OSHA Inspection: MORTON INTERNATIONAL, INC.

Issued

Oct 2, 1998

Abate by

Aug 18, 2000

Penalty

Initial $7,000 · Current $5,000 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 hazards of fire, explosion and being struck by parts
of the processing
equipment:
a)Building #11 - On or about 4/8/98 during the manufacture of Automate
Yellow
96 dye in vessel K-7, the equipment was not designed and/or operated in a
manner which contained the reaction within the confines of the reactor
vessel.
During the manufacturing process a rapid rise in temperature and pressure
occurred in vessel K-7 that resulted in the manway cover being blown off
allowing flammable vapors to enter the work area and ignite.
Among other methods, feasible and acceptable means of abatement to correct
these hazards
include:
1.  Using sound engineering principals, design and install a relief system
that controls the
pressure within the vessel to a safe level and/or releases the vapor to a
safe location
and;
2.  Provide an alarm system that provides sufficient warning of an upset
condition in order to
allow the safe evacuation of employees.
Abatement note:
A comprehensive process hazard analysis designed to identify, evaluate,
and control the hazards
involved in the process is recommenced.  This analysis should include an
emphasis on the
potential for uncontrollable exothermic reactions. The results of the
process hazard analysis
should be reflected in the standard operating procedures used by operators
to manufacturer the
product as well as the installation of equipment used to control potential
hazards.  As changes
are made in the process, an evaluation of the impact these changes have on
safety
and health
should be further evaluated.