OSHA Inspection: MUELLER COPPER TUBE PRODUCTS

Issued

May 2, 2001

Abate by

May 8, 2001

Penalty

Initial $2,625 · Current $1,500 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 :
In the Casting Department, employees were exposed to the hazards of molten
metal
explosions while performing casting operations.  On or about December 22,
2000,
molten copper metal exploded out of mold number six in the east casting
machine during
casting start-up.  The explosion resulted in the injury of two employees
working in the
casting pit/hole and two employees on the floor level above the casting
furnace.
The employer failed to fully identify, evaluate and/or control known
hazards associated
with the casting process.
Among others methods, feasible means of abatement include but are not
limited
to:
1.  Install and/or use accurate temperature monitoring devices to monitor
the
pour temperature of the molten copper during start-up procedures.
2.  Install shields or barriers that more effectively protect employees.
Such
barriers should be provided to protect employees working in the casting
pit/hole,
as well as employees walking/working on the main floor level above the
casting
furnace.
3.  Further upgrade and/or automate the casting process by considering
other
casting techniques and state of the art technology.
4.  Evaluate the possibility of reworking the current system to allow
independent
control of each platen assembly/mold cup to allow the casting crew to
completely
shut down a troublesome spout and mold without a shut-down of the entire
process.
5.  Increase the distance of the employees from the casting machine during
pouring.  Evaluate the use of an automatic leveling system which could be
controlled from a distance.  Metering pins could be controlled by motor
control,
or by some other remotely controlled device.
6.Increase employee distance from the launder and molds during all phases
of the start-up and set-up processes to the extent feasible.
7.Conduct a comprehensive failure analysis of the casting operation, and
develop comprehensive protocols which address each and every failure
scenario.
Then train exposed employees on the protocols.
8.  Complete the development and implementation of a comprehensive training
program for all employees working in the casting area.   The training
should be
accomplished in a manner that assures information is conveyed at the level
of
understanding of exposed employees.  A detailed training video, structured
on-
the-job training, computer based training programs and periodic refresher
courses
should be considered and/or completed and implemented.
9.  Prohibit employees from "rodding out" a clogged spout during the
pouring
process.  In the event that rodding or burning out spouts is necessary
during the
pouring process, bent rods with long handles could be provided, allowing
employees to stand away from the launder during the rodding/burning
process.
10.  Require all employees in the casting pit/hole and on the main floor
level
above the casting furnace to don full personal protective gear including
but not
limited to aluminized coats and leggings, metatarsal guards, casting
gloves, and
helmets with full aluminized hoods during all phases of the casting
process where
the potential of a molten metal explosion or "blow-up" exists (especially
during
change-overs/set-ups and start-ups).
The employer is not limited to any of the abatement methods recommended by
OSHA, but may
use any method that renders its work place free of the hazard.  It is
possible that some of the
recommended methods may not be effective in all circumstances.

Issued

May 2, 2001

Abate by

May 8, 2001

Issued

May 2, 2001

Abate by

May 29, 2001

Penalty

Initial $1,500