OSHA Inspection: WHEATLAND TUBE CO (SHARON PLANT)

Issued

Mar 12, 1999

Abate by

Apr 14, 1999

Penalty

Initial $4,500 · Current $3,500 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 chemical burns and respiratory complications during filling of the
sulfuric acid storage
tank from a tanker truck.  On or about November 24, 1998, an attempt was
made to
pneumatically fill the 5,000 gallon sulfuric acid above ground storage
tank, located in the
Galvanizing Department, from a vendor tanker truck.  The Flowline
Ultrasonic Level
Transmitter and/or the Precision Digital model PD690 Digital Panel Meter
were not working
properly as the digital panel had read approximately 444 gallons for
approximately two weeks.
During the filling procedure, the capacity of the storage tank was
exceeded and the liquid flow,
under pneumatic pressure from the tanker truck, continued to be imposed on
the
system.  The
overflow protection system consisted of unsecured PVC piping running from
the tank to a trough
in the floor.  The weight of the acid caused the unsecured PVC piping to
move and the liquid
acid flow came into contact with steam lines, which resulted in the
generation of a large cloud
of gaseous sulfuric acid.  Feasible and acceptable abatement methods
include, but are not limited
to, the following:
1) Provide an authorized employee to give approval to unload into storage
tank.  This employee
should designate the specific unloading connection to be used, trace the
line to make sure that
all valves are properly set and that the overflow line on the storage tank
will discharge to a safe
location, and make sure that there is room in the tank for the amount of
acid to be transferred.
(Reference the Manufacturing Chemists Association Properties and Essential
Information for the
Handling and Use of Sulfuric Acid, section 7.5.4(f).)
2) Ensure proper operation of tank level indicators by performing routine
inspections of the
system.
3) Install new valves or adjust existing valves on plant air supply to
reduce pressure to 30psi to
prevent excess pressure from being introduced into the system while
unloading tanker truck.
4) Develop written procedures to train affected employees and ensure
compliance with above
abatement methods.t

Issued

Mar 12, 1999

Abate by

Aug 15, 1999

Penalty

Initial $2,625 · Current $500 Reduced