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Archived News Release--Caution:
information may be out of date.
For more information call: (202) 219-8151
Following a 4-month investigation by the Occupational
Safety and Health Administration (OSHA) of an explosion at the Columbus, Ohio,
facility of Georgia-Pacific Resins, Inc., the company and OSHA have agreed upon
a plan for improving safety and health at the plant. The accident claimed the
life of one worker and injured four others.
Under the terms of the settlement, Georgia-Pacific Resins,
Inc., has agreed to pay $432,500 in penalties -- the total proposed by OSHA --
and make significant safety improvements at its Columbus, Ohio, facility. OSHA
issued the citations and penalties today.
"We are pleased that Georgia-Pacific has agreed to resolve
this matter as quickly as possible, in order to ensure maximum protection for
its employees," said Secretary of Labor Alexis M. Herman. "The agreement avoids
the cost and burden of possible prolonged litigation and furthers the efforts
of both Georgia-Pacific and the Labor Department to ensure a safe workplace at
the Columbus facility."
Georgia-Pacific Resins, Inc., a manufacturer of
thermoplastic and thermosetting resins and formaldehyde, is headquartered in
Atlanta. The company employs approximately 50,000 workers nationwide in more
than 400 facilities. The Columbus facility began operations in 1971 and
currently employs 57 workers.
The incident occurred on Sept. 10, 1997, when an
8,500-gallon reactor vessel used for resin production exploded, killing one
worker and injuring four others. During the subsequent investigation, OSHA
found numerous violations, all but one involving the standard for process
safety management of highly hazardous chemicals.
"Georgia-Pacific's Columbus facility cooperated fully
during our investigation," said OSHA administrator Charles N. Jeffress. "Now,
the company wants to move forward. In addition to paying the proposed penalties
and abating hazards discovered in the investigation, the company has agreed to
implement additional safety and health measures to help prevent future
incidents."
Under the settlement agreement, Georgia-Pacific will
implement procedures to promptly and completely address the findings and
recommendations of each process hazard analysis and incident investigation
report. Additionally, the company will train each employee involved in a
covered chemical process or operation in an overview of the process and
pertinent operating procedures, including any actions taken as a result of the
process hazard analyses or incident investigations.
To address employee training requirements, Georgia-Pacific
has agreed to implement a state-of-the-art interactive computer- based training
system within the next 18 months, to train employees in running simulated resin
batches.
Georgia-Pacific is required to report to OSHA the progress
it will be making to comply with this agreement and the process safety
management standard.
# # #
(Editor's Note: See Attached Fact Sheet for Summary of
Citations.)
- Process safety information did not include process chemistry for
Novolak resin batches.
- Process safety information did not include all safe upper and lower
limits.
- Process safety information did not include an evaluation of every
consequence of deviation.
- Process safety information did not include accurate piping and
instrument diagrams.
- The employer did not perform initial process hazard analysis for the
Novolak resin process.
- K-2 process hazard analysis did not consider all the hazards of the
process.
- K-2 process hazard analysis did not address the consequences of
engineering control failure.
- Process hazard analyses did not address facility siting.
- Human factors checklists in the process hazard analyses were not
completed.
- The employer did not communicate the actions of the K-2 process
hazard analysis to all affected employees.
- The employer did not certify annually that the operating procedures
were current and accurate.
- Inspections and tests on process equipment did not address all items
related to mechanical integrity.
- All affected employees who operate resin batches were not informed of
and trained in changes to the written operating procedures.
- The incident investigation reports did not include factors which
contributed to the incidents.
- The incident investigation reports were not reviewed with all
affected personnel.
- The employer did not document that deficiencies found in the
compliance audit were corrected.
- Each affected employee did not wear a hard hat when working in areas
where there was a potential for injury to the head from falling objects.
- The resin reactor vessels and associated controls were not sufficient
to minimize uncontrolled exothermic phenol-formaldehyde reactions.
- The employer did not develop and implement written operating
procedures that provided clear instructions for safely manufacturing resins.
- The written operating procedures did not address all the requirements
for the operating limits.
- The written operating procedures did not effectively address the
requirements for the safety and health considerations.
- The training program for operators did not include all the required
elements.
- The employer did not provide refresher training to each operator.
- The employer did not correct deficiencies in equipment that were
outside acceptable limits before further use or in a safe and timely
manner.
Archived News Release--Caution:
information may be out of date.
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