OSHA Inspection: JBS GREEN BAY, INC.

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $9,239 · Current $9,239

General-duty citation text

29 CFR 1910.28(b)(13)(i):  When work is performed less than 6 feet (1.6 m) from the roof edge, the employer must ensure each employee is protected from falling by a guardrail system, safety net system, travel restraint system, or personal fall arrest system:  On or about July 23, 2018 at the facility located at 1330 Lime Kiln Road, Green Bay, WI 54311; the employer did not ensure a Refrigeration employees was protected from falling by using a guardrail system, safety net system, traveling restraint system or personal fall arrest system when the employee was exposed to a fall from the roof edge to the ground (greater than 24 feet) while accessed the Air Storage Tank on the north side of the roof above the Kill Floor Locker Room. The employee placed a portable ladder less than 6 feet from the roof edge to access the pressure relief valve at the top of the Air Storage Tank.

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.28(b)(13)(iii):  When work is performed 15 feet (4.6 m) or more from the roof edge, the employer must protect each employee from falling by a guardrail system, safety net system, travel restraint system, personal fall arrest system or a designated area and implement and enforce a work rule prohibiting employees from going within 15 feet (4.6 m) of the roof edge without using fall protection in accordance with paragraphs (b)(13)(i) and (b)(13)(ii):     At the facility located at 1330 Lime Kiln Road, Green Bay, WI 54311; the employer did not protect Refrigeration employees from falling by a guardrail system, safety net system, traveling restraint system, personal fall arrest system or a designated area nor did the employer implement and enforce a work rule prohibiting employees from going within 15 feet of the roof edge without using fall protection when employees accessed the roof:    a) At the Rupp HVAC Unit; employees were exposed to falls from the roof edge to the next level (approximately 15 feet) and to the ground (approximately 28 feet) when they changed filters, checked belts and greased equipment on the Rupp HVAC unit. Falls hazards were present along both sides of the northeast corner of the roof.    b) At the Evaporator Control Stations above the Upper Dock; employees were exposed to falls from the roof edge to the next level (approximately 15 feet) and to the ground (approximately 30 feet) when they walked towards and worked on the Evaporator Control Stations. Fall hazards were present along the roof edge directly above the Upper Docks and along the roof edge west of the Upper Docks.     c) At the Evaporators above the New Engine Room; employees were exposed to falls from the roof edge to the ground (greater than 13 feet) when they accessed the roof and inspected valves and equipment by the Evaporators above the New Engine Room. Fall hazards were present along the roof edge directly above the New Engine Room on the south side of the building.    d) At the Kill Floor Roof Access door; employees were exposed to falls from the roof edge to the ground (greater than 15 feet) when they used the access door to get to the Kill Floor HVAC Unit and Air Storage Tank on the northeast side of the building. Fall hazards were present along the roof edge to the west of the Kill Floor Access door.

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.28(b)(15):  Except as provided elsewhere in this section or by other subparts of 29 CFR part 1910, the employer must ensure each employee on a walking-working surface 4 feet (1.2 m) or more above a lower level is protected from falling by guardrail system, safety net system, or personal fall protection systems, such as personal fall arrest, travel restraint, or positioning systems:    On or about July 23, 2018 at the facility located at 1330 Lime Kiln Road, Green Bay, WI 54311; the employer did not ensure a Refrigeration employees was protected from falls by using a guardrail system, safety net system, traveling restraint system or personal fall arrest system when the employee was exposed to falls of approximately 8-9 feet when accessing and working from the top of the:    b)  Rendering Floor Air Storage Tank located on the roof on the southwest side of the facility.

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $9,239 · Current $9,239

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:      At the facility located at 1330 Lime Kiln Road, Green Bay, WI 54311; the employer did not document that equipment complied with recognized and generally accepted good engineering practices (RAGAGEP):    b)  The ammonia detection systems in the Old Engine Room and New Engine Room would not automatically de-energize any equipment at any concentration of ammonia. The employer implemented IIAR 2-2014 for design of the ammonia detectors which required the automatic de-energization of refrigerant compressors, refrigerant pumps and normally closed automatic refrigerant valves that were not part of an emergency control system if ammonia concentrations equaled or exceeded the upper detection limits of the sensors or a concentration of 40,000 ppm (25% LFL).

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $9,239 · Current $9,239

General-duty citation text

29 CFR 1910.119(f)(1):  The employer shall develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information:    At the facility located at 1330 Lime Kiln Road, Green Bay, WI 54311; the employer did not develop and implement written operating procedures that provided clear instructions for safely conducting activities when Refrigeration employees were conducting Shutdown and Isolation of evaporators, such as but not limited to ECC1E17, ECC3C87, ERB134. Employees were conducting Shutdown and Isolation of those evaporators in a method other than how the written operating procedures' step-by-step prescribed.

