Text For Citation: 01 Item/Group: 001 Hazard: EXPLOSION

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to: The hazard of fire/explosion caused by pipe failure resulting in rapid depressurization of entire hydrogenation system (operating at approximately 4,470 psig) and subsequent release of recycle hydrogen gas stream to the atmosphere. (a) Acetylenics Plant, Hydrogenation Unit: Deficiencies in equipment that were outside acceptable limits were not corrected before further use in a safe and timely manner in that a hydrogen gas recycle pipeline (equipment line 4" P-317-645) was not replaced when inspection data showed a wall thickness (at test point known as P-4B) to be below the BASF minimum line specification recommended thickness (i.e.: below retirement thickness). Among other methods, one feasible and acceptable abatement method to correct this hazard is to replace equipment line 4" P-317-645 and all carbon steel sections of the hot hydrogen gas recycle lines with stainless steel prior to resuming production, and evaluate piping inspection procedures to ensure inspection results are properly analyzed, reviewed, and acted upon.