Document 2jKOeXmZN7n9NrQY1kmjYNz06

TO: Plant Engineers, All Plants Plant Engineers ansgers Manufacturing Managers LETTER NO. 28 April 11 # 1973 PLAINTIFF'S EXIUBrr SECTION A: GENERAL INSTRUCTIONS AND INFORMATION No Subjects Included SECTION B: MAINTENANCE INFORMATION Asbestos Pipe Covering and Insulation Standard Handling Procedures Industrial Truck Maintenance Control System Fire Loss Analysis 1972 SECTION C: ENGINEERING AND CONSTRUCTION No Subjects Included M-201 M-202 Complete R. F. Birdsall, Manager Maintenance Department Plant Engineering Office 800* 0596 SCF-FORD-1033 PLANT ENGINEERING LETTER NO. 28 April 11, 1973 ASBESTOS PIPE COVERING AND INSULATION STANDARD HANDLING PROCEDURES The Federal Department of Labor under the authority of the Occupational Safety and Health Act of 1970 (OSHA) has promulgated specific standards for the use of asbestos. Pipe covering and insulation materials may contain asbestos, particularly in older installations. Plants considering new pipe covering and insulation projects should investigate other non-asbestos materials such as calcium silicate and fiberglass. The attached letter recommends procedures to be followed in plants using asbestos pipe covering and insulation to avoid potential health hazard to employes and to be in compliance with OSHA regulations. Attachment M-201 8004 0S97 t f;< PLANT ENGINEERING LETTER NO. 28 April 11, 1973 INDUSTRIAL TRUCK MAINTENANCE CONTROL SYSTEM * The Corporate Industrial Truck Maintenance Control System, required by Manufacturing Procedure III c 8, provides for the collection of vehicle related data and the preparation of reports to assist plants, divisions and staffs in the reduction of operating costs, efficient operation, and proper decision making. The system is a series of standard computer programs that are processed by individual plants or divisions. Pertinent truck data such as purchase price and date, description, manufacturer, and brass tag number are captured at the time of purchase. Subsequently, the following data are collected: Repair Costs Labor and material associated with each repair. Operating Hours - Total number of operating hours submitted weekly. Preventive Maintenance Data Type of inspection and operating hours. These data are used to prepare a series of weekly and monthly reports entitled: 1. Repair Cost by Vehicle. 2. Purchase to Date Repair Cost by Vehicle. 3. Year to Date Detail Repair Log. 4. Weekly Inspection Schedule. 5. Weekly Inspection Schedule Summary. The primary purpose of the Industrial Truck Maintenance Control System is for use as a plant tool in industrial truck operations. The data collected will ultimately be used in Corporate and Division decision making for such alternatives as: o Lease or buy equipment. o Manufacturer preference. o Component longevity and maintainability. o OSHA compliance substantiation. Information on programs and documentation can be had by contacting the Systems Planning and Development Office, World Headquarters. Any other information about the system can be had by contacting the Plant Engineering Office, Maintenance Department, World Headquarters. M-202 8004 0600 FIRE IOSS ANALYSIS - 1972 Introduction The Fire Loss Analysis for the year 1972, is based upon data submitted by Ford Motor Company Overseas and United States locations on Form 3193, "Report of Fire Protection Incidents and Property Damage". The fire incidents for the United States locations include only those where actual property loss amounts were submitted during the calendar year of 1972. Some of the actual losses occurred prior to 1972* but were not determined or sub