OSHA Inspection: DIVERSIFIED FOODS AND SEASONINGS, LLC

Issued

Apr 8, 2016

Abate by

Apr 22, 2016

Penalty

Initial $7,000 · Current $5,000 Reduced

General-duty citation text

1910.119(d)(3)(i)(D): Process safety information pertaining to the equipment in the process did not include relief system design and design basis.      On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer did not document the relief system design and design basis for the ammonia refrigeration system exposing employees to toxic hazards of ammonia exposure.

Issued

Apr 8, 2016

Abate by

May 20, 2016

Penalty

Initial $7,000 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(e)(5): The employer did not assure that PHA recommendations were resolved in a timely manner.    On or about 10/20/2015, at the Diversified Foods and Seasoning facility located in Madisonville Louisiana, the employer did not resolve 2012 PHA recommendations in a timely manner such as but not limited to:      a.  Item # 1.4: Perform a RV Design calculation to verify RV meets minimum required capacity.    b.  Item # 5.18: Install pipe labels per ASME 13.1 to piping in cold rooms. Install warning detection below drain pan of air units.    This condition exposed employees to the hazards of inhalation of ammonia and fire/explosion.

Issued

Apr 8, 2016

Abate by

May 20, 2016

Penalty

Initial $7,000 · Current $2,000 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 (RAGAGEP).      a.       On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer did not document that it complied with recognized and generally accepted good engineering practice such as ANSI/ASHRAE-15 (American Society of Heating Refrigeration Air-Conditioning and Engineering) and ANSI/IIAR-2 (International Institute Ammonia Refrigeration) as it failed to install visual and audible alarms outside the engine room entrance doors exposing employees to the hazards of dangerous concentrations of ammonia following a release in the engine room.      b.      On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer did not document that it complied with recognized and generally accepted good engineering practice such as ANSI/ASHRAE-15 (American Society of Heating Refrigeration Air-Conditioning and Engineering) when it failed to set ammonia detectors in the engine room at a value not greater than TLV-TWA (Threshold limit value-time weighted average) exposing employees to toxic hazards of ammonia exposure.      c.       On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer did not document that it complied with recognized and generally accepted good engineering practice such as ANSI/ASHRAE-15 (American Society of Heating Refrigeration Air-Conditioning and Engineering) when it failed to ensure that alarms would activate upon failure of the ventilation system in the machine room exposing employees to fire, explosion, and toxic hazards following an ammonia release.      d.       On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer did not document that it complied with recognized and generally accepted good engineering practice such as ANSI/ASHRAE-15 (American Society of Heating Refrigeration Air-Conditioning and Engineering) and ANSI/IIAR-2 (International Institute Ammonia Refrigeration) when it failed to post an authorized personnel sign on the West entrance door of the engine room exposing employees to toxic hazards of ammonia exposure.      e.       On or about 10/20/2015, at the Diversified Foods and Seasoning facility located in Madisonville Louisiana, the employer did not document that it complied with recognized and generally accepted good engineering practice such as ANSI/IIAR-2 (International Institute Ammonia Refrigeration) when it failed to install an accessible eyewash and body shower station outside of the engine room exit exposing employees to toxic hazards of ammonia exposure.

Issued

Apr 8, 2016

Abate by

May 20, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(5):  The employer did not correct deficiencies in equipment that were outside acceptable limits in a timely manner.        a)      On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer failed to correct deficiencies in the mechanical ventilation system, in that it could not be activated by an ammonia detector or it ran continuously and was not provided with a supervisory alarm to detect failure or shutdown of the system exposing employees to the hazards of inhalation of ammonia and fire/explosion.  As a result of this deficiency, the engine room does not conform to the requirements of Class 1, Division 2 hazardous location, of the National Electrical Code and ANSI/ASHRAE-15 (American Society of Heating Refrigeration Air-Conditioning and Engineering)     b)      On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer failed to correct deficiencies in the ammonia refrigeration emergency control system when emergency control switches for ventilation fans were not installed/located immediately outside the engine room door in accordance with ANSI/ASHRAE-15 (American Society of Heating Refrigeration Air-Conditioning and Engineering) and ANSI/IIAR-2 (International Institute Ammonia Refrigeration) exposing employees to the hazards of inhalation of ammonia and fire/explosion.