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(1)(i):  The employer shall develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and shall address steps for each operating phase:    At the facility located at 1330 Lime Kiln Road, Green Bay, WI 54311; the employer did not develop and implement written operating procedures that provided clear instructions in the written Standard Operating Procedure for:    g)  New Side Thermosiphon Vessel (EOPV5) during the operating phase for Emergency Shutdown. The written SOP did not include conditions under which emergency shutdown would be required and did not contain the assignment of shutdown responsibilities to qualified operators.

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $9,239 · Current $9,239

General-duty citation text

29 CFR 1910.119(n):  The employer shall establish and implement an emergency action plan for the entire plant in accordance with the provisions of 29 CFR 1910.38. In addition, the emergency action plan shall include procedures for handling small releases. Employers covered under this standard may also be subject to the hazardous waste and emergency response provisions contained in 29 CFR 1910.120 (a), (p) and (q):    At the facility located at 1330 Lime Kiln Road, Green Bay, WI 54311; the employer's Emergency Response and Action Plan did not include distinctions of small versus large releases of anhydrous ammonia from the Old Side and/or New Side Ammonia Refrigeration Systems (ARS).

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B):  The employer shall complete a compilation of written process safety information. This process safety information shall include information pertaining to the equipment in the process including piping and instrument diagrams (P&ID's):    At the facility located at 1330 Lime Kiln Road, Green Bay, WI 54311; the employer did not complete a compilation of all written process safety information (PSI) regarding the piping and instrument diagrams:    a)  On PID-1 valve HS2.04 was drawn as a Plain End Gate valve. The employer's PSI document titled "Vavlelist Master" identifies valve HS2.04 as a Globe type valve.     f)  In the New Engine Room at V-1 Accumulator, PID-5's symbol of Spring Operated Relief Valve V4.01A was not drawn as Spring Operated Relief Valves were defined on PID-Symbols.      q)  In the Old Engine Room at V-1 Accumulator, PID-05 depicted an Angle type valve V1.12 on an EQL line upstream of valves V1.11 and V1.03. On the system, valves were tagged in the order of V1.11 upstream of V1.12 and V1.03.      u)  The following Angle valves reviewed on the P&IDs were not defined on the PID-Symbols; V1.82, V1.70B, V1.15, V1.94, V1.12 on PID-05; HS3.25, HS3.23, HS3.22, HS3.08 on PID-2

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(d)(3)(i)(F):  The employer shall complete a compilation of written process safety information. This process safety information shall include information pertaining to the equipment in the process including design codes and standards employed:    At the facility located at 1330 Lime Kiln Road, Green Bay, WI 54311; the employer did not complete a compilation of all written process safety information (PSI) including design codes and standards employed. The employer utilized International Institute of Ammonia Refrigeration (IIAR) Bulletin 114 in order to label ammonia refrigeration system (ARS) pipes and vessels in a standardized method. However, the employer did not include Bulletin 114 in their PSI.

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $0 · Current $0

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.    c) The Transfer Vessel (Vessel #3 EATV in the Old Machine Room) was not marked/labeled with the pressure level of the vessel. The employer implemented IIAR Bulletin 114-2014 for identification of ARS piping and system components which required labels to including the pressure level (high or low) for system components such as transfer vessels.    d) The Pump Out Vessel (Vessel #4 EPOV4 in the Old Machine Room) was not marked/labeled with the pressure level of the vessel. The employer implemented IIAR Bulletin 114-2014 for identification of ARS piping and system components which required labels to including the pressure level (high or low) for system components such as transfer vessels.    e) On header of the TSS line upstream of High Stage Compressors 1 through 3 was a label that designated the line as TL. The employer implemented IIAR Bulletin 114-2014 for identification of ARS piping. Neither the employers PID-01, PID-Symbols nor the IIAR Bulletin 114-2014 include a designation or definition of TL.    f) On the CD line above the TSS line upstream of High Stage Compressors 1 through 3 was a label that designated the line as CL. The employer implemented IIAR Bulletin 114-2014 for identification of ARS piping. Neither the employers PID-01, PID-Symbols nor the IIAR Bulletin 114-2014 include a designation or definition of CL.

Issued

Sep 19, 2018

Abate by

Oct 29, 2018

Penalty

Initial $9,239 · Current $0 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(iii):  The frequency of inspections and tests of process equipment shall be consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience:    At the facility located at 1330 Lime Kiln Road, Green Bay, WI 54311; the frequency of inspections and tests of process equipment was not consistent with applicable manufacturers' recommendations and good engineering practices. The employer did not schedule or conduct all inspections contained in the employer's Mechanical Integrity Schedules for equipment such as:      a)  Evaporative Condensers monthly inspections and PM were not being conducted      b)  Screw Compressor monthly check and record oil filter DP were not being conducted