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Inspection Detail
Inspection: 1623687.015 - Bp Products North America, Inc.
Inspection Information - Office: Toledo Area Office
Site Address:
Bp Products North America, Inc.
4001 Cedar Point Rd
Oregon, OH 43616
Mailing Address:
4001 Cedar Point Rd, Oregon, OH 43616
Union Status: Union
SIC:
NAICS: 324110/Petroleum Refineries
Inspection Type: Fat/Cat
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Safety
Close Conference: 09/21/2022
Emphasis: N:Chemnep
Case Closed: 06/26/2024
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 1949430 |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 10 | 1 | 11 | |||
| Current Violations | 8 | 8 | ||||
| Initial Penalty | $156,250 | $0 | $0 | $0 | $0 | $156,250 |
| Current Penalty | $125,000 | $0 | $0 | $0 | $0 | $125,000 |
| FTA Penalty | $0 | $0 | $0 | $0 | $0 | $0 |
| # | Citation ID | Citaton Type | Standard Cited | Issuance Date | Abatement Due Date | Current Penalty | Initial Penalty | FTA Penalty | Contest | Latest Event | Note |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1. | 01001 | Serious | 19100119 D03 II | 03/13/2023 | 04/14/2023 | $15,625 | $15,625 | $0 | 04/04/2023 | F - Formal Settlement | |
| 2. | 01002 | Serious | 19100119 E01 | 03/13/2023 | 04/14/2023 | $15,625 | $15,625 | $0 | 04/04/2023 | F - Formal Settlement | |
| 3. | 01003 | Serious | 19100119 E03 III | 03/13/2023 | 04/14/2023 | $0 | $15,625 | $0 | 04/04/2023 | F - Formal Settlement | Citation has been deleted. |
| 4. | 01004 | Serious | 19100119 E03 IV | 03/13/2023 | 04/26/2023 | $15,625 | $15,625 | $0 | 04/04/2023 | F - Formal Settlement | |
| 5. | 01005 | Serious | 19100119 E06 | 03/13/2023 | 04/26/2023 | $0 | $15,625 | $0 | 04/04/2023 | F - Formal Settlement | Citation has been deleted. |
| 6. | 01006 | Serious | 19100119 F01 I C | 03/13/2023 | 04/14/2023 | $15,625 | $15,625 | $0 | 04/04/2023 | F - Formal Settlement | |
| 7. | 01007 | Serious | 19100119 F01 I D | 03/13/2023 | 04/14/2023 | $15,625 | $15,625 | $0 | 04/04/2023 | F - Formal Settlement | |
| 8. | 01008A | Serious | 19100119 F01 I E | 03/13/2023 | 04/14/2023 | $15,625 | $15,625 | $0 | 04/04/2023 | F - Formal Settlement | |
| 9. | 01008B | Serious | 19100119 F04 | 03/13/2023 | 04/26/2023 | $0 | $0 | $0 | 04/04/2023 | F - Formal Settlement | Citation has been deleted. |
| 10. | 01009 | Serious | 19100119 F01 II | 03/13/2023 | 04/26/2023 | $15,625 | $15,625 | $0 | 04/04/2023 | F - Formal Settlement | |
| 11. | 01010 | Serious | 19100119 G01 I | 03/13/2023 | 04/14/2023 | $15,625 | $15,625 | $0 | 04/04/2023 | F - Formal Settlement | |
| 12. | 02001 | Other | 19100119 E03 VI | 03/13/2023 | 04/14/2023 | $0 | $0 | $0 | 04/04/2023 | F - Formal Settlement | Citation has been deleted. |
Investigation Summary
At 6:45 p.m. on September 20, 2022, the south area units of the refinery were experiencing process upset conditions, including lifting pressure safety valves and loss of pump arounds on the crude tower. Due to an incident earlier in the day, the NT/Sat gas unit and Coker gas plant were not in normal operating conditions. During work to troubleshoot and provide stability to the process units, the opening of a flow control valve to the absorber stripper tower in the Coker gas plant resulted in naphtha to flow downstream, eventually filling the TIU fuel gas mix drum with naphtha. This led to liquid in the refinery fuel gas system, which initiated the shutting down of some operating units. During outside employee response to the high liquid level in the TIU fuel gas mix drum, naphtha was released into the atmosphere, forming a flammable vapor cloud at ground level and in the oily water sewer at the refinery. At approximately 6:47 pm, the vapor cloud ignited at/near the TIU fuel gas mix drum, possibly due to nearby fired heaters, in the crude unit. Both of the outside employees who responded to the high liquid levels were severely burned in the explosion. Both of the employees died due to their burn injuries in the early morning of September 21, 2022.
Keywords: Burn, Explosion, Flammable Vapors, Ignite, Ignition, Refinery, Troubleshooting
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 1623687.015 | 34 | M | Fatality | ||
| 2 | 1623687.015 | 32 | M | Fatality |