|
346156557
|
0418300
|
2022-08-18
|
3001 MALLARD FOX DRIVE NW, DECATUR, AL, 35601
|
|
| Inspection Type |
FollowUp
|
| Scope |
Partial
|
| Safety/Health |
Safety
|
| Close Conference |
2023-02-16
|
| Case Closed |
2023-06-13
|
Related Activity
| Type |
Inspection |
| Activity Nr |
1460438 |
| Safety |
Yes |
|
|
|
344887443
|
0418300
|
2020-08-18
|
3001 MALLARD FOX DRIVE NW, DECATUR, AL, 35601
|
|
| Inspection Type |
Referral
|
| Scope |
Partial
|
| Safety/Health |
Safety
|
| Close Conference |
2021-02-05
|
| Case Closed |
2023-02-08
|
Related Activity
| Type |
Referral |
| Activity Nr |
1643083 |
| Safety |
Yes |
|
Violation Items
| Citation ID |
01001A |
| Citaton Type |
Serious |
| Standard Cited |
19100147 C04 I |
| Issuance Date |
2021-02-08 |
| Abatement Due Date |
2022-11-22 |
| Current Penalty |
13516.0 |
| Initial Penalty |
13516.0 |
| Contest Date |
2021-03-08 |
| Final Order |
2022-08-22 |
| Nr Instances |
1 |
| Nr Exposed |
3 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section: (a) On or about 08/12/2020 - Resin Department, authorized employees were exposed to hazardous chemical energy when the employer did not ensure that a procedure was utilized to control the potentially hazardous chemical energy before the employees started conducting a line break to remove a dosing nozzle from a line that contained a monomer consisting of approximately 85% Terephthalic Acid and 15% Ethylene Glycol, Polyester Grade and at a temperature of approximately 265 to 275 degrees C (509 to 527 degrees F). The employer did not ensure that the employees followed all of the steps in the written Work Instruction "Shut Down" reference #PU-WI-RES-SD-030 for shutting down the process between reactors UPR-1 and UPR-2 such as, but not limited to, affixing lockout devices, tagout devices, or other control measures to the valves before the employees conducted the line break. The employer did not ensure that the employees followed all of the steps in the Standard Operating Procedure "Lockout/Tagout Protocal" reference #PU-SOP-ESSH-LOTOP-002 for additional application of the control steps, such as, but not limited to, utilizing a Hazardous Work Permit and performing an energy isolation verification check. |
|
| Citation ID |
01001B |
| Citaton Type |
Serious |
| Standard Cited |
19100147 C04 II D |
| Issuance Date |
2021-02-08 |
| Abatement Due Date |
2022-11-22 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Contest Date |
2021-03-08 |
| Final Order |
2022-08-22 |
| Nr Instances |
1 |
| Nr Exposed |
3 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(c)(4)(ii)(D): The energy control procedures did not clearly and specifically outline the requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures: (a) On or about 08/12/2020 - Resin Department, authorized employees were exposed to hazardous chemical energy when conducting a line break to remove a dosing nozzle from a line that contained a monomer consisting of approximately 85% Terephthalic Acid and 15% Ethylene Glycol, Polyester Grade and at a temperature of approximately 265 to 275 degrees C (509 to 527 degrees F) and the written Work Instruction "Shut Down" reference #PU-WI-RES-SD-030 did not clearly and specifically outline the requirements for testing the lockout devices, tagout devices, or other energy control measures used to verify that the manual hand and automatic control valves were in the correct position and verifying that all hazardous chemical energy or pressure had been released or drained from the line before the employees started the line break. |
|
| Citation ID |
01001C |
| Citaton Type |
Serious |
| Standard Cited |
19100147 D |
| Issuance Date |
2021-02-08 |
| Abatement Due Date |
2022-11-22 |
| Current Penalty |
0.0 |
| Initial Penalty |
13516.0 |
| Contest Date |
2021-03-08 |
| Final Order |
2022-08-22 |
| Nr Instances |
1 |
| Nr Exposed |
