Torque Wrenches for Ammonia refrigeration valves

Yes, it really has come to this. Let’s start with a single citation…

What equipment could this citation be concerning? Take a look at the compliance officer’s narrative:

The officer went on to say in the OSHA 1-B Inspection worksheet:

All valves with flange bolts (Hansen/Parker Hanafin) used in the covered process need to be torqued with a torque wrench consistent with the manufacturer’s specification and their RAGAGEP. Although the FACILITY contracts out the Mechanical Integrity work to CONTRACTOR the FACILITY did not have the specific language in the contract or a way to ensure that valves are torqued properly. Improperly installed flange bolts that aren’t torques properly may result in a release of a highly hazardous chemical such as ammonia.

This may sound absurd to many with experience in the Ammonia industry, but don’t take this lightly: I am aware of at least four facilities that have been cited for not using torque wrenches for flanged valve installation. I am also aware of at least one repeat citation for $25,000! Once something like this has been established, you can expect to see it over and over again.
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Both the RAGAGEP (IIAR) and the PSM/RMP regulations say we should install equipment in accordance with the manufacturer’s recommendations. When the manufacturer includes “published torque specifications”, we have no choice but to follow them.
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For reference: Parker and Hansen
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I‘ll quote Hansen: “For proper sealing, gaskets should be lightly oiled and all bolts must be tightened evenly to published torque specifications”
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Trevor Kletz on “macho culture” in the PSM regulated world

If you are unfamiliar with Trevor Kletz, to the PSM world he’s the equivalent of what Elvis was to Rock ‘n’ Roll…

“Many workers don’t see the need to follow all the rules or the permit-to-work procedures… Our job, they say, is to get stuck in and get the job done, not fill in forms. In time this macho approach becomes the local custom and practice… It’s easy to point the finger at the management and assume that a culture of cutting corners started at the top. It is worth remembering that the same culture can also originate at the bottom, driven by the desire to get the job done. The task of management is to know this and make sure it’s done properly.” –Trevor Kletz

How many times have you heard “I’m a refrigeration tech, not a secretary” in regards to PSM paperwork? We need to work harder to convince our technicians that doing things the PSM way *is* doing things the right way. If the PSM way takes a bit longer – so be it. It’s much more important that they get the job done SAFELY than that they get the job done in the smallest amount of time!

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OSHA cites Kraft in Madison Wisconsin

MADISON, Wis. – The U.S. Department of Labor’s Occupational Safety and Health Administration has cited Kraft Foods Inc. for 12 serious and one other-than-serious safety violation at a facility of its subsidiary, Oscar Meyer, in Madison. Proposed fines total $75,000. –OSHA

You can read the actual citations right here.

There are some things in this citation I’ve been talking about for a while now – things that generally lead to very heated conversations! Here are two of them:

P&ID accuracy REALLY does matter!

As for the next item – let’s consider it a “shot across the bow” to the industry:

The next time this comes up at any Kraft facility it can be considered a Repeat or Willful citation with a penalty cap of $70,000!

Do your Management of Change procedures cover changes to key personnel? They certainly should, shouldn’t they?

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On my way to the RETA conference in Greensboro, North Carolina

Hopefully I’ll run into some of you there!

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Bostik Fines – Following up on Audit Recommendations MATTERS!

BOSTON – The U.S. Department of Labor’s Occupational Safety and Health Administration has cited Bostik Inc. for 50 alleged violations of workplace safety standards following a March 13 explosion at the company’s Middleton plant in which four workers were injured. The adhesives manufacturer faces a total of $917,000 in proposed fines.

OSHA’s inspection identified several serious deficiencies in the company’s process safety management program, a detailed set of requirements and procedures employers must follow to proactively address hazards associated with processes and equipment that involve large amounts of hazardous chemicals…

…”In this case, Bostik knew from prior third party and internal compliance audits conducted at the plant that aspects of its PSM program were incomplete or inadequate, and misclassified electrical equipment was in use. The company did not take adequate steps to address those conditions” OSHA

Do YOU have open recommendations from previous compliance audits, PHA’s, Incident Investigations or other sources?