mitted until 1972. The analysis of fires for Overseas locations does not include loss amounts as only a negligible number of incidents included such information. ANALYSIS OF FIRES United States Fires The following is a tabulation of the number of fires which occurred In the United property loss attributed to the fires for the last five years Year No. of Fires Actual Reported Cost 1968 1969 1970 1971 1972 464 608 519 403 385 $ 428,800.00 1,379,200.00 1,590,000.00 1,307,900.00 1,156,800.00 There were 26 fires for which actual costs were reported during 1972, with losses above $5,000.00. This number was 6.6# of the total number reported, but caused losses totalling $1,079,600.00 or 93.3# of the total property loss. During the year 1971, 37 fires resulted in losses over $5,000.00. This number was 9.2/, of the number of fires, caused a loss of $1,307,900.00 or 91# of the total property loss for 1971* Compilation of 1972 United States Fire losses >. of Lres Loss Range in Dollars Fire Loss # Fires # Loss 327 0-500 14 501-1,000 18 1,001-5,000 9 5,001-10,000 J1 10,001 & Over 385 $ 16,970.00 10,627.00 49,285.00 73,391.00 1.006,444.00 $1,156,800.00 84.9 3.6 4.7 2.4 4.4 100.0 1.5 0.9 4.3 6.3 87.0 100.0 (R-145) 8004 0601 -2- SOURCES OF IGNITION Electrical Failures caused 162 fires (45 in the United States and 117 In Overseas Locations) or 17*3% of all fires reported during 1972. The monetary loss in the United States from this cause was $37,000.00. During the year 1971, there were 287 fires (63 in the United States and 204 in Overseas Locations) or 25.056 of all 1971 fires with a loss of $188,800.00. The reduction in number of fires and amount of loss caused by electrical failures is encouraging. Smoking and Matches again vere a leading cause of fires throughout the Company. There were 116 incidents attributable to careless smoking (27 in the United States and 89 in Overseas Locations) or 12.456 of all reported fires. The monetary loss attributed to careless smoking vas $11,295*00. The number of fires caused by careless smoking in 1971 was 151, but the loss vas only $1,750.00. Nonproduction Cutting and Welding caused 92 fires (51 in the United States and 4l in Overseas Locations) or 9b of all 1972 fires. The loss from these fires vas $59j400.00 - about four times the loss reported in 1971 caused by 104 incidents. Nonproduction cutting and velding fires are preventable. Strict adherence to Company Fire Control Practices as outlined in the Industrial Relations Admini stration Manual, Volume III, Section Q, Topic 550 for the United States and 55OO for Overseas Locations, is mandatory. COMBUSTIBLES INVOICED Rubbish, Dust and T.irvfc still continue to lead all other classifications of mater ials that burned. There vere 355 fires (157 in the United States and 198 in Overseas Locations) or 30$ of the total fires reported during 1972. Again, there vas a significant reduction in the number of fires reported during 1972, as cospared to 1971, from 401 to 355 fires, enhancing good housekeeping efforts and maintaining clean facilities will further reduce the number of fires Involving rubbish, dust, etc. Flanmable liquids, always a worrisome combustible, were involved in 242 fires (10b in the United States and 134 in Overseas Locations) or 25.9$ of all reported fires. The number of fires involving flammable liquids during 1972, increased about 10$ over those reported during 1971* It is mandatory that established good practices regarding storage, handling and use of flammable liquids be established and maintained. Fire Control Bulletin No. 18, Flammable Liquids, and National Fire Protection Association Pamphlet No. 30, Flammable and Combustible liquids, (N.F.P.A. No. 30 is also contained in National Fire Codes, Volume 1, published by N.F.P.A.) should be referred to regarding fire-safe practices concerning flammable liquids. 