The National Institute for Occupational Safety and Health (NIOSH), in conjunction with the Mine Safety and Health Administration (MSHA), has opened an investigation on the performance of the oxygen starter assembly on CSE Corporation’s SR 100 self-contained self-rescuer (SCSR). There is a problem with the functioning of some oxygen starter assemblies in the CSE SR 100 which is designed to furnish breathing air to miners in the case of a mine emergency.
CSE has performed a failure analysis on the oxygen starter used in the SR 100 and believes the problem is related to manufacturing tolerances in the pipe thread and the application of the sealant used in assembling the oxygen starter. As a result, some oxygen starter assemblies could leak. CSE has entered into a voluntary stop sale of the SR 100. Therefore, replacement devices for the SR 100 are not currently available from CSE.
CSE estimates the problem occurs in less than 1% of new units. NIOSH and MSHA have not verified that estimate. However, if the failure rate is less than 1%, the availability of a second SCSR to the miner will provide an acceptable level of safety in the event of an oxygen starter failure pending a resolution of the problem. Extra SCSRs have been required in underground coal mines since the passage of the 2006 MINER Act. This advice also applies if there is a failure of the oxygen starter.
The failure rate of the oxygen starter is not well-characterized in the field-deployed units. NIOSH and MSHA feel it is necessary to accurately determine this failure rate within the population of field-deployed units. At the completion of this analysis, NIOSH and MSHA will evaluate the data from the field audit and offer additional guidance based on the results of the testing.
NIOSH has developed a Sampling Plan for the CSE SR 100s to verify the failure rate of the SR 100 oxygen starter in field-deployed units. The plan employs standard quality control statistics to assure that a large enough sample is used to accurately determine how often an oxygen starter assembly might be expected to fail. On October 4, 2010, NOISH, in cooperation with MSHA, began collecting a representative sample of SR 100 units from the population deployed in underground coal mines. Depending on the test results, this sample could be as large as 500 units. Collection is expected to be complete by mid-December, 2010. Testing of these units for performance of the oxygen starter is expected to start as early as October 2010, and the testing is expected to be complete by December 29, 2010.
At the conclusion of this evaluation, the results will be made public.
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Gun Powder Manufacturer Fined $1.2 Million after Deadly Explosion
The explosion took the lives of two workers who had been on the job for only a month.
“The fines levied here pale in comparison to the value of the two lives lost,” said Secretary of Labor Hilda L. Solis. “Nonetheless, this was a tragedy that easily could have been prevented had the employer valued the health and safety of its employees. Employers should not sacrifice their workers’ lives for a profit, and no one should be injured or killed for a paycheck.”
On May 14, two workers and a plant supervisor were manufacturing a gun powder substitute known as Black Mag powder when the explosion occurred. The workers had been required to hand feed powder into operating equipment due to the employer’s failure to implement essential protective controls. The employer also chose not to implement remote starting procedures, isolate operating stations, establish safe distancing and erect barriers or shielding—all of which are necessary for the safe manufacture of explosive powder. Additionally, the employer chose not to provide the personal protective equipment and other safety measures its employees needed to work safely with such hazardous material. OSHA cited the company with four egregious willful, 12 willful, 36 serious, and two other-than-serious violations with total penalties of $1,232,500.
“Even after a prior incident in which a worker was seriously injured, and multiple warnings from its business partners and a former employee, this employer still decided against implementing safety measures,” said Assistant Secretary of Labor for OSHA Dr. David Michaels. “Unfortunately, we see this kind of disregard time and time again across industries. All employers must find and fix workplace hazards so these types of avoidable tragedies don’t happen, and workers can return home safely at the end of the day.”
The four egregious willful citations were issued for the failure to train each of the four workers involved in the manufacture of the gun powder substitute. In addition to the two workers killed and their supervisor, there was an additional employee who left the job nine days before the explosion. Willful citations are considered egregious when more than one worker is exposed to a single hazard. The citation issued for that hazard is then multiplied by the number of workers exposed.
