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[summary:protected] => A recall notice by the United States Consumer Product Safety Commission affects over 300,000 DeWalt Jobsite Pro Headphones. The recall is a result of a malfunction that can cause earbuds to overheat while charging or during use, leading to fire and burn hazards.
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[summary:protected] => This CPWR Hazard Alert on Working in enclosed cabs provides information on protecting workers from silica dust, how to minimize exposures and the dangers of silica dust. Click on the following links to access the English version and the Spanish version.
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[summary:protected] => The CPWR Toolbox Talk on Suicide Prevention addresses the prevalence of suicide among construction workers. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely.
Available in English and Spanish.
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The CPWR Toolbox Talk on Preventing Exposure to Silica Dust in Enclosed Cabs addresses the risks associated with breathing in silica dust and silicosis. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely.
Available in English and Spanish.
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There is an infographic that accompanies this report: https://www.aiha.org/publications-and-resources/TheSynergist/Digital%20Synergist%20Images/201707-bythenumbers.jpg
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Note from Chris: As this was selected as an external link the billable pages were 0. Bruce, in the more like this field, you may want to enter in the ID's of the CSB videos we have in the database.
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Note from Chris: As this was selected as an external link the billable pages were 0. Bruce, in the more like this field, you may want to enter in the ID's of the CSB videos we have in the database.
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[summary:protected] => Combustible dusts are fine particles that present an explosion hazard when suspended in air in certain conditions. A dust explosion can be catastrophic and
cause employee deaths, injuries, and destruction of entire buildings. OSHA notes that in many combustible dust accidents, employers and employees were unaware that a hazard even existed. In this FactSheet, OSHA helps employers and workers to determine if this hazard is present and what actions are needed to prevent tragic consequences.
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[summary:protected] => The U.S. Chemical Safety Board is an independent, non-regulatory safety agency that investigates chemical incidents and makes recommendations to prevent similar incidents from occurring. This short report is a summary of the lessons from several of the most catastrophic incidents the CSB has investigated. The CSB found common deficiencies in safety management systems, facility maintenance, adequacy of regulations, training. poor hazard awareness among emergency responders and insufficient community notification and planning. The specific incidents reviewed include the West, Texas fertilizer plant explosion, the Deep Water Horizon explosion, and the Richmond California refinery explosion.
There is an infographic that accompanies this report: https://www.aiha.org/publications-and-resources/TheSynergist/Digital%20Synergist%20Images/201707-bythenumbers.jpg
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SAFETY IS GOOD BUSINESS AND GOOD PUBLIC POLICY
"There's an old saying that if you think safety is expensive, try an accident. Accidents cost a lot of money. And, not only in damage to [the] plant and in claims for injury, but also in the loss of the company's reputation." - Trevor Kletz
As an independent, non-regulatory safety agency, the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigates catastrophic chemical incidents and makes recommendations to prevent similar incidents from occurring. The CSB has found that most catastrophic chemical incidents could have been prevented. The agency conducts comprehensive, root cause analyses, examining all the causal or contributing factors. Our investigations have identified deficiencies in areas such as safety management systems, facility maintenance, regulatory requirements and training. In addition to identifying the causes of an incident, the CSB uncovers factors that exacerbate its consequences, contributing to loss of life and property, such as a lack of hazard awareness among emergency responders and insufficient community notification and planning.
The CSB’s vision is a nation safe from chemical disasters. The CSB has published nearly one hundred investigative reports and produced sixty-eight video products to communicate its safety messages to audiences across the country, so that people may benefit from the lessons learned from these tragedies. With over 130 investigations and nearly 800 recommendations issued, the agency has sought to engage industry, unions, standards setting organizations, regulators, academia, and the American people in a collaborative effort to make the chemical industry safer, while maintaining economic productivity and protecting the jobs of workers in industrial facilities nationwide. The CSB has had an enormous impact on chemical safety with a staff of approximately 40 people and $11 million budget.
Here are some examples of our work.
Explosion at Fertilizer Storage Facility (West, Texas)
April 17, 2013
West Fertilizer Company
West, Texas
April 17, 2013
- 15 fatalities and 260+ injuries
- $230 million in insurance-related losses
- $16 million spent on Federal disaster assistance
- $1 million insurance policy held by West Fertilizer Company
On April 17, 2013, a massive explosion at the West Fertilizer Company (WFC), a fertilizer storage and distribution facility located in West, Texas, killed twelve first responders and three members of the public and caused more than 260 other injuries to first responders and the general public. Two of the fatally injured members of the public lived at a nearby apartment complex. The third lived at a nursing home and died shortly after the incident from injuries related to the trauma of the explosion.
The incident caused considerable property damage, including the complete destruction of the fertilizer facility, which was never rebuilt, leaving local farmers, ranchers and businesses without convenient access to needed products. The blast also caused extensive property damage beyond the facility. Two of the city’s school buildings had to be demolished and a third sustained major damage. Also destroyed were a nursing home, an apartment complex and numerous nearby homes. In a community of 700 homes, 350 (50%) were damaged as a result of the explosion, 142 (20%) of which were damaged beyond repair.
Total insurance-related losses from the explosion are estimated to be $230 million and federal disaster assistance is estimated to exceed $16 million. The company was only insured for $1 million, which fell far short of the incident’s damage.
CSB Findings and Recommendations:
- Failure by the insurer to identify the risks posed by fertilizer grade ammonium nitrate (FGAN). A few years prior to the incident, WFC was dropped by one insurer for failing to address safety concerns identified in loss control surveys. The company that insured WFC for $1 million at the time of the incident did not conduct its own safety inspections of the facility.
- The Federal Emergency Management Agency (FEMA) awarded two grants to develop FGAN training. The CSB found that there is no standardized training requirement that applies to volunteer firefighters across the nation. The CSB made a recommendation to FEMA to create a funding mechanism to provide training and curriculum develop for first responders at FGAN incidents. West Volunteer Fire Department did not conduct pre-incident planning or response training at WFC, was likely unaware of the potential for FGAN detonation and did not, nor were required, to have appropriate training in hazardous materials response.
- Gaps in federal and state regulations and standards. The CSB identified several gaps in federal and state regulations that could have reduced the consequences of the WFC disaster. These include the Occupational Safety and Health Administration’s Explosives and Blasting Agents and Process Safety Management standards, the Environmental Protection Agency’s Risk Management Program and Emergency Planning and Community Right-to-Know Act, and training provided or certified by the Texas Commission on Fire Protection and the State Firefighters’ and Fire Marshals’ Association of Texas.
- Local zoning and community planning. The location of the WFC relative to the surrounding community exacerbated the offsite consequences. The CSB found that at least 19 other Texas facilities storing more than 10,000 pounds of FGAN are located within a half-mile of a school, hospital, or nursing home, raising concerns that an incident with offsite consequences of this magnitude could happen again.
Refinery Explosion (Richmond, California)
August 6, 2012
Chevron Refinery
Richmond, California
August 6, 2012
- 15,000 people sought medical treatment
- $2 million in fines and restitution
- $447 million in increased gas prices passed onto California consumers1
On August 6, 2012, the Chevron Refinery in Richmond, California, experienced a catastrophic pipe failure in a crude unit, causing the release of flammable hydrocarbon process fluid which partially vaporized into a large cloud. Nineteen employees engulfed by the vapor cloud escaped, narrowly avoiding serious injury. The ignition and subsequent continued burning of hydrocarbons resulted in a large plume of unknown particulates and vapor. Approximately 15,000 people from the surrounding area sought medical treatment in the weeks following the incident. The CSB’s investigation found that the pipe failure was caused by sulfidation corrosion, a damage mechanism that causes piping walls to thin over time.
Although the company has never reported the decreased production capacity experienced as a result of the incident, the U.S. Energy Information Administration determined that the increase in gas prices cost California consumers approximately $447 million in six months following the incident.
Key Findings and Recommendations:
- Hazard analyses improved at all Chevron refineries in the U.S. The CSB investigation found that the hazard analysis conducted on the piping that failed did not identify corrosion as a potential cause of a leak or rupture. As a result, the CSB issued a recommendation to Chevron to perform damage mechanism hazard reviews (DMRs) on all of its process safety management (PSM) covered equipment and to incorporate the DMRs into their hazard review process at all its U.S. refineries. As a result of the CSB’s recommendation, Chevron has conducted DMRs at all of its U.S. refineries for PSM covered process piping circuits. If more companies were to adopt hazard review programs similar to Chevron’s, safety at refineries would be greatly increased.
- The California Department of Industrial Relations (DIR) revisions to the PSM regulation. Chevron conducted a hazard analysis of the crude unit as required by California’s Process Safety Management of Acutely Hazardous Materials (PSM) program; however, this does not require a formal damage mechanism hazard review to identify sulfidation corrosion. The CSB made several recommendations to improve California’s PSM program. Since 2014, DIR has published several drafts of a revised regulation and received and incorporated extensive stakeholder feedback. If the proposed regulation is approved, process safety in California’s refineries would be greatly improved and chemical safety would be advanced by better preventing major chemical incidents.
Deepwater Horizon/ Macondo Well Blowout (Gulf of Mexico)
April 20, 2010
Deepwater Horizon/Macondo Well Blowout
Gulf of Mexico
April 20, 2010
- $21 billion in settlements
- $13 billion in economic and medical claims
- 11 workers killed, 17 workers injured
- 4 million barrels of oil spilled
On April 20, 2010, a multiplefatality incident occurred at the Macondo oil well approximately 50 miles off the coast of Louisiana in the Gulf of Mexico during temporary well-abandonment activities on the Deepwater Horizon drilling rig. Control of the well was lost, resulting in a blowout—the uncontrolled release of hydrocarbons from the well. On the rig, the hydrocarbons found an ignition source and burst into flames. The resulting explosions and fire led to the deaths of 11 individuals, serious physical injuries to 17 others, evacuation of 115 individuals from the rig, the sinking of the Deepwater Horizon, and massive marine and coastal damage from a reported 4 million barrels of released hydrocarbons.
The operator of the rig, has paid out an estimated $13 billion worth of economic and medical claims as part of an uncapped settlement, in addition to a $20 billion settlement for federal, state and local government economic and environmental claims. Settlements involving other companies have reached $1.24 billion payout at the time of the completion of the CSB’s investigation. Other litigation remains pending.
CSB Findings and Recommendations:
- Blowout preventer (BOP) hazard not identified prior to Deepwater Horizon. Testing limitations masked latent failures of the Deepwater Horizon BOP, affecting its operation on the day of the incident, and these latent failures will continue to exist for similarly designed blowout preventers unless modifications are made to current standard industry testing protocols.
- Pipe buckling prevented drillpipe from working effectively. Pressure conditions in a well can cause drillpipe to buckle (or bend) in a BOP even after a crew has initially sealed a well, potentially incapacitating emergency functions of the BOP intended to cut drillpipe and seal the well.
- Safety-critical controls are necessary for hazard management. Major hazards require concerted efforts by industry to manage and actively monitor the safety-critical controls they rely on for the safe conduct of work, including improved incorporation of human factors, safety performance indicators, and corporate governance.
- Information sharing can be a challenge in offshore drilling. Obstacles continue to exist that limit sharing of lessons from incident investigations in individual companies and across both the operator/drilling contractor boundary and international geographical regions.
- Proper use of process safety indicators can prevent incidents. An equal focus and effort to collect, measure, and improve process safety performance indicators to that currently dedicated to personal safety statistics is necessary to reduce the potential for a major incident.
Texas City Refinery Explosion (Texas City, Texas)
March 23, 2005
BP Texas City
Texas City, Texas
March 23, 2005
- $1.5 billion in financial losses
- 15 workers killed
- 180 people injured
On March 23, 2005, a hydrocarbon isomerization unit (ISOM) exploded at the BP Texas City refinery in Texas City, Texas, resulting in financial losses of more than $1.5 billion. The incident killed 15 workers and injured 180 others. All of the fatalities and many serious injuries occurred in and around the nine temporary trailers sited as close as 121 feet from the ISOM unit. This refinery explosion was the most serious refinery incident ever investigated by the CSB. The CSB’s final investigative report into the incident found organizational and safety deficiencies at all levels of the BP Corporation. The report also noted gaps in standards and practices that likely contributed to other serious incidents over the previous decade.
CSB Findings and Recommendations:
- Trailer siting exacerbated the consequence of the BP Texas City explosion. All of the fatalities and many of the injuries occurred in or near a series of occupied trailers that were as close as 121 feet from the blowdown stack. In October 2005, the CSB issued an urgent recommendation to the American Petroleum Institute (API) to develop new guidance to prevent locating occupied trailers within hazardous areas of process plants.
- Blowdown drums should be replaced by safer alternatives. The CSB made a recommendation to API to eliminate the kind of blowdown drum that released the flammable liquid and vapor at BP. This 1950s-era equipment is unsafe, and many companies around the world have long since eliminated these systems and replaced them with inherently safer flare systems designed to handle a worst-case flammable release.
- A strong safety culture must be embraced at all levels of a corporation. The March 2005 incident was one of a long series of tragedies at the Texas City facility, where a total of 40 workers have died over 32 years. Internal audits revealed deteriorating conditions at the refinery over several years prior to 2005, but the responses focused primarily on improving personal safety and overlooked growing process safety risks.
- Process safety indicators help companies measure and improve process safety performance. The CSB recommended that API and the United Steelworkers develop a consensus standard for new process safety leading indicators to help businesses and government better assess these risks before serious incidents occur. Such leading indicators have been used for years in the nuclear power industry and provide a common method for different facilities to measure and compare system safety performance.
Conclusion
Based on the more than 130 incidents investigated by the CSB, it is clear that hundreds of billions of dollars have been spent as a result of chemical disasters in the United States. To make the safety of Americans our number one priority, it is critical that chemical safety lessons are learned and shared among diverse stakeholders across industries. If the CSB’s many safety lessons prevented at least one catastrophic incident, the money saved by preventing damage to the facility and surrounding community, avoiding legal settlements, and saving human lives far outweighs the agency’s $11 million annual budget. Safety and prosperity are compatible. Strong safety programs are critical for the economic success of the chemical and petrochemical industries. The CSB’s continued collaboration with industry, regulators, standards setting bodies and other professional organizations proves that the CSB has a vital role in driving critical chemical safety change in the United States.
References
1 Gonzales, Dan, Timothy Gulden, Aaron Strong and William Hoyle. Cost–Benefit Analysis of Proposed California Oil and Gas Refinery Regulations. Santa Monica, CA: RAND Corporation, 2016. http://www.rand.org/pubs/research_reports/RR1421.html. Also available in print form.
Data presented for each investigation was current at the time of the approval of the final report. The West Fertilizer Company report was released on January 28, 2016. The final Chevron Richmond refinery report was released on January 28, 2016. The final Deepwater Horizon/Macondo report was released on April 20, 2016. The BP Texas City report was released on March 20, 2007.
[content_transformed:protected] =>SAFETY IS GOOD BUSINESS AND GOOD PUBLIC POLICY
"There's an old saying that if you think safety is expensive, try an accident. Accidents cost a lot of money. And, not only in damage to [the] plant and in claims for injury, but also in the loss of the company's reputation." - Trevor Kletz
As an independent, non-regulatory safety agency, the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigates catastrophic chemical incidents and makes recommendations to prevent similar incidents from occurring. The CSB has found that most catastrophic chemical incidents could have been prevented. The agency conducts comprehensive, root cause analyses, examining all the causal or contributing factors. Our investigations have identified deficiencies in areas such as safety management systems, facility maintenance, regulatory requirements and training. In addition to identifying the causes of an incident, the CSB uncovers factors that exacerbate its consequences, contributing to loss of life and property, such as a lack of hazard awareness among emergency responders and insufficient community notification and planning.
The CSB’s vision is a nation safe from chemical disasters. The CSB has published nearly one hundred investigative reports and produced sixty-eight video products to communicate its safety messages to audiences across the country, so that people may benefit from the lessons learned from these tragedies. With over 130 investigations and nearly 800 recommendations issued, the agency has sought to engage industry, unions, standards setting organizations, regulators, academia, and the American people in a collaborative effort to make the chemical industry safer, while maintaining economic productivity and protecting the jobs of workers in industrial facilities nationwide. The CSB has had an enormous impact on chemical safety with a staff of approximately 40 people and $11 million budget.
Here are some examples of our work.
Explosion at Fertilizer Storage Facility (West, Texas)
April 17, 2013
West Fertilizer Company
West, Texas
April 17, 2013
- 15 fatalities and 260+ injuries
- $230 million in insurance-related losses
- $16 million spent on Federal disaster assistance
- $1 million insurance policy held by West Fertilizer Company
On April 17, 2013, a massive explosion at the West Fertilizer Company (WFC), a fertilizer storage and distribution facility located in West, Texas, killed twelve first responders and three members of the public and caused more than 260 other injuries to first responders and the general public. Two of the fatally injured members of the public lived at a nearby apartment complex. The third lived at a nursing home and died shortly after the incident from injuries related to the trauma of the explosion.
The incident caused considerable property damage, including the complete destruction of the fertilizer facility, which was never rebuilt, leaving local farmers, ranchers and businesses without convenient access to needed products. The blast also caused extensive property damage beyond the facility. Two of the city’s school buildings had to be demolished and a third sustained major damage. Also destroyed were a nursing home, an apartment complex and numerous nearby homes. In a community of 700 homes, 350 (50%) were damaged as a result of the explosion, 142 (20%) of which were damaged beyond repair.
Total insurance-related losses from the explosion are estimated to be $230 million and federal disaster assistance is estimated to exceed $16 million. The company was only insured for $1 million, which fell far short of the incident’s damage.
CSB Findings and Recommendations:
- Failure by the insurer to identify the risks posed by fertilizer grade ammonium nitrate (FGAN). A few years prior to the incident, WFC was dropped by one insurer for failing to address safety concerns identified in loss control surveys. The company that insured WFC for $1 million at the time of the incident did not conduct its own safety inspections of the facility.
- The Federal Emergency Management Agency (FEMA) awarded two grants to develop FGAN training. The CSB found that there is no standardized training requirement that applies to volunteer firefighters across the nation. The CSB made a recommendation to FEMA to create a funding mechanism to provide training and curriculum develop for first responders at FGAN incidents. West Volunteer Fire Department did not conduct pre-incident planning or response training at WFC, was likely unaware of the potential for FGAN detonation and did not, nor were required, to have appropriate training in hazardous materials response.
- Gaps in federal and state regulations and standards. The CSB identified several gaps in federal and state regulations that could have reduced the consequences of the WFC disaster. These include the Occupational Safety and Health Administration’s Explosives and Blasting Agents and Process Safety Management standards, the Environmental Protection Agency’s Risk Management Program and Emergency Planning and Community Right-to-Know Act, and training provided or certified by the Texas Commission on Fire Protection and the State Firefighters’ and Fire Marshals’ Association of Texas.
- Local zoning and community planning. The location of the WFC relative to the surrounding community exacerbated the offsite consequences. The CSB found that at least 19 other Texas facilities storing more than 10,000 pounds of FGAN are located within a half-mile of a school, hospital, or nursing home, raising concerns that an incident with offsite consequences of this magnitude could happen again.
Refinery Explosion (Richmond, California)
August 6, 2012
Chevron Refinery
Richmond, California
August 6, 2012
- 15,000 people sought medical treatment
- $2 million in fines and restitution
- $447 million in increased gas prices passed onto California consumers1
On August 6, 2012, the Chevron Refinery in Richmond, California, experienced a catastrophic pipe failure in a crude unit, causing the release of flammable hydrocarbon process fluid which partially vaporized into a large cloud. Nineteen employees engulfed by the vapor cloud escaped, narrowly avoiding serious injury. The ignition and subsequent continued burning of hydrocarbons resulted in a large plume of unknown particulates and vapor. Approximately 15,000 people from the surrounding area sought medical treatment in the weeks following the incident. The CSB’s investigation found that the pipe failure was caused by sulfidation corrosion, a damage mechanism that causes piping walls to thin over time.
Although the company has never reported the decreased production capacity experienced as a result of the incident, the U.S. Energy Information Administration determined that the increase in gas prices cost California consumers approximately $447 million in six months following the incident.
Key Findings and Recommendations:
- Hazard analyses improved at all Chevron refineries in the U.S. The CSB investigation found that the hazard analysis conducted on the piping that failed did not identify corrosion as a potential cause of a leak or rupture. As a result, the CSB issued a recommendation to Chevron to perform damage mechanism hazard reviews (DMRs) on all of its process safety management (PSM) covered equipment and to incorporate the DMRs into their hazard review process at all its U.S. refineries. As a result of the CSB’s recommendation, Chevron has conducted DMRs at all of its U.S. refineries for PSM covered process piping circuits. If more companies were to adopt hazard review programs similar to Chevron’s, safety at refineries would be greatly increased.
- The California Department of Industrial Relations (DIR) revisions to the PSM regulation. Chevron conducted a hazard analysis of the crude unit as required by California’s Process Safety Management of Acutely Hazardous Materials (PSM) program; however, this does not require a formal damage mechanism hazard review to identify sulfidation corrosion. The CSB made several recommendations to improve California’s PSM program. Since 2014, DIR has published several drafts of a revised regulation and received and incorporated extensive stakeholder feedback. If the proposed regulation is approved, process safety in California’s refineries would be greatly improved and chemical safety would be advanced by better preventing major chemical incidents.
Deepwater Horizon/ Macondo Well Blowout (Gulf of Mexico)
April 20, 2010
Deepwater Horizon/Macondo Well Blowout
Gulf of Mexico
April 20, 2010
- $21 billion in settlements
- $13 billion in economic and medical claims
- 11 workers killed, 17 workers injured
- 4 million barrels of oil spilled
On April 20, 2010, a multiplefatality incident occurred at the Macondo oil well approximately 50 miles off the coast of Louisiana in the Gulf of Mexico during temporary well-abandonment activities on the Deepwater Horizon drilling rig. Control of the well was lost, resulting in a blowout—the uncontrolled release of hydrocarbons from the well. On the rig, the hydrocarbons found an ignition source and burst into flames. The resulting explosions and fire led to the deaths of 11 individuals, serious physical injuries to 17 others, evacuation of 115 individuals from the rig, the sinking of the Deepwater Horizon, and massive marine and coastal damage from a reported 4 million barrels of released hydrocarbons.
The operator of the rig, has paid out an estimated $13 billion worth of economic and medical claims as part of an uncapped settlement, in addition to a $20 billion settlement for federal, state and local government economic and environmental claims. Settlements involving other companies have reached $1.24 billion payout at the time of the completion of the CSB’s investigation. Other litigation remains pending.
CSB Findings and Recommendations:
- Blowout preventer (BOP) hazard not identified prior to Deepwater Horizon. Testing limitations masked latent failures of the Deepwater Horizon BOP, affecting its operation on the day of the incident, and these latent failures will continue to exist for similarly designed blowout preventers unless modifications are made to current standard industry testing protocols.
- Pipe buckling prevented drillpipe from working effectively. Pressure conditions in a well can cause drillpipe to buckle (or bend) in a BOP even after a crew has initially sealed a well, potentially incapacitating emergency functions of the BOP intended to cut drillpipe and seal the well.
- Safety-critical controls are necessary for hazard management. Major hazards require concerted efforts by industry to manage and actively monitor the safety-critical controls they rely on for the safe conduct of work, including improved incorporation of human factors, safety performance indicators, and corporate governance.
- Information sharing can be a challenge in offshore drilling. Obstacles continue to exist that limit sharing of lessons from incident investigations in individual companies and across both the operator/drilling contractor boundary and international geographical regions.
- Proper use of process safety indicators can prevent incidents. An equal focus and effort to collect, measure, and improve process safety performance indicators to that currently dedicated to personal safety statistics is necessary to reduce the potential for a major incident.
