Dhaka University of Engineering & Technology, Gazipur

Department of Chemical Engineering

Presentation Title: BP Texas Refinery Explosion (An Analysis of the Incident)

Course Title: Safety and Quality Management in

Chemical Industries Sessional
Course Code: ChE 4774

Course Teachers,
Presenters,
Md. Shihabuzzaman Apon, Assistant
Md. Liton Mia - 198003
Professor, ChE, DUET
Md. Arifuzzamann - 198013
Md. Jahirul Islam, Lecturer, ChE,
Md. Rifat Khandaker - 198020
DUET
Outlines

Introduction to BP Texas Explosion

Causes of the Explosion

Outlines
Preventing Measures

Conclusions
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Introduction to BP Texas Explosion

The BP Texas City Refinery experienced one

of the worst industrial disasters in U.S. history,
around 1:20 p.m. on March 23, 2005. During
isomerization (ISOM) startup, raffinate
splitter tower was overfilled due to the
malfunction of level indicator. The pressure
relief devices opened, releasing flammable
liquid from the blowdown stack without a
flare. After contacting with an ignition source
and flammable material, they exploded and
burned. Explosions and fire killed 15 and
injured 180, scared the community, and cost
Fig-01: BP Texas City Oil Refinery
over $1.5 billion.
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Causes of BP Texas Explosion

Personnel
Errors

auses Insufficient
Process Safety

Management
Weakness
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Personnel Errors (PE)

Logbook
Miss Entry

Key Safety
Requiremen Late Arrival
ts
PE

Unrepaired
Startup
Key
Procedure
Instruments
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Insufficient Process Safety (IPS)

Malfunction in Level
Indicator
Errors in Alarms and
Instruments
No Automatic Safety
Shutdown

IPS
No Flare System
Vent Valve in The Reflux
Drum Was Closed
Inadequate OSHA
Inspections

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Management Weaknesses (MW)

Minor
• Improper Communications
• Ineffective Supervisory
• Ineffective Response to Serious Safety
Problems and Event

Major
• Management Cut The Budget
• Lack of Human Fatigue-prevention
Policy
• Inadequate Computerized Control
• Poor Level Indicator Design
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Preventing Measures (PM)

Awareness

Risk Mitigation

Investment in Safety

PM Improve Equipment Design

Proper Communication & Response

Well Maintenance

Enhancement Training
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Conclusions

The BP Texas Refinery explosion

underscores the crucial need for precise
safety measures, effective risk
management, and a culture of
accountability in the chemical industry
to prevent dangerous accidents and
safeguard the welfare of workers and
nearby communities.

Fig-02: BP Texas city Refinery

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Questions

Question-01: What are the root causes of the BP Texas refinery explosion?

Answer: The root causes of the BP Texas refinery explosion is Malfunction of the
Level Indicator.

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Questions

Questions-02: What specific OSHA standards were violated at the BP Texas

refinery?

Answer: OSHA standards violated included inadequate training, insufficient

process safety management, and lack of emergency response protocols.

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Questions

Question-03: What is the avoiding hazard when the liquid reaches at the maximum
capacity?
Answer: The avoiding hazard when the liquid reaches at the maximum capacity is
Emergency Purging System.

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 Thank You!

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