Investigation Report
Kuraray Pasadena Release and Fire
Kuraray Pasadena Release and Fire
- CSB
- Investigation Report
- Hazardous SubstancesHot Work and FireProcess Safety
- FireFunctional safetyHydrocarbon releasePressure systemsProcess safety
- Hot work
- Fall protection equipmentPressure vesselProcess pipework and pipelinesValve
- Alarm managementExclusion zonesOperating and work proceduresPressure relief
- Downstream and process industries
- Onshore facility
Summary
Investigation of an ethylene release and fire during reactor startup at Kuraray’s Pasadena plant, injuring 23 workers. It examines unsafe atmospheric pressure-relief discharge, disabled interlocks, alarm flooding, conflicting operating instructions and restricted flare use. Recommendations address safe discharge design, worker exclusion, operating limits, training and independent process safety assessment.
Classifications: Fire; fire safety.
Classifications: Functional safety; safety instrumented systems; SIS.
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: Hot work; welding and cutting.
Classifications: Fall protection equipment; safety harness; fall arrest equipment.
Classifications: Pressure vessel; pressure vessels.
Classifications: Process pipework and pipelines; process piping.
Classifications: Valve; valves.
Classifications: Alarm management.
Classifications: Exclusion zones; red zones; restricted access zones.
Classifications: Operating and work procedures.
Classifications: Pressure relief; overpressure protection.
Classifications: Downstream and process industries; refining; petrochemicals.
Classifications: Onshore facility; onshore plant.
Summary
The investigation examines a chemical release followed by a fire.
Themes: hazardous substances, hot work and fire, process safety.