Texas City Refinery Explosion (Texas City, Texas)
March 23, 2005
BP Texas City
Texas City, Texas
March 23, 2005
- $1.5 billion in financial losses
- 15 workers killed
- 180 people injured
On March 23, 2005, a hydrocarbon isomerization unit (ISOM) exploded at the BP Texas City refinery in Texas City, Texas, resulting in financial losses of more than $1.5 billion. The incident killed 15 workers and injured 180 others. All of the fatalities and many serious injuries occurred in and around the nine temporary trailers sited as close as 121 feet from the ISOM unit. This refinery explosion was the most serious refinery incident ever investigated by the CSB. The CSB’s final investigative report into the incident found organizational and safety deficiencies at all levels of the BP Corporation. The report also noted gaps in standards and practices that likely contributed to other serious incidents over the previous decade.
CSB Findings and Recommendations:
- Trailer siting exacerbated the consequence of the BP Texas City explosion. All of the fatalities and many of the injuries occurred in or near a series of occupied trailers that were as close as 121 feet from the blowdown stack. In October 2005, the CSB issued an urgent recommendation to the American Petroleum Institute (API) to develop new guidance to prevent locating occupied trailers within hazardous areas of process plants.
- Blowdown drums should be replaced by safer alternatives. The CSB made a recommendation to API to eliminate the kind of blowdown drum that released the flammable liquid and vapor at BP. This 1950s-era equipment is unsafe, and many companies around the world have long since eliminated these systems and replaced them with inherently safer flare systems designed to handle a worst-case flammable release.
- A strong safety culture must be embraced at all levels of a corporation. The March 2005 incident was one of a long series of tragedies at the Texas City facility, where a total of 40 workers have died over 32 years. Internal audits revealed deteriorating conditions at the refinery over several years prior to 2005, but the responses focused primarily on improving personal safety and overlooked growing process safety risks.
- Process safety indicators help companies measure and improve process safety performance. The CSB recommended that API and the United Steelworkers develop a consensus standard for new process safety leading indicators to help businesses and government better assess these risks before serious incidents occur. Such leading indicators have been used for years in the nuclear power industry and provide a common method for different facilities to measure and compare system safety performance.
Conclusion
Based on the more than 130 incidents investigated by the CSB, it is clear that hundreds of billions of dollars have been spent as a result of chemical disasters in the United States. To make the safety of Americans our number one priority, it is critical that chemical safety lessons are learned and shared among diverse stakeholders across industries. If the CSB’s many safety lessons prevented at least one catastrophic incident, the money saved by preventing damage to the facility and surrounding community, avoiding legal settlements, and saving human lives far outweighs the agency’s $11 million annual budget. Safety and prosperity are compatible. Strong safety programs are critical for the economic success of the chemical and petrochemical industries. The CSB’s continued collaboration with industry, regulators, standards setting bodies and other professional organizations proves that the CSB has a vital role in driving critical chemical safety change in the United States.
References
1 Gonzales, Dan, Timothy Gulden, Aaron Strong and William Hoyle. Cost–Benefit Analysis of Proposed California Oil and Gas Refinery Regulations. Santa Monica, CA: RAND Corporation, 2016. http://www.rand.org/pubs/research_reports/RR1421.html. Also available in print form.
Data presented for each investigation was current at the time of the approval of the final report. The West Fertilizer Company report was released on January 28, 2016. The final Chevron Richmond refinery report was released on January 28, 2016. The final Deepwater Horizon/Macondo report was released on April 20, 2016. The BP Texas City report was released on March 20, 2007.
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The res... 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The resource includes a case example, steps to prevent a related injury, and questions for discussion. It includes a graphic that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely. Available in English and Spanish. 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The recall is a result of... 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[files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 4426 [old_id:protected] => [elcosh_id:protected] => d001656 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 0 [language_id:protected] => 1 [tagging_id:protected] => Mike Aguilar [priority_id:protected] => 1 [title:protected] => Construction Dive -- DeWalt's Jobsite Pro headphones recalled for fire hazards [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => DeWalt, Fire Hazards, recall, headphones [comments:protected] => [summary:protected] => A recall notice by the United States Consumer Product Safety Commission affects over 300,000 DeWalt Jobsite Pro Headphones. The recall is a result of a malfunction that can cause earbuds to overheat while charging or during use, leading to fire and burn hazards. [transition_comments:protected] => [external_link:protected] => https://www.constructiondive.com/news/dewalts-jobsite-pro-headphones-recalled-for-fire-hazards/611248/?utm_source=Sailthru&utm_medium=email&utm_campaign=Issue:%202021-12-10%20Construction%20Dive%20Newsletter%20%5Bissue:38532%5D&utm_term=Construction%20Dive [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/13/21 [date_completed:protected] => 12/13/21 [date_billed:protected] => [date_modified:protected] => 12/13/21 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [2] => Search_Result Object ( [title] => Working in an Enclosed Cab [image] => /record/images/notavailable-p.png [blurb] => This CPWR Hazard Alert on Working in enclosed cabs provides information on protecting workers from silica dust, how to minimize exposures and the dang... 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[validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [48] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 48 [type:protected] => category [parent:protected] => 2 [label:protected] => Cabinetmaker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [49] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 49 [type:protected] => category [parent:protected] => 2 [label:protected] => Carpenter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [51] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 51 [type:protected] => category [parent:protected] => 2 [label:protected] => Cement Mason [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [53] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 53 [type:protected] => category [parent:protected] => 2 [label:protected] => Concrete Polisher [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [54] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 54 [type:protected] => category [parent:protected] => 2 [label:protected] => Drywall Applicator Specialist [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [56] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 56 [type:protected] => category [parent:protected] => 2 [label:protected] => Elevator Constructor [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [58] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 58 [type:protected] => category [parent:protected] => 2 [label:protected] => Glazier [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [59] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 59 [type:protected] => category [parent:protected] => 2 [label:protected] => Hazardous Waste Cleanup [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [60] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 60 [type:protected] => category [parent:protected] => 2 [label:protected] => HVAC [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [61] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 61 [type:protected] => category [parent:protected] => 2 [label:protected] => Interior Systems Carpenter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [64] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 64 [type:protected] => category [parent:protected] => 2 [label:protected] => Laborer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [66] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 66 [type:protected] => category [parent:protected] => 2 [label:protected] => Lather [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [68] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 68 [type:protected] => category [parent:protected] => 2 [label:protected] => Maintenance Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [69] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 69 [type:protected] => category [parent:protected] => 2 [label:protected] => Millwright [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [71] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 71 [type:protected] => category [parent:protected] => 2 [label:protected] => Painter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [73] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 73 [type:protected] => category [parent:protected] => 2 [label:protected] => PCC/Restoration [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [74] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 74 [type:protected] => category [parent:protected] => 2 [label:protected] => Pile Driver [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [76] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 76 [type:protected] => category [parent:protected] => 2 [label:protected] => Plumber/Pipefitter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [77] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 77 [type:protected] => category [parent:protected] => 2 [label:protected] => Refractory Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [63] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 63 [type:protected] => category [parent:protected] => 2 [label:protected] => Reinforcing Ironworker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [80] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 80 [type:protected] => category [parent:protected] => 2 [label:protected] => Sheetmetal Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [82] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 82 [type:protected] => category [parent:protected] => 2 [label:protected] => Stonemason [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [62] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 62 [type:protected] => category [parent:protected] => 2 [label:protected] => Structural Ironworker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [83] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 83 [type:protected] => category [parent:protected] => 2 [label:protected] => Terrazzo 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workplace, OSHA, silicosis, mining, silica, DOE, EEOICPA, labor, lung, CBD, dust, cab, miner, mine [comments:protected] => [summary:protected] => This CPWR Hazard Alert on Working in enclosed cabs provides information on protecting workers from silica dust, how to minimize exposures and the dangers of silica dust. Click on the following links to access the English version and the Spanish version. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 10/08/20 [date_completed:protected] => 10/08/20 [date_billed:protected] => [date_modified:protected] => 10/08/20 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [3] => Search_Result Object ( [title] => Toolbox Talk: Suicide Prevention [image] => /record/images/notavailable-p.png [blurb] => The CPWR Toolbox Talk on Suicide Prevention addresses the prevalence of suicide among construction workers. The resource includes a brief case example... 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[languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 40 [type:protected] => category [parent:protected] => 9 [label:protected] => Overexertion [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [44] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 44 [type:protected] => category [parent:protected] => 2 [label:protected] => Acoustical Ceiling Carpenter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [45] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 45 [type:protected] => category [parent:protected] => 2 [label:protected] => Asbestos/Insulator [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [46] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 46 [type:protected] => category [parent:protected] => 2 [label:protected] => Boilermaker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [47] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 47 [type:protected] => category [parent:protected] => 2 [label:protected] => Bricklayer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [48] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 48 [type:protected] => category [parent:protected] => 2 [label:protected] => Cabinetmaker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [49] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 49 [type:protected] => category [parent:protected] => 2 [label:protected] => Carpenter 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=> [summary:protected] =>The CPWR Toolbox Talk on Suicide Prevention addresses the prevalence of suicide among construction workers. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely.
Available in English and Spanish. 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dust, exposure, air purifier, enclosed cab, vehicle [comments:protected] => [summary:protected] =>
The CPWR Toolbox Talk on Preventing Exposure to Silica Dust in Enclosed Cabs addresses the risks associated with breathing in silica dust and silicosis. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely.
Available in English and Spanish. 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structural support that prevents collapses during construction. 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The supports for the counterweight must... 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The supports for the counterweight must be designed with a safety factor of four. 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Wire rope supported must be desig... 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Wire rope supported must be designed with a safety factor of 6. The scaffold must be inspected by a competent person daily. 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This is accomplish... 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This is accomplished by setting swing restrictions, marking the ground for allowable crane travel and training of the crane signal persons. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/work/6/184/ [more_like_this:protected] => d001029, d000010, i001280, i001221 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => jpg [img_width:protected] => [img_height:protected] => [img_credit:protected] => Metropark [img_practice:protected] => not_applicable [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => August 28 2015 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 08/28/15 [date_completed:protected] => 08/28/15 [date_billed:protected] => [date_modified:protected] => 08/28/15 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) ) [preview_mode] => [description] => The U.S. Chemical Safety Board is an independent, non-regulatory safety agency that investigates chemical incidents and makes recommendations to prevent similar incidents from occurring. This short report is a summary of the lessons from several of the most catastrophic incidents the CSB has investigated. The CSB found common deficiencies in safety management systems, facility maintenance, adequacy of regulations, training. poor hazard awareness among emergency responders and insufficient community notification and planning. The specific incidents reviewed include the West, Texas fertilizer plant explosion, the Deep Water Horizon explosion, and the Richmond California refinery explosion. There is an infographic that accompanies this report: https://www.aiha.org/publications-and-resources/TheSynergist/Digital%20Synergist%20Images/201707-bythenumbers.jpg [keywords] => Chemical Safety Board, CSB, explosion, chemical incidents, disasters, investigation [related_items] => Array ( [Handouts] => Array ( [0] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 4275 [old_id:protected] => [elcosh_id:protected] => d001552 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 29 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => CSB Infographic about chemical-related incidents [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, CSB, explosion, fires, industrial accidents [comments:protected] => [summary:protected] => This infographic by the Chemical Safety Board shows the enormous cost in lives, injuries and money this nation has experienced from the industrial incidents at the BP Texas City Refinery, BP's Deepwater Horizon, Chevron's Richmond Refinery and the West Fertilizer Company facility in West, Texas. This graphic accompanies the CSB report, "The Business Case for Safety." [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/pipes_vessels/hazard/1643/work-inside-vessels-confined-space.html [more_like_this:protected] => d001174,d001206,d000443 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => png [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => 2017 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/20/17 [date_completed:protected] => 12/22/17 [date_billed:protected] => [date_modified:protected] => 12/22/17 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [1] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 3664 [old_id:protected] => [elcosh_id:protected] => d001206 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 24 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => OSHA FactSheet, Hazard Alert: Combustible Dust Explosions [total_pages:protected] => 2 [billed_pages:protected] => 2 [publication_number:protected] => DSG 3/2008 [part_of:protected] => [keywords:protected] => Combustible dusts, ignition source, settled dust, explosion, dust explosion, secondary explosion [comments:protected] => Two links were present in the consol link field thus creating a broken link. Only one link can be present in this field. I left the first of the two links in the field and removed http://www.cpwrconstructionsolutions.org/carpentry/hazard/1189/cut-boards-and-panels-wood-dust.html [summary:protected] => Combustible dusts are fine particles that present an explosion hazard when suspended in air in certain conditions. A dust explosion can be catastrophic and cause employee deaths, injuries, and destruction of entire buildings. OSHA notes that in many combustible dust accidents, employers and employees were unaware that a hazard even existed. In this FactSheet, OSHA helps employers and workers to determine if this hazard is present and what actions are needed to prevent tragic consequences. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/hazard/792/construction-dust.html [more_like_this:protected] => d000966 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => jpg [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => March 2008 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 04/17/13 [date_completed:protected] => 04/29/13 [date_billed:protected] => [date_modified:protected] => 06/04/13 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [News Articles] => Array ( [0] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 3608 [old_id:protected] => [elcosh_id:protected] => d001174 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 2 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => U.S. Chemical Safety Board Receives Awards for Videos [total_pages:protected] => 1 [billed_pages:protected] => 0 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, explosion, fire, dust explosion, process safety [comments:protected] => This should be placed in the What's New section. Note from Chris: As this was selected as an external link the billable pages were 0. Bruce, in the more like this field, you may want to enter in the ID's of the CSB videos we have in the database. [summary:protected] => The U.S. Chemical Safety Board (CSB) was named the recipient of three Peer Awards from the Television, Internet and Video Association of D.C. (TIVA) for safety videos produced in 2012. Videos on an academic laboratory explosion in Lubbock, Texas, and a flammable vapor explosion near Buffalo, New York, received bronze awards, while a video on a string of dust flash fires at a Tennessee metal powder production company received a silver award. CSB safety videos cover specific incidents investigated by the CSB and include excellent animations. Trainers who don't already used these videos in their health and safety training should check out the site. These free videos represent some of the best training resources available. [transition_comments:protected] => [external_link:protected] => http://www.csb.gov/newsroom/detail.aspx?nid=440 [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => November 2012 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 11/23/12 [date_completed:protected] => 12/17/12 [date_billed:protected] => [date_modified:protected] => 12/17/12 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [1] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 1311 [old_id:protected] => 449 [elcosh_id:protected] => d000443 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => [language_id:protected] => 1 [tagging_id:protected] => Sharon Garber/COD [priority_id:protected] => 1 [title:protected] => Preventing Construction Fires [total_pages:protected] => 5 [billed_pages:protected] => 5 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Occupation, construction, safety, health, hazards, work, worker, workplace, fire, housekeeping, flammable, storage, electical, program [comments:protected] => [summary:protected] => Discusses the typical causes of fires, such as poor housekeeping and careless smoking and provides suggestions on how to prevent them. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => [more_like_this:protected] => d000372, d000860, d001065 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => Feb 2001 [date_permission_requested:protected] => 03/01/01 [date_permission_received:protected] => 03/20/01 [date_review_needed:protected] => [date_received:protected] => 04/11/01 [date_completed:protected] => 04/25/01 [date_billed:protected] => 05/01/01 [date_modified:protected] => 05/08/12 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) ) [collections] => Array ( [4277] => ) [record] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => Array ( ) [organizations:protected] => Array ( [314] => Organization Object ( [id:protected] => 314 [elcosh_id:protected] => o001237 [user_id:protected] => 0 [province_id:protected] => 0 [country_id:protected] => 0 [title:protected] => U.S. Chemical Safety Board [address:protected] => [postal_code:protected] => [city:protected] => [department:protected] => [phone:protected] => [fax:protected] => [email:protected] => [website:protected] => [filename:protected] => [about:protected] => [comments:protected] => [logo_available:protected] => F [no_details:protected] => F [date_received:protected] => [date_completed:protected] => [date_billed:protected] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [collections:protected] => Array ( [4277] => ) [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => Array ( [4275] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => [old_record:protected] => [id:protected] => 4275 [old_id:protected] => [elcosh_id:protected] => d001552 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 29 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => CSB Infographic about chemical-related incidents [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, CSB, explosion, fires, industrial accidents [comments:protected] => [summary:protected] => This infographic by the Chemical Safety Board shows the enormous cost in lives, injuries and money this nation has experienced from the industrial incidents at the BP Texas City Refinery, BP's Deepwater Horizon, Chevron's Richmond Refinery and the West Fertilizer Company facility in West, Texas. This graphic accompanies the CSB report, "The Business Case for Safety." [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/pipes_vessels/hazard/1643/work-inside-vessels-confined-space.html [more_like_this:protected] => d001174,d001206,d000443 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => png [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => 2017 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/20/17 [date_completed:protected] => 12/22/17 [date_billed:protected] => [date_modified:protected] => 12/22/17 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [3608] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => [old_record:protected] => [id:protected] => 3608 [old_id:protected] => [elcosh_id:protected] => d001174 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 2 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => U.S. Chemical Safety Board Receives Awards for Videos [total_pages:protected] => 1 [billed_pages:protected] => 0 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, explosion, fire, dust explosion, process safety [comments:protected] => This should be placed in the What's New section. Note from Chris: As this was selected as an external link the billable pages were 0. Bruce, in the more like this field, you may want to enter in the ID's of the CSB videos we have in the database. [summary:protected] => The U.S. Chemical Safety Board (CSB) was named the recipient of three Peer Awards from the Television, Internet and Video Association of D.C. (TIVA) for safety videos produced in 2012. Videos on an academic laboratory explosion in Lubbock, Texas, and a flammable vapor explosion near Buffalo, New York, received bronze awards, while a video on a string of dust flash fires at a Tennessee metal powder production company received a silver award. CSB safety videos cover specific incidents investigated by the CSB and include excellent animations. Trainers who don't already used these videos in their health and safety training should check out the site. These free videos represent some of the best training resources available. [transition_comments:protected] => [external_link:protected] => http://www.csb.gov/newsroom/detail.aspx?nid=440 [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => November 2012 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 11/23/12 [date_completed:protected] => 12/17/12 [date_billed:protected] => [date_modified:protected] => 12/17/12 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [3664] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => [old_record:protected] => [id:protected] => 3664 [old_id:protected] => [elcosh_id:protected] => d001206 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 24 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => OSHA FactSheet, Hazard Alert: Combustible Dust Explosions [total_pages:protected] => 2 [billed_pages:protected] => 2 [publication_number:protected] => DSG 3/2008 [part_of:protected] => [keywords:protected] => Combustible dusts, ignition source, settled dust, explosion, dust explosion, secondary explosion [comments:protected] => Two links were present in the consol link field thus creating a broken link. Only one link can be present in this field. I left the first of the two links in the field and removed http://www.cpwrconstructionsolutions.org/carpentry/hazard/1189/cut-boards-and-panels-wood-dust.html [summary:protected] => Combustible dusts are fine particles that present an explosion hazard when suspended in air in certain conditions. A dust explosion can be catastrophic and cause employee deaths, injuries, and destruction of entire buildings. OSHA notes that in many combustible dust accidents, employers and employees were unaware that a hazard even existed. In this FactSheet, OSHA helps employers and workers to determine if this hazard is present and what actions are needed to prevent tragic consequences. 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This short report is a summary of the lessons from several of the most catastrophic incidents the CSB has investigated. The CSB found common deficiencies in safety management systems, facility maintenance, adequacy of regulations, training. poor hazard awareness among emergency responders and insufficient community notification and planning. The specific incidents reviewed include the West, Texas fertilizer plant explosion, the Deep Water Horizon explosion, and the Richmond California refinery explosion. 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SAFETY IS GOOD BUSINESS AND GOOD PUBLIC POLICY
"There's an old saying that if you think safety is expensive, try an accident. Accidents cost a lot of money. And, not only in damage to [the] plant and in claims for injury, but also in the loss of the company's reputation." - Trevor Kletz
As an independent, non-regulatory safety agency, the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigates catastrophic chemical incidents and makes recommendations to prevent similar incidents from occurring. The CSB has found that most catastrophic chemical incidents could have been prevented. The agency conducts comprehensive, root cause analyses, examining all the causal or contributing factors. Our investigations have identified deficiencies in areas such as safety management systems, facility maintenance, regulatory requirements and training. In addition to identifying the causes of an incident, the CSB uncovers factors that exacerbate its consequences, contributing to loss of life and property, such as a lack of hazard awareness among emergency responders and insufficient community notification and planning.
The CSB’s vision is a nation safe from chemical disasters. The CSB has published nearly one hundred investigative reports and produced sixty-eight video products to communicate its safety messages to audiences across the country, so that people may benefit from the lessons learned from these tragedies. With over 130 investigations and nearly 800 recommendations issued, the agency has sought to engage industry, unions, standards setting organizations, regulators, academia, and the American people in a collaborative effort to make the chemical industry safer, while maintaining economic productivity and protecting the jobs of workers in industrial facilities nationwide. The CSB has had an enormous impact on chemical safety with a staff of approximately 40 people and $11 million budget.
Here are some examples of our work.
Explosion at Fertilizer Storage Facility (West, Texas)
April 17, 2013
West Fertilizer Company
West, Texas
April 17, 2013
- 15 fatalities and 260+ injuries
- $230 million in insurance-related losses
- $16 million spent on Federal disaster assistance
- $1 million insurance policy held by West Fertilizer Company
On April 17, 2013, a massive explosion at the West Fertilizer Company (WFC), a fertilizer storage and distribution facility located in West, Texas, killed twelve first responders and three members of the public and caused more than 260 other injuries to first responders and the general public. Two of the fatally injured members of the public lived at a nearby apartment complex. The third lived at a nursing home and died shortly after the incident from injuries related to the trauma of the explosion.
The incident caused considerable property damage, including the complete destruction of the fertilizer facility, which was never rebuilt, leaving local farmers, ranchers and businesses without convenient access to needed products. The blast also caused extensive property damage beyond the facility. Two of the city’s school buildings had to be demolished and a third sustained major damage. Also destroyed were a nursing home, an apartment complex and numerous nearby homes. In a community of 700 homes, 350 (50%) were damaged as a result of the explosion, 142 (20%) of which were damaged beyond repair.
Total insurance-related losses from the explosion are estimated to be $230 million and federal disaster assistance is estimated to exceed $16 million. The company was only insured for $1 million, which fell far short of the incident’s damage.
CSB Findings and Recommendations:
- Failure by the insurer to identify the risks posed by fertilizer grade ammonium nitrate (FGAN). A few years prior to the incident, WFC was dropped by one insurer for failing to address safety concerns identified in loss control surveys. The company that insured WFC for $1 million at the time of the incident did not conduct its own safety inspections of the facility.
- The Federal Emergency Management Agency (FEMA) awarded two grants to develop FGAN training. The CSB found that there is no standardized training requirement that applies to volunteer firefighters across the nation. The CSB made a recommendation to FEMA to create a funding mechanism to provide training and curriculum develop for first responders at FGAN incidents. West Volunteer Fire Department did not conduct pre-incident planning or response training at WFC, was likely unaware of the potential for FGAN detonation and did not, nor were required, to have appropriate training in hazardous materials response.
- Gaps in federal and state regulations and standards. The CSB identified several gaps in federal and state regulations that could have reduced the consequences of the WFC disaster. These include the Occupational Safety and Health Administration’s Explosives and Blasting Agents and Process Safety Management standards, the Environmental Protection Agency’s Risk Management Program and Emergency Planning and Community Right-to-Know Act, and training provided or certified by the Texas Commission on Fire Protection and the State Firefighters’ and Fire Marshals’ Association of Texas.
- Local zoning and community planning. The location of the WFC relative to the surrounding community exacerbated the offsite consequences. The CSB found that at least 19 other Texas facilities storing more than 10,000 pounds of FGAN are located within a half-mile of a school, hospital, or nursing home, raising concerns that an incident with offsite consequences of this magnitude could happen again.
