OSHA Inspection: REDDY ICE CORPORATION

Issued

Jun 13, 2016

Abate by

Jun 30, 2016

Penalty

Initial $4,250 · Current $2,125 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): The employer's piping and instrument diagrams were not accurate and did not represent equipment that was existing and was part of the process.    For the facility at 604 N Frontage Rd., Plant City, FL 33563, as observed on or about 04/19/2016, process/piping and instrumentation diagrams (P&IDs) were missing information and contained errors. The most recent P&ID at the time of the inspection was from a revision on 01/20/2015, and it had the following errors:    a) On drawing P3, valves associated with the high pressure receiver containing the prefix CPR were not correctly identified/tagged on P&ID.    b) On drawing P4, valves associated with evaporative condensers EC1 and EC2 were not correctly identified/tagged on P&ID.    c) On drawing P4, valves associated with TSR vessel were not correctly identified/tagged on P&ID.    d) On drawing P5, valves associated with evaporative condensers EC3 and EC4 were not correctly identified/tagged on P&ID.    e) On drawing P3, only one deluge tank for the ammonia relief system was depicted on the P&ID. Two tanks were observed on site.    f) On drawing P3, valves associated with the emergency ammonia refrigeration system/control box were not identified/tagged.     g) On drawing P3, interlocks for valves CPR-08 and CPR-14 are not depicted on P&ID.    h) On drawing P4, interlock with purger is not depicted on P&ID for valve EC1-9.    i) On drawing P4, interlock with purger is not depicted on P&ID for valve EC1-10.    j) On drawing P4, interlock with purger is not depicted on P&ID for valve EC2-9.    k) On drawing P4, interlock with purger is not depicted on P&ID for valve EC2-10.    l) On drawing P8, interlock controls for valves HTR-50 and HTR-03 are not depicted on P&ID.    m) On drawing P9, interlock controls for valve WC-07 is not depicted on P&ID.    n) On drawing P9, Interlock controls for valve LTR-03 is not depicted on P&ID.    o) On drawing P10, interlock controls are not depicted for valves R1-06 through R4-06, R1-12 through R4-12, R1-15 through R4-15, and R1-24 through R4-24.    p) On evaporator drawings P11 ? P13, interlock controls are not available on P&ID for valves R12-03, R13-03, R5-05, R5-16, R5-10, R6-05, R6-16, R6-10, R7-05, R7-16, R7-10, R8-03, R8-16, R8-21, R9-03, R9-16, R9-21, R10-03, R10-16, R10-21, R11-03, R11-16, R11-21.    q) On drawing P5, interlock with purger is not depicted for valves EC4-9 and EC4-10.    r) On drawing P6, interlock controls for valves IM7-13, IM7-3, IM7-19, and IM7-25 are not depicted on the P&ID.    s) On drawing P6, interlock controls for valves IM5-13, IM5-3, IM5-19, and IM5-25 are not depicted on the P&ID.    t) On drawing P6, interlock controls for valves IM3-13, IM3-3, IM3-19, and IM3-25 are not depicted on the P&ID.    u) On drawing P6, interlock controls for valves IM1-13, IM1-3, IM1-19, and IM1-25 are not depicted on the P&ID.    v) On drawing P7, interlock controls for valves IM9-13, IM9-3, IM9-19, and IM9-25 are not depicted on the P&ID.    w) On drawing P7, interlock controls for valves IM8-13, IM8-3, IM8-19, and IM8-25 are not depicted on the P&ID.    x) On drawing P7, interlock controls for valves IM6-13, IM6-3, IM6-19, and IM6-25 are not depicted on the P&ID.    y) On drawing P7, interlock controls for valves IM4-13, IM4-3, IM4-19, and IM4-25 are not depicted on the P&ID.    z) On drawing P7, interlock controls for valves IM2-13, IM2-3, IM2-19, and IM2-25 are not depicted on the P&ID.    aa) On drawing P8, an angle valve is missing on the high stage suction line coming off of the recirculator.    bb) On drawing P8, multiple valves are mislabeled and/or missing labeling.     cc) On drawing P1, compressors C1 and C2 suction incorrectly comes from high stage suction line instead of the low stage suction line that is present in the field.    