OSHA Inspection: ASSOCIATED MILK PRODUCERS, INC.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $9,958 · Current $6,971 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B):  The employer shall complete a compilation of written process safety information including information pertaining to the equipment in the process including piping and instrument diagrams (P&ID's):    On or about July 13, 2017, the employer's P&ID's were not accurate and up to date:    a)  A bleed off valve on Compressor 9 (C9) between C9 and valve C9-05 was not depicted on the P&ID and was not tagged, labeled or identified on the system.    b)  Pump LR1-P1 below the Liquid Accumulator and Recirculator vessel (LR1) was not tagged, labeled or identified on the system.    c)  Pump LR1-P2 below LR-1 was not tagged, labeled or identified on the system.    d)  Valve LR1-09 located between globe valve LR1-08 and level sensor LR1-10 on the HTRL line was mislabeled as LR1-32 on the system.    e)  Valve LR1-44 located between angle valve LR1-43 and Evaporator 12 (EV12) on the HTRS line was mislabeled as LR1-09 on the system.    f)  Angle valve LR1-43 located between LR1 and EV12 on the HTRS line was mislabeled as LR1-41 on the system.    g)  The spring return ball valve LR1-38 of the LR-1 oil pot was not tagged, labeled or identified on the system.    h)  Liquid level sensor LR1-12 was removed from service yet remained on the P&ID. Portions of the insulation for the liquid level sensor remained on the system.    i)  A globe valve located on the system between EV14-18 and evaporator EV14 was not identified on the P&ID and was not tagged, labeled or marked on the system.    j)  Motor control valve GC1-06 was mislabeled as GC1-21    k)  Labels on valves GC2-27 and GC2-28 were incorrectly exchanged. Labels on angles valves GC2-29 and GC2-30 were incorrectly exchanged.    l)  Valve GC2-08 was not tagged, labeled or marked on the system. The P&ID identified valve GC2-08 as a needle valve when it was actually an angle valve.    m)  A welded cap (or plug) shown on the P&ID between valve GC2-08 and GC2-07 on the LSS line could not been seen on the system and was confirmed not to exist on the system.    n)  Valve GC2-25 was identified on the P&ID as a globe valve, the valve was actually a hand expansion valve.    o)  Valve HPR1-13 was an auto closing shut-off valve; however, the P&ID "Valve Legend" did not contain an identification for an Auto Closing Shut-Off valve.    p)  Auto closing shut-off valve HPR1-12 was identified on the P&ID as an angle valve.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $9,958 · Current $6,971 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(ii):  The employer shall document that equipment complies with recognized and generally accepted good engineering practices:    On or about July 13, 2017, the employer had determined to use International Institute of Ammonia Refrigeration (IIAR) Bulletin No. 114 (1991) "Identification of Ammonia Refrigeration Piping and System Components" as the recognized and generally accepted good engineering practices (RAGAGEP) for labeling of piping systems and components. The employer did not document that the piping systems and component labeling complied with the determined RAGEGEP when:    a)  Components were not labeled with the equipment's pressure level (HIGH in red, or LOW in green), including but not limited to Liquid Transfer and Recirculation tanks LR1 LR2 LA1 LA2 LA3 LA4 and a Transfer Drum located in the compressor room.    b)  The phase and pressure abbreviations on two (2) High Temp Recirculated Liquid (HTRL) pipes' labels were not highlighted with the appropriate colors. One label was located behind LR2 and the other was located to the left of LR1.    c)  The phase and pressure abbreviations on a High Stage Suction (HSS) pipe and on a High Gas Defrost (HGD) pipe were not highlighted with the appropriate colors. Those pipes were vertical runs located on the roof of the building adjacent to the northernmost pressure relief stack.    d)  The main lines below LR1 were not labeled with the abbreviations, physical state, ammonia, or pressure level. The main lines not labeled included, but were not limited to the High Temperature Recirculated Suction (HTRS) and HTRL lines on the left side of the LR1 vessel.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $9,958 · Current $6,971 Reduced

General-duty citation text

29 CFR 1910.119(j)(2):  The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment:    On or about July 13, 2017, the employer did not establish and implement written procedures for the annual inspection of insulated and uninsulated piping of the ammonia refrigeration system.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(iv):  The employer shall document each inspection and test that has been performed on process equipment. The documentation shall identify 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.  On or about July 13, 2017, the employer did not document annual inspections of the insulated and uninsulated piping of the ammonia refrigeration system.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $9,958 · Current $6,971 Reduced

General-duty citation text

29 CFR 1910.119(j)(5):  The employer shall 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.    On or about July 13, 2017:    a)  Globe valve LR1-31 was missing its valve handle and icing around the stem of the valve could have prevented operation of shutting the valve.    b)  Pipe insulation between liquid level meters LR1-11 and LR1-12 had been removed for changes in equipment but had not been replaced or repaired after the work had been completed.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $9,959 · Current $6,971 Reduced

General-duty citation text

29 CFR 1910.147(c)(1):  The employer shall establish a program consisting of energy control procedures, employee training and periodic inspections to ensure that before any employee performs any servicing or maintenance on a machine or equipment where the unexpected energizing, startup or release of stored energy could occur and cause injury, the machine or equipment shall be isolated from the energy source and rendered inoperative:    On or about July 27, 2017, the employer did not establish a complete energy control procedure to control unexpected energization, startup or release of stored energy when a maintenance employee was servicing/maintaining a cook room exhaust fan. The employers single source energy control procedure contained in the PowerPoint "Lockout/Tagout Authorized Training 2017" did not specify the procedural step for the isolation of equipment to control hazardous energy.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(B):  Energy control procedures shall clearly and specifically outline specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy:  On or about July 13, 2017, the energy control procedures did not contain specific procedural steps for shutting down equipment prior to isolating and affixing lockout equipment for the following equipment:  a)  Small Blenders  - Slice Lines (Procedure #1)  b)  Large Blenders - Loaf Lines (Procedure #13)

