OSHA Inspection: WELLS MANUFACTURING COMPANY

Issued

Apr 4, 1991

Abate by

May 8, 1991

Penalty

Initial $1,000 · Current $600 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:
A) THE HAZARDS ASSOCIATED WITH AN EXPLOSION (ERUPTION) OF HOT MOLTEN
IRON (B11-1) MATERIAL WHEN A PIECE OF SLAG FELL, ALONG WITH WATER,
INTO THE MOLTEN IRON DURING THE SLAG CLEANING/CHIPPING PROCESS.
WATER WAS USED TO COOL OFF THE JACK HAMMER CHISEL AND THE SLAG RING
ON TOP OF THE BROWN BOVERI #78 CHANNEL INDUCTOR HOLDING FURNACE.
THE EXPLOSION (ERUPTION) OF EXTREMELY HOT MOLTEN IRON WAS THE RESULT
OF VERY RAPID VAPOR FORMATION CAUSED BY THE HEAT TRANSFERFROM THE
MOLTEN IRON MATERIAL TO THE WATER, THEN THE EXPANSION TO AMBIENT
PRESSURE OCCURRED, THE RESULTING ENERGY RELEASE BY THE EXPANDING
STEAM CAUSED THE DISPERSION OF HOT METAL AND SLAG.
AMONG OTHER METHODS, ONE FEASIBLE AND ACCEPTABLE METHOD TO CORRECT THIS
HAZARD IS TO INCLUDE, BUT NOT BE LIMITED TO, THE FOLLOWING:
1) ESTABLISH NORMAL OPERATING PROCEDURES FOR FURNACES:
A) SLAG CLEAN-UP PROCEDURES:
(I) DRAIN OUT (REMOVE) THE MOLTEN IRON MATERIAL FROM THE HOLDING
FURNACE COMPLETELY AND LET THE FURNACE COOL DOWN BEFORE
CLEANING UP THE SLAG.
(II) WATER SHALL NOT BE USED TO COOL DOWN SLAG, JACK HAMMER CHISEL
AND MOLTEN IRON MATERIAL.
(III) REQUIREMENTS FOR OPERATOR PERSONAL PROTECTIVE EQUIPMENT AND
PRACTICES FOR SAFE OPERATION AND SLAG HANDLING.
B) START-UP PROCEDURES FOR FURNACES THAT WILL INCLUDE CHECKS
TO INSURE PROCESS EQUIPMENT AND CONTROLS ARE FUNCTIONING PROPERLY
AND FREE OF POSSIBLE HAZARDOUS CONTAMINANTS BEFORE USE.
C) NORMAL OPERATING PROCEDURES FOR FURNACE:
(I) A DEFINED SEQUENCE OF OPERATING STEPS EMPHASIZING THOS CONSIDERED
TO BE CRITICAL FOR PROCESS SAFETY PLUS REQUIREMENTS FOR
OPERATOR PERSONAL PROTECTIVE EQUIPMENT AND PRACTICES FOR SAFE
OPERATION AND ENFORCED FOR ALL TASKS ASSOCIATED WITH THE HOT
METAL AND SLAG HANDLING.
(II) THE FLOOR AND LADLES SHALL BE MAINTAINED IN A CLEAN AND SO
FAR AS POSSIBLE, A DRY CONDITION DURING POURING OF MOLTEN IRON.
(III) MOLTEN MATERIAL HANDLING.
2) INSTRUCT AND TRAIN ALL AFFECTED MANAGEMENT, SUPERVISORY AND
OPERATIONS PERSONNEL IN THESE PROCEDURES.
3) INSPECTION AND PREVENTION MAINTENANCE PROCEDURE: ASSURE ALL
OPERATING FURNACES ARE INSPECTED, REPAIRED AND/OR REPLACED ON A
PLANNED SCHEDULE BASED ON PROBABLE FAILURE FREQUENCY OF THIS
EQUIPMENT.

Issued

Apr 4, 1991

Abate by

May 8, 1991

Penalty

Initial $1,000 · Current $600 Reduced

Issued

Apr 4, 1991

Abate by

May 8, 1991

Penalty

Initial $1,000 · Current $600 Reduced

Issued

Apr 4, 1991

Abate by

May 8, 1991

Penalty

Initial $1,000 · Current $600 Reduced