OSHA Inspection: CALUMET SHREVEPORT REFINING, LLC

Issued

2024-04-09 00:00:00

Abate by

2024-05-24 00:00:00

Penalty

Initial $16131.00 · Current $5000.00 Reduced

General-duty citation text

29 CFR 1910.22(a)(3): 29 CFR 1910.22(a)(3): The employer did not ensure that walking-working surfaces are maintained free of hazards such as sharp or protruding objects, loose boards, corrosion, leaks, spills, snow, and ice.  Instance a.) On or about 11/08/2023, at No. 4 Vacuum unit, on the first deck northside of heat exchangers, the employer did not ensure that the walking-working floor surface is free of hoses and other objects.  This condition exposed employees to a tripping hazard.  Instance b.) On or about 11/08/2023, at No. 4 Vacuum unit, on the first deck southside of heat exchangers, the employer did not ensure that the walking-working floor is free of hoses.  This condition exposed employees to a tripping hazard.  Instance c.) On or about 02/13/2024, at No. 4 Vacuum unit, on the middle (second) deck, the employer did not ensure that the walking-working floor surface is free of hoses.  This condition exposed employees to a tripping hazard.  Instance d.) On or about 02/13/2024, at No. 4 Vacuum unit, on the top (third) deck, the employer did not ensure that the walking-working floor surface is free of hoses.  This condition exposed employees to a tripping hazard.

Issued

2024-04-09 00:00:00

Abate by

2024-05-24 00:00:00

Penalty

Initial $11524.00 · Current $9000.00 Reduced

General-duty citation text

29 CFR 1910.28(b)(1)(i)(A): The employer did not ensure that each employee on a walking-working surface with an unprotected side or edge that is 4 feet (1.2 m) or more above a lower level was protected from falling by a standard guardrail system.  Instance a.) On or about 11/07/2023, at No. 1 Platformer unit (#18), on the first level platform of reactors (R1 & R2), the east side of the walking-working surface did not have a complete guardrail system installed. This condition exposed the employees to a fall hazard greater than four feet.  Instance b.) On or about 11/07/2023, at No. 1 Platformer unit (#18), on the second level platform of reactors (R1 & R2), the east side of the walking-working surface did not have a complete guardrail system installed. This condition exposed the employees to a fall hazard greater than four feet.  Instance c.) On or about 11/07/2023, at No. 1 Platformer unit (#18), on the platform of Heater No. 3, the west side of the walking-working surface did not have a complete guardrail system installed. This condition exposed the employees to a fall hazard greater than four feet.

Issued

2024-04-09 00:00:00

Abate by

2024-05-24 00:00:00

Penalty

Initial $16131.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.28(b)(3)(iv): Each employee was not protected from falling into the ladderway platform hole at the entrance to the hole by a self-closing gate or an offset.   Instance a.) On or about 11/07/2023, at No.1 Platformer unit (#18), on first level of reactor R4, employees monitoring or inspecting the reactor were exposed to a fall hazard exceeding four feet where the ladderway platform hole was not equipped with a self-closing gate or an offset.  Instance b.) On or about 11/07/2023, at No.1 Platformer unit (#18), on top of reactor R4 at second level, employees monitoring or inspecting the reactor were exposed to a fall hazard exceeding four feet where the ladderway platform hole was not equipped with a self-closing gate or an offset.  Instance c.) On or about 11/07/2023, at No.1 Platformer unit (#18), on top of reactors R1 and R2 at second level, employees monitoring or inspecting the reactors were exposed to a fall hazard exceeding four feet where the ladderway platform hole was not equipped with a self-closing gate or an offset.

Issued

2024-04-09 00:00:00

Abate by

2024-05-24 00:00:00

Penalty

Initial $11524.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.29(b)(5): The employer did not ensure that midrails, screens, mesh, intermediate vertical members, solid panels, and other equivalent intermediate members are capable of withstanding, without failure, a force of at least 150 pounds (667 N) applied in any downward or outward direction at any point along the intermediate member.  On or about 11/07/2023, at Naphtha Unifier Unit (#55), on the top platform of reactor R-01, the middle rail (midrail) of the guardrail system was bent and not intact with the vertical bar. This condition exposed the employees to a falling hazard.