The ventilation system in your compressor room is likely using the ANSI/ASHRAE 15 exception to the NEC. What this means is that as long as your ventilation system conforms to ANSI/ASHRAE 15 you do not need to classify your engine room as a Class 1 Division 2 space – so you don’t need explosion proof electronics. If your ventilation system does NOT conform to ANSI/ASHRAE 15 then you do have to have all your electronics classified for a Class 1 Division 2 space.

If you look at the first portion of the actual citation in this case you will find that there is $350,000 worth of fines for incorrectly classified electrical equipment. There is plenty more to learn from this document; some highlights include:

  • Using non-classified radios and cellphones in classified spaces
  • Lack of training for the Hazmat Team
  • Emergency Response Plan was inadequate
  • Lack of training on Respirators and other Response Gear

We’ll take a look at the second section of the fines in another post.

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A Note on Blog Subscriptions

Quite a few people have signed up for emails when new posts are made via the BlogSubscriptions link.

You may wish to make sure you place bchapin@taocompliance on your safe sender list or the email has a good chance of being trashed as spam. I get about 20 of these failure notices from VersaCold alone every post!

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OSHA 2010 Enforcement Summary and Willful Violations

“In FY 2010, OSHA found 96,742 violations of OSHA’s standards and regulations in the nation’s workplaces, a 15.3% increase since FY 2006.  The total number of serious and repeat violations issued increased by 22.1% and 8.1%, respectively, over the past five years.  The total number of willful violations issued significantly increased by 217.1% since FY 2006 and increased by 278.8% since FY 2009.” —OSHA

It was fairly obvious that OSHA was really concentrating on Willful violations last year but it’s nice to see it quantified. That’s 3x as many as the last four years!

How could this affect you? Do you have an outstanding issue from a PHA, Incident Investigation or Compliance Audit that you have not addressed? If so, you might be looking at a Willful violation.

What is a Willful Violation? Let’s see what OSHA has to say about that:

(1)   A willful violation exists under the Act where the evidence shows either an intentional violation of the Act or plain indifference to its requirements.

(a)      The employer committed an intentional and knowing violation if:

  1. An employer representative was aware of the requirements of the Act, or the existence of an applicable standard or regulation, and was also aware of a condition or practice in violation of those requirements, and did not abate the hazard.
  2. An employer representative was not aware of the requirements of the Act or standards, but was aware of a comparable legal requirement (e.g., state or local law) and was also aware of a condition or practice in violation  of that requirement, and did not abate the hazard.

(2)  The employer committed a violation with plain                   indifference to the law where:

  1. Higher management officials were aware of an OSHA requirement applicable to the company’s business but made little or no effort to communicate the requirement to lower level supervisors and employees.
  2. Company officials were aware of a continuing compliance problem but made little or no effort to avoid violations. EXAMPLE:  Repeated issuance of citations addressing the same or similar conditions.
  3. An employer representative was not aware of any legal requirement, but was aware that a condition or practice was hazardous to the safety or health of   employees and made little or no effort to determine the extent of the problem or to take the corrective action.  Knowledge of a hazard may be gained from such means as insurance company reports, safety committee or other internal reports, the occurrence of illnesses or injuries, media coverage, or, in some cases, complaints of employees or their representatives.
  4. Finally, in particularly flagrant situations, willfulness can be found despite lack of knowledge of either a legal requirement or the existence of a hazard if the circumstances show that the employer would have placed no importance on such knowledge even if he or she had possessed it, or had no concern for the health or safety of employees.

(3)   It is not necessary that the violation be committed with a bad purpose or an evil intent to be deemed “willful.” It is sufficient that the violation was deliberate, voluntary or intentional as distinguished from inadvertent, accidental or ordinarily negligent.

There’s plenty more where that came from. 1(a)(1) Seems to be a pretty clear cut case for not abating a known deficiency from a PHA, Incident Investigation, Compliance Audit, etc.

