OSHA Inspection: BASF CORPORATION, COATINGS AND COLORANTS DIVISION

Issued

Jan 31, 1991

Abate by

Mar 4, 1991

Penalty

Initial $8,000 · Current $8,000

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:
a) 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 in and around the Resin Building were exposed on and
before August 19, 1990, to the increased hazards of fire and explosion
due to the release of flammable materials such as isopropanol, methyl
ethyl ketone, and Blended Cleaning solvent from the reactors in the
building in that:
The employer did not take adequate measures to prevent a hazardous
release of flammable materials in that:
A. The rupture disc discharge line for "D" reactor at that time
terminated in a "J" - shaped elbow and discharged into the atmosphere
in the direction of the rooftop of the building where ignition sources
were located nearby,
B. The rupture disc discharge lines for reactors "A, B, C, and E"
at the time terminated in a 90 degree elbow and discharged in the
atmosphere in a southerly direction toward the ELPO and Tank Storage
buildings and tankwagon loading/unloading platforms.
C. The operating controls for the reactors at that time did not
include high pressure shut down devices for abnormally high pressure
conditions within the reactors.
D. Operating practices were inadequate in that reactors were not
required to be continuously attended by operators while in use.
E. Operating practices were inadequate in that there was no standarized
training program for reactor operators to assure safe operating
techniques in the operation of the reactors.
Among other methods, feasible and acceptable abatement methods to
correct this hazard are:
1. Provide discharge piping for the rupture disc discharge lines
which terminates at a safe location such as but not limited to a blow
down tank or a header pipe to a flare or scrubber system in accordance
with NFPA 35-1987, Standard for the Manufacture of Organic Coatings.
2. Provide control system which will automatically shut down
the reactor in the event of an abnormally high pressure and control
the feedrate of monocar in the event of abnormal reactor conditions
which may result in a runaway reaction.
3. Establish standard operating procedures which will require
the attendance of a trained qualified operator at the reactor controls
during reactor operations.
4. Establish a written training program for reactor operators
which includes proper setup procedures, verification of valve position
for all critical operations, and continquency procedures for abnormal
developments in the processes.

Issued

Jan 24, 1991

Abate by

Jan 29, 1991

Penalty

Initial $500 · Current $500

Issued

Jan 24, 1991

Abate by

Jan 29, 1991

Penalty

Initial $700 · Current $700

Issued

Jan 24, 1991

Abate by

Mar 1, 1991

Penalty

Initial $700

Issued

Jan 24, 1991

Abate by

Mar 1, 1991

Penalty

Initial $500 · Current $500

Issued

Jan 24, 1991

Abate by

Jan 29, 1991

Penalty

Initial $700 · Current $700

Issued

Jan 24, 1991

Abate by

Mar 1, 1991

Penalty

Initial $700

Issued

Jan 24, 1991

Abate by

Mar 1, 1991

Penalty

Initial $500 · Current $500

Issued

Jan 24, 1991

Abate by

Mar 1, 1991

Issued

Jan 24, 1991

Abate by

Mar 1, 1991

Penalty

Initial $500

Issued

Jan 24, 1991

Abate by

Feb 4, 1991