More Incidents that Define Process Safety book describes over 50 incidents which have had a significant impact on the chemical industry as well as the basic elements of process safety. Each incident is presented in sufficient detail to gain an understanding of root causes for the event with a focus on lessons learned and the impact the incident had on process safety. Incidents are grouped by incident type including Reactive chemical; Fires; Explosions; Environmental/toxic releases; and Transportation incidents. The book also covers incidents from other industries that illustrate the safety management elements.
The book builds on the first volume and adds incidents from China, India, Italy and Japan. Further at the time the first volume was being written, CCPS was developing a new generation of process safety management elements that were presented as risk based process safety; these elements are addressed in the incidents covered.
Table of Contents
1 Introduction 41
1.1 Why a Second Volume? 41
1.2 CCPS Risk Based Process Safety Elements 42
1.3 Human Performance 48
1.4 Organization of This Book 48
1.5 Engineering Design 49
1.6 How to Use the Book 50
1.7 Final Note 50
2 Reactive Chemical Incidents 52
2.1 Introduction 52
2.2 T2 Laboratories Runaway Reaction and Explosion, Florida, US, 2007 53
2.3 Hoechst Griesheim Runaway Reaction, Germany, 1993 60
2.4 Arco Channelview Explosion, Texas, US, 1990 64
2.5 Ammonium Nitrate Incidents 68
2.6 West Fertilizer Company an Explosion, Texas, US, 2013 69
2.7 RUI Hai International Logistics an Explosion, Tianjin, China, 2015 78
2.8 Port Neal Ammonium Nitrate Explosion, Iowa, US, 1994 81
2.9 Hickson & Welch Jet Flame, UK, 1992 86
2.10 Other Incidents 92
2.11 Additional Resources 93
3 Fire Incidents 96
3.1 Introduction 96
3.2 Hoeganaes Metal Dust Fires, Tennessee, US, 2011... 97
3.3 Chevron Richmond Refinery Fire, California, US, 2012 105
3.4 Valero-Mckee LPG Refinery Fire, Texas, US, 2007 115
3.5 BLSR Deflagration and Fire, Texas, US, 2003 121
3.6 Similar Incidents 127
3.7 Additional Resources 128
4 Explosion Incidents 131
4.1 Introduction 131
4.2 Buncefield Storage Tank Overflow and Explosion, UK, 2005 135
4.3 Petroleum Oil Lubricants Explosion, Jaipur, India 2009 145
4.4 Celanese Pampa Explosion, Texas, US, 1987 151
4.5 Williams Olefins Heat Exchanger Rupture, Louisiana, US, 2013 158
4.6 Imperial Sugar Dust Explosion, Georgia, US, 2008 165
4.7 Hayes Lemmerz Dust Explosion, Indiana, US, 2003 173
4.8 Varanus Island Pipeline Explosion, Australia, 2008 182
4.9 Natural Gas Purging Explosions 189
4.10 Oil Storage Tank Explosion, Italy, 2006 194
4.11 NDK Crystal Vessel Rupture, Illinois, 2009 199
4.12 Similar Incidents 205
4.13 Additional Resources 205
5 Environmental and Toxic Release Incidents 209
5.1 Introduction 209
5.2 BP Macondo Well/Transocean Deepwater Horizon Fire, Explosion, and Environmental Release, Gulf of Mexico, US, 2010 210
5.3 Freedom Industries, Inc. Chemical Spill, West Virginia, US 2014 222
5.4 Millard Refrigerated Anhydrous Ammonia Release, Alabama, Us, 2010 228
5.5 Dupont Methyl Mercaptan Release, Texas, US, 2014 234
5.6 Dupont Phosgene Release, West Virginia, US, 2010 242
5.7 DPC Enterprises, L.P. Chlorine Release, Missouri, US, 2002 249
5.8 Georgia-Pacific Hydrogen Sulfide Poisoning, Alabama, US, 2002 257
5.9 Citgo HF Release and Fire, Texas, US, 2009 262
5.10 Hube Global HF Release in Gumi, South Korea, 2012 265
5.11 Other Incidents 270
5.12 Additional Resources 270
6 Transportation Incidents 272
6.1 Introduction 272
6.2 Montreal, Maine & Atlantic Railway Derailment and Fire, Quebec, Canada, 2013 273
6.3 Norfolk Southern Collision and Hazardous Materials Release, South Carolina, US, 2005 280
6.4 Gaylord Chemical Nitrogen Tetroxide Release, Louisiana, US, 1995 284
6.5 Pacific Gas and Electric Company Pipeline Rupture and Fire, California, US, 2010 288
6.6 Additional Pipeline Releases 294
6.7 Air France Flight AF 447 Rio De Janeiro to Paris, 2009 299
6.8 Other Incidents 302
6.9 Additional Resources 303
7 Non-Oil/Chemical Incidents 304
7.1 Introduction 304
7.2 Fukushima Daiichi Nuclear Power Plant Release, Japan, 2011 305
7.3 Sewol Ferry Sinking, South Korea, 2014 312
7.4 Pike River Coal Mine Explosion, South Island, New Zealand, 2010 318
7.5 Big Branch Mine Explosion, West Virginia, US, 2010 323
7.6 University Laboratory Incidents 327
7.7 Mars Climate Orbiter Mishap, 1999 334
7.8 Other Incidents 336
7.9 Additional Resources 337
Appendix 1 338
References 342
