Safety Incidents OSHA Severe Injury Reports · 2015–2025
5,189,992Inspections Most recent open 2026-07-18 Last loaded 2026-07-22

OSHA Inspection: RUSSELL STOVER CANDIES, INC.

Complaint inspection · Safety discipline

On , OSHA opened a complaint safety inspection of RUSSELL STOVER CANDIES, INC. in 1995 MARSHMALLOW LANE, IOLA, KS 66749 (NAICS 311352). OSHA activity number 340953157.

What this inspection record means

OSHA opens inspections for many reasons — routine scheduling under a national or local emphasis program, an employee complaint or referral, or a follow-up after a reported injury. Opening or conducting an inspection is not itself an allegation or a finding that this employer broke any rule; any findings appear as the citations listed below, and citations can be contested, reduced, or withdrawn.

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Site address
1995 MARSHMALLOW LANE
City
IOLA
State
KS
ZIP
66749
Mailing
1995 MARSHMALLOW LANE, IOLA, KS 66749
Inspection type
Complaint (B)
Scope
Partial (B)
Discipline
Safety
Advance notice
No
Union status
B
Opened
Closing conference
Case closed
Last modified
Data loaded
NAICS code
311352
Employees
380
Ownership type
A

23 citations on file for this inspection.

1910.119 D02 I E

Serious Gravity 10 1 instance 380 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $7,000 · Current $3,500 Reduced
29 CFR 1910.119(d)(2)(i)(E): The employer failed to perform an evaluation of the consequences of deviations, including those effecting the safety and health of employees:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the employer fails to perform an evaluation of the consequence of deviations from the operating temperature, pressures, and flows.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $3500
  • — Z (S) $7000

1910.119 E03 I

Other-than-serious 1 instance 380 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $7,000 · Current $3,500 Reduced
29 CFR 1910.119(e)(3)(i): The Process Hazard Analysis did not address the hazards of the process:    The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the Process Hazard Analysis fails to address the quality of incoming Ammonia. The Appendix D - 2014 PHA "What-If" questions under the Charging Ammonia to System PHA Notes section does not address this requirement.    29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (O) $3500
  • — Z (S) $7000

1910.119 E03 III

Deleted Serious Gravity 1 1 instance 380 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $3,300 · Current $0 Reduced
29 CFR 1910.119(e)(3)(iii): The process hazard analysis did not address engineering and administrative controls applicable to the hazards and their interrelationships such as appropriate application of detection methodologies to provide early warning of releases. (Acceptable detection methods might include process monitoring and control instrumentation with alarms, and detection hardware such as hydrocarbon sensors.):  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the employer fails to verify that the engine room complied with recognized and generally accepted good engineering practices such as IIAR Bulletin #111 06/02; ASHRAE-15 2013; ANSI/IIAR 2-2012; and the Manufacture Manual. The Scott Instruments QuadScan II - Model 7400 Ammonia Sensors in the North and South Ammonia Rooms are mounted at 20 feet from the floor while the Manufacture Manual states that the unit location should have easy visibility and access for the operator.  29 CFR 1903.19(c)(1) requires certification that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $0
  • — Z (S) $3300

1910.119 E05

Other-than-serious 1 instance 6 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $4,400 · Current $2,200 Reduced
29 CFR 1910.119(e)(5): The employer did not establish a system to promptly address the team's findings and recommendations; assure that the recommendations were resolved in a timely manner and that the resolution was documented; document what actions were to be taken; complete actions as soon as possible; develop a written schedule of when these actions were to be completed; communicate the actions to operating, maintenance and other employees whose work assignments were in the process and who may have been affected by the recommendations or actions:    The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the employer is failing to provide document that it has communicated all the findings and recommendations of the 2000 Process Hazard Analysis (PHA) initial study, the 2004, 2009, and 2014 Process Hazard Analysis (PHA) revalidation studies to the Ammonia Department employees such as, but not limited to the Plant Engineer, Maintenance Supervisors, Skilled Specialists - HVAC, Skilled Specialist - Electrician, and Skilled Specialist - Electronic Technician.    29 CFR 1903.19(c)(1) requires certification that the abatement of the above violation is completed.
Recent events (2)
  • — I (O) $2200
  • — Z (S) $4400

1910.119 F01 I D

Serious Gravity 10 1 instance 6 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $7,000 · Current $3,500 Reduced
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:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the employer is failing to develop a written standard operating procedure with clear instructions such as when or what conditions to activate, how to operate, and who is authorized to activate the Refrigeration Equipment Emergency Stop buttons related to the intended use of the emergency stop buttons located outside each exit of the North and South Ammonia rooms.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $3500
  • — Z (S) $7000