3 |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(d): The established procedure for the application of energy control (the lockout or tagout procedures) did not cover the actions listed in and was not done in sequence as required by 29 CFR 1910.147(d)(1)-(6): (a) On or about 08/12/2020 - Resin Department, authorized employees were exposed to hazardous chemical energy when conducting a line break to remove a dosing nozzle from a line that contained a monomer consisting of approximately 85% Terephthalic Acid and 15% Ethylene Glycol, Polyester Grade and at a temperature of approximately 265 to 275 degrees C (509 to 527 degrees F) and lockout devices, tagout devices, or other control measures were not affixed to the manual hand valves and the control valve before the employees started the line break per the 1910.147(d)(2) requirements. In addition, the remaining applicable energy control elements, d(5)(i) dissipation of residual energy, (d)(5)(ii) continued verification of isolation from the re-accumulation of stored energy to a hazardous level, and (d)(6) verification of isolation were not implemented to protect employees from the hazardous chemical energy. |
|
| Citation ID |
02001 |
| Citaton Type |
Repeat |
| Standard Cited |
19100132 A |
| Issuance Date |
2021-02-08 |
| Abatement Due Date |
2022-11-22 |
| Current Penalty |
76484.0 |
| Initial Penalty |
135167.0 |
| Contest Date |
2021-03-08 |
| Final Order |
2022-08-22 |
| Nr Instances |
1 |
| Nr Exposed |
3 |
| Related Event Code (REC) |
Referral |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.132(a): Protective equipment was not used when necessary whenever hazards capable of causing injury and impairment were encountered: (a) On or about 08/12/2020 - Resin Department, authorized employees were exposed to hazardous chemical energy and thermal burns when the employer did not ensure that the employees wore protective equipment such as, but not limited to, flame-resistant clothing and an aluminized jacket and pants when conducting a line break to remove a dosing nozzle from a line that contained a monomer consisting of approximately 85% Terephthalic Acid and 15% Ethylene Glycol, Polyester Grade at a temperature of approximately 265 to 275 degrees C (509 to 527 degrees F) and working in close proximity to jacketed piping containing a heat transfer media at approximately 285 degrees C (545 degrees F). |
|
|
|
344604384
|
0418300
|
2020-02-03
|
3001 MALLARD FOX DRIVE NW, DECATUR, AL, 35601
|
|
| Inspection Type |
Referral
|
| Scope |
Partial
|
| Safety/Health |
Safety
|
| Close Conference |
2020-02-03
|
| Emphasis |
N: AMPUTATE
|
| Case Closed |
2022-09-09
|
Related Activity
| Type |
Referral |
| Activity Nr |
1537672 |
| Safety |
Yes |
|
| Type |
Inspection |
| Activity Nr |
1460773 |
| Safety |
Yes |
|
Violation Items
| Citation ID |
01001 |
| Citaton Type |
Other |
| Standard Cited |
19100022 D02 |
| Issuance Date |
2020-06-01 |
| Current Penalty |
2000.0 |
| Initial Penalty |
9733.0 |
| Contest Date |
2020-06-30 |
| Final Order |
2022-01-19 |
| Nr Instances |
1 |
| Nr Exposed |
3 |
| Related Event Code (REC) |
Referral |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.22(d)(2): Hazardous conditions on walking-working surfaces were not corrected or repaired before an employee used the walking-working surface: (a) On or about January 25, 2020 - Offline grinding pit, an employee was exposed to slip hazards when the platform next to the offline grinder was too small to maintain balance when used while rotating the grinding blades with a 2x4. |
|
| Citation ID |
01002A |
| Citaton Type |
Serious |
| Standard Cited |
19100147 C04 I |
| Issuance Date |
2020-06-01 |
| Abatement Due Date |
2022-01-31 |
| Current Penalty |
4500.0 |
| Initial Penalty |
6489.0 |
| Contest Date |
2020-06-30 |
| Final Order |
2022-01-19 |
| Nr Instances |
1 |
| Nr Exposed |
3 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section: (a) On or about February 03, 2020 - Grinding area, offline grinder, procedures were not developed, documented, and utilized for clearing jams exposing employees to struck-by hazards when removing a plug in the grinder. |
