OSHA Inspection: AIROSOL COMPANY, INC.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(c)(1): The employer did not develop a written plan of action regarding the implementation of the employee participation required by this paragraph:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to develop and implement a written plan regarding the implementation of employee participation guidelines as part of the process safety management program.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(d): The employer did not complete a compilation of written process safety information, including information pertaining to the hazards of the highly hazardous chemicals used or produced by the process, information pertaining to the technology of the process, and information pertaining to the equipment in the process before conducting the process hazard analysis:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to develop a written compilation of process safety information (PSI) regarding the information pertaining to the technology of the process, and information pertaining to the equipment in the process.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(C): Information pertaining to the equipment in the process did not include the electrical classification:  The employer is failing to protect employees from fire and explosion hazards from flammable vapors. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to complete an evaluation of process covered areas for electrical classifications. A non-intrinsically-safe portable fan was located in a flammable storage area and was turned on by an employee, which resulted in a fire that injured the employee and destroyed much of the facility.   29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.307(a)(4): Division and zone classification. In Class I locations, an installation must be classified as using the division classification system meeting paragraphs (c), (d), (e), and (f) of this section or using the zone classification system meeting paragraph (g) of this section. In Class II and Class III locations, an installation must be classified using the division classification system meeting paragraphs (c), (d), (e), and (f) of this section:  The employer is failing to protect employees from fire and explosion hazards from flammable vapors. This was most recently documented on or about November 22, 2016, at the facility located at 1206 Illinois in Neodesha, Kansas. The employer did not establish a division and zone classification system where two employees were working, which contained flammable vapors above the LFLs and was not electrically classified. A non-intrinsically-safe portable fan was located in a flammable storage area and was turned on by an employee, which resulted in a fire that injured the employee and destroyed much of the facility.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(e)(1): The employer did not perform an initial process hazard analysis (hazard evaluation) on processes covered by 29 CFR 1910.119:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to perform an initial process hazard analysis to identify, evaluate, and control the hazards of flammable process chemical involved in the process.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Sep 30, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(f)(1): The employer did not develop and implement written operating procedures that provided clear instructions for safely conducting activities involved in each covered process consistent the safety information and which address the elements listed in 29 CFR 1910.119(f)(1)(i) through (f)(1)(iv):   The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to develop and implement written operating procedures providing clear instructions for safety activities involved in the flammable process chemical.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(f)(4): The employer did not develop and implement safe work practices to provide for the control of hazards during operations such as lockout/tagout; confined space entry; opening process equipment or piping; and control over entrance into a facility by maintenance, contractor, laboratory, or other support personnel:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to develop and implement safe work practice for opening process equipment or piping.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Sep 30, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(g)(1)(i): The employer did not train each employee presently involved in operating a process, and each employee before being involved in operating a newly assigned process, in an overview of the process and in the operating procedures as specified in paragraph (f) of this section:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to train employees who involved in the flammable process chemical on the specific safety and health hazards, overview of the process, operating procedures, emergency operations including shutdown, and safe work practices.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Sep 30, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(3): The employer did not train each employee involved in maintaining the on-going integrity of process equipment in the procedures applicable to the employee's job tasks to ensure that the employee can perform the job tasks in a safe manner:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to train employees who involved in maintaining the on-going integrity of process equipment on the Mechanical Integrity procedures to safely perform inspection and testing.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Dec 31, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(h)(2)(i): The employer, when selecting a contractor , did not obtain and evaluate information regarding the contract employer's safety performance and program:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about December 13, 2016 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to obtain and evaluate all of the contractor's safety performance and programs for the chemical covered processes. The tank truck driver of a contractor (Barton Solvents, Inc.) participated in the reclaiming process for Methanol tank located next to the North West corner for the warehouse in the tank farm.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish or implement written procedures to maintain the on-going integrity of process equipment:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to develop and implement written operating procedures providing clear instructions for maintenance activities to maintain the on-going integrity of process equipment including Pressure vessels and storage tanks; Piping systems; Relief and vent systems and devices including valves; Emergency shutdown systems; Controls (including monitoring devices and sensors, alarms, and interlocks) and Pumps.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(i): The employer did not perform inspection and tests on process equipment:  The employer is failing to protect employees from fire and explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to perform inspection and tests on process equipment. Fire and explosion hazards from stored flammable liquids and gases in vessels which had not undergone testing.    29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Sep 30, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(iv): The employer did not document each inspection and test that was performed on process equipment wherein the documentation identified the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other identifier of the equipment on which the inspection or test was performed, a description of the inspection or test performed, and the results of the inspection or test:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to document each inspection and test that was performed on process equipment such as but not limited to Pressure vessels, mixing and storage tanks; Piping systems; Relief and vent systems and devices; Valves; Emergency shutdown systems; and Controls (including monitoring devices and sensors, alarms, and interlocks); manifold system and agitators.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jul 31, 2017

Penalty

Initial $8,873 · Current $4,437 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:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to investigate each incident which resulted in a catastrophic release of highly hazardous chemicals in the workplace. An investigation into the incident of November 22, 2016 had not been initiated nor was it in the process of being conducted.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jun 1, 2018

