OSHA Inspection: ALCOA SEPARATIONS, ROCKFORD DIVISION

Issued

Sep 7, 1990

Abate by

Nov 6, 1990

Penalty

Initial $630 · Current $430 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:
In the resin room, employees were exposed to being struck, crushed,
burned, and/or overcome by inhalation of toxic chemicals from the
increased likelihood of catastrophic failure of inadequately designed,
contructed, rated, and maintained pressure vessels used in the
manufacture of ion exchange resins. The employer failed to establishe,
properly implement, and manage an effective program of pressure vessel
safety including design, construction, rating, inspection, maintenance
repair, alteration and/or replacement. In addition, appropriate
records necessary for informed decision making, documenting pressure
vessel actual conditons, were not prepared, retained, or made
available for inspection.
Among other methods, one feasible and acceptable method to correct these
hazards is to establish and properly implement an effective program of
pressure safety including design, construction, rating, inspection,
maintenance, repair, alteration and replacement. Essentail elements of
this program include, but are not necessarily limited to, the following:
1) Assure all resin room pressure vessels used in the manufacture of
ion exchange resins are designed, constructed and rated in accordance
with the 1989 ASME Boiler and Pressure Vessel Code, Division 1.
2) Determine probable corrosion rates, specify a maximum period between
inspections, and perform regular inspections for corrosion monitoring
of all resin room pressure vessels used in the manufacture of ion
exchange resins in accordance with the 1989 ANSI/National Board
Inspection Code.
3) Ensure all employees inspecting resin room pressure vessels used in
the manufacture of ion exchange resins for corrosion using
nondestructive examination methods are properly trained in accordance
with the American Society for Nondestructive Testing (ASNT) RPSNT-TC-
1A, December 1988 Edition.

Issued

Sep 7, 1990

Abate by

Sep 14, 1990

Penalty

Initial $270 · Current $270

Issued

Sep 7, 1990

Abate by

Oct 8, 1990

Penalty

Initial $450 · Current $250 Reduced

Issued

Sep 7, 1990

Abate by

Oct 8, 1990

Penalty

Initial $450 · Current $450