Text For Citation: 01 Item/Group: 001 Hazard: UNAPEQUIP

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: 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 in that employees were exposed to fire and explosion hazards. 1) The employer fails to ensure that the burner management system on boilers located within the facility are in compliance with NFPA 85 Boiler and Combustion Systems Hazards Code 5.3.7.1 and 5.7.2, as well as manufacturer's and design specifications. 2) Perform a risk assessment to identify, evaluate and control the hazards involved with the process in accordance with ANSI/ISA S.84.001 and IEC-61511. 3) Ensure that the boiler maintenance training program for the facility is in compliance with NFPA 85 Boiler and Combustion Systems Hazards Code 4.4.2.2.1 and 4.4.2.2.2: 1)a)This violation most recently occurred at the Valero Refining facility in Texas City, Texas on or about December 4, 2009, and times thereto, when the employer failed to ensure that the response time from flame failure to de-enerigization or closure of the safety shutoff valve did not exceed four seconds on B-28 Boiler. ABATEMENT NOTES: Among other methods, one feasible method of abatement to reduce this hazard is to: Follow the requirements of the National Fire Protection Agency Code 85 Boiler and Combustion Systems Hazards Code (NFPA 85) Section 5.3.7.1, which states that the response time from flame failure to de-energization of the safety shutoff valves shall not exceed four seconds. Note: In addition to abatement certification, the employer is required to submit within 10 calendar days after abatement date, documentation for this item in accordance with 29 CFR 1903.19. b)This violation most recently occurred at the Valero Refining facility in Texas City, Texas on or about December 4, 2009, and times thereto, when the employer failed to ensure that the fuel flow control valve on Boiler B-28 was equipped with an interlock action that would trip fuel flow when the flow control valve left a predetermined setting during the light off sequence. ABATEMENT NOTES: Among other methods, one feasible method of abatement to reduce this hazard is to: Follow the requirements of the National Fire Protection Agency Code 85 Boiler and Combustion Systems Hazards Code (NFPA 85) Section 5.7.2 The following equipment shall be required: A safety interlock system with the capability to provide interlock action that will trip fuel should its flow control valve leave a predetermined setting during fuel transfer. Note: In addition to abatement certification, the employer is required to submit within 10 calendar days after abatement date, documentation for this item in accordance with 29 CFR 1903.19. c)This violation most recently occurred at the Valero Refining facility in Texas City, Texas on or about December 4, 2009, and times thereto, when the employer failed to ensure that the solenoid installed on the main fuel gas control valve798A was appropriate and that the equipment was installed properly and consistent with design specifications and the manufacturer's instructions. ABATEMENT NOTES: Among other methods, one feasible method of abatement to reduce this hazard is to: Follow the requirements of the design specifications and the manufacturer's instructions, which states that Solenoid valves shall be 24 VDC low power type. Note: In addition to abatement certification, the employer is required to submit within 10 calendar days after abatement date, documentation for this item in accordance with 29 CFR 1903.19. 2)a)The employer failed to ensure that the process hazard analysis performed was appropriate to the complexity of the process and did not identify, evaluate and control the hazards involved in the process. This violation most recently occurred at the Valero Refining facility in Texas City, Texas, on or about December 04, 2009, and times thereto, when the employer failed to identify, evaluate and control the hazard of the main fuel gas flow control valve failure on the B28 Boiler. ABATEMENT NOTES: Among other methods, one feasible method of abatement to reduce this hazard is to: Follow the requirements of the IEC-61511 and ANSI/ISA 84.001 which requires the employer to perform a risk assessment to identify and address the hazards and hazardous events that could occur under all reasonably foreseeable circumstances. Note: In addition to abatement certification, the employer is required to submit within 10 calendar days after abatement date, documentation for this item in accordance with 29 CFR 1903.19. 3)a)The employer did not establish a formal training program that was consistent with the equipment and hazards involved, before allowing maintenance personnel to perform all required maintenance task. This violation most recently occurred at the Valero Refining facility in Texas City, Texas on or about December 4, 2009, and times thereto, when the employer failed to establish a program that would train maintenance personnel on, the maintenance of and the hazards associated with working on B26, B27 & B28 Boilers. ABATEMENT NOTES: Among other methods, one feasible method of abatement to reduce this hazard is to: Follow the requirements of the National Fire Protection Agency Code 85 Boiler and Combustion Systems Hazards Code (NFPA 85) Section 4.4.2.2.1, which states the owner or owner's representative shall be responsible for establishing a formal and ongoing program that is consistent with the equipment and hazards involved, for training maintenance personnel to perform all required tasks. Note: In addition to abatement certification, the employer is required to submit within 10 calendar days after abatement date, documentation for this item in accordance with 29 CFR 1903.19. b)The employer did not ensure that Maintenance procedures and their associated training programs were established to cover routine and special techniques. This violation most recently occurred at the Valero Refining facility in Texas City, Texas on or about December 4, 2009, and times thereto, when the employer failed to develop a procedure and provide training for the winterization process on B26, B27 & B28 Boilers. ABATEMENT NOTES: Among other methods, one feasible method of abatement to reduce this hazard is to: Follow the requirements of the National Fire Protection Agency Code 85 Boiler and Combustion Systems Hazards Code (NFPA 85) Section 4.4.2.2.2 which states that maintenance procedures and their associated training programs shall be established to cover routine and special techniques. Note: In addition to abatement certification, the employer is required to submit within 10 calendar days after abatement date, documentation for this item in accordance with 29 CFR 1903.19.