Country: ASIA

An explosion and fire occurred at a gas-to-liquids (GTL) plant in Bintulu, Sarawak. The fire was brought under control on the next day. The plant was one of only two commercially successful GTL plants in the world at the time, with a capacity to produce 12,500 bbl-per-day of middle distillates and waxes from natural gas feedstocks. The explosion occurred in the air separation unit (ASU) which supplied oxygen for the production of synthesis gas feedstock. The investigation into the incident pointed to an initial combustion event in the ASU as the most probable cause. This combustion event is thought to have initiated explosive burning of the aluminium heat exchanger elements in the presence of liquid oxygen, such that the elements ruptured explosively. Twelve people were injured, none seriously, and the plant was shut down for several months for repairs.

[ Property Damage $275 Million. Estimated Current Value $510 Million ]

Image credit: Shell

A release of hot light hydrocarbon during the completion of a maintenance activity resulted in a major fire. The fire occurred on a residual fluid catalytic cracking (RFCC) unit that had recently been commissioned as part of a major expansion, doubling the overall refinery capacity. The fire resulted in the closure of the expanded area of the refinery while extensive rebuilding activity was delivered. The value of the property damage loss is currently estimated to be in excess of US$1 billion.

[ Property Damage $1000 Million. Estimated Current Value $1000 Million ]

Image credit: ADNOC

The incident occurred when workers were weighing a barrel of 4-hydroxybenzohydrazide. There was a short circuiting in the weighing scale which led to an explosion.

Proximate causes:
• Defective equipment

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)
Image Credit: Survival Technologies

A gas leak followed by explosion occurred during an inspection process due to the loose of valve bolt.

Proximate causes:
• Inadequate training/knowledge transfer (Lack of understanding the process);
• Lack of work rules/policies/ standards/procedures (wrong procedures for inspections);
• Inadequate work rules plan (lack of the pre-start safety review before inspection).

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)
Image Credit: Wikipedia

Four people were killed in an explosion and fire at an oil gathering center, gas booster station, and power substation. The explosion occurred after a leak from a buried oil pipeline in the gathering station spread to a power substation, sparking the blaze. The flash explosion and resulting blaze hit the gathering center and the adjacent gas booster station. At least 19 people were injured in the incident, mainly suffering first- and second-degree burns. The fire was extinguished two days after the event.

[ Property Damage $150 Million. Estimated Current Value $246 Million ]

Image credit: BBC

An explosion occurred when 8 personnel were working on the repair of a catalyst tower.

Proximate causes:
• Inadequate training/knowledge transfer (Lack of understanding the process)
• Lack of work rules/policies/ standards/procedures (wrong procedures for inspections);
• Inadequate work rules plan (lack of the pre-start safety review before inspection).

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)

An explosion occurred due to an overflow of a slurry mixing tank, containing potassium sulfide, potassium dihydrogen phosphate, and MAP.

Proximate causes:
• Inadequate training/knowledge transfer (Lack of understanding the process);
• Lack of work rules/policies/ standards/procedures (wrong procedures for inspections);
• Inadequate work rules plan (lack of the pre-start safety review before inspection).

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)

A high-pressure steam (3.7 MPa) discharge occurred during a maintenance process, resulting in three field workers burned to death.

Proximate causes:
• Lack of work rules/policies/ standards/procedures (wrong procedures for inspections);
• Inadequate work rules plan (lack of the pre-start safety review before inspection).

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)

Four reactors exploded after an initial fire in a warehouse in the plant. The toxic gas released due to the fire and explosion affected the local community. Electrical short circuit and improper shutdown was the reason that triggered the incident.

Proximate causes:
• Inadequate tools, equipment & vehicles (Electrical appliances shortcut)
• Failure in following procedure (improper shutdown)

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)

A major explosion occurred at a 145,000-barrels-per-day refinery in the north-eastern city of Sendai, hours after the largest earthquake in the country’s history was followed by a tsunami. The fire at the Sendai refinery originated from a land oil product shipping facility. Workers at the refinery were evacuated, and there was no capacity available to extinguish the fire. Fire in the storage and shipping facilities had also damaged a 35,500 barrels-per-day FCC at the refinery.

[ Property Damage $590 Million. Estimated Current Value $651 Million ]

Image credit: JXTG Nippon Oil & Energy

On March 11, 2011, the Great East Japan Earthquake triggered an extremely severe nuclear accident at the Fukushima Daiichi Nuclear Power Plant, owned and operated by the Tokyo Electric Power Company (TEPCO). This devastating accident was ultimately declared a Level 7 (“Severe Accident”) by the International Nuclear Event Scale (INES).

