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The 25 Major Engineering Failures (1977-2007)

List of Engineering Failures Contributed by Material Failures, Corrosion, Design Flaw, and Construction Defect in Oil and Gas Production Facilities, Hydrocarbon Processing, and Oil and Gas Distribution As key chain in world energy supply, the industry within oil and gas production, hydrocarbon refinery, storage and distribution, and power plant industry strive to achieve the highest level of integrity and reliability of their facilities, structures, tool and equipment system. Industry stakeholders that ranging from oil and gas producer, engineering, procurement, contractors, material suppliers, and inspection companies from day to day improve the quality standards, discovering new technologies, develop new techniques and methodologies in order to raise the engineering integrity for the improvement of safety for people , environment conservation, and securing economic investment. Tak ada gading yang tak retak. As an ancient Indonesian proverb is also happened to engineering structure: there will be no design without flaw and there will be no construction without defect. Failures sometimes occur. In several cases the aftermath of failures have a significant impact to the people safety and economic risk. But industry gain a valuable experience each accident occurs. There always be opportunities to improve operation procedures, value perceptions, technical code revisions, and regulatory improvements. This publication as a result of literature work is aimed is to develop an alternative engineering failure database associated with material failures, corrosion, design flaw and construction defect that lead to material failure in oil and gas production, hydrocarbon industry, oil and gas distribution network, and energy power plant.

1. Umm Said Qatar April 3, 1977 (Weld Failure, Gas Processing Plant, 3 killed, US$ 76,350,000/179,000,000) A tank containing 236,000 barrels of refrigerated propane at 45 F failed at weld. Nearmiss-accident a year earlier reported at similiar tank weld caused 14,000 barrels of propane released. The possible cause of weld failure was corrosion by the influence of sulphate reducing bacteria that remained inside the tank after hydrotest with seawater. The wave of liquid propane swept over the dikes before igniting a near tank contained 125,000 barrels of buthane. It took eight days to completely extinguished the fire. (Source, Location)

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2. Abqaiq Saudi Arabia April 15, 1978 (Corrosion, Gas Processing Plant, US$ 53,700,000/117,000,000) A 22-inch pipe operated at 500 psig in gas transmission system corroded and releasing vapor cloud. The first ignition occured from a flare 1,500 feet downwind. The second ignition occured when jet whipped pipe section struck the vapor space of a 10,000 barrels spheroid tank. (Source, Location)

3. Ekofisk Norway March 27, 1980 (Weld Failure, Offshore Platform, 123 killed)

Alexandra L Kielland Platform, a semi-submersible oil drilling platform located at Ekofisk field North Sea capsized during a storm. The platform supported by five columns standing on five 22 meter diameter pontoons. The five 8.5 diameter columns on the pontoons were interconnected by a network of horizontal bracings. The cracked bracing made five other bracing broke off due to overload, and the vertical column connected with the cracked bracings became separated from the platform. The platform subsequently became unbalanced and capsized. The investigation showed that a fatigue crack had propagated from the double fillet near the hydrophone mounted to one of the horizontal bracing. Some cracks related to lamellar tearing were found in the heat affected zone (HAZ) of the weld around the hydrophone. Learning from this accident some countermeasures were undertaken including the amendment of the standards in for stability, motion characteristics, manueverability, watertight doors, and structural strength in Mobile Offshore Drilling Units (MODU) Code by the International Maritime Organization. (Source 1, 2)

4. Edmonton Canada April 18, 1982 (Fatigue, Petrochemical Plant, US$ 21,000,000/33,000,000) Vibration from the reciprocating compressor was believed causing transverse fatigue of 1/8 stainless steel instrument tubing. High pressure ethylene released causing a fire by

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static electricity ignition. Although the compressor building equipped with gas detection system the gas release was not accurately relayed to the control room. Automatic failsafe valves functioned properly by blocking the flow of more ethylene which was up to 11,000 pounds of gas already released causing damage to this low density polyethylene plant. (Source)