8004 0602 -3 Electrical Insulation fires reported during 1972 totalled 166 (45 in the United States and 121 in Overseas locations) or 17.9$ of all reported fires* During 1971, a total of 256 (70 In the United States and 186 in Overseas locations) were reported. An encouraging reduction in the number of Tires involving elec trical equipment is evident. HOW ALARMS WERE TURNED IN Automatic fire detection equipment. Including automatic sprinkler vaterflov alarms and other fixed fire protection systems, were the means of transmitting alarms in 4l$ of the fires occurring in the United States and 17.3$ of the Overseas fires. The following tabulation indicates how all fire alarms were turned in and who turned them in. In reporting a single fire, more than one means was used in many instances, l.e., automatic fire detection and by Company employes. United States Overseas Company Total Automatic Detection Fire Alarm Box Telephone In Person Security Employe Other Qnploye Water Flow Alarm Carbon Dioxide Alarm _i_ 59 15.3 105 27.3 245 63.6 10 2.6 28 7.3 52 13.5 43 11.2 45 U.7 2i _. 18 3.3 45 6.2 4l4 75.3 55 1.0 70 12.7 102 18.5 26 4.7 15 2.7 77 6.2 150 16.0 659 70.5 65 6.9 98 10.5 154 16.5 69 7.4 60 6.4 HOW FIRES WERE FOUGHT Automatic Sprinkler Protection systems operated during 69 fire incidents (43 in the United States and 26 in Overseas Locations) or 7.3$ of the total fires reported. The sprinkler protection was completely effective in 9^$ of the fires. In 6$ of the fires where sprinkler protection actuated, extinguishment was completed by supplementing sprinkler discharge with application of fire extinguishers and fire hose streams. Fixed Carbon Dioxide fire extinguishing systems were actuated in 52 fires (13 in the United States and 39 in Overseas Locations) or 5 6$ of the total fires reported. The fixed carbon dioxide fire protection systems were effective in 87$ of the fires. Extinguishment was completed in the remaining 13$ of the fires by using fire ex tinguishers and fire hose streams. lAmjclpal Fire Department and Fire Brigades were called on for assistance during 13$ of the fires that occurred in the United States and in 41$ of the Overseas fire incidents. A greater percentage of fire incidents may not have required assistance from municipal fire departments or fire brigades, as 80$ of the United States fires were under $1,000.00 with an average loss of but $93*00. 8004 0603 -4- Notwithstanding the success of our Cong)any personnel in prompt extinguishment of fires and thus limiting monetary loss. It Is only prudent to request the services of professional fire fighters during a fire. All alarms of fire must he promptly transmitted to the municipal fire department or fire brigade to prevent delays in response and the small fire from becoming a catastrophic loss. Portable Fire Extinguishers of various types were used by Conpany enployes during almost all fire Incidents throughout the Company. Small and large diameter fire hose were laid and used at 15# of the United States fires, but only 3# of the fires occurring at Overseas locations. SIGNIFICANT FIRES Fiberglas Reinforced Exhaust System Fire Because of the corrosive atmosphere, a fume exhaust system consisting of fiberglas reinforced plastic was provided over a conveyor system. The conveyor, of steel slat design, carried heavy loads and the conveyor required much maintenance because of friction. A