OSHA Inspection: PPC INC.

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Penalty

Initial $3,500 · Current $2,000 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 from
chemical burns and/or being
struck by the load from a deficient load chain breaking in one of the CM
Lodestar 13.5' Electric
Chain Hoists:
On August 22, 2003, the load chain broke on CM Lodestar Hoist #2, causing
the basket
(weighing approximately 375 pounds), spreader bar (weighing approximately
100 pounds) and
approximately 3600 pounds of steel parts to drop onto one side of a dip
tank on the phosphate
coating line within one to two feet of the hoist operator.  Some of the
dip tanks on this line
contain phosphoric acid and citric acid.
Feasible means to abate is hazard include but are not limited to the
following:
a) Inspecting and maintaining of the hoist in accordance with ASME
B30.16-2003, "Overhead
Hoists (Underhung)" and the manufacturer's recommendations: Periodic
inspection of the hoist
should be conducted on a semi-annual basis or quarterly basis, as required
by ASME B30.16-
2.1.1(b)(2) for heavy hoist service and severe hoist service,
respectively.  Previous inspections
of the hoists have indicated a high exposure to wear, deterioration, and
malfunction, and
performance problems are evidenced by two previous incidents of the load
chain breaking and
one instance of the failure of an internal hoist component.
b) Measuring the load chain to determine if stretching has occurred in
accordance with ASME
B30.16-2.5.1(c) and B30.16-2.5.2(a), as follows:
(1) select an unworn, unstretched length of the chain (e.g. at the slack
end);
(2) suspend the chain vertically under tension and, using a caliper-type
gauge,
measure the outside length of any convenient number of links approximately
12
in. to 24 in. (305 mm to 610 mm) overall;
(3) measure the same number of links in the used sections and calculate the
percentage increase in length;
(4) if the used chain for powered hoists is 1.5longer than the unused
chain,
replace the chain.
c) Making sure that the load chain is kept adequately lubricated,
especially dring hot weather,
according to the manufacturer's instructions, which state:
Do not allow the chain to run dry....Normally, weekly lubrication and
cleaning is
satisfactory, but under hot and dirty conditions, it may be necessary to
clean the chain
at least once a day and lubricate it several times between cleaning.
d) Inspecting and replacing parts that are "mating parts" to the load
chain such as the lift wheel
and the chain guides, as required by ASME B30.16-2.5.2(f).  On August 22,
2003, the load
chain broke close to the top.  This was also true on the two previous
chain
breaks.  Once the
lift wheels and chain guides are worn, they in turn wear the load chain.
This wear would take
place primarily at the top of the load chain.  e) Having chain repair done
by the chain manufacturer, as required by ASME B30.16-2.5.2(a).
f) Having a qualified person determine the need for a load test following
repair operations, as
required by ASME
B30.16-2.2.2(b)(2)(a).   y   0                                                 L

Issued

Nov 18, 2003

Abate by

Feb 20, 2004

Penalty

Initial $1,250 · Current $1,000 Reduced

Issued

Nov 18, 2003

Abate by

Nov 26, 2003

Penalty

Initial $1,250

Issued

Nov 18, 2003

Abate by

Nov 26, 2003

Issued

Nov 18, 2003

Abate by

Dec 1, 2003

Penalty

Initial $1,000 · Current $700 Reduced

Hazardous substances 22602085C136

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Penalty

Initial $1,000

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Penalty

Current $700

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Penalty

Initial $1,000 · Current $700 Reduced

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Penalty

Initial $1,000 · Current $700 Reduced

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Penalty

Initial $3,500 · Current $700 Reduced

Issued

Nov 18, 2003

Abate by

Dec 1, 2003

Penalty

Current $700

Hazardous substances 22602085C136

Issued

Nov 18, 2003

Abate by

Dec 1, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Dec 1, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003

Issued

Nov 18, 2003

Abate by

Nov 21, 2003