Morton International Inc. Runaway Chemical Reaction
Paterson, NJ, Issued on August 16, 2000
Click here for Investigation Information Page Summary
The CSB investigated an explosion and fire at Morton International, a dye factory in Paterson, NJ. Hazard analyses that failed to recognize the reactive hazards of the Yellow 96 dye production process and process safety information that did not warn personnel of the potential for a dangerous runaway reaction were the root causes pf the incident. The fact that previous operational deviations were not analyzed for hazards, and Morton did not follow management of change procedures also contributed to the incident. The CSB issued safety recommendations based on these root and contributing causes.
Morton International, Inc.'s Patterson, New Jersey Plant1998-06-I-NJ-R2
Revalidate Process Hazard Analyses for all reactive chemical processes in light of the findings of the U.S. Chemical Safety and Hazard Investigation Board (CSB) report and upgrade, as needed, equipment, operating procedures, and training.
Status: Closed - Acceptable Action
1998-06-I-NJ-R3
Evaluate pressure relief requirements for all reaction vessels using appropriate technology, such as the Design Institute for Emergency Relief Systems (DIERS)50 method and test apparatus and upgrade equipment as needed.
Status: Closed - No Longer Applicable
1998-06-I-NJ-R4
Evaluate the need for and install, as necessary, devices, such as alarms, added safety instrumentation, and quench or reactor dump systems to safely manage reactive chemical process hazards.
Status: Closed - Acceptable Action
1998-06-I-NJ-R5
Revise operating procedures and training for reactive chemical processes as needed, to include descriptions of the possible consequences of deviations from normal operational limits and steps that should be taken to correct these deviations, including emergency response actions.
Status: Closed - Acceptable Action
1998-06-I-NJ-R6
Implement a program to ensure that deviations from normal operational limits for reactive chemical processes that could have resulted in significant incidents are documented and investigated and necessary safety improvements are implemented.
Status: Closed - Acceptable Action
1998-06-I-NJ-R7
Revise the Yellow 96 Material Safety Data Sheet (MSDS) to show the proper boiling point and National Fire Protection Association reactivity rating. Evaluate the need for and change, as necessary, the MSDSs for other Morton dyes. Communicate the MSDS changes to current and past customers (who may retain inventories of these products).
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