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

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 toxic vapors from the uncontrolled release of an unknown mixture, due to inadequate process hazard evaluations of plating operations: a.) The Electric Materials Company, Plating Area - On or about April 8th, 2010, the Plating Operator transferred used Bright Dip Acid Solution (Nitric Acid/Sulfuric Acid Solution) from one fifty-five gallon drum into another. During the transfer, the Bright Dip Acid Solution reacted with the contents of the drum in which it was being pumped. The reaction resulted in chemical splashing and the formation of a vapor cloud which spread from the plating area into adjacent areas of the plant. The entire facility was evacuated and 20 employees were transported to medical facilities. The reaction also caused the plating operator to be exposed to an uncontrolled release of an unknown substance which resulted in hospitalization. FEASIBLE ABATEMENT METHODS: Among other methods, feasible and acceptable methods to correct the condition include: 1.) Conduct comprehensive process hazard evaluations of the plating processes for the company's chemical products as described in the Center for Chemical Process Safety (CCPS), of the American Institute of Chemical Engineers (AIChE), publication Guidelines for Hazard Evaluation Procedures, Second Edition with Worked Examples; 2.) Develop detailed Standard Operating Procedures (SOPs) for the plating processes. Ensure the SOPs include, normal operating procedures, and emergency procedures with definitions of abnormal operating conditions (I.e. new waste disposal barrels out of stock) and emergency shut down procedures; 3.) Develop and implement standard operating procedures to ensure an adequate supply of new one-piece fifty-five gallon drums remains in stock at all times; 4.) Develop and implement standard operating procedures for proper cleaning of contaminated drums; 5.) Conduct training with personnel covering the hazards of the chemicals used in the plating processes, process hazard evaluations, and SOPs.