major incident english
TRANSCRIPT
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Major incident
Final report
Near miss with potential for fatality involvingrisks of level fall and access the confined space.
ALUMAR - So Luis - 161Z
September, 3rd, 2003
INDEX
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1.0 - SUMMARY 3
2.0 - BACKGROUND 3
3.0 - INVESTIGATION PROCESS 4
3.1 - Investigation team 4
4.0 - EVENTS CRONOLOGY 5
5.0 - KNOWN FACTORS 6
5.1 - General Data 6
5.2 - Personal Data 6
5.3 - Equipment - Task necessity 75.3.1 Developed Activity - Reactor plenun cleanness 7
5.4 - Existent preventive measures for the execution of the task 7
6.0 - CONTRIBUTIVE FACTORS 8
7.0 - ROOT CAUSES 8
8.0 - TAKEN ACTIONS 8
9.0 - ATTACHMENTS 8
9.1- Event simulation 8
1.0- EXECUTIVE SUMMARY
In September, 3rd, 2003 at 4:30 p.m., the 162Z Alumina Distribution specialized
mechanical (Robisley Maia Aguiar), moving to the dressing room near the 141F
building, looked a person get into the 161-RE-009 reactor plenun in a wrong way.
The person was getting into the reactor plenun stepping in its structure beam,
without using the elevator platform neither accomplishing the confined space.
The reactor plenun is located at approximately 8 meters and its classified as
class Cconfined space. To execute a task in this environmental it is necessary to
accomplish the procedures of works in Confined Space and Prevention of fall. In
September 4th, 2003 it was identified that the person who was seen get into the
plenum reactor was the operator Jos Carlos Saraiva.
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2.0 - BACKGROUND
Consortium of Aluminum of Maranho - ALUMAR in So Luis, MA, Brazil - it
is a consortium formed by Alcoa Alumnio S.A., BHP-Billiton Metals S.A.,
Aluminum Alcan of Brazil Ltd. and Abalco, and Alcoa manages its operation. A
Port, an Alumina Refinery with production of 1.244 MTPY and a Smelter of
380.000 MTPY of aluminum compose the plant. There are 2050 direct
employees and 1500 contracted employees approximately at the plant.
The ABC area is located in the Smelter and it is responsible for the
distribution of Alumina and Bath for the Pot Rooms and for the generation and
distribution of air compressed for all the Smelter. In the Alumina Distribution area
are located the Reactors A-398 used in the treatment of the Gases generated in
the eletrolitics pots. We have a total of 55 reactors, distributed in the following
way: 18 reactors in the Line I, 22 reactors in the Line II and 15 reactors in the
Line III.
The reactor has the function of treating the gases generated in the eletrolitics
process. This treatment is done through the adsorption of the existent fluoride in
the gas to the Alumina that passes through the reactor. The Alumina that feeds
the reactor moves above the deviation perforated plates, through the ones the
gas originating from the eletrolitics pots is addressed, passing through the
eletrolitics layer. The holes of these plates in the course of time are obstructed
and it is necessary to substitute the plates for other clean ones, in other words,
other plates with cleared holes. When this activity of plates substitution is done,
also is done the cleaning of the reactor plenun. The plenun is the compartment of
the reactor that is below the deviation plates. This compartment has restricted
access and it is classified as confined space class C.
