Similar Cases:

Explosion in a Chemical Blending Vessel Due To Unrecognized Explosion Hazard

Mechanical Seal Failure and Explosion in a Chemical Blending Vessel

Explosion in an Ammonium Nitrate Fertilizer Manufacturing Plant (Terra Corp.)

Coke Oven Gas Explosion in an Ammonia Scrubber in a Steel Mill

Explosion of a Urea Autoclave Vessel in a Fertilizer Plant

Natural Gas Filter-Separator Vessel Failure and Explosion

The closure of a 40-inch diameter filter separator (a pressure vessel used for filtering natural gas) failed and resulted in an estimated $25 million in damages. The 5000 pound steel head of the vessel was shot approximately 1/4 mile and the vessel was launched 30 feet in the opposite direction. APTECH was contracted by the manufacturer's representative to determine the cause of the failure. Our on site activities in Tracy, California included visual surveying and analysis, photo documentation, video documentation, and dimensional analysis of the wreckage. During the site investigation, it was determined that the operator of the vessel had used oversized o-rings during an overhaul of the vessel just hours prior to the accident. Analysis in our laboratory included metallurgical evaluations, scanning electron microscopy of components involved in the accident, as well as finite element stress analysis and load testing of exemplar components of the closure. Pressure testing was performed on a near-full-scale mockup of the entire vessel. The mock-up also was fitted with strain gages at strategic locations. After performing the tests with both standard-sized and oversized o-rings, it was determined that the stress at critical locations was up to five times higher with the oversized o-rings.

Satish Almaula		Plant failure and root cause analysis; process and design engineering analysis; process technology development and testing; plant engineering, operations, maintenance and safety management; plant and process control system management.

Eric Sullivan, P.E.		Metallurgy, welding, failure analysis, fire and explosion investigations, equipment, piping.

Kimble Clark, Ph.D.		Failure analysis, heat transfer & thermodynamics, process plant equipment failures & explosions, fuel science, combustion, industrial fires and explosions.

Richard Schreiber, P.E.		Machinery and mechanical device failure analysis, mechanical testing, combustion and heat transfer, industrial fires and explosions, gas appliances.