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First Chemical Corp. Reactive Chemical Explosion

Pascagoula, MS, Issued on October 15, 2003

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Summary
The CSB investigated a reactive chemical explosion at the First Chemical Corp. facility in Pascagoula, MS. The investigation found that the First Chemical facility did not have an adequate management system for evaluating the hazards of processing MNT, an explosive material. Furthermore, the facility did not have an adequate system for ensuring sufficient layers of protection, consistent work practices when isolating equipment, and the integrity of isolation valves. The investigation also found that the control room construction and its proximity to the process was not evaluated, and that the community emergency notification system was inadequate. The CSB issued safety recommendations based on these root and contributing causes.

Recommendations Listed by Recipient

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E. I. du Pont de Nemours and Company 2003-01-I-MS-R1
Conduct audits to ensure that the First Chemical Pascagoula facility addresses the issues detailed below, under Ã??DuPontÃ??First Chemical Pascagoula Facility.Ã?? Communicate results of these audits to the workforce.

Status: Closed - Acceptable Action The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.

DuPont-First Chemical Pascagoula Facility 2003-01-I-MS-R2
Establish a program for conducting process hazard analyses of processes involving reactive materials.

Status: Closed - Acceptable Action The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board. 2003-01-I-MS-R3
Evaluate the need for layers of protection and install appropriate safeguards, such as alarms and interlocks, to reduce the likelihood of a runaway reaction and catastrophic release of material.

Status: Closed - Acceptable Action The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board. 2003-01-I-MS-R4
Review and revise as necessary procedures for units that process highly energetic material, effectively communicate the updated procedures, and train workers appropriately. Revised procedures should include:

Specific steps for isolation of energy sources.

Warnings and cautions concerning process chemicals and consequences of deviations from operating limits.

Critical operating limits and guidance when the limits are exceeded.

Instruction on how to perform a shutdown for all foreseeable causes, to ensure proper isolation, and to continue monitoring critical parameters (such as temperature) while the column is shut down; in addition, review conditions under which material must be deinventoried (such as during extended shutdowns).

Status: Open - Acceptable Response or Alternate Response Response from recipient indicates a planned action that would satisfy the objective of the recommendation when implemented. 2003-01-I-MS-R5
Conduct a facility-wide survey of pressure vessels to ensure that all equipment that processes reactive materials has appropriate overpressure protection.

Status: Closed - Acceptable Action The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board. 2003-01-I-MS-R6
Identify equipment critical to safe operation of processes containing reactive materials. Upgrade the maintenance program and establish inspection schedules to ensure the integrity of such equipment.

Status: Closed - Acceptable Action The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board. 2003-01-I-MS-R7
Survey and take appropriate action to ensure that buildings occupied by plant personnel are of adequate construction and are located so as to protect people inside in the event of an explosion in equipment processing reactive materials.

Status: Open - Acceptable Response or Alternate Response Response from recipient indicates a planned action that would satisfy the objective of the recommendation when implemented.

Jackson County Board of Supervisors, Jackson County Emergency Management Agency, Jackson County Local Emergency Planning Committee 2003-01-I-MS-R8
Update the community notification system to:

Immediately alert residents in the Moss Point community when an incident occurs that could affect their health and safety.

Determine when a community response should be initiated.

Communicate the nature of the incident and the appropriate response by residents.

Alert residents when the incident is over (i.e., the all-clear has sounded).

Status: Open - Awaiting Response or Evaluation/Approval of Response Either a recommendation has been issued and no substantive response was received from the recipient; or a response has been received from the recipient but the evaluation by CSB staff is pending or the Board has not yet acted on staff recommendation of status. 2003-01-I-MS-R9
Conduct an awareness campaign to educate residents on the proper steps for a shelter-in-place and orderly evacuation.

American Chemistry Council (ACC) 2003-01-I-MS-R10
Amend the Technical Specifications guidelines in the Responsible Care Management System to explicitly require facilities to identify findings and lessons learned from process hazard analyses and incident investigations in one unit and apply them to other equipment that processes similar material.

Status: Closed - Acceptable Action The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board. 2003-01-I-MS-R11
Ensure that ACC members understand the audit requirements of Responsible Care and accurately identify and address gaps in facility process safety programs.

Status: Closed - Acceptable Action The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board. 2003-01-I-MS-R12
Communicate the findings of this report to your membership.

Status: Closed - Acceptable Action The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.

Synthetic Organic Chemical Manufacturers Association (SOCMA) 2003-01-I-MS-R13
Amend the Technical Specifications in the Responsible Care Management System to explicitly require facilities to identify findings and lessons learned from process hazard analyses and incident investigations in one unit and apply them to other equipment that processes similar material.

Status: Open - Awaiting Response or Evaluation/Approval of Response Either a recommendation has been issued and no substantive response was received from the recipient; or a response has been received from the recipient but the evaluation by CSB staff is pending or the Board has not yet acted on staff recommendation of status. 2003-01-I-MS-R14
Ensure that SOCMA members understand the audit requirements of Responsible Care and accurately identify and address gaps in facility process safety programs.

Status: Open - Awaiting Response or Evaluation/Approval of Response Either a recommendation has been issued and no substantive response was received from the recipient; or a response has been received from the recipient but the evaluation by CSB staff is pending or the Board has not yet acted on staff recommendation of status. 2003-01-I-MS-R15
Communicate the findings of this report to your membership.

Status: Closed - Acceptable Action The recipient has completed action on the recommendation. The action taken meets the objectives envisioned by the Board.