Inspection Detail

Inspection: 110132073 - Stone Container Corporation

Inspection Information - Office: Jacksonville Area Office

Inspection Nr: 110132073

Report ID: 0419700

Date Opened: 04/14/1994

Site Address:
Stone Container Corporation
1 Everett Avenue
Panama City, FL 32402

Mailing Address:
P. O. Box 2560, Panama City, FL 32402

Union Status: Union

SIC:2621

NAICS: 0

Inspection Type: Accident

Scope: Partial

Advanced Notice: N

Ownership: Private

Safety/Health: Safety

Close Conference: 08/04/1994

Emphasis:

Case Closed: 03/26/1997

Related Activity
Type	Activity Nr	Safety	Health
Accident	360147789

Violation Summary
Violations/Penalties	Serious	Willful	Repeat	Other	Unclass	Total
Initial Violations	11	14	2			27
Current Violations	8		1	1	14	24
Initial Penalty	$42,000	$980,000	$50,000	$0	$0	$1,072,000
Current Penalty	$25,000	$0	$15,000	$0	$650,000	$690,000
FTA Penalty	$0	$0	$0	$0	$0	$0

Violation Items
#	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	09/30/1994	10/05/1994	$4,500	$5,000	$0	10/24/1994	R - Review Commission
2.	01002	Serious	19100119 E01	09/30/1994	11/02/1994	$2,500	$2,500	$0	10/24/1994	R - Review Commission
3.	01003	Serious	19100147 C06 II	09/30/1994	10/08/1994	$2,500	$2,500	$0	10/24/1994	R - Review Commission
4.	01004	Serious	19100147 C08	09/30/1994	10/17/1994	$0	$5,000	$0	10/24/1994	R - Review Commission	Citation has been deleted.
5.	01005	Serious	19100147 F02 I	09/30/1994	11/02/1994	$0	$2,500	$0	10/24/1994	R - Review Commission	Citation has been deleted.
6.	01006	Serious	19100261 A04 I	09/30/1994	10/05/1994	$4,000	$5,000	$0	10/24/1994	R - Review Commission
7.	01007	Serious	19100261 A04 I	09/30/1994	10/05/1994	$4,000	$5,000	$0	10/24/1994	R - Review Commission
8.	01008	Serious	19100261 G09	09/30/1994	02/28/1997	$4,000	$5,000	$0	10/24/1994	P - Petition to Mod Abatement
9.	01009	Serious	19101200 G02 II	09/30/1994	10/08/1994	$2,500	$2,500	$0	10/24/1994	R - Review Commission
10.	01010A	Serious	19101200 G02 IV	09/30/1994	10/08/1994	$1,000	$2,000	$0	10/24/1994	R - Review Commission
11.	01010B	Serious	19101200 G02 V	09/30/1994	10/08/1994	$0	$0	$0	10/24/1994	R - Review Commission
12.	01010C	Serious	19101200 G02 VII	09/30/1994	10/08/1994	$0	$0	$0	10/24/1994	R - Review Commission
13.	01010D	Serious	19101200 G02 XII	09/30/1994	10/08/1994	$0	$0	$0	10/24/1994	R - Review Commission
14.	01011A	Other	19101200 G08	09/30/1994	10/08/1994	$0	$5,000	$0	10/24/1994	R - Review Commission
15.	01011B	Other	19101200 H01 III	09/30/1994	11/02/1994	$0	$0	$0	10/24/1994	R - Review Commission
16.	02001A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
17.	02001B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
18.	02001C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
19.	02002A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
20.	02002B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
21.	02002C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
22.	02003A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
23.	02003B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
24.	02003C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
25.	02004A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
26.	02004B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
27.	02004C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
28.	02005A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
29.	02005B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
30.	02005C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
31.	02006A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
32.	02006B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
33.	02006C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
34.	02007A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
35.	02007B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
36.	02007C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
37.	02008A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	J - ALJ Decision
38.	02008B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
39.	02008C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
40.	02009A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
41.	02009B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
42.	02009C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	J - ALJ Decision
43.	02010A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
44.	02010B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
45.	02010C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
46.	02011A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
47.	02011B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
48.	02011C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
49.	02012A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
50.	02012B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
51.	02012C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
52.	02013A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
53.	02013B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
54.	02013C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
55.	02014A	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$46,429	$70,000	$0	10/24/1994	R - Review Commission
56.	02014B	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
57.	02014C	Unclass	19100261 A04 I	09/30/1994	10/05/1994	$0	$0	$0	10/24/1994	R - Review Commission
58.	03001	Repeat	19100261 A04 I	09/30/1994	10/05/1994	$15,000	$25,000	$0	10/24/1994	R - Review Commission
59.	03002	Repeat	19100261 G17 I	09/30/1994	10/05/1994	$25,000	$25,000	$0	10/24/1994	R - Review Commission	Citation has been deleted.

Investigation Summary

Investigation Nr: 170670616

Event: 04/13/1994

3 employees killed, others injured when digester ruptures

At about 3:40 p.m. on April 13, 1994, digester #15, one of 22 digesters operating at the time, ruptured catastrophically during an otherwise normal cook that was processing wood chips into pulp at a pulp and paper mill. The top one-third of the digester tore through a concrete floor and the roof of the digester building, and crashed down through the roof of the paper building. Employees in that building were not injured. The center one-third of the digester split open and exploded outward into the digester room, inverting itself and causing severe damage to the digester building. The base section fell off of the digester rack. Employees #1, #2, and #3 were killed and Employees #4 through #8 were injured. Failure analysis revealed that at the point of initiation of the rupture, the carbon steel wall thickness was .010 inches; the minimum allowable wall thickness was calculated to be .058. This severe breach in minimum wall thickness occurred due to deteriorated stainless steel overlay on the interior of the digester. The area had been reoverlaid a number of times without wall thickness measurements having been taken to ensure maintenance of minimum allowable wall thickness.

Keywords: BURN, FRACTURE, INADEQUATE MAINT, PRESSURE VESSEL, WORK RULES, BOILER, RUPTURE, FLYING OBJECT, PROCESS SAFETY, MILL--PLANT

Investigated Inspection
#	Inspection	Degree of Injury	Nature of Injury	Occupation
1	110132073	Non Hospitalized injury	Fracture	Occupation not reported
2	110132073	Hospitalized injury	Burn/Scald(Heat)	Occupation not reported
3	110132073	Hospitalized injury	Burn/Scald(Heat)	Occupation not reported
4	110132073	Non Hospitalized injury	Burn/Scald(Heat)	Occupation not reported
5	110132073	Hospitalized injury	Burn/Scald(Heat)	Occupation not reported
6	110132073	Fatality	Burn/Scald(Heat)	Occupation not reported
7	110132073	Fatality	Burn/Scald(Heat)	Occupation not reported
8	110132073	Fatality	Burn/Scald(Heat)	Occupation not reported

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