| Inspection Type |
Planned
|
| Scope |
Complete
|
| Safety/Health |
Safety
|
| Close Conference |
2012-08-08
|
| Emphasis |
L: EISAOF, L: FALL, N: SSTARG11
|
| Case Closed |
2014-09-04
|
Violation Items
| Citation ID |
01001 |
| Citaton Type |
Serious |
| Standard Cited |
5A0001 |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-09-10 |
| Current Penalty |
1200.0 |
| Initial Penalty |
2000.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
2 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
OSH ACT of 1970 Section (5)(a)(1): The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to the hazard of being struck by fragments of plastic pipe used to transport compressed air for the operation of air operated tools and air used for cleaning, in the event the piping ruptures: a. At the maintenance shop, polyvinyl chloride ( PVC ) plastic pipe was used to transport compressed air in exposed above ground locations, for the operation of air operated tools and air used for cleaning, a practice not recommended by the Plastics Pipe Institute and prohibited by ANSI/ASME B31.8-1986, Gas Transmission and Distribution Piping Systems standard, on or about 05/17/12. |
|
| Citation ID |
01002 |
| Citaton Type |
Serious |
| Standard Cited |
19100023 C01 |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
720.0 |
| Initial Penalty |
1200.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
3 |
| Nr Exposed |
10 |
| Gravity |
1 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.23(c)(1): Open sided floor(s) or platform(s) 4 feet or more above the adjacent floor or ground level were not guarded by standard railings (or the equivalent as specified in 29 CFR 1910.23(e)(3)(i) through (v)), on all open sides: a. Blender 4 catwalk, employees were exposed to a fall hazard 5 feet 7 inches, in that, standard railings were not installed on all open sides. The front side of the catwalk had a top rail which was 34 inches from the platform. b. Blender 3 catwalk, employees were exposed to a fall hazard 5 feet 9 inches, in that, standard railings were not installed on all open sides. The right side of the catwalk had a top rail which was 30 inches from the platform. c. Wet Process area, the catwalk around the vacuum tank had no railings at the tank side and had a top rail only at the other sides. |
|
| Citation ID |
01003A |
| Citaton Type |
Serious |
| Standard Cited |
19100146 C01 |
| Issuance Date |
2012-08-24 |
| Current Penalty |
1020.0 |
| Initial Penalty |
1700.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
10 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.146(c)(1): The employer did not evaluate the workplace to determine if any spaces were permit-required confined spaces: a. At the site, an evaluation of the workplace was not made to establish the presence of permit required confined spaces and establish measures to protect employees from entering. Employees were exposed to permit required confined spaces such as, but not limited to, hoppers with converging walls and rotating augers, blenders and mixers with rotating parts, and tanks or storage bins containing material which poses engulfment hazards. |
|
| Citation ID |
01003B |
| Citaton Type |
Serious |
| Standard Cited |
19100146 C02 |
| Issuance Date |
2012-08-24 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
10 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.146(c)(2): The employer did not inform exposed employees, by posting danger signs or by any other equally effective means, of the existence and location of and the danger posed by the permit spaces: a. At the site, employees were exposed to permit required confined spaces such as, but not limited to, hoppers with converging walls and rotating augers, blenders and mixers with rotating parts, and tanks or storage bins containing material which poses engulfment hazards. |
|
| Citation ID |
01004 |
| Citaton Type |
Serious |
| Standard Cited |
19100147 C04 II |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-10-24 |
| Current Penalty |
960.0 |
| Initial Penalty |
1600.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
2 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(c)(4)(ii): The energy control procedures did not clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, including, but not limited to Items "A" through "D" of this section: a. At the site, equipment specific lockout/tagout procedures were not developed and implemented to include at a minimum the following: 1. A specific statement of the intended use of the procedure. 2. Specific procedural steps for shutting down, isolating, blocking, and securing machines or equipment to control hazardous energy. 3. Specific procedural steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them. 4. Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices and other energy control measures. 5. The magnitude of hazardous energy. Employees were involved in maintenance operations of equipment such as, but not limited to, mixers, an auger, powder and liquid transfer systems. Employees would work on forklifts, replace bearings on mixing machines and blenders, replace belts on transfer systems and rebuilt pumps, replace hoses and lubricate and adjust chain driven transfer equipment. |
|
| Citation ID |
01005 |
| Citaton Type |
Serious |
| Standard Cited |
19100176 B |
| Issuance Date |
2012-08-24 |
| Current Penalty |
1020.0 |
| Initial Penalty |
1700.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
