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Inspection Detail
Inspection: 109849802 - Dow Chemical Company
Inspection Information - Office: Hartford Area Office
Site Address:
Dow Chemical Company
1761 Route # 12
Gales Ferry, CT 06335
Mailing Address:
, , 00000
Union Status: NonUnion
SIC:2821
NAICS: 0
Inspection Type: Referral
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Health
Close Conference: 07/30/1999
Planning Guide: Health-Manufacturing
Emphasis: N:Psmpqv
Case Closed: 01/03/2000
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Referral | 901743088 | Yes |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 7 | 7 | ||||
| Current Violations | 4 | 1 | 5 | |||
| Initial Penalty | $28,000 | $0 | $0 | $0 | $0 | $28,000 |
| Current Penalty | $8,000 | $0 | $0 | $0 | $0 | $8,000 |
| 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 IC | 11/04/1999 | 12/23/1999 | $0 | $5,000 | $0 | I - Informal Settlement | Citation has been deleted. | |
| 2. | 01002 | Serious | 19100119 D03 IH | 11/04/1999 | 12/23/1999 | $750 | $1,500 | $0 | I - Informal Settlement | ||
| 3. | 01003 | Serious | 19100119 F01 ID | 11/04/1999 | 12/23/1999 | $3,000 | $5,000 | $0 | I - Informal Settlement | ||
| 4. | 01004A | Serious | 19100134 H02 I | 11/04/1999 | 11/09/1999 | $750 | $1,500 | $0 | I - Informal Settlement | ||
| 5. | 01004B | Other | 19100134 H03 IB | 11/04/1999 | 11/09/1999 | $0 | $0 | $0 | I - Informal Settlement | ||
| 6. | 01005A | Serious | 19100146 K01 IIIA | 11/04/1999 | 12/23/1999 | $0 | $5,000 | $0 | I - Informal Settlement | Citation has been deleted. | |
| 7. | 01005B | Serious | 19100146 L01 | 11/04/1999 | 12/23/1999 | $0 | $0 | $0 | I - Informal Settlement | Citation has been deleted. | |
| 8. | 01006 | Serious | 19100147 C04 IIB | 11/04/1999 | 12/23/1999 | $3,500 | $5,000 | $0 | I - Informal Settlement | ||
| 9. | 01007 | Other | 19101045 D01 | 11/04/1999 | 11/09/1999 | $0 | $5,000 | $0 | I - Informal Settlement |
Investigation Summary
At 3:00 a.m. on June 11, 1999, Reactor #1, part of the ABS polymerization process at Dow Chemical Company, began to overheat as the viscosity increased and threatened to stop agitation. This would cause a runaway reaction and ultimately result in an explosion. A small leak had developed in the lower bushing of the agitator and the employer instructed an employee to tighten it with a wrench. The employer replaced the normal feed (a mixture of styrene monomer, ground rubber, and acrylonitrile) with pure styrene monomer, which has a much lower viscosity, to "flush" the process in the hope that this would stop the leak. The mixture began to spill through the lower agitator packing and at approximately 2:30 p.m., there occurred a major spill of styrene monomer (flammable) and acrylonitrile (flammable and carcinogenic). Dow evacuated the plant and called for outside assistance to stop the spill and initiate clean-up. The clean-up was completed on June 12, 1999. This was the third near-miss that Dow experienced on this unit between August, 1998 and June 11, 1999. No information on employee injuries was provided.
Keywords: LEAK, REACTOR, ACRYLIC MONOMER, FLAMMABLE LIQUID, CHEMICAL REACTION, STYRENE, SPILL, ACCIDENTAL DISCHARGE, CHEMICAL
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 109849802 | Occupation Not Listed |