OSHA Inspection: KOPPERS INDUSTRIES, INC.

Issued

Sep 12, 2012

Abate by

Sep 13, 2012

Penalty

Initial $5,000 · Current $2,500 Reduced

General-duty citation text

29 CFR 1910.106(b)(6): In locations where flammable vapors may be present, the employer did not take precautions to prevent ignition by eliminating or controlling sources of ignition. Sources of ignition may include open flames, lightning, smoking, cutting and welding, hot surfaces, frictional heat, sparks (static, electrical, and mechanical), spontaneous ignition, chemical and physical-chemical reactions, and radiant heat.    a) On or about March 30, 2012, at the above located workplace, inside a diked area, tank #300 (having a maximum capacity of 530,000 gallons) was used to store flammable xylene. To prevent flooding the diked area had a general use sump pump (120 volts) and extension cord. The general use sump pump and extension cord were uncontrolled sources of ignition and were not suitable for the Class 1, Division 2, location.    b) On or about March 30, 2012, at the above located workplace, inside a diked area, tank #303 (having a maximum capacity of 530,000 gallons) was used to store flammable xylene. To prevent flooding the diked area had a general use sump pump (120 volts) and extension cord. The general use sump pump and extension cord were uncontrolled sources of ignition and were not suitable for the Class 1, Division 2, location.    c) On or about March 30, 2012, at the above located workplace, inside a diked area, tanks 304A and 304B (each having a maximum capacity of 50,000 gallon) was used to store flammable xylene. A section of electrical conduit (with 120 volt wiring) on one tank had an open end. The open end was an uncontrolled source of ignition and was not suitable for the Class 1, Division 2, location.    d) On or about March 30, 2012, at the above located workplace, in the Ortho heating area (where xylene, a flammable liquid, was heated) two large electrical connection enclosures were not sealed with the required number of fastening screws. The electrical enclosures were uncontrolled sources of ignition and were not suitable for the Class 1, Division 2, location.    e) On or about March 30, 2012, at the above located workplace, at the west Ortho Nozzle (B-train orthoxylene feed platform, where heated xylene was sprayed into an oxygen stream) an energized general use heat tape was installed to prevent freezing. The heat tape was an uncontrolled source of ignition and was not suitable for the Class 1, Division 2, location.    f) On or about March 30, 2012, at the above located workplace, at the west Ortho Nozzle (B-train orthoxylene feed platform, where heated xylene was sprayed into an oxygen stream) an energized general use extension cord was installed. The extension cord was an uncontrolled source of ignition and was not suitable for the Class 1, Division 2, location.

Issued

Sep 12, 2012

Abate by

Sep 13, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(b)(2): Listed or labeled equipment was not used or installed in accordance with instructions included in the listing or labeling:    a) On or about March 30, 2012, at the above located workplace, inside a diked area, tank #300 (having a maximum capacity of 530,000 gallons) was used to store flammable xylene. To prevent flooding the diked area had a general use sump pump (120 volts) and extension cord. The general use sump pump and extension cord were not used or installed in accordance with instructions included in the listing or labeling for the Class 1, Division 2, location.     b) On or about March 30, 2012, at the above located workplace, inside a diked area, tank #303 (having a maximum capacity of 530,000 gallons) was used to store flammable xylene. To prevent flooding the diked area had a general use sump pump (120 volts) and extension cord. The general use sump pump and extension cord were not used or installed in accordance with instructions included in the listing or labeling for the Class 1, Division 2, location.      c) On or about March 30, 2012, at the above located workplace, inside a diked area, tank #304A and 304B (each having a maximum capacity of 50,000 gallon) was used to store flammable xylene. A section of electrical conduit (with 120 volt wiring) on one tank had an open end. The open ended conduit was not used or installed in accordance with instructions included in the listing or labeling for the Class 1, Division 2, location.      d) On or about March 30, 2012, at the above located workplace, in the Ortho heating area (where xylene, a flammable liquid, was heated) two large electrical connection enclosures were not sealed with the required number of fastening screws. The electrical enclosures were not used or installed in accordance with instructions included in the listing or labeling for the Class 1, Division 2, location.       e) On or about March 30, 2012, at the above located workplace, at the west Ortho Nozzle (B-train orthoxylene feed platform, where heated xylene was sprayed into an oxygen stream) an energized general use heat tape was installed to prevent freezing. The heat tape was not used or installed in accordance with instructions included in the listing or labeling for the Class 1, Division 2, location.        f) On or about March 30, 2012, at the above located workplace, at the west Ortho Nozzle (B-train orthoxylene feed platform, where heated xylene was sprayed into an oxygen stream) an energized general use extension cord was installed. The extension cord was not used or installed in accordance with instructions included in the listing or labeling for the Class 1, Division 2, location.