Other willful citations were issued for the failure to locate operators at safe locations while equipment was operating; separate workstations by distance or barriers and ensure that each worker was properly trained; provide adequate personal protective equipment, such as fire resistant clothing, face shields, and gloves; safely store gun powder; and identify explosion hazards in the company’s operating procedures. A willful violation is one committed with intentional knowing or voluntary disregard for the law’s requirements, or with plain indifference to worker safety and health.
Some of the 36 serious citations were issued for the failure to separate small arms ammunition from flammable liquids, solids, and oxidizing materials by a fire-resistive wall or by a distance of 25 feet; establish and implement an emergency action plan and provide written procedures to manage changes; provide personal protective equipment including clothing, respiratory devices, protective shields and barriers for workers exposed to lead; train workers on appropriate protective equipment; train workers in electrical safety-related work; address hazards associated with exit routes; and address hazards associated with handling, storing, and transporting explosives. A serious citation is issued when there is substantial probability that death or serious physical harm could result from a hazard about which the employer knew or should have known.
The two other-than-serious violations are for a failure to perform respirator fit tests and to ensure that facial hair does not interfere with a respirator seal. An other-than-serious violation is one that has a direct relationship to job safety and health, but probably would not cause death or serious physical harm.
OSHA Aims to Improve Worker Training Program
OSHA revised the length of daily classroom instruction to prevent workers from being saturated with so much information that they may miss content that could prevent injuries, illnesses, and death.
Revised program policy now requires OSHA trainers to limit worker training classes to a maximum of 7½ hours per day. Before OSHA made this change, there were no limitations on how long these classes could last each day. With 10 hours of training, along with necessary breaks and lunch, students could sit in classes for up to 13 hours a day. OSHA became concerned that long, mentally-fatiguing class days might cause students to miss essential safety and health training.
Another concern was that, in some cases, one- and three-day training classes were not meeting 10- and 30-hour program time requirements. This concern became evident after OSHA conducted random records audits and unannounced monitoring visits.
To address these issues, the agency now requires OSHA outreach trainers to conduct 10-hour courses over a minimum of two days and 30-hour courses over at least four days.
“Limiting daily class hours will help ensure that workers receive and retain quality safety training,” said Assistant Secretary of Labor for OSHA David Michaels.
This policy change is effective immediately and will be reflected in the next revision of the Outreach Training Program Guidelines. OSHA will not recognize training classes that exceed 7½ hours per day or do not meet all program content requirements. In such cases trainers will not receive completion cards to distribute to students. Trainers may, however, submit written requests for exceptions to limiting training days to 7½ hours based on extenuating circumstances.
New Report Available: Crystalline Silica and Isocyanate Exposures during Parking Garage Repair
The HHE Program investigators found that employees were overexposed to crystalline silica while jackhammering and sandblasting and therefore recommended that the use of respirators and eye protection be required during these tasks. NIOSH recommended that managers explore possible engineering controls to reduce dust levels while jackhammering and sandblasting. Investigators also determined that employees may be exposed to MDI through skin contact and should wear butyl rubber gloves when mixing compounds to minimize exposures.
International Code Council Adopts Emergency Amendment on Fuel Gas Purging
The ICC Board’s action was result of the ANSI Z223.1 committee amendment to the 2009 National Fuel Gas Code—which is the basis for provisions in the IFGC and IRC. These amendments also follow U.S. Chemical Safety Board (CSB) recommendations in June 2009 fatal Natural Gas Explosion at ConAgra Slim Jim Plant in North Carolina.
