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DuraLabel's Weekly Safety News

Blog Author Angelique Sanders

Weekly safety news. Stay in touch with regulations from OSHA, NFPA, and other safety codes. Find out about other companies' best and worst practices. We scour the internet to provide you with helpful training resources and the latest safety information.


Monday, July 29, 2013

OSHA Significant Citations - Arkansas Refinery Fined For Repeat Violations

A summary of recent OSHA and state OSHA significant citations. These are citations that have proposed total fines over $100,000 and that were announced during the past week.



OSHA Cites iVEX Protective Packaging Following Explosion At Sidney, OH Facilty ($128,700)

Echo Lake Foods Fined For 27 Violations ($150,000)
Arkansas Poultry Processor Cited For Chemical Hazards ($170,000)
Arkansas Refinery Cited For Willful and Repeat Violations ($126,900)


iVEX Protective Packaging Inc. received 21 citations as the result of a January inspection. The OSHA inspection resulted from an explosion that injured three workers and caused significant property damage at the Sidney polyethylene foam product manufacturing facility.  The total proposed fines are $128,700.

The explosion occurred when isobutane gas entered exhaust ductwork associated with the foam extrusion manufacturing process, and it was ignited by the regenerative thermal oxidizer. When OSHA inspected the facility, it found multiple violations of OSHA's standards for process safety management of highly hazardous chemicals.

Seventeen serious violations relating to Process Safety Management included failing to address fire and explosion hazards within ventilation ducting, process equipment and pressure vessels through accurate process safety information. This includes documentation showing that all covered equipment complies with generally accepted engineering practices and has a completed process hazard analysis. The company also failed to have detailed operating procedures, failed to provide operator and maintenance technician training, and they hads not developed an inspection and testing program.

Additional serious violations included:
  • a lack of machine guarding
  • failing to document specific hazardous energy control procedures
  • not applying lockout devices to machinery during servicing
  • failing to shut down machinery prior to servicing
  • not providing flame-retardant clothing for workers exposed to fire/explosion hazards
The current citations may be viewed at:
http://www.osha.gov/ooc/citations/IvexProtectivePackaging_850603_071513.pdf.

The company employs 47 workers at its Sidney facility and approximately 192 worldwide. Headquartered in Lachine, Quebec, Canada, the company has 15 business days from receipt of the citations and notice of proposed penalties to contest the citations and proposed penalties before the independent Occupational Safety and Health Review Commission.


Echo Lake Foods Inc. has been cited by OSHA with 27 safety violations carrying fines of $150,000. Multiple violations of OSHA's process safety management standards for facilities that use highly hazardous chemicals were found at the company's Burlington and Franksville frozen food production plants.

OSHA received complaints alleging hazards with the ammonia refrigeration systems at those facilities. A fire at the Burlington facility Jan. 30 resulted in the destruction of a portion of the plant's ammonia refrigeration system, causing significant property damage. No serious injuries were reported.

Twenty-two process safety management violations at both facilities involve multiple instances of not addressing the consequences of the failure of various engineering and administrative controls. The company also failed to address procedures to perform oil draining activities safely for ammonia compressors and provide and document worker training involving the ammonia systems and related operating equipment.

In Burlington, four additional serious violations include:
  • insufficient safety guardrails on platforms
  • inadequate exit routes
  • lack of an emergency eyewash station near a compressor room, posing potential exposure to anhydrous ammonia
  • missing cover plates on several electrical switches.
In Franksville, one additional serious violation includes failing to certify that periodic inspections of hazardous energy control procedures had been performed.

The current citations may be viewed at:
http://www.osha.gov/ooc/citations/EchoLakeFoodsInc_845383and860583_0723_13.pdf.

Echo Lake Foods Inc. employs 450 workers companywide. In addition to Burlington and Franksville, the company operates a production and storage facility in Owensboro, Ky. The Wisconsin facilities have been inspected by OSHA 13 times and issued 45 citations. The Kentucky facility has received two violations.


The De Queen poultry processing plant owned by Pilgrim's Pride Corp. has been cited for 11 safety violations with proposed penalties totaling $170,000 for exposing workers to hazardous chemicals.

The inspection, which began in January, was initiated under OSHA's Process Safety Management Covered Chemical Facilities National Emphasis Program. PSM encompasses a detailed set of requirements and procedures employers must follow to address hazards proactively that are associated with processes and equipment that use large amounts of hazardous chemicals. In this case, it's the use of anhydrous ammonia in the refrigeration system.

A willful violation, with a $70,000 fine, was cited for failing to document that the emergency shutdown system for the engine room was designed to ensure that the mechanical ventilation system was activated by an ammonia leak. A willful violation is one committed with intentional, knowing or voluntary disregard for the law's requirements, or with plain indifference to worker safety and health.

The nine serious violations, with a total of $61,500 in fines, were for deficiencies of the relief valves and failing to provide process hazard analysis, operating procedures, testing procedures and management of change procedures. A serious violation occurs when there is substantial probability that death or serious physical harm could result from a hazard about which the employer knew or should have known.

The repeat violation, with a fine of $38,500, was cited for failing to ensure the adequate frequency of self-inspections and tests of ammonia refrigeration equipment and vessels.  A similar violation was cited in 2011.

The citations can be viewed at:
http://www.osha.gov/ooc/citations/PilgrimsPride_844143_0718_13.pdf

The company, headquartered in Greeley, Colo., employs about 1,400 workers at the De Queen plant.


Martin Operating Partnership LP has been cited for five safety and health violations, including one willful and one repeat, with proposed penalties totaling $126,900. OSHA found deficiencies in the employer's process safety management program and other workplace hazards at its Smackover refinery.

The inspection, which began in January, was a follow-up to a 2010 inspection initiated under the agency's Petroleum Refinery Process Safety Management National Emphasis Program. PSM encompasses a detailed set of requirements and procedures employers must follow to address hazards proactively that are associated with processes and equipment that use large amounts of hazardous chemicals. In this case, it involves the production of naphthenic crude oil.

The one willful violation involve failing to ensure relief valves were properly sized and of adequate capacity to provide relief, for units such as, but not limited to, Crude Unit #1. A willful violation is one committed with intentional, knowing or voluntary disregard for the law's requirements, or with plain indifference to worker safety and health.

The repeat violation involves failing to ensure process safety information included the relief system design for a Crude Unit. A repeat violation exists when an employer previously has been cited for the same or a similar violation of a standard, regulation, rule or order at any other facility in federal enforcement states within the last five years. A similar violation was cited in the 2010 inspection.

Three serious violations were cited for:
  • failing to ensure intervening block valves, upstream and downstream of relief devices, were locked in the open position
  • failing to ensure process hazard analysis recommendations for facility siting were resolved in a timely manner
  • failing to ensure energy control procedures were written to specifically relieve stored energy
The citations can be viewed at:
https://www.osha.gov/ooc/citations/MartinOperatingPartnership_843783_0718_13.pdf.

The company, owned by Martin Midstream Partners LP and headquartered in Kilgore, Texas, has 15 business days from receipt of the citations and penalties to comply, request an informal conference with the area director or contest the findings before the independent Occupational Safety and Health Review Commission.


Related Past Posts:
OSHA Significant Citations - Metal Processing Facility Fined
No Significant OSHA Citations This Week
Significant Citations - Texas Meat Packing Plant Cited

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