On July 14, 2009, Employees #1 and #2 were performing a pneumatic test to verify leak tightness of a new pipeline meter station. The test medium was nitrogen gas, and the system being tested included piping and two (2) pressure vessels.
Numerous leaks were found in the system during the test. The system reached the required test pressure of 2225 psig at approximately 3:25 p.m., and Employee #1 observed that the pressure on the system had dropped to 2205 by approximately 3:30p.m.
Employee #1 was then replaced at the test table by Employee #2. As Employee #1 walked away from the test table, the door on the PECO separator (a pressure vessel) blew off, releasing pressurized nitrogen gas that sent projectiles flying. Employee #2 was killed, and Employee #1 suffered burns and was hospitalized.
Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees, in that, employees were exposed to hazard of being struck by:
(a) SONAT Metering Station – On or about July 15, 2009 employees were exposed to the hazard of being struck by high pressure gas, flying projectiles and other debris from the rupture of piping and pressure vessels during leak testing of gas metering stations that were pressurized with nitrogen gas.
Employees performing pressure test were not protected from the hazards by the use of: hazards that were causing or likely to cause death or serious physical harm to employees, in that, employees were exposed to hazard of being struck by:
(a) SONAT Metering Station – On or about July 15, 2009 employees were exposed to the hazard of being struck by high pressure gas, flying projectiles and other debris from the rupture of piping and pressure vessels during leak testing of gas metering stations that were pressurized with nitrogen gas. Employees performing pressure test were not protected from the hazards by the use of:
a. Hydrostatic testing unless analysis demonstrate that hydrostatic testing is not feasible
b. Remove employees from the area Among other methods, one feasible and acceptable abatement method to correct this hazard is to: Use hydrostatic (liquid) testing when feasible as specified in ASME B31.1- 2007, move non-essential employees to a safe distance as specified in the company’s document entitled “Specifications for Nitrogen Pressure Testing” and provide physical barrier where feasible to protect employees from flying projectiles. Gradually increase pressure in steps until test pressure is reached.
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 2 | 2 | ||||
| Current Violations | 1 | 1 | 2 | |||
| Initial Penalty | $5,500 | $0 | $0 | $0 | $0 | $5,500 |
| Current Penalty | $4,900 | $0 | $0 | $0 | $0 | $4,900 |
| 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 | 5A0001 | 01/11/2010 | 01/14/2010 | $4,900 | $4,900 | $0 | – | ||
| 2. | 01002 | Other | 19261052 C01 | 01/11/2010 | 01/14/2010 | $0 | $600 | $0 | I – Informal Settlement |
Source: https://www.osha.gov/ords/imis/establishment.inspection_detail?id=311420830