flixborough (nypro uk)

46 Nypro (UK) site at Flixborough was severely damaged by a large explosion. The factory produced nylon, the time of the explosion is well documented, the village post office clock stopped as a result of the explosion blast pressure wave, the village located 2 miles from the blast site & around 1800 homes damaged within a mile radius of the site. 28 workers were killed with a further more 36 suffering injuries. Had the accident happened during a weekday then it is likely the accident would have claimed more casualties; the flame jet hit the office block, which would have had over 50 people at work and with 200 people at the factory. Local witnesses reported feeling the blast pressure as window blew out but didn’t hear a blast noise. Prior to the accident it was discovered that reactor 5 was leaking and as a precaution the plant was shut down and by passing the process to reactors 4 and 6 the installation of the bypass failed and caused a fire and ruptured some other process pipes allowing product to escape forming a large flammable cloud and at around 5pm found its way to an ignition source causing an explosion and extensive damage which burned for a during for 10 days A plant modification occurred without a full assessment of the potential consequences and only limited calculations were undertaken to assess the integrity of the bypass line. Therefore. poor management control and poor assessment for the risks. Study of the remaining vessels and items on site suggest the kind of overpressures experienced during the blast, in addition calculation for the vapour cloud and its air fuel mass helped predict the size equivalent to an explosive measure in this case, various reports conclude that the net crushing pressure on the skirts of these vessels must have been in excess of 760 kPa (7.6 bar) and that the explosion its self is as much as 15 bar. Flixborough (Nypro UK) June 1, 1974 Event Statistics 10 Days Lessons Learned Duration of fire Number of casualties Cost to industry References 28 Staff, 38 others suffered injuries £100 million Flixborough. 1974.[Online]. [Accessed 31 October 2014]. http://www.hse.gov.uk/comah/sragtech/caseflixboroug74 Prof. Andrews. 2014. Flixborough incident. Fire Explosion Prediction & Mitigation, October, 2014, Weetwood Hall Leeds. Type of fire Vapour Cloud Unknown Ignition Source

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Nypro(UK)siteatFlixboroughwasseverelydamagedbyalargeexplosion.Thefactoryproducednylon,thetimeoftheexplosioniswelldocumented,thevillagepostofficeclockstoppedasaresultoftheexplosionblastpressurewave,thevillagelocated2milesfromtheblastsite&around1800homesdamagedwithinamileradiusofthesite.28workerswerekilledwithafurthermore36sufferinginjuries.Hadtheaccidenthappenedduringaweekdaythenitislikelytheaccidentwouldhaveclaimedmorecasualties;theflamejethittheofficeblock,whichwouldhavehadover50peopleatworkandwith200peopleatthefactory.Localwitnessesreportedfeelingtheblastpressureaswindowblewoutbutdidn’thearablastnoise.Priortotheaccidentitwasdiscoveredthatreactor5wasleakingandasaprecautiontheplantwasshutdownandbypassingtheprocesstoreactors4and6theinstallationofthebypassfailedandcausedafireandrupturedsomeotherprocesspipesallowingproducttoescapeformingalargeflammablecloudandataround5pmfounditswaytoanignitionsourcecausinganexplosionandextensivedamagewhichburnedforaduringfor10days

Aplantmodificationoccurredwithoutafullassessmentofthepotentialconsequencesandonlylimitedcalculationswereundertakentoassesstheintegrityofthebypassline.Therefore.poormanagementcontrolandpoorassessmentfortherisks.Studyoftheremainingvesselsanditemsonsitesuggestthekindofoverpressuresexperiencedduringtheblast,inadditioncalculationforthevapourcloudanditsairfuelmasshelpedpredictthesizeequivalenttoanexplosivemeasureinthiscase,variousreportsconcludethatthenetcrushingpressureontheskirtsofthesevesselsmusthavebeeninexcessof760kPa(7.6bar)andthattheexplosionitsselfisasmuchas15bar.

Flixborough(NyproUK)June1,1974

EventStatistics

10Days

LessonsLearned

Durationoffire

Numberofcasualties

Costtoindustry

References

28Staff,38otherssufferedinjuries

£100million

Flixborough.1974.[Online].[Accessed31October2014].http://www.hse.gov.uk/comah/sragtech/caseflixboroug74Prof.Andrews.2014.Flixboroughincident.FireExplosionPrediction&Mitigation,October,2014,WeetwoodHallLeeds.

TypeoffireVapourCloud

UnknownIgnitionSource

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