Lee's Loss Prevention in the Process Industries: Hazard Identification, Assessment and Control, Volume 3, Third Edition

Appendix 6: Pasadena

Shortly after 1.00 p.m. on 23 October 1989, a release occurred on a polyethylene plant at the Phillips 66 Company s chemical complex at Pasadena, near Houston, Texas. A vapour cloud formed and ignited, giving rise to a massive vapour cloud explosion. There followed a series of further explosions and a fire. Twenty-two people on the site were killed and one later died from injuries, making a death toll of 23. The number injured are variously given as 130 and 300.

A report on the investigation of the accident has been issued by OSHA (1990a). Other accounts include those of Mahoney (1990), T. Richardson (1991) and J.N. Scott (1992).

Selected references on Pasadena are given in Table A6.1.

Table A6.1: Selected references on Pasadena

Anon. (1989 LPB 90, p. 0); Anon. (1990 LPB 94, p. 30); Mahoney (1990); OSHA (1990a); Redmond (1990); Vervalin (1990b); Bond (1991 LPB 97); Kletz (1991J); T. Richardson (1991); J.N. Scott (1992)

A6.1 The Site and the Plant

The Phillips works was sited in the Houston Chemical Complex along the Ship Channel, the location of a number of process companies.

The plant on which the release occurred was Plant V, one of the two active polyethylene plants in the complex. The plant operated at high pressure (700 psi) and high temperature. The process involved the polymerization of ethylene in isobutane, the catalyst carrier. Particles of polyethylene settled out and were removed from settling legs.

A6.2 Events Prior to the Explosion

On the previous day work...

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