OSHA Inspection: ABBYLAND PORK PACK, INC.

Issued

Aug 7, 2024

Abate by

Sep 26, 2024

Penalty

Initial $9,507 · Current $6,655 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(A):Process safety information pertaining to the equipment in the process did not include materials of construction:  (a) Plate Chiller Room; On or about  March 14, 2024, materials of construction for the 2005 Falling Film RVS Surge Drum FF-SD-01 & 2 (S/N 40664) to include the U-1 Manufacturers Data Report for Pressure Vessels was not provided.

Issued

Aug 7, 2024

Abate by

Sep 26, 2024

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.119(d)(3)(i)(B):The employer's piping and instrument diagrams were not accurate and did not represent equipment that was existing and was part of the process:  (a) Plate Chiller Room, P&ID R030 (dated 9/29/15); On or about  March 14, 2024, the 2005 Falling Film RVS Surge Drum FF-SD-01 & 2 (S/N 40664) was labeled as FF-01 on the P&ID.  (b) Plate Chiller Room, P&ID R030 (dated 9/29/15); On or about  March 14, 2024, the 2005 Falling Film RVS Surge Drum FF-SD-01 & 2 (S/N 40664) valve FF-01 & 02 800, but was labeled as 80A on the P&ID.  (c) Plate Chiller Room, P&ID R030 (dated 9/29/15); On or about  March 14, 2024, the 2005 Falling Film RVS Surge Drum FF-SD-01 & 2 (S/N 40664) associated oil pot FF-OP-01  (S/N 3020803) Hansen relief valve was labeled as FF-01 & 02 503, but was  labeled as FF-OP-01 50 on the P&ID.   (d) Plate Chiller Room, P&ID R030 (dated 9/29/15); On or about  March 14, 2024, the 2005 Falling Film RVS Surge Drum FF-SD-01 & 2 (S/N 40664) associated oil pot FF-OP-01  (S/N 3020803), the relief piping stemming from the Hansen relief valve (FF-01 & 02 503) was not on the P&ID, or other P&IDs provided, and does not show relief location to roof or associated P&ID number.  (e) Plate Chiller Room, P&ID R030 (dated 9/29/15); On or about  March 14, 2024, the 2005 Falling Film RVS Surge Drum FF-SD-01 & 2 (S/N 40664) associated Falling Film Heat Exchanger labeled as FF-01, was labeled as FF01A on the P&ID.  (f) Plate Chiller Room, P&ID R030 (dated 9/29/15); On or about  March 14, 2024, the 2005 Falling Film RVS Surge Drum FF-SD-01 & 2 (S/N 40664) associated Falling Film Heat Exchanger labeled as FF-02, was labeled as FF01B on the P&ID.  (g) Roof; Instrumentation FF-01 & 02 101 and 202 were not found on the P&IDs provided.

Issued

Aug 7, 2024

Abate by

Sep 26, 2024

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.119(d)(3)(i)(D): The employer did not include, in the process safety information compilation, the relief system design and the design basis:   (a) Plate Chiller Room; On or about  March 14, 2024, a relief system vent design analysis was not provided for equipment including, but not limited to, the 2005 Falling Film RVS Surge Drum FF-SD-01 & 2 (S/N 40664), the Falling Film Heat Exchangers  FF-01 & FF-02, the oil pot FF-OP-01 (S/N 3020803), and the relief piping to the roof.

Issued

Aug 7, 2024

Abate by

Dec 24, 2024

Penalty

Initial $0 · Current $0

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:  On or about March 14, 2024, the employer failed to ensure the anhydrous ammonia machinery room complied with recognized and generally accepted good engineering practices (RAGAGEP):  (a) Machinery Room; The employer failed to ensure adequate number of egress doors were provided in compliance with recognized and generally accepted good engineering practices (RAGAGEP) such as, but not limited to, ANSI/IIAR 2 (2021) Standard for Design of Safe Closed-Circuit Ammonia Refrigeration Systems, Chapter 6 Machinery Rooms, section 6.10 Entrances and Exits.   Employees work on and in the vicinity of equipment containing anhydrous ammonia, in a machine room that had one means of entry/exit.  (b) Machinery Room; The employer failed to ensure the electrical and ventilation specifications were in compliance with recognized and generally accepted good engineering practices (RAGAGEP) such as, but not limited to, ANSI/IIAR 2 (2021) Standard for Design of Safe Closed-Circuit Ammonia Refrigeration Systems, Chapter 6 Machinery Rooms, section 6.8 Electrical Safety.  Ventilation requirements were not adequate per electrical classification.  (c) Machinery Room and throughout the facility; The employer failed to ensure the ammonia alarms were in compliance with recognized and generally accepted good engineering practices (RAGAGEP) such as, but not limited to, ANSI/IIAR 2 (2021) Standard for Design of Safe Closed-Circuit Ammonia Refrigeration Systems:  Chapter 6 Machinery Rooms, section 6.13 Ammonia Detection and Alarm; Chapter 7 Refrigeration Equipment Located in Areas Other Than Machinery Rooms, section 7.2.3 Detection and Alarms; and Chapter 17 Ammonia Detection and Alarms.  Ammonia alarm detection was indicated to be set at 200 ppm with no signage adjacent to the devices.

