The Belvidere Daily Republican Featured News

Final report blasts oversight by company, governments

Nov. 21, 2013

By Troy A. Bruzewski

Editor

BELVIDERE – The U.S. Chemical Safety Board (CSB) concluded its investigation into the 2009 explosion at NDK Crystal and the recently-released findings underscore a total failures by plant’s parent company and government agencies obligated to protect the public, in monitoring the facility.

Even worse, the investigation confirmed that NDK was warned about potential danger to surrounding businesses and specifically referenced the Tollway Oasis gas station where a bystander was killed by debris launched by the explosion.

The plant – located at 701 Crystal Parkway – had eight 50-foot pressure vessels used to produce synthetic crystals. According to the CSB, corrosion in those vessels led to an explosion so powerful that building fragments were launched hundreds of feet. One section, weighing over 8,000 pounds, crashed through two concrete walls and traveled 435 feet, hitting an adjacent business office.

“The force of the impact pushed the wall inward, causing furniture to shift and ceiling tiles to fall (in the adjacent office),” the report stated.

The thrust from the escaping liquid, caused the base of the Bessel to violently shear from its foundation and send pieces of structural steel into the parking lot of the nearby gas station, which killed the bystander.

NDK had eight of these vessels that were designed and built for crystal-growing operations, meaning the vessels were to have the proper materials and thickness to withstand high-operating pressures. According to the CSB report, a number of the NDK vessels did not meet standards set by the American Society of Mechanical Engineers (ASME) and lack of inspection allowed for corrosion to go unnoticed.

In 2002, NDK petitioned the State Boiler and Pressure Vessel Safety Division for a special exemption allowing it to continue operations without adhering to code, which was approved. The vessel designer – Engineering Pressure Systems – advised NDK to have annual inspections performed. That advice, according to the CSB, was ignored.

“NDK, nor the state of Illinois, performed regular inspections,” the report stated. “Stress-corrosion cracking went uninspected and undetected, for years.”

It was also determined the coating used on the vessels to protect them from corrosion, did not provide the protection NDK promised it would.

“The CSB learned that NDK never actually tested, or verified, the effectiveness of the coating to prevent corroding,” the report stated.

After an incident in 2007 that led to an uncontrolled leak of caustic material, NDK’s insurer initiated an investigation that provided directives which could have avoided the 2009 incident and saved a life. The investigator in 2007 “had serious reservations” about the potential of “catastrophic scenarios” if the facility resumed operations with the vessels, determined to have “improper design, fabrication and material selection.” The investigation results also referred to potential danger to the plant’s surroundings, even mentioning the gas station where the bystander was killed.

“At every level, the risk of catastrophic vessel failure was overlooked and public safety, literally and figuratively, fell through the cracks,” CSB chairperson Rafael Moure-Eraso said.

Not only was NDK allowed to resume without addressing its code violations or following the recommendations of its insurer, but it did so with almost no oversight by the state.

“The state of Illinois performed only inspections of accessible external areas,” the report stated. “No certified inspector ever inspected the vessels.”

The CSB also determined the facility’s location was poorly selected, stating it was “unsafely sited in a light industrial area, near other businesses and the interstate” and that the city “has no additional requirements for examining the impact” of such an emergency situation. In fact, the installation and operation of the pressure vessels for the manufacturing process, was not included in the application or any documentation submitted to the city during the permitting process.

Several recommendations are listed at the conclusion of the CSB report, but the entity itself does not issue fines or citations. The agency’s board members are appointed by the president and confirmed by the U.S. Senate, with the objective of investigating industrial chemical accidents.

 

City to rename street as memorial to Belvidere native

Nov. 21, 2013

By Troy A. Bruzewski

Editor

BELVIDERE – As of Saturday, Nov. 23, Farmington Way will be known by another name.

The city will rename it to honor Sgt. Anibal Santiago – a Belvidere native who died from injuries resulting from a high-altitude fall while conducting combat operations over mountainous terrain, on July 18, 2010.

