OSHA Inspection: STELLA & CHEWY'S LLC

Issued

Sep 29, 2016

Abate by

Oct 26, 2016

Penalty

Initial $7,496 · Current $5,996 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(d)(2)(i)(C): Process safety information pertaining to the technology of the process did not include the maximum intended quantity:    (a)    Process safety information (PSI) defining the maximum intended quantity of anhydrous ammonia was not accurate. Two contradictory maximum intended quantity values of anhydrous ammonia were disclosed by the employer.  In a document entitled "Operating Refrigerant Charge Summary" the Total Required System Refrigerant Charge was listed as 33,288 lbs.  In a document entitled, "Section II Process Safety Information", the maximum intended inventory was listed as 12,000 lbs.

Issued

Sep 29, 2016

Abate by

Oct 26, 2016

Penalty

Initial $7,496 · Current $0 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(d)(3)(i): Process safety information pertaining to the equipment in the process did not include the elements specified in 29 CFR 1910.119(d)(3)(i)(A) through (H):    (a) The information provided regarding safety systems, specifically addressing ammonia detectors in the plant was not adequately clear and accurate.  In the document entitled, "Ammonia Refrigeration System Ammonia Detection", ammonia detectors in the plant were listed as having alarm set points of 25 ppm.   However, in the document entitled, "AMMONIA SENSOR LAYOUT", the alarm set point was noted as "ALARM SENSOR SET POINT = 35 ppm".    (b) The information provided regarding safety systems, specifically regarding ammonia detectors in the Engine Room was not adequately clear and accurate.  In the document entitled, "Ammonia Refrigeration System Ammonia Detection", the low level ammonia detector (item number AS20002) was listed as having a set point of 25 ppm which would activate alarm lights and horns outside of the engine room doors and the emergency exhaust fan in the engine room.  However, in the document entitled, "SECTION II PROCESS SAFETY INFORMATION",  the alarm set point was stated as "When the ammonia concentration in the machine room exceeds 50 PPM, the ammonia detection system will signal a high level on the indicator panel above the entrance to the machine room."     (c) In the document entitled, "Ammonia Refrigeration System Ammonia Detection", the high level ammonia detector (near RCB-2) was identified as item number AS20007, whereas on the control panel in the Engine Room it was identified as AS20008.    (d) Process safety information did not include the alarm set point for the GasGuard Vent Line Ammonia Sensor.

Issued

Sep 29, 2016

Abate by

Oct 26, 2016

Penalty

Initial $7,496 · Current $0 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(A): The employer did not develop and implement written operating procedures that addressed the consequences of deviations from the operating limits in the covered process:    (a)   In the Engine Room, the operating procedures for compressors did not adequately address the consequences of deviation for high discharge temperature.  For example, the standard operating procedure for "Operation of the High Stage Compressor RC-5",  did not  address the consequences of deviation for high discharge temperature.  These consequences could include compressor damage and release of ammonia.

Issued

Sep 29, 2016

Abate by

Oct 26, 2016

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(f)(3): The operating procedures were not reviewed as often as necessary to assure that they reflect current operating practice, including changes that result from changes in process chemicals, technology, and equipment, and changes to facilities:  (a)   In the Engine Room, the operating procedure for the "Operation of the High Stage Compressor RC-5", which listed a normal operations range for discharge temperature of 75° F to 95° F, did not reflect current operating practice.  For the entire month of July, 2016, as documented on the "Compressor RC-5 Daily Check Log Sheet", recorded discharge temperatures that ranged from 176.1° F to 186.2° F.   (b)   In the Engine Room, the operating procedure for the "Operation of the -20° Low Temp Recirculator, V-6 and Ammonia Pumps AP-5 and AP-6", which listed normal operations range for liquid pumps (AP-5 and AP-6) discharge pressure of 35 to 40 psig, did not reflect current operating practice.  For the entire month of July, 2016, as documented on the "Ammonia System Daily Check Log Sheet", recorded discharge pressures for these pumps that ranged from 47 to 59 psig.

Issued

Sep 29, 2016

Penalty

Initial $7,496 · Current $5,996 Reduced

Hazardous substances 0170

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) In the Engine Room, workers' eyes and bodies were potentially exposed to anhydrous ammonia, a corrosive chemical.  There was not suitable provision of emergency eyewash and safety shower, in-that there was no emergency eyewash and safety shower installed just outside the engine room's exit door (in accordance with IIAR Bulletin 109).