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U. S. Department of Labor +J '*1 March 11, 1983 Mr. Noel Chaplin, Plane Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, Texas 78359 Dear Mr. Chaplin: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Gregory, Texas was conducted on February 28 and March 4, 1983. The inspection was made pursuant to Public Law 91-173 (S3 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been'issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspection report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION I.D. I.D. I.D. I.D. No. No. No. No. TYPE AND NUMBER OF ACTIONS: Issue Term. Modify Extend Rep by Ord Vacate Citations Citations Orders Orders ACTIONS ON PREVIOUS VIOLS. I.D. No. I.D. No. I.D. No. I.D. No. Citations Citations Orders Orders | 1* 1 "If industrial hygiene 'samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." _ _T_rv,rr ViTrc This ODeratior. Industry ratal (Decree 1) ---- .01 i o CO NrDL (Decrees 2-5) 3.00 Time Period Jan/Dec 1982 District Manager Metal and Nontnetnl Mine Safety and Health OOOP^.l U. S. Department Of Labor Mine Safety and Health Administration 1100 Commerce Street. Room 4C50 Dallas. Texas 75242 September 30, 1983 ^ Mr. Noel T. Chaplin, Plant Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, Texas 78408 Dear Mr. Chaplin: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Gregory, Texas was conducted on September 8-9, 1983. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Ar.y actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. I.D. No. I.D. No. I.D. No. Citations Citations 41-00906 A9M0rders 41-00906 Orders Issue 1 Term. Modify Extend Rep by Ora Jw/UWwVmI Withdraw 1 ACTIONS ON PREVIOUS VIOLS. I.D. No. I.D. No. I.D. No. I.D. No. 41-00906 Citations 41-00906 Citations 41-00906 A9M Orders Orders 2 3 1 "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industrv Fatal Degree 1) -6- .01 INCIDENCE RATES NFDL iTime (Degrees 2-5) .-Period -0- January thru June 1983 2.82 January thru June 1983 Sincerely, Dovle/D. Fink. Subdistrict Manager Metal and Ncr.metal Mine 000%7 Form No. DS 5 -3/83 U. S. Department of Labor Mine Safety and Health Administration 1100 Commerce Street. Room 4C50 Dallas, Texas 75242 // September 9, 1983 Mr. Noel T. Chaplin, Plant Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, Texas 78408 Dear Mr. Chaplin: ^ A Federal inspection of the Sherwin Plant, I.D. No. 41-009067 Gregory, Texas was conducted on August 9-16, 1983. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. I.D. No. I.D. No. I.D. No. 41-00906 Citations 41-00906 C4R Citations 41-00906 A9M Citations Orders Issue 9 1 5 Term. 6 1 Modify Extend Rep by Ore Vacate ACTIONS ON PREVIOUS VIOLS. I.D. No. I.D. No. I.D. No. I.D. No. Citations Citations Orders Orders "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Repott upon completion of the analysis." This Operation Industry Sincerely, Fatal Degree 1) NFDL (Degrees 2-5) Time Period .01 2.76 January thru March 1983 Mine reporting employment data only. Dovlc/ D. Fink Subdistrict Manager Metal and Nonmetal Mine Safety and Health GOOW58 Form No. DS 5 3/83 U. S. Department of Labor Wine Safety and Heaitb Administration 1100 Commerce Street, Room 4C50 Dallas,jTexas 75242 October 4, 1983 Mr. Noel T. Chaplin, Plant Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, Texas 78408 Dear Mr. Chaplin: A Federal inspection of the Sherwin Plant, t.D. No. 41-00906, Gregory, Texas was conducted on September 7, 1983. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION I.D. No. I.D. No. I.D. No. I.D. No. 41-00906 TYPE AND NUMBER OF ACTIONS: Citations Citations Orders Orders Issue 1 Term. 1 Modify 1 Extend Rep by Ora Vacate ACTIONS ON PREVIOUS VIOLS. I.D. No. I.D. No. I.D. No. I.D. No. Citations Citations Orders Orders "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis.'' This Operation Industry Fatal Degree 1) -0.01 INCIDENCE RATES NFDL (Degrees 2-5) ` Time .r Period -02.82 January thru June 1983------------January.thru.June 1983 Sincerely, . m&A rUr'Je Doyle/D. Fink Subdistrict Manager Metal and Nonmetal Mine u--UK 000991 Form No. DS 5 3/83 U. S. Department Of Labor November 10, 1983 ^//<- Mine Safety and Health Administration 1100 Commerce Street, Room 4C50 Dallas, Texas 75242 /, rv *//' //-/& ' Mr. Noel T. Chaplin, Plane Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christ!, Texas 78408 Dear Mr. Chaplin: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Gregory, Texas was conducted on October 27, 1983. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-16.4 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION I.D. No. I.D. No. I.D. No. I.D. No. ACTIONS ON PREVIOUS VIOLS. TYPE AND NUMBER OF ACTIONS: Citations Citations Orders Orders Issue Term. Modify ____1 1 Extend Rep by Ord Vacate I.D. No. I.D. No. ' I.D. No. I.D. No. 41-00906 A9M Citations Citations Orders Orders 1 "If industrial hygiene samples were*, collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory' analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industry Sincerely, Fatal Degree 1) INCIDENCE RATES NFDL (Degrees 2-5) Time Period _______ 0)____________ 2.82 January thru June 1981 Information not available on this property Subdistrict Manager Metal and Nonmetal Mine Safety and Health OOOPR6 Form No. DS 5-3/3 U, S. Department of Labor Mine Safety and Health Administration 1100 Commerce Street, Room 4C50 Oallas, Texas 75242 May 23, 1984 Mr. Dave Hopkins, Plant Manager Reynolds Metal Company P. 0. Box 9911 Corpus Christi, Texas 78408 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Gregory, Texas was conducted on April 16-27, 1984. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-16.4 (91 STAT. 1290). Ar.v actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspection report relevant to them. Ace ions ta ken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION I.D. No. 41-00906 I.D. No. I.D. No. I.D. No. ACTIONS ON PREVIOUS VIOLS. I.D. No. 41-00906 I.D. No. I.D. No. I.D. No. typ E AND NUMBER OF ACTIONS: Citations Citations Orders Orders Issue 26. Term. 16 Modify 5 nxtenc Rep by Crd 1 1 1 VOID 2 Citations Citations Orders Orders i ! i 11 1 1 "If industrial hygiene samples were collected and no laboratory analysis was require results will be included in this report. However, if industrial hygiene samples ver collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Ooeracion Indus trv Fatal Decree I) -0.01 INCIDENCE RATES NFDL Time (Decrees 2-5) Period .29 .Tsrmnrv thru T)prprrthpr 1991 3.04 lannja-r-v' f-hru npremhar 1991 1 ^ Sincerely, Doyl Subdistrict Manager\t: --, QGOflSo '-c - /~ HtHMCOMPANY'CORRESPONDENCE P-9S i Rev. l-c-3> P R C xt; Tt A. S. Millsan - Safety 2JtL I Dave Hopkins COPY: DAT 4 rSUajECT: Don Basham> E. W. Varner, Department Heads May 4, 1984 - MSHA INSPECTION 4-17-84/4-27-84 L&0C a(*sc/ MSHA inspector Pas Torres and MSHA supervisor Alex.Baca conducted a safety inspection of the Sherwin Plant beginning on 4-17-84 and ending with 'the * close out meeting on 4-27-84. During the inspection they, were accompanied by Union Representatives Paul Bucey and Clinton Howard. Also they were .accompanied by Don Imig (Mechanical Engineer) and Stan Millsap (Safety Director). The General Foremen (Maintenance, Operations, Powerhouse, Electrical or Instrument) responsible for the area being inspected joined the inspection team upon entering each area of the plant. The items listed below were violations noted and discussed during the course of the inspection. Items that resulted in citations are noted with ** on this report. Copies of the citations are attached. 1. Scaffold boards and 4" x 4" x 12* laying' on pipe in pipe rack at 42 area caustic tank. Boards not tied down. **2. Scaffold board across top guard rail of #2 strong liquor sump. Board obviously used for operator to stand on while operating a valve aligned toward the sump. **3. Safety'shower located at strong liquor pump - not working - also safety shower located directly east and across the road at #3 digester, from the strong liquor pump safety shower, was not working, ih addition, this shower had a steam trap vent line venting directly under the shower. 4. Acid, line located on pipe rack running east and west between strong liquor pump ancj acid leaking to ground from flange.' Area not roped off. 5. Fac. 90 dock. - broken guard rail at end of dock near loading tower. 6. Wooden flooring on dock directly east of loading tower needed replacing. 7. Fixe extinguisher in electrical switch room of Fac. 90 tower had no inspection tag. - '/' rr;"- Unguarded t-a-il pulley shaft end on east end of inclined belt at Fac. 90. ' Start up alarms on both ends of inclined belt at Fac. 90 not working. . Dust collector on east end of Fac. 50 tunnel not working (waiting on parts). o *' 000999 MSHA Inspection 4-17-84/4-27-84 May 4, .1984 Page 2 .. 11* 'BryVp^ not set nor was a wheel chock' installed on cars spotted at Fac. 90. **12. Garage service truck compressor pulley unguarded. Fac. 5 conveyor switch house has no sign on doors stating "unauthorized people keep out". During the discussion Sid Haynes told MSHA that as the signs were repainted on all switch houses* this notice would be included also. - .. *14. Insulation off end of electric cable on screw feeder In.north 15 tunnel. - ' ./ v. x 15. Dust collecting system at cross conveyor in 15 "A" & "B" tunnel not working *' properly. Louvers cannot be locked in place and they.vibrate closed during normal operation. . 16. Leak in roof of boiler control room at power house directly above an electric panel on west wall by door. 17. Unmarked container of liquid in chlorine shack at power house. 18. Corroded and broken conduit and lights burned out on top of cooling towers.__1 at power house. 19. Hoses strung out over walkway for city water make-up at #3 cooling tower sake-up station at power house. **20. Valve leaking on top of rod mill strong liquor feed tank in 22 area. Liquor accumulated on top, overflowing onto walkways in area below tank. **21* Electrical wiring hanging out of back.of compressor hlarm control box on south wall of compressor floor of power house. 22. Scaffold board across corner of walkway guard rail on top level of southwest corner of #4 boiler at power house. 23. Old one section scaffold in walkway on east side - mid level of #1 boiler. **24. Open ended conduit on top level northeast corner of #1 boiler - 2 electrical wires hanging out exposed. **25.' Poor housekeeping on firing aisle of"boilers. Includes stored material besides maintenance- material left from previous jobs. 26. Fire extinguisher on south end of gas turbine generator switch house floor (ground level) not inspected since 3-4-83. 