Missing Safety Features Lead to Explosion at Chemical Factory

Case Overview

This case takes place in Pennsylvania and involves a massive explosion at a facility that specialized in the design and manufacturing of specialty chemicals primarily used for the production of advanced materials for high-end engineering applications. The explosion originated from a large chemical reactor during the production of a notoriously dangerous and volatile compound. The reactor system lacked a number of essential safeguards designed to contain the heat and pressure generated from the reaction, which led to runaway heating of the reactor’s structure. The configuration of the reactor was allegedly in violation of multiple safety codes and regulations at the time of the accident, and the resultant explosion killed several workers and caused millions of dollars in damage. Expert witnesses with specializations in forensic chemistry and explosives were retained for this case.

Questions to the Construction Safety expert and their responses

Please discuss your background as it relates to industrial chemical production.

I have used refurbished vessels in the past. Prior to using them, the maximum pressure that they could tolerate would be calculated by others. In addition, they would be inspected for corrosion by others. However, I have been involved in two kinds of designs of pressure vessels: Development of a 'duty specification' and Development of a complete process design package.

Are you able to opine on the mechanical/structural issues behind the explosion? Given your experience and the brief case summary, what are some potential causes?

In the case of a 'duty specification', I provided the design company with the residence time required to complete the reaction along with the operating temperature and pressure. The design company would be responsible for sizing the vessel, studying potential side reactions, sizing the safety valve for a case of a temperature runaway, and sizing the cooling system, as well as several other areas that are basically chemical engineering related. Confirming the mechanical integrity of the vessel and inspecting for corrosion is critical. For a complete process design package, the operating company would be responsible for various safety and mechanical considerations.

Please tell us why you?re qualified to serve as an expert reviewer of this case.

For my design work, the owner should provide the engineering contractor with a Design Basis Memorandum that describes the reaction and how the safety valve system should work. The design company would then be responsible for all phases—chemical, mechanical, and foundation of the design. The process design package should consist of vessel drawings including all nozzles and piping sizes and should include a discussion of potential runaway reactions and the cooling system.

About the expert

This expert has more than 30 years of experience in safety, industrial hygiene, OSHA, construction management, warehouse operations, chemical plant safety, forklift training, and loading dock trip and falls. He earned a masters degree in safety management from the Indiana University of Pennsylvania and is a certified safety professional. He is currently a private consultant for an environmental health and safety company and a faculty member on the OSHA consultation program at a university in Pennsylvania.