In late February, a steam explosion at a Schumann & Co. metals plant in Bedford, Ohio caused one fatality (a maintenance supervisor) and sent 15 other crew members to the hospital, 2 in critical condition at the time. An investigation has uncovered the reasons the accident occurred.
Image of the wall blown off in the Ohio Foundry Explosion
Michael Swensen/Getty Images – NPR
According to OSHA’s investigation, maintenance personnel were inspecting a water leak on a furnace used for smelting solid metals when the steam explosion happened. It was caused by water having leaked onto the molten metal inside of the furnace. Several safety violations led up to this event.
Before OSHA released an announcement on August 14th, citations were issued officially on August 4th for 6 violations:
1. Employees should be protected from recognized dangerous or fatal hazards. In this case, the hazard was steam explosions caused by water filtration into molten metal. It was found that the February incident was not the only time the crew wasn’t protected from this danger.
2. Procedures should be in place and followed to control potentially hazardous energy when employees are performing work in the area. Schumann & Co. did not ensure the procedure was followed to control the “hazardous gravitational, water, thermal, electrical, natural gas, and oxygen gas energy sources” while one of the rotary furnaces was being inspected by maintenance personnel.
3. Schumann & Co. did not make sure that lockout or tagout procedures were followed by maintenance personnel. These procedures included shutting down the furnace electrical rotation drive motor, both isolating and affixing lockout devices natural gas, oxygen gas, and electrical energy sources in the furnace, among others. Use the link to the violations for a complete list of violations in this section.
4. Failure to ensure that authorized employees (in this case the maintenance lead and maintenance supervisor) had affixed a personal lockout or tagout device to a group lockout device, group lockbox, or other comparable mechanism before inspecting (the furnace).
5. Procedures should outline the control of hazardous energy in complete detail. The organization failed to clearly identify specific procedural steps while inspecting the furnace for water leaks for safe shutdown, isolating, blocking, and securing the electrical, water, and thermal (liquid molten metal bath) energy sources. These procedures are in place to prevent the release of water from contacting the liquid molten metal bath (thermal energy) inside the furnace and causing a steam explosion.
6. Schumann & Co. did not ensure that a periodic inspection of the lockout/tagout procedure for the furnace was being performed at least annually. This inspection exists to make sure that the procedures and standards are being followed.
The citations total a proposed $62,500 in penalties. The organization has 15 days to comply with citations and penalties.
The Ohio foundry steam explosion is unfortunately one of many that highlights the importance of safety procedures including lockout/tagout, shutting down equipment when needed, and regular inspections and reviews of procedures.
The magnitude of the diesel technician shortage in the United States is creating significant challenges for the transportation industry. To combat this shortage, efforts are being made to encourage students to pursue a career as a diesel technician, with innovative initiatives aimed at piquing their interest.
The magnitude of the diesel technician shortage in the United States is creating significant challenges for the transportation industry. To combat this shortage, efforts are being made to encourage students to pursue a career as a diesel technician, with innovative initiatives aimed at piquing their interest.
The US Navy is facing significant challenges procuring spare parts for their submarine fleet, greatly impacting their maintenance program. Nearly 40% of the Navy’s attack submarines are either undergoing repairs or awaiting maintenance. The issue has been attributed to a shortage of skilled workers, delays at shipyards, and disruptions in the supply chain.
The US Navy is facing significant challenges procuring spare parts for their submarine fleet, greatly impacting their maintenance program. Nearly 40% of the Navy’s attack submarines are either undergoing repairs or awaiting maintenance. The issue has been attributed to a shortage of skilled workers, delays at shipyards, and disruptions in the supply chain.
As in all industries, predictive maintenance, AI, and sustainability goals are shaping the textile industry in 2024. What are some of the changes and new products that we will see this year? This article will also explore common equipment used in textile mills, reliability and maintenance advice, and safety tips for the textile workforce.
As in all industries, predictive maintenance, AI, and sustainability goals are shaping the textile industry in 2024. What are some of the changes and new products that we will see this year? This article will also explore common equipment used in textile mills, reliability and maintenance advice, and safety tips for the textile workforce.
An industrial outbreak of blastomycosis is being investigated at a paper and packaging mill in Escanaba, Michigan. This is the first fungal outbreak of its kind in the history of the United States and the mill has decided to temporarily halt operations to ensure the health and safety of workers.
An industrial outbreak of blastomycosis is being investigated at a paper and packaging mill in Escanaba, Michigan. This is the first fungal outbreak of its kind in the history of the United States and the mill has decided to temporarily halt operations to ensure the health and safety of workers.
The manufacturing industry is increasing its efforts in reusing and recycling copper scraps due to a projected doubling in copper demand by 2035. What applications can copper be used for? Why is the demand for copper growing? How is recycled copper used and what are the environmental benefits of recycling more copper?
The manufacturing industry is increasing its efforts in reusing and recycling copper scraps due to a projected doubling in copper demand by 2035. What applications can copper be used for? Why is the demand for copper growing? How is recycled copper used and what are the environmental benefits of recycling more copper?
Mechanical insulation is referred to some in the industry as the "forgotten technology" or the "best kept secret." Why is it so often overlooked? What is mechanical insulation and how is it used? What are the best ways to use it in the manufacturing industry? Why should companies consider using mechanical insulation in their plants?
Mechanical insulation is referred to some in the industry as the "forgotten technology" or the "best kept secret." Why is it so often overlooked? What is mechanical insulation and how is it used? What are the best ways to use it in the manufacturing industry? Why should companies consider using mechanical insulation in their plants?
The surge in battery manufacturing in the US, fueled by a significant investment of up to $3.5 billion from the Infrastructure Law, marks a pivotal step towards achieving a net-zero emissions economy by 2050 and a notable shift towards electric vehicles. The funds are set for upgrading facilities, creating well-paid union jobs, and establishing a robust domestic supply chain. What new technology is being applied? How do we keep manufacturing personnel safe in these facilities?
The surge in battery manufacturing in the US, fueled by a significant investment of up to $3.5 billion from the Infrastructure Law, marks a pivotal step towards achieving a net-zero emissions economy by 2050 and a notable shift towards electric vehicles. The funds are set for upgrading facilities, creating well-paid union jobs, and establishing a robust domestic supply chain. What new technology is being applied? How do we keep manufacturing personnel safe in these facilities?
