OSHA Inspection: HUDAPACK METAL TREATING OF ILLINOIS, INC.

Issued

2019-06-18 00:00:00

Abate by

2019-06-19 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.23(b)(10): Any ladder with structural or other defects was not immediately tagged "Dangerous: Do Not Use" or with similar language in accordance with �1910.145 and removed from service until repaired in accordance with �1910.22(d), or replaced:    a)  On or about December 20 and 21, 2018, employees using a six foot Werner stepladder with structural defects were exposed to fall and burn hazards. Employees were using the step ladder during the cleaning process of the line 2 quench tank to access/egress the top of the tank and to place a pump in the tank for the removal of molten salt, which had a temperature of approximately 600 degrees Fahrenheit.  The stepladder had damaged parts including a broken right main rail, a heat damaged left main rail, a repaired left support rail, a repaired mid-cross brace between the support rails and a repaired top cap that connected both main rails and both support rails.       Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-08-15 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.28(b)(1)(i): The employer did not ensure that each employee on a walking-working surface with an unprotected side or edge that was 4 feet (1.2 m) or more above a lower level was protected from falling by one or more of the following:  Guardrail systems, safety net systems, or personal fall arrest systems:    a)  On or about December 20 and 21, 2018, the employer did not provide fall protection on the perimeter of salt to salt quench tank on line 2 with a fall hazard of approximately 5.9 feet to the exterior of the tank.     b)  On or about December 27, 2018, an employee without fall protection was exposed to a fall hazard of 14 feet while tightening motor cover bolts above line 1.          Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-08-15 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.28(b)(6)(i): (i) Each employee less than 4 feet (1.2 m) above dangerous equipment was not protected from falling into or onto the dangerous equipment by a guardrail system or a travel restraint system, and the equipment was not covered or guarded to eliminate the hazard:    a)  On or about December 20 and 21, 2018, employees without fall protection were exposed to falls of less than 4 feet directly into the uncovered quench tank.  Employees without fall protection occupied the upper surface of the tank wall while engaged in tank cleaning operations.     b)  On or about December 21, 2018, an employee without fall protection was exposed to a fall of less than 4 feet directly into processes tanks while attempting to remove parts which had fallen into tanks on line 1.  Employees were exposed to burns from falling into molten salt at 1600 degrees Fahrenheit.      Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.30(a)(1):  Before any employee was exposed to a fall hazard, the employer did not provide training for each employee who uses personal fall protection systems or who is required to be trained as specified elsewhere in this subpart.  Employers must ensure employees are trained in the requirements of this paragraph on or before May 17, 2017:    a)  On or about December 20, 2018, and days afterward, employees without fall protection training were exposed to fall hazards in the regular course of their duties.          Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-06-19 00:00:00

Penalty

Initial $3978.00 · Current $2390.00 Reduced

General-duty citation text

29 CFR 1910.37(b)(6): Each exit sign was not illuminated to a surface value of at least five foot-candles (54 lux) by a reliable light source and be distinctive in color.  Self-luminous or electroluminescent signs that have a minimum luminance surface value of at least .06 footlamberts (0.21 cd/m2) are permitted:    a) On or about December 27, 2018, the employer did not ensure that the exit sign in the aisle at the northeast exit was illuminated. This exposed employees to smoke inhalation and burns in the case of a fire.     Abatement certification is required for this item in accordance with 29 CFR 1903.19(c).

