OSHA Inspection: WORTHEN INDUSTRIES, INC.

Issued

Oct 5, 1990

Abate by

Oct 17, 1990

Issued

Oct 5, 1990

Abate by

Oct 8, 1990

Issued

Sep 27, 1990

Abate by

Oct 2, 1990

Issued

Sep 27, 1990

Abate by

Nov 19, 1990

Issued

Sep 27, 1990

Abate by

Nov 19, 1990

Issued

Sep 24, 1990

Abate by

Sep 27, 1990

Penalty

Initial $320 · Current $320

Issued

Sep 24, 1990

Abate by

Nov 19, 1990

Issued

Sep 24, 1990

Abate by

Nov 19, 1990

Issued

Sep 17, 1990

Abate by

Nov 19, 1990

Penalty

Initial $560 · Current $560

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
employer did not furnish employment and a place of employment which were
free from recognized hazards that were causing or likely to cause death
or serious physical harm to employees in that employees were exposed to
the hazard of inhalation of toluene diisocyanate (TDI) which can cause
nose and throat irritation, choking, paroxysm coughing, retrosternal
pain, nausea, vomiting, abdominal pain, bronchial spasm, pulmonary
edema, asthma, sensitization, and dematitis.
a) UPACO Adhesives, Inc. - Workers in the churn and reactor areas
involved with making various adhesives and urethanes were potentially
exposed to excessive levels of toluene diisocyanate (TDI) on 7/11/90,
which can cause nose and throat irritation, chokingparoxysm coughing
retrosternal pain, nausea, vomiting, abdominal pain, bronchial
spasms, pulmonary edema, asthma, sensitization, and dermatitis. This
was due to workers relying on a MDA Scientific TDI area monitor which
had not been routinely maintained and calibrated and which workers
were not familiar with the readings.
ABATEMENT NOTE: Among other methods, one feasible and acceptable
abatement method to correct this hazard would be to set up a periodic
maintenance and calibration schedule in conjunction with manufacturer
guidelines and employee training for the TDI monitor.

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $810 · Current $810

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
employer did not furnish employment and a place of employment which were
free from recognized hazards that were causing or likely to cause death
or serious physical harm to employees in that employees were exposed to
the hazard of physical injury and burns due to over pressurization of
the reactor(s) during the manufacture of urethanes:
a) Churn/Reactor Area - Workers involved with manufacturing urethanes
in the reactor kettles were exposed to the hazard of fire and/or
explosion coupled with exposure to hazardous chemicals including
toluene diisocyanate, methyl ethyl ketone, and ethyl acetate on
7/11/90, due to potential of having the atmospheric reactors changed
to pressure reactors changed to pressure reactors with the closing
of a valve on each of the reactor vent lines and also due to the
vent lines not providing a direct and rapid exit of heat and vapors
that can build up during a reaction.
ABATEMETN NOTE: Among other methods, one feasible and acceptable
abatement method to correct this hazard would be to remove the shutoff
valve located on the vent lines of each of the reactors and to properly
size the vent lines from the reactors in accordance with DIERS
technology and to provide a direct path to the outside of the plant
rather than a path with many bends in the piping.

