A CHEMICAL plant worker has told of the "horror" that met him when he went to the aid of a colleague caught up in a toxic gas explosion.
He was speaking at an inquest into the death of Paul Doyley, from Immingham, who died after a blast caused by leaking titanium tetrachloride fumes at Stallingborough's Cristal Global site, formerly known as Millennium Chemicals on March 5, 2010.
The hearing – expected to last four days – got underway at Cleethorpes Coroner's Court yesterday, where process operator Stephen Russell described how he ran to the control room upon hearing the explosion and immediately donned breathing apparatus to head out to find Mr Doyley, whose overalls were round his ankles in a desperate attempt to avoid being burnt.
Mr Doyley, who was aged 48 at the time, received treatment for chemical burns and inhalation of toxic fumes at a specialist burns unit at Wakefield's Pinderfields Hospital following the explosion, but later died on March 18.
Mr Russell said: "When I got there with my colleague I could see Paul, but we didn't exchange words – we just looked at each other.
"He had no suit on, just overalls which were down by his boots. In a typical clumsy move I fell over as I got to him.
"I reassured him he was okay and would be coming with us. I put my arms around him but I struggled as his overalls were stuck in the hot material on the floor, which was up to our boots.
"We took him out of the immediate danger area onto some concrete, where we laid him down and attempted to take his overalls off, which was pretty difficult."
Mr Russell added that what he saw as he arrived on the scene was "a horror".
He was also taken to hospital himself for treatment to burns to his knee, after being spotted alone coughing and vomiting after inhaling fumes.
Dr MacDonald, consultant pathologist at Pinderfields Hospital, said Mr Doyley was wrapped in several bandages consistent with burns following an external examination.
He also added how both lungs had become inflamed and the cause of death, in his opinion, was acute respiratory distress syndrome due to chemical burns.
The first witness to give evidence was Health and Safety Executive investigator Brian Fotheringham.
He said: "A vessel ruptured violently and its contents were released, forming a toxic vapour cloud.
"Mr Doyley was exposed to this vapour cloud after the D650 vessel had failed. The unit ruptured because it was subjected to forces it was not designed to withstand. Amounts of titanium tetrachloride which were not normal had got in to the vessel, which was responsible for the over-pressurisation."
The inquest also heard how fire fighters used a blanket of foam to contain the spillage.
Witness David Stubley told coroner Paul Kelly how a gas vapour cloud had formed and was taken by the wind across the River Humber.
He added: "It became apparent that there was a problem with one of the pumps. I contacted Paul by radio, and he reported back that there was a lot of fumes coming from the pump and that some of its contents was leaking out of the gland.
"All of a sudden the control room shuddered and there was a muffled boom. It soon became clear that something quite serious had happened."
The inquest continues today.
![Toxic gas explosion: Worker tells of 'horror' scene at Cristal Global site, Stallingborough Toxic gas explosion: Worker tells of 'horror' scene at Cristal Global site, Stallingborough]()