Text For Citation: 01 Item/Group: 007 Hazard:

29 CFE 1910.119(j): Mechanical integrity. 29 CFR 1910.119(j)(5):The employer did not correct deficiencies in equipment that were outside acceptable limits (defined by the process safety information on paragraph (d) of this section) before use: Or or about February 28, 2024, the employer had not corrected equipment deficiencies that were outside acceptable limits defined by process safety information; in that equipment was operated with relief system vent line process piping being disconnected from the AC Tower 1 when that piping was documented in P&IDs as connected to the AC Tower 1 equipment. The CESS vent line is connected to relief systems for ten ASME code pressure vessels in the CESS storage area and was disconnected from the AC Tower 1 relief system discharge location. The CESS storage area relief vent line had become "plugged" or blocked by electrolyte material discharged into the piping and was discovered to be leaking electrolyte on December 4, 2023. When attempts to clear the blocked relief vent line failed, the process piping was disconnected and capped on December 9, 2023. As of February 28, 2024, the deficiency in the CESS Storage Area pressure vessel relief system had not been corrected by re-establishing the process piping pathway to the AC Tower 1 discharge location. During an overpressure event, overpressure protection relief systems for pressure vessels are intended to discharge to a safe location, when the pathway for the discharge is blocked and then disconnected, the risk for catastrophic release of highly hazardous chemical from the covered process is increased.