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Polymerization Reactor Explosion at the XYZ Chemical Company

机译:XYZ化学公司的聚合反应器爆炸

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The following is my opinion of the events that led to this explosion as testified to in open court. Others may have different opinions.rnA few years ago, there was an explosion in a reactor at the XYZ Chemical Company that resulted in the death of two workers. The reactor was a block copolymerization reactor where butadiene and styrene monomers were added in a semi-batch manner. The heat of reaction was removed by means of a refrigeration system. The incident occurred when the reactants were not added in the sequence or quantity desired. The resulting runaway reaction overpressurized the reactor system and caused an expansion joint to rupture. The hydrocarbons released formed a vapor cloud that exploded, causing the death of two workers, serious injury to three others and significant damage to the facility.rnThe contributing causes of the incident included most of the Process Safety Management (PSM) elements developed by the Center for Chemical Process Safety of the American Institute of Chemical Engineers in 1989 and codified by OSHA in 1992 in the Process Safety Management Regulation in 1992: lack of information about the hazards of the chemicals in the process; lack of information about the equipment in the process and inadequate equipment; inadequate or no PHA; inadequate training; confusing operating procedures; failure to use management of change procedures; failure to perform a pre-startup safety review; failure to have an adequate contractor safety program and failure to investigate previous near misses and incidents and take corrective actions. The root cause was that the XYZ Chemical Company chose to have an inadequate PSM program; they chose to do no more than they needed to do to appear to be in compliance with OSHA's PSM regulation.
机译:以下是我对导致这场爆炸的事件的看法,公开法庭对此进行了证实。其他人可能有不同的看法。几年前,XYZ化学公司的反应堆发生爆炸,导致两名工人死亡。该反应器是嵌段共聚反应器,其中以半间歇方式添加丁二烯和苯乙烯单体。反应热通过制冷系统除去。当未按期望的顺序或数量添加反应物时发生该事件。所产生的失控反应使反应堆系统过压,并导致膨胀缝破裂。释放出的碳氢化合物形成蒸气云,爆炸,导致两名工人死亡,三人受伤,设施严重受损。rn造成事故的原因包括该中心开发的大多数过程安全管理(PSM)要素1989年获得美国化学工程师协会(American Institute of Chemical Engineers)的化学过程安全认证,并于1992年由OSHA编纂为1992年《过程安全管理条例》(Process Safety Management Regulation)。缺乏有关过程中设备的信息以及设备不足; PHA不足或没有;培训不足;令人困惑的操作程序;未能使用变更程序管理;无法执行启动前的安全审查;未能制定适当的承包商安全计划,以及未能调查先前的未遂事故和事件并采取纠正措施。根本原因是XYZ化工公司选择的PSM程序不足。他们选择做的事情不多于看起来要符合OSHA的PSM法规。

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