Refinery Explosion (Richmond, California)
August 6, 2012
Chevron Refinery
Richmond, California
August 6, 2012
- 15,000 people sought medical treatment
- $2 million in fines and restitution
- $447 million in increased gas prices passed onto California consumers1
On August 6, 2012, the Chevron Refinery in Richmond, California, experienced a catastrophic pipe failure in a crude unit, causing the release of flammable hydrocarbon process fluid which partially vaporized into a large cloud. Nineteen employees engulfed by the vapor cloud escaped, narrowly avoiding serious injury. The ignition and subsequent continued burning of hydrocarbons resulted in a large plume of unknown particulates and vapor. Approximately 15,000 people from the surrounding area sought medical treatment in the weeks following the incident. The CSB’s investigation found that the pipe failure was caused by sulfidation corrosion, a damage mechanism that causes piping walls to thin over time.
Although the company has never reported the decreased production capacity experienced as a result of the incident, the U.S. Energy Information Administration determined that the increase in gas prices cost California consumers approximately $447 million in six months following the incident.
Key Findings and Recommendations:
- Hazard analyses improved at all Chevron refineries in the U.S. The CSB investigation found that the hazard analysis conducted on the piping that failed did not identify corrosion as a potential cause of a leak or rupture. As a result, the CSB issued a recommendation to Chevron to perform damage mechanism hazard reviews (DMRs) on all of its process safety management (PSM) covered equipment and to incorporate the DMRs into their hazard review process at all its U.S. refineries. As a result of the CSB’s recommendation, Chevron has conducted DMRs at all of its U.S. refineries for PSM covered process piping circuits. If more companies were to adopt hazard review programs similar to Chevron’s, safety at refineries would be greatly increased.
- The California Department of Industrial Relations (DIR) revisions to the PSM regulation. Chevron conducted a hazard analysis of the crude unit as required by California’s Process Safety Management of Acutely Hazardous Materials (PSM) program; however, this does not require a formal damage mechanism hazard review to identify sulfidation corrosion. The CSB made several recommendations to improve California’s PSM program. Since 2014, DIR has published several drafts of a revised regulation and received and incorporated extensive stakeholder feedback. If the proposed regulation is approved, process safety in California’s refineries would be greatly improved and chemical safety would be advanced by better preventing major chemical incidents.
Deepwater Horizon/ Macondo Well Blowout (Gulf of Mexico)
April 20, 2010
Deepwater Horizon/Macondo Well Blowout
Gulf of Mexico
April 20, 2010
- $21 billion in settlements
- $13 billion in economic and medical claims
- 11 workers killed, 17 workers injured
- 4 million barrels of oil spilled
On April 20, 2010, a multiplefatality incident occurred at the Macondo oil well approximately 50 miles off the coast of Louisiana in the Gulf of Mexico during temporary well-abandonment activities on the Deepwater Horizon drilling rig. Control of the well was lost, resulting in a blowout—the uncontrolled release of hydrocarbons from the well. On the rig, the hydrocarbons found an ignition source and burst into flames. The resulting explosions and fire led to the deaths of 11 individuals, serious physical injuries to 17 others, evacuation of 115 individuals from the rig, the sinking of the Deepwater Horizon, and massive marine and coastal damage from a reported 4 million barrels of released hydrocarbons.
The operator of the rig, has paid out an estimated $13 billion worth of economic and medical claims as part of an uncapped settlement, in addition to a $20 billion settlement for federal, state and local government economic and environmental claims. Settlements involving other companies have reached $1.24 billion payout at the time of the completion of the CSB’s investigation. Other litigation remains pending.
CSB Findings and Recommendations:
- Blowout preventer (BOP) hazard not identified prior to Deepwater Horizon. Testing limitations masked latent failures of the Deepwater Horizon BOP, affecting its operation on the day of the incident, and these latent failures will continue to exist for similarly designed blowout preventers unless modifications are made to current standard industry testing protocols.
- Pipe buckling prevented drillpipe from working effectively. Pressure conditions in a well can cause drillpipe to buckle (or bend) in a BOP even after a crew has initially sealed a well, potentially incapacitating emergency functions of the BOP intended to cut drillpipe and seal the well.
- Safety-critical controls are necessary for hazard management. Major hazards require concerted efforts by industry to manage and actively monitor the safety-critical controls they rely on for the safe conduct of work, including improved incorporation of human factors, safety performance indicators, and corporate governance.
- Information sharing can be a challenge in offshore drilling. Obstacles continue to exist that limit sharing of lessons from incident investigations in individual companies and across both the operator/drilling contractor boundary and international geographical regions.
- Proper use of process safety indicators can prevent incidents. An equal focus and effort to collect, measure, and improve process safety performance indicators to that currently dedicated to personal safety statistics is necessary to reduce the potential for a major incident.
Texas City Refinery Explosion (Texas City, Texas)
March 23, 2005
BP Texas City
Texas City, Texas
March 23, 2005
- $1.5 billion in financial losses
- 15 workers killed
- 180 people injured
On March 23, 2005, a hydrocarbon isomerization unit (ISOM) exploded at the BP Texas City refinery in Texas City, Texas, resulting in financial losses of more than $1.5 billion. The incident killed 15 workers and injured 180 others. All of the fatalities and many serious injuries occurred in and around the nine temporary trailers sited as close as 121 feet from the ISOM unit. This refinery explosion was the most serious refinery incident ever investigated by the CSB. The CSB’s final investigative report into the incident found organizational and safety deficiencies at all levels of the BP Corporation. The report also noted gaps in standards and practices that likely contributed to other serious incidents over the previous decade.
CSB Findings and Recommendations:
- Trailer siting exacerbated the consequence of the BP Texas City explosion. All of the fatalities and many of the injuries occurred in or near a series of occupied trailers that were as close as 121 feet from the blowdown stack. In October 2005, the CSB issued an urgent recommendation to the American Petroleum Institute (API) to develop new guidance to prevent locating occupied trailers within hazardous areas of process plants.
- Blowdown drums should be replaced by safer alternatives. The CSB made a recommendation to API to eliminate the kind of blowdown drum that released the flammable liquid and vapor at BP. This 1950s-era equipment is unsafe, and many companies around the world have long since eliminated these systems and replaced them with inherently safer flare systems designed to handle a worst-case flammable release.
- A strong safety culture must be embraced at all levels of a corporation. The March 2005 incident was one of a long series of tragedies at the Texas City facility, where a total of 40 workers have died over 32 years. Internal audits revealed deteriorating conditions at the refinery over several years prior to 2005, but the responses focused primarily on improving personal safety and overlooked growing process safety risks.
- Process safety indicators help companies measure and improve process safety performance. The CSB recommended that API and the United Steelworkers develop a consensus standard for new process safety leading indicators to help businesses and government better assess these risks before serious incidents occur. Such leading indicators have been used for years in the nuclear power industry and provide a common method for different facilities to measure and compare system safety performance.
Conclusion
Based on the more than 130 incidents investigated by the CSB, it is clear that hundreds of billions of dollars have been spent as a result of chemical disasters in the United States. To make the safety of Americans our number one priority, it is critical that chemical safety lessons are learned and shared among diverse stakeholders across industries. If the CSB’s many safety lessons prevented at least one catastrophic incident, the money saved by preventing damage to the facility and surrounding community, avoiding legal settlements, and saving human lives far outweighs the agency’s $11 million annual budget. Safety and prosperity are compatible. Strong safety programs are critical for the economic success of the chemical and petrochemical industries. The CSB’s continued collaboration with industry, regulators, standards setting bodies and other professional organizations proves that the CSB has a vital role in driving critical chemical safety change in the United States.
References
1 Gonzales, Dan, Timothy Gulden, Aaron Strong and William Hoyle. Cost–Benefit Analysis of Proposed California Oil and Gas Refinery Regulations. Santa Monica, CA: RAND Corporation, 2016. http://www.rand.org/pubs/research_reports/RR1421.html. Also available in print form.
Data presented for each investigation was current at the time of the approval of the final report. The West Fertilizer Company report was released on January 28, 2016. The final Chevron Richmond refinery report was released on January 28, 2016. The final Deepwater Horizon/Macondo report was released on April 20, 2016. The BP Texas City report was released on March 20, 2007.
[content_transformed:protected] =>SAFETY IS GOOD BUSINESS AND GOOD PUBLIC POLICY
"There's an old saying that if you think safety is expensive, try an accident. Accidents cost a lot of money. And, not only in damage to [the] plant and in claims for injury, but also in the loss of the company's reputation." - Trevor Kletz
As an independent, non-regulatory safety agency, the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigates catastrophic chemical incidents and makes recommendations to prevent similar incidents from occurring. The CSB has found that most catastrophic chemical incidents could have been prevented. The agency conducts comprehensive, root cause analyses, examining all the causal or contributing factors. Our investigations have identified deficiencies in areas such as safety management systems, facility maintenance, regulatory requirements and training. In addition to identifying the causes of an incident, the CSB uncovers factors that exacerbate its consequences, contributing to loss of life and property, such as a lack of hazard awareness among emergency responders and insufficient community notification and planning.
The CSB’s vision is a nation safe from chemical disasters. The CSB has published nearly one hundred investigative reports and produced sixty-eight video products to communicate its safety messages to audiences across the country, so that people may benefit from the lessons learned from these tragedies. With over 130 investigations and nearly 800 recommendations issued, the agency has sought to engage industry, unions, standards setting organizations, regulators, academia, and the American people in a collaborative effort to make the chemical industry safer, while maintaining economic productivity and protecting the jobs of workers in industrial facilities nationwide. The CSB has had an enormous impact on chemical safety with a staff of approximately 40 people and $11 million budget.
Here are some examples of our work.
Explosion at Fertilizer Storage Facility (West, Texas)
April 17, 2013
West Fertilizer Company
West, Texas
April 17, 2013
- 15 fatalities and 260+ injuries
- $230 million in insurance-related losses
- $16 million spent on Federal disaster assistance
- $1 million insurance policy held by West Fertilizer Company
On April 17, 2013, a massive explosion at the West Fertilizer Company (WFC), a fertilizer storage and distribution facility located in West, Texas, killed twelve first responders and three members of the public and caused more than 260 other injuries to first responders and the general public. Two of the fatally injured members of the public lived at a nearby apartment complex. The third lived at a nursing home and died shortly after the incident from injuries related to the trauma of the explosion.
The incident caused considerable property damage, including the complete destruction of the fertilizer facility, which was never rebuilt, leaving local farmers, ranchers and businesses without convenient access to needed products. The blast also caused extensive property damage beyond the facility. Two of the city’s school buildings had to be demolished and a third sustained major damage. Also destroyed were a nursing home, an apartment complex and numerous nearby homes. In a community of 700 homes, 350 (50%) were damaged as a result of the explosion, 142 (20%) of which were damaged beyond repair.
Total insurance-related losses from the explosion are estimated to be $230 million and federal disaster assistance is estimated to exceed $16 million. The company was only insured for $1 million, which fell far short of the incident’s damage.
CSB Findings and Recommendations:
- Failure by the insurer to identify the risks posed by fertilizer grade ammonium nitrate (FGAN). A few years prior to the incident, WFC was dropped by one insurer for failing to address safety concerns identified in loss control surveys. The company that insured WFC for $1 million at the time of the incident did not conduct its own safety inspections of the facility.
- The Federal Emergency Management Agency (FEMA) awarded two grants to develop FGAN training. The CSB found that there is no standardized training requirement that applies to volunteer firefighters across the nation. The CSB made a recommendation to FEMA to create a funding mechanism to provide training and curriculum develop for first responders at FGAN incidents. West Volunteer Fire Department did not conduct pre-incident planning or response training at WFC, was likely unaware of the potential for FGAN detonation and did not, nor were required, to have appropriate training in hazardous materials response.
- Gaps in federal and state regulations and standards. The CSB identified several gaps in federal and state regulations that could have reduced the consequences of the WFC disaster. These include the Occupational Safety and Health Administration’s Explosives and Blasting Agents and Process Safety Management standards, the Environmental Protection Agency’s Risk Management Program and Emergency Planning and Community Right-to-Know Act, and training provided or certified by the Texas Commission on Fire Protection and the State Firefighters’ and Fire Marshals’ Association of Texas.
- Local zoning and community planning. The location of the WFC relative to the surrounding community exacerbated the offsite consequences. The CSB found that at least 19 other Texas facilities storing more than 10,000 pounds of FGAN are located within a half-mile of a school, hospital, or nursing home, raising concerns that an incident with offsite consequences of this magnitude could happen again.
Refinery Explosion (Richmond, California)
August 6, 2012
Chevron Refinery
Richmond, California
August 6, 2012
- 15,000 people sought medical treatment
- $2 million in fines and restitution
- $447 million in increased gas prices passed onto California consumers1
On August 6, 2012, the Chevron Refinery in Richmond, California, experienced a catastrophic pipe failure in a crude unit, causing the release of flammable hydrocarbon process fluid which partially vaporized into a large cloud. Nineteen employees engulfed by the vapor cloud escaped, narrowly avoiding serious injury. The ignition and subsequent continued burning of hydrocarbons resulted in a large plume of unknown particulates and vapor. Approximately 15,000 people from the surrounding area sought medical treatment in the weeks following the incident. The CSB’s investigation found that the pipe failure was caused by sulfidation corrosion, a damage mechanism that causes piping walls to thin over time.
Although the company has never reported the decreased production capacity experienced as a result of the incident, the U.S. Energy Information Administration determined that the increase in gas prices cost California consumers approximately $447 million in six months following the incident.
Key Findings and Recommendations:
- Hazard analyses improved at all Chevron refineries in the U.S. The CSB investigation found that the hazard analysis conducted on the piping that failed did not identify corrosion as a potential cause of a leak or rupture. As a result, the CSB issued a recommendation to Chevron to perform damage mechanism hazard reviews (DMRs) on all of its process safety management (PSM) covered equipment and to incorporate the DMRs into their hazard review process at all its U.S. refineries. As a result of the CSB’s recommendation, Chevron has conducted DMRs at all of its U.S. refineries for PSM covered process piping circuits. If more companies were to adopt hazard review programs similar to Chevron’s, safety at refineries would be greatly increased.
- The California Department of Industrial Relations (DIR) revisions to the PSM regulation. Chevron conducted a hazard analysis of the crude unit as required by California’s Process Safety Management of Acutely Hazardous Materials (PSM) program; however, this does not require a formal damage mechanism hazard review to identify sulfidation corrosion. The CSB made several recommendations to improve California’s PSM program. Since 2014, DIR has published several drafts of a revised regulation and received and incorporated extensive stakeholder feedback. If the proposed regulation is approved, process safety in California’s refineries would be greatly improved and chemical safety would be advanced by better preventing major chemical incidents.
Deepwater Horizon/ Macondo Well Blowout (Gulf of Mexico)
April 20, 2010
Deepwater Horizon/Macondo Well Blowout
Gulf of Mexico
April 20, 2010
- $21 billion in settlements
- $13 billion in economic and medical claims
- 11 workers killed, 17 workers injured
- 4 million barrels of oil spilled
On April 20, 2010, a multiplefatality incident occurred at the Macondo oil well approximately 50 miles off the coast of Louisiana in the Gulf of Mexico during temporary well-abandonment activities on the Deepwater Horizon drilling rig. Control of the well was lost, resulting in a blowout—the uncontrolled release of hydrocarbons from the well. On the rig, the hydrocarbons found an ignition source and burst into flames. The resulting explosions and fire led to the deaths of 11 individuals, serious physical injuries to 17 others, evacuation of 115 individuals from the rig, the sinking of the Deepwater Horizon, and massive marine and coastal damage from a reported 4 million barrels of released hydrocarbons.
The operator of the rig, has paid out an estimated $13 billion worth of economic and medical claims as part of an uncapped settlement, in addition to a $20 billion settlement for federal, state and local government economic and environmental claims. Settlements involving other companies have reached $1.24 billion payout at the time of the completion of the CSB’s investigation. Other litigation remains pending.
CSB Findings and Recommendations:
- Blowout preventer (BOP) hazard not identified prior to Deepwater Horizon. Testing limitations masked latent failures of the Deepwater Horizon BOP, affecting its operation on the day of the incident, and these latent failures will continue to exist for similarly designed blowout preventers unless modifications are made to current standard industry testing protocols.
- Pipe buckling prevented drillpipe from working effectively. Pressure conditions in a well can cause drillpipe to buckle (or bend) in a BOP even after a crew has initially sealed a well, potentially incapacitating emergency functions of the BOP intended to cut drillpipe and seal the well.
- Safety-critical controls are necessary for hazard management. Major hazards require concerted efforts by industry to manage and actively monitor the safety-critical controls they rely on for the safe conduct of work, including improved incorporation of human factors, safety performance indicators, and corporate governance.
- Information sharing can be a challenge in offshore drilling. Obstacles continue to exist that limit sharing of lessons from incident investigations in individual companies and across both the operator/drilling contractor boundary and international geographical regions.
- Proper use of process safety indicators can prevent incidents. An equal focus and effort to collect, measure, and improve process safety performance indicators to that currently dedicated to personal safety statistics is necessary to reduce the potential for a major incident.
Texas City Refinery Explosion (Texas City, Texas)
March 23, 2005
BP Texas City
Texas City, Texas
March 23, 2005
- $1.5 billion in financial losses
- 15 workers killed
- 180 people injured
On March 23, 2005, a hydrocarbon isomerization unit (ISOM) exploded at the BP Texas City refinery in Texas City, Texas, resulting in financial losses of more than $1.5 billion. The incident killed 15 workers and injured 180 others. All of the fatalities and many serious injuries occurred in and around the nine temporary trailers sited as close as 121 feet from the ISOM unit. This refinery explosion was the most serious refinery incident ever investigated by the CSB. The CSB’s final investigative report into the incident found organizational and safety deficiencies at all levels of the BP Corporation. The report also noted gaps in standards and practices that likely contributed to other serious incidents over the previous decade.
CSB Findings and Recommendations:
- Trailer siting exacerbated the consequence of the BP Texas City explosion. All of the fatalities and many of the injuries occurred in or near a series of occupied trailers that were as close as 121 feet from the blowdown stack. In October 2005, the CSB issued an urgent recommendation to the American Petroleum Institute (API) to develop new guidance to prevent locating occupied trailers within hazardous areas of process plants.
- Blowdown drums should be replaced by safer alternatives. The CSB made a recommendation to API to eliminate the kind of blowdown drum that released the flammable liquid and vapor at BP. This 1950s-era equipment is unsafe, and many companies around the world have long since eliminated these systems and replaced them with inherently safer flare systems designed to handle a worst-case flammable release.
- A strong safety culture must be embraced at all levels of a corporation. The March 2005 incident was one of a long series of tragedies at the Texas City facility, where a total of 40 workers have died over 32 years. Internal audits revealed deteriorating conditions at the refinery over several years prior to 2005, but the responses focused primarily on improving personal safety and overlooked growing process safety risks.
- Process safety indicators help companies measure and improve process safety performance. The CSB recommended that API and the United Steelworkers develop a consensus standard for new process safety leading indicators to help businesses and government better assess these risks before serious incidents occur. Such leading indicators have been used for years in the nuclear power industry and provide a common method for different facilities to measure and compare system safety performance.
Conclusion
Based on the more than 130 incidents investigated by the CSB, it is clear that hundreds of billions of dollars have been spent as a result of chemical disasters in the United States. To make the safety of Americans our number one priority, it is critical that chemical safety lessons are learned and shared among diverse stakeholders across industries. If the CSB’s many safety lessons prevented at least one catastrophic incident, the money saved by preventing damage to the facility and surrounding community, avoiding legal settlements, and saving human lives far outweighs the agency’s $11 million annual budget. Safety and prosperity are compatible. Strong safety programs are critical for the economic success of the chemical and petrochemical industries. The CSB’s continued collaboration with industry, regulators, standards setting bodies and other professional organizations proves that the CSB has a vital role in driving critical chemical safety change in the United States.
References
1 Gonzales, Dan, Timothy Gulden, Aaron Strong and William Hoyle. Cost–Benefit Analysis of Proposed California Oil and Gas Refinery Regulations. Santa Monica, CA: RAND Corporation, 2016. http://www.rand.org/pubs/research_reports/RR1421.html. Also available in print form.
Data presented for each investigation was current at the time of the approval of the final report. The West Fertilizer Company report was released on January 28, 2016. The final Chevron Richmond refinery report was released on January 28, 2016. The final Deepwater Horizon/Macondo report was released on April 20, 2016. The BP Texas City report was released on March 20, 2007.
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The resource includes a case example, steps to prevent a related injury, and questions for discussion. It includes a graphic that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely. Available in English and Spanish. 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The recall is a result of... 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[files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 4426 [old_id:protected] => [elcosh_id:protected] => d001656 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 0 [language_id:protected] => 1 [tagging_id:protected] => Mike Aguilar [priority_id:protected] => 1 [title:protected] => Construction Dive -- DeWalt's Jobsite Pro headphones recalled for fire hazards [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => DeWalt, Fire Hazards, recall, headphones [comments:protected] => [summary:protected] => A recall notice by the United States Consumer Product Safety Commission affects over 300,000 DeWalt Jobsite Pro Headphones. The recall is a result of a malfunction that can cause earbuds to overheat while charging or during use, leading to fire and burn hazards. [transition_comments:protected] => [external_link:protected] => https://www.constructiondive.com/news/dewalts-jobsite-pro-headphones-recalled-for-fire-hazards/611248/?utm_source=Sailthru&utm_medium=email&utm_campaign=Issue:%202021-12-10%20Construction%20Dive%20Newsletter%20%5Bissue:38532%5D&utm_term=Construction%20Dive [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/13/21 [date_completed:protected] => 12/13/21 [date_billed:protected] => [date_modified:protected] => 12/13/21 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [2] => Search_Result Object ( [title] => Working in an Enclosed Cab [image] => /record/images/notavailable-p.png [blurb] => This CPWR Hazard Alert on Working in enclosed cabs provides information on protecting workers from silica dust, how to minimize exposures and the dang... 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Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 54 [type:protected] => category [parent:protected] => 2 [label:protected] => Drywall Applicator Specialist [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [56] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 56 [type:protected] => category [parent:protected] => 2 [label:protected] => Elevator Constructor [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [58] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 58 [type:protected] => category [parent:protected] => 2 [label:protected] => Glazier [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [59] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 59 [type:protected] => category [parent:protected] => 2 [label:protected] => Hazardous Waste Cleanup [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [60] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 60 [type:protected] => category [parent:protected] => 2 [label:protected] => HVAC [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [61] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 61 [type:protected] => category [parent:protected] => 2 [label:protected] => Interior Systems Carpenter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [64] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 64 [type:protected] => category [parent:protected] => 2 [label:protected] => Laborer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [66] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 66 [type:protected] => category [parent:protected] => 2 [label:protected] => Lather [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [68] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 68 [type:protected] => category [parent:protected] => 2 [label:protected] => Maintenance Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [69] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 69 [type:protected] => category [parent:protected] => 2 [label:protected] => Millwright [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [71] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 71 [type:protected] => category [parent:protected] => 2 [label:protected] => Painter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [73] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 73 [type:protected] => category [parent:protected] => 2 [label:protected] => PCC/Restoration [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [74] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 74 [type:protected] => category [parent:protected] => 2 [label:protected] => Pile Driver [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [76] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 76 [type:protected] => category [parent:protected] => 2 [label:protected] => Plumber/Pipefitter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [77] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 77 [type:protected] => category [parent:protected] => 2 [label:protected] => Refractory Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [63] => Category Object ( [languages:protected] => [bok_resources:protected] => 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[type:protected] => category [parent:protected] => 2 [label:protected] => Stonemason [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [62] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 62 [type:protected] => category [parent:protected] => 2 [label:protected] => Structural Ironworker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [83] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 83 [type:protected] => category [parent:protected] => 2 [label:protected] => Terrazzo 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workplace, OSHA, silicosis, mining, silica, DOE, EEOICPA, labor, lung, CBD, dust, cab, miner, mine [comments:protected] => [summary:protected] => This CPWR Hazard Alert on Working in enclosed cabs provides information on protecting workers from silica dust, how to minimize exposures and the dangers of silica dust. Click on the following links to access the English version and the Spanish version. 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The resource includes a brief case example... 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[languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 40 [type:protected] => category [parent:protected] => 9 [label:protected] => Overexertion [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [44] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 44 [type:protected] => category [parent:protected] => 2 [label:protected] => Acoustical Ceiling Carpenter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [45] => Category Object ( [languages:protected] => [bok_resources:protected] => 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[type:protected] => category [parent:protected] => 2 [label:protected] => Bricklayer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [48] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 48 [type:protected] => category [parent:protected] => 2 [label:protected] => Cabinetmaker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [49] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 49 [type:protected] => category [parent:protected] => 2 [label:protected] => Carpenter 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=> [summary:protected] =>The CPWR Toolbox Talk on Suicide Prevention addresses the prevalence of suicide among construction workers. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely.
