OSHA Inspection: ADVANCED FOOD PRODUCTS, LLC

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $11,396 · Current $9,000 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): The employer's piping and instrument diagrams (P&IDs) did not include information that provided specific identification of equipment that is part of the process.   a. Roof - On or about July 13, 2022, the 1/2" isolation hand valve on the shared 4" relief header from RC-1, RC-2, RC-3 and RC-7 was not shown on P&ID R2.2 above the roof line below the line sensor. Failure to have accurate P&IDs could result in human error during operations and maintenance and employees not being able to identify or locate equipment in the event of an emergency resulting in exposure to anhydrous ammonia vapors and liquid.  b. Machine Room - On or about July 13, 2022, the screw compressor (RC-6) pressure gauge was not shown on P&ID R2.2. Failure to have accurate P&IDs could result in human error during operations and maintenance and employees not being able to identify or locate equipment in the event of an emergency resulting in exposure to anhydrous ammonia vapors and liquid.  c. Machine Room - On or about July 13, 2022, the High/Low Temp glycol chiller (GC-4) is labeled as HTLT-GC2 instead of (GC-4) in the field on P&ID R2.3. Failure to have accurate P&IDs could result in human error during operations and maintenance and employees not being able to find specific locations in the event of an emergency resulting in exposure to anhydrous ammonia vapors and liquid.   d. Lower Machine Room - On or about July 13, 2022, the AFP glycol chiller (GC-2) is mislabeled as LTST1 in the field on P&ID R2.4. Failure to have accurate P&IDs could result in human error during operations and maintenance and employees not being able to find specific locations in the event of an emergency resulting in exposure to exposure to anhydrous ammonia vapors and liquid.  e. Outside the AFP Cooler - On or about July 13, 2022, the AU-R and AU-L had pressure indicator gauges on them however it does not reflect these gauges near Hause HSB on P&ID 2.5, failure to have correct P&ID's could result in employees not being able to find specific locations in the event of an emergency resulting in exposure to anhydrous ammonia vapors and liquid.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Penalty

Initial $14,502 · Current $9,000 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 (RAGAGEP).  a. The Roof - On or about May 31, 2022, the employer did not document that equipment complies with RAGAGEP such as IIAR-2 -2021 (15.5.1.3) when the employer failed to ensure relief systems relieved to a safe location. The new thermosiphon vessel, TSV-1, was not 7.25 feet above the working platform of the condenser platform.  Failure to properly design and evaluate emergency relief devices and systems can lead to catastrophic failure of pressure vessels, piping and employee exposure to struck by, toxic, fire, explosion, and hazards.   No Abatement Required - Corrected During Inspection

Issued

Nov 30, 2022

Abate by

Jun 3, 2024

Penalty

Initial $14,502 · Current $9,000 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(f)(1)(i)(D): The employer did not develop and implement written operating procedures that provide clear instructions for 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.  a. The Engine Room - On or about May 31, 2022, the employer failed to develop and implement written operating procedures for emergency shutdown of the ammonia system such as but not limited to RSOP 106 Compressor Operations. By failing to develop and implement effective emergency shutdown procedures, employees were exposed to respiratory distress, eye, and nasal irritation, nausea, vomiting and acute over exposure sickness of embedded contractors from Savencia Cheese USA.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

Nov 30, 2022

Abate by

Jun 3, 2024

Penalty

Initial $14,502 · Current $9,000 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(f)(3): The operating procedures were not reviewed as often as necessary to assure that they reflect current operating practice, including changes that result from changes in process chemicals, technology, and equipment, and changes to facilities.  a. Engine room - On or about May 31, 2022, the employer failed to review operating procedure ROSOP 106 "Oil Draining Procedure for Swing Screw Compressor RC-1" referenced 2 operators which the employer does not have 2 employees, additionally the section on the Safety Systems states, "Escape only respirators" despite the employer not having escape respirators available for use. The employer's failure to ensure that the operating procedures were accurate and reflect existing practices that are used in the process of handling anhydrous ammonia under upset and abnormal conditions can lead to process upsets, and expose employees to fire, explosion and toxic hazards.  b. Engine room - On or about May 31, 2022, the employer failed to review operating procedure ROSOP 106A "Normal Operation Procedure for Swing/Screw Compressors" was not accurate as it does not address the safety systems such as interlocks, high level and low-level alarms, PPE required to perform the task. The employer's failure to ensure that the operating procedures were accurate and reflect existing practices that are used in the process of handling anhydrous ammonia under upset and abnormal conditions can lead to process upsets, and expose employees to fire, explosion and toxic hazards.  c. Engine room - On or about May 31, 2022, the employer failed to review operating procedure ROSOP 106B "Swing/Screw Compressor- Normal Start-Up" was not accurate as it does not address the safety systems such as interlocks, high level and low-level alarms, PPE required to perform the task. The employer's failure to ensure that the operating procedures were accurate and reflect existing practices that are used in the process of handling anhydrous ammonia under upset and abnormal conditions can lead to process upsets, and expose employees to fire, explosion and toxic hazards.  d. Silo Alley - On or about May 31, 2022, the employer failed to review operating procedure ROSOP 100 "Fleur De Lait 50 Product Silo" referenced 2 operators which the employer does not have 2 employees perform, additionally the section on the Safety Systems states, "Escape only respirators" despite the employer not having escape respirators available for use. The procedure does not address safety systems such as alarms, interlocks, cutouts, and fails to address consequences of deviation or steps to correct the deviations, such as "Allow the ammonia to boil out of the coil" what happens if it doesn't and you close valve HV 50PS-11 too early. The employer's failure to ensure that the operating procedures were complete, accurate and reflect existing practices that are used in the process of handling anhydrous ammonia under upset and abnormal conditions can lead to process upsets, and expose employees to fire, explosion and toxic hazards.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

