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Published on 04/10/23
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With the fluid catalytic cracker unit (FCCU) running normally, a bypass line around the unsaturated gas plant (USGP) absorber/stripper reflux cooler suddenly ruptured. Approximately 12 tonnes of light hydrocarbons were released over a 10-minute period, creating a vapour cloud covering an area of around 14,000 m2 (150,000 ft2) and engulfing several process units. The cloud reached a fired heater and exploded. The resulting overpressure caused massive damage to the FCCU and USGP and the roof of the local control room collapsed, killing 3 of its occupants. A massive fire caused further loss of containment and escalation.
Ask yourself and your crew:
- How can something like this happen here (e.g. on our site)?
- What safety measures (i.e. procedures, controls/barriers) do we have in place to mitigate the risk?
- How do we know the risk controls/barriers are working?
- What improvements or changes should we make to the procedures, controls/barriers or the way we work?
Original content courtesy of IChemE Safety Centre