Available in English and Spanish. 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dust, exposure, air purifier, enclosed cab, vehicle [comments:protected] => [summary:protected] =>
The CPWR Toolbox Talk on Preventing Exposure to Silica Dust in Enclosed Cabs addresses the risks associated with breathing in silica dust and silicosis. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely.
Available in English and Spanish. 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structural support that prevents collapses during construction. 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The supports for the counterweight must... 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The supports for the counterweight must be designed with a safety factor of four. 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Wire rope supported must be desig... 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Wire rope supported must be designed with a safety factor of 6. The scaffold must be inspected by a competent person daily. 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This is accomplish... 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This is accomplished by setting swing restrictions, marking the ground for allowable crane travel and training of the crane signal persons. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/work/6/184/ [more_like_this:protected] => d001029, d000010, i001280, i001221 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => jpg [img_width:protected] => [img_height:protected] => [img_credit:protected] => Metropark [img_practice:protected] => not_applicable [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => August 28 2015 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 08/28/15 [date_completed:protected] => 08/28/15 [date_billed:protected] => [date_modified:protected] => 08/28/15 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) ) [preview_mode] => [description] => The U.S. Chemical Safety Board is an independent, non-regulatory safety agency that investigates chemical incidents and makes recommendations to prevent similar incidents from occurring. This short report is a summary of the lessons from several of the most catastrophic incidents the CSB has investigated. The CSB found common deficiencies in safety management systems, facility maintenance, adequacy of regulations, training. poor hazard awareness among emergency responders and insufficient community notification and planning. The specific incidents reviewed include the West, Texas fertilizer plant explosion, the Deep Water Horizon explosion, and the Richmond California refinery explosion. There is an infographic that accompanies this report: https://www.aiha.org/publications-and-resources/TheSynergist/Digital%20Synergist%20Images/201707-bythenumbers.jpg [keywords] => Chemical Safety Board, CSB, explosion, chemical incidents, disasters, investigation [related_items] => Array ( [Handouts] => Array ( [0] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 4275 [old_id:protected] => [elcosh_id:protected] => d001552 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 29 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => CSB Infographic about chemical-related incidents [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, CSB, explosion, fires, industrial accidents [comments:protected] => [summary:protected] => This infographic by the Chemical Safety Board shows the enormous cost in lives, injuries and money this nation has experienced from the industrial incidents at the BP Texas City Refinery, BP's Deepwater Horizon, Chevron's Richmond Refinery and the West Fertilizer Company facility in West, Texas. This graphic accompanies the CSB report, "The Business Case for Safety." [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/pipes_vessels/hazard/1643/work-inside-vessels-confined-space.html [more_like_this:protected] => d001174,d001206,d000443 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => png [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => 2017 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/20/17 [date_completed:protected] => 12/22/17 [date_billed:protected] => [date_modified:protected] => 12/22/17 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [1] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 3664 [old_id:protected] => [elcosh_id:protected] => d001206 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 24 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => OSHA FactSheet, Hazard Alert: Combustible Dust Explosions [total_pages:protected] => 2 [billed_pages:protected] => 2 [publication_number:protected] => DSG 3/2008 [part_of:protected] => [keywords:protected] => Combustible dusts, ignition source, settled dust, explosion, dust explosion, secondary explosion [comments:protected] => Two links were present in the consol link field thus creating a broken link. Only one link can be present in this field. I left the first of the two links in the field and removed http://www.cpwrconstructionsolutions.org/carpentry/hazard/1189/cut-boards-and-panels-wood-dust.html [summary:protected] => Combustible dusts are fine particles that present an explosion hazard when suspended in air in certain conditions. A dust explosion can be catastrophic and cause employee deaths, injuries, and destruction of entire buildings. OSHA notes that in many combustible dust accidents, employers and employees were unaware that a hazard even existed. In this FactSheet, OSHA helps employers and workers to determine if this hazard is present and what actions are needed to prevent tragic consequences. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/hazard/792/construction-dust.html [more_like_this:protected] => d000966 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => jpg [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => March 2008 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 04/17/13 [date_completed:protected] => 04/29/13 [date_billed:protected] => [date_modified:protected] => 06/04/13 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [News Articles] => Array ( [0] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 3608 [old_id:protected] => [elcosh_id:protected] => d001174 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 2 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => U.S. Chemical Safety Board Receives Awards for Videos [total_pages:protected] => 1 [billed_pages:protected] => 0 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, explosion, fire, dust explosion, process safety [comments:protected] => This should be placed in the What's New section. Note from Chris: As this was selected as an external link the billable pages were 0. Bruce, in the more like this field, you may want to enter in the ID's of the CSB videos we have in the database. [summary:protected] => The U.S. Chemical Safety Board (CSB) was named the recipient of three Peer Awards from the Television, Internet and Video Association of D.C. (TIVA) for safety videos produced in 2012. Videos on an academic laboratory explosion in Lubbock, Texas, and a flammable vapor explosion near Buffalo, New York, received bronze awards, while a video on a string of dust flash fires at a Tennessee metal powder production company received a silver award. CSB safety videos cover specific incidents investigated by the CSB and include excellent animations. Trainers who don't already used these videos in their health and safety training should check out the site. These free videos represent some of the best training resources available. [transition_comments:protected] => [external_link:protected] => http://www.csb.gov/newsroom/detail.aspx?nid=440 [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => November 2012 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 11/23/12 [date_completed:protected] => 12/17/12 [date_billed:protected] => [date_modified:protected] => 12/17/12 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [1] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 1311 [old_id:protected] => 449 [elcosh_id:protected] => d000443 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => [language_id:protected] => 1 [tagging_id:protected] => Sharon Garber/COD [priority_id:protected] => 1 [title:protected] => Preventing Construction Fires [total_pages:protected] => 5 [billed_pages:protected] => 5 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Occupation, construction, safety, health, hazards, work, worker, workplace, fire, housekeeping, flammable, storage, electical, program [comments:protected] => [summary:protected] => Discusses the typical causes of fires, such as poor housekeeping and careless smoking and provides suggestions on how to prevent them. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => [more_like_this:protected] => d000372, d000860, d001065 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => Feb 2001 [date_permission_requested:protected] => 03/01/01 [date_permission_received:protected] => 03/20/01 [date_review_needed:protected] => [date_received:protected] => 04/11/01 [date_completed:protected] => 04/25/01 [date_billed:protected] => 05/01/01 [date_modified:protected] => 05/08/12 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) ) [collections] => Array ( [4277] => ) [record] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => Array ( ) [organizations:protected] => Array ( [314] => Organization Object ( [id:protected] => 314 [elcosh_id:protected] => o001237 [user_id:protected] => 0 [province_id:protected] => 0 [country_id:protected] => 0 [title:protected] => U.S. Chemical Safety Board [address:protected] => [postal_code:protected] => [city:protected] => [department:protected] => [phone:protected] => [fax:protected] => [email:protected] => [website:protected] => [filename:protected] => [about:protected] => [comments:protected] => [logo_available:protected] => F [no_details:protected] => F [date_received:protected] => [date_completed:protected] => [date_billed:protected] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [collections:protected] => Array ( [4277] => ) [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => Array ( [4275] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => [old_record:protected] => [id:protected] => 4275 [old_id:protected] => [elcosh_id:protected] => d001552 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 29 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => CSB Infographic about chemical-related incidents [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, CSB, explosion, fires, industrial accidents [comments:protected] => [summary:protected] => This infographic by the Chemical Safety Board shows the enormous cost in lives, injuries and money this nation has experienced from the industrial incidents at the BP Texas City Refinery, BP's Deepwater Horizon, Chevron's Richmond Refinery and the West Fertilizer Company facility in West, Texas. This graphic accompanies the CSB report, "The Business Case for Safety." [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/pipes_vessels/hazard/1643/work-inside-vessels-confined-space.html [more_like_this:protected] => d001174,d001206,d000443 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => png [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => 2017 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/20/17 [date_completed:protected] => 12/22/17 [date_billed:protected] => [date_modified:protected] => 12/22/17 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [3608] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => [old_record:protected] => [id:protected] => 3608 [old_id:protected] => [elcosh_id:protected] => d001174 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 2 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => U.S. Chemical Safety Board Receives Awards for Videos [total_pages:protected] => 1 [billed_pages:protected] => 0 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, explosion, fire, dust explosion, process safety [comments:protected] => This should be placed in the What's New section. Note from Chris: As this was selected as an external link the billable pages were 0. Bruce, in the more like this field, you may want to enter in the ID's of the CSB videos we have in the database. [summary:protected] => The U.S. Chemical Safety Board (CSB) was named the recipient of three Peer Awards from the Television, Internet and Video Association of D.C. (TIVA) for safety videos produced in 2012. Videos on an academic laboratory explosion in Lubbock, Texas, and a flammable vapor explosion near Buffalo, New York, received bronze awards, while a video on a string of dust flash fires at a Tennessee metal powder production company received a silver award. CSB safety videos cover specific incidents investigated by the CSB and include excellent animations. Trainers who don't already used these videos in their health and safety training should check out the site. These free videos represent some of the best training resources available. [transition_comments:protected] => [external_link:protected] => http://www.csb.gov/newsroom/detail.aspx?nid=440 [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => November 2012 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 11/23/12 [date_completed:protected] => 12/17/12 [date_billed:protected] => [date_modified:protected] => 12/17/12 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [3664] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => [old_record:protected] => [id:protected] => 3664 [old_id:protected] => [elcosh_id:protected] => d001206 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 24 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => OSHA FactSheet, Hazard Alert: Combustible Dust Explosions [total_pages:protected] => 2 [billed_pages:protected] => 2 [publication_number:protected] => DSG 3/2008 [part_of:protected] => [keywords:protected] => Combustible dusts, ignition source, settled dust, explosion, dust explosion, secondary explosion [comments:protected] => Two links were present in the consol link field thus creating a broken link. Only one link can be present in this field. I left the first of the two links in the field and removed http://www.cpwrconstructionsolutions.org/carpentry/hazard/1189/cut-boards-and-panels-wood-dust.html [summary:protected] => Combustible dusts are fine particles that present an explosion hazard when suspended in air in certain conditions. A dust explosion can be catastrophic and cause employee deaths, injuries, and destruction of entire buildings. OSHA notes that in many combustible dust accidents, employers and employees were unaware that a hazard even existed. In this FactSheet, OSHA helps employers and workers to determine if this hazard is present and what actions are needed to prevent tragic consequences. 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This short report is a summary of the lessons from several of the most catastrophic incidents the CSB has investigated. The CSB found common deficiencies in safety management systems, facility maintenance, adequacy of regulations, training. poor hazard awareness among emergency responders and insufficient community notification and planning. The specific incidents reviewed include the West, Texas fertilizer plant explosion, the Deep Water Horizon explosion, and the Richmond California refinery explosion. 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SAFETY IS GOOD BUSINESS AND GOOD PUBLIC POLICY
"There's an old saying that if you think safety is expensive, try an accident. Accidents cost a lot of money. And, not only in damage to [the] plant and in claims for injury, but also in the loss of the company's reputation." - Trevor Kletz
As an independent, non-regulatory safety agency, the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigates catastrophic chemical incidents and makes recommendations to prevent similar incidents from occurring. The CSB has found that most catastrophic chemical incidents could have been prevented. The agency conducts comprehensive, root cause analyses, examining all the causal or contributing factors. Our investigations have identified deficiencies in areas such as safety management systems, facility maintenance, regulatory requirements and training. In addition to identifying the causes of an incident, the CSB uncovers factors that exacerbate its consequences, contributing to loss of life and property, such as a lack of hazard awareness among emergency responders and insufficient community notification and planning.
The CSB’s vision is a nation safe from chemical disasters. The CSB has published nearly one hundred investigative reports and produced sixty-eight video products to communicate its safety messages to audiences across the country, so that people may benefit from the lessons learned from these tragedies. With over 130 investigations and nearly 800 recommendations issued, the agency has sought to engage industry, unions, standards setting organizations, regulators, academia, and the American people in a collaborative effort to make the chemical industry safer, while maintaining economic productivity and protecting the jobs of workers in industrial facilities nationwide. The CSB has had an enormous impact on chemical safety with a staff of approximately 40 people and $11 million budget.
Here are some examples of our work.
Explosion at Fertilizer Storage Facility (West, Texas)
April 17, 2013
West Fertilizer Company
West, Texas
April 17, 2013
- 15 fatalities and 260+ injuries
- $230 million in insurance-related losses
- $16 million spent on Federal disaster assistance
- $1 million insurance policy held by West Fertilizer Company
On April 17, 2013, a massive explosion at the West Fertilizer Company (WFC), a fertilizer storage and distribution facility located in West, Texas, killed twelve first responders and three members of the public and caused more than 260 other injuries to first responders and the general public. Two of the fatally injured members of the public lived at a nearby apartment complex. The third lived at a nursing home and died shortly after the incident from injuries related to the trauma of the explosion.
The incident caused considerable property damage, including the complete destruction of the fertilizer facility, which was never rebuilt, leaving local farmers, ranchers and businesses without convenient access to needed products. The blast also caused extensive property damage beyond the facility. Two of the city’s school buildings had to be demolished and a third sustained major damage. Also destroyed were a nursing home, an apartment complex and numerous nearby homes. In a community of 700 homes, 350 (50%) were damaged as a result of the explosion, 142 (20%) of which were damaged beyond repair.
Total insurance-related losses from the explosion are estimated to be $230 million and federal disaster assistance is estimated to exceed $16 million. The company was only insured for $1 million, which fell far short of the incident’s damage.
CSB Findings and Recommendations:
- Failure by the insurer to identify the risks posed by fertilizer grade ammonium nitrate (FGAN). A few years prior to the incident, WFC was dropped by one insurer for failing to address safety concerns identified in loss control surveys. The company that insured WFC for $1 million at the time of the incident did not conduct its own safety inspections of the facility.
- The Federal Emergency Management Agency (FEMA) awarded two grants to develop FGAN training. The CSB found that there is no standardized training requirement that applies to volunteer firefighters across the nation. The CSB made a recommendation to FEMA to create a funding mechanism to provide training and curriculum develop for first responders at FGAN incidents. West Volunteer Fire Department did not conduct pre-incident planning or response training at WFC, was likely unaware of the potential for FGAN detonation and did not, nor were required, to have appropriate training in hazardous materials response.
- Gaps in federal and state regulations and standards. The CSB identified several gaps in federal and state regulations that could have reduced the consequences of the WFC disaster. These include the Occupational Safety and Health Administration’s Explosives and Blasting Agents and Process Safety Management standards, the Environmental Protection Agency’s Risk Management Program and Emergency Planning and Community Right-to-Know Act, and training provided or certified by the Texas Commission on Fire Protection and the State Firefighters’ and Fire Marshals’ Association of Texas.
- Local zoning and community planning. The location of the WFC relative to the surrounding community exacerbated the offsite consequences. The CSB found that at least 19 other Texas facilities storing more than 10,000 pounds of FGAN are located within a half-mile of a school, hospital, or nursing home, raising concerns that an incident with offsite consequences of this magnitude could happen again.
Refinery Explosion (Richmond, California)
August 6, 2012
Chevron Refinery
Richmond, California
August 6, 2012
- 15,000 people sought medical treatment
- $2 million in fines and restitution
- $447 million in increased gas prices passed onto California consumers1
On August 6, 2012, the Chevron Refinery in Richmond, California, experienced a catastrophic pipe failure in a crude unit, causing the release of flammable hydrocarbon process fluid which partially vaporized into a large cloud. Nineteen employees engulfed by the vapor cloud escaped, narrowly avoiding serious injury. The ignition and subsequent continued burning of hydrocarbons resulted in a large plume of unknown particulates and vapor. Approximately 15,000 people from the surrounding area sought medical treatment in the weeks following the incident. The CSB’s investigation found that the pipe failure was caused by sulfidation corrosion, a damage mechanism that causes piping walls to thin over time.
Although the company has never reported the decreased production capacity experienced as a result of the incident, the U.S. Energy Information Administration determined that the increase in gas prices cost California consumers approximately $447 million in six months following the incident.
Key Findings and Recommendations:
- Hazard analyses improved at all Chevron refineries in the U.S. The CSB investigation found that the hazard analysis conducted on the piping that failed did not identify corrosion as a potential cause of a leak or rupture. As a result, the CSB issued a recommendation to Chevron to perform damage mechanism hazard reviews (DMRs) on all of its process safety management (PSM) covered equipment and to incorporate the DMRs into their hazard review process at all its U.S. refineries. As a result of the CSB’s recommendation, Chevron has conducted DMRs at all of its U.S. refineries for PSM covered process piping circuits. If more companies were to adopt hazard review programs similar to Chevron’s, safety at refineries would be greatly increased.
- The California Department of Industrial Relations (DIR) revisions to the PSM regulation. Chevron conducted a hazard analysis of the crude unit as required by California’s Process Safety Management of Acutely Hazardous Materials (PSM) program; however, this does not require a formal damage mechanism hazard review to identify sulfidation corrosion. The CSB made several recommendations to improve California’s PSM program. Since 2014, DIR has published several drafts of a revised regulation and received and incorporated extensive stakeholder feedback. If the proposed regulation is approved, process safety in California’s refineries would be greatly improved and chemical safety would be advanced by better preventing major chemical incidents.
Deepwater Horizon/ Macondo Well Blowout (Gulf of Mexico)
April 20, 2010
Deepwater Horizon/Macondo Well Blowout
Gulf of Mexico
April 20, 2010
- $21 billion in settlements
- $13 billion in economic and medical claims
- 11 workers killed, 17 workers injured
- 4 million barrels of oil spilled
On April 20, 2010, a multiplefatality incident occurred at the Macondo oil well approximately 50 miles off the coast of Louisiana in the Gulf of Mexico during temporary well-abandonment activities on the Deepwater Horizon drilling rig. Control of the well was lost, resulting in a blowout—the uncontrolled release of hydrocarbons from the well. On the rig, the hydrocarbons found an ignition source and burst into flames. The resulting explosions and fire led to the deaths of 11 individuals, serious physical injuries to 17 others, evacuation of 115 individuals from the rig, the sinking of the Deepwater Horizon, and massive marine and coastal damage from a reported 4 million barrels of released hydrocarbons.
The operator of the rig, has paid out an estimated $13 billion worth of economic and medical claims as part of an uncapped settlement, in addition to a $20 billion settlement for federal, state and local government economic and environmental claims. Settlements involving other companies have reached $1.24 billion payout at the time of the completion of the CSB’s investigation. Other litigation remains pending.
CSB Findings and Recommendations:
- Blowout preventer (BOP) hazard not identified prior to Deepwater Horizon. Testing limitations masked latent failures of the Deepwater Horizon BOP, affecting its operation on the day of the incident, and these latent failures will continue to exist for similarly designed blowout preventers unless modifications are made to current standard industry testing protocols.
- Pipe buckling prevented drillpipe from working effectively. Pressure conditions in a well can cause drillpipe to buckle (or bend) in a BOP even after a crew has initially sealed a well, potentially incapacitating emergency functions of the BOP intended to cut drillpipe and seal the well.
- Safety-critical controls are necessary for hazard management. Major hazards require concerted efforts by industry to manage and actively monitor the safety-critical controls they rely on for the safe conduct of work, including improved incorporation of human factors, safety performance indicators, and corporate governance.
- Information sharing can be a challenge in offshore drilling. Obstacles continue to exist that limit sharing of lessons from incident investigations in individual companies and across both the operator/drilling contractor boundary and international geographical regions.
- Proper use of process safety indicators can prevent incidents. An equal focus and effort to collect, measure, and improve process safety performance indicators to that currently dedicated to personal safety statistics is necessary to reduce the potential for a major incident.
Texas City Refinery Explosion (Texas City, Texas)
March 23, 2005
BP Texas City
Texas City, Texas
March 23, 2005
- $1.5 billion in financial losses
- 15 workers killed
- 180 people injured
On March 23, 2005, a hydrocarbon isomerization unit (ISOM) exploded at the BP Texas City refinery in Texas City, Texas, resulting in financial losses of more than $1.5 billion. The incident killed 15 workers and injured 180 others. All of the fatalities and many serious injuries occurred in and around the nine temporary trailers sited as close as 121 feet from the ISOM unit. This refinery explosion was the most serious refinery incident ever investigated by the CSB. The CSB’s final investigative report into the incident found organizational and safety deficiencies at all levels of the BP Corporation. The report also noted gaps in standards and practices that likely contributed to other serious incidents over the previous decade.
CSB Findings and Recommendations:
- Trailer siting exacerbated the consequence of the BP Texas City explosion. All of the fatalities and many of the injuries occurred in or near a series of occupied trailers that were as close as 121 feet from the blowdown stack. In October 2005, the CSB issued an urgent recommendation to the American Petroleum Institute (API) to develop new guidance to prevent locating occupied trailers within hazardous areas of process plants.
- Blowdown drums should be replaced by safer alternatives. The CSB made a recommendation to API to eliminate the kind of blowdown drum that released the flammable liquid and vapor at BP. This 1950s-era equipment is unsafe, and many companies around the world have long since eliminated these systems and replaced them with inherently safer flare systems designed to handle a worst-case flammable release.
- A strong safety culture must be embraced at all levels of a corporation. The March 2005 incident was one of a long series of tragedies at the Texas City facility, where a total of 40 workers have died over 32 years. Internal audits revealed deteriorating conditions at the refinery over several years prior to 2005, but the responses focused primarily on improving personal safety and overlooked growing process safety risks.
- Process safety indicators help companies measure and improve process safety performance. The CSB recommended that API and the United Steelworkers develop a consensus standard for new process safety leading indicators to help businesses and government better assess these risks before serious incidents occur. Such leading indicators have been used for years in the nuclear power industry and provide a common method for different facilities to measure and compare system safety performance.
Conclusion
Based on the more than 130 incidents investigated by the CSB, it is clear that hundreds of billions of dollars have been spent as a result of chemical disasters in the United States. To make the safety of Americans our number one priority, it is critical that chemical safety lessons are learned and shared among diverse stakeholders across industries. If the CSB’s many safety lessons prevented at least one catastrophic incident, the money saved by preventing damage to the facility and surrounding community, avoiding legal settlements, and saving human lives far outweighs the agency’s $11 million annual budget. Safety and prosperity are compatible. Strong safety programs are critical for the economic success of the chemical and petrochemical industries. The CSB’s continued collaboration with industry, regulators, standards setting bodies and other professional organizations proves that the CSB has a vital role in driving critical chemical safety change in the United States.
References
1 Gonzales, Dan, Timothy Gulden, Aaron Strong and William Hoyle. Cost–Benefit Analysis of Proposed California Oil and Gas Refinery Regulations. Santa Monica, CA: RAND Corporation, 2016. http://www.rand.org/pubs/research_reports/RR1421.html. Also available in print form.
