Inspection Detail
Inspection: 305893679 - Formosa Plastics Corporation
Inspection Information - Office: Peoria Area Office
Site Address:
Formosa Plastics Corporation
19800 Old Route 36
Illiopolis, IL 62539
Mailing Address:
P.O. Box 27, Illiopolis, IL 62539
Union Status: Union
SIC:2821
NAICS: 325211/Plastics Material and Resin Manufacturing
Inspection Type: Accident
Scope: Complete
Advanced Notice: N
Ownership: Private
Safety/Health: Health
Close Conference: 10/20/2004
Emphasis:
Case Closed: 05/19/2005
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 100272061 |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 43 | 3 | 2 | 48 | ||
| Current Violations | 36 | 9 | 3 | 48 | ||
| Initial Penalty | $150,500 | $210,000 | $0 | $1,000 | $0 | $361,500 |
| Current Penalty | $76,800 | $0 | $0 | $13,200 | $210,000 | $300,000 |
| 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 | 19100027 C01 | 10/22/2004 | 12/10/2004 | $900 | $1,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 2. | 01002A | Serious | 19100106 B02 VIIID | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 3. | 01002B | Serious | 19100106 B06 | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement | |
| 4. | 01003 | Serious | 19100119 C02 | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 5. | 01004 | Serious | 19100119 C03 | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 6. | 01005 | Serious | 19100119 D02 I | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 7. | 01006 | Serious | 19100119 D03 I | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 8. | 01007 | Other | 19100119 D03 II | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 9. | 01008 | Serious | 19100119 E03 I | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 10. | 01009 | Serious | 19100119 E03 V | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 11. | 01010 | Serious | 19100119 E03 VI | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 12. | 01011 | Serious | 19100119 E05 | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 13. | 01012A | Serious | 19100119 F01 I | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 14. | 01012B | Serious | 19100119 F01 IB | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement | |
| 15. | 01013 | Other | 19100119 F01 II | 10/22/2004 | 12/10/2004 | $2,700 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 16. | 01014 | Serious | 19100119 F01 IV | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 17. | 01015A | Serious | 19100119 G02 | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 18. | 01015B | Serious | 19100119 G03 | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement | |
| 19. | 01016 | Serious | 19100119 J02 | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 20. | 01017 | Serious | 19100119 J03 | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 21. | 01018 | Serious | 19100119 J04 I | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 22. | 01019 | Serious | 19100119 J04 III | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 23. | 01020 | Serious | 19100119 J04 IV | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 24. | 01021 | Serious | 19100119 J05 | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 25. | 01022 | Serious | 19100119 J06 II | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 26. | 01023 | Serious | 19100119 J06 III | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 27. | 01024 | Serious | 19100119 L01 | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 28. | 01025 | Serious | 19100119 N | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 29. | 01026 | Other | 19100119 O01 | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 30. | 01027 | Other | 19100119 O04 | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 31. | 01028 | Serious | 19100119 O05 | 10/22/2004 | 12/10/2004 | $900 | $1,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 32. | 01029 | Serious | 19100120 Q06 VD | 10/22/2004 | 12/10/2004 | $1,200 | $2,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 33. | 01030 | Serious | 19100120 Q07 | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 34. | 01031 | Other | 19100146 D06 | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 35. | 01032 | Serious | 19100146 K02 IV | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 36. | 01033 | Serious | 19100156 B01 | 10/22/2004 | 12/10/2004 | $900 | $1,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 37. | 01034A | Serious | 19100156 C01 | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 38. | 01034B | Serious | 19100156 C03 | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement | |
| 39. | 01035A | Serious | 19100269 A02 I | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 40. | 01035B | Serious | 19100269 A02 II | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement | |
| 41. | 01035C | Serious | 19100332 B01 | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement | |
| 42. | 01036 | Serious | 19100269 A03 | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 43. | 01037A | Serious | 19100305 B01 | 10/22/2004 | 12/10/2004 | $900 | $1,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 44. | 01037B | Serious | 19100305 B02 | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement | |
| 45. | 01038A | Serious | 19100333 A | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 46. | 01038B | Serious | 19100335 A01 I | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement | |
| 47. | 01039 | Serious | 19101017 D04 | 10/22/2004 | 12/10/2004 | $3,000 | $5,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 48. | 01040 | Serious | 19101017 I01 | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 49. | 01041A | Other | 19101048 H01 | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 50. | 01041B | Other | 19101048 H01 I | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement | |
| 51. | 01042A | Other | 19100132 F01 | 10/22/2004 | 12/10/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 52. | 01042B | Other | 19101048 N03 IV | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement | |
| 53. | 01043 | Serious | 19261101 F01 I | 10/22/2004 | 10/27/2004 | $1,500 | $2,500 | $0 | 11/10/2004 | F - Formal Settlement | |
| 54. | 02001 | Unclass | 19100106 H06 IV | 10/22/2004 | 12/10/2004 | $70,000 | $70,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 55. | 02002 | Unclass | 19100119 J04 II | 10/22/2004 | 12/10/2004 | $70,000 | $70,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 56. | 02003 | Unclass | 19100119 J05 | 10/22/2004 | 12/10/2004 | $70,000 | $70,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 57. | 03001 | Other | 19040029 B01 | 10/22/2004 | 12/10/2004 | $0 | $1,000 | $0 | 11/10/2004 | F - Formal Settlement | |
| 58. | 03002 | Other | 19100119 C01 | 10/22/2004 | 12/10/2004 | $0 | $0 | $0 | 11/10/2004 | F - Formal Settlement |
Investigation Summary
At approximately 10:45 pm on April 23, 2004, an explosion occurred at Formosa Plastics Corporation in Illiopolis, Illinois. This company manufactured specialty polyvinyl chloride resins. In Mod 3, at reactor 10, where there apparently was a large release, the equipment was found to be open to the atmosphere through the bottom valve and drain valve of the reactor. Employees #1 through #5 were killed. Employees #6 through #9 were hospitalized for burns and other injuries.
Keywords: BURN, EXPLOSION, PLASTIC MFG, CHEMICAL BURN, CHEMICAL
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 305893679 | Fatality | Burn/Scald(Heat) | Machinery maintenance occupations | ||
| 2 | 305893679 | Hospitalized injury | Burn/Scald(Heat) | Machinery maintenance occupations | ||
| 3 | 305893679 | Fatality | Burn/Scald(Heat) | Machinery maintenance occupations | ||
| 4 | 305893679 | Hospitalized injury | Burn/Scald(Heat) | Machinery maintenance occupations | ||
| 5 | 305893679 | Hospitalized injury | Other | Machinery maintenance occupations | ||
| 6 | 305893679 | Fatality | Burn/Scald(Heat) | Machinery maintenance occupations | ||
| 7 | 305893679 | Fatality | Burn/Scald(Heat) | Machinery maintenance occupations | ||
| 8 | 305893679 | Fatality | Burn/Scald(Heat) | Machinery maintenance occupations | ||
| 9 | 305893679 | Hospitalized injury | Burn/Scald(Heat) | Machinery maintenance occupations |
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