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Inspection Detail
Inspection: 1529953.015 - Marathon Galveston Bay Refinery
Inspection Information - Office: Houston South Area Office
Site Address:
Marathon Galveston Bay Refinery
2401 5th Avenue South
Texas City, TX 77590
Mailing Address:
2401 5th Avenue South, Texas City, TX 77590
Union Status: Union
SIC:
NAICS: 324110/Petroleum Refineries
Inspection Type: Complaint
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Safety
Close Conference: 05/10/2021
Emphasis: N:Chemnep
Case Closed: 01/24/2022
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Referral | 1764486 | Yes | |
| Complaint | 1764513 | Yes | Yes |
| Inspection | 1549698 | Yes |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 5 | 5 | ||||
| Current Violations | 2 | 2 | 4 | |||
| Initial Penalty | $56,563 | $0 | $0 | $0 | $0 | $56,563 |
| Current Penalty | $18,500 | $0 | $0 | $26,000 | $0 | $44,500 |
| 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 F01 I G | 10/04/2021 | 12/15/2021 | $13,000 | $13,653 | $0 | I - Informal Settlement | ||
| 2. | 01002 | Serious | 19100119 F04 | 10/04/2021 | 11/22/2021 | $0 | $7,802 | $0 | I - Informal Settlement | Citation has been deleted. | |
| 3. | 01003 | Other | 19100119 L01 | 10/04/2021 | 12/15/2021 | $13,000 | $13,653 | $0 | I - Informal Settlement | ||
| 4. | 01004 | Other | 19100132 A | 10/04/2021 | 12/15/2021 | $13,000 | $13,653 | $0 | I - Informal Settlement | ||
| 5. | 01005 | Serious | 19100147 F04 | 10/04/2021 | 12/15/2021 | $5,500 | $7,802 | $0 | I - Informal Settlement |
Investigation Summary
At 3:15 p.m. on May 4, 2021, two employees working as plant operators for a petroleum refinery were helping start-up an alkylation unit after a turnaround. A 3/4" bull plug was not reinstalled properly after the line was purged. The bull plug blew out of a 2-inch line releasing a hydrofluoric (HF) acid vapor cloud. This resulted in a site and community shelter in place. Both employees were struck by HF acid and hospitalized. The employees were trapped without water or proper egress causing one to have to travel through the vapor cloud and up the tower to get breathing air. The other employee had to jump off an approximate 20-foot platform to escape (captured by camera footage). The deluge system release had a delay that exceeded 30 seconds before activation after the acid cloud was detected. This event sent these employees to the emergency room due to direct concentrated exposure to the acid resulting in extensive tissue damage to the face, eyes and lungs. Employee #1 was hospitalized to treat burns to his eyes, chest, face and respiratory tract. Employee #2 was hospitalized to treat burns to his eyes, abdomen, face and respiratory tract.
Keywords: Abdomen, Bull, Burn, Chemical, Chemical Burn, Chemical Exposure, Chemical Vapor, Chest, Corrosion, Corrosive, Equipment Operator, Eye, Face, Hydrofluoric Acid, Inadequate Maint, Inhalation, Installing, Insufficient Supervision, Lack of Work Procedures, Lung, Maintenance, Operator, Purging, Struck By, Supervision, Training
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 1529953.015 | 49 | M | Hospitalized injury | ||
| 2 | 1529953.015 | 38 | M | Hospitalized injury | Miscellaneous plant and system operators |