Document 7OYNRX3OKzQxG2aNEODJQrKKR

FROM PLANT SAFETY & HEALTH STEERING COMMITTEE TO ROCKDALE WORKS MEMORANDUM 1979 January 23 JAN 2 9 1979 RE: PLANT SAFETY AND HEALTH STEERING COMMITTEE MEETING MINUTES Date, Time, Place 1978 December 14, 2:00-4:00 p.m., Bldg. 80, Room 138 Attending E. R. Goltra.MD, E. B. Parker, J.C. Morgan, C. H. Satcher, Ike Korenek, Finis Black, F. L. Rhodes, R. E. Cox, Arby VanSlyke, H.N. Mueller An updated safety and health project list is attached. Following is the schedule of Department Safety and Health Steering Committee meeting schedule for 1979 January and February. Potrooms - January 17 Ingot - January 15, February 12 Carbon Plant - January 24, Feb. 28 Rodding - January 26, February 23 Atomizer - January 15, February 19 S.A.F.E. - January 4, February 1 Electrical Maint. - January 9 Services - January 24 . The next meeting of this committee will be on February 8 at 2:00 p.m., Building 80, Room 138. H. N. MUELLER HNM:cw Attachment Copy . Plant safety and Health Steering Committee F. P. Bergeron/W. J. Drake Department Heads Superintendents Smelting Safety Managers J. R. Archibald, Pittsburgh T. B. Bonnev, Pittsburgh H. D. Belk, MD, Pittsburgh C. E. Magee, USWA, Rockdale ALCOA PLAINTIFF'S EXHIBIT AL-1737 ARD 001811 SF-4363 DEPARTMENT Plantwide ACTIVE SAFETY PROJECTS ______________ RESPONSIBLE PERSON Item and Brief Description Status Housekeeping improvement program Safety representative recognition A. Purchase safety caps B. Train safety representatives . Safety and health steering committee appointed sub-committee to develop housekeeping improvement program. Sub-committee has met and prepared proposal. Educational and promotional program to be prepared by 1978 October. (Brent Lemons, H.N.Mueller) Safety caps-fluorescent green-received 78-07-31. Distribution complete 78-09-07. J.J.Congleton to develop safety representative's training program Gasoline and diesel pump station main entrance to plant near walkway Present gasoline and diesel pump station to be relocated. Suggested locations are: (1) Vicinity of new vehicle repair shop, (2) Across from Properzi building, (3) Northeast of potroom Line 8. These proposals have been reviewed with R. P. McCracken, Pittsburgh Fire Protection. Review with.plant safety and health steering committee at 78-09-21 meeting. In the meantime*, enforcement of our present rule prohibiting tank trucks from filling the underground tank at shift change will be emphasized. (RFA approved in early 1978 December per W.D.Essary) Safety rule book format (needs revision) > 33 O 8 Ditch road - detour od A. Oil on roads bleeding iv) B. Evaluate installing guard rail to prevent autos from going into lake C. Fill in holes on bypass lake road D. Dust from the bypass lake road After reviewing,safety rule loose leaf notebook, general safety rule concept followed by departmental rules, it was agreed to pursue this format. Letters to appropriate areas of responsibility will be written and sent requesting review and submission of final safety rules for their respective areas. Estimated completion date final form ready for printers 79-02-01. Plant safety rules (draft) will be sent to plant safety and health steering committee members for review and return to J.J.Congleton. 78-09-08. To investigate and take appropriate action. Report at next PS&HSC meeting. Cover roads with slag , Seal the road or water both morning and afternoon . Need reflectors 'down center (J.J.Congleton) Safety billboards A. Temperature hard to read B. Cannot tell whichdept. had Lost Work Day Case . Paint center needle red to help identify present temperature. When the light is turned on a 1& will be added to the number column for the dept, having suffered the Lost Work Day Case -ti.e.. Potlining 1&4 (H.N.flueller) * ' ARD 001812 DEPARTMENT Plantwide ACTIVE SAFETY PROJECTS ` RESPONSIBLE PERSON Item and Brief Description Status Numerous low-profile type vehicles such as bicycles, scooters, payloaders, mowers, small tractors, and some fork trucks have been involved in several accidents and near-misses in the last few years. One of the reasons is lack of visibility. Purchase 1,000 bicycle flags of a bright orange color with green safety logo, ALCOA, and "Drive Safely" printed on them. (1) 500 for in-plant use (2) 500 for employee sales - Alcoa will share in the expense and offer them to employees at the reduced price of $1 each. (Promote off-the-job safety) Complete, however many vehicles still do not have flags. Lights on vehicles Vehicle lighting policy - complete,.however, many not being used. Lights from Bldg 134 that shine on the street-one out of seven working W.O. # . . North road curve is sharp and needs a reflective curve sign and relocated further north Sigh ordered -, P.0. 