Document bapyvZxjGwjYRQRzgw8Ro4Ko

1 BREAKDOWN OF OSHA RECORDABLES* BY TYPE OF INJURY FINGER/ARM CAUSTIC BURNS ANKLE SPRAINS RIB AND TORSO INJURIES CHLORINE INHALATION EYE ABRASION HEAT EXHAUSTION 12 11 7 6 1 1 ____ 1_ 39 *COVERS 1979 - 1982 PERIOD DO 072001 CONFIDENTT AL YEAR 1982 1981 1980 1979 1978 1977 TOTAL DIVISION 57 75 80 97 94 99 2 OSHA RECORDABLE INJURIES BRINE CELL C/A PROD. CAUSTIC cl2 SERVICE 9 1 33 10 0 4 2 " 11 0 2 3 1 9 0 3 31 22 0 4 8 1 16 1 3 4 1 CA II 2 4 5 2 9 7 C/A OSHA Recordable Injuries as 2 of Division 15.782 (14.752 if less 1978 1979) C/A OSHA Recordable Injuries as 2 of Division: 1982 1981 1980 1979' 1978 1977 15.782 13.332 13.752 9.272 23.402 16.162 Using Division 1980 as Basis: 1981 1982 6.32 242 Reduction from 1980 in OSHA Recordables Reduction from 1981 in OSHA Recordables From 1980 to 1982: Division saw a 292 reduction in OSHA Recordables C/A Group saw a 182 reduction in OSHA Recordables From 1981 to 1982 Division saw a 242 decrease in OSHA Recordables C/A saw a 102 decrease in OSHA Recordables Based on Division Statistics: If 1980 is Base If 1981 is Base OSHA RECORDABLES THEO. INJURIES ACT. INJURIES 7.84 7.6 9 9 DO 072002 CONFIDENTIAL 3 INJURIES - OSHA RECORDABLES TIME ON JOB 14 14 7 0 4 0 39 OSHA RECORDABLES C/A GROUP (1979 - 1982) 0 Mos. - 6 Mos. 6 Mos. - 2 Yrs. 3 Yrs. - 5 Yrs. 6 Yrs. - 10 Yrs. 11 Yrs. - 20 Yrs. 21 Yrs. - 30 Yrs. TIME AT DOW 7 13 8 0 9 2 39 OSHA RECORDABLES BASED ON TIME IN CLASSIFICATION 77Z Those 0-2+ Yrs. 13Z Those 3-5 Yrs. 10Z Those 6-30 Yrs. OSHA RECORDABLES BASED ON TIME AT DOW 51Z Those 0-2 Yrs. 21Z Those 2-5 Yrs. 28Z Those 6-30 Yrs. DO 072003 CONFIDENTIAL 4 INDEX SECTION I - HEADLINES A. Power Generation and Utilities 1. Turbines and Generators 2. Boiler and Heat Recovery Units 3. Air Compressors 4. Steam and Condensate B. Brine Treating and Brine Production 1. Miscellaneous 2. Pressure Releases from Wells C. Chlorine Cell Operation 1. D.C. Power (Transformers and Rectifiers) 2. Chlorine-Hydrogen 3. Hydrogen 4. Cell Effluent 5. Materials of Construction 6. Miscellaneous D. Chlorine Collection, Cooling, Drying and Compression 1. Intercoolers 2. Sulfuric Acid 3. Hydrochloric Acid 4. Compressors . Chlorine Liquefaction Loading and Distribution 1. Chlorine-Iron 2. Lines, Valves, and Vessels 3. Emergency Block Valve Failures 4. Laboratory 5. Loading and Unloading F. Chlorine Cell Manufacture and Maintenance 1. Fork Lift Trucks 2. Cranes, Hoists, and Associated Equipment 3. Cathode Drawing, Baking, and Cleaning 4. Series Erection and Dismantlement 5. Cell and Cover Manufacture 6. Miscellaneous G. Caustic Operations 1. Evaporation 2. Salt Removal and Filtration D0 072004 CONFIDENTIAL 5 $***$% 3. Iron Ceils 4. Low Sale Operations 5. Loading and Unloading 6. Miscellaneous H. Caustic Finishing 1. Evaporation 2. Loading and Storage 3. Miscellaneous I. Maintenance 1. Falls 2. Material Handling 3. Electrical 4. Burning and Welding 5. Miscellaneous J. Hydrogen Collection 1, Motors and Compressors DO 072005 CONFIDENTIAL 6 SECTION I - HEADLINES . I. A. Power Generation and Utilities r 1. Turbines and Generators a. Gas turbine trip resulted in chlorine release. b. Employee burned by condensate. 2. Boilers and Heat Recovery Units a. Fingers caught between lid and mud drum. 3. Air Compressors a. Fingers caught between belts and sheave. b. Reciprocating compressor threw counterweight. A compressor discharge line caught on fire when some diesel got into the line. d. A handerank struck an operator on the elbow when he failed to get clear of the motor. 4. Steam and Condensate a. Man burned with condensate when conductivity probe forced from line. b. Earth collapses and man's foot and leg burned by condensate. c. Repairing condensate leak man sprayed with hot caustic when valve accidentally opened. B. Brine Treating and Brine Production 1. Miscellaneous a. Pickup truck struck from rear resulting in a severe neck strain. b. Mowing grass - tree fell across tractor. c. Employee slipped from lines and fell. d. An operator pulled a nail off his finger when his hand got caught between the pulley/cable. 