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Violation Detail
Standard Cited: 19100119 J02 Process safety management of highly hazardous chemicals.
Inspection Nr: 1044850.015
Citation: 01006A
Citation Type: Serious
Abatement Date: 09/25/2015 2
Initial Penalty: $7,000.00
Current Penalty: $3,500.00
Issuance Date: 09/02/2015
Nr Instances: 6
Nr Exposed: 4
Related Event Code (REC): C
Gravity: 10
Report ID: 0729700
Contest Date:
Final Order: 09/22/2015
Emphasis:
| Type | Latest Event | Event Date | Penalty | Abatement Due Date | Citation Type | Failure to Abate Inspection |
|---|---|---|---|---|---|---|
| Penalty | I: Informal Settlement | 09/22/2015 | $3,500.00 | 09/25/2015 | Serious | |
| Penalty | Z: Issued | 09/02/2015 | $7,000.00 | 09/25/2015 | Serious |
Text For Citation: 01 Item/Group: 006A Hazard:
29 CFR 1910.119(j)(2): The employer did not establish or implement written procedures to maintain the on-going integrity of process equipment: Employees engaged in production activities throughout the facility were exposed to chemical hazards associated with the catastrophic release of Ammonia in that the employer did not establish and implement the written mechanical integrity program procedures to ensure the on-going integrity of process equipment such as pressure vessel, storage tanks, piping, emergency shutdown equipment, controls (monitors, high level alarms), relief venting equipment, and pumps. The employer did not address procedures for repairing, rerating, or replacing pressure vessels, receivers, piping, or materials and spare parts control, authorizations, and approval for repairs, steps to accomplish for repairing or replacing equipment, frequency of replacement, employee training and qualifications, welding and heat treating requirements, inspection and testing after repair, and documentation requirements. a) The employer did not develop and implement a comprehensive written mechanical integrity procedure that addressed inspecting pressure vessels, piping for corrosion under the insulation and minimum wall thickness. b) The employer did not develop and implement a written mechanical integrity procedure for evaluating valves such as the King valve in the ammonia process. c) The employer did not develop and implement a written mechanical integrity procedure for evaluating relief and vent systems and devices. d) The employer did not develop and implement a written mechanical integrity procedure for evaluating emergency shutdown systems. e) The employer did not develop and implement a written mechanical integrity procedure for evaluating controls (including monitoring devices and sensors, alarms, and interlocks). f) The employer did not develop and implement a written mechanical integrity procedure for evaluating pumps. 29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is completed.