All MSHA-reportable accidents at Sherwin Alumina Company, LLC operations in 2004. Fatalities appear first.
At 11:15 a dust collector fire was reported. Plant forces responded to the fire. The dust collector polyurethene filters were ignited by cutting slag. Mechanics were cutting on the dust collector when the fire occurred. The fire was extinguished in forty-five minutes.
Cable insulation on a 12KV electrical feeder line caught fire at 2 spliced areas. The fires consumed approximately 2 feet of insulation at both fire points. The fires were extinguished once it was confirmed that the electrical current was shut off. MSHA Inspectors were on site and were immediately notified of the situation.
CO. MIS-JUDGED AMOUNT OF MILKY LIME IN TANK. 12/8 THEY REMOVED TANK DOOR & HARD SCALE FORMED OVER DOOR. CO. CONTACTED ONYX TO CUT SCALE AT BASE TO REMOVE WHAT CO. SAID WAS 2-3 FT OF LIQUID. ONYX USED HIGH PRESSURE WATER TO CUT INTO SCALE. ONCE TECH STARTED, SCALE GAVE WAY & TECH WAS TRAPPED UNDER LIQUIDE THAT CAME OUT. MORE LIQUID WAS IN TANK THAN THOUGHT. CO DID NOT SOUND TANK.
A Mobile Equipment Operator had been working inside of a ship hold collecting bauxite with a pay loader. As he was ascending the ship hold ladder, to exit the hold, a foot slipped and he lost his hand grip on the ladder rung. He fell approximately five feet, landing on his right side. He climbed out of the ship hold and reported the incident. Hairline right rib fracture.
EE was moving a section of grating in place on a platform. He decided to do it on his own and not wait for help. EE was tied off to a handrail with one lanyard & was using the other to drag the grating. He pulled the grating too far & it fell 15 ft, causing him to be pulled down against the existing grating he was standing on. EE was released to return to work the following day.
EE was walking to his office at the beginning of his shift. He stepped on some slippery material on the roadway and landed on his right knee. Eventually had surgery on his right knee on 09/16/2004.
An Instrument Mechanic was re-installing a motor valve acutator stem yoke when his left ring finger was caught between the actuator stem and the valve stem. This resulted in a crush injury to the left ring finger that required surgery to repair, making this a ""Medical Treatment"" injury.
EE was walking in his work area when he stepped on a piece of scale, twisting his left knee. Eventually had surgery on 11/10/2004.
Maintenance Mechanic was working on ID Fan. Walked to the access ladder, grabbed barricade tape instead of handrail for support. Barricade tape broke and employee fell 7 ft. to ground level. Employee sustained a fracture to his right foot. Lost time beginning on 3/18/04.
Employee was lifting a bag of refractory and felt pain in back.
EE using a scaling gun to clean piping. Started feeling discomfort in his right thumb. EE eventually had surgery on his right thumb on 11/10/2004.
Employee was pulling on a rope when he felt discomfort in his right shoulder. Employee eventually had surgery on his right shoulder on 5/15/2004. RTW with restrictions on 07/19/2004. He was released to full duty on 9/15/2004.
EE was using a pipe wrench to do pipefitting work. As he pulled down on the wrench he felt a ""pop"" in his right shoulder. Eventually had surgery on his right shoulder 06/23/2004.
AN EQUIPMENT CLEANER HELPER WAS STANDING ON A PIPE APPROXIMATELY FOUR (4) INCHES ABOVE GROUND LEVEL WHILE TIGHTENING UP BOLTS ON A HEATER. THE EE SLIPPED OFF OF THE PIPE AND STRUCK HIS LEFT UP PER BODY AGAINST AN ADJACENT VALVE HANDLE. THE EE SUSTAINED A FRACTURED RIB, MAKING THIS A REPORTABLE INCIDENT.
Employee was using diluted caustic solution to hose down mud on pad. Hose stream hit a support beam and splashed back. Some of the diluted caustic got onto employee's face and trickled into both eyes. Several days later right eye was still irritated. On 11/4/04, doctor prescribed a steriod solution.
A small metal sliver struck an employee's left ring finger. Treated at plant medical facility and released to work. On February 25, 2005, the employee had to have surgery on the finger to remove scar tissue that was aggravating a nerve in the same finger. RTW on February 31, 2005 with restrictions. Missed two scheduled work days: 26th & 27th.
Employee was using a rivet gun in an attempt to dislodge a flange bolt. A sliver of the bolt broke loose and imbedded itself in the employee's right forearm. Employee had outpatient surgery to remove the imbedded sliver of metal. Restrictions on right arm use only; no lost time
Employee was using an 8 pound sledgehammer to remove bolts from a tank flange. The hammer handle knocked the employee's hard hat and monogoggles off and at that moment a drop of caustic got into his left eye. This resulted in irritation of his left eye. An opthomologist prescribed pain medication and an antibiotic for the prevention of infection.
Employee complaining of numbness to his right thumb. Employee eventually had surgery on his right thumb on 06/16/2004. Released to full duty on 7/12/2004.
EE was using an air impact tool to remove nuts and bolts. The weight of the tool caused a strain on the EE's right shoulder. Eventually had surgery on 06/02/2004 on his right shoulder.