2. Pressure Releases from Wells a. Operator receives a severe fractured elbow when a pipe at high pressure strikes him. C. Chlorine Cell Operation 1. D.C. Power (Transformers and Rectifiers) a. Man fell into high voltage from transformer. c DO 07P006 CONFIDENTIAL 7 ,b. Man fell from platform after receiving electrical shock. C. Electrical shock lancing anoi.it' compart imuit . d. Man fell after electrical shock. e. Electrical shock from contacting steel support. f. Electrical shock with air rod. g. Electrical "tingle1* between buses.. h. Electrical arc taking cell voltages'. i. Regulating transformer ruptured from three-phase fault. j. Possible electrical shock at buses. k. Cathode terminal connections melted. l. Switching error left end of series energized. m. Tool shorted across bus. n. Closed wrong switch caused flash resulting in bums. o. Rectifier improperly tagged. p. Man fell after electrical flash fracturing ankle. q. Burns occurred when man closed wrong switch. r. Closing wrong switch resulted in flash bums. s. Rectifier explosion and fire. t. Rectifier trip resulted in chlorine release. u. Lightning strikes a D.C. bus on the chlorine cells causing severe damage. v. A water leak inside a rectifier causes severe damage. w. A rectifier was damaged when several diodes ruptured simultaneously. C. Chlorine Cell Operation 2. Chlorine-Hydrogen a. Cell cathode failure caused explosion. b. Explosion after a patch job. c. Reaction resulting from putty falling. d. Low brine level from brine filter salting up. e. Same as above. f. Explosion resulting from hydrogen analyzer problems. g. Explosion resulting from low head. h. Explosion resulting from hole in cell body. i. Explosion resulting from low head. j. Explosion resulting from low head. k. Explosion resulting from conmunication error. l. Cell holes resulted in low level and an explosion. 3. Hydrogen a. Explosion in series being dismantled. b. Ignition under roof of cell building. c. Explosion in cooling water trench. d. Several fires and a hydrogen head explosion. e. Large quantity of air into Plant B hydrogen system. f. Ignition in out-of-service water line. g. Explosion under series after erection. h. Explosive mixture where work being performed. DO 072007 CONFIDENTIAL 'W- ' 8 i. Explosion in hydrogen header from overhead burning j. Air into Plant B hydrogen system. k. Ignition under series at cathode end. l. Terminal insulator failure apparently led to fire. m. Arcing and missing backstopper resulted n. Fire when cleaning hydrogen outlets.*''` o. Torch ignited hydrogen at cathode. p. Man fell when installing hydrogen boot and broke elbow. q. A sewer exploded when the H2 vent became plugged with brine. r. Multiple explosions occurred when high Hj levels were generated by startup with cold brine and poor salt precipitation. 4. Cell Effluent a. Man stepped in trench; received leg burns. b. Employee fell in trench sustaining cuts and bums. c. Employee bruised from fall at truck. d. An operator had caustic and H2 blown into his face when removing cell putty from an H2 outlet. 5. Materials of Construction a. Shoulder fracture when wooden walkway collapsed. b. Man fell through wooden walkway breaking bone. 6. Miscellaneous a. Chemical goggles slipped from hand striking his eye. b. Missing step on ladder resulted in fall. c. Guard slipped and caught fingers. d. Cylinder catches on fire and man burned. e. Man slips and falls injuring shin. f. An operator opened a valve to a cell that was red tagged. g. An open bottle of a chemical was left on the cell and it caused a fire when spilled. D. Chlorine Collection, Cooling, Drying and Compression 1. Intercoolers a. Intercooler chlorine-copper reaction resulted in chlorine release. 2. Sulfuric Acid a. Man burned from sulfuric acid in air hose. b. Expansion joint failure at pump discharge. c. Chlorine inhalation at drying towers. d. Sulfuric acid splattering on man from overflow line. e. Pressured acid released through hole in line. f. Hose slips from connection at sulfuric acid truck. 9 3. 