1999 — Feb 1, Boiler Explosion, Ford Motor’s River Rouge complex, Dearborn, MI — 6

— 6  MI CIS. “Ford Settlement.” MI OSHA News, Vol. 3, No. 3, Fall 1999, p. 1.

— 6  OSHA. “Inspection: 127242105 – Ford Power & Utilities Group.” Close case 9-30-2004.

 

Narrative Information

 

MI CIS: “On Sept. 2, 1999, the Michigan Department of Consumer and Industry Services (CIS) concluded its investigation of the fatal explosion at the Ford Rouge Complex power plant with an unprecedented and historic $7 million Settlement Agreement with Ford Motor Company and the UAW.

 

“The tragic explosion was one of the worst automotive industry accidents in Michigan. On Feb. 1, 1999, a catastrophic explosion in the power plant at the Ford Rouge Complex in Dearborn, resulted in the death of six workers and seriously injured 14 others….

 

“The settlement includes a record $1.5 million civil penalty, the largest monetary sanction ever levied in Michigan as a result of a MIOSHA investigation. The key elements of the $7 million agreement include:

  • $1.5 Million-MIOSHA Penalty,
  • $1.5 Million-Establishment of programs to achieve lasting improvements in power generation safety,
  • $1.0 Million-Research to increase the understanding of industrial safety and health,
  • $1.5 Million-Medical research, facilities or equipment in the treatment of burns and other critical care,
  • $1.0 Million-Scholarship Fund, and
  • $0.5 Million-Potential third-party reimbursement.

 

“….BCC inspectors were able to establish cause in this incident. They determined the explosion was caused by a natural gas buildup in Boiler No. 6. The build-up was a result of inadequate controls for the safe shutdown of the boiler. While BCC inspectors look for the cause of an accident, MIOSHA investigations focus on identifying violations of state worker safety and health standards.

 

“Ford Complex Background:  On February 1, 1999, at approximately 1:00 p.m., there was an explosion in the power plant jointly owned by Ford Motor Company and Rouge Steel. The 80-year-old Ford Rouge produces steel for the automotive industry.

 

“About 140 workers were employed at the power plant, which was scheduled to be replaced with a new facility in 2000. The Rouge power plant produced steam by burning a mixture of natural gas, pulverized coal, and blast furnace gas. The new facility, already under construction at the time of the accident, will use natural gas to generate electricity.

 

“BCC Investigation: Boiler accidents are rare in Michigan, but when they do happen the results are often devastating. There are more than 70,000 commercial boilers in Michigan, with 4,000 high-pressure power boilers like those at Ford. Power boilers are inspected annually by licensed inspectors.

 

“The Rouge power house contained seven power boilers used to provide steam at the complex. All boilers were housed in the same building. At the time of the explosion, Boilers No. 2, 3, 4, 5, and 7 were operating. At 8:00 a.m., Boiler No. 6 was being shut down for annual maintenance. At 12:00 noon, workers were completing the shut-down process by blanking the natural gas supply. At about 12:58 p.m., the natural gas control valves were opened to facilitate purging any remaining natural gas from the supply lines through the boiler. The explosion occurred a few minutes after the valve was opened.

 

“The BCC investigation determined that the accident was a natural gas fuel explosion and not a boiler steam explosion. BCC inspectors concluded the cause of the accident was a result of inadequate procedural controls for the safe shutdown of the boiler. Improper valve line-ups and inadequate work group communication allowed natural gas to flow into the boiler furnace chamber. This is believed to be the source of the gas build-up which caused the explosion….

 

“The MIOSHA investigative team found significant workplace safety and health violations at the time of the explosion and a lack of safe industry practices by Ford. The comprehensive and thorough nature of the investigation identified important deficiencies and unsafe workplace practices. MIOSHA findings led to the inclusion in the Settlement Agreement of several items which will positively impact the working conditions for Ford employees nationwide….” (MI CIS. “Ford Settlement.” MI OSHA News, Vol. 3, No. 3, Fall 1999, pp. 1-2 & 17-18.)

 

OSHA: “Six employees were taking a boiler off-line for maintenance. A natural gas valve was inadvertently left open. When a secondary butterfly valve was opened for purging, gas entered the unfired boiler which was still hot. This resulted in an explosion in the boiler and that explosion caused secondary explosions from coal dust that had accumulated on building and equipment surfaces. All six employees were killed in the explosion.” (OSHA)

 

Sources

 

Michigan Consumer & Industry Services, Bureau of Safety & Regulation. “Ford Settlement.” MI OSHA News (Michigan Occupational Safety & Health Act), Vol. 3, No. 3, Fall 1999, pp. 1-2 & 17-18, Lansing, MI. Accessed 12-19-2015 at: http://www.michigan.gov/documents/CIS_WSH_minwsf99_27783_7.pdf

 

Occupational Safety & Health Administration, U.S. Department of Labor. “Inspection: 127242105 – Ford Power & Utilities Group.” Close case date – 9-30-2004. Accessed 12-19-2015 at: https://www.osha.gov/pls/imis/establishment.inspection_detail?id=127242105