Text For Citation: 01 Item/Group: 010 Hazard:

29 CFR 1910.119(j)(4)(ii): Inspection and testing procedures did not follow recognized and generally accepted good engineering practices (note: this standard applies to pressure vessels and storage tanks; piping systems (including piping components and valves); relief and vent systems and devices; emergency shutdown systems; controls (including monitoring devices and sensors, alarms, and interlocks) and; pumps as referenced by sections (j)(1)-(j)(1)(vi) of this standard): a) Ammonia Room - The compressor motors and drive guards were not inspected for wear on the bearing surfaces as per IIAR B110 section 6.3.2. On or about 2/8/12. b) Ammonia Room - The compressor and motor drive alignment were not inspected annually as per IIAR B110 section 6.3.2. On or about 2/8/12. c) Ammonia Room - The condition and tightness of the foundation bolts was not checked annually as per IIAR B110 section 6.3.2. On or about 2/8/12. d) Ammonia Room and Production Areas - The scope of the 5 year independent full inspection did not cover all vessels and heat exchangers, of which conditions not in compliance with the standards and RAGAGEP were noted as per IIAR B110 section 6.4.4.1 (Independent Full Inspection). On or about 2/8/12. e) Ammonia Room - A detailed examination of the external surface or of the insulation applied to the external surface of vessels and heat exchangers was not made at intervals of no more than 12 months. Pump Recirculators A8 and A9 had not been inspected as per IIAR B110 section 6.4.3- Annual Inspection. On or about 2/8/12. f) Ammonia Room - Inspections of underlying vessels or heat exchangers such as but not limited to Pump Recirculators A8 and A9 were not carried out when insulation was unsound or damaged as per IIAR B110 section 6.4.4.3. On or about 2/8/12. g) Ammonia Room and Productions Areas - Access to pumps and adjacent lines was not ensured preventing access and visual inspection for pumps and associated piping including but not limited to HV 926 and HV 923 as per IIAR B110 section 6.5.2. On or about 2/8/12. h) Ammonia Room - All insulated piping and associated components such as flanges and supports were not inspected annually for damage to or deterioration of the piping or its protective finish as per IIAR B110 section 6.7.1. Pitting and rusting was noted on Equalizing line 3-EQ-152 (P&ID 102A). On or about 2/8/12. i) Ammonia Room - All insulated piping and associated components such as flanges and supports were not inspected annually for damage to or deterioration of the piping or its protective finish as per IIAR B110 section 6.7.1. Pitting and rusting was noted on the the Trap from Condensers to Receivers 3-304-HPL (P&ID 102A). On or about 2/8/12. j) Ammonia Room - All insulated piping and associated components such as flanges and supports were not inspected annually for damage to or deterioration of the piping or its protective finish as per IIAR B110 section 6.7.1. Pitting and rusting was noted on 2-HPL-302 to Intermediate Accumulator A1 from Receivers (P&ID 102A & 103A). On or about 2/8/12. k) Ammonia Room - All insulated piping and associated components such as flanges and supports were not inspected annually for damage to or deterioration of the piping or its protective finish as per IIAR B110 section 6.7.1. Pitting and rusting was noted on 6-HPL-309 painted over pipe (P&ID 107A). On or about 2/8/12. l) Ammonia Room - All insulated piping and associated components such as flanges and supports were not inspected annually for damage to or deterioration of the piping or its protective finish as per IIAR B110 section 6.7.1. Pitting and rusting was noted on 2-HPL-350 to Flash Intercooler A8 (P&ID 102A & 110B). On or about 2/8/12. m) Ammonia Room - All insulated piping and associated components such as flanges and supports were not inspected annually for damage to or deterioration of the piping or its protective finish as per IIAR B110 section 6.7.1. Pitting and rusting was noted on Pipe and hand valve off of Receiver R1 into site glass 2HV 104 (no pipe number) (P&ID 102A). On or about 2/8/12. n) Ammonia Room and Production Areas - The external condition of the insulation and supports were not inspected annually as per IIAR B110 section 6.7.2. On or about 2/8/12. o) Ammonia Room - Sections of insulation which were in poor condition were not removed and the integrity of the exposed piping was not determined with the aid of non-destructive testing techniques as per IIAR B110 section 6.7.2. Ice breaking through insulation was noted including but not limited to pipes associated with valves 10HV 915, 10 LAH 916, 10 M 936, 10 HV 918, 10 HV 917, line going into top of Pump Recirculator A9 1-LTRL-674-3, LTRL-675-3, LTRL-676-3 and Pump Recirculator A10 3-LTRL-691-3 in the area near 3 HV 1022, 1065, 1063. On or about 2/8/12. p) Ammonia Room - Protective coatings, insulation and vapor seal was not re-applied as per IIAR B110 section 6.7.2. On or about 2/8/12. NOTE: THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT CERTIFICATION FOR THIS ITEM. FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.