OSHA Inspection: POLYCARBON INDUSTRIES, INC./SEQENS SAS

Issued

2023-11-01 00:00:00

Abate by

2023-12-20 00:00:00

Penalty

Initial $15625.00 · Current $15625.00

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1): The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees.  Location - Throughout; Hastelloy Suite.  On or about 5/4/2023, the employer did not determine the combustibility hazards of materials used during the Dekon 139 production process such as but not limited to Unit 5:  PFN2 - Drying Dekon and Unit 7:  Final Packaging) to protect employees from fire and explosion hazards of combustible dust.

Issued

2023-11-01 00:00:00

Abate by

2023-12-06 00:00:00

Penalty

Initial $15625.00 · Current $15625.00

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish written procedures to maintain the on-going integrity of process equipment.  Location - Throughout; Hastelloy Suite.  On or about 5/4/2023, the employer did not implement written procedures to maintain the on-going integrity of the PFN-2 agitator assembly, including but not limited to the bolt, agitator, and shaft.

Issued

2023-11-01 00:00:00

Abate by

2023-12-06 00:00:00

Penalty

Initial $15625.00 · Current $31250.00

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(A): The employer did not develop and implement written operating procedures that addressed the consequences of deviations from the operating limits in the covered process;    Location - 9 Opportunity Way, Newburyport, MA 01950 - Throughout and Hastelloy Suite.  On or about 5/4/2023, the employer did not establish written operating procedures that provided clear instruction on consequences of deviation from operations including, but not limited to, the following:  a)     Written operating procedures did not address the consequences of deviation for the unexpected opening of the PFN-2 vessel discharge chute during the Dekon 139 production process.  b)      Written operating procedures did not address the consequences of deviation for temperatures of the product within the PFN-2 process vessel during the Dekon 139 production process.

Issued

2023-11-01 00:00:00

Abate by

2023-12-20 00:00:00

Penalty

Initial $15625.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(B): The employer did not develop and implement written operating procedures that provide clear instructions for steps required to correct or avoid deviation from the operating limits in the covered process.  Location - 9 Opportunity Way Newburyport, MA 01950.  On or about 5/4/2023, the employer did not establish written operating procedures that provided clear instruction on steps to correct and avoid deviations from operations including, but not limited to, the following:  a)	Written operating procedures did not address steps to correct or avoid deviations for the unexpected opening of the PFN-2 vessel discharge chute during the Dekon 139 production process.  b)	Written operating procedures did not address steps to correct or avoid deviations for temperatures of the product within the PFN-2 process vessel during the Dekon 139 production process.

Issued

2023-11-01 00:00:00

Abate by

2023-12-06 00:00:00

Penalty

Initial $15625.00 · Current $31250.00

General-duty citation text

29 CFR 1910.119(l)(4): Process safety information required by paragraph (d) of this section was not updated when a change covered by this paragraph resulted in a change in the process safety information.  Location - Throughout; Hastelloy Suite.  On or about 5/4/2023, the employer did not update the process safety information to include steps to avoid consequences of deviation in temperature, properties and hazards of the chemicals used in the process, and operating procedures and safe work practices for use of the temperature probe modification on the PFN-2 vessel.

Issued

2023-11-01 00:00:00

Abate by

2023-12-06 00:00:00

Penalty

Initial $15625.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.119(l)(5): The employer did not update process safety information following a change in the covered process.  Location - Throughout.  On or about 5/4/2023, the standard operating procedures (SOP) for the Dekon 139 production process were not updated to include the addition of the temperature probe and related operating limits for temperature.

Issued

2023-11-01 00:00:00

Abate by

2023-12-06 00:00:00

Penalty

Initial $15625.00 · Current $31250.00

General-duty citation text

29 CFR 1910.1200(d)(2): Chemical manufacturers, importers, or employers classifying chemicals did not identify and/or consider the full range of available scientific literature and other evidence concerning the potential hazards.  Location - Throughout.  On or about 5/4/2023, the employer did not update the Safety Data Sheet (SDS) for Dekon 139 after tests were conducted on the product to determine thermal decomposition as well as flammability.

Issued

2023-11-01 00:00:00

Abate by

2023-12-06 00:00:00

Penalty

Initial $85938.00 · Current $171876.00

General-duty citation text

29 CFR 1910.119(d)(2)(i)(D): Information concerning the technology of the process did not include safe upper and lower limits for such items as temperatures, pressures, flows or compositions:  Location - 9 Opportunity Way, Newburyport, MA 01950 - Throughout and Hastelloy Suite.  On or about 5/4/2023, the Dekon batch record did not include all safe upper limits to include the full range of safe upper limit temperatures up to a point in which the product decomposes.    PolyCarbon Industries, Inc., was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.119(d)(2)(i)(D), which was contained in OSHA inspection number 1463040, Citation 1, Item 1-a and was affirmed as a final order on 11/19/2020, with respect to a workplace located at 9 Opportunity Way, Newburyport, MA 01950.

Issued

2023-11-01 00:00:00

Abate by

2023-12-06 00:00:00

Penalty

Initial $85938.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.119(d)(2)(i)(E): The employer failed to perform an evaluation of the consequences of deviations, including those effecting the safety and health of employees.  Location - 9 Opportunity Way Newburyport, MA 01950.  On or about 5/4/2023, the employer did not evaluate the consequences of deviation for the Dekon 139 production process, including possible consequences of substances spilling out of the PFN-2 discharge chute unexpectedly.  PolyCarbon Industries, Inc., was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.119(d)(2)(i)(D), which was contained in OSHA inspection number 1463040, Citation 1, Item 1-b and was affirmed as a final order on 11/19/2020, with respect to a workplace located at 9 Opportunity Way, Newburyport, MA 01950.

Issued

2023-11-01 00:00:00

Abate by

2023-12-20 00:00:00

Penalty

Initial $1378.00 · Current $1378.00

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:  Location: Throughout; Hastelloy Suite.  On or about May 4, 2023, the employer did not have a program in place that tracked contract employee's injury and illnesses related to the contractor's work in the process areas.