new lubrication system was being Installed to eliminate the lack of an effective means of lubrication. As an Interim measure, a temporary oil mist lubricating system was Installed. The exhaust ventilation system caused air-borne particles of the oil mist to form an oil residue on the Interior surface of the fiberglas reinforced plastic fume exhaust system. ' An electric short caused a fire to start Inside the exhaust system. The municipal fire department was promptly called. Plant employes attacked the fire with hand extinguishers without success. Large diameter fire hose was used by the fire department. A total of 93 building sprinklers operated. Though recompended, auto matic fire protection was not Installed inside the plastic exhaust system. The fume exhaust system. Including scrubber facilities, located on the roof were destroyed. Finished goods and goods in process were destroyed. This fire caused $508,000.00 in damage. The loss could have been greatly reduced by: 1. Use of stainless steel for fume exhaust systems instead of com bustible plastic ducting. 2. Provision of fixed automatic fire protection for Interior of exhaust system where oil condensates occur. pinmnmbic Liquids and Static Electricity An employe, while adding solvent (toluene) to Ink for the purpose of increasing its viscosity, received second degree burns to his legs and arms, about 15# of his body. The solvent was added via a hose line from the tank farm system. The employe had not bonded the hose to the ink container. A static spark occurred flashing the solvent. ' 8004 0604 -5- The eng>loye dropped the hose line and ran outside of the building with his clothing on fire. A fellow enploye rolled the employe who was on fire In snow (there was 2-in. of snow on the ground). While both the plant volunteer fire brigade and the municipal fire department responded promptly, their services were not necessary. The fire was extinguished by the planned protection consisting of fixed total flooding automatic carbon dioxide fire protection. Additionally, elgrt automatic sprinklers operated. To prevent reoccurrence, the following improvements were immediately made: 1. Spring loaded self-closing valves were provided. 2. Conductive and grounded hose was provided. A faulty ground clamp to a flasmable liquids supply line (tetrahydrofuran - 4F. flashpoint) caused a static spark at the nozzle and a flash fire occurred* The solvent was being used to flush a plastic coating supply line. The fire Involved the organic coating font and fabric to be coated. The fixed pipe carbon dioxide fire protection extinguished the fire. Five high temperature sprinkler heads also fused. While the plant fire brigade and mini cipal fire department was in atten dance, their services were not needed. To prevent reoccurrence, the faulty ground connection (a "c" clamp) to the struc tural steel was made secure by using a nut and bolt through a hole in the struc tural steel. Nonproduction Cutting and Welding caused a fire with damage amounting to $41,000. An employe was using oxy-acetylene equipment to remove metal brackets. Sparks from the operation ignited sea coal and core sand saturated with a mixture of fatty acid and kerosene. A cutting and welding permit was not issued. There was damage to electrical panels, approximately 10,000-ft. of electric wiring, conduit, air hoses, hydraulic hoses, air regulators and lubricators. Permits should be issued for all nonproduction cutting and welding. Prior to issuing permits, the area should be thoroughly inspected and all combustible or flMimable material removed or protected. Company policy