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Related Experiment Videos

Explosion caused by flashing liquid in a process vessel.

Russell A Ogle1, Marcus V Megerle, Delmar R Morrison

  • 1Exponent Failure Analysis Associates, 185 Hansen Court, Suite 100, Wood Dale, IL 60191, USA. rogle@exponent.com

Journal of Hazardous Materials
|November 3, 2004
PubMed
Summary
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A polyvinyl chloride (PVC) plant explosion occurred due to uncontrolled flashing of vinyl chloride monomer. Inadequate investigation of prior overpressure incidents and insufficient safeguards led to a vapor cloud explosion, highlighting the need for better hazard recognition and protection systems.

Area of Science:

  • Chemical Engineering
  • Process Safety
  • Accident Investigation

Background:

  • A polyvinyl chloride (PVC) resin manufacturing plant experienced a significant explosion originating from an atmospheric storage vessel receiving slurry discharge.
  • The incident involved uncontrolled flashing of superheated liquid vinyl chloride, leading to a vapor cloud explosion with substantial property damage.

Purpose of the Study:

  • To investigate the root causes of the PVC plant explosion.
  • To identify deficiencies in the facility's hazard recognition, incident investigation, and overpressure protection systems.

Main Methods:

  • Analysis of prior overpressure incidents within the atmospheric storage vessels.
  • Evaluation of the existing venting system and safety instrumentation system (SIS) performance.

Related Experiment Videos

  • Determination of the cause of uncontrolled flashing of residual liquid monomer.

    • Main Results:

    • Prior overpressure incidents were inadequately investigated and documented, leading to a failure to recognize the hazard of flashing liquid vinyl chloride.
    • The existing venting system and SIS were insufficient to protect against the credible overpressure scenario.
    • The rapid flashing of residual liquid monomer in the slurry stream was identified as the cause of previous and the final overpressure events.

    Conclusions:

    • Prior incident data is crucial for recognizing process hazards.
    • Safeguards must have clearly defined performance objectives to protect against credible overpressure scenarios.
    • Superheated liquids above their boiling point pose an overpressure hazard, requiring controlled discharge to match venting capacity.