Powered by GoogleTranslate

Inspection Detail

Inspection: 309847127 - Synthron, Inc.

Inspection Information - Office: Nc Charlotte

Nr: 309847127Report ID: 0453730Open Date: 01/31/2006

Synthron, Inc.
305 Amherst Road
Morganton, NC 28655
Union Status: NonUnion
SIC: 2869/Industrial Organic Chemicals, Not Elsewhere Classified
NAICS: 325998/All Other Miscellaneous Chemical Product and Preparation Manufacturing
Mailing: 420 C West Fleming Drive, Morganton, NC 28655

Inspection Type:Accident
Scope:Partial Advanced Notice:N
Ownership:Private
Safety/Health:Safety Close Conference:07/24/2006
Planning Guide: Safety-Manufacturing Close Case:04/06/2010
Emphasis: N:Psmpqv

Related Activity:TypeIDSafetyHealth
 Accident102095908    

Violation Summary
Serious Willful Repeat Other Unclass Total
Initial Violations 21 8 7 36
Current Violations 21 8 7 36
Initial Penalty $29,400 $315,000 $0 $0 $0 $344,400
Current Penalty $21,525 $168,000 $0 $0 $0 $189,525
FTA Amount $0 $0 $0 $0 $0 $0

Violation Items
# ID Type Standard Issuance Abate Curr$ Init$ Fta$ Contest LastEvent
  1. 01001 Willful 19100119 C01 07/24/2006 08/01/2006 $21,000 $21,000 $0 09/07/2006 F - Formal Settlement
  2. 01002 Willful 19100119 D 07/24/2006 08/01/2006 $21,000 $42,000 $0 09/07/2006 F - Formal Settlement
  3. 01003 Willful 19100119 E01 07/24/2006 08/01/2006 $21,000 $42,000 $0 09/07/2006 F - Formal Settlement
  4. 01004 Willful 19100119 F01 07/24/2006 08/01/2006 $21,000 $42,000 $0 09/07/2006 F - Formal Settlement
  5. 01005 Willful 19100119 G01 I 07/24/2006 08/01/2006 $21,000 $42,000 $0 09/07/2006 F - Formal Settlement
  6. 01006A Willful 19100119 J02 07/24/2006 08/01/2006 $21,000 $42,000 $0 09/07/2006 F - Formal Settlement
  7. 01006B Willful 19100119 J03 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement
  8. 01007 Willful 19100119 L01 07/24/2006 08/01/2006 $21,000 $42,000 $0 09/07/2006 F - Formal Settlement
  9. 01008 Willful 19100307 B 07/24/2006 08/01/2006 $21,000 $42,000 $0 09/07/2006 F - Formal Settlement
  10. 02001 Serious 19100038 F01 07/24/2006 08/01/2006 $1,050 $2,100 $0 09/07/2006 F - Formal Settlement
  11. 02002 Serious 19100106 H03 IIA 07/24/2006 08/01/2006 $1,050 $2,100 $0 09/07/2006 F - Formal Settlement
  12. 02003 Serious 19100106 H04 IVA 07/24/2006 08/01/2006 $1,050 $2,100 $0 09/07/2006 F - Formal Settlement
  13. 02004 Serious 19100106 H04 IIIA 07/24/2006 08/01/2006 $525 $1,050 $0 09/07/2006 F - Formal Settlement
  14. 02005 Serious 19100120 Q01 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  15. 02006 Serious 19100120 Q06 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  16. 02007 Serious 19100120 Q09 I 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  17. 02008 Serious 19100134 F01 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  18. 02009 Serious 19100134 H03 IB 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  19. 02010 Serious 19100134 K03 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  20. 02011 Serious 19100134 M02 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  21. 02012A Serious 19100146 C04 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  22. 02012B Serious 19100146 G01 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement
  23. 02013A Serious 19100147 C01 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  24. 02013B Serious 19100147 F02 I 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement
  25. 02014 Serious 19100165 B05 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  26. 02015 Serious 19100178 C02 IV 07/24/2006 08/01/2006 $1,050 $2,100 $0 09/07/2006 F - Formal Settlement
  27. 02016 Serious 19101001 J02 I 07/24/2006 08/01/2006 $1,050 $2,100 $0 09/07/2006 F - Formal Settlement
  28. 02017 Serious 19101048 D02 II 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  29. 02018 Serious 19101048 M05 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  30. 02019 Serious 19101200 E01 07/24/2006 08/01/2006 $1,050 $2,100 $0 09/07/2006 F - Formal Settlement
  31. 02020 Serious 19101200 F05 07/24/2006 08/01/2006 $1,050 $1,050 $0 09/07/2006 F - Formal Settlement
  32. 02021A Serious 19101200 H01 07/24/2006 08/01/2006 $1,050 $2,100 $0 09/07/2006 F - Formal Settlement
  33. 02021B Serious 19101200 H03 III 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement
  34. 03001 Other 19100132 F01 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement
  35. 03002 Other 19100134 E01 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement
  36. 03003 Other 19100157 E02 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement
  37. 03004 Other 19100178 L01 II 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement
  38. 03005 Other 19100178 L05 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement
  39. 03006 Other 19100178 L06 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement
  40. 03007 Other 19100178 Q07 07/24/2006 08/01/2006 $0 $0 $0 09/07/2006 F - Formal Settlement