'Hydrochloric Acid a. Dome blown off hydrochloric acid truck. b. A graphite block in a HC1 absorber was damaged when an explosion occurred in the HC1 burner. c. An acid gathering tank in the HC1 burner area had its lid pop off when liquid chlorine entered the burner. 4. Compressors a. Compressor thrust bearing failed. b. Iron-chlorine reaction results in chlorine release. c. Positive displacement-compressor valve failure. d. Broken crankshaft on positive displacement compressor. e. Metallized crankshaft fatigue failure. f. Positive displacement compressor crankshaft failure. g. Galvanized crankshaft failure. h. Positive displacement compressor sheavefailure. i. Fire in crankcase of P.D. compressor. j. Chlorine and iron reaction in high stage P.D. compressor results in chlorine release. k. Freon compressor high temperature causes reaction. l. A compressor failure caused a 500 ppm release of chlorine for several minutes. m. A wet chlorine compressor was destroyed by a dry chlorine and titanium reactor. E. Chlorine Liquefaction, Loading and Distribution 1. Chlorine-Iron a. A positive displacement compressor failed. b. A centrifugal compressor failed. c. A centrifugal compressor failed. d. A centribugal compressor failed. e. A centribugal chlorine compressor failed. f. Lawrence pump bearing failure. g. A sea water exchanger ignited. h. Steel packing in a chlorine recovery column ignited during startup. i. A major chlorine release occurred when a liquid chlorine pump erupted causing surrounding pipe damage. j. A chlorine-hydrogen fire occurred in a chlorine absorber when chlorine gas contacted with H2 from packing. k. A liquid chlorine tank caught on fire when a hot bearing on a pump burned a hole in the tank. 2. Lines, Valves, Exchangers a. Liquid chlorine line leak from hydrochloric acid corrosion. b. Exposed underground line leaks chlorine. c. Liquid chlorine line leak from external corrosion. d. Liquid chlorine line leak at support points. DO 072009 CONFIDENTIAL , j,, i` ijie i1'-; ^ ' 10 . e. Chlorine leak from corroded intercooler nipple. f. Chlorine leak from sniff line. g. Chlorine leak from intercooler. h. Chlorine leak at tank car loading results in inhalation, i. Valve bonnet bolts removed permitting liquid chlorine to escape. j. Chlorine release when reboiler tube bundle removed. k. Chlorine valve "exploded" from reaction with grease. l. Liquid chlorine valves tagged open by mistake. m. Ball valve aluminum operator broken. n. Chlorine pressure gauge removal resulted in inhalation, o. Chlorine leaks from defective hose. p. A taffy pot exploded due to a runaway exothermic reaction. q. A reboiler exploded due to a runaway exothermic reactor. r. A tail gas line split open and burned due to a high hydrogen concentration. s. A chlorine-hydrogen fire occurred in a line that had been improperly prepared for service. t. A air-hydrogen explosion occurred in a chlorine tail gas scrubber when the chlorine was scrubbed out a H2~air mixture remained. u. A chlorine-iron fire occurred when a solution of FeCL^ corroded a line fast enough to cause a fire. 3. Emergency Block Valve Failures a. Nitrogen leak activates emergency block valve. b. Aluminum-chlorine reaction results in liquid chlorine release. c. Blown fuses activate emergency block valve. d. Chlorine evaporator overpressure causes gas release. 4. Laboratory a. Chlorine-caustic reaction results in burn to foot. b. Chlorine-carbon bisulfide explosion. c. An operator burned her eyes with caustic after running some laboratory samples. d. A plant operator had a tantalum cylinder explode due to improper sampling procedure. 5. Loading and Unloading a. Truck driver overcome by sodium hydrosulfide. b. Changing valves results in a chlorine release. c. A loaded chlorine tank car nearly collided with a train engine due to lack of communication. F. Chlorine Cell Manufacture and Maintenance 1. Fork Lift Trucks a. Operator struck by fork lift truck. b. Fork lift truck partially fell from ramp. c. Fork lift truck started and moved with no driver present. DO 072010 CONFIDENTIAL n d. Load on fork lift truck strikes man. e. Fork lift truck smashes starter fluid can. f. Caustic splashed forehead of fork truck driver. g. Employee hand caught between tubs. h. Fork truck driven into stream line support. 