OSHA Inspection: TENNECO-WALKER MANUFACTURING

Issued

Jan 25, 2012

Abate by

Feb 12, 2012

Penalty

Initial $6,300 · Current $6,300

General-duty citation text

Title 40.1-51.1.(a); Code of Virginia: At Tenneco-Walker Manufacturing, located
at 3160 Abbott Lane in Harrisonburg, Virginia, the employer did not furnish empl
oyment and a place of employment which were free from recognized hazards that we
re causing or likely to cause death or serious physical harm to employees in tha
t employees were exposed to an aluminum dust explosion, deflagration, and other
fire hazards while the aluminum wire spools were being changed out on the Sulzer
-Metco SmartArc Spray Arc (remetallizer). On 27 July 2011, at approximately 2130
, a deflagration and subsequent explosion occurred in the dust collection system
for the Sulzer-Metco SmartArc Spray Arc. At the time of the explosion, three em
ployees were working at the remetallizer. The tube mill operator was scraping ou
t the remetallizer enclosure while waiting for the tube mill helper to load the
aluminum wire spools. The remetallizer adds an aluminum coating to the weld seam
on automobile exhaust pipes through a thermal spray process. The byproducts of
the thermal spray process are removed through a designated dust collection syste
m at the point of operation. The deflagration and
subsequent explosion occurred within the duct work between the remetallizer's en
closure and the ninety degree turn (135 feet of duct work). a) The aluminum dust
in the spray booth (remetallizer's enclosure) is combustible. The air velocity
of the ducts was not maintained at 4500 ft/ min. The low velocity could be attri
buted to the capped outlet at the point of the removed Abbey Mill and the result
ing accumulation of coarse and fine particles in the duct work. The build up of
these particles, generated during the remetallizer process, was observed in the
open ends of the ducts (blown apart during the explosion) and on the shop floor.
Two feasible and acceptable abatement methods, among others, to correct this ha
zard are: a) Monitor the air velocity in the dust control system, and adjust as
necessary. b) Redesign the dust collection system, so there are not any unused c
apped ends in the duct work. NFPA Standard 484 2002 (Section 4.3.3.2), Standard
for Combustible Metals, Chapter
4 Aluminum: Ducts shall be designed to maintain a velocity of not less than 1364
m/min (4500 ft/ min) to ensure the transport of both coarse and fine particles
and to ensure re-entrainment if, for any reason, the particles can fall out befo
re delivery to the collector (e.g., in the event of a power failure). NFPA Stand
ard 484 2002 (Section 4.3.3.5.2), Standard for Combustible Metals, Chapter 4 Alu
minum: There shall be no unused capped outlets, pockets, or other dead-end space
s that might allow accumulations of dust. b) Employees in the Pipe Department an
d GMOE are exposed to detonation and explosion hazards. The byproducts of the th
ermal spray process are removed through a dust collection system at the point of
operation. The following deficiencies were observed: The aluminum dust in the s
pray booth (remetallizer's enclosure) tested positive for explosibility. The duc
t
system was not inspected and cleaned, thus allowing for the accumulation of alum
inum and aluminum oxide dust within the dust collection system. One feasible and
acceptable method of abatement is to install a dust-collection system designed
and constructed with access doors. NFPA Standard 484 2002 (Section 4.3.5.9), Sta
ndard for Combustible Metals, Chapter 4 Aluminum: The interior of hoods and duct
s shall be regularly cleaned wherever there is the possibility of buildup of wax
, lint, aluminum fines, or other combustible material. c) The aluminum dust in t
he spray booth tested positive for explosibility. The tube mill operators are pr
ovided a metal scraper to clean out the spray booth. The scraper is made of a sp
arking material, and is a potential ignitionsource. One feasible and acceptable
abatement method, among others, to correct this hazard is: a) Provide and ensure
employees use a non-sparking tool while cleaning out the
spray booth. NFPA 484 2002 (Section 4.4.2.2), Standard for Combustible Metalss,
Chapter 4 Aluminum: Periodic Cleanup of fugitive dust shall be accomplished by u
sing one of the following: (1) Conductive, non-sparking scoops and soft brooms.
(2) Brushes that have natural fiber bristles (3) Vacuum-cleaning systems designe
d for handling combustible metals powders in accordance with 4.4.3.

Issued

Jan 25, 2012

Abate by

Feb 12, 2012

Penalty

Initial $6,300 · Current $6,300

General-duty citation text

Title 40.1-51.1.(a); Code of Virginia: At Tenneco-Walker Manufacturing, located
at 3160 Abbot Lane in Harrisonburg, Virginia, the employer did not furnish emplo
yment and a place of employment which were free from recognized hazards that wer
e causing or likely to cause death or serious physical harm to employees in that
employees were exposed to dust or gas explosion, deflagration, and other fire h
azards while working in the Tube Mill or GMOE Departments due to the presence of
a potential thermite reaction and/or hydrogen gas. On 27 July 2011, at approxim
ately 2130, a deflagration and subsequent explosion
occurred in the dust collection system for the Sulzer-Metco SmartArc Spray Arc.
At the time of the explosion, three employees were working at the remetallizer.
The tube mill operator was scraping out the remetallizer enclosure while waiting
for the tube mill helper to load the aluminum wire spools. The remetallizer add
s an aluminum coating to the weld seam on automobile exhaust pipes through a the
rmal spray process. The byproducts of the thermal spray process are removed thro
ugh a designated dust collection system at the point of operation. The deflagrat
ion and subsequent explosion occurred in the duct work between the remetalizer a
nd the ninety degree turn (135 feet upstream). a) The aluminum dust in the spray
both (remetalizer's enclosure) tested positive for explosibility. The accumulat
ion of moisture with in the duct work was not prevented. The presence of moistur
e is evidenced by the visible rust on the inside of the "can" opened duct. Iron
oxide can reduce the structural integrity of the ducts. Also, there is a potenti
al for a thermite reaction between the iron oxide and the aluminum dust produced
during the thermal spray operations. Furthermore, water can react with the alumi
num dust to produce hydrogen gas, thus there would be a potential for a gas expl
osion. One feasible and acceptable abatement method, among others, to correct th
is hazard is to control and monitor the humidity within the dust collection syst
em. NFPA Standard 484 2002 (Section 4.3.5.4), Standard for Combustible Metals, C
hapter 4 Aluminum: The accumulation of condensation of water at any point in the
dry dust collection system shall be prevented.

Issued

Jan 25, 2012

Abate by

Feb 12, 2012

Penalty

Initial $6,300 · Current $6,300

Issued

Jan 25, 2012

Abate by

Feb 12, 2012

Penalty

Initial $3,150 · Current $3,150