OSHA Inspection: US PIPE AND FOUNDRY CO.

Issued

May 24, 1990

Abate by

May 30, 1990

Penalty

Initial $10,000 · Current $8,000 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 engaged in
cupola bottom dropping operations and others working in the vicinity of
the bottom drop were exposed to the hazards of explosions.
a) Employees working in the area of #2 cupola during bottom dropping
operations were exposed to injuries from a hot cupola bottom coming
into contact with water/moisture as the bottom was droppedresulting
in a violent explosion on or about 3/22/90.
Among other methods a feasilbe and acceptable method to correct the
hazard is to implement and enforce a cold bottom dropping technique
comforming to the safety requirements as outlined in theAmerican
Foundrymen's Society Cupola Handbook 1985 edition, page 390 subject
entitled Cold Bottom Drop Technique containing but not limited to the
following procedures:
Cold Bottom-Drop Technique
1) Drain the cupola per usual practice.
2) Introduce quench water onto the coke bed through the charge-door
opening with a 1/2 to 1 inch hose until evidence of water soaking
through the bottom is indicated.
3) Don't attempt to get the sand bottom down for a minimum of 3 hours,
so that any molten iron will have solidified.
4) When bottom doors are dropped the sand bottom usually remainsintact
and in place until punched out; and
5) A large hydraulic or pneumatic cylinder with pointed-tip shaft
extension, mounted on heavy base, is positioned underneath the
cupola and used to punch out the cold mass of sand, unburned bed
coke, etc.,
Or other procedures could be initiated which would assure that all
molten metal has been drained from the well and the area beneath the
cupola suitably dry prior to dropping the bottom.

Issued

May 24, 1990

Abate by

May 30, 1990

Penalty

Initial $10,000 · Current $8,000 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safey and Health Act of 1970: The
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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 of the cupola
melting department who were entering cupolas to prepare bottom and to
perform other functions were exposed to the hazards of potential falls,
being struck by material from above falling into the cupola, heat
prostration, hazardous atmospheres and other confined space type
injuries and procedures were not being implemented to ensure their
safety while working inside the cupola and for their removal from inside
the cupola in emergency situations:
a) Cupola melting department, cupola operations, cupola liners and
helpers were entering cupolas with the doors up to install bottom
and other procedures and were not tied off to an independant life-
line attached to a harness and attended by a monitor employee
stationed at the access opening during the entire period the
employees were inside the cupula. Neither were means provided to
protect employees inside cupola from falling objects nor were
positive means used to assure a nonhazardous atmosphere inside the
cupola. Also methods had not been established to remove employees
from cupolas in emergency situations. On or about 3/22/90.
Among other methods one feasible and acceptable method to correct this
hazard is to implement and enforce a cupola entry programas required by
the American National Standards Safety Requirements for melting and
pouring in the metal casting industry Z 241-2 1981 section 4-2 entitled
Cupolas. The program should contain but not be limited to the following
provisions:
A) WRITTEN PROCEDURES - A written detailed procedure shall be
establshed and followed for:
1) Decending and ascending inside the cupola.
2) Removing an employee who becomes injured or incapacited inside the
cupola; and
3) Communicating between personnel inside and outside the cupola.
B) EMERGENCY PERSONNEL REMOVAL - When the copula bottom doors are closed
personnel inside the cupola shall be equipped with lifeline and
harness or equivalent means to facilitate emergency removal. In
addition, a monitor employee shall be stationed at the access opening
during the entire period the bottom doors are closed with personnel
inside the cupola.
C) PERSONNEL INSIDE CUPOLAS - Prior to and when personnel are inside
the cupola;
1) Means to prevent unintentional opening or closing of the bottom doors
shall be used;
2) The blast gate shall be closed and locked off or the cupola blower
shall be locked off;
3) The charging opening shall be guarded to prevent personnel or
material from falling into the cupola;
4) Means shall be provided and used to protect personnel inside the
cupola from falling objects;
5) Means shall be provided and used to assure a nonhazardous atmosphere
inside the cupola;
6) Personnel inside the cupola shall wear personal protective equipment
as required by the employer; and
7) Cupolas equipped with nuclear charge level indicator(s) shall have
source holder(s) locked in the closed position.
D) ACCESS EQUIPMENT - If mechanical, pneumatic, hydraulic or similar
lifting means are used for cupola access, such equipment shall be
inspected prior to each use. The lifting mechanism shall be provided
with an upper overtral limit device to stop lifting motion. This
device shall operate so as to directly interrupt power to the hoist
motor (primary protection). The upper limit device shall not be used
as an operating control in normal operation. Lift mechanisms shall be
provided with an overtravel limit device in the lowering motion so
that at least three (3) wraps of rope remain on the drum. The service
cage load limit shall not be exceeded.

Issued

May 24, 1990

Abate by

May 30, 1990

Penalty

Initial $10,000 · Current $8,000 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 working in the
Delavaud plant were exposed to the hazards of explosions during cupola
bottom dropping operations:
A) Employees working around cupolas and in other areas of the Delavaud,
plant did not receive the necessary prior warning via audible and/or
visual alarm device that the cupola bottom was being droppedso that
they could take precautionary measures to ensure their safety during
this hazardous procedure. On or about 3/22/90, 8:10 p.m.
Among other methods one feasible and acceptable method to correct this
hazard is to implement and enforce a bottom dropping procedure
conforming to the requirement of the American National Safety
requirements for melting and pouring of metal in the metal casting
industry Z-2-41-2 1981 section 6-3-3-2 entitled Bottom Drops -
containing but not limited to the following procedures:
ANSI 2-241-2 1981
6.3.3.2 BOTTOM DROPS. Prior to the bottom drop personnel shall:
1) Activate audible and/or visual alarm devices;
2) Insure that the area under the drop is free of liquids.
3) Visually verify the cupola drop area is clear of personnel.