|
| Citation ID |
01002B |
| Citaton Type |
Serious |
| Standard Cited |
19100147 F03 II D |
| Issuance Date |
2020-06-01 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Contest Date |
2020-06-30 |
| Final Order |
2022-01-19 |
| Nr Instances |
1 |
| Nr Exposed |
2 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(f)(3)(ii)(D): Each authorized employee did not affix a personal lockout or tagout device to the group lockout device before working on the machine or equipment: (a) On or about January 25, 2020 - Offline grinder pit, employees were exposed to struck-by hazards when there was no group lockout procedure used when clearing a material jam in the offline grinder. |
|
| Citation ID |
03001A |
| Citaton Type |
Other |
| Standard Cited |
19040029 B01 |
| Issuance Date |
2020-06-01 |
| Abatement Due Date |
2022-01-31 |
| Current Penalty |
1000.0 |
| Initial Penalty |
1622.0 |
| Contest Date |
2020-06-30 |
| Final Order |
2022-01-19 |
| Nr Instances |
2 |
| Nr Exposed |
2 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1904.29(b)(1): A Log of all recordable work-related injuries and illnesses (OSHA Form 300 or equivalent) was not completed in the detail as required by the regulation: (a) On or about February 03, 2020 - 2020 log, case no. 1 dated 01/25/2020 was classified as Job Transfer or Restriction with no days of On Job Transfer or Restriction. The injury column had not been checked. Page totals had not been calculated. (b) On or about February 03, 2020 - 2020 log, case no. 2 dated 01/25/2020 was classified as Job Transfer or Restriction with no days of On Job Transfer or Restriction. The injury column had not been checked. Page totals had not been calculated. |
|
| Citation ID |
03001B |
| Citaton Type |
Other |
| Standard Cited |
19040029 B02 |
| Issuance Date |
2020-06-01 |
| Abatement Due Date |
2022-01-31 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Contest Date |
2020-06-30 |
| Final Order |
2022-01-19 |
| Nr Instances |
2 |
| Nr Exposed |
2 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1904.29(b)(2): The employer did not fill out or correctly fill out an OSHA Form 301 or equivalent for each recordable injury or illness: (a) On or about February 03, 2020 - Facility, the employer had not completed the OSHA Form 301 or equivalent for Case No. 2 on the OSHA 300 log. (b) On or about February 03, 2020 - Facility, the equivalent forms for Case No. 1 did not include details such as, but not limited to, the injury (amputation) and the OSHA 300 log Case No. |
|
| Citation ID |
03002A |
| Citaton Type |
Other |
| Standard Cited |
19100147 C04 II B |
| Issuance Date |
2020-06-01 |
| Abatement Due Date |
2020-06-25 |
| Current Penalty |
2000.0 |
| Initial Penalty |
0.0 |
| Contest Date |
2020-06-30 |
| Final Order |
2022-01-19 |
| Nr Instances |
1 |
| Nr Exposed |
3 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(c)(4)(ii)(B): The energy control procedures did not clearly and specifically outline the steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy: (a) On or about February 03, 2020 - Grinding areas, employees were exposed to struck-by hazards when lockout/tagout (LOTO) procedures such as, but not limited to, Offline Grinder Feeder (PPX-975), Offline Grinder Motor (PPX-072), Offline Conveying Blower (PPX-973), and Offline Grinder Hydraulic Motor (PPX-974) did not clearly or specifically describe how to shut down the equipment prior to LOTO. Each procedure said the following: Ensure grinder has come to a complete stop before proceeding. No information on how to shut down the grinder so that it would come to a complete stop was provided in the procedures. |
|
| Citation ID |
03002B |
| Citaton Type |
Other |
| Standard Cited |
19100147 C04 II C |
| Issuance Date |
2020-06-01 |
| Abatement Due Date |
2020-06-25 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Contest Date |
2020-06-30 |
| Final Order |
2022-01-19 |
| Nr Instances |
1 |
| Nr Exposed |
