A new safety video details the events leading up to the November 2019 explosion at the TPC Group Chemical Plant in Port Neches, Texas.
The explosion destroyed a portion of the TPC facility, damaged nearby homes and businesses and led to the mandatory evacuation of residents living within 4 miles of the plant. Several workers and members of the public were injured and fires burned at the facility for more than a month.
There was $450 million in property damage to the facility and $153 million in off-site property damage to nearby homes and businesses.
Video contains animation of events, interviews with investigators
The safety video, produced by the U.S. Chemical Safety and Hazard Investigation Board (CSB), includes an animation of the events leading to the incident along with interviews of CSB member Dr. Sylvia Johnson and lead investigator, Butch Griffin.
CSB investigators found that the incident resulted from inadequate management of a hazard called “popcorn polymer,” a common substance found at plants that handle or produce butadiene. The popcorn polymer grew and formed inside a dead leg in piping that was created when a process pump was taken out of service for several months.
The popcorn polymer exponentially expanded inside the dead leg for 114 days without anyone at the plant being aware. Eventually, pressure caused the piping section to rupture, releasing flammable butadiene that immediately exploded.
“The incident at TPC was the result of a known hazard where popcorn polymer grew and formed inside equipment that was poorly managed and controlled at the facility,” Johnson said in the video. “Gaps in industry good guidance on the management of popcorn polymer formation played a role. The result was a catastrophic incident that disrupted life at the facility as well as the local community.”
The safety video covers four key safety issues that contributed to the incident, including:
- dead leg identification and control
- process hazard analysis action item implementation
- control and prevention of popcorn polymer, and
- remotely operated emergency isolation valves.
Along with these safety issues, the video also highlights the safety recommendations the CSB made to TPC Group and the American Chemistry Council.
