OSHA Inspection: TONAWANDA COKE CORPORATION AND KIRCHNER, LLC

Issued

2014-07-30 00:00:00

Abate by

2014-08-05 00:00:00

Penalty

Initial $6000.00 · Current $4200.00 Reduced

General-duty citation text

29 CFR 1910.23(e)(1): Standard railing(s) did not consist of top rail, intermediate rail and/or posts and/or did not have a vertical height of 42 inches (106.7 cm) nominal from upper surface of top rail to floor, platform runway, or ramp level:      a) On or about 03/05/14, in the automechanics shop area, a mezzanine's railing did not have an intermediate rail exposing employees to a 7.5 feet fall below.      ABATEMENT CERTIFICATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-09-12 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 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 a high hazard area.    a) On or about 03/05/14, at the main entrance of the Power and Boiler House Building, the marked emergency exit door did not swing out in the direction of exit travel.     ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-08-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.36(g)(1): Ceiling of an exit route was not at least seven feet six inches.  Any projection from the ceiling must not reach a point less than six feet eight inches from the floor.   a) On or about 03/05/14, in the Power and Boiler House Building, a marked emergency exit door total projection from the ceiling was 6.2 feet and it was calculated as the sum of an opening of 66.5 inches and a fixed bar at the bottom of the door of 8 inches.    ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-08-30 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.37(a)(3): Exit route(s) were not kept free and unobstructed:      a) On or about 03/05/14, in the Welding Shop, an exit door was blocked by a welding machine, materials and wooden pieces on the floor.      NO ABATEMENT CERTIFICATION REQUIRED      b) On or about 03/05/14, in the Power and Boiler House, an exit door had an 8 inches bar attached to its bottom exposing employees to tripping/falls and fire hazards when exiting this door.       ABATEMENT CERTIFICATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-08-15 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures were not utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:    a) On or about 03/05/14, in the machine shop building, a lockout/tagout procedure was not utilized when changing a blade on a vertical band saw.       ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-09-12 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(A): A specific statement of the intended use of the energy control procedure was not clearly and specifically outlined:    a) On or about 03/05/14, in the establishment, employer did not have a specific statement of the intended use of the lockout/tagout procedure for the vertical band saw located in the machine shop for employees performing maintenance/servicing activities such as, but not limited to changing blades.    ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-09-12 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(B): The energy control procedures did not clearly and specifically outline the steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy.  a) On or about 03/05/14, in the establishment, employer did not outline the steps for shutting down and isolating the vertical band saw located in the machine shop for employees performing maintenance/servicing activities such as, but not limited to changing blades.   ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-09-12 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(C): The energy control procedure did not clearly and specifically outline the steps for placement, removal and transfer of lockout devices or tagout devices and the responsibility for them.  a) On or about 03/05/14, in the establishment, employer did not outline the steps for placement, removal and transfer of lockout devices or tagout devices and the responsibility for them for employees performing maintenance/servicing activities such as, but not limited to changing blades on a vertical band saw located in the machine shop.   ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-09-12 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(c)(4)(ii)(D): The energy control procedures did not clearly and specifically outline the requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control:  a) On or about 03/05/14, in the establishment, employer did not outline the requirements for testing a vertical band saw located in the machine shop to determine and verify the effectiveness of lockout/tagout devices for employees performing maintenance/servicing activities such as, but not limited to changing saw's blades.  ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-08-30 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.179(j)(3): A complete periodic inspection of crane(s) had not been conducted in the past 12 months:     a) On or about 03/05/2014, throughout the plant, the last inspections of overhead cranes such as, but not limited to: 2 ton powered trolley weld shop outside steel storage, 1 ton beam trolley electrical shop, 2 ton manual trolley round house, 2 ton manual bridge trolley machine shop, 3 ton beam trolley A&D belts coke handling, 1 ton beam trolley outside #1DD coke handling, 1 ton beam trolley over #1 DD coke handling, 1 ton beam trolley over # 3DD coke handling, oven door room stationary crane battery, 2 ton beam trolley top of coal handling and 1 ton beam trolley breeze crusher coal handling were conducted on 02/20/2009.    ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-08-30 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.179(m)(1): Thorough monthly inspections of rope conditions, with written, dated and signed reports, were not performed on the running ropes:    a) On or about 03/05/14, throughout the plant, employer did not perform monthly inspections of rope conditions on overhead cranes such as, but not limited to: oven door room stationary crane in battery, 2 ton manual trolley round house, 2 ton manual bridge trolley machine shop, 3 ton beam trolley A&D belts coke handling, 5 ton stationary C&F boom, 1 ton beam trolley over#1DD coke handling, 2 ton beam trolley top of coal handling. The last ropes inspections reports were performed on 02/20/2009.     ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-08-30 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.179(n)(2)(i): Hoist chain(s) or hoist rope(s) were not free from kinks or twists:    a) On or about 03/05/14, in the Coke Handling Area, the hoist rope of overhead crane #1 DD used to lift heavy metal materials (i.e. Steel screens) was not free from kinks.    ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-08-30 00:00:00

