OSHA Inspection: MAGIC VALLEY FRESH FROZEN, LLC

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $4,500 · Current $2,250 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): Employer did not ensure the Piping and Instrument diagrams (P&ID's) were complete and accurate:    This violation was most recently observed on or about July 21, 2015 and times prior thereto and times thereafter, in the Refrigeration Process at Magic Valley Frozen Plant located in McAllen, Texas when the employer did not ensure the Process Safety Information were complete and accurate including but not limited to the Piping and Instrument Diagrams such as:        a)  Current P&ID was not updated to reflect new condensers, purger, thermosiphon and process piping.      b)  Valve #1072, #1055 missing on drawing for Compressor R223.       c)  Inconsistency in equipment identifiers/labels (dual).      d)  Valve #1161, 1162, 1163, 1229 was shown on valve lists, not shown on drawing for R028 Compressor.       e)  P&ID drawings did not include R006, R009, R220 and R008 Recirculators.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $4,500 · Current $2,250 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:    This violation was most recently observed on or about July 21, 2015 and times prior thereto and times thereafter   in the Refrigeration Process at Magic Valley Frozen Plant located in McAllen, Texas when the employer did not ensure and document:          a)  the engine room was equipped with an ammonia detector as stipulated in RAGAGEP such as ANSI/ASHRAE Standard 15-2013.            b)  the ammonia refrigeration piping and system components; included but not limited to the King Valve (HV 100) on the High Pressure Receiver is properly identified. IIAR Bulletin No. 109, IIAR Minimum Safety Criteria for a Safe Ammonia Refrigeration System, section 4.10.3, indicates that the main shut-off valve(s) (king valve(s)); of the ammonia system should be readily accessible and identified with a prominent sign having letters sufficiently large to be easily read.         c)  when the employer did not complete the design calculations and/or verification of current fan design for the mechanical ventilation system in the engine room as stipulated in RAGAGEP such as ANSI/IIAR Standard 15.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $4,500 · Current $2,250 Reduced

General-duty citation text

29 CFR 1910.119(f)(3): The operating procedures were not reviewed as often as necessary to assure that they reflect current operating practice, including changes that result from changes in process chemicals, technology, and equipment, and changes to facilities. The employer shall certify annually that these operating procedures are current and accurate.    This violation was most recently observed on or about July 21, 2015 and time thereafter, in the Magic Valley Frozen Ammonia Refrigeration Process, when the employer failed to ensure the Total System Shut Down Procedure (SOP) was current and accurate to reflect current operating practice, including changes that resulted from changes in process equipment.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $6,300 · Current $3,150 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish and implement written procedures to maintain the on-going integrity of process equipment.    This violation was most recently observed on or about July 21, 2015 and times prior thereto and times thereafter, in the Refrigeration Process at Magic Valley Frozen Plant located in McAllen, Texas, when the employer did not establish and implement written procedures for in-service inspection of process equipment such as but not limited to pressure vessels and process piping.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $4,500 · Current $2,250 Reduced

General-duty citation text

29 CFR 1910.119(j)(5): The employer did not correct deficiencies in equipment that are outside acceptable limits (defined by the process safety information in paragraph (d) of this section) before further use or in a safe and timely manner when necessary means are taken to assure safe operation.    This violation was most recently observed on or about July 21, 2015and times prior thereto and times thereafter, in the engine room when the employer failed to ensure the insulation on process vessel (Recirculator R-220) and piping (Intercooler R-034) was repaired and sealed per IIAR Bulletin No. 109 section 4.7.5 (Minimum Safety Criteria for a Safe Ammonia Refrigeration System) and IIAR Bulletin No. 110 1993 (Guidelines for: Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems) section 6.7.2 to prevent condensation and corrosion.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(ii): The employer shall document that equipment complies with recognized and generally accepted good engineering practices:  This violation was most recently observed on or about July 21, 2015, and times prior thereto and times thereafter, in the engine room, the employer failed to document the deficiencies for the need to repair and seal the insulation on process vessel (Recirculator R-220) and piping (Intercooler R-034) per IIAR Bulletin No. 109 section 4.7.5 (Minimum Safety Criteria for a Safe Ammonia Refrigeration System) and IIAR Bulletin No. 110 1993 (Guidelines for: Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems) section 6.7.2 to prevent condensation and corrosion.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $6,300 · Current $3,150 Reduced

General-duty citation text

29 CFR 1910.119(l)(1): The employer did not 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.    This violation was most recently observed on or about July 21, 2015 in the Refrigeration Process at Magic Valley Frozen Plant located in McAllen, Texas when the employer did not establish and implement the Management of Change (MOC) procedure to manage changes including but not limited to the addition of a new Air purger, Thermosiphon and its associated piping.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(i)(1): The employer did not perform a pre-startup safety review for new facilities and for modified facilities when the modification is significant enough to require a change in the process safety information.  This violation was most recently observed on or about July 21, 2015 in the Refrigeration Process at Magic Valley Frozen Plant located in McAllen, Texas when the employer did not perform a pre-startup safety review (PSSR) when new process equipment was installed including but not limited to the new Air Purger, Condensers, Thermosiphon and its associated piping.

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $4,500 · Current $2,250 Reduced

General-duty citation text

29 CFR 1910.134(d)(2)(i)(A): A full facepiece pressure demand SCBA certified by NIOSH for a minimum service life of thirty minutes.      This violation was most recently observed on or about July 21, 2015 and times prior thereto and times thereafter, in the Refrigeration Process at Magic Valley Frozen Plant located in McAllen, Texas when the employer did not ensure the engine room was equipped with a self contained breathing apparatus (SCBA) located outside of, but close to, the exit door. A second, backup, self contained breathing apparatus shall also be provided as stipulated in RAGAGEP such as IIAR Bulletin 109 (IIRA Minimum Safety Criteria for A Safe Ammonia Refrigeration System).

Issued

Dec 4, 2015

Abate by

Jan 25, 2016

Penalty

Initial $6,300 · Current $3,150 Reduced

General-duty citation text

29 CFR 1910.134(f)(2): The employer did not ensure that an employee using a tight-fitting facepiece respirator is fit tested prior to initial use of the respirator, whenever a different respirator facepiece (size, style, model or make) is used, and at least annually thereafter.    On or about July 21, 2015, in the Ammonia Refrigeration Process Unit at Magic Valley Frozen, LLC located in McAllen, Texas, the employer did not ensure employees were fit tested prior to initial use of a tight-fitting facepiece respirator and at least annually thereafter.