OSHA Inspection: STATE METAL INDUSTRIES, INC.

Issued

Jan 21, 2014

Penalty

Initial $2,100 · Current $1,260 Reduced

General-duty citation text

29 CFR 1910.23(c)(1): Open-sided floors and/or platforms four feet or more above adjacent floor or ground level were not guarded with standard railings (or equivalent) and toeboards:Note:  Toeboards are only required when persons can pass, there is moving equipment or there is equipment with which falling materials could create a hazard.        a) Maintenance department: A railing around the perimeter of the upper level storage area did not have a toprail, on or about 7/23/13.     b) Maintenance department: A storage area located above the bathrooms did not have a top and midrail around its perimeter, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 28, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.36(e)(2): The door(s)  that connected any room to an exit route did not swing out in the direction of exit travel when  the room was designed to be occupied by more than 50 people or  when the room was a high hazard area.     a) Chlorine room: The emergency exit door in the chlorine room did not open in the direction of travel, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 28, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(i)(B): Written process safety information pertaining to equipment in the process did not include piping and instrumentation diagrams (P&IDs):    a) Furnace area: The employer did not ensure that the written process safety information included all the necessary information pertaining to the equipment in the process when information for old Metaullics pumps that are no longer in use was listed on both  the system number one and system number two P&IDs, on or about 7/23/13.    b) Chlorine room: The employer did not ensure that written process safety information included all the necessary information pertaining to the equipment in the process when the incorrect operating temperatures for the evaporators was listed on the P&ID for systems number one and two, on or about 4/15/13.    c) Chlorine room: The employer did not ensure that written process safety information included all the necessary information pertaining to the equipment in the process when the symbol used to identify the chlorine sensors did not match the identification symbol used in the P&ID key for system number one, on or about 7/23/13.     d) Chlorine room: The employer did not ensure that written process safety information included all the necessary information pertaining to the equipment in the process when the symbol used to identify the wet control circuitry on the P&ID for system number one did not match the identification symbol used in the key, on or about 7/23/13.    e) Chlorine room: The employer did not ensure that written process safety information included all the necessary information pertaining to the equipment in the process in that the pressure for the gas pressure reducing valve was incorrectly identified as 30 p.s.i., when it should be listed as 35 p.s.i. on system number two P&ID ., on or about 7/23/13.    f) Chlorine room: The employer did not ensure that written process safety information included all the necessary information pertaining to the equipment in the process when the electrical circuitry for the pressure switch from the gas pressure reducing valve to the pressure relief valve was not correctly depicted on the P&ID for system number one. The gas pressure relief valve was shown as having a direct connection to a separate pressure relief valve, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.119(d)(3)(ii): The employer did not document that equipment complies with recognized and generally accepted good engineering practices:     a) Chlorine room and furnace area leading to furnaces H and M: Pipes carrying chlorine from the evaporators to the H and M furnaces in the plant were observed to be unlabeled. The employer did not document that equipment complies with RAGAGEP such as, but not limited to, the Chlorine Institute Pamphlet 6, Section 10 which states that, "Chlorine lines should be readily identifiable", on or about 7/23/13.       b) Furnace room next to chlorine room entrance: Piping brackets supporting chlorine lines were attached to other pipelines in the facility.  The employer did not document that the piping complied with RAGAGEP such as, but not limited to, the Chlorine Institute Pamphlet 6 which states in section 10.2 that, "Piping should not be hung from chlorine lines and chlorine lines should not be hung from other pipes", on or about 7/23/13.      c) Chlorine room: An unidentified pipeline was zip tied to the chlorine line leaving the evaporator for furnace H. The employer did not document that the piping complied with RAGAGEP such as, but not limited to, the Chlorine Institute Pamphlet 6 which states in section 10.2 that, "Piping should not be hung from chlorine lines and chlorine lines should not be hung from other pipes", on or about 7/23/13.         ABATEMENT NOTE:  It is recommended that replacement of pipe brackets supporting chlorine lines should be done according to Chlorine Institute pamphlet number 6 Piping Systems for Dry Chlorine Edition 15 section 10.2. The pamphlet states that piping should be supported with hangers or pipe shoes made of a non-metallic material, where possible, that will prevent metal to metal wear or corrosion.

