OSHA Inspection: HUNTER PANELS L.L.C.

Issued

2016-07-01 00:00:00

Abate by

2017-06-30 00:00:00

Penalty

Initial $5500.00 · Current $5500.00

Hazardous substances M103

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to  dust deflagration, explosion, or other fire hazards while working at or near unprotected dust collectors and associated upstream equipment handling combustible polyisocyanurate and wood dusts:     a) Hunter Panels L.L.C.: On January 5, 2016, employees were exposed to combustible polyisocyanurate and wood dust hazards from a combination cyclone and fabric filter dust collection system located outside the building and connected to the crosscut saw station and the gang saw station. The combination dust collector lacked means of (1)explosion protection and (2) deflagration propagation protection (isolation) to the upstream process.       b) Hunter Panels L.L.C.:  On or about January 5, 2016, employees were exposed to combustible wood dust hazards from a cyclone (1st stage) and enclosureless filter bag (2nd stage) dust collection system located on the west side of the production area inside the building (cool vent process area) and connected to the Walls Round saws. The 1st and 2nd stage dust  collection system lacked means of (1) explosion protection, (2) deflagration propagation protection (isolation) to the upstream process, the unit?s 2nd stage, and the area beneath the material discharge of the 1st stage, and (3) fire protection. Additionally, the dust collection system discharged exhaust air directly into the work area.     c) Hunter Panels L.L.C.: On or about January 5, 2016, employees were exposed to combustible polyisocyanurate and wood dust hazards from the two (2) Kufo UFO102B enclosureless bag dust collection systems located inside the building (cut-job area) and connected to the table saw #1 and table saw#2, respectively. The enclosureless dust collection systems were located within near proximity to the operator station and within near proximity to each other.      Among other methods, feasible and acceptable means of abatement include following the guidance of the National Fire Protection Association (NFPA) Standards such as, but not limited to, the following:        NFPA 652 "Standard on the Fundamentals of Combustible Dust, 2016 ed." ? Sections 7.1.1 (dust hazard analysis), 8.3.4.1 (indoor air-material separators), 8.5.7.1.4 (flexible connectors), 8.9.2 (risk assessment), 8.9.3 (equipment protection), 8.9.4 (equipment isolation), and 8.9.4.4 (isolation of upstream work areas).         NFPA 654 "Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids, 2013 ed."  - Sections 4.2.1 (process hazard analysis), 7.1.3 (risk evaluation), 7.1.4. (explosion protection for equipment) *, 7.1.6.1 (isolation of equipment), 7.1.7 (isolation of upstream work areas),  and 7.13.1.1 (location of air-material separators). ,       NFPA Standard 664 "Standard for the Prevention of Fires and Explosions in Wood Processing and Woodworking Facilities, 2014 ed.", - Sections 4.3 (process analysis), 8.2.2.5.1.4 (requirements for dust collectors), 8.2.2.5.2 (dust collectors with fire hazards), 8.2.2.5.3 (dust collectors with deflagration hazards), 8.2.2.6 (recycling of air-material separator exhaust), 8.2.4 (conveying system isolation).          Specifically:        For instance (a) ? 1) provide the outdoor dust collector with a recognized method of explosion protection such as deflagration venting to a safe location in accordance with NFPA 68 "Standard on Explosion Protection by Deflagration Venting"; 2) provide either active or passive deflagration isolation devices between the outdoor dust collector and the upstream indoor processes (on the dirty air ducts in accordance with NFPA 69 "Standard on Explosion Prevention Systems".  Examples of active deflagration isolation devices include chemical flame front extinguishing systems, fast-acting mechanical valves, and actuated pinch valves.  Examples of passive deflagration isolation devices include passive flow-actuated flap valves (back-blast dampers); 3) determine if the rotary valve at the material discharge of the dust collector meets the criteria of being a passive deflagration isolation device under NFPA 69.  If not, replace with a rotary valve system that meets the design criteria outlined in NFPA 69; and 4) ensure that the fans/blowers located in the dirty air stream are of Type A or B spark resistant construction in accordance with AMCA 99-0401-86 "Classifications for Spark Resistant Construction", or Type C spark resistant construction protected with spark detection and extinguishment located downstream of the fan.        For instance (b) ? 1a) relocate the dust collectors to an outdoor location, provide a method of explosion protection in accordance with NFPA 68 or 69; 2a) provide methods of deflagration propagation isolation for the unit?s material discharge, the unit's 2nd stage, and the dirty air ducting in accordance with NFPA 69; and 3a) prevent the return of exhaust air back into the facility unless provisions can be made to prevent the transmission of smoke and flame from a fire or pressure effects and flame from a deflagration back into the facility  -OR- 1b) protect the indoor cyclone dust collector (1st stage) with a method of explosion protection and isolation such as chemical deflagration suppression in accordance with NFPA 69; 2b) provide methods to prevent the transfer of exhaust air in the event of a fire such as a fire detection sensor interlocked with the exhaust fans/blower motor; 3b) provide a fire detection and extinguishment system for the dust collection system; and 4b) ensure that the ensclosureless filter bags (2nd stage) are not within 20? from any means of egress or area routinely occupied by personnel and that the fan motor is of TEFC design.        For instance (c) ? 1) Relocate the enclosureless collectors so that they are at least 20? from any means of egress, 20? from the operator workstation, and 20? from other units; and 2) ensure that the fans/blowers are of Type A or B spark resistant construction in accordance with AMCA 99-0401-86 "Classifications for Spark Resistant Construction".

Issued

2016-07-01 00:00:00

Abate by

2016-10-31 00:00:00

Penalty

Initial $5500.00 · Current $1500.00 Reduced

Hazardous substances 1990

General-duty citation text

29 CFR 1910.119(e)(3)(i):  The process hazard analysis did not address the hazards of the process:     a) Hunter Panels L.L.C.- On January 5, 2016, the process hazard analysis did not address the hazards of a combustible dust explosion/deflagration on the pentane process from the dust collectors including, the outdoor main dust collector, the indoor Cool vent dust collector and the two indoor Kufo dust collectors.

Issued

2016-07-01 00:00:00

Abate by

2016-10-24 00:00:00

Penalty

Initial $3300.00 · Current $1500.00 Reduced

Hazardous substances 1990

General-duty citation text

29 CFR 1910.1200(d)(1): Chemical manufacturers and importers did not evaluate chemicals produced in their workplace or those imported to determine if they were hazardous:    a) Hunter Panels L.L.C. - On January 5, 2016, the employer did not evaluate H-Shield F (Polyiso foam with aluminum foil facer), to determine if it was hazardous. The product was identified as an article even though the solid material under normal conditions of use, i.e. cutting during installation would create a dust. The hazards not classified include combustible dust.

Issued

2016-07-01 00:00:00

Abate by

2016-07-28 00:00:00

Penalty

Initial $1100.00 · Current $350.00 Reduced

General-duty citation text

29 CFR 1910.1200(f)(6): The employer did not ensure that each container of hazardous chemicals in the workplace was labeled, tagged or marked with the information specified under paragraphs (f)(6)(i) through (ii) of this section:    a) Hunter Panels L.L.C. - On January 5, 2016, the employer did not ensure that the containers and drums used to collect wood/polyiso dust from the dust collectors were labeled with at least the product identifier and the general information regarding the hazard of the chemical.