regarding nonproduction cutting and welding is outlined in the Industrial Relations Administration Manual, Volume III, Section Q, Topic 550, for United States locations and Topic 5500 for Overseas locations. Propane Fueled Fork Lift Truck A malfunction in the propane vaporizer of a fork lift truck caused propane gas to fill the engine compartment. When the engine was started, a back fire occurred, igniting the gas and enveloping the compartment in flames. Fire spread to the surrounding area. 8004 0605 - 6- Three automatic sprinklers operated. Fire extinguishers and both small and large diameter fire hose were used to extinguish the fire In 15-minutes. Damage to the fork lift truck required replacement of electrical harness, battery, voltage regulator, propane vaporizer, carburetor, hoses, seat cushion and alter nator. Damage to the building consisted of 200-ft. of pipe insulation, electrical wiring, fluorescent fixtures, heating ducts, Toledo Scale and a fire hose stand pipe. Proper maintenance of propane fueled vehicles requires regular inspection of pro pane hoses, hose connections and vaporizers. All defects must be corrected before the vehicle Is placed In service. Partly Closed Gas Valve When a coke oven was not heating properly, the main gas control valve was shut off so that the oven valve could be serviced and cleaned. The valve was not completely closed, and when a plug was removed below the valve, escaping gas was Ignited by heat from the coke oven. Two employes were burned - the first employe received 1st and 2nd degree burns to his face, ears and both thighs from hips to knees and the second employe received 1st and 2nd degree bums to his face, ears, hands and wrists. To prevent accidents of this type, care should always be taken to assure that gas valves that must be closed are actually closed. Safe practice procedures should be reviewed periodically. Friction Heat Excessive sparks and friction heat Ignited a mineral seal coolant (flashpoint 250F) on a grinder. The loss was $46,000.00. The fire was extinguished in 15-minutes by the plant's employes using a length of 1^-lnch fire hose. Three sprinkler heads also operated. The nunlclpal fire department was called, but their services were not needed. To prevent reoccurrence, management has substituted a water soluble coolant and cutting oil In lieu of the mineral seal oil. 8004 0606 UNITED STATES FIRE LOSSES -1972 Chassis Division Ford Parts Division Ford Tractor Operations General Parts Division Industrial and Chemical products Transmission Division Glass Division Company Total Source of Ignition 1!! II 3s Nonprod. Cut. and Weld. 1. B 3 B Smoking and Matches Electrical Failure 2. 7 3. 2 3 1 IB Prod. Cut. end Weld. 4. 3 Friction Heat Open Flames 5. 4 6. 33 2 Hot Surfaces Hot Mat. in Process 7. 2 3 e. 15 4 Sparks and Embers 9. 1 2B Not Elsewhere Classified 10. 17 5 2 Total Number of Fires 41 32 61 Combustibles Involved 1 Rubbish, Dust, Lint, Etc. 1. 15 7 23 Flammable Liquids 2. 6 7 17 Flammable Gases 3. 1 1 Electric Insulation Packing Materials 4. 2 7 9 5. 9 1 Structures 6. 1 Cloth, Rope, Terpe. Etc. 7. 3 1 Rubber Tires and Foam 8. 9 Upholstery Materia Is 9. 3 Acoustical Materials Flammable Metals 10. 1 11. New Units 12. 1 Total Number of Fires Costs 41 32 51 SO - 8500 $501 - $1,000 1. 29 25 47 2. 3 2 81,001 - 85.000 3. 4 4 1 85.001 - 810.000 4. 2 810.001 - Up 5. 3 3 1 >1 | fl iSQ u.0 6 1 1 11 1 2 21 1 71 10 4 21 1 18 1 3 Total Coats (000) B6.6 128.3 13.9 74 II Ii I if 2 o 75 * 71 13 1 2 1 61 13. 31 5 2 5 1 27 7. 11 7 5 10 46 11. 13 1 1 IB 4. 9 2 4 30 66 14. 12 114 11 2. 31 12 24 1 23 3 1 24 6. 1 64 14. 