dd) On drawing P1, economizer suction line is 4 inches when it should be 5 inches.    ee) On drawing P1, high stage suction line is 6 inches when it should be 10 inches.    ff) On drawing P1, low stage suction line is not depicted when it should feed compressors C1 and C2.    gg) On drawing P1, the thermosyphon receiver line is 4 inches when it should be 6 inches.    hh) On drawings P1 and P2, relief valves are depicted on the thermosyphon lines exiting the plate heat exchangers and oil coolers when they are not present in the field.    ii) On drawing P2, for compressors three and four, liquid expansion traps for the thermosyphon line consisting of a regulator, angle valve, and an inline globe valve were not depicted on the P&ID     jj) On drawing P1, compressors C1 and C2 each have an angle valve and a drain valve on their inlet lines to thermosyphon heat exchangers that are not present yet depicted on the P&ID. These same lines are also missing globe valves.    kk) On drawing P1, lines TSS, HSS, ES, HSD, and TSR which go to headers are incorrectly sized.    ll) On drawings P1 and P2, an angle valve is missing at the discharge from the compressors.    mm) On drawings P1 and P2, an angle valve and a check valve are missing on the suction inlet to the compressors.    nn) On drawings P1 and P2, for the economizer suction line entering the compressors, two angle valves are incorrectly depicted with respect to what is in the field, and a globe valve is missing.    oo) On drawing P2 at compressor C5, a globe valve at the thermosyphon inlet to the oil cooler is incorrectly depicted and not in the field, and an angle valve is missing on the P&ID.    pp) On drawing P3, a globe valve, a check valve, and an angle valve and associated piping at the bottom of the receiver (CPR) were not depicted on the P&ID.    qq) On drawing P9 at the low temp. recirculator, an economizer suction line and associated valves were not depicted on the P&ID.    rr) On drawing P9 at the low temp. recirculator, a process line to the control box observed on site was not depicted on the P&ID.    ss) On drawing P9, 1 inch PO piping and associated globe valves and check valves was incorrectly depicted on the P&ID and not present in the field.    tt) On drawing P9, the low stage suction line (LSS) is incorrectly labeled as the high stage suction line (HSS).    uu) On drawing P9, an angle valve and associated piping connecting the 2.5  inch CPL line and the 3 inch LTRL line is missing.    vv) On drawing P11, a globe valve on a 3/8 inch line connecting the HPL and the HTS lines is missing an identification number.    ww) On drawings P1- P11, the relief lines? header piping connections are not depicted.    xx) On drawing P3, the purger had a relief valve that was incorrectly placed on the P&ID.

Issued

Jun 13, 2016

Abate by

Sep 6, 2016

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(o)(4): The employer did not promptly determine and document an appropriate response to each of the findings of the compliance audit, and document that deficiencies have been corrected:    a) For the facility at 604 N Frontage Rd., Plant City, FL 33563, as observed on or about 04/19/2016, 2010 compliance audit recommendation 18.11 was not corrected in that valve identification numbers throughout the facility were not correctly labeled and included in the standard operating procedures.

Issued

Jun 13, 2016

Abate by

Jun 21, 2016

Penalty

Initial $4,250 · Current $2,125 Reduced

General-duty citation text

29 CFR 1910.151(c): Where employees were exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body were not provided within the work area for immediate emergency use:    a) For the facility at 604 N Frontage Rd., Plant City, FL 33563, as observed on or about 04/06/2016, suitable facilities for quick drenching or flushing of the eyes and body were not provided in that eyewash stations with showers were not located just outside of engine room exit doors.