That tragic and preventable accident took four lives, injured 67 others, and led to a decision to close the plant with the loss of hundreds of jobs in the region. The accident occurred during an operation to purge, or clear, air from a new steel gas-supply pipe that was connected to a newly installed industrial water heater. Due to difficulties in lighting the water heater, the purging operation was continued for an unusually long time, eventually causing gas inside the building to accumulate to a concentration above its lower explosive limit. The gas exploded after contacting an ignition source, causing extensive sections of the large facility to collapse. The explosion also damaged piping from the plant’s ammonia-based refrigeration system, causing approximately 18,000 pounds of anhydrous ammonia to be released to the environment.
Under the new code requirements, fuel gas piping systems in industrial, large commercial and large multifamily buildings may not be purged indoors. The provisions, had they been in effect at the time, would have required the gas pipe at ConAgra to be purged outdoors, away from personnel and ignition sources. They also require that purging activities be monitored using appropriate combustible gas detectors to prevent significant releases of flammable fuel gases.
ICC’s Emergency Amendment comes just two months after the National Fire Protection Association announced identical changes to the National Fuel Gas Code.
Acument Global Technologies Receives Indiana Safety Award
The Indiana Department of Labor announced the certification of Rochester, Indiana’s Acument® Global Technologies in the Indiana Safety and Health Achievement Recognition Program (INSHARP). The company provides mechanical fastening products and services used primarily in the automotive industry and employs over 100 workers.
Among other criteria, companies that seek INSHARP certification are required to maintain occupational injury and illness rates below the national average for their respective industries. Acument? Global Technologies’ worker injury and illness rates are more than 75% below the average for their respective industry.
Acument’s Rochester facility credits its low number of work-related injuries and illnesses to its all-inclusive approach to worker safety and health. This comprehensive approach includes management commitment to, and employee involvement in, occupational safety and health programs and activities. Company management allocates the necessary resources, and employees actively participate in a variety of worker safety and health-oriented teams, such as environmental, safety and health, machine guarding, and ergonomics. Acument?
Lockout–Tagout Violations Lead to $140,700 Fine
OSHA has cited C & F Packing Co. Inc., of Lake Villa, Illinois, with two alleged willful and 12 serious violations for failing to ensure lockout procedures and guarding devices were applied to machinery. The company manufactures sausages, meats, and frozen meat toppings. Proposed fines total $140,700.
“C & F Packing has demonstrated a disregard for worker safety by placing workers at risk for serious injury from machine rotating parts,” said OSHA Area Director Diane M. Turek in Des Plaines, Illinois. “That is not acceptable, and we are committed to seeing that the workers at this facility are provided a safe and healthy workplace.”
OSHA initiated its inspection in April. As a result, the company was cited for two willful citations with proposed fines of $112,000 for failing to ensure lockout devices were applied to machinery when workers were performing tasks where lockout was required and for failing to ensure rotating parts on machinery were properly guarded.
The serious violations with proposed penalties of $28,700 were cited for failing to provide standard railings on open-sided platforms, require protective eye and face wear for employees working with corrosive chemicals, conduct required periodic inspections of energy control procedures, provide training on lockout/tagout procedures, and ensure guards were affixed to machinery to cover dangerous areas.
New Tool Helps Food Companies Determine Readiness for Global Good Safety Certification
NSF International, a leading provider of global food safety certifications, has launched a first-of-its-kind online tool to help food companies assess their readiness for certification to Global Food Safety Initiative (GFSI)*-benchmarked standards. Certification to global food safety standards provides organizations independent certification that a product, process, or service complies with international, regulatory, and retailer requirements.
Many of the leading global retail and foodservice companies now require suppliers to comply with international food safety standards through independent, third-party inspection. GFSI-benchmarked food safety standards include Safe Quality Food (SQF), British Retail Consortium (BRC), GlobalGAP, Food Safety System Certification (FSSC), and International Food Standard (IFS), among others.
NSF International offers a free, 21-question online assessment tool to help companies evaluate their facilities’ readiness for compliance. The 10-minute assessment tool covers the core elements of globally-recognized food safety standards. Participants receive a customized report upon completion. The report determines their readiness for certification on a scale of 100 and identifies specific areas that need to be addressed to successfully achieve certification.
