OSHA Inspection: CARBORUNDUM CORPORATION, STRUCTURAL CERAMICS DIV.

Issued

Jan 16, 1997

Abate by

Dec 31, 1997

Penalty

Initial $6,300 · Current $3,800 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  On or
about 8/24/96, 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)  An explosion hazard in the event of a failure in the water cooling
system during the operation
of GCA furnaces #1 and #2.  On 8/24/96, water flow was interrupted in the
particular branch
of the closed loop water cooling system that supplied cooling water to the
bottom head of the
GCA furnace #2.  Overheating occurred in the bottom head, the cooling
water line ruptured, and
a structural failure occurred in the water jacket allowing water/steam to
enter the furnace core
at maximum operating temperature.  The furnace exploded, critically
burning one employee and
seriously burning two other employees.
Among other methods, one feasible and acceptable abatement method to
correct
this hazard is to:
a)  Provide cooling water in the closed furnace loop which complies with
manufacturer's
specifications in section 4.2.1 of the installation, operation, and
maintenance instructions for the
furnaces (see Exhibit A), and NFPA 86D-1979, section 2-6.12 (Exhibit D).
AND
b)  Install individual pressure relief valves on all existing water
circuits as recommended
in section 4.2.3.1 of the installation, operation, and maintenance
instructions for the furnaces (see
Exhibit A).  Install them so that they are readily observable by the
operator.  (see Exhibit D,
NFPA 86D-1979, section 2-6.12)
AND
c)  Install pressure and temperature gages on exit cooling lines as
required in NFPA 86D-
1979, section 2-12.3 (Exhibit D).
AND
d)  Connect the temperature gages to alarms and to de-energize the furnace
system
whenever a set temperature is exceeded.  (see Exhibit D, NFPA 86D-1979,
section
5-3.3)
AND
e)  Provide training about explosion hazards to operators.  (see Exhibit
D, NFPA 86D-
1979, section 1-9(f)(2))
AND
f)  Thoroughly instruct and train all operating, maintenance, and
appropriate supervisory
personnel under the direction of a qualified person(s) and require them to
demonstrate
understanding of the equipment and its operation to ensure knowledge of
and practice of safe
operating procedures.  (see Exhibit H, excerpt from NFPA 86D-1995, section
1-5.2)
AND
g)  Expand maintenance program to ensure that the equipment is in proper
working order.
Program must include operational and maintenance checklists covering
components such as but
not limited to vacuum system, resistance heaters, water cooling system,
thermocouple,
instrumentation, interlocks, and alarms.  (see Exhibit D, NFPA 86D-1979,
sections 11-1, 11-2,
and A-11-2)