Text For Citation: 02 Item/Group: 003 Hazard: REFINERY

29 CFR 1910.119(m)(1): The employer did not investigate each incident which resulted in, or could reasonably have resulted in, a catastrophic release of a highly hazardous chemical in the workplace: ALON USA, LP, 200 Refinery Road, Big Spring, TX. The employer does not ensure incident investigations are conducted for each incident that could reasonably result in a catastrophic release of highly hazardous chemical in the workplace. This violation was observed on or about April 15, 2009 in the following instance: a. Incident 09-062, On April 21, 2009, the #2 SCOT full flow filters auto ignited at site "J". Water and foam was sprayed on the filters, but they continued to auto ignite. The uncontrolled fire could have resulted in generation of H2S, or SO2, H2SO4 resulting in a toxic release and injury to employees. A backhoe was used to cover the filters with catalyst from the ESP and dirt. The uncontrolled fire could have resulted in generation of H2S, or SO2, H2SO4 resulting in a toxic release and injury to employees. b. Incident 09-056, On April 13, 2009, Cathey Construction set grass on fire at Rail Spur 745 while cutting shipping blocks from boiler. Approximately 50' x 100' area was affected. Fire was extinguished by workers on site with portable fire extinguishers. The uncontrolled grass fire could ignite hydrocarbons in the crude unit. c. Incident 09-049, On March 25, 2009, there was a smoldering sulfur fire on the ground at #4 dipleg at #1 Sulfur Recovery Unit. Operators and Safety responded to extinguish the problem. The uncontrolled fire could have resulted in generation of H2S, or SO2, H2SO4 resulting in a toxic release and injury to employees. d. Incident 09-037, on February 25, 2009, the insulation blanket on the bottom flange of the west LDH reactor caught on fire. This was removed during catalyst replacement and caught on fire when the unit was brought back on line and on temperature. The uncontrolled fire could result in ignition of the light distillates processed in the LDH. e. Incident 09-021, On February 1, 2009, The Northside operator found the Aromex sewer box overflowing benzene onto the slab. Aromex stripper overhead receiver water boot level appeared to have stuck at high level, dumping all the water and a lot of hydrocarbon into the already full accumulator which in turn overflowed and overwhelmed the sewer box. The uncontrolled release could have resulted in an explosion / fire of the hydrocarbons as they vaporized and encountered an ignition source f. Incident 09-003, On January 6, 2009, The seal was leaking on the reflux pump 10P038 and ignited a small flame. Operator went after a fire extinguisher and the flame was out when he returned to put it out. The uncontrolled fire could have ignited product in the pump. ALON USA, LP WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIVALENT STANDARD 29 CFR 1910.119(M)(1) WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER 307249987, CITATION NUMBER 01, ITEM NUMBER 008, ISSUED ONAUGUST 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 workplace to investigate each incident which results in, or could reasonably be expected to result in, a catastrophic release of a highly hazardous chemical in the workplace.