OSHA Fines Sherwin-Williams $290K for Garland Plant Explosion

Employees were exposed to fire and explosion hazards from unstable chemical reaction due to the improper storage of Luperox 26 A which was not stored in a temperature-controlled environment.

Relief valve PSV-5408 was not included in the relief system design or design basis associated with the pressure vessel CAT-5 written process safety information, which exposed employees to struck-by hazards.

The 2021 Process Hazard Analysis did not identify the hazards of self-reactive, thermally sensitive chemicals and potential for high ambient temperatures on vessel CAT-5 charged with organic oxidizers.

The employer did not address process equipment siting near the control room when it evaluated the facility siting in the Process Hazard Analysis.

The normal operating procedure, SQ4736P, did not list the operating limits, including specific upper temperature limits, for Luperox-26 (organic peroxide) used in CAT-5. As well, the employer did not address the consequences of deviation from operating limits.

The employer did not provide operator refresher training at least every three years or more often, if necessary. (This was listed as Citation #6 and #7.)

The employer did not establish written procedures for inspecting pressure vessels and piping systems and did not develop a mechanical integrity program for corrosion under insulation inspections.

Repeat violation for not inspecting processing equipment that exposed workers to hazards. This includes the piping from the vessels to the reactors, and reactors to tanks.