Refinery injures 36 and pays $550 million for using old operating procedures
An unfortunate reminder for the industry on how important it is to update and certify operating procedures each year.
It was a day like any other at the Husky Superior Refinery in Superior, Wisconsin. Workers were busy preparing for a planned maintenance shutdown of the fluid catalytic cracking (FCC) unit. Little did they know that their routine day would soon turn into a nightmare resulting in 36 injuries and $550 million in damages.
Here’s what happened
Workers were busy preparing for a planned maintenance shutdown of the fluid catalytic cracking (FCC) unit. Two vessels in the FCC unit exploded, and the subsequent fragments punctured a nearby asphalt storage tank, causing it to spill approximately 17,000 barrels of hot asphalt. This spill ignited and caused multiple fires. The incident led to the evacuation of over 2,500 residents of the City of Superior and a shelter-in-place order in the City of Duluth, Minnesota. The explosion released 39,000 pounds of flammable hydrocarbon vapor into the air.
Watch the Chemical Safety Board (CSB) Husky refinery incident animation video
This is why operating procedures are so important
The U.S. Chemical Safety and Hazard Investigation Board (CSB) identified six key safety issues in its final report. One of these issues was the importance of transient operation safeguards. Transient operation is when a process is not operating in its normal state, such as during a shutdown for maintenance. The CSB emphasized the importance of separating air from flammable hydrocarbons during an FCC shutdown to prevent an explosive mixture.
Note: 29 CFR 1910.119(f)(1)(i)(A-G) lists operating phases that require operating procedures.
This incident reminds us about the critical importance of having robust and updated operating procedures in place. According to the Occupational Safety and Health Administration (OSHA), operating procedures are a key element of the Process Safety Management (PSM) standard. They provide clear instructions for safely conducting activities involved in each covered process.
Do your procedures match current plant operations?
Operating procedures should be as current as the operations they describe. They need to be updated whenever a change affects the process. Changes could include modifications to equipment, technology improvements, or changes in personnel. Additionally, 29 CFR 1910.119(f)(3) requires that each procedure be certified annually to ensure they are current and accurate.
In the case of the Husky Superior Refinery, the operating procedures for the FCC unit shutdown may not have adequately addressed the risks associated with transient operations. This highlights the need for continuous review and updating of operating procedures to ensure they reflect current operations and risks.
Include all involved when developing your procedures
The development and review of operating procedures should involve all affected parties. This includes operators, maintenance personnel, engineering, and other support staff. Their collective knowledge and experience can help identify potential hazards and develop effective safeguards.
Communication is a non-negotiable
Good communication is vital in the implementation of operating procedures. All personnel should understand the procedures and their role in them. Regular training and clear, concise communication can help ensure that everyone understands the procedures and the importance of following them.
Learning from the past to create a safer future
The Husky Superior Refinery incident serves as a stark reminder of the importance of robust operating procedures. It underscores the need for continuous review and updating of these procedures, the involvement of all affected parties in their development, and the crucial role of effective communication.
Disclaimer: this is not legal advice and shall not be construed as such.