Data presented for each investigation was current at the time of the approval of the final report. The West Fertilizer Company report was released on January 28, 2016. The final Chevron Richmond refinery report was released on January 28, 2016. The final Deepwater Horizon/Macondo report was released on April 20, 2016. The BP Texas City report was released on March 20, 2007.
[content_transformed:protected] =>SAFETY IS GOOD BUSINESS AND GOOD PUBLIC POLICY
"There's an old saying that if you think safety is expensive, try an accident. Accidents cost a lot of money. And, not only in damage to [the] plant and in claims for injury, but also in the loss of the company's reputation." - Trevor Kletz
As an independent, non-regulatory safety agency, the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigates catastrophic chemical incidents and makes recommendations to prevent similar incidents from occurring. The CSB has found that most catastrophic chemical incidents could have been prevented. The agency conducts comprehensive, root cause analyses, examining all the causal or contributing factors. Our investigations have identified deficiencies in areas such as safety management systems, facility maintenance, regulatory requirements and training. In addition to identifying the causes of an incident, the CSB uncovers factors that exacerbate its consequences, contributing to loss of life and property, such as a lack of hazard awareness among emergency responders and insufficient community notification and planning.
The CSB’s vision is a nation safe from chemical disasters. The CSB has published nearly one hundred investigative reports and produced sixty-eight video products to communicate its safety messages to audiences across the country, so that people may benefit from the lessons learned from these tragedies. With over 130 investigations and nearly 800 recommendations issued, the agency has sought to engage industry, unions, standards setting organizations, regulators, academia, and the American people in a collaborative effort to make the chemical industry safer, while maintaining economic productivity and protecting the jobs of workers in industrial facilities nationwide. The CSB has had an enormous impact on chemical safety with a staff of approximately 40 people and $11 million budget.
Here are some examples of our work.
Explosion at Fertilizer Storage Facility (West, Texas)
April 17, 2013
West Fertilizer Company
West, Texas
April 17, 2013
- 15 fatalities and 260+ injuries
- $230 million in insurance-related losses
- $16 million spent on Federal disaster assistance
- $1 million insurance policy held by West Fertilizer Company
On April 17, 2013, a massive explosion at the West Fertilizer Company (WFC), a fertilizer storage and distribution facility located in West, Texas, killed twelve first responders and three members of the public and caused more than 260 other injuries to first responders and the general public. Two of the fatally injured members of the public lived at a nearby apartment complex. The third lived at a nursing home and died shortly after the incident from injuries related to the trauma of the explosion.
The incident caused considerable property damage, including the complete destruction of the fertilizer facility, which was never rebuilt, leaving local farmers, ranchers and businesses without convenient access to needed products. The blast also caused extensive property damage beyond the facility. Two of the city’s school buildings had to be demolished and a third sustained major damage. Also destroyed were a nursing home, an apartment complex and numerous nearby homes. In a community of 700 homes, 350 (50%) were damaged as a result of the explosion, 142 (20%) of which were damaged beyond repair.
Total insurance-related losses from the explosion are estimated to be $230 million and federal disaster assistance is estimated to exceed $16 million. The company was only insured for $1 million, which fell far short of the incident’s damage.
CSB Findings and Recommendations:
- Failure by the insurer to identify the risks posed by fertilizer grade ammonium nitrate (FGAN). A few years prior to the incident, WFC was dropped by one insurer for failing to address safety concerns identified in loss control surveys. The company that insured WFC for $1 million at the time of the incident did not conduct its own safety inspections of the facility.
- The Federal Emergency Management Agency (FEMA) awarded two grants to develop FGAN training. The CSB found that there is no standardized training requirement that applies to volunteer firefighters across the nation. The CSB made a recommendation to FEMA to create a funding mechanism to provide training and curriculum develop for first responders at FGAN incidents. West Volunteer Fire Department did not conduct pre-incident planning or response training at WFC, was likely unaware of the potential for FGAN detonation and did not, nor were required, to have appropriate training in hazardous materials response.
- Gaps in federal and state regulations and standards. The CSB identified several gaps in federal and state regulations that could have reduced the consequences of the WFC disaster. These include the Occupational Safety and Health Administration’s Explosives and Blasting Agents and Process Safety Management standards, the Environmental Protection Agency’s Risk Management Program and Emergency Planning and Community Right-to-Know Act, and training provided or certified by the Texas Commission on Fire Protection and the State Firefighters’ and Fire Marshals’ Association of Texas.
- Local zoning and community planning. The location of the WFC relative to the surrounding community exacerbated the offsite consequences. The CSB found that at least 19 other Texas facilities storing more than 10,000 pounds of FGAN are located within a half-mile of a school, hospital, or nursing home, raising concerns that an incident with offsite consequences of this magnitude could happen again.
Refinery Explosion (Richmond, California)
August 6, 2012
Chevron Refinery
Richmond, California
August 6, 2012
- 15,000 people sought medical treatment
- $2 million in fines and restitution
- $447 million in increased gas prices passed onto California consumers1
On August 6, 2012, the Chevron Refinery in Richmond, California, experienced a catastrophic pipe failure in a crude unit, causing the release of flammable hydrocarbon process fluid which partially vaporized into a large cloud. Nineteen employees engulfed by the vapor cloud escaped, narrowly avoiding serious injury. The ignition and subsequent continued burning of hydrocarbons resulted in a large plume of unknown particulates and vapor. Approximately 15,000 people from the surrounding area sought medical treatment in the weeks following the incident. The CSB’s investigation found that the pipe failure was caused by sulfidation corrosion, a damage mechanism that causes piping walls to thin over time.
Although the company has never reported the decreased production capacity experienced as a result of the incident, the U.S. Energy Information Administration determined that the increase in gas prices cost California consumers approximately $447 million in six months following the incident.
Key Findings and Recommendations:
- Hazard analyses improved at all Chevron refineries in the U.S. The CSB investigation found that the hazard analysis conducted on the piping that failed did not identify corrosion as a potential cause of a leak or rupture. As a result, the CSB issued a recommendation to Chevron to perform damage mechanism hazard reviews (DMRs) on all of its process safety management (PSM) covered equipment and to incorporate the DMRs into their hazard review process at all its U.S. refineries. As a result of the CSB’s recommendation, Chevron has conducted DMRs at all of its U.S. refineries for PSM covered process piping circuits. If more companies were to adopt hazard review programs similar to Chevron’s, safety at refineries would be greatly increased.
- The California Department of Industrial Relations (DIR) revisions to the PSM regulation. Chevron conducted a hazard analysis of the crude unit as required by California’s Process Safety Management of Acutely Hazardous Materials (PSM) program; however, this does not require a formal damage mechanism hazard review to identify sulfidation corrosion. The CSB made several recommendations to improve California’s PSM program. Since 2014, DIR has published several drafts of a revised regulation and received and incorporated extensive stakeholder feedback. If the proposed regulation is approved, process safety in California’s refineries would be greatly improved and chemical safety would be advanced by better preventing major chemical incidents.
Deepwater Horizon/ Macondo Well Blowout (Gulf of Mexico)
April 20, 2010
Deepwater Horizon/Macondo Well Blowout
Gulf of Mexico
April 20, 2010
- $21 billion in settlements
- $13 billion in economic and medical claims
- 11 workers killed, 17 workers injured
- 4 million barrels of oil spilled
On April 20, 2010, a multiplefatality incident occurred at the Macondo oil well approximately 50 miles off the coast of Louisiana in the Gulf of Mexico during temporary well-abandonment activities on the Deepwater Horizon drilling rig. Control of the well was lost, resulting in a blowout—the uncontrolled release of hydrocarbons from the well. On the rig, the hydrocarbons found an ignition source and burst into flames. The resulting explosions and fire led to the deaths of 11 individuals, serious physical injuries to 17 others, evacuation of 115 individuals from the rig, the sinking of the Deepwater Horizon, and massive marine and coastal damage from a reported 4 million barrels of released hydrocarbons.
The operator of the rig, has paid out an estimated $13 billion worth of economic and medical claims as part of an uncapped settlement, in addition to a $20 billion settlement for federal, state and local government economic and environmental claims. Settlements involving other companies have reached $1.24 billion payout at the time of the completion of the CSB’s investigation. Other litigation remains pending.
CSB Findings and Recommendations:
- Blowout preventer (BOP) hazard not identified prior to Deepwater Horizon. Testing limitations masked latent failures of the Deepwater Horizon BOP, affecting its operation on the day of the incident, and these latent failures will continue to exist for similarly designed blowout preventers unless modifications are made to current standard industry testing protocols.
- Pipe buckling prevented drillpipe from working effectively. Pressure conditions in a well can cause drillpipe to buckle (or bend) in a BOP even after a crew has initially sealed a well, potentially incapacitating emergency functions of the BOP intended to cut drillpipe and seal the well.
- Safety-critical controls are necessary for hazard management. Major hazards require concerted efforts by industry to manage and actively monitor the safety-critical controls they rely on for the safe conduct of work, including improved incorporation of human factors, safety performance indicators, and corporate governance.
- Information sharing can be a challenge in offshore drilling. Obstacles continue to exist that limit sharing of lessons from incident investigations in individual companies and across both the operator/drilling contractor boundary and international geographical regions.
- Proper use of process safety indicators can prevent incidents. An equal focus and effort to collect, measure, and improve process safety performance indicators to that currently dedicated to personal safety statistics is necessary to reduce the potential for a major incident.
Texas City Refinery Explosion (Texas City, Texas)
March 23, 2005
BP Texas City
Texas City, Texas
March 23, 2005
- $1.5 billion in financial losses
- 15 workers killed
- 180 people injured
On March 23, 2005, a hydrocarbon isomerization unit (ISOM) exploded at the BP Texas City refinery in Texas City, Texas, resulting in financial losses of more than $1.5 billion. The incident killed 15 workers and injured 180 others. All of the fatalities and many serious injuries occurred in and around the nine temporary trailers sited as close as 121 feet from the ISOM unit. This refinery explosion was the most serious refinery incident ever investigated by the CSB. The CSB’s final investigative report into the incident found organizational and safety deficiencies at all levels of the BP Corporation. The report also noted gaps in standards and practices that likely contributed to other serious incidents over the previous decade.
CSB Findings and Recommendations:
- Trailer siting exacerbated the consequence of the BP Texas City explosion. All of the fatalities and many of the injuries occurred in or near a series of occupied trailers that were as close as 121 feet from the blowdown stack. In October 2005, the CSB issued an urgent recommendation to the American Petroleum Institute (API) to develop new guidance to prevent locating occupied trailers within hazardous areas of process plants.
- Blowdown drums should be replaced by safer alternatives. The CSB made a recommendation to API to eliminate the kind of blowdown drum that released the flammable liquid and vapor at BP. This 1950s-era equipment is unsafe, and many companies around the world have long since eliminated these systems and replaced them with inherently safer flare systems designed to handle a worst-case flammable release.
- A strong safety culture must be embraced at all levels of a corporation. The March 2005 incident was one of a long series of tragedies at the Texas City facility, where a total of 40 workers have died over 32 years. Internal audits revealed deteriorating conditions at the refinery over several years prior to 2005, but the responses focused primarily on improving personal safety and overlooked growing process safety risks.
- Process safety indicators help companies measure and improve process safety performance. The CSB recommended that API and the United Steelworkers develop a consensus standard for new process safety leading indicators to help businesses and government better assess these risks before serious incidents occur. Such leading indicators have been used for years in the nuclear power industry and provide a common method for different facilities to measure and compare system safety performance.
Conclusion
Based on the more than 130 incidents investigated by the CSB, it is clear that hundreds of billions of dollars have been spent as a result of chemical disasters in the United States. To make the safety of Americans our number one priority, it is critical that chemical safety lessons are learned and shared among diverse stakeholders across industries. If the CSB’s many safety lessons prevented at least one catastrophic incident, the money saved by preventing damage to the facility and surrounding community, avoiding legal settlements, and saving human lives far outweighs the agency’s $11 million annual budget. Safety and prosperity are compatible. Strong safety programs are critical for the economic success of the chemical and petrochemical industries. The CSB’s continued collaboration with industry, regulators, standards setting bodies and other professional organizations proves that the CSB has a vital role in driving critical chemical safety change in the United States.
References
1 Gonzales, Dan, Timothy Gulden, Aaron Strong and William Hoyle. Cost–Benefit Analysis of Proposed California Oil and Gas Refinery Regulations. Santa Monica, CA: RAND Corporation, 2016. http://www.rand.org/pubs/research_reports/RR1421.html. Also available in print form.
Data presented for each investigation was current at the time of the approval of the final report. The West Fertilizer Company report was released on January 28, 2016. The final Chevron Richmond refinery report was released on January 28, 2016. The final Deepwater Horizon/Macondo report was released on April 20, 2016. The BP Texas City report was released on March 20, 2007.
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The res... 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The resource includes a case example, steps to prevent a related injury, and questions for discussion. It includes a graphic that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely. Available in English and Spanish. 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The recall is a result of... 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Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 70 [type:protected] => category [parent:protected] => 2 [label:protected] => Operating Engineer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [71] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 71 [type:protected] => category [parent:protected] => 2 [label:protected] => Painter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [72] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 72 [type:protected] => category [parent:protected] => 2 [label:protected] => Paper Hanger [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [73] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 73 [type:protected] => category [parent:protected] => 2 [label:protected] => PCC/Restoration [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [74] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 74 [type:protected] => category [parent:protected] => 2 [label:protected] => Pile Driver [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [75] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 75 [type:protected] => category [parent:protected] => 2 [label:protected] => Plasterer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [76] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 76 [type:protected] => category [parent:protected] => 2 [label:protected] => Plumber/Pipefitter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [77] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 77 [type:protected] => category [parent:protected] => 2 [label:protected] => Refractory Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [63] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 63 [type:protected] => category [parent:protected] => 2 [label:protected] => Reinforcing Ironworker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [78] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 78 [type:protected] => category [parent:protected] => 2 [label:protected] => Roofer/Waterproofer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [79] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 79 [type:protected] => category [parent:protected] => 2 [label:protected] => Scaffold Erector [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => 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=> Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 82 [type:protected] => category [parent:protected] => 2 [label:protected] => Stonemason [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [62] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 62 [type:protected] => category [parent:protected] => 2 [label:protected] => Structural Ironworker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [83] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 83 [type:protected] => category [parent:protected] => 2 [label:protected] => Terrazzo Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [84] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 84 [type:protected] => category [parent:protected] => 2 [label:protected] => Tile Setter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [85] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 85 [type:protected] => category [parent:protected] => 2 [label:protected] => Truck Driver [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [86] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 86 [type:protected] => category [parent:protected] => 2 [label:protected] => Welder [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [87] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 87 [type:protected] => category [parent:protected] => 3 [label:protected] => Commercial & 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[files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 4426 [old_id:protected] => [elcosh_id:protected] => d001656 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 0 [language_id:protected] => 1 [tagging_id:protected] => Mike Aguilar [priority_id:protected] => 1 [title:protected] => Construction Dive -- DeWalt's Jobsite Pro headphones recalled for fire hazards [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => DeWalt, Fire Hazards, recall, headphones [comments:protected] => [summary:protected] => A recall notice by the United States Consumer Product Safety Commission affects over 300,000 DeWalt Jobsite Pro Headphones. The recall is a result of a malfunction that can cause earbuds to overheat while charging or during use, leading to fire and burn hazards. [transition_comments:protected] => [external_link:protected] => https://www.constructiondive.com/news/dewalts-jobsite-pro-headphones-recalled-for-fire-hazards/611248/?utm_source=Sailthru&utm_medium=email&utm_campaign=Issue:%202021-12-10%20Construction%20Dive%20Newsletter%20%5Bissue:38532%5D&utm_term=Construction%20Dive [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/13/21 [date_completed:protected] => 12/13/21 [date_billed:protected] => [date_modified:protected] => 12/13/21 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [2] => Search_Result Object ( [title] => Working in an Enclosed Cab [image] => /record/images/notavailable-p.png [blurb] => This CPWR Hazard Alert on Working in enclosed cabs provides information on protecting workers from silica dust, how to minimize exposures and the dang... 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[label:protected] => Laborer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [66] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 66 [type:protected] => category [parent:protected] => 2 [label:protected] => Lather [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [68] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 68 [type:protected] => category [parent:protected] => 2 [label:protected] => Maintenance Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [69] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 69 [type:protected] => category [parent:protected] => 2 [label:protected] => Millwright [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [71] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 71 [type:protected] => category [parent:protected] => 2 [label:protected] => Painter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => 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Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 76 [type:protected] => category [parent:protected] => 2 [label:protected] => Plumber/Pipefitter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [77] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 77 [type:protected] => category [parent:protected] => 2 [label:protected] => Refractory Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [63] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 63 [type:protected] => category [parent:protected] => 2 [label:protected] => Reinforcing Ironworker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [80] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 80 [type:protected] => category [parent:protected] => 2 [label:protected] => Sheetmetal Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [82] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 82 [type:protected] => category [parent:protected] => 2 [label:protected] => Stonemason [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [62] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 62 [type:protected] => category [parent:protected] => 2 [label:protected] => Structural Ironworker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [83] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 83 [type:protected] => category [parent:protected] => 2 [label:protected] => Terrazzo 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workplace, OSHA, silicosis, mining, silica, DOE, EEOICPA, labor, lung, CBD, dust, cab, miner, mine [comments:protected] => [summary:protected] => This CPWR Hazard Alert on Working in enclosed cabs provides information on protecting workers from silica dust, how to minimize exposures and the dangers of silica dust. Click on the following links to access the English version and the Spanish version. 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The resource includes a brief case example... 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[languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 40 [type:protected] => category [parent:protected] => 9 [label:protected] => Overexertion [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [44] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 44 [type:protected] => category [parent:protected] => 2 [label:protected] => Acoustical Ceiling Carpenter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [45] => Category Object ( [languages:protected] => [bok_resources:protected] => 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[type:protected] => category [parent:protected] => 2 [label:protected] => Bricklayer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [48] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 48 [type:protected] => category [parent:protected] => 2 [label:protected] => Cabinetmaker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [49] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 49 [type:protected] => category [parent:protected] => 2 [label:protected] => Carpenter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [50] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 50 [type:protected] => category [parent:protected] => 2 [label:protected] => Carpet Layer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [51] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 51 [type:protected] => category [parent:protected] => 2 [label:protected] => Cement Mason [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [52] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 52 [type:protected] => category [parent:protected] => 2 [label:protected] => Commercial Diver [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [53] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 53 [type:protected] => category [parent:protected] => 2 [label:protected] => Concrete Polisher [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => 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Array ( ) ) [56] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 56 [type:protected] => category [parent:protected] => 2 [label:protected] => Elevator Constructor [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [57] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 57 [type:protected] => category [parent:protected] => 2 [label:protected] => Flagger [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [58] => Category Object ( [languages:protected] => 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=> [summary:protected] =>The CPWR Toolbox Talk on Suicide Prevention addresses the prevalence of suicide among construction workers. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely.
Available in English and Spanish. 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The CPWR Toolbox Talk on Preventing Exposure to Silica Dust in Enclosed Cabs addresses the risks associated with breathing in silica dust and silicosis. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely.
Available in English and Spanish. 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structural support that prevents collapses during construction. 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The supports for the counterweight must... 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The supports for the counterweight must be designed with a safety factor of four. 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Wire rope supported must be desig... 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Wire rope supported must be designed with a safety factor of 6. The scaffold must be inspected by a competent person daily. 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This is accomplish... 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This is accomplished by setting swing restrictions, marking the ground for allowable crane travel and training of the crane signal persons. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/work/6/184/ [more_like_this:protected] => d001029, d000010, i001280, i001221 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => jpg [img_width:protected] => [img_height:protected] => [img_credit:protected] => Metropark [img_practice:protected] => not_applicable [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => August 28 2015 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 08/28/15 [date_completed:protected] => 08/28/15 [date_billed:protected] => [date_modified:protected] => 08/28/15 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) ) [preview_mode] => [description] => The U.S. Chemical Safety Board is an independent, non-regulatory safety agency that investigates chemical incidents and makes recommendations to prevent similar incidents from occurring. This short report is a summary of the lessons from several of the most catastrophic incidents the CSB has investigated. The CSB found common deficiencies in safety management systems, facility maintenance, adequacy of regulations, training. poor hazard awareness among emergency responders and insufficient community notification and planning. The specific incidents reviewed include the West, Texas fertilizer plant explosion, the Deep Water Horizon explosion, and the Richmond California refinery explosion. There is an infographic that accompanies this report: https://www.aiha.org/publications-and-resources/TheSynergist/Digital%20Synergist%20Images/201707-bythenumbers.jpg [keywords] => Chemical Safety Board, CSB, explosion, chemical incidents, disasters, investigation [related_items] => Array ( [Handouts] => Array ( [0] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 4275 [old_id:protected] => [elcosh_id:protected] => d001552 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 29 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => CSB Infographic about chemical-related incidents [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, CSB, explosion, fires, industrial accidents [comments:protected] => [summary:protected] => This infographic by the Chemical Safety Board shows the enormous cost in lives, injuries and money this nation has experienced from the industrial incidents at the BP Texas City Refinery, BP's Deepwater Horizon, Chevron's Richmond Refinery and the West Fertilizer Company facility in West, Texas. This graphic accompanies the CSB report, "The Business Case for Safety." 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Only one link can be present in this field. I left the first of the two links in the field and removed http://www.cpwrconstructionsolutions.org/carpentry/hazard/1189/cut-boards-and-panels-wood-dust.html [summary:protected] => Combustible dusts are fine particles that present an explosion hazard when suspended in air in certain conditions. A dust explosion can be catastrophic and cause employee deaths, injuries, and destruction of entire buildings. OSHA notes that in many combustible dust accidents, employers and employees were unaware that a hazard even existed. In this FactSheet, OSHA helps employers and workers to determine if this hazard is present and what actions are needed to prevent tragic consequences. 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Note from Chris: As this was selected as an external link the billable pages were 0. Bruce, in the more like this field, you may want to enter in the ID's of the CSB videos we have in the database. [summary:protected] => The U.S. Chemical Safety Board (CSB) was named the recipient of three Peer Awards from the Television, Internet and Video Association of D.C. (TIVA) for safety videos produced in 2012. Videos on an academic laboratory explosion in Lubbock, Texas, and a flammable vapor explosion near Buffalo, New York, received bronze awards, while a video on a string of dust flash fires at a Tennessee metal powder production company received a silver award. CSB safety videos cover specific incidents investigated by the CSB and include excellent animations. Trainers who don't already used these videos in their health and safety training should check out the site. These free videos represent some of the best training resources available. [transition_comments:protected] => [external_link:protected] => http://www.csb.gov/newsroom/detail.aspx?nid=440 [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => November 2012 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 11/23/12 [date_completed:protected] => 12/17/12 [date_billed:protected] => [date_modified:protected] => 12/17/12 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [1] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 1311 [old_id:protected] => 449 [elcosh_id:protected] => d000443 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => [language_id:protected] => 1 [tagging_id:protected] => Sharon Garber/COD [priority_id:protected] => 1 [title:protected] => Preventing Construction Fires [total_pages:protected] => 5 [billed_pages:protected] => 5 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Occupation, construction, safety, health, hazards, work, worker, workplace, fire, housekeeping, flammable, storage, electical, program [comments:protected] => [summary:protected] => Discusses the typical causes of fires, such as poor housekeeping and careless smoking and provides suggestions on how to prevent them. 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This graphic accompanies the CSB report, "The Business Case for Safety." 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Note from Chris: As this was selected as an external link the billable pages were 0. Bruce, in the more like this field, you may want to enter in the ID's of the CSB videos we have in the database. [summary:protected] => The U.S. Chemical Safety Board (CSB) was named the recipient of three Peer Awards from the Television, Internet and Video Association of D.C. (TIVA) for safety videos produced in 2012. Videos on an academic laboratory explosion in Lubbock, Texas, and a flammable vapor explosion near Buffalo, New York, received bronze awards, while a video on a string of dust flash fires at a Tennessee metal powder production company received a silver award. CSB safety videos cover specific incidents investigated by the CSB and include excellent animations. Trainers who don't already used these videos in their health and safety training should check out the site. These free videos represent some of the best training resources available. 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Only one link can be present in this field. I left the first of the two links in the field and removed http://www.cpwrconstructionsolutions.org/carpentry/hazard/1189/cut-boards-and-panels-wood-dust.html [summary:protected] => Combustible dusts are fine particles that present an explosion hazard when suspended in air in certain conditions. A dust explosion can be catastrophic and cause employee deaths, injuries, and destruction of entire buildings. OSHA notes that in many combustible dust accidents, employers and employees were unaware that a hazard even existed. In this FactSheet, OSHA helps employers and workers to determine if this hazard is present and what actions are needed to prevent tragic consequences. 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This short report is a summary of the lessons from several of the most catastrophic incidents the CSB has investigated. The CSB found common deficiencies in safety management systems, facility maintenance, adequacy of regulations, training. poor hazard awareness among emergency responders and insufficient community notification and planning. The specific incidents reviewed include the West, Texas fertilizer plant explosion, the Deep Water Horizon explosion, and the Richmond California refinery explosion. There is an infographic that accompanies this report: https://www.aiha.org/publications-and-resources/TheSynergist/Digital%20Synergist%20Images/201707-bythenumbers.jpg [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/pipes_vessels/hazard/1643/work-inside-vessels-confined-space.html [more_like_this:protected] => d001552,d001174,d001206,d000443 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => png [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => 2017 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/21/17 [date_completed:protected] => 12/22/17 [date_billed:protected] => [date_modified:protected] => 12/22/17 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [show_text] => [document_content] => ElcoshItemDocumentContent Object ( [id:protected] => 3053 [item_id:protected] => 4276 [type:protected] => main [title:protected] => [content:protected] =>
SAFETY IS GOOD BUSINESS AND GOOD PUBLIC POLICY
"There's an old saying that if you think safety is expensive, try an accident. Accidents cost a lot of money. And, not only in damage to [the] plant and in claims for injury, but also in the loss of the company's reputation." - Trevor Kletz
As an independent, non-regulatory safety agency, the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigates catastrophic chemical incidents and makes recommendations to prevent similar incidents from occurring. The CSB has found that most catastrophic chemical incidents could have been prevented. The agency conducts comprehensive, root cause analyses, examining all the causal or contributing factors. Our investigations have identified deficiencies in areas such as safety management systems, facility maintenance, regulatory requirements and training. In addition to identifying the causes of an incident, the CSB uncovers factors that exacerbate its consequences, contributing to loss of life and property, such as a lack of hazard awareness among emergency responders and insufficient community notification and planning.
