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Inspection Detail
Inspection: 1331986.015 - Barry Callebaut Usa Llc
Inspection Information - Office: Osha Philadelphia Area Office
Site Address:
Barry Callebaut Usa Llc
903 Industrial Highway
Eddystone, PA 19022
Mailing Address:
903 Industrial Highway, Eddystone, PA 19022
Union Status: NonUnion
SIC:
NAICS: 311352
Inspection Type: Referral
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Health
Close Conference: 07/20/2018
Emphasis:
Case Closed: 04/15/2019
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Referral | 1361723 | Yes | |
| Inspection | 1332346 | Yes |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 5 | 1 | 2 | 8 | ||
| Current Violations | 4 | 1 | 2 | 7 | ||
| Initial Penalty | $59,589 | $0 | $46,195 | $0 | $0 | $105,784 |
| Current Penalty | $32,659 | $0 | $32,337 | $0 | $0 | $64,995 |
| 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 | 19100145 C02 I | 01/17/2019 | 02/06/2019 | $5,497 | $7,853 | $0 | I - Informal Settlement | ||
| 2. | 01002A | Serious | 19100146 C04 | 01/17/2019 | 02/06/2019 | $9,054 | $12,934 | $0 | I - Informal Settlement | ||
| 3. | 01002B | Serious | 19100146 D02 | 01/17/2019 | 02/06/2019 | $0 | $0 | $0 | I - Informal Settlement | ||
| 4. | 01002C | Serious | 19100146 D03 IV | 01/17/2019 | 02/06/2019 | $0 | $0 | $0 | I - Informal Settlement | ||
| 5. | 01002D | Serious | 19100146 D06 | 01/17/2019 | 02/06/2019 | $0 | $0 | $0 | I - Informal Settlement | ||
| 6. | 01002E | Serious | 19100146 D09 | 01/17/2019 | 02/06/2019 | $0 | $0 | $0 | I - Informal Settlement | ||
| 7. | 01003 | Serious | 19100146 C08 II | 01/17/2019 | 02/06/2019 | $0 | $12,934 | $0 | I - Informal Settlement | Citation has been deleted. | |
| 8. | 01004 | Serious | 19100146 D05 I | 01/17/2019 | 02/06/2019 | $9,054 | $12,934 | $0 | I - Informal Settlement | ||
| 9. | 01005 | Serious | 19100146 G01 | 01/17/2019 | 02/06/2019 | $9,054 | $12,934 | $0 | I - Informal Settlement | ||
| 10. | 02001 | Repeat | 19100147 C04 II B | 01/17/2019 | 02/06/2019 | $32,337 | $46,195 | $0 | I - Informal Settlement | ||
| 11. | 03001 | Other | 19100147 C06 II | 01/17/2019 | 02/06/2019 | $0 | $0 | $0 | I - Informal Settlement | ||
| 12. | 03002 | Other | 19101200 F05 II | 01/17/2019 | 02/06/2019 | $0 | $0 | $0 | I - Informal Settlement |
Investigation Summary
At 2:00 p.m. on July 17, 2017, Employee #1, a maintenance mechanic, was working in Building A, at the Black Powder Line 3. The employee opened the upper access hatch on the vessel that contained the Cake Mill Air Heat Exchanger, to replace an old air filter that was located on top of the heat exchanger. During normal operations, nitrogen gas from a near-by cylindrical shape metal tank, flows through the heat exchanger. The employer used nitrogen as an inert gas to remove oxygen from the process equipment to decrease the chance of a fire or explosion. Employee #1 was working alone and later, a coworker discovered him face down with his face, chest, shoulders, arms, and hands inside the heat exchanger. The coworker saw him through the opening of the upper hatch of the vessel and the employee was unconscious and unresponsive. His coworkers pulled him out of the heat exchanger, and the paramedics transported him to a nearby medical center. He remained in the hospital for treatment of nitrogen asphyxiation.
Keywords: Asphyxiated, Maintenance, Nitrogen, Unconsciousness
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 1331986.015 | 47 | M | Hospitalized injury | Mechanical engineering technicians |