OSHA Inspection: OK FOODS

Issued

Oct 17, 2017

Abate by

Nov 7, 2017

Penalty

Initial $10,864 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.23(d)(4): The side rails of through or sidestep ladders did not extend 42 inches (1.1 m) above the top of the access level or landing platform served by the ladder.    For the employees performing inspections and maintenance on the ammonia refrigeration system on or about May 23, 2017 and times prior there to, the employer did not provide ladder access to the roof with hand rails that extended at least 42 inches above the roof landing exposing employees to a fall of greater than 4 feet from the ladder.

Issued

Oct 17, 2017

Abate by

Nov 7, 2017

Penalty

Initial $12,675 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.28(b)(1)(i): The employer did not ensure that each employee on a walking-working surface with an unprotected side or edge that is 4 feet (1.2m) or more above a lower level was protected from falling by guardrail systems, safety net system, or personal fall arrest system:    For the employees accessing the roof to conduct testing and maintenance on or about April 18, 2017 and times prior there to, the employer did not provide fall protection for employees working within 6 feet of the roof edge, exposing employees to fall hazards of greater than 4 feet.

Issued

Oct 17, 2017

Abate by

Dec 7, 2017

Penalty

Initial $5,432 · Current $3,500 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): Piping and instrument diagrams (P&ID's);    This violation was most recently observed on or about April 17, 2017 and times prior thereto and times thereafter, in the Reed Lane engine room when the employer failed to ensure the Process Safety Information (PSI) such as Piping & Instruments Diagrams (P&ID) were updated and accurate. Discrepancies include but are not limited to the HPL piping from the Recirculator to the Hansen Auto-Purger and the discharge lines from PSV's 123 and 107 on the High Pressure Receiver were missing on the P&ID drawings.

Issued

Oct 17, 2017

Abate by

Dec 7, 2017

Penalty

Initial $12,675 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(ii): The employer did not document that equipment complies with recognized and generally accepted good engineering practices (RAGAGEP).    Instance a)  This violation was most recently observed on or about April 17, 2017 and times prior thereto, in the Reed Lane Refrigeration Process at OK Foods located in Fort Smith, Arkansas when the employer failed to document that the ammonia refrigeration process equipment complied with RAGAGEP such as ANSI/ASHRAE Standard 15-2004, Section 8.11.2.1 when the outside to each of the entrances to the machine room was not equipped with visible and audible alarm system . This hazardous condition exposed employees to toxic ammonia inhalation hazards.    Instance b)  This violation was most recently observed on or about  April 17, 2017 and times prior thereto, when the employer failed to document that the ammonia refrigeration process equipment complied with RAGAGEP such as IIAR-2-2008, Section 13.3.3.1 and 13.3.3.2 when the Reed Lane Refrigeration machine room front entry was not equipped with an approved , self-closing fire door. Additionally, the employer did not have a tight-fitting door with panic type hardware for the back entry of the machine room. This hazardous condition exposed employees to toxic ammonia inhalation hazards.      Instance c)  This violation was most recently observed on or about April 17, 2017 and times prior thereto, when the employer failed to document that the ammonia refrigeration process equipment complied with RAGAGEP such as ANSI/ASHARAE Standard 15, Safety Standard for Refrigeration System - 2004, Section 8.11.4 and/or IIAR-2-2008, Section 13.2.3.11 when the Reed Lane machine room's mechanical ventilation fan did not discharge to safe location. This hazardous condition exposed employees to toxic ammonia inhalation hazards.    Instance d)    This violation was most recently observed on or about April 17, 2017 and times prior thereto, when the employer failed to document that the ammonia refrigeration process equipment complied with RAGAGEP such as IIAR-2-1999, Section 7.3.2 when the end of the 3-inch relief header discharging to the atmosphere was less than 15 feet above the adjacent grade or roof level. This hazardous condition exposed employees to toxic ammonia inhalation hazards.

Issued

Oct 17, 2017

Abate by

Dec 7, 2017

Penalty

Initial $12,675 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): Written procedures. The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment.    The employer did not develop and/or implement a mechanical integrity procedure to reinstate the vapor seal of piping such as the CD piping for the Recirculator Oil Pot and the insulation on Valve 196 on the engine room roof which were found to be deteriorated.

