Draft 11 28 2011 Boiler Safety John Newquist.

Draft Boiler Safety John Newquist

$1.6 million settlement reached in boiler explosion
Daniel J. Quaintance, 56, of Appleton was following directions from a technician employed by the service company, when the boiler exploded. Quaintance suffered a traumatic brain injury as well as extreme blood loss, numerous broken bones in his face, respiratory failure, eye damage, hearing loss and some facial nerve damage, according to his lawyers. After the explosion, he was airlifted to Theda Clark Medical Center in Neenah, where he was hospitalized for more than a month, his lawyers said. A former maintenance worker at Appleton Medical Center who was seriously injured when a manhole cover blew off a boiler and struck him in the head in 2009 has reached a $1.6 million settlement with the company that was servicing the boiler and its insurance companies, according to the worker's attorneys. Daniel J. Quaintance, 56, of Appleton was following directions from a technician employed by the service company, BurCon Services, Inc. of Green Bay, when the boiler exploded, a news release from attorneys at Habush Habush and Rottier says. Quaintance suffered a traumatic brain injury as well as extreme blood loss, numerous broken bones in his face, respiratory failure, eye damage, hearing loss and some facial nerve damage, according to his lawyers. After the explosion, he was airlifted to Theda Clark Medical Center in Neenah, where he was hospitalized for more than a month, his lawyers said. Quaintance contended the explosion was a result of the BurCon worker's negligence, according to the complaint. Although Quaintance suffered some permanent residual effects from the explosion, he recovered enough to return to work within about six months, according to his attorney, Craig Christensen. About $90,000 of the settlement money has been set aside for future medical expenses, according to the agreement. "I think most people would be shocked that he wasn't killed," Christensen said Tuesday. "I think he's very thankful that he's been able to make the recovery to the extent he has and get on with his life as best he can." The BurCon worker who was in the boiler room with Quaintance at the time of the explosion was treated for minor injuries and released from Appleton Medical Center, Christensen said. The hospital was not evacuated, he said. The main impact on patients was that surgical instruments were not able to be sterilized for a period of time, he said. Daniel Hurst, a lawyer who represents BurCon and Cincinnati Insurance Co., was out of the country and could not be reached Tuesday. They continue to allege that Hurst Boiler, which manufactured the unit, bears some of the responsibility for the explosion because of negligent design, Christensen said.

Problem Over a hundred boiler explosions and fires in the last ten years. These are pressure vessels. People assigned to operate and maintain the boilers have little or no boiler safety training.

Ford River Rouge Power Plant
2/1/1999 Dearborn, MI General Duty egregious, 1.5M Natural gas boiler explosion triggered secondary coal dust explosion that had accumulated on building and equipment surfaces No flame sensing interlock for the gas lines On February 1, 1999 a natural gas explosion at the power plant for the Ford River Rouge facility near Dearborn, Michigan, triggered subsequent secondary explosions of coal dust that had accumulated on surfaces in the plant. Six people died and another 30 were injured. The power plant had to be completely rebuilt. Six employees were taking a boiler off-line for maintenance. A natural gas valve was inadvertently left open. When a secondary butterfly valve was opened for purging, gas entered the unfired boiler which was still hot. This resulted in an explosion in the boiler and that explosion caused secondary explosions from coal dust that had accumulated on building and equipment surfaces. All six employees were killed in the explosion. Cause and contributing factors The explosion occurred as maintenance workers and welders shut the boiler down so that it could be serviced. The boiler operators had turned the burners off from the control room so that a blank could be installed in the west gas line to start a nitrogen purge flow between the second-floor manual valve and the boiler. In the process, the main valves on the natural gas lines are normally turned off. The operator then opens the burner valves to allow the purged gas to pass through the boiler. Employees in the final stages of inserting the blank opened the gas valves to the west burners and to the east natural gas burners. However, the manual natural gas valve on one of the main gas lines on the second and third floors had not been closed, and gas flowed into the boiler through the three east natural gas burners mixing with air from an operating forced-draft fan for 90 to 120 seconds before the flammable mixture was ignited, probably by hot fly ash residue or the discharge of the electrostatic precipitator. Moments before the explosion, an employee in the control room noticed the mistake and tried to alert the crew, but it was too late. The resulting explosion vented flames and hot gases that raised dense coal dust clouds from the accumulated layers in the building. These dust clouds ignited, causing secondary explosions to propagate through the boiler house to remote areas such as the pulverizer building. The MIOSHA report concluded that several factors contributed to the incident. Among these were the lack of operating igniter and flame-sensing interlocks that would have prevented natural gas flow into the furnace without any flame or igniter and the lack of specific written procedures for shutting down and blanking the natural gas lines. Communication among the boiler operators and the crew performing the gas line blanking procedure was also inadequate. Six people died and another 30 were injured

Injury Prevention Basics
These principles are adopted and recognized by… 2100 VPP Companies 1600 SHARPs , ANSI Z9.10 OHSAS 18001 States AR, CA, LA, HI, MN, MT NV, NH, NY, OR, WA Management Leadership Employee Participation Hazard Prevention and Control Education and Training Program Evaluation and Improvement Communication and coordination on multi-employer sites

Top Five Accident Causation Factors
Maintenance Lockout Startup/Re-ignition Falls Carbon Monoxide

Documentation Plant history of fires Boiler logs Operating manual?
Maintenance manual? Repair History Take Photos Interviews – Boiler Maintenance Technician, Maintenance Supervisor. Companies such as Trainco offer Boiler Maintenance Classes Do all boiler operators know how to operate the boiler within the permit limits? At the beginning of each shift, how do the boiler operators make sure the equipment is operating properly? Where the boiler’s operating and maintenance manual? What training have the Boiler Operators received?

Boiler Log The boiler room log lists boiler operation data that can be used to increase boiler safety and efficiency as well as identifying a potential malfunction. A boiler room log is used to record information regarding operation of the boiler during a given period of time. The number and frequency of the checks to be performed depend on the plant. Some plants maintain a log for every 8-hour period. Other plants maintain a log for a 24-hour period. Maintaining a boiler room log allows the operator to evaluate the past performance of the boiler. In addition, boiler room log information can be useful in determining the cause of a malfunction and/or predicting a possible problem. DISCLAIMER: This material was produced under grant number SH from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U. S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U. S. Government. The U.S. Government does not warrant or assume any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed. 8-8

Warning Signs All boilers that are required to have operating certificates shall have a manufacturer's nameplate attached. The nameplate shall have the appropriate ASME Code symbol, the allowable working pressure, date of manufacture, and the minimum relief valve capacity.

Inspections Regular service should be performed on schedule and recorded. Operating records and inspection records should be reviewed regularly to ensure compliance. Environmental Inspection Post a copy of the air operating permit near the boiler Ensure all boiler operators know how to operate the boiler within the permit limits At the beginning of each shift, make sure the equipment is operating properly Boiler operators should be familiar with the boiler’s operating and maintenance manual Regular service should be performed on schedule and recorded Operating records and inspection records should be reviewed regularly to ensure compliance

Inspection Water and scale buildup on floor indicates the relief valve might have been leaking past seat for some time. This valve should be replaced as soon as possible as it could scale up and become inoperative.

Backflow Preventer Back flow preventer showing scale buildup on drain opening. This indicates the back flow preventer needs to be tested for proper operation.

Relief Valve Test Relief valves are routinely tested to ensure proper operation and must be serviced by an authorized manufacturer representative. There is no routine maintenance on a safety valve. However, safety valves are routinely tested to ensure proper operation. Safety valves are commonly tested by lifting the safety valve try lever.. With the boiler pressure at a minimum of 75% of the safety valve set pressure, the safety valve try lever is lifted to wide open position. Steam is discharged for 5 sec to 10 sec. The try lever is released, and the disk should snap to the closed position against the valve seat. Malfunctioning safety valves must be replaced as soon as possible. Replacement safety valves must comply with the ASME Boiler and Pressure Vessel Code and all design specifications of the boiler. Any adjustments or repairs to a safety valve must be performed by the manufacturer or an authorized manufacturer representative. An evaporation test can also be used it is more accurate because it replicates a more realistic situation The feedwater is secured and water is allowed to evaporate. This is not necessary if a proper type cutoff is used. PPE used for this testing would general require insulation gloves. Refer to your company safety plan for instructions. DISCLAIMER: This material was produced under grant number SH from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U. S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U. S. Government. The U.S. Government does not warrant or assume any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed. 8-13

Manual Test of Relief Valve
The manual test lever on the relief valve should be lifted on a regular basis to determine the valve is functioning properly. The pressure in the boiler should be at least 75% of the set pressure of the relief valve.

Low Water Cutoff Valve This device detects if the water level within your boiler has dropped below the manufacturers recommended level. Should this occur, the low water cutoff will do just as its name implies. It will cut-off the burner and shut the boiler down. Without a properly functioning low water cutoff, the burner can continue to fire allowing for intense heat to build. The results can be catastrophic - explosions, fires and the possibility of severe injuries to personnel and property. This must be a regular boiler test per the Manufacturer’s guidelines. Image from During 1996, a total of 1,211 incidents were reported in North America with respect to heating boilers (both steam and water) and 602 of them (fully 49.7%) were caused by a low water condition. Of the remaining 609 incidents, 346 were reportedly caused by operator error or poor maintenance. This shows that over 78% of all incidents involving heating boilers occur as a result of low water condition and/or operator error or poor maintenance. LOW WATER FUEL CUT OFF shuts off fuel to the burner in the event of a low water condition in the boiler. The low water fuel cut off is located 2" to 6" below the boiler water level. Low water fuel cut offs operate using an electric probe or a float sensor, if the sensor indicates a low water condition a contact to the main burner control circuit opens and shuts down the main gas. Low water fuel cut offs should be tested monthly or more often depending on usage or requirements. If a low water condition is not properly sensed and the gas train does not shut down, the boiler can overheat . Overheated boilers will be permanently damaged. If the safety valve has not been serviced properly and does not relieve the pressure adequately, the boiler may explode and result in injury or worse.

Water Level The Normal Operating Water Level (NOWL) should be approximately in the middle of the gauge glass. Ensuring proper water level may be the most important duty of an operator. The gauge glass is the primary devise used in determining water level and must be maintained in proper condition. It is connected to the water column which levels out the turbulent water in the boiler so it can be accurately read. DISCLAIMER: This material was produced under grant number SH from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U. S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U. S. Government. The U.S. Government does not warrant or assume any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed. 8-16

Blowdown The water column is blown down first and then the gauge glass to remove any sediment. Water should enter the gauge glass quickly when the gauge glass blowdown valve is closed. When blowing down the water column and gauge glass, the operator should carefully monitor the action of the water in the gauge glass. Water should enter the gauge glass quickly when the gauge glass blowdown valve is closed, indicating that the lines are free of sludge, sediment, or scale buildup. If the water returns sluggishly to its normal level, there may be an obstruction partially blocking the flow of water. If the apparent obstruction cannot be removed by blowing down, then the boiler should be shut down and allowed to cool. If the gauge glass is integrated with the low water fuel cutoff, the float (or probe) chamber should be opened and inspected. Mud, scale, or sediment deposits should be removed completely. Linkage should also be examined to ensure proper working order. All connecting piping should be inspected for any obstructions. DISCLAIMER: This material was produced under grant number SH from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U. S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U. S. Government. The U.S. Government does not warrant or assume any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed. 8-17

Another Accident "The fines reflect the company's failure to establish procedures for a restart of the recovery boiler without the power boiler being on-line," said Clyde Payne, OSHA's area director in Jackson, Miss. "Employees were exposed to a fire and explosion because the employer failed to develop written boiler setup and operating procedures.” 23 employees were injured, one fatally. The willful violation is for failing to start the recovery boiler without adequate steam and not developing safe procedures to start up the recovery boiler when the primary power boiler is off-line. Several overhead doors were blown off, and one of these struck 4 employees, injuring them.

