Abstract: Employee #1 was assigned to fill a railroad tank car with sulfuric acid. He performed all the items on the company's preload checklist and then filled the car with 13,000 gallons of 93 percent sulfuric acid. Employee #1 then pressurized the car with 10 psi plant air in order to check for leaks. After waiting 20 minutes for the car to become pressurized, the employee stepped from the acid loading platform to the top of the tank car. At this point, the unloading pipe cap apparently blew off. Employee #1 was sprayed with sulfuric acid over his head, face, and eyes. Employee #1 fell from the car, but was able to get up and walk to the control room for assistance. The employee was not wearing an acid jacket and was using safety glasses instead of splash goggles.