OSHA Inspection: CHEMICALS INC.

Issued

2019-07-25 00:00:00

Abate by

2019-11-07 00:00:00

Penalty

Initial $10741.00 · Current $6445.00 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D): Information pertaining to the equipment in the process did not include relief system design and design basis:    The violation occurred at the Chemicals, Inc. facility located in Baytown, TX on February 28, 2018 when the employer failed to ensure process safety information includes the pressure relief design and design basis, such as but not limited to:      1. Conventional relief valve made by Ferris (S/N F-01117-778-1) for TK-708 Methanol tank  2. Conventional relief valve manufactured by Lonergan (S/N 880573-14-1) for RX-F7 reactor  3. Pressure relief device Lonegran (S/N H-86-791, model D10 J/S4/SP) for RX-F15 reactor

Issued

2019-07-25 00:00:00

Abate by

2019-11-07 00:00:00

Penalty

Initial $10741.00 · Current $6445.00 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):     This violations occurred at the Chemicals, Inc. facility located in Baytown, TX where employees were exposed to fire and explosion hazards from releases of flammable materials when, the employer did not document that it complied with its chosen recognized and generally accepted good engineering practice, including but not limited to, American Society of Mechanical Engineers Boiler Pressure Vessel Code Section VIII (ASME BPVC) and American Petroleum Institute (API) 510 section 7.8.2, when the process safety information did not include manufacturers data report (U-1) for pressure vessels, such as, but not limited to:       a.    RX-F7 Reactor (P&ID Drawing No. 4 Rev. #3 (Date:04/04/17).  b.    RX-F15 Reactor (P&ID Drawing No. 2, Rev. #4 (Date:04/24/17)  c.    TK-739 Methanol Receiver (P&ID Drawing No. 2, Rev. #4 (Date:04/24/17).  d.    F6 Knock out vessel (P&ID Drawing No.3 Rev. #3 (Date:04/04/17).  e.    TK-805 Formalin Feed Tank (P&ID SMD9600 Rev#1 (Date 12/20/2016)  f.    RX-G-2 Reactor (P&ID SMD9600 Rev#1 (Date 12/20/2016)      This violations occurred at the Chemicals, Inc. facility located in Baytown, TX where employees were exposed to fire and explosion hazards from releases of flammable materials when, the employer did not document that it complied with its chosen recognized and generally accepted good engineering practice, including but not limited to,American Petroleum Institute (API) 520  American Petroleum Institute (API) 576 section 7.2.1 when the process safety information did not include specification data, including sizing calculations for pressure relieving devices.    g. Pressure relief device for TK-708 Methanol tank (Drawing No. 7 Rev. #4 (Date:04/24/17)  h. Pressure relief device for RX-F7 reactor (Drawing No. 4 Rev. #3 (Date:04/04/17)  i. Pressure relief device for RX-F15 reactor (Drawing No. 2, Rev. #4 (Date:04/24/17)

Issued

2019-07-25 00:00:00

Abate by

2019-11-07 00:00:00

Penalty

Initial $7672.00 · Current $4603.00 Reduced

General-duty citation text

29 CFR 1910.119(e)(3)(iii): The process hazard analysis did not address engineering and administrative controls applicable to the hazards and their interrelationships such as appropriate application of detection methodologies to provide early warning of releases. (Acceptable detection methods might include process monitoring and control instrumentation with alarms, and detection hardware such as hydrocarbon sensors.);    The violation occurred at the Chemicals, Inc. facility located in Baytown, TX on February 28, 2019 when the employer failed to address in the process hazard analysis the possible need for engineering and administrative controls and identify what detection methodologies would be utilized to provide early warning of releases of highly hazardous chemicals. An example of such a control may include, but not limited to hydrocarbon sensors that annunciate an alarm or early warning system.

Issued

2019-07-25 00:00:00

Abate by

2019-09-07 00:00:00

Penalty

Initial $10741.00 · Current $6445.00 Reduced

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(A): The employer did not develop and implement written operating procedures that addressed the consequences of deviations from the operating limits in the covered process;        The violation occurred in the Chemicals, Inc. facility in Baytown, TX on February 28, 2019 when the employer failed to develop and implement written operating procedures that addressed the consequences of deviations from the operating limits in Unit F and Unit G.

Issued

2019-07-25 00:00:00

Abate by

2019-09-07 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(B): The employer did not develop and implement written operating procedures that provide clear instructions for steps required to correct or avoid deviation from the operating limits in the covered process.    The violation occurred in the Chemicals, Inc. facility in Baytown, TX on February 28, 2019 when the employer failed to develop and implement written operating procedures that provide clear instructions for steps required to correct or avoid deviation from the operating limits in Unit F and Unit G.

