Inspection Detail

Inspection: 301571352 - Chevron Usa, Inc.

Inspection Information - Office: El Paso Area Office

Investigation Summary

Four contract employees were to drain a "dead" line of sulfuric acid. This type of job had been done at this site on several past occasions without incident. On this particular day, the crew consisted of three employees; all were wearing an acid suit, rubber boots, rubber gloves, full-face respirator, face shield, and ear plugs. A few days prior to the accident, a connection was made that would connect the pipe to the truck line. Before the connection was placed on the line, a small bucket was placed under the flange, and then the flange was broken. Some acid was released into the bucket and this acid was "vacuumed" up by the hose connecting to the truck. The coupling fitting appeared to be loose, so Employee #3 stated he walked to Employee #2's truck (which was located outside of the unit) and got a pipe wrench. Employee #2 and Employee #3 tightened the valve coupling. The hose was then connected. Employee #3 walked around to the front of the truck to check for leaks around the motor and pump. The valve was opened just a small amount and leaks were checked for around the connections. When the hose appeared to be full of acid and no leaks were detected, Employee #4, a petroleum company employee began to open the valve fully. A few seconds later, Employee #1 noticed acid beginning to form at the bottom of the coupling. Employee #1 tried to signal Employee #4 to close the valve. As Employee #4 began to close the valve, the coupling gave and acid was sprayed. All four employees all met at a water hose near the truck and began washing the acid from the suits and bodies. It was determined there was not enough water at the hose, so two employees were sent to the emergency eyewash/shower, where Employee #4 had gone to wash the acid from his body. Employee #3 was the least sprayed due to his proximity from the release and did not go to the emergency shower. Employee #3 was the only person with PPE still on, and took it upon himself to close the valve, even though it was against the petroleum company's policy for a contract employee to open or close valves. Sometime during the incident, Employee #3 also turned the PTO off on the truck. Employee #3 was directed to the emergency shower and was told to remove all his PPE and clothing. All four employees were hospitalized.

Keywords: BURN, LEAK, PPE, VALVE, SULFURIC ACID