OSHA Inspection: DOUBLE R BRAND FOODS LLC

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $8315.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.38(c)(2): The employer's emergency action plan did not include procedures for emergency evacuation, including type of evacuation and exit route assignments:    On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not update its emergency action plan to include exit route assignments and muster points for emergency evacuation.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

129 CFR 1910.38(f)(2): The employer did not review the emergency action plan with each employee covered by the plan when the employee's responsibilities under the plan changed:  On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not review and update the emergency action plan with employees when the facility emergency coordinators changed.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $8315.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): The employer's piping and instrument diagrams (P&ID) were not accurate:    On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not ensure that piping and instrument diagrams (P&IDs) were accurate.  The P&IDs were not accurate as the following but not limited to.     a.   P&ID-101, Rev. #0 (Date:12/24/01).  This P&ID did not include relief valves and detail configurations of the high stage compressors HS-5 and HS-6.     b.   P&ID-102, Rev. #0 (Date:12/24/01).  This P&ID did not include detail configurations of the evaporative condenser EC-4.     c.   P&ID-101/102/103 Rev. #0 (Date:12/24/01).  These P&IDs did not include ammonia vent-lines or stacks for the high stage compressors HS-5 and HS-6.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $11641.00 · Current $6760.00 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D): Process safety information (PSI) pertaining to the equipment in the process did not include relief system design and design basis:    On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not ensure that PSI for relief system design and design basis for the ammonia refrigeration systems and pressure relief/safety valves (PRV/PSV) was included for the following:      a.     The relief system design and design basis for the ammonia refrigeration systems   b.     Two (2) PSVs for Re-circulator, V-01   c.     Two (2) PSVs for Re-circulator/ Intercooler, V-04  d.     Two (2) PSVs for Control Pressure Receiver, V-06

Issued

2018-05-03 00:00:00

Abate by

2018-07-13 00:00:00

Penalty

Initial $11641.00 · Current $6760.00 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)  On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not document that it complied with its chosen recognized and generally accepted good engineering practice, including but not limited to, ANSI/ASHRAE-15 1994 (American Society of Heating Refrigeration Air-Conditioning and Engineering) section 11.1 and ANSI/IIAR-2 2008 (International Institute Ammonia Refrigeration) section13.1.2.4, when it did not post an authorized personnel sign on the West entrance door of the machinery (or engine) room.       Instance b)  On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not document that it complied with its chosen recognized and generally accepted good engineering practices, such as ANSI/ASHRAE-15 1994 section 8.13.2 and ANSI IIAR-2 1992 section 4.4.8, when the west door of the machinery room did not open outward, and the South door of the machinery room was not equipped with a self-closing mechanism.        Instance c)  On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not document that it complied with its chosen recognized and  generally accepted  good  engineering practice, such as ANSI/ASHRAE -15 1994 section 8.14(i) and ANSI/ IIAR- 2 1992 section 4.4.11, when a remote control shut off for mechanical equipment in the refrigerating machinery room was not installed immediately outside the west door entrance to the machinery room.    Instance d)  On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not document that it complied with its chosen recognized and generally accepted good engineering practice such as ANSI/ASHRAE -15 1994 Section 8.14(i) when a control switch for the ventilation fan was not installed immediately outside the machinery room entrance doors.      Instance e)  On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer classified the machinery room as electrically non-hazardous, the employer did not document compliance with its chosen recognized and generally accepted good engineering practices, such as ANSI/ASHRAE 15-1994, Section 8.12(h), in that the mechanical ventilation system in the machinery room did not run continuously, and failure of the mechanical ventilation system did not actuate an alarm.       Instance f)  On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not document that it complied with its chosen recognized and generally accepted good engineering practice such as ANSI/ASHRAE -15 1994 Section 8.13.2 where openings in the machinery room walls were not sealed.      Instance g)  On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not document that it complied with its chosen recognized and generally accepted good engineering practice such as ANSI/ASHRAE -15 1994 section 9.7.8 and ANSI/ IIAR- 2 1992 section A.4.1.1 when it failed to ensure that anhydrous ammonia discharged to atmosphere was released at least 15ft above the adjacent ground level.

