OSHA Inspection: PHILLIPS 66

Issued

Jul 5, 2019

Abate by

Jul 24, 2019

Penalty

Initial $10,419 · Current $10,419

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.    a) Pipe Stills    The employer failed to document compliance with their chosen RAGAGEP such as, but not limited to ASME BPVC VIII Section UG-135(d).  Inlet & outlet valves for safety relief device SV5163 that protects vessel D605 from overpressure/rupture were not car sealed open.    Violation observed on or about 3/15/19.

Issued

Jul 5, 2019

Abate by

Aug 21, 2019

Penalty

Initial $10,419 · Current $10,419

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) DSU-1 Unit    The employer failed to follow their chosen RAGAGEP, such as but not limited to, API 574 (2016), Section 7.4.5.3 for inspection and testing procedures when they did not replace and seal inspection plugs at CUI inspection points on the P101 discharge pipe, which operates at approximately 250 degrees F.    Violation observed on or about 4/4/2019.    b) Isomerization Unit, Mixer platform    The employer failed to follow their chosen RAGAGEP, such as but not limited to, API 574 (2016), Section 7.4.5.3 for inspection and testing procedures when they did not replace and seal inspection plugs at CUI inspection points on piping which operates at approximately 50 degrees F.    Violation observed on or about 3/18/2019.    c) Isomerization Unit, Mixer platform    The employer failed to follow their chosen RAGAGEP, such as but not limited to, API 574 (2016), Section 7.4.5.3 for inspection and testing procedures when they did not replace and seal inspection plugs at CUI inspection points on piping leading to rupture disk RD005, which operates at 30-65 degrees F.     Violation observed on or about 3/18/2019    d) SDA area, pipe leading to E603    The employer failed to follow their chosen RAGAGEP, such as but not limited to, API 574 (2016), Section 7.4.5.3 for inspection and testing procedures when they did not replace and seal inspection plugs at CUI inspection points piping leading to E603, which operates at 315-340 degrees F.     Violation observed on or about 3/15/2019.

Issued

Jul 5, 2019

Abate by

Aug 21, 2019

Penalty

Initial $10,419 · Current $10,419

General-duty citation text

29 CFR 1910.119(j)(6)(ii): Appropriate checks and inspections were not performed to assure that equipment was installed properly and consistent with design specifications and the manufacturer's instructions.  a) Alkylation Unit Spent Acid Tank  The employer failed to verify equipment was installed as per design specifications before the TK100 was returned to service, including but not limited to an isolation valve on the instrument drain line. When TK100 was returned to service, employees were exposed to spent sulfuric acid as it leaked from the instrument drain line due to the missing isolation valve.  Violation was determined on or about 1/8/19.

Issued

Jul 5, 2019

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(f)(1)(i)(G): 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 and did not address the startup following a turnaround, or after an emergency shutdown.  a) Alkylation Unit  The employer failed to develop process equipment return to service procedures requiring verification that equipment replaced during the TK100 shut down was installed per design specifications to ensure safe operations. The Equipment Return to Service procedure (01.01.04.01) did not instruct operators to check instrumentation while walking down the line resulting in a leak of spent sulfuric acid from the instrument drain line due to a missing isolation valve.  Violation determined on or about 1/8/19