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Inspection Detail

Inspection: 100596980 - Union Carbide Chemicals & Plastics

Inspection Information - Office: Charleston Area Office

 

Inspection Nr: 100596980
Report ID: 0316400
Date Opened: 01/01/1992

Site Address:
Union Carbide Chemicals & Plastics
437 Maccorkle Avenue
South Charleston, WV 25303

Mailing Address:
, , 00000

Union Status: Union

SIC:2869

NAICS: 0 

Inspection Type: Accident

Scope: Partial

Advanced Notice: N

Ownership: Private

Safety/Health: Safety

Close Conference: 06/09/1992

Emphasis:

Case Closed: 07/01/1996

Related Activity
Type Activity Nr Safety Health
Accident 360338982
Violation Summary
Violations/Penalties Serious Willful Repeat Other Unclass Total
Initial Violations 13 3 5 21
Current Violations 10 3 5 18
Initial Penalty $52,000 $99,000 $0 $0 $0 $151,000
Current Penalty $46,000 $99,000 $0 $0 $0 $145,000
FTA Penalty $0 $0 $0 $0 $0 $0

Violation Items
# Citation ID Citaton Type Standard Cited Issuance Date Abatement Due Date Current Penalty Initial Penalty FTA Penalty Contest Latest Event Note
1. 01001 Serious 5A0001 06/30/1992 07/03/1992 $7,000 $7,000 $0 07/20/1992 F - Formal Settlement  
2. 01002 Serious 5A0001 06/30/1992 07/03/1992 $7,000 $7,000 $0 07/20/1992 F - Formal Settlement  
3. 01003 Serious 19100120 P07 I 06/30/1992 08/03/1992 $2,500 $2,500 $0 07/20/1992 F - Formal Settlement  
4. 01004 Serious 19100120 Q03 II 06/30/1992 08/03/1992 $5,000 $5,000 $0 07/20/1992 F - Formal Settlement  
5. 01005A Serious 19100120 Q03 III 06/30/1992 07/23/1992 $5,000 $5,000 $0 07/20/1992 F - Formal Settlement  
6. 01005B Serious 19100120 Q06 IVD 06/30/1992 07/23/1992 $0 $0 $0 07/20/1992 F - Formal Settlement  
7. 01006 Serious 19100120 Q03 V 06/30/1992 07/23/1992 $5,000 $5,000 $0 07/20/1992 F - Formal Settlement  
8. 01007 Serious 19100120 Q06 VB 06/30/1992 07/23/1992 $5,000 $5,000 $0 07/20/1992 F - Formal Settlement  
9. 01008 Serious 19100120 Q11 II 06/30/1992 07/23/1992 $2,000 $2,000 $0 07/20/1992 F - Formal Settlement  
10. 01009A Serious 19100134 E03 06/30/1992 08/03/1992 $5,000 $5,000 $0 07/20/1992 F - Formal Settlement  
11. 01009B Serious 19101200 H02 III 06/30/1992 07/23/1992 $0 $0 $0 07/20/1992 F - Formal Settlement  
12. 01010 Serious 19100147 C04 II 06/30/1992 08/03/1992 $2,500 $2,500 $0 07/20/1992 F - Formal Settlement Citation has been deleted.
13. 01011 Serious 19100253 B04 III 06/30/1992 07/03/1992 $2,500 $2,500 $0 07/20/1992 F - Formal Settlement  
14. 01012 Serious 19101001 K06 06/30/1992 07/03/1992 $1,500 $1,500 $0 07/20/1992 F - Formal Settlement Citation has been deleted.
15. 01013 Serious 19101200 H01 06/30/1992 07/23/1992 $2,000 $2,000 $0 07/20/1992 F - Formal Settlement Citation has been deleted.
16. 02001 Willful 19040002 A 06/30/1992 07/08/1992 $50,000 $50,000 $0 07/20/1992 F - Formal Settlement  
17. 02002 Willful 19100120 Q03 IV 06/30/1992 07/20/1992 $31,500 $31,500 $0 07/20/1992 F - Formal Settlement  
18. 02003 Willful 19101200 F05 II 06/30/1992 07/13/1992 $17,500 $17,500 $0 07/20/1992 F - Formal Settlement  
19. 03001 Other 19100120 Q02 II 06/30/1992 07/23/1992 $0 $0 $0 07/20/1992 F - Formal Settlement  
20. 03002 Other 19100120 Q02 VII 06/30/1992 07/23/1992 $0 $0 $0 07/20/1992 F - Formal Settlement  
21. 03003 Other 19100120 Q02 X 06/30/1992 07/23/1992 $0 $0 $0 07/20/1992 F - Formal Settlement  
22. 03004 Other 19100120 Q02 XI 06/30/1992 07/23/1992 $0 $0 $0 07/20/1992 F - Formal Settlement  
23. 03005 Other 19100253 B02 IV 06/30/1992 07/03/1992 $0 $0 $0 07/20/1992 F - Formal Settlement  

Investigation Summary

Investigation Nr: 14232714
Event: 12/31/1991
Employee killed during tank explosion

Employee #1, the basement operator at a powerhouse, was purging the liquid residue from the betene entrainment tank to the #16 boiler. Water and steam inadvertently got into the knockout pot, and materials that react to water, such as, but not limited to, acetic anhydride and diketene were in the tank. A reaction occurred, releasing flammable and hazardous materials into the atmosphere through a safety relief valve. The pressure relief device was only sized for an external fire, not a chemical reaction. As a result, the safety relief valves could not withstand the reaction. The overpressurization caused the steel pot to fail and explode. Employee #1 was killed.

Keywords: SAFETY RELIEF VALVE, TOXIC ATMOSPHERE, EQUIPMENT FAILURE, EXPLOSION, CHEMICAL REACTION, HIGH PRESSURE, VALVE, TANK, ACCIDENTAL DISCHARGE

Investigated Inspection
# Inspection Age Sex Degree of Injury Nature of Injury Occupation
1 100596980 Fatality Strain/Sprain Occupation not reported
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