CALEDONIA, NY —
OSHA Inspection: JCI JONES CHEMICAL INC.
Planned inspection · Safety discipline
At a glance
On , OSHA opened a planned safety inspection of JCI JONES CHEMICAL INC. in 100 SUNNY SOL BOULEVARD, CALEDONIA, NY 14423 (NAICS 424690). OSHA activity number 341162105.
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employer broke any rule; any findings appear as the citations listed below, and citations can be contested, reduced, or withdrawn.
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Where did this inspection happen?
- Establishment
- JCI JONES CHEMICAL INC.
- Site address
- 100 SUNNY SOL BOULEVARD
- City
- CALEDONIA
- State
- NY
- ZIP
- 14423
- Mailing
- 100 SUNNY SOL BOULEVARD, CALEDONIA, NY 14423
What kind of inspection was it?
- Inspection type
- Planned (H)
- Scope
- Partial (B)
- Discipline
- Safety
- Advance notice
- No
- Union status
- B
When did the case open and close?
- Opened
- Closing conference
- Case closed
- Last modified
- Data loaded
Establishment context
- NAICS code
- 424690
- Employees
- 15
- Ownership type
- A
Citations
9 citations on file for this inspection.
1910.119 D02 I A
- Issued
- Jul 5, 2016
- Abate by
- Aug 17, 2016
- Penalty
- Initial $4,500 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(d)(2)(i)(A): The employer did not include a block flow diagram or simplified process flow diagram as part of process safety information concerning technology of the process. a) On or about 05/16/16 in the SO2 railcar unloading area; employer had a block flow diagram which inaccurately showed the expansion chamber for the SO2 liquid line that had been removed in 2014 exposing employees who operated and maintained the sulfur dioxide rail car system to inhalation of toxic vapors. ABATEMENT CERTIFICATION REQUIRED
Recent events (3)
- — J (O) $0
- — C (S) $4500
- — Z (S) $4500
1910.119 D03 I B
- Issued
- Jul 5, 2016
- Abate by
- Aug 17, 2016
- Penalty
- Initial $4,500 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(d)(3)(i)(B): The employer did not develop piping and instrument diagrams for the equipment that was part of the process. a) On or about 01/07/16, throughout the process; employer did not have piping and instrumentation drawings which identified the specific valves for each of the three categories of actuated valves used in the process; fail safe, control valves and modulation valves exposing employees who operated and maintained the chlorine and sulfur dioxide repacking and bleach making process from inhalation of these toxic vapors and contact with these corrosive liquids. b) On or about 01/07/16, throughout the process; employer did not have piping and instrumentation drawings which identified gas and liquid process line sizes and materials of construction exposing employee who maintained the chlorine and sulfur dioxide repacking and bleach making process from inhalation of these toxic vapors and contact with these corrosive liquids. c) On or about 01/07/16,throughout the process; employer did not have piping and instrumentation drawings which used accepted process symbols, such as but not limited to valves, gauges, gas detection probes, pressure switch, pressure differential switches exposing employees who operated and maintained the chlorine and sulfur dioxide repacking and bleach making process from inhalation of these toxic vapors and or contact with these corrosive liquids. d) On or about 05/16/16, in the SO2 railcar unloading area; employer did not have piping and instrumentation drawings failed to protect employees who operated and maintained the sulfur dioxide rail car system from inhalation of toxic vapors by maintaining a flow process diagram which inaccurately showed the expansion chamber for the SO2 liquid line that was removed in 2014. ABATEMENT CERTIFICATION REQUIRED
Recent events (3)
- — J (S) $0
- — C (S) $4500
- — Z (S) $4500
1910.119 E01
- Issued
- Jul 5, 2016
- Abate by
- Aug 5, 2016
- Penalty
- Initial $4,500 · Current $4,500
General-duty citation text
29 CFR 1910.119(e)(1): The process hazard analysis did not identify, evaluate, and address the control of the hazards involved in the process: a) On or about 05/17/16, in the Bleach Department; employees involved in bleach process were exposed to sulfur dioxide liquid and vapors when the Process Hazard Analysis conducted March 2014 did not evaluate the hazards associated with using a one ton container of sulfur dioxide located outside the department and by being struck by vehicle traffic. b) On or about 05/17/16, in the Bleach Department; employees involved in bleach process were exposed to sulfur dioxide liquid and vapors when the Process Hazard Analysis conducted March 2014 did not evaluate the hazards associated with not having installed a proper SO2 sensor instead of relying on employees in working in the department to detect leaks from the one ton container of sulfur dioxide located outside the department. c) On or about 05/17/16, in the Bleach Department; employees involved in bleach process were exposed to sulfur dioxide liquid and vapors when the Process Hazard Analysis conducted March 2014 did not evaluate the hazards associated with the lack of an automatic shut-down system for the one ton container of sulfur dioxide located outside the department. d) On or about 05/17/16, in the Bleach Department; employees involved in bleach process were exposed to sulfur dioxide liquid and vapors when the Process Hazard Analysis conducted March 2014 did not evaluate the hazards associated with evacuation of the supply line used with the a one ton container of sulfur dioxide located outside the department. ABATEMENT CERTIFICATION REQUIRED
