OSHA Inspection: STATE METAL INDUSTRIES, INC.

Issued

Jul 20, 2021

Abate by

Aug 13, 2021

Penalty

Initial $9,557 · Current $8,571 Reduced

General-duty citation text

29 CFR  1910.37(a)(4): Safeguard(s) designed to protect employees during an emergency (e.g., sprinkler systems, alarm systems, fire doors, exit lighting), were not in proper working order at all times:   a) Facility: The employer did not have a wind direction indicator in place that could be seen throughout the process area so employees could move in the direction of cross wind to upwind to gain safe access to the refuge area in the event of a chlorine release. The wind sock had blown down by storms and had not been reinstalled, on or about 1/21/21.  NOTE:  IN ADDITION TO ABATEMENT CERTIFICATION, THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT DOCUMENTATION FOR THIS ITEM, FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Nov 19, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.38(d): The employee alarm system did not use a distinctive signal for each purpose:  a) Facility: The facility's evacuation alarm did not use distinctive and recognizable signals to differentiate between a chlorine release or a fire, on or about 1/21/21.  NOTE:  IN ADDITION TO ABATEMENT CERTIFICATION, THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT DOCUMENTATION FOR THIS ITEM, FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Nov 19, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.165(b)(2): The employee alarm could not be perceived above ambient noise or light levels by all employees in the affected portions of the workplace:  a)Facility: The evacuation alarm could not be heard by employees working in the office building and outlying areas of the facility, on or about 1/21/2021.  NOTE:  THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT CERTIFICATION FOR THIS ITEM, FAILURE TO DO SO WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 AS PER 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $9,557 · Current $8,571 Reduced

General-duty citation text

29 CFR  1910.119(d)(3)(i)(H):Process safety information pertaining to the equipment in the process did not include the safety systems (e.g., interlocks, detection or suppression systems):  (a) Facility:  The employer's process safety information failed to include the design and operating information pertaining to the evacuation alarm, on or about 1/21/2021.  NOTE:  IN ADDITION TO ABATEMENT CERTIFICATION, THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT DOCUMENTATION FOR THIS ITEM, FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $9,557 · Current $8,571 Reduced

General-duty citation text

29 CFR  1910.119(f)(1):The employer did not develop and implement written operating procedures that provided clear instructions for safely conducting activities involved in each covered process consistent with the process safety information  addressing at least the elements listed in 1910.119(f)(1)(i)(A)-1910.119(f)(1)(iv):  a) Chlorine Storage Building: Employees perform chlorine cylinder change outs 1-2 times a shift and were using their own unwritten procedures.  The employer's written operating procedure for chlorine cylinder change out/connection was not implemented or utilized, on or about 1/21/2021."  NOTE:  IN ADDITION TO ABATEMENT CERTIFICATION, THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT DOCUMENTATION FOR THIS ITEM, FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $9,557 · Current $8,571 Reduced

General-duty citation text

29 CFR  1910.119(f)(1)(i)(B): The employer did not develop and implement written operating procedures that provided clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and did not address normal operations.   a) Chlorine Storage Building: The operating procedure for tank change out/connection did not identify the types of wrenches to be used and procedures to be followed per the Chlorines Institute's Pamphlet 1 Chlorine Basics Edition 8, Sections 3.8.6 Opening Valves and  3.8.7  Closing Valves. The operating procedures  for tank change out did not address which wrench should be used on the valve stem (top and bottom), packing nuts and outlet caps or the foot pounds  for which the torque wrench should be set, while changing out the chlorine containers, on or about 1/21/21.  b) Chlorine Storage Building: The operating procedure for tank change out/connection was not updated to include the steps that need to be taken to take the Halogen system offline during change out, on or about 1/21/21.  NOTE:  IN ADDITION TO ABATEMENT CERTIFICATION, THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT DOCUMENTATION FOR THIS ITEM, FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.119(f)(1)(i)(D): The employer did not develop and implement written operating procedures that provided clear instructions for emergency shutdown, including the conditions under which emergency shutdown was required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown was executed in a safe and timely manner.   a) Chlorine Storage Building: The SOP Chlorine Training Program, Program "C", did not list the conditions requiring emergency shutdown and the identity of the operators qualified to execute the shutdown, including but not limited to leaking chlorine valves/containers while changing out the chlorine containers, on or about 1/21/21.  NOTE:  IN ADDITION TO ABATEMENT CERTIFICATION, THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT DOCUMENTATION FOR THIS ITEM, FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.119(f)(1)(i)(E): The employer did not develop and implement written operating procedures that provided clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and did not address at least emergency operations.  a) Chlorine Storage Building: The operating procedure for tank change out/connection did not address emergency operations for handling leaking valves/containers during tank change out, on or about 1/21/21.  NOTE:  IN ADDITION TO ABATEMENT CERTIFICATION, THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT DOCUMENTATION FOR THIS ITEM, FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $9,557 · Current $0 Reduced