Boiler Restarting Many accidents during this process
Employee #1 and a coworker were assigned to light a boiler with a series of three pilot lights. They found the gas valve already in the open position. Employee #1 tried to light the third pilot light, which was out of sequence with the lighting directions on the metal plate located on the front of the Peerless low pressure boiler. When the third pilot light would not ignite, Employee #1 went to the first pilot light and attempted to light it when an explosion occurred. Employee #1 and the coworker were blown approximately 10 ft away. Many accidents during this process Exact Start up Procedures Trained Operators Knowledge of what to do if there is a problem Employees #1, #2, #3, #4, and #5 were restarting the recovery boiler under a partial-natural-draft. The power boiler was not online at the time. The boiler exploded. Employee #1 turned on the ignition switch to relight the heater, however, the pilot did not come on, and he heard some rattling noise from the valve. So employee #1 turned off the switch. Employee #1 again turned on the ignition switch and asked the Employee #2 to bend down and see if the heater had ignited. As Employee #2 bent to see the pilot, a flare up occurred which burned Employee #1 and employee #2's face. Employee #1, a systems operator, and Employee #2, were present at the job site while Employee #3, was performing inspections on a boiler. The boiler installation was performed by a third party. During the final installation check up, the third party reported that the boiler would not light off. Employee #3 was sent to perform start-up checks on the boiler. During this process, the boiler exploded. Employee #1 was instantly killed, Employee #2 was seriously injured and Employee #3 was critically injured. Employee #1, #2, and other coworkers were restarting the boiler in the Steam Unit, when the boiler catastrophically failed. The boiler explosion threw Employee #1 under the structure of the B27 boiler, causing him to sustain fatal blunt force trauma. A coworker and Employee #2 suffered unspecified injuries. Employee #2 was transported to a medical center, where he received treatment and was hospitalized The employee went through relighting procedures and then placed a burning wick into the locomotive boiler fire box and opened the fuel line. Due to the position of the wick, more fuel vapor than normal entered the box before the fire lit. This caused a flash fire that came out of the firebox door and struck the employee. Accident One Employee Is Killed, Four Others Are Injured in Explosion Accident Report ID: Event Date: 05/03/2008 Inspection: Open: 05/05/ SIC: M-Co, Inc. Inspection: Open: 05/05/ SIC: Hydrochem Industrial Services, Inc. On May 3, 2008, Employees #1, #2, #3, #4, and #5 were restarting the recovery boiler under a partial-natural-draft. The power boiler was not online at the time. The boiler exploded, and Employee #1 was blown over a standard guard railing on the South side of the sixth floor. He fell down some 25 ft on a scaffold staging. He died from blunt force trauma to the chest. His injuries included lacerations to his both lungs, diaphragm, liver, and thoracic aorta. Employees #2, #3, #4 were burned, and they were hospitalized. Employee #5 sustained sprain and strain of his ankle and was not hospitalized. Review: I Keywords: construction,boiler,fall,scaffold,chest,laceration,lung,liver,burn,sprain, End Use Proj Type Proj Cost Stories NonBldgHt Fatality Powerplant Maintenance or repair $250,000 to $500, X Inspection Age Sex Degree Nature Occupation Construction Marcus Broome 28 M Fatality Burn/Scald(Heat) Occupation Not Reported FallDist: 23 Cause: Installing metal siding FatCause: Fireproofing Robert Townsend 28 M Hospitalized Burn/Scald(Heat) Occupation Not Reported FallDist: 23 Cause: Installing metal siding Kenneth Townsend Eric Wilhite 25 M Hospitalized Burn/Scald(Heat) Occupation Not Reported Jimmy Smith 23 M Non Hospitalized Strain/Sprain Occupation Not Reported Accident Workers Suffer Minor Burns During Boiler Maintenance Accident Report ID: Event Date: 08/27/2007 Inspection: Open: 09/07/ SIC: Acco Engineering Systems (Ymca) At approximately 10:30 AM on August 27, 2007, Employee #1 and Employee #2 were performing a regular maintenance on boiler heater (Teledyne Laars, Model # PW1670IN09C1AR, Serial # ). After performing the maintenance, employee #1 turned on the ignition switch to relight the heater, however, the pilot did not come on, and he heard some rattling noise from the valve. So employee #1 turned off the switch and called his supervisor over the phone for further technical assistance. Employee #1 again turned on the ignition switch and asked the Employee #2 to bend down and see if the heater had ignited. As Employee #2 bent to see the pilot, a flare up occurred which burned Employee #1 and employee #2's face. This explosion disappeared after 1-2 seconds. Nothing else was burned or blackened in the boiler room where other 3 boilers were present. Both employees were taken to the Stanford Hospital where they were observed and released. It was determined that both employees suffered minor first-degree burns. Review: Keywords: burn,boiler,explosion,heater,face,pilot light,electric switch,valve,ignition system, Kevin Fraumeni 41 M Non Hospitalized Burn/Scald(Heat) Mechanical Engineering Technicians Mattew Murphy 20 M Non Hospitalized Burn/Scald(Heat) Mechanical Engineering Technicians Accident Boiler Vessel Explodes During Inspection Process Accident Report ID: Event Date: 11/01/2004 Inspection: Open: 11/02/ SIC: Viking Explosives & Supply, Inc. Inspection: Open: 11/02/ SIC: O'connor Company On November 1, 2004, Employee #1, a systems operator, and Employee #2, a supervisor, working for Viking Explosives and Supply Inc., were present at the job site while Employee #3, a technician working for the O'Connor Co., was performing inspections on a boiler in Gillette, WY. Viking Explosives and Supply Inc. purchased the replacement boiler from the O'Connor Co. On November 29, 2004, the boiler installation was performed by a third party, Powder River Heating and Air Conditioning Inc. During the final installation check up, the third party reported that the boiler would not light off. As part of the purchase contract, the O'Connor Co. sent Employee #3 to perform start-up checks on the boiler. During this process, the boiler exploded. Employee #1 was instantly killed, Employee #2 was seriously injured and Employee #3 was critically injured. Review: I Keywords: boiler,explosion,installing,vessel--container,puncture,laceration,concussion, Mark Haratayk 25 M Fatality Puncture Miscellaneous Plant and System Operators Bruce Carson 53 M Hospitalized Cut/Laceration Supervisors, Mechanics and Repairers Lance Manning 32 M Hospitalized Concussion Mechanical Controls and Valve Repairers Accident Report ID: Event Date: 04/04/2004 Inspection: Open: 04/19/ SIC: Disneyland Resort At approximately 9:00 p.m. on April 4, 2004, Employee #1 was operating a steam locomotive at the Disneyland resort. As the train approached block light Number 8, the engine lost fire to the boiler. The employee went through relighting procedures and then placed a burning wick into the fire box and opened the fuel line. Due to the position of the wick, more fuel vapor than normal entered the box before the fire lit. This caused a flash fire that came out of the firebox door and struck the employee. He suffered second-degree heat burns through his clothing on both knees and first- and second-degree flash burns on his wrist and face. He was hospitalized for 2 days with his injuries. Review: I Keywords: fire,burn,amuse park/carnival ,locomotive,knee,wrist,face,equipment operator,flammable vapors, Donald Philpott 58 M Hospitalized Burn/Scald(Heat) Locomotive Operating Occupations Accident Employee Injured When Boiler Explodes Accident Report ID: Event Date: 11/26/2003 Inspection: Open: 11/26/ SIC: Henderson County Boe - Henderson County Schools At approximately 8:00 a.m. on November 26, 2003, Employee #1 and a coworker were assigned to light a boiler with a series of three pilot lights. They found the gas valve already in the open position. Employee #1 tried to light the third pilot light, which was out of sequence with the lighting directions on the metal plate located on the front of the Peerless low pressure boiler. When the third pilot light would not ignite, Employee #1 went to the first pilot light and attempted to light it when an explosion occurred. Employee #1 and the coworker were blown approximately 10 ft away. Employee #1 was hospitalized with bruises and contusions. Review: I Keywords: explosion,boiler,gas,contusion,abrasion,vapor,work rules,head, Cosby Shelton 41 M Hospitalized Bruise/Contus/Abras Occupation Not Reported Accident Two Employees Are Killed and One Injured in Boiler Explosion Accident Report ID: Event Date: 08/17/2002 Inspection: Open: 08/19/ SIC: Durango - Georgia Paper Company On August 17, 2002, Employees #1 and #2 were attempting to relight the Number 2 recovery boiler. They were standing at the fuel oil gun ports on the first floor when the boiler exploded, spraying out steam and condensate, hot black liquor, smelt, and boiler parts over the surrounding area. Employees #1 and #2 suffered severe scalding and chemical burns and were killed. Employee #3, who was working in the basement approximately 50 feet west of the boiler, also suffered severe scalding and chemical burns, for which he was hospitalized. Review: I Keywords: boiler,explosion,burn,paper,mill--plant,chemical burn,flying object,process safety,pressure vessel,ppe, Mr. John Stephenson 53 M Fatality Burn/Scald(Heat) Production Helpers Mr. Brad Foreman 33 M Fatality Burn/Scald(Heat) Production Helpers Mr. David Boeck 30 M Hospitalized Burn/Scald(Heat) Production Helpers Accident Employee Is Burned in Boiler Explosion, Later Dies Accident Report ID: Event Date: 07/24/2002 Inspection: Open: 07/25/ SIC: Prillaman & Pace, Inc. On July 24, 2002, Employee #1 was trying to start the #2 boiler when a coworker put a jumper on an atomizer in an attempt to energize the circuit. The main fuel switch was controlled by this circuit. When it energized, fuel was fed into the boiler. The fuel ignited and the boiler exploded. Employee #1 sustained burns over 80 percent of his body. He was transported to a hospital, where he died several days later. Review: I Keywords: burn,explosion,boiler,fire,combustible dust,fuel oil,work rules,communication, Manufacturing plant Maintenance or repair Under $50, X John L. Gregory 48 M Fatality Burn(Chemical) Occupation Not Reported FallDist: 23 FatCause: Installing equipment (HVAC and other) Accident Employees Injured When Boiler Explodes Accident Report ID: Event Date: 01/14/2002 Inspection: Open: 01/14/ SIC: Chesapeake Bay Middle School On January 14, 2002, Employee #1 and Employee #2, building engineers for Chesapeake Bay Middle School of Anne Arundel County Schools were struck and burned when a boiler (Hurst Boiler number 2, Model , serial number FB ) exploded. The boiler exploded when the accumulated fuel oil vapor was ignited inside of the boiler. The fuel oil vapor built up due to numerous resets by the employees that morning. Employee #1 received first degree burns on his face and second degree burns on his hands. Employee #2 received a concussion and damage to the neck. Review: I Keywords: boiler,explosion,concussion,neck,fuel oil,burn,face, Qamar Ahmad 50 M Non Hospitalized Burn/Scald(Heat) Engineers, N.E.C. Michael Marshall 42 M Non Hospitalized Burn/Scald(Heat) Engineers, N.E.C. Accident Employee Sustained Burns When Natural Gas Ignites Accident Report ID: Event Date: 11/28/2001 Inspection: Open: 12/07/ SIC: La City Fire Stn 10 At approximately 6:45 p.m. on November 28, 2001, Employee #1, an apparatus operator of the Fire Department at Fire Station Number 10, located in Los Angeles, California was attempting to relight the pilot light of the boiler, which provides heat to the station. The boiler was not used the past summer and apparently the pilot lights were off. As Employee #1 opened the access door to the main burner and pilot light, an undetected cloud of natural gas got ignited and flashed onto face of Employee #1. He sustained first and second degree burns to the face and neck, as well as first, second, and third degree burns on forearms. Employee #1 was hospitalized. According to reports, Employee #1 lighted the pilots but observed that the boiler was not giving off heat. He opened the burner door to find out what was wrong and then the flames flashed onto his face. Review: I Keywords: gas,burn,face,heat,pilot light,natural gas,neck,forearm,boiler,fire fighter, Gary Smith 35 M Hospitalized Burn/Scald(Heat) Firefighting Occupations Accident Employee Injured in Gas Explosion Accident Report ID: Event Date: 11/26/2001 Inspection: Open: 02/14/ SIC: West Coast Recycling Co. At about 12:30 p.m. on November 26, 2001, Employee #1 was assisting with relighting a gas-fired boiler. Gas apparently collected inside of the boiler after several unsuccessful lighting attempts, fueling an explosion which blew off the boiler's end cover, striking Employee #1 in the head. He was hospitalized with a concussion. The ignition source could not be determined. Review: I Keywords: gas,explosion,boiler,pilot light,struck by,flying object,concussion,head, Terry Wilson 33 M Hospitalized Concussion Occupation Not Reported Accident Gases Building Up in A Boiler Ignite and Burns Worker Accident Report ID: Event Date: 11/16/2001 Inspection: Open: 11/16/ SIC: Parsons Energy & Chemical Group Inc At approximately 1:30 p.m. on November 16, 2001, Employee #1, a 21-year-old male, with Parsons Energy & Chemical Group Inc, that operates cogeneration facilities for UCLA. Employee #1 was in the facility where waste heat from boilers is harnessed to generate electrical power. Employee #1 was restarting a stand-by/waste heat boiler; the boiler did not fire the first time it was started, so Employee #1 made a second attempt to fire the boiler, which triggered an explosion in the forced draft fan area (which feeds fresh air and by-pass flue gas.) Employee #1 sustained cuts and a first degree burn on his face. It is suspected that the purging of unused gasses may not have been complete and unused gasses may have been by-passed back to the system causing the explosion at the fan. Review: I Keywords: burn,boiler,gas-fired boiler,gas,ignition system, Philip Egelston Iii 21 M Non Hospitalized Cut/Laceration Supervisors, Production Occupations Accident Employee Burned in Boiler Flareback Accident Report ID: Event Date: 10/24/2001 Inspection: Open: 10/30/ SIC: Sacramento Co. Pwa / Dgs / Facilities Management Employee #1 found a boiler, which was turned on, to be cool. He flipped the switch to turn the system off and squatted down to check the pilot light. He was caught in a flareback as the unvented gas ignited. He suffered second and third degree burns to his hands, arms, and face and was hospitalized. Review: I Keywords: gas,flashback,hand,arm,face,burn,venting,explosion, Guy Alcartado 45 M Hospitalized Burn/Scald(Heat) Stationary Engineers At approximately 8:45 p.m. on December 4, 2009, Employee #1, #2, and other coworkers were restarting the B28 boiler in the Steam Unit, when the boiler catastrophically failed. The boiler explosion threw Employee #1 under the structure of the B27 boiler, causing him to sustain fatal blunt force trauma. A coworker and Employee #2 suffered unspecified injuries. Employee #2 was transported to a medical center, where he received treatment and was hospitalized.