Issued

2019-06-18 00:00:00

Abate by

2019-08-15 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.132(d)(1)(i): The employer did not assess the workplace to determine if hazards are present, or are likely to be present, which necessitate the use of personal protective equipment (PPE). If such hazards are present, or likely to be present, the employer shall: Select, and have each affected employee use, the types of PPE that will protect the affected employee from the hazards identified in the hazard assessment:    a) On or about December 20, 2018, employees were exposed to burn hazards while working around molten salt with temperatures of approximately 600 to 1600 degrees Fahrenheit.  Employees wore plastic face masks and plastic safety glasses.  Both of these items provide limited protection at high temperatures.  Employees were not wearing appropriate personal protective equipment to protect from burns to the face and body.  A hazard assessment was not performed to ensure appropriate personal protective equipment was provided to and worn by employees.     b)  On or about December 20, 2018 through March 15, 2019, employees were exposed to electrical and arc flash hazards while performing live electrical work.  A hazard assessment for arc flash was not performed to ensure appropriate personal protective equipment was provided to and worn by employees.     Abatement documentation is required of this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.146(c)(1): The employer did not evaluate the workplace to determine if any spaces are permit-required confined spaces:     On or about December 20 and 21, 2018, the employer did not evaluate the workplace to identify permit-required confined space existence and location of those spaces including the salt to salt quench tank on line 2.          Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-08-15 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.146(c)(4): When the employer decided that its employees would enter permit spaces, the employer did not develop and implement a written permit space entry program that complied with 29 CFR 1910.146:     On or about December 20 and 21, 2018, employees entered a permit space when they performed maintenance activities on the salt to salt quench tank on line 2.  The employer did not develop and implement a written permit space entry program.  Employees were exposed to thermal burn, electrical, and struck by/caught-in hazards while in the space.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-08-15 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section:     On or about December 20 and 21, 2018, the employer did not develop, document and utilize procedures to control energy while employees performed maintenance activities on the salt to salt quench tank on line 2.       Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(5)(i): Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware was not provided by the employer for isolating, securing or blocking of machines or equipment from energy sources:    On or about December 20 and 21, 2018, the employer did not provide hardware to employees for the control of hazardous energy. Employees were exposed to thermal burn hazards and struck-by/caught-in hazards while performing maintenance activities on the line 2 salt to salt quench tank.       Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer did not conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedures and the requirements of this standard are being followed:    On or about December 20 and 21, 2018, employees were exposed to thermal burn hazards and struck-by/caught in hazards while performing maintenance activities on the line 2 salt to salt quench tank.  The employer did not conduct a periodic inspection of the energy control procedures, at least annually, to ensure that the procedures and the requirements of the standard were being followed.    Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i): The employer did not provide training to ensure that the purpose and function of the energy control program are understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees:     On or about December 20 and 21, 2018, employees were required to clean out the line 2 quench tank.  This task required employees to perform lockout/tagout to safely perform their duties.  The employer did not provide training to the employees on the energy control program and the employees did not lockout the equipment.      Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.147(d): The established procedure for the application of energy control (the lockout or tagout procedures) did not cover the actions listed in and was not done in sequence as required by 29 CFR 1910.147(d)(1)-(6):    On or about December 20 and 21, 2018, employees were exposed to machine hazards associated with rotating parts and thermal hazards when they performed salt cleaning activities on the quench tank.  The employer did not ensure that employees implemented energy control steps prior to allowing them to begin work.  The machine was shut down, but not locked out to prevent unexpected movement or energization of the equipment.        As a result, the remaining applicable energy control elements, involving machine isolation [1910.147(d)(3)], lockout/tagout device application [1910.147(d)(4)], dissipation of residual energy [1910.147(d)(5)(i)], and verification of isolation [1910.147(d)(6)] were not implemented to protect employees from machine servicing hazards.       Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $9282.00 · Current $5900.00 Reduced

General-duty citation text

29 CFR 1910.219(d)(1): Guarding. Pulleys, any parts of which are seven (7) feet or less from the floor or working platform, were not guarded in accordance with the standards of this section:    a) On or about December 27, 2018, the employer did not provide guards of v-belt drives on the agitator drive shaft on line 2 adjacent to the east storage area.  This condition presented a caught-in hazard that could result in an amputation to employees.     b) On or about December 27, 2018, the employer did not provide guards of v-belt drives on the tumbler adjacent to the aisle leading to the northeast exit.  This condition presented a caught-in hazard that could result in an amputation to employees.     Abatement documentation is required for this item in accordance with 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $6630.00 · Current $4215.00 Reduced

General-duty citation text

29 CFR 1910.303(b)(2): Installation and use. Listed or labeled equipment shall be installed and used in accordance with any instructions included in the listing or labeling:        a) On or about December 20, 2018, employees were exposed to electric shock, arc flash and burn hazards while connecting, testing and utilizing a 480 volt pump connected to a flexible cord that was connected to a Cutler-Hammer enclosed switch/disconnect.  The disconnect was used as an on/off switch for the 480 volt pump and was placed unsecured on top of a fiber drum/barrel outside the salt to salt quench tank on line 2.  The disconnect is designed to be mounted to a wall or fixed structure.     Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $6630.00 · Current $4215.00 Reduced