1910.119 F01 II B

Serious Gravity 10 3 instances 6 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $7,000 · Current $5,600 Reduced
29 CFR 1910.119(f)(1)(ii)(B): The employer's written operating procedures covering operating limits did not address the steps required to correct or avoid deviation:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the operating procedures for Ammonia process equipment does not address the steps required to correct or avoid the listed deviations. Identified operating procedures such as but not limited to the following:  a) NH3-N004 Ammonia Compressors RC-1 and RC-2 (-10F System) - Revision June 16, 2011 b) NH3-S003 Ammonia Compressors RC-3 and RC-4 (+20F System) - Revision June 16, 2011 c) NH3-S004 Ammonia Compressors RC-5 and RC-6 (+38F System) - Revision June 16, 2011.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $5600
  • — Z (S) $7000

1910.119 F01 III

Serious Gravity 10 6 instances 6 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $7,000 · Current $3,500 Reduced
29 CFR 1910.119(f)(1)(iii): The employer failed to ensure that the Process Safety Management Standard Operating Procedures included safety and health considerations:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the operating procedures for Ammonia process equipment does not address safety and health considerations such as but not limited to the following:  A) Properties of, and hazards presented by, the chemicals used in the process; C) Control measures to be taken if physical contact or airborne exposure occurs; D) Quality control for raw materials and control of hazardous chemical inventory levels; and, E) Any special or unique hazards.  Identified operating procedures such as but not limited to the following:  a) NH3-N002 North System Start-up and Shutdown - Revision July 12, 2012 b) NH3-N004 Ammonia Compressors RC-1 and RC-2 (-10F System) - Revision June 16, 2011 c) NH3-N005 North System Suction Accumulator SA001 and Draining Oil Pot OP3 - Revision July 12, 2012 d) NH3-N015 North System Ammonia Pumps AP-1 and AP-2 - Revision November 15, 2010 e) NH3-S003 Ammonia Compressors RC-3 and RC-4 (+20F System) - Revision June 16, 2011 f) NH3-S004 Ammonia Compressors RC-5 and RC-6 (+38F System) - Revision June 16, 2011.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $3500
  • — Z (S) $7000

1910.119 F01 IV

Serious Gravity 10 3 instances 6 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $7,000 · Current $3,500 Reduced
29 CFR 1910.119(f)(1)(iv): The employer failed to ensure that the Process Safety Management Standard Operating Procedures included safety systems and their functions:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the operating procedures for Ammonia process equipment does not address safety systems and their functions such as but not limited to the emergency stop buttons, isolation devices (King Valves), interlocks, alarms, level cutouts, water spray systems, and emergency backup power.  Identified operating procedures such as but not limited to the following:  a) NH3-N004 Ammonia Compressors RC-1 and RC-2 (-10F System) - Revision June 16, 2011 b) NH3-S003 Ammonia Compressors RC-3 and RC-4 (+20F System) - Revision June 16, 2011 c) NH3-S004 Ammonia Compressors RC-5 and RC-6 (+38F System) - Revision June 16, 2011.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $3500
  • — Z (S) $7000

1910.119 G01 I

Serious Gravity 10 5 instances 6 exposed
Issued
Mar 30, 2016
Abate by
May 31, 2016
Penalty
Initial $7,000 · Current $7,000
29 CFR 1910.119(g)(1)(i): The employer did not train each employee involved in the operating process, in an overview of the process and in the operating procedures as specified in paragraph (f) of 29 CFR 1910.119:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the employer is failing to provide training as listed below for the Refrigeration Department employees regarding the Iola Russell Stover Candies (RSC) site-specific safety and health hazards, emergency operations to include shut down and safe work practices related to their assigned duties and responsibilities to perform tasks in the Ammonia process.  a) New Maintenance Supervisor and Skilled Specialists have not received training on the site specific operating procedures for processes and Ammonia refrigeration equipment. The covered subject should include but not limited to the operational phases, operational limits, safety and health considerations.  b) New Maintenance Supervisor and Skilled Specialists have not received training on the site specific Ammonia Emergency Response Plan and Ammonia Release Response Plan while required to respond to the recent September Ammonia release incident.  c) The employer does not provide training for all of the Refrigeration Department personnel on the site specific overview of the process.  d) The employer does not provide training for all of the Refrigeration Process Department personnel on the Unloading Anhydrous Ammonia Tank Wagon System Entire Operating Procedure.  e) Adequate training is not provided to personnel performing daily rounds, during which observations and readings were taken on various process equipment in the North and South Ammonia systems. The on the job training provided to these new personnel does not cover the consequences of deviation from operational limits for the process equipment.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $7000
  • — Z (S) $7000

