OSHA found several deficiencies in the plant's process safety
management program, a detailed set of requirements and procedures employers must
follow to address proactively hazards associated with processes and equipment
involving large amounts of hazardous chemicals. In this case, the chemical was
n-pentane, an organic compound used in the manufacturing process. The cited
deficiencies included missing process safety information, failing to develop and
implement safe work practices, correct equipment deficiencies, follow up on the
findings of compliance audits, address all hazards identified during a process
hazard analysis, and document the resolution of corrective actions. A serious
violation occurs when there is substantial probability that death or serious
physical harm could result from a hazard about which the employer knew or should
have known.
"The stringent and comprehensive requirements of OSHA's
process safety management standard are designed to prevent catastrophic
incidents, such as the uncontrolled release of highly hazardous chemicals," said
Kimberly Castillon, OSHA's area director in Albany. "The safety and well-being
of employees requires full, effective and proactive adherence to the standard's
requirements by the employer."
OSHA's inspection also identified deficiencies in the plant's
emergency response, confined space and hazardous energy control programs, lack
of personal protective equipment, accumulation of combustible dust, as well as
fall and respirator hazards.
"One method of enhancing workers' safety is for an employer to
develop and maintain an effective illness and injury prevention program in which
management and employees work together to identify and prevent hazardous
conditions," said Robert Kulick, OSHA's regional administrator in New York.
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