A process upset at an industrial plant produced a thermal release the facility's safety analyses had explicitly identified — and explicitly chosen not to mitigate.
A process-related thermal release at an industrial facility caused catastrophic burn injuries to a worker during a routine production task. The release sequence was traceable to a known hazard scenario in the facility's process-safety documentation.
Process Hazard Analysis documents, management of change records, and prior near-miss reports established that the specific failure pathway had been recognized but inadequately mitigated. Mechanical integrity and inspection records showed deferred maintenance on the affected unit.
The worker sustained severe burn injuries to a substantial percentage of total body surface area, requiring multiple grafting procedures, extended ICU care, and ongoing rehabilitation. Permanent functional impairment and disfigurement were documented.
A jury returned a $14.0M verdict against the facility operator and its contracted maintenance provider.
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