Accident: Sierra Chemical Co. High Explosives Accident
Location: Location: Mustang, NV
Accident Occurred On: 01/07/1998 | Final Report Released On: 09/23/1998
Accident Type: Chemical Manufacturing - Fire and Explosion
Investigation Status: The final report on this investigation was approved on September 23, 1998.
On January 7, 1998, two explosions in rapid succession destroyed the Sierra Chemical Company Kean Canyon plant near Mustang, Nevada, killing four workers and injuring six others.
Develop a program to ensure that reclaimed, demilitarized explosives sold by the Department of Defense are free of foreign materials that can present hazards during subsequent manufacturing of explosives.
Provide access to explosives incident reports and lessons learned information to managers and workers involved in explosives manufacturing, associations such as IME, government agencies, and safety researchers.
Develop and disseminate process and safety training guidelines for personnel involved in the manufacture of explosives that include methods for the demonstration and maintenance of proficiency.
Distribute the CSB report on the incident at Sierra to IME member companies.
Develop safety guidelines for the screening of reclaimed explosive materials.
Increase the frequency of safety inspections of explosives manufacturing facilities due to their potential for catastrophic incidents. (Note: Nevada Governor Bob Miller signed an Executive Order on June 10, 1998, that will require inspections at least twice a year.)
Explosives manufacturers should evaluate the effectiveness of their explosives safety programs using the following recommendations (numbered for identification) to ensure that: - Process hazard analyses include examination of quantity-distance requirements, building, design, human factors, incident reports, and lessons learned from explosives manufacturers.
Explosives manufacturers should evaluate the effectiveness of their explosives safety programs using the following recommendations (numbered for identification) to ensure that: - Written operating procedures are specific to the process being controlled and address all phases of the operation.
Explosives manufacturers should evaluate the effectiveness of their explosives safety programs using the following recommendations (numbered for identification) to ensure that: - Procedures, chemical hazards, and process safety information are communicated in the language(s) understood by personnel involved in manufacturing or handling of explosives.
Explosives manufacturers should evaluate the effectiveness of their explosives safety programs using the following recommendations (numbered for identification) to ensure that: Explosives training and certification programs for workers and line managers provide and require demonstration of a basic understanding of explosives safety principles and job specific knowledge.
Explosives manufacturers should evaluate the effectiveness of their explosives safety programs using the following recommendations (numbered for identification) to ensure that: - Process changes, such as the construction or modification of buildings, or changes in explosive ingredients, equipment, or procedures are analyzed and PSM elements are updated to address these changes.
Explosives manufacturers should evaluate the effectiveness of their explosives safety programs using the following recommendations (numbered for identification) to ensure that: - Pre-startup safety reviews are performed to verify operational readiness when changes are made.
Explosives manufacturers should evaluate the effectiveness of their explosives safety programs using the following recommendations (numbered for identification) to ensure that: - All elements of OSHA's Process Safety Management Standard are verified by performing periodic assessments and audits of safety programs.
Explosives manufacturers should evaluate the effectiveness of their explosives safety programs using the following recommendations (numbered for identification) to ensure that: - The employee participation program effectively includes workers and resolves their safety issues.
Explosives manufacturers should evaluate the effectiveness of their explosives safety programs using the following recommendations (numbered for identification) to ensure that: - Explosives safety programs provide an understanding of the hazards and control of detonation sources. These include: · foreign objects in raw materials; · use of substitute raw materials; · specific handling requirements for raw materials; · impact by tools or equipment; · impingement; · friction; · sparking; and · static discharge.
Explosives manufacturers should evaluate the effectiveness of their explosives safety programs using the following recommendations (numbered for identification) to ensure that: - The following issues are addressed in plant design or modification: · Operations in explosives manufacturing plants are separated by adequate intraplant distances to reduce the risk of propagation. · Unrelated chemical or industrial operations or facilities are separated from explosives facilities using quantity-distance guidelines. · Facilities are designed to reduce secondary fragmentation that could result in the propagation of explosions.