OSHA Inspection: ARCONIC INC.

Issued

Nov 15, 2019

Abate by

Nov 27, 2020

Penalty

Initial $13,260 · Current $9,945 Reduced

General-duty citation text

OSH Act of 1970 Section (5)(a)(1):  The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to combustible titanium and titanium alloy components metal dust flash fire hazards when manually removing and handling dry type media air-material separator filters associated with vacuum recirculation pumps on the weld boxes in Melt Shop #1:     (a)  On or about May 21, 2019 in Melt Shop #1, employees manually removed and handled dry type media air-material separator filters containing dry, combustible titanium and titanium alloy components fines from the vacuum recirculation pump housings on weld boxes such as, but not limited to, weld box #1.  The manual handling of the dry filters exposed employees to burn hazards from recognized flash fire mechanisms associated with combustible titanium and titanium alloy components dust.     Among other methods, one feasible means of abatement that eliminates the interaction of the operator with dry metal fines during the servicing and maintenance of the system is to utilize a wet air-material separator in accordance with the guidance in Arconics Safety Data Sheet (SDS) for Titanium Alloys with Vanadium #341 - Section 7: Handling and Storage, Subsection 7.3 Requirements for Processes which Generate Dusts or Fines: Operations producing dust should be equipped with a dust collection system discharging into a water-type dust collector (note: similar language is provided in Arconic SDS for Titanium Alloys #1164) as well as in accordance with the guidance in National Fire Protection Association (NFPA) Standard 484 Standard for Combustible Metals, 2019 ed.  Section 11.2.3.6.8 of NFPA 484 (2019) states the air-material separator (AMS) selected for the system shall be designed to allow for the characteristics of the combustible dust being separated for the air gas flow.  Annex A, Explanatory Material, of NFPA 484 (2019) - Section A.11.2.3.6.8  explains that a dry-type AMS often cannot be used with combustible metal dusts.  This is due mainly to the inherent operation of such a device and the tendency of combustible metal material to accumulate inside the unit.  A wet-type AMS unit uses a liquid to capture and separate the dust from the air or gas stream.  This quenching of the dust particles (i.e. wetting) inherently reduces the risks as long as the device operates properly.  Proper selection of the AMS for a dust collection system with combustible metal dusts is critical to the safe operation of the system.

Issued

Nov 15, 2019

Penalty

Initial $13,260 · Current $9,945 Reduced

General-duty citation text

29 CFR 1910.132(a): Protective equipment was not used when necessary whenever hazards capable of causing injury and impairment were encountered:    a) On or about May 31, 2019, weld box vessel #1 in the Melt Shop #1 department was entered by an employee during cleaning operations.  The employer did not require that flame-resistant (FR) garments be worn where metal dust flash fire hazards were present.    b) On or about May 31, 2019, weld box vessel #2 in the Melt Shop #1 department was entered by an employee during cleaning operations.  The employer did not require that flame-resistant (FR) garments be worn where metal dust flash fire hazards were present.    c) On or about May 31, 2019, weld box vessel #3 in the Melt Shop #1 department was entered by an employee during cleaning operations.  The employer did not require that flame-resistant (FR) garments be worn where metal dust flash fire hazards were present.    d) On or about May 31, 2019, weld box vessel #4 in the Melt Shop #1 department was entered by an employee during cleaning operations.  The employer did not require that flame-resistant (FR) garments be worn where metal dust flash fire hazards were present.    e) On or about May 31, 2019, weld box vessel #5 in the Melt Shop #1 department was entered by an employee during cleaning operations.  The employer did not require that flame-resistant (FR) garments be worn where metal dust flash fire hazards were present.

Issued

Nov 15, 2019

Abate by

Jan 10, 2020

Penalty

Initial $5,683 · Current $0 Reduced

General-duty citation text

29 CFR 1910.134(f)(2): Employee(s) using tight-fitting facepiece respirators were not fit tested prior to initial use of the respirator, whenever a different respirator facepiece (size, style, model or make) was used, and at least annually thereafter:     On or about July 2, 2019, the employer did not ensure that an employee was fit tested prior to using a new respirator face piece size. An employee was cleaning weld box vessel #3 with the wrong size respirator. The employee was fit tested for a small respirator but was provided a medium respirator by his supervisor.