NSF International also provides useful tips and information about the global standards throughout the survey to help companies properly answer each question.
“This new tool provides a snapshot of a company’s current food safety system and identifies where resources need to be allocated to bring its facilities into compliance with globally-recognized food safety standards,” said Robert Prevendar, Director of Global Food Safety Certification for NSF International.
Bharat Forge America, Inc. Fined $137,750 for Serious Safety Hazards
Michigan Department of Energy, Labor & Economic Growth (DELEG) Acting Director Andrew S. Levin announced the conclusion of a Michigan Occupational Safety and Health Administration (MIOSHA) inspection at Bharat Forge America, Inc., of Lansing, Michigan. MIOSHA identified 42 alleged violations for failing to adequately protect employees from serious safety and health hazards, with proposed penalties totaling $137,750.
“Conditions found during the MIOSHA inspection were very serious. They must fulfill their obligations under the MIOSH Act and provide a safe and healthy work environment for their employees,” said Levin. “It is imperative that Bharat Forge America correct the serious hazards which are endangering their employees.”
Bharat Forge America is a member of Bharat Forge Limited, India, a full service supplier of forged engine and chassis components and non-automotive components and systems. With manufacturing locations in India, the United States, Scotland, Germany, Sweden, and China, Bharat Forge Limited is the flagship company of the $ 2.4 billion Kalyani Group.
Bharat Forge Limited purchased the Lansing facility in June 25, 2005, from Federal Forge, as that company was exiting from bankruptcy. Federal Forge manufactured a variety of forged automotive components such as control arms, links, steering knuckles, connecting rods, etc. This facility was renamed Bharat Forge America, Inc. The facility is operated by many of the same management and employee personnel who worked under Federal Forge.
The current manufacturing processes and equipment did not change when Bharat Forge America, Inc., assumed ownership from Federal Forge. Between 1990 and 2002, MIOSHA conducted 10 inspections at Federal Forge. Management is well aware of the MIOSHA standards regulating their industry.
MIOSHA planned/scheduled inspections target establishments in industries with high injury/illness rates. The intent of the scheduled inspections is to identify hazardous conditions, so that the hazards can be corrected before injuries and illnesses occur.
As a result of the programmed comprehensive inspection MIOSHA identified 42 alleged violations of MIOSHA regulations. The citations consist of 19 serious, four willful, and 19 other-than-serious violations, with a total penalty of $137,750.
The four willful violations were all related to the permit required confined space standard, which protects workers when they are required to enter spaces that hinder their activity and present serious hazards. These violations include:
- An inadequate written program that does not explain how to and when to use ventilation, and relies on local fire department for rescue and there is no contract with any local fire department.
- Confined space gas monitor does not work.
- Inadequate training on entry procedures, gas monitoring, ventilation techniques, attendant duties, and rescue.
- Inadequate rescue procedures that rely on 911 and local fire department, and there was no contract with any fire department.
The inspection also identified 19 serious hazards throughout the facility. Some of these serious violations include:
- No guards or inadequate guards on a wide range of equipment and operations.
- Allowed employees to climb a fixed ladder to perform maintenance without fall protection.
- Allowed employees to stand and perform work duties approximately 12 feet above floor level on forging presses.
- Not locking out while performing die changing operations for forge presses, and a range of other operations.
- No air monitoring or forced air ventilation when welding in a confined space and no rescue provisions.
- Exposed live parts and other electrical hazards.
“Taking the time to follow MIOSHA regulations can not only protect workers—it can greatly enhance a company’s bottom line,” said MIOSHA Director Doug Kalinowski. “Successful Michigan companies have shown that a strong safety and health program contributes to increased production, improved quality and greater profits.”
The MIOSHA Consultation Education and Training (CET) Division has nearly 40 safety and health consultants who can help provide abatement advice to companies, as well as furnish information on building an effective safety and health management system.
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