Texas City refinery explosion
The Texas City refinery explosion occurred on March 23, 2005, when a flammable hydrocarbon vapor cloud ignited and violently exploded at the isomerization process unit of the BP oil refinery in Texas City, Texas, killing 15 workers, injuring 180 others and severely damaging the refinery. All the fatalities were contractors working out of temporary buildings located close to the unit to support turnaround activities. Property loss was $200 million ($300 million in 2024). When including costs of repairs, deferred production, fines and settlements, the explosion is the world's costliest refinery accident. The direct cause of the accident was the ignition of a heavy hydrocarbon vapor cloud which emanated from raffinate liquids overflowing from the top of a blowdown stack. The source of ignition was probably a running vehicle engine. The release of liquid followed the automatic opening of a raffinate splitter column overpressure protection caused by overfilling. Subsequent investigation reports by BP, the U.S. Chemical Safety Board (CSB), and an independent blue-ribbon panel led by James Baker identified numerous technical and organizational failings at the refinery and within corporate BP.
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