Issued

Sep 12, 2012

Abate by

Sep 13, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.307(c): Equipment, wiring methods, and installations of equipment in hazardous (classified) locations was not intrinsically safe, approved for the hazardous (classified) location, or safe for the hazardous (classified) location:        a) On or about March 30, 2012, at the above located workplace, inside a diked area, tank #300 (having a maximum capacity of 530,000 gallons) was used to store flammable xylene.  To prevent flooding the diked area had a general use sump pump (120 volts) and extension cord. The general use sump pump and extension cord were uncontrolled sources of ignition and were not suitable for the Class 1, Division 2, location.      b) On or about March 30, 2012, at the above located workplace, inside a diked area, tank #303 (having a maximum capacity of 530,000 gallons) was used to store flammable xylene. To prevent flooding the diked area had a general use sump pump (120 volts) and extension cord. The general use sump pump and extension cord were uncontrolled sources of ignition and were not suitable for the Class 1, Division 2, location.      c) On or about March 30, 2012, at the above located workplace, inside a diked area, tank 304A and 304B (each having a maximum capacity of 50,000 gallon) were used to store flammable xylene. A section of electrical conduit (with 120 volt wiring) on one tank had an open end. The open end was an uncontrolled source of ignition and was not suitable for the Class 1, Division 2, location.      d) On or about March 30, 2012, at the above located workplace, in the Ortho heating area (where xylene, a flammable liquid, was heated) two large electrical connection enclosures were not sealed with the required number of fastening screws. The electrical enclosures were uncontrolled sources of ignition and were not suitable for the Class 1, Division 2, location.      e) On or about March 30, 2012, at the above located workplace, at the west Ortho Nozzle (B-train orthoxylene feed platform, where heated xylene was sprayed into an oxygen stream) an energized general use heat tape was installed to prevent freezing. The heat tape was an uncontrolled source of ignition and was not suitable for the Class 1, Division 2, location.      f) On or about March 30, 2012, at the above located workplace, at the west Ortho Nozzle (B-train orthoxylene feed platform, where heated xylene was sprayed into an oxygen stream) an energized general use extension cord was installed. The extension cord was an uncontrolled source of ignition and was not suitable for the Class 1, Division 2, location.

Issued

Sep 12, 2012

Penalty

Initial $5,000 · Current $2,500 Reduced

General-duty citation text

29 CFR 1910.303(g)(2)(i):  Live parts of electric equipment operating at 50 volts or more were not guarded against accidental contact by approved cabinets or other forms of approved enclosures, or other means listed under this provision:      a) On or about April 10, 2012, at the above located workplace, in the area just south and west of #2 Tube Heater (# 2/south light end gas burner) in the old flare area, energized 120 volt wiring was exposed. The wiring was not enclosed in an approved box or other approved enclosure. The energized wiring exposed employees to electrical hazards.

Issued

Sep 12, 2012

Penalty

Initial $3,000 · Current $1,500 Reduced

General-duty citation text

29 CFR 1910.334(a)(3)(i): If there is a defect or evidence of damage that might expose an employee to injury, the defective or damaged item shall be removed from service, and no employee may use it until repairs and tests necessary to render the equipment safe have been made.    a) During the period of about April 1, 2012 and April 26, 2012, an extension cord was used by a maintenance employee to power items including, but not limited to, portable tools and lights. The grounding pin on the extention cord was missing. The lack of the grounding pin exposed the employee to electrical hazards.

Issued

Sep 12, 2012

Abate by

Sep 13, 2012

Penalty

Initial $5,000 · Current $2,500 Reduced

General-duty citation text

29 CFR 1910.335(a)(1)(i): Employees working in areas where there was potential electrical hazards were not provided with, and use, electrical protective equipment that was appropriate for the specific parts of the body to be protected and for the work to be performed.    a) Between approximately March 29, 2012 and April 24, 2012, at the above located work place, employees were required to perform voltage testing on electrical equipment of 220 to 440 volts. The employers did not provided and require employees to use personal protective equipment, including but not limited to protective equipment for eyes and face whenever there was danger of injury to from electric arcs or flashes or flying objects resulting from electrical explosion.  Employees were thereby exposed to hazards associated with energized electrical parts.

Issued

Sep 12, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.176(b): Storage of material created a hazard.     a) On or about April 26, 2012, at the above located workplace, in the tar plant, under 48 tank, two compressed gas cylinders were without chains or other means to prevent them from falling. Employees were thereby exposed to the hazards associated with falling compressed gas cylinders.