Text For Citation: 01 Item/Group: 002 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 explosion and struck by hazards during startup and operation of power boilers: The employer does not ensure that two boilers are installed, maintained and operated safely. This was observed on September 17, 2009. Unsafe installation and maintenance included, but was not limited to: Boiler No. 2: Cleaver Books model CB-700-150, serial number L92425: 1) did not have pipe fittings installed to allow for leak testing of each main burner safety shutoff valve. These devices are required by ASME CSD-1-2009, Controls and Safety Devices for Automatically Fired Boilers. 2) did not have a safety shutoff valve installed on the gas pilot line, as required by section CF-180(c) of ASME CSD-1-2009. 3) Boiler No. 2 safety valves did not vent steam to a safe location. The two safety valves discharged horizontally into a plenum area between two roof assemblies where the steam is horizontally directed towards a pedestrian path. 4) Two safety valves on Boiler No. 2 were incorrectly installed. Safety valve piping discharges to a pedestrian path. Piping is not anchored to counter reactions forces during steam discharge from relief valves as required by 2007 ASME Boiler & Pressure Vessel Code Section VIII, Division 1, Subsection A, part UG-135(f), Appendix M-12(a) of the 2009 ASME Boiler & Pressure Vessel Code, Section VIII, Division 1 and Recommended Guidelines for the care of Power Boilers, 2007 BPVC Section VII. 5) There was no evidence of a periodic maintenance program for boiler No. 2 as mandated by Section CM-130 of ASME CSD-1-2009, Controls and Safety devices for Automatically Fired Boilers. 6) Safe operating procedures for the boiler were not documented, and the only licensed boiler operator does not remain on the site whenever the boilers are in operation. For Boiler No. 1, a Williams & Davis model 777, National Board no. 5913: 1) The single safety valve on top of boiler No. 1 did not vent steam to a safety location. The safety valves discharged directly into the boiler room. National Board Inspection Code, Part 1 Section 5.3.6.f requires pressure relief device discharges to be arranged such that they are not a hazard to personnel or otherequipment. 2009 ASME Boiler & Pressure Vessel Code, Section VIII, Division 1, Subsection A, Part UG-135(f) requires discharge lines from pressure relief devices be designed to discharge to a safe location. 2) The single safety valve was incorrectly installed. The discharge piping is not supported or restrained. 2009 ASME Boiler & Pressure Vessel Code, Section VIII, Division 1, Subsection A, Part UG-135(f) requires that discharge lines from pressure relief devices do not reduce the relieving capacity of the devices. Appendix M-12(a) of the 2009 ASME Boiler and Pressure Vessel Code, Section VIII, Division 1 and ASME 2007 Boiler and Pressure Vessel Code, Section VII Recommended Guidelines for the care of Power Boilers require anchoring of discharge piping to counter reaction forces when steam discharges from the safety valve. 3) There was no pipe fitting installed to allow for independently leak testing each main burner safety shutoff valve, as required by Section CF-180(g) of ASME CSD-1-2009, Controls and Safety Devices for Automatically Fired Boilers. 4) There was no documented safe operating procedures for boiler operators and the only licensed boiler operator did not remain on the site at all times when the boiler was in operation. Among others, feasible and acceptable methods to abate these conditions include, but are not limited to: installation of pipe fittings on boilers 1 and 2 for the purpose of allowing a gas leakage test in accordance with ASME CSD-1-2009, Controls and Safety devices for Automatically Fired Boilers, and inclusion of such a test in lockout/tagout procedures; Installation of safety shutoff valve on the gas pilot line of Boiler #2 fuel train as required by ASME CSD-1-2009; Repositioning of steam vents on Boilers No. 1 and 2, and adequate restraint of pressure relieving devices in accordance with ASME Boiler & Pressure Vessel Code, Section VIII, Subsection A, Part UG-135; insure that boiler isolation methods are included in boiler lockout tagout procedures, including complete closure and blocking or locking of steam safety shutoff valves per Section C6.310 of ASME 2007 Boiler and Pressure Vessel Code Section VII, Recommended Guidelines; Installation of safety valves per Nation Board Inspection Code, Part 1, section 5.3.6.f, insuring that steam is vented to a safe location; Develop and implement a formal system of periodic preventive maintenance per the requirements in Section CM-130 of ASME CSD-1-2009, and develop and implement boiler user instructions per ASME 2007 Boiler and Pressure Vessel Code, Section VII, Recommended Guildelines for the care of Power Boilers. Pursuant to 29 C.F.R 1903.19, within ten (10) calendar days from the abatement date for this citation, the employer must submit documentation showing that it is in compliance with the standard, including describing compliance with the installation, maintenance, and operation provisions for Boilers and Pressure Vessels.