3.0 - INVESTIGATION PROCESS
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3.1 - Investigation team
Name Function
Nilson Frazo Ferraz Smelter Manager
Jos Maurcio Macedo EHS Manager
Oder Lima MSVIP Superintendent
Robson Cunha EHS Superintendent
Jos Carlos Viegas EHS Technical
Carlos Augusto Gervsio ABC Supervisor
Wilton de Jesus Sousa ABC Production Foreman
Paulo Rodrigues EHS Supervisor
Jos Carlos Saraiva Smelter Operator
4.0 - CHRONOLOGY OF THE EVENTS
Day 09/03/2003
1. At 3:30 p.m., beginning of the work day shift of the Plates
Maintenance Group in the Reactor 161 - RE-009;
2. At 4:20 p.m., the employee Jos Carlos Saraiva receives a private
phone call informing that his mother was badly sick;
3. At 4:30 p.m. the elevator platform (zealous) that is used for access
to the plenun of the reactors, it presented operational problems;
4. At 4:35 p.m. the electric corrective maintenance group of the Shift
was called to correct the problem of the platform;
5. At 4:40 p.m. the Mechanic Robisley Aguiar observes a person
accessing the plenun of the Reactor 161-RE-009;
6. At 4:41 p.m. the electrician of the corrective maintenance group
begins tests to solve platform problem, without success cause it
was not an electric problem;
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7. At 4:45 p.m. the operator Luis Sergio Freitas got to adjust the
controlling valves of pressure allowing the operation of the
platform;
8. At 4:47 p.m. the group begins the ascent of the platform. When
they arrived to plenun access door, the group observed that the
operator Jos Carlos Saraiva was already inside of the plenun;
9. At 4:49 p.m. in spite of the situation to be atypical, the group
continued the task of cleaning the plenun;
Day 09/04/2003
1. At 08:30 a.m. the mechanic Robisley Aguiar communicates the fact
witnessed to the operation foreman of the area 161Z, Mr. Wilton de
Jesus Sousa;
2. The operation foreman waits for the arrival of the referred group,
foreseen for the 3:30 p.m. to get an explanation of the situation;
3. At 3:30 p.m. after the arrival of the shift, the operation Foreman, Mr.
Wilton de Jesus Sousa identifies that person seen getting into the
reactor plenun was the operator Jos Carlos Saraiva;
5.0 - Known Factors5.1 - General Data
Date: 09/03/2003
Time: 4:50 p.m.
Local: 161Z Alumina Distribution - Reactors Bank
Department: MSVIP/ABC
Locality: So Luis - Alumar - Brazil
5.2 - Personal Data
Name: Jos Carlos Saraiva Junior
Identification number: 203312
Experience at the function: 3 years and 6 months
The employee had been recycled in all of the mandatory norms (fall control,
lockout, tagout and verification procedures, confined space) in the second
semester of 2002.
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5.3 Equipment - Task Necessity
5.3.1- Developed Activity - Cleaning of the Reactor plenun
Whenever it is made the Maintenance of Plates of the Reactor, it is also
made the cleaning of the plenun. The frequency of the cleaning of the
plenun is two years, however due of the total number of reactors in the
Smelter (55 reactors) every two weeks it is made a plenun cleaning.
5.4 Existent preventive measures for the execution of the task
As the referred task (cleaning of the plenun of the reactor) is executed in an
environmental classified as confined space class C, the task is done
following all safety countermeasures included in the mandatory standards for
works in confined space. We can mention among the measures:
Measurement of levels of oxygen and carbon monoxide, before the
people get into the space;
Continuous Monitoring of the levels of oxygen and carbon
monoxide in the space confined during the execution of the task;
Continuous Presence of the confined space observer during theexecution of the task;
The reactor plenun is located approximately to 8 meters above the soil. To
access its entrance door the person has to use the people's elevation equipment,
once access stairway doesn't exist. This way, during the execution of this task all
the safety countermeasures foreseen in the mandatory standards for fall control
must be followed. We can mention the obligation of use the elevator platform.
6.0 - CONTRIBUTIVE FACTORS
6.1 - Phone call received by the operator Jose Carlos Saraiva before the
beginning of the works.
7.0 - ROOT CAUSE
Violation of task execution procedure and mandatory norms of fallsprevention and confined space.
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8.0 - TAKEN ACTIONS
8.5 - Communication of the occurrence to the leaderships
8.6 - Application of discipline measure to the employee Jose Carlos
Saraiva
7.3- Instructions to the others that execute the task
7.4- Deployment of the occurrence for all plant employees
9.0 - ATTACHMENTS9.1 - Simulation of the event