Nov 30, 2022

Abate by

Jun 3, 2024

Penalty

Initial $11,396 · Current $8,000 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(g)(1): The employer did not provide initial training on operating procedures for employees required to work on or near a covered process.  a. The Engine Room - On or about May 31, 2022, the employer failed to initially train employees assigned to operate and maintain the ammonia system on the site-specific ammonia system to include, classification of the engine room, specific procedures for initial startup, normal operations and shutting down the system. Failure to train employees on the process equipment and its safe operation can lead to catastrophic failure and release of anhydrous ammonia and employee exposure to toxic, fire and explosion hazards.   Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $11,396 · Current $8,000 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(h)(2)(i): The employer, when selecting a contractor, did not obtain and evaluate information regarding the contract employer's safety performance and program:   a. Silo Alley - On or about May 31, 2022, the employer failed to collect and evaluate the safety information related to the safety performance of Savencia Cheese USA. Failure to evaluate contract employers' safety and health programs and performance prior to and while working in and around equipment used for the process of handling anhydrous ammonia and under upset conditions can expose employees to fire, explosion and toxic hazards.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jun 3, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(h)(2)(iii): The employer did not explain the applicable provisions of the emergency action plan to contract employers who work on or adjacent to a covered process.  a. Silo Alley - On or about May 31, 2022, the employer failed to communicate the emergency action plan to include the actions to be taken such as when and where to evacuate to in the event of an ammonia alarm or release to employees of Savencia Cheese USA. By failing to ensure contract employees working in and around equipment used for the process of handling anhydrous ammonia and under upset conditions can expose employees to fire, explosion and toxic hazards.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $14,502 · Current $8,000 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(j)(5): The employer did not correct deficiencies in equipment that were outside acceptable limits (defined by the process safety information on paragraph (d) of this section) before use.  a. The Lower Engine Room - On or about May 31, 2022, the employer failed to correct a deficiency of severe corrosion of the bullseye on the HTST-2 serial #48765 that was identified in a December 2020, IIAR 6, 5 year independent Mechanical Integrity audit and is an ongoing hazard. Failure to maintain and repair equipment used in the process of handling anhydrous ammonia can lead to process upsets, and expose employees to fire, explosion and toxic hazards.  b. The Upper Engine Room - On or about May 31, 2022, the employer failed to correct a deficiency of severe corrosion of the bullseye on the LTLA-1 serial #46658 that was identified in a December 2020, IIAR 6, 5 year independent Mechanical Integrity audit and is an ongoing hazard. Failure to maintain and repair equipment used in the process of handling anhydrous ammonia can lead to process upsets, and expose employees to fire, explosion and toxic hazards.  c. The Upper Engine Room - On or about May 31, 2022, the employer failed to correct a deficiency that was identified in a December 2020, IIAR 6, 5 year independent Mechanical Integrity audit and is an ongoing hazard: The shell side PRV is sized for vapor discharge but would be relieving refrigerant oil and should be sized for liquid flow and Shell side PRV discharge termination is atmospheric, which can expose employees to oil heated to the compressor's high- temperature cutout setpoint for OC-2 Serial #80481 resulting in serious injuries or hospitalization.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $11,396 · Current $8,000 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(m)(4): A written incident report was not prepared at the conclusion of the investigation that included at a minimum: the date of the incident; date the investigation began; a description of the incident; the factors that resulted from the investigation; any recommendations resulting from the investigation; and the recommendation's resolutions:  a. Silo Alley - On or about June 8, 2022, the employer had a release of anhydrous ammonia on May 31, 2022, the employer failed to document the investigation, to include at a minimum, when the investigation began, who was involved, description of the incident (the level of specificity required to evaluate the event such as specific pumps that failed, components that relieved, set pressures and necessary information for detailing the accounts of the night, times when specific events took place), the employer failed to compile information related to the individuals harmed by the release. The failure to conduct and document a detailed incident investigation inhibits the employer's ability to fully address and develop recommendations and resolutions to prevent recurrence and evaluate on future PHA's, ultimately resulting in the potential release of ammonia and exposure of employees to toxic, fire and explosion related hazards.   Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jun 3, 2024