Issued

2018-05-03 00:00:00

Abate by

2018-07-13 00:00:00

Penalty

Initial $11641.00 · Current $6760.00 Reduced

General-duty citation text

29 CFR 1910.119(e)(5): The employer did not ensure that PHA recommendations were resolved in a timely manner.    On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not resolve 2014 PHA recommendations in a timely manner, including but not limited to:      a)    PHA Item #2: Ensure operation personnel are fit tested and respirator qualified     b)    PHA Item#3: Consider implementation of at least annual vibration monitoring for all compressors    c)    PHA Item #13:  Connect ammonia detection alarm to 24-hr monitoring    d)    PHA Item # 15 Updated MR sign to list current contractor and include: 1). Name, address and telephone   number of installing/service contractor. 2). Approximate quantity of NH3. 3). Lubrication identify amount.  4). Field test pressure.     e)    PHA Item#17. Install positive means to alarm if continuous ventilation stops.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $8315.00 · Current $4900.00 Reduced

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. The employer did not annually certify that operating procedures were current and accurate.     On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not annually certify operating procedures to ensure that they are current and accurate. The following inaccuracies were noted:      a) SOP-11-Line Opening/Oil Draining, Revision #0 (5/30/14).  The procedure was not annually certified from 2016 through 2017 and was found to be inaccurate, in that the Reference Documents section listed Piping and Instrument Diagrams (P&ID) from 01 through 08, when there are only 3 P&ID (PID 101-103).  The Assemble Equipment section did not include used oil drum. It further stated that a Full face type Air Purifying Respirator (APR) with Ammonia Cartridges installed must be donned above 35ppm, when there is no indicator to detect ammonia release at 35 ppm.  The Oil Pot Training Procedures did not include steps to drain oil from the Pump-out Accumulator V-07 directly to a used oil drum.    b) SOP-02-Compressor Operation, Revision #0 (5/30/14).  The procedure was not annually certified from 2016 through 2017 and was found to be inaccurate. The procedure indicated compressor numbers from #1 through #10 instead of LS1-LS4 and HS1-HS6.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $11641.00 · Current $6760.00 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.       On or about 11/16/2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not develop and implement safe work practices to provide for the control of hazards during operations such as control over entrance into a facility by employees, contractor employees, and other support personnel.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(c)(4)(i): Energy control procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section.     On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not develop energy control procedures for equipment, including but not limited to:      a)     Water pump for Evaporative Condenser #1 (EC1),     b)     Re-circulate pump AP-1 for recirculate vessel V1,    c)     Pump AP-8 Re-circulation/intercooler for V4,    d)     Fan motor for Evaporative Condenser #4 (EC4).

Issued

2018-05-03 00:00:00

Penalty

Initial $4989.00 · Current $3600.00 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 programs.      On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not evaluate information regarding the safety performance and programs of the contractor Hilbig Services prior to the contractor performing work on a covered process.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $8315.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish and implement written procedures to maintain the on-going integrity of process equipment.     On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not ensure that written procedures for testing or inspecting of process equipment were established and implemented including, but not limited to:      a) Corrosion Under Insulation (CUI) for ammonia vessels and piping,    b) Compressors safety cutouts,    c) Engine room emergency ventilation,    d) Emergency stop buttons,     e) Control levels for pressure vessels.

