Chemical Safety Board Shares Safety Video on Fatal Chemical Release
The July 2021 chemical release killed two workers.
The US Chemical Safety and Hazard Investigation Board (CSB) released a new safety video on its investigation into the fatal release of acetic acid at the LyondellBasell La Porte Complex in La Porte, TX, on July 27, 2021, that killed two contract workers.
Approximately 164,000 lb of a highly corrosive acetic acid mixture erupted from equipment when three contract workers inadvertently removed critical components of a plug valve. All three workers were sprayed with the acetic acid mixture. Two of the workers died from their injuries.
CSB's new safety video, “Designed to Fail: Chemical Release at LyondellBasell,” includes an animation of the events leading to the incident, as well as commentary from CSB Board Member Dr. Sylvia Johnson and CSB Investigator Benjamin Schrader.
The CSB released its final investigation report on the incident on May 25, 2023. The agency's investigation found that the incident occurred when three contractors from Turn2 Specialties Companies attempted to isolate a pipe section located between a leaking pipe and an acetic acid reactor. To do so, they decided to lock a plug valve in the closed position by removing the valve’s actuator. However, LyondellBasell did not have a procedure detailing how to remove the actuator, and neither LyondellBasell nor Turn2 trained the Turn2 personnel on how to remove the actuator. Instead, the contractors inadvertently removed pressure-retaining fasteners that were holding the valve cover in place and should not have been removed to uninstall the actuator. The compromised valve failed, and all three Turn2 workers were sprayed by the acetic acid mixture.
The safety video addresses the two key safety issues identified in the CSB’s final report that contributed to the incident: (1) valve design to prevent human error, and (2) providing workers with conditions, procedures, and training to safely conduct work. The video also highlights safety recommendations made by the CSB to the American Society of Mechanical Engineers, the American Petroleum Institute, and LyondellBasell.
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