1910.119 G03

Serious Gravity 1 1 instance 6 exposed
Issued
Mar 30, 2016
Abate by
May 31, 2016
Penalty
Initial $0 · Current $0
29 CFR 1910.119(g)(3): The employer did not prepare a record which contained the identity of the employee, the date of training, and the means used to verify that the employee understood the training:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where the employer is failing to provide documentation of the means that the employer used to verify through demonstration that the Ammonia Technician employees understood any training they received including but not limited to the training on the Iola RSC Plant site-specific standard operating procedures; startup and shutdown; safe work practice.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $0
  • — Z (S) $0

1910.119 G02

Serious Gravity 1 1 instance 6 exposed
Issued
Mar 30, 2016
Abate by
May 31, 2016
Penalty
Initial $0 · Current $0
29 CFR 1910.119(g)(2): Refresher training was not provided at least every three years, and more often if necessary, to each employee involved in operating a process to assure that the employee understood and adhered to the current operating procedures of the process. The employer, in consultation with the employees involved in operating the process, shall determine the appropriate frequency of refresher training:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the employer is failing to consult with Ammonia Technician employees concerning the frequency of their need for refresher training.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $0
  • — Z (S) $0

1910.119 J03

Serious Gravity 10 1 instance 6 exposed
Issued
Mar 30, 2016
Abate by
May 31, 2016
Penalty
Initial $0 · Current $0
29 CFR 1910.119(j)(3): The employer did not train each employee involved in maintaining the on-going integrity of process equipment in the procedures applicable to the employee's job tasks to ensure that the employee can perform the job tasks in a safe manner:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the employer is failing to provide training for refrigeration employees related to the maintenance activities for the process covered-equipment; the inspection, testing and preventive maintenance procedures applicable to the employee's job tasks.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $0
  • — Z (S) $0

1910.119 H02 I

Serious Gravity 5 1 instance 380 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $4,400 · Current $3,500 Reduced
29 CFR 1910.119(h)(2)(i): The employer, when selecting a contractor, did not obtain and evaluate information regarding the contract employer's safety performance and program:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the employer is failing to obtain and evaluate the safety and health performance and written programs of the contractor (Airgas Specialty Products) that delivers Ammonia to the facility.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $3500
  • — Z (S) $4400

1910.119 J04 I

Serious Gravity 10 4 instances 6 exposed
Issued
Mar 30, 2016
Abate by
Oct 3, 2016
Penalty
Initial $7,000 · Current $7,000
29 CFR 1910.119(j)(4)(i): Inspections and tests were not performed on process equipment to maintain its mechanical integrity:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the following inspections and tests were not adequately performed:  a) Inspection and testing is not adequately performed for vessels and tanks such as Evaporators, High Pressure Receivers, and Condensers to determine if there were any corrosion damage and to establish a corrosion rate for the vessel.  b) Inspection and testing is not adequately performed for emergency shutdown systems including but not limited to the Refrigeration Equipment Emergency Stop buttons, Ammonia Alarm buttons, Compressor cutouts including discharge temperature, discharge pressure, oil temperature (upper and lower), oil sump temperature maximum, Accumulator high and low liquid level cutouts, and the King valves.  c) Inspection and testing is not adequately performed for controls (including monitoring devices and sensors, level cutouts, alarms, and interlocks) such as Compressor liquid level control sensors, Compressor thermostats, Compressor liquid level controls, Pump out system level alarms.  d) Inspection and testing is not adequately performed for Ammonia compressors and pumps.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $7000
  • — Z (S) $7000