5. Remeoville Illinois US- July 23, 1984 (Weld Failure, Refinery, 17 killed, US$ 191,000,000/273,000,000)

A vessel for monoethanolamine absorber was constructed ten years earlier with oneinch thick ASTM A516 Gr 70 steel plates rolled and welded with full submerged arc without post weld heat treatment. Just prior to rupture a 6- inches crack detected at circumferential weld and by the time operator close inlet valve crack spread to 24 inches. The area was already cleared for evacuation and when fire brigade arriving the explosion occured. This explosion created sequential fire and explosion within refinery plant. A boiling liquid expanding vapor exposion (BLEVE) occured in a alkylation unit vessel. Technical investigation pointed that crack initiated at HAZ of welded shell of the column by hydrogen cracking, and progressed by the mechanism of hydrogen induced stepwise cracking (HISC). Test according to NACE procedure confirmed that material was susceptible to HISC. (Source 1, 2)

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6. San Juan Ixhuatepec Mexico City Mexico November 19, 1984 (Pipe Leaking, LPG Terminal, 650 killed 64,000 injured, US$ 19,940,000/29,000,000) A 12-inches pipeline between cylinder and sphere storage ruptured. Initial blast caused a series of BLEVEs. The oustanding cause of escalation was the ineffective gas detection system and as a result of lack of emergency isolation. This explosion and fire is perhaps the most devastating incident ever. The high death toll was due to the proximity of the LPG terminal to residence complex. Until now there is no clear information about the cause of pipe rupture. (Source 1, 2)

7. Las Piedras Venezuela- December 13, 1984 (Hydrogen Embrittlement, Refinery, US$ 62,076,000/89,000,000) A fracture occured in 8-inch line carrying hot oil from hydrode sulfurizer. Crack found in heat affected zone about 1 1/2 inches from weld. Hot oil at 700 psi and 650 oF sprayed and ignited at the hydrogen units. Fire causing sequential rupture of 16-inch gas line and successively blow torch to piping system in adjacent areas. Vibration analysis nine years earlier judged that the failed line was having excessive vibration and it strengthened the confidence that the hot oil line failed in fatigue dominantly due to hydrogen embrittlement. (Source)

8. Norco Louisiana- US May 5, 1988 (Erosion-Corrosion, Refinery, 4 killed, 20 injured, 4500 evacuated US$ 254,700,000/336,000,000) An elbow at depropanizer column piping system in a fluid catalytic cracking (FCC) unit failed. A large vapor with estimated 20,000 pounds of C3 hydrocarbon cloud escaped from the failed elbow and ignited in FCC charge heater. The explosion of FCC unit was the most severe damage. A report pointed that the failed elbow suffering excessive locally thinning. The failed elbow was located downstream of the injection point where ammoniated water was added to reduce propanizer condensation or fouling.(Source 1, 2)

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9. Piper Alpha North Sea UK July 8, 1988 (Gas Leaking, Offshore Platform, 167 killed, US$965,000,000/1,270,000,000)

It was dominantly operation error when gas leaking from two blind flanges then gas ignited and exploded. A pump from two available pumps was tripped, and an operator inadvertently changing the backup pump with pressure relief valve that had been removed for maintenance. Severity damage of the explosion was due to large part the contribution of oil and gas pipelines connected to Piper Alpha. While the platform was in fire two other platform Tartan and Claymore continued pumping gas and oil. (Source 1,2, Video)

10. Antwerp Belgium March 7, 1989 (Fatigue/Weld Failure, Petrochemical Plant, US$ 77,000,000/99,000,000) Explosion is believed initiated from a hairline crack in welded seam of piping at the aldheyde column. Ethylene oxide escaped from the leak, formed polyethylene glycol (PEG) in the insulation material and accumulated for a period of time. Sequential explosion was believed by the chemical mechanism inside the insulating material and PEG. The explosion caused extensive damage to the plant and it was closed for at least 24 months with total business interuption cost up to US$ 270,000,000. (Source, Location)