27." Need notice on entrance doors to gas turbine generator floors that-hearing protection is required in the area. 28. 4n x 8* pipe tied to guard rail toe plate sticking out into walkway on 2nd level of #1 turbo generator walkway outside on west side of turbo building. 001000 MSHA Inspection 4--17-84/4-27-84 May 4, 1984 Page 3 - r* 29- Fire extinguisher on north end of gas turbine generator switch house floor*C2hd level) not inspected since 3-4-83. ' - --- ----- - 30. 3" conduit tied up with rope at missing hanger location on 2nd level of gaa turbine switch house floor. 31. 43-1 switch house housekeeping bad. Pipe gaskets, wire rope sling, scaffold boards, rags and junk scattered over floor. . **32. 43-1 switch house had temporary start/stop switch installed and lying on^ floor -- covered with dirt -- `tag dated 3-14-82 showing 1-3 cooling tower fan*. 33. #1 cooling tower sump pump motor conduit broken - wires, exposed. **34. #4 cooling tower, top side, electrical receptical broken, exposed wires hanging out. 35. Fire extinguishers required on all welding and cutting rigs when in use. NOTH: System is already in place to provide extinguishers to each rig. The rig users are not checking them out when going on a job. 36. Electric Department to check code for ground straps from battery powered vehicles to charger and from charger to ground. Do our battery powered vehicles need them or not? 37. Fire extinguisher in 35 building hallway, last inspection 3/83. '38.. 7 desilicator, top, light fixture broken off, wires hanging exposed. *39). #4 desO.teator, top, light fixture broken off, wires (hanging exposed. Equipment cleaner drilling tubes on #5 digester wearing no hearing protection. Sound level reading taken of drill motor running - at 10* distance maximum noise limits exceeded. Ear muffs required by employees and a muffler should be installed on motor to reduce noise level. **41. Guard rail, section cut out on fl4?h tank safety valve level (west side) #5 digester. 42. Audit of supervisors area shift safety inspection records made. Maintenance grrd Operations are not recording hazards found or action taken. Our records do not meet the, required standards. ' . 43- Old scaffold boards and plywood scattered around area west of horizonal heater deck on #4 digester. **44. Top side #3 4 digesters have a great amount of Maintenance and Scaling Department eauipment laying around. Also there is much trash, scale and debris over the entire area. Housekeeping extremely bad. 45. Top side 1 and 2 digesters - very poor houseeking. OOinoi .. .MSHA Inspection 4-17-84/4-27-84 Hay 4, 1984 Page 4 46. Four (4) light fixtures broken off top side-lights of #1 and 2 digesters. Litre wires exposed at each location. ' 1; .. . I. **47. #4 condensate pumps shafts not guarded. .. . ~ _ #2-3<and 2-Zvash water, transfer pumps external ground not connected. BOTE: MSHA's philosophy is that if there is an external ground - it should be hooked up. If one is not necessary the ground wire should be removed. 49. #5 diluter control panel, back side has an open plug box (110V), wires ` exposed. Inspection showed`.that a plug had burned out - someone had cut the plug off, left it laying there and wired in the extension cord direct leaving the front off the junction box. - 50. #11 settler drive motor external ground not connected. **51. Several broken light fixtures on top of 30 and 33 areas, wire exposed. 52. #4-1 diluter circulating pump motor, outside ground not connected. PresS^floor - 35 building - rubber extension cords running from plugs to instrument recorder and another cord running to clock in operator shelter. ' Inspectors told by operators that they had been in place for about two years\ inspector thinks two years is too long for temporary wiring in the plant. Permanent installation recommended for these services. 54. 35-2 switch house - empty oil drums stored in switch house should be removed. 55. (A) Maintenance pipe fab shop (blue hats) has electric extension cords (rubber) running across metal building cross braces po welding machines. These temporary cords must be replaced with properly installed wiring run in conduit. /. (B) Supplie/s, extension cords, trash piled on top of electric welder. (C) Broken conduit on wiring to electric grinder. (D) Old boxes of rusting bolts (unused), scrap metal, bolts, nuts, rags and trash scattered around work areas in fab shop. Housekeeping poor. **56.' V 45-2 switch house - hour recorders installed (4 of them) in temporary hookups to 240V switch gear. One installed 2--26--82, one 9-23-82 and the other two had no date or tag. Investigation failed to reveal any department that would take responsibility for them. Installation was as follows: ' #1 PPT pump off pump #2 PPT pump off pump #3 PPT pump off pump #3 seed charge pump 45 area sump pump electric starting probe panel boxes have backs off the boxes exposing the electrical wiring. 001002 MSHA Inspection 4-17-84/4-27-84 May 4, 1984 Page 5 " 58. Two (2) cne section. scaffolds installed at lighting panel at #146 PPT. Two others located at lighting panel at #195 PPT. Installation was done on 3-27-84 fcr WO #75712 and WO #75736. Work had not begun on these Jobs and scaffold boards were badly deteriorated. **59r. c. Top side PPT employee throwing weights in #120 PPT. Flagman on bottom was in operators* shack when inspection team approached PPT. Area not flagged off. Had the flagman been out doing his job .or the area had been flagged off we would not have been cited on this one. 60. No guard on light bulb at entrance to bottom PPT shack. Light is about head high. * 61. Heat exchanger on south end of 45 area by caustic storage tank had metal ladders leaning on each side of it. These ladders were built to be used In the bottom opening of the digester vessels. Top end metal hooks resting against side of heat exchanger make them unsteady and unsafe in this application.. 62. Scaffold located in roadway in front of heat exchanger on south end of 45 area should be removed. **63. 35 building mezzanine area, old scaffold boards on pipe ways that are completely rotted and loaded with scale. Could give way and fall on someone working on ground level. K/V Jtt*' Top side 45 -- control switch boxes have labels covered with scale. MSHA says all switches must be labeled and the labels must be readable througout the plant. 65. Top side 45 -- #56 wash tank - scaffold board hanging.*from splash foam ring on one end to a length of #9 wire at the middle of the tank tied off to hand rail of walkway'above tank. ^ .66 Safety basket box and basket located on- the south side of the operators * are deteriorated and one completely useless. Should be removed from the area. $t - **67. Ama lights axe out in #3 zone on top side 45 area (mid section on east side of PPT's). **68. #202 PPT fill valve (top side) leaking a stream of acustic. Caustic falling through grating and blown by wind over large area at bottom of PPT*s. Area not roped off. **69. Top side 45 area has very poor housekeeping. Trash originated by both Maintenance and Operations in near equal amounts. ' ... 70. 50-4 (ESP) switch house has electric and maintenance equipment stored in it. 001003 MSHA Inspection 4-17-84/4-27-84 May 4, 1984 " Page 6 --.+*. :'-L ' - - ` *;**-' .V ; T*' . a? 71. Fire hose house #3 locked with **break away" ,,pad lock that could not be - . broken. Lock had to be cut with bolt cutter before entry could be made to inspect the hoses. -. ' ' *>!..,. **72. 50-3 switch house had temporary switch wired into a switch panel. There was no tag or other device to identify the date installed or the service it went to. . 73. 50-3 switch house - very bad housekeeping. . ^ . 74. 5 gallon oiler bucket sitting on top rung of ladder to drive end of 48 area hammer mill. >. 75. Nuts> bolts, and various and sundry other metal objects stacked-over large area of walkway at screen end of area 48 hammer mill. 76. Exposed wire hanging down side of alumina loading storage tank (51 area) reason for wire is unknown. A visual lighting inspection was conducted during the evening shift on 4-24-84. The items listed below resulted from that inspection. 77. North rail for shuttle conveyor dollies appears to be broken or severely bent about half way out on the boom. 78. The two lights located on either side (north and south side) of the shuttle conveyor were not working. Barges being loaded at time of inspection. 79.' Method'of employee having to lean over the side of barges, hold a flashlight in one hand and try to read the depth markings at the water level on the side of the barge is very dangerous. A new method of1 accomplishing this work should be devised as soon as possible. ^ 80. All lights to illuminate the exterior ladders and stairs on the south side of Fac. 90 boom.tower were not working.- 81. Five or six washers and/or settlers had no lights burning at the bottom of the tanks. It is very dark in these areas. **82. Most lights- were out on the top side of the secondaries in 45 area. 83. Two (2) lights out on top side of #2 cooling tower - other lights working. **84. Transformer fence on east side of north end of the Raw Materials offices - -- - gate not locked nor grounded. - * ' **85. Top side 45 area - several safety shower identification lights out on the east_side_- mid section. ___________ ____ __________________ 86. New electric motor installation - shaft guards must cover entire shaft. 001004 MSHA Inspection 4-17-84/4-27-84 May 4, 1984 Page 7 - 87. An audit was made of both Maintenance and Operations Supervisors* system ----- of certifying that their area safety inspection has been made each shift. It was found that the inspections are being made buf no hazards nor follow-up action are being recorded. It should be noted that each inspection record must show the hazards found by each supervisor, each shift, along with the --action the supervisor takes to eliminate the hazards found. 