WAUPACA, WI —
OSHA Inspection: ALLIANCE INDUSTRIES, INC.
Planned inspection · Health discipline
At a glance
On , OSHA opened a planned health inspection of ALLIANCE INDUSTRIES, INC. in N2467 VAUGHAN ROAD, WAUPACA, WI 54981 (NAICS 333511). OSHA activity number 345785166.
What this inspection record means
OSHA opens inspections for many reasons — routine scheduling under a national or local emphasis program, an employee complaint or referral, or a follow-up after a reported injury. Opening or conducting an inspection is not itself an allegation or a finding that this employer broke any rule; any findings appear as the citations listed below, and citations can be contested, reduced, or withdrawn.
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Where did this inspection happen?
- Establishment
- ALLIANCE INDUSTRIES, INC.
- Site address
- N2467 VAUGHAN ROAD
- City
- WAUPACA
- State
- WI
- ZIP
- 54981
- Mailing
- N2467 VAUGHAN ROAD, WAUPACA, WI 54981
What kind of inspection was it?
- Inspection type
- Planned (H)
- Scope
- Complete (A)
- Discipline
- Health
- Advance notice
- No
- Union status
- B
When did the case open and close?
- Opened
- Closing conference
- Case closed
- Last modified
- Data loaded
Establishment context
- NAICS code
- 333511
- Employees
- 58
- Ownership type
- A
Citations
12 citations on file for this inspection.
1910.119 D03 I B
- Issued
- Aug 5, 2022
- Abate by
- Oct 17, 2022
- Penalty
- Initial $9,324 · Current $0 Reduced
2290
General-duty citation text
29 CFR 1910.119(d)(3)(i)(B): The employer shall complete a compilation of written process safety information before conducting any process hazard analysis required by the standard. The compilation of written process safety information is to enable the employer and the employees involved in operating the process to identify and understand the hazards posed by those processes involving highly hazardous chemicals. This process safety information shall include information pertaining to the equipment in the process including piping and instrument diagrams (P&ID's): At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; the employer did not compile process safety information pertaining to the equipment in the process, specifically, P&IDs. The employer's P&IDs for the sulfur dioxide system, which included liquid withdrawal and sand core processing, did not accurately represent the system. a) For the liquid withdrawal portion of the system at the outdoor Sulfur Dioxide One Ton Supply Cylinder; the P&ID did not adequately represent the E-Pro Auto Valve Closure connections or the nitrogen tubing connection. b) For the liquid withdrawal portion of the system in the Core Chem Room; the P&ID did not adequately represent a pressure sensor, two shut-off valves (including type or identifier), the attached "E-Pro Electric Valve Closure System", or the sulfur dioxide expansion chamber and its appurtenances. c) For the liquid withdrawal portion of the system in the Core Room above the core machines; the P&IDs did not adequately represent piping connections to the "Large Gas Box Machine" and "Small Gas Box Machine", a valve that had been dead ended (upstream of the L20 connection), or any of the valves servicing each of the three core machines (including type or identifier). d) For the sand core processing portion of the system in the Core Room; the P&IDs did not adequately present each of the core machines' condensers, accumulators, their connections/ appurtenances, and did not represent any piping, valves, controllers, or other equipment leading to the SO2 application point at the core boxes.
Recent events (2)
- — I (S) $0
- — Z (S) $9324
1910.119 E03 IV
- Issued
- Aug 5, 2022
- Abate by
- Sep 14, 2022
- Penalty
- Initial $9,324 · Current $0 Reduced
2290
General-duty citation text
29 CFR 1910.119(e)(3)(iv): The process hazard analysis (PHA) shall address consequences of failure of engineering and administrative controls: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; the employer's PHAs did not address consequences of failure of engineering or admin controls. The employer's PHAs from 2017 and 2022 did not adequately address the consequences and controls for minimizing or eliminating the potential for inadvertent mixing of incompatible chemicals with sulfur dioxide. Installation of one-ton sulfur dioxide cylinders and application of inert-nitrogen to the one-ton cylinder posed the potential for inadvertent mixing of incompatible chemicals to the system.
Recent events (2)
- — I (S) $0
- — Z (S) $9324
1910.119 F01 III D
- Issued
- Aug 5, 2022
- Abate by
- Sep 14, 2022
- Penalty
- Initial $0 · Current $4,662
2290
General-duty citation text
29 CFR 1910.119(f)(1)(iii)(D): The employer shall 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 shall address safety and health considerations including quality control for raw materials and control of hazardous chemical inventory levels: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; the employer did not develop written operating procedures that provided clear instructions that addressed quality control of raw materials. The employer's operating procedures SOP-2 and SOP-3 did not contain instructions for ensuring deliveries and connections of sulfur dioxide and inert nitrogen to the system did not introduce incompatible chemicals resulting in inadvertent mixing of chemicals.
