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Inspection Detail
Inspection: 100596980 - Union Carbide Chemicals & Plastics
Inspection Information - Office: Charleston Area Office
Site Address:
Union Carbide Chemicals & Plastics
437 Maccorkle Avenue
South Charleston, WV 25303
Mailing Address:
, , 00000
Union Status: Union
SIC:2869
NAICS: 0
Inspection Type: Accident
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Safety
Close Conference: 06/09/1992
Emphasis:
Case Closed: 07/01/1996
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 360338982 |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 13 | 3 | 5 | 21 | ||
| Current Violations | 10 | 3 | 5 | 18 | ||
| Initial Penalty | $52,000 | $99,000 | $0 | $0 | $0 | $151,000 |
| Current Penalty | $46,000 | $99,000 | $0 | $0 | $0 | $145,000 |
| 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 | 5A0001 | 06/30/1992 | 07/03/1992 | $7,000 | $7,000 | $0 | 07/20/1992 | F - Formal Settlement | |
| 2. | 01002 | Serious | 5A0001 | 06/30/1992 | 07/03/1992 | $7,000 | $7,000 | $0 | 07/20/1992 | F - Formal Settlement | |
| 3. | 01003 | Serious | 19100120 P07 I | 06/30/1992 | 08/03/1992 | $2,500 | $2,500 | $0 | 07/20/1992 | F - Formal Settlement | |
| 4. | 01004 | Serious | 19100120 Q03 II | 06/30/1992 | 08/03/1992 | $5,000 | $5,000 | $0 | 07/20/1992 | F - Formal Settlement | |
| 5. | 01005A | Serious | 19100120 Q03 III | 06/30/1992 | 07/23/1992 | $5,000 | $5,000 | $0 | 07/20/1992 | F - Formal Settlement | |
| 6. | 01005B | Serious | 19100120 Q06 IVD | 06/30/1992 | 07/23/1992 | $0 | $0 | $0 | 07/20/1992 | F - Formal Settlement | |
| 7. | 01006 | Serious | 19100120 Q03 V | 06/30/1992 | 07/23/1992 | $5,000 | $5,000 | $0 | 07/20/1992 | F - Formal Settlement | |
| 8. | 01007 | Serious | 19100120 Q06 VB | 06/30/1992 | 07/23/1992 | $5,000 | $5,000 | $0 | 07/20/1992 | F - Formal Settlement | |
| 9. | 01008 | Serious | 19100120 Q11 II | 06/30/1992 | 07/23/1992 | $2,000 | $2,000 | $0 | 07/20/1992 | F - Formal Settlement | |
| 10. | 01009A | Serious | 19100134 E03 | 06/30/1992 | 08/03/1992 | $5,000 | $5,000 | $0 | 07/20/1992 | F - Formal Settlement | |
| 11. | 01009B | Serious | 19101200 H02 III | 06/30/1992 | 07/23/1992 | $0 | $0 | $0 | 07/20/1992 | F - Formal Settlement | |
| 12. | 01010 | Serious | 19100147 C04 II | 06/30/1992 | 08/03/1992 | $2,500 | $2,500 | $0 | 07/20/1992 | F - Formal Settlement | Citation has been deleted. |
| 13. | 01011 | Serious | 19100253 B04 III | 06/30/1992 | 07/03/1992 | $2,500 | $2,500 | $0 | 07/20/1992 | F - Formal Settlement | |
| 14. | 01012 | Serious | 19101001 K06 | 06/30/1992 | 07/03/1992 | $1,500 | $1,500 | $0 | 07/20/1992 | F - Formal Settlement | Citation has been deleted. |
| 15. | 01013 | Serious | 19101200 H01 | 06/30/1992 | 07/23/1992 | $2,000 | $2,000 | $0 | 07/20/1992 | F - Formal Settlement | Citation has been deleted. |
| 16. | 02001 | Willful | 19040002 A | 06/30/1992 | 07/08/1992 | $50,000 | $50,000 | $0 | 07/20/1992 | F - Formal Settlement | |
| 17. | 02002 | Willful | 19100120 Q03 IV | 06/30/1992 | 07/20/1992 | $31,500 | $31,500 | $0 | 07/20/1992 | F - Formal Settlement | |
| 18. | 02003 | Willful | 19101200 F05 II | 06/30/1992 | 07/13/1992 | $17,500 | $17,500 | $0 | 07/20/1992 | F - Formal Settlement | |
| 19. | 03001 | Other | 19100120 Q02 II | 06/30/1992 | 07/23/1992 | $0 | $0 | $0 | 07/20/1992 | F - Formal Settlement | |
| 20. | 03002 | Other | 19100120 Q02 VII | 06/30/1992 | 07/23/1992 | $0 | $0 | $0 | 07/20/1992 | F - Formal Settlement | |
| 21. | 03003 | Other | 19100120 Q02 X | 06/30/1992 | 07/23/1992 | $0 | $0 | $0 | 07/20/1992 | F - Formal Settlement | |
| 22. | 03004 | Other | 19100120 Q02 XI | 06/30/1992 | 07/23/1992 | $0 | $0 | $0 | 07/20/1992 | F - Formal Settlement | |
| 23. | 03005 | Other | 19100253 B02 IV | 06/30/1992 | 07/03/1992 | $0 | $0 | $0 | 07/20/1992 | F - Formal Settlement |
Investigation Summary
Employee #1, the basement operator at a powerhouse, was purging the liquid residue from the betene entrainment tank to the #16 boiler. Water and steam inadvertently got into the knockout pot, and materials that react to water, such as, but not limited to, acetic anhydride and diketene were in the tank. A reaction occurred, releasing flammable and hazardous materials into the atmosphere through a safety relief valve. The pressure relief device was only sized for an external fire, not a chemical reaction. As a result, the safety relief valves could not withstand the reaction. The overpressurization caused the steel pot to fail and explode. Employee #1 was killed.
Keywords: SAFETY RELIEF VALVE, TOXIC ATMOSPHERE, EQUIPMENT FAILURE, EXPLOSION, CHEMICAL REACTION, HIGH PRESSURE, VALVE, TANK, ACCIDENTAL DISCHARGE
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 100596980 | Fatality | Strain/Sprain | Occupation not reported |