At approximately 2:30 p.m. on March 2, 2011, six workers were employed as milling or planing machine operators at a corn and flour milling facility in Lincoln, NE. A chlorine leak was detected in the chlorine room, so the milling superintendent and a miller/operator entered the chlorine storage room and closed a manual valve on a manifold. The facility was evacuated, and members of the local fire department and a hazmat team responded. The expanding cloud of chlorine gas seeped from the storage area on the east side of the facility. It entered the negative pressure mill and surrounding outside area. Employees working in the immediate area and in the mill were exposed. Employees were also exposed as they were evacuating their work areas. Seven employees were transported to three local hospitals. Six of the employees were treated and released without needing hospitalization. One employee remained hospitalized overnight. One additional employee was treated on the scene by fire department paramedics. Only the seven employees who were transported to the hospitals were mentioned in the narrative. Because some 8,000 lbs. of chlorine were at the facility, the site was subject to process safety management standards. It was later determined that a vacuum regulator in the chlorine process piping system had ruptured.
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Violation Summary
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|---|---|---|---|---|---|
| Serious | Willful | Repeat | Other | Total | |
| Initial Violations | 8 | 8 | |||
| Current Violations | 5 | 1 | 6 | ||
| Initial Penalty | $41,400 | $0 | $0 | $0 | $41,400 |
| Current Penalty | $24,000 | $0 | $0 | $3,400 | $27,400 |
| FTA Amount | $0 | $0 | $0 | $0 | $0 |
| Violation Items | |||||||||
|---|---|---|---|---|---|---|---|---|---|
| # | ID | Type | Standard | Issuance | Abate | Curr$ | Init$ | Last Event | |
| 1. | 01001 | Serious |
19100119 E03 – The process hazard analysis shall address:… |
04/18/2011 | 09/30/2011 | $5,000 | $5,000 | I – Informal Settlement | |
| 2. | 01002 | Serious |
19100119 E04 – The process hazard analysis shall be performed by a team with expertise in engineering and process operations, and the team shall include at least one employee who has experience and knowledge specific to the process being evaluated. Also, one member of the team must be knowledgeable in the specific process hazard analysis methodology being used. |
04/18/2011 | 05/20/2011 | $5,000 | $5,000 | I – Informal Settlement | |
| 3. | 01003A | Serious |
19100119 J02 – Written procedures. The employer shall establish and implement written procedures to maintain the on-going integrity of process equipment. |
04/18/2011 | 09/30/2011 | $5,000 | $5,000 | I – Informal Settlement | |
| Deleted | 4. | 01003B | Serious |
19100119 J04 IV – The employer shall document each inspection and test that has been performed on process equipment. The documentation shall identify the date of the inspection or test, the name of the person who performed the inspection or test, the serial number or other identifier of the equipment on which the inspection or test was performed, a description of the inspection or test performed, and the results of the inspection or test. |
04/18/2011 | 06/20/2011 | $0 | $0 | I – Informal Settlement |
| 5. | 01004 | Serious |
19100119 O04 – The employer shall promptly determine and document an appropriate response to each of the findings of the compliance audit, and document that deficiencies have been corrected. |
04/18/2011 | 09/30/2011 | $5,000 | $5,000 | I – Informal Settlement | |
| Deleted | 6. | 01005 | Serious |
19100120 Q06 – First responder operations level. First responders at the operations level are individuals who respond to releases or potential releases of hazardous substances as part of the initial response to the site for the purpose of protecting nearby persons, property, or the environment from the effects of the release. They are trained to respond in a defensive fashion without actually trying to stop the release. Their function is to contain the release from a safe distance, keep it from spreading, and prevent exposures. First responders at the operational level shall have received at least eight hours of training or have had sufficient experience to objectively demonstrate competency in the following areas in addition to those listed for the awareness level and the employer shall so certify: |
04/18/2011 | 05/20/2011 | $7,000 | $7,000 | I – Informal Settlement |
| Deleted | 7. | 01006 | Serious |
19100132 A – Application. Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers, shall be provided, used, and maintained in a sanitary and reliable condition wherever it is necessary by reason of hazards of processes or environment, chemical hazards, radiological hazards, or mechanical irritants encountered in a manner capable of causing injury or impairment in the function of any part of the body through absorption, inhalation or physical contact. |
04/18/2011 | 05/20/2011 | $7,000 | $7,000 | I – Informal Settlement |
| 8. | 01007 | Serious |
19100151 C – Where the eyes or body of any person may be exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body shall be provided within the work area for immediate emergency use. |
04/18/2011 | 05/21/2011 | $4,000 | $4,000 | I – Informal Settlement | |
| 9. | 01008 | Other |
19101200 H03 II – The physical, health, simple asphyxiation, combustible dust, and pyrophoric gas hazards, as well as hazards not otherwise classified, of the chemicals in the work area; |
04/18/2011 | 03/16/2011 | $3,400 | $3,400 | I – Informal Settlement | |
Source: https://www.osha.gov/pls/imis/establishment.inspection_detail?id=314059460