88. We were reminded, during our close out session, by Alex Baca, that'when dust- control fans or systems fail, the areas affected must be monitored by our Industrial Hygiene people and records kept of their findings.. COMMENT: The items listed in this report are each citable. Some were written up as citations and then cancelled after review and discussion. The citations written were intended to show us the type of violations looked for and.of these the most severe citation issued was for caustic leaking from a valve above onto a walkway or work area below. This citation was classified as significant and substantial. It has a penalty that is variable and completely separate from the other citation penalties. It also means that the violation can be considered in determining whether a pattern of violations exist. Attached you will find copies of the items listed below: 1. All citations issued during this inspection. 2. Citation extension for the Fac. 33 torque instrumentation transfer to the new 33 area operators control room. 3. A copy of the torque instrument transfer progress report/work schedule bb attachments A. S. Millsap 001.005 -r` ' t U. S. Department of Labor * Mine Safety and Health Administration 1100 Commerce Street, Room 4CS0 Dallas, Texas 75242 June 11, 1984 Mr. Noel T. Chaplin, Plant" Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, Texas 78408 Dear Mr. Chaplin: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Gregory, Texas was conducted on May 1, 1984. The inspection was pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. -.1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. I.D. No. I.D. No. I.D. No. 41-00906 Citations Citations Orders Orders Issue Term. 2 Modify extend Rep by Ora Vacate | 1 ACTIONS ON PREVIOUS VIOLS. I.D. No. I.D. No. I.D. No. I.D. No. Citations Citations Orders Orders "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis.11 This Ooeration Industrv Fatal Detree 1) -0.01 INCIDENCE RATES NFDL Time (Degrees 2-5) Period .29 Januarv thru December 1983 3.04 Januarv thru December 1983 Sincerely, Dovle^D. Fink - Subdistrict Manager Metal and Nonmecal Mine Safety and Health 000^72 Form No. DS 5-3/3 7 / I UNITED ESTATES D3PAOT4EKT <W LABOR 2 CAmY a HEALTH ADlilHlSTSATtOH 3CCI CCJ3. UG9 COiaJERCZjJfTTSCET &ALLAS, TEXAS SSM2 CJDOAL CVCW2S5 nrroi.rr pea ycrrAn: usz. css Mr. Noel T. Chaplin Reynolds Metals Company P. 0. Box 9911 Corpus Christi, Texas 78408 OfiO<i73 U. S. Department of Labor Mine-Safety and Health Administration 1100 Commerce Street. Room 4C50 Dallas, Texas 75242 June 11, 1984 Mr. Dave Hopkins, Plant Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, Texas 78408 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, X.D. No. 41-00906, Gregory, Texas was conducted on May 17, 1984. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. 41-00906 7.. D. No . I.D. No.' I.D. No. Citations Citations Orders Orders Issue 1 Term. Modify Extend Rep by Ord Vacate ACTIONS ON PREVIOUS VIOLS. I.D. No. I.D. No. - I.D. No. I.D. No. Citations Citations Orders Orders i \1 "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industry Fatal Decree 1) -0- .02 INCIDENCE RATES NFDL (Degrees 2-5) .88 3.22 January January Time Period t-hrn M.irrh thru Mnrrh 1Q84_-----------1984--------------- Sincerely, Subdistrict Manager Metal and Nonmetal Mine Safety and Health 000*74 Form No. DS 5-3/3 tr \ ' 5 _ CtTjriPAt . tiAN U/AJLK/^i6 (9# f0 ,3231^ f C*4 UNITED STATUS DEPARTMENT OF U&OH 3 SATSTf & KZALTK ADiflNJffnW;TtOH DCa CCAS2. t ICO GOiOJC^CE CTTCnZT CALLA2, TCCA3 7SZOI C?naAU CVCWS38 psmalty pea ^civatc usx esao POffTAtc amo rses faio DCPAATHSKT OF ULDOR LAO 441 Mr. Dave Hopkins Reynolds Metals Company P. 6. Box 9911 Corpus Christi, Texas 78408 OOOft^S U. S. Department of Labor July 5, 1984 Mr. Dave Hopkins, Plant Manager Reynolds Metal Company P. 0. Box 9911 Corpus Christ!, Texas 78408 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Gregory, Texas was conducted on June 20, 1984. The inspection was made pursuant to Public Law 91173 (83 STAT. 742) as amended by Public Law 95-164 (9.1 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for, violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. I.D. No. I.D. No. I.D. No. 41-00906 ACTIONS ON PREVIOUS VIOLS. I.D. No. I.D. No. I.D. No. I.D. No. 41-00906 Citations Citations Orders Orders Issue Term. 3 I 1 i Modify Extend Rep by Ora Vacate Citations Citations Orders Orders 19 * 1 "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion .of the analysis." This Operation Industry Fatal Degree 1) -0--------- nrz-------------- INCIDENCE RATES NFDL Time (Degrees 2-5) Period .88 2.38 January thru March 1984 January thru March 1984 Sincerely, Subdistrict Manager Metal and Nonmetal Mine Sai'etv and Health Of)0<J8l Form No. DS 5-3/3 U. S. Department of Labor Mine Safety and Heafth Administration 1100 Commerce Street. Room 4C50 Dallas. Texas 75242 /uly 19, 1984 Dave Hopkins, Plant Manager Reynolds Metals Company r, 0. Box 9911 ( orp'ds Christi, Texas 78408 liiiar Mr. Hopkins: ,* Federal inspection of the Sherwin Plant, I.D. No, 41-00906, Gregory, Texas was .inducted on July 5, 1984. The inspection was made pursuant to Public Law 91^173 (:i3 STAX. 742) as amended by Public Law 95-164 (91 STAT. 1290). \.-.v actions issued for contractor violations are included below with copies of those j.-ticr.s attached. This would be applicable only if there were contractors present this inspection who have been issued a 3-digit identification number and who ,-rc cited for violations. Contractors receive copies of any portions of an inspec- to them. Actions taken as a result of this inspection were: j:- :::nal action 3 inspection !. j . Nn. '-.5. No. 3 " . N . No. `t:ons on ?*:v:ous viols. -B. No. * 7:. No. :.B. No. o. No. 41-00906 TYPE AND NUMBER OF ACTIONS: Citations Citations Orders Orders Issue Term. Modify Extend Rep by Ore Vacate Citations Citations Orders Orders 4 1 * industrial hvgiene samples were collected and no laboratory analysis was required, ';;lcs will be included in this report. However, if industrial hygiene samples were ected during this inspection and require laboratory analysis, you will receive a -*enent to this Inspection Report upon completion of the analysis." s Operation :,jstry Fatal Decree 1) -0.02 INCIDENCE RATES NFDL Time (Decrees 2-5) Period .88 January thru March 1984 2.38 January thru March 1984 :erelv o fj & `C'D. Fink district Manager 'ti end Nonmecai e GOO<*Gl Form No. DS 5 3/P LTHirm STATSS DEPAKTUS&TT OF LACOR CJUTETY a WEALTH ADfcCNISfnATSOM iSI 4CC3* 1100 COitUSTCCS GTTZirr ttJOU^ TTESAD S2M2 cmcm. cuawsss rsau.Y7 poa ptir^ATE oca. easo *otar &mo rac* paid DSPMtruztrr or labor UU 4btt Mr. Dave Hopkins Reynolds Metals Company . P. 0. Box 9911 Corpus Christi, Texas 78408 OOO^fiSj U. S. Department of Labor Wine Safety and Health Administration 1100 Commerce Street, Room 4C50 Dallas, Texas 75242 September 24, 1984 Mr. Dave Hopkins, Plant Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, Texas 78408 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Gregory, Texas was conducted on September 7, 1984. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION I.D. No. I.D. No. I.D. No-.-I.D. No. ACTIONS ON PREVIOUS VIOLS. TYPE AND NUMBER OF ACTIONS: Citations Citations Orders Orders Issue Term. Modify Extend- Rep by Ord Vacate I.D. No. I.D. No. I.D. No. I.D. No. 41-00906 Citations Citations Orders Orders 1 "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industry Fatal Degree 1) -0.02 INCIDENCE RATES NFDL Time (Degrees 2-5) Period .98 Januarv thru June 1984 3.32 Januarv thru June 1984 Sincerely, ,/ Dovl< Subdistrict Manager Metal end Nonmetal Mine Safetv and Health 000*60 Form No. DS 5 3/83 U. S. Department Of Labor Mine Safety and Health Administration 1100 Commerce Street, Room 4C50 Dallas, Texas 75242 September 26, 1984 Mr. Dave Hopkins, Plant Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, Texas 78408 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Gregory, Texas was conducted on August 28, 1984 to September 18, 1984. -The-inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached.* This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION I.D. No. 41-00906 I.D. No. I.D. No.-41-00906 I.D. No. TYPE AND NUMBER OF ACTIONS: Citations Citations Orders Orders Issue 36 ,3 Term. 27 1 Modify 4 3 Extend Rep by Ord 2 Vacate 2 ACTIONS ON PREVIOUS VIOLS. I.D. No. I.D. No. I.D. No. I.D. No. Citations Citations Orders Orders "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Ooeration Industry Fatal Degree 1) -6-------JJ2 INCIDENCE RATES NFDL Time (Degrees 2~5-) Period . 93,-7' January thru June 1984 3-: 32 ^ January thru June 1984 Sincerely, J Dovl< Subdistrict Manager Metal and Nonmetal Mine 000^8 Form No. DS 5 3/83 / CLOSE-OUT MEETING MSHA Inspection 8-28-84/9-13-84 Inspectors Pas Torres and Ralph Gallegos returned to the plant on 9-17-84 - abated citation //2231483 (51 Area Topside housekeeping), met briefly with Clinton Howard, Paul Bucey and Stan Millsap. Then went to Fac. 150 conference room for a close-out meeting with Stan Millsap, Paul Bucey, Clinton Howard, Don Imig, Dave Hopkins, Bill Warner, Roger Nelson and Don Basham. Listed below are the items discussed during the close-out meeting: I. Pas Torres stated the report from Denver on air quality samples taken previously in the washers and settlers, stated that we "definitely" need more ventilation in the tanks being hosed down. He then suggested some fans and cloth sleeves to direct air into tanks like that used in the mines. He is to send us some information on the blowers and air sleeves. NOTE: We do not have a copy of that specific letter. I called MSHA in San Antonio and requested a copy on 9-18-84. II. Pas Torres reported that he had taken dust samples at Fac. 51 and Fac. 90 during.this inspection and that it would be 60 to 90 days before we could expect to receive the results of these samples. III. Pas Torres stated that we had received 33 citations and 3 orders during this inspection. The citations are listed on the attachment to this report. The orders are as listed below: 1) Terex Front End Loader - broken accelerator and bad brakes - not yet abated. 2) Man working atop bridge crane over heater deck on if3 Digester - abated. 