OSHA Inspection: POLYPLEX USA LLC

Issued

Feb 8, 2021

Abate by

Nov 22, 2022

Penalty

Initial $13,516 · Current $13,516

General-duty citation text

29 CFR  1910.147(c)(4)(i):  Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:  (a)  On or about 08/12/2020 - Resin Department, authorized employees were exposed to hazardous chemical energy when the employer did not ensure that a procedure was utilized to control the potentially hazardous chemical energy before the employees started conducting a line break to remove a dosing nozzle from a line that contained a monomer consisting of approximately 85% Terephthalic Acid and 15% Ethylene Glycol, Polyester Grade and at a temperature of approximately 265 to 275 degrees C (509 to 527 degrees F).  The employer did not ensure that the employees followed all of the steps in the written Work Instruction "Shut Down" reference #PU-WI-RES-SD-030 for shutting down the process between reactors UPR-1 and UPR-2 such as, but not limited to, affixing lockout devices, tagout devices, or other control measures to the valves before the employees conducted the line break.  The employer did not ensure that the employees followed all of the steps in the Standard Operating Procedure "Lockout/Tagout Protocal" reference #PU-SOP-ESSH-LOTOP-002 for additional application of the control steps, such as, but not limited to,  utilizing a Hazardous Work Permit and performing an energy isolation verification check.

Issued

Feb 8, 2021

Abate by

Nov 22, 2022

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.147(c)(4)(ii)(D): The energy control procedures did not clearly and specifically outline the requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures:   (a)  On or about 08/12/2020 - Resin Department, authorized employees were exposed to hazardous chemical energy when conducting a line break to remove a dosing nozzle from a line that contained a monomer consisting of approximately 85% Terephthalic Acid and 15% Ethylene Glycol, Polyester Grade and at a temperature of approximately 265 to 275 degrees C (509 to 527 degrees F) and the written Work Instruction "Shut Down" reference #PU-WI-RES-SD-030 did not clearly and specifically outline the requirements for testing the lockout devices, tagout devices, or other energy control measures used to verify that the manual hand and automatic control valves were in the correct position and verifying that all hazardous chemical energy or pressure had been released or drained from the line before the employees started the line break.

Issued

Feb 8, 2021

Abate by

Nov 22, 2022

Penalty

Initial $13,516 · Current $0 Reduced

General-duty citation text

29 CFR  1910.147(d): The established procedure for the application of energy control (the lockout or tagout procedures) did not cover the actions listed in and was not done in sequence as required by 29 CFR 1910.147(d)(1)-(6):  (a)  On or about 08/12/2020 - Resin Department, authorized employees were exposed to hazardous chemical energy when conducting a line break to remove a dosing nozzle from a line that contained a monomer consisting of approximately 85% Terephthalic Acid and 15% Ethylene Glycol, Polyester Grade and at a temperature of approximately 265 to 275 degrees C (509 to 527 degrees F) and lockout devices, tagout devices, or other control measures were not affixed to the manual hand valves and the control valve before the employees started the line break per the 1910.147(d)(2) requirements.  In addition, the remaining applicable energy control elements, d(5)(i) dissipation of residual energy, (d)(5)(ii) continued verification of isolation from the re-accumulation of stored energy to a hazardous level, and (d)(6) verification of isolation were not implemented to protect employees from the hazardous chemical energy.

Issued

Feb 8, 2021

Abate by

Nov 22, 2022

Penalty

Initial $135,167 · Current $76,484 Reduced

General-duty citation text

29 CFR  1910.132(a): Protective equipment was not used when necessary whenever hazards capable of causing injury and impairment were encountered:  (a)  On or about 08/12/2020 - Resin Department, authorized employees were exposed to hazardous chemical energy and thermal burns when the employer did not ensure that the employees wore protective equipment such as, but not limited to, flame-resistant clothing and an aluminized jacket and pants when conducting a line break to remove a dosing nozzle from a line that contained a monomer consisting of approximately 85% Terephthalic Acid and 15% Ethylene Glycol, Polyester Grade at a temperature of approximately 265 to 275 degrees C (509 to 527 degrees F) and working in close proximity to jacketed piping containing a heat transfer media at approximately 285 degrees C (545 degrees F).