Issued

Nov 15, 2019

Abate by

Jan 10, 2020

Penalty

Initial $13,260 · Current $0 Reduced

General-duty citation text

29 CFR 1910.145(c)(3): Safety instruction sign(s) were not used where there was a need for general instructions and suggestions relative to safety measure(s):    On or about May 21, 2019, there were no warning signs in the vicinity of  weld box vessels # 1 through #6 to warn employees of the fire and explosion potential from the titanium alloys with vanadium dust. There were no signs to prohibit the use of standard lift trucks in the area, warn against smoking, and to instruct employees on personal protective equipment requirements during potentially hazardous activities.

Issued

Nov 15, 2019

Abate by

Jun 30, 2020

Penalty

Initial $13,260 · Current $7,956 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 program that complied with 29 CFR 1910.146:    On or about May 1, 2019, employees were assigned to perform cleaning activities inside of weld box vessels #s (1,2,3,4,5) located within the Melt Shop #1. Neither the employer's written permit space program nor the employer's written procedures for the dry weld box vessels included specific information related to the dry weld box vessels such as, but not limited to:      A.  The specification of acceptable entry conditions such as, but not limited to, the isolation of inerting gases, the isolation of mechanical hazards, the isolation of electrical hazards, the removal of hazardous layers of combustible metal dust residues inside the vessel through a safe method from outside of the space, safe levels of any flammable gases and safe levels of any toxic gases.      B. Opportunities for authorized entrants (or their authorized representatives) to observe monitoring and testing of the permit space.      C.  Isolation of the permit spaces from inert gas system hazards, mechanical hazards, and electrical hazards.      D.  Ventilation of the permit spaces as necessary to eliminate or control atmospheric hazards such as oxygen deficiency (i.e. via forced air ventilation) and combustible metal dust residues that could become airborne at a hazardous concentration (i.e. via pre-entry vacuum removal via approved immersion separator wet-type vacuums).

Issued

Nov 15, 2019

Abate by

Jun 30, 2020

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(d)(3)(i):  Under the permit 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, including, but not limited to - specifying acceptable entry conditions:    a) On or about May 31, 2019, weld box vessel #1 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify the acceptable conditions for employee entry into a weld box vessel permit-required confined space under the permit entry process. Employees conducting cleaning and maintenance were exposed to potential atmospheric, mechanical, and electrical hazards.    b) On or about May 31, 2019, weld box vessel #2 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify the acceptable conditions for employee entry into a weld box vessel permit-required confined space under the permit entry process. Employees conducting cleaning and maintenance were exposed to potential atmospheric, mechanical, and electrical hazards.    c) On or about May 31, 2019, weld box vessel #3 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify the acceptable conditions for employee entry into a weld box vessel permit-required confined space under the permit entry process. Employees conducting cleaning and maintenance were exposed to potential atmospheric, mechanical, and electrical hazards.    d) On or about May 31, 2019, weld box vessel #4 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify the acceptable conditions for employee entry into a weld box vessel permit-required confined space under the permit entry process. Employees conducting cleaning and maintenance were exposed to potential atmospheric, mechanical, and electrical hazards.    e) On or about May 31, 2019, weld box vessel #5 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify the acceptable conditions for employee entry into a weld box vessel permit-required confined space under the permit entry process. Employees conducting cleaning and maintenance were exposed to potential atmospheric, mechanical, and electrical hazards.

Issued

Nov 15, 2019

Abate by

Jun 30, 2020

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(d)(3)(ii):  Under the permit 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, including, but not limited to - providing each authorized entrant or that employee's authorized representative with the opportunity to observe any monitoring or testing of permit spaces:    a) On or about May 31, 2019, weld box vessel #1 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify how each authorized entrant would be given an opportunity to observe monitoring and testing of the permit space.     b) On or about May 31, 2019, weld box vessel #2 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify how each authorized entrant would be given an opportunity to observe monitoring and testing of the permit space.     c) On or about May 31, 2019, weld box vessel #3 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify how each authorized entrant would be given an opportunity to observe monitoring and testing of the permit space.     d) On or about May 31, 2019, weld box vessel #4 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify how each authorized entrant would be given an opportunity to observe monitoring and testing of the permit space.     e) On or about May 31, 2019, weld box vessel #5 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify how each authorized entrant would be given an opportunity to observe monitoring and testing of the permit space.