2 Cranes, Hoists, and Associated Devices' a. Chains pinch employee's fingers. b. Hand caught between cell frame and lifting device. c. Man's hand caught by inner cell casting form. d. Bouncing cell catches man's thumb. e. Cathode slipped slicing finger. f. Cathode swings striking crane operator's foot. g. Man's hands mashed under timber. h. Crane pendant control shorted and moved by itself. i. Lug slipped off knob resulting in broken cell. j. Crane lever fails to stop crane. k. Crane rail breaks. l. Shorted pendant moves crane. m. Wheels drop off bridge rail. n. Cab crane runs off bridge. o. Crane cab falls to floor. p. Cable broke when lifting cell. q. Yoke and chain wheel fell to floor. r. Cable snaps when packing up cells. s. Motor falls bouncing through wall. t. Yoke fell and hit man on head and shoulder. u. Man caught between cell bodies. v. Cable breaks dropping cathode into draw tank. w. Outer cell body form falls. x. Hand caught between cell frame and lifting device. y. Crane began moving by itself. z. Crane cable breaks while changing position of a cell, aa. Crane control does not stop travel. bb. Crane rail breaks at welded joint. 3. Cathode Drawing, Drying and Cleaning a. Liquid entering top of boots results in chemical burns. b. Man working without protective apron. c. Electrician's hand got caught in moving equipment. d. Damaged boot results in acid burn. e. Man's heel fractured after slip from ladder. f. Finger caught between cathode jig frame and I-beam. g. Unplugging pressured line causes loss of vision in eye. h. Handle of cathode lifter struck man's cheek. i. Cathode falls from lifter onto employee's foot. j. Cathode fell to floor. k. Pendant shorted and crane moved down rail. 072011 confidential 12 4. Series Erection end Dismantlement a. Man stepped backward from cell and fell. b. Latch box on squeezer broke. c. Iron timber clamp fell on man's foot. d. Foreign body in eye. e. Fingers caught between squeezer and tlOOK ;- f. Employee stepped on back up; it slipped off cover hitting his leg. g. Man's fingers were caught between cover and the floor. h. Failure of lugs on cell squeezer. i. Dummy fell backward off skid. j. Chain link breaks. k. Cell knob failure. l. Employee shocked. m. Cell knob failures. S. Cell and Cover Manufacture a. Employee fell and cover partition landed on foot. b. Man fell from sand hopper car shattering wrist. c. Chemicals in eyes. d. Finger pinned by lining pin. e. Cutting blade rips shirt off employee. f. Angle iron strikes man. g. Chemicals ignite and bum employee. h. Fingers caught in gears of saw. i. Man mashed finger while opening tail gate of truck. j. Plate slips and struck employee's finger. k. Piece of bearing flew out and lodged in man's forearm. l. Electric truck rolled on man's foot. m. Plates fall through rack striking man on shoulder. n. Place falls out of cell and cuts man's lip. o. Abrasive disc broke and struck employee. p. Grinder kicked back striking let. q. Failing box of copper hits employee on foot. r. Graphite board falls on man's foot. s. Improper tool used cutting band. t. Glancing hammer fractures finger. u. Form slips off cell and employee's hand gets caught between form and concrete. v. Lug slipped off cell knob. w. Valve breaks and employee sprayed with chemicals. 6. Miscellaneous a. Window drops on employee's finger causing finger to be amputated. b. Chisel flips up fracturing employee's cheek bone. c. Glove caught by drill bit and injures employee's arm. d. A-frame collapses on floor sweeper. e. Pivot arm falls on employee's foot. f. Saw amputates finger. 