OSHA Inspection: LONE STAR BAKERY

Issued

2015-10-27 00:00:00

Abate by

2015-11-29 00:00:00

Penalty

Initial $5500.00 · Current $3300.00 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): The employer's piping and instrument diagrams were not accurate and did not represent equipment that was existing and was part of the process.    On May 19, 2015 and at times prior thereto and possibly at times subsequent thereto at Lone Star Bakery's Plant 2 in China Grove, Texas the employer's piping and instrument diagrams for the refrigeration system did not accurately represent the piping that is installed and in service.        a) The employer's P&ID P-02 Rev. 2 did not represent piping installed downstream of valves in refrigerant piping at the recirculator pumps for the VRP-2 recirculator.        b) The employer's P&ID P-01B Rev. 2 did not represent piping installed downstream of valves in refrigerant piping at the recirculator pumps for the VRP-3 recirculator.       c) The employer's P&ID P-03 Rev. 2 did not represent piping installed downstream of valves in refrigerant piping at the recirculator pumps for the VRP-1 recirculator.

Issued

2015-10-27 00:00:00

Abate by

2015-11-29 00:00:00

Penalty

Initial $5500.00 · Current $3300.00 Reduced

General-duty citation text

29 CFR 1910.119(e)(1): The process hazard analysis was not appropriate to the complexity of the process and did not identify, evaluate, and control the hazards involved in the process:     On May 19, 2015 and at times prior thereto and possibly at times subsequent thereto at Lone Star Bakery's Plant 2 in China Grove, Texas the employer process hazard analysis did not identify, evaluate, and control potential loss of containment and associated hazards when transferring liquid ammonia between recirculator vessels to relieve high liquid levels.

Issued

2015-10-27 00:00:00

Abate by

2015-11-29 00:00:00

Penalty

Initial $7000.00 · Current $4200.00 Reduced

General-duty citation text

29 CFR 1910.119(f)(1)(ii)(B): The employer did not develop and implement written operating procedures that provide clear instructions for steps required to correct or avoid deviation from the operating limits in the covered process.    On May 10, 2015 and at times prior thereto and possibly at times subsequent thereto at Lone Star Bakery's Plant 2 in China Grove, Texas the employer did not develop and implement  written operating procedures that provide clear instructions for steps required to alleviate high level conditions in the VRP-2 recirculator.

Issued

2015-10-27 00:00:00

Abate by

2015-11-29 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(f)(4): The employer did not develop and implement safe work practices to provide for the control of hazards during operations such as lockout/tagout; confined space entry; opening process equipment or piping; and control over entrance into a facility by maintenance, contractor, laboratory, or other support personnel:  On or around May 19, 2015 and at times prior thereto and possibly at times subsequent thereto, the employer did not implement a safe work practice to provide for and control hazards when opening lines in the refrigeration system while reconfiguring the equipment to transfer liquid ammonia from the VRP-2 recirculator to another recirculator vessel to alleviate high liquid level in the VRP-2 recirculator.

Issued

2015-10-27 00:00:00

Abate by

2015-11-29 00:00:00

Penalty

Initial $5500.00 · Current $3300.00 Reduced

General-duty citation text

29 CFR 1910.119(l)(2)(ii): The employer's management of change procedures did not assure that the impact of changes on safety and health were addressed prior to any change.    On May 19, 2015 and at times prior thereto and possibly at times subsequent thereto at Lone Star Bakery's Plant 2 in China Grove, Texas the employer did not address the impacts that changes to the fixed monitoring would have on safety when:       a) the employer did not ensure that sensors were calibrated as recommended by the sensor manufacturer.      b) the employer silenced alarms and allowed faulted sensors to remain in service in the ammonia monitoring system.