Recent events (3)
- — J (S) $4500
- — C (S) $4500
- — Z (S) $4500
1910.119 J02
- Issued
- Jul 5, 2016
- Abate by
- Aug 5, 2016
- Penalty
- Initial $4,500 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(j)(2): The employer did not establish written procedures to maintain the on-going integrity of process equipment; a) On or about 01/07/16, throughout the facility; employees were not protected from inhalation of chlorine or sulfur dioxide vapors when the procedure described in the JCI Jones Chemical System Inspection procedure, MI IV - 11 for the Gas Detection Systems, EIT-Series 4600, Scott-Freedom 500 and Scott 4600 MB, did not include the following calibration instructions, such as but not limited to; 1) Ensure the transmitter inhibit feature is activated. 2) Verify the span gas being used has not exceeded its expiration date 3) Initiate gas flow and allow the span gas to flow for approximately 5 min at a rate of 500 cc/min 4) Use of a magnet to complete the calibration b) On or about 01/07/16, throughout the facility; employees were not protected from inhalation and or contact with chlorine or sulfur dioxide when the written procedure described in the JCI Jones Chemical System Inspection procedure MI IV - 4 for the Gauges did not include manufacturer's recommended frequency of annual calibration of compound pressure gauges or describe the use of Master gauges for the verification of the remaining plant gauges, such as, but not limited to, those at the following locations; 1) SO2 rail car liquid 2) SO2 filling station liquid 3) SO2 filling station blow 4) SO2 filling station vacuum 5) Ton Room - Valve Hydro tester 6) CL2 Fill Station #2 Liquid - Master Gauge 7) CL2 Fill Station #2 Blow - Master Gauge 8) CL2 Fill Station #2 Vacuum - Master Gauge c) On or about 05/16/16 in the Bleach department; employees were not protected from inhalation or contact of chlorine or sulfur dioxide vapors or liquid when the written procedures described in the JCI Jones Chemical System Inspections procedure MI IV- page 10 for ORP Temperature or pH/Temperature Probe did not include the frequency of the calibration tests, the calibration method for temperature and acceptable temperature range to determine recalibration or replacement. ABATEMENT CERTIFICATION REQUIRED
Recent events (3)
- — J (S) $0
- — C (S) $4500
- — Z (S) $4500
1910.119 J04 III
- Issued
- Jul 5, 2016
- Penalty
- Initial $6,300 · Current $3,000 Reduced
General-duty citation text
29 CFR 1910.119(j)(4)(iii): The frequency of inspections and tests of process equipment shall be 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 01/07/16, throughout the facility; employees were not protected from inhalation of chlorine and sulfur dioxide vapors when the EIT-Series 4600, Scott-Freedom 500, and Scott 4600 MB SO2 and Chlorine gas detection monitors were not calibrated quarterly according to the manufacturers recommendations. Most recent calibration was conducted on 9/21/15. NO ABATEMENT DOCUMENTATION REQUIRED
Recent events (3)
- — J (S) $3000
- — C (S) $6300
- — Z (S) $6300
1910.119 J05
- Issued
- Jul 5, 2016
- Abate by
- Aug 17, 2016
- Penalty
- Initial $6,300 · Current $6,300
General-duty citation text
29 CFR 1910.119(j)(5): The employer did not correct deficiencies in equipment that were outside acceptable limits (defined by the process safety information on paragraph (d) of this section) in a safe and timely manner when necessary means where taken to assure safe operation. a) On or about 01/07/16, in the cylinder filling department; employees who filled and emptied cylinders of chlorine were exposed to chlorine vapors by continuing to use the cylinder whip installed at the following locations beyond their established replacement time period of two years described in Jones Chemical Systems Inspection written program ( MI IV- 1 ); 1) - CL2 Fill Station #2 T- hose .5" - replaced 10/26/11 2) - CL2 Fill Station #3 T- hose .5" - installed 09/14/10 b) On or about 01/07/16,in the cylinder filling department; employees who filled and emptied cylinders of sulfur dioxide were exposed to (SO2) vapors by continuing to use whips installed at the following locations beyond their established replacement time period of two years described in Jones Chemical Systems Inspection written program ( MI IV- 1 ); 1) - SO2 Fill Station #1 T- hose .5" - installed 10/05/11 2) - SO2 Blowdown