Pressure Test Gone Bad (air-cooled heat exchanger)

At 4:00 p.m. on April 14, 2023, an employee, 23, working for a structural sheet metal manufacturer, was performing hydrostatic testing on an air-conditioned heat exchanger. A plug failed under pressure, striking the employee. The employee was killed after being impaled in the chest by the plug.

Violations/PenaltiesSeriousWillfulRepeatOtherUnclassTotal
Initial Violations11
Current Violations11
Initial Penalty$10,938$0$0$0$0$10,938
Current Penalty$8,500$0$0$0$0$8,500
FTA Penalty$0$0$0$0$0$0
#Citation IDCitaton TypeStandard CitedIssuance DateAbatement Due DateCurrent PenaltyInitial PenaltyContestLatest EventNote
1.01001Serious5A000110/11/202310/30/2023$8,500$10,938I – Informal Settlement 

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 struck-by hazards during pressure testing operations:

On or about April 14, 2023, and at times prior to, pressure testing on equipment, including but not limited to air-cooled heat exchangers (ACHE), exposed employees in the vicinity of the test area to struck-by hazards from plugs, fittings, and other projectiles.

Source: https://www.osha.gov/ords/imis/establishment.violation_detail?id=1663973.015&citation_id=01001

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