OSHA Inspection: DOVER CHEMICAL CORPORATION

Issued

2012-04-25 00:00:00

Abate by

2012-05-25 00:00:00

Penalty

Initial $7000.00 · Current $7000.00

General-duty citation text

29 CFR 1910.119(j)(2):     The employer did not implement written procedures to maintain the on-going integrity of process equipment:      a) Written procedures had not been developed and implemented for the by-passing of the discharge valve on the 20 reactor recirculation line exposing employees to contact and inhalation hazards of chlorine, hydrogen chloride, carbon tetrachloride, and chloroform. When bi-passing the 20 reactor recirculating discharge valve mechanical integrity procedures did not assure the reactivation of the valve.  On or about November 3, 2011, a 3" X 18" stainless steel flexible hose lined with PTFE (Polytetrafluoroethylene) on the discharge side of the R-20 recirculation pump ruptured, the 20 reactor recirculating discharge valve was in by-pass mode, resulting in the release of 20 reactor's contents.

Issued

2012-04-25 00:00:00

Abate by

2012-05-25 00:00:00

Penalty

Initial $7000.00 · Current $7000.00

General-duty citation text

29 CFR 1910.119(j)(6)(ii):     Appropriate checks and inspections shall be performed to assure that equipment is installed properly and consistent with design specifications and the manufacturer's instructions.    a) At the establishment in the chlorination department, appropriate checks and inspections were not performed to assure that equipment was installed properly and consistent with design specifications to prevent the installation of a 3" X 18" stainless steel flex hose having a non-static dissipating PTFE liner.  Previously the company used a 3" X 18" stainless steel flex hose having a static dissipating PTFE liner on the 20 reactor recirculation line.

Issued

2012-04-25 00:00:00

Abate by

2012-05-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(j)(6)(iii):     The employer shall assure that maintenance materials, spare parts and equipment are suitable for the process application for which they will be used.    a) At the establishment in the chlorination department, the employer did not assure prior to replacing the 3" X 18" stainless steel flex hose in the 20 reactor recirculation line, that the replacement flex hose was suitable for the application.  Previously the company used a 3" X 18" stainless steel flex hose with a static dissipating PTFE liner. The 3" X 18" stainless steel flex hose was replaced with a 3" X 18" stainless steel flex hose with a PTFE (non-static dissipating) liner. On or about November 3, 2011, a 3" x 18" stainless steel flexible hose lined with PTFE (non-static dissipating) on the discharge side of the R-20 recirculation pump ruptured releasing the contents of 20 reactor exposing employees to contact and inhalation hazards of chlorine, hydrogen chloride, carbon tetrachloride, and chloroform.

Issued

2012-04-25 00:00:00

Penalty

Initial $7000.00 · Current $7000.00

General-duty citation text

29 CFR 1910.119(l)(1):     The employer shall establish and implement written procedures to manage changes (except for "replacements in kind") to process chemicals, technology, equipment, and procedures; and, changes to facilities that affect a covered process.    a) At the facility in the chlorination department, the employer did not assure that a written management of change was established and implemented prior to replacing the 3" x 18" stainless steel flex hose having a static dissipating PTFE liner on the 20 reactor recirculating pump with a 3" x 18" stainless steel flex hose having a PTFE liner (non-static dissipating). Company records indicate that a 3" x 18" stainless steel flex hose having a PTFE liner (non-static dissipating) was installed on or about 9/24/2010, 9/30/2011 and 11/01/2011.

Issued

2012-04-25 00:00:00

Abate by

2012-05-25 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(l)(3):     Employees involved in operating a process and maintenance and contract employees whose job tasks will be affected by a change in the process shall be informed of, and trained in, the change prior to start-up of the process or affected part of the process.    a) At the facility in the chlorination department, process operators and maintenance technicians responsible for installing a 3" X 18" stainless steel flex hose on the 20 reactor recirculation line had not been informed or trained on the differences of the two types of flex hoses that were made available to them for replacement use. The company provided a 3" X 18" stainless steel flex hose with a static dissipating PTFE liner and a 3" X 18" stainless steel flex hose with a PTFE liner (non-static dissipating).