3) Fac. 15A overhead belt idler roller (described as tail pulley) not guarded. IV. Pas Torres questioned our Danger Tag and Lock-out procedure - has contacted Charlie Sisk in Dallas office - requested a special investigation on the plant site. This investigation will be forthcoming and will determine the necessity of Electricians or Operations locking out pulled breakers at the time they are pulled. V. Pas Torres questioned our leaving scaffolds and boards in place for an indefinite period after the job they are built for is completed. Says this results in boards being removed by other employees and misused and left laying around in areas causing housekeeping problems and safety hazards. VI. Ralph Gallegos informed us that MSHA was going to tighten up on its requirements for Industrial compliance with MSHA standards beginning October 1, 1984 and that we have a number of areas that will give us problems. Safety showers, for in stance is an area needing work. He said many of the showers did not work properly or the pull chains broke when pulled. VII. Pas Torres commented that there are 6 citations that are not abated as listed below: 000^82 Pi.Se -2- / ilOCLft i.urfco.j.u*' CONTINUED 1. 2231518 Pac. 48 tail pulley unguarded 2. 2231502 Accelerator and brakes bad on Terex Front End Loader 3. 2231509 Housekeeping very poor all levels - Digesters 4. 2231411 #2 Screen Pump Coupling Guard 5. 2231412 #2 Lime Pump Coupling Guard 6. 2231413 #1 Lime Pump Coupling Guard (Guards do not meet MSHA standards) NOTE: Also mentioned as not abated is the temporary light, hose holder and a safety line for the employee cleaning out rail cars for chemical products use. Pas Torres explained that this was discussed and agreed to at the close-out meeting of our last MSHA inspection. It has not yet been done. Don Basham said he had never heard of it and Dave Hopkins said we could and should do something to protect the employee doing the work until our permanent rail car washing facilities are installed. VIII. Ralph Gallegos stated that one problem we have in the plant is a serious lack of communication between all levels of the line organizations. He said that many problems could be resolved if supervisors would only find out what was happening in their area of responsibility. IX.Pas Torres stated that he had received reports from employees in the plant that employees were instructed to stop work in the areas listed below when MSHA inspectors came into the plant: 1. Rail car washing 2. Evaporator cleaning 3. Bauxite pushing 4. Washer and settler internal hosing operations He said if this is the case, it is a violation of the Act and carries a much more severe penalty than a violation of safety standards. X. Stan Millsap informed Mr. Torres and Mr. Gallegos that we would ask for a conference in Dallas (District Office of MSHA) on the items listed below: 1. 2231411 2231412 2231413 Pump coupling guards not meeting MSHA standards 2. 2231519 3. 2231507 Danger Safety Tag and Lockout procedure Temporary scaffolds left in place after the job it is erected for is completed 000<*83 ` CLOSE-OUT MEETING / MSHA INSPECTION Page -3- CONTINUED 4. 2231518 Unguarded tail pulley - Fac. 48 belt 5. 2231502 (Order) Accelerator and brakes bad on Terex Front End Loader 6. 2231414 Guard rails required on all work stands r egardless of heights 7. 2231418 Control panel vent fans unguarded on #5 & #6 control panels in powerhouse (Fac.* Ill) 8. 2231419 (Order) 2231513 Unguarded tail pulley at #15A overhead belt 9. 2231506 (Order) One employee working on top of structure of #3 Digester bridge crane (one man standing on cranes permanent plat form) . 10. NOTE: Also mentioned was the MSHA requirements for moving bauxite in 15A & B Building. No citation written but letter from Safety Director was required (copy attached). sd Attachments A. S. Millsap 0005*84 October 18, 1984 Mr. Dave Hopkins, Plant Manager Reynolds Metal Company P. 0. Box 9911 Corpus Christi, Texas 78408 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Gregory, Texas, was conducted on October 3, 1984. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued ter contractor violations are included belcv virh copies of those actions attached. This v?culd be applicable only if there vere contractors present during this inspection vho have been issued a 3-cisir identification number and who -are. cited for violations. Contractors receive copies of any portions of an. inspec tion rsoerr relevant to them. Actions taken as a result of this inspection vers: "If industrial hvgiene samples were collected and no laboratory analysis vas required results vili be included in this report. sovsvsr, it industrial hygiene sanpj.es vara collected curing this inspection 'and recuire laboratory analysis, you -"ill receive a sure lament tc this lnsoecti.cn P-eoort upon completion ct trie analysis. 1 Unis Oocration `Indus trv ! ! Fatal Des.ree 1) 0.00 0.02 IN-CIDTN-CZ RA.TZS | NTDL j i (Degrees 1-5) 1 Tima Period 1 0.93 ! Jan. thru June 1984 i 3.52 1 Jan. thru June 1984 | 1 l f Sincer*lv L,.-k J / / s' Subdistrict /:in?.e' c C. i .-.me 000^59 "cm No. IS r 1 /cu U. S. Department of Labor February 6, 1985 Mr. Dave Hopkins, Plant Manager Reynolds Metal Company P. 0. Box 9911 Corpus Christi, Texas 78408 Mine Safety and Health Administration 1100 Commerce Street, Room 4CS0 Dallas, Texas 75242 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Corpus. Christi, Texas, was conducted on November 27, 1984. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. Ko. 41-00906 I.D. No. I.D. No--I.D. No. Citations Citations Orders Orders Issue 0 Term. Modify 0 Extend 0 Rep by Crd 0 Vacate 0 ACTIONS ON PREVIOUS VIOLS. I.D. No. 41-00906 I.D. No. I.D. No. I.D. No. . Citations Citations Orders Orders 1 "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Ooeration Industry Fatal Decree 1) .00 .02 INCIDENCE RATES NFDL (Decrees 2-5) Time Period .93 3.32 .Tan thru .Tim 1Q84_________________ n ii it ii Sincerely, Doyle/D. Fink Subdistrict Manager Metal and Nonmetal Mine Safecv and Health 00001*5 Form No. DS 5 3/83 MSHA INSPECTION 2-26-85 - 3-7-85 1. Met with Falcon Construction Company Manager and Bob Lang. Manager was asked by Ed Lilly if they had received their MSHA training and he said yes. Lilly told the manager that the construction job would be inspected approximately one time each month during the course of the job. 2. Handrail loose at bottom of steps to belt at #2 lime slaker. 3. 15 'A' south sump pump had grating off and not flagged off. Even though sump pit was in process of being readied for pumping and cleaning out, it should have been flagged off. 4. Rocks on beams and grating in 24 area. Paul Hood committed to have them cleaned up before our next inspection. 5. Mud and liquor standing full on top of #7 desilicator - Ronnie Noster commented to Ed Lilly that the tops of these tanks would be cleaned off and kept clean. 6. Two fire extinguishers found with no updated inspection. One at tail pulley area inclined belt from 24 area to 22 area. One on conveyor floor 22 area. 7. Oiler access port guard on the rod mill feed belt tail pulleys not in place. 8. Fan guard on air conditioner in fac. 22 feed belt control room had been removed - fan was unguarded. 9. Pad covered with mud under 3-4 digester units. Area not roped off and no one hosing down to clean pad. Ronnie Noster commented to Ed Lilly that in the future any mud on pad would be roped off until clean up could begin and clean up would be started within 8 hours of any spill. 10. Equipment cleaners opened a line on 2nd level #3 digester unit causing caustic to flow to ground narrowly missing an MSHA inspector. Ground area not roped off - no warning was given. 11. 33 area #14 washer overflowed at feed box causing caustic and foam to fall to pad below - area showed evidence of this situation existing for some time before inspection team arrived in area - area not roped off. 12. 33 area #9 sump flooded when inspection team arrived in area - it was estbalished that this condition had existed since the previous day. Mr. Lilly got a committment from Gene Woodard that flooded sumps would be pumped down during the shift in which they became flooded. In cases when the sumps cannot be immediately pumped down, Woodard stated that a sign or flags would be installed warning people of the condition until conditon can be corrected. 13. Mr. Lilly and Mr. Woodard discussed overflowing tanks in 33 area and agreed that the ultimate solution is better control of tank operations. They agreed however, that roping off overflowing tanks and flooded areas is required as a temporary measure until control can be established to stop spillage. 0OO<*76 MSHA Inspection - 2-26-85 - 3-7-85 Page 2 March 8, 1985 14. On 2-28-85 as inspection team was leaving Medical we observed a front end loader #966 operating on the south end of 45 area. The front window was badly cracked. Mr. Lilly went to the loader and asked the driver if he had done a pre-shift inspection before starting use of this loader the operator said no - upon further checking we found that the garage had been notified of this broken windshield approximately 10 days before and had not yet made repairs. The loader was taken out of service and repairs made that day. 15. About the time we completed work with the front end loader - #85 PPT over flowed to the ground with great enthusiasm. Operations contacted to correct the situation. 16. While in 33 area Mr. Lilly checked a Maintenance and an Operations supervisor "green book" to see if they had inspected the area during the course of the shift. Neither supervisor had a record of inspection for that day or the day before. 17. 22 area portable welding machines had no covers on the lead connections and the stingers needed replacing. Also it was noted that welding leads are being taped up after shorting out without proper splice connections and covers being installed. 18. Training plan and records reviewed. The training plan is not up to date needs revision - training records are summarized on computer to monitor computer print out must be'approved to serve as official record. MSHA form 5000-23 must be completed and issued to all employees who quit, are terminated or laid off. MSHA to furnish us with the forms. Also we are required to report some minor injury cases to MSHA that are not required by Work Comp laws. These first reports will be determined by Dr. Gamble. Safety Office will complete and send to MSHA. 19. Vehicle .inspection records are to be kept permanently in each vehicle. This covers all mobile equipment and pickups that carry equipment in its assigned use. Cars, scooters and personally assigned pickups do not require this inspection procedure. 20. The MSHA training records were audited and it was found that over 100employee training sessions have not been completed. An order has been issued with each individual who has not completed their 1984 MSHA training being withdrawn from work until their training is completed. 