The CSB’s vision is a nation safe from chemical disasters. The CSB has published nearly one hundred investigative reports and produced sixty-eight video products to communicate its safety messages to audiences across the country, so that people may benefit from the lessons learned from these tragedies. With over 130 investigations and nearly 800 recommendations issued, the agency has sought to engage industry, unions, standards setting organizations, regulators, academia, and the American people in a collaborative effort to make the chemical industry safer, while maintaining economic productivity and protecting the jobs of workers in industrial facilities nationwide. The CSB has had an enormous impact on chemical safety with a staff of approximately 40 people and $11 million budget.
Here are some examples of our work.
Explosion at Fertilizer Storage Facility (West, Texas)
April 17, 2013
West Fertilizer Company
West, Texas
April 17, 2013
- 15 fatalities and 260+ injuries
- $230 million in insurance-related losses
- $16 million spent on Federal disaster assistance
- $1 million insurance policy held by West Fertilizer Company
On April 17, 2013, a massive explosion at the West Fertilizer Company (WFC), a fertilizer storage and distribution facility located in West, Texas, killed twelve first responders and three members of the public and caused more than 260 other injuries to first responders and the general public. Two of the fatally injured members of the public lived at a nearby apartment complex. The third lived at a nursing home and died shortly after the incident from injuries related to the trauma of the explosion.
The incident caused considerable property damage, including the complete destruction of the fertilizer facility, which was never rebuilt, leaving local farmers, ranchers and businesses without convenient access to needed products. The blast also caused extensive property damage beyond the facility. Two of the city’s school buildings had to be demolished and a third sustained major damage. Also destroyed were a nursing home, an apartment complex and numerous nearby homes. In a community of 700 homes, 350 (50%) were damaged as a result of the explosion, 142 (20%) of which were damaged beyond repair.
Total insurance-related losses from the explosion are estimated to be $230 million and federal disaster assistance is estimated to exceed $16 million. The company was only insured for $1 million, which fell far short of the incident’s damage.
CSB Findings and Recommendations:
- Failure by the insurer to identify the risks posed by fertilizer grade ammonium nitrate (FGAN). A few years prior to the incident, WFC was dropped by one insurer for failing to address safety concerns identified in loss control surveys. The company that insured WFC for $1 million at the time of the incident did not conduct its own safety inspections of the facility.
- The Federal Emergency Management Agency (FEMA) awarded two grants to develop FGAN training. The CSB found that there is no standardized training requirement that applies to volunteer firefighters across the nation. The CSB made a recommendation to FEMA to create a funding mechanism to provide training and curriculum develop for first responders at FGAN incidents. West Volunteer Fire Department did not conduct pre-incident planning or response training at WFC, was likely unaware of the potential for FGAN detonation and did not, nor were required, to have appropriate training in hazardous materials response.
- Gaps in federal and state regulations and standards. The CSB identified several gaps in federal and state regulations that could have reduced the consequences of the WFC disaster. These include the Occupational Safety and Health Administration’s Explosives and Blasting Agents and Process Safety Management standards, the Environmental Protection Agency’s Risk Management Program and Emergency Planning and Community Right-to-Know Act, and training provided or certified by the Texas Commission on Fire Protection and the State Firefighters’ and Fire Marshals’ Association of Texas.
- Local zoning and community planning. The location of the WFC relative to the surrounding community exacerbated the offsite consequences. The CSB found that at least 19 other Texas facilities storing more than 10,000 pounds of FGAN are located within a half-mile of a school, hospital, or nursing home, raising concerns that an incident with offsite consequences of this magnitude could happen again.
Refinery Explosion (Richmond, California)
August 6, 2012
Chevron Refinery
Richmond, California
August 6, 2012
- 15,000 people sought medical treatment
- $2 million in fines and restitution
- $447 million in increased gas prices passed onto California consumers1
On August 6, 2012, the Chevron Refinery in Richmond, California, experienced a catastrophic pipe failure in a crude unit, causing the release of flammable hydrocarbon process fluid which partially vaporized into a large cloud. Nineteen employees engulfed by the vapor cloud escaped, narrowly avoiding serious injury. The ignition and subsequent continued burning of hydrocarbons resulted in a large plume of unknown particulates and vapor. Approximately 15,000 people from the surrounding area sought medical treatment in the weeks following the incident. The CSB’s investigation found that the pipe failure was caused by sulfidation corrosion, a damage mechanism that causes piping walls to thin over time.
Although the company has never reported the decreased production capacity experienced as a result of the incident, the U.S. Energy Information Administration determined that the increase in gas prices cost California consumers approximately $447 million in six months following the incident.
Key Findings and Recommendations:
- Hazard analyses improved at all Chevron refineries in the U.S. The CSB investigation found that the hazard analysis conducted on the piping that failed did not identify corrosion as a potential cause of a leak or rupture. As a result, the CSB issued a recommendation to Chevron to perform damage mechanism hazard reviews (DMRs) on all of its process safety management (PSM) covered equipment and to incorporate the DMRs into their hazard review process at all its U.S. refineries. As a result of the CSB’s recommendation, Chevron has conducted DMRs at all of its U.S. refineries for PSM covered process piping circuits. If more companies were to adopt hazard review programs similar to Chevron’s, safety at refineries would be greatly increased.
- The California Department of Industrial Relations (DIR) revisions to the PSM regulation. Chevron conducted a hazard analysis of the crude unit as required by California’s Process Safety Management of Acutely Hazardous Materials (PSM) program; however, this does not require a formal damage mechanism hazard review to identify sulfidation corrosion. The CSB made several recommendations to improve California’s PSM program. Since 2014, DIR has published several drafts of a revised regulation and received and incorporated extensive stakeholder feedback. If the proposed regulation is approved, process safety in California’s refineries would be greatly improved and chemical safety would be advanced by better preventing major chemical incidents.
Deepwater Horizon/ Macondo Well Blowout (Gulf of Mexico)
April 20, 2010
Deepwater Horizon/Macondo Well Blowout
Gulf of Mexico
April 20, 2010
- $21 billion in settlements
- $13 billion in economic and medical claims
- 11 workers killed, 17 workers injured
- 4 million barrels of oil spilled
On April 20, 2010, a multiplefatality incident occurred at the Macondo oil well approximately 50 miles off the coast of Louisiana in the Gulf of Mexico during temporary well-abandonment activities on the Deepwater Horizon drilling rig. Control of the well was lost, resulting in a blowout—the uncontrolled release of hydrocarbons from the well. On the rig, the hydrocarbons found an ignition source and burst into flames. The resulting explosions and fire led to the deaths of 11 individuals, serious physical injuries to 17 others, evacuation of 115 individuals from the rig, the sinking of the Deepwater Horizon, and massive marine and coastal damage from a reported 4 million barrels of released hydrocarbons.
The operator of the rig, has paid out an estimated $13 billion worth of economic and medical claims as part of an uncapped settlement, in addition to a $20 billion settlement for federal, state and local government economic and environmental claims. Settlements involving other companies have reached $1.24 billion payout at the time of the completion of the CSB’s investigation. Other litigation remains pending.
CSB Findings and Recommendations:
- Blowout preventer (BOP) hazard not identified prior to Deepwater Horizon. Testing limitations masked latent failures of the Deepwater Horizon BOP, affecting its operation on the day of the incident, and these latent failures will continue to exist for similarly designed blowout preventers unless modifications are made to current standard industry testing protocols.
- Pipe buckling prevented drillpipe from working effectively. Pressure conditions in a well can cause drillpipe to buckle (or bend) in a BOP even after a crew has initially sealed a well, potentially incapacitating emergency functions of the BOP intended to cut drillpipe and seal the well.
- Safety-critical controls are necessary for hazard management. Major hazards require concerted efforts by industry to manage and actively monitor the safety-critical controls they rely on for the safe conduct of work, including improved incorporation of human factors, safety performance indicators, and corporate governance.
- Information sharing can be a challenge in offshore drilling. Obstacles continue to exist that limit sharing of lessons from incident investigations in individual companies and across both the operator/drilling contractor boundary and international geographical regions.
- Proper use of process safety indicators can prevent incidents. An equal focus and effort to collect, measure, and improve process safety performance indicators to that currently dedicated to personal safety statistics is necessary to reduce the potential for a major incident.
Texas City Refinery Explosion (Texas City, Texas)
March 23, 2005
BP Texas City
Texas City, Texas
March 23, 2005
- $1.5 billion in financial losses
- 15 workers killed
- 180 people injured
On March 23, 2005, a hydrocarbon isomerization unit (ISOM) exploded at the BP Texas City refinery in Texas City, Texas, resulting in financial losses of more than $1.5 billion. The incident killed 15 workers and injured 180 others. All of the fatalities and many serious injuries occurred in and around the nine temporary trailers sited as close as 121 feet from the ISOM unit. This refinery explosion was the most serious refinery incident ever investigated by the CSB. The CSB’s final investigative report into the incident found organizational and safety deficiencies at all levels of the BP Corporation. The report also noted gaps in standards and practices that likely contributed to other serious incidents over the previous decade.
CSB Findings and Recommendations:
- Trailer siting exacerbated the consequence of the BP Texas City explosion. All of the fatalities and many of the injuries occurred in or near a series of occupied trailers that were as close as 121 feet from the blowdown stack. In October 2005, the CSB issued an urgent recommendation to the American Petroleum Institute (API) to develop new guidance to prevent locating occupied trailers within hazardous areas of process plants.
- Blowdown drums should be replaced by safer alternatives. The CSB made a recommendation to API to eliminate the kind of blowdown drum that released the flammable liquid and vapor at BP. This 1950s-era equipment is unsafe, and many companies around the world have long since eliminated these systems and replaced them with inherently safer flare systems designed to handle a worst-case flammable release.
- A strong safety culture must be embraced at all levels of a corporation. The March 2005 incident was one of a long series of tragedies at the Texas City facility, where a total of 40 workers have died over 32 years. Internal audits revealed deteriorating conditions at the refinery over several years prior to 2005, but the responses focused primarily on improving personal safety and overlooked growing process safety risks.
- Process safety indicators help companies measure and improve process safety performance. The CSB recommended that API and the United Steelworkers develop a consensus standard for new process safety leading indicators to help businesses and government better assess these risks before serious incidents occur. Such leading indicators have been used for years in the nuclear power industry and provide a common method for different facilities to measure and compare system safety performance.
Conclusion
Based on the more than 130 incidents investigated by the CSB, it is clear that hundreds of billions of dollars have been spent as a result of chemical disasters in the United States. To make the safety of Americans our number one priority, it is critical that chemical safety lessons are learned and shared among diverse stakeholders across industries. If the CSB’s many safety lessons prevented at least one catastrophic incident, the money saved by preventing damage to the facility and surrounding community, avoiding legal settlements, and saving human lives far outweighs the agency’s $11 million annual budget. Safety and prosperity are compatible. Strong safety programs are critical for the economic success of the chemical and petrochemical industries. The CSB’s continued collaboration with industry, regulators, standards setting bodies and other professional organizations proves that the CSB has a vital role in driving critical chemical safety change in the United States.
References
1 Gonzales, Dan, Timothy Gulden, Aaron Strong and William Hoyle. Cost–Benefit Analysis of Proposed California Oil and Gas Refinery Regulations. Santa Monica, CA: RAND Corporation, 2016. http://www.rand.org/pubs/research_reports/RR1421.html. Also available in print form.
Data presented for each investigation was current at the time of the approval of the final report. The West Fertilizer Company report was released on January 28, 2016. The final Chevron Richmond refinery report was released on January 28, 2016. The final Deepwater Horizon/Macondo report was released on April 20, 2016. The BP Texas City report was released on March 20, 2007.
[content_transformed:protected] =>SAFETY IS GOOD BUSINESS AND GOOD PUBLIC POLICY
"There's an old saying that if you think safety is expensive, try an accident. Accidents cost a lot of money. And, not only in damage to [the] plant and in claims for injury, but also in the loss of the company's reputation." - Trevor Kletz
As an independent, non-regulatory safety agency, the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigates catastrophic chemical incidents and makes recommendations to prevent similar incidents from occurring. The CSB has found that most catastrophic chemical incidents could have been prevented. The agency conducts comprehensive, root cause analyses, examining all the causal or contributing factors. Our investigations have identified deficiencies in areas such as safety management systems, facility maintenance, regulatory requirements and training. In addition to identifying the causes of an incident, the CSB uncovers factors that exacerbate its consequences, contributing to loss of life and property, such as a lack of hazard awareness among emergency responders and insufficient community notification and planning.
The CSB’s vision is a nation safe from chemical disasters. The CSB has published nearly one hundred investigative reports and produced sixty-eight video products to communicate its safety messages to audiences across the country, so that people may benefit from the lessons learned from these tragedies. With over 130 investigations and nearly 800 recommendations issued, the agency has sought to engage industry, unions, standards setting organizations, regulators, academia, and the American people in a collaborative effort to make the chemical industry safer, while maintaining economic productivity and protecting the jobs of workers in industrial facilities nationwide. The CSB has had an enormous impact on chemical safety with a staff of approximately 40 people and $11 million budget.
Here are some examples of our work.
Explosion at Fertilizer Storage Facility (West, Texas)
April 17, 2013
West Fertilizer Company
West, Texas
April 17, 2013
- 15 fatalities and 260+ injuries
- $230 million in insurance-related losses
- $16 million spent on Federal disaster assistance
- $1 million insurance policy held by West Fertilizer Company
On April 17, 2013, a massive explosion at the West Fertilizer Company (WFC), a fertilizer storage and distribution facility located in West, Texas, killed twelve first responders and three members of the public and caused more than 260 other injuries to first responders and the general public. Two of the fatally injured members of the public lived at a nearby apartment complex. The third lived at a nursing home and died shortly after the incident from injuries related to the trauma of the explosion.
The incident caused considerable property damage, including the complete destruction of the fertilizer facility, which was never rebuilt, leaving local farmers, ranchers and businesses without convenient access to needed products. The blast also caused extensive property damage beyond the facility. Two of the city’s school buildings had to be demolished and a third sustained major damage. Also destroyed were a nursing home, an apartment complex and numerous nearby homes. In a community of 700 homes, 350 (50%) were damaged as a result of the explosion, 142 (20%) of which were damaged beyond repair.
Total insurance-related losses from the explosion are estimated to be $230 million and federal disaster assistance is estimated to exceed $16 million. The company was only insured for $1 million, which fell far short of the incident’s damage.
CSB Findings and Recommendations:
- Failure by the insurer to identify the risks posed by fertilizer grade ammonium nitrate (FGAN). A few years prior to the incident, WFC was dropped by one insurer for failing to address safety concerns identified in loss control surveys. The company that insured WFC for $1 million at the time of the incident did not conduct its own safety inspections of the facility.
- The Federal Emergency Management Agency (FEMA) awarded two grants to develop FGAN training. The CSB found that there is no standardized training requirement that applies to volunteer firefighters across the nation. The CSB made a recommendation to FEMA to create a funding mechanism to provide training and curriculum develop for first responders at FGAN incidents. West Volunteer Fire Department did not conduct pre-incident planning or response training at WFC, was likely unaware of the potential for FGAN detonation and did not, nor were required, to have appropriate training in hazardous materials response.
- Gaps in federal and state regulations and standards. The CSB identified several gaps in federal and state regulations that could have reduced the consequences of the WFC disaster. These include the Occupational Safety and Health Administration’s Explosives and Blasting Agents and Process Safety Management standards, the Environmental Protection Agency’s Risk Management Program and Emergency Planning and Community Right-to-Know Act, and training provided or certified by the Texas Commission on Fire Protection and the State Firefighters’ and Fire Marshals’ Association of Texas.
- Local zoning and community planning. The location of the WFC relative to the surrounding community exacerbated the offsite consequences. The CSB found that at least 19 other Texas facilities storing more than 10,000 pounds of FGAN are located within a half-mile of a school, hospital, or nursing home, raising concerns that an incident with offsite consequences of this magnitude could happen again.
Refinery Explosion (Richmond, California)
August 6, 2012
Chevron Refinery
Richmond, California
August 6, 2012
- 15,000 people sought medical treatment
- $2 million in fines and restitution
- $447 million in increased gas prices passed onto California consumers1
On August 6, 2012, the Chevron Refinery in Richmond, California, experienced a catastrophic pipe failure in a crude unit, causing the release of flammable hydrocarbon process fluid which partially vaporized into a large cloud. Nineteen employees engulfed by the vapor cloud escaped, narrowly avoiding serious injury. The ignition and subsequent continued burning of hydrocarbons resulted in a large plume of unknown particulates and vapor. Approximately 15,000 people from the surrounding area sought medical treatment in the weeks following the incident. The CSB’s investigation found that the pipe failure was caused by sulfidation corrosion, a damage mechanism that causes piping walls to thin over time.
Although the company has never reported the decreased production capacity experienced as a result of the incident, the U.S. Energy Information Administration determined that the increase in gas prices cost California consumers approximately $447 million in six months following the incident.
Key Findings and Recommendations:
- Hazard analyses improved at all Chevron refineries in the U.S. The CSB investigation found that the hazard analysis conducted on the piping that failed did not identify corrosion as a potential cause of a leak or rupture. As a result, the CSB issued a recommendation to Chevron to perform damage mechanism hazard reviews (DMRs) on all of its process safety management (PSM) covered equipment and to incorporate the DMRs into their hazard review process at all its U.S. refineries. As a result of the CSB’s recommendation, Chevron has conducted DMRs at all of its U.S. refineries for PSM covered process piping circuits. If more companies were to adopt hazard review programs similar to Chevron’s, safety at refineries would be greatly increased.
- The California Department of Industrial Relations (DIR) revisions to the PSM regulation. Chevron conducted a hazard analysis of the crude unit as required by California’s Process Safety Management of Acutely Hazardous Materials (PSM) program; however, this does not require a formal damage mechanism hazard review to identify sulfidation corrosion. The CSB made several recommendations to improve California’s PSM program. Since 2014, DIR has published several drafts of a revised regulation and received and incorporated extensive stakeholder feedback. If the proposed regulation is approved, process safety in California’s refineries would be greatly improved and chemical safety would be advanced by better preventing major chemical incidents.
Deepwater Horizon/ Macondo Well Blowout (Gulf of Mexico)
April 20, 2010
Deepwater Horizon/Macondo Well Blowout
Gulf of Mexico
April 20, 2010
- $21 billion in settlements
- $13 billion in economic and medical claims
- 11 workers killed, 17 workers injured
- 4 million barrels of oil spilled
On April 20, 2010, a multiplefatality incident occurred at the Macondo oil well approximately 50 miles off the coast of Louisiana in the Gulf of Mexico during temporary well-abandonment activities on the Deepwater Horizon drilling rig. Control of the well was lost, resulting in a blowout—the uncontrolled release of hydrocarbons from the well. On the rig, the hydrocarbons found an ignition source and burst into flames. The resulting explosions and fire led to the deaths of 11 individuals, serious physical injuries to 17 others, evacuation of 115 individuals from the rig, the sinking of the Deepwater Horizon, and massive marine and coastal damage from a reported 4 million barrels of released hydrocarbons.
The operator of the rig, has paid out an estimated $13 billion worth of economic and medical claims as part of an uncapped settlement, in addition to a $20 billion settlement for federal, state and local government economic and environmental claims. Settlements involving other companies have reached $1.24 billion payout at the time of the completion of the CSB’s investigation. Other litigation remains pending.
CSB Findings and Recommendations:
- Blowout preventer (BOP) hazard not identified prior to Deepwater Horizon. Testing limitations masked latent failures of the Deepwater Horizon BOP, affecting its operation on the day of the incident, and these latent failures will continue to exist for similarly designed blowout preventers unless modifications are made to current standard industry testing protocols.
- Pipe buckling prevented drillpipe from working effectively. Pressure conditions in a well can cause drillpipe to buckle (or bend) in a BOP even after a crew has initially sealed a well, potentially incapacitating emergency functions of the BOP intended to cut drillpipe and seal the well.
- Safety-critical controls are necessary for hazard management. Major hazards require concerted efforts by industry to manage and actively monitor the safety-critical controls they rely on for the safe conduct of work, including improved incorporation of human factors, safety performance indicators, and corporate governance.
- Information sharing can be a challenge in offshore drilling. Obstacles continue to exist that limit sharing of lessons from incident investigations in individual companies and across both the operator/drilling contractor boundary and international geographical regions.
- Proper use of process safety indicators can prevent incidents. An equal focus and effort to collect, measure, and improve process safety performance indicators to that currently dedicated to personal safety statistics is necessary to reduce the potential for a major incident.
Texas City Refinery Explosion (Texas City, Texas)
March 23, 2005
BP Texas City
Texas City, Texas
March 23, 2005
- $1.5 billion in financial losses
- 15 workers killed
- 180 people injured
On March 23, 2005, a hydrocarbon isomerization unit (ISOM) exploded at the BP Texas City refinery in Texas City, Texas, resulting in financial losses of more than $1.5 billion. The incident killed 15 workers and injured 180 others. All of the fatalities and many serious injuries occurred in and around the nine temporary trailers sited as close as 121 feet from the ISOM unit. This refinery explosion was the most serious refinery incident ever investigated by the CSB. The CSB’s final investigative report into the incident found organizational and safety deficiencies at all levels of the BP Corporation. The report also noted gaps in standards and practices that likely contributed to other serious incidents over the previous decade.
