Inst ToolsInst ToolsInst Tools
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Erection & Commissioning
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
  • Request
Search
  • Books
  • Software
  • Projects
  • Process
  • Tools
  • Basics
  • Formula
  • Power Plant
  • Root Cause Analysis
  • Electrical Basics
  • Animation
  • Standards
  • 4-20 mA Course
  • Siemens PLC Course
Reading: Learnings from the BP Refinery Explosion at Texas City
Share
Font ResizerAa
Inst ToolsInst Tools
Font ResizerAa
  • Courses
  • Design
  • PLC
  • Interview
  • Control System
Search
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Erection & Commissioning
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
  • Request
Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Inst Tools > Blog > Root Cause Analysis (RCA) > Learnings from the BP Refinery Explosion at Texas City

Learnings from the BP Refinery Explosion at Texas City

in this article, we will learn the BP refinery explosion at Texas city and understand the main reasons which caused this accident.

Last updated: October 30, 2023 11:40 am
vicky
Root Cause Analysis (RCA)
No Comments
Share
8 Min Read
SHARE

In 2005, several units of the BP refinery in Texas City were shut down for maintenance jobs. For this shutdown job, many BP employees as well as contractors were engaged 24*7.

Contents
BP Refinery ExplosionWhat we should learn from this refinery accident?

Also, around 10 trailers were placed near the industrial plants for these contractors to do meetings and other purposes like rest and lunch. One of the plants that was near these trailers was the isomerization unit. The distance between the isomerization unit and these trailers was less than 250 meters.

BP Refinery Explosion

BP Texas Refinery Incident Causes

On 23rd March 2003, in the early morning around 02:05 am, the isomerization unit was started after these maintenance activities. The operator started feeding the raffinate inside the splitter tower which is one of the steps of start-up. This splitter tower has a level transmitter which had a range of 9 feet. No other level indicator was used in the splitter tower.

As per the safe operating point, the level was supposed to be maintained near 6 feet, but usually during the start-up, the crew members maintained a level above 9 feet to avoid damage to the furnace due to the low level. While filling, a high alarm actuated but another alarm at a higher level did not actuate. After some time, the feed to the splitter tower was stopped. At this time, the level was 13 feet. The level indication was 100 %.

Now, before an hour of the shift ended, the lead operator left the control room and updated the log book. A new board operator arrived to attend the shift in the morning. This was his 30th shift (12-hour shift without any week off). He read the logbook. But in the log book, the splitter tower’s level was not mentioned.

BP Refinery Explosion
Image Courtesy: CSB

An hour later, the day shift supervisor reached the control room. He did not receive any brief status of the unit start-up activity. The board operator resumed the unit start-up and started feeding the raffinate into the splitter tower. The control valve which controlled the level of the splitter tower was left closed which resulted in more level build-up in the splitter tower. To increase the temperature in the splitter tower, the associated burners were lit.

After a few hours, due to some medical emergency, the day shift supervisor left the site and now only the board operator was present to look after the start-up and other ongoing jobs. The level was still increasing in the splitter and went above 95 feet. The level indicator still showed 9 feet. An alarm was generated which indicated high pressure inside the splitter.

To control this high pressure, the valve to blow down the drum was opened and also, the furnace was turned off. The valve to the storage tanks from the splitter was also opened. The flow to storage tanks was routed through the heat exchanger which exchanged heat with feed to the splitter tower. This increased the temperature of the feed to the splitter to 140 degrees Fahrenheit.

Due to this increased temperature, the liquid started boiling and started coming out of the vapour lines from the top. The high pressure also opened the relief valves and passed this liquid to the blowdown drum. The blowdown drum also got filled fully and began to spill the liquid into the process sewer.

The high-level alarm of the blowdown drum also did not work. As a result, the hot flammable liquid spilled like spray and formed a huge vapour cloud in 90 seconds only which covered the trailers and a standing truck that already had its engine in running condition.

This truck ignited the vapour cloud which led to heavy destruction to nearby areas and fires. Unfortunately, the trailer was also occupied by contractors who have returned to the trailers for meetings. This led to the death of 15 workers and 180 of them got injured.

Updated BP Texas City Animation on the 15th Anniversary of the Explosion

What we should learn from this refinery accident?

