OSHA Inspection: AL SOLUTIONS, INC.

Issued

Jun 8, 2011

Abate by

Jan 17, 2014

Penalty

Initial $7,000 · Current $6,000 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 likely to cause death or serious physical harm in that the
system intended to detect
and monitor hydrogen gas was not properly designed, included air intakes
located in open
process equipment and a sample intake design which allowed for the
dilution of samples, and
failed to detect flammable hydrogen gas produced during blending and
conveying operations
or from ignition of wet titanium and zirconium metal fines.  As designed
the system did not
detect the buildup of hydrogen gas that could result in an explosion
exposing employees to
serious injuries and potential death:
(a)Production Building, Blending and Press Room:  On or about December 9,
2010 the employer used a hydrogen detection system that was not properly
designed in that air intakes were located in open process equipment and a
sample intake design allowed for the dilution of samples.  The system
failed to
detect flammable hydrogen gas produced during blending and conveying
operations or from ignition of wet titanium and zirconium metal fines.  As
designed the system did not detect the buildup of hydrogen gas that could
result in an explosion exposing employees to serious injuries and potential
death.
Among other methods, feasible and acceptable abatement methods the
hydrogen detection
system should be designed to assure sensors and/or sample ports are
located inside closed
equipment and assure samples are not diluted before they are analyzed.
ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED FOR THIS
ITEM

Issued

Jun 8, 2011

Abate by

Jul 25, 2011

Penalty

Initial $7,000 · Current $7,000

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 likely to cause death or serious physical harm to employees in
that the employer
did not provide an over pressurization relief system in the blending and
press room in which
the potential of a hydrogen gas explosion existed:
(a)Production Building, Blending and Press Room:  On or about December 9,
2010, no system to limit the pressure buildup from the explosion of
hydrogen
gas produced during blending and pressing of combustible titanium and
zirconium or in the event of a fire of wet titanium and zirconium was
present.
One feasible and acceptable abatement method is to install an explosion
venting system or an
explosion suppression system specifically designed for the potential of a
hydrogen gas
explosion.
ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED FOR THIS
ITEM

Issued

Jun 8, 2011

Abate by

Jul 25, 2011

Penalty

Initial $7,000 · Current $7,000

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 likely to cause death or serious physical harm to employees in
that large quantities
of combustible titanium and zirconium metals were stored in an unsafe
manner,
including
storage of the wet metal fines in unvented containers and near open
flames, creating the
potential for fire and explosion:
(a) Warehouse:  On or about December 9, 2010 employees of Al Solutions
worked in a warehouse containing several hundred barrels of wet titanium
and
zirconium metal stored in a hazardous manner including, but not limited to,
wet metals stored in unvented containers; wet metals stored near open flame
heaters, wet metals stored next to cardboard boxes, and containers of wet
metals stacked.
One feasible and acceptable abatement method is to store all wet
combustible metals outside;
to store under water in a covered and vented container; to store at least
fifty feet away from
open flames; and to not stack the containers.
ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED FOR THIS
ITEM

Issued

Jun 8, 2011

Abate by

Jun 27, 2011

Penalty

Initial $7,000 · Current $6,000 Reduced

Issued

Jun 8, 2011

Abate by

Jul 11, 2011

Penalty

Initial $7,000 · Current $7,000

Issued

Jun 8, 2011

Abate by

Jun 20, 2011

Penalty

Initial $7,000 · Current $7,000

Issued

Jun 8, 2011

Abate by

Jun 20, 2011

Penalty

Initial $7,000 · Current $6,000 Reduced

Issued

Jun 8, 2011

Abate by

Jan 17, 2014

Penalty

Initial $7,000 · Current $6,000 Reduced

Issued

Jun 8, 2011

Abate by

Jan 17, 2014

Penalty

Current $6,000

Issued

Jun 8, 2011

Abate by

Jan 17, 2014

Penalty

Current $4,000

Issued

Jun 8, 2011

Abate by

Jan 17, 2014

Penalty

Current $6,000

Issued

Jun 8, 2011

Abate by

Jan 17, 2014

Penalty

Current $6,000

Issued

Jun 8, 2011

Abate by

Jun 20, 2011

Penalty

Initial $7,000 · Current $6,000 Reduced

Issued

Jun 8, 2011

Abate by

Jan 17, 2014

Penalty

Initial $7,000 · Current $4,000 Reduced

Issued

Jun 8, 2011

Abate by

Jan 17, 2014

Penalty

Initial $7,000 · Current $6,000 Reduced

Issued

Jun 8, 2011

Abate by

Jan 17, 2014

Penalty

Initial $70,000 · Current $7,000 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 was free from
recognized hazards that
were likely to cause death or serious physical harm to employees in that
the employer used a
water suppression system for the control of fires that could result from
the presence of highly
combustible metals, titanium and zirconium, which were blended, conveyed,
and pressed in
an environment that was conducive for serious fires because of the
existence of large
quantities of combustible metals, the presence of ignition sources
resulting from the lack of
bonding or grounding of metal items, and other spark producing equipment.
(a)Production Building, Blending and Press Room:  On or about December 9,
2010, a water suppression system for the control of fires was used in the
production room where large quantities of highly combustible metals,
zirconium and titanium were processed.  The application of water to burning
combustible metals can result in hydrogen production and explosion.  The
process of blending, conveying, and pressing combustible titanium and
zirconium in the production building was conducive to serious fires.
Conditions in the production room which increased the potential for fires
included the lack of bonding or grounding of metal items and the use of
spark
producing tools.
One feasible and acceptable abatement method to correct this hazard is to
use a sand/salt fire
suppression system and to assure that all equipment is protected from
static electricity
through bonding and grounding of equipment, to assure all non-sealed
bearings on processing
equipment are lubricated and to eliminate use of spark producing tools.
ABATEMENT CERTIFICATION AND DOCUMENTATION REQUIRED FOR THIS
ITEM