Text For Citation: 01 Item/Group: 019 Hazard: REFINERY

29 CFR 1910.119(j)(2): The employer does not establish and implement written procedures to maintain the on-going mechanical integrity of process equipment: (a) This violation occurred on or about January 27, 2009, and times prior thereto, where the employer failed to develop a written procedure for the inspection for corrosion under insulation for pressure vessels in Crude Unit #2. This condition exposed employees to a fire and explosion hazard. Pursuant to 29 CFR 1903.19(d), within 10 calendar days of the date of this citation, the employer must submit documentation showing that it is in compliance with the standard, including describing the steps it is taking to ensure that an inspection procedure for the determination of corrosion under insulation is developed and implemented. (b) This violation occurred on or about January 27, 2009, and times prior thereto, where the employer did not implement a Mechanical Integrity Procedure that required piping inspections to be based on a classification system that prioritizes piping inspections based on consequences of failure. Product piping circuits in Crude Unit #2 such as, but not limited to, Kerosene piping lines (3"-K-20176, 4"-K-20179, 4"-20193, and 3"-K-20201); Diesel piping lines (4"-D-20177, 3"-D-20178, 4"-D20194, 3"-D-20185, 8"-D-50360, and 8"-D-50361); Light Naphtha piping lines (6"-LN-20149, 4"-LN-20150, 3"-LN-20151, 3"-LN-20152, 3"-HN-20224 and 3"-HN-20225) were not given a consequence of failure classification (Class 1, Class 2 or Class 3) as prescribed by API 570 - Piping Inspection code to determine the extent and frequency of inspection. This condition exposed employees to a fire and explosion hazard. Pursuant to 29 CFR 1903.19(d), within 10 calendar days of the date of this citation, the employer must submit documentation showing that it is in compliance with the standard, including describing the steps it is taking to ensure that a piping inspection procedure is developed and implemented that ensures piping circuit mechanical integrity inspections include a consequence of failure classification system. (c) This violation occurred on or about January 27, 2009, and times prior thereto, where the employer did not have the complete owner's equipment manuals for pumps P202A&B-Overhead Reflux & Product Pumps, in Crude Unit #2 which provides minimum preventive maintenance requirements. This condition exposed employees to a fire and explosion hazards. (d) This violation occurred on or about January 27, 2009, and times prior thereto, where the employer did not have complete owner's equipment manuals for pumps P2HN1&P2HN2-Heavy Naphtha Pumps, Crude Unit which provides minimum preventive maintenance requirements. This condition exposed employees to a fire and explosion hazards. Pursuant to 29 CFR 1903.19(d), within 10 calendar days of the date of this citation, the employer must submit documentation showing that it is in compliance with the standard, including describing the steps it is taking to ensure that the owner's equipment manuals are being assembled in their entirety. (e) This violation occurred on or about January 27, 2009, and times prior thereto, where the employer did not outline the training and qualifications each employee would be required to have to maintain the on-going integrity of process equipment. There was no standard training program for I&E Technicians, mechanics and millwrights working in the covered process. This condition exposed employees to a fire and explosion hazard. Pursuant to 29 CFR 1903.19(d), within 10 calendar days of the date of this citation, the employer must submit documentation showing that it is in compliance with the standard, including describing the steps it is taking to ensure that the employer completely develops a written mechanical integrity program, that outlines in detail what training will be required and provided to I&E Technicians, mechanics and millwrights.