Document 3d2q2bZrVE0rNz6nZQB5DNO

TELEGRAM This Copy for TELEGRAPH OFFICE Date 1980 JUNE 06 J. R. ARCHIBALD, PITTSBURGH OFFICE - 6 (MAILED) R. J. HOSFELD, PITTSBURGH OFFICE - 23 (MAILED) R. W. WRENN, PITTSBURGH OFFICE - 23 (MAILED) P. T. WOERZ - BADIN WORKS (BAW) J. R. LOPES - BADIN WORKS (BAW) W. R. DUSO - MASSENA OPERATIONS (MSW) G. H. SCHNEIDER - MASSENA OPERATIONS (MSW) R. R. RIPLEY - PT. COMFORT OPERATIONS (PCW) C. L. NEWTON - PT. COMFORT OPERATIONS (PCW) F. R. HUBBARD - ROCKDALE WORKS (RDW) G. H. LANTZ - ROCKDALE WORKS (RDW) M. A. GAMBILL - TENNESSEE OPERATIONS (ALW) B. M. STARNER - TENNESSEE OPERATIONS (ALW) D. L. WERNER - VANCOUVER OPERATIONS (VAW) W. D. LUDWIG - VANCOUVER OPERATIONS (VAW) J. W. ROSE - WARRICK OPERATIONS (WAW) D. M. FALLS - WARRICK OPERATIONS (WAW) C. C. WATSON - WENATCHEE WORKS (WEW) M. E. GOZA - WENATCHEE WORKS (WEW) T. S. TJIN A LIEN - PARANAM OPERATIONS (PBW) J. H. GREEN - PARANAM OPERATIONS (PBW) T. I. S. BOAK - PITTSBURGH OFFICE - 14 (MAILED) CONFIRMATION FILE RECENTLY ONE OF ALCOA'S COMPETITORS EXPERIENCED A FATALITY IN THEIR SODERBERG POTROOM. THE INCIDENT OCCURRED WHEN A MAINTENANCE MECHANIC WAS CHANGING A TRANSITE PIPE. HE EXPERIENCED A FATAL SHOCK. DETAILS ARE NOT AVAILABLE AT THIS TIME. PLEASE CHECK YOUR JOB PROCEDURE TO DETERMINE IF ANY POTENTIAL PROBLEMS EXIST DURING THE ABOVE OPERATION. ROBERT SHARKEY PITTSBURGH OFFICE - 6 RS: jd 962502 0020 MiCV k.a. isakson MECHANICAL ENGINEERING DIVISION PITTSBURGH OFFICE WPH 3 4*1 F MELtlNG/PLANT"SAFETY MANAGERS MELTING PLANT ENGINEER MANAGERS 79-05-29 RE; SAFETY REVIEW - HYDRAULICALLY OPERATED POTROOM EQUIPMENT Tests have recently been run at ATC simulating a broken high pressure hydraulic line on an "ECL" type carbon changing crane. These tests show that all hydraulic fluids will bum when in . direct contact with molten bath or other ignition sources above 1300F. Note: See Mr. J. T. Bunting's letter of 1979-05-29. To safeguard our people and equipment we have prepared the following list of recommendations for upgrading the safety factor of existing potroom hydraulic equipment. Please review these recommendations with the responsible area engineer and forward the results of this review to our atten tion by 79-07-01. Please include an estimated timetable for completing any required equipment modification at your location. Potroom Cranes (1) Inspect all cranes to ensure that routing of brake lines protects them from physical damage or arc damage. Historically this has occurred between pot and crane cab", (i.e., when carry ing potroom crucibles or other potroom equipment.) (2) Use fire resistant hydraulic fluids in the crane brakes where possible. Check the crane brake manufacturer's literature for recommended fluid. Refer specific questions to Mr. J. G. Freeberg at the Pittsburgh office. (3) Install approved fire extinguisher in crane cab. (4) Enforce strict housekeeping in crane cabs. Spike Pullers - Soderberg Plants The hydraulic system of this equipment is located some distance from continuous high temperature ignition sources. Also, molten bath is not normally exposed during operation of the equipment. For these reasons the hazard to personnel is judged to be low. The following recommendations do, however, apply: (1) Use fire resistant fluid in this machine. (2) Place unit on daily operational check prior to beginning potroom work. 962502 0021 r.inel 15ny. l'lnnl Safniy M.innp.rr Smell ilig Plant Kli^illeei Huiu^ri :i Re: Safety Review - Hydraulically 79-05-29 Page 2 operated Potroom Equipment (3) Use only proof tested commercially made hydraulic hose assemblies compatible with the hydraulic fluid being used. (4) Train operators to react properly to the first signs of hydraulic leaks. Schedule local safety training as required. Crustbreakers The operator of this machine is in close proximity to molten bath and to potential spray from a broken hydraulic line. The hazard to the operator is judged to be significant. The following re commendations apply to this machine: (1) Use fire resistant fluid in these machines. (2) Use only proof testfed commercially made hose assemblies com patible with the hydraulic fluid being used. (3) Add flexible shielding over hydraulic hoses and fittings. Air hose or fabric tubing may be used. Air hose, where used, should be resistant to the hydraulic fluid in the system. Higher temperature covers with less abrasion resistance are available in Guardian "Weldgard" non-asbestos fabric by Southern Asbestos Co., Charlotte, North Carolina. (4) Ensure that all removable sheet metal