17 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.176(b): Material stored in tiers was not stacked, blocked, interlocked or limited in height so that it was stable and secure against sliding and collapse: a. At the material storage area, pallets with bags used during the manufacturing processes were stored two and three high in a manner that they were tilting and could collapse. The pallets were about 2,000 lbs and were not secure and stable. |
|
| Citation ID |
01006A |
| Citaton Type |
Serious |
| Standard Cited |
19100212 A05 |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
960.0 |
| Initial Penalty |
1600.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
4 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.212(a)(5): Fan blade guards, where the periphery of the blades was less than seven feet above the floor or working level, had openings larger than one half inch: a. Dry Process area, a wall mounted fan three feet from the floor did not have the blades completely enclosed exposing employees to the rotating blades. The fan had an opening about 2 feet by 2 feet over the motor allowing access to the rotating blades. |
|
| Citation ID |
01006B |
| Citaton Type |
Serious |
| Standard Cited |
19100219 D01 |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
5 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.219(d)(1): Pulley(s) with part(s) seven feet or less from the floor or work platform were not guarded in accordance with the requirements specified in 29 CFR 1910.219(m) and (o): a. Dry room Process, employees were exposed to a rotating pulley on the motor of the wall mounted fan located about 3 feet from the floor. |
|
| Citation ID |
01006C |
| Citaton Type |
Serious |
| Standard Cited |
19100219 E03 I |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
5 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.219(e)(3)(i): Vertical or inclined belt(s) were not enclosed by guard(s) conforming to the requirements specified at 29 CFR 1910.219(m) and (o): a. Dry room Process, employees were exposed to a belt on the motor of the wall mounted fan located about 3 feet from the floor. |
|
| Citation ID |
01007 |
| Citaton Type |
Serious |
| Standard Cited |
19100242 B |
| Issuance Date |
2012-08-24 |
| Current Penalty |
1020.0 |
| Initial Penalty |
1700.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
14 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.242(b): Compressed air used for cleaning purposes was not reduced to less than 30 p.s.i.: a. Outside the storage area, compressed air was used for cleaning at 100 psi without having the type of nozzle that would reduce the pressure to less than 30 psi. |
|
| Citation ID |
01008A |
| Citaton Type |
Serious |
| Standard Cited |
19100253 E03 II C 2 |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
720.0 |
| Initial Penalty |
1200.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
2 |
| Gravity |
1 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.253(e)(3)(ii)(C)(2): Backflow protection was not provided by an approved device that would prevent oxygen from flowing into the fuel gas system or fuel from flowing into the oxygen system: a. At the maintenance shop, employees were exposed to fire hazards, in that, the oxygen and acetylene torch and hoses used during maintenance activities were not equipped with a backflow prevention valve. |
|
| Citation ID |
01008B |
| Citaton Type |
Serious |
| Standard Cited |
19100253 E03 II C 3 |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
2 |
| Gravity |
1 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.253(e)(3)(ii)(C)(3): Flashback protection was not provided by an approved device that would prevent flame from passing into the fuel gas system: a. At the maintenance shop, employees were exposed to fire hazards, in that, the oxygen and acetylene torch and hoses used during maintenance activities were not equipped with a flashback arrestor. |
|
| Citation ID |
01009 |
| Citaton Type |
Serious |
| Standard Cited |
19100303 G02 I |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
960.0 |
| Initial Penalty |
1600.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
5 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.303(g)(2)(i): Live parts of electric equipment operating at 50 volts or more shall be guarded against accidental contact by approved cabinets or other forms of approved enclosures: a. Dry Process room, employees were exposed to electrical hazards, in that, the control cabinets for the three blenders were not closed. The cabinets could not be maintained closed due to a compromised cover. |
|
| Citation ID |
01010 |
| Citaton Type |
Serious |
| Standard Cited |
19100307 C |
| Issuance Date |
2012-08-24 |
| Current Penalty |
1020.0 |
| Initial Penalty |
1700.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
17 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.307(c): Equipment , wiring methods, and installations of equipment in hazardous (classified) locations were not intrinsically safe, approved for the location, or safe for the hazardous (classified) location: a. At the Polystyrene mechanical and grinding room, employees were exposed to explosion and fire hazards, in that, polystyrene dust was allowed to accumulate in areas where equipment and electrical installations were not approved for Class II Division 1 locations. Unapproved electrical equipment installed were such as, but not limited to, general electrical wiring for lighting and fans, electrical cabinets housing breaker panels and control circuits for the grinding operation, grinding machinery wiring and dust collection-bagging system. |