0 072012 confidential G. Caustic Operations 13 1. Evaporation a. First effect evaporator ruptured. b. Pressure blew out stopper and caustic hit man in face. c. Man sprayed with hoc caustic when removing circulating pump. d. Caustic sprays through open valve striking man. e. Employee stepped into open trench burning ankle and foot. f. First effect heat exchanger ruptured on steam side. g. Expansion joint without stay bolts. h. Level control failed and caustic sprayed to atmosphere. i. Hoc caustic spilled out of evaporator when opened. j. Caustic vented from cyclone. lc. Caustic sprayed from drain valve and employee burned. l. Caustic splashing at cyclone. m. Pump discharge line cracks and 50Z caustic sprayed the area. n. An operator broke his finger when he got the finger caught between the wrench and spool piece. o. A gasket blew caustic and ammonia 20 feet into the air. p. A pipe nipple broke off a caustic feed line dumping several thousand pounds of caustic. q. An expansion joint ruptured allowing 145 gpm of NaOH to contaminate a seawater flume. r. An operator incorrectly blocked in valves to wash a caustic feed line and was sprayed with hot caustic. 2. Salt Removal and Filtration a. Employee burned with caustic when removing hose. b. Pump coupling broke and knocked guard off base. c. Steam hose ruptured spraying hot condensate on man's leg. d. Hot condensate strikes employee's leg. e. Finger caught between pipe and hand rail. f. Coupling fails and caustic splashed on man causing bums. g. Machine runs backwards. h. Caustic sprays in employee's eyes. 3. Iron Cells a. Acid was being added to iron cell and material was sprayed over everything. b. Pyrophoric iron flashes in iron cell. 4. Low Salt Plant a. Maintenance employee fell over drain line and sustained fracture to his leg. b. Nozzle separates at weld and caustic-ammonia mixture sprayed into air. c. Depressuring line and .amnonia suddenly blew out of hose. d. Ammonia released during shutdown. e. Employee sprayed when walking on walkway. 14 5. .Loading and Unloading a. Unloading hose blown out of storage tank and spraying caustic. b. Men sprayed with cell effluent as loading line removed. c. Hoc water burns employee washing caustic from hand. d. Caustic splashed from storage tank and got behind man's chemical goggles. e. Valve wheel and chain operator fell striking man on head. f. Caustic spilled from truck. g. Expansion joint ruptures and area sprayed with caustic. h. Chock slips and car rolls. i. Pressured line slips and sprays employee. j. Hose blew off spraying caustic. k. Caustic blows out of dip pipe. 6. Miscellaneous a. "Water hammer" damages line. b. Operator steps into small hole and got caustic in shoe. c. Ladder fell off rack and knocked man down. d. Aluminum wrench breaks. e. Bonnet blew off valve spraying men with cell effluent. f. Operator violates "red tag" rule. g. Portion of line pressured by mistake and contractors splattered with cell effluent from water line. h. Man caught fingers between fan and housing. i. Employee's sleeve caught on wire holding socket on air motor shaft. j. Employee loosened valve bonnet and sprayed with caustic. H. Caustic Finishing I. Evaporation a. Employee sprayed with caustic from top of level control tank. b. Hole in hot water hose results in burns to foot. c. Hot caustic sprays out between flange on dust collection system. d. Employee putting on chemical goggles when material blown into eye. e. An operator was sprayed with hot caustic when a centrifuge tripped out. f. A flange on top of a tank blew out hot caustic on people below. g. An explosion occurred in a reaction of carbon steel and hot caustic on a tank. 2. Loading and Storage a. Hose lining failed and caustic sprayed out between flanges. b. Steaming lines and blew onto employee. c. Thawing line and end of loading arm swung around knocking man unconscious. d. Filling drum with spout above drum and caustic splashed on an employee. e. Finger broken when caught between capper and Lip on drum. DO 0700*1 A TOL CONF 15 f. Drum fell from conveyor and seam burst spraying molten caustic over area. g. Man slipped and brushed forearm across hot drum. h. When inserting lid, caustic popped onto man's arm, neck, and head. i. Caustic came out a small slot in protective shield and burned man's hand. j. Loading spout hung on drip pan and caustic splattered on employee's thigh. k. Water added to caustic drum and caustic erupted from drum onto man. l. Employee moving drum with 2"x4", drum fell splattering him on arms and chest. m. Drum torn by ram