Line Break Gone Bad (Caustic & $121K)

At 2:30 p.m. on August 28, 2019, employees were removing a flange blank on caustic liquid pipeline that was supposed to be evacuated but wasn’t. The employees were sprayed with caustic liquid and suffered chemical burns to their face and eyes. Two of the employees required hospitalization for treatment and three others were injured but did not require hospitalization.

• The employer did not develop specific procedural steps for shutting down, isolating, and blocking equipment to control hazardous chemical energy for employees performing flange slip removals on the 50% Sodium Hydroxide tank line above rail line 7 and 8 outbound loading pipe, and truck rack #2 outbound loading pipe.
• The employer did not outline specific requirements for testing the machines and equipment to confirm hazardous chemical energy was isolated for employees to safely perform flange slip removals on the 50% Sodium Hydroxide tank line above rail line 7 and 8 outbound loading pipe, and truck rack #2 outbound loading pipe.
• The employer did not conduct a periodic inspection of their energy control procedure with the last such inspection occurring on November 8, 2016. Employees are required to utilize energy control procedures while performing maintenance and servicing activities to include but not limited to flange slip removal from pipelines
• The employer did not train employees in the methods and means necessary for energy isolation when they are required to shut down, isolate, and block equipment to control hazardous chemical energy to include performing flange slip removals on the 50% Sodium Hydroxide tank line above rail line 7 and 8 outbound loading pipe, and truck rack #2 outbound loading pipe
• The employer did not ensure that each authorized employee performing flange slip removals on the 50% Sodium Hydroxide tank line above rail line 7 and 8 outbound loading pipe, and truck rack #2 outbound loading pipe placed their own individual locks into the lockbox used for the group lockout procedure
• The employer did not ensure that the authorized employee verified that isolation and de-energization of the piping circuit containing 50% Sodium Hydroxide above rail line 7 and 8 outbound loading pipe, and truck rack #2 outbound loading pipe, was accomplished
• The employer did not ensure that employees using an aerial lift to perform flange slip removals on the 50% Sodium Hydroxide tank line above rail line 7 and 8 outbound loading pipe, and truck rack #2 outbound loading pipe, inspected and tested all functions of the aerial lift including but not limited to the safety devices.
• The employer did not provide adequate training for employees using an aerial lift to perform flange slip removals on the 50% Sodium Hydroxide tank line above rail line 7 and 8 outbound loading pipe, and truck rack #2 outbound loading pipe. The JLG Model 660SJ Boom Straight 65 foot 4 wheel drive had a magnetic safety cable Skyguard device to protect the platform operator. The employees did not know how to restart the lift after the emergency shutdown occurred, including reconnecting the magnetic safety cable device.
• The individual in charge of the ICS did not implement appropriate emergency operations in that adequate personal protective equipment was not worn by personnel responding to an emergency where a maintenance worker was sprayed with 50% corrosive sodium hydroxide liquid and subsequently trapped approximately 30 above grade in rail rack #7 and #8.
• Appropriate personal protective equipment was not selected and worn by personnel responding to an emergency where a maintenance worker was sprayed with 50% corrosive sodium hydroxide liquid and subsequently trapped approximately 30 above grade in rail rack #7 and #8.

Source: https://www.osha.gov/ords/imis/establishment.inspection_detail?id=1427100.015