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Occupational Safety and Health Administration OSHA

Inspection Detail

Inspection: 304331424 - Orion Safety Products

Inspection Information - Office: Maryland Region 1

Nr: 304331424Report ID: 0352410Open Date: 03/14/2001

Orion Safety Products
2830 St. Michaels Road
Easton, MD 21601
Union Status: NonUnion
SIC: 2899/Chemicals and Chemical Preparations, Not Elsewhere Classified

Inspection Type:Accident
Scope:Partial Advanced Notice:N
Safety/Health:Safety Close Conference:06/26/2001
Planning Guide: Safety-Manufacturing Close Case:09/25/2001

Related Activity:TypeIDSafetyHealth

Violation Summary
Serious Willful Repeat Other Unclass Total
Initial Violations 2 2
Current Violations 2 2
Initial Penalty $0 $0 $0 $6,000 $0 $6,000
Current Penalty $0 $0 $0 $2,000 $0 $2,000
FTA Amount $0 $0 $0 $0 $0 $0

Violation Items
# ID Type Standard Issuance Abate Curr$ Init$ Fta$ Contest LastEvent
  1. 01001 Other 50104 A 07/25/2001 07/28/2001 $1,000 $3,000 $0 I - Informal Settlement
  2. 02001 Other 50104 A 07/25/2001 07/28/2001 $1,000 $3,000 $0 I - Informal Settlement

Accident Investigation Summary
Summary Nr: 202328795Event: 03/14/2001Employee Killed In Explosion
Employee #1 had worked three days as a substitute for the regular employee whose job was mixing the ingredients for the "flare ignition compound" which is applied to the top of highway and road flares, manufactured at the worksite. The ignition compound is first mixed and then an alcohol and shellac mix is added to form wet slurry. After the production day had ended the Employee #1 proceeded to perform a "thorough" cleanup of the area. The area being cleaned included the filling production area, the dry mix room and the wet mix room. Approximately 20 minutes after the departure of other workers in the area, an explosion occurred in the outside dust collector. Responding coworkers found Employee #1's body approximately 45 ft from the left side of the collector. Employee #1 suffered decapitation from an access door which had been ejected. The collector started to break apart at its welded seams and became airborne in a vertical apogee landing approximately 50 ft from it original location. The dust collector contained airborne fine particles generated during both the dry and wet mixing of the flare ignition compound and "Tecsol"(ethanol based) vapors from the wet mix area. These fine particles contained varying amounts of potassium chlorate and perchlorate with various dry fuel compounds, a basic industry formulation for this type of compound. The dust collector, reported to be working when last seen, exhibited signs of deflagration within the filter area. The investigation was unable to determine the specific source of ignition or the sequence of events that transpired prior to and at time of accident. A ferrous metal scraper used for removing the flare ignition residue from the concrete floor and other surface areas was found lying on the floor of the wet mix room. Employee #1 was killed.
Keywords: amputated, cleaning, mixer, dust collector, explosion, decapitated, door
Inspection Degree Nature Occupation
1 304331424 Fatality Amputation Mixing and blending machine operators

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