A pharmaceutical and chemical manufacturer and its parent company could have prevented an employee’s fatal injuries from an explosion on May 4, 2023, but lacked the required safeguards in a chemical manufacturing process. An investigation by OSHA identified numerous deficiencies in the facility’s process safety management program for highly hazardous chemicals for the production and drying of a chemical product called Dekon 139 and for combustible dust hazards. During the process, a pressure vessel exploded, causing the employee’s fatal injuries.
Specifically, OSHA investigators found that the facility did not:
- Determine the combustibility hazards of materials used in the Dekon 139 production process, exposing employees to fire and explosion hazards from combustible dust.
- Include safe upper and lower temperature limits to prevent the decomposition of Dekon 139.
- Evaluate the consequences of deviation in the Dekon 139 production process.
- Establish written procedures to maintain the ongoing integrity of process equipment and provide clear instruction on consequences of deviation from steps in the operating procedures.
- Update the process safety information to include steps to avoid consequences of deviation in temperature, properties and hazards of the chemicals used in the process.
- Update standard operating procedures for producing Dekon 139 and its safety data sheet.
- Review a November 2022 compliance audit report with all affected personnel whose job tasks are relevant to the report findings.
- Track contract employee’s injury and illnesses related to the contractor’s work in the process areas.
These conditions led OSHA to cite the facility for 11 violations, including eight serious and two repeat, and one other-than-serious. The agency assessed $298,254 in proposed penalties.