OSHA Inspection: THE GILMAN BROTHERS COMPANY

Issued

Sep 27, 2018

Abate by

Nov 15, 2018

Penalty

Initial $9,959 · Current $4,980 Reduced

General-duty citation text

29 CFR 1910.106(h)(7)(i)(a):  Precautions shall be taken to prevent the ignition of flammable vapors. Sources of ignition include but are not limited to open flames; lightning; smoking; cutting and welding; hot surfaces; frictional heat; static, electrical, and mechanical sparks; spontaneous ignition, including heat-producing chemical reactions; and radiant heat:    Area around Extruder:  On, or about, June 19, 2018, static electricity was generated from the production process that created potential ignition sources for the iso-butane, a Category 1 flammable liquid, that was off-gassed in the production area.  An ionizing unit was found to be not functional.  The company had not determined all potential areas where static could be present and had not taken effective steps to control the static charge.  Fires occurred in the process area on March 9, 2018 and May 29, 2018.

Issued

Sep 27, 2018

Abate by

Oct 31, 2019

Penalty

Initial $9,959 · Current $4,980 Reduced

General-duty citation text

29 CFR 1910.106(h)(7)(iii)(a): All electrical wiring and equipment shall be installed in accordance with subpart S of this part:  Area around Extruder:  On, or about, June 19, 2018, the following electrical equipment that was designed for use in non-classified locations was used in areas classified as Class 1, Division 2 using the classification method contained in National Fire Protection Association (NFPA)  Standard 497, Recommended Practice for the Classification of Flammable Liquids, Gases or Vapors and of Hazardous (Classified) Locations for Electrical Installations of Chemical Process Areas as required under 29 CFR 1910.119(d)(3)(i)(C).  On March 26, 2018, a fire occurred at the extruder outlet due to exposed heater wires:  A.    Area 4 (as identified on the Fuss & O"Neill 2011 classification document) Process Piping Between Pump Shed and Indoor Extruder.  The following equipment was located in the designated Class 1, Division 2 area:  1.  T27:  460 volt isolation transformer.   2.  T28:  460 volt isolation transformer.   3.  D90:  Harrell Melt Pump drive. 4.  T29:  Federal Pacific transformer.  5.  D91:  Harrel Extruder drive. 6.  T30:  HPS step down transformer.  7.   Raceway and various wiring under the extruder.      B.     Area 5 (as identified on the Fuss & O'Neill 2011 classification document) Indoor Extruder Area.  The following equipment was located in the designated Class 1, Division 2 area:  1.  Dayton fan.   2.   Dayton fan. 3.   T31 transformer. 4.   Duplex outlet.    5.   Blue/gray traverse motor. 6.   Dayton fan under web. 7.   Dayton fan under web.   8.   Extruder thermocouple wiring.      Abatement Note:  Under 29 CFR 1910.119(l)(1), Management of Change must be conducted because the blowing agent has changed from iso-pentane to iso-butane.  The classification recommendation may change as a result of the lower flash and boiling points of iso-butane and the recent history of fires in the process area.

Issued

Sep 27, 2018

Abate by

Dec 15, 2018

Penalty

Initial $9,959 · Current $4,980 Reduced

General-duty citation text

29 CFR 1910.119(l)(1): The employer did not implement procedures to manage changes to process chemicals, technology, equipment, and procedures, and changes to facilities that affect a covered process:   Facility:  On, or about, June 19, 2018, the company had not followed Management of Change procedures when the blowing agent was changed from iso-pentane to iso-butane.  Aspects of the process including, but not limited to, updating the Process Hazard Analysis, updating Process Safety Information, verifying/updating piping and relief design, verifying/updating Class 1areas, reviewing any impact on equipment on the process and verifying/updating Standard Operating Procedures were not addressed.

Issued

Sep 27, 2018

Abate by

Nov 30, 2018

Penalty

Initial $35,570 · Current $17,785 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(i): The employer did not perform inspection and tests on process equipment:  Facility:  On, or about, June 19, 2018, the company had not performed monthly inspections on the Draeger system to ensure that it was functioning properly and would shut down the iso-butane delivery system in the event of a leak or spill.    The Gilman Brothers Company was previously cited for a violation of this Occupational Safety and Health Standard, which was contained in OSHA Inspection Number 909370, Citation Number 2, Item Number 1a and was affirmed as a Final Order on December 17, 2014, with respect to a workplace located at Gilman, Connecticut.