11. Richmond California US April 10, 1989 (Weld Failure, Refinery, 8 injured,US$87,170,000/112,000,000) Failed line carrying hydrogen gas caused a high pressure hydrogen fire and resulted in flame impingement to calcium silicate insulation of the hydrocracker reactor skirt. The reactor which was 10 to 12 feet in diameter and wall thickness of seven inches failed subseqently. The reactor was in maintenance cycle for hydrogen purging. It is believed that leaking started from a failed elbow of 2-inch line at 3,000 psi. (Source, Location)

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12. Baton Rauge Louisiana US December 24, 1989 (Brittle Fracture, Refinery,US$ 68,900,000/89,000,000) The record for low temperature (10 oF and 700 psi) at the region is believed as the major contributor to the failure of 8-inches pipeline carrying gas mixture of ethane and propane. After few minutes of vapor cloud was ignited and piperack containing 70 lines ruptured subsequently. Also with two storage tanks containing 3,600,000 gallons and 12 small tanks containing 882,000 gallons of lube oil also contribute to subsequent fire. (Source, Location)

13. Coatzacoalcos Mexico March 11, 1991 (Pipe Leaking, Petrochemical Plant,US$ 91,300,000/112,000,000) Gas leaking from pipe rack lead to explosion. The first explosion occured and caused additional damage to the pipe rack. Second explosion was more powerful and could be felt more than 15 miles from the facility creating damage to offsite third party facility. The explosion and fire made this vinyl chloride plant, a significant output for Mexico national demand, shut down for seven months. (Source,Location)

14. Dhaka Bangladesh June 20, 1991 (Weld Failure, Petrochemical Plant, US$ 71,000,000) The fertilizer plant which was constructed in 1970 suffer significant damage due to an explosion. The failure of a welded joint between carbondioxide stripper and main cylindrical body resulted in the release of high pressure gas which consisted of ammonia, carbon dioxide, and carbamate liquids. (Source)

15. North Rhine Germany December 10, 1991(Erosion-Corrosion, Refinery, US$ 50,500,000/62,000,000) A Pipe failed at T-junction in hydrocracker unit resulted in hydrocarbon and hydrogen release. The release of the gas ignited and explosion occured and made severe damage to the hydrocracker unit and adjacent substantial part of the plant. The hydrocracker unit was shut down for seven months. The failure of the pipe was contributed by erosion-corrosion due to plant aging. (Source)

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16. Guadalajara Mexico April 22, 1992 (Corrosion, Fuel Pipeline, 206 killed, 500 injured, 15,000 evacuated, US$ 300,000,000)

Guadalajara, Mexico second largest city, experienced series of ten massive explosion that equals to 7,0 richter scale from fuel pipeline blast. An investigation into the disaster revealed that the most possible cause for the explosion was the interference of fuel pipeline with new water piping system. The fuel pipeline was carbon steel and the sewer system was zinc-coated copper. These two lines were close enough to interfere each-other. Three days before the explosion, there were complaints from the city residents about gasoline-like smell coming from the water pipe and sewer system. (Source 1, 2, Location)

17. Westlake Louisiana US July 28, 1992 (Weld Failure/Corrosion, Petrochemical Plant, US$ 25,000,000/30,000,000) A reactor vessel in urea manufacturing unit exploded. The force of the explosion could be felt in areas up to 10 miles from the plant. The fragmented shell of the column propelled up to 900 feet from their original location. The reactor was constructed 25 years earlier with 90 feet tall and 6 feet in diameter. The shell consisted of 4-inches laminations including 3/8 inches stainless steel liner. The explosion resulted from carbamate leaking at the inside vessel. Improper weld on a bracket supporting a tray inside the reactor created carbamate leak and subsequent corrosion and containment of the vessel. (Source,Location)

18. Wilmington California US October 8, 1992 (Erosion-Corrosion, Refinery, US$ 73,300,000/96,000,000) An explosion initiated from hydrogen processing unit. Sequential fire and explosion occured to hydrocracker unit, and hydrode sulfurization. The explosion could be felt approximately 20 miles from the plant. The explosion made the plant operator reduce production capacity to 50 percent from its normal 75,000 barrels per-day. It took 8