Recent events (2)
- — I (S) $4662
- — Z (S) $0
1910.119 F01 I D
- Issued
- Aug 5, 2022
- Abate by
- Sep 14, 2022
- Penalty
- Initial $9,324 · Current $0 Reduced
2290
General-duty citation text
29 CFR 1910.119(f)(1)(i)(D): The employer shall 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 shall address steps for each operating phase including emergency shutdown including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; the employer did not develop written operating procedures that provided clear instructions that addressed each operating phase including elements of emergency shutdown. The employer's operating procedure SOP-8 "Emergency Shutdown of the Isoset Core-Making Process" did not include the conditions under which emergency shutdown was required and did not assign or identify qualified operates responsible to conduct emergency shutdowns.
Recent events (2)
- — I (S) $0
- — Z (S) $9324
1910.119 F01 II
- Issued
- Aug 5, 2022
- Abate by
- Sep 14, 2022
- Penalty
- Initial $0 · Current $4,662
2290
General-duty citation text
29 CFR 1910.119(f)(1)(ii): The employer shall 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 shall address operating limits including consequences of deviation and steps required to correct or avoid deviation: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; the employer did not develop written operating procedures that provided clear instructions that addressed operating limits including consequences of deviation and steps required to correct or avoid deviations. The employer's operating procedure SOP-4 "Start-up and Normal Operations of the Isoset Core-Making Process" did not contain safe operating limits, consequences of deviation from operating limits or the steps required to correct/avoid deviation from those operating limits for the core machines utilizing sulfur dioxide.
Recent events (2)
- — I (S) $4662
- — Z (S) $0
1910.119 F01 III A
- Issued
- Aug 5, 2022
- Abate by
- Sep 14, 2022
- Penalty
- Initial $0 · Current $0
2290
General-duty citation text
29 CFR 1910.119(f)(1)(iii)(A): The employer shall 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 shall address properties of, and hazards presented by, the chemicals used in the process: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; the employer did not develop written operating procedures that provided clear instructions that addressed properties of, and hazards presented by sulfur dioxide (SO2). The employer's operating procedures (including but not limited to SOP-2, SOP-3, SOP-4, SOP-5, SOP-8 and SOP-11) contained references to the SDS for the SO2 chemical used in the process, but did not contain discussions of its chemical properties, health hazards or physical hazards.
Recent events (2)
- — I (S) $0
- — Z (S) $0
1910.119 J02
- Issued
- Aug 5, 2022
- Abate by
- Dec 22, 2022
- Penalty
- Initial $9,324 · Current $4,662 Reduced
2290
General-duty citation text
29 CFR 1910.119(j)(2): The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; the employer did not establish written procedures to maintain the on-going integrity of the sulfur dioxide system: a) The employer did not establish a written piping inspection plan to include the procedural steps contained in API 570, Section 5.1.2 "Minimum Contents of an Inspection Plan", which describe, in part, the scope, next inspection date, inspection/testing techniques, cleaning and types of experienced/anticipated damaged. b) The employer did not establish a written procedure for the frequency of piping inspection consistent with API 570, Sections 6.3.3 "Inspection Intervals" and/or Section 7.1.1.1 "Remaining Life Calculations", which describe, in part, methods for determining the frequency of piping inspection/testing based on experience, incidents and prior inspection/test results. c) The employer did not establish a written procedure to document the required qualifications of inspectors, examiners, or contract inspectors consistent with API 570, Section 3.1.7 definition of "Authorized Piping Inspector" or Section 4.3.5 "Examiners", which, in part, describe minimum qualifications for those directed by the employer to inspect/test piping systems. d) The employer did not establish a written procedure for daily inspections and quarterly calibrations of the RKI SO2 sensor (Model 65-2648RK-SO2). e) The employer did not establish a written procedure for the preventative maintenance of the over-pressure relief system consisting of, but not limited to, the Hydro Instruments expansion chamber, the United Electric Controls (UEC) pressure switch (Model 12SHSN8B) and the Fike Corporation rupture disk (Model 7MU). UEC recommended and described steps for proof testing and frequency of testing for the pressure switch. Fike recommended annual replacement of the rupture disk. The employer did not have written procedures for either piece of equipment or the over-pressure relief system in whole.