21. Must set up system to receive the name, address, officials name, manning level and length of time for every outside contractor who is to work in the plant. 22. On 3-6-85 conducted health survey as follows: 1. Noise and dust samples taken in 15 'A1 & 1BT, 24 & 22 areas - monitored two bauxite transfer attendants. 2. Dust sample taken in 50 area - monitored one car loader. 000^77 MSHA Inspection - 2-26-85 - 3-7-85 Page 3 March 8, 1985 3. Noise sample taken in 30 area - monitored one equipment cleaner. 23. Garage inspected - O.K. 24. Electric shop, machine shop, fab shop and carpenter shop inspected - O.K. 25. Lab inspected - found that there are no specific controls on nitric oxide in lab. Oswaldo Figueroa stated that a system to control accessibility to nitric oxide will be installed. 26. Transformer station gate on north side of Powerhouse has no ground ties between gate section and gate port. These must be installed to meet standards. 27. Welding leads, extension cords, acetylene/oxygen hoses, water hoses, etc. must be cleared from main travelways during course of any job - suggested solution is to hang lines from hooks above walkways or bundle together and cover with appropriate cover to allow safe foot traffic over lines. 28. After completing the inspection and closeout meeting with Plant Management, the inspection team returned to the plant for the MSHA inspector to give Goldston and H & S Construction Companies copies of the citations written on their violations on the 6th. When we exited the car at 33 area to contact H & S we observed two scalers on the 5th level of a six section scaffold scaling a line - the 5th section of the scaffold had no guardrails on the end of that section and one man was using a scaling gun standing within 12" of the edge of the scaffold with his back to the opening. Neither man was wearing a safety belt. Ed Lilly wondered why he had to see this because he was required to take action. The job was stopped, supervisors of the scalers, the scalers, the carpenter who built the scaffold, "their supervisor and both general foremen involved were assembled. Ed asked why - received explanations and wrote an order. He explained to all concerned that this order will trigger a special investigation and review of the facts found before an assessment can be made. It should be pointed out that this order includes violation of 55.3-9 which states "Men shall examine their working places before starting work and frequently there after, and any unsafe conditions shall be corrected." bb SUPPLEMENT TO MSHA INSPECTION OF 2-26-85 - 3-7-85 REPORT DATEO MARCH 8, 1985 Current list of outside contractors must be maintained in the Safety Office at all times. This is to include the following information: 1) Contractors name. 2) MSHA number (if they have ever received one). 3) Area of plant they will be working. 4) Date job started and is to be completed. 5) Manning level of job (number of employees). 6) Name of on-site contractor safety representative. 7) Name of company official who will receive any citations or orders. 8) Company address. 9) List of the names of all employees certifying that they have received the required MSHA training. 29. Building 35 filter leaf covering area covered in one to four inches of mud. Employees covering filter leaves walking around in it - no effort had been made to clean or hose down the area before starting work. MSHA Inspector commented that the area should be cleaned up by the men before starting to work in the area. Gene Woodard responded that this would be done. 30. 45 Area - bottom - MSHA Inspector discussed flooded sumps and hydrate scale on pads with Tommy Ward. Tommy explained his situation and reasons for it. He stated that flooded areas that must remain flooded for a while will be roped off. Scale is being removed and pads hosed down as quickly as possible. Carl Schmidt discussed need for barricades around areas of maintenance men working overhead. 31. 45 Area elevator - top emergency entrance door off. MSHA Inspector said these doors must be kept closed and locked from the outside at all times to prevent exit from inside of elevator. 32. Inspector questioned reason for special danger tag procedure for top side 45 valves. This is the only exception to our standard tagging procedure found'. I could not give reason to justify this variance. 33. Citations given for openings in wall on operating floor of 46 Area. Operations and Maintenance supervisors did not have these listed in their green books. 34. 50 Area - Dust collector piping on #7 kiln had open plug hole. Area showed evidence of this condition existing for some time. Dust had sprayed all over area inside head house for an extended time showing that "nobody really cares." This was an example the MSHA Inspector used to show poor attitudes toward safety by supervisors and hourly employees alike. A helper got a ladder and plugged the hole in about two minutes. 35. 50 Area employee Beltran (car loader) complained to inspector that the dust collectors are broken by other car loaders because they don't care to watch what they are doing and maintenance cannot keep them fixed as fast as they are broken. The inspector asked why the super visors didn't stop their employees from tearing up equipment. We couldn't answer him. ooowg MSHA INSPECTION 8-20-85 - 8-23-85 Ed Lilly - Inspector 1. Tom Novogradac (#2432 - HEOB) complained to Ed Lilly that the air conditioners on the dozers with enclosed cabs do not work and have not worked for two years. Paul Hood said parts for the air conditioners are on order and the air conditioners would be fixed. Ed Lilly stated that equipment with air conditioned cabs are required.to have air conditioners working, or cabs removed and roll protection installed. 2. Fork lift truck #377 has a defective back fork guard - bolts have sheered and side of guard is loose. Needs to be repaired. 3. Raw materials vehicle inspection bocks on vehicles and check sheets in office are all in good shape - properly completed with work orders written (and attached) for all defects noted by operators on their daily inspections. 4. No guard or berm on the culvert crossing at the north west corner of 15B Building. . This needs to be corrected. 5. No handrails on stairway leading down into 15 A&B tunnels. There is an MSHA requirement for these. ED reminded me of it. No citation. 6. 15 A&B Buildings and 24 and 26 Buildings looked very good. Lilly had no complaints - no citations. 7. Emergency signal sufficient to alert scaler monitoring the scaling of two digester vessels is required. Air horn rigged up to serve as emergency horn - it was tested and approved by Ed Lilly. 8. Chain fall maintenance and inspection system reviewed and approved by Lilly. 9. Chain guards on most walkways at attached ladders to platforms in 30 and 33 Area were observed to be unfastened, leaving unprotected openings in walkways. Ed commented that this is a violation and must be corrected before his next inspection. If not, a citation will be issued. 10. Upper levels on the digester vessels have accumulation of tools, bolts, nuts, old pipe, etc. left after maintenance jobs have been completed. This could be from Maintenance crews as such or shift Maintenance working for Operations. *11. Energized extension cord strung out through #4 Digester. It had a double splice on the end with both ends unprotected and lying in a walkway on the metal grating. Citation issued for this. *Citation issued on item. 000992 MSHA Inspection - 8-20-85 - 8-23-85 Page 2 August 26,'1985 12. Caution flags are not being removed at the completion of jobs in most areas of the plant. The procedure for removing the entire flag at the completion of the job must be tightened up. This could become a citeable item in future inspections. 13. Ed Lilly observed two mechanics working on a pump in 33 Area. One was using a `cheater1 pipe on a wrench. The wrench was heavy duty (industrial) quality and is approved for use in the plant with a `cheater* pipe because it will bend before it breaks.1 During the discussions that followed, Ed stated that cheap or light duty wrenches should not be approved for use in the plant because they break and cause injuries instead of bending when*used beyond their designed capacity. 14. Louvers have been removed from the North wall of filter floor in 35 Building and there is a temporary barricade installed. These louvers should be replaced or permanent barricades installed before our next inspection. 15. Inspector commented on the improvements that have been made on the filter floor. He encouraged the General Foreman and employees present to continue their good work. 16. Access openings on the tops of the Washers and Settlers located in open walk areas must be kept covered or guarded in some way to prevent someone stepping in them during routing work. 17. Number 7 and 8 Washers have a great deal of scale and or caustic on them with considerable junk lying around in it. The inspector got a commitment from Glen Reynolds that these specific tanks would be cleaned off before the next inspection. 18. Safety shower head broken off at the Strong Liquor Pad. This needs to be reparied ASAP. 19. Elevator'car roof access door in 45 Area Elevator is open. MSHA requires that they be locked. We did not receive a citation for this but we could have. *20. 45 Area top side 8 safety showers found to be not working - citationsissued for this. It is obvious that these showers are not being checked. *21. 46 Area filter floor hydrate belts have no emergency stop cords and are not protected with a guard. Citation issued for this. 22. Number 8 and 9 Kilns are puffing back enough to cause someone to get burned if they do not exercise care in the area. Inspector requested that Kenneth Hailey install warning signs in the area until puffing problem is resolved. *Citation issued on item. 0009^3 MSHA Inspection - 8-20-85 - 8-23-85 Page 3 August 26, 1985 23. Garage tire repair shop has tires, boxes and junk piled in front of switch boxes on the north end of shop area. Access must be clear to all switch boxes in the plant. 24. The north diesel fuel storage tank needs handle installed on the valve closest to the tank. Inspector states that MSHA requires a valve be installed as close to tank as possible on all piping and hose connect ing areas. 