OSHA Inspection: FUTAMURA USA, INC.

Issued

Aug 8, 2022

Penalty

Initial $5,706 · Current $5,706

General-duty citation text

29 CFR  1910.119(d)(3)(i)(B):Information concerning the equipment of the process did not include a complete and accurate piping and instrument diagram:  Reclassified to Other-than-Serious,  AVD language amended to:    Employee(s) at the Futamura facility located at 6000 SE 2nd Street, Tecumseh, Kansas could be subject to potential exposure to release of extremely flammable vapors to the atmosphere that historically result in fire/explosion hazards leading to injury and death of employees.  (a) PID-461-101 (Pot Still), a union not drawn on the P&ID was observed during the OSHA walk around between gate valve (451-019) and a three way valve (461-020). (b) PID-461-101 (Pot Still), pipe lines 461-?-779 and 461-?-1820 were not correctly labeled on the P&ID.  (c) PID-461-101 (Pot Still), the pipe line drawn between pipe line 461-?-779 and pipe line 461-?-1820 was not correctly drawn on the P&ID as observed during the OSHA walk around. An additional section of piping was observed during the OSHA walk around containing an union and 4-way valve (P516). (d) PID-451-103 (Kettle Tank), a site glass was not drawn on the P&ID after gate valve (451-576). (e) PID-451-103 (Kettle Tank), during the OSHA walk around, labels were missing for gate valves 451-091 and 451-092. (f) PID-451-103 (Kettle Tank), a vacuum gage was observed at the end of pipe line 451-TOL-49-778, but not drawn on the P&ID. (g) PID-451-103 (Kettle Tank), an 1/2 inch gate valve 451-056 was being controlled by the use of string. The string was attached to open / close the 1/2 inch gate valve, but not drawn on the P&ID.  (h) PID-451-103 (Kettle Tank), during the OSHA walk around, PRV 451-PRV-095 was missing a label. (i) PID-451-103 (Kettle Tank), the label for rupture disc 451RD001 did not match the label assigned on the P&ID. (j) PID-451-103 (Kettle Tank), pipe line circuit 441-SOL-49-555 had a pressure indicator device, where aN 1/2 inch gate valve (451-072) was drawn on the P&ID. (k) PID-451-103 (Kettle Tank), 3/4 inch gate valve (451-074) on pipe line 451-N-49-781-1 1/2 was missing a label. (l) PID-451-103 (Kettle Tank), during the OSHA walk around strainer (451-175) was not observed on pipe line 451-TOL-49-776-2", as drawn on the P&ID. Needle valve (566) was found, but not drawn on the P&ID. (m) PID-451-103 (Kettle Tank), during the OSHA walk around a quick connect was observed after 2 inch gate valve (451-559) on pipe line 49-TOL-49-778-2", instead of an end cap that was drawn on the P&ID. (n) PID-451-103 (Kettle Tank), during the OSHA walk around a quick connect was observed before a 1/2 inch gate valve 451-577, but was not drawn on the P&ID.

Issued

Aug 8, 2022

Abate by

Oct 24, 2022

Penalty

Initial $7,133 · Current $7,133

General-duty citation text

29 CFR  1910.119(l)(2):The procedures did not assure that all of the following considerations, including the technical basis for the proposed change, the impact of the change on safety and health, any resulting modifications to the operating procedures, the necessary time period for the change, and the authorization requirements for the proposed change were addressed prior to making any change:  Reclassified to Other-than-Serious, Abatement Period extended to 10/23/2022, AVD language amended to:  Employee(s) at the Futamura facility located at 6000 SE 2nd Street, Tecumseh, Kansas could be subject to potential exposure to release of extremely flammable vapors to the atmosphere that historically result in fire/explosion hazards leading to injury and death of employees.  (a) 2021-033, Coating Tower Nip and Head Roll Cleaning:   (1) Part A, initial required approval signature from the PSSR Team Engineering Manager was missing.  (2) The approval to operate was signed even though the training for all shifts had not been completed.  (3) MOC closure section was not signed.  (4) Action item WR-1 was pre-approved without a completion date for the disposal requirements for trial sponges.  (5) PSSR action item assignments did not include due dates or completion dates.  (b) 2021-023, Temporary Procedure Edit to Blender Changes on Coating Towers:  (1) Action item assignment GE-13 was not provided with a completion date.  (2) The blender change form was not completed, instructions state all blanks MUST be filled in.  (3) PSSR action item assignment for uploading procedures to ISO was not provided with a due date or completion date.  (4) The section for approval to operate was not completed nor had the required signatures for approval to operate for this management of change.  (5) MOC closure section was not completed.    (d) 2021-020, #7 Sub Station Breaker Control:  (1) The section for approval to operate was completed by the team, but the Area Manager did not sign the required approval to operate section.  (2) The MOC closure section was not completed.   (3) Prestart-up Safety Review Form indicated that safety interlocks and e-stops were in place and tested as no, the comments sections says inspect switch gear without any follow-up.  (4) No follow-up addressing if the new or modified TPM has been entered into e-maintenance on the Prestart-up Safety Review Form.  (5) The training section on the Prestart-up Safety Review Form did not indicate yes or no, if training was required prior to start-up.