Issued

Oct 17, 2017

Abate by

Dec 7, 2017

Penalty

Initial $12,675 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(ii): Inspection and testing procedures did not follow recognized and generally accepted good engineering practices (RAGAGEP).    Instance a)    On or about April 17, 2017 and at times prior thereto, at Reed Lane engine room at OK Foods located in Fort Smith, Arkansas the employer did not follow RAGAGEP, such as IIAR Bulletin #111 (Ammonia Machine Room Ventilation) 2002, Section 4.1 and IIAR-2-1999 Section 6.2.2, when it did not include the following in its ventilation fans and intake testing:  for inspection of the mechanical ventilation system in the Reed Lane engine room at OK Foods located in Fort Smith, Arkansas. Examples of such RAGAGEP include but are not limited to IIAR Bulletin #111 (Ammonia Machine Room Ventilation) and/or IIAR-2 (Equipment, Design, and Installation of Ammonia Mechanical Refrigerating Systems).   The employer failed to perform required testing for Ventilation Fans and Intake:      a. Stop the non-emergency continuous ventilation fan(s) using the appropriate electrical disconnect(s). Confirm that the alarm for non-emergency continuous ventilation functions properly.      b. Confirm that control circuitry, ventilation fans, dampers function properly.    This hazardous condition exposed employees to toxic ammonia inhalation hazards.    Instance b)  This violation was most recently observed on or about April 17, 2017 at the Reed Lane ammonia refrigeration process when the employer failed to follow RAGAGEP such as IIAR Bulletin No. 109 Section 4.7.5 (Minimum Safety Criteria for a Safe Ammonia Refrigeration System) and IIAR Section No. 110 1993 (Guidelines for Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems), Section 6.7.2 when it did not inspect at least annually the insulated ammonia refrigeration piping such as the CD piping for the Recirculator Oil Pot and the insulation on Valve 196 on the engine room roof which as damaged/deteriorated. This hazardous condition exposed employees to toxic ammonia inhalation hazards.

Issued

Oct 17, 2017

Abate by

Dec 31, 2017

Penalty

Initial $12,675 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.119(j)(5): Equipment deficiencies. The employer did not correct deficiencies in equipment that are outside acceptable limits (defined by the process safety information in paragraph (d) of this section) before further use or in a safe and timely manner when necessary means are taken to assure safe operation.      This violation was most recently observed on or about April 17, 2017 and times prior thereto, in the Reed Lane Refrigeration Process at OK Foods located in Fort Smith, Arkansas when the ammonia detector and alarm system in the engine room was not in working condition.

Issued

Oct 17, 2017

Abate by

Nov 7, 2017

Penalty

Initial $12,675 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.119(n): The employer did not establish an emergency plan for the entire plant in accordance with the provisions of 29 CFR 1910.38:    For the employees working in the cooler, compressor room, and processing plant on or about April 17, 2017 and times prior there to, the employer did not develop and implement emergency procedures in the emergency action plan addressing procedures in the event of an ammonia release exposing employees to an uncontrolled release of ammonia.

Issued

Oct 17, 2017

Abate by

Nov 7, 2017

Penalty

Initial $12,675 · Current $6,000 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:    On or about April 17, 2017, in the Reed Lane Debone Cooling Area at OK Foods, located in Fort Smith, Arkansas; the employer did not utilize the procedures for the control of hazardous energy, including but not limited to specific lockout/tagout (LOTO) for the removal of residual and/or re-accumulated Ammonia from the Evaporative Unit #12 during an emergency.

Issued

Oct 17, 2017

Penalty

Initial $5,432 · Current $4,000 Reduced

General-duty citation text

29 CFR 1910.303(b)(7)(iv): Electric equipment had damaged parts that may adversely affect safe operation or mechanical strength of the equipment, such as parts that are broken, bent, cut, or deteriorated by corrosion, chemical action, or overheating.    Instance 1)    For the employees working around the outlet with the broken weather resistant cover located outside the Reed Lane Compressor Room on or about May 23, 2017 and times prior there to, the employer did not repair the cover for the 110 Volt outlet exposing employees to the hazard of electric shock.    Instances 2)    For the employees working around the outlet with the broken weather resistant cover located on the walking/working platform on the Ivanco condenser unit on the roof of the Reed Lane facility on or about March 25, 2017 and times prior there to, the employer did not repair cover for the 110 Volt outlet exposing employees to the hazard of electric shock.

Issued

Oct 17, 2017

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in boxes, cabinets, or fittings were not effectively closed:  For the employees working in the Reed Lane ammonia refrigeration compressor room on or about May 23, 2017 and times prior there to the employer did not install a threaded knockout plug on the junction box to the solenoid controller on compressor #1.  This exposes employees to the hazard of electric shock from 110 Volts.