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(D):  Energy control procedures shall clearly and specifically outline specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures:  On or about July 13, 2017, the energy control procedures did not contain specific requirements for testing equipment to determine and verify effective of lockout devices for the following equipment:  a)  Small Blenders  - Slice Lines (Procedure #1)  b)  Large Blenders - Loaf Lines (Procedure #13)

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $9,958 · Current $6,971 Reduced

General-duty citation text

29 CFR 1910.147(d)(2):  The machine or equipment shall be turned off or shut down using the procedures established for the machine or equipment. An orderly shutdown must be utilized to avoid any additional or increased hazard(s) to employees as a result of the equipment stoppage:    On or about July 27, 2017, a maintenance employee did not turn off or shutdown a cook room exhaust fan prior to isolating electric power which was the single energy source of the fan's motor.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(6):  Prior to starting work on machines or equipment that have been locked out or tagged out, the authorized employee shall verify that isolation and deenergization of the machine or equipment have been accomplished:  a)  On or about July 13, 2017, prior to starting work on grinders that had been isolated and locked out, authorized employees in the Grinder Room did not verify that isolation and deenergization of the grinders had been accomplished by trying to turn the machine on to verify no energy.  b)  On or about July 27, 2017, prior to starting work on a cook room exhaust fan that had been isolated and locked out, an authorized maintenance employee did not verify that isolation and deengerization of the exhaust fans had been accomplished. After turning off the electrical disconnect and applying a lockout device, the maintenance employee began work on the machine.

Issued

Dec 7, 2017

Abate by

May 1, 2018

Penalty

Initial $9,958 · Current $6,971 Reduced

General-duty citation text

29 CFR 1910.212(a)(1):  One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc.:    On or about July 13, 2017, the employer did not provide one or more methods of machine guarding to protect Cook employees from rotating parts and ingoing nip points which posed caught-in/caught-between hazards:    a)  The two (2) hatches on top of the Large Loaf Blender of Line 3 were not guarded to protect employees from coming into contact with the rotating portions of the blender's mixers.    b)  The two (2) hatches on top of the Large Loaf Blender of Line 4 were not guarded to protect employees from coming into contact with the rotating portions of the blender's mixers.      c)  The two (2) hatches on top of the Small Slice Blender of Line 5 were not guarded to protect employees from coming into contact with the rotating portions of the blender's mixers.      d)  The two (2) hatches on top of the Small Slice Blender of Line 6 were not guarded to protect employees from coming into contact with the rotating portions of the blender's mixers.      e)  The two (2) hatches on top of the Small Slice Blender of Line 7 were not guarded to protect employees from coming into contact with the rotating portions of the blender's mixers.      f)  The two (2) hatches on top of the Small Slice Blender of Line 8 were not guarded to protect employees from coming into contact with the rotating portions of the blender's mixers.      g)  The two (2) hatches on top of the Small Slice Blender of Line 9 were not guarded to protect employees from coming into contact with the rotating portions of the blender's mixers.      h)  The two (2) hatches on top of the Small Slice Blender of Line 10 were not guarded to protect employees from coming into contact with the rotating portions of the blender's mixers.     i)  The auger on the front of the Large Loaf Blenders of Lines 3 and 4 was not guarded to protect employees from coming into contact with the ingoing nip points between the auger's fins and sides of the blender's trough.    j)  The auger on the front of the Small Slice Blenders of Lines 5 and 6 was not guarded to protect employees from coming into contact with the ingoing nip points between the auger's fins and sides of the blender's trough.      k)  The auger on the front of the Small Slice Blenders of Lines 7 and 8 was not guarded to protect employees from coming into contact with the ingoing nip points between the auger's fins and sides of the blender's trough.      l)  The auger on the front of the Small Slice Blenders of Lines 9 and 10 was not guarded to protect employees from coming into contact with the ingoing nip points between the auger's fins and sides of the blender's trough.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(c)(2):  If the workplace contains permit spaces, the employer shall inform exposed employees, by posting danger signs or by any other equally effective means, of the existence and location of and the danger posed by the permit spaces:  On or about July 13, 2017, the employer did not inform exposed employees by posting danger signs or by any other equally effective means of workplace permit spaces such as, but not limited to:  a)  Truck dock leveler pits (7 and 8)  b)  The Ram-A-Lot (TVB-60-H) compactor adjacent to the Glycol Shell and Tube Chiller equipment  NOTE: A sign reading DANGER -- PERMIT-REQUIRED CONFINED SPACE, DO NOT ENTER or using other similar language would satisfy the requirement for a sign.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(f)(3)(i):  When servicing and/or maintenance is performed by a crew, craft, department or other group, they shall utilize a procedure which affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device:  On or about July 27, 2017, the employer did not develop procedures for group lockout when more than one maintenance employee changed a gear box on a Large Loaf Blender. Neither the employers Lockout/Tagout written program, PowerPoint training document or Large Loaf Blender machine specific energy control procedure described group lockout procedures.

Issued

Dec 7, 2017

Abate by

Jan 18, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(b)(2):  Listed or labeled equipment shall be installed and used in accordance with any instructions included in the listing or labeling:  On or about July 27, 2017, a metallic outlet box (handy box) located on the LA-3's sight glass level sensor was not installed in accordance with the UL identifier QCIT which states that boxes shall be mounted in or on a surface. The handy box was attached to the level sensor unit and connected to a flexible braided conduit.