Read the given acciedent (Flixborough explosion) and answer the following questi
ID: 717941 • Letter: R
Question
Read the given acciedent (Flixborough explosion) and answer the following questions clearly:
a)Prime Cause of the accident
b)Other factors contributing to the accident
c)Procedures required to prevent a re-occurrence.
Flixborough (Nypro UK) Explosion 1st June 1974 Accident summary At about 16:53 hours on Saturday 1 June 1974 the Nypro (UK) site at Flixborough was severely damaged by a large explosion. Twenty-eight workers were killed and a further 36 suffered injuries. It is recognised that the number of casualties would have been more if the incident had occurred on a weekday, as the main office block was not occupied. Offsite consequences resulted in fifty-three reported injuries. Property in the surrounding area was damaged to a varying degree. Prior to the explosion, on 27 March 1974, it was discovered that a vertical crack in reactor No.5 was leaking cyclohexane. The plant was subsequently shutdown for an investigation. The investigation that followed identified a serious problem with the reactor and the decision was taken to remove it and install a bypass assembly to connect reactors No.4 and No.6 so that the plant could continue production. During the late afternoon on 1 June 1974 a 20-inch bypass system ruptured, which may have been caused by a fire on a nearby 8-inch pipe. This resulted in the escape of a large quantity of cyclohexane. The cyclohexane formed a flammable mixture and subsequently found a source of ignition. At about 16:53 hours there was a massive vapour cloud explosiorn which caused extensive damage and started numerous fires on the site. Eighteen fatalities occurred in the control room as a result of the windows shattering and the collapse of the roof. No one escaped from the control room. The fires burned for several days and after ten days those that still raged were hampering the rescue work.Explanation / Answer
Primary cause of explosion: The reason for the explosion is the rupture of the bypass of the reactor. This must have due to bad design of the bypass and not testing it under suitable conditions. Other factors contributing: No signals to indicate the leakage of the hydrocarbons. Not testing the bypass under various pressur and temperature conditions during installation. Procedures required to prevent reocurence: The management should have considered the harmful effects of using cyclcohexane and could have considered a safer option for the process. Proper design and testing of the recycle should be performed. Use blast resistant control rooms. HAZOP analysis before any new installation
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