Text For Citation: 01 Item/Group: 043 Hazard:

29 CFR 1910.119(j)(4)(iv): The employer shall document each inspection and test that has been performed on process equipment. The documentation shall identify the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other identifier of the equipment on which the inspection or test was performed, a description of the inspection or test performed, and the results of the inspection or test: Inspections and tests were not documented for process equipment, including but not limited to: a. 35R reactor: For an August 2010 equipment inspection, the employer did not document the testing equipment or methodology for thickness testing, complete specific testing data was not maintained, the date of testing, and serial number, the U-1 information or other specific identifying information was not documented. The employer did not have the information in a complete inspection report, or in an equipment and/or inspection file. b. 5R reactor: For a May 2008 inspection, complete specific testing data was not maintained, the equipment serial number, board number, U-1 or data plate information was not documented, the employer did not document the testing equipment or methodology for thickness testing and glass liner testing and/or a description of the inspection or test performed. For an August 10, 2010 inspection, the employer did not document the testing equipment or methodology for thickness testing and glass liner testing. Due to the lack of specific identifier(s) for the May 2008 inspection, thickness data for a new 5R reactor was compared to a reactor that was replaced in 2009. c. 1R reactor: For a December 2009 inspection, the employer did not document the testing equipment or methodology for thickness testing and glass liner testing and/or a description of the inspection or test performed. d. 72R reactor: A September 2011 inspection did not document the testing equipment or methodology for thickness testing, the equipment serial number, board number, U-1 or data plate information was not documented and/or a description of the inspection or test performed was not documented. e. 75R reactor: A September 2011 inspection, the equipment serial number, board number, U-1 or data plate information was not documented, the employer did not document the testing equipment or methodology for thickness testing, and/or a description of the inspection or test performed. f. 40R reactor: For a May 2008 inspection, specific thickness measurement testing data for each thickness measurement location was not documented for this vessel. The report summary lists ranges of values and the Corrosion Monitoring Report data table is not populated with the thickness measurement for each thickness monitoring location. g. 45R reactor: For a February 2011 inspection, specific thickness measurement testing data for each thickness measurement location was not documented for this vessel. The report summary lists single values and the Corrosion Monitoring Report data table was not populated with the thickness measurement for each thickness monitoring location. h. 133T storage tank: For a 2002 inspection, no documentation exists. This inspection is referenced in an August 2010 inspection and used in remaining life calculations for this vessel. i. For the following equipment inspections the employer did not document the testing equipment or methodology for thickness testing and/or a description of the inspection or test performed: 4R reactor August 2010 and December 2002, 34R reactor January 2011, 19R May 2008, 2R reactor December 2009, 18R reactor August 2011, 20 reactor (Chlorination R-032-01) May 2008, 38R receiver October 2010, 51R August 2011, 52R January 2011 and 58R August 2011. j. Relief device testing, inspection, recertification and replacement was not documented for the following phosphites department vessels: 34R reactor - rupture disk, 35R reactor - rupture disk, 48R phenol receiver - rupture disk, 51R reactor- rupture disk and pressure relief valve, 72R reactor - rupture disk, 133T storage tank - rupture disk and pressure relief valve, 308T knockout pot - rupture disk, and 425T receiver - rupture disk. k. A 2008 piping inspection of the PCl3 loading line was not documented.