Issued

Apr 8, 2016

Abate by

May 20, 2016

Penalty

Initial $7,000 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.119(f)(1): The employer did not develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information.    On or about 10/20/2015, at the Diversified Foods and Seasoning facility located in Madisonville Louisiana, the employer did not develop and implement written operating procedures for operating the Emergency Dump (water) Tank exposing employees to toxic hazards of ammonia exposure.

Issued

Apr 8, 2016

Abate by

May 20, 2016

Penalty

Initial $5,000 · Current $2,000 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.     On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer did not ensure that the full independent inspections on pressure vessels and heat exchangers were conducted such as but not limited to the following:    a. Re-circulator, V-4 (on PID10)  b. High Pressure Receiver, V1 (on PID07)  c. Evaporative Condenser, EC-1 (PID05)    This condition exposed employees to the hazards of inhalation of ammonia and fire/explosion.

Issued

Apr 8, 2016

Abate by

May 20, 2016

Penalty

Initial $7,000 · Current $5,000 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 10/20/2015, at the Diversified Foods and Seasoning facility located in Madisonville Louisiana, the employer did not test or calibrate ammonia detectors for the ammonia refrigeration systems such as but not limited to the following:    a. Two ammonia detectors located in the engine room  b. One ammonia detector located on the roof of the engine room  at the SRV (Safety Relief Valve) Relief Vent Header    This condition exposed employees to the hazards of inhalation of ammonia and fire/explosion.

Issued

Apr 8, 2016

Abate by

May 20, 2016

Penalty

Initial $7,000 · Current $0 Reduced

General-duty citation text

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 manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience.         a)      On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer failed to ensure that safety inspections for the ventilation system in the engine room was conducted at a frequency consistent with recognized and generally accepted good engineering practice such as IIAR Bulletin No.109 and the employer's Mechanical Integrity (MI) procedure.  This condition exposed employees to the hazards of inhalation of ammonia and fire/explosion.    b)      On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer did not ensure that  inspections and tests are conducted at a frequency consistent with recognized and generally accepted good engineering practice such as IIAR Bulletin No.110 and the employer's Mechanical Integrity (MI) procedures for specific safety systems that include but are not limited to the following:      1.     Oil Pressure Differential Cut Outs for the Compressor, HS-1  2.     High and Low Pressure Cut Out for the compressor, HS-2  3.     High Temperature Cut Out for Compressor, BC-1  4.     High and Low Level Controls for Re-circulator, V-4  5.     High and Low Level Controls for High Pressure Receiver, V-1  6.     Emergency Stop Buttons for the ammonia refrigeration system    This condition exposed employees to the hazards of inhalation of ammonia and fire/explosion.          c)      On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer did not ensure that inspections and tests are conducted at a frequency consistent with recognized and generally accepted good engineering practice such as the employer's Mechanical Integrity (MI) procedures and IIAR Bulletin No.110 for compressors and pumps that include but are not limited to the following:    1.      High Stage Compressor, HS-1  2.      Booster Compressor, BC-1  3.      Recirculator Pump, RP-1  4.      Recirculator Pump, RP-2    This condition exposed employees to the hazards of inhalation of ammonia and fire/explosion.          d)     On or about 10/20/2015, at the Diversified Foods and Seasonings facility located in Madisonville Louisiana, the employer did not ensure that inspections and tests are conducted at a frequency consistent with recognized and generally accepted good engineering practice such as IIAR Bulletin No.110 and the employer's Mechanical Integrity (MI) procedures for piping that include but are not limited to the following:      1.    10" LTRS (Low Temperature Recirculation suction) header  2.    6" HSD (High Stage Discharge) from High Stage Compressors to Evaporated Condensers (EC-1&EC-2)  3.    3" HPL (High Pressure Liquid) from the King Valve to the Intercooler V-3.   4.    6" BD (Booster Discharge) from Booster compressors to the Intercooler V-3.    This condition exposed employees to the hazards of inhalation of ammonia and fire/explosion.

Issued

Apr 8, 2016

Abate by

May 20, 2016

Penalty

Initial $5,000 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.119 (l)(1) : The employer did not establish and implement written procedures to manage changes to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process.      On or about 12/08/2015, at the Diversified Foods and Seasoning facility located in Madisonville Louisiana, the employer did not establish and implement written procedures for managing changes to ammonia detectors (located in the engine room) which were being installed exposing employees to toxic hazards of ammonia exposure.