OSHA Inspection: SGL CARBON, LLC

Issued

Nov 30, 2000

Abate by

Mar 31, 2002

Penalty

Initial $6,300 · Current $5,000 Reduced

General-duty citation text

North Carolina General Statute 95-129(1) of the Occupational Safety and
Health Act of North
Carolina:  The employer did not furnish to each of his employees
conditions of 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)fire and explosion hazards while operating and working near Sagger Pit
Furnace
Number 61, which consisted of nine North American Burners divided into
three
zones that were fired by natural gas on and before June 5, 2000.  The North
American Burners were not protected by the supervision of each burner
flame by
a combustion safeguard.
b)fire and explosion hazards while operating and working near Sagger Pit
Furnace
Number 62, which consisted of nine North American Burners divided into
three
zones that were fired by natural gas on and before June 5, 2000.  The North
American Burners were not protected by the supervision of each burner
flame by
a combustion safeguard.
c)fire and explosion hazards while operating and working near Sagger Pit
Furnace
Number 63, which consisted of nine North American Burners divided into
three
zones that were fired by natural gas on and before June 5, 2000.  The North
American Burners were not protected by the supervision of each burner
flame by
a combustion safeguard.
d)fire and explosion hazards while operating and working near Sagger Pit
Furnace
Number 64, which consisted of nine North American Burners divided into
three
zones that were fired by natural gas on and before June 5, 2000.  The North
American Burners were not protected by the supervision of each burner
flame by
a combustion safeguard.
e)fire and explosion hazards while operating and working near Sagger Pit
Furnace
Number 65, which consisted of nine North American Burners divided into
three
zones that were fired by natural gas on and before June 5, 2000.  The North
American Burners were not protected by the supervision of each burner
flame by
a combustion safeguard.
Reference:  NFPA 86.5-9.1, 1999, Standard for Ovens and Furnaces.
Among other methods, one feasible and acceptable abatement method to
correct
this hazard is to install "Flame Supervision" equipment having a maximum
flame
failure response time of 4 seconds or less, that performs a safe-start
check, and
is interlocked into the combustion safety circuitry on each burner.  This
"Flame
Supervision" is designed to shut down the furnace if it detects no flame
eliminating the possibility of the gas/air mixture continueing when no
flame is
present.  This method of "Flame Supervision" was in use before the
accident on
Furnaces 50, 51, and 52 and is required at NFPA 86.5-9.1, 1999.

Issued

Nov 30, 2000

Abate by

Apr 19, 2001

Penalty

Initial $1,925 · Current $1,600 Reduced

General-duty citation text

North Carolina General Statute 95-129(1) of the Occupational Safety and
Health Act of North
Carolina:  The employer did not furnish to each of his employees
conditions of 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)fire and explosion hazards due to inadequate maintenance of pilots on
each of
nine North American Burners on Sagger Pit Furnace number 61.  These pilots
were not maintained in an operable condition on and before June 5, 2000.
Reference:  NFPA 86.1-6, 1999; Surface Combustion Division of Midland-Ross
Corporation, Operating And Maintenance Instructions for five (5) Direct
Fired
Carbon Baking Pit Furnaces A-VI,3 a; and BAKE FURNACE RUN RECORD
for furnace 62 dated 6/1/00 see REMINDER.
b)fire and explosion hazards due to inadequate maintenance of direct spark
igniters
on each of nine North American Burners on Sagger Pit Furnace number 61.
The
direct spark igniters were not maintained in an operable condition on and
before
June 5, 2000.  Reference:  NFPA 86.1-6, 1999 and Surface Combustion
Division
of Midland-Ross Corporation, Operating And Maintenance Instructions for
five
(5) Direct Fired Carbon Baking Pit Furnaces II,A,24,c.
Among other methods, one feasible and acceptable abatement method to
correct
these hazards is to develop a maintenance program that would insure that
these
devices, as provided by the manufacturer, are maintained in an operable
and safe
condition until and unless they are removed and replaced by equally safe
devices
that are approved by the manufacturer.

Issued

Nov 30, 2000

Abate by

Jun 19, 2001

Penalty

Initial $1,925 · Current $1,600 Reduced

General-duty citation text

North Carolina General Statute 95-129(1) of the Occupational Safety and
Health Act of North
Carolina:  The employer did not furnish to each of his employees
conditions of 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)fire and explosion hazards. Employees including the maintenance
millwright
welding near furnace number 61 at the time of the explosion, had not been
thoroughly instructed and trained under the direction of a qualified
person and had
not been required to demonstrate understanding of the equipment (Sagger Pit
Furnaces) and its operation to ensure knowledge of and practice of safe
operating
procedures on and before June 5, 2000.  Reference:  NFPA 86.1-5.1, 1999.
Among other methods, one feasible and acceptable abatement method to
correct
these hazards is to train maintenance and supervisory employees and
require them
to demonstrate understanding (periodic testing) on the equipment (Sagger
Pit
Furnaces) and their operation to ensure knowledge of and practice of safe
operating procedures as required by NFPA 86.1-5.1.

Issued

Nov 30, 2000

Abate by

Apr 19, 2001

Penalty

Initial $1,925 · Current $1,600 Reduced

General-duty citation text

North Carolina General Statute 95-129(1) of the Occupational Safety and
Health
Act of North
Carolina:  The employer did not furnish to each of his employees
conditions of 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)fire and explosion hazards due to inadequate procedures in inspection,
testing, and
maintenance program that would ensure that the equipment was in working
order
as required.  Reference:  NFPA 86, 10-1.1, 1999.
Among other methods, one feasible and acceptable abatement method to
correct
this hazard is to implement a preventive maintenance program based on the
one
provided by Surface Combustion Division of Midland-Ross Corporation,
Operating And Maintenance Instructions for five (5) Direct Fired Carbon
Baking
Pit Furnaces at A-VI.

Issued

Nov 30, 2000

Abate by

Dec 8, 2000

Penalty

Initial $1,138 · Current $700 Reduced