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On November 9th 2022 a powerful explosion shook the DuPont chemical manufacturing plant in Tonawanda New York a suburb of Buffalo a contract worker was performing maintenance work on a tank that unknown to him contained flammable gas the explosion blew the top of the tank throwing the welder to the ground and killing him instantly a second contract worker was burned the tragic explosion at the DuPont facility is posed witnesses in how process hazards were analyzed and control the result was the death of a welder in a preventable hard work accident hot work accidents occur when workers are welding cutting or grinding near flammable vapor and were the focus of a 2022 CSB safety bulletin deficiencies in the safety management of hot work were among the causes of the tragedy at DuPont dupont's Tonawanda facility manufactures a polymer known as ted'll are used in solar panels and Corian for use in countertops the process of producing tedlar began with a chemical reaction to convert flammable vinyl fluoride gas into a slurry of polyvinyl fluoride polymer or PV F in water the PBF slurry then passed through separators compressors recycled unreacted vinyl fluoride gas into the process while a small flash tank released residual vinyl fluoride into the atmosphere finally the slurry was transferred to one of three insulated holding tanks usually tank number three tanks one and two were reserved for slurry overflow tank one normally remained empty on October 22nd 2022 the tedlar process underwent a planned shutdown during which workers removed the asbestos insulation on tanks one and two removing the insulation revealed that the agitator supports for the tanks were heavily corroded dupont directed contractors to repair the supports which would involve welding and grinding on tanks one and two the hot work on tank 2 occurred during the shutdown without incident but the repairs on tank 1 were delayed while parts were ordered dupont personnel determined that it would be safe to perform hot work on tank 1 after the restart on November 7th dupont operators locked all five valves leading to and from tank one in the closed position in order to stop potential slurry flow the tanks agitator motor was also locked out however dupont personnel did not block the flow of gas inside the overhead piping or overflow line that connected the vapor space of all three tanks they mistakenly believed that flammable vinyl fluoride gas could not reach any of the slurry tanks but the CSB investigation found that even in normal operations vinyl fluoride was not completely removed from the slurry and was always present in the slurry tanks in varying amounts when the process restarted on November 6th the flammable gas was able to travel from tanks 2 & 3 through the open overflow line into tank 1 on the morning of November 9th a DuPont technician tested the atmosphere above tank one where Welding would later take place there were also two continuous air monitors.