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Occupational Safety and Health Administration OSHA

Accident Report Detail

Accident: 2001.015 - Employee Is Killed From Chemical Heat After Exiting Process

Accident: 2001.015 -- Report ID: 0522500 -- Event Date: 05/27/2011
InspectionOpen DateSICEstablishment Name
62878.01505/27/2011E I Dupont
At approximately 1:00 a.m. on May 27, 2011, Employee #1, a 47-year-old male empl oyee exited the Kapton #1 manufacturing line. The employee had exited the proces s line oven after spending approximately 10 minutes inside threading the product to a take up reel. The oven temperature was approximately 120 degrees Fahrenhei t. Kapton is made from Dimethylacetamide. Two employees had entered the process line oven to thread the Kapton sheet. As the Kapton sheet is initially formed, the sheet runs onto the oven floor. The employees entered the oven, cut the Kapt on sheet and threaded the cut end through various rollers and onto the tenner ch ain where it moved to the wind up reel. Employee #1 had gathered together the wa ste Kapton sheeting cut from the beginning of the sheet and disposed of the scra p into a waste receptacle. Both employees had exited the oven, showered, with PP E in place to rinse chemical from their PPE, and exited to an open area between the operator's control room and the oven. Both employees had raised the poly ove r their heads, removed the Nomax hood and butyl hood and removed their air line respirators. The second employee walked to the side of the open area and looked down the hallway to get a visual OK from the process operator that the Kapton sh eet was in one piece and had reached the wind up spool. The operator came to the end of his air line, and because he could go no further, turned back toward the first employee. As he turned, he saw his coworker fall straight back, striking his head hard on the floor. The employee was found to be unconscious. Emergency services were called. The employee never regained consciousness and was pronoun ced dead at the hospital. The employees wore PPE to include a butyl chemical sui t with a thermal Kevlar liner, Nomex/Kevlar socks, poly booties with butyl boots , poly shoulder length gloves, Kevlar gloves with butyl outer gloves, butyl arm sleeves, Nomex hood covered by a butyl hood, covered by a Teflon hood, full face air line respirator, ear protection, and knee pads.
Keywords: chemical, heat
Employee # Inspection Age Sex Degree Nature Occupation
1 62878.015 47 M Fatality Chemical technicians

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