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Occupational Safety and Health Administration OSHA

Inspection Detail

Inspection: 308059088 - Valmont Coatings-Oklahoma Galvanizing

Inspection Information - Office: Oklahoma City

Nr: 308059088Report ID: 0627700Open Date: 08/31/2004

Valmont Coatings-Oklahoma Galvanizing
25055 Alliance Dr.
Claremore, OK 74019
Union Status: NonUnion
SIC: 3479/Coating, Engraving, and Allied Services, Not Elsewhere Classified
NAICS: 332812/ Metal Coating, Engraving (except Jewelry and Silverware), and Allied Services to Manufacturers

Inspection Type:Accident
Scope:Partial Advanced Notice:N
Ownership:Private
Safety/Health:Health Close Conference:02/24/2005
Close Case:06/04/2007

Related Activity:TypeIDSafetyHealth
 Accident100643683    

Violation Summary
Serious Willful Repeat Other Unclass Total
Initial Violations 8 1 9
Current Violations 8 1 9
Initial Penalty $56,000 $70,000 $0 $0 $0 $126,000
Current Penalty $21,000 $0 $0 $0 $56,000 $77,000
FTA Amount $0 $0 $0 $0 $0 $0

Violation Items
# ID Type Standard Issuance Abate Curr$ Init$ Fta$ Contest LastEvent
  1. 01001 Serious 5A0001 02/28/2005 06/01/2005 $4,200 $7,000 $0 04/07/2005 F - Formal Settlement
  2. 01002 Serious 19100120 Q01 02/28/2005 04/02/2005 $4,200 $7,000 $0 04/07/2005 F - Formal Settlement
  3. 01003 Serious 19100120 Q03 I 02/28/2005 04/02/2005 $4,200 $7,000 $0 04/07/2005 F - Formal Settlement
  4. 01004 Serious 19100120 Q03 II 02/28/2005 04/02/2005 $0 $7,000 $0 04/07/2005 F - Formal Settlement
  5. 01005 Serious 19100120 Q03 IV 02/28/2005 04/02/2005 $0 $7,000 $0 04/07/2005 F - Formal Settlement
  6. 01006 Serious 19100120 Q03 V 02/28/2005 04/02/2005 $0 $7,000 $0 04/07/2005 F - Formal Settlement
  7. 01007 Serious 19100120 Q06 02/28/2005 04/02/2005 $4,200 $7,000 $0 04/07/2005 F - Formal Settlement
  8. 01008A Serious 19101200 H01 02/28/2005 04/02/2005 $4,200 $7,000 $0 04/07/2005 F - Formal Settlement
  9. 01008B Serious 19101200 H03 II 02/28/2005 04/02/2005 $0 $0 $0 04/07/2005 F - Formal Settlement
  10. 01008C Serious 19101200 H03 IV 02/28/2005 04/02/2005 $0 $0 $0 04/07/2005 F - Formal Settlement
  11. 02001 Unclass 19100120 Q03 III 02/28/2005 04/02/2005 $56,000 $70,000 $0 04/07/2005 F - Formal Settlement

Accident Investigation Summary
Summary Nr: 200643005Event: 08/30/2004Storage Tank Containing Sulfuric Acid Ruptures
At approximately 9:08 a.m. on August 30, 2004, employees responded to an emergency situation. A storage tank containing 93 percent sulfuric acid ruptured and its contents were released to the environment. Employees responded to the acid spill by constructing a dike, using gravel, lime and sand. Forklift drivers removed galvanized poles from the spill. The acid reacted with the lime, and released a white "cloud" with irritating properties which enveloped many of the responding employees. The employer called the Claremore Fire Department HAZMAT Team who responded to the scene. When the HAZMAT Team arrived employees were ordered to cease activities. This facility used sulfuric acid in the galvanizing process. The horizontal tank that ruptured had a storage capacity of 3,770 gallons of sulfuric acid and was located outside the facility in containment. It was used to replenish the sulfuric acid dip tanks. It was not designed and manufactured as a pressure vessel. The tank ruptured during the transfer of acid from the storage tank to dip tank(s) located inside the plant. Acid was transferred from the storage tank to dip tank(s) by pressurizing the storage tank with compressed plant air. The compressed plant air line went through an in-line air dryer which had not been maintained according to the manufacturer's instructions. The compressed air pressure to the storage tank was normally reduced from 120 psig by a regulator down to 30 psig. However, engineering design criteria specified that the regulator be set at 10-15 psig. After the accident, the regulator was found to be set at 90 psig. In addition, the regulator had recently been replaced and did not meet the engineering design specifications of the original regulator. An accident investigation concluded that the tank ruptured due to over-pressurization within the tank. After their exposure, employees reported burning faces, throats, headaches, and chest pain. Many of the employees coughed and choked, and had difficulty in breathing. The Claremore Fire Department HAZMAT Team decontaminated 18 employees and sent them all to Claremore Regional Hospital where they were treated for their exposure. Fourteen employees were hospitalized overnight.
Keywords: burn, throat, inhalation, storage tank, rupture, explosion, chemical reaction, high pressure, skin, sulfuric acid
Inspection Degree Nature Occupation
1 308059088 Hospitalized injury Other Occupation not reported
2 308059088 Non Hospitalized injury Other Occupation not reported
3 308059088 Hospitalized injury Other Occupation not reported
4 308059088 Hospitalized injury Other Occupation not reported
5 308059088 Hospitalized injury Other Occupation not reported
6 308059088 Hospitalized injury Other Occupation not reported
7 308059088 Hospitalized injury Other Occupation not reported
8 308059088 Hospitalized injury Other Occupation not reported
9 308059088 Non Hospitalized injury Other Occupation not reported
10 308059088 Hospitalized injury Other Occupation not reported
11 308059088 Hospitalized injury Other Occupation not reported
12 308059088 Hospitalized injury Other Occupation not reported
13 308059088 Hospitalized injury Other Occupation not reported
14 308059088 Hospitalized injury Other Occupation not reported
15 308059088 Hospitalized injury Other Occupation not reported
16 308059088 Non Hospitalized injury Other Occupation not reported
17 308059088 Hospitalized injury Other Occupation not reported
18 308059088 Non Hospitalized injury Other Occupation not reported

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