Penalty

Initial $11,396 · Current $8,000 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(n): The employer did not establish and implement an emergency plan for the entire plant in accordance with the provisions of 29 CFR 1910.38:  a. 158 West Jackson Street, New Holland, PA - On or about May 31, 2022, the employer's emergency action plan did not establish and implement procedures to be followed by employees who remain to operate critical plant operations before they evacuate. Two employee's shutdown processes and otherwise secured operations that were not in the danger area before evacuating without procedures for safely shutting down processes and evacuating. Failure to develop and implement these procedures exposes employees to hazards associated with the uncontrolled release of anhydrous ammonia's toxic vapors.   b. Facility: On or about May 31, 2022, the employer did not establish and implement an emergency action plan in accordance with the provisions of 29 CFR 1910.38 for handling small releases. Failure to develop and implement these procedures exposes employees to hazards associated with the uncontrolled release of anhydrous ammonia's toxic vapors.   Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR 1910.120(q)(2)(ii): The emergency response plan did not address, to the extent not addressed elsewhere, personnel roles, lines of authority, and communication:  a. 158 West Jackson Street, New Holland, PA - On or about May 31, 2022, the employer failed to establish and implement a written emergency response plan in accordance with 1910.119(q) to include Personnel roles, lines of authority, training, and communication. The ERP does not identify who is assigned to the company hazardous response team and only states "hazardous response team members." Failure to develop and implement these procedures creates confusion during emergencies which exposes employees to hazards associated with the uncontrolled release of anhydrous ammonia's toxic vapors.   Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $11,396 · Current $8,000 Reduced

General-duty citation text

29 CFR 1910.119(o)(1): The Employer did not verify through the conduction of a compliance audit that the procedures and practices developed under the standard were adequate:   a. 158 West Jackson Street, New Holland, PA - On or about June 8, 2022, the employer failed to certify that they have evaluated compliance with the provisions of this section at least every three years to verify that the procedures and practices developed under the standard are adequate and are being followed. The employer during the 2020 compliance audit failed to identify that the employer's operating procedures did not include emergency shutdown procedures despite having taken credit for it. Failure to conduct a thorough and complete compliance audit can lead to failures in the PSM program which can lead to process upsets, and expose employees to fire, explosion and toxic hazards.  b. 158 West Jackson Street, New Holland, PA - On or about June 8, 2022, the employer failed to certify that they have evaluated compliance with the provisions of this section at least every three years to verify that the procedures and practices developed under the standard are adequate and are being followed. The employer had not conducted PHA's on a 5-year interval, with the most recent PHA at the time of the Compliance audit was in 2010. The employer failed to retain in full their initial and other subsequent PHA's and documented and retained that all PHA findings had been resolved in accordance with 1910.119(e)(1)-(e)(7). Failure to conduct a thorough and complete compliance audit can lead to failures in the PSM program which can lead to process upsets, and expose employees to fire, explosion and toxic hazards.   Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(o)(4): The employer did not promptly determine and document an appropriate response to each of the findings of the compliance audit, and document that deficiencies have been corrected:  a. 158 W. Jackson Street, New Holland, PA - On or about June 8, 2022, the employer had still failed to resolve the 2015 compliance audit finding CA23 - Need documentation showing contractor has read and reviewed the rules and regulations of the emergency action plan, this is an ongoing finding as the employer has not resolved the finding. Failure to resolve CA findings exposed employees to potential exposure to anhydrous ammonia hazards such as but not limited to fire, asphyxiation or death.  b. 158 W. Jackson Street, New Holland, PA - On or about June 8, 2022, the employer had still failed to resolve the 2015 compliance audit finding 158 W. Jackson Street, New Holland, PA - On or about June 8, 2022, the employer failed to resolve the 2015 compliance audit finding CA26 - Information needs to be obtained for future projects to evaluate information regarding the contractor's safety performance this is an ongoing finding as the employer has not resolved the finding. Failure to resolve CA findings exposed employees to potential exposure to anhydrous ammonia hazards such as but not limited to fire, asphyxiation or death.  c. 158 W. Jackson Street, New Holland, PA - On or about June 8, 2022, the employer had still failed to resolve the 2015 compliance audit finding CA -33 pertaining to compliance with 1910.119(n), 1910.38, 1910.120 - Written program needs to be updated for Personnel information (roles and responsibilities), this is an ongoing finding as the employer has not resolved the finding. Failure to resolve CA findings exposed employees to potential exposure to anhydrous ammonia hazards such as but not limited to fire, asphyxiation or death.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $11,396 · Current $8,000 Reduced