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The Regulatory Challenge

I came across two recent articles that touch upon the ever-increasing size of the challenge businesses face when it comes to regulation. It’s interesting to see the size of the regulatory apparatus compared to private enterprise:

“If the federal government’s regulatory operation were a business, it would be one of the 50 biggest in the country in terms of revenues, and the third largest in terms of employees, with more people working for it than McDonald’s, Ford, Disney and Boeing combined.”  — Investors Business Daily

How does this work in action? Here’s one specific project involving a 682-mile pipeline Stretching underground from Opal, Wyoming to Malin, Oregon:

In this case the environmental impact statement was a binding agreement between the government and El Paso about how the Ruby project would proceed. It contained detailed instructions for everything from rights-of-way; to “critical habitat” for the blackfooted ferret and Ute ladies’ tresses (a type of orchid); to housing regulations about when the project’s 5,290 workers would stay in campers or area motels; to paleontology rules. After two and half years, and more than 125 “stakeholder” meetings and agency “scoping” hearings, El Paso received the final sign-off in July 2010.

Did we say paleontology rules? Yes, at the height of construction, El Paso had 215 archeologists in the field “to mitigate affects to cultural resources,” as required by the National Historic Preservation Act of 1966.” —WSJ

Regulatory compliance with PSM and RMP is challenging, but they are hardly the most difficult regulatory challenges facing business today!

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PSM NEP Podcast

I spent about two hours in the recording studio today with Jeremy Williams of GCAP. You can listen to the first part of our conversation on the NEP at GCAPCoolCast.com

I’ve spent the last three weeks at GCAP re-working the NEP course book with the rest of the team. GCAP had one heck of a program in place and we’ve worked together to take it to the next level. I’m very excited for the next NEP class!

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PSM National Emphasis Program

If you aren’t familiar with the NEP (National Emphasis Program) currently going on in specific regions it would be well worth your time to get up to speed. Even if you have a top-notch program you’ve got a LOT of work to do to become compliant with the way OSHA is interpreting the requirements of the PSM standard under the NEP.

What is the NEP?

The NEP is a pilot program implemented in 2009 covering regions 1, 7 and 10 that was supposed to last for a year. It is still going on while they rewrite and extend the program with the intent of making it permanent and nation-wide. The old PQV  (Program Quality Verification) audits under CPL 2-2.45 are child’s play compared to an NEP inspection. NEP focuses on implementation: what your program does rather than what it says – it’s a performance audit. The average NEP compliance audit is done by a specially trained team and results in over 7 citations in each facility inspected.

What can I do?

Arm yourself with the knowledge you need to improve your program’s performance so that it meets the higher standards required under the NEP. Here are some steps I would recommend:

  1. Read the Petroleum Refinery NEP paying specific attention to appendix A. This lists the questions to be asked and the possible violations. Some of what you read here is refinery specific, but the inspection is about Process Safety and the vast majority of it is applicable to an NH3 Refrigeration Process.
  2. Expand your personal library to include CCPS books. The Center for Chemical Process Safety publishes many books on effective implementation of PSM programs. Many of those books are directly referenced as RAGAGEP under the NEP. Specifically consider the following:
    • Guidelines for Mechanical Integrity Systems
    • Guidelines for Investigating Chemical Process Incidents
    • Guidelines for Writing Effective Operating and Maintenance Procedures
  3. Find a good NEP class to attend. Obviously I’m partial to the GCAP NEP course. You’ll learn more in this 40hr class there than you can possible imagine.
  4. Network: At a NEP class, you’ll make some important contacts with fellow PSM practitioners. Join the “Ammonia Refrigeration Operators” discussion group on LinkedIn to discuss implementation strategies and NH3 PSM best practices.

The first response to a lot of this information (especially when reading the questions in the refinery NEP) is usually despair: there’s a lot of work ahead. Just remember – you aren’t alone in this unless you choose to be! There are resources out there to assist you. If you are willing to put in the time and effort, compliance to the NEP is achievable!

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Background information:

Previous post on this subject here.

OSHA memo explaining that the NEP will become permanent here.

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