General-duty citation text

29 CFR  1910.119(l)(5): A change covered by this paragraph resulted in a change in the operating procedures or practices required by paragraph (f) of this section, and such procedures or practices were not updated accordingly:   a) Chemical Storage Building: The employer failed to update the Chlorine Training Program, Program "C", to include the use of a torque wrench (Pittsburg reversible torque wrench item 63882), on or about 1/21/2021.  b) Chemical Storage Building: The operating procedure for tank change out/connection was not updated to reflect the addition of the Halogen Valve System emergency shut off or emergency actions to take when the emergency shut off is offline during container out, on or about 1/21/2021.  NOTE:  IN ADDITION TO ABATEMENT CERTIFICATION, THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT DOCUMENTATION FOR THIS ITEM, FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $9,557 · Current $8,571 Reduced

General-duty citation text

29 CFR  1910.119(f)(1)(iii)(A): Operating procedures did not address properties of, and hazards presented by, the chemicals used in the process:   a) Chlorine Storage Building: The operating procedure titled Chlorine Training Program, Program "C", did not list the properties and hazards of chlorine, on or about 1/21/2021.     b) Production: The operating procedure titled Chlorine Standard Operating Procedures, Program "E", Metal Pumps/Chlorine Injection System/Plumbing at Furnace, did not list the properties and hazards of chlorine, on or about 1/21/2021.    c) Production: The operating procedure titled Chlorine Standard Operating Procedures, Program "F", Chlorine Sensors and Controls, did not list the properties and hazards of chlorine, on or about 1/21/2021.    d) Production: The operating procedure titled Chlorine Standard Operating Procedures, Program "G", Purging of Chlorine System for Shutdown Periods, did not list the properties and hazards of chlorine and nitrogen, on or about 1/21/2021.    e) Facility: The operating procedure titled Chlorine Standard Operating Procedures, Program "H", and Operation: Receiving/Return of 2000 lb. Chlorine Cylinders, did not list the properties and hazards of chlorine, on or about 1/21/2021.    f) Chlorine Storage Building: The operating procedure titled Chlorine Standard Operating Procedures, Program "I", Operation: Evaporator System Basic Operation and Maintenance, did not list the properties and hazards of chlorine, on or about 1/21/2021.   NOTE: THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT CERTIFICATION FOR THIS ITEM. FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Jan 31, 2022

