OSHA Inspection: U.S. POSTAL SERVICE - SAN JOSE

Issued

Jul 20, 2011

Abate by

Aug 15, 2011

Penalty

Initial $5,500 · Current $5,500

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 the hazard of unsafe hoist installation:
(a)Battery Room (J-81) - On or about January 24, 2011 and at times prior
thereto, it was
observed that the Kone Crane CXT-300 overhead underhung hoist was operated
without
the load being centered causing 2-parts of wire rope from a 4-part block
to rub against
the battery charger shelving.   This unsafe practice exposed the wire rope
to increased
frictional wear, abrasion and damage.  The employer failed to ensure that
the load lines,
block and hoist were clear of all obstacles before moving the load lines.
Among other methods, the following feasible and acceptable methods can be
implemented
to correct this hazard by complying with the following:
Comply with the consensus standard promulgated by the American Society of
Mechanical
Engineers (ASME) B30.16-2007, Overhead Hoists (Underhung), Safety
Standards for
Cableways, Cranes, Derricks, Hoists, Hooks, Jacks and Slings:  Chapter
16-3, Section
16-3.1.2 (g) and Section 16-3.1.3 (d):  Hoists shall not be operated
unless the hoist unit
is centered over the load, except when authorized by a qualified person
who has
determined that the components of the hoist and its mounting will not be
overstressed.
Should it be necessary to pick a load that is not centered under the hoist
unit, precautions
shall be taken to control the swing of the load when it is picked clear of
its support.  The
operator shall make sure the load and hoist will clear all obstacles
before moving or
rotating the load.
Either move the overhead hoist and support structure or remove the
shelving
so the 2-
parts of wire rope on the 4-part block will not rub against the shelf.

Issued

Jul 20, 2011

Abate by

Aug 15, 2011

Penalty

Initial $5,500 · Current $5,500

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 the hazard of overhead hoist failure as a result of
inadequate and/or failure to
conduct frequent inspections and to perform preventive maintenance:
(a)Battery Room (J-81) - On or about January 24, 2011 and at times prior
thereto, the
employer failed to implement an effective preventive maintenance and
frequent inspection
program for the Kone Crane CXT-300 overhead underhung hoist to identify
hazards such
as but not limited to proper installation, proper wearing of components,
and unimpeded
hoisting for the load.
Among other methods, the following feasible and acceptable methods can be
implemented
to correct this hazard is to comply with the requirements promulgated in
the consensus
standard ASME B30.16-2007, Overhead Hoists (Underhung), Safety Standards
for
Cableways, Cranes, Derricks, Hoists, Hooks, Jacks and Slings:
1.Designate a person to conduct frequent visual inspections to include the
components of
Section 16-2.1.2.
2.Inspection reports and records should be maintained at time intervals
specified in
paragraph 16-2.1.1 (b) (2).  Records should be stored where they are
available to
appointed persons.
3.A preventive maintenance program should be established based on the
recommendations
outlined by the manufacturer's manual.  Dated records should be placed on
file.  Section
16-2.3.1
4.Any condition disclosed by the inspections performed in accordance with
the
requirements of Section 16-2.1 that is determined to be a hazard to
continued operation
shall be corrected by adjustment, repair or replacement before continuing
the use of the
hoist.  Section 16-2.3.3
5.A long-range rope inspection program should be established and should
include records
on examination of ropes removed from service so a relationship can be
established
between visual observation and actual condition of the rope. Section
16-2.1.5
6.Maintain a copy of the manufacturer's operational and maintenance manual
at the work
site.  Section 16-1.2.17
(b)Battery Room (J-81) - On or about 1/24/11 and at times prior thereto,
it was observed
that the Kone Crane CXT-300 overhead underhung hoist pendant label was
illegible.