Recent events (2)
- — I (S) $4662
- — Z (S) $9324
1910.119 J04 I
- Issued
- Aug 5, 2022
- Abate by
- Dec 22, 2022
- Penalty
- Initial $0 · Current $0
2290
General-duty citation text
29 CFR 1910.119(j)(4)(i): Inspections and tests shall be performed on process equipment: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; the employer did not conduct inspections and tests on process equipment: a) The employer's chosen RAGAGEP API 570 "Piping Inspection Code" required the owner of the piping system to, "provide specific attention to the need for inspection of piping systems that are susceptible to...specific types and areas of deterioration." API 570 also included inspection types including, but not limited to, internal visual inspection, thickness measurement inspection, various NDE examinations, vibrating piping inspection and supplemental inspection. The employer had not implemented an inspection plan and had not conducted the appropriate inspections of the sulfur dioxide piping system. b) The employer did not conduct periodic proof testing of the United Electric Control (UEC) pressure switch (Model 12SHSN8B) as described by the manufacturer's maintenance recommendations.
Recent events (2)
- — I (S) $0
- — Z (S) $0
1910.119 L01
- Issued
- Aug 5, 2022
- Abate by
- Oct 17, 2022
- Penalty
- Initial $9,324 · Current $4,662 Reduced
2290
General-duty citation text
29 CFR 1910.119(l)(1): The employer shall establish and implement written procedures to manage changes (except for "replacements in kind") to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; the employer did not implement written procedures to manage changed to process equipment and procedures: a) A sulfur dioxide (SO2) release incident on December 16, 2021, resulted in a recommended corrective action to update operating procedures to include daily inspection of gas plate seals prior to shift startup on SO2 Isoset core machines. The employer did not implement a written management of change procedure for changes to applicable operating procedures. b) The employer determined to change the gas plate seal material (changed to Dike-O-Seal) on SO2 Isoset core machines to increase seal longevity and effectiveness. The employer did not implement a written management of change procedure for changes to applicable equipment in the PSM covered system.
Recent events (2)
- — I (S) $4662
- — Z (S) $9324
1910.119 L04
- Issued
- Aug 5, 2022
- Abate by
- Oct 17, 2022
- Penalty
- Initial $0 · Current $0
2290
General-duty citation text
29 CFR 1910.119(l)(4): If a change covered by this paragraph results in a change in the process safety information required by paragraph (d) of this section, such information shall be updated accordingly: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; when a material of the system was changed, which was not a replacement in kind, the employer did not update the process safety information (PSI) for the gas plate seal (Dike-O-Seal) product which replaced the previous gasketing material.
Recent events (2)
- — I (S) $0
- — Z (S) $0
1910.119 L05
- Issued
- Aug 5, 2022
- Abate by
- Oct 17, 2022
- Penalty
- Initial $0 · Current $0
2290
General-duty citation text
29 CFR 1910.119(l)(5): If a change covered by this paragraph results in a change in the operating procedures or practices required by paragraph (f) of this section, such procedures or practices shall be updated accordingly: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; when a changed in the operating procedures or practices was implemented as a results of an incident investigation, the employer did not update the operating procedure SOP-4 "Start-up and Normal Operations of the Isoset Core-Making Process" with the requirement for Machine Operators to inspect the gas seal plate each day prior to the shift to validate the seals condition.
Recent events (2)
- — I (S) $0
- — Z (S) $0
1910.119 M05
- Issued
- Aug 5, 2022
- Abate by
- Oct 17, 2022
- Penalty
- Initial $0 · Current $0
2290
General-duty citation text
29 CFR 1910.119(m)(5): The employer shall establish a system to promptly address and resolve the incident report findings and recommendations. Resolutions and corrective actions shall be documented: At a facility located at N2467 Vaughan Road, Waupaca, WI 54981; the employer did not document resolutions and correctives actions of an incident report's findings and recommendations. A sulfur dioxide (SO2) release incident on December 16, 2021, resulted in a recommended corrective action to update operating procedures to include daily inspection of gas plate seals prior to shift startup on SO2 Isoset core machines. The employer did not document that such resolutions or corrective actions had been implemented or completed.
Recent events (2)
- — I (S) $0
- — Z (S) $0
More inspections at Alliance Industries, INC.
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Mar 9, 2022
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Dec 21, 2021
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Nov 21, 2019
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Source
This record is reproduced from the U.S. Department of Labor Open Data API (OSHA inspection dataset). The original IMIS detail view is available at OSHA's Establishment Search for activity number 345785166.
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