OSHA Inspection: STOLLBERG INC.

Issued

2012-01-12 00:00:00

Abate by

2012-01-17 00:00:00

Penalty

Initial $7000.00 · Current $3750.00 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 9/9/11 in the Bag Break area; atomized aluminum dust (an
explosive dust)
and sodium chlorate ( oxidizer ), is pneumatically transported using the
same transfer
system.  Material Safety Data Sheet for sodium chlorate indicates
incompatible with
powdered metals and aluminum.  Reactivity information on aluminum powder
indicates
avoiding strong oxidizers since a violent reaction with considerable heat
can occur.
Compatibility testing of these raw materials was not conducted.  During
the transfer of
the aluminum dust, which occurred after the transfer of sodium chlorate,
an explosion
occurred in silo 7H and the dust collector (40).
NO ABATEMENT DOCUMENTATION REQUIRED
National Fire Protection Association standard, NFPA 654 - 2006 Edition,
Prevention of Fire and
Dust Explosions from the Manufacturing,Processing, and Handling of
Combustible Particulate
Solids, Section 7.3.1.1 requires: "Where more than one material is to be
handled by a system,
compatibility tests shall be run."
Feasible and acceptable methods to enhance this condition would be, such
as but not limited to;
1) Conduct compatibility testing with atomized aluminum dust and sodium
chlorate to determine
proper handling, transporting and process safety requirements.
2) Conduct explosibility testing on atomized aluminum dust to determine
Kst value, prior to
introduction into process stream.
3) Based on test results design system and associated operating procedures
to ensure safe
transport of this material via pneumatic conveying system.

Issued

2012-01-12 00:00:00

Abate by

2012-01-17 00:00:00

Penalty

Initial $7000.00 · Current $3750.00 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 9/9/11 in the 7 Series Silo area; employer pneumatically
transports
atomized aluminum dust ( explosive dust )  and sodium chlorate (oxidizer),
to nine silos
located inside the process area.  During the transfer of these materials
an explosion
occurred in one of the silos (7H) and the dust collector (40),both located
inside.  None
of the silos or dust collector were equipped with explosion protection
devices or methods.
The effects of this event propagated to a weigh car on the production
floor filled with
5,300 pounds of raw materials (dust), resulting in a large metal source
fire.
NO ABATEMENT DOCUMENTATION REQUIRED
National Fire Protection Association standard, NFPA 654 - 2006 Edition,
Prevention of Fire and
Dust Explosions from the Manufacturing,Processing, and Handling of
Combustible Particulate
Solids, Section 7.1.2.1 requires: "Where an explosion hazard exists, fixed
bulk storage
containers shall be protected in accordance with 7.1.2.
Feasible and acceptable methods to enhance this condition would be, such
as but not limited to;
1) Oxidant concentration reduction in accordance with NFPA 69, Standard on
Explosion
Prevention Systems.
2) Deflagration venting.
3) Deflagration pressure containment in accordance with NFPA 69, Standard
on Explosion
Prevention Systems.
4) Deflagration suppression systems in accordance with NFPA 69, Standard
on Explosion
Prevention Systems.
5) Dilution with a noncombustible dust to render the mixture
noncombustible.
6) Deflagration venting through a listed dust retention and
flame-arresting device.

Issued

2012-01-12 00:00:00

Abate by

2012-01-17 00:00:00

Penalty

Initial $7000.00 · Current $3750.00 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 9/9/11 in the 300 Transporter system; employer
pneumatically transports
atomized aluminum dust ( explosive dust ) and sodium chlorate ( oxidizer),
to nine silos
located inside the process building.  Routinely during the transfer of the
atomized
aluminum dust, the transfer system experienced plugging.  After locating
the section of
the transfer piping suspected to be plugged, employees would use a metal
hammer to
strike the section of the piping, thought to be plugged, in an attempt to
dislodge it.
Handling and storage requirements of oxidizers indicate to avoid friction
and impact.
As a result of the transfer and plugging of these materials on 9/9/11, an
explosion
occurred and propagated to a weigh car, filled with 5,300 pounds of raw
materials,
located on the production floor resulting in a metal fire.
NO ABATEMENT DOCUMENTATION REQUIRED
National Fire Protection Association standard, NFPA 654 - 2006 Edition,
Prevention of Fire and
Dust Explosions from the Manufacturing,Processing, and Handling of
Combustible Particulate
Solids, Section 7.3.2.4, Pneumatic conveying systems requires: "All
ductwork shall be sized to
provide the air volume and air velocity necessary to keep the duct
interior clean and free of
residual material.
Feasible and acceptable methods to enhance this condition would be, such
as but not limited to;
1) Evaluate pneumatic transfer system to determine capability to transfer
all materials expected
to enter the system as well as size, materials of construction of ductwork
and transfer velocities.
2) Document the following information contained in National Fire
Protection
Association
standard, NFPA 654 - 2006 Edition, Prevention of Fire and Dust Explosions
from the
Manufacturing,Processing, and Handling of Combustible Particulate Solids,
Section 7.3.2.5,
a) Data on the range of particulate size
b) Concentration in conveyance stream
c) Potential for reaction between transported particulate and the
extinguishing media used to
protect the process equipment.
d) Conductivity of the particulate
e) Other physical and chemical properties that affect the fire protection
of the process.

Issued

2012-01-12 00:00:00

Abate by

2012-03-14 00:00:00

Penalty

Initial $7000.00 · Current $3750.00 Reduced