25. Inspector commented a couple of times about switches not being labeled to identify them - particularly where there are switch boxes involved. We should look into this. 26. Number 3 torque thickner has a conduit rusted in two with wires exposed. Glenn Reynolds said a work order had been written to repair this. This should be repaired before our next inspection. 27. Wall louvers missing from the south wall of the Power House on the generator floor. These need to be replaced as soon as possible - we could have been cited for this one. 28. Switches located on ground floor of Power House Generator room (north wall) blocked with material stored in front of them - no access.- This area needs to be cleaned out to allow access to the switches. 000^4 U. S. Department of Labor March 31, 1986 Mine Safety and Health Administration 1 tOC Commerce Street. Room 4CS0 Dallas. Texas 75242 Mr. Dave Hopkins, Plant Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, TX 78408 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Corpus Christi, Texas, was conducted on March 11-14, 1986. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection, who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION* THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. I.D. No. I.D. No, I.D. No. 41-00906 Citations 41-00906--N2SCitations Orders Orders Issue 4 1 ACTIONS ON PREVIOUS VIOLS. I.D. No. I.D. No. I.D. No. I.D. No. Citations Citations Orders Orders Term. 1 1 Modify 0 0 Extend 0 0 Rep by Ord 0 0 Vacate 0 0 1 uIf industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis.** This Operation Industry Sincerely, Fatal (Degree 1) r___________ JX)________ .01 INCIDENCE RATES NFDL (Degrees 2-S) .00 3.31 Time Period Jan-Dec. 1985 Jan-Dec. 1985 Doyife D. Fink Subdistrict Manager Metal and Nomnecal Mine Safety and Health (214)767-8401 00(R*>4 Form No. DS S 3/83 MSHA INSPECTION REPORT MARCH 17, 1986 MSHA Inspectors, Ed Lilly and Paul Berlanger reported to the plant for a semi-annual inspection on March 11, 1986. They started in their usual manner, by checking records. Items for this report will be listed in the way they occurred. 1. An audit was conducted of training records, accident logs, and first report of injuries to MSHA. They were compared with the first aid records and signed copies of the attendance records for safety training. All records are up to date and in good shape. 2. We were informed that it is necessary on routine plant inspections for samples to be taken, therefore, we put sound meters on Mike Szepessy who was operating one of the plant cranes?- The MSHA sound recorder malfunctioned and we did not get a reading from it, no problem.. 3. Air samples were taken from the area at the north end of Eimco filters and Building 35. These samples ran all day. We attached our own sampling devices, parallel with the MSHA Inspectors. The samples will be analyzed by an outside laboratory for the same elements that MSHA tests for, so we can have our own data in case they find something they question. 4. Area air samples were also taken at 46 building up on the filters. These samples were handled in the same way as air samples at the 35 building. These will be part of that which we send out for analysis. 5. The physical inspection of the plant began at the beginning of the process on the docks. The motor connector on the dock belt drive motor has a bole in the cover. The hole is too large and must be covered. Also, there is a hoist in this area cat the top of the incline belt. The outside insulation to the electric cord has been pulled loose, needs' to be repaired however, I understand that this hoist has been out of service for some time and it may be possible to remove it to eliminate a problem. 6. Extension cords to the new bin lights on the top side of 15 A & B . building was installed last year to test the lights. The lights work well, but the extension cords are still laying on the grating of the walkway. It was pointed out that this constitutes a triping hazard as well as an electric shock hazard. It must be changed before they return for another inspection. If not changed, we will be cited for it. 7. There was a cover off an electrical junction box at the transfer point to 15 'B* building from 15 'A'. Two lights are broken on the top of the west end of each transfer belt, the elements are sticking out, these need to have new bulbs put in or plugs put in them, if ->the lights are no longer needed. GOOSES MSHA INSPECTION REPORT MARCH 17, 1986 Page 2 8. Area 24 top and bottom was checked and looks very good. 9. On incline belt from 24 to 22 area, an extension cord plugged in was lying on grating, also an extension cord on topside of 22 facility was lying on grating, it was moved. Extension cords are oing to cause us problems if they continue to be on the walkways on steel grating where they can be walked on. Also at facility 22, the belts feeding from the hoppers to the mills need a small guard at the feed chute point, where the bauxite drops off the belt, there is a pinch point that can be gotten to. Sid Haynes assured us it would be a simple matter to install a guard at this point*. 10. The desilication area was checked and was okay. 11. During the inspection of 30 .area, a Maintenance employee was changing tubes on a vertical heater on #5 digester, standing on a 5 gallon bucket, using it as a work platform. This was pointed out to me and I told the man to get the proper platform. There was no citation given for this item. 12. All digesters were in good shape. The're were no citations or other suggestions in these areas. - 13: Area 45 and 50 were good. It was pointed out that area 51 needs an expanded metal screen on the back of the car puller cable druni, just in case the cable breaks, it would stop a backlash from hitting an operator who is standing in that area operating the winch. Also noted, but not cited, was a welding cart on the north end of 46 area that was un attended, the tops were off the oxygen and acetylene bottles. 14. While we were in facility 51, Willie Charles Jones talked to Ed about the confusion that is now caused by SP operating in the plant. With one set of instructions, they do not stop at the railroad crossings, the road traffic is expected to stop. -Whereas the planrswitch engine is expected to stop for all road traffic and this causes confusion. There was a' lengthy discussion, MSHA explained that they would not get involved in internal affairs of the company unless someone got hurt. However, ..they did note two standards 56.909 and 56.959, these have to do with having warning signs up to stop the public x^henever a train is going through a crossing. It says Warning Signs and/or signals shall be posted in guarding when trains are passing and crossing shall be planked, or otherx^ise filled betxveen the rails. I x-/as informed that the implication is that the trains have the right of way on these crossings so far as MSHA is concerned and that x*as all the dis cussion that took place on this. 0OO**6 MSHA INSPECTION REPORT MARCH 17, 1986 Page 3 15. We returned to 46 area where a jog switch on a filter had been found blocked open. In looking into this, talking with the operators, supervisors, and electricans involved, we found that this is not a jog switch, but a speed change switch located on these filters. The operators explained that in order to operate the belt without operating the agitators and the feed belts to it, when they need to clean off the filter itself, they normally block these switches open so that every thing else will not work except for the filter belt. The problem with this is that should the system have a power failure and then power returns, the belt would automatically start up. With this information, MSHA did cite this as a violation and we have until the 30th of this month, (March) to change the system to one that will automatically kickout with a power failure and will have to be reset to start the filter up again. I have been assured that such switches are available and this is not an extremely major project. The date set for termination of this citation is March 30th, 1986. 16. During an inspection of the machine shop, a drill press located at the front of the, tool room is not anchored to the floor and is very unstable. It should be anchored so it cannot fall- over when in use. Metal stock racks in machine shop are rusty, beginning to deteriorate in some areas pretty badly. Some of the hold arms are broken and these racks that have rusted and broken hold arms should be taken out of service, repaired or replaced before some employee gets injured very seriously with.the heavy material falling from these racks. 17. In the machine shop a citation was issued at the Cincinnati Lathe. It was being worked on, a contractor was involved in assisting our employees in maintaining the machine. The machine was left unattended with the doors to the electrical contact panel open. This is a violation of MSHA require ments and, therefore, a citation was issued because the doors were not closed. 18. We were informed at the Powerhouse that all pressure vessels must be. inspected and certified, both fired and unfired. This is a new requirement, it includes air compressor lines and vessles. Regulation cited was 56.130.15, we need to look into this and see if we cannot get certification from our insurance carrier who inspects this equipment periodically, he aught be able to certify they are inspected and meet all the requirements. 19. A lighting inspection was held in the early morning of Friday, the 14th. During the inspection, we did a walk thru of the entire plant. We found three areas that have lighting deficiencies. 'Topside walkways of 33 area, the mezzanine deck on the north-of 26, and the top of 45 area west side. All of these areas were noted, lights were out over walkways, travelways and stairs. They must be repaired. We have until March 21 to abate this, citation. 