Issued

2018-05-03 00:00:00

Abate by

2018-07-13 00:00:00

Penalty

Initial $11641.00 · Current $6760.00 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(i): The employer did not perform inspections and tests on process equipment.      On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not perform inspections and testing on process equipment for the ammonia refrigeration systems, including process equipment such as, but not limited to:    a)     Ammonia detectors,    b)     Visual and audible alarms,      c)     Exhaust ventilation fans,    d)     Oil Pressure Differential Cut Out for the compressor #2,    e.     High and Low Pressure Cut Out for the compressor #10,    f.      High temperature Cut out for the compressor #10,    g.     High and Low Level Controls for Re-circulator V-1,    h.     Emergency Stop Buttons for the ammonia refrigeration system,    i.      Liquid King Valve for the high pressure receiver,    j.      Re-circulator V-1,    k.     Re-circulator/ Intercooler V-4,    l.      Control Pressure Receiver V-6,    m.    Evaporative condenser EC-4,    n.     Compressor # 2,    o.     Compressor # 10,    p.     Re-circulator Pump AP-1 for V-1,    q.     Re-circulator/Intercooler Pump AP-8 for V-4,    r.     Visual inspection and non-destructive testing for ammonia refrigeration piping system.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $8315.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.119 (l)(1) : The employer did not establish and implement written procedures to manage changes(except for "replacements in kind")  to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process.    On or about 11/16/2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not establish and implement written procedures to manage changes to equipment, including but not limited to.      a) Control panel for the compressor #10,    b) Two new emergency stop buttons located outside the engine room door entrances (West and South),    C) Two new visible alarms located outside the engine room door entrances (West and South).

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $8315.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.119(o)(1): Employers did not certify that they have evaluated compliance with the provisions of this section at least every three years to verify that the procedures and practices developed under the standard were adequate and were being followed.    On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not conduct Process Safety Management (PSM) compliant audits for the ammonia refrigeration system every three years.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $8315.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.134(c)(1):  In any workplace where respirators were necessary to protect the health of the employee, or whenever respirators were required by the employer, the employer did not establish and implement a written respiratory protection program with worksite-specific procedures:    On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not establish and implement a written respiratory protection program.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace.  On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer required employees to wear respirators during ammonia releases and when draining oil within the ammonia refrigeration system and did not ensure that employees had received medical evaluations.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.134(f)(2): The employer did not ensure that an employee using a tight-fitting facepiece respirator was fit tested prior to initial use of the respirator, whenever a different respirator facepiece (size, style, model or make) was used, and at least annually thereafter:    On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer required employees to wear respirators during ammonia releases and when draining oil within the ammonia refrigeration system and did not ensure that employees had received fit tests.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.134(h)(3)(i)(B): All respirators maintained for use in emergency situations were not inspected at least monthly and in accordance with the manufacturer's recommendations, and were not checked for proper function before and after each use:    On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not inspect ammonia respirators at least monthly.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $4989.00 · Current $3600.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(5)(ii)(D) : Lockout devices and tagout devices did not indicate the identity of the employee applying the device(s).    On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not ensure that lockout devices used identified the employee applying the devices including, but not limited to, the following equipment:      a)     Water pump for Evaporative Condenser #1 (EC1),    b)     Re-circulate pump AP-1 for recirculation vessel V1,    c)     Pump AP-8 for Re-circulation/intercooler, V4,    d)     Fan motor for Evaporative Condenser #4 (EC4).

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $8315.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.151(c): Where the eyes or body of any person may be 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:    On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not provide functional emergency eyewash and body shower stations in locations including, but not limited to:    a) The emergency eyewash/shower station located within the compressors area in the engine room,    b) The emergency eyewash/shower station located within pressure vessels area outside the engine room,     c) The emergency eyewash/shower station located outside at the South door of the engine room .

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $8315.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.212(a)(5): Fan guards had openings exceeding one-half (1/2) inch:    On or about 11/16/2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not ensure that the fan blades of the motor for evaporative condensers EC2 &EC4 were guarded with guards having openings no larger than one-half inch.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $8315.00 · Current $4900.00 Reduced

General-duty citation text

CFR 29 1910.1200(h)(3)(iv): Employee information and training on the hazards of the chemicals to which they could be exposed did not include details about the hazard communication program developed by the employer, including an explanation of the labels received on shipped containers and the workplace labeling system used by their employer; the safety data sheet, including the order of information, and how employees could obtain and use the appropriate hazard information:       On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the employer did not provide effective information and training to employees about the hazard communication program and the hazards of anhydrous ammonia.

Issued

2018-05-03 00:00:00

Abate by

2018-06-20 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.303(g)(2)(iii) : Entrances to rooms and other guarded locations containing exposed live parts were not marked with conspicuous warning signs forbidding unqualified persons to enter:      On or about November 16, 2017, at the Double R Brand Foods facility located in Lufkin Texas, the electrical room/ motor control center (MCC) located next to the engine room was not marked with conspicuous warning signs forbidding unqualified persons to enter.