OSHA Inspection: GLAZIER FOODS COMPANY

Issued

Jan 18, 2019

Abate by

Mar 8, 2019

Penalty

Initial $12,934 · Current $7,000 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 practice:      This violation occurred on or about July 24, 2018, at the work place located at 777 Freeport Parkway, Coppell, TX; where the employer failed to document that the safety pressure relief system (pressure relief valves through the vent piping) design is compliant with ASHRAE 15-2013. In three relief scenarios, for the High Stage Compressor; C-1, the actual back pressure exceeds the maximum allowable back pressure as provided in ASHRAE 15-2013; for the following equipment:    (a) Relief Scenario 1, for all equipment performance    High Stage Compressor C-1:   -actual back pressure 82.7  -allowable back pressure 52.2       (b) Relief Scenario 2 for High Stage Compressor C-1:   -actual back pressure 82.6    -allowable back pressure 52.2      (b) Relief Scenario 3, for all compressor performance   High Stage Compressor C-1:   -actual back pressure 82.6  -allowable back pressure 52.2

Issued

Jan 18, 2019

Abate by

Mar 8, 2019

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(5): 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 occurred on or about July 24, 2018, at the work place located at 777 Freeport Parkway, Coppell, TX; Glazier Foods did not correct deficiencies in the Engine Room pressure relief system equipment in a safe and timely manner. The pressure relief system (pressure relief valves through the vent piping) is deficient in that the High Stage Compressor-C-1, actual backpressure exceeds the maximum allowable backpressure as provided in ASHRAE 15-2013.  Excess back pressure can cause the entire pressure relief system not to function properly, as designed, resulting in a fire and/or explosion.   (a) Relief Scenario 1, for all equipment performance  High Stage Compressor C-1:  -actual back pressure 82.7 -allowable back pressure 52.2  (b)  Relief Scenario 2 for High Stage Compressor C-1:  -actual back pressure 82.6  -allowable back pressure 52.2    (c )   Relief Scenario 3, for all compressor performance     High Stage Compressor C-1:  -actual back pressure 82.6  -allowable back pressure 52.2

Issued

Jan 18, 2019

Abate by

Mar 8, 2019

Penalty

Initial $5,543 · Current $3,000 Reduced

General-duty citation text

29 CFR 1910.119(f)(1): The employer did not 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:     This violation occurred on or about July 24, 2018, at the work place located at 777 Freeport Parkway, Coppell, TX;Glazier Foods did not develop written operating procedures for the ammonia refrigeration system equipment, such as but not limited to, the following:    (a) Evaporator 1 to 24  (b) Condenser   (c) AutoPurger  (d) Refrigerant Pumps/Ammonia Pumps  (e) Glycol Heat Exchanger HX 1  (f) Emergency Ventilation System-Ammonia Detection Engine Room

Issued

Jan 18, 2019

Abate by

Mar 8, 2019

Penalty

Initial $12,934 · Current $7,000 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.      The employer did not implement their mechanical integrity program for ammonia process equipment by not performing or completing the following:    a.   On or about July 24, 2018 Glazier Foods did not have a written procedure for testing its safety cutouts.  b.   On or about July 24, 2018 Glazier Foods did not implement its written procedures for valve maintenance by failing to clean, exercise and neversieze all valves during 2017 and the first quarter of 2018 for the following process equipment: Auto Purger, Evaporators, High Pressure Receiver, Low Temperature Receiver, Condenser, Ammonia Pumps 1-4, and compressors C-1, C-2, C-3.  c.   On or about July 24, 2018 Glazier Foods did not implement its written procedures for exhaust ventilation fan maintenance by failing to lubricate exhaust fan components, confirm proper operation of the fan louvers, check the condition of electrical components, including switches and conduit wire, inspect the condition of belts at least monthly and check for damage and unusual sounds and check for excessive vibration in power supply and exhaust ventilators on a semi-annual basis.  d.   On or about July 24, 2018 Glazier Foods did not implement its written mechanical integrity procedures by failing to perform Class A inspections quarterly and Class B inspections annually for compressors C-1, C-2 and C-3 in accordance with the program maintenance schedule.  e.   On or about July 24, 2018 Glazier Foods did not implement its written        mechanical integrity procedures by failing to check safety controls, assure valve tags are in place, tighten electrical connections, verify sequence of control semi-annually and pressure wash coils with coil cleaner quarterly  for evaporators 1-24.    f.   On or about July 24, 2018 Glazier Foods did not implement its written mechanical integrity procedures by failing to drain the oil and inspect the insulation on a monthly basis for the High Pressure Receiver and Low Temperature Receiver in accordance with the program maintenance schedule.   g.  Oil analysis and Vibration analysis was not performed quarterly for the following compressors: C-1, C-2, C-3, in accordance with their mechanical integrity schedule.

