Text For Citation: 02 Item/Group: 002 Hazard: REFINERY

29 CFR 1910.119(j)(4)(iii): The employer did not ensure the frequency of inspections and tests of process equipment to maintain its mechanical integrity, was consistent with applicable manufacturers' recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience: ALON USA, LP, 200 Refinery Road, Big Spring, TX. The employer does not ensure the frequency of inspections and tests of process equipment to maintain its mechanical integrity is consistent with applicable manufacturers' recommendations and good engineering practices such as, but not limited to API and ASME, or more frequently when determined to be necessary by prior operating experience. This violation was observed on or about April 15, 2009 in the following instances: a) The Alky Plant Air water knockout drum in the plant air system to the Alkylation Unit, operated at a pressure at 85 psig. No inspection records were available for this pressure vessel, designated as 011D-036. This vessel, calculated to have a volume of approximately 11 cubic feet, was clearly required by ASME / API 510 to be provided with regular vessel inspections. b) The Clark Compressor Knockout Drum, feeding a hydrogen stream to the Clark compressor in the Diesel Hydrotreater Unit, operated at a pressure of up to 260 psig. This vessel, designated as 080D-009, received its last internal inspection in 1991 and was due for inspection in 2001. c) The Sour Water Stripper drum in the #2 Sulfur Recovery Unit, designated as 071D-002, operated at a pressure of 22 psig. This vessel had not been inspected since 1991 and was due in 1996. d) The Sulfur Condenser in the #2 Sulfur Recovery Unit, designated as 071E-002, operated at a pressure of 60 psig. This vessel had not been inspected since 1997 and was due in 2007. e) The #2 SCOT Stripper Reboiler, designated as 072D-001, operated at a pressure of 26 psig. It had not been inspected since 1991 and was due in 1996. f) The #2 SCOT Stripper Reflux Drum, designated as 072D-002, operated at a pressure of 112 psig. It had not been inspected since 1996 and was due in 2006. g) The #2 SCOT Waste Heat Exchanger, designated as 072E-001, operated at a pressure of 60 psig. It had not been inspected since 1996 and was due in 2006. h) The #2 SCOT Lean / Rich Exchangers, designated as 072E-004A and B, operated at a pressure of 50 psig. They had not been inspected since 1998 and were due in 2008. i) The #2 SCOT Rich Amine Filter, designated as 072FL-007, operated at a pressure of 92 psig. It had not been inspected since 1998 and was due in 2008. j) The #2 SCOT Lean Solvent Filter, designated as 072FL-003, operated at a pressure of 50 psig. It had not been inspected since 1991 and was due in 1996. k) The #2 SCOT Solvent Drips Filter, designated as 072FL-006, operated at a pressure of 50 psig. It had not been inspected since 1991 and was due in 1996. l) The Sour Water Stripper Reflux Coolers, designated as 074E-003A and B, operated at a pressure of 42 psig. They had not been inspected since 1996 and were due in 2006. m) The Sour Water Stripper Reflux Air Heaters, designated as 074E-004A and B, operated at a pressure of 175 psig. They had not been inspected since 1991 and were due in 2001. ALON USA LP WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIVALENT STANDARD 29 CFR 1910.119(j)(4)(iii) WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER 307249987, CITATION NUMBER 1, ITEM NUMBER 5, ISSUED ON AUGUST 14, 2008, WITH RESPECT TO A WORKPLACE LOCATED AT 200 REFINERY ROAD, BIG SPRING, TX. Pursuant to 29 C.F.R. 1903.19, within ten (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 that it is taking in the facility to ensure the frequency of inspections and tests of process equipment to maintain its mechanical integrity, is consistent with applicable manufacturers' recommendations and good engineering practices, such as, but not limited to API and ASME, or more frequently determined to be necessary by prior operating experience.