Boiler Fall Many falls occur due to work on boilers Scaffold (10)
Boiler Supports/Platform (6) Ladder (4) Floor Opening (4) Unknown Platform (3) Aerial lift (2) Metal Grate Failure Tripped over Boiler piping Cheater Bar slipped and fall backwards Accident Fall From Scaffold Accident Report ID: Event Date: 05/26/2010 Inspection: Open: 06/30/ SIC: Safeway Services Lp Worker 1 was a member of a work team that was dismantling a scaffold that had been erected inside a large boiler, which was part of a power generation plant. An unrelated company had used the scaffold to gain access to all areas of the inside walls of the boiler to clean them. The cleaning process produced a large amount of fine, dark-colored dust on scaffold parts and working platforms. As the planks and frames of each level of the scaffold had been removed, more of the dark-colored dust began to fill the air and settle on the scaffold planks below. By the time all but a couple of planks remained on the second to lowest tier, Worker 1 repositioned himself on the lowest tier in order to reach up and remove the two planks remaining above him. Since the lowest tier was protected by rails on the outside and the wall of the boiler on the inside, Worker 1 believed it was no longer necessary to tie off. At this point in the operation, there was a lot of activity on the lowest tier with workers moving toward the area where scaffold parts were being handed down. There was also a lot of dust in the air which diminished the available light. Worker 1 was walking on the platform planks near the wall while moving to the drop-off point. Unknown to him, someone had removed two inside planks from that working platform and he fell through the hole to the floor approximately feet below. End Use Proj Type Proj Cost Stories NonBldgHt Fatality Commercial building Other Under $50, Inspection Age Sex Degree Nature Occupation Construction Aaron Muffi 35 M Hospitalized Fracture Carpenters FallDist: 16 FallHt: 27 Cause: Temporary work (buildings, facilities) FatCause: Temporary work (buildings, facilities) Accident Employee Fractures Wrist in Fall Accident Report ID: Event Date: 04/24/2010 Inspection: Open: 05/03/ SIC: La County Usc Medical Center At approximately 7:00 a.m. on April 24, 2010, Employee #1, a stationary engineer, was opening an overhead main feed water valve in the attempt to supply water to a boiler that had been shut down, and was being restarted. Employee #1 ensured that the boiler was in a safe condition to restart and that all the valves and controls were in the proper position. Then she began to open the main feed water valve to the boiler that is located over-head and can be opened through a chain drop between boilers three and four. While Employee #1 was opening the valve, she stepped backwards to better view the valve, when she tripped over a permanently installed pipe. The pipe was located 11 inches above the floor and took up about 12 inches in width of the walkway. Employee #1 was taken to the employer's on-site infirmary, where she was treated for a fractured left wrist. The incident investigation concluded that the walkway between the boilers did not lead directly to an exit, but did have impaired clearances that were not posted, guarded, or barricaded, and that presented a tripping hazard. Review: I Keywords: fall,fracture,tripped,work surface,wrist,manual mat handling ,valve,pipe, Jeannie Reynolds 66 F Non Hospitalized Fracture Stationary Engineers Accident Employee Is Killed in Fall From Scaffold Accident Report ID: Event Date: 04/21/2009 Inspection: Open: 04/21/ SIC: Dale Bolton Enterprises, Llc D.B.A. First Coast Sc On April 21, 2009, Employee #1 was working in the unit 2 boiler room dismantling scaffolding. He fell approximately 133 ft from the upper deck through an opening created in the working surface by the dismantling process. His fall was arrested before impact with the surface when his lanyard became caught on the scaffolding structure. Employee #1 was killed. Review: I Keywords: fall,scaffold,lanyard,fall protection, Powerplant Maintenance or repair $1,000,000 to $5,000, X James Stephens 36 M Fatality Other Construction Trades, N.E.C. FallDist: 16 FallHt: 133 Cause: Other Activities-Installing Ornamental And Architectural Steel FatCause: Other Activities-Installing Ornamental And Architectural Steel Accident Employee Falls From Ladder, Sustains Multiple Injuries Accident Report ID: Event Date: 03/15/2009 Inspection: Open: 03/25/ SIC: International Rectifier Corp. At approximately 10:00 p.m. on March 15, 2009, Employee #1, a maintenance mechanic, was repairing a leak on an overhead hot water boiler line located in mechanical room. The employee was working from a 5-ft aluminum A-frame stepladder, positioned on an elevated motor pad approximately 1 to 2 ft off of the ground. One of the legs of stepladder shifted off of the motor pad, causing employee to fall approximately 4 to 5 ft from the ladder to on top of a pump motor below. He sustained multiple rib fractures, injuries to his left lung, cuts to his leg, and a laceration to his chin. Employee #1 was hospitalized. Review: I Keywords: rib,fracture,fall,ladder,repair,leg,laceration,stepladder,lung, Samuel C. Davidson 57 M Hospitalized Fracture Helpers, Mechanics and Repairers Accident One Employee Is Killed, Six Others Are Injured Accident Report ID: Event Date: 11/04/2008 Inspection: Open: 11/04/ SIC: Landcoast Insulation Inc. About 5:30 a.m. on November 4, 2008, Employee #1 and a number of other contractors were inspecting and repairing a scaffold, which was erected inside a Coal-fired Boiler, Number 2, at the Mississippi Power Company's Plant. The scaffold collapsed inside the boiler and killed Employee #1. Six other employees sustained bruises, contusions, and abrasions. Two of them were hospitalized. Review: I Keywords: construction,repair,boiler,scaffold,collapse,contusion,abrasion, Powerplant Maintenance or repair $500,000 to $1,000, X Ulises J. Rodriguez 45 M Fatality Asphyxia Occupation Not Reported FallDist: 16 FallHt: 125 FatCause: Installing equipment (HVAC and other) Alfonso Galvan 37 M Hospitalized Bruise/Contus/Abras Occupation Not Reported David Guillen 31 M Hospitalized Bruise/Contus/Abras Occupation Not Reported Kenneth S. Hernandez 23 M Non Hospitalized Bruise/Contus/Abras Occupation Not Reported Samuel Morfin 53 M Non Hospitalized Bruise/Contus/Abras Occupation Not Reported Perfecto Aguirre Rafael Sanchez 34 M Non Hospitalized Bruise/Contus/Abras Occupation Not Reported Accident Employee Is Killed in Fall From Platform Accident Report ID: Event Date: 06/30/2008 Inspection: Open: 07/02/ SIC: M.I. Electric Inc. On June 30, 2008, an employee was installing new electrical conduit approximately 22 ft above Boiler Number 3, from a platform. Coworkers heard something hit the ground and discovered the employee. Police 100th precinct responded to an emergency medical services call and performed Cardio pulmonary resuscitation until an ambulance arrived. The ambulance took the employee to Peninsula Hospital, Far Rockaway where he was pronounced dead upon arrival. Review: I Keywords: fall,platform,electrician,concussion, Multi-family dwelling Alteration or rehabilitation $1,000,000 to $5,000, X Tomo Maric 62 M Fatality Concussion Electricians Accident Employee Fractures Wrist in Fall Accident Report ID: Event Date: 07/11/2007 Inspection: Open: 07/12/ SIC: Tesoro Refining and Marketing Company At approximately 9:30 a.m. on July 11, 2007, an employee was asked by a coworker to remove the broken pressure gauge on a 60 pound utility steam line at the Number 6 boiler. The employee used a 10-inch crescent wrench in an attempt to remove the nut below the broke pressure gage face. The 10-inch crescent wrench failed to move the nut. The employer was handed a hollow metal pipe by the coworker to be used as a cheater bar. A cheater bar was a pipe placed over the stem side of a wrench to create a greater length and created additional leverage to move a nut by the wrench. The additional leverage afforded with the cheater bar removed the nut. The broken pressure gage was removed. The employee replaced the pressure gage and attempted to tighten the nut associated with the pressure gage with the cheater bar. However, the hollow metal pipe making up the cheater bar slipped off the wrench, and the employee crashed backwards into nearby pump foundation. The employee suffered eight fractured bones in his right wrist. The employee was sent to Mt. Diablo Hospital for surgery. Review: I Keywords: fall,fracture,wrist,construction, Anthony Wagnon 35 M Hospitalized Fracture Laborers, Except Construction Accident Employee Killed When Scaffold Falls Accident Report ID: Event Date: 03/20/2007 Inspection: Open: 03/20/ SIC: Irwin Industries Inc On March 20, 2007, Employee #1, along with other employees, was working in a boiler at a power plant. They were removing heat exchange tubing in the throat area of a boiler. The tubing was supporting the scaffold in the throat area. When the tubing was cut and removed from its normal location, the scaffold support was no longer secure and a portion of it fell into the bottom of the boiler. Employee #1, who was standing on the scaffold, fell with it to the bottom, and was killed. Review: I Keywords: fall,scaffold,boiler,unstable position,unsecured,construction,cutting and burning ,dismantling,head, Powerplant Maintenance or repair $250,000 to $500, X Leo Greyeyes 49 M Fatality Other Welders and Cutters FallDist: 16 FallHt: 25 Cause: Demolition FatCause: Demolition Accident Employee Twists Knee When Ladder Falls Over Accident Report ID: Event Date: 01/25/2007 Inspection: Open: 02/28/ SIC: Pacific Lumber Co On January 25, 2007, Employee #1 was working at a sawmill at which the employer operated a cogeneration plant. The cogeneration plant produced electricity by burning wood waste. Employee #1 worked for the company as a shift operator. Ash and debris from the grates of a boiler bed were removed through an ash drop. Rocks and debris had plugged the bottom of the ash drop on Boiler "A," and Employee #1 was cleaning the material out. He was standing on a ladder at a height of, he estimated, approximately 3 to 5 feet above the floor to clean the ash drop of debris. He leaned too far to the side of the ladder, and the leg of the ladder collapsed. Employee #1 jumped from the ladder as it slid sideways and fell to the floor. He twisted his left knee when he landed, and he sustained a fracture. He was hospitalized for surgery to his left knee. Review: I Keywords: sawmill,boiler,cleaning,ash,ladder,falling object,fall,knee, Darrell James 42 M Hospitalized Fracture Power Plant Operators Accident Employee Dies After Fall Through Floor Opening Accident Report ID: Event Date: 06/14/2006 Inspection: Open: 06/14/ SIC: Hazcorp Environmental Services, Inc. At approximately 2:00 p.m. on June 14, 2006, Employee #1, working for Hazcorp Environmental Services, Inc., and two coworkers were performing an asbestos survey throughout a United States Gypsum (USG) paper mill for wallboard. This facility has multiple buildings, operations and floors. The three Hazcorp employees went through a half-hour contractor safety program with an USG engineering manager and were allowed to conduct their survey throughout the facility unescorted. Around 2:00 p.m. the three employees were taking asbestos suspect samples at the fourth floor level of the boiler house. They entered a small room (approximately 8-ft by 16-ft) in the northwest corner of the boiler house. The west side of the room was barricaded by a 3-ft, 6-inch yellow railing which had been installed by USG in January The railing had no gate and was clearly meant to block passage into that side of the room. The roof over that portion of the room was deteriorated and partially collapsed, leaving a lot of roof debris on the floor area of the barricaded side of the room. The area also contained a 3-ft, 5-inch by 6-ft hole, which at one time was for equipment or a chute (per USG management). USG had placed a piece of styrofoam board over the hole to keep the rain from entering the boiler house and barricaded the area to keep employees from entering that side of the room. Per USG, that area was unoccupied space for their employees the majority of the time. Over time, the roof debris covered the styrofoam board. Thus, the floor area behind the barricade looked like a complete solid surface. The other two HazCorp employees were discussing the need for a sample of the roofing material, which was lying on the floor on the barricaded side when Employee #1 went over the barricade and said he would get the sample. The other two employees did not stop Employee #1 from crossing the barricade or tell him to immediately return from the barricaded area. Employee #1 picked up the roof debris, stepped towards the wall, and fell through the floor hole. He fell 32 feet to the first floor of the boiler house. He most likely struck piping on the way down and landed between the wall and a dumpster. His two coworkers ran down to the first floor. One obtained help from USG and the other contacted 911. Employee #1 was flown by helicopter to Medical University of Ohio, where he was hospitalized in critical condition. He sustained a broken right clavicle, multiple subarachnoid hemorrhages, a left frontal subdural hematoma, right temporal subdural hematoma, pulmonary contusion, basilus skull fracture, and pneumocephalus (presence of air in the intracranial cavity). Employee #1 died from complications of his injuries on June 22, 2006, at 8:30 p.m. Review: I Keywords: fall,fracture,floor opening,work rules,asbestos,head,torso,barrier guard,communication, Kyle Hunlock 22 M Fatality Fracture Occupation Not Reported Accident Employee Is Killed in Fall From Scaffold Accident Report ID: Event Date: 04/09/2006 Inspection: Open: 04/10/ SIC: Southeast Texas Industrial Services, Inc. On April 9, 2006, Employee #1 was a boilermaker setting tubes inside the boiler of a coal power plant. He was climbing the system scaffold frame and was killed, when he fell 90 ft. Review: I Keywords: scaffold,fall,fall protection,coal,boiler,construction, Powerplant Alteration or rehabilitation $1,000,000 to $5,000, X Jason D Parks 34 M Fatality Bruise/Contus/Abras Occupation Not Reported FallDist: 16 FallHt: 90 Accident Employee Is Killed in Fall Accident Report ID: Event Date: 03/11/2005 Inspection: Open: 03/11/ SIC: Chattanooga Boiler and Tank Co. On March 11, 2005, Employee #1, a subcontract employee with Chattanooga Boiler & Tank Co., was performing maintenance work on a blow-down tank at Blue Ridge Paper Company while the plant was shut down. He fell, and was killed. Review: I Keywords: fall,maintenance,tank,boiler, Manufacturing plant Maintenance or repair Under $50, X Victim 38 M Fatality Other Boilermakers FallDist: 21 FallHt: 44 Accident Employee Dies After Being Trapped Under Collapsed Scaffold Accident Report ID: Event Date: 01/28/2005 Inspection: Open: 02/03/ SIC: Apcom Power, Inc. On January 28, 2005, Employee #1 and a coworker, both employees of APCom Power Inc., were repairing a leaking tube in a boiler at the Independence Power and Light Blue Valley Power Plant. Independence Power and Light (IPL) had a service agreement with APCom Power Inc. to service boilers and repair leaks. The contract employees were working as a two-man crew with no direct supervision by IPL. Employee #1 was the foreman and both employees were boilermakers by trade. The coworker was working at the third floor level of the boiler performing welding on casings on the outside of the boiler. Employee #1 had finished all work inside the boiler and was scheduled to break down the basket of the single-point adjustable suspension scaffold and remove it from the boiler. The employees ate lunch together at 4:30 a.m. and the coworker went back to the third floor at 5:00 a.m. to resume his work duties. The next break time occurred at 6:15 a.m. and the coworker returned to the bottom floor of the boiler to check in with Employee #1 when he found him laying unconscious with his head against the boiler door, his feet straddling the scaffold basket, and the scaffold partially collapsed on top of him. The rollers of the scaffold mast were lying just below his navel, his thighs were between the top rail and mid rail of the work cage, and the hoist motor and motor mount were positioned at his knees. The coworker found an IPL employee and emergency services were called. The employees returned to the boiler and attempted to free Employee #1 from the scaffold. The coworker operated the scaffold hoist to take the slack out of the wire rope and lift the scaffold mast, motor, and motor mount from Employee #1's body. Another employee, an IPL shift supervisor, administered CPR to Employee #1 but never got a response. The Fire Department arrived at the scene at 6:24 a.m. followed by the American Medical Response ambulance service at 6:29 a.m. Employee #1 was transported to MCI hospital by ambulance where he was pronounced dead. An autopsy was conducted. The coroner's report indicated that the victim died of mechanical asphyxia from being trapped by the partially collapsed scaffold. Review: I Keywords: scaffold,struck by,equipment failure,asphyxiated,falling object,boiler, Patrick Deckman 47 M Fatality Asphyxia Occupation Not Reported Accident Employee Falls From Scaffold and Dies Accident Report ID: Event Date: 12/13/2004 Inspection: Open: 12/13/ SIC: Atlantic Scaffolding Company On December 13, 2004, ten employees, working for the Atlantic Scaffolding Company, were dismantling a systems scaffold that was built inside of a black liquor reclaim boiler. The scaffold was 100 feet high and 40 feet square. The employees were removing deck pans from the "dance floor" platform. As Employee #1 was about to be handed a deck pan, he stepped into a 9-feet by 7-feet opening in the floor that he and other workers had just created. The employee was not wearing fail protection as he fell 21 feet to the bottom of the boiler. The employee suffered serious injuries and was transported to the hospital, where he died the following day. Review: I Keywords: scaffold,fall,fall protection,fracture,head,work platform,platform,confined space,boiler,decking, Other building Demolition $50,000 to $250, X Louis Anderson 48 M Fatality Fracture Occupation Not Reported FallDist: 16 FallHt: 21 Accident Employee Dies After Fall Into Boiler Cyclone Accident Report ID: Event Date: 06/12/2004 Inspection: Open: 06/15/ SIC: Patent Construction Systems Employee #1 and two coworkers were removing a section of scaffold in the cross-over area between a boiler and its cyclone. One coworker was standing on the existing scaffold inside the boiler and another coworker was standing in the cross-over closest to the boiler scaffold. Employee #1 was next to the unprotected opening of the cyclone. As the employees were dismantling the scaffold section, Employee #1 stepped into the unguarded cyclone and fell approximately 64 feet. He was hospitalized and died 2 days later. Review: I Keywords: