OSHA Inspection: THE ELECTRIC MATERIALS COMPANY

Issued

Aug 12, 2010

Abate by

Sep 15, 2010

Penalty

Initial $5,600 · Current $4,480 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 toxic vapors from the uncontrolled release of an unknown
mixture, due to
inadequate process hazard evaluations of plating operations:
a.) The Electric Materials Company, Plating Area - On or about April 8th,
2010, the Plating
Operator transferred used Bright Dip Acid Solution (Nitric Acid/Sulfuric
Acid Solution) from
one fifty-five gallon drum into another.  During the transfer, the Bright
Dip Acid Solution
reacted with the contents of the drum in which it was being pumped. The
reaction resulted in
chemical splashing and the formation of a vapor cloud which spread from
the plating area into
adjacent areas of the plant. The entire facility was evacuated and 20
employees were transported
to medical facilities. The reaction also caused the plating operator to be
exposed
to an
uncontrolled release of an unknown substance which resulted in
hospitalization.
FEASIBLE ABATEMENT METHODS:
Among other methods, feasible and acceptable methods to correct the
condition include:
1.) Conduct comprehensive process hazard evaluations of the plating
processes for the
company's chemical products as described in the Center for Chemical
Process Safety (CCPS),
of the American Institute of Chemical Engineers (AIChE), publication
Guidelines for Hazard
Evaluation Procedures, Second Edition with Worked Examples;
2.) Develop detailed Standard Operating Procedures (SOPs) for the plating
processes.  Ensure
the SOPs include, normal operating procedures, and emergency procedures
with definitions of
abnormal operating conditions (I.e. new waste disposal barrels out of
stock) and emergency shut
down procedures;
3.) Develop and implement standard operating procedures to ensure an
adequate supply of new
one-piece fifty-five gallon drums remains in stock at all times;
4.) Develop and implement standard operating procedures for proper
cleaning of contaminated
drums;
5.) Conduct training with personnel covering the hazards of the chemicals
used in the plating
processes, process hazard evaluations, and SOPs.