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BP Texas City Explosion
Before and After
• Loss of Containment
• Raffinate splitter start-up
procedure and applicaton of
knowledge and skills
• Control of work and trailer
siting
• Desgn and engineering of the
blowdown stack
BP Texas City Explosion
Baker Report
The report identified numerous failings in
equipment, risk management, staff
management, working culture at the site,
maintenance & inspection & general health &
safety assessments.
• BP management had not distinguished between
“occupational safety” & “process safety”
• Their metrics, incentives, and management
systems focused on measuring & managing
occupational safety & confused improving trends
in occupational safety statistics for a general
improvement in all types of safety.
• An employee survey showed that managers &
white collar workers had a rosier view of process
safety culture than blue collar operators and
maintenance techs.
BP Texas City Explosion
US Chemical Safety Board Report
An interim report cited serious
concerns about:
• The effectiveness of the safety
management system at BP Texas
refinery
• The effectiveness of BP North America’s
corporate safety oversight of it’s refining
facilities
• A corporate safety culture that may have
tolerated serious longstanding deviations
from good safety practice
The final report headlines two major
issues:
• Cost cutting and a ‘cheque book’
mentality
• Failure of all levels of BP management
including the board
What went wrong?
• BP Management over-looked warning
signs of a possible catastrophic accident;
• BP Management had a typical ‘Cheque-
Book mentality’;
• Antiquated equipment design;
• Siting of occupied trailers near ISOM unit;
and
• Human errors.
Source courtesy: CSB Video animation
Source courtesy: CSB Video animation
Fines & Warnings ignored!!
• The Occupational Safety and Health
Administration fined the refinery nearly $110,000
after two employees were burned to death by
superheated water in September 2004.
• Another explosion forced the evacuation of the
plant for several hours last March. Afterward,
OSHA fined the refinery $63,000 for 14 safety
violations, including problems with its emergency
shutdown system and employee training.
Key Lessons Learnt…
• Learn from organization memory;
• If no accident has occurred till today, that
does not mean that no accident is going to
happen!
• Monitor process safety performance using
appropriate indicators;
• Invest sufficient resources to correct
problems; and
• Maintain an open & trusting safety culture.
Key lessons learnt
• Ensure that non-essential personnel &
work trailers are located away from
hazardous process areas;
• Ensure equipment & procedures are
maintained up to date; and
• Carefully manage organizational changes
and budget decisions to ensure safety is
not compromised.
pillai_sreejith@hotmail.com