OSHA Inspection: WESTERN SUGAR COOPERATIVE

Issued

Jan 23, 2024

Abate by

Apr 1, 2024

Penalty

Initial $16,131 · Current $8,066 Reduced

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:  On or about September 3, 2023, at a worksite operated by the Western Sugar Cooperative Corporation located at 2100 East Overland, Scottsbluff, Nebraska, the employer exposed employees to fire and explosion hazards posed by a hazardous buildup of natural gas while attempting to light a kiln used in sugar manufacturing. The procedure for lighting the kiln required an employee to climb stairs to access a manway opening (hatch) at the top of the kiln so that the employee could drop a lighting flare into the kiln in preparation of a "cold start" of the kiln.  The employer opened the kiln's gas line as the employee was climbing the stairs.  A hazardous buildup of gas occurred during the time the gas line was opened, and the employee reached the top of the kiln, opened the hatch, and lit a lighting flare. When the employee dropped the lit lighting flare into the kiln the gas builds up ignited, resulting in an uncontrolled flash explosion that blew the employee back several feet. The employee suffered minor burns.   AMONG OTHER METHODS, FEASIBLE AND ACCEPTABLE ABATEMENT METHODS TO CORRECT THIS HAZARD ARE:  i.	Design and implement procedures and protocols to ensure kiln operators follow the cold start step-by-step lighting procedures outlined per page 18 in the kiln operator's manual which require the lit flares to be inserted in the kiln first, then the manway hatch cover closed, and finally the natural gas valves opened to allow the flow of gas. This should include training employees on the procedures and protocols with an explanation of the purpose of each step and the hazards associated with failing to follow the steps and periodic refresher training.  ii.	Create a document explaining the steps for the start-up of the kiln as outlined in the operator's manual and post it at a place so that it is available for ready reference for employees tasked with lighting the kiln.   iii.	Implement procedures and protocols to monitor whether proper kiln lighting procedures are being followed and enforce them if they are not.