Issued

Aug 7, 2024

Abate by

Sep 26, 2024

Penalty

Initial $9,507 · Current $6,655 Reduced

General-duty citation text

29 CFR  1910.119(f)(1): 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 addressing at least the elements listed in 1910.119(f)(1)(i)-1910.119(f)(1)(iv):  (a) SOP-8 Ammonia Charging Procedure; On or about  March 14, 2024, the charging procedure did not contain information to address elements listed in 1910.119(f)(1)(i)-1910.119(f)(1)(iv) such as, but not limited to, emergency operations & shut down procedures in the instance of an ammonia leak,  consequences of deviation, steps required to correct or avoid deviation, and safety systems and their functions.

Issued

Aug 7, 2024

Abate by

Sep 26, 2024

Penalty

Initial $0 · Current $0

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 and/or the employer did not annually certify that operating procedures were current and accurate:  (a) SOP-8 Ammonia Charging Procedure; On or about  March 14, 2024, the charging procedure was not updated to reflect current changes in technology and equipment to include, but not be limited to, the change in charging location from the high pressure receiver valve #100 to the accumulator valve ACC-01 600.

Issued

Aug 7, 2024

Abate by

Sep 26, 2024

Penalty

Initial $9,507 · Current $6,655 Reduced

General-duty citation text

29 CFR 1910.119(j)(2):The employer did not establish or implement written procedures to maintain the on-going integrity of process equipment:  Equipment specific procedures, to include procedural steps to inspect and test, as well as the criteria for acceptable test results per the anhydrous ammonia equipment, such as but not limited to the following, were not provided:   (a) On or about March 14, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia piping systems and components.   (b) On or about March 14, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia pressure vessels to include, but not be limited to, the HPR-01 High Pressure Receiver, the INT-01 Intercooler, the LTRP-01 Low Temperature Recirculator, the Surge Drums (FF-SD-01 & 02, MAU-01-SD-01), the ACC-01 Accumulator, and the TV-01 Transfer Vessel.  (c) On or about March 14, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia compressors 1-6.  (d) On or about March 14, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia system relief and vent systems.   (e) On or about March 14, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia system emergency shutdown devices.   (f) On or about March 14, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia detection and alarm systems.  (g) On or about March 14, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia system pumps.   (h) On or about March 14, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia system evaporators (AU 10, 11, 12, 15, 16, 17, 18).   (i) On or about March 14, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia system condensers (EC-01 &02).   (j) On or about March 22, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia Make-up Air Unit including, but not limited to, AHU-01.  (k) On or about June 20, 2024, equipment specific written procedures to include inspection and testing criteria were not provided for the anhydrous ammonia machinery room ventilation system.

Issued

Aug 7, 2024

Abate by

Sep 26, 2024

Penalty

Initial $0 · Current $0

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 manufacturer's recommendations and good engineering practices, or more frequently determined to be necessary by prior operating experience:  (a) On or about March 14, 2024, annual inspection and testing of anhydrous ammonia pressure vessels to include safety shutdown systems such as, but not limited to, the float switch sensors were not provided for the following vessels: the INT-01 Intercooler, the LTRP-01 Low Temperature Recirculator, the surge drums (FF-SD-01 & 02, MAU-01-SD-01), and the TV-01 Transfer Vessel.  (b) On or about March 14, 2024, annual inspection and testing of the anhydrous ammonia compressors (1-6)  safety shutdown systems were not provided.

Issued

Aug 7, 2024

Abate by

Sep 26, 2024

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR  1910.119(j)(4)(iv):The documentation of each inspection and test that was performed on the process did not identify the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other identifier of the equipment on which the inspection or test was performed, a description of the inspection or test performed, and the results of the inspection or test:  Documentation of inspection and testing incorporated a checklist that did not include all required information per (j)(4)(iv) to include, but not be limited to, the following inspections:   (a) On or about June 20, 2024, the inspection conducted on the ventilation system did not identify the equipment in which the inspection or test was performed as well as the results of the inspection or test.   (b) On or about March 22, 2024, the inspection conducted on the AHU-01 Make-Up Air Unit did not identify results of the inspection or test.

Issued

Aug 7, 2024

Abate by

Sep 26, 2024

Penalty

Initial $1,068 · Current $748 Reduced

General-duty citation text

29 CFR 1910.22(d)(1): The employer did not ensure that walking-working surfaces are inspected, regularly and as necessary, and maintained in a safe condition:  (a) Roof; On or about March 14, 2024, employees were exposed to slips and falls as the white roof walking surface was slippery.