Accident Investigation Summary
Summary Nr: 202077301Event: 01/31/2006Employees Are Injured In Chemical Explosion; One Dies
On January 31, 2006, a runaway reaction occurred at Synthron, Inc., while employees were making Modarez MFP-BH. The polymerization reaction included toluene, cyclohexane, n-butyl acrylate, and benzoyl peroxide. According to the employer's records, there were 2,689 pounds of the solvent blend and 1,923 pounds of N-Butyl Acrylate in a Pfaudler reactor (M-1). Two 55-gallon drums and one 330-gallon IBC tote were positioned in front of reactor M-1. The containers held a solvent blend of toluene, cyclohexane, and benzoyl peroxide. At the time of the incident, the contents of one of the drums and a portion of a second drum had been transferred to the M-1 reactor. Employee #1 walked away from the reactor, intending to turn a valve on the M-5 reactor to begin a nitrogen purge and move the contents of M-5 to M-1. While walking down a stair to perform this task, Employee #1 heard a loud, high-pitched sound. He immediately went back up and observed the Teflon 18 in. envelope gasket from M-1 hanging down from the manway and vapors coming through the opening. Other employees began to hear the sound. After Employee #1 observed the vapors being emitted, he walked outside and met other employees outside the production door, on the Northwest side of the building. Employee #2 was operating a forklift inside the drumming area when he heard the sound. He left the area and met with Employee #3 and Employee #4. They walked up to the Northwest side of the building. Employee #5 instructed Employee #3 to go get the Plant Manager. Employee #5 then donned a full-face respirator and entered the building to turn on the chill water to the reactor. After a few seconds, Employee #5 returned after failing to obtain a good seal on the respirator and smelling vapors. Employee #1 then donned the respirator and went inside the building. Employee #3 and Employee #6 walked up and joined the other employees outside the production door. When Employee #1 exited the building, an explosion occurred. Twelve employees and two bystanders sustained various injuries. Five of the employees were hospitalized with various injuries, and one died later of burns.
Keywords: burn, leak, fracture, vapor, explosion, chemical reaction, chemical burn, chemical vapor, chemical, respirator
Inspection Degree Nature Occupation
1 309847127 Non Hospitalized injury Strain/Sprain Occupation not reported
2 309847127 Non Hospitalized injury Other Occupation not reported
3 309847127 Hospitalized injury Bruise/Contus/Abras Occupation not reported
4 309847127 Non Hospitalized injury Strain/Sprain Occupation not reported
5 309847127 Non Hospitalized injury Other Managers, marketing, advertising, & public rela.
6 309847127 Non Hospitalized injury Other Occupation not reported
7 309847127 Non Hospitalized injury Other Occupation not reported
8 309847127 Hospitalized injury Burn/Scald(Heat) Not specified mechanics and repairers
9 309847127 Hospitalized injury Fracture Occupation not reported
10 309847127 Hospitalized injury Burn/Scald(Heat) Management related occupations, n.e.c.
11 309847127 Non Hospitalized injury Bruise/Contus/Abras Occupation not reported
12 309847127 Fatality Burn/Scald(Heat) Not specified mechanics and repairers

Thank You for Visiting Our Website

You are exiting the Department of Labor's Web server.

The Department of Labor does not endorse, takes no responsibility for, and exercises no control over the linked organization or its views, or contents, nor does it vouch for the accuracy or accessibility of the information contained on the destination server. The Department of Labor also cannot authorize the use of copyrighted materials contained in linked Web sites. Users must request such authorization from the sponsor of the linked Web site. Thank you for visiting our site. Please click the button below to continue.

Close