General-duty citation text

29 CFR 1910.303(b)(7)(iv): There shall be no damaged parts that may adversely affect safe operation or mechanical strength of the equipment, such as parts that are broken, bent, cut, or deteriorated by corrosion, chemical action, or overheating.    a) On or about December 20 and 21, 2018, employees were exposed to electrical and burn hazards while utilizing an electrical outlet that was arc burned and damaged. The outlet was located on the west wall outside of the salt-to-salt line 2.  The outlet was being used to power a work light adjacent to the salt to salt quench tank on line 2.     b) On or about December 20, 2018 through December 27, 2018, employees were exposed to electrical and burn hazards while utilizing an electrical outlet that was arc burned and damaged.  The outlet was located in the weighing area at the north end of the salt to salt line 2.  The outlet was being used to power a scale and equipment in the weighing area.      Abatement documentation is required for this time in accordance with 29 CFR 1903(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $6630.00 · Current $4215.00 Reduced

General-duty citation text

29 CFR 1910.303(f)(2): Services, feeders, and branch circuits. Each service, feeder, and branch circuit, at its disconnecting means or overcurrent device, shall be legibly marked to indicate its purpose, unless located and arranged so the purpose is evident:    On or about December 27, 2018, the circuit breakers protecting the circuits for the salt to salt line 2 were not labeled.  This condition exposed employees to electric shock and burn hazards from accidental actuation or inability to turn off the power.      Abatement documentation is required of this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $6630.00 · Current $4215.00 Reduced

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(A): Flexible cords and/or cables were used as a substitute for the fixed wiring of a structure:    On or about December 20 and 21, 2018, an extension cord was used as a substitute for fixed wiring to provide electrical power to a Husky portable work lamp in the salt to salt quench tank area on line 2.      Abatement documentation is required for this item in accordance with 1903(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(B): Flexible cords and cables were run through holes in walls, ceilings, or floors:  On or about December 27, 2018, a flexible extension cord was run through a hole in the wall to provide electrical power for the tumbler adjacent to the aisle leading to the northeast exit.  Abatement documentation is required for this item in accordance with 29 FCR 1903(d).

Issued

2019-06-18 00:00:00

Abate by

2019-09-16 00:00:00

Penalty

Initial $6630.00 · Current $4215.00 Reduced

General-duty citation text

29 CFR 1910.332(b)(1): Employees were not trained in and familiar with the safety-related work practices required by 1910.331 through 1910.335 that pertained to their respective job assignments:     Employees were required to perform live electrical work and/or voltage testing.  The employee was not trained in and familiar with safety-related work practices such as the use of special precautionary techniques, personal protective equipment (PPE) and insulating and shielding materials:    a.  On or about December 20, 2018, the maintenance supervisor performed cable connections on energized components inside an electrical supply panel for a 480V pump.    b.  On or about March 15, 2019, the maintenance supervisor performed voltage testing on a 120V control for an agitator motor in the quench cabinet.      Abatement documentation is required for this item in accordance with the requirements of 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-09-16 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.333(a): "General." Safety-related work practices were not employed to prevent electric shock or other injuries resulting from either direct or indirect electrical contacts, when work is performed near or on equipment or circuits which are or may be energized. The specific safety-related work practices were not consistent with the nature and extent of the associated electrical hazards:    Employees were required to perform live electrical work and/or voltage testing.  The employer did not ensure electrical safety-related work practices were employed such as the use of special precautionary techniques, personal protective equipment (PPE) and insulating and shielding materials:    a.  On or about December 20, 2018, the maintenance supervisor performed cable connections on energized components inside an electrical supply panel for a 480V pump.    b.  On or about March 15, 2019, the maintenance supervisor performed voltage testing on a 120V control for an agitator motor in the quench cabinet.      Abatement documentation is required for this item in accordance with the requirements of 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-09-16 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.333(c)(2): "Work on energized equipment." Only qualified persons may work on electric circuit parts or equipment that have not been deenergized under the procedures of paragraph (b) of this section. Such persons were not capable of working safely on energized circuits and was not familiar with the proper use of special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools:    Employees were required to perform live electrical work and/or voltage testing.  The employee was not qualified to safely work on energized circuits and was not familiar with safety-related work practices such as the use of special precautionary techniques, personal protective equipment (PPE) and insulating and shielding materials:    a.  On or about December 20, 2018, the maintenance supervisor performed cable connections on energized components inside an electrical supply panel for a 480V pump.    b.  On or about March 15, 2019, the maintenance supervisor performed voltage testing on a 120V control for an agitator motor in the quench cabinet.      Abatement documentation is required for this item in accordance with the requirements of 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $13260.00 · Current $13260.00