boiler,scaffold,dismantling,fall,guard, Powerplant Alteration or rehabilitation $50,000 to $250, X Timmothy Adamson 32 M Fatality Concussion Occupation Not Reported FallDist: 16 FallHt: 64 Cause: Interior plumbing, ducting, electrical work FatCause: Interior plumbing, ducting, electrical work Accident Employee Dies After Falling Into Fire Box Accident Report ID: Event Date: 06/12/2004 Inspection: Open: 06/12/ SIC: Anderson Hardwood Floors Employee #1 was using wood scrap from a hardwood flooring process to stoke a boiler fire box through a 41-inch by 41-inch floor opening. The employee suffered a heart attack, fell into the fire pit, was burned, and died. There was no guard around the opening. Review: I Keywords: fire,fall,burn,guard,floor opening,heart attack, Raymond Lowman 77 M Fatality Burn/Scald(Heat) Miscellaneous Woodworking Machine Operators Accident Employee Killed in Fall From Boiler Platform Supports Accident Report ID: Event Date: 05/04/2004 Inspection: Open: 05/04/ SIC: W.G. Yates & Sons Construction Company On May 4, 2004, Employee #1, an iron worker and boilermaker, was helping to install a work platform on the side of a modular boiler for a combined-cycle power plant that was under construction. He was standing on the platform supports while bolting up sections of the platform when he fell approximately 75 ft to the ground. Employee #1 died at the scene of injuries sustained in the fall. Review: I Keywords: construction,fall,fall protection,work rules,installing,iron worker,elevated work plat,unstable position, Powerplant New project or new addition $20,000,000 and over 80 X Ryan Mackenzie 21 M Fatality Concussion Boilermakers FallDist: 19 FallHt: 75 Accident Employee Died When Catapulted Out of Aerial Lift Basket Accident Report ID: Event Date: 03/10/2004 Inspection: Open: 03/10/ SIC: W.G. Yates & Sons Construction Company A crew of four employees and one supervisor were installing steel sheeting in a location approximately 4 feet deep. They were working in between two columns on the exterior side of a boiler wall. One employee was working from an aerial lift holding the sheets in place for the welder, who was working from a spider lift (suspended platform), located directly below. The two other coworkers were working from ground level hoisting the sheets into position for installation, while the supervisor was standing at ground level observing the operation. In order for the employee to access the location where the sheeting was to be installed, he turned the aerial lift basket sideways and extended the basket between the columns, through a gap of approximately 3 feet. The dimension of the basket was approximately 3 feet wide by 6 feet long. The steel sheeting was located approximately 4 feet horizontally from the exterior side of the wall. After the installation of the fifth sheet, the employee attempted to reposition the basket when it became lodged between the columns. He attempted to clear the lift and in doing so, hydraulic pressure had increased to the extent that when the basket became unlodged, it caused the lift to catapult and turnover. The basket was extended to reach a height of approximately 55 feet. The victim was tied off in the basket, but died as a result of the injuries he sustained from the fall. Review: I Keywords: aerial lift,fall protection,fall,head,concussion,work surface,elevated work plat,steel erection, Powerplant New project or new addition $20,000,000 and over X Johnny Mack Boyett 48 M Fatality Concussion Construction Trades, N.E.C. FallDist: 17 FallHt: 55 FatCause: Erecting structural steel Accident Employee Receives Injuries in Fall From Fixed Ladder Accident Report ID: Event Date: 12/17/2003 Inspection: Open: 12/22/ SIC: Claremont University Consortium At approximately 11:30 a.m. on December 17, 2003, Employee #1, a boiler operator was replacing a fan in a boiler from a fixed ladder. He first tied a rope to the fan and tried to pull the fan up to the location for its installment; however, the fan struck the wall as it was being raised. To prevent the fans from being damaged, he then decided to carry the fan on the ladder. He took a hold of the fan and started the climb upon the ladder, but lost his balance as he approached the top of the ladder. He fell 13-ft striking the ground and sustaining fractures in his left lower leg. After being taken to the hospital, he received medical treatment and postoperative care for which he was hospitalized. Review: I Keywords: boiler,fixed ladder,fall,fall protection,fracture,leg, Billy Lu 57 M Hospitalized Fracture Specified Mechanics and Repairers Accident Employee Stepped Into A Hot Water Accident Report ID: Event Date: 12/11/2003 Inspection: Open: 12/18/ SIC: Km Industrial At approximately 3:30 p.m. on December 11, 2003, Employee # 1, a mechanic, was working in the number 5 Boiler House Unit for a second employer. The second employer is a refiner of petroleum products. Employee # 1 was attempting to step over an open drain sump that contained a hot substance (190 degrees Fahrenheit). When he attempted to step over the open sump, he stepped into it and immersed the right leg up to the lower thigh. Employee # 1 received second-degree burns over the right leg and was hospitalized for seven days. Review: I Keywords: hot water,hot water tank,burn,leg, Refinery Other Under $50,000 Gary Bower 21 M Hospitalized Burn/Scald(Heat) Laborers, Except Construction Accident Employee Is Injured in Fall Accident Report ID: Event Date: 07/28/2003 Inspection: Open: 07/31/ SIC: Chesapeake Petroleum & Supply Co., Inc. On July 28, 2003, Employee #1 was transferring lines from a 275-gallon transmission oil storage tank for a conversion to another type of oil. The tank was on an 8-ft-high platform in a small boiler room. To access the tank, he placed a partially-opened 12-ft stepladder against the platform. While standing with one foot on the ladder and his other foot on the platform, he used a large pipe wench to tighten a connection. The wench slipped, causing him to lose his balance, strike a storage hook, strike a large air compressor, and then fall to the floor. After crawling out of the boiler room, he was able to obtain assistance, and was subsequently hospitalized for critical injuries. Review: I Keywords: fall,ladder,stepladder,tank,elevated work plat,wrench,slip,lost balance,struck against, Raymond M. Brito 49 M Hospitalized Other Occupation Not Reported Accident Employee Killed in Fall From Boiler Platform Accident Report ID: Event Date: 05/05/2003 Inspection: Open: 05/06/ SIC: Gemma Power Systems, Llc Employee #1, a boilermaker welder, was at the end of his 12-hour shift, had completed his work for the day, and had sent his tools and equipment down from the Heat Recovery Steam Generator (Boiler). The employee was last seen walking on the operating deck platform that was equipped with standard railings on all sides. The employee fell 89 feet to the ground from the west side of the platform and was killed. Review: I Keywords: boiler,platform,fall, Powerplant New project or new addition $20,000,000 and over X Accident Employee Killed in Fall While Removing Flange From Boiler Accident Report ID: Event Date: 02/19/2003 Inspection: Open: 02/24/ SIC: Cintas Corporation On February 19, 2003, Employee #1 fell while attempting to remove a 4-in. flange from a boiler. He sustained a concussion to his head and was killed. Review: I Keywords: construction,fall,concussion,head,boiler,work surface, Commercial building Alteration or rehabilitation $500,000 to $1,000, X Patrick Grohman 55 M Fatality Concussion Occupation Not Reported FallDist: 14 FallHt: 7 Cause: Site clearing and grubbing FatCause: Site clearing and grubbing Accident Employee Injured in Fall From Scaffold Accident Report ID: Event Date: 03/17/2002 Inspection: Open: 03/18/ SIC: Atlantic Scaffolding Erectors Inc Employee #1, along with other workers, was dismantling a tube and coupler scaffold inside a boiler at BGE when he fell through the opening that the sections of the scaffold were being passed down through. The employee fell 32 feet to the scaffolded floor below. He received fractures to two vertebrae in his back. The employer has a fall protection program for dismantling scaffold and the employee was wearing fall protection but was not tied-off at the time. The manufacturer allows personnel to tie-off to the scaffold when two horizontal members meet at a vertical member and within 2 feet of the junction and only to the vertical member. Review: I Keywords: scaffold,fall,dismantling,fall protection,ppe,fracture,back,scaffolding,tubular scaffold,tie-off, Other building Alteration or rehabilitation $20,000,000 and over Walter Celario 27 M Hospitalized Fracture Construction Trades, N.E.C. FallDist: 16 FallHt: 32 FatCause: Installation Of Decking-Flashing Of Decking Accident Employee Slipped and Fell From Pipes Accident Report ID: Event Date: 02/21/2002 Inspection: Open: 02/22/ SIC: Shell Chemical Lp On February 21, 2002, two employees were blocking the boiler feed water to the calcider. Two methods were available to accomplish this, using the double block valve or the root valves. The root valves, being the easiest valves to manipulate, were selected. Because of the location of these valves, the employees walked on the pipe rack. As his coworker began to access the pipe rack, Employee #1 slipped and fell 34 feet from the pipes. Employee #1 died at the scene. Review: I Keywords: fall,pipe,slip,fall protection,walking surface, H N Sutherland 56 M Fatality Other Miscellaneous Plant and System Operators Accident Employee Sustains Concussion in Fall Through Floor Grating Accident Report ID: Event Date: 10/03/2001 Inspection: Open: 10/11/ SIC: Dynegy Midwest Generation, Inc. Employee #1 and a coworker were installing an air line for an acoustic air horn system for the boiler on the fifth-floor boiler level of a fossil fuel electricity generating plant. They were installing piping for the air line near the east side doors to Boiler #1, which were located just below the fifth floor. They reached the doors by lifting a section of the floor grating and descending to the top of the boiler ventilation duct 58 inches below. Employee #1 and his coworker lifted a 22-inch by 35-inch section of the floor grating in order for Employee #1 to lower himself through the floor opening onto the top of the ventilation duct to take measurements. When Employee #1 returned to the fifth-floor level, he assisted his coworker in tightening the overhead portion of a pipe. The coworker was standing on a platform ladder at the south end of the boiler, approximately 5 to 6 feet away from the floor opening and was looking upward while tightening the south end of the pipe. Employee #1 was on a separate ladder and was tightening the north end of the same piece of pipe. Employee #1's ladder was positioned less than 12 inches from the floor opening. After both workers tightened and leveled the pipe, the coworker looked down to get his wrenches. Hearing a noise, he saw Employee #1 falling through the opening in the floor grating. Employee #1 hit the ventilation ductwork below, bounced off it, and fell approximately 15 feet further to the fourth floor grating. Employee #1 lost consciousness and sustained two lacerations to the back of his head, a concussion, and a broken scapula. He was hospitalized. Neither worker could recall what work surface Employee #1 was standing on immediately prior to falling (i.e., both feet on ladder, both feet on floor grating, one foot on ladder, one foot on grating, one foot on a pipe near the floor level, etc.). Employee #1's concussion had caused some memory loss. Review: I Keywords: electrical,construction,lost balance,ladder,fall,floor opening,fracture,concussion,laceration,e ptd, Robert Navaressi 55 M Hospitalized Concussion Painters, Construction and Maintenance Accident Employee Falls From Elevated Work Area Accident Report ID: Event Date: 03/28/2001 Inspection: Open: 03/28/ SIC: Constellation Energy Group, Inc. On March 27, 2001 at 6:00 a.m. at work crew of seven to twelve employees reported to their work site. They were working twelve hours shifts. This work site for the first and second shifts was at a crane power plant. The assignment was to continue the removing of the secondary super heater tubes from a boiler type area. Employee #1, a modification mechanic, was working from the upper platform while a welder was working down on the main header pipe. Employee #1 walked out to the end of the upper platform and then stepped from the platform out and down on top of the section of heater tubes. He was a full body harness. Employee #1 chose not to tie off to the retractable safety device because he felt if he just used the lanyard and he fell it could swing him into the previous cut pieces of sharp jagged steel. If he used the lanyard would catch on the jagged pieces he thought a fall would let him hit the head pipe. He also thought that lanyard would catch on the jagged pieces of previously cut steel and possibly cause him to lose his balance and cause him to fall. He also was concerned that the sharp pieces of steel could damage the lanyard. Employee #1 stood up on the tube section and placed his left hand on a protruding I-Beam coming out of the wall. As he placed his left hand and weight on the I-beam and began to step up to the upper platform the I-beam broke away from the wall. Employee #1's glove caught on the metal of the beam and it pulled him down. It was estimated that the I-beam section weighed approximately 80 to 100 pounds. Mr. Cuba's hand came free of the I-beam and he continued to fall and he landed on the header pipe and then rolled off of the header pipe and fell to the floor below. When he hit the header pipe he landed on his left arm and his face hit the pipe. He was hospitalized. He suffered a broken left wrist, a broken left ankle, and numerous bruises. After the incident it was determined that another welder had cut partially through the I-beam because it was scheduled to be removed. Apparently he cut farther through than he realized. The retractable safety system was not erected in the proper location. Review: I Keywords: heat,boiler,glove,pipe,fall protection,platform,lanyard,fall,mechanic,beam, Powerplant Other $250,000 to $500, Todd Cuba 35 M Hospitalized Fracture Helpers, Mechanics and Repairers FallDist: 21 FallHt: 6 Accident Employee Fractures Bones in Fall From A Boiler Accident Report ID: Event Date: 01/10/2001 Inspection: Open: 01/11/ SIC: Apollo Sheet Metal Inc At approximately 8:30 a.m. on January 10, 2001, Employee #1 fell from a boiler and fractured some bones. He was attempting to tighten bolts on a flange that connected a relief valve to the housing of a portable boiler when the wrench slipped off the bolt he was working on. Employee #1 lost his balance and fell backwards off the top of the boiler approximately 11 feet 8 inches to the black topped surface. He went to a local hospital for treatment. Review: I Keywords: fracture,fall,boiler, Greg Kraft 30 M Hospitalized Fracture Sheet Metal Workers Accident Employee Falls From A Scaffold and Suffers Concussion Accident Report ID: Event Date: 09/25/2000 Inspection: Open: 09/25/ SIC: Anne Arundel County Public Schools An employee was installing a low water level cut-off valve on a boiler system. She was working from an elevated mobile scaffold. The employee fell from the scaffold striking her head on the floor. She was hospitalized with a concussion and afterward had no recollection of why she fell. Review: I Keywords: installing,water,scaffold,struck against,concussion,boiler,head, Wanda Edwards 34 F Hospitalized Concussion Power Plant Operators Accident Employee Dies in Fall When Metal Grate Fails Accident Report ID: Event Date: 08/03/2000 Inspection: Open: 08/07/ SIC: Browning Trucking Employee #1 and coworkers were cleaning up the fifth floor of a recovery boiler. Employee #1 stepped onto a metal grate that had deteriorated too much to support the weight of a man. The grate failed and he fell approximately 18 ft to the level below. Employee #1 struck his head and lost consciousness. He remained in a coma until his death two days later. Review: E Keywords: grating,collapse,fall,head,unconsciousness,inadequate maint,work surface,work rules, Dewey Chaney 32 M Fatality Cut/Laceration Occupation Not Reported Accident Employee Died in Fall From Boiler Tube Accident Report ID: Event Date: 05/25/2000 Inspection: Open: 06/01/ SIC: Aee An electric utility employee was working on a boiler tube 29 meters above the ground. He fell and struck part of the boiler. He died of injuries sustained in the fall. Review: I Keywords: fall,fall protection,elec utility work,boiler, Roberto Aquino 59 M Fatality Concussion Occupation Not Reported Accident Workers Killed in Structure Collapse Accident Report ID: Event Date: 02/02/2000 Inspection: Open: 02/03/ SIC: Black & Veatch Construction, Inc. On February 2, 2000, Employees #1 and #2 were boiler workers employed by Black and Veatch. Employees #1 and #2 were removing the temporary bracing from the west side of the low pressure side of the Heat Recovery Steam Generator (HRSG), Unit 1. The temporary bracing consisted of three steel I beams that had been welded into position on the vertical columns. The three temporary beams on the east side had been removed on January 31, Employees #1 and #2 were using an Arc Gouger to cut the welds. Once the welds were cut, a sling was attached to the beam and to the hook of a crane. The beams were freed from the structure by breaking the slag with a hammer. Once freed, the beam was lowered to the ground. The top beam had been removed between 9:00 a.m. and 0930 a.m. Employees #1 and #2 took a coffee break sometime between 9:30 a.m. and 9:45 a.m. Upon returning from the break, Employees #1 and #2.proceeded to cut the top weld of the second temporary diagonal bracing.. Examination of this weld indicates that it had been almost completely cut. At this point the structure started to move in a southerly direction. The structure struck the boom of the crane. The boom broke and struck the basket of the manlift that Employees #1 and #2 were working from, killing them. The boom also hit a second manlift. The worker in that lift sustained a broken leg. As the structure collapsed, it fell onto the crane trapping the operator. The crane operator sustained serious injuries to his legs. Review: I Keywords: fall,fall protection,crane,brace,boom, Powerplant New project or new addition $20,000,000 and over X Kevin Winslow 42 M Fatality Fracture Occupation Not Reported FallDist: 03 FatCause: Other Activities-Installing Ornamental And Architectural Steel Richard Most 37 M Fatality Fracture Occupation Not Reported FallDist: 03 FatCause: Other Activities-Installing Ornamental And Architectural Steel Robert Fitch 61 M Hospitalized Amputation Occupation Not Reported FallDist: 03 FatCause: Other Activities-Installing Ornamental And Architectural Steel George Scrivener 35 M Hospitalized Fracture Occupation Not Reported FallDist: 03 FatCause: Other Activities-Installing Ornamental And Architectural Steel