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119 (f)(1)(iii)(B) The employer did not develop and implement written operating procedures that provided clear instructions for safely conducting activities involved in each covered process consistent with the process safety information that addressed health and safety considerations, such as precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment.   a) Chlorine Storage Building: The operating procedure titled Chlorine Training Program, Program "C", did not list the precautions necessary to prevent exposure  to chlorine, on or about 1/21/2021.     b) Production: The operating procedure titled Chlorine Standard Operating Procedures, Program "G", Purging of Chlorine System for Shutdown Periods, did not list the precautions necessary to prevent exposure  to chlorine, on or about 1/21/2021.  c) Chlorine Storage Building: The operating procedure titled Chlorine Standard Operating Procedures, Program "I", Operation: Evaporator System Basic Operation and Maintenance, did not list the precautions necessary to prevent exposure to chlorine, on or about 1/21/2021.  NOTE: THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT CERTIFICATION FOR THIS ITEM. FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.119(f)(1)(iii)(C): The employer failed to ensure that the Process Safety Management Standard Operating Procedures included safety and health considerations such as control measures to be taken if physical contact or airborne exposure occurs.  a) Chlorine Storage Building: The operating procedure titled Chlorine Training Program, Program "C", did not list the steps to be taken if physical contact or airborne exposure to chlorine occurs, on or about 1/21/2021.   b) Production: The operating procedure titled Chlorine Standard Operating Procedures, Program "E", Metal Pumps/Chlorine Injection System/Plumbing at Furnace, did not list the steps to be taken if physical contact or airborne exposure to chlorine occurs, on or about 1/21/2021.   c) Production: The operating procedure titled Chlorine Standard Operating Procedures, Program "G", Purging of Chlorine System for Shutdown Periods, did not list the steps to be taken if physical contact or airborne exposure to chlorine occurs, on or about 1/21/2021.   d) Facility: The operating procedure titled Chlorine Standard Operating Procedures, Program "H", and Operation: Receiving/Return of 2000 lb. Chlorine Cylinders, did not list the steps to be taken if physical contact or airborne exposure to chlorine occurs, on or about 1/21/2021.   e) Chlorine Storage Building: The operating procedure titled Chlorine Standard Operating Procedures, Program "I", Operation: Evaporator System Basic Operation and Maintenance, did not list the steps to be taken if physical contact or airborne exposure to chlorine occurs, on or about 1/21/2021.   NOTE: THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT CERTIFICATION FOR THIS ITEM. FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $9,557 · Current $8,571 Reduced

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) Chlorine Storage Building: The employer failed to assure checks and inspections were performed on the cylinder valve of the ton chlorine container prior to connecting the container to the mainfold as required by The Chlorine Institute Inc. Inspection Procedures, Chlorine Cylinder and Ton Container Valves for End Users, on or about 1/21/2021.   NOTE:  IN ADDITION TO ABATEMENT CERTIFICATION, THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT DOCUMENTATION FOR THIS ITEM, FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.119(j)(6)(iii): The employer did not assure that maintenance materials, spare parts, and equipment were suitable for the process application for which they were used:    a) Chemical Building: The employer did not assure that maintenance equipment was suitable for the process application. The employer utilized a Pittsburgh 18 inch torque wrench, 20 -150 foot-pound with an extension for container change out, which did not meet the requirements noted in Chlorine Institute's Pamphlet 1 Chlorine Basics Edition 8 sections 3.8.6 and 3.8.7. The employer also did not inspect and calibrate the torqueing wrenches used on the valves on the ton chlorine containers during change out operations per the manufacturer's instructions, on or about 1/21/21.  NOTE: THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT CERTIFICATION FOR THIS ITEM. FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Jan 31, 2022

Penalty

Initial $9,557 · Current $8,574 Reduced

General-duty citation text

29 CFR  1910.119(n): The employer did not establish an emergency plan for the entire plant in accordance with the provisions of 29 CFR 1910.38:   a) Chlorine Storage Building: The employer failed to develop and implement written procedures for handling small chlorine releases.  Employees were required to respond to any chlorine releases of less than 10 pounds, on or about 1/21/2021.  b) Chlorine Storage Building: The employer failed to develope and implement  written procedures for emergency evacuation, including type of evacuation and exit route assignments for employees who would investigate a possible leak when sensors alarmed and address the leak if the leak contained less than 10 pounds of chlorine, on or about 1/21/2021.   NOTE:  IN ADDITION TO ABATEMENT CERTIFICATION, THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT DOCUMENTATION FOR THIS ITEM, FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jul 20, 2021

Abate by

Oct 12, 2021

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.120(q)(2)(i):The emergency response plan did not address, to the extent not addressed elsewhere, pre-emergency planning and coordination with outside parties:  (a) State Metal Industries: The telephone numbers for in-plant personnel were not updated for emergency contact.  On 1/21/21 the facility experienced a chlorine release, the fire department was unable to make contact with the designated company official.  NOTE:  THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT CERTIFICATION FOR THIS ITEM, FAILURE TO DO SO WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 AS PER 29 CFR 1903.19.