General-duty citation text

29 CFR 1910.334(a)(2)(ii): There was a defect or evidence of damage that could have exposes an employee to injury and the defective or damaged item was not removed from service and an employee was using it before repairs and tests necessary to render the equipment safe were made:  a) On or about December 20 and 21, 2018, employees were exposed to electric shock and burn hazards while using a damaged Husky portable work light that was being used to provide light while cleaning the salt to salt quench tank on line 2.  The light's electrical cord was damaged and had bare conductors exposed.  The light's on/off switch was also damaged and by-passed.  An employee holding the light experienced an electric shock and was subsequently electrocuted and another employee experienced an electric shock when handling the light during a rescue attempt and was subsequently hospitalized.    b) On or about December 20 and 21, 2018, employees were exposed to electric shock and burn hazards from a damaged flexible extension cord that was being used to power portable Husky work light.  The cord had multiple areas that were burned, cut, and/or spliced and covered with tape.  Employees were using the portable light to provide light while cleaning the salt to salt quench tank on line 2.  An employee holding the light experienced an electric shock and was subsequently electrocuted and another employee experienced an electric shock when handling the light during a rescue attempt and was subsequently hospitalized.   c) On or about December 20, 2018, employees were exposed to electric shock and burn hazards while using a 480 volt pump connected to a flexible cord that was damaged and spliced and partially covered with tape.  The pump was being used to remove molten salt from the salt to salt quench tank on line 2.   Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $13260.00 · Current $13260.00

General-duty citation text

29 CFR 1910.334(a)(4): Conductive work locations. Portable electric equipment and flexible cords used in highly conductive work locations (such a those inundated with water or other conductive liquids), or in job locations where employees are likely to contact water or conductive liquids, were not approved for those locations:  a) On or about December 20 and 21, 2018, employees working in a wet environment were exposed to electric shock and burn hazards while using a damaged Husky portable work light that was being used to provide light while cleaning the salt to salt quench tank on line 2.  The light's electrical cord and on/off switch was damaged.  The light was not approved to be used in a wet location. An employee holding the light experienced an electric shock and was subsequently electrocuted and another employee experienced an electric shock when handling the light during a rescue attempt and was subsequently hospitalized.    Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).

Issued

2019-06-18 00:00:00

Abate by

2019-07-10 00:00:00

Penalty

Initial $6630.00 · Current $4215.00 Reduced

General-duty citation text

29 CFR 1910.335(a)(1)(i):  Employees working in areas where there were potential electrical hazards were not provided with electrical protective equipment that was appropriate for the specific parts of the body that needed to be protected and for the work being performed:       Employees were required to perform live electrical work and/or voltage testing:    a.  On or about December 20, 2018, the maintenance supervisor performed cable connections on energized components inside an electrical supply panel for a 480V pump.    b.  On or about March 15, 2019, the maintenance supervisor performed voltage testing on a 120V control for an agitator motor in the quench cabinet.    The employee did not use proper personal protective equipment consistent with safety-related work practices including the following, to protect against electrical shock and arc flash/blast injuries:        1)     Rubber insulating gloves with leather protectors.     2)     Arc-rated long-sleeve shirt and pants, or arc-rated coverall     3)     Arc-rated flash suit hood, or arc-rated face shield and balaclava     4)     Hearing protection (canal inserts)       Abatement documentation is required for this item in accordance with the requirements of 1903.19(d).