Carbon Monoxide Carbon Monoxide is colorless, odorless
Buy a Carbon Monoxide detector to alert of high levels Dampers in building partially closed was one cause Flue exhaust from Boiler has CO another Also…. Defective exhaust system for one of the boilers Plastic covered chimney Downdraft had high CO Working in a kiln that was heated by steam from a direct-fired boiler that vented its combustion products with the steam it generated Many more…. Accident Employee Is Overcome By Carbon Monoxide, Later Dies Accident Report ID: Event Date: 12/05/2008 Inspection: Open: 12/05/ SIC: Anchor Mechanical, Inc. On December 5, 2008, Employee #1 was dispatched to the site to perform normal maintenance on the building's boiler equipment. Two domestic heating boilers and three comfort heating boilers were located in the room. Employee #1 was working alone in the room. An employee of a cleaning service entered the boiler room at approximately 10:00 a.m. to get a ladder and observed that Employee #1 was sweating profusely and the room was extremely warm. At 11:00 a.m. an employee of the building management company tried to reach the victim by phone and did not receive a response. Between 11:30 a.m. and 12:00 p.m. on December 5, 2008, the victim's supervisor arrived at the site (also, after trying to reach him by phone) and found the door to the boiler room locked. At approximately 12:00 p.m. Employee #1 was found unresponsive in a boiler room of a condominium complex. Employee #1's supervisor reported that one of the three comfort heating boilers was operating. When the supervisor obtained the key to the room, he found Employee #1 sitting on the floor leaning against a box unconscious. Employee #1 was pronounced dead at 12:25 p.m. at the scene. The medical examiner called the fire department and requested that carbon monoxide measurements be taken in the boiler room. The fire department measured approximately 1,400 parts-per-million of carbon monoxide in the room. Exhaust dampers on two of the comfort heating boilers were observed by the contractor to be partially closed during troubleshooting following the accident. This included the damper on the boiler that was operating when Employee #1's supervisor entered the boiler room. Following an autopsy, the medical examiner declared Employee #1 died of carbon monoxide intoxication. Review: I Keywords: asphyxiated,carbon monoxide,unconsciousness,boiler,heater, End Use Proj Type Proj Cost Stories NonBldgHt Fatality Multi-family dwelling Maintenance or repair $50,000 to $250, X Inspection Age Sex Degree Nature Occupation Construction Robert Waszak 63 M Fatality Asphyxia Machinery Maintenance Occupations Accident Carbon Monoxide Exposure Accident Report ID: Event Date: 02/02/2008 Inspection: Open: 02/11/ SIC: Eurasian Harbor, Llc Dba Ruth's Chris Steakhouse On Feburary 2, 2008 employees at Eurasian Harbor, LLC dba Ruth's Chris Steak House were exposed to carbon monoxide. A malfunctioning boiler forced pressure through a common flue duct and blew off the end cap of the exhaust duct. Carbon monoxide leaked out of the flue exhaust into the mechanical control room and seeped into the adjacent through cracks and seams in the cement walls. A Baltimore City Fire Department spokesman indicated that carbon monoxide levels at the scene measure 400 parts per million. Oxygen therapy and tests to determine blood levels of carbon monoxide were administered to affected employees by emergency services personnel. Fourteen employees were transported to area hospitals for further evaluation and treatment for exposure to carbon monoxide. No employees were admitted as inpatients and all were released within several hours. Marcelo Salles 28 M Non Hospitalized Poisoning(Systemic) Waiters and Waitresses Adrienne Wynn 35 F Non Hospitalized Poisoning(Systemic) Waiters and Waitresses Henry Coleman 30 M Non Hospitalized Poisoning(Systemic) Waiters and Waitresses Rosalia Imaculada 33 F Non Hospitalized Poisoning(Systemic) Kitchen Workers, Food Preparation Accident Fatal Co Exposure Accident Report ID: Event Date: 01/28/2008 Inspection: Open: 01/28/ SIC: Peacock Oil Company Peacock Oil Company SIC 5541 On January 27, 2008 at approximately 9:40 pm a 44 year old male employee was found unresponsive in an equipment room for the car wash operations. The employee died of carbon monoxide poisoning on January 28, The autopsy reported the death occurred as a result of acute carbon monoxide poisoning. Acute cocaine intoxication was a significant condition reported in the autopsy report. The employee was responsible for the maintenance of the equipment at the car wash. He was called in to work on Sunday evening to fix some of the equipment. Two policemen from the local police department removed the unresponsive employee from the end of the 30' X 8' room, opposite the entry door after being notified by an employee. Surveillance video footage showed the time the employee entered the room. The employee was removed from the room by the two policemen approximately 95 minutes after the employee entered the room. The police reported that 2 tool kits were opened on top of some drums of car wash chemicals. It appeared the employee was working on the car wash equipment. The sources of the employee's exposure may include a defective exhaust system for one of the boilers in the room, lack of make-up air and defective heat exchanger on a room heating unit in the equipment room. Two Raypak boilers were housed in the equipment room. One of the boilers was used to heat water for the water used in the automatic car wash bays and the other boiler was used to heat water for the floors in the automatic car wash bays. One of the boilers, Raypak 724 WP-B, Serial Number had several cracks in the top and side panels and the draft hood. Initial carbon monoxide measurements made by the local fire department indicated 0 ppm carbon monoxide in the room. However, the boilers had not activitated and the room was ventilated with the entry door open when the measurement was made. The gas company made a carbon monoxide measurement when the boiler (with the cracks) was activated. The measurement was approximately 1100 ppm of carbon monoxide at one of the cracks. The employee's carboxyhemoglobin level was 42.7after he arrived at the hospital. His exposure to carbon monoxide based on the carboxyhemoglobin level was calculated to be approximately 258 parts per million (ppm) as an 8-hour TWA, which is 5.15 times the PEL of 50 ppm. Phillip Johnson 44 M Fatality Asphyxia Machinery Maintenance Occupations Accident Employee Dies of Carbon Monoxide Poisoning From Boiler Vent Accident Report ID: Event Date: 12/11/2007 Inspection: Open: 12/13/ SIC: B & J Masonry Co. Inc. On December 11, 2007, Employee #1 was part of a crew engaged in stone work at a residential site. To complete the job, they covered the chimney with plastic. Once the plastic was in place, the coworkers went to put away the tools for the night, and left Employee #1 to stitch closed any openings in the plastic covering. The chimney housed the vent for an Ultra 310 boiler system. When the coworkers returned, they found Employee #1, unconscious, in the plastic enclosure. He died of carbon monoxide poisoning. Review: I Keywords: construction,carbon monoxide,inhalation,boiler,ventilation,chemical vapor,chemical,overexposure,exhaust fumes,work rules, Single family or duplex dwelling New project or new addition $5,000,000 to $20,000, X Everardo Millan 27 M Fatality Asphyxia Occupation Not Reported FallDist: 01 FatCause: Exterior masonry Accident Employee Is Found Dead (Carbon Monoxide)? Accident Report ID: Event Date: 03/22/2007 Inspection: Open: 03/30/ SIC: Lindenhurst Ufsd Lindenhurst Hs On March 22, 2007, Employee #1, a custodian, working the night, was discovered passed out in the boiler room dead. Review: I Keywords: unconsciousness,maintenance,janitor, Fred Frederick 69 M Fatality Other Janitors and Cleaners Accident Five Employees Are Overcome From Carbon Monoxide Exposure Accident Report ID: Event Date: 02/13/2006 Inspection: Open: 02/17/ SIC: Sheraton Hotels On February 13, 2006, Employees #1, #2, #3, #4, and #5 were located downdraft from a boiler, when they were overexposed to carbon monoxide. All five employees were hospitalized and treated for symptoms from overexposure. Review: I Keywords: carbon monoxide,toxic atmosphere,toxic fumes,inhalation,overexposure, Terrance Butts 27 M Hospitalized Other Supervisors, Cleaning and Building Service Workers Solonia Gene 32 F Hospitalized Other Supervisors, Cleaning and Building Service Workers Sawanda Stephenson 35 F Hospitalized Other Supervisors, Cleaning and Building Service Workers Terry Hambrick 26 M Hospitalized Other Supervisors, Cleaning and Building Service Workers Aden Aden 37 M Hospitalized Other Supervisors, Cleaning and Building Service Workers Accident Three Employees in Kiln Suffer Carbon Monoxide Poisoning Accident Report ID: Event Date: 06/14/2004 Inspection: Open: 06/14/ SIC: Atlantic Precast Concrete, Inc. Employees #1, #2, and #3 were working in a kiln that was heated by steam from a direct-fired boiler that vented its combustion products with the steam it generated when they were overcome by carbon monoxide. One employee lost consciousness, one employee became disoriented, and all three were hospitalized and received oxygen and hyperbaric treatment. Review: I Keywords: kiln,carbon monoxide,poisoning,asphyxiated, Bob Mason 25 M Hospitalized Poisoning(Systemic) Not Specified Mechanics and Repairers Albert Boan 30 M Hospitalized Poisoning(Systemic) Not Specified Mechanics and Repairers Robert Steve Blevins 32 M Hospitalized Poisoning(Systemic) Not Specified Mechanics and Repairers Accident Four Employees Overcome By Carbon Monoxide Exposure Accident Report ID: Event Date: 09/17/2003 Inspection: Open: 09/18/ SIC: Sheraton Ferncroft On September 17, 2003, four employees were overcome by high carbon monoxide levels while replacing a fan belt on a boiler. They were taken to local hospital and were released after observation. Review: I Keywords: carbon monoxide,inhalation,fan belt, Wayne Destefano 35 M Non Hospitalized Other Occupation Not Reported Ed Taylor 49 M Non Hospitalized Other Occupation Not Reported Al Silva 50 M Non Hospitalized Other Occupation Not Reported Richard Essler Accident Employees Hospitalized for Carbon Monoxide Poisoning Accident Report ID: Event Date: 06/07/2002 Inspection: Open: 06/11/ SIC: Gold Kist, Inc. On June 7, 2002, six employees of Gold Kist Inc. were hospitalized due to carbon monoxide exposure from a leaking boiler. The boiler refractory was damaged allowing the flue gas to leak through the jacket, instead of exiting through the stack. Review: I Keywords: carbon monoxide,boiler,inhalation,poisoning, Victor Pablo-Fernand 31 M Hospitalized Poisoning(Systemic) Machinery Maintenance Occupations Faustino Cantu 39 M Hospitalized Poisoning(Systemic) Machinery Maintenance Occupations Samuel Garcia 24 M Hospitalized Poisoning(Systemic) Machinery Maintenance Occupations Edwin Santiago 37 M Hospitalized Poisoning(Systemic) Machinery Maintenance Occupations Franscisco Saravia 53 M Hospitalized Poisoning(Systemic) Machinery Maintenance Occupations Fortunato Jiminez 38 M Hospitalized Poisoning(Systemic) Machinery Maintenance Occupations Accident Five Employees Suffer From Apparent Carbon Monoxide Exposure Accident Report ID: Event Date: 10/17/2001 Inspection: Open: 10/18/ SIC: Presbyterian Home Employees #1 through #5 were working in a kitchen when a hot water boiler malfunctioned and they were apparently exposed to carbon monoxide. All five were hospitalized overnight for observation, but their carboxyhemoglobin levels were not elevated. Review: I Keywords: carbon monoxide,boiler,inhalation,ventilation,chemical,chemical vapor,mech malfunction,overexposure, No Injury Accident Four Employees Show Exposure to Carbon Monoxide From Boiler Accident Report ID: Event Date: 12/06/2000 Inspection: Open: 12/06/ SIC: J & B Fabrication & Repair Inc Employees #1 through #4 and a coworker, of J & B Fabrication and Repair, Inc., were evaluated for exposure to carbon monoxide. Employees #1 through #4 had carboxyhemoglobin levels in excess of 10 percent. The employees were also tested on December 4, 2000, and again had elevated levels of carboxyhemoglobin. The source of the carbon monoxide was apparently the facility's heating system. Review: E Keywords: carbon monoxide,carboxyhemoglobin,inhalation,chemical vapor,vapor,boiler,ventilation,gas,work rules, Durrell Prahl 29 M Non Hospitalized Poisoning(Systemic) Welders and Cutters Dallas Prahl 30 M Non Hospitalized Poisoning(Systemic) Welders and Cutters Phillip Kiefer 24 M Non Hospitalized Poisoning(Systemic) Welders and Cutters Darrell Ward 28 M Non Hospitalized Poisoning(Systemic) Welders and Cutters