and molten caustic ran out striking his stomach and hands. n. Ram retracts and pinned man's arm against housing. o. Employee was placing lid on a solid caustic drum when he was splashed with hot molten caustic. p. Water was introduced into a caustic tank and steam generated pressured tank. q. Nitrogen pressure on hopper trailer blew camlock cap into employee's face. r. Valve handle and chain assembly fell striking man on head and stomach. s. A deflector head punctured a drum, spraying molten caustic on operator. t. A drum filled with molten caustic overflowed and splached on a man. u. Wooden pallets ignited by hot caustic drums. v. A tank car released caustic/water through a vent due to the dilution of 73X caustic with water. v. A tank car that was to be loaded with caustic was found to have some acid in the bottom. x. An operator was overcome by breathing NH3 after he began to load caustic in a tank car that had 70 gallons of an ammonia-based product. y. Operators blew a tank of 50Z hot caustic when trying to unplug a SOX line with condensate. z. A major NH3 spill occurred when a tank car that was pumping out NH3 encountered mechanical difficulties. 3. Miscellaneous a. Employee fell as a result of a loose step. b. The yoke and chain wheel for transverse movement fell to the floor. c. Valve yoke broke and assembly fell. d. Employee attempted to use a crane that was attached to a line. e. Fan wheel falls to floor when shaft breaks. f. Fry bar slips and man's finger was pinched and broken. g. Foot flipped into conveyor and he fell. I. Maintenance 1. Falls a. Employee stumbled and pushed wooden shelf on another employee. DO 072015 CONFTOFNTTAL r L DO 072016 CONFTDFNTTAL. 16 b. Inspector falls from a chain ladder. 2. Materials Handling a. Employee's finger caught between shaft and hard toe of his boot. b. Cherry picker tilts against highline pole. c. Fingers smashed between condor lift and crane. d. Cranes almost decapitate man. e. As a walkway was being removed from its support columns, the support column tilted over. 3. Electrical a. Broken switch does not open circuit in open position. b. When attempting to pull down main disconnect breaker arm, an explosion occurred. c. Power on electrical leads to control cable which was being worked on. d. Bus not labelled correctly. e. 440 volt insulated motor lead flashes and burns hand. f. Handle for disconnect turns without opening disconnect. g. End bell blown off crane motor. h. An electrician was killed when his sprayer came in contact with a switch, creating a short circuit. 4. Burning and Welding a. Delayed roof fire after torch used to thaw lines. b. Welding machine not grounded properly. c. Acetylene bottle catches fire. d. Hot tap done on wrong line. e. Valve stem in a tank cut and ammonia fumes fill tank. 5. Miscellaneous a. Finger caught between belts and sheave. b. Employee wearing safety glasses got flake of caustic in his eye. c. Pipe pinwheeled and struck man aobve left eye. d. Pipefitter tightened plug on leading safety valve and it blew out. e. Hot water in eye bath had steam tracing on it. f. Hydrogen blower belts caught on fire. g. Finger mashed between wrench and pump housing. h. An operator in chlorine suffered heat exhaustion when getting overheated in the chlorine loading area. i. An operator had a wrench handle fall 20' to strike him on the forehead. j. An operator jumped out of a piperack and suffered a minor fracture to the pelvic area. k. Two jobs inside a vessel did not realize other was taking place. l. A gasket blew out a salt slurry solution causing chemical burns to both eyes. m. An operator fell 6' when he used a wooden handrail to use as a prop to gain leverage on a valve. 00 072017 coNFrDFNTrA(_ 17 n. A piece of equipment at a sump was started when it was red-tagged, J. Hydrogen Collection 1. Motors and Compressors a. A motor was severely damaged due to the lack of knowledge about the motor. b. A hydrogen-air explosion occurred when a compressor lost positive pressure. c. Two lower power explosions took place during startup due to faulty instrumentation. 00 072038 CONFIDENTIAL