St. #1 .5" - installed 11/24/11 3) - SO2 Blowdown St. #2 .5" - installed new 72" whip for inverter 3/22/13 c) On or about 01/07/16, in the rail car unloading area; employees unloaded rail cars of chlorine ( CL2) and were exposed to the unexpected contact and or inhalation of chlorine vapors/liquids by continuing to use the whips installed at the following locations beyond their established replacement time period of two years described in Jones Chemical Systems Inspection written program ( MI IV- 1 ); 1) - CL2 RC Spot #4, Pad Whip 1" ( rail car unloading) - installed 4/25/13 2) - CL2 RC Spot #5, Pad Whip 1" ( rail car unloading) - installed 1/11/11 d) On or about 01/07/16, in the rail car unloading area; employees who unloaded rail cars of sulfur dioxide ( SO2 ) were exposed to contact and or inhalation of SO2 vapors/liquids by continuing to use whips installed at the following locations which was in use beyond the established replacement time period of two years described in Jones Chemical Systems Inspection written program ( MI IV- 1 ); 1) - SO2 Spot 3 RC, Pad Whip ( rail car unloading ) - needs replacement ASAP e) On or about 01/07/16, in the ton container filling department; employees who filled and emptied ton containers of chlorine were exposed to chlorine vapors by continuing to use the ton container whip(s) installed at the following locations beyond their established replacement time period of two years described in Jones Chemical Systems Inspection written program ( MI IV- 1 ); 1) - CL2 Blow Down Station #1 - past two years 2) - CL2 Fill Station #2 top whip - 10/13/13 3) - CL2 Blow Down Station #2 - installed 1/24/11 4) - CL2 Fill St. #3 whips top and bottom - 10/15/08 5) - CL2 Blow Down Station #3 - installed 11/10/09 f) On or about 01/07/16, in the ton container filling department; employees who filled and emptied ton containers of sulfur dioxide ( SO2) were exposed to sulfur dioxide vapors/liquid by continuing to use the ton container whip(s) installed at the following locations beyond their established replacement time period of two years described in Jones Chemical Systems Inspection written program ( MI IV- 1 ); 1) - SO2 Fill Station whips - 9/10/12 2) - SO2 Blow Down Station - 4/10/13 ABATEMENT DOCUMENTATION REQUIRED
Recent events (3)
- — J (S) $6300
- — C (S) $6300
- — Z (S) $6300
1910.119 J06 II
- Issued
- Jul 5, 2016
- Abate by
- Aug 5, 2016
- Penalty
- Initial $4,500 · Current $4,500
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. a) On or about 05/20/16, in the Bleach department; employees were exposed to chlorine vapors when chlorine sensor #9 was installed at a height of 74 inches from grade instead of the manufacturer's recommended height of 18 inches. ABATEMENT CERTIFICATION REQUIRED
Recent events (3)
- — J (S) $4500
- — C (S) $4500
- — Z (S) $4500
1910.119 L01
- Issued
- Jul 5, 2016
- Abate by
- Aug 17, 2016
- Penalty
- Initial $6,300 · Current $6,300
General-duty citation text
29 CFR 1910.119(l)(1): The employer did not implement procedures to manage changes to process chemicals, technology, equipment, and procedures, and changes to facilities that affect a covered process; a) On or about 01/07/16, in the Upper Warehouse area; employees were not protected from inhalation of chlorine and sulfur dioxide vapors when full cylinders of these highly hazardous chemicals were removed from the upper warehouse and stored in the Bleach department without implementing management of change procedures. b) On or about 01/07/16, in the SBS department; employees were not protected from exposure to sulfur dioxide vapors when the SO2 gas detection sensor #6 was taken out of service and use of this highly hazardous chemical continued in the SBS department without implementing management of change procedures. c) On or about 01/07/16, in the SBS department; employees were not protected from exposure to sulfur dioxide vapors and liquid when the liquid line and expansion chamber were removed from the SO2 rail car process piping system without implementing management of change procedures. ABATEMENT DOCUMENTATION REQUIRED
Recent events (3)
- — J (S) $6300
- — C (S) $6300
- — Z (S) $6300
1910.119 M01
- Issued
- Jul 5, 2016
- Abate by
- Aug 5, 2016
- Penalty
- Initial $6,300 · Current $0 Reduced
General-duty citation text
29 CFR 1910.119(m)(1): The employer did not investigate each incident which resulted in, or could reasonably have resulted in a catastrophic release of highly hazardous chemical in the workplace. a) On or about 05/16/16, in the cylinder department; employer did not conduct an incident investigation when pressure was detected in SO2 Expansion Chamber #1, indicating the rupture disc had failed exposing employees to SO2 vapors and or liquid. ABATEMENT DOCUMENTATION REQUIRED
Recent events (3)
- — J (S) $0
- — C (S) $6300
- — Z (S) $6300
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Source
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 341162105.
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