000^97 MSHA INSPECTION REPORT MARCH 17, 1986 Page 4 20. Inspection was made of the drying beds, the dik'es around the drying beds must contain berms or barriers of some type. We had quite a discussion with Bob West leading the discussion and answering MSHA's questions, noting the problems and putting berms around the tops of the drying bed dikes. We looked at some washed out places that had been caused by standing water, noted the hazards involved in this, and we were not given a citation for this, but told that we need to look at this situation and figure out something that will satisfy them minimally. Bob West is to submit a report with options for discussions and decision making so we can satisfy the MSHA requirements on this. 21. We were unable to find a ground fault system check, the resistance check for our ground fault system in the plant. That is normally done by the power and electrical department each year. We did not do one in 1985, there fore, we have received a citation for this. We will be given a time to .. abate it 30 days at a time. 000*^8 U. S. Department of Labor Wine Safety and Health Administration 1100 Commerce Street. Room 4C50 `Dallas. Texas 75242 October 18, 1985 Mr. Dave Hopkins, Plant Manager Reynolds Metals Company P..0. Box 9911 Corpus Christi, Texas 78408 received Plant Manager o. SHERWIN ^ 0>,n Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Corpus Christi, Texas, was conducted on October 5, 1985. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public taw 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. I.D. No. I.D. No. I.D. No. ACTIONS ON PREVIOUS VIOLS. I.D. No. I.D. No. I.D. No. I.D. No. 41-00906 Citations Citations Orders Orders Issue Term. Modify Extend Rep by Ord Vacate Citations 0 1 0 0 Citations Orders . Orders 0 0 "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industry INCIDENCE RATES Fatal (Degree 1) NFDL (Degrees 2-5) Time Period 1 Non Responc ant Jan. thru June 1985 j 0.02 3.29 Jan. thru June 1985 Sincerely, Doyl'e D. Fink Subdistrict Manager Metal and Nonmetal Mine Safety and Health (214)767-8401 ooo^as Form No. DS 5 3/83 U. S. Department of Labor May 15, 1986 Mine Safey and Health Administration 1100 Commerce Street, Room 4C50 Dallas. Texas 75242 Mr. Dave Hopkins, Plant M nager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, TX 78408 Dear Mr. Hopkins: , A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Corpus Christi, Texas, was conducted on May 13, 1986. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). 'Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and. who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. I.D. No. I.D. No. I.D. No. ACTIONS ON PREVIOUS VIOLS. Citations Citations Orders Orders Issue Term. Modify Extend Rep by Ord Vacate I.D. No. 41-00906 I.D. No. I.D. No. I.D. No. Citations Citations Orders Orders 0 30 0 0 0 "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industry Sincerely, Fatal (Degree 1) .00 .01 INCIDENCE RATES NFDL (Degrees 2-S) .00 3.31 Time Period .Tan-Dec. 1985 Jan-Dec. 1985 Subdistrict Manager Metal and Nonmetal Mine Safety and Health (214)767-8401 000<*5*3 Form No. DS 5 3/83 MSHA INSPECTION August 20-28, 1986 MSHA inspectors Ed Lilly and Bob White reported to the Sherwin Plant for a semi-annual inspection on August 20, 1986. I was informed that the U.S.Department of'Labor is requiring more health sampling now than has been the case in the past. It was stated that at least two full shift monitions of noise, dust, fumes, etc., must be made with each inspection for the insp ection to be considered complete. Therefore we spent two days during the inspection getting noise and dust samples that could be certified as full shift samples. Noise and dust seem to be the most common samples they are taking during each inspection and we have the capability of doing full shift parallel sampling. We do not, however, have the instrumentation to parallel spot samples on noise, and from my observations, I think it is important to be able to do so. Therefore I will be submitting a requisit ion to purchase the equipment to take spot parallel noise samples in the near future. It will probably be fairly expensive to purchase but if we can gain the capability of spotting problem areas before inspections are conducted the necessary corrections can be made at a more reasonable pace and cost than is the case during inspections. Listed below are the items MSHA pointed out needing correction and any comments that seem pertinent to each item listed. I OUTSIDE CONTRACTORS A. Goldston Construction Company Facility 5 Dock Project Engineer - Gerald Smith 1* No safe access from dock to barge 2. Too much weight on 1" swedge on air compressor 3. No fire extinguisher on barge 4. Osygen hose at bottle wired on to fitting 5. No check list for pre-shift inspection on heavy equipment (crane and backhoe mounted on barges) 6. No hearing protection for three men operating jackhammers 7..No life jackets being worn by men on job B. Casanove Insulation Company Facility 50 ESP Project Engineer - Ed Peterson 1. Eye wash removed and water hose connected at safety shower station on filter floor Fac. 50 (8 & 9 kilns) 2. Contractor employees removing asbestos - warning signs too close to the work 3. Not monitoring area for airborn asbestos to determine hazardous area. The area around the job site must have continuous air sampling. 4. Bob White commented that the respirators used by Casanova employees were not the approved respirators for that work. II GENERAL INSPECTION NOTES 1. Large hole in north wall - Fac.14 cross conveyor discharge on west side. .2 Emergency stop lanyard near top of incline belt to 15A building hanging near floor (hangers broken). 000987 MSHA INSPECTION August 1986 Page 2 3. No derail or permanent chock on rails between Fac. 90 and road cross ing tracks. 4. Scaffold boards on beams around hopper cones on operator level in Fac.26 indicate placement by operators. They are unsecured and have no guard rails. 5. Cherry picker driven by Jessie Hinsley (#48) had loose steering ram pin. 6. Employee complained that G.E. switchgear at facility unloading building not working properly and could not be locked out. Upon checking switch and electrical department records, we found that the switch had been repaired and does work properly. MSHA commented that records are very important in these cases of complaint to prove the company is responsive. 7. Access hole on top of #8 desilicator open - access holes on top of tanks must be closed. 8. Hoses piled at bottom of ladder between #6 and #7 desilicator by overflow boxes. 9. Extension cords in 35 Building (noted on previous inspection) have not been changed out as requested. 10. Electrical light switch (lower) in operator's shelter 35 Building had insulation removed.- metal exposed. $1. Facility 45 tray area sump flooded - operations checked - starter kicked out - was reenergized and started pumping sump down. 12. Facility 46 filterfloor - 2 bottom barriers down at big door (we have been cited for this before) no citation this time. 13. Old scaffold on landing of stairs above operator's shack (Fac.46) no handrails or guards - scaffold should be removed. 14. Scaffold in walkway - mezzanine deck Fac. 46, dated .4-7-86 - one cord missing - scaffold should be removed. 15. Facility 50 switch house- #810 fan starter switch had electrical terminal strip hanging through vent holes by some electrical wires. 16. Facility 50: a. exposed hot air pipe on 9-1 filter - northwest corner - insulation missing b. gutters above discharge end of kilns are full of caked alumina, metal is rusted out and large chunks of alumina cake (scale) is falling onwalkways. These gutters need to be removed. 17. Covers off leads at 2 Hobart welding machines located on operating floor discharge end of kilns. 18. Several old welding leads hanging from north wall kiln - discharge end operator floor - leads have broken insulation and are no longer safe to use. GOOP88 MSHA INSPECTION August 1986 Page 3 19. Electrical junction box - cover off wires exposed on north wall operator floor kiln discharge end. 20. Elevator pit roof (50 area) has 6* to 8* of alumina piled on it - needs to be cleaned off. 21. Dracco filter bags stored in 51 switch house - they need to be removed. 22. Noise at burner end of #9 kiln (97 DBA spot reading) need warning signs requiring hearing protection on burner floor (all entrances). 23. Broken light bulb with exposed elements on east end of elevator pit. 24. Dust collector ducts inoperative at car loading - some will not extend or retract. 25. Old scaffolds and scaffold boards on walkways and car loading platforms need to be removed - this is not a proper storage area. 26. Man lift motor shimmed up 2 or 3 inches. Shims are only tack welded together and bottom one is only tack welded to frame work for motor base. Bolt holding motor does not extend through the shims to below frame work therefore -it is not secured properly. 27. Reclaim conveyor north of kiln burner end building needs to have guard installed around tail pully. 28. Auto service shed: a. need plactic shields over florescent bulbs on low ceiling in storage area b. open space in electrical breaker box on south wall needs cover. 29. Sheet metal shop, asked if we test grinding wheels before installing, talked with hourly people also they said no, inspector said testing is required for 6 months now, suggested suspending wheels horizontal with wire through center hole with wheel resting on bolt, gently tap wheel listening for "ring", says cracked wheels will not ring. 30. Carpenter shop, found bad HOv receptical, electrical called to repair. 31. Power house south wall outside offices - electric water heater had open hole in J-box, needs plugged. Ill LIGHTING SURVEY 1. Eight lights out over filter feed tanks and walkway area. 2. Six lights out on #9 washer and walkway lights in area out also. 3. Four lights out on crosswalk from sand classifiers to washers. 4. Seven lights out south^end of walkway on last washer. 5. 15 A and B building for pushing bauxite is very poor lighting - MSHA suggests mounting more lights on equipment to satisfy' requirements 4 additional on dozer and 6 total on front end loaders will eliminate need for permanent or portable light fixtures to light all of storage area in 15 A and B building. 000W9 MSHA INSPECTION August 1986 Page 4 IV CITATIONS Eight citations were issued during this inspection. These are listed below: 1. #2848949 - Windows and mirrors on Euclid #420 not being cleaned by operator - vision impaired. 2. #2848950 - Backup alarm not working on Euclid #420. Operator had not reported it broken and was still using the vehicle. 3. #2848951 - Front end loader #274 was being operated in the plant with defective parking brakes. Operator had not reported them to the Company. 4. #2848952 - Windshield, windows and mirrors on front end loader #274 not being cleaned by operator - vision impaired. 5. #2848953 - Electrical junction box open, flex conduit loose and electrical wires exposed at main entrance to 35 operating floor. Instrument department had installed a wire in box and not properly completed the job. 6. #2848954 - Facility 35 switch house had #3 SOP switch racked out without being tagged or locked as is required by procedure. 