Fly Ash Fly Ash poses an engulfment and a burn hazard.
Develop a cleaning AND unclogging procedure. Provided a PPE hazard analysis (d) Guard against mechanical hazards. Four employees were working at an electric utility facility. Two of the employees were engulfed and burned by a spontaneous release of hot fly ash from a boiler. One employee was killed, and the other was hospitalized for his injuries. Employee #1 was on the seventh floor of an electric power generation facility, cleaning fly ash from a hopper inside a bunker. The hopper, which collected fly ash from a boiler, had become blocked. Employee #1 and two coworkers entered the bunker through a portal and the guardrail was opened so the two coworkers could run a flex hose into the hopper to vacuum the fly ash to a truck. Employee #1 was dislodging ash in the hopper, the ash engulfed him. He died of asphyxia Three employees were clearing a large mass of burned coal fire boiler ash from a boiler ash hopper through a hatch opening. Hot ash material fell into the ash hopper and exited out through the hatch opening, burning Employees #1 and #2. Employee #1 later died in the hospital from his injuries. Employees #1 and #2 suffered fatal burns, when an ash/slag tank of a coal fired boiler exploded shearing the boiler's blow down headers and exposing the employees to live steam, to free the boilers frozen slag tap. Employee #1 and #2 were killed. Employee #1, the operator of the #2 boiler and a coworker were unclogging an ash dump hopper. Initially, they prodded the congested area with a pipe through a clean-out hole with no success. Then they secured the power to the mixing auger, which was below the hopper, and checked for a clog. As Employee #1 reached up into the area around the rotary valve at the bottom of the hopper, four of his fingers on his right hand were amputated.. During the accident investigation it was revealed that the rotary valve had not been deactivated; there were separate control panels for the two pieces of equipment, and neither Employee #1 nor the coworker had locked out both machines. Four employees were working at an electric utility facility. Two of the employees were engulfed and burned by a spontaneous release of hot fly ash from a boiler. One employee was killed, and the other was hospitalized for his injuries. The boiler had been shut down due to a tube leak. Residual ash was left in the particle return system. The employees were testing in order to locate the leak when water entered the particle return system and came in contact with the hot ash. This caused an eruption of steam and ash Accident Employee Dies of Asphyxia When Engulfed By Fly Ash Accident Report ID: Event Date: 10/03/2006 Inspection: Open: 10/04/ SIC: Km Plant Services On October 3, 2006, Employee #1 was on the seventh floor of an electric power generation facility, cleaning fly ash from a hopper inside a bunker. The hopper, which collected fly ash from a boiler, had become blocked. Employee #1 and two coworkers entered the bunker through a portal and the guardrail was opened so the two coworkers could run a flex hose into the hopper to vacuum the fly ash to a truck. Employee #1 was dislodging ash in the hopper, the ash engulfed him. He died of asphyxia. The crew was not using safety harnesses nor were any of them attached to lifelines. Review: I Keywords: construction,asphyxiated,ash,hopper,ppe,buried,clogged,cleaning,lifeline,work rules, End Use Proj Type Proj Cost Stories NonBldgHt Fatality Manufacturing plant Maintenance or repair Under $50, X Inspection Age Sex Degree Nature Occupation Construction Leon Tristan 33 M Fatality Asphyxia Laborers, Except Construction FallDist: 01 FatCause: Site clearing and grubbing Accident One Employee Dies, One Burned While Cleaning Out Boiler Ash Accident Report ID: Event Date: 04/25/2006 Inspection: Open: 04/26/ SIC: Mead Westvaco On April 25, 2006, three employees were clearing a large mass of burned coal fire boiler ash from a boiler ash hopper through a hatch opening. Hot ash material fell into the ash hopper and exited out through the hatch opening, burning Employees #1 and #2. Employee #1 later died in the hospital from his injuries. Review: I Keywords: boiler,ash,cleaning,hopper,coal,hatch,burn, Curtis Jeter 51 M Fatality Burn/Scald(Heat) Occupation Not Reported Norman Martin 58 M Hospitalized Burn/Scald(Heat) Occupation Not Reported Accident Two Employees Iare Killed in Explosion Accident Report ID: Event Date: 07/11/2004 Inspection: Open: 07/12/ SIC: Columbus Southern Power Company On July 11, 2004, Employees #1 and #2 and were assigned working at an electrical power generation company. They suffered fatal burns, when an ash/slag tank of a coal fired boiler exploded shearing the boiler's blow down headers and exposing the employees to live steam, to free the boilers frozen slag tap. Employee #1 and #2 were killed. Review: Keywords: boiler,frozen, Rick Dickson 55 M Fatality Burn/Scald(Heat) Power Plant Operators Greg Smathers 47 M Fatality Burn/Scald(Heat) Power Plant Operators Accident Employee Amputates Fingers in Ash Dump Hopper Accident Report ID: Event Date: 08/24/2002 Inspection: Open: 10/01/ SIC: Sierra Pacific Industries At approximately 9:15 a.m. on August 24, 2002, Employee #1, the operator of the #2 boiler at a cogeneration plant, and a coworker were unclogging an ash dump hopper. Initially, they prodded the congested area with a pipe through a clean-out hole with no success. Then they secured the power to the mixing auger, which was below the hopper, and checked for a clog. As Employee #1 reached up into the area around the rotary valve at the bottom of the hopper, four of his fingers on his right hand were amputated. Emergency services were contacted and Employee #1 was transported to Sutter Roseville Medical Center, where first aid was provided. He was then transferred to Ralph K. Davies Hospital in San Francisco for hospitalization and further observation. During the accident investigation it was revealed that the rotary valve had not been deactivated; there were separate control panels for the two pieces of equipment, and neither Employee #1 nor the coworker had locked out both machines. Review: I Keywords: finger,clogged,communication,blind reaching,rotating knife,amputated,lockout,work rules,struck against, Frank Mireles 49 M Hospitalized Amputation Millwrights Accident Employees Engulfed By Hot Fly Ash Accident Report ID: Event Date: 01/14/2002 Inspection: Open: 01/14/ SIC: Trigen Energy Corporation Inspection: Open: 01/14/ SIC: Mobile Dredging and Pumping Co. Review: I Keywords: elec utility work,burn,high temperature,buried,ash, Eric Allen Tennant 35 M Fatality Burn/Scald(Heat) Supervisors; Electricians & Power Transm. Install. Charlie M. Temple 64 M Hospitalized Burn/Scald(Heat) Electricians No Injury Accident One Employee Killed, Four Injured By Steam Accident Report ID: Event Date: 02/05/2001 Inspection: Open: 02/06/ SIC: Patent Construction System Five employees of a scaffolding company were building a scaffold inside the combustion chamber of a fluidized bed boiler. The boiler had been shut down due to a tube leak. Residual ash was left in the particle return system. The employees were testing in order to locate the leak when water entered the particle return system and came in contact with the hot ash. This caused an eruption of steam and ash. Employee #1 sustained burns on 90 percent of his body and died. Employee #2 sustained second- and third-degree burns on 80 percent of his body. Employee #3 sustained second- and third-degree burns on 60 percent of his body. Employee #4 sustained burns on 30 percent of his body. Employees #2, 3 and 4 were hospitalized. Employee #5 was not hospitalized. Review: I Keywords: steam,burn,abdomen,boiler,ash,high temperature, Powerplant Maintenance or repair Under $50, X Dave Banko 44 M Fatality Burn/Scald(Heat) Construction Trades, N.E.C. Keith Rhine 25 M Hospitalized Burn/Scald(Heat) Construction Trades, N.E.C. Daryl Landrum 41 M Hospitalized Burn/Scald(Heat) Construction Trades, N.E.C. Roger Shaffer 38 M Hospitalized Burn/Scald(Heat) Construction Trades, N.E.C. Dan Murphy 45 M Non Hospitalized Other Construction Trades, N.E.C