Issued

2024-04-09 00:00:00

Abate by

2024-05-24 00:00:00

Penalty

Initial $16131.00 · Current $11250.00 Reduced

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.  On or about 11/07/2023, at No. 1 Platformer and No. 4 Crude units, the employer did not ensure that piping and instrument diagrams (P&IDs) were accurate. The P&IDs were not accurate as the following but not limited to:  a. In P&ID 18-E-54-0020 Rev. 9 (Bates # 494), the pressure relief valve on the recycle discharge Hydrogen line (6"-HH-18-30040-N-BAA1) was labeled incorrectly.  b. In P&ID 18-E-54-0020 Rev. 9 (Bates # 494), the pressure relief valve on the booster discharge Hydrogen line (4"-HH-18-10208-N-B2-1) was labeled incorrectly.   c. In P&ID 18-E-54-3000 Rev. 21 (Bates # 501), the block valve up and down stream of 18-RV-06 were not labeled with car seal open (CSO).   d. In P&ID 58-E-54-2003 Rev. 20 (Bates # 531), two (2) block valves are located down stream of PSV-58-05 were not labeled with car seal open (CSO).

Issued

2024-04-09 00:00:00

Abate by

2024-07-10 00:00:00

Penalty

Initial $16131.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(D): The employer failed to complete and compile information pertaining to equipment in the process and did not include relief system design and design basis.  On or about 11/07/2023, at No.1 Platformer and No. 4 Crude units, the employer failed to ensure process safety information (PSI) pertaining to equipment in the process safety management (PSM) covered processes included the relief system design and design basis to include, but is not limited to the following:  a.	Pressure relief valve, PSV-58-05 (P&ID 58-E-54-2003, No. 20) b.	Rupture disc RD-58-03 (P&ID 58-E-54-4000, No. 33) c.	Rupture disc RD-58-04 (P&ID 58-E-54-4000, No. 33) d.	Pressure relief valve, 18-RV-03A is depicted in P&ID 18-E-54-0020, No. 9.  In the field, on the name plate, this pressure relief valve is labeled as 19-RV-03A. e.	Pressure relief valve, 19-RV-03A is depicted in P&ID 18-E-54-0020, No. 9.  In the field, on the name plate, this pressure relief valve is labeled as 18-RV-03.

Issued

2024-04-09 00:00:00

Abate by

2024-05-24 00:00:00

Penalty

Initial $16131.00 · Current $0.00 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.    Instance a: On or about 11/07/2023, at No.1 Platformer unit, the employer did not document that it complied with its chosen recognized and generally accepted good engineering practices (RAGAGEP), such as API 521 (American Petroleum Institute) section 5.5 (5th Edition), when the outlet of 18-RV-03 is blocked, the capacity of the pressure relief valve (18-RV-03) is less than the capacity of the requirement.   Instance b: On or about 02/13/2024, at No.4 Crude unit, the employer did not document that it complied with its chosen recognized and generally accepted good engineering practices, such as American Standard Mechanical Engineer (ASME) Boiler and Pressure Vessel Code Section VIII when it failed to place a car seal on the first downstream block valve of the pressure relief valve PSV-58-05 which is depicted on piping and instrument diagram (P&ID) 58-E-54-2003 Revision 20.  Instance c: On or about 02/13/2024, at No.4 Crude unit, the employer did not document that it complied with its chosen recognized and generally accepted good engineering practices, such as American Standard Mechanical Engineer (ASME) Boiler and Pressure Vessel Code Section VIII when it failed to place a car seal on the second downstream block valve of the pressure relief valve PSV-58-05 which is depicted on P&ID 58-E-54-2003 Revision 20.

Issued

2024-04-09 00:00:00

Abate by

2024-07-10 00:00:00

Penalty

Initial $16131.00 · Current $11250.00 Reduced

General-duty citation text

29 CFR 1910.119(e)(5): The employer did not assure that PHA recommendations were resolved in a timely manner.  On or about 11/07/2023, at No. 1Platformer unit, the employer did not resolve 2019 PHA recommendations or findings in a timely manner as the following but not limited to:  Instance a.)  "26. Evaluate providing a means of overpressure protection for the shell side of 18-EX-08A/B/C/D, 18-R-01, 18-H-01 for external fire case, with either a PSV or a CSO open path to an existing PSV. (2019 Recommendation)."  Instance b.)  "29. Evaluate providing a means of overpressure protection for the shell side of 18-EX-08A/B/C/D, 18-R-01, 18-H-01, 18-H-02, 18-R-02, 18-H-03, 18-H-04; 18-R-04 for external fire case, with either a PSV or a CSO open path to an existing PSV. (2019 LOPA Recommendation)."

