OSHA Inspection: BP PRODUCTS NORTH AMERICA, INC.

Issued

Mar 13, 2023

Abate by

Apr 14, 2023

Penalty

Initial $15,625 · Current $15,625

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:  (a): BP Products North America Inc. - Oregon, Ohio: On or about September 20, 2022, the employer failed to ensure that it documented that equipment in the process complied with the employer's chosen recognized and generally accepted good engineering practices such as but not limited to API 520 (2020) Section 5 for PSV-1457 located on the tube side of the HVGO/Crude 1 Naphtha Intermediate Reflux Shell & Tube heat exchangers (PR-544011/I2), thereby exposing employees to recognized hazards.  (b): BP Products North America Inc. - Oregon, Ohio: On or about September 20, 2022, the employer failed to ensure that it documented that equipment in the process complied with the employer's chosen recognized and generally accepted good engineering practices such as but not limited to API 520 (2020) and API 521 (2015) for the TIU Fuel Gas Mix Drum (PR-510253) PSV-1164, thereby exposing employees to recognized hazards.

Issued

Mar 13, 2023

Abate by

Apr 14, 2023

Penalty

Initial $15,625 · Current $15,625

General-duty citation text

29 CFR  1910.119(e)(1): The process hazard analysis did not identify, evaluate, and address the control of the hazards involved in the process:  (a): BP Products North America Inc. - Oregon, Ohio: On or about September 20, 2022, the employer, in the Crude 1 PHA, failed to identify, evaluate, and control the hazard of high liquid level resulting from all potential flammable liquid overfill scenarios, including but not limited to detecting flammables and stopping the flow of liquid naphtha to the TIU Fuel Gas Mix Drum. The Crude 1 PHA did not include the Coker Gas Plant as a source of liquid naphtha during an overfill scenario involving the Absorber Stripper Tower (PR550025) to the TIU Fuel Gas Mix Drum, thereby exposing employees to recognized hazards.

Issued

Mar 13, 2023

Abate by

Apr 26, 2023

Penalty

Initial $15,625 · Current $15,625

General-duty citation text

29 CFR  1910.119(e)(3)(iv):The process hazard analysis did not address the consequences of the failure of engineering and administrative controls:  (a) BP Products North America Inc. - Oregon, Ohio: On or about September 20, 2022, the employer failed to ensure that the PHA addressed the consequences of failure of engineering controls when the high-level switch (LSH-805) was not available to detect high level of flammables in the TIU Fuel Gas Mix Drum during an overfill scenario of the Absorber Stripper Tower (PR-550025) and downstream vessels. Failure to evaluate loss of engineering controls resulted in exposing employees to recognized hazards.

Issued

Mar 13, 2023

Abate by

Apr 14, 2023

Penalty

Initial $15,625 · Current $15,625

General-duty citation text

29 CFR  1910.119(f)(1)(i)(C): The employer did not develop and implement written operating procedures that provide clear instructions for safely conducting temporary operations:  a) On or about September 20, 2022, the employer failed to ensure that all operating procedures were implemented for operation of the Crude 1 Unit while the Coker Gas Plant and SatGas/NHT Units were in bypass condition, including operating procedures CGP02.004 - Bypassing and Returning to Service Coker Gas Plant, contributing to FCV-3816 being opened and allowing naphtha to overfill downstream process vessels and flow into the refinery's fuel gas system, thereby exposing employees to recognized hazards.

Issued

Mar 13, 2023

Abate by

Apr 14, 2023

Penalty

Initial $15,625 · Current $15,625

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) BP Products North America Inc. - Oregon, Ohio: On or about September 20, 2022, the employer failed to ensure the emergency shutdown of process equipment in the NHT/Sat Gas units. Upset conditions involving the lifting and reseating of PSV-1457 and PSV- 1462 caused process equipment vibration and instability. A release of naphtha during this upset condition occurred, thereby exposing employees to recognized hazards.

Issued

Mar 13, 2023

Abate by

Apr 14, 2023

Penalty

Initial $15,625 · Current $15,625

General-duty citation text

29 CFR  1910.119(f)(1)(i)(E):The employer did not 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 did not address at least emergency operations:  (a): BP Products North America Inc. - Oregon, Ohio: On or about September 20, 2022, the employer failed to ensure that procedure PSM 025 was implemented for the closing of PSV-1457 in the SatGas/NHT Unit, for the purpose of reseating the relief valve, thereby exposing employees to recognized hazards.

Issued

Mar 13, 2023

Abate by

Apr 26, 2023

Penalty

Initial $15,625 · Current $15,625

General-duty citation text

29 CFR  1910.119(f)(1)(ii):  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 operating limits:  a) BP Products North America Inc. ? Oregon, Ohio: On or about September 20, 2022, the employer failed to ensure that the procedure for Normal Operation of Crude I (CRDI 02.012) included steps to avoid or correct deviations in process parameters. There was a lack of detailing steps to avoid or correct deviations for all process parameters such as liquid level, thereby exposing employees to recognized hazards.

Issued

Mar 13, 2023

Abate by

Apr 14, 2023

Penalty

Initial $15,625 · Current $15,625

General-duty citation text

29 CFR  1910.119(g)(1)(i): Each employee involved in operating a process was not provided training which included emphasis on the specific safety and health hazards, emergency operations including shutdown, and safe work practices applicable to the employee's job tasks: 	 a) On or about September 20, 2022, the employer failed to ensure that operators were sufficiently trained to respond to rising liquid levels and identify the presence of naphtha during transient operating conditions in the TIU Fuel Gas Mix Drum located in the Crude 1 Unit, thereby exposing employees to recognized hazards.