AN EE FELL OFF A WORK PLATFORM THAT IS LOCATED ON TOP OF A FILTER PRESS. THE WORK PLATFORM IS SEVEN FEET ABOVE THE FLOOR AND IS EQUIPPED WITH A ACCESS LADDER, TOP RAIL, MIDRAIL AND TOE BOARD. HE SUSTAINED A LACERATION TO THE LEFT SIDE OF HIS FOREHEAD AND ABOVE HIS LEFT EYE. EACH LACERATION REQUIRED THREE SUTURES TO REPAIR.
A Building Trades Mechanic slipped and fell while attempting to step over a four inch portable pump suction hose. The employee's fell toward the portable pump and struck his head against the pump. Employee was wearing a hard hat. His head glanced off of the pump and he struck his left ear against the pump. This resulted in a laceration that required sutures to repair.
Bauxite Transfer Attendent was using a scaling bar to descale a conveyor discharge chute. He pinched his left hand, fifth finger between the scaling bar and the chute causing a laceration that required sutures to repair.
Scaler was using a 5 foot scaling bar to break apart a piece of hydrate scale. He missed the scale and struck his left foot causing a laceration on his big toe that required suctures to repair.
Maintenance Mechanic was attempting to connect two sections of six inch pipe by bring two six inch flanges together. One of the sections of pipe was being lifted by a crane. One of the sections shifted, pinching the employees left middle finger between the two flanges. Result was a fractured finger and a laceration that required sutures to repair.
Employee was unbolting a vertical drill mast support leg from its anchor point. The employee placed his left hand at the anchor point and with his right hand shook the support leg. The support leg released, catching employee's left index finger between the support leg and the anchorage point. This resulted in a laceration that required sutures to repair.
Employee was installing a screen under a heater when the screen fell, striking the employee on the top of his right foot. X-ray revealed a hair-line fracture of a toe on that foot.
Employee was walking down a stairway. He misjudged the distance to the last step and overstepped directly onto the concrete floor. X-ray reveals a hair-line fracture of an ankle bone.
A mechanic was standing on a 5'x7' scaffold and was using an old pipe wrench to remove a nipple and valve from a tank. The wrench slipped and the employee went backwards over the top rail and onto the ground below. He sustained a laceration to the back of his head which require sutures to repair. No lost time.
A Maintenance Mechanic sustained a laceration that required nine sutures to repair. As the employee was removing an electric motor from a gear reducer, his left hand middle finger got caught between the motor mount and the motor/reducer coupling flange. The equipment had been LOTO and the coupling was disconnected.
An Electrician sustained a small 2nd degree burn to his left arm when a fuse disconnect shorted out as he installed it in a motor control center. The electrician had rebuilt the fuse disconnect prior to installing it. No lost time or restricted duty, the burn was localized in the inner portion of his left arm. The burn area was about 2 inches in diameter.
Employee was working inside of a rotary kiln shoveling castable material. He stepped on a castable anchor bolt. The bolt penetrated his right boot and caused a small punture wound to right foot. Plant doctor prescribed an antibiotic as a precautionary measure against infection. No sutures required.
Employee was using a pipe wrench to remove a vertical drill bit. His right hand got caught between the wrench and the drill bit causing a laceration on his right hand. The laceration required five sutures to repair.
EE was on clean up duty. He was using water to hose down the deck of a bauxite unloader. He slipped on the wet floor & reached out to an adjacent handrail to break his fall. He felt a pain in his right shoulder & wrist. Plant doctor diagnosed as a mild shoulder and wrist sprain. Plant doctor prescribed prescription strength medication for pain as needed.
A maintenance mechanic stepped off process piping and his left foot opened a 1-1/2 inch drain valve. Hot caustic came out of the drain valve and got onto his left calf, causing first degree and second degree burns to contacted area. Area size was 2 inches by 3 inches. No lost time or restricted duty.
A Maintenance Mechanic was using an air impact tool when the air supply hose developed a hole. The escaping air caused dust particles to become airborne. A dust particle got into the mechanics left eye causing a corneal abrasion. An antibiotic was prescribed as a precautionary measure against infection. No lost work days or restrictions.
INJURED EE WAS LOOKING UP WHILE A COWORKER HOISTED A 5-GAL BUCKET OF TOOLS UP TO A WORK PLATFORM. THE INJURED EE FELT A FOREIGN BODY ENTER HIS RIGHT EYE. THE EE'S EYE WAS FLUSHED AT THE PLANT MEDICAL FACILITY & EE FELT FINE. THE FOLLOWING DAY (1/24/04) EE'S RT EYE WAS IRRITATED AGAIN. HE WAS REFERRED TO A LOCAL OPTHOMOLOGIST FOR EVALUATION. OPHTHOMOLOGIST REMOVED A SMALL (<1 MM) FO
EE WAS CLOSING A SIX (6) INCH GATE VALVE USING A CHAIN ACTUTATOR. THE FOURTH FINGER OF HIS LEFT HAND GOT CAUGHT ON ONE OF THE CHAIN LINKS AND CAUSED A HAIRLINE FRACTURE OF THE FINGER.
Employee complaining of soreness in left wrist. On 01/10/2005, employee underwent surgery to repair carpal tunnel syndrome in left wrist. Company disputes carpal tunnel syndrome. Returned to work on 01/28/2005 with work limitations.