Confined Space Lockout Follow 1910.146
Employees vacuum inside or conduct inspections.

Typical 5(a)(1) Violations
Not testing Relief Valves (NBIC) No written operating procedures No daily maintenance procedures Unprotected steam piping No record of Blowdowns Boiler Maintenance Employees not trained No record of all irregular events and repairs in operation of the boiler Inadequate Power pining inspection program Nondestructive testing personnel not ANST qualified Defective controllers, gages etc on boilers Equipment downstream of Boiler not rated for output pressure of the steam Boiler Natural gas not odorized Power piping not inspected Boiler not installed correctly And many more… Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to thermal burns and the employer did not ensure that steam pipes were covered to prevent employees from making contact with the bare pipes. (a)Boiler room; on or about September 23, 2010 and at times prior thereto, employees were exposed to thermal burns from Blow Down Tank steam pipes. (b)Cheese production area, on September 23, 2010, and at times prior thereto, employees are exposed to thermal burns from unprotected steam pipes along the end aisle above the water mixing valve. Note: Among other methods, one feasible and acceptable method to correct the hazards is to insulate each pipe and/or vessel to prevent employee contact. Note: Abatement certification IS required for this item. Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish a place of employment which was free from recognized hazards that were likely to cause death or serious physical harm to employees in that employees were exposed explosion hazards from an inadequately maintained boiler. Boiler Area No procedure implemented to assure that boiler was maintained daily and that relief valves were tested on a periodic basis Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which was free from recognized hazards that were likely to cause death or serious physical harm to employees in that employees were exposed to the hazard of being burned from safety relief valves that had not been tested in years. Boiler room. Safety relief valves had no record of testing to verify that they were in operable condition. Feasible and acceptable abatement methods would include the following: 1)Develop and implement a safety relief valve testing program consistent with the valve manufacturer and the National Board Inspection Code. 2)Develop a written maintenance and operation program for the boiler. This would include: a) Record of all blowdowns of the water column. b) Tests of safety apparatus including relief valves. c) Record all irregular events in operation of the boiler. 3)Train boiler maintenance employees in this program. Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish a place of employment which was free from recognized hazards that were likely to cause death or serious physical harm to employees. The Leffel boiler had no records of maintenance and repairs performed. On or about 10/31/97 and 11/3/97, the boiler safety relief valve relieved steam in the boiler rooThe blowdown of the water column had not been performed for two operating days. Feasible and acceptable abatement would include the following: 1) Develop a written maintenance and operation program for the boiler. This would include: a) Record of all blowdowns of the water column. b) Tests of safety apparatus including relief valves. c) Record of all irregular events and repairs in operation of the boiler. 2) Train boiler maintenance employees in this program. Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to serious hazards including being struck, crushed, burned or asphyxiated resulting from increased likelihood of catastrophic failure of improperlyand inadequately maintained pressure vessels and power piping. The employer failed to establish, properly implement and manage an effective program of pressure vessels and power piping safety including maintenance inspections, rating, repair, alterations and/or replacement. In addition, appropriate records necessary for informed decision making, documenting pressure vessels and power piping actual conditiongs were not prepared, retained, or made available for inspection. Employees working throughout the ethylene unit were exposed to these hazards on a daily basis including September 12, 1989, when a heat exchanger, EA 405, exploded and released flammable gas, vapor and/or liquid. A feasible and useful method of correcting these hazards related to pressure vessel and piping rupture and failure is to establish and properly implement an effective program including maintenance inspection rating, repair and alterative and/or replacement of pressure vessels, piping, and their associated safety devices. such a program must include the following elements as a minumun: 1) Ensure that persons who are authorized to peform and interpret Nondestructive Testing (NDE) are qualified to American Society of Nondestructive Testing (ASNT) SNT-TC-1A or equivalent written requirements or written procedures in accordance with 1989 ASME Boiler and Pressure Vessel Code Section v. Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The %% employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death of serious physical harm to employees in that employees were exposed to rupturing steam pipes in the Washex machines: Washer Area--Washex washing machine used for cleaning clothes and rags had a rated input capacity of 100 psi of steam. 110 psi was generated from the boiler. Among other methods, one feasible and acceptable abatement method to correct this hazard is to comply with the manufacturer's recommendation that maximum input of steam not exceed 100 psi. In lieu of that, install a guage at the input side of the washer to show that steam pressure is not exceeding 100 psi. .L Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to the hazard(s) of combustion, explosion, and fire hazard: a)Back of Package Boiler (Platform Area) On or about January 21, 2009, a natural gas vent was installed close the floor of a leased package boiler platform exposing employees to combustion, explosion, and fire hazards. A feasible means of abatement would be to construct a natural gas vent in accordance with NFPA 85, Boiler and Combustion Systems Hazards Code 2007 edition, where the natural gas discharge area is above and/or away from areas where employees work and/or where ignition sources could be presen Section 5(a)(1) of Public Law , the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees, in that employees were exposed to: fire and explosion hazards from insufficiently odorized natural gas being used as fuel for recovery boiler burners and igniters due to inadequate odorization procedures. (a)International Paper Vicksburg Mill, 3737 Highway 3 North, Redwood, MS 39156, Power Plant On or about Saturday, May 3, 2008 while re-starting the mill's black liquor recovery boiler after an annual outage, employees working round the boiler were exposed to fire and explosion hazards due to no verification that the mill's natural gas supply had been adequately odorized at the mill's gas yard. The gas was being piped to eight class 1 continuous burners and igniters located on four sides of the recoveboiler on the power plant's second floor and to four class 1 continuous burners and igniters located on two sides of the recovery boiler on the power plant's fourth floor. Among other methods, one feasible and acceptable abatement method to correct this hazard is to comply with ASME/ANSI/USAS B , Gas Transmission and Distribution Piping Systems, and with USDOT Standard 49 CFR Part 192 Transportation of Natural and Other Gas by Pipeline: Minimum Federal Safety Standards, specifically Sections , to develop a scientifically derived odorant-injection-rate for the amount of gas delivered to the various usage points inside the mill and furthermore establish well-communicated, written control procedures to ensure that testing is done and records are kept for verifying the presence of odorant in the mill's natural gas piping system. P.L Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer does not furnish employment and a place of employment which are free from recognized hazards that are causing or likely to cause death or serious physical harm to employees in that employees are exposed to the hazard(s) of a high pressure or steam release: a.Boiler "D" On or about 02/07/2008, the employer did not establish, communicate, and implement written operations and maintenance procedures and did not perform and document condition assessment activities of power piping to assure the safe operation of "boiler external piping" inside of the plant. One feasible means of abatement would be to establish, communicate, and implement written operations and maintenance procedures and establish, perform, and document a program of condition assessment activities of all power piping, as referenced in American Society of Mechanical Engineers (ASME) Code for Pressure Piping, Standard B Power Piping, Appendix IV Corrosion Control for ASME B31.1 Power Piping Systems, Section 5.2 Systems, Components Susceptible to Erosion/Corrosion (E/C) and ASME Code for Pressure Piping, Standard B Power Piping, Appendix IV Corrosion Control for ASME B31.1 Power Piping Systems, Section 5.3 Methods of Detection. See also recommendations for an Effective Flow-Accelerated Corrosion Program produced by the Electric Power Research Institute in November 1996 and revised in May of Pursuant to 29 C.F.R , within ten (10) calendar days, the employer must submit an abatement plan describing the actions it is taking to prevent the hazards described in instance a, above.ce Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to struck by hazards as the boiler exploded due to piping that was installed backward during initial installation. The employer did not assure all components of the boiler were installed correctly. Testing identified the #2 fuel oil burner input and return piping was reversed during original installation and nozzle screens were partially clogged. "Among other methods, feasible and acceptable abatement methods to correct this hazard is to:" 1. Test boiler equipment upon initial installation to assure correct installation of the boiler and all associated equipment. (Reference NFPA 85 Boiler and Combustion Systems Hazards2001 Edition, section 1.5 Installation). 2. Follow manufacturer recommendation on application. In accordance with 29 CFR (d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification. This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence of abatement, or other written records. Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to the hazard of burns and bodily injury from the hot ash and steam from leaking or ruptured pressure-retaining items. The following conditions contributed to the existence of the hazard: a) Location Boiler House, Unit #3: On or about November 6, 2007 Dominion Energy New England operated a pressurized coal fired Babcock & Wilcox that was insufficiently inspected and examined in the lower vestibule/dead air space which contains steam at approximately 600 Degrees Fahrenheit under 1000 psig. Three employees were fatally injured on November 6, 2007, when the boiler tubes ruptured in the lower vestibule/dead air space. * The lower vestibule/dead air space had not been entered and inspected in over9 years. No appropriate testing had been preformed to determine the conditions in the lower vestibule/dead air space in that length of time. * Ash was allowed to accumulate in the lower vestibule/dead air space over a long period which does not allow for entry into and inspection of that area. Among other methods, feasible means of abatement would be to: 1. Conduct Operation, Care/Maintenance, and Inspection of power boilers following the most recent National Codes such as ANSI/NB-23, ASME Section 7 Care of Power Boilers and guidance from Electric Power Research Institute and the manufacturer, Babcock and Wilcox. Including cleaning out the ash and debris from the vestibule/dead air space to allow for the inspection. 2. Determine a lower vestibule/lower dead air space inspection interval based on sound engineering principles and scientific data. 3. Install alarm system associated with power boiler operating parameters (eg., feed water make-up, electrostatic precipitator load/current changes, boiler pH, furnace pressure, boiler sodium and leaks in vestibules). 4. Install Leak Acoustic Monitoring system in vestibule

