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Inspection Detail
Inspection: 309178523 - Cgi International, Inc.
Inspection Information - Office: Columbus Area Office
Site Address:
Cgi International, Inc.
Aep Muskingham River Plant 1501 Sparling Rd
Waterford, OH 45786
Mailing Address:
1215 Henderson Avenue, Washington, PA 15301
Union Status: NonUnion
SIC:5169
NAICS: 424690/Other Chemical and Allied Products Merchant Wholesalers
Inspection Type: Accident
Scope: Partial
Advanced Notice: N
Ownership: Private
Safety/Health: Health
Close Conference: 02/07/2007
Emphasis:
Case Closed: 04/23/2009
| Type | Activity Nr | Safety | Health |
|---|---|---|---|
| Accident | 100752666 |
| Violations/Penalties | Serious | Willful | Repeat | Other | Unclass | Total |
|---|---|---|---|---|---|---|
| Initial Violations | 7 | 1 | 8 | |||
| Current Violations | 7 | 1 | 8 | |||
| Initial Penalty | $8,850 | $0 | $0 | $300 | $0 | $9,150 |
| Current Penalty | $5,310 | $0 | $0 | $0 | $0 | $5,310 |
| 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 | 5A0001 | 06/15/2007 | 07/18/2007 | $900 | $1,500 | $0 | I - Informal Settlement | ||
| 2. | 01002A | Serious | 19100103 B01 IIA | 06/15/2007 | 10/04/2007 | $900 | $1,500 | $0 | P - Petition to Mod Abatement | ||
| 3. | 01002B | Serious | 19100103 B01 IIC | 06/15/2007 | 10/04/2007 | $0 | $0 | $0 | P - Petition to Mod Abatement | ||
| 4. | 01003 | Serious | 19100103 B01 IIIA | 06/15/2007 | 10/04/2007 | $900 | $1,500 | $0 | P - Petition to Mod Abatement | ||
| 5. | 01004 | Serious | 19100103 B03 IB | 06/15/2007 | 10/04/2007 | $1,260 | $2,100 | $0 | P - Petition to Mod Abatement | ||
| 6. | 01005 | Serious | 19100132 D02 | 06/15/2007 | 10/04/2007 | $450 | $750 | $0 | P - Petition to Mod Abatement | ||
| 7. | 01006 | Serious | 19100147 C01 | 06/15/2007 | 10/04/2007 | $450 | $750 | $0 | P - Petition to Mod Abatement | ||
| 8. | 01007 | Serious | 19101200 E01 | 06/15/2007 | 10/04/2007 | $450 | $750 | $0 | P - Petition to Mod Abatement | ||
| 9. | 02001 | Other | 19040029 A | 06/15/2007 | 10/04/2007 | $0 | $300 | $0 | P - Petition to Mod Abatement |
Investigation Summary
At approximately 8:55 a.m. on January 8, 2007, an employee, a truck driver arrived at the American Electric Power (AEP) Muskingum River plant located in Waterford, Ohio. The truck driver was delivering hydrogen gas to fill two 6500 cubic feet storage cylinders at the plant. The hydrogen gas was used to cool the generator at the power plant. At approximately 9:22 a.m., the employer, who was working alone at the time, was in the final stages of filling the cylinders. At this time witnesses heard a loud noise, like high pressure gas venting through a relief valve, and within 15 to 20 seconds, the hydrogen gas exploded, killing the employee and injuring eight AEP coworkers. The investigation revealed that the hydrogen gas over pressurized a rupture disk attached to one of the hydrogen cylinders. As the set pressure of the rupture disk was between 3500 and 4000 psi, and the maximum pressure that could have be put on the system during filling was 2600 psi, the rupture disk failed well below its designed pressure. The release of hydrogen through the relief vent piping, which terminated outside above the roof, also caused the copper vent tubing to fail and burst apart at a 45 degree elbow below the roof, therefore releasing hydrogen gas under the roof. This allowed the gas to accumulate into a large cloud that subsequently ignited and exploded. The force of the explosion killed the employee and injured nine AEP workers in an adjacent building.
Keywords: HYDROGEN, GAS, EXPLOSION, TRUCK DRIVER
| # | Inspection | Age | Sex | Degree of Injury | Nature of Injury | Occupation |
|---|---|---|---|---|---|---|
| 1 | 309178523 | Fatality | Bruise/Contus/Abras | Truck drivers, heavy |