June 7 2017 Washington DC USDOLOSHA Directorate of Enforcement Programs Office of Chemical Process Safety and Enforcement Initiatives So We Dont Experience This 2 We Updated This ID: 633921
Download Presentation The PPT/PDF document "CHEM NEP Update Industry Outreach" is the property of its rightful owner. Permission is granted to download and print the materials on this web site for personal, non-commercial use only, and to display it on your personal computer provided you do not modify the materials and that you retain all copyright notices contained in the materials. By downloading content from our website, you accept the terms of this agreement.
Slide1
CHEM NEP UpdateIndustry Outreach
June 7, 2017Washington, DC
USDOL-OSHA, Directorate of Enforcement ProgramsOffice of Chemical Process Safety and Enforcement InitiativesSlide2
So We Don’t Experience This….2Slide3
We Updated This…….
OSHA CHEM
NEP3Slide4
Overview
PSM
CHEM NEP UpdateStatus of PSM enforcement memosCHEM NEP enforcement data
4Slide5
The PSM Covered Chemical Facilities NEP (CHEM NEP) has been updated effective
January 17, 2017
Implementation for programmed inspections on hold until outreach is completedThe revised NEP could be used for unprogrammed PSM activity/inspection since 1/17/2017
CHEM NEP Update
5Slide6
Biggest ChangeAll non-VPP refineries
will be inspected (over time) using the CHEM NEP modelLimited number of questions (~15)Dynamic list only
6Slide7
CHEM NEP - Refineries (Continued)
This is a follow-on to the Refinery NEP using the CHEM NEP approach
Better use of OSHA resourcesAverage current hours for CHEM NEP inspection ~ 125 person-hours
Average
Refinery NEP
inspection ~
1,100
person-hours
Inspections will be distributed proportionally across regions based on the number of refineries per region
7Slide8
CHEM NEP (Continued)
This update requires mandatory
State-Plan adoptionInspection targeting population expanded to include EPA RMP Program 1 and 2 sites.Inspection targeting system set up such that no RMP Program 2 sites which include Ag ammonia are to be inspected under the CHEM NEP8Slide9
CHEM NEP - Pyrotechnics
Clarified targeted population includes both explosive and pyrotechnics
manufacturing facilities9Slide10
CHEM NEP – Target Population
Category 1 – Facilities with NAICS Codes likely to have ammonia used for refrigeration as the only HHC;Category 2
– NAICS 32411 or 324110, Petroleum Refineries;Category 3 – NAICS 325, Chemical Manufacturing;Category 4 - NAICS Codes for facilities that are likely PSM covered but not Category 1, Category 2, or Category 3 (all other PSM-Covered processes).10Slide11
CHEM NEP (Continued)
Some mechanics have changed in this
updated NEPTargeting and dynamic lists are on an internal OSHA website.
Refinery inspections count toward the required number of programmed NEP inspections per area office averaged over each Region
Refinery inspections use the same dynamic list questions as other chemical manufacturing PSM covered facilities
11Slide12
CHEM NEP – Tools for Expanded Inspections
Additional inspection resource tools have been added for expanded inspections:Prior CHEM NEP Dynamic Lists
Appendix A – Static List from Refinery NEPAppendix A - PSM CPL Audit GuidelinesAppendix B - Supplemental Questions for Hazard Identification contained in Guidelines for Hazard Evaluation Procedures (Third Edition), AIChE – CCPS12Slide13
CHEM NEP – Dynamic ListsAmmonia Refrigeration
Chemical Processing Chemical manufacturing (NAICS 325) and petroleum refining (NAICS 324110 )Includes separate questions for explosive and pyrotechnic manufacturingPSM GeneralContractor (Host and contractor)
13Slide14
Dynamic List Utilization Depends on Type FacilityExample: Pyrotechnics Manufacturing
W questions from Explosives and pyrotechnics manufacturing listX questions from Chemical Processing listY questions from PSM General listZ questions from Contractor Employer listExample: Storage Only facilitiesX questions from PSM General list
Y questions from Contractor Employer list14Slide15
CSHO Competencies15Slide16
Status of PSM Enforcement Memos
Retail ExemptionAwaiting decisionRAGAGEPPublished May 11, 2016Covered Concentrations
July 18, 2016Interim enforcement policy thru 3/31/201818Slide17
692 Inspections in 140 NAICS codes491 inspections with violations
23 open and unissued inspections2,202 proposed violationsAverage 4.79 violations per inspection with citationsPenalties proposed – total $13,989,862Mean $26,975 per inspection
Median $14,000 per inspectionMax $430,43017
All
CHEM NEP
Inspections Opened
FY14
thru FY16Slide18
78 standards cited1910, 1926, 1904, 1903, and General Duty Clause84% standards in General Industry (Part 1910)66% of GI violations in PSM (1910.119)
Programmed – 52%Unprogrammed – 48%Unprogrammed includes Complaint, Referral, Fatality/Multiple Hospitalization, etc.
18
All
CHEM NEP
Inspections Opened
FY14 thru FY16Slide19
Standard
Description
%1910.119
Process Safety Management
65.9
1910.134
Respiratory Protection
3.8
1910.1200
HazCom
2.6
1910.147
Lockout / Tagout
2.5
1910.305
Electrical Wiring
2.0
1910.23
Ladders
1.7
1910.120
HazWoper
1.5
5(a)(1)
OSH Act of 1970, Section 5(a)(1)
1.5
1910.132
PPE General
1.5
1910.212
Machine Guarding
1.2
All
CHEM NEP Inspections - Top 10 Violations
FY14
thru FY16
19Slide20
All ChemNEP Violations by PSM
Element
FY14 thru FY16
Element
Description
% of PSM Citations
d
Process Safety Information
23.6
j
Mechanical Integrity
23.6
e
Process Hazard
Analysis
15.3
f
Operating Procedures
13.5
l
Management of Change
6.4
o
Compliance Audits
3.8
h
Contractors
3.4
g
Training
2.8
n
Emergency Planning & Response
2.5
m
Incident Investigation
2.1
c
Employee participation
1.7
i
Pre-startup Review
1.0
76%
20Slide21
All
CHEM NEP
Top PSM - Sub-elements
FY14 thru FY16
Sub-element
Description
% of PSM Citations
119(j)(2)
MI written procedures
7.0
119(d)(3)(ii)
PSI RAGAGEP compliance
6.4
119(d)(3)(i)(B)
PSI P&IDs
4.4
119(j)(5)
MI Equipment
Deficiencies
3.5
119(j)(4)(i)
MI I&T not performed
3.5
119(l)(1)
Management of Change dev & imp
3.5
119(f)(1)
OP Developed & Implemented
3.2
119(e)(5)
PHA findings & recommendations
3.0
119(j)(4)(ii)
MI I&T not in accordance w/ RAGAGEP
3.0
119(j)(4)(iii)
Inspection frequency inconsistent with RAGAGEP
2.7
119(n)
Emergency Planning & Response
2.5
119(e)(3)(i)
PHA Hazards of the Process
2.4
119(d)(3)(i)(D)
Relief System Design
2.4
21Slide22
22
Questions?
Office of Chemical Process Safety & Enforcement InitiativesJeff Wanko: 202-693-2137 jwanko@dol.govJim Lay: 202-693-1827 lay.jim@dol.govMike Marshall: 202-693-2179 marshall.mike@dol.gov