1910.119 J04 IV

Serious Gravity 10 4 instances 6 exposed
Issued
Mar 30, 2016
Abate by
Oct 3, 2016
Penalty
Initial $0 · Current $0
29 CFR 1910.119(j)(4)(iv): The employer did not document the date of inspection, the name of the person performing the inspection, the serial number or other identifier of the equipment on which the inspection or test was performed, a description of the inspection, and the results of the inspection for each piece of process equipment:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the following inspections and tests were not documented:  a) Inspection and testing is not document for vessels and tanks such as Evaporators, High Pressure Receivers, and Condensers to determine if there were any corrosion damage and to establish a corrosion rate for the vessel.  b) Inspection and testing is not document for emergency shutdown systems including but not limited to the Refrigeration Equipment Emergency Stop buttons, Ammonia Alarm buttons, Compressor cutouts including discharge temperature, discharge pressure, oil temperature (upper and lower), oil sump temperature maximum, Accumulator high and low liquid level cutouts, and the King valves.  c) Inspection and testing is not document for controls (including monitoring devices and sensors, level cutouts, alarms, and interlocks) such as Compressor liquid level control sensors, Compressor thermostats, Compressor liquid level controls, Pump out system level alarms.  d) Inspection and testing is not document for Ammonia compressors and pumps.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $0
  • — Z (S) $0

1910.119 M04

Other-than-serious 9 instances 6 exposed
Issued
Mar 30, 2016
Abate by
May 31, 2016
Penalty
Initial $7,000 · Current $1,000 Reduced
29 CFR 1910.119(m)(4): An incident report was not prepared at the conclusion of the investigation that included at a minimum, the date of the incident, date the investigation began, a description of the incident, and any recommendations resulting from the investigation:    The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the incident investigation reports were not prepared to its completeness.    a) Incident Investigation Reference No. 2015-September-23, the Close Out Report does not include recommendations regarding the Investigation Review Sessions to address the leaking coil at the AC-4.     b) Incident Investigation Reference No. 2015-March-29, the Close Out Report does not include recommendations regarding the Investigation Review Sessions to address the leaking coil at the AC-8.    c) Incident Investigation Reference No. Iola 2015-January-29, the Close Out Report does not include recommendations regarding the Investigation Review Sessions to address the leaking at the economizer valve packing on RC-1 Ammonia compressor. Reference number on the last page has the wrong date.    d) Incident Investigation Reference No. Iola 2015-January-18, the Close Out Report does not include recommendations regarding the Investigation Review Sessions to address the leaking coil on the gasket in hot gas valve for the evaporators.    e) Incident Investigation Reference No. Iola 2014-March-12, the Close Out Report does not include recommendations regarding the Investigation Review Sessions to address the Ammonia vapor release on a shaft seal on Ammonia compressor RC-5. Date and time team commenced investigation is not completed to show that the investigation started within 48 hours of the incident. There are no signatures of the submitter or the receiver for approvals, follow-up and reviews. There are no signatures of the team leader and the approver to close-out the incident investigation report.    f) Incident Investigation Reference No. Iola 2013-May-16, date and time team commenced investigation is not completed to show that the investigation started within 48 hours of the incident. The form is not signed by the team leader.    g) Incident Investigation Reference No. Iola 2010-August-1, the Close Out Report does not include recommendations regarding the Investigation Review Sessions. Date and time team commenced investigation is not completed to show that the investigation started within 48 hours of the incident. The form is not signed by any of the management team. The form is marked as DRAFT - Document for development and review only.    h) Incident Investigation Reference No. Iola 2010-June 18, the Close Out Report does not include recommendations regarding the Investigation Review Sessions. Date and time team commenced investigation is not completed to show that the investigation started within 48 hours of the incident. The form is not signed by any of the management team. The form is marked as DRAFT - Document for development and review only.    i) Incident Investigation Reference No. Iola 2010-January 14, the Close Out Report does not include recommendations regarding the Investigation Review Sessions. Date and time team commenced investigation is not completed to show that the investigation started within 48 hours of the incident. The form is not signed by any of the management team. The form is marked as DRAFT - Document for development and review only.    29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (O) $1000
  • — Z (S) $7000