Penalty

Initial $5000.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.184(e)(3)(i): A thorough periodic inspection of alloy steel chain slings was not made on a regular basis and/or were done at intervals greater than once every 12 months:    a) On or 03/05/14, throughout the plant, the last inspections of chains of overhead cranes such as, but not limited to: 2 ton powered trolley weld shop outside steel storage, 1 ton beam trolley electrical shop, 1 ton beam trolley outside #1 DD, 1 ton beam trolley over # 3DD and 1 ton beam trolley breeze crusher coal handling were conducted on 02/20/2009.    ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-08-30 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.212(a)(1): Machine guarding was not provided to protect operator(s) and other employees from hazard(s) created by saws' blades:    a) On or about 03/05/14, in the Welding Shop Building, a Hyd-Mech Model S-20 Horizontal Band Saw did not have a guard on the non-working part of the blade.     ABATEMENT DOCUMENTATION REQUIRED    b) On or about 03/05/14, in the Machine Shop Building, a guard under the table of a Vertical Band Saw was removed and at the other side of this saw's table, another guard did not cover the non-working part of the blade completely.     ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Penalty

Initial $5100.00 · Current $3570.00 Reduced

General-duty citation text

29 CFR 1910.253(b)(4)(iii): Oxygen cylinders in storage were not separated from fuel-gas cylinders, a minimum distance of 20 feet (6.1 m) or by a noncombustible barrier at least 5 feet (1.5 m) high having a fire-resistance rating of at least one-half hour:    a) On or about 03/05/14, in the Boiler House Building, Oxygen cylinders were stored three feet away from Acetylene cylinders.    NO ABATEMENT CERTIFICATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-08-15 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.303(g)(1): Sufficient access and working space was not provided and maintained about all electric equipment (operating at 600 volts, nominal, or less to ground) to permit ready and safe operation and maintenance of such equipment:    a) On or about 03/05/14, in the Machine Shop Building's second floor, there was not access to the electrical disconnect switch of a Vertical Band Saw.    ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-07-30 00:00:00

Abate by

2014-08-30 00:00:00

Penalty

Initial $35000.00 · Current $24500.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i)(A): Authorized employee(s) did not receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control:    a) On or about 03/05/14, in the establishment, employer did not provide training on the application of Machine-Specific Lockout/Tagout(LOTO) Procedures and Group LOTO procedures to employees performing maintenance activities such as, but not limited to: changing rollers on conveyor belts and cleaning burners of Boiler #7.     ABATEMENT DOCUMENTATION REQUIRED      Tonawanda Coke Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.147 (c)(7)(i)(A), which was contained in OSHA inspection number 314846205, citation number 1, item number 1 and was affirmed as a final order on 11/01/10, with respect to a workplace located at 3875 River Road, Tonawanda, NY, 14150.

Issued

2014-07-30 00:00:00

Abate by

2014-08-30 00:00:00

Penalty

Initial $1000.00 · Current $700.00 Reduced

General-duty citation text

29 CFR 1910.303(e)(1)(ii): Other markings giving voltage, current, wattage, or other ratings as necessary had not been placed on equipment being used:    a) On or about 03/05/14, in the Machine Shop Building, an electrical disconnect switch for a Vertical Band Saw did not have a voltage marking.    b) On or about 03/05/14, in the Breeze Crusher Building, an electrical main disconnect switch labeled as Plant Power/Generator Power did not have a voltage marking.       ABATEMENT CERTIFICATION REQUIRED

Issued

2014-04-17 00:00:00

Abate by

2014-05-18 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

General-duty citation text

29 CFR 1910.147(d)(4)(i): Lockout or tagout devices were not affixed to each energy isolating device by authorized employees:      a) On or about 10/23/14, in the Boiler House Building, an employee entered inside permit-required confined space #7 Boiler to inspect and clean burners without affixing his lockout/tagout devices on the energy isolating devices to control energy sources such as, but not limited to: electrical, water, natural gas, steam and coke oven gas. Entrant employee only locked out the burners and other employees locked out the rest of the energy sources. Entrant employee was not in control of #7 Boiler's energy sources because he did not affix his personal lock to the yellow lockout/tagout box containing the keys of locks applied to all energy sources neither he affixed a personal lock to each of the 16 energy isolating devices.      ABATEMENT DOCUMENTATION REQUIRED

Issued

2014-04-17 00:00:00

Abate by

2014-05-18 00:00:00

Penalty

Initial $35000.00 · Current $24500.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(6)(ii): The employer did not certify that periodic inspections of the energy control procedures had been performed:      a) On or about 03/05/14, in the establishment, Employer did not annually certify that Lockout/Tagout (LOTO) periodic inspections had been done to verify accuracy or to correct any deviations/inadequacies of all their machine-specific LOTO procedures (at least 73 LOTO procedures) and the application of them by all authorized employees (around 37 authorized employees for Tonawanda Coke and 8 authorized employees for Kirchner LLC). On 2013, only three LOTO procedures for machines: 3-Belt, Rod Mill and West Hammer were inspected and certified with three authorized employees.          ABATEMENT DOCUMENTATION REQUIRED      Tonawanda Coke Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.147(c)(6)(ii), which was contained in OSHA inspection number 314846205, citation number 2, item number 1 and was affirmed as a final order on 11/02/10, with respect to a workplace located at 3875 River Road, Tonawanda, NY, 14150.