Inspection Detail

Inspection: 101129088 - Corn Products A Unit Of Cpc International

Inspection Information - Office: Chicago South Area Office

Investigation Summary

AT APPROXIMATELY 7:30 AM ON JULY 8, 1987, EMPLOYEE #5 ARRIVED AT THE CAM PRODUCT COMPANY WITH A LOAD OF ABOUT 1,000 POUNDS OF HYPOCHLORITE SOLUTION. THE TRUCK WAS WEIGHED. THEN EMPLOYEE #5, FOLLOWING INSTRUCTIONS, PROCEEDED TO BUILDING #61. HE ISSUED THE BILL OF LADING TO THE PROPER PARTY, THEN, FOLLOWING INSTRUCTIONS, PROCEEDED TO THE ACID STORAGE AREA. THERE HE WAS INSTRUCTED TO OFFLOAD THE HYPOCHLORITE SOLUTION INTO A 22,000 GALLON CAPACITY HYDROCHLORIC ACID STORAGE TANK. APPROXIMATELY 400 GALLONS OF HYPOCHLORITE HAD BEEN UNLOADED INTO THE HYDROCHLORIC ACID TANK (WHICH CONTAINED ABOUT 6,000 GALLONS OF HCL) BEFORE ANYONE REALIZED THAT A MISTAKE HAD BEEN MADE. CHLORINE GAS, PRODUCED WHEN THE HYPOCHLORITE WAS MIXED WITH HYDROCHLORIC ACID, LEAKED OUT OF THE TANK TO THE ATMOSPHERE THROUGH THE VENT PIPES. EMPLOYEES #1 AND #3 WERE FABRICATING PIPE AT GROUND LEVEL APPROXIMATELY 300 FEET EAST OF THE ACID TANK. EMPLOYEES #2 AND #4 WERE RUNNING AIR LINES 30 TO 40 FEET ABOVE THE GROUND, APPROXIMATELY 150 TO 200 FEET NORTHEAST OF THE ACID TANK. BETWEEN 8:30 AND 9 AM EMPLOYEES #1 THROUGH #4 APPARENTLY INHALED THE CHLORINE GAS. THEY WERE TRANSPORTED TO THE LOCAL HOSPITAL. EMPLOYEE #5 STATED THAT HE WAS NOT OVERCOME BY THE GAS. NEVERTHELESS HE WAS TAKEN TO THE HOSPITAL FOR XRAYS AND OTHER TESTS. THE ACCIDENT COULD HAVE BEEN PREVENTED IF A DETAILED CHECK SYSTEM OR LOCKOUT SYSTEM HAD BEEN IMPLEMENTED.

Keywords: RESPIRATORY, INHALATION, CHLORINE, CHEMICAL, INATTENTION