1910.119 M06

Other-than-serious 5 instances 6 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $7,000 · Current $1,000 Reduced
29 CFR 1910.119(m)(6): The report were not reviewed with all affected personnel whose job tasks are relevant to the incident findings including contract employees where applicable:    The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the incident investigation reports were not reviewed with all the Ammonia personnel who can benefit from the information in their daily tasks.    a) Incident Investigation Reference No. 2015-September-23, review process resulting from the investigation is not implemented when Approvals, Follow-up and Reviews or Close-Out the report; the Recommended Employee Reviews of Report section and the Investigation Review Sessions are marked N/A.     b) Incident Investigation Reference No. 2015-March-29, review process resulting from the investigation is not implemented when Approvals, Follow-up and Reviews or Close-Out the report; the Recommended Employee Reviews of Report section and the Investigation Review Sessions are marked N/A.    c) Incident Investigation Reference No. Iola 2015-January-29, review process resulting from the investigation is not implemented when Approvals, Follow-up and Reviews or Close-Out the report; the Recommended Employee Reviews of Report section and the Investigation Review Sessions are marked N/A.    d) Incident Investigation Reference No. Iola 2015-January-18, review process resulting from the investigation is not implemented when Approvals, Follow-up and Reviews or Close-Out the report; the Recommended Employee Reviews of Report section and the Investigation Review Sessions are marked N/A.    e) Incident Investigation Reference No. Iola 2014-March-12, review process resulting from the investigation is not implemented when Approvals, Follow-up and Reviews or Close-Out the report; the Recommended Employee Reviews of Report section and the Investigation Review Sessions are marked N/A and blank without any signatures of the management.    29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (O) $1000
  • — Z (S) $7000

1910.120 Q06 III

Deleted Serious Gravity 10 1 instance 6 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $7,000 · Current $0 Reduced
29 CFR 1910.120(q)(6)(iii): Employees who participated as hazardous materials technicians, or were expected to participate as hazardous materials technicians, had not received at least 24 hours of training equal to the first responder operations level, and in addition have competency in the areas outlined in 29 CFR 1910.120(q)(6)(iii)(A) through (q)(6)(iii)(I) and/or the employer did not so certify:  On or about September 23rd, 2015 and October 21, 2015, the employer failed to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were responding to two different instances of Ammonia leaks and were exposed to inhalation hazards and skin exposures in that the employees tasked with isolating the leaks/releases were not HAZWOPER trained.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (S) $0
  • — Z (S) $7000

1910.119 J02

Repeat Gravity 5 6 instances 6 exposed
Issued
Mar 30, 2016
Abate by
Oct 3, 2016
Penalty
Initial $27,500 · Current $27,500
29 CFR 1910.119(j)(2): The employer did not establish and implement written procedures to maintain the on-going integrity of process equipment:  The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the employer is failing to develop and implement the detail written mechanical integrity program procedures to ensure the maintaining of the on-going integrity of process equipment such as pressure vessels, storage tanks; piping systems (piping components such as valves); relief and vent systems and devices; emergency shutdown systems; controls (monitoring devices and sensors, alarms, and interlocks); and pumps. The employer does not address specific task procedures for the inspection, testing, preventive maintenance, repairing, rerating, or replacing pressure vessels, receivers, piping, or materials and spare parts control; outlining responsibilities, authorizations, and approval for repairs, steps to accomplish for repairing or replacing equipment, frequency of replacement, employee training and qualifications, welding and heat treating requirements, inspection and testing after repair, and documentation requirements.  a) The employer is failing to develop and implement a written mechanical integrity procedure that addressed inspecting pressure vessels and piping; corrosion under the insulation inspections; minimum wall thickness inspections for pressure vessels and piping.  b) The employer is failing to develop and implement a written mechanical integrity procedure for evaluating valves such as the King valve in the Ammonia process.  c) The employer is failing to develop and implement a written mechanical integrity procedure for evaluating relief and vent systems and devices.  d) The employer is failing to develop and implement a written mechanical integrity procedure for evaluating emergency shutdown systems.  e) The employer is failing to develop and implement a written mechanical integrity procedure for evaluating safety critical controls (including monitoring devices, sensors, level cutouts, alarms, and interlocks).  f) The employer is failing to develop and implement a written mechanical integrity procedure for evaluating pumps.  The Russell Stover Candies, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.119(j)(2), which was contained in OSHA inspection number 905429, citation number 1, item number 4, and was affirmed as a final order on 9/12/2013, with respect to a workplace located at 1997 Pecan Delight Ave. Corsicana, TX 75110.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (R) $27500
  • — Z (R) $27500

