Investigation Report
KMCO LLC Fatal Fire and Explosion
KMCO LLC Fatal Fire and Explosion
- CSB
- Investigation Report
- ExplosionHot Work and FireProcess Safety
- ExplosionFireHydrocarbon releasePressure systemsProcess safety
- Fluid transfer
- Process pipework and pipelinesPumpsValve
- Emergency responseEnergy and process isolationPressure reliefRisk assessment
- Downstream and process industries
- Onshore facility
Summary
Investigation of the fatal isobutylene explosion and fire at KMCO’s Crosby facility. Metallurgical testing established pressure-driven brittle fracture of a cast-iron y-strainer. The report examines thermal-expansion hazards, manual versus remote isolation, emergency-response roles and alarm use, identifying weaknesses in hazard evaluation and response that contributed to the incident and its severity.
Classifications: Explosion; explosive atmospheres.
Classifications: Fire; fire safety.
Classifications: Hydrocarbon release; hydrocarbon leak; oil and gas release.
Classifications: Pressure systems; stored pressure; pressurised systems; pressurized systems.
Classifications: Process safety; major accident hazards.
Classifications: Fluid transfer; fluid loading; fluid offloading.
Classifications: Process pipework and pipelines; process piping.
Classifications: Pumps.
Classifications: Valve; valves.
Classifications: Emergency response; emergency preparedness.
Classifications: Energy and process isolation; isolation; energy isolation.
Classifications: Pressure relief; overpressure protection.
Classifications: Risk assessment; hazard assessment.
Classifications: Downstream and process industries; refining; petrochemicals.
Classifications: Onshore facility; onshore plant.
Summary
A fire and explosion at the KMCO custom chemical processing and speciality chemical manufacturing facility caused one fatality and multiple injuries.
Themes: explosion, hot work and fire, process safety.