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Inspection Detail
Inspection: 303486724 - Elkem Metals Company
Inspection Information - Office: Cleveland Area Office
Site Address:
Elkem Metals Company
2700 Lake Road, East
Ashtabula, OH 44005
Mailing Address:
P.O. Box 40, Ashtabula, OH 44004
Union Status: Union
SIC:2819
NAICS: 0
Inspection Type: Accident
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Health
Close Conference: 05/04/2001
Planning Guide: Health-Manufacturing
Emphasis:
Case Closed: 03/26/2002
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 100101591 |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 2 | 1 | 2 | 5 | ||
| Current Violations | 1 | 1 | 1 | 3 | ||
| Initial Penalty | $14,000 | $0 | $3,000 | $0 | $0 | $17,000 |
| Current Penalty | $4,000 | $0 | $1,500 | $0 | $0 | $5,500 |
| FTA Penalty | $0 | $0 | $0 | $0 | $0 | $0 |
| # | Citation ID | Citaton Type | Standard Cited | Issuance Date | Abatement Due Date | Current Penalty | Initial Penalty | FTA Penalty | Contest | Latest Event | Note |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1. | 01001A | Serious | 19101000 A02 | 05/18/2001 | 06/10/2001 | $4,000 | $7,000 | $0 | 05/31/2001 | F - Formal Settlement | |
| 2. | 01001B | Serious | 19101000 E | 05/18/2001 | 06/10/2001 | $0 | $0 | $0 | 05/31/2001 | F - Formal Settlement | |
| 3. | 01002 | Serious | 19100134 D02 IA | 05/18/2001 | 06/05/2001 | $7,000 | $7,000 | $0 | 05/31/2001 | F - Formal Settlement | Citation has been deleted. |
| 4. | 02001 | Repeat | 19100022 A01 | 05/18/2001 | 05/23/2001 | $1,500 | $3,000 | $0 | 05/31/2001 | F - Formal Settlement | |
| 5. | 03001A | Other | 19100146 F07 | 05/18/2001 | 06/10/2001 | $0 | $0 | $0 | 05/31/2001 | F - Formal Settlement | |
| 6. | 03001B | Other | 19100146 F09 | 05/18/2001 | 06/10/2001 | $0 | $0 | $0 | 05/31/2001 | F - Formal Settlement | |
| 7. | 03001C | Other | 19100146 F10 | 05/18/2001 | 06/10/2001 | $0 | $0 | $0 | 05/31/2001 | F - Formal Settlement | |
| 8. | 03001D | Other | 19100146 F11 | 05/18/2001 | 06/10/2001 | $0 | $0 | $0 | 05/31/2001 | F - Formal Settlement | |
| 9. | 03002 | Other | 19101020 D01 II | 05/18/2001 | 05/24/2001 | $0 | $0 | $0 | 05/31/2001 | F - Formal Settlement | Citation has been deleted. |
Investigation Summary
A furnace operator noted lights indicating high carbon monoxide (CO) levels at most or all of the CO sensor locations. Shortly before 12:15 p.m., he notified Employee #1, the supervisor, that he thought the carbide bin might be empty. Employee #1 made a phone call about a different matter and then apparently went to fine feed level 2, where he was found dead at approximately 4:00 p.m. at the end of the shift. On level 2 there was an opening to the chute of the carbide bin and a rod could be inserted into this opening to unjam the chute. During subsequent investigation under non-alarm CO conditions, CO levels of over 1,000 ppm were measured at this opening. Employee #1's carboxyhemoglobin level was 56, which indicates exposure to CO levels over 1,000 ppm for 10 minutes or more. There had been problems with the indicator lights related to material levels in the carbide bin and some repair work had been done, but the problems continued. When the carbide bin and chute were empty, CO could flow up out of the furnace and create the type of alarm pattern noted by the furnace operator.
Keywords: FURNACE, ASPHYXIATED, INHALATION, CARBOXYHEMOGLOBIN, CHEMICAL VAPOR, OVEREXPOSURE, CARBON MONOXIDE, MECH MALFUNCTION, CHEMICAL
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 303486724 | Fatality | Asphyxia | Occupation not reported |