Issued

Jul 20, 2011

Abate by

Aug 15, 2011

Penalty

Initial $5,500 · Current $5,500

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 the hazard of overhead hoist being operated by unqualified
personnel:
(a)Battery Room (J-81) - On or about January 24, 2011, a determination was
made through
employee interviews that employees operating the Kone Crane CXT-300
overhead
underhung hoist did not receive training on the manufacturer's operational
instructions.
The employer did not have a copy of the manufacturer's manual on site to
ensure safe
operation of the overhead hoist.
Among other methods, the following feasible and acceptable methods can be
implemented
to correct this hazard is to comply with the following:
1.Obtain, follow and train/instruct employees on the requirements for safe
operation,
inspection, and maintenance as out lined in the manufacturer's guidelines
as set forth in
the equipment manual.
2.Obtain, follow and train/instruct employees on the requirements for safe
operation,inspection, and maintenance as out lined in the ASME
B30.16-2007, Overhead
Hoists (Underhung), Safety Standards for Cableways, Cranes, Derricks,
Hoists, Hooks,
Jacks and Slings, Chapter 16-3.

Issued

Jul 20, 2011

Abate by

Aug 15, 2011

Penalty

Initial $5,500 · Current $5,500

Issued

Jul 20, 2011

Abate by

Aug 15, 2011

Issued

Jul 20, 2011

Abate by

Aug 15, 2011

Penalty

Initial $60,500 · 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 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 the hazard of wire rope failure:
(a)Battery Room (J-81) and throughout the postal facility: - On or about
January 24, 2011
and at times prior thereto, it was observed that the Kone Crane CXT-300
overhead
underhung hoist's wire rope exhibited birdcaging damage as a result of
lifting an imposed
load greater than the modulus of elasticity of the wire rope.  This action
resulted in
permanent deformation of the wire rope and a decreased lifting capacity of
the hoist due
to the compromised strength of the wire rope.  As a result of the damage,
the running
wire rope for this hoist was in an out-of-service condition on or about
November
1,
2010.  The employer knowingly continued to operate with this damaged
running wire
rope for an extended period of time, thereby exposing employees to the
potential for
severe injury or death in the event of a catastrophic wire rope failure.
The employer
continued to operate even after being informed verbally on several
occasions starting on
or about November 1, 2010.  In addition, the employer continued to operate
the hoist
after being notified by email on several occasions as well.  The employer
was notified
by email on January 1, 2011, January 12, 2011, and January 18, 2011. The
employer
was also notified verbally and in writing by a Kone Crane service
representative on
January 14, 2011 that the running wire rope was damaged and required
replacement.
Furthermore, the employer was notified by OSHA on or about January 24,
2011 of the
unsafe condition.   On January 27, 2011 the employer submitted a request
to Kone
Cranes for replacement of the wire rope. The hoist was continually used
several times
daily until February 1, 2001, when the wire rope was replaced. The
employer elected to
use the Kone Crane CXT-300 overhead underhung hoist in an out-of-service
condition
regardless of the fact that a portable hoist was on site, providing a
feasible means of
temporary abatement.
One feasible and acceptable abatement method to correct the hazard is to
replace the
cable per the manufacturer's specifications and the requirements of ASME
B30.16-2007,
Overhead Hoists (Underhung), Safety Standards for Cableways, Cranes,
Derricks,
Hoists, Hooks, Jacks and Slings.  Additionally, the employer should
develop a
preventative maintenance program which incorporates all manufacturers'
recommendations and the requirements of ASME B30.16-2007, Overhead Hoists
(Underhung), Safety Standards for Cableways, Cranes, Derricks, Hoists,
Hooks, Jacks
and Slings with written signed and dated reports.  In addition, follow the
out
of service
critieria for wire rope as specified in ASME B30.16-2007, Sections
16-2.4.1 and 16-
2.4.2, once a rope reaches any on specified removal criteria, it may be
allowed to
operate to the end of the work the judgment of a qualified person.  The
rope shall be
replaced after that work of the day, or at the latest time prior to the
equipment being
used by the next work shift.

Issued

Jul 20, 2011

Abate by

Aug 15, 2011

Penalty

Initial $5,500 · Current $5,500