Inspection: 103342093 - Shell Chemical Company - Div Of Shell Oil Company

Inspection Information - Office: Columbus
Nr: 103342093Report ID:0522500Open Date: 05/27/1994
Shell Chemical Company - Div Of Shell Oil Company
Route 7 And Route 618
Belpre, OH 45714
Union Status: NonUnion
SIC: 2822/Synthetic Rubber (Vulcanizable Elastomers)
Mailing: P.O. Box 235, Belpre, OH 45714
Inspection Type:Accident
Scope:PartialAdvanced Notice:N
Ownership:Private
Safety/Health:HealthClose Conference:11/10/1994
Close Case:10/03/1996
Related Activity:TypeIDSafetyHealth
 Accident361867336    

Violation Summary
Serious Willful Repeat Other Unclass Total
Initial Violations



53
53
Current Violations



53
53
Initial Penalty



3017000
3017000
Current Penalty



3017000
3017000
FTA Amount






Violation Items
# ID Type Standard Issuance Abate Curr$ Init$ Fta$ Contest LastEvent
  1. 01001 Unclass 5A0001 11/22/1994 12/24/1994 $0 $0 $0 -
  2. 01002 Unclass 19100119 C02 11/22/1994 01/31/1995 $0 $0 $0 -
  3. 01003 Unclass 19100119 D02 ID 11/22/1994 03/01/1996 $0 $0 $0 -
  4. 01004 Unclass 19100119 D02 IE 11/22/1994 03/01/1996 $0 $0 $0 -
  5. 01005 Unclass 19100119 E01 11/22/1994 05/31/1996 $0 $0 $0 -
  6. 01006 Unclass 19100119 E04 11/22/1994 12/24/1994 $0 $0 $0 -
  7. 01007 Unclass 19100119 J04 II 11/22/1994 12/24/1994 $0 $0 $0 -
  8. 01008 Unclass 19100120 Q02 V 11/22/1994 03/31/1995 $0 $0 $0 -
  9. 01009 Unclass 19100120 Q03 IV 11/22/1994 03/31/1995 $0 $0 $0 -
  10. 01010 Unclass 19100120 Q03 V 11/22/1994 06/30/1995 $0 $0 $0 -
  11. 01011 Unclass 19100156 D 11/22/1994 03/31/1995 $0 $0 $0 -
  12. 02001 Unclass 5A0001 11/22/1994 03/01/1996 ######## ######## $0 -
  13. 02002 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  14. 02003 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  15. 02004 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  16. 02005 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  17. 02006 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  18. 02007 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  19. 02008 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  20. 02009 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  21. 02010 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  22. 02011 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  23. 02012 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  24. 02013 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  25. 02014 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  26. 02015 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  27. 02016 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  28. 02017 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  29. 02018 Unclass 5A0001 11/22/1994 03/01/1996 $0 $0 $0 -
  30. 02019A Unclass 19100119 F01 IIB 11/22/1994 03/01/1996 $0 $0 $0 -
  31. 02019B Unclass 19100119 F01 IIIE 11/22/1994 03/01/1996 $0 $0 $0 -
  32. 02019C Unclass 19100119 F01 IV 11/22/1994 03/01/1996 $0 $0 $0 -
  33. 02020 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  34. 02021 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  35. 02022 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  36. 02023 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  37. 02024 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  38. 02025 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  39. 02026 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  40. 02027 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  41. 02028 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  42. 02029 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  43. 02030 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  44. 02031 Unclass 19100119 G01 I 11/22/1994 03/01/1996 $0 $0 $0 -
  45. 02032 Unclass 19100119 J04 III 11/22/1994 06/30/1995 $0 $0 $0 -
  46. 02033 Unclass 19100119 J05 11/22/1994 03/01/1996 $0 $0 $0 -
  47. 02034 Unclass 19100119 J05 11/22/1994 03/01/1996 $0 $0 $0 -
  48. 02035 Unclass 19100119 J05 11/22/1994 03/01/1996 $0 $0 $0 -
  49. 02036 Unclass 19100119 J05 11/22/1994 03/01/1996 $0 $0 $0 -
  50. 02037 Unclass 19100119 J05 11/22/1994 03/01/1996 $0 $0 $0 -
  51. 02038 Unclass 19100119 J05 11/22/1994 03/01/1996 $0 $0 $0 -
  52. 02039 Unclass 19100119 J05 11/22/1994 03/01/1996 $0 $0 $0 -
  53. 02040 Unclass 19100119 J05 11/22/1994 03/01/1996 $0 $0 $0 -
  54. 02041 Unclass 19100119 J05 11/22/1994 03/01/1996 $0 $0 $0 -
  55. 02042 Unclass 19100119 M03 11/22/1994 03/31/1995 $0 $0 $0 -

Accident Investigation Summary
Summary Nr: 170662498Event: 05/27/1994Three Employees Killed In Chemical Plant Explosion
On May 27, 1994, Employees #1 through #3 were working at the Shell-Belpre Chemical Plant in Belpre, OH. A catastrophic failure of a 15,000 gallon polymer reactor vessel was initiated by a runaway chemical reaction involving an abnormally high amount of 1,3-butadiene during the production of Kraton-D, the Shell trademark for polymer. The reactor failure and ensuing fire resulted in the complete destruction of the polymerization unit. Missile fragments from the failed reactor vessel damaged adjacent units in the plant. One fragment punctured a styrene storage tank approximately 600 ft away. This subsequently resulted in the burning of five styrene storage tanks containing approximately 3.5 million gallons of flammable products. Employees #1 through #3 were killed in the explosion.
Keywords: chemical, explosion, chemical burn, flying object, storage tank, flammable liquid, work rules, styrene, fire, flammable vapors
Inspection Degree Nature Occupation
1 103342093 Fatality Burn(Chemical) Chemical technicians
2 103342093 Fatality Burn(Chemical) Chemical technicians
3 103342093 Fatality Burn(Chemical) Chemical technicians