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(n): The employer did not establish and implement an emergency plan for the entire plant in accordance with the provisions of 29 CFR 1910.38. The emergency action plan did not include procedures for handling small releases:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to establish and implement an emergency action plan that includes procedures for handling small releases.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Dec 31, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.119(o)(1): The employer did not certify that they had evaluated compliance with provisions of 29 CFR 1910.119 at least every three years to verify that the procedures and practices developed under this standard were adequate and are being followed:   The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to provide certifications that it had performed compliance evaluations to verify that its procedures and practices developed under the standard are adequate and being followed. The company has been submitting Resource Management Program reports to the Environmental Protection Agency since 2000 which show that they have flammable chemical quantities which exceed the 10,000 pound threshold requiring a Process Safety Management Program.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Dec 31, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.120(q)(1): The employer did not develop and implement an emergency response plan to handle anticipated emergencies prior to commencement of emergency response operations:  The employer is failing to protect employees from explosion hazards while engaged in an emergency response. This was most recently documented on or about November 22, 2016 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to develop and implement an emergency response plan to handle anticipated emergencies such as fire or chemical spills.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jan 31, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.120(q)(6)(iii): Employees who participated as hazardous materials technicians, or were expected to participate as hazardous materials technicians, had not received at least 24 hours of training equal to the first responder operations level, and in addition have competency in the areas outlined in 29 CFR 1910.120(q)(6)(iii)(A) through (q)(6)(iii)(I) and/or the employer did not so certify:  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about November 22, 2016 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to ensure that employees who were expected to participate as hazardous materials technicians had received at least 24 hours of training equal to the first responder operations level, and had been certified as having such training. Employees were expected to respond to leaks or spills of chemical and to contain the chemical such as but are not limited to Methanol, Toluene, Acetone, Heptane, Diethyl Ether, and Hexane.    29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Sep 30, 2017

Penalty

Initial $8,873 · Current $4,437 Reduced

General-duty citation text

29 CFR 1910.132(a): Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers, was not provided, used, and maintained in a sanitary and reliable condition:  The employer is failing to protect employees from burn hazards by providing appropriate fire retardant clothing. This was most recently documented on or about November 22, 2016 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to provide employees with fire retardant clothing while operating, performing preventive maintenance / maintenance, or responding to leaks of extremely flammable vapors in chemical such as Methanol, Toluene, Acetone, Heptane, Diethyl Ether, and Hexane.  29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Sep 30, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.120(q)(10): Chemical protective clothing and equipment to be used by organized and designated HAZMAT team members, or to be used by hazardous materials specialists, did not meet the requirements of 29 CFR 1910.120(g)(3) through (g)(5):  The employer is failing to protect employees from explosion hazards while engaged in chemical mixing activities. This was most recently documented on or about November 22, 2016 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to ensure that chemical protective clothing and equipment to be used by hazardous materials specialists met the requirements of 29 CFR 1910.120(g)(3) through (5). Employees were expected to respond to leaks or spills of chemical and to contain the chemical such as but are not limited to Methanol, Toluene, Acetone, Heptane, Diethyl Ether, and Hexane.    29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $3,802 · Current $1,901 Reduced

General-duty citation text

29 CFR 1910.215(a)(4): Work rest(s) on grinding machinery were not adjusted closely to the wheel with a maximum opening of one eighth inch:  The employer is failing to protect employees from struck-by hazards while engaged in grinding activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to ensure that the distance from the abrasive wheel periphery to the work rest of the Tri Star 10" bench grinder Model #BG-10 located in the Maintenance Shop was found to be approximately 3/8 inch.  29 CFR 1903.19(c)(1) requires certification that the abatement of the above violation is complete.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.215(b)(9): The distance between the abrasive wheel periphery(s) and the adjustable tongue or the end of the safety guard peripheral member at the top exceeded one fourth inch:  The employer is failing to protect employees from struck-by hazards while engaged in grinding activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to ensure that the distance from the abrasive wheel to the adjustable tongue guard of the Tri Star 10" bench grinder Model #BG-10 located in the Maintenance Shop was found to be approximately 0.5 inch.  29 CFR 1903.19(c)(1) requires certification that the abatement of the above violation is complete.

Issued

May 16, 2017

Abate by

Jun 12, 2017

Penalty

Initial $3,232 · Current $1,616 Reduced

General-duty citation text

29 CFR 1910.305(b)(2)(i): All pull boxes, junction boxes, and fittings were not provided with covers approved for the purpose:  The employer is failing to protect employees from electrical shock and fire hazards while engaged in production activities. This was most recently documented on or about February 7, 2017 at the Airosol Company, Inc., located at 1206 Illinois Street in Neodesha, Kansas. The company failed to ensure that the electrical box which controls the GV3000/SE Sensorless Enhanced device located at the breezeway between the fill room and the gas house Line 1 was equipped with a cover to prevent contact with the energized parts within.  29 CFR 1903.19(c)(2) abatement of the above violation was verified at time of inspection, no certification is required.