  1. Always pay attention to every minute detail and mention it in the log books or other records (in this case, the level inside the splitter tower was above 9 feet and this was to be mentioned specifically. This needed extra attention).
  2. Always give proper hand over take over to the relieving shift crew and discuss every critical thing even if it is known by everyone (Even though it was known that the level indicator did not show a level above 9 feet, the operators could have discussed again about this level again inside the splitter tower).
  3. Follow the standard operating procedures (Here, the level was supposed to be maintained near 6 feet which was not followed).
  4. Identify critical equipment in your area (level transmitter in this case) and test it at regular intervals as per PM schedule (In this case, the higher-level alarm did not appear. If PM was done properly, then this could have been known earlier).
  5. Interlocks help in preventing such accidents. Here if on high level interlock feed cut interlock was present, then this accident could have been prevented.
  6. Always have multiple equipment for critical applications (multiple-level transmitters could have been used in this case).
  7. Proper training for the crew members (the board operator was unaware of the hazards associated with high levels inside the splitter tower).
  8. Do not ask team members to work for longer time (the board operator who came in morning shift was attending his 30th continuous 12-hour shift)
  9. During start-up and shut-down activities, try to have sufficient manpower who know the process and are skilled at that particular job.
  10. During start-up and shut-down activities, try to vacant nearby places which are having human occupancy or let them know about the activities going on so that they can have an idea about everything happening near them.

There were multiple reasons out of which if few were followed correctly, then also this accident would have been prevented.

If you liked this article, then please subscribe to our YouTube Channel for Instrumentation, Electrical, PLC, and SCADA video tutorials.

You can also follow us on Facebook and Twitter to receive daily updates.

Read Next:

  • Process Air Compressor Overhauls
  • Root Cause Analysis for Plant Trip
  • Malfunctioning Inlet Check Valves
  • Refrigeration Compressor Turbine
  • Erratic Stroking of Control Valves
Don't Miss Our Updates
Be the first to get exclusive content straight to your email.
We promise not to spam you. You can unsubscribe at any time.
Invalid email address
You've successfully subscribed !

Continue Reading

Arc Fault Breaker (AFB) Electrical Problem Solved
Malfunctioning Inlet Check Valves caused chaos at Compressor stop/trip
NH3 Storage Tanks Ammonia Gas Venting Issue – Root Cause Analysis
Primary Reformer RFG main Hot Spots threaten Indefinite Outage
RCA – Compressor Did Not Trip on Suction Pressure Low Low
Flanged Rotameter Caused Pipe Weld Cracks and Gives Wrong Readings
Share This Article
Facebook Whatsapp Whatsapp LinkedIn Copy Link
Share
Leave a Comment

Leave a Reply Cancel reply

Your email address will not be published. Required fields are marked *

Stay Connected

128.3kFollowersLike
69.1kFollowersFollow
210kSubscribersSubscribe
38kFollowersFollow

Categories

Explore More

Thermowell Shank to Flange Repeat Weld Leaks
Pressure Switch Frozen Screwed Cover Extends the Plant Shutdown
Root Cause Analysis for Vibration Probe Not Responding
18 Temperature Sensors Fault Leads to Plant Shutdown
Finned Tube Steam Leaks – Root Cause Analysis
Instrumentation Engineering Problems Solved – Root Cause Analysis
Control Valves – Repeat Actuator Diaphragm Bursts
Under and Over-Capacity Control Valve Pose Poor Controllability

Keep Learning

Industrial Light Fittings and Street Light Poles Corrosion Problems

Industrial Light Fittings and Street Light Poles Corrosion Problems

Demister Pads Problem

Problems with Demister Pads – Root Cause Analysis (RCA)

Leaky Boiler Drum Level Switch

Leaky Boiler Drum Level Switch Stops NH3 Plant Commissioning

Transformers Coolers Weld Joints Oil

Transformers Coolers Weld Joints Oil Oozes Were Eye Sores

Root Cause Analysis for Valve Problem

Root Cause Analysis for Tank Overflow due to Valve Problem

RF and RTJ Flange Installed Gasket

Flange Joint Errors shutdowns root cause analyzed and eliminated

Innovative Segment Orifice

Pitot-tube Replaced with Innovative Segment Orifice Plate

4 way solenoid valve root cause

Safety Liquid Ammonia Disconnect threatens NH3 Vapor Spill

Learn More

Direct & reverse actions control valve

Direct Acting Control Valves & Reverse Acting Control Valves

Difference Between Skin Effect and Proximity Effect

Difference Between Skin Effect and Proximity Effect

Leading Power Factor

Power Factor

Embedded Systems

Introduction to Embedded Systems – Features, Types, Applications

hall effect speed sensor

Speed Probe Working Principle

Solenoid

Difference between AC and DC Solenoid Valves

Jet Pump

What is a Jet Pump? – Principle, Types, Comparison

Electrical Power Distribution

Electrical Power Distribution

Menu

  • About
  • Privacy Policy
  • Copyright

Quick Links

  • Learn PLC
  • Helping Hand
  • Part Time Job

YouTube Subscribe

Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Welcome Back!

Sign in to your account

Username or Email Address
Password

Lost your password?