hose shields are in place before operating machine. (5) Place machine on daily operational and maintenance check-off log. Deficiencies should be corrected before moving machine into potrooms. Pot Digging Machines - ("in-place" pot digging) These machines are typically placed on or in the pot being dug. Exposed molten bath and metal is not present during normal oper ation of the machine. Consideration must be given, however, to the hazard created by the LPG or diesel fuel supply on the machine. The following recommendations apply to these machines: (1) Do not operate the machine during potroom operations which require the removal of side-covers from adjacent pots. This caution should be included in operator's instructions and in the job safety analysis. 962502 0022 Sun'll 111)'. I ' 1 1111 ::.t 1,1 V Mj 111.1)'i r:: Smelting 1'lanL Lngincci Hiiiili)',i,i Re: Safety Review - Hydraulically 79-05-29 Page 3 operated Potroom Equipment (2) Use fire resistant hydraulic fluid in these machines. (3) Use only proof tested commercially made hydraulic hose assemblies compatible with the hydraulic fluid being used. (4) Add flexible shielding over hydraulic hoses and fittings to turn high pressure spray leaks into drips. (5) Ensure that hydraulic hoses and lines cannot chafe, kink or bind during operation. Check for adequate anchorage. (6) Equip machine with approved fire extinguisher mounted within operator's normal reach. (7) Review routing of uel lines to protect them from physical damage during use or transport of machine. (8) Provide insulating shields to protect fuel and hydraulic tanks from arc damage which might occur between digging machine and adjacent pot. Information on a satisfactory fire resistant fiberglass shield material is attached. (9) Place the machine on a daily operational check-off. Deficiencies to be corrected before moving machine into potrooms. * In addition to the equipment noted above, we are requesting each plant to perform a similar safety review of other pieces of locally used hydraulic equipment. K. A. Isakson KAI/rfb cc: R.C. McCormack/F.J. McGrath AB20 A.G. Rust/R.L. Graves - WPH3 J.T. Bunting AB20 J.R. Roddy AB6 J.G. Freeberg WPH2 J.R. Archibald 736A R.R. Corley 770B Attachments 962502 0023 f i-r FROM K. A. ISAKSON MECHANICAL ENGINEERING DIVISION PITTSBURGH OFFICE - WPH I 10 MR. D. J. ELROD NORTHWEST ALLOYS, INC. ADDY WORKS 1978-09-19 i ^ / v - v , V-.^.-kW bW MW NJf^i/ RE: SPECIFICATIONS FOR FIBERGLASS BUS INSULATION__________ .____________- Attached you will find the written performance specification for fiberglait^T/ column insulators as used at Sebree. Items 3-C, 4 and 5 indicate the perfors&f ance present i> required. T-ro things should be noted: First, the method of obtaining f > re-res 1 s:am resin Is not state''. This is accomplished by Stitt? ^ ing with a Class 11 resin (ASTM E84 ratine of 25-75) and adding to it 31^^-:., antimony trioxide. This will lower flame spread to Class I (0-25). pigment is also added. A typical Class II starting resin is: Dion 6( although there are probably many o.n the market. When ready for use, ] is mixed with a catalyst to initiate curing. ` * ` C' If the Insulators consist*of two or more pieces and must'be Joined at Installation, the above resin system can be used, ''layered" with strip#'; glass cloth. Alternately, a "glue" can be prepared by mixing chopped mln'eral fiber with the resin. Second, potroom colum themselves do not generate resistance heat and therefore, the covers do not aggravate a potential heat problem. If, j other hand, you propose to shield current-carrying buswork, be sure ful!L consideration is given to the altered heat dissipation characteristics the' covers. You may want to forward copies of your proposal drawings Mr. J. A. Smith in Pittsburgh for electrical review. It may be to your advantage to have the parts supplied by an outside --3 fabricator. Included here is information on two eastern fabricators: ' Northern Plastics Corporation 7397 Taft Park Drive East Syracuse, NY 13057 Phone: 1-315-463-1431 ' Advanced Fiberglass Induatrl^*'r\8 7141 Paxton Street \ Harrisburg, PA 17111 Phone: 1-717-564-0820 \ ;' tV.v- Your purchasing people should be able to locate a capable fiberglass : fabricator in I In- Seal Mi- or Spokane area. Please call if you would liki>" additional 1nlnrni.il Ion. K, V isaksOn KA J :dali At t ac hmen t J> cc: R. L. Graves/K. H. Walker - WPH 3 R. C. McCormuok/K. .1. McGrath - AB 20 J. A. Smith - WPH 4 E. F. Hol> I t e 1 de r - WPH 3 File 0D-3-P1O txS A\ r 11 w - V,tv -* 962502 0024