OSHA Inspection: SERMATECH DYNAMIC

Issued

Jun 11, 1998

Abate by

Jun 19, 1998

Penalty

Initial $5,600 · Current $5,600

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 the following conditions:
(a)Burns from aluminum dust fire/explosion due to large accumulation of
aluminum
dust generated from the excess over spray while the Thermion thermal
aluminum
spray coating guns were in operation.
Among other methods, one or more feasible and acceptable abatement method
to
correct this condition may include, but is not limited to:
1.Conformance with NFPA 65 - Standard for the Processing and
Finishing of Aluminum:
Chapter 2 Dust Collection
2-1 General.
2-1.1
Machines that produce fine particles of aluminum shall be provided with
hoods or enclosures connected to a dust collection system having sufficient
suction and capture velocity to collect and transport all the dust
produced.
Hoods and enclosures shall be designed and maintained so that the fine
particles will either fall or be projected into them in the direction of
airflow.
The following safeguards shall be incorporated:
1.Personnel clothing shall be flame retardant and shall be
fabricated without cuffs.
2.The collector shall be designed to dissipate static
electricity. (See NFPA 77, Recommended Practice on
Static Electricity.)
3.Collector system design shall be subjected to a process
hazard analysis to ensure that shrapnel and flash fire
exposure to personnel shall be minimized.
4.Collector retention capacity shall be limited to 1 lb (0.454
kg).
2-2 Ducts and Ductwork.
2-2.1
Ducts shall be designed to maintain a velocity of not less than
4500 ft/min. (1372.5  m/min) to ensure the transport of both
coarse and fine particles to ensure reentrainment if, for any reason
the particles can fall out of the collector (for example, in the event
of power failure).2-2.2
Ducts shall be designed to handle a volumetric flow rate sufficient
to maintain a dust loading safely below the lower explosive limit.
2-2.3
Ducts shall be as short and as straight as possible.
2-2.4
Ducts shall have as few bends and irregularities as possible so that
free airflow is not interfered with.
2-2.5
Ducts shall be of conductive material construction and shall be
carefully fabricated and assembled with smooth interior surfaces
and with internal lap joints facing the direction of airflow. There
shall be  no unused capped outlets, pockets, or other dead end
spaces that might allow accumulations of dust. Duct seams shall be
oriented in the direction away from normal working personnel.
2-2.6
Duct systems, dust collectors, and dust-producing machinery shall
be bonded and grounded to minimize accumulation of static
electric charge.
Chapter 5 Fire Protection
5-3 Equipment Shutdown
In the event of fire, all fans and machinery, including dust
collection systems, shall be shut down. Drafts shall be avoided
wherever possible.
2.Conformance with the Thermion Owner's Manual:
Chapter 2 Safety Measures.
2.1 Reduction of Fire and Explosive Hazard.
To minimize the danger of the dust explosion in an arc spray booth
or other confine spaces, prevent the accumulation of fumes and
dust. Ventilation and good housekeeping in the work area is
essential.
3.Conformance with American National Standard Institute/American
Welding Society C2.18-93, (an American National Standard, Guide for
the Protection of Steel with Thermal Sprayed Coatings of Aluminum
and Zinc and Their Alloys and Composites:
Chapter 2 Safety2.1 General
Airborne metal dusts, finely divided solids, or accumulations
should be treated as explosives. Adequate ventilation in the thermal
spray work area and collection of the overspray should be made to
minimize the danger of dust explosions and fires.
4.Incorporate safety devices on the operational mechanical equipment with
the thermal aluminum spray guns switch to shut down the thermal
aluminum spray guns when it detects a fault in any one of the different
piece of equipment.
(b)Burns from Dust Collector fire/explosion due to not being provided with
explosion vents.
Among other methods, one or more feasible and acceptable
abatement method to correct this condition may include, but is not
limited to:
1.Conformance with NFPA No. 65 - Processing and Finishing of
Aluminum - 1973, An American National Standard ANSI Z12.19-1973:
Chapter 2-4 Dry-type Dust Collectors.
2-4.3
Special care shall be taken to ensure the internal cleanliness of dry dust-
collection systems at all times and to avoid the accumulation of material
except in the discharge hoppers of the dust collectors. Accumulation or
condensation of water shall be prevented.
2-4.5
Dry dust collectors and other equipment where an aluminum dust
explosion hazard exists shall be provided with explosion vents wherever
it is possible and practical to do so. Refer to Guide for Explosion
Venting,
NFPA No. 68.
2.Conformance with the Wheelabrator Operation and Service Manual:
Safety Instructions Sheet
Dust Collectors and Ventilation
Warning - In application involving the use of aluminum media or surface
blasting of aluminum parts, precautionary measures must be taken to
minimize the risk of dust collector fire and/or explosions. The following
precaution should be followed:
No. 200 Mesh Agricultural Limestone (CaCO3) should be added to the
ventilation system at a continuous rate of 0.2 oz. per hour per square foot
of filter area.
3.Incorporate safety devices on the operational mechanical equipment with
the thermal aluminum spray guns switch to shut down the thermal
aluminum spray guns when it detects a fault in any one of the different
piece of equipment.
*** Certification and Documentation of Abatement Required ***

Issued

Jun 11, 1998

Abate by

Jun 15, 1998

Penalty

Initial $4,000 · Current $4,000

Issued

Jun 11, 1998

Abate by

Jun 15, 1998

Penalty

Initial $4,000 · Current $4,000

Issued

Jun 11, 1998

Abate by

Jun 16, 1998

Penalty

Initial $4,000 · Current $4,000

Issued

Jun 11, 1998

Abate by

Jun 19, 1998

Penalty

Initial $4,000 · Current $4,000