Issued

Sep 17, 1990

Abate by

Nov 2, 1990

Penalty

Initial $1,000 · Current $600 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
employer did not furnish employment and a place of employment which were
free from recognized hazards that were causing or likely to cause death
or serious physical harm to employees in that employees were exposed to
the hazard of a reactor fire and/or explosion and exposure to hazardous
chemicals including toluene diisocyanate, methyl ethyl ketone and ethyl
acetate:
a) Churn/Reactor Area - Workers involved with manufacturing urethanes
in the reactor kettles were exposed to the hazard of fire and/or
explosion coupled with exposure to hazardous chemicals including
toluene diisocyanate, methyl ethyl ketone, and ethyl acetate on
7/11/90, through leaving the reactors during the reaction phase
unmonitored and unattended.
b) Churn/Reactor Area - Workers involved with manufacturing urethanes
in the reactor kettles were exposed to the hazard of fire and/or
explosion coupled with exposure to hazardous chemicals including
toluene diisocyanate, methyl ethyl ketone, and ethyl acetate on
7/11/90, through not having a method with the operation of the
reactors to evaluate the amount of heat generated and heat build up
during the reaction and/or the temperature inside the reactor during
the solvent cleaning of the reactors.
c) Churn/Reactor Area - Workers involved with manufacturing urethanes
in the reactor kettles were exposed to the hazard of fire and/or
explosion coupled with exposure to hazardous chemicals including
toluene diisocyanate, methyl ethyl ketone, and ethly acetate on
7/11/90, through not having the means available to monitor the
mixing process of the reactors to assure that the mixing paddles
are indeed rotating.
ABATEMENT NOTE: Among other methods, feasible and acceptable abatement
methods to correct his hazard would be to:
1) Establish a procedure where the reactors and the reaction within
the reactor is monitored. This can be accomplished through having
a worker remain in the reactor area or by setting up a reactor
control room where conditions and stage of the reaction can be
continuously evaluated.
2) Install a temperature guage that would monitor the temperature
inside the reactor for the operators to monitor. The temperature
device should also be designed with a high temperature alarm set to
sound whenever the reactor temperature approaches a certain set
value.
3) Install electrical amp meters on the ground floor and mezzanine
level for each of the reactors that the operators can check on to
assure the paddles within the reactors are indeed mixing the
product.

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $810 · Current $500 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
employer did not furnish employment and a place of employment which were
free from recognized hazards that were causing or likely to cause death
or serious physical harm to employees in that employees were exposed to
the hazard of physical injury and/or burns due to over-pressurization of
the reactor resulting in an exposion and/or a reactor fire coupled with
a potential exposure to hazardous chemicals including toluene
diisocyanae, methyl ethyl ketone and ethyl acetate from a chemical spill
or accidental release:
a) Churn/Reactor Area - Workers involved with manufacturing urethanes
in the reactor kettles were exposed to the hazard of fire and/or
explosion and coupled with exposure to hazardous chemicals including
toluene diisocyanate, methyl ethyl ketone, and ethyl acetate on
7/11/90, through having inadequate reactor operator procedures.
ABATEMENT NOTE: Among other methods, one feasible and acceptable
abatement method to correct this hazard would be to establish standard
written operating procedures for the manufacturing of the urethanes and
the cleaning of the reactor vessels in conjunction with process diagrams
flow charts, and worker training on each of the reactorvessels.
NOTE: As part of this abatement, the exact capacity of the reactors
should be determined and the workers made aware of this. Also, the
reaction temperatures, as well as the heat of reaction, should be
established for each of the reactors.

Issued

Sep 17, 1990

Abate by

Nov 2, 1990

Penalty

Initial $400 · Current $300 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
employer did not furnish employment an a place of employment which were
free from recognized hazards that were causing or likely to cause death
or serious physical harm to employees in that employees were exposed to
the hazard of inhalation of hazardous chemicals including toluene
diisocyanate, methyl ethyl ketone and ethyl acetate:
a) Churn/Reactor Area - Workers involved with manufacturing urethanes
in the reactor kettles were exposed to the hazard of a fire coupled
with exposure to hazardous chemicals including toluene diisocyanate,
methyl ethyl ketone, and ethyl acetate on 7/11/90, through having an
inadequate recovery system (or catch basin) in the event of the
reactors overflowing during the manufacturing process and/or the
reactor cleaning work.
ABATEMENT NOTE: Among other methods, one feasible and acceptable
abatement method to correct this hazard would be to install containers
at the end of the vent lines which are of an adequate size to capture
and retain the maximum amount of materials which could be expected to
excape from the reactors during the manufacturing process and/or the
cleaning process.

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $810 · Current $500 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
employer did not furnish employment and a place of employment which were
free from recognized hazards that were causing or likely to cause death
or serious physical harm to employees in that employees were exposed to
the hazard of exposure to flammable vapors coupled with exposure to
hazardous chemicals including toluene diisocyanate, methyl ethyl ketone
and ethyl acetate:
a) Churn/Reactor Area - Workers involved with manufacturing urethanes
in the reactor kettles were exposed to the hazard of fire and/or
explosion from flammable vapors coupled with exposure to hazardous
chemicals including toluene diisocyanate, methyl ethyl ketone, and
ethyl acetate on 7/11/90, through lack of inerting the reactor
tanks when using flammable liquids during the manufacture of the
urethanes and the cleaning of the of reactors.
ABATEMENT NOTE: Among other methods, one feasible and acceptable
abatement method to correct this hazard would be the use of a blanket
of an inert gas over the flammable liquids within the reactor vessels.

