OSHA Inspection: MULLER-PINEHURST DAIRY, INC.

Issued

Oct 6, 2015

Abate by

Apr 1, 2016

Penalty

Initial $3,500 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D): The employer did not include, in the process safety information compilation, the relief system design and the design basis:    The employer did not document the relief system design and design basis for the ammonia refrigeration system.  The system includes several pressure vessels.  Employees working in the engine room and throughout the facility are exposed to explosion hazards if the relief systems are not designed and sized properly.    Abatement documentation is required of this item in accordance with 1903.19(d).

Issued

Oct 6, 2015

Abate by

May 2, 2016

Penalty

Initial $3,500 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(E): Information pertaining to the equipment in the process did not include a ventilation system design:    The employer did not include in the process safety information a ventilation system design for the ventilation system servicing the refrigeration system and the engine rooms where the equipment is located.  Employees performing tasks in the engine rooms would be exposed to high levels of ammonia in the event of a significant release and insufficient ventilation.    Abatement documentation is required of this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Oct 6, 2015

Abate by

May 2, 2016

Penalty

Initial $3,500 · Current $2,100 Reduced

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:    The employer did not document that the equipment complies with recognized and generally accepted good engineering practices in the following instances:    (a) The employer did not document that the North Ice Bank Oil Pot, a pressure vessel, complied with applicable recognized and generally accepted good engineering practices such as, but not limited to, the ASME Boiler & Pressure Vessel Code, Section VIII, Division 1, Rules for Construction of Pressure Vessels.      (b) The following doors were not tight-fitting to prevent the migration of ammonia into other work areas in the event of a release: The door between the two engine rooms, housing the refrigeration equipment; The two doors leading into the boiler room from the engine room; and the door leading into the water treatment room from the engine room.  Employees performing tasks in the engine room, the boiler room or the water treatment room would be exposed to ammonia in the event of a significant release.  The employer did not document compliance, for these doors, with recognized and generally accepted good engineering practices such as, but not limited to, ANSI/ASHRAE Standard 15-2010 Safety Standard for Refrigeration Systems.    (c)  The engine rooms, which house the refrigeration equipment, contain electrical equipment, such as, but not limited to, outlets, switches and lighting fixtures, which have not been approved for use in classified areas.  The engine rooms do not have an ammonia detection system which would alert in the event of a significant release nor is there an alarm to indicate a failure of the mechanical ventilation system.  Employees are exposed to a potential accumulation of ammonia which would exceed the lower explosive limit for ammonia and cause an explosion.  The employer did not document compliance, for the engine rooms, with recognized and generally accepted good engineering practices such as, but not limited to, ANSI/ASRAE Standard 15-2010  Safety Standard for Refrigeration Systems.    Abatement documentation is required of this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Oct 6, 2015

Abate by

Apr 1, 2016

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.119(f)(1): 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 and addressing at least steps for each operating phase, safe operating limits, safety and health considerations, and safety systems and their functions as outlined by this paragraph:    The employer did not develop and implement written operating procedures for the operation of the ammonia refrigeration system.  Lack of written procedures for the operation of the equipment can lead to employee exposure to the release of ammonia during operation.    Abatement documentation is required of this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Oct 6, 2015

Abate by

Apr 1, 2016

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish written procedures to maintain the on-going integrity of process equipment:    The employer did not establish any written procedures for preventive maintenance tasks which are intended to maintain the integrity of the equipment in the ammonia refrigeration process, including but not limited to, lubricating the motor and pump bearing assembly on the glycol pump, cleaning the bubbler on the refrigeration purger, greasing the motor and changing the oil filters on the reciprocating compressors, calibrating the pressure and temperature sensors on the screw compressors, and changing the oil filters and cleaning the strainers on the screw compressors.  Lack of written procedures for the maintenance of equipment can lead to employee exposure to the release of ammonia during maintenance tasks.    Abatement documentation is required of this item in accordance with the requirements of 29 CFR 1903.(d).

Issued

Oct 6, 2015

Abate by

Jan 7, 2016

Penalty

Initial $3,500 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(i): The employer did not perform inspection and tests on process equipment:     On or about April 8, 2015, the employer did not perform an independent inspection at least once every five years in accordance with recommended and generally accepted good engineering practices such as, but not limited to, IIAR Bulletin No. 110, Guidelines for: the High Pressure Receiver, the Nurse Tank Receiver, the Suction Accumulator, the Intercooler Vessel, the Intercooler Oil Pot Vessel, the North Ice Builder Oil Pot Vessel, the South Ice Builder Oil Pot Vessel, the S & T Glycol Chiller Oil Pot Vessel, the High Side Transfer System Vessel, and the Low side Transfer Vessel.  This condition increases the likelihood that defects in the integrity of the vessels will be missed leading to a significant or catastrophic release of ammonia.      Abatement documentation is required of this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Oct 6, 2015

Abate by

Dec 15, 2015

Penalty

Initial $4,900 · Current $2,850 Reduced

General-duty citation text

29 CFR 1910.147(d): The established procedure for the application of energy control (the lockout or tagout procedures) did not cover the actions listed in and was not done in the following sequence:    Employees who performed servicing and maintenance on and around the Blow Mold Trimmer were not required to:    (1) Know the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy;  (2) Turn off and shut down the machine;  (3) Physically locate and operate energy isolating devices in such a manner as to isolate the machine or equipment from the energy source;  (4) Affix lockout or tagout devices to each energy isolating device;  (5) Prior to starting work on machines that have been locked out or tagged out, verify that isolation and deenergization of the machine or equipment have been accomplished.    Employees required to rely upon electronic control components were exposed to amputation hazards from the unexpected start-up and energizing of the Blow Mold Trimmer.    Abatement documentation is required of this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

Oct 6, 2015

Abate by

Dec 15, 2015

Penalty

Initial $4,900 · Current $2,850 Reduced

General-duty citation text

29 CFR 1910.212(a)(2): Guard(s) on machine(s) were not affixed to the machine or secured elsewhere when attachment to the machine was not possible:    The Plexiglas covers on the Blow Mold Trimmer were not affixed to the machine.  They were hinged at the top, allowing an employee to lift the cover and reach into the point of operation.  The limit switch on the door was not safety rated and was not installed properly and allowed the cover to be opened without stopping the machine.  Employees were exposed to an amputation hazard.    Abatement documentation is required of this item in accordance with the requirement of 29 CFR 1903.19(d).