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Occupational Safety and Health Administration OSHA

Inspection Detail

Inspection: 306447038 - Bayer Polymers Llc

Inspection Information - Office: Cincinnati

Nr: 306447038Report ID: 0522000Open Date: 04/02/2003

Bayer Polymers Llc
356 Three Rivers Parkway
Addyston, OH 45001
Union Status: Union
SIC: 2821/Plastics Materials, Synthetic Resins, and Nonvulcanizable Elastomers
NAICS: 325211/Plastics Material and Resin Manufacturing

Inspection Type:Accident
Scope:Partial Advanced Notice:Y
Ownership:Private
Safety/Health:Safety Close Conference:07/17/2003
Close Case:10/14/2003

Related Activity:TypeIDSafetyHealth
 Accident101960847    

Violation Summary
Serious Willful Repeat Other Unclass Total
Initial Violations 4 4
Current Violations 3 1 4
Initial Penalty $6,500 $0 $0 $0 $0 $6,500
Current Penalty $4,875 $0 $0 $125 $0 $5,000
FTA Amount $0 $0 $0 $0 $0 $0

Violation Items
# ID Type Standard Issuance Abate Curr$ Init$ Fta$ Contest LastEvent
  1. 01001 Serious 19100119 D03 II 08/25/2003 08/28/2003 $1,625 $1,625 $0 I - Informal Settlement
  2. 01002 Serious 19100119 E01 08/25/2003 08/29/2003 $1,625 $1,625 $0 I - Informal Settlement
  3. 01003 Serious 19100119 F03 08/25/2003 08/28/2003 $1,625 $1,625 $0 I - Informal Settlement
  4. 01004 Other 19101200 H03 II 08/25/2003 08/29/2003 $125 $1,625 $0 I - Informal Settlement

Accident Investigation Summary
Summary Nr: 201953429Event: 04/02/2003Employee Killed In Explosion Of Charge Tank
. On April 2, 2003, Employee #1 and a coworker, the technicians, were watching a polymerization process involving styrene and acrylonitrile monomers. Employee #1 and the coworker's jobs involved monitoring a reactor vessel throughout the process. At the end of the batch process, non-polymerized monomer and vapors were stripped from the reactor through a condenser system to a distillate collection tank and were ultimately charged to subsequent batches. Toward the end of the stripping process, Employee #1 left the control room to determine if enough distillate had been removed to allow the remaining water and mixture to be dumped to the "dirty" sewer and a collection system. While Employee #1 was in the vicinity of the reactor, an explosion occurred in a small auxiliary charge tank. A piece of metal struck Employee #1's abdomen and killed him. Although the charge tank was not in use at the time of the accident, a small amount of the batch had back-flowed through a valve between the reactor and the auxiliary tank during the reactive process. The batch continued to react in the auxiliary tank, overheating and overpressurizing the tank.
Keywords: abdomen, reactor, acrylic monomer, explosion, styrene, struck by, overheated, tank, charge bucket
Inspection Degree Nature Occupation
1 306447038 Fatality Other Technicians, n.e.c.

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