698984 (W.J.Davis) People not using walkway to and from showers - using the street ' Publish safetygram (C.H.Satcher - H.N.Mueller) ARD 001813 .t * ' ` ARD 001814 DEPARTMENT Plantwide Item and Brief Description 1. Asbestos is still being used in the plant ACTIVE INDUSTRIAL HYGIENE PROJECTS V . Status RESPONSIBLE PERSON ' 1. Compiling a report on asbestos use and action plan to eliminate its use and find substitutes. Report progress at next PS&HSC meeting. (E.B.Parker) DEPARTMENT POTROOMS ACTIVE SAFETY PROJECTS Item and Brief Description 1. Find another location for breaking up blocks with' backhoe-presently located in Cy.7 west end - dust and noise in Potrooms . Status Under study RESPONSIBLE PERSON H.-McLaughlin t ARD 001815 _ . . ' ARD 001816 DEPARTMENTPOTROOMS Item and Brief Description 1. Pot tenders eating their lunch in potrooms (exposure to fluorides through ingestion) 2. Fluoride exposure . 3. Potroom crane cab environment 4. Dust from ore bucket filling 5. Dust from ore bin filling ACTIVE INDUSTRIAL HYGIENE PROJECTS RESPONSIBLE PERSON Hugh McLaughlin Status 1. Proposal for upgrading lunchrooms reviewed with potroom people and janitors by 78-01-30 - Complete 2. RFA for upgrading lunchrooms has been approved. 3." Project to be complete 79-01-15 (All T-51 lines complete 78-12-31) 1. Proper respirators provided and people trained - complete (Results of OSHA tests indicated compliance. Mandatory respirator use not indicated) 2. Evaluation of experimental Rockdale covers in progress. Engineering design of new covers for Rockdale pots complete. *. 1.. Festoon system design complete, but installation on hold because of cost inequities with present self-storing system. _. 2. Present self-storing system is installed in rooms 20 and 22 and is operational. Operator acceptance has been marginal at best. 3. Efforts are presently being concentrated on the Badin air mover system. First such trial installation scheduled by 78-12-31. Evaluation will commence upon installation. >. 1. Side loading bucket has proven inappropriate due to difficulties in filling. 2. The concept of physically moving bucket out of room and under tank discharge system for top loading of bucket is being investigated. Cost analysis of _ various approaches to this end is underway. Best alternative to be determined by 79-01-31. .. 1. Design for improved dump gate to be started by- Pittsburgh Engineering in 1979 January. It is a Company-wide problem. Schedule of work is being developed in Pittsburgh. Prototype of new bucket to be tested at Badin. Rockdale general arrangement design to begin 1979 February. DEPARTMENT SERVICES DEPARTMENT ACTIVE INDUSTRIAL HYGIENE PROJECTS RESPONSIBLE PERSON Dave Smith ' Item and Brief Description Status 1. Dust from coke blasting flexible riser connections in Potrooms 1. Pangborn refused- to quote on blast enclosure. Process Equipment Division is developing prototype enclosure for trial at Rockdale later this year. Sanding belt alternatives are being studied. ' 2. Dusting at ore unloading station j 1. Investigate standardization of ore cars - complete. Not possible. 2. Investigate use of lean-to obtained from Pt.Comfort to place against rail car during unloading. Does not appear feasible - complete. 3. Investigate ways of keeping floor hoppers full to avoid intermittent dust clouds when opening rail car hoppers. Project is feasible, but has low priority because of low order of dust exposure. Complete. 4. Evaluate vacuum cleaning vs. sweeping in basement - complete. Dust exposure significantly reduced by vacuum cleaning. Permanent vacuum lines installed and in use. Dust leaks in duct system have been repaired. Complete. 5. Shop order for improved ore blending device (to minimize slugs of fine material in ore stream) has been approved. Installation complete. Equipment performing satisfactorily. Complete. , 6. Respiratory protection provided and people trained - complete. . 7. Investigate reducing volume of hoppers to reduce dusting when unloading into an empty hopper. Wooden prototype constructed for evaluation. 3. Dust from ore belt transfer points 1. Engineering project to improve dust collection in progress. Proposal to be complete and request for funds submitted by 78-05-31. Shop order approved. Material being fabricated. Installation by 78-10-31. Complete. ARD 001817 A, Bag changers exposed to unregenerated ore when working in A446 reactors 5. Dust spillage from trash screenA398 systems and 19X tower system 1. Evaluation of English barrier cream complete. Found to be somewhat effective, but not a cure-all. Additional quantities ordered. 2. Evaluation of Airstream helmets complete. Found to be unsatisfactory in this application. ' . 3. Evaluation of cool suit completed. Found to be satisfactory except for weight of the hoses - need lighter equipment. Disposable coveralls and disposable air- supplied hoods and vests with vortex tube being, evaluated. System works, but excessive water in compressed air plugs filters in very short time. Water traps have been ordered and evaluated. Another test is needed. Concern exists that air volume may not be adequate. 4. Proper respiratory protection provided. Complete. 1. Several alternatives investigated. Engineering still active. No. progress. DEPARTMENT CARBON PLANT ACTIVE SAFETY PROJECTS .........'