OSHA Inspection: TYSON FOODS, INC.

Issued

Jan 11, 2016

Abate by

Jan 12, 2016

Penalty

Initial $3,300 · Current $1,980 Reduced

General-duty citation text

29 CFR 1910.23(a)(2): Ladder way floor opening(s) or platform(s) were not guarded by a standard railing with standard toe board(s) on all exposed sides (except at the entrance to opening) with passage through the railing either provided with a swinging gate or so offset that a person could walk directly into the opening.    On or about 27 July 2015,the platform for the High Pressure Receiver and components did not have railing on the side of the vessel.

Issued

Jan 11, 2016

Abate by

Jan 12, 2016

Penalty

Initial $3,300 · Current $1,980 Reduced

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 27 July 2015, and at times prior thereto, the employer did not ensure the King Valve for the High Pressure Receiver was available in order to implement the shutdown procedure in the event of an emergency. The valve was identified by signage but the hand wheel was missing and not available onsite.

Issued

Jan 11, 2016

Abate by

Jan 21, 2016

Penalty

Initial $3,300 · Current $1,980 Reduced

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(A): The employer did not develop and implement written operating procedures that addressed the consequences of deviations from the operating limits in the covered process.     On or about 27 July 2015, and at times prior thereto, the employer did not address the consequences of deviations from the operating limits in the covered anhydrous ammonia system.     b) SOP-DM-HEX Heat Exchanger - Dark Meat HEX and Control Bank did not include the consequences of deviation from the operating limits in the covered process.  c) SOP-DP1-HEX Heat Exchanger - Dapec 1 HEX and Control Bank did not include the consequences of deviation from the operating limits in the covered process.  d) SOP-DP2-HEX Heat Exchanger - Dapec 2 HEX and Control Bank did not include the consequences of deviation from the operating limits in the covered process.  e) The three procedures for draining oil from the Low Temperature 0pF Recirculator Oil Pot, Horizontal Oil Pot, and Vertical Oil Pot, did not include the consequences of deviation from the operating limits in the covered process.

Issued

Jan 11, 2016

Abate by

Jan 21, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(B): The employer did not develop and implement written operating procedures that provide clear instructions for steps required to correct or avoid deviation from the operating limits in the covered process.    On or about 27 July 2015, and at times prior thereto, the employer did not address the steps required to correct or avoid deviation from the operating limits in the covered anhydrous ammonia system.     b) SOP-DM-HEX Heat Exchanger - Dark Meat HEX and Control Bank did not include the steps required to correct or avoid deviation from the operating limits in the covered process.  c) SOP-DP1-HEX Heat Exchanger - Dapec 1 HEX and Control Bank did not include the steps required to correct or avoid deviation from the operating limits in the covered process.  d) SOP-DP2-HEX Heat Exchanger - Dapec 2 HEX and Control Bank did not include the steps required to correct or avoid deviation from the operating limits in the covered process.  e) The three procedures for draining oil from the Low Temperature 0pF Recirculator Oil Pot, Horizontal Oil Pot, and Vertical Oil Pot, did not include the steps required to correct or avoid deviation from the operating limits in the covered process.

Issued

Jan 11, 2016

Abate by

Jan 12, 2016

Penalty

Initial $7,000 · Current $4,200 Reduced

General-duty citation text

29 CFR 1910.119(j)(6)(ii): Appropriate checks and inspections were not performed to assure that equipment was installed properly and consistent with design specifications and the manufacturer's instructions.    On or about 27 July 2015, and at times prior thereto, the employer did not assure that equipment was consistent with design specifications and per the manufacturer's instructions, exposing employees working in and around the system to the hazards associated with anhydrous ammonia. PSV 130183 and PSV 130184: Two Hansen PSV's were incorrectly installed on the Low Temperature 0 Degree Recirculator vessel. The vessel has a maximum allowable working pressure of 150 psi while the two PSV's were for 250 psi.

Issued

Jan 11, 2016

Abate by

Jan 12, 2016

Penalty

Initial $3,300 · Current $1,980 Reduced

General-duty citation text

29 CFR 1910.303(b)(7)(i): Unused openings in boxes, raceways, auxiliary gutters, cabinets, equipment cases, or housings were not effectively closed to afford protection substantially equivalent to the wall of the equipment.    On or about 27 July 2015, and at times prior thereto, a breaker panel within the Machinery Room for the anhydrous ammonia system had two open breaker slots with the panel open at the time of the inspection, exposing employees to an electrical hazard of approximately 110 volts.

Issued

Jan 11, 2016

Abate by

Jan 12, 2016

Penalty

Initial $1,100 · Current $660 Reduced

General-duty citation text

29 CFR 1910.119(f)(3): The employer did not certify annually that operating procedures were current and accurate.    On or about 27 July 2015, and at times prior thereto, the employer did not certify on an annual basis two operating procedures associated with the anhydrous ammonia system, exposing employees to the hazards of ammonia.  a) SOP-2 Personal Protective Equipment - Full Face Respirator had an approval date of 7/16/14 but the last date of certification was 7/2/2014. A similar procedure, SOP-1 Personal Protective Equipment - Gloves had an approval date of 7/16/14 and last certification date of 7/2/2015.  b) SOP-6 Charging Refrigerant into the System had an approved date of 11/28/2014. However, the SOP Revision Tracking Log shows a Rev 01 dated 5/8/2014 as Update Approval Document, without any certification date indicated.