Non Destructive Testing (NDT)
Use ANST qualified inspectors for NDT. Use NDT Techniques; inspection of deposits in tubes of different sections, hardness testing, dye penetrate and ultrasonic testing of weld joints.

Codes 2007 ASME Boiler & Pressure Vessel Code, VII, Division 1, rules for Construction of Pressure Vessels, section UG-125 General NFPA 85 American Society of Mechanical Engineers (ASME) Code for Pressure Piping, Standard B Power Piping, Appendix IV Corrosion Control for ASME B31.1 Power Piping Systems ANSI/NB-23, ASME Section 7 Care of Power Boilers and guidance from Electric Power Research Institute

The Future Some Inspection Less explosions
More eyes and awareness – insurance, S&H professionals, media, bloggers Debate on a standard More Employer Self-assessment

Further This was prepared as a collaborative effort with several friends as a preliminary aid for anyone in the inspecting boilers. These are just some the issues. A comprehensive job hazard analysis should be conducted for any task where someone can get hurt. This is not an official OSHA publication. Those will be on the OSHA.gov website. If you see any errors my is or I want to thank Janet S. for her assistance in reviewing the hazards in this sector.

Draft 11 28 2011 Boiler Safety John Newquist.

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Draft 11 28 2011 Boiler Safety John Newquist.

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