Issued

Nov 15, 2019

Abate by

Jun 30, 2020

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(d)(3)(iii):  Under the permit 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, including, but not limited to - isolating the permit space:    29 CFR 1910.146(d)(3)(iii):  Under the permit 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, including, but not limited to - isolating the permit space:    a) On or about May 31, 2019, weld box vessel #1 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify how the vessel would be removed from service and protected against the release of energy such as, but not limited to, mechanical hazards, electrical hazards, and inert gas.     b) On or about May 31, 2019, weld box vessel #2 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify how the vessel would be removed from service and protected against the release of energy such as, but not limited to, mechanical hazards, electrical hazards, and inert gas.     c) On or about May 31, 2019, weld box vessel #3 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify how the vessel would be removed from service and protected against the release of energy such as, but not limited to, mechanical hazards, electrical hazards, and inert gas.     d) On or about May 31, 2019, weld box vessel #4 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify how the vessel would be removed from service and protected against the release of energy such as, but not limited to, mechanical hazards, electrical hazards, and inert gas.     e) On or about May 31, 2019, weld box vessel #5 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not specify how the vessel would be removed from service and protected against the release of energy such as, but not limited to, mechanical hazards, electrical hazards, and inert gas.

Issued

Nov 15, 2019

Abate by

Jun 30, 2020

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(d)(3)(iv):  Under the permit 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, including, but not limited to  purging, inerting, flushing, or ventilating the permit space as necessary to eliminate or control atmospheric hazards.    a) On or about May 31, 2019, weld box vessel #1 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not require steps to ensure that hazardous accumulations of combustible metal residues on the interior of the vessel were removed prior to entry or otherwise prevented from generating dense cloud form during cleaning methods which utilized techniques such as, but not limited to, sweeping, compressed air, and/or chipping.    b) On or about May 31, 2019, weld box vessel #2 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not require steps to ensure that hazardous accumulations of combustible metal residues on the interior of the vessel were removed prior to entry or otherwise prevented from generating dense cloud form during cleaning methods which utilized techniques such as, but not limited to, sweeping, compressed air, and/or chipping.    c) On or about May 31, 2019, weld box vessel #3 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not require steps to ensure that hazardous accumulations of combustible metal residues on the interior of the vessel were removed prior to entry or otherwise prevented from generating dense cloud form during cleaning methods which utilized techniques such as, but not limited to, sweeping, compressed air, and/or chipping.    d) On or about May 31, 2019, weld box vessel #4 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not require steps to ensure that hazardous accumulations of combustible metal residues on the interior of the vessel were removed prior to entry or otherwise prevented from generating dense cloud form during cleaning methods which utilized techniques such as, but not limited to, sweeping, compressed air, and/or chipping.    e) On or about May 31, 2019, weld box vessel #5 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  The employer's program did not require steps to ensure that hazardous accumulations of combustible metal residues on the interior of the vessel were removed prior to entry or otherwise prevented from generating dense cloud form during cleaning methods which utilized techniques such as, but not limited to, sweeping, compressed air, and/or chipping.

Issued

Nov 15, 2019

Abate by

Jun 30, 2020

Penalty

Initial $13,260 · Current $7,956 Reduced

General-duty citation text

29 CFR 1910.146(d)(6):  The employer did not provide at least one attendant outside the permit space into which entry was authorized for the duration of entry operations:    a) On or about May 31, 2019, weld box vessel #1 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  An attendant was not provided.    b) On or about May 31, 2019, weld box vessel #2 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  An attendant was not provided.    c) On or about May 31, 2019, weld box vessel #3 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  An attendant was not provided.    d) On or about May 31, 2019, weld box vessel #4 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  An attendant was not provided.    e) On or about May 31, 2019, weld box vessel #5 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  An attendant was not provided.

