Text For Citation: 02 Item/Group: 003 Hazard: EXPLOSION

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place or 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: Employees were exposed to hazardous releases of toluene diisocyanate (TDI) when opening TDI transfer piping and/or repairing, removing or placing equipment installed in these lines. Among other methods, one feasible and acceptable method to correct this hazard is to implement and enforce a written Line Breaking and System Opening Procedure. Essential elements of this procedure include, but are not necessarily limited to, the following: 1) Establishing and using a documented work order permit system which requires a supervisor's approval to reactivate process lines upon completion of work. The issuance of the work order permit shall be limited to the supervisor of the area who is completely familiar with the system and who has verified the proper line to be opened and that all steps possible have been taken to drain and vent the line and any connected pumps, valves and tanks. All pumps on the line shall be locked out and all gages and slight glasses checked for zero readings. 2) The personnel assigned to do the work shall be properly equipped and clothed completely with protective equipment as if the line were going to vent or spray when broken. The nearby area shall be enclosed with a barrier rope and signs to exclude personnel not involved in the operation. 3) The procedure for actually breaking the line shall be reviewed with the persons who do the work. The placement of a deflector of suitable material over the flange joints is usually required for initial cracking of corrosive or toxic material lines. Adjacent nuts and bolts are loosened first, slowly, and in the most accesible postition where they can be retightened quickly if necessary. 4) Emergency equipment and materials shall be checked and available in the immediate area. Safety showers, hose lines, fire extinguishers, neutralizers, or other emergency materials shall be on hand and ready for use. Emergency actions to be taken shall be reviewed by the supervisor with the personnel involved prior to starting of the work. 5) Removed sections and involved valves or parts shall be handled carefully until they are inspected for trapped materials or residues are flushed. Lines that have caked or contain residues that cannot be cleaned immediately shall be tagged with warnings identifying the contaminant or condition until they can be properly decontaminated. 6) Broken lines remaining in place shall have all openings blanked off to prevent later drips or spills.