Hazardous substances 0170

General-duty citation text

29 CFR 1910.120(q)(9)(i): Members of an organized and designated HAZMAT team and hazardous materials specialist did not receive a baseline physical examination and/or was not provided with medical surveillance as required in 29 CFR 1910.120(f):  a. 158 West Jackson Street, New Holland, PA - On or about May 31, 2022, employees assigned to the Emergency Response (ER) Team were not provided with baseline physical examination as required by 1910.120(f). Failure to ensure employees assigned to engage in offensive emergency actions were medically healthy enough to fulfill the obligations of emergency response exposes those employees to physical and psychological stressors that their bodies may not be able to handle potentially resulting in life threatening emergency.   Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace:   a. Machine/Engine Room - On or about June 1, 2022, an employee was assigned to utilize a full-face Honeywell RU65001 respirator without having a medical evaluation to determine fitness for work with a respirator.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR 1910.134(f)(1): The employer did not ensure that employee(s) required to use a tight-fitting facepiece respirator passed the appropriate qualitative fit test (QLFT) or quantitative fit test (QNFT):   a. Machine/Engine Room - On or about June 1, 2022, an employee was assigned to utilize a full face Honeywell RU65001 respirator without having a medical evaluation to determine fitness for work with a respirator.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $14,502 · Current $8,000 Reduced

Hazardous substances 0170

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. 158 West Jackson Street, New Holland PA, Packaging Department - On or about August 10, 2022, the employer failed to develop lockout tagout procedures for employee entry into the 331 and 332 Bright Stacker lines to clear any production stoppage. Employees were exposed to caught in hazards caused by the pallet chain mover.  b. 158 West Jackson Street, New Holland PA, Packaging Department - On or about August 10, 2022, the employer failed to develop lockout tagout procedures for employee entry into the caged area of the IMPACO Robot line to clear any production stoppage. Employees were exposed to caught in hazards caused by the chain pallet mover and struck by hazards caused by the movement of the robot arm inside the guarded area.  c. 158 West Jackson Street, New Holland PA, Packaging Department - On or about August 10, 2022, the employer failed to develop lockout tagout procedures for employee entry into the caged areas of the Flexicell line to clear any production stoppage and restock cardboard sheets in the hopper. Employees were exposed to caught in hazards caused by the chain pallet movers and the conveyor belts, and struck by hazards from the lateral movement of the suction head.  d. 158 West Jackson Street, New Holland PA, Packaging Department - On or about August 10, 2022, the employer failed to develop lockout tagout procedures for employees conducting maintenance work on the scissor lift table located next to the IMPACO box maker. Employees were exposed to caught in and amputation hazards caused by the scissor action of the lift tables.  e. 158 West Jackson Street, New Holland PA, Engine Room - On or about May 31, 2022, the employer failed to develop lockout tagout procedures, for ammonia handling equipment, Ammonia pumps 1 and 2; compressors 1, 2, 3, 4, 5, 6, and 7; condensers 1, 2, 3, and 4, heat exchangers WC-1-HX1, WC-2-HX1, GC-1, GC-2, GC-3, GC-4 and HTST-1, Oil Pots, GC-1 OP, GC-2 OP, GC-3 OP, and GC-4 OP. Failure to develop lockout tagout procedures for performing servicing and maintenance of ammonia handling equipment exposes employees to liquid and vapor ammonia.   Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR 1910.147(c)(4)(ii):Procedures did not clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, type and magnitude of energy, and the means to enforce compliance including, but not limited to, 29 CFR 1910.147(c)(4)(ii)(A), (c)(4)(ii)(B), (c)(4)(ii)(C) and (c)(4)(ii)(D):  (a) 158 West Jackson Street, New Holland PA, the Engine Room - On or about June 8, 2022, the lockout tagout procedure ENGRM-001 for Condenser Pumps 1, 2, 3, 4, and 5 did not have means to enforce compliance and did not identify methods or hazardous energy from hydraulics that must be isolated prior to performing maintenance on these pumps. Employees were exposed to hazards associated with release of pressurized water.  (b) 158 West Jackson Street, New Holland PA, the Engine Room - On or about June 8, 2022, the lockout tagout procedure ENGRM-003 for Chill Water Pump # 3 did not have means to enforce compliance and did not identify methods or hazardous energy from pressurized liquid that must be isolated prior to performing maintenance on these pumps. Employees were exposed to hazards associated with release of pressurized water.  (c) 158 West Jackson Street, New Holland PA, the Engine Room - On or about June 8, 2022, the lockout tagout procedure ENGRM-004 for Chill Water Pump # 4 did not have means to enforce compliance and did not identify methods or hazardous energy from pressurized liquid that must be isolated prior to performing maintenance on these pumps. Employees were exposed to hazards associated with release of pressurized water.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR  1910.119(h)(2)(vi): The employer did not maintain a contract employee injury and illness log related to the contractor's work in process areas:  a. Silo Alley - On or about June 8, 2022, the employer failed to maintain an injury and illness log for Savencia Cheese USA personnel nested in the facility that sustained recordable injury/illnesses on or about May 31, 2022, as the result of an ammonia release. Failure to maintain accurate contractor records inhibits the host employer's ability to adequately address human factors and prior incidents and near miss events during PHA revalidations.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR  1910.119(e)(6): The process hazard analysis was not updated and revalidated every five years:   a. 157 W. Jackson Street, New Holland PA - On or about May 31, 2022, the employer had failed to perform PHA's every 5 years as required, the employer performed an PHA in 2010 but did not conduct an update or revalidation until 2021, six years past the due date. Failure to conduct, retain, document PHA's and resolve PHA findings in a timely manner could expose employees to unmitigated hazards associated with ammonia handling.   Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 0170

