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

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: a- Bayway Chemical Plant, Lofi Unit - A 3/4 inch block valve on the inlet of the 7E20 (7R20 P/A Heater) safety valve was not included on P&ID 12566-66BA-1TC Sheet 1 of 1 Revision Number 15. On 01/21/10 workers failed to lock out the above noted block valve resulting in a mechanic being splashed with heated product from the 7R20 Lofi Reactor while removing the safety valve. Feasible and acceptable methods among others to correct these hazards include: Update the above noted P&ID and ensure that all P&IDs on non-PSM covered units are accurate and include all process equipment as per CCPS Guidelines for Process Safety Documentation, Section 5.2.2. b- Bayway Chemical Plant, Calcium Phenate Unit - Block valves on the inlet lines to safety valves for the 10D8 Lower Layer Solvent Drum, 10D9 Upper Layer Solvent Drum and 10D10 Upper Layer Solvent Drum were not car-sealed in their open positions. Condition noted on or about 12/02/10. Feasible and acceptable methods among others to correct these hazards include: On non-PSM covered units provide adequate controls to ensure that intervening valves on the upstream or downstream lines to/from relief devices remained in the open position during pressure vessel operation as per ASME Boiler and Pressure Vessel Code, Division 1 (BPVC), Section VIII, UG-135(d). c- Bayway Chemical Plant, Polybutene Mechanical Shop and LM Finishing Building - Workers were exposed to blast injuries from flying projectiles (glass windows and corrugated metal/fiberglass walls) as a result of exposure to vapor cloud explosions and associated overpressures of 1-3 psi. Condition noted on or about 02/19/10. Feasible and acceptable methods among others to correct these hazards include such as but not limited to complying with API 752 Management of Hazards Associated with Location of Process Plant Buildings: Perform mitigation measures found in API 752 Section 3.3.7.2 to include relocating personnel, eliminating/modifying windows, strengthening doorways, installing external walls for explosion/projectile protection and/or constructing new explosion-resistant structures.esistant