Flammable atmosphere + static charge = explosion

At about 2:00 a.m. on October 15, 1990, Employee #1 was transferring an approximately 20 percent monoethanolamine (ethanolamine) solution from a process vessel, the amine regenerator, to the top of an 11,000 gallon aluminum storage tank. The ethanolamine solution had apparently entrained hydrogen gas, some of which released to the atmosphere of the storage tank upon transfer and apparently caused the hydrogen gas concentration in the tank to exceed 4 percent. A source of ignition, possibly the static charge of the falling ethanolamine solution, caused the hydrogen to explode. Employee #1 was engulfed in the release of ethanolamine solution from the ruptured tank and sustained chemical burns to his left eye. The storage tank was damaged beyond repair, and piping, valves, and windows in the immediate area were destroyed. Damage was estimated at $70,000.

Source:OSHA.gov

Know the location of your emergency shutoff valve switches

Employees #1 and #5 through #7 were near the chlorine unloading area at a bleach plant when the gasket of a recently-installed vaporizer failed, releasing between 500 and 700 gallons of liquid chlorine. When Employees #1 and #7 went to investigate the extent and location of the leak, they found an overwhelming concentration of the chemical. They were not using SCBAs, nor was Employee #6, who used the wrong escape route. Employee #5, the bleach plant operator, attempted to find and assist Employee #6. 

Employees #2 through #4 attempted to shut down the vaporizer system but they did not know the location of the one critical shut-off valve, and the key person was not immediately available to help. Employees #1 through #7 suffered chemical burns from inhaling the chlorine fumes; all were hospitalized except for Employee #2.

Source:OSHA.gov

Handle chemicals with care!

 At approximately 3:00 p.m. on April 29, 1991, Employee #1 was pouring caustic soda into a tank containing water when a flash steam explosion occurred and he was splashed by the solution. His supervisor saw what happened, grabbed Employee #1, and plunged him into a neighboring tank of water. The supervisor told him to get medical treatment, but Employee #1 initially refused. When he could no longer stand the pain, he took himself to the Burn Unit, where he was treated and released. This was not a serious injury accident. The cause of the accident was the reaction of the chemical with water. The water was warm, and the rapid addition of the caustic soda caused the soda to pile up on the bottom of the tank. The increasing heat resulted in the explosion. The supervisor said that he had trained Employee #1 on how to perform this task safely. Employee #1 had been doing it for two months prior to the accident. A coworker who witnessed the accident said that he had also been trained on how to safely complete the procedure. To prevent a recurrence, Employee #1 was to be retrained when he returned to work.

Source:OSHA.gov

Have you identified incompatible chemicals in your facility?

On August 6, 1999, Employees #1 through #5 were present during a transfer operation involving sodium hypochlorite. A chemical reaction occurred between the sodium hypochlorite and an incompatible chemical, causing the tank to erupt. Employee #1 was killed. Employees #2 through #5 sustained injuries, for which Employees #2 and #3 were hospitalized.

Source:OSHA.gov

Are you inspecting your expansion joints?

At 1:45 a.m. there was an accidental release of chemical vapors. Carbon tetrachloride, containing chlorine and hydrochloric acid, formed a cloud after being released through a failed expansion joint on a chlorine absorber feed cooler inlet. Employees #1 through #6 were injured when they inhaled the vapors. Three of them were hospitalized.

Source:OSHA.gov