Issued

Jan 18, 2019

Abate by

Mar 8, 2019

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(j)(4)(iv): The employer did not document for each inspection and test that has been performed on process equipment; 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.   Glazier Foods did not document for each inspection a description of the inspection or test performed and/or the results of the inspection or test for process equipment; such as, but not limited to the following:  (a) Glazier Foods did not implement the written mechanical integrity procedures by failing to document the results of the daily inspection or test of the annunciated or recorded alarms or shut downs for FEA GEA GLX Compressors 1, 2, and 3. (b) Glazier Foods did not implement the written mechanical integrity procedures by failing to document the results of the Class A and Class B inspection of FEA GEA GLX Compressors 1, 2, and 3. (c) Glazier Foods did not implement the written mechanical integrity procedures by failing to provide a description of the inspection or document the results of the inspection conducted between May 29, 2018 and June 25, 2018 for the AutoPurger. (d) Glazier Foods did not implement its written mechanical integrity procedures  by failing to document the results of the inspection of the pump bearing monitor for Ammonia Pump AP-1. (e) Glazier Foods did not implement its written mechanical integrity procedures by failing to document the results of the 2018 annual inspection of the high pressure receiver.

Issued

Jan 18, 2019

Abate by

Mar 8, 2019

Penalty

Initial $12,934 · Current $7,000 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:    (a)  This violation occurred on or about July 24, 2018, at the work place located at 777 Freeport Parkway, Coppell, TX; the employer did not perform testing of safety cutouts on process equipment in accordance with consensus standards such as, but not limited to, IIAR Bulletin 110, 1993, Section 6.3.3 which provides that high pressure cutouts, low pressure cutouts, high temperature cutouts, and oil pressure differential switches cutouts be tested at least annually. The cutouts for Compressors 1, 2, and 3 were not tested annually.       (b) This violation occurred on or about July 24, 2018, at the work place located at 777 Freeport Parkway, Coppell, TX; the employer did not perform testing of safety cutouts on process equipment in accordance with its mechanical integrity program. The Low Level Liquid Safety Cutout for Ammonia Pumps AP-1, AP-2, AP-3, and AP-4 was not done annually:.      And       At yearly intervals, Ammonia Pumps AP-1, AP-2, AP-3, and AP-4 were not inspected for wear or damage which could affect its operation in accordance with  IIAR Bulletin 110, Section 6.5.3.

Issued

Jan 18, 2019

Abate by

Mar 8, 2019

Penalty

Initial $12,934 · Current $7,000 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(iii): The frequency of inspections and tests of process equipment is not consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience:    (a) This violation occurred on or about July 24, 2018, at the work place located at 777 Freeport Parkway, Coppell, TX; the employer did not perform testing of the High Pressure receiver and Low Temperature Receiver in accordance with its mechanical integrity program by failing to annually test and calibrate the liquid level indicator sensor and controls, verify the level control functions, and test the liquid level float switch sensors and controls.      (b) This violation occurred on or about July 24, 2018, at the work place located at 777 Freeport Parkway, Coppell, TX; the employer did not replace pressure relief valve PRV-1 associated with Oil pot OP-1 and PRV-2 associated with Oil pot OP-2 in accordance with applicable manufacturers' recommendations and good engineering practices; and Relief valve vent lines were not visually inspected annually to ensure that the vent line piping is intact and that vent outlets terminated to atmosphere are unobstructed and piped to prevent foreign matter from entering the vent line piping in accordance IIAR Bulletin 110, section 6.6.3.

Issued

Jan 18, 2019

Abate by

Mar 8, 2019

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(3): The employer did not review the operating procedures as often as necessary to assure that they reflect current operating practice. The employer did not certify annually that the operating procedures were current and accurate:   This violation occurred on or about July 24, 2018, at the work place located at 777 Freeport Parkway, Coppell, TX; Glazier Foods did not ensure that operating procedures for the ammonia refrigeration system were certified annually. The operating procedures for the ammonia refrigeration system had not been certified since July 7, 2017; for equipment, such as but not limited to, the following:  (a) High Pressure Receiver (HPR-1) (b) Compressors C1, C2, C3 (c) High Temperature Recirculator (HTR) (d) Low Temperature Recirculator (LTR) (e) ORV1 (f) Equipment Line Opening

Issued

Jan 18, 2019

Abate by

Mar 8, 2019

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(o)(1): The 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 are adequate and are being followed:   (a)This violation occurred on or about July 24, 2018, at the work place located at 777 Freeport Parkway, Coppell, TX;In the 2016 compliance audit the employer failed to certify that they have evaluated compliance with the provisions of 1910.119 to verify that the procedures and practices developed under the standard are adequate and are being followed.        The employer failed to certify the 2016 compliance audit.