Issued

2015-10-27 00:00:00

Abate by

2015-11-29 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(j)(4)(iii): The frequency of inspections and tests of process equipment was not consistent with applicable manufacturers recommendations and good engineering practices, and more frequently if determined to be necessary by prior operating experience.  On/around May 19, 2015 at the Lone Star Bakery Plant 2 facility in China Grove, Texas, the employer failed to calibrate fixed monitors that are installed to warn of and quantify an ammonia release at frequency consistent with manufacturer recommendations and good engineering practices.      (a) Sensor 2-01 in the +45 Process Room was last calibrated on 2/24/2014.      (b) Sensor 2-02 in the +45 Process Room was last calibrated on 2/24/2014.     (c) Sensor 2-03 in the +45 Process Room was last calibrated on 2/24/2014.     (d) Sensor 2-04 on the #1 Dock was last calibrated on 2/24/2014.     (e) Sensor 2-05 in the +34 Cooler was last calibrated on 2/24/2014.     (f) There is no record that shows that Sensor 2-06 in the #1 Freezer was calibrated.      (g) Sensor 2-08 in Spiral #4  was last calibrated on 2/24/2014.     (h) Sensor 2-09 in the Packing Room was last calibrated on 2/24/2014.     (i) Sensor 2-10 in the Packing Room was last calibrated on 2/24/2014.     (j) Sensor 2-11 In the Packing Room was last calibrated on 2/24/2014.     (k) Sensor 2-12 on the #2 Dock was last calibrated on 2/24/2014.      (l) Sensor 2-13 in the #2 Freezer  was last calibrated on 2/24/2014.     (m) Sensor 2-14 in the #2 Freezer was last calibrated on 2/24/2014.      (n) Sensor 2-15 in the Engine Room was last calibrated on 2/24/2014.       (o) Sensor 2-16 in the Engine Room was last calibrated on 2/24/2014.     (p) Sensor 2-17 in the Spiral Freezer #5 was last calibrated on 2/24/2014.      (q) Sensor 2-18 in the Spiral Freezer #6 was last calibrated on 2/24/2014.     (r) Sensor 2-19 in the Engine Room was last calibrated on 2/24/2014.      (s) Sensor 2-20 in the Engine Room was last calibrated on 2/24/2014.      (t) There is no record that shows that Sensor 2-21 was calibrated. The employer did not provide detail of where this sensor is installed.

Issued

2015-10-27 00:00:00

Abate by

2015-11-29 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.119(j)(5): The employer did not correct deficiencies in equipment that were outside acceptable limits (defined by the process safety information on paragraph (d) of this section) in a safe and timely manner when necessary means where taken to assure safe operation.  On May 19, 2015 and at times prior thereto and possibly at times subsequent thereto at Lone Star Bakery's Plant 2 in China Grove, Texas the employer did not correct deficiencies in the ammonia detection system. The employer relied on sensors that were in deficient condition including but not limited to sensors being out of calibration and sensors in faulted condition to monitor process areas for ammonia.        (a) Sensor 2-02 in the +45 Process Room was last calibrated on 2/24/2014. At the control panel for the ammonia monitoring system, a fault was showing for this sensor, the BZ1 alarm was activated, and the sensor registering 6 ppm NH3.     (b) Sensor 2-05 in the +34 Cooler was last calibrated on 2/24/2014.  At the control panel for the ammonia monitoring system, a fault was showing for this sensor and the BZ1 alarm was activated and the sensor was offline.     (c) Sensor 2-11 in the Packing Room was last calibrated on 2/24/2014. At the control panel for the ammonia monitor system, a fault was showing for this sensor, R01 was on and the sensor registering 7 ppm NH3.      (d) Sensor 2-12 on the #2 Dock was last calibrated on 2/24/2014. At the control panel for the ammonia monitoring system, a fault was showing for this sensor, the STR alarm was activated, and the sensor registering 5 ppm NH3.     (e) Sensor 2-13 in the #2 Freezer  was last calibrated on 2/24/2014. At the control panel for the ammonia monitor system, a fault was showing for this sensor and the STR was alarming.     (f) Sensor 2-14 in the #2 Freezer was last calibrated on 2/24/2014. At the control panel for the ammonia monitor system, a fault was showing for this sensor, the BZ1 was alarming while the sensor was registering 0 ppm NH3.     (g) Sensor 2-15 in the Engine Room was last calibrated on 2/24/2014.  At the control panel for the ammonia monitoring system, a fault was showing for this sensor, the STR alarm was activated, and the sensor was registering 0 ppm NH3.     (h) Sensor 2-16 in the Engine Room was last calibrated on 2/24/2014. At the control panel for the ammonia monitoring system, a fault was showing for this sensor and the STR was alarming.     (i) There is no record that shows that Sensor 2-21 was calibrated. The employer did not provide detail of where this sensor is installed. At the control panel for the ammonia monitoring system, a fault was showing for this sensor, the STR was shown to be alarming, and the sensor was shown to be offline.   Although the control panel was showing the alarm annunciators, the alarms  had been silenced and/or were not active in the work areas.