Text For Citation: 01 Item/Group: 006 Hazard:

29 CFR 1910.119(j)(2): The employer did not establish written procedures to maintain the on-going integrity of process equipment: Employees engaged in operating, inspecting, testing, and maintaining activities or performing other critical operations before evacuating such as turning valves on the roof to isolate leaks on the floor at the covered process equipment throughout the plant were exposed to the hazards of being struck-by over-pressured equipment and toxic ammonia inhalation and burns in that the employer fails to fully implement its mechanical integrity procedure, when it did not replace safety relief valves every 5 years or sooner if necessary. The employer did not ensure that the safety relief valves were removed and replaced within 5 years, or developed an alternative replacement interval based on documented in-service relief valve life, or followed the manufacturer's replacement frequency recommendation. Instances where relief valves needed to be changed out include but are not limited to the following: a) HS06-OS; Valve Number HS06-9, 10 Hansen Model H5601, supposed to be changed out by January 2016. b) PO01-OS; Valve Number PO01-9, 10 Hansen Model H5600R, supposed to be changed out by December 2016. c) PO01-TOC; Valve Number PO01-40 Cyrus Shank Model 803-LQ, no information on install date or replace by date. As a result, the service life of this PRV could not be determined, preventing the employer from knowing exactly when the PRV was installed and when it should be replaced. d) PO Oil Pot; Valve Number ACC04-11 Cyrus Shank Model 803-D, no information on install date or replace by date. As a result, the service life of this PRV could not be determined, preventing the employer from knowing exactly when the PRV was installed and when it should be replaced. e) WC Srg Drm; Valve Number Z1-20, 21 Hansen Model H5600R, supposed to be changed out by October 2017. f) PO Vessel; Valve Number ACC04-21, 22 Cyrus Shank Model 812, supposed to be changed out by January 2016. g) Blood Chiller; Valve Number Z66-21, 22 Hansen Model H5600R, supposed to be changed out by November 2016. h) Receiver; Valve Number HPR01-17, 18 Parker Model H3, no information on install date or replace by date. As a result, the service life of this PRV could not be determined, preventing the employer from knowing exactly when the PRV was installed and when it should be replaced. i) -45° Recirc; Valve Number ACC03-30, 31 Hansen Model H5633R, supposed to be changed out by October 2016. j) -10° Recirc; Valve Number ACC02-30, 31 Hansen Model H5600A, supposed to be changed out by October 2016. k) +20° Recirc; Valve Number ACC01-30, 31 Parker Model H2, supposed to be changed out by October 2016. l) Anhydrator; Valve Number ANH-1 Cyrus Shank Model 800, supposed to be changed out by January 2018. 29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is complete.