Williams Geismar Olefins Plant Reboiler Rupture and Fire Geismar, Louisiana

Williams Geismar Case Study ''Blocked In''

Accident Description

Accident: Williams Olefins Plant Explosion and Fire

Location: Location: Geismar, LA

Accident Occured On: 06/13/2013 | 

Final Report Released On: 10/19/2016

Accident Type: Chemical Manufacturing- Fire and Explosion

Investigation Status: The CSB's investigation was released at a news conference in Baton Rouge, LA, on 10.19.2016

This case study examines the June 13, 2013 catastrophic equipment rupture, explosion, and fire at the Williams Olefins Plant in Geismar, Louisiana, which killed two Williams employees. The incident occurred during nonroutine operational activities that introduced heat to a type of heat exchanger called a “reboiler” which was offline, creating an overpressure event while the vessel was isolated from its pressure relief device. The introduced heat increased the temperature of the liquid propane mixture1 confined within the reboiler shell, resulting in a dramatic pressure rise within the vessel due to liquid thermal expansion. The reboiler shell catastrophically ruptured, causing a boiling liquid expanding vapor explosion (BLEVE)2 and fire. Process safety management program weaknesses at the Williams Geismar facility during the 12 years leading to the incident caused the reboiler to be unprotected from overpressure. These weaknesses include deficiencies in implementing Management of Change (MOC), Pre-Startup Safety Review (PSSR), and Process Hazard Analysis (PHA) programs. In addition, the company did not perform a hazard analysis or develop a procedure for the operational activities conducted on the day of the incident. This incident illustrates the importance of: 

• Using the hierarchy of controls when evaluating and selecting safeguards to control process hazards;

• Establishing a strong organizational process safety culture; 

• Developing robust process safety management programs;  

• Ensuring continual vigilance in implementing process safety management programs to prevent major process safety incidents. Following the incident, Williams implemented improvements in managing process safety. 

    To prevent future incidents and further improve process safety at the Geismar plant, the U.S. Chemical Safety and Hazard Investigation Board (CSB) recommends that Williams strengthen existing safety management systems and adopt additional safety programs. The CSB also issues recommendations to the American Petroleum Institute (API) to help prevent future similar incidents industry-wide. 

Source: CSB