Investigation Report
MGPI Processing, Inc. Toxic Chemical Release
MGPI Processing, Inc. Toxic Chemical Release
- CSB
- Investigation Report
- Hazardous SubstancesProcess Safety
- Hazardous substancesHuman factorsLoss of containmentProcess safetyRespiratory hazards
- Fluid transfer
- HoseProcess pipework and pipelinesRespiratorStorage tanksValve
- Competence and trainingEmergency responseHuman-centred designOperating and work procedures
- Downstream and process industries
- Onshore facility
Summary
This case study investigates an incorrect sulfuric acid delivery connection to a sodium hypochlorite tank at MGPI in Atchison, Kansas, producing a chlorine-containing cloud. It examines unloading equipment design, pipe identification, procedure compliance, training, remote shutdown, control-room ventilation and escape respirator access, alongside community emergency planning and subsequent preventive changes.
Classifications: Hazardous substances; hazardous chemicals; chemical exposure.
Classifications: Human factors; human performance; ergonomics.
Classifications: Loss of containment; containment loss.
Classifications: Process safety; major accident hazards.
Classifications: Respiratory hazards; respirable dust; inhalation hazards.
Classifications: Fluid transfer; fluid loading; fluid offloading.
Classifications: Hose; flexible hose.
Classifications: Process pipework and pipelines; process piping.
Classifications: Respirator; respiratory protective equipment; RPE.
Classifications: Storage tanks; atmospheric tanks.
Classifications: Valve; valves.
Classifications: Competence and training; competency assurance; safety training.
Classifications: Emergency response; emergency preparedness.
Classifications: Human-centred design.
Classifications: Operating and work procedures.
Classifications: Downstream and process industries; refining; petrochemicals.
Classifications: Onshore facility; onshore plant.
Themes: hazardous substances, process safety.