OSHA Inspection: SARA LEE CORPORATION

Issued

2019-10-24 00:00:00

Abate by

2019-11-15 00:00:00

Penalty

Initial $9472.00 · Current $5683.00 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(F): The employers compilation of written process safety information pertaining to the equipment in the process did not include an accurate representation of the design codes and standards employed;    On or about April 26, 2019, and times prior thereto, the employers compilation of written process safety information pertaining to the equipment in the process did not include the specific consensus standard employed addressing the ammonia refrigeration equipment at the facility.  The process safety information also did not include the version or the date of the ANSI/IIAR and ASHRAE consensus standard being utilized and currently in effect.

Issued

2019-10-24 00:00:00

Abate by

2019-11-15 00:00:00

Penalty

Initial $13260.00 · Current $7956.00 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.    a. On or about April 26, 2019, and times prior thereto, the employer did not ensure the machinery room was kept free of combustible materials such as, ceiling tiles, cardboard boxes, paper, plastic binders, bags, and a coffee maker box in accordance with ANSI/IIAR 2-2014 Standard for Safe Design of Closed-Circuit Ammonia Refrigeration Systems, Chapter 6 Machinery Rooms, 6.4 Combustible Materials.  Combustible materials shall not be stored in machinery rooms outside of approved fire-rated storage containers.    b. On or about April 26, 2019, and times prior thereto, the employer did not ensure that the king valves in the machinery room were readily accessible in accordance with ANSI/IIAR 2-2014 Standard for Safe Design of Closed-Circuit Ammonia Refrigeration Systems, Chapter 6 Machinery Rooms, 6.3 Access and Egress, 6.3.3 Access to Valves, 6.3.3.2 Manually operated isolation valves identified as being part of the system emergency shutdown procedure shall be directly operable from the floor or chain operated from a permanent work surface.

Issued

2019-10-24 00:00:00

Abate by

2019-11-15 00:00:00

Penalty

Initial $13260.00 · Current $7956.00 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish written and implement 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:    Pressure Vessels and Heat Exchanger  a. On or about April 26, 2019, Sara Lee had not tested the critical isolation valves associated with the heat exchanger (HE-1) every 6 months in accordance with its mechanical integrity program.    Compressors  b. On or about April 26, 2019 Sara Lee did not conduct an annual inspection of Compressor C-3 in accordance with its mechanical Integrity program  c. On or about April 26, 2019 Sara Lee had not tested the safety cutouts every six-months for Compressors C-3, in accordance with its mechanical integrity program.  d. On or about April 26, 2019 Sara Lee had not conducted the six-month compressor safety check in 2019 for Compressor C-3 in accordance with its mechanical integrity program.    Pressure Relief Valves  g. On or about April 26, 2019 Sara Lee did not conduct performance testing on pressure relief valves that had been removed from service in accordance with its mechanical integrity program.    Critical Valve Testing  h. The employer did not conduct a six-month critical valve test in July 2019 for Evaporators AU-4, and AU-8, in July 2019 for the Heat Exchanger HE-1, V2-P1, and in June 2019 for V2-P2, V3-P1, V3-P2-in accordance with its mechanical integrity program.    Pumps  i. On or about April 26, 2019, Sara Lee did not perform quarterly or annual preventative maintenance for Pumps V-2-P1, V-2-P2, V3-P1, V3-P2 in accordance with its mechanical integrity program.    Ventilation System  j. On or about April 26, 2019, the employer did not perform inspection and tests on the engine room ventilation system on a monthly basis. A visual inspection and motor test was not performed in February through April 2019 in accordance with its mechanical integrity program.

Issued

2019-10-24 00:00:00

Abate by

2019-12-16 00:00:00

Penalty

Initial $5683.00 · Current $3410.00 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(iv): The employer did not document each inspection and test that had been performed on process equipment.  The documentation did not identify the date of the inspection or test, the name of the person who performed the inspection or test, 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.     a. The employer did not document for Compressor 1 (C-1), (12 month-Ammonia Compressor Inspection, Work Order 112222), the date of the inspection or test, the name of the person who performed the inspection or test, and the results of the inspection or test.    b. The employer did not document for each inspection on compressors, pumps, piping, the pressure relief system, pressure vessels, critical valves, and the emergency shutdown system a description of the inspection or test performed and the results of the inspection or test.

Issued

2019-10-24 00:00:00

Abate by

2019-11-15 00:00:00

Penalty

Initial $13260.00 · Current $7956.00 Reduced

General-duty citation text

29 CFR 1910.120(q)(1): The employer did not develop and implement an emergency response plan to handle anticipated emergencies prior to commencement of emergency response operations.      a. The employer did not implement the provisions of its emergency response plan in that the refrigeration maintenance employees had not received First Responder Awareness Level training in accordance with 29 CFR 1910.120(q)(6)(i).

Issued

2019-10-24 00:00:00

Abate by

2019-11-15 00:00:00

Penalty

Initial $13260.00 · Current $7956.00 Reduced

General-duty citation text

29 CFR 1910.134(g)(1)(i)(A): The employer did not permit respirators with tight-fitting facepieces to be worn by employees who have facial hair that comes between the sealing surface of the facepiece and the face or that interferes with valve function.    On or about April 26, 2019, and times prior thereto, the employer allowed tight-fitting respirators to be worn by employees with facial hair that came between the sealing surface of the facepiece.

Issued

2019-10-24 00:00:00

Abate by

2019-11-15 00:00:00

Penalty

Initial $9472.00 · Current $5683.00 Reduced

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(A): Flexible cords and/or cables were used as a substitute for the fixed wiring of a structure.    a. On or about April 26, 2019, and times prior thereto, flexible cords secured to metal conduit were used as a substitute for the fixed wiring of the structure in the machinery room.