FLIXBOROUGH DISASTER CPE601

PREPARED BY :
1. AMIRA AMIZA BINTI AMINUDIN (2015429658)
2. NUR FARINA BINTI MOHAMAD SILAN (2015263522)
3. MOHD FAIZ BIN SAIBOL (2015409194)
4. AMAR BIN MOHD MAAROF (2015429558)
OF EH2206a
CHAPTER 1 INTRODUCTION

• Largest explosion ever occur in UK

• The Flixborough disaster was an explosion at a chemical
plant
• The Flixborough Works of Nypro (UK) Ltd.
• 1st June 1974 , Saturday
• Product : cyclohexane (highly flammable)
ACTUAL CONDITION
• Vertical crack in reactor no.5 was leaking cyclohexane.
• A gigantic vapor cloud explosion occurred.
• 28 employees were killed and 36 injured.
• the explosion and subsequent fires totally destroyed the plant
which was never rebuilt.
• Over 1800 houses and 167 businesses in the surrounding
communities were damaged.
• Widespread damage to property within a 6 mile radius around
the plant
 SITUATIONAL ANALYSIS

Reactor 5 developed a
leak in the vessel shell
and had to be removed
for repair
Failure of 20-in
Temporary bypass releases
Formed vapour
bypass assembly An expansion cyclohexane
cloud that
was fabricated to bellow failed vapour
ignited
bridge the gap 30 tons of
cyclohexane vapor
were released to
the air
Depiction of vapour release
CHAPTER 2 Analysis of rupture
20-inch Hypothesis

The reason that leads to the bellows fractured by shear

stress, was that the temporary pipe was installed without
examining what the effect of a pressure surge on the
bellows.

The support of the temporary pipe was a scaffolding

structure in which the pipe is installed, without being
fastened down.

The bending moment was strong enough to tear the

bellows and two 28 inch holes appeared in the plant.
Simplified plan and elevation
It was confirmed by a metallurgical investigation showing
that zinc embrittlement on austenitic stainless steel at a
temperature of between 800 and 900 degree C could occur
in a pipe under a stress of 3.21ton/sq.in. within a few
seconds.

There was evidence that support the possibility that the

stress corrosion cracking of a stainless-steel pipe had been
caused by zinc contamination from galvanized-wire
supporting lagging.

It was shown that rapid creep cavitation of stainless steel

may occur within minutes at temperatures of 950 degree C
or more and under a stress of 4.7ton/sq.in.
Assembly of 20-in bypass
 PREVENTION ACTION THAT
SHOULD BE DONE

• Materials that are least

likely for stress corrosion
cracking to occur. • Manipulating the
temperature or even
changing the material.
• Eliminate the source of
stress or reduce it below • Adding inhibitors,
threshold level. modifying the electrode
MATERIAL potential of the metal, or
• Stress-relief annealing. SELECTION & isolating the metal from
• Engineers may also lower CONTROL the environment with
the peak stress coatings.
mechanically.
• Use of paint or any other
CONTROL OF STRESS polymeric coatings are
CONTROL OF advised since their nature
ENVIRONMENT of high electrical resistance
will hinder motion of
current from the anode to
the cathode thus protect
underlying metal.
Lessons learnt from the event
Reduction of inventory Control of plant
modification
Had it been smaller the leak
would have been less. In No modification should be
fact, it was Flixborough that made until it has been
made chemical engineers authorized in writing by a
realize that it might be competent person who
possible to reduce should normally be
inventories. professionally qualified

Control of process Need for suitably qualified

modifications staff

No change in operating The reference to

conditions, should not be professional qualifications is
made until they have been important especially in
authorized by a designing equipment.
professionally qualified
manager who should first
use a systematic technique
to help him identify the
consequences.
 CONCLUSION
- Flixborough is one of famous industry accident.
- Failing in technical measure is the reason why this
accident occur.
- Because of there is no witnesses, there are 2 theories
been proposed which are the 20 inch pipe theory and
the 8 inch in hypothesis.
- The 20 inch pipe theory is most acceptable compared
from the 8 inche in hypothesis.
- The moral of story, no modification should be made
until it been the authorized from competent person.