Text For Citation: 01 Item/Group: 001 Hazard: BURNS

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: On or about 8/24/96, 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: a) An explosion hazard in the event of a failure in the water cooling system during the operation of GCA furnaces #1 and #2. On 8/24/96, water flow was interrupted in the particular branch of the closed loop water cooling system that supplied cooling water to the bottom head of the GCA furnace #2. Overheating occurred in the bottom head, the cooling water line ruptured, and a structural failure occurred in the water jacket allowing water/steam to enter the furnace core at maximum operating temperature. The furnace exploded, critically burning one employee and seriously burning two other employees. Among other methods, one feasible and acceptable abatement method to correct this hazard is to: a) Provide cooling water in the closed furnace loop which complies with manufacturer's specifications in section 4.2.1 of the installation, operation, and maintenance instructions for the furnaces (see Exhibit A), and NFPA 86D-1979, section 2-6.12 (Exhibit D). AND b) Install individual pressure relief valves on all existing water circuits as recommended in section 4.2.3.1 of the installation, operation, and maintenance instructions for the furnaces (see Exhibit A). Install them so that they are readily observable by the operator. (see Exhibit D, NFPA 86D-1979, section 2-6.12) AND c) Install pressure and temperature gages on exit cooling lines as required in NFPA 86D- 1979, section 2-12.3 (Exhibit D). AND d) Connect the temperature gages to alarms and to de-energize the furnace system whenever a set temperature is exceeded. (see Exhibit D, NFPA 86D-1979, section 5-3.3) AND e) Provide training about explosion hazards to operators. (see Exhibit D, NFPA 86D- 1979, section 1-9(f)(2)) AND f) Thoroughly instruct and train all operating, maintenance, and appropriate supervisory personnel under the direction of a qualified person(s) and require them to demonstrate understanding of the equipment and its operation to ensure knowledge of and practice of safe operating procedures. (see Exhibit H, excerpt from NFPA 86D-1995, section 1-5.2) AND g) Expand maintenance program to ensure that the equipment is in proper working order. Program must include operational and maintenance checklists covering components such as but not limited to vacuum system, resistance heaters, water cooling system, thermocouple, instrumentation, interlocks, and alarms. (see Exhibit D, NFPA 86D-1979, sections 11-1, 11-2, and A-11-2)