1910.119 J04 II

Repeat Gravity 10 1 instance 6 exposed
Issued
Mar 30, 2016
Abate by
Oct 3, 2016
Penalty
Initial $38,500 · Current $38,500
29 CFR 1910.119(j)(4)(ii): Inspection and testing procedures did not follow recognized and generally accepted good engineering practices:    The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that the employer is failing to ensure inspections and tests performed on process equipment to maintain its on-going mechanical integrity following recognized and generally accepted good engineering practices (RAGAGEP) such as IIAR Bulletin 110 3/93 as certified in the company Process Safety Information (PSI) binder by the Plant Manager.     Identified critical equipment include but not limited to the vessels and tanks such as Evaporators, High Pressure Receivers, and Condensers; the emergency shutdown systems including but not limited to the Refrigeration Equipment Emergency Stop buttons, Ammonia Alarm buttons, Compressor cutouts including discharge temperature, discharge pressure, oil temperature (upper and lower), high and low pressure cutouts, oil sump temperature maximum, Accumulator high and low liquid level cutouts, and the King valves; the controls (including monitoring devices and sensors, level cutouts, alarms, and interlocks) such as Compressor liquid level control sensors, Compressor thermostats, Compressor liquid level controls, Pump out system level alarms.    The Russell Stover Candies, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.119(j)(4)(ii), which was contained in OSHA inspection number 905429, citation number 1, item number 5a, and was affirmed as a final order on 9/12/2013, with respect to a workplace located at 1997 Pecan Delight Ave. Corsicana, TX 75110.    29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (R) $38500
  • — Z (R) $38500

1910.119 J04 III

Repeat Gravity 10 5 instances 6 exposed
Issued
Mar 30, 2016
Abate by
Oct 3, 2016
Penalty
Initial $38,500 · Current $0 Reduced
29 CFR 1910.119(j)(4)(iii): The frequency of inspections and tests of process equipment to maintain its mechanical integrity, was not consistent with applicable manufacturer's recommendations and good engineering practices, or more frequently determined to be necessary by prior operating experience:      The employer is failing to protect employees engaged in production activities throughout the facility. This was most recently documented where employees were exposed to chemical hazards associated with a catastrophic release of Ammonia in that inspections and tests have not been performed and documented based on the appropriate inspection frequency as required by the applicable manufacturers' recommendations and good engineering practices for the following process equipment:    a) Mycom Compressors only have records of Daily Rounds and Annual inspection. There are no records showing other various inspections have been performed for the interval of quarterly and bi-annually (Elapsed total runtime x 1000 hours = 0.2, 5, 10, 20, 30, 40, 50.)    b) Evaporators only have records of Daily Rounds. There are no records showing other various inspections have been performed for the interval of weekly, monthly, and bi-annually (0.2, 1, 2, 12, or 52 times per year.)    c) Condensers only have records of Daily Rounds. There are no records showing other various inspections have been performed for the interval of weekly, monthly, and bi-annually (0.02, 1, 2, 4, 12, or 52 times per year.)    d) Ammonia Pumps only have records of Daily Rounds. There are no records showing other various inspections have been performed for the interval of monthly, and bi-annually (0.2, 1 or 12 times per year.)    e) High Pressure Receivers only have records of Daily Rounds. There are no records showing other various inspections have been performed for the interval of weekly, and bi-annually (0.2, 1 or 52 times per year.)    The Russell Stover Candies, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.119(j)(4)(iii), which was contained in OSHA inspection number 905429, citation number 1, item number 5b, and was affirmed as a final order on 9/12/2013, with respect to a workplace located at 1997 Pecan Delight Ave. Corsicana, TX 75110.    29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (R) $0
  • — Z (R) $38500

1910.119 F04

Other-than-serious 1 instance 6 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $0 · Current $0
29 CFR 1910.119(f)(4): The employer did not develop and implement safe work practices to provide for the control of hazards during operations such as lockout/tagout; confined space entry; opening process equipment or piping; and control over entrance into a facility by maintenance, contractor, laboratory, or other support personnel:  The employer is failing to develop a written standard operating procedure with clear instructions for opening of process equipment or piping.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (O) $0
  • — Z (O) $0

1910.119 L03

Deleted Other-than-serious 1 instance 6 exposed
Issued
Mar 30, 2016
Abate by
Apr 21, 2016
Penalty
Initial $0 · Current $0
29 CFR 1910.119(l)(3): Employees involved in operating a process and maintenance and contract employees whose job tasks would be affected by a change in the process were not informed of and trained in the change prior to start-up of the process or affected part of the process:  The employer failed to protect the employees in that the employer submitted the MCF Number 2014-006 document on 6-23-2014 for replacing the Mycom Ammonia Compressor control panels but failed to provide a document to support that the Refrigeration Skilled-Specialists have been trained on operating the new control panels.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.
Recent events (2)
  • — I (O) $0
  • — Z (O) $0

View Russell Stover Candies, INC.'s full OSHA safety record →

This record is reproduced from the U.S. Department of Labor Open Data API (OSHA inspection dataset). The original IMIS detail view is available at OSHA's Establishment Search for activity number 340953157.

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