...... , ...... '................. ............... "RESPONSIBLE PERSON J. L. RODDY Item and Brief Description Status ' . ' 1. Inadequate cleanup of regenerated alumina spilled from A446 units and ' regenerators in Courtyards 58,60,62 Evaluation of ice cream cart Tennant sweeper complete. Equipment did not perform as hoped. Brooms and shovels still best way of cleaning up in tight spaces.Complete. Evaluate small supersucker. Vacuum attachment fabricated and tried. Slow, but effective. Some modifications may be needed. Will be used in connection with manual methods. Complete Coordination of waste removal improved..Continuing attention required. Engineering looking at ways of reducing wet beds. EE working on 4 zone control. ME looking at possibility of using potable water for sprays. This will reduce instances of dumping wet ore into the courtyards. Sincecleanup is now considered adequate, project as originally stated is complete. ` ' *\ ARD 001818 * DEPARTMENT CARBON PLANT Item and Brief Description 1. Coal tar pitch volatiles exposure mixer floor 2. Coal tar pitch volatiles exposure, press room 3. .Dust from belching of Carbon Plant precipitator . 4. Inadequate number of drinking fountains ACTIVE INDUSTRIAL HYGIENE PROJECTS RESPONSIBLE PERSON Jerry Roddy ' Status 1. Provide respirators - Complete. 2. Respirator training - Complete 3. Implement respirator program - Complete. 4. Mixer door project to be complete by 78-09-15 - Complete 5. Replacement of batch cars with screw conveyors to be complete 79 March. On schedule. 1. Compliance testing of modified lube system - Complete. Results still indicate overexposure. Respirator usage made mandatory for press operators. 2. Area has been retested. Results indicate marginal compliance with OSHA standard. Respirator use still recommended. ... .. 3. Engineering considering means of providing additional ventilation. Waiting on drafting. 1. Implementation of Research Cottrell recommendations complete. Still had belching. Research Cottrell representative called in and he pointed out a>few_things needing attention; Unit performance improved. Long range solution is to replace unit. 1. Survey made and additional fountains to be provided. Request for money to reinstall fountain in Bldg. 60 and to install 4 additional fountains, one on the east side of each furnace room has been submitted. Shop order approved, engineering .in progress. New fountain installed in Bldg. 62. New water line required for 60 (2), 62E, 58E - 79 March. Work ticket in for 64E, 160W. 33 O 8 -4 --CxD . CO ARD 001820 DEPARTMENT_____RnnnTNR ROOM Item and Brief Description 1. Excessive noise ACTIVE INDUSTRIAL HYGIENE PROJECTS '' RESPONSIBLE PERSON Jerry Roddy Status 1. Rodding Room modernization complete. Noise exposure survey completed. Over exposure found, money for noise control included in clean-up RFA. Phase 1 to be complete 79-01-31. Exposure survey to be done 1979 March to determine need for Phase 2. '' i DEPARTMENT INGOT & PROPERZI Item and Brief Description 1. Excessive noise . i ACTIVE INDUSTRIAL HYGIENE PROJECTS RESPONSIBLE PERSON Ted Randall Status 1. Evaluation of muffled filter box burners completed at ATC. Sample mufflers to be shipped to Rockdale for evaluation. Evaluation at Rockdale complete. Mufflers effective but overly expensive. Inactive. 2. Relocation of whistle at No.3 DC complete. 3. Modification of operator cubicle at No.3 DC to provide sound damping appears feasible. However, muffling filter box burners is a more satisfactory way of reducing noise exposure. No action planned until results of exposure dosimeter survey are available. Survey scheduled week of 78-11-13. Results) of dosimeter survey 78-11-13 through 11-15 indicated need for hearing protection at No.3 DC but nowhere else in Bldg. 34. A new operator cubicle for No.3 DC has been ordered. To be available for use first quarter, 1979. ARD 001821 " DEPARTMENT ACTIVE SAFETY PROJECTS Atomizer_________________________ Item and Brief Description Status Bldg. 403 airslide crosses over stairway This causes a head-bumping hazard. Need some sort of warning device Painted for hazards - Complete RESPONSIBLE PERSON Larrv Tate ' '# .* /' ARD 001822 . * y -^ `' ' DEPARTMENT ELECTRICAL ENGINEERING ACTIVE INDUSTRIAL HYGIENE PROJECTS' . * ' . - /qi? - //- 2-3- RESPONSIBLE PERSON . ' W. B. HOWELL Item and Brief Description . . Status 1. Carbon monoxide alarm not installed for plant air compressors that are used sometimes for breathing air 1. Installation for monitoring only - Complete 78-02-03. . 2. Have experienced problems with instrument calibration; frequency of false alarms ' has been reduced to one in 12 weeks. However, calibration requirements are excessive. 3. Installation for compressor shutdown delayed pending evaluation of another brand of monitor. It is proposed to select the most reliable monitor and install an 'instrument on each compressor to accomplish shutdown, To.be complete 79-01-31. {$'/ ... :: ky . . * * '' , ARD 001823 f ' . , * . .