OSHA Inspection: CHEMCENTRAL CORPORATION

Issued

Jul 19, 2007

Abate by

Aug 21, 2007

Penalty

Initial $2,500 · Current $2,500

Issued

Jul 19, 2007

Abate by

Aug 21, 2007

Penalty

Initial $55,000 · Current $46,188 Reduced

Hazardous substances B595M250

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:
(a)In that employees at the distribution facility located at 910 N.
Prospect Ave., Kansas
City, Missouri, were exposed to the hazard of explosion and fire due to
the improper
handling and storage of Indopol, a Class III B combustible liquid, that
was unstable at
elevated temperatures.  The Indopol chemical was Polybutene, an
Isobutylene/Butene
Copolymer which decomposed at elevated temperatures into a flammable
atmosphere.
The liquid was required to be handled and stored at elevated temperatures
due to the
product viscosity characteristics.
The employer stored two Indopol grades (H-100 and H-300) in the 10,000
gallon
compartments of a horizontal, insulated, 20,000 gallon capacity, above
ground storage
tank.  Each tank compartment contained a flanged immersion heater that was
operated
in order to elevate the temperature of the Indopol to approximately 225 to
250 degrees
Fahrenheit so the liquid could be transferred to drums, portable storage
tanks, or trailer
tanks for shipment to customers.
The employer did not heed hazard warnings that were published in the
manufacturer's
material safety data sheet (MSDS) regarding the unstable properties of
Indopol
Polybutene when handled and stored at elevated temperatures.  Those hazard
warnings
included, but were not limited to, depolymerization characteristics,
requirements for inert
gas blanketing during storage, short and long term maximum storage
temperatures, and
avoidance of ignition conditions.  The employer did not heed the warnings
published in
the MSDS even though the warnings were passed on to customers by the
employer
via
printed and electronic methods.
On, or about February 7, 2007, an explosion and fire occurred inside, or
in the vicinity
of the Indopol tank during, or after employees transferred Indopol H-300
out of tank
compartment 41.  The explosion and fire resulted in serious injuries to
two employees
and catastrophic loss of the facility.
Among other methods, one feasible and acceptable abatement method to
correct this hazard is
to undertake the following steps;
Follow the Indopol manufacturer's warnings published in the material
safety data sheet
and the transportation, handling, and storage guide in order to prevent
the unstable
decomposition of the Polybutene Copolymer to a flammable atmosphere at
elevated
temperatures and to prevent ignition of any flammable atmosphere that may
be generated.
Do not store Indopol for prolonged periods of time at temperatures of 60
degrees Celsius
(140 degrees Fahrenheit) and above.  Exclude oxygen by use of a nitrogen
blanket to
prevent ignition of a flammable atmosphere in the tank head space.
Install a let down
pressure regulator and pressure/vacuum valve to maintain tank pressure.
Do not use a heating system that may generate localized hot spots at
temperatures above
200 degrees Celsius (392 degrees Fahrenheit).  Do not store Indopol grades
H-100 and
H-300 above the recommended maximum storage temperature of 120 degrees
Celsius
(248 degrees Fahrenheit).  Install temperature gauges to determine the
temperature of the
Indopol.  Install a high temperature cut off switch on the flanged
immersion heater so
the Indopol does not exceed the recommended storage temperature.
Operate the flanged immersion heaters in accordance with manufacturer's
recommendations.  Do not allow the heater to operate when the level of the
Indopol is
at, or below the heater element tubes.  Install a liquid low level
indicator, alarm, and
automatic heater shutoff for conditions when the level of the Indopol is
at the level where
the heater shall be shut off.
Inspect and maintain the above ground storage tank in accordance with NFPA
30
Flammable and Combustible Liquids Code, 2003 Edition, Section 4.6.7 and
Steel Tank
Institute SP001-3.  Conduct periodic internal inspection and testing of
the tank to detect
corrosion, cracks, or other defects.  Inspect and maintain the flanged
immersion heaters
in accordance with manufacturer's recommendations that include heater
element tube
inspection, and heater control testing.
Abatement certification is required for this violation (using the
CERTIFICATION OF
CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating
that
abatement is complete must be included with your certification.  This
documentation
may
include, but is not limited to, evidence of the purchase or repair of the
equipment, photographic
or video evidence of abatement, or other written records.

Issued

Jul 19, 2007

Abate by

Aug 21, 2007

Penalty

Initial $55,000 · Current $46,188 Reduced