

Initial $3,000 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i): The employer did not compile information pertaining to the equipment in the process:  On July 1, 2014 and at times prior thereto and possibly at times subsequent thereto, the employer did not compile complete and accurate information about the equipment in the ammonia refrigeration process at the Surlean Foods facility in San Antonio, Texas.   a) Pump data sheets do not have complete / accurate description and detail of PU-03 and PU-04 b) Process Safety Information on P&ID CS2911-11 conflicts with PSI on P&IDs CS2911-01 and CS2911-02 c) Equipment listed on the equipment list of P&ID  CS2911-12 is not installed in the field d) Equipment shown on PID CS9211-02 is not included in the engine room equipment list of PID CS9211-12 e) PSI for several vessels, including but not limited to V-19 is missing

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

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

General-duty citation text

29 CFR 1910.119(e)(3)(i): The process hazard analysis did not address the hazards of the process:  On June 30, 2014 and at times prior thereto and possibly at times subsequent thereto at the Surlean Foods facility in San Antonio, Texas, the employer did not evaluate the hazards of installing and operating general electrical equipment in a Class I, Division 2 electrically hazardous area when it performed the PHA and PHA revalidations for the Ammonia refrigeration system at its Surlean Foods facility in San Antonio, Texas.

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR 1910.307(c)(3): Equipment was not safe for the location in that it was not of a type and design that the employer demonstrated would provide protection from the hazards arising from the combustibility and flammability of vapors, liquids, gases, dusts, or fibers involved:  On June 30, 2014 and at times prior thereto and possibly at times subsequent thereto at the Surlean  Foods facility in San Antonio, Texas, the employer failed to ensure that electrical equipment, including but not limited to lighting, motors, and wiring, installed in a hazardous (classified) location is safe for the hazardous (classified) location.

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(ii): The employer did not document that equipment complies with recognized and generally accepted good engineering practices:  On June 30, 2014 and at times prior thereto and possibly times subsequent thereto at the Employer did not document that the ventilation system for the engine room of the ammonia refrigeration system at Surlean Foods facility in San Antonio, Texas complies with RAGAGEP when:  a) The employer did not ensure and document that the emergency ventilation rate of the mechanical ventilation system installed in the main engine room meets the International Institute of Ammonia Refrigeration (IIAR) recommendation of at least 10 cfm per square foot of room area to ensure the system is capable of exhausting ammonia vapors from all parts of the engine room.   b) The employer did not ensure and document that electrical equipment installed in the main engine room is safe for operation in a hazardous area.  c) The employer did not ensure that an alarm will be triggered whenever the ventilation system operating under non-emergency  continuous mode fails.  d) The employer did not ensure that there are no openings that permit passage of escaping refrigerant into other parts of the building.  e) The employer did not ensure that openings for inlet air are positioned to avoid recirculation.

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

Initial $5,000 · Current $3,500 Reduced

General-duty citation text

29 CFR 1910.119(g)(1)(i): Each employee involved in operating a process was not trained in the safe work practices applicable to the employee's job tasks:  On June 30, 2014 and at times prior thereto and possibly at times subsequent thereto at the Surlean Foods facility in San Antonio, Texas the employer did not ensure that each employee completed Ammonia Refrigeration training prior to being assigned to operate equipment in the ammonia refrigeration system.

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

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

General-duty citation text

29 CFR 1910.119(j)(4)(i): The employer did not perform inspection and tests on process equipment:  On June 30, 2014 and at times prior thereto and possibly times subsequent thereto at the Surlean Foods facility in San Antonio, Texas, the employer did not perform inspections and tests on equipment of the ammonia refrigeration system when:   a) The employer did not inspect ammonia refrigeration piping components, such as, but not limited to the pressure relief valves 1085A and 1085B to insure mechanical integrity is maintained.  b) The employer did not perform inspections and testing on ammonia sensor / alarms in the engine room.  c) The employer did not perform testing of the engine room ventilation system.

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(5): The employer does not ensure that deficiencies in equipment that are outside acceptable limits are corrected before further use or in a safe and timely manner when necessary means are taken to assure safe operation:  On June 30 2014 and at times prior thereto and possibly at times subsequent thereto in the main engine room at Surlean Foods, in San Antonio, Texas, the employer did not replace pressure relief valves in the ammonia refrigeration system in accordance with the schedule established by the equipment manufacturer.

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

Initial $4,000 · Current $2,800 Reduced

General-duty citation text

29 CFR 1910.119(l)(1): The employer did not establish and implement written procedures to manage changes  to process chemicals, technology, equipment,  and procedures; and, changes to facilities that affect a covered process.   On June 30, 2014 and at times prior thereto and possibly times subsequent thereto, at the Surlean Foods facility in San Antonio, Texas, the employer did not implement procedures to manage changes to the ventilation system of the ammonia refrigeration engine room.

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

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

Hazardous substances 0170

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace:   On June 30, 2014 and at times prior thereto and possibly at times subsequent thereto in the engine room of the ammonia refrigeration system at the Surlean Foods facility, located at 1545 S. San Marcos Street West in San Antonio, TX, the employer did not provide medical evaluations to employees prior to requiring them to use and don air purifying respirators.

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

Initial $5,000 · Current $3,500 Reduced

General-duty citation text

29 CFR 1910.212(a)(5): Fan blade guards, where the periphery of the blades was less than seven feet above the floor or working level, had openings larger than one half inch:  On June 30, 2014 and at times prior and possibly times subsequent thereto, at the Surlean Foods facility in San Antonio, Texas, the employer operated a ventilation fan in the mechanical room with a large opening in the blade guard that was less than seven feet above the floor.

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(c)(2)(i): All exposed part(s) of horizontal shafting seven (7) feet or less from floor or working platform were not protected by stationary casing(s) enclosing shafting completely or by trough(s) enclosing sides and top or sides and bottom of shafting:  On June 30, 2014 and at times prior thereto and possibly times subsequent thereto at the Surlean Foods facility in San Antonio, Texas, shafts of air compressors were not protected.

Issued

Dec 17, 2014

Abate by

Jan 21, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(c)(3): Vertical or inclined shafting seven (7) feet or less from floor or working platform was not enclosed with stationary casing(s):  On June 30, 2014 and at times prior thereto and possibly times subsequent thereto at the Surlean Foods facility in San Antonio, Texas, the employer operated pumps at the ammonia refrigeration condensers with vertical shafts that were not fully guarded.