Text For Citation: 01 Item/Group: 015 Hazard:

29 CFR 1910.119(j)(2): Written procedures. The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment: a. The employer did not establish and implement written procedures to maintain the on-going integrity of storage tanks/process tanks such as the premix tank, off-spec premix tank, paddle blender, intermediate product tanks 1/2 and 1A/2A, recycle tank/hopper, and raw material storage tanks in the Packaged Emulsion Production Building #1. b. The employer did not establish and implement written procedures to maintain the on-going integrity of piping systems including piping components such as valves in the Packaged Emulsion Production Building #1. c. The employer did not establish and implement written procedures to maintain the on-going integrity of piping systems including piping components such as filter baskets in the PETN Dryer Building #1. d. The employer did not establish and implement written procedures to maintain the on-going integrity of emergency shutdown systems in the Packaged Emulsion Production Building #1. e. The employer did not establish and implement written procedures to maintain the on-going integrity of relief and vent systems and devices such as safety relief valves and pressure reducing valves on the steam piping for the kettles in Booster Pour Buildings #1, 2, and 3. f. The employer did not establish and implement written procedures to maintain the on-going integrity of controls such as high pressure sensors, alarms, and shutdown for emulsion pumps; programmable logic controller (PLC) to detect and resolve problems during emulsion pumping process; high level alarms for blender and oxidizer bin 2; and high temperature safety steam valve shut down on fuel tanks in the Emulsion Manufacturing process/unit. g. The employer did not establish and implement written procedures to maintain the on-going integrity of controls such as speed switches and diameter gauging devices on first spin machines to stop the machine in case of a jam; laser safety sensor detection devices for detecting over and under sized cord and shutting down the measuring, sizer, overspin, and rewind machines; extruder safety sensor detection device with warning light and buzzer; speed switches on over spin machines to stop the machine when there was a cord jam; cord cut-off devices to prevent spool detonations in the sizing operation; regulated steam pressure for the PETN dryer; and high temperature safety shutoff switch on the PETN dryer in the Detonating Cord Manufacturing process/unit. h. The written procedure LP-ENG-605, Testing Allweiler Stator, and procedure Allweiler Pumps: 3 or 6 - Month Inspection and Maintenance, which addressed testing the Allweiler pump stator monthly and semi-annually, respectively, were not updated to reflect the actual practice of not performing pump stator testing due to the annual Allweiler pump rebuild schedule in the Packaged Emulsion Production Building #1. i. The employer did not establish and implement written quality assurance procedures to assure that equipment, maintenance materials, and spare parts were suitable for the process application for which they would be used in the following covered processes/units: Cast Booster Manufacturing, Detonating Cord Manufacturing, and Emulsion Manufacturing.