Lessons from a Fatal
Paint Oven Explosion

Fatal Paint Oven Explosion Illustrates Need for Preventive Maintenance of Safety Related Systems and Incident Notification Procedures

The explosion on May 31, 1998 sent the 800 pound fan assembly (left inset) of the auto paint drying oven into the aisle, striking and killing Dennis Schafer.

A paint oven furnace explosion at GM’s N.A.O. Lordstown Assembly plant on Sunday, May 31, 1998 resulted in one worker death. Journeyman Pipe fitter Dennis Schaefer was killed while troubleshooting the #4 "Elpo" furnace for the large oven that dries and cures the paint of new cars. This tragic loss underscores the hazards of gas-fired combustion equipment, the need preventive maintenance of safety related systems, compliance with consensus standards, and incident notification systems.

The explosion occurred following repeated attempts to light a natural gas burner that heats a paint-drying oven. The burner had shut off, and Brother Schaefer and two fellow journeymen were attempting to re-light the pilot by using an electronic igniter. After several attempts, an explosion occurred in the oven, causing a fan housing to break loose striking Schaefer, causing crushing injuries.

The joint investigation concluded that faulty equipment had allowed natural gas to build up in the combustion chamber. Gas accumulated when the purge cycle did not operate properly to ventilate the burner area. Several previous incidents described below signaled problems in similar equipment. This information was not communicated and remedial actions were not taken.