Inspection Detail

Inspection: 301406500 - Phillips Petroleum Co.

Inspection Information - Office: Houston South Area Office

Inspection Nr: 301406500

Report ID: 0626700

Date Opened: 03/27/2000

Site Address:
Phillips Petroleum Co.
1400 Jefferson St.
Pasadena, TX 77501

Mailing Address:
Po Box 792, Pasadena, TX 77501

Union Status: Union

SIC:2821

NAICS: 325211/Plastics Material and Resin Manufacturing

Inspection Type: Accident

Scope: Partial

Advanced Notice: N

Ownership: Private

Safety/Health: Safety

Close Conference: 09/07/2000

Emphasis:

Case Closed: 08/19/2003

Related Activity
Type	Activity Nr	Safety
Accident	101930121
Complaint	77080976	Yes
Inspection	123267890

Violation Summary
Violations/Penalties	Serious	Willful	Repeat	Other	Unclass	Total
Initial Violations	13	34	2	1		50
Current Violations	6		1	1	30	38
Initial Penalty	$66,000	$2,380,000	$70,000	$1,000	$0	$2,517,000
Current Penalty	$33,500	$0	$35,000	$1,000	$2,100,000	$2,169,500
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	19100106 I01	09/21/2000	09/26/2000	$0	$7,000	$0	10/04/2000	R - Review Commission	Citation has been deleted.
2.	01002	Serious	19100119 D03 IB	09/21/2000	09/26/2000	$7,000	$7,000	$0	10/04/2000	R - Review Commission
3.	01003	Serious	19100119 E03 II	09/21/2000	10/24/2000	$7,000	$7,000	$0	10/04/2000	R - Review Commission
4.	01004	Serious	19100119 H02 I	09/21/2000	10/24/2000	$7,000	$7,000	$0	10/04/2000	R - Review Commission
5.	01005	Serious	19100119 H02 II	09/21/2000	10/24/2000	$0	$7,000	$0	10/04/2000	R - Review Commission	Citation has been deleted.
6.	01006	Serious	19100119 J04 IV	09/21/2000	09/26/2000	$7,000	$7,000	$0	10/04/2000	R - Review Commission
7.	01007	Serious	19100119 J05	09/21/2000	10/24/2000	$0	$7,000	$0	10/04/2000	R - Review Commission	Citation has been deleted.
8.	01008	Serious	19100120 Q03 III	09/21/2000	09/26/2000	$0	$2,000	$0	10/04/2000	R - Review Commission	Citation has been deleted.
9.	01009	Serious	19100120 Q03 VII	09/21/2000	09/26/2000	$0	$3,500	$0	10/04/2000	R - Review Commission	Citation has been deleted.
10.	01010	Serious	19100120 Q06	09/21/2000	10/24/2000	$3,500	$3,500	$0	10/04/2000	R - Review Commission
11.	01011	Serious	19100120 Q09 I	09/21/2000	10/24/2000	$2,000	$2,000	$0	10/04/2000	R - Review Commission
12.	01012	Serious	19100120 Q11 I	09/21/2000	10/24/2000	$0	$3,500	$0	10/04/2000	R - Review Commission	Citation has been deleted.
13.	01013	Serious	19101200 G01	09/21/2000	10/24/2000	$0	$2,500	$0	10/04/2000	R - Review Commission	Citation has been deleted.
14.	02001	Willful	19100119 F01 IB	09/21/2000	11/08/2000	$0	$70,000	$0	10/04/2000	R - Review Commission	Citation has been deleted.
15.	02002	Unclass	19100119 G01 I	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
16.	02003	Unclass	19100119 G01 I	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
17.	02004	Unclass	19100119 G01 I	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
18.	02005	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
19.	02006	Unclass	19100119 G01 I	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
20.	02007	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
21.	02008	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
22.	02009	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
23.	02010	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
24.	02011	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
25.	02012	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
26.	02013	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
27.	02014	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
28.	02015	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
29.	02016	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
30.	02017	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
31.	02018	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
32.	02019	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
33.	02020	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
34.	02021	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
35.	02022	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
36.	02023	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
37.	02024	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
38.	02025	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
39.	02026	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
40.	02027	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
41.	02028	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
42.	02029	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
43.	02030	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
44.	02031	Unclass	19100119 G01	09/21/2000	11/23/2000	$70,000	$70,000	$0	10/04/2000	R - Review Commission
45.	02032	Willful	19100119 I02 II	09/21/2000	09/26/2000	$0	$70,000	$0	10/04/2000	R - Review Commission	Citation has been deleted.
46.	02033	Willful	19100119 J05	09/21/2000	11/23/2000	$0	$70,000	$0	10/04/2000	R - Review Commission	Citation has been deleted.
47.	02034	Willful	19100147 D02	09/21/2000	09/26/2000	$0	$70,000	$0	10/04/2000	R - Review Commission	Citation has been deleted.
48.	03001	Repeat	19100119 E05	09/21/2000	10/24/2000	$35,000	$35,000	$0	10/04/2000	R - Review Commission
49.	03002	Repeat	19100119 F01	09/21/2000	12/23/2000	$0	$35,000	$0	10/04/2000	R - Review Commission	Citation has been deleted.
50.	04001	Other	19100120 Q02 X	09/21/2000	09/29/2000	$1,000	$1,000	$0	10/04/2000	R - Review Commission