CSB Findings and Recommendations:
- Trailer siting exacerbated the consequence of the BP Texas City explosion. All of the fatalities and many of the injuries occurred in or near a series of occupied trailers that were as close as 121 feet from the blowdown stack. In October 2005, the CSB issued an urgent recommendation to the American Petroleum Institute (API) to develop new guidance to prevent locating occupied trailers within hazardous areas of process plants.
- Blowdown drums should be replaced by safer alternatives. The CSB made a recommendation to API to eliminate the kind of blowdown drum that released the flammable liquid and vapor at BP. This 1950s-era equipment is unsafe, and many companies around the world have long since eliminated these systems and replaced them with inherently safer flare systems designed to handle a worst-case flammable release.
- A strong safety culture must be embraced at all levels of a corporation. The March 2005 incident was one of a long series of tragedies at the Texas City facility, where a total of 40 workers have died over 32 years. Internal audits revealed deteriorating conditions at the refinery over several years prior to 2005, but the responses focused primarily on improving personal safety and overlooked growing process safety risks.
- Process safety indicators help companies measure and improve process safety performance. The CSB recommended that API and the United Steelworkers develop a consensus standard for new process safety leading indicators to help businesses and government better assess these risks before serious incidents occur. Such leading indicators have been used for years in the nuclear power industry and provide a common method for different facilities to measure and compare system safety performance.
Conclusion
Based on the more than 130 incidents investigated by the CSB, it is clear that hundreds of billions of dollars have been spent as a result of chemical disasters in the United States. To make the safety of Americans our number one priority, it is critical that chemical safety lessons are learned and shared among diverse stakeholders across industries. If the CSB’s many safety lessons prevented at least one catastrophic incident, the money saved by preventing damage to the facility and surrounding community, avoiding legal settlements, and saving human lives far outweighs the agency’s $11 million annual budget. Safety and prosperity are compatible. Strong safety programs are critical for the economic success of the chemical and petrochemical industries. The CSB’s continued collaboration with industry, regulators, standards setting bodies and other professional organizations proves that the CSB has a vital role in driving critical chemical safety change in the United States.
References
1 Gonzales, Dan, Timothy Gulden, Aaron Strong and William Hoyle. Cost–Benefit Analysis of Proposed California Oil and Gas Refinery Regulations. Santa Monica, CA: RAND Corporation, 2016. http://www.rand.org/pubs/research_reports/RR1421.html. Also available in print form.
Data presented for each investigation was current at the time of the approval of the final report. The West Fertilizer Company report was released on January 28, 2016. The final Chevron Richmond refinery report was released on January 28, 2016. The final Deepwater Horizon/Macondo report was released on April 20, 2016. The BP Texas City report was released on March 20, 2007.
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The resource includes a case example, steps to prevent a related injury, and questions for discussion. It includes a graphic that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely. Available in English and Spanish. 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The recall is a result of... 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[files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 4426 [old_id:protected] => [elcosh_id:protected] => d001656 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 0 [language_id:protected] => 1 [tagging_id:protected] => Mike Aguilar [priority_id:protected] => 1 [title:protected] => Construction Dive -- DeWalt's Jobsite Pro headphones recalled for fire hazards [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => DeWalt, Fire Hazards, recall, headphones [comments:protected] => [summary:protected] => A recall notice by the United States Consumer Product Safety Commission affects over 300,000 DeWalt Jobsite Pro Headphones. The recall is a result of a malfunction that can cause earbuds to overheat while charging or during use, leading to fire and burn hazards. [transition_comments:protected] => [external_link:protected] => https://www.constructiondive.com/news/dewalts-jobsite-pro-headphones-recalled-for-fire-hazards/611248/?utm_source=Sailthru&utm_medium=email&utm_campaign=Issue:%202021-12-10%20Construction%20Dive%20Newsletter%20%5Bissue:38532%5D&utm_term=Construction%20Dive [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/13/21 [date_completed:protected] => 12/13/21 [date_billed:protected] => [date_modified:protected] => 12/13/21 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [2] => Search_Result Object ( [title] => Working in an Enclosed Cab [image] => /record/images/notavailable-p.png [blurb] => This CPWR Hazard Alert on Working in enclosed cabs provides information on protecting workers from silica dust, how to minimize exposures and the dang... 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workplace, OSHA, silicosis, mining, silica, DOE, EEOICPA, labor, lung, CBD, dust, cab, miner, mine [comments:protected] => [summary:protected] => This CPWR Hazard Alert on Working in enclosed cabs provides information on protecting workers from silica dust, how to minimize exposures and the dangers of silica dust. Click on the following links to access the English version and the Spanish version. 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The resource includes a brief case example... 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[modifiedColumns:protected] => Array ( ) ) [20] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 20 [type:protected] => category [parent:protected] => 7 [label:protected] => Safety Culture [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [23] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 23 [type:protected] => category [parent:protected] => 7 [label:protected] => Stress & Overtime [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [40] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 40 [type:protected] => category [parent:protected] => 9 [label:protected] => Overexertion [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [44] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 44 [type:protected] => category [parent:protected] => 2 [label:protected] => Acoustical Ceiling Carpenter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [45] => Category Object ( [languages:protected] => [bok_resources:protected] => 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[type:protected] => category [parent:protected] => 2 [label:protected] => Bricklayer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [48] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 48 [type:protected] => category [parent:protected] => 2 [label:protected] => Cabinetmaker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [49] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 49 [type:protected] => category [parent:protected] => 2 [label:protected] => Carpenter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [50] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 50 [type:protected] => category [parent:protected] => 2 [label:protected] => Carpet Layer [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [51] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 51 [type:protected] => category [parent:protected] => 2 [label:protected] => Cement Mason [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [52] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 52 [type:protected] => category [parent:protected] => 2 [label:protected] => Commercial Diver [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [53] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 53 [type:protected] => category [parent:protected] => 2 [label:protected] => Concrete Polisher [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => 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Array ( ) ) [56] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 56 [type:protected] => category [parent:protected] => 2 [label:protected] => Elevator Constructor [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [57] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 57 [type:protected] => category [parent:protected] => 2 [label:protected] => Flagger [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [58] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 58 [type:protected] => category [parent:protected] => 2 [label:protected] => Glazier [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [59] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 59 [type:protected] => category [parent:protected] => 2 [label:protected] => Hazardous Waste Cleanup [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [60] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 60 [type:protected] => category [parent:protected] => 2 [label:protected] => HVAC [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [61] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 61 [type:protected] => category [parent:protected] => 2 [label:protected] => Interior Systems Carpenter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [64] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 64 [type:protected] => category [parent:protected] => 2 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[validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [67] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 67 [type:protected] => category [parent:protected] => 2 [label:protected] => Lead Abatement Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [68] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 68 [type:protected] => category [parent:protected] => 2 [label:protected] => Maintenance Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => 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Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 71 [type:protected] => category [parent:protected] => 2 [label:protected] => Painter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [72] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 72 [type:protected] => category [parent:protected] => 2 [label:protected] => Paper Hanger [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [73] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] 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=> [summary:protected] =>The CPWR Toolbox Talk on Suicide Prevention addresses the prevalence of suicide among construction workers. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely.
Available in English and Spanish. 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dust, exposure, air purifier, enclosed cab, vehicle [comments:protected] => [summary:protected] =>
The CPWR Toolbox Talk on Preventing Exposure to Silica Dust in Enclosed Cabs addresses the risks associated with breathing in silica dust and silicosis. The resource includes a brief case example, steps to prevent a related injury or illness, and questions for discussion. It includes an image that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely.
Available in English and Spanish. 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The supports for the counterweight must be designed with a safety factor of four. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/task/Erect%2Band%2Bdismantle%2Bscaffolds/ [more_like_this:protected] => d000244,d000359,i000253,i000407 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => jpg [img_width:protected] => [img_height:protected] => [img_credit:protected] => MetroPark, Miller and Long [img_practice:protected] => not_applicable [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => August 28 2015 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 08/28/15 [date_completed:protected] => 08/28/15 [date_billed:protected] => [date_modified:protected] => 08/28/15 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [4] => Search_Result Object ( [title] => Suspended scaffold [image] => /record/images/3976-p.jpg [blurb] => Suspended scaffold outrigger beams must have stops to prevent the hangers from sliding of the end of the outriggers. Wire rope supported must be desig... 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Wire rope supported must be designed with a safety factor of 6. The scaffold must be inspected by a competent person daily. 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This is accomplish... 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This is accomplished by setting swing restrictions, marking the ground for allowable crane travel and training of the crane signal persons. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/work/6/184/ [more_like_this:protected] => d001029, d000010, i001280, i001221 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => jpg [img_width:protected] => [img_height:protected] => [img_credit:protected] => Metropark [img_practice:protected] => not_applicable [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => August 28 2015 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 08/28/15 [date_completed:protected] => 08/28/15 [date_billed:protected] => [date_modified:protected] => 08/28/15 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) ) [preview_mode] => [description] => The U.S. Chemical Safety Board is an independent, non-regulatory safety agency that investigates chemical incidents and makes recommendations to prevent similar incidents from occurring. This short report is a summary of the lessons from several of the most catastrophic incidents the CSB has investigated. The CSB found common deficiencies in safety management systems, facility maintenance, adequacy of regulations, training. poor hazard awareness among emergency responders and insufficient community notification and planning. The specific incidents reviewed include the West, Texas fertilizer plant explosion, the Deep Water Horizon explosion, and the Richmond California refinery explosion. There is an infographic that accompanies this report: https://www.aiha.org/publications-and-resources/TheSynergist/Digital%20Synergist%20Images/201707-bythenumbers.jpg [keywords] => Chemical Safety Board, CSB, explosion, chemical incidents, disasters, investigation [related_items] => Array ( [Handouts] => Array ( [0] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 4275 [old_id:protected] => [elcosh_id:protected] => d001552 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 29 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => CSB Infographic about chemical-related incidents [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, CSB, explosion, fires, industrial accidents [comments:protected] => [summary:protected] => This infographic by the Chemical Safety Board shows the enormous cost in lives, injuries and money this nation has experienced from the industrial incidents at the BP Texas City Refinery, BP's Deepwater Horizon, Chevron's Richmond Refinery and the West Fertilizer Company facility in West, Texas. This graphic accompanies the CSB report, "The Business Case for Safety." [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/pipes_vessels/hazard/1643/work-inside-vessels-confined-space.html [more_like_this:protected] => d001174,d001206,d000443 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => png [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => 2017 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/20/17 [date_completed:protected] => 12/22/17 [date_billed:protected] => [date_modified:protected] => 12/22/17 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [1] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 3664 [old_id:protected] => [elcosh_id:protected] => d001206 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 24 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => OSHA FactSheet, Hazard Alert: Combustible Dust Explosions [total_pages:protected] => 2 [billed_pages:protected] => 2 [publication_number:protected] => DSG 3/2008 [part_of:protected] => [keywords:protected] => Combustible dusts, ignition source, settled dust, explosion, dust explosion, secondary explosion [comments:protected] => Two links were present in the consol link field thus creating a broken link. Only one link can be present in this field. I left the first of the two links in the field and removed http://www.cpwrconstructionsolutions.org/carpentry/hazard/1189/cut-boards-and-panels-wood-dust.html [summary:protected] => Combustible dusts are fine particles that present an explosion hazard when suspended in air in certain conditions. A dust explosion can be catastrophic and cause employee deaths, injuries, and destruction of entire buildings. OSHA notes that in many combustible dust accidents, employers and employees were unaware that a hazard even existed. In this FactSheet, OSHA helps employers and workers to determine if this hazard is present and what actions are needed to prevent tragic consequences. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/hazard/792/construction-dust.html [more_like_this:protected] => d000966 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => jpg [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => March 2008 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 04/17/13 [date_completed:protected] => 04/29/13 [date_billed:protected] => [date_modified:protected] => 06/04/13 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [News Articles] => Array ( [0] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 3608 [old_id:protected] => [elcosh_id:protected] => d001174 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 2 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => U.S. Chemical Safety Board Receives Awards for Videos [total_pages:protected] => 1 [billed_pages:protected] => 0 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, explosion, fire, dust explosion, process safety [comments:protected] => This should be placed in the What's New section. Note from Chris: As this was selected as an external link the billable pages were 0. Bruce, in the more like this field, you may want to enter in the ID's of the CSB videos we have in the database. [summary:protected] => The U.S. Chemical Safety Board (CSB) was named the recipient of three Peer Awards from the Television, Internet and Video Association of D.C. (TIVA) for safety videos produced in 2012. Videos on an academic laboratory explosion in Lubbock, Texas, and a flammable vapor explosion near Buffalo, New York, received bronze awards, while a video on a string of dust flash fires at a Tennessee metal powder production company received a silver award. CSB safety videos cover specific incidents investigated by the CSB and include excellent animations. Trainers who don't already used these videos in their health and safety training should check out the site. These free videos represent some of the best training resources available. [transition_comments:protected] => [external_link:protected] => http://www.csb.gov/newsroom/detail.aspx?nid=440 [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => November 2012 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 11/23/12 [date_completed:protected] => 12/17/12 [date_billed:protected] => [date_modified:protected] => 12/17/12 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [1] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 1311 [old_id:protected] => 449 [elcosh_id:protected] => d000443 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => [language_id:protected] => 1 [tagging_id:protected] => Sharon Garber/COD [priority_id:protected] => 1 [title:protected] => Preventing Construction Fires [total_pages:protected] => 5 [billed_pages:protected] => 5 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Occupation, construction, safety, health, hazards, work, worker, workplace, fire, housekeeping, flammable, storage, electical, program [comments:protected] => [summary:protected] => Discusses the typical causes of fires, such as poor housekeeping and careless smoking and provides suggestions on how to prevent them. [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => [more_like_this:protected] => d000372, d000860, d001065 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => Feb 2001 [date_permission_requested:protected] => 03/01/01 [date_permission_received:protected] => 03/20/01 [date_review_needed:protected] => [date_received:protected] => 04/11/01 [date_completed:protected] => 04/25/01 [date_billed:protected] => 05/01/01 [date_modified:protected] => 05/08/12 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) ) [collections] => Array ( [4277] => ) [record] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => Array ( ) [organizations:protected] => Array ( [314] => Organization Object ( [id:protected] => 314 [elcosh_id:protected] => o001237 [user_id:protected] => 0 [province_id:protected] => 0 [country_id:protected] => 0 [title:protected] => U.S. Chemical Safety Board [address:protected] => [postal_code:protected] => [city:protected] => [department:protected] => [phone:protected] => [fax:protected] => [email:protected] => [website:protected] => [filename:protected] => [about:protected] => [comments:protected] => [logo_available:protected] => F [no_details:protected] => F [date_received:protected] => [date_completed:protected] => [date_billed:protected] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [collections:protected] => Array ( [4277] => ) [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => Array ( [4275] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => [old_record:protected] => [id:protected] => 4275 [old_id:protected] => [elcosh_id:protected] => d001552 [type:protected] => document [display_type:protected] => HTML w/ PDF [user_id:protected] => 29 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => CSB Infographic about chemical-related incidents [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, CSB, explosion, fires, industrial accidents [comments:protected] => [summary:protected] => This infographic by the Chemical Safety Board shows the enormous cost in lives, injuries and money this nation has experienced from the industrial incidents at the BP Texas City Refinery, BP's Deepwater Horizon, Chevron's Richmond Refinery and the West Fertilizer Company facility in West, Texas. This graphic accompanies the CSB report, "The Business Case for Safety." [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/pipes_vessels/hazard/1643/work-inside-vessels-confined-space.html [more_like_this:protected] => d001174,d001206,d000443 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => png [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => 2017 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/20/17 [date_completed:protected] => 12/22/17 [date_billed:protected] => [date_modified:protected] => 12/22/17 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [3608] => DocumentRecord Object ( [records:protected] => Array ( ) [recordId:protected] => [searchWordClass:protected] => [searchWordPeerClass:protected] => [bok_record:protected] => [authors:protected] => [organizations:protected] => [collections:protected] => [categories:protected] => [categories_initialized:protected] => [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => [old_record:protected] => [id:protected] => 3608 [old_id:protected] => [elcosh_id:protected] => d001174 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 2 [language_id:protected] => 1 [tagging_id:protected] => Bruce Lippy [priority_id:protected] => 1 [title:protected] => U.S. Chemical Safety Board Receives Awards for Videos [total_pages:protected] => 1 [billed_pages:protected] => 0 [publication_number:protected] => [part_of:protected] => [keywords:protected] => Chemical Safety Board, explosion, fire, dust explosion, process safety [comments:protected] => This should be placed in the What's New section. Note from Chris: As this was selected as an external link the billable pages were 0. Bruce, in the more like this field, you may want to enter in the ID's of the CSB videos we have in the database. [summary:protected] => The U.S. Chemical Safety Board (CSB) was named the recipient of three Peer Awards from the Television, Internet and Video Association of D.C. (TIVA) for safety videos produced in 2012. Videos on an academic laboratory explosion in Lubbock, Texas, and a flammable vapor explosion near Buffalo, New York, received bronze awards, while a video on a string of dust flash fires at a Tennessee metal powder production company received a silver award. CSB safety videos cover specific incidents investigated by the CSB and include excellent animations. Trainers who don't already used these videos in their health and safety training should check out the site. These free videos represent some of the best training resources available. 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Only one link can be present in this field. I left the first of the two links in the field and removed http://www.cpwrconstructionsolutions.org/carpentry/hazard/1189/cut-boards-and-panels-wood-dust.html [summary:protected] => Combustible dusts are fine particles that present an explosion hazard when suspended in air in certain conditions. A dust explosion can be catastrophic and cause employee deaths, injuries, and destruction of entire buildings. OSHA notes that in many combustible dust accidents, employers and employees were unaware that a hazard even existed. In this FactSheet, OSHA helps employers and workers to determine if this hazard is present and what actions are needed to prevent tragic consequences. 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This short report is a summary of the lessons from several of the most catastrophic incidents the CSB has investigated. The CSB found common deficiencies in safety management systems, facility maintenance, adequacy of regulations, training. poor hazard awareness among emergency responders and insufficient community notification and planning. The specific incidents reviewed include the West, Texas fertilizer plant explosion, the Deep Water Horizon explosion, and the Richmond California refinery explosion. There is an infographic that accompanies this report: https://www.aiha.org/publications-and-resources/TheSynergist/Digital%20Synergist%20Images/201707-bythenumbers.jpg [transition_comments:protected] => [external_link:protected] => [consol_link:protected] => http://www.cpwrconstructionsolutions.org/pipes_vessels/hazard/1643/work-inside-vessels-confined-space.html [more_like_this:protected] => d001552,d001174,d001206,d000443 [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => png [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => 2017 [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/21/17 [date_completed:protected] => 12/22/17 [date_billed:protected] => [date_modified:protected] => 12/22/17 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [show_text] => [document_content] => ElcoshItemDocumentContent Object ( [id:protected] => 3053 [item_id:protected] => 4276 [type:protected] => main [title:protected] => [content:protected] =>
SAFETY IS GOOD BUSINESS AND GOOD PUBLIC POLICY
"There's an old saying that if you think safety is expensive, try an accident. Accidents cost a lot of money. And, not only in damage to [the] plant and in claims for injury, but also in the loss of the company's reputation." - Trevor Kletz
As an independent, non-regulatory safety agency, the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigates catastrophic chemical incidents and makes recommendations to prevent similar incidents from occurring. The CSB has found that most catastrophic chemical incidents could have been prevented. The agency conducts comprehensive, root cause analyses, examining all the causal or contributing factors. Our investigations have identified deficiencies in areas such as safety management systems, facility maintenance, regulatory requirements and training. In addition to identifying the causes of an incident, the CSB uncovers factors that exacerbate its consequences, contributing to loss of life and property, such as a lack of hazard awareness among emergency responders and insufficient community notification and planning.
The CSB’s vision is a nation safe from chemical disasters. The CSB has published nearly one hundred investigative reports and produced sixty-eight video products to communicate its safety messages to audiences across the country, so that people may benefit from the lessons learned from these tragedies. With over 130 investigations and nearly 800 recommendations issued, the agency has sought to engage industry, unions, standards setting organizations, regulators, academia, and the American people in a collaborative effort to make the chemical industry safer, while maintaining economic productivity and protecting the jobs of workers in industrial facilities nationwide. The CSB has had an enormous impact on chemical safety with a staff of approximately 40 people and $11 million budget.
Here are some examples of our work.
Explosion at Fertilizer Storage Facility (West, Texas)
April 17, 2013
West Fertilizer Company
West, Texas
April 17, 2013
- 15 fatalities and 260+ injuries
- $230 million in insurance-related losses
- $16 million spent on Federal disaster assistance
- $1 million insurance policy held by West Fertilizer Company
On April 17, 2013, a massive explosion at the West Fertilizer Company (WFC), a fertilizer storage and distribution facility located in West, Texas, killed twelve first responders and three members of the public and caused more than 260 other injuries to first responders and the general public. Two of the fatally injured members of the public lived at a nearby apartment complex. The third lived at a nursing home and died shortly after the incident from injuries related to the trauma of the explosion.
The incident caused considerable property damage, including the complete destruction of the fertilizer facility, which was never rebuilt, leaving local farmers, ranchers and businesses without convenient access to needed products. The blast also caused extensive property damage beyond the facility. Two of the city’s school buildings had to be demolished and a third sustained major damage. Also destroyed were a nursing home, an apartment complex and numerous nearby homes. In a community of 700 homes, 350 (50%) were damaged as a result of the explosion, 142 (20%) of which were damaged beyond repair.
Total insurance-related losses from the explosion are estimated to be $230 million and federal disaster assistance is estimated to exceed $16 million. The company was only insured for $1 million, which fell far short of the incident’s damage.
CSB Findings and Recommendations:
- Failure by the insurer to identify the risks posed by fertilizer grade ammonium nitrate (FGAN). A few years prior to the incident, WFC was dropped by one insurer for failing to address safety concerns identified in loss control surveys. The company that insured WFC for $1 million at the time of the incident did not conduct its own safety inspections of the facility.
- The Federal Emergency Management Agency (FEMA) awarded two grants to develop FGAN training. The CSB found that there is no standardized training requirement that applies to volunteer firefighters across the nation. The CSB made a recommendation to FEMA to create a funding mechanism to provide training and curriculum develop for first responders at FGAN incidents. West Volunteer Fire Department did not conduct pre-incident planning or response training at WFC, was likely unaware of the potential for FGAN detonation and did not, nor were required, to have appropriate training in hazardous materials response.
- Gaps in federal and state regulations and standards. The CSB identified several gaps in federal and state regulations that could have reduced the consequences of the WFC disaster. These include the Occupational Safety and Health Administration’s Explosives and Blasting Agents and Process Safety Management standards, the Environmental Protection Agency’s Risk Management Program and Emergency Planning and Community Right-to-Know Act, and training provided or certified by the Texas Commission on Fire Protection and the State Firefighters’ and Fire Marshals’ Association of Texas.
- Local zoning and community planning. The location of the WFC relative to the surrounding community exacerbated the offsite consequences. The CSB found that at least 19 other Texas facilities storing more than 10,000 pounds of FGAN are located within a half-mile of a school, hospital, or nursing home, raising concerns that an incident with offsite consequences of this magnitude could happen again.