Issued

2024-04-09 00:00:00

Abate by

2024-07-10 00:00:00

Penalty

Initial $16131.00 · Current $11250.00 Reduced

General-duty citation text

29 CFR 1910.119(j)(2): The employer did not establish and implement written procedures to maintain the on-going integrity of process equipment.  Instance a.) On or about 11/07/2023, at No. 4 Crude unit, the employer failed to ensure that written procedures for testing of Pressure Indication Control PIC-401 (P&ID 58-E-54-2003, No. 20) were established.  Instance b). On or about 11/07/2023, at No. 1 Platformer unit, the employer failed to ensure that written procedures for testing of Hydrogen Low Flow Interlocks FT-7302A/B/C/D (P&ID 18-E-54-1000, No. 16) were established.  Instance c). On or about 11/07/2023, at No. 1 Platformer unit, the employer failed to ensure that written procedures for testing of Level Indication Control LIC-7303 (P&ID 18-E-54-3000, No. 21) were established.   Instance d). On or about 11/07/2023, at No. 1 Platformer unit, the employer failed to ensure that written procedures for testing of High-High Level Alarm (High Level Shutdown Switch) LAHH-7351 for No. 1 Platform Product Separator, 18-SE-01 (P&ID 18-E-54-3000, No. 21) were established.  Instance e).  On or about 11/07/2023, at No. 1 Platformer unit, the employer failed to ensure that written procedures for testing of the emergency remote shutdown HS-7370A of Platformer East Compressor, C-0010, (P&ID 18-E-54-5000G, No. 1) were established.

Issued

2024-04-09 00:00:00

Abate by

2024-07-10 00:00:00

Penalty

Initial $16131.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(i): The employer did not perform inspection and tests on process equipment.   Instance a) On or about 11/07/2023, at No. 4 Crude unit, the employer did not perform inspections and tests on Pressure Indication Control or (Pressure indicator Controller) PIC-401 (P&ID 58-E-54-2003, No. 20).  Instance b) On or about 11/07/2023, at No.1 Platformer unit, the employer did not perform inspections and tests on Hydrogen Low Flow Interlocks FT-7302B/C/D, (P&ID 18-E-54-1000, No. 16).  Instance c) On or about 11/07/2023, at No.1 Platformer unit, the employer did not perform inspections and tests on Level Indication Control LIC-7303 (P&ID 18-E-54-3000, No. 21).  Instance d) On or about 11/07/2023, at No.1 Platformer unit, the employer did not perform inspections and tests on High-High Level Alarm (High Level Shutdown Switch) LAHH-7351 for No. 1 Platform Product Separator 18-SE-01 (P&ID 18-E-54-3000, No. 21).  Instance e) On or about 11/07/2023, at No.1 Platformer unit, the employer did not perform inspections and tests on Emergency Remote Shutdown HS-7370A of Platform East Compressor C-0010 (P&ID 18-E-54-5000G, No. 1).  Instance f) On or about 11/07/2023, at No. 4 Crude unit, the employer did not perform inspections on Rupture Disc RD-58-03 (P&ID 58-E-54-4000, No. 33).  Instance g) On or about 11/07/2023, at No. 4 Crude unit, the employer did not perform inspections on Rupture Disc RD-58-04 (P&ID 58-E-54-4000, No. 33).

Issued

2024-04-09 00:00:00

Abate by

2024-07-10 00:00:00

Penalty

Initial $16131.00 · Current $11250.00 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(iii):  The frequency of inspections and tests of process equipment to maintain its mechanical integrity was not consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience.   On or about 11/07/2023, at No. 1 Platformer unit, the employer failed to ensure that thickness measurement locations (TML) on reactor product separator PV-18-01(18-SE-01) are not conducted at a frequency consistent with recognized and generally accepted good engineering practice such as the employer's Pressure Vessel and Tower Inspection Procedure (14-W-0170, Revision Date: 01/16/2019) that includes but are not limited to the following:  a)	Thickness Measurement Location (TML) number 1 at South Head (SH) location. The last thickness measurement of TML number 1was on 2/19/2012. b)	Thickness Measurement Location (TML) number 2 at South Head (SH) location.  The last thickness measurement of TML number 2 was on 2/19/2012. c)	Thickness Measurement Location (TML) number 22 on the bottom nozzle.  The last thickness measurement of TML number 2 was on 2/19/2012.  On or about 11/07/2023, at No. 1 Platformer unit, the employer failed to ensure that thickness measurement locations on piping circuit 18-03-HN-009 are not conducted at a frequency consistent with recognized and generally accepted good engineering practice such as the employer's Inspection Procedure for Piping Systems (14-W-0171, Revision Date: 01/16/2019) that includes but are not limited to the following:  d)	Thickness Measurement Location (TML) number 1 at 6-inch elbow location. The last thickness measurement of TML number 1 was on 4/22/2010. e)	Thickness Measurement Location (TML) number 2 at 6-inch elbow location. The last thickness measurement of TML number 2 was on 4/22/2010. f)	Thickness Measurement Location (TML) number 3 at 6-inch elbow location. The last thickness measurement of TML number 3 was on 4/22/2010. g)	Thickness Measurement Location (TML) number 4 at 6-inch elbow location. The last thickness measurement of TML number 4 was on 4/22/2010. h)	Thickness Measurement Location (TML) number 5 at 6-inch elbow location. The last thickness measurement of TML number 5 was on 4/22/2010.