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Inspection Detail
Inspection: 306447038 - Bayer Polymers Llc
Inspection Information - Office: Cincinnati Area Office
Site Address:
Bayer Polymers Llc
356 Three Rivers Parkway
Addyston, OH 45001
Mailing Address:
, , 00000
Union Status: Union
SIC:2821
NAICS: 325211/Plastics Material and Resin Manufacturing
Inspection Type: Accident
Scope: Partial
Advanced Notice: Y
Ownership: Private
Safety/Health: Safety
Close Conference: 07/17/2003
Emphasis:
Case Closed: 10/14/2003
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 101960847 |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 4 | 4 | ||||
| Current Violations | 3 | 1 | 4 | |||
| Initial Penalty | $6,500 | $0 | $0 | $0 | $0 | $6,500 |
| Current Penalty | $4,875 | $0 | $0 | $125 | $0 | $5,000 |
| 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 | 19100119 D03 II | 08/25/2003 | 08/28/2003 | $1,625 | $1,625 | $0 | I - Informal Settlement | ||
| 2. | 01002 | Serious | 19100119 E01 | 08/25/2003 | 08/29/2003 | $1,625 | $1,625 | $0 | I - Informal Settlement | ||
| 3. | 01003 | Serious | 19100119 F03 | 08/25/2003 | 08/28/2003 | $1,625 | $1,625 | $0 | I - Informal Settlement | ||
| 4. | 01004 | Other | 19101200 H03 II | 08/25/2003 | 08/29/2003 | $125 | $1,625 | $0 | I - Informal Settlement |
Investigation Summary
. On April 2, 2003, Employee #1 and a coworker, the technicians, were watching a polymerization process involving styrene and acrylonitrile monomers. Employee #1 and the coworker's jobs involved monitoring a reactor vessel throughout the process. At the end of the batch process, non-polymerized monomer and vapors were stripped from the reactor through a condenser system to a distillate collection tank and were ultimately charged to subsequent batches. Toward the end of the stripping process, Employee #1 left the control room to determine if enough distillate had been removed to allow the remaining water and mixture to be dumped to the "dirty" sewer and a collection system. While Employee #1 was in the vicinity of the reactor, an explosion occurred in a small auxiliary charge tank. A piece of metal struck Employee #1's abdomen and killed him. Although the charge tank was not in use at the time of the accident, a small amount of the batch had back-flowed through a valve between the reactor and the auxiliary tank during the reactive process. The batch continued to react in the auxiliary tank, overheating and overpressurizing the tank.
Keywords: ABDOMEN, REACTOR, ACRYLIC MONOMER, EXPLOSION, STYRENE, STRUCK BY, OVERHEATED, TANK, CHARGE BUCKET
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 306447038 | Fatality | Other | Technicians, n.e.c. |