Issued

Jan 21, 2014

Abate by

Feb 28, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.119(e)(3)(i): The PHA did not address the hazards of the process.     a) Furnace area: The employer's PHA did not address the potential release of chlorine during removal of the angle tube gas injection pump and motor, on or about 7/23/13.     b) Chlorine room: The employer's PHA did not address failure of the interlocks, namely the gas pressure reducing valve sensor for the evaporators and the Halogen Valve Systems Eclipse Actuator connected to the cylinder, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Mar 28, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.119(h)(2)(i): The employer, when selecting a contractor, did not obtain and evaluate information regarding the contract employer's safety performance and program:    a) Throughout facility: The employer did not review the safety programs or safety performance records of contractors used at the facility, such as, but not limited to those servicing the furnaces, bag houses and electrical systems. The work completed by the contractors was done on equipment that was adjacent to the covered chlorine process, on or about  7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 28, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.119(h)(2)(iv): The employer did not develop and implement safe work practices consistent with paragraph (f)(4) of this section to control the entrance, presence and exit of contract employers and contract employees in the covered process areas.     a) Throughout facility: The employer did not develop a system that would track the entrance, presence and exit of any contractors on site conducting work at the facility on items that interact with the chlorine system, such as, but not limited to the furnaces, bag houses and electrical systems, on or about  7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.119(j)(4)(ii): Inspection and testing procedures did not follow recognized and generally accepted good engineering practices:    a) Chlorine storage room: Appropriate checks and inspections were not performed to assure that valves and lead washers were connected to the one ton cylinders using the proper torqueing values and wrenches as recommended by the manufacturer and RAGAGEP, such as, but not limited to, Chlorine Institute Pamphlet number 1 Chlorine Basics Edition 7 section 3.8.7, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 28, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.119(n): The employer did not establish an emergency plan for the entire plant in accordance with the provisions of 29 CFR 1910.38.In addition, the emergency action plan did not include procedures for handling small releases :     a) Throughout facility: The employer's emergency action plan did not list the specific evacuation route to use based on wind direction in the event of a chlorine release,  on or about 7/23/13.     b) Throughout facility: The employer's emergency action plan did not clarify the specific conditions under which an evacuation would be required, such as, but not limited to the level of chlorine present or the type of chlorine equipment malfunction, on or about 7/23/13.      c) Throughout facility: The employer's emergency action plan did not  have procedures for handling small releases. The plan did not have a  procedure for determining the difference between a large and small release, and what PPE would be needed to respond to each, on or about 7/23/13.

Issued

Jan 21, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.120(f)(2)(iv): A medical surveillance program was not instituted by the employer for members of HAZMAT teams:  a) Throughout facility: The employer did not implement a medical surveillance program for extremely hazardous substance (EHS) employees designated as emergency responders for chlorine leaks at the facility, on or about 7/23/13.

Issued

Jan 21, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.120(q)(6)(iii): Employees who participated as hazardous materials technicians, or were expected to participate as hazardous materials technicians, had not received at least 24 hours of training equal to the first responder operations level, and in addition have competency in the areas outlined in 29 CFR 1910.120(q)(6)(iii)(A) through (q)(6)(iii)(I) and/or the employer did not so certify:  a) Throughout facility: Employees who were required to assess the severity of, and control a release of chlorine did not receive training that, at a minimum, met the training requirements of a hazardous materials technician, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.146(c)(2): The employer did not inform exposed employees, by posting danger signs or by any other equally effective means, of the existence and location of and the danger posed by the permit spaces:     a) Furnace area: Employees were not informed that the pit beneath the ingot conveyor was a permit required confined space. On or about 7/23/13.     ABATEMENT NOTE: A sign reading "DANGER - PERMIT REQUIRED CONFINED SPACE. DO NOT ENTER" or using any other similar language would satisfy the requirement for a sign.     NOTE: THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT CERTIFICATION FOR THIS ITEM. FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jan 21, 2014