Issued

2019-07-25 00:00:00

Abate by

2019-09-07 00:00:00

Penalty

Initial $0.00 · Current $0.00

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:      The violation occurred in the Chemicals, Inc. facility in Baytown, TX on February 28, 2019 when the employer failed to develop and implement written safe work practices to provide for the control of hazards during operations such as lockout/tagout and control over entrance into a facility by maintenance, contractor, laboratory, or other support personnel in Unit F and Unit G.

Issued

2019-07-25 00:00:00

Abate by

2020-02-07 00:00:00

Penalty

Initial $10741.00 · Current $6445.00 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:      The violation occurred in the Chemicals, Inc. facility in Baytown, TX on February 28, 2019 when the employer failed to establish or implement written procedures to maintain the on-going integrity of process equipment, such as but not limited to:       a)    RX-F7 Reactor (P&ID Drawing No. 4 Rev. #3 (Date:04/04/17).  b)    RX-F15 Reactor (P&ID Drawing No. 2, Rev. #4 (Date:04/24/17)  c)    TK-739 Methanol Receiver (P&ID Drawing No. 2, Rev. #4 (Date:04/24/17).  d)    F6 Knock out vessel (P&ID Drawing No.3 Rev. #3 (Date:04/04/17).  e)    TK-805 Formalin Feed Tank (P&ID SMD9600 Rev#1 (Date 12/20/2016)  f)     RX-G-2 Reactor (P&ID SMD9600 Rev#1 (Date 12/20/2016)       The violation occurred in the Chemicals, Inc. facility in Baytown, TX on February 28, 2019 failed to establish or implement written procedures to maintain the on-going integrity of process equipment, such as but not limited to:      g)    2SS SCH 40 from RX-F7 to RX-F15 (P&ID Drawing 2 to Drawing 4)  h)    2SS SCH 40 Methanol feedline to reactor RX-F15 (P&ID Drawing 7 to Drawing 2)  i)     2SS SCH 40 CS2 feedline to reactor RX-F15 (P&ID Drawing 2)  j)     2SS SCH 40 formalin feed TK-805 to RX-G-2 reactor (P&ID SMD9600 Rev. 1)

Issued

2019-07-25 00:00:00

Abate by

2020-02-07 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(j)(4)(i): The employer did not perform inspection and tests on process equipment      The violation occurred in the Chemicals, Inc. facility in Baytown, TX on February 28, 2019 when the employer failed to perform inspection and tests that include, but are not limited to on the following process equipment:       a) RX-F7 Reactor (P&ID Drawing No. 4 Rev. #3 (Date:04/04/17).  b) RX-F15 Reactor (P&ID Drawing No. 2, Rev. #4 (Date:04/24/17)  c) TK-739 Methanol Receiver (P&ID Drawing No. 2, Rev. #4 (Date:04/24/17).  d) F6 Knock out vessel (P&ID Drawing No.3 Rev. #3 (Date:04/04/17).  e) TK-805 Formalin Feed Tank (P&ID SMD9600 Rev#1 (Date 12/20/2016)  f)  RX-G-2 Reactor (P&ID SMD9600 Rev#1 (Date 12/20/2016)  g) 2SS SCH 40 from RX-F7 to RX-F15 (P&ID Drawing 2 to Drawing 4)  h) 2SS SCH 40 Methanol feedline to reactor RX-F15 (P&ID Drawing 7 to Drawing 2)  i)  2SS SCH 40 CS2 feedline to reactor RX-F15 (P&ID Drawing 2)  j)  2SS SCH 40 formalin feed TK-805 to RX-G-2 reactor (P&ID SMD9600 Rev. 1)

Issued

2019-07-25 00:00:00

Abate by

2019-11-07 00:00:00

Penalty

Initial $7672.00 · Current $4603.00 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 .      The violation occurred at the Chemicals, Inc. facility located in Baytown, TX on February 28, 2017 when the employer failed to implement procedures to manage changes to equipment when the set pressure for the relief valve on Methanol tank (TK-708)  was changed that affect a covered process.

Issued

2019-07-25 00:00:00

Abate by

2019-10-07 00:00:00

Penalty

Initial $7672.00 · Current $4603.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(B): The energy control procedures did not clearly and specifically outline the steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy.    The violation occurred at the Chemicals, Inc. facility located in Baytown, TX on February 28, 2019 where employees were exposed to caught-in and struck-by hazards when performing cleaning of tumble dryer without energy control procedures that clearly and specifically outline the steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy.

Issued

2019-07-25 00:00:00

Abate by

2019-10-07 00:00:00

Penalty

Initial $7672.00 · Current $4603.00 Reduced

General-duty citation text

29 CFR 1910.147(f)(3)(i): A procedure was not utilized to afford the employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device when servicing and/or maintenance was performed by a crew, craft      The violation occurred at the Chemicals, Inc. facility located in Baytown, TX on April 15, 2019 when the employer failed to ensure a procedure was not utilized to afford the employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device when servicing and/or maintenance was performed by a crew, craft.