Imperial Sugar and Dust Hazards

¶ … 2008 Imperial Sugar refinery explosion/Fire. Fire at Imperial Sugar Refinery Background Info On February 7, 2008, a massive fire and explosion took place at northwestern Savannah, Georgia's Imperial Sugar factory. The incident claimed the lives of no less than 14 individuals, and left 38 people injured; of these, 14 suffered life-threatening, acute burns. The blast was caused by enormous deposits of inflammable sugar dust all through the packaging unitManagement of the company ought to have been aware of the fact that explosions are likely to occur if the sugar refining process is enclosed.

Comprehensive and precise information (in writing) on process chemicals, equipment, and technology is vital to a sound program for industrial process safety management (PSM) as well as hazard analysis of the process.

The documented knowledge will be an indispensable resource to various users, including the personnel who carry out obligatory hazard analysis, mandated under PSM; personnel in charge of developing operating procedures and training programs; contractors whose workers work with the industrial process; individuals who perform reviews prior to startup; and local disaster preparedness planners, enforcement officials and insurance authorities (Process Safety Management Guidelines for Compliance, 1994).

OSHA Standards Violations It was asserted by federal authorities that the Imperial Sugar Company must face a penalty of over 8.7 million dollars for violation of Occupational Safety and Health Administration (OSHA) standards at two of its plants, including the one at Georgia in which an explosion claimed 13 lives. The aforementioned figure is the third-largest fire in OSHA's almost four-decade-long history. The $8.7 million quoted fine includes 5 million dollars for the 2008 Georgia explosion and 3.7 million dollars for Imperial Sugar's Gramercy, Louisiana plant (Bynum, 2008).

Investigators from OSHA arrived at the conclusion that the explosion most likely occurred because of a spark caused by a huge bucket utilized for sugar-hauling purposes in one of the silo elevators broke free, striking its metal siding. The spark must have set fire to the sugar dust that was stored underneath the 100-foot storage towers. OSHA claims that its investigation unearthed insurance records, factory audits, and other records, which prove Imperial Sugar Company was warned concerning explosive dust risks in its factories since the year 2002.

An inspection of Imperial Sugar's Gramercy plant one month following the incident in Georgia revealed personnel wading through 4-foot-deep sugar dust. Edwin Foulke, OSHA Chief, stated at a Savannah news conference that it would have been possible to avoid a catastrophe if the company had obeyed existing OSHA health and safety standards. The agency found no less than 120 violations of regulations against the refinery in Georgia, including 61 that were deemed shocking (Bynum, 2008).

Further, in the Louisiana refinery, OSHA found 91 more violations, which include 47 that were egregious; several of the Louisiana unit's violations were akin to the Georgian violations. Criminal Liability Investigators from the safety board speculated company managers were reassured and complacent about a number of narrow escapes -- fires and explosions that did not result in any casualty. According to John Vorderbrueggen, the supervisor who headed the investigation, this was the reason for Imperial Sugar's failure in the past several years to check dust explosion threats meticulously and efficiently.

He further stated that, in that period, smaller explosions, and fires continued to occur at Imperial sugar facilities and factories all over the U.S. It has also been stated that improper housekeeping practices gave rise to build-up of granulated sugar and sugar dust within the packaging buildings of the refinery (Peterson, 2009). According to the report, machine operators in the packaging unit reported frequent sugar spills of about 2 to 3 feet in depth.

One of the factory workers informed the safety board that he had to make use of a scraper for clearing a track through the spillage of powdered sugar on the factory floor for reaching the equipment he works on. Cleanup of sugar dust would take place at sporadic intervals, according to the report, and, at times, was done using compressed air -- this technique serves to only disperse the dust that eventually settles and covers other surfaces.

Therefore, criminal liability for the 2008 incident needs to be placed on company executives and cleaning crew. Back Burner Metal Powders Industries Federation's Jim Dale states that his company seeks methods for best addressing dust hazards. He asserts the issue is challenging when several members claim that they have never faced any problems (No combustible dust rules from OSHA any time soon -- Fox News, 2012), and are not keen on spending millions of dollars to address an overstated risk.

Allocation of funds in this regard is an expensive activity and a possible commercial disaster for several companies. Dale claims industrialists will do their best to ensure safety of their workers. It appears the same is applicable to Imperial Sugar Company. Should Industry Disregard the Hazard? Industry must not overlook the hazard. When dusty processes are being conducted, an evaluation must be made for ascertaining if workers are in jeopardy from exposure to dust.

This requires a systematic analysis of the workplace for gauging whether any problem exists, and what may be done, in general, for risk prevention. The evaluation must identify hazardous materials used, quantity of these materials, the amount of dust that can become airborne (resulting in exposure), etc. A preliminary "walk-through" factory survey must be performed. Dust exposure control, together with environmental protection and other safety and health measures, must be prioritized by company board.