Abate by

Feb 28, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(d)(3): Under the permit-required confined space program required by 29 CFR 1910.146(c)(4), the employer did not develop and implement the means, procedures, and practices necessary for safe permit space entry operations, as required by section (d)(3)(i)-(d)(3)(vi) of this section:    a) Main furnace area: There was no written procedure for entering the pit beneath the ingot conveyor which contained hazards including, but not limited to potential mechanical hazards. On or about 7/23/13.     b) Bag houses: There was no written procedure for entering the bag houses which contained hazards including, but not limited to potential atmospheric hazards. On or about 7/23/13.     NOTE: THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT CERTIFICATION FOR THIS ITEM. FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jan 21, 2014

Abate by

Feb 28, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.151(c): Where employees were exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body were not provided within the work area for immediate emergency use:     a)  Chlorine Room: The emergency eyewash station and deluge shower were located inside of the chlorine room and would not be usable in the event of a release of chlorine. The Chlorine Institute's Pamphlet 155, Section 9.3 requires that an emergency eyewash and deluge shower are to be located near the potential exposure site but not so close as to be unusable in an emergency. On or about 7/23/13.     NOTE: THE EMPLOYER IS REQUIRED TO SUBMIT ABATEMENT CERTIFICATION FOR THIS ITEM. FAILURE TO COMPLY WILL RESULT IN AN ADDITIONAL PENALTY OF $1000.00 IN ACCORDANCE WITH 29 CFR 1903.19.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $2,800 · Current $1,680 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): One or more methods of machine guarding was not provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks:    a) Maintenance department: A chuck on a drill press was not guarded, on or about 7/23/13.    b) Maintenance department:  The Wellsaw horizontal band saw, model 58B serial  number 16404, did not have an adjustable guard that extended the length of the blade, on or about 7/23/13.

Issued

Jan 21, 2014

Penalty

Initial $2,800 · Current $1,680 Reduced

General-duty citation text

29 CFR 1910.219(d)(1): Pulley(s) with part(s) seven feet or less from the floor or work platform were not guarded in accordance with the requirements specified in 29 CFR 1910.219(m) and (o):    a) Maintenance department: A pulley that operated a chuck on a drill press was not guarded, on or about 7/23/13.    b) Maintenance department: A pulley that operated a blade on the Wellsaw horizontal band saw, model 58B serial  number 16404, was not guarded, on or about 7/23/13.

Issued

Jan 21, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(e)(1)(i): Horizontal belts which had both runs seven feet or less from the floor level were not guarded with a guard that extended to at least fifteen inches above the belt:   a) Maintenance department: A belt that operated a chuck on a drill press was not guarded, on or about 7/23/13.

Issued

Jan 21, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(e)(3)(i): Vertical or inclined belt(s) were not enclosed by guard(s) conforming to the requirements specified at 29 CFR 1910.219(m) and (o):   a) Maintenance department: A belt that operated a blade on the Wellsaw horizontal band saw, model 58B serial number 16404, was not guarded, on or about 7/23/13.

Issued

Jan 21, 2014

Penalty

Initial $2,100 · Current $1,260 Reduced

General-duty citation text

29 CFR 1910.303(b)(2): Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling:     a) Maintenance room:  An unmounted 4x4 electrical receptacle was being used as an extension cord, on or about 7/23/13.

Issued

Jan 21, 2014

Penalty

Initial $2,100 · Current $1,260 Reduced

General-duty citation text

29 CFR 1910.303(b)(7)(iv): There were damaged parts that adversely affected safe operation or mechanical strength of the equipment, such as parts that were broken, bent, cut, or deteriorated by corrosion, chemical action, or overheating:    a) Ingot Cooling Warehouse: A junction box was crushed, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $2,100 · Current $1,260 Reduced

General-duty citation text

29 CFR 1910.303(g)(1)(ii): The required working space about electric equipment rated 600 volts, nominal, or less to ground, was used for storage:    a) Maintenance Room: A 440V Electrical panel box was blocked by storage of items such as, but not limited to, boxes and an air hose, on or about 7/23/13.    b) Maintenance Room: A disconnect switch was blocked by storage of items, such as, but not limited to, coolers, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $2,100 · Current $1,260 Reduced

