OSHA Inspection: MFG CHEMICAL, INC

Issued

Dec 22, 2014

Abate by

Feb 10, 2015

Penalty

Initial $5,390 · Current $4,851 Reduced

Hazardous substances 1560

General-duty citation text

29 CFR 1910.106(b)(2)(vii)(a): "Drainage and diked areas." The area surrounding a tank or a group of tanks shall be provided with drainage as in subdivision (b) of this subdivision, or shall be diked as provided in subdivision (c) of this subdivision, to prevent accidental discharge of liquid from endangering adjoining property or reaching waterways.      a) MFG Chemical-Kimberly Park: The employer failed to ensure that a dike, barrier, containment or means were maintained to contain flammable materials. There were (2) 4500 gallon storage tanks (ST-88 and ST-89) containing Torq Trim II (isopropyl alcohol) that did not have any means to control the flammable material to the immediate area.

Issued

Dec 22, 2014

Abate by

Jan 12, 2015

Penalty

Initial $5,390 · Current $4,851 Reduced

Hazardous substances 1560

General-duty citation text

29 CFR 1910.106(h)(7)(i)(a): Precautions shall be taken to prevent the ignition of flammable vapors. Sources of ignition include but are not limited to open flames; lightning; smoking; cutting and welding; hot surfaces; frictional heat; static, electrical, and mechanical sparks; spontaneous ignition, including heat-producing chemical reactions; and radiant heat.       a) MFG Chemical-Kimberly Park: The employer failed to ensure that operation of a LP gas industrial truck was not permitted in an area where flammable materials were being dispensed. An employee was operating a Komatsu LP gas forklift in the area where drumming of Torq Trim II (isopropyl alcohol) was being dispensed into 55 gallon drums. The equipment was capable of creating a mechanical spark from its operation in the area.

Issued

Dec 22, 2014

Abate by

Jan 20, 2015

Penalty

Initial $5,390 · Current $4,851 Reduced

Hazardous substances 1560

General-duty citation text

29 CFR 1910.119(d)(2)(i)(A): The process safety information (PSI) pertaining to the technology of the process did not include a block flow diagram that contained accurate information:         a) MFG Chemical, Inc.- Kimberly Park: The employer's PSI (Process Safety Information) pertaining to the technology of the process failed to contain an accurate block flow diagram and/or a simplified process flow diagram for processes to include, but not limited to, Torq Trim II (isopropyl alcohol) to indicate the flow of product within all major vessels. The diagram did not show the transfer of product to ST-88 and ST-89 and dispensing of the material into 55 gallon drums. Employees were exposed to a fire/explosion hazard while performing operator, forklift operations, drumming of materials and other activities for the manufacture of specialty chemicals.

Issued

Dec 22, 2014

Abate by

Jan 20, 2015

Penalty

Initial $2,310 · Current $1,155 Reduced

Hazardous substances 14701560M360

General-duty citation text

29 CFR 1910.119(d)(3)(i)(A): The process safety information (PSI) pertaining to the equipment of the process did not include information pertaining to the material of construction:            a) MFG Chemical, Inc.: The employer's PSI (Process Safety Information) pertaining to the equipment of the process failed to contain information on the material of construction of vessels that may be affected by covered processes such as, but not limited to, Torq Trim II, BU 82076 and BU 82076 base.

Issued

Dec 22, 2014

Abate by

Feb 10, 2015

Penalty

Initial $5,390 · Current $4,851 Reduced

Hazardous substances 15601618T247

General-duty citation text

29 CFR 1910.119(e)(3): The process hazard analysis did not address the identification of any previous incident which had a likely potential for catastrophic consequences in the workplace; engineering and administrative controls applicable to the process hazards; Consequences of failure of engineering and administrative controls; facility siting and human factors affecting the process.         a)  MFG Chemical- Kimberly Park: The PHA (Process Hazard Analysis) for covered processes failed to address all factors required in the PHA evaluation such as, but not limited to, administrative and engineering controls; consequences of failure of engineering and administrative controls, facility siting and human factors,.  Employees were exposed to a fire/explosion hazard and other hazardous conditions while manufacturing industrial specialty chemicals. i.e  Torq Trim II, Amide Chloride and CSTHAI404M.

