OSHA Inspection: INLAND FISHER GUIDE, DIV. OF GENERAL MOTOR CORP.

Issued

Jun 19, 1991

Abate by

Dec 19, 1991

Penalty

Initial $4,250 · Current $1,912 Reduced

General-duty citation text

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 likely to cause death
or serious physical harm to employees in that employees were exposed to
serious injury from toxic vapors and chemical burns:
a.  Inland Fisher Guide:  On April 3,1991 two 5000 gallon bulk
storage tanks of incompatible chemicals (67% nitric acid and 50%
sodium hydroxide) were stored side by side with a common 6 inch
dike and a common 4 inch diameter drain.  These chemicals if mixed
will result in a violent exothermic reaction.  Such a reaction took
place on April 2, 1991 when a small 40 gallon overhead storage tank
of nitric acid leaked onto the sodium hydroxide bulk storage tank
below, thus creating toxic vapors which sent 31 employees to the
hospital.  Among other methods, one feasible and acceptable abatement
method to correct this hazard is to separate the storage tanks by a
safe distance with separate diking and drains.
b.  Inland Fisher Guide, Tank Farm Area:  On April 2, 1991 a gasket
made of hypalon material was used on an overhead 40 gallon day tank
of 67% nitric acid.  This material is not recommended by the manu-
facturer and is incompatible with high concentrations of nitric acid.
Failure of this gasket resulted in a nitric acid spill that caused
1,500 employees to be evacuated from the facility.  Thirty-one of
which were sent to the hospital when the acid reacted with the sodium
hydroxide solution and residue below.  Among other abatement methods,
one feasible and acceptable abatement method to correct this hazard
is to use the teflon gasket material that is recommended for strong
acids.
c.  Inland Fisher Guide - Tank Farm:  On April 3, 1991 the one inch
drip pan on an overhead 40 gallon tank of 67% nitric acid was not
adequate for secondary containment of the acid volume in the event of a
leak or release.  On April 2, 1991 a release from this tank reacted with
sodium hydroxide below and created a toxic vapor which sent 31 employees
to the hospital.  A large overhead 5000 gallon sulfuric acid tank is a
tank-within-a-tank configuration.  Among other methods, one feasible and
acceptable abatement method to correct this hazard is to have all over-
head storage tanks set up in a tank-within-a-tank configuration or to
provide larger capacity drip pans.
d.  Inland Fisher Guide-Tank Farm:  On April 3, 1991 the company had
not established a program of regular storage tank inspections  which
contain but are not limited to 67% nitric acid and 50% sodium hydroxide.
These tanks are located near the anodizing line in the production area
of the facility.  On April 2, 1991 an unplanned release of a 40 gallon
overhead storage tank containing nitric acid reacted with sodium hydro-
xide below and caused toxic vapros to form that sent 31 employees to the
hospital.  Among other methods, one feasible and acceptable abatement
method to correct this hazard is to institute an inspection program for
all chemical storage tanks in the facility.  Such a program may include
but is not limited to the following schedule:
Typical                              Area of
Frequency    Method     Equipment    Concern
*Daily       Sensory
Inspection   All        Leaks, Vibrasion,
External Corrosion,
Wear, Insulation.
*Daily            Inspection      Monitoring          Utility and proces
Instruments         Flows
*Weekly           Calibration
Fouling,
*2 Months         Inspection       Analyzers          Deactivation
Detectors
*6 months         Inspection
Cathodic           Underground
* Annual          Inspection       Protection         Piping
Rectifiers
Corrosions Coupons,
Vessels and       External Corrosion,
Lines             Insulation.
Rupture Disks     Debris, Proper Oper
Flame Arresters   -ation, Conse-
vation Vents, and
Pressure Control
Devices.
Testing          Grounding         Sparks
Systems
Testing          Relief Valves    Actuation Setpoints
Alarms, Inter-   and Proper Activa-
locks.           tion of Control
Equipment
Testing          Vessels and      Wall Thickness,
Lines            Glass lining,
Acoustic
Testing          Shutoff/Iso-     Proper Operation
lation Valves
*5 Years          Testing          Hydrotest* and   All Vessesl
/or Internal
Inspection
Hydrotest*
Testing                           Underground Piping
*Prior to         Inspection       Hoses,           Wear, Damage, Leaks
Use               Flexible
Connections
The alleged violations above have been combined because they involve
similar or related hazards that may increase the potential for injury or
illness.
Abatement Will Be As Follows:
a.  Submit to the Area Director within 30 days a written and
detailed plan of abatement outlining a schedule for implementation of
engineering and/or administrative measures to control employee exposure
to the hazardous conditions referenced in this citation.  This plan
shall include, at a minimum, target dates for the following actions
which must be consistant with dates required by this citation:
1.)  Evaluation of engineering/administrative control options;
2.)  Selection of optimum control methods and completion of design;
3.)  Procurement, installation and operation of selected control
measures;
4.)  Testing and acceptance of controls.

Issued

Jun 19, 1991

Abate by

Jul 19, 1991

Penalty

Initial $1,700 · Current $850 Reduced

Issued

Jun 19, 1991

Abate by

Jun 26, 1991

Penalty

Initial $2,125 · Current $1,062 Reduced

Issued

Jun 19, 1991

Abate by

Sep 19, 1991

Penalty

Initial $4,250 · Current $1,912 Reduced

Issued

Jun 19, 1991

Abate by

Jun 26, 1991

Penalty

Initial $1,700 · Current $1,000 Reduced