Refinery Explosion (Richmond, California)
August 6, 2012
Chevron Refinery
Richmond, California
August 6, 2012
- 15,000 people sought medical treatment
- $2 million in fines and restitution
- $447 million in increased gas prices passed onto California consumers1
On August 6, 2012, the Chevron Refinery in Richmond, California, experienced a catastrophic pipe failure in a crude unit, causing the release of flammable hydrocarbon process fluid which partially vaporized into a large cloud. Nineteen employees engulfed by the vapor cloud escaped, narrowly avoiding serious injury. The ignition and subsequent continued burning of hydrocarbons resulted in a large plume of unknown particulates and vapor. Approximately 15,000 people from the surrounding area sought medical treatment in the weeks following the incident. The CSB’s investigation found that the pipe failure was caused by sulfidation corrosion, a damage mechanism that causes piping walls to thin over time.
Although the company has never reported the decreased production capacity experienced as a result of the incident, the U.S. Energy Information Administration determined that the increase in gas prices cost California consumers approximately $447 million in six months following the incident.
Key Findings and Recommendations:
- Hazard analyses improved at all Chevron refineries in the U.S. The CSB investigation found that the hazard analysis conducted on the piping that failed did not identify corrosion as a potential cause of a leak or rupture. As a result, the CSB issued a recommendation to Chevron to perform damage mechanism hazard reviews (DMRs) on all of its process safety management (PSM) covered equipment and to incorporate the DMRs into their hazard review process at all its U.S. refineries. As a result of the CSB’s recommendation, Chevron has conducted DMRs at all of its U.S. refineries for PSM covered process piping circuits. If more companies were to adopt hazard review programs similar to Chevron’s, safety at refineries would be greatly increased.
- The California Department of Industrial Relations (DIR) revisions to the PSM regulation. Chevron conducted a hazard analysis of the crude unit as required by California’s Process Safety Management of Acutely Hazardous Materials (PSM) program; however, this does not require a formal damage mechanism hazard review to identify sulfidation corrosion. The CSB made several recommendations to improve California’s PSM program. Since 2014, DIR has published several drafts of a revised regulation and received and incorporated extensive stakeholder feedback. If the proposed regulation is approved, process safety in California’s refineries would be greatly improved and chemical safety would be advanced by better preventing major chemical incidents.
Deepwater Horizon/ Macondo Well Blowout (Gulf of Mexico)
April 20, 2010
Deepwater Horizon/Macondo Well Blowout
Gulf of Mexico
April 20, 2010
- $21 billion in settlements
- $13 billion in economic and medical claims
- 11 workers killed, 17 workers injured
- 4 million barrels of oil spilled
On April 20, 2010, a multiplefatality incident occurred at the Macondo oil well approximately 50 miles off the coast of Louisiana in the Gulf of Mexico during temporary well-abandonment activities on the Deepwater Horizon drilling rig. Control of the well was lost, resulting in a blowout—the uncontrolled release of hydrocarbons from the well. On the rig, the hydrocarbons found an ignition source and burst into flames. The resulting explosions and fire led to the deaths of 11 individuals, serious physical injuries to 17 others, evacuation of 115 individuals from the rig, the sinking of the Deepwater Horizon, and massive marine and coastal damage from a reported 4 million barrels of released hydrocarbons.
The operator of the rig, has paid out an estimated $13 billion worth of economic and medical claims as part of an uncapped settlement, in addition to a $20 billion settlement for federal, state and local government economic and environmental claims. Settlements involving other companies have reached $1.24 billion payout at the time of the completion of the CSB’s investigation. Other litigation remains pending.
CSB Findings and Recommendations:
- Blowout preventer (BOP) hazard not identified prior to Deepwater Horizon. Testing limitations masked latent failures of the Deepwater Horizon BOP, affecting its operation on the day of the incident, and these latent failures will continue to exist for similarly designed blowout preventers unless modifications are made to current standard industry testing protocols.
- Pipe buckling prevented drillpipe from working effectively. Pressure conditions in a well can cause drillpipe to buckle (or bend) in a BOP even after a crew has initially sealed a well, potentially incapacitating emergency functions of the BOP intended to cut drillpipe and seal the well.
- Safety-critical controls are necessary for hazard management. Major hazards require concerted efforts by industry to manage and actively monitor the safety-critical controls they rely on for the safe conduct of work, including improved incorporation of human factors, safety performance indicators, and corporate governance.
- Information sharing can be a challenge in offshore drilling. Obstacles continue to exist that limit sharing of lessons from incident investigations in individual companies and across both the operator/drilling contractor boundary and international geographical regions.
- Proper use of process safety indicators can prevent incidents. An equal focus and effort to collect, measure, and improve process safety performance indicators to that currently dedicated to personal safety statistics is necessary to reduce the potential for a major incident.
Texas City Refinery Explosion (Texas City, Texas)
March 23, 2005
BP Texas City
Texas City, Texas
March 23, 2005
- $1.5 billion in financial losses
- 15 workers killed
- 180 people injured
On March 23, 2005, a hydrocarbon isomerization unit (ISOM) exploded at the BP Texas City refinery in Texas City, Texas, resulting in financial losses of more than $1.5 billion. The incident killed 15 workers and injured 180 others. All of the fatalities and many serious injuries occurred in and around the nine temporary trailers sited as close as 121 feet from the ISOM unit. This refinery explosion was the most serious refinery incident ever investigated by the CSB. The CSB’s final investigative report into the incident found organizational and safety deficiencies at all levels of the BP Corporation. The report also noted gaps in standards and practices that likely contributed to other serious incidents over the previous decade.
CSB Findings and Recommendations:
- Trailer siting exacerbated the consequence of the BP Texas City explosion. All of the fatalities and many of the injuries occurred in or near a series of occupied trailers that were as close as 121 feet from the blowdown stack. In October 2005, the CSB issued an urgent recommendation to the American Petroleum Institute (API) to develop new guidance to prevent locating occupied trailers within hazardous areas of process plants.
- Blowdown drums should be replaced by safer alternatives. The CSB made a recommendation to API to eliminate the kind of blowdown drum that released the flammable liquid and vapor at BP. This 1950s-era equipment is unsafe, and many companies around the world have long since eliminated these systems and replaced them with inherently safer flare systems designed to handle a worst-case flammable release.
- A strong safety culture must be embraced at all levels of a corporation. The March 2005 incident was one of a long series of tragedies at the Texas City facility, where a total of 40 workers have died over 32 years. Internal audits revealed deteriorating conditions at the refinery over several years prior to 2005, but the responses focused primarily on improving personal safety and overlooked growing process safety risks.
- Process safety indicators help companies measure and improve process safety performance. The CSB recommended that API and the United Steelworkers develop a consensus standard for new process safety leading indicators to help businesses and government better assess these risks before serious incidents occur. Such leading indicators have been used for years in the nuclear power industry and provide a common method for different facilities to measure and compare system safety performance.
Conclusion
Based on the more than 130 incidents investigated by the CSB, it is clear that hundreds of billions of dollars have been spent as a result of chemical disasters in the United States. To make the safety of Americans our number one priority, it is critical that chemical safety lessons are learned and shared among diverse stakeholders across industries. If the CSB’s many safety lessons prevented at least one catastrophic incident, the money saved by preventing damage to the facility and surrounding community, avoiding legal settlements, and saving human lives far outweighs the agency’s $11 million annual budget. Safety and prosperity are compatible. Strong safety programs are critical for the economic success of the chemical and petrochemical industries. The CSB’s continued collaboration with industry, regulators, standards setting bodies and other professional organizations proves that the CSB has a vital role in driving critical chemical safety change in the United States.
References
1 Gonzales, Dan, Timothy Gulden, Aaron Strong and William Hoyle. Cost–Benefit Analysis of Proposed California Oil and Gas Refinery Regulations. Santa Monica, CA: RAND Corporation, 2016. http://www.rand.org/pubs/research_reports/RR1421.html. Also available in print form.
Data presented for each investigation was current at the time of the approval of the final report. The West Fertilizer Company report was released on January 28, 2016. The final Chevron Richmond refinery report was released on January 28, 2016. The final Deepwater Horizon/Macondo report was released on April 20, 2016. The BP Texas City report was released on March 20, 2007.
[content_transformed:protected] =>SAFETY IS GOOD BUSINESS AND GOOD PUBLIC POLICY
"There's an old saying that if you think safety is expensive, try an accident. Accidents cost a lot of money. And, not only in damage to [the] plant and in claims for injury, but also in the loss of the company's reputation." - Trevor Kletz
As an independent, non-regulatory safety agency, the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigates catastrophic chemical incidents and makes recommendations to prevent similar incidents from occurring. The CSB has found that most catastrophic chemical incidents could have been prevented. The agency conducts comprehensive, root cause analyses, examining all the causal or contributing factors. Our investigations have identified deficiencies in areas such as safety management systems, facility maintenance, regulatory requirements and training. In addition to identifying the causes of an incident, the CSB uncovers factors that exacerbate its consequences, contributing to loss of life and property, such as a lack of hazard awareness among emergency responders and insufficient community notification and planning.
The CSB’s vision is a nation safe from chemical disasters. The CSB has published nearly one hundred investigative reports and produced sixty-eight video products to communicate its safety messages to audiences across the country, so that people may benefit from the lessons learned from these tragedies. With over 130 investigations and nearly 800 recommendations issued, the agency has sought to engage industry, unions, standards setting organizations, regulators, academia, and the American people in a collaborative effort to make the chemical industry safer, while maintaining economic productivity and protecting the jobs of workers in industrial facilities nationwide. The CSB has had an enormous impact on chemical safety with a staff of approximately 40 people and $11 million budget.
Here are some examples of our work.
Explosion at Fertilizer Storage Facility (West, Texas)
April 17, 2013
West Fertilizer Company
West, Texas
April 17, 2013
- 15 fatalities and 260+ injuries
- $230 million in insurance-related losses
- $16 million spent on Federal disaster assistance
- $1 million insurance policy held by West Fertilizer Company
On April 17, 2013, a massive explosion at the West Fertilizer Company (WFC), a fertilizer storage and distribution facility located in West, Texas, killed twelve first responders and three members of the public and caused more than 260 other injuries to first responders and the general public. Two of the fatally injured members of the public lived at a nearby apartment complex. The third lived at a nursing home and died shortly after the incident from injuries related to the trauma of the explosion.
The incident caused considerable property damage, including the complete destruction of the fertilizer facility, which was never rebuilt, leaving local farmers, ranchers and businesses without convenient access to needed products. The blast also caused extensive property damage beyond the facility. Two of the city’s school buildings had to be demolished and a third sustained major damage. Also destroyed were a nursing home, an apartment complex and numerous nearby homes. In a community of 700 homes, 350 (50%) were damaged as a result of the explosion, 142 (20%) of which were damaged beyond repair.
Total insurance-related losses from the explosion are estimated to be $230 million and federal disaster assistance is estimated to exceed $16 million. The company was only insured for $1 million, which fell far short of the incident’s damage.
CSB Findings and Recommendations:
- Failure by the insurer to identify the risks posed by fertilizer grade ammonium nitrate (FGAN). A few years prior to the incident, WFC was dropped by one insurer for failing to address safety concerns identified in loss control surveys. The company that insured WFC for $1 million at the time of the incident did not conduct its own safety inspections of the facility.
- The Federal Emergency Management Agency (FEMA) awarded two grants to develop FGAN training. The CSB found that there is no standardized training requirement that applies to volunteer firefighters across the nation. The CSB made a recommendation to FEMA to create a funding mechanism to provide training and curriculum develop for first responders at FGAN incidents. West Volunteer Fire Department did not conduct pre-incident planning or response training at WFC, was likely unaware of the potential for FGAN detonation and did not, nor were required, to have appropriate training in hazardous materials response.
- Gaps in federal and state regulations and standards. The CSB identified several gaps in federal and state regulations that could have reduced the consequences of the WFC disaster. These include the Occupational Safety and Health Administration’s Explosives and Blasting Agents and Process Safety Management standards, the Environmental Protection Agency’s Risk Management Program and Emergency Planning and Community Right-to-Know Act, and training provided or certified by the Texas Commission on Fire Protection and the State Firefighters’ and Fire Marshals’ Association of Texas.
- Local zoning and community planning. The location of the WFC relative to the surrounding community exacerbated the offsite consequences. The CSB found that at least 19 other Texas facilities storing more than 10,000 pounds of FGAN are located within a half-mile of a school, hospital, or nursing home, raising concerns that an incident with offsite consequences of this magnitude could happen again.
Refinery Explosion (Richmond, California)
August 6, 2012
Chevron Refinery
Richmond, California
August 6, 2012
- 15,000 people sought medical treatment
- $2 million in fines and restitution
- $447 million in increased gas prices passed onto California consumers1
On August 6, 2012, the Chevron Refinery in Richmond, California, experienced a catastrophic pipe failure in a crude unit, causing the release of flammable hydrocarbon process fluid which partially vaporized into a large cloud. Nineteen employees engulfed by the vapor cloud escaped, narrowly avoiding serious injury. The ignition and subsequent continued burning of hydrocarbons resulted in a large plume of unknown particulates and vapor. Approximately 15,000 people from the surrounding area sought medical treatment in the weeks following the incident. The CSB’s investigation found that the pipe failure was caused by sulfidation corrosion, a damage mechanism that causes piping walls to thin over time.
Although the company has never reported the decreased production capacity experienced as a result of the incident, the U.S. Energy Information Administration determined that the increase in gas prices cost California consumers approximately $447 million in six months following the incident.
Key Findings and Recommendations:
- Hazard analyses improved at all Chevron refineries in the U.S. The CSB investigation found that the hazard analysis conducted on the piping that failed did not identify corrosion as a potential cause of a leak or rupture. As a result, the CSB issued a recommendation to Chevron to perform damage mechanism hazard reviews (DMRs) on all of its process safety management (PSM) covered equipment and to incorporate the DMRs into their hazard review process at all its U.S. refineries. As a result of the CSB’s recommendation, Chevron has conducted DMRs at all of its U.S. refineries for PSM covered process piping circuits. If more companies were to adopt hazard review programs similar to Chevron’s, safety at refineries would be greatly increased.
- The California Department of Industrial Relations (DIR) revisions to the PSM regulation. Chevron conducted a hazard analysis of the crude unit as required by California’s Process Safety Management of Acutely Hazardous Materials (PSM) program; however, this does not require a formal damage mechanism hazard review to identify sulfidation corrosion. The CSB made several recommendations to improve California’s PSM program. Since 2014, DIR has published several drafts of a revised regulation and received and incorporated extensive stakeholder feedback. If the proposed regulation is approved, process safety in California’s refineries would be greatly improved and chemical safety would be advanced by better preventing major chemical incidents.
Deepwater Horizon/ Macondo Well Blowout (Gulf of Mexico)
April 20, 2010
Deepwater Horizon/Macondo Well Blowout
Gulf of Mexico
April 20, 2010
- $21 billion in settlements
- $13 billion in economic and medical claims
- 11 workers killed, 17 workers injured
- 4 million barrels of oil spilled
On April 20, 2010, a multiplefatality incident occurred at the Macondo oil well approximately 50 miles off the coast of Louisiana in the Gulf of Mexico during temporary well-abandonment activities on the Deepwater Horizon drilling rig. Control of the well was lost, resulting in a blowout—the uncontrolled release of hydrocarbons from the well. On the rig, the hydrocarbons found an ignition source and burst into flames. The resulting explosions and fire led to the deaths of 11 individuals, serious physical injuries to 17 others, evacuation of 115 individuals from the rig, the sinking of the Deepwater Horizon, and massive marine and coastal damage from a reported 4 million barrels of released hydrocarbons.
The operator of the rig, has paid out an estimated $13 billion worth of economic and medical claims as part of an uncapped settlement, in addition to a $20 billion settlement for federal, state and local government economic and environmental claims. Settlements involving other companies have reached $1.24 billion payout at the time of the completion of the CSB’s investigation. Other litigation remains pending.
CSB Findings and Recommendations:
- Blowout preventer (BOP) hazard not identified prior to Deepwater Horizon. Testing limitations masked latent failures of the Deepwater Horizon BOP, affecting its operation on the day of the incident, and these latent failures will continue to exist for similarly designed blowout preventers unless modifications are made to current standard industry testing protocols.
- Pipe buckling prevented drillpipe from working effectively. Pressure conditions in a well can cause drillpipe to buckle (or bend) in a BOP even after a crew has initially sealed a well, potentially incapacitating emergency functions of the BOP intended to cut drillpipe and seal the well.
- Safety-critical controls are necessary for hazard management. Major hazards require concerted efforts by industry to manage and actively monitor the safety-critical controls they rely on for the safe conduct of work, including improved incorporation of human factors, safety performance indicators, and corporate governance.
- Information sharing can be a challenge in offshore drilling. Obstacles continue to exist that limit sharing of lessons from incident investigations in individual companies and across both the operator/drilling contractor boundary and international geographical regions.
- Proper use of process safety indicators can prevent incidents. An equal focus and effort to collect, measure, and improve process safety performance indicators to that currently dedicated to personal safety statistics is necessary to reduce the potential for a major incident.
Texas City Refinery Explosion (Texas City, Texas)
March 23, 2005
BP Texas City
Texas City, Texas
March 23, 2005
- $1.5 billion in financial losses
- 15 workers killed
- 180 people injured
On March 23, 2005, a hydrocarbon isomerization unit (ISOM) exploded at the BP Texas City refinery in Texas City, Texas, resulting in financial losses of more than $1.5 billion. The incident killed 15 workers and injured 180 others. All of the fatalities and many serious injuries occurred in and around the nine temporary trailers sited as close as 121 feet from the ISOM unit. This refinery explosion was the most serious refinery incident ever investigated by the CSB. The CSB’s final investigative report into the incident found organizational and safety deficiencies at all levels of the BP Corporation. The report also noted gaps in standards and practices that likely contributed to other serious incidents over the previous decade.
CSB Findings and Recommendations:
- Trailer siting exacerbated the consequence of the BP Texas City explosion. All of the fatalities and many of the injuries occurred in or near a series of occupied trailers that were as close as 121 feet from the blowdown stack. In October 2005, the CSB issued an urgent recommendation to the American Petroleum Institute (API) to develop new guidance to prevent locating occupied trailers within hazardous areas of process plants.
- Blowdown drums should be replaced by safer alternatives. The CSB made a recommendation to API to eliminate the kind of blowdown drum that released the flammable liquid and vapor at BP. This 1950s-era equipment is unsafe, and many companies around the world have long since eliminated these systems and replaced them with inherently safer flare systems designed to handle a worst-case flammable release.
- A strong safety culture must be embraced at all levels of a corporation. The March 2005 incident was one of a long series of tragedies at the Texas City facility, where a total of 40 workers have died over 32 years. Internal audits revealed deteriorating conditions at the refinery over several years prior to 2005, but the responses focused primarily on improving personal safety and overlooked growing process safety risks.
- Process safety indicators help companies measure and improve process safety performance. The CSB recommended that API and the United Steelworkers develop a consensus standard for new process safety leading indicators to help businesses and government better assess these risks before serious incidents occur. Such leading indicators have been used for years in the nuclear power industry and provide a common method for different facilities to measure and compare system safety performance.
Conclusion
Based on the more than 130 incidents investigated by the CSB, it is clear that hundreds of billions of dollars have been spent as a result of chemical disasters in the United States. To make the safety of Americans our number one priority, it is critical that chemical safety lessons are learned and shared among diverse stakeholders across industries. If the CSB’s many safety lessons prevented at least one catastrophic incident, the money saved by preventing damage to the facility and surrounding community, avoiding legal settlements, and saving human lives far outweighs the agency’s $11 million annual budget. Safety and prosperity are compatible. Strong safety programs are critical for the economic success of the chemical and petrochemical industries. The CSB’s continued collaboration with industry, regulators, standards setting bodies and other professional organizations proves that the CSB has a vital role in driving critical chemical safety change in the United States.
References
1 Gonzales, Dan, Timothy Gulden, Aaron Strong and William Hoyle. Cost–Benefit Analysis of Proposed California Oil and Gas Refinery Regulations. Santa Monica, CA: RAND Corporation, 2016. http://www.rand.org/pubs/research_reports/RR1421.html. Also available in print form.
Data presented for each investigation was current at the time of the approval of the final report. The West Fertilizer Company report was released on January 28, 2016. The final Chevron Richmond refinery report was released on January 28, 2016. The final Deepwater Horizon/Macondo report was released on April 20, 2016. The BP Texas City report was released on March 20, 2007.
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The resource includes a case example, steps to prevent a related injury, and questions for discussion. It includes a graphic that illustrates the hazard, which can be posted in a central location as a reminder of steps to work safely. Available in English and Spanish. 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The recall is a result of... 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[files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [old_record:protected] => [id:protected] => 4426 [old_id:protected] => [elcosh_id:protected] => d001656 [type:protected] => document [display_type:protected] => HTML only (and links) [user_id:protected] => 0 [language_id:protected] => 1 [tagging_id:protected] => Mike Aguilar [priority_id:protected] => 1 [title:protected] => Construction Dive -- DeWalt's Jobsite Pro headphones recalled for fire hazards [total_pages:protected] => 1 [billed_pages:protected] => 1 [publication_number:protected] => [part_of:protected] => [keywords:protected] => DeWalt, Fire Hazards, recall, headphones [comments:protected] => [summary:protected] => A recall notice by the United States Consumer Product Safety Commission affects over 300,000 DeWalt Jobsite Pro Headphones. The recall is a result of a malfunction that can cause earbuds to overheat while charging or during use, leading to fire and burn hazards. [transition_comments:protected] => [external_link:protected] => https://www.constructiondive.com/news/dewalts-jobsite-pro-headphones-recalled-for-fire-hazards/611248/?utm_source=Sailthru&utm_medium=email&utm_campaign=Issue:%202021-12-10%20Construction%20Dive%20Newsletter%20%5Bissue:38532%5D&utm_term=Construction%20Dive [consol_link:protected] => [more_like_this:protected] => [permission_given_by:protected] => [published:protected] => T [billable:protected] => F [img_name:protected] => [img_ext:protected] => [img_width:protected] => [img_height:protected] => [img_credit:protected] => [img_practice:protected] => [vid_source_id:protected] => [vid_running_time:protected] => [vid_intended_audience:protected] => [vid_acquisition_info:protected] => [vid_cost:protected] => [vid_producer:protected] => [vid_filename:protected] => [vid_filename_downloadable:protected] => [date_summary:protected] => [date_permission_requested:protected] => [date_permission_received:protected] => [date_review_needed:protected] => [date_received:protected] => 12/13/21 [date_completed:protected] => 12/13/21 [date_billed:protected] => [date_modified:protected] => 12/13/21 [collBokExports:protected] => [lastBokExportCriteria:BaseElcoshItem:private] => [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [2] => Search_Result Object ( [title] => Working in an Enclosed Cab [image] => /record/images/notavailable-p.png [blurb] => This CPWR Hazard Alert on Working in enclosed cabs provides information on protecting workers from silica dust, how to minimize exposures and the dang... 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Worker [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [84] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 84 [type:protected] => category [parent:protected] => 2 [label:protected] => Tile Setter [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [86] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 86 [type:protected] => category [parent:protected] => 2 [label:protected] => Welder [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [88] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 88 [type:protected] => category [parent:protected] => 3 [label:protected] => Demolition [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [89] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 89 [type:protected] => category [parent:protected] => 3 [label:protected] => Disasters [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [95] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 95 [type:protected] => category [parent:protected] => 3 [label:protected] => Underground [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) [102] => Category Object ( [languages:protected] => [bok_resources:protected] => [bok_topics:protected] => [bok_keywords:protected] => [id:protected] => 102 [type:protected] => category [parent:protected] => 6 [label:protected] => Handouts [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] => [_deleted:BaseObject:private] => [modifiedColumns:protected] => Array ( ) ) ) [categories_initialized:protected] => 1 [mapped_items:protected] => [content:protected] => [files:protected] => [language:protected] => Language Object ( [id:protected] => 1 [code:protected] => en [name:protected] => English [alreadyInSave:protected] => [alreadyInValidation:protected] => [validationFailures:protected] => Array ( ) [_new:BaseObject:private] =>