Romeoville
- Refinery explosion and fire -
- Refinery explosion and fire -
Video from broadcast news:
Summary
data:
Date: July 23, 1984
Place: Union Oil
Company refinery in Romeoville, Illinois
Type of accident: Explosion & fire
Outcome: 2 major explosions,
Structures burning once isolated burned out on their own;
17 people dead (11 firefighters),
22 injured persons ;
Estimated cost:
$ ~530 million (repairs and
compensation)
Lawsuit: Settlement in 1989 ($29.9 million for victims)
About
the refinery
Union Oil refinery employed more than 700 workers and processed 151,000 barrels of oil
a day.
What happened?
5h45
p.m. : Vapor leak was noticed on a Vessel
About the Vessel :
- Amine absorber removing H2S from acid stream
- 55 foot tall, one-inch thick carbon steel (34-tonne storage)
-
Pressured
Refinery workers, including the outside operator and an
assistant outside operator, unsuccessfully attempted to by-pass the vessel and
to depressurize it.
5:52
p.m. : The leak
in the vessel wall had spread around the entire eight foot circumference of the
vessel and it erupted like a missile. The top 45 feet of the vessel was lifted
by the vapor cloud. The bottom 10 feet of the vessel stayed intact on the
ground. The eruption of the vessel
released a massive vapor cloud which ignited, causing a fire ball.
This explosion engulfed much of the refinery in flames.
Firefighters
from the Union Oil Fire Brigade responded immediately with the company’s two
engines, followed closely by the Romeoville Fire Department.
As a result of the explosion, many towers, tanks, and
other refinery structures began to rupture or collapse and the site’s fire hydrant system was damaged. So firefighers were forced to
draft water from a nearby sanitary canal.
They were just beginning to
attack the flames when a tank containing
liquefied petroleum gas erupted. The explosion created a huge fireball that
rose thousands of feet into the air. Several members of the Union Oil Fire
Brigade were caught in the blast. Later reports stated that the explosion was felt fifteen miles away. Local
residents recalled seeing a “bright mushroom cloud” emanating from the facility
and a very powerfull blast.
The enormity of the fire brought mutual aid fire
apparatus and ambulances from more than 30 cities,
including two medical evacuation helicopters from the University of Chicago
Hospital and a Chicago Fire Department fireboat sent via the sanitary canal. An
AMOCO refinery in Indiana even sent truckloads of Aqueous Film-Forming Foam
(AFFF) to help extinguish the fire.
Firefighters
were needed to both put out the flames and also prevent more refinery
structures from catching fire. Once the
burning structures were isolated, fire officials determined that allowing the
fires to burn out on their own was the safest way to extinguish the blaze.
The fires burned throughout the night at temperatures of 2,200 °C, luckily
without further explosions or loss of life, even though some workers jumped
into the Illinois & Michigan Canal to escape the extreme heat.`
Amine vessel failure analysis
As required by law, the inside of the vessel
was inspected every two years. The inspectors were Union Oil employees in
management positions. The vessel was last inspected three months before the
explosion and the vessel inspectors found no problems with the vessel.
Testimony from one of Union Oil’s own engineers indicated that his
metallurgical testing performed after the explosion indicated that there were
cracks in the vessel walls at least four years before the accident. The
plaintiff’s evidence established that Union Oil’s vessel inspectors made only a
visual inspection which was inadequate to detect cracking within the vessel
walls. The evidence indicated that Ultrasonic and wet magnetic particle testing
techniques were well known and used in the oil industry to detect vessel wall
cracking, but Union Oil did not use them on this vessel.
Three other primary contributors to the
settlement, Santa Fe Braun, Inc., UOP, Inc., and the Ralph M. Parsons Company,
had responsibilities relating to the erection, process design and functioning
of this vessel. One of Santa Fe Braun’s corporate predecessors, C.F. Braun and
Company, was the general contracting firm that erected the vessel. Its
engineers helped to determine the process requirements and capabilities of this
vessel, specifically including what amount of chemical activity would go on
within the vessel. UOP was also involved in those decisions, made with respect
to process engineering. The Ralph M. Parsons Company has been hired by Union
Oil to revamp part of the refinery, including the subject vessel. In its
revamp, Parsons altered some of the process requirements of that vessel, and as
well, made independent determinations of the suitability of the vessel and its
characteristics for use in the amine treating system. The Union Oil Compagny
alleged that the process design work done by these three companies was
inadequate in that it failed to provide for sufficient safeguarding against
corrosion which contributed to the cracking and the failure of the vessel.
Union Oil determined that the operation of
the subject vessel had caused significant metallurgical problems to the bottom
portion of the vessel and that one of the vessel sections would need to be
replaced. Welders from the Morrison Construction Company attempted to replace a
major section of the vessel but due to poor quality control and inadequate
welding work, were taken off the job by Union Oil and replaced by welders from
the Nooter Corporation. Nooter’s welders finished the job using specifications
which the Union Oil Compagny claimed were inadequate. The welding
specifications used by Morrison and Nooter contributed to the "high
hardness" of the metal adjacent to the weld, which made it more brittle
and subject to failure.
Metallurgical testing work done after the
explosion, both by engineers retained by Union Oil and engineers retained by
the Illinois State Fire Marshall, showed that the cracking in this vessel which
lead to the explosion and fire started in the metal adjacent to the welds done
by Morrison and Nooter.
Links:
Broadcast News 1984-07-23:
https://www.youtube.com/watch?v=-UVmtQ_Gm-M
https://www.youtube.com/watch?v=-UVmtQ_Gm-M
News-Post 1984-07-25:
http://www3.gendisasters.com/illinois/6895/romeoville-il-refinery-explosions-july-1984
http://www3.gendisasters.com/illinois/6895/romeoville-il-refinery-explosions-july-1984
Chicago Tribune / 10 Years Later, Survivors
And Witnesses Recall Fatal Refinery Blast In Romeoville:
http://articles.chicagotribune.com/1994-08-03/news/9408030340_1_refinery-explosion-mushroom-cloud-fire
http://articles.chicagotribune.com/1994-08-03/news/9408030340_1_refinery-explosion-mushroom-cloud-fire
Concise recaps:
Jury verdict:
http://www.jvra.com/verdict_trak/article.aspx?id=29401
http://www.jvra.com/verdict_trak/article.aspx?id=29401
US Departement of Labor Analysis:
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