6 3 1 11 1 34 . B 13 2 12 10 3 66 17 1 46 6 2 69 62 70 4 386 100 18 1 31 23 2B 167 40 13 1 2 10 8 36 1 108 28 11 61 10 2 21 8 6 B 5 1 45 11 6 1 24 6 33 17 1 10 2 21 13 3 3 12 2 3c 1 2c 1( 1 46 6 2 69 62 70 4 386 10f 40 1 3 11 10.9 618.8 5 53 40 66 1 322 21 24 21 4 1 0.8 404 26.0 263.3 66.4 3 327 8- 14 18 19 17 386 64 10 11564 - 8004 0607 OVERSEAS FIRE LOSSES - 1972 O ffic e Stamping Plants Tractor Plants Total % of Total Source of Ignition li tm z c <is< ? ui Nonprod. Cut. and Weld. 1. 16 4 Smoking and Matches 2. 47 19 Electrical Failure Prod. Cut. and Wald. Friction Heat Open Flames Hot Sirfaces 3. 67 4. 35 5. 6 6. 7 7. 29 21 9 1 11 Hot Mat. in Process Sparks and Embers 8. 2 9. 17 3 15 Not Elsewhere Classified 10. 21 Total Number of Fires 236 Combustibles Involved 8 91 Rubbish. Dust. Lint, Etc. 1. B7 40 Flammable Liquids Flammable Gases 2. 64 3. 11 25 2 Electric Insulation 4. 64 18 Packing Materials 6. 5 2 Structures 6. 3 1 Cloth, Rope, Tarps, Etc. 7. Rubber Tires and Foam 8. Upholstery Materials 9. 92 a Acoustical Materials 10. Flammable Metals New Units 11. 12. 3 1 Total Number of Fires 236 91 & U5. 1 U. 9 6 4 1 11 9 16 11 6 73 22 21 6 7 2 4 10 1 1 73 h I t 8 8f SJ a.< tStlt?f 1 i2 3 i6 | ].cS tS-Ai. c* ft 21 43 ia* o 5 41 7.6 1 89 16.2 1 4 12 7 1 10 117 21.3 11 1 47 6.5 19 2 27 4.9 1 2 3 1 3 29 5.3 2 3 61 1 3 65 11.8 21 1 25 4.5 1 4 6 1 1 1 4 60 10.9 1 1 46 3 1 50 9.1 46 16 68 13 23 3 28 550 100.0 1 6 18 10 8 1 6 198 36.0 2 6 16 1 4 4 134 24.4 31 1 2 26 4.6 1 3 10 7 1 10 121 22.0 3 61 2 1 22 4.0 11 3 13 2.4 1 11 1 1 1 1 26 2 1 4.7 0.4 0.2 1 3 0.5 1 1 6 0.9 6 4 15 68 13 23 3 28 550 100.0 8004 0608 COMPILATION OP UNITED STATES AND OVERSEAS FIRE LOSSES BY SOURCE OF IGNITION AND COMBUSTIBLES INVOLVED - 1972 Source of Ignition Nonprod. Cut. and Weld. 1. Smoking and Matches Electrical Failure 2. 3. Prod. Cut. and Weld. 4. Friction Heat S. Open F lames Hot Surfaces 6. 7. Hot Mat. in Process 8. Sparks and Embers 9. Not Elsewhere Classified 10. Total Number of Fires Combustibles Involved Rubbish. Dust, Unt. Etc. 1. Flammable Liquids 2. Flammable Gases 3. Electric Insulation Packing Materials Structures 4. 6. ' 6. Cloth. Rope. Tarpe, Etc. 7. Rubber Tires end Foam 8. Upholstery Materials 9. Acoustical Materials Flammable Mete Is 10. 11. New Units 12. Total Number of Flree United States Number 61 27 4$ 16 66 11 24 54 34 66 386 Percent 13.3 7.0 11.7 4.7 14.3 2.9 6.2 14.0 8.8 17.1 100.0 157 40.8 108 28.0 10 2.6 45 11.7 24 6.2 10 2.6 13 3.4 12 3.1 3 0.8 2 0.5 1 0.3 38$ 100.0 Number 41 89 117 47 27 29 65 25 60 50 660 Percent 7.5 16.2 21.3 8.5 4.9 5.3 11.8 4.5 10.9 9.1 100.0 United Statea and Overseas Number 92 116 162 65 82 40 89 79 94 116 936 Percent 9.8 12.4 17.3 7.0 8.8 4.3 9.6 8.4 10.1 12.4 100.0 198 36.0 365 134 24.4 242 26 4.6 36 121 22.0 166 22 4.0 46 13 2.4 23 26 4.7 39 2 0.4 14 1 0.2 4 2 3 0.6 3 5 0.9 6 660 100.0 935 8004 0609 38.0 25.9 3.7 17.8 4.9 2.5 4.2 1.5 0.4 0.2 0.3 0.6 100.0 MISCELLANEOUS STATISTICS The following is data concerning the reported 1972 fire Incidents for general information: United States Overseas Fire Alarm Turned In By: Automatic Detector Security Employe Other 59 18 28 70 52 102 How Alarm Turned In: Telephone Fire Alarm Box In Person Who Fought Fire: 2U5 4l4 105 45 10 55 Plant Fire Brigade Security Personnel Other Bqploye 109 246 36 69 231 212 Mmicipal Assistance Needed: Yes 50 226 No 329 314 Personal Injuries: 12 22 Fixed Fire Protection Activated: Automatic Sprinklers Carbon Dioxide Other 43 26 45 15 11 46 Type of Fire Extinguisher Used: Water Type Carbon Dioxide Dry Chemical Fire Hose 107 145 110 232 56 56 57 15 Area Operating: Yes No 330 462 51 88 8004 0610