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Violation Detail
Standard Cited: 5A0001 OSH Act General Duty Paragraph
Inspection Nr: 107150161
Citation: 02001
Citation Type: Unclass
Abatement Date: 10/04/1994 X
Initial Penalty: $56,000.00
Current Penalty: $28,000.00
Issuance Date: 09/16/1994
Nr Instances: 1
Nr Exposed: 4
Related Event Code (REC): A
Gravity: 10
Report ID: 0317500
Contest Date: 10/03/1994
Final Order: 07/17/1995
Emphasis:
| Type | Latest Event | Event Date | Penalty | Abatement Due Date | Citation Type | Failure to Abate Inspection |
|---|---|---|---|---|---|---|
| Penalty | J: ALJ Decision | 07/17/1995 | $28,000.00 | 10/04/1994 | Unclass | |
| Penalty | Z: Issued | 09/16/1994 | $56,000.00 | 10/04/1994 | Willful |
Text For Citation: 02 Item/Group: 001 Hazard: BURNS
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 were likely to cause death or serious physical harm to employees in that employees were exposed to severe burns due to furnace explosions and molten metal runouts: (a) Melting Department, # 1 Lectromelt Furnace; There were no established procedures developed and/or implemented for the melting, pouring, inspection, and preventative maintenance for the operation of # 1 Lectromelt Furnace. (1) The furnace was being operated with known "hot spots" resulting in furnace shell breakthrough. (2) Safe Job Procedures were not developed to address "hot spots" and the necessary steps/precautions to be taken to prevent furnace blowout. (3) An established campaign life had not been developed and strictly adhered to in order to properly maintain and reline the furnace. Only patching was done in order to prolong furnace operation thereby increasing production. (4) The furnace transformer and taphole have been increased in size (modified) without the manufacturer's approval and/or recommendation. Furthermore, operating and maintenance instructions have not been furnished to include engineering drawings and data. (5) The furnace tilt control panel is not positioned so that the operator has a direct line of site when tapping out the furnace. The control room door blocks the operator's view when in the closed position. (6) Furnace operators were not properly trained so that hazards would be minimized. Operators are tapping out the furnace with known hot spots, charging the furnace beyond it's capacity, charging scrap that has not been analyzed, charging mismarked slugs, and operating the furnace with known water leaks. Among other methods, one feasible and acceptable abatement method to correct this hazard is to develop an operation and preventative maintenance program in accordance with the furnace manufacturer's manuals to insure the correct and proper functioning of all furnace operations. Additionally, written safe job procedures shall be established to address all aspects of furnace operations, particularly the means for emergency cooling of hot spots on the furnace and furnace shutdown for relining.