General-duty citation text

29 CFR 1910.119(e)(7): 29 CFR 1910.119(e)(7): The employer did not retain the process hazard analysis (PHA), updates, or renewals for each process covered and documented resolution of the recommendations described in 29 CFR 1910.119(e)(5) for the life of the process.   a. 157 W. Jackson Street, New Holland PA - On or about June 9, 2022, the employer had failed to retain in its entirety the initial PHA, findings, resolutions and the 2010 PHA, findings and resolutions. Failure to conduct, retain, document PHA's and resolve PHA findings in a timely manner exposed employees to potential exposure to anhydrous ammonia hazards such as but not limited to fire, asphyxiation or death.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 01700689

General-duty citation text

29 CFR 1910.134(d)(1)(iii): The employer did not identify and evaluate the respiratory hazard(s) in the workplace; including a reasonable estimate of employee exposures to respiratory hazards and identification of the contaminant's chemical state and physical form:  a. Facility wide - On or about June 1, 2022, the employer had failed to perform an evaluation to determine the need for respiratory protection from airborne respiratory hazards such as anhydrous ammonia and hexavalent chromium, employees were exposed to environmental hazards.  Abatement certification and documentation required within 10 days after abatement date. The certification shall include a statement that abatement is complete, the date and method of abatement, and state that employees and their representatives were informed of this abatement. Abatement documentation shall include documents demonstrating that abatement is complete, such as evidence of the purchase or repair of equipment, photographic or video evidence of abatement or other written records.

Issued

Nov 30, 2022

Penalty

Initial $0 · Current $0

Hazardous substances 0685

General-duty citation text

29 CFR 1910.1026(d)(1):The employer with a workplace or work operation covered by this standard did not determine the 8-hour time-weighted average exposure for each employee exposed to chromium (VI):  a. Maintenance Shop Storage Building - On or about July 14, 2022, employees were exposed to chromium VI health hazards while engaged in the welding cutting and brazing of stainless steel without the employer determining the average exposure to hexavalent chromium for the purpose of implementing exposure controls.   Corrected During Inspection

Issued

Nov 30, 2022

Abate by

Jan 2, 2024

Penalty

Initial $0 · Current $0

Hazardous substances 0689

General-duty citation text

29 CFR 1910.1026(l)(1): The employer did not ensure that all employees who were assigned to workplaces where there was exposure to chromium (VI) were provided with information and training as required by the Hazard Communication standard, 29 CFR 1910.1200:   a. 157 W. Jackson Street, New Holland, PA - On or about June 8, 2022, the employer failed to ensure that employees assigned to perform hot work on stainless and carbon steel be aware of the hazards associated with the generation of hexavalent chromium (Chromium VI) and how to mitigate exposure.  Abatement certification required within 10 days after abatement date. The certification shall include a statement that abatement is complete, date and method of abatement, and states employees and their representatives were informed of this abatement.