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Occupational Safety and Health Administration OSHA

Inspection Detail

Inspection: 308384890 - Domtar Industries, Inc

Inspection Information - Office: Madison


Inspection Nr: 308384890
Report ID: 0523300
Date Opened: 05/31/2006

Site Address:
Domtar Industries, Inc
100 Wisconsin River Drive
Port Edwards, WI 54469

Mailing Address:
, , 00000

Union Status: Union


NAICS: 322121/Paper (except Newsprint) Mills

Inspection Type: Referral

Scope: Partial

Advanced Notice: N

Ownership: Private

Safety/Health: Safety

Close Conference: 07/25/2006

Planning Guide: Safety-Manufacturing


Case Closed: 09/15/2006

Related Activity
Type Activity Nr Safety Health
Accident 100801349
Referral 200804342 Yes
Violation Summary
Violations/Penalties Serious Willful Repeat Other Unclass Total
Initial Violations 2 2
Current Violations 2 2
Initial Penalty $12,000 $0 $0 $0 $0 $12,000
Current Penalty $7,800 $0 $0 $0 $0 $7,800
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. 01001A Serious 19100147 D04 I 08/03/2006 08/15/2006 $4,550 $7,000 $0 I - Informal Settlement  
2. 01001B Serious 19100147 D06 08/03/2006 08/15/2006 $0 $0 $0 I - Informal Settlement  
3. 01002 Serious 19100133 A01 08/03/2006 08/15/2006 $3,250 $5,000 $0 I - Informal Settlement  

Investigation Summary

Investigation Nr: 200801611
Event: 05/30/2006
Two Employees Are Burned In Weak Black Liquor Release

Between 10:30 and 11:00 a.m. May 30, 2006, Employees #1 and #2, who were maintenance workers, were working in the pump room, removing the pump for the weak black liquor storage tank. This activity required group lockout procedures. Procedures were not developed to identify the specific responsibilities for group lockout. The operators issue the line-breaking permits to the maintenance workers performing the task. The operators are tasked with closing specific valves in this line for this task. Lockout of the main circuit for the weak black liquor pump was done by Employees #1 and #2. The line breaking permit was issued by the operations department, who was at the time of the request working on an evaporator pump. Operations issued the line-break permit without closing the valves because they were "pressed for time." Operations filled out the permit with the intent of coming back in what he thought would be a couple minutes to close the valves for which he was responsible. He did not expect that the maintenance workers would start as soon as they had. The operations department was responsible for closing the valve on the suction side of the pump. This valve was not closed which resulted in the release of the weak black liquor. Employees #1 and #2 checked the bleed off valve for the pump and nothing came out. One employee noticed that the bleed off valve was caked with dried weak liquor. He attempted boring it with a wire brush and still no solvent came out. The gate valves were checked by turning the handles and they did not move which indicated that they were in the 'open' position. One employee stated that the valve on the suction side was not seen, when he checked the other valves. Employees #1 and #2 began removing the bolts from the pump once the coupler was removed. All but four bolts were removed as a matter of practice. The last four bolts were loosened, and Employees #1 and #2 began prying the pump away from the volute, when the weak black liquor was released. Both employees ran out the door to the showers as the release occurred. Employees #1 and #2 sustained chemical burns and were hospitalized.

Keywords:maintenance, work rules, lockout, valve, chemical burn, pump, accidental discharge, chemical

Investigated Inspection
# Inspection Age Sex Degree Nature Occupation
1 308384890 Hospitalized injury Burn(Chemical) Machinery maintenance occupations
2 308384890 Hospitalized injury Burn(Chemical) Machinery maintenance occupations
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