|
| Citation ID |
02001 |
| Citaton Type |
Other |
| Standard Cited |
19100023 D01 III |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
3 |
| Nr Exposed |
17 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.23(d)(1)(iii): Flight(s) of stairs with 4 or more risers, less than 44 inches wide and having both sides open were not equipped with one standard stair railing on each side: a. At the Styrofoam grinding room, a stairway with four steps leading to the exterior of the building was open on both sides and did not have a stair railing system at the open sides. b. Dry Process area, blenders 2, 3 and 4 had stairways leading to the catwalk where the operator's controls were located without having standard railings to protect employees from the fall hazard. c. Wet Process area, a two flight stairway leading to the catwalk over the process was not equipped with standard railings to protect employees from falling. The first flight had no railings and the second flight had only a top rail. |
|
| Citation ID |
02002 |
| Citaton Type |
Other |
| Standard Cited |
19100169 B03 I |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
2 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.169(b)(3)(i): Air receivers were not equipped with one or more spring-loaded safety valves to prevent pressure in the receiver from exceeding the maximum allowable working pressure of the receiver by more than 10 percent: a. Air compressor room, the 150 gal air receiver tank providing compressed air to the plant and the bulk storage system was not equipped with a pressure relief valve. |
|
| Citation ID |
02003 |
| Citaton Type |
Other |
| Standard Cited |
19100212 B |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
2 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.212(b): Machine(s) designed for fixed location(s) were not securely anchored to prevent walking or moving: a. At the maintenance shop, a Clark Metalworker drill press was not secured in place to prevent it from tipping over. |
|
| Citation ID |
02004 |
| Citaton Type |
Other |
| Standard Cited |
19100303 B02 |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
2 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.303(b)(2): Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling: a. Dry process room, employees were exposed to electrical hazards, in that, a 4 way metal outlet box was used in a dusty environment without being approved for the location. The outlet box was not sealed and powder dust was accumulating on top of it. |
|
| Citation ID |
02005 |
| Citaton Type |
Other |
| Standard Cited |
19100303 G01 |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-09-10 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
3 |
| Nr Exposed |
6 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.303(g)(1): Sufficient access and working space was not provided and maintained about all electric equipment to permit ready and safe operation and maintenance of such equipment: a. Dry process behind blender 2, the electrical panels for the process were blocked by the equipment and a support column for the building. A workspace of 30 inches was not allowed in front of the electrical equipment exposing employees to electrical hazards. b. Wet process, the controls for the mixers, the auger, and other power panels were blocked by the mixers, a water tank and the auger. c. Shipping and receiving area, electrical panel A and B were located on the wall behind the shrink wrap machine. The panels did not have the required three foot clear access and working space. |
|
| Citation ID |
02006 |
| Citaton Type |
Other |
| Standard Cited |
19100304 G05 |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
2 |
| Nr Exposed |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.304(g)(5): The path to ground from circuits, equipment, and enclosures was not permanent, continuous and effective: a. Dry Process room, employees were exposed to electrical hazards, in that, the plug to a portable fan used for ventilation was not provided with a ground prong. b, Wet Process room, employees were exposed to electrical hazards, in that, the plug to a portable fan used for ventilation was not provided with a ground prong. |
|
| Citation ID |
02007 |
| Citaton Type |
Other |
| Standard Cited |
19100305 G01 IV A |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
4 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.305(g)(1)(iv)(A): Flexible cords and cables were used as a substitute for the fixed wiring of a structure: a. Shipping and receiving area, employees were exposed to electrical hazards, in that, temporary wiring such as a red extension cord was used in place of fixed wiring providing power to the Ujulftec Shrink Wrap machine. |
|
| Citation ID |
02008 |
| Citaton Type |
Other |
| Standard Cited |
19100305 G02 III |
| Issuance Date |
2012-08-24 |
| Abatement Due Date |
2012-08-27 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Final Order |
2012-09-06 |
| Nr Instances |
1 |
| Nr Exposed |
4 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.305(g)(2)(iii): Flexible cords were not connected to devices and fittings so that tension would not be transmitted to joints or terminal screws: a. Dry Process Room, the flexible cord providing power to the wall mounted fan had the outer sheath of the insulation pulled from the plug thus transmitting pull on the terminals or screws. |
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