3 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(c)(4)(ii)(C): The energy control procedure did not clearly and specifically outline the steps for placement, removal and transfer of lockout devices or tagout devices and the responsibility for them: (a) On or about February 03, 2020 - Grinding areas, employees were exposed to struck-by hazards when lockout/tagout (LOTO) procedures such as, but not limited to, Offline Grinder Feeder (PPX-975), Offline Grinder Motor (PPX-072), Offline Conveying Blower (PPX-973), and Offline Grinder Hydraulic Motor (PPX-974) did not clearly or specifically describe the order that locks were to be installed, the order that locks were to be removed, and how these procedures related to each other when all of these procedures were required to be followed in order to clear an offline grinder jam in the pit/basement. |
|
| Citation ID |
03002C |
| Citaton Type |
Other |
| Standard Cited |
19100147 C04 II D |
| Issuance Date |
2020-06-01 |
| Abatement Due Date |
2022-01-31 |
| Current Penalty |
0.0 |
| Initial Penalty |
0.0 |
| Contest Date |
2020-06-30 |
| Final Order |
2022-01-19 |
| Nr Instances |
1 |
| Nr Exposed |
3 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(c)(4)(ii)(D): The energy control procedures did not clearly and specifically outline the requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures: (a) On or about February 03, 2020 - Grinding areas, employees were exposed to struck-by hazards when a lockout/tagout (LOTO) procedure such as, but not limited to, the Erema Offline Grinder Operation (PU-WI-PET-EOLG-001) did not specify how to verify that the lock placed on the main control panel cabinet was effective. Lockout/tagout procedures such as, but not limited to, Offline Grinder Feeder (PPX-975), Offline Grinder Motor (PPX-072), Offline Conveying Blower (PPX-973), and Offline Grinder Hydraulic Motor (PPX-974) did not clearly or specifically describe how to attempt to restart the machines. |
|
| Citation ID |
03002D |
| Citaton Type |
Other |
| Standard Cited |
19100147 C07 I |
| Issuance Date |
2020-06-01 |
| Abatement Due Date |
2022-01-31 |
| Current Penalty |
0.0 |
| Initial Penalty |
6489.0 |
| Contest Date |
2020-06-30 |
| Final Order |
2022-01-19 |
| Nr Instances |
1 |
| Nr Exposed |
2 |
| Gravity |
5 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(c)(7)(i): The employer did not provide adequate training to ensure that employees acquired the knowledge and skills required for the safe application, usage and removal of energy control devices: (a) On or about February 03, 2020 - Grinding area, employees were exposed to struck-by hazards when no lockout or group lockout was performed when opening the offline grinder in order to remove a material plug. Available written lockout/tagout procedures for the offline grinder were inadequate. Lockout/tagout training was provided on an Erema grinder with significantly fewer steps required to lockout compared to the offline grinder. |
|
|
|
343048666
|
0418300
|
2018-03-28
|
3001 MALLARD FOX DRIVE NW, DECATUR, AL, 35601
|
|
| Inspection Type |
Referral
|
| Scope |
Partial
|
| Safety/Health |
Safety
|
| Close Conference |
2018-03-28
|
| Case Closed |
2018-05-29
|
Related Activity
| Type |
Referral |
| Activity Nr |
1321726 |
| Safety |
Yes |
|
Violation Items
| Citation ID |
01001 |
| Citaton Type |
Serious |
| Standard Cited |
19100147 C04 I |
| Issuance Date |
2018-04-25 |
| Abatement Due Date |
2018-06-21 |
| Current Penalty |
8148.7 |
| Initial Penalty |
11641.0 |
| Final Order |
2018-05-21 |
| Nr Instances |
2 |
| Nr Exposed |
13 |
| Related Event Code (REC) |
Referral |
| Gravity |
10 |
| FTA Current Penalty |
0.0 |
| Citation text line |
29 CFR 1910.147(c)(4)(i): Procedures were not utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section: (a) On or about 03/24/2018 - Pack Line, conveyor, employees working on the lift table without utilizing lockout were exposed to crushing hazards. |
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