At 10:00 p.m. on October 10, 2024, an employee (33) and a coworker, both boilermakers for a facilities support service, were working on a 12-inch pipe to flip the blind. The pipe released hydrogen sulfide gas, exposing the crew. The employee died from poisoning from the hydrogen sulfide gas.
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 3 | 3 | ||||
| Current Violations | 3 | 3 | ||||
| Initial Penalty | $49,650 | $0 | $0 | $0 | $0 | $49,650 |
| Current Penalty | $49,650 | $0 | $0 | $0 | $0 | $49,650 |
| FTA Penalty | $0 | $0 | $0 | $0 | $0 | $0 |
| # | Citation ID | Citaton Type | Standard Cited | Issuance Date | Abatement Due Date | Current Penalty | Initial Penalty | FTA Penalty | Contest | Latest Event | Note |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1. | 01001 | Serious | 19100119 H03 II | 04/10/2025 | 05/22/2025 | $16,550 | $16,550 | $0 | 05/02/2025 | C – Contested | |
| 2. | 01002 | Serious | 19100119 H03 IV | 04/10/2025 | 05/22/2025 | $16,550 | $16,550 | $0 | 05/02/2025 | C – Contested | |
| 3. | 01003A | Serious | 19100147 C04 I | 04/10/2025 | 05/22/2025 | $16,550 | $16,550 | $0 | 05/02/2025 | C – Contested | |
| 4. | 01003B | Serious | 19100147 D06 | 04/10/2025 | 05/22/2025 | $0 | $0 | $0 | 05/02/2025 | C – Contested | Citation Type |
29 CFR 1910.119(h)(3)(iv): The contract employer did not ensure that each contract worker followed the safe work practices of the facility.
On or about October 10, 2024, in ARU #6/7 at Deer Park Refinery Limited located in Deer Park, TX, the contract employer (Repcon, Inc.) did not ensure that its workers follow the required host employer safe work practices including but not limited to:
a) Repcon supervisors and employees did not sign in on the unit entry log before entering the process unit and they did not sign out upon leaving.
b) Repcon supervisors did not discuss the identified hazards and control measures with all craftworkers working on the permits (#410545, #411121 and #411125) in their Job Safety Analyses (JSAs).
c) Repcon supervisors did not follow the instructions in the work permit# 411125 and failed to ensure the unit operator was present for line break work for the CAG header and flare line.
d) Repcon supervisors did not complete the written contingency plan with the unit operator before accepting the work permit# 411125.
e) Repcon supervisors did not ensure that all crew members signed onto the Master Isolation Sheet and reviewed the contingency plan and isolation points.
29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:
On or about October 10, 2024, in ARU #6/7 at Deer Park Refinery Limited located in Deer Park, TX, the contract employer (Repcon, Inc.) failed to utilize and implement its energy control procedure, “Lockout/Tagout and Try”, Policy# SFTY046 included but not limited to the following steps:
a) Repcon supervisors did not train employees in the recognition of hazardous energy sources and the method and means of isolating such sources.
b) Repcon supervisors did not continuously monitor the work to assure compliance with the procedure including required inspections and documentation.
c) Repcon supervisors did not ensure and verify that the Client Operations Department had initiated their lockout procedures and all valves, blinds, blocks, etc., were locked out to assure energy source isolation before the contract employees performing the line break work on CAG header and flare line.
d) Repcon supervisors failed to ensure that the equipment was disconnected from the energy source(s) by first checking that no personnel were exposed, then verified the isolation of the equipment by normal operating control(s) or by testing to make certain the equipment did not operate.
29 CFR 1910.147(d)(6): Prior to starting work on machines or equipment that have been locked out or tagged out, the authorized employee did not verify that isolation and de-energization of the machine or equipment had been accomplished.
On or about October 10, 2024, in ARU #6/7 at Deer Park Refinery Limited located in Deer Park, TX, the contract employer (Repcon, Inc.) did not verify that isolation and de-energization of 12-inch CAG header line/flange had been accomplished prior to starting work on the line.
Source: https://www.osha.gov/ords/imis/establishment.inspection_detail?id=1781440.015