URV Chairs
ENRESA-URV Industrial Safety Chair
Accidents caused by design errors
Below we describe examples of accidents caused by design errors, described in "Manufacturing Chemist Associations" by J.A Davenport.
Explosion of ethyl oxide
A 25 m3 ethyl oxide storage tank accidentally became contaminated with ammonia. The tank exploded and a cloud of OE was formed, and exploded immediately. The force of the explosion was the equivalent of 18t of TNT. One person was killed and nine were injured. The financial losses exceeded 16.5 M $.
The design did not include a system to prevent the return of ammonia into the tank (a simple retaining valve, or a blind would have sufficed). It did not include splinkers or retaining trays for spillages, etc.
Explosion of ethyl
A fault (or breakage) in a 3/8” accessory in a compression system that compressed ethylene from 68 to 136 kg/cm2, located on a line section on a slope, caused the release of 90 to 225 kg of ethylene. The cloud exploded with a force equivalent to 0.12 - 0.30 tons of TNT. The explosion was partially confined, given that it occurred on a patio surrounded by some buildings and walls. Two people were killed, 17 more were injured and the financial losses totalled 6.5 M $. The mechanical design was defective and the component in question had not been correctly specified.
Explosion of butadiene
A bottom valve of a reactor opened accidentally owing to a lack of instrument air. 750 l of butadiene escaped, causing a gas cloud that ignited, exploding after 15 m. The excess pressure resulting from the explosion was 35 to 70 mbar, sufficient to bring down the walls but not excessive. There were three fatal and two injured victims.
The probable causes of the accident were: the installation of a valve that opened due to a shortage of air, the lack of gas detectors, the lack of a shut-off valve that would close in the event of an escape and eliminate the ignition source in the most proximate vicinity.
Historical record of accidents
- Accidents described in the “Case Histories"
- Accidents caused by design errors (described by J.A Davenport)
- Historical record of catastrophes