On January 15, 2008, a pressure vessel at a New Jersey foundry exploded, killing one 60-year-old worker instantly while injuring eight other workers with shrapnel.
The pressure vessel in question was used to pressurize/depressurize molten aluminum to prevent/eliminate porosity from the metal.
The incident occurred while two (2) workers, including the one who was killed, were testing a new O-ring gasket that had just been installed for leaks.
The procedure is one person stands beside the vessel and operates the controls, while the other one stands in front and observes for signs of leaks.
The first sign of a leak occurred at 80 psi on the day in question.
Then, in an attempt to force the O-ring into place, they increased the pressure to 112 psi, at which point the explosion occurred, propelling the worker 38 feet and the vessel’s hatch 35 feet.
It is important to note here that this vessel was rated for a maximum pressure of 100 psi.
Lessons Learned