General-duty citation text

29 CFR 1910.303(g)(2)(i): Except as elsewhere required or permitted by Subpart S of Part 1910, live parts of electric equipment operating  at 50 volts or more were not guarded against accidental contact by use of approved cabinets or other forms of approved enclosures or by any of the means identified in paragraphs (A), (B), (C), and (D) of 29 CFR 1910.303(g)(2)(i):    a) Chlorine room: The door on a 240 volt electrical panel board was not effectively closed, on or about 7/23/13.     b) H Furnace Control room: The door on an electrical panel board was not effectively closed, on or about 7/23/13.     c) Maintenance room: The door on a 440 volt electrical panel board was not effectively closed, on or about 7/23/13.     d) H Furnace Control room: The door on a control panel that operated the furnace was not closed, on or about 7/23/13.      e) H Furnace area: The door on an electrical panel board was not effectively closed, on or about 7/23/13.     f) Rotary Furnace area: The door on an electrical panel board on the shaker table was not effectively closed, on or about 7/23/13.

Issued

Jan 21, 2014

Penalty

Initial $2,100 · Current $1,260 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in boxes, cabinets, or fittings were not effectively closed:    a) M Furnace Area control room: An electrical panel had missing circuit breakers and the openings were not closed, on or about 7/23/13.    b) M Furnace Area control room: An electrical panel had knockouts missing, on or about 7/23/13.

Issued

Jan 21, 2014

Penalty

Initial $2,100 · Current $1,260 Reduced

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(A): Flexible cords were used as a substitute for the fixed wiring of a structure;    a) H Furnace Area: An extension cord was used to permanently power a fan, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $2,100 · Current $1,260 Reduced

General-duty citation text

29 CFR 1910.305(g)(2)(iii): Flexible cords were not connected to devices and fittings so that tension would not be transmitted to joints or terminal screws:    a) Chlorine room: A wire powering the control panel on the M furnace evaporator had a torn strain relief, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.24(h): Standard railings were not provided on the open sides of all exposed stairways and stair platforms:  a) Furnace area: A standard railing was not installed on each side of the stairs leading to the M furnace control booth, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.179(j)(2)(iii): Monthly inspections of hooks, with a certification record which includes the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, of the hook inspected, were not performed:   a) Maintenance shop: Frequent inspections of hooks were not conducted and documented for the  one ton Coffing crane , on or about 7/23/13.   b) Chlorine room: Frequent inspections of hooks were not conducted and documented for the  two ton Budgit crane, on or about 7/23/13.   c) Furnace area H: Frequent inspections of hooks were not conducted and documented for the each of the two ton Budgit cranes, on or about 7/23/13.   d) Furnace area M: Frequent inspections of hooks were not conducted and documented for the each of the two ton Budgit cranes, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.179(j)(2)(iv): Monthly inspections of hoist chains, with a certification record which includes the date of inspection, the signature of the person who performed the inspection and an identifier of the chain which was inspected, were not performed:   a) Maintenance shop: Frequent inspections of chains were not documented for the  one ton Coffing crane, on or about 7/23/13.   b) Chlorine room: Frequent inspections of chains were not documented for the  two ton Budgit crane, on or about 7/23/13.   c) Furnace area H: Frequent inspections of chains were not documented for the each of the two ton Budgit cranes, on or about 7/23/13.   d) Furnace area M: Frequent inspections of chains were not documented for the each of the two ton Budgit cranes, on or about 7/23/13.

Issued

Jan 21, 2014

Abate by

Feb 14, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.179(j)(3): Complete inspections of the crane was not being performed at intervals as generally defined in paragraph (j)(1)(ii)(b) of this section:   a) Maintenance shop: Periodic inspections were not conducted on a  one ton Coffing crane, on or about 7/23/13.    b) Chlorine room: Periodic inspections were not conducted on a two ton Budgit crane, on or about 7/23/13.   c) Furnace area H: Periodic inspections  were not conducted on each of the two ton Budgit cranes, on or about 7/23/13.   d) Furnace area M: Periodic inspections were not conducted on each of the two ton Budgit cranes, on or about 7/23/13.