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Inspection Detail
Inspection: 18181586 - Georgia-Pacific Resins, Inc.
Inspection Information - Office: Columbus Area Office
Site Address:
Georgia-Pacific Resins, Inc.
1975 Watkins Road
Columbus, OH 43207
Mailing Address:
, , 00000
Union Status: NonUnion
SIC:2821
NAICS: 0
Inspection Type: Accident
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Health
Close Conference: 01/30/1998
Emphasis:
Case Closed: 01/03/2000
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 100750272 |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 22 | 22 | ||||
| Current Violations | 22 | 22 | ||||
| Initial Penalty | $0 | $0 | $0 | $0 | $432,500 | $432,500 |
| Current Penalty | $0 | $0 | $0 | $0 | $432,500 | $432,500 |
| 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 | Unclass | 19100119 D02 IB | 03/02/1998 | 12/31/1998 | $284,500 | $284,500 | $0 | - | ||
| 2. | 01002 | Unclass | 19100119 D02 ID | 03/02/1998 | 12/31/1998 | $0 | $0 | $0 | - | ||
| 3. | 01003 | Unclass | 19100119 D02 IE | 03/02/1998 | 12/31/1998 | $0 | $0 | $0 | - | ||
| 4. | 01004 | Unclass | 19100119 D03 IB | 03/02/1998 | 12/31/1998 | $0 | $0 | $0 | - | ||
| 5. | 01005 | Unclass | 19100119 E01 | 03/02/1998 | 06/30/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 6. | 01006 | Unclass | 19100119 E03 I | 03/02/1998 | 06/30/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 7. | 01007 | Unclass | 19100119 E03 IV | 03/02/1998 | 06/30/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 8. | 01008 | Unclass | 19100119 E03 V | 03/02/1998 | 06/30/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 9. | 01009 | Unclass | 19100119 E03 VI | 03/02/1998 | 06/30/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 10. | 01010 | Unclass | 19100119 E05 | 03/02/1998 | 06/30/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 11. | 01011 | Unclass | 19100119 F03 | 03/02/1998 | 06/30/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 12. | 01012 | Unclass | 19100119 J04 I | 03/02/1998 | 06/30/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 13. | 01013 | Unclass | 19100119 L03 | 03/02/1998 | 06/30/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 14. | 01014 | Unclass | 19100119 M04 IV | 03/02/1998 | 12/31/1998 | $0 | $0 | $0 | - | ||
| 15. | 01015 | Unclass | 19100119 M06 | 03/02/1998 | 12/31/1998 | $0 | $0 | $0 | - | ||
| 16. | 01016 | Unclass | 19100119 O04 | 03/02/1998 | 12/31/1998 | $0 | $0 | $0 | - | ||
| 17. | 01017 | Unclass | 19100135 A01 | 03/02/1998 | 03/05/1998 | $0 | $0 | $0 | - | ||
| 18. | 02001 | Unclass | 19100106 H04 IVA | 03/02/1998 | 06/30/1999 | $148,000 | $148,000 | $0 | P - Petition to Mod Abatement | ||
| 19. | 02002A | Unclass | 19100119 F01 | 03/02/1998 | 08/01/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 20. | 02002B | Unclass | 19100119 F01 II | 03/02/1998 | 08/01/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 21. | 02002C | Unclass | 19100119 F01 III | 03/02/1998 | 08/01/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 22. | 02003 | Unclass | 19100119 G01 I | 03/02/1998 | 08/01/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 23. | 02004 | Unclass | 19100119 G02 | 03/02/1998 | 12/31/1998 | $0 | $0 | $0 | - | ||
| 24. | 02005 | Unclass | 19100119 J05 | 03/02/1998 | 06/30/1999 | $0 | $0 | $0 | P - Petition to Mod Abatement |
Investigation Summary
On September 10, 1997, Employee #1, a utility operator at Georgia-Pacific Resins, Inc., was making a Novolak resin (batch type 2140) in an 8,000 gallon K-2 reactor vessel. Novolak resin is a thermoplastic phenolic resin used in foundries. Employee #1 had mischarged phenol, formaldehyde, and sulfuric acid to the K-2 reactor vessel while making the Novolak resin. The vessel also had steam on its coils. The mischarge of chemicals caused an uncontrolled phenol-formaldehyde polymerization reaction, resulting in the over-pressurization and failure of the K-2 reactor vessel. Employee #1 was killed and his coworkers in the resin department sustained injuries.
Keywords: REACTOR, WORK RULES, STEAM, EXPLOSION, CHEMICAL REACTION, HIGH PRESSURE, FORMALDEHYDE, SULFURIC ACID, PRESSURE RELEASE
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 18181586 | Fatality | Concussion | Occupation not reported |