Santiago – who enlisted in the Navy in 1991 – was employed as a police officer in Rockford from 1999-2005 after four years in the Navy and graduating from Elgin Community College. In 2007, he entered the U.S. Army, completing unit training and the Ranger Indoctrination Program before he was assigned to Headquarters Company, 3^rd Battalion, 75^th Ranger Regiment. He was a sniper and sniper team leader, serving his third deployment overall and second in Afghanistan.

Santiago was recognized several times for his service; his list of honors include: the Ranger Tab, the Combat Infantryman Badge, and the Parachutist Badge, the Navy Unit Commendation Medal, the Army Commendation Medal, the Navy Good Conduct Medal, the Army Good Conduct Medal, the National Defense Service Medal, the Global War on Terrorism Service Medal, the Navy Sea Service Deployment Ribbon, the South West Asia Service Medal, the Afghanistan Campaign Medal with Campaign Star, the Iraq Campaign Medal with Campaign Star, and the Army Service Ribbon.

He also was posthumously recommended for the Bronze Star Medal and the Meritorious Service Medal.

Santiago is survived by his wife, Mandy Santiago of Fort Benning, Ga.; son Hannibal of Belvidere; stepsons Desmond and Darian, from Fort Benning; and his parents Anibal and Maria Santiago of Belvidere.

In a dedication ceremony scheduled for 3 p.m., Saturday, Farmington Way will become known as Sgt. Anibal Santiago Memorial Way.

 

Poplar Grove approves wind turbines for residents’ roof

Nov. 20, 2013

By Bob Balgemann

Reporter

POPLAR GROVE - Patrick and Patricia Moss have received permission from the village board to have two wind turbines installed on the roof of their home at the intersection of Abbey Drive and Whiting Road.

One of the turbines would be a maximum of 25 feet tall with the other one being five feet from the peak of the roof.

The planning and zoning commission (P&Z) initially voted 6-0 at its October meeting to recommend approval of the request. The village's administration committee on Oct. 28 voted 2-0 with one absent to also recommend approval.

Finally, the village board approved issuing the special use permit at its Nov. 11 meeting.

Before the committee vote, member Don Bawden asked if there had been a public hearing on the proposal, if neighbors had been notified about the hearing by certified mail and whether anyone attended the hearing.

"Yes, yes and no," village administrator Mark Lynch replied, meaning there had been a public hearing, neighbors were notified by certified and that no one showed up to address the matter.

Village attorney Roxanne Sosnowski said the Boone County Planning Department, which serves the village, took care of the notifications. In addition, interim planning director Kathy Miller and associate planner Gina DelRose also were at the P&Z meeting.

"I just want to be sure there are no problems down the road," Bawden said. Beyond that, he wanted to know if the turbines would be professionally installed.

Patrick Moss said he had been in the construction business for 30 years, adding that he was a licensed mechanical contractor with the city of Rockford.

"Works for me," Bawden said, in response.

"Everything is by the book," Moss interjected.

Also before the vote Lynch asked about the cost of a building permit for the project? "Probably less than $200," answered Phil Long, the village's building inspector.

In supporting documents, Patrick Moss stated that for several years he had been intrigued by solar and wind options for producing power. In addition, he said that over the years he had been exposed to several successful installations.

Cost of materials and equipment has become more affordable, he said, and he'd like to install one while he can afford it - and before he retires.

The plan is to produce enough power for the home and sell any overage to a utility company "to lessen the load on the power grid," he explained. He termed the project "environmentally friendly and reduces fossil fuel use by me and by power plants."

No one had any questions of the applicant.

During their deliberation, P&Z members considered the six criteria that should be met in order to be granted a special use permit. The majority of them have to do with not creating a negative impact on neighbors or the surrounding area.

In each case, staff determined the proposal had complied with the requirements. That led P&Z to approve the findings of fact and issue its positive recommendation.