Issued

Nov 15, 2019

Abate by

Jun 30, 2020

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(d)(8):  The employer did not designate the persons who were to have active roles (as for example, authorized entrants, attendants, entry supervisors, or persons who test or monitor the atmosphere in a permit space) in entry operations,  identify the duties of each such employee, and provide each such employee with the training required by 29 CFR 1910.146(g):    a) On or about May 31, 2019, weld box vessel #1 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  Active roles were not designated for permit entry to include authorized entrants, attendants, and entry supervisors.    b) On or about May 31, 2019, weld box vessel #2 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  Active roles were not designated for permit entry to include authorized entrants, attendants, and entry supervisors.    c) On or about May 31, 2019, weld box vessel #3 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  Active roles were not designated for permit entry to include authorized entrants, attendants, and entry supervisors.    d) On or about May 31, 2019, weld box vessel #4 in the Melt Shop #1was entered by an employee during cleaning operations without a full permit entry.  Active roles were not designated for permit entry to include authorized entrants, attendants, and entry supervisors.    e) On or about May 31, 2019, weld box vessel #5 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  Active roles were not designated for permit entry to include authorized entrants, attendants, and entry supervisors.

Issued

Nov 15, 2019

Abate by

Jun 30, 2020

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(e)(1):  Before entry was authorized, the employer did not document the completion of measures required by 29 CFR 1910.146(d)(3) by preparing an entry permit:    a) On or about May 31, 2019, weld box vessel #1 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  A permit-required confined space entry permit was not completed.    b) On or about May 31, 2019, weld box vessel #2 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  A permit-required confined space entry permit was not completed.    c) On or about May 31, 2019, weld box vessel #3 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  A permit-required confined space entry permit was not completed.    d) On or about May 31, 2019, weld box vessel #4 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  A permit-required confined space entry permit was not completed.    e) On or about May 31, 2019, weld box vessel #5 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  A permit-required confined space entry permit was not completed.

Issued

Nov 15, 2019

Abate by

Jun 30, 2020

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(k)(3):  Retrieval systems or methods were not used to facilitate non-entry rescue whenever an authorized entrant entered a permitted space:    a) On or about May 31, 2019, weld box vessel #1 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  Non entry-rescue retrieval systems or methods were not utilized.    b) On or about May 31, 2019, weld box vessel #2 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  Non entry-rescue retrieval systems or methods were not utilized.    c) On or about May 31, 2019, weld box vessel #3 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  Non entry-rescue retrieval systems or methods were not utilized.    d) On or about May 31, 2019, weld box vessel #4 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  Non entry-rescue retrieval systems or methods were not utilized.    e) On or about May 31, 2019, weld box vessel #5 in the Melt Shop #1 was entered by an employee during cleaning operations without a full permit entry.  Non entry-rescue retrieval systems or methods were not utilized.

Issued

Nov 15, 2019

Abate by

Jan 10, 2020

Penalty

Initial $13,260 · Current $9,945 Reduced

General-duty citation text

29 CFR 1910.179(l)(3)(i): Unsafe conditions disclosed by the inspection requirements of 29 CFR 1910.179(j) were not corrected as required and/or adjustments and repairs were not done only by designated personnel:    On or about May 26, 2019, the employer did not ensure that the 9 ton P & H crane #65 had a safety latch. An employee was using the overhead crane lifting device, when the tong fell off of the hook and onto the employee. The missing safety latch was identified on the 02/05/2019 and 12/21/2017 inspection reports.

Issued

Nov 15, 2019

Abate by

Jan 10, 2020

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.184(c)(6): Slings were not securely attached to their loads:    On or about May 26, 2019, the employer did not ensure that the tong load was secured to the 9 ton P & H crane #65. An employee was using the overhead crane lifting device, when the tong fell off of the hook and onto the employee. The load was unable to be secured do to the missing safety latch which was identified on the 02/05/2019 and 12/21/2017 inspection reports.

Issued

Nov 15, 2019

Abate by

Jan 10, 2020

Penalty

Initial $13,260 · Current $7,956 Reduced

General-duty citation text

29 CFR 1910.1200(h)(1): Employers shall provide employees with effective information and training on hazardous chemicals in their work area at the time of their initial assignment, and whenever a new chemical hazard the employees have not previously been trained about is introduced into their work area. Information and training may be designed to cover categories of hazards (e.g., flammability, carcinogenicity) or specific chemicals. Chemical-specific information must always be available through labels and safety data sheets.      On or about May 31, 2019, the employer did not provide effective training or information to employees working with combustible dust hazard characteristics.