Investigation Summary

Investigation Nr: 201921863

Event: 03/27/2000

One Employee Killed 145 Injured In Fire And Explosion

While preparing a butadiene intermediate vessel for cleaning, chemical residue was left inside the vessel for several weeks forming "popcorn" polymer. During routine checks, someone blocked in the vessel. The chemical continued to polymerize for several days building pressure within the vessel. When the pressure exceeded the limits of the vessel, it ruptured releasing a large quantity of flammable vapor which ignited. Employee #1 was killed and approximately 145 other employees suffered injuries that required medical attention ranging from first aid to hospitalization.

Keywords: EXPLOSION, FIRE, BURN, HEAT, SPRAIN, CHEMICAL, CHEMICAL BURN, CHEMICAL REACTION, CHEMICAL VAPOR

Investigated Inspection
#	Inspection	Degree of Injury	Nature of Injury	Occupation
1	301406500	Non Hospitalized injury	Other	Occupation not reported
2	301406500	Non Hospitalized injury	Other	Occupation not reported
3	301406500	Non Hospitalized injury	Other	Occupation not reported
4	301406500	Non Hospitalized injury	Other	Occupation not reported
5	301406500	Non Hospitalized injury	Other	Occupation not reported
6	301406500	Non Hospitalized injury	Other	Occupation not reported
7	301406500	Non Hospitalized injury	Dislocation	Occupation not reported
8	301406500	Non Hospitalized injury	Other	Occupation not reported
9	301406500	Non Hospitalized injury	Other	Occupation not reported
10	301406500	Non Hospitalized injury	Other	Occupation not reported
11	301406500	Non Hospitalized injury	Other	Occupation not reported
12	301406500	Non Hospitalized injury	Other	Occupation not reported
13	301406500	Non Hospitalized injury	Other	Occupation not reported
14	301406500	Non Hospitalized injury	Other	Occupation not reported
15	301406500	Non Hospitalized injury	Other	Occupation not reported
16	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
17	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
18	301406500	Non Hospitalized injury	Other	Occupation not reported
19	301406500	Non Hospitalized injury	Other	Occupation not reported
20	301406500	Non Hospitalized injury	Other	Occupation not reported
21	301406500	Non Hospitalized injury	Other	Occupation not reported
22	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
23	301406500	Non Hospitalized injury	Hearing Loss	Occupation not reported
24	301406500	Non Hospitalized injury	Hearing Loss	Occupation not reported
25	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
26	301406500	Non Hospitalized injury	Other	Occupation not reported
27	301406500	Non Hospitalized injury	Other	Occupation not reported
28	301406500	Non Hospitalized injury	Other	Occupation not reported
29	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
30	301406500	Non Hospitalized injury	Other	Occupation not reported
31	301406500	Non Hospitalized injury	Other	Occupation not reported
32	301406500	Non Hospitalized injury	Other	Occupation not reported
33	301406500	Non Hospitalized injury	Other	Occupation not reported
34	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
35	301406500	Non Hospitalized injury	Other	Occupation not reported
36	301406500	Non Hospitalized injury	Other	Occupation not reported
37	301406500	Non Hospitalized injury	Other	Occupation not reported
