OSHA Inspection: AURUBIS BUFFALO, INC.

Issued

Jan 6, 2012

Abate by

Mar 30, 2012

Penalty

Initial $7,000 · Current $5,000 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:
a) On or about 9/6/11 in the Casting Department at Station 05 Furnance 70;
prior to the
initiation of casting operations for mold size 26"x10" using alloy 1257
operating
procedures, such as but not limited to, checking and verifying the proper
position of the
casting tank water valve (as being open), was not enforced.  During
casting operations
the north mold experienced a "pull away" and subsequently dropped out of
the mold
allowing molten metal to contact water being retained in the casting tank
as a result of
the closed tank valve.  This condition caused a rapid expansion of the
water into steam
resulting in an explosion causing burns to four employees.
American Society for Testing and Materials, Designation: E-2349-09,
Standard Practice for
Safety Requirements in Metal Casting Operations: Sand Preparation,
Molding, and Core
Making; Melting and Pouring; and Cleaning and Finishing, Section 7:
Operation of Equipment -
General Requirements, 7.1.2 requires: The employer shall enforce
established operating
procedures.
Feasible and acceptable methods to enhance this condition would be, such
as but not
limited to;
Administrative controls:
1) Visually verify the position of the casting tank water valve as part of
change over
procedures.
2) Modification of the Mold Change Sheet to include initials of the
Millwright and
Supervisor to verify tank water and valve position.
Engineering Controls:
1) Install light to indicate valve position.
2) Install water level indicator in the casting tank to provide real time
water level
reading.
ABATEMENT DOCUMENTATION REQUIREDATION

Issued

Jan 6, 2012

Abate by

Mar 30, 2012

Penalty

Initial $7,000 · Current $5,000 Reduced

Issued

Jan 6, 2012

Abate by

Mar 30, 2012

Issued

Jan 6, 2012

Abate by

Mar 30, 2012

Penalty

Initial $7,000 · Current $5,000 Reduced