Text For Citation: 01 Item/Group: 007A 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 repair, replace, inspection and maintenance activities of covered process equipment at the engine rooms, roof top, and production floor areas were exposed to the hazards of inhalation of toxic ammonia, asphyxiation, chemical burns, and fire. A) At the facility the employer did not establish and implement the detail written mechanical integrity program procedures to ensure the maintaining of the on-going integrity of process equipment such as pressure vessel, storage tanks; piping systems (piping components such as valves); relief and vent systems and devices; emergency shutdown systems; controls (monitoring devices and sensors, alarms, and interlocks); and pumps for the following equipment. a) 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) Employer did not develop and implement a written mechanical integrity procedure for evaluating valves or emergency shutdown systems such as the King valve in the Ammonia process. c) Employer did not develop and implement a written mechanical integrity procedure for evaluating relief and vent systems and devices. d) Employer did not develop and implement a written mechanical integrity procedure for evaluating controls (including monitoring devices and sensors, level cutouts, alarms, and interlocks). B) At the facility the employer did not implement its mechanical integrity procedure Mechanical Integrity Guidelines, when it 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. The following are some but not limited to all the safety relief valves that needed to be changed out: a) System #1; High Pressure Receiver, supposed to be changed out by 2016. b) System #1; High Side Accumulator, supposed to be changed out by 2016. c) System #1; #1 Storage Vessel, supposed to be changed out by 2018. d) System #1; #1 Hide Chiller, supposed to be changed out by 2015. e) System #1; #2 High Chiller, no date. f) System #1; Blood Chiller, supposed to be changed out by 2018. g) System #1; PO Compressor 2, supposed to be changed out by 2011. h) System #1; PO Compressor 3, supposed to be changed out by 2011. i) System #1; Booster Compressor 7, supposed to be changed out by 2018. j) System #1; Booster Compressor 8, supposed to be changed out by 2018. k) System #1; Compressor 33, supposed to be changed out by 2015. l) System #1; Compressor 35, supposed to be changed out by 2000. m) System #1; Compressor 36, supposed to be changed out by 2011. n) System #1; Compressor 37, supposed to be changed out by 2017. o) System #1; Compressor 38, supposed to be changed out by 2000. p) System #1; Compressor 44, supposed to be changed out by 2006. q) System #1; Mycom Compressor 34, supposed to be changed out by 2015. r) System #1; Mycom Compressor 1, no date. s) System #1; Mycom Compressor 2, no date. t) System #1; Mycom Compressor 3, no date. u) System #1; Vilter #9 Compressor, no date. v) System #1; Vilter #10 Compressor, no date. w) System #1; Vilter #25 Compressor, no date. x) System #1; Vilter #26 Compressor, no date. y) System #1; Vilter #27 Compressor, no date. z) System #1; Vilter #28 Compressor, no date. aa) System #1; Vilter #29 Compressor, no date. bb) System #1; Vilter #30 Compressor, no date. cc) System #1; Vilter #31 Compressor, no date. dd) System #1; Vilter #32 Compressor, no date. ee) System #1; Vilter #43 Compressor, supposed to be changed out by 2015. ff) System #2; Pilot Receiver, supposed to be changed out by 2017. gg) System #2; Controlled Pressure Receiver, supposed to be changed out by 2018. hh) System #2; High Side Accumulator, supposed to be changed out by 2018. ii) System #2; HSA Oil Pot, supposed to be changed out by 2018. jj) System #2; Low Side Accumulator, supposed to be changed out by 2017. kk) System #2; LSA Oil Pot, supposed to be changed out by 2018. ll) System #2; High Side Accum. Pumper Drum, supposed to be changed out by 2017. mm) System #2; Low Side Accum. Pumper Drum, supposed to be changed out by 2017. nn) System #2; #1 Blood Tank, supposed to be changed out by 2004. oo) System #2; #2 Blood Tank, no date. pp) System #2; #3 Blood Tank, no date. qq) System #2; Chud Chiller Surge Drum, supposed to be changed out by 2012. rr) System #2; Glycol Chiller, supposed to be changed out by 2017. ss) System #2; Plate & Frame Chub Chiller 1, supposed to be changed out by 2012. tt) System #2; Plate & Frame Chub Chiller 2, supposed to be changed out by 2012. uu) System #2; Plate & Frame Chub Chiller 3, supposed to be changed out by 2012. vv) System #2; Auto Purger, supposed to be changed out by 2018. ww) System #2; Freeze Oil Trap, supposed to be changed out by 2018. xx) System #2; Booster Compressor 7, supposed to be changed out by 2018. yy) System #2; Booster Compressor 8, supposed to be changed out by 2018. zz) System #2; Booster Compressor 9, supposed to be changed out by 2012. aaa) System #2; Booster Compressor 10, supposed to be changed out by 2012. bbb) System #2; Compressor 45, supposed to be changed out by 2018. ccc) System #2; Compressor 46, no date. ddd) System #2; Vilter Compressor 12, no date. eee) System #2; Vilter Compressor 13, no date. fff) System #2; Vilter Compressor 14, no date. ggg) System #2; Vilter Compressor 15, no date. hhh) System #2; Vilter Compressor 16, no date. iii) System #2; Vilter Compressor 17, no date. jjj) System #2; Vilter Compressor 18, no date. kkk) System #2; Vilter Compressor 21, no date. lll) System #2; Vilter Compressor 22, no date. mmm) System #2; Vilter Compressor 23, no date. nnn) System #2; Vilter Compressor 24, no date. ooo) System #2; Swing Compressor #35, supposed to be changed out by 2017. ppp) System #2; Compressor #36, supposed to be changed out by 2011. qqq) System #2; Compressor #37, supposed to be changed out by 2017. rrr) System #2; Compressor #38, supposed to be changed out by 2017. sss) System #3; High Stage Suction Accumulator, supposed to be changed out by 2017. ttt) System #3; Compressor 39, supposed to be changed out by 2018. uuu) System #3; Compressor 40, supposed to be changed out by 2018. vvv) System #3; Compressor 41, supposed to be changed out by 2018. www) System #3; Compressor 42, supposed to be changed out by 2018. xxx) System #3; Compressor 48, no date. yyy) Frick #49 Compressor in Engine Room #1, no date. zzz) HPR System #3 in Engine Room #4, no date. 29 CFR 1903.19(d)(1) requires certification and documentation that the abatement of the above violation is complete.