In 2008, a blast at a propylene splitter, injured
five people, including one passerby.OSHA fined the facility for the following citations:
- All plant fire protection facilities were not adequately maintained and/or periodically inspected and tested to make sure they were always in satisfactory operating condition and would serve their purpose in time of emergency. Fine: $6,300.
- Process safety information pertaining to the equipment in the process did not include the relief system design and design basis. Employees working for the propylene splitter, alkylation area, catalytic cracker, Cat Light Ends and other units relieved by this flare system were "potentially exposed to equipment failure and subsequent catastrophic release of flammable or toxic materials resulting in toxic exposure, explosion and fire hazards. Proposed penalty: $6,300.
- The process hazard analysis for the propylene splitter unit did not address engineering controls to indicate to board operators the fluid levels in the three propylene splitter towers resulting in a hazard to employees. Proposed penalty: $6,300.
- The company did not develop and implement written operating procedure that involved clear instructions for safely conducting activities. According to information from OSHA, written operating procedures used for start-up of the propylene splitter unit did not provide clear instructions for safely conducting activities, nor did they address operating limits, safety and health considerations, safety systems and their functions. Proposed penalty: $6,300.
- Frequency of inspections and tests of process equipment to maintain its mechanical integrity was not consistent with manufacturer's recommendations and good engineering practices. Also, recommended piping inspection intervals were not followed. Proposed penalty: $6,300.
- The company did not correct deficiencies in equipment outside acceptable limits before further use or in a safe and timely manner. Piping and components at the propylene unit were outside acceptable limits as defined by design codes and standards employed by the company. These design codes and standard limits were exceeded in that component set points and thinning of piping beyond safe and acceptable limits was evident in process equipment. Proposed penalty: $6,300.
- Piping inspection drawings for the reboiler area were not consistent with design specifications. Improper piping thicknesses were indicated and piping retirement thicknesses were not consistent with design specs and recommended good engineering practices. Proposed penalty: $6,300.
- The company did not investigate each incident which result in, or could reasonably have resulted in, a catastrophic release of a highly hazardous chemical in the workplace. Proposed penalty: $1,875.
- The employee alarm system did not provide warning for necessary emergency action as called for in the emergency action plan, or for reaction time for safe escape of employees from the workplace, immediate area or both. Proposed penalty: $6,300.
Source: OSHA.gov