Issued

Dec 22, 2014

Abate by

Jan 20, 2015

Penalty

Initial $5,390 · Current $4,851 Reduced

Hazardous substances 1560

General-duty citation text

29 CFR 1910.119(l)(1): The employer shall establish and implement written procedures to manage changes (except for "replacements in kind") to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process.    a) MFG Chemical-Kimberly Park: The employer failed to implement a MOC (management of change) to establish a protocol that addressed the impact of safety and health on employees when assigned duties involving drumming of Torq Trim II which was moved to a new location. The change reflects deviation from normal operating procedures of drumming Torq trim II in the new production area to transferring the batch to a remote holding tank that was utilized to dispense the material into 55 gallon drums. The change impacted the safety and health considerations for other processes in the immediate area. Employees were exposed to the hazard of fire/explosion and other hazardous conditions while performing duties for the manufacture of industrial materials. (Torq Trim II).

Issued

Dec 22, 2014

Abate by

Jan 12, 2015

Penalty

Initial $7,700 · Current $6,160 Reduced

Hazardous substances 15602150

General-duty citation text

29 CFR 1910.110(e)(4)(iii): Permanent and removable fuel containers were not securely mounted to prevent jarring loose, slipping, or rotating:     a) Old Process Area: The employer failed to ensure that a LP gas cylinder was adequately secured on the Clark powered industrial truck. The latch designed to secure the cylinder was broken. Employees were exposed to a fire/explosion hazard while operating the industrial truck to move totes and drums containing chemicals in and around the production area.           MFG Chemical, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.110 (e)(4)(iii), which was contained in OSHA inspection number 438031, citation number 1, item number 2 and was affirmed as a final order on December 04, 2012, with respect to a workplace located at 453 Callahan Road, Dalton, Georgia.

Issued

Dec 22, 2014

Abate by

Feb 10, 2015

Penalty

Initial $10,780 · Current $8,624 Reduced

Hazardous substances 1560

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): The employer did not develop piping and instrument diagrams for the equipment that was part of the process.     a) MFG Chemical, Inc.: The employer did not develop an adequate P&ID (Piping and Instrumentation Diagram) that included all piping, equipment, valves and other components of the process equipment that existed within all major vessels exposing employees to a fire/explosion hazard. The P&ID did not show the transfer of product from the reactor to the holding tank ST-88 and ST-89; transfer of product from the holding tanks to drumming; and batching in reactor 11 and 12. Employees were exposed to materials such as, but not limited to, isopropyl alcohol, hydrogen peroxide, and other highly hazardous materials utilized in the processes. i.e. Torq Trim II.           MFG Chemical, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.119 (d)(3)(i)(B) which was contained in OSHA inspection number 438031, citation number 1, item number 3 and was affirmed as a final order on December 04, 2012, with respect to a workplace located at 453 Callahan Road, Dalton, Georgia.

Issued

Dec 22, 2014

Abate by

Nov 30, 2015

Penalty

Initial $10,780 · Current $8,624 Reduced

Hazardous substances 1560T247

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D): The process safety information (PSI) pertaining to the equipment of the process did not include the relief system design and the design basis:          a) MFG Chemical, Inc.: The employer's PSI (Process Safety Information) pertaining to the equipment in the process failed to provide the relief system calculations and sizing of safety relief devices for the reactors, condensers, receivers and other pressure vessels. Employees were exposed to a fire/explosion hazard while performing duties involving the manufacture of specialty chemicals. i.e. Torq Trim II, Amide Chloride and 404.         MFG Chemical, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.119 (d)(3)(i)(D), which was contained in OSHA inspection number 438031, citation number 1, item number 4 and was affirmed as a final order on December 04, 2012, with respect to a workplace located at 453 Callahan Road, Dalton, Geo

Issued

Dec 22, 2014

Abate by

Feb 10, 2015

Penalty

Initial $10,780 · Current $8,624 Reduced

Hazardous substances 14701618

General-duty citation text

29 CFR 1910.165(b)(1): The employee alarm system did not provide warning for necessary emergency action as called for in the emergency action plan, or for reaction time for safe escape of employees from the workplace or the immediate work area, or both:          a) MFG Chemical, Inc. (Old Production Area-small): No warning signal, as indicated by the company's emergency action plan, was activated to notify personnel in an adjoining production area or throughout other areas of the plant to evacuate.       On or about July 07, 2014 a massive vapor release occurred that resulted in serious life threatening injury to an employee. It was determined that failure to close and adequately secure the manway on K-3 reactor was not completed as charging of reactive chemical (hydrogen peroxide) were introduced into the reactor.       MFG Chemical, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.165(b)(1), which was contained in OSHA inspection number 438031, citation number 1, item number 15 and was affirmed as a final order on December 04, 2012, with respect to a workplace located at 453 Callahan Road, Dalton, Georgia.