7. #2848955 - Agitator motor coupling guard off on north mix tank in 46 area. 8. #2849181 - D-7 Dozer #280 being used in 15 B building to push bauxite. Motor noise exceeded acceptable noise level. Operator not using hearing protection. Engineering (mechanical) controls noise before personal protection can be utilized as part of the permanent solution to this problem. V COMMENT It was pointed out during the inspection and at the close-out meeting that most every violation (those cited and those not cited) were ones that could* have been seen and corrected by supervisors on their normal daily work area inspections. 000^90 U. S. Department of Labor November 6, 1986 Mine Safety and Health Administration 1100 Commerce Street. Room 4C50 Dallas, Texas 75242 Mr. Dave Hopkins, Plant Mg Reynolds Metals Company P. 0. Box 9911 Corpus Christi, TX 78408 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I. D. No. 41-00906, Corpus Christi, Tex as, was conducted on October 28-29, 1986. The inspection was made pursuant to Public Law 91-173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. I.D. No. I.D. No. I.D. No. ACTIONS ON PREVIOUS VIOLS. Citations Citations Orders Orders Issue Term. Modify Extend. Rep by Ord Vacate I.D. No. 41-00906 Citations 0 0 0 3 I.D. No. Citations I.D.- No. Orders I.D. No. Orders 0 0 "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industry INCIDENCE RATES j Fatal 1 (Degree 1) NFDL (Degrees 2-5) Time Period .00 .94 Jan-June 1986 .ou -------- 3755------------------ Jan-June 1986 Sincerely, Doyr6 D. Fink Subdistrict Manager Metal and Nonmetal Mine Safety and Health (214)767-8401 OOOWU Form No. DS 5 3/83 U. S. Department Of Labor K November 6, 1986 Mine Safety and Health Administration 1100 Commerce Street. Room 4C50 Dallas, Texas 75242 Mr. Dave Hopkins, Plant Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, Texas 78408 Dear Mr. Hopkins: A Hazard Investigation of the Sherwin Plant, I.D. No. 41-00906, Corpus Christi, Texas, was conducted on October 7-9, 1986. The inspection was amde pursuant to Public Law 91173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. 41-00906 I.D. No. I.D. No. I.D. No. ACTIONS ON PREVIOUS VIOLS. Citations Citations Orders Orders Issue 2 Term. Modify Extend Rep by Ord Vacate 0000 0 I.D. No. I.D. No. I.D. No. I.D. No. Citations Citations Orders Orders "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industry Sincerely, Fatal (Degree 1) 0 0 INCIDENCE RATES NFDL (Degrees 2-5) 0 3.46 Time Period Jan. '86 thru June 1986 ............................................... Doyle D. Fink Subdistrict Manager Metal and Nonmetal Mine Safety and Health (214)767-8401 GOOWJO Form No. DS S 3/83 U. S. Department Of Labor r December 5 1986 Mine Safety and Health Administration 1100 Commerce Street. Room 4CS0 Dallas. Texas 75242 Hr. Dave Hopkins, Plant Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christ!, TX 78408 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I. D. No. 41-00906, Corpus Christi, Texas, was conducted on December 2, 1986. The inspection was made pursuant to Public Law 91173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. ActiSfts taken as a result of -this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. I.D. No. I.D. No. I.D. No. ACTIONS ON PREVIOUS VIOLS. Citations Citations Orders Orders Issue Term. Modify Extend Rep by Ord Vacate I.D. No. 41-00906 Citations 0 1 0 1 0 I.D. No. Citations I.D.- No. Orders I.D. No. Orders 0 "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industry INCIDENCE RATES Fatal (Degree 1) 1 ---------------- ------------------ NFDL (Degrees 2-5) .94 3746 Time Period Jan-June 1986 jan-juhe Sincerely, Ay' Doyle D. Fink Subdistrict Manager Metal and Nonmetal Mine Safety and Health (214)767-8401 000952 Form No. DS 5 3/83 U. S. Department of Labor February 6, 1987 Mine Safety and Health Administration 1100 Commerce Street, Room 4C50 Dallas, Texas 75242 Mr. Dave Hopkins, Plant Manager' Reynolds Metals Company P. 0. Box 9911 Corpus Christi, TX 78408 Dear Mr. Hopkins: A Federal inspection of the Sherwin Plant, I.D. No. 41-00906, Corpus Christi, Texas, was conducted on January 26, 1987. The inspection was made pursuant to Public Law 91173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below yith copies of those actions attached. This would be applicable only if there were contractors, present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. I.D. No. I.D. No. I.D. No. ACTIONS ON PREVIOUS VIOLS. Citations Citations Orders Orders Issue Term. Modify Extend Rep by Ord Vacate - I.D. No. I.D. No. I.D. No. I.D. No. 41-00906. Citations Citations Orders Orders 0 1 0 0 00 "If industrial hygiene samples were collected and no laboratory analysis was required results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industry 1 | | Fatal Degree 1) 0 0 INCIDENCE RATES NFDL Time (Degrees 2-5) Period .83 Jan-Sept. 1986 3.41 Jan-Sept. 1986 Sincerely, / Subdistrict Manager Metal and Nonmetal Mine Safety and Health 000WS6 Form No. DS 5-3/83 U. S. Department of Labor March 31, 1987 Mine Safety and Health Administration 1100 Commerce Street. Room 4C50 Dallas. Texas 75242 Mr. Dave Hopkins, Plant Manager Reynolds Metals Company P. 0. Box 9911 Corpus Christi, TX 78408 Dear Mr. Hopkins: & A Federal inspection of the Shervin M&nt, I. D. No. 41-00906, Corpus Christi, Texas, was conducted on March 24-27, 1987^/ The inspection was made pursuant to Public Law 91173 (83 STAT. 742) as amended by Public Law 95-164 (91 STAT. 1290). Any actions issued for contractor violations are included below with copies of those actions attached. This would be applicable only if there were contractors present during this inspection who have been issued a 3-digit identification number and who were cited for violations. Contractors receive copies of any portions of an inspec tion report relevant to them. Actions taken as a result of this inspection were: ORIGINAL ACTION THIS INSPECTION TYPE AND NUMBER OF ACTIONS: I.D. No. 41-00906 I.D. No. 41-00906 T6X I.D. No. 41-0Su> WA1 I.D. No. Citations Citations Orders Orders Issue 14 4 1 ACTIONS ON PREVIOUS VIOLS. Term. 9 0 1 Modify 0 0 0 Extend 0 0 0 Rep by Ord 0 0 0 Vacate __Q _____ 0 I.D. No. I.D. No. I.D. No. I.D. No. - Citations Citations Orders Orders "If industrial hygiene samples were collected and no laboratory analysis was required, results will be included in this report. However, if industrial hygiene samples were collected during this inspection and require laboratory analysis, you will receive a supplement to this Inspection Report upon completion of the analysis." This Operation Industry Fatal (Degree 1) 0 .01 INCIDENCE RATES NFDL (Degrees 2-5) .01 3.81 Time Period .Tar>--nor 1 QP6 Jan-Dec. 1986 Sincerely, // J) Doyle D. Fink Subdistrict Manager Metal and Nonmetal Mine Safety and Health (214)767-8401 000^5 Form No. DS 5 3/83 ;o QMPANY CORRESPONDENCE - O M: --* T 'O : Stan Mill sap < Dave Hopkins COPY: cate a 3-3JSCT: * Listed Below September 3, 1987 . .. MSHA INDUSTRIAL HYGIENISTS Roger Nelson Bi I! Warner Tom King Bob West Clinton Howard Dave Riner Rodney Walden Merfe Singleterry PauI Bucey Three MSHA Industrial Hygienists arrived at the plant at 10:00 AM on September 2, 1987. They came in response to the formal complaint filed by Ronnie Hesseltine. They checked only #8 and #9 evaporators being concerned with access to tubes, fumes, gases, ventilation, etc., when employees must enter effects to plug tubes or perform other work traditionally done inside these vessels without removing the domes. After an inspection and interviews with the Area Engineer (Rodney Walden), an Equipment Cleaning Supervisor (Buddy Hamilton) and the Union Representatives (Paul Bucey and Clinton Howard) they verbally gave u's their findings stating that the verbal report would be followed by a written report to verify. Listed below are their findings followed by some suggestions and alternatives: 1. There is no safe access to the top of the tubes in the effects of #8 and #9 evaporators without removing the domes. 2. Proper ventilation cannot be made available to top of tube sheet due to lack of openings in each effect without removing domes. 3. Liquor stream antifoam agents and additives in washing acids can produce various gases harmful to people - this must be analyzed. Listed below are actions required of us to eliminate the hazards and potential hazards to the men working in the top of #8 and #9 evaporator effects: 1. Cut an access port in the side of each effect above the tube sheet and below the dome. This will allow ventilation fans to be used and the result will be proper ventilation and safe access. Alternative - remove the dome before anyone is a/lowed to enter an evaporator effect. Recommendation - it is my recommendation that properly sized access ports be provided on each evaporator effect.- A project for this was started in 1985 by Chuck Taylor but was stopped when these evaporators were taken out of service, it was not picked up again when the evaporators were put.back in service. GOOCHS -2 2. The air and gases must be analyzed in the next evaporator effect taken out of service after acid cleaning. This must be done by a qualified chemist before the effect is opened and vented at the top. Readings must be recorded for oxygen, combustible gases, carbon dioxide, carbon monoxide and hydrogen. Also samples of any foam present must be taken with one sample being analyzed by our Laboratory and one held for possible shipment to MSHA In Denver. Alternative - we can do the sampling and analysis if the sampling is witnessed by Union Representatives to verify they were taken and the Chemist must certify the readings. Or - MSHA must be notified in time for them to do the testing and analysis them selves. Recommendation - I recommend that Serment Guerra be designated to collect the samples while Bucey, Howard and I watch. He can then document any readings he gets and MSHA will call me to give readings over the phone. It should be noted that no citations were written because the evaporators were in service and could not be checked internally. The next time MSHA checks however, could be different if we cannot show them physical evidence of of changes to equipment of* a JSP establishing the requirement for pulling domes any 'time we must send a man into an evaporator effect. 0005*86