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2018/1/8· The driver inadvertently connected his truck’s sulfuric acid hose to the sodium hypochlorite line. The incorrect connection meant thousands of gallons of sulfuric acid from the tanker truck entered the facility’s sodium hypochlorite tank – creating a dense green cloud of toxic gas that traveled in the wind toward a densely populated area of the community.
protective equipment. During this time, the operator unlocked the gate in front of the transfer equipment and removed the lock on the cam lever dust cap for the sulfuric acid fill line. The operator placed the lock from the sulfuric acid fill line on the angle iron above
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The chemical release occurred when sulfuric acid was inadvertently unloaded from a tanker truck into a fixed sodium hypochlorite tank at the plant. The two materials coined to produce chlorine gas that sent over 140 individuals, both workers and meers of the public, to area hospitals and resulted in shelter-in-place and evacuation orders for thousands of local residents.
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Figure 1 No plant employees were in the vicinity of the transfer area. When the driver arrived at the transfer area, a transfer hose was already connected to a pipe, marked “FERROUS SULFATE,” on the side of the transfer building during the post-accident.
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Although the sulfuric acid dust cap was unlocked immediately prior to unloading, the CSB found the sodium hypochlorite fill line was also accessible to the driver. The driver connected the sulfuric acid discharge hose to the unsecured fill line for the sodium hypochlorite bulk tank, which resulted in the inadvertent mixing of approximately 4,000 gallons of sulfuric acid and 5,850 gallons of
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