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months to recover the production capacity. The explosion resulted from ruptered carbon-steel-elbow suffering locally thinning due to long term erosion-corrosion. (Source, Location)

19. Sodegaura Japan- October 16, 1992 (Fatigue, Refinery, 10 killed, 7 injured, US$ 160,500,000/196,000,000) An explosion from failed heat exchanger in the hydrode-sulphurization unit caused hydrogen release and ignited fire and explosion. Technical investigation to the failure noted a complexity of the failure mechanism. The cause of the failure initiated by repetition of variation of temperature lead to decrease of diameter gasket retainer and bending deformation of rock ring. These events contributed to break out of rock ring and made spouts hydrogen gas. (Source, Location)

20. La Mede, France November 9, 1992 (Pipe Leaking, Refinery, US$ 260,000,000/318,000,000) A pipe failed at T-junction in hydrocracker unit resulted in hydrocarbon and hydrogen release detection. Subsequent fire and explosion caused severe damage to FCC unit, gas plant, control room, and two new process unit under construction. The explosion also causing offsite damage nearby residential within the radius of 6 miles away. The business interuption loss due to this accident is estimated at US$ 180,000,000. (Source, Location)

21. Baton Rouge Louisiana US August 2, 1993 (Creep, Refinery Plant, USD 65,200,000/78,000,000) An elbow in the feed line of coker unit ruptured when feed switching were performed. Other pipes in unit ruptured subsequently releasing more hydrocarbons and fueling more fire to the plant. Because of the accident the coker unit was shut down for three weeks. Investigation to the failed elbow noted that carbon steel elbow was wrong material chosen with less creep resistance instead of 5Cr alloy steel.

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22. Simpsonville Sacramento US- June 6, 1996 (Pitting Corrosion, Fuel Pipeline, USD 27,000,000/33,000,000) An aboveground pipe segment failed by corrosion releasing 22,800 barrels of diesel fuel. The pipe manufactured in 1962 with 36-inches in diameter, 0.28-inches in thickness, and has specified maximum yield strength (SMYS) 52 kpsi. The pressure of pipe at the time of failure was 399 psi, the designed maximum pressure was 803 psi. (Source)

23. Rio Piedras San Juan Puerto Rico November 21, 1996 (Wrong Material in HCA, Gas Distribution Pipeline, 33 killed, 69 injured, USD 5,000,000)

Polyethylene pipe transporting propane gas to consumer was failed leading to fire and explosion. The explosion occurred in five stories full occupied business center at shopping district Rio Piedras San Juan Puerto Rico. The leaking of plastic pipe was believed due to construction excavation damage around the pipeline. More than 20 pipes and conduits surrounding the plastic pipe which were being constructed, being used and had been abandoned. Construction excavation damage to plastic pipe was rather unavoidable and there should be pipeline design with higher integrity within high consequence area (HCA) like Rio Piedras shopping district. (Source)

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24. Martinez California US January 27, 1997 (Creep, Refinery, USD 80,000,000/82,000,000) An effluent line from reactor in hydrocracker unit failed at pipe body leading to fire and explosion. Released hydrocarbon were auto-ignited because high temperature of the line seconds before explosion. Analysis of the failed pipe noted that the failure mechanism was creep above 1300 F which expanded the 12-inches pipe circumferentially by 5-inches causing localized bulge in the pipe prior to rupture. (Source)

25. Yokkaichi Mie Japan May 2, 1997 (Erosion-Corrosion, Petrochemical Plant) A T-joint of high-pressure piping for recycle ethylene gas failed and lead to explosion. The explosion occurred by the ignition of released ethylene gas by static electricity. Failure was contributed by erosion corrosion event by the evidence of presence of water and a local vortex accompanying a high-speed flow. Erosion corrosion caused a local thinning and the pipe could no longer withstand internal pressure. (Source)

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