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Penalty

Initial $560 · Current $300 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
employer did not furnish employment and a place of employment which were
free from recognized hazards that were causing or likely to cause death
or serious physical harm to employees in that employees were exposed to
the hazard of chemical burns and loss of eyesight from the carrying of
a corrosive liquid in an open portable container:
a) Churn/Reactor Area - Workers involved with mixing adhesives
in the churns were observed on 6/22/90 and 7/11/90, carrying
muriatic acid in a two-gallon uncovered plastic container,
exposing other workers to contact with the acid in the event of a
splash or a spill during the transport from the acid area to the
mezzanine area of the churns.
ABATEMENT NOTE: Among other methods, one feasible an acceptable
abatement method to correct this hazard would be to require the
transport of the acid in an appproved covered container.

Issued

Sep 17, 1990

Abate by

Oct 1, 1990

Penalty

Initial $480 · Current $480

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $400 · Current $200 Reduced

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $400 · Current $200 Reduced

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Penalty

Initial $320 · Current $200 Reduced

Issued

Sep 17, 1990

Abate by

Oct 1, 1990

Penalty

Initial $320 · Current $320

Issued

Sep 17, 1990

Abate by

Oct 1, 1990

Penalty

Initial $320 · Current $150 Reduced

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Penalty

Initial $640 · Current $500 Reduced

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $400 · Current $350 Reduced

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $400 · Current $250 Reduced

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $640 · Current $500 Reduced

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Penalty

Initial $640 · Current $500 Reduced

Issued

Sep 17, 1990

Abate by

Nov 19, 1990

Penalty

Initial $480 · Current $480

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $640 · Current $300 Reduced

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $560 · Current $300 Reduced

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $640 · Current $500 Reduced

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Penalty

Initial $560 · Current $300 Reduced

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Penalty

Initial $400 · Current $400

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $560 · Current $250 Reduced

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $560 · Current $250 Reduced

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $400 · Current $400

Issued

Sep 17, 1990

Abate by

Nov 2, 1990

Penalty

Initial $560 · Current $400 Reduced

Issued

Sep 17, 1990

Abate by

Nov 2, 1990

Penalty

Initial $480 · Current $400 Reduced

Issued

Sep 17, 1990

Abate by

Nov 2, 1990

Penalty

Initial $560 · Current $250 Reduced

Issued

Sep 17, 1990

Abate by

Nov 2, 1990

Penalty

Initial $480 · Current $300 Reduced

Issued

Sep 17, 1990

Abate by

Nov 2, 1990

Penalty

Initial $560 · Current $400 Reduced

Issued

Sep 17, 1990

Abate by

Oct 1, 1990

Penalty

Initial $560 · Current $350 Reduced

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $810 · Current $700 Reduced

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $640 · Current $640

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $350 · Current $350

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $640 · Current $640

Issued

Sep 17, 1990

Abate by

Sep 24, 1990

Penalty

Initial $1,620 · Current $800 Reduced

Issued

Sep 17, 1990

Abate by

Oct 1, 1990

Issued

Sep 17, 1990

Abate by

Oct 17, 1990

Penalty

Initial $200 · Current $200

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Penalty

Initial $80 · Current $80

Issued

Sep 17, 1990

Abate by

Sep 24, 1990

Penalty

Initial $80 · Current $80

Issued

Sep 17, 1990

Abate by

Sep 24, 1990

Issued

Sep 17, 1990

Abate by

Oct 2, 1990

Penalty

Initial $240

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Issued

Sep 17, 1990

Abate by

Nov 19, 1990

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Issued

Sep 17, 1990

Abate by

Sep 20, 1990

Issued

Sep 17, 1990

Abate by

Oct 17, 1990