When the earthquake occurred, Unit 1 of the Fukushima Daiichi plant was in normal operation at the rated electricity output according to its specifications; Units 2 and 3 were in operation within the rated heat parameters of their specifications; and Units 4 to 6 were undergoing periodical inspections. The emergency shut-down feature, or SCRAM, went into operation at Units 1, 2 and 3 immediately after the commencement of the seismic activity.

Although there were no immediate fatalities, a worker later died from radiation exposure (https://www.reuters.com/article/us-japan-fukushima-radiation/japan-acknowledges-first-radiation-death-among-fukushima-workers-idUSKCN1LL0OA)

Image Credit: NY Times

A fire broke out in a wet gas scrubber while heavy maintenance on a unit was being carried out. Personnel were evacuated from the site and there were no injuries. The site was conducting a planned shutdown and maintenance of the plant equipment including the polypropylene plant.

[ Property Damage $150 Million. Estimated Current Value $162 Million ]

Image credit: ORPIC

An explosion occurred when 6 personnel were working on the repair of a catalyst tower

Proximate causes:
• Lack of work rules/policies/ standards/procedures (wrong procedures for inspections);
• Inadequate work rules plan (lack of the pre-start safety review before inspection).

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)

An accident occurred at a methylcellulose manufacturing facility. An explosion occurred and was followed by a fire, which was extinguished about seven hours later. A total of 17 people working at the site were injured in this accident; three critically, five seriously, and nine with minor injuries. There was one minor injury off site. Ignition of the methylcellulose powder is though to have been due to static electricity, resulting in a powder dust explosion. All methylcellulose operations were suspended for two months before sequentially restarting.

[ Property Damage $240 Million. Estimated Current Value $306 Million ]

Image credit: Shin-Etsu

On 21 March 2019, a major explosion occurred at a chemical plant in Chenjiagang Chemical Industry Park, Chenjiagang, Xiangshui County, Yancheng, Jiangsu, China. According to reports published on March 25, 78 people were killed and 617 injured.

The State Council of China officially recognized the severity of the accident, often referred to as “3.21 Explosive Accident”.

The explosion occurred at a local time of 14:48 (06:48 GMT). 78 people were killed, and at least 94 were severely injured, 32 of whom were critically injured. Around 640 people required hospital treatment and were taken to 16 hospitals. The injured included children at a local kindergarten. CENC detected an ML2.2 artificial earthquake whose epicenter is at 34.331°N 119.724°E.

The force of the blast started numerous fires in Yancheng, knocked down several buildings, and reportedly destroyed windows several kilometers away. The fire was reported to have been controlled by 03:00 local time. Considerable damage was caused to nearby factories and offices; the roof of Henglida Chemical Factory, 3 km from the explosion, fell in. At least one of the people killed was in another building destroyed by the blast. Windows are reported to have been blown out up to 6 km away from the explosion, and houses and other buildings were damaged in the nearby village-level administrative divisions including Hai’an Town (Haianju) (海安社区) and Shadang (沙荡社区). This explosion was strong enough that it registered on earthquake sensors and could be seen by satellites. The blast created a crater resulting in a magnitude 2.2 seismic shock that took over 900 firefighters to get the fire under control.

Ref: https://en.wikipedia.org/wiki/2019_Xiangshui_chemical_plant_explosion
Image Credit: Reuters

A major explosion in a firecracker unit occurred. The unit was run illegally by the owner who was later taken under custody. Explosions in firecracker units have been a prevalent problem in the state of Seemandhra, India which needs to be addressed.

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)
Image Credit: PTI

A blast occurred in a pumping station, after leaking oil caught fire. 177 fire engines and more than 800 firefighters were rushed to the blaze, and more than 14,000 residents in the surrounding area were evacuated.

Proximate causes:
• Improper use of protective methods (Improper welding of conveying pipe)

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)
Image Credit: Getty

A chemical drum which is speculated to have contained an old chemical exploded at Echotech fiber manufacturing factory workshop.

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)
Image Credit: Unidentified

Two employees accidently fell in an aerobic tank sewage treatment station. Two more employees fell into the aerobic tank in the subsequent rescue.

Proximate causes:
• Inadequate tools, equipment & vehicles (Aerobic tank no special ventilation equipment)

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)

A crack occurred in a pipeline (diameter 200 mm) conveying oil and gas, and the following fire damaged three pumps and some instrumentation

Proximate causes:
• Inadequate tools, equipment & vehicles (Equipment failure: sealing failure and pipe leak)

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)

A fire occurred in a company producing ammonia, and other chemical products. The facility was severely damaged in the catastrophic fire.

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)

An explosion occurred in a glycol unit refining tower of a petrochemical plant

Source: A web-based collection and analysis of process safety incidents (https://www.sciencedirect.com/science/article/abs/pii/S0950423016302285)
Image Credit: CCTV