38	301406500	Fatality	Burn/Scald(Heat)	Occupation not reported
39	301406500	Non Hospitalized injury	Other	Occupation not reported
40	301406500	Non Hospitalized injury	Other	Occupation not reported
41	301406500	Non Hospitalized injury	Other	Occupation not reported
42	301406500	Hospitalized injury	Other	Occupation not reported
43	301406500	Non Hospitalized injury	Other	Occupation not reported
44	301406500	Non Hospitalized injury	Other	Occupation not reported
45	301406500	Non Hospitalized injury	Other	Occupation not reported
46	301406500	Non Hospitalized injury	Other	Occupation not reported
47	301406500	Hospitalized injury	Burn/Scald(Heat)	Occupation not reported
48	301406500	Hospitalized injury	Burn/Scald(Heat)	Occupation not reported
49	301406500	Hospitalized injury	Burn/Scald(Heat)	Occupation not reported
50	301406500	Hospitalized injury	Other	Occupation not reported
51	301406500	Hospitalized injury	Burn/Scald(Heat)	Occupation not reported
52	301406500	Hospitalized injury	Other	Occupation not reported
53	301406500	Non Hospitalized injury	Other	Occupation not reported
54	301406500	Non Hospitalized injury	Other	Occupation not reported
55	301406500	Non Hospitalized injury	Other	Occupation not reported
56	301406500	Non Hospitalized injury	Other	Occupation not reported
57	301406500	Non Hospitalized injury	Other	Occupation not reported
58	301406500	Non Hospitalized injury	Other	Occupation not reported
59	301406500	Non Hospitalized injury	Other	Occupation not reported
60	301406500	Non Hospitalized injury	Other	Occupation not reported
61	301406500	Non Hospitalized injury	Other	Occupation not reported
62	301406500	Non Hospitalized injury	Other	Occupation not reported
63	301406500	Non Hospitalized injury	Other	Occupation not reported
64	301406500	Non Hospitalized injury	Other	Occupation not reported
65	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
66	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
67	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
68	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
69	301406500	Non Hospitalized injury	Hearing Loss	Occupation not reported
70	301406500	Non Hospitalized injury	Other	Occupation not reported
71	301406500	Non Hospitalized injury	Other	Occupation not reported
72	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
73	301406500	Non Hospitalized injury	Other	Occupation not reported
74	301406500	Non Hospitalized injury	Other	Occupation not reported
75	301406500	Non Hospitalized injury	Other	Occupation not reported
76	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
77	301406500	Non Hospitalized injury	Other	Occupation not reported
78	301406500	Non Hospitalized injury	Other	Occupation not reported
79	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
80	301406500	Non Hospitalized injury	Other	Occupation not reported
81	301406500	Non Hospitalized injury	Other	Occupation not reported
82	301406500	Non Hospitalized injury	Strain/Sprain	Occupation not reported
83	301406500	Non Hospitalized injury	Other	Occupation not reported
84	301406500	Non Hospitalized injury	Other	Occupation not reported
85	301406500	Non Hospitalized injury	Other	Occupation not reported
86	301406500	Non Hospitalized injury	Other	Occupation not reported

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